Doosan G35C-5 Manuals

Doosan G35C-5 Service Manual (306 pages)

LP and LP/dual fuel engines

Brand: Doosan | Category: Engine | Size: 15.54 MB

Important Safety Information
3
Table of Contents
5
Index

6
Chapter 1. GENERAL INFORMATION

9
Precautions before Service

9
- Electrical System
  10
Tightening Torque

12
Recommended Lubricants and Capacities

13
Engine Model and Engine Serial Number

14
General Specification

15
G424F/G424FE Engine Power and Torque

17
Chapter 2. RECOMMENDED MAINTENANCE

18
General Maintenance

18
Cooling System Maintenance

22
- Coolant Recommendation
  22
- Check Coolant Level
  22
- Inspect Coolant Hoses
  22
- Checking Coolant Leaks
  23
- Specific Gravity Test
  23
- Relation between Coolant Concentration and Specific Gravity
  23
- Checking and Adjusting Drive Belt
  24
- Adjusting
  24
- Checking Belt for Damage
  24
Ignition System Maintenance

25
- Inspect Battery System
  25
- Inspect Ignition System
  25
- Inspection of Ignition Timing
  25
- Inspection of Spark Plug
  26
Fuel System Maintenance

28
Exhaust System Maintenance

29
- Inspect Engine for Exhaust Leaks
  29
Maintenance Schedule

30
Chapter 3. ENGINE MECHANICAL SYSTEM

32
General Information

32
- Engine Outline
  32
- Technical Specifications
  33
- Shells Selection Table
  35
- Recommended Torque Values
  38
- Troubleshooting
  40
Engine Exploded View

41
Intake Manifold and Gasket

43
Exhaust Manifold and Gasket

47
Timing Belt

49
Timing Belt Tensioner

53
PCV Valve

54
- Crankcase Ventilation
  55
- Service Procedure
  56
Camshaft Timing Pulley And/Or Seal

57
Crankshaft Timing Pulley

57
Crankshaft Front Seal

58
Crankshaft Accessory Pulley

59
Timing Belt Rear Cover

59
Camshaft Case Cover and Gasket

59
Rocker Arms, Linkage, Valve Lifters with

61
Cylinder Head and Eegine

61
Cooling System

62
- Testing and Adjusting
  64
- Cooling System Recommendation
  67
Thermostat Housing

68
Water Pump

69
Lubrication System

70
Oil Pan

73
Oil Pump

74
Oil Pump Assembly

75
Camshaft Case Assembly

76
Cylinder Head

80
Valve, Spring or Seal

81
Engine Disassembly

83
Engine Assembly

87
Cylinder Block

92
Crankshaft

93
Pistons And/Or Connecting Rods

99
Rings

101
Chapter 4. ENGINE ELECTRICAL SYSTEM

103
Specifications

103
Ignition System

104
- Wasted Spark DIS Ignition System
  104
- Inspection of Ignition Coil
  105
- Spark Plug Wire Inspection
  106
- Spark Plug Wire Replacement
  106
- Spark Plug Replacement
  107
- Spark Plug Inspection
  107
Charging System

109
- General Description
  109
- Troubleshooting Procedure
  112
Starting System

117
- General Description
  117
- Diagnosis Procedure
  118
- Start Relay Tests
  120
- Troubleshooting
  121
Chapter 5. ENGINE MANAGEMENT SYSTEM (EMS)

123
General Information

123
- Specifications
  123
- Service Standard
  128
- Component Location
  129
G424FE EMS (Engine Management System) Overview

133
- General Description
  133
- LPG Fuel System Operation
  136
- MPI Gasoline System Operation
  143
- Electronic Throttle System
  144
- Ignition System
  145
- Exhaust System
  146
- Secm
  148
- SECM Wiring Diagrams for G424FE
  151
G424F EMS (Engine Management System) Overview

154
- General Description
  154
- LPG Fuel System Operation
  157
- Electronic Throttle System
  161
- Ignition System
  161
- Secm
  161
- SECM Wiring Diagrams for G424F LP Engine
  162
EMS Inspection and Repair

163
- Engine Control Module (SECM)
  163
- Camshaft Position Sensor
  165
- IAT (Intake Air Temperature) Sensor
  169
- Oxygen Sensor (Pre-Catalyst)
  170
- Oxygen Sensor (Post-Catalyst)
  171
- ECT (Engine Coolant Temperature) Sensor
  172
- LP Fuel Temperature Sensor
  174
- Angle Sensor-Accelerator
  175
- Transmission Oil Temperature Switch
  176
- Ground Speed Limit Switch (Optional)
  177
- Electronic Throttle Body
  178
Chapter 6. LPG FUEL DELIVERY SYSTEM

179
G424FE LP System Inspection and Repair

179
- Removal and Installation
  179
- Tests and Adjustments
  185
  - N-2007 Regulator Service Testing
    185
  - AVV (Air Valve Vacuum) Testing
    187
  - Connection of the MI-07 Service Tool
    187
  - Idle Mixture Adjustment
    188
- Parts Description
  191
  - CA100 Mixer for G424FE Engine
    191
  - N-2007 Regulator for G424FE Engine
    193
G424F LPG System Inspection and Repair

195
- Removal and Installation
  195
- Tests and Adjustments
  200
  - N-2001 Regulator Service Testing
    200
  - AVV (Air Valve Vacuum) Testing
    202
  - Connection of the MI-07 Service Tool
    202
  - Idle Mixture Adjustment
    203
- Parts Description
  205
  - CA100 Mixer for G424F Engine
    205
  - CA100 Disassembly and Service
    207
  - CA100 Disassembled Service
    208
  - N-2001 Regulator for G424F Engine
    209
  - N2001 Regulator Disassembly Steps
    211
  - N2001 Disassembled Service
    213
Chapter 7. MPI GASOLINE FUEL DELIVERY SYSTEM

214
Specification

214
Components Location

215
Fuel Pressure Test

216
Injector

218
- Injector Inspection
  219
Fuel Pump

221
Chapter 8. BASIC TROUBLESHOOTING

222
Preliminary Checks

222
- Before Starting
  222
- Visual/Physical Check
  222
Basic Troubleshooting Guide

223
- Customer Problem Analysis Sheet
  223
- Basic Inspection Procedure
  224
- Connector Inspection Procedure
  225
- Symptom Troubleshooting Guide Chart
  229
Basic Troubleshooting

235
- Intermittents
  235
- Surges And/Or Stumbles
  236
- Engine Cranking but will Not Start / Difficult to Start
  237
- Lack of Power, Slow to Respond / Poor High
  239
- Acceleration
  239
- Detonation / Spark Knock
  241
- Backfire
  242
- Dieseling, Run-On
  242
- Rough, Unstable, Incorrect Idle, or Stalling
  243
- Cuts Out, Misses
  245
- Poor Fuel Economy / Excessive Fuel Consumption LPG Exhaust Smell
  246
- High Idle Speed
  247
- Excessive Exhaust Emissions or Odors
  248
- Diagnostic Aids for Rich / Lean Operation
  249
- Chart T-1 Restricted Exhaust System Check
  250
Chapter 9. ADVANCED DIAGNOSTICS

251
Reading Diagnostic Fault Codes

251
Displaying Fault Codes (DFC) from SECM Memory

251
Clearing Fault (DFC) Codes

251
Fault Action Descriptions

252
Fault List Definitions

252
- Table 1. Fault List Definitions
  253
Dfc Probable Fault Action

263
- Table 2. Diagnostic Fault Codes (Flash Codes)
  263
  - Turnonmil
    268
  - For Open Circuit
    268
  - SECM Pin A6 (EST4) to OEM Ignition
    268
  - Ignition Module Pin a
    268
  - B (of both Connectors)
    268
  - Refer to Application Manual for Specific
    269
  - N/A
    270
  - For Shorts
    270
  - Module Pin D (4-Pin Connector)
    270
  - Verify GND on Ignition Module Pin a
    270
  - Engine Details
    270
Appendix

281
Service Tool Software (Motoview)

281
- Introduction
  281
- Connection of the Service Tool
  282
- Motoview Display Screens
  283
- SECM Field Update with Service Tool
  295
Ground Speed Limits (Option)

299
LPG and LPG Fuel Tanks

301
- Lpg Fuel Tanks
  302
- Lpg Fuel Tank Components
  302
Regulatory Compliance

305
Special Conditions for Safe Use

305
Abbreviations

306

Doosan G35C-5 Manuals

Doosan G35C-5 Service Manual (306 pages)

Table of Contents

Index

Chapter 1. GENERAL INFORMATION

Precautions before Service

Tightening Torque

Recommended Lubricants and Capacities

Engine Model and Engine Serial Number

General Specification

G424F/G424FE Engine Power and Torque

Chapter 2. RECOMMENDED MAINTENANCE

General Maintenance

Cooling System Maintenance

Ignition System Maintenance

Fuel System Maintenance

Exhaust System Maintenance

Maintenance Schedule

Chapter 3. ENGINE MECHANICAL SYSTEM

General Information

Engine Exploded View

Intake Manifold and Gasket

Exhaust Manifold and Gasket

Timing Belt

Timing Belt Tensioner

PCV Valve

Camshaft Timing Pulley And/Or Seal

Crankshaft Timing Pulley

Crankshaft Front Seal

Crankshaft Accessory Pulley

Timing Belt Rear Cover

Camshaft Case Cover and Gasket

Rocker Arms, Linkage, Valve Lifters with

Cylinder Head and Eegine

Cooling System

Thermostat Housing

Water Pump

Lubrication System

Oil Pan

Oil Pump

Oil Pump Assembly

Camshaft Case Assembly

Cylinder Head

Valve, Spring or Seal

Engine Disassembly

Engine Assembly

Cylinder Block

Crankshaft

Pistons And/Or Connecting Rods

Rings

Chapter 4. ENGINE ELECTRICAL SYSTEM

Specifications

Ignition System

Charging System

Starting System

Chapter 5. ENGINE MANAGEMENT SYSTEM (EMS)

General Information

G424FE EMS (Engine Management System) Overview

G424F EMS (Engine Management System) Overview

EMS Inspection and Repair

Chapter 6. LPG FUEL DELIVERY SYSTEM

G424FE LP System Inspection and Repair

G424F LPG System Inspection and Repair

Chapter 7. MPI GASOLINE FUEL DELIVERY SYSTEM

Specification

Components Location

Fuel Pressure Test

Injector

Fuel Pump

Chapter 8. BASIC TROUBLESHOOTING

Preliminary Checks

Basic Troubleshooting Guide

Basic Troubleshooting

Chapter 9. ADVANCED DIAGNOSTICS

Reading Diagnostic Fault Codes

Displaying Fault Codes (DFC) from SECM Memory

Clearing Fault (DFC) Codes

Fault Action Descriptions

Fault List Definitions

Dfc Probable Fault Action