Daewoo GC18S-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

Important Safety Information

CHAPTER 1 ENGINE SPECIFICATION

Indication of Engine Serial Number

Shows where to find the engine serial number on the engine.

Specifications(G420 E)

Detailed specifications for the G420E engine model.

Specifications(G424 E)

Detailed specifications for the G424E engine model.

CHAPTER 2 MI-04 LPG SYSTEM OPERATIONAL OVERVIEW

MI-04 General Description

Overview of the MI-04 LPG control system and its purpose.

MI-04 LP Fuel Filter

Description of the MI-04 LP fuel filter and its function.

MI-04 Fuel Lock-Off (Electric)

Explanation of the electric fuel lock-off safety feature.

MI-04 N-2001 Regulator;Converter

Details on the N-2001 regulator/converter and its function.

N-2001 Theory of Operation

In-depth explanation of how the N-2001 regulator/converter operates.

MI-04 N-CA55-500 TR Mixer

Description of the N-CA55-500TR air/fuel mixer.

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

Explanation of the N-CA55-500-TR mixer's operational principles.

MI-04 Electronic Throttle

Information on the MI-04 electronic throttle control system.

MI-04 Fuel Trim Valve

Details on the MI-04 Fuel Trim Valve and its function.

Heated Exhaust Gas Oxygen Sensor (HEGO)

Explanation of the HEGO sensor's role in the MI-04 system.

MI-04 SECM (General Description)

General description of the MI-04 Small Engine Control Module (SECM).

MI-04 SECM (Fuel Management)

How the SECM manages fuel delivery for emissions control.

MI-04 SECM (Load;Speed Management)

SECM's role in managing engine load and speed.

MI-04 Ignition management

Explanation of the MI-04 ignition system control.

CHAPTER 3 MI-04 MAINTENANCE SCHEDULE

Test Fuel System for Leaks

Procedure for testing the fuel system for leaks.

Inspect Engine for Fluid Leaks

Steps to inspect the engine for oil and coolant leaks.

Inspect Vacuum Lines and Fittings

How to inspect vacuum lines and fittings for damage.

Inspect Electrical System

Check electrical connectors and wiring for issues.

Inspect Acceleration Pedal Operation

Verifying smooth operation of the acceleration pedal.

Check Coolant Level

Procedure for checking the engine coolant level.

Inspect Coolant Hoses

Inspecting coolant hoses for signs of wear or damage.

Inspect Battery System

Checking the battery for damage and cleaning connections.

Inspect Ignition System

Inspecting spark plugs, cables, and distributor.

Replace Spark Plugs

Step-by-step guide for replacing spark plugs.

Replace LP Fuel Filter Element

Procedure for replacing the LP fuel filter element.

Testing Fuel Lock-off Operation

How to test the fuel lock-off valve's operation.

Fuel Trim Valve Inspection (FTV)

Inspecting the Fuel Trim Valve for leaks and damage.

Inspect Air;Fuel Valve Mixer Assembly

Refer to mixer section for inspection procedures.

Pressure Regulator;Converter Testing and Inspection

Inspecting the pressure regulator/converter for leaks.

Inspect for Intake Leaks

Checking intake manifold and adapters for leaks.

Inspect Engine for Exhaust Leaks

Inspecting the exhaust system for leaks.

Replace Oxygen Sensor

Procedure for replacing the oxygen sensor.

Checking the TMAP Sensor

Verifying TMAP sensor mounting and tightness.

Inspect Throttle Assembly

Inspecting the throttle assembly for damage.

CHAPTER 4 MI-04 LP BASIC TROUBLESHOOTING

CHAPTER 5 MI-04 LP ADVANCED DIAGNOSTICS

Reading Diagnostic Fault Codes

How to retrieve diagnostic fault codes using the MIL.

Displaying Fault Codes (DFC) From SECM Memory

Procedure to enter code display mode and view codes.

Clearing Fault (DFC) Codes

Steps to clear stored diagnostic fault codes.

Fault Action Descriptions

Explains the actions taken by the SECM for detected faults.

Fault List Definitions

Definitions for various fault codes and sensor issues.

CHAPTER 6 MI-04 ELECTRICAL CONNECTIONS

Resistance Checks

Procedures for performing resistance checks on sensors.

Voltage Checks

Procedures for performing voltage checks on sensors.

CHAPTER 7 N2001 PRESSURE REGULATOR;CONVERTER

Removal and Installation of N2001 LP Regulator;Converter

Safety warnings and precautions for removal/installation.

Hose Connections

Diagram and description of proper hose routing and lengths.

N2001 Removal Steps:

Step-by-step instructions for removing the N2001 regulator.

N2001 Regulator Disassembly Steps:

Illustrated steps for disassembling the N2001 regulator.

N2001 Disassembled Service

Procedures for cleaning and servicing disassembled regulator parts.

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

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

Safety warnings and precautions for mixer R&I.

N-CA55-500 TR Mixer Removal Steps:

Step-by-step instructions for removing the mixer.

N-CA55-500 TR Disassembly and Service

Illustrated steps for disassembling and servicing the mixer.

Installing the Mixer;Throttle Assembly

Procedures for installing the mixer and throttle assembly.

CHAPTER 9 TEST AND ADJUSTMENTS

N2001 Service Testing

Tests for checking N2001 regulator/converter operation.

Secondary Stage Test Hardware

List of hardware needed for secondary stage testing.

Secondary Stage (Break-Off) Test

Procedure for testing the secondary stage break-off pressure.

Primary Stage Test Hardware

List of hardware needed for primary stage testing.

Primary Stage Pressure Test

Procedure for testing primary stage pressure.

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

Testing the air valve vacuum (AVV) on the mixer.

Ignition Timing Adjustment

Procedure for adjusting ignition timing.

Idle Mixture Adjustment

Procedure for adjusting the idle mixture using service tool.

CHAPTER 10 SERVICE TOOL KIT

Daewoo GC18S-2 Specifications

General

Brand	Daewoo
Model	GC18S-2
Category	Engine
Language	English