Operation MaintenanceGE08TI

65.
99897-8099
Operation and
Maintenance Manual
Generator Natural Gas Engine
GE08TIC
PS-MMG0416-E1A
GE08TIC
Operation and Maintenance Manual
FOREWORD
This manual is designed to serve as a reference for DOOSAN Infracore (here after
DOOSAN’s) customers and distributors who wish to gain basic product knowledge on
DOOSAN's GE08TIC compressed natural gas engines.
These economical and high-performance natural gas engines (6 cylinders, 4 strokes, in-line
type) have been so designed and manufactured to be used for the automotive & industrial
application. They meet all the requirements such as low noise, fuel economy, high engine
speed and durability.
To maintain the engine in optimum condition and retain maximum performance for a long
time, CORRECT OPERATION and PROPER MAINTENANCE are essential.
In this manual, the following symbols are used to indicate the type of service operations to be
performed.
Removal Adjustment
Installation Cleaning
Disassembly Pay close attention-Important
Reassembly Tighten to specified torque
Align the marks Use special tools of manufacturer's
Directional Indication Lubricate with oil
Inspection Lubricate with grease
Measurement
During engine maintenance, please observe following instructions to prevent environmental

damage;
z Take old oil to an old oil disposal point only.
z Ensure without fail that oil will not get into the sea or rivers and canals or the
ground.
z Treat undiluted anti-corrosion agents, antifreeze agents, filter element and
cartridges as special waste.
z The regulations of the relevant local authorities are to be observed for the
disposal of spent coolants and special waste.
If you have any question or recommendation in connection with this manual, please do not
hesitate to contact our head office, dealers or authorized service shops near by your location
for any services.
For the last, the content of this maintenance instruction may be changed without notice for
some quality improvement. Thank you.
May 2005
Printed in May 2005 PS-MMG0416-E1A

GE08TIC
CONTENTS
1. Safety Regulations & Engine Specifications
1.1. General notes 1
1.2. Handle compressed natural gas safety 1
1.3. General Information 8
1.4. Engine assembly 10
2. Technical Information
2.1. Engine model and serial number 13
2.2. Engine characteristic 13
2.3. Diagnosis and remedy 32
2.4. Engine inspection 39
3. Disassembly and Reassembly of Major Components

3.1. Disassembly 41
3.2. Inspection 54
3.3. Reassembly 73
3.4. Starting and trial operation 97
3.5. Speed controller setting 99
3.6. Electrical system 105
4. Commissioning and Operation

4.1. Operation preparation 118
4.2. Breaking-in 118
4.3. Inspections after starting 120
4.4. Operation in winter time 121
4.5. Tuning the engine 121
4.6. Maintenance and care 122
4.7. Cooling system 123
4.8. Adjustment of valve clearance 125
4.9. Tightening the cylinder head bolts 127
4.10. Cylinder compression pressure 127
4.11. Belts 128
5. Maintenance of Major Components

5.1. Cooling system 130
5.2. Lubricating system 132
5.3. Turbocharger 136
5.4. Air intake system 144
6. Special Tool List 147
● Appendix 148

GE08TIC
1. Safety Regulations & Engine Specifications
1.1. General notes

Day-to-day use of power engines and the service products necessary for running
them presents no problems if the persons occupied with their operation,
maintenance and care are given suitable training and think as they work.
This summary is a compilation of the most important regulations. These are broken
down into main sections which contain the information necessary for preventing
injury to persons, damage to property and pollution. In addition to these regulations
those dictated by the type of engine and its site are to be observed also.
IMPORTANT:
If despite all precautions, an accident occurs, in particular through contact
with caustic acids, fuel penetrating the skin, scalding from oil, antifreeze being
splashed in the eyes etc, consult a doctor immediately.
1.2. Handle compressed natural gas safety

Natural gas is highly flammable and explosive and may be extremely cold. The
following cautions must be taken to avoid personal injury or engine damage.
z Do not smoke when installing or
servicing the engine or fuel system.
z Installation or servicing of natural
gas equipment must only be
conducted in well ventilated, natural
gas compatible areas. Do not install
or service equipment in an enclosed
area where ignition sources are
present without ensuring that an
undetected gas leak may be safely
vented without being ignited.
z Do not vent natural gas or permit
leaks inside an enclosed area.
Bleed natural gas lines before
installing or servicing any
component connected to the fuel
lines.
1 General Information
GE08TIC
1.2.1. Avoid heating near pressurized fluid lines

z Wear welding goggles and gloves
when welding or using an acetylene
torch.
z Insure a that metal shield separated
the acetylene and oxygen which
must be chained to a cart.
z Do not weld or heat areas near fuel
tanks or fuel lines.
1.2.2. Venting an operable engine to relieve natural gas pressure

z To avoid personal injury an operable
natural gas engine must be kept in a
well ventilated area away from open
flames and sparks.
z If the engine can run, use the
following venting procedure to relive
the natural gas pressure downstream
of the shutoff valve.
1) Shut off manual valves on natural gas supply lines and main shutoff valve on
natural gas fuel supply line.
2) Start engine and run until it stalls due to fuel starvation.
3) Check to make sure gauge pressure at point on the natural gas fuel line to be
vented has been reduced to zero. If not, repeat step 1) Then repeat step 2).
4) Disconnect engine batteries using switch in battery compartment or by
disconnecting battery ground cable.
5) Slightly loosen the CNG fuel line fitting to be serviced in a well ventilated area
to allow any remaining gas to vent.
6) Completely open the fitting that was slightly opened and allow to vent in a well
ventilated area.
1.2.3. During commissioning, starting and operation

z This is the safety alert symbol. When you see this symbol in this manual, be alert
to the potential for personal injury.
z Carefully read all safety message in this manual and on your engine safety signs.
Be sure new equipment components and repair parts include the current safety
signs.
GE08TIC
z Avoid possible injury or death from vehicle runaway. Do not start engine by
shorting across starter terminals. Vehicle will start in gear if normal circuitry is
bypassed. Start engine only from operator’s seat with transmission in neutral or
park.
z Prevent fires by keeping machine clean of accumulated trash, grease, fuel and
debris.
z When the engine is running, do not get too close to the rotating parts.
z Do not touch the engine with bare hands when it is warm from operation risk of
bums.
z Exhaust gases are toxic. If it is necessary to run an engine in an enclosed area,
remove the exhaust gases from the area with an exhaust pipe extension. If you
do not have an exhaust pipe extension, open the doors and get outside air into
the area.
z Keep vicinity of engine free of oil and grease. Accidents caused by slipping can
have serious consequences.
1.2.4. During maintenance and care

z Always carry out maintenance work when the engine is switched off. If the
engine has to be maintained while it is running, e.g. changing the elements of
change-over filters, remember that there is a risk of scalding. Do not get too
close to rotating parts.
z Change the oil when the engine is warm from operation.
CAUTION:
There is a rise of burns and scalding. Do not touch oil drain plug or oil filters
with bare hands.
z Take into account the amount of oil in the sump. Use a vessel of sufficient size to
ensure that the oil will not overflow.
z Open the coolant circuit only when the engine has cooled down. If opening while
the engine is still warm is unavoidable, comply with the instructions in the
chapter "Maintenance and Care".
z Neither tighten up nor open pipes and hoses (lube oil circuit, coolant circuit and
any additional hydraulic oil circuit) during the operation. The fluids which flow out
can cause injury.
GE08TIC
z Fuel is inflammable. Do not smoke or use naked lights in its vicinity.

z When using compressed air, e.g. for cleaning the radiator, wear goggles.
z Keep service products (anti-freeze) only in containers which can not be confused
with drinks containers.
z Comply with the manufacturer's instructions when handling batteries.
CAUTION:
Accumulator acid is toxic and caustic. Battery gases are explosive.
1.2.5. When carrying out checking, setting and repair work

z Checking, setting and repair work must be carried out by authorized personnel
only.
z Use only tools which are in satisfactory condition. Worn open-end wrench slip,
which could lead to injury.
z When the engine is hanging on a crane, no-one must be allowed to stand or
pass under it. Keep lifting gear in good condition.
z When working on parts which contain asbestos, comply with the notes at the end
of this chapter.
z When working on the electrical system disconnect the battery earth cable first.
Connect it up again last in prevent short circuits.
1.2.6. To prevent damage to engine and premature wear

(1) Never demand more of the engine than it was designed to yield for its intended
purpose.
(2) If faults occur, find the cause immediately and have it eliminated in order to
prevent more serious of damage.
(3) Use only genuine DOOSAN’s spare parts. DOOSAN’s will accept no
responsibility for damage resulting from the installation of other parts which are
supposedly "just as good".
(4) In addition to the above, note the following points.
z Never let the engine run when dry, i.e. without lube oil or coolant.
z Use only DOOSAN’s approved service products (engine oil, anti-freeze and
anticorrosion agent).
z Pay attention to cleanliness. The Natural gas must be free of water. See
"Maintenance and care"
GE08TIC
z Have the engine maintained at the specified intervals.

z Do not switch off the engine immediately when it is warm, but let it run without
load for about 5 minutes so that temperature equalization can take place.
z Never put cold coolant into an overheated engine. See "Maintenance and
care".
z Do not add so much engine oil that the oil level rises above the max. marking
on the dipstick. Do not exceed the maximum permissible tilt of the engine.
Serious damage to the engine may result if these instructions are not adhered
to.
z Always ensure that the testing and monitoring equipment (for battery charge,
oil pressure, coolant temperature) function satisfactorily.
z Comply with instructions for operation of the alternator. See "Commissioning
and operation".
z Do not let the raw water pump run dry, If there is a risk of frost, drain the pump
when the engine is switched off.
1.2.7. To prevent pollution

(1) Engine oil, filter elements, fuel filters
z Take old oil only to an oil collection point.
z Take strict precautions to ensure that oil does not get into the drains or into the
ground. The drinking water supply could be contaminated.
z Filter elements are classed as dangerous waste and must be treated as such.
(2) Coolant
z Treat undiluted anti-corrosion agent and / or antifreeze as dangerous waste.
z When disposing of spent coolant comply with the regulations of the relevant
local authorities.
1.2.8. Notes on safety in handling used engine oil

Prolonged or repeated contact between the skin and any kind of engine oil
decreases the skin.
Drying, irritation or inflammation of the skin may therefore occur. Used engine oil
also contains dangerous substances which have caused skin cancer in animal
experiments. If the basic rules of hygiene and health and safety at work are
observed, health risks are not to the expected as a result of handling used engine oil
Health precautions:
z Avoid prolonged or repeated skin contact with used engine oil.
GE08TIC
z Protect your skin by means of suitable agents (creams etc.) or wear protective
gloves.
z Clean skin which has been in contact with engine oil.
- Wash thoroughly with soap and water, A nailbrush is an effective aid.
- Certain products make it easier to clean your hands.
- Do not use petrol, Diesel fuel, gas oil, thinners or solvents as washing agents.
z After washing apply a fatty skin cream to the skin.
z Change oil-soaked clothing and shoes.
z Do not put oily rags into your pockets.
Ensure that used engine oil is disposed of properly.

- Engine oil can endanger the water supply -
For this reason do not let engine oil get into the ground, waterways, the drains or
the sewers. Violations are punishable.
Collect and dispose of used engine oil carefully. For information on collection points
please contact the seller, the supplier or the local authorities.
GE08TIC
1.2.9. General repair instructions

1. Before performing service operation, disconnect the grounding cable from the
battery for reducing the chance of cable damage and burning due to short-
circuiting.
2. Use covers for preventing the components from damage or pollution.
3. Engine oil and anti-freeze solution must be handled with reasonable care as they
cause paint damage.
4. The use of proper tools and special tools where specified is important to efficient
and reliable service operation.
5. Use genuine DOOSAN’s parts necessarily.
6. Used cotter pins, gaskets, O-rings, oil seals, lock washer and self-lock nuts
should be discarded and new ones should be prepared for installation as normal
function of the parts can not be maintained if these parts are reused.
7. To facilitate proper and smooth reassemble operation, keep disassembled parts
neatly in groups. Keeping fixing bolts and nut separate is very important as they
vary in hardness and design depending on position of installation.
8. Clean the parts before inspection or reassembly. Also clean oil ports, etc. using
compressed air to make certain they are free from restrictions.
9. Lubricate rotating and sliding faces of parts with oil or grease before installation.
10. When necessary, use a sealer on gaskets to prevent leakage.
11. Carefully observe all specifications for bolts and nuts torques.
12. When service operation is completed, make a final check to be sure service has
been done property.
GE08TIC
1.3. General Information
1.3.1. Engine Specifications

Engine model
Items
GE08TI
Water-cooled,
Engine type 4 cycle in-line type
Turbo charged & intercooled(water to air)
Ignition system Spark ignition
Combustion chamber type Stoichiometric, Premixed and spark ignited
Used fuel NG(Natural gas)
Cylinder liner type Replaceable dry liner
Timing gear system Gear driven type
No. of piston ring 2 compression ring, 1 oil ring
No. of cylinder-bore x stroke (mm) 6 - 111 × 139
Total piston displacement (cc) 8,071
Compression ratio 10.5 : 1
Engine dimension (length x width x height) (mm) 1,224 x 760 x 973
Engine weight (kg) 750
Rotating direction (from flywheel) Counter clockwise
Firing order 1–5–3–6–2–4
Fuel ignition timing (B.T.D.C static) 13°
Engine control system Engine speed controller type
Compression pressure (kg/cm2) 16 (at 200 rpm)
Intake and exhaust valve clearance (at cold) (mm) 0.3
Open at 16° (B.T.D.C)
Intake valve
Close at 36° (A.B.D.C)
Open at 46° (B.B.D.C)
Exhaust valve
Close at 14° (A.T.D.C)
Lubrication method Full forced pressure feed type
Oil pump type Gear type driven by crankshaft
Low idle (bar) 0.8 ~ 1.4
Engine oil pressure
High idle (bar) 3.0 ~ 4.8
Oil filter type Full-flow, cartridge type
Lubricating oil capacity (max./min.) (lit) 23/17
Oil cooler type Water cooled
Water pump Impeller type driven by belt
Cooling Method Forced circulation by centrifugal impeller pump
Cooling water capacity (engine only) (lit) 11
Alternator voltage – capacity (V - A) 24 – 120
Starting Motor voltage – output (V - kW) 24 – 4.5
GE08TIC
Items Engine model GE08TI
Carburetor Impco 200 varifuel carburetor

Gas regulator RV61
Fuel system
Max. inlet pressure 1.0 psi at the engine inlet
Shut-off valve Solenoid valve (24VDC)
Spark plug Woo jin 0.38 ~ 0.40mm air gap
Ignition controller Altronic CD-1 or CD-200 unit
Ignition system
Ignition coil One coil per cylinder
Trigger system Magnetic pick-up sensor and trigger wheel
Model HX35G
Turbocharger Type Water cooled, Exhaust gas driven
Exhaust temperature Max : 720℃
1.3.2. Engine Power

Production tolerance : ±5%
Performance
Engine model
Stand by Prime Continuous
50Hz 141 kW 128 kW 115 kW

(1,500 rpm) (192 PS) (174 PS) (156 PS)
GE08TIC
60Hz 165 kW 150 kW 135 kW
(1,800 rpm) (224 PS) (204 PS) (184 PS)
Note : All data are based on operation without cooling fan at ISO 3046.
GE08TIC
1.4. Engine Assembly

1.4.1. Engine sectional view (longitudinal)
3 4 5 6 7 8
10
2
11
1 12
16 13
14
15
17
18 19 20 21 22
1 Cooling water pump 12 Push rod

2 Piston 13 Tappet
3 Exhaust valve 14 Cam shaft
4 Intake valve 15 Oil seal(rear)
5 Ignition coil 16 Oil seal(front)
6 Intake valve spring 17 Crank gear
7 Breather 18 Vibration damper
8 Exhaust valve spring 19 Oil pump
9 Cylinder head cover 20 Oil suction pipe
10 Cylinder head 21 Oil pan
11 Cylinder block 22 Crank shaft
GE08TIC
1.4.2. Engine sectional view (cross)
5 7
10
1 Oil spray nozzle 6 Spark plug

2 Connecting rod 7 Rocker arm
3 Oil drain pump 8 Rocker arm bracket
4 Gas regulator 9 Exhaust manifold
5 Throttle valve 10 Oil cooler
GE08TIC
1.4.3. Engine assembly views
2 3 13
1
14
12
4
11
5 6 7 8 9 10
17 18 19 20 23 24 25
16
22
26
15
21
1 Lifting hook 14 Water inlet(for Intercooler)

2 Ignition coil 15 Flywheel housing
3 Exhaust manifold 16 Water outlet(for Intercooler)
4 Oil drain pump 17 Inter cooler
5 Vibration damper 18 Throttle valve ass`y
6 Oil filter 19 Gas regulator
7 Oil cooler 20 Intake manifold
8 Oil pan 21 Speed controller
9 Oil level gauge 22 Cooling water pump
10 Starter 23 Breather
11 Mounting bracket 24 Water outlet(by Water pump)
12 Water inlet(by Water pump) 25 Exhaust elbow
13 Fuel mixer 26 Alternator
GE08TIC
2. Technical Information
2.1. Engine model and serial number

z The engine model and serial
number is located on the engine as
illustrated.
z These numbers are required when
requesting warranty and ordering
parts. They are also referred to as Engine serial
number
engine model and serial number
because of their location.
z Engine serial No. (GE08TIC)

EEPOD 5 00001
Serial no.
Production year (2005)
Engine model
2.2. Engine Characteristic

The DOOSAN’s GE08TIC natural gas engine is an overhead valve, turbo charged,
air-to-water charge cooled, electronically controlled engine.
2.2.1. Natural gas

z Spark-ignited by the spark plug.
z Turbocharger with a water cooled bearing-housing.
13 Technical Information
GE08TIC
2.2.2. Natural gas

z Natural gas is a clean burning fuel, and offers a low particulate emission. Natural
gas is also a very economical fuel.
z From the gas producing areas in the country, the distribution companies and local
utilities from a complex nation-wide-delivery-network that supplies natural gas for
home and industry use. The network is highly developed and extended to all
major population center in the country.
2.2.3. Engine ignition system

z This system changes the general combustion concept of the diesel engine.
Specifically, it changes a compression-ignition diesel to a spark-ignited engine.
However, this engine is unlike the typical generator engine that has spark plugs.
z The primary difference is this system uses a combustion concept. That is, excess
air is mixed in with the combustion system. When combined with a gaseous fuel
like natural gas, it allows greatly reduced emissions compared to diesel, plus high
efficiencies and excellent high-performance.
z The GE08TIC engine is an integrated package featuring computer-controlled
electronic engine system by the engine speed controller. This system controls
fuel, ignition and speed, and has engine protection features.
GE08TIC
2.2.4. Engine speed controller : ESC

z The Engine Speed Control is
designed to provide basic
isochronous speed control for gas
engines using the Flo-Tech Throttle.
Speed controller
z Engines with mechanical loads and
generator loads are handled
equally well.
2.2.5. Ignition control module : ICM

z This digital ignition system has
been designed for application on
nature gas fueled engines.
z This system is offers a variety of
advanced control, emissions
reduction, primary and spark
diagnostics, self diagnostic serial
communications and engine
protection features.
2.2.6. Cylinder block

z The cylinder block is a single piece of alloy cast iron. To increase its stiffness, it is
extended to a level below the crankshaft center line. The engine has replaceable
dry cylinder liners and individual cylinder heads with struck-in valve seat rings
and replaceable valve guides,
2.2.7. Piston, con-rod and crankshaft

z The forged crankshaft is an ingrate type (Counterweight is integrated with crank
shaft body). Radial oil seal on crankshaft and flywheel are provided to seal the
flywheel housing inside penetrations.
z The con-rods (connecting rods) are die-forged, diagonally split and can be
removed through the top of the cylinders together with the pistons. Crankshaft
and connecting rods run in steel-backed lead bronze ready to fit type bearings.
GE08TIC
2.2.8. Engine timing

z Camshaft, oil pump and ignition timing sensor gear are driven by a gear train
arranged at the front end.
2.2.9. Valves
z The overhead valves are actuated via chilled cast iron tappets, push rods and
rocker arms from the camshaft.
GE08TIC
2.2.10. Lubrication system

z The engine is equipped with force-feed lubrication.
The pressure is produced by a gear pump whose drive gear is in direct mesh with
the crankshaft gear at the front end of cylinder block.
z The oil pump draws the oil from the oil sump and delivers it through the oil cooler
and oil filter to the main distributor gallery and from there to the main bearings,
big-end bearings and camshaft bearings as well as to the small-end bearings and
the rocker arms.
z The turbocharger is also connected to the engine lubricating system.
The cylinder walls and timing gears are splash-lubricated.
z Each cylinder has an oil jet provided for cooling the underside of the pistons.
z The lube oil is cleaned in a full-flow oil filter.
2.2.11. Engine oil

z Check oil level with the oil level gauge and replenish if necessary.
z Check the oil level with the engine cooled. If the engine is warm, allow time for 5 ∼
10 minutes for oil drain into the crankcase before checking oil level. The oil level
must be between Max. and Min. lines on the gauge.
z Engine oil should be changed at the specified intervals.
Oil in the oil filter cartridge should be changed simultaneously.
z The oil viscosity grades should be selected SAE NO.15W40 and API CD or CE.
First oil change After 50hr operation
Engine model GE08TIC every 200hr
GE08TIC
z The following oils are also recommended

SAE No. API No. Sulfated ash content
15W40 above CD or CE Bellow 0.5 %

Recommend oil : TOTAL LMG-405
Mobil Delvac super GEO 15W40
z Engine oil capacity

Engine oil capacity
in Oil pan
Total
Engine model Max. Min.
(lit)
(lit) (lit)
GE08TIC 23 17 25
Engine oil viscosity – ambient temperature
Ambient
temperature
GE08TIC
2.2.12. Exchanging of lubrication oil

z Engine oil and the oil filter are
important factors affecting engine
life. They affect ease of starting,
fuel economy, combustion
chamber deposits and engine wear.
z While the oil is still hot, discharge
Engine oil
drain pump
the sump oil by motion oil drain
pump lever manually as figure.
z Refill new engine oil to the filler

Oil filler cap
neck on the head cover in
Cylinder head
cover
accordance with the oil capacity of
the engine. Be careful about the
mixing of dust or contaminator
during the supplement of oil. Then
confirm whether the oil level gauge
indicates the vicinity of its
maximum level.
z For a few minutes, operate the engine at idling in order to circulate oil through
lubrication system. Thereafter shut down the engine. After waiting for about 10
minutes measure the quantity of oil and refill the additional oil if necessary.
2.2.13. Oil cooler & oil filter

z An oil cooler is provided between
the oil filter and the cylinder block. Oil filter Oil cooler
z This cooler is a flat tube type with
turbulence inserts and operated by
the coolant.
z Check for oil pressure and oil leaks,
and repair or replace the oil filter if
necessary.
z Change the oil filter cartridge
simultaneously at every
replacement of engine oil.
GE08TIC
2.2.14. Cooling system

z The engine has a liquid-cooling system. The fresh water pump is a maintenance-
free by belt from the crankshaft pulley.
z Depending on the agreed extent of delivery and the design of the engine, the
coolant circuit can be equipped with temperature monitors which, in the event of
loss of coolant, shut the engine down.
2.2.15. Cooling water

z Regarding the cooling water that is to be used for engine, the soft water not the
hard water must be used.
z The engine cooling water can be used diluting it with antifreezing solution 40%
and the additive for rust prevention (DCA4) 3 ～ 5 %.
z The density of above solution and additive must be inspected every 500 hours to
maintain it properly.
NOTE:
The proper density control of antifreezing solution and rust preventing
additive will be able to prevent the rusting effectively and maintain the stable
quality of engine.
For the improper control might give the fatal damage to the cooling water
pump and cylinder liners, detail care is needed.
z Since GE08TIC cylinder liner is dry type, particularly the cooling water control
should be applied thoroughly.
GE08TIC
z The density of antifreezing solution and additive for rust prevention is able to be
confirmed by the cooling water test kit.
(Fleetguard CC2602M or DOOSAN’s 65.99901-0038)
z How to use the cooling water test kit
(1) When the cooling water temp. of engine is in the range of 10 ～ 55 °C,
loosen the plug for cooling water discharge and fill the plastic cup about a half.
NOTE:
In taking the cooling water sample, if the water in auxiliary tank were taken, it
is hard to measure the accurate density. Take the cooling water sample
necessarily loosening the cooling water discharge plug.
(2) At the state of a test paper soaked in the sampled water, after taking the paper
out through water agitation, shake off the water.
(3) Wait for about 45 sec. till the color change of test paper.
NOTE:
However, it should not elapse longer than 75 sec, and if it did, the hue would
change.
(4) Make the numerical value by comparing the test paper which hue has
changed with the color list of label on storage bottle.
(5) By comparing the hue changed into yellowish green or so with the green color
indication of test paper storage bottle, confirm the density. (Then, the density
indication must be in the hue range of 33% to 50%).
(6) The brown at the middle of test paper and the lower pink color indication
represent the additive state for rust prevention, and the proper range is that
the meeting numerical value of brown (vertical) and pink color (horizontal)
locates in the range of 0.3 to 0.8 at the color list of label on the test paper
storage bottle.
(7) In case of less than 0.3, replenish the additive for rust prevention (DCA4), and
in case of more than 0.8, pour out the cooling water about 50% and then
readjust the density after refilling with clean fresh water.
z Amount of Anti-freeze in winter

Ambient
Cooling water (%) Anti-freeze (%)
Temperature (°C)
Over -10 85 15
-10 80 20
-15 73 27
-20 67 33
-25 60 40
-30 56 44
-40 50 50
GE08TIC
2.2.16. V - belt
z Use a fan belt of specified
dimensions, and replace if
damaged, frayed, or deteriorated.
z Check the fan belt for belt tension.
z If belt tension is lower than the
specified limit, adjust the tension
by relocating the alternator.
(specified deflection: 10 ∼ 15 mm
when pressed down with thumb)
2.2.17. Air cleaner

z In case that elements are
deformed, damaged or if the air
cleaner has a crack, replace it.
z By the definite interval, the
elements must be cleaned and
replaced.
2.2.18. Intercooler
z The intercooler is air to water type.
Throttle valve
The intercooler life and
performance depends on the intake
air condition greatly. Fouled air
pollutes and clogs the air fins of Intake manifold
intercooler. As a result of this, the

Inter cooler
engine output is decreased and
engine malfunction is occurred.

z So you always check whether the
intake air systems like air filter
element are worn or polluted.
GE08TIC
2.2.19. Valve clearance adjust procedure

z After letting the #1 cylinder's piston come at the compression top dead center
by turning the crankshaft, adjust the valve clearances.
z Loosen the lock nuts of rocker arm adjusting screws and push the feeler gauge
of specified value between a rocker arm and a valve stem and adjust the
clearance with adjusting screw respectively and then tighten with the lock nut.
z As for the valve clearance, adjust it when in cold, as follow.
Model Intake Valve Exhaust Valve

GE08TIC 0.3 mm 0.3 mm
z Adjusting Sequence of Valve Clearance (1 Type)

- By cranking the engine, let #6 cylinder's valves overlap.
- In time, adjust the valve clearance corresponding to “ ” of lower lists.
- Adjust the valve clearance corresponding to “ ” of lower lists.
- After reinsuring the valve clearances, retighten if necessary.
z No. 1 Cylinder is located at the side where flywheel was installed.
Crankshaft pulley Intake valve Exhaust valve Cylinder no. Fly wheel

1 Type is the conventional and simple method, but if you have some problem to
adjust your engine, please try 2 type sequence. This is a precision method, but it
takes more times.
Valve overlapping on cylinder

1 5 3 6 2 4
(Intake & Exhaust valve)
Adjusting valves on cylinder
6 2 4 1 5 3
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2.2.20. Spark plug

z Remove spark plug. Clean threads
by hand with brush and solvent.
z Clean any deposits from electrode
and Inspect insulator area
z Measure the spark plug distance at
electrode position.(A)
z Replace spark plug if necessary.
Standard
Distance (A) 0.39~0.40mm
z Install spark plug
Torque 2.6~3.0 kg.m
Eroded
New plug electrode
Electrode surfaces Flashover on

not parallel insulator
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2.2.21. Cylinder compression pressure

z Stop the engine after warming up,
and take out spark plug.
z Install the special tool (compression

gauge adapter) at the spark plug
hole and connect the compression
pressure gauge there.
Standard value 16kg/cm2 over

Limit value 13kg/cm2
Difference
Within ± 10 %
between each cylinder
♦ Condition : Water temperature 20°C,
Engine rotation 200rpm
2.2.22. Battery
z Inspect for any leakage of electrolytic solution owing to battery crack, and replace
the battery in case of poor condition.
z Inspect for amount of electrolytic solution, and replenish if insufficient.
z Measure the gravity of electrolytic solution, if less than specified value (1.12 ～
1.28), replenish.
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2.2.23. Turbocharger
z The exhaust gases of the engine are
passed through the turbine rotor of
the turbocharger. Air compressor
impeller mounted on the same shaft
draws in fresh air and delivers it at a
higher pressure to the cylinders.
z The turbocharger is naturally air-
cooled. Lubrication of the main
bearing is by oil under pressure
from the engine lubricating system.
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2.2.24. Alternator
z Alternator (24Vx45A)
The alternator is fitted with integral silicon rectifiers. A transistorized regulator
mounted on the alternator body interior limits the alternator voltage. The alternator
should not be operated except with the regulator and battery connected in circuit to
avoid damage to the rectifier and regulator.
24V × 45A
The alternator is maintenance-free, nevertheless, it must be protected against dust

and, above all, against moisture and water.
Wiring Diagram
Operate the alternator according to the instructions given in the chapter.
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2.2.25. Starting motor

The sliding-gear starter motor is flanged to the rear of the flywheel housing on the left-
hand side. As parts of every engine overhaul, the starter pinion and ring gear should
be cleaned with a brush dipped in fuel and then a coat of grease should be applied
again.
24Vx4.5kW
Always protect starter motor against moisture.
Key switch
Wiring harness
Magnetic switch
Battery
Starting motor
WARNING:
Always disconnect the battery earth cable before starting work on the
electrical system. Connect up the earth cable last, as there is otherwise a risk
of short-circuits.
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2.3. Diagnosis and Remedy

z The following description summarizes the probable cause of and remedy for
general failure by item.
z Immediate countermeasures should be taken before a failure is inflamed if any
symptom is detected.
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Condition Causes Remedies

1) Starting difficult
(1) Compression pressure z Valve's poor shut, stem Repair or replace
distortion
z Valve spring damage Replace valve spring
z Cylinder head gasket's leak Replace gasket
z Wear of piston, piston ring Adjust
or liner
2) Idle operation abnormal z Ignition timing incorrect Adjust
3) Engine output insufficient
(1) Continuous output z Valve clearance incorrect Adjust
insufficient
z Valve tightness poor Repair
z Cylinder head gasket's leak Replace gasket
z Wear, stick, damage of Replace piston ring
piston ring
z Ignition timing incorrect Adjust
z Damage of spark plug & Adjust or replace
ignition coil
z Air suction amount Clean or replace air
insufficient cleaner
z Turbocharger poor Repair or replace
(2) Output insufficient z Compression pressure Disassemble engine
when in acceleration insufficient
z Ignition timing incorrect Adjust
z Damage of spark plug & Repair or replace
ignition coil
z Air intake amount Clean or
insufficient replace air cleaner
4) Overheating
z Engine oil insufficient or Replenish or replace
poor
z Cooling water insufficient Replenish or replace
z Fan belt loosened, worn, Adjust or replace
damaged
z Cooling water pump's Repair or replace
function lowered
z Water temperature Replace
regulator's operation poor
z Valve clearance incorrect Adjust
z Exhaust system's resistance Clean or replace
increased
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5) Engine noisy
For noises arise compositely
such as rotating parts, lapping
parts etc., there is necessity to
search the cause of noises
accurately.
(1) Crankshaft z As the wear of bearing or Replace bearing &
crankshaft progress, the oil grind crankshaft
clearances increase.
z Lopsided wear of crankshaft Grind or replace
z Oil supply insufficient due to Clean oil passage
oil passage clogging
z Stuck bearing Replace bearing &
Grind
(2) Connecting rod and z Lopsided wear of con rod Replace bearing
Connecting rod bearing bearing
z Lopsided wear of crank pin Grind crankshaft
z Connecting rod distortion Repair or replace
z Stuck bearing Replace &
grind crankshaft
z Oil supply insufficiency as Clean oil passage
clogging at oil passage
progresses
(3) Piston, piston pin & z Piston clearance increase Replace piston &
piston ring as the wear of piston and piston ring
piston ring progresses
z Wear of piston or piston pin Replace
z Piston stuck Replace piston
z Piston insertion poor Replace piston
z Piston ring damaged Replace piston
(4) Others z Wear of crankshaft, thrust Replace thrust bearing
bearing
z Camshaft end play Replace thrust plate
increased
z Idle gear end play increased Replace thrust washer
z Timing gear backlash Repair or replace
excessive
z Valve clearance excessive Adjust valve clearance
z Abnormal wear of tappet, Replace tappet, cam
cam
z Turbocharger inner part Repair or replace
damaged
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6) Oil Consumption
Excessive
(1) Oil level elevated z Clearance between cylinder Replace
liner & piston
z Wear of piston ring, ring Replace piston,
groove piston ring
z Piston ring's damage, stick, Replace piston ring
wear
z Piston ring opening's Correct position
disposition improper
z Piston skirt part damaged or Replace piston
abnormal wear
z Oil ring's oil return hole Replace piston ring
clogged
z Oil ring's contact poor Replace piston ring
(2) Oil level lowered z Looseness of valve stem & Replace in set
guide
z Wear of valve stem seal Replace seal
z Cylinder head gasket’s leak Replace gasket
(3) Oil leak z Looseness of connection Replace gasket, repair
parts
z Various parts' packing poor Replace packing
z Oil seal poor Replace oil seal
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2.4. Engine inspection

2.4.1. Stopping engine
z Cut off the main circuit breaker of the generator control panel. After checking the
engine for any unusual condition at the idling speed, then press the stop button to
stop the engine.
2.4.2. General engine inspection cycle
z In order to insure maximum, trouble-free engine performance at all times, regular
inspection, adjustment and maintenance are vital.
- Daily inspections in below figure should be checked every day.
- The following maintenance details should be executed thoroughly at regular
internals.
О : Check & adjust ● : Replace
Every Every Every Every Every
Inspection Item Daily
50hrs 200hrs 500hrs 1500hrs 3000hrs
Remark
Check for leakage(hoses, clamp) О

Cooling Check the water level О
System Adjust the V-belt tension О
Change the coolant water ● 1 year
Check for leakage О
Check the oil level gauge О
Lubrication ●
Change the lubricating oil ● Every 200hr
System 1st
●
Replace the oil filter cartridge ● Every 200hr
1st
Check the leakage for intercooler
О ●
(hoses, clamp)
Intake &
Exhaust Check the air cleaner indicator О
О
System Clean the air cleaner element and/or repair ●
Clean
Clean the exhaust system О
Check the leakage fuel line О
Check the fuel mixer О 1 year
Fuel
Check the throttle body О 1 year
System
Check the speed controller О 1 year
Check the gas pressure regulator О 1 year
When
Check the state of ignition timing necessary
Ignition Check the spark plug ● ●
system Check the ignition cable ● 1 year
Check the ignition coil О 1 year
Check the sensors(ignition or timing) О
Check the state of exhaust gas О
When
Check the exhaust gas pressure necessary
Engine Check the battery charging О
Adjust Check the compression pressure
When
necessary
Adjust Intake/Exhaust When
О necessary
valve clearance
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2.4.3. Use of original parts for repair and replacement

z For engine is being mechanically harmonized with many parts, only when the
original parts that the manufacture recommends to use is used, the engine trouble
would be preventively maintained and capable to keep up the maximum
performances.
z For the analogous parts not the original parts are poor in qualities and gives ill
performances, it may rather bring early engine failure
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3. MAINTENANCE
3.1. Engine Disassembly
3.1.1. Heed at disassembly

z Before disassembly, the part shelf should be prepared for various tools and repair
parts.
z When assembling, clean empty hand should be used and clean environment
maintained.
z In case of storing the disassembled parts, each part should not touch each other.
z In case of disassembly, the parts should be laid in order.
3.1.2. Oil level gauge

z Pull out the oil level gauge.
3.1.3. Cooling water

z Remove the drain plug from the
cylinder block and drain out the
cooling water into a container.
Drain valve
3.1.4. Engine oil

z Turn the valve opening and then
move the oil drain pump lever as
figure by hand, and let engine oil
discharge into the prepared vessel
Engine oil
drain pump
41 Engine disassembly
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3.1.5. Engine speed controller: ESC

z Disconnect the harness and the
various sensors. Engine speed
controller(ESC)
3.1.6. Ignition control module (ICM)

z Disconnect the harness and the
Ignition control
various sensors. module
z Loosen the fixing bolt, then
disassemble the ignition control
module(ICM).
3.1.7. Ignition coil & gas pressure regulator

z Remove the high voltage cables by
Gas pressure
hand from each cylinder head. regulator
z Remove the gas pressure regulator

fixing bolts and then tear down the
gas pressure regulator and other High voltage cable Ignition coil
parts. Harness
3.1.8. Fuel mixer

z Remove the air cleaner from fuel
Fuel mixer
mixer.
z Remove the fuel mixer and air pipe
from the turbo charger.
Turbo charger
Gas pressure
regulator
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3.1.9. Turbo charger

z Remove the oil supply pipe and oil
Oil pipe Turbo charger
return pipe between the turbo
Water
charger and the cylinder block. hose(inlet)
z Unclamp the rubber hose
connected the intercooler and air Water
hose(outlet)
pipe.
z Unscrew the turbo charger fixing
nuts and take off the turbo charger Exhaust elbow
from the exhaust manifold
3.1.10. Intercooler
z Tear down the various hoses and
air pipes from the inter cooler.
z Remove the intercooler fixing bolts
and tear it down.
Throttle valve
Inter Intake manifold

cooler
3.1.11. Belt
z Loosen the tension adjusting bolts
of the alternator and take off the
belts.
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3.1.12. Starter
z Unscrew the starter fixing nuts and
remove the starter being careful not
to damage its gears.
3.1.13. Breather
z Unscrew the hose clamp fixing
bolts and remove the breather hose.
3.1.14. Alternator
z Remove the alternator fixing bolts
and take off the alternator.
3.1.15. Oil cooler & oil filter

z Loosen the cooling water pump
and the rubber hose clamps of Oil filter
cartridge Oil cooler
connected pipes, and disassemble
it.
z Remove the oil cooler fixing bolts
and take off the oil cooler and oil
filter cartridge.
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Oil cooler housing
Oil cooler element

Water drain valve
3.1.16. Water pump

z Unclamp the rubber hose connected
to the oil cooler.
z Unscrew the water pump fixing bolts
from the cylinder block and take off
the water pump.
3.1.17. Cylinder head cover

z Remove the head cover fixing bolts
and lift the cylinder head cover.
3.1.18. Exhaust manifold

z Unscrew the exhaust manifold
fixing bolts.
z Then disassemble the exhaust
manifold and gasket.
z Scrap the used gasket.
CAUTION:
Be careful to remove the exhaust
manifold. It is very heavy.
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3.1.19. Intake manifold

z Unscrew the intake manifold fixing
bolts and remove the intake
manifold from the cylinder head.
z Disassemble the intake manifold
gasket and discard it.
3.1.20. Cooling water pipe

z Unscrew the cooling water pipe
fixing bolts and remove the cooling
water pipe from the cylinder head.
z Remove the cooling water pipe
gasket and finish the surface with a
scraper.
CAUTION:
Be sure that piece of the gasket do
not come into the cooling water
passage.
3.1.21. Spark plug

z Loosen the high pressure cable
then remove the ignition coil. High pressure cable
z Remove the spark plug using
socket tool.
Spark plug
Spark plug Hex. Head : 16mm
Socket tool (5/8 inch)
3.1.22. Rocker arm

z Remove the rocker arm bracket
fixing bolts in reverse order (zigzag
method) of assembling and
disassemble the rocker arm.
z Take out the push rod upwards.
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z Disassembly of rocker arm

assembly
- Remove the snap ring from the
both ends of rocker arm shaft by
means of a plier.
- Remove the washer, rocker arm,
bracket and spring from the rocker
arm shaft in sequence.
- Press out the rocker arm bush.
Rocker arm shaft

CAUTION :
When reassembling the bush, cool Rocker arm
the bush in dry ice and press the

bush while aligning the bush with
the oil hole of the rocker arm.
3.1.23. Cylinder head

z Remove the cylinder head bolts in
the reverse order of tightening but
remove it step by step.
- First step : Loosen 1 ～2 threads

- Second step : Remove by loosening
fully.
z However, remove the total bolts

simultaneously by the step of 1 and 2.
z Lay the removed bolts orderly not
to damage the threads at all and
store.
CAUTION:
Prevent a collision between the bolt thread each other.
z Take out the cylinder head gasket and scrap it.

z Remove the foreign residues from the cylinder head surface and block surface.
CAUTION:
Try not to make any damage on the contact surfaces.
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z Disassembly of cylinder head

- Place the cylinder head on a
individual shelf.
- As pressing the valve spring with a
special tool, remove the cotter
pin, valve spring.
- Take out the intake and exhaust
valves.
- For removal of the valve seat,

apply arc welding work to two
points of valve seat insert, and pull
out the valve seat insert with inner
extractor.
3.1.24. Oil pan

z Unscrew the oil pan fixing bolts and
remove the oil pan.
z Remove the oil pan gasket and
discard it.
3.1.25. Vibration damper

z Unscrew the vibration damper
fixing bolts in reverse sequence of
installing sequence and remove the
vibration damper assembly.
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3.1.26. Timing gear case cover

z Disassemble the oil seal using an
oil seal removing jig.
z Remove the cover fixing bolts and
disassemble the cover from the
timing gear case.
3.1.27. Oil pump

z Unscrew the bracket fixing bolts of
the oil suction pipe.
z Unscrew the pipe fixing bolts of oil
pump and disassemble the suction
and supply oil pipe.
z Unscrew the oil pump fixing bolts,
and disassemble the oil pump.
3.1.28. Piston and connecting rod

z Remove the connecting rod cap
bolts in the reverse order of
assembling but do same as the
cylinder head bolt removal.
z Disassemble the upper/lower of
connecting rod caps by tapping
lightly with urethane hammer, and
remove the bearing.
z By pushing the connecting rod with
wooden bar from the direction of oil
pan toward cylinder head,
disassemble the piston assembly.
z The disassembled piston assembly
should be handled to prevent
bumping each other, and stored as
the cylinder's order.
z In order for connecting rod cap not
to be swapped, temporarily
assemble to the corresponding
connecting rod.
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<Disassembly of piston>
(1) Remove the snap rings by
means of a plier.
(2) Heat the piston with an electric

heater, then take out the piston
pin from the piston as tapping it
with a round wooden bar.
(3) Remove the piston ring with a

plier.
(4) Clean the piston thoroughly.
3.1.29. Cylinder liner

z Disassemble the cylinder liner with
a special tool or hand but be careful
not to generate any damage at
cylinder block.
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3.1.30. Cam shaft gear and idle gear

z Unscrew the camshaft gear fixing
bolts and remove the camshaft gear.
z Unscrew two bolts fixing the idle

gear, then remove the idle gear and
its pin.
3.1.31. Water chamber cover

z Unscrew the fixing bolts and remove
the water chamber cover.
z Remove the remnant gasket
thoroughly.
3.1.32. Fly wheel

z Remove the flywheel fixing bolts and
disassemble it.
z The bolt removal is done by the
reverse order of assembling and by
the steps.
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3.1.33. Fly wheel housing

z Remove the flywheel housing fixing Stopper ring
bolts and disassemble the flywheel
housing.
z Disassemble the oil seal of
flywheel housing.
Ignition timing
check hole Oil seal
3.1.34. Trigger wheel & timing sensor

z Loosen the magnetic pick-up
Magnet pick-up
sensor fixing nut and remove the sensor
magnetic pick-up sensor. Trigger wheel

z Remove the fixing bolts and
Timing drive
disassemble the trigger wheel gear coupling
cover and trigger wheel.
Trigger wheel cover
3.1.35. Timing drive gear

z Unscrew the drive gear housing
fixing bolts and remove the drive
gear assembly.
3.1.36. Timing gear case

z Remove the timing gear case
assembling bolts.
z By tapping lightly with a urethane
hammer the right and left back of
timing gear case's connecting part,
disassemble the timing gear case.
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3.1.37. Bearing cap

z Remove the bearing cap
assembling bolts by the step in the
reverse order of assembling, and
disassemble the bearing cap.
(Remove by the same way as the
cylinder head bolts' removal.)
z Disassembled bearing caps are
kept laid in order.
3.1.38. Camshaft and tappet

z In order for camshaft not to be
damaged, disassemble turning it.
z In order for the disassembled
camshaft to be prevented from
bends or damage, put it on the
special lathe and store.
z Pull out the tappet.
z As required, pull out the camshaft
bush from the cylinder block by a
press.
z Check for damage, scratch,
wearing state and if abnormal, tear
down.
3.1.39. Oil spray nozzle

z Remove the valve screws of oil
spray nozzle and disassemble it.
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3.2. Inspection and Measurement on Major Parts

z Clean the cylinder block thoroughly, and check for any crack or damage.
z If there is any crack or severe damage, replace it and if there is minor one, correct
it.
z Check for any clogging or corrosion in the oil passage and water passage.
z Carry out a leakage test for any crack or air leaking. (Hydraulic test)
z Plug each cylinder block's water and oil discharge ports, and apply the air
pressure of about 4kg/cm2 to intake port and soak it in water for about 1 minute to
check if there is any leakage. (Water temperature : 70°C)

(1) Cylinder head assembly & disassembly
1) Disassemble the cylinder
assembly, and put it on the shelf
for assembly or clean lathe.
CAUTION :
Prevent any damage to gasket's
contact surface of the cylinder
head.
2) Disassemble the cotter pin, spring,

spring seat pushing valve spring
by a special tool.
3) Pull out the intake and exhaust
valves.
4) The disassembled parts are kept
laid in turn.
5) Disassemble the valve stem seal.
(2) Inspection of cylinder head

1) Check for the cylinder head.
z Remove carbon from the
cylinder head lower surface, and
then should be careful not to
scratch the surface.
z Check any crack or damage that
can not found by naked eyes
through the hydraulic or
magnetic particle test.
54 Inspection
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2) Distortion of lower surface

z As shown in figure, measure the
cylinder head's distortion at 6
directions with horizontal ruler
and clearance gauge.
z If the measured value is beyond
the limit value, correct it by
means of the fine grinding paper
or grinding machine.
z If it is beyond the max.
allowable value, replace the
cylinder head
< Lower face warpage and height >
Standard Limit
Warpage 0.2 mm or less 0.3 mm
Thickness : t
109.9 ∼ 110.1 mm 108.4 mm
(reference)
3) Flatness
z Check the flatness of the
installing surface of cylinder
head's intake and exhaust
manifolds with horizontal ruler
and clearance gauge.
Standard Limit
0.05 mm 0.2 mm
4) The hydraulic test

z The hydraulic test of cylinder
head is same as the cylinder
block test.
55 Inspection
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3.2.3. Spark plug

z Remove spark plug. Clean threads by
hand with brush and solvent.
z Clean any deposits from electrode
and inspect insulator area
z Measure the spark plug distance at
electrode position.(A)
z Correct or replace the spark plug if
necessary. A
Standard(A) 0.39~0.40mm
z Insert the spark plug into cylinder

Cylinder head
head and measure distance(B)
Spark plug torque 2.5~3.0kg.m Spark plug
Standard (B) 3.38 ~ 3.76mm

“B”
3.2.4. Valve and valve guide

1) Valve
z After cleaning valve with fuel, check it.
z Valve stem outer diameter

Measure the valve stem outer
diameter at 3 positions (top, middle,
and bottom), and check for any
wear and if beyond the limit value,
replace the valve.
Dimension
Standard Limit
Description
Intake valve stem φ8.950 ∼ φ8.970 mm φ8.93 mm
Exhaust valve stem φ8.935 ∼ φ8.955 mm φ8.91 mm
z Valve seat contacting faces

Check the valve seat contact
surface for any crack and wear, and
if necessary, correct with grinding
paper, and if excessive, replace it.
56 Inspection
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z Valve head thickness

Measure the thickness of valve
head and if beyond the limit value,
replace the valve
Dimension
Standard Limit
Description
Intake valve 2.7 mm 1 mm or less
Exhaust valve 2.2 mm 1 mm or less
2) Valve guide
z Insert a valve into cylinder head
and measure the clearance
between valve guide and valve by
valve movement. If the clearance is
excessive, measure the valve and
replace the excessively worn valve
or valve guide.
z Valve stem end play
Standard Limit
Intake valve 0.04 ∼ 0.07 mm 0.2 mm
Exhaust valve 0.06 ∼ 0.09 mm 0.25 mm
z Assemble the valve at cylinder

head's valve guide and see if it is
centered with the valve seat using a
special tool.
3) Valve seat
z Contacting face amount
As for the valve seat's wear,
measure the width of the contact
surface with intake valve seat and
exhaust valve seat. If beyond the
limit value, replace the valve seat.
z Assemble the valve at the valve

seat of the cylinder head, and
check the amount of depression of
the valve from the lower portion of
the cylinder head using a dial
gauge.
57 Inspection
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z Valve depression
If the amount of depression is
beyond the specified limit, replace
the valve seat.
Standard Limit
Intake &
0 ∼ 0.3 mm 0.55 mm
Exhaust
z For the disassembling of valve seat,

by welding the welding bead to a
valve seat rotating tool or valve
seat, pull it out with a special tool.
z For the assembling of a new valve
seat, by putting it among the dry
ices of an ice box previously for
about 2 hours for the cold
shrinkage, and press it in the
cylinder head by a special tool.
(bench press)
z It is necessary to work boring of inner diameter of it when replace the valve seat
and valve guide.
z Apply valve lapping compound to the valve head seating face on the valve seat
and lap the valve seat by turning it until it is seated in position, then wipe out the
lapping compound.
4) Valve spring
z Visual check
Check the appearance of valve
spring and if necessary replace the
spring.
z Valve spring free length
Use a vernier caliper to measure
the valve spring free length.
If the measured value is less than
the specified limit, the valve spring
must be replaced.
Spring free Length Standard
Intake valve 64 mm
Exhaust Inner 60mm

valve Outer 71mm
58 Inspection
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z Valve spring inclination

Use a surface plate and a square
to measure the valve spring
inclination.
If the measured value exceeds the
specified limit, the valve spring
must be replaced.
Standard Limit
Valve spring
Less than 1.5mm 2.7 mm
Inclination
z Valve spring tension

Use a spring tester to measure the
valve spring tension if the
measured value is less than the
specified limit, the valve spring
must be replaced.
Spring
Set Length Limit
Force
Intake Valve spring
Valve tension at 41mm 70 kg ± 3kg
set length
Exhaust Inner 38 mm 28.6 kg ±6%
valve
Outer 41 mm 66 kg ±5%
5) Assembling cylinder head

z Clean the cylinder head thoroughly.
z Replace the valve stem seal with
new one, and by means of a
special tool, press the stem seal
into the valve guide of cylinder
head.
z Coat engine oil to valve stem and
valve guide and assemble the
valve. However, be careful for the
damage of valve stem seal.
z Install the lower seat of valve spring to the valve guide of cylinder head.
z After putting inner, outer springs, install the spring upper seat on it.
z Assemble the valve by inserting the valve cotter pressing the valve spring with
special tool.
z After installing the valve, check whether the valve is correctly installed or not
tapping it lightly with urethane hammer.
59 Inspection
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3.2.5. Rocker arm assembly
(1) Disassembly
z Disassemble the snap rings that
are located at both ends of rocker
arm shaft by a plier.
z Disassemble in the order of
washer, rocker arm bracket, rocker
arm spring, rocker arm.
(2) Inspection of rocker arm assembly

1) Rocker arm shaft
z Rocker arm shaft run-out
Place the rocker arm shaft on
two V blocks and inspect the
shaft for bend using a dial gauge.
If the amount of this run-out is
small, press the shaft with a
bench press to correct the run-
out.
Replace the shaft if the
measured value exceeds the
limit.
Limit 0.2 mm
z Rocker arm shaft diameter

With an outside micrometer,
measure the rocker arm shaft
diameter at the point where the
rocker arms have been installed.
Replace the rocker arm if the
amount of wear is beyond the
specified limit.
Standard Limit
φ23.939 ∼ φ23.960 mm φ23.75 mm
2) Rocker arm
z Visual check
Visually check the face of the rocker arm in contact with the valve stem end
for scores and step wear. If the wear is small, correct it with an oil stone or
grinding paper of fine grain size. Rocker arm with a considerable amount of
step wear should be replaced.
60 Inspection
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z Rocker arm bushing diameter

Measure the inside diameter of
the rocker arm bushing with an
inside micrometer or vernier
calipers, and compare the
measured values with the rocker
arm shaft diameter. If the
clearance exceeds the limit,
replace either bushing or shaft,
whichever worn more.
Standard Limit
0.040 ∼ 0.113 mm 0.3 mm or less
3) Tappet and push rod

z Clearance
Measure the clearance of the tappet and tappet holes of the cylinder block. If
the value is beyond the specified limit, replace tappets.
Standard Limit
0.035 ∼ 0.077 mm 0.15 mm
z Visual check of tappet

Visually check the face of the
tappets in contact with the cam
for pitting, scores or cracks,
and replace if severely
damaged. If the amount of
cracks or pitting is small,
correct with an oil stone or
grinding paper.
z Outside diameter of tappet

With an outside micrometer,
measure the tappet outside
diameter If the measured value
is beyond the limit, replace
tappets.
Standard φ19.944 ∼ φ19.965 mm
61 Inspection
GE08TIC
z Push rod run-out

Use a feeler gauge to measure
the push rod run-out.
Roll the push rod along a
smooth flat surface as shown in
the figure
Limit 0.3 mm or less

.
4) Reassembling rocker arm assembly

Reassembling can be done in the reverse order of disassembling and following
things should be heeded
z Check the oil supply hole of rocker arm shaft for any clog and clean
thoroughly.
z Be careful not to occur any swap of position and reverse assembly.
3.2.6. Camshaft
(1) Camshaft end play
z Push the thrust plate toward the
cam gear.
z With a feeler gauge, measure
the clearance between the
thrust plate and camshaft
journal.
z If the end play is excessive,
replace the thrust plate.
Standard Limit
0.28 ∼ 0.43 mm 0.6 mm
(2) Cam
z Cam lobe height
Use a micrometer to measure
the cam lobe height and journal
diameter.
If the measured number is less
than the specified limit, the
camshaft must replaced.
Standard Limit
Cam lobe Intake 49.15 mm 48.85 mm
Height (C)
Exhaust 49.35mm 49.00 mm
Cam journal
diameter (A,B) φ57.86 ∼ φ57.88 mm φ57.52 mm
62 Inspection
GE08TIC
z Cam surface
Inspect the cam face for scratch or damage.
Slight step wear or damage on the cam face may be corrected with oil stone
or oiled grinding paper. But, replace if severely damaged.
(3) Cam shaft

z Clearance
Between camshaft journal and camshaft bush
- With an outside micrometer,
measure the camshaft journal
diameter.
- Measure the inside diameter
of the camshaft bushing on
the cylinder block using a
cylinder bore indicator, and
compare the measured value
with the camshaft outside
diameter to determine the
clearance.
<Clearance>
Standard Limit
0.12 ∼ 0.17 mm 0.24 mm
- Replace the bushing if the measured value is beyond the specified limit.
z Run-out
- Support the camshaft on two
V blocks and check for run-out
using a dial indicator.
- Correct or replace the cam
shaft if the amount of run-out
is beyond the value indicating
need for servicing.
Standard Limit
0.05 mm 0.2 mm
63 Inspection
GE08TIC
3.2.7. Crankshaft
(1) Inspection of crankshaft
1) Defect check
z By naked eyes, check for any scratch or damage on the crankshaft journal
and crank pin.
z By means of magnetic particle test and color check, check the crankshaft for
any crack and if found, replace it.
2) Wear measuring
z With an outside micrometer
measure the diameter of the
crankshaft journals and pins in
the directions as shown, and
compare the measured values
to determine the amount of
wear.
z If the amount of wear is beyond

the limit, have the crankshaft
ground and install undersize
bearings. However, if the
amount of wear is within the
limit, you can correct the wear
using an oil stone or oiled
grinding paper of fine grain size.
(Be sure to use grinding paper
which has been immersed in oil.)
Standard Limit
Journal diameter φ83.966 ∼ φ83.988 mm φ83.000 mm
Pin diameter φ70.971 ∼ φ70.990 mm φ70.000 mm
z In case that pin's wear is more

than the limit value, grind the
crankshaft journal and crank pin,
and use the undersized
bearings.
CAUTION:
Be sure to use grinding paper
which has been immersed in oil.
64 Inspection
GE08TIC
<Undersize bearings available>
Standard
0.25 (Inside diameter is 0.25 mm lesser than the standard size.)
Undersize bearings are available in 4 different sizes as indicated above, and the
crankshaft can be reused through the regrinding as described above.
* “R” parts specified value

0
① Crank pin's "R" : 4.5 − 0.2
0
② Crank Journal "R" : 4 − 0.2
CAUTION:
In case of regrinding, the grinding the "R" part of bearing end should be
correctly done and keep in mind to remove any jaws or coarse surface
absolutely.
3) Crankshaft run-out
z Support the crankshaft on V
blocks.
z Turn the crankshaft with a dial
indicator placed on the surface
plate and take the amount of
crankshaft run-out.
Standard Limit
0.06 mm 0.1 mm
(2) Crankshaft bearing and connecting rod

1) Visual check
Visually check the crankshaft bearing and connecting rod bearing for scores,
uneven wear or damage.
2) Oil clearance between crankshaft and bearing (Method 1 : dial gauge)

z Main bearing clearance
Install the main bearing in the
cylinder block, tighten the
bearing cap to specified torque,
then measure the inside
diameter.
Torque 30 kg.m
65 Inspection
GE08TIC
z Compare the two values

obtained through measurement
of main bearing inside diameter
with the outside diameters of
crankshaft journals to
determine the oil clearance.
<Main bearing oil clearance>

Standard Limit
0.052 ∼ 0.122 mm 25 mm
3) Connecting rod bearing clearance

z Install the connecting rod
bearing in the connecting rod
bearing cap, tighten the
connecting rod cap bolts to the
specified torque, then measure
the inside diameter.
Torque 18 kg.m
z Compare the two values

obtained through measurement
of connecting rod bearing
inside diameter with the
outside diameters of crankshaft
pins to determine the oil
clearance.
Standard Limit
0.034 ∼ 0.098 mm 0.25 mm
z If the clearance deviates from the specified range, have the crankshaft
journals and pins ground and install undersize bearings.
4) Oil clearance between crankshaft and bearing (Method 2 : plastic gauge)

z Assemble the crankshaft on the cylinder block and put plastic gauge on the
journal and pin of crankshaft and then after assembling bearing cap, tighten
the bolts at the specific torque. Again after disassembling the bearing cap by
removing the bolts, take out the flatted plastic gauge and measure the width
of plastic gauge by means of plastic gauge measuring scale. This is the oil
clearance.
z The oil clearance too can be measured in the same manner
66 Inspection
GE08TIC
5) Bearing spread and crush

z Inspection
Check to see that the bearing
requires a considerable
amount of finger pressure at
reassembly operation.
z Crankshaft bearing crush

Install the bearing and cap in
the cylinder block, retighten the
bolts to specified torque,
unscrew out one bolt
completely, then measure the
clearance between the bearing
cap and cylinder block using a
feeler gauge.
Standard 0.08 ∼ 0.110 mm
z Connecting rod bearing crush

Install the bearing and cap in
the connecting rod big end,
retighten the bolts to specified
torque, unscrew out one bolt
completely, then measure the
clearance between the bearing
cap and connecting rod big
end using a feeler gauge.
Standard 0.04 ∼ 0.07 mm
67 Inspection
GE08TIC
6) Crank shaft end play

z Assemble the crankshaft to the
cylinder block.
z With a dial gauge, measure
crankshaft end play.
Standard Limit
0.15 ∼ 0.325 mm 0.5 mm
3.2.8. Piston assembly

(1) Disassemby of piston assembly
Disassemble piston according to
the disassembly process.
(2) Piston inspection

1) Visual check
Visually check the pistons for
cracks, scuff or wear, paying
particular attention to the ring
groove.
2) Clearance between the piston and cylinder liner

z With an outside micrometer,
measure the piston outside
diameter at a point 13mm
away from the lower end of
piston skirt in a direction at a
right angle to the piston pin
hole. 13mm
Standard φ110.758 ∼ φ110.772 mm
z Using a cylinder bore gauge,

measure cylinder liner inside
diameter at 3 points (cylinder
top ring contacting face, middle,
and oil ring contacting face on
BDC) in a direction at an angle
of 45°.
z Take the mean value with the
largest and smallest values
excepted.
68 Inspection
GE08TIC
Standard Limit
φ111 ∼ φ111.022 mm φ111.122 mm
z The clearance is computed by

subtracting the piston outside
diameter from the cylinder liner
inside diameter.
z Replace either piston or cylinder
liner, whichever damaged more,
if the clearance is beyond the
specified limit.
< Clearance between piston and liner >

Standard Limit
0.228 ∼ 0.264 mm 0.3mm
(3) Piston rings

1) Visual check
Replace the piston rings with new ones if detected worn or broken when the
engine is overhauled.
2) Piston ring gap

z Insert the piston ring into the
upper portion of the cylinder
liner bore so that it is held at a
right figure to the cylinder liner
wall.
z Measure the piston ring gap
with a feeler gauge.
Standard Limit
Top ring 0.40 ∼ 0.60 mm 1.5 mm
2nd ring 0.40 ∼ 0.60 mm 1.5 mm
Oil ring 0.30 ∼ 0.50 mm 1.5 mm
z Replace piston rings with new

ones if the gap is beyond the limit
69 Inspection
GE08TIC
3) Piston ring side clearance

z Fit the compression ring and oil
ring in the piston ring groove.
z With a feeler gauge, measure
side clearance of each ring, and
replace either the ring or piston
if the measured value is beyond
the specified limit.
Standard Limit
Top ring - -
2nd ring 0.07 ∼ 0.102 mm 0.15 mm
Oil ring 0.05 ∼ 0.085 mm 0.15 mm
4) Piston ring tension

z With a tension tester, measure piston ring tension.
z Replace the piston ring if the measured value is beyond the limit.
Standard
Top ring 2.58 ∼ 3.88 kg
2nd ring 1.81 ∼ 2.71 kg
Oil ring 3.57 ∼ 5.03 kg
(4) Piston pin inspection

1) Wear
Measure the amount of wear on
the piston pin at the points as
shown. The measured values are
beyond the limit (0.08 mm or
greater), replace the pin.
Standard Limit
φ41.994 ∼ φ 42.000 mm φ 41.94 mm
2) Clearance
Measure the clearance between
the piston pin and connecting rod
bushing, and replace either of
them, whichever damaged more,
if the measured value is beyond
the limit.
70 Inspection
GE08TIC
Standard Limit
0.003 ∼ 0.015 mm 0.08 mm
3) Condition check
Check the engaged condition of
the piston and piston pin. If it is
possible to force the pin into the
piston heated with piston heater,
the piston is normal. When
replacing the piston, be sure to
replace the piston pin together.
(5) Connecting rod inspection

1) Distorsion
Check the connecting rod for
distortion. As shown in the figure
below, install the connecting rod to
the connecting rod tester, and
check for distortion using a feeler
gauge. If the connecting rod is
found distorted, never re-use it but
replace with a new one.
2) Holes alignment (parallelism)

Measure the alignment of the
connecting rod piston pin bushing
holes with connecting rod big end
holes. At this time also, use both
connecting rod tester and feeler
gauge.
Standard Limit
0.05 mm 0.1 mm or less
3) Wear
z Assemble the connecting rod to
the crankshaft and measure
connecting rod big end side
clearance using a feeler gauge.
z Assemble the connecting rod to
the piston and measure
connecting rod small end side
clearance.
71 Inspection
GE08TIC
z If the measured values are

beyond the limit, replace the
connecting rod.
Limit 0.5 mm
72 Inspection
GE08TIC
3.3. Engine Reassembly
3.3.1. General precautions

z Clean all the disassembled parts, particularly oil and water ports, using
compressed air, then check that they are free from restrictions.
z Arrange the general and special tools in order for engine assembly operation.
z To wet each sliding part, prepare the clean engine oil.
z Prepare service materials such as sealant, gaskets, etc.
z Discard used gaskets, seal rings, and consumable parts, and replace with new
ones.
z Apply only the specified torque for bolts in the specified tightening order and avoid
over-tightening.
z Be sure to check that all the engine parts operate smoothly after being
reassembled.
z Check the bolts for looseness after reassembly.
z After completing the engine reassembly operation, check if there is missing parts
or shortage of parts.
z Keep your hands clean during the working.

z Cover the floor of the workshop
with wood plate or thick paper to
prevent damage to the cylinder
head and place the cylinder block
with the head fitting surface facing
downward.
3.3.3. Oil spray nozzle

z Tighten and assemble the oil spray
nozzle flange with fixing bolts using
the spray nozzle jig.
Torque 0.9 kg.m
3.3.4. Tappet and cam shaft

z Undercool a new bush with dry ice
for about 2 hours and press it into
position in the cylinder block using
a bench press.
z After the pressing operation,
measure the inside diameter of the
cam bush to check if it is not
deformed.
73 Engine reassembly
GE08TIC
z Apply engine oil to the entire face of

the tappets and slide them into the
tappet holes on the cylinder block.
z Wet the cam bush inside diameter

and camshaft with oil, and carefully
assemble them while turning the
camshaft.
CAUTION:
Be careful not to generate a damage
to camshaft and bush.
z Check to see that the camshaft

rotates smoothly.
3.3.5. Crankshaft
z Install the main bearing (refer to
assemble sequence : right figure)
machined with two holes in the
cylinder block so that the key is
aligned with the key groove, then
apply oil to the bearing surface.
GE08TIC
z Heat the crankshaft gear for at least

10 minutes to 120°C, then apply
sealant (Loctite # 641) to the inside
wall of the heated crankshaft gear
evenly before inserting it to the end
of crankshaft.
z Semi-tighten a bolt at both sides of

the crankshaft, apply engine oil to
journals and pins, then assemble
the crankshaft with the cylinder
block by tightening the fixing bolts.
z Coat engine oil to the pin and
journal of crankshaft.
z Install the oiled thrust washers with

the oil groove facing outward.
z Install the bearing and thrust

washers to the bearing cap and
apply oil to the bearing and thrust
washers.
GE08TIC
z Install the bearing cap by matching

the cylinder block No. with the
bearing cap No.
z Apply oil to the entire part of the

bearing cap bolts, then tighten in
tightening sequence to specified
torque.
Torque 30 kg.m
z After semi-tightening both bolts

evenly, tighten them diagonally to
the specified torque using a torque
wrench as follows.
<Tightening Order>
(1) First stage : Coat the cap bolts with engine oil
(2) Second stage : Temporary bolt screwing about 1 ～2 threads
(3) Third stage : With impact wrench, tighten up to about 15 kg.m
(4) Fourth stage : With torque wrench, tighten up to about 25 kg.m
(5) Fifth stage : By means of torque wrench, tighten finally in the specified
torque. (30 kg.m).
z Tighten the bearing cap in the sequence of 4 – 3 – 5 – 2 – 6 – 1 - 7.

z Check to see that the assembled crankshaft turns smoothly with hand.
3.3.6. Flywheel housing

z Temporarily install the guide bar on Stopper ring
the cylinder block.
z Apply gasket to the cylinder block.
z Using the dowel pin and guide bar,
install the flywheel housing and
tighten the fixing bolts in a diagonal
sequence to specified torque.
(Zigzag method)
Ignition timing
check hole Oil seal
Torque 8 kg.m
GE08TIC
z When the bolts are tightened,

remove the guide bar.
z The flywheel housing is assembled
after the new oil seal was pressed
(Coat engine oil over the outside of
oil seal) before in the housing by a
press.
z If any peripheral scar was
generated due to oil seal at the oil
seal contact surface of crankshaft,
after inserting about 1mm shim or
thereabout in front of oil seal
(Direction toward crankshaft.),
measure and adjust.
3.3.7. Oil seal (rear side)

z Apply lubricating oil to the outside
of the oil seal and flywheel housing
inside diameter and fit them over
the crank shaft, then assemble the
oil seal using an oil seal fitting jig.
3.3.8. Flywheel and ring gear

z Installation of flywheel ring gear
With a gas burner, heat the ring
gear evenly until heat expansion
takes place, then install it using a
hammer.
NOTE:
Do not allow the temperature of the
ring gear to exceed 200 °C (390 °F).
z By means of mandrel, assemble

pilot bearing to the flywheel.
GE08TIC
z Install a guide bar into a bolt hole

on the crank shaft, and lift the
flywheel to align the dowel pin with
the pin hole on the flywheel for
temporary assembly operation.
z Coat the adhesive (#271 Loctite)
over the assembling bolts and
install bolts in the remaining holes.
After that take out the guide bar,
then install a bolt in the hole where
the guide bar had been inserted.
z According to the order of tightening
tighten the fixing bolts using a
torque wrench in a diagonal
sequence to specified torque.
Torque 18 kg.m
3.3.9. Water chamber cover

z Coat the adhesive over the water
chamber cover (Particular around
bolt holes) and after attaching the
gasket, assemble it to the cylinder
block using the bolts for assembling.
z As for tightening of bolts, after
primarily tightening the bolts
located at the both ends of cover
(4ea at both sides) and middle bolts
(Upper, lower 2ea), tighten the rest.
3.3.10. Cylinder liner

z Stand the cylinder block so that the
flywheel faces downward.
z Thoroughly clean the liner flange
fitting surface and bore inside with
compressed air to prevent the
entry of foreign substances.
z After the cleaning operation, make
the cylinder liner dried up and push
it into the cylinder block by hand.
z Wet the liner inside diameter with
engine oil.
GE08TIC
3.3.11. Piston and connecting rod

z Use a piston heater to heat the
piston approximately 100 °C (212
°F) for 5 minutes.
z Align the piston pin hole with the

oiled connecting rod small end and
press the piston pin (by lightly
tapping with a rubber hammer) to
assemble the connecting rod with
the piston.
z Nothing the direction of the piston,

make the longer side(machined
with key groove on the bearing) of
the connecting rod big end. Valve seating
z On the piston head surface, the
longer side connecting rod big end
is in opposite direction from the
valve seating surface as well as in
the same direction with the narrow
margin of the combustion chamber.
GE08TIC
z Install the snap rings and check to

see that it is securely assembled. Piston
z Install the piston ring in the piston Top ring
using piston ring pliers.
z Identify the mark "Y" or "TOP" on Second ring
the ring end to prevent the top and
Oil ring
bottom of the piston ring from
being interchanged and make the
marked portion face upward.
(The surface marked as “Y” is
upper surface.)
z Adjust the angle among individual

piston ring gaps to 90° and fit a
piston assembling jig onto the
piston, Use care not to match the
ring gaps with the pin direction.
z Install the bearing by aligning it
with the connecting rod key groove
and apply oil to the bearing and
piston.
z Position the valve seating surface

toward the tappet hole and insert
the piston with hand.
CAUTION:
Use care not to damage the cylinder
liner and piston, and slightly lift and
insert the piston into the cylinder so
that the ring may not be damaged
by the fillet of the liner.
GE08TIC
z Install the bearing in the connecting

rod cap and apply oil.
CAUTION:
Make sure that the manufacture
serial numbers impressed on the
connecting rod cap and connecting
rod big end are identical, and install
the connecting rod cap by aligning
it with dowel pin.
z Wet the fixing bolts with engine oil, semi-tighten them with hand, tighten them to
the specified torque using a torque wrench as follows.
<Tightening Order>
(1) First stage : Coat engine oil over bolts.
(2) Second stage : Temporary bolt screwing about 1～2 threads
(3) Third stage : With torque wrench, tighten up to about 10 kg.m
(4) Fourth stage : With torque wrench, tighten up to about 15 kg.m
(5) Fifth stage : By means of torque wrench, tighten finally in the specified
torque. (18 kg.m).
Torque 18 kg.m
z When the connecting rod bearing

cap bolts are tightened, check the
connecting rod end play to the right
and left with hand.
z If no end play is found, remove and
reinstall or replace the connecting
rod bearing cap.
3.3.12. Timing gear case

z Mount a new gasket using dowel
pin on the cylinder block.
z Put the time gear case to the
cylinder block by aligning the
dowel pin hole of timing gear case
with its pin, and then assemble it
by tapping lightly with an urethane
hammer to the right and left
(Particularly around dowel pin).
GE08TIC
z Tighten the bolts for assembling to

the specified torque. However, in
case of tightening the bolts, tighten
primarily the bolts of both end
parts and then do the rest.
3.3.13. Timing gear and idle gear pin

z Install the oil pump idle gear onto
the No.7 bearing cap.
z Install a thrust washer over the
camshaft and assemble the cam
gear by aligning it with camshaft
dowel pin. Tighten the cam gear
assembling bolts to the specified
torque. (Zigzag method)
Torque 2.2 kg.m
z With the oil port on the idle gear pin

facing the cylinder block, install the
idle gear pin.
z Idler gear pin with oil hole is
assembled toward cylinder block.
Oil hole
direction
z Install the idle gear by coinciding

the marks impressed on the crank
gear, cam gear, ignition taming Ignition timing
drive gear
drive gear, and idle gear.
z Install a thrust washer on the idle
gear and tighten to specified torque.
Torque 3.1 kg.m
z Check and adjust the amount of

backlash between gears using a
feeler gauge.
GE08TIC
Measuring position
Backlash Limit
(between)
cam gear & idle gear 0.16 ∼ 0.28 mm 0.35 mm
Crank gear & idle gear 0.16 ∼ 0.28 mm 0.35 mm
Injection pump & idle gear 0.16 ∼ 0.28 mm 0.35 mm
3.3.14. Oil pump and oil pipe

z Install a dowel pin in the No.7
bearing cap, then assemble the oil
pump by tapping lightly with
urethane hammer.
z Tighten the assembling bolts with
specified torque.
Torque 4.4 kg.m
z Assemble the oil suction pipe with

the delivery pipe to oil pump by the
bolts.
3.3.15. Water pump

z Mount a new gasket.
z Install the water pump on the
cylinder block and tighten the
assembling bolts with specified
torque.
Torque 2.2 kg.m
z Connect water pipes and by-pass

pipe to the water pump.
z Connect a water pipe to the
expansion tank.
3.3.16. Oil seal (front side)

z Apply lubricating oil to the outside
of the oil seal and the oil seal hole
of the timing gear case cover.
z Put the new oil seal on the oil seal
hole of timing gear case cover
aligning the center of them, then
assemble the oil seal using an oil
seal fitting jig.
GE08TIC
3.3.17. Timing gear case cover

z Install dowel pin on the timing gear
case.
z Mount a gasket by aligning the
fixing bolt holes with those on the
gasket.
z Align the dowel pin with the cover
pin hole, then install the cover with
light tap.
z Tighten the fixing bolts beginning
with the oil pan fitting face.
z In the assembling, be careful not to be damaged by the crankshaft.
3.3.18. Vibration damper

z Insert the vibration damper to the
crankshaft, and assemble by
tightening the assembling bolts at
the specified tightening torque
according to bolt tightening order.
(refer to right figure.)
Torque 13 kg.m
3.3.19. Oil pan

z Remove the gaskets thoroughly that
project at the timing gear case, case
cover of cylinder block, and the
contacting part of flywheel housing
by means of a scraper.
CAUTION:
Be careful for the gasket pieces not
fall into the engine during the work.
GE08TIC
z Coat the silicone at the gasket part

that was removed (Contacting part),
and attach the new oil pan gasket.
z Assemble the oil pan by tightening
the oil pan assembling bolts, and
when tightening bolts, primarily
tighten the bolts (4ea) at the both
ends, and then tighten the rest
bolts to specified torque.
Torque 2.2 kg.m
z Align the bolt holes with gasket

holes to prevent damage to the
gasket and tighten.
3.3.20. Oil filter & oil cooler

z Install the gasket on the cylinder
block. Oil filter Oil cooler
cartridge
z Assemble the oil cooler by
tightening the assembling bolts.
Torque 2.2 kg.m
z Apply engine oil to the oil filter

cartridge o-ring and assemble the
Oil cooler housing
cartridge using a filter wrench.
z Connect the cooling water pipe
with the cooling water pump and
tighten a hose clamp.
Oil cooler element

Water drain valve
GE08TIC
3.3.21. Starting motor

z Assemble the starter in position on
the flywheel housing.
Torque 4.4 kg.m
3.3.22. Intake and exhaust valves

z Identify the marks of "GI" and "GE"
impressed on the valve head
before assembling the valve with
the valve head.
z With a valve stem seal fitting jig, Valve identify the marks
assemble the valve stem seal on

the valve guide.
Intake valve Exhaust valve
z After installing valve springs and

spring retainer, press the retainer
with a jig, then install the cotter pin.
z Tap the valve stem lightly with a
rubber hammer to check that the
valve is assembled correctly.
GE08TIC

z Blow the bolt holes of cylinder
block with a compressed air and
remove the foreign matter.
z Clean the head gasket contact
surface thoroughly.
z However, be careful for the foreign
material not to enter into the
combustion chamber.
z Assemble the new head gasket by
aligning the holes with dowel pins
of cylinder block with “TOP” mark
facing upward.
z Check the inside of combustion

chamber for foreign substances,
and carefully mount the cylinder
head assembly in the block by
aligning the dowel pin with the
dowel pin hole.
z Be careful not to damage the
cylinder head gasket. If the dowel
pin is not in alignment, lift the
cylinder head again and then
remount it.
CAUTION:
After tightening the cylinder head
bolts, even at disassembling, the
cylinder head gasket should be
changed a new one.
z Coat the cylinder head bolts with

Front side Rear side
engine oil, and tighten in proper
sequence to the specified torque
according to bolt tightening order.
(right figure).
GE08TIC
<Cylinder Head Bolts>

Type 1 Type 2
Specification
M14×1.5×146 M14×1.5×150
1st : 6 kg.m
2nd : 180°
Torque 24.5 kg.m
final : 150°
(Angle torque)
z However, before tightening bolts,

the side parallel degree between
cylinder heads should be adjusted.
<Tightening order of bolts by steps>

(1) First stage : Coat the bolts with engine oil.
(2) Second stage : Tighten 1 ～2 threads with hands.
(3) Third stage : Tighten at about 6 kg.m with a wrench.
(4) Fourth stage : Tighten at rotating angle method 180° with a wrench.
(5) Fifth stage : Finally, tighten at rotating angle method 150° with a torque
wrench .
z However, all bolts are tightened

simultaneously by above steps.
z Coat the push rod with engine oil
and insert it into the push rod hole.
3.3.24. Rocker arm assembly

z Apply lubricating oil to the rocker
arm bush and shaft, and assemble
the intermediate bracket with the
rocker arm (rocker arm assembly)
on the cylinder block using fixing
bolts. In tightening the bolts, it must
be done at the specified value
using zigzag method.
M10x1.5 4.4 kg.m

Torque
M12x1.5 8.0 kg.m
GE08TIC
z Semi-install valve clearance

adjusting bolts onto the rocker arm.
z Install the spring, rocker arm,
bracket, rocker arm, spring, washer,
and snap ring in the described
sequence.
z Install the rocker arm and bracket
in the same direction.
3.3.25. Ignition coil and spark plug

z Tighten the spark plug at cylinder
head with socket tool. High pressure cable
z Assemble the high pressure cable
on the spark plug and ignition coil.
Spark plug
Hex. head
Socket tool
16mm (5/8inch)
Spark plug torque 2.5 ~ 3.0 kg.m
3.3.26. Adjust the valve clearance as following guide.

z By turning the crankshaft, when overlap the intake and exhaust of #6 cylinder,
that is, when #1 cylinder’s piston come at the compression top dead center (OT),
adjust the valve clearances by mark indicated.
z After having turned the crankshaft by 360° and overlap the intake & exhaust
valves of #1 cylinder, that is, when #6 cylinder is in the state of compression TDC
(OT), adjust the valve clearances by mark indicated.
GE08TIC
z To adjust the clearance, loosen the lock nuts of rocker arm adjusting screws and
push the feeler gauge of specified value between a rocker arm and a valve stem
(to measure the clearance of the valve and rocker arm contacting part) and
adjust the clearance with adjusting screw respectively and then tighten with the
lock nut.
z As for the valve clearance, adjust it when in cold.

CAUTION :
(1) Crankshaft revolution is done by hands without using a starting motor.
(2) Turn it to the direction of engine rotation, but do not use the installing bolts
at the turn.
(3) The cylinder no. and the order of intake and exhaust can be determined
from the crank shaft pulley.
z Adjust valve clearance with a feeler

gauge and tighten the fixing nuts to
specified torque.
Torque 5.0 kg.m
3.3.27. Ignition timing drive gear

z Mount gasket by aligning the bolt
holes with pin holes on the timing
drive gear housing.
z After tighten the fixing bolts in the
direction of the coupling.
Trigger wheel
Bellow 0.2mm
run-out
GE08TIC
3.3.28. Ignition timing adjustment

z Ignition timing sensor and trigger wheel location is affected the engine starting
that refer to bellow the described order.
z Check ignition timing angle

1) Turning the crankshaft, let the
valves of #6 cylinder’s valves #1 cylinder
Pin hole
ignition position
overlap.
2) Check notch mark of the right
figure corresponding to the
ignition timing aligner with the
pointer ( ) on the flywheel
housing.
Fly wheel
Model GE08TIC
Ignition timing Ignition timing
0° check mark
(B.T.D.C static)
OT mark
z Adjust ignition timing angle

1) Loosen the trigger wheel lock
Magnet pick-up
bolts, and align the sensor on sensor
the trigger wheel at starting Trigger wheel

position of the undivided holes
Timing drive
(as bellow figure) and then gear coupling
tighten the trigger wheel lock
bolts.
Trigger wheel cover
Trigger wheel lock bolts
Trigger wheel lock

4.4kg.m
bolt torque
Timing sensor gap 1.0mm±0.1mm
View flywheel
housing side
GE08TIC
z Adjust ignition timing sensor gap

1) Move the lock nut to hexagonal
side of sensor completely.
Timing
2) Rotate (Clockwise) the timing sensor
sensor on the coupling housing,
until the end of it reach on the
timing drive gear.
3) Then rotate (Counter clockwise)
the timing sensor for 270° (gap
1.0 mm) and fix lock nut. Tolerance limit
4) Tolerance limit is 27°. (gap ± 0.1
mm)
3.3.29. Intake manifold

z Put in the new gasket between the
cylinder head and manifold, and
assemble the intake manifold by
tightening the assembling bolts.
Torque 2.2kg.m
3.3.30. Exhaust manifold

z Assemble the exhaust manifold
with steel gasket in order to be
installed and be sure to check the
squared port of the gasket whether
square port of the cylinder head is
aligned before assembling.
z Tighten the fixing bolts with
specified torque.
Torque 4.4kg.m
3.3.31. Turbocharger
z Fit a new gasket over the stud Oil pipe Turbo charger
bolts of the exhaust manifold
Water
before tightening those hose(inlet)
turbocharger fixing nuts.

Water
hose(outlet)
Torque 4.4kg.m
Flange
Exhaust elbow
GE08TIC
z Install the oil supply pipe and return

pipe.
z Tighten the clamps of rubber hose that
is connected air pipe to the intercooler.
z Assemble the cooling water inlet &
outlet pipe on the turbocharger.
3.3.32. Intercooler & throttle valve

z After sub-assembling the air inlet &
outlet pipe and water inlet & outlet
cooling water pipe.
z Install the intercooler on the
bracket of flywheel housing and
tightening the fixing bolt on it.
z Assemble the throttle valve & air
pipe on the intake manifold.
CAUTION:
Check assembled after the all engine parts install and tighten fuel line.
Open fuel line valve and check for leaks using soapy water or commercial leak
detector.
Throttle valve
Inter Intake manifold

cooler
3.3.33. Fuel mixer & gas pressure regulator

z Assemble the fuel mixer and air
Fuel mixer
pipe from the turbo charger.
z Tighten the gas pressure regulator
and nature gas pipe from the fuel
mixer. Air pipe
Turbo charger
Gas pressure
regulator
GE08TIC
CAUTION:
Check assembled after the all
engine parts install and tighten fuel
line.
Open fuel line valve and check for
leaks using soapy water or
commercial leak detector.
3.3.34. Ignition control module : ICM

z Mount the ignition control
Ignition control
module(ICM) bracket on the module
cylinder block.
z Assemble the fixing bolts with the
ignition control module.
3.3.35. Ignition coil & high voltage cable

z Install the bracket on the intake
High pressure cable
manifold and assemble the ignition
coils Ignition coil
z Assemble the high voltage cables

by hand from each cylinder head.
Intake manifold
Ignition harness
3.3.36. Cooling water pipe

z Attach a new gasket on the cylinder
head.
z Install the cooling water pipe and
tightening the fixing bolt on it.
Torque 2.2kg.m
GE08TIC
3.3.37. Alternator
z Install the alternator mounting
bracket and supporter to the
cylinder block, then tighten the
fixing bolts.
z Install the alternator with fixing
bolts to the mounting bracket.
Torque 8.0kg.m
3.3.38. Cylinder head cover

z Attach a new gasket on the cylinder
head cover.
z Assemble the cylinder head cover
to the cylinder head by tightening
the cap bolts for fixing the cylinder
head cover.
Torque 1.2 kg.m
z Assemble the breather and

breather hose.
z Fit the oil filler cap on the cylinder
head cover.
GE08TIC
3.3.39. V-Belt
z Install the V-belt on the crank pulley,
alternator pulley and water pump
pulley.
z Adjust the V-belt tension using the
tension adjusting support.

z Apply sealant (Locktite #262) to the
bottom side of the guide tube.
z Then assemble the guide tube and
oil level gauge on the oil pan.
3.3.41. Engine speed controller: ESC

z Install engine speed controller
(ESC) and connect the harness Engine speed
Controller(ESC)
and various sensors.
GE08TIC
3.4. Starting and Trial Operation
3.4.1. Preparations for breaking-in
z Fill of new engine oil through the oil filler cap.
z When measuring the oil level with the oil level gauge with the engine mounted,
the oil level must indicate about 10mm above the max. line.
z Connect water hoses and fill up cooling water.
z Connect the fuel hoses to the fuel tank and to top(radiator or surge tank).
z Check the air bleeding of the fuel system.
z Connect the electrical systems such as starter, air heater, etc. with power source.
3.4.2. Operation of a new engine (Break-In)

Because the sliding surfaces of a new engine are not lapped enough, the oil film can
be destroyed easily by overload or overspeed and the engine life-time may be
shortened.
Therefore the following things must be obeyed by all means.
Up to the first 50 hours

z Engine should be run at fast idling until the temperature of the engine becomes
normal operating condition.
z Overload or continuous high speed operation should be avoided.
z High speed operation with no load should be prevented.
z Abrupt start and stop of the engine should be avoided.
z Engine speed must be under 70% of its maximum speed.
z Maintenance and inspection must be accomplished thoroughly.
3.4.3. Check points for break-in
During the break-in (the initial running of the engine) period, be particularly
observant as follows:
Check engine oil level frequently. Maintain oil level in the safe range, between the
"min." and “max." marks on dipstick.
97 Major electric parts replacement

GE08TIC
Note:
If you have a problem getting a good oil level reading on dipstick, rotate
dipstick 180° and re-insert for check.
Watch the oil pressure warning lamp. If the lamp blinks, it may be the oil pick-up
screen is not covered with oil. Check oil dipstick. Add oil to the oil pan, if required.
Do not overfill. If level is correct and the status still exists, see your DEALER for
possible switch or oil pump and line malfunction.
Note:
Oil pressure will rise as RPM increases, and fall as RPM decreases. In addition,
cold oil will generally show higher oil pressure for any specific RPM than hot
oil. Both of these conditions reflect normal engine operation.
c) Watch the engine water temperature gauge and be sure there is proper water
circulation. The water temperature gauge needle will fluctuate if water level in
expansion tank is too low. At the end of the break-in period, remove break-in oil
and replace the oil filter. Fill oil pan with recommended engine oil. Refer to
following table.
Engine oil capacity Recommend oil

Engine in Oil pan
model Total Sulfated
Max. Min. API No.
(lit) ash content
(lit) (lit)
SAE 15W40
GE08TIC 23 17 25 Bellows 0.5%
above CD or CE


GE08TIC
3.5. Speed controller setting
3.5.1. Installation checks

Do the checks in the order indicated. Terminal numbers in this chapter refer to the
speed controller.
1) Check that all electrical connections are correctly made and terminal screws
tightened, the magnetic pickup is properly installed and the jam nut tightened,
and the fuel valve and drain line are securely fastened and correctly installed.
2) Do not start the engine now. Turn on governor power. Check the battery voltage
at terminals 1(+) and 2(–). It must be from 18 to 32Vdc.
3) If a signal generator is available : Attach the output to terminals 5 and 6, leaving

the magnet pick-up connections off. Set the signal-generator output between 2
and 10 Vrms. If a signal generator is not available, proceed to step 8.
4) Set the signal-generator frequency to about half of idle speed. Close the
IDLE/RATED switch. Turn the signal generator and governor power on. The
voltage across terminals 3 and 4 should measure about 5Vdc (START FUEL
LIMIT must be fully clockwise).
5) Set the signal generator for magnet pick-up frequency at rated speed. Close the
IDLE/RATED switch. Set the external speed trim pot (if used) at mid position.
Observe the output from terminals 3 and 4.
a) If the output is at max-fuel position (about 5Vdc), slowly turn the rated-speed
potentiometer counterclockwise until the signal just begins to move to
minimum.
b) If the output is at minimum, slowly turn the rated-speed potentiometer

clockwise until the signal just begins to move to maximum.
c) Continue to adjust the rated-speed pot very slowly, trying to stop the signal
between minimum and maximum. Stop adjusting when the signal moves
slowly. It will not be possible to stop the motion. The rated-speed reference is
now set very close to desired speed.

GE08TIC
6) Open the IDLE/RATED switch. Set the signal generator for magnet pick-up
frequency at idle speed. (Preset the idle speed only after presetting rated speed.)
a) If the signal is at maximum-fuel position, slowly turn the idle-speed

potentiometer counterclockwise until the signal begins to move to minimum.
b) If the signal is at minimum, slowly turn the idle-speed potentiometer clockwise

until the signal just begins to move to maximum.
7) Continue to adjust the idle-speed pot very slowly, trying to stop the signal
between minimum and maximum. Stop adjusting when the signal moves slowly.
It will not be possible to stop the signal. The idle-speed reference is now set very
close to desired idle speed.
8) If a signal generator is not available: turn the rated speed pot fully
counterclockwise. Turn the idle-speed pot fully clockwise. Remove the magnet
pick-up wires from the speed control and measure resistance across the magnet
pick-up wires. If the resistance is correct replace the connection.
3.5.2. Initial pre-start settings

In case the newly installed the speed controller does not control engine speed, be
prepared to bellows sequence.
1. Rated Speed
If RATED SPEED was not set with a signal generator, set the RATED SPEED
potentiometer to minimum (fully counterclockwise). Set the external speed trim, if
used, to mid-position.
2. Stability
Set the RATED and IDLE STABILITY potentiometers to mid position.
3. Gain
Set the RATED and IDLE GAIN potentiometers to mid position.
4. Idle Speed
If IDLE SPEED was not set with a signal generator, set the IDLE SPEED
potentiometer at maximum (fully clockwise).

GE08TIC
5. Start Fuel Limit

Set the START FUEL LIMIT pot at mid point (maximum is fully clockwise).
6. Close the circuit between terminals 9 and 10 (Close for rated).
3.5.3. Start-up and stable adjustments

Prepare to start the engine. Read this entire chapter before attempting to start the
engine. Interrelated problems can occur, and an understanding of all possibilities is
needed before using a control for the first time.
CAUTION:
To protect against possible injury, loss of life, and/or property damage when
starting the engine, turbine, or other type of prime mover, be prepared to make
an emergency shutdown to protect against runaway or overspeed should the
fuel control(s), the driving mechanism(s), or the control device(s) fail.
1) Adjust for stable operation

Read the following paragraphs before attempting initial engine start up. Dynamics
must be quickly adjusted after initial start up.
2) Immediately after the initial start up, it will be necessary to adjust the governor for
stable operation. Idle and Rated dynamics are completely separate. In most
cases the idle speed has been preset at maximum (fully clockwise) and Rated
Speed is selected. In many cases the selection of rated speed will not indicate a
desire for rated dynamics, which will be used when the engine is loaded. Idle
dynamics may be selected and adjusted while rated speed is selected.
3) If the engine is hunting at a rapid rate, slowly decrease the GAIN (turn the
potentiometer counterclockwise) until performance is stable.
4) If the engine is hunting at a slow rate, increase the STABILITY (turn the
potentiometer clockwise) until the engine stabilizes. If increasing the STABILITY
potentiometer does not stabilize the engine, it also may be necessary to slowly
decrease the GAIN (turn the potentiometer counterclockwise).
a) Start cranking the engine. If the signal from terminals 3 and 4 does not show a
positive voltage (2 to 6 Vdc) check the magnetic pick-up sensor.
b) Minimum voltage required from the magnetic pick-up sensor to operate the
electronic control is 1.0 Vrms, measured at cranking speed or the lowest
controlling speed. Measure the voltage while cranking with the speed sensor
connected to the control. Be sure to prevent the engine from starting.

GE08TIC
5) If the engine stops, it indicates a magnetic pick-up problem. The magnetic pick-up
must produce a minimum of 1 Vac rms to activate the control. Failure to produce
the minimum signal can be caused by improper magnetic pick-up installation,
selection of an incorrect gear, improper wiring between the magnetic pick-up and
the control, or a defective magnetic pick-up.
6) With the engine running and stable, slowly increase the rated-speed setting with
the RATED SPEED pot until the desired rated speed is reached.
7) Dynamic adjustment
The object of the GAIN and STABILITY potentiometer adjustments is to obtain
the optimum, or desired, stable engine-speed response.
8) Increasing the setting of the GAIN potentiometer provides faster transient

response (decreases the amount of speed change from a sudden change in load).
To achieve the best response, slowly increase the GAIN (turn the potentiometer
clockwise) until the engine becomes slightly unstable, then slowly turn the GAIN
back counterclockwise as necessary to stabilize engine speed.
9) Step load the engine to make sure the engine returns to the proper speed with
little overshoot or undershoot of the speed setting. (To reduce overshoot, increase
the STABILITY setting by turning the potentiometer clockwise).
10) Increasing the STABILITY clockwise will require decreasing the GAIN (turning
the GAIN potentiometer counterclockwise) to maintain stable operation.
11) If the engine is slow in returning to the proper speed, decrease the STABILITY
by turning the potentiometer counterclockwise.
12) Low idle speed adjustment: The engine should be at rated speed with the
IDLE SPEED potentiometer set at maximum (fully clockwise). Open the external
CLOSE FOR RATED contact.
13) Decrease the IDLE SPEED (turn the potentiometer counterclockwise) until the
desired idle speed is reached. It may be necessary to adjust the idle dynamics to
maintain stability as speed is lowered.
14) Dynamic Adjustment

a) Gain is too high and stability too low. There are secondary overshoots on
transients and large overshoots on starts (under damped)

GE08TIC
Load Load Ringing

Start
on off
Speed
b) Optimum performance on load transients with slight overshoot on starts

(optimum damping)
Speed
c) Optimum performance on start with slight time extension of load transients

(optimum damping)
Speed
d) Stability too high, long time to settle to rated speed (over damped)
Setting
Time
Speed
15) If idle dynamics were selected on initial start-up, it will now be necessary to set
rated dynamics. Load the engine, then select rated dynamics.

GE08TIC
16) Engine response will change as the engine warms up. It may be necessary to
tune dynamics after warm-up. It may be necessary to compromise optimum
control dynamics with a cold engine in order to have optimum dynamics when
the engine is at operating temperature.
17) The START FUEL LIMIT was set at a point that allowed the cold engine to start
during initial start up procedures. If START FUEL LIMIT is to be used, it should
now be adjusted after engine stability and response rates are correctly adjusted.
a) Adjusting the START FUEL LIMIT counterclockwise will prevent the fuel valve
from delivering a maximum amount of fuel to the injectors until the selected
speed (Idle or Rated) is reached. Adjust for desired engine performance
during start up. The Start Fuel Limit must be set high enough to allow the
engine to reach the selected speed.
b) The START FUEL LIMIT should be adjusted from counterclockwise to obtain

the desired characteristics while starting the engine. There may be
differences in startup characteristics of cold and hot engines.

GE08TIC
3.6. Electrical System
3.6.1. Electrical component of engine
1 3
4 5 9 10
6
11
7 8
No. Part Name No. Part Name
1 Ignition coil 7 Ignition control module (ICM)
2 Starter 8 Oil pressure unit
3 Nature gas air mixer 9 Cooling water temperature switch
4 Throttle valve 10 Cooling water temperature sender
5 Gas pressure regulator 11 Alternator
6 Ignition timing sensor

GE08TIC
3.6.2. Engine control system

GE08TIC
3.6.3. Engine control harness

GE08TIC
3.7. Speed Controller

3.7.1. Speed controller description
z The speed controller is designed to provide basic isochronous speed
control for gas engines.
z Engines with mechanical loads and generator loads are handled equally
well.
Speed controller

GE08TIC
3.7.2. Speed controller circuit
z 1 Shield wires to be twisted pairs with shield grounded at one end only.
z 2 No. 18AWG or 20AWG standard wire. Must be as short as possible.

50ft. maximum wire length for 20AWG wire. 80ft. maximum wire length
for 18AWG wire.
z 3 Use 24 volt system.
z 4 Open for minimum fuel.
z 5 For positive ground systems, switch and fuse to be located in series

with battery (-) and terminal 2. Positive terminal becomes chassis
ground. Leads from battery to terminals 1 & 2 must be direct and not
pass through distribution points.
z 6 Approximate speed change with trim potentiometer

◈ ±2.5% using a 1KΩ potentiometer
◈ ±5% using a 2KΩ potentiometer
z 7 About one second ramp time per 50µF. Capacitor specifications :

200µF maximum, 15WVdc minimum. 15WVdc maximum. Less than
30µA DC leakage current over temperature range.
z 8 Idle range about 25% to 100% rated using 50K potentiometer.
z 9 Use a 1 amp fuse(3 AWG)

GE08TIC
3.8. Ignition controller

3.8.1. Ignition controller circuit
Ignition control
module

GE08TIC
3.8.2. DC power hookup of ignition system
3.8.3. Engine firing order
Engine model GE08TIC

Firing order 1–5–3–6–2-4
3.8.4. Engine cylinder no.

GE08TIC
3.8.5. Primary wiring
Terminal position Terminal symbol Wiring Connector position

1+ 1.25R Connector A
1- 1.25B Connector J
2+ 1.25R Connector E
2- 1.25B Spark coil 1-
3+ 1.25R Connector C
Spark coil 4+ 1.25R Connector F
5+ 1.25R Connector B
6+ 1.25R Connector D
Ground 1.25B Spark coil 6-
3.8.6. Tacho sensor wiring
Terminal position Terminal symbol Wiring Connector position
Signal(SIG) 0.85W Connector A

Tacho sensor
Ground(GND) 0.85W Connector B

GE08TIC
3.9. Ignition control module
3.9.1. Installation instruction

CAUTION:
Deviation from these installation instructions may lead to improper engine
operation which could cause personal injury to operations or other nearby
personnel.
3.9.2. Description
z The CD1 ignition system consists of these basic components.
1) CD1 unit
2) Magnetic pick-up sensor
3) Harness
4) Individual coils
z The system requires a battery or a suitable power supply with a nominal 24

VDC. The CD1 unit steps up the DC supply voltage to charge an energy
storage capacitor and contains microcircuit logic and SCR(Silicon controlled
rectifier switching) devices to release the stored energy to the ignition coils in
programmed, timed sequence according to the application. Holes drilled in the
trigger wheel signal the position of the trigger coupling to the logic circuitry in
the CD1 unit.
3.9.3. CD1 unit

z Select a location for the CD1 unit that will be at least 600 mm away from the
ignition coils and spark plug leads. In addition, the mounting location must be
relatively cool. The outside case temperature of the CD1 unit should not exceed
90°C (195°F) in operation.
NOTE:
Plastic-case CD1 units have a maximum case temperature of 65°C (150°F).
3.9.4. Pick-up sensor

z Locate a suitable mounting position for the pick-up sensor so that it may sense
either the outside diameter of the trigger wheel.

GE08TIC
IMPORTANT:
Rotate the trigger wheel an entire revolution to be sure that there are holes in
the path that will pass under the pick-up sensor.
z Set the engine with no. 1 cylinder in the most advanced timing position. Mark the
point on the trigger wheel that will be directly opposite the pick-up sensor.
z Drill the remaining holes spaced as shown in the appropriate wiring diagram in
these instructions.
NOTE:
The angular spacing is extremely important as this establishes the basic
timing accuracy of the system. In addition, make sure each hole is drilled so
that its center passes directly in line with the center of the pick-up sensor.
z Secure the pick-up sensor to a rigid bracket or surface to maintain an air gap(1.0
mm ± 0.1 mm) not exceeding. The center of the pick-up face must line up with the
center of the drilled holes as the engine is rotated.
z Plug the 2-pin pick-up sensor connector fully into its mating receptacle connected
to the CD1 unit.
NOTE:
Keep the pick-up sensor wires at least 50 mm away from the coil primary wires
and at least 200 mm away from the spark plug leads.
3.9.5. Trigger wheel

z A trigger wheel with the appropriate hole pattern must be prepared for mounting
at camshaft speed. The angular spacing is extremely important as this establishes
the basic timing accuracy of the system.
z Set the engine with no. 1 cylinder in the most advanced timing position. Noting
the direction of rotation, set the drilled disc opposite the pick-up in the position
shorn in circuit diagram.
z Plug the 2-pin pick-up sensor connector fully into its mating receptacle connected
to the CD1 unit.

GE08TIC
3.9.6. Ignition coils

z Mount the ignition coils as close to the spark plugs as possible keeping the high-
tension lead length to a minimum but also keeping temperatures below 95°C
(200°F) during operation.
3.9.7. Primary wiring

z The CD1 system requires a battery or other DC power source providing
12~28VDC for running and a minimum of 8 volts for engine starting. Refer to
details the connection to the DC power source.
z Plug the multi-pin harness connector fully into its mating receptacle connected to
the CD1 unit.
NOTE:
Keep the primary wiring at least 50 mm away from the spark plug leads.
3.9.8. Shutdown wiring

The CD1 system can be shut-off in two ways.
(Refer to 3.7.1. Ignition controller circuit – CD1 system)
z Method 1: (use to DC power source)

Interrupt the DC power to the unit.
- Use a switch or relay with contacts rated 24VDC, 10 amps refer to drawing.
- Do not run the input power line through a series of normally closed switches.

GE08TIC
z Method 2: (use to “G” ground)

- Ground the appropriate harness lead. This option may be used if the
shutdown panel was powered from an ignition system.
- When the shutdown lead is grounded, the CD1 unit will draw about 0.1 amp
from the power source.
NOTE:
If desired, the shutdown lead may be used to power display instruments in the
panel.
3.9.9. Operation
z The CD1 unit steps up the DC supply voltage to charge an energy storage
capacitor. SCR switching devices release this stored energy in response to
signals from the unit's logic circuitry which processes signals from the magnetic
pick-up. The pick-up senses one hole for every firing of the engine.
Each firing occurs a programmed number of degrees after the hole is sensed.
This delay in degrees is adjustable.
z The CD1 unit has a timing switch located under a white plastic cap at one end of
the box.
- 6 cylinder engine : 1.9 degrees per switch interval = 13 degrees total
z Switch position 7 gives the most advanced timing. The timing retards as indicated
above for each switch position as the switch is moved to position 1-5-3-6-2-4.
Switch position 0 is full retard.
CAUTION:
Do not switch from position 7 to 0, or 0 to 7 while the engine is running. The
large timing change may cause the engine to shutdown or be damaged.
NOTE:
Using a timing light, set the timing to the desired position with the engine
running at normal operating speed. Replace the white cap over the timing
switches once the proper timing setting is set.
z Two LED indicators on either side of the timing switch give an indication of proper
operation of the magnetic pick-up (left LED) and the output circuits of the CD1
unit (right LED). See troubleshooting procedures.

GE08TIC
3.9.10. Troubleshooting chart

z Normal operation
Check the two LED indicators next to the timing switch.
- After power is turned on to the CD1 unit, the output indicator will turn on.
- When the engine is cranked, both indicators will blink at the same rate.
- At normal running speeds, both indicators glow continuously.
- If engine is stopped with power off, the output indicator will turn off for a few
seconds and then stay on continuously.
z Trouble shooting
- Check the two LED indicators next to the timing switch.
- If the engine will not start or run correctly, crank engine with fuel turned off and
check per the chart bellow.
Indication and checks Remedy

1. Both indicators off.
z Check 12~24 VDC power to CD1 unit. z Must be in range of 12~29
z If above check is OK. VDC.
z Replace CD1 unit.
2. Pick-up indicator off / Output indicator On.
1) Check gap between pick-up and sensed z Correct gap.
surface.
- must be greater than 1.0 mm ±0.1 mm.
2) Check connections between CD1 unit and z Correct connections.
the pick-up sensor.
3) Unplug connection to pick-up and measure z Replace pick-up.
resistance between the two pick-up leads.
4) If above checks are OK. z Replace CD1 unit.
3. Pick-up indicator OK / Output indicator off or
blinks at slower rate.
1) Check connections between CD1 unit and z Correct connections.
ignition coil module or coils.
2) If above check is OK. z Replace CD1 unit.
4. Both indicators blink at the same rate.

1) Indicates proper operation of CD1 unit and z Check or replace ignition coils.
magnetic pick-up sensor. z Check other items such as fuel
supply.

GE08TIC
4. Commissioning and Operation
4.1. Operation Preparation

At the time of initial commissioning of a new or overhauled engine make sure to have
observed the "Technical information for the installation DOOSAN’s generator
engines".
z Oil filler neck on cylinder head cover

- Before daily starting of the engine, check the fuel, coolant and oil level, replenish
if necessary.
- The notches in the oil level gauge indicate the highest and lowest permissible oil
levels.
IMPORTANT:
Do not fill above the top of the mark. Oil levels anywhere within the crosshatch
are considered in the acceptable operating range. Over lifting will result in
damage to the engine.
z Cleanliness
Ensure outmost cleanliness when handling fuels, lubricants and coolants
4.2. Breaking-in
4.2.1. Preparations for breaking-in
z Fill of new engine oil through the oil filler cap.
z When measuring the oil level with the oil level gauge with the engine mounted,
the oil level must indicate about 10mm above the max. line.
z Connect water hoses and fill up cooling water.
z Connect the electrical systems such as starter, alternator, etc. with power source.
4.2.2. Operation of a new engine (Break-In)

Because the sliding surfaces of a new engine are not lapped enough, the oil film can
be destroyed easily by overload or overspeed and the engine life-time may be
shortened. Therefore the following things must be obeyed by all means.
Up to the first 50 hours

z Engine should be run at fast idling until the temperature of the engine
becomes normal operating condition.
z Overload or continuous high speed operation should be avoided.
z High speed operation with no load should be prevented.
z Abrupt start and stop of the engine should be avoided.
z Engine speed must be under 70% of its maximum speed.
z Maintenance and inspection must be accomplished thoroughly.
118 Commissioning and Operation

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4.2.3. Check points for break-in

During the break-in (the initial running of the engine) period, be particularly observant
as follows:
a) Check engine oil level frequently. Maintain oil level in the safe range, between
the "min." and “max." marks on dipstick.
Note :
If you have a problem getting a good oil level reading on dipstick, rotate the
level gauge 180° and re-insert for check.
b) Watch the oil pressure warning lamp. If the lamp blinks, it may be the oil pick-up
screen is not covered with oil. Check oil level gauge. Add oil to the oil pan, if
required. Do not overfill. If level is correct and the status still exists, see your
DEALER for possible switch or oil pump and line malfunction.
Note :
Oil pressure will rise as RPM increases, and fall as RPM decreases. In addition,
cold oil will generally show higher oil pressure for any specific RPM than hot
oil. Both of these conditions reflect normal engine operation.
c) Watch the engine water temperature gauge and be sure there is proper water
circulation. The water temperature gauge needle will fluctuate if water level in
expansion tank is too low.
At the end of the break-in period, remove break-in oil and replace the oil filter. Fill
oil pan with recommended engine oil. Refer to following table.
z The following oils are also recommended

SAE No. API No. Sulfated ash content
15W40 above CD or CE Bellow 0.5 %

* Recommend oil : TOTAL LMG-405
z Engine oil capacity

Engine oil capacity
in Oil pan
Total
Engine model Max. Min.
(lit)
(lit) (lit)
GE08TIC 23 17 25

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4.2.4. Operating after break-in

When starting a cold engine, always allow the engine to warm up gradually. Never
run the engine at full throttle until the engine is thoroughly warmed up. Be sure to
check the oil level frequently during the first 1,000km(50 hours) of operation, since
the oil consumption will be high until the piston rings are properly seated.
4.3. Inspections after Starting

During operation the oil pressure in the engine lubrication system must be monitored.
If the monitoring devices register a drop in the lube oil pressure, switch off the engine
immediately. And the charge warning lamp of the alternator should go out when the
engine is running.
z Do not disconnect the battery or pole terminals or the cables.

z If, during operation, the battery charge lamp suddenly lights up, stop the
engine immediately and remedy the fault in the electrical system.
z Engine should be stopped if the color, the noise or the odor of exhaust gas is
not normal.
z Confirm the following things through warning lamps and gauge panel.
4.3.1. Pressure of lubricating oil

The normal pressure comes up to 1 kg/cm2 (1.0 bar) at idling and 3 ~ 5 kg/cm2 (3.0 ~
4.9 bar) at maximum speed. If the pressure fluctuates at idling or does not reach up
to the expected level at high speed, shut down the engine immediately and check
the oil level and the oil line leakage.
4.3.2. Temperature of cooling water

The cooling water temperature should be 79 ~ 95 °C in normal operating conditions.
Abnormally high cooling water temperature could cause the overheating of engine
and the sticking of cylinder components. And excessively low cooling water
temperature increases the fuel consumption, accelerates the wears of cylinder liners
and shortens the engine life-time.

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4.4. Operation in Winter Time

Pay special attention to the freezing of cooling water and the viscosity of lubricating
oil.
4.4.1. Prevention against the freeze of cooling water

When not using anti-freeze, completely discharge the whole cooling water after
engine running. The freeze of cooling water causes the fatal damages of the engine.
Because the anti-freeze is used to prevent cooling water from freeze, consult "The
amount of anti-freeze".
4.4.2. Prevention against excessive cooling

Drop of thermal efficiency caused by excessive cooling increases fuel consumption,
therefore prevent the engine from excessive cooling. If the temperature of coolant
does not reach to normal condition (79 ~ 95°C) after continuous operation, examine
the thermostat or the other cooling lines.
4.4.3. Lubricating oil

As cold weather leads to the rise of oil viscosity, engine speed becomes unstable
after starting. Therefore the lubricating oil for winter should be used to prevent this
unstability. Refer to lubricating system section.
4.5. Tuning the Engine

The purpose of an engine tune-up is to restore power and performance that's been
lost through wear, corrosion or deterioration of one or more parts or components. In
the normal operation of an engine, these changes can take place gradually at a
number of points, so that it's seldom advisable to attempt an improvement in
performance by correction of one or two items only. Time will be saved and more
lasting results will be obtained by following a definite and thorough procedure of
analysis and correction of all items affecting power and performance.
Economical, trouble-free operation can better be ensured if a complete tune-up is
performed once every years, preferably in the spring. Components that affect power
and performance to be checked are:
z Components affecting fuel system ;

Ignition coil, spark plug, metering valve etc.
z Components affecting intake & exhaust ;
Air cleaner, inter-cooler, turbo charger, silencer, etc.
z Components affecting lubrication & cooling ;
Air & oil filter, anti- freeze, etc.

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4.6. Maintenance and Care

4.6.1. Periodical inspection and maintenance
In order to insure maximum, trouble-free engine performance at all times, regular
inspection, adjustment and maintenance are vital.
z Daily inspections in below figure should be checked every day.

z The maintenance should be executed thoroughly at regular internals.
(refer to appendix “General engine inspection cycle”.)
4.6.2. Exchanging of lubrication oil

Engine oil and the oil filter are important factors affecting engine life. They affect
ease of starting, fuel economy, combustion chamber deposits and engine wear.
At the end of the break-in period 1,000km (50hours), change the oil sump oil and
replace the oil filter cartridge.

Check the oil level in the engine sump
daily with an oil level gauge.
z The notches in oil level gauge must
indicate the oil level between the
max. and the min. permissible.
z The oil level should be checked
with the engine horizontal and only
after it has been shut down for
about 5 minutes.
z Examining the viscosity and the
contamination of the oil smeared at
the oil level gauge replace the
engine oil if necessary.
CAUTION:
Do not add so much engine oil that the oil level rises above the max. marking
on the oil level gauge. Over lifting will result in damage to the engine.
4.6.4. Oil exchange procedure

While the oil is still hot, exchange oil
as follows:
z Take out the oil level gauge.
z Turn the valve opening and then
move the oil drain pump lever as
figure by hand, and let engine oil
Engine oil
discharge into the prepared vessel drain pump

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z Refill with new engine oil at the oil

filler neck on the head cover and
the lubricating oil in accordance
with the oil capacity of the engine
through oil filler. Be careful about
the mixing of dust or contaminator
during the supplement of oil. Then
confirm that oil level gauge
indicates the vicinity of its
maximum level.
z For a few minutes, operate the engine at idling in order to circulate oil through
lubrication system.
z Thereafter shut down the engine. After waiting for about 10 minutes measure the
quantity of oil and refill the additional oil if necessary
4.6.5. Replacement of oil filter cartridge

z At the same times of oil exchanges,
replace the oil filter cartridge. Oil filter Oil cooler
cartridge
z Drain engine oil by hand pump.
IMPORTANT:
Don't forget closing the drain pump
after having drained engine oil.
z Loosen the oil filter by turning it

counter-clockwise with a filter
wrench.
z With a rag wipe clean the fitting face of the filter body and the oil filter body so
that new oil filter cartridge can be seated properly.
z Lightly oil the O-ring and turn the oil filter until sealing face is fitted against the O-
ring. Turn 1-1/4 turns further with the filter wrench.
NOTE:
It is strongly advisable to use DOOSAN’s genuine oil filter cartridge for
replacement.
4.7. Cooling System

The coolant must be changed at intervals of 40,000km operation or six months
whichever comes first. If the coolant is being fouled greatly, it will lead an engine
overheat or coolant blow off from the expansion tank.

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4.7.1. Coolant draining

z Remove the drain plug from the
cylinder block and drain out the
cooling water into a container.
CAUTION :
When removing the drain plug
while the engine is still hot, so that
turn it slowly to release the internal
steam pressure. This will prevent a
person from scalding with hot Drain valve
steam spouted out.
4.7.2. Cleaning of the cooling inside system circuit

When the cooling system circuits are fouled with water scales or sludge particles, the
cooling efficiency will be lowered. When the cooling system circuits are clogged, the
water pump mechanical seal is damaged.
The poor condition of the cooling system is normally due to use of unsuitable or no
anti-freezing agents and corrosion inhibitor or defect.
If twice in a short time (within 6 months) the water pump of an engine develops
leases or the coolant is heavily contaminated (dull, brown, mechanically
contaminated, gray or black sings of a leakage on the water pump casing) clean the
cooling system prior to removing that water pump as follows.
a) Drain coolant.
b) Remove thermostats, so that the whole cooling system is immediately flown
through when cleaned.
c) Fill the cooling system with a mixture of potable water and 1.5% by volume of
cleaner. (Henkel P3T5175)
d) Warm up engine under load. After a temperature of 60°C is reached, run engine
for a further 15 minutes.
e) Drain cleaning fluid.
f) Repeat steps c) and d).
g) Fill cooling system with hot water.
h) Run engine at idle for 30 minutes. At the same time continuously replenish the
water leaking from the bore in drain plug by adding fresh water.
CAUTION:
Periodically clean the circuit interior with a cleaner.

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4.8. Adjustment of Valve Clearance

4.8.1. General information
The valve clearances are to be adjusted at the times of the following situations.
z After initial 1,000km (50hours) operation.
z When the engine is overhauled and the cylinder heads are disassembled.
z When severe noise comes from valve train.
z When the engine is not normally operated, even though there is no trouble in the
fuel system. The valve clearance of the cold engine are as follows.
4.8.2. Adjusting order of the valve clearance

1) After letting the #1 cylinder's piston come at the compression top dead center by
turning the crankshaft, adjust the valve clearances.
2) Loosen the lock nuts of rocker arm adjusting screws and push the feeler gauge
of specified value between a rocker arm and a valve stem and adjust the
clearance with adjusting screw respectively and then tighten with the lock nut.
3) As for the valve clearance, adjust it when in cold, as follow.


- By cranking the engine, let #6 cylinder's valves overlap.
- In time, adjust the valve clearance corresponding to “ ” of lower lists.
- Adjust the valve clearance corresponding to “ ” of lower lists.
- After reinsuring the valve clearances, retighten if necessary.
z No. 1 Cylinder is located at the side where flywheel was installed.

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1 Type is the conventional and simple method, but if you have some problem to
adjust your engine, please try 2 type sequence. This is a precision method, but it
takes more times.
Valve overlapping on cylinder

1 5 3 6 2 4
Adjusting valves on cylinder
6 2 4 1 5 3
4.8.3. Method of adjusting the valve clearance

1) Loosen the lock-nuts ① using a
ring spanner.
2) Insert a thickness gauge of 0.3mm
between valve stem ② and rocker
arm ③.
3) Turn the adjusting bolts ④ using a
screw driver until the gauge can be
pulled out with some restriction.
4) After the adjustment fix the
adjusting bolt not to rotate and
tighten the lock-nut at the same
time.
5) Measure the clearance one more time and if necessary adjust again.

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4.9. Tightening the Cylinder Head Bolts

z The cylinder head bolts are to be
tightened in the sequence shown in
the illustrations, First tighten the
bolts slightly, then slightly more
again and finally tighten with a
torque wrench.
<Cylinder head bolts>

Bolt Type
Specification
M14×1.5×146
1st : 6kg.m
2nd : 180°
Torque
3rd : 180°
(Angle torque)
z The tightening by excessive torque may cause the damages of the cylinder head
gaskets, the flanges of cylinder liners and the cylinder head bolts, therefore obey
the regular torque.
4.10. Cylinder Compression Pressure

z Stop the engine after warming it up,
then remove the spark plugs.
z Install a special tool (gauge
adapter) in spark plug hole and
connect the compression pressure
gauge to the adapter.
z Cut off fuel circulation, rotate the
starter, then measure compression
pressure of each cylinders.
Standard value 16 kg/cm2 over

13 kg/cm2
Limit valve
or less
Difference between
±10% or less
each cylinder
- Testing conditions:
At water temperature of 20°C
and speed of 200 rpm

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4.11. Belts
The tension of the belts should be checked after every 2,000 hours of operation.
1) Change the belts if necessary

If in the case of a multiple belt drive, wear or differing tensions are found, always
replace the complete set of belts.
2) Checking condition
Check belts for cracks, oil, overheating and wear.
3) Testing by hand
By the finger-pressure the belt is
pressed by 10-15mm between the
pulleys in normal
condition.(Pressed mid-way
between the belt pulleys)
A more precise check of the V-belt
tension is possible only by using a
V-belt tension tester.
4) Measuring tension
① Lower indicator arm (1) into the
scale.
z Apply tester to belt at a point
midway between two pulleys
so that edge of contact
surface (2) is flush with the
V- belt.
z Slowly depress pad (3) until
the spring can be heard to
disengage. This will cause
the indicator to move
upwards.

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z If pressure is maintained after

the spring has disengaged a
false reading will be obtained.
② Reading of tension
z Read of the tensioning force
of the belt at the point where
the top surface of the
indicator arm (1) intersects
with the scale.
z Before taking readings make
ensure that the indicator arm
remains in its position.
z V-belt tension
Tensioning forces on the tester
new installation
Type Drive belt width When servicing after
After 10 min.
Installation long running time
running time
M 9.5 mm 50 kg 45 kg 40 kg
A 11.8 mm 55 kg 50 kg 45 kg
B 15.5 mm 75 kg 70 kg 60 kg
C 20.2 mm 75 kg 70 kg 60 kg
5) Tensioning and changing belts

z Loosen fixing bolts and nuts.
z Adjust the alternator until belts
have correct tensions.
z Retighten fixing bolts and nuts.
To change the belts loosen

fixing bolts and nuts. Then push
the alternator toward water
pump pulley by hand.

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5. Maintenance of Major Components
5.1. Cooling System

5.1.1. General information
z This engine is water-cooling type. Heat from the combustion chamber and engine
oil heat are cooled down by coolant, resulting in the normal operation of the
engine.
z Looking into the cooling system, the water pumped up by the water pump
circulates around the oil cooler through the water pipe to absorb the oil heat, and
then flows through the water jacket of the cylinder block and water passage of the
cylinder head to absorb the heat of the combustion chamber.
5.1.2. Specification
Item Specification
Type Centrifugal type
Pump speed 2,000 rpm 2,700 rpm
Water pump Delivery capacity about 190 liter/min about 280 liter/min
Operation pressure 0.5 bar 0.8 bar
Allowable back pressure bellow 0.5 bar
130 Maintenance of Major Components

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5.1.3. Diagnostics and troubleshooting
Complaints Possible causes Corrections

1. Engine overheating z Lack of coolant z Replenish coolant
z Belt loosened or broken z Adjust or replace fan belt
z Belt fouled with oil z Replace fan belt
z Water pump defective z Repair or replace
z Restrictions in water z Clean intercooler and water
passages due to passages
deposit of scales
z Ignition timing incorrect z Adjust ignition timing
correctly
z Gases leaking into z Replace cylinder head
water jacket due to gasket
broken cylinder head
gasket
2. Lack of coolant z Intercooler leaky z Correct or replace
z Intercooler hoses z Retighten clamps or replace
loosely connected or hoses
damaged
z Water pump leaky z Repair or replace
z Cylinder head gasket z Replace cylinder head
leaky gasket
z Cylinder head or z Replace cylinder head or
cylinder block cracked block
3. Cooling system z Water pump bearing z Replace bearing
noisy defective

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5.2. Lubricating System

5.2.1. General descriptions and specifications
z General descriptions
All the engine oil pumped up from the oil pan by the gear type oil pump is filtrated
through the oil cooler and oil filter, and this filtrated oil is forced through the main
oil gallery in the cylinder block from where it is distributed to lubricate the various
sliding parts in order to ensure normal engine performance.
z Specifications
Item Specifications Item Specifications
Lubricating system Forced pressure Oil filter type Full flow
circulation
Oil pump type Gear type Bypass for filter element
2
Relief valve opening pressure 10±1.5 kg/cm Valve opening pressure 1.8 ~ 2.3 kg/cm2
Bypass for oil cooler Bypass for entire oil filter
2 2
Opening pressure 5+1 kg/cm Valve opening pressure 4.0 ~ 4.8 kg/cm
Adjusting valve for spray nozzle
Opening pressure 1.5 ~ 1.8 kg/cm2
z Diagram of lubricating system

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5.2.2. Oil pump

z Disassembly
(1) Disassembly of oil pump drive
gear
a. Unscrew the screw and
disassemble the oil relief valve.
b. Unfold the washer for the oil
pump drive gear fixing nut and
remove the nut.
c. Disassemble the drive gear.
(2) Remove the oil pump cover

fixing nuts and disassemble the
oil pump cover.
The oil pump cover is fixed with
the two dowel pins.
(3) Disassemble the drive gear and

driven gear.
z Inspection and correction

(1) With steel rule and feeler gauge,
measure the axial end play of
the oil pump gear. Replace if the
measured value is beyond the
limit.
End play limit 0.025 ~ 0.089 mm
(2) With a feeler gauge, measure

the amount of backlash between
the oil pump drive gear and
driven gear. Replace if the
measured value is beyond the
limit.
Backlash limit 0.50 ~ 0.64 mm

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(3) Measuring clearance between

drive shaft and bushing
a. Measure the outside
diameters of the drive shaft
and driven shaft, and replace
if the measured values are
less than the limit
(φ16.95mm)
Standard φ16.95 ∼ φ16.968 mm
b. Measure the inside diameter

of the pump body bushing to
determine the clearance
between the bushing and
shaft, and compare the
measured value with the
standard value to determine
whether to replace or not.
Clearance 0.032 ～ 0.077 mm
z Reassembly
(1) For reassembly, reverse the
disassembly sequence.

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1. Oil consumption
z Poor oil z Use suggested oil
excessive
z Oil seal or packing leaky z Replace
z Pistons or piston rings z Replace pistons and/or
worn piston rings
z Cylinder liner worn z Replace cylinder liner
z Replace pistons and/or

z Piston rings sticking
piston rings
z Valve guide oil seals or
valve guides, or valve stem z Replace
worn
2. Oil pressure too low z Poor oil z Use suggested oil
z Relief valve sticking z Replace
z Restrictions in oil pump
z Clean strainer
strainer
z Oil pump gear worn z Replace
z Oil pump feed pipe cracked z Replace
z Oil pump defective z Correct or replace
z Oil pressure gauge
z Correct or replace
defective
z Various bearings worn z Replace
3. Oil deteriorates
z Restriction in oil filter z Replace filter element
quickly
z Replace piston rings and
z Gases leaking
cylinder liner
z Wrong oil used z Use suggested oil

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5.3. Turbocharger
5.3.1. Main data and specifications

1) Main data and specifications
Specification GE08TIC
Turbocharger model HX35G-8233AJ/J13S11

Air pressure 2
1.8 kg/cm
at compressor outlet
at maximum
output Air suction volume 16.8 m3/min
Speed of turbine revolution 80,000 rpm
Maximum allowable speed 130,000 rpm

Max. allowable temperature of exhaust gas
720 °C
at turbine inlet
Lubricating system External oil supply
Weight 14 kg
2) Construction
1. Impeller casing A. Air inlet

2. Turbine casing B. Gas outlet
3. Bearing casing C. Gas inlet
4. Impeller D. Oil supply
5. Turbine E. Oil return

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3) Construction
4 Bearing housing 32 O-ring 67 Hex bolt

5 Turbine housing 33 Oil baffle 74 Actuator ass`y
6 Turbine wheel ass`y 34 Inlet baffle 75 Hose clamp
7 Compressor wheel 36 Thrust collar 77 Actuator clip
8 Compressor housing 38 Heat protector cover 80 Cover plate
11 Journal bearing 43 Oil seal plate 81 Hose
12 Thrust bearing 46 Gasket 82 Elbow
13 Piston ring seal(turbine) 57 Hex bolt 83 Hex nut
16 Piston ring seal 61 Lock nut 88 Clamp plate
22 Retainer ring 64 Snap ring 91 Retaining ring
31 Oil stopper

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3) Operating principle
The turbocharger is a system designed to make use of the engine exhaust gas
energy to charge high-density air into the cylinders, thereby to increase the
engine output.
5.3.2. General descriptions

The engine output is determined by the fuel delivery volume and engine efficiency.
To burn the supplied fuel completely to change into effective power for the engine,
the volume of air enough to burn the fuel completely should be supplied into the
cylinders.
Therefore, the engine output is determined substantially by the cylinder capacity, and
a greater volume of compressed air is charged into cylinders of given capacity, the
greater engine output can be obtained as a greater volume of air charged into the
cylinders burns so much more fuel.
As explained, the compressing of air to supply into the cylinders is called
"Supercharging" and the making use of the energy of exhaust gas discharged from
the combustion chamber to charge the compressed air into the cylinders is called
"Turbocharging".
5.3.3. Functions
1) Turbine
Exhaust gas discharged from the combustion chamber distributes its own energy
to the turbine blades while passing the inside of the turbine housing, with the
result that the turbine shaft can get rotating force. This is the operating principle of
'turbine', which is mounted with seal rings and heat protector to prevent exhaust
gas from affecting the bearings adversely.

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2) Compressor
The compressor, which is connected to the turbine over the one and same shaft
to form a rotating body, takes in and compresses ambient air with rotating force
transmitted from the turbine shaft. Then, the compressed air is delivered to the
intake stake. This is the operating principle of the compressor.
3) Bearings
(1) Thrust bearing
The turbine wheel creates thrust force. Therefore, exercise care so that the
shaft is not deviated from its the original position due to this thrust.
(2) Journal bearing

This journal bearing of floating type forms a dual oil film on both the inside and
outside of the bearing so that the bearing can rotate independently. As the dual
oil film plays a role as a damper, the sliding speed of the bearing surface
becomes lower than the rotating speed of the shaft, resulting in assurance of
stability in its movement.
4) Sealing - Compressor shaft

The compressor is of a dual construction type composed of seal plate and seal
ring to prevent the leak of compressed air or lubricating oil.
5.3.4. Precautions for operation

1) Precautions for operation of engine
The following precautions should be observed when starting, operating, or
stopping the engine:
Operations Precautions Reasons

When starting 1) Check oil level
the engine
2) Crank the engine with starter to 2) Abrupt starting of the engine
check the increase in oil causes the engine to rotate with
pressure(until the needle of oil not being distributed not only
pressure gauge starts to move or to each part but also to the
pressure indicator lamp is turbocharger, resulting in
actuated) before starting the abnormal wear or seizure on the
engine. bearing due to insufficient supply
of oil.
3) When having replaced oil, oil 3) In the case of the engine stopped
filter element, or lubricating parts, for extended time or in a cold
or when having stopped the place, oil fluidity within the pipes
engine for extended period of can be deteriorated
time, or in a cold place, loosen
the oil pipe connections and
operate the starter motor until oil
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is discharged. After completing
the operation, be sure to
retighten the oil pipe connections
portion before starting the engine.
Immediately 1) Run the engine at idle for 5 1) Applying load abruptly If load is
after starting minutes after starting off. abruptly applied with the engine
and turbocharger rotating
unsmoothly, such parts that a
sufficient amount of oil has not
reached can be seized up.
2) Check each part for leakage of 2) Leakage of oil, gas, and air
oil, gas, and air, and take proper (especially, oil leak) causes drop
measure. in oil pressure and loss of oil
results in seizure of the bearing.
During operation Check the followings:
1) Oil pressure At idle: 0.8 kg/cm2 or 1) Excessively low oil pressure
2
more At full load: 3.0～4.8 kg/cm causes unusual wear or seizure
of the bearing. Too high pressure
causes oil leakage.
2) If unusual sound or vibration is 2) The engine Is operated
heard or felt, reduce engine continuously with unusual sound
revolutions slowly and locate the or vibration not corrected, it can
cause. be damaged beyond repair.
When stopping 1) Run the engine at idle for 5 1) If the engine is put to a stop after
the engine minutes before stopping. being operated at high load, heat
from the red-hot turbine blades is
transmitted to the bearing portion
and burns oil to cause seizure of
the bearing metal and rotating
shaft.
5.3.5. Walk-around check and servicing

As the condition of turbocharger depends greatly on how well the engine is serviced,
it is very important to maintain the engine in accordance with the specified
maintenance procedure.
1) Intake system
Pay particular attention to the air cleaner when servicing the intake system.
In the case of wet-type air cleaner, if the level of oil surface is lower than specified,
cleaning effect is poor; if too high, the cleaner draws in oil to foul the case.
Especially, if the rotor is fouled, the sophisticatedly-tuned balance is broken to
create vibration and to cause seizure and unusual wear to the bearing.
Therefore, it is very important to use a good quality air cleaner all the time.
In the case of dry-type air cleaner, it is essential to clean it to reduce intake
resistance as much as possible.

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2) Exhaust system
Pay particular attention to prevent gas leaks and seizure when servicing the
exhaust system because leakage of exhaust gas from discharge pipes,
turbocharger fixing portions, etc. lowers charging effect.
As such components as turbine chamber that becomes red-hot during operation
use heat resisting steel nuts, do not interchange these nuts with ordinary steel
nuts. In addition, apply anti-seizure coating to fixing nuts on the portions as
designated.
3) Lubricating system
Pay particular attention to oil quality and oil filter change intervals when servicing
the lubricating system. Deteriorated engine oil affects adversely not only the
engine but torso the turbocharger. Suggested engine oils for the turbocharger-
mounted engine are as follows:
Recommend oil Sulfated ash

Engine model
SAE No. API No. content
GE08TIC SAE 15W40 above CD or CE Bellow 0.5 %

5.3.6. Periodical checking and servicing

Make it a rule to check the turbocharger assembly for condition and contamination
periodically.
1) Guide for checking the rotor for rotating condition

The inspection of the rotor assembly for rotating condition should be performed by
the degree of unusual sound. If a sound detecting bar is used, install its tip on the
turbocharger housing and increase the engine revolutions slowly. If a high-pitch
sound is heard continuously, it means that the rotor assembly is not normal. In
this case, as the metal bearing and rotor are likely to be in abnormal conditions,
the turbocharger should be replaced or repaired.
2) Guide for checking rotor end play

Disassemble the turbocharger from the engine, then check the rotor axial play
and radial play.
When disassembling the turbocharger, be sure to plug the oil inlet and outlet ports
with taps, etc.

GE08TIC
(1) Rotor axial play
(2) Rotor radial play
(3) If the measured axial and radial plays are beyond the limit of wear, replace or
repair the turbocharger.
3) Guide for disassembling/cleaning and checking the turbocharger

First, disassemble the turbocharger from the engine and clean/check it with the oil
inlet and outlet plugged with tape and so on.
4) Precautions for reassembling the turbocharger onto the engine

For reassembly of the turbocharger or handling it after reassembly operation, be
sure to observe the following precautions:
Especially, exercise extreme care to prevent foreign matters from entering the
inside of the turbocharger.
(1) Lubricating system

z Before reassembling the turbocharger onto the engine, inject new oil in the
oil inlet port and lubricate the journal and thrust bearings by rotating them
with hand.

GE08TIC
z Clean not only the pipes installed between the engine and oil inlet port but
also the oil outlet pipe and check them for damage or foreign matters.
z Assemble each joint on oil pipes securely to prevent oil leaks.
(2) Intake system

z Check the inside of the intake system for foreign matters.
z Assemble each joint on the intake duct and air cleaner securely to prevent
air leaks.
(3) Exhaust system

z Check the inside of the exhaust system for foreign matters.
z Be sure to use heat resisting steel bolts and nuts. Do not interchange them
with ordinary steel bolts and nuts when performing reassembly operation.
Apply anti-seizure coating to the bolts and nuts.
z Assemble each joint on the exhaust pipes securely to prevent gas leaks.

1. Excessive black smoke 1) Air cleaner element clogged Replace or clean
2) Restrictions in air duct Check and correct
3) Leakage at intake manifold Check and correct

Disassemble/repair
4) Turbocharger seized up and not rotating
or replace
5) Turbine blades and compressor blades coming Disassemble/repair
in contact with each other or damaged or replace
6) Exhaust piping deformed or clogged Check and correct
2. Excessive white smoke Disassemble/repair
1) Oil leak into turbine and compressor
or replace
2) Worn or damaged seal ring due to excessive Disassemble/repair
wear of bearing or replace
3. Low engine output 1) Gas leak at each part of exhaust system Check and correct
2) Air cleaner element restricted Replace or clean

Disassemble/repair
3) Turbocharger fouled or damaged
or replace
4) Leakage at discharge port on compressor side Check and correct
4. Unusual sound or Disassemble/repair
1) Rotor assembly coming in contact
vibration or replace
Disassemble/repair
2) Unbalanced rotation of rotor
or replace
Disassemble/repair
3) Seized up
or replace
4) Each joint loosened Check and correct

GE08TIC
5.4. Air Intake System
5.4.1. Maintenance
(only when engine is switched off)
Empty the dust bowl (7) regularly. The bowl should never be filled more than halfway
with dust.
On slipping off the two clamps (3), the dust bowl can be removed. Take off the cover
(6) of the dust bowl and empty.
Be careful to assemble cover and bowl correctly.
There is a recess in the cover rim and a lug on the collector which should register.
Where the filter is installed horizontally, watch for “top” mark on cleaner bowl.
1. Connection port,
fouling indicator
2. Cleaner housing
3. Clamp
4. Element
5. Hexagon nut
6. Cover
7. Dust bowl
5.4.2. Changing filter element

z On removing the hexagon nut, take
out the dirty cartridge and renew or
clean.
z Wipe the cleaner housing with a
damp cloth, in particular the sealing
surface for the element.
NOTE:
Do not allow dirt to get into the
clean air end.

GE08TIC
5.4.3. Cleaning filter elements

z By compressed air
(wear goggles)
- For the purpose, the air gun should
be fitted with a nozzle extension
which is bent 90° at the discharge
end and which is long enough to
reach down inside to the bottom of
the element.
- Moving the air gun up and down,
blow out the element from the
inside (maximum 500kPa - 5 bar)
until no more dust comes out of the filter pleats.
z By washing
- Before washing, the element should
be precleaned by means of
compressed air, as described
above.
- Then allow the element to soak in
lukewarm washing solvent for 10
minutes, and then move it to and
for in the solvent for about 5
minutes.
- Rinse thoroughly in clean water, shake out and allow drying at room temperature.
The cartridge must be dry before it is reinstalled.
- Never use steam sprayers, petrol (gasoline), alkalis or hot liquids etc. to clean
the filter elements.
z Knocking out dirt by hand
- In emergencies, when no compressed air or cleaning agent is available, it is
possible to clean the filter cartridge provisionally by hitting the end disk of the
cartridge with the ball of one's thumb.
- Under no circumstances should the element be hit with a hard object or knocked
against a hard surface to loosen dirt deposits.
z Checking the filter cartridge
- Before reinstalling the cartridge, it
must be checked for damage e.g.
to the paper pleats and rubber
gaskets, or for bulges and dents
etc. in the metal jacket.
- Cracks and holes in the paper
pleating can be established by
inspecting the cartridge with a
flashlight.
- Damaged cartridges should not be reused under any circumstances. In cases of
doubt, discard the cartridge and install a new one.
GE08TIC
6. Special Tool List
No. Part no. Tool name Descriptions Applications
1 EF.123-173 Oil seal insert ass’y(Front)
Tool
2 EF.123-184 Oil seal insert ass’y (Rear)
3 EF.123-052 Oil seal puller ass’y (Front)
4 EF.123-048 Oil seal puller ass’y (Rear)
5 EF.123-193 Cylinder pressure tester adapter
6 EF.123-365 Cylinder liner puller ass’y
Tool
7 EF.123-179 Valve stem seal punch
8 EU.2-0131 Valve clearance adjust ass’y -
9 EF.123-065 Valve spring press
146 Special Tool List

GE08TIC
No. Part No. Tool name Descriptions Applications
10 EU.2-0647 Crankshaft gear punch
Tool
EF.123-064
(GE08TIC only)
11 Piston sleeve
EF.120-208
(All engine)
12 60.99901-0027 Feeler gauge
13 65.98801-0001 Filter wrench
14 T7610001E Snap ring plier
15 T7621010E Piston ring plier
147 Special Tool List

GE08TIC
Appendix
z Tightening torque for major parts

Screw Strength
Major Parts Tightening torque Remarks
(Diameter x pitch) (grade)
1st : 6.0 kg.m
2nd : 180。
Cylinder head bolt M14 x 1.5 10.9T
3rd : 150。
(Angle method)
1st : 10 kg.m
Connecting rod bearing cap bolt M14 x 1.5 12.9T 2nd : 15 kg.m
3rd : 18 kg.m
1st : 15 kg.m
Crankshaft main bearing cap bolt M16 x 1.5 12.9T 2nd : 25 kg.m
3rd : 30 kg.m
Balance weight fixing bolt M12 x 1.5 10.9T 9.0 kg.m
Flywheel housing fixing bolt M14 x 1.5 10.9T 8.0 kg.m
Flywheel fixing bolt M14 x 1.5 10.9T 21.5 kg.m
Crankshaft pulley fixing bolt M12 x 1.5 10.9T 13.4 kg.m
Oil spray nozzle M14 x 1.5 - 7.0 kg.m
z Tightening torque for plug screw

Diameter
M10x1.0 M12x1.5 M14x1.5 M16x1.5 M18x1.5 M22x1.5 M26x1.5 M30x1.5
x pitch
Torque
5.0 5.0 8.0 8.0 10.0 12.0 12.0 15.0
(kg.m)
z Tightening torque for hollow screw(4-hole)

Material M8 M10 M12 M14 M16 M18 M22 M26 M30 M38
SM25C - 1.6 2.5 3.5 4.5 5.5 9.0 13.0 18.0 30.0
*
SUM22L 0.8 1.8 3.0 4.0 5.5 6.5 11.0 16.0 20.0 35.0
STS304 0.8 1.8 3.0 4.0 5.5 6.5 11.0 16.0 20.0 35.0
* : Adopted in DOOSAN’s engine
148 Appendix
GE08TIC
z Standard bolt tightening torque table

Refer to the following table for bolts other then described above
Degree of strength
3.6 4.6 4.8 5.6 5.8 6.6 6.8 6.9 8.8 10.9 12.9
Diameter
x (4A) (4D) (4S) (5D) (5S) (6D) (6S) (6G) (8G) (10K) (12K)
pitch Limit value for elasticity (kg/mm2)
(mm)
20 24 32 30 40 36 48 54 64 90 108
Tightening torque (kg.m)
M5 0.15 0.16 0.25 0.22 0.31 0.28 0.43 0.48 0.5 0.75 0.9
M6 0.28 0.30 0.45 0.4 0.55 0.47 0.77 0.85 0.9 1.25 0.5
M7 0.43 0.46 0.7 0.63 0.83 0.78 1.2 1.3 1.4 1.95 2.35
M8 0.7 0.75 1.1 1 1.4 1.25 1.9 2.1 2.2 3.1 3.8
M8x1 0.73 0.8 1.2 1.1 1.5 1.34 2.1 2.3 2.4 3.35 4.1
M10 1.35 1.4 2.2 1.9 2.7 2.35 3.7 4.2 4.4 6.2 7.4
M10x1 1.5 1.6 2.5 2.1 3.1 2.8 4.3 4.9 5 7 8.4
M12 2.4 2.5 3.7 3.3 4.7 4.2 6.3 7.2 7.5 10.5 12.5
M12x1.5 2.55 2.7 4 3.5 5 4.6 6.8 7.7 8 11.2 13.4
M14 3.7 3.9 6 5.2 7.5 7 10 11.5 12 17 20
M14x1.5 4.1 4.3 6.6 5.7 8.3 7.5 11.1 12.5 13 18.5 22
M16 5.6 6 9 8 11.5 10.5 17.9 18.5 18 26 31
M16x1.5 6.2 6.5 9.7 8.6 12.5 11.3 17 19.5 20 28 33
M18 7.8 8.3 12.5 11 16 14.5 21 24.2 25 36 43
M18x1.5 9.1 9.5 14.5 12.5 18.5 16.7 24.5 27.5 28 41 49
M20 11.5 12 18 16 22 19 31.5 35 36 51 60
M20x1.5 12.8 13.5 20.5 18 25 22.5 35 39.5 41 58 68
M22 15.5 16 24.5 21 30 26 42 46 49 67 75
M22x1.5 17 18.5 28 24 34 29 47 52 56 75 85
M24 20.5 21.5 33 27 40 34 55 58 63 82 92
M24x1.5 23 25 37 31 45 38 61 67 74 93 103
Others :
1. The above torque rating have been determined to 70% or so of the limit value
for bolt elasticity.
2. Tension is calculated by multiplying tensile strength by cross section of thread.
3. Special screws should be tightened to 85% or so of the standard value.
For example, a screw coated with MoS2 should be tightened to 60% or so of
the standard value.
149 Appendix
GE08TIC
z Maintenance specification table

(Unit : mm)
Stand value Limit
Group Part Inspection Item Correction Remark
for assembly for use
Measure unworn
Inside diameter of portion beneath the
φ111~φ111.022 φ111.122 Replace liner
cylinder liner for wear rim of the upper
side
Projection
Need amount of
Cylinder Amount of liner difference between
0.03~0.08 - projection without
block & projection adjacent liners :
fail
liner 0.15 ↓
The flatness of upper
Engine Correct with a Referenced length :
surface of cylinder 0.05 -
body surface grinder 200mm
block
Hydraulic test for 1
4 - Replace if leaky
minute (kg/cm2)
Valve seat Intake 0~0.3 0.55 Replace valve
depression Exhaust 0~0.3 0.55 seat
Cylinder
Replace cylinder
head & Cylinder head height 109.9 ~110.1 108.4
head
valve
Hydraulic test for 1 Water temperature
4 - Replace if leaky
minute (kg/cm2) 70°C
Measure at 13mm
Outer diameter of
φ110.758~φ110.772 Replace liner away from lower
piston
surface of piston
Clearance between Replace one worn
0.228~0.264 0.3
piston and liner more
Top ring - - Replace piston if
Width of
groove width is
piston ring 2nd ring 3.06~3.08 -
beyond specified
Piston grooves
Oil ring 4.04~4.06 - value
Measure unworn
Piston projection from
portion beneath the
cylinder block upper 0 ~ 0.12 Must exist
rim of the upper
surface
side
Major Permissible weight
moving difference of each ±15 g 96 g↓ Replace piston
parts piston
Top ring 0.40~0.60 1.5 Standard gauge
Piston ring 2nd ring 0.40~0.60 1.5 inside diameter :
Replace ring
gap Oil ring 0.30~0.50 1.5 φ108
Piston
Piston ring Top ring - -
ring Replace ring or Limit for use is if for
side 2nd ring 0.07~0.102 0.15
piston standard clearance
clearance Oil ring 0.05~0.085 0.15
Cross Install by
Direction of ring gap - -
120°
Outer diameter of
φ41.994 ~ φ42.000 φ41.94 Replace piston pin
Piston piston pin
pin Clearance between Replace one worn
0.003~0.015 0.08
piston pin and its bush more
150 Appendix
GE08TIC
(Unit : mm)
Stand value Limit
Measure in horizontal
Radial run-out of Correct
- 0.01 and vertical directions
journal and pin with a grinder (against axial direction)
Outside diameter of Use under sized
φ83.966~φ83.988 φ83
journal bearings
Outside diameter of respectively
φ70.971~φ70.990 φ70 (0.25,0.5,0.75,1.0)
pin
Ellipticity of journal 0.008 0.025
and pin
Concentricity of 0.01 0.03
journal and pin
Taper of journal and 0.02 0.03
pin
Clearance between Measure at crown
crankshaft and 0.052~0.122 0.25 Replace bearings part not parting line
Crank bearing
shaft Replace
End play of crankshaft 0.15~0.325 0.5 thrust bearing
Measure at No.4
Adjust by a press
Run-out of crankshaft 0.06 0.1 ↓ bearing (No. 1 & 7
if bended bearing supported)
Balance of crankshaft 60 or less Check dynamic
60 ↓ Measure at 400 rpm
(g.cm) balance
Torque value journal Clean out foreign
Coat the bolt with
bearing cap bolt 30 - objects on joining
engine oil
(kg.m) surface
Measure after
Crush height of tightening metal cap
0.08~0.110 -
journal bearing and releasing one
stud
Oil seal for wear(crank Replace oil seal
- -
shaft rear) if oil leaking
Major End play of con-rod 0.170 ~ 0.248 0.50 Replace con-rod
moving Clearance between
con-rod bearing and 0.034 ~ 0.098 0.25 Replace bearing
parts crank pin
Clearance between
small end bush & 0.050~0.081 0.12
piston pin
Measure after installing
Crush height of con-
Connecting 0.04~0.07 - the bearing and
rod bearing releasing one bolt
rod
Side clearance of big- - 0.50 Replace con-rod
end and small-end
Allowable weight
difference per con- 30 g ↓ -
rods
Torque value of Clean out foreign
Coat the bolt with
con-rod bearing cap 18 - objects on joining
engine oil
bolt (kg.m) surface
Diameter of cam shaft φ57.86~φ57.88 φ57.52
journal
Clearance between
Cam cam shaft and cam 0.12~0.17 0.24 Replace cam bush
bush
shaft Replace thrust
End play of camshaft 0.28~0.43 0.6 washer
Correct or replace
Run-out of camshaft 0.05 0.2 the cam shaft
Clearance between
idle shaft bush and 0.025~0.091 0.15
idle shaft
Timing End play of idle gear Replace thrust
0.043~0.167 0.3
gear shaft collar
Back-lash between Correct or replace
gears(cam, idle, crank 0.16~0.28 0.35 gear
and ignition timing)
151 Appendix
GE08TIC
(Unit : mm)
Stand value Limit
Diameter of intake φ8.950~φ8.970 φ8.93 Replace When replacing
valve stem Valve & valve valve, replace valve
Diameter of φ8.935~φ8.955 φ8.91 guide guide alike
exhaust valve stem
Clearance
between Intake 0.030~0.065 0.15 Replace Replace one worn
valve stem valve or valve more
and valve Exhaust 0.045~0.080 0.15 guide
guide
Thickness Intake 2.7
of valve Max. 1 Replace valve
head Exhaust 2.2
Clearance
between Intake 2.0 -
valve guide
and valve Exhaust 2.0 -
spring seat
Clearance between Spread oil over
valve guide and -0.039~-0.010 valve guide and
cylinder head (Press fit) press it into the
installing hole hole
Concentricity between
valve stem and valve 0.05 Without spring seat
head
Free length Approx. 64 -
(mm)
Valve Tension force
Intake (when pressed 67~73 66.5 Replace
valve to 41mm)kg valve spring
spring Squareness
(along free 1.5° -
length
direction)
Valve Free
system length 60 -
(mm)
Tension
force(when Replace
Inner pressed to 26.9~30.3 -
valve spring
38mm)kg
Squreness
(along free 1.5° -
Exhaust length
valve direction)
spring Free 71 -
length
Tension
force(when 62.7~69.3 - Replace
Outer pressed to
41mm)kg valve spring
Squreness
(along free 1.5° -
length
direction)
Valve Intake 0.3 -
clearance Adjust
(at cold) Exhaust 0.3 -
Grind or replace if
Joining surface of severely pitted on
valve stem and rocker - - tip of rocker arm
arm bush and stem
Clearance between Replace bush
rocker arm shaft & 0.040~0.113 0.2 or shaft
rocker arm bush
Diameter of rocker φ23.939~φ23.96 φ23.75 Replace
arm shaft for wear
Run-out of push rod - 0.3 Replace
152 Appendix
GE08TIC
(Unit : mm)
Stand value Limit
Clearance between
tappet & tappet hole 0.035~0.077 0.15 Replace tappet
of cyl. block
Valve
Tappet Diameter of tappet φ19.944~φ19.965 - Replace tappet
system
Replace
Tappet face in contact
- - if severely worn or
with cam
deformed
Oil pressure Check oil leakage
(at normal speed) 4.8 or less 3.5 and clearance
Oil kg/cm2 between each part
pressure Use
Oil pressure
2 0.8~1.4 0.6 recommended
(idling) kg/cm
oil
Max. permissible
- 105
oil temperature °C
Oil Must not exceed
Permissible
temperature this value
oil temperature - 120
in short time °C
Axial play 0.055 ~ 0.105 -
of oil pump gear
Replace gear
Clearance between
or cover
gear shaft & oil pump 0.032 ~ 0.077 -
cover hole
Clearance between
Replace bush
drive gear shaft and 0.040 ~ 0.094 -
or cover
cover hole
Replace gear
Diameter of gear shaft φ16.950~φ16.968 φ17e7
Lubrica Oil shaft
ting pump Diameter of driving
φ28.000~φ28.033 Replace bush φ28e7
system gear bush
Between
crank
0.15 ~ 0.25 0.8
gear & idle
gear
Backlash Adjust back-lash
Between oil
pump drive
0.15 ~ 0.25 0.8
gear &
idle gear
Oil pressure control
2 4.0 ~ 4.8 -
valve (kg/cm )
By-pass valve for filter
1.8 ~ 2.3 - Replace valve
element (kg/cm2 )
Valve
By-pass valve for full
opening 2 4.0 ~ 4.8 -
oil filter (kg/cm )
pressure
Relief valve for oil
2 8.5 ~ 11.5 -
pump (kg/cm )
Replace valve
Spray nozzle control
2 1.5 ~ 1.8 -
valve (kg/cm )
Damage of oil filter
Oil filter - - Clean or replace
cartridge
153 Appendix
GE08TIC
(Unit : mm)
Stand value Limit
for assembly For use
Delivery volume l/min
- Engine speed
Check the water
2,700rpm 280 - For any restrictions
passage
- Water temp. 80°C
- Pressure : 0.8 kg/cm2
Water Replace if impeller
pump Clearance between
0.35 - & housing are
impeller & housing
damaged
Cooling
Perpendicularity of Adjust by a bench
system 0.3
pulley press
Belt depression
Approx. 15 - Adjust
(with thumb) mm
Operating temperature
79~95 -
Cooling (permissible temp.) °C
Must not exceed
water Permissible
this value
temp temperature - 105
in a short time °C
Ignition Spark
Gap of spark plug 0.39-0.40 - Correct or replace
system plug
Refer to
Running-in the engine - - supplement
“running-in”
Inspection
Compression pressure 13 or
at 2 16 or more Correct
completion of cylinder (kg/cm ) more
Cylinder at 200rpm or more
pressure
Compression pressure ±10% or less
(20°C)
difference of each against Correct
cylinder average
154 Appendix
GE08TIC
z Engine Assembly
155 Appendix

Operation MaintenanceGE08TI

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Operation MaintenanceGE08TI

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What are the symbols used in the manual to indicate service operations?

What are the symbols used in the manual to indicate service operations?

What are some of the engine specifications mentioned in the manual?

What are some of the engine specifications mentioned in the manual?

65.

Generator Natural Gas Engine

Disassembly Pay close attention-Important

Reassembly Tighten to specified torque

Align the marks Use special tools of manufacturer's

Directional Indication Lubricate with oil

Inspection Lubricate with grease

During engine maintenance, please observe following instructions to prevent environmental

Printed in May 2005 PS-MMG0416-E1A

3. Disassembly and Reassembly of Major Components

4. Commissioning and Operation

5. Maintenance of Major Components

6. Special Tool List 147

Printed in May 2005 PS-MMG0416-E1A

1. Safety Regulations & Engine Specifications

1.1. General notes

1.2. Handle compressed natural gas safety

1.2.1. Avoid heating near pressurized fluid lines

1.2.2. Venting an operable engine to relieve natural gas pressure

1.2.3. During commissioning, starting and operation

1.2.4. During maintenance and care

z Fuel is inflammable. Do not smoke or use naked lights in its vicinity.

1.2.5. When carrying out checking, setting and repair work

1.2.6. To prevent damage to engine and premature wear

z Have the engine maintained at the specified intervals.

1.2.7. To prevent pollution

1.2.8. Notes on safety in handling used engine oil

Ensure that used engine oil is disposed of properly.

1.2.9. General repair instructions

1.3. General Information

1.3.1. Engine Specifications

Items Engine model GE08TI

Carburetor Impco 200 varifuel carburetor

1.3.2. Engine Power

50Hz 141 kW 128 kW 115 kW

1.4. Engine Assembly

1 Cooling water pump 12 Push rod

1.4.2. Engine sectional view (cross)

1 Oil spray nozzle 6 Spark plug

1.4.3. Engine assembly views

1 Lifting hook 14 Water inlet(for Intercooler)

2.1. Engine model and serial number

z Engine serial No. (GE08TIC)

2.2. Engine Characteristic

2.2.1. Natural gas

2.2.2. Natural gas

2.2.3. Engine ignition system

2.2.4. Engine speed controller : ESC

2.2.5. Ignition control module : ICM

2.2.6. Cylinder block

2.2.7. Piston, con-rod and crankshaft

2.2.8. Engine timing

2.2.10. Lubrication system

2.2.11. Engine oil

First oil change After 50hr operation

Engine model GE08TIC every 200hr

z The following oils are also recommended

15W40 above CD or CE Bellow 0.5 %

z Engine oil capacity