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Doosan G643E - User Manual

Doosan G643E
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Service Manual
G643E LP Engine
G643LP 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
SB4263E01
Dec. 2008

Table of Contents

Questions and Answers

  • K
    Kimberly RochaAug 5, 2025
    What to do if the warning lamp doesn't turn off on my Doosan G643E Engine?
    • D
      Dylan ReyesAug 5, 2025
      If the charging warning lamp on your Doosan Engine doesn't turn off after the engine starts, and the battery frequently needs charging, there might be several reasons. Check for a loose or worn drive belt and correct or replace it if necessary. Also, inspect for a blown fuse and replace it. A cut-off circuit breaker should be reset or replaced. The voltage regulator or alternator could be faulty, so inspect the alternator. Examine the wiring for faults and repair them. Finally, look for corrosion or wear on the battery cable; repair or replace it as needed.
  • I
    ijonesAug 13, 2025
    Why is the battery discharged on my Doosan Engine?
    • B
      bradley65Aug 13, 2025
      If the battery of your Doosan Engine is discharged, several factors could be responsible. Start by checking for a loose or worn drive belt and correct or replace it if necessary. Inspect for loose wiring connections and retighten them. Look for a short circuit or ground fault and repair it. A cut-off circuit breaker should be reset or replaced. If the charging warning lamp illuminates, the voltage regulator might be faulty, so inspect the alternator. Lastly, the battery might be dead and require replacement.
  • J
    Joel EllisonAug 20, 2025
    How to fix a charging warning lamp that doesn't illuminate on a Doosan G643E Engine?
    • R
      Ryan LeeAug 20, 2025
      If the charging warning lamp on your Doosan Engine does not illuminate when the ignition switch is turned ON, it could be due to several reasons. Check if the fuse is blown and replace it if needed. The bulb might be burnt out, requiring replacement. Inspect for loose wiring connections and retighten them. Also, check the L terminal for a bad connection and inspect and replace the wiring if necessary.
  • J
    Janet BurkeAug 27, 2025
    Why is my Doosan G643E Engine overcharged?
    • P
      Patricia WhiteAug 27, 2025
      If your Doosan Engine is overcharged, it could be due to a faulty voltage regulator, especially if the charging warning lamp illuminates. In this case, replace the voltage regulator. Another potential cause is a voltage detection wiring fault, which would also require replacement.

Summary

Chapter 1. GENERAL INFORMATION

Precautions before Service

General safety guidelines and practices before performing service on the engine.

Tightening Torque

Specifications and tables for proper tightening torque values for various bolts.

Recommended Lubricants and Capacities

Details on recommended lubricants and their capacities for engine parts.

General Specification

Technical specifications and data for G643E and G643 engines.

Chapter 2. RECOMMENDED MAINTENANCE

General Maintenance

Routine maintenance checks for fuel, fluid, vacuum, and electrical systems.

Cooling System Maintenance

Procedures for maintaining the engine's cooling system, including coolant and hoses.

Ignition System Maintenance

Steps for inspecting and maintaining the battery, ignition system, and timing.

Maintenance Schedule

A schedule outlining maintenance tasks based on operating hours or time intervals.

Chapter 3. ENGINE MECHANICAL SYSTEM

Specification

Detailed technical specifications for engine components and tolerances.

Torque Specification

Specific torque values required for engine component assembly.

Piston Assembly

Steps for assembling pistons and connecting rods, including pin installation.

Engine Setup and Testing

Procedures for setting up and testing the engine after overhaul, including leak checks.

Chapter 4. ENGINE ELECTRICAL SYSTEM

Specifications

Specifications for ignition timing, firing order, ignition coil, and spark plugs.

Ignition System Inspection

Procedures for inspecting ignition components like the distributor cap, rotor, and wires.

Ignition Timing Adjustment for G643 Engine

Step-by-step guide for adjusting ignition timing on the G643 engine.

Charging System

General description of the alternator and charging system components.

Starting System

General description of the starting motor and its components.

Diagnosis Procedure

A simplified procedure to diagnose starting motor issues.

Chapter 5. ENGINE MANAGEMENT SYSTEM (EMS)

Specifications

Specifications for SECM and sensor/switch inputs.

Component Location

Visual identification of key EMS components and sensors on the engine.

G643 E EMS (Engine Management System) Overview

Detailed overview of the MI-07 LP Fuel System for G643E engines.

EMS Inspection and Repair

General procedures for inspecting and repairing EMS components and sensors.

Engine Control Module[G643 E]

Specifications for SECM inputs and outputs, including sensor types and ranges.

MAP (Manifold Absolute Pressure) Sensor [G643 E and G643]

Description and circuit diagram for the MAP sensor.

Oxygen Sensor (Pre-Catalyst) [G643 E]

Description, component location, and specifications for the pre-catalyst oxygen sensor.

ECT Sensor

Description, component location, and inspection of the Engine Coolant Temperature Sensor.

Chapter 6. LPG FUEL DELIVERY SYSTEM

G643 E LP System Inspection and Repair

Procedures for inspecting and repairing the G643E LP fuel system.

Removal and Installation of N-2007 LP Regulator

Step-by-step procedures for removing and installing the N-2007 LP regulator.

CA100 Mixer Removal Steps

Procedures for removing the CA100 mixer from the engine.

N-2001 Regulator Service Testing

Tests for checking the secondary stage operation of the N-2001 regulator.

Idle Mixture Adjustment

Procedures for adjusting the idle mixture on the CA100 mixer for optimal performance.

Chapter 7. BASIC TROUBLESHOOTING

Preliminary Checks

Initial checks to perform before starting troubleshooting, including visual and basic system checks.

Visual;Physical check

Detailed list of visual and physical checks to perform for troubleshooting.

Basic Troubleshooting Guide

Customer problem analysis sheet to gather information about symptoms.

Engine Cranking but Will Not Start; Difficult to Start

Troubleshooting steps for engine starting problems, covering fuel, ignition, and SECM.

Lack of Power, Slow to Respond; Poor High Speed Performance; Hesitation During Acceleration

Troubleshooting steps for engine performance issues like lack of power or hesitation.

Detonation; Spark Knock

Troubleshooting probable causes and corrective actions for engine detonation or spark knock.

Rough, Unstable, Incorrect Idle, or Stalling

Troubleshooting steps for engine idle issues, including fuel, ignition, and component malfunctions.

Poor Fuel Economy; Excessive Fuel Consumption; LPG Exhaust Smell

Troubleshooting steps for poor fuel economy and exhaust smells.

Chart T-1 Restricted Exhaust System Check

Procedure for checking the exhaust system for restrictions using a backpressure gauge.

Chapter 8. ADVANCED DIAGNOSTICS

Reading Diagnostic Fault Codes

Procedures for retrieving diagnostic fault codes (DFCs) from the SECM memory.

Clearing Fault (DFC) Codes

Steps to clear stored diagnostic fault codes from the SECM memory.

Fault Action Descriptions

Descriptions of actions taken by the SECM when specific faults are detected.

Appendix

LPG And LPG Fuel Tanks

Information on LPG fuel composition, properties, and tank handling.

Special Conditions for Safe Use

Precautions for safe use of SECM and electronic components, including ESD awareness.

Abbreviations

Glossary of abbreviations used throughout the manual.

Doosan G643E Specifications

General IconGeneral
BrandDoosan
ModelG643E
CategoryEngine
LanguageEnglish

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