Motor Doosan - Gv158-180-222ti (C)

950106-058010EN
Operation &
Maintenance Manual
GAS GENERATOR ENGINE
GV158TIC, GV180TIC, GV222TIC

FOREWORD
This manual is designed to serve as a reference for DOOSAN Infracore (here after DOOSAN) customers and distributors
who wish to gain basic product knowledge on DOOSAN GV158TIC, GV180TIC, GV222TIC natural gas engines.
These economical and high-performance natural gas engines (GV158TIC 8 cylinders), (GV180TIC 10 cylinders),
(GV222TIC 12 cylinders) are 4 strokes and V-type have been so designed and manufactured to be used for the generator
& power unit 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;
● Take old oil to an old oil disposal point only.

● Ensure without fail that oil and diesel fuel will not get into the sea or rivers and canals or the ground.
● Treat undiluted anti-corrosion agents, antifreeze agents, filter element and cartridges as special waste.
● 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.
For the last, the content of this maintenance instruction may be changed without notice for some quality improvement and
please feel free to contact to our agents near by your location for any services. Thank you.
2020. 06.
950106-058010EN
Doosan Infracore
* Items exempted from warranty coverage
● Malfunctions resulting from failing to comply with the proper handling instructions, regular inspections, and machine
storage techniques specified in the user manual
● Malfunctions resulting from failing to have the machine repaired at a designated dealer or center, or resulting from
the use of non-genuine parts
● Malfunctions resulting from unauthorized modifications, changes, or external hardware
● Malfunctions resulting from incorrect operation by the user, delayed repairs, accidents, and natural disasters
* The contents of this operation and maintenance manual are the exclusive property of Doosan Infracore. Any unautho-
rized reproduction, printing and distribution thereof are strictly prohibited.
CONTENTS
1. Safety Regulations & Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1. General Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2. Handle Compressed Natural Gas Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3. Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4. Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2. Technical Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1. Engine Model and Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.2. Diagnostic Display Module (CPU - 95) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.3. Engine Characteristic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.4. Diagnosis and Remedy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.5. Engine Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3. Disassembly and Reassembly of Major Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

3.1. Engine Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.2. Measurement and Inspection of Major Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.3. Engine Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
3.4. Starting and Trial Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3.5. Speed Controller Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3.6. Display Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
3.7. Diagnosis and Remedies of Trouble Causes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
4. Electrical Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

4.1. Gas Fuel Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
4.2. Electrical Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
4.3. Speed Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
4.4. Ignition Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
4.5. Ignition Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
5. Maintenance of Major Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

5.1 Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
5.2 Lubricating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
5.3. Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
5.4. Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
5.5. V-Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
5.6. Air Intake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
6. Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
6.1. Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
6.2. Inspection Prior to Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
● Appendix
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 prob-
lems 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 sec-
tions 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.
● Do not smoke when installing or servicing
the engine or fuel system.
● 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 unde-
tected gas leak may be safely vented with- EB8O2001
out being ignited.
● 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.
EB8O2002
-1- Safety Regulations & Engine Specifications

1.2.1. Avoid heating near pressurized fluid lines
● Wear welding goggles and gloves when

welding or using an acetylene torch.
● Insure a that metal shield separated the
acetylene and oxygen which must be
chained to a cart.
● Do not weld or heat areas near fuel tanks
or fuel lines.
HDO1049I
1.2.2. Venting an operable engine to relieve natural gas pressure
● To avoid personal injury an operable nat-

ural gas engine must be kept in a well
ventilated area away from open flames
and sparks.
● 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 EB8O2003
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 vehicle batteries using switch in battery compartment or by disconnecting battery ground
cable.
5) Slightly loosen the NG 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.
Safety Regulations & Engine Specifications -2-

1.2.3. During commissioning, starting and operation
● This is the safety alert symbol. When you see this symbol in this manual, be alert to the potential for
personal injury.
● Carefully read all safety message in this manual and on your safety signs. Be sure new equipment
components and repair parts include the current safety signs.
● Avoid possible injury or death from runaway. Do not start engine by shorting across starter termi-
nals.
● Prevent fires by keeping machine clean of accumulated trash, grease, fuel and debris.
● When the engine is running, do not get too close to the rotating parts.
● Do not touch the engine with bare hands when it is warm from operation risk of bums.
● 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.
● Keep vicinity of engine free of oil and grease. Accidents caused by slipping can have serious conse-
quences.
1.2.4. During maintenance and care
● Always carry out maintenance work when the engine is switched off. If the engine has to be main-
tained 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.
● 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.
● Take into account the amount of oil in the sump. Use a vessel of sufficient size to ensure that the oil
will not overflow.
● 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".
● 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.
● Fuel is inflammable. Do not smoke or use naked lights in its vicinity. The tank must be filled only
when the engine is switched off.
● When using compressed air, e.g. for cleaning the radiator, wear goggles.
● Keep service products (anti-freeze) only in containers which can not be confused with drinks con-
tainers.
● 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
● Checking, setting and repair work must be carried out by authorized personnel only.
● Use only tools which are in satisfactory condition. Worn open-end wrench slip, which could lead to
Injury.
● When the engine is hanging on a crane, no-one must be allowed to stand or pass under it. Keep lift-
ing gear in good condition.
● When working on parts which contain asbestos, comply with the notes.
● When checking spark plug do not put your hands under the electric.
● 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) If faults occur, find the cause immediately and have it eliminated in order to prevent more seri-
ous of damage.
(2) Use only genuine DOOSAN spare parts. DOOSAN will accept no responsibility for damage resulting
from the installation of other parts which are supposedly "just as good".
(3) In addition to the above, note the following points.
● Never let the engine run when dry, i.e. without lube oil or coolant.
● Use only DOOSAN-approved service products (engine oil, anti-freeze and anticorrosion agent).
● Have the engine maintained at the specified intervals.
● Do not switch off the engine immediately when it is hot, but let it run without load for about 5 min-
utes so that temperature equalization can take place.
● Never put cold coolant into an overheated engine. See "Maintenance and care".
● 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.
● Always ensure that the testing and monitoring equipment (for battery charge, oil pressure, cool-
ant temperature) function satisfactorily.
● 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.
(4) Keep no-load operation to a minimum. During no-load operation combustion chamber temperatures
drop to the point where fuel does not burn completely, causing slobbering and white smoke. Always
have some load connected when the gen set is run for long periods.

1.2.7. To prevent pollution
(1) Engine oil, filter elements, fuel filters

● Take old oil only to an oil collection point.
● Take strict precautions to ensure that oil does not get into the drains or into the ground. The
drinking water supply could be contaminated.
● Filter elements are classed as dangerous waste and must be treated as such.
(2) Coolant
● Treat undiluted anti-corrosion agent and / or antifreeze as dangerous waste.
● When disposing of spent coolant comply with the regulations of the relevant local authorities.
(3) Cold Start
● The preheat lamp turns on when the key switch is set to "ON." W h e n the preheat lamp goes off,
proceed as follows. The pre-heater device activates when the coolant temperature is below 25°C,
and the preheating system is automatically adjusted based on the coolant temperature. (The
max. preheating time is around 25 seconds) It does not activate when the coolant temperature is
over 25°C.
Caution:
The engine is equipped with a preheating system for enhancing cold start ability.
● In order to start the engine after the preheat lamp turns off, turn the key switch to the ignition posi-
tion. When the key switch is turned to the ignition position, the pre-heater plug or air heater runs
continuously to make starting the engine easier and reduce white exhaust gas. If the coolant tem-
perature is over 25°C, it is not necessary to operate the pre-heater plug or air heater.
● When the engine starts, set the key switch in the ON position. The timer runs for another 5 min-
utes even after the engine starts to heat the intake air and quickly eliminate white exhaust gas.
Caution:
Do not run the start motor for over 10 seconds. If the engine still cannot be started after
preheating, wait for 30 seconds and then perform preheating again before the second attempt
to start the engine.
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 danger-
ous 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:
● Avoid prolonged or repeated skin contact with used engine oil.
● Protect your skin by means of suitable agents (creams etc.) or wear protective gloves.
● 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.
● After washing apply a fatty skin cream to the skin.
● Change oil-soaked clothing and shoes.
● 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. Viola-
tions 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.
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 dam-
age.
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 depend-
ing 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.

1.3. Engine Specifications
1.3.1. Specifications
Engine Model
GV158TIC GV180TIC GV222TIC
Items
Water-cooled, 4 cycle Vee type
Engine type
Turbocharger & intercooled
Ignition system Spark plug ignition
Combustion chamber type Open dish type
Used fuel NG (Natural Gas)
Fuel supply system Venturi mixer throttle valve type
Cylinder liner type Wet type, chromated or casting liner
Timing gear system Gear driven type
No. of piston ring 2 compression ring, 1 oil ring
No. of cylinder bores x stroke (mm) 8 - 128 x 142 10 - 128 X 142 12 - 128 x 142
Total piston displacement (cc) 14,618 18,273 21,927
Compression ratio 10.2 : 1
Engine dimensions (length x width x height) (mm) 1,388 x 1,222 x 1,238 1,546 x 1,222 x 1,334 1,704 x 1,222 x 1,369
Engine weight (kg) 950 1,175 1,509
Fuel injection order 1 -5-7-2-6-3-4-8 1-6-5-10-2-7-3-8-4-9 1-12-5-8-3-10-6-7-2-11-4-9
Fuel ignition tim- Adjust angle 40° (B.T.D.C) 40° (B.T.D.C)
ing Operate angle 14° (B.T.D.C) 12° (B.T.D.C)
Engine control system ECM (engine control module) type
Compression pressure (kg/cm2) 16 (at 200 rpm)
Intake and exhaust valve clearance (at cold) (mm) 0.30 ±0.05 / 0.40 ±0.05
Open at. 24° (B.T.D.C)
Intake valve
Close at. 36° (A.B.D.C)
Open at. 63° (B.B.D.C)
Exhaust valve
Close at. 27° (A.T.D.C)
Lubrication method Pressurized circulation
Oil pump type Gear type driven by crank shaft
Engine oil Low idle 0.8 - 1.4
pressure High idle 3.0 - 4.8
Oil filler type Full-flow, cartridge type
Lubricating oil capacity (max./min.) (lit) 28 / 26 35 / 28 40 / 33
Oil cooler type Water-cooled
Water pump type Belt driven centrifugal type
Cooling method Pressurized circulation
Cooling water capacity (engine only) (lit) 20 21 23
Thermostat type Wax pallet type
Alternator voltage - capacity (V - A) 24 - 45
Starting motor voltage - output (V - kW) 24 - 7.0
System Air-fuel mixer
Fuel system
Control Throttle valve control

Engine Model
Items
Ignition type One coil per cylinder (no waste spark)
Spark plug Iridium / Platinum electrode plug
Ignition system Spark plug gap 0.3 ~ 0.4
Ignition coil Inductive coil pack
Ignition timing adjustment Controlled by ESC and ICM
Control system On-highway heavy-duty
Control system Voltage (V) 24
Component ESC, ICM, sensor, harness
Model Holset HX35
Turbo charger Type Water cooled, Exhaust gas driving
Exhaust gas temperature (°C) Max. 560
Battery capacity (V - AH) 24 - 200

1.3.2. Engine Power
Production tolerance: ±5%
Condition
Engine model
Stand-by Prime Continuous
50 Hz 253 kW 230 kW 207 kW

(1,500 rpm) (344 PS) (313 PS) (281 PS)
GV158TIR
60 H z 300 kW 270 kW 243 kW
(1,800 rpm) (408 PS) (367 PS) (330 PS)
50 Hz 230 kW 207 kW
-
(1,500 rpm) (313 PS) (281 PS)
GV158TIC
60 H z 270 kW 243 kW
-
(1,800 rpm) (367 PS) (330 PS)
50 Hz 319 kW 290 kW 261 kW

(1,500 rpm) (434 PS) (394 PS) (355 PS)
GV180TIR
60 Hz 375 kW 340 kW 306 kW
(1,800 rpm) (510 PS) (462 PS) (416 PS)
50 Hz 290 kW 261 kW
-
(1,500 rpm) (394 PS) (355 PS)
GV180TIC
60 Hz 340 kW 306 kW
-
(1,800 rpm) (462 PS) (416 PS)
50 Hz 385 kW 350 kW 315 kW

(1,500 rpm) (523 PS) (476 PS) (428 PS)
GV222TIR
60 Hz 451 kW 410 kW 369 kW
(1,800 rpm) (613 PS) (557 PS) (502 PS)
50 Hz 350 kW 315 kW
-
(1,500 rpm) (476 PS) (428 PS)
GV222TIC
60 Hz 410 kW 369 kW
-
(1,800 rpm) (557 PS) (502 PS)
Note: All data are based on operation without cooling fan at ISO 3046.

1.4. Engine Assembly
Note: The images shown represent the standard model; they do not include all models.
1.4.1. Engine sectional view (longitudinal)
5 6 7 8 9 10 11
4
12
13
14 15 16 17 18 19 20
EE3OM001
1. Crank shaft pulley 11. Turbo charger

2. Connecting rod 12. Flywheel
3. Piston 13. Flywheel housing
4. Cylinder liner 14. Vibration damper
5. Valve 15. Oil spray nozzle
6. Rocker arm 16. Oil pan
7. Push rod 17. Oil suction pipe
8. Tappet 18. Crank shaft
9. Gas regulator 19. Cam shaft
10. Ignition coil 20. Oil pump
Safety Regulations & Engine Specifications - 10 -

1.4.2. Engine sectional view (cross)
6 7 8
5 9
4
10
3
11
2
12
13
EE3OM002
1. Oil level gauge 8. Intake manifold

2. Oil filter 9. Spark plug
3. Oil cooler 10. Cylinder head
4. Exhaust manifold 11. Cylinder block
5. Cylinder head cover 12. Oil drain pump
6. Throttle valve 13. Starting motor
7. Inter cooler
- 11 - Safety Regulations & Engine Specifications

1.4.3. Engine assembly views
(1) GV158TIC
9 10
11
5 6 13 14 15 16
4 - + - + - +
17
12
3
7
2 8
18 19 20
EE3OM003
1. Alternator 11. Gas fuel mixer

2. Oil cooler & oil cooler 12. Lifting hook
3. Cooling water pump 13. Inter cooler
4. Water outlet 14. Ignition coil
5. Gas pressure regulator 15. Intake manifold
6. Throttle valve 16. Turbo charger
7. Oil drain pump 17. Exhaust elbow
8. Mounting bracket 18. Vibration damper
9. Oil filler cap 19. Oil pan
10. Exhaust manifold 20. Starting motor

(2) GV180TIC
10
11
5 6 13 14 15 16
- + - + - + - +
17
4
12
3
7
2
8
18 19 20
EE3OM004
\
1. Alternator 11. Gas fuel mixer

2. Oil cooler & oil cooler 12. Lifting hook
3. Cooling water pump 13. Inter cooler
4. Water outlet 14. Ignition coil
5. Gas pressure regulator 15. Intake manifold
6. Throttle valve 16. Turbo charger
7. Oil drain pump 17. Exhaust elbow
8. Mounting bracket 18. Vibration damper
9. Oil filler cap 19. Oil pan
10. Exhaust manifold 20. Starting motor
- 13 - Safety Regulations & Engine Specifications

(3) GV222TIC
18
17
5 6 10 11 12
4
9 - + - + - + - + - +
13
3 7
2 8
14 15 16
EE3OM005
1. Alternator 10. Inter cooler

2. Oil filter & cooler 11. Ignition coil
3. Cooling water pump 12. Turbo charger
4. Water outlet 13. Exhaust elbow
5. Gas pressure regulator 14. Crank shaft pulley
6. Throttle valve 15. Oil pan
7. Oil drain pump 16. Starting motor
8. Mounting bracket 17. Oil filler cap
9. Lifting hook 18. Gas fuel mixer

2. Technical Information
2.1. Engine Model and Serial Number

● The engine model and serial number is
located on the engine as illustrated.
- + - + - + - + - +
● These numbers are required when

requesting warranty and ordering parts.
They are also referred to as engine model
and serial number because of their loca- Engine
tion. serial
number
EE3OM006
● Engine serial No. (example1: GV158TIC)

EEZOD 4 00001
Serial No.
Production year (2004)
Engine model

EI6OM012
EESOA 4 00001
Serial No.
Engine model

EEYOC 4 00001
Serial No.
Engine model
- 15 - Technical Information
2.2. Diagnostic Display Module (CPU - 95)
● The diagnostic display module is designed
to operate in conjunction with a variety of
display/control options.
● This facilitates the application of diagnostic
display module systems to gas engines
operating at varying stages of automation
and sophistication.
IB3O302S
Caution:
1. Do not connect or disconnect the
diagnostic display module to/from
the wiring harness without first
removing the negative (-) battery
cable from the battery.
2. Do not perform remove the inner
parts of the Diagnostic display
module.
R
CPU-95
AUTO MAN DIAG
SETUP TIMING NEXT
F1 F2 RESET ESC
ALARM
F3 F4 ENTER
ACK
EE3OM008
2.3. Engine Characteristic

The DOOSAN GV158TIC, GV180TIC, GV22TIC natural gas engine is an overhead valve, turbocharged,
water-to-air charge cooled, electronically controlled engine.
2.3.1. Design characteristic

● Spark-ignited by the spark plug.
● Electric engine control through the ECM (Engine Control Module) system.
● Turbocharger with a water cooled bearing-housing
2.3.2. Natural gas

● Natural gas is a clean burning fuel, and offers a low particulate emission. Natural gas is also a very
economical fuel.
● 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.
Technical Information - 16 -
2.3.3. Engine ignition system
● 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.
● 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.
● The GV158TIC, GV180TIC, GV222TIC 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.
Installed parts of genertor maker

Gas pressure
Manual shut-off valve Gas filter regulator Gas pressure gauge
Nature gas
Gas pressure
regulator
Inter cooler
Speed Ignition control

controller module
Throttle
valve
R
ALTRONIC CPU-9
5
PART NO.
IGNITION YSTE
S M
S/N
Ignition coil
Fuel mixer
MUST BE INSTALLED PER FORM CPU-95 II
INSTALLE CONFORMEMANT CPU-95 II
WARNING: KEEP COVER TIGHT

R WHILE CIRCUITS ARE LIVE.
AVERTISSEMENT: GARDER LE
COUVERCLE BIEN FERME
LORSQUE LES.
CERTIFIED
CLASS I, GROUP D, DIV. 2 T4
ALTRONIC, INC. YOUNGSTOWN, OHIO
(Gas + air)
Turbo
charger
Hall-effect sensor
Air cleaner
Magnetic pick-up sensor(Timing check)

R
CPU-95
Display AUTO
SETUP
MAN
TIMING
DIAG
NEXT
Magnetic pick-up sensor(reset)
module F1
F3
F2
F4
RESET
ALARM
ACK
ESC
ENTER
Exhaust gas
EE3OM009
2.3.4. Engine speed controller : ESC

● The Engine Speed Control is designed to
provide basic isochronous speed control
for gas engines using the Flo-Tech
Throttle.
● Engines with mechanical loads and
generator loads are handled equally well.
1 2 3 4 5 6 7 8 9 10 11 12
EE3OM010
2.3.5. Ignition control module : ICM
● This digital ignition system has been ?
designed for application on nature gas
fueled engines.
● This system is offers a variety of
advanced control, emissions reduction,
primary and spark diagnostics, self
diagnostic serial communications and
engine protection features.
EE3OM011
2.3.6. Cylinder block

● 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 wet cylinder liners and individual
cylinder heads.
2.3.7. Piston, con-rod and crankshaft

● The forged crankshaft has screwed-on the balance weights. Radial seals with replaceable wearing
rings on crankshaft and flywheel are provided to seal the crankcase penetrations.
● The 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.
2.3.8. Engine timing
● Camshaft, oil pump and hall-effect sensor are driven by a gear train arranged at the flywheel end.
Hall-effect sensor gear

(Z=51)
Drive gear of hall-effect sensor Camshaft gear

(Z=51) (Z=86)
Crankshaft gear
(Z=43)
Oil pump gear
(Z=7)
Oil pump drive gear

Oil pump gear
(Z=44)
(Z=7)
EE3OM012
2.3.9. Valves
● The overhead valves are actuated via chilled cast iron tappets, push rods and rocker arms from the
camshaft.
2.3.10. Engine lubrication system

● 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 flywheel end.
● The oil pump draws the oil from the oil sump and delivers it through the oil filter and oil cooler 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.
● The turbocharger is also connected to the engine lubricating system. The cylinder walls and timing
gears are splash-lubricated.
● Each cylinder has an oil jet provided for cooling the underside of the pistons. The lube oil is cleaned
in a full-flow oil filter.
CYLINDER BLOCK MAIN GALLERY
OVER FLOW VALVE
OIL FILTER
BYPASS VALVE OIL SPRAY NOZZLE ROCKER ARM BUSH CRANK JOURNAL CAM SHAFT BUSH
REGULATOR
VALVE
OIL COOLER
CRANK PIN
RELIEF VALVE
VALVE PUSH ROD TURBO CHARGER

OIL PUMP PISTON PIN
PISTON TAPPET
OIL STRAINER
OIL PAN
EE3OM013
● Depending on the agreed extent of delivery and the design of the engine, the lube oil circuit can be
equipped with oil pressure monitors (advance warning and cut-off function) which shut the engine
down in the event of a sudden loss of pressure.
2.3.11. Oil cooler

● An oil cooler is provided between the oil filter and the crankcase. This cooler is of the flat tube type
with turbulence inserts and operated by the coolant.
2.3.12. Engine oil

● Check oil level with the oil level gauge and replenish if necessary.
● 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.
● Engine oil should be changed at the specified intervals. Oil in the oil filter cartridge should be
changed simultaneously.
First oil change After 50 hr operation

GV158TIC
Engine model GV180TIC Every 200 hr
GV222TIC
● The following oils are also recommended
SAE No. Sulfated ash content

15W40(CNG) Bellow 0.5%
● Engine oil capacity
Engine oil capacity

In oil pan
Total
Engine model Max. Min.
(lit)
(lit) (lit)
GV158TIC 28 26 31
GV180TIC 35 28 38
GV222TIC 40 33 43
Engine oil viscosity - ambient temperature
SAE 5W - 30
SAE 10W - 30
Ambient -40 C -20 C 0 C 20 C 40 C 50 C

temperature (-40 F) (-14 F) (+32 F) (68 F) (104 F) (122 F)
SAE 5W - 40
SAE 10W - 40
SAE 15W - 40
SAE 15W - 50
SAE 20W - 50
EE3OM014
2.3.13. Exchanging of lubrication oil
● Engine oil and the oil filter are important
factors affecting engine life. They affect
ease of starting, fuel economy, combus-
tion chamber deposits and engine wear.
● While the oil is still hot, discharge the
Engine oil drain pump
sump oil by motion oil drain pump lever
manually as figure.
● Refill new engine oil to the filler neck on
the head cover in accordance with the oil EE3OM015
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.
● 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. EB2M5001
2.3.14. Replacement of oil filter cartridge

● Every time oil exchanges, replace the oil filter cartridge.
● Drain engine oil by loosening the drain plug on the filter head.
Caution:
Don't forget tightening the drain plug after having drained engine oil.
● Remove the oil filter by turning it counter-

clockwise with a filter wrench.
● Wipe, clean the fitting face of the filter
body and the oil filter body with a rag so
that the new oil filter cartridge can be
seated properly.
● Lightly oil the O-ring and turn the oil filter
until O-ring is fitted against the seal face.
And then turn it in addition by 3/4 ~ 1
EFM2010I
turns further with hand or the filter
wrench.
Note:
It is strongly advisable to use DOOSAN genuine oil filter cartridge for replacement.
2.3.15. Cooling system
● The engine has a liquid-cooling system. The water pump is a maintenance-free impeller pump
driven by V-belts from the crankshaft pulley.
● 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.
Ø12 Ø40
EXHAUST MANIFOLD
Ø55
AIR VENT
HEAT EXCHANGER
INTER COOLER
Ø48.6
TIRBO CHARGER
CYLINDER BLOCK THERMOSTAT
Ø45 BY PASS
Ø67
FRESH WATER PUMP
Ø12 Ø55
OIL COOLER
Ø12
Ø40
EXHAUST MANIFOLD
TIRBO CHARGER
WATER PUMP
EE3OM016
2.3.16. Cooling water

● Regarding the cooling water that is to be used for engine, the soft water not the hard water must be
used.
● The engine cooling water can be used diluting it with antifreezing solution 40% and the additive for
rust prevention (DCA4) 3 ~ 5%.
● 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.
● Since GV158TIC, GV180TIC, GV222TIC (Engine of D28 base engine) cylinder liner is wet type, par-
ticularly the cooling water control should be applied thoroughly.
● The density of antifreezing solution and additive for rust prevention is able to be confirmed by the
cooling water test kit. (Fleetguard no.: CC2602M or DOOSAN no.: 60.99901-0038)
● 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 (ver-
tical) 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.
● Amount of anti-freeze in winter
Ambient Temperature (°C) Cooling water (%) Anti-freeze (%)

Over -10 85 15
-10 80 20
-15 73 27
-20 67 33
-25 60 40
-30 56 44
-40 50 50
2.3.17. V - belt
● Use a V-belt of specified dimensions, and
replace if damaged, frayed, or deterio-
rated.
● Check the V-belt for belt tension. If belt
tension is lower than the specified limit,
adjust the tension by relocating the alter-
nator, (specified deflection: 10 ~ 15 mm
when pressed down with thumb)
EE3OM017
2.3.18. Air cleaner

● Air cleaner is mounted on the engine to
purify the air for combustion. The inter-
vals at which the air cleaner requires
servicing depend on the specific oper-
ating conditions encountered. Clogged
air filters may cause black smoke and
reduce power.
● A check should be made from time to
time to see that the fastening elements EFM1002I
securing the air cleaner to the intake
manifold seal the connection tightly.
Any ingress of unfiltered air is liable to
cause a high rate of cylinder and piston
wear.
2.3.19. Intercooler
● The intercooler is water to air type.
The intercooler life and performance
depends on the intake air condition
greatly. Fouled air pollutes and clogs
the air fins of intercooler. As a result of
this, the engine output is decreased
and engine malfunction is occurred.
● So you always check whether the
intake air systems like air filter element EFM2014I
are worn or polluted.
2.3.20. Valve clearance adjust procedure
● Adjust the valve clearance.
- When disassembling the engine or cylinder head.
- When there is excessive noise in the valve connection.
- When the engine runs abnormally even if the fuel injection system is normal.
● Adjusting sequence of valve clearance (1 type)

1) Rotate the crankshaft so that #1. cylinder may be positioned at the compression TDC (Top Dead
Center).
Note:
#1. Cylinder is located at the side where cooling water pump was installed.
In case of 8/12 cylinder engine, #6. cylinder is positioned at the valve overlap when #1.
cylinder is positioned at the compression TDC (Top Dead Center).
In case of 10 cylinder engine, #7. cylinder is positioned at the valve overlap when #1. cylinder
is positoned at the compression TDC (Top Dead center).
Cooling fan
7
1
6 8
1 2
5 7 9 12
1 2 11 3
10
6 8 10 10 9
8
2 9 3 8
7
4
7 8
7 6
9
7
6 11 6
5
5
4
3 5 4 4 5
3 4 3
8 2
10
3 12 2
1 4 2
1 5 1 6
Flywheel
8 Cylinder engine 10 Cylinder engine 12 Cylinder engine
EA6O6008
2) Loosen the lock nut of the #1. cylinder

rocker arm.
3) Push the feeler gauge between a
rocker arm and a valve stem.
4) Adjust the clearance screw respec-
tively and then tighten with the lock
nut.
2 3
1 EDV2218007
5) As for the valve clearance, adjust it when in cold, as follows.
Specified value Measurement tolerance
Intake valve Exhaust valve Intake valve Exhaust valve
0.30 mm 0.40 mm ±0.05 mm
6) Rotate the crankshaft. When a cylinder reaches the compression TDC (Top Dead Center), adjust
the valve clearance of the cylinder.
7) When a cylinder valve overlap, adjust the valve clearance cylinder of the compression TDC (Top
Dead Center), as follow.
* 8 Cylinder engine (GV158TIC)
Valve overlapping on cylinder
1 5 7 2 6 3 4 8
(Intake & Exhaust valve)
Adjusting valves on cylinder
6 3 4 8 1 5 7 2

1 6 5 10 2 7 3 8 4 9
7 3 8 4 9 1 6 5 10 2

1 12 5 8 3 10 6 7 2 11 4 9
6 7 2 11 4 9 1 12 5 8 3 10
2.3.21. Cylinder compression pressure
● Stop the engine after warming up, and
take out the spark plug.
EFM1004I
● Install the special tool (compression

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

Limit value 13 kg/cm2
Difference between
Within ±10%
each cylinder EFM1005I
◆ Condition: water temperature 20°C,

engine rotation 200 rpm
2.3.22. Spark plug
● Remove spark plug. Clean threads by
hand with brush and solvent.
● Clean any deposits from electrode and
Inspect insulator area.
● Measure the spark plug distance at elec-
trode position. (A)
● Replace spark plug if necessary.
Standard
Distance (A) 0.3 ~ 0.4 mm
● Install spark plug.
Torque 2.5 ~ 3.0 kg.m
EB3O310I
Eroded electrode
New spark plug
Flashover on
Electrode surfaces insulator
not parallel
EB3O311S
2.3.23. Battery
● Inspect for any leakage of electrolytic solution owing to battery crack, and replace the battery in case
of poor condition.
● Inspect for amount of electrolytic solution, and replenish if insufficient.
● Measure the gravity of electrolytic solution, if less than specified value (1.12 ~ 1.28), replenish.
Viewing
Liquid level Liquid level upper limit Isotator
the gravity
indicating line Liquid level lower limit
meter
1,100
1,200
1,300 UPPER LEVEL
LOWER LEVEL
EFM1007I
2.3.24. Turbocharger
● The turbocharger needs not arty special equipment.
● Every time of engine replacement, a leakage or clogging of oil pipes should be inspected.
Air cleaner should be maintained carefully for nut or foreign material not to get in. Periodic inspection
should be applied on the compressed air and exhaust gas pipes, For leaking air will bring the over-
heat engine, an immediate repair must be done.
● During the operation that is surrounded by the dust and oil mixed air, frequent cleaning must be
done on the impellers. Tear down the impeller casing (attention: be careful not to bend) and must
clean with non-acid solvent solution. If necessary, use plastic scraper If impeller is severely polluted,
dip the impeller into solution and may be better to clean it with stiff brush. Then one thing to beware
is to dip only impeller part and so do not support by impeller but bearing housing.
2.3.25. Alternator
● The alternator is fitted with integral silicon rectifiers. A transistorized regulator mounted on the alter-
nator 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 X 45A
Ignition Lamp terminal Lamp terminal
terminal
Ignition terminal Ignition terminal
Indicator lamp
terminal
Vehicle side female connector Alternator side male connector
Housing : KET MG 620042 P/N : 12162193OR12162195
Phase terminal : KET GP 890545

Tachometer charge indicator
ADLO System frequency = rpm/10
BAT
M6 X 1.0 Thread
Battery terminal
Delco Remy
Korea
EE3OM019
● The alternator is maintenance-free, nevertheless, it must be protected against dust and, above all,
against moisture and water.
Wiring Diagram To Battery +
0.5 MFD
Phase terminal
Trio diode Regulator
Lamp
terminal
Ignition
terminal
EE3OM020
Operate the alternator according to the instructions given in the chapter.
2.3.26. 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.
24V x 7.0kW
M5 X 0.8 Bolt M10 X 1.25 Bolt
Switch terminal Battery terminal(+)
M10 X 1.5 Bolt

Battery ground(-)
EE3OM021
Always protect starter motor against moisture
Battery : 24-C
Torque(KgM)
(JIS D 5004)
Speed(RPM)
Output(KW)
Voltage(V)
(Temperature. : 20 C)
32 4000 16 8.0
Output
28 14 7.0
Torque
24 3000 12 6.0
20 10 5.0
Voltage
16 2000 8 4.0
12 6 3.0
8 1000 4 2.0
Speed
4 2 1.0
100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400
Ampere(A) EE3OM022
IMPORTANT
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.
EE3OM075
2.3.27 Precautions in use

● Pay attention to dropping the battery voltage capacity when they are left for long time even without
use.
● As starting may not be done well sometime in cold winter season, do not try it to be continuous
● immediately but try to start again after waiting about 30 seconds.
● Prior to operating the gauge panel, make sure the polarity of battery once again (In majority of polar-
ities, red side is "+" and black one is "-")
● On disassembling the gauge panel may be accompanied a risk of electrical shock, always work after
pulling off the connector at rear side of it without fail.
● If the silver paper etc is used for connecting the cut-off fuse, because the excessive current might
flow into the parts to damage, when fuse is cut off, after resolving the problem locating the cause,
replace it with new fuse.
● Since battery has a danger of explosion by a heat, it must not be placed at the spot where generates
a lot of heat.
● When engine is in stop, pull out the key always. Thus, a hazard of fire or wound due to wrong oper-
ation may not happen.
● In case of scrapping the batteries, observe the followings.
Note:
Do not throw it in the fire to scrap. It should not be thrown away into the places where are
liable to cause the environmental pollution such as stream, river and mountain. Pack them as
far as possible and dispose it as rubbish that is unable to use again.
● DOOSAN will not be responsible to the problems that might be raised by the disassembling and
structural change of this product without consultation.
2.4. Diagnosis and Remedy
● The following description summarizes the probable cause of and remedy for general failure by item.
● Immediate countermeasures should be taken before a failure is inflamed if any symptom is detected.
● Inspect the electrical parts problem by the display module.
1. Engine Starting Impossible
Starting motor operation poor Starting motor revolution
Inspection of battery electorlytic Engine Nature gas fuel

liquid amount & gravity
Inspect air cleaner Inspect amount of gas fuel
Normal Too low
Normal Polluted Normal None

Adjustment.
Recharging
Replace or Replenish
Inspection of loose electric clean element
wiring & short Inspect ignition timing
Check compression
Normal Retighten. pressure
Normal Adjust
Replace
Normal Too low
Inspection of starting switch Inspect ignition system
(Control module, ignition module,
Repair. harness, Ignition coil, spark plug,
Normal Repair. Replace boots etc.)
Replace
Inspect of
Inspection of starting relay
other parts
Normal Replace Check valve

clearance
Inspection of magnetic switch Normal Adjust
Normal Repair. Check cylinder

Replace Replace
head gasket
Starting motor
disassembly Normal
Engine disassembly
(valve assembly, piston,
cylinder liner etc.)
2. Engine Overheated
Operating state
1. Overload
2. Radiator core clogged
Cooling system
Check coolant level
Normal Too low
Check fan belt Replenish

tension, wear
or damage etc.
Inspect cooling
water leakage
Normal Repair.
Replace External Internal
Check fresh Retighten. Engine

Replace
radiator tank cap Replace disassembly
Normal
Check thermostat Replace
Normal
Inspect radiator Damage Repair .

Replace
Normal Check cooling

water pump
Clean cooling
water passage Normal Repair.
Replace
Engine
disassembly
3. Output insufficient
Inspect by display module Engine Generator set

diagnostic tool
Inspect gas fuel filter Others
Polluted Inspect air cleaner
Normal Repair . Normal Repair .

Replace Replace
Inspect air leakage

Inspect ignition timing Check valve clearance
of air piping line
Normal Adjust Normal Adjust

Normal Retighten.
Replace
Inspect cylinser head
Inspect ignition system gasket for damage
(ICM, Harness, Ignition coil,
Inspect air leakage
spark plug, boots etc.)
Normal Replace of intercooler
Engine disassembly
(valve assembly)
Disassemble engine
Check turbocharger
Normal Repair .
Replace
Disassemble engine
4. Oil pressure lowered
Check oil amount Check if oil pressure

gauge indicates wrongly
Normal To low
Check cooling
temperature Use recommened oil
(replenish)
Too high
Normal
Inspect oil quality Refer to engine overheat
Normal
Check oil Water mixed in oil Improper

relief valve
Disassemble engine Replace with

Normal Retighten. recommended oil
Replace
Disassemble
engine
5. Fuel Consumption Excessive
Cause according to use conditions

1. Overload
2. Generator set
Inspect nature gas leakage
Normal Nature gas leakage
Retighten.
Inspect ignition timing Replace
Normal Adjust
Inspect ignition system

(ICM, Harness, Ignition coil,
spark plug, boots etc.)
Inspect compressed
pressure
Check valve Repair. replace

clearance (cylinder liner,
Normal Adjust
piston ring, piston)
Disassemble engine
(valve assembly, piston,
cylinder liner etc.)
6. Oil Consumption Excessive
Cause according to use conditions

1. Excessive oil infusing
2. Continuous operation in low speed
or extremely cold state
Inspect oil leakage Inspect air cleaner
Clean. Replace
Normal Oil leakage
Check oil quality

External Internal
Retighten. Check compressed

Replace pressure
Replace with
specified oil
Engine disassembly Normal

(piston, cylinder liner)
Disassemble
cylinder head
(valve stem seal)
7. Engine Knocking
Inspect combustion of fuel & oil

(carbon residue of exhaust gas)
Unconfirmed Confirm
Inspect compressed
pressure Disassemble
engine
Normal Too low
Inspect ignition Check valve clearance and

timing cylinder head gasket crush
Normal Adjust Normal Replace.

Adjust
Disassemble
Check gas fuel quality
engine
Use specified gas fuel
8. Battery Discharge
Battery Wiring, Switch Alternator
Check electrolytic Inspect cut wire Check fan belt

liquid amount shorts and loose tension & damage
connections
Repair. Replace
Normal Battery room Battery self Battery over

damage discharge charging
Electrolytic
liquid`s standard Replace Charging Inspect alternator
voltage regulator
Replenish
Normal Abnormal
Check charged stated Adjust.

Replace
Discharging
Disassemble alternator.
Voltage regulator
Condition Causes Remedies
1) Starting difficult
(1) Compression pressure ● Valve's poor shut, stem distortion Repair or replace
● Valve spring damage Replace valve spring
● Cylinder head gasket's leak Replace gasket
● Wear of piston, piston ring or liner Adjust
2) Idle operation abnormal ● Ignition timing incorrect Adjust
3) Engine output insufficient
(1) Continuous output Insufficient ● Valve clearance incorrect Adjust
● Valve tightness poor Repair
● Wear, stick, damage of piston ring Replace piston ring
● Ignition timing incorrect Adjust
● Damage of spark plug & ignition coil Adjust or replace
● Air suction amount insufficient Clean or replace air cleaner
● Turbocharger poor Repair or replace
(2) Output insufficient when in ● Compression pressure insufficient Disassemble engine
acceleration ● Ignition timing incorrect Adjust
● Damage of spark plug & ignition coil Repair or replace
● Air intake amount insufficient Clean or replace air cleaner
4) Overheating ● Engine oil insufficient or poor Replenish or replace
● Cooling water insufficient Replenish or replace
● Fan belt loosened, worn, damaged Adjust or replace
● Cooling water pump's function lowered Repair or replace
● Thermostat operation poor Replace
● Valve clearance incorrect Adjust
● Exhaust system's resistance increased Clean or replace
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 ● As the wear of bearing or crankshaft Replace bearing &grind crankshaft
progress, the oil clearances increase.
● Lopsided wear of crankshaft Grind or replace
● Oil supply insufficient due to oil pas- Clean oil passage
sage clogging
● Stuck bearing Replace bearing &grind
(2) Connecting rod and connect- ● Lopsided wear of con rod bearing Replace bearing
ing rod bearing ● Lopsided wear of crank pin Grind crankshaft
● Connecting rod distortion Repair or replace
● Stuck bearing Replace & grind crankshaft
● Oil supply insufficiency as clog- Clean oil passage
ging at oil passage progresses
(3) Piston, piston pin &piston ring ● Piston clearance increase as the wear Replace piston & piston ring
of piston and piston ring progresses
● Wear of piston or piston pin Replace
● Stuck piston Replace piston
● Piston insertion poor Replace piston
● Piston ring damaged Replace piston
(4) Others ● Wear of crankshaft, thrust bearing Replace thrust bearing
● Camshaft end play increased Replace thrust plate
● Idle gear end play increased Replace thrust washer
● Timing gear backlash excessive Repair or replace
● Valve clearance excessive Adjust valve clearance
● Abnormal wear of tappet, cam Replace tappet, cam
● Turbocharger inner part damaged Repair or replace
6) Oil Consumption excessive
(1) Oil level elevated ● Clearance between cylinder liner Replace
& piston
● Wear of piston ring, ring groove Replace piston, piston ring
● Piston ring's damage, stick, wear Replace piston ring
● Piston ring opening's disposition Correct position
improper
● Piston skirt part damaged or Replace piston
abnormal wear
● Oil ring's oil return hole clogged Replace piston ring
● Oil ring's contact poor Replace piston ring
(2) Oil level lowered ● Looseness of valve stem & guide Replace in set
● Wear of valve stem seal Replace seal
(3) Oil leak ● Looseness of connection parts Replace gasket, repair
● Various part's packing poor Replace packing
● Oil seal poor Replace oil seal
2.5. Engine Inspection
2.5.1. Stopping engine

● 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.
2.5.2. General engine inspection cycle

● In order to insure maximum, trouble-free engine performance at all times, regular inspection, adjust-
ment 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.
○ : Check & adjust ● : Replace
Every Every Every Every Every

Inspection item Daily Remark
50hrs 200hrs 500hrs 1,500hrs 3,000hrs
Check for leakage (hoses, clamp) ○
Cooling Check the water level ○
system Adjust the V-belt tension ○
Change the coolant water ● 1 year
Check for leakage ○
Lubrication Check the oil level gauge ○
system Change the lubricating oil ● 1st ● Every 200hr
Replace the oil filter cartridge ● 1st ● Every 200hr
Check the leakage for
○ ●
intercooler (hoses, clamp)
Intake &
Check the air cleaner indicator ○
exhaust
Clean the air cleaner element ○
system ●
and/or repair Clean
Clean the exhaust system ○
Check the leakage fuel line ○
Check the fuel mixer ○ 1 year
Fuel
Check the throttle body ○ 1 year
system
Check the speed controller ○ 1 year
Check the gas pressure regulator ○ 1 year
Check the state of ignition timing When necessary
Check the spark plug ● ●
Ignition Check the ignition cable ● 1 year
system Check the ignition coil ○ 1 year
Check the sensors
○
(ignition or timing)
Check the state of exhaust gas ○
Check the exhaust gas pressure When necessary
Engine Check the battery charging ○
adjust Check the compression pressure When necessary
Adjust Intake/exhaust
○ 1st ○ When necessary
valve clearance
2.5.3. Use of original parts for repair and replacement
● 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.
● For the analogous parts not the original parts are poor in qualities and gives ill performances, it may
rather bring early engine failure.
3. Disassembly and Reassembly of Major Components
3.1. Engine Disassembly

● Engine parts' disassembly procedures are as follows;
3.1.1. General precautions

● For the various tool storage before disassembly and parts storage after disassembly, the shelf for
parts is prepared.
● At the time of disassembly and reassembly, do the work with the naked and clean hand, and also
the working place must be maintained clean.
● The torn parts after disassembly must be kept not to collide each other.
● In disassembling, torn parts should be laid in disassembled order.
● Always close all the fuel valves before serving the system.
3.1.2. Oil level gauge

● Take out the oil level gauge.
EE3OM023
3.1.3. Engine oil

● 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
EE3OM015
- 45 - Disassembly and Reassembly of Major Components

3.1.4. Cooling water
● Remove the cooling water drain plug
from the cylinder block and oil cooler,
various pipes, etc. and let the cooling
water discharge into the prepared ves-
sel.
EE3OM023
EE3OM024
3.1.5. V-belt.
● Loosen the V-belt tension adjusting bolts,
and remove the V-belt.
EFM2002I
3.1.6. Ignition coil & gas pressure regulator

● Remove the high voltage cable by hand
Gas pressure
from each cylinder. regulator
● Remove the gas pressure regulator fixing
bolts and then tear down the gas pres-
sure regulator arid others parts.
Ignition coil
High votage cable EE3OM025
Disassembly and Reassembly of Major Components - 46 -

3.1.7. Intercooler
● Tear down the various hoses and air
pipes from the inter cooler.
● Remove the intercooler fixing bolts and
tear it down.
EFM2014I
EE3OM026
3.1.8. Turbocharger and gas fuel mixer

● Loosen the gas hose and air cleaner
hose for connecting the gas fuel mixer. Gas fuel mixer
● Loosen the clamp and fixing bolt for con-

necting the turbocharger and then tear
down the air intake stake and gas fuel
mixer.
● Remove the hollow screws of pipes for
turbocharger and its discharge, and tear
the pipes down. EE3OM027
● Remove the turbocharger fixing routs and
separate the turbocharger from the
exhaust manifold.

3.1.9. Exhaust manifold
● Remove the exhaust manifold fixing bolts
and tear the manifold from the cylinder
head.
Caution:
Be careful not to drop the manifold
because it is very heavy.
EFM2015I
3.1.10. Intake manifold & throttle valve

● Remove the throttle valve fixing bolts and
tear the throttle valve down from the Throttle valve
intake stake.
● Remove the manifold fixing bolts and tear
the manifold down from the cylinder
head.
Intake stake
Intake manifold
EE3OM028
3.1.11. Alternator
● Remove the supporting guide piece for
installing the alternator and the bracket
bolts.
● Disassemble the alternator.
EFM2003I
3.1.12. Oil filter

● Disassemble the oil filter cartridge with fil-
ter wrench by means of a filter wrench.
● Do not use again the cartridge removed
after use.
EFM2010I

● Remove the oil filter head fixing bolts and
disassemble the filter head.
Oil filter
catridge
Oil filter
head
EE3OM029
3.1.13. Cooling water pump

● Loosen the various hose clamps for the
Thermostat
connections. Water pump
● Remove the cooling water discharging
pipe and disassemble the thermostat.
● Remove the cooling water pump fixing
bolts and disassemble the cooling water Water pump
pump. pulley
EE3OM030
3.1.14. Oil cooler

● By removing the plug screw of cooling
water discharge port, the cooling water is
discharged.
● Remove the oil cooler cover fixing bolts
and disassemble the oil cooler.
EFM2012I
● By removing the cooler housing fixing

bolts and disassemble the oil cooler
housing from the cylinder block. Oil cooler
Oil cooler
housing
EE3OM031

● Remove the oil cooler insert fixing bolts,
and then disassemble the cooler insert.
Oil cooler
Oil cooler
cover
EE3OM032

● Remove the starting motor fixing nuts and
disassemble the starting motor.
EFM2008I
3.1.16. Timing drive & sensor

● Remove the timing drive fixing bolts and
disassemble the timing drive and timing Timing sensor
sensor.
Timing drive
Timing drive
gear
EE3OM033
3.1.17. Flywheel housing cover

● Separate the side cover.
● Disassemble the fly wheel housing cover.
EE3OM034

3.1.18. Cylinder head cover
● Remove the fixing bolts and tear the cyl-
inder head cover down.
EFM2020I
3.1.19. Spark plug

● By means of a long impact tool, loosen
the spark plug and take it out.
EE3OM035
3.1.20. Rocker arm

● Remove the rocker arm bracket fixing
bolts and take the rocker arm assembly
out.
● Pull out the push rod.
EFM2022I
3.1.21. Cylinder head

● Loosen the cylinder head fixing bolts in
the reverse order of assembling, and
remove them all and then take the cylin-
der head out.
● Remove the cylinder head gasket and
scrap it.
● Eliminate the residue from the cylinder
head face and cylinder block face.
EFM2023I

Note:
Be careful not to damage the cylinder
head face where its gasket contacts.
3.1.22. Vibration damper

● Remove the fixing bolts for crankshaft
pulley in reverse order of assembling and
disassemble the crankshaft pulley and
vibration damper.
EFM2004I
3.1.23. Oil pan

● Remove the oil pan fixing bolts and sepa-
rate the pan.
● Remove the oil pan gasket and scrap it.
EFM2024I
3.1.24. Oil pump

● Remove the oil suction pipe fixing bolts
and tear them down.
● Remove the oil relief valve fixing bolts
and take them out.
● Remove the oil pump fixing bolts and
separate it.
EFM2025I

3.1.25. Piston
● Remove the connecting rod cap bolts in
the reverse order of assembling and fol-
low the similar method as in the cylinder
head bolt removal.
● Tapping the upper and lower connecting
rod caps lightly with an urethane ham-
mer, separate them and take the bear-
ings out.
● By pushing the piston assembly with a EFM2026I
wooden bar toward the cylinder head's
direction remove the piston.
Note:
● Be careful for the removed pistons not to collide each other or with the other parts.
● At the storage of pistons, maintain them in the order of cylinders. (In order for connect-
ing rod caps not to mix one another, temporarily assemble them to the corresponding
connecting rods.)
3.1.26. Front oil seal holder

● Remove the oil seal holder fixing bolts
and tear down.
● Remove the oil seal and gasket from the
oil seal holder and scrap them.
EFM2027I
3.1.27. Fly wheel

● Remove the flywheel fixing bolts in the
order of disassembling and remove the
flywheel.
EFM2028I

● Remove the flywheel ring gear.
- Heat the ring gear evenly with a gas
burner (up to 200°C) to invite volumet-
ric expansion.
- Tapping around the edges of the ring
gear with a hammer and brass bar to
remove it.
Caution: EA0M4028
Do not damage the flywheel.
3.1.28. Flywheel housing

● Remove the flywheel housing fixing bolts
and take them out.
● Remove the oil seal from the flywheel
housing. Thrust washer
Oil seal
EA6M2010
3.1.29. Crank shaft

● Remove the bolts from bearing caps.
● Remove the main bearing cap fixing bolts
in the reverse order of assembling.
● Maintain the removed bearing caps in the
order of cylinders.
● Temporarily install the bolts at the both
side of crankshaft, and lift the shaft with a
rope.
EFM2029I
1 3 5 7 6 4 2
EA6M2011

Note:
Do not mingle with the metal bearings
and bearing caps randomly. To prevent
mixing, temporarily assemble the metal
bearings to the corresponding bearing
caps in turn.
3.1.30. Camshaft and tappet

● Pull out the tappets from the cylinder
block.
● Remove the camshaft being careful not to
damage the camshaft and its bearings.
3.1.31. Oil spray nozzle

● Remove the oil spray nozzle fixing bolts
and tear down the oil injection nozzles.
3.1.32. Cylinder liner

● By means of a special tool (Extractor),
pull out the liner from the cylinder block.
EE3OM036

3.2. Measurement and Inspection of Major Parts
3.2.1. Cleaning and inspection of cylinder block

● Clean the cylinder block and inspect it for any crack or damaged.
● Inspect the oil passage and water passage for any clog and erosion.
● By performing the hydraulic test, inspect for any leaks. With plugging the water and oil passages of
cylinder block, put in the air of 5 kg/cm2 pressure in the Inlet port of cylinder block and then soak the
cylinder block in the water for about 1 minute to check for any leaks.(water temperature: 70°C)
● Inspect the cylinder block's camshaft bush to any damage and the alignment of oil supply holes and
if abnormal, replace it.
3.2.2. Cylinder liner measurement

● Assemble the cylinder liner at the cylinder
block and measure inner diameters at
upper, middle, lower 3 levels by 45° inter-
val and calculate the average values after 20mm
eliminating the max. and min. values.
● If the measured values are very close to
the limit value or beyond, replace it.
Standard Limit
Liner EA3M2043
ø127.990 ~
inner dia. 0.15 mm
ø128.010 mm

1) Cylinder head disassembly
● Be careful for the cylinder head gasket
contacting surface of cylinder head
not to be damaged.
● Remove the cotter pin pressing the
valve spring by means of a special
tool.
Valve spring
● Take out the valve stem seal. compressor
● Pull out the intake and exhaust valves.
EA0M4007

3.2.4. Spark plug
● Remove spark plug. Clean threads by
hand with brush and solvent.
● Clean any deposits from electrode and
inspect insulator area.
● Measure the spark plug distance at elec-
trode position. (A)
● Correct or replace the spark plug if nec- A
essary.
EE3OM037
Standard (A) 0.3 ~ 0.4 mm
● Insert the spark plug into cylinder head

and measure distance. (B)
Standard (B) 3.38 ~ 3.76 mm
EE3OM038
3.2.5. Inspection and measurement of cylinder head

1) Damage check
● Inspect the cylinder head for any crack or damage.
● Eliminate the carbon residue and gasket piece from the cylinder head lower face thoroughly,
Then be careful for the valve seat not to be damaged.
● The cracks or damages that are difficult to search may be inspected by a hydraulic test or a mag-
netic powder test. (Hydraulic test is same as for cylinder block.)

2) Distortion
● Measure the flatness degree (any dis-
(t)
tortion) of cylinder head. Even beyond
the limit value of maintenance, it may
B
be corrected by grinding. (if more than A
limit value of use, replace it.) C
D
Standard Limit
Warpage E
0.05 mm or less 0.2 mm
F
EA3M2031
EA6M2002
3.2.6. Inspection and measurement of valve

and valve guide
1) Valve
● After cleaning the valves with clean
diesel oil, measure the valve stem's
outside diameter at upper, middle, and
lower to determine the wears and
when the wear limit is more than
Stem tip
allowable limit, replace the valves.
Valve Standard Limit

ø11.969 ~
Intake ø11.934 mm EFM2036I
ø11.980 mm
ø11.969 ~
Exhaust ø11.905 mm
ø11.980 mm

● Inspect the scratch and wear of valve
stem seal contacting face, and if nec-
essary correct with the grinding paper
but if severe replace it.
● If valve head thickness (A) becomes
less than 1.6 mm for intake and A
1.3 mm for exhaust, replace the valve.
Valve Standard Limit EE3OM039

Intake (A) 4.6 ~ 5.0 mm 4.10 mm
Exhaust (B) 4.33 ~ 4.83 mm 3.83 mm
2) Valve guide
● Insert the valve into valve guide and
measure the clearance between valve
and valve guide by the shaking
degree of valve. If the clearance is
bigger, measure the valve and then
replace the more worn cylinder head.
Valve Standard Limit

EA0M4052
Intake 4.6 ~ 5.0 mm 0.10 mm
Exhaust 4.33 ~ 4.83 mm 0.20 mm
3) Valve seat
● Assemble the valves at the cylinder 10
0 20
head and using the measuring instru- 90
80
30
40
ment from the lower face, measure

70
50
60
the projection amount of valve. If the

measured value is more than the use
limit, replace the valve or cylinder
head.
< Valve seat thickness > EFM2038I
Standard Limit
0.65 ~ 0.95 mm 2.5 mm

3.2.7. Valve spring
● Inspect the outlook of valve spring and if
necessary replace it.
● By means of spring tester, measure the
tension and free length.
● Measure the perpendicularity of valve
spring.
● In case that the measured value exceeds
the limit value, replace it.
EA3M2033
< Dual spring perpendicularity regular >
Free length
Inside 65.5 mm
Spring
Outside 64 mm
< Single spring perpendicularity regular >
Free length
Intake/
Outside 61.9 mm
exhaust
< Valve spring tension standard >
Spring
Length
tension Limit
(mm)
(kg)
Intake/ Out- 46.8/ 47.0/ ±2.5/
exhaust side 32.8 90.5 ±4.5
Spring tester
EA0M4056
● Squareness of valve spring:

Measure the sequareness of the valve
Inclination
spring with the surface plate and the
right-angle square. If the reading exceeds
the tolerance limit, replace the valve
Free length
spring.
Standard Limit
Square
Intake/
Outside 1.2 mm 2.0 mm EJM2050I
exhaust

3.2.8. Valve spring
● Clean the cylinder head thoroughly.
● Coat the valve stems and valve guides Valve
cotter
with engine oil and assemble the valves.
● Replace the valve stem seals with new
ones and insert the stem seals to the
valve guides of cylinder head with a spe- Stem seal
cial tool. (Be careful for the valve stem
Intake Exhaust
seals not to be damaged)
valve valve
EE3OM040
Valve
cotter
Stem sea
Intake Exhaust
valve valve
EGV2218001
● Install the valve spring washer to valve

gulde.
Painted in yellow
● After putting on the inside, outside spring,
Install the valve spring seat on them.
Note:
Install the valve spring seat with "TOP"
(painted in Yellow) side up.
EE3OM041
● Pressing the spring down with a special

tool, assemble by inserting the valve cot-
ter.
● After the valve is assembled, inspect the
valve tapping it lightly with an urethane
hammer if accurate assembling was
done.
EFM2040I

3.2.9. Rocker arm
1) Rocker arm disassembling
● Remove the snap rings in both ends of
rocker arm with a pair of pliers.
● Tear down washer, rocker arm.
● Disassemble the rocker arm bush by
means of a press.
EFM2091I
2) Inspection rocker arm bracket

● Measure the outer diameter of rocker
arm bracket with outside micrometer
at the position that the rocker arm is
installed, and in case that it exceeds
the limit value, replace.
Standard Limit
Diameter
Bush ø25.005 ~
ø25.325 mm
inner dia. ø25.035 mm EA6M2003
Shaft ø24.967 ~
ø24.930 mm
outer dia. ø24.990 mm
0.015 ~
Clearance 0.14 mm
0.068 mm
● Inspect the rocker arm surface that

contacts with the valve stem for any
scratch, step wear and correct the
minor degree of wear with an oil stone
or the fine grinding paper and replace
if they are severe.

3.2.10. Tappet and push rod
● By means of outside micrometer, mea-
sure the outer diameter of tappet and
replace the severe ones.
Standard Limit (1) Unevenness (2) Crank (3) Nomal

Tappet
clearance 0.035 ~ 0.077 mm 0.15 mm
● By inspecting the tappet surface that con- Abnormal

EA0M4070
tacts with the camshaft's cam for any
crack and scratch etc., and if the degree
is small, correct them with an oil stone or
the grinding paper but if severe replace
them.
● Place the push rod on the surface plate
and rolling it, Inspect the curving degree
with a clearance gauge and if abnormal,
replace it.
< Run-out >
Limit 0.3 mm or less
feeler gauge
EA0M4073
● Inspect the oil passages of rocker arm
and rocker arm bracket for any clogs and
reassemble them in the reverse order of
disassembling after thorough cleaning.
3.2.11. Camshaft
1) Axial end play
● Push the camshaft toward the pulley
side.
● Place a dial gauge onto the camshaft
gear.
EPM2016S

● Measure the camshaft's axial end
play, moving the camshaft gear by
means of a driver.
Standard Limit
End play
0.24 ~ 0.86 mm 0.9 mm
● If excessive end play, assemble it by
means of other thrust washer.
EPM2017S
2) Inspection and measurement

● With inspecting the cam surface for
any damage with naked eyes and cor-
rect any minor scratch by means of an
oil stone grinding and if severe,
replace it.
3) 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.
(mm)
Standard Limit A I II I II
Cam lobe Intake 56.37 56.032 C B B
D A
height (C) Exhaust 56.43 56.091 EA0M4062
4) Cam journal diameter

● By means of outside micrometer,
measure the camshaft journal.
Cam journal Standard Limit

diameter (A, B) ø69.91 ~ ø69.94 ø69.560
EFM2045I

5) Cam bearing diameter
● Measure the camshaft bush inside
diameter with cylinder gauge and by Camshaft bearing
comparing the inside and outside
diameters (after press-fit bearing fabri-
cated) with the following standard,
replace if abnormal.
(mm)
Standard Limit
Thrust ø70.07 ~ ø70.09 ø69.464 EA0M4063
Middle ø70.00 ~ ø70.03 ø69.192
● Clearance between camshaft outside

diameter and bush inner diameter of
cylinder block.
(mm)
Standard Limit
Thrust 0.060 ~ 0.120 0.240
Middle 0.130 ~ 0.180 0.240
6) Camshaft bearing replacement

● Remover, installer
EF8OM059
7) Camshaft run-out
● With placing the camshaft on the 2ea
of V-blocks, and inspect the run-out of
the camshaft, adjust or replace the
severe one.
Standard Limit
0.05 mm 0.15 mm
Disassembly
& assembly tool
EF8OM058

3.2.12. Crank shaft
1) Inspection and measurement
● Inspect for any scratch or damage
with naked eyes, and grind to the
undersize according to the damaged
degree and use the undersized bear-
ing.
● Inspect for any crack by means of
magnetic powder and color check,
and replace the cracked ones.
2) Journal and pin diameter

● With outside micrometer, measure the
outside diameter of crank journal and A
crank pin at the direction and position
of the figure shown and take the wear. B B
<Crankshaft journal outside diameter> A
Standard ø103.98 ~ ø104.00 mm
EA3M2050
<Crankshaft pin outside diameter>

1 3 4
Standard ø89.98 ~ ø90.00 mm
● In case that the lopsided wear is more 2 2

than the limit value, grind to the under
3 4
size, and use the undersized bearing. 1
EA0M4017
<Main bearing >

(a) Standard
(b) 0.10 (Inside diameter 0.10 mm less than standard)
(c) 0.25 (Inside diameter 0.25 mm less than standard)
(d) 0.50 (Inside diameter 0.50 mm less than standard)
(e) 0.75 (Inside diameter 0.75 mm less than standard)
(f) 1.00 (Inside diameter 1.00 mm less than standard)
<Connecting rod bearing >
(a) Standard
(b) 0.25 (Inside diameter 0.25 mm less than standard)
(c) 0.50 (Inside diameter 0.50 mm less than standard)

● There are 4 kinds as above, and the
"R"
crankshaft also can be used by
regrinding as above.
"R"
<"R part" standard value >
(a) Crank pin "R part" : 4.0-0.5
0
"R" "R" "R"

(b) Crank journal "R part" : 4.0-0.5
0
Normal Poor Poor

EFM2048I
Note:
In case of crankshaft regrinding, the "R
part" at the end of bearing must
accurately be ground with out fall and
should avoid any processed jaw or
coarse surface.
3) Run out of crankshaft

● Place the crankshaft on the V-block.
● Place the dial gauge on the surface
plate and measure the run out of
crankshaft rotating the crankshaft.
Standard Limit
0.06 mm 0.4 mm
4) Inspection on crankshaft bearing and

connecting rod bearing
● Inspect the crankshaft bearing and
connecting rod bearing for any dam-
ages such as lopsided wear, scratch
etc. and if abnormal, replace it.
● Inspect the oil clearance between the
crankshaft and bearing.

(a) How to utilize the cylinder gauge
● Assemble the main bearing at the cyl-
inder block and after tightening the
bearing cap at the specified torque,
measure the inside diameter.
Journal bearing ø104.066 ~

nominal diameter ø104.115 mm
Bearing cap bolt Initial 30 kg.m +

torque angle 90°
● Assemble the bearing at the bigger

end of connecting rod, and after tight-
ening the bearing cap at the specified
torque, measure the inside diameter.
Connecting rod
ø90.056 ~
bearing journal
ø90.098 mm
diameter
EAMD060I
Connecting rod Initial 10 kg.m +
bolt torque angle 90°
● Crankshaft pin and bearing clearance

value exceeds the limit value, grind Section
A 10 A-B
the crankshaft journal and pin and
10
then use the undersized bearing.
2 8
1 3
Standard Limit 8
0.056 ~ 0.118 mm 0.143 mm
B
EFM2049I
(b) How to utilize plastic gauge

● Install the crankshaft in the cylinder block and place the plastic gauge on the crankshaft journal
and pin at axial direction and then after tightening the bearing cap at the specified torque and
again after tearing apart the bearing cap, measure the flatten plastic gauge thickness by pick it
up. This is the oil clearance.
● With the same points, the oil clearance of connecting rod also can be measured.

5) End play
● Assemble the crankshaft in the cylin-
der block.
● Install the dial gauge, and measure
the end play of crankshaft by pushing
the crankshaft to axial direction.
Standard Limit
0.140 ~ 0.361 mm 0.4 mm
EFM2050I
3.2.13. Piston
1) Piston disassembling
● Pull out the snap ring for piston pin
and with a pair of snap ring pliers.
● With a round bar, remove the piston
pin.
EA3M2029
● With a pair of pliers, remove the piston

rings.
● Clean the piston thoroughly.
EFM2051I

2) Piston inspection
● With naked eyes, inspect the piston
for any wear, crack and scratch and
particularly inspect carefully at the ring
grooves for any wear.
● With the outside micrometer, measure
the piston's out side diameter the
measuring position is 71.5 mm from
71.5mm
the piston lower end, and the direction
of measurement must be perpendicu-
lar to the piston pin direction.
Standard ø127.739 - ø127.757 mm

● By comparing the measured value of
the piston outside diameter with the
cylinder liner inside diameter, the big-
ger clearance is replaced.
3) Piston ring and ring groove

● In case of piston ring's wear, damage
or engine overhaul, replace piston
rings.
● Insert the piston ring at the cylinder
liner's upper part perpendicularly.
● With a feeler gauge, measure the gap
clearance of piston ring.
● If the measured value exceeds the
limit value, replace it.
<Piston ring gap>
Division Standard Limit

Top ring 0.30 ~ 0.45 mm 1.5 mm
2nd ring 0.40 ~ 0.60 mm 1.5 mm
Oil ring 0.4 ~ 0.7 mm 1.5 mm

4) Piston side clearance
● Assemble the piston ring at the piston.
● Measure the each ring's side clear-
Feeler gauge
ance and if the measured value
exceeds the limit value, replace rings
or piston.
<Piston side clearance>
Limit
Division Specified value
value
Top ring 0.095 ~ 0.145 mm 1.5 mm EA0M4032
2nd ring 0.050 ~ 0.082 mm 1.5 mm

Oil ring 0.03 ~ 0.07 mm 1.5 mm
5) Piston pin
● With the outside micrometer, measure
the piston pin's outside diameter and if
the value is same as the use limit
value or less, replace it.
Standard Limit
ø45.994 ~
ø45.983 mm or less
ø46.000 mm
EA0M4031
6) Piston pin and connecting rod bush

clearance
● Inspect the clearance between the
piston pin and the connecting rod
bush, if it is more than the use limit
value, replace either one that is more
severe.
Standard Limit
0.055 ~ 0.071 mm 0.1 mm
EA3M2047

7) Connecting rod
● Inspect and measure the bigger end
bearing hole and the smaller end
bearing hole with respect to the paral-
lelness and if abnormal, replace the
rod.
Standard Limit Feeler gauge

0.02 mm 0.2 mm
EA0M4034
8) Piston reassembling
● After heating the piston at the piston
heater for about 5 min (120 ~ 150°C),
by aligning the piston pin hole with the
pin hole of connecting rod's smaller
end, insert the oil coated piston pin.
Note:
Confirm the direction of connecting
rod and assemble.
EA3M2058
● With the snap ring plier, insert the piston pin snap ring.
● With confirming the upper side indication of piston ring, after assembling the ring in the piston ring
groove, inspect if the movement of ring is smooth.
● Keep in order of the assembled piston as the cylinder No. turn.
3.2.14. Thermostat
● Inspect the wax case and spring for any
damage.
● With putting the water temperature gauge Ruler
Thermometer
in to water and heating the water at the
indirect method, when the water temp
reaches to 71°C (Opening temperature), Woodplate
the valve begin to open and fully open
when it reaches to 85°C (FuII opening
temperature). EFM2055I

● Measure the valve opening temperature
and the valve full opening temperature
and inspect if the valve lift is more than
8 mm and if abnormal, replace it.
Opening Full opening

No.
temperature temperature
300738 -00159 71°C 85°C
300738-00161 83°C 95°C

3.3. Engine Reassembly
3.3.1. Preparation and precaution before and after engine reassembly

● Clean all the parts thoroughly and also clean thoroughly by blowing into each passage of oil and
cooling water.
● Disposition the various special and general tools for assembling in order.
● In order to coat the lapping parts with engine oil, prepare the clean engine oil.
● Prepare the sub-material such as an adhesive etc.
● Use three bond as an adhesive in the engine oil system and use silicone in the cooling system.
● Scrap the used gasket and seal ring, consumable parts etc. and replace with new ones.
● Tighten the various bolts in the specified tightening torque, and also according to the tightening
order but the excessive torque must be avoided.
● Inspect if the movement of engine is smooth after assembling.
● After completion of assembling, whether various bolts are loose or not should necessarily be
insured.
● Make sure that there is any missing parts or insufficient parts after full completion of assembling.
Work only with clean hands.
● Before serving any fuel system component make certain that the fuel lines are fully closed and the
fuel line pressure properly relieved.
3.3.2. Cylinder liner

● Replace O-ring with new one without fail
and at the upper side, insert to the cylin-
der liner, but at the lower side, to the cyl-
inder block.
● Coat the joint parts where O-ring contacts
O-ring
with oil.
for cylinder liner
O-ring
for cylinder block
EA6M2008
● After slipping the cylinder liner smoothly

Cylinder liner
into the cylinder block, press it in being
insert tool
careful for O-ring not to damage.
● After completion of assembling the cylin-
der liner, confirm no leaks with 4 kg/cm2
hydraulic test.
EE3OM042

3.3.3. Oil spray nozzle
● Tighten the oil injection nozzle flange with
hollow screws.
● Assemble the oil injection nozzle with the
fixing bolts.
Hollow screw 7 kg.m

Torque
Fixing bolt 1.2 kg.m
3.3.4. Tappet
● Coat the tappet wholly clean oil and push
in the tappet hole of the cylinder block.
EAMD072S
3.3.5. Crank shaft
● Put the wear ring into the heater to heat it
up to 150 ~ 200°C level, push it over the
crankshaft by means of a jig.
Wear ring
EA6M2009
● Assemble the main bearing to the cylin-

der block and coat it with engine oil. Then
assemble the bearing that has a hole to
the cylinder block side and one that has
no hole to the bearing cap and be careful
not to change.
EFM2060I

● Assemble temporarily one bolt each at
both bolt holes and by connecting the
wire to the bolts, lift it with crane or chain
block and put down on the cylinder block
carefully.
● Coat the crankshaft journal and pin parts
with engine oil, and after fitting the main
bearing into the bearing cap and assem-
ble it to the cylinder block making sure of 7 5 3 1 2 4 6
the number in order not to change the
bearing cap.
EFM2061
● According to the tightening order, tighten

the bearing cap bolts with 30 kg.m and
with rotating angle method (90° +10°) and
tightening order are as follows.
EFM2062I
< Bearing cap bolt's tightening order >

(1) First step : Tighten with a bout 15 kg.m by wrench.
(2) Second step : Tighten with a bout 25 kg.m by torque wrench.
(3) Third step : Tighten with 30 kg.m by torque wrench.
(4) Fourth step : Tighten with final rotating angle method 90° +10°
However, according to above tightening order, tighten step by step.
● Inspect if the crank shaft's rotation is smooth.

● Assemble the crankshaft gear on the crankshaft and coat a white paint mark on "1" part in order to
find easily.

3.3.6. Camshaft
● Coat the cam bush of cylinder block and
camshaft with engine oil.
● Assemble the cam bush and camshaft for
Crankshaft gear
them not to be damaged.
● Assemble the crankshaft gear and the
camshaft gear making sure that the gear
1
marks on both gears are aligned 1 1
together.
Camshaft gear
EFM2063I
3.3.7. Flywheel housing

● Coat the thrust washer fixing bolt with an
adhesive and tighten it with specified
torque.
Torque 4 kg.m
EFM2065I
● Coat the oil seal (P.T.F.E.) with lubricat-

ing oil and assemble the oil seal carefully
for it not to deviate or be damaged by
means of special tool. (Mandrel for
Thrust washer
assembling).
Oil seal
EA6M2010
● Attach the gasket on the surface of cylin-

Flywheel housing
der block where the flywheel housing is to Oil seal(Rear)
Crank shaft
be installed. (In order to prevent the gas-
ket slip down, coat a grease on the cylin-
der block surface.) Flywheel
● Temporarily assemble 2ea of guide bolts
for installing the flywheel housing to the
cylinder block.
EOA1031I

● After fitting the flywheel housing holes to
the guide pins and engage temporarily 2
~ 3 threads of fixing bolts, and according
to the tightening order (zigzag method)
tighten them in the specified torque.
M12 x 1.5 10 kg.m

Torque
M10 7.5 kg.m
3.3.8. Flywheel
● 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.
● Do not allow the temperature of the ring
gear to exceed 200°C (390°F).
● By means of mandrel, assemble pilot
bearing to the flywheel.
EA0M4029
● By means of mandrel, press in the wear

ring at the backward face.
● Install two guide bolts for installing the fly-
wheel to the crankshaft.
Wear ring Ring gear

EA6M2004
● After letting the guide pin insert through

the flywheel holes and engaging the fix-
ing bolts by 2 ~ 3 threads temporarily,
tighten them to the specified torque
according to lightening order. (Zigzag 2
9
4 7
5
1
6 10
order). 8 3
Torque 26 kg.m Lubricate with engine oil
EA6M2005

3.3.9. Front oil seal holder
● After placing the oil seal in the oil holder
hole properly, press it in with a mandrel.
(Be careful for oil seal must not be dam-
aged.)
● Attach a gasket at the oil seal holder.
EFM2073I
● Align the dowel pin with the oil seal holder

Crankshaft pulley Oil seal holder
dowel hole and assemble them by tap-
ping lightly the dowel pin part with an ure- Oil seal
(front)
thane hammer when in assembling, take
care not to hurt the oil seal by the crank-
Cylinder
shaft. block
Note: Crankshaft
Without coating the oil seal with oil or
EOA1032I
lubricant, assemble it in the dry state.
● Tighten the fixing bolts in the zigzag

method.
3.3.10. Piston
● Line up the piston assembly in the order
of cylinders and fit the bearings to the 120 O
connecting rods and bearing caps. How-

2nd ring gap Top ring gap
ever, take care not to swap between the
Piston pin
connecting rods and bearing caps.
● Coat the pistons and connecting rod
bearings sufficiently with clean engine oil. 120 O
120 O
Piston
Oil ring gap
EFM2069I

● By means of a special tool, insert the pis-
ton rings and adjust the angles between Top ring
the ring gaps at 120°.
2nd ring
● Push in the piston with hands or wooden
bar into cylinder. (Be careful for piston Oil ring
and rings not be damaged.)
● Pushing the piston down, rotate the
crankshaft about 180° and fit the bearing
cap to the connecting rod. EA6M2006
● After engaging 2 ~ 3 threads of bolts pri-
marily rind then tighten them to the
specified torque. (10 kg.m + 90° +10°)
< Connecting rod bolt tightening order >

(1) First step : Engage 2 ~ 3 threads by hands.
(2) Second step : Tighten to about 7 kg.m with wrench.
(3) Third step : By means of torque wrench tighten to 10 kg.m.
(4) Fourth step : Finally assemble means of rotating angle method 90° +10°
However, according to above tightening order, tighten step by step.
* Standard length of bolt and use limit:

- From head seat to bolt tip
Standard length Use limit

67.5-0.3 mm 69 mm
● By moving the connecting rod bearing

cap by hands, make sure if there is any
play in left and right.
● With the same method as above, assem-
ble in each cylinder rotating the crank-
shaft.
EFM2070I

3.3.11. Oil pump
● Put the oil pump at the place to be
installed on the cylinder block.
● Attach a gasket at the surface of oil pump
where the pressure regulating valve is to
installed and place the regulating valve
on a gasket.
● Assemble the oil pump by tightening the
fixing bolts.
EFM2074I
Torque 2.2 kg.m
● Attach a gasket at the surface of the oil

pump where the oil suction pipe is to be
installed, and install the oil suction pipe
by tightening the fixing bolts.
● Assemble the pipe bracket on the cylin-
der block side with bolts.
Torque 2.2 kg.m
3.3.12. Vibration damper

● Assemble the vibration damper tightening
firstly by the crankshaft pulley and the fix-
ing bolts.
● Insert the crankshaft pulley assembly to
the crankshaft and tighten the fixing bolts
in the method of zigzag to the specified
torque.
Vibration damper EFM2092I

6 kg.m
Torque & pulley
Crank shaft pulley 21 kg.m

3.3.13. Oil pump
● Clean thoroughly the gasket that is pro-
jecting at the junction parts of front oil
seal holder and flywheel housing of cylin-
der block' s lower face with a scraper.
● In the process of gasket removal, be
careful for the gasket pieces not to get
into the engine inside.
● Attach a gasket to the cylinder block.
● Install the oil pan and tighten the fixing EFM2075I
bolts. Then takes care not to squeeze out
the gasket.
● Install the guide tube and insert the oil
level gauge.
Torque 2.2 kg.m
3.3.14. Intake and exhaust valve

● Identify the marks of "Gl" and "GE"
impressed on the valve head before
assembling the valve with the valve head.
● With a valve stem seal fitting jig, assem-
Valve identify the marks
ble the valve stem seal with the valve
guide.
GI GE
Intake valve Exhaust valve

EE3OM043

● Blow the cylinder head bolt holes with
compressed air to remove the foreign
material cleanly.
● Wipe off cleanly the junction part of cylin-
der block's head gasket.
● After confirming whether there is foreign
material or not necessarily, if there is,
remove it.
● Assemble a gasket fitting with the fixing EFM2076I
pin of cylinder block.
● Position the cylinder head assembly on
the cylinder block aligning with its dowel
pin. (Take care not to damage the head
gasket.)

● Tighten the cylinder head bolts to the
Intake side(Spark plug)
specified torque according to step by
1
step.
6 3
● However, prior to tightening the bolts,
with a long steel rule, the parallelness
between the cylinder heads must be
adjusted. 4 5
Exhaust side EFM2077I
< Cylinder head bolts tightening order >

(1) First step : Tighten temporarily 1 ~ 2 threads by hands.
(2) Second step : Tighten to a bout 8 kg.m with wrench.
(3) Third step : Tighten to 15 kg.m with a torque wrench.
(4) Fourth step : Rotate 90 by rotation angle method.
(5) Fifth step : Finally tighten additionally rotating 90°.
* Standard length of bolt and use limit:

- From the head seat face to tip
Bolt No. Standard length Use limit

3, 6 168 mm 171 mm
2, 4, 5 144 mm 147 mm
1 109 mm 112 mm L
Caution:
Take care for the foreign material not EOA11115
to get into the cylinder head suction
passages.

3.3.16. Spark plug
● Put the spark plug hole of cylinder head
and after inserting the spark plug assem-
bly into it, tighten to assemble.
EE3OM035
3.3.17. Rocker arm

● Coat the push rod with engine oil and put
it into the push rod hole.
● Position the rocker arm assembly on the
cylinder head and tighten the fixing bolts
to the specified tightening torque.
Torque 6.2 kg.m
● Adjust the valve clearance. Regarding EFM2091I

the adjustment, refer to the regular main-
tenance part.
3.3.18. Timing drive & sensor

● Attach an O-ring to the cylinder block and
install the timing drive on the cylinder Timing sensor
block and then tighten the fixing bolts.
Timing drive
O-ring
Torque 6.5 kg.m
Timing drive
gear
● Install the timing sensor on the timing
drive and rotate (CW) the timing sensor.
(Be careful for sensor magnet not to be EE3OM044
broken)

● Until the end of it reach on trigger magnet
Assemble the sensor
and reverse rotate (CCW) the timing sen- angle
sor for 255° (gap 1.0 mm) and then fix
178
lock nut.
C A
0.7 ~ 1.0 mm B
Timing sensor gap
(178° ~ 255°)
77
Tolerance
limit
EE3OM045
3.3.19. Ignition timing angle check & adjustment

1) Check ignition timing angle
● Turning crankshaft, let the valves of #7
(10 cylinder engine) or #6 (8 cylinder
engine and 12 cylinder engine) cylin-
der's valves overlap.
● Rotate the flywheel to the opposite
direction about 30° (in order to remove
a back lash) and then rotate in normal
Magnetic pick
direction to set the flywheel timing sensor
Magnetic pick
angle and effect-hole sensor magnet sensor EE3OM046
position.
40
● If not aligned, the start of effect-hole

sensor setting has to be corrected. Timing check
& sensor hole
Engine GV158 GV180 GV222

model TIC TIC TIC Timing sensor
magnet
Adjusting angle of
ignition timing 40° 40° 40°
(BTDC)
Operating angle of EE3OM047
ignition timing 14° 14° 12°
(BTDC)

2) Adjust ignition timing angle
● Remove the effect-hole sensor drive
gear cover.
● Correct start of effect-hole sensor set-
ting by turning the drive gear flange in
the oblong holes of the drive gear.
● Mark sure after every adjustment that
fastening bolts are carefully tightened.
● Check start of effect-hole sensor set-
ting once more. EA6O6005
3.3.20. Flywheel housing cover

● Attach a gasket to the flywheel housing
cover.
● Install the flywheel housing cover and
tighten the fixing bolts by the zigzag
method.
Torque 2.2 kg.m
EFM2072I
3.3.21. Intake manifold & gas regulator

● Attach a new gasket to the cylinder head
side. Throttle valve
● Assemble the intake manifold by tighten-
ing the fixing bolts.
● Attach a gasket to the inlet flange and
assemble by tightening the fixing bolts.
● Attach a gasket to the equalizing pipe Intake stake
Intake manifold
and gas regulator that connects the
intake manifolds of both sides and EE3OM028
assemble both manifolds by tightening
the fixing bolts.
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.

3.3.22. Cylinder head cover
● Attach a new gasket on the surface of cyl-
inder head where the cover is to be
installed.
● Assemble the cylinder head cover by
tightening the fixing bolts.
● Insert the oil filler cap.
Torque 2.2 kg.m
EFM2020I
3.3.23. Exhaust manifold

● Prior to assembling the exhaust manifold,
Exhaust
attach a gasket firstly to the cover and elbow
exhaust elbow pipe and assemble them
tightening the bolts evenly as the right fig- Exhaust
ure. manifold
Gasket
O-ring
EE3OM048
● Attach new gaskets to the exhaust mani-

fold and then assemble the exhaust man-
ifold with the fixing bolts.
Torque 5.0 kg.m
Caution:
Be careful not to drop the manifold
because it is very heavy. EFM2083I
3.3.24. Reset & magnetic pick-up sensor

● Move the lock nut to hexagonal side of
Flywheel
sensor completely.
Reset pin
● Rotate (CW) the Magnetic pick-up sensor
Magnetic sensor
on fly wheel housing, until the end of it
reach on flywheel ring gear and/or reset
pin.
Magnetic sensor Ring gear

EE3OM049

● Rotate (CCW) the Magnetic pick-up sen-
sor for 270°(gap 1.0 mm) and fix lock nut.
Flywheel
● Tolerance limit is 27°.(gap ±0.1 mm) Housing
Tolerance
limit
27
27
27
0
EPM2031I
3.3.25. Oil cooler

● Attach a gasket on the surface in the oil
cooler housing where the oil cooler is
installed.
● Tighten the oil cooler with fixing bolts.
● Install the oil cooler assembly by tighten-
ing the fixing bolts in the zigzag order.
Torque 3.1 kg.m
EFM2067I
Oil cooler
Oil cooler
housing
EE3OM031
Oil cooler
Oil cooler
cover
EE3OM032

3.3.26. Oil filter
● Attach the oil filter gasket on the oil
cooler.
● Install the filter head on the oil cooler and
then tighten bolts in a diagonal sequence. Oil filter
catridge
Torque 4.4 kg.m Oil filter

head
EE3OM029
● Lubricate the cartridge gasket and spin

filter until gasket contacts oil filter head,
then tighten additional 3/4 to 1 turn.
● Start engine and check for licks.
EFM2079I

● Attach a gasket at the cooling water
Thermostat
pump. (at cylinder block side) Water pump
● Assemble the cooling water pump by
tightening the fixing bolts. (zigzag
method)
Water pump
Water pump 2.2 kg.m pulley
Torque Water pump
2.2 kg.m
pulley EE3OM030
● Insert the thermostat of cooling water
pump.
● Insert the O-ring to the thermostat and
assemble the cooling water pipes by
tightening the fixing bolts.
Thermostat torque 2.2 kg.m

● Install stud bolts at the bolt holes on the
flywheel housing for installing the starter.
● Insert the starter into the fly wheel hous-
ing and tighten the fixing bolts.
Torque 8 kg.m
EFM2008I
3.3.29. Turbocharger
● Attach a gasket to the exhaust elbow and
assemble the turbocharger with fixing
bolts.
Turbo
charger
M8 2.2 kg.m
Torque
M10 6.2 kg.m
● Attach a gasket on the oil supply pipe and

assemble the pipe with the fixing bolts. EE3OM050
● Attack a gasket on the oil discharge pipe
and assemble the pipe by tightening the
bolts.
● At the same method as above, both sides
are assembled.
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.

3.3.30. Gas fuel mixer
● Attach a gasket to the intake elbow and
assemble the gas fuel mixer with fixing Gas fuel mixer
bolts.
● At the same method as above, both sides
are assembled.
Caution:
parts install and tighten fuel line. EE3OM027
leak detector.
3.3.31. Inter cooler

● After assembling the intercooler fixing
bracket on the intake manifold and then
assemble the intercooler with the fixing
bolts.
● Assemble the various hoses and pipes.
Caution:
parts install and tighten fuel line. EE3OM026
leak detector.

3.3.32. Ignition coil & gas pressure regulator
● Attach a bracket to the intake manifold
Gas pressure
and assemble the gas pressure regulator regulator
with fixing bolts.
● Assemble the ignition coil and high volt-
age cable.
Caution:
Check assembled after the all engine Ignition coil
parts install and tighten fuel line. High votage cable EE3OM025
leak detector.
3.3.33. Alternator
● Assemble the alternator bracket to the
lower part of cylinder block by tightening
the fixing bolts.
● Install the alternator supporting plate (belt
tension plate) to the oil pan by means of
bolts.
● Assemble the alternator to the bracket
and supporting plate tightening the bolts.
● Connect the crankshaft pulley and the EFM2002I
alternator pulley and water pump Pulley
with V-belts by inserting them into the
respective pulleys.
● Adjust the driving belt tension by regulat-
ing the alternator supporting plane.
(Belt tension adjusting bolts: 10 mm ~
15 mm by pushing with thumb)
EE3OM051

3.4. Starting and Trial Operation
3.4.1. Preparations for breaking-in

● Fill of new engine oil through the oil filler cap.
● When measuring the oil level with the oil level gauge with the engine mounted, the oil level must
indicate about 10 mm above the max. line.
● Connect water hoses and fill up cooling water.
● Connect the fuel hoses to the fuel tank and to top (radiator or surge tank).
● Check the air bleeding of the fuel system.
● 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 eas-
ily 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

● Engine should be run at fast idling until the temperature of the engine becomes normal operating
condition.
● Overload or continuous high speed operation should be avoided.
● High speed operation with no load should be prevented.
● Abrupt start and stop of the engine should be avoided.
● Engine speed must be under 70% of its maximum speed.
● 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:.
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 dipstick 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 cov-
ered 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
breaker) 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 model In oil pan Sulfated ash
Total (lit) API No.
Max. (lit) Min. (lit) content
GV158TIC 28 26 31
GV180TIC 35 28 38 SAE 15W40 Bellow 0.5%
GV222TIC 40 33 43

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.
(4.3. 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 coun-
terclockwise 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.
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 counterclock-
wise 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 mea-
sure 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 min-
imum (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).
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 shut down
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 counter-
clockwise) 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 m a y 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.
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 potentiom-
eter counterclockwise) to maintain stable operation.
11)If the engine is slow in returning to the proper speed, decrease the STABILITY by turning the poten-
tiometer counterclockwise.
12)Low idle speed adjustment: The engine should be at rated speed with the IDLE SPEED potenti-
ometer 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)
Start Load Load Ringing

on off
Speed
EE3OM052
b) Optimum performance on load transients with slight overshoot on starts (optimum damping)
Speed
EE3OM053
c) Optimum performance on start with slight time extension of load transients (optimum damping)
Speed
EE3OM054

d) Stability too high, long time to settle to rated speed (over damped)
Setting
Time
Speed
EE3OM055
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.
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 charac-
teristics while starting the engine. There may be differences in startup characteristics of cold and
hot engines.

3.6. Display Module
3.6.1. Display module system

The Display module, typically mounted in an engine control panel or other enclosure off the engine,
offers users comprehensive display and control functionality. It features a two-line, backlit, alphanu-
meric display, in conjunction with a front accessible, sealed membrane keypad and gives users
access to critical operating, setup, and diagnostic information.
System status E1: Energy level and Engine level

number of strikes
FIRING E1S 900 rpm

15.0 mA 10.0˚ Btdc
Ignition timing ampere Engine timing

EGV2218002
3.6.2. Typical system diagnostics

1) Engine overspeed has been reached with
the maximum observed speed displayed.
ENGINE OVER SPEED

1800 rpm
EGV2218003
2) Indicative of a condition where an incor-

rect number of gear tooth pulses have
been received between reset events
Often the result of an improperly gapped
magnetic pickup or a damaged ring gear. RING-GEAR FAULT
160 TEETH READ
EGV2218004

3) This diagnostic is flagged when zero gear
tooth pulses are between two reset
pulses. An open, shorted, or damaged
magnetic pickup cable is typically the
source of this fault. GT PICK-UP FAULT
MISSING PULSES
EGV2218005
4) Diagnostic faulted when too many gear

tooth pulses are received without detec-
tion of reset pulse. An open, shorted, or
damaged magnetic pickup cable is also
typically the source of this fault. RS PICK-UP FAULT
MISSING PULSES
EGV2218006
5) No Hall-effect pickup (4-cycle indicator)

signal has been detected or it is improp-
erly synchronized with the reset pickup.
HE PICK-UP FAULT
MISSING / / NO - SYNC
EGV2218007
6) The expected 4 - 20 mA control signal

used for timing control is either below
2 mA or above 22 mA. Annunciated
when timing control loop is either not
present or out of range. CURRENT LOOP
OUT OF RANGE
Timing control sensor

4 - 20 mA
ampere
EGV2218019

3.6.3. Patented primary and secondary diagnostic
1) Indicates the ignition system has
detected an open circuit on output "A";
usually the result of faulty wiring or a
failed coil.
PRIMARY OPEN
A
EGV2218008
2) A short circuit condition detected on out-

put "B"; may be the result of an improp-
erly wired coil or a short to ground inside
the conduit.
PRIMARY SHORT
B
EGV2218009
3) A low voltage demand condition on out-

put "C"; typically indicates a shorted
spark plug or secondary wire.
LO SPARK VOLT.
C
EGV2218010
4) A high voltage demand condition

detected on output "D"; generally
encountered when spark plugs become
worn and require replacement.
HI SPARK VOLT.
D
EGV2218011

5) No secondary spark on output "E"; indi-
cates disconnected secondary lead or
voltage demand exceeding the coiPs out-
put.
NO SEC. SPARK
E
EGV2218012
6) Output "F" is indicating that its monitored

spark voltage demand is dramatically
lower than the average of the cylinders.
This indicates potentially an overly rich
air/fuel mixture, a short in the secondary LO FROM ENGINE
F
wiring, or perhaps an improperly gapped
spark plug.
EGV2218013
7) A high spark voltage demand than that

seen the other engine power cylinders
has been detected on output "K". This
may also be related to air/fuel ratio or the
condition of the secondary wiring and/or HI FROM ENGINE
K
spark plugs.
EGV2218014

3.6.4. Understanding the home screen
1) The READY message is displayed when
the ignition is ready for the engine to
crank for starting.
READY 0 rpm
15.0 mA 10.0˚ Btdc
EGV2218015
2) Once theengine begin sturning, the

SYNCING message is displayed while
the ignition system verifies signals from
the engine pickups.
SYNCING 155 rpm
15.0 mA 10.0˚ Btdc
EGV2218016
3) The FIRING message is displayed when

the ignition begins firing. Additional data
is provided on this screen to describe the
selected mode of operation for the igni-
tion. The energy mode (E1, E2, E3) and FIRING E1S 1000 rpm
15.0 mA 10.0˚ Btdc
the single-strike/multi-strike type (S or M)
are described in the middle of the upper
line in small characters.
EGV2218017
4) The STALLED message is displayed

when a loss of rotation is detected after
the ignition is firing and neither a Shut-
down or Fault has occurred. This signifies
that the engine has stopped without any STALLED 0 rpm
15.0 mA 10.0˚ Btdc
detected cause from the ignition system.
EGV2218018

5) The WARNING message will supersede all of the above home screens if a diagnostic warning con-
dition is present. When a diagnostic warning exists, a View Diagnostics message will flash on the
bottom line of the display.
(a) The Ignition Module will continue to operate under a warning condition while alerting the operator
of a potential problem in several ways: by turning on the Alarm LED in the Ignition Module and by
changing the state of the Alarm Out switch (switch opens).
(b) The Display Module will display the Warning message. The various types of diagnostic warnings
are described in section.
WARNING 1000 rpm WARNING 1000 rpm

15.0 mA 10.0˚ Btdc VIEW DIAGNOSTICS
EGV2218020
6) The FAULT message will supersede all of the above home screens if a diagnostic fault condition is
present.
(a) When a diagnostic fault exists, a View Diagnostics message will flash on the bottom line of the
display.
(b) The ignition system will stop operating under a fault condition and will alert the operator to the
problem in several ways: by changing the state of the Fire Confirm Out switch (switch opens), by
turning on the alarm LED inside the Ignition Module, by changing the state of the Alarm Out
switch (switch opens), by changing the state of the Fault Out switch (switch opens), and by dis-
playing the Fault message.
(c) The various types of diagnostic faults are described in section.
FAULT 0 rpm FAULT 0 rpm

EGV2218021
7) The SHUTDOWN screen will supersede all other home displays if the logic level shutdown input of
the Ignition Module or the G-Lead of the output primary connector is grounded or was previously
grounded and the engine has not stopped rotating.
(a) This screen indicates that the ignition is not firing because a shutdown input was triggered to
shutdown the engine. If a diagnostic fault or warning exists while the ignition is in shutdown, a
View Diagnostics message will flash on the bottom line of the display.
(b) The Fire Confirm Out switch will change state (switch opens) and the other outputs will function
as described above based on the existence of faults or warnings.
SHUTDOWN 0 rpm SHUTDOWN 0 rpm

EGV2218022

8) The following types of screens can be viewed by pressing enter to start and next to advance.
- GV158TIC
H4A160 . FS100#001
UNIT 791950-16
EGV2218023
- GV180TIC
J4H160 . FS100#001
UNIT 791950-16
EGV2218024
- GV222TIC
L4B160 . FS100#001
UNIT 791950-16
EGV2218025
- H : Represents the engine model

(H:GV158TIC, J:GV180TIC, L:GV222TIC) Date configured Time configured
- 4 : 4-cycle engine
- A : Represents the altronic pattern code
(A:GV158TIC, H:GV180TIC, B:GV222TIC) 10 - 01 - 95 12 : 00
BY : name V 1.00
- 160: Represents the number ofgear teeth
or holes to be sensed
- FS100#001 : Special pattern code Configured by Terminal version#
- UNIT 791950 -16 : Ignition module no. EGV2218026

3.6.5. Ignition state checks
1) The last setup screen permits the operator to enter an ignition test mode. This test mode can fire all
outputs in rotation, or individual outputs at a slow rate. This feature can be used to troubleshoot pri-
mary wiring and operation. Test mode will terminate if rotation of the engine is sensed. Diagnostic
features do not function while in test mode.
RUN TEST MODE

Next Esc Enter
ENTER NEXT ESC
Press for test mode Press for next option Press to exit
EGV2218027
Caution:
the operator must fully purge the engine of combustible mixtures prior to selecting the test
mode operation. Pressing the enter key again is a confirmation of this action.
Then before starting test mode
IS ENGINE PURGED
Esc Enter
ENTER ESC
Press to verify purged Press to exit
EGV2218028
2) Then the test mode screen indicates that the ignition is firing and permits the operator to select the
output to be fired.
TEST - Mode ALL

Esc
ESC
Press to select Press to select Press to exit

Previous output Next output
EGV2218029

3.6.6. Ignition control module diagnostics
1) A diagnostic fault represents the most severe classification of problems. The presence of a diagnos-
tic fault will inhibit the ignition from firing. When a fault is detected several things will occur:
(a) The ignition will stop firing.
(b) The Fire Confirm Out switch will open.
(c) The Fault Out switch will open.
(d) The Alarm Out switch will open.
(e) The Alarm LED in the ignition unit will turn on.
(f) The home status will read Fault, and the bottom line will flash View Diagnostics.
Note:
Diagnostic FAULTS will supersede
diagnostic WARNINGS.
FAULT 0 rpm
VIEW DIAGNOSTICS
EGV2218030
2) A diagnostic warning represents the least

severe classification of problems. The
ignition will continue to fire in the pres-
ence of a diagnostic warning. When a
warning is detected, several things will WARNING 3000 rpm
VIEW DIAGNOSTICS
occur:
a) The Alarm Out switch will open.
b) The Alarm LED in the ignition unit will
turn on. EGV2218031
c) The home status will read WARNING,
and the bottom line will flash View
Diagnostics.
3) If the Alarm Out switch is being used to

turn on an audible alarm or flasher, the
user can acknowledge the alarm as
described below.
ALARM
ACK
EGV2218032

4) Acknowledgment of the alarm results in
the following until a reset is commanded
or until another fault or warning may
occur.
a) The Alarm Out switch will return to its
closed position.
b) The Alarm LED will flash to indicate
that an alarm is present but acknowl-
edged.
5) When a fault or warning is present, the operator can display the actual cause of the diagnostic as
depicted below.
From the home FAULT 0 rpm

Screen
DIAG
VIEW DIAGNOSTICS
EGV2218033
6) Then from the diagnostic description screens use the following keys.
DIAG NEXT ESC
Press to view next Or press to view next Press to exit

diagnostics diagnostics
EGV2218034
7) Diagnostic Fault screens, in order of dis-

play priority, are described below.
a) When zero gear-tooth pluses are seen
between two reset pluses.
GT PICK-UP FAULT
MISSING PULSES
EGV2218005

b) When too many gear-tooth pluses are
seen without a reset pluses.
GT PICK-UP FAULT
MISSING PULSES
EGV2218005
c) When there are no hall-effect pickup

pluses or when the pick-ups are not
synchronized.
HE PICK-UP FAULT
MISSING / / NO - SYNC
EGV2218007
d) When too many or to few gear-tooth

pluses are seen between reset
pluses. The received number or
pluses is displayed.
RING-GEAR FAULT
352 TEETH READ
EGV2218035
e) When the engine speed exceeds the

over speed set point. Maximum
observed speed is also displayed.
ENGINE OVER SPEED

1023 rpm
EGV2218036

f) When the check-sum of microproces-
sor firmware cannot be verified. Unit
requires service.
BOTTOM BOARD uP
CHECKSUM FAILED
EGV22180037

3.7. Diagnosis and Remedies of Trouble Causes
● Prior to asking for repair, please check the following items
Generated Problem Inspection Items Inspecting Position
● Confirm connector that connects electric Backward of gauge panel

wiring to gauge panel if it is correctly
connected
Starting failure, starting motor
● Confirm connection of electric wiring and Battery terminal
not rotate
batteries if it is connected correctly.
● Confirm connection of electric wiring and Starting motor terminal
starting motor if it is connected correctly.
Starting motor rotates but
● Make sure that fuel quantity is sufficient. Fuel tank
starting fail
● Confirm connector that connects wiring and Backward of gauge panel
Engine revolution meter not gauge panel if it is correctly connected.
operates ● Check if terminal resistance of tacho Tacho sensor terminal
sensor is pulled out
● Confirm connector that connects wiring and Backward of gauge panel
gauge panel if it is correctly connected.
Cooling water temp, gauge fails
● Confirm connector of cooling temp sensor Cooling water pipe
if it is correctly connected.
● Confirm connector that is connected to
Engine oil pressure gauge not Side of oil filter
engine oil pressure sensing sensor if it is
operate
pulled out.
● Confirm that the electric wiring terminal that Alternator terminal
Charging abnormality warning
is connected to generator's L terminal if it is
lamp lights continuously
pulled out and touched to engine body.
Though engine stopped, engine ● Characteristics of engine revolution meter Starting key
revolution meter works continu- is so designed that it may slowly drop
ously down, and so it's not trouble.
● Confirm if the present position of start
Backward of gauge panel
switch is at ACC.
● For power source of gauge panel goes
from starting key, if the start key is at OFF,
Cooling water temp, gauge and
though engine is running, gauge panel
engine revolution meter not
does not move.
operate simultaneously.
● Confirm connector that connects wiring and
gauge panel if it is correctly connected.
● Confirm if connector that connected to
solenoid and wiring is pulled out.
Though engine switch is ● Confirm if the cable that connects electric Electric governor
pushed, it does not stall. governor and injection pump is cut.

4.1. Gas Fuel Circuit
Installed parts of generator maker

Gas pressure
Manual shut-off valve Gas filter regulator Gas pressure gauge
Nature gas
4. Electrical Equipment
Gas pressure
regulator
Inter cooler
Speed Ignition control

controller module Throttle
valve
- 113 -
Ignition coil
Fuel mixer
Turbo (Gas + air)
charger
Hall-effect sensor
Air cleaner
Magnetic pick-up sensor(Timing check)
Display
Magnetic pick-up sensor(reset)
module
Exhaust gas
EE3OM056
Electrical equipment
Display module idle-open
rated-closed
idle
potentiometer
Ignition close for
switch rated
0.85R
+ + +
open for
speed minimum
- - -
0.5Y
0.5Y
trim/jump
10A
F1
+ 7 8 3 4 5 6 1 1 7 8 10 9 (9)
Power Panel Power standard option
0.85R
P1 H1 P2 H2 P3 H3 H5 H6 H7
4.2. Electrical Wiring Diagram
+ + + Dispaly Panel out in

+ + + + + + module
S S S
3.0Y N T Pr CPU95 CPU95
Control module
Speed controler
- - - - - -
BR - - -
ACC C Magnetic pick-up 4-Cycle pick-up pick-up throttle
Power Power
ON
START
- A B A B A B C 2 5 6 3 4 11 12 G A B C D E F K L M N P R J
0.5L
0.5G
0.5LY
0.5WB
0.5GW
B
3.0Y
0.5WB
S1 Shut-off
ignition
0.85B
S1.BR(1.25W)
C1
C2 + -
R P L
- 114 -
G + + B
WK
St.+ E D
A C
M ˚C bar B+ G P T PU PU PU
0.5bar 93˚C A B
C1.E C1.E C1.E - - St.+ C1.E C1.E
Water temp. Engine oil Alternator Engine Water Speed Reset Cam Throttle Spark plug
Battery Starter
Sensor Sensor Oil Temp. Pick-up Pick-up Pick-up
Pins no. of Ignition connector

Parts list Ignition harness connector No.
Cylinder No
GV158TI GV180TI GV222TI
C1-C2 1 Main Connector 1 A A A
F1 1 Circuit Breaker 10A 2 D E M
3 F K E
H1-H3 3 Light lamp 24V 2W 4 K M P
H5 1 Cahrge indicator lamp LED DAEWOO Engine Firing order 5 B C C
H6 1 Low oil pressure warning lamp LED Model Firing order 6 E B K
H7 1 High coolant temp. warning lamp LED GV158TI 1-5-7-2-6-3-4-8 7 C F L
1 - 6 - 5 - 10 - 2 - 7 - 3 - 8 - 4 - 9 8 L L D
P1 1 Tacho meter 0-3000rpm GV180TI
GV222TI 1 - 12 - 5 - 8 - 3 - 10 - 6 - 7 - 2 - 11 - 4 - 9 9 N R
P2 1 Coolant temperature gauge 40-120˚C 10 D F
P3 1 Engine oil pressure gauge 0-10bar 11 N
S1 1 Engine start key switch Rotary 12 B
*Spark plug harness connection
EE3OM057
4.3. Speed Controller
4.3.1. Speed controller description

● The Speed Controller is designed to provide basic isochronous speed control for gas engines.
● Engines with mechanical loads and generator loads are handled equally well.
152.4
133.35
139.7
127
1 2 3 4 5 6 7 8 9 10 11 12
4-O5.94
FLO-TECH SPEED
69.85
4.8
EE3OM058
- 115 - Electrical equipment

4.3.2. Speed controller circuit
FLOTECH
SPEED CONTROL
EE3OM059
● 1 Shield wires to be twisted pairs with shield grounded at one end only.
● 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.
● 3 Use 24 volt system.
● 4 Open for minimum fuel.
● 5 For positive ground systems, switch and fuse to be located in series with battery (-) and termi-
nal 2. Positive terminal becomes chassis ground. Leads from battery to terminals 1 & 2 must be
direct and not pass through distribution points.
● 6 Approximate speed change with trim potentiometer
◈ ±2.5% using a 1K Ω potentiometer

◈ ±5% using a 2K Ω potentiometer
● 7 About one second ramp time per 50㎌. Capacitor specifications: 200㎌ maximum, 15WVdc
minimum. 15WVdc maximum. Less than 30㎂ DC leakage current over temperature range.
● 8 Idle range about 25% to 100% rated using 50K potentiometer.
● 9 Use a 1 amp fuse (3 AWG)
Electrical equipment - 116 -

4.4. Ignition Controller
4.4.1. Ignition controller circuit
Spark plug
CPU-95 Ignition coil
"G" lead-shutdown,
instrument power
& oscilloscope diagnostics
Display module *Hall-effect

cycle sensor
RS485 serial
data link & power Hall-effect pickup to line-
24 Vdc power
~
up with magnet coincident
Note: with reset pickup lined-up
Power grounds for the with reset pin on compression
ignition module and stroke of #1 cylinder
the display module
must be at the same
ground potential for
proper operation of the Magnetic pickups
RS485 serial data, RS485 communication.
control inputs & outputs
~
reset
Timing counts
EE3OM060
a) Display module
- Displays operating mode, rpm, timing, status
- Displays diagnostic fault messages
- 24 Vdc nominal input power
- Digital input (MISC)
- 4 - 20 mA input for timing control
- Digital output, alarm or overspeed via RS485
b) RS485 serial data, control inputs and outputs

- RS485 serial communications from P.C.
- Low voltage shutdown input
- Miscellaneous input
- Alarm output switch
- Fault output switch
- Fire confirm output switch
Note:
RS485 serial communications & MISC. input to either display module or P.C., not both at same
time.

4.4.2. DC power hookup of ignition system
Regulator
Battery CPU-95 UNIT

+
-
Alternator
Switch rating
Battery charger Battery 10A min
+
R
+
+
- - -
Fuse rating
10A
Power supply
+
-
Power supply spec: 5A continuous
EE3OM061
● Operating voltage requirements
Starting 20 VDC min.

Running 24 ~ 28 VDC
● Dimensions of cable
* It is recommended that each system be connected separately back to the power source. Determine the wire
size required.
Distance in Cm Minimum wire size Distance in Cm Minimum wire size

up to 762 16 AWG 2,012 - 3,048 10 AWG
793 - 1,219 14 AWG 3,079 - 4,877 8 AWG
1,250 - 1,981 12 AWG

● Dimensions of cable
* If multiple units are powered from a source located in a separate building, Determine the wire size required
between the power source and the engine room. Create a common power hookup point in the engine room,
Then use determine the wire size required from this common point to each ignition module.
Distance in Cm Minimum wire size Distance in Cm Minimum wire size

790 - 1,220 14 AWG 3,080 - 4,880 8 AWG
1,250 - 1,980 12 AWG 4,910 - 7,620 6 AWG
2,010 - 3,050 10 AWG 7,650 - 12,190 4 AWG
Note:
Above 12,190 cm use multiple pairs of wires from the power source to the engine room.
4.4.3. Display module

1)Feature of display module
165.1 4-O5 152.4
139.7
152.4
165.1
31.76 139.7
55.6
EE3OM062

2)Display module circuit
Use shielded 2 conductor

cable or twisted pair MISC. input: Colse to
Auxiliary terminal
acivate selected feature
User 4-conduct shielded cable for

2-wire transmitter
power & RS-485 connections.
Connect shield in ignition module - +
+
Power module (See "A")
24Vdc supply
-
1 2 3 4 5 6 7 8 9 10 + - - +
POWER COMMUNICATIONS INPUT +
+ - + - + - + - LOOP POWER
MISC. INPUT OUT IN 24Vdc supply
SHIELD
POWER INPUT
SERIAL RS485
SERIAL RS485
AUX. RS485
AUX. RS485
CURRENT LOOP
CURRENT LOOP
24 VDC
-
Note: 1.Loop input impedance : 250 + 1%
2.Field wiring must be 24AWG
Note: 1.Input power requirement for dispaly module is 24Vdc 150mA nominal
2.Power ground for display module & the ignition module must be at the same ground
potential for proper operation of the RS-485 in communications. EE3OM063
3)Voltage supply of display module
Display module
2-Wire
transmiter
24V supply
Display module
3-Wire
transmiter
24V supply
EE3OM064
Note:
1. Loop input impedance : 250Ω ±1%
2. Field wiring must be 24 AWG

4.5. Ignition Control Module
4.5.1. Ignition control module views
19-PIN CONNECTOR
222 140
94 58
Fuse
4-CYCLE P.U. POWER

C
B
A
S
ALTRONIC, ING. YOUNGSTOWN, OHIO
MAGN. PICKUPS
B
MUST BE INSTALLED PER FORM CPU-95 II
INSTALLE CONFORMEMANT CPU-95 II
WARNING : KEEP COVER TIGHT
AVERTISSEMENT : GARDER LE
251
A
R
ALTRONIC CPU-95
IGNITION SYSTEM
WHILE CIRCUITS ARE LIVE.
COUVERCLE BIEN FERME
CLASS I, GROUP D. DIV. 2 T4
S
S/N
B
A
LORSQUE LES.
152
94
10 11 12
COMMUNICATIONS
235
CERTIFIED
47
8
7
PART NO.
6
PANEL OUT
76
5
4
3
2
IN
1
1/2" CONDUITFITTINGS
86 19 18
210
257
EEprom Microprocessor EE3OM065
4.5.2. Ignition control circuit

GEAR TOOTH P.U.(RED)
GEAR TOOTH P.U.(BLACK)

FIRE CONFIRM OUT
RESET P.U.(BLACK)
RESET P.U.(RED)
SERIAL RS485 -
SERIAL RS485 +
CABLE SHIELDS
SHUTDOWN IN
COMMON OUT
CABLE SHIELD
ALARM OUT
FAULT OUT
COMMON -
GROUND -
SWITCH +
24 VDC +
MISC. IN
SUPLY +
SHIELD
IN PANEL OUT COMMUNICATIONS MAGN. PICKUPS 4-CYCLE PU POWER

1 2 3 4 5 6 7 8 9 10 11 12 A B S A B S A B C
To pickups
CR CR
CR
USER INPUT,
CLOSE TO STOP
IGNITION.
+
NOTE RECOMMEND ALTRONIC
24V 4-CONDUCTOR CABLE
- 503194-500
10 A fuse
3 4 1 2 24 VDC +
USER INPUT, CLOSE TO SUPLY
ACTIVATE SELECTED FEATURE
Ref to display 5 OR 10 AMP. -
(ONE-STEP TIMING) module circuit "A"
Engine
ground
Note : Alarm, fault & fire confirm outputs are
isolated terminals which are not connected to Note : Use minimum
ground or +/- 24 volt supply. These terminals 16AWG standard wire for
can be referenced to an external isolated supply input power supply wires
if required.
EE3OM066

4.5.3. Ignition harness connector
Cylinder Connector pin no. of ignition harness

no. GV158TIC GV180TIC GV222TIC A M L
B N U K
1 A A A
C P V T J
2 D E M
D R S H
3 F K E E F G
4 K M P
5 B C C
6 E B K Ignition harness connector EE3OM067
7 C F L
8 L L D
9 - N R
10 - D F
11 - - N
12 - - B
GND G G G
Off to GND J J J
4.5.4. Ignition harness connector
Engine model Firing order

GV158TIC 1-5-7-2-6-3-4-8
GV180TIC 1-6-5-10-2-7-3-8-4-9
GV222TIC 1-12-5-8-3-10-6-7-2-11-4-9
4.5.5. Engine cylinder no.
Cylinder no.
Fly wheel
6
12
5 5 11
10
4 8 4 4
9 10
3 3 3
7 8 9
2 2 2
6 7 8
1 1 1
5 6 7
Cooling fan
EE3OM068

Right bank leads
Junction box
4.5.6. Ignition system
"G" lead, ground to shut-off

Panel "G" lead ignition power instruments and
G oscilloscope diagnostics.
+ - + - + - + - + - + -
Harness COIL
connector + + + + + +
A M L
J
- - - - - -
B N U K
Junction C P V T J
box
D R S H
- - - - - -
E F G
ENGINE Ground
- 123 -
+ + + + + + to engine
at end
Harness 22-14S cylinders
Spark plug
Igniton
control
module Spark plug lead
Coil
+ - + - + - + - + - +
Ignition control -
module must be
grounded
Separate grounds
in junction box
Left bank leads
EE3OM069
5. Maintenance of Major Parts
5.1 Turbocharger
5.1.1. Main data and specification
Generator engine GV158TI GV180TI GV222TI

Turbocharger model HOLSET HX35
Rated revolution (rpm) 80,000 80,000 60,000
Intake air quality (m3/sec) 0.28 0.35 0.43
Compression efficiency (%) 77 75.0 76
Compression ratio 1.8 2.0 1.66
Weight 14 kg 14 kg 14 kg
5.1.2. Operating principle
1 D
2
3
A B
4
E
EA05008I
1. Impeller casing A. Air inlet

2. Turbine housing B. Gas outlet
3. Bearing casing C. Gas inlet
4. Impeller D. Oil supply
5. Turbine E. Oil return
- 125 - Maintenance of major parts

5.1.3. Construction
Make sure that servicing should be performed at the professional maintenance shop as authorized
by HOLSET or DOOSAN Company.
22
23
24
15
7
6
3
4
14 8
19
18
16
2
17 13
21
5
1
10
27,30,31
11
EFM3001I
1. Turbine shaft 15. Seal plate

2. Thrust bush 16. Thrust bearing
3. Oil shut off 17. Journal bearing
4. Fixing nut 18. Screw
5. Seal ring 19. Screw
6. Seal ring 21. Heat dissipater
7. Seal ring 22. Compressor housing
8. Compressor wing wheel 23. Clamp
9. Turbine housing 24. Bolt
10. Bolt 27. Liquid gasket
11. Clamp 30. Loctite
13. Bearing housing 31. Liquid anti-burn agents
14. Retainer ring
Maintenance of major parts - 126 -

5.1.4. General information
● The engine output depends upon the supplied fuel quantity and the engine efficiency. In order to
transform into the effective work of engine by burning the supplied fuel fully, the sufficient air to burn
the fuel should be supplied to the cylinder.
● Therefore, the engine output is essentially determined by the size of the cylinder, and for if the air is
supplied to the given volume of cylinder with the air being compressed, the air quantity in the cylin-
der will Increase as much to result in that it may burn more fuel, the output will also be able to
increase.
● Supplying the air by compressing like this into the engine cylinder is called as supercharging, and
super charging by means of exhaust gas energy that discharges to the atmosphere is called as the
turbocharging.
Turbine wheel
Outlet
Compressor
Engine
Exhaust
cylinder
gas
Exhaust gas inlet outlet
Compressor air supply
Intake air Turbine
Exhaust Exhaust gas passage inlet
Compressor wheel Compressor air passage
EFM3002I EFM3003I
5.1.5. Function
1) Turbine
● The exhaust gas that is discharged from combustion chamber passes through turbine housing
conveying an energy to turbine wings to give the rotating power, This is called as the turbine and
in order not to influence a bad effect at bearing part, there are the seal ring and heat dissipater.
2) Compressor
● It is connected to the same shaft with the turbine to make a revolving assembly, and receive the
revolving force of turbine, and sends air to the suction manifold by suctioning and compressing it.
This is called as the compressor.
3) Bearing
● Thrust bearing force is applied to the turbine wheel and an arrangement is made for the shaft not
to shift.
● Journal bearing (floating bearing) is adopted and it forms the double oil films at the inner and outer
surfaces in comparison to the general stationary type so that the bearing may be able to rotate
independently and consequently the double layers of films act as the damper to make the slipping
speed on the bearing surface less than the rotating speed of shaft so that the dynamic stability
may be obtained.
4) Sealing at compressor shaft
● In order for the compressed intake air and lubricating oil not to leak, a seal plate and a seal ring
are made to the double structures.

5.1.6. How to handle the engine
1) Precautions for operation of the engine
Operation following items must be observed at the starting, operation and stop of engine.
Operation Caution Reason

At starting 1) Inspect oil quantity 1)
2) After confirming that oil pressure rises 2) If engine is started quickly, of course
by starting engine with starter (until the beginning with every parts of engine, for
pointer of oil pressure gauge moves or it revolves without oil that is to reach to
pressure indicating lamp operates), the the turbocharger, the bearing's abnor-
starting must be done. mal wear or stuck may be caused.
3) In case that oil, oil filter and lubricating 3) In case that engine stalled for long time
system's part are replaced or engine and of cold weather, the fluidity of oil
was stalled for long time (more than a may be get worse.
week), and in case of operation under
cold weather, loosen the oil pipe con-
necting parts of turbocharger inlet, and
operate the starting motor until oil
comes out the connecting parts.
Care must be paid that after the con-
firming above, retighten the pipe con-
necting parts without fail, and proceed
with the normal starting.
Immediately 1) Perform idling operation for about 5 min. 1) Sudden load at time soon after engine
after starting immediately after engine starting. starting and at the state when turbo-
charger did not yet reach to smooth rev-
olution , if abrupt load is applied to
engine, some parts where oil did still not
reach may cause a burn to be stuck.
2) Various inspections must insure that 2) If there are the leakage of oil, gas, air,
there are no leakage of oil, gas and air. particularly oil, for the oil pressure low-
ers, it causes a burn of bearing to be
stuck.
During operation Following items must be confirmed. 1) If the pressure is too low, abnormal
1) Oil pressure at wear or stuck may be caused. Or if too
idling: 0.9 ~ 3.0 bar high, the oil leak may be generated.
at full load: 3.0 ~ 6.5 bar
2) When abnormal noises and vibration 2) If the engine operation were continued
are generated, slow down the revolution with abnormal noises and vibration, it
and must stop it to investigate the causes the engine trouble that can not
causes. be repaired or some other troubles.

Operation Caution Reason
At stop 1) At stopping the engine, perform the idling 1) After heavy load operation, if the engine
operation for 5 min. and then stop it. were stopped suddenly, the heat would
be conducted to bearing parts from red
hot turbine wings that would result in
burning the oil to cause the stuck bear-
ing metal and revolving shaft.
5.1.7. Routine inspection and maintenance

● Since the state of turbocharger depends largely on the state of engine maintenance, to perform the
specified keep up thoroughly is needed.
1) Air intake system
● System in the intake air system, care must be taken to the air cleaner. In case of oil passing
type air cleaner, if the oil level is lower than the specified value, the cleaning efficiency get
worse, if higher, the sucked oil pollutes a case.
● Particularly, for if the rotor were polluted, the balance adjusted precisely would be deviated to
cause a vibration that may cause the stuck or abnormal wear by loading large force to the
bearing, the perfect air cleaner must always be used.
● In case of dry type filter, according to the indication of a dust indicator, cleaning must be done
to make the intake air resistance as small as possible.
2) Exhaust system
● In exhaust system, a care must be taken to the gas leak and the stuck prevention. If exhaust
gas leaks from the exhaust pipe and turbocharger etc., for the super charging effect will be
lowered, the installed states of various parts must be paid with careful attention.
● Since the parts that reach to high temperature during operation such as the turbine room use
the anti-heat nuts, a care must be paid not to mix with the general nuts and at the same time,
bolt stuck preventing paint should be coated on the nut for the designated places.
3) Lubricating system
● In the lubricating system, a care must be paid to the oil quality and oil element replacement
cycle.
● For the oil deterioration of turbocharger equipped engine, needless to speak of engine assem-
bly itself, influences badly to the turbocharger too, the specified engine oil should used.

5.1.8. Periodical servicing
The turbocharger assembly must be inspected periodically.
1) Rotating condition of the rotor and checking tips
● Inspection on the revolving state of rotor is performed according to abnormal noises.
● In case of using an acoustic bar, touch the turbocharger housing with a tip of bar and raise the
engine revolution slowly. Then, in case that high sound is heard by every 2 ~ 3 sec. continuously,
for there should be the possibility to be abnormal metal and rotor, replace or repair the turbo-
charger.
2) Measuring rotor clearance
● Disassemble the turbocharger from the engine and should inspect the end plays in axial and cir-
cumference direction.
● In case of disassembling the turbocharger, the oil inlet and outlet should necessarily be sealed
with a tape.
a) Rotor axial direction end play
● Wear limit: 0.20 mm
Turbine wheel room
Magnet vise
Shift the
turbine shaft to
Dial gauge axial direction
Wear limit : 0.20mm EFM3004I
b) Rotor's circumference direction end play.

● Wear limit : 0.65 mm
Dial indicator
Magnetic stand
Oil outlet
Move turbine shaft

at both right and
left sides
simultaneously in
radial direction
Oil inlet
EFM3005I

c) In case that the end plays to axial and circumference directions, replace or repair the tur-
bocharger.
3) Overhaul and cleaning points

● Be sure to dismantle the turbocharger from the engine before cleaning.
● Also, make sure to seal the oil inlet and outlet with tape or similar.
4) Precautions for turbocharger reassembly

● When in assembling the turbocharger or the handling after assembling should work observing the
following precautions necessarily.
● Particularly, precise care should be taken for foreign material not to get into the turbocharger.
a) Lubricating system
● Prior to assembling it into the engine, fill new oil into oil Inlet and turning turbine shaft with
hand, lubricate journal and thrust bearing.
● In order for oil not to leak from various connections, assemble securely.
b) Air intake system

● Confirm if there is any foreign material inside the air intake system.
● Assemble securely the air intake duct and air cleaner so that the connections from them
may not leak an air.
c) Exhaust system
● Confirm if there is any foreign material in the exhaust system.
● Bolts and nuts must be made of anti-heat steel and in assembling, care should be taken not
use the general nuts and coat the bolts and nuts with the anti-stuck agents at the same
time.
● Assemble securely for gas not to leak from various connecting parts of exhaust pipes.

5.1.9. Trouble cause diagnosis and remedy

1.Exhaust gas 1) Air cleaner elements clogged Replace or clean
excessive 2) Air Inlet port clogged Inspect or repair
3) Air leaks from air intake system Inspect or repair
4) Turbocharger impossible to rotate due to Overhaul and repair or replace
stuck
5) Turbine wing's contact Overhaul and repair or replace
6) Piping deformation or clogging of Inspect and repair
exhaust system
2.White smoke 1) Oil leaks into turbine and compressor. Overhaul and repair or replace
excessive 2) Seal ring's abnormal wear or damage Overhaul and repair or replace
1) Gas leak from various parts of exhaust Inspect and repair
system
2) Air cleaner's elements clogged Replace or clean
3.Output lowered
3) Turbocharger's pollution or damage Overhaul and repair or replace
4) Air leaks from discharge part of com- Inspect and repair
pressor side
1) Revolving parts' contact Overhaul and repair or replace
4.Abnormal noises 2) Revolving imbalance of rotor Overhaul and repair or replace
or vibrations 3) Stuck Overhaul and repair or replace
4) Various connections loose Inspect and repair

5.2 Lubricating System
● Lubricating oil pumped by the gear oil pump in the oil pan is filtrated in the oil filter. This filtrated oil
passed on the oil cooler and next the main oil gallery of the cylinder block where is distributed to lubri-
cate the various sliding parts and turbocharger etc also in order to ensure normal engine performance.
5.2.1. Specifications
Item Specifications Item Specifications

Forced pressure
Lubricating system Oil filter type Full flow
circulation
Oil pump type Gear type Filter element type Cartridge type
Relief valve opening pressure 10 -1.0 kg/cm2 Bypass valve opening pressure 2.5 ±0.3 kg/cm2
Adjusting valve for spray nozzle Bypass for oil cooler valve
1.5 - 1.8 kg/cm2 5.0 ±0.5 kg/cm2
opening pressure opening pressure
5.2.2. Oil pump
7
5
0.5
1
4
EB4O7001
1. Oil pump housing 4. Oil pump gear

2. Cover 5. Oil pump drive gear
3. Oil pump gear 6, 7. Hex bolt

5.3. Cooling System
● The engine has a liquid-cooling system. The water pump is a maintenance-free impeller pump driven
by v-belts from the crankshaft pulley.
Ø12 Ø40
EXHAUST MANIFOLD
Ø55
HEAT EXCHANGER
AIR VENT
INTER COOLER
Ø48.6
TIRBO CHARGER
CYLINDER BLOCK THERMOSTAT
Ø45
BY PASS
Ø67
FRESH WATER PUMP
Ø12 Ø55
OIL COOLER
Ø12
Ø40
EXHAUST MANIFOLD
TIRBO CHARGER
WATER PUMP
EE3OM071
Impeller
Cover
þ137
Spline shaft
Mechanical seal
Hub
Insert
Rubber seal
Pump housing
EB4O7002-E

5.4. Thermostat
5.4.1. General descriptions and main data

● The thermostat maintains a constant tem-
To radiator
perature of coolant (90 - 95°C) and
improves thermal efficiency of the engine
by preventing heat loss.
● Namely, when the temperature of coolant
is low, the thermostat valve is closed to
make the coolant bypass to directly enter Bypass
From cooling valve
the water pump; when the coolant tem- To bypass tube
water pipe
perature rises to open wide the thermo- EAMC002I
stat valve, the bypass circuit is closed
and the water passage to the radiator is
opened so that the coolant is forced to
flow into the radiator.
Item Specification
Part No. 300738- 00159 300738-00161
Type Wax-pallet type
Open temperature 71°C 83°C
Full open temperature 85°C 95°C
Valve lift 8 mm or more
5.4.2. Inspecting
● Check the wax pallet and spring for dam-
age.
● Put the thermostat in a container of Ruler
Thermometer
water, then heat the water slowly and
check temperature with a thermometer.
If the valve lift is 0.1 mm (starting to open) Woodplate
at temperature of 71°C (Opening tem-
perature) at and 8 mm or more (opening
wide) at temperature of 85°C (Full open- EFM2055I
ing temperature), the thermostat is nor-
mal.
Opening Full opening

No.
temperature temperature
300738 -00159 71°C 85°C
300738-00161 83°C 95°C

5.4.3. Replacing thermostat and precautions for handling
● Precautions for handling
The wax pallet type thermostat does not react as quickly as bellows type one to a variation of tem-
perature of coolant. Such relatively slow reaction is mainly due to the large heat capacity of the wax
pellet type thermostat. Therefore, to avoid a sharp rise of coolant temperature, it is essential to idle
the engine sufficiently before running it. In cold weather, do not run the engine at overload or over-
speed it immediately after starting off.
● When draining out or replenishing coolant, doing it slowly so that air is bleed sufficiently from the
entire cooling system.
● Replacing thermostat
If the thermostat is detected defective, replace with a new one.
5.4.4. Diagnostics and troubleshooting
Condition Possible causes Corrections

● Lack of coolant ● Replenish coolant
● Radiator cap pressure valve spring ● Replace cap
weakened
● Fan belt loosened or broken ● Adjust or replace fan belt
● Fan belt fouled with oil ● Replace fan belt
● Thermostat inoperative ● Replace thermostat
1. Engine over ● Repair or replace
● Water pump defective
heating
● Restrictions in water passages due to ● Clean radiator and water passages
deposit of scales sages
● Adjust ignition timing correctly
● Ignition timing incorrect
● Clean exterior of radiator
● Restriction in radiator core
● Replace cylinder head gasket
● Gases leaking into water jacket due to
broken cylinder head gasket
2. Engine over ● Thermostat inoperative ● Replace thermostat
cooling ● Ambient temperature too low ● Install radiator curtain
● Radiator leaky ● Correct or replace
● Radiator hoses loosely connected or ● Retighten clamps or replace
damaged hoses
3. Lack of coolant ● Radiator cap valve spring weakened ● Replace cap
● Water pump leaky ● Repair or replace
● Cylinder head gasket leaky ● Replace cylinder head gasket
● Cylinder head or cylinder block cracked ● Replace cylinder head or block
● Water pump bearing defective ● Replace bearing
4. Cooling system
● Fan out of balance ● Replace fan
noisy
● Fan belt defective ● Replace fan belt

5.5. V-Belts
● The tension of the belts should be checked after every 2,000 hours of operation.
5.5.1. Change the belts if necessary

● If in the case of a multiple belt drive, wear or differing tensions are found, always replace the com-
plete set of belts.
5.5.2. Checking condition

● Check belts for cracks, oil, overheating and wear.
5.5.3. Testing by hand

● By the finger-pressure the belt is pressed
by 10 ~ 15 mm between the pulleys in
normal condition. (Pressed midway
between the belt pulleys)
● A more precise check of the V-belt ten-
sion is possible only by using a V-belt
tension tester.
EFM2002I
5.5.4. Measuring tension

a) Lower indicator arm (1) into the scale.
● Apply tester to belt at a point midway
between two pulleys so that edge of (1)
contact surface (2) is flush with the V-
belt.
● Slowly depress pad (3) until the spring
can be heard to disengage. This will
cause the indicator to move upwards.
● If pressure is maintained after the EA6O6011
spring has disengaged a false reading
will be obtained!

b) Reading of tension
● Read of the tensioning force of the belt
at the point where the top surface of (3)
the indicator arm (1) intersects with the
scale.
● Before taking readings make ensure
that the indicator arm remains in its
position.
(2)
EA6O6012
● V-belt tension
Tensioning forces on the tester

New installation
Type Drive belt width When servicing after long
After 10 min.
Installation 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
*: Adopted in GV158TIC, GV180TIC, GV222TIC engine
5.5.5. Tensioning and changing belts

● Loosen fixing bolts and nuts.
● Adjust the alternator until belts have cor-
rect tensions.
● Retighten fixing bolts and nuts.
● To change the belts loosen fixing bolts and
nuts. Then push the alternator toward water (1)
pump pulley by hand. (2)
EA6O6014

5.6. Air Intake System
5.6.1. Maintenance
(Only when engine is switched off)
Empty the dust bowl regularly. The bowl should never be filled more than halfway with dust
On slipping off the two clamps, the dust bowl can be removed. Take off the cover 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 filter is installed horizontally, watch for "top" mark the
collector which should register. Where the on cleaner bowl.
Air cleaner
assembly
EK00352A
5.6.2. Changing filter element

● On removing the hexagon nut, take out
the dirty cartridge and renew or clean.
● 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.
EA6O5013

5.6.3. Changing filter element
● 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 (maxi-
mum 500kPa - 5 bar) until no more dust
comes out of the filter pleats. EA6O5014
● By washing
- Before washing, the element should be
precleaned by means of compressed
air, as described above.
- Then allow the element to soak in luke-
warm washing solvent for 10 minutes,
and then move it to and for in the sol-
vent for about 5 minutes.
- Rinse thoroughly in clean water, shake
out and allow drying at room tempera- EA6O5015
ture. The cartridge must be dry before it
is reinstalled.
- Never use steam sprayers, petrol (gas-
oline), alkalis or hot liquids etc. to clean
the filter elements.
● Knocking out dirt by hand
- In emergencies, when no compressed
air or cleaning agent is available, it is
possible to clean the filter cartridge pro-
visionally by hitting the end disk of the
cartridge with the ball of one's thumb.
- Under no circumstances should the ele-
ment be hit with a hard object or
knocked against a hard surface to
loosen dirt deposits.

● 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 EA6O5016
under any circumstances. In cases of
doubt, discard the cartridge and install a
new one.

6. Engine Installation
6.1. Installing
● The center alignment of engine and Generator set is the most important factor for the extension of
performance and life. Although aligning the center perfectly and accurately requires only few minutes,
it is able to prevent unnecessary mechanical trouble at the future.
6.1.1. Bed rail

● At the installation of Generator set's bed
Supporting bracket
rail, use steel. Engine bracket
Rubber cushion
● If the bed rail is strong enough, the center
alignment of engine with Generator gets
Engine
worse so that the excessive vibration may
occur.
Bed rail
Generator
EFM8001I
6.1.2. Supporting
● As in the engine installation, the supporting brackets are used even at the installation of Generator.
● The bracket must be solidly fixed at the Generator installing platform and the bed rail.
6.1.3. Aligning center

● The center alignment of engine and Generator is the most important factor for the extension of life
cycle.
● Output shaft flange and opponent side flange of Generator should be aligned in their centers hori-
zontal and parallel direction.
● The adjustment between flange surfaces at the lower part should maintain less than 0.15 mm when
the upper part's surfaces just meet and the deviation around the circumference should be main-
tained within 0.1 mm as following figure.
Surface (TIR) Less than 0.15 mm

Center (TIR) Less than 0.1 mm
Less than 0.1mm

Less than 0.15mm
EA3O3001I
● For bed rail is apt to deform for 6 months after initial performance, adjusting the center should be
checked after 1 ~ 2 months.
- 143 - Engine installation

6.2. Inspection Prior to Installation
6.2.1. Inspection prior to installation

● Measure the correctness of flywheel and flywheel housing. Prior to inspection, clean the flywheel
and flywheel housing.
1) Measuring flywheel housing

● Measure the flywheel housing surface
and install the dial gauge (1/1,000) at Dial gauge
the flywheel so as to be vertical to the
flywheel housing, and let the gauge Flywheel
stem to contact to the flange.
● Rotate the flywheel, and measure the
surface error of flywheel housing
flange. The surface error should not Flywheel housing
exceed 0.2 mm. EFM6017I
2) Measuring bore of flywheel housing

● Attach the gauge as above so that the
gauge stem may contact the flywheel Dial gauge
housing bore as the right figure.
● Measure the eccentrics of flywheel Flywheel
housing bore by rotating the flywheel.
● The eccentrics should not exceed
0.2 mm.
Flywheel housing
EFM6018I
3) Measuring deformation of flywheel installing surface

● Fix the dial gauge to the flywheel
housing so as for the gauge stem to Dial gauge
be vertical to the surface to be
Flywheel
installed.
● The deviation quantity should not
exceed 0.127 mm/inch.
Flywheel housing
EFM6019I
Engine installation - 144 -

4) Measuring pilot bore of flywheel
● Install the gauge as below so as for
the gauge stem to contact to the pilot Dial gauge
bore of the surface to be installed.
● The eccentrics of the pilot bore of fly- Flywheel
wheel should not exceed 0.127 mm at

maximum.
Flywheel housing
EFM6020I
- 145 - Engine installation

Engine installation - 146 -
Appendix
● Standard table of tightening torque
Specification Screw Strength Tightening torque

Cylinder block bearing cap
- main bolt M18 x 2 12.9 Initial 30 kg.m + rotating angle 90°
- side bolt M12 x 1.5 10.9 11.2
Flywheel housing
- tightening bolt M12 x 1.5 10.9 11.2
- cover bolt M10 12.9 7.5
M8 8.8 2.2
Counter weight M16 x 1.5 10.9 Initial 14 kg.m + rotating angle 90°
Crank pulley M16 x 1.5 10.9 21
Vibration damper M10 10.9 6
Flywheel M16 x 1.5 12.9 26
Cooling fan M8 8.8 2.2
Connecting rod cap M16 x 1.5 10.9 Initial 10 kg.m + rotating angle 90°
Cylinder head M15 x 2 12.9 8 kg.m + 15 kg.m + angle 90° + angle 90°
Cylinder intermediate cover M8 8.8 2.2
Cylinder head cover M14 x 1.25 - 2.5 ~ 3.0
Camshaft timer M10 10.9 9
Rocker arm bracket M10 10.9 6.2
Lock nut (adjusting screw) M12 x 1 8.8 5.0 ±0.5
Oil pump cover M8 8.8 2.2
Oil pump M8 8.8 2.2
Oil cooler M12 10.9 5
Oil pan M8 8.8 2.2
Oil pan drain plug M26 x 1.5 - 8
Exhaust manifold M10 10.9 6.2
Intake manifold M8 8.8 2.2
Starting motor M12 x 1.5 8 8
Alternator bracket M14 8.8 12
Oil pressure switch PT1/8 - 0.4
Water temperature switch M14 8.8 1.2
● Tightening torque for plug screw
Diameter x pitch M10 x 1.0 M12 x 1.5 M14 x 1.5 M16 x 1.5 M18 x 1.5 M22 x 1.5 M26 x 1.5 M30 x 1.5
Torque (kg.m) 5.0 5.0 8.0 8.0 10.0 12.0 12.0 15.0
- 147 - Appendix
● 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 engine
● 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/mm3)
(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
M8 x 1 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
M10 x 1 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
M12 x 1.5 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
M14 x 1.5 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
M16 x 1.5 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
M18 x 1.5 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
M20 x 1.5 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
M22 x 1.5 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
M24 x 1.5 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.
Appendix - 148 -
● Engine assembly tolerance
(Unit: mm)
Items Specifications Remark

Cylinder Inside dia. of liner forced in joint part (upper part) ø145.800 ~ ø145.840 ø145.8 H7
block Inside dia. of liner forced in joint part (lower part) ø144.500 ~ ø144.540 ø144.5 H7
Inside dia. of liner color forced in part ø153.900 ~ ø154.150 ø153.9 H11
Liner colored surface depth 9.965 ~ 9.995
Cylinder Outside dia. of liner forced in joint part (upper) ø145.761 ~ ø145.786 ø145.8 g6
liner Outside dia. of liner forced in joint part (lower) ø144.432 ~ ø144.457 ø144.5 f6
Outside dia. of liner color part ø153.65 ~ ø0153.75 ø153.8
Liner collar height 10.03 ~ 10.05
Liner forced in joint part (upper) 0.014 ~ 0.099
Liner forced in joint part (lower) 0.043 ~ 0.108
Liner collar part clearance 0.150 ~ 0.500
Inside dia. of liner ø127.990 ~ ø128.010 ø128 ±0.01
Liner's roundness & columness (upper) 0.01 From top up to 168 mm
From bottom up to
Liner's roundness & columness (lower) 0.015
85 mm
Liner's projection 0.04 ~ 0.08 Measure at 4 place
Piston Outside diameter of piston ø127.739 ~ ø127.757 Measure 71.5 mm part
from bottom
(long length)
Inside diameter of piston pin ø 46.003 ~ ø46.009
Max. allowable weight per engine 50g
1st ring groove width 3.5
2nd ring groove width 3.040 ~ 3.060
Oil ring home width 4.020 ~ 4.040
Piston Top ring height (thickness) 3.075 ~ 3.095
ring 2nd ring height (thickness) 2.978 ~ 2.990
Oil ring height (thickness) 3.97 ~ 3.99
Top ring axial direction clearance 0.095 ~ 0.145
2nd ring axial direction clearance 0.050 ~ 0.082
Oil ring axial direction clearance 0.030 ~ 0.070
Top ring end part clearance 0.30 ~ 0.45
2nd ring end part clearance 0.40 ~ 0.60
Oil ring end part clearance 0.40 ~ 0.70
Piston Piston pin's outside diameter ø45.994 ~ ø46.000
pin
Clearance between piston pin & pin hole 0.003 ~ 0.015
Connecting Con rod small end part width 38.700 ~ 39.000
rod
Con rod large end part width 35.341 ~ 35.380 35.5 C8
Con rod cap 32.800 ~ 33.100 32.8 +0.3
Con rod axial direction clearance 0.240 ~ 0.392
Con rod small end part axial direction clearance 0.064 ~ 0.126
Con rod bush oil clearance 0.055 ~ 0.071
Con rod small end inside diameter (w/h bush) ø46.055 ~ ø46.065
- 149 - Appendix
(Unit: mm)

Connecting Con rod small end inside diameter (w/o bush) ø50.600 ~ ø50.630 ø50.6 H7
rod Con rod bush's diameter ø50.670 ~ ø50.700
Tighteness 0.04 ~ 0.10
Con rod large end part's inside diameter ø95.000 ~ ø95.022 ø95 H6
Con rod bearing spread (MIBA) 95.5 ~ 97.0
Con rod max. weight tolerance per engine 50g
Perpendicularity of large end inside diameter 0.035 Reference to con
-rod side face
Large end part's inside roundness & cylindricity 0.04/0.015
Large end part's inside straightness 0.01
Parallelness of small end inside with large end 0.02
Crank Bearing housing diameter ø111.000 ~ ø111.022 ø111H7
shaft Maximum shaking ø0.05
Main bearing journal diameter
Standard ø103.98 ~ ø104.00
Undersize 0.10 ø103.88 ~ ø103.90
Undersize 0.25 ø103.73 ~ ø103.75
Undersize 0.50 ø103.48 ~ ø103.50
Undersize 0.75 ø103.23 ~ ø103.25
Undersize 1.00 ø102.98 ~ ø103.00
Thrust bearing journal width
Standard 38.000 ~ 38.062 38H9
Con rod bearing journal diameter
Standard ø89.98 ~ ø90.00
Undersize 0.25 ø89.73 ~ ø89.75
Undersize 0.50 ø89.48 ~ ø89.50
Main bearing journal's roundness 0.005
Main bearing journal's cylindricity 0.010
Medium main bearing journal's shake 0.06 No 1, No 5 support
Wear ring press in part's journal diameter ø99.985 ~ ø100.020 ø100 j7
Wear ring's inside diameter ø99.9907 ~ ø99.942 ø100 S7
Overlap 0.043 ~ 0.113
Thrust bearing width
Standard 37.74 ~ 37.81
Oversize 38.24 ~ 38.31
Oversize 38.74 ~ 38.81
Crankshaft's axial direction's clearance 0.14 ~ 0.361
Main bearing thickness 3.585 ~ 3.597
Standard 3.454 ~ 3.467
Oversize 0.10 3.504 ~ 3.517
Oversize 0.25 3.579 ~ 3.592
Oversize 0.50 3.704 ~ 3.717
Oversize 0.75 3.829 ~ 3.842
Oversize 1.00 3.954 ~ 3.967
Main bearing oil gap 0.066 ~ 0.134
Main bearing spread 0.3 ~ 1.2
Thrust bearing's spread 0.3 ~ 1.2
Appendix - 150 -
(Unit: mm)

Flywheel Ring gear assembly part's outside diameter ø432.490 ~ ø432.645
Ring gear inside diameter ø432.000 ~ ø432.200
Overlap 0.290 ~ 0.645
Heat fitting temp. (°C) 200 ~ 230
Allowable shaking amount after assembly 0.5
Outside diameter after reassembly used ring ø114.980 ~ ø115.015
Cylinder Head gasket thickness (after tightening bolts) 1.205 ~ 1.295
head
Cylinder head height 113.9 ~ 114.0
& valve
Cylinder head seal surface roughness Max. 16μ
Valve projecting amount -0.65 ~ -0.95
Exhaust valve
Stem diameter ø11.954 ~ ø11.965
Radius direction clearance 0.045 ~ 0.083
Seat angle 45°
Head diameter ø50.9 ~ ø51.1
"A" thickness of valve head 4.33 ~ 4.83
Valve seat part diameter of head ø53.00 ~ ø53.03
Outside diameter of valve seat ø53.10 ~ ø53.11
Intake valve
Stem diameter ø11.935 ~ ø11.955
Radius direction clearance 0.035 ~ 0.064
Seat angle 30°
Head diameter ø57.85 ~ ø58.15
"A" thickness of valve head 4.6 ~ 5.0
Valve seat part diameter of head ø61.00 ~ ø61.03 ø61 H7
Outside dia. of valve seat ø61.10 ~ ø61.11
Depth of head's valve seat assembly part 12.5 ~ 12.6
Valve guide inside diameter ø12.000 ~ ø12.018 ø12 H7
Valve guide's inside diameter of head ø18.000 ~ ø18.018 ø18 H7
Valve guide's outside diameter ø18.028 ~ ø18.046 ø18.25 S7
Valve guide assembly locking piece 0.010 ~ 0.046
Valve seat's shaking 0.04 Reference to valve
guide
Valve spring Valve lift 14.1
Spring projecting amount of valve guide 17.1 ~ 17.5 Above valve spring
Free length of inside spring 72.43
Spring load of inside spring 15 ~ 17 kg at 46.3 mm
Spring load of inside spring 27 ~ 32 kg at 32.3 mm
Free length of outside spring 61.9
Spring load of outside spring 44.5 ~ 49.5 kg at 46.8 mm
Spring load of outside spring 86 ~ 95 kg at 32.8 mm
- 151 - Appendix
(Unit: mm)

Timing Rocker arm bush's inside diameter ø25.005 ~ ø25.035 When assembled
Rocker arm bearing journal's diameter ø24.967 ~ ø24.990
Bearing's clearance 0.015 ~ 0.068
Push rod's shaking 0.3
Valve tappet ass'y part's inside dia. of block ø20.000 ~ ø20.021
Push rod's outside diameter ø19.944 ~ ø19.965 ø20 H7
Tappet clearance 0.035 ~ 0.077
Bush assembly's inside diameter of block ø70.077 ~ ø70.061
Camshaft diameter ø69.910 ~ ø69.940 ø70 e7
Camshaft bearing oil gap (thrust) 0.060 ~ 0.120
Camshaft bearing oil gap (middle) 0.130 ~ 0.180
Camshaft axial direction play 0.24 ~ 0.86
Backlash (crank gear - camshaft gear) 0.118 ~ 0.242
Backlash (driving gear - injection pump gear) 0.102 ~ 0.338
Intake valve clearance 0.30 ±0.05
Exhaust valve clearance 0.40 ±0.05
Engine Oil pressure at idling 0.9 ~ 3.0 bar
lubricating Oil pressure at rated speed operation 3.0 ~ 6.5 bar
system
Oil temperature Less than 110°C
Instantaneous allowable temperature Max. 100°C
Bypass valve opening pressure 1.8 ~ 2.4 bar
Pressure regulating valve of oil pump 8.5 ~ 10 bar
Spray nozzle
Operating pressure 1.6 ~ 1.9 bar
Crossing pressure 1.3 ~ 1.6 bar
Tip diameter ø2
Backlash (crankshaft gear-oil pump drive gear) 0.10 ~ 0.45
Oil pump housing's depth/gear width 43.000 ~ 43.039 43 H8
42.910 ~ 42.950 43 e8
Oil pump housing axial play 0.050 ~ 0.128
Engine Cooling water pump shaft diameter ø21.930 ~ ø21.950
cooling Bearing gap 0.050 ~ 0.091
system
Impeller clearance (impeller - body) 1.0 ~ 1.5
Thermostat operating temperature (°C) 71°C
Inspection Good Above 16 bar
on Need up keep Bellow 13 bar
compressed
Allowable max pressure difference between 4 bar
pressure
cylinders
Fuel ignition Ignition plug clearance 0.3 ~ 0.4
system Project ignition plug from cylinder head low 3.38 ~ 3.76
surface
Appendix - 152 -
● GV158TIC Engine assembly
1018 236.5
996.5
736
AIR C OOLER COOLING WATER IN & OUTLE

T 283
Ø75
66.7 256.1
GAS INLET PT 2-11
ENGINE COOLING WATER OUTLET 196.1
39.6
Ø75
25.4
ENGINE COOLINGWATER INLET
16.7 Ø75
30¡Æ
12x
¡Æ
8x45
392.5
405
.2
D 530
PC
225
Ø352.425
Ø466.725
Ø511.2
Ø306
Ø487
Ø504
111
PCD
438.
15
363.5
392.5
12-M10 Depth20 8-M12x1.5 Depth2 2
318
AIR COOLER COOLING WATER IN & OUTLE T 736 236.5
Ø75
392.5 392.5
363.5 363.5 4-Ø12
AIR INLET
154.5 154.5 Ø77.8
AIR INLET
Ø77.8
150
150
- + - + - +
862
(777.5)
738
711.5
702
641
631
630
584
(1238.5)
455.5
52
150
376.5
100
80
40
375 375 Ø17 52

405 603.6 706.5
(1222.5) 984
1076.5
1388
M16x2
2-Ø17
12
80
40
150
200
EE3OM072
- 153 - Appendix
1176 236.5
1154.5
75
894
66.7 Air cooler cooling
water in & outle t 354.1
39.6
283
25.4 75 PT 2-11
Gas inlet 260
16.7 Enginecooling
9 water outlet
Æ 75
30¡
12x Enginecooling
water inlet
30.2
¡Æ D5
8x45 PC
466.725
511.2
352.425
504
487
306
392.5
405
PCD
225
438.1
5
111
8-M12x1.5
12-M10
Tap depth 22
363.5
392.5
Tap depth20
Power train
318
75 894 236.5
Air cooler cooling
water in & outlet
392.5 392.5
363.5 363.5
77.8 4- 12
154.5 154.5
77.8 Air inlet
Air inlet
150
150
- + - + - + - +
862
(777.5)
711.5
738
702
641
631
630
584
455.5
(1334)
52
150
472
100
40
80
375 375
17 52
405 603.6 864.5
(1222.5) 1142
1234.5
1546
M16x2
2- 17
80
150
12
40
200
EE3OM073
Appendix - 154 -
1334 236.5
1312.5
936
401.5
GAS INLET PT 1-1/4 355.5
66.7 AIR COOLER COOLING WATER IN & OUTLE
T
Ø75 283
39.6 ENGINE COOLING WATER OUTLET
Ø75
25.4
ENGINE COOLING WATER INLET
16.7 Ø75
9
30
12x
8x45
392.5
405
363.5
30.2
D5
225
PC
Ø352.425
Ø466.725
Ø511.2
Ø306
Ø487
Ø504
PCD
438.
15
363.5
392.5
8-M12x1.5 Depth22
12-M10 Depth20
318
AIR COOLER COOLING WATER IN & OUTLE
T 1053.5 236.5
Ø75
392.5 392.5
AIR INLET 4-Ø12
363.5 363.5 Ø77.8
154.5 154.5
AIR INLET
Ø
Ø77.8
150
150
- + - + - + - + - +
-
GND.
I , III , V
+ -
GND.
I , III , V
+ -
GND.
I , III , V
+ -
GND.
I , III , V
+ -
GND.
I , III , V
+
IGNITIONCOIL 501 06
1 IGNITIONCOIL 501 06
1
867.5
(777.5)
744.5
711.5
702
641
631
630
584
455.5
(1369)
52
150
501.5
100
80
40
375 375 Ø17 52

405 603.6 1022.5
(1222.5) 1352.5
1418.8
1730.3
M16x2
2-Ø17
12
80
40
150
200
EE3OM074
- 155 - Appendix
Appendix - 156 -

Motor Doosan - Gv158-180-222ti (C)

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What safety precautions should be taken when handling compressed natural gas?

What safety precautions should be taken when handling compressed natural gas?

What are the main components of the natural gas engine?

What are the main components of the natural gas engine?

950106-058010EN

GV158TIC, GV180TIC, GV222TIC

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

● Take old oil to an old oil disposal point only.

1. Safety Regulations & Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3. Disassembly and Reassembly of Major Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

4. Electrical Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

5. Maintenance of Major Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

6.2. Inspection Prior to Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

1.1. General Notes

1.2. Handle Compressed Natural Gas Safety

-1- Safety Regulations & Engine Specifications

● Wear welding goggles and gloves when

1.2.2. Venting an operable engine to relieve natural gas pressure

● To avoid personal injury an operable nat-

Safety Regulations & Engine Specifications -2-

1.2.4. During maintenance and care

-3- Safety Regulations & Engine Specifications

1.2.6. To prevent damage to engine and premature wear

Safety Regulations & Engine Specifications -4-

(1) Engine oil, filter elements, fuel filters

1.2.8. Notes on safety in handling used engine oil

-5- Safety Regulations & Engine Specifications

Ensure that used engine oil is disposed of properly.

1.2.9. General repair instructions

Safety Regulations & Engine Specifications -6-

-7- Safety Regulations & Engine Specifications

Safety Regulations & Engine Specifications -8-

Production tolerance: ±5%

50 Hz 253 kW 230 kW 207 kW

50 Hz 319 kW 290 kW 261 kW

50 Hz 385 kW 350 kW 315 kW

-9- Safety Regulations & Engine Specifications

1.4.1. Engine sectional view (longitudinal)

1. Crank shaft pulley 11. Turbo charger

Safety Regulations & Engine Specifications - 10 -

1. Oil level gauge 8. Intake manifold

- 11 - Safety Regulations & Engine Specifications

1. Alternator 11. Gas fuel mixer

Safety Regulations & Engine Specifications - 12 -

1. Alternator 11. Gas fuel mixer

- 13 - Safety Regulations & Engine Specifications

1. Alternator 10. Inter cooler

Safety Regulations & Engine Specifications - 14 -

2.1. Engine Model and Serial Number

● These numbers are required when

● Engine serial No. (example1: GV158TIC)

● Engine serial No. (example1: GV180TIC)

● Engine serial No. (example1: GV222TIC)

AUTO MAN DIAG

SETUP TIMING NEXT