Doosan G643E - Page 5

G643(E) Service Manual Index 3
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