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G643
Doosan G643 User Manual
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G35S-5, G40S-5, G45S-5, G50C-5, G55C-5
GC35S-5, GC40S-5, GC45S-5, GC50C-5, GC55C-5
G40SC-5, G45SC-5, G50SC-5, G55SC-5
G50S-5, G60S-5, G70S-5
SB4263E0
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Table of Contents
Default Chapter
3
Important Safety Information
3
Chapter 1. General Information
9
Precautions before Service
9
Removal and Disassembly
9
Special Tool
9
Tightening Torque
12
Recommended Lubricants and Capacities
14
Engine Model and Engine Serial Number
15
General Specification
16
Chapter 2. Recommended Maintenance
19
General Maintenance
19
Inspect Electrical System
19
Engine Oil Classification
20
Checking Engine Oil Level
21
Replacing Engine Oil and Filter
21
Checking Compressed Pressure
22
Cooling System Maintenance
23
Checking Coolant Leaks
24
Relation between Coolant Concentration and Specific Gravity
24
Specific Gravity Test
24
Checking and Adjusting Drive Belt
25
Checking Belt for Damage
25
Ignition System Maintenance
26
Inspection of Spark Plug
27
Fuel System Maintenance
29
Replace LP Fuel Filter Element
29
Testing Fuel Lock-Off Operation
29
Exhaust System Maintenance
30
Inspect Throttle Assembly
30
Pressure Regulator/Converter Inspection
30
Maintenance Schedule
31
Chapter 3. ENGINE MECHANICAL SYSTEM
33
Torque Specification
35
Engine Exploded View
43
Engine Construction
47
Statement on Cleanliness and Care
47
Use of Rtv Sealer and Anaerobic Gasket Eliminator
48
Replacing Engine Gaskets
49
Thread Repair
49
Special Tools
50
Cooling System
53
General Description
53
Testing & Adjusting
54
Operation
56
Cooling System Recommendation
57
Engine Lubrication
59
Disassembly of Engine
62
Engine Flywheel Removal
63
Exhaust Manifold Removal
63
Thermostat Removal
65
Valve Rocker Arm Cover Removal
65
Intake Manifold Removal
66
Valve Train Component Removal
66
Cylinder Head Removal
67
Oil Pan Removal
68
Torsional Damper Removal
68
Engine Front Cover Removal
69
Oil Pump Removal
69
Timing Chain and Camshaft Sprocket Removal
69
Camshaft Removal
70
Piston and Connecting Rod Removal
71
Crankshaft Rear Oil Seal Removal
72
Crankshaft Removal
73
Cleaning, Inspection, and Repair
74
Cylinder Block
74
Cylinder Bore
75
Piston Disassembly
78
Piston Assembly
80
Piston Selection
80
Intake and Exhaust Manifolds
82
Camshaft Bearings
83
Balance Shaft
84
Timing Chain and Sprockets
84
Coolant Pump
85
Oil Pump
85
Valve Train Components
87
Cylinder Head
88
Valve Lifters
88
Torsional Damper
92
Crankshaft Bearings
93
Connecting Rod Bearings
95
Crankshaft End Play
95
Crankshaft Runout
95
Connecting Rod Side Clearance
96
Prior to Assembly
97
Crankshaft Rear Oil Seal Installation
98
Piston and Connecting Rod Installation
98
Balance Shaft Installation
100
Camshaft Installation
101
Engine Front Cover Installation
102
Oil Pump Installation
103
Torsional Damper Installation
103
Oil Pan Installation
104
Cylinder Head Installation
106
Valve Train Component Installation
106
Intake Manifold Installation
107
Rocker Arm Cover Installation
107
Valve Adjustment
107
Exhaust Manifold Installation
109
Flywheel Housing Installation
109
Engine Flywheel Installation
110
Engine Accessory Installation
111
Engine Setup and Testing
111
Chapter 4. ENGINE ELECTRICAL SYSTEM
112
Specifications
112
General Description
114
Ignition System
114
Ignition System Inspection
117
Disassembly and Assembly
122
Charging System
128
General Description
128
Troubleshooting
129
Troubleshooting Procedure
131
Diagnosis Procedure
137
Start Relay Tests
139
Installation
141
Chapter 5. ENGINE MANAGEMENT SYSTEM (EMS)
142
Specifications
142
Component Location
147
General Description
150
LPG Fuel System Operation
153
Electronic Throttle System
161
System Overview
170
Ignition Management
180
EMS Inspection and Repair
183
IAT (Intake Air Temperature) Sensor
186
Specification
189
Chapter 6. LPG FUEL DELIVERY SYSTEM
195
Hose Connections
196
Removal and Installation of N-2007 LP Regulator
198
Tests and Adjustments
201
AVV (Air Valve Vacuum) Testing
203
Idle Mixture Adjustment
203
Parts Description
207
Removal and Installation of N-2001 LP Regulator/Converter
213
CA100 Disassembly and Service
222
CA100 Disassembled Service
223
N2001 Regulator Disassembly Steps
226
N2001 Disassembled Service
228
Before Starting
229
Chapter 7. Basic Troubleshooting
229
Preliminary Checks
229
Visual/Physical Check
229
Customer Problem Analysis Sheet
230
Basic Inspection Procedure
231
Connector Inspection Procedure
232
Surges And/Or Stumbles
237
Engine Cranking but will Not Start / Difficult to Start
238
Detonation / Spark Knock
242
Rough, Unstable, Incorrect Idle, or Stalling
244
Cuts Out, Misses
246
Poor Fuel Economy / Excessive Fuel Consumption / LPG Exhaust Smell
247
High Idle Speed
248
Excessive Exhaust Emissions or Odors
249
Diagnostic Aids for Rich / Lean Operation
250
Chapter 8. Advanced Diagnostics
252
Fault Action Descriptions
253
Fault List Definitions
253
LPG and LPG Fuel Tanks
254
LPG Fuel Supply
254
Installing LPG Fuel Tanks
255
LPG Fuel Tank Components
255
Fuel Gauge
256
Service Valve
256
Filler Valve
257
Quick Disconnect Coupling
257
Regulatory Compliance
258
Special Conditions for Safe Use
258
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Doosan G643 Specifications
General
Brand
Doosan
Model
G643
Category
Engine
Language
English
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