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D50S-5-D90S-5 G50S-5-G70S-5 Service Manual (SB4271E00)

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0% found this document useful (0 votes)

355 views1,064 pages

D50S-5-D90S-5 G50S-5-G70S-5 Service Manual (SB4271E00)

Uploaded by

Carlos Garcia Pequeño

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

For use in service manual

form SB4271E
SB4272E00
Sep. 2007

SERVICE MANUAL CONTENTS

NOTICE

This form lists the contents of the complete Service Manual for this product.
The items listed with form numbers are available and included in the manual.
If form numbers are listed with mark(*), they are not available for the initial
release of the manual. When items are updated, or supplements are added,
they will be provided separately.

TITLE FORM NUMBER

Service Manual Contents SB4272E00

Safety SB2003E00
Torque Specifications SB2004E00

ENGINE

Alternator SB4261E00
Starting Motor SB4262E00
G643(E) Engine SB4263E00
DB58S Diesel Engine (Tier Ⅱ) SB4118E01

POWER TRAIN

Power Train (Two Speed Transmission, Drive axle) SB4274E00

Three Speed Power Shift Transmission Systems SB4121E01
Three Speed Power Shift Transmission D & A SB4122E01

VEHICLE SYSTEMS

Vehicle Systems SB4276E00

Vehicle Systems D & A SB4277E00
Hydraulic System Schematic SB4278E00
Electric System Schematic SB4279E00
Mast (D50/60/70S-5, G50/60/70S-5) SB4132E01
Mast (D80/90S-5) SB4280E00

OPERATION & MAINTENANCE

Operation & Maintenance Manual SB2356E00

Models ; D50S-5, D60S-5, D70S-5, D80S-5, D90S-5

G50S-5, G60S-5, G70S-5
SB2003E00
Dec. 1998

WARNING

SAFETY

WARNING WARNING

The proper and safe lubrication and maintenance Do not operate this machine unless you have
for this machine, recommended by DOOSAN, are read and understand the instructions in the
outlined in the OPERATION & MAINTENANCE OPERATOR'S GUIDE. Improper machine
GUIDE for this machine. operation is dangerous and could result in
Improper performance of lubrication or injury or death.
maintenance procedures is dangerous and could
result in injury or death. Read and understand the
OPERATION & MAINTENANCE GUIDE before 5. Use steps and grab handles (if applicable) when
performing any lubrication or maintenance. mounting or dismounting a machine. Clean any mud or
debris from steps, walkways or work platforms before
using. Always face machine when using steps, ladders
Theserviceman or mechanic maybe unfamiliar with many and walkways. When it is not possible to use the
of the systems on this machine. This makes it important designed access system, provide ladders, scaffolds, or
to use caution when performing service work. A work platforms to perform safe repair operations.
knowledge of the system and/or components is 6. To avoid back injury, use a hoist when lifting
important before the removal or disassembly of any components which weigh 23 kg (50 lb.) or more. Make
component. sure all chains, hooks, slings, etc., are in good
Because of the size of some of the machine condition and are of the correct capacity. Be sure
components, the serviceman or mechanic should check hooks are positioned correctly. Lifting eyes are not to
the weights noted in this Manual, Use proper lifting be side loaded during a lifting operation.
procedures when removing any components. 7. To avoid burns, be alert for hot parts on machines
Following is a list of basic precautions that should always which have just been stopped and hot fluids in lines,
be observed. tubes and compartments.

1. Readand understand all Warning plates and decals on 8. Be careful when removing cover plates. Gradually
the machine before operating, lubricating or repairing back off the last two bolts or nuts located at opposite
the product. ends of the cover or device and pry cover loose to
relieve any spring or other pressure, before removing
2. Always wear protective glasses and protective shoes the last two bolts or nuts completely.
when working around machines. In particular, wear
protective glasses when pounding on any part of the 9. Be careful when removing filler caps, breathers and
machine or its attachments with a hammer or sledge. plugs on the machine. Hold a rag over the cap or plug
Use welders gloves, hood/goggles, apron and other to prevent being sprayed or splashed by liquids under
protective clothing appropriate to the welding job pressure. The danger is even greater if the machine
being performed. Do not wear loose-fitting or torn has just been stopped because fluids can be hot.
clothing. Remove all rings from fingers when working 10. Always use tools that are in good condition and be
on machinery. sure you understand how to use them before
3. Do not work on any machine that is supported only by performing any service work.
lift jacks or a hoist. Always use blocks or jack stands 11. Reinstall all fasteners with same part number. Do not
to support the machine before performing any use a lesser quality fastener if replacements are
disassembly. necessary. Do not mix metric fasteners with
4. Lower the forks or other implements to the ground standard nuts and bolts.
before performing any work on the machine. If this 12. If possible, make all repairs with the machine parked
cannot be done, make sure the forks or other on a level, hard surface. Block machine so it does
implements are blocked correctly to prevent them not roll while working on or under machine.
from dropping unexpectedly.
1 of 2
WARNING

13. Disconnect battery and discharge any capacitors 21. Do not operate a machine if any rotating part is
(electric trucks) before starting to work on machine. damaged or contacts any other part during
Hang "Do Not Operate" tag in the Operator's operation. Any high speed rotating component that
Compartment. has been damaged or altered should be checked
for balance before reusing.
14. Repairs, which require welding, should be
performed only with the benefit of the appropriate 22. On LP equipped lift trucks, be sure to close the
reference information and by personnel adequately valve on the LP tank before service work is
trained and knowledgeable in welding procedures. performed. Always close the valve on the LP tank
Determine type of metal being welded and select when the lift truck is being stored. Do not check for
correct welding procedure and electrodes, rods or LP leaks with an open flame.
wire to provide a weld metal strength equivalent at
23. Caution should be used to avoid breathing dust that
least to that of parent metal.
may be generated when handling components
15. Do not damage wiring during removal operations. containing asbestos fibers. If this dust is inhaled, it
Reinstall the wiring so it is not damaged nor will it can be hazardous to your health. Components in
be damaged in operation by contacting sharp DOOSAN products that may contain asbestos
corners, or by rubbing against some object or hot fibers are brake pads, brake band and lining
surface. Do not connect wiring to a line containing assemblies, clutch plates and some gaskets. The
fluid. asbestos used in these components is usually
bound in a resin or sealed in some way. Normal
16. Be sure all protective devices including guards and
handling is not hazardous as long as airborne dust
shields are properly installed and functioning
which contains asbestos is not generated.
correctly before starting a repair. If a guard or shield
must be removed to perform the repair work, use If dust which may contain asbestos is present, there are
extra caution. several common sense guidelines that should be
followed.
17. Always support the mast and carriage to keep
carriage or attachments raised when maintenance a. Never use compressed air for cleaning.
or repair work is performed, which requires the
b. Avoid brushing or grinding of asbestos containing
mast in the raised position.
materials.
18. Loose or damaged fuel, lubricant and hydraulic
c. For clean up, use wet methods or a vacuum
lines, tubes and hoses can cause fires. Do not
equipped with a high efficiency particulate air
bend or strike high pressure lines or install ones
(HEPA) filter.
which have been bent or damaged. Inspect lines,
tubes and hoses carefully. Do not check for leaks d. Use exhaust ventilation on permanent machining
with your hands. Pin hole (very small) leaks can jobs.
result in a high velocity oil stream that will be
e. Wear an approved respirator if there is no other
invisible close to the hose. This oil can penetrate
way to control the dust.
the skin and cause personal injury. Use cardboard
or paper to locate pin hole leaks. f. Comply with applicable rules and regulations for the
work place (for example in the U.S.A., OSHA
19. Tighten connections to the correct torque. Make
requirements as set forth in 29 CFR 1910. 1001).
sure that all heat shields, clamps and guards are
installed correctly to avoid excessive heat, vibration g. Follow environmental rules and regulations for
or rubbing against other parts during operation. disposal of asbestos.
Shields that protect against oil spray onto hot
h. Avoid areas where asbestos particles may be in the
exhaust components in event of a line, tube or seal
air.
failure must be installed correctly.

20. Relieve all pressure in air, oil or water systems

before any lines, fittings or related items are
disconnected or removed. Always make sure all
raised components are blocked correctly and be
alert for possible pressure when disconnecting any
device from a system that utilizes pressure.

2 of 2
SB2004E00
Dec.1998

Specifications
TORQUE
SPECIFICATIONS
STANDARD TORQUE FOR METRIC FASTENERS

NOTE : Take care to avoid mixing metric and inch dimensioned fasteners.
Mismatched or incorrect fasteners can result in vehicle damage or malfunction, or
possible injury. Exceptions to these torques are given in the Service Manual where
needed.

NOTE : Prior to installation of any hardware, be sure components are in near new
condition. Bolt and nut threads must not be worn or damaged. Hardware must be
free of rust and corrosion. Clean hardware with a non-corrosive cleaner and apply
engine oil to threads and bearing face. If thread lock or other compounds are to be
applied, do not apply engine oil.

METRIC NUTS AND BOLTS

THREAD
SIZE STANDARD TORQUE
(mm) (N i m) (lb i ft)
M6 12 ±3 9 ± 2
M8 28 ±7 20 ± 5
M10 55 ± 10 40 ± 7
M12 100 ± 20 75 ± 15
M14 160 ± 30 120 ± 22
M16 240 ± 40 175 ± 30
M20 460 ± 60 340 ± 44
M24 800 ± 100 600 ± 75
M30 1600 ± 200 1200 ± 150
M36 2700 ± 300 2000 ± 225

METRIC TAPERLOCK STUDS

THREAD
SIZE STANDARD TORQUE
(mm) (N i m) (lb i ft)
M6 8 ± 3 6 ± 2
M8 17 ± 5 13 ± 4
M10 35 ± 5 26 ± 4
M12 65 ± 10 48 ± 7
M16 110 ± 20 80 ± 15
M20 170 ± 30 125 ± 22
M24 400 ± 60 300 ± 45
M30 650 ± 80 480 ± 60
M36 870 ± 100 640 ± 75

1 of 7
STANDARD TORQUE FOR INCH FASTENERS

Exceptions to these torques are given in the Service

Manual where needed.

INCH NUTS AND BOLTS

THREAD
SIZE STANDARD TORQUE
inch (N i m) (lb i ft)
1/4 12 ± 3 9 ± 2
5/16 25 ± 6 18.0 ± 4.5
3/8 47 ± 9 35 ± 7
7/16 70 ± 15 50 ± 11
1/2 105 ± 20 75 ± 15
9/16 160 ± 30 120 ± 20
5/8 215 ± 40 160 ± 30
3/4 370 ± 50 275 ± 35
7/8 620 ± 80 460 ± 60
1 900 ± 100 660 ± 75
1-1/8 1300 ± 150 950 ± 100
1-1/4 1800 ± 200 1325 ± 150
1-3/8 2400 ± 300 1800 ± 225
1-1/2 3100 ± 350 2300 ± 250

INCH TAPERLOCK STUDS

THREAD
SIZE STANDARD TORQUE
inch (N i m) (lb i ft)
1/4 8 ± 3 6 ± 2
5/16 17 ± 5 13 ± 4
3/8 35 ± 5 26 ± 4
7/16 45 ± 10 33 ± 7
1/2 65 ± 10 48 ± 7
5/8 110 ± 20 80 ± 15
3/4 170 ± 30 125 ± 22
7/8 260 ± 40 190 ± 30
1 400 ± 60 300 ± 45
1-1/8 500 ± 70 370 ± 50
1-1/4 650 ± 80 480 ± 60
1-3/8 750 ± 90 550 ± 65
1-1/2 870 ± 100 640 ± 75

2 of 7
O-RING FACE SEAL FITTINGS

O-RING FACE SEAL FITTING

O-RING GROOVE

STRAIGHT THREAD O-RING

O-RING FACE SEAL NUT O-RING PORT FITTING END
IDAS001B

STRAIGHT THREAD O-RING

FITTING (FOR O-RING FACE
SEAL FITTING ONLY)
THREAD
SIZE STANDARD TORQUE
inch (N i m) (lb i ft)
5/16-24 5.0 ± 1.5 45±15 lb i in
3/8-24 12 ± 2 110±20 lb i in
7/16-20 20 ± 4 15 ± 3
1/2-20 30 ± 5 22 ± 4
9/16-18 40 ± 5 30 ± 4
3/4-16 100 ± 15 75 ± 10
7/8-14 135 ± 15 100 ± 10
1 1/16-12 200 ± 25 150 ± 20
1 3/16-12 250 ± 25 185 ± 20
1 5/16-12 300 ± 40 225 ± 30
1 5/8-12 300 ± 40 225 ± 30
1 7/8-12 300 ± 40 225 ± 30
2 1/2-12 300 ± 40 225 ± 30

O-RING FACE SEAL FITTING NUT

THREAD
SIZE STANDARD TORQUE
inch (N i m) (lb i ft)
9/16-18 16 ± 3 12 ± 2
11/16-16 30 ± 4 22 ± 3
13/16-16 50 ± 7 37 ± 5
1-14 90 ± 10 65 ± 7
1 3/16-12 120 ± 15 90 ± 10
1 7/16-12 160 ± 20 120 ± 15
1 11/16-12 190 ± 20 140 ± 15
2-12 215 ± 25 160 ± 20

3 of 7
FITTING INSTALLATION

HYDRAULIC LINE INSTALLATION 1. Put locknut (3), backup washer (4) and O-ring seal
(5) as far back on fitting body (2) as possible. Hold
these components in this position. Turn the fitting
1. For a metal tube to hose installation, install the tube into the part it is used on until backup washer (4) just
and tighten all bolts finger tight. makes contact with the face of the part it is used on.
2. Tighten the bolts at the rigid end. 2.To put the fitting assembly in its correct position, turn
3. Install the hose and tighten all bolts finger tight. the fitting body (2) out (counterclockwise) a
maximum of 359û. Tighten locknut (3) to the torque
4. Put the hose in a position so that it does not make shown in the correct chart for the fitting used.
contact with the machine or another hose.
NOTE: If the fitting is a connector (straight fitting), the
5. Tighten the bolts on both connections. hex on the body takes the place of the locknut. To
6. Start the engine. install this type fitting, tighten the hex against the face
of the part it goes into.
7. Move the implement control levers to all positions.
8. Look at the hose during movement of the
implement. Make sure hose is not in contact with TORQUES FOR FLARED AND O-RING FITTINGS
the machine or other hoses.
The torques shown in the charts that follow are to be
9. Shut off the engine.
used on the nut part of 37û Flared, 45û Flared and
10. If necessary, put the hose in a new position where it Inverted Flared fittings (when used with steel tubing),
will not make contact when the implement is moved. O-ring plugs, O-ring fittings and swivel nuts when
used in applications to 3000 psi (20 700 kPa).

ASSEMBLY OF FITTINGS WITH STRAIGHT

THREADS AND O-RING SEALS HOSE CLAMP-BAND TYPE

This type of fitting is used in many applications. The tube

end of the fitting will be different in design so that it can
be used in many different applications. However, the
installation procedure of the fitting is the same. If the tube
end of the fitting body is the same as in the illustration
(either an elbow or a straight body) it will be necessary to
assemble the sleeve on the tube before connecting the
tube to the end.

2
1 IDAS003B

4 CLAMP TORQUE ON RETIGHTENING

3 WIDTH NEW HOSE TORQUE
7.9 mm 0.9 ± 0.2 N i m 0.7 ± 0.2 N i m
(.312 in) 8 ± 2 lb i in 6 ± 2 lb i in
5
13.5 mm 4.5 ± 0.5 N i m 3.0 ± 0.5 N i m
(.531 in) 40 ± 5 lb i in 25 ± 5 lb i in
IDAS002B 6 15.9 mm 7.5 ± 0.5 N i m 4.5 ± 0.5 N i m
ELBOW BODY ASSEMBLY (.625 in) 65 ± 5 lb i in 40 ± 5 lb i in
(1) End of fitting body (connects to tube). (2) Fitting body.
(3) Lock-nut. (4) Backup washer. (5) O-ring seal. (6) End of fitting
that goes into other part.

4 of 7
37û FLARED AND STRAIGHT THREAD O-RING FITTINGS

37û FLARED O-RING SWIVEL NUTS

FITTING-PLUG
IDAS004B

37û FLARED AND STRAIGHT THREAD O-RING FITTINGS

(EXCEPT O-RING FACE SEAL FITTINGS)

TIGHTENING OTHER FITTINGS

Hi Duty (Shear sleeve) Tube Fittings
After tube has been put through the nut and makes
contact against the tube shoulder in the fitting body,
turn the nut with a wrench until a small decrease in
torque is felt. This is an indication that the sleeve has
been broken off the nut. Hold the tube to prevent IDAS005B
turning and tighten the nut 1-1/2 turns.

Hi Seal Fittings
Put nut and sleeve over the tubing with the short
heavy end of the sleeve facing the end of tubing. Put
the tube end against the counterbore in the body of
the fitting and tighten until nut is over the last thread IDAS006B
on the body. The remainder of space is used
whenever the fitting is removed and installed again.

5 of 7
45û FLARED AND 45û INVERTED FLARE FITTINGS

INVERTED
45û FLARED 45û FLARED
IDAS007B

45û FLARED AND 45û INVERTED FLARE FITTINGS

TIGHTENING OTHER FITTINGS

Ermeto Tube Fittings
Put nut and sleeve over the tube with head or
shoulder end of sleeve next to nut. Push tube into
counterbore of fitting body as far as possible. Turn
nut clockwise until sleeve holds tube and prevents
movement. Tighten the nut 1-1/4 turns more to seat IDAS008B
sleeve and give a locking action. When necessary to
assemble again, put sleeve over tube and tighten nut
until a sudden increase in torque is felt. Then tighten
1/6 to 1/3 turn more to seat the sleeve.

Flex Fittings
Put nut and sleeve over the tubing and push tube in
to counterbore of fitting body as far as possible.
Tighten the nut until it is against the hex part of the
fitting body.
IDAS009B

6 of 7
AIR CONDITIONING AND TAPERED PIPE THREAD FITTINGS

O-RING 45û FLARE

IDAS010B

AIR CONDITIONING FITTINGS

O-RING FITTING END 45û FLARE FITTING END
STEEL TUBES ALUMINUM TUBES
THREAD
SIZE STANDARD TORQUE STANDARD TORQUE STANDARD TORQUE
inch N im (lb i ft) N im (lb i ft) N im (lb i ft)
5/8-18 18 ±4 13 ± 3 30 ± 3 22 ± 2 23 ± 3 17 ± 2
3/4-16 37 ±4 27 ± 3 52 ± 5 38 ± 4 33 ± 4 24 ± 3
7/8-14 40 ±4 30 ± 3 60 ± 7 44 ± 5 38 ± 4 28 ± 3
1 1/16-14 45 ±5 33 ± 4 75 ± 8 55 ± 6 50 ± 5 37 ± 4

TAPERED PIPE THREAD FITTINGS

STANDARD TORQUE
PIPE
THREAD THREADS WITH THREADS WITHOUT
SIZE 1E2200E SEALANT SEALANT
inch Nim (lb i ft) Nim (lb i ft)
1/16-27 15 11 20 15
1/8-27 20 15 25 18
1/4-18 25 18 35 26
3/8-18 35 26 45 33
1/2-14 45 33 60 45
3/4-14 60 45 75 55
1-11 1/2 75 55 90 65
1 1/4-11 1/2 95 70 110 80
1 1/2-11 1/2 110 80 130 95
2-11 1/2 130 95 160 120

7 of 7
SB4261E00
May. 2007

Service Manual
DELCO REMY KOREA Ltd.
HC45 Series Alternators
Important Safety Information

Most accidents involving product operation, maintenance and repair are caused by failure to observe basic
safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations
before an accident occurs. A person must be alert to potential hazards. This person should also have the
necessary training, skills and tools to perform these functions properly.

Read and understand all safety precautions and warnings before operating or performing lubrication,
maintenance and repair on this product.

Basic safety precautions are listed in the “Safety“ section of the Service or Technical Manual. Additional safety
precautions are listed in the “Safety“ section of the owner/operation/maintenance publication.
Specific safety warnings for all these publications are provided in the description of operations where hazards
exist. WARNING labels have also been put on the product to provide instructions and to identify specific
hazards. If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons.
Warnings in this publication and on the product labels are identified by the following symbol.

WARNING

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read
and understood the operation, lubrication, maintenance and repair information.

Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.

DOOSAN cannot anticipate every possible circumstance that might involve a potential hazard. The warnings
in this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or
operating technique not specifically recommended by DOOSAN is used, you must satisfy yourself that it is
safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the
operation, lubrication, maintenance or repair procedures you choose.

The information, specifications, and illustrations in this publication are on the basis of information available at
the time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and
other items can change at any time. These changes can affect the service given to the product. Obtain the
complete and most current information before starting any job. DOOSAN dealers have the most current
information available.

1
Index

Specifications

Alternator............................................................... 5

Systems Operation

Alternator............................................................... 6
Introduction..................................................... 6
HC45 Alternator Operation.............................. 6
Alternator Components ............................ 7
Alternator Operation Schematic ............... 9

Testing And Adjusting

Troubleshooting....................................................10
Troubleshooting Problem List.........................10
Troubleshooting Problems .............................10
Alternator..............................................................11
Alternator Output Test....................................11
Machine Test ..........................................11

Alternators 3 Index
Specifications
Alternator

D.R.K. ALTERNATOR COVERAGE CHART

DOOSAN D.R.K. Series Voltage
Part No. Part No.
A134153 390104-8 HC45 24V

HC45 Alternator End View

ALTERNATOR SPECIFICATIONS
DOOSAN Part No. A134153
D.R.K. HC45
Voltage Rating 24V
Polarity Neg. Gnd.
Rotation CW
Test Speed 5000 rpm
Rated Output (Cold) 45A
Output Voltage 28.5 ± 0.4V
Rotor Field Winding Resistance
-
[At 27°C(80°F)]
Field Current [At 14.0V or
-
27.5V and 27°C(80°F)]
Stator Winding Resistance -
Turn On Speed (Max.) -
Slip Rings :
-
Maximum Runout (TIR)
HC45 Alternator Cross-Sectional View
Minimum Diameter -
Brush Length (Measured On
-
Longest Side) : New
Minimum
80~110 N·m
Pulley Nut (2) Torque
(60~82 .5 lb·ft)
Thru Bolt (1) Torque -
8.0 N·m max
Terminal Torques : Bat
(6 lb·ft max)
Gnd -

Service Manual 5 Specifications

Systems Operation The alternator converts mechanical and magnetic
energy to alternating current (AC) and voltage. This
process is done by rotating a direct current (DC)
Alternator
electromagnetic field (rotor) inside a three phase
stator. The alternating current and voltage
Introduction (generated by the stator) are changed to direct
current by a three phase, full wave rectifier system
The HC45 Alternators have three phase, full-wave, using six silicone rectifier diodes. This circuit
rectified output. produces the sine wave signals through P terminal.
The Tachometer is operated by this signal. This
alternator have a diode trio.
HC45 Alternator Operation
A solid state regulator is installed in the back of the
alternator. Two brushes conduct current through two
slip rings to the field coil on the rotor.

There is also a capacitor mounted in the back of the

alternator. The capacitor protects the rectifier from
high voltages. It also suppresses electrical noise
through a radio, if equipped.

The alternator is connected to the battery through

terminal “L” and the ignition or key start switch for
alternator turn-on. Therefore, alternator excitation
HC45 Alternator occurs when the switch is turned on.

The alternator is an electrical and mechanical

component driven by belt rotation from the engine.

It is used to charge the storage battery during

engine operation. This alternator is cooled by two
fans that are a part of the alternator. The external
fan is mounted behind the pulley. The fan pulls air
through holes in the back of the alternator. The air
exits the front of the alternator, cooling it in the
process.

The internal fan is mounted on the rotor. This fan

pulls air through the holes in the back of the
alternator to cool the rectifier bridge and regulator.
The air exits the front of the alternator.

Service Manual 6 Systems Operation

Alternator Components The major components of the alternator are stator
(4), rotor (3), rectifier (10), regulator (9), brush holder
(7) and frames (2) and (5). The HC45 alternators
feature a high ampere output per pound of weight,
with a totally new and different regulator. A wye
wound stator, rectifier bridge, rotor with slip rings
and brushes are electrically similar to the CS-121
series alternators. The HC stands for heavy duty
charging system. The 45 denotes the output (A) of
the alternators. This series of alternators has two
fans for cooling the alternator.

Alternator Components-Cross-Sectional View

(1) Slip rings. (2) Rear frame. (3) Rotor. (4) Stator.
(5) Drive end frame. (6) External fan. (7) Brush holder.
(8) Internal fan.

Stator
(4) Stator.

Stator (4) consists of a stator core and coils. As the

rotor turns, its varying magnetic field causes the
stator coil to produce three phase alternating current
(AC).

Alternator Components-Inside View of Rear Frame

(2) Rear frame. (7) Brush holder. (9) Regulator.
(10) Rectifier.

Service Manual 7 Systems Operation

Rotor
(1) Slip rings. (3) Rotor. (8) Internal fan.

Rotor (3) consists of a core, coils and slip rings (1).

The rotor provides the magnetic field between the
rotor field winding and the stator. Slip rings (1)
provide the surfaces for brush contact. Internal fan
(8) pulls air through the rear frame to cool the Rectifier
rectifier bridge and regulator. (10) Rectifier.

Rectifier (10) contains three positive (+) and three

negative (-) diodes to form the full wave rectifier
bridge which is connected to the stator. Rectifier
(10) changes or rectifies three phase AC to DC.

Brush Holder
(7) Brush holder. (11) Brushes. (12) Spring.

Brush holder (7) contains two brushes (11). They

contact the two rotating slip rings on the rotor.
Current flows to the rotor coil through the brushes
and slip rings. There is one positive (+) and one Regulator
negative (-) brush. The brush material is copper (9) Regulator.

graphite.
Regulator (9) controls alternator output. Most
regulators limit the alternator voltage to a preset
value by controlling the field current. It operates
electronically to alternately "turn off" and "turn on"
the voltage across the field winding. By varying the
on-off time, the correct average field current for
proper system voltage control is obtained. The
regulator is mounted in the back of the alternator.

Service Manual 8 Systems Operation

Alternator Operation Schematic On some models, a resistor is used in parallel with
the indicator lamp. This feature insures alternator
The integral charging system schematic and turn-on in the event the lamp burns out. The zener
explanation that follow indicate the terminals and diodes in the rectifier bridge protect the system
basic circuitry for the HC45 series alternator. against high voltages in the stator.

Most regulators are temperature compensated to

provide the maximum voltage needed for battery
charging. As the temperature increases, the voltage
setting will decrease. Under cold weather conditions,
the regulator will operate at a higher voltage setting
to provide the higher voltage required by the battery
for charging under these conditions.

HC45 Integral Charging System Schematic

When the switch is closed, the indicator lamp turns

on and a voltage is applied to the regulator at the "L"
terminal to cause transistor to rapidly "turn on" and
"turn off". The battery will supply field current which
will flow into “L” terminal or Bat terminal and then
through transistor and the field coil to ground.

The field current is sufficient to cause the alternator

to turn on when the engine is started. At engine idle
speeds, voltage induced in the stator will cause the
stator to supply field current and also output voltage
and current at the Bat terminal for the vehicle
electrical system.

Service Manual 9 Systems Operation

Testing And Adjusting Troubleshooting Problems

Troubleshooting Problem 1 : Alternator Does Not Charge

Probable Cause:

Troubleshooting can be difficult. On the page that

1. Loose Drive Belt For Alternator :
follows is a list of possible problems. To make a
Adjust the alternator drive belt.
repair to a problem, make reference to the probable
cause.
2. Loose Alternator Drive Pulley :
Check the pulley for wear. If it is worn, install a
This list of problems and probable causes will only
new pulley. Tighten the pulley nut to the correct
give an indication of where a possible problem can
torque shown in Specifications.
be and what repairs are needed. Sometimes more
or other repair work is needed beyond the
3. Charging or Ground Return Circuit or Battery
recommendations in the list. Remember that a
Connection Are Defective:
problem is not normally caused by one part, but by
Inspect all cables and connections. Clean and
the relation of one part with other parts. This list
tighten all connections. Replace defective parts.
cannot give all possible problems and probable
causes. The serviceman must find the problem and
4. Rotor Field Winding or Regulator Is Defective:
its source, then make the necessary repairs.
Install a new rotor or regulator.

NOTE : The HC45 alternator is only serviced as a

Problem 2 : Alternator Charge Rate Is Low Or
complete unit. If the alternator has any internal
Not Regular
problems, the alternator must be replaced.
Probable Cause:

1. Loose Drive Belt For Alternator:

Troubleshooting Problem List
Adjust the alternator drive belt.

1. Alternator Does Not Charge. 2. Loose Alternator Drive Pulley:

Check the pulley for wear. If it is worn, install a
2. Alternator Charge Rate is Low or Not Regular. new pulley. Tighten the pulley nut to the correct
torque shown in Specifications.
3. Alternator Charges Too Much.
3. Charging or Ground Return Circuit or Battery
4. Alternator is Noisy. Connections Defective:
Inspect all cables and connections. Clean and
tighten all connections. Replace defective parts.

4. Regulator Is Defective:
Replace the regulator.

5. Rectifier Is Defective:
Replace the rectifier.

6. Brushes Are Worn Or Dirty:

Install a new brush.

Service Manual 10 Testing And Adjusting

Problem 3 : Alternator Charges Too Much Machine Test
Probable Cause:
1. Put the multimeter positive (+) lead on the Bat
1. Alternator or Regulator Has Loose Connections: terminal of the alternator. Put the negative (-) lead
Tighten all connections to alternator or regulator. on the ground terminal or the frame of the
alternator. Put the clamp-on ammeter around the
2. Regulator Is Defective: positive output wire of the alternator.
Install a new regulator.
2. Turn off all electrical accessories. With the fuel off,
Problem 4 : Alternator Is Noisy crank the engine for 30 seconds. Wait two
Probable Cause: minutes to let the starter cool. If the system
appears to be up to specifications, crank the
1. Drive Belt For Alternator Is Worn or Defective: engine again for 30 seconds.
Install a new drive belt for the alternator.
NOTE : Cranking the engine for 30 seconds partially
2. Loose Alternator Drive Pulley: discharges the batteries in order to do a charging
Check the pulley for wear. If it is worn, install a test. If the battery is already low in charge, skip this
new pulley. Tighten the pulley nut to the correct step. Jump-start engine or charge as required.
torque shown in Specifications.
3. Start the engine and run at approximately 1/2
3. Drive Belt And Drive Pulley For Alternator Are Not throttle.
In Alignment:
Make an adjustment to put the drive belt and 4. Immediately check output current. This initial
drive pulley in correct alignment. charging current should be equal to or greater
than the full output current shown below:
4. Alternator Bearings Are Worn:
Install new bearings in the alternator. 5. Within approximately 10 minutes at 1/2 throttle
(possible longer, depending upon battery size,
condition and alternator rating), the alternator
output voltage should be as follows to indicate the
alternator is performing within spec. See the Fault
Alternator Conditions And Possible Causes Chart.
Alternator Output Test 24V System.................................... 28.5 ± 0.4V

NOTE : If the HC45 alternator fails this test, it must 6. The charging current during this period should
be replaced. It is only serviced as a complete unit. taper off the less than approximately 10 Amps,
depending again upon battery and alternator
Tools Needed capacities. See the Fault Conditions And Possible
Digital Multimeter or Equivalent 1 Causes Chart.
AC/DC Clamp-On Ammeter 1

Service Manual 11 Testing And Adjusting

FAULT CONDITIONS AND POSSIBLE CAUSES CHART
Current At Voltage After About Voltage After About Voltage After About
Start-Up 10 Min. Is Below Spec. 10 Min. Is In Spec. 10 Min. Is Above Spec.
Below Specification. alternator (Defective Turn on all accessories. If
regulator, open stator voltage drops below spec.,
phase, and/or rectifier). repair alternator (Open -
Check ignition or key rectifier and/or stator phase).
start switch circuit.*
Reached Specification Repair alternator Alternator and battery in Repair alternator
and then tapered off. (Defective regulator). spec. Turn on all (Shorted regulator).
accessories to verify.
Voltage must stay in spec.
Exceeds Specification Check battery. Alternator in spec. Repair alternator
and stays high. Check battery. (Shorted regulator).
Also check battery for
possible damage.

* Some models that have the HC45 alternator do not have a resistor in the ignition of key start switch circuit, if the indicator lamp
is burned out, the alternator cannot turn on. Also, if a machine is jump started because the battery is too low, the alternator may
not have any output. This is because the battery may be too low to send current to the alternator. The alternator needs current to
start the charging process.

Service Manual 12 Testing And Adjusting

SB4262E00
May. 2007

Service Manual
Poong Sung R4.5
Reduction Starting Motor
Important Safety Information

Read and understand all safety precautions and warnings before operating or performing lubrication,
maintenance and repair on this product.

Basic safety precautions are listed in the “Safety” section of the Service or Technical Manual. Additional safety
precautions are listed in the “Safety” section of the owner/operation/maintenance publication.
Specific safety warnings for all these publications are provided in the description of operations where hazards
exist. WARNING labels have also been put on the product to provide instructions and to identify specific
hazards. If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons.
Warnings in this publication and on the product labels are identified by the following symbol.

WARNING

Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.

1
Index

Specification
Starting Motor ...................................................... 5

Systems Operation
Starting Motor ...................................................... 7
Introduction....................................................... 7
Starting Motor Operation Diagrams..................10

Testing And Adjusting

Troubleshooting ..................................................13
Troubleshooting Problem List...........................13
Troubleshooting Problems ...............................13

Starting Motor .....................................................14

On Machine Starting Motor Diagnosis Procedure
........................................................................14
Off Machine No Load Test ...............................17
Starting Motor Component Tests......................18

Disassembly And Assembly

Starting Motor .....................................................23
Disassemble Starting Motor .............................23
Assemble Starting Motor..................................26

Service Manual 3 Index

Specification
Starting Motor

Service Manual 5 Specification

REDUCTION STARTING MOTOR SPECIFICATIONS
Starting Motor Series R4.5
Rated Voltage 24 V
Solenoid (Switch):
0.86 Ω
Pull-In Winding Resistance
Hold-In Winding Resistance 2.88 Ω
Pull-In Winding Current Draw at 24V 45 A
Hold-In Winding Current Draw at 24V 15 A
No Load Test:
24 V
Minimum Voltage
Minimum Speed 3500 rpm
Maximum Current Draw 90 A
Load Test:
18.5 V
Minimum Voltage
Minimum Speed 1080 rpm
Maximum Current Draw 450 A
Commutator(1)
36 mm (1.42 in)
New Diameter
Minimum Diameter 35 mm (1.38 in)
Minimum Mica Depth 0.2 mm (0.008 in)
Maximum TIR 0.05 mm (0.002 in)
Brush (3) Length:
19.5 mm (0.77 in)
New Length
Minimum Length 13 mm (0.51 in)
Torques:
17.6 to 24.5 N•m (157 to 218 lb•in)
Battery (Bat) Terminal (4)
Ground (G) Terminal –
Switch (S) Terminal (6) 1.7 ± 0.25 N•m (15 ± 2 lb•in)
Motor (Mtr) Terminal (8) 17.6 to 24.5 N•m (157 to 218 lb•in)
Through Bolts (2) 6.9 to 11.8 N•m (61 to 105 lb•in)
Bolts (7) 6.9 to 11.8 N•m (61 to 105 lb•in)
Screws (5) 2.6 to 4.6 N•m (23 to 41 lb•in)

Service Manual 6 Specification

Systems Operation
Starting Motor
Introduction
The Poong Sung Reduction Starting Motor is a
medium duty unit that is offered in 24 Volt versions.

Poong Sung Starting Motor

The starting Motor is used to turn the engine

flywheel fast enough to make the engine run. The
starting motor has a solenoid. When the ignition or
key start switch is activated, electricity from the
electrical system will cause the solenoid to move the
pinion toward the flywheel ring gear of the engine.
The electrical contacts in the solenoid close the
circuit between the battery and starting motor just
before the pinion engages the ring gear. This
causes the starting motor to rotate. This type of
motor "turn on" is a positive shift starting motor.

When the engine begins to run, the overrunning

clutch prevents damage to the armature caused by
excessive speeds. The clutch does this by breaking
the mechanical connection. The pinion will stay
meshed with the ring gear however, until the ignition
or key start switch is released. A return spring in the
overrunning clutch returns the clutch to its rest
position.

Service Manual 7 Systems Operation

Starting Motor Components

(1) Housing. (2) Armature. (3) Brushes. (4) Brush holder. (5) Starting motor case. (6) Frame. (7) Idler reduction gear.
(8) Overrunning clutch gear. (9) Field winding. (10) Pinion gear. (11) Overrunning clutch. (12) Solenoid (switch).

The major components of the starting motor are

case (5), field winding (9), armature (2), brushes (3),
brush holder (4), gears (7) and (8), pinion gear (10),
overrunning clutch (11) and solenoid (switch) (12).

The reduction starting motor operates a little

differently than the conventional starting motor.
Solenoid (12), overrunning clutch (11) and pinion
gear (10) are mounted below armature (2) and field
winding (9). When the starting motor is activated,
armature reduction gear will turn clockwise. Idler
reduction gear (7) will turn counterclockwise and
overrunning clutch gear (8) with pinion gear (10) will
turn clockwise. In the reduction starting motor, the
armature speed is reduced by about one-fourth to Field Winding And Starting Motor Case
one-third speed of pinion gear (10) by reduction (5) Starting motor case. (9) Field winding.
gears (7) and (8).
Starting motor case (5) supports field winding (9),
the brush holder and brushes. The two positive (+)
brushes are welded to the field winding leads. Field
winding (9) provides the magnetic field for the
armature.

Service Manual 8 Systems Operation

Brushes (3) are made of carbon and conduct
electricity. The brushes transmit current from the
field winding to the commutator. There are four
brushes. Two of the brushes are positive (+) and are
welded to the field winding leads. Two of the
brushes are negative and are connected to case
ground.

Armature
(2) Armature.

Armature (2) consists of a laminated iron core which

is assembled on the armature shaft. The armature
also has a commutator on one end which is make of
copper segments (bars) insulated from each other
and the armature shaft. The armature windings are Overrunning Clutch Components
wound in the slots of the core and connected to the (8) Overrunning clutch gear. (10) Pinion gear.
commutator segments. (11) Overrunning clutch.

The armature is positioned in the field winding and is

supported by bearings in the starting motor case. Overrunning clutch consists of pinion gear (10),
The armature and field winding are connected in overrunning clutch gear (8) and ball bearings. The
series so the same current flows through both of one way outer-roller type clutch works the same way
them, generating high torque especially when the as the one used in the conventional starting motor.
motor is first started. Due to the screw splines cut on the pinion shaft, the
pinion gear advances while in rotation, instead of
using a shift lever to move the pinion.

As the engine starts to run, its speed eventually

exceeds the starting motor speed. Overrunning
clutch (11) protects the starting motor from this
overspeed condition by disengaging the mechanical
connection between the engine flywheel and starting
motor.
Pinion gear (10) engages the flywheel ring gear. In
case of butt engagement the pinion gear will stop.
As a result, the overrunning clutch spring is
compressed until the solenoid contacts meet the
solenoid terminals. The starting motor is now turned
on which turns the pinion gear until it meshes with
the ring gear to turn the engine.
Brush Holder
(3) Brushes. (4) Brush holder. (13) Brush springs.

Brush holder (4) is mounted over the commutator to

the starting motor case. Four brushes are held
against the commutator. Brush springs (13) keep
pressure on the brushes so they stay in contact with
the commutator.

Service Manual 9 Systems Operation

General Information

Solenoid (Switch)
(12) Solenoid. (17) Solenoid contacts. (18) Hold-in coil.
(19) Pull-in coil. (20) Return spring. (21) Plunger.

Solenoid (12) contains solenoid contacts (17), hold-

in coil (18), pull-in coil (19), return spring (20) and
plunger (21). When the ignition or key start switch is
closed, pull-in coil (19) and hold-in coil (18) are
energized. This moves plunger (21), which in turn,
moves the pinion. When solenoid contacts (17)
close, full battery current is sent to the motor and the Rest Position
engine begins to crank. (1) Armature reduction gear. (2) Armature. (3) Field winding.
(4) Brushes. (5) Idler reduction gear.
(6) Overrunning clutch gear. (7) Pinion.
When the engine starts, the overrunning clutch
(8) Overrunning clutch. (9) Solenoid contacts. (10)Plunger.
protects the armature from excessive speed until the
(11) Return spring. (12) Hold-in winding. (13) Solenoid.
ignition or key start switch is released. After the (14) Pull-in winding. (15) lgnition or key start switch.
switch is released, return spring (20) moves over to (16) Battery.
disengage the pinion.

A DC Series wound motor is used as the starting

motor. It has field (3) and armature (2) windings.
Starting Motor Operation Diagrams The excitation and armature windings are connected
in series. The armature drives overrunning clutch (8)
NOTE: The brushes location on the diagrams that through gears (1), (5) and (6). The clutch end of
follow are at the back of the armature. On some solenoid (13) has splines for overrunning clutch (8).
starting motors, the brushes are at the front of the
armature. The electrical operation of the motor is the The solenoid is an integral part of the starting motor.
same for all motors. It pushes overrunning clutch (8) with pinion (7)
toward the flywheel ring gear. The end of plunger
(10) is a spool which is connected to the
overrunning clutch through splines. Return spring
(11) helps return the overrunning clutch to its rest
position after ignition or key start switch (15) is
released and solenoid contacts (9) are opened.

Overrunning clutch (8) protects armature (2) from an

overspeed condition. The clutch also allows a
smooth engagement of pinion (7) into the flywheel
ring gear. The overrunning clutch is held on the
splines of solenoid. The speed of pinion (7) is about
one-fourth to one-third of the armature speed due to
the reduction gears.

Service Manual 10 Systems Operation

Operation

Solenoid Contacts Closed

(1) Armature reduction gear. (2) Armature. (3) Field winding.
Ignition Or Key Start Switch Closed (4) Brushes. (5) Idler reduction gear.
(1) Armature reduction gear. (2) Armature. (3) Field winding. (6) Overrunning clutch gear. (7) Pinion.
(4) Brushes. (5) Idler reduction gear. (8) Overrunning clutch. (9) Solenoid contacts. (10) Plunger.
(6) Overrunning clutch gear. (7) Pinion. (11) Return spring. (12) Hold-in winding. (13) Solenoid.
(8) Overrunning clutch. (9) Solenoid contacts. (10) Plunger. (15) Ignition or key start switch. (16) Battery.
(11) Return spring. (12) Hold-in winding. (13) Solenoid.
(14) Pull-in winding. (15) Ignition or key start switch.
(16) Battery. When plunger (10) is pulled to the left, solenoid
contacts (9) close. At this point, pinion (7) is just
about to mesh with the flywheel ring gear. When this
When switch (15) is closed, battery current will flow happens, pull-in winding (14) is shorted which
in two directions. Current flows from battery (16) to causes current to flow through solenoid contacts (9)
switch (15). It then flows through pull-in winding (14), to field winding (3), armature (2), brushes (4) to
field winding (3), armature (2), brushes (4) and then ground. Current still flows through hold-in winding
to ground. Current also flows through hold-in (12) to ground. The starting motor is turned ON, the
winding (12) to ground. pinion engages the flywheel ring gear and the
engine begins to crank.
The activation of pull-in winding (14) and hold-in
winding (12) produces a magnetic force, which in At this time the plunger is kept in the pull-in position
turn pulls plunger (10) to the left. This moves clutch only by the magnetic force of hold-in winding (12).
(8) and pinion (7) toward the flywheel ring gear.

Service Manual 11 Systems Operation

Ignition Or Key Start Switch Released
(1) Armature reduction gear. (2) Armature. (3) Field winding.
(4) Brushes. (5) Idler reduction gear.
(6) Overrunning clutch gear. (7) Pinion.
(8) Overrunning clutch. (9) Solenoid contacts.
(10) Plunger. (11) Return spring. (12) Hold-in winding.
(13) Solenoid. (14) Pull-in winding.
(15) Ignition or key start switch. (16) Battery.

As soon as the engine starts, the flywheel ring gear

turns pinion (7) faster than the starting motor.
Overrunning clutch (8) breaks the mechanical
connection between the clutch and the starting
motor. When switch (15) is released, current now
flows through both hold-in winding (12) and pull-in
winding (14) in the same direction. This causes the
hold-in winding magnetic force to be reduced.
Solenoid contacts (9) are opened. Plunger (10) and
overrunning clutch (8) are pulled back to their
original position by the force of return spring (11).
The rotating armature stops. The motor is now
turned OFF.

Service Manual 12 Systems Operation

Testing And Adjusting 5. Solenoid windings disconnected or short circuited:
Replace the solenoid (switch).

Troubleshooting 6. Ignition or key start switch or solenoid or relay (if

equipped) damaged:
Troubleshooting can be difficult. Following is a list of Replace ignition or key start switch or solenoid or
possible problems. To make a repair to a problem, relay as needed.
refer to the probable cause.
7. Excessive voltage drop in cables or damaged
This list of problems and probable causes will only cables or loose cable connections or corroded
give an indication of where a possible problem can terminal connections:
be and what repairs are needed. Sometimes more Check starting motor cables and their
or other repair work is needed beyond the connections.
recommendations in the list. Remember that a
problem is not normally caused by one part, but by 8. Brushes worn or shorted:
the relation of one part with other parts. This list Replace the brush holder and/or starting motor
cannot give all possible problems and probable case.
causes. The serviceman must find the problem and
its source, then make the necessary repairs. 9. Commutator is worn:
Undercut the mica.

Troubleshooting Problem List 10. Field winding shorted or grounded:

Replace the starting motor case.
1. Starting motor does not turn or turns too slow.
11. Armature winding shorted or grounded:
2. Armature turns, but pinion does not engage
Replace the armature.
flywheel ring gear.
12. Not enough brush spring tension:
3. Armature turns, and pinion engages ring gear, but
Check brush spring tension. Replace the springs
engine does not crank.
if necessary.
4. Starting motor continues to run after ignition or
13. Poor contact between solenoid and field
key start switch has been released.
winding:
Repair connections.
5. Pinion does not disengage after engine starts to
run.
14. Armature contacts field winding because of worn
bearing or bent armature:
Replace the bearing or armature.
Troubleshooting Problems
15. Overrunning clutch is defective:
Problem 1: Starting motor does not turn or turns Replace the overrunning clutch.
too slow.
Probable Cause: Problem 2: Armature turns, but pinion does not
1. Battery is discharged: engage flywheel ring gear.
Charge battery. Probable Cause:
2. Battery is defective: 1. Overrunning clutch is defective or pinion teeth are
Replace Battery. worn:
Replace the overrunning clutch.
3. Battery cable terminals loose, corroded or poor
ground connection: 2. Overrunning clutch does move freely on splines of
Tighten cable terminals, clean terminals and the solenoid:
battery posts if corroded and apply anti-acid Remove dirt and foreign material on the solenoid
grease. splines.

4. Solenoid contacts burnt or worn out: 3. Damaged flywheel ring gear:

Replace the solenoid (switch). Replace flywheel ring gear.

Service Manual 13 Testing And Adjusting

4. Damaged or broken solenoid: Starting Motor
Replace solenoid.
On Machine Starting Motor Diagnosis
5. Damaged or broken armature or idler or clutch
gear: Procedure
Replace armature or idler gear or overrunning
clutch as needed. The following is a simplified procedure intended to
help the serviceman to determine if a starting motor
needs to be removed and replaced or repaired. It is
Problem 3: Armature turns and pinion engages not intended to cover all possible problems and
ring gear, but engine does not crank. conditions, but to serve only as a guide.
Probable Cause:

1. Low battery:
Charge battery.

2. Not enough brush spring tension:

Check brush spring tension. Replace the springs
if necessary.

3. Relay mounted away from starting motor (if

equipped) is defective:
Replace relay.

4. Excessive voltage drop in cables:

Check cables and their connections.

5. Overrunning clutch slips:

Replace overrunning clutch.

Problem 4: Starting motor continues to run after

ignition or key start switch has been released.
Probable Cause:

1. Defective ignition or key start switch or solenoid

or relay.
Replace ignition or key start switch or solenoid or
relay as needed.

Problem 5: Pinion does not disengage after

engine starts to run.
Probable Cause:

1. Solenoid return spring is weak or broken:

Replace solenoid.

2. Defective ignition or key start switch or relay:

Replace ignition or key start switch or relay.

Service Manual 14 Testing And Adjusting

Typical Starting Circuit
(1) Test point. (2) Test point. (3) Test point. (4) Test point. (5) Test point. (W) Pull-in coil. (X) Hold-in coil.

General Information
All starting systems are made up of four elements. The starting motor solenoid has two coils. Pull-in coil
They are the ignition or key start switch, start relay, (W) draws about 40 amps and hold-in coil (X)
the starting motor solenoid and starting motor. The requires about 5 amps. The instant the start relay
only exception to this is that on some small engines closes, both coils (W) and (X) receive power. Battery
the start relay may not be required. In this case, the voltage is applied to the high end of both coils and at
start switch powers the starting motor solenoid test point (3) which is the start (S) terminal. The low
directly. end of hold-in coil (X) is permanently grounded to
the ground post of the starting motor. Grounding for
Start switches are relatively low current devices. the low end, test point (4), of pull-in coil (W) is
They are rated to switch approximately 5 to 20 amps. momentary, and takes place through the DC
Because the coil of a start relay [between test point resistance of the starting motor. As soon as
(1) and (2)] draws about 1 amp, the start switch can magnetic force builds in both coils, the pinion moves
easily turn on the start relay and have long life. toward the flywheel ring gear. The pinion will stop
short of engaging the flywheel ring gear. Only then
The switch contacts of a typical start relay are rated will the solenoid contacts close to power the starting
to switch between 100 and 300 amps. motor. This temporarily removes the ground from
pull-coil (W), and puts battery voltage on both ends
Because a solenoid requires 5 to 50 amps, the start of it while the motor cranks. During this period, the
relay can easily switch this load. pull-in coil is out of the circuit. Cranking continues
until power to the solenoid is broken by releasing the
The starting motor solenoid has two functions: 1) it ignition or key start switch.
engages the pinion with the flywheel, and 2) it is a
high current switch rated about 1000 amps that The purpose of these switches and relays is to
actually turns on the starting motor. permit a 5 amp dash-mounted switch to turn on a
500 to 1000 amp motor used to crank an engine.

Service Manual 15 Testing And Adjusting

Battery voltage (power) available during cranking If the starting motor cranks real slow or not at all, do
varies according to the temperature of the batteries. the following procedure:
The following chart is a guide as to what to expect
from a normal system. 1. Measure battery voltage at the battery posts with
the multimeter while cranking or attempting to
TYPICAL SYSTEM VOLTAGE DURING CRANKING crank the engine. Make sure to measure the
AT VARIOUS AMBIENT TEMPERATURES battery posts. Do not measure on the cable post
Temperature 24V System 12V System clamps.

-23 to -7°C (-10 to 20°F) 12 to 16 Volts 6 to 8 Volts 2. Is battery voltage equal to or greater than shown
-7 to 10°C (20 to 50°F) 14 to 18 Volts 7 to 9 Volts in Figure 1?

10 to 27°C (50 to 80°F) 16 to 20 Volts 8 to 10 Volts a. If the battery voltage is OK, go to Step 3.
Figure 1
NOTE: Low batteries can be caused by battery
The next chart shows maximum acceptable voltage condition or a shorted starter.
loss in the high current battery circuit feeding the
starting motor. These values are maximums for 3. Measure current draw on the (+) battery cable
machines of approximately 2000 SMH and up. between the battery and the starting motor
Newer machines would be less than those shown. solenoid with the clamp-on ammeter. The
maximum current draw and minimum voltage
allowed are shown in Specifications under Load
MAXIMUM ACCEPTABLE SYSTEM VOLTAGE Test.
DROPS DURING CRANKING
The figures shown in Specifications are taken at a
Circuit 24V System 12V System temperature of 27°C (80°F). At temperatures below
27°C (80°F), the voltage will be less and the current
Battery (-) post to starting
1.4 Volts 0.7 Volts draw will be higher. If current draw is too much, the
motor (-) terminal
starting motor has a problem and must be removed
Battery (+) post to
1.0 Volts 0.5 Volts
for repair or replacement.
solenoid (+) terminal
Solenoid Bat terminal to NOTE: If voltage at the battery post is within
0.8 Volts 0.4 Volts approximately 2 volts of the lowest value in the
solenoid Mtr terminal
Figure 2 applicable temperature range of Figure 1 and if the
large starting motor cables get hot, then the starting
Voltages greater than those shown are most often motor has problem and the Ammeter is not needed.
caused by loose and/or corroded connections or
defective switch contacts. 4. Measure starting motor voltage from test point (4)
to (5) with the multimeter while cranking or
attempting to crank the engine.
Diagnosis Procedure
5. Is voltage equal to or greater than shown in
Figure 1?
Tools Needed
a. If the starting motor voltage is OK, the batteries
Digital Multimeter or Equivalent 1
and starting motor cables down to the motor
AC/DC Clamp-On Ammeter or Equivalent 1 are within specifications, Go to Step 8.

b. If the starting motor voltage is low, the voltage

NOTICE drop between the batteries and the starting
Do not operate the starting motor for more than 30 motor is too great. Go to Step 6.
seconds at a time. After 30 seconds, the cranking
must be stopped for two minutes to allow the 6. Measure the voltage drops in the cranking circuits
starting motor to cool. This will prevent damage to with the multimeter. Compare the results with
the starting motor due to excessive heat buildup. maximum voltage drops allowed in Figure 2.

Service Manual 16 Testing And Adjusting

7. Are all the voltages within specifications?

a. If the voltage drops are OK, go to Step 8, to

check the engine.

b. If the voltage drops are too high, repair and/or

replace the faulty electrical component.

8. Turn the engine over by hand to make sure it is

not locked up. Check oil viscosity and any
external loads that would affect engine rotation.

9. Is the engine locked up and/or hard to turn?

a. If it is, repair the engine as required.

b. If the engine is not hard to turn over, go to Step

10.

10. Does the starting motor crank?

a. If it does crank, remove the starting motor for

repair and/or replacement.
No Load Test Diagram
b. If it does not crank, check for blocked
engagement of the pinion and flywheel ring 1. Connect fully charged 12 volt batteries to the
gear. starting motor as shown. Connect the (+) battery
cable to the Bat terminal of the starting motor
NOTE: Blocked engagement and open solenoid solenoid. Connect the (-) battery cable to the
contacts will give the same electrical symptoms. starting motor negative (-) terminal.

2. Connect an open switch between the S terminal

Off Machine No Load Test and Bat terminal of the solenoid as shown.

3. Connect the multimeter red lead to the Mtr

Tools Needed terminal of the solenoid. Connect the black lead
Digital Multimeter or Equivalent 1 to the starting motor negative (-) terminal.
AC/DC Clamp-On Ammeter or Equivalent 1 4. Use an rpm indicator or photo tach to measure
armature speed.
Do the procedure that follows to perform a no load
test after the starting motor has been repaired or 5. Close the switch. The maximum current draw and
removed from the machine. It should be noted to minimum voltage allowed are shown in
completely check a starting motor, the complete Specifications under No Load Test.
procedure should be done as shown in On Machine
Starting Motor Diagnosis Procedure. To check the 6. If the voltage is below the minimum, the battery
starting motor components, see Starting Motor are low and need to be charged. It should be
Component Tests. noted that if the voltage is higher, the speed will
be proportionally higher.

Service Manual 17 Testing And Adjusting

No Load Test Results Starting Motor Component Tests
Following are some no load test results that could
be seen and corresponding possible problems. Tools Needed
Digital Multimeter or Equivalent 1
1. Rated current draw and no load speed indicates
normal starting motor condition. Growler Tester 1

2. Low free speed and high current draw indicate:

Field Winding Tests
a. Too much friction caused by tight, dirty, worn
bearings, bent armature or loose field pole Visually check the field windings first. Check for
shoes that allow armature to drag. wear and damage. Check all connections for clean
and tight solder joints.
b. Shorted armature. This can be further checked
on a growler after disassembly.
Field Winding Ground Test
c. Grounded armature or field winding. Check for
grounds after disassembly.

3. Failure to operate with high current draw

indicates:

a. A direct ground in the terminal or field windings.

b. Frozen bearings. This can be seen by turning

the armature by hand.

4. Failure to operate with no current draw indicates:

a. Open field circuit. This can be checked with the

multimeter after disassembly. Field Winding Ground Test
(1) Field winding leads. (2) Motor (Mtr) terminal lead.
b. Open armature. Inspect the commutator for
badly burned bars.
1. Put the multimeter on the 20M resistance (Ω)
c. Broken brush springs, worn brushes or high scale. Touch the meter leads between each field
insulation between the commutator bars which winding lead (1) and the starting motor case.
prevents good contact between the brushes
and commutator. 2. Touch the meter leads between motor (Mtr)
terminal lead (2) and the starting motor case.
5. Low no load speed and low current draw indicate:
3. Each reading should be greater than 100,000
a. High internal resistance due to poor ohms.
connections, defective leads, dirty commutator
and/or causes listed in Step 4. 4. If the meter reading is less than 100,000 ohms,
the field winding is grounded and the starting
6. High free speed and high current draw indicate: motor case and field windings must be replaced.

a. Shorted field circuit. Check the field winding for

shorts after disassembly.

Service Manual 18 Testing And Adjusting

Field Winding Continuity Test Armature Tests
Armature Short Circuit Test

Field Winding Continuity Test

(1) Field winding leads. (2) Motor (Mtr) terminal lead.

1. Put the multimeter on the 200 ohm resistance (Ω) Armature Short Circuit Check
scale. Touch the meter leads between field (3) Armature. (4) Growler tester.
winding leads(1).

2. Touch the meter leads between each field 1. Place armature (3) on growler tester (4). Turn the
winding lead (1) and motor (Mtr) terminal lead (2). tester on.

3. Each reading should be 0.0 to 0.1 ohms. 2. Hold a hacksaw blade against the armature core
while slowly rotating the armature.
4. If the meter reading is higher than shown in Step
3, there is an open in the field winding and the 3. The blade should not vibrate or be attracted to the
starting motor case and field windings must be armature core.
replaced.
4. If the blade does vibrate or is attracted to the core,
the armature has a short and must be rebuilt or
replaced.

Service Manual 19 Testing And Adjusting

Armature Ground Test Armature Runout Check

Armature Winding Ground Test Armature Runout Check

(3) Armature. (5) Commutator.

1. Put the multimeter on the 20M resistance (Ω) 1. Check the armature runout (TIR) of commutator
scale. Touch one meter lead on each commutator (5). The maximum TIR allowed is 0.05mm (.002
bar and the other lead on the armature core. in.).

2. Each reading should be greater than 100,000 2. If the TIR is too much, the armature must be
ohms. replaced.

3. If the meter reading is lower than 100,000 ohms,

the armature is grounded and must be rebuilt or Commutator Outside Diameter Check
replaced.

Armature Continuity Test

To test the armature for an open is difficult without
special equipment. If the commutator shows signs of
pitting or any of the commutator bars are black
(burned), the armature has an open circuit and must
be replaced.

Commutator Outside Diameter Check

(5) Commutator.

1. Check the outside diameter of commutator (5).

The new and minimum diameters are shown in
Specifications under Commutator.

2. If the commutator is worn, It must be replaced.

Service Manual 20 Testing And Adjusting

Brush and Brush Holder Checks
Brush Holder Test

Depth Of Segment Mica

(X) Depth of segment mica.

Brush Holder Insulation Test

3. Measure the depth of commutator segment mica. (6) Brush holder plate. (7) Brush holder. (8) Brush spring.
The minimum depth should be 0.20 mm (.008 in.)

1. Check brush holder springs (8) for damage or rust.

NOTICE Replace them if necessary.
Failure to remove the insulation shavings and
particles will cause the brushes to wear at a fast rate. 2. Put the multimeter on the 20M resistance (Ω)
scale. Touch one meter lead to each positive (+)
brush holder (7) and the other lead to brush
4. If the depth is under the minimum, the mica can holder plate (6). Check both positive brush
be undercut. If the mica is undercut, make sure to holders.
remove all shavings and mica particles.
3. Each reading should be greater than 100,000
ohms.

4. If the meter reading is less than 100,000 ohms,

the brush holder is grounded and must be
replaced.

Service Manual 21 Testing And Adjusting

Brush Length Check Overrunning Clutch Check

Brush Length Measurement Overrunning Clutch Check.

(X) Brush Length. (9) Housing. (10) Pinion.

1. Measure brush length (X) for wear. The new and 1. Visually inspect the overrunning clutch for
minimum brush lengths are shown in damage.
Specifications under Brush Length.
2. Hold housing (9) and turn pinion (10) in the
2. If the brushes are worn below the minimum length, direction of operation. A clicking noise should be
replace the brush. heard during this check.

3. Hold housing (9) and turn pinion (10) in the

opposite direction of operation. The pinion should
be locked which will not allow rotation.

4. Hold housing (9) and press pinion (10) into the

housing as far as it will go, then release the pinion.
The pinion must spring back into its rest position.

5. If any of the checks in steps 1-4 are not correct,

replace the overrunning clutch.

Service Manual 22 Testing And Adjusting

Disassembly And
Assembly
Starting Motor

NOTE: The disassembly and assembly that follows

is of a R2.0 series starting motor. The other motors
are similar.

Disassemble Starting Motor

Start By:
3. Remove motor case (3) from solenoid (2).
a. remove starting motor

4. If the motor case has an end frame, remove it.

1. Disconnect motor (Mtr) terminal lead wire (1) from Release the tension of brush springs (5) with a
solenoid (2). pair of long nosed pliers. Pull brushes (6) away
from the commutator. Remove brush holder (7).

2. Remove the through bolts from drive end housing

(4) that hold starting motor case (3) onto the
solenoid.

Service Manual 23 Disassembly And Assembly

5. Remove armature (8) from motor case (3). It may 7. Remove housing (4) from solenoid (2).
be necessary to use a plastic or rubber hammer
to drive the case from the armature.

8. Remove overrunning clutch (9) from the housing

(4).
6. Remove the screws that hold drive end housing
(4) to solenoid (2).

Service Manual 24 Disassembly And Assembly

9. Remove steel ball (10) from overrunning clutch 11. Remove retainer (12) and rollers (13) from
(9). housing (4).

12. Remove return spring (14) from solenoid (2).

10. Remove idler gear (11) from housing (4).

NOTICE
Do not use a liquid cleaning agent to clean the
armature, field winding, or overrunning clutch. A
liquid cleaning agent can damage the insulation in
the armature and field windings. It could also
dissolve the grease in the overrunning clutch.

13. Clean the armature, field winding and

overrunning clutch with mineral spirits and a
brush.

14. If the commutator is dirty, it may be cleaned with

No. 00 sandpaper. Do not use emery cloth.

15. Inspect all parts for wear and damage.

Service Manual 25 Disassembly And Assembly

Assemble Starting Motor

1. Install return spring (14) into solenoid (2).

R2.0 Series Reduction Starting Motor

(1) Motor (Mtr) Terminal Lead Wire. (2) Solenoid.
(3) Starting Motor Case. (4) Drive End Housing.
(5) Brush Springs.
(6) Brushes. (7) Brush Holder. (8) Armature.
(9) Overrunning Clutch. (10) Steel Ball.
(11) Idler Gear. (12) Retainer. (13) Roller.
(14) Return Spring.

2. Install rollers (13) and retainer (12) into drive end

housing (4).

3. Put idler gear (11) on housing (4).

Service Manual 26 Disassembly And Assembly

4. Put steel ball (10) into overrunning clutch (9). 6. Put drive end housing (4) on solenoid (2) and
install the screws. Tighten the screws to a torque
of 0.6 to 0.9 N•m (5 to 8 lb•in).

5. Put overrunning clutch (9) into housing (4).

7. Put armature (8) into starting motor case (3).

Service Manual 27 Disassembly And Assembly

8. Put brush holder (7) in position over the 10. If the motor case has an end frame (15), install it
commutator. Put the positive brushes [connected onto the case. Engage the tab on the end frame
to motor case (3)] in the positive holders with the lead wire grommet on the motor case.
(separated from the plate with insulator). Put the
negative brushes [connected to brush holder (7)]
in the negative holders (not insulated).

11. Put motor case (3) in position onto solenoid (2).

Engage the tab on the case with the notch in the
solenoid. Install the through bolts. Tighten them
9. Make sure the positive brush lead wires are not to a torque of 1.5 to 2.4 N•m (13 to 21 lb•in).
grounded. Put brush springs (5) on top of brushes
(6) with a pair of long nosed pliers. Make sure
there is no oil on brush holder (7) or the
commutator.

Service Manual 28 Disassembly And Assembly

12. Connect lead wire (1) to the motor (Mtr)
terminal of solenoid (2).

End By:

a. install starting motor

Service Manual 29 Disassembly And Assembly

SB4263E00
May. 2007

Service Manual
G643E LP Engine
G643 LP Engine

G35S-5, G40S-5, G45S-5, G50C-5, G55C-5

GC35S-5, GC40S-5, GC45S-5, GC50C-5, GC55C-5
G40SC-5, G45SC-5, G50SC-5, G55SC-5
G50S-5, G60S-5, G70S-5
Important Safety Information

Read and understand all safety precautions and warnings before operating or performing lubrication,
maintenance and repair on this product.

WARNING

Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.

The information, specifications, and illustrations in this publication are on the basis of information available at the
time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other
items can change at any time. These changes can affect the service given to the product. Obtain the complete and
most current information before starting any job. DOOSAN dealers have the most current information available.

1
Index
Inspect for Intake Leaks................................ 28
Chapter 1. GENERAL INFORMATION Inspect Throttle Assembly............................. 28
Checking the TMAP Sensor(G643E only) ..... 28
Precautions before Service ................................. 7
Tightening Torque ............................................. 10 Exhaust System Maintenance........................... 28
Recommended Lubricants and Capacities....... 12 Inspect Engine for Exhaust Leaks................. 28
Engine Model and Engine Serial Number ......... 13
General Specification ........................................ 14 Maintenance Schedule ...................................... 29
G643F/G643FE Engine Power and Torque........ 16

Chapter 3. ENGINE MECHANICAL

Chapter 2. RECOMMENDED SYSTEM
MAINTENANCE
General Information........................................... 31
General Maintenance......................................... 17 Engine Outline.............................................. 31
Test Fuel System for Leaks........................... 17 Specification ................................................. 32
Inspect Engine for Fluid Leaks ...................... 17 Torque Specification ..................................... 33
Inspect Vacuum Lines and Fittings................ 17 Engine Exploded View .................................. 41
Inspect Electrical System .............................. 17 Engine Construction ..................................... 45
Inspect Foot Pedal Operation........................ 17 Statement On Cleanliness And Care............. 45
Engine Oil Classification................................ 18 Use Of Rtv Sealer And Anaerobic Gasket
Checking Engine Oil Level ............................ 19 Eliminator ..................................................... 46
Replacing Engine Oil and Filter ..................... 19 Replacing Engine Gaskets............................ 47
Checking Compressed Pressure ................... 20 Thread Repair .............................................. 47
Special Tools................................................ 48
Cooling System Maintenance............................ 21
Coolant Recommendation............................. 21 Cooling System ................................................. 51
Check Coolant Level ..................................... 21 General Description ...................................... 51
Inspect Coolant Hoses .................................. 21 Testing & Adjusting....................................... 52
Checking coolant leaks ................................. 22 Cooling System Recommendation ................ 55
Specific gravity test ....................................... 22
Relation between Coolant concentration and Engine Lubrication ............................................ 57
Specific Gravity............................................. 22 General Description ...................................... 57
Checking and Adjusting Drive Belt ................ 23 Testing and Adjusting ................................... 58
Checking Belt for Damage ............................ 23
Disassembly of Engine...................................... 60
Ignition System Maintenance ............................ 24 Tools And Shop Equipment .......................... 60
Inspect Battery System ................................. 24 Accessory Removal...................................... 60
Inspect Ignition System ................................. 24 Cleaning ....................................................... 60
Inspection of Ignition Timing.......................... 24 Draining The Engine ..................................... 60
Inspection of Spark Plug ............................... 25 Engine Flywheel Removal ............................ 61
Exhaust Manifold Removal ........................... 61
Fuel System Maintenance ................................. 27 High Mounted Fan Bracket Removal............. 62
Replace LP Fuel Filter Element..................... 27 Coolant Pump Removal ................................ 62
Testing Fuel Lock-off Operation .................... 27 Valve Rocker Arm Cover Removal................ 63
Pressure Regulator/Converter Inspection ...... 28 Thermostat Removal .................................... 63
Inspect Air/Fuel Valve Mixer Assembly.......... 28 Intake Manifold Removal .............................. 64

G643(E) Service Manual 3 Index

Valve Train Component Removal.................. 64 Connecting Rod Bearings ............................. 93
Cylinder Head Removal ................................ 65 Connecting Rod Side Clearance ................... 94
Torsional Damper Removal........................... 66
Oil Pan Removal........................................... 66 Assembly of Engine .......................................... 95
Oil Pump Removal ........................................ 67 Prior to Assembly ......................................... 95
Engine Front Cover Removal ........................ 67 Crankshaft And Crankshaft Bearing Installation
Timing Chain and Camshaft Sprocket Removal ..................................................................... 95
..................................................................... 67 Crankshaft Rear Oil Seal Housing Installation ... 96
Camshaft Removal ....................................... 68 Crankshaft Rear Oil Seal Installation............. 96
Balance Shaft Removal................................. 68 Piston and Connecting Rod Installation......... 96
Piston and Connecting Rod Removal ............ 69 Balance Shaft Installation ............................. 98
Crankshaft Rear Oil Seal Removal................ 70 Camshaft Installation .................................... 99
Crankshaft Rear Oil Seal Housing Removal .. 70 Timing Chain and Camshaft Sprocket
Crankshaft Removal...................................... 71 Installation ...................................................100
Engine Front Cover Installation ....................100
Cleaning, Inspection, and Repair ...................... 72 Torsional Damper Installation ......................100
Cylinder Block............................................... 72 Torsional Damper Installation ......................101
Cylinder Bore ................................................ 73 Oil Pump Installation....................................101
Measuring Cylinder Bore Taper and Out-Of- Oil Pan Installation.......................................102
Round........................................................... 73 Cylinder Head Installation ............................104
Cylinder Bore Reconditioning ........................ 74 Cylinder Head Installation ............................104
Boring .................................................... 75 Valve Train Component Installation..............104
Honing ................................................... 75 Valve Adjustment.........................................105
Piston Disassembly....................................... 76 Intake Manifold Installation...........................105
Measuring Piston Pin-To-Piston Clearance ... 77 Rocker Arm Cover Installation......................105
Piston Selection ............................................ 78 Exhaust Manifold Installation .......................107
Piston Assembly ........................................... 78 Flywheel Housing Installation.......................107
Intake and Exhaust Manifolds ....................... 80 Engine Flywheel Installation.........................108
Camshaft ...................................................... 80 Coolant Pump Installation ............................109
Camshaft Bearings ....................................... 81 Engine Accessory Installation ......................109
Balance Shaft ............................................... 82 Engine Setup and Testing............................109
Timing Chain and Sprockets ......................... 82
Crankshaft Sprocket Replacement ................ 82
Coolant Pump ............................................... 83 Chapter 4. ENGINE ELECTRICAL
Oil Pan and Valve Rocker Covers ................. 83 SYSTEM
Oil Pump....................................................... 83
Valve Train Components............................... 85 Specifications ...................................................110
Valve Lifters.................................................. 86 Ignition Timing .............................................110
Cylinder Head ............................................... 86 Ignition Sequence (Firing Order) ..................110
Disassembly .......................................... 86 Ignition Coil .................................................110
Cleaning, Inspection, and Measurement.... 86 Spark Plug...................................................110
Repair.................................................... 88 Distributor....................................................111
Valve Rocker Arm Stud Replacement .... 89 Sensor Gap .................................................111
Assembly............................................... 89
Thermostat and Coolant Outlet ..................... 90 Ignition System.................................................112
Torsional Damper ......................................... 90 General Description .....................................112
Crankshaft Bearings...................................... 91 Ignition System Control.........................113
Crankshaft Runout ........................................ 93 lgnition System Schematic for G643E ...114
Crankshaft End Play ..................................... 93 lgnition System Schematic for G643 .....114

G643(E) Service Manual 4 Index

Ignition System Inspection .......................... 115 SECM..........................................................177
Ignition Component Checks ................. 115 SECM (Load/Speed Management) ..............177
Inspection of Spark Plug Wires ............ 116
Inspection of Spark Plug ...................... 117 EMS Inspection and Repair..............................182
Inspection of EST Distributor................ 118 Engine Control Module [G643E]...................182
Inspection of Ignition Coil ..................... 120 Crank Shaft Position Sensor [G643E] ..........183
Disassembly and Assembly......................... 120 IAT (Intake Air Temperature) Sensor [G643E
Ignition Coil.......................................... 120 and G643] ...................................................185
EST Distributor .................................... 121 OxygenSensor (Pre-Catalyst) [G643E].........186
Ignition Timing Adjustment for G643 Engine ... 123 Oxygen Sensor(Post-Catalyst [G643E] ........187
Connection of the Service Tool Software ECT (Engine Coolant Temperature) Sensor
............................................................ 124 [G643E and G643].......................................188
Final Timing Verification....................... 125 Angle Sensor-Accelerator [G643E and G643]
Ignition Timing Adjustment for G643E Engine ....................................................................191
................................................................... 126 Transmission Oil Temperature Switch [G643E]
....................................................................192
Charging System ............................................. 127 Electronic Throttle Body [G643E and G643] ....193
General Description .................................... 127
Troubleshooting Procedure ......................... 130
Chapter 6. LPG FUEL DELIVERY
STARTING SYSTEM......................................... 135 SYSTEM
General Description .................................... 135
Diagnosis Procedure................................... 136 G643E LP System Inspection and Repair........194
Start Relay Tests ........................................ 138 Removal and Installation..............................194
Troubleshooting .......................................... 139 Hose Connections ................................195
Starter Repair ............................................. 140 Removal and Installation of...................197
N-2007 LP Regulator ............................197
Removal and Installation of CA100 Mixer
Chapter 5. ENGINE MANAGEMENT for G643E.............................................198
SYSTEM (EMS) Tests and Adjustments ................................200
N-2007 Regulator Service Testing ......... 20
General Information......................................... 141 AVV (Air Valve Vacuum) Testing ..........202
Specifications.............................................. 141 Connection of the MI-07 Service Tool ...202
Component Location ................................... 146 Idle Mixture Adjustment ........................203
Parts Description .........................................206
G643E EMS (Engine Management System) CA100 Mixer for G643E Engine ............206
Overview .......................................................... 149 N-2007 Regulator for G643E Engine.....208
General Description .................................... 149
LPG Fuel System Operation........................ 152 G643 LPG System Inspection and Repair .......210
Electronic Throttle System .......................... 160 Removal and Installation..............................210
SECM......................................................... 164 Hose Connections ................................211
SECM Wiring Diagrams for G643E.............. 167 Removal and Installation of N-2001 LP
Regulator/Converter .............................212
G643 EMS (Engine Management System) Removal and Installation of CA100 Mixer
Overview .......................................................... 169 for G643 ...............................................213
General Description .................................... 169 Tests and Adjustments ................................215
LPG Fuel System Operation........................ 172 N-2001 Regulator Service Testing ........215
Electronic Throttle System .......................... 175 AVV (Air Valve Vacuum) Testing ..........217
Ignition System ........................................... 176 Connection of the MI-07 Service Tool ...217

G643(E) Service Manual 5 Index

Idle Mixture Adjustment........................ 218 Chapter 8. ADVANCED DIAGNOSTICS
G643 LP Fuel Systems with O2 Sensor ...218
Parts Description......................................... 220 Reading Diagnostic Fault Codes .....................252
CA100 Mixer for G643 Engine.............. 220 Displaying Fault Codes (DFC) from SECM
CA100 Disassembly and Service ......... 222 Memory .............................................................252
CA100 Disassembled Service .............. 223 Clearing Fault (DFC) Codes .............................252
N-2001 Regulator for G643 Engine ...... 224 Fault Action Descriptions ................................253
N2001 Regulator Disassembly Steps: .. 226 Fault List Definitions ........................................253
N2001 Disassembled Service .............. 228 Table 1. Fault List Definitions.......................254
Table 2. Diagnostic Fault Codes (Flash Codes)
for G643E....................................................260
Chapter 7. BASIC TROUBLESHOOTING Table 3. Diagnostic Fault Codes (Flash Codes)
for G643. .....................................................273
Preliminary Checks.......................................... 229
Before Starting............................................ 229
Visual/Physical check.................................. 229 Appendix

Basic Troubleshooting Guide ......................... 230 Service Tool Software (MotoView)...................280

Customer Problem Analysis Sheet .............. 230 Introduction .................................................280
Basic Inspection Procedure......................... 231 Connection of the Service Tool ....................281
Connector Inspection Procedure ................. 232 MotoView Display Screens ..........................282
SECM field update with Service Tool ...........294
Basic Troubleshooting .................................... 236 Ground Speed Limits (Option).........................298
Intermittents................................................ 236 LPG And LPG Fuel Tanks ................................301
Corrective Action......................................... 236 Regulatory Compliance....................................305
Surges and/or Stumbles.............................. 237 Special Conditions for Safe Use ......................305
Engine Cranking but Will Not Start / Difficult to Abbreviations ...................................................306
Start............................................................ 238
Engine Cranking but Will Not Start / Difficult to
Start (cont’d.) .............................................. 239
Lack of Power, Slow to Respond / Poor High
Speed Performance / Hesitation During
Acceleration................................................ 240
Detonation / Spark Knock............................ 242
Backfire ...................................................... 243
Dieseling, Run-on ....................................... 243
Rough, Unstable, Incorrect Idle, or Stalling.. 244
Cuts Out, Misses......................................... 246
Poor Fuel Economy / Excessive Fuel
Consumption / LPG Exhaust Smell.............. 247
High Idle Speed .......................................... 248
Excessive Exhaust Emissions or Odors....... 249
Diagnostic Aids for Rich / Lean Operation ... 250
Chart T-1 Restricted Exhaust System Check .. 251

G643(E) Service Manual 6 Index

Chapter 1. GENERAL INFORMATION
Precautions before Service Tightening Torque

Removal and Disassembly

Tighten the part properly to specified torque.

For prevention of wrong installation or reassembly Sealant

and for ease of operation, put mating marks to the
parts where no function is adversely affected.

Special Tool

Use specified brand of sealant.

Use of sealant other than specified sealant may
cause water or oil leaks.

Be sure to use Special Tools when their use is

specified for the operation.
Use of substitute tools will result in malfunction of
the part or damage it.

G643(E) Service Manual 7 Chapter 1. General Information

Replacement Part Genuine Part

When oil seal, O-ring, packing and gasket have When the part is to be replaced, be sure to use
been removed, be sure to replace them with new genuine part.
parts. For selection of appropriate parts, refer to the Parts
However, rocker cover gasket may be reused if it is Catalog.
not damaged.
Electrical System
Rubber Parts

1. Be sure to disconnect the battery cable from the

Do not stain timing belt and V-belt with oil or water.
negative (-) terminal of the battery.
Therefore, do not clean the pulley and sprocket with
detergent.
2. Never pull on the wires when disconnecting
connectors.
Oil and Grease
3. Locking connectors will click when the connector
is secure.

4. Handle sensors and relays carefully. Be careful

not to drop them or hit them against other parts.

Before reassembly, apply specified oil to the rotating

and sliding parts.

G643(E) Service Manual 8 Chapter 1. General Information

Precautions for catalytic Converter

CAUTION
If a large amount of unburned gasoline flows
into the converter, it may overheat and create a
fire hazard. To prevent this, observe the
following precautions and explain them to your
customer.

1. Use only unleaded gasoline.

2. Do net run the engine while the truck is at rest for

a long time. Avoid running the engine at fast idle
for more than 5 minutes and at idle speed for
more than 10 minutes.

3. Avoid spark-jump tests. Do spark-jumps only

when absolutely necessary. Perform this test as
rapidly as possible and, while testing, never race
the engine.

4. Do not measure engine compression for an

extended time. Engine compression tests must be
made as rapidly as possible

5. Do not run the engine when the fuel tank is nearly

empty. This may cause the engine to misfire and
create and extra load on the converter.

6. Avoid coasting with the ignition turned off and

during prolonged braking

7. Do not dispose of a used catalytic converter

together with parts contaminated with gasoline or
oil.

G643(E) Service Manual 9 Chapter 1. General Information

Tightening Torque
Tightening Torque Table of Standard Parts

Bolt nominal diameter Torque (kg·m)

Pitch (mm)
(mm) Head mark 4 Head mark 7

M5 0.8 0.3 ~ 0.4 0.5 ~ 0.6

M6 1.0 0.5 ~ 0.6 0.9 ~ 1.1

M8 1.25 1.2 ~ 1.5 2.0 ~ 2.5

M10 1.25 2.5 ~ 3.0 4.0 ~ 5.0

M12 1.25 3.5 ~ 4.5 6~8

M14 1.2 7.5 ~ 8.5 12 ~ 14

M16 1.5 11 ~ 13 18 ~ 21

M18 1.5 16 ~ 18 26 ~ 30

M20 1.5 22 ~ 25 36 ~ 42

M22 1.5 29 ~ 33 48 ~ 55

M24 1.5 37 ~ 42 61 ~ 70
M5 0.8 0.3 ~ 0.4 0.5 ~ 0.6

M6 1.0 0.5 ~ 0.6 0.9 ~ 1.1

M8 1.25 1.2 ~ 1.5 2.0 ~ 2.5

M10 1.25 2.5 ~ 3.0 4.0 ~ 5.0

NOTE: The torques shown in the table are standard 1. When spring washers, toothed washers and the
vales under the following conditions. like are inserted.

1. Nuts and bolt are made of steel bar and 2. If plastic parts are fastened.
galvanized.
3. If oil is applied to threads and surfaces.
2. Galvanized plain steel washers are inserted.
NOTE: If you reduce the torques in the table to the
3. All nuts, bolts, plain washers are dry. percentage indicated below under the following
conditions, it will be the standard value.
NOTE: The torques shown in the table are not
applicable, 1. If spring washers are used : 85%

2. If threads and bearing surfaces are stained with

oil: 85%

G643(E) Service Manual 10 Chapter 1. General Information

General tightening torque
for bolts, nuts and taperlock studs

The following charts give the standard toque thread

values for bolts, nuts and taperlock studs of Standard torque
size
SAE Grade 5 or better quality. Exceptions are
given in other sections of the Service Manual
where needed. inches Ib•ft. N•m*

1/4 9±3 12 ± 4
Use these torques for 5/16 18 ± 5 25 ± 7
bolts and nuts with 3/8 32 ± 5 45 ± 7
standard threads (con- 7/16 50 ± 10 70 ± 15
versions are 1/2 75 ± 20 100 ± 15
approximate). 9/16 110 ± 15 150 ± 20
5/8 150 ± 20 200 ± 25
3/4 265 ± 35 360 ± 50
7/8 420 ± 60 570 ± 80
1 640 ± 80 875 ± 100
standaed thread 1-1/8 800 ± 100 1100 ± 150
1-1/4 1000 ± 120 1350 ± 175
1-3/8 1200 ± 150 1600 ± 200
1-1/2 1500 ± 200 2000 ± 275

5/16 13 ± 2 20 ± 3
Use these torques for 3/8 24 ± 2 35 ± 3
bolts and nuts on 7/16 39 ± 2 50 ± 3
hydraulic valve bodies. 1/2 60 ± 3 80 ± 4
5/8 118 ± 4 160 ± 6

1/4 5±2 7±3

Use these torques for 5/16 10 ± 3 15 ± 5
studs with taperlock 3/8 20 ± 3 30± 5
threads. 7/16 30 ± 5 40 ± 10
1/2 40 ± 5 55 ± 10
9/16 60 ± 10 80 ± 15
5/8 75 ± 10 100 ± 15
3/4 110 ± 15 150 ± 20
7/8 170 ± 20 230 ± 30
taperlock stud 1 260 ± 30 350 ± 40
1-1/8 320 ± 30 400 ± 40
1-1/4 400 ± 40 550 ± 50
1-3/8 480 ± 40 650 ± 50
1-1/2 550 ± 50 750 ± 70
B80625X1

G643(E) Service Manual 11 Chapter 1. General Information

Recommended Lubricants and Capacities

Recommended Lubricants

Lubricant Specification Remarks

Engine Oil API Classification SJ or above SAE 10W30 or SAE 5W30
Automotive antifreeze
Concentration level 50%(normal)
Coolant (Antifreeze) suitable for gasoline engines
Concentration level 40%(tropical)
having aluminum alloy parts

Lubricant Capacities

Description G(C)35/40/45S-5,G50/60/70S-5

Oil Pan 4.3

Engine Oil (liters) Oil Filter 0.5
Total 4.8

Engine 7.6

Coolant (liters) Radiator & Hoses 11.4

Total 19

G643(E) Service Manual 12 Chapter 1. General Information

Engine Model and Engine Serial Indication of Engine Model and Serial
Number Number

Engine Emission
Fuel Type
Model Regulation
EPA/CARB*
G643E LP 2007
Compliant

G643 LP

* EPA: Environmental Protection Agency

* CARB: California Air Resources Board

G643E Engine
Engine Model Engine Serial Number
• Comply with EPA 2007 Emission Regulation G643E/G643 30700001 to 39999999
• Electronic Control by ECM
Features and Benefits of G643E/G643 Engine
• Certified LP System available
• Valve seat inserts
– Closed loop LP Carburetion system
– Valve seat system
• 3-way Catalytic Muffler is standard
• SOHC valve system
G643 Engine
• Timing chain system
• Not comply with EPA 2007 Emission Regulation
• Distributor Ignition system
• Electronic Control by ECM
• Electronic control system by ECM (Engine control
• Standard LP System available module)

– Open loop LP Carburetion system – Drive-by-wire system

• Muffler is standard – Higher efficiency and lower fuel consumption

– Min./Max. governor control

– Automatic engine protection from overheating

and/or low engine oil pressure

– Automatic transmission protection from

overheating (G643E Engine only)

– Engine diagnostics by service-tool software

– Forklift ground speed limit (optional)

G643(E) Service Manual 13 Chapter 1. General Information

General Specification
G643E Engine G643 Engine
GENERAL DESCRIPTION
ENGINE TYPE: 90°4-Cycle V6, Water Cooled
COMBUSTION SYSTEM: Naturally Aspirated
INTAKE MANIFOLD Cast Iron, Dry
EXHAUST MANIFOLD Cast Iron, Dry
Pushrod Actuated Overhead Valves - 2 Per Cylinder
VALVE CONFIGURATION:
Auto Lash adjustment by hydraulic valve lifter
CAMSHAFT DRIVING: Timing Chain System
BALANCE SHAFT: One Balance Shaft System
DISPLACEMENT: 4294 cc (262 CID)
BORE: 101.60 mm (4.00 in.)
STROKE: 88.39 mm (3.48 in.)
COMPRESSION RATIO: 9.4:1
COMPRESSIONPRESSURE: 690 kPa (100 psi) Minimum
FIRING ORDER: 1-6-5-4-3-2
WEIGHT: 296 Kg (653 lbs.), Wet
ENGINE ROTATION: Counter-Clockwise (CCW) when viewed from Flywheel End
FUEL TYPE: LPG
CRANK VENTILATION PCV System
IGNITION SYSTEM
IGNITION TYPE: Distributor System
IGNITIOIN TIMING: Electronic controlled by ECM
IGNITION COIL: 12 V operation volt
DISTRIBUTOR: Delco EST Distributor with ignition module
SPARK PLUGS: BOSCH 4205, 0.9mm (0.035in.) Air Gap
LUBRICATION SYSTEM
28 kPa (4 psi) @ 700 RPM
OIL PRESSURE (MIN. HOT):
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: 4.3 L (4.5 qts.)
OIL FILTER: 0.47 L (0.5 qt.)
ENGINE OIL SPECIFICATION: API - SJ, SAE 10W30
COOLING SYSTEM
WATER PUMP ROTATION: Serpentine Belt Drive - Clockwise (CW) when viewed from engine front
Opening Temperature: 82°C (180°F)
THERMOSTAT:
Fully Open Temperature: 96°C (205°F)
COOLING WATER CAPACITY 7.6 L (block only)

G643(E) Service Manual 14 Chapter 1. General Information

G643E Engine G643 Engine
LP FUEL SYSTEM
Closed loop LP Carburetion Open loop LP Carburetion
LP FUEL SYSTEM
System System
Diaphragm Type Air Valve Diaphragm Type Air Valve
MIXER:
Assembly inside, Downdraft Assembly inside, Downdraft
(Model: CA-100) (Model: CA-100)
Two-Stage Negative Pressure Two-Stage Negative Pressure
REGULATOR:
Regulator (Model: N-2007) Regulator (Model: N-2001)
FUELTRIMVALVE (FTV): Dual Dither System None
FUEL FILTRATION: 40 Microns Maximum 40 Microns Maximum
ENGINE ELECTRICAL
ENGINECONTROLMODULE(ECM): 12 V operation volt, 48 pins of I/O 12 V operation volt, 24 pins of I/O
CRANK SENSOR Hall effect Sensor VR sensor built in Distributor
Intake Air Temp. & Manifold Intake Air Temp. & Manifold
TMAP:
Absolute Press. Sensor Absolute Press. Sensor
Two-Output Signals (Installed on Two-Output Signals (Installed
PEDAL ANGLE SENSOR:
Accelerator Pedal) on Accelerator Pedal)
OXYGEN SENSOR: Heated Exhaust Gas Oxygen
None
Sensor (HEGO)
12 V operation volt
Engine Coolant Temperature Engine Coolant Temperature
ECT-ECM:
Sensor for ECM Sensor for ECM
Engine Coolant Temp. Sensor
Engine Coolant Temp. Sensor for
ECT-GAUGE for GAUGE on Instrument
GAUGE on Instrument Panel
Panel
Throttle Position Sensor (built in Throttle Position Sensor (built
TPS:
Throttle Body) in Throttle Body)
THROTTLE BODY: Electronic Throttle Body Electronic Throttle Body
LP FUEL LOCK-OFF: 12 V operation volt 12 V operation volt
ENGINE OIL PR. S/W: 21.4 kPa (3.1 psi) 21.4 kPa (3.1 psi)
STARTER MOTOR: 12 Volt, 2.0 kW 12 Volt, 2.0 kW
ALTERNATOR: 12 Volt, 80 A 12 Volt, 80 A

EXHAUST SYSTEM
Three-way Catalyst with Metal Muffler without Catalyst
CATALYTIC MUFFLER:
Substrate

G643(E) Service Manual 15 Chapter 1. General Information

G643/G643E Engine Power and Torque

ENGINE MODEL unit G643E-LP G643-LP

RATED POWER kW 69.4 69.4

hp 93.0 93.0
PS 94.3 94.3

rpm 2,450 2,450

MAX TORQUE N-m 284 294
lbf-ft 210 217

kgf-m 29.0 30.0

rpm 1600 1600

GOVERNED SPEED rpm 2500 2500

LOW IDLE rpm 750 750

G643(E) Service Manual 16 Chapter 1. General Information

Chapter 2. RECOMMENDED MAINTENANCE
Suggested maintenance requirements for an engine equipped with an MI-07 fuel system are contained in this
section. The operator should, however, develop a customized maintenance schedule using the requirements
listed in this section and any other requirements listed by the engine manufacturer.

General Maintenance Inspect Engine for Fluid Leaks

Test Fuel System for Leaks • Start the engine and allow it to reach operating
temperatures.

• Turn the engine off.

• Inspect the entire engine for oil and/or coolant

leaks.

• Repair as necessary before continuing.

Inspect Vacuum Lines and Fittings

• Visually inspect vacuum lines and fittings for

physical damage such as brittleness, cracks and
kinks. Repair/replace as required.

• Obtain a leak check squirt bottle or pump spray • Solvent or oil damage may cause vacuum lines to
bottle. become soft, resulting in a collapsed line while
the engine is running.
• Fill the bottle with an approved leak check solution.
• If abnormally soft lines are detected, replace as
• Spray a generous amount of the solution on the necessary.
fuel system fuel lines and connections, starting at
the storage container. Inspect Electrical System
• Wait approximately 15-60 seconds, then perform a • Check for loose, dirty or damaged connectors and
visual inspection of the fuel system. Leaks will wires on the harness including: fuel lock-off,
cause the solution to bubble. TMAP sensor, O2 sensors, electronic throttle,
control relays, fuel trim valves, crank position
• Listen for leaks sensor, and cam position sensor.

• Smell for LPG odor which may indicate a leak • Repair and/or replace as necessary.

• Repair any leaks before continuing. Inspect Foot Pedal Operation

• Crank the engine through several revolutions. This • Verify foot pedal travel is smooth without sticking.
will energize the fuel lock-off and allow fuel to
flow to the pressure regulator/converter. Apply
additional leak check solution to the regulator/
converter fuel connections and housing. Repeat
leak inspection as listed above.

• Repair any fuel leaks before continuing.

G643(E) Service Manual 17 Chapter 2. Recommended Maintenance

Engine Oil Classification

Recommended API classification: Above SJ

Recommended SAE viscosity classification

*1. 10W-30 engine oil is recommended

If 10W-30 is not applicable, proper engine oil will be possible according to temperature ranges.

The following lubricants should be selected for all

engines to enhance excellent performance and
maximum effect.

1. Observe the API classification guide.

2. Proper SAE classification number should be

selected within ambient temperature ranges. Do
not use the lubricant with SAE classification
number and API grade not identified on the
container.

G643(E) Service Manual 18 Chapter 2. Recommended Maintenance

Checking Engine Oil Level Replacing Engine Oil and Filter

CAUTION
Prolonged and repeated contact with mineral oil
will result in the removal of natural fats from the
skin, leading to dryness, irritation and dermatitis.
In addition, used engine oil contains potentially
harmful contaminants which may cause skin
cancer.
Exercise caution in order to minimize the length
and frequency of contact of your skin to used oil.
In order to preserve the environment, used oil
and used oil filter must be disposed of only at
1. Check that the oil level is between “MIN” and designated disposal sites.
“Max” marks on the engine oil level gauge.

2. If the oil level is below “MIN” mark, add oil until 1. Drain engine oil.
the level is within the specified ranges.
1) Remove the oil filler cap.
3. Check the engine for oil contamination and
viscosity and replace if necessary. 2) Remove the oil drain plug, and drain the oil into
a container.

2. Replace oil filter.

1) Remove the oil filter.

2) Check and clean the oil filter installation

surface.

3) Check the part number of the new oil filter is as

same as old one.

4) Apply clean engine oil to the gasket of a new

oil filter.

5) Lightly screw the oil filter into place, and

tighten it until the gasket contacts the seat.

6) Tighten it an additional 3/4 turn.

G643(E) Service Manual 19 Chapter 2. Recommended Maintenance

3. Refill with engine oil filter.

1) Clean and install the oil drain plug with a new

CAUTION
gasket. At this time, necessarily screen the spark plug
hole with a rag. Because hot coolant, oil, fuel,
Torque 40~70 N•m and other foreign material, being penetrated in
the cylinder through cracks can come into the
spark hole during checking compressed
2)Fill with fresh engine oil. pressure.
When cranking the engine to test compressed
Capacity Drain and refill 4.3 L pressure, necessarily open the throttle valve be-
fore cranking.
Oil filter 0.5 L

6. Install the compression gauge to the spark plug

3) Install the oil filler cap.
hole.
4. Start engine and check for oil leaks.
7. With the throttle valve opened, crank the engine
to measure the compressed pressure.
5. Recheck engine oil level.

Checking Compressed Pressure Standard (250~400 rpm) Limit 690 kPa

8. If any of all cylinders is out of limit, add a small

amount of engine oil to the spark plug hole, and
re-proceed the procedures (no.6-7) to the cylinder.

At this time, if the compressed pressure is increased,

it means that the piston, piston ring or cylinder
surface are worn or damaged, and if the
compressed pressure is decreased, it means that
the valve is clogged, the valve contact is faulty, or
the pressure leaks through gasket.

CAUTION
1. Prior to inspection, check that the engine oil, If a large amount of incomplete combustion
starter motor and battery are normal. gasoline comes into the catalytic converter,
emergency such as a fire can occur due to
2. Start the engine and run it until the engine coolant overheating. So this job should be done quickly
temperature reaches 80 ~ 95°C. with the engine not operated.

3. Stop the engine and disconnect the ignition coil

and air cleaner element.

4. Remove the spark plug.

5. After opening the throttle valve completely, crank

the engine to remove foreign material from the
cylinder.

G643(E) Service Manual 20 Chapter 2. Recommended Maintenance

Cooling System Maintenance Antifreeze

DOOSAN recommends selecting automotive

Coolant Recommendation antifreeze suitable for gasoline engines using
aluminum alloy parts. The antifreeze should meet
The engine cooling system is provided with a ASTM-D3306 standard.
mixture of 50% ethylene glycol anti-freeze and 50%
water (For the vehicles of tropical area, the engine Check Coolant Level
cooling system is provided with a mixture of 40%
ethylene glycol anti-freeze and 60% water at the
• The items below are a general guideline for
time of manufacture.)
system checks. Refer to the engine
Since the cylinder head and water pump body are
manufacturer’s specific recommendations for
made of aluminum alloy casting, be sure to use a 30
proper procedures.
to 60% ethylene glycol antifreeze coolant to assure
corrosion protection and freezing prevention.
• Engine must be off and cold.

CAUTION WARNING—PROPER USE

If the concentration of the antifreeze is below
Never remove the pressure cap on a hot engine.
30%, the anticorrosion property will be adversely
affected. In addition, if the concentration is
above 60%, both the antifreeze and engine • The coolant level should be equal to the “COLD”
cooling properties will decrease, adversely mark on the coolant recovery tank.
affecting the engine. For these reasons, be sure
• Add approve coolant to the specified level if the
to maintain the concentration level within the
system is low.
specified range.
Inspect Coolant Hoses
Coolant Water
• Visually inspect coolant hoses and clamps.
Hard water, or water with high levels of calcium and Remember to check the two coolant lines that
magnesium ions, encourages the formation of connect to the pressure regulator/converter.
insoluble chemical compounds by combining with
cooling system additives such as silicates and • Replace any hose that shows signs of leakage,
phosphates. swelling, cracking, abrasion or deterioration.

The tendency of silicates and phosphates to

precipitate out-of-solution increases with increasing
water hardness. Hard water, or water with high
levels of calcium and magnesium ions encourages
the formation of insoluble chemicals, especially after
a number of heating and cooling cycles.

DOOSAN prefers the use of distilled water or

deionized water to reduce the potential and severity
of chemical insolubility.

Acceptable Water
Water Content Limits (ppm)
Chlorides (CI) 40 maximum
Sulfates (SO4) 50 maximum
Total Hardness 80mg/ℓ maximum
Total Solids 250 maximum
pH 6.0 ~ 8.0
ppm = parts per million

G643(E) Service Manual 21 Chapter 2. Recommended Maintenance

Checking coolant leaks

1. After the coolant temperature drops below 38°C

loosen the radiator cap.

2. Check that the coolant level reaches filler neck.

3. Install the radiator cap tester to the radiator filler

neck and apply a pressure of 1.4kg/cm2 .
While maintaining it for 2 minutes, check the radiator,
hose, and connecting part for leak.

CAUTION
Because the coolant in the radiator is too hot,
never open the cap when it hot, or injury may
occur due to an outburst of hot water.
Dry out the inspection part.
When removing the tester, take care not to spill
the coolant.
When removing/installing the tester as well as
testing, take care not to deform the filler neck.

4. Replace parts if leak is detected.

Specific gravity test

1. Measure specific gravity of the coolant using a

hydrometer.

2. After measuring the coolant temperature,

calculate specific gravity using the following table.

Relation between Coolant concentration and Specific Gravity

Temperature and Specific gravity of coolant (Temp.:℃) Freezing Coolant Concentration

10 20 30 40 50 temp(℃) Specific Volume
1.054 1.050 1.046 1.042 1.036 -16 30%
1.063 1.058 1.054 1.049 1.044 -20 35%
1.071 1.067 1.062 1.057 1.052 -25 40%
1.079 1.074 1.069 1.064 1.058 -30 45%
1.087 1.082 1.076 1.070 1.064 -36 50%
1.095 1.090 1.084 1.077 1.070 -42 55%
1.103 1.098 1.092 1.084 1.076 -50 60%

G643(E) Service Manual 22 Chapter 2. Recommended Maintenance

Checking and Adjusting Drive Belt Checking Belt for Damage

Check the following items and replace the belt if

defective.

1. Check the belt surface for damage, wear and

crack.

2. Check the belt surface for oil or grease

contamination.
1. Checking tension
3. Check the rubber part for wear or hardening.
1) Press the middle of the water pump pulley and
alternator pulley with 10kgf.
4. Check the pulley surface for crack or damage.
2) Inspect the belt deflection by pressing it.

3) If the belt deflection is out of the standard,

Inspect the belt tensioner.
(The belt tensioner is pre-set and spring
loaded)

Standard
Item
New belt Used belt
Drive belt deflection (L) 4.0~4.4mm 5.1~5.7mm

G643(E) Service Manual 23 Chapter 2. Recommended Maintenance

Ignition System Maintenance 4) If ignition timing is out of the standard, inspect
sensors concerned with ignition timing.
Inspect Battery System
CAUTION
• Clean battery outer surfaces with a mixture of
Because ignition timing is fixed by set data
baking soda and water.
value in ECU, it is impossible to control on
• Inspect battery outer surfaces for damage and purpose. (G643E Engine)
replace as necessary. Fist, check that sensors send output properly to
help determine ignition timing control.
• Remove battery cables and clean, repair and/or
replace as necessary.
NOTE: Affective ECU input to Ignition timing control
Inspect Ignition System
• Coolant temperature sensor
• Remove and inspect the spark plugs. Replace as
required. • Oxygen sensor

• Inspect the ignition coil for cracks and heat • Battery voltage
deterioration. Visually inspect the coil heat sink
fins. If any fins are broken replace as required. • MAP sensor (Engine load)

• Crankshaft position sensor

Inspection of Ignition Timing
• Throttle position sensor
1. Inspection condition
• Intake Air Temperature sensor
Coolant temperature : 80-90°C(At normal
Temperature) 5) Check that actual ignition timing is changed
with engine RPM increased.
Lamp and all accessories : OFF

Transmission : In neutral position

Parking brake : ON

2. Inspection

1) Connect the timing light.

2) Measure RPM.

RPM
Low Idle 750±15 rpm

NOTE: If RPM is not normal, it is impossible to

measure the proper ignition timing, so measure it at
a normal RPM.

3) Inspect the standard ignition timing.

G643E BTDC 19±5˚

G643 BTDC 0±5˚

G643(E) Service Manual 24 Chapter 2. Recommended Maintenance

Inspection of Spark Plug

Inspection and clean

3. Check the spark plug as below.

1) Insulator broken
1) Ignition cable
2) Terminal worn

3) Carbon deposit
1. Disconnect the ignition cables from spark plugs.
4) Gasket damaged or broken
2. Remove all spark plugs from the cylinder head
using a sparkplug wrench.
5) Porcelain insulator of spark plug clearance

CAUTION
Take care not to come foreign materials into
spark-plug mounting hole.

4. Check the plug clearance using a plug clearance

gauge and if the value is not within the specified
values, adjust it by bending the ground clearance.
When installing a new sparkplug, install it after
checking the uniform plug clearance.

Spark plug clearance 0.8~0.9 mm

G643(E) Service Manual 25 Chapter 2. Recommended Maintenance

Spark Plugs

5. Install the spark plug and tighten it to the specified

torque.
Take care not to over tighten it to prevent cylinder
head threads from damage.

Tightening torque 25~30 N•m

SPARK PLUG ANALYSIS

State Contact point is Contact point is

black white
Description • Density of the • Density of the
fuel mixture is fuel mixture is
thick thin
• Lack of air • Ignition timing is
intake fast
• Spark plug is
tight
• Lack of torque

G643(E) Service Manual 26 Chapter 2. Recommended Maintenance

Fuel System Maintenance 8. Re-assemble the filter assembly aligning the
scribe lines on the top and bottom covers.

Replace LP Fuel Filter Element 9. Install the cover retaining screws, tightening the
screws in an opposite sequence across the cover.
Park the lift truck in an authorized refueling area with
the forks lowered, parking brake applied and the 10. Open the fuel valve by slowly turning the valve
transmission in Neutral. counterclockwise.

11. Crank the engine several revolutions to open the

fuel lock-off. DO NOT START THE ENGINE.
Turn the ignition key switch to the off position.

12. Check the filter housing, fuel lines and fittings for
leaks. Repair as necessary.

Testing Fuel Lock-off Operation

• Start engine.

• Locate the electrical connector for the fuel lock (A).

1. Close the fuel shutoff valve on the LP-fuel tank.
Run the engine until the fuel in the system runs
• Disconnect the electrical connector.
out and the engine stops.
• The engine should run out of fuel and stop within a
2. Turn off the ignition switch.
short period of time.
3. Scribe a line across the filter housing covers,
which will be used for alignment purposes when
re-installing the filter cover.
NOTE
FUEL FILTER DISASSEMBLY (Steps 4-7)
The length of time the engine runs on trapped fuel
vapor increases with any increase in distance
between the fuel lock-off and the pressure regulator
/converter.

• Turn the ignition key switch off and re-connect the

fuel lock-off connector.

4. Remove the cover retaining screws (1).

5. Remove top cover (2), magnet (3), spring (4), and

filter element (7) from bottom cover (5).

6. Replace the filter element (7).

7. Check bottom cover O-ring seal (6) for damage.

Replace if necessary.

G643(E) Service Manual 27 Chapter 2. Recommended Maintenance

Pressure Regulator/Converter Checking the TMAP Sensor(G643E only)
Inspection
• Verify that the TMAP sensor (F) is mounted tightly
• Visually inspect the pressure regulator/converter into the manifold or manifold adapter (E), with no
(B) housing for coolant leaks. leakage.

• Refer to Chapter 6 if the pressure • If the TMAP is found to be loose, remove the
regulator/converter requires replacement. TMAP retaining screw and the TMAP sensor from
the manifold adapter.
Fuel Trim Valve Inspection (FTV)
• Visually inspect the TMAP O-ring seal for damage.
• Visually inspect the fuel trim valves (C) for Replace as necessary.
abrasions or cracking. Replace as necessary.
• Apply a thin coat of an approved silicon lubricant
• To ensure a valve is not leaking a blow-by test can to the TMAP O-ring seal.
be performed.
• Re-install the TMAP sensor into the manifold or
1. With the engine off, disconnect the electrical manifold adapter and securely tighten the
connector to the FTVs. retaining screw.

2. Disconnect the vacuum line from the FTVs to the

pressure regulator/converter at the converter’s Exhaust System Maintenance
tee connection.
Inspect Engine for Exhaust Leaks
3. Lightly blow through the vacuum line connected to
the FTVs.
• Start the engine and allow it to reach operating
Air should not pass through the FTVs when de-
temperatures.
energized.
If air leaks past the FTVs when de-energized,
• Perform visual inspection of exhaust system from
replace the FTVs.
the engine all the way to the tailpipe. Any leaks,
even after the post-catalyst oxygen sensor, can
Inspect Air/Fuel Valve Mixer Assembly cause the sensor output to be effected (due to
exhaust pulsation entraining air upstream).
• Refer to Chapter 6 for procedures regarding the Repair any/all leaks found. Ensure the length
LP mixer (D). from the post-catalyst sensor to tailpipe is the
same as original factory.
Inspect for Intake Leaks
• Ensure that wire routing for the oxygen sensors is
• Visually inspect the intake throttle assembly (E), still keeping wires away from the exhaust system.
and intake manifold for looseness and leaks. Visually inspect the oxygen sensors to detect any
Repair as necessary. damage.(G643E only)

Inspect Throttle Assembly

• Visually inspect the throttle assembly motor

housing for coking, cracks, and missing cover-
retaining clips. Repair and/or replace as
necessary.

NOTE: Refer to Chapter 6 for procedures on

removing the mixer and inspecting the throttle plate.

G643(E) Service Manual 28 Chapter 2. Recommended Maintenance

Maintenance Schedule
NOTE: The MI-07 fuel system was designed for use with LPG fuel that complies with HD5 or HD10 LPG fuel
standards. Use of non-compliant LPG fuel may require more frequent service intervals and will disqualify the
user from warranty claims.

INTERVAL HOURS

Every Every Every Every Every Every

CHCK POINT 250 500 1000 1500 2500 3000
Daily Hours Hours Hours Hours Hours Hours
or or or or or or
1 month 3 month 6 month 9 month 15 month 18 month

General Maintenance

Test fuel system for leaks. Prior to any service or maintenance activity

Inspect engine for fluid leaks. X

Inspect all vacuum lines and fittings X

Inspect electrical system; check for loose,

X
dirty, or damaged wires and connections.
Inspect isolation mounts on engine control
module for cracks and wear; replace as X
necessary.

Inspect all fuel fittings and hoses. X

Inspect foot pedal travel and operation X

Check for MIL lamp test at key-on.

If MIL lamp remains illuminated(indicating a
x
fault),use pedal to recover fault
code(s).Repair faults.
Engine Coolant

Check coolant level. X

Inspect coolant hoses and fittings for leaks,

X
cracks, swelling, or deterioration.

Engine lgnition

Inspect battery for damage and corroded

X
cables.

Inspect ignition system. X

Replace spark plugs X

Fuel Lock-Off/Filter

Replace LP fuel filter element. X

Inspect lock-off and fuel filter for leaks. X

Ensure lock-off stops fuel flow when engine

X
is off.

G643(E) Service Manual 29 Chapter 2. Recommended Maintenance

INTERVAL HOURS

Every Every Every Every Every Every

CHCK POINT 250 500 1000 1500 2500 3000
Daily Hours Hours Hours Hours Hours Hours
or or or or or or
1 month 3 month 6 month 9 month 15 month 18 month

Pressure Regulator/Converter

Test regulator pressures. X

Inspect pressure regulator vapor hose for

deposit build-up. Clean or replace as X
necessary.
Inspect regulator assembly for fuel/coolant
X
leaks

Fuel Trim Valve(G420FE only)

Inspect valve housing for wear, cracks or

X
deterioration.

Ensure valve seals in the closed position

X
when the engine is off.

Replace FTV When indicated by MIL

Carburetor(Mixer)

Check air filter indicator X

Check for air leaks in the filter system. X

Inspect air/fuel valve mixer assembly for

Cracks, loose hoses, and fittings. Repair or x
Replace as necessary.
Check for vacuum leaks in the intake
system including manifold adapter and x
mixer to throttle adapter

Repair or replace throttle assembly When indicated by MIL

Inspect air filter. X

Replace air filler element X

Check TMAP sensor for tightness and

leaks. X

Exhaust & Emission

Inspect engine for exhaust leaks X

Replace PCV valve and breather element. X

Replace HEGO sensors When indicated by MIL

G643(E) Service Manual 30 Chapter 2. Recommended Maintenance

Chapter 3. ENGINE MECHANICAL SYSTEM
General Information
Engine Outline

G643 (E) Service Manual 31 Chapter 3. Engine Mechanical System

Specification Crankshaft
Crankshaft Journal
General Diameter #1
Type ................................................90 Degree V6 ...............62.199-62.217 mm (2.4488-2.4495 in)
Displacement ................................. 4.3L (262 CID) Diameter 2, #3
RPO (VIN Code) ......................... L35 (W), LF6 (X) ...............62.192-62.215 mm (2.4485-2.4494 in)
Bore.........................................101.6 mm (4.00 in) Diameter #4
Stroke.................................... 88.39 mm (3.480 in) ...............62.180-62.202 mm (2.4480-2.4489 in)
Compression Ratio ....................................... 9.2:1 Taper.......................0.0254 mm (.001 in.) MAX.
Firing Order .........................................1-6-5-4-3-2 Out-of Round...........0.025 mm (.0010 in.) MAX.
Crankshaft Bearing Clearance
Lubrication System Bearing #1
Oil Capacity ...................0.0254-0.0381 mm (.0010-.0015 in)
Without Filter Change .........................4.3 Liters Bearing #2, #3
With Filter Change Add .......................0.5 Liters ...................0.0254-0.0635 mm (.0010-.0025 in)
Oil Pressure (Minimum Hot) Bearing #4
.................. 41.4 kPa (6.0 psi) at 1,000 engine rpm ...................0.0635-0.0889 mm (.0025-.0035 in)
.............. 124.1 kPa (18.0 psi) at 2,000 engine rpm Crankshaft End Play
.............. 165.5 kPa (24.0 psi) at 4,000 engine rpm .......................... 0.0508-0.2032 mm (.002-.008 in)
OIl Filter System ..................................... Full Flow
OIl Pump Type................................... Gear Driven Connecting Rod
Connecting Rod Journal
Cylinder Bore Diameter.57.117-57.142 mm (2.2487-2.2497 in)
Diameter.101.618-101.643 mm (4.0007-4.0017 in) Taper........................0.0254 mm (.001 in) MAX.
Out-of Round .............. 0.0508 m (.002 in) MAX. Out-of-Round............0.0254 mm (.001 in) MAX.
Taper........................ 0.0254 mm (.001 in) MAX Rod Bearing Clearance
...................0.0254-0.0762 mm (.0010-.0030 in)
Piston Rod Side Clearance
Piston Bore Clearance ...................... 0.1524-0.4318 mm (.006-.017 in)
............................ 0.06096 mm (.0024 in) MAX.
Camshaft
Piston Rings Journal Diameter
Piston Compression Ring ...................47.440-47.490 mm (1.8677-1.8697 in)
Groove Clearance........ 0.010668 mm (.0042 in) End Play...........0.0254-0.2286 mm (.001-0.009 in)
Gap ........................... 0.889 mm (.035 in) MAX. Lobe Lift ................................. ± 0.05 mm (.002 in)
Piston Oil Ring Intake .............................. 7.018 mm (0.2763 in)
Groove Clearance.... 0.2032 mm (.008 in) MAX. Exhaust ........................... 7.252 mm (0.2855 in)
Gap .....................................1.651 mm (.065 in)
Balance Shaft
Oil Pan Front Bearing Journal Diameter
Engine Block Clearance ...............55.985-55.001 mm (2.1648-2.1654 in)
Tolerance ................... 0.254 mm (.010 in) MAX. Rear Bearing Journal Diameter
.................38.084-38.100 mm (1.4994-1.500 in)
Piston Pin Rear Bearing Journal Clearance
Diameter............ 23.545-23.548 mm (.927-.926 in) ...................0.0254-0.09144 mm (.001-.0036 in)
Clearance in Piston.. 0.0254 mm (.001 in) MAX.
Fit In Connecting Rod Valve System
0.02032-0.04064 mm (.0008-.0016 in) Interference Valve Lifter ................................... Hydraulic Roller
Valve Rocker Arm Ratio ..............................1.50:1
Exhaust Manifold Valve Lash ......................Net Lash No Adjustment
Surface Flatness........ 0.254 mm (.010 in) MAX. Face Angle ............................................45 degree
Seat Angle.............................................46 degree
Intake Manifold Seat Runout .................0.0508 mm (.002 in) MAX.
Surface Flatness........ 0.254 mm (.010 in) MAX. Seat Width Intake
.......................... 1.016-1.651 mm (.040-.065 in)
Cylinder Head Exhaust ............. 1.651-2.489 mm (.065-.098 in)
Surface Flatness...... 0.1016 mm (.004 in) MAX. Stem Clearance
Intake

G643 (E) Service Manual 32 Chapter 3. Engine Mechanical System

..... High Limit Production + 0.0257 mm (.001 in) Intake Manifold Bolts
Exhaust First Pass .................................. 3 N·m (27 lb·ft)
..... High Limit Production + 0.0508 mm (2.03 in) Second Pass ......................... 12 N·m (106 lb·ft)
Valve Spring Free Length..............52 mm (2.03 in) Final Pass ............................... 15 N·m (11 lb·ft)
Pressure
Closed Oil Filter Bypass Valve Bolt.......... 27 N·m (20 lb·ft)
..... 338-374 N at 43 mm (76-84 lb. at 1.70 in) Oil Level Indicator Tube Bolt ...... 12 N·m (106 lb·ft)
Open OIl Pan Nuts................................ 23 N·m (17 lb·ft)
. 832-903 N at 32 mm (187-203 lb. at 1.27 in) Bolts........................................ 25 N·m (18 lb·ft)
Installed Height Studs in Engine Block.............. 25 N·m (18 lb·ft)
...................... 42.92-43.43 mm (1.690-1.710 in) Oil Pan Drain Plug ....................... 25 N·m (18 lb·ft)
Valve Lift Oil Pump Bolt .............................. 90 N·m (66 lb·ft)
Intake...................................10.51 mm (.414 in) OIl Pump Cover Bolt.................. 12 N·m (106 lb·ft)
Exhaust ...............................10.87 mm (.428 in) Oxygen Sensor Wire Support Bracket Nut
.................................................... 11 N·m (97 lb·ft)
Spark Plugs
Torque Specification Cylinder Head (New) ............... 30 N·m (22 lb·ft)
Cylinder Head (All Subsequent Installation)
Balance Shaft Driven Gear Bolt ................................................ 20 N·m (15 lb·ft)
.......................20 N·m (15 lb·ft) (Plus 35 Degrees) Spark Plug Wire Support ........... 12 N·m (106 lb·ft)
Camshaft Retainer Bolt ..............12 N·m (106 lb·ft) Valve Lifter Guide Retainer Bolt ... 16 N·m (12 lb·ft)
Camshaft Sprocket Bolts..............28 N·m (21 lb·ft) Valve Rocker Arm Cover Bolts... 12 N·m (106 lb·ft)
Coolant Sensor ............................20 N·m (15 lb·ft) Water Outlet Bolt ......................... 25 N·m (18 lb·ft)
Connecting Rod Nut Water Pump Bolt ......................... 41 N·m (30 lb·ft)
.......................27 N·m (20 lb·ft) (Plus 70 Degrees)
Crankshaft Balancer Bolt ...........100 N·m (74 lb·ft)
Crankshaft Bearing Cap Bolt......105 N·m (77 lb·ft)
Crankshaft Position Sensor Bolt.....9 N·m (80 lb·ft)
Crankshaft Rear Oil Seal Housing
Nut and Bolt.................................15 N·m (11 lb·ft)
Crankshaft Rear Oil Seal Housing Stud
......................................................4 N·m (35 lb·ft)
Cylinder Head Bolt
First Pass.................................30 N·m (22 lb·ft)
Second Pass Torque Angle all Bolts in Sequence:
Short Length Bolt........................ 55 Degrees
Medium Length Bolt.................... 65 Degrees
Long Length Bolt ........................ 75 Degrees
Distributor Clamp Bolt ..................25 N·m (18 lb·ft)
EGR Valve Bolt
First Pass.................................10 N·m (89 lb·ft)
Final Pass................................25 N·m (18 lb·ft)
EGR Valve Pipe Bracket Bolt .......25 N·m (18 lb·ft)
EGR Valve Inlet Pipe Nut.............35 N·m (26 lb·ft)
Engine Block Drain Plug ..............20 N·m (15 lb·ft)
Engine Block Oil Gallery Plug Left Rear
....................................................20 N·m (15 lb·ft)
Engine Block Oil Gallery Plug Right Rear
....................................................25 N·m (18 lb·ft)
Engine Block Oil Gallery Plug Left Side Rear
....................................................20 N·m (15 lb·ft)
Engine Front Cover Bolt.............12 N·m (106 lb·ft)
Exhaust Manifold Stud and Bolt
First Pass.................................15 N·m (11 lb·ft)
Final Pass................................30 N·m (22 lb·ft)
Engine Flywheel Bolt .................100 N·m (74 lb·ft)
Front Lift Bracket Stud .................40 N·m (30 lb·ft)
Ignition Coil Bolt...........................11 N·m (97 lb·ft)

G643 (E) Service Manual 33 Chapter 3. Engine Mechanical System

Oil Pan Oil Filter

Tightning Specifications for Oil Pan Tightening Specifications for Oil Filter

(1) ............................................................Oil Pan (1) Wipe clean the filter adapter in the area that the
new filter makes contact. Put clean engine oil on
(2) Torque for Plug....................... 45 N·m (33 lb·ft) the new filter gasket. Install filter until contack is
(4) Torque for ten bolts................. 25 N·m (18 lb·ft) made the tighten 3/4 turn more.

(5) Torque for two nuts................. 25 N·m (18 lb·ft) (2) Torque for adapter is

................................54 ± 14 N·m (40 ± 10 lb·ft)

Oil Pump

Tightening Specifications for Oil Pump to Main Bearing Cap Bolt

(1)...........................................................Oil Pump

(2) Torque for bolt ...................... 90 N·m (66 lb·ft)

G643 (E) Service Manual 34 Chapter 3. Engine Mechanical System

Exhaust Manifolds Intake Manifolds

Exhaust Manifold Left Side

Tightening Specifications for Intake Manifolds

Intake manifold bolt in three steps using sequence

shown in IAGS023S

First pass ...................................... 3 N·m (27 lb·ft)

Second pass ............................. 12 N·m (106 lb·ft)

Third pass ................................... 15 N·m (11 lb·ft)

Exhaust Manifold Right Side

Tightening Specifications for Exhaust Manifold.

Exhaust manifold tighten bolts in two steps, begin
with the center bolts.

(1) Torque for exhaust manifold bolts

...................................................... 15 N·m (11 lb·ft)

(2) Torque for exhaust manifold bolts (second pass)

...................................................... 30 N·m (22 lb·ft)

G643 (E) Service Manual 35 Chapter 3. Engine Mechanical System

Flywheel Housing Flywheel

(1) Flywheel housing bolts should be torqued to (1) Torque for the bolts that hold the flyweel to the
...................................40 to 45 N·m (30 to 35 lb·ft) crankshaft100 N·m (74 lb·ft)

(2) Use a torch. Heat the ring around the entire

Flywheel Face Runout circumference, then drive the gear off the
flywheel using care not to damage the flywheel

NOTICE
Never heat the ring to a red hot condition this will
change the metal structure

Uniformly heat the ring gear to a temperature that

will expand the gear to permit installation.
Temperature must not exceed 204℃ (400 ℉).

As soon as the ring gear has been heated install it

on the flywheel.

Face Runout Check

Maximum permissible face runout of the flywheel

housing......................................0.20 mm (.008 in)
(See Flywheel Housing Checks in Testing And
Adjusting).

G643 (E) Service Manual 36 Chapter 3. Engine Mechanical System

Flywheel Runout Pressure Cap

For checking procedure, see Flywheel And Flywheel

Housing in the Testing And Adjusting section.

Face Runout (Axial Eccentricity).

For testing procedure, see Cooling System Tests in

the Testing And Adjusting section.

Pressure valve opening pressure

.....................................85 to 110 kPa (12 to 16 psi)

Maximum permissible face runout of the flywheel Vacuum valve opening pressure
................................................0.19 mm (.0075 in) ........................................... 0 to 5 kPa (0 to 0.7 psi)

Outside Diameter Runout (Radial Eccentricity) Thermostat

Outside Diameter Runout Check

Full open temperature...... 85 to 95℃ (185 to 195℉)

Maximum permissible outside diameter runout of the

flywheel .......................................... 0.1 mm (.004 in)

G643 (E) Service Manual 37 Chapter 3. Engine Mechanical System

Camshaft Balance Shaft

(1) Torque for camshaft sprocket bolts (1) Front Bearing Journal Diameter
................................................ 20 N·m (15 lb·ft) ...... 55.985 to 55.001 mm (2.1648 to 2.1654 in)

(2) Torque for retainer mounting bolts (2) Rear Bearing Journal Diameter
.............................................. 12 N·m (106 lb·ft) ........ 38.084 to 38.100 mm (1.4994 to 1.500 in)
Rear Bearing Journal Clearence
(3) End play for the camshaft .......... 0.0254 to 0.09144 mm (.001 to .0036 in)
..............0.0254 to .02286 mm (.001 to .009 in)
(3) Balance Shaft Drive Gear Bolt
(4) Diameter of the surface journals for the camshaft ................................................ 20 N·m (15 lb·ft)
bearings new Torque plus 35 Degrees
..............51.03 to 51.05 mm (2.009 to 2.010 in)
(4) Balance Shaft Retainer Bolt
.............................................. 14 N·m (124 lb·ft)

NOTE : Balance shaft must be timed to camshaft

gear.

G643 (E) Service Manual 38 Chapter 3. Engine Mechanical System

Front Gear Cover

Height of camshaft lobes

(A) Intake lobe ....................... 7.018 mm (.2763 in)

(B) Exhaust lobe .................... 7.252 mm (.2855 in)

(C) Maximum permissible difference actual & (1) The front gear cover (1) of the engine must be
specified lobe lift.................± 0.05 mm (.022 in) replaced if it is removed for any reason. The
cover is made of high impact plastic but can
See procedure under Testing And Adjusting section warp do to heat. To prevent oil leaks replace the
of manual on to due measurements cover.

(2) The front gear cover bolts should be torqued to

............................................... 15 N·m (11 lb·ft)

G643 (E) Service Manual 39 Chapter 3. Engine Mechanical System

Cylinder Heads Valve Clearence

Tools Needed A
Torque Angle Meter 1

(1) The 4.3 liter engine has screw-in rocker arm

studs with positive stop shoulders, NO valve
adjustment is necessary. When the valve train
requires service you simply tighten the rocker
arm nuts to 25 N·m (18 lb·ft).
NOTE : When installing the cylinder heads use a
new head gasket. Do not use sealer on the
composite gasket.

Tighten the cylinder head bolts in the following

sequence.

All bolts are torqued to a torque of 30 N·m (22 lb·ft).

On the second pass a tool A degree wheel must be
used.

Bolts in sequence.

1. Short length bolts (11, 7, 3, 2, 6, 10) 55 degrees

2. Medium length bolts (12, 13) 65 degrees

3. Long length bolts (1, 4, 8, 5, 9) 75 degrees

G643 (E) Service Manual 40 Chapter 3. Engine Mechanical System

Engine Exploded View

G643 (E) Service Manual 41 Chapter 3. Engine Mechanical System

UPPER ENGINE PARTS

ITEM # DESCRIPTION ITEM # DESCRIPTION

1 COVER, VALVE ROCKER ARM (RH) 56 MODULE, DIST. IGN. CONT. (PT OF 3)
COVER, VALVE ROCKER ARM (LH) 61 SHAFT, DISTRIBUTOR (PT OF 3)
2 CAP, OIL FILL 62 RETAINER, DIST. IGN P/U COIL
3 DISTRIBUTOR 63 BOLT, IGNITION COIL
4 BOLT, DISTRIBUTOR CLAMP 64 COIL, IGN. (INCL. BRKTS, COIL, SCREW & NUT)
5 CLAMP, DISTRIBUTOR 67 OUTLET, WATER
6 GASKET, DISTRIBUTOR 68 GASKET, WATER OUTLET
9 GROMMET, VALVE ROCKER ARM COVER 69 THERMOSTAT, ENGINE COOL
11 PLUG, INTAKE MANIFOLD VACUUM HOLE 72 SENSOR, ENGINE COOL TEMP
12 PLUG, SQ HD FILL & DRAIN 77 VALVE, PCV
13 BOLT, INTAKE MANIFOLD 78 GROMMET, PCV VALVE
14 MANIFOLD, INTAKE 81 CAP, DISTRIBUTOR (PT OF 3)
15 GASKET KIT, 95 GUIDE, VALVE LIFTER PUSH ROD
17 BOLT, VALVE ROCKER ARM COVER 96 BOLT, VALVE LIFTER GUIDE
19 NUT, VALVE ROCKER ARM 97 NIPPLE, HTR INL HOSE
21 ARM, VALVE ROCKER 99 HOSE, WATER PUMP INLET (INCL. CLAMPS)
22 GASKET, VALVE ROCKER 2A GASKET KIT, INTAKE MANIFOLD
23 BOLT, CYLINDER HEAD (LONG)
24 BOLT, CYLINDER HEAD (MEDIUM)
25 BOLT, CYLINDER HEAD (SHORT)
26 SPARK PLUG
28 VALVE, EXHAUST
29 VALVE, INTAKE
30 LIFTER, VALVE
32 ROD, VALVE PUSH
33 GASKET, CYLINDER HEAD
34 HEAD, CYLINDER
35 STUD, VALVE ROCKER ARM BALL
36 SEAL, INTAKE VALVE STEM OIL
37 SPRING, VALVE (W/O DAMPER)
39 SEAL, EXHAUST VALVE STEM OIL
41 KEY, VALVE STEM
42 CAP, VALVE SPRING
44 BOLT, VALVE LIFTER GUIDE
48 PIN, DIST. GEAR (PT OF 3)
49 GEAR, DIST. SHAFT (PT OF 3)
50 WASHER, DIST. SHAFT (PT OF 3)
51 WASHER, DIST. SHAFT THR (PT OF 3)
52 SHIELD, DIST. IGN. P/U COIL (PT OF 3)
53 COIL, DISTRIBUTOR PICK UP (PT OF 3)
54 OLE PIECE & PLATE, DISTRIBUTOR (PT OF 3)
55 BOLT, DISTR. IGNITION ICM (PT OF 3)

G643 (E) Service Manual 42 Chapter 3. Engine Mechanical System

G643 (E) Service Manual 43 Chapter 3. Engine Mechanical System
LOWER ENGINE PARTS

ITEM # DESCRIPTION ITEM # DESCRIPTION

1 RING KIT, PISTON (STD) 48 FITTING, O IL FILTER
KIT, PISTON (0.50 MM O.S.) 49 FILTER, O IL
2 PISTON KIT, ENGINE (STD) 50 GEAR, FLYWHEEL RING
PISTON KIT, ENGINE (0.50 MM O.S.) 58 BALANCER, CRANKSHAFT
3 ROD, CONN (INCL. BOLTS, CAP, NUT& ROD) 60 BOLT, ENGINE FRONT COVER
4 BOLT, CONN ROD 61 COVER, ENG FRT
5 BEARING KIT, CONN ROD (STD) (INCLS BOLTS, COVER, GROMMETS & SEAL)
7 NUT, CONN ROD (GASKET MOLDED TO COVER)
9 PLUG, ENGINE BLK OIL GAL (RR)(RH) 62 KEY, CRANKSHAFT BALANCER
PLUG, ENGINE BLK OIL GAL (RR)(LH) 63 BEARING KIT, CRANKSHAFT (#1, 2, & 3)
10 PLUG, CM/SHF RR BRG HOLE 64 BEARING KIT, CRANKSHAFT (RR #4)
11 PIN, CR/SHF RR OIL SEAL HSG 65 BOLT, CRANKSHAFT BEARING CAP
12 PIN, CYL. HEAD LOC. 67 GASKET, CRANKSHAFT RR OIL SEAL HSG
13 PIN, TRANS. LOC. 68 STUD, CRANKSHAFT RR OIL SEAL RETAINER
14 PLUG, ENG BLK CORE HOLE 69 BOLT, CRANKSHAFT RR OIL SEAL HOUSING
15 VALVE, OIL FILTER BYPASS 70 BOLT, CRANKSHAFT RR OIL SEAL HOUSING
16 PIN, CM/SHF SPKT LOC. 71 HOUSING, CR/SHF RR OIL SEAL
17 PLUG, ENGINE BLK OIL GAL (FRT)(RH) 75 GASKET, OIL PAN
PLUG, ENGINE BLK OIL GAL (FRT)(LH) 76 AN, OIL (INCL BAFFLE, BOLTS, GSKT, INSER PAN,
18 CAMSHAFT, ENGINE (INCL. #16) PLUG, & SEALER)
19 CHAIN, CM/SHF TMG (IS A ROLLER CHAIN) 77 SEAL, OIL PAN DRAIN PLUG (O-RING)
20 SPROCKET, CM/SHF (SEE ITEM 2A @ END) 78 PLUG, OIL PAN DRAIN (W/MAGNET & SEAL)
21 SPROCKET, CR/SHF (SEE ITEM 2A @ END) 79 BOLT, OIL PAN (HFH 5/16 - 18 X 7/8)
22 BOLT, CM/SHF SPROCKET 80 NUT, OIL PAN (5/16 - 18 X 20)
23 BOLT, CM/SHF SPROCKET RETAINER 82 PLUG, ENG BLK OIL GAL (CUP 15/32 X 5/16)
24 RETAINER, CM/SHF 83 SEAL, CRANKSHAFT SEAL (61.5MM)
25 BEARING, CM/SHF (#1 POSITION) 84 NUT, CR/SHF RR OIL SEAL RET
26 BEARING, CM/SHF (#2 POSITION) 87 PLUG, KNOCK SENSOR HOLE
27 BEARING, CM/SHF (#3 POSITION) 88 BOLT, BALANCER SHAFT GR
28 BEARING, CM/SHF (#4 POSITION) 90 RETAINER, BALANCER SHAFT
31 GASKET, W /PMP (PART O F 35) 91 BALANCER (INCL'S ITEM 121)(INTERNAL)
32 BOLT, WATER PUMP 92 PLUG, BALANCER SHAFT RR BRG HOLE
35 PUMP, W/P (INCLS GASKET & PLUG) 93 BEARING KIT, BALANCER SHAFT
36 SHAFT, O IL PUMP DRIVE 94 BOLT, BALANCER SHAFT RETAINER
37 PIN, O IL PUMP DRIVE 105 GASKET, WATER PUMP COVER
38 RETAINER, O IL PUMP DRIVE SHAFT 106 WASHER, INT-EXT TOOTH
39 PUMP, O IL 107 BOLT, WATER PUMP COVER
40 BOLT, O IL PUMP 108 FLYWHEEL, ENGINE
41 SCREEN, O IL PUMP 109 PLUG, ENGINE BLOCK COOL DRAIN HOLE
42 PLUG, O /P RLF VLV BORE (PT O F 39 & 47) 113 GROMMET, ENGINE FRONT COVER
43 ALVE, O IL PRESSURE RELIEF (PT OF 39 &47 1A GEAR KIT, BAL SHF (INCL DRIVE & DRIVEN GEAR)
44 SPRING, O IL PRESSURE RELIEF VALVE 2A CHAIN KIT, TIMING (INCLS CHAIN, CR/SHF
45 BOLT, O IL PUMP COVER (PT OF 39) SPROCKET & CM/SHF PROCKET)
46 PIN, O /P RLF VLV SPR ST (PT O F 39 & 47) N.S.S. NOT SOLD SEPARATELY
47 COVER, O IL PUMP (PART O F 39)

G643 (E) Service Manual 44 Chapter 3. Engine Mechanical System

Engine Construction the bearing uses a sleeve-type bearing.

The 4.3L (262 CID) engine is a liquid-cooled 90 V6 Valve Train

type with overhead valves, cast-iron block, cylinder
heads, and cast-iron balance shaft. The valve train is a ball pivot type. Motion is
transmitted from the camshaft through the valve
Cylinder Block lifter and valve pushrod to the rocker arm. The valve
rocker arm pivots on its ball and transmits the
The cylinder block has 6 cylinders arranged in a “V” camshaft motion to the valve.
shape with 3 cylinders in each bank. Starting at the
front of the engine, cylinders in the right bank are The valve lifters with roller followers keep all parts of
numbered 1-3-5 and cylinders in the left bank are the valve train in constant contact. Each lifter acts as
numbered 2-4-6 (when viewed from the front of the an automatic adjuster and maintains zero lash in the
engine). The firing order of the cylinders is 1-6-5-4- valve train and eliminates the need for periodic valve
3-2. The cylinders are encircled by coolant jackets. adjustment.

Cylinder Heads

The cylinder heads have one intake and one Statement On Cleanliness And Care
exhaust valve for each cylinder. A spark plug is
located between the valves in the side of the An engine is a combination of many machined,
cylinder head. The valve guides are integral and the honed, polished, and lapped surfaces with very fine
rocker arms are retained on individual threaded tolerances.
studs. Whenever valve train components, cylinder head,
cylinder, crankshaft, or connecting rod components
Crankshaft are removed for service, they should be retained in
order. At the time of installation, they should be
The crankshaft is supported by four crankshaft installed in the same locations and with the same
bearings. The number four bearing at the rear of the mating surfaces as when removed.
engine is the end thrust bearing. The bearings are
retained by bearing caps that are machined with the Any time the air cleaner or TBI unit is removed, the
block for proper alignment and clearances. intake opening must be covered. This will protect
against the entrance of foreign material which could
Camshaft follow the intake passage into the cylinder and
cause extensive damage when the engine is started.
The camshaft is supported by four full round, sleeve-
type bearings. A sprocket on the crankshaft drives a When any internal engine parts are serviced, care
timing chain which in turn drives the camshaft and cleanliness are important. A liberal coating of
through a sprocket. engine oil should be applied to friction areas during
assembly to protect and lubricate the surfaces on
Pistons and Connecting Rods initial operation. Throughout this Section, it should
be understood that proper cleaning and protection of
The pistons are made of cast aluminum alloy using machined surfaces and friction areas is part of the
two compression rings and one oil control ring. repair procedure. This is considered standard shop
Piston pins are offset 0.9 mm (0.0354 in.) toward the practice even if not specifically stated.
major thrust side (right side) to reduce piston slap as
the connecting rod travels from one side of the
piston to the other side after a stroke. The pins are a
press fit in the connecting rod and a floating fit in the
piston.

Balance Shaft

A cast-iron balance shaft is mounted in the

crankcase above and in line with the camshaft.
A camshaft gear drives the gear attached to the
balance shaft. The front end of the balance shaft is
supported by a ball-type bearing. The rear end of

G643 (E) Service Manual 45 Chapter 3. Engine Mechanical System

Use Of Rtv Sealer And Anaerobic Gasket Using Anaerobic Gasket Eliminator
Eliminator
1. Clean surfaces to be resealed with a chlorinated
Two types of sealer are commonly used in the solvent (GM P/N 1050454 or equivalent) to
engines covered by this manual. These are RTV remove all oil, grease, and old material.
sealer and anaerobic “gasket eliminator” sealer. It is
important that these sealers be applied properly and 2. Apply a continuous bead of gasket eliminator to
in their proper place to prevent oil leaks. THE TWO one flange.
TYPES OF SEALERS ARE NOT INTER-
CHANGEABLE. Use the sealer recommended in the 3. Spread the bead evenly with your finger to get a
procedure. uniform coating on the complete flange.
RTV (room temperature vulcanization) sealer is
used where a non-rigid part is assembled to a rigid 4. Assemble parts in the normal manner and torque
part. Common examples are oil pans and rocker immediately to specifications.
covers. Anaerobic gasket eliminator hardens in the
absence of air. This sealer is used where two rigid IMPORTANT: Anaerobic sealed joints that are
parts (such as castings) are assembled together. partially torqued and allowed to cure more than
When two rigid parts are disassembled and sealer five minutes may result in incorrect shimming of
or gasket is readily noticeable, the parts were the joint.
probably assembled using gasket eliminator.

Using RTV Sealer

1. Do not use RTV when extreme temperatures are

expected, such as exhaust manifold, head
gasket or where gasket eliminator is specified.

2. When separating components sealed with RTV,

use a rubber mallet and “bump” the part
sideways to shear the RTV sealer. “Bumping”
should be done at bends or reinforced areas to
prevent distortion of parts. RTV is weaker in
shear (lateral) strength than in tensile (vertical)
strength.

NOTICE: Attempting to pry or pull components apart

may result in damage to the part.

3. Surfaces to be resealed must be clean and dry.

Remove all traces of oil and RTV with a
chlorinated solvent (GM P/N 1050454 or
equivalent). Do not use petroleum cleaners such
as mineral spirits. They leave a film onto which
RTV will not stick.

4. Apply RTV to one of the clean surfaces. Use a

bead size as specified in the procedure. Run the
bead to the inside of any bolt holes. Do not allow
the sealer in any blind threaded holes, as it may
prevent the bolt from seating properly or cause
damage when the bolt is tightened.

5. Assemble while RTV is still wet (within 3

minutes). Do not wait for RTV to skin over.

6. Torque bolts to specifications. Do not overtorque.

G643 (E) Service Manual 46 Chapter 3. Engine Mechanical System

Replacing Engine Gaskets 1. Determine size, pitch, and depth of damaged
thread. If necessary, adjust stop collars on
cutting tool and tap to required depth.
CAUTION
Composite type gaskets are used in some areas IMPORTANT: Refer to the kit manufacturer's
of the engine assembly. These gaskets have a instructions regarding the size of drill and tap to
thin metal core. Use caution when removing or be used.
handling composite gaskets to help avoid
personal injury. 2. Drill out damaged thread.

3. Tap hole. Lubricate tap with light engine oil.

Clean the thread.

Thread Repair IMPORTANT: Avoid build-up of chips. Back out

the tap every few turns and remove chips.
Figure 12-2
4. Thread the thread insert onto the mandrel of the
Tool Required: installer. Engage the tang of the insert on the
end of the mandrel.
• General purpose thread repair kits are
available commercially. 5. Lubricate the insert with light engine oil (except
when installing in aluminum) and install.
Damaged threads may be reconditioned by drilling
out, rethreading, and installing a suitable thread IMPORTANT: When correctly installed, the insert
insert. should be flush to one turn below the surface.

6. If the tang of the insert does not break off when

CAUTION backing out the installer, break the tang off with a
drift.
Wear safety glasses to avoid eye damage.

Figure 12-2 Repairing Thread Holes

G643 (E) Service Manual 47 Chapter 3. Engine Mechanical System

Special Tools

Tool # Description

J 21882 Oil Pickup Tube and Screen Installer

J 23738-A Valve Seal Leak Detector

J 24086-B Piston Pin Remover and Installer Set

J 24270 Ridge Reamer

J 3049-A Valve Lifter Remover

J 33049 Camshaft Bearing Remover and Installer

J 34673 Straightedge

J 35621 Crankshaft Rear Seal Installer

J 36669 Torque Angle Meter

J 36996 Bearing Remover

J 38834 Balance Shaft Bearing Service Kit

J 39046 Torsional Damper Puller and Installer

J 5239 Connecting Rod Guide Set

J 5590 Crankshaft Sprocket Installer

J 5715 0.0762 mm (0.003 in.) Reamer

J 5825-A Crankshaft Sprocket Puller

J 5830-02 Reamer Set J 5830-1, 5830-2, and 5830-3

J 5830-1 0.08 mm (0.003 in.) Reamer

J 5830-2 0.38 mm (0.015 in.) Reamer

J 5830-3 0.76 mm (0.030 in.) Reamer

J 6036 0.3302 mm (0.013 in.) Reamer

J 6098-01 Camshaft Bearing Remover and Installer

J 6621 0.13 mm (0.005 in.) Reamer

J 7872 Magnetic Base Dial Indicator

J 8001 Dial Indicator

J 8037 Ring Compressor

J 8056 Valve Spring Tester

J 8062 Valve Spring Compressor

J 8087 Cylinder Bore Gage

J 8089 Wire Brush

J 8092 Driver Handle

J 8101 Valve Guide Cleaning Tool

J 9290-01 Valve Lifter Remover

G643 (E) Service Manual 48 Chapter 3. Engine Mechanical System

J 5590
J 3049-A
Crankshaft Sprocket
Valve Lifter Remover
Installer

J 6098-01
J 5715 or J 6036
Camshaft Bearing
Rocker Stud Hole Reamer
Remover/Installer

J 5239
J 8062
Connecting Rod Bolt Guide
Valve Spring Compressor
Set

J 8087 J 8089
Cylinder Bore Gauge Carbon Remover Brush

J 7872
J 8001
Magnetic Base Dial
Dial Indicator
Indicator

G643 (E) Service Manual 49 Chapter 3. Engine Mechanical System

J 9290-01
J 8 037
Valve Lifter Remover
Piston Ring Compressor
(Slide Hammer Type)

J 24086-C
J 24270
Piston Pin Remover/
Ridge Reamer
Installer Set

J 24420-C
Universal J 21882
Crankshaft Pulley Oil Suction Pipe Installer
Remover

J 35621
Crankshaft Rear Oil
Seal Installer

G643 (E) Service Manual 50 Chapter 3. Engine Mechanical System

Cooling System
General Description

Cooling System Schematic

(1) Cylinder head. (2) Thermostat. (3) Recovery tank. (5) Radiator top hose. (6) Radiator pressure cap.
(7) Cylinder walls. (8) Radiator. (9) Radiator lower hose. (10) Water pump.

Water pump (10) is installed on the front of the thermostat (2) is open the coolant will go through
cylinder block. The water pump is driven by a single radiator top hose (5) and into the top tank of radiator
V belt from the crankshaft pulley. The inlet opening (8). Coolant then goes through the cores of the
of the water pump is connected to the radiator lower radiator. The air from the fan will make the coolant
hose (9). The outlet flow from the water pump goes cool as the coolant flows to the bottom of the
through passages inside the cylinder block. radiator and out hose (9) where the coolant returns
to water pump (10).
The coolant from the water pump through the
cylinder block passages has primary coolant flow to The radiator is equipped with a shroud to increase
and around the seats for the exhaust valves. This the efficiency of the fan and cause the air to be
method gives the coolant with the coolest pushed through the radiator and away from the lift
temperature flow to the hottest area during engine truck.
operation.
If the coolant is hot and the cooling system pressure
Cylinder walls (7) are cooled by the coolant flow is too high, some coolant flows to the top of radiator
through the block. After the coolant goes through the (8) through the tube to recovery tank (3). The
cylinder block it flows through cylinder head (1) to cooling system pressure is controlled by cap (6).
the thermostat housing, where the bypass type When the cooling system pressure goes above its
thermostat (2) is installed. The thermostat controls rated pressure, a valve opens in pressure cap (6)
the opening to radiator (8) to control the temperature which releases the cooling system pressure to the
in the cooling system. atmosphere. After the engine is at normal
temperature for operation, a development of vacuum
If the coolant is cold (cool), the thermostat will be is present in the cooling system. Pressure cap (6)
closed. The coolant circulates (makes a complete permits air in the radiator to remove the vacuum at
circuit) from the water pump and through the the same time coolant from recovery tank (3) is
cylinder block until the temperature of the coolant is pulled back into the radiator.
warm enough to make the thermostat open. When

G643 (E) Service Manual 51 Chapter 3. Engine Mechanical System

Testing & Adjusting 5. Inspect the drive belts for the fan.

Adhere to the following warnings when performing 6. Check for damage to the fan blades.
any tests or adjustments while the engine is running:
7. Look for air or combustion gas in the cooling
system.
WARNING
Work carefully around an engine that is running. 8. Inspect the filler cap and the surface that seals
Engine parts that are hot, or parts that are the cap. This surface must be clean.
moving, can cause personal injury.
9. Look for a large amount of dirt in the radiator core
and on the engine.
WARNING
10. Check for loose or missing fan shrouds that
Exhaust fumes contain carbon monoxide (CO)
cause poor flow of cooling air.
which can cause personal injury or death. Start
and operate the engine in a well ventilated area
only. In an enclosed area, vent the exhaust to
Cooling System Tests
the outside.

This engine has a pressure type cooling system. A

pressure type cooling system gives two advantages.
The first advantage is that the cooling system can
have safe operation at a temperature that is higher
than the normal boiling (steam) point of water. The
second advantage is that this type system prevents
cavitation (the sudden making of low pressure
bubbles in liquids by mechanical forces) in the water
pump. With this type system, it is more difficult for
an air or steam pocket to be made in the cooling
system.

The cause for an engine getting too hot is generally

because regular inspections of the cooling system
were not made. Make a visual inspection of the
cooling system before testing with testing equipment.
Remember that temperature and pressure work
Cooling System Visual Inspection
together. When making a diagnosis of a cooling
system problem, temperature and pressure must
WARNING both be checked. Cooling system pressure will have
an effect on cooling system temperatures. For an
Do not loosen the filler cap or pressure cap on a example, look at the chart to see the effect of
hot engine. Steam or hot coolant can cause pressure and height above sea level on the boiling
severe burns. (steam) point of water.

1. After the engine is cool, loosen the filler cap (on a

radiator with a pressure cap, turn it to the first
stop) to let pressure out of the cooling system.
Then remove filler or pressure cap.

2. Check coolant level in the cooling system.

3. Look for leaks in the system.

4. Look for bent radiator fins. Be sure that air flow

through the radiator does not have a restriction.

G643 (E) Service Manual 52 Chapter 3. Engine Mechanical System

Pressure Cap Test Cooling System Leak Check

To test the cooling system for leaks, use the

following procedure:

WARNING
If the engine has been in operation and the
coolant is hot, slowly loosen the pressure cap to
the first stop and let the pressure out of the
cooling system, then remove the pressure cap.

1. Remove pressure cap from the radiator.

Pressure Cap Diagram 2. Make sure the radiator is full (hot) or nearly full
(A) Sealing surface of cap and radiator. (cold) of coolant.

One cause for a pressure loss in the cooling system 3. Attach the Cooling System Pressurizing Pump
can be a bad seal on the pressure cap of the system. Tool to the radiator filler neck.
Inspect the pressure cap carefully. Look for damage
to the seal or the sealing surface. Any foreign 4. Pump the pressure to 20 kPa (3 psi) more than
material or deposits on the cap, seal or seal or the rated pressure of the cap.
sealing surface must be removed.
5. Check the radiator for outside leakage.
To check the pressure cap opening pressure, do the
following procedure. 6. Check all connections and hoses of the cooling
system for outside leakage.
WARNING
7. If there is no outside leakage and the pressure
If the engine has been in operation and the reading on the gauge is still the same after 5
coolant is hot, slowly loosen the pressure cap to minutes, the radiator and cooling system do not
the first stop and let the pressure out of the have leakage. If the reading on the gauge goes
cooling system, then remove the pressure cap. down and there is no outside leakage, there is
leakage on the inside of the cooling system. Make
repairs as necessary.
1. Remove pressure cap from the radiator.

2. Put the pressure cap on the Cooling System

Pressurizing Pump Tool.

3. Look at the gauge for the pressure that makes the

pressure cap open. It must be as follows:
A403658 ............. 76 to 100 kPa (11 to 14.5 psi)

4. If the pressure cap is bad, install a new pressure

cap.

G643 (E) Service Manual 53 Chapter 3. Engine Mechanical System

Thermostat Cooling System Heat Problems

The thermostat is the wax pellet type. A jiggle valve To check if there is a good reason for heat problems
(which improves air bleeding during water supply) is do the checks that follow:
provided on the flange part. When the thermostat is
closed, the circulation of coolant is stopped, thereby 1. The indications of a heat problem are as follows:
making warm-up faster.
a. High coolant temperature indicator light is on
Operation or needle of coolant temperature gauge is in
red range.
When the temperature of the coolant is low, the
valve is closed by the spring, with the result that the b. Coolant boils out (comes out because of too
coolant circulates within the engine, without passing much heat) of the cooling system during
through the radiator. operations.
When the temperature of the coolant rises and
reaches a certain specified temperature, the valve c. Coolant boils out on the floor when the engine
opens and the coolant also circulates through the is stopped.
radiator.
d. Coolant must be added at the end of each
When the temperature increases further and shift but Steps b and c are not present.
reaches a certain specified temperature, the valve
opens fully, allowing even more coolant to circulate 2. If indication in Step 1a is only present. It is
through the radiator. possible the problem is only a damaged gauge,
light or sender. Make a replacement of the
Thus, in this way the degree of valve opening is defective part.
varied according to the temperature of coolant, and
the temperature of coolant is adjusted by varying the 3. If indication in Step 1b is present, do the
amount of coolant caused to circulate through the procedure that follows:
radiator.
a. Run the engine at medium idle (1200 rpm) for
Thermostat Test three minutes after high idle operation. This
cools off the hottest parts of the engine before
To test the thermostat opening temperature, use the it is stopped.
following procedure: b. Install a coolant recovery system on the truck,
if not already equipped.

WARNING 4. If indications in Step 1b, 1c or 1d are present, but

The pan, water and thermostat will be very hot Step 1a is not and the high temperature indicator
and can cause burns. Do not touch the pan, light does work, the problem can be a damaged
water or thermostat. Handle the components radiator cap seal or there can be a leak in the
with an insulated device for protection. cooling system. Complete the procedure that
follows:

1. Remove the thermostat from the engine. a. Do the Pressure Cap Test, Cooling System
Leak Check, Thermostat Test and Belt
2. Hang the thermostat in a pan of water. Put a Adjustment in the Testing And Adjusting.
thermometer in the water. Put the thermostat
completely under water. Do not let the thermostat b. Clean the radiator with hot water (steam
make contact with the pan. clean) at low pressure and use detergent or air
according to the different types of debris that
3. Put heat to the pan of water. Make the water in caused the radiator to be dirty (plugged).
the pan move around. This keeps all of the water
at the same temperature. c. Check the engine high idle setting.

4. The thermostat must start to open when the

temperature is 82°C (180°F). The thermostat must
be fully open at 96°C (205°F).

G643 (E) Service Manual 54 Chapter 3. Engine Mechanical System

NOTE: Another condition that can cause heat Filling at over 20 liters per minute can cause air
problems is the ignition timing. Retarded (late) pockets in the cooling system.
timing causes the engine to send more heat to the
cooling system. Advanced (early) timing causes the After draining and refilling the cooling system,
engine to send less heat to the cooling system. operate the engine with the radiator cap removed
until the coolant reaches normal operatin
temperature and the coolant level stabilizes. Add
coolant as necessary to fill the system to the proper
Cooling System Recommendation level.

Coolant Information Operate with a thermostat in the cooling system all

year-round. Cooling system problems can arise
The engine cooling system is provided with a without a thermostat.
mixture of 50% ethylene glycol anti-freeze and 50%
water (For the vehicles of tropical area, the engine Coolant Water
cooling system is provided with a mixture of 40%
ethylene glycol anti-freeze and 60% water at the Hard water, or water with high levels of calcium and
time of manufacture.) magnesium ions, encourages the formation of
Since the cylinder head and water pump body are insoluble chemical compounds by combining with
made of aluminum alloy casting, be sure to use a 30 cooling system additives such as silicates and
to 60% ethylene glycol antifreeze coolant to assure phosphates.
corrosion protection and freezing prevention.
The tendency of silicates and phosphates to
precipitate out-of-solution increases with increasing
WARNING water hardness. Hard water, or water with high
If the concentration of the antifreeze is below levels of calcium and magnesium ions encourages
30%, the anticorrosion property will be adversely the formation of insoluble chemicals, especially after
affected. In addition, if the concentration is a number of heating and cooling cycles.
above 60%, both the antifreeze and engine
cooling properties will decrease, adversely DOOSAN prefers the use of distilled water or
affecting the engine. For these reasons, be sure deionized water to reduce the potential and severity
to maintain the concentration level within the of chemical insolubility.
specified range.
Acceptable Water
To prevent damage to your engine, never add Water Content Limits (ppm)
coolant to an overheated engine. Allow the engine to Chlorides (CI) 40 maximum
cool first. Sulfates (SO4) 50 maximum
If the lift truck is to be stored in, or shipped to, an
area with freezing temperatures, the cooling system Total Hardness 80mg/ℓ maximum
must be protected to the lowest expected outside Total Solids 250 maximum
(ambient) temperature. pH 6.0 ~ 8.0
ppm = parts per million
The engine cooling system is protected with a
commercially available automotive antifreeze, when Using water that meets the minimum acceptable
shipped from the factory. water requirement may not prevent drop-out of
these chemical compounds totally, but should
Check the specific gravity of the coolant solution minimize the rate to acceptable levels.
frequently in cold weather to ensure adequate
protection. Antifreeze

Clean the cooling system if it is contaminated, if the DOOSAN recommends selecting automotive
engine overheats or if foaming is observed in the antifreeze suitable for gasoline engines using
radiator. aluminum alloy parts. The antifreeze should meet
ASTM-D3306 standard.
Old coolant should be drained, system cleaned and
new coolant added as recommended with the
commercially available automotive antifreeze.

G643 (E) Service Manual 55 Chapter 3. Engine Mechanical System

Make proper antifreeze additions.

Adding pure antifreeze as a makeup solution for

cooling system top-up is an unacceptable practice. It
increases the concentration of antifreeze in the
cooling system which increases the concentration of
dissolved solids and undissolved chemical inhibitors
in the cooling system. Add antifreeze mixed with
water to the same freeze protection as your cooling
system.

G643 (E) Service Manual 56 Chapter 3. Engine Mechanical System

Engine Lubrication Filtered oil flows into the main gallery and then to
the camshaft, balance shaft, rear bearing, and
General Description crankshaft bearings. The valve lifter oil gallery
supplies oil to the valve lifters. Oil flows from the
Full pressure lubrication, through a full-flow oil filter valve lifters through the hollow valve pushrods to the
is supplied by a gear-type oil pump. Oil is drawn up rocker arms. Oil drains back to the crankcase
through the oil pump screen and passes through the through oil drain holes in the cylinder head. The
pump to the oil filter. The oil filter is a full-flow paper camshaft timing chain is drip fed from the front
element unit with an anti-drain back valve. An oil camshaft bearing. The pistons and piston pins are
filter bypass valve is used to ensure adequate oil lubricated by oil splash.
supply in the event the filter becomes plugged or
develops excessive pressure drop.

Figure 12-1 Engine Lubrication Flow

G643 (E) Service Manual 57 Chapter 3. Engine Mechanical System

Testing and Adjusting

Adhere to the following warnings when performing

any tests or adjustments while the engine is running.

WARNING
Work carefully around an engine that is running.
Engine parts that are hot, or parts that are
moving, can cause personal injury.

WARNING
Engine Oil Viscosity Recommendation
Exhaust fumes contain carbon monoxide (CO)
which can cause personal injury or death. Start NOTE: In normal case, the recommended engine oil
and operate the engine in a well ventilated area for G643(E) engine is SAE 10W - 30.
only. In an enclosed area, vent the exhaust to
the outside. But, if the excessive valve noise occurs up to five
minutes after a cold start and if the maximum
Engine Oil ambient temperature is lower than 10°C (50°F), it is
recommended to change engine oil to SAE 5W - 30
Engine Oil Recommendation for that application.
The following oil specifications provide the Synthetic Oils
guidelines for the selection of commercial products :
Use gasoline engine oil. Recommended API service Synthetic engine oils are not recommended for use
classification is class SJ grade. in G643(E) Engine. Synthetics may offer advantages
in cold-temperature pumpability and high-
temperature oxidation resistance.
However, synthetic oils have not proven to provide
NOTICE operational or economic benefits over conventional
petroleum-based oils in G643(E) Engine. Their use
Failure to follow the oil recommendations can cause does not permit the extension of oil change intervals.
shortened engine life due to carbon deposits or
excessive wear. Lubrication System Problems

One of the problems in the list that follows will

Prior to changing oil, select an oil based on the generally be an indication of a problem in the
prevailing daytime temperature in the area in which lubrication system for the engine.
the engine is operated. The chart in figure is a guide
to selection the proper crankcase oil. • Too much oil consumption.
IMPORTANT: Oils containing “solid” additives, non- • Low oil pressure.
detergent oils, or low-quality oils are not
recommended for use in G643(E) Engine. • High oil pressure.

• Too much component wear.

G643 (E) Service Manual 58 Chapter 3. Engine Mechanical System

Too Much Oil Consumption Before starting the engine, the engine oil light(1) on
the instrument panel will turn on when the key
• Engine outside oil leakage switch is turned to the ON position. The light will turn
off after the engine is started and while the engine is
Check for leakage at the seals at each end of the running, lidicating normal oil pressure. The light will
crankshaft. Look for leakage at the oil pan gasket turn on during operation only when there is
and all lubrication system connections. Check to see insufficient engine oil pressure to properly lubricate
if oil comes out of the crankcase breather. This can the engine’s internal parts.
be caused by combustion gas leakage around the
pistons. A dirty crankcase breather will cause high If the oil light comes on, indicating the pressure is
pressure in the crankcase, and this will cause low, check for the causes that follow:
gasket and seal leakage.
1. Low oil level in the crankcase.
• Combustion area oil leakage
2. Defect in the oil pressure indicator light or oil
Oil leakage into the combustion area of the cylinders pressure sensor unit.
can be the cause of blue smoke. There are three
possible ways for oil leakage into the combustion 3. Restriction to oil pump screen.
area of the stems.
4. Leakage at the oil line connections.
1. Oil leakage between worn valve guides and valve
stems. 5. Worn connecting rod or main bearings. Worn
gears in the oil pump.
2. Worn or damaged piston rings, or dirty oil return
holes. 6. Oil pressure relief valve worn or stuck in the
OPEN position.
3. Compression ring and/or intermediate ring not
installed correctly. 7. Oil filter bypass valve stuck open. Oil filter is
restricted. Replace oil filter.
NOTE: Too much oil consumption can also be the
result if oil with the wrong viscosity is used. Oil with High Oil Pressure
a thin viscosity can be caused by fuel leakage into
the crankcase, or by increased engine temperature. Oil pressure will be high if the oil pressure relief
valve in the oil pump cannot move from the closed
Low Oil Pressure position.

Too Much Component Wear

When some components of the engine show

bearing wear in a short time, the cause can be a
restriction in an oil passage. A broken oil passage
can also be the cause.
If an oil pressure check is done and the oil pressure
is correct, but a component is worn because it does
not get enough lubrication, look at the passage for
oil supply to that component. A restriction in a
supply passage will not let enough lubrication get to
a component and this will cause early wear.
Instrument Panel
(1) Engine Oil Light

G643 (E) Service Manual 59 Chapter 3. Engine Mechanical System

Disassembly of Engine It is beyond the scope of this Section to cover in
detail the many different accessory installations.
English and Metric Fasteners Refer to the appropriate service manual section for
this information.

CAUTION Diagrams of emissions and vacuum hose routings,

wiring harness routing, accessory drive belt layout,
Late model engines use a combination of etc. should be made before removing accessories.
English and Metric threaded fasteners. The
components effected are starter motor, engine Cleaning
mounts, and flywheel housing mounting. Verify
that the proper fasteners are used whenever It is important that the engine be as clean as
removing or replacing one of these components. possible to prevent dirt from entering critical areas
during disassembly.

Tools And Shop Equipment Remove the engine accessories before cleaning, to
provide better access to the engines exterior
A clean well-lit work area should be available. Other surfaces. After removing the TBI unit, distributor,
necessary equipment includes: a suitable parts etc., cover the openings with tape to prevent the
cleaning tank, compressed air supply, trays to keep entry of contaminants.
parts and fasteners organized, and an adequate set
of hand tools. Methods used to clean the engine will depend on
the means which are available. Steam cleaning,
An approved engine repair stand will aid the work pressure washing, or solvent cleaning are some of
and help prevent personal injury or component the acceptable methods. Allow the engine to dry
damage. thoroughly before beginning any work.

Special tools are listed and illustrated throughout

this Section with a complete listing at the end of the Draining The Engine
Section. These tools (or their equivalents) are
specially designed to quickly and safely accomplish Remove or Disconnect
the operations for which they are intended. The use
of these special tools will also minimize possible 1. Oil pan drain plug and washer.
damage to engine components.
IMPORTANT: Allow the oil to drain into a proper
Some precision measuring tools are required for container.
inspection of certain critical components. Torque
wrenches are necessary for the correct assembly of 2. Oil filter.
various parts.
3. Coolant drain plug and/or knock sensor from the
Accessory Removal block.

The various procedures in this manual assume that IMPORTANT: Allow the coolant to drain from the
the engine accessories have been removed. These block into a proper container.
accessories may include one or more of the
following: Install or Connect

• Hydraulic Pump NOTICE: Refer to “Notice” on page 1.

• Drive Belt Tensioner
• Alternator 1. Oil pan drain bolt.
• Cooling Fan
• Distributor 2. Coolant drain plug and/or knock sensor into the
• Accessory Mounting Brackets block.
• Starter Motor
• Carburetor / Mixer Components

G643 (E) Service Manual 60 Chapter 3. Engine Mechanical System

Tighten Exhaust Manifold Removal

• Coolant drain plug and/or knock sensor to Figure 12-4

14 N·m (124 lb. in.).

• Drain plug to 25 N·m (18 lb·ft.).

Engine Flywheel Removal

Figure 12-3

Remove or Disconnect

1. Engine flywheel bolts.

2. Engine flywheel.
Figure 12-4 Exhaust Manifold

Remove or Disconnect

1. Exhaust manifold bolts and / or nut.

2. Heat shields.

3. Exhaust manifold.

4. Gaskets.

Figure 12-3 Engine Flywheel

G643 (E) Service Manual 61 Chapter 3. Engine Mechanical System

High Mounted Fan Bracket Removal

Start By:

a. Remove fan belt.

b. Remove wires from alternator.

1. Remove bolts from pump pulley.

1. Remove (5) Bolts from bracket.

2. Remove the bracket assembly.

2. Remove pulley from pump.

Note: For installation of the fan bracket, reverse the

removal steps and torque mounting bolts to 50 N·m
(37 lb·ft.).

Coolant Pump Removal 3. Remove bolts from pump.

Remove or Disconnect

Start By:

a. Draining coolant from radiator.

b. Remove by-pass hose and

c. LP hose from pump.

d. Remove fan belt.

G643 (E) Service Manual 62 Chapter 3. Engine Mechanical System

< Components >

4. Remove pump from engine.

5. Remove gasket and clean surface.

1. Gasket-Thermostat Housing 2. Thermostat Housing Spacer

Valve Rocker Arm Cover Removal 3. Thermostat Assembly 4. Housing-Thermostat 5. Bolt
6. ECT Sensor-SECM 7. Plug 8. Fitting
Figure 12-5 9. Water Temp Sender

Remove or Disconnect

1. Valve rocker arm cover bolts.

2. Valve rocker arm covers.

3. Gaskets.

1. Remove bolts. Remove thermostat housing and

gasket.

Figure 12-5 Valve Rocker Arm Cover

Thermostat Removal

Start By: 2. Remove failed thermostat.

a. Draining coolant from radiator. 3. Clean both mounting surfaces, engine and
thermostat housing of any gasket material.
b. Removing upper radiator hose from thermostat
housing.

G643 (E) Service Manual 63 Chapter 3. Engine Mechanical System

Intake Manifold Removal Remove or Disconnect

Start By: IMPORTANT: Store all reusable components in

an exact order so they can be reassembled in
a. Remove fuel lines and linkage from carburetor. the same wear pattern location from which they
were removed. Mark the front end of the retainer.
b. Remove coolant bypass line from manifold.
1. Rocker arm nuts, balls, and valve rocker arms.
c. Remove the distributor from the manifold.
2. Valve pushrods.

3. Bolt.

4. Valve lifter retainer.

5. Valve lifters.

1. Remove the bolts from manifold.

Figure 12-6 Valve Rocker Arm and Components

IMPORTANT:

2. Remove the intake manifold from the engine. • Remove the lifters one at a time using a
magnet. Place the lifters in the organizer rack,
3. Remove the intake manifold gaskets from location. or tag them in some way to ensure they can
be returned to the valve lifter bore from which
4. Clean mounting surface where RTV sealant was they were removed.
used. • Some lifters may be stuck in their bores due
to gum or varnish deposits. These lifters can
be removed using either J 3049-A (figure 12-7)
Valve Train Component Removal or J 9290-01 (figure 12-8).

Tools Required:

J 3049-A Valve Lifter Remover (Plier Type)

J 9290-01 Valve Lifter Remover
(Slide Hammer Type)

Figures 12-6 through 12-8

G643 (E) Service Manual 64 Chapter 3. Engine Mechanical System

1. Remove spark plugs from cylinder head
assemblies.
Figure 12-7 Removing Valve Lifter

2. Remove bolts from cylinder head.

Figure 12-8 Removing Valve Lifter

Cylinder Head Removal

Remove or Disconnect
3. Remove cylinder heads from block.
Start By:

a. Removing high mounted fan bracket.

b. Remove distributor from intake manifold.

c. emove intake manifold assembly.

d. Remove exhaust manifold assemblies.

e. Remove rocker arm assemblies.

G643 (E) Service Manual 65 Chapter 3. Engine Mechanical System

Oil Pan Removal

Figures 12-10 and 12-11

Remove or Disconnect

1. Oil filter adapter bolts.

2. Oil filter adapter gasket.
3. Oil filter adapter O-ring seal, if equipped.
4. Oil filter adapter.
5. Oil pan nuts.
6. Oil pan bolts.
4. Remove head gasket. 7. Oil pan.
8. Gasket.

Torsional Damper Removal

Figure 12-9

Remove or Disconnect

Tool Required:

J 39046 Torsional Damper Puller and Installer

NOTICE: The inertial weight section of the torsional

damper is assembled to the hub with a rubber
sleeve. The removal procedures must be followed
(with the proper tools) or movement of the inertia
weight section of the hub will destroy the tuning of
the torsional damper and the engine timing
reference.
Figure 12-10 Oil Filter Adapter Equipped with Oil Cooler (Typical)
1. Torsional damper bolt.

2. Torsional damper using J 39046 (figure 12-12).

3. Crankshaft key.

Figure 12-9 Removing Torsional Damper Figure 12-11 Oil Pan

G643 (E) Service Manual 66 Chapter 3. Engine Mechanical System

Oil Pump Removal

Figure 12-12

Remove or Disconnect

1. Bolt from oil pump to main bearing cap.

2. Oil pump assembly.

3. Driveshaft and retainer.

1. Remove bolts from cover.

2. Remove cover from engine.

Figure 12-12 Oil Pump

Timing Chain and Camshaft Sprocket

Engine Front Cover Removal Removal

IMPORTANT: Once the composite cover is Figure 12-13

removed, DO NOT reinstall it. Always install a
new engine front cover. Measure

Start By: • Check camshaft timing chain free play. If the

camshaft timing chain can be moved back and
a. Removing crankshaft pulley. forth in excess of 16 mm (0.625 in.), make a note
that the camshaft timing chain should be replaced
b. Remove crankshaft balancer. during assembly.

G643 (E) Service Manual 67 Chapter 3. Engine Mechanical System

B. Pull the camshaft out from the block being
careful to prevent damage to the camshaft
bearings.

Figure 12-13 Timing Chain and Sprockets

Remove or Disconnect

1. Camshaft sprocket bolts.

2. Camshaft sprocket and camshaft timing chain

together.
Figure 12-14 Removing Camshaft
IMPORTANT: The sprocket has a light inter-
ference fit on the camshaft. Tap the sprocket on
its lower edge to loosen it.
Balance Shaft Removal
3. Balance shaft drive gear.
Figures 12-15 through 12-17

Camshaft Removal Tools Required:

Figure 12-14 J 38834 Balance Shaft Bearing Service Kit

J 36996 Bearing Remover
Remove or Disconnect
Remove or Disconnect
1. Camshaft retainer bolts and camshaft retainer.
1. Bolt.

2. Driven gear.

3. Retainer bolts.

4. Retainer.

5. Balance shaft using a soft faced hammer (figure

12-16).

6. Balance shaft rear bearing using J 38834 and J

36996 (figure 12-17).
2. Camshaft.

A. Install three 5/16 - 18 bolts 100 - 125 mm (4-

5 in.) long into the camshafts threaded holes.
Use these bolts to handle the camshaft (figure
12-14).

G643 (E) Service Manual 68 Chapter 3. Engine Mechanical System

IMPORTANT: The balance shaft with front
bearing are serviced as an assembly. Use only
the correct tools for bearing and shaft
installation. Inspect the balance shaft driven
gear and the drive gear for nicks and burrs.

Piston and Connecting Rod Removal

Figures 12-18 and 12-19

Tools Required:

J 24270 Ridge Reamer

Figure 12-15 Balance Shaft and Components J 5239 Guide Set

Remove or Disconnect

1. Ridge or deposits from the upper end of the

cylinder bores as follows:

A. Rotate the crankshaft until the piston is at

BDC.

B. Place a cloth on top of the piston.

Figure 12-16 Removing Balance Shaft

Figure 12-18 Removing Cylinder Ridge

C. Perform the cutting operation with J 24270

(figure 12-18).

D. Rotate the crankshaft until the piston is at

TDC.

E. Remove the cloth and cuttings.

F. Repeat this procedure for each piston.

Figure 12-17 Removing Balance Shaft Rear Bearing
2. Mark the cylinder numbers on the tops of each
piston.

G643 (E) Service Manual 69 Chapter 3. Engine Mechanical System

IMPORTANT: Marking them from the front to the Crankshaft Rear Oil Seal Removal
rear, with the engine in an upright position and
viewed from the front: Figure 12-20

• The right bank is numbered 1-3-5. Remove or Disconnect

• The left bank is numbered 2-4-6. NOTICE: Take care when removing the rear crank-
shaft oil seal so as not to damage the crankshaft
3. Check the connecting rod and cap for identify- sealing surface.
cation marks.
1. Crankshaft rear oil seal. Insert a screwdriver into
IMPORTANT: Mark the parts if required. Marking the notches provided in the seal retainer and pry
them from the front to the rear, with the engine the seal out.
in an upright position and viewed from the front:

• The right bank is numbered 1-3-5.

• The left bank is numbered 2-4-6.

Store the connecting rod, bearings and cap together

as mating parts, so they may be reassembled in the
same position from which they were removed.

4. Connecting rod cap.

5. Connecting rod and piston.

Figure 12-20 Seal Removal Notches

Crankshaft Rear Oil Seal Housing

Removal

Figure 12-21

Remove or Disconnect

1. Bolts and nuts.

2. Oil seal housing.
3. Gasket.

Figure 12-19 Removing Piston and Connecting Rod

IMPORTANT: Attach J 5239 to the connecting

rod bolts (figure 12-19). Use the long guide rod
of J 5239 to push the connecting rod and piston
out of the bore through the top of the engine.

6. Connecting rod bearings.

Figure 12-21 Removing Crankshaft Rear Oil Seal Housing

G643 (E) Service Manual 70 Chapter 3. Engine Mechanical System

Crankshaft Removal

Inspect

• Check the main bearing caps for location

markings. Mark the caps if necessary. The caps
must be returned to their original locations during
assembly.

Remove or Disconnect

Notice

Be sure to mark bearings, rod and piston 3. Remove the crankshaft from the cylinder block
assemblies so when they are installed they will be in with extreme care, take care to avoid damage to
the correct location. crankshaft journals and thrust flange surfaces.

1. Remove crankshaft bearing cap bolts. 4. Remove upper main bearing inserts.

2. Remove the crankshaft bearings and lower

bearing inserts

G643 (E) Service Manual 71 Chapter 3. Engine Mechanical System

Cleaning, Inspection, and Repair

A solvent tank large enough to hold the larger

Cylinder Block
engine parts will be needed as well as various bristle
Figures 12-22 through 12-25
brushes and gasket scrapers. A source of
compressed air will also be helpful in the cleaning
Remove or Disconnect
operations.
1. Oil pressure fitting and sensor.
Special tools are listed and illustrated throughout
this Section, with a complete listing at the end of the
2. Coolant drain plugs.
Section. These tools (or their equivalents) are
specially designed to quickly and safely accomplish
3. Camshaft and balance shaft cup plugs.
the operations for which they are intended.
4. Front oil gallery cup plugs.
They should not be used in operations for which
they are not designed. These special tools, when
5. Rear oil gallery plugs.
they are properly used, will also minimize possible
damage to engine.

Some precision measuring tools are required for

inspection of certain critical components. These
include micrometers, torque wrenches, feeler gages,
dial indicator set, etc. The inspection work, when
performed with the proper methods and tools, is
most important.

The rebuilt engine cannot be expected to perform

properly if the parts are worn beyond acceptable
limits are reused.

NOTICE: Use only a razor-blade type scraper on

engine component surfaces. Use extreme care so
sealing surfaces are not scratched. Do not use any
other method or technique to remove gasket
Figure 12-22 Front Cylinder Block Oil Gallery Plugs
material except where indicated. Do not use
abrasive pads, sand paper or power tools to clean
gasket surfaces. These methods of cleaning can
damage the part. Abrasive pads also produce a fine
grit that the oil filter cannot remove from the oil.
THIS GRIT IS ABRASIVE AND HAS BEEN KNOWN
TO CAUSE INTERNAL ENGINE DAMAGE.

NOTICE: If the engine is damaged internally and

needs to be rebuilt, make sure all foreign material is
completely flushed out of the cooling system / oil
cooler system (if equipped). Failure to flush out the
debris can result in damage to the rebuilt engine.

Figure 12-23 Left Side Cylinder Block Coolant Drain and Oil
Gallery Plugs

G643 (E) Service Manual 72 Chapter 3. Engine Mechanical System

Figure 12-24 Rear Cylinder Block Oil Gallery Plugs Figure 12-25 Measuring Cylinder Block Surface Flatness

Clean - If the gap is greater than 0.05 mm (0.002 in.)

within 152 mm (6 in.) at any sealing location,
• Sealing material from mating surfaces. the block must be replaced.
• Boil cylinder block in caustic solution. Flush with - If the gap is found to be less than 0.05 mm
clean water or steam. (0.002 in.) at any sealing location and a cause
• Cylinder bores. for leakage is suspected, then the minor
• Threaded holes. irregularities may be carefully machined from
• Oil galleries and passages. the block.
• Scale deposits from coolant passages.
• Spray or wipe cylinder bores and machined • Oil pan, timing cover, and intake manifold
surfaces with engine oil. mounting surfaces for nicks. Minor irregularities
may be cleaned up with a flat file.

Inspect
Cylinder Bore
• All expansion plugs for lack of fit or leakage.
Inspect
• Valve lifter bores for deep scratches and deposits.
• Cylinder bores for scoring or other damage.
• Cracks in the block.
- Cylinder walls. • Cylinder bore taper and out-of-round.
- Coolant jackets.
- Engine mount bosses.
- Main bearing webs. Measuring Cylinder Bore Taper and Out-
Of-Round
• Main bearing bores and caps.
- All main bearing bores should be rounded and Figure 12-26
uniform in ID at all of the bearing supports.
- The area were the main bearing inserts contact Tool Required:
the main bearing bore should be smooth.
- If a main bearing cap is found to be damaged, J 8087 Cylinder Bore Gage (or equivalent)
replace the cap and line-bore the block.
IMPORTANT: If one or more cylinder bores are
• Cylinder head mounting surface for flatness, rough, scored or worn beyond limits, it will be
using a precision straightedge and feeler gage necessary to smooth or true up such bores to fit
(figure 12-25). new pistons. No attempt should be made to cut
- Set the straightedge on the sealing surface to down oversize pistons to fit cylinder bores as
be inspected. this will destroy the surface treatment and affect
- Take the feeler gage and at various locations, the weight. The smallest possible oversize
check the gap between the straightedge and pistons should be used and the cylinder bores
the sealing surface. should be honed to size for proper clearances.

G643 (E) Service Manual 73 Chapter 3. Engine Mechanical System

1. Refer to “Specifications” for tolerances.

2. Set the gage so the thrust pin must be forced in

about 7 mm (0.250 in.) to enter the gage in the
cylinder bore.

3. Center the gage in the cylinder and turn the dial

to “0”.

4. Carefully work the gage up and down to

determine taper and turn it to different points
around the cylinder wall to determine the out-of- Figure 12-27 Typical Cylinder Wear Pattern
round condition. Measure the bore both parallel
to and at right angles to the engine centerline.
Measure at the top, middle, and bottom of the
bore and note the readings.

5. Recondition the cylinder bore as necessary, as

outlined later.

Figure 12-28 Measuring Cylinder Bore Gage

3. If the cylinders are found to exceed the specified

out-of-round or taper, honing or boring will be
necessary. Any cylinders that were found to have
less than 0.13 mm (0.005 in.) wear or taper may
not entirely clean up when fitted to a high limit
Figure 12-26 Checking the Cylinder Bore piston. If it is desired to entirely clean up the bore
in these cases, it will be necessary to rebore for
an oversize piston. If more than 0.13 mm (0.005
in.) taper or wear, they should be bored and
Cylinder Bore Reconditioning honed to the smallest oversize that will permit
complete resurfacing of all cylinders.
Figures 12-27 and 12-28
4. Fine vertical scratches made by ring ends will
1. Measure the cylinder bore for out of round and not, by themselves, cause excessive oil
taper as outlined previously. consumption; therefore, honing to remove them
is unnecessary.
2. Measure for wear at the top of the bore (point
“A”) and at the bottom (point “B”). 5. Make sure the honing stones are clean, sharp,
and straight. Move the hone up and down to
• Cylinder bores can be measured by setting the produce a 45° to 65° cross-hatch pattern. Clean
cylinder gage dial at zero in the cylinder at the the bore thoroughly with soap and water. Dry
point of desired measurement. Lock the dial and rub in clean engine oil, then remeasure.
indicator at zero before removing from the
cylinder, and measure across the gage contact 6. If honing is not required, the cylinder bores
points with an outside micrometer, with the should be cleaned with a hot water and
gage at the same zero setting when removed detergent wash. Apply clean engine oil to the
from the cylinder (figure 12- 28). bore after cleaning.

G643 (E) Service Manual 74 Chapter 3. Engine Mechanical System

Boring 2. Occasionally, during the honing operation, the
cylinder bore should be thoroughly cleaned and
1. Before the honing or reboring operation is the piston selected for the individual cylinder
started, measure all new pistons with the checked for correct fit.
micrometer contacting at points exactly 90° from
the piston pin centerline. Some pistons must be 3. When honing to eliminate taper in the cylinder,
measured at a specified distance from the piston full strokes of the hone in the cylinder should be
crown. Refer to the proper Section for additional made in addition to checking measurement at
instructions. Then select the smallest piston for the top, middle and bottom of the bore
the first fitting. The slight variation usually found repeatedly.
between pistons in a set may provide for
correction in case the first piston is fitted too NOTICE: Handle the pistons with care and do not
loose. attempt to force them through the cylinder until the
cylinder has been honed to the correct size as the
2. Before using any type of boring bar, the top of piston can be distorted through careless handling.
the cylinder block should be filed to remove any
dirt or burrs. This is very important. If not 4. When finish honing a cylinder bore to fit a piston,
checked, the boring bar may be tilted which the hone should be moved up and down at a
would result in the re-bored cylinder wall not sufficient speed to obtain very fine uniform
being at right angles to the crankshaft. surface finish marks in a cross-hatch pattern at
the specified angle of 45° to 65°.
3. The instructions furnished by the manufacturer
of the equipment used should be carefully 5. The finish marks should be clean but not sharp,
followed. free from imbedded particles and torn or folded
metal.
4. When reboring cylinders, all crankshaft bearing
caps must be in place and tightened to the 6. By measuring the piston to be installed at the
proper torque to avoid distortion of the bores in sizing point specified in the proper Section, and
the final assembly. Always make sure the adding the average of the clearance specification,
crankshaft is out of the way of the boring cutter the finish hone cylinder measurement can be
when boring each cylinder. Crankshaft bearings determined. It is important that the block and the
and other internal parts must be covered or piston be measured at room temperature.
taped to protect them during the boring or honing
operation. 7. It is of the greatest importance that refinished
cylinder bores are trued up to have the less than
5. When taking the final cut with a boring bar, leave specified out-of-round taper. Each bore must be
0.025 mm (0.001 in.) on the diameter for finish final honed to remove all stone or cutter marks
honing to give the required position to the and provide a smooth surface.
cylinder clearance specifications. (The honing or
boring operation must be done carefully so the 8. Refer to “Specifications” in the proper Section
specified clearance between pistons, rings, and piston to bore clearance tolerances.
cylinder bores is maintained).
9. After final honing and before the piston is
checked for fit, clean the bores with hot water
Honing and detergent. Scrub with a stiff bristle brush and
rinse thoroughly with hot water. It is essential
that a good cleaning operation be performed. If
1. When honing the cylinders, follow the hone any of abrasive material is allowed to remain in
manufacturer's recommendations for use, the cylinder bores, it will wear the new rings and
cleaning, and lubrication during honing. Use only cylinder bores in addition to the bearings
clean, sharp stones of the proper grade for the lubricated by contaminated oil. After washing, the
amount of material to be removed. Dull, dirty dry bore should then be brushed clean with a
stones cut unevenly and generate excessive power-driven fiber brush.
heat. When using coarse or medium grade
stones, use care to leave sufficient metal so that 10. Permanently mark the piston for the cylinder
all stone marks may be removed with the fine which it has been fitted.
stones used for finishing to provide proper
clearance.

G643 (E) Service Manual 75 Chapter 3. Engine Mechanical System

11. Apply clean engine oil to each bore to prevent Remove or Disconnect
rusting.
1. Piston rings. In most cases, the rings should be
NOTICE: Refer to “Notice” on page 1. discarded and replaced with new ones at
assembly.
Install or Connect 2. Connecting rod bearing inserts. If the inserts are
to be reused, place them in a rack so they may
1. Front oil gallery plugs. Coat plug outside be reinstalled in their original connecting rod and
diameter with sealant (GM P/N 12346004) or cap.
equivalent. 3. Piston pin.
2. Rear oil gallery plugs. • Place the piston / connecting rod on support
fixture J 24086-20. Make sure the connecting
Tighten rod is fully supported.
• Press out the piston pin.
• Left rear plug to 20 N·m (15 lb. ft.).
• Right rear plug to 25 N·m (18 lb. ft.). Clean
• Left side plug to 20 N·m (15 lb. ft.).
1. Piston.
IMPORTANT: Do not have residue on camshaft • Remove all varnish and carbon deposits. DO
bearing or seizure may result. NOT USE A WIRE BRUSH.
• Remove the carbon from the ring grooves.
3. Camshaft and balance shaft cup plugs to proper • Oil control ring groove holes.
depth. Coat plug outside diameter with sealant
(GM P/N 12346004) or equivalent. Inspect

4. Oil filter adapter, gasket, and bolts. 1. Piston pin bore in the piston and connecting rod.
Check for scuffing, burrs, etc.
Tighten 2. Piston for scratches wear, etc.
3. Connecting rod for cracks, nicks, etc. If a
• Bolts to 25 N·m (18 lb·ft.). suitable jig is available, check the connecting rod
for a bent or twisted condition.
5. Coolant drain plugs.

Tighten

• Plugs to 20 N·m (15 lb·ft.)

6. Oil pressure fitting and sensor.

Tighten

• Fitting to 11 N·m (97 lb. in.) plus turn for

alignment if necessary.

Piston Disassembly

NOTICE: The connecting rod, bearing and cap need

to be stored together as mating parts, so they may
be reassembled in the same position from which
they were removed.

Figures 12-29 through 12-31

Tool Required:
• J 24086-B Piston Pin Remover and Installer
Set Figure 12-29 Piston Rings and Components

G643 (E) Service Manual 76 Chapter 3. Engine Mechanical System

Measure

1. Piston pin diameter. Check against

“Specifications.”

2. Piston pin-to-piston clearance.

A. Measure the piston pin hole diameter.

B. Subtract the piston pin diameter from the

piston pin hole diameter to obtain the
clearance.
Figure 12-30 Removing Piston Rings
C. Replace the piston and piston pin if the
4. Piston. clearance exceeds specifications. The piston
• Ring land for cracking, wear, etc. and piston pin are a matched set and not
• Ring grooves for burrs, nicks, etc. available separately.
• Skirts and pin bosses for cracking.
• Skirts for scuffing.

5. Connecting rod bearing inserts for scratches or

deep pitting.

Figure 12-32 Measuring Piston Pin Diameter

Figure 12-31 Removing Piston Pin

Measuring Piston Pin-To-Piston

Clearance

Figures 12-32 and 12-33 Figure 12-33 Measuring Piston Pin Bore Diameter

G643 (E) Service Manual 77 Chapter 3. Engine Mechanical System

Piston Selection Piston Assembly

Figures 12-34 and 12-35 Assembling the Piston and Connecting Rod

1. Check the used piston to cylinder bore clearance. Figure 12-36

Measure Tool Required:

A. Cylinder bore diameter. Use a telescoping J 24086-B Piston Pin Remover and Installer Set
bore gage, located 65 mm (2.5 in.) below the
top of the cylinder bore (figure 12-34). Install or Connect

1. Piston and connecting rod.

A. The valve cutouts in the piston crown must be

opposite the connecting rod bearing tangs.
B. Lubricate the piston pin holes in the piston
and connecting rod with engine oil.
C. Install the pin guide to hold the piston and
connecting rod together. Be sure to use the
proper pin guide. Refer to the instructions
supplied with the tool.

Figure 12-34 Measuring Cylinder Bore Diameter

B. Piston diameter. Measure the piston skirt at a

right angle to the piston pin, at the centerline
of the piston pin (figure 12-35).
C. Subtract the piston diameter from the cylinder
bore diameter to determine piston to bore
clearance.
D. Refer to “Specifications” in the proper Section.
Determine if the piston clearance is in the
acceptable range.

2. If the used piston is not acceptable, determine if

a new piston will fit the cylinder bore.
3. If a new piston does not bring the clearance
within tolerances, the cylinder bore must be
reconditioned.
4. Mark the piston to identify the cylinder for which
it was fitted.

Figure 12-36 Installing Piston Pin

2. Piston pin.

A. Insert the piston pin into the piston pin hole.

B. Place the assembly on the support fixture.

Figure 12-35 Measuring Piston Skirt

G643 (E) Service Manual 78 Chapter 3. Engine Mechanical System

C. Adjust the piston pin installer (J 24086-9) to Inspect
the correct length, using the letter-number
scale on the installer adjuster. This is 1. Ring fit as follows:
necessary to ensure that the piston pin is
pressed into the piston to the correct depth. A. Fit each compression ring to the piston on
Refer to the instructions supplied with the tool which it is going to be used.
for the proper setting.
D. Lock the adjuster in place with the lock ring.

NOTICE: After the installer hub bottoms on the

support assembly, do not exceed 35,000 kPa (5,000
PSI) pressure, as this could cause damage to the
tool.

E. Place the adjuster in the support fixture. Press

the piston pin into place (until the adjustable
installer bottoms in the support fixture).
F. Remove the piston and connecting rod
assembly from the tool and check the piston
for freedom of movement on the piston pin. Figure 12-38 Checking Ring Fit

B. Slip the outer surface of the top and second

Installing the Piston Rings compression ring into the respective piston
ring groove, to make sure that the ring is free.
Figures 12-37 through 12-39 If binding occurs at any point, the cause
should be determined. If binding is caused by
Measure the ring groove, correct by depressing the
groove with a fine cut file. If the binding is
1. Ring end gap as follows: caused by a distorted ring, try a new ring.

A. Select rings comparable in size to the piston NOTICE: All compression rings are marked on the
being used. upper side of the ring. When installing the
B. Slip the compression ring into the cylinder compression rings, make sure the MARKED SIDE
bore and press it down about 7 mm (0.250 in.) IS TOWARD THE TOP OF THE PISTON.
above ring travel. Make sure the ring is square
with the cylinder wall. NOTICE: The oil control rings are three piece types,
C. Measure the space or gap between the ends consisting of two rails and an expander.
of the ring with a feeler gage.
D. Refer to “Specifications” in the proper Section Assemble
for correct gap.
E. If the gap between the ends of the ring is not 1. Expander.
as specified, remove the ring and try another
for fit. 2. Lower rail.

3. Upper rail.

4. Lower compression ring.

5. Upper compression ring.

• Flex all rings to make sure they are free. If

binding occurs at any point the cause should be
determined. If binding is caused by the ring
groove, correct by dressing the groove with a
fine cut file. If binding is caused by a distorted
ring, try a new ring.
• Ring gaps must be 180° apart.
Figure 12-37 Measuring Ring End Gap • Rail gaps must be 180° apart.

G643 (E) Service Manual 79 Chapter 3. Engine Mechanical System

Measure Camshaft

• Ring clearance. Use a feeler gage and compare Figures 12-41 and 12-42
with “Specifications”.
Tool Required:

J 7872 Dial Indicator or Equivalent

IMPORTANT: Do not attempt to repair the

camshaft, replace it if damaged. Whenever the
camshaft is replaced, a new set of lifters must
also be installed.

Inspect

• Bearing surfaces and lobes for wear.

• Sprockets.
Figure 12-39 Measuring Ring-to-Land Clearance • Keyway and threads for galling, gouges, or
overheating.
• Camshaft journal diameters (figure 12-41). Refer
to “Engine Specifications” for proper diameters.
Intake and Exhaust Manifolds • Camshaft runout (figure 12-42). Mount the
camshaft in V-blocks or between centers. Using J
Figure 12-40 7872, check the intermediate camshaft journal.
Compare camshaft runout with “Specifications”. If
Clean the camshaft is excessively bent, replace the
camshaft and camshaft bearings.
• Mating surfaces on intake manifold and cylinder
head.
• Excessive carbon buildup in the exhaust
passages of the intake manifold.
• Scale and deposits from the coolant passages of
the intake manifold.
• EGR passage of excessive carbon deposits.

Inspect

• Manifolds for cracks, broken flanges, and gasket

surface damage.
• Alignment of manifold flanges. Use a straightedge
and feeler gage. If the flanges do not align, the
manifold is warped and should be replaced.
Figure 12-41 Measuring Camshaft Journals

Figure 12-42 Measuring Camshaft Runout

Figure 12-40 Checking Manifold Flange Alignment

G643 (E) Service Manual 80 Chapter 3. Engine Mechanical System

Camshaft Bearings Cleaning and Inspection

Camshaft Bearing Removal Clean

Figure 12-43 • Camshaft bearing bores in the block.

Tool Required: Inspect

• J 33049 Camshaft Bearing Remover and • Camshaft bearings for scratches, pits, or loose fit
Installer in their bores. Replace the camshaft bearings if
necessary.
Remove or Disconnect • Camshaft lobes and journals for scratches, pitting,
scoring, and wear. Minor irregularities may be
1. Rear camshaft plug. cleaned up with emery cloth.

2. All camshaft bearings. Use J 33049 (figure 12- Camshaft Bearing Installation
43).
Figure 12-43
A. Insert the tool with the correct collet into the
camshaft bearing you want to replace. Install or Connect

B. Turn the tool until the collet has tightened in Tool Required:
the bearing.
• J 33049 Camshaft Bearing Remover and
Installer

NOTICE: The outer camshaft bearings must be

installed first. These bearings serve as guides for
the pilot, and help center the inner bearings during
the installation process.

NOTICE: Make sure to fit the correct cam bearing

into the bore. The cam bearing bores vary in size.

1. Rear camshaft bearings. Drive the bearings into

place using J 33049 from front of engine (figure
12-43).

IMPORTANT: Make sure the camshaft bearing

hole (or holes) align with the oil hole (or holes)
in the block. On some engines, the oil holes may
be difficult to see. If so, use a piece of 2 mm rod
to check alignment.

Figure 12-43 Removing / Installing Camshaft Bearings 2. Front camshaft bearing using tool J 33049
(figure 12-43).
C. Push the center cone against the block and
into the bearing bore to center the tool. IMPORTANT: Make sure the camshaft bearing
hole (or holes) align with the oil hole (or holes)
D. Drive the bearing from the block. in the block.

E. Repeat this procedure to remove the 3. Inner camshaft bearings using tool J 33049.
remaining inner camshaft bearings. Note that Reverse of removal procedure.
the rear bearing must be removed from the
front of the block and the front bearing from 4. Camshaft rear plug.
the rear. This allows the tool to remain
centered.

G643 (E) Service Manual 81 Chapter 3. Engine Mechanical System

A. Coat a new camshaft plug with sealer GM P/N Crankshaft Sprocket Replacement
12345493 or equivalent.
Figure 12-44
B. Install the plug. The plug must be installed
deep enough in camshaft bore. Tools Required:

J 5825-A Crankshaft Sprocket Puller

J 5590 Crankshaft Sprocket Installer
Balance Shaft
Remove of Disconnect
Inspect
1. Crankshaft Sprocket. Use J 5825-A
• Balance shaft front roller bearing and rear sleeve (figure 12-44).
for damage or excessive wear. The bearings are
serviced as an assembly. Use the correct tools 2. Key, if necessary.
for properly servicing the bearings.
Install or Connect
• Balance drive and driven gears for nicks or burrs.
Replace gears that are damaged. 1. Key, if necessary.

• Front and rear bearing journal diameters. Replace 2. Crankshaft sprocket. Use J 5590
the balance shaft if the diameter exceeds the (figure 12-44).
specifications. Refer to “Specifications”.

• Rear sleeve bearing journal clearance. Replace

the balance shaft if the clearance exceeds the
specification. Refer to “Specifications”.

Timing Chain and Sprockets

Inspect

• Sprockets for chipped teeth and wear.

• Timing chain for damage.
• It should be noted that excessively worn
sprockets will rapidly wear a new chain. Likewise,
an excessively worn chain will rapidly wear a new
set of sprockets.

Figure 12-44 Crankshaft Sprocket Replacement

G643 (E) Service Manual 82 Chapter 3. Engine Mechanical System

Coolant Pump Oil Pump
Clean Figures 12-46 and 12-47

• Old gasket from the gasket surface. Remove or Disconnect

NOTICE: Do not immerse the pump in solvent. The 1. Driveshaft and retainer.
solvent may enter the pump's permanently
lubricated bearings and cause premature bearing IMPORTANT: Do not remove pickup pipe and
failure. screen unless replacement is required.

Inspect • The pickup pipe has a press fit in to the pump

cover.
• Coolant pump shaft for rotation and end play. The
shaft and fan hub should turn straight and • Do not remove the screen from the pipe. The
smoothly. If the hub wobbles or the shaft is noisy pickup screen and pipe are serviced as a
or feels “lumpy” when turned, replace the coolant complete assembly only.
pump. If the shaft end play exceeds 0.381 mm
(0.015 in.), replace the coolant pump. 2. Oil pump screen pickup.

• Coolant pump body at the drain (weep) hole. 3. Screws.

Slight staining around the weep hole is normal.
Only replace the pump if coolant is dripping from 4. Pump cover.
the weep hole while the engine is running or while
the system is pressurized. IMPORTANT: Mark where the idler gear, drive
gear and shaft mesh together so they can be
reinstalled with the same gear teeth indexed.

5. Idler gear, drive gear and shaft.

Oil Pan and Valve Rocker Covers
6. Retaining pin.
Figure 12-45
7. Pressure regulator spring.
Clean
8. Pressure regulator valve.
• Parts in solvent. Remove all sludge and varnish.

• Old gaskets from the gasket surfaces.

Inspect

• Gasket flanges for bending or damage.

• Rubber grommets and parts on the valve rocker

cover for deterioration.

• Oil pan for rock damage or cracks.

• Oil pan baffle for lack of fit.

• Drain plug threads for stripping.

Figure 12-45 Inspecting Oil Pan and Components

G643 (E) Service Manual 83 Chapter 3. Engine Mechanical System

2. Pressure regulator spring into the pump cover.

3. Retaining pin into the pump cover.

4. Drive gear and shaft into the pump body.

5. Idler gear into the pump body.

IMPORTANT: Match together the index marks on

the two gears made during disassembly.

6. Pump cover.

NOTICE: Refer to “Notice” on page 1.

Figure 12-46 Oil Pump and Components 7. Bolts.

Clean Tighten

• All parts in clean solvent and dry them with • Bolts to 12 N·m (106 lb. in.)
compressed air.

Inspect

• Pump body for cracks, wear, or other damage.

• Inside of the cover for cracks and wear that would

permit oil to leak past the ends of the gears.

• Idler and drive gears for wear.

• Drive gear and shaft for lack of fit in the pump

body.

IMPORTANT: The pump gears, cover, and body

are not serviced separately. If any of the parts
are damaged or worn, the entire oil pump
assembly must be replaced.

Inspect

• Oil pump screen damage or loose fit of the pipe.

• Pressure regulator valve for fit. The regulator

valve should slide freely in its bore without
sticking or binding.

Install or Connect

Tool Required:

J 21882 Pickup Tube and Screen Installer

1. Pressure regulator valve into the pump cover.

IMPORTANT: Replace the pressure relief valve

spring when reusing the oil pump assembly.

G643 (E) Service Manual 84 Chapter 3. Engine Mechanical System

Figure 12-47 Installing Oil Pump Screen

Inspect Valve Train Components

• With the shaft extension installed on the pump, IMPORTANT: Store all reusable components in
turn the drive shaft by hand to check for smooth an exact order, so they may be reassembled in
operation. the same position from which they were
removed.
NOTICE: Be careful of twisting, shearing, or
collapsing the pipe when installing it to the pump. A Clean
damaged pipe can cause lack of lubrication and
engine failure. • All parts in clean solvent and dry them with
compressed air.
8. Pickup screen and pipe.
• Make sure the oil passages through the pushrods
A. If the pickup screen and pipe assembly was are clear.
removed, it should be replaced with a new
part. Loss of press fit condition could result in Inspect
an air leak and loss of oil pressure.
• Valve rocker arms and balls at their mating
B. Mount the oil pump in a soft-jawed vise. surfaces. These surfaces should be free from
wear or damage.
C. Apply sealer to the end of the pipe.
• Valve rocker arm areas that contact the valve
D. Tap the pickup screen and pipe into place, stems and the socket areas that contact the ends
using J 21882 and a hammer. of the pushrods. These areas should be free of
wear or damage.
E. The pump screen must be parallel with the
bottom of the oil pan when installed. • Valve rocker arm nuts.

9. Oil pump drive shaft and connector. • Valve pushrod ends for scoring, roughness, or
bends.

- Roll the pushrod on a flat surface to determine

its straightness. If the rod is bent, the rod will
not roll freely. Replace if necessary.

G643 (E) Service Manual 85 Chapter 3. Engine Mechanical System

Valve Lifters

This engine uses hydraulic valve lifters. Valve lifters

are serviced only as an assembly. No internal parts
are available. Service is limited to disassembly and
cleaning. Discard valve lifters that are excessively
worn or damaged.

IMPORTANT: Whenever the camshaft needs to

be replaced, a new set of hydraulic lifters must
also be installed.

Cylinder Head

Disassembly Figure 12-49 Valves and Components

Figures 12-48 and 12-49 Cleaning, Inspection, and Measurement

Tool Required: Figures 12-50 through 12-54

J 8062 Valve Spring Compressor Tool Required:

Remove or Disconnect J 8089 Wire brush

1. Compress the springs with J 8062 Clean

(figure 12-48).
• Carbon from the combustion chambers using J
2. Keys. 8089.
• Valve stems and heads on a wire wheel.
3. Valve spring cap. • Carbon and old gasket from the cylinder head
gasket surface.
4. Spring. • Valve guides using a valve guide cleaner.

5. Seal. Inspect

6. Valves. • Cylinder head for cracks in the exhaust ports,

combustion chambers, or external cracks to the
IMPORTANT: Place the valves in an organizer coolant chamber. Gasket surfaces should be free
rack so they can be replaced in their original of damage.
position at reassembly. • Valves for burning, pitting, or warpage. Refer to
“Valve Grinding” in this Section. Check the valve
stems for scoring or excessive wear. Stems must
not be bent.
• Valve rocker arm studs for wear, damage, or
improper fit.
• Valve seats for pitting or other damage. Grind or
reface as needed.
• Rotators (if used). The rotators should move
smoothly without binding.
• Cylinder head for surface flatness (figure 12-51).

Figure 12-48 Compressing Valve Springs

G643 (E) Service Manual 86 Chapter 3. Engine Mechanical System

D. Move the stem of the valve from side to side
using light pressure to obtain a clearance
reading. If clearance exceeds specifications,
ream the valve guide bores for oversize valves
as outlined later.

2. Valve spring tension. Use J 8056 or equivalent.

• Compress the springs, with dampers removed,

to the specified height and check against the
specifications chart.

Figure 12-50 Cleaning the Combustion Chambers • Springs should be replaced if not within 44 N
(10 lb.) of the specified load.

3. Valve spring length. Replace the spring if the

length is not as specified.

Figure 12-51 Measuring Cylinder Head Surface

Measure

Tools Required:

J 8001 Dial Indicator (or equivalent)

J 8056 Valve Spring Tester

1. Valve stem to guide bore clearance.

NOTICE: Excessive valve stem to guide bore Figure 12-52 Measuring Stem-to-Bore Clearance (Typical)
clearance will cause excessive oil consumption and
may cause valve breakage. Insufficient clearance
will result in noisy and sticky functioning of the valve
and disturb the engine's smoothness.

A. Clamp a dial indicator (J 8001 or equivalent)

on one side of the cylinder head rocker arm
cover gasket rail.

B. Observe dial indicator movement while

moving valve from side to side (crosswise to
the head). The dial indicator measurement
must be taken just above the valve guide bore.

C. Drop the valve head about 1.6 mm (0.063 in.)

off the valve seat.

G643 (E) Service Manual 87 Chapter 3. Engine Mechanical System

Figure 12-53 Measuring Valve Spring Tension Figure 12-55 Valve / Seat Grinding

Figure 12-54 Measuring Valve Spring Length

Repair
Figure 12-56 Critical Valve Dimensions
Figures 12-55 through 12-58

Valve Grinding

Pitted valves must be refaced to the proper angle.

Valve stems that show excessive wear, or valves
that are warped excessively must be replaced.
When an excessively warped valve head is refaced,
a sharp or thin valve margin may result because of
the amount of metal that must be removed.
Undersize valve margins lead to breakage, burning,
or preignition due to heat localizing on this knife
edge (figure 12-55). Refer to “Specifications”. If the
edge of the valve head is less than specification
after grinding, replace the valve.

Several different types of equipment are available

for refacing valves. The manufacturer's instructions
for how to use the equipment should be carefully Figure 12-57 Measuring Valve Seat Concentricity
followed to attain the proper results.

G643 (E) Service Manual 88 Chapter 3. Engine Mechanical System

Valve Seat Grinding

Reconditioning the valve seats is very important.

The seating of the valves must be perfect for the
engine to deliver the power and performance it was
designed to produce.

Another important factor is the cooling of the valve

head. Good contact between each valve and its seat
will ensure that heat will be carried away properly.

Several different types of equipment are available

for refacing valves. The manufacturer's instructions
for how to use the equipment should be carefully
followed to attain the proper results.

Regardless of what type of equipment is used, it is

essential that valve guide bores be free from carbon
or dirt to ensure proper centering of the pilot in the
guide. Refer to “Specifications” for valve seat angle Figure 12-58 Reaming Valve Guides
specifications.
Assembly
Reaming Valve Guide
Figures 12-48, 12-49, 12-59 and 12-60
The valve guides used in this engine are simply
holes bored in the cylinder head. The valve guides Install or Connect
are not replaceable.
1. Valves.
If the valve stem-to-bore clearance as previously
measured is excessive, the valve guides should be A. Lubricate the valve stems with clean engine
reamed and a valve with an oversize stem installed. oil.
Oversize valves are available. Refer to “Specifica- B. Insert the valves into the proper valve guides
tions”. until the face of the valve contacts the valve
seat.
Select a reamer that will provide a straight, clean
bore through the entire length of the valve guide 2. Seal.
(figure 12-58).
A. Install the seal over the valve stem.
B. Hold the valve against the valve seat.
Valve Rocker Arm Stud Replacement C. Push the seal down the valve stem until it
bottoms out against the head.
Remove or Disconnect
3. Springs.
1. Valve rocker arm stud by unscrewing.
4. Valve spring cap.
Install or Connect
A. Compress the valve spring using J 8062
1. Valve rocker arm stud into cylinder head. (figure 12-48), enough so the lower valve stem
groove can be seen clearly.
Tighten B. Apply a small amount of grease to the area of
the upper valve stem groove.
• Rocker arm stud to 47 N∙m (35 lb·ft.). C. Assemble the two valve keys into the upper
groove using the grease to hold them in place.
D. Release the compressor tool J 8062, making
sure the valve keepers stay in place.
E. Repeat the preceding steps on the remaining
valves.

G643 (E) Service Manual 89 Chapter 3. Engine Mechanical System

Measure Thermostat and Coolant Outlet

1. Valve spring installed height of each spring as Remove or Disconnect

follows:
1. Bolts.
A. Use a narrow thin scale. A cutaway scale may
be helpful. 2. Stud.

B. Spring seat in the cylinder head to the top of 3. Coolant outlet.

the valve spring cap.
4. Gasket.
C. If this measurement exceeds the amount in
“Specifications,” install valve seat spring shims, 5. Thermostat (with gasket).
approximately 1.58750 mm (0.0625 in.) thick,
between the spring and cylinder head. NEVER Inspect
shim the spring so as to give an installed
height under the specified amount. • Coolant outlet for cracks.

Install or Connect

1. Thermostat

2. New gasket.

3. Coolant outlet.

Figure 12-59 Cutaway Scale NOTICE: Refer to “Notice” on page 1.

4. Bolt.

5. Stud.

Tighten

• Bolts to 28 N·m (21 lb·ft.).

• Stud to 28 N·m (21 lb·ft.).

Torsional Damper

Inspect

Torsional damper weight for signs of shifting on the

Figure 12-60 Measuring Valve Spring Installed Height hub. Replace as needed. The area of the torsional
damper hub shaft that contacts the front crankshaft
seal for roughness or nicks. Replace the damper if
this condition exists. If damper is replaced, new
damper weights of the same size must be installed
on the new damper in the same location as the old
damper.

G643 (E) Service Manual 90 Chapter 3. Engine Mechanical System

Crankshaft Bearings Micrometer Method

Figures 12-61 through 12-63 Measure

Cleaning and Inspection 1. The crankshaft journal diameter with a

micrometer in several places, approximately 90°
Clean apart. Average the measurements.

• Crankshaft with solvent. 2. Compute taper and runout. Refer to “Specifi-

- Do not scratch the bearing journals. cations” for allowable limits.
- Remove all sludge from the oil passages with
compressed air. Install or Connect
• Crankshaft bearing.
- Wipe free of oil with a soft cloth. 3. Crankshaft bearings into the crankshaft cap and
engine block.
Inspect
4. Install crankshaft caps and bolts.
• Crankshaft for cracks.
- Use the magnaflux method if available. 5. Tighten bolts to specification.
- Crankshaft, crankshaft bearing journals, and
thrust surfaces for scoring, nicks or damage Measure
caused by lack of lubrication.
- Main bearing inserts for scoring or other 6. Bearing inside diameter (I.D.) using an inside
damage. In general, the lower crankshaft micrometer.
bearings (except the #1 bearing) show the
greatest wear and distress from fatigue. Upon 7. Compare crankshaft bearing clearance with
inspection, if a lower crankshaft bearing is “Specifications”.
suitable for reuse, it can be assumed that the
upper crankshaft bearing is also satisfactory. If 8. If bearing clearances exceed specification, install
a lower bearing shows evidence of wear or new crankshaft bearings.
damage, both the upper and lower crankshaft
bearings must be replaced. A. Measure inside diameter with an inside
micrometer at 90° to the split line of the
Measuring Bearing Clearance crankshaft bearing.
B. Subtract journal diameter from bearing inside
Crankshaft bearings are of the precision insert type diameter to obtain bearing clearance. Refer to
and do not use shims for adjustment. If clearances “Specifications” for bearing inside clearance.
are excessive, new upper and lower bearings will be Replace or repair the crankshaft if clearance
required. Service bearings are available in standard exceeds specification.
size and undersize.

Selective fitting of crankshaft bearings is necessary

in production to obtain close tolerances. For
example, you may find one-half of a standard
crankshaft bearing with one-half of an undersize
crankshaft bearing.

To determine the correct replacement bearing size,

the bearing clearance must be measured accurately.
Either of the following two methods may be used,
however, the micrometer method gives more reliable
results and is preferred.

Figure 12-61 Measuring Crankshaft Journals

G643 (E) Service Manual 91 Chapter 3. Engine Mechanical System

Plastigage Method

Install or Connect

1. Main bearing inserts and crankshaft.

2. Gauging plastic.

A. Begin with the rear main bearing.

B. Wipe the oil from the crankshaft journal and
the lower main bearing insert.
C. Place a piece of gauging plastic the full width
of the lower bearing insert (parallel to the
crankshaft) on the journal (figure 12-62). Do
not rotate the crankshaft while the gauging
plastic is between the bearing and journal.

3. Main bearing cap and bolts. Figure 12-63 Measuring Gauging Plastic

4. Tighten bolts to specification. c. If the flattened plastic tapers toward the middle
or ends, there is a difference in clearance
Remove or Disconnect indicating taper, low spot, or other irregularity
of the bearing or journal.
• Main bearing cap. DO NOT REMOVE THE d. Normally, crankshaft bearing journals wear
GAUGING PLASTIC FROM THE JOURNAL OR evenly and are not out-of-round. However, if a
LOWER MAIN BEARING INSERT. bearing is being fitted to an out-of-round
0.0254 mm (0.001 in.) (maximum) journal, be
sure to fit to the maximum diameter of the
journal. If the bearing is fitted to the minimum
diameter and the journal is excessively out-of-
round, interference between the bearing and
the journal will result in rapid bearing failure.
e. If the bearing clearance is within specifications,
the bearing is satisfactory. If the clearance is
not within specifications, replace the bearing.
Always replace both upper and lower bearings
as a unit.
f. A standard or undersize bearing combination
may result in the proper clearance. If the
proper bearing clearance cannot be achieved
using standard or undersize bearings, it will be
necessary to replace the crankshaft.
Figure 12-62 Placing Gauging Plastic on Journal
NOTICE: Crankshaft bearings must not be shimmed,
scraped, or filed. Do not touch the bearing surface
Measure with bare fingers. Skin oil will etch the bearing
surface.
• Gauging plastic as follows:
g. Remove the flattened gauging plastic.
a. The flattened gauging plastic will be found
adhering to either the lower bearing insert or h. Measure remaining journals.
journal.
b. On the edge of the gauging plastic envelope
there is a graduated scale. Without removing
the gauging plastic, measure its compressed
width (at the widest point) with the graduations
on the gauging plastic envelope (figure 12-63).

G643 (E) Service Manual 92 Chapter 3. Engine Mechanical System

Crankshaft Runout b. Tighten bolts to specification.

Figure 12-64 c. Firmly thrust end of the crankshaft first

rearward then forward. This will line up the
Measure rear main bearing and crankshaft thrust
surfaces.
Tool Required:
d. With the crankshaft wedged forward, measure
J 7872 Magnetic Base Dial Indicator at the front end of the rear main bearing with a
feeler gage (figure 12-65). Refer to
1. Crankshaft run-out. “Specifications”.

A. Mount the crankshaft in V-blocks at crankshaft IMPORTANT: If correct end play cannot be
journals 1 and 4. obtained, be certain that the correct size rear
B. Use a dial indicator as shown (figure 12-64). main bearing has been installed. Some
C. If the main journals are misaligned, the production engines may use crankshaft
crankshaft is bent and must be replaced. The bearings that are wider across the thrust faces
main bearings must also be replaced at the than standard size bearings. Refer to
same time. “Specifications” for available bearing sizes.
D. Grind or replace the crankshaft if necessary.
In general, the lower inserts (except the # 1 Inspect
bearing) show the greatest wear and distress
from fatigue. Upon inspection, if a lower insert • Crankshaft for binding. Turn crankshaft to check
is suitable for reuse, it can be assumed that for binding. If the crankshaft does not turn freely,
the upper insert is also satisfactory. If a lower loosen the crankshaft bearing bolts, one pair at a
insert shows evidence of wear or damage, time until the tight bearing is located. Burrs on the
both the upper and lower inserts must be bearing cap, foreign matter between the bearing
replaced. and the block or the bearing cap, or a faulty
bearing could cause a lack of clearance at the
bearing.

Figure 12-64 Measuring Crankshaft Runout

Figure 12-65 Measuring Crankshaft End Play

Crankshaft End Play

Figure 12-65 Connecting Rod Bearings

Measure Follow all procedures outlined for crankshaft bearing

cleaning, inspection, and measurement. Refer to
• Crankshaft end play as follows: “Specifications”.

a. Install crankshaft bearings, crankshaft, caps,

and bolts.

G643 (E) Service Manual 93 Chapter 3. Engine Mechanical System

Connecting Rod Side Clearance

Figure 12-66

Measure

• Connecting rod side clearance as shown in figure

12-66. Refer to “Specifications”.

Figure 12-66 Measuring Connecting Rod Side Play

G643 (E) Service Manual 94 Chapter 3. Engine Mechanical System

Assembly of Engine
NOTICE
English and Metric Fasteners
If any undersized bearing are used, they must be
fitted to the proper journals.
CAUTION
Late model engines use a combination of
English and Metric threaded fasteners. The
components effected are starter motor, engine
mounts, and flywheel housing mounting. Verify
that the proper fasteners are used whenever
removing or replacing one of these components.

Prior to Assembly

The importance of cleanliness during the assembly

procedure cannot be overstressed. Dirt will cause 2. Lubricate all moving parts lightly with engine oil or
premature wear of the rebuilt engine. Lubricate all engine assembly lubricant.
moving parts lightly with engine oil or engine
assembly lubricant (unless otherwise specified) 3. Install crankshaft to cylinder block.
during assembly. This will provide initial lubrication
when the engine is started.

Crankshaft And Crankshaft Bearing

Installation

Install or Connect

IMPORTANT: If any undersized bearings are

used, they must be fitted to the proper journals.

Start by:
a. Making sure everything is clean
b. Then lubricate all moving parts before they are 4. Assemble lower crankshaft bearing to crankshaft
installed. bearing caps.

5. Install crankshaft bearing caps (except rear cap)

and bolts to the block.

1. Install upper crankshaft bearings to the block.

6. Torque crankshaft bearing cap bolts (except rear

cap) to : 105 N∙m (77lb∙ft)

G643 (E) Service Manual 95 Chapter 3. Engine Mechanical System

Crankshaft Rear Oil Seal Installation

Figure 12-68

Tool Required:

J 35621 Seal Installer

Install or Connect

1. Crankshaft rear oil seal.

A. Lubricate the inner and outer diameter of the
seal with engine oil.
7. Install rear crankshaft bearing and bolts Torque B. Install the seal on J 35621.
to : 105 N∙m (77lb∙ft) C. Position J 35621 against the crankshaft.
Thread the attaching screws into the tapped
holes in the crankshaft.
D. Tighten the screws securely with a
screwdriver. This will ensure that the seal is
Crankshaft Rear Oil Seal Housing installed squarely over the crankshaft.
Installation E. Turn the handle until it bottoms.
F. Remove J 35621.
Figure 12-67

Clean

• Gasket surfaces on the block and seal retainer.

Install or Connect

1. New gasket to the block.

IMPORTANT: It is not necessary to use sealant

to hold the gasket in place.

2. Seal retainer.
3. Screws and nuts. Figure 12-68 Installing Crankshaft Rear Oil Seal

NOTICE: Refer to “Notice” on page 1.

Tighten
Piston and Connecting Rod Installation
• Screws and nuts to 15 N∙m (11 lb∙ft.)
Connecting Rod Bearing Selection

Figures 12-69 and 12-70

Tools Required:

J 5239 Connecting Rod Guide Set

J 8037 Ring Compressor
J 36660 Torque Angle Meter

Figure 12-67 Crankshaft Rear Oil Seal Housing and Components

G643 (E) Service Manual 96 Chapter 3. Engine Mechanical System

IMPORTANT: Connecting rod bearings are of the C. Without disturbing the ring end gap location,
precision insert type and do not use shims for install J 8037 over the piston.
adjustment. DO NOT FILE RODS OR ROD CAPS. D. The piston must be installed so that the notch
If clearances are excessive, install a new bearing. in the piston faces the front of the engine.
Service bearings are available in standard size E. Place the piston in its matching bore. The
and 0.050 mm (0.002 in.), 0.254 mm (0.010 in.), connecting rod bearing tang slots must be on
0.508 mm (0.020 in.), undersize for use with new the side opposite the camshaft. Using light
and used standard size crankshafts. taps with a hammer handle, tap the piston
down into its bore (figure 12-71). Guide the
Install or Connect connecting rod to the crankpin with J 5239
(figure 12-69). Hold the ring compressor
1. Lubricate the cylinder walls lightly with engine oil. against the block until all rings have entered
the cylinder bore.
2. Make sure the piston is installed in the matching F. Remove J 5239 from the connecting rod bolts
cylinder.

3. Connecting rod bearings.

A. Make sure that the bearing inserts are of the

proper size.
B. Install the bearing inserts in the connecting
rod and connecting rod cap.
C. Lubricate the bearings with engine oil.

4. Piston and connecting rod into the proper bore.

A. With the connecting rod cap removed, install

J 5239 onto the connecting rod bolts
(figure 12-69).
B. Locate the piston ring end gaps (figure 12-70).
Lubricate the piston and rings with engine oil.

Figure 12-70 Piston Ring End Gap Location

Figure 12-71 Installing Piston

Figure 12-69 Guiding Connecting Rod

G643 (E) Service Manual 97 Chapter 3. Engine Mechanical System

IMPORTANT: Each connecting rod and bearing Tighten
cap should be marked, beginning at the front of
the engine. Cylinders 1, 3, and 5 are the right • Balance shaft retainer bolts to 14 N•m (124 lb.in.).
bank and 2, 4, and 6 are the left bank (when
viewed from the front of the engine). The 4. Balance shaft driven gear (2) and bolt (1).
numbers on the connecting rod and bearing cap
must be on the same side when installed in the
cylinder bore. If a connecting rod is ever
transposed from one block or cylinder to
another, new connecting rod bearings should be
fitted and the connecting rod should be
numbered to correspond with the new cylinder
number.

NOTICE: Refer to “Notice” on page 1.

5. Connecting rod cap with bearing insert and nut.

Tighten

• Connecting rod bolt nuts to 27 N∙m (20 lb∙ft.). Figure 12-72 Rear Balance Shaft Sleeve Bearing
• Connecting rod bolt nuts an additional 70° using
J 36660.

Measure

• Connecting rod side clearance as outlined

previously.

Balance Shaft Installation

Figures 12-72 through 12-76

NOTICE: Refer to “Notice” on page 1. Figure 12-73 Installing Balance Shaft Rear Bearing

Tools Required:

J 38834 Balance Shaft Bearing Service Kit

J 36996 Balance Shaft Installer
J 8092 Driver Handle
J 36660 Torque Angle Meter

Install or Connect

1. Balance shaft rear bearing using J 38834

(figures 12-72 and 12-73).

2. Balance shaft into block using J 36996 and

J 8092 (figure 12-74).

A. Dip the front balance shaft bearing into clean

engine oil before assembly. Figure 12-74 Balance Shaft and Components
B. Retaining ring on balance shaft front bearing
must be seated on case.

3. Install balance shaft bearing retainer and bolts.

G643 (E) Service Manual 98 Chapter 3. Engine Mechanical System

Tighten

• Balance shaft driven gear bolt to 20 N∙m

(15 lb. ft.) plus an additional turn of 35° using
J 36660.

IMPORTANT: Rotate balance shaft by hand to

make sure there is clearance between the
balance shaft and retainer. If balance shaft does
not rotate freely, check to be sure retaining ring
on front bearing is seated on case. Turn the
camshaft so, with the balance shaft drive gear
temporarily installed, the timing mark on the
drive gear is straight up. With the balance shaft
drive gear removed, turn the balance shaft so
the timing mark on the driven gear points
straight down.
Figure 12-76 Balance Shaft Drive Gear-to- Driven Gear Timing
5. Balance shaft drive gear onto camshaft. Marks

IMPORTANT: Make sure the timing marks on the

balance shaft drive gear and driven gear line up
(figure 12-76).
Camshaft Installation
6. Balance shaft drive gear bolt.
Figure 12-77
Tighten
Install or Connect
• Bolt to 16 N∙m (12 lb. ft.).
IMPORTANT: Coat camshaft lobes and journals
with Engine Oil Supplement (GM P/N 1052367) or
equivalent. Apply Engine Oil Supplement (GM
P/N 1052367) or equivalent, to all the teeth on the
distributor drive gear.

1. Install three 5/16 x 18 bolts 100 - 125 mm (4 - 5

in.) long into the camshaft threaded holes. Use
these bolts to handle the camshaft.

2. Camshaft to the engine (figure 12-77). Handle

the camshaft carefully to prevent damage to the
camshaft bearings.

Figure 12-75 Installing Balance Shaft NOTICE: Refer to “Notice” on page 1.

3. Camshaft retainer and retainer bolts. Coat

camshaft retainer plate with Engine Oil
Supplement (GM P/N 1052367) or equivalent.

Tighten

• Bolts to 14 N∙m (124 lb. in.).

G643 (E) Service Manual 99 Chapter 3. Engine Mechanical System

Engine Front Cover Installation

IMPORTANT: Once the composite front engine

cover is removed, DO NOT reinstall it. Always
install a new engine front cover.

Install or Connect

1. Engine front cover to engine.

2. Front cover bolts.

Figure 12-77 Installing Camshaft NOTICE: Refer to “Notice” on page 1.

Tighten

Timing Chain and Camshaft Sprocket • Front cover to block bolts to 9 N∙m (80 lb. in.).
Installation

Figure 12-78

Install or Connect

1. Camshaft sprocket and timing chain (figure 12-78).

IMPORTANT: Line up the timing marks on the

camshaft sprocket and crankshaft sprocket
(view A, figure 12-78). The number 4 cylinder is
at top dead center of the compression stroke
with the timing marks in this position.

2. Camshaft sprocket bolts and nut.

Tighten

• Camshaft sprocket bolts and nut to 28 N∙m

(21 lb·ft.).

Figure 12-78 Camshaft Timing Chain and Sprockets

G643 (E) Service Manual 100 Chapter 3. Engine Mechanical System

Torsional Damper Installation Oil Pump Installation

Figure 12-79 Figure 12-80

Tool Required: Install or Connect

J 39046 Torsional Damper Puller and Installer 1. Oil pump to the engine.

Install or Connect • Align the slot in the oil pump shaft with the tang
on the distributor shaft.
1. Apply RTV sealant GM P/N 12345739 to • The oil pump should slide easily into place.
crankshaft keyway (if removed). • No gasket is used.
2. Crankshaft key (if removed).
2. Oil pump to main bearing cap bolt.
NOTICE: The inertial weight section of the torsional
damper is assembled to the hub with rubber type NOTICE: Refer to “Notice” on page 1.
material. The correct installation procedures (with
the proper tool) must be followed or movement of Tighten
the inertial weight section of the hub will destroy the
tuning of the torsional damper. • Oil pump to main bearing cap bolt to 90 N∙m
(66 lb. ft.).
3. Stud (part of J 39046) to the crankshaft. Thread
the stud fully into the tapped hole in the
crankshaft.

4. Torsional damper over the end of the stud. Align

the keyway in the torsional damper shaft with the
crankshaft key.

5. Bearing, washer, and nut.

A. Turn the nut to pull the torsional damper into

place (figure 12-79).
B. Remove the tool.

6. Torsional damper bolt and washer.

NOTICE: Refer to “Notice” on page 1.

Tighten

• Bolt to 95 N∙m (70 lb. ft.).

Figure 12-80 Oil Pump Installation

Figure 12-79 Installing Torsional Damper

G643 (E) Service Manual 101 Chapter 3. Engine Mechanical System

Oil Pan Installation

Figures 12-81 through 12-85

Tool Required:

J 34673 Straightedge or equivalent

Install or Connect

1. Apply RTV sealant (GM P/N 12346141) or

equivalent to the front cover to block joint and to
the crankshaft rear retainer seal to block joint.
Apply the sealant about 25 mm (1.00 in.) in both
directions from each of the four corners (figures
12-81 and 12-82).

Figure 12-83 Installing Oil Pan to Engine Block

2. Oil pan gasket onto pan.

3. Oil pan to cylinder block (figure 12-83).

4. Slide oil pan back against straightedge using J

34673 or equivalent.

5. Oil pan bolts and nuts but do not tighten.

NOTICE: Refer to “Notice” on page 1.

Tighten
Figure 12-81 RTV Sealing Points - Front of Oil Pan
• Bolts to 25 N·m (18 lb·ft.) in the sequence shown
(figure 12-84).
• Nuts to 23 N·m (17 lb·ft.).

6. Oil filter gasket.

7. Oil filter adapter O-ring seal, if equipped.

8. Oil filter adapter bolts (figure 12-85).

Tighten

• Bolts to 25 N·m (18 lb·ft.).

Inspect

• Oil filter adapter bypass valve and spring for

operation.
Figure 12-82 RTV Sealing Points - Rear of Oil Pan • Bypass valve for cracks. If bypass valve looks
damaged in any way, replace the oil filter adapter
assembly.

9. Lubricate new oil filter seal with clean engine oil.

10. Oil filter.

G643 (E) Service Manual 102 Chapter 3. Engine Mechanical System

Figure 12-84 Oil Pan Tightening Sequence

Figure 12-85 Oil Filter Adapter Installation With Oil Cooler

(Typical)

G643 (E) Service Manual 103 Chapter 3. Engine Mechanical System

Cylinder Head Installation

Figure 12-86

Tool Reqired:

J 36660 Torque Angle Meter

Clean

• Gasket surfaces on the block and cylinder head

Install or Connect Figure 12-86 Cylinder Head Bolt Tightening Sequence

1. Head Gasket

IMPORTANT: Do not use sealer on head gaskets.

Place the gasket over the block dowel pins with
the head up.

2. Cylinder head. Carefully guide the cylinder head

into place over the dowel pins and gasket.

Notice: Refer to “Notice” on page 1.

3. Cylinder head bolts. Coat threads of the cylinder

head bolts with sealing compound (GM P/N Figure 12-87 Valve Train Components
12346004) or equivalent and install fingertight.

Tighten

A. Bolts to 30 N·m (22 lb.ft.).

B. Bolts in sequence using J 36660 to:
- Short length bolt (11, 7, 3, 2, 6, 10) 55°
- Medium length bolt (12, 13) 65°
- Long length bolt (1, 4, 8, 5, 9) 75°

4. Spark plugs.

Tighten

• Spark plug - new cylinder head to 30 N·m

(22 lb·ft.).
• All other subsequent installations to 20 N·m
(15 lb·ft.).

Figure 12-88 Valve Rocker Arms and Components

Valve Train Component Installation

Figure 12-87 and 12-88

IMPORTANT: Replace all valve roller lifters,

change the engine oil and filter, and add GM
Engine Oil Supplement GM P/N 1052367 (or
equivalent) to the engine oil whenever a new
camshaft is installed. Lubricate the valve lifters
bodies and roller with GM Engine Oil
Supplement GM P/N 1052367 (or equivalent)

G643 (E) Service Manual 104 Chapter 3. Engine Mechanical System

Install or Connect 4. Intake manifold bolts.

1. Valve lifters to the block. Tighten

2. Valve lifter guide and bolts. Note previously
made mark on the valve lifter guide. Reference • Intake manifold bolts in three steps using
mark should be pointing toward front of engine. sequence shown in figure 12-90.

Tighten - Bolts in sequence to 3 N·m (27 lb. in.).

- Bolts in sequence to 12 N·m (106 lb. in.).
• Guide bolts to 16 N·m (12 lb·ft.). - Bolts in sequence to 15 N·m (11 lb·ft.).

3. Valve pushrods.

A. Seat the valve pushrods into the socket of the Rocker Arm Cover Installation
valve lifters.
B. Coat the mating surfaces of the valve rocker Figure 12-91
arms and balls with Engine Oil Supplement
GM P/N 1052367 (or equivalent). Install or Connect

4. Valve rocker arms with balls on to the proper 1. New gasket.

stud. 2. Valve rocker arm cover.
5. Valve rocker arm nuts onto the studs (figure 12- 3. Valve rocker arm cover bolts.
88). Align the push rod into the valve rocker arm
while tightening valve rocker arm nut. No lash Tighten
adjustment is needed.
• Rocker arm cover bolts to 12 N·m (106 lb. in.).
Tighten

• Valve rocker arm nuts to 25 N·m (18 lb·ft.).

Valve Adjustment

The 4.3L engine has screw-in rocker arm studs with

positive stop shoulders, no valve adjustment is
necessary. When the valve train requires service,
you simply tighten the rocker arm nuts to 25 N·m (18
lb. ft.).

Intake Manifold Installation

Figures 12-89 and 12-90

Install or Connect

1. Gaskets to the cylinder head with the port

blocking plates facing the rear of the engine.
2. RTV to the front and rear sealing surfaces on the
block. Apply a 13 mm (1/2 in.) bead of RTV (GM
P/N 1052366) or equivalent to the front and rear
of the block as shown in figure 12-89. Extend the
bead 4 mm (5/32 in.) up each cylinder head to
seal and retain the gaskets.
3. Intake manifold to the engine.

G643 (E) Service Manual 105 Chapter 3. Engine Mechanical System

Figure 12-89 Intake Manifold Sealer Application

Figure 12-90 Intake Manifold Tightening Sequence

Figure 12-91 Valve Rocker Arm Cover Installation

G643 (E) Service Manual 106 Chapter 3. Engine Mechanical System

Exhaust Manifold Installation

Figures 12-92

Install or Connect

1. Exhaust manifold gaskets.

2. Exhaust manifold.

3. Heat shield.

4. Exhaust manifold bolts and / or nuts.

Tighten

• Bolts in two steps, beginning with the two center

bolts:

A. Bolts to 15 N·m (11 lb·ft.).

B. Bolts to 30 N·m (22 lb·ft.).

Figure 12-92 Exhaust Manifold

Flywheel Housing Installation

1. Place the flywheel housing to location.

2. Install the eight bolts that hold the flywheel

housing to location. Tighten the bolts to a torque
of 40 to 45 N·m (30 to 35 lb·ft.)

3. See Testing and Adjusting for correct procedure

to check flywheel housing runout.

G643 (E) Service Manual 107 Chapter 3. Engine Mechanical System

Engine Flywheel Installation

Figure 12-93

Install or Connect

1. Flywheel.

2. Flywheel bolts.

Tighten

• Bolts to 100 N•m (74 lb·ft.).

3. Check flywheel runout using a dial indicator. If

runout is excessive, remove flywheel, check and
clean mounting surfaces and install flywheel.
Check runout again.

Measure

• Maximum flywheel runout: 0.20 mm (0.008 in.)

Figure 12-93 Engine Flywheel

G643 (E) Service Manual 108 Chapter 3. Engine Mechanical System

Coolant Pump Installation 4. Crank the engine several times. Listen for
anyunusual noises or evidence that parts are
Install or Connect binding.

1. Install gasket to block 5. Refer to “Specifications” for ignition timing

adjustment.
2. Install pump to location.
6. Start the engine and listen for unusual noises.
7. Run the engine at about 1000 RPM until it is at
operating temperature.

8. Listen for sticking lifters and other unusual

noises.

9. Check for oil and coolant leaks while the engine

is running.

3. Assemble bolts to pump and toque to: 40 N·m

(30 lb·ft.)

4. Assemble pulley to pump.

5. Assemble bolts to pulley and torque to 25 N·m ±

6 (18.0 ± 4.5 lb·ft.)

Engine Accessory Installation

Install the engine accessories (distributor, oil filter,

generator, etc.). Connect all vacuum hoses and
electrical equipment the same way as removed.

Engine Setup and Testing

After overhaul, turn the engine over manually and

inspect for any unusual noises or evidence that
parts are binding. If parts are binding disassemble
engine to determine the source.

1. Install oil filter (if not already installed).

2. Fill the crankcase with the proper quantity and

grade of engine oil.

IMPORTANT: If a new camshaft or hydraulic

lifters were installed, add Engine Oil Supplement
GM P/N 1052367 (or equivalent) to the engine oil.

3. Fill the cooling system with the proper quantity

and grade of coolant.

G643 (E) Service Manual 109 Chapter 3. Engine Mechanical System

Chapter 4. ENGINE ELECTRICAL SYSTEM
Specifications Ignition Coil

Ignition Timing

Rating.........................................................12 Volts

The correct timing is when the flywheel housing Resistance between B+ and ground (coil mounting
pointer is in alignment with the correct mark on the bracket) ....................................................... in finite
flywheel or when the single digit mark on the
flywheel is in alignment with the correct timing mark Resistance between B+ and C-................. 0.4 ohms
on the timing plate.
Resistance between B+ coil high voltage tower.......
............................................................. 8,000 ohms
Ignition Sequence (Firing Order)
Spark Plug

Spark plug gap (gasoline & LP) ..... 0.8 mm (.035 in)

Engine firing order..................................1-6-5-4-3-2 Torque for spark ............................. 30 N·m (22 lb·ft)

Spark plug wire Resistance

0-15 inch .................................. 3,000-10,000 ohms

15-25 inch ................................ 4,000-15,000 ohms

25-35 inch ................................ 6,000-20,000 ohms

G643(E) Service Manual 110 Chapter 4. Engine Electrical System

Distributor Sensor Gap

The Air gap (X) between the trigger wheel and the
module is preset by General Motors. Therefore no
adjustment can be made or is required.

(1) Shaft end play ...197 to 198 mm (7.75 to 7.80 in)

The distributor end play will be checked with the

distributor in an inverted position from normal.
Measure from the mounting surface to the face of
the gear.

G643(E) Service Manual 111 Chapter 4. Engine Electrical System

Ignition System
General Description

Ignition System Schematic

(1) Battery. (2) Ignition switch. (3) Coil. (4) Distributor. (5) Spark plug.

The ignition system has battery (1), ignition switch

(2), coil (3), distributor (4) with inner electronics
circuits and spark plugs (5). The battery and ignition
switch have terminals and closed contacts to permit
battery current flow through the ignition system.
These components must have closed current
connections to complete the operation of the ignition
circuit. Coil (3) and spark plugs (5) are of the
standard type. The ignition coil changes the low
voltage current into high voltage current to make a
spark at the gap of the spark plug. The coil has two
windings around a soft iron core. The primary has a
Distributor Components small number of turns of heavy wire, and the
(6) Sensor. (7) Trigger wheel secondary has many thousand turns of a very fine
wire. The primary winding is on the outside of the
secondary windings. The distributor has a sensor (6),
trigger wheel (7) with lobes and the electric circuit
that is a sealed unit inside the distributor housing.

G643(E) Service Manual 112 Chapter 4. Engine Electrical System

Ignition System Control rotor arm and spark plug wires. The SECM uses the
signal from the GM (General Motors) Delco Ignition
Spark-ignited engines require accurate control of Module to determine the engine position and RPM
spark timing and spark energy for efficient at any time. It uses this information together with the
combustion. The MI-07 ignition system provides this information from the TPS sensor and TMAP to
control. The system consists of the following calculate the appropriate ignition timing settings.
components:
The General Motors (GM) distributor (Figure 14)
• SECM used in the Delco EST ignition system, incorporates
a Variable Reluctance (VR) sensor, which transmits
• Distributer with ignition module * a reference signal to the GM ignition module (Figure
15) located on the distributor. A variable reluctance
• Ignition coil(s) * sensor is an electromagnetic device consisting of a
permanent magnet surrounded by a winding of wire.
• Crankshaft position sensor * The sensor is used in conjunction with a ferrous
signal rotor on the distributor shaft. The signal rotor
• Crankshaft timing wheel * has six lobes, one for each cylinder. Rotation of the
signal rotor near the tip of the sensor changes the
• Spark plugs * magnetic flux, creating an analog voltage signal in
the sensor coil.
(*) Customer-supplied components

The SECM, through use of embedded control

Figure 15. GM Ignition Module

The rising edge of the VR signal is converted to a

rising 5-volt signal by the ignition module. As the VR
signal passes back through zero volts, a falling edge
is created producing a square wave or digital signal,
similar to the signal produced by a Hall effect sensor.
This falling edge signal provides a stable engine
position reference at all engine speeds for the
SECM.

Figure 14. GM Distributor

The MI-07 system is capable of operating with either

a distributor based ignition system or a
distributorless ignition system. The current
application uses a distributor based ignition system.
The distributor will have no internal advance
mechanisms giving the SECM consistent authority
over ignition timing. The spark is sent to the
appropriate cylinder in the conventional way via the

G643(E) Service Manual 113 Chapter 4. Engine Electrical System

lgnition System Schematic for G643E

V+

CRANK SECM48

lgnition System Schematic for G643

V+

IGNITION COIL

DISTRIBUTOR

ECUP_AN1
EST1 (5V)
CNK +

SECM24
CONNECTION CLOSE
TO THE MODULE

SPARK PLUGS

G643(E) Service Manual 114 Chapter 4. Engine Electrical System

Ignition System Inspection

Adhere to the following warnings when performing

any tests or adjustments while the engine is running.

WARNING
Work carefully around an engine that is running.
Engine parts that are hot, or parts that are
moving, can cause personal injury.

WARNING Inspection of Distributor Rotor

(2) Distributor rotor.
Exhaust fumes contain carbon monoxide (CO)
which can cause personal injury or death. Start
NOTE: Current models do not have a resistor in the
and operate the engine in a well ventilated area
rotor and do not need to be checked for resistance.
only. In an enclosed area, vent the exhaust to
the outside.
2. Inspect the rotor (2) for breaks and cracks. Check
the rotor blade and the spring for tension. Check
If the engine will not start, do the steps for ignition the rotor for fit on the distributor shaft. Replace the
Component Checks. Check the starting and the fuel rotor if the spring tensionor its fit on the distributor
systems for correct operation. If these systems are is not correct
correct, use the procedures given in ignition System
Test to check the ignition system. For the correct resistance value of rotor, see
Distributer in Specifications.
Ignition Component Checks

Spark Plug Wires Inspection

Distributor Cap Inspection
(1) Distributor cap. 3. Inspect the spark plug wires and the ignition coil
wire for wear, burnt and high voltage leaks. Check
The procedures that follow are given as a guide. the resistance of the spark plug wires, with a
Use these procedures to find possible solutions for Digital Multimeter.
ignition problems.
For the correct resistance value, see Spark Plug
Tools Needed And Spark Plug Wires in Specifications.

Digital Mutimeter or Equivalent 1 NOTE: The Electrical System Analyzer can be used
on the ohmmeter scale for the spark plug resistance
1. Inspect distributor cap (1). Look for breaks, cracks test.
or dirt inside and on the outside. Clean the
distributor cap inside and out.

G643(E) Service Manual 115 Chapter 4. Engine Electrical System

Resistance Testing

1. Disconnect both ends of ignition cable (rotate

boot and pull at the boot only) being tested and
clean terminals.

2. Set ohmmeter on high scale and connect

ohmmeter to each end of cable being tested.
Twist cable gently while observing ohmmeter.

3. If ohmmeter reads above 25,000 ohms or

flucuates from infinity to any value, replace cable
Spark Plug Inspection being tested.
(3) Spark plug.
4. If the resistance of each cable is not within the
4. During installation of the spark plug wires, following bands, replace the cable being test-ed.
makesure the wire terminals make good
connections inthe distributor cap and on the spark 0 to 15 inch cable................. 3,000 / 10,000 Ohms
plugs. Inspectspark plug (3) insulator for cracks.
Clean the sparkplug of any oil or dirt before 15 to 25 inch cable............... 4,000 / 15,000 Ohms
installation.
25 to 35 inch cable............... 6,000 / 20,000 Ohms

Inspection of Spark Plug Wires Spark Plug Wire Routing

General Description

The spark plug wires are a carbon-impregnatedcord

conductor encased in an 8 millimeter diameter
silicone rubber jacket. Silicone wiring will withstand
very high temperature and is an excellent insulator
for the higher voltages.

Silicone is soft, pliable, and therefore, more

susceptible to scuffing and cutting. It is extremely
important that the spark plug cables be handled with
care. They should be routed so as not to cross
each other, or be in contact with, other parts of the
engine to prevent rubbing.

NOTICE: For proper operation, it is necessary to

keep ignition wires and distributor clean and free of
any dirt or corrosion.

G643(E) Service Manual 116 Chapter 4. Engine Electrical System

Inspection of Spark Plug

Inspection and clean

1. Disconnect the ignition wires from the ignition

coil ass’y.

2. Remove all spark plugs from the cylinder head

using a spark plug wrench.

CAUTION
Take care not to come foreign materials into
spark-plug mounting hole. 4. Check the plug clearance using a plug clearance
auge and if the value is not within the specified
values, adjust it by bending the ground clearance.
When installing a new sparkplug, install it after
checking the uniform plug clearance.

Spark plug clearance 0.8 ~ 0.9 mm

3. Check the spark plug as below.

1) Insulator broken

2) Terminal worn

3) Carbon deposit

4) Gasket damaged or broken

5. Install the spark plug and tighten it to the specified
5) Porcelain insulator of spark plug clearance torque.
Take care not to over tighten it to prevent cylinder
head threads from damage.

Tightening torque 30 N·m

Spark Plug Analysis

Contact point Contact point

State
is black is white
• Density of the • Density of the
Description fuel mixture fuel mixture is
is thick thin
• Lack of air • Ignition timing
intake is fast
• Spark plug is
tight
• Lack of torque

G643(E) Service Manual 117 Chapter 4. Engine Electrical System

Inspection of EST Distributor Delco Distributor Module Testing

Description
NOTICE
The Delco EST ignition system consists of the An approved module tester must be used in order to
distributor, ignition coil, wiring and spark plugs. The check the module. Use a Kent-Moore Module Tester
distributor contains a module, pickup coil and or equivalent.
conventional cap and rotor. There are no points or
condenser to adjust or change and no moving parts
except for the distributor shaft and rotor. Spark 1. Remove module from distributor.
advance and dwell are controlled by the distributor
module. The distributor module and pickup coil are 2. Connect red battery-cable clamp to positive
self-contained solid-state devices which are not (+)terminal and black battery-cable clamp to
repairable. If necessary, they may be replaced negative(-) terminal of a fully charged 12V battery.
separately but must be serviced as a complete unit.
3. Connect the adapter to yellow 2-way terminal
connector, and the adapter to black 3-
wayconnector of the tester (IAGS054S).

4. Connect black 4-way and 2-way connectors to

module terminals. Connect yellow 2-way
connector to yellow module terminals and engage
locking tabs.

5. Connect module ground clip of the tester to the

metal base of the module.

6. Hold the toggle switch in the 3-terminal test

position. If a momentary indication of the red "Fail"
light and then a steady indication of the green
"Pass" light occurs, go on to the next step. If a
steady indication of the red "Fail" light occurs, the
module is defective and should be replaced.

7. Disconnect black 4-way connector from module.

Disconnect yellow 2-way connector, rotate it 180
degrees so the lock and tab are opposite each
other, and reconnect it to the module terminals
(IAGS058S).

Delco Distributor Component Testing 8. Hold the toggle switch in the 3-terminal test
position. A momentary indication of the red "Fail"
light and then a steady indication of the green
NOTICE "Pass" light mean the module is good. A steady
In the test procedures that follow, check the ignition indication of the red "Fail" light means the module
coil and each component of the distributor is defective and should be replaced.
separately to identify defective or good components.
These tests can be made with the distributor and
coil mounted on the engine or on the repair bench.

G643(E) Service Manual 118 Chapter 4. Engine Electrical System

Pickup Coil Testing

Test 1 Tester Connections

1. Remove The distributor cap and rotor.

2. Disconnect the pickup coil leads from the module.

3. Connect an ohmmeter between the pickup coil

lead and housing (test 1, IAGS059S).
Reding should be infinite (no continuity).

4. Connect an ohmmeter to both pickup coil leads

(test 2, IAGS059S). Reading should be a constant,
unchanging value between 500-1500 ohms. Flex
leads by hand at coil and connector to locate
intermittent opens. Replace pickup coil if not
within specifications.

Test 2 Tester Connections

G643(E) Service Manual 119 Chapter 4. Engine Electrical System

Inspection of Ignition Coil Disassembly and Assembly

Ignition Coil

Remove & Install Coil

1. Connect ohmmeter between "B+" or "C-" 1. Disconnect wire connectors (1) from the coil.
terminals and ground (coil-mounting bracket). On
high scale, reading should be infinite (test 1,
IAGS004S).

2. Connect ohmmeter between "B+" and "C-

"terminals. On low scale, reading should be nearly
zero (approximately 0.4 ohm) (test 2, IAGS004S).

3. Connect ohmmeter between "B+" or "C-"

terminals and coil high-voltage tower. On high
scale, reading should be approximately 8000
ohms. Reading should not be infinite(test 3,
IAGS004S).

NOTICE 2. Remove two bolts from coil mounting bracket and

On tests 2 and 3, reading may vary slightly remove the coil.
depending on coil temperature.
NOTE: For installation of the coil, reverse the
removal steps.
4. If reading is not within specification, replace coil.

G643(E) Service Manual 120 Chapter 4. Engine Electrical System

EST Distributor Install Distributor

Remove Distributor

1. Install the distributor (1) in position in the intake

manifold. Make sure that the rotor (2) is in
1. Disconnect coil harness (1) from distributor. alignment with the scribe mark and number one
cylinder.
2. Bring the engine to TDC on the compression
stroke before removing the distributor. 2. Install the distributor clamp and bolt to the
distributor.

3. Remove the coil wire, spark plug wires (3) and

cap (4) from the distributor. 3. Install cap (4) and plug and coil wires to the
distributor.

NOTE: Scribe an alignment mark on the distributor 4. Connect the coil harness to the distributor and the
and intake manifold to show the position of the rotor. coil wire to the coil.5.Check the ignition timing.
(See Test and Adjustment)
4. Remove the bolt, distributor clamp, and distributor.

G643(E) Service Manual 121 Chapter 4. Engine Electrical System

Disassemble Distributor

Start By: Removing the distributor.

6. Pry off spring washer and remove retainer (8).

1. Remove rotor (1)

7. Unplug and remove the pickup coil (9).

8. Remove two screws (10) and remove pickup

module (11).
2. Remove gasket (2) from location.

3. Drive roll pin (3) from gear (4). Assemble Distributor

4. Remove gear (4), thrustwasher (5) and tabbed 9. Wipe distributor base and module clean, apply
thrustwasher (6). silicone lubricant between module and base for
heat dissipation.
NOTE: mark gear and shaft for correct assembly.
10. Attach module (11) to base with two screws (10).
Connect pickup coil (9) connector to module and
mount coil.

11. Assemble retainer (8) and fasten with a new

spring washer (7).

12. Assemble shaft, thrust washers, gear and roll pin

in proper alignment.

13. Spin shaft to ensure that teeth to not touch.

14. Install rotor.

5. Remove shaft assembly (7).

G643(E) Service Manual 122 Chapter 4. Engine Electrical System

Ignition Timing Adjustment for G643
Engine
DISTRIBUTOR
The ignition timing advance of G643 is controlled by
the SECM. The initial ignition timing setting of the
distributor is described in the following steps. It will IGNITION
be necessary to mechanically adjust the distributor MODULE
to an initial setting for startup, and then adjust the
final timing using the Service Tool.

1. Be sure engine is turned OFF.

2. Remove distributor cap (Figure 34).

Figure 35. Four-Pin Connector to Ignition Module
3. Disconnect the fuel lock-off connector at the lock
off so that fuel cannot flow during cranking.

4. Disconnect the 4-pin connector (Figure 35) to the

ignition module. This eliminates the +12 Vdc
power on Pin D and puts the ignition to a default
value not controlled by the SECM.

5. Connect standard inductive timing light (Figure

36) to the #1 cylinder.

6. Manually bar the engine so that the timing

indicator on the crankshaft pulley lines up to 0°
Top Dead Center (TDC) of the #1 cylinder (Figure
37). Figure 36. Standard Inductive Timing Light

7. Verify that the distributor rotor is lined up with #1 8. Using standard inductive timing light with no offset
cylinder on the distributor cap (Figure 38). adjustment set the initial timing to 4° BTDC
(advanced) by rotating the distributor while
cranking the engine with the ignition key.

9. Tighten the distributor hold-down bolt to the

specified torque value and re-connect the 4-pin
ignition module connector and the fuel lock-off
connector.
1

(1) lgnition Coil. (2) lgnition Module.

Figure 34. GM Ignition Module

Figure 37. Engine Set at 0° Top Dead Center

(TDC)

G643(E) Service Manual 123 Chapter 4. Engine Electrical System

Figure 39. KVaser Communication Adapter

Figure 38. Topside of Engine Showing Position

of Cylinders

NOTE: This completes the initial ignition timing. The

final ignition adjustment can be made at engine
start-up using the software Service Tool.

Connection of the Service Tool Software

To use the Service Tool, a USB (Universal Serial

Bus) to CAN (Controller Area Network)
communication adapter by KVaser will be required Figure 40. Crypt Token Installed on Laptop
along with a Crypt Token (Figure 39). The Crypt
Token acts as a security key allowing the laptop to
retrieve the necessary data from the SECM.

1. Install the Crypt Token in an available USB port in

the computer (Figure 40).

2. With the ignition key in the OFF position, connect

the KVaser 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).

3. Connect a timing light to the engine. Figure 41. Opening the Service Tool Display

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 (Figure 41).

G643(E) Service Manual 124 Chapter 4. Engine Electrical System

Final Timing Verification

To verify the mechanical timing adjustment of the

distributor you will need to lock the spark using the
Service Tool Test Screen and use the timing light to
verify adjustment.

NOTE: Service Tool software (Moto TuneViewer)

and the security Crypt Token is obtainable by
certified technicians through authorized dealers.

1. Without starting the engine turn the Key switch to

the ON position and open the Service Tool
Display Test Screen. The Spark Control Lock
parameter should be “Unlocked” as in (Figure 42).
The Spark Offset should read 0.00 and “OFF” in Figure 43. Spark Control Lock Parameter
the Units column of the display. When a value is “Locked”
entered in the Spark Offset, the offset value is
added to the value displayed in the Spark 3. Select the Spark Control Lock “Unlocked” check
Advance parameter. box. The check box display will change to read
“Locked” as in Figure 43. You have now locked
NOTE: You must always return the Spark Offset the SECM ignition timing at a fixed value (Spark
value to 0.00 before closing the Service Tool or the Advance + Spark Offset).
offset will be applied during engine operation
causing inaccurate ignition timing with the possibility 4. Start the engine, using the timing light verify the
of misfire or engine damage. engine is running at the correct timing, in this case
10° BTDC. If it is not 10° BTDC loosen the
distributor hold down bolt and slightly adjust the
distributor for 10° BTDC using your timing light.
Tighten the distributor hold down bolt.

5. Un-check the Spark Control Lock, it should now

read “Unlocked” as in Figure 42 allowing the
SECM to control spark advance.

6. Enter 0.00 in the Spark Offset, the Warning

message should now read OFF as in Figure 44.
The SECM is in full control of the spark advance
with no offset.

7. Setting the distributor position is now complete.

Figure 42. Spark Control Lock Parameter
“Unlocked”

2. The preferred reference timing to use for

verification with a timing light is 10 degrees BTDC.
In Figure 42 the Spark Advance with the engine
not running is 5.0° BTDC. To lock the spark at 10°
BTDC a Spark Offset value of 5.0 would need to
be entered (5.0 + 5.0 = 10). Enter the appropriate
offset value that will equal 10 when added to your
engine’s spark advance. (10 – Spark Advance =
Spark Offset). Once an offset value is entered the
“OFF” description will change and display
“WARNING” to alert you that the offset value is
not set to 0.00.
Figure 44. SECM in Full Control of Spark
Advance

G643(E) Service Manual 125 Chapter 4. Engine Electrical System

Ignition Timing Adjustment for G643E 1. Install distributor shaft into engine, aligning marks
Engine made at time of removal (see, figure). Be sure that
the shaft engages oil pump
On G643 engine, crankshaft position was sensed
from the distributor. Adjusting the distributor has a 2. Secure distributor with clamp
direct affect on ignition timing - 1 degree of the
distributor rotation would produce a 2 degree 3. Install distributor cap
change in spark timing.

G643E engine senses crank position from the crank

position sensor and the target wheel. Rotating the
distributor will not directly affect ignition timing,
except in extreme conditions. When engine is
disturbed and ignition timing is incorrect, inspect the
sensors concerned with ignition timing, at first.

[Figure] Crank Position Sensor of G643E Engine

NOTE: Affective SECM input to ignition timing

control

• Coolant temperature sensor

• Oxygen sensor

• Battery voltage

• MAP sensor (Engine load)

• Crankshaft position sensor

• Throttle position sensor

• Intake Air Temperature sensor

If the distributor is severely misaligned, the rotor will

not properly align with the distributor cap and spark
will misfire or go to the wrong cylinder. When
replace the distributor, install new distributor as
follows;

G643(E) Service Manual 126 Chapter 4. Engine Electrical System

Charging System Alternators

The alternators used on these engines have three

General Description phase, full-wave, rectified output. They are the brush
type. Refer to the Alternator Coverage chart for
The alternator is an electrical and mechanical
detailed systems operation information
components driven by a belt from engine rotation. It
is used to charge the storage battery during the
engine operation. The alternator is cooled by an ALTERNATOR COVERAGE
external fan mounted behind the pulley. The fan
Alternator Manufacturer/
pulls air through the holes in the back of the
alternator. The air exits the front of the alternator, Part Number Series
cooling it in the process. The valeo alternator also
has an internal fan. This fan is mounted on the rotor. D167411 Korea-Delphi CS121D
This fan pulls air through the holes in the back of the
D187478 MICO/K1 Sealed
alternator to cool the rectifier bridge and regulator.
The air exits the front of the alternator.

The alternator converts mechanical and magnetic

energy to alternating current (AC) and voltage. This
process is done by rotating a direct current (DC)
electromagnetic field (rotor) inside a three phase
stator. The alternating current and voltage
(generated by the stator) are changed to direct
current by a three phase, full wave rectifier system
using six silicone rectifier diodes. Some alternators
have three exciter diodes or a diode trio. They rectify
the current needed to start the charging process.
Direct current flows to the alternator output terminal.

A solid state regulator is installed in or on the back

of the alternator. Two brushes conduct current,
through two slip rings, to the rotor field. Some
alternators have a capacitor mounted on them. The
capacitor protects the rectifier from high voltages. It
also suppresses electrical noise through a radio, if
equipped.

The alternator is connected to the battery through

the ignition switch for alternator turn on. Therefore,
alternator excitation occurs when the switch is
turned on.
D187478

G643(E) Service Manual 127 Chapter 4. Engine Electrical System

Troubleshooting

Charging system defect is almost caused by lack of

pan belt tension and faulty function of wiring,
connector, and voltage regulator.
One of most important thing during troubleshooting
of charging system is determining the reason
between overcharging and lack of charging. So,
prior to inspection of alternator, check the battery for
charging. Faulty alternator causes the following
symptoms.

1. Faulty battery charging

1) IC regulator fault (Short circuit)

2) Field coil fault

3) Main diode fault

4) Stator coil fault

5) Brush contact fault

2. Overcharging : IC regulator fault(Short circuit)

Other faults such as voltage adjusting problem
except above symptoms rarely happen.

G643(E) Service Manual 128 Chapter 4. Engine Electrical System

Refer to the following troubleshooting table

Symptom Possible cause Remedy

With ignition Fuse cut off Replace

switch ON,
charging Bulb burnt out Replace
warning lamp Loose wiring connection Retighten
does not
illuminate Bad connection of L terminal Inspect and replace wiring

Loose or worn drive belt Correct or replace

With the
Fuse cut off Replace
engine started,
warning lamp Circuit breaker cut off Reset or replace
is not turned
off (Battery Faulty voltage regulator or alternator Inspect alternator
needs often
Faulty wiring Repair
charging)
Corrosion or wear of battery cable Repair or replace

Faulty voltage regulator (Charging warning lamp illuminates) Replace

Overcharged
Voltage detection wring fault Replace

Loose or worn drive belt Correct or replace

Loose wiring connection Retighten

Short circuit Repair

Battery is
discharged Circuit breaker cut off Reset or replace
Ground fault Repair

Faulty voltage regulator (Charging warning lamp illuminates) Inspect alternator

Battery out Replace

G643(E) Service Manual 129 Chapter 4. Engine Electrical System

Troubleshooting Procedure

Inspection before Starting

1. Alternator and drive belt tension inspection.

G643(E) Service Manual 130 Chapter 4. Engine Electrical System

2. Alternator and outer terminal connection inspection.

G643(E) Service Manual 131 Chapter 4. Engine Electrical System

3. Battery outer terminal inspection.

Inspection after Starting

1. When starting, belt slip and noise inspection

13.2~15.4V

2. Inspection of battery voltage at idling (At this time charge battery only)

G643(E) Service Manual 132 Chapter 4. Engine Electrical System

Drop of Electric Pressure Test of Alternator Test
Output Wire
1. Start the engine.
This test is to check that wiring is correctly
connected between the alternator “B“ terminal and 2. Repeating ON and OFF of headlight and small
battery (+) terminal. light, adjust the engine speed until an ammeter
reads 20A and at that time measure voltage.

Result

1. If voltmeter reading is within the standard, it is

normal.

2. If voltmeter reading is more than the standard,

mostly wiring is faulty. In this case, inspect
wirings between the alternator and the battery (+)
terminal as well as between the alternator “B”
terminal and the fusible link.

3. Also prior to re-test, check and repair the

connecting part for looseness and the harness for
discoloration by overheating.

4. After test, adjust the engine speed at idle and turn

the light and ignition switch OFF.

5. Disconnect the battery ground cable.

Preparation
6. Disconnect the ammeter and voltmeter.
1. Turn the ignition switch OFF.
7. Connect the alternator output lead wire to the
2. Disconnect the battery ground cable. alternator “B” terminal.

3. Disconnect the alternator output wire from the 8. Connect the battery ground cable.
alternator “B” terminal.
Output Current Test
4. Connect a DC ampere meter (0-100A) between
the terminal and the disconnected output wire. This test is to check that the alternator output
Connect (+) lead wire to the terminal “B” and (-) current is identified with the rated current.
lead wire to the disconnected output wire.
Preparation
NOTE: In case of using a clamp type ammeter, it is
possible to measure current without disconnecting 1. Prior to test, inspect the following items and repair
the harness. if necessary.

5. Connect a digital voltmeter between the alternator 1) Be sure that the battery installed in the vehicle
“B” terminal and the battery (+) terminal. is normal. (See “Battery”)
Connect (+) lead wire to the terminal and (-) lead
wire to the battery (+) terminal. NOTE: When measuring output current, necessarily
use a slightly discharged battery. Fully charged
6. Connect the battery ground cable. battery is not enough to use for correct test owing to
insufficient load.
7. Be sure that the hood is opened.
2) Inspect the drive belt for tension. (See “Engine
body” )

G643(E) Service Manual 133 Chapter 4. Engine Electrical System

2. Turn the ignition switch OFF. 3. With the engine running at 2,500 rpm, turn ON the
high beam headlights, place the heater blower
3. Disconnect the battery ground cable. switch at ”HIGH” measure the maximum output
current using a ammeter.
4. Disconnect the alternator output wire from the
alternator “B” terminal. NOTE: This test should be done as soon as
possible to measure the exact maximum current
because output current drops rapidly after starting
the engine.

Result

1. Ammeter reading should be as same as the load.

If the reading is low even though the alternator
output wire is normal, remove the alternator from
the vehicle and inspect it.

Output current As same as Elecrical load

NOTE: Output current varies according to electrical

load or temperature of the alternator, so during test,
lack of electrical load causes impossibility of
measuring the rated output current. In this case, turn
on headlight to induce the battery discharging or
turn on other lights to increase the electrical load. If
alternator temperature or ambient temperature is too
high, it is impossible to measure the rated output
5. Connect a DC ampere meter (0-100V) between current, so prior to re-test, necessarily drop the
“B” terminal and the disconnected output wire. temperature.
Connect (+) lead wire to the terminal “B” and (-)
lead wire to the disconnected output wire.
Ambient temperature
Voltage adjust(V)
NOTE: Do not use clips or equivalent owing to high of voltage regulator(℃)
current and Use bolts and nuts to tighten each
-30 14.5 ~ 15.4
connecting part securely.
25 14.3 ~ 14.9
6. Connect a volt meter (0-20V) between “B”
terminal and the ground. 60 14.0 ~ 14.8
Connect (+) lead wire to the alternator “B”
90 13.6 ~ 14.6
terminal and (-) lead wire to the proper position.

7. Connect the engine tachometer and then battery 2. After test, adjust the engine speed at idle and turn
ground cable. the light and ignition switch OFF.

8. Be sure that the hood is opened. 3. Disconnect the battery ground cable.

Test 4. Disconnect the ammeter and voltmeter.

1. Be sure that voltmeter reading is identified with 5. Connect the alternator output lead wire to the
battery voltage. alternator “B” terminal.
If voltmeter reading is 0V, it means short circuit of
wire between “B” terminal and the battery (-) 6. Connect the battery ground cable.
terminal, fusible link cut off or ground fault.

2. Turn the headlight ON and start the engine.

G643(E) Service Manual 134 Chapter 4. Engine Electrical System

STARTING SYSTEM
General Description

The starting motor is used to turn the engine

flywheel lfast enough to make the engine run. The
starting motor has a solenoid. When the ignition
switch is activated, voltage from the electrical
system will cause the solenoid to move the pinion
toward the flywheel ring gear of the engine. The
electrical contacts in the solenoid close the circuit
between the battery and the starting motor just
before the pinion engages the ring gear. This
causes the starting motor to rotate. This type of
motor "turn on" is a positive shift starting motor.
When the engine begins to run, the overrunning
clutch portion of the pinion drive prevents damage to
the armature caused by excessive speeds. The
clutch does this by breaking the mechanical
connection. The pinion will stay meshed with the
ring gear until the ignition switch is released. A
return spring in the overrunning clutch returns the
clutch to its rest position.

Components

G643(E) Service Manual 135 Chapter 4. Engine Electrical System

Circuit Diagarm For Starting System

Diagnosis Procedure The starting motor solenoid has two functions:

The following simplified procedure is intended to 1. Engages the pinion with flywheel.
help the serviceman determine if a starting motor
needs to be removed and replaced or repaired. It is 2. Is a high current switch rated about 1000 amps
not intended to cover all possible problems and that actually turns on the starting motor.
conditions, but to serve only as a guide. The most
common 12 volt circuit is shown and discussed. The starting motor solenoid has two coils. Pull-in coil
(W) draws about 40 amps and hold-in coil (X)
General Information requires about 5 amps. The instant the start relay
closes, both coils (W) and (X) receive power. Battery
All starting systems are made up of four elements. voltage is applied to the high end of both coils, at
They are the ignition switch, start relay, the starting test point (3) which is the start (S) terminal. The low
motor solenoid and starting motor. end of hold-in coil (X) is permanently grounded to
the ground post or motor housing of the starting
Start switches are relatively low current devices. motor. Grounding for the low end, test point (4), of
They are rated to switch approximately 5 to 20 amps. pull-in coil (W) is momentary, and takes place
Because the coil of a start relay [between test point through the DC resistance of the starting motor. As
86 and 85] draws about 0.2 amp, the start switch soon as magnetic force builds in both coils, the
can easily turn on the start relay and have long life. pinion moves toward the flywheel ring gear. The
pinion will stop short of engagement of the flywheel
The switch contacts of a typical start relay are rated ring gear. Only then will the solenoid contacts close
to switch 30 amps. Because the solenoid requires 5 to power the starting motor. This temporarily
to 20amps the start relay can easily switch this load. removes the ground from pull-in coil (W), and puts
battery voltage on both ends of it while the starting
motor cranks. During this period, the pull-in coil is
out of the circuit. Cranking continues until power to
the solenoid is broken by releasing the ignition
switch.

G643(E) Service Manual 136 Chapter 4. Engine Electrical System

The result of these switches and relays is to permit a
5 amp dash-mounted switch to turn on a 500 to
1000amp motor used to crank an engine. Battery NOTICE
voltage (power) available during cranking varies
according to the temperature of the batteries. The Do not operate the starting motor for more than
following chart is a guide as to what to expect from a 30seconds at a time. After 30 seconds, the cranking
normal system. must be stopped for two minutes to allow the
starting motor to cool. This will prevent damage to
the starting motor due to excessive heat buildup.
TYPICALSYSTEM VOLTAGE DURING
CRANKING AT VARIOUS AMBIENT
TEMPERATURES
If the starting motor cranks real slow or does not
Temperature 12V System
crank at all, do the following procedure:
-23 to -7 C (-10 to 20 F) 6 to 8 Volts
1. Measure battery voltage at the battery posts with
-7 to 10 C (20 to 50 F) 7 to 9 Volts the multimeter while cranking or attempting to
crank the engine. Make sure to measure the
10 to 27 C (50 to 80 F) 8 to 10 Volts
battery posts. Do not measure the cable post
clamps.
Figure 1
The next chart shows maximum acceptable voltage 2. Is battery voltage equal to or greater than shown
loss in the high current battery circuit feeding the in Figure 1?
starting motor. These values are maximums for
machines of approximately 2000 SMH and up. • If the battery voltage is correct, go to Step 3.
Newer machines would be less than those shown.
• If the battery voltage is too low, Charge or
MAXIMUM ACCEPTABLE SYSTEM VOLTAGE replace the battery.
DROPS DURING CRANKING
NOTE: Alow battery can be caused by battery
Circuit 12V System condition or a shorted starting motor.

Battery(-) post to starting motor (-) 3. Measure current draw on the (+) battery cable
0.7 Volts
terminal between the battery and the starting motor
Battery (+) post to solenoid (+) solenoid with the clamp-on ammeter. The
0.5 Volts maximum current draw allowed is 350 Amp. At
terminal
temperatures below27°C (80°F), the voltage will
Solenoid Bat terminal to solenoid be less and the current draw will be higer. If
0.4 Volts
Mtr terminal current draw is too much, the starting motor has a
problem and must be removed for repair or
Figure 2 replacement.
Voltages greater than those shown are most often
caused by loose and/or corroded connections or NOTE: If voltage at the battery post is within
defective switch contacts. approximately 2 volts of the lowest value in the
applicable temperature range of Figure1 and if the
Diagnosis Procedure large starting motor cables get hot, then the starting
motor has a problem and the Ammeter test is not
TOOLS NEEDED needed.

Digital Multimeter or Equivalent 1 4. Measure starting motor voltage from test point (4)
to (5) with the multimeter while cranking or
DC Clamp-On Ammeter or Equivalent 1 attempting to crank the engine.

G643(E) Service Manual 137 Chapter 4. Engine Electrical System

5. Is voltage equal to or greater than shown in Start Relay Tests
Figure1?
Relay
• If the starting motor voltage is correct, the
battery and starting motor cables down to the 1. Put the multimeter on the 200 ohm scale.
motor are within specifications. Go to Step 8.
2. Put the multimeter lead to the 85 and 86 terminals.
• If the starting motor voltage is low, the voltage
drop between the battery and the starting motor 3. The indication on the meter must be 82 5 ohms. If
is too great. Go to Step 6. the indication is not correct, the start relay must
be replaced.
6. Measure the voltage drops in the cranking circuits
with the multimeter. Compare the results with 4. Put the multimeter leads to the 30 and 87
maximum voltage drops allowed in Figure 2. terminals.

7. Are all the voltages within specifications ? 5. The indication must be "OL"(Over Load). If the
indication is not correct, the start relay must be
• If the voltage drops are correct, go to Step 8, to replaced.
check the engine.
6. Connect WH wire to 86 and BK wire to 85
• If the voltage drops are too high, repair and/ or terminal with the ignition switch to start position.
replace the faulty electrical component. Put the meter lead to 30 and 87 terminal.

8. Rotate the crankshaft by hand to make sure it is 7. The indication must be Zero ohm. If the indication
not locked up. Check oil viscosity and any is not correct the start relay must be replaced.
external loads that would affect engine rotation.

9. Is the engine locked up or hard to turn ?

• If it is, repair the engine as required. If the

engine is not hard to turn, go to Step 10.

10. Does the starting motor crank?

• If it does crank, remove the starting motor for

repair and/or replacement.

• If it does not crank, check for blocked

engagement of the pinion and flywheel ring
gear.

NOTE: Blocked engagement and open solenoid

contacts will give the same electrical symptoms.

G643(E) Service Manual 138 Chapter 4. Engine Electrical System

Troubleshooting

Starting system problem can be classified into “Start

motor is not operating”, “Start motor is operating but
engine is not starting” , and “There is a lot of time
taken to start engine”.

When the starting system has problems, before

removing the start motor, find where the problem
happens. Generally if it is difficult to start, there are
problems in ignition system, fuel system, and
electrical system. In this case, necessarily inspect
and repair step by step, or the same problem will
happen.

Symptom Possible cause Remedy

Low battery charging voltage Charge or replace

Loose, corroded or worn battery cable Repair or replace

Impossible cranking Inhibitor switch fault Adjust or replace

Circuit breaker cut off Reset or replace

Start motor fault Repair

Ignition switch fault Replace

Low battery charging voltage Charge or replace

Slow cranking Loose, corroded or worn battery cable Repair or replace

Start motor fault Repair

Continuous rotating of start
Ignition switch fault Replace
motor
Start relay fault Replace

Short circuit of wiring Repair

Start motor is rotating but Worn or broken pinion gear tooth or motor fault Repair
engine is not cranking
Replace flywheel ring gear
Worn or broken ring gear tooth
or torque converter

G643(E) Service Manual 139 Chapter 4. Engine Electrical System

Starter Repair

Removal

Remove or disconnect

WARNING
Always disconnect the cable at the battery
before you make repairs to the engine.
Disconnect the cable at the negative terminal
first. Install a tag on the battery terminals first.
Install a tag on the battery terminals so that no
one connects the cable on the terminal.

Specifications

SECM and Sensor/Switch Inputs

Q’ty
Components Items Specifications
G643E G643
Environmental / Ambient Operating -20 °F to 221°F [-29 °C to 105 °C]
Electrical Temperature
None None
Specifications 8-16 Vdc
Operating Voltage
Engine Control Module Operating Temperature -20 °F to 221°F [-29 °C to 105 °C]
(SECM )
8-16 Vdc
Operating Voltage SECM microprocessor may reset at
1 1
voltages below 6.3 Vdc

On-engine mounting, underhood

Operating Environment automotive
Crankshaft Position Type VR sensor
1 None
Sensor Tooth wheel 3X
TMAP Sensor MAP sensor Piezo- Resistivity type
0-5V output
1 1 Intake Air Temp Sensor Thermistor type
(built in MAP sensor)
2.0-3.0kohms at 20°C
LP Fuel Temperature Type Thermister
Sensor 1 None Resistance 2.5kΩ@20℃
243Ω@90℃
Oxygen Sensor Type Zirconia Sensor (Heated)
2 None
Output Voltage 0 - 1V
Coolant Temperature Type Thermistor Type
1 1
Sensor Resistance 1.0-4.0 kohms at 20°C
Acceleration Pedal Type Hall IC
Angle Sensor APP1(Low idle) 0.4 ± 0.1 V
1 1 APP2(Low idle) 4.5 ±0.1 V
APP1(Hi idle) 3.6 ±0.15 V
APP2(Hi idle) 1.39 ± 0.15 V
Engine Oil Pressure Actuation Pressure 0.3 +/- 0.1 kgf/cm^2
1 1
Switch
Transmission Oil Actuation Temperature 125°C
1 1
Temperature Switch
Ground speed limit Sensor Magnetic Pick-up
option option
device Controller Digital output

G643(E) Service Manual 141 Chapter 5. Engine Management System (EMS)

Electronic Throttle System

Q’ty
Components Items Specifications
G643E G643

Electronic Throttle Minimum Electrical 1.5 ohms

System 1 1 Resistance of Throttle
Actuator

G643(E) Service Manual 142 Chapter 5. Engine Management System (EMS)

LP Fuel Components Specification

Q’ty
Components Items Specifications
G643E G643
LP Fuel System Operating Temperature -20 °F to 221°F [-29 °C to 105 °C]
Requirements
LPG Composition HD5 / HD10 LPG. Failure to use fuel
- -
Requirements compliant with
HD5 or HD10 standards will void the
user warranty.
LP Fuel Filter 1 1 Fuel Filter Micron Size 40 micron
LP Fuel Lock-off 1 1 Electrical Resistance 20~25Ω
N-2007 LP Regulator Fuel Supply Pressure 10 psi to 250 psi (68.95 kPa to
For G643E 1723.69 kPa)

Fuel Inlet Fitting 1/4” NPT

Fuel Outlet Fitting Two 3/4” NPT fittings with one plugged
and one 1/8” NPT fitting with plug

Fuel Supply -20 °F to 120 °F [-29 °C to 49 °C]

Temperature at Tank Outlet

Primary Pressure Tap 1/8” NPT with plug

Max Flow 50 lbm/hr LPG

Coolant Flow to Vaporizer > 1.0 gpm/100bhp, equipped with

1 None
140 °F (60 °C) thermostat

Fuel Outlet Pressure -0.7 ± 0.2 inH2O @ 1.7 lbm/hr LPG

Setpoints (-1.744 ± 0.498 mbar) @ 1.7 lbm/hr
LPG)
-2.0 ± 0.2 inH2O @ 50 lbm/hr LPG
(-4.982 ± 0.498 mbar) @ 50 lbm/hr
LPG)

Mounting Regulator should be installed with

centerline of outlet at least 15° below
horizontal to permit drainage of any
liquid precipitates from LPG fuel.

Diaphragm should be vertically

oriented.

G643(E) Service Manual 143 Chapter 5. Engine Management System (EMS)

Q’ty
Components Items Specifications
G643E G643
N-2001 LP Regulator Fuel Supply Pressure 10 psi to 250 psi (69 kPa to 1724 kPa)
For G643
Fuel Inlet Fitting 1/4” NPT

Fuel Outlet Fitting One 3/4” NPT and one 1/8” NPT fitting
with plug

Fuel Supply -20 °F to 120 °F [-29 °C to 49 °C]

Temperature
At Tank Outlet

None 1 Primary Pressure Tap 1/8” NPT with plug

Max Flow 50 lbm/hr LPG

Coolant Flow to Vaporizer >1.0 gpm/100bhp, equipped with

140 °F (60°C) thermostat

Fuel Outlet Pressure -0.5 ± 0.35 inH2O@1.7 lbm/hr LPG

Setpoints (-1.25 ± 0.87 mbar)@1.7 lbm/hr LPG)
-1.35 ± 0.5 inH2O@32.1 lbm/hr LPG
(-3.36 ± 1.25 mbar)@32.1 lbm/hr
LPG)
CA100 Mixer Fuel LPG
For G643
Fuel Inlet Fitting 1/2” NPT Fuel inlet fitted with Delphi
temperature sensor

Air Intake Flange 2.25” (57.15mm) ID inlet, four #10-

24 screws in
1.94” (49.28mm) square pattern

Mixer Mounting Flange 1.87” (47.49mm ID outlet, four #12-

24 screws arranged in a rectangular
pattern

1 None Reference Pressure Ports Two 1/8-NPT ports. Pressure

readings must be identical within
0.25 inH2O (0.623 mbar) at all
airflows.

Air Valve Vacuum (AVV) 1/4-28 UNF

Port Size

Fuel Inlet Adjustments None

Idle Air Adjustment None

Mounting Suitable for on-engine mounting in

vertical orientation

G643(E) Service Manual 144 Chapter 5. Engine Management System (EMS)

Q’ty
Components Items Specifications
G643E G643
CA100 Mixer Fuel LPG
For G643
Fuel Inlet Fitting 1/2” NPT
Fuel inlet fitted with Delphi
temperature sensor

Air Intake Flange 2.25” (57.15mm) ID inlet, four #10-

24 screws in 1.94” (49.28mm)
square pattern

Mixer Mounting Flange 1.87” (47.49mm ID outlet, four #12-

24 screws arranged in a rectangular
pattern
None 1
Reference Pressure 1/4-1/8 NPT ports. Pressure
Ports readings must be identical within
0.25 inH2O (0.623 mbar) at all
airflows.

Air Valve Vacuum (AVV) 1/4-28 UNF

Port Size

Fuel Inlet Adjustments Power valve

Idle Air Adjustment Idle adjustment screw

Mounting Suitable for on-engine mounting in

vertical orientation
Fuel Trim Valve (FTV) Actuator Type On/off two-position valve compatible
2 None
Operating Voltage with LPG 8-16 Vdc

G643(E) Service Manual 145 Chapter 5. Engine Management System (EMS)

Component Location

LP Fuel Lock-off
Engine Control Module (SECM48)

TMAP Sensor
Crankshaft Position Sensor

Coolant Temperature Sensor

LP Fuel Temperature Sensor

G643(E) Service Manual 146 Chapter 5. Engine Management System (EMS)

Pre-Catalyst Oxygen Sensor Post-Catalyst Oxygen Sensor

Pedal Angle Sensor Engine Oil Pressure Switch

Ground Speed limit (option) – Sensor Ground speed limit (option) - Controller
-

G643(E) Service Manual 147 Chapter 5. Engine Management System (EMS)

Electronic Throttle Body Fuel Trim Valve(FTV)

Ignition Coil Distributor

N-2007 LP Regulator CA100 Mixer

G643(E) Service Manual 148 Chapter 5. Engine Management System (EMS)

G643E EMS (Engine Management System) Overview

General Description
MI-07 control system provides a complete, fully MI-07 is a closed loop system utilizing a catalytic
integrated engine management system that meets muffler to reduce the emission level in the exhaust
or exceeds 2007 emission standards for Large gas. In order to obtain maximum effect from the
Spark Ignited (LSI) engines established by the catalyst, an accurate control of the air fuel ratio is
California Air Resources Board (CARB) and the required. A small engine control module (SECM)
Environmental Protection Agency (EPA). uses two heated exhaust gas oxygen sensors
(HEGO) in the exhaust system to monitor exhaust
The control system is applicable to naturally gas content. One HEGO is installed in front of the
aspirated engines running on LPG and/or gasoline. catalytic muffler and one is installed after the
It provides accurate, reliable, and durable control of catalytic muffler.
fuel, spark, and air over the service life of the engine
in the extreme operating environment found in
heavy-duty, under hood, on-engine electronic
controls.

[Figure 1] MI-07 LP Fuel System for G643E Engine

The SECM makes any necessary corrections to the connecting the accelerator pedal to the electronic
air fuel ratio by controlling the inlet fuel pressure to throttle through the electrical harness; mechanical
the air/fuel mixer by modulating the dual fuel trim cables are not used. A throttle position sensor (TPS)
valves (FTV) connected to the regulator. Reducing monitors throttle position in relation to the
the fuel pressure leans the air/fuel mixture and accelerator pedal position sensor (APP) command.
increasing the fuel pressure enriches the air/fuel Even engine coolant temperature and adequate oil
mixture. To calculate any necessary corrections to pressure are monitored by the SECM. The SECM
the air fuel ratio, the SECM uses a number of controller has full adaptive learning capabilities,
different sensors to gain information about the allowing it to adapt control function as operating
engine’s performance. Engine speed is monitored conditions change. Factors such as ambient
by the SECM through a Variable reluctance (VR) temperature, fuel variations, ignition component
sensor. Intake manifold air temperature and wear, clogged air filter, and other operating variables
absolute pressure are monitored with a TMAP are compensated.
sensor. MI-07 is a drive-by-wire (DBW) system

G643(E) Service Manual 149 Chapter 5. Engine Management System (EMS)

LP Fuel System of G643E (certified engine system)

INPUT OUTPUT
Crank Sensor Throttle body

TMAP sensor
lgnition module
(built in Distributor)
Coolant Temp
2 Fuel trim valves

EG oil pressure switch

LP fuelock valve

T/M Temp switch

CAN communication

Accel pedal angle sensor SECM

Throttle position sensor

Pre Oxygen sensor

Post Oxygen sensor

LP fuel temp sensor

Ground speed Limit

device(option)

G643(E) Service Manual 150 Chapter 5. Engine Management System (EMS)

MI-07 System Components • Intake/Exhaust manifold design

• Catalytic converter and exhaust system

The MI-07 control system provides electronic control
to the following subsystems on mobile industrial
• Throttle body
engines:
• Air intake and air filter
• Fuel delivery system
• LPG mixer
• Spark-ignition control system
• LPG pressure regulator
• Air throttle
• Fuel trim valves
• Sensors/Switches/Speed inputs
• Fuel trim orifices
The chart below lists the MI-07 components required
for a G643 (E) engine operating on LP fuel.
• Small engine control module (SECM), firmware
and calibration †
Q’ty DESCRIPTION
G643E G643
• Fuel system sensors and actuators
1 1 Engine Control Module
(SECM) • Ignition system including spark plugs, cables, coils
None None Camshaft Position and drivers
Sensor
1 1 Crankshaft Position
MI-07 System Features
Sensor
1 1 TMAP Sensor
1 None Fuel Temperature The MI-07 system uses an advanced speed-density
Sensor control strategy for fuel, spark, and air throttle
1 None Transmission Oil control. Key features include the following.
Temperature Switch
2 None Oxygen Sensors • Closed-loop fuel control
1 1 Coolant Temperature
Sensor • Speed-load spark control with tables for dwell,
timing, and fuel type
1 1 Engine Oil Pressure
Switch
• Speed-load throttle control with table for maximum
2 None Fuel Trim Valve
TPS limiting
1 1 Ignition Coil
1 1 Fuel Lock Off Solenoid
• Closed-loop fuel control with two oxygen sensors
N-2007 N-2001 LP Regulator (one installed pre catalyst and one installed post
CA-100 CA-100 LP Mixer catalyst). The pre-catalyst oxygen sensor includes
(Certified) adaptive learn to compensate for fuel or
1 1 Electronic Throttle Body component drift. The post-catalyst oxygen sensor
includes adaptive learn to compensate the pre-
catalyst oxygen sensor setting for pre-catalyst
oxygen sensor drift and catalyst aging. The pre-
Key Components
catalyst oxygen sensor function includes
parameters for transport delay, O2 set point,
The MI-07 system functions primarily on engine excursion rich/lean, jump back rich/lean, and
components that affect engine emissions and perturbation.
performance. These key components include the
following: • LPG fuel temperature compensation

• Engine/Combustion chamber design • Min/max governing

• Intake/Exhaust valve configuration, timing and lift • All-speed isochronous governing

G643(E) Service Manual 151 Chapter 5. Engine Management System (EMS)

• Fixed-speed isochronous governing with three Limp Home Mode
switch-selectable speeds The system is capable of "limp-home" mode in the
event of particular faults or failures in the system. In
• Fuel enrichment and spark timing modifiers for limp-home mode the engine speed is approximately
temperature and fuel type 1000 rpm at no load. A variety of fault conditions can
initiate limp-home mode. These fault conditions and
• Transient fuel enrichment based on rate of change resulting actions are determined during calibration
of TPS and are OEM customer specific.

• Transient wall wetting compensation for gasoline Service Tool

A scan tool/monitoring device is available to monitor
• Input sensor selection and calibration system operation and assist in diagnosis of system
faults This device monitors all sensor inputs, control
• Auxiliary device control for fuel pump, fuel lock-off outputs, and diagnostic functions in sufficient detail
solenoid, tachometer, MIL, interlocks, vehicle through a single access point to the SECM to allow
speed limiting, etc. a qualified service technician to maintain the system.
This Mototune software (licensed by Mototron
• CANBus data transfer for speed, torque, etc. Communication) is secure and requires a crypt-
token USB device to allow access to information.

Other system features include:

LPG Fuel System Operation

Tamper-Resistance The principles outlined below describe the operation

Special tools, equipment, knowledge, and of MI-07 on an LPG fuel system.
authorization are required to effect any changes to
the MI-07 system, thereby preventing unauthorized An LPG fuel system consists of the following
personnel from making adjustments that will affect components:
performance or emissions.
• Fuel filter
Diagnostics
MI-07 is capable of monitoring and diagnosing • Electric fuel lock-off solenoid valve
problems and faults within the system. These
include all sensor input hardware, control output • Fuel pressure regulator/vaporizer
hardware, and control functions such as closed-loop
fuel control limits and adaptive learn limits. Upon • Two orificed fuel trim valves
detecting a fault condition, the system notifies the
operator by illuminating the MIL and activating the • Gas/Air mixer with fixed orifice for trim system and
appropriate fault action. The action required by each fuel temperature sensor
fault shall be programmable by the OEM customer
at the time the engine is calibrated. • Miscellaneous customer-supplied hoses and
fittings
Diagnostic information can be communicated
through both the service tool interface and the MIL Fuel is stored in the customer-supplied LPG tank in
lamp. With the MIL lamp, it is possible to generate a saturated liquid phase and enters the fuel system
string of flashing codes that correspond to the fault from the tank as a liquid and at tank pressure. Fuel
type. These diagnostics are generated only when passes through a high-pressure fuel filter and lock-
the engine is not running and the operator initiates a off solenoid, and is then vaporized and regulated
diagnostic request sequence such as repeated down to the appropriate pressure to supply the
actuations of the pedal within a short period of time mixer. The regulator controls the fuel pressure to the
following reset. gas/air mixer.

G643(E) Service Manual 152 Chapter 5. Engine Management System (EMS)

Dual Dither Valve SECM

The key to meeting emissions requirements when The Small Engine Control Module (SECM) controls
operating in LPG is the dual dither valve hardware in the LPG lock-off solenoid valve and the FTVs. The
the fuel system. Similar to the MI-04 system, the lock-off solenoid is energized when fueling with LPG
dual dither system modulates the fuel pressure and the engine is turning. FTV modulation frequency
regulator outlet pressure by providing an offset to will be varied as a function of rpm by the SECM in
the regulator secondary stage reference pressure. order to avoid resonance phenomena in the fuel
By adding a second dither valve, or fuel trim valve system. FTV commands will be altered by the
(FTV), to the MI-07 system, smoother, more SECM in order to maintain a stoichiometric air-fuel
accurate control of supply pressure is achieved, ratio. Commands are based primarily on feedback
resulting in better control of air fuel ratio and from the exhaust gas oxygen sensor, with an offset
emissions. This smoother control also minimizes for fuel temperature.
wear on fuel system components such as the
regulator diaphragm and lever by significantly
reducing the pressure pulsations observed with a MI-07 LP Fuel Filter
single FTV.

After exiting the fuel tank, liquid propane passes

Regulator Pressure Offset through a serviceable inline fuel filter to the electric
fuel lock off. Figure 3 shows a typical inline type LP
fuel filter manufactured by Century. The primary
Regulator pressure offset is achieved through the function of the fuel filter is to remove particles and
use of a fixed orifice and a variable orifice in series. sediments that have found their way into the tank.
The inlet to the fixed orifice is connected to the The LP fuel filter will not remove heavy end solids
mixer inlet pressure (roughly equal to ambient and paraffins that build up in LPG fuel systems as a
pressure). The outlet of the fixed orifice is connected result of vaporization.
to both the pressure regulator reference port and the
inlet to the two FTVs (the variable orifice) that act in
parallel. The outlets of the FTVs are connected to
the mixer outlet, referred to as Air Valve Vacuum
(AVV). Thus, by modulating the FTVs, the pressure
regulator reference pressure can be varied between
mixer inlet pressure and AVV. For a given change in
the pressure regulator reference pressure, the
pressure regulator outlet pressure changes by the
same amount and in the same direction. The end
result is that a change in FTV modulation changes
the outlet pressure of the regulator/fuel inlet
pressure of the mixer, and thus the AFR. A major
benefit of this trim system results from the use of Figure 3. Inline LP Fuel Filter
mixer inlet pressure and AVV as the reference
pressure extremes. The pressure differential across
the mixer fuel valve is related to these same two
pressures, and thus so is fuel flow. Given this
arrangement, the bias pressure delta scales with the
fuel cone delta pressure. The result is that the trim
system control authority and resolution on AFR
stays relatively constant for the entire speed and
load range of the engine.

G643(E) Service Manual 153 Chapter 5. Engine Management System (EMS)

MI-07 Fuel Lock-Off (Electric) the Run state, when the engine reaches pre-idle rpm.
When an operator turns on the key switch the lock-
off is opened, but if the operator fails to crank the
The fuel lock-off is a safety shutoff valve, normally engine the SECM will close the lock-off after 5
held closed by spring pressure, which is operated by seconds.
an electric solenoid and prevents fuel flow to the
regulator/ converter when the engine is not in
operation. This is the first of three safety locks in the
MI-07 system. N-2007 Pressure Regulator/Vaporizer

The pressure regulator/vaporizer receives liquid

LPG from the fuel storage tank, drops the pressure,
changes the LPG phase from liquid to vapor, and
provides vapor phase LPG at a regulated outlet
pressure to the mixer. To offset the refrigeration
effect of the vaporization process, the regulator will
be supplied with engine coolant flow sufficient to
offset the latent heat of vaporization of the LPG.

A thermostat provided in the coolant supply line to

maintain regulator outlet coolant temperature at or
below 140oF (60°C) will minimize the deposit of fuel
Figure 4. Electric Fuel Lock Assembly
contaminants and heavy ends in the regulator and
assure a more controlled vaporization process with
In the MI-07 design, power is supplied to the fuel
reduced pressure pulsations.
lock-off via the main power relay with the SECM
controlling the lock-off ground (earth) connection.
A higher flow pressure regulator is required on
The lock-off remains in a normally closed (NC)
larger engines.
position until the key switch is activated.
This supplies power to the lock-off and the SECM,
but will not open the lock-off via the main power
relay until the SECM provides the lock-off ground
connection. This design gives the SECM full control
of the lock-off while providing additional safety by
closing the fuel lock-off in the unlikely event of a
power failure, wiring failure or module failure.

When the liquid service valve in the fuel container is

opened, liquid propane flows through the LP filter
and through the service line to the fuel lock-off.
Liquid propane enters the lock-off through the 1/4”
NPT liquid inlet port and stops with the lock-off in the
Figure 5. N-2007 Regulator
normally closed position. When the engine is
cranked over the main power relay applies power to
The regulator is normally closed, requiring a vacuum
the lock-off and the SECM provides the lock-off
signal (negative pressure) to allow fuel to flow. This
ground causing current to flow through the windings
is the second of three safety locks in the MI-07
of the solenoid creating a magnetic field. The
system. If the engine stops, vacuum signal stops
strength of this magnetic field is sufficient to lift the
and fuel flow will automatically stop when both the
lock-off valve off of its seat against spring pressure.
secondary (2nd stage) valve and the primary (1st
When the valve is open liquid propane, at tank
stage) valve closes. Unlike most other
pressure, flows through the lock-off outlet to the
regulator/converters, the N-2007 primary valve
pressure regulator/converter. A stall safety shutoff
closes with fuel pressure rather than against
feature is built into the SECM to close the lock-off in
pressure, extending primary seat life and adding
case of a stall condition. The SECM monitors three
additional safety.
engine states: Crank, when the crankshaft position
sensor detects any engine revolutions; Stall, when
the key is in the ON position but the crankshaft
position sensor detects no engine revolutions; and

G643(E) Service Manual 154 Chapter 5. Engine Management System (EMS)

Liquid propane must be converted into a gaseous When the engine is cranking or running a negative
form in order to be used as a fuel for the engine. pressure signal (vacuum) travels through the vapor
When the regulator receives the desired vacuum fuel outlet connection of the regulator, which is the
signal it allows propane to flow to the mixer. As the regulator secondary chamber, and the vapor fuel
propane flows through the regulator the pressure is inlet of the mixer. The negative pressure in the
reduced in two stages from tank pressure to slightly secondary chamber causes a pressure/force
less than atmospheric pressure. As the pressure of imbalance on the secondary diaphragm, which
the propane is reduced, the liquid propane vaporizes overcomes the secondary spring force, opening the
and refrigeration occurs inside the regulator due to secondary valve and allowing vapor propane to flow
the vaporization of liquid propane. To replace heat out of the expansion chamber, through the
lost to vaporization, engine coolant is supplied by secondary chamber to the mixer.
the engine driven water pump and pumped through
the regulator. Heat provided by this coolant is
transferred through to the fuel vaporization chamber.

N-2007 Operation
(Refer to Figure 6.)
Liquid propane, at tank pressure, enters the N-2007
through the fuel inlet port (1). Propane liquid then
flows through the primary valve (2). The primary
valve located at the inlet of the expansion chamber
(3), is controlled by the primary diaphragm (4),
which reacts to vapor pressure inside the expansion
chamber. Two springs are used to apply force on Figure 6. Parts View of N-2007 Regulator
the primary diaphragm in the primary diaphragm
chamber (5), keeping the primary valve open when Because vapor propane has now left the expansion
no fuel pressure is present. chamber, the pressure in the chamber will drop,
causing the primary diaphragm spring force to re-
A small port connects the expansion chamber to the open the primary valve allowing liquid propane to
primary diaphragm chamber. At the outlet of the enter the regulator, and the entire process starts
expansion chamber is the secondary valve (6). The again. This creates a balanced condition between
secondary valve is held closed by the secondary the primary and secondary chambers allowing for a
spring on the secondary valve lever (7). The constant flow of fuel to the mixer as long as the
secondary diaphragm controls the secondary lever. demand from the engine is present. The fuel flow is
When the pressure in the expansion chamber maintained at a constant output pressure, due to the
reaches 1.5 psig (10.3 kPa) it causes a calibrated secondary spring. The amount of fuel
pressure/force imbalance across the primary flowing will vary depending on how far the
diaphragm (8). This force is greater than the primary secondary valve opens in response to the negative
diaphragm spring pressure and will cause the pressure signal generated by the air/fuel mixer. The
diaphragm to close the primary valve. strength of that negative pressure signal developed
by the mixer is directly related to the amount of air
Since the fuel pressure has been reduced from tank flowing through the mixer into the engine. With this
pressure to 1.5 psig (10.3 kPa) the liquid propane process, the larger the quantity of air flowing into the
vaporizes. As the propane vaporizes it takes on heat engine, the larger the amount of fuel flowing to the
from the expansion chamber. This heat is replaced mixer.
by engine coolant, which is pumped through the
coolant passage of the regulator. At this point vapor
propane will not flow past the expansion chamber of
the regulator until the secondary valve is opened. To
open the secondary valve, a negative pressure
signal must be received from the air/fuel mixer.

G643(E) Service Manual 155 Chapter 5. Engine Management System (EMS)

CA100 Mixer

The mixer is installed above the throttle body and

meters gaseous fuel into the airstream at a rate that
is proportional to the volumetric flow rate of air. The
ratio between volumetric airflow and volumetric fuel
flow is controlled by the shaping of the mixer fuel
cone and biased by the controllable fuel supply
pressure delivered by the pressure regulator. Fuel
flow must be metered accurately over the full range
of airflows. Pressure drop across the mixer air valve
must be minimized to assure maximum power Figure 8. CA100 Mixer Attached to Throttle Body
output from the engine.
(Refer to Figure 98.)
The mixer fuel inlet is fitted with a thermistor-type The air/fuel mixer is mounted in the intake air stream
temperature sensor. This permits the SECM to between the air cleaner and the throttle. The design
correct fuel pressure to compensate for variations in of the main body incorporates a cylindrical bore or
fuel temperature. Left uncorrected, fuel temperature mixer bore, fuel inlet (1) and a gas discharge jet (2).
variations can cause significant variations in air fuel In the center of the main body is the air valve
ratio. assembly, which is made up of the air valve (3), the
gas-metering valve (4), and air valve diaphragm (5)
A higher flow mixer is required on larger engines. A and air valve spring (6). The gas-metering valve is
lower flow mixer is required on smaller engines. permanently mounted to the air valve diaphragm
assembly with a face seal mounted between the two
parts.

When the engine is not running this face seal

creates a barrier against the gas discharge jet,
preventing fuel flow with the aid (downward force) of
the air valve spring. When the engine is cranked
over it begins to draw in air, creating a negative
pressure signal. This negative pressure signal is
transmitted through four vacuum ports in the air
valve.

Figure 7. CA100 Mixer

CA100 Mixer Operation

Vapor propane fuel is supplied to the CA100 mixer
by the N-2007 pressure regulator/converter. The
mixer uses a diaphragm type air valve assembly to
operate a gas-metering valve inside the mixer. The
gas-metering valve is normally closed, requiring a
negative pressure (vacuum) signal from a cranking
or running engine to open. This is the third of the
Figure 9. Parts View of CA100 Mixer
three safety locks in the MI-07 system. If the engine
stops or is turned off, the air valve assembly closes
the gas-metering valve, stopping fuel flow past the
mixer. The gas-metering valve controls the amount
of fuel to be mixed with the incoming air at the
proper ratio. The air/fuel mixture then travels past
the throttle, through the intake manifold and into the
engine cylinders where it is compressed, ignited and
burned.

G643(E) Service Manual 156 Chapter 5. Engine Management System (EMS)

A pressure/force imbalance begins to build across A main mixture adjustment valve on the fuel inlet of
the air valve diaphragm between the air valve the CA100 is not used in the MI-07 system, however
vacuum (AVV) chamber (above the diaphragm) and an idle mixture adjustment is incorporated into the
atmospheric pressure below the diaphragm. mixer (Figure 12). The idle mixture adjustment is an
Approximately 6 inH2O (14.945 mbar) of negative air bypass port, adjusting the screw all the way in,
pressure is required to overcome the air valve spring blocks off the port and enriches the idle mixture.
force and push the air valve assembly upward off Backing out the idle adjustment screw opens the
the valve seat. Approximately 24 inH2O (59.781 port and leans the idle mixture. The idle mixture
mbar) pulls the valve assembly to the top of its travel screw is a screw with locking threads that is factory
in the full open position. set with a tamper proof cap installed after
adjustment. Accurate adjustment of the idle mixture
The amount of negative pressure generated is a can be accomplished by adjusting for a specific fuel
direct result of throttle position and the amount of air trim valve (FTV) duty cycle with the Service Tool
flowing through the mixer to the engine. At low software or with a voltmeter.
engine speeds, low AVV causes the air valve
diaphragm assembly to move upward a small NOTE: Adjustments should only be performed by
amount, creating a small venturi. At high engine trained service technicians.
speeds, high AVV causes the air valve diaphragm
assembly to move much farther creating a large
venturi. The variable venturi air/fuel mixer constantly
matches venturi size to engine demand.

Figure 12. Idle Mixture Adjustment Screw

(with tamper proof cap removed)

Figure 10. Bottom View of Air Valve Assembly

Figure 11. CA100 Mixer Installed with Electronic

Throttle

G643(E) Service Manual 157 Chapter 5. Engine Management System (EMS)

Fuel Trim Valve (FTV)

The Fuel Trim Valve (FTV) is a two-way electric

solenoid valve and is controlled by a pulse-width
modulated (PWM) signal provided by the SECM.
Two FTVs are used to bias the output fuel pressure
on the LPG regulator/converter (N-2007), by
metering air valve vacuum (AVV) into the
atmospheric side of the N-2007 secondary regulator
diaphragm. An orifice balance line connected to the
air inlet side of the mixer provides atmospheric
reference to the N-2007 when the FTV is closed.
The SECM uses feedback voltage from the O2
sensor to determine the amount of bias needed to
the regulator/converter.

In normal operation the N-2007 maintains fuel flow

at a constant output pressure, due to the calibrated
secondary spring. The amount of fuel flowing from
the N-2007 will vary depending on how far the
secondary diaphragm opens the secondary valve in
response to the negative pressure signal generated
by the air/fuel mixer. One side of the N-2007
secondary diaphragm is referenced to FTV control
pressure while the other side of the diaphragm
reacts to the negative pressure signal from the mixer.
If the pressure on the reference side of the N-2007
secondary diaphragm is reduced, the diaphragm will
close the secondary valve until a balance condition
exists across the diaphragm, reducing fuel flow and
leaning the air/fuel mixture.

G643(E) Service Manual 158 Chapter 5. Engine Management System (EMS)

Branch-Tee Fitting

secondary diaphragm, which lowers the reference

A branch-tee fitting is installed in the atmospheric
pressure, closing the N-2007 secondary valve and
vent port of the N-2007 with one side of the branch-
leaning the air/fuel mixture. The MI-07 system is
tee connected to the intake side of the mixer forming
calibrated to run rich without the FTV. By modulating
the balance line and referencing atmospheric
(pulsing) the FTVs the SECM can control the
pressure. The other side of the branch-tee fitting
amount of AVV applied to the N-2007 secondary
connects to the FTV inlet (small housing side). The
diaphragm. Increasing the amount of time the FTVs
FTV outlet (large housing connector side) connects
remain open (modulation or duty cycle) causes the
to the AVV port. When the FTVs are open AVV is
air/fuel mixture to become leaner; decreasing the
sent to the atmospheric side of the N-2007
modulation (duty cycle) enriches the mixture.

Figure 13. Fuel Trim Valves Connected to MI-07 System

G643(E) Service Manual 159 Chapter 5. Engine Management System (EMS)

Electronic Throttle System MI-07 Electronic Throttle
Conventional throttle systems rely on a mechanical
linkage to control the throttle valve. To meet
The electronic throttle system controls engine output
fluctuating engine demands a conventional system
(speed and torque) through electronic control of
will typically include a throttle valve actuator
mass airflow to the engine. Any DC motor-actuated
designed to readjust the throttle opening in response
or Limited Angle Torquemotor (LAT)-actuated
to engine demand, together with an idle control
throttle with less than 5A peak and 2A steady state
actuator or idle air bypass valve.
can be controlled. The TPS must be directly coupled
to the throttle shaft for direct shaft position
In contrast, the MI-07 system uses electronic throttle
measurement.
control (ETC). The SECM controls the throttle valve
based on engine RPM, engine load, and information
A commonly used throttle is the Bosch DV-E5. This
received from the foot pedal. Two potentiometers on
throttle is available in a variety of bore sizes to meet
the foot pedal assembly monitor accelerator pedal
specific engine needs: 32mm, 40mm, and 54mm are
travel. The electronic throttle used in the MI-07
readily available throttle bore sizes; other sizes are
system is a Bosch 40mm electronic throttle body
possible. The Bosch throttle is a fully validated
DV-E5 (Figure 14). The DV-E5 is a single unit
automotive component incorporating a brushed DC
assembly, which includes the throttle valve, throttle-
motor with gear reduction, dual throttle position
valve actuator (DC motor) and two throttle position
sensors, throttle plate, and cast aluminum housing.
sensors (TPS). The SECM calculates the correct
In the event of an electrical disconnection or other
throttle valve opening that corresponds to the
related failure, the throttle plate returns to a limp-
driver’s demand, makes any adjustments needed for
home idle position at a no-load engine speed above
adaptation to the engine’s current operating
curb idle speed. This provides sufficient airflow for
conditions and then generates a corresponding
the engine to move the vehicle on level ground. Any
electrical (driver) signal to the throttle-valve actuator.
throttle bodies used for MI-07 meet or exceed the
specification for the Bosch throttle bodies.

In terms of response, the throttle is capable of fully

opening and closing in less than 50 msec. Position
resolution and steady state control should be 0.25%
of full travel or better.

Figure 14. Bosch Electronic Throttle Body

The MI-07 uses a dual TPS design (TPS1 and

TPS2). The SECM continuously checks and
monitors all sensors and calculations that effect
throttle valve position whenever the engine is
running. If any malfunctions are encountered, the
SECM’s initial response is to revert to redundant
sensors and calculated data. If no redundant signal
is available or calculated data cannot solve the
malfunction, the SECM will drive the system into one
of its limp-home modes or shut the engine down,
storing the appropriate fault information in the SECM.

G643(E) Service Manual 160 Chapter 5. Engine Management System (EMS)

There are multiple limp-home modes available with Ignition System Control
electronic throttle control:
Spark-ignited engines require accurate control of
1. If the throttle itself is suspected of being spark timing and spark energy for efficient
inoperable, the SECM will remove the power to combustion. The MI-07 ignition system provides this
the throttle motor. When the power is removed, control. The system consists of the following
the throttle blade returns to its “default” position, components:
approximately 7% open.
• SECM
2. If the SECM can still control the throttle but some
other part of the system is suspected of failure, • Distributor with ignition module
the SECM will enter a “Reduced Power” mode. In
this mode, the power output of the engine is • Ignition coil *
limited by reducing the maximum throttle position
allowed. • Crankshaft position sensor *

3. In some cases, the SECM will shut the engine • Crankshaft timing wheel *
down. This is accomplished by stopping ignition,
turning off the fuel, and disabling the throttle. • Spark plugs *

The SECM, through use of embedded control

Picture courtesy of Robert Bosch GmbH

Figure 15. Throttle Body Assembly Exploded View

Figure 14. GM Distributor

G643(E) Service Manual 161 Chapter 5. Engine Management System (EMS)

The MI-07 system is capable of operating with either Exhaust System
a distributor based ignition system or a
distributorless ignition system. The current Heated Exhaust Gas Oxygen Sensors (HEGO)
application uses a distributor based ignition system. The MI-07 system utilizes two HEGO (O2) sensors.
The distributor will have no internal advance One sensor is a pre-catalyst sensor that detects the
mechanisms giving the SECM consistent authority amount of oxygen in the exhaust stream and is
over ignition timing. The spark is sent to the considered the primary control point. Based upon
appropriate cylinder in the conventional way via the the O2 sensor feedback, the MI-07 system supplies
rotor arm and spark plug wires. The SECM uses the a stoichiometric air-fuel ratio to the catalytic
signal from the GM (General Motors) Delco Ignition converter. The catalytic converter then reduces
Module to determine the engine position and RPM emissions to the required levels. The second sensor
at any time. It uses this information together with the is a post-catalyst sensor that detects the amount of
information from the TPS sensor and TMAP to oxygen after the catalyst. This sensor is used as a
calculate the appropriate ignition timing settings. secondary control point to adjust the pre-catalyst
setpoint to ensure proper catalyst conversion
The General Motors (GM) distributor (Figure 14) efficiency.
used in the Delco EST ignition system, incorporates

Figure 18. HEGO (O2) Sensor

a Variable Reluctance (VR) sensor, which transmits
a reference signal to the GM ignition module (Figure Once a HEGO sensor reaches approximately 600°F
15) located on the distributor. A variable reluctance (316°C), it becomes electrically active. The
sensor is an electromagnetic device consisting of a concentration of oxygen in the exhaust stream
permanent magnet surrounded by a winding of wire. determines the voltage produced. If the engine is
The sensor is used in conjunction with a ferrous running rich, little oxygen will be present in the
signal rotor on the distributor shaft. The signal rotor exhaust and voltage output will be relatively high.
has six lobes, one for each cylinder. Rotation of the Conversely, in a lean situation, more oxygen will be
signal rotor near the tip of the sensor changes the present and a smaller electrical potential will be
magnetic flux, creating an analog voltage signal in noticed.
the sensor coil.
(1) lgnition coil (2) Ignition module In order for the sensor to become active and create
an electrical signal below 600°F (316°C) a heated
Figure 15. GM Ignition Module element is added to the sensor housing. Two wires
provide the necessary 12 Vdc and ground signal for
The rising edge of the VR signal is converted to a the heater element. A fourth wire provides an
rising 5-volt signal by the ignition module. As the VR independent ground for the sensor. The pre-catalyst
signal passes back through zero volts, a falling edge sensor heater is powered by the main power relay
is created producing a square wave or digital signal, and is always powered. The post-catalyst sensor
similar to the signal produced by a Hall effect sensor. heater is powered from an additional relay that is
This falling edge signal provides a stable engine controlled by the SECM. This relay is only energized
position reference at all engine speeds for the when the SECM calculates that water condensation
SECM. in the exhaust system and catalytic muffler prior to
the sensor should be evaporated. This is to avoid
thermal shock of the sensor that could prematurely
fail the sensor.

G643(E) Service Manual 162 Chapter 5. Engine Management System (EMS)

The HEGO stoichiometric air-fuel ratio voltage target over a platinum and palladium catalyst. Cerium is
is approximately 500 mV and changes slightly as a also used to promote oxygen storage and improve
function of speed and load. When the pre-catalyst oxidation efficiency.
HEGO sensor sends a voltage signal less than 450
mV the SECM interprets the air-fuel mixture as lean.
The SECM then decreases the PWM duty cycle sent
to the fuel trim valves in order to increase the fuel
pressure to the mixer inlet; thus richening air-fuel
mixture. The opposite is true if the SECM receives a
voltage signal above 450 mV from the HEGO. The
air-fuel mixture would then be interpreted as being
too rich and the SECM would increase the duty
cycle of the trim valves.

CAUTION
The HEGO sensors are calibrated to work with
the MI-07 control system. Use of alternate senso- As exhaust and catalyst temperatures rise the
rs may impact performance and the ability of the following reaction occurs:
system to diagnose rich and lean conditions.
• Oxides of nitrogen (NOx) are reduced into simple
nitrogen (N2) and carbon dioxide (CO2).

Catalytic Muffler • Hydrocarbons (HC) and carbon monoxide (CO)

are oxidized to create water (H2O) and carbon
In order to meet 2007 emission requirements a 3- dioxide (CO2).
way catalyst is necessary.

All exhaust gases pass through a catalyst that is

mounted in the catalytic muffler. It filters the harmful
gases through a dense honeycomb structure coated
with precious metals such as platinum, palladium,
and rhodium. Chemical reactions occur on these
surfaces to convert the pollutants into less harmful
gases. Catalysts store oxygen on lean mixtures
(less than optimal amount of fuel) and release
oxygen on rich mixtures (more than optimal amount
of fuel). The primary pollutant produced on the lean
swing is nitrous oxide. Oxygen is removed from
nitrous oxide by the converter, resulting in nitrogen
gas, a harmless emission. On the rich cycle, the
primary pollutant is carbon monoxide. By adding the
The MI-07 control system monitors the exhaust
oxygen that was stored on the lean cycle to the
stream pre and post catalyst and uses this
carbon monoxide, carbon dioxide is produced.
information to control the air-fuel mixture. By using
the signals from the HEGOs, the SECM can
Inside the catalytic muffler is a three-way catalyst as
increase or decrease the amount of oxygen in the
well as sound dampening and spark arresting
exhaust by modulating the FTVs and adjusting the
features. The three-way catalyst section consists of
air-fuel ratio. This control scheme allows the SECM
a honeycomb coated with a mixture of platinum,
to make sure that the engine is running at the
palladium and rhodium. As engine exhaust gases
correct air to fuel ratio so that the catalyst can
flow through the converter passageways, they
perform as required to meet the emissions
contact the coated surface, which initiate the
certification.
catalytic process. The reduction catalyst is the first
stage of the catalytic converter. It uses platinum and
rhodium to help reduce the NOx emissions. The
oxidation catalyst is the second stage of the catalytic
converter. It reduces the unburned hydrocarbons
and carbon monoxide by burning (oxidizing) them

G643(E) Service Manual 163 Chapter 5. Engine Management System (EMS)

SECM position sensor (TPS), and the accelerator pedal
position sensors (APP1 & APP2).
General Description
The SECM provides a transducer ground for all the
The Small Engine Control Module (SECM) controller sensors, and a low side driver signal controlling the
has full authority over spark, fuel and air. Utilizing a fuel lock-off, MIL, gasoline injectors, gasoline fuel
Freescale micro controller, the SECM has 48 pins of pump, and FTVs.
I/O and is fully waterproof and shock hardened. To
optimize engine performance and drivability, the
SECM uses several sensors for closed loop Fuel Management
feedback information. These sensors are used by
the SECM for closed loop control in three main During engine cranking at startup, the SECM
categories: provides a low side driver signal to the fuel lock-off,
which opens the lock-off allowing liquid propane to
• Fuel Management flow to the N-2007 regulator. A stall safety shutoff
feature is built into the SECM to close the lock-off in
• Load/Speed Management case of a stall condition. The SECM monitors three
engine states:
• Ignition Management
Crank, when the crankshaft position sensor detects
any engine revolutions
Stall, when the key is in the ON position but the
crankshaft position sensor detects no engine
revolutions
Run state, when the engine reaches pre-idle RPM.

When an operator turns on the key switch the lock-

off is opened but if the operator fails to crank the
engine, the SECM will close the lock-off after 5
seconds.

To maintain proper exhaust emission levels, the

SECM uses a heated exhaust gas oxygen sensor
The SECM monitors system parameters and stores (HEGO) mounted before the catalyst, to measure
any out of range conditions or malfunctions as faults exhaust gas content in the LP gas system. Engine
in SECM memory. Engine run hours are also stored speed is monitored by the SECM through a variable
in memory. Stored fault codes can be displayed on reluctance (VR) sensor or Hall-Effect type sensor.
the Malfunction Indicator Light (MIL) as flash codes Intake manifold air temperature and absolute
or read by the MI-07 Service Tool software through pressure are monitored with a (TMAP) sensor.
a CAN (Controller Area Network) communication The HEGO voltage is converted to an air/fuel ratio
link. value. This value is then compared to a target value
in the SECM. The target value is based on
Constant battery power (12 Vdc) is supplied through optimizing catalyst efficiency for a given load and
the fuse block to the SECM and the main power speed. The SECM then calculates any corrections
relays. Upon detecting a key-switch ON input, the that need to be made to the air/fuel ratio.
SECM will fully power up and energize the main The system operates in open loop fuel control until
power relays. the engine has done a certain amount of work.
The energized main power relays supply 12 Vdc This ensures that the engine and HEGO are
power to the heated element of the oxygen sensors, sufficiently warmed up to stay in control. In open
fuel lock-off, fuel trim valves (FTVs), gasoline loop control, the FTV duty cycle is based on engine
injectors, gasoline fuel pump, crank sensor, cam speed and load.
sensor, and the ignition coils. Once the HEGO reaches operating temperature the
The SECM supplies voltage to the electronic throttle fuel management is in closed loop control for all
actuator, oil pressure switch, fuel temperature steady state conditions, from idle through full throttle.
sensor, and the coolant temperature sensor. In closed loop mode, the FTV duty cycle is based on
Transducer or sensor power (+ 5 Vdc) is regulated feedback from the HEGO sensor. The system may
by the SECM and supplied to the manifold return to open-loop operation when engine load or
temperature/air pressure (TMAP) sensor, throttle engine speed vary beyond a chosen threshold.

G643(E) Service Manual 164 Chapter 5. Engine Management System (EMS)

The SECM makes any necessary corrections to the
air-fuel ratio by controlling the inlet fuel pressure to
the air-fuel mixer Reducing the fuel pressure leans
the air/fuel mixture and increasing the fuel pressure
enriches the air-fuel mixture. Control is achieved by
modulating the fuel trim valves.

Speed Management

Drive-by-wire refers to the fact that the MI-07 control

system has no throttle cable from the foot pedal to
the throttle body. Instead, the SECM is electronically Figure 20. Throttle Position Sensor (TPS) on DV-E5
connected both to the foot pedal assembly and the Throttle
throttle body.
The SECM monitors the foot pedal position and NOTE : The DV-E5 throttle is not a serviceable
controls the throttle plate by driving a DC motor assembly. If a TPS sensor fails, the assembly
connected to the throttle. The DC motor actuates the should be replaced.
throttle plate to correspond to the foot pedal position
when the operator depresses the pedal. The SECM The MI-07 system also performs minimum (min) and
will override the pedal command above a maximum maximum (max) speed governing through the
engine speed and below a minimum idle speed. SECM and DBW throttle. For min governing, or idle
speed control, the idle speed is fixed by the SECM.
Unlike a mechanical system, the idle speed is not
adjustable by the end user. The idle speed is
adjusted by the SECM based on engine coolant
temperature. At these low engine speeds, the SECM
uses spark and throttle to maintain a constant speed
regardless of load.

The MI-07 system eliminates the need for air

velocity governors. This substantially increases the
peak torque and power available for a given system
as shown in Figure 21. When the engine speed
reaches the max governing point the speed is
Figure 19. Foot Pedal controlled by closing the DBW throttle. Using the
DBW throttle as the primary engine speed control
The use of electronic throttle control (ETC) ensures allows for a smooth transition into and out of the
that the engine receives only the correct amount of governor. If excessive over speed is detected, the
throttle opening for any given situation, greatly engine is shut down.
improving idle quality and drivability.

Two throttle position sensors (TPS1 and TPS2),

which are integral to the drive-by-wire (DBW) throttle
assembly, provide feedback for position control by
monitoring the exact position of the throttle valve.
See Figure 20.

SECM self-calibration and “cross checking”

compares both signals and then checks for errors.

G643(E) Service Manual 165 Chapter 5. Engine Management System (EMS)

Drive-By-Wire Signal Flow Process

Figure 21. Peak Torque and Power Available with

MI-07 System

Figure 22. Drive-By-Wire Signal Flow Process

Figure 22 describes the signal flow process of the

MI-07 DBW section. The foot pedal assembly uses
two potentiometers to detect pedal position.
These two signals, accelerator pedal position 1
(APP1) and accelerator pedal position 2 (APP2) are
sent directly to the SECM.
The SECM uses a series of algorithms to self
calibrate and cross check the signals from the pedal
assembly. A demand position for the throttle will
then be derived and sent to the throttle as a throttle
position sensor demand (TPSd). This signal will be
processed through a PID (Proportional, Integral,
Derivative) controller in the SECM to achieve the
appropriate motor-current response then passed to
the throttle. The throttle moves to the commanded
position and provides a feedback signal from the
throttle position sensors (TPS1 and TPS2) to the
SECM.

G643(E) Service Manual 166 Chapter 5. Engine Management System (EMS)

Ignition Management SECM Wiring Diagrams for G643E

In the normal course of events, with the engine CAUTION—PROPER WIRING

operating at the correct temperature in defined
conditions, the SECM will use load and engine To prevent system faults be sure to follow good
speed to derive the correct ignition timing. In wiring practices. Poor wiring may cause unexpe-
addition to load and speed there are other cted or intermittent failures not related to MI-07
circumstances under which the SECM may need to components.
vary the ignition timing, including low engine coolant
temperature, air temperature, start-up, and idle
speed control.

SECM Electrical Mounting

Recommendations

In order to prevent the possibility of any SECM

malfunctions due to EMI/RFI emissions, the SECM
mounting and harness recommendations listed
below:

• The SECM should be mounted in a location that

minimizes the amount of EMI the module is
exposed to by locating it as far as practical from
all high tension components, such as ignition coils,
distributors, spark plug wires, etc. It is
recommended that the SECM be mounted at least
29.5” (749 mm) away from the distributor and
ignition coil, and at least 20” (508 mm) from the
nearest plug wire.

• All wiring harnesses should be routed to minimize

coupling (both radiated and conducted), and be
securely fastened to minimize movement and
maintain proper clearance between the SECM
and all ignition system components.

• The OEM must ensure that a high-quality ground

connection between the SECM and battery
negative (–) is provided and can be maintained for
the useful life of the vehicle. This may require the
use of star-type washers on all ground lug
connections between the SECM and the battery
and/or special preparation of all mating surfaces
that complete the ground connection in order to
ensure that the connection is sound.

G643(E) Service Manual 167 Chapter 5. Engine Management System (EMS)

RED 12 AWG

BATTERY

F1 15A
12V

IGN SWITCH

14 AWG
85

30
O-START F4 2A

MPR1
87
F5 2A
RED 18 AWG RED 14 AWG
CRANK SENSOR

SED 14 AWG
BATT_B22 RED
N
S

RED
A B C

COLOR B5_CRNK+ KEY_ON_B8 PINK

MPRD_A22 COLOR
COLOR

LS01_A5
LS03_A4

B10_CAM+ LS04_A7
LS02_A8
A24_LSO9_MIL
TRANSMISSION OIL

COLOR
1

2
TEMP SWITCH

MIL

DRVP_A23 RED
COLOR B2_AN6_TOTS

NEAR MODULE
RED 18 AWG

ENG GND
OIL PRESSURE
TO ENGINE
LAMP

DISTRIBUTOR COIL
OIL PRESSURE CAN SAE J1939 FUEL SELECT

ABCD
SWITCH

COLOR B9_AN13_OPS EST1_A9

COLOR
COLOR

B21_CAN1- EST2_A10

B A
COLOR
120 OHM
K

1/4 W
J

COLOR B20_CAN1+
EST3_A3
JUMPER A15 TO B1 FOR GASOLINE.
JUMPER A12 TO B1 FOR LP.
A JUMPER MUST BE USED.
IF NO SELECT SWITCH IS USED,
FUEL SELECT NOTE:

COLOR A15_EST8_FSS-LIQ
SWITCH

EST4_A6
FOOT PEDAL

COLOR B7_AN4_APP1
E
D
C

COLOR B16_AN5_APP2
B
A
TEMPERATURE

DRVG-A_A16
ENGINE GND

BLACK 16 AWG
SENSOR

COLOR B14_AN10_FTS DRVG-B_B17

FUEL

BLACK 16 AWG
GROUND SPEED

A21_EST6_GRNDSPD_SW
SWITCH

LOCK-OFF VALVE 1 VALVE 2

COLOR

RED
A B

LO_LS08_A11 COLOR
COLOR

B18_AN1_MAP
MAP/MAT

MAP COLOR
4 3

B12_AN8_MAT
DITHER DITHER

MAT COLOR
DUAL

VLV1_LSO11_A1
2

COLOR
1 2

COLOR
1

RED
COLOR B24_XDRP_XPWR
COLOR B1_XDRG_XGND VLV2_LSO10_A2
TEMPERATURE

COLOR
1 2

COLOR
DUAL

RED
COOLANT
SENSOR

COLOR B15_AN9_ECT
A

FUELPMP_LS 05_A13
THROTTLE BODY

B23_AN2_TPS1
O2_A SENSOR (WIRE SIDE) O2_B SENSOR

COLOR
B4_AN3_TPS2
6

COLOR
PRE-CAT
3

A18_H1-_ETC_TB- BLACK
5

COLOR
2

A17_H1+_ETC_TB+
4

COLOR
1

2 1

O2A+_AN11_B13 COLOR
COLOR
3
BLACK

CONNECTOR

A20_LSO7_O2B_HTR
O2 SENSOR

COLOR
COLOR
1 2
86

3 4
85

O2HR

GREY
87

BLACK
4

POST-CAT
2 1

O2B+_AN12_B19 COLOR
COLOR
3

RED

1
A
CONNECTOR
B
1 CONNECTOR

24 24

Figure21. SECM Wiring Diagram for G643E LP Fuel

G643(E) Service Manual 168 Chapter 5. Engine Management System (EMS)

G643 EMS (Engine Management
System) Overview

General Description

MI-04 control system provides a complete, fully Engine speed is monitored by the SECM through a
integrated engine management system for naturally variable reluctance (VR) sensor. Intake manifold air
aspirated engines. temperature and absolute pressure are monitored
with a TMAP sensor. MI-04 is a drive-by-wire (DBW)
It provides accurate, reliable, and durable control of system connecting the accelerator pedal to the
spark and air over the service life of the engine in electronic throttle through the electrical harness;
the extreme operating environment found in heavy- mechanical cables are not used. A throttle position
duty, under hood, on-engine electronic controls. sensor (TPS) monitors throttle position in relation to
the accelerator pedal position sensor (APP)
The SECM monitors the engine through a number of command. Even engine coolant temperature and
different sensors to ensure optimal performance. adequate oil pressure are monitored by the SECM

Figure 2. G643 LP System

The LPG regulator and the mixer operate as an

open loop system since no mixture adjustments are
made by the SECM. The mixer does have an idle
mixture adjustment and a power valve adjustment.
Manifold pressure from the TMAP, rpm from the
crank position sensor and throttle position is used by
the SECM to calculate load. Feedback from the
electronic throttle is provided to the SECM by the
throttle position sensors (TPS).

G643(E) Service Manual 169 Chapter 5. Engine Management System (EMS)

LP System of G643

INPUT OUTPUT
Speed pick-up in Throttle body
Distributor

lgnition Module
TMAP sensor

Coolant Temp

EG oil pressure switch LP fuelock valve

SECM
Accel pedal angle sensor CAN communication

Throttle position sensor

Ground speed limit

Device

G643(E) Service Manual 170 Chapter 5. Engine Management System (EMS)

MI-07 System Components • Min/max governing

• All-speed isochronous governing

The MI-07 control system provides electronic control
to the following subsystems on mobile industrial • Fixed-speed isochronous governing with three
engines: switch-selectable speeds

• Spark-ignition control system • Spark timing modifiers for temperature and fuel
type
• Air throttle
• Input sensor selection and calibration
• Sensors/Switches/Speed inputs
• Auxiliary device control for fuel pump, fuel lock-off
Key Components solenoid, tachometer, MIL, interlocks, vehicle
speed limiting, etc.
The MI-07 system functions primarily on engine
components that affect engine emissions and • CANBus data transfer for speed, torque, etc.
performance. These key components include the
following:

• Engine/Combustion chamber design Other system features include:

• Intake/Exhaust valve configuration, timing and lift

Tamper-Resistance
• Intake/Exhaust manifold design
Special tools, equipment, knowledge, and
authorization are required to effect any changes to
• Throttle body
the MI-07 system, thereby preventing unauthorized
personnel from making adjustments that will affect
• Air intake and air filter
performance or emissions.
• LPG mixer
Diagnostics
• LPG pressure regulator
MI-07 is capable of monitoring and diagnosing
problems and faults within the system. These
• Small engine control module (SECM), firmware
include all sensor input hardware, control output
and calibration †
hardware, and control functions such as closed-loop
fuel control limits and adaptive learn limits. Upon
• Fuel system sensors and actuators
detecting a fault condition, the system notifies the
operator by illuminating the MIL and activating the
• Ignition system including spark plugs, cables, coils
appropriate fault action. The action required by each
and drivers
fault shall be programmable by the OEM customer
at the time the engine is calibrated.

MI-07 System Features Diagnostic information can be communicated

through both the service tool interface and the MIL
lamp. With the MIL lamp, it is possible to generate a
The MI-07 system uses an advanced speed-density
string of flashing codes that correspond to the fault
control strategy for fuel, spark, and air throttle
type. These diagnostics are generated only when
control. Key features include the following.
the engine is not running and the operator initiates a
diagnostic request sequence such as repeated
• Open-loop fuel control with fuel specific controls
actuations of the pedal within a short period of time
for LPG
following reset.
• Speed-load spark control with tables for dwell,
timing, and fuel type

• Speed-load throttle control with table for maximum

TPS limiting

G643(E) Service Manual 171 Chapter 5. Engine Management System (EMS)

Limp Home Mode MI-07 LP Fuel Filter

The system is capable of "limp-home" mode in the The LP fuel filter of G643 engine is the same as that
event of particular faults or failures in the system. In of G643E engine. See, “G643E EMS overview”
limp-home mode the engine speed is approximately
1000 rpm at no load. A variety of fault conditions can MI-07 Fuel Lock-Off (Electric)
initiate limp-home mode. These fault conditions and
resulting actions are determined during calibration The LP fuel lock-off of G643 engine is the same as
and are OEM customer specific. that of G643E engine. See, “G643E EMS overview”

N-2001 Regulator/Converter
Service Tool
After passing through the electric fuel lock-off, liquid
A scan tool/monitoring device is available to monitor propane enters the N-2001 regulator/converter
system operation and assist in diagnosis of system (Figure 4). The N-2001 functions as a fuel vaporizer,
faults This device monitors all sensor inputs, control converting liquid propane to vapor propane and as a
outputs, and diagnostic functions in sufficient detail two-stage negative pressure regulator, supplying the
through a single access point to the SECM to allow correct vapor propane fuel pressure to the mixer.
a qualified service technician to maintain the system.
This Mototune software (licensed by Mototron The regulator is normally closed requiring a vacuum
Communication) is secure and requires a crypt- signal (negative pressure) to allow fuel to flow. This
token USB device to allow access to information. is the second of three safety locks in the MI-07
system. If the engine stops, vacuum signal stops
and fuel flow will automatically stop when both the
LPG Fuel System Operation secondary (2nd stage) valve and the primary (1st
stage) valve closes. Unlike most other
The principles outlined below describe the operation regulator/converters, the N-2001 primary valve
of MI-07 on an LPG fuel system. closes with fuel pressure rather than against
pressure, extending primary seat life and adding
An LPG fuel system consists of the following additional safety.
components:

• Fuel filter (supplied by customer)

• Electric fuel lock-off solenoid valve
• Fuel pressure regulator/vaporizer
• Gas/Air mixer
• Miscellaneous customer-supplied hoses and
fittings

Fuel is stored in the customer-supplied LPG tank in

saturated liquid phase and enters the fuel system
from the tank as a liquid and at tank pressure. Fuel
passes through a high-pressure fuel filter and lock-
off solenoid, and is then vaporized and regulated Figure 4. N-2001 Regulator
down to the appropriate pressure to supply the
mixer. The regulator controls the fuel pressure to the Liquid propane must be converted into a gaseous
gas/air mixer. The mixer meters fuel delivery based form in order to be used as a fuel for the engine.
upon airflow into the engine. When the regulator receives the desired vacuum
signal it allows propane to flow to the mixer. As the
SECM propane flows through the regulator the pressure is
reduced in two stages from tank pressure to slightly
The Small Engine Control Module (SECM) controls less than atmospheric pressure. As the pressure of
the LPG lock-off solenoid valve. The lock-off the propane is reduced the liquid propane vaporizes
solenoid is energized when fueling with LPG and the and refrigeration occurs inside the regulator due to
engine is turning. The lock-off is de-energized when the large temperature drop inside the regulator from
engine rpm is not detected. the vaporization of liquid propane. To replace heat
lost to vaporization, engine coolant is supplied by
the engine driven water pump and pumped through

G643(E) Service Manual 172 Chapter 5. Engine Management System (EMS)

the regulator. Heat provided by this coolant is
transferred through to the fuel vaporization chamber.
Figure 5 shows the heat chamber and the coolant
passage in the N-2001 regulator.

Figure 6. Parts View of N-2001 Regulator

Since the fuel pressure has been reduced from tank

pressure to 1.5 psi (10.342 kPa) the liquid propane
vaporizes. As the propane vaporizes it takes on heat
Figure 5. Heat Chamber and Coolant Passage from the expansion chamber. This heat is replaced
by engine coolant, which is pumped through the
coolant passage of the regulator. At this point vapor
propane will not flow past the expansion chamber of
N-2001 Operation the regulator until the secondary valve is opened.
To open the secondary valve a negative pressure
Refer to Figure 6. signal must be received from the air/fuel mixer.
When the engine is cranking or running a negative
Liquid propane, at tank pressure, enters the N-2001 pressure signal (vacuum) travels through the vapor
through the fuel inlet port (1). Propane liquid then fuel outlet connection of the regulator (9), which is
flows through the primary valve (2). The primary the regulator secondary chamber, and the vapor fuel
valve located at the inlet of the expansion chamber inlet of the mixer. The negative pressure in the
(3), is controlled by the primary diaphragm (4), secondary chamber causes a pressure/force
which reacts to vapor pressure inside the expansion imbalance on the secondary diaphragm, which
chamber. Two springs are used to apply force on overcomes the secondary spring force, opening the
the primary diaphragm in the primary diaphragm secondary valve and allowing vapor propane to flow
chamber (5), keeping the primary valve open when out of the expansion chamber, through the
no fuel pressure is present. secondary chamber to the mixer.

A small port connects the expansion chamber to the Because vapor propane has now left the expansion
primary diaphragm chamber. At the outlet of the chamber, the pressure in the chamber will drop,
expansion chamber is the secondary valve (6). The causing the primary diaphragm spring force to re-
secondary valve is held closed by the secondary open the primary valve allowing liquid propane to
spring on the secondary valve lever (7). The enter the regulator, and the entire process starts
secondary diaphragm controls the secondary lever. again. This creates a balanced condition between
When the pressure in the expansion chamber the primary and secondary chambers allowing for a
reaches 1.5 psi (10.342 kPa it causes a pressure/ constant flow of fuel to the mixer as long as the
force imbalance across the primary diaphragm (8). demand from the engine is present. The fuel flow is
This force is greater than the primary diaphragm maintained at a constant output pressure, due to the
spring pressure and will cause the diaphragm to calibrated secondary spring. The amount of fuel
close the primary valve. flowing will vary depending on how far the
secondary valve opens in response to the negative
pressure signal generated by the air/fuel mixer. The
strength of that negative pressure signal developed
by the mixer is directly related to the amount of air
flowing through the mixer into the engine. With this
process, the larger the quantity of air flowing into the
engine, the larger the amount of fuel flowing to the
mixer.

G643(E) Service Manual 173 Chapter 5. Engine Management System (EMS)

CA100 Mixer

The mixer is installed above the throttle body and

meters gaseous fuel into the airstream at a rate that
is proportional to the volumetric flow rate of air. The
ratio between volumetric airflow and volumetric fuel
flow is controlled by the shaping of the mixer fuel
cone and biased by the controllable fuel supply
pressure delivered by the pressure regulator. Fuel
flow must be metered accurately over the full range
of airflows. Pressure drop across the mixer air valve
must be minimized to assure maximum power Figure 8. CA100 Mixer Attached to Throttle Body
output from the engine.
(Refer to Figure 98.)
A higher flow mixer is required on larger engines. A The air/fuel mixer is mounted in the intake air stream
lower flow mixer is required on smaller engines. between the air cleaner and the throttle. The design
of the main body incorporates a cylindrical bore or
mixer bore, fuel inlet (1) and a gas discharge jet (2).
In the center of the main body is the air valve
assembly, which is made up of the air valve (3), the
gas-metering valve (4), and air valve diaphragm (5)
and air valve spring (6). The gas-metering valve is
permanently mounted to the air valve diaphragm
assembly with a face seal mounted between the two
parts.

When the engine is not running this face seal

creates a barrier against the gas discharge jet,
preventing fuel flow with the aid (downward force) of
Figure 7. CA100 Mixer the air valve spring. When the engine is cranked
over it begins to draw in air, creating a negative
pressure signal. This negative pressure signal is
CA100 Mixer Operation transmitted through four vacuum ports in the air
valve.

Vapor propane fuel is supplied to the CA100 mixer

by the N-2001 pressure regulator/converter. The
mixer uses a diaphragm type air valve assembly to
operate a gas-metering valve inside the mixer. The
gas-metering valve is normally closed, requiring a
negative pressure (vacuum) signal from a cranking
or running engine to open. This is the third of the
three safety locks in the MI-07 system. If the engine
stops or is turned off, the air valve assembly closes
the gas-metering valve, stopping fuel flow past the
mixer. The gas-metering valve controls the amount
of fuel to be mixed with the incoming air at the
proper ratio. The air/fuel mixture then travels past Figure 9. Parts View of CA100 Mixer
the throttle, through the intake manifold and into the
engine cylinders where it is compressed, ignited and
burned.

G643(E) Service Manual 174 Chapter 5. Engine Management System (EMS)

Figure 12. Idle Mixture Adjustment Screw

Electronic Throttle System

Figure 10. Bottom View of Air Valve Assembly
The electronic throttle system of G643 engine is the
same as that of G643E engine. See, “Electro-nic
throttle system of G643E EMS overview”

Figure 11. CA100 Mixer Installed with Electronic

Throttle

G643(E) Service Manual 175 Chapter 5. Engine Management System (EMS)

Ignition System GM Delco EST Ignition System

The MI-07 system is capable of operating with either

Spark-ignited engines require accurate control of
a distributor based ignition system or a
spark timing and spark energy for efficient
distributorless ignition system. The current
combustion. The MI-07 ignition system provides this
application uses a distributor based ignition system.
control. The system consists of the following
The distributor will have no internal advance
components:
mechanisms giving the SECM consistent authority
over ignition timing. The spark is sent to the
• SECM
appropriate cylinder in the conventional way via the
rotor arm and spark plug wires. The SECM uses the
• Distributer with Ignition module
signal from the GM (General Motors) Delco Ignition
Module to determine the engine position and RPM
• Ignition coil(s) *
at any time. It uses this information together with the
information from the TPS sensor and TMAP to
• Crankshaft position sensor *
calculate the appropriate ignition timing settings.
• Crankshaft timing wheel *

• Spark plugs *

(*) Customer-supplied components

The SECM, through use of embedded control

algorithms and calibration variables, determines the
proper time to start energizing the coil and fire the
spark plug. This requires accurate crank/camshaft
position information, an engine speed calculation,
coil energy information, and target spark timing. The
SECM provides a TTL compatible signal for spark
control. The coil must contain the driver circuitry
Figure 14. GM Distributor
necessary to energize the primary spark coil
otherwise an intermediary coil driver device must be
The General Motors (GM) distributor (Figure 14)
provided. The SECM controls spark energy (dwell
used in the Delco EST ignition system, incorporates
time) and spark discharge timing.
a Variable Reluctance (VR) sensor, which transmits
a reference signal to the GM ignition module (Figure
15) located on the distributor. A variable reluctance
sensor is an electromagnetic device consisting of a
permanent magnet surrounded by a winding of wire.
The sensor is used in conjunction with a ferrous
signal rotor on the distributor shaft. The signal rotor
has six lobes, one for each cylinder. Rotation of the
signal rotor near the tip of the sensor changes the
magnetic flux, creating an analog voltage signal in
the sensor coil.

G643(E) Service Manual 176 Chapter 5. Engine Management System (EMS)

The SECM monitors system parameters and stores
any out of range conditions or malfunctions as faults
in SECM memory. Engine run hours are also stored
in memory. Stored fault codes can be displayed on
the Malfunction Indicator Light (MIL) as flash codes
or read by the Service Tool software through a CAN
(Controller Area Network) communication link.

Battery power (12 Vdc) is supplied through the fuse

block to the main power relay. The ignition key
switch is used to energize the main power relay. A
main power relay supplies 12 Vdc power to the
(1) Ignition Coil (2) Ignition Module SECM, fuel lock-off, and the Smart Coil. The SECM
supplies positive voltage to the electronic throttle
Figure 15. GM Ignition Module actuator, oil pressure switch and the coolant
temperature sensor. Transducer or sensor power
The rising edge of the VR signal is converted to a (+5 Vdc) is regulated by the SECM and supplied to
rising 5-volt signal by the ignition module. As the VR the temperature/manifold air pressure sensor
signal passes back through zero volts, a falling edge (TMAP), throttle position sensor (TPS), and the
is created producing a square wave or digital signal, accelerator pedal position sensors (APP1 & APP2).
similar to the signal produced by a Hall effect sensor. The SECM provides a constant voltage (VCC) to the
This falling edge signal provides a stable engine Smart Coil Driver, transducer ground for the all
position reference at all engine speeds for the sensors, and a low side driver signal controlling the
SECM. fuel lock-off and MIL.

SECM (Load/Speed Management)

SECM
Drive by wire refers to the fact that the MI-07 control
Small Engine Control Module (SECM) controller has system has no throttle cable from the foot pedal
full authority over spark and air. the SECM has 24 (Figure 17) to the throttle body. Instead, the SECM
pins of I/O and is fully waterproof and shock is electronically connected both to the foot pedal
hardened (Figure 16). assembly and the throttle body. The SECM monitors
the foot pedal position and controls the throttle plate
To optimize engine performance and drivability, the by driving a dc motor connected to the throttle. The
SECM uses several sensors for closed loop dc motor actuates the throttle plate to correspond to
feedback information. These sensors are used by the foot pedal position when the operator depresses
the SECM for closed loop control in two main the pedal.
categories:
The use of electronic throttle control (ETC) ensures
• Load/Speed Management that the engine only receives the correct amount of
throttle opening for any given situation, greatly
• Ignition Management improving idle quality and drivability.

Figure 16. Small Engine Control Module (SECM) Figure 17. Foot Pedal

G643(E) Service Manual 177 Chapter 5. Engine Management System (EMS)

A Throttle Position Sensor (TPS), (Figure 18) which
is integral to the Drive By Wire (DBW) throttle
assembly, provides feedback for position control by
monitoring the exact position of the throttle valve.

NOTE: The DV-E5 is not a serviceable assembly.

If the TPS sensor fails, the assembly should be
replaced.

Figure 19. TMAP Sensor

The MI-07 system also performs minimum (min) and

maximum (max) governing through the SECM and
DBW throttle. For min governing, or idle speed
control, the idle speed is fixed by the SECM. Unlike
a mechanical system, the idle speed is not
adjustable by the end user. The idle speed is
adjusted by the SECM based on engine coolant
Figure 18. Throttle Position Sensor (TPS) on DV- temperature. At these low engine speeds, the SECM
E5 Throttle uses spark and throttle to maintain a constant speed
regardless of load.
SECM self-calibration and “cross checking” of the
TPS is accomplished by comparing the TPS signal
to a calculated throttle position in the SECM
software (Predicted TPS). In addition to the throttle
position sensor, a temperature/manifold air pressure
sensor (TMAP) is used to monitor intake manifold
temperature and pressure (Figure 19). This enables
the SECM full control capabilities monitoring actual
airflow in relationship to desired airflow. The TMAP
sensor is a single unit incorporating both intake
manifold temperature and manifold pressure
measurement.

G643(E) Service Manual 178 Chapter 5. Engine Management System (EMS)

Figure 21. Drive-By-Wire Signal Flow Process

(Figure 21) describes the signal flow process of the MI-07 Ignition Management
MI-07 DBW section. The foot pedal assembly uses
two potentiometers to detect pedal position. These In the normal course of events, with the engine
two signals, accelerator pedal position 1 (APP1) and operating at the correct temperature in defined
accelerator pedal position 2 (APP2) are sent directly conditions, the SECM will use load and engine
to the SECM. The SECM uses a series of algorithms speed to derive the correct ignition timing. In
to self calibrate and cross check the signals from the addition to load and speed there are other
pedal assembly. A demand position for the throttle circumstances under which the SECM may need to
will then be derived and sent to the throttle as a vary the ignition timing, including low engine coolant
throttle position sensor demand (TPSd). This signal temperature, air temperature, start-up, idle speed
will be processed through a PID (Proportional, control.
Integral, Derivative) controller in the SECM to
achieve the appropriate motor-current response
then passed to the throttle. The throttle moves to the
commanded position and provides a feedback signal
from the throttle position sensor (TPS) to the SECM.

G643(E) Service Manual 179 Chapter 5. Engine Management System (EMS)

SECM Wiring Diagrams for G643 LP Engine

G643(E) Service Manual 180 Chapter 5. Engine Management System (EMS)

G643(E) Service Manual 181 Chapter 5. Engine Management System (EMS)
EMS Inspection and Repair • Fuel Temperature Sensor (FTS)
-40°F to 266°F (-40ºC to 130ºC) range,
48K ohm to 57 ohm sensor range
Engine Control Module[G643E]
• HEGO (3) 0 to 1 V
The 48-pin Small Engine Control Module (SECM)
• Auxiliary Analog Input (2) 0 to 5 V
and sensors provide the computational power,
algorithm logic, sensor inputs and control outputs to
• Battery Voltage (Vbatt) (1) 8-18 V
control the system. The SECM receives signals from
the sensors, digitizes these signals, and then,
With the exception of battery voltage, all inputs are
through algorithms and calibration MAPs, computes
0-5 Vdc, ground referenced. Resolution should be
the desired output response to effect control of fuel,
0.1% or better. Accuracy should be 2% or better.
spark and air to the engine. The SECM also
provides a variety of other functions and features.
These include system monitoring and diagnostics to Frequency/Position Inputs
aid in maintaining efficient system operation and
auxiliary control. • Crankshaft position

Variable reluctance (2-wire, 200 Vpp max) or 0-5

V Hall Effect with calibration selectable pull-up
resistor for open collector sensors Permits speed
resolution of 0.25 rpm and crankshaft position
resolution of 0.5º

• Camshaft position

Variable reluctance (2-wire, 200 Vpp max) or 0-5

V Hall Effect with calibration selectable pull-up
resistor for open collector sensors.

SECM/sensor inputs and control output specifica- Digital Inputs

tions are specific to the application, but include a
selection of the following:
• Oil pressure switch
Normally open, internal pull-up resistor provided
to detect external switch to ground
Analog Inputs
• Transmission oil temperature switch
The 48-pin SECM is equipped with sufficient analog Normally open, internal pull-up resistor provided
inputs for the following sensors. to detect external switch to ground

• Manifold Absolute Pressure (MAP) 1bar MAP, 0 to • Fuel select switch

5V Three-position switch for bi-fuel applications to
detect gasoline mode, LPG mode, and fuel off
• Manifold Air Temperature (MAT) (center switch position)
-40°F to 266°F (-40ºC to 130ºC) range, 48 kohm
to 85 ohm sensor range • Ground speed select switch
Permits selecting two different maximum engine
• Throttle Position Sensor 1&2 (TPS1 & TPS2) 0 to speeds
5V
• Vswitched
• Foot Pedal Position 1&2 (FPP1 & FPP2) 0 to 5 V Switched battery voltage

• Coolant Temperature Sensor (CTS)

-40°F to 266°F (-40ºC to 130ºC) range,
48K ohm to 85 ohm sensor range

G643(E) Service Manual 182 Chapter 5. Engine Management System (EMS)

Outputs Crank Shaft Position Sensor [G643E]

• Saturated injector drivers (4) Component Location

10A peak, 45 V max, 1 injector per channel
capable of continuous on-time
Driver circuit designed for minimum turn-on/turn-
off delay
Minimum pulse width resolution of 1 usec

• FTV drivers (2)

10A peak, 45V max. To drive an on/off fuel trim
valve with a minimum impedance of 5 ohms
Capable of continuous on-time
Drive circuit designed for minimum turn-on /turn-
off delay
FTVs will be pulse width modulated between 8
and 40 Hz with a minimum pulse width resolution
of 50 usec
Description
• Fuel lock-off solenoid valve
Low side switch, 10A peak, 4A continuous 45 V The Crankshaft Position Sensor (CKPS) is a hall
max effect type sensor that generates voltage using a
sensor and a target wheel mounted on the
• Gasoline fuel pump drive crankshaft;
Low side switch, 10A, 4A continuous 45 V max During one crankshaft rotation there are the
rectangular signals. The ECM calculates engine
• Electronic Spark Timing (EST) (4) RPM by using the sensor’ signal and controls the
TTL compatible outputs Software configured for the ignition timing.
coil-on-plug ignition system

• Throttle control (1)

H-Bridge, 5A peak, 2.5A continuous at 2500 Hz
PWM includes current feedback for diagnostic
purposes.

• MIL (malfunction indicator lamp)

Low side switch, sufficient to drive a 7W incandes-
cent lamp continuously

• CANBus
CAN 2.0b serial communication for J1939 com-
munications, programming and diagnostics.
Requires proper termination resistance per CAN
2.0b.

G643(E) Service Manual 183 Chapter 5. Engine Management System (EMS)

Schematic Diagram for G643E MAP (Manifold Absolute Pressure)
Sensor [G643E and G643]

Sensor Inspection
MAP sensor

The manifold absolute pressure (MAP) sensor is a

pressure sensitive variable resistor. It measures
changes in the intake manifold pressure which result
from engine load and speed changes, and converts
this to a voltage output. The MAP sensor is also
3 2 1
used to measure barometric pressure at start up,
and under certain conditions, allows the ECM to
automatically adjust for different altitudes. The ECM
supplies 5 volts to the MAP sensor and monitors the
ECM supplies 5 volts to the MAP sensor and
monitors the voltage on a signal line. The sensor
provides a path to voltage on a signal line. The
1. Turn ignition switch to OFF position and then
sensor provides a path to ground through its
disconnect CKPS connector.
variable resistor. The MAP sensor in put affects fuel
delivery and ignition timing controls in the ECM.
2. Remove the CKPS from the engine.
Circuit Diagram (G643E)
3. Turn ignition switch to ON position.

4. Apply battery voltage to the terminal 1 and ground MAP & IAT
terminal 1 and ground terminal 3 of CKPS as sensor
MAP
shown in the figure. IAT

5. Install a LED between +5V power and CKPS

3 2 1 4
terminal 2, and then set a steel wheel (or anything
made of steel ; hammer, wrench, bolt and nut etc.)
at the CKPS's tip.

6. Rotate the steel wheel slowly and check if the

LED flashes light.

• If the LED blinks, the CKPS works normally

Sensor IAT Sensor MAP
power signal ground signal
B24 B12 B1 B18

ECM

G643(E) Service Manual 184 Chapter 5. Engine Management System (EMS)

Circuit Diagram (G643) 2. Connect the electrical connector to the MAP/MAT
sensor. Verify that the connector clicks/locks into
place.

3. Connect the negative battery cable.

IAT (Intake Air Temperature) Sensor

[G643E and G643]

Sensor Inspection

1. Measure the voltage between terminals 1 and 4 of

MAP sensor
the MAP sensor connectors.
Terminal 4 : MAP sensor ground
The intake air temperature sensor (IAT Sensor),
Terminal 1 : MAP sensor output
built in to the MAT sensor, is a resistor-based
sensor detect the intake air temperature. According
Engine state Test specification to the intake air temperature information frim the
Ignition SW. ON 4~5V sensor, the ECM will control the necessary amount
of fuel injection.
At idle 0.5~2.0V

2. If the voltage deviates from the standard value, Circuit Diagram (G643E)
replace the MAP sensor assembly.

Removal
MAP & IAT
sensor
1. Disconnect the negative battery cable. MAP
IAT

2. Disconnect the electrical connector from the

MAP/MAT sensor. 3 2 1 4

3. Remove the two screws retaining the MAP/MAT

sensor to the intake manifold.

4. Remove MAP/MAT sensor.

Installation Sensor IAT Sensor MAP

power signal ground signal
B24 B12 B1 B18
1. Place the MAP/MAT Sensor in position on the
intake manifold and install the two retaining ECM
screws. Tighten retaining screws to 6 N•m (53 lbf•
ft)

G643(E) Service Manual 185 Chapter 5. Engine Management System (EMS)

Circuit Diagram (G643) OxygenSensor (Pre-Catalyst) [G643E]

Component Location

Pre - Catalyst Oxygen Sensor

Description

The heated oxygen sensor is mounted on the front

side of Catalytic Muffler, which detects the oxygen
concentration in the exhaust gas. The heated
Sensor Inspection oxygen sensor produces a voltage that varies
between 0V and 1V. When the air/fuel ratio is lean,
1. Using a multimeter, measure the IAT sensor the oxygen concentration in the exhaust gas
resistance between terminals 3 and 4. increases and the front HO2S outputs a low voltage
(approximately0~0.1V). When the air/fuel ratio is
IG.SW.ON Temperature rich, the oxygen concentration in the exhaust gas
Resistance(kΩ) decreases and the front HO2S outputs a high
℃ (°F) voltage (approximately0.8~1V). The ECM constantly
0 (32) 4.5 ~ 7.5 monitors the HO2S and increases or decreases the
fuel injection duration by using the HO2S signal,
20 (68) 2.0 ~ 3.0 which is called closed-loop fuel control operation.
40 (104) 0.7 ~ 1.6
80 (176) 0.2 ~ 0.4 Specification

Temperature Front Temperature

2. If the resistance deviates from the standard value, Front HO2S
HO2S
replace the intake air temperature sensor Heater
Heater
assembly. (℃) (℉) (℃) (℉) Resistance
Resis-
(Ω)
tance(Ω)
20 68 9.2 400 752 17.7
100 212 10.7 500 932 19.2
200 392 13.1 600 1,112 20.7
300 572 14.6 700 1,292 22.5

G643(E) Service Manual 186 Chapter 5. Engine Management System (EMS)

Schematic Diagram (G643E) Oxygen Sensor (Post-Catalyst) [G643E]

[CIRCUIT DIAGRAM] Component Location

HO2S (B1/S1) ECM

3 A23 - HO2S HEATER

(B1/S1)
1
B13 - HO2S SIGNAL

2
B1 - HO2S GND

After Main Relay

[HARNESS CONNECTORS]

Description
The rear heated oxygen sensor is mounted on the
2 1 rear side of the Catalytic Muffler, which detects the
catalyst efficiency. The rear heated oxygen sensor
4 3
(HO2S) produces a voltage between 0V and 1V.
This rear heated oxygen sensor is used to estimate
C16 the oxygen storage capability. If a catalyst has good
HO2S (B1/S1) conversion properties, the oxygen fluctuations are
smoothed by the oxygen storage capacity of the
catalyst. If the conversion provided by the catalyst is
low due to aging, poisoning or misfiring, then the
oxygen fluctuations are similar to signals from the
Signal Wave Form front oxygen sensor.

Schematic Diagram (G643E)

[CIRCUIT DIAGRAM]
HO2S (B1/S2) ECM
3

4 A23 - HO2S HEATER

(B1/S2)
2
B19 - HO2S SIGNAL

1 B1 - HO2S GND

If you release the accelerator pedal suddenly after

engine running about 2600 rpm, fuel supply will stop After Main Relay
for short period and the O2 sensor service data will
display values 200mV or lower. When you suddenly [HARNESS CONNECTORS]
press on the accelerator pedal down, the voltage will
reach 0.6 ~ 1.0 V. When you let the engine idle
again, the voltage will fluctuate between 200 mV or 1 2
lower and 0.6 ~ 1.0 V. In this case, the O2sensor 3 4
can be determined as good.
C22

G643(E) Service Manual 187 Chapter 5. Engine Management System (EMS)

Signal Wave Form ECT Senser

Description
The Engine Coolant Temperature Sensor (ECTS) is
located in the engine coolant passage of the cylinder
head for detecting the engine coolant temperature.
The ECTS uses a thermister whose resistance
changes with the temperature. The electrical
resistance of the ECTS decreases as the
temperature increases, and increases as the
temperature decreases. The reference 5 V in the
ECM is supplied to the ECTS via a resistor in the
ECM. That is, the resistor in the ECM and the
thermistor in the ECTS are connected in series.
When the resistance value of the thermistor in the
The amplitude of the signal output of the rear HO2S ECTS changes according to the engine coolant
is small compared to the front HO2S because the temperature, the output voltage also changes.
rear HO2S detects emission gas purified by the
catalytic converter. This illustration is the normal Sensor Inspection
signal waveform of the rear HO2S at idle.

Specification

Temperature Rear Temperature Rear

HO2S HO2S
(℃) (℉) Heater (℃) (℉) Heater
Resis- Resistanc
tance(Ω) e(Ω)
20 68 9.2 400 752 17.7
10 212 10.7 500 932 19.2
200 392 13.1 600 1,112 20.7
1. Remove the engine coolant temperature sensor
300 572 14..6 700 1,272 22.5 from the intake intake manifold.

2. With the temperature sensing portion of the

engine coolant temperature sensor immersed in
hot water, check resistance.
ECT (Engine Coolant Temperature)
Sensor [G643E and G643] Temperature ℃ (℉) ECTS Resistance(kΩ)
20(68) 2.31~2.59
Component Location

3. If the resistance deviates from the standard value

greatly, replace the sensor.

G643(E) Service Manual 188 Chapter 5. Engine Management System (EMS)

Schematic Diagram (G643E) Installation

1. Install engine coolant temperature sensor and

tighten it to specified torque.

Tightning torque

Engine coolant temperature sensor "

15~20Nm (150~200 kg·cm, 11~15 lb·ft)

2. Connect the harness connector securely.

[HARNESS CONNECTORS]

Schematic Diagram (G643)

G643(E) Service Manual 189 Chapter 5. Engine Management System (EMS)

LP Fuel Temperature Sensor [G643E]

[Harness Connectors]
Location

Inspection
Description
1. Remove the LP fuel temperature sensor from the
The LP Fuel Temperature Sensor (FTS) is located in
adapter connected to LP mixer.
the LP fuel passage of the LP mixer for detecting the
LP fuel temperature. The FTS uses a thermistor
2. With the temperature sensing portion of the LP
whose resistance changes with the temperature.
engine fuel temperature immersed in hot water,
The electrical resistance of the FTS decrease as the
check resistance.
temperature increase, and increase as the
temperature decrease. The reference 5V in the ECM
is supplied to the FTS by way of a resister in the Temperature °C (°F) FTS Resistance (Ohms)
ECM. That is, the resistor in the ECM and the -20(-4) 15462
thermistor in the FTS are connected in series. When
the resistance value of the thermistor in the FTS 0(32) 5896
changes according to the LP fuel temperature, the 20(68) 2498
output voltage also change.
40(104) 1175

Circuit Diagram [G643E] 60(140) 596

80(176) 323

3. If the resistance deviates from the standard value

greatly, replace the sensor.

G643(E) Service Manual 190 Chapter 5. Engine Management System (EMS)

Angle Sensor-Accelerator
[G643E and G643] Circuit Diagram (G643)

Location

[Harness Connectors]
Description
Angle Sensor-Accelerator is located in the
accelerator pedal assembly. The engine speed
management deals with a Drive-by-wire system.
Drive-by-wire refers to the fact that the MI-07 control
system has no throttle cable from the foot pedal to
the throttle body. Instead, the ECM is electronically
connected both to the foot pedal assembly and the
throttle body. The SECM monitors the foot pedal
position and controls the throttle plate by driving a
DC motor connected to the throttle. The DC motor
actuates the throttle plate to correspond to the foot
pedal position when the operator depresses the
pedal. The SECM will override the pedal command
above a maximum engine speed and below a Inspection
minimum idle speed. The foot pedal assembly uses
1. Disconnect the Accelerator Pedal’s connector
two potentiometers to detect pedal position. These
from the main engine harness.
two signals, accelerator pedal position 1 (APP1) and
accelerator pedal position 2 (APP2) are sent directly
2. Inspect the electrical conditions with a follow
to the SECM. The SECM uses a series of algorithms
basic specification.
to self calibrate and cross check the signals from the
pedal assembly.
Signal output is on condition that input voltage
is ....................................................... 5V±0.5%
Circuit Diagram [G643E] Rated current :....................................... 20 mA
Power : ............................................... 100 mW
Wire width :.......................................... 20AWG
- At start point : Signal ’A’................... 0.4V±0.1V
Signal ‘B’................... 4.5V±0.1V
- At end point(Push for end) :
Signal ’A’............... 3.60V±0.15V
Signal ‘B’............... 1.39V±0.15V

3. If the result value is out of the specification,

replace the Accelerator Pedal.

G643(E) Service Manual 191 Chapter 5. Engine Management System (EMS)

Transmission Oil Temperature [Harness Connectors]

Switch [G643E]

Description
Transmission Oil Temperature Switch is located in
the adapter on transmission (T/M) for operating by
the transmission (T/M) oil temperature change. This
switch is normally open, and then it is closed as the
T/M oil temperature Increases to the 125±3°C.
Actually if the switch is closed by high T/M oil
temperature, the ECM makes engine shutdown with
fault set. If the T/M oil temperature decreases to the
118°C, the switch is open again and the engine also
can run. This function can protect the engine of Tier- Inspection
3 and Non cert folk lift trucks from damage as
overheating. 1. Remove the Transmission Oil Temperature
Switch from the transmission.

Circuit Diagram [G643E] 2. Use an ohmmeter to check the continuity between

the 1 terminal and the 2 terminal. If there is
continuity, replace the Transmission Oil
Temperature Switch.

3. The Transmission Oil Temperature Switch is the

‘ON/OFF’ switch. So during the normal status the
switch circuit should be open.

G643(E) Service Manual 192 Chapter 5. Engine Management System (EMS)

Electronic Throttle Body Circuit Diagram [G643]

[G643E and G643]

Location

[Harness Connectors]

Description
The MI-07 system uses electronic throttle control
(ETC). The SECM controls the throttle valve based
on engine RPM, engine load, and information
received from the foot pedal. Two potentiometers on
the foot pedal assembly monitor accelerator pedal
travel. The electronic throttle used in the MI-07
system is a Bosch 32mm electronic throttle body
DV-E5. The DV-E5 is a single unit assembly, which
includes the throttle valve, throttle-valve actuator
(DC motor) and two throttle position sensors (TPS). Inspection
The SECM calculates the correct throttle valve
1. Check for loose, dirty or damaged connectors and
opening that corresponds to the driver’s demand,
wires on the harness
makes any adjustments needed for adaptation to the
engine’s current operating conditions and then
2. Check the throttle assembly motor housing for
generates a corresponding electrical (driver) signal
coking, cracks, and missing cover-retaining clips
to the throttle-valve actuator.
3. Check the resistance of TPS sensor. (refer as
Circuit Diagram[G643E]
blow chart)

EXPECTED
SENSOR POINT TO POINT
RANGE
TPS PIN 2(GND) TO 1.25KΩ +/-
TPS PIN 6(TPS1 SIGNAL) 30%
(Throttle TPS PIN 3(PWR) TO 1.25KΩ +/-
Position PIN 6(TPS1 SIGNAL) 30%
Sensor) TPS PIN 1(+DRIVER) ~3.0KΩ +/-
TO PIN 4(-DRIVER) 30%

G643(E) Service Manual 193 Chapter 5. Engine Management System (EMS)

Chapter 6. LPG FUEL DELIVERY SYSTEM

G643E LP System Inspection and

Repair
Removal and Installation

WARNING - PROPER USE

• LP gas is highly flammable. To prevent

personal injury, keep fire and flammable mate-
rials away from the lift truck when work is
done on the fuel system.

• Gas vapor may reduce oxygen available for

breathing, cause headache, nausea, dizziness
and unconsciousness and lead to injury or
death. Always operate the forklift in a well
ventilated area

• Liquid propane may cause freezing of tissue or

frostbite. Avoid direct contact with skin or tis-
sue; always wear appropriate safety protection
including gloves and safety glasses when
working with liquid propane.

CAUTION
The regulator/converter and mixer are part of a
certified system complying with EPA and CARB
2007 requirements. Only trained, certified techni-
cians should perform disassembly, service or
replacement of the regulator/ converter or mixer.

G643(E) Service Manual 194 Chapter 6. LPG FUEL DELIVERY SYSTEM

Hose Connections

Proper operation of the closed loop control greatly

depends on the correct vacuum hose routing and
fuel line lengths. Refer to the connection diagrams
below for proper routing and maximum hose lengths
when reinstalling system components.

NOTE: Preferred mounting of regulator is off engine.

Hose Specifications

Vacuum hose to comply to SAE 1403 Type I or SAE

J30 R7 R8 / EPDM textile reinforced / -40° F to
+257° F (-40° C +125° C / Inside Diameter: 7/32”
(5.56mm)

Certified System Connections

DWG NO 5555-1201

Figure 26. Hose Connections for Certified Systems

G643(E) Service Manual 195 Chapter 6. LPG FUEL DELIVERY SYSTEM

DIAGRAM NOTES

Trim valves must be positioned 1 N-2007 Regulator 8 Solenoid (AFS Lock Off Valve)
1
vertically with flow arrows in position
Plastic WYE Fitting (black color) Brass Tee Fitting. 1/4 Tube x 1/8
shown 2 9
for 7/32” (5.56mm) ID Tube NPTF x 1/4 Tube
Fuel outlet must be min 15° Hose
2
below horizontal position CA100 Mixer
10
Only one 90° fitting permissible on 3 Valve (TEV Bosch Canister)
3
vapor fuel line between mixer and 1/4” (6.35mm) hose barb to 1/8”
Plastic WYE Fitting (blue color) 11
regulator (As shown the temp 4 (3.2mm) male pipe, 125HBL, .062
for 7/32” (5.56mm) ID Tube
sensor adaptor is considered the flow ID
Hose
one 90° fitting.)
5 Adapter (temperature sensor) 12 1/4-28 UNF x 1/4” (6.35mm)
Vapor fuel fittings (regulator and
4 hose barb
mixer) must have minimum ID of
Sensor (coolant, temperature)
0.46” (11.68mm) 6
Nipple (.625 hex 4mp, 2.5L
Vapor hose length to be as short as 7
8 steel)
possible and have no restrictions for
best regulator performance

G643(E) Service Manual 196 Chapter 6. LPG FUEL DELIVERY SYSTEM

Removal and Installation of N-2007 LP N-2007 Installation Steps
Regulator
Refer to Figure 28.
Follow the procedures below for removal and
reinstallation of the N-2007 regulator in certified 1. Install the nipple extension (6) with the lock-off to
systems. the regulator.

N-2007 Removal Steps 2. Install the fuel vapor outlet hose (5) to the
regulator.
Refer to Figure 28.
3. Install the two cooling lines (4) and a thermostat
1. Close the liquid outlet valve in the forklift cylinder (7) to the regulator.
or fuel storage container.
4. Install the four rear-mounting bolts that hold the
2. Purge the system of fuel by starting the engine regulator to the support bracket. Use a torque
and running until all trapped fuel in the system is wrench and tighten each bolt to 60-70 lbf•in (6.78-
exhausted and the engine shuts down. 7.91 N·m).

3. Key switch in “OFF” position. 5. Install the fuel inlet line (1) to the lock-off, the two
vacuum lines (2) to the branch-tee fitting in the
regulator vent and re-connect the lock-off
4. Remove the fuel inlet line (1) from the lock-off, the
connector (3).
two vacuum lines (2) from the branch-tee fitting in
the regulator vent and disconnect the lock-off
6. Open the liquid outlet valve in the forklift cylinder
connector (3).
or fuel storage container.
5. Remove the four rear-mounting bolts that hold the
regulator to the support bracket. This will allow
easier access to the remaining hose clamps.

6. Remove the two cooling lines (4) and a

thermostat (7) from the regulator.

NOTE: Either drain the coolant system or clamp off

the coolant lines as close to the regulator as
possible to avoid a coolant spill when these lines are
disconnected.

7. Remove the fuel vapor outlet hose (5) from the

regulator.

8. Remove the nipple extension (6) with the lock-off

from the regulator.

Figure 28. N-2007 Regulator in Certified System

G643(E) Service Manual 197 Chapter 6. LPG FUEL DELIVERY SYSTEM

Removal and Installation of CA100 Mixer for 3. Key switch in “OFF” position.
G643E
4. Remove the air cleaner hose (1).
Follow the procedures below for removal and
reinstallation of the CA100 mixer. 5. Mark the two vacuum lines (2) to the mixer for
identification, as they must be reinstalled
CA100 Certified Mixer Removal Steps correctly for proper operation. Remove the two
vacuum lines (2).
14 12 6. Remove vapor fuel inlet line (3) from the fuel
13 temperature sensor fitting (4).
15
7. Disconnect the fuel temperature sensor
connector (5).
16
8. Disconnect the wires leading to the electronic
17
throttle body by pinching the lock tabs on either
10 side of the wiring harness connector. (See Figure
11 31 for location of connector)

9
9. Loosen the four bolts (6) that secure the
4 mixer/adapter/throttle body assembly to the
5 intake manifold.
6
8 10. Remove the mixer (9), the adapter (7), and the
throttle body (8) as an assembly by gently pulling
7 upwards. Take care not to drop anything down
2 the intake manifold.
3
1
11. Gently wiggle and pull to separate mixer and
1. Gasket 2. Adapter 3. Fitting adapter from the throttle body. Take note of the
4. Tmap 5. Washer 6. Bolt adapter orientation on the mixer, as it must be
7. Bolt 8. Gasket-ITB 9. ITB reinstalled correctly for proper fit on the throttle.
10. O-Ring 11. O-Ring 12. Mixer
13. Adapter 14. Fuel Temp Sensor 15. Fitting
16. Apollo Adapter 17. Bolt 12. Remove the four mounting screws that attach the
throttle body adapter to the mixer.

13. Remove the fuel temperature sensor (not shown)

from the tee (4).

14. Remove the fuel temperature sensor fitting

from the mixer. Take note of the fitting’s
orientation on the mixer, as it must be
reinstalled correctly for proper fit.

15. Remove the short vacuum port barb from the

mixer. (See Figure 32 for location of port barb
on mixer.)
Figure 30. CA100 Mixer in Certified System

1. Close the liquid outlet valve in the forklift cylinder

or fuel storage container.

2. Purge the system of fuel by starting the engine

and running until all trapped fuel in the system is
exhausted and the engine shuts down.

G643(E) Service Manual 198 Chapter 6. LPG FUEL DELIVERY SYSTEM

NOTE: A plastic O-ring spacer and an O-ring are CA100 Certified Mixer Installation Steps
inside the mixer/adapter assembly. Be careful not to
lose these items when removing the assembly from Refer to Figure 30.
the throttle (Figure 31).
1. Install the vacuum port barb onto the mixer (9).
Wiring harress
connection
2. Install the fuel temperature sensor fitting (4) onto
the mixer.

3. Install the fuel temperature sensor into the fitting.

4. Ins tall the four mounting screws that attach the

throttle adapter (7) to the mixer. See Figure 32.
Torque bolts to 30-40 lbf·in (3.39-4.52 N·m).

5. Position the mixer/adapter assembly onto the

throttle body (8), then drop in the four mounting
Figure 31. O-Ring and Spacer Within Mixer Adapter
bolts (6) and gently push down on the assembly
Assembly
until it rests on the throttle body. Be careful not to
pinch the O-ring. (See Figure 31.)
VACUUM PORT BARB
Used only on certified
6. Attach the mixer/throttle body assembly to the
systems. Location may intake manifold, making sure gasket is in place.
vary depending upon Tighten the four mounting bolts.
application.

7. Connect the wiring harness to the throttle body.

ALTERNATE VACUUM
(See Figure 31 for location of connector.) Connect
PORT BARB the fuel temperature sensor connector (5) to the
sensor.

8. Install the vapor fuel inlet line (3) to the fuel

Figure 32. Throttle Adapter Mount Screws temperature sensor fitting.

9. Install the two vacuum lines (2) to the mixer using

the previous marks for identification. Vacuum lines
must be installed correctly for proper operation.

10. Install the air cleaner hose (1).

G643(E) Service Manual 199 Chapter 6. LPG FUEL DELIVERY SYSTEM

Tests and Adjustments N-2007 Regulator Service Testing

For checking the N-2007 regulator/converter

WARNING—PROPER USE operation, the following tests can be performed (See
Chapter 5 for removal/installation of the N-2007
• LP gas is highly flammable. To prevent perso- regulator). To check the secondary regulation
nal injury, keep fire and flammable materials (output) a simple vacuum hand pump can be used
away from the lift truck when work is done on to simulate the vacuum signal transmitted from the
the fuel system. air/fuel mixer when the engine is running. See listing
below for required hardware.
• Gas vapor may reduce oxygen available for
breathing, cause headache, nausea, dizziness Break-Off Test
and unconsciousness and lead to injury or
death. Always operate the forklift in a well Secondary Stage Test Hardware
ventilated area
1. Hand vacuum pump
• Liquid propane may cause freezing of tissue or
frostbite. Avoid direct contact with skin or tis- 2. Regulator vapor outlet test fitting 3/4” NPT x 1/4”
sue; always wear appropriate safety protect- hose barb
ion including gloves and safety glasses when
working with liquid propane. 3. Union Tee 1/4” NPT with three 1/4” NPT x 1/4”
hose barb

4. Vacuum hose

CAUTION 5. 0-3” WC Magnehelic gauge (inches of water

column)
The regulator/converter and mixer are part of a
certified system complying with EPA and CARB Secondary Stage (Break-Off) Test
2007 requirements. Only trained, certified techni-
cians should perform disassembly, service or 1. Connect the vacuum pump, the Magnehelic
replacement of the regulator converter or mixer. gauge and the regulator vapor outlet to the Union
Tee fitting (Figure 34). Make sure there is no
leakage at any of the fittings.

2. Using the vacuum pump slowly apply enough

vacuum to measure above -2” WC on the gauge.
This vacuum signal opens the secondary valve in
the N-2007 regulator/converter.

3. Release the vacuum pump lever and you will see

the gauge needle start falling back toward zero.
When the pressure drops just below the specified
break-off pressure (-0.5 +/- 0.35 “ WC) of the
secondary spring, the needle should stop moving.

4. At this point the secondary valve should close. If

the secondary valve seat or the secondary
diaphragm is leaking the gauge needle will
continue to fall toward zero (proportional to the
leak size). An excessively rich air/fuel mixture can
be caused by a secondary valve seat leak and the
regulator should be replaced.

G643(E) Service Manual 200 Chapter 6. LPG FUEL DELIVERY SYSTEM

3. Apply compressed air, wait for air to exit the hose
barb in the test port, and then connect the
Magnehelic gauge (Figure 36) to the hose barb
using the vacuum hose or vinyl tubing. This
prevents the gauge from reading maximum
pressure due to the large velocity of compressed
air entering the primary chamber.

4. Make sure there is no leakage at any of the

fittings. The static pressure should read between
40-60” of water column on the Magnehelic gauge
and maintain a constant pressure for 60 seconds.

Figure 34. Secondary Stage Test Connection

Pressure Test

Primary Stage Test Hardware

1. Shop air pressure regulator adjusted to 100 psi

2. Shop air hose fitting (1/4” NPT to air hose)

3. Air hose

4. Test gauge fitting (1/16” NPT x 1/4” hose barb)

Figure 36. Magnehelic Gauge Connection to Hose
5. Vacuum hose or vinyl tubing Barb

6. 0-60” WC Magnehelic gauge (inches of water 5. If the pressure reading begins to increase, a leak
column) is most likely present at the primary valve, either
the primary valve o-ring or the valve itself. If a leak
Primary Stage Pressure Test is present the regulator should be replaced.

1. Remove the primary test port plug from the side 6. If the pressure begins to decrease, the secondary
of the regulator and install the 1/16” NPT hose seat is probably not making an adequate seal and
barb fitting (Figure 35). is leaking. The regulator should be replaced.

2. Connect a compressed air line (shop air ~100psi) 7. If the test is successful, re-install the primary test
to the liquid propane fuel inlet of the N-2007 port plug and check the fittings for leaks. See
regulator (Figure 35). Chapter 5 for installation of the N-2007 regulator.

NOTE : The N-2007 primary stage pressure can

also be tested at idle on a running engine. The N-
2007 primary pressure should be between 40 inH20
(99.6mbar) and 55 inH20 (137 mbar) at 750 rpm,
idle.

Figure 35. Primary Stage Test Connection

G643(E) Service Manual 201 Chapter 6. LPG FUEL DELIVERY SYSTEM

5. If the measured pressure drop is low, check for
vacuum leaks in the manifold, throttle, mixer,
CAUTION TMAP sensor and attached hoses.

• LP gas is highly flammable. To prevent

personal injury, keep fire and flammable mate-
rials away from the lift truck when work is
done on the fuel system.

• Gas vapor may reduce oxygen available for

breathing, cause headache, nausea, dizziness
and unconsciousness and lead to injury or
death. Always operate the forklift in a well
ventilated area

Liquid propane may cause freezing of tissue or

frostbite. Avoid direct contact with skin or tis-
sue; always wear appropriate safety protection Figure 37. Magnehelic Gauge Connection
including gloves and safety glasses when
working with liquid propane.
Ignition Timing Adjustment

AVV (Air Valve Vacuum) Testing With the MI-07 system, ignition-timing advance is
controlled by the SECM see, chapter 4. Ignition
Purpose of Test system for the detail information.

Check for excessive or inadequate pressure drop

across CA100 mixer. Connection of the MI-07 Service Tool

AVV Test Hardware To use the Service Tool, a USB (Universal Serial
Bus) to CAN (Controller Area Network)
1. Union Tee fitting, 1/4” (6.35mm) NPT with three communication adapter by KVaser will be required
1/4” (6.35mm) NPT x 1/4” (6.35mm) hose barbs along with a Crypt Token (Figure 38). The Crypt
Token acts as a security key allowing the laptop to
2. Vacuum hose retrieve the necessary data from the SECM.

3. 0-20” H2O differential pressure Magnehelic gauge 1. Install the Crypt Token in an available USB port in
the computer (Figure 39).

AVV Test 2. With the ignition key in the OFF position, connect
the KVaser communication cable from a second
1. Install Union Tee fitting in the hose between the USB port on the computer to the CAN
FTVs and the AVV fitting. Connect this fitting to communications cable on the engine. (*If your
the low pressure port of the Magnehelic gauge laptop computer does not have a second USB
(Figure 37). port an appropriate USB hub will need to be used).

2. Leave high pressure port of the Magnehelic 3. Connect a timing light to the engine.
gauge exposed to ambient pressure (Figure 37).
4. Turn the ignition key to the ON position (Do Not
3. With the engine fully warmed up and running at Start the Engine).
idle (750 rpm) place the transmission in Neutral.
The AVV should be between 5” and 8” H2O of 5. Launch the MotoView program on your computer
pressure vacuum. and open the Service Tool display (Figure 40).

4. If the measured pressure drop is excessively high,

check for sticking or binding of the diaphragm air
valve assembly inside the mixer. Replace mixer if
necessary.

G643(E) Service Manual 202 Chapter 6. LPG FUEL DELIVERY SYSTEM

Idle Mixture Adjustment

The CA100 mixer requires adjustment of the idle

mixture screw to assure optimal emissions and
performance. This adjustment accounts for minor
part-to-part variations in the fuel system and assures
stable performance of the engine at idle. Once
adjusted, the idle mixture screw is sealed with a
tamper proof cap, after which it need not be
adjusted for the life of the vehicle.

Therefore, the only situations in which the idle

mixture screw needs to be adjusted are when the
Figure 38. KVaser engine is initially fitted with a fuel system at the
Communication Adapter factory and following the field replacement of the
mixer. Under these situations, follow the procedures
below for adjustment of the idle mixture screw.

Factory Test Preparation:

1. Install the MI-07 fuel system, wiring harness and

SECM-48 control module on the engine.

2. All coolant hoses should be attached, filled with

coolant and bled to remove any air.

3. Attach LPG fuel lines.

Figure 39. Crypt Token Installed on Laptop 4. Attach wiring harness to battery power.

5. Attach exhaust system.

6. If present, set fuel select switch to LPG fuel.

When operated at the factory, it is critical to simulate

the airflow found on a forklift at idle as nearly as
possible in order to achieve the proper air valve lift
in the mixer. It may be necessary to place a load on
the engine to achieve the required airflow without
overspeeding the engine. Means of achieving this
load include:

a) Place an electrical load on the alternator. The

Figure 40. Opening the Service Tool Display alternator should be able to briefly hold loads
of approximately 1.2 kW.

b) Attach the engine to a dynamometer.

Attach the Mototune Service Tool to the wiring

harness and add parameter MAFPort to the display
screen.

G643(E) Service Manual 203 Chapter 6. LPG FUEL DELIVERY SYSTEM

Factory Adjustment Procedure: 9. Use the Mototune Service Tool to lock the FTV
duty cycle. Set display parameter
NOTE : Be sure engine is fully warm (ECT>167°F DitherValveDC_ovr = locked (displayed in screen
[75°C]) before performing the idle mixture tab Manual Override 1 under AFR Trim Vales,
adjustment. select “locked” under box labeled Lock DC%).

1. Operating the engine on LPG fuel, start the 10. Use the Mototune Service Tool to monitor
engine and permit the engine to warm up until the throttle position (TPS1) and Exhaust gas oxygen
coolant temperature (ECT on Mototune display) is equivalence ratio (“O2 Value” in Figure 1). While
approximately 167°F (75 oC). monitoring O2, slowly increase the pedal input
(APP) to achieve a TPS1 value of 15%.
2. Set APP input to minimum.
11. Use the Mototune Service Tool to unlock the
3. Adjust the load until engine speed reaches 750 FTV duty cycle. Set display parameter
rpm. DitherValveDC_ovr = unlocked (displayed in
screen tab Manual Override 1 under AFR Trim
4. Mototune display parameter LP Fuel Control must Vales, select “unlocked” under box labeled Lock
display “Closed Loop.” DC%).

5. Use the Mototune Service Tool to monitor Duty 12. If at any time in step 10, O2 was greater than 1.2
Cycle % on the Mototune display. go to step 13. If 02 remained below 1.2,
proceed to Step 15.
6. To adjust the idle mixture screw, use a 5mm hex
or Allen-type wrench. Turning the screw in 13. Adjust the idle mixture screw on the mixer until a
(clockwise) should increase the duty cycle; turning reading of 50-55% is reached for the FTV Duty
the screw out (counter-clockwise) should Cycle in Closed Loop Idle (Figure 35).
decrease the duty cycle.
14. Use the accelerator pedal to increase RPM
7. Adjust the idle mixture screw on the mixer until a above idle momentarily (rev the engine) then
reading of 40-45% is reached for the FTV Duty release the pedal to return to idle RPM. The duty
Cycle in Closed Loop Idle (Figure 35). cycle setting should remain within the adjustment
range (50-55%). 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.

NOTE : If the FTV Duty Cycle reading is NOT

between 25-60%, check for possible vacuum leaks,
manifold leaks, or a faulty mixer.

15. Turn the ignition key to the OFF position to shut

down the engine.

16. Install the tamper proof cap on the idle mixture

screw adjustment port using a large pin punch,
Figure 41. FTV Duty Cycle Percentage Displayed on so that no further adjustments can be made
Service Tool (Figure 36).
8. 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 (40-
45%). 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.

G643(E) Service Manual 204 Chapter 6. LPG FUEL DELIVERY SYSTEM

1. After installing a new mixer, operate the engine
Bon LPG fuel. Start the engine and permit it to
warm up until the coolant temperature (ECT on
Mototune display) is approximately 167°F (75°C).

2. Place the transmission in Neutral.

3. Mototune display parameter LP Fuel Control must

display “Closed Loop”.

4. Use the Mototune Service Tool to monitor Duty

Cycle % on the Mototune display.

5. To adjust the idle mixture screw, use a hex or

Figure 42. Installing Tamper Proof Cap Allen-type wrench. Turning the screw in
(clockwise) should increase the duty cycle; turning
the screw out (counterclockwise) should decrease
the duty cycle.

6. Adjust the idle mixture screw on the mixer until a

reading of 45-55% is reached for the FTV Duty
Cycle in Closed Loop Idle (Figure 41). If engine
idle performance is unstable screw the idle screw
in slightly to see if stability is obtained, but in no
case should duty cycle exceed 60%.

7. 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 (45-
55%). 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.

8. If the FTV duty cycle reading is above 55% adjust

the idle adjustment screw outward and re-check
the duty cycle reading. Continue to do this until
the FTV duty cycle reading is within the optimum
Field Adjustment Procedure: range (45-55%). DO NOT adjust the screw so far
outward that the tamper proof cap cannot be
The idle mixture adjustment should only be installed. A duty cycle measurement at Closed
necessary on a new mixer that does not have the Loop Idle of 40-60% is acceptable if the optimum
tamper proof cap installed. The method for making range of 45-55% cannot be reached through
the idle mixture adjustment to a running engine is to adjustment. If the FTV duty cycle cannot be
use the Service Tool software by connecting a adjusted below 60%, the mixer is faulty and
laptop computer to the SECM. If you do not have the should be replaced.
Service Tool a multimeter capable of measuring
duty cycle, such as a Fluke 87 III, can be used. If NOTE : If the FTV Duty Cycle reading is NOT
using a multimeter, connect the meter positive lead between 25-60%, check for possible vacuum leaks,
to between battery positive and the meter negative manifold leaks, or a faulty mixer.
to the FTV signal wire. For the Fluke 87, press the
“RANGE” button until 4 or 40 appears in the lower 9. Turn the ignition key to the OFF position to shut
right-hand corner of the display. Press the “Hz” down the engine.
button twice so that the percent sign (%) appears on
10. Install the tamper proof cap on the idle mixture
the right-hand side of the display. The multimeter
screw adjustment port using a large pin punch,
will then read the duty cycle percentage the same as
so that no further adjustments can be made
the Service Tool shown in Figure 41.
(Figure 42).

G643(E) Service Manual 205 Chapter 6. LPG FUEL DELIVERY SYSTEM

Parts Description

CA100 Mixer for G643E Engine

Parts List of CA100 Mixer (Certified)

REF NO DESCRIPTION QTY

1 Torx Screws (T-25) #10-24 x 5/8” 4
2 Lockwashers (T-210) #10 SST 4
3 Mixer Cover 1
4 Mixer Spring 1
5 Diaphragm 1
6 Air Valve Assembly 1
7 Gas Valve Cone (part of air valve assembly) 1
8 Mixer Body 1
9 Expansion Plug Cap Ø 1/2” x 1/16” thick (Ø 12.7mm x 27mm) 1
10 Fuel Inlet 1
11 Air Horn Gasket 1
12 Air Horn Adapter 2-1/16” (52.37mm) 1
13 Fillister Head Screws SEMS Lockwasher 10-24 UNC x 5/8” 4
14 Throttle Body Gasket 1
15 Fillister Head Screws SEMS Split Lockwasher #12-24 x 5/8” 4

G643(E) Service Manual 206 Chapter 6. LPG FUEL DELIVERY SYSTEM

Exploded View of CA100 Mixer (Certified)

Figure 44. CA100 Certified Mixer Exploded View

G643(E) Service Manual 207 Chapter 6. LPG FUEL DELIVERY SYSTEM

N-2007 Regulator for G643E Engine

Parts List of N-2007 Regulator (Certified)

REF NO DESCRIPTION QTY

1 N-2007 Body 1
2 Diaphragm, Primary Assembly 1
3 Springs, Primary Assembly 2
4 Cover, Primary Assembly 1
5 Spring, Secondary Seat, Red 1
6 Dowel Pin Ø 0.094” x 1” L (Ø 2.39mm x 25.4mm L) Hardened Steel 1
7 Diaphragm, Secondary Assembly 1
8 Lever, Secondary 1
9 Seat, Secondary 1
10 Valve Primary 1
11 Fillister Head Screws SEMS Split Lockwasher #12-24 x 5/8” 6
12 Pan Head Screw SEMS Ext. Tooth Lockwasher #12-24 x 1/4” 1
13 Body Gasket 1
14 Back Plate 1
15 O-ring, Size 107 GLT Viton® 1
16 Bottom Plate Gasket 1
17 Plate Cover 1
18 Fillister Head Screws SEMS Split Lockwasher #12-24 x 1-3/8” 6
19 Hex Head Screws SEMS Split Lockwasher 1/4-20 x 5/8” 4
20 Plug, Socket Head Pipe (T-086) 1
21 Cover, Secondary Diaphragm 1
22 Lockwasher, Int. Tooth (T-210) #8 SST 6
23 Torx Screws (T-15) #8-32 x 5/8” 6

G643(E) Service Manual 208 Chapter 6. LPG FUEL DELIVERY SYSTEM

Exploded View of N-2007 Regulator (Certified)

Figure 46. N-2007 Certified Regulator Exploded View

G643(E) Service Manual 209 Chapter 6. LPG FUEL DELIVERY SYSTEM

G643 LPG System Inspection and
Repair
Removal and Installation

WARNING – PROPER USE

• LP gas is highly flammable. To prevent perso-

nal injury, keep fire and flammable materials
away from the lift truck when work is done on
the fuel system.

• Gas vapor may reduce oxygen available for

breathing, cause headache, nausea, dizziness
and unconsciousness and lead to injury or
death. Always operate the forklift in a well
ventilated area

• Liquid propane may cause freezing of tissue or

frostbite. Avoid direct contact with skin or tis-
sue; always wear appropriate safety protection
including gloves and safety glasses when
working with liquid propane.

CAUTION
The regulator/converter and mixer are part of a
certified system complying with EPA and CARB
2007 requirements. Only trained, certified
technicians should perform disassembly, ser-
vice or replacement of the regulator / converter
or mixer.

G643(E) Service Manual 210 Chapter 6. LPG FUEL DELIVERY SYSTEM

Hose Connections

Proper operation of the closed loop control greatly depends on the correct vacuum hose routing and fuel line
lengths. Refer to the connection diagram below for proper routing and maximum hose lengths when
reinstalling system components.

NOTE: Preferred mounting of regulator is off engine.

Hose Specifications
Vacuum hose to comply to SAE 1403 Type I or SAE J30 R7 R8 / EPDM textile reinforced / -40˚ F to +257˚ F
(-40˚ C +125˚ C / Inside Diameter: 7/32” (5.56mm)

DWG NO 5555-1236
Figure 25. Hose Connections for G643 Engines

DIAGRAM NOTES

1 Fuel outlet must be positioned vertically in the down position

2
Only one 90 fitting permissible on vapor fuel line between mixer and regulator

3 Vapor fuel fittings (regulator and mixer) must have minimum ID of 0.59” (14.99mm)

5
Vapor hose length to be as short as possible and have no restrictions for best regulator performance

G643(E) Service Manual 211 Chapter 6. LPG FUEL DELIVERY SYSTEM

Removal and Installation of N-2001 LP
Regulator/Converter

Follow the procedures below for removal and

reinstallation of the N-2001 regulator.

N-2001 Removal Steps

Refer to Figure 29.

1. Close the liquid outlet valve in the forklift cylinder

or fuel storage container.

2. Purge the system of fuel by starting the engine Figure 29. N-2001 Regulator in Non-Certified
and running until all trapped fuel in the system is System
exhausted and the engine shuts down.
N-2001 Installation Steps
3. Remove the fuel inlet line (1) from the lock-off, the
vacuum lines (2) the regulator and disconnect the Refer to Figure 29.
lock-off connector (3).
1. Install the fuel vapor outlet hose (5) onto the
4. Remove the two rear-mounting bolts that hold the regulator.
regulator to the support bracket. This will permit
easier access to the remaining hose clamps. 2. Install the two cooling lines (4) onto the regulator.

5. Remove the two cooling lines (4) from the 3. Install the two rear-mounting bolts that hold the
regulator. regulator to the support bracket. Use a torque
wrench and tighten each bolt to 50-60 lbf-in (5.65-
NOTE: It will be necessary to either drain the 6.78 N-m)
coolant system or clamp off the coolant lines as
close to the regulator as possible to avoid a coolant 4. Install the fuel inlet line (1) onto the lock-off, the
spill when these lines are disconnected. vacuum line (2) onto the regulator and connect
the lock-off connector (3).
6. Remove the fuel vapor outlet hose (5) from the
regulator. 5. Open the liquid outlet valve in the forklift cylinder
or fuel storage container.

G643(E) Service Manual 212 Chapter 6. LPG FUEL DELIVERY SYSTEM

Removal and Installation of CA100 Mixer for
G643

Follow the procedures below for removal and

reinstallation of the CA100 mixer in non-certified
systems.

CA100 Mixer Removal Steps

12
12-01 Figure 33. CA100 Mixer in Non-Certified System

1. Close the liquid outlet valve in the forklift cylinder

or fuel storage container.

15 2. Purge the system of fuel by starting the engine

13 and running until all trapped fuel in the system is
16
exhausted and the engine shuts down.
10
11 3. Key switch in “OFF” position.
14
4
4. Remove the air cleaner hose (1).

9 5. Remove the vacuum line (2).

6
5
6. Remove vapor fuel inlet line (3) from the mixer (6).
8
7 7. Disconnect the wires leading to the electronic
3 throttle body by pinching the lock tabs on either
2 side of the wiring harness connector (8).
1
8. Loosen the four bolts (4) that secure the
(1) Gasket-Adapter Plate MTG. mixer/adapter/throttle body assembly to the intake
(2) Adapter-Intake Manifold
(3) Fitting manifold.
(4) TMAP sensor
(5) Washer-Tamp MTG
(6) Bolt-Tamp MTG 9. Remove the mixer (6) and the throttle body (7) as
(7) Gasket-ITB an assembly by gently pulling upwards. Take care
(8) Bolt-Adapter not to drop anything down the intake manifold.
(9) ITB
(10) O-Ring
(11) O-Ring Spacer 10. Gently wiggle and pull to separate mixer and
(12) Mixer
(13) Fitting
adapter from the throttle body. Take note of the
(14) Fitting- Vacuum Small adapter orientation on the mixer, as it must be
(15) Apollo Adapter reinstalled correctly for proper fit on the throttle.
(16) Bolt
(17) Fitting
11. Remove the four mounting screws that attach the
throttle adapter to the mixer.

12. Remove the vapor fuel inlet fitting from the mixer.

G643(E) Service Manual 213 Chapter 6. LPG FUEL DELIVERY SYSTEM

CA100 Mixer Installation Steps NOTE : A plastic O-ring spacer and an O-ring are
inside the mixer/adapter assembly. Be careful not to
1. Install the vapor fuel inlet fitting onto the mixer. lose these items when removing the assembly from
the throttle (Figure 31).
2. Install the four mounting screws that attach the
throttle adapter (5) to the mixer. (See Figure 32).
Torque bolts to 30-40 lbf-in (3.39-4.52 N-m).

3. Position the mixer/adapter assembly onto the

throttle body (7), then drop in the four mounting
bolts (4) and gently push down on the assembly
until it rests on the throttle body. Be careful not to
pinch the O-ring. (See Figure 31.)

4. Attach the mixer/throttle body assembly to the

intake manifold, making sure gasket is in place.
Tighten the four mounting bolts. Figure 31. O-Ring and Spacer Within Mixer Adapter
Assembly
5. Connect the wiring harness (8) to the throttle body.

6. Install the vapor fuel inlet line (3) to the mixer.

7. Install the vacuum line (2) to the mixer.

8. Install the air cleaner hose (1).

Figure 32. Throttle Adapter Mount Screws

G643(E) Service Manual 214 Chapter 6. LPG FUEL DELIVERY SYSTEM

Tests and Adjustments Secondary Stage (Break-Off) Test

1. Connect the vacuum pump, the Magnehelic

gauge and the regulator vapor outlet to the Union
WARNING – PROPER USE Tee fitting (Figure 30). Make sure there is no
leakage at any of the fittings.
• LP gas is highly flammable. To prevent perso-
nal injury, keep fire and flammable materials 2. Using the vacuum pump slowly apply enough
away from the lift truck when work is done on vacuum to measure above -2” WC on the gauge.
the fuel system. This vacuum signal opens the secondary valve in
the N-2001 regulator/converter.
• Gas vapor may reduce oxygen available for
3. Release the vacuum pump lever and you will see
breathing, cause headache, nausea, dizziness
the gauge needle start falling back toward zero.
and unconsciousness and lead to injury or
When the pressure drops just below the specified
death. Always operate the forklift in a well
break-off pressure (-1.2 “ WC) of the secondary
ventilated area spring, the needle should stop moving.
• Liquid propane may cause freezing of tissue or 4. At this point the secondary valve should close. If
frostbite. Avoid direct contact with skin or the secondary valve seat or the secondary
tissue; always wear appropriate safety diaphragm is leaking the gauge needle will
protection including gloves and safety glasses continue to fall toward zero (proportional to the
when working with liquid propane. leak size). An excessively rich air/fuel mixture can
be caused by a secondary valve seat leak and the
regulator should be replaced.

N-2001 Regulator Service Testing

For checking the N-2001 regulator/converter

operation, the following tests can be performed. To
check the secondary regulation (output) a simple
vacuum hand pump can be used to simulate the
vacuum signal transmitted from the air/fuel mixer
when the engine is running. See listing below for
required hardware.

Break-Off Test

Secondary Stage Test Hardware

1. Hand vacuum pump

2. Regulator vapor outlet test fitting 3/4” NPT x 1/4”

hose barb
Figure 30. Secondary Stage Test Connection
3. Union Tee 1/4” NPT with three 1/4” NPT x 1/4”
hose barb

4. Vacuum hose

5. 0-3” WC Magnehelic gauge (inches of water

column)

G643(E) Service Manual 215 Chapter 6. LPG FUEL DELIVERY SYSTEM

Pressure Test Primary Stage Pressure Test

Primary Stage Test Hardware 1. Remove the primary test port plug from the side
of the regulator and install the 1/16” NPT hose
1. Hand vacuum pump barb fitting (Figure 31).

2. Regulator fuel inlet test fitting 1/4 NPT standard 2. Connect a compressed air line (shop air ~100 psi)
air coupling) to the liquid propane fuel inlet of the N-2001
regulator (Figure 31).
3. Test gauge fitting (1/4” NPT X 1/4” hose b)

4. Vacuum hose or vinyl tubing

5. 0-60” WC Magnehelic gauge (inches of water

column)

Figure 32. Magnehelic Gauge Connection to Hose

Barb

3. Apply compressed air, wait for air to exit the hose

barb in the test port, and then connect the
Figure 31. Primary Stage Test Connection Magnehelic gauge (Figure 32) to the hose barb
using the vacuum hose or vinyl tubing. This
prevents the gauge from reading maximum
pressure due to the large velocity of compressed
air entering the primary chamber.

4. Make sure there is no leakage at any of the

fittings. The static pressure should read between
40-60” WC on the Magnehelic gauge and
maintain a constant pressure for 60 seconds.

5. If the pressure reading begins to increase, a leak

is most likely present at the primary valve, either
the primary valve o-ring or the valve itself. If a leak
is present the regulator should be replaced.

6. If the pressure begins to decrease, the secondary

seat is probably not making an adequate seal and
is leaking. The regulator should be replaced.

7. If the test is successful, re-install the primary test

port plug and check the fittings for leaks. See
Chapter 5 for installation of the N-2001 regulator.

NOTE : The N-2001 primary stage pressure can

also be tested at idle on a running engine. The N-
2001 primary pressure should be between
40 inH20 (99.635 mbar) and 55 inH20 (136.999
mbar) at 750 rpm, idle.

G643(E) Service Manual 216 Chapter 6. LPG FUEL DELIVERY SYSTEM

AVV (Air Valve Vacuum) Testing Connection of the MI-07 Service Tool

Purpose of Test To use the Service Tool, a USB (Universal Serial

Bus) to CAN (Controller Area Network) communica-
Check for excessive or inadequate pressure drop tion adapter by KVaser will be required along with a
across CA100 mixer. Crypt Token (Figure 38). The Crypt Token acts as a
security key allowing the laptop to retrieve the
AVV Test Hardware necessary data from the SECM.

1. Union Tee fitting, 1/4” (6.35mm) NPT 1. Install the Crypt Token in an available USB port in
with three 1/4” (6.35mm) NPT x 1/4” (6.35mm) the computer (Figure 39).
hose barbs
2. Vacuum hose 2. With the ignition key in the OFF position, connect
3. 0-20” H2O differential pressure Magnehelic gauge the KVaser communication cable from a second
USB port on the computer to the CAN
AVV Test communications cable on the engine. (*If your
laptop computer does not have a second USB
1. Install Union Tee fitting in the hose between the port an appropriate USB hub will need to be used).
FTVs and the AVV fitting. Connect this fitting to
the low pressure port of the Magnehelic gauge 3. Connect a timing light to the engine.
(Figure 37).
4. Turn the ignition key to the ON position (Do Not
2. Leave high pressure port of the Magnehelic Start the Engine).
gauge exposed to ambient pressure (Figure 37).
5. Launch the MotoView program on your computer
3. With the engine fully warmed up and running at and open the Service Tool display (Figure 40).
idle (750 rpm) place the transmission in Neutral.
The AVV should be between 5” and 8” H2O of
pressure vacuum.

4. If the measured pressure drop is excessively high,

check for sticking or binding of the diaphragm air
valve assembly inside the mixer. Replace mixer if
necessary.

5. If the measured pressure drop is low, check for

vacuum leaks in the manifold, throttle, mixer,
TMAP sensor and attached hoses.

Figure 38. KVaser Communication Adapter

Figure 37. Magnehelic Gauge Connection

Ignition Timing Adjustment

Figure 39. Crypt Token Installed on Laptop
With the MI-07 system, ignition-timing advance is
controlled by the SECM.
The initial ignition timing setting of the distribytor is
described in chapter 4 Ignition System.

G643(E) Service Manual 217 Chapter 6. LPG FUEL DELIVERY SYSTEM

Power Valve Adjustment

1. The power valve should only be adjusted after the

idle screw has been adjusted properly. The
engine and vehicle drive train and hydraulics
should also be at normal operating temperatures.

2. Apply a load to the engine while the engine is

operating above idle speed. Torque converter stall
is the preferred operating mode for this test. If a
torque converter speed test cannot be performed,
the engine can be run at another speed (max
Figure 40. Opening the Service Tool Display governor), but a load must be applied by using
hydraulics.
Idle Mixture Adjustment NOTE : While adjusting the power valve, do not hold
engine at load point for longer than 5-10 seconds.
NOTE : Be sure engine is fully warm (ECT>167°F Holding for a longer period of time will cause the fuel
[75°C]) before performing the idle mixture temperature to drop, which could adversely affect
adjustment. the power valve setting.

G643 LP Fuel Systems with O2 Sensor 3. Monitor the output of the UEGO or HEGO sensor
while the engine is at the higher speed with the
Idle Adjustment load applied (phi = 1.00 to 1.05 is optimal).

1. Install mixer and a UEGO or HEGO sensor. (A 4. If the phi reading is not at the desired level, bring
UEGO sensor should be used when desired phi the engine back to idle and adjust the power valve.
settings are not at stoichiometric.)
5. Bring the engine back to the higher speed with a
2. After the mixer is installed, start and warm up the load applied and verify the power valve setting.
engine to normal operating temperature Adjust further as needed.
(ECT>167°F [75°C]). Also ensure that the vehicle
drive train and hydraulic systems are at normal 6. Once the power valve is set, bring the engine
operating temperatures per vehicle manufacturer back to idle and verify the idle screw setting.
recommendations.

3. Allow the engine to reach steady state at idle. G643 LP Fuel Systems Without O2 Sensor

4. While monitoring the output of the UEGO or Idle Adjustment

HEGO sensor adjust the idle screw using a
standard screwdriver until the desired phi reading 1. After the mixer is installed, start and warm up the
is achieved (phi = 1.00 to 1.01 is optimal). To engine to normal operating temperature
make the mixture richer, turn the screw clockwise; (ECT>167°F [75°C]). Also ensure that the vehicle
to make the mixture leaner, turn the screw drive train and hydraulic systems are at normal
counter-clockwise. operating temperatures per vehicle manufacturer
recommendations.
5. Rev the engine to take it off of idle and let it return
to idle. 2. Allow the engine to reach steady state at idle.

6. Once the engine has reached steady state at idle, 3. With the idle screw completely tightened
verify the phi reading. Adjust further as needed. clockwise, use a standard screwdriver to adjust
the idle screw counterclockwise until a minimum
average MAP value has been reached. The MAP
value is displayed on the Service Tool screen.

G643(E) Service Manual 218 Chapter 6. LPG FUEL DELIVERY SYSTEM

Power Valve Adjustment

1. The power valve should only be adjusted after the

idle screw has been adjusted properly. The
engine and vehicle drive train and hydraulics
should also be at normal operating temperatures.

2. Apply a load to the engine while the engine is

operating above idle speed. Torque converter stall
is the preferred operating mode for this test. If a
torque converter speed test cannot be performed,
the engine can be run at another speed (max
governor), but a load must be applied by using
hydraulics.
The power valve should be adjusted to obtain
maximum torque converter stall speed.

NOTE : While adjusting the power valve, do not hold

engine at load point for longer than 5-10 seconds.
Holding for a longer period of time will cause the fuel
temperature to drop, which could adversely affect
the power valve setting.

3. Once the power valve is set, bring the engine

back to idle and verify the idle screw setting.

Figure 43. Main Mixture Adjustment on Bottom of

Mixer (partial view)

G643(E) Service Manual 219 Chapter 6. LPG FUEL DELIVERY SYSTEM

Parts Description

CA100 Mixer for G643 Engine

Refer to Figure 45 exploded view on facing page.

REF NO. DESCRIPTION QTY

1 Screws 10-24 x 5/8” T-25 Button Head SEMS 4
2 Mixer Cover 1
3 Mixer Spring 1
4 Diaphragm 1
5 Gas Valve Cone (part of air valve assembly) 1
6 Mixer 1
7 Throttle Body Gasket 1
8 Screws 12-24 x 5/8” Fillister Head SEMS 8
9 Air Horn Adapter 1
10 Air Horn Gasket 1

Parts List for CA100 Mixer

G643(E) Service Manual 220 Chapter 6. LPG FUEL DELIVERY SYSTEM

Exploded View
CA100 Mixer

Figure 44. CA100 Non-Certified Mixer Exploded View

G643(E) Service Manual 221 Chapter 6. LPG FUEL DELIVERY SYSTEM

CA100 Disassembly and Service

5 Figure M4

4
1. With the mixer/adapter assembly removed from the
engine, and the throttle adapter removed from the
mixer, remove the four cover retaining screws from
9 the top of the mixer (Figure M4).
3 14
2

7
Figure M5

1 15
2. Gently remove the diaphragm cover from the top of
the mixer. Take care not to loose the air-valve
10
spring shown in (Figure M5).
11

(1) BODY (2) VALVE (3) SPRING (4) COVER

(5) WASHER (6) SCREW (7) GASKET (8) ADAPTER
(9) SCREW (10)GASKET (11) SCREW

Figure M6

3. Remove the air-valve assembly from the mixer as

shown in (Figure M6).

G643(E) Service Manual 222 Chapter 6. LPG FUEL DELIVERY SYSTEM

CA100 Disassembled Service

1. Clean the air valve assembly with soap and warm

water to remove heavy-end deposits. Inspect the
fuel metering valve and sealing ring for wear.
Replace worn components as necessary.

Replace all gaskets before assembly.

Clean the mixer body (casting) with a parts cleaning

solvent. Be sure to remove all seals and gaskets
Figure M7
before cleaning the casting with solvent. Make sure
all parts are completely dry before re-assembly.
4. Clean the heavy end deposits from the mixer body
with solvent. Be sure the mixer body is completely NOTE
dry before installing the new air-valve assembly. For re-assembly of the CA100
Replace the air-valve assembly as shown (Figure reverse the disassembly steps.
M7).
WARNING
DO NOT spray car carburetor cleaner or
solvent into the mixer while installed on
the engine. These chemicals may damage
the oxygen sensor and cause pre-mature
failure of the catalytic muffler.

Figure M8

5. Place the alignment mark on top of the air valve

assembly toward the fuel inlet of the mixer; this
places the small notches in the fuel metering valve
(fuel cone) inline with the fuel inlet and the large
notches of the fuel metering valve “cone”,
perpendicular to the fuel inlet of the mixer. Now
reinstall the air-valve spring and diaphragm cover
(Figure M8).

Figure M9

6. Tighten the cover fastners and reinstall the mixer

on the engine (Figure M9).

G643(E) Service Manual 223 Chapter 6. LPG FUEL DELIVERY SYSTEM

N-2001 Regulator for G643 Engine

Refer to Figure 47 exploded view on facing page.

Parts List
N-2001-RSA Regulator

REF NO. DESCRIPTION QTY

1 Cover Screws 8-32 x 5/8” SEMS 4
2 Torx Screws (T-15) 8-32 x 5/8” Tamper Resistant 2
3 Lockwasher #8 Internal Tooth 2
4 Secondary Cover 1
5 Secondary Diaphragm Assembly 1
6 Pan Head Screw 10-24 x 1/4” w/Star Washer 1
7 Secondary Lever 1
8 Secondary Valve 1
9 Secondary Lever Fulcrum Pin 1
10 Red Secondary Spring 1
11 Pilot Valve Lever 1
12 Pilot Valve Lever Fulcrum Pin 1
13 Internal Hex Head Set Screw 8-32 x 1/4” 1
14 Cover Screws 12-24 x 5/8” SEMS 6
15 Primary Diaphragm Cover 1
16 Primary Regulator Springs 2
17 Primary Diaphragm Assembly 1
18 1/8 NPT Hex Pipe Plug Fitting 1
19 Body Assembly 1
20 Body Seal O-ring 1
21 Body Gasket 1
22 Regulator Back Plate 1
23 Primary Seal O-Ring 1
24 Primary Regulator Valve 1
25 Cover Screws 12-24 x 5/8” SEMS 6
26 Inlet Seal O-Ring 1
27 Inlet Plug 1
28 Hex Head Screws 1/4-20 UNC-2A x 5/8” SEMS 2

G643(E) Service Manual 224 Chapter 6. LPG FUEL DELIVERY SYSTEM

Exploded View
N-2001-RSA Regulator

Figure 47. N-2001 Regulator Exploded View

G643(E) Service Manual 225 Chapter 6. LPG FUEL DELIVERY SYSTEM

N2001 Regulator Disassembly Steps:

1 Figure R5

Figure R3

Figure R5

Remove the six primary diaphragm cover screws (4)

Figure R4 and the primary cover assembly (5).

1. Remove the six secondary cover screws (1), the

secondary cover (2) and the secondary
diaphragm (3).

2. Remove the six primary diaphragm cover screws

(4) and the primary cover assembly (5).

Figure R6

Remove the primary diaphragm by sliding the

diaphragm to one side, releasing the primary valve
pin (Figure R6).

G643(E) Service Manual 226 Chapter 6. LPG FUEL DELIVERY SYSTEM

10
3

Figure R7

6. Remove the body gasket (10), body o-ring seal

(11) and the fuel inlet plate, exposing the fuel inlet
expansion chamber and the coolant passage.

NOTE
For re-assembly of the N2001
regulator/converter, reverse the steps for
8 disassembly. Tighten all fasteners to
recommended torque values and test the
9 regulator before installing in the vehicle.
Torque primary cover screws to (40-50
Figure R8 inch lbs.), secondary cover screws to (15-
18 inch lbs.).

Figure R9

Turn the regulator body over with the rear fuel inlet
plate facing up. Remove the primary valve access
plug (7), the primary valve (8) and the primary valve
o-ring seal (9). The primary valve goes through the
inlet plate, then through the body assembly and is
retained by the primary diaphragm (Figure R9).

G643(E) Service Manual 227 Chapter 6. LPG FUEL DELIVERY SYSTEM

N2001 Disassembled Service

1. Clean the primary and secondary valves with

soap and warm water to remove heavy-end
deposits. Inspect the valve seats and o-rings for
wear. Replace worn components as necessary.

2. Clean the primary and secondary diaphragms

with soap and warm water. Inspect for wear, tears
or pinholes and deformations that may cause
leaks or poor performance of the .
regulator/converter.

3. Replace the body gasket of the coolant chamber

and body o-ring seal when servicing the N2001 to
avoid coolant leaks from the fuel expansion
chamber to the coolant passage.

4. Clean the regulator body (casting) with a parts

cleaning solvent. Be sure to remove all seals and
gaskets before cleaning the casting with solvent.

Figure R11

5. Make sure all parts (Figure R11) are completely

dry before re-assembly.

G643(E) Service Manual 228 Chapter 6. LPG FUEL DELIVERY SYSTEM

Chapter 7. BASIC TROUBLESHOOTING
Preliminary Checks Visual/Physical check

MI-07 systems are equipped with built-in fault Several of the procedures call for a “Careful
diagnostics. Detected system faults can be Visual/Physical Check” which should include:
displayed by the Malfunction Indicator Lamp (MIL)
and are covered in Chapter 9, Advanced • SECM grounds for being clean and tight
Diagnostics. However, items such as fuel level,
plugged fuel lines, clogged fuel filters, and • Vacuum hoses for splits, kinks, and proper
malfunctioning pressure regulators may not set a connection.
fault code and usually can be corrected with the
basic troubleshooting steps described on the • Air leaks at throttle body mounting and intake
following pages. manifold

If engine or drivability problems are encountered • Exhaust system leaks

with your MI-07 system, perform the checks in this
section before referring to Advanced Diagnostics. • Ignition wires for cracking, hardness, proper
routing, and carbon tracking
NOTE: Locating a problem in a propane engine is
done exactly the same as with a gasoline engine. • Wiring for pinches and cuts
Consider all parts of the ignition and mechanical
systems as well as the fuel system. Also check:

Before Starting • Connections to determine that none are loose,

cracked, or missing
1. Determine that the SECM and MIL light are
operating. Verify operation by keying on engine • Fuel level in vehicle is sufficient
and checking for flash of MIL light. When the
• Fuel is not leaking
ignition key is turned on, the MIL will illuminate
and remain on until the engine is started. Once
• Battery voltage is greater than 11.5 volts
the engine is started, the MIL lamp will go out
unless one or more fault conditions are present. If
• Steering, brakes, and hydraulics are in proper
a detected fault condition exists, the fault or faults
condition and vehicle is safe to operate
will be stored in the memory of the small engine
control module (SECM). Once an active fault
NOTE: The Visual/Physical check is very important,
occurs the MIL will illuminate and remain ON.
as it can often correct a problem without further
This signals the operator that a fault has been
troubleshooting and save valuable time.
detected by the SECM.

2. Determine that there are no diagnostic codes

stored, or there is a diagnostic code but no MIL
light.

G643(E) Service Manual 229 Chapter 7. Basic Troubleshooting

Basic Troubleshooting Guide
Customer Problem Analysis Sheet

1. Forklift Information

(I) VIN:

(II) Production Date:

(III) Hour meter Reading: (hrs)

2. Symptoms

□ Engine does not turn over □Incomplete combustion

□ Unable to start
□ Initial combustion does not occur

□ Difficult to start □ Engine turns over slowly □ Other_________________

□ Rough idling □ Incorrect idling
□ Poor idling □Unstable idling (High: ______ rpm, Low: ______ rpm)
□ Other__________________________________
□ Soon after starting □ After accelerator pedal depressed
□After accelerator pedal released
□ Engine stall
□ Shifting from N to D-range
□ Other_______________________________________________

□ Poor driving (Surge) □ Knocking □ Poor fuel economy

□ Others
□ Back fire □ After fire □ Other____________________________

3. Environment

□ Constant □ Sometimes (_________________) □ Once only

Problem frequency
□ Other___________________________________________

Weather □ Fine □ Cloudy □ Rainy □ Snowy □ Other__________________

Outdoor temperature Approx._____ ℃/℉

□ Suburbs □ Inner City □ Uphill □ Downhill

Place
□ Rough road □ Other___________________________________

Engine temperature □ Cold □ Warming up □ After warming up □ Any temperature

□ Starting □ Just after starting (____min) □ Idling □ Racing
Engine operation □ Driving □ Constant speed □ Acceleration □ Deceleration
□ Other_____________________________

4. MIL/DTC

MIL (Malfunction Indicator Lamp) □ Remains ON □ Sometimes lights up □ Does not light

DTC □ Normal □ DTC(_______________________________________)

G643(E) Service Manual 230 Chapter 7. Basic Troubleshooting

Basic Inspection Procedure 4. Repair or replace the component that has a
problem.
Measuring Condition Of Electronic Parts
Resistance 5. Verify that the problem has disappeared with the
road test.
The measured resistance at high temperature after
vehicle running may be high or low. So all resistance • SIMULATING VIBRATION
must be measured at ambient temperature (20℃, 68
℉), unless there is any notice. 1) Sensors and Actuators
: Slightly vibrate sensors, actuators or relays
NOTE: The measured resistance in except for with finger.
ambient temperature (20℃, 68℉) is reference value.
WARNING
Intermittent Problem Inspection Procedure
Strong vibration may break sensors, actuators
Sometimes the most difficult case in troubleshooting or relays.
is when a problem symptom occurs but does not
occur again during testing. An example would be if a 2) Connectors and Harness
problem appears only when the vehicle is cold but : Lightly shake the connector and wiring
has not appeared when warm. In this case, harness vertically and then horizontally.
technician should thoroughly make out a
"CUSTOMER PROBLEM ANALYSIS SHEET" and • Simulating Heat
recreate (simulate) the environment and condition
which occurred when the vehicle was having the 1) Heat components suspected of causing the
issue. malfunction with a hair dryer or other heat
sourre.

WARNING
DO NOT heat components to the point where
they may be damaged.
DO NOT heat the ECM directly.

• Simulating Water Sprinkling

1) Sprinkle water onto vehicle to simulate a rainy

day or a high humidity condition.

WARNING
DO NOT sprinkle water directly into the engine
compartment or electronic components.

1. Clear Diagnostic Trouble Code (DTC).

• Simulatingelectricalload
2. Inspect connector connection, and check terminal 1) Turn on all electrical systems to simulate
for poor connections, loose wires, bent, broken or excessive electrical loads (Radios, fans, lights,
corroded pins, and then verify that the connectors etc.).
are always securely fastened.

3. Slightly shake the connector and wiring harness

vertically and horizontally.

G643(E) Service Manual 231 Chapter 7. Basic Troubleshooting

Connector Inspection Procedure

Handling of Connector

4. When a tester is used to check for continuity, or to

measure voltage, always insert tester probe from
wire harness side.

1. Never pull on the wiring harness when

disconnecting connectors.

5. Check waterproof connector terminals from the

connector side. Waterproof connectors cannot be
accessed from harness side.
2. When removing the connector with a lock, press
or pull locking lever. NOTE: Use a fine wire to prevent damage to the
terminal. Do not damage the terminal when inserting
the tater lead.

3. Listen for a click when locking connectors. This

sound indicates that they are securely locked.

G643(E) Service Manual 232 Chapter 7. Basic Troubleshooting

Checking Point for Connector Wire Harness Inspection Procedure

1. Before removing the wire harness, check the wire

harness position and crimping in order to restore
it correctly.

2. Check whether the wire harness is twisted, pulled

or loosened.

3. Check whether the temperature of the wire

harness is abnormally high.

4. Check whether the wire harness is rotating,

moving or vibrating against the sharp edge of a
part.
1. While the connector is connected:
Hold the connector, check connecting condition 5. Check the connection between the wire harness
and locking efficiency. and any installed part.

2. When the connector is disconnected: 6. If the covering of wire harness is damaged;

Check missed terminal, crimped terminal or secure, repair or replace the harness.
broken core wire by slightly pulling the wire
harness. Visually check for rust, contamination,
deformation and bend.

3. Check terminal tightening condition:

Insert a spare male terminal into a female ter-
minal and then check terminal tightening
conditions.

4. Pull lightly on individual wires to ensure that each

wire is secured in the terminal.

Repair Method of Connector Terminal

1. Clean the contact points using air gun and/or

shop rag.

NOTE: Never uses and paper when polishing the

contact points, otherwise the contact point may be
damaged.

2. In case of abnormal contact pressure, replace the

female terminal.

G643(E) Service Manual 233 Chapter 7. Basic Troubleshooting

Electrical Circuit Inspection Procedure normal). To find exact break point, check sub line of
line 1as described in next step.
• Check Open Circuit

b. Disconnect connector (B), and measure for

1. Procedures for Open Circuit resis tance between connector (C) and (B1)
and between (B2) and (A) as shown in [FIG.3].
• Continuity Check In this case the measured resistance between
connector (C) and (B1) is higher than 1㏁ and
• Voltage Check the open circuit is between terminal 1 of
connector (C) and terminal 1 of connector (B1).
If an open circuit occurs (as seen in [FIG.1]), it can
be found by performing Step 2 (Continuity Check) or
Step 3 (Voltage Check Method) as shown below.

2. Continuity Check Method

NOTE: When measuring for resistance, lightly shake

the wire harness above and below or from side to
side.

Specification (Resistance)
1Ω or less → Normal Circuit
1㏁ or Higher → Open Circuit
3. Voltage Check Method

a. With each connector still connected, measure

the voltage between the chassis ground and
terminal1 of each connectors (A), (B) and (C)
as shown in [FIG.4].

The measured voltage of each connector is 5V,

5V and 0V respectively. So the open circuit is
between connector (C) and (B).

a. Disconnect connectors (A), (C) and measure

resistance between connector (A) and (C) as
shown in [FIG.2].

In [FIG.2.] the measured resistance of line1and

2 is higher than 1㏁ and below 1Ω respectively.
Specifically the open circuit is line 1(Line 2 is

G643(E) Service Manual 234 Chapter 7. Basic Troubleshooting

• Check Short Circuit

b. Disconnect connector (B), and measure the

resistance between connector (A) and chassis
1. Test Method for Short to Ground Circuit ground, and between (B1) and chassis ground
as shown in [FIG.7].
• Continuity Check with Chassis Ground
The measured resistance between connector (B1)
If short to ground circuit occurs as shown in [FIG.5], and chassis groundis1Ω or less. The short to
the broken point can be found by performing below ground circuit is between terminal 1 of connector (C)
Step 2 (Continuity Check Method with Chassis and terminal 1 of connector (B1).
Ground) as shown below.

2. Continuity Check Method (with Chassis Ground)

NOTE: Lightly shake the wire harness above and

below, or from side to side when measuring the
resistance.

Specification (Resistance)
1Ω or less → Short to Ground Circuit
1㏁ or Higher → Normal Circuit

a. Disconnect connectors (A), (C) and measure

for resistance between connector (A) and
Chassis Ground as shown in [FIG.6].

The measured resistance of line 1 and 2 in this

example is below 1Ω and higher than 1㏁
respectively. Specifically the short to ground circuit
is line 1 (Line 2is normal). To find exact broken point,
check the sub line of line1 as described in the
following step.

G643(E) Service Manual 235 Chapter 7. Basic Troubleshooting

Basic Troubleshooting An intermittent “Service Engine Soon” light with no
stored diagnostic code may be caused by:
Intermittents • Ignition coil shortage to ground and arcing at
spark plug wires or plugs
An intermittent fault is the most difficult to
troubleshoot since the MIL flashes on at random,
• MIL light wire to ECM shorted to ground
causing uncertainty in the number of flashes or the
conditions present at the time of the fault. Also, the
• SECM grounds (refer to SECM wiring diagrams).
problem may or may not fully turn “ON” the MIL light
or store a code.
Check for improper installation of electrical options
such as lights, 2-way radios, accessories, etc.
Therefore, the fault must be present or able to be
recreated in order to locate the problem. If a fault is
EST wires should be routed away from spark plug
intermittent, use of diagnostic code charts may
wires, distributor wires, distributor housing, coil and
result in the unnecessary replacement of good
generator. Wires from SECM to ignition should have
components.
a good connection.
Corrective Action
Most intermittent problems are caused by faulty
electrical connections or wiring. Perform careful
visual/physical check for:

• Poor mating of the connector halves or terminal

not fully seated in the connector body (backed
out)

• Improperly formed or damaged terminal. All

connector terminals in problem circuit should be
carefully reformed or replaced to insure proper
contact tension

• Loose connections or broken wires

• Poor terminal to wire connection crimp

If a visual/physical check does not find the cause of

the problem, perform the following:

(1) Drive the vehicle with a voltmeter or “Service”

tool connected to a suspected circuit. Check if
circuit is active and signal is reasonable.

(2) Using the “Service” tool, monitor the input signal

to the SECM to help detect intermittent
conditions.

(3) An abnormal voltage, or “Service” reading, when

the problem occurs, indicates the problem may
be in that circuit.

(4) If the wiring and connectors check OK, and a

diagnostic code was stored for a circuit having a
sensor, check sensor.

G643(E) Service Manual 236 Chapter 7. Basic Troubleshooting

Surges and/or Stumbles
Engine power varies under steady throttle or cruise. Feels like the vehicle speeds up and slows down with no
change in the acceleration pedal.

Preliminary Checks
Perform the visual checks as described at start of “ Basic Troubleshooting” chapter.
Be sure driver understands vehicle operation as explained in the operator manual.

PROBABLE CAUSE CORRECTIVE ACTION

The fuel management should maintain a stoichiometric air-fuel ratio under all
Oxygen sensor steady state operating conditions following engine warmup. Failure of the Pre-
malfunction catalyst O2 sensor should cause an O2 sensor fault that can be diagnosed with
the MIL lamp or Service Tool.

NOTE: To determine if the condition is caused by a rich or lean system, the

vehicle should be driven at the speed of the complaint. Monitoring pre-catalyst
O2 adapts*, dither valve duty cycle, or mechanical injector pulse width will help
Fuel system malfunction identify problem.
Check fuel supply while condition exists.
Check in-line fuel filter. Replace if dirty or plugged.
Check fuel pressure.

Check for proper ignition voltage output using spark tester.

Check spark plugs.
• Remove spark plugs, check for wet plugs, cracks, wear, improper gap, burned
Ignition system electrodes, or heavy deposits.
malfunction • Repair or replace as necessary.
• Check condition of distributor cap, rotor and spark plug wires (where
applicable).
Check ignition timing. Refer to application manual for specs.

Check vacuum lines for kinks or leaks.

Component malfunction
Check alternator output voltage. Repair if less than 9 or more than 16 volts.
Check condition of exhaust system.
Exhaust backpressure
Check backpressure before catalyst. It should be less than 3.5 psig (24.13 kPa).

(*) Refer to Table 1 for description of gaseous and liquid O2 adapts.

Related MIL Faults:

Pre-catalyst O2 sensor errors / O2 control errors
Dither valve DC faults / EST faults / ETC faults

G643(E) Service Manual 237 Chapter 7. Basic Troubleshooting

Engine Cranking but Will Not Start / Difficult to Start

Engine cranks OK, but does not start for a long time. Does eventually run, or may start but immediately dies.

Preliminary Checks

Perform the visual checks as described at start of “ Basic Troubleshooting” chapter.

Be sure driver is using correct method to start engine as explained in operator’s manual. Use “clear flood”
mode during cranking by fully depressing the pedal and cranking the engine. If engine does not start, continue
troubleshooting.

PROBABLE CAUSE CORRECTIVE ACTION

Verify “selected” fuel with Service Tool. Make sure fuel select switch
CORRECTIVE ACTION
is in proper position.
Check for LPG vapor from LPG liquid outlet valve on tank.
Fuel container empty
Fill fuel container. Do not exceed 80% of liquid capacity.
Liquid valve closed Slowly open liquid valve.
Propane excess flow Reset excess flow valve in LPG tank.
valve closed Close liquid valve. Wait for a “click” sound; slowly open liquid valve.

Remove obstruction from the fuel line.

• Close liquid fuel valve.
• Using caution, disconnect the fuel line (some propane may
escape).
Plugged fuel line
• Clear obstruction with compressed air.
• Re-connect fuel line.
• Slowly open liquid fuel valve.
• Leak test.

Repair/replace as required.
Clogged fuel filter
See Chapter 2 Fuel Filter replacement.
Check connection
Faulty vapor connection between the
• Verify no holes in hose.
pressure regulator/converter and the
• Clamps must be tight.
mixer
• Look for kinked, pinched and/or collapsed hose.
Repair/replace fuel lock-off.
Fuel lock-off malfunction
See Chapter 5 Fuel Lock-off.
Pressure regulator/converter Test regulator/converter operation and pressure.
malfunction See Chapter 6 LPG Fuel Delivery System.
Incorrect air/fuel or ignition/spark
See Chapter 8 Advanced Diagnostics.
control
Verify the crankshaft position signal is present
No crankshaft position sensor signal
See Chapter 8 Advanced Diagnostics.

G643(E) Service Manual 238 Chapter 7. Basic Troubleshooting

Engine Cranking but Will Not Start / Difficult to Start (cont’d.)

PROBABLE CAUSE CORRECTIVE ACTION

Check Coolant Temperature Sensor using the Service Tool; compare coolant
temperature with ambient temperature on cold engine.
If coolant temperature reading is 5° greater than or less than ambient air
temperature on a cold engine, check resistance in coolant sensor circuit or
sensor itself. Compare CTS resistance value to “Diagnostic Aids” chart at end
SECM / control system of this section.
malfunction Verify that there is no code for ETC spring check fault.
Check for 0% APP during cranking.
Cycle key ON and OFF and listen for throttle check (movement) on key OFF.
Check for oil pressure switch faults.
Check for sensor “sticking” faults.
Check TPS for stuck binding or a high TPS voltage with the throttle closed.

Check fuel lock off (propane) or fuel pump relay gasoline operation: actuator
should turn “ON” for 2 seconds when ignition is turned “ON”.
Check fuel pressure.
Check for contaminated fuel.
Check both gasoline injector and lock off fuses (visually inspect).
Fuel system malfunction
Check propane tank valve & pickup. A faulty
in-tank fuel pump check valve will allow the fuel in the lines to drain back to the
tank after engine is stopped. To check for this condition, perform fuel system
diagnosis.
Check FTV system for proper operation.

Check for proper ignition voltage output with spark tester.

Check spark plugs. Remove spark plugs, check for wet plugs, cracks, wear,
improper gap, burned electrodes, or heavy deposits. Repair or replace as
necessary.
Check for:
Ignition system malfunction • Moisture in distributor cap*
• Bare or shorted wires
• Worn distributor shaft/rotor*
• Loose ignition coil ground
• Pickup coil resistance and connections
(*) Where present

Related MIL Faults:

ETC spring check / ETC faults / EST faults / TPS conflict
APP faults / Encoder error / MAP faults
Injector faults / Oil pressure faults

G643(E) Service Manual 239 Chapter 7. Basic Troubleshooting

Lack of Power, Slow to Respond / Poor High Speed Performance / Hesitation During
Acceleration

Engine delivers less than expected power. Little or no increase in speed when accelerator pedal is pushed
down part way. Momentary lack of response as the accelerator is pushed down. Can occur at all vehicle
speeds. Usually most severe when first trying to make vehicle move, as from a stop. May cause engine to stall.

PRELIMINARY CHECKS
Perform the visual checks as described at start of “ Basic Troubleshooting” chapter.
Drive vehicle; verify problem exists.
Remove air filter and check for dirt or other means of plugging. Replace if needed.

PROBABLE CAUSE CORRECTIVE ACTION

Check for restricted fuel filter.
Check fuel supply.
Check for LPG vapor from LPG liquid outlet valve on tank.
Check for contaminated fuel.
Check for clogged fuel filter and repair or replace as required. See Chapter 4
Fuel Filter replacement
Check for plugged fuel line and remove any obstruction from the fuel line:
• Close liquid fuel valve.
• Using caution, disconnect the fuel line (some propane may escape).
• Clear obstruction with compressed air.
Fuel system malfunction • Re-connect fuel line.
• Slowly open liquid fuel valve and leak test.
Check for faulty vapor connection between pressure regulator/converter and
mixer:
• Verify that there are no holes in hose.
• Observe that clamps are tight.
• Look for kinked, pinched and/or collapsed hose.
Monitor pre-catalyst O2 with Service Tool.
Check for proper pressure regulator operation.
See Chapter 6 Test and Adjustments.
Check for proper air/fuel mixer operation.

Check spark advance for excessive retarded ignition timing. Use Service Tool.
Check secondary voltage using an oscilloscope or a spark tester to check for a
Ignition system malfunction weak coil.
Check spark plug condition.
Check poor spark plug primary and secondary wire condition.

G643(E) Service Manual 240 Chapter 7. Basic Troubleshooting

Lack of Power, Slow to Respond / Poor High Speed Performance / Hesitation During
Acceleration (cont’d.)

PROBABLE CAUSE CORRECTIVE ACTION

Check SECM grounds for cleanliness and secure

connection. See SECM wiring diagrams.
Check alternator output voltage. Repair if less than 9
volts or more than 16 volts.
Check for clogged air filter and clean or replace as
required.
Check exhaust system for possible restriction.
Refer to Chart T-1 on later pages.
Component malfunction Inspect exhaust system for damaged or collapsed
pipes.
• Inspect muffler for heat distress or possible internal
failure.
• Check for possible plugged catalytic converter by
comparing exhaust system backpressure on each
side at engine. Check backpressure by removing
Pre-catalyst O2 sensor and measuring
backpressure with a gauge.
See Chapter 3 Engine Mechanical System.
Engine mechanical Check engine valve timing and compression
Check engine for correct or worn camshaft.

Related MIL Faults:

EST faults
ETC faults
ETC spring check
TPS faults
APP faults
Encoder error
Delayed Shutdown faults

G643(E) Service Manual 241 Chapter 7. Basic Troubleshooting

Detonation / Spark Knock
A mild to severe ping, usually worse under acceleration. The engine makes sharp metallic knocks that change
with throttle opening (similar to the sound of hail striking a metal roof).

PRELIMINARY CHECKS

Perform the visual checks as described at start of “ Basic Troubleshooting” chapter.

PROBABLE CAUSE CORRECTIVE ACTION

Check for proper fuel level:
• Check for LPG vapor from LPG liquid outlet valve on tank.
• Fill fuel container. Do not exceed 80% of liquid capacity.
Fuel system
malfunction Check fuel pressure.
To determine if the condition is caused by a rich or lean system, the vehicle
should be driven at the speed of the complaint. Monitoring with the Service
tool will help identify problem.

Check for obvious overheating problems:

• Low engine coolant
• Loose water pump belt
• Restricted air flow to radiator, or restricted water flow through radiator
Cooling system malfunction
• Inoperative electric cooling fan
• Correct coolant solution should be a mix of anti-freeze coolant (or
equivalent) and water
• High coolant temperature

Ignition system Check ignition timing.

malfunction Check spark module wiring.
Check exhaust backpressure.
Exhaust system malfunction Check for debris clogging the catalyst.
Check that pre-catalyst O2 sensor is functioning.

Check for excessive oil in the combustion chamber and/or blow by from
excessive PCV flow.
Engine mechanical Check combustion chambers for excessive carbon build up.
Check combustion chamber pressure by performing a compression test.
Check for incorrect basic engine parts such as cam, heads, pistons, etc.

Related MIL Faults:

EST faults
Encoder error
High coolant temperature faults

G643(E) Service Manual 242 Chapter 7. Basic Troubleshooting

Backfire
Fuel ignites in intake manifold or in exhaust system, making loud popping noise.

PRELIMINARY CHECKS
Perform the visual checks as described at start of “ Basic Troubleshooting” chapter.
Simulate condition by reviewing operation procedure practiced by vehicle operator.

PROBABLE CAUSE CORRECTIVE ACTION

Perform fuel system diagnosis check:
Fuel system • Check for fuel leaks
malfunction • Check for MIL faults
• Check for damaged components
Check proper ignition coil output voltage with spark tester.
Check spark plugs. Remove spark plugs, check for wet plugs, cracks, wear,
improper gap, burned electrodes, or heavy deposits. Repair or replace as
Ignition system
necessary.
malfunction
Check spark plug wires for crossfire; also inspect distributor cap, spark plug
wires, and proper routing of plug wires.
Check ignition timing.
Check compression: look for sticking or leaking valves.
Check intake and exhaust manifold for casting flash and gasket
Engine mechanical
misalignment.
Refer to Chapter 3 Engine Mechanical System.

Related MIL Faults: EST faults / ETC faults / Encoder error

Pre-catalyst O2 sensor faults

Dieseling, Run-on
Engine continues to run after key is turned “OFF,“ but runs very roughly. If engine runs smoothly, check
ignition switch and adjustment.

PRELIMINARY CHECKS

Perform the visual checks as described at start of “ Basic Troubleshooting” chapter.

PROBABLE CAUSE CORRECTIVE ACTION

Fuel system
Check for fuel leaks or leaking injector.
malfunction
Ignition switching Make sure power to system is shut off when key is in OFF position.

Fuel lock off valve Make sure lock off valve is closing properly.

Ignition system malfunction Check spark advance at idle.

Related MIL Faults: EST faults / ETC faults / Pre-catalyst O2 sensor faults

G643(E) Service Manual 243 Chapter 7. Basic Troubleshooting

Rough, Unstable, Incorrect Idle, or Stalling
Engine cranks OK, but does not start for a long time. Does eventually run, or may start but immediately dies.

PRELIMINARY CHECKS

Perform the visual checks as described at start of “Basic Troubleshooting” chapter.

Check for vacuum leaks.
Check that SECM grounds are clean and tight. See SECM wiring diagram

PROBABLE CAUSE CORRECTIVE ACTION

Monitor oxygen feedback to help identify the cause of the problem. If

the system is running lean or if the system is running rich evaluate
further i.e. dither valve duty cycle and injector pulse width.
Check for incorrect minimum idle speed that may be caused by foreign
material accumulation in the throttle bore, on the throttle valve, or on
the throttle shaft.
Fuel system Check that the injectors are clean and functioning.
malfunction Check for liquid fuel in propane pressure regulator hose. If fuel is
present, replace regulator assembly.
The pre-catalyst oxygen (O2) sensor should respond quickly to
different throttle positions. If it does not, then check the pre-catalyst O2
sensor for contamination. If the pre-catalyst O2 sensor is aged or
contaminated, the SECM will not deliver correct amount of fuel,
resulting in a drivability problem.
Check for LPG vapor from LPG liquid outlet valve on tank.
Fuel container empty
Fill fuel container. Do not exceed 80% of liquid capacity.
Ignition system
Check ignition system; wires, plugs, rotor, etc.
malfunction
Test regulator operation and pressure.
LPG pressure regulator malfunction
See Chapter 6 Tests and Adjustments
Air/fuel mixer malfunction Check mixer.

Check throttle for sticking or binding.

Check PCV valve for proper operation by placing finger over inlet hole
in valve end several times. Valve should snap back. If not, replace
Component malfunction
valve.
Check alternator output voltage. Repair if less than 9 or more than 16
volts.
Perform a cylinder compression check.
Engine mechanical
See Chapter 3 Engine Mechanical System.

G643(E) Service Manual 244 Chapter 7. Basic Troubleshooting

Rough, Unstable, Incorrect Idle, or Stalling (cont’d.)

PROBABLE CAUSE CORRECTIVE ACTION

Reset excess flow valve.
Excess flow valve closed • Close liquid valve.
• Wait for a “click” sound. Slowly open liquid valve.
Repair/replace as required
Clogged fuel filter
See Chapter 2 Fuel Filter Replacement
Remove obstruction from the fuel line.
• Close liquid fuel valve.
• Using caution, disconnect the fuel line (some
Plugged fuel line propane may escape).
• Clear obstruction with compressed air.
• Re-connect fuel line.
• Slowly open liquid fuel valve & leak test.
Repair/replace fuel lock-off.
Fuel lock-off malfunction
See Chapter 2 Fuel Lock-Off.
Check connection.
Faulty vapor connection
• Verify no holes in hose.
between the pressure regulator/converter and the
• Clamps must be tight.
mixer
• Look for kinked, pinched and/or collapsed hose.
Check level in cooling system:
• Must be full, check coolant strength
• -35°F (-37°C) minimum
Pressure regulator freezes Check coolant hoses.
• Watch for kinks and/or pinched hoses.
• Verify one pressure hose and one return hose.
Test regulator. See Chapter 6
Check for vacuum leaks.
• Between mixer and throttle body
Vacuum leak
• Between throttle body and intake manifold
• Between intake manifold and cylinder head

Related MIL Faults:

EST faults
ETC Sticking fault
Pre-catalyst adapts error

G643(E) Service Manual 245 Chapter 7. Basic Troubleshooting

Cuts Out, Misses
Steady pulsation or jerking that follows engine speed, usually more pronounced as engine load increases,
sometimes above 1500 rpm. The exhaust has a steady spitting sound at idle or low speed.

PRELIMINARY CHECKS

Perform the visual checks as described at start of “ Basic Troubleshooting” chapter.

PROBABLE CAUSE CORRECTIVE ACTION

Check fuel system specifically for plugged fuel filter, low pressure.
Fuel system Check for contaminated fuel.
malfunction Check lock off intermittent connection.
Check dither valve operation.

Check for spark on the suspected cylinder(s) using a shop oscilloscope or

spark tester or equivalent. If no spark, check for intermittent operation or
miss. If there is a spark, remove spark plug(s) in these cylinders and check
for cracks, wear, improper gap, burned electrodes, heavy deposits.
Ignition system
Check spark plug wires by connecting ohmmeter to ends of each wire in
malfunction
question. If meter reads over 30,000 ohms, replace wire(s).
Visually inspect distributor cap, rotor, and wires for moisture, dust, cracks,
burns, etc. Spray cap and plug wires with fine water mist to check for shorts.
Check engine ground wire for looseness or corrosion.

Check for electromagnetic interference (EMI). A missing condition can be

caused by EMI on the reference circuit. EMI can usually be detected by
monitoring engine rpm with Service Tool. A sudden increase in rpm with little
Component malfunction
change in actual engine rpm indicates EMI is present. If problem exists,
check routing of secondary wires and check distributor ground circuit.
Check intake and exhaust manifolds for casting flash or gasket leaks.
Perform compression check on questionable cylinders. If compression is low,
repair as necessary.
Engine mechanical Check base engine. Remove rocker covers and check for bent pushrods,
worn rocker arms, broken valve springs, worn camshaft lobes, and valve
timing. Repair as necessary.

Related MIL Faults:

EST faults
ETC Sticking fault

G643(E) Service Manual 246 Chapter 7. Basic Troubleshooting

Poor Fuel Economy / Excessive Fuel Consumption / LPG Exhaust Smell
Fuel economy, as measured during normal operation, is noticeably lower than expected. Also, economy is
noticeably lower than what it has been in the past. Propane fuel smell near vehicle sets off carbon monoxide
sensors.

PRELIMINARY CHECKS

Perform the visual checks as described at start of “ Basic Troubleshooting” chapter.

Verify operator complaint: identify operating conditions.
Check operator’s driving habits:
Are tires at correct pressure?
Are excessively heavy loads being carried?
Is acceleration too much, too often?
Check air cleaner element (filter) for being dirty or plugged.
Visually (physically) check vacuum hoses for splits, kinks, and proper connections as shown on application
manual.

PROBABLE CAUSE CORRECTIVE ACTION

Check for faulty gasoline pressure regulator.

Check for leaking injector.
Fuel system Check that dither valve duty cycle is < 15%.
malfunction Check for too high propane pressure at mixer
(> 1” positive pressure).
Monitor Pre-catalyst O2 sensor with Service Tool.

Check engine coolant level.

Cooling system
Check engine thermostat for faulty part (always open) or for
malfunction
wrong heat range.

Check ignition timing. Refer to application manual.

Check for weak ignition and/or spark control.
Ignition system
Check spark plugs. Remove spark plugs and check for wet
malfunction
plugs, cracks, wear, improper gap, burned electrodes, or heavy
deposits. Repair or replace as necessary.

Check for exhaust system restriction or leaks.

Check induction system and crankcase for air leaks.
Check for clogged air filter; clean or replace as required.
Component malfunction Check FTV for housing cracks or obstructions; repair or replace
as required.
Check for vacuum leak. Check system vacuum hoses from
regulator to FTV and mixer. Repair or replace as required.
Air/fuel mixer malfunction Check mixer.
Pressure regulator malfunction / Test regulator operation and pressure.
fuel pressure too high See Chapter 6 Tests and Adjustments.
Check compression.
Engine mechanical
Refer to Chapter 3 Engine Mechanical System.

Related MIL Faults:

Pre-catalyst O2 sensor faults / Low side driver / Dither valve duty cycle
EST faults / Fuel adapt faults / Low coolant temperature

G643(E) Service Manual 247 Chapter 7. Basic Troubleshooting

High Idle Speed
Engine idles above the range of 750-1100 rpm.

PRELIMINARY CHECKS

Perform the visual checks as described at start of “ Basic Troubleshooting” chapter.

PROBABLE CAUSE CORRECTIVE ACTION

Check all hoses and gaskets for cracking, kinks, or leaks.

Verify that there are no vacuum leaks.
Incorrect idle speed control
See Chapter 8 Advanced Diagnostics & Chapter 6 Tests and
Adjustments
Replace throttle.
Throttle sticking
See Fault Code 461: ETC_Sticking
Check pedal return spring travel for binding.
Check APP function with Service Tool.
Foot pedal sticking or incorrect pedal signal
Verify smooth change of APP reading with pedal movement.
See Chapter 8 Advanced Diagnostics.
Check for vacuum hose leak.
Engine mechanical Check for PCV malfunction.
Check for defective intake gasket.

Related MIL Faults:

ETC Sticking fault
Idle adapt out of range
MAP Sticking fault
MAP high value

G643(E) Service Manual 248 Chapter 7. Basic Troubleshooting

Excessive Exhaust Emissions or Odors

Vehicle has high CO emissions.

NOTE: Excessive odors do not necessarily indicate excessive emissions.

PRELIMINARY CHECKS
Verify that no stored codes exist.
If emission test shows excessive CO and HC, check items that cause vehicle to run rich.
If emission test shows excessive NOx, check items that cause vehicle to run lean or too hot.

PROBABLE CAUSE CORRECTIVE ACTION

If the Service tool indicates a very high coolant temperature and the system
is running lean:
Cooling system • Check engine coolant level.
malfunction • Check engine thermostat for faulty part (always open) or for wrong heat
range.
• Check fan operation

If the system is running rich, refer to “Diagnostic Aids” chart on the next
page.
Fuel system If the system is running lean, refer to “Diagnostic Aids” chart on the next
malfunction page.
Check for properly installed fuel system components.
Check fuel pressure.

Ignition system Check ignition timing. Refer to application manual.

malfunction Check spark plugs, plug wires, and ignition components.

Check for vacuum leaks.

Check for contamination for catalytic converter (look for the removal of fuel
filler neck restrictor).
Check for carbon build-up. Remove carbon with quality engine cleaner.
Component malfunction
Follow instructions on label.
Check for plugged PCV valve.
Check for stuck or blocked PCV hose.
Check for fuel in the crankcase.

Related MIL Faults:

Low side driver
Fuel adapt faults
EST faults

G643(E) Service Manual 249 Chapter 7. Basic Troubleshooting

Diagnostic Aids for Rich / Lean Operation

SERVICE TOOL ITEM RICH LEAN

Pre-catalyst O2 A/ D counts Consistently > 250 Consistently < 170

Pre-catalyst O2 sensor switching
Always high ADC Always low ADC
between high and low
Trim valve duty cycle > 90% < 10%
• Pre-catalyst O2 sensor failed rich • Pre-catalyst O2 sensor failed rich
Malfunction codes • Pre-catalyst O2 sensor high • Pre-catalyst O2 sensor high
• Fuel adapts • Fuel adapts
Closed loop operation Stuck in open loop Stuck in open loop

(*) The duty cycle injector pulse width criteria for lean or rich operation apply only if the O2 sensor is
functioning properly. If the sensor is not operating properly the criteria may be reversed.

Rich Operation Lean Operation

LP (Trim valve duty cycle>90%) LP (Trim valve duty cycle<10%)

• Inspect hoses from AVV port (port on bottom of • Check for vacuum leaks, replace hoses, o-rings,
mixer) to trim valves and regulator for leaks or and gaskets as necessary
blockages, replace as necessary.
• Check balance line for blockage, replace as
• Inspect in-line orifices for blockages (in wye), necessary
replace as necessary
• Check vapor hose for restrictions, replace as
• Check trim valves for proper operation, replace as necessary
necessary

• Check regulator out pressure, replace if out of • Check trim valves for proper operation, replace as
spec necessary

• Inspect fuel cone for damage, replace mixer • Check regulator out pressure, replace if out of
assembly as necessary spec

G643(E) Service Manual 250 Chapter 7. Basic Troubleshooting

Chart T-1 Restricted Exhaust System Diagnosis:
Check
1. With the engine idling at normal operating
Proper diagnosis for a restricted exhaust system is temperature, observe the exhaust system
essential before replacement of any components. backpressure reading on the gage. Reading
The following procedures may be used for diagnosis, should not exceed 1.25 psig (8.61 kPa).
depending upon engine or tool used.
2. Increase engine speed to 2000 rpm and observe
gage. Reading should not exceed 3 psig (20.68
Check Atpre - Catalystoxygen (O2) Sensor kPa).

1. Carefully remove pre-catalyst oxygen (O2) sensor. 3. If the backpressure at either speed exceeds
specification, a restricted exhaust system is
2. Install exhaust backpressure tester or equivalent indicated.
in place of O2 sensor using Snap-On P/N
EEVPV311A kit and YA8661 adapter or Mac tool 4. Inspect the entire exhaust system for a collapsed
(see illustration). pipe, heat distress, or possible internal damage,
split welds, or cracked pipe.
3. After completing test described below, be sure to
coat threads of O2 sensor with anti-seize 5. If there are no obvious reasons for the excessive
compound prior to re-installation. backpressure, the catalytic converter is restricted
and should be replaced using current
recommended procedures.

Illustration Notes

1. Backpressure gage

2. Pre-catalyst Oxygen (O2) sensor

3. Exhaust manifold

G643(E) Service Manual 251 Chapter 7. Basic Troubleshooting

Chapter 8. ADVANCED DIAGNOSTICS
MI-07 systems are equipped with built-in fault which is the beginning of the fault list. It will then
diagnostics. Detected system faults can be pause for 1.2 seconds (long pause) and flash two
displayed by the Malfunction Indicator Lamp (MIL) times (2), pause, then flash six times (6). This
as Diagnostic Fault Codes (DFC) or flash codes, identifies a twenty-six (26), which is the ETCSticking
and viewed in detail with the use of the Service Tool fault. If any additional faults were stored the SECM
software. When the ignition key is turned on, the MIL would again have a long pause, then display the
will illuminate and remain on until the engine is next fault by flashing each digit. Since no other
started. Once the engine is started, the MIL lamp will faults were stored there will be a long pause then
go out unless one or more fault conditions are one flash (1), pause, then two flashes (2). This
present. If a detected fault condition exists, the fault identifies a twelve meaning the fault list will begin
or faults will be stored in the memory of the small again.
engine control module (SECM). Once an active fault
occurs the MIL will illuminate and remain ON. This Displaying Fault Codes (DFC)
signals the operator that a fault has been detected
by the SECM. from SECM Memory
To enter code display mode you must turn OFF the
Reading Diagnostic Fault Codes ignition key. Now turn ON the key but do not start
the engine. As soon as you turn the key to the ON
G643E Engines
position you must cycle the foot pedal by depressing
it to the floor and then fully releasing the pedal
All fault codes are three-digit codes. When the fault
(pedal maneuver). You must fully cycle the foot
codes are retrieved (displayed) the MIL will flash for
pedal three (3) times within five (5) seconds to
each digit with a short pause (0.5 seconds) between
enable the display codes feature of the SECM.
digits and a long pause (1.2 seconds) between fault
Simply turn the key OFF to exit display mode. The
codes. A code 12 is displayed at the end of the code
code list will continue to repeat until the key is
list.
turned OFF.
EXAMPLE: A code 461 (ETCSticking) has been
detected and the engine has shut down and the MIL Clearing Fault (DFC) Codes
has remained ON. When the codes are displayed
the MIL will flash four times (4), pause, then flash six To clear the stored fault codes from SECM memory
times (6), pause, then flash one time (1) This you must complete the reset fault pedal maneuver.
identifies a four sixty one (461), which is the
ETCSticking fault. If any additional faults were
stored, the SECM would again have a long pause, CAUTION
then display the next fault by flashing each digit.
Since no other faults were stored there will be a long Once the fault list is cleared it cannot be
pause then one flash (1), pause, then two flashes restored.
(2). This identifies a twelve, signifying the end of the
fault list. This list will then repeat. First turn OFF the ignition key. Now turn ON the key
but do not start the engine. As soon as you turn the
G643 Engines key to the ON position you must cycle the foot pedal
by depressing it to the floor and then fully releasing
All fault codes are two digit codes. When the fault the pedal (pedal maneuver). You must fully cycle the
codes are retrieved (displayed) the MIL will flash for foot pedal ten (10) times within five (5) seconds to
each digit with a short pause (.5 seconds) between clear the fault code list of the SECM. Simply turn the
digits and a long pause (1.2 seconds) between fault key OFF to exit the reset mode. The code list is now
codes. A code 12 is displayed at the beginning of clear and the SECM will begin storing new fault
the code list. codes as they occur.
EXAMPLE: A code 26 has been detected
(ETCSticking) and the engine has shutdown and the
MIL has remained ON. When the codes are
displayed the MIL will flash one time (1), pause, then
flash two times (2). This identifies a twelve (12),

G643(E) Service Manual 252 Chapter 8. Advanced Diagnostics

Fault Action Descriptions Fault List Definitions
Each fault detected by the SECM is stored in All the analog sensors in the MI-07 system have
memory (FIFO) and has a specific action or result input sensor range faults. These are the coolant
that takes place. Listed below are the descriptions of temperature sensor, fuel temperature sensor,
each fault action. throttle position sensors, pedal position sensors,
manifold pressure sensor, HEGO sensors, and
Engine Shutdown: The most severe action is an intake air temperature sensor. Signals to these
Engine Shutdown. The MIL will light and the engine sensors are converted into digital counts by the
will immediately shutdown, stopping spark, closing SECM. A low/high range sensor fault is normally set
the fuel lock-off closing, and turning off the fuel when the converted digital counts reach the
pump and fuel injectors. minimum of 0 or the maximum of 1024 (1024 = 5.0
Vdc with ~ 204 counts per volt).
Delayed Engine Shutdown: Some faults, such as
low oil pressure, will cause the MIL to illuminate for
30 seconds and then shut down the engine.

Cut Throttle: The throttle moves to its default

position. The engine will run at idle but will not
accelerate.

Cut Fuel: Fuel flow will be turned off.

Turn on MIL: The MIL will light by an active low

signal provided by the SECM, indicating a fault
condition. May illuminate with no other action or may
be combined with other actions, depending on which
fault is active. Additionally, the SECM includes software to learn
the actual range of the pedal position and throttle
Soft Rev Limit / Medium Rev Limit / Hard Rev position sensors in order to take full advantage of
Limit: System will follow various sequences to bring the sensor range. Faults are set if the learned
engine speed back to acceptable levels. values are outside of the normal expected range of
the sensor (e.g. APP1AdaptLoMin).
Level4 Power Limit / Level3 Power Limit / Level2
Power Limit / Level1 Power Limit: The maximum
engine power output will be limited to one of four
possible levels. The engine power is calculated from
measured engine parameters (e.g. MAP, rpm, fuel
flow, etc).

Disable Gas O2 Control: In LPG mode, closed loop

correction of air fuel ratio based on the Pre-catalyst
O2 sensor is disabled.

G643(E) Service Manual 253 Chapter 8. Advanced Diagnostics

Table 1. Fault List Definitions

CODE : G643E
FAULT DESCRIPTION
(CODE : G643)
Learned full pedal end of APP1 sensor range higher than 641*
APP1AdaptHiMax
expected (64)

APP1AdaptHiMin Learned full pedal end of APP1 sensor range lowe 651

APP1AdaptLoMax than expected 661

Learned idle end of APP1 sensor range higher than 631

APP1AdaptLoMin
expected (63)

Learned idle end of APP1 sensor range lower than 621

APP1RangeHigh
expected (62)

APP1 sensor voltage out of range high, normally set if the

611
APP1RangeLow APP1 signal has shorted to power or the ground for the
(61)
sensor has opened
APP1 sensor voltage out of range low, normally set if the
642
APP2AdaptHiMax APP1 signal has shorted to ground, circuit has opened or
(68)
sensor has failed

Learned full pedal end of APP2 sensor range lower than

APP2AdaptHiMin 652
expected

Learned idle end of APP2 sensor range higher than

APP2AdaptLoMax 662
expected

Learned idle end of APP2 sensor range lower than 632

APP2AdaptLoMin
expected (67)

APP2 sensor voltage out of range high, normally set if the

622
APP2RangeHigh APP2 signal has shorted to power or the ground for the
(66)
sensor has opened
APP2 sensor voltage out of range low, normally set if the
612
APP2RangeLow APP2 signal has shorted to ground, circuit has opened or
(65)
sensor has failed
APP2 sensor voltage out of range high, normally set if the
622
APP2RangeHigh APP2 signal has shorted to power or the ground for the
(66)
sensor has opened
APP2 sensor voltage out of range low, normally set if the
612
APP2RangeLow APP2 signal has shorted to ground, circuit has opened or
(65)
sensor has failed

APP position sensors do no not track well, intermittent 691

APP_Sensors_Conflict
connections to APP or defective pedal assembly (69)
* Fault Code of G643E : Three Digits
Fault Code of G643 : Two Digits

G643(E) Service Manual 254 Chapter 8. Advanced Diagnostics

Table 1. Fault List Definitions (cont’d.)

CODE : G643E
FAULT DESCRIPTION
(CODE : G643)
No crankshaft signal when engine is known to be rotating, broken
CrankEdgesFault 193
crankshaft sensor leads or defective crank sensor
Loss of synchronization on the crankshaft sensor, normally due to
CrankSyncFault noise on the signal or an intermittent connection on the crankshaft 194
sensor
Engine Coolant Temperature is High. The sensor has measured
161
ECTOverTempFault an excessive coolant temperature typically due to the engine
(16)
overheating.
Engine Coolant Temperature Sensor Input is High. Normally set if
151
ECTRangeHigh coolant sensor wire has been disconnected or circuit has opened
(15)
to the SECM.
Engine Coolant Temperature Sensor Input is Low. Normally set if
141
ECTRangeLow the coolant sensor wire has shorted to chassis ground or the
(14)
sensor has failed.
ECT_IR_Fault Engine Coolant Temperature not changing as expected 171
EST1 output open, possibly open EST1 signal or defective spark 421
EST1_Open
module (42)
EST1 output shorted high or low, EST1 signal shorted to ground or
EST1_Short 431
power or defective spark module
Electronic Throttle Control Spring Return Test has Failed. The
SECM will perform a safety test of the throttle return spring
following engine shutdown. If this spring has become weak the
481
ETCSpringTest throttle will fail the test and set the fault.
(28)
NOTE: Throttle assembly is not a serviceable item and can only
be repaired by replacing the DV-EV throttle assembly.
Electronic Throttle Control Driver has failed. Normally set if either
ETC_Open_Fault of the ETC driver signals have opened or become disconnected, 471
electronic throttle or SECM is defective.

Electronic Throttle Control is Sticking. This can occur if the throttle

plate (butterfly valve) inside the throttle bore is sticking. The plate
sticking can be due to some type of obstruction; a loose throttle
461
ETC_Sticking plate or worn components shaft bearings.
(26)
NOTE: Throttle assembly is not a serviceable item and can only
be repaired by replacing the DV-EV throttle assembly.

Conflict in fuel select signals, normally set if one or both of the fuel
FuelSelectConflict 181
select signals are shorted to ground

Fuel Temperature Sensor Input is High. Normally set if the fuel

FuelTempRangeHigh temperature sensor wire has been disconnected or the circuit has 932
opened to the SECM.
Fuel Temperature Sensor Input is Low. Normally set if the fuel
FuelTempRangeLow temperature sensor wire has shorted to chassis ground or the 931
sensor has failed.

G643(E) Service Manual 255 Chapter 8. Advanced Diagnostics

Table 1. Fault List Definitions (cont’d.)

CODE : G643E
FAULT DESCRIPTION
(CODE : G643)
731
GasFuelAdaptRangeHi In LPG mode, system had to adapt lean more than expected
(73)
721
GasFuelAdaptRangeLo In LPG mode, system had to adapt rich more than expected
(72)
Pre-catalyst O2 sensor indicates extended lean operation on
GasO2FailedLean 751
LPG

Pre-catalyst O2 sensor indicates extended rich operation on 771

GasO2FailedRich
LPG (77)

Pre-catalyst O2 sensor inactive on LPG, open O2 sensor 741

GasO2NotActive
signal or heater leads, defective O2 sensor, or defective FTVs (74)

Post-catalyst O2 sensor control on LPG has reached rich limit

and sensor still reads to lean. This could be caused by oxygen
leak before or just after sensor, catalyst failure, sensor failure,
GasPostO2FailedRich 772
or wiring/relay failure causing the sensor to not be properly
heated. If any Pre-O2 sensor faults are set, diagnose these
first and after correcting these faults recheck if this fault sets.

Post-catalyst O2 sensor control on LPG has reached lean limit

and sensor still reads to rich. This could be caused by catalyst
failure, sensor failure, or wiring/relay failure causing the
GasPostO2FailedLean 752
sensor to not be properly heated. If any Pre-O2 sensor faults
are set diagnose, these first and after correcting these faults
recheck if this fault sets.

Post-catalyst O2 sensor control on LPG has sensed the O2

sensor is not responding as expected. If any Pre-O2 sensor
faults are set diagnose these first and after correcting these
GasPostO2Inactive faults recheck if this fault sets. Possible causes for this fault 742
are sensor disconnected, sensor heater failed, sensor
element failed, heater relay, or SECM control of heater relay
is disconnected or failed.

Reserved for Future Use 743

G643(E) Service Manual 256 Chapter 8. Advanced Diagnostics

Table 1. Fault List Definitions (cont’d.)

CODE : G643E
FAULT DESCRIPTION
(CODE : G643)
(Electronic Throttle Control Driver has Failed) Indeterminate
fault on Hbridge driver for Electronic Throttle Control. 491
HbridgeFault_ETC
Possibly either ETC+ or ETC- driver signals have been shorted (29)
to ground

Engine speed has exceeded the third level (3 of 3) of 571

HardOverspeed
overspeed protection (57)

Intake Air Temperature Sensor Input is High normally set if the

381
IATRangeHigh IAT temperature sensor wire has been disconnected, the circuit
(38)
has opened to the SECM, or a short to Vbatt has occurred.

Intake Air Temperature Sensor Input is Low normally set if the

371
IATRangeLow IAT temperature sensor wire has shorted to chassis ground or
(37)
the sensor has failed.

IAT_IR_Fault Intake Air Temperature not changing as expected 391

Dither Valve 1 Fault, signal has opened or shorted to ground or 711

LSDFault_Dither1
power or defective dither 1 valve (71)

Dither Valve 2 Fault, signal has opened or shorted to ground or

LSDFault_Dither2 712
power or defective dither 2 valve

Fuel lock off Valve Fault, signal has opened or shorted to

LSDFault_LockOff 717
ground or power or defective Fuel lock off valve

Malfunction Indicator Lamp Fault, signal has opened or shorted

LSDFault_MIL 718
to ground or power or defective MIL lamp
521
LowOilPressureFault Low engine oil pressure
(52)
Manifold Absolute Pressure Sensor Input is High, normally set
if the TMAP pressure signal wire has become shorted to
MAPRangeHigh 342
power, shorted to the IAT signal, the TMAP has failed or the
SECM has failed.
Manifold Absolute Pressure Sensor Input is Low, normally set if
MAPRangeLow the TMAP pressure signal wire has been disconnected or 332
shorted to ground or the circuit has opened to the SECM

Manifold Absolute Pressure Sensor Input is High, normally set

if the TMAP pressure signal wire has become shorted to 341
MAPTimeRangeHigh
power, shorted to the IAT signal, the TMAP has failed or the (34)
SECM has failed
Manifold Absolute Pressure Sensor Input is Low, normally set if
331
MAPTimeRangeLow the TMAP pressure signal wire has been disconnected or
(33)
shorted to ground or the circuit has opened to the SECM

G643(E) Service Manual 257 Chapter 8. Advanced Diagnostics

Table 1. Fault List Definitions (cont’d.)

CODE : G643E
FAULT DESCRIPTION
(CODE : G643)

MAP_IR_HI MAP sensor indicates higher pressure than expected 351

MAP_IR_LO MAP sensor indicates lower pressure than expected 352

MAP_STICKING MAP sensor not changing as expected 353

MediumOverspeed Engine speed has exceeded the second level (2 of 3) of

572
overspeed protection

Pre -catalyst O2 sensor voltage out of range high, sensor

O2RangeHigh 921
signal shorted to power

Pre-catalyst O2 sensor voltage out of range low, sensor signal

O2RangeLow 911
shorted to ground

Post-catalyst O2 sensor voltage out of range high, sensor

O2_PostCatRangeHigh 922
signal shorted to voltage source (5V or battery)

Post -catalyst O2 sensor voltage out of range low, sensor

O2_PostCatRangeLow 912
signal shorted to ground
561
SensVoltRangeHigh Sensor reference voltage XDRP too high
(56)
551
SensVoltRangeLow Sensor reference voltage XDRP too low
(55)
ServiceFault1 Service Interval 1 has been reached 991

ServiceFault2 Service Interval 2 has been reached 992

ServiceFault3 Service Interval 3 has been reached 993

ServiceFault4 Service Interval 4 has been reached 994

ServiceFault5 Service Interval 5 has been reached 995

Engine speed has exceeded first level (1 of 3) of overspeed

SoftOverspeed 573
protection
TPS1AdaptHiMin Learned WOT end of TPS1 sensor range lower than expected 271

541
SysVoltRangeHigh System voltage too high
(54)
531
SysVoltRangeLow System voltage too low
(53)

G643(E) Service Manual 258 Chapter 8. Advanced Diagnostics

Table 1. Fault List Definitions (cont’d.)

CODE : G643E
FAULT DESCRIPTION
(CODE : G643)
251
TPS1AdaptHiMax Learned WOT end of TPS1 sensor range higher than expected
(25)
TPS1AdaptHiMin Learned WOT end of TPS1 sensor range lower than expected 271

Learned closed throttle end of TPS1 sensor range higher than

TPS1AdaptLoMax 281
expected
Learned closed throttle end of TPS1 sensor range lower than 241
TPS1AdaptLoMin
expected (24)
TPS1 sensor voltage out of range high, normally set if the
231
TPS1RangeHigh TPS1 signal has shorted to power or ground for the sensor has
(23)
opened
TPS1 sensor voltage out of range low, normally set if TPS1
221
TPS1RangeLow signal has shorted to ground, circuit has opened or sensor has
(22)
failed

TPS2AdaptHiMax Learned WOT end of TPS2 sensor range higher than expected 252

TPS2AdaptHiMin Learned WOT end of TPS2 sensor range lower than expected 272

Learned closed throttle end of TPS2 sensor range higher than

TPS2AdaptLoMax 282
expected
Learned closed throttle end of TPS2 sensor range lower than
TPS2AdaptLoMin 242
expected
TPS2 sensor voltage out of range high, normally set if the
TPS2RangeHigh TPS2 signal has shorted to power or ground for the sensor has 232
opened
TPS2 sensor voltage out of range low, normally set if TPS2
TPS2RangeLow signal has shorted to ground, circuit has opened or sensor has 222
failed

TPS sensors differ by more than expected amount.

TPS_Sensors_Conflict 291
NOTE: The TPS is not a serviceable item and can only be
repaired by replacing the DV-EV throttle assembly

TransOilTemp Excessive transmission oil temperature 933

G643(E) Service Manual 259 Chapter 8. Advanced Diagnostics

Table 2. Diagnostic Fault Codes (Flash Codes) for G643E

CORRECTIVE ACTION
DFC PROBABLE FAULT FAULT ACTION*
FIRST CHECK
NONE
None, used as end of the fault list
12 Signifies the end of one pass NONE
identification
through the fault list
Check ECT sensor connector and wiring
for a short to GND
ECTRangeLow
141 SECM (Signal) Pin B15 To ECT Pin 3
Coolant Sensor failure or TurnOnMil
(14) SECM (Sensor GND) Pin B1 to
shorted to GND
ECT Pin 1
SECM (Sensor GND) Pin A16, B17

Check if ECT sensor connector is

Check coolant system for radiator

ECTOverTempFault blockage, proper coolant level and for leaks
Engine coolant temperature in the system.
(1) TurnOnMil
is high. The sensor has Possible ECT short to GND, check ECT
161 (2) Delayed Engine
measured an excessive signal wiring
(16) Shutdown
coolant temperature typically SECM (Signal) Pin B15 to ECT Pin 3
(3) CheckEngineLight
due to the engine SECM (Sensor GND) Pin B1 to ECT Pin 1
overheating. SECM (System GND) Pin A16, B17 Check
regulator for coolant leaks
ECT_IR_Fault
Check for coolant system problems, e.g.
171 Engine coolant temperature None
defective or stuck thermostat
not changing as expected

FuelSelectConflict Check fuel select switch connection for a

Conflict in fuel select signals, short to GND
181 normally set if both of the TurnOnMil SECM (SIGNAL) Pin A12
fuel select signals are SECM (SIGNAL) Pin A15
shorted to ground SECM (Sensor GND) Pin B1

Check Crankshaft sensor connections

CrankEdgesFault
SECM (SIGNAL) Pin B5 to Crank sensor
No crankshaft signal when
Pin 3
engine is known to be
193 None SECM (Sensor GND) PIN B1 to Crank
rotating, broken crankshaft
sensor Pin 2
sensor leads or defective
Switched 12V to Crank sensor Pin 1 Check
crank sensor
for defective Crank sensor

CrankSyncFault Check Crankshaft sensor connections

Loss of synchronization on SECM (SIGNAL) Pin B5 to Crank sensor
the crankshaft sensor, Pin 3
194 normally due to noise on the None SECM (Sensor GND) Pin B1 to Crank
signal or an intermittent sensor Pin 2
connection on the crankshaft Switched 12V to Crank sensor Pin 1 Check
sensor for defective Crank sensor

(*) Fault actions shown are default values specified by the OEM.

G643(E) Service Manual 260 Chapter 8. Advanced Diagnostics

Table 2. Diagnostic Fault Codes (Flash Codes) for G643E cont’d.

FAULT CORRECTIVE ACTION

DFC PROBABLE FAULT
ACTION * FIRST CHECK
Check throttle connector connection and
TPS1RangeLow
TPS1 sensor for an open circuit or short to
TPS1 sensor voltage out of range
221 GND
low, normally set if the TPS1 signal TurnOnMil
(22) SECM Pin B23 (signal) to ETC Pin 6 SECM
has shorted to ground, circuit has
Pin B1 (sensor GND) to ETC Pin 2
opened or sensor has failed
SECM (system GND) Pin A16, B17
Check throttle connector connection and
TPS2RangeLow
TPS2 sensor for an open circuit or short to
TPS2 sensor voltage out of range
GND
222 low, normally set if the TPS2 signal TurnOnMil
SECM Pin B4 (signal) to ETC Pin 5
has shorted to ground, circuit has
SECM Pin B1 (sensor GND) to ETC Pin 2
opened or sensor has failed
SECM (system GND) Pin A16, B17
TPS1RangeHigh
Check throttle connector and TPS1 sensor
TPS1 sensor voltage out of range
231 wiring for a shorted circuit
high, normally set if the TPS1 TurnOnMil
(23) SECM Pin B23 (signal) to ETC Pin 6
signal has shorted to power or the
SECM Pin B1 (sensor GND) to ETC Pin 2
ground for the sensor has opened
TPS2RangeHigh
Check throttle connector and TPS1 sensor
TPS2 sensor voltage out of range
wiring for a shorted circuit
232 high, normally set if the TPS2 TurnOnMil
SECM Pin B4 (signal) to ETC Pin 5
signal has shorted to power or the
SECM Pin B1 (sensor GND) to ETC Pin 2
ground for the sensor has opened
Check the throttle connector and pins for
corrosion.
TPS1AdaptLoMin To check the TPS disconnect the throttle
241 Learned closed throttle end of connector and measure the resistance from:
None
(24) TPS1 sensor range lower than TPS Pin 2 (GND) to
expected Pin 6 (TPS1 SIGNAL) (0.7Ω ± 30%)
TPS Pin 3 (PWR) to
Pin 6 (TPS1 SIGNAL) (1.4Ω ± 30%)
Check the throttle connector and pins for
corrosion.
TPS2AdaptLoMin To check the TPS disconnect the throttle
Learned closed throttle end of connector and measure the resistance from:
242 None
TPS2 sensor range lower than TPS Pin 2 (GND) to
expected Pin 5 (TPS2 SIGNAL) (1.3KΩ ± 30%)
TPS PIN 3 (PWR) to
PIN 5 (TPS2 SIGNAL) (0.6KΩ ± 30%)
TPS1AdaptHiMax
251
Learned WOT end of TPS1 sensor None N/A
(25)
range higher than expected
TPS2AdaptHiMax
252 Learned WOT end of TPS2 sensor None N/A
range higher than expected
TPS1AdaptHiMin
271 Learned WOT end of TPS1 sensor None N/A
range lower than expected

(*) Fault actions shown are default values specified by the OEM.

G643(E) Service Manual 261 Chapter 8. Advanced Diagnostics

Table 2. Diagnostic Fault Codes (Flash Codes) for G643E cont’d.

CORRECTIVE ACTION
DFC PROBABLE FAULT FAULT ACTION *
FIRST CHECK
TPS2AdaptHiMin
Learned WOT end of TPS2
272 None N/A
sensor range lower than
expected
TPS1AdaptLoMax
Learned closed throttle end
281 None N/A
of TPS1 sensor range higher
than expected
TPS2AdaptLoMax
Learned closed throttle end
282 None N/A
of TPS2 sensor range higher
than expected
TPS_Sensors_Conflict
TPS sensors differ by more
than expected amount (1) TurnOnMil
291 NOTE: The TPS is not a Perform checks for DFCs 241 & 242
serviceable item and can (2) Engine Shutdown
only be repaired by replacing
the DV-EV throttle assembly.
Check TMAP connector and MAP
signal wiring for an open circuit TMAP
Pin 4 to SECM Pin B18 (signal)
MAPTimeRangeLow TMAP Pin 1 to SECM Pin B1 (sensor
Manifold Absolute Pressure GND)
sensor input is low, normally TMAP Pin 3 to SECM Pin B24 (XDRP
331 set if the TMAP pressure +5 Vdc)
None
(33) signal wire has been Check the MAP sensor by
disconnected or shorted to disconnecting the TMAP connector and
ground or the circuit has measuring at the sensor:
opened to the SECM TMAP Pin 1(GND) to Pin 4 (pressure
signal KPA) (2.4kΩ - 8.2k)
TMAP Pin 3 (power) to Pin 4 (pressure
signal KPA) (3.4kΩ - 8.2k)
Check TMAP connector and MAP
signal wiring for an open circuit TMAP
Pin 4 to SECM Pin B18 (signal)
MAPRangeLow TMAP Pin 1 to SECM Pin B1 (sensor
Manifold Absolute Pressure GND)
sensor input is low, normally TMAP Pin 3 to SECM Pin B24
(1) TurnOnMil
set if the TMAP pressure (XDRP +5 Vdc)
332
signal wire has been Check the MAP sensor by disconnect-
(2) CutThrottle
disconnected or shorted to ing the TMAP connector and
ground or the circuit has measuring at the sensor:
opened to the SECM TMAP Pin 1(GND) to Pin 4 (pressure
signal KPA) (2.4kΩ - 8.2kΩ)
TMAP Pin 3 (power) to Pin 4 (pressure
signal KPA) (3.4k Ω- 8.2kΩ)

(*) Fault actions shown are default values specified by the OEM.

G643(E) Service Manual 262 Chapter 8. Advanced Diagnostics

Table 2. Diagnostic Fault Codes (Flash Codes) for G643E cont’d.

FAULT CORRECTIVE ACTION

DFC PROBABLE FAULT
ACTION * FIRST CHECK
Check TMAP connector and MAP
signal wiring for a shorted circuit
MAPTimeRangeHigh TMAP Pin 4 to SECM Pin B18 (signal)
Manifold Absolute Pressure TMAP Pin 1 to SECM Pin B1 (sensor
Sensor Input is High, GND)
normally set if the TMAP TMAP Pin 3 to SECM Pin B24 (XDRP
341
pressure signal wire has None +5 Vdc) Check the MAP sensor by
(34)
become shorted to power, disconnecting the TMAP connector and
shorted to the IAT signal, the measuring at the sensor:
TMAP has failed or the TMAP Pin 1(GND) to Pin 4 (pressure
SECM has failed. signal KPA) (2.4kΩ - 8.2kΩ)
TMAP Pin 3 (power) to Pin 4 (pressure
signal KPA) (3.4kΩ - 8.2kΩ)
Check TMAP connector and MAP
signal wiring for a shorted circuit
TMAP Pin 4 to SECM Pin B18 (signal)
MAPRangeHigh
TMAP Pin 1 to SECM Pin B1 (sensor
Manifold Absolute Pressure
GND)
Sensor Input is High,
TMAP Pin 3 to SECM Pin B24 (XDRP
normally set if the TMAP (1) TurnOnMil
+5 Vdc)
342 pressure signal wire has
Check the MAP sensor by
become shorted to power, (2) CutThrottle
disconnecting the TMAP connector and
shorted to the IAT signal, the
measuring at the sensor:
TMAP has failed or the
TMAP Pin 1(GND) to Pin 4 (pressure
SECM has failed
signal KPA) (2.4kΩ - 8.2kΩ)
TMAP Pin 3 (power) to Pin 4 (pressure
signal KPA) (3.4kΩ - 8.2kΩ)
MAP_IR_HI Check for vacuum leaks. Check that
351 MAP sensor indicates higher None TMAP sensor is mounted properly.
pressure than expected Possible defective TMAP sensor.
MAP_IR_LO
352 MAP sensor indicates lower None Possible defective TMAP sensor.
pressure than expected
MAP_STICKING Check that TMAP sensor is mounted
353 MAP sensor not changing as None properly. Possible defective TMAP
expected sensor.
Check TMAP connector and IAT signal
wiring for a shorted circuit
IATRangeLow
TMAP Pin 2 to SECM Pin B12 (signal)
Intake Air Temperature
TMAP Pin 1 to SECM Pin B1 (sensor
Sensor Input is Low normally
371 GND)
set if the IAT temperature TurnOnMil
(37) To check the IAT sensor of the TMAP
sensor wire has shorted to
disconnect the TMAP connector and
chassis ground or the sensor
measure the IAT resistance
has failed.
Resistance is approx 2400 ohms at
room temperature.

(*) Fault actions shown are default values specified by the OEM.

G643(E) Service Manual 263 Chapter 8. Advanced Diagnostics

Table 2. Diagnostic Fault Codes (Flash Codes) for G643E cont’d.

CORRECTIVE ACTION,
DFC PROBABLE FAULT FAULT ACTION *
FIRST CHECK
Check TMAP connector and IAT signal
wiring for a shorted circuit
IATRangeHigh
TMAP Pin 2 to SECM Pin B12 (signal)
Intake Air Temperature
TMAP Pin 1 to SECM Pin B1 (sensor
Sensor Input is High normally
381 GND)
set if the IAT temperature TurnOnMil
(38) To check the IAT sensor of the TMAP
sensor wire has been
disconnect the TMAP connector and
disconnected or the circuit
measure the IAT resistance Resistance
has opened to the SECM.
is approx 2400 ohms at room
temperature.
IAT_IR_Fault Check connections to TMAP sensor.
391 Intake Air Temperature not None Check that TMAP sensor is properly
changing as expected mounted to manifold.
Check coil driver wiring and connector
for open circuit
SECM Pin A9 (EST1) to OEM ignition
EST1_Open EST1 system. See application note.
output open, possibly open Verify GND on ignition module Pin A
421 TurnOnMil
EST1 signal or defective (of both connectors)
spark module Verify +12 Vdc on ignition module Pin
B (of both connectors)
Refer to application manual for specific
engine details

Check coil driver wiring and connector

for shorts
SECM Pin A9 (EST1) to ignition
EST1_Short EST1
module Pin D (4-pin connector)
output shorted high or low,
Verify GND on ignition module Pin A
431 EST1 signal shorted to TurnOnMil
(of both connectors) Verify +12
ground or power or defective
Vdc on ignition module Pin B (of both
spark module
connectors)
Refer to application manual for specific
engine details.

(*) Fault actions shown are default values specified by the OEM.

G643(E) Service Manual 264 Chapter 8. Advanced Diagnostics

Table 2. Diagnostic Fault Codes (Flash Codes) for G643E cont’d.

CORRECTIVE ACTION FIRST

DFC PROBABLE FAULT FAULT ACTION *
CHECK
Check for debris or obstructions
ETC_Sticking
inside the throttle body
Electronic Throttle Control is
Check throttle-plate shaft for bearing
sticking. This can occur if the
wear
throttle plate (butterfly valve)
Check the ETC driver wiring for an
inside the throttle bore is sticking. (1)TurnOnMil
open circuit
The plate sticking can be due to
461 SECM Pin A17 to ETC + Pin 1
some type of obstruction, a loose (2) EngineShutdown
(26) SECM Pin A18 to ETC - Pin 4
throttle plate, or worn components
(3)CutThrottle Check the ETC internal motor drive
shaft bearings. NOTE: The throttle
by disconnecting the throttle
assembly is not a serviceable item
connector and measuring the motor
and can only be repaired by
drive resistance at the throttle
replacing the DV-EV throttle
TPS Pin 1 (+DRIVER) to
assembly
Pin 4 (-DRIVER) ~3.0-4.0
Check the ETC driver wiring for an
open circuit SECM Pin A17 to ETC +
ETC_Open_Fault
Pin 1
Electronic Throttle Control Driver
SECM Pin A18 to ETC - Pin 4 Check
has failed, normally set if either of
the ETC internal motor drive by
471 the ETC driver signals have None
disconnecting the throttle connector
opened or become disconnected,
and measuring the motor drive
electronic throttle or SECM is
resistance at the throttle
defective.
TPS Pin 1 (+DRIVER) to Pin 4 (-
DRIVER) ~3.0-4.0
ETCSpringTest
Electronic Throttle Control Driver
has failed, normally set if either of
the ETC driver signals have
opened or become disconnected,
electronic throttle or SECM is
defective.
Electronic Throttle Control Spring
(1) TurnOnMil Perform throttle spring test by
481 Return Test has failed. The SECM
cycling the ignition key and re-check
(28) will perform a safety test of the
(2) EngineShutdown for fault
throttle return spring following
engine shutdown. If this spring
has become weak the throttle will
fail the test and set the fault.
NOTE: The throttle assembly is
not a serviceable item and can
only be repaired by replacing the
DV-EV throttle assembly.

(*) Fault actions shown are default values specified by the OEM.

G643(E) Service Manual 265 Chapter 8. Advanced Diagnostics

Table 2. Diagnostic Fault Codes (Flash Codes) for G643E cont’d.

CORRECTIVE ACTION
DFC PROBABLE FAULT FAULT ACTION *
FIRST CHECK
Check ETC driver wiring for a shorted
HbridgeFault_ETC
circuit
Electronic Throttle Control
SECM Pin A17 to ETC + Pin 1
Driver has failed.
SECM Pin A18 to ETC - Pin 4
Indeterminate fault on
491 Check the ETC internal motor drive by
Hbridge driver for electronic TurnOnMil
(29) disconnecting the throttle connector
throttle control. Possibly
and measuring the motor drive
either ETC+ or ETC- driver
resistance at the throttle
signals have been shorted to
TPS Pin 1 (+DRIVER) to
ground
Pin 4 (-DRIVER) ~3.0-4.0Ω

(1) TurnOnMil
Check engine oil level
521 LowOilPressureFault (2) DelayedEngine Check electrical connection to the oil
(52) Low engine oil pressure Shutdown pressure switch
SECM Pin B9 to Oil Pressure Switch
(3) CheckEngine Light

Check battery voltage

• Perform maintenance check on
electrical connections to the battery
and chassis ground
• Check battery voltage during starting
and with the engine running to verify
531 SysVoltRangeLow charging system and alternator
TurnOnMil
(53) System voltage too low function
• Measure battery power at SECM with
a multimeter (with key on) SECM Pin
A23 (DRVP) to
SECM Pin A16 (DRVG)
SECM Pin A23 (DRVP) to
SECM Pin B17 (DRVG)

Check battery and charging system

voltage
•Check battery voltage during starting
and with the engine running
•Check voltage regulator, alternator,
and charging system
541 SysVoltRangeHigh •Check battery and wiring for
TurnOnMil
(54) System voltage too high overheating and damage
• Measure battery power at SECM with
a multimeter (with key on) SECM Pin
A23 (DRVP) to
SECM Pin A16 (DRVG)
SECM Pin A23 (DRVP) to
SECM Pin B17 (DRVG)

(*) Fault actions shown are default values specified by the OEM.

G643(E) Service Manual 266 Chapter 8. Advanced Diagnostics

Table 2. Diagnostic Fault Codes (Flash Codes) for G643E cont’d.

CORRECTIVE ACTION
DFC PROBABLE FAULT FAULT ACTION *
FIRST CHECK

Measure transducer power at the

TMAP connector with a multimeter
TMAP Pin 3 XDRP +5 Vdc to TMAP
Pin 1 XDRG GND
Verify transducer power at the SECM
SensVoltRangeLow (1) TurnOnMil
551 with a multimeter
Sensor reference voltage
(55) SECM Pin B24 +5 Vdc to SECM Pin
XDRP too low (2) EngineShutdown
B1 XDRG GND Verify transducer
power at ETC with a multimeter
ETC Pin 3 XDRP PWR to ETC Pin 2
XDRG GND Verify transducer power to
the foot pedal with a multimeter.

Measure transducer power at the

TMAP connector with a multimeter
TMAP Pin 3 XDRP +5 Vdc to TMAP
Pin 1 XDRG GND
Verify transducer power at the SECM
SensVoltRangeHigh (1) TurnOnMil with a multimeter
561
Sensor reference voltage SECM Pin B24 +5 Vdc to SECM Pin
(56)
XDRP too high (2) EngineShutdown B1 XDRG GND Verify transducer
power at ETC with a multimeter
ETC Pin 3 XDRP PWR to ETC Pin 2
XDRG GND
Verify transducer power to the foot
pedal with a multimeter.
Usually associated with additional ETC
HardOverspeed
(1) TurnOnMil faults
571 Engine speed has exceeded
Check for ETC Sticking or other ETC
(57) the third level (3 of 3) of
(2) HardRevLimit faults Verify if the lift truck was motored
overspeed protection
down a steep grade
Usually associated with additional ETC
MediumOverspeed
(1) TurnOnMil faults
Engine speed has exceeded
572 Check for ETC Sticking or other ETC
the second level (2 of 3) of
(2) MediumRevLimit faults Verify if the lift truck was motored
overspeed protection
down a steep grade
Usually associated with additional ETC
SoftOverspeed
(1) TurnOnMil faults
Engine speed has exceeded
573 Check for ETC Sticking or other ETC
the first level (1 of 3) of
(2) SoftRevLimit faults Verify if the lift truck was motored
overspeed protection
down a steep grade

APP1RangeLow
APP1 sensor voltage out of
(1) TurnOnMil
611 range low, normally set if the Check foot pedal connector
(61) APP1 signal has shorted to Check APP1 signal at SECM PIN B7
(2) CheckEngineLight
ground, circuit has opened or
sensor has failed

(*) Fault actions shown are default values specified by the OEM.

G643(E) Service Manual 267 Chapter 8. Advanced Diagnostics

Table 2. Diagnostic Fault Codes (Flash Codes) for G643E cont’d.

CORRECTIVE ACTION
DFC PROBABLE FAULT FAULT ACTION *
FIRST CHECK
APP2RangeLow
APP2 sensor voltage out of range
Check foot pedal connector
612 low, normally set if the APP2
TurnOnMil • Check APP2 signal at SECM PIN
(65) signal has shorted to ground,
B16
circuit has opened or sensor has
failed
APP1RangeHigh
APP1 sensor voltage out of range (1) TurnOnMil
621 Check foot pedal connector
high, normally set if the APP1
(62) • Check APP1 signal at SECM PIN B7
signal has shorted to power or the (2) CheckEngine Light
ground for the sensor has opened
APP2RangeHigh
APP2 sensor voltage out of range Check foot pedal connector
622
high, normally set if the APP2 TurnOnMil • Check APP2 signal at SECM PIN
(66)
signal has shorted to power or the B16
ground for the sensor has opened
Check APP connector and pins for
APP1AdaptLoMin
631 corrosion
Learned idle end of APP1 sensor None
(63) • Cycle the pedal several times and
range lower than expected
check APP1 signal at SECM Pin B7
Check APP connector and pins for
APP2AdaptLoMin
632 corrosion
Learned idle end of APP2 sensor None
(67) • Cycle the pedal several times and
range lower than expected
check APP2 signal at SECM Pin B16
APP1AdaptHiMax
641 Learned full pedal end of APP1
None N/A
(64) sensor range higher than
expected
APP2AdaptHiMax
642 Learned full pedal end of APP2
None N/A
(68) sensor range higher than
expected
APP1AdaptHiMin
651 Learned full pedal end of APP1 None N/A
sensor range lower than expected
APP2AdaptHiMin
652 Learned full pedal end of APP2 None N/A
sensor range lower than expected
APP1AdaptLoMax
661 Learned idle end of APP1 sensor None N/A
range higher than expected
APP2AdaptLoMax
662 Learned idle end of APP2 sensor None N/A
range higher than expected
Check APP connector and pins for
APP_Sensors_Conflict
corrosion
APP position sensors do no not (1) TurnOnMil
691 • Cycle the pedal several times and
track well, intermittent connections
(69) check APP1 signal at SECM Pin B7
to APP or defective pedal (2) Level1PowerLimit
• Cycle the pedal several times and
assembly
check APP2 signal at SECM Pin B16

(*) Fault actions shown are default values specified by the OEM.

G643(E) Service Manual 268 Chapter 8. Advanced Diagnostics

Table 2. Diagnostic Fault Codes (Flash Codes) for G643E cont’d.

CORRECTIVE ACTION
DFC PROBABLE FAULT FAULT ACTION *
FIRST CHECK
Check FTV1 for an open wire or FTV
connector being disconnected FTV1
LSDFault_Dither1
Pin 1 (signal) to SECM Pin A1
Dither Valve 1 Fault, signal
711 FTV1 Pin 2 (power) to SECM (DRVP)
has opened or shorted to TurnOnMil
(71) Pin A23 Check
ground or power or defective
FTV1 for an open coil by disconnecting
dither 1 valve
the FTV connector and measuring the
resistance (~26 Ω ± 2 Ω )
Check FTV1 for an open wire or FTV
connector being disconnected or signal
LSDFault_Dither2 shorted to GND
Dither Valve 2 Fault, signal FTV2 Pin 1 (signal) to SECM Pin A2
712 has opened or shorted to TurnOnMil FTV2 Pin 2 (power) to SECM (DRVP)
ground or power or defective Pin A23 Check
dither 2 valve FTV1 for an open coil by disconnecting
the FTV connector and measuring the
resistance (~26 Ω ± 2 Ω )

LSDFault_CheckEngine
Check Engine Lamp Fault,
Check ‘Check Engine Lamp’ for an
714 signal has opened or shorted None
open wire or shorted to GND
to ground or power or
defective check engine lamp

LSDFault_CrankDisable
Crank Disable Fault, signal
715 has opened or shorted to None N/A
ground or power or defective
crank disable relay

Check fuel lock off valve for an open

wire or connector being disconnected
LSDFault_LockOff or signal shorted to GND
Fuel lock off Valve Fault, Lockoff Pin B (signal) to SECM Pin
717 signal has opened or shorted TurnOnMil A11 Lockoff Pin A (power) to SECM
to ground or power or (DRVP) Pin A23 Check CSV for an
defective Fuel lock off valve open coil by disconnecting the CSV
connector and measuring the
resistance (~26 Ω ± 3 Ω)

LSDFault_MIL
Malfunction Indicator Lamp
Check MIL lamp for an open wire or
718 Fault, signal has opened or None
short to GND.
shorted to ground or power
or defective MIL lamp
GasFuelAdaptRangeLo
Check for vacuum leaks. Check fuel
721 In LPG mode, system had to
TurnOnMil trim valves, e.g. leaking valve or hose
(72) adapt rich more than
Check for missing orifice(s).
expected

(*) Fault actions shown are default values specified by the OEM.

G643(E) Service Manual 269 Chapter 8. Advanced Diagnostics

Table 2. Diagnostic Fault Codes (Flash Codes) for G643E cont’d.

CORRECTIVE ACTION
DFC PROBABLE FAULT FAULT ACTION *
FIRST CHECK
GasFuelAdaptRangeHi
Check fuel trim valves, e.g. plugged
731 In LPG mode, system had
TurnOnMil valve or hose. Check for plugged
(73) to adapt lean more than
orifice(s).
expected
Check that Pre-catalyst O2 sensor
connections are OK.
O2 (signal) Pin 3 to SECM Pin B13 O2
GasO2NotActive Pin 2 (HEATER GND) to SECM
Pre-catalyst O2 sensor (DRVG GNG)
(1) TurnOnMil
741 inactive on LPG, open O2 Pins A16, B17 O2 Pin 1 (HEATER
(74) sensor signal or heater PWR) to SECM (DRVP + 12V) Pin A23
(2) DisableGas O2Ctrl
leads, defective O2 Verify O2 sensor heater circuit is
sensor operating by measuring heater
resistance (2.1 Ω ± 0.4 Ω) O2 Pin 2
(HEATER GND) to Pin 1 (HEATER
PWR)
Check that Post-catalyst O2 sensor
connections are OK.
O2 (signal) Pin 3 to SECM Pin B19
O2 Pin 2 (HEATER GND) to SECM
(DRVG GNG) Pins A16, B17
O2 Pin 1 (HEATER PWR) to Post O2
Heater Relay. Relay pin 87. This relay
only turns on after engine has been
GasPostO2NotActive running for some time and SECM has
Post-catalyst O2 sensor calculated that water condensation in
(1) TurnOnMil
inactive on LPG, open O2 exhaust has been removed by exhaust
742
sensor signal or heater heat. Post O2 Heater Relay has SECM
(2) DisableGasPost O2Ctrl
leads, defective O2 (DRVP + 12V) applied to the relay coil
sensor. power. The relay coil ground is
controlled by SECM Pin A20 to activate
the relay to flow current through the
post O2 heater.
Verify O2 sensor heater circuit is
operating by measuring heater
resistance (2.1 Ω ± 0.4 Ω)
O2 Pin 2 (HEATER GND) to Pin 1
(HEATER PWR)
743 Reserved
GasO2FailedLean
(1) TurnOnMil Check for vacuum leaks. Check fuel
Pre-catalyst O2 sensor
751 trim valves, e.g. leaking valve or hose.
indicates extended lean
(2) DisableGas O2Ctrl Check for missing orifice(s).
operation on LPG
Correct other faults that may contribute
to 752 (e.g. faults pertaining to dither
valves, Pre-Cat O2, Post Cat O2
GasPostO2FailedLean
(1) TurnOnMil sensor)
Pre-catalyst O2 sensor
752 Check for vacuum leaks
indicates extended lean
(2) DisableGasPost O2Ctrl Check for leaks in exhaust, catalytic
operation on LPG
converter, HEGO sensors; repair leaks.
Check all sensor connections (see fault
742 corrective actions).
(*) Fault actions shown are default values specified by the OEM.

G643(E) Service Manual 270 Chapter 8. Advanced Diagnostics

Table 2. Diagnostic Fault Codes (Flash Codes) for G643E cont’d.

CORRECTIVE ACTION
DFC PROBABLE FAULT FAULT ACTION *
FIRST CHECK

GasO2FailedRich
(1) TurnOnMil Check fuel trim valves, e.g. plugged
771 Pre-catalyst O2 sensor
valve or hose.
(77) indicates extended rich
(2) DisableGas O2Ctrl Check for plugged orifice(s).
operation on LPG

Correct other faults that may

contribute to 772 (e.g. faults pertaining
to FTVs, Pre-Cat O2, Post Cat O2
GasPostO2FailedRich
(1) TurnOnMil sensor)
Pre-catalyst O2 sensor
772 Look for leaks in exhaust, catalytic
indicates extended rich
(2) DisableGasPostO2Ctrl converter, HEGO sensors; repair
operation on LPG
leaks.
Check all sensor connections (see
fault 742 corrective actions).

Check if O2 sensor installed before

O2RangeLow (1) TurnOnMil
the catalyst is shorted to GND or
Pre-catalyst O2 sensor
sensor GND.
911 voltage out of range low, (2) DisableLiquid O2Ctrl
O2 (signal) Pin 3 to SECM Pin B13
sensor signal shorted to
(3) DisableGas O2Ctrl SECM (DRVG GND) Pins A16, B17
ground
SECM (XDRG sensor GND) Pin B1

(1) TurnOnMil Check if O2 installed after the catalyst

O2_PostCatRangeLow sensor is shorted to GND or sensor
Post-catalyst O2 sensor (2) Disable Gasoline Post GND.
912 voltage out of range low, catalyst O2Ctrl O2 (signal) Pin 3 to SECM Pin B19
sensor signal shorted to Possible sources: SECM (DRVG
ground (3) Disable LPG Post GND) Pins A16, B17 and SECM
catalyst O2Ctrl (XDRG sensor GND) Pin B1

O2RangeHigh (1) TurnOnMil Check if O2 sensor installed before

Pre-catalyst O2 sensor catalyst is shorted to +5Vdc or battery.
921 voltage out of range high, (2) DisableLiquid O2Ctrl O2 (signal) Pin 3 to SECM Pin B13
sensor signal shorted to SECM (XDRP + 5V) Pin B24
power (3) DisableGas O2Ctrl SECM (DRVP + 12V) Pin A23

(1) TurnOnMil
Check if O2 sensor installed after
O2_PostCatRangeHigh
catalyst is shorted to +5Vdc or battery.
Post-catalyst O2 sensor (2) Disable Gasoline Post
O2 (signal) Pin 3 to SECM Pin B19
922 voltage out of range low, catalyst O2Ctrl
Possible voltage sources: SECM
sensor signal shorted to
(XDRP + 5V) Pin B24 and SECM
ground (3) Disable LPG Post
(DRVP + 12V) Pin A23
catalyst O2Ctrl

(*) Fault actions shown are default values specified by the OEM.

G643(E) Service Manual 271 Chapter 8. Advanced Diagnostics

Table 2. Diagnostic Fault Codes (Flash Codes) for G643E cont’d.

CORRECTIVE ACTION
DFC PROBABLE FAULT FAULT ACTION *
FIRST CHECK

FuelTempRangeLow
Check fuel temp sensor connector and
Fuel Temperature Sensor
wiring for a short to GND
Input is Low normally set
SECM (signal) Pin B14 to FTS Pin 1
931 if the fuel temperature TurnOnMil
SECM (sensor GND) Pin B1 to FTS
sensor wire has shorted
Pin 2
to chassis ground or the
SECM (system GND) Pin A16, B17
sensor has failed.

FuelTempRangeHigh
Fuel Temperature Sensor Check if fuel temp sensor connector is
Input is High normally set disconnected or for an open FTS
if the fuel temperature circuit
932 TurnOnMil
sensor wire has been SECM (signal) Pin B14 to FTS Pin 1
disconnected or the SECM (sensor GND) Pin B1 to FTS
circuit has opened to the Pin 2
SECM.

(1) TurnOnMil
TransOilTemp
Refer to drivetrain manufacturer’s
933 Excessive transmission
(2) Delayed transmission service procedures
oil temperature
EngineShutdown

ServiceFault1 Perform service procedure related to

991 Service Interval 1 has None Service Interval 1 (determined by
been reached OEM)
ServiceFault2 Perform service procedure related to
992 Service Interval 2 has None Service Interval 2 (determined by
been reached OEM)
ServiceFault3 Perform service procedure related to
993 Service Interval 3 has None Service Interval 3 (determined by
been reached OEM)
ServiceFault4
Service Interval 4 has Replace Pre-catalyst HEGO sensor
994 TurnOnMil
been reached—replace Replace Post-catalyst HEGO sensor
HEGO sensors

ServiceFault5
Service Interval 5 has
995 TurnOnMil Replace engine timing belt
been reached—replace
timing belt

(*) Fault actions shown are default values specified by the OEM.

G643(E) Service Manual 272 Chapter 8. Advanced Diagnostics

Table 3. Diagnostic Fault Codes (Flash Codes) for G643.

CORRECTIVE ACTION
DFC PROBABLE FAULT FAULT ACTION
FIRST CHECK

NONE: Signifies the end of None, used as a beginning and end of

12 NONE
one pass through the fault list the fault list identification

Check ECT sensor connector and wiring

ECTSensorInputLow
Stored Fault Code for a short to GND
14 Coolant sensor failure or
(MIL Only) SECM (SIGNAL) PIN 16 to ECT PIN A
shorted to GND
SECM (GND) PIN 1 to ECT PIN B

Check if ECT sensor connector is

ECTSensorInputHigh
Stored Fault Code disconnected or for an open ECT circuit
15 Coolant sensor disconnected
(MIL Only) SECM (SIGNAL) PIN 16 to ECT PIN A
or open circuit
SECM (GND) PIN 1 to ECT PIN B

Check coolant system for radiator

blockage, proper coolant level and for
leaks in the system. Possible ECT short
ECTRangeHigh Delayed Engine
16 to GND, check ECT signal wiring
Engine Overheating Shutdown
SECM (SIGNAL) PIN 16 to ECT PIN A
SECM (GND) PIN 1 to ECT PIN B
• Check regulator for coolant leaks

ThrottleSensorInputLo
TPS1 signal disconnected or Check throttle connector connection and
open circuit TPS1 sensor for an open circuit
22 Disable Throttle
(Expected faults when ETC ETC PIN 6 to SECM PIN 17 (SIGNAL)
connector is unplugged ETC PIN 2 to SECM PIN 1 (GND)
CODES: 22 & 24)
Check throttle connector and TPS1
ThrottleSensorInputHi
sensor wiring for a shorted circuit
23 TPS1 sensor failure or shorted Disable Throttle
ETC PIN 6 to SECM PIN 17 (SIGNAL)
circuit
ETC PIN 2 to SECM PIN 1 (GND)

Check the throttle connector and pins

for corrosion.
• Perform Throttle test with the Service
Tool several times to clean sensor
ThrottleSensorRangeLo
To check the TPS disconnect the
TPS1 potentiometer
Stored Fault Code throttle connector and measure the
24 malfunction. mproper TPS resistance (1.25KΩ +/-30%) from:
(MIL Only)
reading may be due to dirt or TPS PIN 2 (GND) to PIN 6 (TPS1
oxidation on the sensor traces. SIGNAL)
TPS PIN 3 (PWR) to PIN 6 (TPS1
SIGNAL)
See Chapter 5 for sensor checks

G643(E) Service Manual 273 Chapter 8. Advanced Diagnostics

Table 3. Diagnostic Fault Codes (Flash Codes) for G643 cont’d.

CORRECTIVE ACTION
DFC PROBABLE FAULT FAULT ACTION
FIRST CHECK
Check the throttle connector and pins
for corrosion.
• Perform throttle test with the Service
Tool several times to clean sensor
ThrottleSensorRangeHi
To check the TPS disconnect the
TPS1 potentiometer
Stored Fault Code throttle connector and measure the
25 malfunction. Improper TPS
(MIL Only) resistance (1.25KΩ +/-30%) from :
reading may be due to dirt or
TPS PIN 2 (GND) to PIN 6 (TPS1
oxidation on the sensor traces.
SIGNAL)
TPS PIN 3 (PWR) to PIN 6 (TPS1
SIGNAL)
See Chapter 5 for sensor checks
Check for debris or obstructions inside
the throttle body
• Perform the throttle test using the
Service Tool and re-check for fault
• Check throttle-plate shaft for bearing
wear
ETCSticking Check the ETC driver wiring for an open
Throttle plate sticking inside Engine Shutdown circuit
26
the throttle body or the ETC ETC+ PIN 1 to SECM PIN 22
driver signal is open ETC-PIN 4 to SECM PIN 24
Check the ETC internal motor drive by
disconnecting the throttle connector and
measuring the motor drive resistance at
the throttle
TPS PIN 1 (+DRIVER) to PIN 4
(-DRIVER) ~3.0Ω+/-30%

PredictedTPS
Difference
Check for manifold leaks between the
27 Measured TPS1 is different Engine Shutdown
throttle and the engine
than SECM Calculated throttle
position

ETCSpringTestFailed
Upon initial key-up the internal Perform throttle spring test by cycling
28 Power Limit
throttle return spring has the ignition key and re-check for fault
become weak
Check ETC driver wiring for a shorted
circuit
ETC+ PIN1 to SECM PIN 22
ETC- PIN 4 to SECM PIN 24
ETCDriverFault • Perform throttle test using Service
Tool and re-check for fault
29 Throttle driver over-current or Disable Throttle
Check the ETC internal motor drive by
driver signals shorted
disconnecting the throttle connector and
measuring the motor drive resistance at
the throttle
TPS PIN 1 (+DRIVER) to PIN 4
(-DRIVER) ~3.0Ω +/-30%

G643(E) Service Manual 274 Chapter 8. Advanced Diagnostics

Table 3. Diagnostic Fault Codes (Flash Codes) for G643 cont’d.

CORRECTIVE ACTION
DFC PROBABLE FAULT FAULT ACTION
FIRST CHECK
Check SECM chassis ground and
31 RunningResetCnt Engine Shutdown ignition harness for cracked insulation.
Check battery voltage and connections.

Check TMAP connector and MAP signal

wiring for an open circuit
TMAP PIN 4 to SECM PIN 5(SIGNAL)
TMAP PIN 1 to SECM PIN 1 (GND)
MapSensorInputLow TMAP PIN 3 to SECM PIN 18
MAP signal disconnected, (XDCR +5VDC)
open circuit or sensor Check the MAP sensor by
33 malfunction Disable Throttle disconnecting the TMAP connector and
(Expected faults when TMAP measuring at the sensor
connector is unplugged TMAP PIN 1(GND) to PIN 4
CODES: 33 & 38) (PRESSURE SIGNAL KPA)
(2.4kΩ- 8.2kΩ)
TMAP PIN 3(PWR) to PIN 4
(PRESSURE SIGNAL KPA)
(3.4kΩ- 8.2kΩ)

Check TMAP connector and MAP signal

wiring for a shorted circuit
TMAP PIN 4 to SECM PIN 5 (SIGNAL)
TMAP PIN 1 to SECM PIN 1 (GND)
TMAP PIN 3 to SECM PIN 18
(XDCR +5VDC)
MapSensorInputHigh Check the MAP sensor by
34 TMAP sensor failure or Disable Throttle disconnecting the TMAP connector and
shorted circuit measuring at the sensor
TMAP PIN 1(GND) to PIN 4
(PRESSURE SIGNAL KPA)
(2.4kΩ- 8.2kΩ)
TMAP PIN 3(PWR) to PIN 4
(PRESSURE SIGNAL KPA)
(3.4kΩ- 8.2kΩ)

Check TMAP connector and IAT signal

wiring for a shorted circuit
TMAP PIN 2 to SECM PIN 4 (SIGNAL)
TMAP PIN 1 to SECM PIN 1 (GND
IATSensorInputLow
Stored Fault Code TMAP PIN 3 to SECM PIN 18
37 TMAP sensor failure or
(MIL Only) (XDCR +5VDC)
shorted circuit
To check the IAT sensor of the TMAP
disconnect the TMAP connector and
measure the IAT resistance
See the IAT table in Chapter 5

G643(E) Service Manual 275 Chapter 8. Advanced Diagnostics

Table 3. Diagnostic Fault Codes (Flash Codes) for G643 cont’d.

CORRECTIVE ACTION
DFC PROBABLE FAULT FAULT ACTION
FIRST CHECK

Check TMAP connector and IAT signal

wiring for an open circuit
TMAP PIN 2 to SECM PIN 4 (SIGNAL)
TMAP PIN 1 to SECM PIN 1 (GND)
IATSensorInputHigh
Stored Fault Code TMAP PIN 3 to SECM PIN 18
38 IAT signal disconnected, open
(MIL Only) (XDCR +5VDC)
circuit or sensor malfunction
To check the IAT sensor of the TMAP
disconnect the TMAP connector and
measure the IAT resistance
See the IAT table in Chapter 5

Check coil driver wiring and connector

for shorts
SECM PIN 7(EST1) to IGNITION
MODULE PIN D (4-PIN CONNECTOR)
VERIFY GND ON IGNITION MODULE
PIN A (OF BOTH CONNECTORS)
EST1Low
Stored Fault Code VERIFY +12VDC ON IGNITION
42 Coil driver signal low or under-
(MIL Only) MODULE PIN B (OF BOTH
current
CONNECTORS)
To check the Ignition module internal
circuit disconnect both connectors and
measure the resistance from pin to pin
See Ignition Module resistance check in
Chapter 4

Check coil driver wiring and connector

for open circuit
SECM PIN 7(EST1) to IGNITION
MODULE PIN D (4-PIN CONNECTOR)
VERIFY GND ON IGNITION MODULE
PIN A (OF BOTH CONNECTORS)
EST1High
Stored Fault Code VERIFY +12VDC ON IGNITION
43 Coil driver signal high or over-
(MIL Only) MODULE PIN B (OF BOTH
current
CONNECTORS)
To check the Ignition module internal
circuit disconnect both connectors and
measure the resistance from pin to pin
See Ignition Module resistance check in
Chapter 4

G643(E) Service Manual 276 Chapter 8. Advanced Diagnostics

Table 3. Diagnostic Fault Codes (Flash Codes) for G643 cont’d.

CORRECTIVE ACTION
DFC PROBABLE FAULT FAULT ACTION
FIRST CHECK
Check engine oil level
Check electrical connection to the oil
LowOilPressure Delayed Engine
52 pressure switch
Low Engine Oil Pressure Shutdown
SECM PIN 23 TO OIL PRESSURE
SWITCH

Check battery voltage

• Perform maintenance check on
electrical connections to the battery
and chassis ground
• Check battery voltage during starting
BatterySensorInputLow
Stored Fault Code and with the engine running to verify
53 Battery voltage measured
(MIL Only) charging system and alternator
below +8.0 Vdc
function
Measure battery power at the SECM
with a multimeter
SECM PIN 13 (BATT +) to SECM PIN
14 (BATT -)

Check battery and charging system

voltage
• Check battery voltage during starting
and with the engine running
• Check voltage regulator, alternator
BatterySensorInputHigh
Stored Fault Code and charging system
54 Battery voltage measured
(MIL Only) • Check battery and wiring for
above +15.9 Vdc
overheating and damage
• Measure battery power at the SECM
with a multimeter
SECM PIN 13 (BATT +) to SECM PIN
14 (BATT -)

Measure transducer power at the TMAP

connector with a multimeter
TMAP PIN 3 +5VDC to TMAP PIN 1
XDRPSensorInputLow XDCR GND
+5Vdc Transducer power Verify transducer power at the SECM
supplied by the SECM to the with a multimeter
sensors is below +4.60Vdc SECM PIN 18 +5VDC to SECM PIN 1
55 Engine Shutdown
(Expected faults when XDCR GND
Transducer power is lost Verify transducer power at ETC with a
CODES: 22, 24, 33, 62, 64, multimeter
66, 68 & 69) ETC PIN 3 XDCR PWR to ETC PIN 2
XDCR GND
Verify transducer power to the foot
pedal with a multimeter

G643(E) Service Manual 277 Chapter 8. Advanced Diagnostics

Table 3. Diagnostic Fault Codes (Flash Codes) for G643 cont’d.

CORRECTIVE ACTION
DFC PROBABLE FAULT FAULT ACTION
FIRST CHECK

Measure transducer power at the TMAP

connector with a multimeter
TMAP PIN 3 +5VDC to TMAP PIN 1
XDCR GND
Verify transducer power at the SECM
XDRPSensorInputHigh with a multimeter
+5Vdc Transducer power SECM PIN 18 +5VDC to SECM PIN 1
56 Engine Shutdown
supplied by the SECM to the XDCR GND
sensors is above +5.20Vdc Verify transducer power at ETC with a
multimeter
ETC PIN 3 XDCR PWR to ETC PIN 2
XDCR GND
Verify transducer power to the foot
pedal with a multimeter

Usually associated with additional ETC

Engine OverSpeed faults
Engine RPM increased • Check for ETC Sticking or other
57 Engine Shutdown
beyond maximum RPM set ETC faults
point • Verify if the lift truck was motored
down a steep grade

Pedal1SensorInputLo
APP1 signal disconnected,
open circuit or sensor
Check foot pedal connector
61 malfunction MIN Power Limit
• Check APP1 signal at SECM PIN 15
(Expected faults when APP
connector is unplugged
CODES: 61 & 66)

Pedal1SensorInputHi
Check foot pedal connector
62 APP1 sensor failure or shorted MIN Power limit
• Check APP1 signal at SECM PIN 15
circuit
Pedal1SensorRangeLo
APP1 potentiometer Check foot pedal connector
Stored Fault Code
63 malfunction. Improper APP1 • Cycle the pedal several times and
(MIL Only)
reading may be due to dirt or check APP1 signal at SECM PIN 15
oxidation on the sensor traces.
Pedal1SensorRangeHi
APP1 potentiometer Check foot pedal connector
Stored Fault Code
64 alfunction. Improper APP1 • Cycle the pedal several times and
(MIL Only)
reading may be due to dirt or check APP1 signal at SECM PIN 15
oxidation on the sensor traces

Pedal2SensorInputLo Check foot pedal connector

65 APP2 sensor failure or shorted MIN power Limit • Cycle the pedal several times and
circuit check APP2 signal at SECM PIN 2

G643(E) Service Manual 278 Chapter 8. Advanced Diagnostics

Table 3. Diagnostic Fault Codes (Flash Codes) for G643 cont’d.

CORRECTIVE ACTION
DFC PROBABLE FAULT FAULT ACTION
FIRST CHECK
Pedal2SensorInputHi
APP2 signal disconnected,
open circuit or sensor
Check foot pedal connector
66 malfunction MIN power Limit
• Check APP2 signal at SECM PIN 2
(Expected faults when APP
connector is unplugged
CODES: 61 & 66)
Pedal2SensorRangeLo
APP2 potentiometer Check foot pedal connector
Stored Fault Code
67 malfunction. Improper APP2 • Cycle the pedal several times and
(MIL Only)
reading may be due to dirt or check APP2 signal at SECM PIN 2
oxidation on the sensor traces.

Pedal2SensorRangeHi
APP2 potentiometer Check foot pedal connector
Stored Fault Code
68 malfunction. Improper APP2 • Cycle the pedal several times and
(MIL Only)
reading may be due to dirt or check APP2 signal at SECM PIN 2
oxidation on the sensor traces.

Pedal1ToPedal2
Check foot pedal connector
Difference
• Cycle the pedal several times and
69 Measured APP2 pedal position MIN power Limit
check APP1 signal at SECM PIN 15
signal is different than APP1
• Check APP2 signal at SECM PIN 2
signal

G643(E) Service Manual 279 Chapter 8. Advanced Diagnostics

Appendix
Service Tool Software Kit
Service Tool Software
(MotoView) Service tool software kit consists of USB-CAN
converter, Service tool software (MotoView) and
Introduction Extension cable.

The MI-07 Service Tool is a graphic interface to the

SECM (Small Engine Control Module) and is made
up of several screens to aid the technician in system
diagnostics using a personal computer. The
software application that is used to connect to the
SECM is MotoView and is described in the next
section. Once MotoView is connected to the SECM
through the CAN cable a display file is opened
(MI_07RevJ.dis) to display the available diagnostic
features. The use of these features is described in
Appendix.

A408026
USB (Universal Serial Bus) to CAN (Controller Area
Network) Converter Assembly

Figure 1. Opening MotoView Software

A343080
Service Tool Software (includes CD and Crypt
Token (License Dongle))

Figure 2. Display File of Available Diagnostic

Features

G643(E) Service Manual 280 Appendix

Figure 4. Crypt Token Installed on Laptop
A334071
Extension Cable (L=200 cm)

A334082
Extension Cable (L=20 cm)

Connection of the Service Tool

To use the Service Tool, a USB (Universal Serial

Bus) to CAN (Controller Area Network)
communication adapter by KVaser will be required
along with a Crypt Token (Figure 3). The Crypt
Token acts as a security key allowing the laptop to
retrieve the necessary data from the SECM.
Figure 5. Opening the Service Tool Display
1. Install the Crypt Token in an available USB port in
the computer (Figure 4).

2. With the ignition key in the OFF position, connect

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 (Figure 5).

Figure 3. KVaser Communication Adapter

G643(E) Service Manual 281 Appendix

MotoView Display Screens

Service Screen Tab

The first screen displayed when connecting to the

SECM-48 is the Main Service Screen. The screen
format is designed to give the technician a quick
reference to the state of the MI-07 system and the
engine. Main sections of this screen include the
Engine category, Faults, Fault States, AFR Control,
Sensors, Throttle, Accelerator Pedal, and Ignition.

Figure 6 Main Service Screen

Engine

This category displays the engine RPM, one of three engine states (Stall, Crank, Run) and the selected fuel
type. Engine run hours are also displayed in this category directly below the engine state. If the LPG fuel lock
off or liquid fuel pump is active the adjacent data box will display a “1” meaning the device is on and the data
box will turn green. Brief parameter notes are listed to the right of the parameter filed throughout the display
screens. The indicated Torque parameter will inform you as to the amount of load placed on the engine and
the Ground Speed Switch parameter displays the switch on or off, again the box will turn green if the switch is
closed. The engine category also displays the status of the post O2 sensor heater replay and the cold start
circuit.

G643(E) Service Manual 282 Appendix

AFR (Air Fuel Ratio) Control

The AFR Control category is divided into two

separate sections, one for LP and a second for
Gasoline, (active on bi-fuel units). Key parameters
for AFR Control include the “Open-Loop”/ “Closed-
Loop” control listing. This description informs the
technician whether the emission system is using
closed loop feedback from the oxygen sensors to Figure 7 Clearing Faults
control the AFR delivered to the exhaust catalyst or
using tables in the engine control module for AFR Sensors
control in open loop mode.
Key sensor values are displayed in this category.
Both the pre catalyst (pre-CAT) and post catalyst Oxygen sensor values have been converted to
(post-CAT) oxygen sensor setpoint values are voltage for easier troubleshooting using a multi-
displayed in Phi along with adaptive learn values. meter. ECT (Engine Coolant Temperature) will turn
When in LP mode the FTV (Fuel Trim Valves) duty green when the correct engine operating
cycle is displayed in percent. If the system is running temperature is reached (75°C [167°F]).
rich in closed loop, the duty cycle will increase to
lean out the LP mixture to the engine. When in Throttle
Gasoline operation the average fuel injector pulse
width is displayed along with each individual fuel The throttle category displays the throttle setpoint,
injector signal. which is the value the SECM is trying to control the
throttle to. TPS (Throttle Position Sensor) 1 & 2
Faults values are also displayed in percent.

A brief fault list is displayed in the Fault category. Accelerator Pedal

Active faults display the description of all active
faults—faults that are actively taking place when APP (Accelerator Pedal Position sensor) 1&2 values
connected to the SECM. Occurred faults display the are displayed in percent.
description of all stored faults. The first five stored
faults of the ten possible fault stored record are Ignition
displayed by the three digit fault codes. Definitions
of these fault codes can be located on the DFC Camshaft and crankshaft sensor synchronization is
screens. displayed along with a designator for the spark
enable and the actual spark dwell.
Fault States

Suspected possible faults are displayed here.

(These may be redundant of the occurred fault list.)
All faults can be cleared from the Clear Faults pull
down parameter. Place your mouse pointer over the
Clear Fault parameter box, then simply click the pull
down arrow and select the Arm option. You have
now armed the clear fault function. Using your
mouse click the pull down arrow again and select
the ClearFaults option. You must select another
area on the screen by clicking that area with your
mouse to complete the Clear Faults function; you
will then see all faults clear. Any faults that are
active will immediately be stored in the fault record.
Different fault actions such as engine shutdown are
also listed in this category. Any fault that causes one
of these actions will be displayed next to the action
itself. Only one fault at a time will be displayed next
to the fault action.

G643(E) Service Manual 283 Appendix

Faults Screen Tab

The second available screen in the service tool display is the Fault screen. All ten stored fault codes are
displayed in order of their occurrence. If a fault occurs and is stored it will not be stored again in the fault
record until the fault has been cleared. This prevents the same re-occurring fault from being saved to all the
stored records. Stored faults do not contain any type of date or time stamp to indicate when they occurred.

Figure 8. Faults Screen

Faults

Faults are displayed in the Fault category. Active faults display the description of all active faults, faults that
are actively taking place when connected to the SECM. Occurred faults displays the description of all stored
faults. The ten stored fault records are displayed by the three digit fault codes. Definitions of these fault codes
can be located on the DFC screens.

Fault States

Suspected possible faults are displayed here. (These may be redundant of the occurred fault list.) All faults
can be cleared from the Clear Faults pull down parameter. Place your mouse pointer over the Clear Fault
parameter box, then simply click the pull down arrow and select the Arm option (Figure 7). You have now
armed the clear fault function. Using your mouse click the pull down arrow again and select the ClearFaults
option. You must select another area on the screen by clicking that area with your mouse to complete the
Clear Faults function; you will then see all faults clear. Any faults that are active will immediately be stored in
the fault record. Different fault actions such as engine shutdown are also listed in this category. Any fault that
causes one of these actions will be displayed next to the action itself. Only one fault at a time will be displayed
next to the fault action.

Fault Action

A list of possible fault actions is provided. Any fault that may induce one of these actions will be displayed next
to the action.

G643(E) Service Manual 284 Appendix

Ground Speed Screen Tab

The Ground Speed screen displays parameters for the ground speed option. The Engine category of this
screen gives the technician a quick reference of the engine state when making setpoint changes without
having to switch screens. See the Service Screen display definitions for parameter explanations. If not used
the Ground Speed Switch indicator will be open and the High Max RPM setpoint will still be active. See below
for description.

Figure 9. Ground Speed Screen

Ground Speed RPM Setpoints

The ground speed RPM setpoints are active values used by the SECM. Simply highlight these values and
enter a new value from your laptop computer. These values will be saved and used by the SECM even after
disconnecting from the SECM and closing the display screen. If the ground switch input is closed (grounded),
the Switched MAX RPM value will be used by the SECM as the maximum RPM. If the ground switch is open
or not used, the High MAX RPM value will be used by the SECM as the maximum RPM. There is a limit
placed on these values, the range is (1400 RPM – 2600 RPM). Any number lower than 1400 will cause the
SECM to control at a maximum of 1400 RPM, any number entered above 2600 RPM will cause the SECM to
control at 2600 RPM. Normal maximum governing RPM is approximately 2600RPM so the default value of
3500 RPM will not limit engine RPM in any way. The setpoint box will turn red if any value below 3500 is
entered; this is simply a visual indication for the technician that a number other than the default value is being
used.

G643(E) Service Manual 285 Appendix

DFC 12-353 Screen Tab

Figure 10. Diagnostic Fault Codes 12-43 Screen

DFC (Diagnostic Fault Codes) 12 through 353 are

defined on this display for quick reference. Faults
that are displayed in yellow have been enabled on
the MI-07 system. Faults that appear in grey are
included for future use but are not enabled. Refer to
the service manual or the Advanced Diagnostics
section of this manual for repair steps and further
troubleshooting.

G643(E) Service Manual 286 Appendix

DFC 371-641 Screen Tab

Figure 11. Diagnostic Fault Codes 371-641 Screen

DFC (Diagnostic Fault Codes) 371 through 641 are

G643(E) Service Manual 287 Appendix

DFC 642-995 Screen Tab

Figure 12. Diagnostic Fault Codes 642-995 Screen

DFC (Diagnostic Fault Codes) 642 through 995 are

G643(E) Service Manual 288 Appendix

Signal I/O Screens 1-4

There are four Signal I/O (Inputs & Outputs) screens available to assist in troubleshooting. Each screen will
display SECM inputs and outputs to the various system sensors, solenoids, relays and drivers. Components
are listed in categories with the signal names, values and SECM pin location. A pin out of each sensor is
given along with the signal type and the corresponding SECM pin connection. System power and sensor
power is actively displayed in red or orange. Ground connections are displayed in grey.

Figure 13. Signal I/O Screen 1

G643(E) Service Manual 289 Appendix

Manual Override Screens 1 & 2

There are two manual override screens available for

CAUTION
the technician to test for failed components or to Be aware of fuel flow and ignition when
isolate problems during troubleshooting. Manual performing any manual override of a system
overrides can override normal system function component as engine damage may result.
regardless of engine state. Active, suspected and
occurred faults are displayed on each override
screen for quick reference along with the ability to
clear all faults.

Manual Override Screen 1

Components that can be overridden on override

screen 1 include the Main Power Relay, LP fuel
Lock-off, Fuel Select Switch, Electric Fuel Pump (Bi-
Fuel Units), Fuel Trim Valves, O2 Sensor, and the
Cold Start Valve.

Figure 14. Manual Override Screen 1

G643(E) Service Manual 290 Appendix

Switched Components

To override a switched state component such as the LP lock-off, enter the desired ON/OFF (1=On, 0=Off) in
the Manual Value box. Place your mouse pointer over the Override Select parameter box, then simply click
the pull down arrow and select the Override option. The SECM will now be overridden and the manual value
will be used to either turn on or turn off the component. The override select box will turn red when in manual
override. To stop the override mode simply click the pull down arrow in the override select box and choose the
“pass-through” option. Normal operation will resume. While in override you can change the manual value for
ON/OFF and the component will react to the new value. Once the key switch is cycled ON then OFF, all
manual overrides will return to normal operation (pass-through), regardless of the override state on the display
screen.

Figure 15. Overriding a Switched State Component

DC% COMPONENTS

To override a DC% (Duty Cycle%) component such as the FTVs, place your mouse pointer over the Lock
DC% parameter box, then simply click the pull down arrow and select the “Locked” option. Enter the desired
duty cycle in percent (0-100%) in the DC Offset box. This offset value will be added to the Status DC% value.
For example: when locked the status value is 30%. If you wish to drive the component at 50% you would enter
20% in the DC Offset box (30%+20%=50%). The SECM will now be overridden and the manual value will be
used to drive the component with a PWM (Pulse Width Modulated) signal. The Lock DC% box will turn red
when in manual override or locked. To stop the override mode simply click the pull down arrow in the Lock
DC% box and choose the “unlocked” option. Reset the DC offset to 0 % and normal operation will resume.
While in override you can change the DC Offset duty cycle and the component will react to the new value.
Once the key switch is cycled ON then OFF, all manual overrides will return to normal operation (pass-
through) or (unlocked), regardless of the override stat on the display screen.

Figure 16. Overriding a Duty Cycle % Component

Components that can be overridden on override screen 2 include the Low Oil Pressure Switch, Transmission
Temperature Switch, Ground Speed Switch, Spark Advance and the MIL. Four of the five selections are
switched components with the exception of the manual Spark Advance.

G643(E) Service Manual 291 Appendix

Manual Spark Advance

To override the ignition spark advance place your

mouse pointer over the Lock Spark Adv., parameter
box, then simply click the pull down arrow and select
the “Locked” option.

Figure 17. Overriding Ignition Spark Advance

Spark advance will be overridden and locked from

the SECM. This locked spark advance value will be
displayed in the (Degrees +/- TDC) box. Enter the
desired spark advance in the Spark Offset box. This
offset value will be added to the Spark (Degrees +/-
TDC) value. For example: when locked the +/- TDC
value is +8.0. If you wish to advance the spark to 10
degrees BTDC you would enter 2.0 in the Spark
Offset box (8.0 + 2.0=10.0). The SECM control will
now be overridden and the manual value will be
used to set the spark advance through the SECM at
the fixed value. The Lock Spark Adv., box will turn
red when in manual override or locked. To stop the
override mode simply click the pull down arrow in
the Lock Spark Adv., box and choose the “unlocked”
option. Reset the Spark offset to 0 and normal
operation will resume. While in override you can
change the Spark Offset and the ignition timing will
react to the new value. Once the key switch is
cycled ON then OFF, all manual overrides will return
to normal operation (pass-through) or unlocked.

G643(E) Service Manual 292 Appendix

Manual Override Screen 2

Components that can be overridden on override

CAUTION
screen 2 include the Low Oil Pressure Switch, Be aware of fuel flow and ignition when
Transmission Temperature Switch, Ground Speed performing any manual override of a system
Switch, Spark Advance, and the Malfunction component as engine damage may result.
Indicator Light (MIL).

Figure 18. Manual Override Screen 2

G643(E) Service Manual 293 Appendix

SECM field update with Service Tool

SECM controllers can be upgraded in the field using

MotoUpdate software. Typically, MotoUpdate and
MotoViewer applications are packaged together in
the MotoService software application. Software
upgrade files may be released to the field to
enhance performance, provide additional features,
and/or correct software problems.

This document provides step-by-step instructions for

upgrading a SECM using MotoUpdate software. In
order to illustrate the process, the following example
upgrade is used throughout this document.

Current SECM software version:

VARSPEDDRAAF-01-2-5-D-000-000.siz (calibration ID)

Upgrade to software version:

VARSPEDDRAAG-01-2-5-D-000-000.siz (calibration ID)

Using field update file:

VARSPEDDRAAG -01-1-5-D-000.mfu

NEW Corresponding DLL file:

VARSPEDDRAAG.dll

STEP1 - LOAD UPDATE FILES INTO THE

APPROPRIATE DIRECTORY

Software upgrade packages include an upgrade file

(.mfu) and translation file (.dll). The (.mfu) file is
required to upgrade the module, and the (.dll) is
required by MotoViewer software to communicate
with the module after the upgrade. Therefore, both
files are provided together. Copy the field update
file (.mfu) to the C:/ECUF Files/Updates directory,
and the corresponding (.dll) file to C:/ECU
Files/TDBDLL.

Copy the .dll file to the

TDDBLL directory

Copy the .mfu update file to

the Updates directory

G643(E) Service Manual 294 Appendix

STEP 2 - CONNECT THE COMPUTER

Prior to launching the MotoUpdate software, a valid

Criptoken must be installed in one of the available
USB ports on the update computer. A second
available USB port will be used by the USB to CAN
converter. The USB to CAN coverter must then be
connected to the SECM. (A USB hub must be
used with computers that do not have two USB
ports).

STEP 3 - LAUNCH THE MOTOUPDATE

APPLICATION

Launch the MotoUpdate application. You will see a

Welcome scree.

Select “PCM-1” in the

location field, then select
Next

G643(E) Service Manual 295 Appendix

The next screen will provide a list of all of the
available software upgrades available for the current
engine, based upon what update files have been
placed in the “Update” directory (as shown in Step-1
above). Please note that during this process, the
software must query the SECM for the current
software version, and therefore, the computer must
be connected to the SECM and the ignition key must
be in the ON position.

In general, it is usually best to see the latest revision

(e.g. 001 is later than 000) in situations where
multiple revisions are available. Additional
information is provided in the revision matrix and/or
service bulletins.

This Upgrade Options screen shows

that there are no upgrades available
for the listed Calibration ID. Note: If
no upgrades are shown, consult the
revision matrix for latest software
versions.

No Upgrader Available for this Engine

This calibration ID has one (1)

available upgrade

No Upgrader Available for this Engine

Selecting the “Details” button on the

pervious screen will bring up the
Upgrade Details screen

G643(E) Service Manual 296 Appendix

STEP 4 - PROGRAM THE MODULE

Once the desired upgrade is located and highlighted,

select Next to upgrade ithe module.

Highlight the upgrade option desired,

then select Next

Follow the on-screen instructions to complete the

update process. Once the programming process
begins, it must run to completion. If power is
interrupted or the process fails, the SECM may be
rendered unusable. Several update screens will
provide a running status of the upgrade process, as
shown below.

Note 1: After successfully upgrading the SECM,

MotoViewer software will not function without the
appropriate translation file (.dll) discussed in Step-1
above.

Once the upgrade process is complete, a “complete” Note 2: If the programming is unsuccessful, the
message will appear and will give the operator the programming process may be repeated. If
option of upgrading another module. If another repeatedly unsuccessful, please contact .
module is to be upgraded, select the “Upgrade
again” button and select next. If another upgrade is
not required, select finish.

G643(E) Service Manual 297 Appendix

Ground Speed Limits (Option)
The maximum allowable speed of Doosan forklifts is
an optional feature that can be easily activated using
the MotoView Service tool. This feature is very
useful to customers with indoor warehouse
operations.

Here’s how you can activate the speed-limiting

feature.

1) Install Speed control option onto the trucks

[Figure1] Speed Sensor
2) Set the new speed limit using the MotoView
Service tool, if required. 1. Assemble the speed sensor ass’y onto the
transmission [Figure 1].
HOW TO INSTALL SPEED LIMIT OPTION

1) Speed Sensor Ass’y

2) Jumper Harness Ass’y

3) Controller

[Figure2] Controller and Wire harness

2. Assemble the controller and harness ass’y

between the speed sensor and engine wiring
harness [Figure 2]

- OUTPUT VOLTAGE (P_P)

OUTPUT Min. 12V
CONDI Min. 7V
GEAR M=3, Z=32 M=3, Z=32
CLEARANCF 1.0–0.1mm 1.0–0.1mm
REVOLUTION 1,000–20 RPM 1,000–20 RPM
LOAD OPEN

ECU
A21 EST6 (5V)
From Main Power Realy(87) BK B1 DRVG

IGN 1 RD 1
SWITCH 4 GN 2
GND 2 BK 3
SENSOR 3 BU
CONTROLLER AS-SPEED SW(ot 6.5Km/h)

1 BU 2
2 BK 1
SPEED SENSOR SPEED SENSOR-ASC

[Figure 3] Circuit Diagram for G643E

G643(E) Service Manual 298 Appendix

- OUTPUT VOLTAGE (P_P)
OUTPUT Min. 12V
CONDI Min. 7V
GEAR M=3, Z=32 M=3, Z=32
CLEARANCF 1.0–0.1mm 1.0–0.1mm
REVOLUTION 1,000–20 RPM 1,000–20 RPM
LOAD OPEN

ECU
20 EST2 (5V)
From Main Power Realy(87) BK 14 DRVG

IGN 1 RD 1
SWITCH 4 GN 2
GND 2 BK 3
SENSOR 3 BU
CONTROLLER AS-SPEED SW(ot 6.5Km/h)

1 BU 2
2 BK 1
SPEED SENSOR SPEED SENSOR-ASC

[Figure 4] Circuit Diagram for G643

How To Set New Speed Limit

Default Engine Maximum Speed

Once speed control option is assembled, the default

engine maximum speed is as followed;

Engine max. speed

Forklift Engine (rpm)
Model Model Neutral In-Gear
(High) (Switched)
G(C)15/18S-5
G420F(E) 2,450 2,000
G(C)20SC-5
G(C)20/25/30E-5 G420F(E) 2,600 2,000
G(C)20/25/30/33P-5
G424F(E) 2,600 2,000
G35C-5
G(C)35/40/45S-5
G(C)50/55C-5 G643(E) 2,500 2,000
G50/60/70S-5

How to Set New Speed Limit

Maximum RPM for both the NEUTRAL state

(Normal) and IN-GEAR state (Speed Limiting) are
configurable using the MotoView Service Tool.

G643(E) Service Manual 299 Appendix

[Figure 5] Ground Speed Select Screen of the MotoView Service Tool

[Figure 5] shows the Speed Limit screen of the Allowable Range of RPM Limits
MotoView service tool. The ground speed RPM
setpoints are active values used by the SECM. There is a limit placed on these values, the range is
Simply highlight these values and enter a new value (1400 RPM – 2600 RPM). Any number lower than
from your laptop computer. These values will be 1400 will cause the SECM to control at a maximum
saved and used by the SECM even after of 1400 RPM, any number entered above 2600
disconnecting from the SECM and closing the RPM will cause the SECM to control at 2600 RPM.
display screen. If the ground switch input is closed Normal maximum governing RPM is approximately
(grounded), the Switched MAX RPM value will be 2600RPM so the default value of 3500 RPM will not
used by the SECM as the maximum RPM. If the limit engine RPM in any way. The setpoint box will
ground switch is open or not used, the High MAX turn red if any value below 3500 is entered; this is
RPM value will be used by the SECM as the simply a visual indication for the technician that a
maximum RPM. number other than the default value is being used.

G643(E) Service Manual 300 Appendix

LPG And LPG Fuel Tanks The same principle is applied to LPG in a container,
commonly referred to as an LPG tank or cylinder.
LPG Fuel Supply Typically an LPG tank is not filled over 80% capacity
allowing for a 20% vapor expansion space. Outside
Liquefied petroleum gas (LPG) consists mainly of air temperature effect’s an LPG tank and must be
propane, propylene, butane, and butylenes in considered when using an LPG system. (Figure 2)
various mixtures. LPG is produced as a by-product shows the relationship between pressure and
of natural gas processing or it can be obtained from temperature in a LPG tank at a steady state
crude oil as part of the oil refining process. LPG, like condition.
gasoline, is a compound of hydrogen and carbon,
commonly called hydrocarbons. LPG Tank Pressure VS Temperature
300

In its natural state, propane is colorless and 250

odorless; an odorant (ethyl mercaptan) is added to
the fuel so its presence can be detected. There are 200

Pressure, psig
currently three grades of propane available in the 150

United States. A propane grade designation of HD5 100

(not exceeding 5% propylene), is used for internal
combustion engines while much higher levels of 50

propylene (HD10) are used as commercial grade 0

-20 0 20 40 60 80 100 120 140
propane along with a commercial propane /butane Figure 2 Temperature, deg F
mixture.
With 128 PSIG vapor pressure acting against the
APPROXIMATE COMPOSITION OF HD5 liquid propane the boiling point has been raised to
PROPANE BY VOLUME slightly more than 80 deg. F / 27 deg. C.

Propane Propy Butane Iso- Methane

TOTAL
(C3H8) lene (C4H10) Butane (CH4)
90.0% 5%
2.0% 1.5% 1.5% 100% Compressed
min. max.
Vapor
An advantage of LPG is the ability to safely store 128 PSIG Liquid
and transport the product in the liquid state. In the Propane
liquid state propane is approximately 270 times as
dense as it is in a gaseous form. By pressurizing a
container of LPG we can effectively raise the boiling
point above –44 deg. C / -42 deg. C, keeping the LPG Tank
propane in liquid form. The point at which the liquid Figure 3
becomes a gas (boiling point) depends on the
amount of pressure applied to the container. NOTE: Vapor pressure inside an LPG tank depends
on the ambient air temperature outside the tank, not
This process operates similarly to an engine coolant the amount of liquid inside the tank. A tank that is ¾
system where water is kept from boiling by full of liquid propane at 80 deg. F will contain the
pressurizing the system and adding a mixture of same vapor pressure as a tank that is only ¼ full of
glycol. For example water at normal atmospheric liquid propane.
pressure will boil at 212 deg. F / 100 deg. C. If an
engines operating temperature is approximately 230 LPG’s relative ease of vaporization makes it an
deg. F / 110 deg. C, then the water in an open un- excellent fuel for low-rpm engines on start-and-stop
pressurized cooling system would simply boil off into operations. The more readily a fuel vaporizes the
steam, eventually leaving the cooling system empty more complete combustion will be.
and over heating the engine. If we install a 10 PSIG Because propane has a low boiling point (-44F), and
cap on the radiator, pressurizing the cooling system is a low carbon fuel, engine life can be extended due
to 10 PSIG, the boiling point of the water increases to less cylinder wall wash down and little, if any,
to 242 deg. F / 117 deg. C, which will cause the carbon build up.
water to remain in liquid state at the engines
operating temperature.

G643(E) Service Manual 301 Appendix

LPG Fuel Tanks Installing LPG Fuel Tanks

The two styles of LPG storage containers available When installing a tank on a lift truck, the tank must
for industrial use and lift truck applications are be within the outline of the vehicle to prevent
portable universal cylinders and permanently damage to the valves when maneuvering in tight
mounted tanks. Portable universal cylinders are spaces. Horizontal tanks must be installed on the
used primarily for off-highway vehicles and are saddle that contains an alignment pin, which
constructed in accordance with the DOT-TC (United matches the hole in the collar of the tank. When the
States Department of Transport – Transport pin is in the hole, the liquid withdrawal tube is
Canada). The cylinders are referred to as universal positioned to the bottom of the tank. A common
because they can be mounted in either a vertical or problem is that often these guide-pins are broken off,
horizontal position (Figure 4). allowing the tank to be mounted in any position. This
creates two problems. 1). When the liquid
withdrawal tube is exposed to the vapor space, it
may give a false indication that the tank is empty,
when it actually is not. 2). The safety relief valve
may be immersed in liquid fuel. If for any reason the
valve has to vent, venting liquid can cause a serious
safety problem,

CAUTION
When empty, the tank is exchanged with a pre-
filled replacement tank. When exchanging a tank,
Figure 4 safety glasses and gloves should be worn.

NOTE: A 375-psig, relief valve is used on a DOT

forklift tank. The relief valve must be replaced with a
new valve after the first 12 years and every 10 years LPG Fuel Tank Components
thereafter.

The tank must be discarded if the collar is damaged

2 3 7 8
to the point that it can no longer protect the valves. It 9
must also be replaced if the foot ring is bent to the
1
point where the tank will not stand or is easily
knocked over.

4
6 12 10
11
5
Figure 5

(1) Fuel Gauge (2) 80% Stop Bleeder

(3) Pressure Relief Valve
(4) Service Valve (Tank end male coupling) (5) Filler Valve
(6) Alignment Pin
(7) Vapor Withdrawal Tube (Only used with Vapor Withdrawal)
(8) 80% Limiter Tube (9) Liquid Withdrawal Tube
(10) Foot Ring (11) Fuel Level Float (12) Collar

G643(E) Service Manual 302 Appendix

Fuel Gauge Service Valve

In figure 5 a visual fuel gauge is used to show the The service valve is a manually operated valve
fuel level in the tank. A mechanical float mechanism using a small hand wheel to open and close the fuel
detects the liquid propane level. A magnet on the supply to the service line (fuel supply line). The
end of the float shaft moves a magnetic pointer in service valve installs directly into the tank and has
the fuel gauge. Some units have an electronic two main categories, liquid and vapor service valves.
sending unit using a variable resistor, installed in Liquid service valves used on portable LPG tanks
place of a gauge for remote monitoring of the fuel use a 3/8” (3/8” NPT) male pipe thread on the
level. The gauge may be changed with fuel in the service valve outlet for attachment of a quick
tank. DO NOT REMOVE THE FOUR LARGE disconnect coupler.
FLANGE BOLTS THAT RETAIN THE FLOAT
ASSEMBLY, WITH FUEL IN THE TANK! An excess flow valve is built into the inlet side of the
service valve as a safety device in case of an
accidental opening of the service line or damage to
CAUTION the service valve itself. The excess flow valve shuts
It is not a legal practice to fill the tank through off the flow of liquid propane if the flow rate of the
the liquid contents gauge. liquid propane exceeds the maximum flow rate
specified by the manufacturer.
In some applications a fixed tube fuel indicator is
used in place of a float mechanism. A fixed tube
indicator does not use a gauge and only indicates
when the LPG tank is 80% full. The fixed tube
indicator is simply a normally closed valve that is
opened during refueling by the fueling attendant. Outlet
When opened during refueling and the tanks LPG
level is below 80%, a small amount of vapor will exit
the valve. When the LPG tank level reaches 80%
liquid propane will begin exiting the valve in the form Excess Flow
of a white mist (Always wear the appropriate Valve
protective apparel when refueling LPG cylinders). In Figure 6
order for this type of gauge to be accurate, the tank
must be positioned properly. When full (80% LPG)
the valve is closed by turning the knurled knob
clockwise. Typically a warning label surrounds the CAUTION
fixed tube gauge which reads STOP FILLING When the tank is in use the service valve should
WHEN LIQUID APPEARS. be completely open. If the valve is partly open,
the vehicle may not be getting enough fuel to
operate efficiently.

In addition to possibly starving the engine for

fuel, a partly open valve may restrict the flow
enough to prevent the excess flow valve from
closing in the event of a ruptured fuel line.

G643(E) Service Manual 303 Appendix

Most liquid service valves have an internal Filler Valve
hydrostatic relief valve and are usually labeled
“LIQUID WITH INTERNAL RELIEF”. The The liquid filler valve (Figure 9) has a male thread to
hydrostatic relief valve protects the fuel service line receive a fuel nozzle and typically has a plastic or
between the tank and the lock off from over brass screw on cap that is retained with a small
pressurization. The internal hydrostatic relief valve chain or plastic band to keep debris out of the filler
has a minimum opening pressure of 375 PSIG and a valve. The filler valve is a one-way flow device that
maximum pressure of 500 PSIG. These type of relief uses two check valves to allow fuel to enter the tank
valves have an advantage over external relief valves but prevent it from exiting. Both check valves are
because the propane is returned to the tank in the backpressure type check valves, designed so that
event of an over pressurization instead of venting backpressure from the tank assists the check valves
the propane to atmosphere. own spring pressure to close the valve. The first
valve uses a neoprene on metal seal and the
second valve uses a metal on metal seal.
Quick Disconnect Coupling
A weakness ring is machined into the filler valve just
The liquid withdrawal or service valve on a DOT above the check valves and will allow the filler valve
tank has male threads and accepts the female to shear off in case of an accident. The valve will
portion of a quick disconnect coupling (Figure 8). break or shear off above the check valves so that
The female portion is adapted to the liquid hose the tank will be sealed and no liquid propane can
going to the fuel system. Both halves are equipped escape.
with 100% shutoffs, which open when coupled
together to allow fuel flow. The coupler has two
seals. One is an o-ring and the other is a flat washer.
The o-ring prevents leakage from the shaft on the
other coupling and the flat washer seals when the
coupler is fully connected.
Weakness
NOTE: The flat seal and / or the o-ring will Ring
sometimes pop off when disconnecting and slide up
the shaft of the mating connector, causing the valve
not to open when fully mated. The extra washer or
o-ring must be removed from the shaft and the
coupling reconnected. Figure 9

Figure 8

G643(E) Service Manual 304 Appendix

Regulatory Compliance
WARNING—EXPLOSION HAZARD
EPA / CARB Emissions Certification Do not connect or disconnect while circuit is live
unless area is known to be non-hazardous.
When properly applied and calibrated, ’s MI-07
control system is capable of meeting EPA 2007 LSI
Substitution of components may impair suitabil-
emission standards (40 CFR Part 1048.101) when
operating properly with an approved three-way ity for Class I, Division 2, or Zone 2 applications.
catalyst. The emission standards, including
appropriate deterioration factors over the useful life
of the system, are as follows:
Electrostatic Discharge Awareness
HC+NOx: 2.0 g/hp-hr [2.7 g/kW-hr]
All electronic equipment is static-sensitive, some
CO: 3.3 g/hp-hr [4.4 g/kW-hr]
components more than others. To protect these
components from static damage, you must take
Evaporative emissions comply with 40 CFR Part
special precautions to minimize or eliminate
1048.105. These standards apply only to volatile
electrostatic discharges.
liquid fuels such as gasoline. Note that the engine
crankcase must be closed.
Follow these precautions when working with or near
the control.
North American Compliance 1. Before doing maintenance on the electronic
control, discharge the static electricity on your
The N-2007 regulator is UL listed per Category ITPV
body to ground by touching and holding a
LP-Gas Accessories, Automotive Type.
grounded metal object (pipes, cabinets,
equipment, etc.).
The N-2007 regulator and CA100 mixer have
tamper-resistant features approved by CARB.
2. Avoid the build-up of static electricity on your
body by not wearing clothing made of synthetic
materials. Wear cotton or cotton-blend materials
as much as possible because these do not store
Special Conditions for Safe Use static electric charges as much as synthetics.

Field wiring must be suitable for at least 248°F 3. Keep plastic, vinyl, and Styrofoam materials (such
(120°C). as plastic or Styrofoam cups, cup holders,
cigarette packages, cellophane wrappers, vinyl
SECM-48 inputs are classified as permanently books or folders, plastic bottles, and plastic ash
connected IEC measurement Category I. To avoid trays) away from the control, the modules, and the
the danger of electric shock, do not use inputs to work area as much as possible.
make measurements within measurement
categories II, III, or IV.

SECM-48 input power must be supplied from a

power supply/battery charger certified to IEC
standard with a SELV (Safety Extra Low Voltage)
classified output.

SECM-48 inputs and outputs may only be

connected to other circuits certified as SELV (Safety
Extra Low Voltage).

G643(E) Service Manual 305 Appendix

Abbreviations

ACFM Actual cubic feet per minute at the specified suction conditions
AFR Air fuel ratio
BHP Brake horsepower
Bi-Fuel Able to operate on either of two fuels
CTS Coolant temperature sensor
CNG Compressed natural gas
Dual Fuel Able to run simultaneously on two fuels, e.g. diesel and natural gas.
Often this term is incorrectly used to describe bi-fuel operation.
Spark-ignited engines are typically bi-fuel while compression ignition
engines are dual-fuel.
ECM Engine control module
FPP Foot pedal position
FPV Fuel primer valve
FTS Fuel temperature sensor
FTV Fuel trim valve
GPM Gallons per minute of flow
HEGO Heated exhaust gas oxygen (sensor)
LAT Limited-angle torque motor
LPG Liquified petroleum gas
MAP Manifold absolute pressure
MAT Manifold air temperature
MIL Malfunction indicator lamp
MOR Manufacturer of record for emissions certification on the engine
OEM Original equipment manufacturer
PHI Relative fuel-air ratio or percent of stoichiometric fuel
(actual fuel-air ratio / stoichiometric fuel-air ratio)
RPM Revolutions per minute
SECM Small engine control module
TMAP Temperature and manifold absolute pressure
TPS Throttle position sensor
VDC Voltage of direct current type
VE Volumetric efficiency
WOT Wide open throttle

G643(E) Service Manual 306 Appendix

SB4118E01
May. 2007

Service Manual
Diesel Engine 5.8 Liter (DB58S)

D35S-5, D40S-5, D45S-5, D50C-5, D55C-5

D50S-5, D60S-5, D70S-5, D80S-5, D90S-5 (3 speed)
D50S-5, D60S-5, D70S-5 (2 speed)
Important Safety Information

Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety
rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an
accident occurs. A person must be alert to potential hazards. This person should also have the necessary training,
skills and tools to perform these functions properly.

Read and understand all safety precautions and warnings before operating or performing lubrication,
maintenance and repair on this product.

Basic safety precautions are listed in the “Safety” section of the Service or Technical Manual. Additional safety
precautions are listed in the “Safety” section of the owner/operation/maintenance publication.
Specific safety warnings for all these publications are provided in the description of operations where hazards exist.
WARNING labels have also been put on the product to provide instructions and to identify specific hazards. If
these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. Warnings in this
publication and on the product labels are identified by the following symbol.

WARNING

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result
in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and
understood the operation, lubrication, maintenance and repair information.

Operations that may cause product damage are identified by NOTICE labels on the product and in this publication.

DOOSAN cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in
this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating
technique not specifically recommended by DOOSAN is used, you must satisfy yourself that it is safe for you and
others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication,
maintenance or repair procedures you choose.

The information, specifications, and illustrations in this publication are on the basis of information available at the
time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other
items can change at any time. These changes can affect the service given to the product. Obtain the complete and
most current information before starting any job. DOOSAN dealers have the most current information available.
FOREWORD

This maintenance manual is designed to serve as a reference for DOOSAN Infracore Ltd's (here after DOOSAN’s)
customers and distributors who wish to gain basic product knowledge on DOOSAN's DB58S Diesel engine.

This economical and high-performance diesel engine (6 cylinders, 4 strokes, in-line, direct injection type) has been
so designed and manufactured to be used for the overland transport or industrial purpose. That meets all the
requirements such as low noise, fuel economy, high engine speed, and durability.

To maintain the engine in optimum condition and retain maximum performance for a long time, CORRECT
OPERATION and PROPER MAINTENANCE are essential.
In this manual, the following symbols are used to indicate the type of service operations to be performed.

Removal Adjustment

Installation Cleaning 15

Disassembly Pay close attention-Important

Reassembly Tighten to specified torque

Align the marks Use special tools of manufacturer's

Directional Indication Lubricate with oil

Inspection Lubricate with grease

Measurement

During engine maintenance, please observe following instructions to prevent environmental damage;

z Take old oil to an old oil disposal point only.

z Ensure without fail that oil will not get into the sea or rivers and canals or the ground.
z Treat undiluted anti-corrosion agents, antifreeze agents, filter element and cartridges as special waste.
z The regulations of the relevant local authorities are to be observed for the disposal of spent coolants and
special waste.

If you have any question or recommendation in connection with this manual, please do not hesitate to contact our
head office, dealers or authorized service shops near by your location for any services.

For the last, the content of this maintenance instruction may be changed without notice for some quality
improvement. Thank you.
CONTENTS

1. GENERAL INFORMATION 2.8. Cooling system ........................................ 20

1.1. Engine specifications..................................1 2.8.1. Anti-freeze.................................21
1.2. Performance curve.....................................2 2.8.2. Cooling water ............................21
1.2.1. Performance curve (ECRFA), 2.9. V-belt tension check and adjust............... 23
D50/60/70/80/90S-5 (3 speed).... 2 2.10. Valve clearance and adjustment............ 24
1.2.2. Performance curve (ECRFD), 2.11. Cylinder compression pressure ............. 25
D35/40/45S-5, D50/55C-5 .......... 3 2.12. Injection nozzle...................................... 26
1.2.3. Performance curve (ECRFE), 2.13. Battery ................................................... 26
D50/60/70S-5 (2 speed).............. 4 2.14. Starting motor ........................................ 26
1.3. Engine assembly........................................5 2.15. Diagnosis and remedy........................... 27
1.3.1. Engine assembly view (ECRFA), 2.16. Engine inspection .................................. 36
D50/60/70/80/90S-5 (3 speed).... 5 2.16.1. Stopping engine ......................36
1.3.2. Engine assembly view (ECRFD), 2.16.2. General engine inspection cycle36
D35/40/45S-5, D50/55C-5 .......... 6 2.17. Use of original parts for repair and
1.3.3. Engine assembly views (ECRFE), replacement.................................................... 37
D50/60/70S-5 (2 speed).............. 7
1.4. Safety regulations.......................................8 3. Maintenance
1.4.1. General notes ............................. 8 3.1. Engine Disassembly ................................ 38
1.4.2. Regulations designed to prevent 3.1.1. Major part fixing nuts and bolts ..38
accidents .................................... 8 3.1.2. Main structure parts (1) .............49
1.4.3. Regulations designed to prevent 3.1.3. Main structure parts (2) .............51
damage to engine and premature 3.1.4. Rocker arm disassembly ...........53
wear ........................................... 9 3.1.5. Cylinder head disassembly........54
1.4.4. Regulations designed to prevent 3.1.6. Piston and connecting rod
pollution.................................... 10 disassembly ..............................55
1.4.5. General repair instructions ........ 11 3.2. Engine Inspection .................................... 57
3.2.1. Cylinder block............................57
2. TECHNICAL INFORMATION 3.2.2. Cylinder head............................57
2.1. Engine model and serial number..............12 3.2.3. Valve stem and valve guide
2.2. Engine type ..............................................13 clearance ..................................58
2.2.1. Cylinder block ........................... 13 3.2.4. Valve spring ..............................62
2.2.2. Piston con-rod / crankshaft........ 13 3.2.5. Tappet ......................................63
2.3. Engine timing............................................13 3.2.6. Push rod ...................................63
2.4. Valves.......................................................14 3.2.7. Rocker arm correction ...............64
2.5. Lubrication system ...................................14 3.2.8. Idler gear and shaft ...................65
2.5.1. Recommend of lubricating oil .... 15 3.2.9. Camshaft ..................................65
2.5.2. Oil cooler .................................. 16 3.2.10. Cylinder liner ...........................67
2.5.3. Oil filter ..................................... 16 3.2.11. Cylinder block..........................68
2.6. Air cleaner ................................................17 3.2.12. Piston......................................71
2.7. Fuel system..............................................17 3.2.13. Maintenance of cylinder block,
2.7.1. Injection pump .......................... 18 cylinder liner and piston...........74
2.7.2. Fuel filter................................... 18 3.2.14. Connecting rod........................75
2.7.3. Fuel requirements..................... 18 3.2.15. Crankshaft...............................77
2.7.4. How to select fuel oil ................. 19 3.2.16. Flywheel and flywheel housing 81
3.3. Engine Reassembly .................................82 5. Maintenance of Major Components
3.3.1. Piston and connecting rod assembly 5.1. Lubrication system................................. 121
................................................. 82 5.1.1. Oil pump ................................. 121
3.3.2. Cylinder head assembly parts ... 84 5.1.2. Oil cooler................................. 123
3.3.3. Rocker arm and shaft assembly 87 5.2. Cooling system ...................................... 124
3.3.4. Main components ..................... 88 5.2.1. Water pump ............................ 124
3.3.5. Major component assembly ...... 94 5.2.2. Thermostat.............................. 128
3.3.6. External parts ........................... 98 5.3. Fuel system ........................................... 129
5.3.1. Fuel filter ................................. 129
4. Commissioning and Operation 5.3.2. Injection nozzle ....................... 130
4.1. Preparation.............................................103 5.3.3. Injection Pump Calibration....... 134
4.1.1. Starting................................... 103 5.3.4. Precautions for operation......... 137
4.2. Starting and operation............................104 5.3.5. Walk-around check and servicing
4.2.1. Operation of a new engine (Break- ............................................... 138
In)........................................... 104 5.3.6. Diagnostics and troubleshooting139
4.2.2. Check points for break-in ........ 104
4.3. Inspections after starting ........................106 6. Special Tool List ......................... 140
4.4. Operation in winter time .........................106
4.4.1. Prevention against the freeze of
• Appendix ...............................................142
cooling water .......................... 106
4.4.2. Prevention against excessive
cooling.................................... 106
4.4.3. Lubricating oil ......................... 107
4.4.4. Starting of engine in winter...... 107
4.4.5. Tuning the engine ................... 107
4.5. Maintenance and care............................108
4.5.1. Periodical inspection and
maintenance........................... 108
4.5.2. Exchanging of lubrication oil.... 108
4.5.3. Oil level................................... 108
4.5.4. Oil exchange procedure .......... 108
4.5.5. Replacement of oil filter cartridge109
4.6. Cooling system.......................................110
4.6.1. Coolant draining...................... 110
4.6.2. Cleaning of the cooling inside
system circuit.......................... 111
4.7. Valve clearance and adjustment ............111
4.8. Injection timing .......................................113
4.9. Tightening the cylinder head bolts..........116
4.10. Fuel injection pump ..............................116
4.11. Feed pump strainer ..............................117
4.12. Separator (Add if necessary)................117
4.13. Air bleeding ..........................................117
4.14. Belts .....................................................118
1. GENERAL INFORMATION
1.1. Engine specifications

DB58S ECRFA DB58S ECRFD DB58S ECRFE

Engine Model
D50/60/70/80/90S-5 D35/40/45S-5, D50/60/70S-5
Items
(3 speed) D50/55C-5 (2 speed)
Engine type 4 cycle in-line Naturally aspirated
Combustion chamber type Direct injection type
Cylinder liner type Dry type
Timing gear system Gear driven type
No. of piston ring 2 Compression 1 ring, oil ring
No. of cylinder-bore x stroke (mm) 6 – 102 × 118
Total piston displacement (cc) 5,785
Compression ratio 17.5 : 1 18.5 : 1
Engine dimension
(length X width X height) 1,173 x 666 x 793
(mm)
Engine weight (kg) 450
Rotating direction (from fly wheel) counter clockwise
Fuel injection order 1–5-3–6-2–4
Fuel injection timing (B.T.D.C static) 15°
Injection pump type Bosch in-line A type
Governor type Mechanical governor RSV type
Injection nozzle type Multi-hole type (5 hole)
Fuel injection pressure (kg/cm²) 220
Compression pressure (kg/cm²) 28 (at 200 rpm)
Intake & exhaust valve clearance (mm)
0.4
(at cold)
Open at 17° B.T.D.C
Intake valve
Close at 51° A.B.D.C
Open at 60° B.B.D.C
Exhaust valve
Close at 18° A.T.D.C
Lubrication method Pressurized circulation
Oil pump type Gear type
Oil filter type Full-flow, cartridge type
Lubricating oil capacity (oil pan) (lit) 20.5(19)
Oil cooler type Water cooled
Water pump Belt driven impeller type
Cooling Method Pressurized circulation
Cooling water capacity(engine only) (lit) 12
Thermostat type Wax pallet type (82 ∼95°C)
Cooling fan 10- Ø 520.7 blower 7 – Ø 457 blower 10- Ø 520.7 blower
Starting Motor
24 – 4.5
(voltage – output) (V - kW)

-1- General information

1. 2. Performance curve

1. 2.1. Performance curve (ECRFA), D50/60/70/80/90S-5 (3 speed)

General information -2-

1. 2.2. Performance curve (ECRFD), D35/40/45S-5, D50/55C-5

-3- General information

1. 2.3. Performance curve (ECRFE), D50/60/70S-5 (2 speed)

General information -4-

-7- General information

1.4. Safety regulations

1.4.1. General notes

Day-to-day use of power engines and the service products necessary for running them presents no
problems if the persons occupied with their operation, maintenance and care are given suitable training
and think as they work.

This summary is a compilation of the most important regulations. These are broken down into main
sections which contain the information necessary for preventing injury to persons, damage to property and
pollution. In addition to these regulations those dictated by the type of engine and its site are to be
observed also.

IMPORTANT.
If, despite all precautions, an accident occurs, in particular through contact with caustic acids, fuel
penetrating the skin, scalding from oil, antifreeze being splashed in the eyes etc., consult a doctor
immediately.

1.4.2. Regulations designed to prevent accidents

a) During commissioning, starting and operation
Before putting the engine into operation for the first time, read the operating instructions carefully and
familiarize yourself with the "critical" points. If you are unsure, ask your DOOSAN representative.

z For reasons of safety we recommend you attach a notice to the door of the engine room prohibiting
the access of unauthorized persons and that you draw the attention of the operating personal to
the fact that they are responsible for the safety of persons who enter the engine room.
z The engine must be started and operated only by authorized personnel. Ensure that the engine
cannot be started by unauthorized persons.
z When the engine is running, do not get too close to the rotating parts. Wear close-fitting clothing.
z Do not touch the engine with bare hands when it is warm from operation risk of burns.
z Exhaust gases are toxic. Comply with the installation instructions for the installation of DOOSAN
diesel engines which are to be operated in enclosed spaces. Ensure that there is adequate
ventilation and air extraction.
z Keep vicinity of engine, ladders and stairways free of oil and grease.
Accidents caused by slipping can have serious consequences.

b) During maintenance and care

z Always carry out maintenance work when the engine is switched off. If the engine has to be
maintained while it is running, e.g. changing the elements of change-over filters, remember that
there is a risk of scalding. Do not get too close to rotating parts.
z Change the oil when the engine is warm from operation.

CAUTION
There is a risk of burns and scalding. Do not touch oil drain valve or oil filters with bare hands.

Safety regulations -8-

z Take into account the amount of oil in the sump. Use a vessel of sufficient size to ensure that the
oil will not overflow.
z Open the coolant circuit only when the engine has cooled down. If opening while the engine is still
warm is unavoidable, comply with the instructions In the chapter entitled "Cooling".
z Neither tighten up nor open pipes and hoses (lube oil circuit, coolant circuit and any additional
hydraulic oil circuit) during the operation. The fluid which flow out can cause injury.
z Fuel is inflammable. Do not smoke or use naked lights in its vicinity. The tank must be filled only
when the engine is switched off.
z Keep service products (anti-freeze) only in containers which can not be confused with drinks
containers.
z Comply with the manufacturer's instructions when handling batteries.

CAUTION
Accumulator acid is toxic and caustic. Battery gases are explosive.

c) When carrying out checking, setting and repair work

z Checking, setting and repair work must be carried out by authorized personnel only.
z Use only tools which are in satisfactory condition. Slip caused by the worn open-end wrench could
lead to Injury.
z When the engine is hanging on a crane, no-one must be allowed to stand or pass under it. Keep
lifting gear in good condition.
z When checking injectors, do not put your hands under the jet of fuel.
z Do not inhale at atomized fuel.
z When working on the electrical system disconnect the battery earth cable first. Connect it up again
last in prevent short circuits.

1.4.3. Regulations designed to prevent damage to engine and premature wear

(1) Never demand more of the engine than it was designed to yield for its intended purpose.
Detailed information on this can be found in the sales literature. The injection pump must not be
adjusted without prior written permission of DOOSAN.
(2) If faults occur, find the cause immediately and have it eliminate in order to prevent more serious of
damage.
(3) Use only genuine DOOSAN spare parts. DOOSAN will accept no responsibility for damage resulting
from the installation of other parts which are supposedly "just as good".
(4) In addition to the above, note the following points.
z Never let the engine run when dry, i.e. without lube oil or coolant. Use only DOOSAN-approved
service products. (engine oil, anti-freeze and anticorrosion agent)
z Pay attention to cleanliness. The Diesel fuel must be free of water. See "Maintenance and care".
z Have the engine maintained at the specified intervals.
z Do not switch off the engine immediately when it is warm, but let it run without load for about 5
minutes so that temperature equalization can take place.
z Never put cold coolant into an overheated engine. See "Maintenance and care".

-9- Safety regulations

z Do not add so much engine oil that the oil level rises above the max. marking on the dipstick. Do
not exceed the maximum permissible tilt of the engine. Serious damage to the engine may result if
these instructions are not adhered to.
z Always ensure that the testing and monitoring equipment (for battery charge, oil pressure, and
coolant temperature) function satisfactorily.
z Comply with instructions for operation of the alternator. See "Commissioning and operation".
z Do not let the water pump run dry. If there is a risk of frost, drain the water when the engine
switched off.

1.4.4. Regulations designed to prevent pollution

a) Engine oil, filter element, fuel filter
z Take old oil only to an oil collection point. Take strict precautions to ensure that oil does not get into
the drains or into the ground.
z The drinking water supply may be contaminated.
z Oil and fuel filter elements are classed as dangerous waste and must be treated as such.

b) Coolant
z Treat undiluted anti-corrosion agent and / or antifreeze as dangerous waste.
z When disposing of spent coolant comply with the regulations of the relevant local authorities.

1.4.5. Notes on safety in handling used engine oil

Prolonged or repeated contact between the skin and any kind of engine oil decreases the skin.
Drying, irritation or inflammation of the skin may therefore occur. Used engine oil also contains dangerous
substances which have caused skin cancer in animal experiments. If the basic rules of hygiene and health
and safety at work are observed, health risks are not to the expected as a result of handling used engine oil.

<Health precautions>
z Avoid prolonged or repeated skin contact with used engine oil.
z Protect your skin by means of suitable agents (creams etc.) or wear protective gloves.
z Clean skin which has been in contact with engine oil.
z Wash thoroughly with soap and water, A nailbrush is an effective aid.
z Certain products make it easier to clean your hands.
z Do not use petrol, Diesel fuel, gas oil, thinners or solvents as washing agents.
z After washing apply a fatty skin cream to the skin.
z Change oil-soaked clothing and shoes.
z Do not put oily rags into your pockets.

Ensure that used engine oil is disposed of properly.

- Engine oil can endanger the water supply -

For this reason do not let engine oil get into the ground, waterways, the drains or the sewers. Violations
are punishable. Collect and dispose of used engine oil carefully.
For information on collection points please contact the seller, the supplier or the local authorities.

Safety regulations - 10 -
1.4.5. General repair instructions
1. Before performing service operation, disconnect the grounding cable from the battery for reducing the
chance of cable damage and burning due to short-circuiting.
2. Use covers for preventing the components from damage or pollution.
3. Engine oil and anti-freeze solution must be handled with reasonable care as they cause paint damage.
4. The use of proper tools and special tools where specified is important to efficient and reliable service
operation.
5. Use genuine DOOSAN parts necessarily.
6. Used cotter pins, gaskets, O-rings, oil seals, lock washer and self-lock nuts should be discarded and
new ones should be prepared for installation as normal function of the parts can not be maintained if
these parts are reused.
7. To facilitate proper and smooth reassemble operation, keep disassembled parts neatly in groups.
Keeping fixing bolts and nut separately is very important as they vary in hardness and design depending
on position of installation.
8. Clean the parts before inspection or reassembly. Also clean oil ports, etc. using compressed air to make
certain they are free from restrictions.
9. Lubricate rotating and sliding faces of parts with oil or grease before installation.
10. When necessary, use sealer on gaskets to prevent leakage.
11. Carefully observe all torque specifications for bolts and nuts.
12. When service operation is completed, make a final check to be sure service has been done properly.

- 11 - Safety regulations
2. TECHNICAL INFORMATION
2.1. Engine model and serial number

The engine model and serial number is located on the

ENGINE SERIAL NO.
engine as illustrated. These numbers are required
when requesting warranty and ordering parts. They
are also referred to as engine model and serial
number because of their location.

Engine serial No. (example : DB58)

DB58S 3 00001 FA

Engine suffix (ECRFA)

Serial no. EC90M011
Production year (2003)
Engine model

Technical information - 12 -
2.2. Engine type

The Engines DB58S are in-line vertical, water-cooled, 6-cylinder four stroke diesel engines with direct
injection. DB58S is natural aspiration.

2.2.1. Cylinder block

The cylinder block is a single piece of alloy cast iron. To increase its stiffness, it is extended to a level
below the crankshaft center line. The engine has replaceable dry cylinder liners and common cylinder
heads with struck-in valve seat rings and replaceable valve guides,

2.2.2. Piston con-rod / crankshaft

The forged crankshaft is a integrate type (Counterweight is integrated with crank shaft body). Radial oil
seal on crankshaft and flywheel are provided to seal the flywheel housing inside penetrations.
The con-rods (connecting rods) are die-forged and can be removed through the top of the cylinders
together with the pistons. Crankshaft and connecting rods run in steel-backed lead bronze ready-to fit type
bearings.

2.3. Engine timing

Camshaft, oil pump, PTO (power take off) pump and injection pump are driven by a gear train arranged at
the front end.

Camshaft gear
Injection pump gear Idle gear Oil pump drive gear
(Z = 50) P.T.O Drive gear
(Z = 50) (Z = 51) (Z = 12)
(Z=24)

Oil pump gear P.T.O gear (Option)

Crankshaft gear
(Z = 9) (Z = 25)
(Z = 25)

EC90M013

- 13 - Technical information
2.4. Valves

The overhead valves are actuated via chilled cast iron tappets, push rods and rocker arms from the
camshaft.

2.5. Lubrication system

The engine is equipped with force-feed lubrication.

The pressure is produced by a gear pump whose drive gear is in direct mesh with the camshaft gear at the
middle of cylinder block.
The oil pump draws the oil from the oil sump and delivers it through the oil cooler and oil filter to the main
distributor gallery and from there to the main bearings, big-end bearings and camshaft bearings as well as
to the small-end bearings and the rocker arms.
The injection pump are also connected to the engine lubricating system.
The cylinder block walls and timing gears are splash-lubricated.
The lube oil is cleaned in a full-flow oil filter.

EC90M014

Technical information - 14 -
2.5.1. Recommend of lubricating oil
Initial factory fill is high quality break-in oil for API Service. During the break-in period (50 hours),
frequently check the oil level. Somewhat higher oil consumption is normal until piston rings are seated.
The oil level should be maintained in the safe range between the Min. and Max. marks on the dipstick. The
safe range between the marks represents approximately 3 liters. To obtain the best engine performance
and engine life, grade of engine oil is recommended. Engine oils are specified by API Service, letter
designations and SAE viscosity numbers. If the specified motor oil is not available, use a reputable brand
of engine oil labeled for API Service CH-4 and SAE viscosity 30 or 15W40. Refer to oil identification
symbol on the container.

z Engine oil should be changed at the specified intervals.

Oil filter cartridge should be changed simultaneously.
- First oil change : 50 hr operating
- After 50hr operation ; 250

z The following oils are also recommended

Engine oil capacity Recommend oil

Oil pan
Engine model Total
Max. Min. SAE No. API No.
(liter)
(liter) (liter)

SAE10W40 ACEA-E2 or ACEA-E3

DB58S 19 14 20.5
SAE15W40 (API CH-4)

- 15 - Technical information
* If long oil change intervals are to be used, ACEA-E3 oil must be used.

EA4M1008

2.5.2. Oil cooler

An oil cooler is provided between the oil filter and the cylinder block. This cooler is a flat tube type with
turbulence inserts and operated by the coolant.

2.5.3. Oil filter

• Check for oil pressure and oil leaks, and
repair or replace the oil filter if necessary.
• Change the oil filter cartridge
simultaneously at every replacement of
engine oil.

EDM3001I

<ECRFD>

Technical information - 16 -
Head, oil filter

Cartridge,
Oil filter EC9OM015

<ECRFA, ECRFE>
2.6. Air cleaner

In case that elements are deformed, damaged

or if the air cleaner has a crack, replace it.
By the definite interval, the elements must be
cleaned and replaced.

EFM1002I

2.7. Fuel system

The fuel is delivered by the fuel feed pump via the fuel filter to the injection pump and from there to the
injection nozzles.

EC9OM065

- 17 - Technical information
The fuel is sprayed into the cylinders through nozzles fitted in screw-fit injection nozzle holders in the
cylinder heads.
Excessively delivered fuel and leak fuel from the nozzle flow through the return pipe back to the tank.
A strainer is arranged ahead of the fuel feed pump.

2.7.1. Injection pump

The in-line injection pump is driven via gears
from the crankshaft. It is connected to the
force feed lubricating system of the engine
and consequently maintenance-free. The
governor flange-mounted on the pump casing
is a variable range governor designed to
keep the speed set of varying load.

EC9OM016

2.7.2. Fuel filter

This fuel filter has two functions not only oil
Air bleeding plug
filtering but
Seal ring
also water separating
Before entering the suction chamber of the
injection pump, the fuel is cleaned in a Head, fuel filter
strainer of fuel feed pump and a fuel filter.
Drain water in filter with loosening the drain Cartridge, fuel filter
plug under filter manually from time to time.
The fuel filter element should be replaced at
Water drain plug
every 200 hours. EC9OM017

2.7.3. Fuel requirements

DOOSAN diesel engines was designed to use Number 2-D diesel fuel or equivalent that meets
specification DIN 51601-DK. For maximum fuel economy, Number 2-D fuel whenever possible. When
temperatures are below -7 °C (20 °F), use Number 1-D fuel. If Number 1-D fuel is not available, the
mixture of one kerosene to two gallons of Number 2-D fuel can be used. Once kerosene has been added,
the engine should be run for several minutes to mix the fuel.

Technical information - 18 -
2.7.4. How to select fuel oil
Fuel quality is an important factor in obtaining satisfactory engine performance, long engine life, and
acceptable exhaust emission levels. DOOSAN engines are designed to operate on most diesel fuels
marketed today. In general, fuels meeting the properties of ASTM Designation D975 (grades 1-D and 2-D)
have provided satisfactory performance.
The ASTM 975 specification, however, does not in itself adequately define the fuel characteristics needed
for assurance of fuel quality.
The properties listed in the fuel oil selection chart below have provided optimum engine performance.
Grade 2-D fuel is normally available for generator service. Grade 1-D fuel should not be used in pleasure
craft engines, except in an emergency.

Fuel Oil Selection Chart

General Fuel ASTM No. 1 No. 2

DIN 51601
Classification Test ASTM 1-D ASTM 2-D
#)
Gravity, °API D 287 40 ~ 44 33 ~ 37 0.815 ~ 0.855

Flash Point
D 93 100 (38) 125 (52) 131 (55)
Min. °F (°C)
Viscosity, Kinematic
D 445 1.3 ~ 2.4 1.9 ~ 4.1 1.8 ~ 10
CST 100 °F (40 °C )

Cloud Point °F #) D 2500 See Note 1) See Note 1) See Note 1)

Sulfur Content
D 129 0.5 0.5 0.15
wt%, Max.
Carbon Residue
D 524 0.15 0.35 0.1
on 10%, wt%, Max.
Accelerated Stability
Total Insolubles D 2274 1.5 1.5
mg/100 ml, Max. #)

Ash, wt%, Max. D 482 0.01 0.01

Cetane Number, Min. +) D 613 45 45 > 45

Distillation
Temperature, ℉(℃)
IMP, Typican #) 350(177) 375(191)
10% Typical #) D 86 385(196) 430(221)
50% Typical #) 45(218) 510(256)
90% +) 500 (260) Max. 625(329) Max. 680(360)
End Point #) 550(288) Max. 675(357) Max.

Water & Sediment

D 1796 0.05 0.05 0.05
%, Max.

#) Not specified In ASTM D 975

+) Differs from ASTM D 975

NOTE
1) The cloud point should be 6 °C (10 °F) below the lowest expected fuel temperature to prevent clogging
of fuel fitters by crystals.
- 19 - Technical information
2.8. Cooling system

The engine has a liquid-cooling system. The fresh water pump is a maintenance-free by V-belt from the
crankshaft pulley.
Depending on the agreed extent of delivery and the design of the engine, the coolant circuit can be
equipped with temperature monitors which, in the event of loss of coolant, shut the engine down.

z Check the coolant level of the expansion tank by removing the expansion tank filler cap, and add coolant
if necessary.
z When injecting antifreeze solution, first drain out the old coolant from the cylinder block and radiator, and
then clean them with cleaning solution.
z Be sure to mix soft water with antifreeze solution.

Technical information - 20 -
2.8.1. Anti-freeze
The anti-freeze, 50% of the whole coolant, is always to be used to prevent the cooling system from the
corrosion. And in winter the amount of anti-freeze shown in the following table should be used in
accordance with the ambient temperature.

Ambient
Cooling water (%) Anti-freeze (%)
Temperature (°C)
Over -10 85 15
-10 80 20
-15 73 27
-20 67 33
-25 60 40
-30 56 44
-40 50 50

As the individual freezing points corresponding to the proportions of antifreeze in the table are subject to
change slightly according to the kind of antifreeze, you must follow the specifications provided by the
antifreeze manufacturer.
As the ratio of antifreeze in the mixture decrease each time new coolant is added to make up for the loss
coolant resulting from engine operation, Check the mix ratio with every replenishment of coolant, and top
up as necessary.

2.8.2. Cooling water

z Regarding the engine cooling water, the hard water must be used (Do not use the soft water).
z The engine cooling water can be used diluting it with antifreezing solution 40% and the additive for rust
prevention (DCA4) 3 ∼ 5 %.
z The density of above solution and additive must be inspected every 500 hours to maintain it properly.

NOTE
The proper density control of antifreezing solution and rust preventing additive will be able to
prevent the rusting effectively and maintain the stable quality of engine.
For the improper control might give the fatal damage to the cooling water pump and cylinder liners,
detail care is needed.

z Since DB58 cylinder liner is dry type, particularly the cooling water control should be applied thoroughly.
z The density of antifreezing solution and additive for rust prevention is able to be confirmed by the
cooling water test kit. (Fleetguard CC2602M)
z How to use the cooling water test kit
(1) When the cooling water temp. of engine is in the range of 10 ∼ 55 °C, loosen the plug for cooling
water discharge and fill the plastic cup about a half.

- 21 - Technical information
NOTE:
In taking the cooling water sample, if the water in auxiliary tank were taken, it is hard to measure
the accurate density. Take the cooling water sample necessarily loosening the cooling water
discharge plug.

(2) At the state of a test paper soaked in the sampled water, after taking the paper out through water
agitation, shake off the water.
(3) Wait for about 45 sec. till the color change of test paper.

NOTE:
However, it should not elapse longer than 75 sec, and if it did, the hue would change.

(4) Make the numerical value by comparing the test paper which hue has changed with the color list of
label on storage bottle.
(5) By comparing the hue changed into yellowish green or so with the green color indication of test paper
storage bottle, confirm the density. (Then, the density indication must be in the hue range of 33% to
50%).
(6) The brown at the middle of test paper and the lower pink color indication represent the additive state
for rust prevention, and the proper range is that the meeting numerical value of brown (vertical) and
pink color (horizontal) (7) locates in the range of 0.3 to 0.8 at the color list of label on the test paper
storage bottle.
(8) In case of less than 0.3, replenish the additive for rust prevention (DCA4), and in case of more than
0.8, pour out the cooling water about 50% and then readjust the density after refilling with clean fresh
water.

Technical information - 22 -
2.9. V-belt tension check and adjust

z V-Belt
By the finger-pressure the belt is pressed by
10mm ∼ 15mm between the fan pulley and
the alternator pulley in normal condition. For
the adjustment of the tension, loosen the
adjusting bolts which support the alternator,
adjust the tension and tighten the bolts
again.

EA9O2006

z Poly belt
Poly belt will be properly tensioned if the
deflection force “F” is applied midway
between the belt`s tangent points with the
pulley.

T = 0.015 x S (about 1.5mm per 100mm)

EB5O6003

- 23 - Technical information
2.10. Valve clearance and
adjustment

NOTE:
The cylinder head bolts were previously
tightened with the torque wrench.
Therefore it is not necessary to retighten
the cylinder head bolts before adjusting
the valve clearance.

Rocker arm screw

2.6 ±0.5kg.m
lock nut torque

EAOO4014

z After letting the #1 cylinder's piston come

at the compression top dead center by
turning the crankshaft, adjust the valve
clearances.
z Loosen the lock nuts of rocker arm
adjusting screws and push the feeler
gauge of specified value between a rocker
arm and a valve stem and adjust the
clearance with adjusting screw
respectively and then tighten with the lock
EJM1035S
nut.
z As for the valve clearance, adjust it when
in cold, as follows.

Model Intake Valve Exhaust Valve

DB58S 0.4 mm 0.4 mm

1) Rotate the crankshaft to overlap the intake and the exhaust valves of #6, then #1 cylinder become the
compression state of top dead center.
2) Therefore adjust the valve clearance corresponding to “ ” of lower figure. At this time there are
no force on the push rods of #1 cylinder.
3) Rotating the crankshaft by one revolution, #6 cylinder become the compression state of top dead center.
4) Thereafter adjust the valve clearances corresponding to “ ” of lower figure.
5) After reinsuring the valve clearances, retighten if necessary.

Technical information - 24 -
• No. 1 cylinder is located at the side where flywheel was installed.

Cooling fan Cylinder no. Exhaust valve Intake valve Fly wheel

EC9OM020

2.11. Cylinder compression

pressure

z Stop the engine after warming up, and

take out preheating plug and injection pipe.

z Install the special tool (compression gauge

adapter) at the preheating plug hole, and
connect the compression pressure gauge
there.

EJM1046S

z Check the compression pressure at gauge

several times until highest compression
reading is reached.

Standard value 28kg/cm² over

Limit value 24kg/cm²
Difference
between each Within ± 10 %
cylinder

EJM1047I
z Condition : Water temperature 75°C.

- 25 - Technical information
2.12. Injection nozzle

EFM1006I

z Install a nozzle on the nozzle tester.

z If the inspected injection pressure is less than the specified value, adjust using the adjusting shims.

Engine model Injection nozzle pressure

DB58S 220 kg/cm²

z Check the atomizing state and replace it if abnormal.

2.13. Battery

z Inspect for any leakage of electrolytic solution owing to battery crack, and replace the battery in case of
poor condition.
z Inspect for amount of electrolytic solution, and replenish if insufficient.
z Measure the gravity of electrolytic solution, if less than specified value (1.12 ∼ 1.28), replenish.

2.14. Starting motor

z In case of engine maintenance, clean pinion and ring gear thoroughly putting in the fuel, and coat them
with grease.
Also, in case of washing engine room and so forth, inspect the wiring state being careful for water not to
get in.

EFM1007I

Technical information - 26 -
2.15. Diagnosis and remedy

z The following description summarizes the probable cause of and remedy for general failure by item.
z Immediate countermeasures should be taken before a failure is inflamed if any symptom is detected.

1. Engine Starting Impossible

Starting motor does not turn Starting motor turns but

engine does not revolution

Inspection of battery electrolytic Engine Fule

Iiquid amount & gravity
Inspect air cleaner Inspect amount of fule
Normal Too Iow

Adjustment, Normal Polluted Normal No fule

Recharging
Replace or Replenish
Inspection of Ioose electric Clean element
Wiring & short
Inspect fule injection
Check compression
Normal Retighten. pressure
Replace
Normal No fule injection
Normal Too low
Inspection of starter switch Inspect
Repair injection Air bleeding
Retighten. Replace timing and re-start
Replace
Inspect of Normal
Inspection of starter relay other parts Adiust

Normal Replace Check valve Inspect injust

clearance nozzle (injection
pressure, injection
Normal Adjust state ect.)
Inspection of starter switch Repair
Replace
Normal Retighten. Check Normal
Replace clinder Replace
head gasket Disassemble and
Starting motor Inspect injection pump
disassembly Normal

Engine disassembly
(valve assembly, piston,
cylinder liner ect.

Inspect fule feed pump for function

Normal Inspect feed pump valne and Air mixture in fule

Disassemble and Normal Clean Retighten connection

Inspect injection pump Replace Parts. Replace gasket
Inspect fule filter
Air bleeding
Dirty element ald/or
overflow valve faulty Continuous entry of air
In fuel system
Replace
Disassemble and
Check fuel feed pump
- 27 - Technical information
2. Engine Overheated

Operating state
1. Overload
2. Radiator core clogged
3. Continuous over-run
Cooling system Fule system

Check coolant level Inspect fule quality Fuel excessive supply

Poor Check injection nozzle

Normal Too low
Clean and replace
with specified fule Normal Abnormal
Check fan belt
tension, wear
or damage etc. Replenish Adjust or Repair
repair Replace
Normal Repair. Injection
Replace Inspect cooling pump
water leakage

Check fresh Extemal Intemal

radiator tank cap
Repair Engine
Normal Repair
Replace disassembly

Check thermostat

Normal Repair

Inspect radiator Damage

Repair.
Replace

Normal Check cooling

water pump
Check cooling
water passage Normal Repair.
Replace

Engine
disassembly

Technical information - 28 -
3. Output insufficient

Engine Chassis

Check for clutch silp

Fule system Others Adjust or replace clutch

Check for air maxing Inspect air cleaner

In fule

Inspect fule supply pump Normal Clean.

Replace

Normal Clean. Inspect engine control Inspect air leakage

Replace rod, link, cable, ect of air piping line

Inspect fule filter Normal Repair Normal Retighten.

and over flow valve Replace Replace

Normal Replace Check valve clearance Inspect air leakage

of intercooler
Inspect injection pipes Normal Adjust

Normal Repair Inspect cylinser head

Replace gasket for damage

Inspect injection nozzle Normal Replace

(injection pressure,
atomizing state ect.) Engine disassembly
(valve assembly)
Normal Adjust.
Replace

Check injection timing

Normal Adjust.

Disassemble engine
Check turbocharger
or injection pump

Normal Repair
Replace

Disassemble injection
pump or engine

- 29 - Technical information
4. Oil Pressure Iowered

Check if pressure
Check oil amount
gauge indicates wrongly

Normal To Iow

Check cooling
temperature Use recommened oil
(replenish)
Too high
Normal

Refer to engine overheat

Inspect oil quality

Normal

Check oil Water and fule Improper

relief valve mixed in oil

Disassemble engine Replace with

Normal Reyighten. or injection pump recommended oil
Replace

Disassemble
engine

Technical information - 30 -
5. Fule Consumption Excessive

Cause according to use conditions

1. Overlow
2. Frequent use of low gear position
3. Frequent use of high gear position
at low speed
Inspect fule Ieakage
4. Clutch slip
5. Too low tire inflation pressure

Normal Fule leakage

Inspect injection nozzle Retighten

(injection pressure Replace
atomizing state, ect.)

Normal Adjust
Replace

Inspect injection timing

Normal Adjust

Inspect compressed
pressure
Check valve Pepair, Replace
Normal Adjust clearance (cylinder liner,
piston ring, piston)

Disassemble
injection pump

Normal Adjust

Inspect head gasket

Normal Replace

Disassemble engine
(valve assembly, pistion,
cylinder er, ect.)

- 31 - Technical information
6. Oil Consumption Excessive

Cause according to use conditions

1. Excessive oil infusing
2. Continuous operation in low speed
or extremely cold state

Inspect oil leakage Inspect air cleaner

Clean Replace
Normal Oil leakage

Check oil quality

Extermal Internal

Replace with Retighten. Check compressed

specified oil Replace pressure

Engine disassembly Normal

(piston, cylinder liner)
Disassemble
cylinder head
(valve stem seal)

7. Engine Knocking

Inspection combustion of fule & oil

(carbon residue of exhaust gas)

Unconfirmed Confirm

Inspect compressed
pressure Disassemble
engine

Normal Too Low

Inspect injection Check valve clearance and

timing cylinder head gasket crush

Normal Adjust Normal Replace

Adjust

Check fule quality Disassemble

engine

Use specified fule

Technical information - 32 -
8. Battery Discharge

Battery Wiring, Switch Altemator

Check electrolytic Inspect cut wire Check fan belt

liquid amount shorts and loose tension & damage
connections, etc.

Repair. Replace

Normal Damaged Battery self Battery over

battery case dischage charging

Electrolytic
liquid’s standard Replace Charging Inspect altemator
and voltage regulator

Replenish

Normal Abnormal

Check charged stated Adjust

Replace
Discharging

Disassemble altemator
and voltage regulator

- 33 - Technical information
Condition Causes Remedies
1) Starting difficult
(1) Compression pressure z Valve's poor shut, stem distortion Repair or replace
z Valve spring damage Replace valve spring
z Cylinder head gasket's leak Replace gasket
z Wear of piston, piston ring or liner Adjust
2) Idle operation abnormal z Injection timing incorrect Adjust
z Air mixing at injection pump Remove air
3) Engine output insufficient
(1) Continuous output z Valve clearance incorrect Adjust
Insufficient
z Valve tightness poor Repair
z Cylinder head gasket's leak Replace gasket
z Wear, stick, damage of piston ring Replace piston ring
z Injection timing incorrect Adjust
z Fuel injection amount insufficient Adjust injection pump
z Nozzle injection pressure improper or stuck Adjust or replace
z Supply pump's function lowered Repair or replace
z Fuel pipe system clogged Repair
z Air suction amount insufficient Clean or replace air cleaner
z Turbocharger poor Repair or replace
(2) Output insufficient z Compression pressure insufficient Disassemble engine
when in acceleration
z Injection timing incorrect Adjust
z Fuel injection amount insufficient Adjust injection pump
z Injection pump timer's function insufficient Repair or replace
z Nozzle injection pressure, injection angle Repair, replace
improper
z Supply pump's function lowered Repair or replace
z Air intake amount insufficient Clean or replace air cleaner
4) Overheating z Engine oil insufficient or poor Replenish or replace
z Cooling water insufficient Replenish or replace
z Fan belt loosened, worn, damaged Adjust or replace
z Cooling water pump's function lowered Repair or replace
z Water temperature regulator's operation poor Replace
z Valve clearance incorrect Adjust
z Exhaust system's resistance increased Clean or replace

Technical information - 34 -
Condition Causes Remedies
5) Engine noisy For noises arise compositely such as
rotating parts, lapping parts etc., there is
necessity to search the cause of noises
accurately.
(1) Crankshaft z As the wear of bearing or crankshaft Replace bearing & grind
progress, the oil clearances increase. crankshaft
z Lopsided wear of crankshaft Grind or replace
z Oil supply insufficient due to oil passage Clean oil passage
clogging
z Stuck bearing Replace bearing & grind
(2) Connecting rod and z Lopsided wear of connecting rod bearing Replace bearing
Connecting rod bearing
z Lopsided wear of crank pin Grind crankshaft
z Connecting rod distortion Repair or replace
z Stuck bearing Replace & grind crankshaft
z Oil supply insufficiency as clogging at oil Clean oil passage
passage progresses
(3) Piston, piston pin & z Piston clearance increase as the wear of Replace piston &
piston ring piston and piston ring progresses piston ring
z Wear of piston or piston pin Replace
z Piston stuck Replace piston
z Piston insertion poor Replace piston
z Piston ring damaged Replace piston
(4) Others z Wear of crankshaft, thrust bearing Replace thrust bearing
z Camshaft end play increased Replace thrust plate
z Idle gear end play increased Replace thrust washer
z Timing gear backlash excessive Repair or replace
z Valve clearance excessive Adjust valve clearance
z Abnormal wear of tappet, cam Replace tappet, cam
6) Fuel Consumption excessive z Injection timing incorrect Adjust
z Fuel injection amount excessive Adjust injection pump
7) Oil consumption excessive
excessive
(1) Oil level elevated z Clearance between cylinder liner & Replace
piston
z Wear of piston ring, ring groove Replace piston, piston ring
z Piston ring's damage, stick, wear Replace piston ring
z Piston ring opening's disposition Correct position
improper
z Piston skirt part damaged or abnormal Replace piston
wear
z Oil ring's oil return hole clogged Replace piston ring
z Oil ring's contact poor Replace piston ring
(2) Oil level lowered z Looseness of valve stem & guide Replace in set
z Wear of valve stem seal Replace seal
z Cylinder head gasket’s leak Replace gasket
(3) Oil leak z Looseness of connection parts Replace gasket, repair
z Various parts' packing poor Replace packing
z Oil seal poor Replace oil seal

- 35 - Technical information
2.16. Engine inspection

2.16.1. Stopping engine

After checking the engine for any unusual condition at the idling speed, then turn the key switch to the stop
the engine.

2.16.2. General engine inspection cycle

In order to insure maximum, trouble-free engine performance at all times, regular inspection, adjustment
and maintenance are vital.
z Daily inspections in below figure should be checked every day.
z The following maintenance details should be executed thoroughly at regular internals.

O : Check & adjust ● : Replace

Every Every Every Every Every
Inspection Daily Remark
50hrs 200hrs 500hrs 600hrs 1200hrs
Check for leakage(hoses,
O
clamp)
Check the water level O
Cooling
System
Change the coolant water ●
Every
Adjust the V-belt tension O
2,000hrs
Clean the radiator O
Check for leakage O
Check the oil level gauge O
Lubrication
Change the lubricating oil
● ●
System 1st
Replace the oil filter ● ●
cartridge 1st
Check the leakage for
O
Intake & Exhaust intercooler (hoses, clamp)
System Clean and change O
the air cleaner element clean
●
Check the leakage fuel
O
line
Clean the fuel strainer
O
of fuel feed pump
Remove sediment from
O
fuel tank
Fuel Drain the water in
O
System separator
Replace the fuel filter
element
●
When
Check fuel injection timing O
necessary
Check the injection When
O
nozzles necessary
Check the state of
O
exhaust gas
Check the battery
O
Engine charging
Adjust Check the compression When
O
pressure necessary
Adjust Intake/Exhaust O When
valve clearance 1st necessary

Technical information - 36 -
2.17. Use of original parts for repair and replacement

For engine is being mechanically harmonized with many parts, only when the original parts that the
manufacture recommends to use is used, the engine trouble would be preventively maintained and
capable to keep up the maximum performances.
For the analogous parts not the original parts are poor in qualities and gives ill performance, it may rather
bring early engine failure.

- 37 - Technical information
3. Maintenance
3.1. Engine Disassembly

3.1.1. Major part fixing nuts and bolts

1) Cylinder head cover

(Unit : kg.m)

EJM1001S

Engine disassembly - 38 -
2) Cylinder block

(Unit : kg.m)

EJM1002S

- 39 - Engine disassembly
3) Oil pan and level gauge

(Unit : kg.m)

EJM1003S

Engine disassembly - 40 -
4) Camshaft and rocker arm

(Unit : kg.m)

EJM1004S

- 41 - Engine disassembly
5) Crankshaft, piston and flywheel

(Unit : kg.m)

EJM1005S

Engine disassembly - 42 -
6) Thermostat and housing

(Unit : kg.m)

EJM1006S

- 43 - Engine disassembly
7) Intake and exhaust manifold

(Unit : kg.m)

EJM1009S

Engine disassembly - 44 -
8) Timing gear case and flywheel housing

(Unit : kg.m)

EFM1010S

- 45 - Engine disassembly
9) Oil cooler, oil filter and oil pump

(Unit : kg.m)

EFM1011S

Engine disassembly - 46 -
10) Fuel system

(Unit : kg.m)

EFM1012S

- 47 - Engine disassembly
11) Engine repair parts

2 3 5
1 4

9 10
8
7
6

13 14 15
11 12

20 21 22
16 17 18
19
EC9OM064

1. Cover to timing gear case gasket 12. Oil filter cover gasket
2. Gear case to cylinder block gasket 13. Oil cooler gasket
3. Timing gear case oil seal 14. Intake manifold gasket
4. Flywheel housing gasket 15. Oil pan gasket
5. Crank shaft rear oil seal 16. Turbocharger gasket
6. Cylinder head gasket 17. Turbocharger outlet gasket
7. Cylinder head cover gasket 18. Water pump gasket
8. Valve guide oil seal 19. Water pump housing gasket
9. Tappet chamber cover gasket 20. Exhaust manifold gasket
10. Air heater gasket 21. Thermostat gasket
11. Thermostat housing gasket 22. Oil pump hole cover gasket

Engine disassembly - 48 -
3.1.2. Main structure parts (1)

EJM2010S

1. Rubber hose (Coolant by-pass) 9. Oil pump driving pinion

▲ 2. Rocker arm shaft assembly 10. Nut
3. Push rod ▲ 11. Crankshaft pulley and dust cover
4. Cylinder head bolt ▲ 12. Taper bushing
▲ 5. Cylinder head assembly 13. Timing gear cover
6. Cylinder head gasket 14. Oil thrower
7. Coolant pump assembly ▲ 15. Fly wheel
8. Tappet chamber cover

2) Rocker arm shaft

Loosen the rocker arm shaft fixing bolts a
little in numerical sequence as specified.

EJM2013S

- 49 - Engine disassembly
5) Cylinder head
Loosen the cylinder head bolts a little in the
numerical order shown in the figure.

EJM2014S

11) Crankshaft pulley

Use an appropriate wrench (54 mm) to
remove the crankshaft pulley nut.

EJM2015S

12) Taper bushing

Use the taper bushing remover to remove
the crankshaft end taper bushing.

EDM1010I

15) Flywheel
Loosen the flywheel bolts a little in the
numerical order as specified.

EJM2017S

Engine disassembly - 50 -
3.1.3. Main structure parts (2)

EJM2018S

1. Oil cooler 9. Timing gear case

2. Oil pan 10. Idler gear shaft
3. Oil pump and coupling ▲ 11. Crank shaft bearing cap
4. Flywheel housing 12. Crank shaft bearing (lower part)
5. Piston and connecting rod 13. Thrust bearing
▲ 6. Idler gear 14. Crank shaft
▲ 7. Cam shaft 15. Crank shaft bearing (upper part)
8. Tappet

- 51 - Engine disassembly
6) Idler gear
Measure the following points before
disassembly.

<Idler gear end play>

Standard Limit
0.058 ∼ 0.115 mm 0.2 mm

EJM2022S

<Timing gear back lash>

Standard Limit
0.10 ∼ 0.17 mm 0.3 mm
Includes the crankshaft gear, the camshaft
gear and the idler gear

EJM2019S

7) Camshaft
Measure the following points before
disassembly.

<Cam Gear End Play>

Standard Limit
0.050 ∼ 0.114 mm 0.2 mm

EJM2020S

11) Crankshaft bearing cap

Measure the crankshaft endplay at the thrust
bearing (center main bearing) before
disassembly.

<Crankshaft End Play>

Standard Limit
0.15 ∼ 0.33 mm 0.4 mm

EJM2021S

Engine disassembly - 52 -
3.1.4. Rocker arm disassembly

EJM2023S

1. Bracket 3. Spring
2. Rocker arm 4. Rocker arm shaft

- 53 - Engine disassembly
3.1.5. Cylinder head disassembly

EJM2024S

1. Exhaust manifold and gasket 7. Spring seat (upper)

2. Intake manifold and gasket 8. Valve spring
3. Coolant outlet pipe 9. Spring seat (lower)
4.Thmostat 10.Valve
5. Thermostat housing and gasket 11. Valve stem oil seal
▲ 6. Valve cotter

Engine disassembly - 54 -
Importance

6) Valve cotter
Use the valve spring compressor to remove
the valve cotter.

EJM2027S

3.1.6. Piston and connecting rod disassembly

EJM2028I

▲ 1. Piston rings 4. Piston

▲ 2. Snap ring 5. Connecting rod bearing
▲ 3. Piston pin and connecting rod

- 55 - Engine disassembly
IMPORTANT:
Remove any carbon deposits from the
upper part of the cylinder bore.
This will prevent damage to the piston and
the piston rings when they are removed
from the cylinder bore.

EDM1011I

1) Piston rings
Use a piston ring remover to remove the piston
rings.
Do not attempt to use other tools. Stretching
piston ring will result in reduced piston ring
tension.

EJM2030I

2) Snap ring
Use a pair of snap ring pliers to remove the
snap ring.

EJM2031S

3) Piston pin
Tap the piston pin out with a hammer and
brass bar.

EJM2032S

Engine disassembly - 56 -
3.2. Engine Inspection

3.2.1. Cylinder block

z Clean the cylinder block thoroughly and make a visual inspection for cracks or damage.
z Replace if cracked or severely damaged, and correct if slightly damaged.
z Check oil and water flow lines for restriction or corrosion.
z Make a hydraulic test to check for any cracks or air leaks.
(Hydraulic test) :
Stop up each outlet port of water/oil passages in the cylinder block, apply air pressure of about
5kg/cm2 against the inlet ports, then immerse the cylinder block in water for about 3 minute to check
any leaks. (Water temperature : 70 °C)

3.2.2. Cylinder head

1) Inspection
z Carefully remove carbon from the lower lace of the cylinder head using nonmetallic material to
prevent scratching of the valve seat faces.
z Check the entire cylinder head for very fine cracks or damage invisible to ordinary sight using a
hydraulic tester or a magnetic flaw detector.

2) Distortion at the lower face

z Measure the amount of distortion using a
straight edge and a feeler gauge at six
positions (A ∼ F) as shown in the right
figure.
z If the measured value exceeds the
standard value, retrace the head with
grinding paper of fine grain size to correct
such defect.
z If the measured value exceeds the
maximum allowable limit, replace the
cylinder head. EA3M2031

<Lower face warpage and height>

Standard Limit
0.2 mm or
Warpage 0.3 mm
less
89.95 ∼ 90.05
Thickness : t 89.65 mm
mm

EJM2034S

- 57 - Engine inspection
3) Flatness
Measure flatness of the intake/exhaust
manifolds fitting surfaces on the cylinder
head using a straight edge and a feeler
gauge.

Standard Limit
0.05 mm 0.2 mm

4) Hydraulic test
Hydraulic test method for the cylinder head
is same as that for cylinder block.

EJM2036S

3.2.3. Valve stem and valve guide

clearance
1) Measuring method - I
z After install dial gauge needle on the
inserted valve stem, set up calibrator to
“0”. (as shown in figure)
z Move valve head from side to side.
z Record total dial indicator reading.
z This valve is the clearance between the
valve stem and valve guide.
z Valve and guide set must be replaced if
measured value exceed the specified
limit
EJM2037S

<Valve stem clearance (T.I.R)>

Standard Limit

0.039 ∼
Intake side 0.20mm
0.071mm
0.064 ∼
Exhaust side 0.25mm
0.096mm

Engine inspection - 58 -
2) Measuring method – II
z Measure valve stem outside diameter.
z Measure valve guide inside diameter by
using of caliper calibrator of telescoping
gauge.
z The difference between the valve stem
outside diameter and the valve guide
inside diameter is the valve stem
clearance.

EJM2038S

3) Valve guide replacement

z Removal of valve guide
z Pull out the valve guide, by using
hammer and valve guide remover, from
bottom of cylinder head.

EJM2039S

z Install of valve guide

z The height from the bottom of the

cylinder head to the edge of valve guide
top should be 14.1mm.

EJM2040S

4) Valve depression
z Install the valve① to the cylinder head②.
z Measure valve depression by using the
depth gauge or calibrator from the bottom
of cylinder head.
z Seat insert and valve must be replaced if
the measured value exceed the specified
limit.
z If the valve is replaced, the valve guide
must be also replaced.

EJM2041I

- 59 - Engine inspection
Standard Limit
Intake and exhaust
1.0 mm 2.5mm
valve depression

5) Valve contact width

z Inspect the valve contact faces for the
roughness and unevenness.
z Make valve contact surfaces smooth.
z Measure the width of valve contact.

Standard
Valve contact width, Intake 2.4mm
Valve contact width, Exhaust 1.6mm

EJM2042I

6) Valve seat replacement

z Arc weld entire inside circumference① of
the valve seat②. (see figure)
z Cool valve seat for a few minutes. This
will make removal of the valve seat
easier.
z Pull out the valve seat by using the inner
extractor.
z Carefully remove the carbon and other
foreign material from the cylinder head
insert bore. EJM2043S

7) Valve seat installation

z Carefully place Jig①.

CAUTION:
The smooth face of jig must contact the
valve seat.

z Assemble valve insert by slowly pressing

it against the jig with the bench press.
(The amount of needed pressure is more
than 2,500kg.) EJM2044I

IMPORTANT:
Do not press the valve seat excessively with the bench press.
It may damage the valve seat.

Engine inspection - 60 -
8) Valve seat correction
z Remove the carbon deposits from the
valve seat surface.
z Remove the rough areas by using valve
cutter. (30°, 90° or 150°)
Do not cut the valve seat too much.

Angle Location Standard

Intake valve seat 90°
Exhaust valve seat 90°

IMPORTANT:
Use an adjustable valve cutter pilot.
Do not allow the cutter pilot to wobble
inside the valve guide.

EJM2046S

z Spread compound on the surface of

valve seat.
z Insert valve into valve guide.
z Lap the valve and valve seat with the
lapping tool.
z Check that valve contact width is correct.

EJM2047I

z Check that the entire surface of valve

seat is in contact with the valve.

EJM2048S

- 61 - Engine inspection
3.2.4. Valve spring
1) Valve spring free length
z Measure the valve spring with the vernier
caliper.
z Replace the spring if the measured value
is less than the specified limit.

Standard Limit
Exhaust and intake
valve spring free 53.65 mm
52 mm
length
EJM2049I

2) Valve spring inclination

z Measure the valve spring inclination by
the using of square.
z Replace the valve spring if the measured
value exceed the specified limit.

Standard Limit
Valve spring
2.5 mm 3.5 mm
Inclination

EJM2050I

3) Valve spring tension

z Measure the valve tension by using
spring tester.
z Replace the valve spring if the measured
value exceed the specified limit.

Standard Limit
Valve spring tension
22.5 kg 20.0 kg
at 44mm set length

EA0M4056

Engine inspection - 62 -
3.2.5. Tappet
z Check the valve tappets for excessive
wear, damage or abnormalities.

EA0M4070

z Measure the outside diameter of tappet

with the micrometer.

Standard Limit
Tappet
∅27.96 ∼ ∅27.92
outside
∅27.98mm mm
diameter

EJM2052S

z Measure the clearance between tappets

and cylinder motion parts by the using
dial indicator.

Standard Limit
Tappet and tappet 0.020 ∼
0.1mm
bore clearance 0.054mm

EJM2053S

3.2.6. Push rod

z Measure the run out of push rod with the
feeler gauge.
z Roll the push rod along a smooth flat
surface as shown in the figure.

Limit
Push rod of run-out 0.2mm

EA0M4073

- 63 - Engine inspection
3.2.7. Rocker arm correction
z Check the valve stem contact part of
rocker arm.
z Grind contact surface with an oil stone if it
is irregularly contacted.
z Replace the rocker arm if it is extremely
damaged.

EJM2055S

1) Rocker arm and shaft

z Check the disassembled parts for wear,
damage and abnormalities.

EC9OM054

2) Rocker arm shaft outside diameter

z Measure the outside diameter of rocker
arm with the micrometer.
z Replace shaft if measured value exceed
the specified limit.

Standard Limit
diameter of
∅18.98-∅19.00 ∅18.85
rocker arm
mm mm
shaft
EJM2057S

3) Rocker arm and shaft clearance

z Measure the inside diameter of rocker
arm bushing with the vernier caliper.
the out side diameter of rocker arm
shaft.
z Replace the rocker arm or rocker arm
shaft if measured value exceed the
specified limit.

Standard Limit
Diameter of rocker ∅19.02 ∼ ∅19.07 EJM2058S
Arm bushing ∅19.05mm mm

Engine inspection - 64 -
Standard Limit
Rocker arm
bushing and 0.02 ∼ 0.07
0.2 mm
rocker arm shaft mm
clearance

z Check the rocker arm oil port whether

alien substance is in it or not.
z Clean the rocker arm oil port with
compressed air if necessary. EJM2059I

3.2.8. Idler gear and shaft

z Replace the idler gear shaft if the
measured value exceeds the specified
limit.

Standard Limit
Diameter of
∅44.945 ∼ ∅44.9
idler gear
∅44.975 mm mm
shaft

EJM2060S

z Measure the inside diameter of idler gear

with the dial indicator,

Standard Limit
Clearance of idle 0.045 ∼
0.2 mm
gear and shaft 0.105 mm

EJM2061I

3.2.9. Camshaft
z Use the jig to install or overhaul camshaft
bearing in cylinder block.
z Measure the clearance between the cam
journal and the camshaft bearing.

EJM2062S

- 65 - Engine inspection
Standard Limit
Clearance of
0.03 ∼ 0.09 0.15
cam journal and
mm mm
cam bearing

EJM2063S

z Align the camshaft bearing oil port with the

mating oil port (machined on the cylinder
block).

EJM2064S

z Measure the cam lobe with the micrometer.

Replace the camshaft if the measured
values exceed the specified limit.

Standard Limit
Cam lobe height 6.94
7.44 mm
(C-D), In mm
Cam lobe height 7.21
7.71 mm
(C-D), Ex mm
Cam journal ∅55.6 EA0M4062
∅56.0 mm
diameter mm

z Set up the camshaft on a measuring stand.

z Measure the run out of camshaft with the
dial indicator.
Record the measured value (T.I.R)
Replace the camshaft if the measured value
exceeds the specified limit.

Limit
Camshaft run-out 0.12 mm

EJM2066I

Engine inspection - 66 -
3.2.10. Cylinder liner
1) Cylinder liner bore measurement
z Measure the bore at measuring position
① in line with the crankshaft③ and
across the crankshaft②.

EJM2067I

z Measured position: 20 mm from the top

of liner. (max. wear portion)
z Replace the cylinder liner if the measured
value exceeds specified limit.

Standard Limit
Diameter of
∅102.017∼ ∅102.20
cylinder liner
∅102.046 mm mm
bore
EJM2068I

CAUTION:
The casting liner is specially honed without
the chrome plating inside, so that chrome
plated ring (top ring and oil ring) must be
used.

2) Cylinder liner inspection

z Set up the straight square along the top
edge of cylinder liner.
z Measure liner projection with the feeler
gauge.

Standard
0.02 ∼ 0.07
Cylinder Cast liner
mm
liner
0.015 ∼
projection Steel liner
0.115mm EJM2069S

z The difference in the liner projection

height between any two adjacent
cylinders must NOT exceed 0.3mm

- 67 - Engine inspection
3) Cylinder liner replacement
z Set the cylinder liner remover to the
cylinder liner.
z Check that cylinder liner remover shaft
ankle is firmly gripping the cylinder liner
bottom edge.
z Slowly turn the remover shaft handle
counter-clockwise to pull the cylinder liner
free.

IMPORTANT: EDM3004S
Take care not to damage the cylinder body
upper face when remove the cylinder liner.

3.2.11. Cylinder block

1) Grade selection of cylinder liner
z Select a grade from the outside diameter
of the cylinder liner and inside diameter
of block combination.
z Determine a grade of the cylinder liner
after measuring the inside diameter of the
cylinder block.
z Loose fitting cylinder liners (the liner is
too small for the cylinder bore) will
adversely affect engine cooling efficiency
and may lead to serious engine damage.
EA3M2043
Cylinder liners which are too large for the
cylinder bore will be difficult to install.

2) Cylinder block bore measurement

z Measure at measuring point① across
the positions W- W, X-X, Y-Y and Z-Z.

Measuring pointL diameter : 115 mm

z Calculate average value of four

measurements to determine the correct
cylinder liner grade.

EJM2072I

Engine inspection - 68 -
Grade
Cylinder block bore diameter
marking
1 ∅105.090 ∼ ∅106.000 mm
2 ∅106.000 ∼ ∅106.010 mm

EJM2073S

3) Cylinder liner outside diameter

z Measure the liner outside diameter at ①,
② and ③measuring point across X-X,
Y-Y.

Measuring Points :
① 20.0 mm
② 105.0 mm
③ 185.0 mm

z Calculate the average value of 6 EJM2074S

measurements to determine the correct
cylinder liner grade.
z Combination of the cylinder bore and the
cylinder liner outside diameter.

Steel liner Cast iron liner

(tightness) (clearance)
Cylinder liner fitting clearance 0.001 ∼ 0.019mm 0.005 ∼ 0.026mm

<Cylinder bore and liner outside diameter>

(A) Steel cylinder liner

Grade Cylinder bore Cylinder liner outside diameter

1 ∅105.001 ∼ ∅105.010mm ∅105.011 ∼ ∅105.020mm
2 ∅105.011 ∼ ∅105.020mm ∅105.021 ∼ ∅105.030mm
3 ∅105.021 ∼ ∅105.030mm ∅105.031 ∼ ∅105.040mm

(B) Cast iron cylinder liner

Cylinder liner diameter

Grade marking
② position ①, ③ position
∅D ∅102.020 ∼ ∅102.031mm ∅102.017 ∼ ∅102.035mm 1
(Inner diameter) ∅102.031 ∼ ∅102.042mm ∅102.028 ∼ ∅102.046mm 2
∅E ∅105.973 ∼ ∅105.984mm ∅105.970 ∼ ∅105.988mm A
(Outer diameter) ∅105.984 ∼ ∅105.995mm ∅105.981 ∼ ∅105.999mm B

- 69 - Engine inspection
Part no of Cylinder liner Marking
cylinder diameter
liner grade Outer Inner
65.01201-
1 A 1A
0068
65.01201-
1 A 1B
0069
65.01201-
2 B 2A
0070
EJM2074S
65.01201-
2 B 2B
0071

4) Cylinder liner assembly

z Carefully wipe away any foreign material
from the cylinder liner inside and outside
surfaces and the cylinder bore.
z Cleanly wash cylinder liner and bore
surfaces with new kerosene or diesel oil.
z Use a clean rag to remove all traces of
kerosene or diesel oil from cylinder liner
and bore surfaces.
z Insert the cylinder liner into cylinder block
from the top of the cylinder block.
z Set the cylinder liner installer to the top of
EJM2074S
the cylinder liner.
z Position the cylinder body so that the
installer center is directly beneath the
bench press shaft center.
z Check that the cylinder liner is set
perpendicular to the cylinder.
z Use the bench press to apply an initial
seating force of 500kg to the cylinder
liner.
z Use the bench press to apply a final
seating force of 2,500kg to fully seat the
cylinder liner. EJM2074S
z After installing the cylinder liner, measure
the cylinder liner projection.
5) Piston grade selection
z ”Piston grade” refers to the piston diameter and the cylinder liner bore combination.
z Selection of the proper piston grade will ensure efficient engine operation, free from cylinder liner and
piston problems.
z Measure the cylinder liner bore after installing the cylinder liner.
z Determine the appropriate piston grade after measuring cylinder liner bore.

Engine inspection - 70 -
6) Cylinder liner bore measurement
z Loacte the two measuring points.
Cylinder liner measuring point
- ① : 20mm
- ② : 105mm
z Measure cylinder liner bore at measuring
points ① and ② in four different
directions (X-X, Y-Y, W-W and Z-Z).
z Calculate the average value of the 8
measurements. EJM2077I

Standard
∅102.020 ∼
Cylinder liner bore
∅102.042 mm

CAUTION:
It is most important to use correct piston-
liner combination. Incorrect combination
will result in piston seizure.
Always measure the cylinder bore and
select the appropriate piston grade. EJM2073S

3.2.12. Piston
1) Piston outside diameter
z Piston outside diameter vary depending
on the piston type to be used.
z Measure the piston outside diameter ②
(see figure).

Grade Limit
A ∅101.953 ∼ ∅101.967 mm

B ∅101.963 ∼ ∅101.977 mm EJM2078I

- 71 - Engine inspection
<Cylinder liner bore and piston>

Clearance 0.053 ~ 0.077 mm

CAUTION:
The cylinder liner-piston kit clearances are
preset. However, the cylinder liner
installation procedure may result in slight
decreases in the cylinder liner bore
EJM2079S
clearances.
Always measure the cylinder liner bore
clearance after installation to be sure that it
is correct.

2) Piston ring and piston groove clearance

z Measure the piston ring and the piston
ring groove clearance with a feeler gauge.
z Measure it at several points around the
piston.
z Replace the piston ring If the measured
value exceeds the specified limit.

<Piston ring and piston groove clearance>

Standard Limit EJM2080S

Top ring 0.070 ∼ 0.120 mm 0.20
2nd ring 0.050 ∼ 0.085 mm 0.15
Oil ring 0.030 ∼ 0.070 mm 0.15

3) Piston ring gap

z Insert the piston ring horizontally (in the
position it will assume if it were installed
to the piston) into the cylinder liner.
z Push the piston ring with an inverted
piston into the cylinder liner until it
reaches measuring point ① or ②.
The cylinder liner diameter is the smallest
at these two points.
Do not allow the piston ring to slant to
one side or the other. It must be perfectly EJM2082S
horizontal.
Cylinder liner measuring point
- ① : 10mm
- ② : 130mm

Engine inspection - 72 -
z Measure piston ring gap with a feeler gauge.
z The piston ring must be replaced if the measured value exceeds the specified limit.

Standard Limit
Top ring gap 0.25-0.45 mm 1.50 mm
2nd ring gap 0.40-0.60 mm 1.50 mm
Oil ring gap 0.20-0.40 mm 1.50 mm

4) Piston pin
z Measure piston pin outside diameter with
micrometer at several points.
z Replace the piston pin if the measured
value exceeds the specified limit.

Standard Limit
Piston pin
Ø35.000 ∼
outside ∅34.95 mm
Ø35.005mm
diameter
EJM2083S

5) Piston pin hole

z Measure diameter of the piston pin hole
with inside dial gauge.

Standard
Piston pin and piston Ø35.010 ∼
clearance Ø35.018 mm

EJM2084S

6) Piston pin and piston pin hole clearance

z Determine the clearance between the
piston pin and the piston pin hole by
calculating the difference between the
piston pin hole diameter and the piston
pin outside diameter.

Limit
Piston pin and piston
0.005 ∼ 0.018 mm
pin hole clearance
EJM2085S

- 73 - Engine inspection
z If an inside dial indicator is not available,
use the following procedure to check the
piston pin fit.
(1) Heat piston to approximately 60°C
with the piston heater.
(2) Push strongly against the piston pin
with your thumb. The piston pin fitting
should feel tight.

EJM2086S

3.2.13. Maintenance of cylinder block, cylinder liner and piston

To maintain the engine in optimum condition and retain maximum performance for a long time, the cylinder
block, cylinder liner and piston which have the same grade marking number (the same size tolerance)
should be assembled. The marking number (the part’s grade) and marking position is as follows.

z Cylinder block
a) Marking number ; 1 or 2
ENGINE SERIAL NO.
(Size grade for of cylinder bore
diameter)
b) Marking position ; Top of the cylinder
block side surface

EC9OM021

z Cylinder liner
a) Marking number; 1A, 1B, 2A or 2B
1A
Can used the piston A grade

Can used the cylinder block 1

b) Marking position ; Cylinder liner
lower surface

EJM2172I

z Piston
a) Marking number ; A or B
(Size grade for piston outer diameter)
b) Marking position ; Center of the piston upper surface

Engine inspection - 74 -
z Assembly process of cylinder block, cylinder liner and piston
(1) Check the marking number (1 or 2) of cylinder block. (Top of side surface)
(2) Then assemble the liner whose first digit of the marking (1A, 1B, 2A, 2B) is just the same with it on
the cylinder block.
(3) Assemble the piston whose marking is just same with the second digit (A or B) of the assembled
cylinder liner’s marking.

3.2.14. Connecting rod

1) Connecting rod alignment
z Measure the parallelism between the
connecting rod big end hole and small
end hole with a connecting rod aligner.
z Replace the connecting rod if the
measured value exceeds the specified
limit.

Standard Limit
Connecting
rod 0.05mm or less 0.20 mm
EJM2087S
parallelism

2) Piston pin and bush clearance

z Measure an inside of connecting rod
bushing and outside of piston pin with the
caliper gauge and micrometer.
z Replace a connecting rod bush or piston
pin if the measured value exceeds the
specified.

Standard Limit
Piston pin and
0.012 ∼
bushing 0.05 mm
0.030mm
clearance EJM2088S

3) Connecting rod bush replacement

z Connecting rod bush removal
1) Clamp the connecting rod in a vise.
2) Pull out connecting rod bush by using
a brass bar with a bench press or a
hammer.
z Connecting rod bush assembly
(1) Use special jig to assemble the
connecting rod bush.

EJM2089S

IMPORTANT:
Align the connecting rod bush oil hole with
the connecting rod oil hole.

- 75 - Engine inspection
(2) Use a piston pin hole grinder① fitted
with a reamer② or an adjustable pilot
reamer to ream the piston pin hole.

Standard
Connecting rod bush Ø35.017 ∼
inside diameter Ø35.030 mm

EJM2090S

4) Connecting rod bearing Inspection

z Fit the connecting bearing lower half into
the connecting rod bearing cap.
z Check the tension of the connecting rod
bearing lower half.
z If the tension is insufficient, the bearing
must be replaced.
z Tighten the connecting rod and the
bearing cap to the specified torque.

A type B type EJM2091S

Connecting
12 0± 9.75±
rod bolt
0.25kg.m 0.25kg.m
torque

A type :

B type : TY or TY
11 12

z Measure the inside diameter of the

connecting rod bearing with an inside dial
gauge.

Standard
Connecting rod Ø63.974 ∼
bearing diameter Ø64.005 mm

EJM2044I

Engine inspection - 76 -
3.2.15. Crankshaft
1) Crankshaft and bearing inspection
z Check the crankshaft journal surfaces and pin surfaces for excessive wear and damage.
z Check oil seal fitting surfaces of the crankshaft front and rear ends for excessive wear and damage.
z Replace or repair the crankshaft if any excessive wear or damage is discovered.
z Check the crankshaft oil ports for obstructions.
z Clean oil port with high pressure air if necessary.

2) Crankshaft journal and pin diameter

z Measure the crankshaft journal outside
diameter with the micrometer across ①-
① and ②-②.
z Measure crankshaft journal outside
diameter at two points ③ and ④ by
using the micrometer.
z Repeat step 1 and 2 to measure the
crankshaft outside diameter.
z The crankshaft must be reground if the
measured value of the crank pin outside EJM2093S
diameter and/or crankshaft journal
diameter exceeds the specified limit.

Standard
Crankshaft
journal outside Ø79.905 ∼ Ø79.925mm
diameter

Standard
Crankshaft pin
Ø63.924 ∼ Ø63.944 mm
outside diameter

z Measure the crankshaft journal outside diameter (and/or crankshaft pin outside diameter) and bearing
inside diameter to determine the bearing clearance.

3) Crankshaft journal and bearing clearance

z If the bearing clearance exceeds the specified limit, the crankshaft must be reground and/or the
bearing must be replaced.

Standard Limit
Main bearing 0.025 ∼
0.11 mm
clearance 0.090 mm

- 77 - Engine inspection
Standard Limit
Rod bearing
0.03 ∼ 0.073 mm 0.10 mm
clearance

4) Crankshaft bearing diameter

z Install the main bearing cap with bearings
to the cylinder block with the specified
torque and facing the arrow mark on the
bearing cap toward front. Place them in
order of punched cylinder numbers.
z Measure the main bearing diameter with
an inside dial gauge.

Main bearing cap torque 24.1±1kg.m

EA0M4019
Main bearing diameter Ø80 mm

5) Crankshaft run-out
z Mount the crankshaft on a set of V-blocks.
z Set the dial gauge to the center of the
crankshaft journal.
z Gently rotate the crankshaft in the normal
direction of engine rotation.
z Read the dial indicator (TIR) as you turn
the crankshaft.
z The crankshaft must be replaced if the
measured value exceeds the specified
limit. EAMD056S

Standard Limit
Crankshaft run-out 0.05 mm 0.40 mm

z If the repaired crankshaft generated a crack, replace it.

Engine inspection - 78 -
6) Main bearing and con-rod bearing
tension
z Check to see if the bearing has enough
tension, and set bearing into its regular
position with the finger pressure.

EAMD056S

7) Crankshaft regrinding
z Pay close attention to the following steps in order to ensure the reground-crankshaft reliability.

Undersize bearing
0.25 mm 0.50 mm
Availability

<Crankshaft regrinding procedure>

(1) Grind the crankshaft journal part and
pin part.
(2) Fillet the crankshaft journal and crank
pin radius to a minimum of R3.5±0.2.
There must be no stepping around the
fillet area.
(3) Finish the crankshaft journal, crank
pin and oil hole corners to a smooth
surface having a chamfer radius of
1mm.
EAMD056S

Crankshaft Journal and

0.4μ or less
crank pin roughness

(4) Measure the clearance between crankshaft journal and crank pin.
(5) Measure the crankshaft run-out.

8) Crankshaft grinding limit

Classification Limit
Crank journal outside
∅79.419 mm
Diameter
Crank pin outside
∅63.424mm
Diameter

z Undersize bearings (0.25 and 0.5 mm) are available to compensate for excessive clearance between
the crankshaft journal bearing and the crankshaft. Regrinding of the crankshaft to fit the undersize
bearings is require

- 79 - Engine inspection
Standard Limit
Main bearing 0.039 ∼
0.11 mm
clearance 0.098 mm

Standard Limit
Connecting 0.03 ∼
0.10 mm
rod bearing 0.073 mm

9) Crankshaft gear replacement

z Visually inspect the crankshaft gear.

z Replace the crankshaft gear as following

steps if excessive wear or damage is
discovered.

(1) Disassemble the crankshaft gear by

using the crankshaft remover.

EJM2097S

(2) Replace new part.

(3) Heat the crankshaft gear for at least
10 minutes to 120oC
(4) Use the crankshaft gear installer to
install the crankshaft gear.

EJM2098S

Engine inspection - 80 -
3.2.16. Flywheel and flywheel housing
1) Ring gear inspection
z Inspect the ring gear.
z If the ring gear teeth are broken or
excessively worn the ring gear must be
replaced.

EJM2099S

2) Ring gear replacement

z Strike around the edges of the ring gear
with a hammer and chisel to remove it.

3) Ring gear installation

z Heat the ring gear evenly with a gas
burner to invite thermal expansion.
Pay attention that temperature of ring
gear is not exceeded 200°C.
z Use a hammer to install the ring gear
when it is sufficiently heated.
EJM2100S

4) Oil seal replacement (rear)

z Use a pry bar to remove the flywheel
housing oil seal.
z Assemble the oil seal to flywheel housing
by using the oil seal assemble jig.

EJM2101S

5) Oil seal replacement (front)

z Use an adapter and a hammer to remove
the crankshaft front end oil seal.
z Assemble the oil seal to flywheel housing
by using the oil seal assemble jig.

EJM2102S

- 81 - Engine inspection
3.3. Engine Reassembly

3.3.1. Piston and connecting rod assembly

EJM2103I

▲ 1. Piston ▲ 4. Piston ring

▲ 2. Piston Pin and connecting rod ▲ 5. Connecting rod
▲ 3. Snap ring 6. Connecting rod bolt

1) Piston
z Use a piston heater to heat piston to
approximately 60°C.

EJM2104S

Engine reassembly - 82 -
2) Connecting rod
z Install the piston and connecting rod with
setting the marks as illustrated.
z Assemble the piston pin into the piston
and connecting rod bushing.

EJM2105S

3) Snap ring
z Assemble the snap rings by using snap
ring flyer.
z Check that the piston moves smoothly on
the piston pin.

EJM2031S

4) Piston ring
z Assemble the piston ring by using piston
ring assembly jig.
z Systematically assemble piston rings as
follows:
(1) Oil ring
(2) 2nd compression ring
(3) 1st compression ring
Rightly assemble the 1st and 2nd
compression rings that the marked side
must be facing ”up”. EJM2106I
Oil ring may be assembled any way
because it is not indicated.

z Lubricate the surface of piston ring with engine oil.

z Check it whether piston rings are smoothly rotating in the piston ring grooves.

5) Connecting rod bearing

z Assemble the connecting rod bearing to the big end and the cap.
z Lubricate the bearing with engine oil.
z Assemble the connecting rod and connecting rod bearing, and tighten cap bolt as the specified torque.

- 83 - Engine reassembly
3.3.2. Cylinder head assembly parts

EJM2107S

▲ 1. Valve stem oil seal 7. Thermostat housing and gasket

▲ 2. Intake and exhaust valve 8. Thermostat
3. Spring seat (lower) 9. Cooling water outlet
▲ 4. Intake and exhaust valve spring ▲ 10. Intake manifold and gasket)
▲ 5. Spring seat (upper) ▲ 11. Exhaust manifold and gasket
▲ 6. Valve cotter

1) Valve stem oil seal

z Lubricate the oil seals and valve stem
sealing area with engine oil.
z Assemble the valve stem oil seal by
using oil seal installer.

EJM2106I

Engine reassembly - 84 -
2) Intake and exhaust valves
z Place the cylinder head on a flat wooden
surface.
z Lubricate valve stem with the engine oil.
z Assemble the valves to the intake or
exhaust valve guides.

EJM2110S

4) Intake and exhaust valve springs

z Assemble the valve spring with their
painted end facing top.

EJM211I

5) Spring seat
6) Valve cotter
z Use a spring compressor to push the
valve spring into position.
z Install the spring seat split collar.

EJM2112S

z Set the spring seat split collar by tapping

lightly around the head of the collar with a
rubber hammer.

EJM2113S

- 85 - Engine reassembly
10) Intake manifold and gasket
z Assembly the intake manifold gasket.
The intake manifold gasket must be
installed with its unchamfered corner
facing “up” and to the front of the engine.

EJM2114S

z Assemble the intake manifold.

z Tighten the intake manifold bolts to the
specified torque a little at a time in the
numerical order. (see figure)

Intake manifold bolt torque 2.2 kg.m

EJM2115S

11) Exhaust manifold and gasket

z Install the exhaust manifold gasket.
z The “TOP” mark must be facing up.

EJM2116I

z Install the exhaust manifold

z Tighten the exhaust manifold bolts to the
specified torque a little at a time in the
numerical order. (see figure)

Exhaust manifold bolt

2.2 kg.m
torque

EJM2117S

Engine reassembly - 86 -
3.3.3. Rocker arm and shaft assembly

EJM2119S

▲1. Rocker arm shaft 2. Spring

3. Rocker arm 4. Bracket

1) Rocker arm shaft

z The rocker arm shaft must be installed with the oil holes facing up.

- 87 - Engine reassembly
3.3.4. Main components

EJM2120S

▲2. Crankshaft bearing (lower) ▲ 9. Idler gear shaft

▲3. Crank shaft ▲10. Idler gear
▲4. Thrust washer ▲11. Piston and connection rod
▲5. Crank shaft bearing (upper) and cap ▲12. Oil pump and coupling
▲6. Timing gear case ▲13. Flywheel housing
7. Tappet ▲14. Oil pan
▲8. Camshaft ▲15. Oil cooler

* The tappet must be installed before the camshaft installation.

Engine reassembly - 88 -
2) Crankshaft bearing (lower)
z There is no oil hole and oil groove on the
lower bearing. But opposite upper
bearing has oil hole and oil groove.

EJM2122S

3) Crankshaft
z Assemble the crankshaft gear in front
side.

CAUTION:
Make sure the part number of crankshaft
because its counterweight size may be
different depending upon engines.

EJM2123S

4) Thrust washer
z Assemble thrust washer with the oil
groove side facing the crankshaft sliding
face.

EJM2124S

5) Crankshaft bearing cap

z Lubricate the bearing cap bolts with
engine oil.
z Assemble the bearing caps to the
crankshaft.
The arrow mark must be pointing to the
front of the engine.

EJM2125S

- 89 - Engine reassembly
z Tighten the bearing cap bolts to the
specified torque a little at a time in the
numerical order. (see figure)

Crankshaft bearing
24.0±1kg.m
cap bolt torque

z Check that the crankshaft turns smoothly

by manually rotating it.

EJM2126S

6) Timing gear case

z Tighten timing gear case bolt to the
specified torque.

Timing gear case bolt torque 2.2 kg.m

z Apply silicon to the indicated area. (see

figure)

EJM2127S

8) Camshaft
z Tighten thrust plate bolt through the
camshaft gear hole.

Thrust plate bolt torque 2.2 kg.m

Camshaft gear bolt torque 13 kg.m

EJM2128S

9) Idler gear shaft

z Assemble an idler gear shaft by using the
thrust collar fixing bolt as a guide.

z The oil hole must be facing the camshaft.

z Lubricate the idle gear shaft with engine

oil.

EJM2129S

Engine reassembly - 90 -
10) Idler gear
z Assemble the idle gear.
Set the timing marks “A”, ”B”, and ”C” as
shown in the figure.
z Tighten the idle gear bolts seating the
thrust collar to the specified torque.
z The thrust collar must be installed with
the chamfered side facing the front of the
engine.

Idle gear bolt torque 4.4 kg m EJM2130S

11) Piston and connecting rod

z Set the piston ring gaps as shown in the
figure.
z Lubricate the piston, the piston ring and
the connecting rod bearings with engine
oil.

EJM2131S

z Position the piston front mark towards the

front of the engine.
z Use the piston ring compressor to
compress the piston rings.
z Push the piston in until it makes contact
with the crank pin by using a hammer
grip.
At the same time, rotate the crankshaft
until the crank pin reaches its highest
point.
EJM2132S

z Set the bearing cap cylinder number

marks and the connecting rod cylinder
number marks.
z Lubricate the connecting rod cap bolt
threads and setting face with MoS2
grease.
z Tighten the connecting rod cap bolts to
the specified torque.
Refer to the following table.
EJM2133S

- 91 - Engine reassembly
12± 9.75±
Torque
0.25kg.m 0.25kg.m

TY TY
Bolt head 11 12

EJM2134S

12) Oil pump assembled

z Lubricate the oil pump with the specified
engine oil.
z Install the oil pump with the coupling.
z Tighten the oil pump bolts to the specified
torque.

Oil pump bolt torque 5.0 kg.m

EJM2135S

13) Flywheel housing

z Apply silicon to the shaded area. (see
figure)
z Install the flywheel housing.
z Tighten the flywheel housing bolts to the
specified torque.

M14 x 1.5 13 kg.m

M14 x 1.5 18 kg.m

EJM2136S

14) Oil pan

z Apply liquid gasket to the area indicated
by the arrows in the figure.
z Install the gasket and oil pan.
z Tighten the oil pan bolts to the specified
torque.

Oil pan bolt torque 2.2 kg m

EJM2137S

Engine reassembly - 92 -
15) Oil cooler
z Assemble the oil cooler with gasket after
applying sealant to the oil cooler gasket.
z Tighten the oil cooler bolts to the
specified torque. in the numerical order
(see figure)

Oil Cooler Torque 2.2 kg m

EJM2138S

- 93 - Engine reassembly
3.3.5. Major component assembly

EJM2139S

▲ 1. Flywheel 9. Oil pump driving pinion

▲ 2. Crankshaft pulley nut 10. Push rod
▲ 3. Tappet chamber cover 11. Taper bushing
▲ 4. Water pump 12. Crankshaft pulley and dust cover
▲ 5. Cylinder head gasket 13. Timing gear cover
▲ 6. Cylinder head bolt 14. Oil thrower
▲ 7. Cylinder head 15. Rubber hose
▲ 8. Rocker arm shaft Assembly

Engine reassembly - 94 -
1) Flywheel
z Lubricate the flywheel bolt with engine oil.

z Install the flywheel.

Tighten the flywheel bolts to the specified
torque in the numerical order. (see figure)

Flywheel Bolt torque 18 kg.m

EJM2142S

2) Injection pump
z Align the injection pump gear "C" timing
mark with the idler gear “C” timing mark.

EJM2130S

z Tighten the injection pump bolts to the

specified torque.

Injection Pump Bolt Torque 2.2 kg.m

EJM1029S

3) Crankshaft pulley nut

z Tighten the crankshaft pulley nut to the
specified torque by using a wrench.

Crankshaft pulley nut torque 60 kg.m

EJM2144S

- 95 - Engine reassembly
3) Tappet chamber cover
z Apply silicon to the tappet chamber cover
gasket.
z Assemble the tappet chamber cover and
tighten the bolts to the specified torque.

Tappet chamber cover

2.2 kg.m
bolt torque

EJM2145S

4) Water pump
z Apply silicon to the pump gasket before
installing the water pump.

EJM2146S

5) Cylinder head gasket

z The gasket “TOP" mark should be faced
up and "FRONT" mark is towards the
front of the engine.

EJM2147S

6) Cylinder head bolts

7) Cylinder head
z Carefully place the cylinder head on the
cylinder block.
z Tighten the cylinder head bolts to the
specified steps and torque in the
numerical order as figure and following
table.

EJM2148S

Engine reassembly - 96 -
Bolt type Torque
1st step : 7.0kg.m
hexagonal bolt
2nd step: 11.5+0.5kg.m
1st step : 4.4 kg.m
Dodecagonal bolt 2nd step : 90°
3rd step : 90°

<12-gonal bolt limited value>

Standard(mm) Limit(mm)
115 116.2
102 103.2

z Apply engine oil to the cylinder head bolts threads and setting faces.

8) Rocker arm shaft assembly

z Tighten the rocker arm bolts to the
specified torque a little at a time in the
numerical order. (see figure)

Rocker arm shaft

7 13 12
1 11
14 17 26
15
21 22 27

24 18 25 23

1 Oil filter 11 C.C.V 21 Push rod chamber cover

Engine reassembly - 100 -

1) Cylinder head cover
z Tighten the cylinder head cover bolts to
the specified torque a little at a time in the
sequence. (see figure)

Cylinder head cover bolt

2.2 kg.m
torque

Fan belt
z Adjust the fan belt tension. EJM2154S

2) Starter
z Tighten the starter bolts to the specified
torque after install the starter to the
flywheel housing.

Starter fixing nuts torque 2.2 kg.m

EJM2155S

3) Injection nozzle
z Install the injection nozzle with the Hex nut
injection nozzle gaskets. Spring
h

Injection nozzle nuts torque 2.2 kg.m

O-ring
Injection
z Be careful not to damage the nozzle tips. l
Seal ring

EC9OM055
4) Fuel injection pipe
z Install the fuel injection pipes① and
tighten the bolts to the specified torque.

Injection pipe torque 3.0 kg.m

z Carefully position and set the clips②.

It is very important that each clip be
positioned correctly.
1
EJM2164S

- 101 - Engine reassembly

An improperly positioned clip will result in objectionable fuel pulsing noise and injection pipe breakage.
z Install the fuel return pipes③.

5) Oil filter
z Install the oil filter assembly with
tightening the bolts securely.

Oil filter assembly

5.0 kg.m
mounting bolts torque

EJM2175I

<ECRFD>

Head, oil filter

Cartridge,
Oil filter EC9OM015

<ECRFA, ECRFE>

6) Fuel pipe
z Install the fuel pipe and tighten the fuel
pipe joint bolts to the specified torque.
z Take care not to interchange the check
valves and joint bolts.

Fuel pipe joint bolt torque 1.7 kg.m

7) Fuel hose
z Install the fuel filter hoses and tighten the
hollow screws to the specified torque

Fuel filter hose bolt

4.2 kg.m
torque

EC9OM056

Engine reassembly - 102 -

4. Commissioning and Operation
4.1. Preparation

At the time of initial commissioning of a new or overhauled engine make sure to have observed the
"Technical Information for the installation DB58S engine".

z Oilfiller neck on cylinder head cover

z Before daily starting of the engine, check the fuel, coolant and oil level, replenish if necessary.
z The notches in the dipstick indicate the highest and lowest permissible oil levels.
z The oil required in the sump is specified in the "Engine Specification”.

NOTE
The oil required to fill the oil fillers and pipes depends upon the engine and use and must be
determined individually at the time of initial commissioning. (Make the Max and Min. marks of the
determined quantity on the oil level gauge.)

z Cleanliness
Ensure outmost cleanliness when handling fuels, lubricants and coolants

4.1.1. Starting
For engine starting, please confer the instruction.

NOTE:
1. Preheating devices are attached to the engine for improving the starting abilities at extremely low
temperature.
2. Do not actuate the starter for longer than 10 seconds. If starting fails regardless of the preheating,
start the preheating again after 30 seconds.

a) Pre-heating system
Operation 1: Turn the key switch to the HEAT position, then the pilot lamp lights up for about 20 seconds
When the pilot lamp is extinguished, do operation 2
Behavior - When the coolant temperature is below 10 °C in cold weather, you’d better operate the
pre-heating system (Glow plug)
- If the pre-heating is not necessary, the pre-heating system is not operated with the pilot
lamp.
Operation 2: After checking the pilot lamp, turn the key switch to the START position to crank the engine,
at once.
Behavior - When the key switch is placed in the START position, glow plug is continuously heated to
facilitate starting operation
- If the coolant temperature is above 10 °C, glow plug needs not be heated.
Operation 3: After the engine is cranked, convert the key switch to the ON position.

- 103 - Commissioning & operation

4.2. Starting and operation

4.2.1. Operation of a new engine (Break-In)

Because the sliding surfaces of a new engine are not lapped enough, the oil film can be destroyed easily by
overload or overspeed and the engine life-time may be shortened.
Therefore the following things must be obeyed by all means.

Up to the first 150 hours

z Engine should be run at fast idling until the temperature of the engine becomes normal operating
condition.
z Overload or continuous high speed operation should be avoided.
z High speed operation with no load should be prevented.
z Abrupt start and stop of the engine should be avoided.
z Maintenance and inspection must be accomplished thoroughly.

4.2.2. Check points for break-in

During the break-in (the initial running of the engine) period, be particularly observant as follows:

a) Check engine oil level frequently. Maintain oil level in the safe range, between the "min." and “max."
marks on dipstick.

Note:
If you have a problem getting a good oil level reading on dipstick, rotate dipstick 180° and re-insert
for check.

When adding engine oil, refer to Lubrication Section.

b) Watch the oil pressure warning lamp. If the lamp blinks, it may be the oil pick-up screen is not covered
with oil. Check oil dipstick. Add oil to the oil pan, if required. Do not overfill. If level is correct and the
status still exists, see your DEALER for possible switch or oil pump and line malfunction.

Note:
Oil pressure will rise as RPM increases, and fall as RPM decreases. In addition, cold oil will
generally show higher oil pressure for any specific RPM than hot oil. Both of these conditions
reflect normal engine operation.

Commissioning & operation - 104 -

c) Watch the engine water temperature gauge and be sure there is proper water circulation. The water
temperature gauge needle will fluctuate if water level in expansion tank is too low.
At the end of the break-in period, remove break-in oil and replace the oil filter element. Fill oil pan with
recommended engine oil. Refer to Lubricating System.

z Engine oil should be changed at the specified intervals.

Oil filter cartridge should be changed simultaneously.
- First oil change : 50 hr operating
- After 50hr operation ; 250hr

z The following oils are also recommended

* If long oil change intervals are to be used, ACEA-E3 oil must be used.

Recommend oil
Engine model
SAE No. API No.

SAE15W40 ACEA-E2 or ACEA-E3

DB58S
SAE10W40 OVER(API CH-4)

- 105 - Commissioning & operation

4.3. Inspections after starting

z It is advisable to operate an engine at idling until the engine reaches up to normal operating temperature.
z Engine should be stopped if the color, the noise or the odor of exhaust gas is not normal.
z Confirm the following things through warning lamps and gauge panel.
- Pressure of lubricating oil
The normal pressure comes up to 100 kPa (1.0 bar) at idling and 300 ~ 480 kPa (3.0 ~ 4.8 bar) at
maximum speed. If the pressure fluctuates at idling or does not reach up to the expected level at high
speed, shut down the engine immediately and check the oil level and the leakage.
- Temperature of cooling water
The cooling water temperature should be 80 ~ 95 °C in normal operating conditions. Abnormally high
cooling water temperature could cause the overheating of engine and the sticking of cylinder
components. And excessively low cooling water temperature increases the fuel consumption,
accelerates the wears of cylinder liners and shortens the engine life-time.

NOTE:
When engine is overheated, do not stop the engine immediately. Lower the engine load and run the
engine and its cooling systems continuously.

4.4. Operation in winter time

Pay special attention to the freezing of cooling water and the viscosity of lubricating oil.

4.4.1. Prevention against the freeze of cooling water

When not using anti-freeze, completely
discharge the whole cooling water after engine
running. The freeze of cooling water causes
Water
Water
the fatal damages of the engine. Because the
drain valve
drain valve
anti-freeze is used to prevent cooling water
from freeze, consult "The amount of anti-
freeze".

EC9OM031

4.4.2. Prevention against excessive cooling

Drop of thermal efficiency caused by excessive cooling increases fuel consumption, therefore prevent the
engine from excessive cooling. If the temperature of coolant does not reach to normal condition (80 ~ 95
°C) after continuous operation, examine the thermostat or the other cooling lines.

Commissioning & operation - 106 -

4.4.3. Lubricating oil
As cold weather leads to the rise of oil viscosity, engine speed becomes unstable after starting. Therefore
the lubricating oil for winter should be used to prevent this unstability. Refer to Lubrication System section.

4.4.4. Starting of engine in winter

It is necessary to preheat engine satisfactorily under 10 °C (50 °F) in winter. Refer to Starting.

4.4.5. Tuning the engine

The purpose of an engine tune-up is to restore power and performance that's been lost through wear,
corrosion or deterioration of one or more parts or components. In the normal operation of an engine, these
changes can take place gradually at a number of points, so that it's seldom advisable to attempt an
improvement in performance by correction of one or two items only. Time will be saved and more lasting
results will be obtained by following a definite and thorough procedure of analysis and correction of all items
affecting power and performance.
Economical, trouble-free operation can better be ensured if a complete tune-up is performed once every
years, preferably in the spring. Components that affect power and performance to be checked are:

z Components affecting fuel injection ;

Nozzle, delivery valve, fuel filter, water separator, etc.
z Components affecting Intake & exhaust ;
Air filter, inter-cooler, turbo, silencer, etc.
z Components affecting lubrication & cooling ;
Air & oil filter, antifreeze, etc.

- 107 - Commissioning & operation

4.5. Maintenance and care

4.5.1. Periodical inspection and maintenance

In order to insure maximum, trouble-free engine performance at all times, regular inspection, adjustment
and maintenance are vital.
z Daily inspections in below figure should be checked every day.
z The maintenance should be executed thoroughly at regular internals.

4.5.2. Exchanging of lubrication oil

Engine oil and the oil filter are important factors affecting engine life. They affect ease of starting, fuel
economy, combustion chamber deposits and engine wear. Refill and drain oil pan every 500 hours of
operation whichever occurs first. At the end of the break-in period (50 hours), change the oil sump oil and
replace the oil filter.

4.5.3. Oil level

Check the oil level in the engine sump daily
with a dipstick.
z The notches in dipstick must indicate the oil
level between the max. and the min.
permissible.
z The oil level should be checked with the
engine horizontal and only after it has
been shut down for about 5 minutes.
z Examining the viscosity and the
contamination of the oil smeared at the
EA4O4001
dipstick replace the engine oil if necessary.

IMPORTANT:
Do not add so much engine oil that the oil level rises above the max. marking on the dipstick. Over
lifting will result in damage to the engine.

4.5.4. Oil exchange procedure

While the oil is still hot, exchange oil as
follows:
z Take out the oil dip dipstick.
z Remove the drain valve from oil pan, then
drain out the engine oil into a container.

Oil drain
Oil dra
valve
valve EC9OM032

Commissioning & operation - 108 -

z Refill with new engine oil at the oil filler
neck on the head cover and the lubricating Oil filler cap
oil in accordance with the oil capacity of
the engine through oil filler. Be careful
about the mixing of dust or contaminator
during the supplement of oil. Then confirm
that oil level gauge indicates the vicinity of
its maximum level.
z For a few minutes, operate the engine at Cylinder head cover
idling in order to circulate oil through EC9OM057
lubrication system. < ECRFD >
z Thereafter shut down the engine. After
waiting for about 10 minutes measure the
quantity of oil and refill the additional oil if
necessary.

< ECRFA, ECRFE >

4.5.5. Replacement of oil filter cartridge
At the same times of oil exchanges, replace
the oil filter cartridge.

IMPORTANT:
Don't forget tightening the drain valve after
having drained engine oil.

z Loosen the oil filter by turning it counter-

clockwise with a filter wrench.
z With a rag wipe clean the fitting face of the
filter body and the oil filter body so that
new oil filter cartridge can be seated
properly. EDM3001I
z Lightly oil the O-ring and turn the oil filter
< ECRFD >
until sealing face is fitted against the O-
ring. Turn 1-1/4 turns further with the filter Head, oil filter
wrench.

IMPORTANT:
It is strongly advisable to use DOOSAN
genuine oil filter cartridge for replacement.

Cartridge,
Oil filter EC9OM015
< ECRFA, ECRFE >

- 109 - Commissioning & operation

4.6. Cooling system

The coolant must be changed at intervals of 1,200 hours operation or six months whichever comes first. If
the coolant is being fouled greatly, it will lead an engine overheat or coolant blow off from the expansion
tank.

4.6.1. Coolant draining

z Remove the pressure cap.
z Open the drain valve at the radiator lower
part to drain the coolant as the right figure.
z Loosen the coolant drain plug of the
cylinder block and oil cooler.

CAUTION:
When removing the pressure filler cap
while the engine is still hot, cover the cap
with a rag, then turn it slowly to release the
Water
Water
internal steam pressure This will prevent a drain valve
drain valve
person from scalding with hot steam
spouted out from the filler port.

EC9OM031

Commissioning & operation - 110 -

4.6.2. Cleaning of the cooling inside system circuit
(by authorized specialist personnel)
When the cooling system circuit are fouled with water scales or sludge particles, the cooling efficiency will
be lowered.
Investigations have shown that in many cases the poor condition of the coolant and /or the cooling system
accounts for damage to the water pump mechanical seal, The poor condition of the cooling system is
normally due to use of unsuitable or no anti-freezing agents and corrosion inhibitor or defect, not early
enough replaced covers for filler neck and working valves.
If twice in a short time the water pump of an engine develops leases or the coolant is heavily contaminated
(dull, brown, mechanically contaminated, grey or black sings of a leakage on the water pump casing) clean
the cooling system prior to removing that water pump as follows.
a) Drain coolant.
b) Remove thermostats, so that the whole cooling system is immediately flown through when cleaned.
c) Fill the cooling system with a mixture of potable water and 1.5% by volume of cleaner. (Henkel
P3T5175)
d) Warm up engine under load. After a temperature of 60°C is reached, run engine for a further 15
minutes.
e) Drain cleaning fluid.
f) Repeat steps c) and d).
g) Flush cooling system.
h) Replace drain plug by drain plug with a bore of 8mm diameter.
i) Fill cooling system with hot water.
j) Run engine at idle for 30 minutes. At the same time continuously replenish the water leaking from the
bore in drain plug by adding fresh water.

CAUTION:
Periodically clean the circuit interior with a cleaner.

4.7. Valve clearance and adjustment

NOTE:
The cylinder head bolts were previously
tightened with the torque wrench.
Therefore it is not necessary to retighten
the cylinder head bolts before adjusting the
valve clearance.

Rocker arm screw

2.6 kg.m
lock nut torque

EAOO4104

- 111 - Commissioning & operation

z After letting the #1 cylinder's piston come
at the compression top dead center by
turning the crankshaft, adjust the valve
clearances.
z Loosen the lock nuts of rocker arm
adjusting screws and push the feeler
gauge of specified value between a rocker
arm and a valve stem and adjust the
clearance with adjusting screw
respectively and then tighten with the lock EJM1035S
nut.
z As for the valve clearance, adjust it when in cold, as follows.

Model Intake Valve Exhaust Valve

DB58S 0.4 mm 0.4 mm

1) Rotate the crankshaft to overlap the intake and the exhaust valves of #6, then #1 cylinder become the
compression state of top dead center.
2) Therefore adjust the valve clearance corresponding to “ ” of lower figure. At this time there are
no force on the push rods of #1 cylinder.
3) Rotating the crankshaft by one revolution, #6 cylinder become the compression state of top dead
center.
4) Thereafter adjust the valve clearances corresponding to “ ” of lower figure.
5) After reinsuring the valve clearances, retighten if necessary.

z No. 1 cylinder is located at the side where flywheel was installed.

Cooling fan Cylinder no. Exhaust valve Intake valve Fly wheel

EC9OM020

Commissioning & operation - 112 -

4.8. Injection timing
CAUTION:
Take care to avoid entry of dust or foreign particles into the pump interior when the timing
adjustment is made.

<Check procedure>
z Align the crankshaft pulley TDC mark with
the pointer.
z Remove the inspection hole cover at the
front of the injection pump on the timing
gear case cover.

EJM1035S

z Check the alignment between the pointer

④ on the injection pump gear nut lock
plate and the projection area mark③ on
the injection pump gear case.
z If it is in misalignment, recheck with
turningthe crankshaft pulley one more turn
to repeat the foregoing procedure to mark
sure that it is in alignment.

EJM1038S

z Check the alignment of the notched lines①

and ②. (These notched lines were aligned
at the factory to set the injection pump
body and the mounting flange.)
Next, inspect the crank angle position of
the injection timin

EJM1039I

- 113 - Commissioning & operation

<Check procedure>
z Turn the crankshaft pulley
counterclockwise about 30° crank angle.
z Disconnect the injection pipe from the No.1
plunger.
This will allow you to visually check the full
injection starting flow at No. 1 plunger.

EC9OM033

z Remove the delivery valve holder①, the

valve seat②, valve spring③, and the
delivery valve④ from the No.1 plunger.
z Assemble the delivery holder① and
tighten it to the specified torque.
Do not reassemble the delivery valve, the
delivery valve spring and the valve seat.
These parts will be reassembled later.

EJM1041S

z Hold the fuel control lever at the fully open

position.
z Slowly turn the crankshaft pulley clockwise,
at the same time, continue to feed the fuel
with pumping the priming pump.
When the fuel stop to flow out from the
No.1 delivery valve holder, stop the pump
instantaneously.
This crank angle position is the injection
starting of the engine.
EJM1042S

z Observe and make sure that mark (injection

starting angle line αo) on the crankshaft
pulley is aligning with the pointer.
Blow out the remaining fuel from the
delivery valve holder.
Make sure that there is no fuel being
delivered from the priming pump.

EJM1044I

Commissioning & operation - 114 -

z Remove the delivery valve holder from the
No.1 plunger
z Reassemble the delivery valve internal
parts to the delivery valve holder.
z Reassemble the delivery valve holder
assembly to the No.1 plunger and tighten it
to the specified toque.

Delivery valve holder torque 4.25 kg m

EJM1041S

z Assemble the No.1 cylinder injection pipe and tighten it to the specified torque.

Injection pipe nut torque 3.1 kg m

INPORTANT:
1) Do not overtighten the injection pump body. The injection pump body is made of aluminum.
2) Overtighten will distort the injection pump body shape and adversely affect control rack
operation.

<Adjusting procedure>
z Align the pointer and the specified timing mark on the crank pulley.
z Perform the steps of “checking procedure” of Injection Timing.
z Loosen the 4 injection pump fixing nuts.

z Timing adjustment
To advance the timing
Pivot the injection pump at the pump drive
shaft toward out.
To retard the timing
Pivot the injection pump at the pump drive
shaft toward in. (toward the cylinder block)

IMPORTANT:
The 1 mm misalignment between the two
EJM1045S
setting mark lines corresponds to about 2o
in crank angle.

- 115 - Commissioning & operation

z Do a fine injection pump position adjustment, while continue the pumping operation to feed the fuel, and
stop to pivot the injection pump when the fuel stop to flow out from the No. 1 delivery valve holder.
z Tighten the four injection pump fixing nuts.
z Once remove the No. 1 delivery valve holder, and reassemble the delivery valve, spring and the valve
holder with the specified torque.
z Install the No.1 injection pipe and tighten it to the specified torque.

4.9. Tightening the cylinder head bolts

z The cylinders head bolts are to be tightened

in the sequence shown in the illustrations.
First tighten the bolts slightly, then slightly
more again and finally tighten with a torque
wrench as follows.
z The tightening by excessive torque may
cause the damages of the cylinder head
gaskets, the flanges of cylinder liners and
the cylinder head bolts, therefore obey the
regular torque. EJM2148S

Bolt type Torque

1st step : 7.0kg.m

hexagonal bolt
2nd step: 11.5+0.5kg.m
1st step : 4.4kg.m
dodecagonal
2nd step : 90°
bolt
3rd step : 90°

<Dodecagonal bolt limited value>

Standard(mm) Limit(mm) EC9OM058

115 116.2
102 103.2

4.10. Fuel injection pump

z Check the housing crack, damage etc. and

replace it if abnormal.
z Check if the idle operation and speed
regulating lever's sealing is removed.
z The adjustment and testing of fuel injection
pump should necessarily be done at the test
bench.

EC9OM016

Commissioning & operation - 116 -

4.11. Feed pump strainer

z Release joint bolt A.

z Remove the strainer with a screwdriver and
wash the strainer with clean diesel fuel.

EJM1029S

EJM1030S

4.12. Separator (Add if necessary)

z Check water level of the separator.

z Release the plug at the bottom to eliminate
water when water level (floating) reaches
the warning point.

Elimination plug torque 1.2 kg.m

EJM1031S

4.13. Air bleeding

z Loosen the priming pump cap(1) on the

Injection pump.
z Loosen the hollow screw for air bleed(2).
z Operate the priming pump until there are no
more bubbles visible in the fuel being
discharged from the fuel filter fuel return eye
bolt.
z Retighten the hollow screw.
z Operate the priming pump several times
and check for fuel leakage around the
EJM1032S
injection pump and the fuel filter.

- 117 - Commissioning & operation

4.14. Belts

The tension of the belts should be checked after every 2,000 hours of operation.
1) Change the belts if necessary
If in the case of a multiple belt drive, wear or differing tensions are found, always replace the complete
set of belts.
Checking condition
2) Check belts for cracks, oil, overheating and wear.
3) Testing by hand
z V-belt
By the finger-pressure the belt is pressed
by 10-15mm between the pulleys in
normal condition.(Pressed mid-way
between the belt pulleys)
A more precise check of the V-belt
tension is possible only by using a V-belt
tension tester.

EA9O2006

z Poly belt
Poly belt will be properly tensioned if the
deflection force “F” is applied mid-way
between the belt’s tangent points with the
pulley.

T = 0.015 x S(about 1.5mm per 100mm)

T = 0.015 x *S (mm)
(T : Deflection , S : Span)

EB5O6001
* (D − d )2
S= C − 2
(mm)
2
C : Distance of pulleys (mm),
D : Large pulley diameter (mm),
d : Small pulley diameter (mm)

Commissioning & operation - 118 -

4) Measuring tension
① Lower indicator arm (1) into the scale.
z Apply tester to belt at a point midway
between two pulleys so that edge of
contact surface (2) is flush with the V-
belt.
z Slowly depress pad (3) until the spring
can be heard to disengage. This will
cause the indicator to move upwards.
If pressure is maintained after the spring
has disengaged a false reading will be EA6O6011
obtained!
② Reading of tension

z Read of the tensioning force of the belt at

the point where the top surface of the
indicator arm (1) intersects with the scale.
z Before taking readings make ensure that
the indicator arm remains in its position.

EA6O6012

z V-belt tension

Tensioning forces on the tester

new installation
Type Drive belt width When servicing after
After 10 min.
Installation long running time
running time
M 9.5 mm 50 kg 45 kg 40 kg
A 11.8 mm 55 kg 50 kg 45 kg
B 15.5 mm 75 kg 70 kg 60 kg
C 20.2 mm 75 kg 70 kg 60 kg

z Poly belt tension

No of rib
(PK type) Force(kgf)
3 20 - 27
4 27 - 36
5 34 – 45
6 41 – 57
7 48 – 66
8 59 - 73

EB5O6002

- 119 - Commissioning & operation

5) Tensioning and changing belts
z Loosen fixing bolts and nuts.
z Adjust the alternator until belts have
correct tensions.
z Retighten fixing bolts and nuts.
z To change the belts loosen fixing bolts
and nuts. Then push the alternator
toward water pump pulley by hand.

EC9OM034

Commissioning & operation - 120 -

5. Maintenance of Major Components
5.1. Lubrication system

5.1.1. Oil pump

1) Disassembly

1
EC9OM034

1. Oil suction pipe 4. Pinion Gear

2. Cover and dowel 5. Pinion gear shaft
3. Drive shaft and gear

- 121 - Maintenance of major components

2) Inspection
z Visually inspect the disassembled parts
for the excessive wear and damage.
z Correct or replace the parts if the wear or
damage is discovered during inspection.

EC9OM060

3) Oil Pump Drive Gear

z Use a feeler gauge to measure the
clearance between the oil pump cover (oil
pump case) inside surface and the drive
gear.
z If the clearance exceeds the specified
limit, the drive gear and/or the oil pump
cover must be replaced.

Limit
0il pump cover and drive EJM3004S
0.18 mm
gear clearance

4) Oil pump pinion gear

z Use a feeler gauge to measure the
clearance between the oil pump case
cover inside surface and the pinion gear.

z If the clearance exceeds the specified

limit, the pinion gear and/or the oil pump
cover must be replaced.

Limit
0il pump cover and pinion EJM3005S
0.12 mm
gear clearance

5) Oil pump reassembly

z To assemble, follow the disassembly procedures in reverse order.

Maintenance of major components - 122 -

5.1.2. Oil cooler
1) Disassembly

EJM3008S

1. Oil cooler element 4. O-ring

2. Gasket 5. By-pass valve spring
3. By-pass plug 6. By-pass valve

2) Inspection
z Correct or replace the part if the wear or
damage is discovered during inspection.

3) Oil cooler element

z Install the oil cooler element to the oil
cooler, then tighten the oil cooler element
fixing bolts to the specified torque.

Oil cooler element fixing

2.2 kg.m
bolts torque

4) Oil cooler reassembly

z To assemble, follow the disassembly
procedures in reverse order.
EJM3010S

- 123 - Maintenance of major components

5.2. Cooling system

5.2.1. Water pump

1) Disassembly

1 8

6
EC9OM061

1. Pulley flange ▲ 5. Impeller

▲ 2. Snap ring 6. Pump housing
▲ 3. Unit bearing 7. Cover
4. Mechanical seal 8. Gasket

(1) Impeller
z Remove the impeller by using the jig.

EJM4008I

Maintenance of major components - 124 -

(2) Unit bearing
z Remove the unit bearing by using a
bench press and a suitable remover.

EJM4008I

(3) Mechanical seal

z Remove the mechanical seal by using a
suitable remover.

EJM4009S

(4) Hub
z Remove the hub by using a bench press
and a suitable rod.

EJM4006S

(5) Snap ring

z Remove the snap ring by using a pair of
the snap ring plier.

EJM4007S

- 125 - Maintenance of major components

2) Inspection
(1) Unit bearing
z Correct or replace the part if the wear,
defect or other damage is discovered
during inspection.

EJM4011I

3) Water pump reassembly

(1) Unit bearing
z Lubricate the bearing with multipurpose
grease.
z Use a bench press to assemble the unit
bearing at the pump.

EJM4011S

(2) Snap Ring

z Use a pair of snap ring plier to install the
snap ring.

EJM4007S

(3) Hub
z Use a bench press and a bar to install the
hub.

EJM4015S

Maintenance of major components - 126 -

(4) Mechanical seal
z Apply sealant to the seal unit outer
periphery before installation.

EJM4016S

z Use a bench press and a bar to install the

seal unit into the pump body.

EJM4017S

(5) Impeller
z Use a bench press to install the impeller
to the shaft.
z Use a feeler gauge to measure the
clearance between the impeller and the
pump body.

Clearance
between impeller and 0.3 ~ 0.8mm
pump body
EJM4018S

(6) Pulley
z Install the pulley and tighten the pulley
bolts to the specified torque.

Pulley fixing bolts torque 2.2 kg.m Fan flange

Pulley

Cooling fan
EC9OM062

- 127 - Maintenance of major components

5.2.2. Thermostat
z Correct or replace thermostat if the wear,
defect or other damage is discovered
during inspection.

EFM2055I

Maintenance of major components - 128 -

5.3. Fuel system

5.3.1. Fuel filter

1) Cartridge type

Air vent plug

Fuel filter head

Cartridge, fuel filter

Water drain plug

EC9OM063

2) Inspection
z Make the necessary adjustments, repairs and part replacements if excessive wear or damage is
discovered during inspection.

3) Fuel filter reassembly

z To reassemble the fuel filter, follow the disassembly procedure in the reverse order.

- 129 - Maintenance of major components

5.3.2. Injection nozzle
1) Disassembly

EJM5008S

1. Nozzle holder body 7. Push rod spring

2. Seal ring 8. Spring seat
3. Injection pipe connector 9. Nozzle adjusting screw
▲ 4. Injection nozzle 11. Nozzle holder cap nut
5. Retaining nut
6. Nozzle holder push rod

2) Injection nozzle
z Remove the nozzle assembly from the nozzle body. Keep the parts separately to maintain the proper
needle valve to body combination.

3) Inspection
z Make the necessary adjustments, repairs and parts replacements if excessive wear or damage is
discovered during inspection.

Maintenance of major components - 130 -

(1) Push rod spring
z Check the push rod spring for wear,
weakness and corrosion.

EJM5005S

(2) Nozzle holder push rod

z Check the nozzle holder push rod
curvature.
z Check the nozzle holder push rod and
needle valve contact surface for
excessive wear and poor contact.

EJM5006S

(3) Injection nozzle

z Check the injection nozzle needle valve,
the valve seat, and the injection nozzle
hole for carbon deposits.
If carbon deposits are present, the
injection nozzle and the needle valve
must be replaced.
Hold the nozzle body vertically.
z Pull the needle valve about one-third of
the way out of the nozzle body. Release
the needle valve.
Check that the needle valve falls back EJM5007S

into the nozzle body as far as the valve

seat.
If the needle does not fall back into the
nozzle body as far as the valve seat, the
injection nozzle and the needle valve
must be replaced.

- 131 - Maintenance of major components

4) Reassembly
(1) Injection pipe connector

Injection pipe
5.5 kg.m
connector torque

EJM5009S

(2) Injection nozzle

z There must be no oil on the contact
surface of the injection nozzle and the
injection nozzle holder.
z Clean these contact surface with diesel
fuel before installation.
z The nozzle dowel pin must be aligned
with the dowel hole in the nozzle holder
body.

EJM5010S

(3) Retaining nut

z Clamp the injection nozzle in a vise.
z Tighten the retaining nut to the specified
torque by using a wrench.

Nozzle retaining nut Torque 7 kg.m

EJM5011S

(4) Nozzle holder cap nut

z Clamp the injection nozzle in a vise.
z Tighten the nozzle holder cap nut to the
specified torque by using a wrench.

Nozzle holder cap nut

4.5 kg.m
torque

EJM5013S

Maintenance of major components - 132 -

(5) Nozzle adjusting screw (injection starting pressure check)
z Attach the injection nozzle holder to the
injection nozzle tester.

EA0M3033

z Loosen the adjustment screw①.

EJM5024S

z Check the injection nozzle starting

pressure and the spray condition by
operating the injection tester.

<spray condition check>

Operate the injection nozzle tester hand
lever 4 to 6 times while looking for
abnormal injection nozzle spray
conditions. (See figure)
(1) Correct (Good)
(2) Incorrect (Bad - orifice)
(3) Incorrect (Bad - dripping)

z Adjust the injection nozzle starting

pressure.
EA3M1022
Turn the adjusting screw clockwise while
operating the injection nozzle tester
handle.

CAUTION:
Keep away your skin from the tester because pressure of nozzle tester is very high when inject.

- 133 - Maintenance of major components

5.3.3. Injection Pump Calibration
1) DB58S engine (ECRFD)

D.H.I 65.11101-7404
NO.
INJ.PUMP CALIBRATION DATA MAKER 101605-
NO. 996H(DOOWON)
DATE 2003. 11. 04
E/G DB58S SUFFIX ECRFD FOR D35/40/45S,D50C-2 F/L
MODEL USE
INJ.PUMP BODY :101062-830A GOVERNOR :105419-1340
TIMING DEVICE : LESS
(KP-PES6A95C410RS2000) (KP-EP/RSV200-1450AQ43A311)
NOZZLE & HOLDER ASS'Y 105780-8140 (FOR E/G : 105160-465B)
NOZZLE 105780-0000 (FOR E/G : 105025-138B)
NOZZLE HOLDER 105780-2080 (FOR E/G : 105031-386D)
NOZZLE OPENING
175 kg/㎠ (FOR E/G : 220 kg/㎠)
PRESSURE
TEST TRANSFER PUMP
1.6 kg/㎠
CONDITION PRESSURE
INJ.PIPE(BENCH) INNER x OUTER x LENGH = Ø2.0 x Ø6.0 x 600 mm
INJ.PIPE(ENGINE) INNER x OUTER x LENGH = Ø1.6 x Ø6.0 x 580 mm
ISO4113 or SAE STANDARD TEST OIL(SAE J967d) or KS2
TEST OIL
OIL TEMPERATURE : 40 P5 ℃
OVERFLOW VALVE OPENING PRESSURE 1.6 kg/㎠
INJ.TIMING : NO.1 PLUNGER 4.3 P0.05mm INJ.ORDER : 6-2-4-1-5-3 DRIVE
SIDE
GOVERNOR ADJUSTMENT INJ.QUANTITY(FOR BENCH STATE)
CHECK RACK PUMP INJ. VARIATIO
POINT POSITIO SPEED QUANTITY NRATE
REMARK
N (rpm) (cc/1000ST) (%)
(mm)
A 10.3 1100 70.0 P4 기준
B 7.3 400 8.0 P14
Rack
D - 100 40.0 -
limit

SPRING CONSTANT(kg/mm) FLY WEGHT (g) 740

GOVERNOR 12.0 PLUNGER LEAD 20˚
IDLING 1.9 DEL.V/V HDR MARK -
IDLE SUB 2.1 DAMPING V/V ORIF.DIA -
START 0.005 D.V RET. VOL.
59 mm3/st
DEL.VALVE 1.63 (Ø6X2.5mm/t=0.11mm)
LEVER MINIMUM 1 : 1.2
ADAPTER 11
RATIO MAXIMUM 1 : 1.2
TIMING DIVICE BOOST COMPENSATOR

LESS LESS

REMARK DRY WEIGHT

Maintenance of major components - 134 -

2) Injection pump

EJM5018S

1. Pump housing 56. Shim 117a. Connection bolt

2. Cover assembly 61. Plunger spring 118a. Gasket
3. Bolt, cover 62. Seat, spring(upper) 121. Plug screw
4. O-ring 63. Seat, spring(lower) 122. Gasket
5. Gasket 67. Control rack 130. Connect
16. Screw, plug 68. Stop bolt 130a. Adapter
18. Bolt, stud 76. Pinion 131a. Bolt
20. Spring washer 77. Sleeve 132a. Gasket
21. Nut 78. Bolt 133a. Gasket
23. O-ring 90. Camshaft 145. Plug screw
30. Plunger 91.91a. Taper roller bearing 146 Gasket
36. Delivery valve 92.92a Camshaft ring 152. Connection bolt
37. Delivery valve spring 93.93a. Shim 154. Packing
40. Delivery valve holder 95. Center bearing 191. Bracket
45. Lock plate assembly 101a. Bearing cover 192. O-ring
49. O-ring 104a Bolt 194. Washer
55. Tappet 112a. Woodruf key 195. Spring washer
115a. Adapter 196. Nut

- 135 - Maintenance of major components

3) Governor

EJM5019S

1. Governor housing 80. Cover 182. Lever shaft

4. Plate 82. Bolt 183. Collar
6. Adapter 83. Bolt 190. Control lever
7. Bolt 100.Fly wheel 192. Nut
9. Spring 101. Woodruf key 195. Return spring
10. Bolt 102. Spring washer 198. Spring washer
13. Nut 103. Nut 201. O-ring
19. Adapter 117. Sleeve 202. Bush
20. Bolt 118. Shim 203. Shim
21. Gasket 130. Governor spring 205. Shaft lever
35. Governor cover 132. Starting spring 207. Support lever
38. Tension lever bolt 136. Nut 211. Snap ring
39. Nut 137. Gasket 220. Damper spring
44. Stop bolt 138. Cap 236. Gasket
46. Cap 140. Idle spring 239. Gasket
47. Plug 141. Nut 240. Lead seal
48. Adjusting bolt 150. Speed setting lever 241. Wire, lead seal
49. Nut 170. Guide lever 255. Bracket
50. Stop bolt 173. Split pin 331. Angleich spring
51. Bolt 174. Floating lever link 332. Connection nut
52. Bolt 181. Tension lever

Maintenance of major components - 136 -

5.3.4. Precautions for operation
1) Precautions for operation of engine
The following precautions should be observed when starting, operating, or stopping the engine:

Operations Precautions Reasons

When starting 1) Check oil level

the engine
2) Crank the engine with starter to check 2) Abrupt starting of the engine causes
the increase in oil pressure(until the the engine to rotate with oil not being
needle of pressure gauge starts to distributed not only to each part but
move or pressure indicator lamp is also to the turbocharger, resulting in
actuated) before starting the engine. abnormal wear or seizure on the
bearing due to insufficient supply of oil.
3) When having replaced oil, oil filter 3) In the case of the engine stopped for
element, or lubricating parts, or when extended time or in a cold place, oil
having stopped the engine for fluidity within the pipes can be
extended period of time, or in a cold deteriorated
place, loosen the oil pipe connections
and operate the starter motor until oil is
discharged. After completing the
operation, be sure to retighten the oil
pipe connections portion before starting
the engine.

Immediately 1) Check each part for leakage of oil, gas, 1) Leakage of oil, gas, and air (especially,
after starting and air, and take proper measure. oil leak) causes drop in oil pressure
and loss of oil results in seizure of the
bearing.

During operation Check the followings:

1) Oil pressure At idle: 0.8 kg/cm2 or 1) Excessively low oil pressure causes
more At full load: 3.0∼4.8 kg/cm2 unusual wear or seizure of the bearing.
Too high pressure causes oil leakage.
2) If unusual sound or vibration is heard 2) The engine Is operated continuously
or felt, reduce engine revolutions slowly with unusual sound or vibration not
and locate the cause. corrected, it can be damaged beyond
repair.

- 137 - Maintenance of major components

5.3.5. Walk-around check and servicing
As the condition of turbocharger depends greatly on how well the engine is serviced, it is very important to
maintain the engine in accordance with the specified maintenance procedure.

1) Intake system
Pay particular attention to the air cleaner when servicing the intake system.
In the case of wet-type air cleaner, if the level of oil surface is lower than specified, cleaning effect is
poor; if too high, the cleaner draws in oil to foul the case.
Especially, if the rotor is fouled, the sophisticatedly-tuned balance is broken to create vibration and to
cause seizure and unusual wear to the bearing.
Therefore, it is very important to use a good quality air cleaner all the time.
In the case of dry-type air cleaner, it is essential to clean it to reduce intake resistance as much as
possible.

2) Exhaust system
Pay particular attention to prevent gas leaks and seizure when servicing the exhaust system because
leakage of exhaust gas from discharge pipes, turbocharger fixing portions, etc. lowers charging effect.
As such components as turbine chamber that becomes red-hot during operation use heat resisting steel
nuts, do not interchange these nuts with ordinary steel nuts. In addition, apply anti-seizure coating to
fixing nuts on the portions as designated.

3) Lubricating system
Pay particular attention to oil quality and oil filter change intervals when servicing the lubricating system.
Deteriorated engine oil affects adversely not only the engine but torso the turbocharger. Suggested
engine oils for the turbocharger-mounted engine are as follows:

Recommend oil
Engine model
SAE No. API No.

SAE15W40 ACEA-E2 or ACEA-E3

DB58S
SAE10W40 (API CH-4)

Maintenance of major components - 138 -

5.3.6. Diagnostics and troubleshooting

Complaints Possible causes Corrections

1. Excessive black smoke 1) Air cleaner element clogged Replace or clean

2) Restrictions in air duct Check and correct

3) Leakage at intake manifold Check and correct

Disassemble/repair or
4) Turbocharger seized up and not rotating
replace

5) Turbine blades and compressor blades coming in Disassemble/repair or

contact with each other or damaged replace

6) Exhaust piping deformed or clogged Check and correct

2. Excessive white smoke Disassemble/repair or

1) Oil leak into turbine and compressor
replace

2) Worn or damaged seal ring due to excessive wear Disassemble/repair or

of bearing replace

3. Low engine output 1) Gas leak at each part of exhaust system Check and correct

2) Air cleaner element restricted Replace or clean

Disassemble/repair or
3) Turbocharger fouled or damaged
replace

4) Leakage at discharge port on compressor side Check and correct

4. Unusual sound or Disassemble/repair or

1) Rotor assembly coming in contact
vibration replace

Disassemble/repair or
2) Unbalanced rotation of rotor
replace

Disassemble/repair or
3) Seized up
replace

4) Each joint loosened Check and correct

- 139 - Maintenance of major components

6. Special Tool List

No. Part No. Figure Tool Name Remark

1 EU.2-0529 Compression gauge adapter

2 EF122-249 Valve spring compressor

3 EF.122-265 Crankshaft gear punch

4 EF.122-253 Crankshaft pilot bearing remover

5 EF.122-251 Pilot bearing punch

6 EF.122-262A Crankshaft rear oil seal installer

7 EF.122-255 Crankshaft front oil seal installer

8 EF.122-289 Valve stem oil seal installer

Special tool list - 140 -

No. Part No. Figure Tool Name Remark

9 E1.03901-0124 Piston insert sleeve

10 EF.122-281 Cylinder liner remover

11 EF122-261 Cylinder liner installer

12 EU.1-0022 Pulley bush puncher

13 EU.2-0328 Pulley bush puller

14 60.99901-0027 Feeler gauge

15 T7610001E Snap ring plier

16 T7621010E Piston ring plier

- 141 - Special tool list

• Appendix

1) Tightening torque for major parts

Screw Strength
Major Parts Tightening Torque Remarks
(Diameter x pitch) (grade)

1st : 4.4 kg.m

Cylinder head bolt M12 x 1.5 10.9T 2nd : 150°
(Angle method)

Connecting rod bearing cap bolt M12 x 1.5 12.9T 9.75 kg.m

Crankshaft main bearing cap

M16 x 2 12.9T 24.0 kg.m
bolt
M14 x 1.5 10.9T 13 kg.m
Flywheel housing fixing bolt
M16 x 1.5 10.9T 16 kg.m
Flywheel fixing bolt M16 x 1.5 10.9T 18 kg.m
Crankshaft pulley fixing nut M36 x 1.5 8.8T 60 kg.m
Oil spray nozzle hollow screw
M10 x 1.25 - 2.1 kg.m
(Relief valve assembly)

2) Tightening torque for fuel injection pump system

Screw Strength
Major Parts Tightening Torque Remarks
(Diameter x pitch) (grade)
Injection nozzle nut M28 x 1.5 - 7.0 kg.m
Injection pump bracket bolt M10 8.8T 4.4 kg.m
Injection pump coupling bolt - - 6.0 ~ 6.5 kg.m
Injection pump driving gear nut M24 x 1.5 8.8T 25.0 kg.m
Injection pipe nut M14 x 1.5 8.8T 3.0 kg.m
Injection pump delivery valve
- - 11.0 ~ 12.0 kg.m
holder

Appendix - 142 -
3) Tightening torque for hollow screw (4-hole)

Material M8 M10 M12 M14 M16 M18 M22 M26 M30 M38
SM25C - 1.6 2.5 3.5 4.5 5.5 9.0 13.0 18.0 30.0
★SUM22L 0.8 1.8 3.0 4.0 5.5 6.5 11.0 16.0 20.0 35.0
STS304 0.8 1.8 3.0 4.0 5.5 6.5 11.0 16.0 20.0 35.0

★ : Adopted in DOOSAN engine

4) Standard bolt tightening torque table

Refer to the following table for bolts other then described above

Degree of strength
3.6 4.6 4.8 5.6 5.8 6.6 6.8 6.9 8.8 10.9 12.9
Diameter
x (4A) (4D) (4S) (5D) (5S) (6D) (6S) (6G) (8G) (10K) (12K)
pitch Limit value for elasticity (kg/mm ) 2

(mm)
20 24 32 30 40 36 48 54 64 90 108
Tightening torque (kg.m)
M5 0.15 0.16 0.25 0.22 0.31 0.28 0.43 0.48 0.50 0.75 0.90
M6 0.28 0.30 0.45 0.40 0.55 0.47 0.77 0.85 0.90 1.25 0.50
M7 0.43 0.46 0.70 0.63 0.83 0.78 1.20 1.30 1.40 1.95 2.35
M8 0.70 0.75 1.10 1.00 1.40 1.25 1.90 2.10 2.20 3.10 3.80
M8x1 0.73 0.80 1.20 1.10 1.50 1.34 2.10 2.30 2.40 3.35 4.10
M10 1.35 1.40 2.20 1.90 2.70 2.35 3.70 4.20 4.40 6.20 7.40
M10x1 1.50 1.60 2.50 2.10 3.10 2.80 4.30 4.90 5.00 7.00 8.40
M12 2.40 2.50 3.70 3.30 4.70 4.20 6.30 7.20 7.50 10.50 12.50
M12x1.5 2.55 2.70 4.00 3.50 5.00 4.60 6.80 7.70 8.00 11.20 13.40
M14 3.70 3.90 6.00 5.20 7.50 7.00 10.00 11.50 12.00 17.00 20.00
M14x1.5 4.10 4.30 6.60 5.70 8.30 7.50 11.10 12.50 13.00 18.50 22.00
M16 5.60 6.00 9.00 8.00 11.50 10.50 17.90 18.50 18.00 26.00 31.00
M16x1.5 6.20 6.50 9.70 8.60 12.50 11.30 17.00 19.50 20.00 28.00 33.00
M18 7.80 8.30 12.50 11.00 16.00 14.50 21.00 24.20 25.00 36.00 43.00
M18x1.5 9.10 9.50 14.50 12.50 18.50 16.70 24.50 27.50 28.00 41.00 49.00
M20 11.50 12.00 18.00 16.00 22.00 19.00 31.50 35.00 36.00 51.00 60.00
M20x1.5 12.80 13.5 20.50 18.00 25.00 22.50 35.00 39.50 41.00 58.00 68.00
M22 15.50 16.00 24.50 21.00 30.00 26.00 42.00 46.00 49.00 67.00 75.00
M22x1.5 17.00 18.50 28.00 24.00 34.00 29.00 47.00 52.00 56.00 75.00 85.00
M24 20.50 21.50 33.00 27.00 40.00 34.00 55.00 58.00 63.00 82.00 92.00
M24x1.5 23.00 25.00 37.00 31.00 45.00 38.00 61.00 67.00 74.00 93.00 103.0

Others :
1. The above torque rating have been determined to 70% or so of the limit value for bolt elasticity.
2. Tension is calculated by multiplying tensile strength by cross section of thread.
3. Special screws should be tightened to 85% or so of the standard value.
For example, a screw coated with MoS2 should be tightened to 60% or so of the standard value

- 143 - Appendix
SB4274E00
Sep. 2007

Power Train
Specification
System Operation
Testing & Adjusting
Disassembly & Assembly

D50S-5, D60S-5, D70S-5, D80S-5, D90S-5

G50S-5, G60S-5, G70S-5
Two Speed Transmission
Drive Axle (OCDB, SHOE)
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.

Improper operation, Iubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.

Do not operate or perform any Iubrication, maintenance or repair on this product, until you have read
and understood the operation, Iubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are
not heeded, bodily injury or death could occur to you or other persons.

The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as "WARNING"
as shown below.

WARNING

The meaning of this safety alert symbol is as follows :

Attention! Become Alert! Your Safety is Involved.

The Message that appears under the warning, explaining the hazard, can be either written or pictorially
presented.

Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.

DOOSAN cannot anticipate every possible circumstance that might involve a potential hazard. 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, Iubrication, maintenance or repair procedures you choose.

Obtain the complete and most current information before starting any job. DOOSAN dealers have the most
current information available.

1
Index

Specification
Wheel Brake Adjustment .....................................30
General Tightening Torque ................................... 5
Inching Pedal Adjustment ....................................32
Drive Axle Specification ........................................ 6
Torque Converter.................................................. 7
Transmission Pump .............................................. 7 Disassembly and Assembly
Drive Axle Mounting.............................................. 8
Differential ............................................................ 8 Drive Shaft and Universal Joint............................35
Wheel Bearing and Drive Wheel ........................... 8 Engine, Torque Converter and Transmission .......36
Brake Assembly.................................................... 9 Transmission Control Valve.................................40
Brake Drum Diameter ......................................... 10 Transmission.......................................................43
U - joint ............................................................... 10 Drive Axle ...........................................................54

System Operation

General Information ............................................ 11

Power Shift Transmission.................................... 12
General Information ......................................... 12
Power Flow at Low Speed Forward.................. 13
Power Flow at High Speed Forward ................. 14
Power Flow at Low Speed Reverse.................. 15
Power Flow at High Speed Reverse................. 16
Transmission Control Valve ................................ 17
Cross-Section View.......................................... 17
Hydraulic Schematic ........................................ 18
Differential and Drive Axles ................................. 20
Differential ....................................................... 20
Wheel Hub....................................................... 20
Brake Components ............................................. 21
Shoe Brake...................................................... 21
Brake Adjuster ................................................. 21
OCDB.............................................................. 22

Testing and Adjusting

Troubleshooting .................................................. 23
Visual Checks .................................................. 23
Checks During Operation ................................. 23
Check List During Operation ............................ 23
Check List From Operation Noise..................... 25
Check List From Pressure Test ........................ 26
Differential ....................................................... 27
Transmission Pressure ....................................... 28
Converter Stall Test ............................................ 29
Shimming of Transmission Shaft......................... 30

Power Train 3 Index

Specification
General Tightening Torque

GENERAL TIGHTENING TORQUE FOR

BOLTS, NUTS AND TAPERLOCK STUDS

The following charts give the standard torque values for bolts, nuts
and taperlock studs of SAE Grade 5 of better quality. Exceotions
are given in other sections of Service Manual where needed.
THREAD DIAMETER STANDARD TORQUE
inches millimeters lb•ft. N•m*
Standard thread
Use these torques for bolts and nuts with standard
threads (conversions are approximate).

1/4 6.35 9±3 12 ± 4

5/16 7.94 18 ± 5 25 ± 7
3/8 9.53 32 ± 5 45 ± 7
7/16 11.11 50 ± 10 70 ± 15
1/2 12.70 75 ± 10 100 ± 15
9/16 14.29 110 ± 15 150 ± 20
5/8 15.88 150 ± 20 200 ± 25
3/4 19.05 265 ± 35 360 ± 50
7/8 22.23 420 ± 60 570 ± 80
1 25.40 640 ± 80 875 ± 100
1 1/8 28.58 800 ± 100 1100 ± 150
1 1/14 31.75 1000 ± 120 1350 ± 175
1 3/8 34.93 1200 ± 150 1600 ± 200
1 1/2 38.10 1500 ± 200 2000 ± 275
Use these torques for bolts and nuts on hydraulic
valve bodies.
5/16 7.94 13 ± 2 20 ± 3
3/8 9.53 24 ± 2 35 ± 3
1/16 11.11 39 ± 2 50 ± 3
1/2 12.70 60 ± 3 80 ± 4
5/8 15.88 118 ± 4 160 ± 6
Taperlock stud
Use these torques for studs with Taperlock threads

1/4 6.35 6±2 8±3

5/16 7.94 13 ± 4 17 ± 5
3/8 9.53 26 ± 4 35 ± 5
7/16 11.11 33 ± 7 45 ± 10
1/2 12.70 48 ± 7 65 ± 10
9/16 14.29 65 ± 11 90 ± 15
5/8 15.88 80 ± 11 110 ± 15
3/4 19.05 125 ± 15 170 ± 20
7/8 22.23 190 ± 22 260 ± 30
1 25.40 300 ± 30 400 ± 40
1 1/8 28.58 370 ± 30 500 ± 40
1 1/4 31.75 480 ± 37 650 ± 50
1 3/8 34.93 550 ± 37 750 ± 50
1 1/2 38.10 640 ± 37 870 ± 50
*1 newton meter(N•m) is approximately the same as 0.1 mkg.

Power Train 5 Specification

Drive Axle Specification

Shoe Type

2.636 / D(G) 50/70S-5

Differential
3.100 / D80/90S-5
Gear Ratio Planetary 4

Drive Axle 10.545 / D(G) 50/70S-5

Total
12.400 / D80/90S-5
Axle Oil SAE #80 or #90

Oil Volume 12.5 L

Service Brake Shoe Brake

Brake Brake Oil AZOLLA - ZS10

Parking Brake Drum Brake

Gear Type Spiral Bevel Gear

Differential
Differential Type 4 Pinions

OCDB Type

D(G)50/70S-5 : 2.636
Differential
D80/90S-5 : 3.100
Gear Ratio Planetary 4

Drive Axle D(G)50/70S-5 : 10.545

Total
D80/90S-5 : 12.400
Axle Oil MOBIL #424

Oil Volume 12.5 L

Service Brake Oil Cooled Disk Brake

Brake Brake Oil AZOLLA - ZS10

Parking Brake Drum Brake

Gear Type Spiral Bevel Gear

Differential
Differential Type 4 Pinions

Power Train 6 Specification

Torque Converter Transmission Pump

1
4

(1) Clearance between outside of drive gear and

crescent 0.36 to 0.43 mm (0.014 to 0.017 in)

(1) Torque for bolts (plate to torque converter)

..................................... 45 ± 7 N∙m (33 ± 5 lb•ft)
Apply LOCTITE NO. 277 sealant to threads of
bolts.
(2) Clearance between inside of driven gear and
crescent 0.25 to 0.33 mm (0.010 to 0.013 in)
(2) Torque for bolts (plate to flywheel)
.....................................25 ± 7 N•m (18 ± 5 lb•ft)

(3) End play of turbine hub (new) .

............................... 0 to 0.99 mm (0 to 0.039 in)
Maximum end play of turbine hub (worn)
............................................. 1.65 mm (0.065 in)

(4) Torque for bolts (torque converter to PTO gear)

.....................................20 ± 3 N•m (15 ± 2 lb•ft)

Apply LOCTITE NO. 277 sealant to threads of

bolts.

NOTE : For Torque values not given, see the page

of specifications for general tightening torques.
(3) Gear end play....................... 0.025 to 0.064 mm
(0.0010 to 0.0025 in)

Power Train 7 Specification

Drive Axle Mounting 3. Apply Loctite No.271 to threads of bolts.
Torque for bolts.......... 157 ± 5 N•m (116 ± 4 lb•ft)
Consider same marking on brackets to the
housing.

4. Apply Loctite No.271 to threads of bolts.

Torque for bolts................ 10 ± 2 N•m (7 ± 2 lb•ft)

5. Apply Loctite No.271 to threads of bolts.

Torque for bolts.......... 177 ± 5 N•m (130 ± 4 lb•ft)

6. Torsional backlash of bevel gear... 0.18~0.23 mm

Wheel Bearing and Drive Wheel

Shoe Axle

(1) Torque for nuts ..... 800 ± 50 N•m (590 ± 37 lb•ft)

Apply LOCTITE NO. 271 sealant to threads of

bolts.

Differential

OCDB Axle

1. Apply Loctite No.271 to threads of bolt. Torque

for bolts that hold bevel gear to differential
housing is....................132 ± 5 N•m (98 ± 4 lb•ft).

2. Apply Loctite No.271 to threads of bolts. Torque

for bolts is...................... 59 ± 5 N•m (43 ± 4 lb•ft).

Power Train 8 Specification

Slotted nut adjustment Brake Assembly
a. Tighten slotted nut (1) slightly by hand.

b. Tighten slotted nut (1) to 640 N•m (472 lb•ft).

c. Rotate wheel hub several times.

1
d. Turn back slotted nut (1) slightly and retighten
until bearing friction torque reaches to 10~14
N•m (7.4 to 10.3 lb•ft).

e. Apply Loctite No.271 on the threads of bolt (2).

Secure slotted nut (1) with bolt (2) with tightening
torque of 19~24 N•m (14~18 lb•ft).

f. Assemble thrust washer (3) with Loctite # 609.

g. Torque for Spindle bolt (5) ...............118 ± 5 N•m

(87 ± 4 lb•ft)
h. Torque for Service piston bolt (6) ....15 ± 0.1 N•m
(11 ± 0.01 lb•ft)

ICPS0005S

Torque for bolts (1) .......19 to 22 N•m (14 to 16 lb•ft)

i. Torque for wheel nut (7) ................550 ± 50 N•m Torque for bolts (2) ...... 120 ± 20 N•m (90 ± 15 lb•ft)
(406 ± 37 lb•ft)

Power Train 9 Specification

Brake Drum Diameter

(1)

Brake drum diameter (1) ............ 315.0 to 315.2 mm

(12.402 to 12.409 in)

Maximum total diameter of brake drums which can

be machined from the original diameter....... 2.0 mm
(0.079 in)

U - joint

(1)

Torque for bolts (1) ................................55 ± 7 N•m

(40 ± 5 lb•ft)

Power Train 10 Specification

System Operation

General Information

(1) Engine (2) Torque Converter (3) Power Shift Transmission (4) Universal joint (5) Drive Axle (6) Drive Wheels.

The basic components of the power train are: Power from the transmission is sent through its
engine (1), torque converter (2), power shift output gear through the drive shaft and reduction
transmission (3), universal joint (4), drive axle (5), gears to the differential. The differential sends
drive wheels (6). power out the axles and to the wheels.

Power from the engine flywheel goes from the

torque converter to the input shaft of the NOTICE
transmission. The power shift transmission is a Damage can be caused to the transmission if the
constant mesh countershaft type and has four truck is moved with the engine not running. There
hydraulically operated clutches that are spring will be no lubrication to the transmission
released. The transmission has two speeds in components. Disconnect and remove the universal
forward and two speeds in reverse. joint before the truck is moved.

Power Train 11 System Operation

Power Shift Transmission
In the power flow diagrams that follow, the
components are shown in a position to make it
General Information easier to follow the power flow through the
transmission. Illustration shows the transmission
The transmission is a constant mesh power shift from the converter end with the correct location of
transmission and gives two forward and two the components.
reverse speeds. The transmission has four
clutches that are engaged hydraulically and
released by spring force. The direction and speed
A
are changed electrically. 22
B

20
2

B 3
A
13
AB B
AB
11

10 9
5

A
ICPS044S B 14

(2) Clutch Gear. (3) Clutch Gear. (5) Gear(Reverse low).

(9) Gear(Reverse high). (10) Intermediate Shaft Gear.
(11) Gear(Low). (13) Gear(High). (14) Output Shaft Gear.
(20) Gear(Forward high). (22) Gear(Forward low).

Most all of the components inside the transmission

turn when the controls are in either of the
FORWARD or REVERSE speeds. Only those
components that have been made dark in the
Power Shift Transmission
diagrams that follow are used in the flow of power
(1) Input Shaft. (2) Cylinder Clutch(Forward)
through the transmission.
(3) Cylinder Clutch(Reverse). (4) Reverse Shaft.
(5) Gear(Reverse low) (6) Clutch(Reverse low).
(7) Piston. (8) Clutch(Reverse high).
(9) Gear(Reverse high). (10) Intermediate Shaft.
(11) Gear(low). (12) Intermediate Shaft Gear.
(13) Gear(High) (14) Output Shaft. (15) Output Shaft Gear.
(16) Clutch(Forward low) (18) Valve Ass’y. (19) Yoke.
(20) Gear(Forward high). (21) Clutch(Forward high).
(22) Gear(Forward low).

Power Train 12 System Operation

Power Flow at Low Speed Forward

SECTION : A-A

Power Flow In Low Speed Forward

(1) Input Shaft. (2) Cylinder Clutch(Forward). (7) Piston. (10) Intermediate Shaft. (11) Gear(Low). (12) Intermediate Shaft Gear.
(13) Gear(High). (14) Output Shaft. (15) Output Shaft Gear. (16) Clutch(Forward low). (18) Valve Ass’y (19) Yoke.
(20) Gear(Forward high). (21) Clutch(Forward high). (22) Gear(Forward low).

Input shaft (1) of the transmission is turned by the When FORWARD low clutch (16) is engaged, gear
turbine of the torque converter. The clutch cylinder (22) is turned through the clutch. Gear (22) is
(2) for the forward clutches is connected to the input engaged with gear (11) and turns gears (11) and
shaft by rivets. (13) gears (11) and (13) are both connected to shaft
(10) by splines. Shaft (10) is engaged with output
shaft gear (15) by intermediate shaft gear (12). This
sends the power from shaft (10) through output
shaft gear (15) into output shaft (14) of the
transmission.

Power Train 13 System Operation

Power Flow at High Speed Forward

SECTION : A-A

Power Flow In High Speed Forward

(1) Input Shaft. (2) Cylinder Clutch(Forward). (7) Piston. (10) Intermediate Shaft. (11) Gear(Low). (12) Intermediate Shaft Gear.
(13) Gear(High). (14) Output Shaft.. (15) Output Shaft Gear. (16) Clutch(Forward low). (18) Valve Ass’y (19) Yoke.
(20) Gear(Forward High). (21) Clutch(Forward High). (22) Gear(Forward low).

Input shaft (1) of the transmission is turned by the When FORWARD high clutch (21) is engaged, gear
turbine of the torque converter. The clutch cylinder (2) is turned through the clutch. Gear (20) is
(2) for the forward clutches is connected to the input engaged with gear (13) and turns gears (13) and
shaft by rivets. (11) gears (13) and (11) are both connected to shaft
(10) by splines. Shaft (10) is engaged with output
shaft gear (15) by intermediate shaft gear (12). This
sends the power from shaft (10) through output
shaft gear (15) into output shaft (14) of the
transmission.

Power Train 14 System Operation

Power Flow at Low Speed Reverse

SECTION : B-B

Power Flow In Low Speed Reverse

(1) Input Shaft. (2) Clutch Cylinder Gear(Forward). (3) Clutch Cylinder Gear(Reverse). (4) Reverse Shaft. (5) Gear(Reverse
low). (6) Clutch(Reverse low). (7) Piston. (8) Clutch(Reverse high). (9) Gear(Reverse high). (10) Intermediate Shaft.
(11) Gear(Low). (12) Intermediate Shaft Gear. (13) Gear(High). (14) Output Shaft. (15) Output Shaft Gear. (18) Valve Ass’y.
(19) Yoke.

Input shaft (1) of the transmission is turned by the When REVERSE low clutch (6) is engaged, gear (5)
turbine of the torque converter. The clutch cylinder is turned through the clutch. Gear (5) is engaged
(2) for the forward clutches is connected to the input with gear (11) and turns gears (11) and (13) gears
shaft by rivets. Clutch cylinder (2) is engaged with (11) and (13) are both connected to shaft (10) by
and turns clutch cylinder (3). splines. Shaft (10) is engaged with output shaft gear
(15) by intermediate shaft gear (12). This sends the
power from shaft (10) through output shaft gear (15),
into output shaft (14) of the transmission.

Power Train 15 System Operation

Power Flow at High Speed Reverse

SECTION : B-B

Power Flow In High Speed Reverse

(1) Input Shaft. (2) Clutch Cylinder Gear(Forward). (3) Clutch Cylinder Gear(Reverse). (4) Reverse Shaft.
(5) Gear(Reverse low). (6) Clutch(Reverse low). (7) Piston. (8) Clutch(Reverse high). (9) Gear(Reverse high).
(10) Intermediate Shaft. (11) Gear(Low). (12) Intermediate Shaft Gear. (13) Gear(High). (14) Output Shaft.
(15) Output Shaft Gear. (18) Valve Ass’y. (19) Yoke

Input shaft (1) of the transmission is turned by the When REVERSE high clutch (8) is engaged, gear
turbine of the torque converter. The clutch cylinder (9) is turned through the clutch. Gear (9) is engaged
(2) for the forward clutches is connected to the input with gear (13) and turns gears (13) and (11) gears
shaft by rivets. Clutch cylinder (2) is engaged with (13) and (11) are both connected to shaft (10) by
and turns clutch cylinder (3). splines. Shaft (10) is engaged with output shaft gear
(15) by intermediate shaft gear (12). This sends the
power from shaft (10) through output shaft gear (15),
into output shaft (14) of the transmission.

Power Train 16 System Operation

Transmission Control Valve

Cross-Section View

RELIEF VALVE
INCHING VALVE

ACCUMULATOR
F1 F2 R1 R2 VALVE

SOLENOID VALVE

SECTION "B-B"

F1 F2 R1 R2

R2 R1 F2 F1

(1) BODY. (2) SPOOL. (3) SPRING. (4) PLUG. (5) O-RING. (6) ORIFICE. (7) STOPPER. (8) O-RING. (9) SPRING.
(10) PISTON. (11) PLUG. (12) FILTER ASS'Y. (13) O-RING. (14) SPOOL. (15) SPRING. (16) SPRING. (17) PLUNGER.
(18) PIN. (19) STOP BOL (20) OIL SEAL. (21) PLUG. (22) O-RING. (23) PLUG. (24) O-RING. (25) SOLENOIDE VALVE ASS'Y.
(26) PLUG. (27) O-RING. (28) BS CONNECTOR ASS'Y. (29) GASKET. (30) O-RING. (31) SPRING. (32) PLATE. (33) PISTON.
(34) GASKET.

Power Train 17 System Operation

Hydraulic Schematic

(1) RELIEF VALVE. (2) INCHING VALVE. (3) ACCUMULATOR VALVE. (4) SOLENOID VALVE.

(1) RELIEF VALVE

◆ OPERATION
◆ FUNCTION The oil from the PUMP is fed to VALVE via “A.”
To maintain constant pressure in the CONTROL As pressure rises, the oil through “A” overcomes
VALVE, preventing excessive rise or fall of the spring force and pushes SPOOL to left.
pressure, and supply oil to TORQUE
CONVERTER. When the SPOOL is pushed to left by oil
pressure, “A” and “B” are connected and the oil
from “A” enters TORQUE CONVERTER through
“B” and pressure falls.

When the pressure fell, PISTON returns reducing

the inflow to the TORQUE CONVERTER, raising
pressure again. The minimum pressure is
maintained by the repeated operation of the
SPOOL.

In the event that the pressure is keep rising when

oil flows to TORQUE CONVERTER, SPOOL is
pushed to right, and at the preset pressure, the
oil entered through “A” is drained through “C”
preventing the pressure rise higher than the
preset value.

Power Train 18 System Operation

(2) INCHING VALVE

◆ FUNCTION
The INCHING VALVE controls the pressure of oil
entering CLUTCH and smoothens the CLUTCH
contact.
In addition, by enabling the vehicle to move
smoothly at high RPM, it provides fast
functionality of the implement in low speed.

Therefore, wash the plug when replacing the T/M

oil.

(4) SOLENIOD VALVE

◆ FUNCTION
Supplies the oil from accumulator to each clutch
according to the change of step.

◆ OPERATION
When the INCHING PEDAL is not pressed, the
oil from the main pressure line "A" is fed to
ACCUMULATOR VALVE through valve and “D.”

When the INCHING PEDAL is pressed, SPOOL

moves toward left, isolating the main pressure
line "A" stopping oil supply. The oil in the
ACCUMULATOR is drained through “C” via “D”
lowering pressure at CLUTCH.

(3) ACCUMULATOR VALVE

◆ FUNCTION ◆ OPERATION
Smoothens CLUTCH operation by enlarging the When the shift lever is moved, the spool in the
time for pressure rise since from the CLUTCH solenoid valve moves toward bottom by electric
contact and beginning of slip. signal, forming oil path.

◆ OPERATION The oil from accumulator enters “G”, flows

When the INCHING PEDAL is pressed and let through the internal path of solenoid valve, and
free, oil enters “E(1st orifice)” from inching to fed to clutch via “H.”
move piston to right. Then, pressure rises slowly
to open “F(2nd orifice).” When the piston reaches When the shift lever is at neutral position, the
right side, pressure rises up to the relief setting electric signal us cut-off, the spool moves
value. upwards by the force of the spring in the solenoid
valve, forming an oil path from “G” to “C(tank)”
In the oil path of the accumulator valve plug to removing residual pressure in the clutch.
solenoid valve is #100 screen which filters
foreign material.

Power Train 19 System Operation

Differential and Drive Axles
When the machine moves straight forward, traction
Differential under each wheel is the same, so the torque from
each axle is the same and pinions (3) do not turn on
spider (6). This gives the same effect as if both
wheels were the same axle. In a turn the torque that
is sent to the axles is not the same. Thus torques
that are not the same are put on opposite sides of
the spider (5). The rotation of pinions (3) stops or
slows the inside wheel and makes the outside wheel
go faster. This moves the machine through a turn
under full power.

The differential gets lubrication from oil thrown about

inside the housing. A flat surface on each side of
spider (6) lets lubricant go to pinions (3) and to the
thrust washers.

Wheel Hub

Differential
(1) Ring Gear. (2) Pinion Gear. (3) Differential Pinion Gears.
(4) Differential. (5) Side Gears. (6) Spider.

Power from the transmission goes to the pinion and

ring gear of the differential. The differential turns the
axles through the final drive housing.

The drive axles are used to supply torque only. The

load bearing hubs on the axle housing are used as a
support for the weight of the truck. The axles are
connected through planetary gears and carrier to the
wheel hubs and drive the wheels.

The differential is used to send the power from the

transmission to the wheels. When on wheel is
turned slower than the other, the differential lets the
inside wheel stop or turn slower in relation to the
Wheel hub
outside wheel. (1) Bearings. (2) Nuts. (3) Axle Shaft. (4) Planetary Gears.
(5) Planetary Carrier.
The drive shaft from the transmission turns pinion
gear (2) which sends the power to the differential.
Bevel pinion gear (2) turns ring gear (1) which is The wheel hubs run on tapered roller bearings (1).
fastened to the differential. The differential has four The hub bearing are held in position by nuts (2). The
pinions (3), spider (6) and two side gears (5). The hub and bearings are turned by axle shat (3) and
connection between four pinions (3) and two side planetary gears (4) through planetary carrier.
gears (5) is at right angles through a gear mesh.
Splines make the connection between side gears (5)
and the axles.

Power Train 20 System Operation

Brake Components

Shoe Brake Brake Adjuster

Brake Adjuster
(1) Adjusting Bolt. (2) Sleeve. (3) U-shaped Bracket.
(4) Adjusting Lever. (5) Adjusting Screw. (6) Spring.
(1) Wheel Cylinder. (2) Wheel Cylinder Pistons. (7) Adjusting Wheel. (8) Spring.
(3) Secondary Shoe. (4) Return Springs. (5) Primary Shoe.
(6) Return Spring.
By means of an adjusting bolt (1), the primary shoe
pushes a sleeve (2) through a U-shaped bracket (3),
When the brake pedal is pushed down the master which at the same time acts as the bearing bracket.
cylinder sends brake of (hydraulic oil) to wheel This trust movement causes the adjusting lever (4)
cylinder (1). Wheel cylinder pistons (2) are pushed to be actuated by means of an adjusting disc (5) and
out and move primary shoe (5) and secondary shoe to migrate to the side as the result of transmission.
(3). The brake shoes move out until they make As soon as the braking process and the associated
contact with brake drum. movement of the bake shoes have finished, and the
shoes have returned to their idle position supported
When the brake action first starts, primary shoe (5) by the compression spring (6) which at the same
comes in contact with the rotating brake drum. This time serves as a centering point, a toothed adjusting
contact of the primary shoe puts some force on wheel (7) is indexed on as a result of engagement
secondary shoe (3) to help put in position against by the adjusting lever which is tensioned by
the drum. As a result, the braking action is compressed spring (8) and which is restored by the
increased. support of the compression spring (6) and the
adjusting disc (5). In this way, the adjusting bolt (1),
When the brake pedal is released, brake shoe return in which the brake shoe is mounted, is unscrewed.
springs (6) and (4) pull brake shoes (3) and away This adjusting process per braking action is
from the drum surface. They also push wheel repeated until the sliding movement of the primary
cylinder pistons (2) back into wheel cylinder (1). brake shoe is no longer sufficient to overcome a
fixed clearance marked in the adjusting lever. This
set clearance ensures that the diameter of the brake
remains constantly adjustable at a certain dimension.

Power Train 21 System Operation

OCDB

(1) Spindle. (2) Steel plate. (3) Disk plate. (4) Service piston.
(5) Drive shaft. (6) Service piston adjust bolt. (7) Spline collar.
(8) Parking brake.

Sealed up structure of hydraulic disk brake system

secures good brake performance even in the high
humid or dusty area.

Because it is possible to use the brake semi-

permanently, there is no need to replace or change
the lining as drum type brake do.

Major components are 3 disk plates (3), 4 steel

plates (2), service piston (4). Braking force is applied
by restricting the driving force from drive shaft (5)
and spline collar (7).

Power Train 22 System Operation

Testing and Adjusting 4. Check the strainer behind the transmission oil plug
and the filter foreign material.

a. Particles of friction paper material give an

Troubleshooting indication of a clutch failure.

b. Metallic(metal) particles in the filter give an

Troubleshooting can be difficult. A list of possible indication of wear or mechanical failure in the
problems and corrections is on the pages that follow. transmission.

Use this as a reference for the location and c. Rubber particles give an indication of seal or
correction of problems in the transmission. When hose failure.
more testing and adjusting is necessary. use the
procedures that are given in Transmission Pressure d. Aluminum particles give an indication of a torque
Tests, Inching Pedal Adjustments and Converter converter or control valve failure.
Stall Tests, Always make visual checks first,
operation checks second and then make checks on If metal or rubber particles are found, all
the transmission with instruments. components of the transmission hydraulic system
must be flushed. Make a replacement of all parts
that show damage.
WARNING
When testing and adjusting the power train,
move the machine to an area clear of Checks During Operation
obstructions, and with safe ventilation for the
exhaust. To prevent personal injury when drive NOTICE
wheels are off the ground for testing, keep away Before these checks are started, fill the transmission
from wheels that are in rotation. with oil to the correct level. Improper oil level can
cause damage to the transmission components.

Operate the machine in each direction. Make note of

all noises that are not normal and find their source. If With the engine running and brakes on, move the
the operation is not correct, make reference to the selector lever for transmission speeds to all
troubleshooting chart for “problems” and “probable positions. The detents must be felt in each position.
causes” Operate the machine in each direction and in all
speeds. Make note of all noises that are not normal
and find their sources. If the operation is not correct,
Visual Checks make reference to the CHECK LIST DURING
OPERATION for “problems” and “probable causes”

1. Check the oil level in the transmission with the

engine running and with the transmission in Check List During Operation
NEUTRAL.
Problem : Transmission does not operate in any
2. Check all oil lines, hoses and connections for leaks speed or does not engage (slips) in all speeds.
and damage. Look for oil on the ground under the
machine. Probable Cause :

3. Move and turn the lever for the speed control and 1. Low oil pressure or no oil pressure caused by :
the direction control to all REVERSE and
FORWARD positions. The detents must be felt in a. Low oil, no oil, or thick oil.
each position.
b. Inching control valve linkage loose, broken or
adjustment is not correct.

c. Inching valve spool stuck (held) open.

d. Failure of the oil pump or a defect in the oil

pump.

Power Train 23 Testing and Adjusting

e. Converter drive tangs worn off or not engaged 9. Too much stalling of torque converter.
into pump.
10. Cooler bypass valve stuck (held) open, full oil
f. Main regulator valve stuck open. flow does not go through oil cooler.

g. Restriction in the oil flow circuit such as dirty Problem : Clutch engagement is slow or loss of
oil screen. power during engagement.

h. Leakage inside the transmission. Probable Cause :

ㆍ Control valve gasket has the damage. 1. Low oil pressure.

ㆍ Worn or broken metal seal rings on clutch 2. Low converter pressure.

shaft.
3. Air mixed in the oil.
ㆍ Worn or broken seals around clutch piston.
a. Air leaks on suction side of pump.
i. Control valve gasket is worn that causes
leakage. b. Low oil level also causes aeration.

2. Cooler external lines are not connected correctly. 4. Inching valve linkage adjustment is not correct.

3. Mechanical failure in the transmission. Problem : Transmission operates in forward

speeds only.
Problem : Transmission does not shift.
Probable Cause :
Probable Cause :
1. Discs and plates have too much wear in reverse
1. Low oil pressure. direction clutches.

2. Main regulator valve will not move (stuck). 2. Leakage at the seals.

3. Solenoids or related electric components are out 3. Reverse clutch components have damage.
of order.
a. Leakage caused by worn or broken metal
Problem : Transmission gets hot. sealing rings.
b. Leakage caused by worn or broken seal
Probable Cause : around clutch piston.
c. Failure of other components.
1. Restriction in cooling circuit.
4. Solenoids or related electric components are out
2. Oil level too high or too low. of order.

3. Low pump pressure -worn or damaged pump. Problem : Transmission operates in reverse
speeds only.
4. Converter one way clutch worn and slipping.
Probable Cause :
5. Air mixed in the oil. Air leaks on the intake side of
the pump. 1. Discs and plates have too much wear in forward
direction clutches.
6. Low oil flow through converter.
2. Leakage at the seals.
7. Wrong application for vehicle, (loads are too
heavy for the lift truck). 3. Forward clutch components have damage.

8. Too much inching operation (slipping the clutch a. Leakage caused by worn or broken seal
plates and discs). around metal sealing rings.

Power Train 24 Testing and Adjusting

b. Leakage caused by worn or broken seal Problem : Vehicle operates in one direction and
around clutch piston. creeps in that direction in NEUTRAL. Engine
stalls when shifted to the other direction.
c. Failure of other components.
Probable Cause :
4. Solenoids or related electric components are out
of order. 1. Failure of clutch in the direction the lift truck
moves. Clutch discs or plates are warped
Problem : Low stall speed. (damaged) or held together because of too much
heat.
Probable Cause :
2. Failure of the valve spool in the direction the lift
1. Engine performance is not correct. truck moves. The spool stuck(held) in the
engaged position possibly caused by metal
2. The one-way clutch of the torque converter does burrs(particles) or dirt.
not hold.

Problem : High stall speed in all transmission Check List From Operation Noise
speeds and directions.
Problem : Noise in NEUTRAL only.
Probable Cause :
Probable Cause :
1. Low oil level.
1. Worn bushing in pump assembly.
2. Air in the oil.
2. Worn one-way clutch in torque converter.
3. Clutches slip(clutch plates slide in relation to one
another). 3. Oil level low.

4. Torque converter failure. 4. Converter housing or converter tangs not in

alignment with engine or transmission pump.
Problem : High stall speed in one speed or one
direction. Problem : Pump noise not normal.

Probable Cause : Probable Cause :

1. There is a leak in that clutch circuit. 1. A loud sound at short time periods gives an
indication that foreign material is in the
2. There is a failure of the clutch in that speed or transmission hydraulic system.
direction.
2. A constant loud noise is an indication of pump
Problem : Clutch engagement is slow and makes failure.
rough shifts.
Problem : Noise in the transmission that is not
Probable Cause : normal.

1. Inching valve adjustment is not correct. Probable Cause :

2. Inching valve is not completely closed or orifice 1. Converter housing or converter tangs not in
has dirt (plugged). alignment with engine or transmission pump.

3. Low main pressure. 2. Transmission components have wear or damage.

4. Low directional clutch pressure. a. Damaged gears.

b. Worn teeth or clutch plates and/or clutch discs.
5. Internal oil leaks. c. Slipping clutch plates and discs noise.
d. Failure of the thrust washers.
6. Valve spool springs are weak or have damage. e. Other component parts have wear or damage.

Power Train 25 Testing and Adjusting

Problem : Noise in the control valve. Problem : Low main line pressure.

Probable Cause : Probable Cause :

1. Air in the hydraulic system. 1. Low oil level.

a. Air leakage on suction side of the pump. 2. Main regulator valve movement is restricted.

b. Low oil level that causes aeration. 3. Transmission pump is worn.

2. Restrictions in oil passage. 4. Inner oil leakage.

3. Valve spools movement has restriction. 5. Low oil pressure.

Problem : Low lubrication pressure or no

Check List From Pressure Test lubrication pressure.

Probable Cause :
Problem : Low pressure to FORWARD and
REVERSE clutches. 1. Low oil pressure or no oil pressure caused by :

Probable Cause : a. Failure of the oil pump or a defect in the oil

pump
1. Inching valve linkage adjustment is not correct.
b. Restriction in the oil flow circuit such as a dirt,
2. Inching valve spool held (stuck) open. oil screen.
c. Converter drive tangs worn off or not engaged
3. Clutch piston seals cause leakages. in pump.

4. A defective regulator valve spring. d. Main regulator valve spool stuck closed.

5. Low oil pressure, see Probable Cause for Low Oil e. Leakage inside of the transmission caused by
Pressure. component defect.

6. Cooler external lines are not connected correctly. 2. Oil cooler has restriction to oil flow.

Problem : Clutch pressure and main pressure Problem : High lubrication pressure.
are high.
Probable Cause :
Probable Cause :
1. High converter inlet pressure.
1. Pressure regulator valve is not free to move
(stuck). 2. Cooler and oil filter external lines are not
connected correctly.
2. A restriction in the hydraulic circuit.
Problem : High converter pressure.
Problem : Pressure to one clutch is low.
Probable Cause :
Probable Cause :
1. Main regulator valve stuck open so most of the
1. Clutch piston seal alignment is not correct, oil flow goes to the converter.
leaks through.
2. A restriction inside the converter assembly.
2. Seal rings on shaft or clutch piston seals are
broken or worn. 3. A plugged (restriction) oil flow passage.

3. Control valve surface not flat or gasket has

damage.

Power Train 26 Testing and Adjusting

Problem : Low converter pressure. Problem : Noise at different intervals.

Probable Cause : Probable Cause :

1. Main regulator valve movement is restricted. 1. Ring gear does not run even.

a. bolts on drive gear not tightened correctly.

Problem : Converter outlet pressure or cooler
inlet pressure is low. b. Drive gear has a defect(warped)

Probable Cause : 2. Loose or broken differential bearings.

1. Low oil pressure.

Problem : Noise on turns only.
2. Cooler bypass valve stuck open.
Probable Cause :

Problem : Converter outlet pressure or cooler 1. Differential pinion gears tight on the spider or the
inlet pressure too high. pinion shaft.

Probable Cause : 2. Side gears tight in differential case.

1. Restriction in oil cooler lines or a plugged oil 3. Differential pinion or side gears have a defect.
cooler.
4. Thrust washers worn or have a damage.

Differential 5. Too much clearance (backlash) between side

gears and pinions.
Problem : Constant noise in differential.

Probable Cause : Problem : Leakage of lubricant.

1. Lubricant not to the specific level. Probable Cause :

2. Wrong type of lubricant. 1. Loss through axle hub carrier

3. Wheel bearings out of adjustment or have a a. Lubricant above specification level.

defect.
b. Wrong kind of lubricant.
4. Drive gear and pinion not in adjustment for
correct tooth contact. c. Restriction of axle housing breather.

5. Teeth of drive gear and pinion have damage or 2. Loss at pinion shaft.
wear.
a. Lubricant above specification level.
6. Too much or too little pinion to gear backlash.
b. wrong kind of lubricant.
7. Loose or worn pinion bearings.
c. Restriction of axle housing breather.
8. Loose or worn side bearing.
d. Oil seal worn or not installed correctly.

e. Universal joint flange loose on the pinion shaft.

Power Train 27 Testing and Adjusting

Transmission Pressure

5 1 2 3 4

ICPS054S

(1) Forward low clutch pressure tap. (2) Forward high clutch pressure tap. (3) Reverse low clutch pressure tap
(4) Reverse high lutch pressure tap. (5) Main line pressure tap. (6) Converter pressure tap.

Transmission Pressure

Main Line Converter Forward Low Forward High Reverse Low Reverse High
Engine
Unit (Neutral) (Neutral) Clutch Clutch Clutch Clutch
RPM
Min Max Min Max Min Max Min Max Min Max Min Max

Idle psi 62 170 51 113 47 103 47 103 47 103 47 103

1300 psi 103 194 93 187 103 170 103 170 103 170 103 170

2500 psi 103 235 113 235 113 176 113 176 113 176 113 176

Idle KPa 426 1,175 355 780 324 709 324 709 324 709 324 709

1300 KPa 709 1,337 638 1,287 709 1,175 709 1,175 709 1,175 709 1,175

2500 KPa 709 1,621 780 1,621 780 1,216 780 1,216 780 1,216 780 1,216

Power Train 28 Testing and Adjusting

Converter Stall Test 2. Engage the wheel brakes and push the
accelerator pedal down completely. Read the
RPM on he tachometer, then release the
The converter stall test is a test to check engine accelerator pedal. Turn the speed control lever to
power. It can also be used to locate a problem in the LOW. Push the accelerator pedal down
transmission when the condition of the engine is completely and read the RPM again. Release the
known. An engine which does not have correct accelerator pedal.
performance will give an indication of a stall speed
that is not correct. If the engine performance is
correct, and the stall speed is not correct, the NOTICE
problem in the converter or transmission can be To make sure that the transmission oil does not get
found with this test. too hot, do not hold the transmission in a stall
condition for more than ten seconds. After the
NOTE : To check the engine performance, see transmission is stalled, put the controls in NEUTRAL
Service Manual for the DB58S Diesel Engines. and run the engine at 1200 to 1500 RPM to cool the
oil.
The test checks the maximum RPM that the engine,
at full throttle, can turn the converter with the turbine
held stationary. To hold the converter turbine, 3. Repeat the procedure above for both REVERSE
engage the brakes with the transmission in either speeds.
FORWARD or REVERSE and in HIGH speed.
4. The stall speed is in the chart below.
The drive wheels must not turn during the stall test.
Put a heavy load on the forks and put the truck in
Stall Speed
position against a solid object that will not
move(such as a loading dock). Engage the parking Without power With power
brake. When the tests are made, the wheel brakes Brakes applied Brakes applied
must be engaged with the left foot ; the accelerator DB58S Diesel 1,690 ± 70 1,590 ± 70
pedal can be operated with the right foot. Make sure
that the transmission oil is at the correct temperature G643(E) LP 1,640 ± 70 1,540 ± 70
for operation before tests are made.
Stall speeds that are low are an indication that the
Check the high idle setting before the stall test is
engine performance is not correct or the one-way
made. The high idle on the diesel engine is shown in
clutch of the torque converter does not hold in
the chart below.
reverse direction. If the one-way clutch has a defect,
the stall speed will probably be more than 800 RPM
High Idle Setting low.

Engine High Idle RPM The stall speed must be the same in all forward and
reverse speeds. If the stall speed is high in all
DB58S Diesel 2,600 ± 50 forward and reverse speeds, one or more of the
problems that follow can be present ; low oil level,
G643(E) LP 2,500 ± 50
air in the oil, a torque converter failure, or low oil
pressure to all clutches.

WARNING If the stall speed is high in both speeds in one

direction, check the clutch operation for that
Make tests in a clear, level area only. There must direction. If the stall speed is high in one speed only,
be one operator. Keep all other personnel away both forward and reverse, check the clutch operation
from the lift truck. Check to be sure the for that speed.
operation of the brakes is correct before the
tests are made.

1. Connect a tachometer to the engine. Start the

engine and move the control levers to the
FORWARD direction and HIGH speed.

Power Train 29 Testing and Adjusting

Shimming of Transmission Shaft 9. If you reshim input shaft or counter shaft, turn
transmission input shaft by hand. It should be
turned smoothly. If you reshim intermediate shaft
1. Assemble shaft assembly (including taper bearing or output shaft, turn output shaft by hand. It
cone and cup). should be turned smoothly.

2. Insert shaft assembly into transmission case. 10. If the input shaft or output shaft does not turn
smoothly, remove shims about 0.025 - 0.05 mm.

Wheel Brake Adjustment

Shoe Brake Axle

The brakes make an adjustment automatically when

an application is made in forward and reverse. With
each application, there will be an adjustment made,
until the lining-to-drum clearance is made small
enough to stop the movement of the automatic
adjuster.

3. Measure the dimension ‘X’ from surface of Brake setting is essential when:
transmission case to surface of bearing cup.
1. Enewing, removing or mounting the automatic
NOTE : Use depth gage and block gage because adjuster.
the height of bearing cup is higher than surface of
transmission case. 2. Mounting new brake shoes and brake drums at all
stages of repair.

3. Repair work on the brake, where by the basic

setting of the threaded bolts has been altered at
the automatic adjuster.

Setting work, as well as checking of the clearance

between the brake shoes and brake drum must be
carried out when the brake is cold. The driving and
parking brake must always be adjusted together.

4. Measure the dimension ‘Y’ from surface of

transmission cover to bottom of bore where
bearing cup is installed.

5. Calculate required shim thickness as following

formula. Required shim thickness ‘Z’= Y - X +
0.45 mm

6. Select shims to have (-0.04) to 0.11mm (-0.002)

to 0.004 in of axial clearance.

7. Assemble transmission case, cover and gasket. Brake Adjuster

(1) Adjusting Screws. (2) Adjusting Wheels.
8. Set up transmission assembly vertically.

Power Train 30 Testing and Adjusting

Setting Procedure

During setting, the parking brake must be released. CAUTION

The cable should not be tensioned. Correction of wheels which are not equally
difficult to turn may only be carried out at the
1. Jack up the vehicle brake cables and not at the automatic adjuster.
2. Release the brake cable
12. Lower the vehicle
3. Remove the brake drum
13. Carry out appr. 10 braking processes (not
4. Carefully raise the adjusting lever using a screw emergency braking) with a starting speed of
driver or similar tool through the opening in the around 10kph in forward/reverse travel,
brake plate to permit the adjusting wheel to turn observing the braking characteristics of the
freely. vehicle. The automatic adjuster is then ideally
set.
5. Adjust the brake diameter to meet “diameter = Ø
313 +0.2
+0 mm” by turning the adjusting wheel. This setting procedure must be carried out always at
all the brakes of the vehicle.
Remark:

During this setting work, take care to ensure an WARNING

even distance “b” of the adjusting screws (1) to the
After new adjustment of brake diameter, it will
relevant adjusting wheel (2).
take times until the lining-to-drum clearance is
made small enough to stop the movement of the
Remark:
automatic adjuster. So, Please keep enough
braking distance to avoid accident.
Precise adjustment of the relevant brake diameter is
of decisive importance for the function of the
automatic adjuster. An insufficiently high setting
could result in damage to the adjuster.

6. Adjust the brake cables in such a way that the

relevant brake diameter is not altered.

Remark:

The brake cables may not be pretensioned, as

otherwise it is not possible to guarantee perfect
function of the adjuster.

7. Mount the brake drum

8. Release hexagonal for fastening the automatic

adjuster.

9. Actuate the brake several times to centre the brake

shoes/ the adjuster in the brake drum.

10. Afterwards tighten hexagonal screw to a torque of

120±20 N•m (88.6±14.7 lb•ft)

11. Tighten the hands brake lever. The wheels should

be equally difficult to turn in this setting.

Power Train 31 Testing and Adjusting

Inching Pedal Adjustment WARNING
To prevent personal injury, when the inching
To check the inching valve adjustment and pedal is adjusted, move the truck to a clear area
operation, do the procedure that follows : that is level. Keep all other personnel away from
the lift truck. Use lifting equipment or a safe
method to lift the front of the lift truck until the
drive wheels are off the floor. Put wood blocks
When this procedure is used, the lift truck must or jack stands of the correct capacity under it to
be in an area clear of obstructions. There must hold it in this position while the inching pedal is
be one operator with all other personnel away adjusted.
from the lift truck. Check the operation of the
brakes before the test is made.
2. Raise the front of the lift truck off the floor. Put
wood blocks or jack stands of the correct capacity
1. With the engine at idle speed, put the under it while the inching pedal is adjusted.
transmission in FORWARD.

Inching Pedal Adjustment

(1) Lug. (2) Bolt. (3) Nut.
Inching Operation Test
(1) Inching pedal.
3. Start the engine and put the transmission
FORWARD.
2. Slowly push down on inching pedal (1) until the
movement of the brake pedal causes the brake 4. With the drive wheels turning, depress inching
discs (or, shoes) to make contact (small drag) with pedal until the drive wheels stop.
the brake plates (or, the brake drum).
5. Now depress the brake pedal until disc (or, shoe)
3. Increase the engine speed to high idle. The truck contact is felt.
must not move.
6. Loosen nut (3) and adjust bolt (2) to contact lug
(1) that rotates the brake control cross shaft.
If the operation of the inching valve is not correct, do Tighten nut (3).
the procedure that follows.
7. Check the inching valve operation again.

1. Adjust and bleed the brake system as shown in a. If something is wrong, inspect all points again
the Vehicle Systems module. one by one very carefully.

Power Train 32 Testing and Adjusting

The adjusting procedure is as follows. Be sure that
the air bleeding of brake system should be done in
advance.

< OCDB >

(B )
0
(10
)
2. Adjust the length (B) of rod by fixing the nuts at
both ends. (B) is about 100 mm.

< Shoe Brake >

(C)

1. Adjust the length (A). Be sure that 1mm of gap

between the piston and the rod should exist. In
case of no gap, it would result in brake drag or 3. Adjust the height (C) of inching pedal and brake
overheating of axle oil. In case of too loose, the pedal by using (2) bolts. (C) is about 140 mm at
performance of service brake become lowered. the same level.

4. Adjust the gap (D) for engaging brake pedal by

inching pedal.

(D)

Power Train 33 Testing and Adjusting

5. The stroke of inching spool when the brake pedal
is engaged should be 3 ± 1 mm.

6. Before doing the truck test, inspect again all

relevant dimensions.

7. Inspect the service brake and then, inching

operation.

Power Train 34 Testing and Adjusting

Disassembly and 6. Connect the other of the drive shaft (3) to the
transmission yoke (2) and, fasten with four bolts
Assembly (1).

NOTE : Tighten all bolts that fasten universal joints

Drive Shaft and Universal Joint to a torque of 60 ± 7 N•m (45 ± 5 lb•ft).

End By:
Remove Drive Shaft and Universal Joint
a. Install floor plate (front three sections).
Start By :

a. Remove floor plate (front three sections) Disassemble and Assemble Drive Shaft

Start By:

a. Remove drive shaft and universal joints.

1. Remove four bolts (1) that hold universal joint (3)

to the transmission end yoke.

2. Remove four bolts (2) that hold universal joint (3)

to the drive axle end yoke. And, remove drive 1. Loosen cap (1) and slid off of the yoke (3).
shaft (3) from the machine.
2. Pull yokes (2) and (3) apart from each other.

3. Remove eight bolts (4) from drive shaft (3) and

remove two universal joints. 3. Check all parts of the drive shaft for wear and
damage. Use new parts for replacement.
NOTE : The following steps are for installation of the
drive shaft and universal joints. NOTE : The following steps are for the assembly of
the drive shaft.
4. Put two universal joints in position on drive shaft
(3) and fasten with eight bolts (4),

5. Put drive shaft (3) in position on drive axle and

transmission yoke and, fasten with four bolts.

Power Train 35 Disassembly and Assembly

Engine, Torque Converter and
NOTICE
The flanges of the two yokes can be assembled out Transmission
of parallel. Wrong assembly of the universal joint will
cause very short joint life. Assemble the spline yoke Remove & Install Engine, Torque
into the slip yoke. Both flanges mush be parallel. Converter and Transmission

Start By:

a. Remove drive shaft and universal joints

b. Remove hood

c. Remove counter weight

d. Remove hydraulic pump drive shaft and universal

3
joints
1
2

ICPD335P

4. Make an alignment of yokes (2) and (3) so that

the flanges on the yokes are parallel.

5. Slide yokes (2) and (3) together.

6. Fasten cap (1) to yoke (3) of the drive shaft.

End By:

a. Install drive shaft and universal joints.

1. Remove seat and support assembly (1) and floor

plate (2),

2. Put identification on each of wires to solenoids (3)

and, disconnect the wire assemblies at
connectors.

3. Disconnect Hyd. Lines (4), (5), (6) & (7) on the

pump.

Power Train 36 Disassembly and Assembly

4. Disconnect two cooling lines (8).

5. Disconnect two cooling lines (9).

6. Remove two water cooling lines (10).

7. Remove engine harness assembly (11).

9. Loosen bolts (14) and nuts (18). Remove muffler

and exhaust tube assembly (15).

10. Remove radiator reservoir hose (19).

11. Remove radiator assembly (17).

8. Loosen two bolts (12) and remove air cleaner and

air intake hose assembly (13).

Power Train 37 Disassembly and Assembly

12. Remove bolts (20) and nuts from engine mounts.

NOTICE
Make sure the engine is supported underneath by
suitable wooden blocks. Failure to support engine
will result in possible damage.

13. Remove engine and transmission with a hoist.

14. Install the engine and transmission in the

reverse order of removal.

End By:

a. Install hydraulic pump drive shaft and universal

joints.

b. Install counter weight.

c. Install hood.

d. Install drive shaft and universal joints.

Power Train 38 Disassembly and Assembly

Separation of Torque Converter and Connection of Torque Converter and
Transmission from Engine Transmission to Engine

Start By:

a. Remove engine, torque converter and

transmission.

1. Put the transmission and torque converter (5) into

position and make a connection of the
transmission and torque converter.

2. Move torque converter plate (4) toward flywheel

1. Remove bolts (1) and plate (2) from flywheel until plate (4) makes contact with the flywheel and
housing. check if torque converter turns freely.

3. Install bolts (3) finger tight that hold plate (4) to

the flywheel.

4. Turn the flywheel in a counterclockwise direction

and tighten the bolts (3) to a torque of
........................................................ 19 ± 1 N•m
(14±1 lb•ft)

1
2. Remove six bolts (3) that hold plate (4) to the
flywheel.

3. Move plate (4) and torque converter away from

the flywheel.

4. Separate transmission and torque converter (5)

from the engine.
5. Put plate (2) in position and install bolts (1).

End By:

a. Install engine torque converter and transmission.

Power Train 39 Disassembly and Assembly

Transmission Control Valve

Disassembly of Transmission Control

Valve

3. Disassemble Accumulator Valve

a. Disassemble the Plug (11) fitted with filter, O-

Ring (13)(31), and Spring(9) from main body.

b. Disassemble Stopper (7) and O-Ring (8) from

main body.

1. Disassemble Solenoid Valve

a. Remove nut (C), remove Coil (B), and

disassemble Solenoid Valve body (A).

4. Disassemble Relief Valve

a. Disassemble Orifice (6), Plug (4), Spring (3),

O-Ring (5) and Spool (2), in the said order

2. Disassemble Inching Valve

a. Disassemble Plug (21) and O-Ring (5),(22)

from the main body.

b. Unscrew STOP Bolt (19), remove Pin (18).

c. Disassemble Spool (14), Springs (31),(15),(16)

and Plunger(17) from the main body.

5. Disassemble Body Sub

a. Disassemble Lug (26), O-Ring (27) and Plug

(23), O-Ring (24) from the main body.

Power Train 40 Disassembly and Assembly

Assembly of Transmission Control
Valve

1. Preparation for Assembling

a. Refer to the valve disassembling/assembling

procedure in advance.

b. Arrange the work area.

c. Prepare assembling tools.

d. Prepare necessary parts according to the

number of valves to be assembled. 3. Assemble Relief Valve

e. Wash the parts, put in separate boxes and a. Assemble SPOOL (2) and SPRING (3) in the
mark names and part numbers. said order

b. Assemble O-RING (5) with PLUG (4), and

WARNING assemble them with the main body (torque: 50
When handling the parts, take care not to be N•m)
injured by sharp edges of body and spool (all
the sharp edges must be removed). c. Apply Loctite # 603 to ORIFICE (6), and
assemble with the main body (check looseness.
Conduct caulking when necessary).
Fix the main body when assembling the parts.
Otherwise, your hands may be cut).

Take care that wash fluid does not enter eyes

when washing the parts. Keep the working area
clean to prevent foreign matter. Seals have to be
applied with grease or oil to prevent damage.

4. Assemble Accumulator Valve

a. Apply Loctite # 609 to Filter Assy (12), and

assemble it with Plug (11).

b. Assemble Stopper (7) with O-Ring (8), and

assemble them with the main body (torque : 68
N•m)

c. Assemble Spring (9) and Piston (11) with the

main body.
2. Assemble Body Sub
d. Assemble Plug (11) fitted with filter with O-Ring
a. Assemble Plug (23) with O-Ring (24), and (13) and O-Ring (31), and assemble them with
assemble them with the main body (3 points; the main body. (torque : 100 N•m)
torque : 27 N•m)

b. Assemble Plug (26) with O-Ring (27), and

assemble them with the 5 pressure detecting
points on the main body (torque : 10 N•m)

Power Train 41 Disassembly and Assembly

CAUTION
Be Sure that the SEAL is not twisted.

5. Assemble Inching Valve

a. Assemble Body with Spool (14), Spring (31),

Spring (15), and Spring (16) in the said order.
Insert Plunger and push it down, insert Pin (18)
and tighten with Stop Bolt (19). (Stop Bolt must
not project from the bottom surface).

b. Assemble Plug (21) with O-RING (5) and O-

RING (23), tighten with the main body (torque :
50 N•m)

6. Assemble Solenoid Valve

a. Assemble Body with Solenoid Valve body (A)

(at 4 points) (torque : 27 N•m)

b. Insert Coil (B) to the Solenoid Valve body (A),

which is assembled with the main body, tighten
with Nut (C) (torque : 6.8 N•m)

CAUTION
The voltage marking on the Coil has to face
outwards.

c. Insert SEAL (20) into Inching Plunger, and

assemble the SEAL with the main body using
assembling jig.

Power Train 42 Disassembly and Assembly

Transmission

Disassembly of Transmission

4. Isolate plug (20), O-ring, spring (21) and ball (22)

from cover.

5. Disassemble plug (18), O-ring, spring (17) and

spool (16).
1. Isolate torque converter from housing. Remove 6
bolts (3) from the torque converter, isolate plate(2) 6. Disassemble plug (15).
and flexible plate (1).

2. From the torque converter (4), unscrew 6 socket CAUTION

bolts (6), disassemble Gear P.T.O Input (5).
Bearing cup and seam(64) are inside the cover,
or on the shaft in the transmission case. Mark
the position on the transmission cover or on the
shaft in the transmission case.

3. From the housing (7), disassemble oil seal (10), 4

bolts (8), 4 bolts (9) and washer.

Power Train 43 Disassembly and Assembly

7. Unscrew 5 bolts (11) from the Stator Hub (12) 9. From the bearing plate (14), isolate 2 thrust
fixed on the Bearing Plate (14), and isolate them washers (31), needle bearing (32), and Gear-
from the plate. Use rubber hammer to protect P.T.O Idle (33).
Stator Hub from damage.

10. Disassemble 2 bolts (35), 9 bolts (36), and valve

gasket (34).

8. Isolate 4 socket bolts (26) from the bearing plate

(14), disassemble flange pump (25).

Isolate socket bolt (28) and 4 socket bolts (30) 11. Unscrew 8 bolts (37) and 5 socket bolts (38)
from the flange pump. Isolate charging pump (29) from transmission. Isolate valve plate (69) slowly
and gasket (27). Disassemble Gear-P.T.O Output
(23) and ball bearing, and isolate elbow (24).

Power Train 44 Disassembly and Assembly

12. Isolate plug (41) and O-ring. Disassemble spring 17. Disassemble 2 thrust washers (48) and gear
(39) and oil screen (40) from the case (49)

18. Disassemble needle bearing and washer from

front shaft of the high speed clutch face

13. Use plastic hammer when pushing-out the tube

(45) from transmission case.

14. From the T/M case, disassemble the backward 19. Using a screw driver, disassemble snap ring (50)
drive shaft assembly (42). from cylinder.

15. Disassemble input shaft assemble (44).

20. Disassemble pressure plate, 7 clutch discs (51),

8 clutch plates, and band plate (67) from the
16. Disassemble the bearing cone (47), for high cylinder.
speed backward, in front of the clutch assemble,
using gear puller.

Power Train 45 Disassembly and Assembly

21. Push down the retainer (53) with pressure. 26. Disassemble 2 thrust washers (59) and pin (57).
Isolate snap ring (52) with a screw driver.
Remove the tension force on the assembly 27. Push retainer (53) down with press and remove
slowly. snap ring (52). Slowly release the tension force
of spring assemble, and remove retainer and
22. Disassemble retainer (53) and spring assembly spring.
from cylinder.
28. Using compressed air, isolate piston (54), and
23. Disassemble piston (54) using compressed air. remove O-ring from the shaft.
Disassemble O-ring from shaft.
CAUTION
The disassembling procedure of the input shaft
assembly is the same as that of the counter
shaft assembly.

24. Isolate sealing from the low speed forward clutch

assembly. Remove bearing (56), thrust washer
(57), gear (58), needle bearing, and spacer.

29. First, remove intermediate gear (43) from the

transmission case.

25. Remove snap ring (50), then remove

compression plate, 7 clutch discs, 8 clutch plates,
and band plate from the cylinder.

Power Train 46 Disassembly and Assembly

CAUTION
When removing the spacer, take care not to tear
the O-ring in the spacer.

30. Remove bearing cone(71) and gear(72) from the

intermediate gear using puller. Remove the
bearing cone(73) on the opposite side in the
same manner.

CAUTION
33. Disassemble the bearing cup (62) from the
Be sure to mark the positions of each gear and transmission case.
bearing.

CAUTION
Mark the bearing for identification.

31. Remove the oil collector (75) and bolt (74) from
output shaft assemble (70).

34. Remove lip-shaped oil seal (63) from the gear.

32. Remove spacer (77) and bearing cone (76) from

the output shaft assembly.

Power Train 47 Disassembly and Assembly

Assembly of Transmission

7. Install spring assembly and retainer (53) in the

cylinder.
1. Wash all the parts clean. Apply transmission oil
on all the parts. 8. Place the shaft assembly on press. Press down
the retainer, and assemble snap ring (52) using a
2. Assemble oil seal (63) on the transmission case screw driver.
using jig.
9. Assemble pin (57) and 2 thrust washers (59) in
the counter shaft of the low speed backward
clutch.

10. Assemble needle bearing, spacer, needle

bearing, gear (58), thrust washer (59) and
bearing (56).

3. Assemble bearing cup (62) on relevant positions

on the transmission case.

11. Apply clean transmission oil on the clutch discs

and plates. Assemble the 7 discs and 8 plates in
following order.

a. First, install the clutch plate having toothed

surface on its outer diameter.

b. Then, assemble the clutch disc having toothed

surface on the inner diameter.

c. Repeat above procedures (1) and (2) to

complete the assembling of the clutch discs
and plates.

d. Assemble the bending plate (67) with the

bended part facing downwards.

Power Train 48 Disassembly and Assembly

12. Install the pressure plate at its place in the
cylinder.

13. Assemble the pressure plate at its place in the

cylinder, mount the snap ring (50) using a screw
driver.

14. Assemble 3 seal rings on the shaft.

CAUTION
Take care not to damage the seal ring in the
counter shaft.
17. Install the pressure plate in the cylinder.

18. Assemble the snap ring(50) which sets the

pressure plate in the cylinder, using a screw
driver.

19. Assemble thrust washer and needle bearing on

the counter shaft of the high speed clutch.

15. Refer clauses 5 through 8 for the opposite side

of the shaft assembly.

16. Apply clean transmission oil on the clutch plates

and discs. Assemble clutch disc plates in
following procedures.

a. First, assemble the plate having teeth on outer 20. Assemble gear (46), thrust washer (45). Adjust
diameter. bearing cone (44) using assembling jig.

b. Next, assemble the clutch disc having teeth on

inner diameter.
CAUTION
c. Repeat procedures (1) and (2) until all the
discs and plates are assembled. Do not exert excessive force when assembling
gears.
d. Assemble the bending plate (67) with its
bended part downward. Move the gear forward/backward in to the clutch
assembly, until the gear spline aligns with the
teeth of the disc.

Power Train 49 Disassembly and Assembly

21. Mount gear (72) on the intermediate gear. 23. Install tube (45) on the transmission case with
Assemble bearing cone (71) with press. plastic hammer.
Assemble the bearing cone (73) on the opposite
side in the same manner. 24. Assemble backward shaft and input power shaft
in the following procedures.
CAUTION 25. Install the backward driving shaft (42) carefully
Bearings and gear must be assembled at their at its due position of the transmission case.
due positions as marked during disassembling.
26. Set the transmission case at correct position,
install input power shaft assembly (44) carefully,
and turn the gear until the tooth face aligns with
the gear on other shaft assembly.

22. Assemble the spacer (77) and bearing cone (76)

with the output shaft assembly.

27. Assemble the oil collector and bolt at their due

CAUTION places, in order to install on the output shaft
assembly (70).
Take care not to tear O-ring in the spacer when
assembling the spacer.

Power Train 50 Disassembly and Assembly

28. Assemble the oil screen (40), spring (39), plug 31. For the bearing plate (14), assemble thrust 2
(41) and O-ring in the transmission case. washers (31), needle bearing (32), and Gear-
P.T.O Idle (33).

29. Apply Loctite #5172 on the gasket surface of the

case, and fix it. Assemble the valve plate (69)
with 11 bolts (37) and 5 socket bolts (38)

32. Assemble flange pump (25) with Gear-P.T.O

Output (23) and 2 ball bearings using jigs.
Assemble 4 bolts (26) with the bearing plate.
Assemble flange pump (25) with charging pump
30. Place gasket (34), assemble 2 bolts (36) and 9 (29) and gasket (27) with bolt (28) and 4 bolts
bolts (35) with the control valve. (30). Assemble elbow (24)

Power Train 51 Disassembly and Assembly

33. Assemble Stator Hub assembly (12), bush (13),
piston ring, and 6 bolts (11), and assemble them
with the bearing plate (14).

39. When using a new part, calculate the shim

thickness as follows.

34. Assemble plug (15) and O-ring on the Measuring method of shim on shaft
transmission cover. : Transmission cover depth – from transmission case
to bearing step rise on shaft assembly
35. Assemble valve (16), spring (17), plug (18) and Name Thickness of shims
O-ring in the transmission cover.
Input Shaft Y – X – 0.01
36. Assemble the plug (19). Counter Shaft Y – X – 0.05

37. In the transmission cover, assemble ball (22), Output Shaft Y – X – 0.05
spring(21), plug(20), and O-ring.
a. Assemble shaft assembly (including taper
38. Mount bearing cup and shim on the transmission bearing cone and cup)
cover.
b. Install shaft assembly on the transmission case.

CAUTION
CAUTION
The bearing cup and shim have to be installed at
Since depth gauge and block gauge are used, the
correct positions on the transmission cover, in
height of the bearing cup must be higher than the
order to be aligned with shaft in the
transmission case surface.
transmission case.

c. Select the shim of which thickness(0~0.05㎜)

fits with the shaft.

d. Assemble cover on the transmission case.

Power Train 52 Disassembly and Assembly

e. Set the transmission assembly vertically.

f. Check the shim adjustment on the input and

counter shafts. The input shaft of the
transmission must be able to rotate freely.

g. If the input or output shaft does not rotate freely,

remove 0.025~0.05㎜ shim.

CAUTION
Do not tilt the cover while assembling.
Otherwise, the seal ring on the input power shaft
may be damaged. 42. On the torque converter, assemble plate (2) and
flexible plate (1) with 6 bolts (3). Then, assemble
torque converter and housing.

40. With the housing (7), assemble oil seal (10), 4

bolts (8), 4 bolts (9) and washer.

41. Mount Gear P.T.O Input (5) on the torque

converter (4), assemble with 6 socket bolts (6).

Power Train 53 Disassembly and Assembly

Drive Axle

Disassembly

4. Loosen cylindrical bolts and remove planetary

carrier. Detach and remove O-ring from axle hub.

1. Drain oil after loosening drain plug with a torque

wrench (1)

5. Remove snap ring (5) from the housing of

planetary

2. Loosen and remove two cylindrical bolts from

brake drum. Loosen brake drum by beating
slightly with a plastic hammer onto the outer
diameter and remove it.

6. Remove 3 pins (6) with a plastic hammer.

3. Loosen oil filler plug on wheel hub and drain oil.

NOTE: Same step to be made at the other side !

Power Train 54 Disassembly and Assembly

7. Remove needle bearing (8), planetary gear (7) 10. After removing bolt (13), remove ring gear (14)
and thrust washer (9). and torque plate assembly from the axle tube.

8. Remove sun gear (10) and drive shaft (11). 11. Remove snap ring from the ring gear (14) and
disassemble internal gear carrier

9. Remove snap ring (12) and then, remove sun

gear (10) from the shaft (11).
12. Remove bearing cup from the wheel hub by
using jig and hammer. Shaft seal will be
damaged.

Power Train 55 Disassembly and Assembly

Removal and Strip Down of Brake Removal and Strip Down of Axle
Housing

1. Remove 2 tension springs with the aid of pliers or

a screwdriver 1. Loosen 12 bolts (1) and then, remove carrier from
the housing by using a lifting machine.

2. Squeeze, unhook and remove compression

springs. Remove spring. Unhook and remove the 2. For the reassembly, check rolling resistance and
two brake shoes. Then, unhook the brake cable at record it. After loosening 2 bolt (2), remove
the pressure rid of the brake shoes and remove it. backing plate (3).

3. Loosen 16 cylindrical bolts. Detach and remove 3. Before removing differential assembly from carrier
brake plate from axle flange. (4), check the location of cap (5) and mark it for
reassembly.
NOTE : Make the same steps on the second side of
the wheel hub if required! 4. Remove 4 hexagon bolts (6) and cap (5).

Power Train 56 Disassembly and Assembly

5. Disassemble bearing (7) from the differential 9. Remove thrust washer, side gear, pinion gear and
housing and remove 12 bolts (8). spider and then, place them on the clean bench.

6. Remove differential assembly from the carrier. 10. Loosen 4 bolts (10) and then, remove Drum from
the Parking Brake.
7. After removing 12 mounting bolts (9) from the
housing, disassemble ring gear.

11. After removing lock nut (11), remove yoke (12).

8. Check the mark on the housing and separate the 12. Loosen 4 bolts (13) and then, remove Parking
housing from the differential. If there is no mark, Brake (14) from the Carrier housing.
be sure to mark on the housing. When
reassembling, it must be placed at the same 13. Remove carefully drive bevel pinion shaft (15) by
position as before. using a plastic hammer.

Power Train 57 Disassembly and Assembly

CAUTION
Be careful not to damage bevel pinion shaft.

16. Remove outer race of taper roller bearing from

the opposite side.

Reassembly of Drive Axle

14. Remove shim (16) and spacer (17) from pinion Clean all of the parts with cleanser and then,
shaft. remove remained loctite.
Using a bearing puller, disassemble inner race of
taper roller bearing from the pinion shaft.
WARNING
Be careful not to spill cleanser on your body.
Avoid drinking cleanser or breathing its fumes.
Wear protective clothing, glasses and gloves.
If spilled on the skin, flush your skin with water
immediately.
If swallowed, get medical attention immediately.

• Check wear, damage or crack for all the parts and

replace if needed.

• If the teeth of gear are damaged, replace it as a

set.
15. Remove outer race of taper roller bearing and
shim from the housing by using a jig and hammer. • Replace damaged tapered roller bearing.

• Do not reuse deformed shims or worn thrust

washers.
CAUTION
Do not reuse damaged shims. • Rasp off the seal contacted surface.

Power Train 58 Disassembly and Assembly

Adjustment of Bevel Pinion Shaft

2. Using different kinds of shims, adjust shim

thickness as measured by previous equation.
Adjusting shim of bevel pinion shaft. Place shims at the bearing place. Using a jig,
assemble drive bearing so that the outer race
1. Adjust shim thickness and bevel pinion shaft with contact with the bearing place.
following method.

- Measure "E" at the housing.

- By the equation " X = E - B - T ± C " define the

shim thickness (1).

B : Mounting dimension of bevel pinion shaft,

131.10mm

T : Height of bearing.

C : Dimension of carved seal on the pinion.

If there's no carved seal C=0.
3. Heat inner race of bearing to max 100℃ and then,
Ex : From the housing, "E" = 162.85㎜, assemble it to the pinion shaft. Also inner race
should contact with bearing place.
B is factory dimension, "B" = 131.10㎜,
Front the bearing, "T" = 31.5㎜,
Carved seal on the pinion, "C" = 0.05㎜,

Shim thickness:

"X "= 162.85-131.10-31.5-0.05 = 0.20㎜.

CAUTION
If teeth are damaged, replace it as a set. (bevel
gear and shaft)
Do not reuse damaged shims and bearings.

Power Train 59 Disassembly and Assembly

Adjustment of Pinion Shaft

1. Assemble bearing cup. Assemble spacer to the

pinion shaft and then, install measured shims onto
the spacer.

Measure shim thickness by following method.

Dimension "Q" : Distance from bearing outer race

surface to spacer surface.

Dimension "S" : Distance from bearing outer race

surface to inner race surface.

From the below equation, define required shim

thickness "Z"............................................ Z = S + Q

EX) From the bearing, "S" = 2.25㎜

From the housing, "Q" = 3.15㎜
Needed shim thickness "Z", Z = 2.25 + 3.15
= 5.40 ㎜

(unit : mm)
S Q Z 2. Insert pinion shaft into the carrier. After
2.25 3.15 5.40 assembling bearing cone, Parking Brake and
2.30 3.15 5.45 Yoke, assemble lock nut.
2.35 3.15 5.50
Apply grease on the outer bearing. Apply loctite
2.40 3.15 5.55
#271 or #277 on the thread of pinion and then,
2.45 3.15 5.60
tighten lock nut.

• Tightening torque : ....................... 440~500N•m

(327~370 lb•ft)
Measure rolling resistance of pinion shaft.

• Rolling resistance :.............. 2~4 N•m (1~3 lb•ft)

Coke lock nut into the slot. of pinion shaft

Power Train 60 Disassembly and Assembly

Assembly of Differential
CAUTION
Check marks on the housing.
Match two marks at the same position.

1. Assemble thrust washer, side gear and spider

gear and then, install them to the differential
housing. Apply grease on the bevel gear and
thrust washer.

3. Tighten 12 bolts (1) to the differential housing.

Apply loctite #271 or #277 on the thread of bolt.

• Tightening torque : 49~74 N•m (36~54 lb•ft)

2. Assemble differential housing.

4. Assemble ring gear by tightening 12 bolts (2).

Apply loctite #271 or #277 on the thread of bolt.

• Tightening torque :122~142 N•m (91~105 lb•ft)

5. Install differential assembly onto the carrier. Place

the bearing cup and screw into the housing.

Power Train 61 Disassembly and Assembly

At this moment, by adjust rotation backlash. By Assembling Carrier
Install the dial gauge on the gear tooth and measure
the backlash while rotating bevel gear.

• Rotation backlash : 0.18~0.23 ㎜

6. Assemble bearing cap.

CAUTION
Fix bearing cap with hexagon bolt.

• Tightening torque : 147~167N•m(109~123 lb•ft)

Measure rolling resistance of tapered roller bearing. 1. Assemble carrier assembly into the axle housing.
The following table shows the relation between
preload (P) of bevel pinion shaft and rolling 2. Fix the carrier assembly with hexagon bolt (1).
resistance (Z). Apply loctite #271 or #277 to thread of bolt and
(calculated at ADJUSTMENT OF PINION SHAFT ) then, assemble at the tightening torque of
108~127N•m (80~94 lb•ft).
(unit : Kgf•cm)
P Z
20 44~47 Assembling Shoe Brake
25 49~52
30 55~58
35 59~62

7. Confirm that the screw contacts to bearing closely.

8. After completing assembly of bearing, measure

rotation backlash once more and readjust with a
screw if needed.

9. Apply loctite #271 to the thread of bearing cap

bolt and then, assemble at the tightening torque of
.............................. 147~167 N•m (109~123 lb•ft)

10. Assemble plate with hexagon bolts. Apply loctite 1. Apply Loctite #271 onto threads of the bolts (1).
#271 or #277 to the tapped side of bolt and Fasten brake plate and axle flange with cylindrical
then ,assemble at the tightening torque of .......... bolts (1) and lock washers to the axle housing.
...........................................9~12 N•m (6~9 lb•ft)
• Tightening torque……………200N•m (147 lb•ft)

CAUTION
Assemble oposite side with the same methods.

11. Apply marking liquid to 3~4 teeth of crown gear

and then bring bevel pinion gear contact with the
crown gear several times. Check out the
contacted shape.

Power Train 62 Disassembly and Assembly

2. Lead brake cable through the provided borehole 2. Install wheel hub assembly to the tube flange of
of the brake carrier and hook it on the pressure axle completely. Install bearing cone.
rod of the brake shoes. Assemble brake shoes,
compression springs and tension springs as
described in the Dosassembly Section in reverse
order.

Assembling Wheel Hub

3. Insert shim, fix the torque plate and ring gear with
snap ring and assemble them to the axle tube.

Apply loctite #271 or #277 to thread of bolt (2) and

then, assemble at the tightening torque of
147~167 N•m (109~123 lb•ft). Apply grease on
the bushing
1. Insert bearing into wheel hub. Confirm that the
bearing and wheel hub contact completely.

CAUTION

Apply grease or oil to shaft seal and then,

assemble it from the direction of outre side of
wheel hub.

4. Assemble sun gear (3) to axle shaft and fix it with

snap ring (3). Assemble axle shaft to the axle
assembly. Apply grease on the shaft where
bushing contcts. Apply grease to teeth parts of
planetary gear.

Power Train 63 Disassembly and Assembly

7. Assemble wheel hub and tighten plug (1).

• Tightening torque : 35~59 N•m (25~44 lb•ft)

5. Assemble internal components of planetary

carrier in the reverse order of disassembly.

8. Install brake drum and tighten the bolts.

Assembling Wheel Hub Ass’y (OCDB)

6. Install planetary carrier assembly to wheel hub

and tighten bolt.

• Tightening torque : 25~39 N•m (18~29 lb•ft)

1. Insert bearing into wheel hub. Confirm that the

bearing and wheel hub contact completely.

CAUTION
Apply grease or oil to shaft seal and then,
assemble it from the direction of outre side of
wheel hub.

Power Train 64 Disassembly and Assembly

2. Install wheel hub assembly to the tube flange of 5. Insert shim, fix the torque plate and ring gear with
axle completely. Install bearing cone. snap ring and assemble them to the axle tube.

Apply loctite #271 or #277 to thread of bolt (2) and

then, assemble at the tightening torque of
.................................. 147~167 N•m (109~123 lb•ft)
Apply grease on the bushing.

3. Insert flange into ring gear and secure it with

circlip.

6. Assemble square ring (6),(7) with oil (MOBIL

#424) to the Axle housing (1). Assemble bushing
(5) to piston (2) and then, assemble piston (2) to
axle housing after applying oil sufficiently and
4. Place heated tapered roller bearing inner race applying loctite # 271 to spring (4) and 4 bolts (3).
onto flange until contact. Install subsequently until
contact after cooling down. • Tightening torque : 14~16N•m (10~12 lb•ft)

Assemble 3 brake pins (8) to axle housing.

CAUTION
Check the status of square ring and replace if
damage.

Power Train 65 Disassembly and Assembly

Assembling OCD Brake

8. After assembling sun gear (9) to axle shaft, fix it

with snap ring (10). Assemble axle shaft to the
axle assembly.
Apply grease on the shaft where bushing contcts.
Apply grease to teeth parts of planetary gear.

7. Assemble Brake plate and disc.

a. Assemble 5 plates(1) and 4 disks (2) with spline

collar (3) and then, lock with snap ring (4).

b. Assemble spline collar joined with plates and

disks, and drive shaft (5) to axle housing (6).

- Before assembling, clean all of the parts

completely and remove burrs.

c. After assembling plate and disk, confirm that 9. Assemble internal components of planetary
the tolerance with axle housing surface is carrier in the reverse order of disassembly.
1.3~2.7mm

d. Apply loctite #5127 on spindle side of alxe

housing (6).

Power Train 66 Disassembly and Assembly

10. Install planetary carrier assembly to wheel hub
and tighten bolt

＊Tightening torque : 25~39 N•m (18~29 lb•ft)

11. Assemble wheel hub and tighten plug (1).

• Tightening torque : 35~59 N•m (25~44 lb•ft)

Power Train 67 Disassembly and Assembly

SB4121E01

Systems Operation
Description of
Fault Codes
Lift Trucks
Three Speed Power Shift
Transmission
3WG 116/161
Important Safety Information

Read and understand all safety precautions and warnings before operating or performing lubrication,
maintenance and repair on this product.

Basic safety precautions are listed in the “Safety” section of the Service or Technical Manual. Additional
safety precautions are listed in the: Safety” section of the owner/operation/maintenance publication. Specific
safety warnings for all these publications are provided in the description of operations where hazards exist.
WARNING labels have also been put on the product to provide instructions and to identify specific hazards.
If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons.
Warnings in this publication and on the product labels are identified by the following symbol.

WARNING

Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.

1
Index

IMPORTANT INSTRUCTIONS................................4 Gearbox Diagram............................................ 25

Table – 6 ......................................................... 25
Power flow Forward speed ............................. 26
Systems Operation Table – 7 ......................................................... 26
Power flow Reverse speed ............................. 27
Function of the Converter .....................................5 Table – 8 ......................................................... 27
Function of a hydrodynamic Torque converter Electro – Hydraulic control with proportional
(Schematic view) ...............................................5 valves.............................................................. 28
Powershift transmission.....................................6 Table - 9.......................................................... 28
Transmission control .........................................6 Fully – Automatic control EST - 37A ............... 29
Controller DW-3.................................................7 Circuit diagram standard................................. 29
Display...............................................................7 Table - 10........................................................ 29
Possible Indications on the Display................7 Controller DW – 3 ........................................... 31
Error code definition .....................................10 Table – 11 ....................................................... 31
Electronic Control unit TCU .............................10
Electronic Controls for Powershift transmissions Description of Fault Codes
.........................................................................11
Description of the Basic functions ................11
Independent calibration of the Shifting elements Introduction ........................................................ 32
(AEB)............................................................12 Abbreviations .................................................. 32
Inching device ..............................................13 Display ............................................................ 32
OPERATION.......................................................14 Display during operation ................................. 33
Driving preparation and Maintenance..............14 Display during AEB-Mode............................... 34
Driving and Shifting .........................................14 Display during Inchpedal Calibration .............. 35
Cold start .........................................................15 Definition of operating modes ............................ 36
Transmission control in the Driving mode NORMAL......................................................... 36
Automatic.........................................................15 SUBSTITUTE CLUTCH CONTROL ............... 36
Stopping and Parking ......................................15 LIMP-HOME.................................................... 36
Towing .............................................................15 TRANSMISSION-SHUTDOWN ...................... 36
Oil temperature................................................15 TCU-SHUTDOWN .......................................... 36
AEB STARTER................................................16 Table of fault codes......................................... 37
- Introduction ................................................16 Measuring of resistance at actuator/sensors and
- List of abbreviations ...................................16 cable................................................................... 55
- Procedure to start AEB ..............................16 actuator ........................................................... 55
- Display during AEB-Mode ..........................17 cable ............................................................... 55
- Procedure to start ISK................................18
- Display during ISK mode............................18
Layout..............................................................19
Table - 1 ..........................................................19
Installation Front view......................................20
Table - 2 ..........................................................20
Installation Rear view ......................................21
Table - 3 ..........................................................21
Schedule of measuring points and
connections .....................................................22
Table – 4..........................................................22
Oil circuit diagram............................................24
Forward 1st Speed ..........................................24
Table – 5..........................................................24

Power Shift Transmission 3 Index

IMPORTANT INSTRUCTIONS

Oil level check:

In the cold start phase, the engine must be running about 2 – 3 minutes at idling speed and the marking on
the oil dipstick must then be lying above the cold start mark.
The oil level check in the transmission must be carried out at engine idling speed and operating
temperature of the transmission (80° to 90° C).

At stationary engine, the oil level in the transmission is rising essentially, according to the installation
conditions !

At every oil change, the Fine filter must be exchanged. In addition, it is recommended to start the
autonomous calibration of the shifting elements (AEB).

The independent calibration of the shifting elements (AEB) must be started after the initial installation of
the transmission and the Electronics in the vehicle at the Vehicle Manufacturer and after every
replacement of the transmission, the electrohydraulic control or the TCU in case of a failure.
After every AEB-start the ISK (Inch-Sensor-Calibration) should be started for vehicles with inching device.

Put the Controller at the starting of the engine always to the Neutral position.
At running engine and transmission in Neutral, the parking brake must be engaged or the service brake be
actuated, to prevent the vehicle from rolling.

Prior to every start off, loosen the parking brake.

The engagement of the speed out of Neutral is only possible under the programmed transmission input
speed (turbine speed).
Neutral position of the selector switch at higher vehicle speeds (above stepping speed) is not admissible.
Either a suitable gear is to be shifted immediately, or the vehicle must be stopped at once.

At stopped engine, there is on the Controller, despite a preselected gear, no power flow between
transmission and engine, i.e. the transmission is in the idling position.
The parking brake must therefore be completely actuated !
When leaving the vehicle, secure it additionally by brake blocks !

The towing speed must in no case be higher than 10 km/h, the towing distance not longer than 10 km.
It is imperative to observe this Specification because otherwise the transmission will be damaged due to
insufficient oil supply !
At a longer distance, the best solution would be to transport the defective vehicle with a Low loader.

Operating temperature behind the converter at least 65° and 100° C in continuous operation, a short-time
increase up to max. 120° C is permitted.

Temperature in the sump 60° - 90° C.

By overstepping results by 105 ° C notice "WS" on the display.

In case of irregularities on the transmission, put the vehicle out of service and ask for Specialists.

Protective measures for the Electronics at electrical operations on the vehicle:

At the following operations, the ignition must be switched off and the control unit plug must be pulled off
from the Electronics:

• At any kind of electrical operations on the vehicle.

• At welding operations on the vehicle.
• At insulation tests on the electric system.

Power Shift Transmission 4 Systems Operation

Systems Operation
Function of the Converter
Function of a hydrodynamic Torque converter (Schematic view)

Pump wheel Turbine TP = Torque pump wheel

wheel
TT = Torque turbine wheel

TR = Torque reaction member

TT
(Reaction wheel)

From
engine
TP

To
gearbox

Condition at the NT = 0
time of starting 1 1,5 TR 2,5 Vehicle standing still
Reaction element
(Reaction wheel)
Intermediate <n
1 <1,5 <2,5 n T = Mot
condition

Condition in the 0.8n

1 0 1 nT = Mot
coupling point

The converter is working according to the Trilok- Pressure oil from the transmission pump is constantly
System, i.e. it assumes at high turbine speed the streaming through the converter. In this way, the
characteristics, and with it the favourable efficiency of converter can fulfill its task to multiply the torque of
a fluid clutch. the engine and at the same time, the heat created in
The converter is designed according to the engine the converter is dissipated via the escaping oil.
power so that the most favourable operating The oil which is streaming out of the impeller, enters
conditions are obtained for each installation case. the turbine wheel and is there reversed in the
direction of flow.
The Torque converter is composed of 3 main According to the rate of reversion, the turbine wheel
components: and with it also the output shaft is receiving a more or
Impeller – Turbine wheel – Stator (Reaction less high reaction torque.
member) The stator (reaction member), following the turbine,
has the task to reverse the oil streaming out of the
These 3 impellers are arranged in such a ring-shaped turbine once more and to deliver it under the suitable
system that the fluid is streaming through the circuit discharge direction to the impeller.
components in the indicated order.

Power Shift Transmission 5 Systems Operation

Due to the reversion, the stator is receiving a reaction The transmission pump, necessary for the oil supply
torque. of the converter, and for the transmission control, is
The relation turbine torque/pump torque is called sitting in the transmission on the engine-dependent
torque multiplication. This is the higher, the greater input shaft.
the speed difference of impeller and turbine wheel will
be. The feed rate of the pump is
Q = 85 l /min, with nMotor = 2000 min-1 3 WG-116
Therefore, the maximum torque multiplication is Q = 105 l /min, with nMotor = 2000 min-1 3 WG-161
created at stationary turbine wheel. This pump is sucking the oil via the coarse filter out of
With increasing output speed, the torque the oil sump and delivers it via the Fine filter to the
multiplication is decreasing. The adaption of the main pressure valve.
output speed to a certain required output torque will
be infinitely variable and automatically achieved by If because of contamination, resp. damage, the
the torque converter. through-flow through the Fine filter is not ensured, the
oil will be directly conducted via a filter differential
When the turbine speed is reaching about 80% of the pressure valve (bypass valve Δp= 5.5+3 bar) to the
pump speed, the torque multiplication becomes 1.0 lubrication.
i.e. the turbine torque becomes equal to that of the
pump torque. In this case, an error indication is shown on the
From this point on, the converter is working similar to Display.
a fluid clutch.
The five clutches of the transmission are selected via
A stator freewheel serves to improve the efficiency in the 6 proportional valves P1 to P6 (P1 will not be
the upper driving range, in the torque multiplication under current i.e. without function !!).
range it is backing-up the torque upon the housing, The proportional valve (pressure regulator unit) is
and is released in the clutch range. composed of pressure regulator (e.g. Y6), follow-on
In this way, the stator can rotate freely. slide and vibration damper.

The control pressure of 9 bar for the actuation of the

Powershift transmission follow-on slides is created by the pressure reducing
valve. The pressure oil (16+2 bar) is directed via the
The multi-speed reversing transmission in follow-on slide to the respective clutch.
countershaft design is power shiftable by hydrauli-
cally actuated multi-disk clutches. Due to the direct proportional selection with
separated pressure modulation for each clutch, the
All gears are constantly meshing and carried on pressures to the clutches, which are engaged in the
antifriction bearings. gear change, will be controlled. In this way, a
The gear wheels, bearings and clutches are cooled hydraulic intersection of the clutches to be engaged
and lubricated with oil. and disengaged becomes possible.
The transmission is equipped with 5 multi-disk This is creating spontaneous shiftings without traction
clutches. force interruption.
At the shifting, the actual plate pack is compressed by
a piston, movable in axial direction, which is At the shifting, the following criteria will be
pressurized by pressure oil. considered:
- Speed of engine, turbine, central gear train and
A compression spring takes over the pushing back of output.
the piston, thus the release of the plate pack. As to - Transmission temperature.
the layout of the transmission as well as the - Shifting mode (up-, down-, reverse shifting and
specifications of the closed clutches in the single
speed engagement out of Neutral).
speeds, see Table-1, 4 and 5.
- Load condition (full and part load, traction, overrun
inclusive consideration of load cycles during the
Transmission control shifting).

Transmission control, see Schedule of measuring The main pressure valve is limiting the max. control
points, Oil circuit diagram to Electro- hydraulic control pressure to 16+2.5 bar and releases the main stream
unit, see Table- 4.5 and 10. to the converter and lubricating circuit.

Power Shift Transmission 6 Systems Operation

In the inlet to the converter, a converter safety valve Display
is installed which protects the converter from high
internal pressures (opening pressure 11+2 bar). Possible Indications on the Display
Within the converter, the oil serves to transmit the
power according to the well-known hydro-dynamic
principle (see Chapter “Function of the Converter). Display
To avoid cavitation, the converter must be always
Left Central Right
completely filled with oil. h f ed Side Side Side
This is achieved by a converter pressure back-up
valve, rear-mounted to the converter, with an opening
pressure of at least 4.3+3 bar.
The oil, escaping out of the converter, is directed to a
heat exchanger.

From the heat exchanger, the oil is directed to the

transmission and there to the lubricating oil circuit,
so that all lubricating points are supplied with cooled
oil. a bc g
In the Electrohydraulic control unit are 6 pressure
regulators installed – see Table-9.
Spec. charact. Display
The allocation of the pressure regulators to the single
Automatic range
speeds can be seen on the Tables 4 and 5. a, f
(up- and downshifting)
b, c, d, e Preselected gear
EST-37A has recognized an
Controller DW-3 g
error, is flashing
Disturbance in AEB mode /
- see Table-11 h
Calibration ISK
For the moment still without
The Controller is designed for the mounting on the Left Side
function
steering column left side. By a rotative motion, the
On the two alphanumeric 16-
positions (speeds) 1 to 3 are selected and by tilting
segment displays, the EST-
the lever, the driving direction (Forward (F) – Neutral
37A issues the actual state
(N ) – Reverse (R). Central and Right
of gear and driving direction.
Side
Besides, a two-digit error
For the protection from unintended start off, a Neutral
code will be indicated via
interlock is installed:
these two segments.
Position “N” – Controller lever blocked in this position
Position “D” – Driving

Controller DW-3

Gear positions Type plate

N N N D

Power Shift Transmission 7 Systems Operation

Display of the Driving direction: V: Forward
(Right Side) N: Neutral
R: Reverse

Display of the engaged gear: Display 1, 2, 3

(Central Side)

Waiting for Controller-Neutral: Indication on the Display: NN (Central and Right Side).
In this condition, Neutral is pending on transmission.
To engage a gear, at first Neutral must be shifted on the Controller
before the electronics allows to engage a gear again.

Preselected Driving range: The number of the lines indicates the driving range, resp. the gear
(Special characters b, c, d, e) preselection:
1 Bar: Manual Mode 1 speed
2 Bars: Manual Mode 2 speed
3 Bars: Manual Mode 3 speed

Display Manual/ Automatic: If the two Symbols a , f (Arrows) and the bars b, c, d, e are indicated,
(Special characters a, f) the system is in the Automatic mode (automatic up- and
downshiftings).

Display of the Cold-start phase: Transmission remains in Neutral

Bars are flashing: Downshifting mode active

Error display: If the system is recognizing an error, the spanner (Special symbol “g”)
is flashing.
If Neutral is preselected on the Controller, a two-digit error number
appears on the two alphanumeric indicating positions (Central and
Right Side).

If more than one error is pending, the different error numbers will be
indicated one after the other on the Display in cycles (about 1 second).

) The error code will be only then indicated if the

Controller is in Neutral !

Warning display: At exceeding the warning threshold Temperature – Sump / behind the
Converter and the warning threshold Speed – Engine, changes the
indication on the Display to the actual gear and the corresponding
warning indicator.

) If several warnings are simultaneously active, only the

warning with the highest priority will be indicated.

Warning
Warning Priority
code
WT Temperature behind Converter 1
WS Temperature in the Sump 2
WE Engine speed 3

Power Shift Transmission 8 Systems Operation

Display PN Driving direction F or R selected while the parking brake is actuated.
Transmission in Neutral until parking brake will be released.
After the release of the parking brake, the vehicle begins to
roll.

F or R flashing Driving direction F or R selected, while the turbine speed is too high.
) Speed will be engaged when the turbine speed is
decreasing.

Display EE Indication on Display: EE (Central and Right side).

In this state, the Display has a timeout, i. e. it is receiving no Data from
the EST-37A.

Main reasons:
- EST-37A is in TOTAL RESETTING MODE
(e.g. because of output train disconnection or external power supply
at the lines to the gear-solenoid valves).
- EST-37A without supply
Data line not correctly connected, etc.

Power Shift Transmission 9 Systems Operation

Error code definition Electronic Control unit TCU
The error codes are composed of two hexadecimal The electrohydraulic transmission control can be
numbers: automated by connection on the electronic TCU.
The first number indicates the kind of signal, the The basic functions of the automatic system are the
second number the signal and the kind of error. automatic shifting of speeds, adaption of the optimum
shifting points as well as comprehensive safety
First Number Meaning of the Number functions in relation to operating errors and
1 hex Digital input signal overloadings of the power-transmitting components
2 hex Analog input signal with a comprehensive fault storage.
3 hex Speed signal
4 hex CAN signal error
5 hex CAN signal error
6 hex CAN signal error
7 hex Analog current output signal
8 hex Analog current output signal
9 hex Digital output signal
A hex Digital output signal
B hex Transmission error, Clutch error
C hex Logical error
D hex Power supply
E hex Highspeed signal
F hex General error

Power Shift Transmission 10 Systems Operation

Electronic Controls for Powershift transmissions

Description of the Basic functions

The Powershift transmission of 3 WG-116/161 is equipped with the Electronic control unit EST-37A, developped
for it.

The system is processing the desire of the driver according to the following criteria:

* Gear determination depending on controller position, driving speed and load condition.
* Protection from operating error as far as necessary, is possible via electronic protection (programming).
* Protection from over-speeds (on the base of engine and turbine speed).
* Change-over possibility for Auto- / Manual mode.
* Electronic inching

7
14 10
5
4

8
1
13 12

2
3

11
15

(1) Display (2) Controller DW-3 (3) Power supply connection (4) Switch for enable inching
(5) Automatic Transmission Switch (6) TCU (7) Wiring
(8) Cable to Inductive transmitter Speed Central gear train (9) Cable to Inductive Speed Engine
(10) Cable to Inductive transmitter Speed Turbine
(11) Cable to Temperature measuring point behind the Converter “No. 63”
(12) Cable to Plug connection on the electrohydraulic Control unit
(13) Cable to filter contamination switch (14) Cable to Speed sensor Output
(15) Cable from angle sensor/inch-sensor

Power Shift Transmission 11 Systems Operation

Independent calibration of the Shifting elements (AEB)

The AEB has the task to compensate tolerances (plate clearance and pressure level) which are influencing the
filling procedure of the clutches. For each clutch, the correct filling parameters are determined in one test cycle for:

• Period of the quick-filling time

• Level of the filling compensating pressure

The filling parameters are stored, together with the AEB-Program and the driving program in the transmission
electronics. Because the Electronics will be separately supplied, the AEB-Cycle must be started after the
installation of both components in the vehicle, thus ensuring the correct mating (Transmission and
Electronics).

It is imperative, to respect the following Test conditions:

- Shifting position Neutral
- Engine in idling speed
- Parking brake actuated
- Transmission in operating temperature

) After a replacement of the transmission, the electrohydraulic control or the TCU in the vehicle, the
AEB-Cycle must be as well carried out again.

The AEB-Cycle continues for about 3 to 4 minutes.

The determined filling parameters are stored in the EEProm of the Electronics.
In this way, the error message F6 shown on the Display
will be cancelled also at non-performed AEB.

) Start of the AEB by AEB starter(A138759)

which is connected on the diagnostic port
of the wiring.

) At the operating of the transmission, the paper friction linings, installed in the transmissions are
settling, i.e. the plate clearance becomes creater.
Because these settling appearances can affect the shifting quality, it is recommended to repeat the
AEB-Cycle at the Maintenance intervals.

) At a deterioration of the shifting quality, it is recommended likewise as first measure to repeat the
AEB-Cycle.

) ISK (Inch-Sensor-Calibration) should also be carried out after every AEB-Start.

Power Shift Transmission 12 Systems Operation

Inching device

It allows to reduce the driving speed infinitely variable without modification of the engine speed in such a way that
driving with a very low speed will be possible. In this way, the driver can move the vehicle very exactly to a
determined position.
At the same time, an important part of the engine power for the output of the hydraulic system is at disposal by the
high engine speed.

Operation is carried out by a separate inching pedal, where an angle of rotation sensor is mounted.
By means of the proportional valve technology the TCU regulates the pressure in the driving direction clutch in
such a way that the driving speed is adjusted in accordance with the inch rotating angle sensor position. Clutch
overloading is avoided thanks to the electronic protection.

) After each new adjustment of the inch linkage , the ISK (Inch Sensor Calibration) must be carried out.

During the inch calibration modus the position of the inch pedal in neutral position and with full
actuation is controlled by the calibration process and stored in the TCU.

) The inching function is only active after successful completion of AEB and ISK start.

Power Shift Transmission 13 Systems Operation

OPERATION
Driving preparation and Maintenance
Prior to the commissioning of the transmission, take care that the recommended oil grade will be filled in with the
correct quantity. At the initial filling of the transmission has to be considered that the oil cooler, the pressure filter
as well as the pipes must get filled with oil.
According to these cavities, the quantity of oil to be filled in, is greater than at the later oil fillings in the course of
the usual Maintenance service.

) Because the converter and also the heat exchanger, installed in the vehicle, as well as the pipes can
empty at standstill into the transmission, the

Oil level check must be carried out at engine idling speed and operating
Temperature of the transmission.

Driving and Shifting

- Neutral position:
Neutral position will be selected via the Controller.
After the ignition is switched on, the electronics remains in the waiting state. By the position NEUTRAL of the
Controller, the EST-37A becomes ready for operation.
Now, a gear can be engaged.
- Starting:
The starting of the engine has always to be carried out in the NEUTRAL POSITION of the Controller.
For safety reasons it is to recommend to brake the vehicle securely in position with the parking brake prior to
start the engine.
After the starting of the engine and the preselection of the driving direction and the gear, the vehicle can be set in
motion by acceleration.

At the start off, the converter takes over the function of a master clutch.
On a level road it is possible to start off also in higher gears.
- Upshifting under load.
Upshifting under load will be then realized if the vehicle can continue to accelerate by it.
- Downshifting under load.
Downshifting under load will be then realized if more traction force is needed.
- Upshifting in overrunning condition.
In the overrunning mode, the upshifting will be suppressed by accelerator pedal idling position, if the speed of the
vehicle on a downgrade should not be further increased.
- Downshifting in overrunning condition.
Downshifting in overrunning mode will be then carried out if the vehicle should be retarded.

If the vehicle will be stopped and is standing with running engine and engaged transmission, the engine cannot be
stalled. On a level and horizontal roadway it is possible that the vehicle begins to crawl, because the engine is
creating at idling speed a slight drag torque via the converter.
It is convenient to brake the vehicle at every stop securely in position with the parking brake.
At longer stops, the Controller has to be shifted to the NEUTRAL POSITION.

At the start off, the parking brake has to be released. We know from experience that at a converter transmission it
might not immediately be noted to have forgotten this quite normal operating step because a converter, due to its
high ratio, can easily overcome the braking torque of the parking brake.
Temperature increases in the converter oil as well as overheated brakes will be the consequences to be find out
later.
Neutral position of the selector switch at higher vehicle speeds (above stepping speed) is not admissible.
Either a suitable gear is to be shifted immediately, or the vehicle must be stopped at once.

Power Shift Transmission 14 Systems Operation

Cold start
At an oil temperature in the shifting circuit < -12° C, the transmission must be warmed-up for some minutes.
This must be carried out in Neutral with an increased engine speed (about 1500 min-1).
Until this oil temperature is reached, the Electronics remains in Neutral, and the symbol of the cold start phase will
be indicated on the Display.

Indication on the Display :

After the indication on the Display is extinguished, the full driving programm can be utilized out of NEUTRAL.

Transmission control in the Driving mode Automatic

A manual intervention into the automatic shift sequence is only then practical if the roadway condition or the
configuration of the ground is suitable.

Stopping and Parking

Since due to the converter there is no rigid connection existing from the engine to the axle, it is recommended to
secure the vehicle on upgrades, resp. downgrades against unintended rolling not only by applying the parking
brake but additionally by a block on the wheel, if the driver has the intention to leave the vehicle.

Towing
See Important Instructions – Page 5.

Oil temperature
The oil temperature in the transmission sump is monitored by a temperature sensor in the electrohydraulic control
unit.

The service temperature in the sump of 60° - 90°C must not be exceeded!

) By overstepping results by 105 °C notice "WS" on the display.

At a trouble-free unit and an adequate driving mode, a higher temperature will not occour. The notice "WS"
results at the display, the vehicle has to be stopped and controlled for external oil loss and the engine must run
with a speed of 1200 – 1500 min-1 at NEUTRAL POSITION of the transmission.
Now, the temperature must drop quickly (in about 2 – 3 minutes) to normal values. If this is not the case, there is a
trouble pending, which must be eliminated prior to continue working.
The monitoring of the oil temperature is additionally realized behind the converter with an indication on the Display.

Operating temperature behind the converter at least 65°C and 100°C in continuous operation, a short-time
increase up to max. 120°C is permitted.

The temperature is measured on the measuring point “63”

(see Schedule of measuring points – Table-4 !)

Power Shift Transmission 15 Systems Operation

AEB STARTER
- Introduction

The AEB-Starter is s tool to start the AEB and ISK of ergopower

transmissions. AEB Storter
It's useful to work with the Transmission Display because Stort
all messages about the AEB state is shown in the Display.
The AEB-Starter itself doesn't show any informations.

The AEB-Starter works with the diagnostic plug of

TCU which is in the engine hood.
TCU
To insure the highest level of shift quality, Diagnostic plug

AEB must be carried out under following conditions :

- After every replacement of the transmission,
TCU or the electrohydraulic control valve
TCU

ISK must be carried out under following conditions :

-After TCU or inching sensor is replaced. 3WG161 3WG161
-After each new adjustment of the inching linkage
<D50/60/70S-2> <D100/120/150>
AEB and ISK can be carried out independantly each other.
AEB is started by pressing the button of AEB starter with
the engine ignition swith turned at 'Start' position.
ISK is started by pressing the button of AEB starter
with the engine ignition swich turned at 'On' position.

NOTE : The errot code "F6" will be shown in the display TCU
as long as the AEB or ISK is not done. After the
replacement of TCU, the inching fuction is only active
after successful completion of AEB and ISK start.
<D110/130/160S-5>
- List of abbreviations

AEB : Automatic Filling Parameter Adjustment ISK : Inching Sensor Calibration TCU : Transmission Control Unit

- Procedure to start AEB

Step to do Disply message Remarks

Set the transmission oil temperature
1 Warm up transmission Normal operating messages
around 85℃
Turn off the engine ignition
2
switch
3 Plug in AEB-Starter
Rotate shift lever to "N"
4
position. Engage parking brake.
Turn the engine ignition switch
5 Nothing
to 'Start' Position
TCU must recognize PL for at least
6 Start engine 'PL'
2s before you can press the button
Keep to press for 2-3 seconds until
7 Press button of the AEB-Starter 'ST' if start conditions are ok
TCU has started the AEB
'K1'(Information about the When TCU has started the AEB, K1
8 AEB has started
AEB state) displayed for a short time
Press the accelerator pedal
slightly and maintain the engine 'KR'→'KV'→'K1'→'K2'→'K3'
9 AEB on progress automatically
rpm at the range of 900~1200 with bars flashing
rpm
10 Wait until AEB has finished 'OK' (AEB completed)
Turn off the ignition switch and
11 Nothing
unplug the AEB-Starter

Power Shift Transmission 16 Systems Operation

- Display during AEB-Mode

Symbol Meaning Remarks

AEB-Starter is plugged at the diagnostic
PL
plug
ST AEB-Starter-button is pressed
K1.. K3, KV, KR Calibrating clutch K1.. K3, KV, KR
Wait for start, initialization of clutch Kx,
_and Kx
x : 1,2,3,V,R
≡and Kx Fast fill time determination of clutch Kx
Compensating pressure determination of
=and Kx
clutch Kx
Transmission stays in neutral, you have to
OK Calibration for all clutches finished restart the TCU (ignition switch start off/on)
after removing AEB-Starter
Transmission stays in neutral, you have to
STOP AEB canceled(activation stopped)
restart the TCU(ignition switch start off/on)
Transmission stays in neutral, you have to
STOP and Kx AEB stopped, clutch Kx can't be calibrated
restart the TCU(ignition switch start off/on)
Transmission stays in neutral, you have to
Spanner and Kx Kx couldn't be calibrated, AEB finished
restart the TCU(ignition switch start off/on)
Engine speed too low,
△E
→ raise engine speed
Engine speed too high,
▽E
→ lower engine speed
Transmission oil temperature too low,
△T
→ heat up transmission
Transmission oil temperature too high,
▽T
→ cool down transmission
Transmission temperature not in defined Transmission stays in neutral, you have to
FT
range during calibration restart the TCU(ignition switch start off/on)
Operating mode not NORMAL or
transmission temperature sensor defective Transmission stays in neutral, you have to
FB
or storing of calibrated values to EEPROM- restart the TCU(ignition switch start off/on)
has failed.
Transmission stays in neutral, you have to
FO Outputspeed_not_zero
restart the TCU(ignition switch start off/on)
Transmission stays in neutral, you have to
FN Shift lever not in Neutral position
restart the TCU(ignition switch start off/on)
Transmission stays in neutral, you have to
FP Parking brake_not_applied
restart the TCU(ignition switch start off/on)
AEB-Starter was used incorrect or is
Transmission stays in neutral, you have to
STOP defective. Wrong device or wrong cable
restart the TCU(ignition switch start off/on)
used.

To prevent the transmission oil temperature from falling down during AEB calibration, keep the transmission
oil temperature about 85°C before starting AEB.
(Temperature Range : 70°C ~90°C)

Power Shift Transmission 17 Systems Operation

- Procedure to start ISK
Step to do Display message Remarks
1 Turn off the engine ignition switch Nothing
2 Plug in AEB-Starter
Rotate shift lever to ‘N’ position.
3
Engage parking brake.
Turn the engine ignition switch to TCU must recognize PL for at least
4 'PL' if start conditions are ok
'On' Position (Not 'Start' position) 2s before you can press the button
'↓IP' if start conditions are Press the button for at least 2
5 Press button of the AEB-Starter
ok seconds.
Turn the engine ignition switch
6 '↓IP'
further to 'Start' Position
Depress to the end position as long
7 Push down the pedal slowly '↓IP'
as this symbol is displayed
Start to release when bar arrow
8 Release the pedal slowly '↑IP'
directed upward
9 Wait until ISK has finished 'OK' (ISK completed)
Turn off the ignition switch and
10 Nothing
unplug AEB-Starter

1) When 'IP' is displayed with ISK start after pressing the button of AEB starter with the engine ignition switch
turned at 'On' position, Turn the switch further to 'Start' position and then start to push down the inching
pedal.
2) In case of D100/150 truck models installed with air type brake, push down the inching pedal after air is
charged enough.

- Display during ISK mode

Symbol Meaning Remarks
Push down the pedal slowly until end
↓IP position is reached and hold this
position
Release the pedal slowly until end
↑IP position is reached and wait until ‘OK’
is displayed
If the expected end position could not be reached,
release the pedal and try again. If caliabration can’t
A problem occurred, release the be completed after 2~3 times of re-trial, “STOP” sign
↑IP flashing pedal slowly until end position is is on display. In this case, switch off the ignition key
reached and remove AEB starter, and check inching sensor
& pedal linkage within the specified range. After
correction, repeat ISK procedure.
Finished inching pedal calibration
OK
successful
FN and Stop Shift lever not in Neutral position Calibration is aborted
Sensor supply voltage AUI is out of
FS and Stop Calibration is aborted
the specified range
FO and Stop Output speed is not zero Calibration is aborted
SL and Stop Sensor voltage below specified range Calibration is aborted
Sensor voltage above specified
SU and Stop Calibration is aborted
range
Sensor position for released pedal
IL and Stop Calibration is aborted
out of specified range
Sensor position for pressed pedal out
IU and Stop Calibration is aborted
of specified range
Time-out calibration, pedal not
To and Stop Calibration is aborted
moved after calibration start
Angle between pedal positions
DL and Stop Calibration is aborted
released and pressed to small
Angle between pedal positions
DU and Stop Calibration is aborted
released and pressed to big
Sensor signal 1 and 2 don’t match
FI and Stop Calibration is aborted
together

Power Shift Transmission 18 Systems Operation

Layout
Table - 1

Gearbox diagram

1 2 4 3 5 7

(1) Engine connection (2) Converter (3) Input shaft (4) Transmission pump (5) Input gear (6) Clutch shaft “K2”
(7) Power take-off (8) Clutch shaft “KV” (9) Clutch shaft “KR” (10) Clutch shaft “K1” (11) Output flange
(12) Clutch shaft “K3”/Output

Power Shift Transmission 19 Systems Operation

Installation Front view
Table - 2

1 2 3 4

11 10 9

(1) Converter (2) Converter bell (3) Lifting lugs (4) Inductive transmitter n Central gear train
(5) Inductive transmitter n Turbin (6) Gearbox housing – front section (7) Oil level tube with oil dipstick(rear side)
(8) Gearbox housing – rear section (9) Transmission suspension holes
(10) Attachment possibility oil level tube with oil dipstick(rear side) – 3 WG161 (11) Oil drain plug

Power Shift Transmission 20 Systems Operation

Installation Rear view
Table - 3

1 2 3

13
6

12 11 10

(1) Power take-off; coaxial (2) Lifting lugs (3) Breather (4) Electro – hydraulic control
(5) Measuring point for temperature behind the converter (6) Connection to the heat exchanger
(7) Filter head (8) Connection from the heat exchanger (9) Exchange filter
(10) Transmission suspension holes (11) Speed sensor n Output (12) Output flange (13) Oil filler tube with oil dipstick
(14) Type plate

Power Shift Transmission 21 Systems Operation

Schedule of measuring points and connections
Table – 4

65 51 54 10

60
57
34 48
53
52
58 55
55 56

21
15 16

47 Coding

• Pressure regulator active Engaged clutches

Driving direction Speed Y1 Y2 Y3 Y4 Y5 Y6
Forward 1 N • • K1 KV
2 o • • KV K2
3 t • • K3 KV
Reverse 1 • • KR K1
u
2 • • KR K2
s
3 e • • KR K3
Neutral d
Engaged clutches K4 KR K1 K3 KV K2
Position on the valve block F E D C B A
Consecutively No. of the measurement points 60 55 56 58 53 57

The marked positions(e.g. 53) correspond with the positions on the table – 5!
The measurements have to be carried out at hot transmission(about 80° - 95° C)

Power Shift Transmission 22 Systems Operation

NO. DENOMINATION OF THE POSITION CONNECTION MARKING ON THE
VALVEBLOCK
MEASURING POINTS FOR HYDRAULIC OIL AND TEMPERATURE:
51 = In front of the converter – opening pressure 11+2 bar M10x1 H
52 = Behind the converter – opening pressure 4.3+3 bar M14x1.5
53 = Clutch Forward 16+2 bar KV M10x1 B
55 = Clutch Reverse 16+2 bar KR M10x1 E
56 = Clutch 16+2 bar K1 M10x1 D
57 = Clutch 16+2 bar K2 M10x1 A
58 = Clutch 16+2 bar K3 M10x1 C
60 = Not applicable K4 M10x1 F
63 = Behind the converter M14x1.5
Temperature 100℃; short- time 120℃
65 = System pressure 16+2.5 bar M10x1 K
MEASURING POINTS FOR DELIVERY RATES:
15 = Connection to the heat exchanger 15/16” – 12 UN-2B
16 = Connection from the heat exchanger 15/16” – 12 UN-2B
INDUCTIVE TRANSMITTERS, SPEED SENSOR AND SWITCHES
21 = Inductive transmitter n Turbine M18x1.5
34 = Speed sensor n Output
47 = Inductive transmitter n Central gear train M18x1.5
48 = Inductive transmitter n Engine M18x1.5
54 = Filter contamination switch M14x1.5
CONNECTIONS:
10 = Breather
49 = Plug connection on the electro – hydraulic control unit

Power Shift Transmission 23 Systems Operation

Oil circuit diagram
Forward 1st Speed
Table – 5

KR K1 K3 KV K2

F 60 E 55 D 56 C 58 B 53 A 57
P1 P2 P3 P4 P5 P6
B D B D B D B D B D B D

Y1 Y2 Y3 Y4 Y5 Y6
NFS NFS NFS NFS NFS NFS

RV-9

TEMP

HDV K 65

Valve block control circuit

Converter
51

H WSV
Fine filter
63 52
Legend
WT FDV
= Main pressure
WGV
= Regulate main pressure
= Pilot pressure Bypass- 15 WS
= Converter input pressure Bypassvalve
p=1,5 bar Transmission pump
= Converter output pressure P = 16 + 2 bar
= Lubrication 16
= Return into the sump
Coarse filter

Oil sump Main oil circuit

Lubrication

Coding
WT = Heat exchanger
WGV = Converter back pressure valve 4.3+3 bar • Pressure regulator active Engaged clutches
Driving direction Speed Y1 Y2 Y3 Y4 Y5 Y6
WSV = Converter safety valve 11+2 bar Forward 1 N • • K1 KV
HDV = Main pressure valve 16+2.5 bar 2 o
t
• • KV K2
3 • • K3 KV
RV-9 = Pressure reducing valve 9 bar Reverse 1 • • KR K1
u
NFS = Follow-on slide 2 • • KR K2
s
3 e • • KR K3
D = Vibration damper Neutral d
B = Orifice Engaged clutches K4 KR K1 K3 KV K2
Position on the valve block F E D C B A
P1 = Not used Consecutively No. of the measurement points 60 55 56 58 53 57
P2 = Proportional valve KR
P3 = Proportional valve K1
P4 = Proportional valve K3
P5 = Proportional valve KV
P6 = Proportional valve K2
Y1...Y6 = Pressure regulators
TEMP = Temperature sensor
UEDV = Pressure relief valve 40±5bar
WS = Maintenance switch
FDV = Filter pressure differential valve
(Bypass-valve) Δp=5.5 bar

The marked positons (e.g. 53) correspond with the positions on the table-4

Power Shift Transmission 24 Systems Operation

Gearbox Diagram
Table – 6

KV
AN PTO
AN

KV
KR
K2

K1
K3/AB
K1

K3/AB

Diagram Clutches
AN = Input Driving direction Speed Clutch
KV = Clutch forward
Forward 1 KV/K1
KR = Clutch reverse
K1 = Clutch 1st speed 2 KV/K2
K2 = Clutch 2nd speed 3 KV/K3
K3/AB = Clutch 3rd speed / Output
Reverse 1 KR/K1
PTO = Power take-off
2 KR/K2
3 KR/K3

Power Shift Transmission 25 Systems Operation

Power flow Forward speed
Table – 7

1st speed-forward 2nd speed-forward 3rd speed-forward

KV KV KV

AN AN AN

KR KR KR
K2 K2 K2

K1 K1 K1
K3/AB K3/AB K3/AB

Transmission diagram

AN PTO
Diagram Clutches
Driving direction Speed Clutch
KV Forward 1 KV/K1
2 KV/K2
3 KV/K3
KR Reverse 1 KR/K1
2 KR/K2
Opinion direction 3 KR/K3
of rotation
K1
AN = Input
KV = Clutch forward
KR = Clutch reverse
K3/AB K1 = Clutch 1st speed
K2 = Clutch 2nd speed
K3/AB = Clutch 3rd speed / Output
PTO = Power take-off
K2

Power Shift Transmission 26 Systems Operation

Power flow Reverse speed
Table – 8

1st speed-reverse 2nd speed-reverse 3rd speed-reverse

KV KV KV

AN AN AN

KR KR KR
K2 K2 K2

K1 K1 K1
K3/AB K3/AB K3/AB

Transmission diagram

AN PTO
Diagram Clutches
Driving direction Speed Clutch
KV
Forward 1 KV/K1
2 KV/K2
3 KV/K3
KR Reverse 1 KR/K1
2 KR/K2
Opinion direction 3 KR/K3
of rotation
K1
AN = Input
KV = Clutch forward
KR = Clutch reverse
K3/AB K1 = Clutch 1st speed
K2 = Clutch 2nd speed
K3/AB = Clutch 3rd speed / Output
PTO = Power take-off
K2

Power Shift Transmission 27 Systems Operation

Electro – Hydraulic control with proportional valves
Table - 9

Main pressure valve 6+2.5 bar Pressure reducing valve 9 bar

Housing

Plug(cable harness)

A A
Y6 Y1

Y5 Y2

B
Y4 Y3

Cover Cover

Housing Valve block

Main pressure valve 16+2.5 bar Valve block Pressure reducting valve 9 bar

Plug(cable harness)

Duct plate Intermediate plate

SECTION A - A

Y5
Vibaration damper
Pressure regulator

Follow-on slide

SECTION B - B
Proportional valve P5

Power Shift Transmission 28 Systems Operation

F1
KI.30
Table - 10
KI.15
F2 S8 S15 S31 S3 S25 K2
1 1 1 1 1 86
B4 3 2 2 2 2 2 1
85 A9
SuperSeal 2
3-pin
6029 199 071 AMP M-N-L
45 23 68 66 66 21 29 31 7

Power Shift Transmission

1 A5 6-pin
36 6029 199 074
62 VPE1 VPE1 VPE2 ED8 ED9 ED10 ED11 ED13 ADM2 SD4
4 1
15 2
SDDK
4
EUPR 18 A6
61
Circuit diagram standard

EU2 4
3
4
37 14 1 3
AU1 SD1 2
38 EU1
24 1
VMGA1 56 1
VP AIP1 3
4 43 A1 10 2 AMP MNL
ED4 AIP2 Y2 4-pin
N 5 67 ED6 AIP3 32 3
Y3 6029 199 xxx
R 6 64 ED5 AIP4 55 4 Y4
A2 B1 7 63 ED1 AMP Timer AIP5 9 5
Y5
B2 8 65 ED2 68-pin AIP6 51 6
9 Y6
B3 6029 199 063 VPS1 12 7 VPSI (+)
Fully – Automatic control EST - 37A

function buttion 10 VPS1 13

ER1 39 8 TEMP
VMGA2 46 9 TEMP
1 19
EF1
2 3
86 B1 VMG1

29
3 6 9 12 2
A3
ER2 49 1
2 5 8 11 85 1 41 EF2 22
68 45
B2 2
1 4 7 10 1 2
3 4 5
K1 B15 6 7 8 9 Kostal
1 42 ER3 17
EF3 VGS CANF_H CANF_L CANF_T VM1 VM2 VPS2 VPS2 ADM5 16-pin
AMP M-N-L B3 2 10 11 12 13
12-pin 28 25 26 27 2 53 8 57 6029 199 072
14 15 16
6029 199 xx
AMP Miniyimer
4 2-pin
85 6029 199 011

86
K9
1 2

4 3 2 1
2 1 A7
S10
AMP JPT
4-pin K1.31
6029 199 076 1
2

AMP Superseal
2-pin
6029 199 045
TWISED LINES (30 WINDINGS/METER) FROM A LENGTH OF > 2 METERS ON
pole patterns are corresponding with the plugs on the wining!
BUS TERMINATION IF PIN 26 AND 27 ARE CONNETED ALL RELAYS WITH PROTECTIVE DIODES 1A/400V

Systems Operation
ITEM LEGEND ITEM LEGEND
A1 ELECTRONIC CONTROL UNIT TCU F1 FUSE 7,5 A*
A2 CONTROLLER DW-3 F2 FUSE 7,5 A*
A3 ELECTRO HADRAULIC CONTROL UNIT
A5 DIAGNOSIS – INTERFACE(PLUG) H3 ACOUSTIC - / OPTICAL WARNING*
A6 DISPLAY
A7 CAN-INTERFACE(PLUG) S3 SWITCH DRIVING PROGRAM
AUTOMATIC/MANUAL
A9 SPEEDOMETER WITH FREQUEMCY DIVIDER* S8 SWITCH SELCTION STARTING GEAR(OPTION)
S10 SWITCH FILTER CONTAMINATION
B1 SPEED SENSOR N ENGINE S15 SWITCH ENABLE INCHING
B2 SPEED SENSOR N TURBINE S25 SWITCH LIMP HOME MONITORING
ON/OFF(OPTION)
B3 SPEED SENSOR N CENTRAL GEAR TRAIN S31 SWITCH ACKNOWLEDGMENT PARKING BRAKE
B4 SPEED SENSOR N OUTPUT
B6 INCHING POTENTIOMETER K1 RELAIY STARTER INTERLOCK*
B15 SENSOR TEMPERATURE BEHIND CONVERTER K2 RELAIY REVERSE DRIVE*

Power Shift Transmission 30 Systems Operation

LEVER FOR MECHANICAL
Table – 11

NEUTRAL INTERLOCK
CONDING CONTROLLER CONNECTION DIAGRAM CONTROLLER
(+)
OUTPUT KD
SPEED FORQARD REVERSE NEUTRAL
Controller DW – 3

1 2 3 4 1 2 3 4 1 2 3 4 X2:A

Power Shift Transmission

N D (+)
AD1 B1 X1:C
B1 X1:B
AD2 B2 B2
X1:A
AD3 B3 A2 B3 A1
V X1:B
IN POSITION (NEUTRAL), AD4 V R X1:C
F-R NOT SWITCHABLE AS X1:D
AD5 R
AD6 AS
AD7

K1 K2
(-)

K1 = RELAY STARTER INTERLOCK

AB CD
AB CD

31
K2 = RELAY REVERSING LIGHTS
X2 X1
A1 = ELECTRONIC UNIT EST-37
A2 = CONTROLLER
F GEAR POSITIONS TYPE PLATE
CIRCUIT DIAGRAM CONTROLLER
F
SW
A AD3(B3)
N N D 1 1 1
N S6 S4 S5
2 2 2
R GN B AD2(B2)
BL C AD1(B1)
VI
D AD7(KD)
R X1
RT A ED1(+/VP)
F = FORWARD S1 1
N = NEUTRAL 3 2 GR D AD6(N)
R = REVERSE TYPE PLATE S2 1
D = MECHANICAL NEUTRAL INTERLOCK 3 2 GE B AD4(FORWARD)
CONTROL
1 = 1st SPEED 12/24 NR. S3
1
2 = 2nd SPEED 3 2 RS C AD5(REVERSE)
3 = 3rd SPEED STUECKL 0501 210 148
X2

Systems Operation
Description of Fault Codes
Introduction
Abbreviations
o.c. open circuit
s.c. short circuit
OP-Mode operating mode
TCU transmission control unit
EEC electronic engine controller
PTO power take off

Display
If a fault is detected, the display shows a spanner symbol
(g) for a fault. The display shows the fault code, left right
h f e d character character
if the gear selector is on neutral position.
If more than one fault is detected, each fault code
is shown for about 1 second.
S
T
O
P

a b c g
(special symbols a-h)

Power Shift Transmission 32 Description of Fault Codes

Display during operation
Symbol Meaning Remarks
1F, 1R actual gear and direction
2F, 2R left digit shows actual gear
3F, 3R right digit shows actual direction
LF, LR limp home gear
F or R, no gear Clutch Cutoff
F or R flashing direction F or R selected while turbine CAUTION gear will engage if turbine speed drops
speed is too high
NN not neutral, waiting for neutral after to engage a gear, first move shift selector to neutral
power up or a severe fault position and again to F or R position
** oil temperature too low, no gear warm up engine / transmission
available
*N oil temperature low, only one gear warm up engine / transmission
available
1 bar (special manual mode 1st gear
symbol)
2 bars manual mode 2 nd gear
3 bars manual mode 3 rd gear
4 bars and 2 automatic mode
arrows
Spanner at least one fault active select neutral to get fault code displayed
Fault code see faultcode list
WS warning sump temperature changes between actual gear/direction while driving,
in neutral only displayed if no fault is detected
(spanner)
WR warning retarder temperature changes between actual gear/direction while driving,
in neutral only displayed if no fault is detected
(spanner)
WT warning torque converter temperature changes between actual gear/direction while driving,
in neutral only displayed if no fault is detected
(spanner)
WE warning high engine speed changes between actual gear/direction while driving,
in neutral only displayed if no fault is detected
(spanner)
PN direction F or R selected while transmission in neutral until parking brake is
parking brake engaged released
CAUTION: vehicle starts to move after release of
parking brake
EE flashing no communication with display checked wiring from TCU to display

Power Shift Transmission 33 Description of Fault Codes

Display during AEB-Mode
Symbol Meaning Remarks
PL AEB - Starter is plugged at the
diagnostic plug
ST AEB-Starter-button is pressed
K1..K3,KV,KR calibrating clutch K1..K3, KV or KR
resp.
_ and Kx wait for start, initialization of clutch Kx,
x: 1, 2, 3, V, R
≡ and Kx fast fill time determination of clutch Kx
= and Kx compensating pressure determination
of clutch Kx
OK calibration for all clutches finished Transmissions stays in neutral, you have to restart
the TCU (ignition off/on) after removing AEB-Starter
STOP AEB canceled (activation stopped) Transmissions stays in neutral, you have to restart
the TCU (ignition off/on)
STOP and Kx AEB stopped, clutch Kx can't be Transmissions stays in neutral, you have to restart
calibrated the TCU (ignition off/on)
Spanner and Kx Kx couldn't be calibrated, AEB finished Transmissions stays in neutral, you have to restart
the TCU (ignition off/on)
ΔE engine speed too low,
Ö raise engine speed
∇E engine speed too high,
Ö lower engine speed
ΔT transmission oil temperature too low,
Ö heat up transmission
∇T transmission oil temperature too high
Ö cool down transmission
FT transmission temperature not in Transmissions stays in neutral, you have to restart
defined range during calibration the TCU (ignition off/on)
FB operating mode not NORMAL or Transmissions stays in neutral, you have to restart
transmission temperature sensor the TCU (ignition off/on)
defective or storing of Calibrated
values to EEPROM-has failed.
FO Outputspeed_not_zero Transmissions stays in neutral, you have to restart
the TCU (ignition off/on)
FN Shift lever not in Neutral position Transmissions stays in neutral, you have to restart
the TCU (ignition off/on)
FP Parkbrake_not_applied Transmissions stays in neutral, you have to restart
the TCU (ignition off/on)
STOP AEB - Starter was used incorrect or is Transmissions stays in neutral, you have to restart
defective. Wrong device or wrong the TCU (ignition off/on)
cable used

Power Shift Transmission 34 Description of Fault Codes

Display during Inchpedal Calibration
Symbol Meaning Remarks
push down the pedal slowly until
IP ⇓ endposition is reached and hold this
position
Release the pedal slowly until
IP ⇑ endposition is reached

A problem occurred, release the pedal If the expected enposition could not be reached,
IP ⇑flashing slowly until endposition is reached release the pedal and try again

OK Finished inchpedal calibration

successful
FN and Stop Shift lever not in Neutral position Calibration is aborted
FS and Stop sensor supply voltage AU1 is out of Calibration is aborted
the specified range
FO and Stop Outputspeed is not zero Calibration is aborted
SL and Stop sensor voltage below specified range Calibration is aborted
SU and Stop sensor voltage above specified range Calibration is aborted
IL and Stop sensor position for released pedal out Calibration is aborted
of specified range
IU and Stop sensor position for pressed pedal out Calibration is aborted
of specified range
TO and Stop time-out calibration, pedal not moved Calibration is aborted
after calibration start
DL and Stop angle between pedalpositions Calibration is aborted
released and pressed to small
DU and Stop angle between pedalpositions Calibration is aborted
released and pressed to big
FI and Stop sensor signal 1 and 2 don't match Calibration is aborted
together

Power Shift Transmission 35 Description of Fault Codes

Definition of operating modes

NORMAL
There's no failure detected in the transmission-system or the failure has no or slight effects on transmission control.
TCU will work without or in special cases with little limitations. (see following table)

SUBSTITUTE CLUTCH CONTROL

TCU can't change the gears or the direction under the control of the normal clutch modulation. TCU uses the
substitute strategy for clutch control. All modulations are only time controlled.

LIMP-HOME
The detected failure in the system has strong limitations to transmission control. TCU can engage only one gear in
each direction. In some cases only one direction will be possible.
TCU will shift the transmission into neutral at the first occurrence of the failure. First, the operator must shift the
gear selector into neutral position.
If output speed is less than a threshold for neutral to gear and the operator shifts the gear selector into forward or
reverse, the TCU will select the limp-home gear .
If output speed is less than a threshold for reversal speed and TCU has changed into the limp-home gear and the
operator selects a shuttle shift, TCU will shift immediately into the limp-home gear of the selected direction.
If output speed is greater than the threshold, TCU will shift the transmission into neutral. The operator has to slow
down the vehicle and must shift the gear selector into neutral position.

TRANSMISSION-SHUTDOWN
TCU has detected a severe failure that disables control of the transmission.
TCU will shut off the solenoid valves for the clutches and also the common power supply (VPS1). Transmission
shifts to Neutral. The park brake will operate normally, also the other functions which use ADM 1 to ADM 8.
The operator has to slow down the vehicle. The transmission will stay in neutral.

TCU-SHUTDOWN
TCU has detected a severe failure that disables control of system.
TCU will shut off all solenoid valves and also both common power supplies (VPS1, VPS2). The park brake will
engage, also all functions are disabled which use ADM 1 to ADM 8.
The transmission will stay in neutral.

Power Shift Transmission 36 Description of Fault Codes

Table of fault codes
Fault SPN FMI MEANING OF THE Reaction of Possible steps to Remarks
Code FAULT CODE the TCU repair
(hex) possible reason for fault
detection
12 5010 12 LOGICAL ERROR AT TCU shifts z check the cables fault is taken
DIRECTION SELECT transmission from TCU to shift back if TCU
SIGNAL to neutral lever detects a valid
TCU detected a wrong OP-Mode: z check signal signal for the
signal combination for the transmission combinations of direction at the
direction shutdown shift lever positions shift lever
z cable from shift lever to F-N-R
TCU is broken
z cable is defective and is

contacted to battery
voltage or vehicle
ground
z shift lever is defective

21 5090 3 S.C. TO BATTERY clutch cutoff z check the cable

VOLTAGE AT CLUTCH function is from TCU to the
CUTOFF INPUT disabled sensor
the measured voltage is OP-Mode: z check the
too high: normal connectors
z cable is defective and is z check the clutch
contacted to battery cutoff sensor
voltage
z clutch cut off sensor has

an internal defect
z connector pin is

contacted to battery
voltage

22 5090 4 S.C. TO GROUND OR clutch cutoff z check the cable

O.C. AT CLUTCH function is from TCU to the
CUTOFF INPUT disabled sensor
the measured voltage is OP-Mode: z check the
too low: normal connectors
z cable is defective and is z check the clutch
contacted to vehicle cutoff sensor
ground
z cable has no connection

to TCU
z clutch cut off sensor has

an internal defect
z connector pin is

contacted to vehicle
ground or is broken

Power Shift Transmission 37 Description of Fault Codes

Fault SPN FMI MEANING OF THE Reaction of Possible steps to Remarks
Code FAULT CODE the TCU repair
(hex) possible reason for fault
detection
25 5110 3 S.C. TO BATTERY no reaction, z check the cable
VOLTAGE OR O.C. AT TCU uses from TCU to the
TRANSMISSION SUMP default sensor
TEMPERATURE temperature z check the
SENSOR INPUT OP-Mode: connectors
the measured voltage is normal z check the
too high: temperature sensor
z cable is defective and is

contacted to battery
voltage
z cable has no connection

to TCU
z temperature sensor has

an internal defect
z connector pin is

contacted to battery
voltage or is broken

26 5110 4 S.C. TO GROUND AT no reaction, z check the cable

TRANSMISSION SUMP TCU uses from TCU to the
TEMPERATURE default sensor
SENSOR INPUT temperature z check the
the measured voltage is OP-Mode: connectors
too low: normal z check the
z cable is defective and is temperature sensor
contacted to vehicle
ground
z temperature sensor has

an internal defect
z connector pin is

contacted to vehicle
ground

2B 5313 12 INCHSENSOR-SIGNAL During inching z check the cable

MISMATCH mode: TCU from TCU to the
the measured voltage from shifts to sensor
CCO and CCO2 signal neutral z check the
don’t match: While not connectors
z cable is defective inching: no z check sensor
z sensor has an internal change
defect OP-Mode:
normal

Power Shift Transmission 38 Description of Fault Codes

Fault SPN FMI MEANING OF THE Reaction of Possible steps to Remarks
Code FAULT CODE the TCU repair
(hex) possible reason for fault
detection
31 5140 3 S.C. TO BATTERY OP-Mode: z check the cable
VOLTAGE OR O.C. AT substitute from TCU to the
ENGINE SPEED INPUT clutch control sensor
TCU measures a voltage z check the
higher than 7.00 V at connectors
speed input pin z check the speed
z cable is defective and is sensor
contacted to battery
voltage
z cable has no connection

to TCU
z speed sensor has an

internal defect
z connector pin is

contacted to battery
voltage or has no
contact

32 5140 4 S.C. TO GROUND AT OP-Mode: z check the cable

ENGINE SPEED INPUT substitute from TCU to the
TCU measures a voltage clutch control sensor
less than 0.45V at speed z check the
input pin connectors
z cable / connector is z check the speed
defective and is sensor
contacted to vehicle
ground
z speed sensor has an

internal defect

33 5140 12 LOGICAL ERROR AT OP-Mode: z check the cable This fault is

ENGINE SPEED INPUT substitute from TCU to the reset after
TCU measures a engine clutch control sensor power up of
speed over a threshold z check the TCU
and the next moment the connectors
measured speed is zero z check the speed
z cable / connector is sensor
defective and has bad z check the sensor
contact gap
z speed sensor has an

internal defect
z sensor gap has the

wrong size

Power Shift Transmission 39 Description of Fault Codes

Fault SPN FMI MEANING OF THE Reaction of Possible steps to Remarks
Code FAULT CODE the TCU repair
(hex) possible reason for fault
detection
34 5150 3 S.C. TO BATTERY OP-Mode: z check the cable
VOLTAGE OR O.C. AT substitute from TCU to the
TURBINE SPEED INPUT clutch control sensor
TCU measures a voltage if a failure is z check the
higher than 7.00 V at existing at connectors
speed input pin output speed, z check the speed
z cable is defective and is TCU shifts to sensor
contacted to battery neutral
voltage OP-Mode: limp
z cable has no connection home
to TCU
z speed sensor has an

internal defect
z connector pin is

contacted to battery
voltage or has no
contact

35 5150 4 S.C. TO GROUND AT OP-Mode: z check the cable

TURBINE SPEED INPUT substitute from TCU to the
TCU measures a voltage clutch control sensor
less than 0.45V at speed if a failure is z check the
input pin existing at connectors
z cable / connector is output speed, z check the speed
defective and is TCU shifts to sensor
contacted to vehicle neutral
ground OP-Mode: limp
z speed sensor has an home
internal defect

36 5150 12 LOGICAL ERROR AT OP-Mode: z check the cable This fault is

TURBINE SPEED INPUT substitute from TCU to the reset after
TCU measures a turbine clutch control sensor power up of
speed over a threshold if a failure is z check the TCU
and at the next moment existing at connectors
the measured speed is output speed, z check the speed
zero TCU shifts to sensor
z cable / connector is neutral z check the sensor
defective and has bad OP-Mode: limp gap
contact home
z speed sensor has an

internal defect
z sensor gap has the

wrong size

Power Shift Transmission 40 Description of Fault Codes

Fault SPN FMI MEANING OF THE Reaction of Possible steps to Remarks
Code FAULT CODE the TCU repair
(hex) possible reason for fault
detection
37 5160 3 S.C. TO BATTERY OP-Mode: z check the cable
VOLTAGE OR O.C. AT substitute from TCU to the
INTERNAL SPEED INPUT clutch control sensor
TCU measures a voltage z check the
higher than 7.00 V at connectors
speed input pin z check the speed
z cable is defective and is sensor
contacted to battery
voltage
z cable has no connection

to TCU
z speed sensor has an

internal defect
z connector pin is

contacted to battery
voltage or has no
contact

38 5160 4 S.C. TO GROUND AT OP-Mode: z check the cable

INTERNAL SPEED INPUT substitute from TCU to the
TCU measures a voltage clutch control sensor
less than 0.45V at speed z check the
input pin connectors
z cable / connector is z check the speed
defective and is sensor
contacted to vehicle
ground
z speed sensor has an

internal defect

39 5160 12 LOGICAL ERROR AT OP-Mode: z check the cable This fault is

INTERNAL SPEED INPUT substitute from TCU to the reset after
TCU measures a internal clutch control sensor power up of
speed over a threshold z check the TCU
and at the next moment connectors
the measured speed is z check the speed
zero sensor
z cable / connector is z check the sensor
defective and has bad gap
contact
z speed sensor has an

internal defect
z sensor gap has the

wrong size

Power Shift Transmission 41 Description of Fault Codes

Fault SPN FMI MEANING OF THE Reaction of Possible steps to Remarks
Code FAULT CODE the TCU repair
(hex) possible reason for fault
detection
3A 5170 3 S.C. TO BATTERY special mode z check the cable
VOLTAGE OR O.C. AT for gear from TCU to the
OUTPUT SPEED INPUT selection sensor
TCU measures a voltage OP-Mode: z check the
higher than 12.5 V at substitute connectors
speed input pin clutch control z check the speed
z cable is defective and is if a failure is sensor
contacted to battery existing at
voltage turbine speed,
z cable has no connection TCU shifts to
to TCU neutral
z speed sensor has an OP-Mode: limp
internal defect home
z connector pin is

contacted to battery
voltage or has no
contact

3B 5170 4 S.C. TO GROUND AT special mode z check the cable

OUTPUT SPEED INPUT for gear from TCU to the
TCU measures a voltage selection sensor
less than 1.00V at speed OP-Mode: z check the
input pin substitute connectors
z cable / connector is clutch control z check the speed
defective and is if a failure is sensor
contacted to vehicle existing at
ground turbine speed,
z speed sensor has an TCU shifts to
internal defect neutral
OP-Mode: limp
home

3C 5170 12 LOGICAL ERROR AT special mode z check the cable This fault is
OUTPUT SPEED INPUT for gear from TCU to the reset after
TCU measures a output selection sensor power up of
speed over a threshold OP-Mode: z check the TCU
and at the next moment substitute connectors
the measured speed is clutch control z check the speed
zero if a failure is sensor
z cable / connector is existing at z check the sensor
defective and has bad turbine speed, gap
contact TCU shifts to
z speed sensor has an neutral
internal defect OP-Mode: limp
z sensor gap has the home
wrong size

Power Shift Transmission 42 Description of Fault Codes

Fault SPN FMI MEANING OF THE Reaction of Possible steps to Remarks
Code FAULT CODE the TCU repair
(hex) possible reason for fault
detection
3E 5180 2 OUTPUT SPEED ZERO special mode z check the sensor This fault is
DOESN’T FIT TO OTHER for gear signal of output reset after
SPEED SIGNALS selection speed sensor power up of
if transmission is not OP-Mode: z check the sensor TCU
neutral and the shifting substitute gap of output
has finished, clutch control speed sensor
TCU measures if a failure is z check the cable
outputspeed zero and existing at from TCU to the
turbine speed or internal turbine speed, sensor
speed not equal to zero. TCU shifts to
z speed sensor has an neutral
internal defect OP-Mode: limp
z sensor gap has the home
wrong size

71 5480 3 S.C. TO BATTERY TCU shifts to z check the cable 1)

see chapter
VOLTAGE AT CLUTCH neutral from TCU to the “Measuring of
K1 OP-Mode: limp gearbox resistance”
the measured resistance home z check the
value of the valve is out of if failure at connectors from
limit, the voltage at K1 another clutch TCU to the gearbox
valve is too high. is pending z check the regulator
z cable / connector is TCU shifts to resistance1)
defective and has neutral z check internal wire
contact to battery OP-Mode: harness of the
voltage TCU shutdown gearbox
z regulator has an internal

defect

72 5480 4 S.C. TO GROUND AT TCU shifts to z check the cable 1)

see chapter
CLUTCH K1 neutral from TCU to the “Measuring of
the measured resistance OP-Mode: limp gearbox resistance”
value of the valve is out of home z check the
limit, the voltage at K1 if failure at connectors from
valve is too low. another clutch gearbox to TCU
z cable / connector is is pending z check the regulator
defective and has TCU shifts to resistance1)
contact to vehicle neutral z check internal wire
ground OP-Mode: harness of the
z cable / connector is TCU shutdown gearbox
defective and has
contact to another
regulator output of the
TCU
z regulator has an internal

defect

Power Shift Transmission 43 Description of Fault Codes

Fault SPN FMI MEANING OF THE Reaction of Possible steps to Remarks
Code FAULT CODE the TCU repair
(hex) possible reason for fault
detection
73 5480 5 O.C. AT CLUTCH K1 TCU shifts to z check the cable 1)
see chapter
the measured resistance neutral from TCU to the “Measuring of
value of the valve is out of OP-Mode: limp gearbox resistance”
limit. home z check the
z cable / connector is if failure at connectors from
defective and has no another clutch gearbox to TCU
contact to TCU is pending z check the regulator
z regulator has an internal TCU shifts to resistance1)
defect neutral z check internal wire
OP-Mode: harness of the
TCU shutdown gearbox

74 5490 3 S.C. TO BATTERY TCU shifts to z check the cable 1)

see chapter
VOLTAGE AT CLUTCH neutral from TCU to the “Measuring of
K2 OP-Mode: limp gearbox resistance”
the measured resistance home z check the
value of the valve is out of if failure at connectors from
limit, the voltage at K2 another clutch gearbox to TCU
valve is too high. is pending z check the regulator
z cable / connector is TCU shifts to resistance1)
defective and has neutral z check internal wire
contact to battery OP-Mode: harness of the
voltage TCU shutdown gearbox
z regulator has an internal
defect

75 5490 4 S.C. TO GROUND AT TCU shifts to z check the cable 1)

see chapter
CLUTCH K2 neutral from TCU to the “Measuring of
the measured resistance OP-Mode: limp gearbox resistance”
value of the valve is out of home z check the
limit, the voltage at K2 if failure at connectors from
valve is too low. another clutch gearbox to TCU
z cable / connector is is pending z check the regulator
defective and has TCU shifts to resistance1)
contact to vehicle neutral z check internal wire
ground OP-Mode: harness of the
z cable / connector is TCU shutdown gearbox
defective and has
contact to another
regulator output of the
TCU
z regulator has an internal
defect

76 5490 5 O.C. AT CLUTCH K2 TCU shifts to z check the cable 1)

see chapter
the measured resistance neutral from TCU to the “Measuring of
value of the valve is out of OP-Mode: limp gearbox resistance”
limit. home z check the
z cable / connector is if failure at connectors from
defective and has no another clutch gearbox to TCU
contact to TCU is pending z check the regulator
z regulator has an internal TCU shifts to resistance1)
defect neutral z check internal wire
OP-Mode: harness of the
TCU shutdown gearbox

Power Shift Transmission 44 Description of Fault Codes

Fault SPN FMI MEANING OF THE Reaction of Possible steps to Remarks
Code FAULT CODE the TCU repair
(hex) possible reason for fault
detection
77 5500 3 S.C. TO BATTERY TCU shifts to z check the cable 1)
see chapter
VOLTAGE AT CLUTCH neutral from TCU to the “Measuring of
K3 OP-Mode: limp gearbox resistance”
the measured resistance home z check the
value of the valve is out of if failure at connectors from
limit, the voltage at K3 another clutch gearbox to TCU
valve is too high. is pending z check the regulator
z cable / connector is TCU shifts to resistance1)
defective and has neutral z check internal wire
contact to battery OP-Mode: harness of the
voltage TCU shutdown gearbox
z regulator has an internal
defect

78 5500 4 S.C. TO GROUND AT TCU shifts to z check the cable 1)

see chapter
CLUTCH K3 neutral from TCU to the “Measuring of
the measured resistance OP-Mode: limp gearbox resistance”
value of the valve is out of home z check the
limit, the voltage at K3 if failure at connectors from
valve is too low. another clutch gearbox to TCU
z cable / connector is is pending z check the regulator
defective and has TCU shifts to resistance1)
contact to vehicle neutral z check internal wire
ground OP-Mode: harness of the
z cable / connector is TCU shutdown gearbox
defective and has
contact to another
regulator output of the
TCU
z regulator has an internal
defect

see chapter
REVERSE WARNING OP-Mode: from TCU to the “Measuring of
ALARN normal backup alarm resistance”
TCU detected a wrong device
voltage at the output pin, z check the
that looks like a o.c. for connectors from
this output pin backup alarm
z cable is defective and device to TCU
has no connection to z check the
TCU resistance1) of
z backup alarm device has backup alarm
an internal defect device
z connector has no

connection to TCU

B1 5660 2 SLIPPAGE AT CLUTCH TCU shifts to z check pressure at

K1 neutral clutch K1
TCU calculates a OP-Mode: limp z check main
differential speed at closed home pressure in the
clutch K1. If this calculated if failure at system
value is out of range, TCU another clutch z check sensor gap
interprets this as slipping is pending at internal speed
clutch. TCU shifts to sensor
z low pressure at clutch neutral z check sensor gap
K1 OP-Mode: at output speed
z low main pressure TCU shutdown sensor
z wrong signal at internal z check signal at
speed sensor internal speed
z wrong signal at output sensor
speed sensor z check signal at
z wrong size of the sensor output speed
gap sensor
z clutch is defective z replace clutch

Power Shift Transmission 48 Description of Fault Codes

Fault SPN FMI MEANING OF THE Reaction of Possible steps to Remarks
Code FAULT CODE the TCU repair
(hex) possible reason for fault
detection
B2 5665 2 SLIPPAGE AT CLUTCH TCU shifts to z check pressure at
K2 neutral clutch K2
TCU calculates a OP-Mode: limp z check main
differential speed at closed home pressure in the
clutch K2. If this calculated if failure at system
value is out of range, TCU another clutch z check sensor gap
interprets this as slipping is pending at internal speed
clutch. TCU shifts to sensor
z low pressure at clutch neutral z check sensor gap
K2 OP-Mode: at output speed
z low main pressure TCU shutdown sensor
z wrong signal at internal z check signal at
speed sensor internal speed
z wrong signal at output sensor
speed sensor z check signal at
z wrong size of the sensor output speed
gap sensor
z clutch is defective z replace clutch

B3 5670 2 SLIPPAGE AT CLUTCH TCU shifts to z check pressure at

K3 neutral clutch K3
TCU calculates a OP-Mode: limp z check main
differential speed at closed home pressure in the
clutch K3. If this calculated if failure at system
value is out of range, TCU another clutch z check sensor gap
interprets this as slipping is pending at internal speed
clutch. TCU shifts to sensor
z low pressure at clutch neutral z check sensor gap
K3 OP-Mode: at output speed
z low main pressure TCU shutdown sensor
z wrong signal at internal z check signal at
speed sensor internal speed
z wrong signal at output sensor
speed sensor z check signal at
z wrong size of the sensor output speed
gap sensor
z clutch is defective z replace clutch

Power Shift Transmission 49 Description of Fault Codes

Fault SPN FMI MEANING OF THE Reaction of Possible steps to Remarks
Code FAULT CODE the TCU repair
(hex) possible reason for fault
detection
B5 5680 2 SLIPPAGE AT CLUTCH TCU shifts to z check pressure at
KV neutral clutch KV
TCU calculates a OP-Mode: limp z check main
differential speed at closed home pressure in the
clutch KV. If this calculated if failure at system
value is out of range, TCU another clutch z check sensor gap
interprets this as slipping is pending at internal speed
clutch. TCU shifts to sensor
z low pressure at clutch neutral z check sensor gap
KV OP-Mode: at turbine speed
z low main pressure TCU shutdown sensor
z wrong signal at internal z check signal at
speed sensor internal speed
z wrong signal at turbine sensor
speed sensor z check signal at
z wrong size of the sensor turbine speed
gap sensor
z clutch is defective z replace clutch

B6 5685 2 SLIPPAGE AT CLUTCH TCU shifts to z check pressure at

KR neutral clutch KR
TCU calculates a OP-Mode: limp z check main
differential speed at closed home pressure in the
clutch KR. If this if failure at system
calculated value is out of another clutch z check sensor gap
range, TCU interprets this is pending at internal speed
as slipping clutch. TCU shifts to sensor
z low pressure at clutch neutral z check sensor gap
KR OP-Mode: at turbine speed
z low main pressure TCU shutdown sensor
z wrong signal at internal z check signal at
speed sensor internal speed
z wrong signal at turbine sensor
speed sensor z check signal at
z wrong size of the sensor turbine speed
gap sensor
z clutch is defective z replace clutch

B7 5700 0 OVERTEMP SUMP no reaction z cool down machine

TCU measured a OP-Mode: z check oil level
temperature in the oil normal z check temperature
sump that is over the sensor
allowed threshold.

Power Shift Transmission 50 Description of Fault Codes

Fault SPN FMI MEANING OF THE Reaction of Possible steps to Remarks
Code FAULT CODE the TCU repair
(hex) possible reason for fault
detection
BA 5730 0 DIFFERENTIAL no reaction z check oil filter
PRESSURE OIL FILTER OP-Mode: z check wiring from
TCU measured a voltage normal TCU to differential
at differential pressure pressure switch
switch out of the allowed z check differential
range pressure switch
z oil filter is polluted (measure
z cable/connector is resitance)
broken or
cable/connector is
contacted to battery
voltage or vehicle
ground
z differential pressure

switch is defective

D1 5810 3 S.C. TO BATTERY see fault codes z check cables and fault codes no.
VOLTAGE AT POWER no. 21 to 2B connectors to 21 to no. 2B
SUPPLY FORSEN SORS sensors, which are may be a
TCU measures more than supplied from AU1 reaction of this
6V at the pin AU1 (5V z check the power fault
sensor supply) supply at the pin
AU1
(should be appx.
5V)

D2 5810 4 S.C. TO GROUND AT see fault codes z check cables and fault codes no.
POWER SUPPLY FOR no. 21 to 2B connectors to 21 to no. 2B
SENSORS sensors, which are may be a
TCU measures less than supplied from AU1 reaction of this
4V at the pin AU1 (5V z check the power fault
sensor supply) supply at the pin
AU1
(should be appx.
5V)

D3 5820 4 LOW VOLTAGE AT shift to neutral z check power supply

BATTERY OP-Mode: battery
measured voltage at TCU shutdown z check cables from
power supply is lower than batteries to TCU
10 V (12V device) z check connectors
lower than 18 V (24V from batteries to
device) TCU

Power Shift Transmission 51 Description of Fault Codes

Fault SPN FMI MEANING OF THE Reaction of Possible steps to Remarks
Code FAULT CODE the TCU repair
(hex) possible reason for fault
detection
D4 5820 3 HIGH VOLTAGE AT shift to neutral z check power supply
BATTERY OP-Mode: battery
measured voltage at TCU shutdown z check cables from
power supply is higher batteries to TCU
than 18 V (12V device) z check connectors
higher than 32.5 V (24V from batteries to
device) TCU

D5 5830 2 ERROR AT VALVE shift to neutral z check fuse

POWER SUPPLY VPS1 OP-Mode: z check cables from
TCU switched on VPS1 TCU shutdown gearbox to TCU
and measured VPS1 is z check connectors
off or TCU switched off from gearbox to
VPS1 and measured TCU
VPS1 is still on z replace TCU
cable or connectors are
defect and are contacted
to battery voltage
cable or connectors are
defect and are contacted
to vehicle ground
permanent power supply
KL30 missing
TCU has an internal defect

D6 5840 2 ERROR AT VALVE shift to neutral z check fuse

POWER SUPPLY VPS2 OP-Mode: z check cables from
TCU switched on VPS2 TCU shutdown gearbox to TCU
and measured VPS2 is off z check connectors
or TCU switched off VPS2 from gearbox to
and measured VPS2 is still TCU
on z replace TCU
z cable or connectors are

defect and are contacted

to battery voltage
z cable or connectors are

defect and are contacted

to vehicle ground
z permanent power supply

AEB was not able to adjust stay neutral the affected
clutch filling parameters OP-Mode: clutch on the
One of the AEB-Values is TCU shutdown Display
out of limit

Power Shift Transmission 53 Description of Fault Codes

Fault SPN FMI MEANING OF THE Reaction of Possible steps to Remarks
Code FAULT CODE the TCU repair
(hex) possible reason for fault
detection
F6 5930 13 CLUTCH ADJUSTMENT default values z execute AEB
DATA LOST OR = 0 for AEB
INCHPEDAL offsets used
CALIBRATION DATA OP-Mode:
LOST normal
TCU was not able to read no Inchmode
correct clutch adjustment available
parameters
z interference during

saving data on non

volatile memory
z TCU is brand new

Power Shift Transmission 54 Description of Fault Codes

Measuring of resistance at
actuator/sensors and cable
actuator cable

U
1 Bat

P (power supply)
TCU
R 1 2 Actuator/
Sensor
C (chassis)

2 Gnd
G

open circuit: R12 ≈ R1G ≈ R2G ≈ ∞ open circuit: R12 ≈ R1P ≈ R1C ≈ R2P ≈ R2C ≈
∞
short cut to ground: R12 ≈ R; short cut to ground: R12 ≈ 0;
R1G ≈ 0, R2G ≈ R or R1C ≈ R2C ≈ 0,
R1G ≈ R, R2G ≈ 0 R1P ≈ R2P ≈ ∞
(for s.c. to ground, G is short cut to battery: R12 ≈ 0,
connected to vehicle R1C ≈ R2C ≈ ∞,
ground) R1P ≈ R2P ≈ 0

short cut to battery: R12 ≈ R;

R1G ≈ 0, R2G ≈ R or
R1G ≈ R, R2G ≈ 0
(for s.c. to battery, G is
connected to battery
voltage)

Power Shift Transmission 55 Description of Fault Codes

SB4122E01

Disassembly &
Assembly
Lift Trucks
Three Speed Power Shift
Transmission
3WG 116/161
Index

IMPORTANT SAFETY INFORMATION ON 4. DISASSEMBLY

INDUSTRIAL SAFETYandyle4 Clutches KV/KR/K1/K2/K3 and Input.............33
TORQUE LIMITS FOR SCREWS...........................5
4.1 Clutch KV.................................................33
4.2 Clutch KR.................................................35

LIST OF SPECIAL TOOLS FOR DIS- AND 4.3 Clutch K1 .................................................38

REASSEMBLY........................................................6 4.4 Clutch K2 .................................................40
COUPLING K1...............................................15
4.5 Clutch K3 .................................................42
COUPLING K2...............................................16
4.6 Input.........................................................44
COUPLING K3...............................................17
COUPLING KV ..............................................18
COUPLING KR ..............................................19 5. REASSEMBLY
Clutches KV/KR/K1/K2/K3 and Input.............45
ENGINE CONNECT ......................................10
5.1 Clutch KV.................................................45
FILTER ..........................................................13
5.2 Clutch KR.................................................48
GEARSHIFT SYS. .........................................20
5.3 Clutch K1 .................................................51
INPUT ............................................................11
5.4 Clutch K2 .................................................54
POWER TAKE OFF.......................................12
5.5 Clutch K3 .................................................57
PRESS. REGULATOR ..................................14
5.6 Input.........................................................61

1. DISASSEMBLY
Electro-Hydraulic Control And Micro Filter 6. REASSEMBLY
Engine Connection, Pressure Oil Pump and
(Exchange Filter) ...........................................22
Installation of the Clutches.............................62
1.1 Removal of the Filter................................22
1.2 Removal of the Electric Shift System.......23

7. REASSEMBLY
Inductive Transmitters, Valves, Oil Filler and
2. DISASSEMBLY
Oil Drain Plug, Screw Plugs...........................70
Inductive transmitters, Valves, Oil Filler and Oil
Drain Plug, Screw Plugs ................................27

8. REASSEMBLY
Electro-hydraulic control unit with proportional
3. DISASSEMBLY
valves.............................................................72
Engine Connection, Pressure Oil Pump and
8.1 Mounting of the Electric Control Unit .......73
Removal of the Clutches................................28
8.2 Mounting of Micro Filter
(Pressure Filter)........................................78

Power Shift Transmission 3 Index

Important information on industrial safety
Generally, the persons repairing units are responsible on their own for the industrial safety.

The observation of all valid safety regulations and legal impositions is the pre-condition for avoiding
damage to persons and to the product during maintenance and repair works.
Persons performing repair works must familiarize themselves with these regulations.

The proper repair of these products requires the employment of suitably trained and skilled staff.
The repairer is obliged to perform the training.

The following safety references are used in the present Manual:

) Serves as reference to special working procedures, methods,

information, the use of auxiliaries etc.

Is used, if a deviating and improper working procedure can

CAUTION
damage the product.

Is used, if lacking care can lead to personal injury or danger to

DANGER
life.

___________________________________________________

REFERENCE Prior to starting the checks and repair works, thoroughly study the present instructions.

Illustrations, drawings and parts do not always represent the original; the working procedure is
shown.
CAUTION The illustrations, drawings, and parts are not drawn to scale; conclusions regarding size and
weight must not be drawn (not even within one representation).
The works must be performed according to the description.

After the repair works and the checks, the expert staff must convince itself that the product is
REFERENCE:
properly functioning again.

Power Shift Transmission 4 Disassembly & Assembly

TORQUE LIMITS FOR SCREWS (in Nm)
Friction value: µ total= 0.12 for screws and nuts without after-treatment, as well as phophatized
nuts. Tightening by hand!
Torque limits, if not especially indicated, can be taken from the following list:

Metric ISO-Standard thread

Size 8.8 10.9 12.9
M4 2.8 4.1 4.8
M5 5.5 8.1 9.5
M6 9.5 14 16.5
M7 15 23 28
M8 23 34 40
M10 46 68 79
M12 79 115 135
M14 125 185 215
M16 195 280 330
M18 280 390 460
M20 390 560 650
M22 530 750 880
M24 670 960 1100
M27 1000 1400 1650
M30 1350 1900 2250
M33 1850 2600 3000
M36 2350 3300 3900
M39 3000 4300 5100

Metric ISO-Fine thread

Size 8.8 10.9 12.9
M8x1 24 36 43
M9x1 36 53 62
M 10 x 1 52 76 89
M 10 x 1.25 49 72 84
M 12 x 1.25 87 125 150
M 12 x 1.5 83 120 145
M 14 x 1.5 135 200 235
M 16 x 1.5 205 300 360
M 18 x 1.5 310 440 520
M 18 x 2 290 420 490
M 20 x 1.5 430 620 720
M 22 x 1.5 580 820 960
M 24 x 1.5 760 1100 1250
M 24 x 2 730 1050 1200
M 27 x 1.5 1100 1600 1850
M 27 x 2 1050 1500 1800
M 30 x 1.5 1550 2200 2550
M 30 x 2 1500 2100 2500
M33 x 1.5 2050 2900 3400
M 33 x 2 2000 2800 3300
M 36 x 1.5 2700 3800 4450
M 36 x 3 2500 3500 4100
M 39 x 1.5 3450 4900 5700
M 39 x 3 3200 4600 5300

Power Shift Transmission 5 Disassembly & Assembly

LIST OF SPECIAL TOOLS FOR DIS- AND REASSEMBLY
ERGOPOWER 3 WG 116 / 161

Disassembly Reassembly
Designation and Application Part Number
Chapter/Fig. Chapter/Fig.

Assembly truck cpl. # with tilting device 5870 350 000

1.1
Holding fixture # 5870 350 124
2.1
For mounting and swivelling of the cpl. transmission on the
3.1
assembly truck.

Strap wrench 5870 105 005

1.2 Universal use.
To loosen the filter cartridge from the filter head .

Socket spanner # TX-40 / 1/2“ 5873 042 004

Universal use.
1.3 1.26 To loosen and to tighten the TORX – Screws M8 on the
filter head .
Also see : Torque spanner 5870 203 034

Socket spanner TX-27 / 1/2“ 5873 042 002

1.4 / 1.5
1.7 / 1.9 Universal use.
1.7 / 1.8
1.10 / 1.13 To loosen and to tighten the TORX – Screws(M5, M6)
1.10 / 1.11
1.16 on the control system HSG-94 .
1.12 / 1.14
Also see : Torque spanner 5870 203 031

Adjusting screws # M6 5870 204 063

1.4 1.18 Universal use.
1.5 1.24 As dis- and reassembly aid to remove and to install shift
components.

Adjusting screws # M5 5870 204 036

1.13 1.7
As dis- and reassembly aid to remove and to install the
1.14 1.12
housings on the valve block of the control system HSG-94.

1.7 Torque spanner # 1 – 12 Nm / ¼“ 5870 203 031

1.9 Universal use.
1.10 To tighten the bolted connection on the control unit.
1.16 To be used in combination with :
1.25 Reducer # ½“ in ¼“ 5870 656 056

Power Shift Transmission 6 Disassembly & Assembly

LIST OF SPECIAL TOOLS FOR DIS- AND REASSEMBLY
ERGOPOWER 3 WG 116 / 161

Disassembly Reassembly
Designation and Application Part Number
Chapter/Fig. Chapter/Fig.

Drive mandrel # 5870 705 012

1.23 To insert the pressure relief valve and the indented ring
into the transmission housing.

Torque spanner # 10 – 90 Nm / ½“ 5870 203 034

1.26 Universal use.
To tighten the bolted connections M8 on the filter head.

Eyebolts assortment 5870 204 002

3.2 6.5 Lifting chain 3-strand 5870 281 047
3.3 6.20 Universal use.
3.13 6.28 Dis- and reassembly aid to remove and install transmission
components.

Hammer 60 mm 5870 280 004

Universal use.
3.4
For cautious dis- and reassembly of sensitive
components .

Two-armed puller 5870 970 003

3.8 Universal use.
To pull off or separate transmission components.

3.9 Set of internal pliers # I1 –I2 – I3 – I4 5870 900 013

5.4
4.7 Universal use.
5.18
4.16 To snap in and unsnap externally clamped
5.35
4.24 retaining rings.

Lifting chain 3-strand

Eyebolt M20 / 2 pcs. 5870 281 047
6.10
3.11 Ring nut M12 0636 804 003
Universal use. 0664 462 774
To separate and to lift off the housing halves.

Handle
3.13 6.2 To lift out and in the cpl. clutch K1 – K2 - KR and KV 5870 260 014
from the transmission housing .

Power Shift Transmission 7 Disassembly & Assembly

LIST OF SPECIAL TOOLS FOR DIS- AND REASSEMBLY
ERGOPOWER 3 WG 116 / 161

Disassembly Reassembly
Designation and Application Part Number
Chapter/Fig. Chapter/Fig.

Gripping insert # OR 5873 001 057

4.3 / 4.10
Rapid grip # 5873 011 011
4.12 / 4.21
To pull off the taper roller bearing
4.23 / 4.29
from the clutch shaft KV / KR / K1 / K2 / K3 .
4.31 / 4.37
Used with :
4.39
Back-off insert # 580 026 100

Gripping insert # OR 5873 001 058

4.44
Rapid grip # 5873 011 014
4.46
To pull off the taper roller bearing
4.47
from the clutch shaft K3 and the input shaft
Used with :
Back-off insert # 580 026 100

4.4
Two-armed puller 5870 970 003
4.13
Universal use.
4.35
To pull off the clutch from the shaft KV .
4.42

5.6 / 5.16 Set of external pliers A1 – A2 – A3- A4 5870 900 015

4.5 / 4.14
5.20 / 5.35 Universal use.
4.18 / 4.32
5.47 To snap in and unsnap externally clamped retaining rings.

4.6 Parting tool # 5870 300 028

4.15 To separate the idler from the shaft KV + KR .

Gripping insert # 5873 001 058

To pull off the taper roller bearing
4.46
from the input shaft .
4.47
Used with :
Back-off insert # 580 026 100

5.7 Hot-air blower # 230 V 5870 221 500

5.14 Hot-air blower # 115 V 5870 221 501
5.21 Universal use.
5.29 To heat up housing and transmission components.

Power Shift Transmission 8 Disassembly & Assembly

LIST OF SPECIAL TOOLS FOR DIS- AND REASSEMBLY
ERGOPOWER 3 WG 116 / 161

Disassembly Reassembly
Designation and Application Part Number
Chapter/Fig. Chapter/Fig.

Lever riveting tongs # 5870 320 016

5.62 Universal use.
To install the screw plug in the shaft K3.

Mounting tool # 5870 048 057

6.12 To insert the shaft seal 70 x 100 x 10
into the transmission housing. Output.

Mounting tool # 5870 057 011

To press the tab washer on the bolted connection output
6.13 flange .
Only to be used in combination with :
Handle # 5870 260 002

Adjusting screw # 5870 204 007

6.17
To align and to position the stator shaft on the transmission
6.19
housing.

Drive mandrel # 5870 705 012

6.18 To install the converter – safety valve the pressure relief
valve and the toothed ring into the transmission housing.

Mounting tool # 5870 055 070

To install the shaft seal 75 x 95 x 10 into the pump
6.23 housing.
Only to be used in combination with :
Handle # 5870 260 002

Power Shift Transmission 9 Disassembly & Assembly

3 WG 116 / 161
ENGINE CONNECT

Power Shift Transmission

ENGINE CONNECT

10
5870 204 002 5870 281 047 5870 204 007 5870 280 004

Disassembly & Assembly

3 WG 116 / 161
INPUT

INPUT

Power Shift Transmission

11
ODER / OR

5870 204 002 5870 281 047 5870 204 007 5873 011 014 5873 001 058 5870 026 100 5870 280 004

Disassembly & Assembly

3 WG 116 / 161
POWER TAKE OFF

Power Shift Transmission

POWER TAKE OFF

12
ODER / OR

5873 011 014 5873 001 058 5870 026 100 5870 900 013 5870 280 004

Disassembly & Assembly

3 WG 116 / 161
FILTER

FILTER

Power Shift Transmission

23Nm

13
10-90Nm
5873 042 004 5870 203 034 5870 105 005

3 WG 116 / 161
GEARSHIFT SYS.
GEARSHIFT SYS.

Power Shift Transmission

9.5Nm

20
1/2" 1/2"-1/4" 1-12 Nm M6 M6 1/2"-1/4" 1-12 Nm
5873 042 002 5870 656 056 5870 203 031 5870 204 063 5870 204 063 5873 042 002 5870 656 056 5870 203 031

Disassembly & Assembly

3 WG 116 / 161
GEARSHIFT SYS.
GEARSHIFT SYS.

Power Shift Transmission

21
5.5Nm

5.5Nm

1/2" 1/2"-1/4" 1-12Nm M5 M6

5873 042 002 5870 656 056 5870 203 031 5870 204 036 5870 204 063

Disassembly & Assembly

1. DISASSEMBLY
Electro-Hydraulic Control
And Micro Filter (Exchange Filter)

Mount the transmission to the assembly truck.

(S) Assembly truck 5870 350 000

(S) Holding fixture 5870 350 124

Prior to start the disassembly, drain the oil!

Figure 1

1.1 Removal of the Filter

By means of the strap wrench separate the Micro

Filter (1) from the filter head.

(S) Strap wrench 5870 105 005

Figure 2

Loosen the cap screws (2) and separate the filter

head (1) from the transmission housing.

Remove the O-rings

(S) Socket spanner 5873 042 004

Figure 3

Power Shift Transmission 22 Disassembly & Assembly

1.2 Removal of the Electric Shift System

2 Remove the shift system (1).

Loosen the Torx screws (2) and separate the gearshift

housing from the intermediate sheet.

(S) Socket spanner TX-27 5873 042 002

(S) Adjusting screws M6 5870 204 063
Figure 4

Remove the complete shift system (1) and the

intermediate sheet (2).
S

2
(S) Adjusting screws M6 5870 204 063

Figure 5

Mark the installation position of the cover (1) to the

2
1 valve block (2).

Figure 6

Loosen the Torx screws (1).

(S) Socket spanner TX-27 5873 042 002

Figure 7

Power Shift Transmission 23 Disassembly & Assembly

Separate the duct plate (3), and intermediate sheet (2)
from the valve block (1).

2
3

Figure 8

Remove the retaining clamp (1).

Figure 9

Loosen the cap screws (1) and remove the cover.

1 Remove the opposite cover.

(S) Socket spanner TX-27 5873 042 002

Figure 10

Remove the wiring harness (1).

2
Loosen the cap screws (3), remove the fixing plates
and the pressure regulators (1).

(S) Socket spanner TX-27 5873 042 002

Figure 11 3

Power Shift Transmission 24 Disassembly & Assembly

Loosen the cap screws, remove the fixing plates and
1 the pressure regulators (1).

(S) Socket spanner TX-27 5873 042 002

Figure 12

Loosen two cap screws (1) and fasten the adjusting

S
1 screws (S) preliminarily (housing is spring-loaded).
Following to this loosen the remaining cap screws.
S

(S) Adjusting screws 5870 204 036

(S) Socket spanner 5873 042 002

Figure 13

Separate the housing from the valve housing by

loosening the adjusting screws equally.

(S) Adjusting screws 5870 204 036

Figure 14

Remove the single parts:

1 = Pressure reducing valve

3 2 = Vibration damper
3 = Follow-on slide

2
1
Figure 15

Power Shift Transmission 25 Disassembly & Assembly

Remove the single parts on the opposite side
analogously:

1 = Main pressure valve

1 2 = Vibration damper
3 = Follow-on slide

2
Figure 16 3

Power Shift Transmission 26 Disassembly & Assembly

2. DISASSEMBLY
Inductive transmitters, Valves, Oil Filler and
Oil Drain Plug, Screw Plugs

Mount the transmission to the assembly truck.

(S) Assembly truck 5870 350 000

(S) Holding fixture 5870 350 124

Figure 1

Remove the converter pressure back-up valve (1) and

3
differential pressure switch (3) for the Micro Filter (2).

) Do not remove the pressure relief valve.

Figure 2

Remove the positioned parts.

1 1 = Breather
5 2 = Inductive transmitter - n engine
2
3 = Screw plug (measuring point after converter)
3 4 = Screw plug (option for temperature sensor)
6
5 = Fixing strap Oil filler tube
4 6 = Oil filler tube with oil dipstick)
7 = Screw plug (oil drain bore))
Figure 3 7

Remove the positioned parts.

1 = Inductive transmitter n – Internal speed input

2 = Inductive transmitter n – Turbine
3 = Speed transmitter n – Output
3
1 4 = Cover (mounting possibility for oil filler tube)

2
4
Figure 4

Power Shift Transmission 27 Disassembly & Assembly

3. DISASSEMBLY
2 Engine Connection, Pressure Oil Pump and
1 Removal of the Clutches

Mount the transmission to the assembly truck.

3
(S) Assembly truck 5870 350 000
(S) Holding fixture 5870 350 124

Loosen the hexagon screw (2) and separate the

Figure 1 flexplate (1) from the converter (3).

By means of the lifting equipment separate the

converter (1) from the transmission. Loosen the
1 bolted connection (4) and (5).
4
3 5 1 = Converter
2 = Converter bell
6 3 = Pressure oil pump
4 = Bolted connection Converter bell/Transm.
2 hsg rear section
Figure 2 5 = Bolted connect. Pressure oil pump/Transm.
hsg rear section
6 = Transmission housing rear section

(S) Eyebolts assortment 5870 204 002

(S) Lifting chain 5870 281 047

By means of the lifting equipment the converter bell (1)

5
with pressure oil pump (5) are commonly to be
separated from the transmission housing rear section
(4).

1
Remove the intermediate sheet (3) and the stator
3 hollow shaft (2).
4
2

Figure 3
(S) Eyebolts assortment 5870 204 002
(S) Lifting chain 5870 281 047

Power Shift Transmission 28 Disassembly & Assembly

Separate the pressure oil pump (1) from the converter
bell.
1

) (S) Hammer 5870 280 004

Figure 4

Loosen both cap screws and remove the cam disc.

) If running-in marks should be found in the pump

housing or on the cam disc, the complete pump
has to be replaced!

Figure 5

Squeeze out the snap ring (1) and remove the single
parts.
5
3
1 = Pump housing with rotor
2 = Snap ring
3 = Shaft seal
1 4 = Support shim
6 5 = Needle bearing
4
2 6 = Ring
Figure 6

Remove the tab washer (2) and loosen the hexagon

1 screws (1).
2

Figure 7

Power Shift Transmission 29 Disassembly & Assembly

Pull off the input shaft (1).
S
1

S Remove the shaft seal.

(S) Two-armed puller 5870 970 003

Figure 8

Unsnap the retaining ring (1) from the power take-off

and remove the O-ring (2).
1
2
(S) Set of internal pliers 5870 900 013

Figure 9

Pull the pump shaft (1) out of the housing bore.

2
3 Unsnap the rectangular ring (2).
1

Press off the ball bearing (3) from the shaft.

5
4
Expel both cyl. pins (5) (see Figure 12).

Loosen the bolted connection (4) Transmission housing

Figure 10 rear section/ Transmission housing front section.

1
By means of the lifting equipment separate the
transmission housing rear section (1) from the
transmission housing front section (2).

(S) Eyebolts 2x (M20) 0636 804 003

(S) Ring nut (M12) 0664 462 774
2
(S) Lifting chain 5870 281 047
Figure 11

Power Shift Transmission 30 Disassembly & Assembly

Loosen the cap screws (2) and remove the suction tube
3 (1). Remove the O-ring from the suction tube.

4 Loosen the cap screws (6) and remove the screen

1 sheet (5).

5 Remove the pipes (4) with O-rings.

2 6

Figure 12 3
) Cyl. pins (3) see Figure 10.

6
The clutch is to be removed from the transmission
S housing according to the sequence of numbers as
5 S
described in the legend.

1 = Clutch K3
2 = Clutch K1
3 = Clutch K2
4
4 = Clutch KR
5 = Clutch KV
2
Figure 13
3 1 6 = Input shaft

) (S) Handle
(S) Eyebolt
5870 260 014
5870 204 002
(K1/K2/KV/KR)
(K3)

Loosen the cap screws (1) and remove the screen

sheet (2).

Figure 14

Remove the pipes (system pressure from the electro-

3 4 hydraulic control to the respective clutch).
6

Remove the holding segment (6).

The pipes are to disassembled in the following

sequence:
5
1
2
1 = Pipe K3
Figure 15 2 = Pipe K1
3 = Pipe K2
4 = Pipe KR
5 = Pipe KV
4 = Pipe KR
5 = Pipe KV

Power Shift Transmission 31 Disassembly & Assembly

Remove all bearing outer rings (see arrows).

) Should contrary to the Recommendations the taper

roller bearings of the clutches as well as of the
input not be replaced, the assignment (bearing
inner and outer ring) has to be kept at least!
Mark the bearing inner and bearing outer rings to
each other accordingly!

Figure 16

Power Shift Transmission 32 Disassembly & Assembly

AN K2
4. DISASSEMBLY
Clutches KV/KR/K1/K2/K3 and Input
KV

See figure on the left.

KR
K3

Figure 1

4.1 Clutch KV
1

Remove the stud (1) and unsnap the piston ring (2).
2

Figure 2

Pull the taper roller bearing (inner ring) from the shaft.

(S) Gripping insert 5873 001 057

S
(S) Back-off insert 5870 026 100
or
(S) Rapid grip 5873 001 011

Figure 3

Pull the clutch (1) from the shaft.

(S) Two-armed puller 5870 970 003

Figure 4

Power Shift Transmission 33 Disassembly & Assembly

Unsnap the retaining ring (1).

1
(S) Set of external pliers 5870 900 015

Figure 5

Press the clutch shaft (1) out of the idler (2).

S
(S) Parting tool 5870 300 028
2

Figure 6

Unsnap the retaining ring (2) from the idler (1) and
remove the ball bearing (3).
2
3 (S) Set of internal pliers 5870 900 013

Figure 7

Remove the needle cage (1) from the shaft (2).

Figure 8

Power Shift Transmission 34 Disassembly & Assembly

Rotate the shaft (2) by 180° and unsnap the piston ring
(1).
1

Figure 9

Pull the taper roller bearing (inner ring) from the shaft.

(S) Gripping insert 5873 001 057

S (S) Back-off insert 5870 026 100
or
(S) Rapid grip 5873 011 011

Figure 10

4.2 Clutch KR
1

2
Remove the stud (1) and unsnap the piston ring (2).

Figure 11

Pull the taper roller bearing (inner ring) (2) from the
shaft.

S (S) Gripping insert 5873 001 057

(S) Bush 5870 026 016

Figure12

Power Shift Transmission 35 Disassembly & Assembly

Pull the clutch (1) from the shaft.

(S) Two-armed puller 5870 970 003

Figure 13

Unsnap the retaining ring (1).

1 (S) Set of external pliers 5870 900 015

Figure 14

Press the clutch shaft (1) out of the idler (2).

(S) Parting tool 5870 300 028

2 S

Figure 15

Disassemble the idler (1).

Figure 16

Power Shift Transmission 36 Disassembly & Assembly

Unsnap the retaining ring (2) from the idler (1) and
2
remove the ball bearing.

(S) Set of internal pliers 5870 900 013

Figure 17

Remove the needle cage (1) from the shaft (2).

Figure 18

Shaft (2) and gear (1) cannot be separated (shrink fit).

Figure 19

Rotate the shaft (2) by 180° and unsnap the piston ring
(1).
1

Figure 20

Power Shift Transmission 37 Disassembly & Assembly

Pull the taper roller bearing (inner ring) from the shaft.
S

(S) Gripping insert 5873 001 057

(S) Back-off insert 5870 026 100
or
(S) Rapid grip 5873 011 011

Figure 21

4.3 Clutch K1
1

2 Remove the stud (1) and unsnap the piston ring (2).

Figure 22

Pull the taper roller bearing (inner ring) from the shaft.
S

(S) Gripping insert 5873 001 057

(S) Back-off insert 5870 026 100
or
(S) Rapid grip 5873 011 011

Figure 23

Unsnap the retaining ring (1).

1
(S) Set of internal pliers 5870 900 013

Figure 24

Power Shift Transmission 38 Disassembly & Assembly

Remove the complete axial bearing (1).

Figure 25

Take off the idler (1), remove the needle cage (2) and
the complete axial bearing (3).

Figure 26

Pull the clutch (1) from the shaft.

(S) Two-armed puller 5870 970 003

Figure 27

Rotate the shaft (2) by 180° and unsnap the piston ring
(1).
1

Figure 28

Power Shift Transmission 39 Disassembly & Assembly

Pull the taper roller bearing (inner ring) from the shaft.

S
(S) Gripping insert 5873 001 057
(S) Back-off insert 5870 026 100
or
(S) Rapid grip 5873 011 011

Figure 29

4.4 Clutch K2
1

2 Remove the stud (1) and unsnap the piston ring (2).

Figure 30

Pull the taper roller bearing (inner ring) from the shaft.

(S) Gripping insert 5873 001 057

S
(S) Back-off insert 5870 026 100
or
(S) Rapid grip 5873 011 011

Figure 31

Unsnap the retaining ring (1).

1 (S) Set of external pliers 5870 900 015

Figure 32

Power Shift Transmission 40 Disassembly & Assembly

Remove the complete axial bearing (1).

Figure 33

Take off the idler (1), remove the needle cage (2) and
the complete axial bearing (3).

Figure 34

Pull the clutch (1) from the shaft.

(S) Two-armed puller 5870 970 003

Figure 35

Rotate the shaft (2) by 180° and unsnap the piston ring
(1).
1

Figure 36

Power Shift Transmission 41 Disassembly & Assembly

Pull the taper roller bearing (inner ring) from the shaft.

(S) Gripping insert 5873 001 057

S (S) Back-off insert 5870 026 100
or
(S) Rapid grip 5873 011 011

Figure 37

4.5 Clutch K3

1 Unsnap the piston ring (1).

Figure 38

Pull the taper roller bearing (inner ring) from the shaft.

(S) Gripping insert 5873 001 057

S
(S) Back-off insert 5870 026 100
or
(S) Rapid grip 5873 011 011

Figure 39

Remove the complete axial bearing (1).

Figure 40

Power Shift Transmission 42 Disassembly & Assembly

Take off the idler (1), remove the needle cage (2) and
the complete axial bearing (3).
1

Figure 41

Pull the clutch (1) from the shaft.

(S) Two-armed puller 5870 970 003

Figure 42

Rotate the shaft (2) by 180° and unsnap the piston

rings (1).
1

2
Figure 43

Pull the taper roller bearing (inner ring) from the shaft.

(S) Gripping insert 5873 001 058

S (S) Back-off insert 5870 026 100
or
(S) Rapid grip 5873 011 014

Figure 44

Power Shift Transmission 43 Disassembly & Assembly

4.6 Input

2 Unsnap the piston ring (1).

The turbine wheel shaft (2) and the input gear (3) are
1
attached with a snap ring.

)
3
The components are destroyed at the separation !!
Figure 45

Pull the taper roller bearing (inner ring) from the input
gear.

(S) Gripping insert 5873 001 058

S
(S) Back-off insert 5870 026 100
or
(S) Rapid grip 5873 011 014

Figure 46

Pull the taper roller bearing (inner ring) from the input
gear.

S
(S) Gripping insert 5873 001 058
(S) Back-off insert 5870 026 100
or
(S) Rapid grip 5873 011 011

Figure 47

Power Shift Transmission 44 Disassembly & Assembly

5. REASSEMBLY
Clutches KV/KR/K1/K2/K3 and Input

) In the EST-37A (electronic transmission control) the gear changes ( filling times and
pressure level) are controlled via the drive program of the transmission electronics.
Additionally, the EST-37A monitors the disc clearance (clearance) of the clutches and if
exceeded, a fault message is given in the Display.

To ensure the shifting quality continuously, no repairs are allowed to be made on the
clutches KV/KR/K1/K2/K3 (see Figure), which means that only the complete clutch is
allowed to be replaced.

5.1 Clutch KV
1

Press the taper roller bearing (inner ring) (1) onto the
shaft (2) until contact is obtained.

Figure 1

Install the piston ring (1).

Figure 2

Mount the needle bearing (1) onto the shaft.

Figure 3

Power Shift Transmission 45 Disassembly & Assembly

Put the ball bearing (2) into the idler (1) until contact is
obtained and fasten it by means of retaining ring (3).
3
(S) Set of internal pliers

Figure 4

Press in the preassembled idler (1) until contact.

Figure 5

Fasten the idler (1) by means of retaining ring (2).

2
(S) Set of external pliers 5870 900 015

Figure 6

Heat up the inner diameter of the clutch (1)

(approx. 120° C).
S

(S) Hot-air blower 220 V 5870 221 500

(S) Hot-air blower 110 V 5870 221 501

Figure 7

Power Shift Transmission 46 Disassembly & Assembly

Mount the clutch (1) until contact is obtained.

Wear safety gloves!

Figure 8

Press the taper roller bearing (inner ring) (1) until

1 contact is obtained.

Figure 9

Install the piston ring (1)

Figure 10

Install the stud (1).

2 1

Tightening torque ................................ MA = 17 Nm

Check closing resp. opening of the clutch by means

of compressed air at the bore (2).
Closing resp. opening of the clutch must be clearly
audible.
Figure 11

Power Shift Transmission 47 Disassembly & Assembly

5.2 Clutch KR
1

Press the taper roller bearing (inner ring) (1) onto the
shaft (2) until contact is obtained.

Figure 12

Install the piston ring (1).

Figure 13

Heat up the inner diameter of the gear (1) (approx.

120° C) .

(S) Hot-air blower 220 V 5870 221 500

1 (S) Hot-air blower 110 V 5870 221 501

Figure 14 Wear safety gloves!

Undercool the shaft (2) ( approx. 80° C).

C hamfer
Mount the gear until contact is obtained.
1

Install the chamfer of the gear (see arrow) showing

upwards!
2
Observe the radial installation position!

Figure 15
Wear safety gloves!

Power Shift Transmission 48 Disassembly & Assembly

Fasten the gear (1) by means of retaining ring (2).

(S) Set of internal pliers 5870 900 015

Figure 16

Mount the needle bearing (1) onto the shaft (2).

Figure 17

Put the ball bearing (2) into the idler (1) until contact is
obtained and fasten it by means of retaining ring (3).
3

2 (S) Set of internal pliers 5870 900 013

Figure 18

Press in the preassembled idler (1) until contact.

Figure 19

Power Shift Transmission 49 Disassembly & Assembly

Fasten the idler (1) by means of retaining ring (2).
2
(S) Set of external pliers 5870 900 015

Figure 20

Heat up the inner diameter of the clutch (1) (approx.

120° C).
S
(S) Hot-air blower 220 V 5870 221 500
(S) Hot-air blower 110 V 5870 221 501

Figure 21

Mount the clutch (1) and press it until contact is

obtained.

Wear safety gloves!

Figure 22

Press the taper roller bearing (inner ring) (1) until

1
contact is obtained.

Figure 23

Power Shift Transmission 50 Disassembly & Assembly

Install the piston ring (1).
1

Figure 24

Install the stud (1).

2
1
Tightening torque ................................... MA = 17 Nm

Check closing resp. opening of the clutch by means

of compressed air at the bore (2).
Closing resp. opening of the clutch must be clearly
audible.
Figure 25

5.3 Clutch K1
1
Press the taper roller bearing (inner ring) (1) onto the
shaft until contact.

Figure 26

Install the piston ring (1).

Figure 27

Power Shift Transmission 51 Disassembly & Assembly

Install the sealing cap (1)
2

) Wet the contact surface with (Loctite Type No. 262) !

Figure 28

Heat up the inner diameter of the clutch (1) (approx.

120° C).
S
(S) Hot-air blower 220 V 5870 221 500
(S) Hot-air blower 110 V 5870 221 501

Figure 29

Mount the clutch (1) until contact is obtained.

1
Wear safety gloves!

Figure 30

Mount the running disc (1), axial cage (2) and axial
Chamfer
3
washer (3).
2
1

) Install chamfer (see arrow) of the running disc (2)

showing towards the axial cage!

Figure 31

Power Shift Transmission 52 Disassembly & Assembly

Mount the needle cage (1).
1

Figure 32

Install the idler (1).

Figure 33

Mount the axial washer (1), axial cage (2) and running
Chamfer
2
disc (3).

3
1
) Install chamfer (see arrow) of the running disc (3)
showing towards the axial cage!

Figure 34

Fasten the idler (1) and the single parts by means of

the retaining ring (2).
2

(S) Set of external pliers 5870 900 015

Figure 35

Power Shift Transmission 53 Disassembly & Assembly

Press the taper roller bearing (inner ring) (1) until
1 contact is obtained.

Figure 36

Install the piston ring (1).

Figure 37

Install the stud (1).

1
Tightening torque ..................................... MA = 17 Nm
2

Check closing resp. opening of the clutch by means

of compressed air at the bore (2).
Closing resp. opening of the clutch must be clearly
audible.

Figure 38

5.4 Clutch K2
1
Press the taper roller bearing (inner ring) (1) onto the
shaft until contact.

Figure 39

Power Shift Transmission 54 Disassembly & Assembly

Install the piston ring (1).
1

Figure 40

Heat up the inner diameter of the clutch (1) (approx.

120° C).
S

(S) Hot-air blower 220 V 5870 221 500

(S) Hot-air blower 110 V 5870 221 501

Figure 41

Mount the clutch (1) until contact is obtained.

Wear safety gloves!

Figure 42

Mount the running disc (1), axial cage (2) and axial
washer (3).
Chamfer
3

)
2
1 Install chamfer (see arrow) of the running disc (1)
showing towards the axial cage!

Figure 43

Power Shift Transmission 55 Disassembly & Assembly

Mount the needle cage (1).

Figure 44

Install the idler (1).

Figure 45

Mount the axial washer (1), axial cage (2) and running
Chamfer
disc (3).
2

)
1
Install chamfer (see arrow) of the running disc (3)
showing towards the axial cage!

Figure 46

Fasten the idler (1) and the single parts by means of

2 the retaining ring (2).

1 (S) Set of external pliers 5870 900 015

Figure 47

Power Shift Transmission 56 Disassembly & Assembly

Press the taper roller bearing (inner ring) (1) until
1
contact is obtained.

Figure 48

Install the piston ring (1).

Figure 49

Install the stud (1).

2
1 Tightening torque .....................................MA = 17 Nm

Check closing resp. opening of the clutch by means

of compressed air at the bore (2).
Closing resp. opening of the clutch must be clearly
audible.
Figure50

5.5 Clutch K3

1 Press the taper roller bearing (inner ring) (1) onto the
shaft until contact.

Figure 51

Power Shift Transmission 57 Disassembly & Assembly

Install the piston ring (1).

Figure 52

Install the sealing cap (1)

Wet the contact surface with (Loctite Type No. 262) !

Figure 53

Heat up the inner diameter of the clutch (1) (approx.

120° C).
S
(S) Hot-air blower 220 V 5870 221 500
(S) Hot-air blower 110 V 5870 221 501

Figure 54

Mount the clutch (1) until contact is obtained.

1
Wear safety gloves!

Figure 55

Power Shift Transmission 58 Disassembly & Assembly

Mount the running disc (1), axial cage (2) and axial
washer (3).
Chamfer 3

)
1
Install chamfer (see arrow) of the running disc (3)
showing towards the axial cage!

Figure 56

Mount the needle cage (1).

Figure 57

Install the idler (1).

Figure 58

Chamfer
Mount the axial washer (1), axial cage (2) and running
3 disc (3).

1 2

) Install chamfer (see arrow) of the running disc (3)

showing towards the axial cage!

Figure 59

Power Shift Transmission 59 Disassembly & Assembly

Press the taper roller bearing (inner ring) (1) until
contact is obtained.

Figure 60

Install the piston ring (1).

Figure 61

Install the screw plug (1).

1
(S) Lever riveting tongs 5870 320 016

Figure 62

) Check closing resp. opening of the clutch by means

of compressed air at the bore (1).
1 Closing resp. opening of the clutch must be clearly
audible.

Figure 63

Power Shift Transmission 60 Disassembly & Assembly

5.6 Input

1 Press the taper roller bearing (inner ring) (1) until

contact is obtained.

Figure 64

Press the taper roller bearing (inner ring) (1) until

contact is obtained.

Figure 65

Have the snap ring (1) engaged into the annular groove
of the turbine wheel shaft (2).

Figure 66

Mount the turbine wheel shaft until the snap ring

engages into the recess of the input gear – turbine
wheel shaft is axially fixed!

Figure 67

Power Shift Transmission 61 Disassembly & Assembly

6. REASSEMBLY
Engine Connection, Pressure Oil Pump and
Installation of the Clutches

Install all bearing outer rings into the bearing bores of

both transmission housing sections.

) Should contrary to the Recommendations the taper

Transmission housing front section

KV AN
AN = Input
KR K2 KV = Clutch - Forward
KR = Clutch - Reverse
K1 K3 K1 = Clutch - 1st gear
K2 = Clutch - 2nd gear
K3 = Clutch - 3rd gear
Figure 1

Transmission housing rear section

AN
KR
) Put the bearing outer rings with assembly grease into
the bearing bores.
K2
K1
K3

Figure 2

Install the pipes (system pressure from the electro-

hydraulic control to the respective clutch)
The pipes are to be installed in the following sequence:

2
6 1 = Pipe KV
3
2 = Pipe KR
3 = Pipe K2
4 = Pipe K1
5 = Pipe K3
1
5
Tightening torque ..................................... MA = 42 Nm
4

Figure 3 Install the holding segment (6).

Tightening torque (M8/8.8) .................... MA = 23 Nm

Power Shift Transmission 62 Disassembly & Assembly

Fasten the screen sheet (1) by means of cap screws
(2).

Tightening torque (M8/8.8) ................... MA = 23 Nm

2
Figure 4

The clutch is to be put into the transmission housing

1
S S front section as described in the legend.

1 = Input shaft
2
2 = Clutch KV
3 = Clutch KR
3 4 = Clutch K2
5 = Clutch K1
5 6 = Clutch K3
6
Figure 5 4

(S) Handle 5870 260 010 (K1/K2/KV/KR)

(S) Eyebolt 5870 204 002 (K3)

Put the pipes and O-rings into the bores and grease
1
them.

Figure 6

Fasten the screen sheet (1) by means of cap screws

2 (2).
1

Tightening torque (M6/8.8) .................. MA = 9.5 Nm

Figure7

Power Shift Transmission 63 Disassembly & Assembly

Install the O-ring (3) and fasten the suction pipe (1) by
2 2
1
means of cap screws (2).

3
Tightening torque (M8/8) ...................... MA = 23 Nm

Figure 8

Grease the rectangular rings (see arrows) and align

them centrically.

Wet the mounting face with sealing compound Loctite

(Type No. 574)

Figure 9

Cautiously place the transmission housing rear section

(1) by means of the lifting equipment to the
transmission housing front section (2) until contact is
obtained.

1
(S) Eyebolts 2x (M20) 0636 804 003
2 (S) Ring nut (M12) 0664 462 774
(S) Lifting chain 5870 281 047
Figure 10

Install both cyl. pins (1) centrally to the mounting face.

1
1 3
2 By means of cap screws (2 and 3) fasten the
transmission housing rear section to the transmission
housing front section.

Cap screws with different lengths.

Figure 11 Tightening torque (M8/8) ....................... MA = 46 Nm

Power Shift Transmission 64 Disassembly & Assembly

Install the shaft seal (1) with the sealing lip showing to
the oil sump.
1

) The exact installation position is obtained by using the

specified mounting tool (S)!

Figure 12
) Fill the shaft seal between dust lip and sealing lip with
grease.

Wet the outer diameter with spirit.

) (S) Mounting tool 5870 048 057

Insert the input flange (1) until contact and put in the O-
S
ring. Fix the input flange (1) by means of washer (2)
1
3 and hexagon screws (3).
4

2 Then fix the hexagon screws (3) with the tab washer (4)
by means of the mounting tool (S).

Tightening torque (M8/10.9) ...................... MA = 34 Nm

Figure 13

(S) Mounting tool 5870 057 011

(S) Handle 5870 260 002

Press the ball bearing (1) onto the pump shaft (2) until
1
contact is obtained.

2
Figure 14

Install the pump shaft (1) until contact is obtained.

Figure 15

Power Shift Transmission 65 Disassembly & Assembly

Install the retaining ring (1) and the O-ring (2).
1 2

) Grease the O-ring

Figure 16

Install two adjusting screws and mount the stator

1 hollow shaft (1).

) Observe the radial installation position!

(S) Adjusting screws 5870 204 007

Figure 17

Install the converter safety valve (1) until contact.

(S) Drive mandrel 5870 705 012

Figure18

Install two adjusting screws and mount the intermediate

sheet (1).

)
1
The intermediate sheet has always to be replaced!

(S) Adjusting screws 5870 204 007

Figure 19

Power Shift Transmission 66 Disassembly & Assembly

Cautiously place the converter bell (1) by means of the
lifting equipment to the transmission until contact is
obtained.

(S) Eyebolts assortment 5870 204 002

1
(S) Lifting chain 5870 281 047

Figure 20

Pressure oil pump:

6
) If running-in marks should be found in the pump
housing or on the cam disc, the complete pump
4
5 1 has to be replaced!
3

)
2
Items 1 - 6 are allowed to be replaced!

1 = Pump housing with rotor

2 = Snap ring
3 = Shaft seal
Figure 21
4 = Support shim
5 = Needle bearing cpl. (bearing outer ring and
needle bearing)
6 = Ring

Install the following parts into the pump housing (1).

4
5B 6 = Ring
5A = Bearing outer ring
6 5A 5B = Needle cage
4 = Support shim

Figure 22

Cautiously put the shaft seal (3) with the sealing lip
2
showing downwards into the pump housing (1) until
contact and fasten it by means of the snap spring (2).

) Wet the outer diameter of the shaft seal with spirit!

1 (S) Mounting tool 5870 055 070

(S) Handle 5870 260 002
Figure 23

Power Shift Transmission 67 Disassembly & Assembly

Installation of the external and internal rotor:

Install the external rotor.

Chamfer shows to the pump base (cannot be seen
in the picture) !

Install the internal rotor.

Figure 24 Gearing (arrow) shows downwards !!

Put on the cam disc and by means of two cap screws

(1) fasten it radially.

1
Do not tighten the cap screws – just turn them in
until contact is obtained and then make approx. ½
rotation back!
2
Observe the installation position of the cam disc,
see figure!
Figure 25

Put the O-ring (2) into the annular groove and oil

Mount the preassembled pressure oil pump (1) and

1 with the cap screws (3 pcs.) first place it equally until
contact is obtained.

Observe the radial installation position!

Then remove the cap screws again.

Figure 26

Fasten the converter bell, pressure oil pump and stator

hollow shaft together by means of cap screws.

2
Different bolted connections!
1
1 = Bolted connection converter bell/transmiss. hsg
rear section

Tightening torque (M10/8.8) .................. MA = 46 Nm

2 = Bolted connect. pressure oil pump/ stator hollow

Figure 27 shafttransmission housing rear section

Cap screws with O-rings!

Grease the O-rings!

Power Shift Transmission 68 Disassembly & Assembly

Mount the converter (1) by means of lifting equipment
until contact is obtained.

1 (S) Eyebolts assortment 5870 204 002

(S) Lifting chain 5870 281 047

Figure 28

Fasten the flexplate (1) by means of hexagon screws

1 (2).

3 2
Install washers between converter (3) and flexplate (1)
under the hexagon screws.

Lock the hexagon screws with Loctite (Type No. 262)!

Figure 29
Tightening torque (M12/10.9) ................ MA = 115 Nm

Power Shift Transmission 69 Disassembly & Assembly

7. REASSEMBLY
Inductive Transmitters, Valves, Oil Filler and
Oil Drain Plug, Screw Plugs

Install the converter pressure back-up valve.

1 1 = Piston
2 2 = Compression spring
3 = O-Ring (27x2)
4 = Screw plug (30x1.5)

)
3
4 Tightening torque ................................... MA = 100 Nm
Figure 1

Install the differential pressure switch for the pressure

filter.
1
3
1 = Compression spring
2 = Piston
3 = Tappet switch

Figure 2
) Tightening torque ................................. MA = 30 Nm

Installation of:
1
1 = Inductive transmitter - n Engine
2 = Screw plug M10x1 (measuring point pressure
after converter)
3 = Temperature transmitter M14x1.5 (measuring point
temperature after converter)

2
3 ) Tightening torque
Tightening torque
(1) .......................... MA = 30 Nm
(2) .......................... MA = 9.5 Nm
Figure 3 Tightening torque (3) .......................... MA = 25 Nm

Power Shift Transmission 70 Disassembly & Assembly

Installation of:
3 4 1 = Inductive transmitter - n Internal speed input
5
2 = Inductive transmitter - n Turbine
3 = Breather

Tightening torque (1 and 2) .................. MA = 30 Nm

Tightening torque (3) ............................ MA = 12 Nm

1
Fasten the coverplate (4) by means of hexagon screws
2
Figure 4 (5).

Tightening torque (M16/8.8)................. MA = 46 Nm

Installation of:
1 1 = Speed transmitter
2 = Cap screw
2
Tightening torque (2) (M8/8.8)............. MA = 23 Nm

3 = Install the coverplate (3) with gasket.

4 = Hexagon screw
4

Figure 5 3 Tightening torque (2) (M8/8.8)............. MA = 23 Nm

Fasten the oil filler tube (1) with O-ring (2) to the
transmission housing by means of the hexagon screws
6
4 (3).
7

Turn the oil dipstick (4) into the oil filler tube.
1

Tightening torque (M8/8.8).............. MA = 23 Nm

Install the oil drain plug (5) with the O-ring.

Tightening torque............................. MA = 140 Nm

Fasten the fixing plate (6) by means of cap screws (7).

2
5
3
Tightening torque (M10/8.8) ........... MA = 46 Nm
Figure 6

Power Shift Transmission 71 Disassembly & Assembly

8. REASSEMBLY
Electro-hydraulic control unit with proportional valves

The following sketches shows the sections of the electro-hydraulic control unit.

Figure 1

Section B-B Section A-A

Figure 2 Figure 3

Power Shift Transmission 72 Disassembly & Assembly

8.1 Mounting of the Electric Control Unit
1

)
1
All single parts are to be checked for damage and
replaced, if required!
Prior to installation check the mobile parts in the
housing for functionality! Pistons can be replaced
individually!
2
Oil the single parts prior to installation acc. to the
lubricants Specificoction!
Figure 4

Place the orifices (1) with the concave side showing

upwards, until contact!

) Installation position, see arrows!

The figure on the left shows the following single parts:

1 = Pressure reducing valve (1x, Piston a. compr.spring)

3
2 = Vibration damper (3x, Piston a. compr.spring)
3 = Follow-on slide (3x, Piston a. compr.spring)

1 2
Figure 5

Install the single parts acc. to Figure 5.

) Preload the compression springs of the follow-on

slides and fasten the pistons preliminarily by means
of cylindrical pins ∅ 5.0 mm (assembly aid), see
arrows (S)!

S
Figure 6

Install two adjusting screws.

1
Assemble flat gasket (1) and housing cover.
S
Then place the housing cover by means of adjusting
S
screws equally until contact.

(S) Adjusting screws 5870 204 036

Figure 7

Power Shift Transmission 73 Disassembly & Assembly

Preload the pistons with cap screws and remove the cyl.
pins (assembly aid) again.

Figure 8

Fasten the housing cover by means of cap screws (1).

) Tightening torque ................................ MA = 5.5 Nm

(S) Torque spanner 5870 203 031

(S) Reducer 5870 656 056
(S) Socket spanner TX-27 5873 042 002

Figure 9

Mount the pressure regulators (1) and fasten them by

1 3 means of fixing plates (2) and cap screws (3).

)
2
Install the fixing plate with the neck showing
downwards!
Observe radial installation position of the pressure
regulators, see Figure!

Tightening torque ............................... MA = 5.5 Nm

Figure 10
(S) Torque spanner 5870 203 031
(S) Reducer 5870 656 056
(S) Socket spanner TX-27 5873 042 002

Preassemble the opposite side

The figure on the left shows the following single parts:

1 1 = Main pressure valve (1x, Piston a. compr.spring)

2 = Vibration damper (3x, Piston a. compr.spring)
3 = Follow-on slide (3x, Piston a. compr.spring)

2
Figure 11 3

Power Shift Transmission 74 Disassembly & Assembly

Install the single parts acc. to Figure 11.

1
) Preload the compression springs of the follow-on
slides and fasten the pistons preliminarily by
means of cylindrical pins (S) ∅ 5.0 mm (assembly
aid), see arrows (S)!

Install two adjusting screws.

Figure 12 (S) Adjusting screws M5 5870 204 036

Assemble flat gasket (1) and housing cover. Then

place the housing cover by means of adjusting screws
equally until contact.

Preload the pistons with cap screws and remove the

1 cyl. pins (assembly aid) again.

Then fasten the housing cover by means of cap screws

(1).

Tightening torque .................................. MA = 5.5 Nm

Figure 13 (S) Adjusting screws 5870 204 036

(S) Torque spanner 5870 203 031
(S) Reducer 5870 656 056
(S) Socket spanner TX-27 5873 042 002

Mount the pressure regulators (1) and fasten them by

1
means of fixing plates and cap screws.

) Install the fixing plate with the neck showing

downwards!
Observe radial installation position of the pressure
regulators, see Figure!

Tightening torque .................................. MA = 5.5 Nm

Figure 14

Assemble the wiring harness (1) and connect the

pressure regulators (6x).

1
) See Figure 1 for installation position of pressure
regulators!

) Pay attention to the installation position of the wiring

harness!
Figure 15

Power Shift Transmission 75 Disassembly & Assembly

Put on the flat gasket (1).
1

Assemble the plug socket with the slot showing to the

lug of the cover until contact.

Fasten the cover by means of cap screws.

Tightening torque ................................ MA = 5.5 Nm

Figure 16 (S) Torque spanner 5870 203 031

(S) Socket spanner TX-27 5873 042 002

Fix the wiring harness by means of retaining clamp (1).

) Install the opposite cover.

Figure 17

Install two adjusting screws.

(S) Adjusting screws 5870 204 063

Figure 18

Screens (1) are to be flush mounted into the bores of

the intermediate sheet, see arrows !
2

) Observe the installation position – the screens are

showing upwards (to the duct plate)!

Figure 19

Power Shift Transmission 76 Disassembly & Assembly

Put on the intermediate sheet (1).
1

) Screens (2) must show upwards!

Figure 20

Put on the duct plate (1) and tighten it equally with Torx
2
screws (2).
1

Tightening torque ................................... MA = 9.5 Nm

(S) Socket spanner TX-27 5873 042 002

Figure 21

Provide the screw plugs (1) with new O-rings and install
them.
1

Tightening torque ...................................... MA = 6 Nm

Figure 22

Insert the pressure relief valve (1) and lock it with the
indented ring (2).

(S) Drive mandrel 5870 705 012

S
Figure 23

Power Shift Transmission 77 Disassembly & Assembly

Mount the gasket (1) and the cpl. shift system (2).
1
2 (S) Adjusting screws M6 5870 204 063

Figure 24

Fasten the electro-hyraulic control unit (1) equally by

means of Torx screws (2).

Tightening torque (M6) .......................... MA = 11 Nm

(S) Torque spanner 5870 203 031

(S) Reducer 5870 656 056
2 (S) Socket spanner TX-27 5873 042 002
Figure 25

8.2 Mounting of Micro Filter (Pressure Filter)

Fasten the filter head (1 ) with new O-rings by means of

cap screws (2) to the transmission housing.
1

Tightening torque (M8) .............................. MA = 23 Nm

2
(S) Torque spanner 5870 203 034
Figure 26 (S) Socket spanner TX-40 5870 042 004

The filter is to be installed as follows:

- Oil the gasket slightly

- Turn in the filter until contact with the sealing
surface is obtained and then tighten it by hand
1 with an approx. 1/3 to 1/2 rotation.

Prior to initial operation of the transmission make

Figure 27
the oil filling in accordance with the Operating
Instructions!

Power Shift Transmission 78 Disassembly & Assembly

SB4276E00
Sep. 2007

Vehicle System
Specifications
Systems Operation
Testing & Adjusting

D50S-5, D60S-5, D70S-5, D80S-5, D90S-5

G50S-5, G60S-5, G70S-5
Important Safety Information

Read and understand all safety precautions and warnings before operating or performing lubrication,
maintenance and repair on this product.

WARNING

Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.

1
Index

Specifications

Hydraulic Control Valve ...................................... 5

Tilt Cylinder ........................................................ 7
Tilt Cylinder Installation ................................. 7
Steering Wheel and Gear Group......................... 8
Steering Gear..................................................... 8
Steer Wheels and Steer Axle .............................. 8
Priority Valve ...................................................... 9
Hydraulic Pump .................................................. 9

Systems Operation

Hydraulic System.............................................. 11
Pressure Adjustment of the Control Valve......... 13
Hydraulic Steering system ................................ 14
Hydraulic Schematic ..................................... 14
Control valve .................................................... 16
External configuration & Circuit ..................... 16
Lift Spool....................................................... 17
Tilt Spool....................................................... 20
Brake Power Master Cylinder ........................... 23
Steering Unit .................................................... 25
Oil Flow......................................................... 25

Testing and Adjusting

Troubleshooting................................................ 27
Visual Checks ............................................... 27
Operation Checks ......................................... 27
Hydraulic System and Mast........................... 28
Hydraulic Control Valve................................. 30
Lift and Tilt Cylinders..................................... 31
Hydraulic Pump............................................. 32
Steering System............................................ 33
Brake Valve .................................................. 34
Brake System ............................................... 34
Hydraulic System.............................................. 36
Relief Valve Pressure Check......................... 36
Steering System Pressure Check.................. 38
Brake System................................................... 39
Deaeration of the Brake System.................... 39
Steering System ............................................... 40
Adjusting the Steering Wheel Bearing ........... 40
Stop Adjustment of the Steering Axle ............ 41
Parking Brake Test........................................ 42
Tilt Cylinder Alignment .................................. 42

Vehicle Systems 3 Index

Specifications

Hydraulic Control Valve

(1) torque for main relief valve : 42 N·m

(2) torque for auxiliary relief valve: 42 N·m

(3) torque for nuts that hold control valve sections

together : 42 N·m

Vehicle Systems 5 Specifications

SETTING PRESSURE FOR MAIN RELIEF VALVE (LIFT AND TILT) AND AUXILIARY RELIEF VALVE

Mast Load Relief pressure

type capacity Lift & tilt Auxiliary
2,460 (+0,70) psi
5 Ton
17,000 (+0,+500) Kpa
STD 2,755 (+0,70) psi
D50/60/70S-5(3S) 6 Ton
19,000 (+0,500) Kpa
2,755 (+0,70) psi
7 Ton
19,000 (+0,500) Kpa
2,460 (+0,70) psi
5 Ton
17,000 (+0,+500) Kpa
G50/60/70S-5 2,755 (+0,70) psi
STD 6 Ton
D50/60/70S-5(2S) 19,000 (+0,500) Kpa
2,755 (+0,70) psi 2,035 (+0,70) psi
7 Ton
19,000 (+0,500) Kpa 14,000 (+0,500) Kpa
2,460 (+0,70) psi
5 Ton
17,000 (+0,+500) Kpa
G50/60/70S-5
2,755 (+0,70) psi
D50/60/70S-5(2S) FFT 6 Ton
19,000 (+0,500) Kpa
D50/60/7005-5(3S)
3,030 (+0,70) psi
7 Ton
20,900 (+0,500) Kpa
3,300 (+0,70) psi
8 Ton
22,500 (+0,500) Kpa
D80/90S-5 STD
3,480 (+0,70) psi
9 Ton
24,000 (+0,+500) Kpa

Vehicle Systems 6 Specifications

Tilt Cylinder

Truck p/no Closed length (Y) Stroke (X) Tube O.D (mm) x Rod (mm)
D50/60/70S(3S) D518037 715 mm 345 mm 110 x 50

D50/60/70S(2S) D518038 715 mm 345 mm 100 x 50

G50/60/70S(2S) D518038 715 mm 345 mm 100 x 50

D518159 (LH)
D80/90S (3S) 718 mm 365 mm 124 x 50
D518160 (LH)

Tilt Cylinder Installation

ICCS033S

1. Adjust clevises (2) to have Forward Tilt Angle (A)

and backward Tilt Angle (B) as per Tilt Cylinder
specifications.

2. Both clevises (2) must also be adjusted so both

cylinder rods stop evenly and have the same
length.

3. After clevis adjustment, tighten bolt (1) to a torque

of.......................115.6 ~ 133.3 N·m (86 ~ 99 lb·ft)

Vehicle Systems 7 Specifications

Steering Wheel and Gear Steer Wheels and Steer Axle
Group

1
3
1

ICCS035I

(1) Torque for nut........ 645 ± 35 N·m (475 ± 26 lb·ft)

ICCS005I
(2) Steer wheel bearing adjustment :

(1) Torque for nut............... 40 ± 5 N·m (30 ± 4 lb·ft) a. Tighten nut that holds the hub on the spindle to a
torque of ...................200 ± 10 N·m (147 ± 7 lb·ft)
(2) Torque for bolts that hold the steering gear to the
column ...................... 30 ± 3 N·m (22 ± 2.2 lb·ft) b. Loosen the nut to one-fourth of one turn.

c. Fix the nut by using cotter pin.

Steering Gear (3) Torque for nuts ...... 15 to 20 N·m (11 to 15 lb·ft)
See Steer Wheel Bearing Adjustment in Testing
And Adjusting.

ICCS006S

(1) Torque for bolts ............ 30 ± 5 N·m (22 ± 4 lb·ft)

Vehicle Systems 8 Specifications

Priority Valve Hydraulic Pump
Relief Pressure 14,000 (+500/0) kPa, D50/60/70S(2S)-5
035 (+70/0) psi

Type: Triple gear pump

Displacement: 39 cc/rev (front) + 17 cc/rev (middle)
+ 6 cc/rev (rear) for ODB system
39 cc/rev (front)+17 cc/rev (middle) +
16 cc/rev (rear) for SHOE BRAKE
system
Max working pressure: 26 Mpa (front) + 25 Mpa
(middle) + 25 Mpa (rear)
Max speed 3,000 rpm, minimum speed 600 rpm

Vehicle Systems 9 Specifications

G50/60/70S-5 D50/60/70/80/90S(3S)-5

Type: Triple gear pump Type: Triple gear pump

Displacement: 39 cc/rev (front) + 12 cc/rev (middle) Displacement: 34.5 cc/rev(front)+34.5 cc/rev(middle)
+ 6 cc/rev (rear) for ODB system + 6 cc/rev(rear) for ODB system
39 cc/rev (front) + 12 cc/rev (middle) 34.5 cc/rev(front)+34.5 cc/rev(middle)
+ 16 cc/rev (rear) for SHOE BRAKE + 16 cc/rev(rear) for SHOE BRAKE
system system
Max working pressure: 26 Mpa (front) + 25 Mpa Max working pressure: 26 Mpa (front) + 26 Mpa
(middle) + 25 Mpa (rear) (middle) + 25 Mpa (rear)
Max speed 3,000 rpm, minimum speed 600 rpm Max speed 3,000 rpm, minimum speed 600 rpm

Vehicle Systems 10 Specifications

Systems Operation
Hydraulic System

FULL FREE TRIPLE MAST

STANDARD MAST 17 20
18
21
16
19
15
15

14 14

32
35
13 36
7
33
30
25
37

TO STEERING UNIT

12 28
6

9
5 34 22 29

23 24
FLUID LINE 26
10
3
PILOT LINE M
4
DRAIN LINE
31 8
2
1

Basic Hydraulic Actuator System Schematic

(1) Hydraulic tank (2) Suction strainer (3) Triple pump (4) Drive axle(ODB) (5) Priority valve (6) Reducing pressure valve
(7) Control valve (8) Power master cylinder(brake valve) (9) Brake reservoir (10) PTO of transmission (11) Pilot control lever
(12) Return oil filter (13) Needle valve (14) Flow regulator (15) Flow protector-STD, SEC. (16) Lift cylinder-STD. (17) Tilt cylinder
(18) Side shift cylinder (19) Lift cylinder-SEC. (20) Lift cylinder-PRI. (21) Flow protector-PRI. (22) Unload solenoid valve
(23~31) Hydraulic line (32~34) Drain line (35) Main relief valve-lift & tilt (36) Auxiliary port relief valve. (37) Flow control valve

Vehicle Systems 11 Systems Operation

The hydraulic system has a hydraulic tank (1) which The main relief valve (35) releases the excessive
holds a fluid for a hydraulic triple pump (3). A pressure to the hydraulic tank when the pressure in
hydraulic pump has three section type. The first the lift cylinder or tilt cylinder goes higher than a
section pump supplies a pressure fluid through the setting pressure shown a CONTROL VALVE
priority valve (5) and a hydraulic line (25) to control SECTION OF SPECIFICATION. The auxiliary port
valve (7), and also supplies a pressure fluid to the relief valves (36) are installed into each auxiliary
reducing pressure valve (6) by which the reduced section in control valve. The auxiliary relief valve
pressure fluid is fed to the pilot port of each section releases he excessive pressure to the hydraulic tank
in control valve. And, Part of the fluid as much as when the pressure in side shift cylinder circuit or
the demand of load sensing signal from steering unit auxiliary circuit goes higher than a setting pressure
goes to the steering unit. At the same time, the shown a CONTROL VALVE SECTION OF
second section pump sends a pressure fluid through SPECIFICATION.
a hydraulic line (24) to control valve (7). These two
pump flows are merged at the inlet port of the The speed at which lift cylinder is lowered is
control valve. The fluid from the third section pump controlled by the flow regulator valve (14). Flow
goes to the flow control valve (37) and the controlled protectors (15) & (21) acts as a fuse valve if the line
flow (0.8GPM) from the flow control valve supplies between control valve (flow regulator) and flow
to the power master cylinder (8). protector is broken when the lift cylinder is raised or
lowered. This prevents the sudden fall of mast or
Each section of pilot control lever (11) matches each carriage if a hydraulic line is broken.
section of control valve (7) in pairs. The paired
sections are connected by the hydraulic pilot lines,
through which the modulated pilot pressure to the
stroke of the pilot control lever is fed to the pilot port
of each section in control valve, which makes it
possible to shift in or out the spool of each section in
control valve.
Accordingly, the pilot control levers move spool in
control valve. The movement of spool makes a fluid
to a lift cylinder (16) and/or tilt cylinder (17) and/or
side shift cylinder (18). The return hydraulic oil from
each cylinder flows through control valve, hydraulic
line (30) and return oil filter (12) back to hydraulic
tank.

The reducing pressure valve (6) to feed the

modulated pilot pressure to pilot control lever has a
solenoid valve which is electrically connected to the
electrical on-off switch beneath a seat. When the
operator leaves a seat more than 3 seconds or a
start key is off, the solenoid valves automatically
becomes off, which makes the pilot pressure to pilot
control lever lead to almost zero bar. And then, any
actuator couldn’t be worked, even though any pilot
control lever is shifted out or in.
Once a start key is on and operator sits on seat, the
solenoid valve is on and immediately it is possible to
work all functions normally.

On the emergency that the lowering doesn’t work

normally, in the needle valve (13) the locknut is
loosened, and lowering is possible while slowly
rotating a screw by about 3 counterclockwise turns.
The more detailed instruction guide will be shown in
TESTING and ADJUSTING.

Vehicle Systems 12 Systems Operation

Pressure Adjustment of the
Control Valve

Stud Lift, tilt main

Relief valve
Lock Nut

Attachment (auxiliary) relief valve

IF2M053P

In the event that pressure has to be readjusted by

tonnage, loosen the lock nut of the main relief valve,
and turn the stud clockwise using “L” wrench to
increase the pressure, and turn in an anti-clockwise
direction to decrease the pressure. Retighten the
lock nut after adjustment (the pressure
measurement point is on the elbow connector
between the priority valve mounted on the pump and
the port connected to the c/v).

Vehicle Systems 13 Systems Operation

Hydraulic Steering system

Hydraulic Schematic

1 4
6

8
11 To control valve
9

To oil cooler

To control valve
7
To flow control valve
12
10

3 13
C 2

Steering system schematic

(1) Steering unit (2) Suction strainer (3) Pump (4) Hydraulic line (5) Hydraulic line (6) Power steering cylinder (7) Priority valve
(8) Hydraulic line (9) Hydraulic line (10) PTO of transmission (11) Hydraulic line (12) Hydraulic line (13) Hydraulic tank

Vehicle Systems 14 Systems Operation

The steering system uses the hydraulic fluid for
operation. The system has priority valve (7) which
sends the fluid to steering unit (1) as needed before
the requirements of mast operation are filled.
The fluid is pulled from a hydraulic tank (13) to a
hydraulic pump (10). Pump supplies a fluid through
a hydraulic hose (12) to a priority valve (12).
When the steering unit (1) is neutral position, pilot
pressure in load sensing line (9) is reduced and the
spool of priority valve is moved to the left. The fluid
goes to control valve.

During a right turn, pilot pressure is increased in

load sensing line (9) and the spool of priority valve is
moved to the right. The fluid flows through hydraulic
line (8) to the steering unit. From the steering unit
the fluid flows through a hydraulic line (5) for right
turn. The return fluid flows through a hydraulic line
(4) back through steering unit, a hydraulic line (11)
and to the oil cooler, back to the hydraulic tank.

During a left turn, a pilot pressure is again increased

in load sensing line (9) which moves the spool of
priority valve to the right. A fluid flows through a
hydraulic line (8) to a steering unit. From the
steering unit, the fluid flows through a hydraulic line
(4) to a power steering cylinder (6) to make a left
turn. The return fluid flows through a hydraulic line
(11) back to steering unit, to the oil cooler and back
to the hydraulic tank.

A check valve is installed into the port of steering

unit connected to hydraulic line (8) to prevent a fluid
back to priority valve right after a turn is made,
Relief valve in priority valve will be opened if
steering pressure goes above 14,000 (+500,-0) kpa
or 2,035 (+70,0) psi.

Vehicle Systems 15 Systems Operation

Control valve

External configuration & Circuit

This main control valve assembly is consisted of the
3 section (Lift, Tilt, and Auxiliary sections).
(Refer to the below Fig.1), Fig.2 shows the hydraulic
circuit of main control valve.

Fig.1 Body configuration for main control valve

① Lift spool assembly ② Tilt spool assembly ③ Auxiliary spool (V5, V6, V7) ④ Relief valve (first section)
⑤ Relief valve (second section)

Fig.2 Hydraulic circuit for main control valve

Vehicle Systems 16 Systems Operation

Lift Spool

Neutral position

Fig.3 Neutral position

① Inlet from hydraulic pump ② Outlet to tank ③ Pilot passage ④ Plugged passage (Not used) ⑤ Passage to head end of lift
cylinder ⑥ Return passage to tank ⑦ Lift spool ⑧ Pv1(hydraulic pressure from joystick) ⑨ Pv2(hydraulic pressure from joystick)

Working actuation

P→ A→B→T Closed with through line (Lc) open

If the control valve is in the neutral position, oil is not
allowed into lift cylinder, and returns to tank because
the spool of lift interrupts the pump flow.

Vehicle Systems 17 Systems Operation

Lifting position

Fig.4 Lift position

① Inlet from hydraulic pump ② Outlet to tank ③ Pilot passage ④ Plugged passage (Not used) ⑤ Passage to head end of lift cylinder
⑥ Return passage to tank ⑦ Lift spool ⑧ Pv1 (hydraulic pressure from joystick) ⑨ Pv2 (hydraulic pressure from joystick)

Working actuation

P→B open (A: Plugged passage)

Apply pressure on Pv2 Port, Lift spool⑦ is moved
to the lift position. The movement of lift spool⑦
opens a path for oil to flow from inlet③ into passage
⑤. From passage③, the oil goes to passage⑤ and
then to lift cylinder moves the piston up and thus the
mast is lifted.

Vehicle Systems 18 Systems Operation

Lowering position

Fig.5 Lower position

① Inlet from hydraulic pump ② Outlet to tank ③ Pilot passage ④ Plugged passage ⑤ Passage to head end of lift cylinders (lift
upward) ⑥ Return passage to tank ⑦ Lift spool ⑧ Pv1(hydraulic pressure from joystick) ⑨ Pv2(hydraulic pressure from joystick)

Working actuation

B→T open
Apply pressure on Pv1 Port, Lift spool⑦ is moved
to the lower position. The movement of lift spool⑦
opens a path for oil to flow from lift cylinder to return
passage⑥. Pressure oil from the head end of lift
cylinder goes through passage⑥ back to tank and
then lift cylinder lower

Vehicle Systems 19 Systems Operation

Tilt Spool

Neutral position

Fig.6 Neutral position

① Inlet from hydraulic pump ② Outlet to tank ③ Pilot passage ④ Passage to rod end of tilt cylinders (tilt forward) ⑤ Passage to
head end of tilt cylinders (tilt backward) ⑥ Return passage to tank ⑦ Tilt spool ⑧ Tilt locking spool ⑨ Metering orifice ⑩ Pilot
passage ⑪ Pv3 (hydraulic pressure from joystick) ⑫ Pv4 (hydraulic pressure from joystick)

Steering Unit Oil Flow

ICCS017S
ICCS016S
Steering Unit (Shown in RIGHT TURN Position)
Steering Unit (1) Spool. (2) Sleeve. (3) Outlet To Tank. (4) Check Valve.
A. Control Section. B. Metering Section. (5) Inlet from Pump. (8) Centering Springs. (9) Pin.
(1) Spool. (2) Sleeve. (3) Outlet To Tank. (4) Check Valve. (10) Left Turn Port. (11) Right Turn Port. (13) Drive.
(5) Inlet From Pump. (6) Rotor. (7) Stator. (14) Passage. (15) Passage. (16) Gerotor. (17) Passage.
(8) Centering Springs. (9) Pin. (10) Left Turn Port.
(11) Right turn Port. (12) Body. (13) Drive. When the steering wheel is turned for a right turn,
pump oil flows into the STEERING UNIT through
The steering unit has two main sections ; control inlet (5) and passage (14). From passage (14) it
section (A) and pump or metering section (B). These goes into the gerotor through passage (17). With the
two sections work together to send oil to the steering steering wheel turning, gerotor (16) is turning and
cylinder. pumping oil. The Metered flow comes out through
passage (15), where it is directed out to the steering
Oil from the priority valve enters the steering unit cylinder through right turn port (11). When the
through inlet (5) into the control section. When the steering wheel started to turn ; spool (1), pin (9) and
steering wheel is turned, the control section sends drive (13) also started to turn. Sleeve (2) did not
the oil to and from the metering section, and also to start to turn at the same time as the spool because
and from the steering cylinder. the diameter of the holes in the sleeve are slightly
larger than the diameter of pin (9). This allows spool
The metering section is a small hydraulic pump. It (1) to turn inside of sleeve (2) enough to put the
meters the oil that goes to the steering cylinder, As small holes in sleeve (2) in line with the grooves in
the steering wheel is turned faster, there is an spool (1). The alignment of the small holes in the
increase in the flow of oil to the steering cylinder. sleeve with the grooves In the spool provides the
This increased flow causes the steering cylinder to path for oil flow to gerotor (16) and also to the
move farther and faster. As the steering cylinder steering cylinder. Centering springs (8) are
moves farther, more oil can flow from the metering compressed when the spool moves in relation to the
section to the steering cylinder and a faster turn is sleeve. When the steering wheel is no longer turning,
made. the springs will bring the spool and sleeve back to a
NEUTRAL position. This means that the wheels will
stay in the position they were in when the steering
effort stopped. The steering wheel must be turned in
the opposite direction to bring the wheels back to
straight ahead, or to make a left turn. As the
metered oil goes out to the cylinder through outlet
(11) for a right turn, return oil from the cylinder is
coming back into the STEERING UNIT through
outlet (10). This oil is sent to the tank.

Vehicle Systems 25 Systems Operation

ICCS018S ICCS019S

Steering Unit (Shown in a LEFT TURN Position) Spool And Sleeve

(1) Spool. (2) Sleeve. (3) Outlet To Tank. (1) Spool. (2) Sleeve. (18) Slots for Spring.
(5) Inlet From Pump. (9) Pin. (10) Left Turn Port. (19) Holes For pin. (20) Small Holes For Oil Flow.
(1) Right Rurn Port. (13) Drive. (14) Passage. (21) Grooves For Oil Flow.
(15) Passage. (16) Gerotor. (17) Passage.
The rate of flow the gerotor sections is determined
by how fast the steering wheel is turned. The faster
When the steering wheel is turned to the left, spool the steering wheel turns, the greater the flow and
(1), pin (9) and drive (13) turn with it. After spool (1) the faster the vehicle will turn.
has turned a small amount pin (9) will cause sleeve
(2) to move with the spool. They will rotate together
but will be a few degrees apart.

The flow of oil through the STEERING UNIT is in the

opposite direction to that of a right turn. It comes in
through inlet (5) and passage (14) and then goses
into gerotor (16) through passage (15). From the
gerotor, the oil leaves through passage (17), goes
through the sleeve spool combination and then to
left turn port (10). From the left turn port it goes to
the steering cylinder.

Vehicle Systems 26 Systems Operation

Testing and Adjusting Visual Checks
A visual inspection is the first step when diagnosis of
Troubleshooting a problem is made in the hydraulic system, air brake
system and their components. Lower the mast and
Troubleshooting can be difficult. A list of possible carriage to the ground. If the mast and carriage
problems and probable causes are on the pages cannot be on the ground, make sure they are
that follow. blocked correctly to prevent a fall that is not
expected.
This list of problems and probable causes will give
an indication of where a problem can be and what 1. Measure the oil level in the tank. Look for air
repairs are needed. Normally, more or other repair bubbles in the oil.
work is needed beyond the recommendations on the
list. 2. Remove the filter element and look for particles
removed from the oil by the filter element. A
Remember that a problem is not necessarily caused magnet will separate ferrous particles from
only by one part, but by the relation of one part with nonferrous particles (piston rings, O-ring seals,
other parts. This list cannot give all possible problem etc.).
and its source, then make the necessary repairs.
3. Check all oil lines and connections for damage or
The Fittings Group can be used to make the leaks.
pressure tests of the hydraulic system. Before any
test is made, visually inspect the complete hydraulic 4. Check the lift chains and the mast and carriage
system for oil eakage and damaged parts. welds for wear or damage.

WARNING Operation Checks

To prevent personal injury when testing and The operation checks can be used to find leakage in
adjusting the hydraulic system, move the lift the system. They can also be used to find a bad
truck to a smooth horizontal location and lower valve or pump. The speed of cylinder rod movement
the mast and carriage to the ground. If the mast can be used to check the condition of the cylinders
and carriage cannot be on the ground, make and the pump.
sure they are blocked correctly to prevent a fall
that is not expected. Move away from other Lift, lower, tilt forward and tilt backward the forks
machines and personnel that are at work. There several times.
must be only one operator. Keep all other
personnel away from the lift truck or where the 1. Watch the cylinders as they are extended and
operator can seethe other personnel. Before any retracted. Movement must be smooth and regular.
pressure hose, line, fitting or plug is removed,
make sure all hydraulic pressure is released. 2. Listen to noise from the pump.

3. Listen to the sound of the relief valve. It must not

1. Move the machine to a smooth horizontal location. open except when the cylinders are fully extended
or retracted, when the forks are empty
2. Permit only one operator on the machine.

3. Activate the parking brake.

4. Move the hydraulic control levers to all positions

to release the pressure in the hydraulic system.

Vehicle Systems 27 Testing and Adjusting

Hydraulic Oil Temperature (Too Hot) Hydraulic System and Mast
When the temperature of the hydraulic oil goes over During a diagnosis of the hydraulic system,
98.8° C (210° F), polyurethane seals in the system remember that correct oil flow and pressure are
start to fail. Followings are some reasons the oil necessary for correct operation. The output of the
temperature will be this hot. pump (oil flow) increases with an increase in engine
speed (rpm) and decreases when engine speed
1. Hydraulic pump is badly worn. (rpm) decreases.
2. Heavy hydraulic loads that cause the relief valve Visual checks and measurements are the first step
to open. when troubleshooting a possible problem. Then do
the Operation Checks and finally do instrument tests
3. The setting on the relief valve is too low. with pressure gauges.
4. Too many restrictions in the system. Use the fittings Group, a stop watch, a magnet, a
thermometer and a mm (inch) ruler for basic tests to
5. Hydraulic oil level in the tank is too low. measure:
6. High pressure oil leaks in one or more circuits. 1. The pressure of the oil to open the relief valve.
Relief valve pressures that are too low will cause
7. Very dirty oil. a decrease in the lift and the tilt characteristics of
the lift truck. Pressures that are too high will
8. Air in the hydraulic oil. cause a decrease in the life of hoses and
components.
a. Return oil to the tank goes in above the level of
the oil in the tank. 2. Drift rates in the cylinders.
Cylinder drift is caused by a leakage past cylinder
b. Air leaks in the oil suction line between the pistons, O-ring seals in the control valve, check
pump and the tank. valves that do not seat correctly or poor
adjustment or fit in the control valve spools.
NOTE: If the problem is caused by of air in the oil, it
must be corrected before the system will operate at 3. Cycle times in the lift and tilt circuits.
normal temperatures. Cycle times that are too long are the result of
leakage, pump wear and/or pump speed (rpm).
9. Contaminated priority valve.

10. Clogged hydraulic oil cooler.

11. Failed fan-driven motor.

12. Failed third pump for fan-driven motor.

Vehicle Systems 28 Testing and Adjusting

Mast and Carriage Probable Mechanical Cause:

Problem: The hydraulic system will not lift the 1. Damage or failure of the piston rods on the tilt
load. cylinders.

Probable Hydraulic Cause: Problem: The carriage will not lower correctly.

1. There is an air leak, which lets air into the Probable Hydraulic Cause:
hydraulic system on the inlet side of the hydraulic
pump. 1. There are restrictions in the lift line.

2. The main relief valve in the mast control valve 2. The lift spool in the control valve has a restriction
opens at low oil pressure. caused by foreign material or hydraulic leakage in
the caps.
3. The hydraulic pump has too much wear.
3. The lift cylinder flow control valve has a restriction.
4. The load is not correct (too heavy).
4. Insufficient pilot pressure from the remote control
5. The dead engine lowering needle valve is not valve.
closed.
Probable Mechanical Cause:
6. Insufficient pilot pressure from the remote control
valve. 1. The mast is not in alignment with the other lifting
components and does not slide freely.
Probable Mechanical Cause:
2. Carriage chains need an adjustment.
1. The mast is not in alignment with the other lifting
components and does not slide freely. 3. Not enough lubricant on the part of the mast that
slides.
2. Not enough lubricant on the parts of the mast that
slide. 4. The carriage or mast rollers and bearings are
worn and do not move (seized).
3. The carriage or mast rollers and bearings are
worn and do not move (seized). Problem: The lift or tilt cylinders do not hold
their position with the valve control levers in
Problem: The mast does not tilt correctly or neutral position.
moves too slowly.
Probable Cause:
Probable Hydraulic Cause:
1. The valve spools do not hold their positions
1. There is an air leak, which lets air into the because the springs for the valve spools are
hydraulic system on the inlet side of the hydraulic weak or broken.
pump.
2. Control valve leakage caused by worn valve
2. The relief valve opens at low oil pressure. spools.

3. The hydraulic pump has too much wear. 3. The check valves in the control valve are
defective.
4. Oil leakage around spools has filled caps which
cause a restriction of spool movement. 4. Leakage of the cylinder lines or piston seals.

5. Oil leakage through tilt cylinder piston seals. 5. Dirt or foreign particles between check valve
poppet and its seat.
6. Insufficient pilot pressure from the remote control
valve.

Vehicle Systems 29 Testing and Adjusting

Problem: Any function (lift cylinder, tilt cylinder, Hydraulic Control Valve
auxiliary cylinder) does not work.
Problem: The levers of remote control valve do
WARNING not move freely.

In case that lowering is inoperable, forks should Probable Cause:

be safely lowered down to ground before fixing
the problem. For doing so, if the screw bolt of 1. The oil is too thick.
needle valve is rotated slowly by the
counterclockwise turn like the picture below, the 2. There is foreign material in the oil.
fork will be lowered. But, don’t turn it more than
3 turns. After completing a lowering, tighten a 3. The fastening bolts of the valve assembly are too
screw bolt clockwise. tight and have the body twisted.

4. Bent lift or tilt spools.

5. Damage in the return springs of the spools.

Problem: Control valve spools have leakage

around the seals.

Probable Cause:

1. There is foreign material under the seal.

2. The valve spools are worn.

3. The seal plates are loose.

4. The seals have damage or are badly worn.

Probable Electric Cause
Problem: The load lowers when the lift spool is
1. A broken solenoid valve in pressure reducing moved from the NEUTRAL position to the LIFT
valve. position.

2. A broken seat switch related with a solenoid valve Probable Cause:

of pressure reducing valve.
1. There is foreign material in the check valve area.
3. A broken electric harness to supply a electric
power to a solenoid valve of pressure reducing 2. The check valve poppet and seat show wear.
valve.
3. Sudden loss of pump oil pressure.
Probable Hydraulic Cause
4. Pilot lines are switched between remote control
1. Lower pilot pressure from pressure reducing valve. valve and main control valve.

5. Damage to the relief valve which causes low oil

pressure.

Vehicle Systems 30 Testing and Adjusting

Problem: Lever of remote control valve doesn’t Lift and Tilt Cylinders
return to the neutral position.
Problem: There is leakage of oil inside the
Probable Cause: cylinder or, loss of lift or tilt power.
1. The springs are broken. Probable Cause:
2. The spool is bent. 1. The piston seals are worn and let oil go through.
3. The system or valve has foreign particles in it. 2. Cylinder has damage.
4. The fastening bolts of the valve have too much Problem: The tilt piston rods show wear.
torque.
Probable Cause:
Problem: No motion or slow, then a sudden
action of the hydraulic system. 1. The cylinders are not in correct alignment.
Probable Cause: 2. Oil is dirty.
1. The relief valve is not correctly set, or will not Problem: Foreign material behind the wiper
move in base and/or is worn. rings which causes scratches on the cylinder
rod.
2. There is air in the system.
Probable Cause:
3. Dirt or foreign particles between relief valve
control poppet and its seat. 1. The wiper rings show wear and do not remove dirt
and foreign material.
4. Valve body has a crack inside.
Problem: Too much tilt drift.
5. Spools not moved to a full stroke in remote
control valve. Probable Cause:
Problem: No relief valve action (high pressure). 1. Defective tilt cylinder seals.
Probable Cause: 2. Defective control valve
1. Small particle of dirt stopping (plugging) orifice in Problem: Too much lift drift
relief valve assembly.
Probable Cause:
2. The relief valve is installed backwards.
1. Defective lift cylinder seals.

2. Defective control valve.

3. Dead engine lowering needle valve is not closed

or is leaking.

Vehicle Systems 31 Testing and Adjusting

Hydraulic Pump Problem: There is failure of the pump to deliver
fluid.
Problem: Noise in the pump.
Probable Cause:
Probable Cause:
1. The oil level is too low.
1. The oil level is low.
2. There is a restriction in the pump inlet line.
2. The oil is thick (viscosity is too high).
3. There is air leakage into the pump inlet line.
3. The pump inlet line has a restriction.
4. The viscosity of the oil is wrong.
4. Worn parts in the pump.
5. The pump has too much wear.
5. Dirt in the filter.
6. Failure of the pump shaft or coupling
6. Air leaks into the inlet line.
Problem: Oil leakage at the cylinder.
Problem: the oil temperature is too high.
Probable Cause:
Probable Cause:
1. Loose hose connection.
1. The oil level is low.
2. Defective seals at the piston rod end of the
2. There is a restriction in an oil passage. cylinder.

3. The relief valve setting is too low. 3. Piston rod has damage.

4. The oil is too thin.

5. There is air leakage in the system.

6. The pump has too much wear.

7. Overload in the system.

Problem: Leakage on the shaft seal.

Probable Cause:

1. The shaft seal is worn.

2. The inner parts of the pump body are worn.

3. Operation with too low oil level in tank causes the

seal deterioration.

4. Seal cut on shoulder of pump or keyway during

installation.

5. Seal lips are dry and hardened from heat.

Vehicle Systems 32 Testing and Adjusting

Steering System
4. Oil leakage inside or outside of the system.
Problem : Too much force needed to turn 5. Defective pump.
steering wheel.
Problem : Pump makes noise and the steering
Probable Cause : cylinder rod does not move smoothly.
1. Priority valve releases pressure oil at a low setting. Probable Cause :
2. Pump oil pressure is low, worn pump. 1. Air in the steering hydraulic circuit.
3. Steering gear covers are too tight. 2. The pump has too much wear.
4. Steering column not aligned with steering gear. 3. Loose connection of the oil line on the inlet side of
the pump.
5. Priority valve spool is held in one position.
4. The viscosity of the oil is wrong.
6. Steering gear without lubrication.
5. The oil level in the hydraulic tank is low.
7. Low fluid level in the hydraulic supply tank.
6. Worn steer cylinder piston seal.
8. Steer axle damaged.
Problem : Lift truck does not turn when steering
9. Worn steer cylinder piston seal. wheel is slowly turned.
Problem : Steering wheel does not return to Probable Cause :
center position correctly.
1. The oil level of the tank is low.
Probable Cause :
2. There is air in the steering system.
1. Steering gear covers are too tight.
3. The pump operation is not correct.
2. Steering column is not in correct alignment.
4. Dirt in the steering system.
3. Valve spool in the steering gear has a restriction.
5. Steering gear operation is not correct.
4. Priority valve check valve permits lift and tilt
hydraulic oil to affect steering hydraulic circuit. 6. Steering cylinder has worn parts.
Problem : Oil leakage at the pump 7. Restriction in the steer axle linkage.
Probable Cause : Problem : The temperature of the oil is too hot.
1. Loose hose connections. Probable Cause :
2. Defective shaft seal. 1. The viscosity of the oil is wrong.
Problem : Low oil pressure. 2. Air is mixed with the oil.
Probable Cause : 3. The relief valve is set too high (priority valve).
1. Low oil level. 4. There is a restriction in the line circuit.
2. Priority valve relief valve spring weak. 5. Unit being held in relief mode for long periods of
time.
3. Relief valve (priority valve) will not move from the
open position.

Vehicle Systems 33 Testing And Adjusting

Brake Valve Brake System

Problem : Low power braking pressure or loss of NOTE: If excessive force is applied to the brake
power braking. pedal the pedal can be forced to the end of the
storke. This is normal and should not be interpreted
Probable Cause : as a problem.

1. Insufficient pedal stroke.

Problem : Pedal resistance is not solid (spongy)
2. Lines connected to wrong ports. (under normal pedal pressure).

3. Insufficient brake flow from the first section of Probable Cause :

control valve due to a stuck brake spool.
1. Air in the brake hydraulic system.
4. Relief valve in brake valve damaged.
2. Brake valve is loose.
5. Seals of servo piston in brake valve damaged.
3. Servo piston seals worn or defective in brake
valve.
Problem : Low manual braking pressure or loss
of manual braking. 4. Adjustment of brake pedal linkage is not correct.

Probable Cause : 5. Piston seals worn or Defective in drive axle brake.

1. Insufficient pedal stroke. 6. Low oil level of reservoir of brake valve.

2. Air in lines.
Problem : Extra (excessive) pedal travel (under
3. Damaged servo piston seals and sleeve due to normal pedal pressure).
contamination.
Probable Cause :

Problem : Pedal instability 1. Pedal adjustment is not correct.

Probable Cause : 2. Air in the brake hydraulic system.

1. Air in lines. 3. Brake valve is loose.

2. Damaged a check valve of brake port in the first 4. Servo piston seals worn or Defective in brake
section of control valve. valve.

3. Damaged a spring of relief valve in brake valve. 5. Low oil level of reservoir of brake valve.

4. Damaged a spring for brake spool in the first 6. Piston seals worn or defective in drive axle brake.
section of control valve.

Problem : External leakage Problem : Brakes will not make application.

Probable Cause : Probable Cause :

1. Damaged master piston or seal of master piston. 1. Low oil level of reservoir of brake valve.

2. Casting porosity 2. Air in the brake hydraulic system.

3. Fitting or line leakage. 3. Linkage is not in correct adjustment or is bent.

Vehicle Systems 34 Testing And Adjusting

4. Defective brake valve.

5. Bent plates or discs.

6. Piston seals worn or defective in drive axle.

Problem: Hard pedal.

Probable Cause:

1. Mechanical resistance at pedal or disc assembly.

2. Restriction in the brake line

3. Defective brake valve.

4. Brake discs look like glass (glazed) or are worn.

Problem: Both brake disc assemblies will not

release all the way (drag).

Probable Cause:

1. Brake disc assemblies defective (pistons stuck).

2. Brake disc uneven (out of flat).

3. Restriction in the brake line

4. Defective brake valve.

Problem: Brakes will not make application after

being bled.

1. Leak in hydraulic line or connection.

2. Damaged seals in the brake valve.

Vehicle Systems 35 Testing And Adjusting

Hydraulic System

Relief Valve Pressure Check

WARNING

Hydraulic oil, under pressure can remain in the

hydraulic system after the engine and pump
have been stopped. Personal injury can be
caused if this pressure is not released before
any work is done on the hydraulic system. To
prevent possible injury, lower the carriage to the
ground. Turn the engine off and move the
control levers to make sure all hydraulic
pressure is released before any fitting, plug,
hose or component is loosened, tightened
removed or adjusted. Always move the lift truck
to a clean and level location away from the travel
of other machines. Be sure that other personnel
are not near the machine when the engine is
running and tests or adjustments are made.

1. With the engine off, remove plug (1) from the

elbow of control valve. Install pressure-checking
adapter (4), connect pressure-tube (5) and
pressure gage (6). Pressure gage has a range of
28,000 kPa (4,000psi).

IF2M152P
Pressure Tap Location
(1) Plug.

2. Start the engine and tilt the mast back to the end
of its travel.

3. With the engine at high idle, hold the tilt control

lever in the TILT BACK position and watch the
gauge. The gauge shows relief valve opening
pressure.

Vehicle Systems 36 Testing And Adjusting

SETTING PRESSURE FOR MAIN RELIEF VALVE (LIFT AND TILT) AND AUXILIARY RELIEF VALVE

Mast Load Relief pressure

type capacity Lift & tilt Auxiliary
2,460 (+0,70) psi
5 Ton
17,000 (+0,+500) Kpa
STD 2,755 (+0,70) psi
D50/60/70S-5(3S) 6 Ton
19,000 (+0,500) Kpa
2,755 (+0,70) psi
7 Ton
19,000 (+0,500) Kpa
2,460 (+0,70) psi
5 Ton
17,000 (+0,+500) Kpa
G50/60/70S-5 2,755 (+0,70) psi
STD 6 Ton
D50/60/70S-5(2S) 19,000 (+0,500) Kpa
2,755 (+0,70) psi 2,035 (+0,70) psi
7 Ton
19,000 (+0,500) Kpa 14,000 (+0,500) Kpa
2,460 (+0,70) psi
5 Ton
17,000 (+0,+500) Kpa
G50/60/70S-5
2,755 (+0,70) psi
D50/60/70S-5(2S) FFT 6 Ton
19,000 (+0,500) Kpa
D50/60/7005-5(3S)
3,130 (+0,70) pis
7 Ton
21,600 (+0,500) Kpa
3,030 (+0,70) pis
8 Ton
20,900 (+0,500) Kpa
D80/90S-5 STD
3,300 (+0,70) pis
9 Ton
22,500 (+0,+500) Kpa

Vehicle Systems 37 Testing And Adjusting

Steering System Pressure Check
If the steering system does not work correctly, check
the hydraulic tank for the correct oil level and the
(6)
hoses and connections for leakage. If all these items
are correct, use the Pressure Gauge Kit to check the
steering hydraulic system and its relief pressure
setting.

(5)

(1) Pressure gage plug (M10 x P1).

(4) WARNING

Hydraulic pressure can cause personal injury.

ICCS024S
Before any steering system hydraulic lines or
components are disconnected, make sure all
(4) Pressure-Checking Adapter. (5) Pressure-Tube.
hydraulic pressure is released in the steering
(6) Pressure Gauge.
system. Move the steer wheels to the left and
right and then to the straight forward direction.
4. If an adjustment to the relief valve pressure is
necessary, do the steps that follow.
Check steering system relief pressure as
a. Remove the out-cap (acorn nut) and jam nut follows:
from the relief valve.
1. Turn the engine off.
b. Turn the adjusting screw either clockwise for an
increase or counter clockwise for a decrease. 2. Remove plug (1) from elbow. Install pressure-
checking adapter (4) and connect pressure-tube
c. Check the relief pressure again. (5) and pressure gage (6). Pressure gage (6) has
a range of 2,800 kpa (4,000 psi).

3. Move the seat to the normal position for operation,

turn the key switch to the ON position and
activate the hydraulic controls until the oil is at a
temperature for normal operation.

4. Turn the steer wheels to the left or right against

the stops and make a note of the indication on the
pressure gauge.

5. The indication on the pressure gauge must be the

priority valve relief setting of 14,000 (0, + 500)
kpa, 2,035 (+ 70, 0) psi. If the indication is correct
and a problem exists, then there is possibly a
mechanical failure in the steering system.

Vehicle Systems 38 Testing And Adjusting

6. If the indication is not correct, then there is Brake System
steering hydraulic failure in the components.
Deaeration of the Brake System

IF2M151P

If the brake pedal feels like a sponge, and is not

rigid, some air may be trapped in the hydraulic
system of the brake. Air may enter the system if the
M10x1.0 THD
refill liquid level is low, if there is a fluid leak in the
system, if the brake lining is damaged, or if the
brake line is not connected.

1. Check the oil level of the hydraulic system. Refill if

(4) Pressure-checking adapter (5) Pressure-tube necessary. Refer to the maintenance manual.
(6) Pressure gauge
2. Turn on the engine, maintain in a relatively idle
state.
a. With the motor running, turn the steer wheels in
any directions and read the indication on 3. Step on the brake pedal, and open the bleed
pressure gauge (6). screw (1) so that the air in the system can be
expelled. While stepping on the brake pedal,
tighten the bleed screw, then release the brake
b. If the indication is approximately the pressure pedal.
shown in Step 5, then the steering gear has a
hydraulic failure. 4. Repeat the action described in Clause 3 above
until all the air has been expelled from the brake
c. If the indication is too low or too high, then the fluid.
priority valve or its components must be
replaced. 5. Perform the actions described in Clauses 3 and 4
above on the right bleed screw as well.
7. If the steering gear and the priority valve are
working properly, the steering cylinder is defective 6. Check the hydraulic oil level, and refill if
and must be repaired. necessary. Refer to the maintenance manual.

8. Correct the problem and check steering relief

valve pressure again.

Vehicle Systems 39 Testing And Adjusting

Steering System
Adjusting the Steering Wheel Bearing

M10x1.0THD
ICCS025P
Outer Wheel Bearing
IDCS134 (1) Outer wheel bearing.

7. If the scales do not agree, then there is a problem 1. Assemble the outer wheel bearing (1). Grease the
with the steering hydraulic system. wheel bearing.

a. With the engine ON, turn the steering wheel in

any direction. Read the indication on the
pressure gauge.

b. If the pressure is approximately the same as

that in process #5, then the hydraulic
component of the steering gear has a problem.

c. If the measurement value is too high or too low,

replace the priority valve of the relevant
component of the priority valve.
ICCS037P

8. If the steering gear and the priority valve are Lock Nut Assembly
operated separately, replace the steering cylinder (2) Washer. (3) Nut-castle. (4) Pin-cotter.
which has a problem.
2. Assemble washer (2) and nut-castle (3).
9. When all the problems have been corrected,
check the pressure of the steering relief valve 3. Turn the wheel so that the bearing (1) can settle.
again. Tighten the nut-castle (3) by 200±10N.m of torque.

4. Unscrew the nut (3) by 1/4 turn.

5. Install the pin-cotter (4) to fix the position.

Vehicle Systems 40 Testing And Adjusting

Stop Adjustment of the Steering Axle 4. If the measurement (X) is larger than the specified
length, adjust the nut and bolt at the stop (1) and
(2).
Values (A) and (B) are the rotation in degrees until
WARNING it touches a stop on any side.
This value is the rotation angle from the center of
To avoid accidents, activate the parking brake,
the vehicle axis to the center of the tyre, in turning
and place a stopping block in front of the drive
right or left. Measurement (A) shall be 139.4˚, and
wheel.
measurement (B) shall be 15˚.

NOTE: Each steering knuckle must contact the stop

when rotated to the maximum.
To Vehicle Front

To Vehicle Front

Rear wheels facing straight forward

1. Lift the rear wheels up so that they can be rotated Rear wheel in turning right
freely. (3) Front left stop. (4) Rear right stop. (A) 139.4˚.
(B) 15˚. (X) 426.2±0.5 mm (16.78±0.02 in).
2. Turn the rear wheel in a straight forward direction.
Draw a line in parallel with the vehicle axis, for a 5. Turn the steering wheel to the left so that the left
length of the wheel’s width, with a chalk pencil. of the steering cylinder protrudes. Measure the
Draw a line at 90 degrees to the center of the length (X) from the steering cylinder’s surface to
wheel. Draw a line around the centers of the rear the end of the steering cylinder rod, which must
wheels. be 426.2±0.5 mm(16.78±0.02in).

NOTE: Each steering knuckle must contact the stop

To Vehicle Front when rotated to the maximum.

6. If the adjustment of the stop is required, adjust the

nut and bolt at stops (3) and (4) so that the
specified length can be obtained while the cylinder
protrudes and the stop is in contact.

Rear wheel when turning right

(1) Front right stop. (2) Rear left stop. (A) 139.4˚.
(B) 15˚. (X) 426.2±0.5 mm (16.78±0.02 in).

3. Turn on the engine. Turn the steering wheel to the

right. At this time, the right side of the steering
wheel protrudes and the left side turns inwardly.
Measure the length (X) from the steering
cylinder’s surface to the end of the cylinder rod.
This length must be 426.2±0.5 mm
(16.78±0.02in).

Vehicle Systems 41 Testing And Adjusting

Parking Brake Test Tilt Cylinder Alignment

ICCS032P
Parking Brake Test (Typical Example)

1. Drive the lift truck fully loaded up a 15% incline.

2. Halfway up the incline stop the lift truck with the ICCS033S
service brake. Apply the parking brakes.
Mast Tilt Degrees.
3. If the parking brakes have the correct adjustment, (1) Bolt. (2) Clevis. (A) Forward tilt angle.
the lift truck will be held in this position. (B) Backward tilt angle.

If the tilt cylinders are out of alignment, extra

stresses in the mast assembly and the mast hinge
WARNING
area will be occurred. To prevent damage, the tilt
The operator must be ready to use the service cylinders must stop evenly at the end of the tilt back
brakes if the parking brakes are not adjusted and tilt forward strokes.
correctly and the lift truck starts to move.

4. If the parking brakes do not hold, repeat the Steps

in Parking Brake Adjustment.

Vehicle Systems 42 Testing And Adjusting

SB4277E00
Sep. 2007

Vehicle System
Disassembly & Assembly

D50S-5, D60S-5, D70S-5, D80S-5, D90S-5

G50S-5, G60S-5, G70S-5
Important Safety Information

Read and understand all safety precautions and warnings before operating or performing lubrication,
maintenance and repair on this product.

WARNING

Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.

1
Index
Master cylinder ..................................................... 5
Remove & Install Master cylinder.......................... 5
Disassemble & assemble brake valve................... 6
Tilt Cylinder .......................................................... 9
Counter Weight ...................................................12
Hood ...................................................................13
Overhead Guide ..................................................14
Seat ....................................................................14
Hydraulic Control Valve .......................................15
Main control valve................................................16
Precaution ...........................................................16
Replacing the parts..............................................17
Hydraulic Pump Two Speed.................................20
General Instruction ..............................................20
Lubrication of moving parts..................................20
Tools required for assembly.................................20
Disassembly Process ..........................................20
Rear section ........................................................20
Center section .....................................................21
Front section .......................................................22
Reassembly Process...........................................22
Front cover area ..................................................23
Center section .....................................................23
Rear section ........................................................25
Reference............................................................26
Three Speed Pump General Instruction (Three
Speed) ................................................................27
Cleanliness..........................................................27
Lubrication of moving parts..................................27
Tools required for assembly.................................27
Disassembly Process ..........................................27
Rear section ........................................................27
Center section .....................................................28
Front section .......................................................28
Reassembly Process...........................................29
Front cover area ..................................................29
Center section .....................................................29
Rear section ........................................................31
Reference............................................................32
Hydraulic Oil Filter Assembly ...............................33
Steering Wheel....................................................34
Steering Column and Steering Gear ....................34
Steer Axle............................................................41
Tires and Rims (Steer).........................................47

WARNING

Disconnect batteries before performance of any

service work.

Vehicle Systems 3 Disassembly & Assembly

Master cylinder
2

Remove & Install Master

cylinder
NOTE: Plug and cap all openings to avoid
contamination and debris from entering the system
after removing any tubes or lines.

1. Before disconnecting the lines to master cylinder

(1), prepare the proper plugs.

3. Disconnect the yoke (3) from bell crank.

4. Dismount the master cylinder.

5. Install the waster cylinder in the reverse order of

removal.

6. Fill the oil reservoir with the correct oil

recommended at Operating & Maintenance
manual.

7. Bleed the brake system. Refer to the Testing and

Adjusting Manual for the further information.
2. Disconnect the hoses and the tubes assembled to
master cylinder, one by one.

Be sure that the oil in reservoir will be drained

once the hose (2) is disconnected.

NOTE: Put the proper marking on the hoses not to

be confused. Also, after being disconnected, put the
proper plug or plugging on the hoses and tube.

Vehicle Systems 5 Disassembly & Assembly

Disassemble & assemble brake valve

1. Take off bellows (4) and lift push rod (3), remove vent air (25) and bolts (28).

2. Separate the front housing (1) and rear housing (2), remove servo spring (10), servo piston (9) and master
piston (5).

3. Take off seal u-cup (14) from master piston (5). Notice the direction of the seal.

Vehicle Systems 6 Disassembly & Assembly

4. Remove lock washer (6) and ball (7) from servo piston (9). Pull off piston ring (8), seal u-cup (13), seal u-
cup (12) and seal u-cup (11) in sequence. Notice the direction of each seal.

No Color Material

11 Translucency Urethane

12 Black NBR Hs70

13 Yellow Urethane

5. Remove relief plug (18), o-ring (19), spring (17), shims (16) and piston (15) from front housing (1).

Vehicle Systems 7 Disassembly & Assembly

6. Remove check valve parts from rear housing (2): plug (26), o-ring (27), cage (24), spring (23), ball (21) and
o-ring (22). Remove o-ring (20).

7. Assemble brake valve in the reverse order of disassembly.

Vehicle Systems 8 Disassembly & Assembly

Tilt Cylinder < Assembly >

6. Fix the tilt cylinder firmly to a hoist. Push the tilt

Disassembling and Assembling the cylinder head to the frame to place it at the fixing
Tilt Cylinder point.

7. Fix the tilt cylinder head and frame with the fixing
pin, and tighten the bolt.

8. Connect the hydraulic line to the tilt cylinder.

9. Start the engine, extend the tilt cylinder, fix the

rod fixing pin, and turn the engine off.

10. Fix the tilt cylinder rod fixing pin by tightening

with the bolt.

IF2M002P NOTE: Adjusting the Tilt Cylinder: Unscrew the nut

of the clevis at the end of the cylinder to adjust its
position at the mast fix position. Extend the tilt
1. Start the engine. Extend the tilt cylinder full length
cylinder full length and fix it with the pin. When fixing
for easier isolation of the rod fix pin (2).
the pin with the mast, operate the tilt cylinder
outwardly/inwardly.
WARNING
11. Remove air from the tilt cylinder.
When removing the tilt cylinder, fix it firmly to a (Start the engine, and operate the tilt cylinder
hoist, or place support blocks under the cylinder. outwardly and inwardly at least 10 times.).
(Check the hydraulic oil tank level. Fill it up to the
proper level, if necessary).

2. Fix the tilt cylinder firmly to a hoist. Unscrew the

fix bolt (1) of the rod fixing pin (2) and isolate the
rod fixing pin (2). Start the engine, retreat the tilt
cylinder rod, and turn the engine off.

3. Isolate the hydraulic line from the tilt cylinder.

4. Remove the fixing pin bolt on the tilt cylinder head,

and remove the pin.

5. Remove the tilt cylinder from the vehicle.

(Tilt cylinder weighs about 50kg.)

Vehicle Systems 9 Disassembly & Assembly

a . Remove the tilt cylinder.

ICCD002P

1. Isolate clevis (1) from the tilt cylinder rod (4).

ICCD031I

3. Isolate the cylinder rod from cylinder tube.

4. Isolate the nut fix pin (5) from the cylinder rod (4),
and remove the nut (6).

5. Isolate the piston (7) from the cylinder rod.

6. Remove the wear ring (9.17) and slipper seal (10)

ICCD003P from the piston (7).

2. Using a dedicated tool, isolate the cylinder head

from the tilt cylinder tube.

NOTE: Take care not to damage the rod and bore

with the cylinder tube while disassembling and
assembling the tilt cylinder.

Vehicle Systems 10 Disassembly & Assembly

Disassembling and Assembling the
Lift Cylinder
a . Remove the lift cylinder.

ICCD005P

7. Remove the O-ring seal (8) from the cylinder rod.

ICCD009P

1. Isolate the lift cylinder head using a dedicated tool.

2. Isolate the rod (2) from the lift cylinder tube.

ICCD007P

8. Remove the O-ring seal (11) and back-up ring (2)

from the cylinder head.

ICCD094I

3. Remove the dust ring (11), wear ring (3), U-

packing (4), and back-up ring (5) from the piston
head (6).

ICCD008P

9. Remove the wiper seal (13), back-up ring (14), U-

packing (15), and DU bush (16) from the cylinder
head.

NOTE: Assembling procedures should be carried

out in reverse to the disassembling procedures.
ICCD011P

4. Remove the O-ring seal (7) from the head (1).

Vehicle Systems 11 Disassembly & Assembly

ICCD012P IF2M003P

5. Remove the wiper seal (8), U-packing(9), and DU 2. Isolate the fixing bolt (1) and washer from the
bush (10) from the cylinder head. counter weight, and remove the counter weight
from the vehicle.
NOTE: Assembling procedures should be carried (Counter weight weighs 2,010kg ~ 3,385kg)
out in reverse to the disassembling procedures.
< Assembling >

Counter Weight 3. Install an M30×3.5 eyebolt on the counter weight.

Connect the hoist with the eyebolt.

Removal and Replacement of 4. Fix the counter weight to the frame with the fixing
Counter Weight bolt (1).
(Be sure to insert a washer on the fixing bolt (1)).
a. Remove hood.
• Torque for the fixing bolt: 600±50N•m

Assemble hood.

IF2M147P

1. Install an M30×3.5 eyebolt on the counter weight.

Connect the hoist with the eyebolt and tighten the
hoist chain.

Vehicle Systems 12 Disassembly & Assembly

Hood <Assembling>

Disassembling and Assembling Hood

ICCD013P

1. Raise the hood.

IF2M148P

2. Remove the gas spring cylinder on the left. Left-hand gas cylinder

3. Remove the gas spring cylinder on the right.

4. Bind the hood firmly to the hoist.

5. Unscrew the hood fixing bolt, and isolate the hood

from the weight.

IF2M149P

Right-hand gas cylinder

6. Bind the hood firmly to the hoist.

7. Attach the hood to the weight hood bracket, and

fix the hood with the bolt (2).

8. Lower the hoist, and isolate the joist from the

hood.

Vehicle Systems 13 Disassembly & Assembly

Overhead Guide Seat

Removal and Replacement of the Removal and Replacement of the

Overhead Guide Seat

IF2M005P IF2M007P

1. Fix the overhead guide firmly with the hoist. 1. Unscrew the 4 bolts (1) which are tightened on
the seat bracket.
2. Unscrew the fixing bolt (1) on the rear side of the
overhead guide. NOTE: Assembling procedures should be carried
out in reverse to the disassembling procedures.

IF2M006P

3. Unscrew the fixing bolt (2) in front of the overhead

guide.

4. Fix the overhead guide firmly with the hoist.

Tighten the fixing bolt (1) with the guide in the fix
position.

5. Tighten the bolt (2) in front of the overhead guide.

Vehicle Systems 14 Disassembly & Assembly

Hydraulic Control Valve <Assembling >

4. Fix the control valve firmly with the hoist, and

Removal and Replacement of the assemble the 4 bolts, washers, and spring
Hydraulic Control Valve washers (2).

5. Connect the hydraulic line to the control valve.

(Confirm the marking for connecting the hydraulic
line).

6. Start the engine. Operate the tilt-lift cylinder more

than 10 times to remove air from the control valve.
After the operation, check the hydraulic oil tank
level. Fill it up to the appropriate level as
necessary.

7. Check the relief pressure of the control valve, and

IF2M008P adjust the pressure as necessary.

1. Start engine. Extend the tilt cylinder full length.

Stop the engine and remove the bottom plate.

WARNING

Never loosen any hydraulic line unless the tilt

cylinder has been extended full length.

2. To isolate the pilot hydraulic pressure line (1)

connected with the control valve, mark the
hydraulic line and isolate it.

3. Remove the 4 control valve fixing bolts, washers,

and spring washers (2), and remove the control
valve.
When removing the control valve, fix it firmly with
the hoist.

Vehicle Systems 15 Disassembly & Assembly

Main control valve 3. Operation

Max input pressure range should be less than 315

Precaution bar (4630psi).

Back pressure of tank port should be less than 25

1. Warning
bar (367psi).
In the system, all of the pipes must be carefully
The oil temperature should be between - 200C ~
cleaned before installation in order to remove dirt,
800C. And ambient temperature should be from -
rust, and deposits.
400C ~ 600C. Because that very high viscosity of
oil will be cause defect of spool operation, warm
The following cleaning procedures are
up the machine to avoid it,
recommended: Sanding, brushing, pickling, and
flushing with a solvent to remove contaminating
15/12-ISO4406 level of filtration is required in the
particles.
hydraulic circuit for long life cycle of each
components without mechanical trouble.
The use of Teflon tape, hemp, or other "fillers" for
joints is PROHIBITED
4. Tools needed for reworking
3, 8, 5, 12 mm wrench.
Verify that the pipes, fittings and connections not
17, 30, 36 mm spanner.
subjected to mechanical stress.
Torque wrench adjustable from 9 to 42 N•m.
Make sure that the pipes are not wound and that
there are no abrasions on the surface.

2. Installation

Valve piping joint should be tightened with the

specified torque value. When piping, care should
be taken not to apply excess pressure to the valve
is installed with incorrect torque values, it might
cause defect of spool operation, noise or vibration.
* Recommended tightening torque of SAE12 (1"
1/16-12UNF) & SAE16 (1"5/6-12UNF) is 42 N•m
and SAE6 (9/16-18UNF) is 24 N•m

Care must be taken not to damage the seals by

excess temperature or spatter of welding, when
welding near by the valve

During the installation, care must be taken not to

damage spool. It might cause defect of operation
such as the spool getting stuck in valve body.
Fit the rubber hosepipe for the machine, which
expected vibration.

Until piping, don't remove the blinds from each

port.

Vehicle Systems 16 Disassembly & Assembly

Replacing the parts.
1. Replacing complete working section.

Prepare two sizes of O-rings.

And fix the O-rings on the right positions with some
grease in order to avoid separation from the surface
while moving.

Loosen tightening bolts with two 17mm spanner.

Locate new or repaired working section in right

position according to the order of functions.
Taking out working section one by one.

Tighten four nuts (M17) in a crisscross pattern with

Remove O-rings on the surface of working section proper assembling torque 42 N·m.
properly.
Pay special attention not to give any scratch on the
surface.

Vehicle Systems 17 Disassembly & Assembly

2. Replacing spool & control kit

<Control kit for Lift & Aux>

Loosen 4 screws holding Aluminum kits to the body

with 5mm wrench.

< Control kit of MRV side for Tilt>

Take off all components and O-ring, valve inside, Prepare all components before starting
with attention not to give any damage to it. reassembling spool control kit.
Don’t use anything with sharp edge.

Fit Aluminum kit to the body with 5mm wrench by

Take out the spool, as straight as possible. Even 9.8 N·m.
very little force on the spool while disassembling &
assembling could make deformation on the spool.
Pay attention for the position of each spools and
direction.
Lift & tilt spools are not symmetrical,
So it should not be assembled in reverse.

Vehicle Systems 18 Disassembly & Assembly

3. Replacing Relief valve

Prepare a new relief valve

Replace old relief valve with new one

Relief valve should be fitted with proper tool, 36 mm
spanner, with 42 N·m torque.

Vehicle Systems 19 Disassembly & Assembly

Hydraulic Pump Two Disassembly Process
Speed
Rear section
General Instruction

Cleanliness
1. Cleanliness is the primary means of assuring
satisfactory hydraulic pump life.
Components such as flanges and covers are best
cleansed in soap and hot water, then air dried.
Gears should be washed in solvent, air dried, and
oiled immediately.

Certain cleaning solvents are flammable. Do not

allow sources of ignition in the area when using 1. Loosen and remove the clamp bolts (18) from
cleaning solvents. rear working section (1).
Related parts
2. Protect all exposed surfaces and open cavities Washer (22), Rear cover (4), Dowel pin (35),
from damage and foreign material. Square-ring (26).
Gear journals and gear faces are super finished.
Take care not to touch these surfaces after oil and
solvent.

Lubrication of moving parts

During assembly, all running surfaces (Bearing and
wear plate) must be lightly lubricated with a clean oil
or aerosol lubricant.

Tools required for assembly 2. Remove driving gear (10), driven gear (12) with
thrust plate parts (8, 23, 29), keeping gear as
1. Socket sets straight as possible, and working section (1) also.
Related parts
2. Internal snap ring pliers Back-up ring (29), O-ring (23), Thrust plate (8),
Working body (1), Square ring (26).
3. Shaft seal sleeve or clear tape

4. Torque wrench (200lbf ∙ft capacity)

5. Plastic hammer

6. Torque wrench box end adapters

Vehicle Systems 20 Disassembly & Assembly

Center section

1. Remove through shaft (33) from driving shaft (11). 4. Remove through shaft (34) from driving shaft (14).

2. Remove the flange (32) and the working section 5. Loosen and remove the clamp bolt (17) with
(2) with dowel pin (35). washer (21), and then remove the working section
Related parts (3) from mounting flange (5)
Square ring (26) Related parts
Square ring (25), Dowel pin (35)

3. Remove driving gear (11), driven gear (13) with

thrust plate parts (8, 23, 29), keeping gear as
straight as possible, from first working body (3).
Related parts
Back-up ring (29), O-ring (23), Thrust plate (8).

Vehicle Systems 21 Disassembly & Assembly

Front section Reassembly Process
Information for assembly way of thrust plates
It is important that all of thrust plate parts in this
hydraulic pump should be assembled such as below
picture during reassembly. Picture 8, 9 show
assembling sequence and direction.

1. Remove the snap-ring (28) and shaft seal (27),

and then remove mounting flange (5) from
working section (3).

2. Remove driving gear (14), driven gear (15) with

through shaft (34) and thrust plate parts (9,24,30)
from the working body (3), keeping gear as (9) Thrust plate (19) Plug
straight as possible, (14) Driving gear (24) O-ring
Related parts (15) Driven gear (30) Back-up ring
Plug (19), Back-up ring (30), O-ring (24), Thrust
plate (9).

Vehicle Systems 22 Disassembly & Assembly

Front cover area

1. Insert the shaft seal (27) carefully and fit it inside 2. Locate the o-ring (24) on the groove pre-arranged
of mounting flange (5) with proper tool. on the thrust plate (9).

2. Fit the snap-ring (28) in pre-arranged position with 3. Then, locate back-up ring (30) on the groove pre-
proper tool. arranged on the seals (9, 24) with plug (19).
Smear clean grease on the seal (24, 30)
(The front and rear thrust plates and seals and
Center section back-up ring are same.)

1. Fit the square ring (25) on the pre-arranged 4. Insert the driving gear (14) and driven gear (15)
groove of the working section (3). into working section (3) while keeping the gears
Smear clean grease on the square ring (25) to straight.
avoid drifting away of square ring from the Locate thrust plate (9+24+30) with care for the
working section (3). direction.

Vehicle Systems 23 Disassembly & Assembly

5. Locate the completed mounting flange (5+27+28) 10. Insert the driving shaft (11) and driven gear (13)
to working section (3) while tacking care not to including the completed thrust plate (8+23+29)
give any damage on the shaft seal by edge of into working section (3) while keeping the plate
shaft (14). straight.

6. Insert the through shaft (34) to rear side of the

driving shaft (14).

11. Insert the through shaft (33) into driving shaft

(11), and then locate the working body (2) and
flange (32) after inserting the squaring ring (26)
7. Tighten the bolt (17) with washer (21) in a cross to body (2).
pattern to torque valve of 140 N•m. Smear clean grease on the square ring (26) to
avoid drifting away of square ring from the
working body (2).

8. Locate the o-ring (23) on the groove ore-arranged

on the thrust plate (8).

9. Then, locate back-up ring (29) on the groove pre-

arranged on the seals (8, 23).
Smear clean grease on the seal (8, 23)
(The front and rear thrust plates and seals and
back-up ring are same.)

Vehicle Systems 24 Disassembly & Assembly

Rear section

1. Locate the o-ring (23) on the groove pre-arranged 5. Locate the rear cover (4) after inserting the
on the thrust plate (8). square ring (26) and the dowel pin (35) into the
rear working section (1).
2. Then, locate back-up ring (29) on the groove pre- Smear clean grease on the square ring (26) to
arranged on the seals (8, 23). avoid drifting away of square ring (26) from the
Smear clean grease on the seal (8, 23) rear cover (4).
(The front and rear thrust plates and seals and
back-up ring are same.)

6. Tighten the bolt (18) with washer (22) in a cross

pattern to torque valve of 45Nm.
3. Locate the driving gear (10) and driven gear (12) Check that the pump rotate freely when the
with thrust plate parts (8+23+29) into working driving shaft is turned by hand. If not a thrust plate
section (2). seal may be pinched.

4. Insert the dowel pin (35) into the working section

(2) and then, locate the rear working section (1) to
working section (2) while keeping the gear straight.
Smear clean grease on the square ring (26) to
avoid drifting away of square ring from the rear
working section (1).

Vehicle Systems 25 Disassembly & Assembly

Reference

PIC.23 Torque configuration for hydraulic pump

Vehicle Systems 26 Disassembly & Assembly

Three Speed Pump Disassembly Process
General Instruction
Rear section
Cleanliness
1. Cleanliness is the primary means of assuring
satisfactory hydraulic pump life.
Components such as flanges and covers are best
cleansed in soap and hot water, then air dried.
Gears should be washed in solvent, air dried, and
oiled immediately.

Certain cleaning solvents are flammable. Do not

allow sources of ignition in the area when using
cleaning solvents.

2. Protect all exposed surfaces and open cavities 1. Loosen and remove the clamp bolts (18) from
from damage and foreign material. rear working section (1).
Gear journals and gear faces are super finished. Related parts
Take care not to touch these surfaces after oil and Washer (21), Rear cover (4), Dowel pin (36),
solvent. Square-ring (26).

Lubrication of moving parts

During assembly, all running surfaces (Bearing and
wear plate) must be lightly lubricated with a clean oil
or aerosol lubricant.

Tools required for assembly

1. Socket sets

2. Internal snap ring pliers 2. Remove driving gear (11), driven gear (12) with
thrust plate parts (8, 22, 29), keeping gear as
3. Shaft seal sleeve or clear tape straight as possible, and working section (1) also.
Related parts
4. Torque wrench (200lbf ∙ft capacity) Back-up ring (29), O-ring (22), Thrust plats (8),
Working body (1), Square ring (26).
5. Plastic hammer

6. Torque wrench box end adapters

Vehicle Systems 27 Disassembly & Assembly

Center section Front section

1. Remove through shaft (35) from driving shaft (15). 1. Remove the snap-ring (28) and shaft seal (27),
and then remove mounting flange (5) and square
2. Loosen and remove the clamp bolt (17) with ring (25) from working section (3).
washer (21), and then remove the working section
(2) with dowel pin (36).
Related parts
Square ring (25)

2. Remove driving gear(10), driven gear(32) with

through shaft(34) and thrust plate parts(10,24,32)
from the working body(3), keeping gear as straight
as possible,
3. Remove driving gear (9), driven gear (14) with Related parts
thrust plate parts (9, 23, 30), keeping gear as Plug (19), Back-up ring (31), O-ring (24), Thrust
straight as possible, from first working body. plats (10).
Related parts
Back-up ring (30), O-ring (23), Thrust plats (9).

Vehicle Systems 28 Disassembly & Assembly

Reassembly Process Front cover area
Information for assembly way of thrust plates
It is important that all of thrust plate parts in this
hydraulic pump should be assembled such as below
picture during reassembling. Picture 7, 8 show
assembling sequence and direction.

1. Insert the shaft seal (27) carefully and fit it inside

of mounting flange (5) with proper tool.

2. Fit the snap-ring (28) in pre-arranged position with

Front view
proper tool.

Center section

Side view

(10) Thrust plate (24) O-ring

(13) Driving gear (31) Back-up ring
(19) Plug (32) Driven gear

1. Fit the square ring (25) on the pre-arranged

groove of the working section (3).
Smear clean grease on the square ring (25) to
avoid drifting away of square ring from the
working section (3).

Vehicle Systems 29 Disassembly & Assembly

2. Locate the o-ring (24) on the groove pre-arranged 5. Locate the completed mounting flange (5+27+28)
on the thrust plate (10). to working section (3) while tacking care not to
give any damage on the shaft seal by edge of
3. Then, locate back-up ring (31) on the groove pre- shaft (33).
arranged on the seals (10, 24) with plug (19).
Smear clean grease on the seal (24, 31) 6. Insert the through shaft (34) to rear side of the
(The front and rear thrust plates and seals and driving shaft (33).
back-up ring are same.)

7. Locate the o-ring (23) on the groove ore-arranged

4. Insert the driving gear (13) and driven gear (32) on the thrust plate (9).
into working section (3) while keeping the gears
straight. 8. Then, locate back-up ring (30) on the groove pre-
Locate thrust plate (10+24+31) with care for the arranged on the seals (9, 23).
direction Smear clean grease on the seal (9, 23)
(The front and rear thrust plates and seals and
back-up ring are same.)

Vehicle Systems 30 Disassembly & Assembly

Rear section

9. Insert the driving shaft (14) and driven gear (15)

including the completed thrust plate (9+23+30)
into working section (3) while keeping the plate
straight. 1. Locate the o-ring (22) on the groove pre-arranged
on the thrust plate (8).

2. Then, locate back-up ring (29) on the groove pre-

arranged on the seals (8, 22).
Smear clean grease on the seal (8, 22)
(The front and rear thrust plates and seals and
back-up ring are same.)

10. Insert the through shaft (35) into driving shaft

(15), and then locate the working body (2) after
inserting the squaring ring (25) to body (2).
Smear clean grease on the squaring (25) to
avoid drifting away of square ring from the
working body (2).

3. Locate the driving gear (11) and driven gear (12)

with thrust plate parts (8+22+29) into working
section (2).

4. Insert the dowel pin into the working section (2)

and then, locate the rear working section (1) to
working section (2) while keeping the gear straight.
Smear clean grease on the square ring (26) to
avoid drifting away of square ring from the rear
working section (1).

11. Tighten the bolt (17) with washer (21) in a cross

pattern to torque valve of 140 N•m.

Vehicle Systems 31 Disassembly & Assembly

Reference

5. Locate the rear cover (4) after inserting the

square ring (26) and the dowel pin (36) into the
rear working section (1).
Smear clean grease on the square ring (36) to
avoid drifting away of square ring (26) from the
rear cover (4).

6. Tighten the bolt (18) with washer (21) in a cross Torque configuration for hydraulic pump
pattern to torque valve of 45Nm.
Check that the pump rotate freely when the
driving shaft is turned by hand. If not a thrust plate
seal may be pinched.

Vehicle Systems 32 Disassembly & Assembly

Hydraulic Oil Filter Assembly Disassemble And Assemble
Hydraulic Oil Filter Assembly
Remove And Install Hydraulic Oil
Start By :
Filter Assembly
a. Remove hydraulic oil filter assembly.

IF2M156P
ICCD058P
1. Remove floor plate over the hydraulic oil filter.
1. Remove four bolts (2) that hold housing (1) to
2. Disconnect two oil lines (1). head (3).

3. Remove four bolts and washers (2) that hold the 2. Separate head (3) from housing (1).
oil filter assembly to the truck. Remove the oil filter.

NOTE: The following steps are for installation of the

hydraulic oil filter assembly.

4. Put the hydraulic oil filter assembly in position on

the lift truck. Attach the hydraulic oil filter
assembly with four bolts and washers (1).

5. Connect two oil lines (2).

6. Install floor plate.

ICCD059P
7. Fill hydraulic oil tank to the correct level. See the
Operation and Maintenance Manual. 3. Remove oil filter (5) and O-ring (4).

NOTE: The following steps are for the assembly of

the hydraulic oil filter assembly.

4. Install new filter (5). Put clean hydraulic oil on a

new O-ring seal (4) and install on housing (1).

5. Connect head (3) to housing (1) with four bolts (2).

b. End By : Install hydraulic oil filter assembly.

Vehicle Systems 33 Disassembly & Assembly

Steering Wheel Steering Column and Steering
Gear
Disassembling and Assembling the
Steering Wheel Removal and Replacement of the
Steering Column and Steering Gear

IF2M150P

1. Remove the button (1).

2. Remove and unscrew the wire (3) and screw (2).

IF2M157P

1. Remove the footing.

2. Unscrew the cover bolt (1) and remove the cover

(2).

IF2M159P 3. Isolate the hose from the steering gear. Mark the
hose before removal.
3. Unscrew the nut (4) carefully so as not to damage
the wire.

4. Remove the steering wheel.

NOTE: Assembling procedures shall be carried out

in reverse to the disassembling procedures.

Vehicle Systems 34 Disassembly & Assembly

IF2M158P

4. Disassemble the wheel tilting cylinder (3).

5. Unscrew the steering wheel fixing bolt (4) and

remove the steering gear.

NOTE: Assembling procedures should be carried

out in reverse to the disassembling procedures.

NOTE: Separate the steering gear and column if

necessary. When reassembling, tighten the bolt by
tightening torque of 15±2N∙m.

Vehicle Systems 35 Disassembly & Assembly

Disassemble & Assemble Steering
Unit
Start By :

a. Remove steering unit from the truck.

ICCD081P

4. Remove the components from housing (3) as

follows:

a. Remove plate (6) from housing (3).

b. Remove shaft (7) from gerotor (9).

ICCD079P

c. Remove gerotor (9) from housing (3).

1. Remove the elbows (1) from the body.
d. Remove O-rings seal (8) from housing (3).

e. Remove O-ring seal (10) from cap (4).

ICCD080P

2. Remove seven bolts (5) from gerotor housing (3).

ICCD082P

NOTICE 5. Remove suction valve balls (12) and pins (11).

Make a note of the position of special bolt with a pin.
It is located at a mark in line with check valve. 6. Remove screw (13) and check valve ball (14).

3. Separate housing (3) and cap (4) from steering

unit body (2).

Vehicle Systems 36 Disassembly & Assembly

ICCD083P ICCD086P

7. Remove O-ring seal (15) from steering unit body 10. Remove O-ring seal (24) and king-ring (25) from
(2). body.

8. Remove sleeve (16) from the body. 11. Check the condition of dust seal ring(26).
Replace seals with new if worn or damaged.

ICCD084P
ICCD087P

12. Remove plug (27) and washer (28) from steering

unit body.

ICCD085P

9. Remove the components from sleeve (16) as

follows :
ICCD088P
a. Remove pin (18) from spool (17) and sleeve
(16). 13. Remove plug (31) and spring (32) from the body
(2).
b. Remove spool (17) from sleeve (16).
14. Remove poppet (34) and relief valve housing
c. Remove two bearing races (19), (20) and (35) from the body.
bearing (21) from spool (17).

d. Remove six springs (23) and ring (22) from

spool (17).

Vehicle Systems 37 Disassembly & Assembly

ICCD089P ICCD087P

15. Remove plug (36) and washer (37) from the 19. Install washer (28) and plug (27) into body (2).
body. Tighten plugs to a torque 30 N·m (22 lb·ft).

NOTE: The following steps are for assembling the

steering pump.

ICCD086P

20. Install dust seal ring (26). Install O-ring seal (24)
ICCD089P
with king-ring (25) into body.

16. Install washer (37) and plug (36) into the

steering unit body.

ICCD085P

ICCD088P NOTICE
For purposes of installation, note that springs (23)
17. Install housing (35) and poppet (34) into the are installed in two stacks of three. Make sure the
pump body. curves of the two stacks are in contact and
positioned in the center of spool (17). The notched
18. Install spring (32) and plug (31) into body (2). side of springs (23) must be positioned toward
Tighten plug (31) to a torque 50 N·m (37 lb·ft). sleeve (16).

Vehicle Systems 38 Disassembly & Assembly

ICCD084P ICCD090S

21. Install springs (23) into spool (17).

22. Install spool (17) into sleeve (16).

23. Install pin (18), ring (22), two bearing races (19),
(20) and bearing (21) in their original positions on
spool (17).

ICCD081P

28. Install plate (6) onto steering unit body.

NOTICE
Make sure the notch of shaft (7) properly seats on
pin (18) when installed into body and spool (17).
ICCD083P

24. Install sleeve (16) into steering unit body (2). 29. Install shaft (7) into body (2) and spool (17).

25. Install O-ring seal (15) into body (2).

NOTICE
Gerotor (9) must be aligned with shaft (7) and pin
(18) as shown in the illustration.

30. Install O-ring seal (8) and housing (3).

31. Install O-ring seal (10) and cap (4).

ICCD082P

26. Install check valve ball (14) and screw (13).

Tighten the screw (13).

27. Install suction valve balls (12) and pins (11) in

their original positions into the steering unit body.

Vehicle Systems 39 Disassembly & Assembly

NOTICE
To assure proper operation of the steering unit,
make sure bolts (5) are clean and dry before
installing. Tighten bolts (5) in the sequence shown in
the illustration.

ICCD080P

32. Install bolts (5) into cap (4). Tighten bolts (5) in
correct sequence to a torque of 30 ± 6 N·m (22 ±
4.4 lb·ft).

End by :

a. Install steering unit to the truck.

Vehicle Systems 40 Disassembly & Assembly

Steer Axle
NOTICE
Make identification marks on all hydraulic
Remove & Install Steer Axle connectors and hoses to assure proper installation.
Plug and cap all hydraulic connectors and hoses to
Start By : avoid debris and contamination from entering the
system.
a. Remove counter weight.

3. Put block in position under the steer axle. Lift the

WARNING frame off the steer axle.

To prevent personal injury, all the control levers

backward or forward to release any pressure in
hydraulic system. Slowly loosen the cap of the
hydraulic tank to release any pressure in the
tack. Be cautious of hot hydraulic oil when any
lines are disconnected in the hydraulic system.

ICCD107P

4. Remove eight steer axle mounting bolts (4) and

washers from front and rear of the steer axle.

5. Pull steer axle (6) clear of the frame (5). Put

blocks under the axle to keep the axle stationary.
ICCD061P
NOTE: The following steps are for installation of the
steer axle.
1. Put block in position under both side of the frame.
Loosen six nuts (1) from steer tire wheel (2) (both
side).

ICCD107P

ICCD107P 6. Move the axle into position under the frame.

2. Disconnect two power steering hoses (3).

Vehicle Systems 41 Disassembly & Assembly

ICCD107P ICCD107P

7. Put Loctite No.271 on the threads of bolts (4). 11. Connect steering hoses (3) to elbows.

8. Install the washers and bolts (4) at front and rear 12. Start the engine. Run the steering cylinder
of the steer axle. through full stroke until all air is removed from the
hydraulic system. Add oil if needed to the
9. Tighten bolts (4) to a torque of........240 ± 40 N·m hydraulic tank. Stop the engine. See the
(178±30 lb·ft) Maintenance Manual.

End By :

a. Install counter weight

ICCD061P

10. Lift the rear of the frame and remove block from
under the frame.
Install steer tire wheel (2) and nut (1) (both side).
Torque spec : 645 ± 35 N·m (475 ± 26 lb·ft)

Vehicle Systems 42 Disassembly & Assembly

Remove And Install Steering Cylinder 6. Put steering cylinder (5) in position on the steer
axle.
Start By:
7. Tighten bolts (4) to a torque of 460 ± 60 N·m
a. Remove steer axle (339 ± 44 lb·ft) with Loctite No 271.

8. Connect two steering hoses (6).

9. Install the bolts, seals, washers and nuts (1) that

hold the links at each and of the steering cylinder
to the knuckle rod.

ICCD108P

1. Remove nut (1) washer and pin (2)

2. Turn the wheels (3) as needed to get clearance

for removal of the steering cylinder.

3. Repeat (1) through (2) at the opposite end of the

steering cylinder.

ICCD109P

4. Disconnect two power steering hoses.(6).

5. Remove bolts (4) and the washers that hold

steering cylinder (5) in place. Remove the steering
cylinder.

NOTE: The following steps are for installation of the

steer cylinder.

Vehicle Systems 43 Disassembly & Assembly

Disassemble and Assemble Steering
Cylinder
Start By :

a. Remove steering cylinder.

ICCD110P

5. Remove wear rings (5) and slipper seal (6) from

the piston.

ICCD065P

1. Put the steering cylinder in position in a vise.

2. Loosen head (1) from tube (2) with a spanner

wrench.

ICCD066P

6. Inspect the bushings (7) in the ends of the rod (3).

If a replacement of the bushings is needed,
remove the bushings from the rod.

7. Loosen the head in the opposite end of the tube.

ICCD066P

3. Remove rod assembly (3) from the tube (2).

ICCD112P

8. Remove O-ring seal (8) and backup ring (9) from

each head (1).

ICCD067P

4. Remove two spacers (4).

Vehicle Systems 44 Disassembly & Assembly

ICCD113P ICCD115P

9. Remove stopper (14), wiper seal (10) backup ring 2. Remove cotter pin (4) and nut (5), washer (6).
(11) U-packing (12) and DU-bush (13) from the
bore of each head.

NOTE: Assemble the steering cylinder in the

reverse order of disassembly.

Disassemble & Assemble Steer Axle

Start By :

a. Remove steer tire and steer axle ass’y

ICCD116P

3. Remove hub (3) with bearing (7).

ICCD108P

ICCD073P

4. If needed, remove bearing and seal (8) from the

hub (3).

ICCD114P

1. Remove the bolt (1) and cover, gasket (2) from

the hub (3).

Vehicle Systems 45 Disassembly & Assembly

ICCD117P ICCD117P

5. Remove nut (9), washer and link plates (10), shim, 11. Install link plates (10), shim rubber bush, pin (11),
rubber bush, pin (11). washer and nut. Tightem nut to a torque of 15 to
20 N·m (11 to 15 lb·ft).
6. Remove bolts (12) and plate, gasket.
12. Put clean grease in to both upper and lower hole
on the beam. Install plate and gasket, bolts (12).

ICCD118P

7. Remove set screw (13). ICCD119P

8. Remove king pin and knuckle (14), thrust bearing 13. Put clean grease on the knuckle shaft and into
(15). the hub ass’y

NOTE: The following steps are for assembly of the 14. Install bearing (7) and hub ass’y (3).
steer axle.

ICCD115P
ICCD118P
15. Put clean grease on the bearing.
9. Install thrust bearing (15) and knuckle (14), king
pin with clean grease. 16. Install washer (6) and nut (5). Tighten nut (5) to
a torque of 200 ± 10 N·m (147 ± 7 lb·ft).
10. Install set screw (13). Loosen the nut by one-fourth turn of one turn.
Install cotter pin (4).

Vehicle Systems 46 Disassembly & Assembly

Tires and Rims (Steer)

Remove and Install Tires and Rims

(Steer)

ICCD114P

ICCD061P

1. Put a hydraulic jack in position under the steer

axle.

2. Loosen nuts (1) that hold the tire and rim in place.
ICCD108P
3. Lift the steer axle until the tire is clear of the
ground.
17. Put clean grease around the bearing. Remove nuts (1). Remove the tire and rim.

18. Put gasket (2), cover and bolts. NOTE: The following steps are for installation of the
tires and rims (steer).

4. Put the tire and rim in position on the hub.

5. Install nuts (1) that hold the tire and rim in place.
Tighten the nuts to a torque of 645~35 N·m (475
± 25 ib·ft).

6. Lower the steer axle and remove the hydraulic

jack.

Vehicle Systems 47 Disassembly & Assembly

SB4278E00
Sep. 2007

Hydraulic Schematic
D50S-5, D60S-5, D70S-5, D80S-5, D90S-5
G50S-5, G60S-5, G70S-5
P/S CYLINDER HYDRAULIC SCHEMATIC
T (D511853)
T MODEL : D(G)50/60/70S-5
P

AUX3 5B TILT CYLINDER 2SPEED D518051

1 2 3 4 5 6 7 8 9 10 MAIN 3SPEED D518050
5A
CONTROL VALVE
(LIFT) (TILT) (AUX.1) (AUX.2) (AUX.3) P5b P5a
2S D514170
P1a P2a P3a P3b P4a P4b P5a P5b 3S D514171 AUX2 4B
(LIFTING) (FORWARD) 4S D514172
L 4A
P1b P2b PILOT CONTROL VALVE 5S D514173
R
(LOWERING) (BACKWARD) 2SPOOL P4b P4a
D514186
3SPOOL D514187
A AUX1 3B
PRESSURE 4SPOOL D514188 STD or SEC
REDUCING VALVE 5SPOOL D514189 3A
CYLINDER
(D514199) P3b P3a
HYD PUMP AS
(HYD PUMP+PRIORITY V/V)
STEERING UNIT 140bar
D50/80S (3S, ODB) D514193
(D512741) PRIMARY
D50/80S (3S, SHOE) D514196 TILT 2B
CYLINDER
D50/70S (2S, ODB) D514195
D50/70S (2S, SHOE) D514196 2A
G50/70S (ODB) D514197 P2b P2a FLOW
T P G50/70S (SHOE) D514198 PROTECTOR
CHECK V/V
(A135281) LIFT (D510892)
1B

< SHOE BRAKE > FLOW

SHOE BRAKE P1b P1a
T1 PROTECTOR
B P T (A135266)
235bar
BRAKE
PEDAL P FLOW
T2 P
MASTER CYLINDER REGULATOR
CF EF
(A135011)
TO BRAKE (SHOE:P, ODB:FLOW C/V(P)) THROTTLE CYLINDER
(A135457)
< OIL COOLED DISC BRAKE > LS
PRIORITY NEEDLE VALVE
MASTER CYL. VALVE (ONLY AVAILABLE (D512743)
(A335006) P ON G50/70S-5)
(D514190)
T
40bar M
W P A T FROM MASTER CYLINDER (SHOE:T1)
FLOW
CONTROL V/V HYD PUMP STANDARD CYLINDER FFT CYLINDER FORK MOVER & S/S CYLINDER
(D512959) F/M A135268
D(G)50/60S(A)-5, G70S-5 A135247 PRI. A135286
D70S-5, D80S-5 A135257 SEC. A135420 S/S A135214

Mast Load Relief pressure

Model type capacity Lift & tilt Auxiliary
2,460 (0,+70) psi
5 Ton 17,000 (0,+500) Kpa
D50/60/70S-5 (3S) STD 2,755 (0,+70) psi
6 Ton 19,000 (0,+500) Kpa
2,755 (0,+70) psi
7 Ton 19,000 (0,+500) Kpa
2,460 (0,+70) psi
5 Ton 2,035 (0,+70) psi
AXLE / BRAKE SUCTION RETURN
17,000 (0,+500) Kpa
G50/60/70S-5 2,755 (0,+70) psi 14,000 (0,+500) Kpa
STD 6 Ton
FILTER FILTER D50/60/70S-5 (2S) 19,000 (0,+500) Kpa
(A135050) (D501554) 2,755 (0,+70) psi
7 Ton 19,000 (0,+500) Kpa
FROM BRAKE (SHOE:T2, ODB:BRAKE V/V(T)) 2,460 (0,+70) psi
5 Ton 17,000 (0,+500) Kpa
G50/60/70S-5
D50/60/70S-5 (2S) FFT 2,755 (0,+70) psi
6 Ton
D50/60/70S-5 (3S) 19,000 (0,+500) Kpa
3,130 (0,+70) psi
7 Ton 21,600 (0,+500) Kpa
D502602
HYDRAULIC SCHEMATIC
MODEL : D80/90S-5

Mast Load Relief pressure

Model type capacity Lift & tilt Auxiliary
3,030 (+0,70) pis
8 Ton 20,900 (+0,500) Kpa 2,035 (+0,70) psi
D80/90S-5 STD 14,000 (+0,500) Kpa
3,300 (+0,70) pis
9 Ton 22,500 (+0,+500) Kpa

D500090
SB4279E00
Sep. 2007

Electric Schematic
D50S-5, D60S-5, D70S-5, D80S-5, D90S-5
G50S-5, G60S-5, G70S-5
ELECTRIC SCHEMATIC
MODEL : G50/60/70S-5 (2 SPEED, TIER-2 & Non-Certi)

A454005-00
ELECTRIC SCHEMATIC
MODEL : D50/60/70/80/90S-5 (2 SPEED)

A454009-00
ELECTRIC SCHEMATIC
MODEL : G50/60/70S-5 (2 SPEED, TIER-3)

A454027-00
ELECTRIC SCHEMATIC
MODEL : D50/60/70/80/90S-5 (3 SPEED)

A454000-00
SB4132E01
Sep. 2007

Mast System
Disassembly & Assembly
Specifications
Systems Operation
Testing & Adjusting

D50S-2, D60S-2, D70S-2, D80S-2

D50S-5, D60S-5, D70S-5
G50S-5, G60S-5, G70S-5
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.

Specific safety warnings for all these publications are provided in the description of operations where hazards exist.
WARNING labels have also been put on the product to provide instructions and to identify specific hazards. If
these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. Warnings in this
publication and on the product labels are identified by the following symbol.

WARNING

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result
in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and
understood the operation, lubrication, maintenance and repair information.

Operations that may cause product damage are identified by NOTICE labels on the product and in this publication.

DOOSAN cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in
this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating
technique not specifically recommended by DOOSAN is used, you must satisfy yourself that it is safe for you and
others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication,
maintenance or repair procedures you choose.

The information, specifications, and illustrations in this publication are on the basis of information available at the
time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other
items can change at any time. These changes can affect the service given to the product.
Obtain the complete and most current information before starting any job. DOOSAN dealers have the most
current information available.

1
Index

Disassembly & Assembly

Carriage......................................................................5
Carriage Rollers .........................................................6
Mast............................................................................8

Specifications
Carriage....................................................................12
Lift Chains ................................................................12
Mast..........................................................................12

Systems Operations
Lift Cylinder & Mast ..................................................13

Testing & Adjusting

Carriage Adjustment.................................................15
Chain Adjustment Check..........................................16
Chain Adjustment .....................................................16
Chain Adjustments ...................................................16
Chain Wear Test ......................................................16
Cylinder Adjustment .................................................14
Drift Test...................................................................18
Mast Adjustment.......................................................14
Mast And Carriage ...................................................14
Measurement Of Carriage And Forks ......................17
Tilt Angle Check .......................................................17

Mast Systems 3 Index

Disassembly & Assembly NOTE: The following steps are for installation of the
carriage. See the topic entitled Carriage Adjustment,
in the Testing and Adjusting Section before installing
Carriage the carriage on the mast.

Remove & Install Carriage

Start By :

a. Remove forks

1. Completely lower carriage and inner mast.

7. Attach a hoist to the carriage as shown.

8. Start the engine. Raise the mast until the carriage

will go under the inner mast.

9. Move the carriage in position under the mast.

10. Completely lower the mast over the carriage

2. Attach a hoist to the carriage as shown. making sure the rollers are properly aligned
inside the inner mast.
3. Lift the carriage with the hoist until the chains and
hoses hang loosely.

ICMT002P

ICMT002P
11. Pull the chains into position on the carriage.
Install pin (2) and the cotter pin in each of the lift
4. Remove the cotter pin and pin (1) from each of chains.
the lift chains.
12. Make an adjustment to the lift chains. See the
5. Start the engine. Raise the mast until the inner topic entitled Chain Adjustments in the Testing
mast clears the carriage. and Adjusting Section.

6. Remove the carriage. The weight of the carriage End By :

is 521 kg (1150 lb).
a. Install forks.

Mast Systems 5 Disassembly & Assembly

Carriage Rollers
Remove & Install Carriage Main (&
Middle) Rollers
Start By :

a. Remove carriage 3

ICMT008P

4. Remove four bolts (3) to remove side roller.

7
4

ICMT005P

1. Remove the snap ring that holds main roller in

place.
5

ICMT009P

ICMT006P
5. Remove brackets (4), washers (5), roller (6) and
shims (7), pins
2. Remove load roller (1) from the carriage.
6. Install all rollers in reverse order of disassembly.

End by :

2 a. Install carriage.

ICMT007P

3. Remove snap ring and middle roller (2) (if

equipped)

Mast Systems 6 Disassembly & Assembly

Disassemble & Assemble Carriage
Rollers
Start By :

a. Remove carriage rollers.

ICMT0011P

3. Install snap ring in the roller.

4. Put (pack) clean grease in the bearings for the

rollers.

ICMT0010P

1. Remove the bearings from the roller with brass

bar and hammer in both side.

ICMT0013P

5. Install the bearings in the roller with the correct

size press tool so that the bearings are against
the snap ring. The side of the bearing without a
ICMT0011P cover (shield) must be toward the inside of the
roller.
2. Remove snap ring from the roller.
End By :
NOTE: The following steps are for the assembly of
the carriage rollers. a. Install carriage rollers

Mast Systems 7 Disassembly & Assembly

Disassemble & Assemble Carriage Mast
Pad & Shims
Start By :
Start By :
a. Remove carriage
a. Remove carriage
1. Fully lower mast.

ICMT0014P

1. Remove two bolts (1).

2. Fasten a hoist to the mast as shown.
2. Remove shims, bar and pad in both sides.

NOTE: Put identification marks on the shims in

each position for installation.

3. Install all above parts in reverse order of

disassembly.

End by :

a. Install carriage
1
ICMT0016P

3. Tilt the mast forward. Disconnect two lines (1).

Mast Systems 8 Disassembly & Assembly

NOTE: If lift cylinders were removed from the mast,
adjust both lift chains to equal tension. Run the mast
to full lift. If mast does not kick to either side, no
shims are required. If mast does kick to one side.
disconnect cylinder from support assembly on that
side. Add shims, reassemble and repeat. Repeat
3 process until “Kicking” is corrected. Do not exceed 3
mm(.12”) of shims.
4
End By :

ICMT0036P a. Install carriage.

(Shoe Axle)

3 4

S2010011

(ODB Axle)

4. Remove bolt (3) and pin (4). By using steel bar to

remove mast from axle.

5
ICMT0037P

5. Remove bolts (5) and pin ass’y (6).

6. Repeat Steps 4, 5 for the other side of the mast.

7. Start the engine. Operate the control lever for the

tilt cylinders until the rods are fully retracted.

8. Remove the mast from the frame of the vehicle.

The weight of the mast (D70S-2 STD 3.0 M) is
1250 kg (2756 lb).

9. Install mast in reverse order of assembly.

Mast Systems 9 Disassembly & Assembly

Disassemble and Assemble Mast
Start By :
6

a. Remove mast

1
7
ICMT0025P

6. Disconnect lines (6).

7. Remove two bolts (7) and the flow regulating

2
assembly.
ICMT0019P

1. Remove nut (1) and chain (2) from the mast.

ICMT0023P

3 8. Remove bolts and nuts (8) from each side.

ICMT0020P

2. Remove snap ring.

3. Remove sheave (3).

4. Repeat Steps (1) Through (3) for the other side of

the mast.

ICMT0038P

9. Remove bolt (9).

5
4
ICMT0021P

5. Remove bolts (4) and bracket (5).

Mast Systems 10 Disassembly & Assembly

ICMT0025P

10. Lift carefully lift cylinder (10) by hoist.

11. Remove lift cylinder (10). The weight of the lift

cylinder (D70S-2 STD 3M) is 72 kg (159 lb). Mark
for identification and remove the shims at the top
of cylinder (10).

NOTE: At installation, adjust both lift chains to equal

tension. Run the mast to full lift. If mast does not not
kick to either side, no shims are required. If mast
does kick to one side, disconnect cylinder from
support assembly on that side. Add shims,
reassemble and repeat. Repeat process until
“Kicking” is corrected. Do not exceed 3 mm(.12”) of
shims.

12. Repeat steps (8) through (11) for the other side.

13. Fasten a hoist to outer mast (11). Use a lift truck

to separate inner mast (12) from outer mast (11).

NOTE: Assemble in reverse order.

End By :

a. Install mast

Mast Systems 11 Disassembly & Assembly

Specifications Lift Chains

Mast WARNING
Do not put a lift truck into service if the chain
2 wear indication is 2% or more. A reading of 2% or
more could cause damage or injury to persons.

1
Maximum chain wear .............................Less than 2%
Lift chain must be replaced at 2% wear (See Chain
Wear Test in Testing And Adjusting).

Carriage

X 1

4
ICMT010I Y
(1) Clearance between outside face of PAD and
outside surface of inner mast flange maximum
width 0.0 to 0.5 mm 2
See Mast Adjustment in Testing And Adjusting.

(2) Clearance between load roller of outer mast and

inner mast flange .... 0.0 to 0.5 mm (.00 to 0.02 in)

See Mast Adjustment in Testing And Adjusting. ICMT0101I

(3) Clearance between outside face of thrust roller (1) Shim as required so dimension (X) between block
and the inside surface of the outer mast at its and mast upright surface, each side, is tight
minimum width.......0.0 to 0.5 mm (0.00 to 0.02 in) without restricting carriage movement.

See Mast Adjustment in Testing And Adjusting. (2) Shim as required so dimension (Y) between thrust
roller and most upright surface, each side, is tight
(4) Clearance between load roller of inner mast and without restricting carriage movement.
outer mast flange ...........................0.0 to 1.5 mm
(0.00 to 0.06 in) See Carriage Adjustment in Testing And
Adjusting.

Mast Systems 12 Specifications

Systems Operations 5

Lift Cylinder & Mast

The pistons and rods of lift cylinders are moved up by
hydraulic oil pressure and returned to their original
position by gravity. 4

The single action of the lift cylinders together with 3

other mechanical lifting components will operate as ICMT0028P 1
follows : Lift Components (Up Position)
When the lift lever of the control valve is pulled back, (1) Stationary Mast. (3) Inner Mast. (4) Carriage.
the hydraulic oil pressure pushes against the inner (5) Lift Chains.
pistons at the bottom of the lift cylinders. Inner mast
(3) and chain sheave (2) start to move up. At the The mast components are inner mast (3), stationary
same time, carriage (4) also starts to move up mast (1), lift cylinders and lift chains (5). The mast
because it is connected to chains (5) which move on assembly has movement with upper and lower rollers
the rollers of chain sheave (2). Carriage (4) moves at installed on sealed bearings. Upper side thrust blocks
2:1 ratio with the rods of the lift cylinders. This and rollers control the side thrust movement and are
movement of inner mast (3) and carriage (4) goes on adjustable with shims. Carriage (4) also has rollers.
until lift cylinders are at the end of their stroke. The carriage side thrust movement is also controlled
by thrust blocks and rollers which are adjustable with
2 shims.
3

1
5
4

ICMT0027P

Lift Components (Down Position)

(1) Stationary Mast. (2) Chain Sheave. (3) Inner Mast.
(4) Carriage. (5) Lift Chains.

When the lift lever of the control valve is pushed

forward, the cycle to lower the mast starts. The
hydraulic oil pressure is released in the lift cylinders
and gravity lowers the inner mast and carriage. The
carriage moves down at 2:1 ratio with the cylinder
rods. The inner mast moves at the same speed as
the cylinder rods. This movement of the mast and
carriage goes on until the mast has lowered
completely and the forks are on the floor.

Mast Systems 13 Systems Operation

Testing & Adjusting Upper Side Rollers
1. Measure the distance (U1) between two upper
Mast And Carriage side Pad (4).

2. Measure the distance (U2), at least three point,

Mast Adjustment on inner mast (2) across the mast rail by using
proper scale.
The carriage must be removed from the mast. The
mast must be removed from the lift truck. The inner 3. Adjust shims (6) to keep the gab (U1 min-U2
mast must be removed from the outer mast. max) is within 1mm.

The side rollers are adjusted by shims installed

equally on each side of the channel. Use the following Lower Side Rollers
procedure to adjust the channel side rollers :
4. Measure the distance (N1) between two lower
side rollers (3).
2 1
5. Measure the distance (N2), at least three point,
4 on outer mast (1) across the mast rail by using
6 proper scale.
U1

U2 6. Adjust shims (5) to keep the gab (N2min-N1max)

is within 1mm.

NOTE: When adjusting shim, divide the shims in to

the two groups that have the same thickness.

7. Slide the masts completely together. Install the

mast on vehicle. Install the carriage.
N1
8. With a rated load on the forks, fully raise and
lower the mast a minimum of 30 times for break-
3 in.
N2

5 Cylinder Adjustment
INNER MAST OUTER MAST
ICMT003I
1. Make sure the lift chains are adjusted for equal
Mast tension and proper performance. See topic Chain
(1) Outer Mast. (2) Inner Mast. (3) Lower Side Roller. Adjustment in this section. Run mast to full lift. If
(4) Side Pad. (5), (6) Shims. mast does not kick to either side, no shims are
required. If mast does kick to one side,
disconnect the cylinder from the support
assembly on that side. Add shim and reassemble.
Adjust chains for equal tension and raise mast
fully to check for kicking. Repeat process if
necessary, adding 3mm (.12 in) of shims
maximum. Adjust chains per topic Chain
Adjustment in this section.

Mast Systems 14 Testing & Adjusting

Carriage Adjustment

1 4
X

ICMT005I

Carriage
(1) Shims. (2) Shims. (3) Thrust Roller. (4) Slider Block.

NOTE: Shims (1) are located under upper slider

block & under bracket of roller.

NOTE: Shims are required so clearance (X), (Y)

between slider block and inner mast, thrust rollers
and inner mast side surface is 0.0 to 0.5 mm.
Shims (2) are located between carriage plate & thrust
roller bracket.

Mast Systems 15 Testing & Adjusting

Chain Adjustments 2. Loosen locknut (2) and adjust chains with
adjustment nut (1) to be just taut (no slack).
Chain Adjustment Check 3. Raise carriage 305 mm (12 in).

4. Adjust by shortening the loose chain to create

equal tension on both chains.

5. After the chain adjustment, fully raise the mast.

Some clearance must exist between the upper
carriage rollers or side plates and the inner mast
top support. If no clearance exists, lengthen both
chains equally to provide clearance. Tighten
locknut (2).

ICMT0029P
Chain Adjustment Check (Typical Example) Chain Wear Test
1. Completely lower the carriage and the inner mast. Chain wear test is a measurement of wear of the
chain links and pins. Do the steps that follow to check
2. The chains must not be too loose when the chain wear.
carriage is completely lowered. There must be
just a small amount of movement (deflection) of 1. Lift the mast and carriage enough to put tension
each chain. on the lift chains.

3. Lift the carriage until its weight is supported by 2. Measure precisely ten links of chain distance at
the chains. the center of pins in millimeter.
A chain wear gauge can also be used.
4. The tension on the chains must be equal.
3. Calculate chain wear rate.

Chain Adjustment New one pitch = 25.4 mm

Chain wear rate (%)

If the tension is not the same on both chains, do the
procedure that follows :
Actual measurement – 254
= X 100
254

WARNING
Do not put a lift truck into service if the chain
wear indication is 2% or more. A reading of 2% or
1 more could cause damage or injury to persons.

2
ICMT0030P 4. If the chain wear indication is 2% or more,
replace the lift chain.
Chain Anchor Bolt Adjustment
(1) Chain adjustment nut. (2) Locknut.

1. Lower the carriage and inner mast until bottomed

on the stationary mast section.

Mast Systems 16 Testing & Adjusting

Measurement Of Carriage
And Forks
The adjustment of the carriage must be correct before
doing this procedure. Measure the distance from the
bottom of the fork shaft to the ground on both sides of
the carriage. The fork shaft must be horizontal within
6.4 mm (.25 in) on the outer edges of the carriage.

ICMT0033P
Fork Heel Height Check

Finally, make sure each fork is parallel. Measure the

distance between the heel and the ground and then
the distance between the tip and the ground on each
fork. The difference between these measurements
must not be more than 12.7 mm (.50 in).

ICMT0031P
Fork Shaft Height Check Tilt Angle Check
The tilt angle of the mast must be checked in the full
tilt back and full tilt forward positions. A tilt indicator or
a protractor can be used to measure the angles. Both
sides of the mast must be checked to make sure that
the mast is not twisted.

ICMT0032P

Fork Tip Height Check

Check the distance from the tips of the forks to the

ground. They must be within 12.7 mm (.50 in) in the
same flat surface (plane).
Tilt Angle Check (Typical Example)
Check the distance from heels of the forks to the
ground. They must be within 6.4 mm (.25 in) in the 1. With the mast tilted completely forward, tilt angle
same flat surface (plane). (A) must be either 5 ± 1/2°, 6 ± 1/2° or 15 ± 1/2°
The proper forward tilt angle for the truck is
stamped on the truck identification plate.

2. With the mast tilted completely backward, tilt

angle (B) must be either 5 ± 1/2° or 10 ± 1/2° The
proper backward tilt angle for the truck is
stamped on the truck identification plate.

Mast Systems 17 Testing & Adjusting

3. A visual inspection must be made to see if the Drift Test
cylinders extend and retract evenly. If one
cylinder rod has travel (movement) with the other Drift is movement of the mast or carriage that is the
one stopped in forward or backward tilt, one result of hydraulic leakage in the cylinders or control
cylinder rod must be adjusted to make them both valve. Before testing the drift.
stop evenly.
1. Check the chain adjustment and tilt cylinder
4. Bolt (1) and nut that holds the cylinder rod in alignment and make necessary adjustments.
position must be loosened from clevis (2).
2. Lift the mast approximately 762 mm (30 in).
5. Tighten or loosen the cylinder rod at the grooves.
If the cylinder rod needs to be moved forward,
turn the rod out of the clevis. Turn the rod into the WARNING
clevis to move the cylinder rod backward.
To prevent personal injury, use wood blocks and
clamps to hold the mast in this position.
WARNING
Always make sure the cylinder rod has a depth 3. Remove the blocks and clamps and lower the
into the clevis that is equal to or greater than the mast.
outside diameter of the rod.
4. Tighten the tilt cylinder jam nuts to 115.6 ~ 133.3
N•m (86 ~ 99 lb•ft).
6. Check the cylinders again after the adjustments
have been made to be sure of the rods correct
travel.

ICMT0037P
Nut Cylinders Support
(1) Bolt. (2) Clevis.

7. Tighten bolts (1) a torque of 115.6 ~ 133.3 N•m

(86 ~ 99 lb lb•ft).

Mast Systems 18 Testing & Adjusting

Drift Test For the Lift System Drift Test for The Tilt System
1. Put rated capacity load on the forks of the lift Tilt drift is the change in the tilt cylinder rod stroke
truck. Operate the lift truck through a complete lift with a rated load on the forks.
and tilt cycle until oil is at normal temperature for
operation 45 to 55°C (113 to 131°F). 1. With the hydraulic oil at normal temperature for
operation 45 to 55°C (113 to 131°F), lift a rated
2. With the load on the forks and the mast at zero capacity load off the ground with the mast in
degrees of tilt, lift the carriage until the bottom of vertical position.
the forks are even with the top of the cowl. Make
a mark on the mast outer assembly, even with the 2. Measure the tilt cylinder rods stroke from the nut
bottom of the forks. Measure the amount of drift to the cylinder housing.
in a 10 minute period from the mark to the bottom
of the forks. Following are the maximum 3. Operate the mast to the complete forward
permissible drift rates for the different models. position and to the reverse position three or four
times.
D50S-2...................................................100 mm (4 in)
4. Put the mast back to the vertical position
D60S-2...................................................100 mm (4 in)
5. Stop the engine, wait 10 minutes and take
D70S-2...................................................100 mm (4 in) another measurement of the tilt cylinder rods
stroke.
D80S-2....................................................100mm (4 in)
6. If the measurement changed from the
D50S-5....................................................100mm (4 in) measurement taken in Step 2 then the tilt system
has drifted.
D60S-5....................................................100mm (4 in)
7. Following are the maximum permissible drift rates
D70S-5....................................................100mm (4 in) for the different models.

G50S-5....................................................100mm (4 in) D50S-2 ................................................. 53 mm (2.1 in)

G60S-5....................................................100mm (4 in) D60S-2 ................................................. 53 mm (2.1 in)

G70S-5....................................................100mm (4 in) D70S-2 ................................................. 53 mm (2.1 in)

D80S-2 ................................................. 53 mm (2.1 in)

D50S-5 ................................................. 53 mm (2.1 in)

D60S-5 ................................................. 53 mm (2.1 in)

D70S-5 ................................................. 53 mm (2.1 in)

G50S-5 ................................................. 53 mm (2.1 in)

G60S-5 ................................................. 53 mm (2.1 in)

G70S-5 ................................................. 53 mm (2.1 in)

Mast Systems 19 Testing & Adjusting

SB4280E00
Sep. 2007

Mast System
Disassembly & Assembly
Specifications
Systems Operation
Testing & Adjusting

D80S-5, D90S-5
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 or the Service or Technical Manual. Additional safety
precautions are listed in the “Safety” section of the owner/operation/maintenance publication.
Specific safety warnings for all these publications are provided in the description of operations where hazards exist.
WARNING labels have also been put on the product to provide instructions and to identify specific hazards. If
these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. Warnings in this
publication and on the product labels are identified by the following symbol.

WARNING

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result
in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and
understood the operation, lubrication, maintenance and repair information.

Operations that may cause product damage are identified by NOTICE labels on the product and in this publication.

DOOSAN cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in
this publication and on the product are therefore not all inclusive. If a tool, procedure, work method or operating
technique not specifically recommended by DOOSAN is used, you must satisfy yourself that it is safe for you and
others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication,
maintenance or repair procedures you choose.

The information, specifications, and illustrations in this publication are on the basis of information available at the
time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other
items can change at any time. These changes can affect the service given to the product.
Obtain the complete and most current information before starting any job. DOOSAN dealers have the most current
information available.

1
Index

Disassembly & Assembly

Systems Operations
Lift Cylinder & Mast ..................................................13

Testing & Adjusting

Mast Systems 3 Index

a. Remove forks

1. Completely lower carriage and inner mast.

7. Attach a hoist to the carriage as shown.

8. Start the engine. Raise the mast until the carriage

will go under the inner mast.

9. Move the carriage in position under the mast.

10. Completely lower the mast over the carriage

making sure the rollers are properly aligned
2. Attach a hoist to the carriage as shown. inside the inner mast.

3. Lift the carriage with the hoist until the chains and
hoses hang loosely.
2

ICMT002P

11. Pull the chains into position on the carriage.

ICMT002P
Install pin (2) and the cotter pin in each of the lift
chains.
4. Remove the cotter pin and pin (1) from each of
the lift chains. 12. Make an adjustment to the lift chains. See the
topic entitled Chain Adjustments in the Testing
5. Start the engine. Raise the mast until the inner and Adjusting Section.
mast clears the carriage.
End By :
6. Remove the carriage. The weight of the carriage
is 820kg (1810 lb). a. Install forks.

Mast Systems 5 Disassembly & Assembly

Carriage Rollers
Remove & Install Carriage Main (&
Middle) Rollers
Start By :

a. Remove carriage 3

ICMT008P

4. Remove four bolts (3) to remove side roller.

7
4

ICMT005P

1. Remove the snap ring that holds main roller in

place.
5

ICMT009P

ICMT006P
5. Remove brackets (4), washers (5), roller (6) and
shims (7), pins
2. Remove load roller (1) from the carriage.
6. Install all rollers in reverse order of disassembly.

End by :

2 a. Install carriage.

ICMT007P

3. Remove snap ring and middle roller (2) (if

equipped)

Mast Systems 6 Disassembly & Assembly

Disassemble & Assemble Carriage
Rollers
Start By :

a. Remove carriage rollers.

ICMT0011P

3. Install snap ring in the roller.

4. Put (pack) clean grease in the bearings for the

rollers.

ICMT0010P

1. Remove the bearings from the roller with brass

bar and hammer in both side.

ICMT0013P

5. Install the bearings in the roller with the correct

Mast Systems 7 Disassembly & Assembly

Disassemble & Assemble Carriage Mast
Pad & Shims
Start By :
Start By :
a. Remove carriage
a. Remove carriage
1. Fully lower mast.

ICMT0014P

1. Remove two bolts (1).

2. Fasten a hoist to the mast as shown.
2. Remove shims, bar and pad in both sides.

NOTE: Put identification marks on the shims in

each position for installation.

3. Install all above parts in reverse order of

disassembly.

End by :

a. Install carriage
1
ICMT0016P

3. Tilt the mast forward. Disconnect two lines (1).

Mast Systems 8 Disassembly & Assembly

ICMT0036P a. Install carriage.

(Shoe Axle)

3 4

S2010011

(ODB Axle)

4. Remove bolt (3) and pin (4). By using steel bar to

remove mast from axle.

5
ICMT0037P

5. Remove bolts (5) and pin ass’y (6).

6. Repeat Steps 4, 5 for the other side of the mast.

7. Start the engine. Operate the control lever for the

tilt cylinders until the rods are fully retracted.

8. Remove the mast from the frame of the vehicle.

The weight of the mast (D80/90S-5 STD 3.1 M) is
1348kg (2970 lb).

9. Install mast in reverse order of assembly.

Mast Systems 9 Disassembly & Assembly

Disassemble and Assemble Mast
Start By :
6

a. Remove mast

1
7
ICMT0025P

6. Disconnect lines (6).

7. Remove two bolts (7) and the flow regulating

2
assembly.
ICMT0019P

1. Remove nut (1) and chain (2) from the mast.

ICMT0023P

3 8. Remove bolts and nuts (8) from each side.

ICMT0020P

2. Remove snap ring.

3. Remove sheave (3).

4. Repeat Steps (1) Through (3) for the other side of

the mast.

ICMT0038P

9. Remove bolt (9).

5
4
ICMT0021P

5. Remove bolts (4) and bracket (5).

Mast Systems 10 Disassembly & Assembly

ICMT0025P

10. Lift carefully lift cylinder (10) by hoist.

11. Remove lift cylinder (10). The weight of the lift

cylinder (D80/90S-5 STD 3.1M) is 80kg (176 lb).
Mark for identification and remove the shims at
the top of cylinder (10).

NOTE: At installation, adjust both lift chains to equal

tension. Run the mast to full lift. If mast does not kick
to either side, no shims are required. If mast does
kick to one side, disconnect cylinder from support
assembly on that side. Add shims, reassemble and
repeat. Repeat process until “Kicking” is corrected.
Do not exceed 3 mm (.12”) of shims.

12. Repeat steps (8) through (11) for the other side.

13. Fasten a hoist to outer mast (11). Use a lift truck

to separate inner mast (12) from outer mast (11).

NOTE: Assemble in reverse order.

End By :

a. Install mast

Mast Systems 11 Disassembly & Assembly

Specifications Lift Chains

Mast WARNING
Do not put a lift truck into service if the chain
2 wear indication is 2% or more. A reading of 2% or
more could cause damage or injury to persons.

1
Maximum chain wear .............................Less than 2%
Lift chain must be replaced at 2% wear (See Chain
Wear Test in Testing And Adjusting).

Carriage

4
ICMT010I

(1) Clearance between outside face of PAD and

outside surface of inner mast flange maximum
width 0.0 to 0.5 mm

See Mast Adjustment in Testing And Adjusting.

(2) Clearance between load roller of outer mast and

inner mast flange .... 0.0 to 0.5 mm (.00 to 0.02 in) (1) Shim as required so dimension (X) between block
and mast upright surface, each side, is tight
See Mast Adjustment in Testing And Adjusting. without restricting carriage movement.

(3) Clearance between outside face of thrust roller (2) Shim as required so dimension (Y) between thrust
and the inside surface of the outer mast at its roller and most upright surface, each side, is tight
minimum width.......0.0 to 0.5 mm (0.00 to 0.02 in) without restricting carriage movement.

See Mast Adjustment in Testing And Adjusting. See Carriage Adjustment in Testing And
Adjusting.
(4) Clearance between load roller of inner mast and
outer mast flange ...........................0.0 to 1.5 mm
(0.00 to 0.06 in)

Mast Systems 12 Specifications

Systems Operations 5

Lift Cylinder & Mast

The pistons and rods of lift cylinders are moved up by
hydraulic oil pressure and returned to their original
position by gravity. 4

The single action of the lift cylinders together with 3

1
5
4

ICMT0027P

Lift Components (Down Position)

(1) Stationary Mast. (2) Chain Sheave. (3) Inner Mast.
(4) Carriage. (5) Lift Chains.

When the lift lever of the control valve is pushed

Mast Systems 13 Systems Operation

Testing & Adjusting Upper Side Rollers
1. Measure the distance (U1) between two upper
Mast And Carriage side Pad (4).

2. Measure the distance (U2), at least three point,

The side rollers are adjusted by shims installed

U2 6. Adjust shims (5) to keep the gab (N2min-N1max)

is within 1mm.

NOTE: When adjusting shim, divide the shims in to

the two groups that have the same thickness.

7. Slide the masts completely together. Install the

mast on vehicle. Install the carriage.
N1
8. With a rated load on the forks, fully raise and
lower the mast a minimum of 30 times for break-
3 in.
N2

Mast Systems 14 Testing & Adjusting

Carriage Adjustment

ICMT005I

Carriage
(1) Shims. (2) Shims. (3) Thrust Roller. (4) Slider Block.

NOTE: Shims (1) are located under upper slider

block & under bracket of roller.

NOTE: Shims are required so clearance (X), (Y)

between slider block and inner mast, thrust rollers
and inner mast side surface is 0.0 to 0.5 mm.
Shims (2) are located between carriage plate & thrust
roller bracket.

Mast Systems 15 Testing & Adjusting

Chain Adjustments 2. Loosen locknut (2) and adjust chains with
adjustment nut (1) to be just taut (no slack).
Chain Adjustment Check 3. Raise carriage 305 mm (12 in).

4. Adjust by shortening the loose chain to create

equal tension on both chains.

5. After the chain adjustment, fully raise the mast.

Chain Adjustment New one pitch = 38.1 mm

Chain wear rate (%)

If the tension is not the same on both chains, do the
procedure that follows :
Actual measurement – 381
= X 100
381

WARNING
Do not put a lift truck into service if the chain
wear indication is 2% or more. A reading of 2% or
1 more could cause damage or injury to persons.

2
ICMT0030P 4. If the chain wear indication is 2% or more,
replace the lift chain.
Chain Anchor Bolt Adjustment
(1) Chain adjustment nut. (2) Locknut.

1. Lower the carriage and inner mast until bottomed

on the stationary mast section.

Mast Systems 16 Testing & Adjusting

ICMT0033P
Fork Heel Height Check

Finally, make sure each fork is parallel. Measure the

distance between the heel and the ground and then
the distance between the tip and the ground on each
fork. The difference between these measurements
must not be more than 12.7 mm (.50 in).

ICMT0032P

Fork Tip Height Check

Check the distance from the tips of the forks to the

2. With the mast tilted completely backward, tilt

angle (B) must be either 5 ± 1/2° or 10 ± 1/2° The
proper backward tilt angle for the truck is
stamped on the truck identification plate.

Mast Systems 17 Testing & Adjusting

2. With the load on the forks and the mast at zero

degrees of tilt, lift the carriage until the bottom of
the forks are even with the top of the cowl. Make
a mark on the mast outer assembly, even with the
bottom of the forks. Measure the amount of drift
ICMT0037P in a 10 minute period from the mark to the bottom
of the forks. Following are the maximum
Nut Cylinders Support
permissible drift rates for the different models.
(1) Bolt. (2) Clevis.

D80S-5 .................................................. 100 mm (4 in)

7. Tighten bolts (1) a torque of 115.6 ~ 133.3 N•m
(86 ~ 99 lb lb•ft).
D90S-5 .................................................. 100 mm (4 in)

Mast Systems 18 Testing & Adjusting

Drift Test for The Tilt System
Tilt drift is the change in the tilt cylinder rod stroke
with a rated load on the forks.

1. With the hydraulic oil at normal temperature for

operation 45 to 55°C (113 to 131°F), lift a rated
capacity load off the ground with the mast in
vertical position.

2. Measure the tilt cylinder rods stroke from the nut

to the cylinder housing.

3. Operate the mast to the complete forward

position and to the reverse position three or four
times.

4. Put the mast back to the vertical position

5. Stop the engine, wait 10 minutes and take

another measurement of the tilt cylinder rods
stroke.

6. If the measurement changed from the

measurement taken in Step 2 then the tilt system
has drifted.

7. Following are the maximum permissible drift rates

for the different models.

D80S-5..................................................53 mm (2.1 in)

D90S-5..................................................53 mm (2.1 in)

Mast Systems 19 Testing & Adjusting

SB2356E01

Operation &
Maintenance Manual
LIFT TRUCKS
D50S-5, D60S-5, D70S-5
D80S-5, D90S-5
G50S-5, G60S-5, G70S-5

0705
Table of Contents

Table of Contents
Information Section Maintenance Section

Foreword .....................................................................2 Inspection, Maintenance and Repair of Lift Truck

Forks ....................................................................... 121
Tire Inflation Information........................................ 125
Torque Specifications ............................................ 126
Safety Section Cooling System Specifications.............................. 128
Fuel Specifications................................................. 130
Safety ..........................................................................5 Lubricant Specifications......................................... 132
Warning Signs and Labels .................................5 Maintenance Intervals............................................ 136
General Hazard Information.............................10 When Required ...................................................... 140
Operation Information.......................................11 Every 10 Service Hours or Daily ........................... 147
Maintenance Information..................................14 First 50-100 Service Hours or a Week ................. 152
Operator Restraint System (If Equipped)........17 First 250 Service Hours or a Month ...................... 159
Avoiding Lift Truck Tipover...............................21 Every 250 Service Hours or Monthly .................... 160
Safety Rules ......................................................23 Every 500 Service Hours or 3 Months.................. 168
How to Survive in a Tipover (If Operator Every 1000 Service Hours or 6 Months................ 172
Restraint System Equipped) ............................28 Every 1500 Service Hours or 9 Months................ 178
Every 2000 Service Hours or Yearly..................... 181
Every 2500 Service Hours or 15 Months.............. 185
General Section

Specifications............................................................30 Index Section

Noise &Vibration.......................................................38
Capacity Chart - Without Side Shifter .....................39 Index ....................................................................... 187
Capacity Chart - With Side Shifter ..........................41
Serial Number...........................................................43
Operator's Warning and Identification Plate ...........45

Operation Section

Operator’s Station and Monitoring Systems...........47

Seat Switch System .................................................52
Lift Truck Controls ....................................................56
Refueling ...................................................................60
Before Starting the Engine.......................................63
Starting the Engine...................................................66
After Starting the Engine..........................................69
Lift Truck Operation................................................105
Auto Shift Controller ASC-200/201 (If Equipped) ..107
Operating Techniques............................................112
Parking the Lift Truck .............................................116
Lift Fork Adjustment ...............................................117
Storage Information................................................118
Transportation Hints ...............................................119
Towing Information.................................................120

1
Information Section

Foreword Safety

Literature Information The Safety Section lists basic safety precautions. In

addition, this section identifies the text and locations
of warning signs and labels used on the lift truck.
This manual should be stored in the operator's
Read and understand the basic precautions listed in
compartment in the literature holder or seat back
the Safety Section before operating or performing
literature storage area.
lubrication, maintenance and repair on this lift truck.
This manual contains safety, operation,
transportation, lubrication and maintenance Operator Restraint System (If Equipped)
information.
This manual contains safety, operation and
Some photographs or illustrations in this publication maintenance information for the DOOSAN operator
show details or attachments that can be different restraint system. Read, study and keep it handy.
from your lift truck. Guards and covers might have
been removed for illustrative purposes. WARNING
Continuing improvement and advancement of Your DOOSAN truck comes equipped with an
product design might have caused changes to your operator restraint system. Should it become
lift truck which are not included in this publication. necessary to replace the seat for any reason, it
Read, study and keep this manual with the lift truck. should only be replaced with another DOOSAN
operator restraint system.
Whenever a question arises regarding your lift truck,
or this publication, please consult your DOOSAN
dealer for the latest available information.
Photographs or illustrations guide the operator
through correct procedures of checking, operation
and maintenance of the DOOSAN operator restraint
system.

SAFE and EFFICIENT OPERATION of a lift truck

depends to a great extent on the skill and alertness
on the part of the operator. To develop this skill the
operator should read and understand the Safe
Driving Practices contained in this manual.

Forklift trucks seldom tipover, but in the rare event

they do, the operator may be pinned to the ground
by the lift truck or the overhead guard. This could
result in serious injury or death.

Operator training and safety awareness is an

effective way to prevent accidents, but accidents
can still happen. The DOOSAN operator restraint
system can minimize injuries. The DOOSAN
operator restraint system keeps the operator
substantially within the confines of the operator's
compartment and the overhead guard.

This manual contains information necessary for Safe

Operation. Before operating a lift truck make sure
that the necessary instructions are available and
understood.

2
Information Section

Operation Environment Management

The Operation Section is a reference for the new Note that DOOSAN INDUSTRIAL VEHICLE
operator and a refresher for the experienced one. DIVISION is ISO 14001 certified which is
This section includes a discussion of gauges, harmonized with ISO 9001. Periodic
switches, lift truck controls, attachment controls, ENVIRONMENTAL AUDITS & ENVIRONMENTAL
transportation and towing information. PERFORMANCE EVALUATIONS have been made
Photographs and illustrations guide the operator by internal and external inspection entities.
through correct procedures of checking, starting, LIFECYCLE ANALYSIS has also been made
operating and stopping the lift truck. through out the total product life. ENVIRONMENT
Operating techniques outlined in this publication are MANAGEMENT SYSTEM includes DESIGN FOR
basic. Skill and techniques develop as the operator ENVIRONMENT from the initial stage of the design.
gains knowledge of the lift truck and its capabilities. ENVIRONMENT MANAGEMENT SYSTEM
considers environmental laws & regulations,
Maintenance reduction or elimination of resource consumption as
well as environmental emission or pollution from
industrial activities, energy saving, environment
The Maintenance Section is a guide to equipment friendly product design(lower noise, vibration,
care. The illustrated, step-by-step instructions are emission, smoke, heavy metal free, ozone depleting
grouped by servicing intervals. Items without specific substance free, etc.), recycling, material cost
intervals are listed under "When Required" topics. reduction, and even environmentally oriented
Items in the "Maintenance Intervals" chart are education for the employee.
referenced to detailed instructions that follow.

Maintenance Intervals
Use the service hour meter to determine servicing
intervals. Calendar intervals shown (daily, weekly,
monthly, etc.) can be used instead of service hour
meter intervals if they provide more convenient
servicing schedules and approximate the indicated
service hour meter reading. Recommended service
should always be performed at the interval that
occurs first.

Under extremely severe, dusty or wet operating

conditions, more frequent lubrication than is
specified in the "Maintenance Intervals" chart might
be necessary.

Perform service on items at multiples of the original

requirement. For example, at "Every 500 Service
Hours or 3 Months", also service those items listed
under "Every 250 Service Hours or Monthly" and
"Every 10 Service Hours or Daily".

3
Information Section

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, and use common sense. Persons
must also have the necessary training, skills and tools before attempting to perform these functions.

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have read
and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or other persons.

The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as "WARNING"
as shown below.

WARNING

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning, explaining the hazard, can be either written or pictorially
presented.

Operations that may cause product damage are identified by NOTICE labels on the product and in this
publication.

DOOSAN cannot anticipate every possible circumstance that might involve a potential hazard, and common
sense is always required. The warnings in this publication and on the product are therefore not all inclusive.
Before any tool, procedure, work method or operating technique not specifically recommended by DOOSAN is
used, you must be sure that it is safe for you and others. You should also ensure that the product will not be
damaged or made unsafe by the operation, lubrication, maintenance or repair procedures you choose.

The information, specifications, and illustration in this publication are on the basis of information available at
the time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and
other items can change at any time. These changes can affect the service given to the product. Obtain the
complete and most current information before starting any job. DOOSAN dealers have the most current
information available.

4
Safety Section

Safety Warning Signs and Labels

The safety rules and regulations in this section are There are several specific safety signs on your lift
representative of some, but not all rules and truck. Their exact location and description of the
regulations noted under the Occupational Safety hazard are reviewed in this section. Please take the
and Health Act (OSHA) and are paraphrased time to familiarize yourself with these safety signs.
without representation that the OSHA rules and
regulations have been reproduced verbatim. Make sure that you can read all warning and
instruction labels. Clean or replace these labels if
Please refer to 1910. 178 in Federal Register Vol. you cannot read the words or see the pictures.
37, No. 202, the National Fire Protection Association When cleaning the labels use a cloth, water and
No. 505 (NFPA), American National Standard, ANSI soap. Do not use solvent, gasoline, etc.
B56. 1 Safety Standard for Low lift and High Lift
Trucks and subsequent revisions for a complete list You must replace a label if it is damaged, missing or
of OSHA rules and regulations as to the safe cannot be read. If a label is on a part that is replaced,
operation of powered industrial lift trucks. Since make sure a new label is installed on the replaced
regulations vary from country to country outside in part. See your dealer for new labels.
U.S.A., operate this lift truck in accordance with local
regulations. Training Required To Operate or Service
DOOSAN lift trucks are manufactured according to Warning
the regulations and standards laid down in EU
Machinery Directive 98/37/EC and EMC directive
89/336/EC. Please refer to the Directives 89/655/
EC and 89/391/EC and its amendments for the safe
use of DOOSAN lift trucks.

The most effective method of preventing serious

injury or death to the lift truck operator or others is
for the lift truck operator to be familiar with the
proper operation of the lift truck, to be alert and to
avoid actions or conditions which can result in an
accident.

Do not operate a lift truck if in need of repair, Located on the right side of the fire wall.
defective or in any way unsafe. Report all defects
and unsafe conditions immediately. Do not attempt WARNING
any adjustments or repairs unless trained and
authorized to do so. Improper operation or maintenance could result
in injury or death. Do not operate or work on the
lift truck unless you are properly trained. Read
and understand the Operation and Maintenance
Manual. Additional manuals are available from
DOOSAN Lift Truck dealers.

This label also provides allowable lift truck capacity

information.

5
Safety Section

General Warnings to Operator 10. Be sure operating surface can safely support
machine.

11. Operate machine and attachments only from

operator's position.

12. Do not handle unstable or loosely stacked loads.

13. Use minimum tilt when picking up or depositing

a load.

14. Use extreme care when handling long, high, or

wide loads.

Located on the right side of the operator's seat. 15. Forks should be completely under load and
spread apart as far as load permits.
WARNING 16. Machine should be equipped with overhead
guard or equivalent protection. Where load
Only trained and authorized personnel may
requires it, use load backrest extension. Use
operate this machine. For safe operation, read
extreme caution if operating without these
and follow the operation and maintenance
devices.
Manual furnished with this lift truck and observe
the following warnings : 17. Parking-Lower lifting mechanism to floor. Put
directional control or shift lever in neutral. Set
1. Before starting machine. Check all controls and parking/secondary brake. Turn "ON - OFF"
warning devices for proper operation. switch off. Chock wheels if machine is on incline.
Disconnect battery when storing electric
2. Refer to machine identification plate for machines.
allowable machine capacity. Do not overload.
Operate machines equipped with attachments 18. Observe safety rules when handling fuel for
as partially loaded machines when not handling engine powered machine and when changing
a load. batteries for electric machines.

3. Put directional control or shift lever in neutral

before "ON-OFF" switch is turned on.

4. Start, turn and brake smoothly. Slow down for

turns, slippery or uneven surfaces. Extremely
poor surfaces should be repaired. Avoid running
over loose objects or holes in the roadway
surfaces. Use extreme caution when turning on
inclines.

5. Travel with load as low as possible and tilted

back. If load interferes with visibility, travel with
load trailing.

6. On grade operations travel with load up grade.

7. Watch out for pedestrians and obstructions.

Check overhead clearances.

8. Do not permit riders on forks or machine at any

time.

9. Do not allow anyone to stand or pass under the

elevated portion of any machine.

6
Safety Section

Pressure Warning No Standing On Forks Warning, No

Standing Under Forks Warning
WARNING
WARNING
Contents under pressure may be hot. Allow to
cool before opening. Do not stand or ride on the forks. Do not stand
or ride on a load or pallet on the forks. Do not
stand or walk under the forks.

Located on the radiator top tank by the radiator cap.

Hand Placement Warning Located on the lift cylinder.

WARNING Load Backrest Must Be In Place Warning

WARNING
Operation without this device in place may be
No hands. Do not place hands in this area. Do hazardous.
not touch, lean on, or reach through the mast or
permit others to do so.

Located on the load backrest.

Located on the mast.

7
Safety Section

Overhead Guard Must Be In Place Moving Fan Warning

Warning
WARNING
WARNING
To avoid personal injury, stay clear of moving
Operation without this device in place may be fan.
hazardous. This guard conforms to A.N.S.I.B56.1
and F.E.M. Section IV. This design has been
tested with an impact of appropriate value.

Located inside the engine compartment cover.

Located on the Overhead Guard.

No Riders Warning Parking brake

WARNING
To avoid personal injury, allow no riders. A lift
truck is designed for only one operator and no
riders.

Pull the lever BACK to engage the

parking brake.

Push the lever FORWARD to release

Located beside the operator's station. the parking brake.

Applying the parking brake puts the transmission in

NEUTRAL. The parking brake must be applied when
leaving the lift truck and when starting the engine. If
the operator leaves the seat without applying the
parking brake, an audible alarm will sound.

8
Safety Section

WARNING
When leaving machine apply parking brake!
Parking brake is not automatically applied.
Alarm will sound if parking brake is not applied.

WARNING

Correct adjustment is necessary to provide

adequate braking. See the MAINTENANCE
section for adjustment procedures. The lift truck
may creep at engine idle and can cause damage,
injury or death. Always apply the parking brake
when leaving the lift truck. The parking brake is
NOT automatically applied.

9
Safety Section

General Hazard Information Do not raise loads any higher than necessary and
never raise a load higher than 1830 mm (72 in) with
the overhead guard removed.

Always use load backrest extension when the

carriage or attachment does not fully support the
load. The load backrest extension is intended to
prevent the load or any part of the load from falling
backwards into the operator's station.

When operating the lift truck, Do not depend only on

flashing lights or back-up alarm (if equipped) to warn
pedestrians.

Always be aware of pedestrians and Do not proceed

until the pedestrians are aware of your presence
and intended actions and have moved clear of the
Attach a "Do not Operate" or similar warning tag to
lift truck and/or load.
start switch or controls before servicing or repairing
the lift truck. Do not drive lift truck up to anyone standing in front
of an object.
Do not start or service the lift truck when a "DO NOT
OPERATE" or similar warning tag is attached to the
Obey all traffic rules and warning signs.
start switch or controls.
Keep hands, feet and head inside the operator
Wear a hard hat, protective glasses and other station. Do not hold onto the overhead guard while
protective equipment as required by job conditions.
operating the lift truck. Do not climb on any part of
the mast or overhead guard or permit others to do
Know the width of your attachments so proper
so.
clearance can be maintained when operating near
fences, boundary obstacles, etc.
Do not allow unauthorized personnel to ride on the
forks or any other part of the lift truck, at any time.
Do not wear loose clothing or jewelry that can catch
on controls or other parts of the lift truck. When working in a building or dock, observe floor
load limits and overhead clearances.
Keep the lift truck, especially the deck and steps,
free of foreign material such as debris, oil tools and
Inhaling Freon gas through a lit cigarette or other
other items which are not part of the lift truck. smoking method or inhaling fumes released from a
flame contacting Freon can cause bodily harm or
Secure all loose items such as lunch boxes, tools
death. Do not smoke when servicing air conditioners
and other items which are not part of the lift truck.
or wherever Freon gas may be present.
Know the appropriate work-site hand signals and Never put maintenance fluids into glass containers.
who gives them. Accept signals from one person
only. Use all cleaning solutions with care.
Always use the overhead guard. The overhead
Do not use steam, solvent, or high pressure to clean
guard is intended to protect the lift truck operator
electrical components.
from overhead obstructions and from falling objects.
Report all needed repairs.
A truck that is used for handing small objects or
uneven loads must be fitted with a load backrest.

If the lift truck must be operated without the

overhead guard in place due to low overhead
clearance, use extreme care. Make sure there is no
possibility of falling objects from any adjacent
storage or work area. Make sure the load is stable
and fully supported by the carriage and the load
backrest extension (if equipped).

10
Safety Section

Operation Information

Mounting and Dismounting

Mount and dismount the lift truck carefully.

Clean your shoes and wipe your hands before

mounting.

Face the lift truck when mounting and dismounting.

Use both hands face the lift truck when mounting

and dismounting.
Inspect the part of the chain that is normally
operated over the crosshead roller. When the chain
Use the handgrips for mounting and dismounting.
bends over the roller, the movement of the parts
against each other causes wear.
Do not try to climb on or off the lift truck when
carrying tools or supplies.
Inspect to be sure that chain link pins Do not extend
outside of the bore hole.
Never get on or off a moving lift truck.
If any single link pin is extended beyond its
Do not use any controls as handholds when entering
connecting corresponding link, it should be
or leaving the operator's station.
suspected of being broken inside of its bore hole.
Never get on or off a moving lift truck. Never jump
Inspect the chain anchor and the anchor links for
off the lift truck.
wear.
Keep hands and steering wheel free of slippery
Do not change any factory set adjustment values
material.
(including engine rpm setting) unless you have both
authorization and training. Especially Safety
equipment and switches may not be removed or Before Starting the Lift Truck
adjusted incorrectly. Repairs, adjustments and
maintenances that are not correct can make a Perform a walk-around inspection daily and at the
dangerous operating condition. start of each shift. Refer to the topic "Walk-around
Inspection" in "Every 10 Service Hours or Daily"
For any checkup, repair, adjustments, maintenance section of this manual.
and all other work concerning your forklift truck,
please contact your DOOSAN dealer. We would like Adjust the seat so that full brake pedal travel can be
to draw your attention to the fact that any secondary obtained with the operator's back against the
damages due to improper handling, insufficient seatback.
maintenance, wrong repairs or the use of other than
original DOOSAN spare parts waive any liability by Make sure the lift truck is equipped with a lighting
DOOSAN. system as required by conditions.

Make sure all hydraulic controls are in the HOLD

position.

Make sure the direction control lever is in the

NEUTRAL position.

Make sure the parking brake is engaged.

Make sure no one is standing and/or working on,

underneath or close to the lift truck before operating
the lift truck.

11
Safety Section

Operate the lift truck and controls only from the Operating the Lift Truck
operator's station.
Always keep the lift truck under control.
Make sure the lift truck horn, lights, backup alarm (if
equipped) and all other devices are working Obey all traffic rules and warning signs.
properly.
Never leave the lift truck with the engine operating,
Check for proper operation of mast and attachments. or with the parking brake disengaged.
Pay particular attention to unusual noises or erratic
movement which might indicate a problem. Operate the engine only in a well ventilated area.

Make sure service and parking brakes, steering, and Lower the mast, with or without load, before turning
directional controls are operational. or traveling. Tip over could result. Watch out for
Make sure all personnel are clear of lift truck and overhead obstructions.
travel path.
Always observe floor load limits and overhead
Refer to the topic "Lift Truck Operation" in the clearance.
"Operation Section" of this manual for specific
starting instructions. Start, turn, and brake smoothly. Slow down for turns,
grades, slippery or uneven surfaces.
Starting the Lift Truck
Watch the road carefully for any obstacle when
driving the truck. Do not go fast over bumps, pot
holes or other rough grounds, otherwise the engine
might go OFF by a severe impact.
In case of engine going OFF, press the brake pedal
at one time as hard as possible in order to stop the
truck. Pressing the brake pedal several times has a
risk that the brake would not work.

Do not start the engine or move any of the controls if

there is a "DO NOT OPERATE" or similar warning
tag attached to the start switch or controls.

Before Operating the Lift Truck

Test brakes, steering controls, horn and other
devices for proper operation. Report any faulty Use special care when operating on grades. Do not
performance. Do not operate lift truck until repaired. angle across or turn on grades. Do not use a lift
truck on slippery grades. Travel with forks
Learn how your lift truck operates. Know its safety downgrade when unloaded. Travel with load
devices. Know how the attachments work. Before upgrade.
moving the lift truck, look around. Start, turn and
brake smoothly. Do not overload, or handle offset, unstable, or
loosely stacked loads. Refer to load capacity plate
An operator must constantly observe his lift truck for on the lift truck. Use extreme caution when handling
proper operation. suspended, long, high or wide load.

12
Safety Section

some trailers, extra supports may be needed to

prevent upending or corner dipping.

Be certain dock plates are in good condition and

properly placed and secured. Do not exceed the
rated capacity of dock boards or bridge plates.

Lift Truck Parking

When leaving the operator station, park the lift truck
in authorized areas only. Do not block traffic.
Tilt an elevated load forward only when directly over
unloading area and with load as low as possible.

Do not stunt ride or indulge in horseplay.

Always look and keep a clear view of the path of
travel.

Travel in reverse if load or attachment obstructs

visibility. Use extreme caution if visibility is
obstructed.

Stay in designated travel path, clear of dock edges,

ditches, other drop-
offs and surfaces which cannot safely support the lift
z Park the lift truck level, with the forks lowered
truck.
and the mast tilted forward until the fork tips
touch the floor.
Slow down and use extra care through doorways,
intersections and other location where visibility is z Move the direction control lever to NEUTRAL.
reduced.
z Engage the parking brake.
Slow down for cross aisles, turns, ramps, dips,
uneven or slippery surfaces and in congested areas z Turn the key switch off and remove the key.
and avoid pedestrians, other vehicles, obstruction, z Turn the disconnect switch to OFF.
pot holes and other hazards or objects in the path of
travel. z Block the drive wheels when parking on an
incline.
Always use overhead guards except where
operation conditions Do not permit. Do not operate
lift truck in high stacking areas without overhead
guards.

When stacking, watch for falling objects. Use load

backrest extension and overhead guard.

Refer to the topic "Operation Techniques" in the

"Operation Section" of this manual.

Loading or Unloading Trucks/Trailers

Do not operate lift trucks on trucks or trailers which

are not designed or intended for that purpose. Be
certain truck or trailer brakes are applied and wheel
chocks in place (or be certain unit is locked to the
loading dock) before entering onto trucks or trailers.

If trailer is not coupled to tractor, make sure the

trailer landing gear is properly secured in place. On

13
Safety Section

Maintenance Information Do not use a kinked or frayed wire rope cable. Wear
gloves when handling the wire rope cable.
Perform all maintenance unless otherwise specified Retainer pins, when struck with force, can fly out
as follows : and injure nearby persons. Make sure the area is
clear of people when driving retainer pins.
z Park the lift truck in authorized areas only.
z Park the lift truck level, with the forks lowered Wear protective glasses when striking a retainer pin
and the mast tilted forward until the fork tips to avoid injury to your eyes.
touch the floor. Chips or other debris can fly off objects when struck.
Make sure no one can be injured by flying debris
z Place the transmission controls in neutral. before striking any object.

z Engage the parking brake.

z Stop the engine. Falling Objects Protective Structure (FOPS)
z Remove the start switch key and turn the This is an attached guard located above the
disconnect switch OFF (if equipped). operator's compartment and secured to the lift truck.

z Block the drive wheels when parking on an To avoid possible weakening of the Falling Objects
incline. Protective Structure (FOPS), consult a DOOSAN
dealer before altering, by adding weight to, welding
Pressure Air on, or cutting or drilling holes into the structure.
Pressure air can cause personal injury. When using The overhead guard is not intended to protect
pressure air for cleaning, wear a protective face against every possible impact. The overhead guard
shield, protective clothing and protective shoes. may not protect against some objects penetrating
into the operator's station from the sides or ends of
The maximum air pressure must be below 205 kPa the lift truck.
(30 psi) for cleaning purposes.
The lift truck is equipped with an overhead guard
Fluid Penetration and FOPS as standard. If there is a possibility of
overhead objects falling through the guard, the
Always use a board or cardboard when checking for guard must be equipped with smaller holes or a
a leak. Escaping fluid under pressure, even a Plexiglas cover.
pinhole size leak, can penetrate body tissue,
causing serious injury, and possible death. If fluid is Any altering done that is not specifically authorized
injected into your skin, it must be treated by a doctor by DOOSAN invalidates DOOSAN’s FOPS
familiar with this type of injury immediately. certification. The protection offered by this FOPS will
be impaired if it has been subjected to structural
Crushing or Cutting Prevention damage. Structural damage can be caused by an
overturn accident, by falling objects, etc.
Support equipment and attachments properly when
working beneath them. Do not depend on hydraulic Do not mount any item such as fire extinguishers,
cylinders to hold it up. Any attachment can fall if a first aid kits and lights by welding brackets to or
control is moved, or if a hydraulic line breaks. drilling holes in any FOPS structure. See your
DOOSAN dealer for mounting guidelines.
Never attempt adjustments while the lift truck is
moving or the engine is running unless otherwise
specified.

Where there are attachment linkages, the clearance

in the linkage area will increase or decrease with
movement of the attachment.

Stay clear of all rotating and moving parts.

Keep objects away from moving fan blades. They

will throw or cut any object or tool that falls or is
pushed into them.

14
Safety Section

Burn Prevention Fire or Explosion Prevention

Coolant All fuels, most lubricants and some coolant mixtures
are flammable.
At operating temperature, the engine coolant is hot
and under pressure. The radiator and all lines to
Fuel leaked or spilled onto hot surfaces or electrical
heaters or the engine contain hot water or steam.
components can cause a fire.
Any contact can cause severe burns.
Do not smoke while refueling or in a refueling area.
Steam can cause personal injury.
Do not smoke in areas where batteries are charged,
Check the coolant level only after engine has been
or where flammable materials are stored.
stopped and the filter cap is cool enough to remove
with your bare hand. Batteries in series can be located in separate
Remove the cooling system filter cap slowly to
compartments. When using jumper cables always
relieve pressure.
connect positive(+) cable to positive(+) terminal of
battery connected to starter solenoid and negative(-)
Cooling system additive contains alkali that can
cable from external source to starter negative(-)
cause personal injury. Avoid contact with the skin
terminal.
and eyes and Do not drink.
(If not equipped with starter negative (-) terminal,
connect to engine block.)
Allow cooling system components to cool before
draining.
See the Operation Section of this manual for specific
starting instructions.
Oils
Hot oil and components can cause personal injury. Clean and tighten all electrical connections. Check
Do not allow hot oil or components to contact the daily for loose or frayed electrical wires. Have all
skin. loose or frayed electrical wires tightened, repaired or
replaced before operating the lift truck.
At operation temperature, the hydraulic tank is hot
and can be under pressure. Keep all fuels and lubricants stored in properly
marked containers and away from all unauthorized
Remove the hydraulic tank filter cap only after the persons.
engine has been stopped and the filter cap is cool
enough to remove with your bare hand. Store all oily rags or other flammable material in a
protective container, in a safe place.
Remove the hydraulic tank filter cap slowly to relieve
pressure. Do not weld or flame cut on pipes or tubes that
contain flammable fluids. Clean them thoroughly
Relieve all pressure in air, oil fuel or cooling systems with nonflammable solvent before welding or flame
before any lines, fittings or related items are cutting on them.
disconnected or removed.
Remove all flammable materials such as fuel, oil
Batteries and other debris before they accumulate on the lift
truck.
Batteries give off flammable fumes which can
explode. Do not expose the lift truck to flames, burning brush,
etc., if at all possible.
Do not smoke when observing the battery electrolyte
levels. Shields, which protect hot exhaust components from
oil or fuel spray in the event of a line, tube or seal
Electrolyte is an acid and can cause personal injury failure, must be installed correctly.
if it contacts skin or eyes.
Do not operate in areas where explosive gases exist
Always wear protective glasses when working with or are suspected.
batteries.

15
Safety Section

Fire Extinguisher Tire Information

Have a fire extinguisher-type BC and 1.5KG Explosions of air-inflated tires have resulted from
minimum capacity-on rear overhead guard leg with heat-induced gas combustion inside the tires. The
latch and know how to use it. Inspect and have it heat, generated by welding or heating rim
serviced as recommended on its instruction plate. components, external fire, or excessive use of
brakes can cause gaseous combustion.
Ether
A tire explosion is much more violent than a blowout.
Ether is poisonous and flammable.
The explosion can propel the tire, rim and axle
Breathing ether vapors or repeated contact of ether
components as far as 500 m (1500 ft) or more from
with skin can cause personal injury.
the lift truck. Both the force of the explosion and the
flying debris can cause personal injury or death, and
Use ether only in well-ventilated areas.
property damage.
Do not smoke while changing ether cylinders.

Use ether with care to avoid fires.

Do not store replacement ether cylinders in living
areas or in the operator's compartment.

Do not store ether cylinders in direct sunlight or at

temperatures above 39°C (102°F).

Discard cylinders in a safe place. Do not puncture or

burn cylinders.

Keep ether cylinders out of the reach of

unauthorized personnel.

Lines, Tubes and Hoses Do not approach a warm tire closer than the outside
of the area represented by the shaded area in the
Do not bend or strike high pressure lines. Do not above drawing.
install bent or damaged lines, tubes or hoses.
Dry nitrogen (N2) gas is recommended for inflation
Repair any loose or damaged fuel and oil lines, of tires. If the tires were originally inflated with air,
tubes and hoses. Leaks can cause fires. Contact nitrogen is still preferred for adjusting the pressure.
your DOOSAN dealer for repair or replacement. Nitrogen mixes properly with air.

Check lines, tubes and hoses carefully. Do not use Nitrogen inflated tires reduce the potential of a tire
your bare hand to check for leaks. Use a board or explosion, because nitrogen does not support
cardboard to check for leaks. See Fluid Penetration combustion. Also, nitrogen helps prevent oxidation
in the Safety Section for more details. Tighten all and the resulting deterioration of rubber and
connections to the recommended torque. Replace if corrosion of rim components.
any of the following conditions are found.
Proper nitrogen inflation equipment and training in
z End fittings damaged or leaking. its use are necessary to avoid over inflation. A tire
blowout or rim failure can result from improper or
z Outer covering chafed or cut and wire
misused equipment.
reinforcing exposed.
z Outer covering ballooning locally. Stand behind the tread and use a self-attaching
chuck when inflation a tire.
z Evidence of kinking or crushing of the flexible
part of hose. Servicing, changing tires and rims can be dangerous
and should be done only by trained personnel using
z Armoring embedded in the outer cover. proper tools and procedures. If correct procedures
are not followed while servicing tires and rims, the
z End fittings displaced.
assemblies could burst with explosive force and
Make sure that all clamps, guards and heat shields cause serious personal injury or death. Follow
are installed correctly to prevent vibration, rubbing carefully the specific information provided by your
against other parts, and excessive heat during tire or rim servicing personnel or dealer.
operation.

16
Safety Section

Operator Restraint System (If

Equipped)

Warning Signs and Labels

Your DOOSAN lift truck has the following tipover
warning decals.

Make sure that you can read all safety signs. Clean
or replace these if you cannot read the words or see
the pictures. When cleaning the labels use a cloth,
water and soap. Do not use solvent, gasoline, etc. The "Survive in tipover" warning is located on the
You must replace a label if it is damaged, missing or overhead guard. It shows the proper use of the
cannot be read. If a label is on a part that is replaced, operator restraint system.
make sure a new label is installed on the replaced
part. See you DOOSAN Lift Truck dealer for new Seat Adjustment
labels.

The most effective method of preventing serious

injury or death to yourself or others is to familiarize
yourself with the proper operation of the lift truck, to
be alert, and to avoid actions or conditions which
can result in an accident.

WARNING
Tipover can occur if the truck is improperly
operated. In the event of tipover, injury or death
could result.

Move the lever, slide the seat to the desired position,

and release the lever.
Adjust the seat before operating the lift truck. After
adjusting, set the seat to make sure it is properly
locked. Do not adjust the seat while the truck is in
motion.

WARNING
Do not place your hand or fingers under the seat.
Injury may occur as the seat moves up and
down.

17
Safety Section

If Optional Suspension Seat Equipped Weight adjustment

Forward and Backward Adjustment Pull the weight adjustment lever upwards and move
right or left side.
The seat can be adjusted by pushing the lever on Adjust to driver’s weight in 7 steps (50 ~ 110 kg)
the right side of seat.

NOTICE

Do not place your hand or fingers under the seat.

Injury may occur as the seat moves up and down.
Forward and Backward
Adjustment

Backrest Inclination

The backrest angle can be adjusted by using the

lever on the left side of seat.

Adjust the seat before operating the lift truck. After

adjusting, set the seat to make sure it is properly
locked. DO NOT adjust the seat while the truck is in
motion.

18
Safety Section

Seat Belt
The Operator Restraint System, Prevents the
operator from the operator's compartment in the
event of forward or side tipover. The system is
designed to keep the operator on the seat and in the
operator's compartment in the event of tipover.

Inspection

3. In the event of tipover, the seat and restraint

system should be inspected for damage and
replaced, if necessary.

NOTE: Operator restraints shall be examined at the

regular truck service intervals. It is
recommended that they be replaced if any
of the following conditions are found:
1. If the seat belt is torn, if pulling motion is
interrupted during extension of the belt, or if the z Cut or frayed strap
belt cannot be inserted into the buckle properly, z Worn or damaged hardware including anchor
replace the seat belt assembly. points
z Buckle or retractor malfunction
z Loosen stitching

WARNING
The seat belt may cause the operator to bend at
the waist. If you are pregnant or have suffered
from some abdominal disease, consult a doctor
before you use the seat belt.

Fasten the Seat Belt

2. Belt Maintenance – Every 500 service hours.
Check that the belt fastening works properly and
that winding device is free from run lock when
jerked. Check that the belt is suitably fastened to
the seat. Check that the seat is correctly
secured to the hood and the chassis. On visual
inspection, fastenings must be intact, otherwise,
contact the safety manager.

WARNING
Your DOOSAN truck comes equipped with a
DOOSAN operator restraint system. Should it
become necessary to replace the seat for any 1. Grip the plate (connector) of the belt and pull the
reason, it should only be replaced with another belt from the retractor. Then insert the plate into
DOOSAN operator restraint system. the slot of the buckle until a snap is heard. Pull
on the belt to confirm it is latched.

2. Make sure the belt is not twisted.

19
Safety Section

Release the Seat Belt

WARNING
If you fasten the belt across your abdomen, the
belt may injure your abdomen in an accident.

Push the button of the buckle to release the belt.

The belt will automatically retract when released.
Hold the plate of the belt and allow the belt to slowly
retract.

3. Be sure to fasten the belt across your hips, not

across your abdomen.

NOTE: The belt is designed to automatically adjust

to your size and movement. A quick pull on
the belt will confirm that the automatic
adjuster will hold the belt position in the
event of an accident.

20
Safety Section

Avoiding Lift Truck Tipover Stability and Center of Gravity

Lift Truck Stability

The stability of the lift truck is determined by the

location of its CG; or, if the truck is loaded, the
combined CG of the truck and load. The lift truck
has moving parts and, therefore, has a CG that
moves. The CG moves forward or backward as the
mast is tilted forward or backward. The CG moves
Counterbalanced lift truck design is based on the up or down as the mast moves up or down. The CG
balance of two weights on opposite sides of a and, therefore, the stability of the loaded lift truck,
fulcrum (the front axle). The load on the forks must are affected by a number of factors such as:
be balanced by the weight of the lift truck. z the size, weight, shape and position of the load
The location of the center of gravity of both the truck
and the load is also a factor. This basic principle is z the height to which the load is lifted
used for picking up a load. The ability of the lift truck
to handle a load is discussed in terms of center of z the amount of forward or backward tilt
gravity and both forward and sideways stability. z tire pressure

Center of Gravity (CG) z dynamic forces created when the lift truck is
accelerated, braked or turned
z condition and grade of surfaces on which the lift
truck is operated

The point within an object, at which the whole weight

of the object may be regarded as being
concentrated, is called the center of gravity or CG. If
the object is uniform, its geometric center will
These same factors are also important for unloaded
coincide with its CG. If it is not uniform, the CG
lift trucks. They tip over sideways easier than a
could be at a point outside of the object. When the
loaded lift truck carrying its load in the lowered
lift truck picks up a load, the truck and load have a
position.
new combined CG.

21
Safety Section

Lift Truck Stability Base capacity load shown on the nameplate is for a
standard lift truck with standard backrest, forks and
mast, and having no special-purpose attachment. In
addition, the capacity load assumes that the load
center is no further from the top of the forks than it is
from the face of the backrest. If these conditions Do
not exist, the operator may have to reduce the safe
operating load because the truck stability may be
reduced. The lift truck should not be operated if its
capacity/nameplate does not indicate capacity load.

NOTE: If the load is not uniform, the heaviest

portion should be placed closer to the
backrest and centered on the forks.

For the lift truck to be stable (not tip over forward or

to the side), the CG must stay within the area of the NOTICE
lift truck stability base – a triangular area between
the front wheels and the pivot of the steer wheels. If 1. Capacity/Nameplates originally attached to
the CG moves forward of the front axle, the lift truck forklifts sold by DOOSAN shall not be removed,
will tip forward. If the CG moves outside of the line altered or replaced without DOOSAN’s approval.
on either side of the stability base, the lift truck will 2. DOOSAN assumes no responsibility for lift trucks
tip to the side. placed in service without a valid DOOSAN
Nameplate.
3. If necessary to change your specification,
WARNING contact your DOOSAN lift truck dealer.
Dynamic forces (braking, acceleration, turning)
also affect stability and can produce tipover
even when the CG is within the stability triangle.

Capacity Load (Weight and Load Center)

The capacity load of the lift truck is shown on the

capacity/nameplate riveted to the truck. It is
determined by the weight and load center. The load
center is determined by the location of the CG of the
load.

The load center shown on the nameplate is the

horizontal distance from the front face of the forks,
or the load face of an attachment, to the CG of the
load. The location of the CG in the vertical direction
is the same as the horizontal dimension.

Remember that, unless otherwise indicated, the

22
Safety Section

Safety Rules

Do not operate a lift truck unless you are in the

operator’s seat. Keep hands and feet inside the
operator’s compartment. Do not put any part of the
body outside of the operator’s compartment. Never
Only properly trained and authorized personnel put any part of body into the mast structure or
should operate forklift trucks. Wear a hard hat and between the mast and the truck
safety shoes when operating a lift truck. Do not wear
loose clothing.

Do not start, stop, turn or change direction suddenly

or at high speed. Sudden movement can cause the
Inspect and check the condition of your forklift truck lift truck to tip over. Slow the speed of your truck and
using the operator's check list before starting work. use the horn near corners, exits, entrances, and
Immediately report to your supervisor any obvious near people.
defects or required repairs.

Never operate a lift truck with wet hands or shoes.

Do not operate your truck in unauthorized areas. Never hold any controls with grease on your hands.
Know your forklift truck and think safety. Your hands or feet will slide off of the controls and
Do not compromise safety. cause an accident.
Follow all safety rules and read all warning signs.

23
Safety Section

Do not raise anyone on the forks of your lift truck. Do not overload. Always handle loads within the
Do not let other people ride on the truck. Lift trucks rated capacity shown on the capacity plate.
are designed to carry loads, not people. Do not add extra counterweight to the truck. An
overload can cause the truck to roll over and cause
injury to personnel and damage to the lift truck.

Do not operate your truck without the load backrest

extension and overhead guard. Keep the load
against the backrest with the mast tilted backward. Do not drive on soft ground.
Observe all signs, especially those on maximum
permitted floor loadings, elevator capacities and
clearance heights.
Handle loads carefully and check them closely for
stability and balance.

Do not lift or move loads that are not safe. Do not

pick up an off center load. Such a load increases the
possibility of a tipover to the side. Make sure loads
are correctly stacked and positioned across both
forks. Always use the proper size pallet. Position the
forks as wide as possible under the load. Position Do not drive on slippery surfaces.
loads evenly on the forks for proper balance. Do not Sand, gravel, ice or mud can cause a tipover.
lift a load with one fork. If unavoidable, slow down.

24
Safety Section

Do not permit anyone to stand or walk under the Do not elevate the load with the mast tilted forward.
load or lifting mechanism. The load can fall and Do not tilt the elevated loads forwards.
cause injury or death to anyone standing below. This will cause the lift truck to tip over forward.

Look out for overhead obstructions when raising or Do not jump off if your truck starts to tip over.
stacking loads. Do not travel with a raised load. Do Stay in your seat to survive.
not travel with the mast raised. The lift truck can roll
over and cause injury or death to you or other
personnel.

Go up ramps in forward direction and down ramps in

reverse direction when moving loads.
Never elevate a load with the forklift truck on an
Do not move loose loads that are higher than the incline.
load backrest. Go straight off and straight down. Use an assistant
Be alert for falling loads when stacking. when going up or down a ramp with a bulky load.
Travel with the load tilted back and the forks as low
as possible.
This will increase stability to the truck and load and
permit better visibility for you.

25
Safety Section

Do not stack or turn on ramps. Do not drive in forward direction when loads restrict
Do not attempt to pick-up or deposit a load unless your visibility. Operate your lift truck in reverse to
the lift truck is level. Do not turn on or drive across improve visibility except when moving up a ramp.
an incline.

Be careful when operating a lift truck near the edge

Do not go over rough terrain. If unavoidable, slow of a loading dock or ramp. Maintain a safe distance
down. from the edge of docks, ramps and platforms.
Cross railroad tracks slowly and diagonally Always watch tail swing.
whenever possible. A railroad crossing can give a The truck can fall over the edge and cause injury or
loaded forklift truck a real jolt. For smoother crossing, death.
cross the railroad diagonally so one wheel crosses
at a time.

Do not operate on bridge plates unless they can

support the weight of the truck and load. Make sure
Avoid running over loose objects. Look in the that they are correctly positioned. Put blocks on the
direction of travel. Look out for other persons or vehicle you enter to keep it from moving.
obstructions in your path of travel. An operator must
be in full control of his lift truck at all times.

26
Safety Section

Do not operate your truck close to another truck. Park your lift truck in authorized areas only. Fully
Always keep a safe distance from other trucks and lower the forks to the floor, put direction lever in
make sure there is enough distance to stop safely. NEUTRAL position, engage the parking brake, and
Never overtake other vehicles. turn the key to the OFF position. Remove the key
and put blocks behind the wheels to prevent the
truck from rolling. Shut off your forklift truck when
leaving it unattended.
Check the condition of your forklift truck after the
day's work.

Do not use your lift truck to push or tow another

truck.
Do not let another push or tow your truck.
If a truck will not move, call a service technician.
Exhaust from all internal combustion engines
contains carbon monoxide, a colorless, odorless,
tasteless, poisonous gas. Exposure to carbon
monoxide can cause serious injury or health
problems, including death. and avoid unnecessary
idling of the engine. If nausea, dizziness or
headaches are experienced stop the truck and seek
fresh air.

Forklift trucks may only be refueled at specially

reserved locations. Switch off the engine when
refueling.
Smoking and handling of naked flames during
refueling are strictly prohibited. This prohibition also
applies during the changing of the LPG (liquefied
propane gas) tank.
Mop up spilt fuel and Do not forget to close the fuel
tank before restarting the engine.

27
Safety Section

How to Survive in a Tipover (If

Operator Restraint System
Equipped)

WARNING
In the event of a tipover, the risk of serious
injury or death will be reduced if the operator is
using the operator restraint system and follows
the instructions provided.
Hold on tight.

Always use operator restraint system.

Brace your feet and keep them within the operator's
compartment.

Don’t jump.

28
Safety Section

Lean away from the direction of fall.

Lean forward.

29
General Section

Specifications
CHRACTERISTICS 3 Speed
1 Manufacturer DOOSAN DOOSAN
2 MODEL D50S-5 D60S-5
3 Capacity at rated load center kg 5000 6000
4 Load center distance mm 600 600
5 Power type electric,diesel,gasoline,LPG diesel diesel
6 Operator type stand-on, rider-seated rider-seated rider-seated
7 Tire type c=cushion, p=pneumatic p p
8 Wheels(x=driven) number, front/rear 4/2 4/2
DIMENSIONS
maximum fork height with rated
9 Lift with STD mm 3000 3000
load
10 two stage mast free lift mm 205 205
thickness x width x length mm 60x150x1200 60x180x1200
13 Forks
fork spacing(minimum x maximum) mm 350x2032 410x2032
14 Tilt of mast forward / backward deg 15/10 15/10
15 length to face of forks mm 3507 3568
16 width mm 2108 2108
17 Overall mast lowered height mm 2500 2500
18 dimensions mast extended height mm 4340 4340
19 overhead guard height mm 2455 2455
20 seat height mm 1333 1333
21 Turning radius (minimum outside) mm 3301 3331
22 Load moment constant mm 632 632
23 90 stacking aisle add load length and clearance mm 3924 3958
23a 90 intersecting aisle mm 2990 3020
PERFORMANCE
24 travel, loaded/unloaded km/h 29.6/32.4 29.1/32.2
25 Speed lift, loaded/unloaded mm/s 500/530 490/530
26 lowering, loaded/unloaded mm/s 501/450 501/450
28 Drawbar pull at 1.6 km/h, loaded kg 5990 5945
30 Gradeability at 1.6 km/h, loaded % 49.2 42.4
WEIGHT
32 Total weight unloaded kg 8570 9240
33 Axle load with loaded, front/rear kg 12175/1395 13585/1655
34 without loaded, front/rear kg 4435/4135 4300/4940
CHASSIS
35 number of front/rear 4/2 4/2
36 Tires size, front 8.25x15-14PR 8.25x15-14PR
37 size, rear 8.25x15-14PR 8.25x15-14PR
38 Wheel base mm 2250 2250
39 Tread width front/rear mm 1584/1550 1584/1550
40 loaded, at the lowest point mm 176 176
Ground clearance
41 loaded, at center of wheelbase mm 205 205
42 service brake foot/hydraulic foot/hydraulic
Brakes
43 parking brake hand/mechanical hand/mechanical
DRIVE
45 Battery voltage/capacity v/ah 24/75 24/75
49 manufacturer/model DOOSAN/DB58S DOOSAN/DB58S
50 rated output (at rpm) KW(hp)/rpm 73.6(99.2)/2200 73.6(99.2)/2200
Engine
51 max. torque N-m(lb-ft)/rpm 363(268)/1600 363(268)/1600
52 cycle/cylinders/displacement cc 4/6/5785 4/6/5785
55 type
Transmission
56 no. speeds forward/reverse Full Auto Full Auto

30
General Section

3 Speed
DOOSAN DOOSAN DOOSAN 1
D70S-5 D80S-5 D90S-5 2
7000 8000 9000 3
600 600 600 4
diesel diesel diesel 5
rider-seated rider-seated rider-seated 6
p p p 7
4/2 4/2 4/2 8

3000 3100 3100 9

205 215 215 10
60x180x1200 70x180x1200 70x180x1200
13
410x2032 410x2092 410x2092
15/10 15/10 15/10 14
3647 3970 4040 15
2108 2230 2230 16
2500 2835 2835 17
4340 4375 4375 18
2455 2648 2648 19
1333 1526 1526 20
3380 3610 3680 21
632 725 725 22
4000 4330 4355 23
3058 3308 3327 23a

28.5/32.0 29.8/33.8 27.7/33.4 24

445/470 430/470 430/470 25
499/450 500/450 500/450 26
5915 5498 5449 28
37.2 30.6 28.6 30

9970 11545 12195 32

14980/1990 14920/4360 16920/4705 33
4150/5820 4600/6500 4680/7315 34

4/2 4/2 4/2 35

8.25x15-14PR 9.00x20-14PR 9.00x20-14PR 36
8.25x15-14PR 9.00x20-14PR 9.00x20-14PR 37
2250 2500 2500 38
1584/1550 1640/1750 1646/1750 39
176 258 258 40
205 205 205 41
foot/hydraulic foot/hydraulic foot/hydraulic 42
hand/mechanical hand/mechanical hand/mechanical 43

24/75 24/75 24/75 45

DOOSAN/DB58S DOOSAN/DB58S DOOSAN/DB58S 49
73.6(99.2)/2200 73.6(99.2)/2200 73.6(99.2)/2200 50
363(268)/1600 363(268)/1600 363(268)/1600 51
4/6/5785 4/6/5785 4/6/5785 52

Full Auto Full Auto Full Auto 55

3/3 3/3 3/3 56

31
General Section

Specifications
CHRACTERISTICS
1 Manufacturer
2 MODEL
3 Capacity at rated load center kg
4 Load center distance mm
5 Power type electric,diesel,gasoline,LPG
6 Operator type stand-on, rider-seated
7 Tire type c=cushion, p=pneumatic
8 Wheels(x=driven) number, front/rear
DIMENSIONS
9 Lift with STD maximum fork height with rated load mm
10 two stage mast free lift mm
thickness x width x length mm
13 Forks
fork spacing(minimum x maximum) mm
14 Tilt of mast forward / backward deg
15 length to face of forks mm
16 width mm
17 Overall mast lowered height mm
18 dimensions mast extended height mm
19 overhead guard height mm
20 seat height mm
21 Turning radius (minimum outside) mm
22 Load moment constant mm
23 90 stacking aisle add load length and clearance mm
23a 90 intersecting aisle mm
PERFORMANCE
24 travel, loaded/unloaded km/h
25 Speed lift, loaded/unloaded mm/s
26 lowering, loaded/unloaded mm/s
28 Drawbar pull at 1.6 km/h, loaded kg
30 Gradeability at 1.6 km/h, loaded %
WEIGHT
32 Total weight unloaded kg
33 Axle load with loaded, front/rear kg
34 without loaded, front/rear kg
CHASSIS
35 number of front/rear
36 Tires size, front
37 size, rear
38 Wheel base mm
39 Tread width front/rear mm
40 loaded, at the lowest point mm
Ground clearance
41 loaded, at center of wheelbase mm
42 service brake
Brakes
43 parking brake
DRIVE
45 Battery voltage/capacity v/ah
49 manufacturer/model
50 rated output (at rpm) KW(hp)/rpm
Engine
51 max. torque N-m(lb-ft)/rpm
52 cycle/cylinders/displacement cc
55 type
Transmission
56 no. speeds forward/reverse

32
General Section

2 Speed
DOOSAN DOOSAN DOOSAN 1
D50S-5 D60S-5 D70S-5 2
5000 6000 7000 3
600 600 600 4
diesel diesel diesel 5
rider-seated rider-seated rider-seated 6
p p p 7
4/2 4/2 4/2 8

3000 3000 3000 9

205 205 205 10
60x150x1200 60x180x1200 60x180x1200
13
350x2032 410x2032 410x2032
15/10 15/10 15/10 14
3507 3568 3647 15
2108 2108 2108 16
2500 2500 2500 17
4340 4340 4340 18
2455 2455 2455 19
1333 1333 1333 20
3301 3331 3380 21
632 632 632 22
3924 3958 4000 23
2990 3020 3058 23a

25/26.5 24.5/26.5 24.0/26.5 24

415/445 415/445 415/445 25
490/460 490/460 490/460 26
4908 4875 4875 28
39.4 34.1 30.3 30

8395 9085 9810 32

12010/1385 13430/1655 14820/1990 33
4270/4125 4145/4940 3985/5830 34

4/2 4/2 4/2 35

8.25x15-14PR 8.25x15-14PR 8.25x15-14PR 36
8.25x15-14PR 8.25x15-14PR 8.25x15-14PR 37
2250 2250 2250 38
1584/1550 1584/1550 1584/1550 39
176 176 176 40
205 205 205 41
foot/hydraulic foot/hydraulic foot/hydraulic 42
hand/mechanical hand/mechanical hand/mechanical 43

24/75 24/75 24/75 45

DOOSAN/DB58S DOOSAN/DB58S DOOSAN/DB58S 49
69.1(93.1)/2400 69.1(93.1)/2400 69.1(93.1)/2400 50
323(238)/1600 323(238)/1600 323(238)/1600 51
4/6/5785 4/6/5785 4/6/5785 52

Power Shift Power Shift Power Shift 55

2/2 2/2 2/2 56

33
General Section

Specifications
CHRACTERISTICS TIER-2
1 Manufacturer DOOSAN DOOSAN
2 MODEL G50S-5 G60S-5
3 Capacity at rated load center kg 5000 6000
4 Load center distance mm 600 600
5 Power type electric,diesel,gasoline,LPG LPG LPG
6 Operator type stand-on, rider-seated rider-seated rider-seated
7 Tire type c=cushion, p=pneumatic p p
8 Wheels(x=driven) number, front/rear 4/2 4/2
DIMENSIONS
9 Lift with STD maximum fork height with rated load mm 3000 3000
10 two stage mast free lift mm 205 205
thickness x width x length mm 60x150x1200 60x180x1200
13 Forks
fork spacing(minimum x maximum) mm 350x2032 410x2032
14 Tilt of mast forward / backward deg 15/10 15/10
15 length to face of forks mm 3507 3568
16 width mm 2108 2108
17 Overall mast lowered height mm 2500 2500
18 dimensions mast extended height mm 4340 4340
19 overhead guard height mm 2455 2455
20 seat height mm 1333 1333
21 Turning radius (minimum outside) mm 3301 3331
22 Load moment constant mm 632 632
23 90 stacking aisle add load length and clearance mm 3924 3958
23a 90 intersecting aisle mm 2990 3020
PERFORMANCE
24 travel, loaded/unloaded km/h 24.0/25.4 23.8/25.4
25 Speed lift, loaded/unloaded mm/s 380/410 380/410
26 lowering, loaded/unloaded mm/s 490/460 490/460
28 Drawbar pull at 1.6 km/h, loaded kg 5010 4990
30 Gradeability at 1.6 km/h, loaded % 40.9 35.5
WEIGHT
32 Total weight unloaded kg 8235 8905
33 Axle load with loaded, front/rear kg 11840/1395 13260/1645
34 without loaded, front/rear kg 4100/4135 3975/4930
CHASSIS
35 number of front/rear 4/2 4/2
36 Tires size, front 8.25x15-14PR 8.25x15-14PR
37 size, rear 8.25x15-14PR 8.25x15-14PR
38 Wheel base mm 2250 2250
39 Tread width front/rear mm 1584/1550 1584/1550
40 loaded, at the lowest point mm 176 176
Ground clearance
41 loaded, at center of wheelbase mm 205 205
42 service brake foot/hydraulic foot/hydraulic
Brakes hand/mechanic hand/mechanic
43 parking brake
al al
DRIVE
45 Battery voltage/capacity v/ah 12/75 12/75
49 manufacturer/model G643E(TIER-2) G643E(TIER-2)
50 rated output (at rpm) KW(hp)/rpm 69.0/2450 69.0/2450
Engine
51 max. torque N-m(lb-ft)/rpm 301/1400 301/1400
52 cycle/cylinders/displacement cc 4/6/4294 4/6/4294
55 type
Transmission
56 no. speeds forward/reverse Power Shift Power Shift

34
General Section

TIER-2 TIER-3
DOOSAN DOOSAN DOOSAN DOOSAN 1
G70S-5 G50S-5 G60S-5 G70S-5 2
7000 5000 6000 7000 3
600 600 600 600 4
LPG LPG LPG LPG 5
rider-seated rider-seated rider-seated rider-seated 6
p p p p 7
4/2 4/2 4/2 4/2 8

3000 3000 3000 3000 9

205 205 205 205 10
60x180x1200 60x150x1200 60x180x1200 60x180x1200
13
410x2032 350x2032 410x2032 410x2032
15/10 15/10 15/10 15/10 14
3647 3507 3568 3647 15
2108 2108 2108 2108 16
2500 2500 2500 2500 17
4340 4340 4340 4340 18
2455 2455 2455 2455 19
1333 1333 1333 1333 20
3380 3301 3331 3380 21
632 632 632 632 22
4000 3924 3958 4000 23
3058 2990 3020 3058 23a

23.6/25.4 24.0/25.4 23.8/25.4 23.6/25.4 24

380/410 380/410 380/410 380/410 25
490/460 490/460 490/460 490/460 26
4965 5010 4990 4965 28
31.3 40.9 35.5 31.3 30

9635 8235 8905 9635 32

14650/1985 11840/1395 13260/1645 14650/1985 33
3815/5820 4100/4135 3975/4930 3815/5820 34

4/2 4/2 4/2 4/2 35

8.25x15-14PR 8.25x15-14PR 8.25x15-14PR 8.25x15-14PR 36
8.25x15-14PR 8.25x15-14PR 8.25x15-14PR 8.25x15-14PR 37
2250 2250 2250 2250 38
1584/1550 1584/1550 1584/1550 1584/1550 39
176 176 176 176 40
205 205 205 205 41
foot/hydraulic foot/hydraulic foot/hydraulic foot/hydraulic 42
hand/mechanical hand/mechanical hand/mechanical hand/mechanical 43

12/75 12/75 12/75 12/75 45

G643E(TIER-2) G643E(TIER-3) G643E(TIER-3) G643E(TIER-3) 49
69.0/2450 69.0(93)/2450 69.0(93)/2450 69.0(93)/2450 50
301/1400 294(217)/1600 294(217)/1600 294(217)/1600 51
4/6/4294 4/6/4294 4/6/4294 4/6/4294 52

Power Shift Power Shift Power Shift Power Shift 55

2/2 2/2 2/2 2/2 56

35
General Section

36
General Section

NON_CERTI
DOOSAN DOOSAN DOOSAN 1
G50S-5 G60S-5 G70S-5 2
5000 6000 7000 3
600 600 600 4
LPG LPG LPG 5
rider-seated rider-seated rider-seated 6
p p p 7
4/2 4/2 4/2 8

3000 3000 3000 9

24.0/25.4 23.8/25.4 23.6/25.4 24

380/410 380/410 380/410 25
490/460 490/460 490/460 26
5010 4990 4965 28
40.9 35.5 31.3 30

8235 8905 9635 32

11840/1395 13260/1645 14650/1985 33
4100/4135 3975/4930 3815/5820 34

4/2 4/2 4/2 35

12/75 12/75 12/75 45

G643 G643 G643 49
69(93) /2450 69(93) /2450 69(93) /2450 50
301(222)/1400 301(222)/1400 301(222)/1400 51
4/6/4294 4/6/4294 4/6/4294 52

Power Shift Power Shift Power Shift 55

2/2 2/2 2/2 56

37
General Section

Capacity Chart - Without Side Shifter

MODEL STD FFT
D80S-5

A-FFT 4350~5400mm MAST

B-FFT 5850mm MAST
D90S-5

A-FFT 4350~5400mm MAST

B-FFT 5850mm MAST

40
General Section

Capacity Chart - With Side Shifter

MODEL STD FFT
D50S-5, G50S-5

A. 3000 ~ 4000 mm (118 in - 158 in) A. FFT 4550mm MAST

MFH MAST B. FFT 5000mm MAST
B. 4500 mm (177 in) MFH MAST C. FFT 5600mm MAST
C. 5000 mm (197 in) MFH MAST D. FFT 6050mm MAST
D. 5500 mm (217 in) MFH MAST
E. 6000 mm (236 in) MFH MAST
D60S-5, G60S-5

A. 3000 ~ 4000 mm (118 in - 158 in) A. FFT 4550mm MAST

MFH MAST B. FFT 5000mm MAST
B. 4500 mm (177 in) MFH MAST C. FFT 5600mm MAST
C. 5000 mm (197 in) MFH MAST D. FFT 6050mm MAST
D. 5500 mm (217 in) MFH MAST
E. 6000 mm (236 in) MFH MAST
D70S-5, G70S-5

A. FFT 4550mm MAST

A. 3000 ~ 4000 mm (118 in - 158 in) B. FFT 5000mm MAST
MFH MAST C. FFT 5600mm MAST
B. 4500 mm (177 in) MFH MAST D. FFT 6050mm MAST
C. 5000 mm (197 in) MFH MAST
D. 5500 mm (217 in) MFH MAST
E. 6000 mm (236 in) MFH MAST

41
General Section

Capacity Chart - With Side Shifter

MODEL STD FFT
D80S-5

A-STD 3100~3600mm MAST A-FFT 4350mm MAST

B-STD 4100mm MAST B-FFT 4800mm MAST
C-STD 4600mm MAST C-FFT 5400mm MAST
D-STD 5100mm MAST D-FFT 5850mm MAST
E-STD 5600mm MAST
D90S-5

A-STD 3100~3600mm MAST A-FFT 4350mm MAST

B-STD 4100mm MAST B-FFT 4800mm MAST
C-STD 4600mm MAST C-FFT 5400mm MAST
D-STD 5100mm MAST D-FFT 5850mm MAST
E-STD 5600mm MAST

42
General Section

Serial Number
Serial Number Locations
For quick reference, record your lift truck's serial
numbers in the spaces provided below the
photographs.

4.3 liter GM Vortec Engine Serial Number (G643E)

.______________________________

Typical Example

Lift Truck Serial Number

.______________________________

D50/60/70/80/90S-5(3 speed)

Transmission Serial Number

.______________________________

Typical Example Diesel Engine

5.8 liter (DB58S) Diesel Engine Serial Number

.______________________________

D50/60/70S-5(2 speed), G50/60/70S-5

Transmission Serial Number

.______________________________ID6OM001

Typical Example G50/60/70S-5

4.3 liter GM Vortec Engine Serial Number (G643)

.______________________________

43
General Section

D50/60/70/80/90S-5(3 speed), G50/60/70S-5

Side shifter Serial Number (If equipped)
Transmission Serial Number .______________________________
.______________________________ID6
OM001

DRIVE AXLE Serial Number (OCDB type)

.______________________________ D50/60/70S-5(2 speed), G50/60/70S-5

DRIVE AXLE Serial Number (Shoe type)

.______________________________

ID6OM004

44
General Section

Operator's Warning and Identification Plate

Familiarize yourself with the Operator’s WARNING Plate and IDENTIFICATION, LIFT CAPACITY and
ATTACHMENT PLATES. DO NOT exceed Capacity as equipped load ratings.

WARNING Identification, Lift Capacity and

The load capacity of lift truck should never be
Attachment Plate
exceeded. Overloading of the lift truck could be
a hazard to the safety of others, material, or
damage the truck.

Operator's Warning Plate

Typical Example

Located on the cowl to the right side of the steering

column.

Lift Truck Capacity Rating

DO NOT exceed allowable lift truck working capacity
Typical Example load ratings.
Located by the right side of the operator's seat. The capacity of the lift truck is given by weight and
distance to the load center. For example: a capacity
of 1200kg(2640 lb) at 600mm(24in) means that the
lift truck can lift 1200kg(2640lb) if the load center is
600 mm (24in) from both the vertical and horizontal
faces of the forks.
Before attempting to lift any load, ensure that the
weight and load center combination is within the
capacity of the lift truck as shown on the capacity
rating plate. To determine the load center, measure
the distance from the face of the carriage to the
gravitational center of the load.
The rated capacity on the plate refers to the capacity
of the lift truck as it left the factory. Subsequent
changes of any form to the equipment or battery can
alter the lift truck's rating.
The rated capacity of the lift truck applies to
operating conditions where the lift truck is on level
ground. The capacity of the lift truck is reduced on
inclines.

45
General Section

Below are abbreviations that may appear on the Attachment Abbreviations

Identification, Lift Capacity and Attachment Plate
and their meanings. (includes Special Forks)

Mast Abbreviations SC- Special Carriage-increased width, height

or outreach
STD - Standard Mast SSS - Shaft-type Sideshift Carriage
(single inner member, low free lift)
HSS - Hook-type Sideshift Carriage (ITA)
FF - Full Free Lift Mast
CW - Counterweight
(single inner member with high free lift
duplex cylinder) SF - Special Forks
FFT - Triple Lift Mast (two inner members) with SWS - Swing Shift, Sideshift
either low or full free lift characteristics.
RAM - Ram or Boom
QUAD Quadruple (Quad) Mast(with three inner
members) DBCBH - Double Cube Block Handler
HFP - Hydraulic Fork Positioner
NOTE: When only a mast-type is listed on the CR -
identification plate, a standard carriage and Crane Arm or Crane Boom
forks are used. TH - Tire Handler
CTH - Container Handler
LPP - Load Push-Pull Device
CC - Carton Clamp
RC - Roll Clamp
LS - Load Stabilizer
PWH - Pulp Wood Handler
SS-ST - Sideshift-Side Tilt Carriage

46
Operation Section

Operator’s Station and Monitoring Systems

1. Horn Switch
1
2 2. Steering Handwheel
8 3. Turn Signal Lever
3 4. Instrument Panel
5. Parking Brake Lever
4 5 6. Lift Lever
9 7 7. Tilt Lever
8. Direction Control Lever
6 9. Engine Ignition Start Switch
10. Accelerator Pedal
11. Service Foot Brake Pedal
12. Inching Control Pedal
14. Transmission oil temperature
gauge
15. Speed Meter
16. Fuel Level Gauge
11 17. Engine coolant gauge
12 10
18. Transmission Display
19. Hour Counter
20. Warning Light
Typical Example

6 7

26
27
5 23

16 22

25
28
21
24
14 29

15 17 30 31

32
33

19 20

Typical Example

21. Hazard Lamp Switch 28. Empty plug

22. Automatic Transmission 29. Air Conditioner
23. Eco & Power Switch(Inching Switch) 30. Fan
24. Light Switch 31. Heater
25. Wiper Switch 32. Cigar Jack Connector
26. Engine Emergency stop Switch 33. Power Jack Connector
27. Engine Diagnostic Switch

47
Operation Section

Instrument Panel 5. Hour Counter

1. Engine Ignition Start Switch Indicates the total number of
hours the engine and the lift
The key switch is a four position truck have operated. The hour
switch. Position (1) is meter will operate when the
ACCESSORY ON. Position (2) is ignition switch is in the ON
OFF. Position (3) is ON or RUN position, whether the engine is
and accessory ON. running or not.
Position (4) is START, which The hour meter is used to determine lubrication and
engages the starter. maintenance intervals.
After the key has been turned to the START position,
the key must be returned to the OFF position before 6. Speed meter
it can be turned to the START position again.
Indicates the truck travelling
2. Engine Coolant Gauge speed(km/h).

Indicates coolant temperature. If

the pointer moves beyond the
green band while operating the
lift truck, overheating is indicated.
7. Turn Signal Lever
Park the lift truck and stop the
engine.
This is the lever to indicate the
Check the cooling system for a
turning direction of the lift truck.
malfunction. The point will be at the end of the green
band when the coolant temperature reaches As this lever is maneuvered, the
signal lamp blinks.
approximately 103°C(217°F) on all engines.

3. Transmission Oil Temperature Gauge R Turn to the right

N Neutral
Indicates transmission oil L Turn to the left
temperature. If the pointer moves
beyond the green band while
operating the lift truck, excessive 8. Horn Switch
transmission oil temperature is
indicated. Park the lift truck and To give alarm to fellow worker(s)
stop the engine around and in the path of your
Check the system for a truck, press the rubber at the
malfunction. The pointer will be at the end of the center of the handwheel.
green band when the transmission oil temperature
reaches approximately 120°C (248°F).

4. Fuel Level Gauge

WARNING
Indicates fuel level in the fuel
Don’t run the truck while the alarm is sounding.
tank.
It is dangerous to do so, since poor effect is
expected.

48
Operation Section

9. Light Switch
st nd
1 2
Switch Light Ste Ste
p p
Clearance Lamp O X
Tail Lamp O X
License plate Lamp O X
Instrument Lamp O X
Head Lamp O X

O : means “lights on”

X : means “lights off”

These lamps light up regardless of position of the

ignition switch.

10. Hazard Lamp Switch

Push the button to active the hazard lamp. Hazard
lamp put the same with turn signal lamp.

49
Operation Section

Warning Light

1. Upper Indicator Light 8. Parking Indicator Light

2. Air Cleaner Indicator Light 9. Levering Light
3. Alternator Indicator Light 10. Seat Belt Warning wight
4. Diesel Engine Start Preheat Indicator Light 11. Seat Leaving Warning Light
5. Air Dryer Heater Light 12. Transmission Neutral Position Light
6. Front Flood Light 13. Engine Malfunction Indicator Light
7. Engine Oil Pressure Indicator Light 14. Directional Turning Indicator Lights

(1) Upper Indicator Light (4) Diesel Engine Start Preheat Indicator Light
Indicates the upper indicator light is on. The light will come ON when the key is
turned to the ON position from the OFF
position. This indicates that the glow plugs
(2) Air Cleaner Indicator Light are preheating the pre-combustion chambers for
Indicates that the air filter is blocked. If the easier starting.
light stays on after starting the engine, stop
the engine, remove the air filter element and The amount of time needed to preheat the
clean it thoroughly using compressed air. Refit the pre-combustion chambers is approximately seven
filter, and check that the light goes out when the seconds, depending on the surrounding air
engine is started. temperature. When the light goes OFF the
maximum pre-combustion chamber temperature has
(3) Alternator Indicator Light been reached and the key can be turned to the
Indicates if the battery charging system is START position to start the engine.
operational. The light will come on when the
ignition switch is turned to the ON position. (5) Air-Dryer heater Light
The light should go off after the engine is This indicates that an air-dryer heater
started, indicating the alternator is producing begins to work to steam up water vapor
sufficient voltage to charge the battery. If the light from the air chamber.
turns on with the engine running, check the After water vapor is eliminated, the lamp should go
alternator charging system for a malfunction. off. If the lamp doesn’t go off for a long ting check
the air brake system for a malfunction.

50
Operation Section

(6) Front Floodlights (14) Directional Turning Indicator Light

Push down on the switch(14), to the first Pull the lever to activate the right turn signal.
step, to turn the front floodlights on. Push the lever to activate the left turn signal.

(7) Engine Oil Pressure Indicator Light

Indicates insufficient engine oil pressure.
The light will come on when the ignition
switch is turned to the ON position. The light
should go off after the engine is started. If the light
turns on while operating the lift truck, insufficient
engine oil pressure is indicated. Park the lift truck
and stop the engine.

(8) Parking indicator light

The light will come ON when the parking
lever is applied.

(9) Levering light(If Equipment)

Indicates tilt and lift control lever.
The light comes on when lift and tild lever
move forward/backward with installed
solenoid valve.

(10) Seat Belt Warning Light

Indicates when the seat belt dose not
fastened by operator.
The light will come on when the ignition
switch is turned to the on position.
The light should go off after engine is started.

(11) Seat Leaving warning Light

When operator leaves seat without engine
stop, hydraulic control lever cannot operate.

(12) Transmission Neutral Position Light

Indicates the neutral position of
transmission.

(13) Engine Malfunction Indicator Lamp

Engine control systems are equipped with
built-in fault diagnostics. Detected system
faults can be displayed by the Malfunction
Indicator Lamp (MIL) as Diagnostic Fault Codes
(DFC) or flash codes, and viewed in detail with the
use of service tool software. When the ignition key is
turned ON the MIL will perform a self-test, illuminate
once and then go OFF. If a detected falut condition
exists, the fault or faults will be stored in the memory
of the engine control unit(ECM). Once a fault occurs
the MIL will illuminate and remain ON. This signals
the operator that a faults has been detected by the
ECU.

51
Operation Section

Seat Switch System NOTICE

1. Prior to operating the lift truck, be sure to

understand and check the SEAT SWITCH
SYSTEM.

2. While in normal operation and on level

ground, select a direction with the
derectional lever and with the park brake
released. You will note that the truck will
move slowly in the selected direction. If you
lift yours hips off of the seat, within three
seconds, the SEAT SWITCH SYSTEM will
desengage the transmission allowing the
truck to coast but not automatically stop.
The lift truck is equipped with a SEAT SWITCH
SYSTEM. In normal operation if the direction lever is
3. To restore the lift truck to normal operation,
placed in either forward or reverse, the lift truck
while sitting in the operator's seat depress
will move at a speed proportional to the accelerator the brake pedal to hold the lift truck, return
pedal's position. If the operator leavers the seat the directional lever to the neutral position,
without setting the parking brake, within three and then reselect a direction of travel (either
seconds after leaving the seat, the SEAT SWITCH forward or reverse). The transmission will
SYSTEM will automatically disengage the then re-engage.
transmission. The directional lever, however, will
remain in that forward or reverse location although
internally the transmission will have shifted into 4. If seat or seat switch replacement becomes
necessary, be sure to use genuine DOOSAN
neutral.
Infracore lift truck parts. Lift trucks should
never be operated without an operational
Before exiting the lift truck, the parking brake should SEAT SWITCH SYSTEM.
always be applied.

WARNING
WHEN LEAVING MACHINE APPLY PARKING
BRAKE!

PARKING BRAKE IS NOT AUTOMATICALLY

APPLIED.

NOTE: Some trucks may be equipped (ask your

dealer if this applies to your truck) with an
alarm that will sound if the parking brake is
not applied when leaving the machine.

52
Operation Section

Steering Column Tilting Angle Fuse Box

Adjustment

Typical Example
Typical Example

The tilting angle of the steering wheel is adjustable

within a range of 15 degrees to suit individual Fuse Locations
operators. The steering column is unlocked by
turning the lever counter clockwise and locked by
turning it clockwise.

Tow Eye

Fuses protect the electrical system from damage

caused by overloaded circuits. Change a fuse if the
element separates. If the element of a new fuse
separates, have the circuit checked and repaired.
Typical Example

It is for emergency use in towing a disabled vehicle

or being towed by another truck when your truck is
disabled. Use wire rope strong enough according to
the weight and size of the vehicle to be towed.

53
Operation Section

1. D50/60/70S-5 (2 Speed) 3. G50/60/70S-5 (2 Speed)

Rated Rated
No. Description E Description
Capacity Capacity
1 Engine Start 10A 1 Engine Start 10A
Engine Stop Motor Relay Coil, Preheat ECU(Engine Control Unit) Main Relay Coil,
2 10A 2 10A
System, Iso3691 Valve Iso3691 Valve
3 T/M Solenoid Valve Control Sys. 10A 3 T/M Solenoid Valve Control Sys. 10A
4 Cabin Relay Coil, Aircon Relay Coil 15A 4 Cabin Relay Coil, Aircon Relay Coil 15A
5 Gague Panel, Stop Lamp, Strobe Light 15A
5 Gague Panel, Stop Lamp, Strobe Light 15A
6 Horn 10A
6 Horn 10A
7 Spare 10A
7 Spare 10A
Head Lamp Relay Coil, Rear Lamp, Turn
Head Lamp Relay Coil, Rear Lamp, Turn
8 Signal Lamp 15A
8 Signal Lamp 15A
Clearance Lamp
Clearance Lamp
Head Lamp(Hi Beam), Head Lamp(Low
9 15A Head Lamp(Hi Beam), Head Lamp(Low
Beam) 9 15A
Beam)
Cigar Lighter, Power Socket, CD Player,
10 15A Cigar Lighter, Power Socket, CD Player,
Wiper Motor (CABIN) 10 15A
Wiper Motor (CABIN)
11 Ignition Switch (St, Ign, Acc) 30A
11 Ignition Switch (St, Ign, Acc) 30A
12 Aircon, Heater 30A
12 Aircon, Heater 30A

2. D50/60/70/80/90S-5 (3 Speed)
Rated
No. Description
Capacity
1 Engine Start 10A
Engine Stop Motor Relay Coil, Preheat
2 10A
System, Iso3691 Valve
TCU(T/M Control Unit) Ignition, T/M
3 10A
Display
4 Cabin Relay Coil, Aircon Relay Coil 15A
5 Gague Panel, Stop Lamp, Strobe Light 15A
6 Horn 10A
7 TCU(T/M Control Unit) Power 10A
Head Lamp Relay Coil, Rear Lamp, Turn
8 Signal Lamp 15A
Clearance Lamp
Head Lamp(Hi Beam), Head Lamp(Low
9 15A
Beam)
Cigar Lighter, Power Socket, CD Player,
10 15A
Wiper Motor (CABIN)
11 Ignition Switch (St, Ign, Acc) 30A
12 Aircon, Heater 30A

54
Operation Section

Circuit Breaker

Typical Example Diesel Engine Truck

Circuit Breaker protects the main electrical circuit. It

is located in the engine compartment on the left
side.

To reset the circuit breaker, push the button in. If the

button comes back out, have the electrical circuits
checked.

Seat
Seat Adjustment
NOTE: Seat arrangements may vary. Basic
operation will be similar.

Seat adjustment should be checked at the beginning

of each shift and when operators change.
Lock the seat into position before operating, to
prevent an unexpected seat change.

Typical Example

Adjust seat to allow full brake pedal travel with

operator's back against seat back.

NOTE: The seat can only be correctly adjusted with

the operator fully seated.

55
Operation Section

Lift Truck Controls WARNING

“LOCK” the direction control lever. Whenever
machine is parked, "LOCK" the direction control
Direction Control Lever lever in "NEUTRAL" to prevent accidental
machine movement.

Transmission Display (3 Speed

Only)
A transmission display is to the right of the steering
wheel on the dash. The LCD indicates gears,
direction of travel and error codes.

Typical Example

Forward – Reverse
F Forward
N Neutral
R Reverse

Speed Select (A) Indicates travel direction and gear selection. See
the figure below for more detailed information.
1 1st
2 2nd (B) Indicates normal operation and error codes. For
3 3rd (3 speed ONLY) a list of error codes, see "Transmission Error
Codes" in "When Required" maintenance
Rotating the direction control lever changes the section.
speed of travel. With handle rotated counter NOTE : Most codes are only two digits.
clockwise (towards the operator), the lift truck is in
FIRST speed. (C) Indicates that error codes have occurred and are
stored.
Rotate the lever clockwise (away from the operator)
for the SECOND and THIRD speeds. (D) Indicates that operation must be stopped
Always brake to a full stop before reversing the immediately to prevent damage to transmission
direction of travel. and hazardous operation condition.

Do not fail to place the forward-reverse lever in the

neutral position before starting the engine. FORWARD INDICATOR
GEAR RANGE INDICATOR
Neutral Lever Lock (3 Speed Only) BARS
A transmission neutral lever lock is in base of the REVERSE INDICATOR
direction control lever. This neutral lever lock
prevents the direction control lever from being
moved out of "NEUTRL".
The gear range indicator bars will indicate which
N "NEUTRAL LOCK" position. Prevents the gear is selected by displaying the corresponding
direction control lever to be moved out of number of bars.
"NEUTRAL".
The forward and reverse indicator bars will be "OFF”
D "DRIVE" position. Allows the direction control when the transmission is in "MANUAL MODE".
lever to be moved from "NEUTRAL" to When transmission is in "AUTOMATIC MODE", all
"FORWARD and REVERSE". the gear range indicator bars and both travel
direction indicators will be "ON".

56
Operation Section

Automatic Transmission Switch (3 Inching Switch (3 Speed Only)

Speed Only)

This switch changes over the modes of the inching

Automatic speed range:
control pedal, inching and no-inching.
. FORWARD: 3 speeds.
. REVERSE: 3 speeds.

DR In this position, the "NO INCHING" mode is

MAN When this switch is in "MAN"(manual) position, selected. In the "NO INCHING" mode, the inching
travel mode is switched to "MANUAL" and pedal control is disabled but braking function by
allows operator to choose speeds manually. pushing on the inching pedal is still active.

A-1ST When this switch is in "A-1ST"(automatic 1ST ) OP In this position, the "INCHING" mode is
position, gears are started from 1ST speed and selected. In the "INCHING" mode, normal inching
changed "AUTOMATICALLY" to the function is enabled by pushing on the inching pedal.
appropriate speed up to the limit set by the
gear ratio according to travel load and engine NOTE: When driving a middle or long distance
rpm. without using the inching function, set this
switch to "DR" position to prevent the
A-2ND When this switch is in "A-2ND"(automatic 2ND ) transmission clutch pedals from
position, gears are started from 2ND speed and unnecessary wear or overheat.
changed "AUTOMATICALLY” to the
appropriate speed up to the limit set by the
gear ratio according to travel load and engine
rpm.

57
Operation Section

Transmission Inching Control Service Foot Brake Pedal

Pedal

Typical Example

Typical Example Push DOWN on the brake pedal to slow or

stop the lift truck.
Inching Control Pedal - Pushing down on
the inching pedal, modulates the hydraulic
pressure to the clutch packs, permitting RELEASE the brake pedal to allow the lift
disc slippage. truck to move.
Further pushing on the pedal completely relieves
clutch pack pressure and applies the service brakes
to stop and hold the lift truck. Accelerator Pedal
NOTE: The purpose of the inching control pedal is
to provide precise inching control at slow
travel speed, with high engine rpm. This is
used for fast hydraulic lift during load
approach, pickup or positioning.

Typical Example

Push DOWN on the pedal to increase

engine rpm (speed).

RELEASE the pedal to decrease engine

rpm (speed).

58
Operation Section

Parking Brake Lever Tilt Control

NOTICE
Do not engage the parking brake while the lift truck
is moving unless an emergency exists. The use of
the parking brake as a service foot brake in regular
operation will cause severe damage to the parking
brake system.

The mast can be tilted by operation of this tilt lever.

Pulling on this lever backwards will tilt the mast
backwards, and pushing it forwards will tilt the mast
forwards. The tilt speed can be controlled by tilt
angle of the lever and accelerator pedal effort.

The parking brake lever is located at the left side of

the steering wheel.

Lift Control

The forks can be raised or lowered by pulling

backwards or pushing forwards on this lever. The lift
speed is controlled by tilt angle of the lever and
accelerator pedal effort. The lowering speed can be
controlled by tilt angle of the lever. The engine
speed or accelerator pedal has nothing to do with
the lowering speed of the forks.

59
Operation Section

Refueling
Diesel Engine Equipped

WARNING
Explosive fumes may be present during
refueling.
Do not smoke in refueling areas. Lift truck
should be refueled only at designated safe
locations. Safe outdoor locations are preferable Typical Example
to those indoors.
Stop the engine and get off the lift truck during 2. Remove the filter cap.
refueling.
3. Fill the fuel tank slowly. See topic, "Refill
Capacities." in maintenance section. Install the
NOTICE filter cap. If spillage occurs, wipe off excess fuel
and absorb any excess fuel with absorbent
Do not allow the lift truck to become low on fuel or material.
completely run out of fuel. Sediment or other
impurities in the fuel tank could be drawn into the NOTE: Drain water and sediment from fuel tank as
fuel system. This could result in difficult starting or required by prevailing conditions. Also,
damage to components. drain water and sediment from the main fuel
Fill the fuel tank at the end of each day of operation storage tank weekly and before the tank is
to drive out moisture laden air and to prevent refilled. This will help prevent water or
condensation. In the cold weather, the moisture sediment being pumped from the storage
condensation can cause rust in the fuel system and tank into the lift truck fuel tank.
hard starting due to its freezing. Do not fill the tank
to the top. Fuel expands when it gets warm and may
overflow.

Typical Example

1. Park the lift truck only at a designated safe

location. Place the transmission in NEUTRAL.
Lower the forks to the ground. Engage the
parking brake. Stop the engine.

60
Operation Section

Changing LP Tanks

WARNING
Only trained, authorized personnel should fill or
exchange LP tanks.
Personnel engaged in filling of LP containers
should wear protective clothing such as face
shield, long sleeves and gauntlet gloves. Do not
refuel or store LP powered lift trucks near any
underground entrance, elevator shafts or any
other place where LP could collect in a pocket
4. Grasp the tank support bar (1). Pull and release
causing a potentially dangerous condition.
the latch switch (2).
Examine all LP containers before filling and
again before reuse, for damage to various valves,
5. Grasp the tank support bar (1) and rotate cradle
liquid gauge, fittings and hand valve wheels.
slowly to the rear of a tank.
All defective or damaged LP containers must be
removed from service.
Explosive fumes may be present during
refueling.
Do not smoke in refueling areas.
Lift truck should be refueled only at designated
safe locations. Safe outdoor locations are
preferable to indoor locations.
Stop the engine and get off the lift truck during
refueling.
The careless handling of LP containers can
result in a serious accident.
Use extreme care when transporting containers
to prevent damage to them. 6. Pull the release knob (1) and then push down
the tank.
1. Park the lift truck on level ground, with the
parking brake applied, the transmission in
NEUTRAL, the forks lowered and the engine
running at low idle.

7. Lock the tank cradle by knob (1). Loosen the

retaining clamps (2) and remove the tank.

8. Check the mounting to be sure the locating pin

(dowel) is not missing or broken.
2. Close the fuel inlet valve at the LP - Gas tank.
Run the engine until it stops, then turn off the
ignition switch and the electrical disconnect NOTICE
switch (if equipped).
If the location pin (dowel) is missing or broken, be
3. Disconnect the fuel supply line. sure the pin is replaced.

61
Operation Section

CAUTION
The LP tank must not extend past the
counterweight.

9. Check to be sure that the LP warning plate is in

position on the lift truck, and is legible.

10. Check to be sure the replacement tank is of the

correct type.

11. Inspect the replacement tank for damage such

as dents, scrapes or gouges and for indication of 15. Grasp a new tank and clamp securely. Pull the
leakage at valves or threaded connections. release knob (1) and push the tank cradle
upward when locked.

16. Rotate the tank cradle forward of the truck and

lock it with latch. Connect the fuel supply line.

17. Open the fuel valve by slowly turning the valve

counterclockwise. If the fuel valve is opened too
quickly, a back pressure check valve will shut off
the fuel supply. If this happens, close the fuel
valve completely. Wait five seconds and then
open the fuel valve very slowly.

18. Inspect the LP fuel lines and fittings with a soap

solution after filling the tank or when looking for
12. Check for debris in the relief valve, for damage
leaks.
to various valves and liquid level gauge.

13. Inspect the quick-disconnect couplings for

deterioration, damage or missing flexible seals.

14. Position the replacement tank so that the

locating pin (dowel) is in place.

62
Operation Section

Before Starting the Engine

Walk-Around Inspection 7. Inspect the overhead guard for damage and

loose or missing mounting bolts.
8. Inspect the hydraulic system for leaks, worn
Make a thorough walk-around inspection before hoses or damaged lines.
mounting the lift truck or starting the engine. Look
for such items as loose bolts, debris buildup, oil or
9. Look for transmission and drive axle leaks on
coolant leaks. Check condition of tires, mast, the lift truck and on the ground.
carriage, forks or attachments. Have repairs made
as needed and all debris removed.

Typical Example Diesel Engine(3 speed)

Typical Example

1. Inspect the operator's compartment for loose

items and cleanliness.

2. Inspect the instrument panel for broken or

damaged indicator lights or gauges.

3. Test the horn and other safety devices for

proper operation.

Typical Example Diesel Engine(2 speed)

Typical Example

4. Inspect the mast and lift chains for wear, broken

links, pins and loose rollers.

5. Inspect the carriage, forks or attachments for

wear, damage and loose or missing bolts.

6. Inspect the tires and wheels for cuts, gouges,

foreign objects, inflation pressure and loose or
missing bolts.

63
Operation Section

Typical Example LP Engine Typical Example Diesel Engine

10. Inspect the engine compartment for oil, coolant

and fuel leaks.

Typical Example LP Engine

Typical Example Diesel Engine 12. Observe the engine coolant level in the coolant
recovery bottle. With the engine cold, maintain
the level to the COLD mark. If the recovery
bottle is empty, also fill the radiator at the top
tank.

Typical Example LP Engine

11. Measure the engine crankcase oil level with the

dip stick. Maintain the oil level between the MAX.
and MIN., (or FULL and ADD) notches on the Typical Example
dip stick.
13. Observe the fuel level gauge after starting the
truck. Add fuel if necessary.

64
Operation Section

WARNING
Personal injury may occur from accidents
caused by improper seat adjustment.
Always adjust the operator's seat before starting
the lift truck engine.
Seat adjustment must be done at the beginning
of each shift and when operators change.

Typical Example

14. To position the seat, PUSH the lever away from

the seat track and move the seat forward or
backward to a comfortable position.

15. Inspect seat belt for wear and correct operation.

65
Operation Section

Starting the Engine

Prestart Conditions Starting a Warm Diesel Engine

1. Turn the ignition key to the ON position and then
to START position, without waiting for the
NOTE: The engine will not start unless the preheat light to go OFF. At the same time fully
transmission directional control lever is in depress the accelerator.
the NEUTRAL position.
2. Release the ignition key when the engine starts
and release the accelerator pedal to a low idle
position.

LP Engine

WARNING
LP fuel is flammable and can cause personal
injury.
Inspect LP fuel lines and fitting for leaks.
Inspect tank for secure mounting.
Typical Example

1. Engage the parking brake, if not already

engaged.

2. Place the transmission directional control lever

in NEUTRAL position.

Diesel Engine
Starting a Cold Diesel Engine
1. Turn the ignition key to the ON position. The
start preheat light will come ON. The preheat
light will stay ON approximately seven seconds,
depending on the ambient air temperature.
1. Open the tank fuel valve by slowly turning the
valve counterclockwise. Observe the LP gauge
(if equipped).
NOTICE
Do not engage the starter for more than 10 seconds. 2. Turn the ignition switch to the START position.
Release it when the engine starts.

2. When the preheat light goes OFF, turn the 3. If the engine does not start, Do not press on the
ignition key to the START position, with the accelerator pedal. Turn the starter switch to OFF
accelerator pedal fully depressed. position, the repeat step 2 and depress the
accelerator pedal slightly during cranking.
3. Release the ignition key when the engine starts
and release the accelerator pedal to a low idle 4. Allow the engine to warm up slowly.
position.

4. If the engine stalls or does not start, turn the

ignition key to the OFF position, then repeat
steps 1 thru 3.

66
Operation Section

Starting From a 24/12 Volt External Starting with Jumper Cables

Source
WARNING

WARNING Batteries give off flammable fumes that can

explode.
Sparks occurring near the battery could cause Prevent sparks near the batteries. They could
vapors to explode. cause vapors to explode. Do not allow jump
Always connect the external power source cable ends to contact each other or the lift truck.
ground cable to a point away from and below the Do not smoke when checking battery electrolyte
battery, and well clear of fuel system levels.
components. Electrolyte is an acid and can cause personal
injury if it contacts skin or eyes.
Always wear eye protection when starting a lift
truck with jump cables.
Improper jump procedures can cause an
explosion resulting in personal injury.
Always connect battery positive (+) to battery
positive (+) and battery negative (-) to be battery
negative (-).
Jump only with a battery source and with the
same voltage as the stalled lift truck.
Turn off all lights and accessories on the stalled
lift truck. Otherwise, they will operate when the
jump source is connected.

Typical Example Diesel Engine Truck

NOTICE
When starting from another machine, make sure the
machines Do not touch. This could prevent damage
to engine bearings and electrical circuits.
Turn on (close) the disconnect switch prior to the
boost connection to prevent damage to electrical
components on the stalled machine.
Severely discharged maintenance free batteries
might not fully recharge by the alternator alone after
jump starting.
The batteries must be charged to the proper voltage
by the battery charger.
Typical Example LP Engine Truck Many batteries thought to be unusable, are still
rechargeable.
This machine has a 24 volt starting system. Use
only equal voltage for jump starting. Use of a welder
NOTICE
or higher voltage equipment will damage the
Do not reverse battery cables. It can cause damage electrical system.
to the alternator.
Always connect the external power source cables in
parallel with the lift truck battery cables :
POSITIVE(+) to POSITIVE(+) and NEGATIVE(-) to
NEGATIVE(-).
Attach ground cable last, remove first.
All lift trucks equipped with DOOSAN built internal
combustion engines are NEGATIVE(-) ground.

67
Operation Section

Use of Jumper Cables 10. Connect one end of the negative (-) jumper
cable to the other terminal (negative) of the
When auxiliary start receptacles are not available,
boost battery.
use the following procedure.
11. Make final connection of negative (-) cable to the
1. Make initial determination as to failure of lift
stalled truck frame (not battery negative post)
truck to crank. Procedure applies even if lift truck
away from battery, fuel or hydraulic lines, or
does not have diagnostic connector.
moving parts.
2. Place the directional control in NEUTRAL on the
12. Start the engine on the boost lift truck, or
stalled lift truck. Engage the parking/secondary
energize the charging system on the auxiliary
brake. Lower all attachments to the ground.
power source.
Move all controls to HOLD (CENTER).
13. Wait a minimum of two minutes for the batteries
3. On stalled lift truck, turn the start switch to OFF.
in the stalled lift truck to partially charge.
Turn off all accessories.
14. Attempt to start the stalled engine. Refer to
4. On stalled lift truck, turn on (close) the
section on ‘ Engine Starting’ .
disconnect switch (if equipped).

5. Move boost start lift truck near enough to stalled 15. Immediately after starting the stalled engine,
lift truck for cables to reach, but DO NOT disconnect the jumper cables in reverse order.
ALLOW LIFT TRUCKS TO TOUCH.
16. Conclude failure analysis on starting/charging
6. Stop the engine on the boost lift truck. Or, if system of the stalled lift truck as required with
using an auxiliary power source, turn off the the engine running and charging system in
charging system. operation.

7. Make sure battery caps are all in place and tight

on both lift trucks.

Typical Example of 24 Voltage

8. Connect positive (+) jumper cable (red) to

positive (+) cable terminal of discharged battery,
or battery set on the stalled lift truck. Do not
allow positive cable clamps to touch any metal
other than battery terminals.

9. Connect the other end of this positive jumper

cable (red) to positive (+) terminal of boost
battery. Use procedure of Step 8 to determine
correct terminal.

68
Operation Section

NOTE: At an oil temperature in the shifting circuit

After Starting the Engine lower than -12°C, the transmission must be
Observe all indicator lights and gauges frequently warmed-up for some minutes. This must be
during operation, to make sure all systems are carried out in Neutral with an increased
working properly. engine speed (about 1500 rpm). Until this
oil temperature is reached, the Electronics
remains in Neutral, and the symbol of the
WARNING cold start phase will be indicated on the
Transmission Display.
If any light comes on, have corrections made
before operating truck.
Indication on the Transmission Display

After the indication on the Transmission Display is

extinguished, the full driving program can be utilized
out of "NEUTRAL".

4. The engine oil pressure indicator light (1), will not

come ON with the engine running, unless there
is low or no oil pressure. Stop the engine
immediately, if the light comes ON.

Typical Example 5. The G643E engine MIL (Malfunction indicator

Light) will not come ON with engine running,
1. Alternator indicator light will be OUT in normal unless the fault or faults are stored in the
operation. If the light comes ON with the engine memory of the engine control module (ECM).
running, the alternator is not charging. Stop the engine and check the electric engine
control system if the light comes ON. Refer
G643E Engine of this section.

Typical Example

2. Observe fuel gauge and service hour meter (1) Engine oil pressure indicator light
frequently to assure they are operating properly. (2) Engine malfunction indicator light

3. Observe the brake air pressure gauge and

indicator light frequently (if equipped) while
engine is running. Air pressure indicator must be
in the green range. If light comes on, it indicates
loss of air pressure.

NOTE: Do not idle engines for prolonged periods of

time. These engines can be started easily,
even when hot.

69
Operation Section

Electronic Controlled Spark-Ignition Engines

G643E Engine
EMS (Engine management system) of G643E uses two heated exhaust gas oxygen sensors
engine is a closed loop system utilizing a catalytic (HEGO) in the exhaust system to monitor exhaust
muffler to reduce the emission level in the exhaust gas content. One HEGO is installed in front of the
gas. In order to obtain maximum effect from the catalytic muffler and one is installed after the
catalyst, an accurate control of the air fuel ratio is catalytic muffler.
required. A small engine control module (SECM)

EMS schematic of G643E LP engine

The SECM makes any necessary corrections to the cables are not used. A throttle position sensor (TPS)
air fuel ratio by controlling the inlet fuel pressure to monitors throttle position in relation to the
the air/fuel mixer by modulating the dual fuel trim accelerator pedal position sensor (APP) command.
valves (FTV) connected to the regulator. Reducing Even engine coolant temperature and adequate oil
the fuel pressure leans the air/fuel mixture and pressure are monitored by the SECM. The SECM
increasing the fuel pressure enriches the air/fuel controller has full adaptive learning capabilities,
mixture. To calculate any necessary corrections to allowing it to adapt control function as operating
the air fuel ratio, the SECM uses a number of conditions change. Factors such as ambient
different sensors to gain information about the temperature, fuel variations, ignition component
engine’s performance. Engine speed is monitored wear, clogged air filter, and other operating variables
by the SECM through a variable reluctance (VR) or are compensated.
Hall Effect sensor. Intake manifold air temperature
and absolute pressure are monitored with a TMAP
sensor. MI-07 is a drive-by-wire (DBW) system
connecting the accelerator pedal to the electronic
throttle through the electrical harness; mechanical

70
Operation Section

G643 Electronic Controlled LP Engines (If Equipped)

General Description

EMS

LP Fuel Line
Key switch
Fault Light
Fuel Filter Fuel Lock
Main
PWR
Foot Pedal Relay Converter
APP
Coolant Line
Vacuum
Air Cleaner Mixer Line

DBW Throttle TPS

TMAP
Ignition Coil

SECM

Coolant Temperature Sensor

Muffler

Engine speed is monitored by the SECM through a operating conditions change. Factors such as
variable reluctance (VR) sensor. Intake manifold air ambient temperature, fuel variations, ignition
temperature and absolute pressure is monitored component wear, clogged air filter, and other
with a (TMAP) sensor. The MI-04 is a drive by wire operating variables are compensated.
(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

71
Operation Section

Basic Troubleshooting
The EMS systems are equipped with built-in fault checks that should be made before referring to the
diagnostics. Detected system faults can be Advanced Diagnostics section, if engine or drivability
displayed by the Malfunction Indicator Lamp (MIL) problems are encountered.
and are covered in the Advanced Diagnostics Locating a problem in a propane engine is done
section. Items such as fuel level, plugged fuel lines, exactly the same way as with a gasoline engine.
clogged fuel filters and malfunctioning pressure Consider all parts of the ignition and mechanical
regulators may not set a fault code by the Small systems as well as the fuel system.
Engine Control Module (SECM). Below are basic

Problem Probable Cause Corrective Action

Engine Cranking Fuel container empty Fill fuel container
but Will Not Start z Do not exceed 80% of liquid
capacity
Liquid valve closed Slowly open liquid valve
Excess flow valve closed Reset excess flow valve
z Close liquid valve
z Wait for a “click” sound
z Slowly open liquid valve
Plugged fuel line Remove obstruction from the fuel line
z Close liquid fuel valve
z Using caution, disconnect the fuel
line (some propane may escape)
z Clear obstruction with compressed
air
z Re-connect fuel line
z Slowly open liquid fuel valve
z Leak test
Broken Fuse - SECM Replace Fuse for SECM
z See Maintenance Section, Fuses
replacement
Clogged fuel filter Repair/replace as required
z See Maintenance Section, LP Fuel
Filter replacement
Faulty vapor connection between Check connection
the pressure regulator/converter z Verify no holes in hose
and the mixer
z Clamps must be tight
z Look for kinked, pinched and/or
collapsed hose
Fuel Lock-off malfunction Repair/replace Fuel Lock-off
z See Engine Service Manual
Pressure regulator/converter Test pressure regulator/converter operation
malfunction z See Engine Service Manual
Incorrect air/fuel or ignition/spark See Advanced Diagnostics
control

72
Operation Section

Problem Probable Cause Corrective Action

Engine Cranking No VR Sensor Signal Verify the VR signal is present
but Will Not Start z See Advanced Diagnostics

Difficult to Start Fuel container almost empty LPG Vapor from liquid outlet
z Fill fuel container
z Do not exceed 80% of liquid
capacity
Excess flow valve closed Reset excess flow valve
z Close liquid valve
z Wait for a “click” sound
Slowly open liquid valve
Clogged fuel filter Repair/replace as required
z See Maintenance Section, LP Fuel
Filter replacement
Plugged fuel line Remove obstruction from the fuel line
z Close liquid fuel valve
z Using caution, disconnect the fuel
line (some propane may escape)
z Clear obstruction with compressed
air
z Re-connect fuel line
z Slowly open liquid fuel valve
z Leak test
Faulty vapor connection between Check connection
the pressure regulator/converter z Verify no holes in hose
and the mixer
z Clamps must be tight
z Look for kinked, pinched and/or
collapsed hose
Pressure regulator/converter Test pressure regulator/converter operation
malfunction z See Engine Service Manual
Fuel container almost empty LPG Vapor from liquid outlet
z Fill fuel container
z Do not exceed 80% of liquid
capacity
Air filter clogged Check air filter
z Clean/replace as required
Incorrect air/fuel or ignition control See Advanced Diagnostics
Engine Mechanical See Engine Service Manual

73
Operation Section

Problem Probable Cause Corrective Action

Will Not Run Fuel container almost empty LPG Vapor from liquid outlet
Continuously z Fill fuel container
z Do not exceed 80% of liquid
capacity
Excess flow valve closed Reset excess flow valve
z Close liquid valve
z Wait for a “click” sound
Slowly open liquid valve
Clogged fuel filter Repair/replace as required
z See Maintenance Section, LP Fuel
Filter replacement

Plugged fuel line Remove obstruction from the fuel line

z Close liquid fuel valve
z Using caution, disconnect the fuel
line (some propane may escape)
z Clear obstruction with compressed
air
z Re-connect fuel line
z Slowly open liquid fuel valve & Leak
test
Pressure regulator freezes Check level in cooling system
z Must be full, check coolant strength
z -35F minimum
Check coolant hoses
z Watch for kinks and/or pinched
hoses
z Verify one pressure hose and one
return hose
Fuel Lock-off malfunction Repair/replace Fuel Lock-off
z See Engine Service Manual
Incorrect idle speed or ignition See Advanced Diagnostics
problem
Engine Mechanical See Engine Service Manual
Will Not Fuel container almost empty LPG Vapor from liquid outlet
Accelerate/Hesitat z Fill fuel container
ion During z Do not exceed 80% of liquid
Acceleration capacity
Excess flow valve closed Reset excess flow valve
z Close liquid valve
z Wait for a “click” sound
z Slowly open liquid valve

74
Operation Section

Problem Probable Cause Corrective Action

Will Not Clogged fuel filter Repair/replace as required
Accelerate/Hesitat z See Maintenance Section, LP Fuel
ion During Filter replacement
Acceleration Faulty vapor connection between Check connection
the pressure regulator/converter z Verify no holes in hose
and the mixer
z Clamps must be tight
z Look for kinked, pinched and/or
collapsed hose
Throttle butterfly valve not See Advanced Diagnostics
opening or sticking
Foot Pedal signal incorrect or
intermittent
Incorrect air/fuel or ignition control
Engine Mechanical See Engine Service Manual
Engine Stalls Fuel container almost empty LPG Vapor from liquid outlet
z Fill fuel container
z Do not exceed 80% of liquid
capacity
Excess flow valve closed Reset excess flow valve
z Close liquid valve
z Wait for a “click” sound
Slowly open liquid valve
Clogged fuel filter Repair/replace as required
z See Maintenance
Section, LP Fuel Filter replacement
Plugged fuel line Remove obstruction from the fuel line
z Close liquid fuel valve
z Using caution, disconnect the fuel
line (some propane may escape)
z Clear obstruction with compressed
air
z Re-connect fuel line
z Slowly open liquid fuel valve & Leak
test

75
Operation Section

Problem Probable Cause Corrective Action

Engine Stalls Fuel Lock-off malfunction Repair/replace Fuel Lock-off
z See Engine Service Manual
Faulty vapor connection between Check connection
the pressure regulator/converter z Verify no holes in hose
and the mixer
z Clamps must be tight
z Look for kinked, pinched and/or
collapsed hose
Pressure regulator freezes Check level in cooling system
z Must be full, check coolant strength
z -35F minimum
Check coolant hoses
z Watch for kinks and/or pinched
hoses
z Verify one pressure hose and one
return hose
Pressure regulator malfunction Test pressure regulator operation
z See Engine Service Manual
Vacuum leak Check for vacuum leaks
z Between mixer and throttle body
z Between throttle body and intake
manifold
z Between intake manifold and
cylinder head
Air/Fuel Mixer malfunction Check mixer
z See Engine Service Manual
Engine Mechanical See Engine Manufacturers Service Manual

Rough Idle Faulty vapor connection between Check connection

the pressure regulator/converter z Verify no holes in hose
and the mixer
z Clamps must be tight
z Look for kinked, pinched and/or
collapsed hose
Pressure regulator malfunction Test pressure regulator operation
z See Engine Service Manual

Vacuum leak Check for vacuum leaks

z Between mixer and throttle body
z Between throttle body and intake
manifold
z Between intake manifold and
cylinder head
Air/Fuel Mixer malfunction Check mixer
z See Engine Service Manual

76
Operation Section

Problem Probable Cause Corrective Action

Rough Idle Incorrect Idle speed control See Advanced Diagnostics & See Engine
Incorrect timing or spark control Service Manual
Engine Mechanical See Engine Service Manual
High Idle Speed Incorrect Idle speed control See Advanced Diagnostics & See Engine
Throttle sticking Service Manual
Foot pedal sticking or incorrect Check pedal return spring travel for binding
pedal signal z See Advanced Diagnostics
Poor High Speed Clogged fuel filter Repair/replace as required
Performance z See Maintenance section, Fuel
Filter replacement
Plugged fuel line Remove obstruction from the fuel line
z Close liquid fuel valve
z Using caution, disconnect the fuel
line (some propane may escape)
z Clear obstruction with compressed
air
z Re-connect fuel line
z Slowly open liquid fuel valve & Leak
test
Air filter clogged Check air filter
z Clean/replace as required
Faulty vapor connection between Check connection
the pressure regulator/converter z Verify no holes in hose
and the mixer
z Clamps must be tight
z Look for kinked, pinched and/or
collapsed hose
Pressure regulator malfunction Test pressure regulator operation
z See Engine Service Manual
Air/Fuel Mixer malfunction Check mixer
z See Engine Service Manual
Restricted exhaust system Check exhaust system
z Measure exhaust back pressure
Incorrect ignition control See Advanced Diagnostics & See Engine
Incorrect air/fuel control Service Manual
Incorrect throttle position

77
Operation Section

Problem Probable Cause Corrective Action

Excessive Fuel Air/Fuel Mixer malfunction Check mixer
Consumption/LPG z See Engine Service Manual
Exhaust Smell Air filter clogged Check air filter
z Clean/replace as required
Vacuum leak Check system vacuum hoses from regulator
to FTV and mixer
z Repair/replace as necessary
Pressure regulator Test pressure regulator operation
malfunction/fuel pressure too high z See Engine Service Manual
Faulty FTV Check FTV for housing cracks or
(G643E only) obstructions
z See Advanced Diagnostics FTV
operation
z Repair and/or replace as necessary
Weak ignition and/or spark control See Advanced Diagnostics
Incorrect air/fuel control See Advanced Diagnostics
Exhaust system leaks Repair exhaust system
Oxygen sensor failure Replace as necessary
z See Advanced Diagnostics

78
Operation Section

Mixer Idle Screw / Power Valve Adjust

(G643 Engine Only)

• Forklift have Unstable Idle RPM, You can adjust

idle screw. Idle Screw turn to rich side (turn in
screw)

• Forklift have Poor High Speed Performance, you

can adjust power valve, power valve turn to rich
side. Power valve marked “R” and “L”. “R” is rich
side and “L” is lean side.
R
L

79
Operation Section

Advanced Diagnostics Reading Diagnostic Fault Codes

(G643 Engine Only) All MI-04 fault codes are two digit codes. When the
fault codes are retrieved (displayed) the MIL will
flash for each digit with a short pause (0.5 seconds)
Advanced Diagnostics between digits and a long pause (1.2 seconds)
The MI-04 systems are equipped with built-in fault between fault codes. A code 12 is displayed at the
beginning of the code list.
diagnostics. Detected system faults can be
displayed by the Malfunction Indicator Lamp (MIL)
as Diagnostic Fault Codes (DFC) or flash codes, EXAMPLE: A code 26 has been detected
and viewed in detail with the use of service tool (ETCSticking) and the engine has shutdown and the
software. When the ignition key is turned ON the MIL has remained ON. When the codes are
MIL will perform a self-test, illuminate once and then displayed the MIL will flash one time (1), pause, then
go OFF. If a detected fault condition exists, the fault flash two times (2). This identifies a twelve (12),
or faults will be stored in the memory of the small which is the beginning of the fault list. It will then
engine control module (SECM). Once a fault occurs pause for 1.2 seconds (long pause) and flash two
the MIL will illuminate and remain ON. This signals times (2), pause, then flash six times (6). This
the operator that a fault has been detected by the identifies a twenty-six (26), which is the ETCSticking
SECM. fault. If any additional faults were stored the SECM
would again have a long pause, then display the
next fault by flashing each digit. Since no other
faults were stored there will be a long pause then
one flash (1), pause, then two flashes (2). This
identifies a twelve meaning the fault list will begin
again.

(1) Malfunction Indicator Lamp(MIL) for Engine control system

80
Operation Section

Displaying Fault Codes (DFC) From

SECM Memory
To enter code display mode you must turn OFF the
ignition key. Now turn ON the key but Do not start
the engine. As soon as you turn the key to the ON
position you must cycle the foot pedal by depressing
it to the floor and then fully releasing the pedal
(pedal maneuver). You must fully cycle the foot
pedal three (3) times within five (5) seconds to
enable the display codes feature of the SECM.
Simply turn the key OFF to exit display mode. The
code list will continue to repeat until the key is
turned OFF. An automatic code display feature is
activated if a foot pedal fault condition exists. This
feature enables the service technician to view the
fault codes by turning the key to the ON position, if a
foot pedal malfunction is preventing the retrieval of
the stored fault codes from the SECM.

Malfunction Indicator Light (MIL)

= CODE 12
ON OFF ON ON OFF

81
Operation Section

Table a. MI-04 Diagnostic Fault Codes (Flash Codes)

DFC Probable Fault Action Corrective Action, First Check

12 NONE NONE None, used as a beginning and end
of the fault list identification
Signifies the end of one pass
through the fault list
14 ECTSensorInputLow Stored Fault Code Check ECT sensor connector and
Coolant sensor failure or shorted (MIL Only) wiring for a short to GND
to GND
15 ECTSensorInputHigh Stored Fault Code Check if ECT sensor connector is
Coolant sensor disconnected or (MIL Only) disconnected or for an open ECT
open circuit circuit

16 ECTRangeHigh Delayed Engine Check coolant system for radiator

Engine Overheating Shutdown blockage, proper coolant level and
for leaks in the system. Possible
ECT short to GND, check ECT
signal wiring

Check regulator for coolant leaks

22 ThrottleSensorInputLo Disable Throttle Check throttle connector connection
TPS1 signal disconnected or and TPS1 sensor for an open circuit
open circuit
(Expected faults when ETC
connector is unplugged
CODES: 22 & 24)

23 ThrottleSensorInputHi Disable Throttle Check throttle connector and TPS1

TPS1 sensor failure or shorted sensor wiring for a shorted circuit
circuit

24 ThrottleSensorRangeLo Stored Fault Code Check the throttle connector and

pins for corrosion.
TPS1 potentiometer malfunction. (MIL Only)
Improper TPS reading may be
due to dirt or oxidation on the
sensor traces.
25 ThrottleSensorRangeHi Stored Fault Code Check the throttle connector and
TPS1 potentiometer malfunction. (MIL Only) pins for corrosion.
Improper TPS reading may be
due to dirt or oxidation on the
sensor traces.

82
Operation Section

Table a. MI-04 Diagnostic Fault Codes (Flash Codes)

DFC Probable Fault Action Corrective Action, First Check

26 ETCSticking Engine Shutdown Check for debris or obstructions
Throttle plate sticking inside the inside the throttle body
throttle body or the ETC driver Check throttle-plate shaft for
signal is open bearing wear

z Check the ETC driver wiring for

an open circuit
27 PredictedTPSDifference Engine Shutdown Check for manifold leaks between
Measured TPS1 is different than the throttle and the engine
SECM Calculated throttle position Note: Fault Code 27 is predicted
TPS. This fault means that the
throttle and our calculated
prediction for throttle Do not agree.
This code often comes up as
suspected during transient
manuevers. It is not system trouble.
If the fault really sets, then the
engine will shut down.
28 ETCSpringTestFailed Power Limit Perform throttle spring test by
Upon initial key-up the internal cycling the ignition key and
re-check for fault
throttle return spring has become
weak
29 ETCDriverFault Disable Throttle Check ETC driver wiring for a
Throttle driver over-current or shorted circuit
driver signals shorted ETC+ PIN1 to SECM PIN 22
ETC- PIN 4 to SECM PIN 24

Perform Throttle test and with the

Service Tool and re-check for fault

Check the ETC internal motor drive

by disconnecting the throttle
connector and measuring the motor
drive resistance at the throttle

TPS PIN 1 (+DRIVER) to PIN 4

(-DRIVER) ~3.0Ω +/-30%
33 MapSensorInputLow Disable Throttle Check TMAP connector and MAP
MAP signal disconnected, open signal wiring for an open circuit
circuit or sensor malfunction
(Expected faults when TMAP
connector is unplugged
CODES: 33 & 38)

83
Operation Section

Table a. MI-04 Diagnostic Fault Codes (Flash Codes)

DFC Probable Fault Action Corrective Action, First Check

34 MapSensorInputHigh Disable Throttle Check TMAP connector and MAP
TMAP sensor failure or shorted signal wiring for a shorted circuit
circuit

37 IATSensorInputLow Stored Fault Code Check TMAP connector and IAT

TMAP sensor failure or shorted (MIL Only) signal wiring for a shorted circuit
circuit

38 IATSensorInputHigh Stored Fault Code Check TMAP connector and IAT

IAT signal disconnected, open (MIL Only) signal wiring for an open circuit
circuit or sensor malfunction TMAP PIN 2 to SECM PIN 4
(SIGNAL)
TMAP PIN 1 to SECM PIN 1 (GND)
TMAP PIN 3 to SECM PIN 18
(XDCR +5VDC)

To check the IAT sensor of the

TMAP disconnect the TMAP
connector and measure the IAT
resistance
*See the IAT table in Chapter 6.0

42 EST1Low Stored Fault Code Check coil driver wiring and

Coil driver signal low or (MIL Only) connector for shorts
under-current SECM PIN 7(EST1) to COIL PIN A

Verify GND on COIL PIN B

Verify GND on COIL PIN C
Verify GND on COIL PIN D
Verify +12vdc on COIL PIN E

To check the Smart Coil internal

circuit disconnect the coil connector
and measure the resistance from
pin to pin

*See Smart Coil resistance check in

Chapter 6.0

43 EST1High Stored Fault Code Check coil driver wiring for an open
Coil driver signal high or (MIL Only) circuit or disconnected connector
over-current

84
Operation Section

Table a. MI-04 Diagnostic Fault Codes (Flash Codes)

DFC Probable Fault Action Corrective Action, First Check

53 BatterySensorInputLow Stored Fault Code Check battery voltage
Battery voltage measured below (MIL Only) Perform maintenance check on
+8.0 VDC electrical connections to the battery
and chassis ground

z Check battery voltage during

starting and with the engine
running to verify charging
system and alternator function

z Measure battery power at the

SECM with a multimeter

54 BatterySensorInputHigh Stored Fault Code Check battery and charging system

Battery voltage measured above (MIL Only) voltage
+15.9 VDC Check battery voltage during
starting and with the engine running
Check voltage regulator, alternator
and charging system
Check battery and wiring for
overheating and damage
Measure battery power at the
SECM with a multimeter

55 XDRPSensorInputLow Engine Shutdown Measure transducer power at the

+5VDC Transducer power TMAP connector with a multimeter
supplied by the SECM to the
sensors is below +4.60VDC Verify transducer power at the
(Expected faults when SECM with a multimeter
Transducer power is lost
CODES: 22, 24, 33, 62, 64, 66, Verify transducer power at ETC with
68 & 69) a multimeter

Verify transducer power to the foot

pedal with a multimeter

85
Operation Section

Table a. MI-04 Diagnostic Fault Codes (Flash Codes)

DFC Probable Fault Action Corrective Action, First Check

56 XDRPSensorInputHigh Engine Shutdown Measure transducer power at the
+5VDC Transducer power TMAP connector with a multimeter
supplied by the SECM to the
sensors is above +5.20VDC Verify transducer power at the
SECM with a multimeter

Verify transducer power at ETC with

a multimeter

Verify transducer power to the foot

pedal with a multimeter

57 Engine OverSpeed Engine Shutdown Usually associated with additional

Engine RPM increased beyond ETC faults
maximum RPM set point z Check for ETC Sticking or
other ETC faults
z Verify if the lift truck was
motored down a steep grade

61 Pedal1SensorInputLo MIN Power Limit Check foot pedal connector

APP1 signal disconnected, open
circuit or sensor malfunction
(Expected faults when APP
connector is unplugged
CODES: 61 & 66)

62 Pedal1SensorInputHi MIN Power limit Check foot pedal connector

APP1 sensor failure or shorted
circuit

63 Pedal1SensorRangeLo Stored Fault Code Check foot pedal connector

APP1 potentiometer malfunction. (MIL Only)
Improper APP1 reading may be
due to dirt or oxidation on the
sensor traces.

64 Pedal1SensorRangeHi Stored Fault Code Check foot pedal connector

APP1 potentiometer malfunction. (MIL Only)
Improper APP1 reading may be
due to dirt or oxidation on the
sensor traces

86
Operation Section

Table a. MI-04 Diagnostic Fault Codes (Flash Codes)

DFC Probable Fault Action Corrective Action, First Check

65 Pedal2SensorInputLo MIN power Limit Check foot pedal connector
APP2 sensor failure or shorted
circuit

66 Pedal2SensorInputHi MIN power Limit Check foot pedal connector

APP2 signal disconnected, open
circuit or sensor malfunction
(Expected faults when APP
connector is unplugged
CODES: 61 & 66)

67 Pedal2SensorRangeLo Stored Fault Code Check foot pedal connector

APP2 potentiometer malfunction. (MIL Only)
Improper APP2 reading may be
due to dirt or oxidation on the
sensor traces.

68 Pedal2SensorRangeHi Stored Fault Code Check foot pedal connector

APP2 potentiometer malfunction. (MIL Only)
Improper APP2 reading may be
due to dirt or oxidation on the
sensor traces.

69 Pedal1ToPedal2Difference MIN power Limit Check foot pedal connector

Measured APP2 pedal position
signal is different than APP1
signal

71 AFRTrimValveOutput Stored Fault Code Check FTV for an open wire or FTV
FTV modulation driver signal fault (MIL, Disable Adaptive connector being disconnected
(G643E only) learns)

87
Operation Section

Table a. MI-04 Diagnostic Fault Codes (Flash Codes)

DFC Probable Fault Action Corrective Action, First Check

72 AFRTrimValveLowerDC Stored Fault Code Engine measured Air/Fuel ratio at
FTV duty cycle at lower (lean) (MIL, Disable Adaptive the O2 sensor is excessively lean.
limit learns) If LP fuel in LP tank is not enough,
(G643E only) this fault code can be set. If LP tank
is frozen, this fault code can be set,
too. It is not system trouble.

z Check for intake manifold leaks

z Check balance line (vacuum
hose) connection at the
regulator
z Check N-CA55-500-TR mixer
for heavy end build-up and
operation (see mixer section)
z Check N2001 secondary for
operation or low primary
pressure (see N2001
Regulator section)

73 AFRTrimValveUpperDC Stored Fault Code Engine measured Air/Fuel ratio at

FTV duty cycle at high (rich) limit (MIL, Disable Adaptive the O2 sensor is excessively rich
(Expected fault when FTV learns)
connector is unplugged) Check FTV connector wiring for an
(G643E only) open circuit

z Check N-CA55-500-TR mixer

for heavy end build-up and
operation (see mixer section)
z Check N2001 secondary for
operation (see N2001
Regulator section)

88
Operation Section

Table a. MI-04 Diagnostic Fault Codes (Flash Codes)

DFC Probable Fault Action Corrective Action, First Check

74 O2SensorSwitching Stored Fault Code Note : If LP fuel in LP tank is not
O2 sensor is not switching across (MIL, Disable Adaptive enough, this fault code can be set.
the reference AFR voltage learns) If LP tank is frozen, this fault code
can be set, too. It is not system
(G643E only)
trouble.

Check the FTV for proper operation

z Check FTV Hose Connections

77 OxygenSensorInputHigh Stored Fault Code Check if O2 sensor is shorted to

O2 sensor SECM driver signal is (MIL, Disable Adapts) +5VDC or Battery.
shorted to power
(G643E only) (AFRTrimValveLowerDC fault
should also occur)

89
Operation Section

Advanced Diagnostics Reading Diagnostic Fault Codes

(G643E Engine Only)
All MI-07 fault codes are three-digit codes. When the
MI-07 systems are equipped with built-in fault fault codes are retrieved (displayed) the MIL will
diagnostics. Detected system faults can be flash for each digit with a short pause (0.5 seconds)
displayed by the Malfunction Indicator Lamp (MIL) between digits and a long pause (1.2 seconds)
as Diagnostic Fault Codes (DFC) or flash codes, between fault codes. A code 12 is displayed at the
and viewed in detail with the use of the Service Tool end of the code list.
software. When the ignition key is turned on, the MIL
will illuminate and remain on until the engine is EXAMPLE: A code 461 (ETCSticking) has been
started. Once the engine is started, the MIL lamp will detected and the engine has shut down and the MIL
go out unless one or more fault conditions are has remained ON. When the codes are displayed
present. If a detected fault condition exists, the fault the MIL will flash four times (4), pause, then flash six
or faults will be stored in the memory of the small times (6), pause, then flash one time (1) This
engine control module (SECM). Once an active fault identifies a four sixty one (461), which is the
occurs the MIL will illuminate and remain ON. This ETCSticking fault. If any additional faults were
signals the operator that a fault has been detected stored, the SECM would again have a long pause,
by the SECM. then display the next fault by flashing each digit.
Since no other faults were stored there will be a long
pause then one flash (1), pause, then two flashes
(2). This identifies a twelve, signifying the end of the
fault list. This list will then repeat.

Displaying Fault Codes (DFC) from

SECM Memory

To enter code display mode you must turn OFF the

ignition key. Now turn ON the key but do not start
the engine. As soon as you turn the key to the ON
position you must cycle the foot pedal by depressing
(1) Malfunction Indicator Lamp(MIL) for Engine control system it to the floor and then fully releasing the pedal
(pedal maneuver). You must fully cycle the foot
pedal three (3) times within five (5) seconds to
enable the display codes feature of the SECM.
Simply turn the key OFF to exit display mode. The
code list will continue to repeat until the key is
turned OFF.

90
Operation Section

Table 2. MI-07 Diagnostic Fault Codes (Flash Codes)

CORRECTIVE ACTION
DFC PROBABLE FAULT FAULT ACTION *
FIRST CHECK
NONE
None, used as end of the fault list
12 Signifies the end of one pass NONE
identification
through the fault list
Check ECT sensor connector and
wiring for a short to GND
ECTRangeLow SECM (Signal) Pin B15 To ECT Pin 3
141
Coolant Sensor failure or TurnOnMil SECM (Sensor GND) Pin B1 to ECT
(14)
shorted to GND Pin 1
SECM (System GND) Pin A16, B17

Check if ECT sensor connector is

(1) TurnOnMil
ECTRangeHigh disconnected or for an open ECT circuit
151 (2) DelayedEngine
Coolant sensor disconnected SECM (Signal) Pin B15 to ECT Pin 3
(15) Shutdown
or open circuit SECM (Sensor GND) Pin B1 to
(3) CheckEngineLight
ECT Pin 1
Check coolant system for radiator
blockage, proper coolant level and for
ECTOverTempFault
leaks in the system.
Engine coolant temperature
(1) TurnOnMil Possible ECT short to GND, check
is high. The sensor has
161 (2) DelayedEngine ECT signal wiring
measured an excessive
(16) Shutdown SECM (Signal) Pin B15 to ECT Pin 3
coolant temperature typically
(3) CheckEngineLight SECM (Sensor GND) Pin B1 to
due to the engine
ECT Pin 1
overheating.
SECM (System GND) Pin A16, B17
Check regulator for coolant leaks
ECT_IR_Fault
Check for coolant system problems,
171 Engine coolant temperature None
e.g. defective or stuck thermostat
not changing as expected

FuelSelectConflict Check fuel select switch connection for

Conflict in fuel select signals, a short to GND
181 normally set if both of the TurnOnMil SECM (SIGNAL) Pin A12
fuel select signals are SECM (SIGNAL) Pin A15
shorted to ground SECM (Sensor GND) Pin B1

Check Crankshaft sensor connections

CrankEdgesFault
SECM (SIGNAL) Pin B5 to Crank
No crankshaft signal when
sensor Pin 3
engine is known to be
193 None SECM (Sensor GND) PIN B1 to Crank
rotating, broken crankshaft
sensor Pin 2
sensor leads or defective
Switched 12V to Crank sensor Pin 1
crank sensor
Check for defective Crank sensor

(*) Fault actions shown are default values specified by the OEM.

91
Operation Section

Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d.

CORRECTIVE ACTION
DFC PROBABLE FAULT FAULT ACTION*
FIRST CHECK
CrankSyncFault Check Crankshaft sensor connections
Loss of synchronization on SECM (SIGNAL) Pin B5 to Crank
the crankshaft sensor, sensor Pin 3
194 normally due to noise on the None SECM (Sensor GND) Pin B1 to Crank
signal or an intermittent sensor Pin 2
connection on the crankshaft Switched 12V to Crank sensor Pin 1
sensor Check for defective Crank sensor
Check throttle connector connection
TPS1RangeLow
and TPS1 sensor for an open circuit or
TPS1 sensor voltage out of
short to GND
221 range low, normally set if the
TurnOnMil SECM Pin B23 (signal) to ETC Pin 6
(22) TPS1 signal has shorted to
SECM Pin B1 (sensor GND) to
ground, circuit has opened or
ETC Pin 2
sensor has failed
SECM (system GND) Pin A16, B17
Check throttle connector connection
TPS2RangeLow
and TPS2 sensor for an open circuit or
TPS2 sensor voltage out of
short to GND
range low, normally set if the
222 TurnOnMil SECM Pin B4 (signal) to ETC Pin 5
TPS2 signal has shorted to
SECM Pin B1 (sensor GND) to
ground, circuit has opened or
ETC Pin 2
sensor has failed
SECM (system GND) Pin A16, B17
TPS1RangeHigh
Check throttle connector and TPS1
TPS1 sensor voltage out of
sensor wiring for a shorted circuit
231 range high, normally set if
TurnOnMil SECM Pin B23 (signal) to ETC Pin 6
(23) the TPS1 signal has shorted
SECM Pin B1 (sensor GND) to
to power or the ground for
ETC Pin 2
the sensor has opened
TPS2RangeHigh Check throttle connector and TPS1
TPS2 sensor voltage out of sensor wiring for a shorted circuit
range high, normally set if SECM Pin B4 (signal) to ETC
232 TurnOnMil
the TPS2 signal has shorted Pin 5
to power or the ground for SECM pin B1 (sensor GND) to
the sensor has opened ETC Pin 2
Check the throttle connector and pins
for corrosion.
To check the TPS disconnect the
TPS1AdaptLoMin
throttle connector and measure the
241 Learned closed throttle end
None resistance from:
(24) of TPS1 sensor range lower
TPS Pin 2 (GND) to Pin 6 (TPS1
than expected
SIGNAL) (0.7 Ω ± 30%)
TPS Pin 3 (PWR) to Pin 6 (TPS1
SIGNAL) (1.4 Ω ± 30%)

(*) Fault actions shown are default values specified by the OEM.

92
Operation Section

Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d.

CORRECTIVE ACTION
DFC PROBABLE FAULT FAULT ACTION *
FIRST CHECK
Check the throttle connector and pins
for corrosion.
To check the TPS disconnect the
TPS2AdaptLoMin
throttle connector and measure the
Learned closed throttle end
242 None resistance from:
of TPS2 sensor range lower
TPS Pin 2 (GND) to Pin 5 (TPS2
than expected
SIGNAL) (1.3K Ω ± 30%)
TPS PIN 3 (PWR) to PIN 5 (TPS2
SIGNAL) (0.6K Ω ± 30%)
TPS1AdaptHiMax
251 Learned WOT end of TPS1 N/A
None
(25) sensor range higher than
expected
TPS2AdaptHiMax
Learned WOT end of TPS2 N/A
252 None
sensor range higher than
expected
TPS1AdaptHiMin
Learned WOT end of TPS1 N/A
271 None
sensor range lower than
expected
TPS2AdaptHiMin
Learned WOT end of TPS2 N/A
272 None
sensor range lower than
expected
TPS1AdaptLoMax
Learned closed throttle end N/A
281 None
of TPS1 sensor range higher
than expected
TPS2AdaptLoMax
Learned closed throttle end N/A
282 None
of TPS2 sensor range higher
than expected
TPS_Sensors_Conflict
TPS sensors differ by more
than expected amount
NOTE: The TPS is not a (1) TurnOnMil
291 Perform checks for DFCs 241 & 242
serviceable item and can (2) Engine Shutdown
only be repaired by
replacing the DV-EV
throttle assembly.

(*) Fault actions shown are default values specified by the OEM.

93
Operation Section

Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d.

CORRECTIVE ACTION
DFC PROBABLE FAULT FAULT ACTION *
FIRST CHECK
Check TMAP connector and MAP
signal wiring for an open circuit
TMAP Pin 4 to SECM Pin B18 (signal)
MAPTimeRangeLow TMAP Pin 1 to SECM Pin B1
Manifold Absolute Pressure (sensor GND)
sensor input is low, normally TMAP Pin 3 to SECM Pin B24
331 set if the TMAP pressure (XDRP +5 Vdc)
None
(33) signal wire has been Check the MAP sensor by
disconnected or shorted to disconnecting the TMAP connector and
ground or the circuit has measuring at the sensor
opened to the SECM TMAP Pin 1(GND) to Pin 4 (pressure
signal KPA) (2.4kΩ - 8.2kΩ)
TMAP Pin 3 (power) to Pin 4 (pressure
signal KPA) (3.4kΩ - 8.2kΩ)
Check TMAP connector and MAP
signal wiring for an open circuit
TMAP Pin 4 to SECM Pin B18 (signal)
MAPRangeLow TMAP Pin 1 to SECM Pin B1
Manifold Absolute Pressure (sensor GND)
sensor input is low, normally TMAP Pin 3 to SECM Pin B24
set if the TMAP pressure (1) TurnOnMil (XDRP +5 Vdc)
332
signal wire has been (2) CutThrottle Check the MAP sensor by
disconnected or shorted to disconnecting the TMAP connector and
ground or the circuit has measuring at the sensor:
opened to the SECM TMAP Pin 1(GND) to Pin 4 (pressure
signal KPA) (2.4kΩ - 8.2kΩ)
TMAP Pin 3 (power) to Pin 4 (pressure
signal KPA) (3.4kΩ - 8.2kΩ)
MAPTimeRangeHigh Check TMAP connector and MAP
Manifold Absolute Pressure signal wiring for a shorted circuit
Sensor Input is High, TMAP Pin 4 to SECM Pin B18 (signal)
normally set if the TMAP TMAP Pin 1 to SECM Pin B1
pressure signal wire has (sensor GND)
become shorted to power, TMAP Pin 3 to SECM Pin B24
341 shorted to the IAT signal, the (XDRP +5 Vdc)
None
(34) TMAP has failed or the Check the MAP sensor by
SECM has failed. disconnecting the TMAP connector and
measuring at the sensor
TMAP Pin 1(GND) to Pin 4 (pressure
signal KPA) (2.4kΩ - 8.2kΩ)
TMAP Pin 3 (power) to Pin 4 (pressure
signal KPA) (3.4kΩ - 8.2kΩ)

94
Operation Section

Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d.

CORRECTIVE ACTION
DFC PROBABLE FAULT FAULT ACTION *
FIRST CHECK
MAPRangeHigh Check TMAP connector and MAP
Manifold Absolute Pressure signal wiring for a shorted circuit
Sensor Input is High, TMAP Pin 4 to SECM Pin B18 (signal)
normally set if the TMAP TMAP Pin 1 to SECM Pin B1
pressure signal wire has (sensor GND)
become shorted to power, TMAP Pin 3 to SECM Pin B24
shorted to the IAT signal, the (1) TurnOnMil (XDRP +5 Vdc)
342
TMAP has failed or the (2) CutThrottle Check the MAP sensor by
SECM has failed disconnecting the TMAP connector
and measuring at the sensor:
TMAP Pin 1(GND) to Pin 4 (pressure
signal KPA) (2.4kΩ - 8.2kΩ)
TMAP Pin 3 (power) to Pin 4 (pressure
signal KPA) (3.4kΩ - 8.2kΩ)
MAP_IR_HI Check for vacuum leaks. Check that
351 MAP sensor indicates higher None TMAP sensor is mounted properly.
pressure than expected Possible defective TMAP sensor.
MAP_IR_LO
352 MAP sensor indicates lower None Possible defective TMAP sensor.
pressure than expected
MAP_STICKING Check that TMAP sensor is mounted
353 MAP sensor not changing as None properly. Possible defective TMAP
expected sensor.
Check TMAP connector and IAT signal
wiring for a shorted circuit
IATRangeLow
TMAP Pin 2 to SECM Pin B12 (signal)
Intake Air Temperature
TMAP Pin 1 to SECM Pin B1
Sensor Input is Low normally
371 (sensor GND)
set if the IAT temperature TurnOnMil
(37) To check the IAT sensor of the TMAP
sensor wire has shorted to
disconnect the TMAP connector and
chassis ground or the sensor
measure the IAT resistance
has failed.
Resistance is approx 2400 ohms at
room temperature.
Check TMAP connector and IAT signal
IATRangeHigh wiring for a shorted circuit
Intake Air Temperature TMAP Pin 2 to SECM Pin B12 (signal)
Sensor Input is High TMAP Pin 1 to SECM Pin B1
381 normally set if the IAT (sensor GND)
TurnOnMil
(38) temperature sensor wire has To check the IAT sensor of the TMAP
been disconnected or the disconnect the TMAP connector and
circuit has opened to the measure the IAT resistance
SECM. Resistance is approx 2400 ohms at
room temperature.
IAT_IR_Fault Check connections to TMAP sensor.
391 Intake Air Temperature not None Check that TMAP sensor is properly
changing as expected mounted to manifold.

(*) Fault actions shown are default values specified by the OEM.

95
Operation Section

Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d.

CORRECTIVE ACTION
DFC PROBABLE FAULT FAULT ACTION *
FIRST CHECK
Check coil driver wiring and connector
for open circuit
SECM Pin A9 (EST1) to OEM ignition
EST1_Open system. See application note.
EST1 output open, possibly Verify GND on ignition module Pin A
421 TurnOnMil
open EST1 signal or (of both connectors)
defective spark module Verify +12 Vdc on ignition module Pin
B (of both connectors)
Refer to application manual for specific
engine details.
Check coil driver wiring and connector
for shorts
SECM Pin A9 (EST1) to ignition
EST1_Short
module Pin D (4-pin connector)
EST1 output shorted high or
Verify GND on ignition module Pin A
431 low, EST1 signal shorted to TurnOnMil
(of both connectors)
ground or power or defective
Verify +12 Vdc on ignition module Pin
spark module
B (of both connectors)
Refer to application manual for specific
engine details.
ETC_Sticking Check for debris or obstructions inside
Electronic Throttle Control is the throttle body
sticking. This can occur if the Perform the throttle test using the
throttle plate (butterfly valve) Service Tool and re-check for fault
inside the throttle bore is Check throttle-plate shaft for bearing
sticking. The plate sticking wear
can be due to some type of Check the ETC driver wiring for an
(1) TurnOnMil
461 obstruction, a loose throttle open circuit
(26) (2) EngineShutdown
plate, or worn components SECM Pin A17 to ETC + Pin 1
(3) CutThrottle
shaft bearings. SECM Pin A18 to ETC - Pin 4
NOTE: The throttle Check the ETC internal motor drive by
assembly is not a disconnecting the throttle connector
serviceable item and can and measuring the motor drive
only be repaired by resistance at the throttle
replacing the DV-EV TPS Pin 1 (+DRIVER) to
throttle assembly. Pin 4 (-DRIVER) ~3.0-4.0Ω
Check the ETC driver wiring for an
ETC_Open_Fault open circuit
Electronic Throttle Control SECM Pin A17 to ETC + Pin 1
Driver has failed, normally SECM Pin A18 to ETC - Pin 4
set if either of the ETC driver Check the ETC internal motor drive by
471 None
signals have opened or disconnecting the throttle connector
become disconnected, and measuring the motor drive
electronic throttle or SECM is resistance at the throttle
defective. TPS Pin 1 (+DRIVER) to
Pin 4 (-DRIVER) ~3.0-4.0Ω

(*) Fault actions shown are default values specified by the OEM.

96
Operation Section

Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d.

CORRECTIVE ACTION
DFC PROBABLE FAULT FAULT ACTION *
FIRST CHECK
ETCSpringTest
Electronic Throttle Control
Spring Return Test has
failed. The SECM will
perform a safety test of the
throttle return spring
following engine shutdown. If
(1) TurnOnMil
481 this spring has become weak Perform throttle spring test by cycling
(28) (2) EngineShutdown
the throttle will fail the test the ignition key and re-check for fault
and set the fault.
NOTE: The throttle
assembly is not a
serviceable item and can
only be repaired by
replacing the DV-EV
throttle assembly.
Check ETC driver wiring for a shorted
circuit
HbridgeFault_ETC
SECM Pin A17 to ETC + Pin 1
Electronic Throttle Control
SECM Pin A18 to ETC - Pin 4
Driver has failed.
Perform the throttle test using the
Indeterminate fault on
491 Service Tool and re-check for fault
Hbridge driver for electronic TurnOnMil
(29) Check the ETC internal motor drive by
throttle control. Possibly
disconnecting the throttle connector
either ETC+ or ETC- driver
and measuring the motor drive
signals have been shorted to
resistance at the throttle
ground
TPS Pin 1 (+DRIVER) to
Pin 4 (-DRIVER) ~3.0-4.0Ω
(1) TurnOnMil Check engine oil level
521 LowOilPressureFault (2) DelayedEngine Check electrical connection to the oil
(52) Low engine oil pressure Shutdown pressure switch
(3) CheckEngine Light SECM Pin B9 to Oil Pressure Switch
Check battery voltage
Perform maintenance check on
electrical connections to the battery
and chassis ground
Check battery voltage during starting
and with the engine running to verify
531 SysVoltRangeLow charging system and alternator
TurnOnMil
(53) System voltage too low function
Measure battery power at SECM with a
multimeter (with key on)
SECM Pin A23 (DRVP) to
SECM Pin A16 (DRVG)
SECM Pin A23 (DRVP) to
SECM Pin B17 (DRVG)

(*) Fault actions shown are default values specified by the OEM.

97
Operation Section

Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d.

CORRECTIVE ACTION
DFC PROBABLE FAULT FAULT ACTION *
FIRST CHECK
Check battery and charging system
voltage
Check battery voltage during starting
and with the engine running
Check voltage regulator, alternator,
and charging system
541 SysVoltRangeHigh Check battery and wiring for
TurnOnMil
(54) System voltage too high overheating and damage
Measure battery power at SECM with a
multimeter (with key on)
SECM Pin A23 (DRVP) to
SECM Pin A16 (DRVG)
SECM Pin A23 (DRVP) to
SECM Pin B17 (DRVG)
Measure transducer power at the
TMAP connector with a multimeter
TMAP Pin 3 XDRP +5 Vdc to TMAP
Pin 1 XDRG GND
Verify transducer power at the SECM
with a multimeter
SensVoltRangeLow (1) TurnOnMil
551 SECM Pin B24 +5 Vdc to SECM Pin
Sensor reference voltage (2) EngineShutdown
(55) B1 XDRG GND
XDRP too low
Verify transducer power at ETC with a
multimeter
ETC Pin 3 XDRP PWR to ETC Pin 2
XDRG GND
Verify transducer power to the foot
pedal with a multimeter.
Measure transducer power at the
TMAP connector with a multimeter
TMAP Pin 3 XDRP +5 Vdc to TMAP
Pin 1 XDRG GND
Verify transducer power at the SECM
with a multimeter
SensVoltRangeHigh (1) TurnOnMil
561 SECM Pin B24 +5 Vdc to SECM Pin
Sensor reference voltage (2) EngineShutdown
(56) B1 XDRG GND
XDRP too high
Verify transducer power at ETC with a
multimeter
ETC Pin 3 XDRP PWR to ETC Pin 2
XDRG GND
Verify transducer power to the foot
pedal with a multimeter.
Usually associated with additional ETC
HardOverspeed faults
(1) TurnOnMil
571 Engine speed has exceeded Check for ETC Sticking or other ETC
(2) HardRevLimit
(57) the third level (3 of 3) of faults
overspeed protection Verify if the lift truck was motored down
a steep grade
(*) Fault actions shown are default values specified by the OEM.

98
Operation Section

Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d.

CORRECTIVE ACTION
DFC PROBABLE FAULT FAULT ACTION *
FIRST CHECK
Usually associated with additional ETC
MediumOverspeed faults
(1) TurnOnMil
Engine speed has exceeded Check for ETC Sticking or other ETC
572 (2) MediumRevLimit
the second level (2 of 3) of faults
overspeed protection Verify if the lift truck was motored down
a steep grade
Usually associated with additional ETC
SoftOverspeed faults
(1) TurnOnMil
Engine speed has exceeded Check for ETC Sticking or other ETC
573 (2) SoftRevLimit
the first level (1 of 3) of faults
overspeed protection Verify if the lift truck was motored down
a steep grade
APP1RangeLow
APP1 sensor voltage out of
(1) TurnOnMil
611 range low, normally set if the Check foot pedal connector
(2) CheckEngine Light
(61) APP1 signal has shorted to Check APP1 signal at SECM PIN B7
ground, circuit has opened or
sensor has failed
APP2RangeLow
APP2 sensor voltage out of
612 range low, normally set if the Check foot pedal connector
TurnOnMil
(65) APP2 signal has shorted to Check APP2 signal at SECM PIN B16
ground, circuit has opened or
sensor has failed
APP1RangeHigh
APP1 sensor voltage out of
621 range high, normally set if 1) TurnOnMil Check foot pedal connector
(62) the APP1 signal has shorted (2) CheckEngine Light Check APP1 signal at SECM PIN B7
to power or the ground for
the sensor has opened
APP2RangeHigh
APP2 sensor voltage out of
622 range high, normally set if Check foot pedal connector
TurnOnMil
(66) the APP2 signal has shorted Check APP2 signal at SECM PIN B16
to power or the ground for
the sensor has opened
APP1AdaptLoMin Check APP connector and pins for
631 Learned idle end of APP1 corrosion
None
(63) sensor range lower than Cycle the pedal several times and
expected check APP1 signal at SECM Pin B7
APP2AdaptLoMin Check APP connector and pins for
632 Learned idle end of APP2 corrosion
None
(67) sensor range lower than Cycle the pedal several times and
expected check APP2 signal at SECM Pin B16
APP1AdaptHiMax
641 Learned full pedal end of
None N/A
(64) APP1 sensor range higher
than expected
APP2AdaptHiMax
642 Learned full pedal end of
None N/A
(68) APP2 sensor range higher
than expected
(*) Fault actions shown are default values specified by the OEM.

99
Operation Section

Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d.

CORRECTIVE ACTION
DFC PROBABLE FAULT FAULT ACTION *
FIRST CHECK
APP1AdaptHiMin
Learned full pedal end of
651 None N/A
APP1 sensor range lower
than expected
APP2AdaptHiMin
Learned full pedal end of
652 None N/A
APP2 sensor range lower
than expected
APP1AdaptLoMax
Learned idle end of APP1
661 None N/A
sensor range higher than
expected
APP2AdaptLoMax
Learned idle end of APP2
662 None N/A
sensor range higher than
expected
Check APP connector and pins for
APP_Sensors_Conflict
corrosion
APP position sensors do no
691 1) TurnOnMil Cycle the pedal several times and
not track well, intermittent
(69) (2) Level1PowerLimit check APP1 signal at SECM Pin B7
connections to APP or
Cycle the pedal several times and
defective pedal assembly
check APP2 signal at SECM Pin B16
Check FTV1 for an open wire or FTV
connector being disconnected
LSDFault_Dither1
FTV1 Pin 1 (signal) to SECM Pin A1
Dither Valve 1 Fault, signal
711 FTV1 Pin 2 (power) to SECM (DRVP)
(71) has opened or shorted to TurnOnMil
Pin A23
ground or power or defective
Check FTV1 for an open coil by
dither 1 valve
disconnecting the FTV connector and
measuring the resistance (~26Ω ± 2Ω )
Check FTV1 for an open wire or FTV
connector being disconnected or signal
LSDFault_Dither2 shorted to GND
Dither Valve 2 Fault, signal FTV2 Pin 1 (signal) to SECM Pin A2
712 has opened or shorted to TurnOnMil FTV2 Pin 2 (power) to SECM (DRVP)
ground or power or defective Pin A23
dither 2 valve Check FTV1 for an open coil by
disconnecting the FTV connector and
measuring the resistance (~26Ω ± 2Ω )
LSDFault_CheckEngine
Check Engine Lamp Fault,
Check ‘Check Engine Lamp’ for an
714 signal has opened or shorted None
open wire or shorted to GND
to ground or power or
defective check engine lamp
(*) Fault actions shown are default values specified by the OEM.

100
Operation Section

Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d.

CORRECTIVE ACTION
DFC PROBABLE FAULT FAULT ACTION *
FIRST CHECK
LSDFault_CrankDisable
Crank Disable Fault, signal
715 has opened or shorted to None N/A
ground or power or defective
crank disable relay
Check fuel lock off valve for an open
wire or connector being disconnected
LSDFault_LockOff or signal shorted to GND
Fuel lock off Valve Fault, Lockoff Pin B (signal) to SECM Pin A11
717 signal has opened or shorted TurnOnMil Lockoff Pin A (power) to SECM (DRVP)
to ground or power or Pin A23
defective Fuel lock off valve Check CSV for an open coil by
disconnecting the CSV connector and
measuring the resistance (~26Ω ± 3Ω)
LSDFault_MIL
Malfunction Indicator Lamp
Check MIL lamp for an open wire or
718 Fault, signal has opened or None
short to GND.
shorted to ground or power
or defective MIL lamp
GasFuelAdaptRangeLo Check for vacuum leaks.
721 In LPG mode, system had to Check fuel trim valves, e.g. leaking
TurnOnMil
(72) adapt rich more than valve or hose
expected Check for missing orifice(s).
GasFuelAdaptRangeHi Check fuel trim valves, e.g. plugged
731 In LPG mode, system had to valve or hose.
TurnOnMil
(73) adapt lean more than Check for plugged orifice(s).
expected
Check that Pre-catalyst O2 sensor
connections are OK.
O2 (signal) Pin 3 to SECM Pin B13
O2 Pin 2 (HEATER GND) to SECM
GasO2NotActive (DRVG GNG) Pins A16, B17
Pre-catalyst O2 sensor O2 Pin 1 (HEATER PWR) to SECM
741 (1) TurnOnMil
inactive on LPG, open O2 (DRVP + 12V) Pin A23
(74) (2) DisableGas O2Ctrl
sensor signal or heater Verify O2 sensor heater circuit is
leads, defective O2 sensor operating by measuring heater
resistance
(2.1Ω ± 0.4Ω)
O2 Pin 2 (HEATER GND) to Pin 1
(HEATER PWR)

(*) Fault actions shown are default values specified by the OEM.

101
Operation Section

Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d.

CORRECTIVE ACTION
DFC PROBABLE FAULT FAULT ACTION *
FIRST CHECK
Check that Post-catalyst O2 sensor
connections are OK.
O2 (signal) Pin 3 to SECM Pin B19
O2 Pin 2 (HEATER GND) to SECM
(DRVG GNG) Pins A16, B17
O2 Pin 1 (HEATER PWR) to Post O2
Heater Relay. Relay pin 87. This relay
turns on only after engine has been
running for some time and SECM has
GasPostO2NotActive
calculated that water condensation in
Post-catalyst O2 sensor (1) TurnOnMil
exhaust has been removed by exhaust
742 inactive on LPG, open O2 (2) DisableGas
heat. Post O2 Heater Relay has SECM
sensor signal or heater Post O2Ctrl
(DRVP + 12V) applied to the relay coil
leads, defective O2 sensor.
power. The relay coil ground is
controlled by SECM Pin A20 to activate
the relay to flow current through the
post O2 heater.
Verify O2 sensor heater circuit is
operating by measuring heater
resistance (2.1Ω ± 0.4Ω)
O2 Pin 2 (HEATER GND) to Pin 1
(HEATER PWR)
743 Reserved
GasO2FailedLean Check for vacuum leaks.
Pre-catalyst O2 sensor (1) TurnOnMil Check fuel trim valves, e.g. leaking
751
indicates extended lean (2) DisableGas O2Ctrl valve or hose.
operation on LPG Check for missing orifice(s).
Correct other faults that may contribute
to 752 (e.g. faults pertaining to fuel trim
valves, Pre-Cat O2, Post Cat O2
GasPostO2FailedLean
(1) TurnOnMil sensor)
Pre-catalyst O2 sensor
752 (2) DisableGas Check for vacuum leaks
indicates extended lean
Post O2Ctrl Check for leaks in exhaust, catalytic
operation on LPG
converter, HEGO sensors; repair leaks.
Check all sensor connections (see fault
742 corrective actions).
GasO2FailedRich Check fuel trim valves, e.g. plugged
771 Pre-catalyst O2 sensor (1) TurnOnMil valve or hose.
(77) indicates extended rich (2) DisableGas O2Ctrl Check for plugged orifice(s).
operation on LPG

(*) Fault actions shown are default values specified by the OEM.

102
Operation Section

Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d.

CORRECTIVE ACTION
DFC PROBABLE FAULT FAULT ACTION *
FIRST CHECK
Correct other faults that may contribute
to 772 (e.g. faults pertaining to FTVs,
GasPostO2FailedRich
(1) TurnOnMil Pre-Cat O2, Post Cat O2 sensor)
Pre-catalyst O2 sensor
772 (2) DisableGas Look for leaks in exhaust, catalytic
indicates extended rich
PostO2Ctrl converter, HEGO sensors; repair leaks.
operation on LPG
Check all sensor connections (see fault
742 corrective actions).
843 Reserved
Check if O2 sensor installed before the
O2RangeLow
catalyst is shorted to GND or sensor
Pre-catalyst O2 sensor
(1) TurnOnMil GND.
911 voltage out of range low,
(2) DisableGas O2Ctrl O2 (signal) Pin 3 to SECM Pin B13
sensor signal shorted to
SECM (DRVG GND) Pins A16, B17
ground
SECM (XDRG sensor GND) Pin B1
Check if O2 installed after the catalyst
O2_PostCatRangeLow sensor is shorted to GND or sensor
Post-catalyst O2 sensor (1) TurnOnMil GND.
912 voltage out of range low, (2) Disable LPG O2 (signal) Pin 3 to SECM Pin B19
sensor signal shorted to Post-catalyst O2Ctrl Possible sources: SECM (DRVG GND)
ground Pins A16, B17 and SECM (XDRG
sensor GND) Pin B1
O2RangeHigh Check if O2 sensor installed before
Pre-catalyst O2 sensor catalyst is shorted to +5Vdc or battery.
(1) TurnOnMil
921 voltage out of range high, O2 (signal) Pin 3 to SECM Pin B13
(2) DisableGas O2Ctrl
sensor signal shorted to SECM (XDRP + 5V) Pin B24
power SECM (DRVP + 12V) Pin A23
Check if O2 sensor installed after
O2_PostCatRangeHigh
catalyst is shorted to +5Vdc or battery.
Post-catalyst O2 sensor (1) TurnOnMil
O2 (signal) Pin 3 to SECM Pin B19
922 voltage out of range low, (2) Disable LPG
Possible voltage sources: SECM
sensor signal shorted to Post-catalyst O2Ctrl
(XDRP + 5V) Pin B24 and SECM
ground
(DRVP + 12V) Pin A23

(*) Fault actions shown are default values specified by the OEM.

103
Operation Section

Table 2. MI-07 Diagnostic Fault Codes (Flash Codes) cont’d.

CORRECTIVE ACTION
DFC PROBABLE FAULT FAULT ACTION *
FIRST CHECK
FuelTempRangeLow Check fuel temp sensor connector and
Fuel Temperature Sensor wiring for a short to GND
Input is Low normally set if SECM (signal) Pin B14 to FTS Pin 1
931 the fuel temperature sensor TurnOnMil SECM (sensor GND) Pin B1 to
wire has shorted to chassis FTS Pin 2
ground or the sensor has SECM (system GND) Pin A16, B17
failed.
FuelTempRangeHigh Check if fuel temp sensor connector is
Fuel Temperature Sensor disconnected or for an open FTS circuit
Input is High normally set if SECM (signal) Pin B14 to FTS Pin 1
932 the fuel temperature sensor TurnOnMil SECM (sensor GND) Pin B1 to
wire has been disconnected FTS Pin 2
or the circuit has opened to
the SECM.
TransOilTemp (1) TurnOnMil
Refer to drivetrain manufacturer’s
933 Excessive transmission oil (2) Delayed
transmission service procedures.
temperature EngineShutdown

ServiceFault1 Perform service procedure related to

991 Service Interval 1 has been None Service Interval 1
reached (determined by OEM)

ServiceFault2 Perform service procedure related to

992 Service Interval 2 has been None Service Interval 2
reached (determined by OEM)
ServiceFault3 Perform service procedure related to
993 Service Interval 3 has been None Service Interval 3
reached (determined by OEM)
ServiceFault4
Service Interval 4 has been Replace Pre-catalyst HEGO sensor
994 TurnOnMil
reached—replace HEGO Replace Post-catlyst HEGO sensor
sensors
ServiceFault5
995 Service Interval 5 has been TurnOnMil Replace engine timing belt
reached—replace timing belt

(*) Fault actions shown are default values specified by the OEM.

104
Operation Section

Lift Truck Operation

Power Shift Transmission / Drive WARNING
Axle A lift truck with the engine running but without
an operator can move slowly (creep) if the
1. Start the engine. See item "Starting the Engine" transmission is left engaged.
This could result in personal injury.
Always place the transmission control levers in
the NEUTRAL (center) position and apply the
parking brake before dismounting from the lift
truck.

6. RELEASE the service foot brake.

7. PUSH DOWN on the accelerator pedal to obtain

the desired travel speed. RELEASE the pedal to
decrease travel speed.

8. Transmission speed changes to second and

Typical Example
third speed range can be made on the go,
without deceleration or braking. When faster
2. PUSH DOWN on the service foot brake pedal to travel speed is needed.
hold the lift truck until ready to move it.

3. RELEASE the parking brake. NOTICE

Come to a complete stop before changing direction
of travel.

WARNING
Sudden reversal of a loaded lift truck traveling
forward can cause the load to fail or the lift truck
to tip over.
Stop the loaded lift truck completely, before
shifting to reverse.
Failure to comply could result in personal injury.

Typical Example
9. To change the lift truck direction of travel,
4. Select the direction of travel by PUSHING the RELEASE the accelerator pedal.
directional lever FORWARD for forward direction
or PULLING the lever BACK for reverse 10. PUSH DOWN on the service foot brake pedal to
direction. bring the lift truck to a complete stop.
5. Rotate the speed range control to first (low) 11. SHIFT the directional lever to the desired
speed range. direction of travel. Rotate the speed selector
lever to first (low) speed range, if it is not already
NOTE: From a stopped position, move the lift truck in this position.
in first (low) range ONLY.
12. RELEASE the service foot brake. PUSH DOWN
on the accelerator pedal to obtain the desired
travel speed.

105
Operation Section

WARNING Inching
Watch the road carefully for any obstacle when
driving the truck. Do not go fast over bumps, pot NOTE: The purpose of the inching pedal is to
holes or other rough grounds, otherwise the provide precise lift truck inching control at
engine might go OFF by a severe impact. very slow travel speed and high engine rpm.
In case of engine going OFF, press the brake This is used for fast hydraulic lift during load
pedal at one time as hard as possible in order to approach, pick up or load positioning.
stop the truck. Pressing the brake pedal several
times has a risk that the brake would not work.

Typical Example

1. To inch (creep) in either direction, slowly push

down on the inching pedal. This will start to
Typical Example apply the service foot brakes and allow the
transmission clutch discs to slip.
13. To stop the lift truck when travelling in either
direction, RELEASE accelerator pedal (1). 2. Vary the position of inching pedal and the
accelerator pedal to control the inching speed
14. PUSH DOWN on service foot brake pedal (2) and distance.
and bring the lift truck to a smooth stop.
3. Pushing down further on the inching pedal will
disengage the transmission completely and
apply the service brakes fully to stop and hold
the lift truck. This will provide full engine power
for fast hydraulic lift.

106
Operation Section

Auto Shift Controller ASC-200/201 (If Equipped)

Product Description Adjustments

The Autoshift controller is an electrical control
system, specially designed for use on forklift trucks
with internal combustion engines.
Its primary purpose is to prevent the operator from
operating the truck outside of the design parameters,
e.g. selecting the reverse gear when travelling in
excess of 5 km/h (3.11 mph) in a forward direction,
and vice versa.

The Autoshift controller is mounted on a convenient

position away from excessive heat sources and
retrofits into the truck's electrical system. An
inductive speed sensor is mounted on the Adjustment Switch
transmission case where it will pick up a pulse from
• Low-High Shift Point (SW1)
a gear tooth pattern. This pulse is used to monitor
the truck in motion and its travel speed. To enable ASC-200/201 allows you to set the 2 speed Auto
the system to change gears smoothly, the shift Gear Shift Point, the maximum travel speed at which
points for offset speed are adjustable. the Auto Shift Controller up-shift or down-shift the
transmission automatically according to the vehicle
An operator no longer has to change gears with his speed. For adjustment of 2 speed Auto Gear Shift
hands, therefore he can be more productive. speed, the SW1 switch is used on the printed circuit
board.
The Autoshift controller prevents strain and abuse to
the transmission by changing gears up and down SW1(Low-High SHIFT)
automatically. It also prevents damage to the half Tow Speed Auto Gear Shift Point
shaft, excessive tire wear and heat to the Vehicle Speed
transmission. Notch
ASC-200 ASC-201
0 2.5km/h(1.55mph)
Features 1 3.0km/h(1.86mph)
2 3.5km/h(2.17mph) 5.57km/h(3.46mph)
Product Adaptable To
3 4.0km/h(2.49mph)
ASC-200 D50/60/70S-5 (2 Speed)
4 4.5km/h(2.80mph)
ASC-201 G50/60/70S-5
5 5.0km/h(3.11mph) 6.17km/h(3.84mph)
6 5.5km/h(3.42mph) 6.78km/h(4.21mph)
1) 2 - speed auto shift control
2) Prevent downshifting at high speed 7 6.0km/h(3.73mph) 7.29km/h(4.53mph)
3) Inhibit selecting direction at high speed outside 8 6.5km/h(4.04mph) 7.89km/h(4.90mph)
of the design parameters. 9 7.0km/h(4.35mph) 8.40km/h(5.22mph)

For example if SW1 is put 5th notch, the 2 speed

auto gear shift speed will be 5.0km/h(3.11mph) in
ASC-200 or 6.17km/h(3.84mph) in ASC-201. The
factory setting value as a default for SW1 of each
model is as follows.

Product Notch Vehicle Speed

ASC-200 5 5.0km/h (3.11mph)
ASC-201 6 6.78km/h (4.21mph)

107
Operation Section

• Direction Inhibit Point (SW2) Diagnostics Features

Auto Shift allows you to set the Direction Inhibit
Speed, the maximum travel speed at which the
transmission can be reversed. For adjustment of
direction inhibit speed, the SW2 switch is used on
the printed circuit board.
Using a philips screwdriver, turn the SW1
adjustment until the white dot is next to the notch
corresponding to the selected vehicle speed. You
may reset lnhibit Speed to one of ten settings
between a minimum of 3.3km/h(2.05mph) and a
maximum of 6.0km/h(3.75mph) travel speed.

SW2(FWD RVS SHIFT)

Direction lnhibit Point ASC-200/201 has internal indicator on the right side
Notch Vehicle Speed of the controller for displaying the selected gear and
the abnormal condition.
0 3.3km/h (2.05mph)
1 3.6km/h (2.24mph)
WARNING
2 3.9km/h (2.42mph)
3 4.2km/h (2.61mph) Do not diagnose or repair Auto Shift Controller
Faults unless trained and authorized to do so.
4 4.5km/h (2.80mph) Improper performance of maintenance
5 4.8km/h (2.98mph) procedures is dangerous and could result in
6 5.1km/h (3.17mph) personal injury or death.
7 5.4km/h (3.36mph)
8 5.7km/h (3.54mph)
Below is a description applicable for many
9 6.0km/h (3.73mph) ASC-200/201 implementations.

For example if SW2 is put 7th notch, the Direction • Display for Operator
lnhibit Speed will be 5.4km/h(3.36mph) which is
factory setting value as a default. Display Description Remark
A Automatic operation
Product Notch Adaptable H High speed At 2nd shift gear
ASC-200 7 5.4km/h(3.36mph) L Low speed At 1st shift gear
PT/M Speed sensor open Flashing
ASC-201 3 4.2km/h(2.61mph)
E/G Speed sensor
E Flashing
open
NOTICE F Controller fault Flashing
5 H/L Sol. Short Flashing
The transmission of your lift truck may be reversed
under full power up to a travel of 6.0 km/h (3.73 6 Forward Sol. Short Flashing
mph). But the Inhibit Speed of Auto Shift is set by 7 Reverse Sol. Short Flashing
the factory at 4~5 km/h (2.5~3.2 mph) because
reversing the transmission at lower travel speeds This information is given during normal operating
prolongs the lift of the transmission, axle shafts and when something special happens.
tires. For example, on ASC-200/201's with the speed
sensor, one of the indicators is used to indicate a
sensor problem.

108
Operation Section

• Display for Troubleshooting Operation

Display Description Remark
A Automatic operation This system can be basically operated in two
preselected modes, automatic mode and manual
2 High speed s/w input Lever input test mode.
3 Forward s/w input Lever input test NOTE: In ASC-200 factory-setting controller,
4 Reverse s/w input Lever input test automatic mode is selected for both
direction inhibit and two-speed auto shift
control as a default on the PCB(Printed
This information is input for signal diagnostics.
Circuit Board).In ASC-201 factory-setting
This test is used to verify operation of direction
controller, manual mode(Fail-Safe Mode) is
control lever.
selected as a default for direction inhibit
while automatic mode is selected as a
default for two-speed auto shift control.

Automatic mode
Direction Inhibit
1. Start the engine with the direction control lever
in NEUTRAL and the parking brake engaged.

2. Press down on the service brake pedal,

disengage the parking brake and move the
direction control lever to FORWARD.

NOTE: Release the parking brake before using the

directional control lever.

3. Observe the LED on the Auto Shift Controller.

The LED should indicate "A" while the direction
control lever is in FORWARD, NEUTRAL and
REVERSE. Report Auto Shift as faulty if the
LED indicates anything other than "A".
4. Keep the service brake pushed down until ready
to move the truck.

5. To change directions of a traveling lift truck

when the Auto Shift Controller LED displays "A",
shift the direction control lever to the opposite
direction and wait for the lift truck to change
direction.

6. If however, your travel speed is higher than the

pre-selected direction change speed as direction
inhibit point in the controller, Auto Shift will shift
the transmission to NEUTRAL until the lift truck's
travel speed slows to the pre-selected direction
change speed, and then shift the transmission to
the direction selected.

7. You should be prepared to help slow the lift

truck to the pre-selected direction change speed
by pressing down on the service brake pedal.

109
Operation Section

WARNING Manual Mode (Fail-Safe mode)

When you want to change the travel direction, In case that the controller is broken down or you
you must press down on the service brake pedal don't want to use the functions of the Auto Shift
to reduce the travel speed. Be cautious that the Controller, you can select Manual Mode. In Manual
lift truck's stopping distance may be longer than Mode, you can operate your lift truck in the same
manner as any lift truck without Auto Shift Controller.
in manual mode because the lift truck continues
You can select the Manual mode or the Automatic
to travel forward regardless of the selection of
mode by doing following procedures.
reverse with the direction control lever until the
vehicle speed is sufficiently reduced.
WARNING
In the manual mode, direction inhibition function
8. The direction of travel will change automatically
can not be operated normally. The sudden
when the vehicle speed is reduced as much as
reversal of a loaded lift truck traveling forward
the pre-selected speed in the controller.
can cause the load to fall or the lift truck to tip
over.
WARNING
Bring the loaded lift truck to a complete stop 1. Park the lift truck in a designed service area.
before changing travel direction.
Changing travel direction while traveling may 2. Lower the lift truck's forks or lode engaging
cause the lift truck to lose the load or tip over. attachment to the travel surface, shift the
direction control lever to NEUTRAL, engage the
parking brake, shut OFF the engine and remove
9. When the direction change is completed, the key.
continue to push down on the accelerator pedal
to obtain the desired travel speed. 3. Turn OFF the electrical disconnect switch, if
equipped. Chock the front and rear tires to
prevent unintentional movement of the lift truck.
NOTICE
The transmission of your lift truck may be reversed 4. Remove the Controller cover plate screws and
under full power up to a travel of 6.0 km/h (3.73 cover plates.
mph). But the Inhibit Speed of Auto Shift is set by
the factory at 4~5 km/h (2.5~3.2 mph) because 5. Locate the FWD/RVS selection switch (1) and
reversing the transmission at lower travel speeds the High/Low(H/L) selection switch (2) on the
prolongs the lift of the transmission, axle shafts and printed circuit board.
tires.
6. Move the switches as indicated, up for
Automatic(AUTO) operation or down for
Two-Speed Auto Shift Control Manual(MANUAL) operation.
While traveling forward with the high speed gear,
that is, 2nd gear selected, the ASC-200 /201 can
upshift or down-shift the transmission automatically
according to the vehicle speed by its own speed
ratio control so that the appropriate gear may be
engaged in every situation.

NOTICE
Two-Speed Auto Shift Control function can be
accomplished only when the direction control lever
is placed in the high speed (2nd gear) position.

110
Operation Section

Typical Example of ASC-200

NOTE: In ASC-200 factory-setting controller,

automatic mode is selected for both
direction inhibit and two-speed auto shift
control as a default on the PCB(Printed
Circuit Board).In ASC-201 factory-setting
controller, manual mode(Fail-Safe Mode) is
selected as a default for direction inhibit
while automatic mode is selected as a
default for two-speed auto shift control.

7. Replace the Controller cover plate and screws.

8. Turn ON the electrical disconnect switch, if

equipped.

9. Start engine. check the Controller LED indication

for "A". For indications other than "A", see
following section on Fault Diagnosis.

NOTE: After operating the truck manually by

selecting the Manual Mode switch on
PCB(Printed Circuit Board), the position of
mode must be checked before operating the
truck automatically.

111
Operation Section

Operating Techniques Lifting the Load

Inching into Loads 1. Lift the load carefully and tilt the mast back a
short distance.

loads.

113
Operation Section

Turning

Typical Example

3. Deposit the load and BACK away carefully to

disengage the forks. 1. When turning sharp corners, keep close to the
inside corner. Begin the turn when the inside
drive wheel meets the corner.

Typical Example

4. Lower the carriage and forks to the travel

position or to the park position. 2. In narrow aisles, keep away from the stockpile
when turning into the aisle. Allow for
counterweight swing.

114
Operation Section

Lifting Drums or Round Objects Operating in Hot Weather

Keep the following points in mind when you operate

the lift truck in hot weather.

1. Check the radiator. Clogging can cause the

overheating. Clean them out regularly with a
blast of compressed air. Also, check the leakage
of water.

2. Check the fan belt tension and adjust to proper

tension

3. Even if the engine overheats and the coolant

boils over, let the engine idle for a while with
1. Block drums or round objects. Tilt the mast opening engine hood until temperature falls
FORWARD and side the fork tips along the floor before shut off the engine.
to get under the load.

2. Before lifting, tilt the mast BACK slightly until the

load is cradled on the forks.

115
Operation Section

Parking the Lift Truck

WARNING
Blocking the wheels will prevent unexpected lift
truck movement, which could cause personal
injury.

5. Turn the ignition key switch to the OFF position

and remove the key.

Typical Example

Park the lift truck level, with the forks lowered and
the mast tilted forward until the fork tips touch the
floor.
Block the drive wheels when parking on an incline.

1. Park in authorized area only. Do not block traffic.

NOTE: If a LP equipped lift truck is stopped or

parked for an indefinite or prolonged period
of time, close the fuel shutoff valve on the
LP tank. Run the engine until fuel in the line
runs out and the engine stops. Turn off the
ignition switch and disconnect switch (if
equipped).

6. Actuate each loading lever several times to

remove the residual pressure in the respective
cylinders and hoses.
Typical Example
7. Block the drive wheels if parking on an incline.
2. Place the transmission controls in NEUTRAL.

3. Engage the parking brake.

Typical Example

4. Lower the forks to the ground.

116
Operation Section

Lift Fork Adjustment

WARNING WARNING
When adjusting the fork spread, be careful not to Make sure the forks are locked before carrying a
pinch your hand between forks and the carriage load.
slot.

For load stability, always adjust the forks as wide as

possible. Position the load evenly on both forks.

Typical Example of Shaft type Fork

Typical Example of Hook-on type Fork

1. Move up the hook pin(1) in each fork to slide the

fork(2) on the carriage bar.

2. Adjust the forks in the position most appropriate

for the load and as wide as possible for load
stability.

3. When adjusting the forks, make sure that the

weight of the load is centered on the truck.

4. After adjustment, set the hook pins to keep the

forks in place.

117
Operation Section

Storage Information
5. Cover components such as the breather and air
Before Storage cleaner which may be caught with humidity.

6. The machine should be operated at least once a

Before storing your lift truck, clean and inspect as week. Fill the cooling system, if cooling water is
per the following procedures. discharged, and mount the battery. Start the
engine and warm up thoroughly. Move the
1. Wipe away grease, oil, etc. adhering to the body machine a little forwards and backwards. Operate
of the truck with waste cloth, and use water, if the hydraulic controls several times.
needed.

2. While cleaning the truck, check general condition

of the truck. Especially check the truck body for To Operate the Lift Truck After a
dents or damage and tires for wear or nails or Long Time Storage
stones in the tread.

3. Fill the fuel tank with fuel specified. 1. Remove covers and antirust from each of the
components and exposed parts.
4. Check for leakage of hydraulic oil, engine oil, fuel,
or coolant, etc. 2. Drain the engine crankcase, transmission (clutch
type machine), differential and final reduction
5. Apply grease, where needed.
gear, clean the inside of them and add new oil.
6. Check for looseness of nuts and bolts, especially
3. Drain off foreign matter and water from the
hub nuts.
hydraulic oil tank and fuel tank.
7. Check mast rollers to see that they rotate
4. Remove the head cover from the engine cylinder.
smoothly.
Oil valves and rocker shaft and check each valve
8. Prime the oil into the lift cylinders by actuating the for proper operation.
lift lever all the way several times.
5. Add cooling water to the specified level.
9. Drain off coolant completely in cold weather, if
6. Charge the battery and mount it on the machine.
antifreeze is not used.
Connect the cables.
Long Time Storage 7. Perform pre - operational checks carefully. (refer
to "Before Starting the Engine")
Perform the following service and checks in addition
to the "Parking the lift truck" services. 8. Warm up the machine.

1. Taking the rainy season into consideration, park

the machine on higher and hard ground.

2. Avoid parking on soft grounds such as an asphalt

ground in summer.

3. Dismount the battery from the machine. Even

though the machine is parked indoors, if the place
is hot or humid, the battery should be kept in a
dry, cool place. Charge the battery once a month.

4. Apply antirust to the exposed parts which tend to

rust.

118
Operation Section

Transportation Hints

Lift Truck Shipping Machine Lifting and Tiedown

Information
Check travel route for overpass clearances. Make
sure there is adequate clearance if the lift truck
being transported is equipped with a high mast,
NOTICE
overhead guard or cab.
Improper lifting or tiedowns can allow load to shift
To prevent the lift truck from slipping while loading, and cause injury and/or damage.
or shifting in transit, remove ice, snow or other
slippery material from the loading dock and the truck
bed before loading. 1. Weight is given on the serial plate.

2. Use proper rated cables and slings for lifting.

NOTICE Position the crane for level lift truck lift.
Obey all state and local laws governing the height,
3. Spreader bar widths should be sufficient to
weight, width and length of a load.
prevent contact with the lift truck
Observe all regulations governing wide loads.
4. Use the tiedown locations provided for lift truck
tiedown.
NOTICE
Remove ice, snow or other slippery material from Check the state and local laws governing weight,
the shipping vehicle and the loading dock. width, and length of a load.
Contact your DOOSAN Lift Truck dealer for shipping
instructions for your lift truck.

Typical Example

Always block the trailer or the rail car wheels before

loading the lift truck.

Position the lift truck on the truck bed or the rail car.
Apply the parking brake and place the transmission
control in NEUTRAL.

Turn ignition switch to the OFF position and remove

the key.
If LP equipped, remove the LP fuel tank.

Block the wheels and secure lift truck with tiedowns.

119
Operation Section

Consult your DOOSAN Lift Truck dealer for towing a

Towing Information disabled lift truck.

WARNING
Personal injury or death could result when
towing a disabled lift truck incorrectly.
Block the lift truck wheels to prevent movement
before releasing the brakes. The lift truck can
roll free if it is not blocked.
Follow the recommendations below, to properly
perform the towing procedure.

These towing instructions are for moving a disabled

lift truck a short distance, at low speed, no faster Typical Example
than 2 km/h (1.2 mph), to a convenient location for
repair. These instructions are for emergencies only. 1. Release the parking brake.
Always transport the lift truck if long distance moving
is required.
NOTICE
Shield must be provided on the towing lift truck to Release the parking brake to prevent excessive
protect the operator if the tow line or bar should wear and damage to the parking foot brake system.
break.

Do not allow riders on the lift truck being towed 2. Check that the service foot brake pedal is
unless the operator can control the steering and/or released.
braking.
3. Key switch is in the OFF position.
Before towing, make sure the tow line or bar is in
good condition and has enough strength for the
4. Direction control lever is in neutral.
towing situation involved. Use a towing line or bar
with a strength of at least 1.5 times the gross weight
5. Fasten the tow bar to the lift truck.
of the towing lift truck for a disabled lift truck stuck in
the mud or when towing on a grade.
6. Remove the wheel blocks. Tow the lift truck
slowly. Do not tow any faster than 2 km/h (1.2
Keep the tow line angle to a minimum. Do not
mph).
exceed a 30° angle from the straight ahead position.
Connect the tow line as low as possible on the lift
truck that is being towed. WARNING

Quick lift truck movement could overload the tow Be sure all necessary repairs and adjustments
line or bar and cause it to break. Gradual and have been made before a lift truck that has been
smooth lift truck movement will work better. towed to a service area is put back into
operation.
Normally, the towing lift truck should be as large as
the disabled lift truck. Satisfy yourself that the towing
lift truck has enough brake capacity, weight and
power, to control both lift trucks for the grade and
the distance involved.

To provide sufficient control and braking when

moving a disabled lift truck downhill, a larger towing
lift truck or additional lift trucks connected to the rear
could be required. This will prevent uncontrolled
rolling.The different situation requirements cannot
be given,as minimal towing lift truck capacity is
required on smooth level surfaces to maximum on
inclines or poor surface conditions.

120
Maintenance Section

Inspection, Maintenance and Repair of Lift Truck Forks

The following section gives practical guidelines for Users may also refer to the International
inspection, maintenance and repair of lift truck forks. Organization For Standardization-ISO Technical
It also provides general information on the design Report 5057-Inspection and Repair of Fork Arms
and application of forks and the common cause of and ISO Standard 2330-Fork Arms-Technical
fork failures. Characteristics and Testing.

Lift truck forks can be dangerously weakened by While there are no specific standards or regulations
improper repair or modification. They can also be in the United States, users should be familiar with
damaged by the cumulative effects of age, abrasion, the requirements for inspection and maintenance of
corrosion, overloading and misuse. lift trucks as provided by the 29 Code Federal
Register 1910.178 Powered Industrial Truck, and
A fork failure during use can cause damage to the ANSI/ASME Safety Standard(s) B56.1, B56.5 or
equipment and the load. A fork failure can also B56.6 as applicable to the type of machine(s) in use.
cause serious injury.

A good fork inspection and maintenance program Environment Protection

along with the proper application can be very
effective in preventing sudden failures on the job. When servicing this lift truck, use an authorized
servicing area and an approved container to collect
Repairs and modifications should be done only by coolant, oil, fuel, grease, electrolyte and any other
the fork manufacturer or a qualified technician who potential environmental pollutant before any lines,
knows the material used and the required welding fittings or related items are disconnected or removed.
and heat treatment process. After servicing, dispose of those materials in an
authorized place and container. When cleaning the
Users should evaluate the economics of returning lift truck, be sure to use an authorized area.
the forks to the manufacturer for repairs or
purchasing new forks. This will vary depending on
many factors including the size and type of fork.

Forks should be properly sized to the weight and

length of the loads, and to the size of the machine
on which they are used. The general practice is to
use a fork size such that the combined rated
capacity of the number of forks used is equal to or
greater than the "Standard(or rated) Capacity" of
the lift truck.

The individual load rating, in most cases, will be

stamped on the fork in a readily visible area. This is
generally on the top or side of the fork shank.

z A fork rated at 1500 pounds at 24 inch load

center will be stamped 1500X24.
z A fork rated at 2000 kg at 600 mm load center
will be stamped 2000X600.
The manufacturer identification and year and date of
manufacture is also usually shown.
Some countries have standards or regulations which
apply specifically to the inspection and repair of
forks.

121
Maintenance Section

Causes of Fork Failure z Wear

Improper Modification or Repair Forks are constantly subjected to abrasion as

they slide on floors and loads. The thickness of
Fork failure can occur as a result of a field the fork blade is gradually reduced to the point
modification involving welding, flame cutting or other where it may not be capable of handling the
similar processes which affect the heat treatment load for which it was designed.
and reduces the strength of the fork.
z Stress Risers
In most cases, specific processes and techniques Scratches, nicks and corrosion are points of
are also required to achieve proper welding of the high stress concentration where cracks can
particular alloy steels involved. Critical areas most develop. These cracks can progress under
likely to be affected by improper processing are the repetitive loading in a typical mode of fatigue
heel section, the mounting components and the fork failure.
tip.
Overloading
Bent or Twisted Forks
Extreme overloading can cause permanent bending
Forks can be bent out of shape by extreme or immediate failure of the forks. Using forks of less
overloading, glancing blows against walls or other capacity than the load or lift truck when lifting loads
solid objects or using the fork tip as a pry bar. and using forks in a manner for which they were not
designed are some common causes of overloading.
Bent or twisted forks are much more likely to break
and cause damage or injury. They should be
removed from service immediately.

Fatigue
Parts which are subjected to repeated or fluctuating
loads can fail after a large number of loading cycles
even though the maximum stress was below the
static strength of the part.

The first sign of a fatigue failure is usually a crack

which starts in an area of high stress concentration
This is usually in the heel section or on the fork
mounting.

As the crack progresses under repetitive load

cycling, the load bearing cross section of the
remaining metal is decreased in size until it
becomes insufficient to support the load and
complete failure occurs.

Fatigue failure is the most common mode of fork

failure. It is also one which can be anticipated and
prevented by recognizing the conditions which lead
up to the failure and by removing the fork service
prior to failing.
z Repetitive Overloading
Repetitive cycling of loads which exceeds the
fatigue strength of the material can lead to
fatigue failure. The overload could be caused by
loads in excess of the rated fork capacity and
by use of the forks tips as pry bars. Also, by
handling loads in a manner which causes the
fork tips to spread and the forks to twist laterally
about their mountings.

122
Maintenance Section

Fork Inspection First Installation

1. Inspect forks to ensure they are the correct size
for the truck on which they will be used. Make
sure they are the correct length and type for the
loads to be handled.
If the forks have been previously used, perform
the "12 Month Inspection".
If the forks are rusted, see "Maintenance and
Repair".

2. Make sure fork blades are level to each other

within acceptable tolerances. See "Forks, Step
4," in the "2000 Service Hours or Yearly" in
"Maintenance Intervals"
Establish a daily and 12 month inspection routine by
keeping a record for the forks on each lift truck. 3. Make sure positioning lock is in place and
working Lock forks in position before using truck.
Initial information should include the machine serial See "Forks, Step 7", in the "2000 Service Hours
number on each the forks are used, the fork or Yearly" in "Maintenance Intervals".
manufacturer, type, original section size, original
length and capacity. Also list any special Daily Inspection
characteristics specified in the fork design.
1. Visually inspect forks for cracks, especially in
Record the date and results of each inspection, the heel section, around the mounting brackets,
making sure the following information is included. and all weld areas. Inspect for broken or jagged
fork tips, bent or twisted blades and shanks.
z Actual wear conditions, such as percent of
original blade thickness remaining. 2. Make sure positioning lock is in place and
z Any damage, failure or deformation which might working. Lock the forks in position before using
impair the use of the truck. the truck. See "2000 Service Hours or Yearly" in
"Maintenance Intervals".
z Note any repairs or maintenance.
3. Remove all defective forks from service.
An ongoing record of this information will help in
identifying proper inspection intervals for each
operation, in identifying and solving problem areas
and in anticipating time for replacement of the forks.

123
Maintenance Section

12 Months Inspection permanent deformation.

Consult the fork manufacturer for further
information as may be applicable to the specific
Forks should be inspected, at a minimum, every 12 fork involved.
months. If the truck is being used in a multi-shift or
heavy duty operation, they should be checked every Testing is not required for repairs to the
six months. See "Forks" in the "2000 Service Hours positioning lock or the markings.
or Yearly" in "Maintenance Intervals."

Maintenance and Repair

1. Repair forks only in accordance with the
manufacturer's recommendations.

Most repairs or modifications should be done

only by the original manufacturer of the forks or
an expert knowledgeable of the materials,
design, welding and heat treatment process.

2. The following repairs or modifications SHOULD

NOT be attempted.

z Flame cutting holes or cutouts in fork blades.

z Welding on brackets or new mounting hangers.
z Repairing cracks or other damage by welding.
z Bending or resetting.
3. The following repairs MAY be performed.

z Forks may be sanded or lightly ground, to

remove rust, corrosion or minor defects from the
surfaces.
z Heel sections may be ground with a carbon
stone to remove minor surface cracks or defects.
Polish the inside radius of the heel section to
increase the fatigue life of the fork. Always grind
or polish in the direction of the blade and shank
length.
z Repair or replace the positioning locks on hook
type forks.
z Repair or replace most fork retention devices
used with other fork types.
4. A fork should be load tested before being
returned to service on completion of repairs
authorized and done in accordance with the
manufacturer's recommendations.

Most manufacturers and standards require the

repaired fork to be tested with a load 2.5 times
the specified capacity and at the load center
marked on the fork arm.

With the fork restrained in the same manner as

its mounting on the lift truck, apply the test load
twice, gradually and without shock. Maintain the
test for 30 seconds each time.

Check the fork arm before and after the second

application of the test load. It shall not show any

124
Maintenance Section

Tire Inflation Information Tire Shipping Pressure

Tires Inflation The tire inflation pressures shown in the following

chart are cold inflation shipping pressures.

Shipping
WARNING Size
Ply Rating Or
Pressure
Strength Index
Personal injury or death could result when tires kPa psi
are inflated incorrectly. 8.25 x 15 14PR 790 115
8.25 x 15 16PR 880 128
Use a self-attaching inflation chuck and stand 9.00 x 20 14PR 790 115
behind the tread when inflating a tire.
Standard tire, ply rating and inflation pressures.
Proper inflation equipment, and training in using
the equipment, are necessary to avoid The operating inflation pressure is based on the
overinflation. A tire blowout or rim failure can weight of a ready-to-work machine without
result from improper or misused equipment. attachments, at rated payload, and in average
operating conditions. Pressures for each application
may vary and should always be obtained from your
tire supplier.
Always remove (deflate) all air from a single tire and
from both tires on a dual assembly before changing
them. NOTE: Fill tires to the recommended pressures
listed ± 35 kPa (5 psi). Tires can be filled
with nitrogen.
NOTICE
When changing tires, change them in sets, even if
only one of the tires is damaged. If new and used Tire Inflation Pressures
tires are used on the same axle, tilting of the mast Adjustment
and rapid tire wear will result.
The mounting faces of the hub, wheel nuts and A tire inflation in a warm shop area, 18° to 21°C (65°
wheels must be free of any foreign material and to 70°F), will be underinflated if the machine works
lubricants of any kind. Tighten wheel nuts again in freezing temperatures. Low pressure shortens the
after 24 hours of operation. life of a tire.

Do not reinflate a tire that has been driven on while

flat or underinflated, without first checking to be sure
the locking ring on the wheel is not damaged and in
position.

Always deflate tires before changing them.

125
Maintenance Section

Torque Specifications Torques for Standard Bolts, Nuts

and Taperlock Studs
Metric Hardware - This lift truck is almost
totally metric design. Specifications are
given in metric and U.S.Customary
measurement. NOTICE
Metric hardware must be replaced with metric The following charts give general torques for bolts,
hardware. Check parts books for proper nuts and taperlock studs or SAE Grade 5 or better
replacement. quality.

NOTE : Use only metric tools on most hardware for

proper fit. Other tools could slip and Torques for Bolts and Nuts With
possibly cause injury. Standard Threads

Torques for Standard Hose Thread Size Standard Nut and Bolt Torque
Inch
Clamps - Worm Drive Band Type N•m lb•ft
1/4 12 ± 4 9±3
5/16 25 ± 7 18 ± 5
NOTICE
The following chart gives the torques for initial 3/8 45 ± 7 33 ± 5
installation of hose clamps on new hose and for 7/16 70 ± 15 50 ± 11
reassembly or retightening of hose clamps on
1/2 100 ± 15 75 ± 11
existing hose.
9/16 150 ± 20 110 ± 15
5/8 200 ± 25 150 ± 18
Initial Installation
3/4 360 ± 50 270 ± 37
Clamp Width Torque On New Hose
7/8 570 ± 80 420 ± 60
N•m1 lb•in
1 875 ± 100 640 ± 75
16 mm (.625 in) 7.5 ± 0.5 65 ± 5
1 1/8 1100 ± 150 820 ± 110
13.5 mm (.531 in) 4.5 ± 0.5 40 ± 5
1 1/4 1350 ± 175 1000 ± 130
8 mm (.312 in) 0.9 ± 0.2 8±2
1 3/8 1600 ± 200 1180 ± 150
Reassembly or
1 1/2 2000 ± 275 1480 ± 200
Retightening 1
Clamp Width 1 Newton meter (N•m) is approximately the same as 0.1 kg
Torque On Existing Hose •m.
1
N•m lb•in
16 mm (.625 in) 4.5 ± 0.5 40 ± 5
13.5 mm (.531 in) 3.0 ± 0.5 25 ± 5
8 mm (.312 in) 0.7 ± 0.2 6±2
1
1 Newton meter (N•m) is approximately the same as 0.1
kg•m.

126
Maintenance Section

Torques for Taperlock Studs Torques for Metric Fasteners

Thread Size Standard Taperlock Stud Torque
Inch 1 NOTICE
N•m lb•ft
Be very careful never to mix metric with U.S.
1/4 8±3 6±2
customary (standard) fasteners. Mismatched or
5/16 17 ± 5 13 ± 4 incorrect fasteners will cause lift truck damage or
malfunction and may even result in personal injury.
3/8 35 ± 5 26 ± 4
7/16 45 ± 10 33 ± 7 Original fasteners removed from the lift truck should
1/2 65 ± 10 48 ± 7 be saved for reassembly whenever possible. If new
fasteners are needed, they must be of the same size
5/8 110 ± 20 80 ± 15 and grade as the ones that are being replaced.
3/4 170 ± 30 125 ± 22
The material strength identification is usually shown
7/8 260 ± 40 190 ± 30 on the bolt head by numbers (8.8, 10.9, etc). The
1 400 ± 60 300 ± 45 following chart gives standard torques for bolts and
nuts with Grade 8.8.
1/8 500 ± 700 370 ± 50
1/4 650 ± 80 480 ± 60
NOTE: Metric hardware must be replaced with
3/8 750 ± 90 550 ± 65 metric hardware. Check parts book for
1/2 870 ± 100 640 ± 75 proper replacement.
1
1 Newton meter (N•m) is approximately the same as 0.1
kg•m. Thread Size Standard Torque
Metric N•m1 lb•ft
M6 12 ± 4 9±3
M8 25 ± 7 18 ± 5
M10 55 ± 10 41 ± 7
M12 95 ± 15 70 ± 11
M14 150 ± 20 110 ± 15
M16 220 ± 30 160 ± 22
M20 450 ± 70 330 ± 50
M24 775 ± 100 570 ± 75
M30 1600 ± 200 1180 ± 150
M36 2700 ± 400 2000 ± 300
1
1 Newton meter (1 N•m) is approximately the same as 0.1
kg•m.
2
ISO - International Standards organization.

127
Maintenance Section

Cooling System Specifications

Coolant Information Refer to topic, "Cooling System - Clean, Change" in
Every 2000 Service Hours or Yearly section.
Filling at over 20 liters (5 U.S. gallons) per minute
NOTE: The following information is generic and can cause air pockets in the cooling system.
valid for lift trucks.
After draining and refilling the cooling system,
Engine operating temperatures have increased to operate the engine with the radiator cap removed
improve engine efficiency. This means proper until the coolant reaches normal operating
cooling system maintenance is especially important. temperature and the coolant level stabilizes. Add
Overheating, overcooling, pitting, cavitation erosion, coolant as necessary to fill the system to the proper
cracked heads, piston seizures, and plugged level.
radiators are classic cooling system failures. In fact,
coolant is as important as the quality of fuel and Never operate without a thermostat in the cooling
lubricating oil. system. Cooling system problems can arise without
a thermostat.
NOTICE
DOOSAN recommends that the coolant mixture
contain a minimum of 30% antifreeze or equivalent.

Never add coolant to an overheated engine, engine

damage can result. Allow the engine to cool first.

All water is corrosive at engine operating

temperature. The cooling system should be
protected with a 3 to 6% concentration of liquid
supplemental coolant additive at all times,
regardless of the concentration of antifreeze.

Excessive supplemental coolant additive greater

than the recommended 6%, together with
concentrations of antifreeze greater than 65% can
cause deposits to form and can result in radiator
tube blockage, overheating, and/or water pump seal
damage.

If the machine is to be stored in, or shipped to, an

area with freezing temperatures, the cooling system
must be protected to the lowest expected outside
(ambient) temperature.

The engine cooling system is normally protected to

-28°C(-20°F) with antifreeze, when shipped from the
factory unless special requirements are defined.

Check the specific gravity of the coolant solution

frequently in cold weather to ensure adequate
protection.

Clean the cooling system if it is contaminated, the

engine overheats or foaming is observed in the
radiator.

Old coolant should be drained, the system cleaned

and new coolant added every 2000 service hours or
yearly.

128
Maintenance Section

Coolant Water Use a greater concentration (above 50%) of

commercially available automotive antifreeze only
Hard water, or water with high levels of calcium and as needed for anticipated outside (ambient)
magnesium ions, encourages the formation of temperatures. Do not exceed the recommendations,
insoluble chemical compounds by combining with provided with the commercially available automotive
cooling system additives such as silicates and antifreezes, regarding the coolant mixture of
phosphates. antifreeze to water.
The tendency of silicates and phosphates to
precipitate out-of-solution increases with increasing
water hardness. Hard water, or water with high
Make proper antifreeze additions.
levels of calcium and magnesium ions encourages Adding pure antifreeze as a makeup solution for
the formation of insoluble chemicals, especially after cooling system top-up is an unacceptable practice. It
a number of heating and cooling cycles. increases the concentration of antifreeze in the
cooling system which increase the concentration of
DOOSAN prefers the use of distilled water or dissolved solids and undissolved chemical inhibitors
deionized water to reduce the potential and severity in the cooling system. Add antifreeze mixed with
of chemical insolubility. water to the same freeze protection as your cooling
system.
Acceptable Water
Use the chart below to assist in determining the
Water Content Limits (PPM) concentration of antifreeze to use.
Chlorides (Cl) 50 maximum
Sulfates (SO4) 50 maximum Antifreeze Concentrations

Total hardness 80 mg/l Protection Temperature Concentrations

Total solids 250 maximum Protection to -15 °C (5 °F)
30% antifreeze and 70%
water
PH 6.0 to 8.0 40% antifreeze and 60%
Protection to -23 °C (-10 °F)
ppm = parts per million water
50% antifreeze and 50%
Protection to -37 °C (-34 °F)
Using water that meets the minimum acceptable water
water requirement may not prevent drop-out of 60% antifreeze and 40%
Protection to -51 °C (-60 °F)
these chemical compounds totally, but should water
minimize the rate to acceptable levels.

Antifreeze

NOTICE
DOOSAN recommends using automotive antifreeze
suitable for gasoline engines having aluminum alloy
parts. Antifreeze of poor quality will cause corrosion
of the cooling system, and thus always use
automotive antifreeze prepared by a reliable maker,
and never use it mixed with antifreeze of different
brand.

DOOSAN recommends that the coolant mix contain

50% commercially available automotive antifreeze,
or equivalent and acceptable water to maintain and
adequate water pump cavitation temperature for
efficient water pump performance.

Premix coolant solution to provide protection to the

lowest expected outside (ambient) temperature.
Pure undiluted antifreeze will freeze at –23°C (-
10°F).

129
Maintenance Section

Fuel Specifications

General Fuel Information

PREFERRED DISTILLATE FUEL
Use only fuel as recommended in this section. FOR DIESEL ENGINES
Specifications Requirements*
Aromatics (AST D1319) 35% Max.
NOTICE
Ash (ASTM D482) 0.02% Weight Max.
Fill the fuel tank at the end of each day of operation
to drive out moisture laden air and to prevent Cetane Number 35 Min. for 45 Max.
condensation. Maintain a constant level near the top (ASTM D613) 40 Min. for Dl Engines
of the day tank to avoid drawing moisture into the
tank as the level decreases. Not Above Lowest Expected
Cloud Point (ASTM D97)
Ambient Temperature
Do not fill the tank to the top. Fuel expands as it gets
warm and can overflow.
Gravity API (ASTM D287) 30 Min. and 45 Max.
Do not fill the fuel filters with fuel before installing
6 C (10 F) Below
them. Contaminated fuel will cause accelerated Pour Point (ASTM D97)
Ambient Min.
wear to the fuel system parts.
Sulfur (ASTM D2788, 0.5 Max.
D3605 or D1552) (See Sulfur Topic)
Drain the water and sediment from main fuel storage Viscosity, Kinematic @
20.0 cSt Max.
tank before it is refilled. This will help prevent water 38°C (100°F)(ASTM
1.4 cSt Min.
and/or sediment from being pumped from the fuel D445)
storage tank into the engine fuel tank. Water & Sediment
0.01% Max.
(ASTM D1796)
Diesel Specifications *As delivered to fuel system

Fuel Sulfur Content

Fuel Types The percentage of sulfur in the fuel will affect the
DOOSAN Diesel Engines have the ability to burn a engine oil recommendations. Fuel sulfur is
chemically changed during combustion to form both
wide variety of fuels. These fuels are divided into
sulfurous and sulfuric acid. These acids chemically
two general groups, preferred and permissible.
attack metal surfaces and cause corrosive wear.
The Preferred Fuels provide maximum engine
Certain additives used in lubricating oils contain
service life and performance. They are distillate
alkaline compounds that are formulated to neutralize
fuels. They are commonly called diesel fuel, MDO
these acids. The measure of this reserve alkalinity in
diesel, furnace oil, gas oil or kerosene (for cold
lubricating oil is known as its Total Base Number
weather operation).
(TBN). TBN is essential to neutralize the acids from
combustion gases and to minimize corrosive wear.
Experience has proven that distillate fuels meeting
the following basic specifications will result in
optimum engine performance and durability.

DOOSAN strongly encourages the use of fuels that

meet the Preferred Fuels specification.

The permissible fuels are crude oils or blended fuels.

Use of these fuels can result in higher maintenance
costs and reduced engine service life.

Crude oil is used to describe oils/fuels that are not

refined and are in the original state as when pumped
from the ground. Certain types of crude oils can be
burned in DOOSAN Engines.

130
Maintenance Section

Any API classification performance of oil should LP Specifications

have sufficient TBN for fuels with less than 0.5%
sulfur. For fuels with 0.5% to 1.5% sulfur by weight,
engine oil must have a TBN of 20 times the LP is "liquefied petroleum gas". The exact
percentage of fuel sulfur as measured by the ASTM composition of LP varies slightly between different
(American Society of Testing Materials) D-2896 parts of the country and different refineries. HD5 is
method. (ASTM D-2896 can normally be found at recommended for DOOSAN forklift trucks.
your local technological society, library or college). Remember LP is heavier than air and will sink to the
lowest spot possible. Avoid areas near floor drains
DOOSAN recommends infrared analysis (in or lubrication pits where escaped fuel may collect.
conjunction with wear metal analysis) of used oil in
determining the effectiveness of oil TBN and acid Composition of HD5
neutralization.
Propane (C3H9) 90.0 %
For fuel with sulfur exceeding 1.5% by weight, use
an oil with a TBN of 30 and reduce the oil change Propylene up to 5 %
interval by one half. Also, infrared analysis and wear
metal analysis should be used to establish oil Butane (C4H10) 2.0 %
change intervals.
iso-Butane 1.5 %
Periodically request fuel sulfur content information
from your fuel supplier. Fuel sulfur content can Methane (CH4) 1.5 %
change with each bulk delivery.
Total 100 %

131
Maintenance Section

Lubricant Specifications

Lubricant Information Hydraulic Oil (HYDO)

Some classifications and abbreviations we use in The following commercial classifications can be
this section follow S.A.E. (Society of Automotive used in the hydraulic system.
Engineers) J754 nomenclature and others follow
S.A.E. J183. z ISO 6743/4 HM
z AFNOR NFE 48-603 HM
All MIL specifications are U.S.A. Military. z DIN 51524 TEIL 2 H-LP
z HAGGLUNDS DENISON HFO-HF2
Recommended oil viscosities are given in the z CINCINNATI P68, 69, 70
"Lubricant Viscosities" chart later in this section of
the manual. Viscosity : ISO VG32

Greases are classified according to the National Industrial premium hydraulic oils that have passed
Lubricating Grease Institute (NLGI) based on ASTM the Vickers vane pump test (35VQ25).
D217-68 worked Penetration characteristics which These oils should have antiwear, antifoam, antirust
give a defined consistency number. and antioxidation additives for heavy duty use as
stated by the oil supplier. ISO viscosity grade of 32
Engine Oil (DEO and EO) would normally be selected.

The following oil specifications provide guidelines for Transmission Oil (TDTO)
the selection of commercial products :

.Gasoline/LP Engine : API SJ NOTICE

.Diesel Engine : API CH4 or ACEA E5 These oils are formulated for transmissions and
drive trains only, and should not be used in engines.
Shortened engine life will result.
NOTICE
Failure to follow the oil recommendations can cause
shortened engine life due to carbon deposits or NOTE: Multi-grade oils are not blended by
excessive wear. DOOSAN for use in transmissions.
Multi-grade oils which use high molecular
weight polymers as viscosity index
Consult the EMA Lubricating Oils Data Book for a improvers lose their viscosity effectiveness
listing of oil brands. by permanent and temporary shear of the
viscosity index improver and therefore, are
NOTE: The percentage of sulfur in the fuel will not recommended for transmission and
affect the engine oil recommendations. For drive train compartments.
fuel sulfur effects, the Infrared Analysis or
the ASTM D2896 procedure can be used to NOTE: Failure to follow this recommendation can
evaluate the residual neutralization cause shortened transmission life due to
properties of engine oil. The sulfur products material incompatibility, inadequate frictional
formation depends on the fuel sulfur content, requirements for disk materials and/or
oil formulation, crankcase blowby, engine excessive gear wear.
operating conditions and ambient
temperature. Select Oil that meets below specifications.

z D50/60/70/80/90S-5(3 Speed)
: API CD/TO-2 or MIL-L-2104D,E
z D50/60/70S-5 (2 Speed), G50/60/70S-5
: GM DEXRON

132
Maintenance Section

Drive Axle Oil Brake Oil (Only for OCDB)

NOTE : Failure to follow the recommendation will As brake oil for oil cooled disc brake system (OCDB),
cause shortened life due to excessive gear use the oil that has the same specifications with
wear. hydraulic oil.

• Shoe Brake The following commercial classifications can be

used in the brake system.

z ISO 6743/4 HM
z AFNOR NFE 48-603 HM
z DIN 51524 TEIL 2 H-LP
z HAGGLUNDS DENISON HFO-HF2
z CINCINNATI P68, 69, 70

Viscosity : ISO VG32

These oils should have antiwear, antifoam, antirust

and antioxidation additives for heavy duty use as
stated by the oil supplier. ISO viscosity grade of 32
would normally be selected.
Select oil that meets below specifications. The following products are authorized for use.

z API GL-5
z MIL-L-2105 C, D Supplier Product Name

Gear Oil offers maximum protection against the TOTAL AZOLLA ZS

scoring and pitting of gear teeth and rolling element
bearings. SHELL TELLUS

Gear Oil can also provide excellent stability under MOBIL DTE20S'
high temperature conditions and has superior low
temperature performance. It will also give protection CALTEX RANDO HD
against rust and corrosion.
ESS NOTO H
• Oil Cooled Disc Brake (OCDB)
Select oil that meets below specifications. CASTROL HYSPIN AWS
: Universal Transmission Tractor Oil (UTTO)
The following UTTO products are authorized for use.

Supplier Product Name

TOTAL TRANSMISSION MP

MOBIL MOBIL FLUID 424

133
Maintenance Section

Lubricating Grease

NOTICE
Use MPGM for heavily loaded bearings and joints
where an extreme pressure grease will maximize
the life of DOOSAN equipment. This NLGI No. 2
grade is suitable for most temperatures.
If MPGM is not available, use a multipurpose type
grease which contains 3 to 5% molybdenum.

This NLGI no. 2 grade is recommended for light duty

automotive type applications where a high
temperature [ up to 175°C (350°F) ] is required.
This grease offers excellent mechanical stability,
high resistance to oxidation, good rust protection
and excellent breakaway torque.

If this grease is not available, use a similar

multipurpose grease.

134
Maintenance Section

Lubricant Viscosities and Refill Capacities

Lubricant Viscosities Refill Capacities

LUBRICANT VISCOSITIES Refill D50/60/70/

D50/60/70S-5
FOR AMBIENT (OUTSIDE) TEMPERATURES Capacities 80/90S-5
(2 speed)
G50/60/70S-5
(Approximate) (3 speed)
Compartment Oil °C °F
Compartment
or System Viscosities Min Max Min Max Liters Liters Liters
or System
Engine SAE Engine
-20 +40 -4 +104
Crankcase 10W30 Crankcase 20.5 20.5 4.3
(LP) and Lift w/Filter
Chains SAE
-30 +30 -22 +86 Cooling System
API SJ 5W30
w/Coolant 23 18.5 19.0
Engine Recovery Bottle
Crankcase Fuel Tank -
SAE Diesel
140 140 -
(Diesel) -15 +50 +5 +122
15W40 Power Shift
API CH4 or 23 11 11
ACEA E5 Transmission
Power Shift SAE 10W -20 -22 -4 +72 Hydraulic
Power 117 117 117
Transmission Steering
SAE 30 +10 +50 +50 +122 Proper quantity Proper quantity Proper quantity
API CD/TO-2 System
Hydraulic and ISO VG32 -20 +30 -4 +86 Shoe
11.8 11.8 11.8
Power Steering ISO VG46 -10 +40 +14 +104 Drive Brake
System Axle
Disc
ISO 6743/4 HM ISO VG68 0 +50 +32 +122 Brake 14.0 14.0 14.0
Shoe (OCDB)
Brake SAE Brake
-20 +50 -4 +122 Reservoir
API 80W90 1.0 1.0 1.0
Drive (Only for
GL-5 OCDB)
Axle
Housing Disc
Brake
ISO VG68 -20 +80 -4 +176
(OCDB)
UTTO
Brake Reservoir
(Only for OCDB) ISO VG32 -20 +30 -4 +86
ISO 6743/4 HM

The SAE grade number indicates the viscosity of oil.

A proper SAE grade number should be selected
according to ambient temperature.

135
Maintenance Section

Maintenance Intervals First 250 Service Hours or a Month

Hydraulic Return Filter – Change.......................... 159

NOTICE Every 250 Service Hours or Monthly

All maintenance and repair, except every 10 service
hours or daily, on the lift truck must be performed by Air Intake System - Check, Clean......................... 160
qualified and authorized personnel only. Engine Oil & Filter(LP Engine Only) - Change..... 163
Hydraulic Oil Level – Check .................................. 164
Drive Axle Oil Level – Check................................. 164
NOTICE Mast, Carriage, Lift Chains & Attachments - Inspect,
Lubricate ................................................................. 165
Careless disposal of waste oil can harm the Steering Mechanism - Check, Lubricate .............. 166
environment and can be dangerous to persons. Battery Terminal - Clean, Inspect ......................... 167
Always dispose of waste oil to an authorized Wheel Bolts & Nuts - Inspect................................. 167
personnel only.
Every 500 Service Hours or 3 Months

Belts (Diesel E/G Only) - Check, Adjust ............... 168

When Required
Mast Hinge Pins – Lubricate ................................. 168
Tilt Cylinders - Check, Adjust, Lubricate .............. 169
Engine Valve Lash (Diesel E/G Only) - Check, Crosshead Rollers - Inspect.................................. 169
Adjust.......................................................................140 Transmission Oil Filter (2 Speed Only) – Change ... 169
Priming the Fuel System (Diesel Engine Only) ....140 Parking Brake - Test, Adjust.................................. 169
Test Fuel System for Leaks (LP Engine Only) .....141 Drive Axle Oil (OCDB) - Change........................... 169
Fuel Tank Filter Cap & Screen - Clean.................142 Horn and Lights(If Equipped) – Check ................. 170
Seat - Check, Lubricate..........................................142 Overhead Guard – Inspect .................................... 170
Fuses, Bulbs & Circuit Breaker - Change, Reset...143 Steer Susension – Inspect..................................... 170
Tires and Wheels - Inspect, Check .......................144 Universal Joint - Inspect, Lubricate....................... 170
Radiator Cap - Clean, Change ..............................145 Engine Oil & Filter(Diesel Engine Only) – Change
Carriage Roller Extrusion - Adjust.........................145 ................................................................................. 171
Brake Oil (OCDB) – Check ....................................146 Inspect Vacuum Lines and Fittings (G643(E) Engine
only)......................................................................... 171
Every 10 Service Hours or Daily Fuel Trim Valve(FTV) Inspection (G643E Engine
only)......................................................................... 171
Inspection Engine for Fluid Leaks .........................147 Inspect Electrical System (G643E Engine only) .. 171
Engine Oil Level - Check .......................................147
Coolant Level – Check ...........................................147 Every 1000 Service Hours or 6 Months
Air Cleaner Indicator – Check................................148
Inspect Foot Pedal Operation (LP Engine Only)..149 Carburetor (LP - Gas Engine Only) - Adjust, Clean
Inspect Engine for Exhaust Leaks.........................149 ................................................................................. 172
Walk-Around Inspection - Inspect .........................149 Fuel Filter - Check, Clean, Change ...................... 172
Mast Channels – Lubricate ....................................150 Air Intake System - Change .................................. 172
Transmission Oil Level – Check............................151 Inspect Coolant Hoses (LP Engines Only)........... 173
LP Regulator/Converter Inspection (LP Engine Only)
First 50-100 Service Hours or a Week ................................................................................. 173
Fuel Lines & Fittings – Check ............................... 173
Engine Oil & Oil Filter (Diesel E/G Only) - Change Inspect Mixer Assembly (LP Engine Only)........... 173
.................................................................................152 Inspect Throttle Assembly (LP Engine Only) ....... 173
Transmission Oil & Oil Filter – Change.................153 Hydraulic Oil, Return Filter, Strainer & Breather -
Drive Axle Oil - Change..........................................155 Check, Clean, Change........................................... 174
Parking Brake - Test, Adjust..................................157 Transmission Oil & Filter (3 Speed Only) – Change
................................................................................. 175
Transmission Oil (2 Speed Only) – Change......... 175
Lift Chains - Test, Check, Adjust........................... 175

136
Maintenance Section

Every 1500 Service Hours or 9 Months

Drive Axle Oil (Shoe Brake Only) - Change .........178

Inspect Ignition System (LP Engine Only) ............178
Replace Spark Plugs (LP Engine Only)................178
Replace LP Fuel Filter Element (LP Engine Only)
.................................................................................179
Testing Fuel Lock-off Operation (LP Engine Only)
.................................................................................180

Every 2000 Service Hours or Yearly

Steer Wheel Bearings - Reassemble....................181

Cooling System - Clean, Change..........................182
Fork – Inspect .........................................................183

Every 2500 Service Hours or 15 Months

Inspect Battery System ..........................................185

Checking the TMAP Sensor (LP Engine Only) ....185
Inspect for Intake Leaks (LP Engine Only)...........186
Replace PCV Valve and breather element - Change
(LP Engine Only) ....................................................186
Replace Oxygen Sensor (G643E Engine Only) ...186

137
Maintenance Section

Quick Reference to Maintenance Schedule FIRST EVERY

2500 Service Hours or 15 Months

1000 Service Hours or 6 Months

1500 Service Hours or 9 Months

50-100 Service Hours or a Week

250 Service Hours or a Monthly

500 Service Hours or 3 Months

250 Service Hours or a Month

2000 Service Hours or Yearly

10 Service Hours or Daily
ITEMS SERVICES PAGE

When Required
Air Cleaner Indicator Check 148 O
Air Intake System Change 172 O
Air Intake System Check, Clean 160 O
Battery Terminal Clean, Inspect 167 O
Belts (Diesel E/G Only) Check, Adjust 168 O
Brake Oil (OCDB) Check 146 O
Carburetor (LP - Gas Engine Only) Adjust, Clean 172 O
Carriage Roller Extrusion Adjust 145 O
Checking the TMAP Sensor (LP Engine Only) 185 O
Coolant Level Check 147 O
Clean,
Cooling System 182 O
Change
Crosshead Rollers Inspect 169 O
Drive Axle Oil Change 155 O
Drive Axle Oil (OCDB) Change 169 O
Drive Axle Oil (Shoe Brake Only) Change 178 O
Drive Axle Oil Level Check 164 O
Engine Oil & Filter(Diesel Engine Only) Change 171 O
Engine Oil & Filter(LP Engine Only) Change 163 O
Engine Oil & Oil Filter (Diesel E/G Only) Change 152 O
Engine Oil Level Check 147 O
Engine Valve Lash (Diesel E/G Only) Check, Adjust 140 O
Fork Inspect 183 O
Check, Clean,
Fuel Filter 172 O
Change
Fuel Lines & Fittings Check 173 O
Fuel Tank Filter Cap & Screen Clean 141 O
Fuel Tank Filter Cap & Screen Clean 142 O
Fuel Trim Valve(FTV) Inspection (G643E
171 O
Engine only)
Change,
Fuses, Bulbs & Circuit Breaker 143 O
Reset
Horn and Lights(If Equipped) Check 170 O
Hydraulic Oil Level Check 164 O
Check, Clean,
Hydraulic Oil, Return Filter, Strainer & Breather 174 O
Change
Hydraulic Return Filter Change 159 O
Inspect Mixer Assembly (LP Engine Only) 173 O
Inspect Battery System 185 O
Inspect Coolant Hoses (LP Engines Only) 173 O
Inspect Electrical System (G643E Engine only) 171 O
Inspect Engine for Exhaust Leaks 149 O
Inspect Foot Pedal Operation (LP Engine Only) 149 O

138
Maintenance Section

Quick Reference to Maintenance Schedule FIRST EVERY

2500 Service Hours or 15 Months

1000 Service Hours or 6 Months

1500 Service Hours or 9 Months

50-100 Service Hours or a Week

250 Service Hours or a Monthly

500 Service Hours or 3 Months

250 Service Hours or a Month

2000 Service Hours or Yearly

10 Service Hours or Daily
ITEMS SERVICES PAGE

When Required
Inspect for Intake Leaks (LP Engine Only) 186 O
Inspect Ignition System (LP Engine Only) 178 O
Inspect Throttle Assembly (LP Engine Only) 173 O
Inspect Vacuum Lines and Fittings (G643(E)
171 O
Engine only)
Inspection Engine for Fluid Leaks 147 O
Lift Chains - Test, Check, Adjust 175 O
LP Regulator/Converter Inspection (LP Engine
173 O
Only)
Mast Channels Lubricate 150 O
Mast Hinge Pins Lubricate 168 O
Inspect,
Mast, Carriage, Lift Chains & Attachments 165 O
Lubricate
Overhead Guard Inspect 170 O
Parking Brake Test, Adjust 157 O
Parking Brake Test, Adjust 169 O
Priming the Fuel System (Diesel Engine Only) 140 O
Radiator Cap Clean, Change 145 O
Replace LP Fuel Filter Element (LP Engine
179 O
Only)
Replace Oxygen Sensor (G643E Engine Only) 186 O
Change (LP
Replace PCV Valve and breather element 186 O
Engine Only)
Replace Spark Plugs (LP Engine Only) 178 O
Check,
Seat 142 O
Lubricate
Steer Susension Inspect 170 O
Steer Wheel Bearings Reassemble 181 O
Check,
Steering Mechanism 166 O
Lubricate
Test Fuel System for Leaks (LP Engine Only) 141 O
Testing Fuel Lock-off Operation (LP Engine
180 O
Only)
Check, Adjust,
Tilt Cylinders 169 O
Lubricate
Tires and Wheels Inspect, Check 144 O
Transmission Oil & Filter (3 Speed Only) Change 175 O
Transmission Oil & Oil Filter Change 153 O
Transmission Oil (2 Speed Only) Change 175 O
Transmission Oil Filter (2 Speed Only) Change 169 O
Transmission Oil Level Check 151 O
Inspect,
Universal Joint 170 O
Lubricate
Walk-Around Inspection Inspect 149 O
Wheel Bolts & Nuts Inspect 167 O

139
Maintenance Section

When Required
You must read and understand the warnings and instructions contained in the Safety section of this manual,
before performing any operation or maintenance procedures.

Engine Valve Lash (Diesel E/G Priming the Fuel System (Diesel
Only) - Check, Adjust Engine Only)

NOTICE Bleeding the Fuel System

The valve clearances are to be adjusted at the times After changing the fuel filter, or after having serviced
of the following situations. any part of the fuel system, make sure that the air is
z When the engine is overhauled and the cylinder bled from the system.
heads are disassembled.
z When severe noise comes from valve train. 1. Release the feed pump cap (1) on the injection
z When the engine is not normally operated even pump.
though there is no trouble in the fuel system.
2. Release an air bleed nut (2) on the injection
pump.

WARNING 3. Operate feed pump vertical until completely

remove an air.
To prevent possible injury when adjusting diesel
engines, Do not use the starter motor to turn the 4. Tighten air bleed nut (2).
flywheel.
Hot engine components can cause burns. Allow 5. Make sure to check leakage of injection pump &
additional time for the engine to cool before filter after operating feed pump many times.
measuring valve clearance.

NOTICE
Measure the valve lash with the engine stopped. To
obtain an accurate measurement, allow at least 20
minutes for the engine cylinder head and block to
cool.

Set the clearance to the nominal appropriate

clearance given in the "Valve Clearance Setting"
chart shown below.

Valve Clearances
Engine Valve Clearance

5.8 Liter Exhaust Valves .40 mm (.16 in)

(DB58S) Diesel Intake Valves .40 mm (.16 in)

Refer to the "Service Manual" for the complete valve

adjustment procedure.

NOTE: In case of LP Engine, no valve adjustment is

necessary.

140
Maintenance Section

Draining the Water From the Fuel Filter Test Fuel System for Leaks (LP
Diesel Engine Only Engine Only)

Check
Points

Typical Example

1. Turn the wing nut counter clockwise to open the z Obtain a leak check squirt bottle or pump spray
drain valve on the bottom of the fuel filter. bottle.
z Fill the bottle with an approved leak check
2. Drain some fuel (and any water) until clean fuel solution.
flows from the filter.
z Spray a generous amount of the solution on the
fuel system fuel lines and connections, starting
at the storage container.
z Wait approximately 15-60 seconds then perform
a visual inspection of the fuel system. Leaks will
cause the solution to bubble.
z Repair any leaks before continuing.
z Crank the engine through several revolutions.
This will energize the fuel lock-off and allow fuel
to flow to the pressure regulator/converter.
Apply additional leak check solution to the
regulator/converter fuel connections and
housing. Repeat leak inspection as listed above.
z Repair any fuel leaks before continuing.

WARNING
Prior to any service or maintenance activity, Test
Fuel System for Leaks

141
Maintenance Section

Fuel Tank Filter Cap & Screen - Seat - Check, Lubricate

Clean
Park the lift truck with the forks lowered, parking
brake applied, transmission in neutral and the
engine stopped.

Typical Example

Check the operation of the seat adjuster rod. Make

sure that the seat slides freely on its track. Lightly oil
the seat slider tracks if necessary.

Typical Example

1. Raise the left side cover.

2. Remove the filter cap assembly. Separate the

cap from the screen. Clean both in clean,
nonflammable solvent.

3. Dry and assemble cap and screen.

4. Install cap assembly.

WARNING
Fuel leaked or spilled onto hot surfaces or
electrical components can cause a fire.

5. Drain moisture and sediment from fuel tank as

required by prevailing conditions.

142
Maintenance Section

Fuses, Bulbs & Circuit Breaker - Fuse & Relay ( LP Engine Only)
Change, Reset
Fuses
NOTE: If a fuse filament separates, use only the
same type and size fuses for replacement. If
the filament in a new fuse separates. have
the circuits and instruments checked.

NOTICE
Always replace fuses with ones of the correct
ampere rating.
(1)Relay
(2)Fuse

Remove the front cover of fuse box. The fuses are Located on top of engine
located under the cover.
Circuit Breaker
Fuse - Protects an electrical circuit from
an overload. Opens (filament separates) 1. Raise the floor mat.
if an overload occurs.

Typical Example LP Engine Truck

2. The main circuit breaker is located on the rear of

the support for the controls.

Typical Example NOTE: To reset circuit breakers push on the button.

Check the fuses. Use a flashlight, if necessary. The button should stay in if the breaker is
reset. If the button will not stay in, or comes
Fuses are identified as follows :
out shortly after reset, have the circuits
checked.
1. Horn - 10 amp.

2. Head Lamp - 15 amp

3. Fwd./Rev. Solenoid, lamp Relay & Back-up

Lamp/alarm - 10 amp.

4. Instrument Panel & Fuel Shutoff - 15 amp.

5. Turn Signal Lamp, Stop/Strobe Lamp - 15 amp

6. Start Relay - 10 amp

143
Maintenance Section

Bulbs Check Inflation and Damage

Bulbs are identified as follows Inspect tires for wear, cuts, gouges and foreign
objects. Look for bent rims and correct seating of
[Diesel Engine] locking ring.
1. Bulb-head lamp halogen(24V-70/75W)
Check tires for proper inflation. See "Tire Inflation
2. Bulb-rear(24V-55W) Pressures".
3. Bulb-turn signal(Front, 24V-25/10W)
4. Bulb-turn signal(Rear, 24V-25W) To inflate tires always use a clip-on chuck with a
5. Bulb-stop & tail(24V-25/10W) minimum 60 cm (24 inches) length of hose to an
6. Bulb-back up(24V-10W) inline valve and gauge.
[LP Engine] Always stand behind the tread of the tire. NOT in
1. Bulb-head lamp halogen(12V-60/55W) front of the rim.
2. Bulb-rear(12V-55W)
3. Bulb-turn signal(Front, 12V-23/8W)
4. Bulb-turn signal(Rear, 12V-23W)
5. Bulb-stop & tail(12V, 23/8W)
6. Bulb-back up(12V-10W)

Tires and Wheels - Inspect, Check

WARNING
Servicing and changing tires and rims can be
dangerous and should be done only by trained Typical Example
personnel using proper tools and procedures.
Deflate tire before removing wheel nuts from the Do not reinflate a tire that has been run while flat or
truck. underinflated, without first checking to make sure
the rim is not damaged and is in the correct position.
If correct procedures are not followed while
servicing tires and rims, the assemblies could When tires are changed, be sure to clean all rim
burst with explosive force and cause serious parts and, if necessary, repaint to stop detrimental
physical injury or death. effects of corrosion. Sand blasting is recommended
for removal of rust.
Follow carefully the specific information
provided by your tire servicing man or dealer. Check all components carefully and replace any
cracked, badly worn, damaged and severely rusted
or corroded parts with new parts of the same size
and type. If there is any doubt, replace with new
parts.

Do not, under any circumstances, attempt to rework,

weld, heat or braze any rim components.

144
Maintenance Section

Radiator Cap - Clean, Change Clean Outside of Radiator Core

Clean Pressure Cap WARNING

Pressure air can cause personal injury.
When using pressure air for cleaning, wear a
protective face shield, protective clothing and
protective shoes.
The maximum air pressure must be below 205
kPa (30 psi) for cleaning purposes.

Compressed air, high pressure water or steam can

be used to remove dust, leaves and general debris
from a radiator. Clean as required by condition of
radiator.
The use of compressed air is preferred.
The radiator cap is located on the left side of the lift
truck. (Diesel Engine Truck)
The radiator cap is located on the right side of the lift Carriage Roller Extrusion - Adjust
truck. (LP Engine Truck)
1. Set the mast vertical.
WARNING
2. Lower the carriage completely.
Hot oil and components can cause personal
injury. Do not allow hot oil or components to 3. On full free lift and full free triple lift models, the
contact skin. bottom of the inner mast must be flush with the
bottom of the stationary mast.

4. Measure the distance from the bottom of the

inner upright to the bottom of carriage bearing.
1. Remove the radiator cap slowly to relieve
5. The measurement (A) must be as follows in
pressure.
Chart below.
2. Inspect the cap for damage, deposits or foreign
material. Clean the cap with a clean cloth or Height of carriage roller extrusion (A)
change the cap as necessary. STD mast FF mast FFT mast
D50/60/70S-5 (3 Speed, 2 Speed), G50/60/70S-5
3. Install the cap.
23 - 26
D80/90S-5(3 Speed)
42 - 42

145
Maintenance Section

Brake Oil (OCDB) – Check

Only for Oil Cooled Disc Brake

The brake reservoir is located on the left side of the

steering column.

1. Remove the filter cap.

2. Maintain the brake fluid level to the fluid level

mark on the brake system reservoir.

3. Clean and install the filter cap.

146
Maintenance Section

Every 10 Service Hours or Daily

You must read and understand the warnings and instructions contained in the Safety section of this manual,
before performing any operation or maintenance procedures.

Inspection Engine for Fluid Leaks Coolant Level – Check

WARNING
1. Start the engine and allow it to reach operating
temperatures. At operating temperature, the engine coolant is
hot and under pressure.
2. Turn the engine off.
Steam can cause personal injury.
3. Inspect the entire engine for oil and/or coolant
leaks. Check the coolant level only after the engine has
been stopped and the filter cap is cool enough
4. Repair as necessary before continuing. to touch with your bare hand.

Remove the filter cap slowly to relieve pressure.

Engine Oil Level - Check Cooling system conditioner contains alkali.

Avoid contact with the skin and eyes to prevent
personal injury.
1. Raise the hood and seat assembly.

WARNING
Hot oil and components can cause personal
injury. Do not allow hot oil or components to
contact skin.

Typical Example Diesel Engine Truck

Typical Example

2. Maintain oil level between the MAX. and MIN.

marks on the dipstick.

Typical Example LP Engine Truck

1. Observe the coolant level with engine cold.

Maintain coolant level to the proper line on
expansion bottle. If the expansion bottle has no
coolant, it will be necessary to check coolant at
the radiator filter neck.

147
Maintenance Section

2. Remove the radiator cap. Fill radiator to the top Air Cleaner Indicator – Check
of the filter neck. Inspect radiator cap. Replace if
damaged. Install the radiator cap.
Service Indicator

Typical Example
Typical Example Diesel Engine Truck
3. Start and run the engine to stabilize the coolant
level in the filter neck. If low, add coolant until it
reaches the top of the filter neck. Install the 1. Observe the air cleaner service indicator.
radiator cap. Observe coolant level in the
expansion bottle. If necessary, add coolant to 2. Service the air cleaner when the RED band in
bring the coolant to the appropriate line on the the service indicator, locks in the visible position.
expansion bottle. See topic, "Air Intake System - Check, Clean" in
"Every 250 Service Hours or Monthly".
4. Stop the engine.
NOTE: Service the element more frequently, as
5. Inspect the cooling system for leaks, hose required, in severe dust or lint conditions.
cracks or loose connections. Also, service it more frequently where the
operator is required to wear a respirator.

WARNING 3. Close hood and seat assembly.

Pressure air can cause personal injury.
When using pressure air for cleaning, wear a
protective face shield, protective clothing and
protective shoes.
Maximum air pressure must be less than 205
kPa (30 psi) for cleaning purposes.

6. Blow any dust and lint from the radiator fins.

148
Maintenance Section

Inspect Foot Pedal Operation (LP

3. Inspect the hydraulic system for leaks, worn
Engine Only) hoses or damaged lines.

4. Look for transmission and driveaxle leaks on the

1. Verify foot pedal travel is smooth without sticking. lift truck and on the ground.

WARNING
When the acceleration pedal harness is
connected or disconnected, should be worked
key OFF condition.
If not, occurred malfunction, can cause the
personal injury.

Inspect Engine for Exhaust Leaks

Typical Example
1. Start the engine and allow it to reach operating
temperatures. 5. Inspect the operator's compartment for loose
items and cleanliness.
2. Perform visual inspection of exhaust system.
Repair any/all leaks found. 6. Inspect the instrument panel for broken gauges
and indicator lights.

Walk-Around Inspection - Inspect 7. Test the horn and other safety devices for
proper operation.
For maximum service life of the lift truck, make a
thorough walk-around inspection. Look around and
under the truck for such items as loose or missing
bolts, debris or dirt buildup, fuel, oil or coolant leaks
and cut or gouged tires.

Have any repairs made and debris removed, as

needed.

Typical Example Diesel Engine(3 Speed)

Typical Example

1. Inspect the tires and wheels for cuts, gouges,

foreign objects, inflation pressure and loose or
missing bolts.

2. Inspect the mast and lift chains for wear, broken

Typical Example Diesel Engine(2 Speed)
links, pins and loose rollers.

149
Maintenance Section

Mast Channels – Lubricate

LP Engine

8. Inspect engine compartment for oil, coolant and Typical Example

fuel leaks.
The channels on the roller-type mast require a
9. Inspect the cooling system for leaks, worn hoses break-in period. Apply a light film of lubricant on the
and debris buildup. channels where the rollers ride. This will prevent
metal peel until the rollers set a pattern.
10. Inspect the carriages, forks or attachments for
wear, damage, and loose or missing bolts.

z Visually inspect forks for cracks, especially in

the heel section, around the mounting brackets,
and all weld areas.

z Inspect for broken or jagged fork tips, bent or

twisted blades and shanks.

z Make sure positioning lock is in place and

working. Lock the forks in position before using
the truck. See Step 7 of "Forks" in "Every 2000
Service Hours or Yearly".

z Remove all defective forks from service.

150
Maintenance Section

Transmission Oil Level – Check 4. Shift the transmission into NEUTRAL. Engage
the parking brake.

WARNING
Hot oil and components can cause personal
injury. Do not allow hot oil or components to
contact skin. 5. Loosen the oil dipstick counter-clockwise,
remove and clear it. Insert the oil dipstick slowly
into the oil level tube until contact is obtained,
1. Start and operate the lift truck until the and pull the dipstick out again.
transmission reaches normal operating
temperature (about 80°C). 6. When the oil temperature is around 40°C, the
marking on the oil dipstick must be lying above
2. Park the lift truck level with the forks lowered, the cold start mark, "COLD". When the oil
parking brake applied and the transmission temperature is around 80°C, the oil level must
controls in NEUTRAL. be lying in the zone "HOT".

3. With the service brake applied and the engine at 7. Install the oil dipstick again and tighten it
low idle, shift the directional control lever to clockwise.
forward and then to reverse, to fill the clutches.
8. Check for oil leaks at the filter and drain plug.

9. Stop the engine.

Typical Example D50/60/70/80/90S-5 (3 Speed)

Typical Example D50/60/70S-5 (2 Speed), G50/60/70S-5

151
Maintenance Section

First 50-100 Service Hours or a Week

You must read and understand the warnings and instructions contained in the Safety section of this manual,
before performing any operation or maintenance procedures.

Engine Oil & Oil Filter (Diesel E/G

Only) - Change NOTICE
Careless disposal of waste oil can harm the
The percentage of sulfur in the fuel will affect the environment and can be dangerous to persons.
engine oil recommendations. If the fuel has over Always dispose of waste oil to authorized and
0.5% sulfur content, the engine oil must have a TBN licensed personnel only.
of 20 times the percentage of fuel sulfur (TBN as
measured by the ASTM D-2896 method). Your oil
supplier should be able to furnish the correct oils. 3. Remove the crankcase drain plug and allow oil
to drain. Clean and install drain plug.
1. Operate lift truck a few minutes to warm oil. Park
the lift truck with the forks lowered, parking 4. Raise the left side cover.
brake applied, transmission in neutral and the
engine stopped. 5. Remove and discard oil filter element.
2. Raise rear of lift truck off the ground and block 6. Wipe sealing surface of oil filter element
securely. mounting base. Make sure all of the old gasket
is removed.
WARNING
7. Before installing a new filter element, apply a
Hot oil and components can cause personal small amount of clean engine oil to the filter
injury. Do not allow hot oil or components to element gasket.
contact skin.
8. Install the new filter element. When the gasket
contacts the base, tighten it 3/4 of a turn more.
Do not overtighten.

9. Raise the lift truck, remove the blocking and

lower the lift truck.

Typical Example Diesel Engine Truck

152
Maintenance Section

Transmission Oil & Oil Filter –

Change

WARNING
Hot oil and components can cause personal
injury. Do not allow hot oil or components to
contact skin.

Park the lift truck level, with the forks lowered,

Typical Example Diesel Engine Truck
parking brake engaged, transmission in NEUTRAL
and the engine stopped.
10. Fill the crankcase. See "Refill Capacities".

11. Start the engine and allow the oil to fill the filter
and passages.

12. Check for oil leaks.

13. Stop the engine and measure the oil level.

Maintain the oil level between the MAX. and MIN
marks on dip stick.

14. Close side cover.

Typical Example D50/60/70/80/90S-5 (3 Speed)

NOTICE
Servicing of the engine oil and oil filter element will
largely affect the engine performance as well as the
engine life.

Engine oil and filter element must be changed after

the first 50-100 Service hours or a week.

Typical Example D50/60/70S-5 (2 Speed), G50/60/70S-5

1. Remove drain plug. Allow the oil to drain.

NOTICE
Careless disposal of waste oil can harm the
environment and can be dangerous to persons.
Always dispose of waste oil to authorized and
licensed personnel only.

153
Maintenance Section

5. Put a small amount of clean oil on the seal

gasket on the new filter. Install the filter by hand.
When the filter contacts the base, tighten it an
additional 3/4 turn.

6. Close the hood and seat assembly.

7. Open the access door in the floor plate.

Typical Example D50/60/70S-5 (2 Speed), G50/60/70S-5

2. Wash the strainer (screen) , spring and drain

plug in clean, nonflammable solvent. Dry the
strainer, spring and drain plug. [D50/60/ 70S-5
(2 Speed), G50/60/70S-5 Only]

3. Install the drain plug.

Typical Example D50/60/70/80/90S-5 (3 Speed)

Typical Example D50/60/70S-5 (2 Speed), G50/60/70S-5

8. Remove the dip stick/filter cap. Fill the

compartment with oil. See "Refill Capacities".
Install the dip stick/filter cap.

9. Start the engine.

10. With the service brake applied and engine at low

idle, shift the transmission to forward and
reverse to fill the clutches.
Typical Example D50/60/70S-5 (2 Speed), G50/60/70S-5
11. Shift the transmission into NEUTRAL. Engage
4. Rotate the oil filter counter clockwise to remove the parking brake.
it.
12. Loosen the oil dipstick counter-clockwise,
• Replacement Interval of Transmission Oil Filter remove and clear it. Insert the oil dipstick slowly
into the oil level tube until contact is obtained,
D50/60/70S-5 (3 Speed) and pull the dipstick out again.
: Every 1,000 Service Hours or 6 Months.

D50/60/70S-5 (2 Speed), G50/60/70S-5

: Every 500 Service Hours or 3 Months.

154
Maintenance Section

13. When the oil temperature is around 40°C, the Drive Axle Oil - Change
marking on the oil dipstick must be lying above
the cold start mark, "COLD". When the oil
Park the lift truck on a level surface, parking brake
temperature is around 80°C, the oil level must
applied, transmission in neutral.
be lying in the zone "HOT".

14. Install the oil dipstick again and tighten it WARNING

clockwise.
Hot oil and components can cause personal
15. Check for oil leaks at the filter and drain plug. injury. Do not allow hot oil or components to
contact skin.
16. Stop the engine.

Shoe Brake Type

Typical Example

1. Raise the carriage high enough to access the

drive axle housing level/fill plug with breather.

2. Block the bottom of the carriage with a block of

wood to hold the carriage in the raised position.

3. Turn the ignition switch OFF.

4. Remove the drive axle housing level/fill plug with

breather.
Wash them in clean, nonflammable solvent.

5. Place an appropriate container under the axle to

catch the oil as it drains.
Remove the drive axle housing drain plug.

6. Allow the oil to drain completely out.

Discard the old oil according to local regulations.

7. Clean and reinstall the drive axle housing drain

plug.

155
Maintenance Section

Oil Cooled Disc Brake (OCDB) Type

Park the lift truck on a level surface. Apply the
parking brake. Place the directional control level in
NEUTRAL and stop the engine.

Typical Example

8. Remove planetary hub level/drain/fill plugs.

Allow the oil to drain completely out.
Reinstall the planetary hub plugs.

9. Fill the drive axle housing with sufficient fresh oil

through the drive axle housing level/fill plug 1. Remove three drain plugs of the drive axle
opening until it reaches the bottom of the hole. housing and both wheel ends. Allow the oil to
See the section, "Lubricant the Viscosities." and drain into a suitable container. Clean the
"Refill Capacities" for the type and amount of oil magnetic drain plugs. Check O-ring seal and
to use. replace if necessary.

10. Remove the wood blocking and Lower the 2. Install the drain plug.
carriage.
3. Remove strainer assembly.
11. Operate the lift truck for a few minutes.
And align the planetary hub drain/fill/level plugs
to the horizontal position. Remove the plugs.

12. Fill the planetary hubs, through the drain/fill/level

hole, until the oil reaches the hole.
See the section, "Refill Capacities".

13. Clean and reinstall the planetary hub drain/fill/

level plugs.

4. Wash the strainer assembly in clean,

nonflammable solvent and dry it.

5. Install the strainer assembly and reconnect the

hose and harness.

156
Maintenance Section

Parking Brake - Test, Adjust

WARNING
To prevent personal injury, the operator must be
ready to use the service brake if the parking
brake is not adjusted correctly and the lift truck
starts to move.

NOTE: Be sure area around the lift truck is clear of

6. Remove the dip stick/filter cap. Fill the drive axle personnel and obstructions.
housing with oil. See "Lubricant Specification -
Drive Axle Oil" and "Refill Capacity". 1. Drive the lift truck with a rated load up a 15%
incline.
7. Start the lift truck. With the engine at low idle,
place the directional control lever to the 2. Halfway up the incline, stop the lift truck by
NEUTRAL. applying the service brakes.

8. Maintain the oil level between lower mark and

upper mark on the dip stick/filter cap.

9. Install the dip stick/filter cap.

Typical Example

3. Engage the parking brake and slowly release the

service brake.

4. If the parking brake has the correct adjustment

the lift truck will be hold in place. If the parking
brake does not hold, adjust the parking brake.

157
Maintenance Section

To Adjust
Park the lift truck level, with the forks lowered,
transmission in NEUTRAL, the engine stopped and
the wheels securely blocked.

Typical Example

1. Release the parking brake

2. Turn the adjustment knob, clockwise to tighten

the brake.

3. Test the parking brake adjustment. Repeat the

adjustment procedure, if necessary.

158
Maintenance Section

First 250 Service Hours or a Month

You must read and understand the warnings and instructions contained in the Safety section of this manual,
before performing any operation or maintenance procedures.

Hydraulic Return Filter – Change 4. Clean the filter housing with a clean,
nonflammable solvent.

5. Clean the housing base.

WARNING
6. Insert a new filter element into the filter housing.
Hot oil and components can cause personal
injury. Do not allow hot oil or components to 7. Inspect the filter housing seal. Replace if
contact skin. necessary.

8. Apply a small amount of clean oil to the filter

Park the lift truck level with the forks lowered, element seal and housing seal.
parking brake engaged, transmission in NEUTRAL
and the engine stopped. 9. Install the filter housing with filter to the housing
base. Install bolts and tighten 20 to 30 N•m (15
to 20 lb•ft).

10. Start the engine and operate the hydraulic

controls, and the steering system, through a few
cycles to fill the lines. Look for oil leaks.

11. Stop the engine and check the oil level. With all
cylinders retracted, maintain the oil level to the
FULL mark on the dip stick/filter cap assembly.

1. Remove the floor plate.

2. Remove bolts and filter housing.

3. Remove and discard filter element from filter

housing.

159
Maintenance Section

Every 250 Service Hours or Monthly

You must read and understand the warnings and instructions contained in the Safety section of this manual,
before performing any operation or maintenance procedures.

Air Intake System - Check, Clean Servicing Filter Element

Precleaner (If Equipped)

NOTICE
Never service filter with the engine running.

NOTICE
Never service precleaner with the enginerunning.

Typical Example Diesel Engine Truck

Typical Example

1. Check the precleaner bowl for dirt build-up. If the

dirt is up to the line, remove the precleaner bowl
and empty it. Periodically wash the cover and
bowl in water.

Typical Example LP Engine Truck

Service the air cleaner when the red target in the

service indicator stays locked in the visible position
with the engine stopped.

1. To service the air cleaner, raise the side cover.

Loosen the cover latches and remove the cover.

160
Maintenance Section

Diesel Engine Truck (Dual Element) 10. Start the engine and observe the position of the
indicator. If the indicator shows RED after the
installation of the primary element, install
another clean or a new element or, replace the
secondary element. See topic, "Air Intake
1 System - Change" in Every 1000 Service Hours
or 6 months section.

11. Stop the engine and close the right side cover.

Typical Example

LP Engine Truck

Typical Example

2. Replace the nut or clamp(1).

3. Remove the element to separate it from its base

and remove it from the air cleaner housing.

4. Clean and inspect the element (2).

5. Clean the inside of air cleaner housing and the

cover. Inspect all connections between the air
cleaner and carburetor. Check intake hose for
cracks, damage and loose clamps. Tighten or
replace parts as necessary to prevent leakage.

NOTICE
Do not allow dirty air to enter the intake hose when
cleaning the inside of the cleaner housing.

6. Check the air cleaner housing for loose latches.

7. Reset the air cleaner service indicator.

8. Install the air filter element.

9. Install the cover and tighten the cover latches.

161
Maintenance Section

Cleaning Primary Filter Elements Water-280 kPa (40 psi) Maximum

Pressure
WARNING
Pressure air can cause personal injury.

When using pressure air for cleaning, wear a

protective face shield, protective clothing and
protective shoes.

The maximum air pressure must be below 205

kPa (30 psi) for cleaning purposes.

NOTICE Direct water on the inside and outside of the

element along the length of the pleats. Air dry it
Do not clean the elements by bumping or thoroughly and then examine it.
tapping them.
Detergent
Inspect filter elements after cleaning. Do not use
a filter with damaged pleats, gaskets or seals. 1. Wash the element in warm water and mild
household detergent.
When cleaning with pressure air, use 205 kPa
(30 psi) maximum pressure to prevent filter 2. Rinse the element with clean water. See
element damage. instructions in preceding topic for cleaning with
water.
When cleaning with pressure water, use 280 kPa
(40 psi) maximum pressure to prevent filter 3. Air dry it thoroughly, and then examine it.
element damage.

Checking Element
Have spare elements on hand to use while cleaning
used elements.

The primary element should be replaced after a

year’s service or after cleaning no more than 6
times.

Air-205 kPa (30 psi) Maximum Pressure

1. Insert a light inside the clean dry element and

examine it. Discard the element if tears, rips or
damage are found.

2. Wrap and store good elements in a clean, dry

place..

Direct air on the inside and outside of the element

along the length of the pleats. Check the element for
any tears, rips or damage.

162
Maintenance Section

Engine Oil & Filter(LP Engine 10. Fill the crankcase. See " Refill Capacities ".

Only) - Change 11. Start the engine and allow the oil to fill the filter
and passages.

LP Engine Crankcase 12. Check for oil leaks.

1. Operate lift truck a few minutes to warm oil. Park

the lift truck with the forks lowered, parking
brake applied, transmission in neutral and the
engine stopped.

2. Raise rear of lift truck off ground and block

securely.

WARNING
Hot oil and components can cause personal
injury. Do not allow hot oil or components to
contact skin. 13. Stop the engine and measure the oil level.
Maintain the oil level to the FULL mark on the
dip stick.

14. Close hood and seat assembly.

3. Remove the crankcase drain plug and allow oil

to drain. Clean and install drain plug.
4. Raise the hood and seat assembly.

5. Remove and discard oil filter element.

6. Wipe sealing surface of oil filter element

mounting base. Make sure all of the old gasket
is removed.

7. Before installing a new filter element, apply a

small amount of clean engine oil to the filter
element gasket.

8. Install the new filter element. When the gasket

contacts the base, tighten it 3/4 of a turn more.
Do not overtighten.

9. Raise the lift truck, remove the blocking and

lower the lift truck.

163
Maintenance Section

Hydraulic Oil Level – Check Drive Axle Oil Level – Check

WARNING WARNING
At operating temperature, the hydraulic tank is Hot oil and components can cause personal
hot and under pressure. injury. Do not allow hot oil or components to
Hot oil can cause burns. contact skin.

Remove the filter cap only when the engine is

stopped, and the cap is cool enough to touch
with your bare hand. Remove the filter cap Shoe Brake Type
slowly to relieve pressure.
Park the lift truck on a level surface, parking brake
applied, transmission in neutral.

1. Operate the lift truck for a few minutes to warm 1. Raise the carriage high enough to access the
the oil. Park the lift truck on a level surface, with drive axle hosing level/fill plug.
the forks lowered, mast tilted back, parking
brake engaged, transmission in NEUTRAL and 2. Block the bottom of the carriage with a block of
the engine stopped. wood to hold the carriage in the raised position.

2. Raise the hood and seat assembly. Make sure 3. Turn the ignition switch OFF.
the air lift cylinder securely holds the hood open.

4. Remove the drive axle housing level/fill plug.

Typical Example

3. Check the oil level. 5. Check if oil reaches the bottom of level/fill hole.

4. Maintain the oil level to the FULL mark on the 6. Maintain oil level to the bottom of level/fill hole.
dip stick/filter cap assembly.
7. Install the drive axle housing level/fill plug.
5. Install the dip stick/filter cap assembly.
8. Remove the wood blocking and lower the
carriage.

9. Align planetary hub level/drain/fill plugs to the

horizontal position.

10. Remove the plugs and check if oil reaches the

level/drain/fill hole.

11. Maintain the oil level to the hole.

12. Install the planetary hub level/drain/fill plugs.

164
Maintenance Section

Oil Cooled Disc Brake (OCDB) Type Mast, Carriage, Lift Chains &
Park the lift truck on a level surface. Apply the Attachments - Inspect, Lubricate
parking brake. The engine is at the low idle. Place
the directional control level in NEUTRAL.
1. Operate the lift, tilt and attachment controls.
Listen for unusual noises. These may indicate a
need for repair.

2. Check for loose bolts and nuts on the carriage.

Remove any debris from the carriage and mast.

3. Check the forks and attachments for free

operation and damage. Have repairs made if
necessary.

1. Remove the dip stick/filter cap. Observe the oil

level.

2. Maintain the oil level between lower mark and

upper mark on the dip stick/filter cap.

3. Install the dip stick/filter cap.

Typical Example

4. Brush a film of oil on all links of the chain.

5. Raise and lower the carriage a few times to

allow lubricant to enter into the chain links.

NOTICE
Lubricate chains more frequently than normal in
applications where the lift truck is operating in a
atmosphere which could cause corrosion of
components or when lift truck must work in rapid lift
cycles.

6. Check the air cleaner housing for loose latches.

165
Maintenance Section

Lubricate Mast Side Rollers Steering Mechanism - Check,

Lubricate

Typical Example
Typical Example
1. Lubricate the 2 fittings on the inner mast.
1. Lubricate the steer axle king pins, total of four
fittings. Two on the right side and two on the left
Lubricate Carriage Side Rollers side.

2. Lubricate the steering link bearings, total of four

fittings. Two on the right side and two on the left
side

3. Check for any worn or loose components of the

steering mechanism. Remove any debris or
trash as required.

Typical Example

1. Lubricate the 4 fittings for the carriage side

rollers, two on each side of the carriage side
rollers.

Typical Example

2. Lubricate the 2 fittings for the carriage middle

rollers, one on each side of the carriage middle
rollers.

166
Maintenance Section

Battery Terminal - Clean, Inspect Wheel Bolts & Nuts - Inspect

WARNING Inspect Tightness

Batteries give off flammable fumes that can

explode. Steer Wheels
Do not smoke when observing the battery
electrolyte levels.

Electrolyte is an acid and can cause personal

injury if it contacts skin or eyes.

Always wear protective glasses when working

with batteries.

Typical Example

1. Install steer wheel. Put two nuts opposite each

other (180°). Tighten bolt.

2. Inspect tightness of wheel nuts in a sequence

opposite each other 610 ~ 680 N.m (370~450
lb.ft).

Typical Example Diesel Engine Truck Drive Wheels

Typical Example LP Engine Truck Typical Example

1. Clean the top of the battery and terminals. 1. Install drive wheel. Put two nuts opposite each
other (180°).
2. Check terminals for corrosion. Coat terminals
with heavy grease. 2. Inspect tightness of wheel nuts in a sequence
opposite each other to 500~600 N.m (370~450
lb.ft).

167
Maintenance Section

Every 500 Service Hours or 3 Months

You must read and understand the warnings and instructions contained in the Safety section of this manual,
before performing any operation or maintenance procedures.

Belts (Diesel E/G Only) - Check,

Adjust

Typical Example

Typical Example D50/60/70/80S-5(3 Speed) NOTICE

Failure to loosen the alternator mounting bolt(2) will
cause excessive stress and break the alternator
mounting ear.

2. To adjust the alternator drive belt, loosen

adjusting bracket nut (1), mounting bolt and nut
(2) and nut (3). Move the nut (1) in or out as
required. Tighten the mounting bolt and nut (1, 2,
3).

Mast Hinge Pins – Lubricate

Typical Example D50/60/70S-5(2 Speed)

1. Check the condition and adjustment of the belt.

Correct adjustment allows 10 mm (3/8 inch)
deflection under 110 N (25 lb) of force.

Typical Example

1. Lower the forks and tilt the mast forward.

2. Lubricate the two fittings for the mast hinge pins,

one on each side of the mast.

168
Maintenance Section

Tilt Cylinders - Check, Adjust, Crosshead Rollers - Inspect

Lubricate
1. Operate the mast through a lift cycle. Watch the
chains move over the crosshead rollers. Make
Chassis Pivot Eyebolts sure the chain is tracking over the rollers
properly.

Typical Example

1. Lubricate two fittings for the pivot eyebolts, one Typical Example
on each tilt cylinder. 2. Check for damaged crosshead rollers, guards
and retainer rings.
2. Check the pivot eye pins for loose retainer bolts
and wear.

Transmission Oil Filter (2 Speed

Mast Pivot Eyes Only) – Change

Only for D50/60/70S-5(2 Speed),

G50/60/70S-5
See topic, "Transmission Oil & Oil Filter - Change" in
"First 50-100 Service Hours or a Week".

Parking Brake - Test, Adjust

See topic, "Parking Brake - Test, Adjust " in " First
50-100 Service Hours or a Week."
Typical Example

1. Lubricate two fittings for the mast pivot eyes,

one on each side of the mast. Drive Axle Oil (OCDB) - Change
2. Check the pivot eye pins for loose retainer bolts See topic, "Drive Axle Oil - Change" in "First 50-100
and wear. Service Hours or a Week".

169
Maintenance Section

Horn and Lights(If Equipped) – Steer Susension – Inspect

Check

1. Inspect the suspension mounting bolts. Tighten

Typical Example
suspension each four mounting bolts(total eight
1. Press horn button, to determine if horn is bolts), if necessary, to 240±40N•m(177±29
operational. lb•ft) .

2. Check and replace all defective gauges. 2. Look for leaks at the power steering hose and
tube connections .
3. Check all lights such as warning, directional,
backup, driving and flood lights for correct 3. Remove any trash buildup on the suspension or
operation. Replace all burned out bulbs. Have steer axle.
repairs made if needed.
Universal Joint - Inspect, Lubricate
Overhead Guard – Inspect

Typical Example
Typical Example
Check for worn or damaged bearings. Check for
1. Check tightness of overhead guard mounting loose retaining bolts and nuts. Tighten the bolts and
bolts at 240 N•m (175 lb•ft). nuts, if necessary.(55N•m, 41 lb•ft) Lubricate one
fitting on the universal joint.
2. Check overhead guard for bent or cracked
sections. Have repairs made if needed.

170
Maintenance Section

Engine Oil & Filter(Diesel Engine Fuel Trim Valve(FTV) Inspection

Only) – Change (G643E Engine only)

Diesel Engine Crankcase z Visually inspect the Fuel trim valve(3) for
abrasions or cracking. Replace as necessary.
See topic, "Engine Oil & Filter (Diesel E/G Only) - z To ensure the valve is not leaking a blow-by test
Change" in "First 50-100 Service Hours or a Week". can be performed.

1. With the engine off, disconnect the electrical

Inspect Vacuum Lines and Fittings connector to the FTV.
(G643(E) Engine only)
2. Disconnect the vacuum line from the FTV to the
pressure regulator/converter, at the converter’s
z Visually inspect vacuum lines and fittings for tee connection.
physical damage such as brittleness, cracks 3. ightly blow through the vacuum line connected to
and kinks. Repair/replace as required. the FTV. Air should not pass through the FTV
z Solvent or oil damage may cause vacuum lines when de-energized. If air leaks past the FTV
to become soft resulting in a collapsed line while when de-energized replace the FTV.
the engine is running.
z If abnormally soft lines are detected, replace as Inspect Electrical System (G643E
necessary. Engine only)

z Check for loose, dirty or damaged connectors

1
and wires on the harness including: Fuel lock-off,
TMAP sensor, O2 sensor, Electronic throttle,
6 Control Relays, Fuel Trim Valve, Foot Pedal,
and Distributor sensor.

4
z Repair and/or replace as necessary
7
3
2 5

(1) LP fuel lock-off,

(2) LP regulator/converter
(3) Fuel Trim Valve(FTV) : G643E only)
(4) LP mixer
(5) Vacuum lines,
(6) Coolant lines,
(7) LP fuel line

171
Maintenance Section

Every 1000 Service Hours or 6 Months

You must read and understand the warnings and instructions contained in the Safety section of this manual,
before performing any operation or maintenance procedures.

Carburetor (LP - Gas Engine Only) 2. Remove fuel filter cartridge assembly.

- Adjust, Clean 3. Before installing a new cartridge assembly,

apply a small amount of clean fuel to the filter
If the engine is hard to start or the exhaust is cartridge gasket.
smoking, the carburetor may need cleaning and
adjusting.
NOTICE
Before adjusting the carburetor make sure the Do not fill fuel filters with fuel before installing them.
engine is at normal operating temperature. Park the Contaminated fuel will cause accelerated wear to
lift truck with the forks lowered, parking brake fuel system parts.
applied, transmission in neutral and the engine
stopped.
4. Install the new fuel filter cartridge assembly.
For the complete procedure and specifications for
your specific engine, see the " Service Manual ". 5. Turn the new fuel filter cartridge assembly until
the filter gasket is fitted against the sealing face.

Fuel Filter - Check, Clean, Change 6. Turn the fuel filter cartridge assembly an
additional 2/3 of turn.
Diesel Engine
Park lift truck with the forks lowered, parking brake Air Intake System - Change
applied, transmission in neutral, engine stopped and
Changing Primary Element
cool.
See topic, “Air Intake System - Check, Clean” in
1. Raise the right side cover. “Every 250 Service Hours or Monthly”.

WARNING Changing Secondary Element

Replace the secondary element after the primary
Fuel leaked or spilled onto hot surfaces or element has been cleaned three times or yearly.
electrical components can cause a fire.
Turn the disconnect switch OFF or disconnect 1. Remove the primary air cleaner element. See
the battery when changing fuel filters. topic “Servicing Filter Element”. Clean the inside
of the air cleaner housing and cover.

2. Remove the secondary element. Inspect the

gasket between the air cleaner housing and the
Typical Example Diesel Engine Truck
engine inlet. Replace the gasket if it is damaged.

172
Maintenance Section

LP Regulator/Converter Inspection
NOTICE (LP Engine Only)
z Visually inspect the pressure regulator/converter
Always replace the secondary element. Do not
housing(2) for coolant leaks. Refer to the
attempt to reuse it by cleaning.
pressure regulator/converter section of the
service manual if maintenance is required.

3. Install a new secondary element. Install a new or

cleaned primary element. Install the cover. NOTE: For pressure testing and internal inspection
Tighten the latches. of the pressure regulator/converter, refer to
the pressure regulator/converter section of
4. Start the engine and observe the air cleaner the service manual.
service indicator. If the indicator shows RED after
installing a new secondary element and a
cleaned primary (outer) element, replace the Fuel Lines & Fittings – Check
cleaned primary filter with a new element.

5. Stop the engine. Close the hood and seat assembly. Visually inspect fuel lines and fittings for physical
damage. Replace as required.

Inspect Coolant Hoses (LP Inspect Mixer Assembly (LP

Engines Only) Engine Only)

z Visually inspect coolant hoses and clamps. Refer to the LP mixer section of the engine service
Remember to check the two coolant lines that manual for procedures.
connect to the pressure regulator/converter.
z Replace any hose that shows signs of swelling,
cracking, abrasion or deterioration.
Inspect Throttle Assembly (LP
Engine Only)
1
z Visually inspect the throttle assembly motor
housing for coking, cracks and missing
6
cover-retaining clips. Repair and/or replace as
necessary.
4
7 NOTE: Refer to the LP mixer and throttle section of
the service manual for procedures on
3 removing the mixer and inspecting the
2 5
throttle plate.
(1) LP fuel lock-off,
(2) LP regulator/converter
(3) Fuel Trim Valve(FTV),
(4) LP mixer
(5) Vacuum lines,
(6) Coolant lines,
(7) LP fuel line

173
Maintenance Section

Hydraulic Oil, Return Filter,

Strainer & Breather - Check, Clean,
Change

WARNING
Hot oil and components can cause personal
injury. Do not allow hot oil or components to
contact skin.

Park the lift truck level with the forks lowered, 6. Remove the breather.
parking brake engaged, transmission in NEUTRAL
and the engine stopped. 7. Wash the breather in clean, nonflammable
solvent and dry it.

8. Fill the hydraulic tank. See topic, "Refill

Capacities."

9. Install the breather.

1. Remove the hydraulic tank drain plug located on

the bottom of the frame. Allow the oil to drain in
a suitable container. Clean and install the plug.

10. Remove the floor plate.

11. Remove bolts and filter housing.

12. Remove and discard filter element from filter

housing.

13. Clean the filter housing with a clean,

nonflammable solvent.

14. Clean the housing base.

2. Loosen the bolts of the hydraulic tank cover. 15. Insert a new filter element into the filter housing.
3. Remove the strainer from the tank.
16. Inspect the filter housing seal. Replace if
necessary.
4. Install the new strainer by hand.
17. Apply a small amount of clean oil to the filter
5. Install the hydraulic tank cover and fasten the
element seal and housing seal.
bolts.
18. Install the filter housing with filter to the housing
base. Install bolts and tighten 20 to 30 N•m (15
to 20 lb•ft).

174
Maintenance Section

19. Start the engine and operate the hydraulic Lift Chains - Test, Check, Adjust
controls, and the steering system, through a few
cycles to fill the lines. Look for oil leaks.
Lift Chain Wear Test
20. Stop the engine and check the oil level. With all
cylinders retracted, maintain the oil level to the Inspect the part of the chain that is normally
FULL mark on the dip stick/filter cap assembly. operated over the cross head roller. When the chain
bends over the roller, the movement of the parts
against each other causes wear.
Transmission Oil & Filter (3 Speed Inspect to be sure that chain link pins Do not extend
outside of the link hole. If any single link pin is
Only) – Change extended beyond its connecting corresponding link,
it should be suspected of being broken inside of its
Only for D50/60/70/80/90S-5 (3 Speed) link hole. Lift chains are required to check for weare
about every 1,000 service hours or 6 months.
See topic, "Transmission Oil & Oil Filter - Change" in Chain wear test is a measurement of wear of the
"First 50-100 Service Hours or a Week". chain links and pins. Take the following steps to
check chain wear.
Transmission Oil (2 Speed Only) – 1. Lift the mast and carriage enough for getting
Change tension on lift chains.

Only for D50/60/70S-5 (2 Speed),

G50/60/70S-5
See topic, "Transmission Oil & Oil Filter - Change" in
"First 50-100 Service Hours or a Week".

Typical example

2. Measure precisely ten links of chain distance at

the center of pins in millimeter.

3. Calculate chain wear rate*.

4. If the chain wear rate is 2% or more, replace the

lift chain.

175
Maintenance Section

Check for Equal Tension Carriage Chain Adjustment - STD Mast

Typical example for carriage chain of STD mast

Typical example
Make sure that carriage height is correct. If correct,
Lift the carriage and the mast high enough for
adjust chain for equal tension. If not, adjust chain for
getting tension on lift chains. Check the chains, and
correct carriage height by adjusting anchor nuts(1).
make sure the tension is the same. Lift chains are
required to check for equal tension about every
NOTE: See the previous section, "Carriage Roller
1,000 service hours or 6 months.
Extrusion" in "When Required" for proper
carriage height.
WARNING
1. Fully lower the carriage and tilt mast forward or
Personal injury can be caused by sudden lift the carriage and put blocks under the carriage
movement of the mast and carriage. to release the tension from the lift chains.
Keep hands and feet clear of any parts that can
move. 2. Adjust nut(1) to get proper distance from the
bottom of inner upright to the bottom of carriage
bearing.
Lift Chain Adjustment 3. Make adjustment anchor nut(1) for equal chain
tension.

4. Set the mast vertical and raise the carriage and

check equal chain tension. If not equal, repeat
the same procedure as step 1 through step 3.

5. Put LOCTITE No. 242 tread lock on the threads

of the anchor nuts(1) after the adjustment is
completed.

Typical example for carriage equal tension

If the tension is not the same on both chains, take

the procedure as follows.

NOTE: If carriage height is not correct, make

adjustments by following procedures.

176
Maintenance Section

Carriage Chain Adjustment - FFT Mast Chain Adjustment - FFT

Typical example for carriage chain of FFT mast Typical example for FFT mast

Make sure that carriage height is correct. if correct, Make sure that mast height is correct. If correct,
adjust chain for equal tension. If not, adjust chain for adjust chain for equal tension. If not, adjust mast
correct carriage height by adjusting anchor nuts(2). chain for correct mast height by adjusting anchor
nuts(6).
NOTE: See the previous section, "Carriage Roller
Extrusion" in "When Required" for proper NOTE: See the previous section, "Carriage Roller
carriage height. Extrusion" in "When Required" for proper
inner mast height.
1. Fully lower the carriage and tilt mast forward or
lift the carriage and put blocks under the 1. Lift the inner mast and put blocks under the
carriage to release the tension from the lift inner mast to release the tension from the lift
chains. chains.

2. Remove bolt(3), washer(4) and stopper(5) and 2. Adjust nut(6) to make inner mast bottom flush
adjust nut(2) to get proper distance from bottom with outer mast bottom.
of inner upright to the bottom of carriage
bearing. 3. Make adjustment anchor nut(6) for equal chain
tension.
3. Make adjustment anchor nut(2) for equal chain
tension. 4. Raise the inner mast and check equal chain
tension. If not equal, repeat the same procedure
4. Set the mast vertical and raise the carriage and above step 1 through step 3.
check equal chain tension. If not equal, repeat
the same procedure as step 1 through step 3. 5. Put LOCTITE No. 242 tread lock on the threads
of the anchor nuts(6) after the adjustment is
5. Put LOCTITE No. 242 tread lock on the threads completed.
of the anchor nuts(2) after the adjustment is
completed.

177
Maintenance Section

Every 1500 Service Hours or 9 Months

You must read and understand the warnings and instructions contained in the Safety section of this manual,
before performing any operation or maintenance procedures.

Drive Axle Oil (Shoe Brake Only) - Replace Spark Plugs (LP Engine
Change Only)
See topic, "Drive Axle Oil - Change" in "First 50-100
Service Hours or a Week. 1. Disconnect Battery Cables.

2. Using a gentle twisting motion remove the high

Inspect Ignition System (LP voltage cables from the spark plugs. Replace
Engine Only) any damaged cables.

3. Remove the spark plugs.

1. Disconnect Battery Cables.
4. Gap the new spark plugs to the proper
2. Remove and inspect the spark plugs. Replace specifications.
as required. G643(E) Engine : 0.9mm (0.035 inch)

3. Test secondary cables with an Ohmmeter. If 5. Apply anti-seize compound to the spark plug
maximum resistance is higher than 25 kOhms, threads and install.
repair and/or replace. G643(E) Engine : 30 N•m (22 lb•ft)

4. Remove distributor cap and perform visual

inspection. Replace cap and rotor if corrosion is CAUTION
found on the contacts.
DO NOT OVERTIGHTEN THE SPARK PLUGS.
5. Inspect the ignition coil for cracks and heat
deterioration. Visually inspect the coil heat sink
fins. If any fins are broken replace as required. 6. Re-install the high voltage cables.

178
Maintenance Section

Replace LP Fuel Filter Element (LP Fuel Filter - Disassembly

Engine Only)
2
4
Park the lift truck in an authorized refueling area with
the forks lowered, parking brake applied and the 1
transmission in Neutral.
5 3
1. Close the fuel shutoff valve on the LP-Fuel tank.
Run the engine until the fuel in the system runs
out and the engine stops.
6
2. Turn off the ignition switch.
7
3. Scribe a line across the filter housing covers,
which will be used for alignment purposes when
re-installing the filter cover. 5. Remove top cover (2), magnet (3), spring (4), and
filter element (7) from bottom cover (5).

6. Replace the filter element (7).

Filter
Housing 1 7. Check bottom cover O-ring seal (6) for damage.
Scribe Replace if necessary.
Point
8. Re-assemble the filter assembly aligning the
scribe lines on the top and bottom covers.

9. Install the cover retaining screws, tightening the

screws in an opposite sequence across the cover.

10. Open the fuel valve by slowly turning the valve

counterclockwise.
(1) SCREW
11. Crank the engine several revolutions to open the
4. Remove the cover retaining screws (1) fuel lock-off. DO NOT START THE ENGINE.
Turn the ignition key switch to the off position.

12. Check the filter housing, fuel lines and fittings for
leaks. Repair as necessary.

179
Maintenance Section

Testing Fuel Lock-off Operation

(LP Engine Only)

z Start engine.
z Locate the electrical connector for the fuel lock
z Disconnect the electrical connector.
z The engine should run out of fuel and stop
within a short period of time.
z Turn the ignition key switch off and re-connect
the fuel lock-off connector.

NOTE: The length of time the engine runs on

trapped fuel vapor increases with any
increase in distance between the fuel lock
-off and the pressure regulator/converter.

(1) LP fuel lock-off,

(2) LP regulator/converter

180
Maintenance Section

Every 2000 Service Hours or Yearly

You must read and understand the warnings and instructions contained in the Safety section of this manual,
before performing any operation or maintenance procedures.

Steer Wheel Bearings -

Reassemble
Park the lift truck level with the forks lowered,
parking brake engaged, transmission in NEUTRAL
and the engine stopped.

Typical Example

4. Remove the wheel assembly. Examine the

wheel for damage and wear. Replace the wheel
if necessary.

5. Remove the inner bearing. Clean and lubricate

the steering knuckle. Reassemble both the inner
and outer bearing cones.
Typical Example

1. Lift the steer wheels off the ground. Place 6. Install the inner bearing. Lubricate the seal and
stands or blocking under the frame and steer install the wheel assembly on the knuckle.
axle to support the lift truck.
7. Install the outer wheel bearing and the outer nut.
2. Remove the hub cap and gasket.
8. Tighten the nut to 200 N•m (148 lb•ft), while
turning wheel hub to seat the bearing.

9. Install the pin.

10. Install the hub cap.

11. Raise the lift truck and remove the blocking

Lower the lift truck to the ground.

Typical Example

3. Remove the pin (1) and nut (2). Remove the

outer wheel bearing.

181
Maintenance Section

Cooling System - Clean, Change

WARNING
At operating temperature, the engine coolant is
hot and under pressure.
Steam can cause personal injury.
Check the coolant level only after the engine has
been stopped and the filter cap is cool enough
to touch with your bare hand.
Remove the filter cap slowly to relieve pressure. Typical Example
Cooling system conditioner contains alkali.
Avoid contact with the skin and eyes to prevent 3. Open radiator drain valve. Allow the coolant to
personal injury. drain. Drain the recovery bottle.
Use all cleaning solutions with care.
4. Close radiator drain valve and install block drain
plug. Fill the cooling system with 1 kg (2 lb)
sodium bisulphate per 40 liters (10 gallons) of
The lift truck must be level, the forks lowered, the water. Most commercial cooling system cleaners
parking brake engaged, the transmission in can be used.
NEUTRAL and the engine stopped and cool.
5. Start and run the engine for 30 minutes.

6. Stop the engine and drain the cleaning solution.

7. Flush the system with clean water, until draining

water is clear.

8. Close the drain valve and install the block drain

plug. Fill the system with neutralizing solution,
250 g (1/2 lb) sodium carbonate per 40 liters (10
gallons) of water.

9. Start and run the engine for 10 minutes.

Typical Example
10. Stop the engine and drain the neutralizing
1. Turn the radiator cap slowly to relieve the solution.
pressure, then remove the cap.
11. Flush the system with clean water until draining
2. Remove the block drain plug. water is clear.

12. Close the drain valve and install the block drain
plug. Add coolant to the top of the filter neck.

13. Start and run the engine to stabilize the coolant

level. See topic, "Coolant level - Check" in
"Every 10 Service Hours or Daily".

182
Maintenance Section

Fork – Inspect

3. Check the straightness of the upper face of

blade (D) and the front face of shank (E) with a
Forks should be inspected, at a minimum, every 12 straight edge.
months. If the truck is being used in a multi-shift or The fork should be withdrawn from service if the
heavy duty operation, they should be checked every deviation from straightness exceeds 0.5 percent
six months. of the length of the blade and/or the height of the
shank respectively 5 mm/1000 mm (0.18"/36").
1. Inspect the forks carefully for cracks. Special
attention should be given to the heel section (A),
all weld areas and mounting brackets (B).
Inspect the top and bottom hooks on forks used
on hook type carriages and tubes on shaft
mounted forks.
Forks with cracks should be removed from
service.
"Wet Test" magnetic particle inspection is
generally preferred due to its sensitivity and the
ease of interpreting the results. Portable
equipment is usually recommended so it can be
moved to the lift truck.
Inspectors should be trained and qualified in 4. Check the difference in height of one fork tip to
accordance with The American Society for Non the other when mounted on the fork carrier. A
Destructive Testing, Level II Qualifications. difference in fork tip height can result in uneven
support of the load and cause problems with
entering loads.
The maximum recommended difference in fork
tip elevation (F) is 6.5 mm (0.25") for pallet forks
and 3 mm (0.125") for fully tapered forks. The
maximum allowable difference in fork tip
elevation between the two or more forks is 3
percent of blade length (L).
Replace one or both forks when the difference in
fork tip height exceeds the maximum allowable
difference. Contact your local DOOSAN Lift
Truck Dealer for further information.

2. Check the angle between the upper face of the

blade and the front face of the shank. The fork
should be withdrawn from service if angle (C)
exceeds 93 degrees or deviates by more than 3
degrees from an original angle other than 90
degrees, as may be found in some special
application forks.

183
Maintenance Section

Shaft mounted forks may use set collars or

spacers on the shaft to either side of the fork.
They may also use U bolts, pins, or similar
devices which engage the fork through the top
structure of the carriage.

5. Check the fork blade (J) and shank (H) for wear
with special attention to the heel (G). The fork
should be withdrawn from service if the
thickness is reduced to 90 percent or less of the
original thickness.
Fork blade length may also be reduced by wear,
8. Check fork markings (N) for legibility. Renew
especially on tapered forks and platens.
markings as required to retain legibility.
Remove the forks from service when the blade
length is no longer adequate for the intended
9. a. Lift the mast and operate the tilt control
loads.
lever, until the top surface of the forks is
parallel with the floor. Place two straight
bars that are the same width as the
carriage, across the forks as shown.
b. Measure the distance from the bottom of
each end of the two bars to the floor. The
forks must be parallel within 3 mm (.12 in)
for Full Tapered and Polished (FTP) forks,
all other forks 6.4 mm (.25 in), for their
complete length.
c. Put one fork, one third from the tip, under a
fixture that will not move. Then operate the
tilt control with caution until the rear of the
truck lifts just off the floor. Follow the same
6. Check the fork mountings (K) for wear, crushing procedure with the second fork. Repeat
and other local deformation, which can cause Step a.
excessive side to side wobble of the forks.
Excessive clearance on hook type forks may
allow them to fall from the carrier. Forks which
show visible signs of such damage should be
removed from service.

7. Check the positioning lock and other fork

retention devices to make sure they are in place
and working.
Hook type forks use a spring loaded pin (M),
located in the top hook, to engage notches in the
top carriage bar to hold the fork in place.
When adjusting the fork spacing, the forks are
prevented from sliding off the end of the carriage
by stop blocks. These stop blocks are at both
ends of the carriage and in the path of the
bottom fork hook. The load backrest extension
may be used in place of the stop blocks in some
cases.

184
Maintenance Section

Every 2500 Service Hours or 15 Months

You must read and understand the warnings and instructions contained in the Safety section of this manual,
before performing any operation or maintenance procedures.

Inspect Battery System Checking the TMAP Sensor (LP

Engine Only)
z Clean battery outer surfaces with a mixture of
baking soda and water. 1. Verify that the TMAP sensor (2) is mounted
z Inspect battery outer surfaces for damage and tightly into the manifold adapter (3), with no
replace as necessary. leakage.
2. If the TMAP is found to be loose, remove the
z Remove battery cable and clean, repair and/or
TMAP retaining screw and the TMAP sensor
replace as necessary.
from the manifold adapter.
3. Visually inspect the TMAP O-ring seal for
damage. Replace as necessary.
4. Apply a thin coat of an approved silicon lubricant
to the TMAP o-ring seal.
5. Re-install the TMAP sensor into the manifold
adapter and securely tighten the retaining screw.

1 4

2
(1) Adapter-Throttle body
(2) TMAP sensor,
(3) Adapter-Manifold,
(4) Throttle body

185
Maintenance Section

Inspect for Intake Leaks (LP Replace Oxygen Sensor (G643E

Engine Only) Engine Only)

1. Visually inspect the intake manifold, throttle

assembly (4), and manifold adapters (3), for
looseness and leaks. Repair as necessary.

Replace PCV Valve and breather

element - Change (LP Engine
Only)

1. Loosen the hose clamps and remove the PCV Exhaust Tube
valve.

2. Assemble new PCV valve and hose.

3. Tighten the hose clamps

Muffler Ass’y

When indicated by MIL, replace oxygen sensors on

the exhaust tube and muffler assembly.

1. Stop engine and wait until the exhaust pipe and

exhaust pipe is cooled.
2. Disconnect the electrical connector of oxygen
sensor.
3. Remove oxygen sensor.
4. Assemble new oxygen sensor Tightening
torque : 45 N•m (32.5 lb•ft)
5. Connect the electrical connector of oxygen
sensor.

186
Index Section

Index
Brake Oil (Only for OCDB) .................................... 133
#
Bulbs ....................................................................... 144
Burn Prevention........................................................ 15
12 Months Inspection .............................................124

C
A

Capacity Chart - With Side Shifter ....................41, 42

Accelerator Pedal .....................................................58
Capacity Chart - Without Side Shifter...............39, 40
Adjustments ............................................................107
Capacity Chart - Without Side Shifter..................... 40
Advanced Diagnostics..............................................80
Carburetor (LP - Gas Engine Only) - Adjust, Clean
Advanced Diagnostics (G643 Engine Only) ...........80
................................................................................. 172
Advanced Diagnostics (G643E Engine Only).........90
Carriage Roller Extrusion - Adjust......................... 145
After Starting the Engine..........................................69
Causes of Fork Failure........................................... 122
Air-205 kPa (30 psi) Maximum Pressure ..............162
Center of Gravity (CG) ............................................. 21
Air Cleaner Indicator – Check................................148
Changing LP Tanks.................................................. 61
Air Intake System - Change...................................172
Changing Primary Element.................................... 172
Air Intake System - Check, Clean .........................160
Changing Secondary Element............................... 172
Antifreeze ................................................................129
Chassis Pivot Eyebolts .......................................... 169
Attachment Abbreviations (includes Special Forks)
Check for Equal Tension ....................................... 176
...................................................................................46
Check Inflation and Damage ................................. 144
Auto Shift Controller ASC-200/201 (If Equipped).107
Checking Element .................................................. 162
Automatic mode......................................................109
Checking the TMAP Sensor (LP Engine Only) .... 185
Automatic Transmission Switch (3 Speed Only) ....57
Circuit Breaker..................................................55, 143
Avoiding Lift Truck Tipover ......................................21
Clean Outside of Radiator Core............................ 145
Clean Pressure Cap............................................... 145
B
Cleaning Primary Filter Elements ......................... 162
Coolant Information................................................ 128
Basic Troubleshooting..............................................72
Coolant Level – Check........................................... 147
Battery Terminal - Clean, Inspect..........................167
Coolant Water......................................................... 129
Before Operating the Lift Truck ...............................12
Cooling System - Clean, Change.......................... 182
Before Starting the Engine.......................................63
Cooling System Specifications.............................. 128
Before Starting the Lift Truck...................................11
Crosshead Rollers - Inspect .................................. 169
Before Storage........................................................118
Crushing or Cutting Prevention ............................... 14
Belts (Diesel E/G Only) - Check, Adjust................168
Bent or Twisted Forks ............................................122
Bleeding the Fuel System ......................................140
Brake Oil (OCDB) – Check ....................................146

187
Index Section

D Every 500 Service Hours or 3 Months.................. 168

Daily Inspection ......................................................123 F

Detergent.................................................................162
Diagnostics Features..............................................108 Fatigue .................................................................... 122
Diesel Engine Crankcase.......................................171 Features.................................................................. 107
Diesel Engine Equipped...........................................60 Fire or Explosion Prevention ................................... 15
Diesel Engine................................................... 66, 172 First 250 Service Hours or a Month ...................... 159
Diesel Specifications ..............................................130 First 50-100 Service Hours or a Week ................. 152
Displaying Fault Codes (DFC) From SECM Memory First Installation ...................................................... 123
............................................................................ 81, 90 Fluid Penetration ...................................................... 14
Draining the Water From the Fuel Filter................141 Foreword..................................................................... 2
Drive Axle Oil - Change..........................................155 Fork – Inspect......................................................... 183
Drive Axle Oil (OCDB) - Change ...........................169 Fork Inspection....................................................... 123
Drive Axle Oil (Shoe Brake Only) - Change .........178 Fuel Filter - Check, Clean, Change....................... 172
Drive Axle Oil Level – Check .................................164 Fuel Filter - Disassembly ....................................... 179
Drive Axle Oil ..........................................................133 Fuel Lines & Fittings – Check................................ 173
Fuel Specifications................................................. 130
E Fuel Sulfur Content ................................................ 130
Fuel Tank Filter Cap & Screen - Clean.........141, 142
Electronic Controlled Spark-Ignition Engines .........70 Fuel Trim Valve(FTV) Inspection (G643E Engine
Engine Oil & Filter(Diesel Engine Only) – Change only)......................................................................... 171
.................................................................................171 Fuel Types .............................................................. 130
Engine Oil & Filter(LP Engine Only) - Change .....163 Fuse & Relay ( LP Engine Only) ........................... 143
Engine Oil & Oil Filter (Diesel E/G Only) - Change Fuse Box................................................................... 53
.................................................................................152 Fuse Locations ......................................................... 53
Engine Oil (DEO and EO) ......................................132 Fuses....................................................................... 143
Engine Oil Level - Check........................................147 Fuses, Bulbs & Circuit Breaker - Change, Reset. 143
Engine Valve Lash (Diesel E/G Only) - Check,
Adjust.......................................................................140 G
Environment Management.........................................3
Environment Protection..........................................121 G643 Electronic Controlled LP Engines (If
Every 10 Service Hours or Daily............................147 Equipped).................................................................. 71
Every 1000 Service Hours or 6 Months ................172 G643E Engine .......................................................... 70
Every 1500 Service Hours or 9 Months ................178 General Description ................................................. 71
Every 2000 Service Hours or Yearly .....................181 General Fuel Information....................................... 130
Every 250 Service Hours or Monthly.....................160 General Hazard Information .................................... 10
Every 2500 Service Hours or 15 Months ..............185 General Warnings to Operator............................. 6

188
Index Section

H L

Hand Placement Warning ..........................................7 Lift Chain Adjustment............................................. 176

Horn and Lights(If Equipped) – Check..................170 Lift Chain Wear Test .............................................. 175
How to Survive in a Tipover (If Operator Restraint Lift Chains - Test, Check, Adjust........................... 175
System Equipped) ....................................................28 Lift Control................................................................. 59
Hydraulic Oil (HYDO) .............................................132 Lift Fork Adjustment ............................................... 117
Hydraulic Oil Level – Check...................................164 Lift Truck Capacity Rating ....................................... 45
Hydraulic Oil, Return Filter, Strainer & Breather - Lift Truck Controls .................................................... 56
Check, Clean, Change ...........................................174 Lift Truck Operation................................................ 105
Hydraulic Return Filter – Change ..........................159 Lift Truck Parking ..................................................... 13
Lift Truck Shipping ................................................. 119
I Lift Truck Stability Base ........................................... 22
Lift Truck Stability ..................................................... 21
Identification, Lift Capacity and Attachment Plate..45 Lifting Drums or Round Objects............................ 115
If Optional Suspension Seat Equipped ...................18 Lifting the Load....................................................... 112
Improper Modification or Repair ............................122 Literature Information................................................. 2
Inching into Loads ..................................................112 Load Backrest Must Be In Place Warning................ 7
Inching Switch (3 Speed Only) ................................57 Long Time Storage................................................. 118
Inching .....................................................................106 LP Engine Crankcase ............................................ 163
Inspect Battery System ..........................................185 LP Engine ................................................................. 66
Inspect Coolant Hoses (LP Engines Only) ...........173 LP Regulator/Converter Inspection (LP Engine Only).. 173
Inspect Electrical System (G643E Engine only)...171 LP Specifications.................................................... 131
Inspect Engine for Exhaust Leaks.........................149 Lubricant Information ............................................. 132
Inspect Foot Pedal Operation (LP Engine Only)..149 Lubricant Specifications......................................... 132
Inspect for Intake Leaks (LP Engine Only) ...........186 Lubricant Viscosities and Refill Capacities........... 135
Inspect Ignition System (LP Engine Only) ............178 Lubricant Viscosities .............................................. 135
Inspect Mixer Assembly (LP Engine Only) ...........173 Lubricate Carriage Side Rollers ............................ 166
Inspect Throttle Assembly (LP Engine Only)........173 Lubricate Mast Side Rollers................................... 166
Inspect Tightness....................................................167 Lubricating Grease................................................. 134
Inspect Vacuum Lines and Fittings (G643(E) Engine
only).........................................................................171
Inspection Engine for Fluid Leaks .........................147 M
Inspection, Maintenance and Repair of Lift Truck
Forks........................................................................121 Machine Lifting and Tiedown Information............. 119
Instrument Panel.......................................................48 Maintenance and Repair........................................ 124
Index........................................................................187 Maintenance Information ......................................... 14
Maintenance Intervals........................................3, 136

189
Index Section

Maintenance................................................................3 Overhead Guard – Inspect .................................... 170

Make proper antifreeze additions..........................129 Overhead Guard Must Be In Place Warning............ 8
Manual Mode (Fail-Safe mode).............................110 Overloading ............................................................ 122
Mast Abbreviations ...................................................46
Mast Channels – Lubricate ....................................150 P
Mast Hinge Pins – Lubricate..................................168
Mast Pivot Eyes......................................................169 Parking Brake - Test, Adjust..........................157, 169
Mast, Carriage, Lift Chains & Attachments - Inspect, Parking Brake Lever................................................. 59
Lubricate..................................................................165 Parking brake ............................................................. 8
Mixer Idle Screw / Power Valve Adjust (G643 Parking the Lift Truck ............................................. 116
Engine Only) .............................................................79 Power Shift Transmission / Drive Axle ................. 105
Mounting and Dismounting ......................................11 Precleaner (If Equipped)........................................ 160
Moving Fan Warning ..................................................8 Pressure Air .............................................................. 14
No Riders Warning .....................................................8 Pressure Warning....................................................... 7
No Standing On Forks Warning, No Standing Under Prestart Conditions................................................... 66
Forks Warning.............................................................7 Priming the Fuel System (Diesel Engine Only).... 140
Product Description................................................ 107
N
R
Noise &Vibration .......................................................38
Noise..........................................................................38 Radiator Cap - Clean, Change.............................. 145
Reading Diagnostic Fault Codes.......................80, 90
O Refill Capacities...................................................... 135
Refueling................................................................... 60
Oil Cooled Disc Brake (OCDB) Type ........... 156, 165 Replace LP Fuel Filter Element (LP Engine Only)
Only for D50/60/70/80/90S-5 (3 Speed) ...............175 ................................................................................. 179
Only for D50/60/70S-5 (2 Speed), G50/60/70S-5 Replace Oxygen Sensor (G643E Engine Only)... 186
........................................................................ 169, 175 Replace PCV Valve and breather element - Change
Only for Oil Cooled Disc Brake..............................146 (LP Engine Only) .................................................... 186
Operating in Hot Weather ......................................115 Replace Spark Plugs (LP Engine Only)................ 178
Operating Techniques............................................112
Operating the Lift Truck............................................12 S
Operation Information...............................................11
Operation............................................................ 3, 109 Safety Rules ............................................................. 23
Operator's Warning and Identification Plate ...........45 Safety ...................................................................... 2, 5
Operator's Warning Plate.........................................45 Seat - Check, Lubricate ......................................... 142
Operator Restraint System (If Equipped)........... 2, 17 Seat Adjustment.................................................17, 55
Operator’s Station and Monitoring Systems ...........47 Seat Switch System ................................................. 52

190
Index Section

Seat ...........................................................................55 Torques for Standard Hose Clamps - Worm Drive

Serial Number Locations..........................................43 Band Type............................................................... 126
Serial Number ...........................................................43 Torques for Taperlock Studs ................................. 127
Service Foot Brake Pedal ........................................58 Tow Eye .................................................................... 53
Service Indicator .....................................................148 Towing Information................................................. 120
Servicing Filter Element .........................................160 Training Required To Operate or Service Warning . 5
Shoe Brake Type........................................... 155, 164 Transmission Display (3 Speed Only) .................... 56
Specifications.........................................30, 32, 34, 36 Transmission Inching Control Pedal ....................... 58
Stability and Center of Gravity.................................21 Transmission Oil & Filter (3 Speed Only) – Change.... 175
Starting From a 24/12 Volt External Source ...........67 Transmission Oil & Oil Filter – Change ................ 153
Starting the Engine ...................................................66 Transmission Oil (2 Speed Only) – Change......... 175
Starting the Lift Truck ...............................................12 Transmission Oil (TDTO)....................................... 132
Starting with Jumper Cables....................................67 Transmission Oil Filter (2 Speed Only) – Change ... 169
Steer Susension – Inspect.....................................170 Transmission Oil Level – Check............................ 151
Steer Wheel Bearings - Reassemble....................181 Transportation Hints............................................... 119
Steering Column Tilting Angle Adjustment .............53 Traveling with the Load.......................................... 113
Steering Mechanism - Check, Lubricate...............166 Turning .................................................................... 114
Storage Information................................................118
U
T
Universal Joint - Inspect, Lubricate....................... 170
Test Fuel System for Leaks (LP Engine Only) .....141 Unloading................................................................ 113
Testing Fuel Lock-off Operation (LP Engine Only).......180
Table of Contents .......................................................1 V
Tilt Control.................................................................59
Tilt Cylinders - Check, Adjust, Lubricate...............169 Vibration (weighted overall value)........................... 38
Tire Inflation Information ........................................125
Tire Inflation Pressures Adjustment ......................125 W
Tire Shipping Pressure...........................................125
Tires and Wheels - Inspect, Check .......................144 Walk-Around Inspection - Inspect ......................... 149
Tires Inflation ..........................................................125 Walk-Around Inspection........................................... 63
To Adjust .................................................................158 Warning Light ........................................................... 50
To Operate the Lift Truck After a Long Time Storage ..118 Warning Signs and Labels...................................5, 17
Torque Specifications.............................................126 Water-280 kPa (40 psi) Maximum Pressure ........ 162
Torques for Bolts and Nuts With Standard Threads.....126 Wheel Bolts & Nuts - Inspect................................. 167
Torques for Metric Fasteners.................................127 When Required....................................................... 140
Torques for Standard Bolts, Nuts and Taperlock
Studs .......................................................................126

191

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D50S-5-D90S-5 G50S-5-G70S-5 Service Manual (SB4271E00)

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D50S-5-D90S-5 G50S-5-G70S-5 Service Manual (SB4271E00)

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For use in service manual

SERVICE MANUAL CONTENTS

TITLE FORM NUMBER

Service Manual Contents SB4272E00

Power Train (Two Speed Transmission, Drive axle) SB4274E00

Vehicle Systems SB4276E00

OPERATION & MAINTENANCE

Operation & Maintenance Manual SB2356E00

Models ; D50S-5, D60S-5, D70S-5, D80S-5, D90S-5

20. Relieve all pressure in air, oil or water systems

METRIC NUTS AND BOLTS

METRIC TAPERLOCK STUDS

Exceptions to these torques are given in the Service

INCH NUTS AND BOLTS

INCH TAPERLOCK STUDS

O-RING FACE SEAL FITTING

STRAIGHT THREAD O-RING

STRAIGHT THREAD O-RING

O-RING FACE SEAL FITTING NUT

ASSEMBLY OF FITTINGS WITH STRAIGHT

This type of fitting is used in many applications. The tube

4 CLAMP TORQUE ON RETIGHTENING

37û FLARED O-RING SWIVEL NUTS

37û FLARED AND STRAIGHT THREAD O-RING FITTINGS

NOMINAL TUBE O.D. THREAD STANDARD TORQUE

TIGHTENING OTHER FITTINGS

45û FLARED AND 45û INVERTED FLARE FITTINGS

NOMINAL TUBE O.D. THREAD STANDARD TORQUE

TIGHTENING OTHER FITTINGS

O-RING 45û FLARE

AIR CONDITIONING FITTINGS

TAPERED PIPE THREAD FITTINGS

Testing And Adjusting

D.R.K. ALTERNATOR COVERAGE CHART

HC45 Alternator End View

Service Manual 5 Specifications

There is also a capacitor mounted in the back of the

The alternator is connected to the battery through

The alternator is an electrical and mechanical

It is used to charge the storage battery during

The internal fan is mounted on the rotor. This fan

Service Manual 6 Systems Operation

Alternator Components-Cross-Sectional View

Stator (4) consists of a stator core and coils. As the

Alternator Components-Inside View of Rear Frame

Service Manual 7 Systems Operation

Rotor (3) consists of a core, coils and slip rings (1).

Rectifier (10) contains three positive (+) and three

Brush holder (7) contains two brushes (11). They

Service Manual 8 Systems Operation

Most regulators are temperature compensated to

HC45 Integral Charging System Schematic

When the switch is closed, the indicator lamp turns

The field current is sufficient to cause the alternator

Service Manual 9 Systems Operation

Troubleshooting Problem 1 : Alternator Does Not Charge

Troubleshooting can be difficult. On the page that

NOTE : The HC45 alternator is only serviced as a

1. Loose Drive Belt For Alternator:

1. Alternator Does Not Charge. 2. Loose Alternator Drive Pulley:

6. Brushes Are Worn Or Dirty:

Service Manual 10 Testing And Adjusting

Service Manual 11 Testing And Adjusting

Service Manual 12 Testing And Adjusting

Testing And Adjusting

Starting Motor .....................................................14

Disassembly And Assembly

Service Manual 3 Index

Service Manual 5 Specification

Service Manual 6 Specification

Poong Sung Starting Motor

The starting Motor is used to turn the engine

When the engine begins to run, the overrunning

Service Manual 7 Systems Operation

Starting Motor Components

The major components of the starting motor are