Evaporadortoyota

NAME SECTION
GENERAL
OPERATION DESCRIPTION
LPG REGULATOR OVERHAUL
ELECTRICAL TROUBLESHOOTING
APPENDIX
SECTION INDEX
Service Manual Change History
Description Page # Date
1 Added bookmarks All 3/31/13
2 Added Information Bulletin page 3-4 3/31/13
3 Added SIB FS08-001 101 3/31/13
1 HTT 2007-02 Transmission Control Valve Identification; Proper Chasis Lubrication
2 HTT 2007-03 Idle Surge/Hunt; Quick Facts; Rotten Egg/Ammonia Smell
3 HTT 2007-04 Limiting Travel Speed; A5-1 Code
4 HTT 2007-05 LPG Regulator Adjustment; Engine/Transmission "Knocking" Complaint
5 HTT 2007-06 Troubleshooting Diesel Smoke; Multifunction Display
6 HTT 2007-07 LPG Regulator Maintenance
7 HTT 2007-08 Engine Surge
8 HTT 2007-09 Propshaft Cover
9 HTT 2007-10 Error Code 68-3; Flow Regulator Valve Parts Replacement
10 HTT 2007-11 Wet Brake Option Hydraulic Oil; Error Code AD-1 And AD-7
Service Information Buletin
1 SIB CC08-005 4Y ECS Controller Programming Change Chapter 19
2 SIB CE07-008 Error Code AD-1 and AD-7 Chapter 19
3 SIB CE09-004 A5, A5-1 or 1-1 Error Codes For OPSS Chapter 19
4 SIB CE10-003 Horn Relocation Chapter E2
5 SIB CE10-005 Main Wiring Harness Change (Error Code 73-1) Chapter 19
6 SIB CE11-001R Clamp Release Interlock (Mini Lever Units) Chapter 19, 14, E3
7 SIB CE11-003 Clamp Release Interlock (Standard Lever Units) Chapter 14, E3
8 SIB EN07-001 4Y Engine Ignition Timing Procedure Chapter 1.3-10
9 SIB EN08-001 Repair Manual (00700-X8880-71) Revision Embedded
13 SIB EN10-001 Engine Block Heaters Chapter 1.2-4
14 SIB FS08-001 LPG Regulator Chapter 1.3-2
15 SIB HS07-003 Flow Regulator Replacement Parts Chapter 14
16 SIB MA07-001 Hourmeter Fuse Installation Chapter 0
17 SIB MA07-003 Transmission Oil Level Inspection Chapter 2 & 2.1
18 SIB MA07-004R Grease Specifications Chapter 0
19 SIB MA10-001 Overhead Guard Mounting Bolt Torque Chapter 9
20 SIB MA10-007 Oil Pressure Switch Chpater 0 & E3
21 SIB MA11-001 Service Hint For Greasing Rear Axle Beam Pivot Pin Chapter 0
22 SIB MA13-001 Exhaust Mounting Clamp with Rubber Bushing Inspection Chapter 0
23 SIB RA08-001 Updated Horn Pad Chapter 7
24 SIB ST07-001 Special Service Tools Chapter 17
25 SIB TR07-001 Transmission Control Valve Identification Chapter 2 & 2.1
26 SIB TR07-002 Propeller Shaft Cover Chapter 2 & 2.1
Technical News Brief
1 TNB 2007-03R1 Hydraulic Oil Change
2 TNB 2007-05 Transmission Knocking Noise At Idle
3 TNB 2007-06 LPG Regualtor Slow Path Tamper Resistant Cap
4 TNB 2007-11 Torque Specificaion Of Outer Mast Support Bolts
5 TNB 2008-07 Fuel Mixture Adjustment Procedure For The 4Y ECS Engine
6 TNB 2008-20 Gasoline Fuel System
7 TNB 2008-12 Installation of Fuel Line Fittings
8 TNB 2009-03 Suppliment to TNB 2008-07 For Adjusting VF (Voltage Fuel)
Hotline Tech Tips
11 HTT 2007-12 Horn Pad Improvements; Correct Timing Mark On Crank Pulley
12 HTT 2008-01 "L-OFF" Complaint
13 HTT 2008-02 Error Code List; Rear Pillar Assist Relay Location; New Cab
14 HTT 2008-03 Carriage Roller Replacement
15 HTT 2008-04 Fuel Shut Off Valve Orientation On Gasoline And Dual Fuel Trucks
16 HTT 2008-05 Driveability Issues Due To Dirty Throttle Body
17 HTT 2008-06 Shift Interlock (Intelli-Shift) Adjustments; Overheat Trouble Shooting
18 HTT 2008-07 LPG Tamper Resistant Cap
19 HTT 2008-08 Cam Positions Sensor
20 HTT 2008-09 SAS Matching; Transmission Repair
21 HTT 2008-10 Seatbelt Interlock; Function Menu w/ Travel & Load Handling Option; Gas Tank Pressure
22 HTT 2008-11 Accelerator Sensor Codes; LPG Filter Kit Service Parts
23 HTT 2008-12 CNG Trucks Using The Analyzer; Extra Long Feeler Gauges for Mast Shimming Checks
24 HTT 2009-01 Error Code 73-1, Or Missing Plug On New Harness
25 HTT 2009-03 Load Sensor Wire Breakage; Dual Brake Pedal "Low Pedal" Complaint
26 HTT 2009-06 Error Code OB-1
27 HTT 2009-07 Horn Pad Improvements; Flow Regulator Update; Overheat Diagnostics
28 HTT 2009-08 Engine Controller Version Identification
29 HTT 2009-09 Identifying LPG Regulator 1st Valve Material; High Engine Idle Issues
30 HTT 2009-10 Using the Engine Analyzer To Check The Engine Function
31 HTT 2009-11 Error Codes Without An Hour Meter Reading; LPG Filter Kit PN
32 HTT 2010-01 Reverse Polarity Damage Issues
33 HTT 2010-02 Ignition Timing Value (IGT) Shown On Analyzer
34 HTT 2010-03 Error Code 06-3; Error Code 01-5
35 HTT 2010-04 To Throttle Valve Actuation And Error Code 06-3 E-THRO Fuse Location
36 HTT 2010-05 Error Code AD-7 After Replacing The Main Harness
37 HTT 2010-06 SAS Manual Lowering Valve Location; Flow Regulator W/ Part Numbers
38 HTT 2010-07 SAS Code History Check Without The Analyzer
39 HTT 2010-08 Clearing 01-1, 01-2, 01-3, 01-4, 01-5, 01-6 Codes After Making The Repair
40 HTT 2010-09 Error Code 73-1 After Replacing The Main Harness
41 HTT 2010-10 Hour Meter Diagnostics & Memory
42 HTT 2010-11 Diagnosing Diesel Smoke
43 HTT 2010-12 LPG Regulator Adjustment & Tar Draining: Idle Speed Adjustment
44 HTT 2011-01 How To Read An O2 Sensor
45 HTT 2011-02 Required Adjustments For New LP Regulator, And Installation Of Anti-Tamper Caps
46 HTT 2011-03 Engine Analyzer Screen 1/10; Throttle Body Cleaning
47 HTT 2011-04 Engine Analyzer Screen 2/10; Analyzer Speed Versus Displayed Speed
48 HTT 2011-05 Engine Analyzer Screen 3/10
56 HTT 2012-01 Error Code 09-1; LPG Filter Kit; Cold Soak Lack Of Travel
…..This Page Intentionally Left Blank…..

LPG Device for 4Y-E Engine 0-1
GENERAL
Page
TYPE OF LPG DEVICES........................................0-2
ENGINE PERFORMANCE CURVES .....................0-3 0
1
ENGINE SPECIFICATIONS ...................................0-6
PRINCIPAL DIFFERENCES
FROM GASOLINE VEHICLE ...............................0-7
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
PRECOATED BOLTS
(BOLTS WITH SEAL LOCK AGENT
COATING ON THREADS)..................................0-12
PERIODIC MAINTENANCE.................................0-13
10
INSPECTION METHOD ..........................................0-13
11
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Section 1.3.0
0-2 LPG Device for 4Y-E Engine
PERIODIC REPLACEMENT PARTS.........................0-13

12
13
14
15
16
Cylinder
Bracket opening Fuel hose connecting
External Removal/installation method
Weight direction position
diameter
20.0 kg 797 mm Sinple type (STD)
(44.1 lb) (31.4 in) Swing down type (OPT) Right Bottom
15.0 kg 637 mm
(33.1 lb) (25.1 in)
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18
19
TYPE OF LPG DEVICES
1. Types of LPG cylinders
Pneumatic Cushion
Gas weight Cylinder length Specification models models
General purpose — STD
15 kg (33.1 lb) 637 mm (25.1 in)
With level gauge and quick coupling — OPT
General purpose STD —
20 kg (44.1 lb) 797 mm (31.4 in)
With level gauge and quick coupling OPT —
2. Types of LPG cylinder brackets
Section 1.3.0
ENGINE PERFORMANCE CURVES

4Y Engine (8FGU15 to 25, 8FGCU20 to 32)
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Section 1.3.0
Section 1.3.0
4Y Engine (8FGU30, 32)
Section 1.3.0
4Y Engine (8FGU15 to 32 series, 8FGCU15, 18 and 8FGCSU20)
Section 1.3.0
ENGINE SPECIFICATIONS
4Y
8FGU15 to 25 8FGU30,
8FGCU20 to 32 8FGCU15, 18 and 8FGCSU20
32
A B C A B C A B C 0
N·m 160 165 162 160 160
Maximum shaft (kgf·m) (16.3) (16.8) (16.5) (16.3) (16.3)
torque rpm 2100 2570 2200 2100
kW 38 44 43 42 36
Maximum shaft (PS) (51) (59) (58) (57) (48)
output rpm 2570 2570 2250
Minimum fuel g/kW·h 298 233 233 310 298

consumption (g/PS·h) (219) (171) (171) (228) (219)
ratio rpm 2000 2000 1600 2000
Idle speed rpm 750 750 750
No-load
maximum rpm 2570 2570 2250
governed speed
A: Gasoline (Exclusive)
B: Gasoline (Convertible)
C: LPG (Exclusive, Convertible)
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Section 1.3.0
PRINCIPAL DIFFERENCES FROM GASOLINE VEHICLE

LPG
Gasoline vehicle
Exclusive vehicle Convertible vehicle
Gasoline tank and
Fuel tank LPG cylinder 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
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
thefunction 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
andscratching.
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
(tighteningtorques, adjustment values, etc.).
• Be sure to use genuine parts for replacement of existing parts.
Section 1.3.0
• 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
orgrease 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.
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 Strength class
4 = 4T
5 = 5T
Number in relief or hallmark on head 6 = 6T
7 = 7T
8 = 8T
4T
No mark
Hexagon head
bolt
(standard bearing 5T
surface) Bolt with two raised lines on head
7T
Bolt with three raised lines on head
8T
Bolt with four raised lines on head
Welded bolt 4T
Stud bolt 4T
No mark
Section 1.3.0
6T
About 2 mm (0.08 in.) groove(s) on one/both edge(s)
Identification by Part No.

Type Part No. Shape
91611-40625
Nominal
length
Hexagon bolt (mm)
Nominal
diameter (mm) Nominal length
Strength class
Nominal diameter
92132-40614
Nominal
length
Stud bolt (mm)
Nominal Length
diameter (mm)
Nominal diameter
Strength class
Tightening Torque Table

Standard tightening torque
Nominal diameter Pitch
Strength class
mm mm N·m kgf·cm ft·lbf
6 1.0 5.4 55 4.0

8 1.25 13 130 9.4
10 1.25 25 260 18.8
4T 12 1.25 47 480 34.7
14 1.5 75 760 54.9
16 1.5 113 1150 83.0
6 1.0 6.5 65 4.7
8 1.25 16 160 11.6
10 1.25 32 330 23.8
5T 12 1.25 59 600 43.3
14 1.5 91 930 67.1
16 1.5 137 1400 101.1
6 1.0 7.8 80 5.8
8 1.25 19 195 14.1
10 1.25 39 400 28.9
6T 12 1.25 72 730 52.7
14 1.5 108 1100 79.4
16 1.5 172 1750 126.6
6 1.0 11 110 7.9
8 1.25 25 260 18.8
10 1.25 52 530 38.3
7T 12 1.25 95 970 70.0
14 1.5 147 1500 108.3
16 1.5 226 2300 166.1
Section 1.3.0
6 1.0 12 125 9.0

8 1.25 29 300 21.7
10 1.25 61 620 44.9
8T 12 1.25 108 1100 79.4
14 1.5 172 1750 126.6
16 1.5 265 2700 195.3
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
Nominal diameter Pitch
Strength class
mm mm N·m kgf·cm ft·lbf
6 1.0 5.5 56 4
8 1.25 13 130 9
10 1.25 27 280 20
4.8T 12 1.25 50 510 37
14 1.5 78 800 58
16 1.5 120 1220 88
6 1.0 7.5 80 6
8 1.25 19 190 14
10 1.25 39 400 29
6.8T 12 1.25 71 720 52
14 1.5 110 1120 81
16 1.5 170 1730 125
6 1.0 12 120 9
8 1.25 29 300 22
10 1.25 61 620 45
8.8T 12 1.25 110 1120 81
14 1.5 175 1780 129
16 1.5 270 2750 199
6 1.0 15.5 160 12
8 1.25 38 390 28
10 1.25 80 820 59
10.9T 12 1.25 145 1480 107
14 1.5 230 2350 170
16 1.5 360 3670 266
Section 1.3.0
6 1.0 17.5 180 13

8 1.25 42 430 31
10 1.25 89 910 66
11.9T 12 1.25 160 1630 118
14 1.5 260 2650 192
16 1.5 400 4080 295
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) Note:
For torque check, tighten the bolt at the lower limit of the
allowable tightening torque range; if the bolt moves,
Seal lock agent
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.
Section 1.3.0
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
Item Hours 170 500 1000 2000
Gas leak from piping and joint I*1
Damage of piping and joint I*2
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
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
Section 1.3.0
LPG Device for 4Y-E Engine 1-1 0
OPERATION DESCRIPTION
Page
OUTLINE OF LPG DEVICE....................................1-2 FUEL FILTER
FOR LPG ........................................1-3
1
SOLENOID VALVE.................................................1-3
ADAPTER...............................................................1-4 2
REGULATOR..........................................................1-5 3
SPECIFICATIONS....................................................1-5 4
REGULATORS SYSTEM COMPONENTS .................1-11 5
6
7
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Section 1.3.1
17
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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.
FUEL FILTER FOR LPG
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 intothe regulator causing start difficulty due to cloggi
slow 1
path. The filtering performance has been improved to be able to
remove foreign matters of 2 m or more in size. 2

3
SOLENOID VALVEThe solenoid valve is mounted between the LPG filter and the
4
regulator, and controls gas flow according to the engine condition.For example, when the engine is running, the solenoid
valve is ON 5 and supplies fuel. Once the engine stops running, it turns
OFF and
cuts off the gas flow. 6

When the current flows through the solenoid valve, which consists
Section 1.3.1
Filtering Performance m
0
of a slide valve, back spring, and solenoid coil, magnetic force isgenerated. The slide valve overcomes the spring force by
such 7 magnetic force to move forward the IN side, and fuel flows.When the current stop flowing through the solenoid
valve, the slide 8

valve is forced to back to the OUT side by the LPG pressure and
spring force to shut off the flow. 9

10
11
12
13
14
15
16
17
18
19
ADAPTER
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
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Section 1.3.1
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.
Specifications
Ventury diameter mm (in) 24 (0.9)
Needle valve seat diameter mm (in) 11 (0.4)
Needle valve seat angle 60
FCM specifications
Magnetized way 1-2 magnetized type
Stroke mm (in) 5 (0.2)

[0.05 (0.002) / step]
Pulse generation rate pulse / second 140
Section 1.3.1
REGULATOR
The regulator supplies vaporized LPG after pressure reduction to the engine while maintaining the pressure at a fixed
level.
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Section 1.3.1
10
SPECIFICATIONS 13
First chamber pressure kPa (psi) 24.5 to 34.3 (3.6 to 5.0)
14
First seat inner diameter mm (in) 3.2 (0.1)
Secondary seat inner diameter mm (in) 6.0 (0.2) 15
Slow system flow shut off method Solenoid valve
Drain cock Optionally available
16
17
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19
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).
Section 1.3.1
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Section 1.3.1
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.
Section 1.3.1
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.
3. During normal operation
Section 1.3.1
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.
4. When stopping the engine
Section 1.3.1
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.
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.
Section 1.3.1
Ignition
switch ST
ON LPG-
AM Gasoline Starter
switch relay
Gasoline LPG
Starter
EFI LPG motor
main Solenoid
relay relay
Igniter
Slow Main
solenoid solenoid
Engine ECU
Battery
Section 1.3.1
LPG REGULATOR OVERHAUL

Page
PRECAUTION FOR LPG FORKLIFT OPERATION
AND REPAIR........................................................2-2
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
6
7
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9
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Section 1.3.2
17
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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 applyliquid
packing to the first and the second threads of the screw tip.
Section 1.3.2
20
21
E
Section 1.3.2
Components
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 13
6 09819-23600-71 Gauge
7 09819-22000-71 Gauge
14
8
9
23627-22000-71
09820-23600-71
Spring
Tester SUB-ASSY
15
9-1 09823-23600-71 Union
9-2 09822-22000-71 Gauge
9-3 09821-22000-71 Bellows
Section 1.3.2
SSTs for LPG Regulator Overhaul
5 0
1
1
6
2
7
2 3
4
3 9-3
5
9-1
6
8 7
9-2
8
9
10
11
12
16
17
18
19
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.
20
21
E
Section 1.3.2
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)
(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.
(2) Using SST, adjust the protrusion of the screw. SST 09819-22000-71
3. Install the tamper proof ring (21673-13370-71).
Section 1.3.2
Troubleshooting
Section 1.3.2
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
OK The pointer moves to 0 position. NG The pointer stays at the position.
Normal • Second diaphragm defect

• Elastic face valve 2 (in C chamber)
defect.
• Loosen of elastic face valve 2

mounting screw
Individual Inspection
1. Inspect the slow solenoid.
Section 1.3.2
V
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.
Section 1.3.2
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)
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)
Point Operations
[Point 1]
Removal:
Section 1.3.2
Discharge LPG from the piping according to the procedure below.

(1) Close the LPG supply piping valve 1 (green).
(2) Close the LPG outlet valve 2 (amber).
(3) Start the engine, and run the engine in the idling state until it stops naturally.
Section 1.3.2
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.
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.
[Point 1]
Reassembly:
1. Install the diaphragm by matching its pin with the concave portion of the second valve lever.
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]
[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.
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.
(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.
Section 1.3.2
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
Section 1.3.2
LPG Device for 4Y-E Engine
If not satisfied, use the SST to bend the lever for adjustment.
SST 09814-22000-71.................................(1)
09815-22000-71.................................(2)
During lever height adjustment, do not push the valve seat
against the port.
[Point 3]
Disassembly:
Since the spring force is applied at each portion, do not try
quick removal but loosen each bolt equally for removal.
Reassembly:
Tighten each bolt equally step by step so as not to let springs
be fallen. Tighten in the illustrated order for final tightening.
Tightening torque:
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.
Section 1.3.2
Reassembly:
Engage the diaphragm hook onto the first valve lever tip.
[Point 4]
Disassembly:
1. Remove the first valve ASSY.
2. Disassemble the first valve.
Reassembly:
1. Reassemble the first valve ASSY.
Note:
Replace the O-ring with a new one.
2. Install the first valve sub-assembly.
Tightening torque:
3. Check the first valve air-tightness.
(1) Put the SST (spring) between the lever tip and regulator
body.
SST 23627-22000-71
(2) Connect the SST (gauge) to the fuel inlet.

SST 09820-23600-71
(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. Check and adjust the first lever height.

(1) Push the first valve at the elastic face valve side.
Section 1.3.2
(2) Check contact with the lever when passing through the S
side of the SST, and no contact when passing through the
T side.
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)
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.
6. Hang the diaphragm hook at the tip of the first valve lever and
set the diaphragm to the regulator body.
7. 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]
8. Adjust the first diaphragm adjust screw.
(1) Loosen the adjust screw nut.
Section 1.3.2
(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]
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

1. Temporarily install the second valve ASSY.
2. Remove the idle adjusting screw and install the SSTs.
SST (union) tightening torque:
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.
Section 1.3.2
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).
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 80C (176F) 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. 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:
Section 1.3.2
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.
6. Adjust LPG regurator primary pressure
(2) Loosen the adjust screw nut and adjust the primary pressure by
turning the screw. Standard:
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. Reference:
(5) After racing the engine several times, check that the VF voltage is within the specified range. Note:
E • Adjust the VF voltage to the 2.5 V as possible.
• If VF VF voltage
Condition Measures
voltage battery negative cable, and perform this step
Air fuel ratio: Turn the screw (7) again.
0V RICH CLOCKWISE
Air fuel ratio: Turn the screw
5V LEAN COUNTERCLOCKWISE
Section 1.3.2
ELECTRICAL TROUBLESHOOTING
Page
BEFORE TROUBLESHOOTING............................3-2
CONNECTOR HANDLING.........................................3-2
1
WIRE HARNESS AND CONNECTOR INSPECTION
PROCEDURE ........................................................3-2 2
BEFORE BEGINNING TROUBLESHOOTING ......3-4 3
DIAGNOSIS (SELF DIAGNOSIS FUNCTION).......3-5 4
GENERAL...............................................................3-5 5
HOW TO INTERPRET THE FLOW-CHARTS........3-6
ANALYZER.............................................................3-7 6
EXPLANATION........................................................3-7 7
ANALYZER MENU SCREEN LIST..............................3-8 8
ABOUT TROUBLE SHOOTING 9
BY ERROR CODES .............................................3-9 10
TABLE OF DIAGNOSIS CODES ..............................3-10
TROUBLESHOOTING BY SYMPTOMS..............3-12 11
PARTS INSPECTION AND ADJUSTMENT.........3-37 12
13
14
20
21
E
Section 1.3.3
15
16
17
18
19
BEFORE TROUBLESHOOTING
CONNECTOR HANDLING
1. Disconnect the battery plug before connecting or
disconnecting each connector or terminal.
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 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.
Section 1.3.3
0
Short Circuit Check
2. Measure the resistance between the corresponding connector terminal and N1.
Always inspect the connectors at both ends.
Standard: 1 M or above
Note:
Move the wire harness slightly from side to side and up and down while
measuring.
3. Measure the resistance between the relative terminals of the appricable connector.
Standard: 1 M or above
Note:
The wiring may short-circuit due to pinching by the body or defective clamping.
1
4 2 Visual
2. Perform a visual check to make sure that there is no rust or
foreign matter contaminating the connector terminal.
5 and Contact Pressure Checks 3
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.
6
7
4. Insert a male terminal same as that of the terminal to a female 8
connector and check the extracting force.
Defective contact may exist at a terminal where the extracting 9
force is less than that of other terminals.
Note: 10
If a problem, such as rust or foreign matter on the terminal, or
a drop in the contact pressure of male/female terminals 11
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
12
several times. If such a defect is recognized, it is likely that
there is a defective terminal contact. 13
14
15
16 20
17 21
18 E
Section 1.3.3
19
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 c. Incomplete combustion
2. Does not start well Poor cranking (when cold · when warm · at all times)
3. Poor idle a. Poor idle speed b. Unstable idle speed c. Hunting (Regular fluctuation in idle speed)
a. Directly after startup (when cold · when warm) b. During reduction of speed
4. Engine stalling 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
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
a. Excessive fuel consumption b. Excessive oil consumption c. Overheat
6. Others d. Water / Oil leakage e. Abnormal noise f. Others ( )
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 b. In certain conditions c. Occasionally
Sunny · Cloudy · Rain ·
Weather Snow · Thunderstorm Temperature Approximately C Humidity Approximately %
Temperature conditions Coolant: a. When cool b. When warm Temperature inside engine room: C
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
Operation conditions 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 b. Lights occasionally c. Does not light
Section 1.3.3
0
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.
6
lamp flashes as a warning.
When this happens, stop the vehicle quickly and check the error 7
code.
2. Diagnosis display system 8
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. 9
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). 10
(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:
11
• The maximum number of error codes that can be in the memory is 10, and the smaller diag number
represents a newer error.
12
• 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.
13
1
Error code display Diagnosis display system
1. Diagnosis display system 2
An orange colored lamp lights Lamp blinks

(Engine ECU only )
20
21
E
Section 1.3.3
The diagnosis is displayed by means of an error code as shown in the illustration to the left, and by the lights turning on. 3
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. 4
When the IG switch is ON, if an abnormality occurs when the vehicle is stopped, travelling, or when it is performing
materials 5 handling operations, on detection of the abnormality an error code is displayed, the engine light turns on, and
the spanner
14
15
16
17
18
19
Section 1.3.3
0
HOW TO INTERPRET THE FLOW-CHARTS
Turn the key switch OFF and ON again
Is there an error code 31-1?
Inspect the VF voltage. NG

Drive controller defect
Standard: 2.5 ± 0.5 V
OK 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.
20
21
E
Section 1.3.3
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.
Section 1.3.3
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)
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 8FGU/8FDU15-32, 8FGCU20-32 Repair Manual Vol.1 (Pub. No.
CU053) and 8FGCU15-18 Repair Manual Vol.2 (Pub. No. CU055) 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.
Section 1.3.3
TABLE Blinking4Y-ECSFuel
OF DIAGNOSIS feedback control abnormality (LPG/CNG) rich
3-10
Blinking4Y-ECSFuel feedback control abnormality (LPG/CNG) lean

IndicationMemorySpanner
CODES Detectio Error modePhenomenon on vehicle
Blinking4Y-ECSO EC
Blinking4Y-ECSOn U
Blinking4Y-ECSIntake temperature sensor-open abnormality The engine speed is unstable and it
Blinking4Y-ECSIntake temperature sensor short abnormality may stop.
2 sensor open abnormalityThe engine speed is unstable and it may stop.
pressure
Blinking4Y-ECSIntake pipe2 sensor sensor-open
heater abnormality
open abnormalityDisplay only
Blinking4Y-ECSIntake pipe pressure sensor short abnormality The engine may become out of
Blinking4Y-ECSWater temperature sensor open abnormality
adjustment
temperatur at low
Blinking4Y-ECSWater temperature sensor short abnormality es.
01-501-5 Blinking4Y-ECSThrottle position sensor 1 open abnormality The engine may begin to run
01-601-6 Blinking4Y-ECSThrottle position sensor 1 short abnormality rough
The engine may become out of
Blinking4Y-ECSThrottle position sensor 2 open abnormality
adjustment
temperatur at low
Blinking4Y-ECSThrottle position sensor 2 short abnormality es.
01-301-3 Blinking4Y-ECSThrottle position sensor offset abnormality
01-401-4 Blinking4Y-ECSThrottle position sensor out of range abnormality Limited speed of traveling and materials
Blinking4Y-ECSThrottle motor drive circuit open abnormality due to limited engine power
handling
02-102-1 Blinking4Y-ECSThrottle motor drive circuit short abnormality output
02-202-2 Blinking4Y-ECSThrottle motor power supply circuit open abnormality
Blinking4Y-ECSThrottle motor power supply circuit short abnormality
03-103-1 Blinking4Y-ECSThrottle motor seizing abnormality
03-203-2 Blinking4Y-ECSElectronic throttle system abnormality
04-104-1 Limited speed of traveling and materials
04-204-2 Blinking4Y-ECSAir-fuel ratio motor open abnormalityThe engine speed due unstable
is to limitedand it may
engine stop.
power
handling
05-105-1 Blinking4Y-ECSLow voltage (battery line open) abnormalityDisplay only
output
05-205-2 Blinking4Y-ECSIgnition signal abnormalityThe engine speed is unstable and it may stop.
05-305-3
05-405-4
Section 1.3.3
05-505-5
A-10A-1Blinking4Y-ECSFuel specification determination signal abnormalityDisplay only
05-605-6
06-106-1 A-20A-2Blinking4Y-ECSFuel specification changeover switch abnormalityDisplay only

06-206-2 A-30A-3Blinking4Y-ECSFuel specification type does not matchEngine may stop
A-40A-4Blinking4Y-ECSEngine specification determination abnormality Limited speed of traveling and materials
06-506-5 due to limited engine power
handling
06-306-3
06-406-4
06-606-6 output
08-108-1
0
07-107-1
0
0
09-109-1
0
Limited speed of traveling and materials handling
due to limited engine power output
Section 1.3.3
3-11
Error modePhenomenon on vehicle
3-12
Y-ECSCam angle sensor open abnormalityEngine stop

ASCEngine speed sensor open abnormalityPartial limitation of the drive control function.
Y-ECSCam angle sensor open abnormality (on start up)Engine will not start
ASCEngine speed sensor GND short abnormalityPartial limitation of the drive control function.
Blinking4Y-ECSCrank angle sensor open abnormalityDisplay only
AD-2AD-2Blinking4Y-ECSCAN communication SAS/OPS data reception abnormalityPartial limitation of the drive control function.
Accelerator sensor 1 open abnormality
Accelerator sensor 1 short abnormality
Accelerator sensor 2 open abnormality
Accelerator sensor 2 short abnormality
Accelerator sensor offset abnormality
Section 1.3.3
Detection
IndicationMemorySpanner ECU
4
18-118-1 Blinking
4
18-218-2 Blinking
Symptom Chart
18-318-3
Y-ECS
C4-1C4-1Blinking 4
ASC
Y-ECS
C4-2C4-2Blinking 4
ASC
Y-ECS
C4-3C4-3Blinking 4
ASC
Y-ECS
C4-4C4-4Blinking 4
Symptom
ASC
Y-ECS
C4-5C4-5Blinking 4
ASC
C4-6C4-6Blinking4Y-ECSAccelerator sensor out of range abnormality
Section 1.3.3
TROUBLESHOOTING BY SYMPTOMS
Page for reference

3-13
Does not start Starting motor turns over but engine does not start 3-13
Unstable idle speed 3-15
Poor idle adjustment Idle speed low and unstable 3-17
Idle speed high 3-18
Knocking 3-19
Poor drivability Hesitation 3-20
Insufficient power output 3-22
Engine stalling in general 3-25
Engine stalling a short time after start up 3-28
Engine stall Engine stalling when A/C, lights, or defogger are turned on, or when the steering
is operated 3-30
Engine stalling on releasing the accelerator 3-31
Charts by System
LPG injector system 3-33
Air-fuel ratio control motor system 3-35
Slow solenoid valve system 3-36
Section 1.3.3
<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.
Section 1.3.3
Section 1.3.3
OK NG
Repair or replace LPG regulator
Inspect LPG regulator primary pressure NG Adjust primary pressure of LPG regulator.
(Refer to parts inspection and adjustment 1) (Refer to parts inspection and adjustment 2)
OK
NG
Defect of ignitor or engine ECU Check starting ability
OK
Finish
Section 1.3.3
<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.
Section 1.3.3
Section 1.3.3
<POOR IDLE ADJUSTMENT> IDLE SPEED LOW AND UNSTABLE

Probable cause
• Air-fuel ratio over-lean
• Blockage around the electric throttle valve
Section 1.3.3
<POOR IDLE ADJUSTMENT> IDLE SPEED HIGH

Probable cause
• Throttle valve return defect
• Air leakage
• VF voltage abnormality
Note:
Inspect parts related to the items listed above.
Section 1.3.3
<POOR DRIVABILITY> KNOCKING

Probable cause
• Excess deposition in combustion chamber or on spark plug electrode • Ignition timing off
Check initial advance timing NG Adjust initial advance timing
(Refer to page 2-16) ( Refer to page 2-16)
OK
Inspect spark plugs

(1) Check that there is no obvious deposition. NG
Replace spark plug
(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
Section 1.3.3
<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
NG
Inspect LPG filter Replace LPG filter
OK
Inspect electronic throttle

Operate the accelerator pedal and inspect to see that the NG
Inspect throttle system
throttle PA value changes smoothly.
Standard: PA value changes smoothly.
OK
Inspect VF voltage
(Refer to parts inspection and adjustment14) NG
Inspect changes in VF voltage and OX value (0 or 1) at
1800 r/min. (idle OFF).
Standard: 2.5 ± 0.5 V*
OK *:0 V, 2.50 V, or 5.0 V will be displayed when the
plug-in analyzer is used for the inspection.
Inspect initial advance timing

NG
(Refer to page 2-16) Adjust initial advance timing
Standard: 7.0
OK
Inspect, repair, or replace the feedback-related

components (injectors, O2 sensor, etc.) and
the relevant wire harnesses and connectors
(Refer to parts inspection and adjustment)
Section 1.3.3
When traveling: Rated under-load maximum speed
Section 1.3.3
<POOR DRIVABILITY> INSUFFICIENT POWER OUTPUT

Probable cause
• Air-fuel ratio abnormality (over-lean)
• Initial advance timing off Note:
Section 1.3.3
• 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).
Section 1.3.3
Section 1.3.3
<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.
OK NG
Section 1.3.3
between engine ECU and vacuum
sensor NG Repair wire harness
(Refer toDevice
the wiring diagram at the back connectors
LPG for 4Y-E Engine 3-29
of the book)
OK
Replace engine ECU
NG (Standard value or
Inspect LPG regulator primary pressure more, or not airtight) Repair LPG regulator
(Refer to parts inspection and adjustment 1) (Refer to section 2)
OK NG (Standard value or below)
Adjust primary pressure of LPG regulator.
(Refer to parts inspection and adjustment 2)
•LPG regulator (secondary system) defect OK NG

•Engine ECU defect
•Or unsuitable fuel used (winter only)
Finish
Inspect and repair blockages

in fuel piping system
Section 1.3.3
Inspect LPG regulator primary pressure OK LPG regulator (secondary system) defect or
(Refer to parts inspection and adjustment1) unsuitable specification fuel (winter only)
NG NG (Airtightness defect)
(Outside Repair LPG regulator
standard (Refer to section 2)
value)
Adjust LPG regulator primary pressure NG Inspect and repair blockages in fuel piping
(Refer to parts inspection and adjustment2) system
OK
Check that the engine restarts
OK
Finish
Section 1.3.3
<ENGINE STALL> ENGINE STALLING A SHORT TIME AFTER START UP

Probable cause
• 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.
Section 1.3.3
Inspect initial advance timing NG

Adjust initial advance timing
(Refer to page 2-16)
OK
Inspect VF voltage NG
(Refer to parts inspection and adjustment14)
Inspect changes in VF voltage and OX value
(0 or 1) at 1800 r/min. (idle OFF).
Standard: 2.5 ± 0.5 V*
*:0 V, 2.50 V, or 5.0 V OK Inspect, repair, or replace the feedback-related
will be displayed components (injectors, O2 sensor, etc.) and
when the plug-in the relevant wire harnesses and connectors
analyzer is used for
(Refer to parts inspection and adjustment)
the inspection.
Inspect LPG filter NG

Clean or replace LPG filter
(Refer to page 2-8)
OK
Inspect LPG regulator primary pressure NG Adjust primary pressure of LPG regulator
(Refer to parts inspection and adjustment1) (Refer to parts inspection and adjustment2)
OK
•Unsuitable fuel used

•Engine ECU defect
<ENGINE STALL> ENGINE STALLING WHEN A/C, LIGHTS, OR DEFOGGER ARE TURNED ON, OR WHEN
THE STEERING IS OPERATED
Probable cause
• Pay attention to air-fuel ratio abnormalities (injector blocked, idle adjustment defect) • Battery defect
Section 1.3.3
Section 1.3.3
<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
Section 1.3.3
NG
Inspect LPG filter Replace LPG filter
OK
Inspect injector system operation and inspect NG To LPG injector system

for blockages ( Refer to page 3-33)
(Refer to parts inspection and adjustment 6, 7)
OK
Inspect LPG regulator primary pressure NG

Adjust LPG regulator primary pressure
(Refer to parts inspection and adjustment 1)
OK
Engine ECU defect
Section 1.3.3
Section 1.3.3
Section 1.3.3
Section 1.3.3
Section 1.3.3
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:
Note:
The pressure remains as above one.
Section 1.3.3
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:
(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 (20C) [68F]
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

(2) Put a sound scope on the air fuel ratio control motor.
2 1
Section 1.3.3
(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.
(7) Disconnect the connector from the FCM.
(8) Measure the resistance between the terminals.
Standard:
Terminals Resistance
15 to 25 at cold temp.
2-1 , 3
20 to 30 at hot temp.
15 to 25 at cold temp.
5-4 , 6
20 to 30 at hot temp.
Note:
Cold temp. = -10 to 50C (14 to 122F)
Hot temp. = 50 to 100C (122 to 212F)
(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:
Section 1.3.3
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.
(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.
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.
(4) Lightly pinch the injector hose with fingers and check the
pulsation.
Standard: Pulsation occurs continuously.
CLOSE side
(5) Check the idle condition when disconnecting the injector
connector.
Standard:
The engine idle speed decreases when disconnecting the
connector.
OPEN side
(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.
2 1
Section 1.3.3
(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 at 20C (68F)
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
Section 1.3.3
(1) Remove the air temperature sensor.

(2) Measure the resistance of the sensor.
Standard:
Temperature Resistance
20C (68F) 2 to 3 k
80C (176F) 0.2 to 0.4 k
9. Inspect coolant temperature sensor (1) Remove the
coolant temperature sensor.
(2) Measure the resistance of the sensor.
Standard:
Temperature Resistance
20C (68F) 2 to 3 k
80C (176F) 0.2 to 0.4 k
Section 1.3.3
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 k
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 20C (68F) 0.33 to 0.55
Hot 80C (176F) 0.42 to 0.65
(6) Inspect the secondary coil.
(a) Measure the resistance between the terminals B
and C. Standard:
Cold 20 C (68 F) 6.7 to 12.9 k
Hot 80 C (176 F) 8.6 to 15.1 k
(7) Inspect the insulation of the ignition coils.
(a) Measure the resistance between the terminal A and
body ground D.
Standard: 1 M or higher
Section 1.3.3
13. Inspect signal generator

(1) Disconnect the pickup coil connector.
(2) Measure the resistance between the terminals. Standard:
Cold 20C (68F) 370 to 550
Hot 80C (176F) 475 to 650
(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.
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:
(5) After racing the engine several times, check that the VF
COUNTERCLOCKWISE CLOCKWISE
VF Condition Measures
voltage
Turn the screw
0V Air fuel ratio: RICH CLOCKWISE
Turn the screw
5V Air fuel ratio: LEAN COUNTERCLOCKWISE
voltage is within the specified range.
Note:
Adjust the VF voltage to nearly 2.5 V.
Section 1.3.3
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 engine,
measure the compression pressure. 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.
Section 1.3.3
4-1
APPENDIX
Page
SST LIST ................................................................4-2 0

SERVICE STANDARDS.........................................4-4
1
WIRING DIAGRAM.................................................4-5
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Section 1.3.4
21
E
4-2
SST LIST
Section
Illustration Part number Part name
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
Section 1.3.4
09819-22000-71 Gauge
4-3
Section
Illustration Part number Part name
2 3
09819-23600-71 Gauge
23627-22000-71 Spring
09820-23600-71 Tester SUB-ASSY
09240-26600-71 Plug-in Analyzer
0
1
2
3
4
Section 1.3.4
5
6
7
8
9
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

11.8 to 15.0 (120 to 150) [8.7 to 11.0]
(Distance from the body face to the screw tip)
Mounting height of the first spring adjuster mm (in) 13.9 (0.5)
Pressure in the first reducing chamber kPa (kgf/cm2) [psi] 24.5 to 34.3 (0.25 to 0.35) [3.6 to 5.0]
First valve lever height
11.8 to 12.3 (0.47 to 0.48)
(From first cover contact surface) mm (in)
Section 1.3.4
Second valve lever height
0 to 2.0 (0 to 0.08)
(From second cover contact surface) mm (in)
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]
Section 1.3.4
4-5
WIRING DIAGRAM
Fuel System
FS08-001
September 15, 2008
8-Series LPG Regulators
8FGU15-32 (LPG and Dual Fuel)
8FGCU15-32 (LPG and Dual Fuel)
SERVICE INFORMATION BULLETIN
Subject: 8-Series LPG Regulators Page 1 of 1
MODEL APPLICATION: Return To FS Index

8FGU15-32 and 8FGCU15-32 LPG and Dual Fuel Return To Main Index
GENERAL INFORMATION:
Service Parts have been made available for improvement to 1 st Valve durability where failures are
related to Amine that is contained in LP fuel. It has been determined that Amine may be mixed in the
LP fuel that is distributed to certain areas of the country. An Amine resistant valve has been added to
service parts for cases where Amine may be added to the fuel. The updated 1 st Valve and Overhaul kit
uses a material based from Nitrile Butyl Rubber which is resistant to damage from the Amine that may
be in the LP fuel.
REPAIR INFORMATION:
When damage to the 1st Valve is found, especially after very low hours of operation, use the service
parts listed below to repair the LP Regulator.
PARTS INFORMATION:
Part Number Parts Name Model
23502-U2230-71* First Valve SUB-ASSY 8FGU15-32 and 8FGCU15-32
04221-U2050-71 First Valve Overhaul Kit 8FGU15-32 and 8FGCU15-32
23540-U1250-71 Regulator Assembly 8FGCU15-18 Only
23540-U2230-71 Regulator Assembly 8FGU15-32 and 8FGCU20-32
*Note – Part number 23502-U2230-71 is included in kit p/n 04221-U2050-71.

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NAME SECTION

LPG REGULATOR OVERHAUL

…..This Page Intentionally Left Blank…..

METHOD AND TIGHTENING TORQUE ....................0-9

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

ENGINE PERFORMANCE CURVES

4Y Engine (8FGU30, 32)

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

Minimum fuel g/kW·h 298 233 233 310 298

Idle speed rpm 750 750 750

PRINCIPAL DIFFERENCES FROM GASOLINE VEHICLE

Adapter For LPG For LPG Not provided

GENERAL RULES OF SERVICING WORK

BOLT & NUT TIGHTENING TORQUES

BOLT STRENGTH CLASS IDENTIFICATION METHOD AND

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

Identification by Part No.

Tightening Torque Table

6 1.0 5.4 55 4.0

6 1.0 12 125 9.0

Tightening Torque Table (Hexagon flange bolt)

6 1.0 17.5 180 13

PERIODIC REPLACEMENT PARTS

remove foreign matters of 2 m or more in size. 2

cuts off the gas flow. 6

valve, the slide 8

spring force to shut off the flow. 9

Needle valve seat diameter mm (in) 11 (0.4)

Needle valve seat angle 60

Stroke mm (in) 5 (0.2)

Drain cock Optionally available

1. When starting the engine

3. During normal operation

4. When stopping the engine

REGULATORS SYSTEM COMPONENTS

LPG REGULATOR OVERHAUL

No. Part No. Part Name

SSTs for LPG Regulator Overhaul

2. Install the regulator primary pressure adjusting screw.

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

OK The pointer moves to 0 position. NG The pointer stays at the position.

Normal • Second diaphragm defect

• Loosen of elastic face valve 2

LPG Device for 4Y-E Engine 2-9

2. Inspect the main solenoid.

1 Fully discharge LPG from the fuel piping. [Point 1] 2

8 Remove the regulator ASSY. Installation Procedure

Discharge LPG from the piping according to the procedure below.

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

4. Check and adjust the first lever height.

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

Second Valve Airtightness Check

5. Inject compressed air through the SSTs and make adjustment

LPG LEAK INSPECTION

3. Check the initial advanced ignition timing.

4. Adjust the initial advaced ignition timing.

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

7. Check and adjust VF voltage