Doosan G643E Manuals

Manuals and User Guides for Doosan G643E. We have 1 Doosan G643E manual available for free PDF download: Service Manual

Doosan G643E Service Manual (261 pages)

LP Engine for G35S-5, G40S-5, G45S-5, G50C-5, G55C-5, GC35S-5, GC40S-5, GC45S-5, GC50C-5, GC55C-5, G40SC-5, G45SC-5, G50SC-5, G55SC-5, G50S-5, G60S-5, G70S-5

Brand: Doosan | Category: Engine | Size: 47.37 MB

Important Safety Information
3
Chapter 1. General Information

9
Chapter 2. Recommended Maintenance

19
- General Maintenance
  19
- Inspect Electrical System
  19
- Engine Oil Classification
  20
- Checking Engine Oil Level
  21
- Replacing Engine Oil and Filter
  21
- Checking Compressed Pressure
  22
- Cooling System Maintenance
  23
- Checking Coolant Leaks
  24
- Relation between Coolant Concentration and Specific Gravity
  24
- Specific Gravity Test
  24
- Checking and Adjusting Drive Belt
  25
- Checking Belt for Damage
  25
- Ignition System Maintenance
  26
- Inspection of Spark Plug
  27
- Fuel System Maintenance
  29
- Replace LP Fuel Filter Element
  29
- Testing Fuel Lock-Off Operation
  29
- Exhaust System Maintenance
  30
- Inspect Throttle Assembly
  30
- Pressure Regulator/Converter Inspection
  30
- Maintenance Schedule
  31
Chapter 3. ENGINE MECHANICAL SYSTEM

33
- Torque Specification
  35
- Engine Exploded View
  43
- Engine Construction
  47
- Statement on Cleanliness and Care
  47
- Use of Rtv Sealer and Anaerobic Gasket Eliminator
  48
- Replacing Engine Gaskets
  49
- Thread Repair
  49
- Special Tools
  50
- Cooling System
  53
- General Description
  53
- Testing & Adjusting
  54
- Operation
  56
- Cooling System Recommendation
  57
- Engine Lubrication
  59
- Disassembly of Engine
  62
- Engine Flywheel Removal
  63
- Exhaust Manifold Removal
  63
- Thermostat Removal
  65
- Valve Rocker Arm Cover Removal
  65
- Intake Manifold Removal
  66
- Valve Train Component Removal
  66
- Cylinder Head Removal
  67
- Oil Pan Removal
  68
- Torsional Damper Removal
  68
- Engine Front Cover Removal
  69
- Oil Pump Removal
  69
- Timing Chain and Camshaft Sprocket Removal
  69
- Camshaft Removal
  70
- Piston and Connecting Rod Removal
  71
- Crankshaft Rear Oil Seal Removal
  72
- Crankshaft Removal
  73
- Cleaning, Inspection, and Repair
  74
- Cylinder Block
  74
- Cylinder Bore
  75
- Piston Disassembly
  78
- Piston Assembly
  80
- Piston Selection
  80
- Intake and Exhaust Manifolds
  82
- Camshaft Bearings
  83
- Balance Shaft
  84
- Timing Chain and Sprockets
  84
- Coolant Pump
  85
- Oil Pump
  85
- Valve Train Components
  87
- Cylinder Head
  88
- Valve Lifters
  88
- Torsional Damper
  92
- Crankshaft Bearings
  93
- Connecting Rod Bearings
  95
- Crankshaft End Play
  95
- Crankshaft Runout
  95
- Connecting Rod Side Clearance
  96
- Prior to Assembly
  97
- Crankshaft Rear Oil Seal Installation
  98
- Piston and Connecting Rod Installation
  98
- Balance Shaft Installation
  100
- Camshaft Installation
  101
- Engine Front Cover Installation
  102
- Oil Pump Installation
  103
- Torsional Damper Installation
  103
- Oil Pan Installation
  104
- Cylinder Head Installation
  106
- Valve Train Component Installation
  106
- Intake Manifold Installation
  107
- Rocker Arm Cover Installation
  107
- Valve Adjustment
  107
- Exhaust Manifold Installation
  109
- Flywheel Housing Installation
  109
- Engine Flywheel Installation
  110
- Engine Accessory Installation
  111
- Engine Setup and Testing
  111
Chapter 4. ENGINE ELECTRICAL SYSTEM

112
- Specifications
  112
- General Description
  114
- Ignition System
  114
- Ignition System Inspection
  117
- Disassembly and Assembly
  122
- Charging System
  128
- General Description
  128
- Troubleshooting
  129
- Troubleshooting Procedure
  131
- Diagnosis Procedure
  137
- Start Relay Tests
  139
- Installation
  141
Chapter 5. ENGINE MANAGEMENT SYSTEM (EMS)

142
- Specifications
  142
- Component Location
  147
- General Description
  150
- LPG Fuel System Operation
  153
- Electronic Throttle System
  161
- System Overview
  170
- Ignition Management
  180
- EMS Inspection and Repair
  183
- IAT (Intake Air Temperature) Sensor
  186
- Specification
  189
Chapter 6. LPG FUEL DELIVERY SYSTEM

195
- Hose Connections
  196
- Removal and Installation of N-2007 LP Regulator
  198
- Tests and Adjustments
  201
- AVV (Air Valve Vacuum) Testing
  203
- Idle Mixture Adjustment
  203
- Parts Description
  207
- Removal and Installation of N-2001 LP Regulator/Converter
  213
- CA100 Disassembly and Service
  222
- CA100 Disassembled Service
  223
- N2001 Regulator Disassembly Steps
  226
- N2001 Disassembled Service
  228
- Before Starting
  229
Chapter 7. Basic Troubleshooting

229
- Preliminary Checks
  229
- Visual/Physical Check
  229
- Customer Problem Analysis Sheet
  230
- Basic Inspection Procedure
  231
- Connector Inspection Procedure
  232
- Surges And/Or Stumbles
  237
- Engine Cranking but will Not Start / Difficult to Start
  238
- Detonation / Spark Knock
  242
- Rough, Unstable, Incorrect Idle, or Stalling
  244
- Cuts Out, Misses
  246
- Poor Fuel Economy / Excessive Fuel Consumption / LPG Exhaust Smell
  247
- High Idle Speed
  248
- Excessive Exhaust Emissions or Odors
  249
- Diagnostic Aids for Rich / Lean Operation
  250
Chapter 8. Advanced Diagnostics

252
- Fault Action Descriptions
  253
- Fault List Definitions
  253
- LPG and LPG Fuel Tanks
  254
- LPG Fuel Supply
  254
- Installing LPG Fuel Tanks
  255
- LPG Fuel Tank Components
  255
- Fuel Gauge
  256
- Service Valve
  256
- Filler Valve
  257
- Quick Disconnect Coupling
  257
- Regulatory Compliance
  258
- Special Conditions for Safe Use
  258

Doosan Categories

Air Compressor Excavators Engine Forklifts Compact Loader

More Doosan Manuals

Doosan G643E Manuals

Doosan G643E Service Manual (261 pages)

Table of Contents

Chapter 1. General Information

Chapter 2. Recommended Maintenance

Chapter 3. ENGINE MECHANICAL SYSTEM

Chapter 4. ENGINE ELECTRICAL SYSTEM

Chapter 5. ENGINE MANAGEMENT SYSTEM (EMS)

Chapter 6. LPG FUEL DELIVERY SYSTEM

Chapter 7. Basic Troubleshooting

Chapter 8. Advanced Diagnostics

Related Products

Doosan Categories