Doosan G643 LP Engine User Manual

SB4263E01 Dec. 2008 Service Manual G 643 E LP Engine G 643 LP Engine 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

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Important Safety Information Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly. Read and understand all safety precautions and warnings before operating or performing lubrication, maintenance and repair on this product. Basic safety precautions are listed in the “Safety” section of the Service or Technical Manual.

Additional safety precautions are listed in the Safety section of the owner/operation/maintenance publication. Specific safety warnings for all these publications are provided in the description of operations where hazards exist. WARNING labels have also been put on the product to provide instructions and to identify specific hazards. If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. Warnings in this publication and on the product labels are identified by the following symbol. Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. Operations that may cause product damage are identified by NOTICE labels on the product and in this publication. DOOSAN cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are therefore not all inclusive. 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. The information, specifications, and illustrations in this publication are on the basis of information available at the time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service given to the product. Obtain the complete and most current information before starting any job. DOOSAN dealers have the most current information available. 1 WARNING

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Index Chapter 1. GENERAL INFORMATION Precautions before Service................................. 7 Tightening Torque ............................................. 10 Recommended Lubricants and Capacities....... 12 Engine Model and Engine Serial Number......... 13 General Specification ........................................ 14 G643F/G643FE Engine Power and Torque........ 16 Chapter 2. RECOMMENDED MAINTENANCE General Maintenance......................................... 17 Test Fuel System for Leaks........................... 17 Inspect Engine for Fluid Leaks ...................... 17 Inspect Vacuum Lines and Fittings................ 17 Inspect Electrical System ..............................

17 Inspect Foot Pedal Operation........................ 17 Engine Oil Classification................................ 18 Checking Engine Oil Level ............................ 19 Replacing Engine Oil and Filter..................... 19 Checking Compressed Pressure................... 20 Cooling System Maintenance............................ 21 Coolant Recommendation............................. 21 Check Coolant Level..................................... 21 Inspect Coolant Hoses.................................. 21 Checking coolant leaks ................................. 22 Specific gravity test.......................................

22 Relation between Coolant concentration and Specific Gravity............................................. 22 Checking and Adjusting Drive Belt ................ 23 Checking Belt for Damage ............................ 23 Ignition System Maintenance............................ 24 Inspect Battery System ................................. 24 Inspect Ignition System................................. 24 Inspection of Ignition Timing.......................... 24 Inspection of Spark Plug ............................... 25 Fuel System Maintenance ................................. 27 Replace LP Fuel Filter Element..................... 27 Testing Fuel Lock-off Operation ....................

27 Pressure Regulator/Converter Inspection...... 28 Inspect Air/Fuel Valve Mixer Assembly.......... 28 Inspect for Intake Leaks................................ 28 Inspect Throttle Assembly............................. 28 Checking the TMAP Sensor(G643E only) ..... 28 Exhaust System Maintenance........................... 28 Inspect Engine for Exhaust Leaks................. 28 Maintenance Schedule...................................... 29 Chapter 3. ENGINE MECHANICAL SYSTEM General Information........................................... 31 Engine Outline.............................................. 31 Specification.................................................

32 Torque Specification..................................... 33 Engine Exploded View.................................. 41 Engine Construction ..................................... 45 Statement On Cleanliness And Care............. 45 Use Of Rtv Sealer And Anaerobic Gasket Eliminator ..................................................... 46 Replacing Engine Gaskets............................ 47 Thread Repair .............................................. 47 Special Tools................................................ 48 Cooling System ................................................. 51 General Description......................................

51 Testing & Adjusting....................................... 52 Cooling System Recommendation ................ 55 Engine Lubrication ............................................ 57 General Description...................................... 57 Testing and Adjusting ................................... 58 Disassembly of Engine...................................... 60 Tools And Shop Equipment .......................... 60 Accessory Removal...................................... 60 Cleaning....................................................... 60 Draining The Engine..................................... 60 Engine Flywheel Removal ............................

61 Exhaust Manifold Removal ........................... 61 High Mounted Fan Bracket Removal............. 62 Coolant Pump Removal................................ 62 Valve Rocker Arm Cover Removal................ 63 Thermostat Removal .................................... 63 Intake Manifold Removal .............................. 64 G643(E) Service Manual Index 3

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Valve Train Component Removal.................. 64 Cylinder Head Removal ................................ 65 Torsional Damper Removal........................... 66 Oil Pan Removal........................................... 66 Oil Pump Removal........................................ 67 Engine Front Cover Removal ........................ 67 Timing Chain and Camshaft Sprocket Removal ..................................................................... 67 Camshaft Removal ....................................... 68 Balance Shaft Removal................................. 68 Piston and Connecting Rod Removal............ 69 Crankshaft Rear Oil Seal Removal................

70 Crankshaft Rear Oil Seal Housing Removal .. 70 Crankshaft Removal...................................... 71 Cleaning, Inspection, and Repair...................... 72 Cylinder Block............................................... 72 Cylinder Bore................................................ 73 Measuring Cylinder Bore Taper and Out-Of- Round........................................................... 73 Cylinder Bore Reconditioning........................ 74 Boring.................................................... 75 Honing................................................... 75 Piston Disassembly....................................... 76 Measuring Piston Pin-To-Piston Clearance ...

77 Piston Selection............................................ 78 Piston Assembly ........................................... 78 Intake and Exhaust Manifolds ....................... 80 Camshaft ...................................................... 80 Camshaft Bearings ....................................... 81 Balance Shaft ............................................... 82 Timing Chain and Sprockets ......................... 82 Crankshaft Sprocket Replacement ................ 82 Coolant Pump............................................... 83 Oil Pan and Valve Rocker Covers ................. 83 Oil Pump.......................................................

83 Valve Train Components............................... 85 Valve Lifters.................................................. 86 Cylinder Head............................................... 86 Disassembly .......................................... 86 Cleaning, Inspection, and Measurement .... 86 Repair.................................................... 88 Valve Rocker Arm Stud Replacement .... 89 Assembly............................................... 89 Thermostat and Coolant Outlet ..................... 90 Torsional Damper ......................................... 90 Crankshaft Bearings...................................... 91 Crankshaft Runout........................................

93 Crankshaft End Play ..................................... 93 Connecting Rod Bearings ............................. 93 Connecting Rod Side Clearance ................... 94 Assembly of Engine .......................................... 95 Prior to Assembly ......................................... 95 Crankshaft And Crankshaft Bearing Installation ..................................................................... 95 Crankshaft Rear Oil Seal Housing Installation ... 96 Crankshaft Rear Oil Seal Installation............. 96 Piston and Connecting Rod Installation......... 96 Balance Shaft Installation ............................. 98 Camshaft Installation ....................................

99 Timing Chain and Camshaft Sprocket Installation...................................................100 Engine Front Cover Installation....................100 Torsional Damper Installation ......................100 Torsional Damper Installation ......................101 Oil Pump Installation....................................101 Oil Pan Installation.......................................102 Cylinder Head Installation ............................104 Cylinder Head Installation ............................104 Valve Train Component Installation..............104 Valve Adjustment.........................................105 Intake Manifold Installation...........................105 Rocker Arm Cover Installation......................105 Exhaust Manifold Installation .......................107 Flywheel Housing Installation.......................107 Engine Flywheel Installation.........................108 Coolant Pump Installation............................109 Engine Accessory Installation ......................109 Engine Setup and Testing............................109 Chapter 4.

ENGINE ELECTRICAL SYSTEM Specifications...................................................110 Ignition Timing.............................................110 Ignition Sequence (Firing Order)..................110 Ignition Coil .................................................110 Spark Plug...................................................110 Distributor....................................................111 Sensor Gap.................................................111 Ignition System.................................................112 General Description.....................................112 Ignition System Control.........................113 lgnition System Schematic for G643E...114 lgnition System Schematic for G643 .....114 Ignition System Inspection....................115 G643(E) Service Manual Index 4

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