Daewoo GC15S-2 - User Manual

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

Summary

Chapter 0 LPG and LPG Fuel Tanks

LPG Fuel Supply

Details the composition and properties of liquefied petroleum gas used as fuel.

LPG Fuel Tanks

Describes the two types of LPG storage containers for industrial use and lift trucks.

LPG Fuel Tank Components

Identifies and explains the function of various components found on LPG fuel tanks.

Service Valve

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

Quick Disconnect Coupling

Describes the function and connection of the quick disconnect coupling for fuel systems.

Filler Valve

Explains the design and safety features of the liquid filler valve for LPG tanks.

Chapter 1 Engine Specification

Indication of Engine Serial Number

Shows where to find the engine serial number and important engine information.

Specifications (G420 E)

Provides detailed technical specifications for the G420E engine model.

Specifications (G424 E)

Provides detailed technical specifications for the G424E engine model.

Chapter 2 MI-04 LPG System Operational Overview

MI-04 General Description

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

MI-04 LP Fuel Filter

Describes the function and purpose of the inline fuel filter in the MI-04 system.

MI-04 Fuel Lock-Off (Electric)

Explains the electric fuel lock-off as a safety shutoff valve in the MI-04 system.

MI-04 N-2001 Regulator;Converter

Details the function of the N-2001 regulator/converter as a vaporizer and regulator.

N-2001 Theory of Operation

Explains the step-by-step operational process of the N-2001 regulator/converter.

MI-04 N-CA55-500 TR Mixer

Describes the N-CA55-500TR mixer's role in controlling fuel-air mixture.

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

Explains how the N-CA55-500TR mixer uses an air valve to meter fuel.

MI-04 Electronic Throttle

Details the electronic throttle control system and its operation.

MI-04 Fuel Trim Valve

Explains the function of the Fuel Trim Valve in controlling air-fuel ratio.

Heated Exhaust Gas Oxygen Sensor (HEGO)

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

MI-04 SECM (General Description)

Provides an overview of the Small Engine Control Module (SECM) and its functions.

MI-04 SECM (Fuel Management)

Details the SECM's fuel management strategies and control loops.

MI-04 SECM (Load;Speed Management)

Explains how the SECM manages engine load and speed for optimal performance.

MI-04 Ignition management

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

Chapter 3 MI-04 Maintenance Schedule

RECOMMENDED MAINTENANCE SCHEDULE

Outlines the suggested maintenance intervals and tasks for the MI-04 fuel system.

Test Fuel System for Leaks

Provides procedures for testing the fuel system for any leaks.

Inspect Engine for Fluid Leaks

Details how to inspect the engine for oil and coolant leaks.

Inspect Vacuum Lines and Fittings

Guides inspection of vacuum lines and fittings for damage and proper condition.

Inspect Electrical System

Covers checks for loose or damaged electrical connectors and wiring.

Inspect Acceleration Pedal Operation

Verifies smooth operation and travel of the acceleration pedal.

Check Coolant Level

Outlines the procedure for checking the engine coolant level.

Inspect Coolant Hoses

Details visual inspection of coolant hoses for signs of wear or damage.

Inspect Battery System

Describes checks for battery condition, damage, and cable integrity.

Inspect Ignition System

Covers inspection of spark plugs, cables, distributor, and ignition coil.

Replace Spark Plugs

Provides step-by-step instructions for replacing spark plugs.

Replace LP Fuel Filter Element

Details the procedure for replacing the LP fuel filter element.

Testing Fuel Lock-off Operation

Explains how to test the functionality of the electric fuel lock-off.

Fuel Trim Valve Inspection (FTV)

Guides inspection of the Fuel Trim Valve for leaks and damage.

Pressure Regulator;Converter Testing and Inspection

Outlines procedures for testing and inspecting the pressure regulator/converter.

Inspect Air;Fuel Valve Mixer Assembly

Refers to procedures for inspecting the air/fuel mixer assembly.

Inspect for Intake Leaks

Details inspection of intake manifold, throttle assembly, and adapters for leaks.

Inspect Engine for Exhaust Leaks

Provides steps to inspect the exhaust system for leaks.

Replace Oxygen Sensor

Gives instructions for replacing the oxygen sensor.

Chapter 4 MI-04 LP Basic Troubleshooting

Basic Troubleshooting

Provides initial checks for engine and drivability problems before advanced diagnostics.

Engine Cranking but Will Not Start

Lists probable causes and corrective actions for an engine that cranks but won't start.

Difficult to Start

Addresses probable causes and solutions for an engine that is difficult to start.

Will Not Run Continuously

Lists causes and corrective actions for an engine that stops running intermittently.

Will Not Accelerate;Hesitation During Acceleration

Details issues related to acceleration problems and their solutions.

Engine Stalls

Covers probable causes and corrective actions for an engine that stalls.

Rough Idle

Lists causes and solutions for an engine experiencing a rough idle.

High Idle Speed

Addresses issues with excessively high idle speed and their fixes.

Poor High Speed Performance

Details problems affecting high-speed engine performance and their remedies.

Excessive Fuel Consumption;LP G Exhaust Smell

Lists causes for high fuel consumption or LPG exhaust smell and their corrective actions.

Chapter 5 MI-04 LP Advanced Diagnostics

Advanced Diagnostics

Introduces the MI-04 system's built-in fault diagnostics and code retrieval.

Reading Diagnostic Fault Codes

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

Displaying Fault Codes (DFC) From SECM Memory

Provides steps to enter code display mode and view stored fault codes.

Clearing Fault (DFC) Codes

Details the procedure for clearing stored diagnostic fault codes from SECM memory.

Fault Action Descriptions

Describes the actions taken by the SECM for detected faults.

Fault List Definitions

Defines various fault codes and their associated sensor inputs or system conditions.

Chapter 6 MI-04 Electrical Connections

Resistance Checks

Provides expected resistance ranges for various sensors and components.

Voltage Checks

Lists expected voltage readings for sensor outputs and system power.

Chapter 7 N2001 Pressure Regulator;Converter

Removal and Installation of N2001 LP Regulator;Converter

Outlines the steps for removing and installing the N2001 regulator/converter.

Hose Connections

Illustrates proper routing of vacuum and fuel lines for the regulator/converter.

N2001 Removal Steps:

Provides a detailed sequence for removing the N2001 regulator.

N2001 Regulator Disassembly Steps:

Details the step-by-step process for disassembling the N2001 regulator.

N2001 Disassembled Service

Provides instructions for cleaning and servicing disassembled N2001 regulator components.

Chapter 8 N-CA55-500 TR Air;Fuel Mixer

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

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

N-CA55-500 TR Mixer Removal Steps:

Details the step-by-step process for removing the N-CA55-500TR mixer.

N-CA55-500 TR Disassembly and Service

Provides instructions for disassembling and servicing the N-CA55-500TR mixer.

Installing the Mixer;Throttle Assembly

Guides the installation of the mixer and throttle assembly.

Chapter 9 Test and Adjustments

N2001 Service Testing

Describes tests to check the operation of the N2001 regulator/converter.

Secondary Stage Test Hardware

Lists the necessary hardware for secondary stage testing.

Secondary Stage (Break-Off) Test

Details the procedure for testing the secondary stage of the N2001 regulator.

Primary Stage Test Hardware

Lists the necessary hardware for primary stage pressure testing.

Primary Stage Pressure Test

Provides instructions for testing the primary stage pressure of the N2001 regulator.

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

Details the procedure for testing the Air Valve Vacuum (AVV).

Ignition Timing Adjustment

Explains how to adjust the distributor for correct ignition timing.

Idle Mixture Adjustment

Provides steps for adjusting the idle mixture using service tool software.

Chapter 10 Service Tool Kit

Service Tool Kit Components

Lists the components included in the MI-04 service tool kit.

Daewoo GC15S-2 Specifications

General

Brand	Daewoo
Model	GC15S-2
Category	Engine
Language	English