Toyota Forklift LPG DEVICE for 4Y-E ENGINE 8FGU15-32 8FGCU20-32, 8FGCU15-18 series & 8FGCSU20 Repair

LPG DEVICE for 4Y-E ENGINE (USA Production)

Pub. No. CU666

…..This Page Intentionally Left Blank…..

FOREWORD This repair manual describes the construction, operation and repair method of a device for Liquefied Petroleum Gas (LPG) mounted on the Toyota forklift of 8FGU15 to 32, 8FGCU20 to 32, 8FGCU15, 18 series and 8FGCSU20.

This Manual has been compiled to provide you with useful information on the proper maintenance of Toyota’s forklift to maintain its high performance and excellent durability sufficiently for a long time.

This manual covers vehicles introduced in January 2007. All subsequent improvements will be explained in the Toyota Industrial Equipment Parts & Service News.

…..This Page Intentionally Left Blank…..

SECTION INDEX NAME

SECTION

GENERAL

0

OPERATION DESCRIPTION

1

LPG REGULATOR OVERHAUL

2

ELECTRICAL TROUBLESHOOTING

3

APPENDIX

4

…..This Page Intentionally Left Blank…..

0-1

GENERAL Page

TYPE OF LPG DEVICES........................................0-2 ENGINE PERFORMANCE CURVES .....................0-3 ENGINE SPECIFICATIONS ...................................0-6 PRINCIPAL DIFFERENCES FROM GASOLINE VEHICLE ...............................0-7

0 1 2 3

ABBREVIATIONS...................................................0-7

4

GENERAL RULES OF SERVICING WORK ..........0-8

5

BOLT & NUT TIGHTENING TORQUES.................0-9

6

BOLT STRENGTH CLASS IDENTIFICATION METHOD AND TIGHTENING TORQUE ....................0-9

7

PRECOATED BOLTS (BOLTS WITH SEAL LOCK AGENT COATING ON THREADS) ..................................0-12

8 9

PERIODIC MAINTENANCE .................................0-13

10

INSPECTION METHOD ..........................................0-13

11

PERIODIC REPLACEMENT PARTS .........................0-13

12 13 14 15 16 17 18 19 20 21 E

0-2

TYPE OF LPG DEVICES 1.

Types of LPG cylinders Gas weight

15 kg (33.1 lb)

637 mm (25.1 in)

20 kg (44.1 lb)

797 mm (31.4 in)

2.

Pneumatic models

Cushion models

General purpose

—

STD

With level gauge and quick coupling

—

OPT

General purpose

STD

—

With level gauge and quick coupling

OPT

—

Cylinder length

Specification

Types of LPG cylinder brackets Cylinder Weight

External diameter

Removal/installation method

Bracket opening direction

Fuel hose connecting position

20.0 kg (44.1 lb)

797 mm (31.4 in)

Sinple type (STD) Swing down type (OPT)

Right

Bottom

15.0 kg (33.1 lb)

637 mm (25.1 in)

↑

↑

↑

0-3

ENGINE PERFORMANCE CURVES 4Y Engine (8FGU15 to 25, 8FGCU20 to 32)

0 Gasoline (Exclusive, Convertible) LPG (Exclusive, Convertible)

1 2

Shaft torque

3 4 5 6 7 8 Shaft output

9 10 11 12 13 14 Fuel consumption ratio

15 16 17 18 19 20 Engine speed

21 E

0-4

4Y Engine (8FGU30, 32)

Gasoline (Exclusive)

Shaft output

Shaft torque

Gasoline (Convertible with LPG) LPG (Exclusive, Convertible)

Fuel consumption ratio

Gasoline (Exclusive, Convertible) LPG (Exclusive, Convertible)

Engine speed

0-5

4Y Engine (8FGU15 to 32 series, 8FGCU15, 18 and 8FGCSU20)

0 Gasoline (Exclusive, Convertible) LPG (Exclusive, Convertible)

1 2

Shaft torque

3 4 5 6 7 8

Shaft output

9 10 11 12 13

Fuel consumption ratio

14 15 16 17 18 19 Engine speed

20 21 E

0-6

ENGINE SPECIFICATIONS 4Y 8FGU15 to 25 8FGCU20 to 32

Maximum shaft torque Maximum shaft output

8FGU30, 32

8FGCU15, 18 and 8FGCSU20

A

B

C

A

B

C

A

B

C

N·m (kgf·m)

160 (16.3)

←

←

165 (16.8)

162 (16.5)

160 (16.3)

160 (16.3)

←

←

rpm

2100

←

←

2570

←

2200

2100

←

←

kW (PS)

38 (51)

←

←

44 (59)

43 (58)

42 (57)

36 (48)

←

←

rpm

2570

←

←

2570

←

←

2250

←

←

Minimum fuel consumption ratio

g/kW·h (g/PS·h)

298 (219)

←

233 (171)

233 (171)

←

310 (228)

298 (219)

←

←

rpm

2000

←

←

2000

←

1600

2000

←

←

Idle speed

rpm

750

←

←

750

←

←

750

←

←

No-load maximum rpm governed speed

2570

←

←

2570

←

←

2250

←

←

A: Gasoline (Exclusive) B: Gasoline (Convertible) C: LPG (Exclusive, Convertible)

0-7

PRINCIPAL DIFFERENCES FROM GASOLINE VEHICLE LPG Exclusive vehicle

Convertible vehicle

Gasoline vehicle

Fuel tank

LPG cylinder

Gasoline tank and LPG cylinder

Gasoline tank

Adapter

For LPG

For LPG

Not provided

Regulator

For LPG

For LPG

Not Provided

Fuel pump

Not provided

For gasoline

For gasoline

Fuel filter

For LPG

For gasoline, For LPG

For gasoline

Solenoid valve

For LPG

For LPG

Not provided

ABBREVIATIONS Abbreviation (code)

Meaning

Abbreviation (code)

Meaning

ASSY

Assembly

O/S

Oversize

ABDC

After bottom dead center

OPT

Option

ATDC

After top dead center

RH

Right hand

BBDC

Before bottom dead center

rpm

Revolution per minute

BTDC

Before top dead center

SST

Special service tool

BDC

Bottom dead center

STD

Standard

EX

Exhaust

SUB-ASSY

Sub-assembly

IN

Intake

T=

Tightening torque

LH

Left hand

U/S

Undersize

0-8

GENERAL RULES OF SERVICING WORK 1.

Preparation before disassembly • Prepare necessary mechanic tools, measuring instruments and SST before starting operation.

• When disassembling a complicated assembly, put punch or matching marks at places not affecting the function to facilitate reassembly operation. When repairing an electrical system, start operation after disconnecting the cable from the battery negative terminal.

2.

Inspection during disassembly • Each time a part is removed, check the part installed state, deformation, damage, roughening state and scratching.

3.

Orderly arrangement of disassembled parts • Disassembled parts shall be arranged orderly. Distinguish the parts to be replaced from the parts to be reused.

4.

Cleaning of disassembled parts • Parts to be reused shall be cleaned and washed thoroughly.

5.

Inspection and measurement • Detailed inspection and measurement shall be carried out as required for parts to be reused.

6.

Installation • Install good parts according to the correct procedure and observing the determined standards (tightening torques, adjustment values, etc.).

• Be sure to use genuine parts for replacement of existing parts.

• Be sure to use new packings, gaskets and cotter pins because they are non-reusable parts.

• Coat seal packing on gaskets depending on the places, coat oil on the sliding contact places, coat oil or grease at specified places, and coat MP grease on oil seal lips before reassembly.

7.

Adjustment and operation check • Adjust to the service standard values by using gages, a multimeter, etc.

0-9

BOLT & NUT TIGHTENING TORQUES Standard Bolt & Nut Tightening Torque Tightening torques of standard bolts and nuts are not indicated throughout the manual.

Use the procedures and table below to judge the standard tightening torque.

1.

Judge the tightening torque for the hexagon head bolt, welded bolt or stud bolt having the standard bearing surface according to the tightening torque table by identifying the bolt strength class from the table below.

2.

Judge the tightening torque for the hexagon flange bolt based on the threading diameter.

3.

The nut tightening torque can be judged from its corresponding bolt type by using procedure 1.

BOLT STRENGTH CLASS IDENTIFICATION METHOD AND TIGHTENING TORQUE Identification by Actual Part Type

Shape and Strength class

Number in relief or hallmark on head

Hexagon head bolt (standard bearing surface)

Strength class 4 = 4T 5 = 5T 6 = 6T 7 = 7T 8 = 8T

No mark

4T

Bolt with two raised lines on head

5T

Bolt with three raised lines on head

7T

Bolt with four raised lines on head

8T

Welded bolt

4T

No mark

4T

About 2 mm (0.08 in.) groove(s) on one/both edge(s)

6T

Stud bolt

0-10

Identification by Part No. Type

Part No.

Shape

91611-40625 Nominal diameter

Nominal length (mm) Hexagon bolt

Nominal diameter (mm) Strength class Nominal length

92132-40614 Nominal diameter

Nominal length (mm) Stud bolt

Nominal diameter (mm) Strength class

Length

Tightening Torque Table Standard tightening torque

Strength class

Nominal diameter mm

Pitch mm

N·m

kgf·cm

ft·lbf

4T

6 8 10 12 14 16

1.0 1.25 1.25 1.25 1.5 1.5

5.4 13 25 47 75 113

55 130 260 480 760 1150

4.0 9.4 18.8 34.7 54.9 83.0

5T

6 8 10 12 14 16

1.0 1.25 1.25 1.25 1.5 1.5

6.5 16 32 59 91 137

65 160 330 600 930 1400

4.7 11.6 23.8 43.3 67.1 101.1

6T

6 8 10 12 14 16

1.0 1.25 1.25 1.25 1.5 1.5

7.8 19 39 72 108 172

80 195 400 730 1100 1750

5.8 14.1 28.9 52.7 79.4 126.6

7T

6 8 10 12 14 16

1.0 1.25 1.25 1.25 1.5 1.5

11 25 52 95 147 226

110 260 530 970 1500 2300

7.9 18.8 38.3 70.0 108.3 166.1

8T

6 8 10 12 14 16

1.0 1.25 1.25 1.25 1.5 1.5

12 29 61 108 172 265

125 300 620 1100 1750 2700

9.0 21.7 44.9 79.4 126.6 195.3

0-11

Identification by Bolt Shape (Hexagon flange bolt) Class

4.8T

6.8T

8.8T

10.9T

11.9T

-

-

No mark

Hexagon flange bolt

No mark

Tightening Torque Table (Hexagon flange bolt) Standard tightening torque

Strength class

Nominal diameter mm

Pitch mm

N·m

kgf·cm

ft·lbf

4.8T

6 8 10 12 14 16

1.0 1.25 1.25 1.25 1.5 1.5

5.5 13 27 50 78 120

56 130 280 510 800 1220

4 9 20 37 58 88

6.8T

6 8 10 12 14 16

1.0 1.25 1.25 1.25 1.5 1.5

7.5 19 39 71 110 170

80 190 400 720 1120 1730

6 14 29 52 81 125

8.8T

6 8 10 12 14 16

1.0 1.25 1.25 1.25 1.5 1.5

12 29 61 110 175 270

120 300 620 1120 1780 2750

9 22 45 81 129 199

10.9T

6 8 10 12 14 16

1.0 1.25 1.25 1.25 1.5 1.5

15.5 38 80 145 230 360

160 390 820 1480 2350 3670

12 28 59 107 170 266

11.9T

6 8 10 12 14 16

1.0 1.25 1.25 1.25 1.5 1.5

17.5 42 89 160 260 400

180 430 910 1630 2650 4080

13 31 66 118 192 295

0-12

PRECOATED BOLTS (BOLTS WITH SEAL LOCK AGENT COATING ON THREADS) 1.

Do not use the precoat bolt as it is in either of the following cases: (1) After it has been removed.

(2) When it has been moved by tightness check, etc. (loosened or tightened)

Seal lock agent

Note: For torque check, tighten the bolt at the lower limit of the allowable tightening torque range; if the bolt moves, retighten it according to the steps below.

2.

How to reuse precoated bolts (1) Wash the bolt and threaded hole.

(The threaded hole must be washed even when replacing the bolt with a new one.)

(2) Completely dry the washed parts by blowing with air.

(3) Apply the specified seal lock agent to the bolt threaded portion.

0-13

PERIODIC MAINTENANCE INSPECTION METHOD I: Inspection. Repair or replacement if required.

C: Cleaning *1: Soapy water *2: Detector Inspection Period

Months

1

3

6

12

Hours

170

500

1000

2000

I*1

{

←

←

←

Damage of piping and joint

2

I*

{

←

←

←

Tar removal from regulator

C

{

←

←

←

Regulator adjustment status

I

{

←

←

←

Regulator function

I

{

←

←

Adapter

I

{

←

←

Filter clogging

C

{

←

←

Loosened installation and functioning of solenoid valve

I

{

←

←

Gas cylinder

I

{

←

←

←

Looseness and damage of gas cylinder mounting

I

{

←

←

←

Item Gas leak from piping and joint

PERIODIC REPLACEMENT PARTS Item

Replacement timing

O-ring for LPG cylinder valve

Every 24 months

LPG high and low-pressure rubber hoses

Every 24 months

LPG regulator diaphragm and O-ring

Every 36 months or 2500 hours

Fuel filter

Every 36 months or 2500 hours

…..This Page Intentionally Left Blank…..

1-1

OPERATION DESCRIPTION Page

OUTLINE OF LPG DEVICE....................................1-2 FUEL FILTER FOR LPG ........................................1-3 SOLENOID VALVE .................................................1-3 ADAPTER...............................................................1-4 REGULATOR..........................................................1-5

0 1 2 3

SPECIFICATIONS ....................................................1-5

4

REGULATORS SYSTEM COMPONENTS ................. 1-11

5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 E

1-2

OUTLINE OF LPG DEVICE LPG (in liquid form supplied from the cylinder) passes through the LPG filter in the engine room to remove foreign matter and reaches to the regulator through the main solenoid valve. LPG is reduced and gasified in the regulator, and supplied to engine with its pressure kept at a certain rate.

Engine coolant is led to the regulator for use as the heat source for LPG gasification.

Battery

Ignition switch

Regulator set Fuse

Injector path Slow solenoid valve

Regulator

Main LPG solenoid filter valve

Main path

Coolant path

Adapter Injector

Cylinder Valve LPG

Engine

1-3

FUEL FILTER FOR LPG From LPG cylinder

To Main solenoid valve Filter element

The filter is mounted between the LPG cylinder and the right before the solenoid valve to remove various kinds of foreign materials in LPG. It consists of a filter element and permanent magnet, and the filter element is detachable for easy cleaning and has sufficiently strong construction to withstand LPG vapor pressure.

When low-grade LPG is used, vary small impurity particles flow into the regulator causing start difficulty due to clogging of the slow path. The filtering performance has been improved to be able to remove foreign matters of 2 µm or more in size.

Filtering Performance

Solenoid coil

To Regulator

From LPG filter IN

OUT Back spring

2 µm

SOLENOID VALVE The solenoid valve is mounted between the LPG filter and the regulator, and controls gas flow according to the engine condition.

For example, when the engine is running, the solenoid valve is ON and supplies fuel. Once the engine stops running, it turns OFF and cuts off the gas flow.

When the current flows through the solenoid valve, which consists of a slide valve, back spring, and solenoid coil, magnetic force is generated. The slide valve overcomes the spring force by such magnetic force to move forward the IN side, and fuel flows.

When the current stop flowing through the solenoid valve, the slide valve is forced to back to the OUT side by the LPG pressure and spring force to shut off the flow.

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 E

1-4

ADAPTER

Ventury diameter

Seat diameter

Seat angle

Ventury

The adapter is installed on the right upper position of the electric governor, and mixes air with gaseous LPG decompressed in the regulator. The air-mixed fuel is led to the engine. The adapter has a FCM (Fuel/air Control Motor) at the ventury part and the FCM controls the amount of fuel based on the engine ECU signal. The motor has a taper-shaped needle valve that moves right or left based on the engine ECU signal. This sliding of the valve changes the opening space of the fuel path.

Needle FCM valve Electronic governor

Specifications Ventury diameter

mm (in)

24 (0.9)

Needle valve seat diameter

mm (in)

11 (0.4)

°

60

Needle valve seat angle

FCM specifications Magnetized way Stroke Pulse generation rate

1-2 magnetized type mm (in)

5 (0.2) [0.05 (0.002) / step]

pulse / second

140

1-5

REGULATOR The regulator supplies vaporized LPG after pressure reduction to the engine while maintaining the pressure at a fixed level.

0 1 2 3 4 5 6 7 8 9 10 11 12 SPECIFICATIONS

13

First chamber pressure

kPa (psi)

24.5 to 34.3 (3.6 to 5.0)

First seat inner diameter

mm (in)

3.2 (0.1)

Secondary seat inner diameter

mm (in)

Slow system flow shut off method Drain cock

6.0 (0.2) Solenoid valve Optionally available

14 15 16 17 18 19 20 21 E

1-6

Regulator Function The LPG is gasified by depriving the engine coolant, led into the regulator, of heat. The regulator consists of chamber A where LPG vaporization starts, chamber B (first reducing chamber) where the gasified LPG pressure is reduced, chamber C (second reducing chamber) for reducing the pressure down to almost atmospheric level to supply fuel using the adopter venturi vacuum, and chamber D for forced fuel supply during engine start and idling.

LPG flowing into chamber A of the regulator pushes elastic face valve 1 open by vapor pressure allowing it to enter first reducing chamber B where it is vaporized by pressure reduction. When the pressure in chamber B becomes in the range of 24.5 to 34.3 kPa (0.25 to 0.35 kgf/cm2) (3.6 to 5.0 psi), first diaphragm pushes first regulator spring, so first diaphragm hook acuates first valve lever to close elastic face valve 1. When LPG flows out to second reducing chamber C, the first pressure drops and first valve lever is operated by first regulator spring to open elastic face valve 1 to cause fuel to flow into first reducing chamber B again. Opening and closing of elastic face valve is repeated to maintain the first pressure at a fixed level. The pressure of the fuel entering from chamber B into chamber C through elastic face valve 2 is reduced to atmospheric level. Chamber C is connected to the adapter.

The vacuum of the ventury nozzle at the adapter operates second diaphragm to open elastic face valve 2 via second valve lever. The valve is closed by the force of second regulator spring to maintain a constant pressure (atmospheric pressure).

Injector path (to injector)

Slow path

Chamber D Slow solenoid valve Main path (to adaptor)

Elastic face valve 2 Chamber B

Chamber C

Secondary diaphragm First diaphragm hook

Second valve lever

First regulator spring First diaphragm First valve lever Elastic face valve 1 Chamber A

1-7 1.

When starting the engine When the ignition switch and LPG switch are both turned to ON, the LPG led from the IN port flows into chamber A. Upon entering chamber A, the LPG pushes open the elastic face valve 1 by its own vapor pressure, and enters the primary pressure reduction chamber B for pressure reduction and vaporization. When the pressure in chamber B reaches in the range of 24.5 to 34.3 kPa (3.6 to 5.0 psi), first diaphragm pushes first regulator spring to operate first valve lever by means of first diaphragm hook. As a result elastic face valve is closed and the pressure in the primary pressure reduction chamber B remains at a constant level. When the starting motor runs, the current flowing in the coil of the slow solenoid operates the valve to connect chambers B and D. Since the pressure in chamber B at 24.5 to 34.3 kPa (3.6 to 5.0 psi) is higher than the atmospheric pressure, LPG flows into chamber D. The LPG entering chamber D flows through the slow path, and main path into the adapter, and is then supplied to the engine from the venturi nozzle to start initial explosion. When the throttle valve at the electric governor is opened slightly then, vacuum is generated in the venturi of the adapter. The vacuum in the adapter acts on the secondary pressure reduction chamber C via the main path. At this time, secondary diaphragm is operated to open elastic face valve 2 via second valve lever to cause LPG to flow from the primary pressure reduction chamber B to the secondary pressure reduction chamber C. As a result, a large amount of LPG enters the adapter for consecutive combustion.

Injector path (to injector)

Slow path

Chamber D Slow solenoid valve Main path (to adaptor)

Elastic face valve 2 Chamber B

Chamber C

Secondary diaphragm First diaphragm hook

Second valve lever

First regulator spring IN port

First diaphragm First valve lever Elastic face valve 1 Chamber A

1-8 2.

During idling When the engine is idling, current flows to the slow solenoid valve coil to operate the valve, resulting in opening of the closed path to connect chambers B with D. Since the pressure in chamber B is high enough, the depressurized LPG flows chamber D. Though most of the fuel flown to chamber D is led to the adapter through the slow path, main path, and venturi nozzle of the adapter, and then supplied to the engine, fuel is also delivered to the engine by the LPG injector to compensate the air-fuel ratio. The idle adjusting screw controls main flow rate of fuel. Since vacuum at the adapter is very low during idling, elastic face valve 2 is not opened and the fuel is supplied not from the chamber C, but from the slow path.

Idle adjusting screw Injector path

Slow path Main path

Chamber D Slow solenoid valve

Elastic face valve 2

Ventury nozzle

Chamber B Adapter

LPG injector

Chamber C

1-9 3.

During normal operation When the throttle valve is opened, vacuum arises at the adapter venturi nozzle, which is applied to chamber C through the main path. This vacuum pulls second diaphragm to open elastic face valve 2. As a result, LPG flows from chamber B to chamber C, and enters the adapter venturi nozzle through the main path.

As a current also flows in the slow solenoid valve, LPG also flows from chamber B to chamber D, and through the slow path to the venturi nozzle, and is also supplied to the engine by the LPG injector through the injector path.

While the engine is running in medium load range, LPG fuel is mostly supplied through the main path, and LPG injector injects the shortage amount of fuel to the ideal air-fuel ratio.

While the engine is in high load range, the FCM at adapter changes the amount of fuel flow to adjust the overall fuel amount, on the other hand, the injector supplies a fixed amount of fuel with engine.

Injector path

Slow path Main path

Chamber D Slow solenoid valve

Elastic face valve 2

Chamber B Second diaphragm

Ventury nozzle Adapter

Throttle valve Chamber C

FCM

LPG injector

1-10 4.

When stopping the engine When the engine stopped, the current to the slow solenoid valve is cut off to close the path between chambers B and D, resulting in suspension of LPG supply through the slow path. Since the vacuum at the adapter venturi does not exist, LPG supply through the slow path also stops.

Slow path

Chamber D Slow solenoid valve Chamber B

Adapter

LPG injector

1-11

REGULATORS SYSTEM COMPONENTS LPG Cutoff Device The solenoid valve for slow path control is integrated with the regulator. The solenoid valve is opened and closed according to the engine speed, starter signal etc. detected by means of engine ECU. When the ignition switch is ON, with the engine not running, the valve is closed not to flow LPG to the adapter.

Ignition switch

ST ON AM Gasoline EFI main relay

Igniter Main solenoid

Engine ECU Battery

Starter relay

Starter motor

LPG Solenoid relay

Slow solenoid

LPGGasoline switch LPG

…..This Page Intentionally Left Blank…..

2-1

LPG REGULATOR OVERHAUL Page

PRECAUTION FOR LPG FORKLIFT OPERATION AND REPAIR ........................................................2-2

0

REGULATOR..........................................................2-3

1

REMOVAL·INSTALLATION .....................................2-10

2

DISASSEMBLY·REASSEMBLY ...............................2-12

3

LPG LEAK INSPECTION .....................................2-17

4

ENGINE ADJUSTMENT.......................................2-18

5

WIRING DIAGRAM...............................................2-20

6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 E

2-2

PRECAUTION FOR LPG FORKLIFT OPERATION AND REPAIR Handle LPG with special attention, because it is inflammable and may cause explosion resulting in the fatal accident.

1.

Never smoke tobacco, strike a match and light a lighter near the LPG forklift. Never park and stop the LPG forklift near a stove, gas burner, electric heater, electric apparatus (a motor, etc), bonfire, etc. (near the fire).

Avoid the direct sunlight, if possible.

2.

Never operate the LPG forklift near the fire.

3.

When Operating, inspecting and repairing the LPG forklift, put up “CAUTION INFLAMMABLE” to avoid any fire.

4.

When repairing the LPG forklift, remove the engine key so that it cannot be operated by persons other than the operator.

5.

Use a gas leak detector, soapsuds or neutral detergent solution to detect gas leak. Never use other device or liquid, etc.

6.

To check gas leak at night, be sure to light a flashlamp outside the chamber before approaching to the LPG forklift (to prevent a hazard by switching spark).

7.

When gas should leak, ventilate air after confirming that there is no fire.

8.

Pay special attention to keep the LPG cylinder. Keep it in the place free from the fire and install a gas leak detector.

9.

When a LPG forklift is used for a long time, impurities in fuel and tank rust accumulate in its inside. The operation of the LPG devices becomes defective by various causes. In this case, the LPG devices must be inspected, repaired and washed. When disassembling and reassembling the regulator, pay special attention to its adjustment and airtightness.

10. Be sure to apply liquid packing to the threaded parts of each part (the union, solenoid valve, etc.). Never apply liquid packing to the first and the second threads of the screw tip.

2-3

REGULATOR General

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 E

2-4

Components

First valve ASSY

Idle adjust screw

O-ring Solenoid valve

Second cover

Second valve ASSY

First diaphragm

First cover

Second diaphragm

2-5

SSTs for LPG Regulator Overhaul 4

0

5

1

1 6

2 7

2

3 4

3

5

9-3

9-1

6 7

8

8

99-2

9 10 No.

Part No.

Part Name

1

09813-26600-71

Gauge

2

09814-22000-71

Tool

3

09815-22000-71

Tool

4

80339-76026-71

Automatic choke pipe plug

5

09817-23600-71

Union

6

09819-23600-71

Gauge

7

09819-22000-71

Gauge

8

23627-22000-71

Spring

9 9-1 9-2 9-3

09820-23600-71 09823-23600-71 09822-22000-71 09821-22000-71

Tester SUB-ASSY Union Gauge Bellows

11 12 13 14 15 16 17 18 19 20 21 E

2-6

How to Deal with Tamper Proof Ring General It is not basically necessary to adjust VF voltage and regulator primary pressure, but at regulator overhauling, remove the tamper proof rings to adjust them. Follow the procedure described below to treat the tamper proof rings.

Disassembly: 1.

Cut off the head of the tamper proof ring using a hacksaw shown in the illustration.

2.

Remove the idle adjusting screw and/or regulator primary pressure adjust screw.

3.

Using a pair of nippers, remove the ring.

Reassembly: 1.

Install the idle adjusting screw temporarily.

(1) Set the mixture adjust screw temporarily to the following dimension: Temporal set value: 6.2 mm (0.25 in)

6.2 mm (0.25 in)

Idle adjusting screw

(2) Make sure to install a new cap (21673-13370-71) after this adjustment is made on the vehicle.

Make sure to adjust the engine speed after installing the regulator on the vehicle.

2.

Install the regulator primary pressure adjusting screw.

(1) Install the screw and nut.

SST

(2) Using SST, adjust the protrusion of the screw.

SST 09819-22000-71

3.

Install the tamper proof ring (21673-13370-71).

2-7

Troubleshooting Inspection 1 SST

1.

SST

SST (Union) tightening torque: T=0.2 to 0.3 N·m (2 to 3 kgf·cm) [0.14 to 0.19 ft·lbf]

SST

2.

Supply compressed air at 400 kPa (4 kgf/cm2) [57 psi] through the IN port and maintain the air pressure.

Note: Don't apply compressed air more than 780 kPa (8 kgf/cm2) [110 psi].

Compressed air OK

Remove the idle adjusting screw and install the SST.

3.

Check that the SST gauge indicates 0.

0

NG

More than 0

Slow solenoid valve defect

Inspection 2 SST

1.

Put the SST to the injector port to prevent air from blowing.

2.

Apply 12 V to the slow solenoid valve.

3.

See that the SST gauge indicates 24.5 to 34.3 kPa (0.25 to 0.35 kgf/cm2) [3.6 to 5.0 psi].

SST SST

Compressed air OK

12 V

24.5 to 34.3 kPa (0.25 to 0.35 kgf/cm2) [3.6 to 5.0 psi].

NG

0

Slow solenoid valve defect

NG

Other than 24.5 to 34.3 kPa (0.25 to 0.35 kgf/cm2) [3.6 to 5.0 psi].

• In appropriate adjustment of first pressure • Elastic face valve 1 defect • Elastic face valve 2 defect • First diaphragm defect • Clogging of slow path

Inspection 3 SST

1.

Stop supllying the compressed air in state of Inspection 2.

2.

Read the SST gauge.

SST SST

12 V

OK

The pointer stays at the same position as that of inspection 2.

NG To flow (1)

The pointer gradually moves toward the 0 position.

2-8 From Inspection 3 OK

Inspection 4 1.

Stop supplying the compressed air in the state of Inspection 2.

2.

Breathe air into the inner vent port and read the SST gauge.

Air

The pointer moves to 0 position.

OK Normal

NG

The pointer stays at the position.

• Second diaphragm defect • Elastic face valve 2 (in C chamber) defect.

Flow (1) (from inspection 3) NG

Inspection 5 Apply soapy water on portions A to F of the regulator to check any air leakage in state of Inspection 2.

B

C D

Compressed air E A F Leak from A or F. Result 1 Leak from B: Defect of idle adjusting screw O-ring.

Leak from F: Body defect.

Leak from A, C, D, or E. Result 2 Re-check after retightening each part. (Since the fitting at A is applied with a sealing agent, reassemble it.)

OK

No leak from any portion

To Inspection 3

NG

Leak from D

• Elastic face valve 2 contact defect • First diaphragm defect • Loosen of elastic face valve 2 mounting screw

2-9

Individual Inspection 1.

Inspect the slow solenoid.

Check that the operating sound is heard when applying 12 V to the slow solenoid.

2.

Inspect the main solenoid.

Check that the operating sound is heard when applying 12 V to the main solenoid.

12 V

12 V

2-10

REMOVAL·INSTALLATION Caution: • Perform working at a well-ventilated job site and never put fire sources around the vehicle.

• Perfectly discharge LPG from the piping before starting removal.

• Disconnect the battery negative terminal before handling the fuel system.

• After installation, using soapy water, check no LPG leak from any part of each piping before starting the engine.

• After installation, adjust the idling speed. (See page 2-17)

Removal Procedure 1

Fully discharge LPG from the fuel piping. [Point 1]

2

Disconnect the battery cable from the negative terminal.

3

Drain engine coolant.

4

Disconnect the wiring from the main and slow solenoid valves.

5

Disconnect the fuel piping.

6

Disconnect the coolant piping.

7

Remove the filter and main solenoid.

8

Remove the regulator ASSY.

Installation Procedure The install procedure is the reverse of the removal procedure.

Note: After installation, adjust the idling speed. (See page 2-17)

2-11

Point Operations [Point 1] 2

Removal: Discharge LPG from the piping according to the procedure below.

(1) Close the LPG supply piping valve 1 (green).

1

(2) Close the LPG outlet valve 2 (amber).

(3) Start the engine, and run the engine in the idling state until it stops naturally.

2-12

DISASSEMBLY·REASSEMBLY Caution: Perform working at a well-ventilated job site and never put fire sources around the vehicle.

Note: • Wash the outer surface of the regulator and keep the work bench clean.

• First, perform individual check of the filter for clogging and the solenoid valve for any abnormality, and then disassemble the regulator only when its internal abnormality is found by the inspection according to the troubleshooting given in this manual.

• Disassemble the regulator carefully, or defects such as diaphragm or valve contacts may occur.

T = N·m (kgf·cm) [ft·lbf]

4

6

5

1

2

3

Disassembly Procedure 1

Remove the regulator second cover and diaphragm. [Point 1]

2

Remove the second valve ASSY. [Point 2]

3

Remove the first cover, first diaphragm and spring. [Point 3]

4

Remove the first valve ASSY. [Point 4]

5

Remove the slow solenoid valve.

6

Remove the idle adjust screw and O-ring. [Point 5]

Reassembly Procedure The install procedure is the reverse of the removal procedure.

2-13 [Point 1] Reassembly: 4

1

Pin

2

1.

3

2. Tighten the screws in the illustrated order.

Tightening torque: T = 3.5 to 4.4 N·m (36 to 45 kgf·cm) [2.6 to 3.5 ft·lbf]

Install the diaphragm by matching its pin with the concave portion of the second valve lever.

Concave portion

[Point 2] Reassembly: Install the spring by holding it manually so as not to be freed from the convex portion of the lever.

Carefully perform the work to prevent the lever seat portion from being pressed against the housing.

Seat portion Spring

Convex portion

Snap ring

Spring washer

Reassembly: Follow the steps below when the second valve ASSY is replaced with a new one: (1) Insert the seat.

(2) Install the spring washer.

(3) Install the snap ring.

Seat

(4) Perform valve airtightness test in the state of step 3 above. (See page 2-13) (5) Apply adhesive agent (Castle Super Cement) on the snap ring and spring washer. Do not let the adhesive agent adhere on the valve seat portion.

B A

SST

Inspection: Inspect the second valve lever height.

Check contact with the lever when passing through the A side of the SST, and no contact when passing through the B side.

SST 09819-23600-71

2-14 If not satisfied, use the SST to bend the lever for adjustment.

SST (2)

SST 09814-22000-71................................. (1) 09815-22000-71................................. (2) During lever height adjustment, do not push the valve seat against the port.

SST (1)

[Point 3]

8 1

9 7

Disassembly: Since the spring force is applied at each portion, do not try quick removal but loosen each bolt equally for removal.

4

Reassembly: Tighten each bolt equally step by step so as not to let springs be fallen. Tighten in the illustrated order for final tightening.

5

3

6

Tightening torque: T = 3.5 to 4.4 N·m (36 to 45 kgf·cm) [2.6 to 3.5 ft·lbf]

2

Diaphragm hook

Disassembly: Since the diaphragm hook is engaged with the first valve lever, move the diaphragm in the direction of the arrow in the illustration for removal.

Reassembly: Engage the diaphragm hook onto the first valve lever tip.

First valve lever

[Point 4] Disassembly: 1.

Remove the first valve ASSY.

2.

Disassemble the first valve.

Reassembly: 1.

O-ring

Reassemble the first valve ASSY.

Note: Replace the O-ring with a new one.

2.

Install the first valve sub-assembly.

Tightening torque: T = 3.5 to 4.4 N·m (36 to 45 kgf·cm) [2.6 to 3.3 ft·lbf]

2-15 3.

Check the first valve air-tightness.

(1) Put the SST (spring) between the lever tip and regulator body.

SST 23627-22000-71

SST

(2) Connect the SST (gauge) to the fuel inlet.

SST 09820-23600-71

SST

(3) Check that the air does not leak from the valve until air pressure become in the range of 49.0 to 58.8 kPa (0.5 to 0.6 kg/cm2) [2.7 to 7.0 psi]. If air leaks before the air pressure reaches at the range, replace the elastic face valve 1.

4.

SST

Check and adjust the first lever height.

(1) Push the first valve at the elastic face valve side.

(2) Check contact with the lever when passing through the S side of the SST, and no contact when passing through the T side.

T S

SST 09813-26600-71 Reference height: 11.8 to 12.3 mm (0.47 to 0.48 in) from the regulator contact surface.

5.

Using SSTs, adjust the first valve lever height if it is not within the specified range.

SST 09814-22000-71................................. (1) 09815-22000-71................................. (2)

SST (2)

Note: • Do not apply force to the valve seat, or the valve seat will be damaged.

• Be sure to set the SST with a cut on the valve lever.

SST (1)

6.

7.

Hang the diaphragm hook at the tip of the first valve lever and set the diaphragm to the regulator body.

Install the regulator first cover to the body, with pushing the diaphragm spring manually.

Tightening torque: T = 3.5 to 4.4 N·m (36 o 45 kgf·cm) [2.6 to 3.3 ft·lbf]

2-16 8.

Adjust the first diaphragm adjust screw.

(1) Loosen the adjust screw nut.

SST

(2) Using SST, adjust the protrusion of the screw.

SST 09819-22000-71 Reference height: 13.9 mm (0.5 in) 9.

Adjust the pressure of first reducing chamber. (See page 2-17)

[Point 5] Idle adjusting screw

Reassembly: Temporarily adjust the idle adjusting screw.

After tightening until the tip end of the adjusting screw come into contact with the body loosen the screw by 3 turns.

Note: • Do not tighten the adjusting screw too hard.

• After installing the regulator on the vehicle, be sure to adjust the VF voltage. (See page 2-18)

Second Valve Airtightness Check

SST (2) SST (1) SST (3)

1.

Temporarily install the second valve ASSY.

2.

Remove the idle adjusting screw and install the SSTs.

SST (union) tightening torque: T = 0.2 to 0.3 N·m (2 to 3 kgf·cm) [0.14 to 0.19 ft·lbf] SST 09817-23600-71................................. (1) 09820-23600-71................................. (2) 3.

Put the SST to the injector port.

SST 80339-76026-71................................. (3)

4.

Apply 12 V to the slow solenoid valve.

5.

Inject compressed air through the SSTs and make adjustment of the seat position to ensure no air leakage by tilting the valve, as shown in the illustration.

2-17

LPG LEAK INSPECTION Caution: • After repairing each part of the LPG system, use soapy water to check no LPG leakage from any part before starting the engine.

• Never use fire for inspecting gas leakage.

• Never use a match or lighter for illumination at the time of inspection at night.

1.

Open the valve between the LPG cylinder and hose. (The LPG is led to the regulator by this operation.)

2.

Remove the idle adjust screw and install the SST. SST 09817-23600-71

3.

Apply 12 V to the main and slow solenoid valves.

4.

Using soapy water or aqueous solution of a neutral detergent, check no gas leakage from each joint (illustrated below).

5.

Be sure to wipe the liquid off after the leak check.

2-18

ENGINE ADJUSTMENT Note: To measure values described below, use the multifunction display or plug-in analyzer.

1.

Warm up the engine until the coolant temperature be 80°C (176°F) or higher.

2.

Check the engine idle speed.

Standard: 750 ± 150 rpm 3.

Check the initial advanced ignition timing.

(1) Using SST, connect the terminal TC and E1 of the diagnosis connector.

SST 09238-13130-71 Notice: Be sure to connect the correct terminals.

If connecting wrong terminals, malfunction may occur.

(2) Using a timing light, check the ignition timing.

Standard: 7° BTDC/750 rpm

4.

Adjust the initial advaced ignition timing.

(1) If the ignition timing is not as specified above, loosen the two distributor clamp bolts and turn the distributor for adjustment.

When delayed: Turn counterclockwise.

When advanced: Turn clockwise.

(2) After adjustment, tighten the bolts and check the ignition timing again.

5.

SST (2) SST (1)

Check LPG regurator primary pressure (1) Install the SST to the LPG regulator.

SST 09817-23600-71................................. (1) 09820-23600-71................................. (2) (2) Start the engine.

(3) Check the LPG regulator primary pressure.

Standard: 24.5 to 34.3 kPa (0.25 to 0.35 kgf/cm2) [3.6 to 5.0 psi] Note: The pressure remains as above one.

2-19 6.

Adjust LPG regurator primary pressure (1) Start the engine.

(2) Loosen the adjust screw nut and adjust the primary pressure by turning the screw.

Standard: 24.5 to 34.3 kPa (0.25 to 0.35 kgf/cm2) [3.5 to 5.0 psi]

7.

Check and adjust VF voltage (1) Warm up the heated oxygen sensor by maintaining the engine speed at 1800 rpm for approximately 2 minutes.

(2) Check the oxygen sensor feedback signal (OX) value changes alternately between 0 and 1.

Standard: The feedback signal (OX) value changes alternately more than 4 times for 20 seconds.

Note: Maintain the engine rpm at 1800 rpm.

(3) Measure the VF voltage while engine idling.

Standard: 2.5 ± 0.5 V (4) If the standard condition is not satisfied adjust the VF voltage into the specified range by turning the idle adjust screw of the regulator slowly.

COUNTERCLOCKWISE

CLOCKWISE

Reference: VF voltage

Condition

Measures

0V

Air fuel ratio: RICH

Turn the screw CLOCKWISE

5V

Air fuel ratio: LEAN

Turn the screw COUNTERCLOCKWISE

(5) After racing the engine several times, check that the VF voltage is within the specified range.

Note: • Adjust the VF voltage to the 2.5 V as possible.

• If VF voltage is 2.5 V, but OX signal value is not changed alternately, disconnect and reconnect the battery negative cable, and perform this step (7) again.

2-20

WIRING DIAGRAM

IGNITION

ST

LPG/ GASOLINE SELECT SWITCH

FUEL

GAS LPG

IG

IGNITION COIL MAIN RELAY

LPG RELAY

IGNITER

DESTRIBUTOR

CRANKSHAFT ANGLE SENSOR

MAIN SOLENOID SLOW SOLENOID

ENGINE ECU

3-1

ELECTRICAL TROUBLESHOOTING Page

BEFORE TROUBLESHOOTING............................3-2 CONNECTOR HANDLING.........................................3-2 WIRE HARNESS AND CONNECTOR INSPECTION PROCEDURE ........................................................3-2

0 1 2

BEFORE BEGINNING TROUBLESHOOTING ......3-4

3

DIAGNOSIS (SELF DIAGNOSIS FUNCTION).......3-5

4

GENERAL ...............................................................3-5

HOW TO INTERPRET THE FLOW-CHARTS ........3-6 ANALYZER .............................................................3-7

5 6

EXPLANATION ........................................................3-7

7

ANALYZER MENU SCREEN LIST..............................3-8

8

ABOUT TROUBLE SHOOTING

BY ERROR CODES .............................................3-9

9

TABLE OF DIAGNOSIS CODES ..............................3-10

TROUBLESHOOTING BY SYMPTOMS ..............3-12 PARTS INSPECTION AND ADJUSTMENT .........3-37

10 11 12 13 14 15 16 17 18 19 20 21 E

3-2

BEFORE TROUBLESHOOTING CONNECTOR HANDLING 1.

Disconnect the battery plug before disconnecting each connector or terminal.

connecting

or

2.

When unplugging a connector, first remove the lock then, without pulling the harness, pull out the connector while holding the main unit.

To connect, push the connector fully until it is locked in position.

3.

When applying tester probes, always do so from the rear of the connector (harness side).

4.

When this is not possible, such as with waterproof tester probes, make sure that inserting will not deform the connector terminal.

5.

Do not touch connector terminals directly with your hand.

6.

When bringing tester probes into contact with live terminals, prevent two tester probes from coming into contact with each other.

WIRE HARNESS AND CONNECTOR INSPECTION PROCEDURE When any trouble occurs, first inspect the connectors and wire harness of the related circuit according to the following procedure.

Continuity Inspection 1.

Disconnect connectors at both ends of the relevant harness.

2.

Measure the resistance between corresponding terminals of the connectors at both ends.

Standard: 10 Ω or less

Note: Move the wire harness slightly from side to side and up and down while measuring.

Reference: The cause of disconnections is almost always the connector as disconnections in the vehicle's central wiring are rare. Inspect especially the sensor connectors with sufficient care.

Short Circuit Check 1.

Disconnect connectors at both ends of the relevant harness.

2.

Measure the resistance between the corresponding connector terminal and N1. Always inspect the connectors at both ends.

Standard: 1 MΩ or above

Note: Move the wire harness slightly from side to side and up and down while measuring.

3-3 3.

Measure the resistance between the relative terminals of the appricable connector.

Standard: 1 MΩ or above

Note: The wiring may short-circuit due to pinching by the body or defective clamping.

0 1 2

Visual and Contact Pressure Checks 1.

Disconnect connectors at both ends of the relevant harness.

2.

Perform a visual check to make sure that there is no rust or foreign matter contaminating the connector terminal.

3.

Check that the caulking is not loose or damaged, and, after checking that there is no damage, gently tug the connector or wire harness to make sure that it cannot be pulled out.

3 4 5 6 7

4.

Insert a male terminal same as that of the terminal to a female connector and check the extracting force.

Defective contact may exist at a terminal where the extracting force is less than that of other terminals.

Note: If a problem, such as rust or foreign matter on the terminal, or a drop in the contact pressure of male/female terminals occurs, a solution that often works is simply disconnecting and re-connecting the connected connector to change the contact conditions. Try disconnecting and re-connecting several times. If such a defect is recognized, it is likely that there is a defective terminal contact.

8 9 10 11 12 13 14 15 16 17 18 19 20 21 E

3-4

BEFORE BEGINNING TROUBLESHOOTING It is not appropriate to begin trouble shooting for the 4Y engine on the basis of results only. It can lead to mistaken corrective action, wasted time, and sometimes to an increase in abnormalities. Therefore, please pay careful attention to the details surrounding the time when a fault occurs, to be supplied by the customer based on the following.

Diagnostic Procedure First, it is necessary to get the "fault history and service history" for the vehicle, and then to gather definite information about the fault occurrence such as "when", "at what times", "in what places", "during what operations or actions", and "what happened afterwards".

Also, try to recreate the conditions for the fault occurrence. (a. The fault cannot be recreated, b. The fault can be recreated: Upon doing what?)

General items Customer name

Date of shipment of vehicle

Date of fault occurrence / hour meter reading

Vehicle model

Frame No.

Engine No. (punched)

Fuel used Gasoline

LPG

Gasoline/LPG combination (Reference LPG fuel company name:

)

Condition of the defect (Tick the items that apply) Defect phenomena 1. Cannot start

a. Does not crank

b. Combustion does not start

2. Does not start well

Poor cranking (when cold · when warm · at all times) b. Unstable idle speed

c. Incomplete combustion

3. Poor idle

a. Poor idle speed

4. Engine stalling

a. Directly after startup (when cold · when warm) b. During reduction of speed c. After reduction of speed d. Without warning e. After engine running rough f. When steering g. During material handling h. Can be re-started immediately

c. Hunting (Regular fluctuation in idle speed)

a. Insufficient power output b. Hesitation 5. Defective operational status c. Surging (swaying forward and backward during acceleration) d. Knocking e. Back fire f. After fire 6. Others

a. Excessive fuel consumption b. Excessive oil consumption d. Water / Oil leakage e. Abnormal noise f. Others (

c. Overheat )

Phenomena at the time of the defect's occurrence The time when the fault began a. Since the vehicle was new b. Recently (From which month and year) to occur c. After putting in for maintenance Frequency of occurrence

a. Always

Weather

Sunny · Cloudy · Rain · Snow · Thunderstorm

b. In certain conditions

c. Occasionally

Temperature conditions

Coolant: a. When cool

Operation conditions

a. No relation b. When idling c. When revving d. When accelerating e. When travelling at constant speed f. When reducing speed g. When travelling uphill h. During material handling operations When not loaded (when steering · lifting · tilting) When loaded (Load weight: approx. kg) (when steering · lifting · tilting) i. Other (when using the inching brake · when steering · other)

Lamps

a. Lights constantly

Temperature Approximately b. When warm

b. Lights occasionally

°C Humidity

Approximately

Temperature inside engine room:

c. Does not light

°C

%

3-5

DIAGNOSIS (SELF DIAGNOSIS FUNCTION) GENERAL When the computer detects a problem in the system, the fault is made known by a lighting a warning lamp and displaying an error code on the combination meter, while at the same time failsafe functions operate to stop the engine or control the engine to a low speed.

Diagnosis display system Error code display

1.

An orange colored lamp lights Lamp blinks (Engine ECU only)

2.

Diagnosis display system The diagnosis is displayed by means of an error code as shown in the illustration to the left, and by the lights turning on.

When the IG switch is turned ON, the lamp lights once to allow checking for the bulb, and then turns off again if the status is normal.

When the IG switch is ON, if an abnormality occurs when the vehicle is stopped, travelling, or when it is performing materials handling operations, on detection of the abnormality an error code is displayed, the engine light turns on, and the spanner lamp flashes as a warning.

When this happens, stop the vehicle quickly and check the error code.

Diagnosis display system The diag memory has a system using the hour meter and tilt lever, a system using the option display, and a system using a plug-in analyzer.

Here the display system using the hour meter and tilt lever is described.

(1) Open the diag memory menu from the main menu (Refer to 8FG Repair Manual).

(2) With each press and release of the knob switch, the respective error code and time of occurrence are alternately displayed at 2 second intervals.

Note: • The maximum number of error codes that can be in the memory is 10, and the smaller diag number represents a newer error.

• An error code appearing just when the key is turned ON may have its stored time such as 0.0.

(3) Connect the matching connector and turn the key switch to OFF. Knob switch Diagnosis memory menu

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Press the knob switch to return it.

Switches automatically every 2 seconds

16 17 18 19 20 21 E

3-6

HOW TO INTERPRET THE FLOW-CHARTS Turn the key switch OFF and ON again

Is there an error code 31-1?

NG

Inspect the VF voltage.

Standard: 2.5 ± 0.5 V OK

Drive controller defect To next procedure depending on result

Single frames indicate measurement using a circuit tester and normal procedures.

Double frames indicate items that can be inspected using mask function.

3-7

ANALYZER EXPLANATION Analyzer function supports operations for inspecting/investigating faulty section by displaying the condition of the control system, using communication between each controller and the multifunction display or plug-in analyzer.

By switching the multifunction display to analyzer mode, or connect the plug-in analyzer to the diagnosis connector, operative conditions of the sensor actuator that is used for traveling functions, or the error information detected by the controller can be read. This is very useful for checking operative condition of each function and saving time for repairing when there is a defect.

The analyzer functions can be used to make servicing faster and easier.

Refer to 8FG series repair manual for how to use the analyzer functions.

The analyzer functions include the following functions.

1.

Diagnosis memory function (DIAG MEMORY) The controller stores a maximum of the past 10 error codes (diagnosis codes) for faults that have occurred in the electrical system. The diagnosis function is the function that reads these error codes and displays them on the display.

The error code and its time of occurrence as a key ON hour meter time are displayed on the display.

2.

In/out monitor function (I/O MONITOR) This function displays the analog input value of each sensor relating to driving, material handling, FHRS, SAS, and OPS on the display. By monitoring this display it is possible to judge whether each circuit and sensor has a fault or not.

I/O ENGINE CTRL: The display shows various kinds of input value such as the analog input voltage from each sensor to the controller, as well as control correction values and the status of the output to the relay.

3-8

ANALYZER MENU SCREEN LIST ANALYZER MENU screen

Display item

Description

DIAG MEMORY

1. - 10.

Indications of errors occurred

I/O ENGINE CTRL

IGSW

Key switch (IG)

STA

Key switch (ST)

BATT

Battery voltage

G/LP

Fuel changeover switch

SEL

Fuel specification discrimination signal

ADJ

Engine specification discrimination signal

MREL

EFI main relay drive signal

FC

Circuit opening relay drive signal

LPR

LP gas main relay drive signal

LFC

LP gas slow solenoid drive signal

OXHT

O2 sensor heater drive signal

THA

Intake temperature sensor voltage

THW

Coolant temperature sensor voltage

PIM

Intake pipe negative pressure sensor voltage

VPA1

Accelerator sensor (1) voltage

VPA2

Accelerator sensor (2) voltage

PA

Accelerator opening angle

VTA1

Throttle position sensor (1) voltage

VTA2

Throttle position sensor (2) voltage

TA

Throttle opening angle

IM

Electronic throttle motor current

NE

Engine speed

IGT

Ignition timing (spark advance amount)

OX

O2 sensor voltage

VF

VF voltage (LPG/CNG)

LINJ

Injector correction value (LPG/CNG)

FCM

Air-fuel ratio motor correction value (LPG/CNG)

3-9

ABOUT TROUBLE SHOOTING BY ERROR CODES 1.

Defective contact of connectors may cause error codes to appear and disappear. Therefore before performing troubleshooting, check the battery cable connection, turn the key switch ON, and check that the error code appears.

If the error code does not appear, inspect the connection status of the relevant connector.

2.

Once an error occurs, the error code is stored in the controller. Even if an error code appears only temporarily and then disappears due to a defective contact, the error code will still be stored.

3.

This volume contains a flow chart relating to symptoms that are particular to LPG. When an error code is showing, refer to 8FG Repair Manual and perform inspection and repair first. When an error code is not showing, refer to the page for the relevant symptom and perform inspection and repair.

06-6

06-6

0A-4

06-5

06-5

0A-4

06-4

06-4

0A-3

06-3

06-3

0A-2

06-2

06-2

0A-3

06-1

06-1

0A-2

05-6

05-6

0A-1

05-5

05-5

0A-1

05-4

05-4

09-1

05-3

05-3

09-1

05-2

05-2

07-1

05-1

05-1

08-1

04-2

04-2

08-1

04-1

04-1

07-1

03-1

03-2

02-2

02-2

03-2

02-1

02-1

03-1

01-5

01-6

01-4

01-4

01-6

01-3

01-3

01-5

Memory

Indication

Blinking

Blinking

Blinking

Blinking

Blinking

Blinking

Blinking

Blinking

Blinking

Blinking

Blinking

Blinking

Blinking

Blinking

Blinking

Blinking

Blinking

Blinking

Blinking

Blinking

Blinking

Blinking

Blinking

Blinking

Blinking

Blinking

Blinking

Blinking

Blinking

Spanner

4Y-ECS

4Y-ECS

4Y-ECS

4Y-ECS

4Y-ECS

4Y-ECS

4Y-ECS

4Y-ECS

4Y-ECS

4Y-ECS

4Y-ECS

4Y-ECS

4Y-ECS

4Y-ECS

4Y-ECS

4Y-ECS

4Y-ECS

4Y-ECS

4Y-ECS

4Y-ECS

4Y-ECS

4Y-ECS

4Y-ECS

4Y-ECS

4Y-ECS

4Y-ECS

4Y-ECS

4Y-ECS

4Y-ECS

Detection ECU

TABLE OF DIAGNOSIS CODES

Engine specification determination abnormality

Fuel specification type does not match

Fuel specification changeover switch abnormality

Fuel specification determination signal abnormality

Ignition signal abnormality

Low voltage (battery line open) abnormality

Air-fuel ratio motor open abnormality

Electronic throttle system abnormality

Throttle motor seizing abnormality

Throttle motor power supply circuit short abnormality

Throttle motor power supply circuit open abnormality

Throttle motor drive circuit short abnormality

Throttle motor drive circuit open abnormality

Throttle position sensor out of range abnormality

Throttle position sensor offset abnormality

Throttle position sensor 2 short abnormality

Throttle position sensor 2 open abnormality

Throttle position sensor 1 short abnormality

Throttle position sensor 1 open abnormality

Water temperature sensor short abnormality

Water temperature sensor open abnormality

Intake pipe pressure sensor short abnormality

Intake pipe pressure sensor-open abnormality

Intake temperature sensor short abnormality

Limited speed of traveling and materials handling due to limited engine power output

Engine may stop

Display only

Display only

The engine speed is unstable and it may stop.

Display only

The engine speed is unstable and it may stop.

Limited speed of traveling and materials handling due to limited engine power output

Limited speed of traveling and materials handling due to limited engine power output

The engine may become out of adjustment at low temperatures.

The engine may begin to run rough

The engine may become out of adjustment at low temperatures.

Display only

Intake temperature sensor-open abnormality

The engine speed is unstable and it may stop.

O2 sensor open abnormality

The engine speed is unstable and it may stop.

Phenomenon on vehicle

O2 sensor heater open abnormality

Fuel feedback control abnormality (LPG/CNG) lean

Fuel feedback control abnormality (LPG/CNG) rich

Error mode

3-10

C4-1

C4-2

C4-3

C4-4

C4-5

C4-6

C4-1

C4-2

C4-3

C4-4

C4-5

C4-6

Blinking

18-3

AD-2

18-3

AD-2

Blinking

18-2

18-2

Blinking

Blinking

Blinking

Blinking

Blinking

Blinking

Blinking

Blinking

18-1

18-1

Spanner

Memory

Indication

4Y-ECS

ASC

4Y-ECS

ASC

4Y-ECS

ASC

4Y-ECS

ASC

4Y-ECS

ASC

4Y-ECS

4Y-ECS

4Y-ECS

ASC

4Y-ECS

ASC

4Y-ECS

Detection ECU

Accelerator sensor out of range abnormality

Accelerator sensor offset abnormality

Accelerator sensor 2 short abnormality

Accelerator sensor 2 open abnormality

Accelerator sensor 1 short abnormality

Accelerator sensor 1 open abnormality

CAN communication SAS/OPS data reception abnormality

Crank angle sensor open abnormality

Engine speed sensor GND short abnormality

Cam angle sensor open abnormality (on start up)

Engine speed sensor open abnormality

Cam angle sensor open abnormality

Error mode

Limited speed of traveling and materials handling due to limited engine power output

Partial limitation of the drive control function.

Display only

Partial limitation of the drive control function.

Engine will not start

Partial limitation of the drive control function.

Engine stop

Phenomenon on vehicle

3-11

3-12

TROUBLESHOOTING BY SYMPTOMS Symptom Chart Symptom Does not start Idling rough

Poor drivability

Engine stalling

Page for reference

Starting motor turns over but engine does not start

3-13

Unstable idle speed

3-15

Idle speed low

3-17

Idle speed high

3-18

Knocking

3-19

Hesitation

3-21

Insufficient power output

3-23

Engine stalling in general

3-26

Engine stalling a short time after start up

3-28

Engine stalling when A/C, lights, or defogger are turned on, or on operating the steering

3-30

Engine stalling on releasing the accelerator

3-31

Charts by System LPG injector system

3-32

Air-fuel ratio control motor system

3-34

Slow solenoid valve system

3-35

3-13 z <DOES NOT START> STARTING MOTOR TURNS OVER BUT ENGINE DOES NOT START Probable cause • Ignition system defect (When combustion does not start) • Fuel system defect (When combustion does start, but does not continue.)

• Regulator primary pressure abnormality during cranking (When the pressure is high there is a possibility of rich air-fuel ratio) Note: When low vapour pressure LPG fuel is used in winter, engine may stall when longer idling or while traveling and be difficult to start immediately afterwards. In this case pour warm water over the LPG regulator to vaporize the fuel, and at the same time turn the LPG switch OFF to stop the fuel supply momentarily and crank after fully opening the accelerator.

Inspect the ignition system.

(Refer to parts inspection and adjustment 10, 11, 12, 13)

NG

Inspect ignition OK

NG

Inspect LPG filter

Replace LPG filter

OK

Inspect main solenoid valve operating noise Inspect the operation sound of the solenoid NG valve when the ignition switch is turned ON. Standard: The valve makes an operation noise

Inspect the wire harness and connectors to the main solenoid OK valve. (Refer to the wiring diagram at the back of the book)

Replace main solenoid valve

NG

OK

Repair wire harness and connectors

Inspect slow solenoid valve operating noise Inspect the operation sound of the solenoid NG valve when the ignition switch is turned ON. Standard: The valve makes an operation noise

Inspect the wire harness and connectors to the slow solenoid OK valve. (Refer to the wiring diagram at the back of the book)

Replace slow solenoid valve

NG

OK

Repair wire harness and connectors

Inspect LPG injector piping internal pressure SST (1) Disconnect the fuel hose between the LPG regulator and the LPG injector at the regulator side.

(2) Connect the SST to the LPG regulator, and inspect the pressure during cranking.

SST 09820-23600-71 Standard: The pressure rises.

OK

NG

3-14

OK

NG

Repair or replace LPG regulator

Inspect LPG regulator primary pressure (Refer to parts inspection and adjustment 1)

NG

Adjust primary pressure of LPG regulator.

(Refer to parts inspection and adjustment 2)

OK

Defect of ignitor or engine ECU

NG

Check starting ability OK

Finish

3-15 z <POOR IDLE ADJUSTMENT> UNSTABLE IDLE SPEED Probable cause • Air leakage • 1 or more cylinders misfiring • VF voltage abnormality during idling • Ignition timing off Note: When fuel of a low vapor pressure is used in winter, insufficient vaporization may cause unstable idle speed.

Inspect power balance Cause one cylinder at a time to misfire by removing its resistive cord, and inspect for a drop in idle speed.

Only a particular cylinder NG

OK Inspect for air leakage NG between the throttle body and cylinder head.

OK

Inspect spark plugs (1) Check that there is no obvious deposition.

(2) Inspect the plug gap.

Standard: 0.7 to 1.0 mm (0.028 to 0.039 in)

NG

Replace spark plug

OK Repair air leak

Inspect distributor cap and NG resistive cord (Refer to parts inspection and adjustment 10, 11)

Replace distributor cap and resistive cord

OK Inspect compression (Refer to parts inspection and adjustment 15)

OPT.

Inspect inner vent piping and LPG regulator drain cock (1) Inspect the installation of the inner vent piping.

Standard: Connected.

(2) Remove the drain plug (STD.), or open the LPG regulator drain cock (OPT.), remove any tar and close the drain cock again.

Caution: Be sure to intall the drain plug (STD.), or close the cock after removing tar.

Inspect initial advance timing (Refer to page 2-18) OK

NG

Close STD.

Drain plug

Open

Adjust initial advance timing

3-16

Inspect VF voltage (Refer to parts inspection and adjustment 14) Standard: 2.5 ± 0.5V

NG

Adjust VF voltage

OK Inspect injector function (Refer to parts inspection and adjustment 6)

NG

To injector system (Refer to 3-32)

OK Inspect compression (Refer to parts inspection and adjustment 15)

NG

Inspect and repair engine

OK Inspect spark plugs (1) Check that there is no obvious deposition.

(2) Inspect the plug gap.

Standard: 0.7 to 1.0 mm (0.028 to 0.039 in)

NG

Clean or replace spark plug

OK Inspect distributor cap and resistive cord (Refer to parts inspection and adjustment 10, 11)

NG

Replace distributor cap and/or resistive cord

OK Inspect ignition coil (Refer to parts inspection and adjustment 12)

NG

Replace ignition coil

OK NG

Inspect LPG filter

Clean or replace LPG filter

OK Inspect LPG regulator primary pressure (Refer to parts inspection and adjustment 1)

NG

Adjust primary pressure of LPG regulator.

(Refer to parts inspection and adjustment 2)

NG

Repair LPG regulator (Refer to section 2)

OK Inspect LPG regulator (secondary system) (Refer to page 2-7) OK Switch to a fuel with high vaporization pressure and inspect the idle speed.

(Winter only) OK

Engine ECU defect

NG

Fuel is defective

3-17 z <POOR IDLE ADJUSTMENT> IDLE SPEED LOW AND UNSTABLE Probable cause • Air-fuel ratio over-lean • Blockage around the electric throttle valve Inspect the VF voltage.

(Refer to parts inspection and adjustment 14) Standard: 2.5 ± 0.5 V Note: A over-lean air-fuel ratio may result in a low and unsable idle speed.

NG

Adjust VF voltage

OK Check whether the engine idle speed changes.

Idle speed gradually increases to within standard value

The idle speed remains low and does not change

Finish

Inspect electronic throttle Operate the accelerator pedal and inspect to see that the throttle PA value changes smoothly.

Standard: PA value changes smoothly.

NG

• Check throttle system • Clean or replace electric throttle

OK Inspect LPG regulator Check LPG regulator for tar accumulation and drain plug loosening/cock opening Standard: Tar is not accumulated and plug is not loosened/cock is not opened

NG

• Tighten drain plug/close cock • Clean LPG regulator (Refer to section 2)

OK Check adaptor for tar accumulation

NG

Clean adaptor

OK Inspect FCM operation (Refer to parts inspection and adjustment 5) OK

Replace engine ECU

NG

Clean or replace FCM

3-18 z <POOR IDLE ADJUSTMENT> Probable cause • Throttle valve return defect • Air leakage • VF voltage abnormality

IDLE SPEED HIGH

Note: Inspect parts related to the items listed above.

3-19 z <POOR DRIVABILITY> KNOCKING Probable cause • Excess deposition in combustion chamber or on spark plug electrode • Ignition timing off Check initial advance timing (Refer to page 2-18)

NG

Adjust initial advance timing (Refer to page 2-18)

OK Inspect spark plugs (1) Check that there is no obvious deposition.

(2) Inspect the plug gap.

Standard : 0.7 to 1.0 mm (0.028 to 0.039 in) OK Excess deposition in combustion chamber, or on piston head portion

NG

Replace spark plug

3-20 z <POOR DRIVABILITY> HESITATION Probable cause • Electronic throttle abnormality • VF voltage abnormality • Initial advance timing off • O2 sensor abnormality Caution: Since pulsating combustion occurs on fuel cut operation at high rpm, operate in a range below the rpm at which hesitation occurs.

Reference: When not loaded: Rated no-load maximum speed When traveling: Rated under-load maximum speed NG

Inspect LPG filter

Replace LPG filter

OK Inspect electronic throttle Operate the accelerator pedal and inspect to see that the throttle PA value changes smoothly.

Standard: PA value changes smoothly.

NG

Inspect throttle system

OK Inspect VF voltage Inspect the VF voltage at 1800 r/min (Refer to parts inspection and adjustment 14) Standard: 2.5 ± 0.5 V

NG

OK Inspect initial advance timing (Refer to page 2-17) Standard: 7.0°

NG

Adjust initial advance timing

OK OX value alternates between 1 and 0

Adjust VF voltage Standard: 2.5 ± 0.5 V OX value does not alternate between 1 and 0 Disconnect and reconnect battery negative cable Note: It is possible to erase data of FCM and [IN] from the engine ECU, which reset the engine ECU

3-21

Inspect LPG regulator primary pressure (Refer to parts inspection and adjustment 1)

NG

Adjust primary pressure of LPG regulator (Refer to parts inspection and adjustment 2)

OK Inspect injector operation and inspect for NG blockages (Refer to parts inspection and adjustment 6, 7)

To injector system (3-32)

OK Inspect O2 sensor feedback (Refer to parts inspection and adjustment 14)

NG

O2 Sensor system defect

OK Inspect spark plugs (1) Check that there is no obvious deposition.

(2) Inspect the plug gap.

Standard: 0.7 to 1.0 mm (0.028 to 0.039 in)

NG

Clean or replace spark plug

OK Inspect distributor cap and resistive cord (Refer to parts inspection and adjustment 10, 11)

NG

Replace distributor cap and resistive cord

OK Inspect ignition coil (Refer to parts inspection and adjustment 12)

NG

Replace ignition coil

OK Inspect air-fuel ratio control motor operation (Refer to parts inspection and adjustment 5)

NG

To air-fuel ratio control motor system (Refer to page 3-35)

OK Inspect inner vent system (1) Check inner vent tube for damage, bent or disconnection (2) Check resonator for damage

NG

Repair or replace

OK Inspect wire harness and connectors related to the air-fuel ratio controll system OK

Replace engine ECU

NG

Repair or replace

3-22 z <POOR DRIVABILITY> INSUFFICIENT POWER OUTPUT Probable cause • Air-fuel ratio abnormality (over-lean) • Initial advance timing off Note: • After disconnecting the battery terminal or removing the LPG fuse, the fuel system learning value will be cleared. This may cause temporary insufficient power output. (Power output will return after being driven for a short while.)

• If a fuel with low pressure vaporization is used in winter, it is possible that the air-fuel ratio may be abnormal (over-rich).

NG

Inspect LPG filter

Replace LPG filter

OK

Inspect water temperature (THW)

NG

Inspect, identify fault, and repair, cleaning system

OK Inspect the full open status of the throttle valve NG Inspect the aperture (TA) of the throttle valve when the accelerator pedal is depressed once.

Standard: 96 %

Inspect electronic throttle system

OK Inspect vacuum piping of vacuum sensor Standard: No hoses disconnected, blocked or bent

NG

Repair vacuum piping

OK Inspect initial advance timing (Refer to page 2-18)

NG

Adjust initial advance timing (Refer to page 2-18)

OK Inspect O2 sensor feedback (Refer to parts inspection and adjustment 14)

NG

O2 Sensor system defect

OK Inspect inner vent system (1) Check inner vent tube for damage, bent or disconnection (2) Check resonator for damage OK

NG

Repair or replace

3-23

Inspect VF voltage Inspect VF voltage value when engine speed is 1800 r/min Standard: 2.5 ± 0.5 V

NG OX value alternates between 1 and 0

OK

Adjust VF voltage Standard: 2.5 ± 0.5 V

OX value does not alternate between 1 and 0 Disconnect and reconnect battery negative cable Note: It is possible to erase data of FCM and [IN] from the engine ECU, which reset the engine ECU Inspect spark plugs (1) Check that there is no obvious deposition.

(2) Inspect the plug gap.

Standard: 0.7 to 1.0 mm (0.028 to 0.039 in)

NG

Clean or replace spark plug

OK Inspect compression (Refer to parts inspection and adjustment 15)

NG

Inspect and repair engine body

OK Inspect distributor cap and resistive cord (Refer to parts inspection and adjustment 10, 11)

NG

Replace distributor cap and resistive cord

OK Inspect ignition coil (Refer to parts inspection and adjustment 12)

NG

Replace ignition coil

OK Inspect battery voltage (BATT) Standard: 10 to 14 V OK During idling, measure the voltage NG between PIM - E2 of the engine ECU. Standard: 3.0 to 4.0 V (For engine stop) OK

NG

Repair wire harness between engine ECU LPG fuse (Refer to the wiring diagram at the back of the book)

Disconnect the vacuum sensor connector and measure the voltage between VC - E2 terminals of the vehicle harness.

Standard: 4.5 to 5.0 V

OK

Replace vacuum sensor

3-24 OK

NG

Inspect wire harness and connectors between engine ECU and vacuum sensor (Refer to the wiring diagram at the back of the book)

Repair wire harness connectors

NG

OK

Replace engine ECU

Inspect LPG regulator primary pressure (Refer to parts inspection and adjustment 1) OK

NG (Standard value or more, or not airtight)

Repair LPG regulator (Refer to section 2)

NG (Standard value or below) Adjust primary pressure of LPG regulator.

(Refer to parts inspection and adjustment 2)

• LPG regulator (secondary system) defect • Engine ECU defect • Or unsuitable fuel used (winter only)

OK

NG

Finish

Inspect and repair blockages in fuel piping system

3-25 z <ENGINE STALL> ENGINE STALLING IN GENERAL Probable cause • Charging system • LPG regulator primary pressure adjustment defect • Air leak in (over-lean) intake system • Ignition timing defect • Idling air-fuel ratio adjustment defect • LPG slow solenoid defect • Injector defect Note: • Pay attention to the warning light lighting when the engine stall occurs.

• Be careful about inappropriate LPG in winter (low vaporization pressure).

• When using low vaporization pressure fuel, if the engine stalls during idling, or when travelling when the engine is not sufficiently warmed up, there is a high possibility that the air-fuel ratio is over-rich. Open the accelerator up fully and crank it for a while, and wait for the engine to start.

Stays off

Check the charge warning lamp Light comes on during engine stall Check the "check engine" warning light Light comes on during engine stall

• Combination meter power supply • Inspect and repair charge warning light

Light comes on before engine stall Inspect and repair charging system

Stays off Light comes on before engine stall

Inspect the "check engine" warning light by short circuiting between the engine ECU MZL E1 terminals.

Standard: Turns on

NG

Inspect and repair the "check engine" warning lamp system

OK Inspect the engine ECU

Measure the voltage between +B - E1 terminals of the engine ECU. Standard: 10 to 14 V

NG

Replace engine ECU

NG

Inspect and repair the ignition switch system

NG

Replace engine ECU

OK Measure the voltage between IGSW - E1 terminals of the engine ECU. Standard: 10 to 14 V OK Measure the voltage between MREL - E1 terminals of the engine ECU. Standard: 10 to 14 V OK

Inspect and repair the main relay system

NG

Inspect LPG filter OK

Clean or replace LPG filter

3-26

Inspect LPG regulator primary pressure (Refer to parts inspection and adjustment 1)

NG

Adjust primary pressure of LPG regulator.

(Refer to parts inspection and adjustment 2)

OK NG (Does not start at all)

Check the vehicle re-starts OK

Inspect ignition OK

OK Recreation test

Inspect for air leakage between the adapter and cylinder head.

NG

LPG regulator defect or unsuitable fuel used (winter only)

NG

Inspect and repair ignition system

Repair air leak

OK Inspect initial advance timing (Refer to 2-13)

NG

Adjust initial advance timing

OK Inspect VF voltage (Refer to parts inspection and adjustment 14)

NG OX value alternates between 1 and 0

OK

Adjust VF voltage Standard: 2.5 ± 0.5 V

OX value does not alternate between 1 and 0 Disconnect and reconnect battery negative cable Note: It is possible to erase data of FCM and [IN] from the engine ECU, which reset the engine ECU

Does knocking occur on gentle racing of the engine?

Inspect distributor pickup coil (Refer to parts inspection and adjustment 12)

YES

OK

NO

NG

Inspect wire harness and connectors between the engine ECU and pick up coil (Refer to the wiring diagram at the back of the book) OK Replace engine ECU Inspect slow solenoid valve (Refer to parts inspection and adjustment 4)

NG

NG Repair wire harness and connectors To slow solenoid valve system (Refer to page 3-35)

OK Inspect injector system operation and inspect NG (Non-operational) for blockages (Refer to parts inspection and adjustment 6, 7) NG (Outside standard value)

Inspect distributor pickup coil

To injector system (Refer to page 3-32)

3-27

Inspect LPG regulator primary pressure (Refer to parts inspection and adjustment 1) NG (Outside standard value)

Check that the engine restarts OK Finish

LPG regulator (secondary system) defect or unsuitable specification fuel (winter only)

NG (Airtightness defect)

Adjust LPG regulator primary pressure (Refer to parts inspection and adjustment 2) OK

OK

Repair LPG regulator (Refer to section 2) NG

Inspect and repair blockages in fuel piping system

3-28 z <ENGINE STALL> ENGINE STALLING A SHORT TIME AFTER START UP Probable cause • LPG regulator primary pressure adjustment defect • Blocked injector, air control valve, or by-pass route • Charging system defect • LPG solenoid defect • Fuel supply cut Note: • Pay attention to the fuel used during winter.

Replace main solenoid valve OK

NG

Does the engine re-start?

OK Inspect the charge warning light OK

NG

Inspect main solenoid valve operating noise Inspect the solenoid valve operation noise when the ignition switch is turned ON Standard: The valve makes an operation noise

NG

Inspect the wire harness and connectors of the main solenoid valve.

(Refer to the wiring diagram at the back of the book) NG

OK

Repair wire harness and connectors

Inspect and repair the charger

Replace slow solenoid valve OK Inspect slow solenoid valve operating noise Inspect the slow solenoid valve operation noise when the ignition switch is turned ON Standard: The valve makes an operation noise OK

NG

Inspect the wire harness and connectors of the slow solenoid valve.

(Refer to the wiring diagram at the back of the book) NG Repair wire harness and connectors

Inspect LPG injector piping internal pressure SST

(1) Disconnect the fuel hose between the LPG regulator and the LPG injector at the regulator side.

(2) Connect the SST to the LPG regulator, and inspect the pressure during cranking.

SST: 09820-23600-71 Standard: The pressure rises.

OK

NG Repair or replace LPG regulator (See section 2)

3-29

Inspect initial advance timing (Refer to page 2-13)

NG

Adjust initial advance timing

OK Inspect VF voltage (Refer to parts inspection and adjustment 14)

NG OX value alternates between 1 and 0

OK

Adjust VF voltage Standard: 2.5 ± 0.5 V

OX value does not alternate between 1 and 0 Disconnect and reconnect battery negative cable Note: It is possible to erase data of FCM and [IN] from the engine ECU, which reset the engine ECU

NG

Inspect LPG filter (Refer to page 2-8)

Clean or replace LPG filter

OK Inspect LPG regulator primary pressure (Refer to parts inspection and adjustment 1)

NG

Adjust primary pressure of LPG regulator (Refer to parts inspection and adjustment 2)

OK Inspect injector system operation and inspect NG for blockages (Refer to parts inspection and adjustment 6, 7) OK • Unsuitable fuel used • Engine ECU defect

To injector system (Refer to page 3-32)

3-30 z <ENGINE STALL> ENGINE STALL WHEN A/C, LIGHTS OR DEFOGGER ARE TURNED ON, OR WHEN THE STEERING IS OPERATED Probable cause • LPG regulator primary pressure adjustment defect • Pay attention to air-fuel ratio abnormalities (injector blocked, idle adjustment defect) • Battery defect Inspect battery voltage (BATT) Standard: 10 to 14 V

NG

Charge or replace the battery

OK Inspect VF voltage (Refer to parts inspection and adjustment 14) Standard: 2.5 ± 0.5 V

NG OX value alternates between 1 and 0

OK

Adjust VF voltage Standard: 2.5 ± 0.5 V

OX value does not alternate between 1 and 0 Disconnect and reconnect battery negative cable Note: It is possible to erase data of FCM and [IN] from the engine ECU, which reset the engine ECU

Inspect initial advance timing (Refer to page 2-17)

NG

Adjust initial advance timing (Refer to page 2-17)

NG

Adjust primary pressure of LPG regulator (Refer to parts inspection and adjustment 2)

OK Inspect LPG regulator primary pressure (Refer to parts inspection and adjustment 1) OK Inspect O2 sensor feedback (Refer to parts inspection and adjustment 14)

NG

Inspect and repair the O2 sensor system

OK Inspect injector system operation and inspect NG for blockages (Refer to parts inspection and adjustment 7, 8)

To injector system (Refer to page 3-32)

OK Inspect inner vent system (1) Check inner vent tube for damage, bent or disconnection (2) Check resonator for damage OK

• Engine ECU defect

NG

Repair or replace

3-31 z <ENGINE STALL> ENGINE STALLING ON RELEASING THE ACCELERATOR Probable cause • Idling air-fuel ratio adjustment defect • Ignition timing off • Air leakage • Injector defect • LPG filter defect Inspect VF voltage (Refer to parts inspection and adjustment 14)

NG OX value alternates between 1 and 0

OK

Adjust VF voltage Standard: 2.5 ± 0.5 V

OX value does not alternate between 1 and 0 Disconnect and reconnect battery negative cable Note: It is possible to erase data of FCM and [IN] from the engine ECU, which reset the engine ECU

Inspect initial advance timing (Refer to page 2-17)

NG

Adjust initial advance timing

OK Inspect main solenoid valve (Refer to parts inspection and adjustment 3)

NG

Replace main solenoid valve

OK Inspect slow solenoid valve (Refer to parts inspection and adjustment 4)

NG

To slow solenoid valve system (Refer to page 3-35)

YES

Inspect distributor pickup coil (Refer to parts inspection and adjustment 12)

OK Does knocking occur on racing of the engine?

NO

OK

NG Replace distributor pickup coil

Inspect wire harness and connectors between engine ECU - pickup coil (Refer to wiring diagram) OK Inspect or replace engine ECU

Inspect the air intake system for air leaks OK

NG

Repair air leak

NG Repair wire harness and connectors

3-32

NG

Inspect LPG filter

Replace LPG filter

OK Inspect injector system operation and inspect NG for blockages (Refer to parts inspection and adjustment 6, 7)

To LPG injector system (Refer to page 3-32)

OK Inspect LPG regulator primary pressure (Refer to parts inspection and adjustment 1) OK Engine ECU defect

NG

Adjust LPG regulator primary pressure

3-33 z LPG INJECTOR SYSTEM Inspect the injectors for air-tightness (Refer to parts inspection and adjustment 6)

NG

Clean or replace injectors

OK Perform startup operation inspection and idle operation inspection of injectors.

(Refer to parts inspection and adjustment 6) OK Measure the voltage between RES - E1 terminals of the engine ECU. Standard: 10 to 14 V

NG (Only during startup) NG

NG

OK

To *A To *B

Measure the voltage between INJ - E1 terminals of the engine ECU. Standard: 10 to 14 V

OK

Inspect LPG injectors (Refer to parts inspection and adjustment 6, 7)

NG Inspect the solenoid resistor (1) Inspect the resistance value of the solenoid resistor.

Standard: 5.7 to 6.3 Ω (20°C) [68°F]

NG

Replace the solenoid resistor

NG

Repair wire harness and connectors

OK Inspect the wire harness and connectors between engine ECU - solenoid resistor (Refer to the wiring diagram at the back of the book) OK Inspect or replace engine ECU

Measure the voltage between INJ - E1 terminals of the engine ECU. Standard: 10 to 14 V

NG

Inspect wire harness and connectors between INJ - E1 of the engine ECU

Repair wire harness and connectors

OK Inspect LPG injectors (Refer to parts inspection and adjustment 6, 7)

Inspect or replace engine ECU

*A

Measure the voltage between STA - E1 terminals of the engine ECU. Standard: 10 to 14 V OK

Inspect or replace engine ECU

NG

Inspect and repair the STA system

3-34 *B

Inspect voltage between connectors on vehicle wire harness side with injector connector disconnected (1) Disconnect the injector connector.

(2) Turn the ignition switch on.

(3) Inspect the voltage between connector terminals on the vehicle wire harness side when the engine is stopped and when it is idling.

Standard: When engine is stopped 0 V When engine is raced Pulsation occurs

OK

Inspect and replace injectors (Refer to parts inspection and adjustment 6, 7)

NG Inspect voltage between connector 1 terminal on vehicle wire harness side and body earth, with injector connector disconnected (1) Turn the ignition switch on.

(2) Inspect voltage between connector 1 terminal on vehicle wire harness side and body earth.

Standard: 10 to 14 V (Battery voltage)

NG

Inspect and repair injector power supply system

NG

Repair wire harness and connectors

OK Inspect wire harness and connectors between engine ECU and injectors (Refer to the wiring diagram at the back of the book) OK

Inspect or replace engine ECU

3-35 z AIR-FUEL RATIO CONTROL MOTOR SYSTEM Inspect air-fuel ratio control motor operation (Refer to parts inspection and adjustment 5)

OK

System normal

NG Disconnect the intake temperature sensor and carry out the above inspection again

OK

Measure the voltage between THA - E2 terminals of the engine control computer OK Standard: 0.5 to 3.5 V (When cold) 0.2 to 1.0 V (When warm)

NG

Inspect and replace engine control computer

NG Inspect intake temperature sensor (Refer to parts inspection and adjustment 8)

NG

Replace intake temperature sensor

NG

Repair wire harness and connectors

OK Inspect wire harness and connectors between the engine ECU and intake temperature sensor (Refer to the wiring diagram at the back of the book) OK

Inspect or replace engine ECU

Inspect the input voltage of the air-fuel ratio control motor (1) Disconnect the connectors of the air-fuel ratio control motor.

(2) Turn the ignition switch on.

(3) Inspect the voltages between the connector terminals 2 and 5 on the wire harness side and body earth.

Standard: Between terminal 2 - body earth 10 to 14 V (Battery voltage) Between terminal 5 - body earth 10 to 14 V (Battery voltage)

NG

Inspect and repair the power supply system for the air-fuel ratio control motor

OK Inspect air-fuel ratio control motor (Refer to parts inspection and adjustment 5)

NG

Replace air-fuel ratio control motor

OK Inspect wire harness and connectors between NG engine ECU - air-fuel ratio control motor (Refer to the wiring diagram at the back of the book) OK

Inspect or replace engine ECU

Repair wire harness and connectors

3-36 z SLOW SOLENOID VALVE SYSTEM Inspect slow solenoid valve for airtightness (Refer to parts inspection and adjustment 4)

NG

Replace slow solenoid valve

OK Inspect slow solenoid valve operation (Refer to parts inspection and adjustment 4)

OK

System normal

NG Inspect voltage between connector terminal 2 and terminal 1 on the slow solenoid valve wire harness side.

OK

(1) Disconnect the connectors of the slow solenoid valve.

(2) Inspect the voltages between the connector terminal 2 - terminal 1 on the wire harness side when the ignition switch is turned ON. Standard: Momentarily 10 to 14 V (Battery voltage)

Inspect and replace the slow solenoid valve

Slow solenoid valve harness side

NG

Inspect voltage between connector terminal 2 on the slow solenoid valve wire harness side and body earth.

(1) Disconnect the connectors of the slow solenoid valve.

(2) Inspect the voltage between the connector terminal 2 on the wire harness side and body earth when the ignition switch is turned ON. Standard: Momentarily 10 to 14 V (Battery voltage)

NG

Inspect and repair the power supply system for the slow solenoid valve

OK Inspect wire harness and connectors between engine ECU - slow solenoid valve (Refer to the wiring diagram at the back of the book) OK

Inspect or replace engine ECU

NG

Repair wire harness and connectors

3-37

SST (2) SST (1)

PARTS INSPECTION AND ADJUSTMENT 1.

Check LPG regurator primary pressure.

(1) Remove the tamper proof ring. (Refer to 2-5-1) (2) Install the SST to the LPG regulator.

SST 09817-23600-71 ......................... (1) 09820-23600-71 ......................... (2) (3) Crank the engine.

(4) Check the LPG regulator primary pressure.

Standard: 24.5 to 34.3 kPa (0.25 to 0.35 kgf/cm2) [3.6 to 5.0 psi]

Note: The pressure remains as above one.

2.

Adjust LPG regurator primary pressure (1) Remove the tamper proof ring. (Refer to 2-5-1) (2) Turn the ignition switch ON. (3) Loosen the adjust screw nut and adjust the primary pressure by turning the screw.

Standard: 24.5 to 34.3 kPa (0.25 to 0.35 kgf/cm2) [3.6 to 5.0 psi] (4) Adjust the VF voltage. (See step 14.)

3.

Inspect main solenoid valve (1) Turn the ignition switch ON. (2) Check the solenoid valve operating sound.

Standard: Solenoid valve makes operating sound.

(3) Disconnect the solenoid connector.

(4) Measure the resistance of the solenoid valve.

Standard resistance: 8.0 to 9.0 Ω (20°C) [68°F]

2 1

3-38 4.

Inspect slow solenoid valve (1) Disconnect the injector hose from the LPG injector.

(2) Turn the ignition switch ON and OFF promptly.

(3) Check that the LPG blows.

Standard: LPG blows for a split second.

(4) Turn the ignition switch OFF. (5) Disconnect the solenoid connector.

(6) Turn the ignition switch ON. (7) Check for the LPG leakage.

Standard: No leakage occurs.

5.

Inspect air fuel ratio control motor (1) Start the engine.

(2) Put a sound scope on the air fuel ratio control motor.

(3) Check the air fuel ratio control motor operating sound.

Standard: Motor makes click sound for several seconds.

(4) Remove the air fuel ratio control motor.

Note: Do not disconnect the connector.

(5) Put masking tape on the contact surface with the adaptor, to prevent air from blowing.

(6) Measure the length (A) when the engine stops and is idling.

Standard: 13 to 14 mm (0.51 to 0.55 in) when engine stops 14 to 18 mm (0.55 to 0.71 in) when engine is idling Notice: Do not apply excessive force to the needle valve portion.

3-39 (7) Disconnect the connector from the FCM. (8) Measure the resistance between the terminals.

3 6

2 5

1 4

Standard: Terminals

Resistance

2-1, 3

15 to 25 Ω at cold temp.

20 to 30 Ω at hot temp.

5-4, 6

15 to 25 Ω at cold temp.

20 to 30 Ω at hot temp.

Note: Cold temp. = -10 to 50°C (14 to 122°F) Hot temp. = 50 to 100°C (122 to 212°F) (9) Check the air fuel ratio control motor operation. (a) Apply battery positive (+) voltage to the terminal 2, negative (-) voltage to terminals in the order of 1, 3, 4, and 6. (b) Check that the needle valve movement.

Standard: The needle valve gradually moves to the CLOSE side. (c) Apply battery positive (+) voltage to the terminal 5, negative (-) voltage to terminals in the order of 1, 3, 4, and 6.

CLOSE side

(d) Check that the needle valve movement.

Standard: The needle valve gradually moves to the OPEN side.

Notice: Do net apply excessive force to the needle valve portion.

OPEN side

3-40 6.

Inspect LPG injector (1) Put a sound scope on the LPG injector.

(2) Check the injector operating sound while cranking the engine.

Standard: Injector makes operating sound.

Reference: Injector injects fuel twice per engine revolution while cranking.

(3) Start the engine.

(4) Lightly pinch the injector hose with fingers and check the pulsation.

Standard: Pulsation occurs continuously.

(5) Check the idle condition when disconnecting the injector connector.

Standard: The engine idle speed decreases when disconnecting the connector.

(6) Check air tightness of the LPG injector. (a) Disconnect the LPG injector connector and remove the injector with the hose connected.

Note: Do not disconnect the injector hose. (b) Check for the leakage of LPG from the injector while turning the ignition switch ON and OFF. Standard: No leakage occurs.

(7) Measure the resistance of the LPG injector.

Standard: 3.5 to 4.5 Ω at 20°C (68°F)

2 1

3-41 7.

Clean LPG injector (1) With a clean shop rag, wipe off the carbon around the nozzle.

(2) Insert and desert a wire with diameter of less than 1.2 mm (0.047 in), while applying compressed air of 343 to 490 kPa (3.5 to 5.0 kgf/cm2, 49.8 to 71.1 psi) from the intake port.

Notice: Insert the wire within the range of 20 mm (0.79 in).

8.

Inspect air temperature sensor (1) Remove the air temperature sensor.

(2) Measure the resistance of the sensor.

Standard: Temperature

9.

Resistance

20°C (68°F)

2 to 3 kΩ

80°C (176°F)

0.2 to 0.4 kΩ

Inspect coolant temperature sensor (1) Remove the coolant temperature sensor.

(2) Measure the resistance of the sensor.

Standard: Temperature

Resistance

20°C (68°F)

2 to 3 kΩ

80°C (176°F)

0.2 to 0.4 kΩ

3-42 10. Inspect distributor cap (1) Check the distributor cap and center piece contact visually.

Standard: • There is no crack on the distributor cap.

• There is no damage on the center piece.

• Center piece moves smoothly.

• The cap inside is not considerably dirty.

11. Inspect resistive code (1) Measure the resistance of the resistive codes.

Standard: 25 kΩ 12. Inspect ignition coil (1) Disconnect the 4 resistive codes from the spark plug.

(2) Remove the distributor cap.

(3) Remove the distributor rotor.

(4) Remove the dust-proof cover.

(5) Inspect the primary coil. (a) Measure the resistance between the terminals A and C. Standard: Condition

Resistance

Cold 20°C (68°F)

0.33 to 0.55 Ω

Hot 80°C (176°F)

0.42 to 0.65 Ω

(6) Inspect the secondary coil. (a) Measure the resistance between the terminals B and C. Standard: Condition

Resistance

Cold 20 °C (68 °F)

6.7 to 12.9 kΩ

Hot 80 °C (176 °F)

8.6 to 15.1 kΩ

(7) Inspect the insulation of the ignition coils. (a) Measure the resistance between the terminal A and body ground D. Standard: 1 MΩ or higher

3-43 13. Inspect signal generator (1) Disconnect the pickup coil connector.

(2) Measure the resistance between the terminals.

Standard:

2

1

Condition

Resistance

Cold 20°C (68°F)

370 to 550 Ω

Hot 80°C (176°F)

475 to 650 Ω

(3) Remove the distributor cap, rotor, and dust-proof cover.

(4) Using a feeler gauge, measure the air gap between the signal rotor tooth and pickup coil projection.

Standard: 0.2 to 0.4 mm (0.008 to 0.016 in)

14. Adjust VF voltage (1) Warm up the heated oxygen sensor by maintaining the engine speed at 1800 rpm for approximately 2 minutes.

(2) Using plug-in analyzer or multi-function display, check that OX value alternates between 0 and 1.

VF voltage

OX value

Note: Maintain the engine rpm at 1800 rpm.

Standard: The OX value alternates more than 4 times, between 0 and 1 for 10 seconds.

(3) Measure the VF voltage while engine idling.

Standard: 2.5 ± 0.5 V (4) If the VF voltage is not within the specified range, adjust the VF voltage to the specified value by turning the idle adjust screw slowly.

Reference:

COUNTERCLOCKWISE

CLOCKWISE

VF voltage

Condition

Measures

0V

Air fuel ratio: RICH

Turn the screw CLOCKWISE

5V

Air fuel ratio: LEAN

Turn the screw COUNTERCLOCKWISE

(5) After racing the engine several times, check that the VF voltage is within the specified range.

Note: Adjust the VF voltage to nearly 2.5 V.

3-44 15. Check cylinder compression pressure (1) Warm up the engine to the normal operating temperature.

(2) Disconnect the distributor connectors.

(3) Disconnect the resistive codes from the spark plugs.

(4) Remove the spark plugs.

(5) Check the cylinder compression pressure. (a) Install a compression gauge into the spark plug hole. (b) Fully depress the accelerator pedal. (c) While cranking the compression pressure.

engine,

measure

the

Standard: 1000 to 1373 kPa (10.2 to 14.0 kgf/cm2) [145 to 199 psi] Note: The difference between each cylinder is within 196 kPa (2.0 kgf/cm2) [28 psi] (d) If the cylinder compression in 1 or more cylinders is low, pour a small amount of engine oil into the spark plug hole and perform steps (a) through (c) for the cylinders with low compression.

• If the compression pressure increases, piston rings and/or cylinder bore may be worn or damaged.

• If the compression stays low, valves may be sticking, valve seating may be improper, or gas leakage through the gasket may occur.

4-1

APPENDIX Page

SST LIST ................................................................4-2 SERVICE STANDARDS .........................................4-4 WIRING DIAGRAM.................................................4-5

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 E

4-2

SST LIST Illustration

Part number

Part name

Section 2

3

09238-13130-71

Sub harness

{

{

09814-22000-71

Tool

{

{

09815-22000-71

Tool

{

{

09813-26600-71

Gauge

{

{

80339-76026-71

Automatic choke pipe plug

{

{

09817-23600-71

Union

{

{

09819-22000-71

Gauge

{

{

4-3 Illustration

Part number

09819-23600-71

Part name

Gauge

Section 2

3

{

{

0 1 2

23627-22000-71

Spring

3 {

{

4 5 6

09820-23600-71

Tester SUB-ASSY

{

{

7 8 9

09240-26600-71

Plug-in Analyzer

{

{

10 11 12 13 14 15 16 17 18 19 20 21 E

4-4

SERVICE STANDARDS FILTER Tightening Torque

T=N·m (kgf·cm) [ft·lbf]

Cover set bolt

6.4 to 7.8 (65 to 80) [4.7 to 5.8]

Element tightening nut

1.0 to 1.2 (100 to 150) [0.7 to 1.1]

REGULATOR Protrusron of the idle adjust screw (Distance from the body face to the screw tip) Mounting height of the first spring adjuster Pressure in the first reducing chamber

11.8 to 15.0 (120 to 150) [8.7 to 11.0] mm (in) 13.9 (0.5) kPa (kgf/cm2) [psi] 24.5 to 34.3 (0.25 to 0.35) [3.6 to 5.0]

First valve lever height (From first cover contact surface)

mm (in)

Second valve lever height (From second cover contact surface)

mm (in)

11.8 to 12.3 (0.47 to 0.48) 0 to 2.0 (0 to 0.08)

Tightening Torque

T=N·m (kgf·cm) [ft·lbf]

Regulator first cover set screw

3.5 to 4.4 (36 to 45) [2.6 to 3.5]

First valve set screw

3.5 to 4.4 (36 to 45) [2.6 to 3.5]

First spring adjuster lock nut

3.5 to 4.4 (36 to 45) [2.6 to 3.5]

Regulator second cover set screw

3.5 to 4.4 (36 to 45) [2.6 to 3.5]

Second valve set screw

3.5 to 4.4 (36 to 45) [2.6 to 3.5]

Slow solenoid valve set screw

3.5 to 4.4 (36 to 45) [2.6 to 3.5]

Intake union

3.5 to 4.4 (36 to 45) [2.6 to 3.5]

WIRING DIAGRAM

4-5

…..This Page Intentionally Left Blank…..

imprint.fm

2 ページ

２００６年１２月８日

金曜日

午後８時４５分

Published by

1st Printing: Dec. 2006 Pub. No. CU666 Printed in USA

C

PRINTED IN USA Pub. No. CU666