Daewoo G420E Service Manual Download

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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

Summary of Contents for G420E

Page 1: ...420E 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 SB4...

Page 2: ...ollowing symbol WARNING Improper operation lubrication maintenance or repair of this product can be dangerous and could result in injury or death Do not operate or perform any lubrication maintenance...

Page 3: ......

Page 4: ...arging device make sure the charging device is turned off before disconnecting the battery from the system Electronic controls contain static sensitive parts Observe the following precautions to preve...

Page 5: ......

Page 6: ...CHEDULE RECOMMENDED MAINTENANCE SCHEDULE 30 Test Fuel System for Leaks 30 Inspect Engine for Fluid Leaks 30 Inspect Vacuum Lines and Fittings 30 Inspect Electrical System 30 Inspect Acceleration Pedal...

Page 7: ...L MIXER Removal and Installation of the N CA55 500TR Mixer 70 N CA55 500TR Mixer Removal Steps 71 N CA55 500TR Disassembly and Service 72 N CA55 500TR Disassembled Service 74 Installing the Mixer Thro...

Page 8: ...converter and mixer are part of a certified system complying with EPA and CARB 2004 requirements Only trained certified technicians should perform disassemble service or replacement of the regulator c...

Page 9: ...e will boil at 212 deg F 100 deg C If an engines operating temperature is approximately 230 deg F 110 deg C then the water in an open un pressurized cooling system would simply boil off into steam eve...

Page 10: ...t to the point where the tank will not stand or is easily knocked over Installing LPG Fuel Tanks When installing a tank on a lift truck the tank must be within the outline of the vehicle to prevent da...

Page 11: ...rled knob clockwise Typically a warning label surrounds the fixed tube gauge which reads STOP FILLING WHEN LIQUID APPEARS Service Valve The service valve is a manually operated valve using a small han...

Page 12: ...o ring must be removed from the shaft and the coupling reconnected Filler Valve The liquid filler valve Figure 9 has a male thread to receive a fuel nozzle and typically has a plastic or brass screw...

Page 13: ...G420E G424E Tier LP Engine Engine Specification 12 CHAPTER 1 ENGINE SPECIFICATION Indication of Engine Serial Number...

Page 14: ...180 F THERMOSTAT Fully Open Temperature 95 C 203 F COOLING WATER CAPACITY 3 1 L block only LUBRICATION SYSTEM 450 kPa 65 psi Hi Idle OIL PRESSURE 50 kPa 7 psi Low Idle Upper Limit 125 C 257 F Recommen...

Page 15: ...rature 82 C 180 F Fully Open Temperature 95 C 203 F COOLING WATER CAPACITY 3 1 L block only LUBRICATION SYSTEM OIL PRESSURE 50 kPa 7 psi Low Idle 450 kPa 65 psi Hi Idle Upper Limit 125 C 257 F Recomme...

Page 16: ...tem utilizing a catalytic muffler to reduce the emission level in the exhaust gas In order to obtain maximum effect from the catalyst an accurate control of the air fuel ratio is required A small engi...

Page 17: ...to the electronic throttle through the electrical harness mechanical cables are not used A throttle position sensor TPS monitors throttle position in relation to the accelerator pedal position sensor...

Page 18: ...the SECM full control of the lock off while providing additional safety by closing the fuel lock off in the unlikely event of a power failure wiring failure or module failure When the liquid service v...

Page 19: ...l pressure rather than against pressure extending primary seat life and adding additional safety Liquid propane must be converted into a gaseous form in order to be used as a fuel for the engine When...

Page 20: ...the secondary valve is opened To open the secondary valve a negative pressure signal must be received from the air fuel mixer When the engine is cranking or running a negative pressure signal vacuum t...

Page 21: ...f Operation The air fuel mixer is mounted in the intake air stream between the air cleaner and the throttle The design of the main body incorporates a cylindrical bore or mixer bore fuel inlet 1 and a...

Page 22: ...ine reversion pulses commonly encountered in small displacement engines from having an effect on the piston AVV chamber a check valve is incorporated on the check valve plate control port to the AVV c...

Page 23: ...tiple limp home modes available with ETC 1 If the throttle itself is suspected of being inoperable the SECM will remove the power to the throttle motor When the power is removed the throttle blade ret...

Page 24: ...eacts to the negative pressure signal from the mixer If the pressure on the atmospheric side of the N2001 secondary diaphragm is reduced the diaphragm will close the secondary valve until a balance co...

Page 25: ...gen will be present in the exhaust few ions will attach to the outer electrode and voltage output will be relatively high In a lean situation more oxygen will be present and that translates into more...

Page 26: ...or A stall safety shutoff feature is built into the SECM to close the lock off in case of a stall condition The SECM monitors three engine states Crank when the VR sensor detects any engine revolution...

Page 27: ...cess The reduction catalyst is the first stage of the catalytic converter It uses platinum and rhodium to help reduce the NOx emissions The oxidation catalyst is the second stage of the catalytic conv...

Page 28: ...situation greatly improving idle quality and drivability A Throttle Position Sensor TPS Figure 27 which is integral to the Drive By Wire DBW throttle assembly provides feedback for position control by...

Page 29: ...s shutdown Figure 30 describes the signal flow process of the MI 04 DBW section The Acceleration Pedal assembly uses two potentiometers to detect pedal position These two signals accelerator pedal pos...

Page 30: ...tributor less ignition system The current application uses a distributor based ignition system The distributor will have no internal advance mechanisms giving the SECM consistent authority over igniti...

Page 31: ...el lock off and allow fuel to flow to the pressure regulator converter Apply additional leak check solution to the regulator converter fuel connections and housing Repeat leak inspection as listed abo...

Page 32: ...faces for damage and replace as necessary z Remove battery cable and clean repair and or replace as necessary Inspect Ignition System z Disconnect Battery Cables z Remove and inspect the spark plugs R...

Page 33: ...s 1 Fuel Filter Disassembly 5 Remove top cover 2 magnet 3 spring 4 and filter element 7 from bottom cover 5 6 Replace the filter element 7 7 Check bottom cover O ring seal 6 for damage Replace if nece...

Page 34: ...pressure regulator converter section of the service manual if maintenance is required NOTE For pressure testing and internal inspection of the pressure regulator converter refer to the pressure regul...

Page 35: ...old adapter E with no leakage z If the TMAP is found to be loose remove the TMAP retaining screw and the TMAP sensor from the manifold adapter z Visually inspect the TMAP O ring seal for damage Replac...

Page 36: ...Acceleration Pedal travel and operation X Engine Coolant Section Check Coolant Level X Inspect coolant hoses and fittings for leaks cracks swelling or deterioration X Engine Ignition Section Inspect b...

Page 37: ...ck air filter indicator X Check for air leaks in the filter system X Inspect air fuel valve mixer assembly X Inspect air fuel mixer assembly throat X Check for vacuum leaks in the intake system includ...

Page 38: ...alve closed Slowly open liquid valve Excess flow valve closed Reset excess flow valve z Close liquid valve z Wait for a click sound z Slowly open liquid valve Plugged fuel line Remove obstruction from...

Page 39: ...e z Using caution disconnect the fuel line some propane may escape z Clear obstruction with compressed air z Re connect fuel line z Slowly open liquid fuel valve z Leak test Faulty vapor connection be...

Page 40: ...onnect fuel line z Slowly open liquid fuel valve Leak test Pressure regulator freezes Check level in cooling system z Must be full check coolant strength z 35F minimum z Check coolant hoses z Watch fo...

Page 41: ...5 Advanced Diagnostics Will Not Accelerate Hesita tion During Acceleration Engine Mechanical See Engine Manufacturers Service Manual Fuel container almost empty LPG Vapor from liquid outlet z Fill fu...

Page 42: ...ests and Adjustments Vacuum leak Check for vacuum leaks z Between mixer and throttle body z Between throttle body and intake manifold z Between intake manifold and cylinder head Air Fuel Mixer malfunc...

Page 43: ...line z Close liquid fuel valve z Using caution disconnect the fuel line some propane may escape z Clear obstruction with compressed air z Re connect fuel line z Slowly open liquid fuel valve Leak tes...

Page 44: ...malfunction fuel pressure too high Test pressure regulator operation z See Chapter 9 Tests and Adjustments Faulty FTV Check FTV for housing cracks or obstructions z See Chapter 5 Advanced Diagnostics...

Page 45: ...All MI 04 fault codes are two digit codes When the fault codes are retrieved displayed the MIL will flash for each digit with a short pause 5 seconds between digits and a long pause 1 2 seconds betwe...

Page 46: ...the key to the ON position you must cycle the Acceleration Pedal by depressing it to the floor and then fully releasing the pedal pedal maneuver You must fully cycle the Acceleration Pedal ten 10 tim...

Page 47: ...he sensor traces NOTE The TPS is not a serviceable item and can only be repaired by replacing the DV EV throttle assembly ETCSticking Electronic Throttle Control is Sticking is normally set if either...

Page 48: ...ator Pedal Position 1 Sensor Range is Low the APP1 potentiometer has malfunctioned An improper APP1 reading may be due to dirt or oxidation on the sensor traces Pedal1SensorRangeHi Accelerator Pedal P...

Page 49: ...rcuit Stored Fault Code MIL Only Check if ECT sensor connector is disconnected or for an open ECT circuit SECM SIGNAL PIN 16 to ECT PIN A SECM GND PIN 1 to ECT PIN B 16 ECTRangeHigh Engine Overheating...

Page 50: ...or corrosion Perform Throttle test with the Service Tool several times to clean sensor To check the TPS disconnect the throttle connector and measure the resistance 1 25K 30 from TPS PIN 2 GND to PIN...

Page 51: ...rive by disconnecting the throttle connector and measuring the motor drive resistance at the throttle TPS PIN 1 DRIVER to PIN 4 DRIVER 3 0 30 27 PredictedTPSDifference Measured TPS1 is different than...

Page 52: ...by disconnecting the throttle connector and measuring the motor drive resistance at the throttle TPS PIN 1 DRIVER to PIN 4 DRIVER 3 0 30 33 MapSensorInputLow MAP signal disconnected open circuit or s...

Page 53: ...8 XDCR 5VDC Check the MAP sensor by disconnecting the TMAP connector and measuring at the sensor TMAP PIN 1 GND to PIN 4 PRESSURE SIGNAL KPA 2 4k 8 2k TMAP PIN 3 PWR to PIN 4 PRESSURE SIGNAL KPA 3 4k...

Page 54: ...TMAP PIN 3 to SECM PIN 18 XDCR 5VDC To check the IAT sensor of the TMAP disconnect the TMAP connector and measure the IAT resistance See the IAT table in Chapter 6 0 42 EST1Low Coil driver signal low...

Page 55: ...L PIN D Verify 12vdc on COIL PIN E To check the Smart Coil internal circuit disconnect the coil connector and measure the resistance from pin to pin See Smart Coil resistance check in Chapter 6 0 53 B...

Page 56: ...ating and damage z Measure battery power at the SECM with a multimeter SECM PIN 13 BATT to SECM PIN 14 BATT 55 XDRPSensorInputLow 5VDC Transducer power supplied by the SECM to the sensors is below 4 6...

Page 57: ...ing or other ETC faults z Verify if the lift truck was motored down a steep grade 61 Pedal1SensorInputLo APP1 signal disconnected open circuit or sensor malfunction Expected faults when APP connector...

Page 58: ...Acceleration Pedal connector z Cycle the pedal several times and check APP2 signal at SECM PIN 2 68 Pedal2SensorRangeHi APP2 potentiometer malfunction Improper APP2 reading may be due to dirt or oxid...

Page 59: ...y pressure see N2001 Regulator section Note If LP Gas fuel in LP tank is not enough this fault code can be set If LP tank is frozen this fault code can be set too It is not system trouble 73 AFRTrimVa...

Page 60: ...the FTV connector and measuring the resistance 26 2 FTV PIN A SIGNAL TO PIN B PWR Note If LP Gas fuel in LP tank is not enough this fault code can be set If LP tank is frozen this fault code can be s...

Page 61: ...G420E G424E Tier LP Engine Electrical Connections 60 CHAPTER 6 MI 04 ELECTRICAL CONNECTIONS Figure E1...

Page 62: ...ART COIL D A B FUEL LOCK OFF A B FUEL TRIM VALVE 2 3 4 TMAP SENSOR 1 B C D OXYGEN SENSOR A E R01 120 OHM XDCR GND APP2 O2 Sensor IAT MAP CAN1 Coil Drive Signal VR Sensor VR Sensor MIL FTV SECM PWR 12v...

Page 63: ...Temperature in F 1 Temperature in C 1 MINIMUM NOMINAL MAXIMUM 4 20 14 0K 15 6K 17 3K 32 0 5 4K 5 9K 6 5K 68 20 2 3K 3 0K 3 3K 104 40 1 1K 1 2K 1 3K 140 60 572 612 655 176 80 309 329 351 212 100 176 18...

Page 64: ...ANGE FTV FUEL TRIM VALVE FTV PIN A SIGNAL TO PIN B PWR 26 2 CONNECTOR POINT TO POINT EXPECTED RANGE FUEL LOCK OFF LOCK OFF PIN A PWR TO PIN B GND SIGNAL 20 25 Voltage Checks SENSOR POINT TO POINT EXPE...

Page 65: ...t remove this because it is not dirt or debris but part of the liquid propane As these deposits build up over time regulator fuel ports and valve seats can be affected reducing the performance of the...

Page 66: ...rced 15 inch maximum length C 3 8 I D Hose Coolant D 1 2 I D Hose Breather E 7 32 I D Vacuum Hose 10 inch recommended maximum length F 7 32 I D Vacuum Hose 11 5 inch recommended maximum length G 7 32...

Page 67: ...the regulator to the support bracket This will allow you easier access to the remaining hose clamps 5 Remove the two cooling lines 4 from the regulator NOTE It will be necessary to either drain the c...

Page 68: ...e secondary diaphragm 3 2 Remove the six primary diaphragm cover screws 4 and the primary cover assembly 5 3 Remove the six primary diaphragm cover screws 4 and the primary cover assembly 5 4 Remove t...

Page 69: ...ined by the primary diaphragm Figure R9 6 Remove the body gasket 10 body o ring seal 11 and the fuel inlet plate exposing the fuel inlet expansion chamber and the coolant passage NOTE For re assembly...

Page 70: ...wear tears or pinholes and deformations that may cause leaks or poor performance of the regulator converter Replace components as necessary 3 Replace the body gasket of the coolant chamber and body o...

Page 71: ...move this because it is not dirt or debris but part of the liquid propane As these deposits build up over time regulator fuel ports and valve seats can be affected reducing the performance of the regu...

Page 72: ...r identification they must be installed correctly for proper operation Remove the two vacuum lines Figure M1 2 5 Remove the vapor fuel inlet line Figure M1 3 6 Remove the electronic throttle connector...

Page 73: ...ABEL 13 LABEL 14 CAP 1 With the mixer adapter assembly removed and the Air Horn removed from the mixer remove the four adapter retaining screws from the bottom of the mixer Figure M4 2 Gently remove t...

Page 74: ...the main body Figure M8 6 Next install the air valve spring Figure M9 7 After the air valve spring install the check valve plate Figure M10 8 Place the mixer to throttle body gasket over the check va...

Page 75: ...fitting passage way If this fitting is damaged the mixer will need to be replaced N CA55 500TR Disassembled Service 1 Clean the air valve assembly with soap and warm water to remove heavy end deposit...

Page 76: ...ixer throttle assembly to a two bolt intake manifold The air horn adapter allows the intake hose from the air cleaner to be attached to the mixer air intake along with the vent line from the engine PC...

Page 77: ...motor assembly cover of the electronic throttle assembly should be facing opposite of the TMAP sensor mounting holes 6 Place the O ring Spacer over the outside throat of the throttle This spacer is n...

Page 78: ...TMAP sensor mounting bracket to the manifold adapter Apply a small amount of vacuum grease to the TMAP sensor O ring and install the sensor into the manifold adapter tighten the fasteners to specified...

Page 79: ...simple vacuum hand pump can be used to simulate the vacuum signal transmitted from the air fuel mixer when the engine is running You will need the following hardware Secondary Stage Test Hardware 1 Ha...

Page 80: ...cuum hose or vinyl tubing 5 0 60 in W C Magnehelic Gauge inches of water column Primary Stage Pressure Test 1 Remove the primary test port plug from the side of the regulator and install the NPT hose...

Page 81: ...is probably not making an adequate seal and is leaking If a leak is present you will need to disassemble the secondary cover of the regulator repair the cause of the leak re assemble the regulator and...

Page 82: ...igure T1 You should now have the gauge inline between the FTV and the mixer to throttle adapter 3 With the engine running at idle 700 RPM the AVV should be between 5 and 10 water column NOTE If the me...

Page 83: ...bed in the following steps 1 Using the timing indicator on the crankshaft pulley set the engine on 0 degrees Top Dead Center TDC of number 1 cylinder Figure G1 2 Remove the distributor rotor cap and v...

Page 84: ...linder tooth with the leading edge of the VR sensor pickup Figure G5 Keep in mind that the distributor rotates in a clockwise direction 6 Once the proper alignment is obtained lock the distributor in...

Page 85: ...tween the sensor and the gear tooth from 1 25mm to 1 5mm Re tighten the sensor retaining bolts when complete 10 Rotate the crankshaft pulley 180 degrees and align a timing gear tooth in the center of...

Page 86: ...SB port in the computer Figure G8 2 With the ignition key in the OFF position connect the Kavaser communication cable from a second USB port on the computer to the CAN communications cable on the engi...

Page 87: ...Cycle reading when the tamper proof is not installed place your thumb over the idle screw port so that no air will leak past the screw threads 11 If the FTV Duty Cycle reading is above 50 back the idl...

Page 88: ...e Tool Kit 87 CHAPTER 10 SERVICE TOOL KIT A343079 USB Universal Serial Bus to CAN Controller Area Network Converter Assembly A343080 Service Tool Software includes CD and Crypt Token License Dongle A3...

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