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Daewoo G18S-2 User Manual

Daewoo G18S-2
88 pages
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Service Manual
G420E/G424E Tier LP Engine
Lift Trucks
G15S-2, G18S-2, G20SC-2
GC15S-2, GC18S-2, GC20SC-2
With G420E Tier LP Engine
G20E-3, G25E-3, G30E-3, G32E-3
GC20E-3, GC25E-3, GC30E-3, GC32E-3
with G424E Tier LP Engine
SB4136E00
Jun. 2004

Table of Contents

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Daewoo G18S-2 Specifications

General IconGeneral
Compression Ratio8.5:1
Fuel SystemCarburetor
Engine type4-stroke, single cylinder, air-cooled
Cooling SystemAir-cooled
Starting SystemRecoil starter

Summary

Important Safety Information

Important Definitions

CHAPTER 0 LPG AND LPG FUEL TANKS

LPG Fuel Supply

Explains the composition and properties of Liquefied Petroleum Gas (LPG).

LPG Fuel Tanks

Describes the types of LPG storage containers and their characteristics.

Installing LPG Fuel Tanks

Provides guidelines for the correct and safe installation of LPG tanks.

LPG Fuel Tank Components

Details the various components of an LPG fuel tank system.

Service Valve

Explains the function and operation of the manual service valve on LPG tanks.

Quick Disconnect Coupling

Describes the quick disconnect coupling used for fuel line connections.

Filler Valve

Details the function and safety features of the LPG tank filler valve.

CHAPTER 1 ENGINE SPECIFICATION

Indication of Engine Serial Number

Shows how to locate and identify the engine's serial number.

Specifications (G420E)

Presents detailed technical specifications for the G420E engine model.

Specifications (G424E)

Presents detailed technical specifications for the G424E engine model.

CHAPTER 2 MI-04 LPG SYSTEM OPERATIONAL OVERVIEW

MI-04 General Description

Overview of the MI-04 control system and its role in emission standards.

MI-04 LP Fuel Filter

Explains the function of the MI-04 inline fuel filter in removing particles.

MI-04 Fuel Lock-Off (Electric)

Details the operation of the electric fuel lock-off as a safety shutoff mechanism.

MI-04 N-2001 Regulator/Converter

Introduces the N-2001 component for propane vaporization and pressure regulation.

N-2001 Theory of Operation

Explains the detailed internal workings of the N-2001 regulator/converter.

MI-04 N-CA55-500TR Mixer

Describes the N-CA55-500TR mixer and its function in the fuel system.

N-CA55-500-TR Air/Fuel Mixer Theory of Operation

Details the operational theory behind the N-CA55-500TR air/fuel mixer.

MI-04 Electronic Throttle

Explains the electronic throttle control (ETC) system and its components.

MI-04 Fuel Trim Valve

Describes the function and operation of the Fuel Trim Valve (FTV).

Heated Exhaust Gas Oxygen Sensor (HEGO)

Explains the HEGO sensor's role in monitoring exhaust gas content.

MI-04 SECM (General Description)

Provides a general overview of the Small Engine Control Module (SECM).

MI-04 SECM (Fuel Management)

Details SECM fuel management strategies for optimal emissions and performance.

MI-04 SECM (Load/Speed Management)

Explains SECM control of engine load and speed via electronic throttle.

MI-04 Ignition management

Describes how the SECM controls ignition timing based on engine operating conditions.

CHAPTER 3 MI-04 MAINTENANCE SCHEDULE

RECOMMENDED MAINTENANCE SCHEDULE

Presents a schedule for routine maintenance tasks for the MI-04 system.

Test Fuel System for Leaks

Outlines procedures for checking the fuel system for leaks.

Inspect Electrical System

Covers inspection of electrical connectors and wiring for damage.

Check Coolant Level

Procedure for checking and maintaining the engine's coolant level.

Replace LP Fuel Filter Element

Instructions for replacing the inline LP fuel filter element.

Testing Fuel Lock-off Operation

Procedure to test the functionality of the electric fuel lock-off valve.

Replace Oxygen Sensor

Step-by-step instructions for replacing the oxygen sensor.

CHAPTER 4 MI-04 LP BASIC TROUBLESHOOTING

Basic Troubleshooting

Provides common problems and corrective actions for the MI-04 LP system.

CHAPTER 5 MI-04 LP ADVANCED DIAGNOSTICS

Reading Diagnostic Fault Codes

Explains how to retrieve and interpret diagnostic fault codes using the MIL.

Displaying Fault Codes (DFC) From SECM Memory

Details the procedure to enter code display mode and view stored fault codes.

Clearing Fault (DFC) Codes

Provides instructions on clearing stored diagnostic fault codes from SECM memory.

Fault Action Descriptions

Lists and describes the actions taken by the SECM for specific fault codes.

Fault List Definitions

Defines various sensor input and range faults recognized by the MI-04 system.

Table a. MI-04 Diagnostic Fault Codes (Flash Codes)

A table listing diagnostic fault codes, probable faults, actions, and checks.

CHAPTER 6 MI-04 ELECTRICAL CONNECTIONS

Resistance Checks

Provides expected resistance ranges for various sensors and components.

Voltage Checks

Details voltage checks for sensors and components, including the acceleration pedal.

CHAPTER 7 N2001 PRESSURE REGULATOR /CONVERTER

Removal and Installation of N2001 LP Regulator/Converter

Safety precautions and procedures for removing and installing the N2001 regulator/converter.

Hose Connections

Diagrams and details for correct vacuum hose and fuel line routing for the N2001.

N2001 Removal Steps:

Step-by-step instructions for safely removing the N2001 regulator/converter.

N2001 Regulator Disassembly Steps:

Detailed steps for disassembling the N2001 regulator for service.

N2001 Disassembled Service

Procedures for cleaning and servicing disassembled components of the N2001 regulator.

CHAPTER 8 N-CA55-500TR AIR/FUEL MIXER

Removal and Installation of the N-CA55-500TR Mixer

Safety warnings and procedures for removing and installing the N-CA55-500TR mixer.

N-CA55-500TR Mixer Removal Steps:

Step-by-step instructions for safely removing the N-CA55-500TR mixer assembly.

N-CA55-500TR Disassembly and Service

Detailed steps for disassembling and servicing the N-CA55-500TR mixer.

Installing the Mixer/Throttle Assembly

Instructions for correctly installing the mixer and throttle assembly.

CHAPTER 9 TEST AND ADJUSTMENTS

N2001 Service Testing

Tests to check the operation of the N2001 regulator/converter after overhaul.

Secondary Stage Test Hardware

Lists necessary hardware for secondary stage tests on the N2001.

Secondary Stage (Break-Off) Test

Procedure for testing the secondary valve's break-off pressure.

Primary Stage Test Hardware

Lists necessary hardware for primary stage pressure tests.

Primary Stage Pressure Test

Procedure for testing the primary stage pressure of the N2001 regulator.

N-CA55-500TR Service AVV (Air Valve Vacuum) Testing

Tests the Air Valve Vacuum (AVV) on the N-CA55-500TR mixer.

Ignition Timing Adjustment

Details distributor alignment for setting ignition timing.

Idle Mixture Adjustment

Explains idle mixture adjustment using service tool software.

CHAPTER 10 SERVICE TOOL KIT

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