* BEST * Doosan G355 2 G40S 2 G45S 2 With G643E Tier II LP Engine Lift Trucks Service Repair Workshop Manual - Download PDF

Service Manual
G430E/G643E Tier LP Engine
Lift Trucks
G20P-3, G25P-3, G30P-3, G32P-3, G33P-3
GC20P-3, GC25P-3, GC30P-3, GC32P-3
With G430E Tier LP Engine
G35S-2, G40S-2, G45S-2, G50C-2
G50S-2, G60S-2, G70S-2
with G643E Tier LP Engine

Index
WORKING WITH LPG EQUIPMENT
CHAPTER 0 LPG AND LPG FUEL TANKS
LPG Fuel Supply........................................................8
LPG Fuel Tanks..........................................................9
Installing LPG Fuel Tanks ..........................................9
LPG Fuel Tank Components ......................................9
Fuel Gauge ..............................................................10
Pressure Relief Valve...............................................10
Service Valve ...........................................................10
Quick Disconnect Coupling...................................... 11
Filler Valve................................................................ 11
CHAPTER 1 G430E & G643E ENGINE
SPECIFICATION
Indication of Engine Serial Number .........................12
Specifications (G430E) ............................................13
Specifications (G643E) ............................................14
CHAPTER 2 MI-04 LPG SYSTEM
OPERATIONAL OVERVIEW G430E &
G643E
MI-04 General Description .......................................15
MI-04 LP Fuel Filter..................................................18
MI-04 Fuel Lock-Off (Electric) ..................................18
MI-04 N-2001 Regulator/Converter..........................19
N-2001 Theory of Operation ....................................20
MI-04 N-CA55-500TR Mixer ....................................21
N-CA55-500-TR Air/Fuel Mixer Theory of
Operation .................................................................21
MI-04 (N-CA100TR Mixer) .......................................23
N-CA100TR Air/Fuel Mixer Theory of Operation......24
MI-04 Electronic Throttle ..........................................25
MI-04 Fuel Trim Valve ..............................................26
Heated Exhaust Gas Oxygen Sensor (HEGO) ........27
MI-04 SECM (General Description) .........................28
MI-04 SECM (Fuel Management) ............................28
MI-04 SECM (Load/Speed Management)................30
MI-04 Ignition management .....................................32
CHAPTER 3 MI- 4 MAINTENANCE
SCHEDULE
RECOMMENDED MAINTENANCE SCHEDULE.....33
Test Fuel System for Leaks ......................................33
Inspect Engine for Fluid Leaks .................................33
Inspect Vacuum Lines and Fittings...........................33
Inspect Electrical System .........................................33
Inspect Acceleration Pedal Operation ......................34
Check Coolant Level ................................................34
Inspect Coolant Hoses .............................................35
Inspect Battery System ............................................35
Inspect Ignition System ............................................35
Replace Spark Plugs ................................................36
Replace LP Fuel Filter Element................................36
Testing Fuel Lock-off Operation ...............................37
Pressure Regulator/Converter Testing and
Inspection .................................................................38
Fuel Trim Valve Inspection (FTV) .............................38
Inspect Air/Fuel Valve Mixer Assembly.....................38
Inspect for Intake Leaks ...........................................38
Inspect Throttle Assembly ........................................39
Checking the TMAP Sensor .....................................39
Inspect Engine for Exhaust Leaks............................39
Replace Oxygen Sensor ..........................................39
Maintenance Schedule.............................................40
CHAPTER 4 MI-04 LP BASIC
TROUBLESHOOTING
Basic Troubleshooting ..............................................42
CHAPTER 5 MI-04 LP ADVANCED
DIAGNOSTICS
Advanced Diagnostics..............................................49
Reading Diagnostic Fault Codes..............................49
Displaying Fault Codes (DFC) From SECM
Memory ....................................................................50
Clearing Fault (DFC) Codes.....................................50
Fault Action Descriptions..........................................50
Fault List Definitions .................................................51
Table a. MI-04 Diagnostic Fault Codes
(Flash Codes)...........................................................53
CHAPTER 6 MI-04 ELECTRICAL
CONNECTIONS
Resistance Checks...................................................67
Voltage Checks ........................................................68
G430E/G643E Tier LP Engine 6 Table of contents
CHAPTER 7 N2001 PRESSURE
REGULATOR/CONVERTER
Removal and Installation of N2001 LP
Regulator/Converter.................................................69
Hose Connections....................................................70
N2001 Removal Steps: ............................................72
N2001 Regulator Disassembly Steps: .....................73
N2001 Disassembled Service..................................75
CHAPTER 8 N-CA55-500TR AIR/FUEL
MIXER
Removal and Installation of the N-CA55-500TR
Mixer ........................................................................76
N-CA55-500TR Mixer Removal Steps: ....................77
N-CA55-500TR Disassembly and Service...............78
N-CA55-500TR Disassembled Service....................80
Installing the Mixer/Throttle Assembly .....................81
CHAPTER 9 N-CA100TR AIR/FUEL MIXER
Removal and Installation of the N-CA100TR Mixer .84
N-CA100TR Mixer Removal Steps: .........................85
N-CA100TR Disassembly and Service ....................86
N-CA100TR Disassembly and Service ....................86
N-CA100TR Disassembled Service.........................87
Installing the Mixer/Throttle Assembly .....................88
CHAPTER 10 TEST AND ADJUSTMENTS
N2001 Service Testing .............................................90
Primary Stage Test Hardware ..................................91
Primary Stage Pressure Test....................................92
N-CA55-500TR Service AVV (Air Valve Vacuum)
Testing......................................................................93
N-CA100TR Service AVV (Air Valve Vacuum)
Testing......................................................................93
Ignition Timing Adjustment .......................................94
Final Timing and Idle Mixture Adjustment ................95
Idle Mixture Adjustment............................................97
CHAPTER 11 SERVICE TOOL KIT
Service Tool Kit ........................................................98