Doosan GC33E-5 Manuals

Doosan GC33E-5 Service Manual (326 pages)

LP/gasoline and LP/dual fuel engines

Brand: Doosan | Category: Engine | Size: 14 MB

Important Safety Information
2
Table of Contents
4
Chapter 1. General Information

8
Precautions before Service

8
- Electrical System
  9
Tightening Torque

11
Recommended Lubricants and Capacities

12
Engine Model and Engine Serial Number

13
General Specification

14
Engine Power and Torque

16
Chapter 2 . RECOMMENDED

17
General Maintenance

17
Cooling System Maintenance

22
- Coolant Recommendation
  22
- Check Coolant Level
  22
- Inspect Coolant Hoses
  22
- Checking Coolant Leaks
  23
- Specific Gravity Test
  23
- Checking and Adjusting Drive Belt
  24
- Adjusting
  25
- Checking Belt for Damage
  25
- Ignition System Maintenance
  26
- Inspect Battery System
  26
- Inspect Ignition System
  26
- Inspection of Spark Plug
  27
Fuel System Maintenance

29
Maintenance Schedule

32
Chapter 5 . ENGINE MANAGEMENT

34
General Information

34
- Specifications
  36
Chapter 3 . ENGINE MECHANICAL

39
- Torque Specification
  39
Special Tools

40
- Troubleshooting
  42
Timing Belt System

43
- Removal
  44
- Inspection
  45
- Assembly
  47
PCV Valve

49
- Outline and Operation Principle
  49
- Service Procedure
  50
Intake and Exhaust System

51
- Exhaust Manifold
  53
- Cooling System
  55
- Testing and Adjusting
  56
- Cooling System Recommendation
  59
- Coolant Pipe and Hose
  61
- Water Pump
  62
- Thermostat
  64
Cylinder Head Assembly

66
Lubrication System

75
- Testing and Adjusting
  76
- Oil Pressure Switch
  78
- Front Case and Oil Pump
  79
CAM Shaft, HLA, Timing Chain

84
- Removal
  85
- Inspection
  86
Crankshaft

91
Flywheel and Housing

95
Piston and Connection Rod

96
- Engine Block
  102
Cylinder Block

111
- Specifications
  119
- Coil-On-Plug Ignition System
  120
- Cop Components
  120
- Ignition System
  120
- Inspection of Ignition Timing
  123
- Inspection of Ignition Coil
  124
- Inspection of Spark Plug
  125
Charging System

127
- Troubleshooting
  129
- Troubleshooting Procedure
  130
- Disassembly and Installation
  135
Starting System

140
- Diagnosis Procedure
  141
- Start Relay Tests
  143
- Starter
  145
  - Removal and Installation
    146
  - General Information
    151
- Service Standard
  156
- Component Location
  157
- G420FE EMS (Engine Management System Overview
  161
- LPG Fuel System Operation
  164
- MPI Gasoline System Operation
  171
- Electronic Throttle System
  172
Chapter 4 . ENGINE ELECTRICAL

173
Ignition System

173
- Exhaust System
  174
- Secm
  176
  - SECM Wiring Diagrams for G420FE
    179
  - G420F EMS (Engine Management System Overview
    181
- LPG Fuel System Operation
  184
- MPI Gasoline System Operation
  188
- SECM Wiring Diagrams for G420F
  189
EMS Inspection and Repair

190
- Engine Control Module (Secm)
  190
- Camshaft Position Sensor
  192
- Crank Shaft Position Sensor
  193
- MAP (Manifold Absolute Pressure) Sensor
  194
- Iat (Intake Air Temperature)
  195
- Oxygen Sensor (Pre-Catalyst)
  196
- Oxygen Sensor (Post-Catalyst)
  197
- ECT (Engine Coolant Temperature) Sensor
  198
- LP Fuel Temperature Sensor
  200
- Angle Sensor-Accelerator
  201
- Transmission Oil Temperature Switch
  202
- Ground Speed Limit Switch (Optional)
  203
- Electronic Throttle Body
  204
Chapter 6 . LPG FUEL DELIVERY

205
G420FE LP System Inspection and Repair

205
- Hose Connections
  206
- Removal and Installation of
  207
- Removal and Installation of CA100 Mixer for G420FE
  208
- Tests and Adjustments
  210
  - N-2007 Regulator Service Testing
    211
  - AVV (Air Valve Vacuum) Testing
    213
  - Idle Mixture Adjustment
    214
- Parts Description
  217
G420F LPG System Inspection and Repair

221
- G420F Fuel System Connections
  222
  - Removal and Installation of N-2001 LP Regulator/Converter
    223
  - Removal and Installation of CA100 Mixer for G420F
    224
- Tests and Adjustments
  226
  - AVV (Air Valve Vacuum) Testing
    228
- Idle Mixture Adjustment
  229
- Parts Description
  231
Chapter 7 . MPI GASOLINE FUEL

240
Specification

240
Components Location

241
Fuel Pressure Test

242
Injector

244
Injector Inspection

246
Fuel Pump

248
Chapter 8. Basic Troubleshooting

249
- Visual/Physical Check
  249
- Before Starting
  249
Preliminary Checks

249
Basic Troubleshooting Guide

250
- Customer Problem Analysis Sheet
  250
- Basic Inspection Procedure
  251
- Connector Inspection Procedure
  252
- Symptom Troubleshooting Guide Chart
  256
Basic Troubleshooting

262
Chapter 9. Advanced Diagnostics

278
Reading Diagnostic Fault Codes

278
Clearing Fault (Dfc) Codes

278
Fault Action Descriptions

279
Fault List Definitions

279
- Table 1. Fault List Definitions
  280
Dfc Probable Fault Action

290
- Table 2. Diagnostic Fault Codes (Flash Codes)
  290
  - Output Open, Possibly Open EST5 Signal or Defective
    295
  - Spark Module
    295
  - Output Open, Possibly Open EST6 Signal or Defective
    295
  - For Open Circuit
    295
  - SECM Pin A6 (EST4) to OEM Ignition
    295
  - Ignition Module Pin a
    295
  - B (of both Connectors)
    295
  - Refer to Application Manual for Specific
    296
  - N/A
    297
  - For Shorts
    297
  - Module Pin D (4-Pin Connector)
    297
  - Verify GND on Ignition Module Pin a
    297
  - Engine Details
    297
Appendix Service Tool Software (Motoview)

308
- Service Tool Connection to SECM
  309
- Service Tool Display
  310
- SECM Field Update with Service Tool
  315
Ground Speed Limits (Option)

319
LPG and LPG Fuel Tanks

321
- Lpg Fuel Tank Components
  322
- Lpg Fuel Tanks
  322
Regulatory Compliance

325
Special Conditions for Safe Use

325
Abbreviations

326

Doosan GC33E-5 Manuals

Doosan GC33E-5 Service Manual (326 pages)

Table of Contents

Chapter 1. General Information

Precautions before Service

Tightening Torque

Recommended Lubricants and Capacities

Engine Model and Engine Serial Number

General Specification

Engine Power and Torque

Chapter 2 . RECOMMENDED

General Maintenance

Cooling System Maintenance

Fuel System Maintenance

Maintenance Schedule

Chapter 5 . ENGINE MANAGEMENT

General Information

Chapter 3 . ENGINE MECHANICAL

Special Tools

Timing Belt System

PCV Valve

Intake and Exhaust System

Cylinder Head Assembly

Lubrication System

CAM Shaft, HLA, Timing Chain

Crankshaft

Flywheel and Housing

Piston and Connection Rod

Cylinder Block

Charging System

Starting System

Chapter 4 . ENGINE ELECTRICAL

Ignition System

EMS Inspection and Repair

Chapter 6 . LPG FUEL DELIVERY

G420FE LP System Inspection and Repair

G420F LPG System Inspection and Repair

Chapter 7 . MPI GASOLINE FUEL

Specification

Components Location

Fuel Pressure Test

Injector

Injector Inspection

Fuel Pump

Chapter 8. Basic Troubleshooting

Preliminary Checks

Basic Troubleshooting Guide

Basic Troubleshooting

Chapter 9. Advanced Diagnostics

Reading Diagnostic Fault Codes

Clearing Fault (Dfc) Codes

Fault Action Descriptions

Fault List Definitions

Dfc Probable Fault Action

Appendix Service Tool Software (Motoview)

Ground Speed Limits (Option)

LPG and LPG Fuel Tanks

Regulatory Compliance

Special Conditions for Safe Use

Abbreviations

Doosan GC33E-5 Operation & Maintenance Manual (252 pages)

Table of Contents

Table of Contents

Information Section

Safety Section

General Section

Operation Section

Maintenance Section

Maintenance Intervals

Every 10 Service Hours or Daily

First 50 - 100 Service Hours or a Week

First 250 Service Hours or a Month

Every 250 Service Hours or Monthly

Every 500 Service Hours or 3 Months

Every 1000 Service Hours or 6 Months

Every 1500 Service Hours or 9 Months

Every 2000 Service Hours or Yearly

Every 2500 Service Hours or 15 Months

Every 3000 Service Hours or 18 Months

Index Section