Doosan D35S-5 Service Manual
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Doosan D35S-5 Service Manual

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Service Manual
439
D
E Diesel Engine
D35S-5, D40S-5, D40SC-5, D45SC-5
D45S-5, D50C-5, D55C-5, D50SC-5, D55SC-5
D60S-5, D70S-5
D80S-5, D90S-5
SB4323E00
Nov. 2008

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  • Page 1 SB4323E00 Nov. 2008 Service Manual E Diesel Engine D35S-5, D40S-5, D40SC-5, D45SC-5 D45S-5, D50C-5, D55C-5, D50SC-5, D55SC-5 D60S-5, D70S-5 D80S-5, D90S-5...
  • Page 3 If a tool, procedure, work method or operating technique not specifically recommended by DOOSAN is used, you must satisfy yourself that it is safe for you and others. You should also ensure that the product will not be damaged or made unsafe by the operation, lubrication, maintenance or repair procedures you choose.

  • Page 5: Table Of Contents

    Index 1. General Information Turbocharger ............89 Components ..........89 General ..............7 Removal ............91 General............7 Inspection............92 General Precautions for Servicing ....11 Installation .............93 Intake Manifold ...........95 Components ..........95 2. Engine Mechanical System (D439E) Removal ............96 Installation .............97 General ............... 16 Description............
  • Page 6 3. Engine Electrical System (D439E) Coolant Temperature Sensor......186 Inspection............186 General ............. 126 Installation ...........187 Specification ..........126 Service Standards........128 Camshaft Position Sensor .......188 Troubleshooting .......... 129 Inspection............188 Charging System ..........131 Crankshaft Position Sensor ......189 Description..........131 Inspection............189 Adjustment..........132 Rail Pressure Sensor........190 Alternator ............
  • Page 7 5. Service Tool Check before use..........203 Read me first ..........203 Safety Warning and Caution before Use..204 Hardware ............208 Specification ..........208 Introduction of Components ......211 Basic Usage of G-scan ........212 Power supply ..........212 Power ON/OFF ...........

  • Page 9: General

    1. General Information Unit The SI unit is used. Metric notation is also presented General in parentheses. General Note, Warning and Caution How to Read Disassembly and Reassembly Drawings NOTE : This refers to a piece of useful information to the customers. 1.
  • Page 10 Conversion Table for Foot-Pound Units Into is units Unit Unit symbol of foot-pound unit Conversion rate 1 kg = 2.2046 lbs Weight 1 g = 0.035274 oz 1 mm = 3.2808 ft. Length 1 mm = 0.03937 in 1 lit. = 0.2642 gal. (U.S.) 0.220 gal.
  • Page 11 Tightening Torque Table of Standard Parts Torque Nm (kg.cm, lb.ft) Bolt nominal diameter Pitch (mm) Head Mark 4 Head Mark 7 3~4 (30~40, 2.2~2.9) 5~6 (50~60, 3.6~4.3) 5~6 (50~60, 3.6~4.3) 9~11 (90~110, 6.5~8.0) 20~25 (200~250, 1.25 12~15 (120~150, 9~11) 14.5~18.0) 25~30 (250~300, 30~50 (300~500, 1.25...
  • Page 12 Engine Identification Number Example : 1) D : DIESEL ENGINE G : GASOLINE ENGINE C : CNG ENGINE 2) 4 : 4 CYCLE 4 CYLINDER 6 : 4 CYCLE 6 CYLINDER 8 : 4 CYCLE 8 CYLINDER 3) Engine development order 4) Engine version 5) Model year X : 1999 Y : 2000 1 : 2001 2 : 2002 3 : 2003...

  • Page 13: General Precautions For Servicing

    General Precautions for Servicing Removal of Parts Protection of the vehicle Always make sure to cover fenders, seats, and floor areas before commencing service works. CAUTION The support rod must be inserted into the hole near the edge of the hood whenever you inspect the engine compartment to prevent the hood from falling and possible resulting injury.
  • Page 14 8. Oil should be applied to the moving components of parts. 9. Specified oil or grease should be applied to the prescribed locations (oil seals, etc.) before When replacing parts, be sure to use Doosan assembly. genuine parts. D439E Service Manual...
  • Page 15 4. Check wire insulation and coating for any damage, Adjustment cracks or degrading. Use gauges and testers to adjust the parts correctly to the specification. 5. Check to see if the conductive parts of terminals contact other metallic parts (vehicle body and other parts).
  • Page 16 Servicing the Electrical System 3. If any section of a wiring harness interferes with 1. Prior to servicing the electrical system, be sure to the edge of parts, or corners, wrap the section of turn off the ignition switch and disconnect the battery ground cable.
  • Page 17 6. The electronic parts used in the computer, relays, 9. Disconnect the connectors by pressing the etc. are subject to thermal damage easily. If any catches in the arrow direction as shown in the service work is needed that may cause the illustration.

  • Page 18: General

    2. Engine Mechanical 4. For better I efficient cooling of combustion chamber, water director is press-fit under cylinder System (D439E) head floor, which induces the coolant flow. General Valve Mechanism Description Combustion 1. Heat resistant steel with surface treatment is used for intake and exhaust valve.
  • Page 19 7. Camshaft assembly (1) consists of cam sensor 3. Cylinder sleeve made of special cast iron is plate, thrust plate, cam and journal. Camshaft pressed fit into the crankcase. gear is coupled with the idler gear A (2). Piston Crankcase and Cylinder Sleeve 1.
  • Page 20 4. Crankshaft pulley and crankshaft gear are Piston Ring installed at the front end of crankshaft. The crankshaft pulley drives alternator and water pump using V-belt. 5. Crankshaft damper pulley absorbs the distorting vibration of crankshaft. Piston has two compression rings and one oil ring. All sliding surfaces of rings are coated with hardened chrome.
  • Page 21 Timing Gear Flywheel 1. Timing gear is installed in the timing gear case at 1. Flywheel is made of forged iron. Pilot bearing of the front of engine. transmission drive pinion is disposed at the center portion. Ring gear which can be geared with 2.

  • Page 22: Specification

    Specification Standard Corrective Items ([] indicates standard Limit action diameter) Serial 4-cylinder 4stroke General lyre common rail system 104mm Cylinder inner diameter 115mm Cylinder stroke 3,907cc Displacernent 17.5 : 1 Compression ratio 1-3-4-2 Firing order 100ps/2300rpm Adjustment Maximum output 92ps/2300rpm (As the 38kgf.m/1600rpm difference...
  • Page 23 Standard Corrective Items Limit ([] indicates standard action diameter) Outer side valve Spring Free height 66.1mm 63mm Load installed 26.5~29.3kg 23.7kg Winding direction To the right Out of squareness 1.5mm 2.1mm Replace Inner side valve spring Free lenqth 60.0mm 57mm Load Installed 11.5~12.7kg 10.3kg...
  • Page 24 Standard Corrective Items Limit ([] indicates standard action diameter) Cylinder sleeve lnner diameter 104.00~104.03mm 100.25mm Repair with Below oversize or Out of roundness 0.005mm 0.01mm replace Below Out of cylinderness 0.015mm 0.03mm Cylinder head Repair or Flatness of cylinder head bottom Below 0.1mm 0.2mm replace...
  • Page 25 Standard Corrective Items Limit ([] indicates standard action diameter) Timing gear backlash Crankshaft gear and idler gear A 0.062~0.159mm Idler gear A and cam shaft gear 0.068~0.175mm Idler gear A and idler gear B 0.062~0.160mm Repair or Idler gear B and supply pump gear 0.073~0.169mm replace Camshaft gear and power steering pump...

  • Page 26: Tightening Torque

    Tightening Torque Screw size Items (diameter x length) O.D x Kgf.m lb•ft pitch(mm) Main bearing cap bolt M14x2.0 49+90° 5.0+90° 36.4+90° Front plate flange bolt(8 x16) 18.6~27.4 1.9~2.8 13.8~20.4 Rear oil seal slinger flange bolt(6 7.8~11.8 0.8~1.2 5.8~8.7 X12) Supply pump side timing gear case 18.6~27.4 1.9~2.8 13.8~20.4...
  • Page 27 Screw size Items (diameter x length) Kgf.m lb•ft O.D x pitch(mm) Cylinder head mounting bolt M14X2.0 147+90° 15.0+90° 109+90° Cylinder Cylinder head stud (10 X25) 34.3 25.4 head Cylinder head stud (10 X48) 34.3 25.4 Fan clutch mounting flange bolt (8) 21.6~32.3 2.2~3.3 16~24...
  • Page 28 Screw size Items (diameter x length) Kgf.m lb•ft O.D x pitch(mm) Piston and Connecting rod and connecting rod M12.5X1.25 29.4+90° 3.0+90° 21.8+90° connecting bearing cap mounting bolt Flywheel mounting bolt M14X1.5 39.2+40° 4.0+40° 29.1+90° Flywheel and damper Crankshaft damper pulley M24X1.5 pulley mounting nut...
  • Page 29 Screw size Items (diameter x length) Kgf.m lb•ft O.D x pitch(mm) Engine speed sensor mounting 7.8~11.8 0.8~1.2 5.8~8.7 bolt Sensor Cam speed sensor mounting bolt 7.8~11.8 0.8~1.2 5.8~8.7 Booster pressure sensor (M. A. P) 7.8~11.8 0.8~1.2 5.8~8.7 mounting bolt D439E Service Manual 2.

  • Page 30: Special Tool

    Special Tool Tool (part no. and part name) Shape Usage 09212-41200 Installation and removal of Camshaft bushing remover and camshaft bushing installer 09246-41000 Installation and removal of Idler gear bushing puller connecting rod bushing 09222-83200 Installation of piston Piston guide clamp 09222-83300 Installation and removal of valve Valve spring compressor...
  • Page 31 Tool (part no. and part name) Shape Usage 09222-45100 Installation of valve stem seal Valve stem seal Installer 09353-45100 Measurement of compression Air compressor adapter pressure 0922283200 Installation and removal of piston Piston ring tool ring 09222-45000 Installation and removal of rocker Rocker bush puller bush 09211-41000...

  • Page 32: Diagnosis

    Diagnosis Symptom Possible cause Maintenance Cylinder head Gasket is melt Replace gasket (check the status of head surface, block head) Compression Piston ring is worn or damaged Piston Replace the ring pressure is or cylinder is damaged Repair or replace piston or cylinder excessively low block Valve seat worn or damaged...
  • Page 33 Symptom Possible cause Maintenance Oil cooling system Hose or pipe connection is loose Hose Retighten leaks and pipe is cracked or damaged Replace Radiator fan is Damage Repair or replace inoperative Connection is loose Retighten Exhaust gas leaks Pipe or muffler is damaged Repair or replace Baffle plate inside the muffler fell off Replace...

  • Page 34: Adjustment

    Adjustment CAUTION Compression Pressure a. Take care that fuel is not injected. b. Since compression pressure varies depending on the engine speed, be careful in measuring. c. Since worn amounts of each cylinder are different, measure the pressure at all cylinders. 8.

  • Page 35: Timing System

    Timing System Timing Gear Assembly Components Tightening Torque : Nm (kgf.m, Ib-ft) 1. Crankshaft damper pulley nut 16. Cam sensor plate 2. Crankshaft damper pulley 17. Camshaft gear 3. Front oil slinger 18. Idler gear A mounting bolt 4. Front oil seal 19.
  • Page 36 Tightening Torque : Nm (kgf.m, Ib-ft) 1. Thrust plate 2. Semicircular key 3. No.1 camshaft bush 4. No.2 camshaft bush 5. No.3 camshaft bush 6. No.4 camshaft bush 7. No.5 camshaft bush 8. Sealing cap D439E Service Manual 2. Engine Mechanical System (D439E)

  • Page 37: Removal

    Removal 3. Remove the power steering pump (1). 1. Loosen the alternator (1) tensioner screw (2) and remove the V-belt (3). 4. Align the timing mark "0" of crankshaft damper 2. Remove the water pump pulley (1) and water pulley (1) with the indicator (2) of the timing gear pump assembly (2).
  • Page 38 5. Remove the crank shaft damper pulley nut (2) 7. Remove the cam speed sensor (1) from the and remove the crankshaft damper pulley (1). timing gear case and then remove the timing gear case (2). 6. Remove the engine coolant temperature sensor NOTE : Check the front oil seal (1) state.
  • Page 39 9. Remove the oil pump gear (1). CAUTION Before removing the timing gear case, remove timing gear case mounting bolt (1) at the supply pump first. If the mounting bolt at the supply pump is not removed, timing gear case will not be removed. 10.
  • Page 40 13. Remove the camshaft assembly. 11. Remove the idler gear B (1). 1) Remove the thrust plate-mounting bolt (4) through cam sensor plate (2) hole (3) of camshaft gear (1). 12. Remove the supply pump gear (1). NOTE : Do not remove the cam sensor plate (2), if it is not damaged.

  • Page 41: Inspection

    Inspection 1. Measure inner diameter of idler gear (1) and outer 14. Remove the front plate (1). diameter of idler shaft (2). If the gap exceeds the limit, replace the idler gear bush. Reference gap between idler bush and idler shaft ([]indicates reference diameter) : [45] 0.025 ~ 0.06 mm Limit : 0.1 mm.
  • Page 42 Unit : mm 3. Measure the outer diameter of camshaft journal Min cam Max cam Items and the inner diameter of camshaft bush in the diameter (2) diameter (1) lift crankcase. If the gap exceeds the limit, repair the Intake camshaft bushing with oversize.
  • Page 43 6. Measure the backlash of each gear and replace it if necessary. 4. Measure the distortion of camshaft. If it exceeds the limit, replace or repair it with press. NOTE : When measuring the backlash, fix the gear contacting the corresponding gear and move the gear to the left and right to measure the backlash.

  • Page 44: Replacement

    e. Oil pump gear (1) and crankshaft gear (2) c. Idler gear A (1) and idler gear B (2) Reference : 0.049 ~ 0.169 mm Reference : 0.062 ~ 0.160 mm Replacement d. Idler gear B (1) and supply pump gear (2) 1.

  • Page 45: Installation

    2. Replacement of camshaft bush a. Remove the sealing cap from the crankcase camshaft hole. d. Press fit the bush using the special tool b. Remove the camshaft bush using the special (0921241200) so that the camshaft bush end tool (09212-41200). aligns crankcase end.
  • Page 46 4. Install idler A and B. 2. Install the crankshaft gear (1). 3. Install the idler shaft A (1) and idler shaft B (2). CAUTION CAUTION a. When installing, align the timing mark “1” of a. When installing the idler shaft A and B, do not idler gear A (1) with the timing mark “1”...
  • Page 47 5. Install the camshaft gear assembly. c. Measure the endplay between camshaft gear (1) and thrust plate (2) and install them as the a. Install the thrust plate (1) so that the “F” mark of clearance to be within the reference. its oil hole faces to the camshaft gear (2).
  • Page 48 CAUTION 6. Install the supply pump gear. When installing, align the timing mark “2” of camshaft gear A (1) with the timing mark “2” of CAUTION idler gear A (2). When installing, align the timing mark “5” of supply pump (1) with the timing mark “5” of idler gear B (2).
  • Page 49 8. Install the front oil seal slinger (1). 10. Install the power steering pump (1). 9. Install the front timing gear case (1). 11. Install the water pump pulley (1) and water pump assembly (2). Tightening torque : 21.6 ~ 32.3 Nm (2.2 ~ 3.3 kgf.m, 16 ~ 24 Ib-ft) CAUTION a.
  • Page 50 12. Install the crankshaft damper pulley (1) and damper pulley mounting nut (2). 14. Install the V-belt (1). Adjust the belt tension using the tension adjusting screw (2) of Tightening torque : 588 Nm alternator. (60 kgf.m, 436 Ib-ft) 13. Install the alternator assembly (2). D439E Service Manual 2.

  • Page 51: Cylinder Head Assembly

    Cylinder head Assembly Components 3. Cylinder head cover 4. Cylinder head cover gasket 5. Rocker and bracket assembly 6. Cylinder head bolt 7. Cylinder head assembly 8. Cylinder head gasket 9. Crank case 10. Push rod 11. Oil filler cap D439E Service Manual 2.
  • Page 52 1. Valve cap 2. Valve cotter 3. Valve retainer 4. Outer side spring 5. Inner side spring 6. Valve stem seal 7. Push rod 8. Cylinder head 9. Water director 10. Intake valve 11. Exhaust valve 12. Cylinder head gasket 13.

  • Page 53: Removal

    Removal 4. Loosen the hexa-bolt (2) of injector nozzle bridge 1.2. Remove the glow plug and glow plug plate (1). (1) and remove the injector (3). 3. Remove the injection pipe (1) No 1, 2, 3 and 4 running from the common rail assembly to the injector.
  • Page 54 9. Remove the turbocharger heater protector cover (1) and exhaust manifold heater protector cover 6. Remove the oil level gauge (1). (2). 7. Remove the intake manifold assembly (1). 10. Remover the turbocharger assembly (1) from the cylinder head. NOTE : Do not remove the actuator (2) of the intake manifold if its operation is normal.
  • Page 55 NOTE a. Since push rod is pressing the rocker, loosen the rocker adjusting screws (1) toremove the cylinder head bolts (2). b. When removing the cylinder head bolts, remove them according to the sequence as shown in the following figure. 12.

  • Page 56: Disassembly

    Disassembly Rocker and Rocker Shaft bracket Assembly 16. Remove the cylinder head gasket (1). 1. Remove the set bolt from the front rocker shaft CAUTION bracket. When removing the cylinder head gasket, be 2. Remove the front and rear rocker shaft bracket. careful not to damage the cylinder head and crankcase.

  • Page 57: Inspection

    2. Remove the retainer (1), valve spring (2), valve 4. Remove the cylinder gasket (1). stem seal (3) and intake and exhaust valve from the cylinder head. CAUTION CAUTION When removing the cylinder head gasket, check the cylinder head and crankcase for any damage. Valve stem seal should be replaced with new one.
  • Page 58 3. Check the valve tappet (1) for any damage or 5. Inspect the out of squareness (A), free length (B), wear. load installed (C) of valve spring, replace it if any of them exceeds the limit. Items Standard Limit Free length 66.1 mm 63 mm Outer...
  • Page 59 7. Measure the run-out of push rod (1). Replace it if it exceeds the limit. Limit of pushrod run-out : 0.4 mm 6. Measure the outer diameter of tappet (1) and inner diameter of crankcase tappet hole (2). Replace the tappet if the gap exceeds the limit. Reference : 0.045 ~ 0.096 mm Limit : 0.2 mm 8.
  • Page 60 9. Measure the outer diameter of valve stem. If the 10. Measure the inner diameter of valve guide and measurement is below the limit, replace the valve outer diameter of valve stem. If the clearance stem. exceeds the limit, replace the valve guide. Outer diameter of valve stem Clearance between valve stem and valve guide - Intake valve...

  • Page 61: Replacement

    11. Check the contacting state of valve seat and Replacement valve. Replacement of Rocker Bush a. Apply light blue coating on the valve surface. b. Check the valve contacting state by pressing the valve to the valve seat. 1. Remove the bush from rocker using the special CAUTION tool (09222-45000).
  • Page 62 Valve Seat Repair 3. Install the valve seat using the caulking tool body 1. Repair the valve face using valve refacer (1). (1) and locking ring (2). CAUTION CAUTION Valve seat angle is 45°. Press the valve seat (3) with the chamfered side of the locking ring.

  • Page 63: Reassembly

    Reassembly Rocker and rocker shaft assembly 5. Apply the compound evenly over the valve seat surface (1). CAUTION 1. Install rocker shaft bracket No. 1, 2, 3 and 4 to the rocker shaft. a. Valve stem (2) should be free from any compound.
  • Page 64 Valve and cylinder head Assembly 1. Install the water director to the cylinder head. 3. Apply the engine oil on the valve stem seal lip and install the valve stem seal using the special tool (09222-45100). NOTE : Tap the seal until the special tool (09222- 45100) contacts the cylinder head.

  • Page 65: Installation

    4. Install the retainer, valve spring and valve cotter CAUTION using the special tool (09222-83300). When installing the cylinder head gasket (1), cylinder head installing surface should be free from any impurities or foreign materials such as Installation oil. a. Assemble the cylinder head so that “UP” mark of the cylinder head gasket faces to the cylinder head.
  • Page 66 NOTE : If the max protrusion of the piston is 0.05 2) At the TDC of compression stroke of cylinder mm more than average protrusion, then use the No. 1, check and adjust the clearance of the valve with “O” mark at the following table. And grade up (A→B) gasket.

  • Page 67: Crankcase

    Crankcase Flywheel Components Tightening Torque : Nm(kgf.m, Ib-ft) 1. Front plate 2. Gasket 3. Crankcase 4. Rear plate 5. Rear oil seal 6. Pilot bearing 7. Flywheel 8. Flywheel mounting bolt D439E Service Manual 2. Engine Mechanical System (D439E)

  • Page 68: Removal

    Removal 4. Remove the rear oil seal slinger (1). 1. Remove the flywheel mounting bolt (1), and then remove the flywheel (2). Inspection 2. Remove the rear plate mounting bolt (1), and then remove the rear plate (2). 1. Distorsion check of frictional surface a.

  • Page 69: Installation

    Installation 2. Replacement of flywheel ring gear a. When removing the ring gear (1), hear the ring gear evenly using acetylene torch or equivalent tools and then remove the ring gear by tapping the circumference with rod or hammer. b. When installing, heat the ring gear with piston heater for 3 minutes (about 100℃).
  • Page 70 3. Install the rear plate (1). Tightening torque : 63.7 Nm (6.5 kgf.m, 47.3 Ib-ft) 2. Apply the sealant (Loctite #5699) to the rear oil seal (1), and then install the rear oil seal. Tightening torque : 7.8 ~ 11.8 Nm (0.8 ~ 1.2 kgf.m, 5.8 ~ 8.7 Ib-ft) 4.

  • Page 71: Cylinder Block Assembly

    Cylinder Block Assembly Components Tightening Torque : Nm (kgf.m, Ib-ft) 1. Compression ring No.1 2. Compression ring No.2 3. Oil ring No.3 4. Snap ring 5. Piston 6. Piston pin 7. Connecting rod 8. Connecting rod upper bearing 9. Crankcase 10.
  • Page 72 Tightening Torque : Nm (kgf.m, Ib-ft) 1. Oil jet 2. Oil jet mounting bolt 3. Upper main bearing 4. Thrust plate 5. Rear oil seal singer 6. Lower main bearing 7. Main bearing cap 8. Crankshaft assembly 9. Semicircular key 10.

  • Page 73: Removal

    Removal 1. Remove the engine and transaxle. 7. Align the timing mark (2 ~ 3 side) of crankshaft damper pulley to the compression TDC of cylinder 2. Remove the flywheel and rear plate. No.1. 3. Remove the intake and exhaust manifold. NOTE : As for the removal of cooling fan pulley, crankshaft damper pulley and timing gear case, 4.
  • Page 74 9. Remove timing gear train [(oil pump gear (6), 12. Remove the oil pan (1). camshaft assembly (2), idler gear A (3), idler supply pump gear (5)), and then remove front plate. 13. Remove the oil strainer (1). 10. Remove the power steering pump (1). 11.
  • Page 75 15. Remove the connecting rod bearing cap (1). NOTE : Make marks at the connecting rod and cap to be reassembled correctly. 14. Remove rear oil seal (1) and oil seal slinger (2). 16. Remove the piston and connecting rod assembly (1) from cylinder block.

  • Page 76: Disassembly

    17. Remove the front, rear and main bearing caps. 19. Remove the oil jet (1) from the cylinder block. a. Remove the front bearing cap and rear end bearing cap. Remove the thrust plate (2) from the rear-bearing cap (1). Disassembly b.

  • Page 77: Inspection

    Inspection Cylinder Block 2. Remove the piston pin snap ring (2) using the snap ring pliers (1). NOTE a. Before repairing, clean each part to remove dust, oil, carbon and fur. b. Before cleaning the cylinder block, check water leakage or damages. c.
  • Page 78 3. Check the cylinder wall to see if it is cracked or damaged. If it is abnormal, repair (oversize) or replace the cylinder sleeve. 4. Measure the cylinder sleeve ID using the cylinder gauge. If it is excessively worn, repair it with oversize and replace the piston and piston ring.
  • Page 79 Piston Ring 3. Measure the clearance between piston pin and piston hole by measuring the inner diameter of 1. Check the piston ring for any damage, unusual piston pin (1) and piston boss. wear or breakage. If damaged, replace the ring. 2.
  • Page 80 Crankshaft 1. Measure the endplay of crankshaft. Crankshaft endplay Reference : 0.10 ~ 0.26 mm Limit : 0.4 mm a. If the endplay exceeds the limit, replace the 4. After installing the piston ring to the cylinder bore, thrust plate with the oversize. push the piston ring to the vertical direction with the piston.
  • Page 81 3) Install the main bearing cap and fasten the 3. Measure roundness and cylindricity of crankshaft bolt. journal and pin. If the measurement exceeds the limit, repair it with under size. Tightening torque : 49.0 Nm + 90° (5.0 kgf.m + 90°, 36.4 Ib-ft + 90°) Roundness of crankshaft Reference : less than 0.01 mm Limit : 0.03 mm...
  • Page 82 Connecting Rod Bearing d. Remove the connecting rod bearing cap and measure the oil gap at each pin journal. 1. Before removing the connecting rod cap, measure the connecting rod endplay. If the gap exceeds the reference, replace the connecting rod. Connecting rod oil gap Reference : 0.040 ~ 0.099 mm Limit : 0.2 mm...

  • Page 83: Reassembly

    Reassembly Riston and connecting Rod Assembly 2. Apply engine oil at the piston rod end and piston 1. Install the piston ring using the special tool pin hole, and then install the piston pin (1). (09222-83200). 3. Install the piston pin snap ring (2) using snap ring pliers (1).

  • Page 84: Installation

    Installation 3. Install the crankshaft (1) to the cylinder block. 1. Install oil jet (1) to the cylinder block. CAUTION Handle crankshaft care fully not to be damaged. 2. Install thrust plate (1) and upper main bearing (2) to the crankcase. CAUTION 4.
  • Page 85 c. Install the main bearing cap with the specified CAUTION torque. When installing connecting rod cap, align mark (1) on connecting rod big end cap with mark (2) Tightening torque : 49.0 Nm + 90° on connecting rod cap. (5.0kgf.m + 90°, 36.4 Ib-ft + 90°) 5.
  • Page 86 e. Tighten the connecting rod cap with specified 7. Apply the sealant (Loctite #5699) to the rear oil torque. seal, and then install the rear oil seal (1). Tightening torque : 29.4 Nm + 90° (3.0 kgf.m + 90°, 21.8 Ib-ft + 90°) 8.
  • Page 87 10. After installing the cylinder block assembly, measure the piston protrusion, Install the right cylinder head gasket. NOTE : As for the cylinder head gasket selection and assembly, refer to the cylinder head assembly procedure. 11. Install the timing system. 12.

  • Page 88: Intake And Exhaust System

    Intake and Exhaust System Specifications Items Specifications Air cleaner type Dry type Element type Paper type Type Turbocharger (TD04HL-11T-6) Length 168 mm Width 154 mm Turbocharger Height 165 mm Max rpm allowed 170,000 rpm Maximum exhaust gas temperature 760℃ Tightening Torque Screw size Items (diameter x Length) O,D x pitch...

  • Page 89: Troubleshooting

    Troubleshooting Output drop Intake system Is air cleaner clogged? Replace the element Does air leak at the connection of intake Repair system? Exhaust system • Is muffler or exhaust pipe deformed? Repair or replace • Is carbon accumulated? Does gas leak at exhaust system? Repair Is exhaust brake opened? Repair or replace...
  • Page 90 Unusual noise and vibration Are fixing bolts and nuts of intake system Intake system Tighten fastened securely? Are fixing bolts and nuts of exhaust Exhaust system Repair or replace system fastened securely Is exhaust pipe or muffler damaged? Repair or replace Turbocharger Are bearing and rotating parts Inspect the following.

  • Page 91: Turbocharger

    Turbocharger Components Tightening Torque : Nm (kgf.m, Ib-ft) 1. Cylinder head assembly 2. Exhaust manifold assembly 2. Plain washer 4. Distance piece 5. Exhaust manifold self lock flange nut (M10 x 1.25) 6. Oil pipe 7. Turbocharger oil pipe eye bolt (M8 x 1.25) 8.
  • Page 92 Tightening Torque : Nm (kgf.m, Ib-ft) 2. Compressor cover 3. O-ring 4. Cartridge assembly 5. Snap ring 6. Coupling 7. Turbine housing D439E Service Manual 2. Engine Mechanical System (D439E)

  • Page 93: Removal

    Removal 3. Make an aligning mark on the coupling (1), 1. Remove the turbocharger heater protector cover turbine housing (2), compressor cover (3), and (1). cartridge assembly (4). 4. Remove the turbine housing (1). 2. Remove the turbocharger assembly (1). CAUTION a.

  • Page 94: Inspection

    2. Check the shaft directional clearance of shaft and turbine wheel assembly. 5. Remove the compressor cover (1). a. Check the clearance of shaft and turbine wheel CAUTION assembly. Lightly compressor cover circumference with rubber hammer so that compressor cover is not damaged. b.

  • Page 95: Installation

    Installation 3. After assembling the turbocharger assembly (1), turn each wheel (2) to see if it rotates smoothly. 1. When assembling the snap ring (1) to compressor cover (2), assemble it so that the snap ring taper side (3) faces up. CAUTION When installing the snap ring, install it to the compressor cover by holding the snap with one...
  • Page 96 3. Install the turbocharger heater protector cover (1). Tightening torque : 11.8 Nm (1.2 kgf.m, 8.7 Ib-ft) D439E Service Manual 2. Engine Mechanical System (D439E)

  • Page 97: Intake Manifold

    Intake Manifold Components Tightening Torque : Nm (kgf.m, Ib-ft) 1. Intake manifold gasket 2. Intake manifold assembly 3. Actuator 4. Intake manifold front hanger D439E Service Manual 2. Engine Mechanical System (D439E)

  • Page 98: Removal

    Removal 1. Remove the injection pipe (1) No. 1,2,3 and 4 from common rail assembly to the injector. 2. Remove the intake manifold assembly (1). D439E Service Manual 2. Engine Mechanical System (D439E)

  • Page 99: Installation

    Installation 1. Install the intake manifold (1). Tightening torque : 18.6 ~ 27.4 Nm (1.9 ~ 2.8 kgf.m, 13.8 ~ 20.4 Ib-ft) 2. Install the injection pipe (1) No. 1, 2, 3 and 4. Tightening torque : 39.2 ~ 49 Nm (4.0 ~ 5.0 kgf.m, 29.1 ~ 36.4 Ib-ft) D439E Service Manual 2.

  • Page 100: Exhaust Manifold

    Exhaust Manifold Components Tightening Torque : Nm (kgf.m, lb-ft) 1. Cylinder head assembly 2. Exhaust manifold gasket 3. Exhaust manifold assembly 4. Plain washer 5. Distance piece 6. Exhaust manifold self lock flange nut (M10 x 1.25) D439E Service Manual 2.

  • Page 101: Removal

    Removal 3. Remove the exhaust manifold assembly (1). 1. Remove the turbocharger assembly. 2. Remove the exhaust manifold heater protector cover (1). D439E Service Manual 2. Engine Mechanical System (D439E)

  • Page 102: Installation

    Installation 1. Install the exhaust manifold assembly (1). Tightening torque : 41.2 Nm 3. Install the turbocharger assembly. (4.2 kgf.m, 30.5 Lb-ft) Tightening torque : 41.2 Nm (4.2 kgf.m, 30.5 lb-ft) 2. Install the exhaust manifold heater protector cover (1). Tightening torque : 11.8 Nm (1.2 kgf.m, 8.7 lb-ft) D439E Service Manual...

  • Page 103: Lubrication System

    Lubrication System Description Flow Chart of Lubrication System Engine is lubricated by a gear-type oil pump that forces engine oil through the oil cooler and oil filter into the engine for lubrication of various engine parts. Oil Pump The oil pump, of a gear type, is driven by the crankshaft rotation engaged with oil pump gear.
  • Page 104 Oil Cooler Regulator Valve Oil cooler is equipment for heat exchange between When oil pressure in main oil gallery exceeds the the coolant and oil fed from the crankcase water specification, regulator valve (1) opens and some jacket and oil pump, respectively. The oil cooler has engine oil drains to the oil pan to adjust the oil a bypass valve that opens when the element (1) pressure.
  • Page 105 Oil Filter Lubrication of Parts The engine oil routed from the oil filter to oil main gallery lubricates all engine parts as detailed below before returning to the oil pan. 1. Main bearing and connecting rod bearing a. There is an oil passage (1) provided from the oil 1.
  • Page 106 2. Camshaft Camshaft bushings are lubricated by the oil flowing through the oil passages leading from the oil main gallery to each bushing. 3. Valve mechanism The engine oil that has lubricated No. 1 camshaft bushing passes through the oil hole and pipe provided at the top portion of crankcase to the cylinder head.

  • Page 107: Specification

    Specification Oil Cooler Item Specification Bypass valve open 3.5~4.5kg/cm (361~419kpa) Regulator oil pump valve open 5~7kg/cm (490~686kpa) Oil Pump Item Specification Module Pressure angle 20° Head gear No. of gear teeth Distortion angle 19.5° Backlash (mm) 0.049~0.151 Pump rotation (rpm) 550~3100 Oil Temperature (℃) -25~130...
  • Page 108 Service Standard Nominal value([] Corrective Item indicates base Limit action and diameter) remarks Oil pressure At idle 1~5 kg/cm 0.5 kg/cm Adjust (oil temperature At max speed 3~5 kg/cm 2 kg/cm Adjust 70~90℃) Oil pump case and gear teeth 0.10~0.9 Replace end clearance Difference between oil pump...

  • Page 109: Troubleshooting

    Troubleshooting Is oil pressure decreasing? Check for oil leaks or mixture with coolant. Is oil level proper? Repair the damaged parts and replenish it with oil to the proper level. Replace the oil with the proper viscosity. Is the oil viscosity normal? Check fuel supply.
  • Page 110 Excessive oil consumption Check the following items for a leakage • Oil filter • Oil cooler Repair the leaking parts. • Oil pan • Oil pipe • Oil cover Is oil leaking from the oil seals of front Repair or replace the faulty parts. and rear crankshaft? Repair the damage of oil cooler and Is any damage in cooling system?

  • Page 111: Adjustment

    Adjustment Engine oil Change Engine Oil Inspection 1. Park the vehicle on the flat surface. 2. Stop the engine. NOTE a. Warm up the engine for minutes if the vehicle has not been inspected. b. Stop the engine and wait for 5 minutes at least to measure the oil level.
  • Page 112 4. Fill in the new engine oil into the oil filler. Oil Pressure check NOTE : Overfilling may cause oil saturation or pressure drop. Oil capacity Oil pan : 8ℓ Total capacity : 9ℓ 5. Close oil filler cap. 6. Start the engine. 7.

  • Page 113: Oil Pump

    Oil Pump Components Tightening Torque : Nm (kgf.m, lb-ft) 1. Crankcase 2. Oil strainer 3. O-ring 4. Oil pan drain plug 5. Oil pan 6. Stiffener D439E Service Manual 2. Engine Mechanical System (D439E)
  • Page 114 Tightening Torque : Nm (kgf.m, lb-ft) 1. Oil pump assembly 2. O-ring 3. Crankshaft gear 4. O-ring 5. Oil pump case assembly 6. Snap ring 7. Relief valve 8. Spring 9. Seat 10. Oil pump cover 11. O-ring 12. Drive gear 13.

  • Page 115: Disassembly

    Disassembly 3. Measure the clearance between driven gear and driven shaft. If the clearance exceeds the limit, replace the parts. Clearance between driven gear and driven shaft Standard : 0.04~0.07 mm Limit : 0.15 mm 1. If the clearance between the end of the drive (1) and driven gear (2) and oil pump case exceeds the limit, replace those parts.

  • Page 116: Oil Cooler

    Oil Cooler Components Tightening Torque : Nm (kgf.m, lb-ft) 1. Oil cooler element 2. Oil cooler body assembly 3. Plug 4. Spring 5. Bypass valve 6. Plug 7. Spring 8. Regulator valve 9. Out packing 10. Seaming cap assembly 11. Bypass element assembly 12.

  • Page 117: Disassembly

    Disassembly Inspection 1. Remove the exhaust manifold. 1. Cover oil cooler element (1) and connect hose to the engine oil filler. And immerse it into the water tank. 2. Apply air pressure of 3 kg/cm to hose side and check the oil cooler element. 3.

  • Page 118: Reassembly

    b. Check the continuity between oil pressure switch terminal (2) and body (3) using a tester (1). If there is no continuity, replace the switch. c. lnsert the slim rod (1) Into oil hole of all pressure switch and check the continuity. If there is continuity, replace the parts because it is faulty.

  • Page 119: Cooling System

    Cooling System Thermostat Description Cooling System A : form cylinder head B : to radiator C : to water pump 1. The thermostat. of a bottom bypass configuration has a valve controlled by a special wax enclosed In a pellet 2.

  • Page 120: Specification

    Specification Item Specification Cooling method Water cooling, forced circulation Coolant capacity 20ℓ (includes engine, radiator and heater) Type Volute pump Water pump Drive V-belt V-belt Quantity Type Wax-pellet, bottom bypass (installed with jiggle valve) Thermostat Valve opening temperature 82℃ Service Standards Nominal value Correction Item...
  • Page 121 Tightening torque Screw size Description (diameter x length) kgf.m Ib-ft ODxPitch (mm) Thermostat cover case flange bolt M8x1.25 21.6~32.3 2.2~3.3 16~24 Coolant temperature sensor and gauge PT 3/8 29.4~39.2 3.0~4.0 21.8~29.1 Thermostat case flange bolt(10x25) M10x1.5 35.3~52.9 3.6~5.4 26.2~39.3 Alternator adjusting plate mounting...

  • Page 122: Trouble Shooting

    Trouble Shooting Overheat Adjust the tension of the belt and after Is the tension of V-belt normal? checking the belt, replace it if necessary. Add the coolant, and if there is a leak, Is coolant level proper? check the cooling system. Clean the radiator core and adjust the Is there any clogged radiator fan? deformation of core if necessary.
  • Page 123 There is heavy loss of coolant. Is the radiator hose leaking? Does the hose clamp tighten Tighten the clamp. properly? Replace the hose. Cracked or damaged hose? Repair or replace the Is the radiator core leaking? radiator. Replace the O-ring Is the water pump leaking? Is the radiator pressure pump leaking? •...

  • Page 124: Water Pump

    Water pump Components Tightening Torque : Nm(kgf.m, lb-ft) 4. Water pump pulley 5. V-belt 6. Water pump assembly 7. O-ring 8. Crankshaft damper pulley 9. Thermostat housing D439E Service Manual 2. Engine Mechanical System (D439E)

  • Page 125: Removal

    Removal 4. Remove water pump pulley (1) and water pump 1. Remove the coolant drain plug and drain the assembly (2). coolant. 2. Loosen the alternator (1) tension adjusting screw (2) and remove V-belt (3). 5. Disassemble the coolant temperature sensor connector and remove the thermostat housing (1) from the cylinder head.

  • Page 126: Inspection

    Inspection V-Belt Tension Check Water Pump 1. Inspect the crack, damage, and wear of the parts, and replace the water pump if necessary. 2. Inspect the bearing to see any damage, unusual noise, and poor revolution and replace it, if necessary.

  • Page 127: Installation

    Installation 1. Install thermostat housing (1) to the cylinder head. 3. Install the \/-belt (1) and adjust the tension using the alternator mounting nuts and adjusting bolts(2). V-belt tension : 12~16mm deflection (with a force of 10kg) 2. Install the water pump (1) and water pump pulley (2) to the timing gear case.

  • Page 128: General

    3. Engine Electrical System (D439E) General Specification Starting System Item Specification Type Pro-engaged drive (Assistance drive) Rated output 24V-5.0 KW No. of pinion teeth Rotation direction Clockwise from pinion side No of ring gear teeth Input angle of pinion 20° Center distance between ring gear and pinion 187.2 mm Terminal voltage...
  • Page 129 NOTE • Cold Cranking Ampere : It refers to the current that the battery can supply for 30 seconds with maintaining the 7.2 V terminal voltage at a specific temperature. • Reserve Capacity : It refers to the total time duration in which the battery can supply 25A current at a temperature of 26.7°C with maintaining the min.

  • Page 130: Service Standards

    Service Standards Corrective Item Nominal value (Base diameter in [ ]) Limit action Commutator OD 32 mm 31 mm Replace Commutator run Correct or Above 0.5 mm replace Starter Motor Brush length 7.5 mm Replace Brush spring 2.0~3.8 kgf Replace pressure Adjust with Pinion gap...

  • Page 131: Troubleshooting

    Troubleshooting Alternator Troubles Possible causes Corrective action Fuse is broken. Replace the fuse Charge warning lamp is Bulb is broken. Replace the bulb not turned on when ignition switch is ON Loose wiring connection Retighten the loose connection state. Check and replace wiring or Wrong connection of L-S terminals replace the voltage regulator.
  • Page 132 Starter Troubles Possible causes Corrective action Battery voltage is low Charge or replace the battery Battery cable is loose corroded or worn Repair or replace the cable Engine does not crank Fusible link is short Replace the fusible link Starter is defective Replace the starter Ignition switch is defective Replace the Ignition switch...

  • Page 133: Charging System

    Charging System Description Stator Alternator Stator core forms the magnetic flux path together Alternator is of a built-In type with an IC regulator. A brush holder is installed in the rear bracket. with rotor core. The magnetic flux in the stator core is affected by the passage of the rotor core field so When IC regulator falls, regulator assembly should that electricity is generated as each rotor core...

  • Page 134: Adjustment

    Adjustment 2. Test 1) Start the engine. Voltage Drop Test of Alternator Output Wire 2) With turning ON/OFF the headlight adjust the This is a test to check the wiring between" B" engine speed as the ammeter indicator points terminal of alternator and (+) terminal of battery. 20A.
  • Page 135 2. Test Output Current Test This test is to check whether the alternator output 1) Check to see If the voltmeter Indicates the current coincides with the rated current. same voltage value with battery voltage. If voltmeter Indicates OV It means wiring 1.
  • Page 136 3) Disconnect the battery ground cable. 7) Install engine tachometer. Connect battery ground cable. 4) Remove ammeter, voltmeter and tachometer. 2. Test 5) Connect alternator output wire to "B" terminal of the alternator. 1) Turn the Ignition switch "ON” and check to see whether voltmeter indicates the reference value.
  • Page 137 3) After the test, adjust the engine speed to idle rpm, and turn the Ignition switch "OFF”. 4) Disconnect the battery ground cable. 5) Remove ammeter, voltmeter and engine tachometer. 6) Connect alternator output wire to "B" terminal of alternator. 7) Connect the battery ground cable.

  • Page 138: Alternator

    Alternator Components Tightening Torque : Nm(kgf.m, lb-ft) 1. Rear cover 2. Commutator assembly 3. Rear bracket mounting bolt 4. Rear bracket 5. Stator 6. Rotor 7. Front bracket 8. Alternator pulley 9. Alternator pulley nut D439E Service Manual 3. Engine Electrical System (D439E)

  • Page 139: Disassembly

    Disassembly 3. Remove the commutator mounting screws using 1. Remove rear cover (2) using a drive (1) a drive (1) so as to disassemble the commutator (2). 2. Remove the end portions of the 4 stator coils soldered to the commutator main diodes using a 4.
  • Page 140 5. Remove the pulley (1) using air tool and CAUTION disassemble the rotor (2) and the front bracket (3). Be careful not to damage the parts when removing rear bracket. CAUTION Be careful not to be injured from the rotor rotation when removing the pulley.

  • Page 141: Inspection

    Inspection Rotor Inspection Brush Inspection 1. Check for continuity between slip rings (1). 1. Replace the brush If It is worn exceeding to the Replace tile rotor If there is no continuity. limit (A). 2. Check for the continuity between slip ring (1) and 2.

  • Page 142: Reassembly

    Reassembly Assembly is performed In the reverse order of disassembly. NOTE : When assembling commutator, fix the brush with wire. Assemble the commutator after fixing the brush with wires through small hole of the commutator. Then, remove the wire before assembling the rear cover.

  • Page 143: Starting System

    Starting System a. Check solenoid plunger and switch for any troubles. Description b. Check pinion gear or overrunning clutch for any damage. 3. Check the connection state of each battery, terminals, the connection state between battery (-) cable and the body, the engine ground cable, the connection state of the starter "B"...

  • Page 144: Inspection

    Inspection Pull-in Coil Test in The Magnetic Switch Pinion GAP Pull-in coil is normal if the plunger is inserted and then the pinion pops out when the battery is connected between “S" and "M" terminals of magnetic switch. If it does not pop out, replace the magnetic switch.
  • Page 145 Unloading Test CAUTION Do not try continually the connection longer than 10 seconds. Magnetic Switch Return Test 1. Connect starter motor (A), battery (B), ammeter(C), voltmeter (D) and rheostat (E) as shown in the following figure. 2. Turn the switch ON with setting the rheostat at max.

  • Page 146: Preheating System

    Preheating System Glow Plug Inspection Preheating Plug Inspection Pre-Heating System Operating Inspection 1. Conditions before inspection : battery voltage is 24 V coolant temperature is below 30°C ( or perform the test as the coolant temperature sensor is disconnected) 2. Connect the voltmeter between glow plug plate and plug body (earth) 3.

  • Page 147: General

    4. Fuel System General Specification Items Specification Supply voltage Operating 4.5~5.5V voltage BPS (Booster Operating -40~125℃ Pressure sensor) temperature Operating 32.5~284kpa (244~2130mmHg) pressure Current MAX, 10mA Type Thermistor type IAT (Intake Air Temperature) 2.31~2.56kΩ [at 20℃(68℉)] Resistance sensor 0.30~0.34kΩ [at 80℃(176℉)] Sensors Type Thermistor type...

  • Page 148: Sealant

    Sealant Engine Coolant Temperature Sensor Three Bond 2310 or equivalent Tightening Torque Items Kgf.m Ib.ft Commeom rail installation 21.6~32.4 2.2~2.3 15.9~23.9 Engine Coolant Temperature sensor 29.4~39.2 3.0~4.0 21.6~28.9 Pipe (rall-injector 1/2/3/4) 39.2~49 4.0~5.0 29~36.2 Injector clamping bolt 30.4~34.3 3.1~3.5 22.4~25.3 Supply pump fixing bolt 18.6~27.5 1.9~2.8...
  • Page 149 Troubles Possible causes Corrective actions Loose fuel hose connection between Tighten or repair. filter and supply pump Air in the fuel system Air bleeding of fuel system Fuel filter is clogged. Or fuel supply is Check hose or fuel line. Replace fuel no good because fuel line or injection filter.

  • Page 150: Engine Control

    Troubles Possible causes Corrective actions Air cleaner filter is polluted Clean, replace air cleaner element. Check, replace or tighten every Fuel leaks connection of hose and pipe. Check and replace the return line, Excessive fuel Return pipe and hose are clogged blow air if clogged and drain the fuel.

  • Page 151: Fuel Tank And Fuel Line

    Fuel Tank and Fuel Line Troubles Possible causes Corrective actions Fuel pipe is twisted or broken Repair or replace. Fuel pipe or hose is clogged Clean or replace. Fuel filter is clogged Replace. Poor engine performance due to Replace fuel filter or clean fuel Water intrudes into fuel filter.

  • Page 152: Troubleshooting Procedure

    Troubleshooting Procedure Troubles Check items Self-diagnosis Vehicle supply voltage Main relay Fuse/plug wire harness Terminal 46 (Ignition ON/OFF signal) CKP sensor Run out of fuel Wrong fuel Fuel shortage Air mixture in fuel Low pressure circuit (fuel) High pressure circuit (fuel) Fuel filter Supply pump Fuel pre-heater...
  • Page 153 Troubles Check items Self-diagnosis Rail pressure sensor (RPS) Accel position sensor (APS) Mechanical defect of accel Booster pressure sensor Air filter is clogged Defective turbo charger Waist gate valve connection Check the valve tension Clutch switch Brake switch Vehicle speed signal Check the Oil level Radiator fan Radiator is defective or clogged...
  • Page 154 Troubles Check items Self-diagnosis Vehicle voltage supply Main relay Fuse/plug wire harness Terminal 15 (Ignition ON/OFF signal) CKP sensor Run out of fuel Wrong fuel Fuel shortage Air into the fuel Fuel filter Supply pump Fuel pre-heater Wrong injector connection Injector Mechanical components (Pressure valve gap, compression etc)
  • Page 155 Troubles Check items Rail pressure sensor (RPS) Accel position sensor (APS) Mechanical defect of accel Booster pressure sensor Air filter is clogged Defective turbo charger Waist gate valve connection Check the valve tension Clutch switch Brake switch Vehicle speed signal Check the oil level Radiator fan Radiator is defective or clogged...

  • Page 156: Troubleshooting Procedure

    Troubleshooting Procedure When communication with diagnosis equipment is not possible (Communication with any system is not possible) Measure the data link connector Check and repair wire harness Voltage when grounded with 16 : between power source and data battery voltage link connector.
  • Page 157 Hard to start the engine. (cranking is possible) Trouble code Self diagnosis • Use Hi-scan Trouble code No trouble code • Leakage • Fuel line Check injector • Fuel filter • Fuel pump Check fuel supply to injector • Oil filler cap •...
  • Page 158 Unstable idle or engine stall. Trouble code Self diagnosis • Use Hi-scan • Fuel line (Leakage, deformation) • Fuse Check fuel supply to injector • Supply pump • Fuel in the tank • Fuel filter • Fuel pressure • Fuel pressure Check air cleaner element Clean or replace element Check idle speed...
  • Page 159 Engine hesitation or poor acceleration • Clutch slip Check clutch or brake • Brake slip Check sir cleaner element Clean or replace element Trouble code Self diagnosis check • Use Hi-scan Check injection timing Check fuel system • Supply pump •...
  • Page 160 Trouble diagnosis flow when HUNTING is occurred Fix the single fall of sensors, Currently ECU, pump SCV and TWV malfunction Check based on Currently Idle rotation system each trouble code malfunction hunting (change) CKP (Crankshaft Position) Sensor system PC sensor system (rail pressure sensor) Accel sensor system ECU sensor system (CPUI...
  • Page 161 Trouble diagnosis flow when FCCB (Fuel control cylinder balance) fails Repair or correct the wiring (Continue checking Check Flow Check FCCB with the key on) Damper chamber operation trouble codes Faulty because and injector injection (with dia gnosis Check injector P0301, P0302, of FCCB equipment).
  • Page 162 Trouble diagnosis flow when engine is lack of power Fix the single fail of sensor, Currently ECU, pump SCV and TWV malfunction Lack of power in Currently Check based on system engine, Insufficient malfunction each trouble code CKP (Crank shaft Position) injection quantity Sensor system PC sensor system (rail...
  • Page 163 Trouble diagnosis flow in systems of sensors and wirings Sensors and wirings check flow Check connectors Repair or replace connector and wires for connection (DCP, TDC, connection and wiring PC, Accel sensor) Check and replace flywheel for any damage (Check to see if the air Check rotation gap between sensor and flywheel signals, and active conditions of CKP...
  • Page 164 Trouble diagnosis flow in fuel system Fuel system check flow Check fuel tank Repair or replace fuel tank (airtightness, dirt, moisture, etc.) Check fuel hose for damage Repair or replace hose (both sides) Clean or replace fuel filter or fuel line. De-moisturize the element Check fuel filter “After replacing fuel filter, perform air...
  • Page 165 Trouble diagnosis flow for engine stall Defective relay Check main relay Replace the relay Engine stop Communication error Replace fuse Defective fuse Check ECU fuse Key switch : 5A Main power : 10A Check ECU connector for Connect connector connection Check ECU Check wire Not applied state...
  • Page 166 Check fuel hose Oil leak Repair Engine stop (for damage etc) Check the Check locking. Leak leakage between supply Replace the pipe if pump and common leaks. rail pipe PC sensor, unusual Clean the clogged out put Check if fuel line area and replace clogged fuel filter...
  • Page 167 Measure Below the standard Injector ground the ground resistance Replace the Engine stop short between terminal and injector body Check harness ground short Replace ECU between ECU and injector Short Repair the short harness Short Injector B+ is Check injector harness. It Repair the harness short shouldn’t be +B short...
  • Page 168 Fuel system Check the Insufficient fuel Check the fuel filter remaining fuel and Engine stop No trouble code outiet for the fuel fuel system (for supply hose damage etc) Vapor check Rerform air Check any air in the bleeding until vapor fuel.

  • Page 169: Engine Control System-Electronic

    Engine Control System- CAUTION Electronic If a sensor connector is disconnected with being the ignition switch turned ON, the diagnostic Description trouble code (DTC) is recorded in most diesel control unit. In this case, if the battery negative Inspection of The Diesel Control System terminal (-) is disconnected for 15 seconds or more, then the diagnosis memory will be erased.
  • Page 170 CAUTION • When erasing the diagnostic trouble codes, use Hi-scan if possible. Though OTC can be erased by disconnecting the battery terminal, doing so, the data for learning control in ECU would be erased at the same time. Diesel Control Unit Component Location 3.
  • Page 171 6. Rail pressure sensor 7. Supply Control Valve (SCV) D439E Service Manual 4. Fuel system...

  • Page 172: Engine Control Unit (Ecu)

    Engine Control Unit (ECU) ECU Pin Connector D439E Service Manual 4. Fuel system...
  • Page 173 <34 pin connector> Terminal Terminal name Function Connection part Battery (+) via fuse (A) Main relay Battery (+) via fuse (A) Main relay Battery (+) via fuse (A) Main relay Engine speed signal TAC2 Speedometer (TACHOMETER) (sent to speedometer) KWP 2000 K-LINE Accelerator pedal position sensor 1 Accelerator pedal position sensor...
  • Page 174 <35 pin connector> Terminal Terminal name Function Connection part +B FOR FLYABCK NE-SLD Sealed ground of engine RPM sensor Engine RPM sensor (+) Engine RPM sensor (-) OUT2 Overheater warning lamp OUT4 Glow lamp Key switch Starter switch Idle up switch A-GND4 Booster pressure sensor GND Engine coolant temperature, Fuel...
  • Page 175 <32 pin connector> Terminal Terminal name Function Connection part OUT19 Glow relay OUT20 Glow relay Signal GND Signal GND OUT17 Main relay OUT18 Main relay S-OUT1 Engine check lamp D439E Service Manual 4. Fuel system...
  • Page 176 <35 pin connector> Terminal Terminal name Function Connection part P-GND Power GND TWV1 Injector 1 TWV3 Injector 3 COMMON1 Injector Power 1 COMMON1 Injector Power 1 Cam speed sensor signal 1 Common rail pressure sensor 1 A-VCC3 Accelerator position sensor 2 power A-VCC2 Accelerator position sensor 1 power A-VCC1...

  • Page 177: Ecu Circuit Diagram

    ECU Circuit Diagram D439E Service Manual 4. Fuel system...
  • Page 178 D439E Service Manual 4. Fuel system...

  • Page 179: Removal

    Removal 1. After the engine stops wait for about 30 seconds. 2. Disconnect the battery ground line. 3. Remove ECU connector wiring sequentially. 4. Loosen ECU bracket fixing bolt and remove ECU. CAUTION When replacing ECU with new one, ECU data corresponding vehicle should...

  • Page 180: Inspection

    Inspection Check Sheet of Engine ECU Pin Input/output signal Check items Condition Remarks LEVEL Type (normal → operating) Battery (+) via fuse (A) IG. ON Battery voltage Battery (+) via fuse (A) IG. ON Battery voltage Battery (+) via fuse (A) IG.
  • Page 181 Input/output signal Check items Condition Remarks LEVEL Type (normal → operating) IG. ON(20℃) Analogue Above 0.791V 0.116KΩ ~ Intake air temperature sensor 48.14 KΩ IG. ON(40℃) Analogue Below 0.406V +B FOR FLYBACK IG ON Battery voltage Engine RPM sensor shield Below 0.5V ground Engine RPM sensor +...
  • Page 182 Input/output signal Check items Condition Remarks LEVEL Type (normal → operating) Battery voltage > below Idle switch IG ON 0.5V Battery voltage > below Neutral switch IG.ON 0.5V Below 0.5V > Battery Glow relay IG.ON voltage Below 0.5V > Battery Glow relay IG.ON voltage...
  • Page 183 Input/output signal Check items Condition Remarks LEVEL Type (normal → operating) Below 0.5V > Battery Idle down switch IG.ON voltage Below 0.5V > Battery voltage Power GND Below 0.5V engine Injector 1 drive(injector Analogue operation) engine Injector 3 drive(injector Analogue operation) engine Injector COMMON 1...
  • Page 184 Input/output signal Check items Condition Remarks LEVEL Type (normal → operating) Spherical Cam speed sensor signal IG ON wave Common rail pressure IDLE=1.72V IG ON Analogue sensor 1 level(45MPa) Accelerator position IG ON sensor 2 Power IG ON Accelerator position IG ON sensor 1 Power Common rail pressure...
  • Page 185 Input/output signal Check items Condition Remarks LEVEL Type (normal → operating) Engine drive Injector 4 Analogue (injector) Power GND Below 0.5V Power GND Below 0.5V Engine drive Injector COMMON 2 Analogue (injector) Engine drive Injector COMMON 2 Analogue (injector) HP3.4 LO Engine drive Analogue HP3.4 LO...

  • Page 186: Intake Air Temperature Sensor

    Intake Air Temperature Sensor 3. If the resistance exceeds the normal range, replace the intake air temperature sensor assembly. Inspection NOTE : Intake air temperature sensor is a built-in ATS (Air Temperature Sensor) Harness type assembled with the intake air pressure sensor. Inspection Procedure Refer to P0113 P0112 DTC inspection procedures.

  • Page 187: Intake Air Pressure Sensor

    Intake Air Pressure Sensor Inspection Intake Pressure Sensor Harness Inspection Procedure Refer 10 P0236 P0237 and P0238 DTC inspection procedures. Sensor Inspection 1. Check tile sensor resistance using multi-tester. 2. Measure the voltage of Intake air pressure sensor. Intake air Condition Voltage (V) pressure...

  • Page 188: Coolant Temperature Sensor

    Coolant Temperature Sensor Inspection Engine coolant temperature sensor is a resistance type sensor, which is installed on the engine coolant passage of Intake manifold. Based on the output voltage of this sensor, ECU determines the engine temperature and supplies the optimal fuel quantity to Injector when engine is cold.

  • Page 189: Installation

    Inspection Method Using a Multi-Tester Installation 1. Apply locktite 962T or the equivalent around the bolt. 2. Install coolant temperature sensor and tighten with specified torque Specification Torque : 3.0 ~ 4.0 kgf.m 3. Connect the harness connector correctly. 1. Remove engine coolant temperature sensor from the coolant passage of the cylinder head.

  • Page 190: Camshaft Position Sensor

    Camshaft Position Sensor Inspection TDC sensor senses the TDC (Top Dead Center) of compression strokes of cylinder No 1 and 4, and then it transforms it to pulse signals and then Inputs it to ECU. Then, ECU sets the fuel injection sequence based on the signals Crank angle sensor senses each crank angle (piston position) and transforms it to pulse signals and then inputs it to...

  • Page 191: Crankshaft Position Sensor

    Crankshaft Position Sensor Inspection Piston position in the combustion chamber is critical to define the starting of Injection timing. All engine pistons are connected to crankshaft by connecting rod. Sensor on crankshaft can supply the information concerning all piston positions. Revolution speed is defined by the crankshaft revolution number per minute.

  • Page 192: Rail Pressure Sensor

    Rail Pressure Sensor Harness Inspection Procedure Refer to P0192, P0193, and P0194 DTC Inspection Inspection procedure. Sensor Inspection 1. If the rail pressure sensor falls, replace the common rail assembly. 2. Tightening torque of common rail bracket flange bolt is 22~33kgf.m. In order to output a voltage signal corresponding to the applied pressure to the ECM, the rail pressure sensor must measure the instant pressure in the rail.

  • Page 193: Supply Control Valve

    Supply Control Valve Inspection SCV is solenoid type valve, in which ECU controls the valve opening and closing time and the pumping start time. To meet the target rail pressure, pump fuel amount is controlled by the current supplied to SCV.

  • Page 194: Fuel Delivery System-Electronic

    Fuel Delivery System-Electronic Components 1. Injection Pipe No.1 2. Injection Pipe No.2 3. Injection Pipe No.3 4. Injection Pipe No.4 5. Injector assembly 6. Injection pipe (Pipe from pump to common rail) 7. Common rail assembly 8. Fuel return tube 9.

  • Page 195: Fuel Filter

    Fuel Filter • When bubbles are removed completely fasten tile air plug and continue to pump until pump operation effort feels heavy. Replacement 3. Water drain from the fuel filter Removal When water-warning lam p of fuel filter is turned on It Indicates that fuel filter is filled with water So that water should be drained by the following sequence...

  • Page 196: Injector

    Injector Components CAUTION • Since common rail fuel injection system operates at high pressure (1600bar), a special caution should be exercised. • While engine is running or within 1 minute after engine stops no works should be made In relation to common rail fuel injection system. •...

  • Page 197: Cleaning

    Cleaning CAUTION Clean the Injector as follows to be reused. When removing injector, stop the engine and 1. Clean the Injector by setting the Injector vertically wait until the engine cools down enough. Since to the clean container. solenoid surface has high temperature, cool it down enough before starting the service work.

  • Page 198: Replacement

    Replacement Injector and ECU Reference : Input injector QR code into Hi-scan : Using Hi-scan, input injector QR adjusting value into ECU : Reprogram ECU using Hi-scan when replacing ECU D439E Service Manual 4. Fuel system...

  • Page 199: Injector Replacement

    Injector Replacement ECU Replacement 1. Remove the Injector according to the removal 1. Key must be turned off before replacing ECU procedure. Otherwise. ECU may be Inoperative or have troubles. 2. Install new Injector. 2. When replacing ECU, ECU data of the 3.

  • Page 200: Installation

    Installation 5. Install injector and Injection pipe No. 1, 2, 3 and 4 1. The ignition key must be turned off between rails. 2. Install new O-ring to the injector. Tightening torque : 4.0~4.5kgf.m 3. Install new nozzle gasket to the Injector nozzle. CAUTION •...

  • Page 201: Common Rail Assembly

    Common Rail Assembly Removal Installation 1. Remove the high-pressure pipe (1~4) connecting 1. Install the mounting bolt of the common rail fall and Injector. assembly. Tightening torque : 2.2~3.3kgf.m 2. Fasten high-pressure fuel pipe. Tightening torque : 4.0—5.0kgf.rn 2. Remove tile injector pipe (1) connecting high- pres- sure pipe to common rail.

  • Page 202: Injection Pump-Electronic

    Injection Pump-Electronic Supply pump Component 1. Suppply pump mounting nut 2. Supply pump gear 3. O-ring 2 4. Spacer 5. O-ring 1 6. Supply pump Removal 2. Remove supply pump mounting bolt (1) 1. Disconnect the high-pressure pipe (1) connected 3.
  • Page 203 Installation 4. Insert the pump assembly (1) and gear (2) Into the timing gear case. 1. Rotate the crankshaft to align the engine No 1 At this time, insert It as the *mark of the supply cylinder at the TDC (Top Dead Center) position. pump gear tooth aligns to ▽...
  • Page 204 7. The ignition key should be turned off more than 10sec. later after [pump learning initialization] is completed. 8. Start the engine and let the vehicle for 10 minutes at idle. NOTE : Above mentioned [pump learning initialization] actuator test should be performed when the pump is replaced with new one.

  • Page 205: Check Before Use

    5. Service Tool Check before use Read me first Introduction Thank you for purchasing G-scan. This manual describes the basic information for using G-scan. Before operation, please read this manual to be familiar with important information. Copyright Global Information Technology Co., Ltd. copyrights this Manual. All rights reserved. No part of this manual may be reproduced in any form without prior written permission of Global Information Technology Co., Ltd.

  • Page 206: Safety Warning And Caution Before Use

    Safety Warning and Caution before Use This section contains WARNING and CAUTION for safe usage of G-scan. Before use, user should read the following information carefully. WARNING This indicates incorrect handling may result in a major accident involving death or serious injury. •...
  • Page 207 • If the rechargeable battery shows any abnormal symptoms such as odor, heat, deformation or discolor, do not use it. And stop operation and remove the battery immediately. • Do not reverse the positive(+) and negative(-) terminals for the rechargeable battery. •...
  • Page 208 CAUTION This indicates incorrect handling may lead to injury or damage to properties. Under certain conditions more serious consequences may result. • Do not drop G-scan. • Do not place any objects (tools, manuals, etc.) on G-scan module. • When connecting cables under the hood, secure the cables to avoid damage caused by hot or moving parts. •...
  • Page 209 • Do not expose the LCD to humidity. • When LCD is broken, the liquid crystal material will be flown out. Do not contact liquid crystal. If you contact it, clean it out immediately with soap and water. • When LCD surface is contaminated, clean it using soft clothes with alcohol. •...

  • Page 210: Hardware

    Hardware Specification Main Specification Item Specifications Micro Controller ARM9 (S3C2440A) @400MHz NOR Flash Memory 16MB Memory NAND Flash 64MB SDRAM Memory 32MB×2 External Memory 0℃~45℃(32℉~113℉) : Battery Charging Operating 0℃~50℃(32℉~122℉) : Battery Discharging or without Battery Temperature -10℃~70℃(14℉~158℉) Storage (Refer to cautions of manual) Noncondensing @ 0℃~10℃(32℉~50℉) Operating 90%RH @ 10℃~30℃(50℉~86℉)
  • Page 211 Vehicle Communication Interface Item Specifications ISO - 11898, ISO - 11519 K-Line/L-Line ISO-9141, ISO-9141-CARB, KWP-2000 Commercial Vehicle SAE-J1708, RS-232C Data/Control Line Melco Pull-Down UART Added interface Item Specifications Vehicle Speed Simulation Voltage Output 5~20 VDC AC/DC Adapter Item Specifications Input Voltage 100~240 VAC Frequency 50/60 Hz...
  • Page 212 FCC ID: TMGG1PDDMN001 NOTE: This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications.

  • Page 213: Introduction Of Components

    Introduction of Components G-scan Hardware Components G-SCAN KIT (Parts No. 150109 - 00048) Part Description Qty. Part Name: G-scan Main Module P/No: 150109 - 00049 G-scan main module for communication with vehicles. P/Name: Carrying Case P/No: 150109 - 00051 Preserving G-scan main module and components. For preventing from being damaged and lost, G-scan should be stored in this case after using.

  • Page 214: Basic Usage Of G-Scan

    Basic Usage of G-scan Power supply 1. Supply external power There are 4 methods for supplying external DC power to G-scan. • With DLC cable(P/No: 150109 - 00050) • From the cigar lighter terminal in Center Facia with cable-cigar • From the battery of vehicle through cable-battery •...
  • Page 215 How to connect the external power <Figure 2: Connect the External DC power to G-scan> D439E Service Manual 5. Service Tool...
  • Page 216 Description of Power Supplying Method Power supply with the DLC cable The vehicle with diagnosis connector terminal of the 20-Pin connector or which is satisfying the OBD-II communication regulation can get electric power from the DLC cable without any additional power line. NOTE : The DLC connector, in general, is located on the lower part of the driver’s front panel.

  • Page 217: Power On/Off

    Power ON/OFF <Figure 1: Location of the Power S/W> Power ON/OFF Method Power ON 1. Please connect the power before turn on G-scan. NOTE : For the details of power connection to G-scan, refer to “Power Supply” of the “Basic usage of G-scan”. 2.
  • Page 218 <Figure 2: Main Screen of G-scan> Power OFF Press the power switch for 2.5 seconds and G-scan will be turned off. D439E Service Manual 5. Service Tool...

  • Page 219: Description For Main Components Of H/W

    Description for Main Components of H/W Even G-scan is operated through the touch screen, for more fluent operation, please be familiar with the functions and positions of the buttons, connecters and LEDs. Touch Screen and Hardware Buttons <Figure 1: Front view of G-scan> D439E Service Manual 5.
  • Page 220 1. Description of front side of main module Use the specified stylus pen at selecting functions and items on TOUCH SCREEN ① the touch screen Buttons for operating functions relative to buttons on the bottom ② of diagnosis screen. • Exits from the screen currently executed. •...
  • Page 221 • POWER LED Lighting Condition Charging Full Charged With DC power LED (Green) ON LED (Red) ON Battery Pack Installation Without DC power LED OFF LED OFF NOTE : If the battery pack is not installed, when the external power is connected, the Power LED light will be Green.
  • Page 222 2. Description for the Communication Connecter and COM port <Figure 2: G-scan COM port> Connecter for connecting DLC cable to communicate with vehicle ① Control Module. The USB Host port prepared for expanding the function by OPTION ② connecting to additional equipments in the future. The USB port for PC to communicate with vehicle through G-scan PASS-THRU in the future.
  • Page 223 3. SD Memory Slot & Reset Button <Figure 3: SD Memory Slot and Reset Button> SD Memory Slot Slot for inserting the SD card restoring the various data for driving G-scan. ① When program has errors with the OS or others, press the Reset button to RESET Button ②...

  • Page 224: Description For Layout Of S/W Screen

    Description for layout of S/W screen Unlike the conventional diagnostic tool, G-scan is equipped with touch screen. The images on G-scan screen are not simple pictures but the functional buttons for operation. This chapter describes the functions and marks commonly applied to the main screen of G-scan and other diagnosing screen.
  • Page 225 Description for the components of the main screen Configuration and User’s Guide Configure the “Setup”, “User Information”, “Software version” and ① “Self-diagnosis”. Summarized user’s manual. ② Vehicle Selection Selects the vehicle model and system for diagnosing. ③ * The selected system will be shown in the blank box. Diagnosis Menu Shows the Diagnosis Trouble Code(DTC) on the screen by communication with the selected vehicle system.
  • Page 226 Diagnosis Screen Layout <Figure 2: Diagnosis Screen> Showing the Diagnosing System and Hot Key <Figure 3. Selected vehicle system and Hot Keys> The diagnosing item and the model under process are shown. For the icons, refer to the following table. Description for the Common Icons in Diagnosing Window Closes the current window and, return to the initial main screen.
  • Page 227 Window for current data <Figure 3: Current data> Screen Function Button <Figure 4: Screen Function Button> Function button and corresponding screen function button are same. NOTE : The screen function button will be changed according to the diagnosis mode (Activated window on the dual mode).

  • Page 228: Connecting The Dlc Cable

    Connecting the DLC cable For the communication between the control module installed on the vehicle and G-scan, the DLC cable should be connected. <Figure 1: Connecting the DLC cable> Vehicle with the OBD-II connector OBD-II standard connector support communication and power. NOTE : In general, the DLC connector is located on the bottom part of the driver’s front panel.
  • Page 229 CAUTION <Figure 2: Disconnecting DLC cable> Before disconnecting the main DLC cable, release the lock and disconnect. Do not pull the wire or distort it. It may cause the damages on the cable or connector. D439E Service Manual 5. Service Tool...
  • Page 230 CAUTION <Figure 3: Connecting the main DLC to G-scan> Connecting the main DLC connector to G-scan, tighten the 3 clamping screws to the body of G-scan firmly. <Figure 4: Caution for carrying G-scan> Carrying G-scan, do not hold the DLC cable. Hold the main module or hand strap. D439E Service Manual 5.

  • Page 231: Self Test Adapter

    Self Test Adapter The self-test functions are used to check the Main DLC cable (P/No: 150109 - 00050) and specific related circuits. Not all G-scan circuits are checked through the self-test functions. Purpose and Scope of Self Test (Semi-Test) Basic operation of the self-test function is the loop-back theory. Loop-back theory is verification between sent data from G-scan module and returned data, which passed through the pins of all the outside connectors during the self-test.

  • Page 232: Configuration

    Configuration Setup Selecting in the main screen, “Setup” screen will be shown. In this item, the brightness of touch screen can be adjusted for the user’s favor, the language can be selected and the operation of key pad and calibration of the touch screen can be controlled.
  • Page 233 Operating Order and References Screen Brightness Adjustment 1. How to select the “Back Light” • Select button. • Select the at the bottom of screen. • Select the “Back Light (F1)” on screen. <Figure 2: Back Light Adjustment> Adjust the brightness using stylus pen or pressing the on the key pad.
  • Page 234 Language Selection 1. How to select the “Language”. • Select button . • Select the at the bottom of screen. • Select the “Language (F2)” on screen. <Figure 3: Move to Language Selection> D439E Service Manual 5. Service Tool...
  • Page 235 2. Using the stylus pen, select your language or press , and press the . Then language list will be shown. (ENGLISH, KOREAN) <Figure 4: Language Selection> 3. Move to another setup • Using stylus pen, move to another setup if required •...
  • Page 236 Keypad Test 1. How to select the “Keypad Test” • Select button. • Select at the bottom of the screen. • Select the “Keypad Test (F3)” on screen. <Figure 5: Keypad Test> 2. Upon pressing the function button , arrow keys, , the color of selected item will be changed to orange.
  • Page 237 Calibration of Touch Screen 1. How to select the “Touch Screen Calibration (F4)”, the screen will be shown as follows. • Select button. • Select the at the bottom of the screen. • Select the “Touch Screen Calibration (F4)” on screen. <Figure 6: Calibration of Touch Screen>...
  • Page 238 Setup for Unit and Buzzer ON/OFF 1. Selecting , following setup window will be shown. <Figure 8: Unit & Buzzer setup> 2. Setup the Unit and Buzzer operation in the setup window. • Using stylus pen, setup on the touch screen. •...
  • Page 239 Exit from “Setup” 1. After completing “Setup”, move to other Tab. • Select to move to “User Info”. • Using stylus pen, select the “Tab” on the upper portion of the touch screen directly to move. 2. Move to the main screen •...

  • Page 240: User Information

    User Information This is how to input user’s personal information. How to input the User Information How to select the “User Info” • Selecting the “User Info” on the touch screen using the stylus pen, following screen will be shown. •...
  • Page 241 Input the personal information Use the stylus pen on the touch screen to input personal information. Inputting by using H/W buttons are not supported. How to input 1. Using stylus pen, at the “User Info” screen, select the blank box or using and then select the then input panel will be shown.
  • Page 242 Exit from “User Info” Move to other Tap after fill-out user information • Select the to move to “Version”. • Using stylus pen, select the next “Tab” to move. Move to main screen • Select to move to the main screen. •...

  • Page 243: Version

    Version S/W versions and serial number can be checked. Description of Version Information Screen <Figure 1: Version Information Screen> Operating System G-scan OS version S/W Version S/W version on SD card Serial Number Serial number of G-scan main module TPMS VAERSION TPMS Version How to check Version How to move to the “Version”...
  • Page 244 Exit from “Version” Move to other Tab after check the version. • Select the to move to the “Self Test”. • Using the stylus pen, select the Tab at the upper side of the touch screen. Move to the main screen •...

  • Page 245: Self Test

    Self Test This is the function for checking if the circuits relating to the communication of G-scan and the DLC cable have defects or not. If G-scan has problems relating to the vehicle communication function, conduct the test following the instruction of the screen. Description of Self Test Screen <Figure 1: Description of Self Test Screen>...
  • Page 246 Self Diagnosis Test How to move “Self Test” • Selecting the “Self Test” on the touch screen using the stylus pen, the following screen will be shown. • Press the button at “Version” to move to the “Self Test”. <Figure 2: Move to the Self Test> •...
  • Page 247 STEP-A Test The purpose of STEP-A test is for diagnosing the specific vehicle communication circuit of G-scan. During proceeding with this test, the power is supplied by the DLC cable and the Self Test adapter. For the details of Self Test adapter, refer to the ‘Connecting the Self Test adapter’ in the ‘Basic usage of G-scan’. <Figure 3: STEP-A Screen>...
  • Page 248 4. Check the ‘Test Result’ shown on the test result window. <Figure 5: STEP-A Result> No Error Found : Proceed another test of 16-pin DLC cable; begin the “STEP-B” test. Error Found : G-scan main module may be inoperative. Contact the authorized service provider D439E Service Manual 5.

  • Page 249: Step-B Test

    STEP-B Test STEP-B test is to check if the DLC main cable is broken or short on the condition that communication module of G-scan is normal. During this test, the power is supplied by DLC cable and Self Test adapter. For the details of Self Test adapter, please refer to the ‘Connecting Self Test adapter’...
  • Page 250 4. Check the ‘Test Result’ shown on the test result window. <Figure 8: STEP-B Result> The test result messages are explained below: No Error Found: You may still need to test cable integrity by wiggling to test for intermittent connections. If the test results indicate “No Error Found”...
  • Page 251 Exit from the “Self Test” After setup the “Self Test”, move to other Tab. • Select the to move to the “Setup”. • Using stylus pen, select the “Tab” at the upper side of the touch screen to move. Move to main screen to move to main screen.

  • Page 252: Vehicle Communication Function

    Vehicle Communication Function Vehicle Selection In order to diagnose the vehicle through G-scan vehicle model and system should be selected before the start. More than one system can be selected and diagnosed at one time. Introduction of Vehicle Selection Screen For the convenience of user, it is categorized into the Model, Year, Engine, System and Option.
  • Page 253 Vehicle Selection using the H/W Button Select the on the main screen, then below screen will be displayed. How to select Vehicle <Figure 2: Model Selection Screen> 1. Model Selection On vehicle selection screen, the cursor will be located at the upper portion of the Model Selecting Zone as follows.
  • Page 254 <Figure 3: Year Selection> 2. Year Selection Move and set the cursor on the year of model Select the year of model to be diagnosed. Move to “Engine” zone. <Figure 4: Engine Selection> 3. Engine Selection Move and set the cursor on the year of model Select the year of model to be diagnosed.
  • Page 255 <Figure 5: System Selection> 4. System Selection Move and set the cursor on the system of model After selecting the system of model to be diagnosed ① When there is one system option : The system is registered in the “Selected” zone. ②...
  • Page 256 <Figure 6: Option Selection> 5. Option Selection Move and set the cursor on the system option of model Selected option type is registered in “Selected” zone 6. Multiple System Selection When the number of the Systems to be diagnosed is more than one, press buttons to move to “system”...
  • Page 257 <Figure 7: Main Diagnosis System Selection> 7. Main Diagnosis System Selection buttons in the “Selected” zone, locate the cursor on the wanted system and Using press button. Then the mark will be shown in front of the system name as following figure.
  • Page 258 System Selection using touch screen • The vehicle selection process and its caution for using the touch screen are the same for using the H/W button described. • When the wanted items are not shown in each zone, move the scroll bar up and down to find the items. •...

  • Page 259: Fault Code Searching

    Fault Code Searching In this screen, you can check DTCs of all selected systems at one time and directly move to DTC analysis or DATA analysis screen. Introduction for Fault Code Searching Screen <Figure 1: Fault Code Searching Screen> Moves to DTC analysis of selected system. Moves to DATA analysis of selected system.
  • Page 260 Operating Sequence and Reference Processing of fault Code Searching Select in the main screen after completing system selection, and it will show fault codes of selected systems as below. <Figure 2: processing of fault Code Searching> Move to DTC Analysis or Data Analysis buttons, select the detected DTC.
  • Page 261 • When is selected, you can erase DTC or check the data of related DTC. <Figure 3: When ‘GOTO DTC’ is selected> • When is selected, you can check the current data of related control module. <Figure 4: When ‘GOTO DATA’ is selected> D439E Service Manual 5.

  • Page 262: Dtc Analysis

    DTC Analysis In DTC Analysis, it shows detected DTC and provides related information. After item repaired related DTC can be erased in this function. There are 3 methods to move to DTC Analysis. • On the main screen, select the →...
  • Page 263 NOTE • When fault code is many and all are not shown in one screen, move the scroll bar at right side using the stylus pen or buttons to find. • If you want to move back to main screen, press the button or on top right side.
  • Page 264 Check Freeze Frame 1. Select the DTC for the Freeze Frame you want to see. Freeze Frame : Specific Current data of control module at the time of DTC detected. 2. Select button on DTC Analysis screen, you can check Freeze Frame. <Figure 3: See the Freeze Frame>...
  • Page 265 Erase DTC 1. Select button on DTC Analysis screen. <Figure 4: Erase DTC> 2. As shown in <Figure 4>, pop-up window to ask your confirmation is displayed. • When is selected: →All DTCs are erased and the message will be shown. <Figure 5: DTC erased message>...
  • Page 266 Selective erase of DTC 1. Select the DTC to be erased on DTC Analysis Screen. 2. Select the button. 3. The message for confirming erasion is displayed. • When is selected : DTC selected in step 1) is erased and message is displayed. •...
  • Page 267 DTC Analysis with Dual Diagnosis Mode • Check DTC Analysis and Data Analysis at the same time 1. On the DTC Analysis screen <Figure 1>, select button, and then Function Menu is shown as in <Figure 7>. <Figure 7: DTC Analysis “Function Menu”> 2.
  • Page 268 • Check DTC Analysis and Actuation Test at the same time 1. On DTC Analysis screen, select button, and then Function Menu will be shown as in <Figure 7>. 2. Select the “Actuation Test” on function menu, then it changes to Dual diagnosis mode as shown in <Figure 9>.
  • Page 269 • Check the ECU Information 1. On DTC Analysis screen, select button, then the Function Menu is shown as in <Figure 7>. Select the “ECU Info” and then ECU Information is displayed as shown in <Figure 10>. • Using the stylus pen, select it on the touch screen directly. •...

  • Page 270: Data Analysis

    • Change to the Vehicle S/W Management 1. On DTC Analysis screen, select the button, then the Function Menu is shown as <Figure 7>. 2. Select the “Vehicle S/W Management” in the function menu, and then the screen changes to the Vehicle S/W Management as <Figure 11>.
  • Page 271 Introduction of Data Analysis <Figure 1: Data Analysis Screen> Fixes the selected item at the top of the screen. Splits the current data screen into left and right sides and shows maximum 26 data. Shows the current data in graph mode. Starts recording the selected items.
  • Page 272 Operating Sequence and References Fix the Data Items • How to fix the items 1. Select a item to fix. 2. Select at the bottom of the screen, button, or double click the item using the stylus pen on the touch screen, then the selected item will be fixed at the top of the screen as shown in <Figure 2>.
  • Page 273 Full • Display maximum item number of current data on screen. On the Data Analysis screen, select button, then the screen will be divided as shown in <Figure 3> and maximum 26 data items are shown. <Figure 3: See in Full> •...
  • Page 274 Graph 1. Select the item to fix in text mode. 2. Select button, then the selected item will be shown in graph mode as in <Figure 4>. <Figure 4: Graph mode> Maximum value of selected item’s output ① Current Current value of selected item’s output ②...
  • Page 275 • Add/Delete the graph list using <Figure 5: Item List> ① In graph mode, select , then Item List is shown as in <Figure 5>. (The item having “*” mark among the List is currently displayed in graph mode.) ② Select the item to be deleted among the list in graph mode using buttons or using the stylus pen on the touch screen.
  • Page 276 Record 1. Users should fix the data before recording. Please refer to “Fix” function in the Data Analysis chapter. <Figure 6: Fixing record items before record> 2. Select button or <Figure 7: Select record mode> Select Record mode and click button as in <Figure 7>.
  • Page 277 <Figure 8-1: Recording in text mode> <Figure 8-2: Recording in graph mode> Finishes recording data Marks the moment of triggering during recording the data. Recording check lamp. During recording data, it turns on in red. (Normal: black, Record: red) NOTE : Please refer to <A-04-009> for data record and how to use buttons. NOTE : Record screen can be switched to graph mode by select buttons in <Figure 6>.
  • Page 278 Data Analysis on Dual Diagnosis Mode • Check the Data Analysis and the DTC Analysis at one 1. On Data Analysis screen select button, and then the Function Menu will be shown as in <Figure 9>. <Figure 9: Function menu in Data Analysis> 2.
  • Page 279 • Check Data Analysis and the Actuation Test at one time 1. On Data Analysis screen, select button, and then the Function Menu will be shown as in <Figure 9>. 2. On the function menu, select “Actuation Test”, and screen will be changed to Dual mode as shown in <Figure 11>.
  • Page 280 • Check the ECU Information 1. On Data Analysis screen, select button, and then Function Menu will be shown as in <Figure 9>. 2. On the function menu, select the “ECU Info”, then the ECU Information popup window as in <Figure 12> is shown.
  • Page 281 • Change to Vehicle S/W Management 1. On Data Analysis screen, select button and then Function Menu will be shown as in <Figure 9>. 2. On function menu, select the “Vehicle S/W Management”, then screen will be changed to Vehicle S/W Management as in <Figure 13>...

  • Page 282: Actuation Test

    Actuation Test Through the "Actuation Test", you can check whether control module or component is defected or not. There are two methods of using “Actuation Test”. At “DTC Analysis”, select the "Actuation Test" on function menu. → “DTC Analysis” and "Actuation Test" will be displayed on dual mode. At “Data Analysis”, select "Actuation Test"...
  • Page 283 Left Zone of "Actuation Test" Screen: You can check the list for actuation test. Move the scroll bar by using the stylus pen or button to select. Right Zone of "Actuation Test" Screen: You can check the Duration, Test Condition and Test Result. Bottom zone of “Actuation Test”...

  • Page 284: Vehicle S/W Management

    Vehicle S/W Management It contains all supplementary functions except the DTC Analysis, Data Analysis, Actuation Test. It provides various supplementary functions according to vehicle control module. Main Screen of Vehicle S/W Management <Figure 1: Vehicle S/W Management Screen> Function for initializing the adaptive value in ECU. Function for setting the option such as ABS and TCS configured in ECU.
  • Page 285 Example of Vehicle S/W Management Function Resetting Adaptive Values The "Resetting Adaptive Values" function is used to reset adaptive learn data on specific ECUs. On the main screen, select , then screen will show the window as in <Figure 2>. After checking the conditions shown in screen, select button.
  • Page 286 Checking the following message, select to complete initialization of adaptive value. <Figure 4: Resetting Adaptive Values - STEP 3> Version Configuration The “Version Configuration” function is used to configure the functionality of the ECU or to activate or deactivate additional modules. On the main screen, select , then following window will be shown.
  • Page 287 After checking the conditions on the message window, select the button. <Figure 6: Version Configuration – STEP 2> After showing the following message, select . Then the ECU option setup is completed. <Figure 7: Version Configuration - STEP 3> D439E Service Manual 5.

  • Page 288: Ecu Upgrade

    ECU Upgrade This is to upgrade the ECU program to enhance the performance of ECU. Please be familiar with the instruction and caution before ECU upgrade and then perform the ECU upgrade. Incompliant ECU upgrade may cause serious damages on the ECU. Introduction of the ECU Upgrade screen <Figure 1: ECU Upgrade Screen>...
  • Page 289 Check all list Select button on ECU upgrade screen, and you will see all events list to upgrade ECU. <Figure 2: List All screen> Note: Upgrading ECU or checking TSB is not available on “List All” function. Please select button to go back to ECU upgrade screen main for further operation. How to ECU Upgrade How to use the Auto Upgrade When the ECU of relating vehicle has event to be upgraded and not upgraded yet, the auto upgrade is...
  • Page 290 <Figure 4: TSB> Notice: After selecting the event to be upgraded, select at the bottom of the screen and check Technical Service Bulletin. 2. After selecting the event on the event selection screen, select button, then the screen will be changed to prepare ECU upgrade as follows. <Figure 5: ECU Auto Upgrade –...
  • Page 291 Error or Information Message: When the vehicle was upgraded already with selected event <Figure 6: ECU Auto Upgrade -Information> Wrong event is selected and applied. <Figure 7: ECU Auto Upgrade – Error > D439E Service Manual 5. Service Tool...
  • Page 292 3. Select in <Figure 5> at the bottom of ECU upgrade windows, then following message will be shown. <Figure 8: ECU Auto Upgrade – STEP 2> CAUTION <Figure 9: Low Voltage> The pop up screen warns low voltage of battery prompted in the STEP 2 battery voltage check level. To follow the instruction given before proceeding the ECU upgrade.
  • Page 293 4. As it confirms the voltage is normal, select button, and upgrade will be started as shown in following figure. <Figure 10: ECU Auto Upgrade – STEP 3> 5. After completing all ECU upgrade procedure, the following message will be shown. <Figure 11: ECU Auto Upgrade –...
  • Page 294 Error Message: If an error occurred during upgrade ECU, the following message will be displayed. <Figure 12: ECU Auto Upgrade – Error> Caution for processing The time required to complete an ECU upgrade will vary. Menus and buttons are all disabled during the upgrade process.
  • Page 295 How to conduct the Manual Upgrade The manual upgrade of ECU is required only when auto upgrade is failed, Unlike the auto upgrade, user should select the event and enter the password. 1. On the main screen, select , then the screen will be changed as following figure and all events to the vehicle are shown.
  • Page 296 2. After selecting the event, select button, then the screen will be changed to the system selection screen as shown in following figure. <Figure 15: ECU Manual Upgrade – STEP 1> CAUTION Please make sure to select compliant system of the vehicle specification. 3.
  • Page 297 4. After entering the password using the stylus pen as following figure, select at the bottom of the message window. <Figure 17: ECU Manual Upgrade – STEP 3> How to input the password: ① When the cursor move to blank text to prompt input panel. ②...
  • Page 298 6. Select at the bottom of the upgrade proceeding window, then following message will be shown. <Figure 19: ECU Manual Upgrade – STEP 5> CAUTION <Figure 20: Low Voltage> The pop up screen warns low voltage of battery prompted in the STEP 5 battery voltage check level. To follow the instruction given before proceeding the ECU upgrade.
  • Page 299 7. As it confirm the voltage is normal, select to start upgrading as shown in the following figure. <Figure 21: ECU Manual Upgrade – STEP 6> 8. After completing all ECU upgrade, the following message will be displayed. <Figure 22: ECU Manual Upgrade – STEP 7> D439E Service Manual 5.
  • Page 300 ◈ Error Message: If any error occurred during ECU upgrade, the following message will be displayed. <Figure 23: ECU Manual Upgrade- Error> ◈ Error Message: No ROM Data <Figure 24: ECU Upgrade Data Error Message> This is the error message appeared when ECU upgrade is tried without ROM data for ECU upgrading. (When there is no ROM data, the event item is shown in vague.) <...

  • Page 301: Carb Obd-Ii

    CARB OBD-II CARB OBD-II is to diagnose the power train of the vehicle which uses CARB OBD-II protocol. CARB OBD-II <Figure 1. CARB OBD-II Function List> CARB OBD-II Function Menu On the CARB OBD-II screen, select button. And then the pop-up menu for the OBD-II function will be shown as <Figure 1>.
  • Page 302 Readiness Test The type and result of the READINESS TESTS supported by more than one MODULE within the vehicle will be displayed. The number of DTCs present and the MIL status will also be displayed. <Figure 2: DTC & Readiness Test> Current Data The CURRENT DATA MODE allows for sensor values and switch states to be displayed, based upon the concept that one item may be supported by several modules.
  • Page 303 Freeze Frame Data The FREEZE FRAME DATA displays the data values stored in the Engine Control Module at the point when the first conformed DTC is detected. < Figure 4: DTC Analysis & Freeze Frame> Diagnostic Trouble Code At this level, DIAGNOSTIC TROUBLE CODES (DTC) are Displayed based upon the concept that several modules may support one DTC.
  • Page 304 O2 Test Result The results of the on board oxygen sensor monitoring test can be displayed in this mode. Note that only items related to the oxygen sensor will be displayed. <Figure 6: O2 Test Result> Monitoring Test Result The results of on board monitoring tests conducted during normal driving are displayed this mode. <...
  • Page 305 Test or Component Control <Figure 8: Test or Component Control > Vehicle Information <Figure 9: Vehicle Information > D439E Service Manual 5. Service Tool...
  • Page 306 In-USE Performance Tracking This data is used to support possible regulatory requirements for In-use Performance Tracking. Manufacturers are required to implement software algorithms that track in-use performance for each of the flowing component: Catalyst bank 1 Catalyst bank 2 Primary oxygen sensor bank 1 Primary oxygen sensor bank 2 Evaporative 0.020”...

  • Page 307: Flight Record

    Flight Record The function of flight record is to save the current data of control module in order to offer valuable data which can be retrieved at any time for analysis. Providing the trigger function (marking specific timing) and “DTC Record” mode, the staus of the control module can be checked at the moment of the DTC occurred or abnormal symptom.
  • Page 308 Starting the Record Mode 1. In the selection box of <Figure 1>, select the Record Mode using the stylus pen or buttons and press button or , then <Figure 2> screen will be shown. <Figure 2: Flight Record Main Screen> Recording check lamp.
  • Page 309 2. On the screen of <Figure 2>, choose the items and select button to fix. <Figure 3: Selecting the item for saving> Note: When the number of selected item is large, the data recording speed would be slower according to the vehicle communication protocol.
  • Page 310 4. In <Figure 4>, select the Record Mode and select , then it starts recording as shown in <Figure 5-1> or <Figure 5-2>. The recording lamp will turn on in red. <Figure 5-1: Text mode recording> <Figure 5-2: Graph mode recording> Stop recording data When user wants to mark a certain moment during recording data, user selects the Trigger button to mark the time.
  • Page 311 Stop Recording the Data in each Record Mode Stop Recording the Data and Create the Data file in Manual Record Mode 1. During recording the data, press button, the data saving confirm window is shown as in <Figure 6>. <Figure 6: Data Saving Confirm> 2.
  • Page 312 NOTE <Figure 8: Saving Stop Recording Pop-up in 1hr of Data Recording > When data recording time reaches to 1 hour, the message as in <Figure 8> will be shown and the data recording is stopped automatically. If additional Data recording is required, save the currently recorded data and re-start the record mode. 3.
  • Page 313 Stop the Recording Data and Create the Data file in DTC Record Mode 1. When DTC occurs or the user selects as in the manual mode, the window for confirming the stop recording will be shown as in <Figure 10> or <Figure 6>. <Figure 10: Saving Stop Message by DTC occurrence>...
  • Page 314 NOTE <Figure 12: Saving Stop Pop-up at 1hr of Data Recording > When for data recording time reaches to 1 hour, the message as in <Figure 12> will be shown and the data recording is stopped automatically. If additional data recording is required, save the currently recorded data and re-start the record mode. 2.
  • Page 315 How to change file name <Figure 14: Change the saving file name> NOTE How to change the file name ③ On the screen of <Figure 13>, select the region under the file name using stylus pen, then an Input Panel is shown.
  • Page 316 How to use the function button at analyzing the recording data of flight record Function Button of Flight Record Data Analyzing Screen After completing Flight Record, the screen is changed to <Figure 15-1> or <Figure 15-2>, as the recorded Data can be analyzed. <Figure 15-1: Data analyzing in graph mode>...
  • Page 317 Function Menu of Flight Record Data Analyzing Screen <Figure 16: Show the Function Menu> Among the data item recorded in the Flight Record function, change the data ① Item List item to show in graph mode (Available in graph mode only). ②...
  • Page 318 1) Change the data item in graph mode using “Item List” <Figure 17: Change item to display in graph> ① In graph mode, select and select “Item List” to be seen as <Figure 17>. (The item having “*” mark in front of item name in the List is currently shown in graph.) Note: In graph mode, Maximum 4 items can be selected and shown at one time.
  • Page 319 3) Check the Min/Max using “Two Cursor” function “Maximum” and “Minimum” value can be checked by using “Two cursor function” <Figure 19: Data analysis using “Two cursor” function> Cursor “A” Cursor “B” Green Note: “Two cursor function is only enabled in graph mode. Convert text mode to graph mode <Repositioning “A”...
  • Page 320 <Repositioning “B” cursor location> ① Select to retrieve list then select “ Two Cursor B” ② Use stylus pen or H/W button to reposition “B” Cursor. Touch Screen Use stylus pen to position cursor “B”. Arrow Key button when cursor “B” is activated <Figure 21: Repositioning Cursor “B”...
  • Page 321 4) Check the Data at Trigger timing using “Go To Trigger” <Select “Go to Trigger” in graph mode> Select and select “Go To Trigger” then the Cursor “A” is going to be positioned where user marked using during recording the data by Flight Record function. <Figure 23: Select “Go To Trigger”...
  • Page 322 5) Reset Min/Max Select and select “Reset Min/Max”, then all the data shown in the right zone are reset. ① ② ④ ③ <Figure 25: Reset Min/Max> ① Maximum value among the data detected at Cursor “A” position ② Current Data value detected at Cursor “A”...
  • Page 323 6) Recorded Data Info. In the function menu shown by selecting , select “Recorded Data Info.” function, then the information regarding the saved data can be checked. ① ② <Figure 26-2: Pop-up window for Record Data Information > ③ ④ <Figure 26-1: Pop-up window for Record Data Information>...
  • Page 324 How to use the Data Review function This is the function to review for analysis of recorded data in Flight Record function. Retrieving of the recorded data 1. Select on the main screen and select “Review” in the pop-up window as <Figure 27>. select <Figure 27: Record/Review Selection Box>...
  • Page 325 Finding data directories for individual vehicle Move to upper folder using selecting “••” After moving the cursor, select “••” using buttons and press button or using the stylus pen. <Figure 29-1: Move to Upper Folder> Select the Data After moving the cursor, select the folder using buttons and press button or using the stylus pen.
  • Page 326 How to analyze the recorded data The method for analyzing the recorded data is the same with the method described in the “How to use the function for analyzing the recorded data of Flight Record”. <Figure 30: Data Review in graph mode> <Figure 31: Data Review in text Mode>...

  • Page 327: Pc Utility

    PC Utility PC Utility Installation NOTE : G-scan PC Utility requires the Microsoft Windows 2000 operating system or later. 1. Insert G-scan PC Utility Software to the CD ROM. NOTE : You may see the following dialogue box during installation of PC Utility on PC with Windows Vista, and select "Allow"...
  • Page 328 2. Install Shield will start automatically in a few seconds. 3. Press “Next” button in following dialog. D439E Service Manual 5. Service Tool...
  • Page 329 4. Press “Install” Button in following dialog. 5. Installing PC Utility S/W. D439E Service Manual 5. Service Tool...
  • Page 330 6. Installing G-scan USB driver. 7. After Installing USB driver, Adobe Reader program will be installed automatically. D439E Service Manual 5. Service Tool...
  • Page 331 8. Press "Next" button in following dialog. 9. Press "Next" button in following dialog. D439E Service Manual 5. Service Tool...
  • Page 332 10. Press "Next" button in following dialog. 11. Press "Install" button in following dialog. D439E Service Manual 5. Service Tool...
  • Page 333 12. Installing "Adobe Reader” S/W. 13. Please press "Finish" button to complete Adobe Reader installation. D439E Service Manual 5. Service Tool...
  • Page 334 14. “G-scan PC utility” installation is completed. Please press “Finish” button to complete the installation. 15. The icon will be displayed after installation is completed. D439E Service Manual 5. Service Tool...
  • Page 335 NOTE : You may see the following dialogue box when you run PC Utility on PC with Windows Vista, and select "Allow" to start PC Utility. D439E Service Manual 5. Service Tool...

  • Page 336: How To Use Pc Utility

    How to use PC Utility PC Utility is the specific program for maintaining the Data and S/W of G-scan at the latest version and for recovering the system. Before using the PC utility program, you should read the manual carefully. Description for the PC Utility <Figure 1: PC Utility Main Screen>...
  • Page 337 Updates the Data of G-scan and the O/S saved in SD card. ① Checks the version of the S/W installed in the SD card and the ② version of S/W registered in the server. Function for recovering this equipment to initial condition when G- ③...
  • Page 338 How to use PC Utility Run the PC Utility <Figure 2: PC Utility Main Screen> Double click the PC Utility icon on the desktop to run. The main screen of the PC Utility will be shown as in <Figure 2>. NOTE : Your PC should be connected to internet prior to use PC Utility.
  • Page 339 Start Update Performs the update so that G-scan maintains up to its latest version of O/S and data. Method of G-scan update <Figure 3: Choosing the method to update> Select on the main screen of PC utility, pop up windows as <Figure 3> will be shown. If PC is connected to the internet, G-scan can be updated by lastest version file that downloaded from update server.
  • Page 340 Internet Update <Figure 4: Run the Start Update> is selected, It will download the update file through the internet to update the data and O/S files to SD card. NOTE : Execution of is available when SD card is inserted to PC drive through the reader.
  • Page 341 <Figure 5: Update Reinstall Message> NOTE : When the latest version registered in G-scan Update server is the same with the version registered in the SD card, the follow message will be shown. If you want to reinstall with the same version, select When update file is downloaded, the following message will be shown.
  • Page 342 <Figure 7: Update Error Message> 1. Generated errors during updating This is the message shown when error is occurred during Update. Check if the drive of SD card is found. Run the Update function again. <Figure 8: Update Drive Found Message> 2.
  • Page 343 <Figure 9: Disconnecting with Server during update > 3. Disconnected during proceeding of update This is the message when PC is disconnected from internet. Check the internet connection of PC and retry. D439E Service Manual 5. Service Tool...
  • Page 344 Manual Update This is the function for updating when internet update from the server is impossible because the PC is not connected to the internet. <Figure 10: File search window of Manual update> On the PC Utility main screen, select button, then the file search window will be shown as in <Figure 10>.
  • Page 345 Recovery On G-scan PC Utility Main Screen, select , then G-scan Data and O/S files saved in the SD card will be recovered to the initial state as follows. <Figure 11: Run G-scan Recovery> Unknown Error during Recovery function <Figure 12: Error during Recovery> This is the message shown when unknown error is occurred during Recovery.
  • Page 346 <Figure 13: Setup Window for selecting SD card drive of Reader> NOTE : When previous Data of G-scan is not in the SD card by formatting the card or replacing with new one, message as in <Figure 13> will be shown. After setting up the drive installed with SD card exactly, press the “OK”...
  • Page 347 Check Version <Figure 14: G-scan Version Check Window> This is the function for checking the latest version of G-scan S/W in the server and the current version (Local Version) of G-scan S/W installed in SD card. On G-scan PC Utility main screen, press button.
  • Page 348 Data Viewer <Figure 15: Recorded Data selection> When button is clicked from the PC Utility main screen, following pop up screen will be displayed as shown in <Figure 15>. From <Figure.15>, select the recorded data. Function to review and analyze the recorded data from Flight Record function.
  • Page 349 ◆ Flight Record Data Review <Figure 16. Recorded fie list> Copies the recorded file from SD memory card to PC to directory [C:\g- scanupdate\BACKUP\Flight Record]. Deletes the selected file from the PC or SD memory card. Retrieves the selected data from PC or SD memory card. Closes the selection window.
  • Page 350 <Figure 17. Flight Record data viewer> NOTE : Please refer to the Flight Record <Module : A-04-009> of Vehicle Communication Function for functions on buttons. D439E Service Manual 5. Service Tool...
  • Page 351 ◆ Screen Capture Data Review <Figure 18. Captured image list> Copies the captured image from SD memory card to PC to directory [C:\g- scanupdate\BACKUP\IMAGES]. Deletes the selected file from the PC or SD memory card. Prints the selected image from the list. Closes the image list window.
  • Page 352 User’s Manual <Figure 19: List of User’s Guide> On the PC Utility main screen, select button. The User’s Manual list is shown as in <Figure 19>. <Figure 20: Show the User’s Guide> Select the list in <Figure 19>, then the details of list can be shown. D439E Service Manual 5.
  • Page 353 Q&A <Figure 21: Q&A Page> On the PC Utility main screen, select button. Through the internet, Q&A page is connected as shown in <Figure 21>. <Figure 22: Page for writing the Q&A > Select in <Figure 21>, then it changes to the window for making comments and questions of user.

  • Page 354: Appendix

    Appendix Optional Item Installation and Expenditure Exchange The optional item should be installed to G-scan according to the method described in the manual. Otherwise, it may cause defects on the product. Battery Pack Installation <Figure 1: Position of the Pack Mounting Bolt> 1.
  • Page 355 Exchanging the Rechargeable Battery <Figure 2: Open the battery cover> 1. For installation and removal of the Pack, refer to the Battery Pack Installation. 2. Open the battery cover of Pack disassembled as shown in <Figure 2>. <Figure 3: Remove the battery> 3.
  • Page 356 <Figure 4: Install the New battery> 4. Check the battery terminal shape of the new rechargeable battery, insert it properly. 5. Locate the new rechargeable battery into the case correctly. 6. Close the battery cover and attach the pack according to the manual. CAUTION •...
  • Page 357 Exchanging the Cigar-Cable Fuse <Figure 5: Disassemble the Cable . Cigar> 1. Turning the portion marked in the <Figure 5> to the counter clockwise direction with the 10mm Hexagonal wrench, it is disassembled as shown in <Figure 5>. 2. After exchanging the fuse (250V, 4A), assemble it in reversed order of disassemble. D439E Service Manual 5.

  • Page 358: O/S Update

    O/S Update This is the chapter for how to update the O/S which are the basic system for operating this equipment. O/S Update With SD card installed, press the & buttons at the same time and turn on the power. O/S Update Conditions •...
  • Page 359 <Figure 2: Message for confirming the O/S update condition > It is the message when the condition for updating the O/S is not satisfied. Please check the data upgrade condition of SD card and the connection of the AC/DC power adapter. •...
  • Page 360 <Figure 4: Screen for confirming the O/S update> When the screen as in <Figure 4> is shown, press the “Enter” button. (Pressing “ESC” button, the power will be OFF automatically.) <Figure 5: Screen for completing the O/S update> After completing the O/S update, the pop-up window as in <Figure 5> will be shown. According to the update completing message as in <Figure 5>, press “Enter”...
  • Page 361 <Figure 6: Touch Screen Calibration Screen> NOTE Korean sentence in the box means. Carefully press and briefly hold stylus on the center of the target. Repeat as the target moves around the screen. Since above screen comes right after OS updating it says in Korean as default. After OS update, language should be configured again.
  • Page 362 <Figure 7: Completing the Touch Screen Calibration > After selecting all centers of 5 (+) marks, the message as in <Figure 7> will be shown. To save the new setup, select button. To keep the previous setup, press NOTE Korean sentence in the box means. New calibration setting have been measured.
  • Page 363 Main screen will appear automatically after O/S update is completed. <Figure 8: Main screen will appear after O/S update > ◈ Error Message: • When the external power is not connected <Figure 9: When external power is not connected > When the error message pop-up is shown, press Any Key, then the power of main module will be turned OFF automatically.
  • Page 364 • When the O/S update file saved in the SD card has an error <Figure 10: When update file is not stored in SD Card > 1. When this error message pop-up is shown, press any key to turn OFF the power. 2.
  • Page 365 GIT’s entire liability, and your exclusive remedy under this warranty shall be limited to the replacement, of any defective parts or functions in the product, which is returned to GIT’s Service Center, together with a copy of the purchase receipt, during the aforementioned warranty period. Anything in the foregoing to the contrary notwithstanding, GIT shall have no obligation for any defects in the product resulting from your storage thereof, or for defects that have been caused by operation of the product other than on the operation manual or in environmental conditions other than those specified by GIT or by alteration, accident, misuse, abuse, neglect,...

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