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Daewoo GC20SC-2 User Manual

Daewoo GC20SC-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 GC20SC-2 Specifications

General IconGeneral
BrandDaewoo
ModelGC20SC-2
CategoryEngine
LanguageEnglish

Summary

Important Safety Information

IMPORTANT DEFINITIONS

CHAPTER 0 LPG AND LPG FUEL TANKS

LPG Fuel Supply

Details on the composition and properties of Liquefied Petroleum Gas (LPG) used as fuel.

CHAPTER 1 ENGINE SPECIFICATION

Indication of Engine Serial Number

Information on locating and identifying the engine serial number and specifications.

CHAPTER 2 MI-04 LPG SYSTEM OPERATIONAL OVERVIEW

MI-04 General Description

Overview of the MI-04 control system for TIER-2 emission standards.

CHAPTER 3 MI-04 MAINTENANCE SCHEDULE

RECOMMENDED MAINTENANCE SCHEDULE

Scheduled maintenance tasks for the MI-04 LP fuel system based on interval hours.

CHAPTER 7 N2001 PRESSURE REGULATOR /CONVERTER

Removal and Installation of N2001 LP Regulator/Converter

Procedures for removing and installing the N2001 regulator/converter unit.

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

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

Steps for removing and installing the N-CA55-500TR air/fuel mixer.

WORKING WITH LPG EQUIPMENT

LPG Fuel Supply

Details on the composition and properties of Liquefied Petroleum Gas (LPG) used as fuel.

CHAPTER 0 LPG AND LPG FUEL TANKS

LPG Fuel Tanks

Description of the two styles of LPG storage containers for industrial use.

CHAPTER 0 LPG AND LPG FUEL TANKS

Installing LPG Fuel Tanks

Guidelines for correctly mounting LPG tanks on lift trucks to prevent damage.

CHAPTER 0 LPG AND LPG FUEL TANKS

LPG Fuel Tank Components

Identification and description of various components found on LPG fuel tanks.

Service Valve

Function and operation of the manually operated service valve on LPG tanks.

CHAPTER 0 LPG AND LPG FUEL TANKS

Quick Disconnect Coupling

Description of the quick disconnect coupling used for fuel system connections.

Filler Valve

Details on the one-way flow filler valve and its safety features.

CHAPTER 1 ENGINE SPECIFICATION

Indication of Engine Serial Number

Information on locating and identifying the engine serial number and specifications.

CHAPTER 1 ENGINE SPECIFICATION

Specifications(G420E)

Detailed technical specifications for the G420E engine model.

CHAPTER 1 ENGINE SPECIFICATION

Specifications(G424E)

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 for TIER-2 emission standards.

CHAPTER 2 MI-04 LPG SYSTEM OPERATIONAL OVERVIEW

MI-04 Closed Loop LP Fuel System

Diagram and explanation of the MI-04 system in closed loop fuel control.

CHAPTER 2 MI-04 LPG SYSTEM OPERATIONAL OVERVIEW

MI-04 Fuel Lock-Off (Electric)

Explanation of the electric fuel lock-off safety shutoff valve.

CHAPTER 2 MI-04 LPG SYSTEM OPERATIONAL OVERVIEW

MI-04 N-2001 Regulator/Converter

Description of the N-2001 regulator/converter and its function as vaporizer.

CHAPTER 2 MI-04 LPG SYSTEM OPERATIONAL OVERVIEW

N-2001 Theory of Operation

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

CHAPTER 2 MI-04 LPG SYSTEM OPERATIONAL OVERVIEW

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

Explanation of how the N-CA55-500TR air/fuel mixer functions.

CHAPTER 2 MI-04 LPG SYSTEM OPERATIONAL OVERVIEW

MI-04 Electronic Throttle

How the SECM controls throttle opening via electronic throttle control (ETC).

CHAPTER 2 MI-04 LPG SYSTEM OPERATIONAL OVERVIEW

MI-04 Fuel Trim Valve

Function and control of the Fuel Trim Valve (FTV) in the MI-04 system.

CHAPTER 2 MI-04 LPG SYSTEM OPERATIONAL OVERVIEW

Heated Exhaust Gas Oxygen Sensor (HEGO)

Description of the HEGO sensor and its role in monitoring exhaust gas content.

CHAPTER 2 MI-04 LPG SYSTEM OPERATIONAL OVERVIEW

MI-04 SECM (General Description)

Overview of the Woodward Small Engine Control Module (SECM).

CHAPTER 2 MI-04 LPG SYSTEM OPERATIONAL OVERVIEW

MI-04 SECM (Load/Speed Management)

SECM's role in managing engine load and speed via electronic throttle.

CHAPTER 2 MI-04 LPG SYSTEM OPERATIONAL OVERVIEW

MI-04 Ignition management

How the SECM controls ignition timing based on engine parameters.

CHAPTER 3 MI-04 MAINTENANCE SCHEDULE

RECOMMENDED MAINTENANCE SCHEDULE

Scheduled maintenance tasks for the MI-04 LP fuel system based on interval hours.

CHAPTER 3 MI-04 MAINTENANCE SCHEDULE

Test Fuel System for Leaks

Procedure for testing the fuel system for leaks using a leak check solution.

CHAPTER 3 MI-04 MAINTENANCE SCHEDULE

Inspect Acceleration Pedal Operation

Verifying smooth travel of the acceleration pedal without sticking.

CHAPTER 3 MI-04 MAINTENANCE SCHEDULE

Replace LP Fuel Filter Element

Step-by-step guide for replacing the LP fuel filter element.

CHAPTER 3 MI-04 MAINTENANCE SCHEDULE

Testing Fuel Lock-off Operation

Procedure to test the fuel lock-off valve's functionality.

CHAPTER 3 MI-04 MAINTENANCE SCHEDULE

Inspect for Intake Leaks

Checking intake manifold, throttle assembly for leaks.

CHAPTER 3 MI-04 MAINTENANCE SCHEDULE

Inspect air/fuel valve mixer assembly

Procedure to inspect the air/fuel valve mixer assembly.

CHAPTER 3 MI-04 MAINTENANCE SCHEDULE

Replace Oxygen Sensor

Procedure for replacing the oxygen sensor.

CHAPTER 4 MI-04 LP BASIC TROUBLESHOOTING

Basic Troubleshooting

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

CHAPTER 4 MI-04 LP BASIC TROUBLESHOOTING

Engine Cranking but Will Not Start

Troubleshooting steps for an engine that cranks but won't start.

CHAPTER 4 MI-04 LP BASIC TROUBLESHOOTING

Will Not Run Continuously

Troubleshooting for issues where the engine stops running after starting.

CHAPTER 4 MI-04 LP BASIC TROUBLESHOOTING

Will Not Accelerate/Hesitation During Acceleration

Diagnosing and fixing acceleration issues or hesitation.

CHAPTER 4 MI-04 LP BASIC TROUBLESHOOTING

Engine Stalls

Troubleshooting steps for when the engine stalls.

CHAPTER 4 MI-04 LP BASIC TROUBLESHOOTING

Rough Idle

Addressing issues with rough idling.

CHAPTER 4 MI-04 LP BASIC TROUBLESHOOTING

Excessive Fuel Consumption/LP G Exhaust Smell

Troubleshooting high fuel consumption and LP exhaust smell.

CHAPTER 5 MI-04 LP ADVANCED DIAGNOSTICS

Reading Diagnostic Fault Codes

How to retrieve and interpret Diagnostic Fault Codes (DFC) using the MIL.

CHAPTER 5 MI-04 LP ADVANCED DIAGNOSTICS

Displaying Fault Codes (DFC) From SECM Memory

Procedure to display stored Diagnostic Fault Codes from SECM memory.

CHAPTER 5 MI-04 LP ADVANCED DIAGNOSTICS

Fault List Definitions

Definitions of various sensor input faults and range faults.

CHAPTER 5 MI-04 LP ADVANCED DIAGNOSTICS

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

Table listing MI-04 Diagnostic Fault Codes, probable faults, actions, and checks.

CHAPTER 6 MI-04 ELECTRICAL CONNECTIONS

Resistance Checks

Procedures and expected resistance ranges for sensor checks.

CHAPTER 6 MI-04 ELECTRICAL CONNECTIONS

Voltage Checks

Procedures and expected voltage readings for sensor checks.

CHAPTER 7 N2001 PRESSURE REGULATOR /CONVERTER

Removal and Installation of N2001 LP Regulator/Converter

Procedures for removing and installing the N2001 regulator/converter unit.

CHAPTER 7 N2001 PRESSURE REGULATOR /CONVERTER

Hose Connections

Diagram and guidelines for correct vacuum hose and fuel line routing.

CHAPTER 7 N2001 PRESSURE REGULATOR /CONVERTER

N2001 Removal Steps:

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

CHAPTER 7 N2001 PRESSURE REGULATOR /CONVERTER

N2001 Regulator Disassembly Steps:

Detailed steps for disassembling the N2001 regulator.

CHAPTER 7 N2001 PRESSURE REGULATOR /CONVERTER

N2001 Disassembled Service

Cleaning and inspection procedures for disassembled N2001 regulator components.

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

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

Steps for removing and installing the N-CA55-500TR air/fuel mixer.

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

N-CA55-500TR Mixer Removal Steps:

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

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

N-CA55-500TR Disassembly and Service

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

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

N-CA55-500TR Disassembly and Service

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

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

Installing the Mixer/Throttle Assembly

Steps for installing the mixer and throttle assembly.

CHAPTER 9 TEST AND ADJUSTMENTS

N2001 Service Testing

Tests to perform on the N2001 regulator/converter after overhaul or checking.

CHAPTER 9 TEST AND ADJUSTMENTS

Secondary Stage (Break-Off) Test

Procedure for testing the secondary stage break-off pressure of the N2001 regulator.

CHAPTER 9 TEST AND ADJUSTMENTS

Primary Stage Pressure Test

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

CHAPTER 9 TEST AND ADJUSTMENTS

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

Procedure for testing the Air Valve Vacuum (AVV) of the N-CA55-500TR mixer.

CHAPTER 9 TEST AND ADJUSTMENTS

Ignition Timing Adjustment

Procedure for adjusting the ignition timing by setting distributor position.

CHAPTER 9 TEST AND ADJUSTMENTS

Idle Mixture Adjustment

Procedure for adjusting the idle mixture using service tool software.

CHAPTER 10 SERVICE TOOL KIT

USB to CAN Converter Assembly

Description of the USB to CAN converter assembly.

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