65.99897-8099
Operation and
Maintenance Manual
Generator Natural Gas Engine
GE08TIC
PS-MMG0416-E1A
GE08TIC
Operation and Maintenance Manual
FOREWORD
This manual is designed to serve as a reference for DOOSAN Infracore (here after
DOOSAN’s) customers and distributors who wish to gain basic product knowledge on
DOOSAN's GE08TIC compressed natural gas engines.
These economical and high-performance natural gas engines (6 cylinders, 4 strokes, in-line
type) have been so designed and manufactured to be used for the automotive & industrial
application. They meet all the requirements such as low noise, fuel economy, high engine
speed and durability.
To maintain the engine in optimum condition and retain maximum performance for a long
time, CORRECT OPERATION and PROPER MAINTENANCE are essential.
In this manual, the following symbols are used to indicate the type of service operations to be
performed.
Removal
Adjustment
Installation
Cleaning
Disassembly
Pay close attention-Important
Reassembly
Tighten to specified torque
Align the marks
Use special tools of manufacturer's
Directional Indication
Inspection
Lubricate with oil
Lubricate with grease
Measurement
During engine maintenance, please observe following instructions to prevent environmental
damage;
z Take old oil to an old oil disposal point only.
z Ensure without fail that oil will not get into the sea or rivers and canals or the
ground.
z Treat undiluted anti-corrosion agents, antifreeze agents, filter element and
cartridges as special waste.
z The regulations of the relevant local authorities are to be observed for the
disposal of spent coolants and special waste.
If you have any question or recommendation in connection with this manual, please do not
hesitate to contact our head office, dealers or authorized service shops near by your location
for any services.
For the last, the content of this maintenance instruction may be changed without notice for
some quality improvement. Thank you.
May 2005
Printed in May 2005 PS-MMG0416-E1A
GE08TIC
Operation and Maintenance Manual
CONTENTS
1. Safety Regulations & Engine Specifications
1.1. General notes
1.2. Handle compressed natural gas safety
1.3. General Information
1.4. Engine assembly
1
1
8
10
2. Technical Information
2.1. Engine model and serial number
2.2. Engine characteristic
2.3. Diagnosis and remedy
2.4. Engine inspection
13
13
32
39
3. Disassembly and Reassembly of Major Components
3.1. Disassembly
3.2. Inspection
3.3. Reassembly
3.4. Starting and trial operation
3.5. Speed controller setting
3.6. Electrical system
41
54
73
97
99
105
4. Commissioning and Operation
4.1. Operation preparation
4.2. Breaking-in
4.3. Inspections after starting
4.4. Operation in winter time
4.5. Tuning the engine
4.6. Maintenance and care
4.7. Cooling system
4.8. Adjustment of valve clearance
4.9. Tightening the cylinder head bolts
4.10. Cylinder compression pressure
4.11. Belts
118
118
120
121
121
122
123
125
127
127
128
5. Maintenance of Major Components
5.1. Cooling system
5.2. Lubricating system
5.3. Turbocharger
5.4. Air intake system
130
132
136
144
6. Special Tool List
147
● Appendix
148
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GE08TIC
Operation and Maintenance Manual
1. Safety Regulations & Engine Specifications
1.1. General notes
Day-to-day use of power engines and the service products necessary for running
them presents no problems if the persons occupied with their operation,
maintenance and care are given suitable training and think as they work.
This summary is a compilation of the most important regulations. These are broken
down into main sections which contain the information necessary for preventing
injury to persons, damage to property and pollution. In addition to these regulations
those dictated by the type of engine and its site are to be observed also.
IMPORTANT:
If despite all precautions, an accident occurs, in particular through contact
with caustic acids, fuel penetrating the skin, scalding from oil, antifreeze being
splashed in the eyes etc, consult a doctor immediately.
1.2. Handle compressed natural gas safety
Natural gas is highly flammable and explosive and may be extremely cold. The
following cautions must be taken to avoid personal injury or engine damage.
z Do not smoke when installing or
servicing the engine or fuel system.
z Installation or servicing of natural
gas
equipment
must
only
be
conducted in well ventilated, natural
gas compatible areas. Do not install
or service equipment in an enclosed
area where ignition sources are
present without ensuring that an
undetected gas leak may be safely
vented without being ignited.
z Do not vent natural gas or permit
leaks inside an enclosed area.
Bleed natural gas lines before
installing
or
servicing
any
component connected to the fuel
lines.
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General Information
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GE08TIC
Operation and Maintenance Manual
1.2.1. Avoid heating near pressurized fluid lines
z Wear welding goggles and gloves
when welding or using an acetylene
torch.
z Insure a that metal shield separated
the acetylene and oxygen which
must be chained to a cart.
z Do not weld or heat areas near fuel
tanks or fuel lines.
1.2.2. Venting an operable engine to relieve natural gas pressure
z To avoid personal injury an operable
natural gas engine must be kept in a
well ventilated area away from open
flames and sparks.
z If the engine can run, use the
following venting procedure to relive
the natural gas pressure downstream
of the shutoff valve.
1) Shut off manual valves on natural gas supply lines and main shutoff valve on
natural gas fuel supply line.
2) Start engine and run until it stalls due to fuel starvation.
3) Check to make sure gauge pressure at point on the natural gas fuel line to be
vented has been reduced to zero. If not, repeat step 1) Then repeat step 2).
4) Disconnect engine batteries using switch in battery compartment or by
disconnecting battery ground cable.
5) Slightly loosen the CNG fuel line fitting to be serviced in a well ventilated area
to allow any remaining gas to vent.
6) Completely open the fitting that was slightly opened and allow to vent in a well
ventilated area.
1.2.3. During commissioning, starting and operation
z This is the safety alert symbol. When you see this symbol in this manual, be alert
to the potential for personal injury.
z Carefully read all safety message in this manual and on your engine safety signs.
Be sure new equipment components and repair parts include the current safety
signs.
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Printed in May 2005 PS-MMG0416-E1A
GE08TIC
Operation and Maintenance Manual
z Avoid possible injury or death from vehicle runaway. Do not start engine by
shorting across starter terminals. Vehicle will start in gear if normal circuitry is
bypassed. Start engine only from operator’s seat with transmission in neutral or
park.
z Prevent fires by keeping machine clean of accumulated trash, grease, fuel and
debris.
z When the engine is running, do not get too close to the rotating parts.
z Do not touch the engine with bare hands when it is warm from operation risk of
bums.
z Exhaust gases are toxic. If it is necessary to run an engine in an enclosed area,
remove the exhaust gases from the area with an exhaust pipe extension. If you
do not have an exhaust pipe extension, open the doors and get outside air into
the area.
z Keep vicinity of engine free of oil and grease. Accidents caused by slipping can
have serious consequences.
1.2.4. During maintenance and care
z Always carry out maintenance work when the engine is switched off. If the
engine has to be maintained while it is running, e.g. changing the elements of
change-over filters, remember that there is a risk of scalding. Do not get too
close to rotating parts.
z Change the oil when the engine is warm from operation.
CAUTION:
There is a rise of burns and scalding. Do not touch oil drain plug or oil filters
with bare hands.
z Take into account the amount of oil in the sump. Use a vessel of sufficient size to
ensure that the oil will not overflow.
z Open the coolant circuit only when the engine has cooled down. If opening while
the engine is still warm is unavoidable, comply with the instructions in the
chapter "Maintenance and Care".
z Neither tighten up nor open pipes and hoses (lube oil circuit, coolant circuit and
any additional hydraulic oil circuit) during the operation. The fluids which flow out
can cause injury.
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GE08TIC
Operation and Maintenance Manual
z Fuel is inflammable. Do not smoke or use naked lights in its vicinity.
z When using compressed air, e.g. for cleaning the radiator, wear goggles.
z Keep service products (anti-freeze) only in containers which can not be confused
with drinks containers.
z Comply with the manufacturer's instructions when handling batteries.
CAUTION:
Accumulator acid is toxic and caustic. Battery gases are explosive.
1.2.5. When carrying out checking, setting and repair work
z Checking, setting and repair work must be carried out by authorized personnel
only.
z Use only tools which are in satisfactory condition. Worn open-end wrench slip,
which could lead to injury.
z When the engine is hanging on a crane, no-one must be allowed to stand or
pass under it. Keep lifting gear in good condition.
z When working on parts which contain asbestos, comply with the notes at the end
of this chapter.
z When working on the electrical system disconnect the battery earth cable first.
Connect it up again last in prevent short circuits.
1.2.6. To prevent damage to engine and premature wear
(1) Never demand more of the engine than it was designed to yield for its intended
purpose.
(2) If faults occur, find the cause immediately and have it eliminated in order to
prevent more serious of damage.
(3) Use only genuine DOOSAN’s spare parts. DOOSAN’s will accept no
responsibility for damage resulting from the installation of other parts which are
supposedly "just as good".
(4) In addition to the above, note the following points.
z Never let the engine run when dry, i.e. without lube oil or coolant.
z Use only DOOSAN’s approved service products (engine oil, anti-freeze and
anticorrosion agent).
z Pay attention to cleanliness. The Natural gas must be free of water. See
"Maintenance and care"
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General Information
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GE08TIC
Operation and Maintenance Manual
z Have the engine maintained at the specified intervals.
z Do not switch off the engine immediately when it is warm, but let it run without
load for about 5 minutes so that temperature equalization can take place.
z Never put cold coolant into an overheated engine. See "Maintenance and
care".
z Do not add so much engine oil that the oil level rises above the max. marking
on the dipstick. Do not exceed the maximum permissible tilt of the engine.
Serious damage to the engine may result if these instructions are not adhered
to.
z Always ensure that the testing and monitoring equipment (for battery charge,
oil pressure, coolant temperature) function satisfactorily.
z Comply with instructions for operation of the alternator. See "Commissioning
and operation".
z Do not let the raw water pump run dry, If there is a risk of frost, drain the pump
when the engine is switched off.
1.2.7. To prevent pollution
(1) Engine oil, filter elements, fuel filters
z Take old oil only to an oil collection point.
z Take strict precautions to ensure that oil does not get into the drains or into the
ground. The drinking water supply could be contaminated.
z Filter elements are classed as dangerous waste and must be treated as such.
(2) Coolant
z Treat undiluted anti-corrosion agent and / or antifreeze as dangerous waste.
z When disposing of spent coolant comply with the regulations of the relevant
local authorities.
1.2.8. Notes on safety in handling used engine oil
Prolonged or repeated contact between the skin and any kind of engine oil
decreases the skin.
Drying, irritation or inflammation of the skin may therefore occur. Used engine oil
also contains dangerous substances which have caused skin cancer in animal
experiments. If the basic rules of hygiene and health and safety at work are
observed, health risks are not to the expected as a result of handling used engine oil
Health precautions:
z Avoid prolonged or repeated skin contact with used engine oil.
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General Information
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GE08TIC
Operation and Maintenance Manual
z Protect your skin by means of suitable agents (creams etc.) or wear protective
gloves.
z Clean skin which has been in contact with engine oil.
- Wash thoroughly with soap and water, A nailbrush is an effective aid.
- Certain products make it easier to clean your hands.
- Do not use petrol, Diesel fuel, gas oil, thinners or solvents as washing agents.
z After washing apply a fatty skin cream to the skin.
z Change oil-soaked clothing and shoes.
z Do not put oily rags into your pockets.
Ensure that used engine oil is disposed of properly.
- Engine oil can endanger the water supply For this reason do not let engine oil get into the ground, waterways, the drains or
the sewers. Violations are punishable.
Collect and dispose of used engine oil carefully. For information on collection points
please contact the seller, the supplier or the local authorities.
6
General Information
Printed in May 2005 PS-MMG0416-E1A
GE08TIC
Operation and Maintenance Manual
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 shortcircuiting.
2. Use covers for preventing the components from damage or pollution.
3. Engine oil and anti-freeze solution must be handled with reasonable care as they
cause paint damage.
4. The use of proper tools and special tools where specified is important to efficient
and reliable service operation.
5. Use genuine DOOSAN’s parts necessarily.
6. Used cotter pins, gaskets, O-rings, oil seals, lock washer and self-lock nuts
should be discarded and new ones should be prepared for installation as normal
function of the parts can not be maintained if these parts are reused.
7. To facilitate proper and smooth reassemble operation, keep disassembled parts
neatly in groups. Keeping fixing bolts and nut separate is very important as they
vary in hardness and design depending on position of installation.
8. Clean the parts before inspection or reassembly. Also clean oil ports, etc. using
compressed air to make certain they are free from restrictions.
9. Lubricate rotating and sliding faces of parts with oil or grease before installation.
10. When necessary, use a sealer on gaskets to prevent leakage.
11. Carefully observe all specifications for bolts and nuts torques.
12. When service operation is completed, make a final check to be sure service has
been done property.
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General Information
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GE08TIC
Operation and Maintenance Manual
1.3. General Information
1.3.1. Engine Specifications
Engine model
Items
Water-cooled,
4 cycle in-line type
Turbo charged & intercooled(water to air)
Engine type
Ignition system
Spark ignition
Combustion chamber type
Stoichiometric, Premixed and spark ignited
Used fuel
NG(Natural gas)
Cylinder liner type
Replaceable dry liner
Timing gear system
Gear driven type
No. of piston ring
2 compression ring, 1 oil ring
No. of cylinder-bore x stroke
(mm)
Total piston displacement
(cc)
Compression ratio
Engine dimension (length x width x height)
(mm)
Engine weight
(kg)
Rotating direction (from flywheel)
1–5–3–6–2–4
Fuel ignition timing (B.T.D.C static)
13°
Engine control system
Engine speed controller type
(kg/cm2)
Compression pressure
Intake and exhaust valve clearance (at cold)
Exhaust valve
(mm)
16 (at 200 rpm)
0.3
Open at
16° (B.T.D.C)
Close at
36° (A.B.D.C)
Open at
46° (B.B.D.C)
Close at
14° (A.T.D.C)
Lubrication method
Full forced pressure feed type
Oil pump type
Gear type driven by crankshaft
Engine oil pressure
Low idle
(bar)
0.8 ~ 1.4
High idle
(bar)
3.0 ~ 4.8
Oil filter type
Lubricating oil capacity (max./min.)
Full-flow, cartridge type
(lit)
Oil cooler type
Impeller type driven by belt
Cooling Method
Cooling water capacity (engine only)
Alternator voltage – capacity
Starting Motor voltage – output
23/17
Water cooled
Water pump
8
6 - 111 × 139
8,071
10.5 : 1
1,224 x 760 x 973
750
Counter clockwise
Firing order
Intake valve
GE08TI
Forced circulation by centrifugal impeller pump
(lit)
11
(V - A)
24 – 120
(V - kW)
24 – 4.5
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GE08TIC
Operation and Maintenance Manual
Items
GE08TI
Engine model
Carburetor
Impco 200 varifuel carburetor
Gas regulator
Fuel system
RV61
Max. inlet pressure
1.0 psi at the engine inlet
Shut-off valve
Solenoid valve (24VDC)
Spark plug
Woo jin 0.38 ~ 0.40mm air gap
Ignition controller
Ignition system
Altronic CD-1 or CD-200 unit
Ignition coil
Trigger system
Turbocharger
One coil per cylinder
Magnetic pick-up sensor and trigger wheel
Model
HX35G
Type
Water cooled, Exhaust gas driven
Exhaust temperature
Max : 720℃
1.3.2. Engine Power
Production tolerance : ±5%
Performance
Engine model
Stand by
Prime
Continuous
50Hz
(1,500 rpm)
141 kW
(192 PS)
128 kW
(174 PS)
115 kW
(156 PS)
60Hz
(1,800 rpm)
165 kW
(224 PS)
150 kW
(204 PS)
135 kW
(184 PS)
GE08TIC
Note : All data are based on operation without cooling fan at ISO 3046.
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General Information
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GE08TIC
Operation and Maintenance Manual
1.4. Engine Assembly
1.4.1. Engine sectional view (longitudinal)
3
4
6
5
7
8
9
10
2
11
1
12
16
13
14
15
17
18
1
2
3
4
5
6
7
8
9
10
11
10
19
20
21
Cooling water pump
Piston
Exhaust valve
Intake valve
Ignition coil
Intake valve spring
Breather
Exhaust valve spring
Cylinder head cover
Cylinder head
Cylinder block
22
12
13
14
15
16
17
18
19
20
21
22
Push rod
Tappet
Cam shaft
Oil seal(rear)
Oil seal(front)
Crank gear
Vibration damper
Oil pump
Oil suction pipe
Oil pan
Crank shaft
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GE08TIC
Operation and Maintenance Manual
1.4.2. Engine sectional view (cross)
6
7
5
8
9
4
3
10
2
1
11
1
2
3
4
Oil spray nozzle
Connecting rod
Oil drain pump
Gas regulator
5
Throttle valve
6
7
8
9
10
Spark plug
Rocker arm
Rocker arm bracket
Exhaust manifold
Oil cooler
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GE08TIC
Operation and Maintenance Manual
1.4.3. Engine assembly views
2
3
13
1
14
12
4
11
5
6
7
17
8
9
18
10
19
20
23
24 25
16
22
26
15
21
12
1
Lifting hook
14
Water inlet(for Intercooler)
2
3
4
5
6
7
8
9
10
11
12
13
Ignition coil
Exhaust manifold
Oil drain pump
Vibration damper
Oil filter
Oil cooler
Oil pan
Oil level gauge
Starter
Mounting bracket
Water inlet(by Water pump)
Fuel mixer
15
16
17
18
19
20
21
22
23
24
25
26
Flywheel housing
Water outlet(for Intercooler)
Inter cooler
Throttle valve ass`y
Gas regulator
Intake manifold
Speed controller
Cooling water pump
Breather
Water outlet(by Water pump)
Exhaust elbow
Alternator
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GE08TIC
Operation and Maintenance Manual
2. Technical Information
2.1. Engine model and serial number
z The engine model and serial
number is located on the engine as
illustrated.
z These numbers are required when
requesting warranty and ordering
parts. They are also referred to as
engine model and serial number
because of their location.
Engine serial
number
z Engine serial No. (GE08TIC)
EEPOD 5 00001
Serial no.
Production year (2005)
Engine model
2.2. Engine Characteristic
The DOOSAN’s GE08TIC natural gas engine is an overhead valve, turbo charged,
air-to-water charge cooled, electronically controlled engine.
2.2.1. Natural gas
z Spark-ignited by the spark plug.
z Turbocharger with a water cooled bearing-housing.
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GE08TIC
Operation and Maintenance Manual
2.2.2. Natural gas
z Natural gas is a clean burning fuel, and offers a low particulate emission. Natural
gas is also a very economical fuel.
z From the gas producing areas in the country, the distribution companies and local
utilities from a complex nation-wide-delivery-network that supplies natural gas for
home and industry use. The network is highly developed and extended to all
major population center in the country.
2.2.3. Engine ignition system
z This system changes the general combustion concept of the diesel engine.
Specifically, it changes a compression-ignition diesel to a spark-ignited engine.
However, this engine is unlike the typical generator engine that has spark plugs.
z The primary difference is this system uses a combustion concept. That is, excess
air is mixed in with the combustion system. When combined with a gaseous fuel
like natural gas, it allows greatly reduced emissions compared to diesel, plus high
efficiencies and excellent high-performance.
z The GE08TIC engine is an integrated package featuring computer-controlled
electronic engine system by the engine speed controller. This system controls
fuel, ignition and speed, and has engine protection features.
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GE08TIC
Operation and Maintenance Manual
2.2.4. Engine speed controller : ESC
z The Engine Speed Control is
designed
to
provide
basic
isochronous speed control for gas
engines using the Flo-Tech Throttle.
z Engines with mechanical loads and
generator loads are handled
equally well.
Speed controller
2.2.5. Ignition control module : ICM
z This digital ignition system has
been designed for application on
nature gas fueled engines.
z This system is offers a variety of
advanced
control,
emissions
reduction, primary and spark
diagnostics, self diagnostic serial
communications
and
engine
protection features.
2.2.6. Cylinder block
z The cylinder block is a single piece of alloy cast iron. To increase its stiffness, it is
extended to a level below the crankshaft center line. The engine has replaceable
dry cylinder liners and individual cylinder heads with struck-in valve seat rings
and replaceable valve guides,
2.2.7. Piston, con-rod and crankshaft
z The forged crankshaft is an ingrate type (Counterweight is integrated with crank
shaft body). Radial oil seal on crankshaft and flywheel are provided to seal the
flywheel housing inside penetrations.
z The con-rods (connecting rods) are die-forged, diagonally split and can be
removed through the top of the cylinders together with the pistons. Crankshaft
and connecting rods run in steel-backed lead bronze ready to fit type bearings.
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GE08TIC
Operation and Maintenance Manual
2.2.8. Engine timing
z Camshaft, oil pump and ignition timing sensor gear are driven by a gear train
arranged at the front end.
2.2.9. Valves
z The overhead valves are actuated via chilled cast iron tappets, push rods and
rocker arms from the camshaft.
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GE08TIC
Operation and Maintenance Manual
2.2.10. Lubrication system
z The engine is equipped with force-feed lubrication.
The pressure is produced by a gear pump whose drive gear is in direct mesh with
the crankshaft gear at the front end of cylinder block.
z The oil pump draws the oil from the oil sump and delivers it through the oil cooler
and oil filter to the main distributor gallery and from there to the main bearings,
big-end bearings and camshaft bearings as well as to the small-end bearings and
the rocker arms.
z The turbocharger is also connected to the engine lubricating system.
The cylinder walls and timing gears are splash-lubricated.
z Each cylinder has an oil jet provided for cooling the underside of the pistons.
z The lube oil is cleaned in a full-flow oil filter.
2.2.11. Engine oil
z Check oil level with the oil level gauge and replenish if necessary.
z Check the oil level with the engine cooled. If the engine is warm, allow time for 5 ∼
10 minutes for oil drain into the crankcase before checking oil level. The oil level
must be between Max. and Min. lines on the gauge.
z Engine oil should be changed at the specified intervals.
Oil in the oil filter cartridge should be changed simultaneously.
z The oil viscosity grades should be selected SAE NO.15W40 and API CD or CE.
First oil change
Engine model
17
GE08TIC
After 50hr operation
every 200hr
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GE08TIC
Operation and Maintenance Manual
z The following oils are also recommended
SAE No.
API No.
Sulfated ash content
15W40
above CD or CE
Bellow 0.5 %
Recommend oil : TOTAL LMG-405
Mobil Delvac super GEO 15W40
z Engine oil capacity
Engine oil capacity
Engine model
GE08TIC
in Oil pan
Max.
Min.
(lit)
(lit)
23
Total
(lit)
17
25
Engine oil viscosity – ambient temperature
Ambient
temperature
18
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GE08TIC
Operation and Maintenance Manual
2.2.12. Exchanging of lubrication oil
z Engine oil and the oil filter are
important factors affecting engine
life. They affect ease of starting,
fuel
economy,
combustion
chamber deposits and engine wear.
z While the oil is still hot, discharge
the sump oil by motion oil drain
Engine oil
drain pump
pump lever manually as figure.
z Refill new engine oil to the filler
neck
on
the
head
cover
in
accordance with the oil capacity of
Oil filler cap
Cylinder head
cover
the engine. Be careful about the
mixing of dust or contaminator
during the supplement of oil. Then
confirm whether the oil level gauge
indicates
the
vicinity
of
its
maximum level.
z For a few minutes, operate the engine at idling in order to circulate oil through
lubrication system. Thereafter shut down the engine. After waiting for about 10
minutes measure the quantity of oil and refill the additional oil if necessary.
2.2.13. Oil cooler & oil filter
z An oil cooler is provided between
the oil filter and the cylinder block.
z This cooler is a flat tube type with
turbulence inserts and operated by
the coolant.
z Check for oil pressure and oil leaks,
and repair or replace the oil filter if
necessary.
z Change the oil filter cartridge
simultaneously
at
every
replacement of engine oil.
19
Oil filter
Oil cooler
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GE08TIC
Operation and Maintenance Manual
2.2.14. Cooling system
z The engine has a liquid-cooling system. The fresh water pump is a maintenancefree by belt from the crankshaft pulley.
z Depending on the agreed extent of delivery and the design of the engine, the
coolant circuit can be equipped with temperature monitors which, in the event of
loss of coolant, shut the engine down.
2.2.15. Cooling water
z Regarding the cooling water that is to be used for engine, the soft water not the
hard water must be used.
z The engine cooling water can be used diluting it with antifreezing solution 40%
and the additive for rust prevention (DCA4) 3 ~ 5 %.
z The density of above solution and additive must be inspected every 500 hours to
maintain it properly.
NOTE:
The proper density control of antifreezing solution and rust preventing
additive will be able to prevent the rusting effectively and maintain the stable
quality of engine.
For the improper control might give the fatal damage to the cooling water
pump and cylinder liners, detail care is needed.
z Since GE08TIC cylinder liner is dry type, particularly the cooling water control
should be applied thoroughly.
20
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GE08TIC
Operation and Maintenance Manual
z The density of antifreezing solution and additive for rust prevention is able to be
confirmed by the cooling water test kit.
(Fleetguard CC2602M or DOOSAN’s 65.99901-0038)
z How to use the cooling water test kit
(1) When the cooling water temp. of engine is in the range of 10 ~ 55 °C,
loosen the plug for cooling water discharge and fill the plastic cup about a half.
NOTE:
In taking the cooling water sample, if the water in auxiliary tank were taken, it
is hard to measure the accurate density. Take the cooling water sample
necessarily loosening the cooling water discharge plug.
(2) At the state of a test paper soaked in the sampled water, after taking the paper
out through water agitation, shake off the water.
(3) Wait for about 45 sec. till the color change of test paper.
NOTE:
However, it should not elapse longer than 75 sec, and if it did, the hue would
change.
(4) Make the numerical value by comparing the test paper which hue has
changed with the color list of label on storage bottle.
(5) By comparing the hue changed into yellowish green or so with the green color
indication of test paper storage bottle, confirm the density. (Then, the density
indication must be in the hue range of 33% to 50%).
(6) The brown at the middle of test paper and the lower pink color indication
represent the additive state for rust prevention, and the proper range is that
the meeting numerical value of brown (vertical) and pink color (horizontal)
locates in the range of 0.3 to 0.8 at the color list of label on the test paper
storage bottle.
(7) In case of less than 0.3, replenish the additive for rust prevention (DCA4), and
in case of more than 0.8, pour out the cooling water about 50% and then
readjust the density after refilling with clean fresh water.
z Amount of Anti-freeze in winter
Ambient
Cooling water (%)
Temperature (°C)
85
Over -10
80
-10
73
-15
67
-20
60
-25
56
-30
50
-40
21
Anti-freeze (%)
15
20
27
33
40
44
50
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Printed in May 2005 PS-MMG0416-E1A
GE08TIC
Operation and Maintenance Manual
2.2.16. V - belt
z Use a fan belt of specified
dimensions,
and
replace
if
damaged, frayed, or deteriorated.
z Check the fan belt for belt tension.
z If belt tension is lower than the
specified limit, adjust the tension
by relocating the alternator.
(specified deflection: 10 ∼ 15 mm
when pressed down with thumb)
2.2.17. Air cleaner
z In case that elements are
deformed, damaged or if the air
cleaner has a crack, replace it.
z By the definite interval, the
elements must be cleaned and
replaced.
2.2.18. Intercooler
z The intercooler is air to water type.
Throttle valve
The
intercooler
life
and
performance depends on the intake
air condition greatly. Fouled air
pollutes and clogs the air fins of
Intake manifold
intercooler. As a result of this, the
Inter cooler
engine output is decreased and
engine malfunction is occurred.
z So you always check whether the
intake air systems like air filter
element are worn or polluted.
22
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GE08TIC
Operation and Maintenance Manual
2.2.19. Valve clearance adjust procedure
z After letting the #1 cylinder's piston come at the compression top dead center
by turning the crankshaft, adjust the valve clearances.
z Loosen the lock nuts of rocker arm adjusting screws and push the feeler gauge
of specified value between a rocker arm and a valve stem and adjust the
clearance with adjusting screw respectively and then tighten with the lock nut.
z As for the valve clearance, adjust it when in cold, as follow.
Model
Intake Valve
Exhaust Valve
GE08TIC
0.3 mm
0.3 mm
z Adjusting Sequence of Valve Clearance (1 Type)
- By cranking the engine, let #6 cylinder's valves overlap.
- In time, adjust the valve clearance corresponding to “
” of lower lists.
- Adjust the valve clearance corresponding to “
” of lower lists.
- After reinsuring the valve clearances, retighten if necessary.
z No. 1 Cylinder is located at the side where flywheel was installed.
Crankshaft pulley
Intake valve
Exhaust valve
Cylinder no.
Fly wheel
z Adjusting Sequence of Valve Clearance (2 Type)
1 Type is the conventional and simple method, but if you have some problem to
adjust your engine, please try 2 type sequence. This is a precision method, but it
takes more times.
23
Valve overlapping on cylinder
(Intake & Exhaust valve)
1
5
3
6
2
4
Adjusting valves on cylinder
(Intake & Exhaust valve)
6
2
4
1
5
3
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GE08TIC
Operation and Maintenance Manual
2.2.20. Spark plug
z Remove spark plug. Clean threads
by hand with brush and solvent.
z Clean any deposits from electrode
and Inspect insulator area
z Measure the spark plug distance at
electrode position.(A)
z Replace spark plug if necessary.
Standard
Distance (A)
z
0.39~0.40mm
Install spark plug
Torque
2.6~3.0 kg.m
New plug
Electrode surfaces
not parallel
24
Eroded
electrode
Flashover on
insulator
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GE08TIC
Operation and Maintenance Manual
2.2.21. Cylinder compression pressure
z Stop the engine after warming up,
and take out spark plug.
z Install the special tool (compression
gauge adapter) at the spark plug
hole and connect the compression
pressure gauge there.
Standard value
16kg/cm2 over
Limit value
13kg/cm2
Difference
between each cylinder
Within ± 10 %
♦ Condition : Water temperature 20°C,
Engine rotation 200rpm
2.2.22. Battery
z Inspect for any leakage of electrolytic solution owing to battery crack, and replace
the battery in case of poor condition.
z Inspect for amount of electrolytic solution, and replenish if insufficient.
z Measure the gravity of electrolytic solution, if less than specified value (1.12 ~
1.28), replenish.
25
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GE08TIC
Operation and Maintenance Manual
2.2.23. Turbocharger
z The exhaust gases of the engine are
passed through the turbine rotor of
the turbocharger. Air compressor
impeller mounted on the same shaft
draws in fresh air and delivers it at a
higher pressure to the cylinders.
z The turbocharger is naturally aircooled. Lubrication of the main
bearing is by oil under pressure
from the engine lubricating system.
26
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GE08TIC
Operation and Maintenance Manual
2.2.24. Alternator
z Alternator (24Vx45A)
The alternator is fitted with integral silicon rectifiers. A transistorized regulator
mounted on the alternator body interior limits the alternator voltage. The alternator
should not be operated except with the regulator and battery connected in circuit to
avoid damage to the rectifier and regulator.
24V × 45A
The alternator is maintenance-free, nevertheless, it must be protected against dust
and, above all, against moisture and water.
Wiring Diagram
Operate the alternator according to the instructions given in the chapter.
27
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GE08TIC
Operation and Maintenance Manual
2.2.25. Starting motor
The sliding-gear starter motor is flanged to the rear of the flywheel housing on the lefthand side. As parts of every engine overhaul, the starter pinion and ring gear should
be cleaned with a brush dipped in fuel and then a coat of grease should be applied
again.
24Vx4.5kW
Always protect starter motor against moisture.
Wiring harness
Key switch
Magnetic switch
Battery
Starting motor
WARNING:
Always disconnect the battery earth cable before starting work on the
electrical system. Connect up the earth cable last, as there is otherwise a risk
of short-circuits.
28
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GE08TIC
Operation and Maintenance Manual
2.3. Diagnosis and Remedy
z The following description summarizes the probable cause of and remedy for
general failure by item.
z Immediate countermeasures should be taken before a failure is inflamed if any
symptom is detected.
29
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GE08TIC
Operation and Maintenance Manual
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Operation and Maintenance Manual
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GE08TIC
Operation and Maintenance Manual
32
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GE08TIC
Operation and Maintenance Manual
33
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GE08TIC
Operation and Maintenance Manual
34
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GE08TIC
Operation and Maintenance Manual
35
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Printed in May 2005 PS-MMG0416-E1A
GE08TIC
Operation and Maintenance Manual
Condition
1) Starting difficult
(1) Compression pressure
Causes
z
Replace valve spring
Replace gasket
Adjust
z
Valve's poor shut, stem
distortion
Valve spring damage
Cylinder head gasket's leak
Wear of piston, piston ring
or liner
Ignition timing incorrect
z
Valve clearance incorrect
Adjust
z
z
z
2) Idle operation abnormal
3) Engine output insufficient
(1) Continuous output
insufficient
z
z
z
z
z
z
(2) Output insufficient
when in acceleration
Remedies
z
z
z
z
z
Valve tightness poor
Cylinder head gasket's leak
Wear, stick, damage of
piston ring
Ignition timing incorrect
Damage of spark plug &
ignition coil
Air
suction
amount
insufficient
Turbocharger poor
Compression pressure
insufficient
Ignition timing incorrect
Damage of spark plug &
ignition coil
Air intake amount
insufficient
Repair or replace
Adjust
Repair
Replace gasket
Replace piston ring
Adjust
Adjust or replace
Clean or replace air
cleaner
Repair or replace
Disassemble engine
Adjust
Repair or replace
Clean or
replace air cleaner
4) Overheating
z
z
z
z
z
z
z
36
Engine oil insufficient or
poor
Cooling water insufficient
Fan belt loosened, worn,
damaged
Cooling
water
pump's
function lowered
Water temperature
regulator's operation poor
Valve clearance incorrect
Exhaust system's resistance
increased
Replenish or replace
Replenish or replace
Adjust or replace
Repair or replace
Replace
Adjust
Clean or replace
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Operation and Maintenance Manual
Condition
5) Engine noisy
(1) Crankshaft
(2) Connecting rod and
Connecting rod bearing
Causes
For noises arise compositely
such as rotating parts, lapping
parts etc., there is necessity to
search the cause of noises
accurately.
z As the wear of bearing or
crankshaft progress, the oil
clearances increase.
z Lopsided wear of crankshaft
z Oil supply insufficient due to
oil passage clogging
z Stuck bearing
z
z
z
z
z
(3) Piston, piston pin &
piston ring
(4) Others
z
z
z
z
z
z
z
z
z
z
z
z
37
Remedies
Replace bearing &
grind crankshaft
Grind or replace
Clean oil passage
Replace bearing &
Grind
Lopsided wear of con rod Replace bearing
bearing
Lopsided wear of crank pin
Grind crankshaft
Connecting rod distortion
Repair or replace
Stuck bearing
Replace &
grind crankshaft
Oil supply insufficiency as Clean oil passage
clogging at oil passage
progresses
Piston clearance increase Replace piston &
as the wear of piston and piston ring
piston ring progresses
Wear of piston or piston pin Replace
Piston stuck
Replace piston
Piston insertion poor
Replace piston
Piston ring damaged
Replace piston
Wear of crankshaft, thrust Replace thrust bearing
bearing
Camshaft
end
play Replace thrust plate
increased
Idle gear end play increased Replace thrust washer
Timing
gear
backlash Repair or replace
excessive
Valve clearance excessive
Adjust valve clearance
Abnormal wear of tappet, Replace tappet, cam
cam
Turbocharger inner part Repair or replace
damaged
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Operation and Maintenance Manual
Condition
6) Oil Consumption
Excessive
(1) Oil level elevated
Causes
z
z
z
z
z
z
(2) Oil level lowered
z
z
(3) Oil leak
z
z
z
z
z
38
Remedies
Clearance between cylinder
liner & piston
Wear of piston ring, ring
groove
Piston ring's damage, stick,
wear
Piston
ring
opening's
disposition improper
Piston skirt part damaged or
abnormal wear
Oil ring's oil return hole
clogged
Oil ring's contact poor
Looseness of valve stem &
guide
Wear of valve stem seal
Cylinder head gasket’s leak
Looseness of connection
parts
Various parts' packing poor
Oil seal poor
Replace
Replace piston,
piston ring
Replace piston ring
Correct position
Replace piston
Replace piston ring
Replace piston ring
Replace in set
Replace seal
Replace gasket
Replace gasket, repair
Replace packing
Replace oil seal
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GE08TIC
Operation and Maintenance Manual
2.4. Engine inspection
2.4.1. Stopping engine
z Cut off the main circuit breaker of the generator control panel. After checking the
engine for any unusual condition at the idling speed, then press the stop button to
stop the engine.
2.4.2. General engine inspection cycle
z In order to insure maximum, trouble-free engine performance at all times, regular
inspection, adjustment and maintenance are vital.
- Daily inspections in below figure should be checked every day.
- The following maintenance details should be executed thoroughly at regular
internals.
О : Check & adjust
Inspection Item
Cooling
System
Check for leakage(hoses, clamp)
Check the water level
Adjust the V-belt tension
Change the coolant water
Check for leakage
Check the oil level gauge
Daily
Fuel
System
Clean the exhaust system
Check the leakage fuel line
Check the fuel mixer
Check the throttle body
Check the speed controller
Check the gas pressure regulator
● 1 year
●
1st
●
1st
●
Every 200hr
●
Every 200hr
О
●
О
О
Clean
●
О
О
О
О
О
О
●
Check the spark plug
Check the ignition cable
Check the ignition coil
Check the sensors(ignition or timing)
Check the state of exhaust gas
Check the battery charging
О
О
When
necessary
39
О
Check the compression pressure
Adjust Intake/Exhaust
valve clearance
●
● 1 year
О 1 year
Check the exhaust gas pressure
Engine
Adjust
1 year
1 year
1 year
1 year
When
necessary
Check the state of ignition timing
Ignition
system
Remark
О
О
Replace the oil filter cartridge
Intake &
Exhaust Check the air cleaner indicator
System Clean the air cleaner element and/or repair
Every Every
Every Every Every
50hrs 200hrs 500hrs 1500hrs 3000hrs
О
О
О
Lubrication
Change the lubricating oil
System
Check the leakage for intercooler
(hoses, clamp)
● : Replace
О
When
necessary
When
necessary
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Operation and Maintenance Manual
2.4.3. Use of original parts for repair and replacement
z For engine is being mechanically harmonized with many parts, only when the
original parts that the manufacture recommends to use is used, the engine trouble
would be preventively maintained and capable to keep up the maximum
performances.
z For the analogous parts not the original parts are poor in qualities and gives ill
performances, it may rather bring early engine failure
40
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Printed in May 2005 PS-MMG0416-E1A
GE08TIC
Operation and Maintenance Manual
3. MAINTENANCE
3.1. Engine Disassembly
3.1.1. Heed at disassembly
z Before disassembly, the part shelf should be prepared for various tools and repair
parts.
z When assembling, clean empty hand should be used and clean environment
maintained.
z In case of storing the disassembled parts, each part should not touch each other.
z In case of disassembly, the parts should be laid in order.
3.1.2. Oil level gauge
z Pull out the oil level gauge.
3.1.3. Cooling water
z Remove the drain plug from the
cylinder block and drain out the
cooling water into a container.
Drain valve
3.1.4. Engine oil
z Turn the valve opening and then
move the oil drain pump lever as
figure by hand, and let engine oil
discharge into the prepared vessel
Engine oil
drain pump
41
Engine disassembly
Printed in May 2005 PS-MMG0416-E1A
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Operation and Maintenance Manual
3.1.5. Engine speed controller: ESC
z Disconnect the harness and the
various sensors.
Engine speed
controller(ESC)
3.1.6. Ignition control module (ICM)
z Disconnect the harness and the
various sensors.
z Loosen the fixing bolt, then
disassemble the ignition control
module(ICM).
Ignition control
module
3.1.7. Ignition coil & gas pressure regulator
z Remove the high voltage cables by
hand from each cylinder head.
Gas pressure
regulator
z Remove the gas pressure regulator
fixing bolts and then tear down the
gas pressure regulator and other
High voltage cable
Ignition coil
parts.
3.1.8. Fuel mixer
z Remove the air cleaner from fuel
mixer.
z Remove the fuel mixer and air pipe
from the turbo charger.
Harness
Fuel mixer
Turbo charger
Gas pressure
regulator
42
Engine disassembly
Printed in May 2005 PS-MMG0416-E1A
GE08TIC
Operation and Maintenance Manual
3.1.9. Turbo charger
z Remove the oil supply pipe and oil
return pipe between the turbo
charger and the cylinder block.
z Unclamp
the
rubber
hose
connected the intercooler and air
pipe.
z Unscrew the turbo charger fixing
nuts and take off the turbo charger
from the exhaust manifold
Oil pipe
Turbo charger
Water
hose(inlet)
Water
hose(outlet)
Exhaust elbow
3.1.10. Intercooler
z Tear down the various hoses and
air pipes from the inter cooler.
z Remove the intercooler fixing bolts
and tear it down.
Throttle valve
Inter
cooler
Intake manifold
3.1.11. Belt
z Loosen the tension adjusting bolts
of the alternator and take off the
belts.
43
Engine disassembly
Printed in May 2005 PS-MMG0416-E1A
GE08TIC
Operation and Maintenance Manual
3.1.12. Starter
z Unscrew the starter fixing nuts and
remove the starter being careful not
to damage its gears.
3.1.13. Breather
z Unscrew the hose clamp fixing
bolts and remove the breather hose.
3.1.14. Alternator
z Remove the alternator fixing bolts
and take off the alternator.
3.1.15. Oil cooler & oil filter
z Loosen the cooling water pump
and the rubber hose clamps of
connected pipes, and disassemble
it.
z Remove the oil cooler fixing bolts
and take off the oil cooler and oil
filter cartridge.
44
Oil filter
cartridge
Oil cooler
Engine disassembly
Printed in May 2005 PS-MMG0416-E1A
GE08TIC
Operation and Maintenance Manual
Oil cooler housing
Oil cooler element
Water drain valve
3.1.16. Water pump
z Unclamp the rubber hose connected
to the oil cooler.
z Unscrew the water pump fixing bolts
from the cylinder block and take off
the water pump.
3.1.17. Cylinder head cover
z Remove the head cover fixing bolts
and lift the cylinder head cover.
3.1.18. Exhaust manifold
z Unscrew the exhaust manifold
fixing bolts.
z Then disassemble the exhaust
manifold and gasket.
z Scrap the used gasket.
CAUTION:
Be careful to remove the exhaust
manifold. It is very heavy.
45
Engine disassembly
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GE08TIC
Operation and Maintenance Manual
3.1.19. Intake manifold
z Unscrew the intake manifold fixing
bolts and remove the intake
manifold from the cylinder head.
z Disassemble the intake manifold
gasket and discard it.
3.1.20. Cooling water pipe
z Unscrew the cooling water pipe
fixing bolts and remove the cooling
water pipe from the cylinder head.
z Remove the cooling water pipe
gasket and finish the surface with a
scraper.
CAUTION:
Be sure that piece of the gasket do
not come into the cooling water
passage.
3.1.21. Spark plug
z Loosen the high pressure cable
then remove the ignition coil.
z Remove the spark plug using
socket tool.
Spark plug
Hex. Head : 16mm
Socket tool
(5/8 inch)
High pressure cable
Spark plug
3.1.22. Rocker arm
z Remove the rocker arm bracket
fixing bolts in reverse order (zigzag
method)
of
assembling
and
disassemble the rocker arm.
z Take out the push rod upwards.
46
Engine disassembly
Printed in May 2005 PS-MMG0416-E1A
GE08TIC
Operation and Maintenance Manual
z Disassembly of rocker arm
assembly
- Remove the snap ring from the
both ends of rocker arm shaft by
means of a plier.
- Remove the washer, rocker arm,
bracket and spring from the rocker
arm shaft in sequence.
- Press out the rocker arm bush.
Rocker arm shaft
CAUTION :
When reassembling the bush, cool
the bush in dry ice and press the
bush while aligning the bush with
the oil hole of the rocker arm.
Rocker arm
3.1.23. Cylinder head
z Remove the cylinder head bolts in
the reverse order of tightening but
remove it step by step.
- First step : Loosen 1 ~2 threads
- Second step : Remove by loosening
fully.
z However, remove the total bolts
simultaneously by the step of 1 and 2.
z Lay the removed bolts orderly not
to damage the threads at all and
store.
CAUTION:
Prevent a collision between the bolt thread each other.
z Take out the cylinder head gasket and scrap it.
z Remove the foreign residues from the cylinder head surface and block surface.
CAUTION:
Try not to make any damage on the contact surfaces.
47
Engine disassembly
Printed in May 2005 PS-MMG0416-E1A
GE08TIC
Operation and Maintenance Manual
z Disassembly of cylinder head
- Place the cylinder head on a
individual shelf.
- As pressing the valve spring with a
special tool, remove the cotter
pin, valve spring.
- Take out the intake and exhaust
valves.
- For removal of the valve seat,
apply arc welding work to two
points of valve seat insert, and pull
out the valve seat insert with inner
extractor.
3.1.24. Oil pan
z Unscrew the oil pan fixing bolts and
remove the oil pan.
z Remove the oil pan gasket and
discard it.
3.1.25. Vibration damper
z Unscrew the vibration damper
fixing bolts in reverse sequence of
installing sequence and remove the
vibration damper assembly.
48
Engine disassembly
Printed in May 2005 PS-MMG0416-E1A
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Operation and Maintenance Manual
3.1.26. Timing gear case cover
z Disassemble the oil seal using an
oil seal removing jig.
z Remove the cover fixing bolts and
disassemble the cover from the
timing gear case.
3.1.27. Oil pump
z Unscrew the bracket fixing bolts of
the oil suction pipe.
z Unscrew the pipe fixing bolts of oil
pump and disassemble the suction
and supply oil pipe.
z Unscrew the oil pump fixing bolts,
and disassemble the oil pump.
3.1.28. Piston and connecting rod
z Remove the connecting rod cap
bolts in the reverse order of
assembling but do same as the
cylinder head bolt removal.
z Disassemble the upper/lower of
connecting rod caps by tapping
lightly with urethane hammer, and
remove the bearing.
z By pushing the connecting rod with
wooden bar from the direction of oil
pan
toward
cylinder
head,
disassemble the piston assembly.
z The disassembled piston assembly
should be handled to prevent
bumping each other, and stored as
the cylinder's order.
z In order for connecting rod cap not
to
be
swapped,
temporarily
assemble to the corresponding
connecting rod.
49
Engine disassembly
Printed in May 2005 PS-MMG0416-E1A
GE08TIC
Operation and Maintenance Manual
<Disassembly of piston>
(1) Remove the snap rings by
means of a plier.
(2) Heat the piston with an electric
heater, then take out the piston
pin from the piston as tapping it
with a round wooden bar.
(3) Remove the piston ring with a
plier.
(4) Clean the piston thoroughly.
3.1.29. Cylinder liner
z Disassemble the cylinder liner with
a special tool or hand but be careful
not to generate any damage at
cylinder block.
50
Engine disassembly
Printed in May 2005 PS-MMG0416-E1A
GE08TIC
Operation and Maintenance Manual
3.1.30. Cam shaft gear and idle gear
z Unscrew the camshaft gear fixing
bolts and remove the camshaft gear.
z Unscrew two bolts fixing the idle
gear, then remove the idle gear and
its pin.
3.1.31. Water chamber cover
z Unscrew the fixing bolts and remove
the water chamber cover.
z Remove
the
remnant
gasket
thoroughly.
3.1.32. Fly wheel
z Remove the flywheel fixing bolts and
disassemble it.
z The bolt removal is done by the
reverse order of assembling and by
the steps.
51
Engine disassembly
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GE08TIC
Operation and Maintenance Manual
3.1.33. Fly wheel housing
z Remove the flywheel housing fixing
bolts and disassemble the flywheel
housing.
z Disassemble the oil seal of
flywheel housing.
Stopper ring
Ignition timing
check hole
Oil seal
3.1.34. Trigger wheel & timing sensor
z Loosen the magnetic pick-up
sensor fixing nut and remove the
magnetic pick-up sensor.
z Remove the fixing bolts and
disassemble the trigger wheel
cover and trigger wheel.
Magnet pick-up
sensor
Trigger wheel
Timing drive
gear coupling
Trigger wheel cover
3.1.35. Timing drive gear
z Unscrew the drive gear housing
fixing bolts and remove the drive
gear assembly.
3.1.36. Timing gear case
z Remove the timing gear case
assembling bolts.
z By tapping lightly with a urethane
hammer the right and left back of
timing gear case's connecting part,
disassemble the timing gear case.
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Engine disassembly
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Operation and Maintenance Manual
3.1.37. Bearing cap
z Remove
the
bearing
cap
assembling bolts by the step in the
reverse order of assembling, and
disassemble the bearing cap.
(Remove by the same way as the
cylinder head bolts' removal.)
z Disassembled bearing caps are
kept laid in order.
3.1.38. Camshaft and tappet
z In order for camshaft not to be
damaged, disassemble turning it.
z In order for the disassembled
camshaft to be prevented from
bends or damage, put it on the
special lathe and store.
z Pull out the tappet.
z As required, pull out the camshaft
bush from the cylinder block by a
press.
z Check
for
damage,
scratch,
wearing state and if abnormal, tear
down.
3.1.39. Oil spray nozzle
z Remove the valve screws of oil
spray nozzle and disassemble it.
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Engine disassembly
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3.2. Inspection and Measurement on Major Parts
3.2.1. Cylinder block
z Clean the cylinder block thoroughly, and check for any crack or damage.
z If there is any crack or severe damage, replace it and if there is minor one, correct
it.
z Check for any clogging or corrosion in the oil passage and water passage.
z Carry out a leakage test for any crack or air leaking. (Hydraulic test)
z Plug each cylinder block's water and oil discharge ports, and apply the air
pressure of about 4kg/cm2 to intake port and soak it in water for about 1 minute to
check if there is any leakage. (Water temperature : 70°C)
3.2.2. Cylinder head
(1) Cylinder head assembly & disassembly
1) Disassemble
the
cylinder
assembly, and put it on the shelf
for assembly or clean lathe.
CAUTION :
Prevent any damage to gasket's
contact surface of the cylinder
head.
2) Disassemble the cotter pin, spring,
spring seat pushing valve spring
by a special tool.
3) Pull out the intake and exhaust
valves.
4) The disassembled parts are kept
laid in turn.
5) Disassemble the valve stem seal.
(2) Inspection of cylinder head
1) Check for the cylinder head.
z Remove carbon from the
cylinder head lower surface, and
then should be careful not to
scratch the surface.
z Check any crack or damage that
can not found by naked eyes
through
the
hydraulic
or
magnetic particle test.
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Operation and Maintenance Manual
2) Distortion of lower surface
z As shown in figure, measure the
cylinder head's distortion at 6
directions with horizontal ruler
and clearance gauge.
z If the measured value is beyond
the limit value, correct it by
means of the fine grinding paper
or grinding machine.
z If it is beyond the max.
allowable value, replace the
cylinder head
< Lower face warpage and height >
Warpage
Thickness : t
Standard
Limit
0.2 mm or less
0.3 mm
109.9 ∼ 110.1 mm
108.4 mm
(reference)
3) Flatness
z Check the flatness of the
installing surface of cylinder
head's intake and exhaust
manifolds with horizontal ruler
and clearance gauge.
Standard
Limit
0.05 mm
0.2 mm
4) The hydraulic test
z The hydraulic test of cylinder
head is same as the cylinder
block test.
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Operation and Maintenance Manual
3.2.3. Spark plug
z Remove spark plug. Clean threads by
hand with brush and solvent.
z Clean any deposits from electrode
and inspect insulator area
z Measure the spark plug distance at
electrode position.(A)
z Correct or replace the spark plug if
necessary.
Standard(A)
A
0.39~0.40mm
z Insert the spark plug into cylinder
head and measure distance(B)
Spark plug torque
2.5~3.0kg.m
Standard (B)
3.38 ~ 3.76mm
Cylinder head
Spark plug
“B”
3.2.4. Valve and valve guide
1) Valve
z After cleaning valve with fuel, check it.
z Valve stem outer diameter
Measure the valve stem outer
diameter at 3 positions (top, middle,
and bottom), and check for any
wear and if beyond the limit value,
replace the valve.
Dimension
Standard
Limit
Intake valve stem
φ8.950 ∼ φ8.970 mm
φ8.93 mm
Exhaust valve stem
φ8.935 ∼ φ8.955 mm
φ8.91 mm
Description
z Valve seat contacting faces
Check the valve seat contact
surface for any crack and wear, and
if necessary, correct with grinding
paper, and if excessive, replace it.
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z Valve head thickness
Measure the thickness of valve
head and if beyond the limit value,
replace the valve
Dimension
Standard
Limit
Description
Intake valve
2.7 mm
1 mm or less
Exhaust valve
2.2 mm
1 mm or less
2) Valve guide
z Insert a valve into cylinder head
and
measure
the
clearance
between valve guide and valve by
valve movement. If the clearance is
excessive, measure the valve and
replace the excessively worn valve
or valve guide.
z Valve stem end play
Standard
Limit
0.04 ∼ 0.07 mm
0.2 mm
Exhaust valve 0.06 ∼ 0.09 mm
0.25 mm
Intake valve
z Assemble the valve at cylinder
head's valve guide and see if it is
centered with the valve seat using a
special tool.
3) Valve seat
z Contacting face amount
As for the valve seat's wear,
measure the width of the contact
surface with intake valve seat and
exhaust valve seat. If beyond the
limit value, replace the valve seat.
z Assemble the valve at the valve
seat of the cylinder head, and
check the amount of depression of
the valve from the lower portion of
the cylinder head using a dial
gauge.
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z Valve depression
If the amount of depression is
beyond the specified limit, replace
the valve seat.
Intake &
Exhaust
Standard
Limit
0 ∼ 0.3 mm
0.55 mm
z For the disassembling of valve seat,
by welding the welding bead to a
valve seat rotating tool or valve
seat, pull it out with a special tool.
z For the assembling of a new valve
seat, by putting it among the dry
ices of an ice box previously for
about 2 hours for the cold
shrinkage, and press it in the
cylinder head by a special tool.
(bench press)
z It is necessary to work boring of inner diameter of it when replace the valve seat
and valve guide.
z Apply valve lapping compound to the valve head seating face on the valve seat
and lap the valve seat by turning it until it is seated in position, then wipe out the
lapping compound.
4) Valve spring
z Visual check
Check the appearance of valve
spring and if necessary replace the
spring.
z Valve spring free length
Use a vernier caliper to measure
the valve spring free length.
If the measured value is less than
the specified limit, the valve spring
must be replaced.
58
Spring free Length
Standard
Intake valve
64 mm
Exhaust
Inner
60mm
valve
Outer
71mm
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z Valve spring inclination
Use a surface plate and a square
to measure the valve spring
inclination.
If the measured value exceeds the
specified limit, the valve spring
must be replaced.
Valve spring
Inclination
Standard
Limit
Less than 1.5mm
2.7 mm
z Valve spring tension
Use a spring tester to measure the
valve spring tension if the
measured value is less than the
specified limit, the valve spring
must be replaced.
Set Length
Intake
Valve
Spring
Force
Limit
Valve spring
tension at 41mm 70 kg
± 3kg
set length
Exhaust Inner
valve
Outer
38 mm
28.6 kg
±6%
41 mm
66 kg
±5%
5) Assembling cylinder head
z Clean the cylinder head thoroughly.
z Replace the valve stem seal with
new one, and by means of a
special tool, press the stem seal
into the valve guide of cylinder
head.
z Coat engine oil to valve stem and
valve guide and assemble the
valve. However, be careful for the
damage of valve stem seal.
z Install the lower seat of valve spring to the valve guide of cylinder head.
z After putting inner, outer springs, install the spring upper seat on it.
z Assemble the valve by inserting the valve cotter pressing the valve spring with
special tool.
z After installing the valve, check whether the valve is correctly installed or not
tapping it lightly with urethane hammer.
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3.2.5. Rocker arm assembly
(1) Disassembly
z Disassemble the snap rings that
are located at both ends of rocker
arm shaft by a plier.
z Disassemble in the order of
washer, rocker arm bracket, rocker
arm spring, rocker arm.
(2) Inspection of rocker arm assembly
1) Rocker arm shaft
z Rocker arm shaft run-out
Place the rocker arm shaft on
two V blocks and inspect the
shaft for bend using a dial gauge.
If the amount of this run-out is
small, press the shaft with a
bench press to correct the runout.
Replace the shaft if the
measured value exceeds the
limit.
Limit
0.2 mm
z Rocker arm shaft diameter
With an outside micrometer,
measure the rocker arm shaft
diameter at the point where the
rocker arms have been installed.
Replace the rocker arm if the
amount of wear is beyond the
specified limit.
Standard
Limit
φ23.939 ∼ φ23.960 mm
φ23.75 mm
2) Rocker arm
z Visual check
Visually check the face of the rocker arm in contact with the valve stem end
for scores and step wear. If the wear is small, correct it with an oil stone or
grinding paper of fine grain size. Rocker arm with a considerable amount of
step wear should be replaced.
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Operation and Maintenance Manual
z Rocker arm bushing diameter
Measure the inside diameter of
the rocker arm bushing with an
inside micrometer or vernier
calipers, and compare the
measured values with the rocker
arm shaft diameter. If the
clearance exceeds the limit,
replace either bushing or shaft,
whichever worn more.
Standard
Limit
0.040 ∼ 0.113 mm
0.3 mm or less
3) Tappet and push rod
z Clearance
Measure the clearance of the tappet and tappet holes of the cylinder block. If
the value is beyond the specified limit, replace tappets.
Standard
Limit
0.035 ∼ 0.077 mm
0.15 mm
z Visual check of tappet
Visually check the face of the
tappets in contact with the cam
for pitting, scores or cracks,
and
replace
if
severely
damaged. If the amount of
cracks or pitting is small,
correct with an oil stone or
grinding paper.
z Outside diameter of tappet
With an outside micrometer,
measure the tappet outside
diameter If the measured value
is beyond the limit, replace
tappets.
Standard
61
φ19.944 ∼ φ19.965 mm
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z Push rod run-out
Use a feeler gauge to measure
the push rod run-out.
Roll the push rod along a
smooth flat surface as shown in
the figure
Limit
0.3 mm or less
.
4) Reassembling rocker arm assembly
Reassembling can be done in the reverse order of disassembling and following
things should be heeded
z Check the oil supply hole of rocker arm shaft for any clog and clean
thoroughly.
z Be careful not to occur any swap of position and reverse assembly.
3.2.6. Camshaft
(1) Camshaft end play
z Push the thrust plate toward the
cam gear.
z With a feeler gauge, measure
the clearance between the
thrust plate and camshaft
journal.
z If the end play is excessive,
replace the thrust plate.
Standard
Limit
0.28 ∼ 0.43 mm
0.6 mm
(2) Cam
z Cam lobe height
Use a micrometer to measure
the cam lobe height and journal
diameter.
If the measured number is less
than the specified limit, the
camshaft must replaced.
Cam lobe
Height (C)
Standard
Limit
Intake
49.15 mm
48.85 mm
Exhaust
49.35mm
49.00 mm
Cam journal
diameter (A,B)
62
φ57.86 ∼ φ57.88 mm
φ57.52 mm
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z Cam surface
Inspect the cam face for scratch or damage.
Slight step wear or damage on the cam face may be corrected with oil stone
or oiled grinding paper. But, replace if severely damaged.
(3) Cam shaft
z Clearance
Between camshaft journal and camshaft bush
- With an outside micrometer,
measure the camshaft journal
diameter.
- Measure the inside diameter
of the camshaft bushing on
the cylinder block using a
cylinder bore indicator, and
compare the measured value
with the camshaft outside
diameter to determine the
clearance.
<Clearance>
Standard
Limit
0.12 ∼ 0.17 mm
0.24 mm
- Replace the bushing if the measured value is beyond the specified limit.
z Run-out
- Support the camshaft on two
V blocks and check for run-out
using a dial indicator.
- Correct or replace the cam
shaft if the amount of run-out
is beyond the value indicating
need for servicing.
63
Standard
Limit
0.05 mm
0.2 mm
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3.2.7. Crankshaft
(1) Inspection of crankshaft
1) Defect check
z By naked eyes, check for any scratch or damage on the crankshaft journal
and crank pin.
z By means of magnetic particle test and color check, check the crankshaft for
any crack and if found, replace it.
2) Wear measuring
z With an outside micrometer
measure the diameter of the
crankshaft journals and pins in
the directions as shown, and
compare the measured values
to determine the amount of
wear.
z If the amount of wear is beyond
the limit, have the crankshaft
ground and install undersize
bearings. However, if the
amount of wear is within the
limit, you can correct the wear
using an oil stone or oiled
grinding paper of fine grain size.
(Be sure to use grinding paper
which has been immersed in oil.)
Standard
Limit
Journal diameter
φ83.966 ∼ φ83.988 mm
φ83.000 mm
Pin diameter
φ70.971 ∼ φ70.990 mm
φ70.000 mm
z In case that pin's wear is more
than the limit value, grind the
crankshaft journal and crank pin,
and
use
the
undersized
bearings.
CAUTION:
Be sure to use grinding paper
which has been immersed in oil.
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<Undersize bearings available>
‹ Standard
‹ 0.25 (Inside diameter is 0.25 mm lesser than the standard size.)
‹ 0.50 (Inside diameter is 0.50 mm lesser than the standard size.)
‹ 0.75 (Inside diameter is 0.75 mm lesser than the standard size.)
‹ 1.00 (Inside diameter is 1.00 mm lesser than the standard size.)
Undersize bearings are available in 4 different sizes as indicated above, and the
crankshaft can be reused through the regrinding as described above.
* “R” parts specified value
① Crank pin's "R"
: 4.5
② Crank Journal "R" : 4
0
− 0.2
0
− 0.2
CAUTION:
In case of regrinding, the grinding the "R" part of bearing end should be
correctly done and keep in mind to remove any jaws or coarse surface
absolutely.
3) Crankshaft run-out
z Support the crankshaft on V
blocks.
z Turn the crankshaft with a dial
indicator placed on the surface
plate and take the amount of
crankshaft run-out.
Standard
Limit
0.06 mm
0.1 mm
(2) Crankshaft bearing and connecting rod
1) Visual check
Visually check the crankshaft bearing and connecting rod bearing for scores,
uneven wear or damage.
2) Oil clearance between crankshaft and bearing (Method 1 : dial gauge)
z Main bearing clearance
Install the main bearing in the
cylinder block, tighten the
bearing cap to specified torque,
then measure the inside
diameter.
Torque
65
30 kg.m
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z
Compare the two values
obtained through measurement
of main bearing inside diameter
with the outside diameters of
crankshaft
journals
to
determine the oil clearance.
<Main bearing oil clearance>
Standard
Limit
0.052 ∼ 0.122 mm
25 mm
3) Connecting rod bearing clearance
z Install the connecting rod
bearing in the connecting rod
bearing cap, tighten the
connecting rod cap bolts to the
specified torque, then measure
the inside diameter.
Torque
18 kg.m
z Compare the two values
obtained through measurement
of connecting rod bearing
inside diameter with the
outside diameters of crankshaft
pins to determine the oil
clearance.
z
Standard
Limit
0.034 ∼ 0.098 mm
0.25 mm
If the clearance deviates from the specified range, have the crankshaft
journals and pins ground and install undersize bearings.
4) Oil clearance between crankshaft and bearing (Method 2 : plastic gauge)
z Assemble the crankshaft on the cylinder block and put plastic gauge on the
journal and pin of crankshaft and then after assembling bearing cap, tighten
the bolts at the specific torque. Again after disassembling the bearing cap by
removing the bolts, take out the flatted plastic gauge and measure the width
of plastic gauge by means of plastic gauge measuring scale. This is the oil
clearance.
z The oil clearance too can be measured in the same manner
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5) Bearing spread and crush
z Inspection
Check to see that the bearing
requires
a
considerable
amount of finger pressure at
reassembly operation.
z Crankshaft bearing crush
Install the bearing and cap in
the cylinder block, retighten the
bolts to specified torque,
unscrew
out
one
bolt
completely, then measure the
clearance between the bearing
cap and cylinder block using a
feeler gauge.
Standard
0.08 ∼ 0.110 mm
z Connecting rod bearing crush
Install the bearing and cap in
the connecting rod big end,
retighten the bolts to specified
torque, unscrew out one bolt
completely, then measure the
clearance between the bearing
cap and connecting rod big
end using a feeler gauge.
Standard
67
0.04 ∼ 0.07 mm
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6) Crank shaft end play
z Assemble the crankshaft to the
cylinder block.
z With a dial gauge, measure
crankshaft end play.
Standard
Limit
0.15 ∼ 0.325 mm
0.5 mm
3.2.8. Piston assembly
(1) Disassemby of piston assembly
Disassemble piston according to
the disassembly process.
(2) Piston inspection
1) Visual check
Visually check the pistons for
cracks, scuff or wear, paying
particular attention to the ring
groove.
2) Clearance between the piston and cylinder liner
z With an outside micrometer,
measure the piston outside
diameter at a point 13mm
away from the lower end of
piston skirt in a direction at a
right angle to the piston pin
hole.
13mm
Standard
φ110.758 ∼ φ110.772 mm
z Using a cylinder bore gauge,
measure cylinder liner inside
diameter at 3 points (cylinder
top ring contacting face, middle,
and oil ring contacting face on
BDC) in a direction at an angle
of 45°.
z Take the mean value with the
largest and smallest values
excepted.
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Operation and Maintenance Manual
Standard
Limit
φ111 ∼ φ111.022 mm φ111.122 mm
z The clearance is computed by
subtracting the piston outside
diameter from the cylinder liner
inside diameter.
z Replace either piston or cylinder
liner, whichever damaged more,
if the clearance is beyond the
specified limit.
< Clearance between piston and liner >
Standard
Limit
0.228 ∼ 0.264 mm
0.3mm
(3) Piston rings
1) Visual check
Replace the piston rings with new ones if detected worn or broken when the
engine is overhauled.
2) Piston ring gap
z Insert the piston ring into the
upper portion of the cylinder
liner bore so that it is held at a
right figure to the cylinder liner
wall.
z Measure the piston ring gap
with a feeler gauge.
Standard
Limit
Top ring
0.40 ∼ 0.60 mm
1.5 mm
2nd ring
0.40 ∼ 0.60 mm
1.5 mm
Oil ring
0.30 ∼ 0.50 mm
1.5 mm
z Replace piston rings with new
ones if the gap is beyond the limit
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3) Piston ring side clearance
z Fit the compression ring and oil
ring in the piston ring groove.
z With a feeler gauge, measure
side clearance of each ring, and
replace either the ring or piston
if the measured value is beyond
the specified limit.
Standard
Limit
Top ring
-
-
2nd ring
0.07 ∼ 0.102 mm
0.15 mm
Oil ring
0.05 ∼ 0.085 mm
0.15 mm
4) Piston ring tension
z With a tension tester, measure piston ring tension.
z Replace the piston ring if the measured value is beyond the limit.
Standard
Top ring
2.58 ∼ 3.88 kg
2nd ring
1.81 ∼ 2.71 kg
Oil ring
3.57 ∼ 5.03 kg
(4) Piston pin inspection
1) Wear
Measure the amount of wear on
the piston pin at the points as
shown. The measured values are
beyond the limit (0.08 mm or
greater), replace the pin.
Standard
Limit
φ41.994 ∼ φ 42.000 mm φ 41.94 mm
2) Clearance
Measure the clearance between
the piston pin and connecting rod
bushing, and replace either of
them, whichever damaged more,
if the measured value is beyond
the limit.
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Standard
Limit
0.003 ∼ 0.015 mm
0.08 mm
3) Condition check
Check the engaged condition of
the piston and piston pin. If it is
possible to force the pin into the
piston heated with piston heater,
the piston is normal. When
replacing the piston, be sure to
replace the piston pin together.
(5) Connecting rod inspection
1) Distorsion
Check the connecting rod for
distortion. As shown in the figure
below, install the connecting rod to
the connecting rod tester, and
check for distortion using a feeler
gauge. If the connecting rod is
found distorted, never re-use it but
replace with a new one.
2) Holes alignment (parallelism)
Measure the alignment of the
connecting rod piston pin bushing
holes with connecting rod big end
holes. At this time also, use both
connecting rod tester and feeler
gauge.
Standard
Limit
0.05 mm
0.1 mm or less
3) Wear
z Assemble the connecting rod to
the crankshaft and measure
connecting rod big end side
clearance using a feeler gauge.
z Assemble the connecting rod to
the
piston
and
measure
connecting rod small end side
clearance.
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z If the measured values are
beyond the limit, replace the
connecting rod.
Limit
72
0.5 mm
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3.3. Engine Reassembly
3.3.1. General precautions
z Clean all the disassembled parts, particularly oil and water ports, using
compressed air, then check that they are free from restrictions.
z Arrange the general and special tools in order for engine assembly operation.
z To wet each sliding part, prepare the clean engine oil.
z Prepare service materials such as sealant, gaskets, etc.
z Discard used gaskets, seal rings, and consumable parts, and replace with new
ones.
z Apply only the specified torque for bolts in the specified tightening order and avoid
over-tightening.
z Be sure to check that all the engine parts operate smoothly after being
reassembled.
z Check the bolts for looseness after reassembly.
z After completing the engine reassembly operation, check if there is missing parts
or shortage of parts.
z Keep your hands clean during the working.
3.3.2. Cylinder block
z Cover the floor of the workshop
with wood plate or thick paper to
prevent damage to the cylinder
head and place the cylinder block
with the head fitting surface facing
downward.
3.3.3. Oil spray nozzle
z Tighten and assemble the oil spray
nozzle flange with fixing bolts using
the spray nozzle jig.
Torque
0.9 kg.m
3.3.4. Tappet and cam shaft
z Undercool a new bush with dry ice
for about 2 hours and press it into
position in the cylinder block using
a bench press.
z After the pressing operation,
measure the inside diameter of the
cam bush to check if it is not
deformed.
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z Apply engine oil to the entire face of
the tappets and slide them into the
tappet holes on the cylinder block.
z Wet the cam bush inside diameter
and camshaft with oil, and carefully
assemble them while turning the
camshaft.
CAUTION:
Be careful not to generate a damage
to camshaft and bush.
z Check to see that the camshaft
rotates smoothly.
3.3.5. Crankshaft
z Install the main bearing (refer to
assemble sequence : right figure)
machined with two holes in the
cylinder block so that the key is
aligned with the key groove, then
apply oil to the bearing surface.
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Engine reassembly
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z Heat the crankshaft gear for at least
10 minutes to 120°C, then apply
sealant (Loctite # 641) to the inside
wall of the heated crankshaft gear
evenly before inserting it to the end
of crankshaft.
z Semi-tighten a bolt at both sides of
the crankshaft, apply engine oil to
journals and pins, then assemble
the crankshaft with the cylinder
block by tightening the fixing bolts.
z Coat engine oil to the pin and
journal of crankshaft.
z Install the oiled thrust washers with
the oil groove facing outward.
z Install the bearing and thrust
washers to the bearing cap and
apply oil to the bearing and thrust
washers.
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Engine reassembly
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z Install the bearing cap by matching
the cylinder block No. with the
bearing cap No.
z Apply oil to the entire part of the
bearing cap bolts, then tighten in
tightening sequence to specified
torque.
Torque
30 kg.m
z After semi-tightening both bolts
evenly, tighten them diagonally to
the specified torque using a torque
wrench as follows.
<Tightening Order>
(1) First stage
: Coat the cap bolts with engine oil
(2) Second stage : Temporary bolt screwing about 1 ~2 threads
(3) Third stage
: With impact wrench, tighten up to about 15 kg.m
(4) Fourth stage : With torque wrench, tighten up to about 25 kg.m
(5) Fifth stage
: By means of torque wrench, tighten finally in the specified
torque. (30 kg.m).
z Tighten the bearing cap in the sequence of 4 – 3 – 5 – 2 – 6 – 1 - 7.
z Check to see that the assembled crankshaft turns smoothly with hand.
3.3.6. Flywheel housing
z Temporarily install the guide bar on
the cylinder block.
z Apply gasket to the cylinder block.
z Using the dowel pin and guide bar,
install the flywheel housing and
tighten the fixing bolts in a diagonal
sequence to specified torque.
(Zigzag method)
Stopper ring
Ignition timing
check hole
Torque
76
Oil seal
8 kg.m
Engine reassembly
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GE08TIC
Operation and Maintenance Manual
z When the bolts are tightened,
remove the guide bar.
z The flywheel housing is assembled
after the new oil seal was pressed
(Coat engine oil over the outside of
oil seal) before in the housing by a
press.
z If any peripheral scar was
generated due to oil seal at the oil
seal contact surface of crankshaft,
after inserting about 1mm shim or
thereabout in front of oil seal
(Direction
toward
crankshaft.),
measure and adjust.
3.3.7. Oil seal (rear side)
z Apply lubricating oil to the outside
of the oil seal and flywheel housing
inside diameter and fit them over
the crank shaft, then assemble the
oil seal using an oil seal fitting jig.
3.3.8. Flywheel and ring gear
z Installation of flywheel ring gear
With a gas burner, heat the ring
gear evenly until heat expansion
takes place, then install it using a
hammer.
NOTE:
Do not allow the temperature of the
ring gear to exceed 200 °C (390 °F).
z By means of mandrel, assemble
pilot bearing to the flywheel.
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Operation and Maintenance Manual
z Install a guide bar into a bolt hole
on the crank shaft, and lift the
flywheel to align the dowel pin with
the pin hole on the flywheel for
temporary assembly operation.
z Coat the adhesive (#271 Loctite)
over the assembling bolts and
install bolts in the remaining holes.
After that take out the guide bar,
then install a bolt in the hole where
the guide bar had been inserted.
z According to the order of tightening
tighten the fixing bolts using a
torque wrench in a diagonal
sequence to specified torque.
Torque
18 kg.m
3.3.9. Water chamber cover
z Coat the adhesive over the water
chamber cover (Particular around
bolt holes) and after attaching the
gasket, assemble it to the cylinder
block using the bolts for assembling.
z As for tightening of bolts, after
primarily tightening the bolts
located at the both ends of cover
(4ea at both sides) and middle bolts
(Upper, lower 2ea), tighten the rest.
3.3.10. Cylinder liner
z Stand the cylinder block so that the
flywheel faces downward.
z Thoroughly clean the liner flange
fitting surface and bore inside with
compressed air to prevent the
entry of foreign substances.
z After the cleaning operation, make
the cylinder liner dried up and push
it into the cylinder block by hand.
z Wet the liner inside diameter with
engine oil.
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Operation and Maintenance Manual
3.3.11. Piston and connecting rod
z Use a piston heater to heat the
piston approximately 100 °C (212
°F) for 5 minutes.
z Align the piston pin hole with the
oiled connecting rod small end and
press the piston pin (by lightly
tapping with a rubber hammer) to
assemble the connecting rod with
the piston.
z Nothing the direction of the piston,
make the longer side(machined
with key groove on the bearing) of
the connecting rod big end.
z On the piston head surface, the
longer side connecting rod big end
is in opposite direction from the
valve seating surface as well as in
the same direction with the narrow
margin of the combustion chamber.
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Valve seating
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GE08TIC
Operation and Maintenance Manual
z Install the snap rings and check to
see that it is securely assembled.
z Install the piston ring in the piston
using piston ring pliers.
z Identify the mark "Y" or "TOP" on
the ring end to prevent the top and
bottom of the piston ring from
being interchanged and make the
marked portion face upward.
(The surface marked as “Y” is
upper surface.)
Piston
Top ring
Second ring
Oil ring
z Adjust the angle among individual
piston ring gaps to 90° and fit a
piston assembling jig onto the
piston, Use care not to match the
ring gaps with the pin direction.
z Install the bearing by aligning it
with the connecting rod key groove
and apply oil to the bearing and
piston.
z Position the valve seating surface
toward the tappet hole and insert
the piston with hand.
CAUTION:
Use care not to damage the cylinder
liner and piston, and slightly lift and
insert the piston into the cylinder so
that the ring may not be damaged
by the fillet of the liner.
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Operation and Maintenance Manual
z Install the bearing in the connecting
rod cap and apply oil.
CAUTION:
Make sure that the manufacture
serial numbers impressed on the
connecting rod cap and connecting
rod big end are identical, and install
the connecting rod cap by aligning
it with dowel pin.
z Wet the fixing bolts with engine oil, semi-tighten them with hand, tighten them to
the specified torque using a torque wrench as follows.
<Tightening Order>
(1) First stage
: Coat engine oil over bolts.
(2) Second stage : Temporary bolt screwing about 1~2 threads
(3) Third stage
: With torque wrench, tighten up to about 10 kg.m
(4) Fourth stage : With torque wrench, tighten up to about 15 kg.m
(5) Fifth stage : By means of torque wrench, tighten finally in the specified
torque. (18 kg.m).
Torque
18 kg.m
z When the connecting rod bearing
cap bolts are tightened, check the
connecting rod end play to the right
and left with hand.
z If no end play is found, remove and
reinstall or replace the connecting
rod bearing cap.
3.3.12. Timing gear case
z Mount a new gasket using dowel
pin on the cylinder block.
z Put the time gear case to the
cylinder block by aligning the
dowel pin hole of timing gear case
with its pin, and then assemble it
by tapping lightly with an urethane
hammer to the right and left
(Particularly around dowel pin).
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Operation and Maintenance Manual
z Tighten the bolts for assembling to
the specified torque. However, in
case of tightening the bolts, tighten
primarily the bolts of both end
parts and then do the rest.
3.3.13. Timing gear and idle gear pin
z Install the oil pump idle gear onto
the No.7 bearing cap.
z Install a thrust washer over the
camshaft and assemble the cam
gear by aligning it with camshaft
dowel pin. Tighten the cam gear
assembling bolts to the specified
torque. (Zigzag method)
Torque
2.2 kg.m
z With the oil port on the idle gear pin
facing the cylinder block, install the
idle gear pin.
z Idler gear pin with oil hole is
assembled toward cylinder block.
Oil hole
direction
z Install the idle gear by coinciding
the marks impressed on the crank
gear, cam gear, ignition taming
drive gear, and idle gear.
z Install a thrust washer on the idle
gear and tighten to specified torque.
Torque
Ignition timing
drive gear
3.1 kg.m
z Check and adjust the amount of
backlash between gears using a
feeler gauge.
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Operation and Maintenance Manual
Measuring position
Backlash
Limit
cam gear & idle gear
0.16 ∼ 0.28 mm
0.35 mm
Crank gear & idle gear
0.16 ∼ 0.28 mm
0.35 mm
Injection pump & idle gear 0.16 ∼ 0.28 mm
0.35 mm
(between)
3.3.14. Oil pump and oil pipe
z Install a dowel pin in the No.7
bearing cap, then assemble the oil
pump by tapping lightly with
urethane hammer.
z Tighten the assembling bolts with
specified torque.
Torque
4.4 kg.m
z Assemble the oil suction pipe with
the delivery pipe to oil pump by the
bolts.
3.3.15. Water pump
z Mount a new gasket.
z Install the water pump on the
cylinder block and tighten the
assembling bolts with specified
torque.
Torque
2.2 kg.m
z Connect water pipes and by-pass
pipe to the water pump.
z Connect a water pipe to the
expansion tank.
3.3.16. Oil seal (front side)
z Apply lubricating oil to the outside
of the oil seal and the oil seal hole
of the timing gear case cover.
z Put the new oil seal on the oil seal
hole of timing gear case cover
aligning the center of them, then
assemble the oil seal using an oil
seal fitting jig.
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Operation and Maintenance Manual
3.3.17. Timing gear case cover
z Install dowel pin on the timing gear
case.
z Mount a gasket by aligning the
fixing bolt holes with those on the
gasket.
z Align the dowel pin with the cover
pin hole, then install the cover with
light tap.
z Tighten the fixing bolts beginning
with the oil pan fitting face.
z In the assembling, be careful not to be damaged by the crankshaft.
3.3.18. Vibration damper
z Insert the vibration damper to the
crankshaft, and assemble by
tightening the assembling bolts at
the specified tightening torque
according to bolt tightening order.
(refer to right figure.)
Torque
13 kg.m
3.3.19. Oil pan
z Remove the gaskets thoroughly that
project at the timing gear case, case
cover of cylinder block, and the
contacting part of flywheel housing
by means of a scraper.
CAUTION:
Be careful for the gasket pieces not
fall into the engine during the work.
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Operation and Maintenance Manual
z Coat the silicone at the gasket part
that was removed (Contacting part),
and attach the new oil pan gasket.
z Assemble the oil pan by tightening
the oil pan assembling bolts, and
when tightening bolts, primarily
tighten the bolts (4ea) at the both
ends, and then tighten the rest
bolts to specified torque.
Torque
2.2 kg.m
z Align the bolt holes with gasket
holes to prevent damage to the
gasket and tighten.
3.3.20. Oil filter & oil cooler
z Install the gasket on the cylinder
block.
z Assemble the oil cooler by
tightening the assembling bolts.
Torque
Oil filter
cartridge
Oil cooler
2.2 kg.m
z Apply engine oil to the oil filter
cartridge o-ring and assemble the
cartridge using a filter wrench.
z Connect the cooling water pipe
with the cooling water pump and
tighten a hose clamp.
Oil cooler housing
Oil cooler element
Water drain valve
85
Engine reassembly
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Operation and Maintenance Manual
3.3.21. Starting motor
z Assemble the starter in position on
the flywheel housing.
Torque
4.4 kg.m
3.3.22. Intake and exhaust valves
z Identify the marks of "GI" and "GE"
impressed on the valve head
before assembling the valve with
the valve head.
z With a valve stem seal fitting jig,
assemble the valve stem seal on
the valve guide.
Valve identify the marks
Intake valve
Exhaust valve
z After installing valve springs and
spring retainer, press the retainer
with a jig, then install the cotter pin.
z Tap the valve stem lightly with a
rubber hammer to check that the
valve is assembled correctly.
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Operation and Maintenance Manual
3.3.23. Cylinder head
z Blow the bolt holes of cylinder
block with a compressed air and
remove the foreign matter.
z Clean the head gasket contact
surface thoroughly.
z However, be careful for the foreign
material not to enter into the
combustion chamber.
z Assemble the new head gasket by
aligning the holes with dowel pins
of cylinder block with “TOP” mark
facing upward.
z Check the inside of combustion
chamber for foreign substances,
and carefully mount the cylinder
head assembly in the block by
aligning the dowel pin with the
dowel pin hole.
z Be careful not to damage the
cylinder head gasket. If the dowel
pin is not in alignment, lift the
cylinder head again and then
remount it.
CAUTION:
After tightening the cylinder head
bolts, even at disassembling, the
cylinder head gasket should be
changed a new one.
z Coat the cylinder head bolts with
engine oil, and tighten in proper
sequence to the specified torque
according to bolt tightening order.
(right figure).
87
Front side
Rear side
Engine reassembly
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GE08TIC
Operation and Maintenance Manual
<Cylinder Head Bolts>
Type 1
Type 2
M14×1.5×146
M14×1.5×150
Specification
1st : 6 kg.m
Torque
2nd : 180°
24.5 kg.m
final : 150°
(Angle torque)
z However, before tightening bolts,
the side parallel degree between
cylinder heads should be adjusted.
<Tightening order of bolts by steps>
(1) First stage
: Coat the bolts with engine oil.
(2) Second stage : Tighten 1 ~2 threads with hands.
(3) Third stage
: Tighten at about 6 kg.m with a wrench.
(4) Fourth stage : Tighten at rotating angle method 180° with a wrench.
(5) Fifth stage : Finally, tighten at rotating angle method 150° with a torque
wrench .
z However, all bolts are tightened
simultaneously by above steps.
z Coat the push rod with engine oil
and insert it into the push rod hole.
3.3.24. Rocker arm assembly
z Apply lubricating oil to the rocker
arm bush and shaft, and assemble
the intermediate bracket with the
rocker arm (rocker arm assembly)
on the cylinder block using fixing
bolts. In tightening the bolts, it must
be done at the specified value
using zigzag method.
M10x1.5
4.4 kg.m
M12x1.5
8.0 kg.m
Torque
88
Engine reassembly
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Operation and Maintenance Manual
z Semi-install
valve
clearance
adjusting bolts onto the rocker arm.
z Install the spring, rocker arm,
bracket, rocker arm, spring, washer,
and snap ring in the described
sequence.
z Install the rocker arm and bracket
in the same direction.
3.3.25. Ignition coil and spark plug
z Tighten the spark plug at cylinder
head with socket tool.
z Assemble the high pressure cable
on the spark plug and ignition coil.
High pressure cable
Spark plug
Socket tool
Spark plug torque
Hex. head
16mm (5/8inch)
2.5 ~ 3.0 kg.m
3.3.26. Adjust the valve clearance as following guide.
z By turning the crankshaft, when overlap the intake and exhaust of #6 cylinder,
that is, when #1 cylinder’s piston come at the compression top dead center (OT),
adjust the valve clearances by
mark indicated.
z After having turned the crankshaft by 360° and overlap the intake & exhaust
valves of #1 cylinder, that is, when #6 cylinder is in the state of compression TDC
(OT), adjust the valve clearances by
mark indicated.
Crankshaft pulley
89
Intake valve
Exhaust valve
Cylinder no.
Fly wheel
Engine reassembly
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GE08TIC
Operation and Maintenance Manual
z To adjust the clearance, loosen the lock nuts of rocker arm adjusting screws and
push the feeler gauge of specified value between a rocker arm and a valve stem
(to measure the clearance of the valve and rocker arm contacting part) and
adjust the clearance with adjusting screw respectively and then tighten with the
lock nut.
z As for the valve clearance, adjust it when in cold.
Model
GE08TIC
Intake Valve
Exhaust Valve
0.3 mm
0.3 mm
CAUTION :
(1) Crankshaft revolution is done by hands without using a starting motor.
(2) Turn it to the direction of engine rotation, but do not use the installing bolts
at the turn.
(3) The cylinder no. and the order of intake and exhaust can be determined
from the crank shaft pulley.
z Adjust valve clearance with a feeler
gauge and tighten the fixing nuts to
specified torque.
Torque
5.0 kg.m
3.3.27. Ignition timing drive gear
z Mount gasket by aligning the bolt
holes with pin holes on the timing
drive gear housing.
z After tighten the fixing bolts in the
direction of the coupling.
Trigger wheel
run-out
90
Bellow 0.2mm
Engine reassembly
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GE08TIC
Operation and Maintenance Manual
3.3.28. Ignition timing adjustment
z Ignition timing sensor and trigger wheel location is affected the engine starting
that refer to bellow the described order.
z Check ignition timing angle
1) Turning the crankshaft, let the
valves of #6 cylinder’s valves
overlap.
2) Check notch mark of the right
figure corresponding to the
ignition timing aligner with the
pointer (
) on the flywheel
housing.
Model
Ignition timing
(B.T.D.C static)
#1 cylinder
ignition position
Fly wheel
GE08TIC
0°
Pin hole
Ignition timing
check mark
OT mark
z Adjust ignition timing angle
1) Loosen the trigger wheel lock
bolts, and align the sensor on
the trigger wheel at starting
position of the undivided holes
(as bellow figure) and then
tighten the trigger wheel lock
bolts.
Magnet pick-up
sensor
Trigger wheel
Timing drive
gear coupling
Trigger wheel cover
Trigger wheel lock bolts
Trigger wheel lock
bolt torque
Timing sensor gap
4.4kg.m
1.0mm±0.1mm
View flywheel
housing side
91
Engine reassembly
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Operation and Maintenance Manual
z Adjust ignition timing sensor gap
1) Move the lock nut to hexagonal
side of sensor completely.
2) Rotate (Clockwise) the timing
sensor on the coupling housing,
until the end of it reach on the
timing drive gear.
3) Then rotate (Counter clockwise)
the timing sensor for 270° (gap
1.0 mm) and fix lock nut.
4) Tolerance limit is 27°. (gap ± 0.1
mm)
Timing
sensor
Tolerance limit
3.3.29. Intake manifold
z Put in the new gasket between the
cylinder head and manifold, and
assemble the intake manifold by
tightening the assembling bolts.
Torque
2.2kg.m
3.3.30. Exhaust manifold
z Assemble the exhaust manifold
with steel gasket in order to be
installed and be sure to check the
squared port of the gasket whether
square port of the cylinder head is
aligned before assembling.
z Tighten the fixing bolts with
specified torque.
Torque
4.4kg.m
3.3.31. Turbocharger
z Fit a new gasket over the stud
bolts of the exhaust manifold
before
tightening
those
turbocharger fixing nuts.
Turbo charger
Oil pipe
Water
hose(inlet)
Water
hose(outlet)
Torque
4.4kg.m
Flange
Exhaust elbow
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Operation and Maintenance Manual
z Install the oil supply pipe and return
pipe.
z Tighten the clamps of rubber hose that
is connected air pipe to the intercooler.
z Assemble the cooling water inlet &
outlet pipe on the turbocharger.
3.3.32. Intercooler & throttle valve
z After sub-assembling the air inlet &
outlet pipe and water inlet & outlet
cooling water pipe.
z Install the intercooler on the
bracket of flywheel housing and
tightening the fixing bolt on it.
z Assemble the throttle valve & air
pipe on the intake manifold.
CAUTION:
Check assembled after the all engine parts install and tighten fuel line.
Open fuel line valve and check for leaks using soapy water or commercial leak
detector.
Throttle valve
Intake manifold
Inter
cooler
3.3.33. Fuel mixer & gas pressure regulator
z Assemble the fuel mixer and air
pipe from the turbo charger.
z Tighten the gas pressure regulator
and nature gas pipe from the fuel
mixer.
Fuel mixer
Air pipe
Turbo charger
Gas pressure
regulator
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Operation and Maintenance Manual
CAUTION:
Check assembled after the all
engine parts install and tighten fuel
line.
Open fuel line valve and check for
leaks using soapy water or
commercial leak detector.
3.3.34. Ignition control module : ICM
z Mount
the
ignition
control
module(ICM) bracket on the
cylinder block.
z Assemble the fixing bolts with the
ignition control module.
Ignition control
module
3.3.35. Ignition coil & high voltage cable
z Install the bracket on the intake
manifold and assemble the ignition
coils
High pressure cable
Ignition coil
z Assemble the high voltage cables
by hand from each cylinder head.
Intake manifold
Ignition harness
3.3.36. Cooling water pipe
z Attach a new gasket on the cylinder
head.
z Install the cooling water pipe and
tightening the fixing bolt on it.
Torque
94
2.2kg.m
Engine reassembly
Printed in May 2005 PS-MMG0416-E1A
GE08TIC
Operation and Maintenance Manual
3.3.37. Alternator
z Install the alternator mounting
bracket and supporter to the
cylinder block, then tighten the
fixing bolts.
z Install the alternator with fixing
bolts to the mounting bracket.
Torque
8.0kg.m
3.3.38. Cylinder head cover
z Attach a new gasket on the cylinder
head cover.
z Assemble the cylinder head cover
to the cylinder head by tightening
the cap bolts for fixing the cylinder
head cover.
Torque
1.2 kg.m
z Assemble the breather and
breather hose.
z Fit the oil filler cap on the cylinder
head cover.
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Operation and Maintenance Manual
3.3.39. V-Belt
z Install the V-belt on the crank pulley,
alternator pulley and water pump
pulley.
z Adjust the V-belt tension using the
tension adjusting support.
3.3.40. Oil level gauge
z Apply sealant (Locktite #262) to the
bottom side of the guide tube.
z Then assemble the guide tube and
oil level gauge on the oil pan.
3.3.41. Engine speed controller: ESC
z Install engine speed controller
(ESC) and connect the harness
and various sensors.
96
Engine speed
Controller(ESC)
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Operation and Maintenance Manual
3.4. Starting and Trial Operation
3.4.1. Preparations for breaking-in
z Fill of new engine oil through the oil filler cap.
z When measuring the oil level with the oil level gauge with the engine mounted,
the oil level must indicate about 10mm above the max. line.
z Connect water hoses and fill up cooling water.
z Connect the fuel hoses to the fuel tank and to top(radiator or surge tank).
z Check the air bleeding of the fuel system.
z Connect the electrical systems such as starter, air heater, etc. with power source.
3.4.2. Operation of a new engine (Break-In)
Because the sliding surfaces of a new engine are not lapped enough, the oil film can
be destroyed easily by overload or overspeed and the engine life-time may be
shortened.
Therefore the following things must be obeyed by all means.
Up to the first 50 hours
z Engine should be run at fast idling until the temperature of the engine becomes
normal operating condition.
z Overload or continuous high speed operation should be avoided.
z High speed operation with no load should be prevented.
z Abrupt start and stop of the engine should be avoided.
z Engine speed must be under 70% of its maximum speed.
z Maintenance and inspection must be accomplished thoroughly.
3.4.3. Check points for break-in
During the break-in (the initial running of the engine) period, be particularly
observant as follows:
Check engine oil level frequently. Maintain oil level in the safe range, between the
"min." and “max." marks on dipstick.
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Major electric parts replacement
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Operation and Maintenance Manual
Note:
If you have a problem getting a good oil level reading on dipstick, rotate
dipstick 180° and re-insert for check.
Watch the oil pressure warning lamp. If the lamp blinks, it may be the oil pick-up
screen is not covered with oil. Check oil dipstick. Add oil to the oil pan, if required.
Do not overfill. If level is correct and the status still exists, see your DEALER for
possible switch or oil pump and line malfunction.
Note:
Oil pressure will rise as RPM increases, and fall as RPM decreases. In addition,
cold oil will generally show higher oil pressure for any specific RPM than hot
oil. Both of these conditions reflect normal engine operation.
c) Watch the engine water temperature gauge and be sure there is proper water
circulation. The water temperature gauge needle will fluctuate if water level in
expansion tank is too low. At the end of the break-in period, remove break-in oil
and replace the oil filter. Fill oil pan with recommended engine oil. Refer to
following table.
Engine oil capacity
Engine
model
GE08TIC
in Oil pan
Max.
Min.
(lit)
(lit)
23
17
Recommend oil
Total
(lit)
API No.
Sulfated
ash content
25
SAE 15W40
above CD or CE
Bellows 0.5%
Recommend oil : TOTAL LMG-405
Mobil Delvac super GEO 15W40
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Major electric parts replacement
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Operation and Maintenance Manual
3.5. Speed controller setting
3.5.1. Installation checks
Do the checks in the order indicated. Terminal numbers in this chapter refer to the
speed controller.
1) Check that all electrical connections are correctly made and terminal screws
tightened, the magnetic pickup is properly installed and the jam nut tightened,
and the fuel valve and drain line are securely fastened and correctly installed.
2) Do not start the engine now. Turn on governor power. Check the battery voltage
at terminals 1(+) and 2(–). It must be from 18 to 32Vdc.
3) If a signal generator is available : Attach the output to terminals 5 and 6, leaving
the magnet pick-up connections off. Set the signal-generator output between 2
and 10 Vrms. If a signal generator is not available, proceed to step 8.
4) Set the signal-generator frequency to about half of idle speed. Close the
IDLE/RATED switch. Turn the signal generator and governor power on. The
voltage across terminals 3 and 4 should measure about 5Vdc (START FUEL
LIMIT must be fully clockwise).
5) Set the signal generator for magnet pick-up frequency at rated speed. Close the
IDLE/RATED switch. Set the external speed trim pot (if used) at mid position.
Observe the output from terminals 3 and 4.
a) If the output is at max-fuel position (about 5Vdc), slowly turn the rated-speed
potentiometer counterclockwise until the signal just begins to move to
minimum.
b) If the output is at minimum, slowly turn the rated-speed potentiometer
clockwise until the signal just begins to move to maximum.
c) Continue to adjust the rated-speed pot very slowly, trying to stop the signal
between minimum and maximum. Stop adjusting when the signal moves
slowly. It will not be possible to stop the motion. The rated-speed reference is
now set very close to desired speed.
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6) Open the IDLE/RATED switch. Set the signal generator for magnet pick-up
frequency at idle speed. (Preset the idle speed only after presetting rated speed.)
a) If the signal is at maximum-fuel position, slowly turn the idle-speed
potentiometer counterclockwise until the signal begins to move to minimum.
b) If the signal is at minimum, slowly turn the idle-speed potentiometer clockwise
until the signal just begins to move to maximum.
7) Continue to adjust the idle-speed pot very slowly, trying to stop the signal
between minimum and maximum. Stop adjusting when the signal moves slowly.
It will not be possible to stop the signal. The idle-speed reference is now set very
close to desired idle speed.
8) If a signal generator is not available: turn the rated speed pot fully
counterclockwise. Turn the idle-speed pot fully clockwise. Remove the magnet
pick-up wires from the speed control and measure resistance across the magnet
pick-up wires. If the resistance is correct replace the connection.
3.5.2. Initial pre-start settings
In case the newly installed the speed controller does not control engine speed, be
prepared to bellows sequence.
1. Rated Speed
If RATED SPEED was not set with a signal generator, set the RATED SPEED
potentiometer to minimum (fully counterclockwise). Set the external speed trim, if
used, to mid-position.
2. Stability
Set the RATED and IDLE STABILITY potentiometers to mid position.
3. Gain
Set the RATED and IDLE GAIN potentiometers to mid position.
4. Idle Speed
If IDLE SPEED was not set with a signal generator, set the IDLE SPEED
potentiometer at maximum (fully clockwise).
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5. Start Fuel Limit
Set the START FUEL LIMIT pot at mid point (maximum is fully clockwise).
6. Close the circuit between terminals 9 and 10 (Close for rated).
3.5.3. Start-up and stable adjustments
Prepare to start the engine. Read this entire chapter before attempting to start the
engine. Interrelated problems can occur, and an understanding of all possibilities is
needed before using a control for the first time.
CAUTION:
To protect against possible injury, loss of life, and/or property damage when
starting the engine, turbine, or other type of prime mover, be prepared to make
an emergency shutdown to protect against runaway or overspeed should the
fuel control(s), the driving mechanism(s), or the control device(s) fail.
1) Adjust for stable operation
Read the following paragraphs before attempting initial engine start up. Dynamics
must be quickly adjusted after initial start up.
2) Immediately after the initial start up, it will be necessary to adjust the governor for
stable operation. Idle and Rated dynamics are completely separate. In most
cases the idle speed has been preset at maximum (fully clockwise) and Rated
Speed is selected. In many cases the selection of rated speed will not indicate a
desire for rated dynamics, which will be used when the engine is loaded. Idle
dynamics may be selected and adjusted while rated speed is selected.
3) If the engine is hunting at a rapid rate, slowly decrease the GAIN (turn the
potentiometer counterclockwise) until performance is stable.
4) If the engine is hunting at a slow rate, increase the STABILITY (turn the
potentiometer clockwise) until the engine stabilizes. If increasing the STABILITY
potentiometer does not stabilize the engine, it also may be necessary to slowly
decrease the GAIN (turn the potentiometer counterclockwise).
a) Start cranking the engine. If the signal from terminals 3 and 4 does not show a
positive voltage (2 to 6 Vdc) check the magnetic pick-up sensor.
b) Minimum voltage required from the magnetic pick-up sensor to operate the
electronic control is 1.0 Vrms, measured at cranking speed or the lowest
controlling speed. Measure the voltage while cranking with the speed sensor
connected to the control. Be sure to prevent the engine from starting.
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5) If the engine stops, it indicates a magnetic pick-up problem. The magnetic pick-up
must produce a minimum of 1 Vac rms to activate the control. Failure to produce
the minimum signal can be caused by improper magnetic pick-up installation,
selection of an incorrect gear, improper wiring between the magnetic pick-up and
the control, or a defective magnetic pick-up.
6) With the engine running and stable, slowly increase the rated-speed setting with
the RATED SPEED pot until the desired rated speed is reached.
7) Dynamic adjustment
The object of the GAIN and STABILITY potentiometer adjustments is to obtain
the optimum, or desired, stable engine-speed response.
8) Increasing the setting of the GAIN potentiometer provides faster transient
response (decreases the amount of speed change from a sudden change in load).
To achieve the best response, slowly increase the GAIN (turn the potentiometer
clockwise) until the engine becomes slightly unstable, then slowly turn the GAIN
back counterclockwise as necessary to stabilize engine speed.
9) Step load the engine to make sure the engine returns to the proper speed with
little overshoot or undershoot of the speed setting. (To reduce overshoot, increase
the STABILITY setting by turning the potentiometer clockwise).
10) Increasing the STABILITY clockwise will require decreasing the GAIN (turning
the GAIN potentiometer counterclockwise) to maintain stable operation.
11) If the engine is slow in returning to the proper speed, decrease the STABILITY
by turning the potentiometer counterclockwise.
12) Low idle speed adjustment: The engine should be at rated speed with the
IDLE SPEED potentiometer set at maximum (fully clockwise). Open the external
CLOSE FOR RATED contact.
13) Decrease the IDLE SPEED (turn the potentiometer counterclockwise) until the
desired idle speed is reached. It may be necessary to adjust the idle dynamics to
maintain stability as speed is lowered.
14) Dynamic Adjustment
a) Gain is too high and stability too low. There are secondary overshoots on
transients and large overshoots on starts (under damped)
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Start
Load
on
Ringing
Load
off
Speed
b) Optimum performance on load transients with slight overshoot on starts
(optimum damping)
Speed
c) Optimum performance on start with slight time extension of load transients
(optimum damping)
Speed
d) Stability too high, long time to settle to rated speed (over damped)
Setting
Time
Speed
15) If idle dynamics were selected on initial start-up, it will now be necessary to set
rated dynamics. Load the engine, then select rated dynamics.
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16) Engine response will change as the engine warms up. It may be necessary to
tune dynamics after warm-up. It may be necessary to compromise optimum
control dynamics with a cold engine in order to have optimum dynamics when
the engine is at operating temperature.
17) The START FUEL LIMIT was set at a point that allowed the cold engine to start
during initial start up procedures. If START FUEL LIMIT is to be used, it should
now be adjusted after engine stability and response rates are correctly adjusted.
a) Adjusting the START FUEL LIMIT counterclockwise will prevent the fuel valve
from delivering a maximum amount of fuel to the injectors until the selected
speed (Idle or Rated) is reached. Adjust for desired engine performance
during start up. The Start Fuel Limit must be set high enough to allow the
engine to reach the selected speed.
b) The START FUEL LIMIT should be adjusted from counterclockwise to obtain
the desired characteristics while starting the engine. There may be
differences in startup characteristics of cold and hot engines.
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3.6. Electrical System
3.6.1. Electrical component of engine
1
3
2
4
5
9
10
6
11
7
No.
105
Part Name
8
No.
Part Name
1
Ignition coil
7
Ignition control module (ICM)
2
Starter
8
Oil pressure unit
3
Nature gas air mixer
9
Cooling water temperature switch
4
Throttle valve
10
Cooling water temperature sender
5
Gas pressure regulator
11
Alternator
6
Ignition timing sensor
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3.6.2. Engine control system
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3.6.3. Engine control harness
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3.7. Speed Controller
3.7.1. Speed controller description
z The speed controller is designed to provide basic isochronous speed
control for gas engines.
z Engines with mechanical loads and generator loads are handled equally
well.
Speed controller
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3.7.2. Speed controller circuit
109
z
1
Shield wires to be twisted pairs with shield grounded at one end only.
z
2
No. 18AWG or 20AWG standard wire. Must be as short as possible.
50ft. maximum wire length for 20AWG wire. 80ft. maximum wire length
for 18AWG wire.
z
3
Use 24 volt system.
z
4
Open for minimum fuel.
z
5
For positive ground systems, switch and fuse to be located in series
with battery (-) and terminal 2. Positive terminal becomes chassis
ground. Leads from battery to terminals 1 & 2 must be direct and not
pass through distribution points.
z
6
Approximate speed change with trim potentiometer
◈ ±2.5% using a 1KΩ potentiometer
◈ ±5% using a 2KΩ potentiometer
z
7
About one second ramp time per 50µF. Capacitor specifications :
200µF maximum, 15WVdc minimum. 15WVdc maximum. Less than
30µA DC leakage current over temperature range.
z
8
Idle range about 25% to 100% rated using 50K potentiometer.
z
9
Use a 1 amp fuse(3 AWG)
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3.8. Ignition controller
Ignition control
module
3.8.1. Ignition controller circuit
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3.8.2. DC power hookup of ignition system
3.8.3. Engine firing order
Engine model
Firing order
GE08TIC
1–5–3–6–2-4
3.8.4. Engine cylinder no.
Crankshaft pulley
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Intake valve
Exhaust valve
Cylinder no.
Fly wheel
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3.8.5. Primary wiring
Terminal position
Spark coil
Terminal symbol
Wiring
Connector position
1+
1.25R
Connector
1-
1.25B
Connector J
2+
1.25R
Connector E
A
2-
1.25B
Spark coil
3+
1.25R
Connector C
1-
3-
1.25B
Spark coil
4+
1.25R
Connector F
4-
1.25B
Spark coil
5+
1.25R
Connector B
5-
1.25B
Spark coil
6+
1.25R
Connector D
234-
6-
1.25B
Spark coil
5-
Ground
1.25B
Spark coil
6-
Terminal symbol
Wiring
Connector position
Signal(SIG)
0.85W
Connector A
Ground(GND)
0.85W
Connector B
3.8.6. Tacho sensor wiring
Terminal position
Tacho sensor
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3.9. Ignition control module
3.9.1. Installation instruction
CAUTION:
Deviation from these installation instructions may lead to improper engine
operation which could cause personal injury to operations or other nearby
personnel.
3.9.2. Description
z The CD1 ignition system consists of these basic components.
1) CD1 unit
2) Magnetic pick-up sensor
3) Harness
4) Individual coils
z The system requires a battery or a suitable power supply with a nominal 24
VDC. The CD1 unit steps up the DC supply voltage to charge an energy
storage capacitor and contains microcircuit logic and SCR(Silicon controlled
rectifier switching) devices to release the stored energy to the ignition coils in
programmed, timed sequence according to the application. Holes drilled in the
trigger wheel signal the position of the trigger coupling to the logic circuitry in
the CD1 unit.
3.9.3. CD1 unit
z Select a location for the CD1 unit that will be at least 600 mm away from the
ignition coils and spark plug leads. In addition, the mounting location must be
relatively cool. The outside case temperature of the CD1 unit should not exceed
90°C (195°F) in operation.
NOTE:
Plastic-case CD1 units have a maximum case temperature of 65°C (150°F).
3.9.4. Pick-up sensor
z Locate a suitable mounting position for the pick-up sensor so that it may sense
either the outside diameter of the trigger wheel.
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IMPORTANT:
Rotate the trigger wheel an entire revolution to be sure that there are holes in
the path that will pass under the pick-up sensor.
z Set the engine with no. 1 cylinder in the most advanced timing position. Mark the
point on the trigger wheel that will be directly opposite the pick-up sensor.
z Drill the remaining holes spaced as shown in the appropriate wiring diagram in
these instructions.
NOTE:
The angular spacing is extremely important as this establishes the basic
timing accuracy of the system. In addition, make sure each hole is drilled so
that its center passes directly in line with the center of the pick-up sensor.
z Secure the pick-up sensor to a rigid bracket or surface to maintain an air gap(1.0
mm ± 0.1 mm) not exceeding. The center of the pick-up face must line up with the
center of the drilled holes as the engine is rotated.
z Plug the 2-pin pick-up sensor connector fully into its mating receptacle connected
to the CD1 unit.
NOTE:
Keep the pick-up sensor wires at least 50 mm away from the coil primary wires
and at least 200 mm away from the spark plug leads.
3.9.5. Trigger wheel
z A trigger wheel with the appropriate hole pattern must be prepared for mounting
at camshaft speed. The angular spacing is extremely important as this establishes
the basic timing accuracy of the system.
z Set the engine with no. 1 cylinder in the most advanced timing position. Noting
the direction of rotation, set the drilled disc opposite the pick-up in the position
shorn in circuit diagram.
z Plug the 2-pin pick-up sensor connector fully into its mating receptacle connected
to the CD1 unit.
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3.9.6. Ignition coils
z Mount the ignition coils as close to the spark plugs as possible keeping the hightension lead length to a minimum but also keeping temperatures below 95°C
(200°F) during operation.
3.9.7. Primary wiring
z The CD1 system requires a battery or other DC power source providing
12~28VDC for running and a minimum of 8 volts for engine starting. Refer to
details the connection to the DC power source.
z Plug the multi-pin harness connector fully into its mating receptacle connected to
the CD1 unit.
NOTE:
Keep the primary wiring at least 50 mm away from the spark plug leads.
3.9.8. Shutdown wiring
The CD1 system can be shut-off in two ways.
(Refer to 3.7.1. Ignition controller circuit – CD1 system)
z Method 1: (use to DC power source)
Interrupt the DC power to the unit.
- Use a switch or relay with contacts rated 24VDC, 10 amps refer to drawing.
- Do not run the input power line through a series of normally closed switches.
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z Method 2: (use to “G” ground)
- Ground the appropriate harness lead. This option may be used if the
shutdown panel was powered from an ignition system.
- When the shutdown lead is grounded, the CD1 unit will draw about 0.1 amp
from the power source.
NOTE:
If desired, the shutdown lead may be used to power display instruments in the
panel.
3.9.9. Operation
z The CD1 unit steps up the DC supply voltage to charge an energy storage
capacitor. SCR switching devices release this stored energy in response to
signals from the unit's logic circuitry which processes signals from the magnetic
pick-up. The pick-up senses one hole for every firing of the engine.
Each firing occurs a programmed number of degrees after the hole is sensed.
This delay in degrees is adjustable.
z The CD1 unit has a timing switch located under a white plastic cap at one end of
the box.
- 6 cylinder engine : 1.9 degrees per switch interval = 13 degrees total
z Switch position 7 gives the most advanced timing. The timing retards as indicated
above for each switch position as the switch is moved to position 1-5-3-6-2-4.
Switch position 0 is full retard.
CAUTION:
Do not switch from position 7 to 0, or 0 to 7 while the engine is running. The
large timing change may cause the engine to shutdown or be damaged.
NOTE:
Using a timing light, set the timing to the desired position with the engine
running at normal operating speed. Replace the white cap over the timing
switches once the proper timing setting is set.
z Two LED indicators on either side of the timing switch give an indication of proper
operation of the magnetic pick-up (left LED) and the output circuits of the CD1
unit (right LED). See troubleshooting procedures.
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3.9.10. Troubleshooting chart
z Normal operation
Check the two LED indicators next to the timing switch.
- After power is turned on to the CD1 unit, the output indicator will turn on.
- When the engine is cranked, both indicators will blink at the same rate.
- At normal running speeds, both indicators glow continuously.
- If engine is stopped with power off, the output indicator will turn off for a few
seconds and then stay on continuously.
z Trouble shooting
- Check the two LED indicators next to the timing switch.
- If the engine will not start or run correctly, crank engine with fuel turned off and
check per the chart bellow.
Indication and checks
1. Both indicators off.
z Check 12~24 VDC power to CD1 unit.
z If above check is OK.
2. Pick-up indicator off / Output indicator On.
1) Check gap between pick-up and sensed
surface.
- must be greater than 1.0 mm ±0.1 mm.
2) Check connections between CD1 unit and
the pick-up sensor.
3) Unplug connection to pick-up and measure
resistance between the two pick-up leads.
4) If above checks are OK.
3. Pick-up indicator OK / Output indicator off or
blinks at slower rate.
1) Check connections between CD1 unit and
ignition coil module or coils.
2) If above check is OK.
4. Both indicators blink at the same rate.
1) Indicates proper operation of CD1 unit and
magnetic pick-up sensor.
117
Remedy
z Must be in range of 12~29
VDC.
z Replace CD1 unit.
z Correct gap.
z Correct connections.
z Replace pick-up.
z Replace CD1 unit.
z Correct connections.
z Replace CD1 unit.
z Check or replace ignition coils.
z Check other items such as fuel
supply.
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4. Commissioning and Operation
4.1. Operation Preparation
At the time of initial commissioning of a new or overhauled engine make sure to have
observed the "Technical information for the installation DOOSAN’s generator
engines".
z Oil filler neck on cylinder head cover
- Before daily starting of the engine, check the fuel, coolant and oil level, replenish
if necessary.
- The notches in the oil level gauge indicate the highest and lowest permissible oil
levels.
IMPORTANT:
Do not fill above the top of the mark. Oil levels anywhere within the crosshatch
are considered in the acceptable operating range. Over lifting will result in
damage to the engine.
z Cleanliness
Ensure outmost cleanliness when handling fuels, lubricants and coolants
4.2. Breaking-in
4.2.1. Preparations for breaking-in
z Fill of new engine oil through the oil filler cap.
z When measuring the oil level with the oil level gauge with the engine mounted,
the oil level must indicate about 10mm above the max. line.
z Connect water hoses and fill up cooling water.
z Connect the electrical systems such as starter, alternator, etc. with power source.
4.2.2. Operation of a new engine (Break-In)
Because the sliding surfaces of a new engine are not lapped enough, the oil film can
be destroyed easily by overload or overspeed and the engine life-time may be
shortened. Therefore the following things must be obeyed by all means.
Up to the first 50 hours
z Engine should be run at fast idling until the temperature of the engine
becomes normal operating condition.
z Overload or continuous high speed operation should be avoided.
z High speed operation with no load should be prevented.
z Abrupt start and stop of the engine should be avoided.
z Engine speed must be under 70% of its maximum speed.
z Maintenance and inspection must be accomplished thoroughly.
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4.2.3. Check points for break-in
During the break-in (the initial running of the engine) period, be particularly observant
as follows:
a) Check engine oil level frequently. Maintain oil level in the safe range, between
the "min." and “max." marks on dipstick.
Note :
If you have a problem getting a good oil level reading on dipstick, rotate the
level gauge 180° and re-insert for check.
b) Watch the oil pressure warning lamp. If the lamp blinks, it may be the oil pick-up
screen is not covered with oil. Check oil level gauge. Add oil to the oil pan, if
required. Do not overfill. If level is correct and the status still exists, see your
DEALER for possible switch or oil pump and line malfunction.
Note :
Oil pressure will rise as RPM increases, and fall as RPM decreases. In addition,
cold oil will generally show higher oil pressure for any specific RPM than hot
oil. Both of these conditions reflect normal engine operation.
c) Watch the engine water temperature gauge and be sure there is proper water
circulation. The water temperature gauge needle will fluctuate if water level in
expansion tank is too low.
At the end of the break-in period, remove break-in oil and replace the oil filter. Fill
oil pan with recommended engine oil. Refer to following table.
z The following oils are also recommended
SAE No.
API No.
Sulfated ash content
15W40
above CD or CE
Bellow 0.5 %
* Recommend oil : TOTAL LMG-405
Mobil Delvac super GEO 15W40
z Engine oil capacity
Engine oil capacity
Engine model
GE08TIC
119
in Oil pan
Max.
Min.
(lit)
(lit)
23
17
Total
(lit)
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4.2.4. Operating after break-in
When starting a cold engine, always allow the engine to warm up gradually. Never
run the engine at full throttle until the engine is thoroughly warmed up. Be sure to
check the oil level frequently during the first 1,000km(50 hours) of operation, since
the oil consumption will be high until the piston rings are properly seated.
4.3. Inspections after Starting
During operation the oil pressure in the engine lubrication system must be monitored.
If the monitoring devices register a drop in the lube oil pressure, switch off the engine
immediately. And the charge warning lamp of the alternator should go out when the
engine is running.
z Do not disconnect the battery or pole terminals or the cables.
z If, during operation, the battery charge lamp suddenly lights up, stop the
engine immediately and remedy the fault in the electrical system.
z Engine should be stopped if the color, the noise or the odor of exhaust gas is
not normal.
z Confirm the following things through warning lamps and gauge panel.
4.3.1. Pressure of lubricating oil
The normal pressure comes up to 1 kg/cm2 (1.0 bar) at idling and 3 ~ 5 kg/cm2 (3.0 ~
4.9 bar) at maximum speed. If the pressure fluctuates at idling or does not reach up
to the expected level at high speed, shut down the engine immediately and check
the oil level and the oil line leakage.
4.3.2. Temperature of cooling water
The cooling water temperature should be 79 ~ 95 °C in normal operating conditions.
Abnormally high cooling water temperature could cause the overheating of engine
and the sticking of cylinder components. And excessively low cooling water
temperature increases the fuel consumption, accelerates the wears of cylinder liners
and shortens the engine life-time.
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4.4. Operation in Winter Time
Pay special attention to the freezing of cooling water and the viscosity of lubricating
oil.
4.4.1. Prevention against the freeze of cooling water
When not using anti-freeze, completely discharge the whole cooling water after
engine running. The freeze of cooling water causes the fatal damages of the engine.
Because the anti-freeze is used to prevent cooling water from freeze, consult "The
amount of anti-freeze".
4.4.2. Prevention against excessive cooling
Drop of thermal efficiency caused by excessive cooling increases fuel consumption,
therefore prevent the engine from excessive cooling. If the temperature of coolant
does not reach to normal condition (79 ~ 95°C) after continuous operation, examine
the thermostat or the other cooling lines.
4.4.3. Lubricating oil
As cold weather leads to the rise of oil viscosity, engine speed becomes unstable
after starting. Therefore the lubricating oil for winter should be used to prevent this
unstability. Refer to lubricating system section.
4.5. Tuning the Engine
The purpose of an engine tune-up is to restore power and performance that's been
lost through wear, corrosion or deterioration of one or more parts or components. In
the normal operation of an engine, these changes can take place gradually at a
number of points, so that it's seldom advisable to attempt an improvement in
performance by correction of one or two items only. Time will be saved and more
lasting results will be obtained by following a definite and thorough procedure of
analysis and correction of all items affecting power and performance.
Economical, trouble-free operation can better be ensured if a complete tune-up is
performed once every years, preferably in the spring. Components that affect power
and performance to be checked are:
z Components affecting fuel system ;
Ignition coil, spark plug, metering valve etc.
z Components affecting intake & exhaust ;
Air cleaner, inter-cooler, turbo charger, silencer, etc.
z Components affecting lubrication & cooling ;
Air & oil filter, anti- freeze, etc.
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4.6. Maintenance and Care
4.6.1. Periodical inspection and maintenance
In order to insure maximum, trouble-free engine performance at all times, regular
inspection, adjustment and maintenance are vital.
z Daily inspections in below figure should be checked every day.
z The maintenance should be executed thoroughly at regular internals.
(refer to appendix “General engine inspection cycle”.)
4.6.2. Exchanging of lubrication oil
Engine oil and the oil filter are important factors affecting engine life. They affect
ease of starting, fuel economy, combustion chamber deposits and engine wear.
At the end of the break-in period 1,000km (50hours), change the oil sump oil and
replace the oil filter cartridge.
4.6.3. Oil level gauge
Check the oil level in the engine sump
daily with an oil level gauge.
z The notches in oil level gauge must
indicate the oil level between the
max. and the min. permissible.
z The oil level should be checked
with the engine horizontal and only
after it has been shut down for
about 5 minutes.
z Examining the viscosity and the
contamination of the oil smeared at
the oil level gauge replace the
engine oil if necessary.
CAUTION:
Do not add so much engine oil that the oil level rises above the max. marking
on the oil level gauge. Over lifting will result in damage to the engine.
4.6.4. Oil exchange procedure
While the oil is still hot, exchange oil
as follows:
z Take out the oil level gauge.
z Turn the valve opening and then
move the oil drain pump lever as
figure by hand, and let engine oil
discharge into the prepared vessel
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z Refill with new engine oil at the oil
filler neck on the head cover and
the lubricating oil in accordance
with the oil capacity of the engine
through oil filler. Be careful about
the mixing of dust or contaminator
during the supplement of oil. Then
confirm that oil level gauge
indicates the vicinity of its
maximum level.
z For a few minutes, operate the engine at idling in order to circulate oil through
lubrication system.
z Thereafter shut down the engine. After waiting for about 10 minutes measure the
quantity of oil and refill the additional oil if necessary
4.6.5. Replacement of oil filter cartridge
z At the same times of oil exchanges,
replace the oil filter cartridge.
z Drain engine oil by hand pump.
Oil filter
cartridge
Oil cooler
IMPORTANT:
Don't forget closing the drain pump
after having drained engine oil.
z Loosen the oil filter by turning it
counter-clockwise with a filter
wrench.
z With a rag wipe clean the fitting face of the filter body and the oil filter body so
that new oil filter cartridge can be seated properly.
z Lightly oil the O-ring and turn the oil filter until sealing face is fitted against the Oring. Turn 1-1/4 turns further with the filter wrench.
NOTE:
It is strongly advisable to use DOOSAN’s genuine oil filter cartridge for
replacement.
4.7. Cooling System
The coolant must be changed at intervals of 40,000km operation or six months
whichever comes first. If the coolant is being fouled greatly, it will lead an engine
overheat or coolant blow off from the expansion tank.
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4.7.1. Coolant draining
z Remove the drain plug from the
cylinder block and drain out the
cooling water into a container.
CAUTION :
When removing the drain plug
while the engine is still hot, so that
turn it slowly to release the internal
steam pressure. This will prevent a
person from scalding with hot
steam spouted out.
Drain valve
4.7.2. Cleaning of the cooling inside system circuit
When the cooling system circuits are fouled with water scales or sludge particles, the
cooling efficiency will be lowered. When the cooling system circuits are clogged, the
water pump mechanical seal is damaged.
The poor condition of the cooling system is normally due to use of unsuitable or no
anti-freezing agents and corrosion inhibitor or defect.
If twice in a short time (within 6 months) the water pump of an engine develops
leases or the coolant is heavily contaminated (dull, brown, mechanically
contaminated, gray or black sings of a leakage on the water pump casing) clean the
cooling system prior to removing that water pump as follows.
a) Drain coolant.
b) Remove thermostats, so that the whole cooling system is immediately flown
through when cleaned.
c) Fill the cooling system with a mixture of potable water and 1.5% by volume of
cleaner. (Henkel P3T5175)
d) Warm up engine under load. After a temperature of 60°C is reached, run engine
for a further 15 minutes.
e) Drain cleaning fluid.
f) Repeat steps c) and d).
g) Fill cooling system with hot water.
h) Run engine at idle for 30 minutes. At the same time continuously replenish the
water leaking from the bore in drain plug by adding fresh water.
CAUTION:
Periodically clean the circuit interior with a cleaner.
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4.8. Adjustment of Valve Clearance
4.8.1. General information
The valve clearances are to be adjusted at the times of the following situations.
z After initial 1,000km (50hours) operation.
z When the engine is overhauled and the cylinder heads are disassembled.
z When severe noise comes from valve train.
z When the engine is not normally operated, even though there is no trouble in the
fuel system. The valve clearance of the cold engine are as follows.
4.8.2. Adjusting order of the valve clearance
1) After letting the #1 cylinder's piston come at the compression top dead center by
turning the crankshaft, adjust the valve clearances.
2) Loosen the lock nuts of rocker arm adjusting screws and push the feeler gauge
of specified value between a rocker arm and a valve stem and adjust the
clearance with adjusting screw respectively and then tighten with the lock nut.
3) As for the valve clearance, adjust it when in cold, as follow.
Model
Intake Valve
Exhaust Valve
GE08TIC
0.3 mm
0.3 mm
z Adjusting Sequence of Valve Clearance (1 Type)
- By cranking the engine, let #6 cylinder's valves overlap.
- In time, adjust the valve clearance corresponding to “
” of lower lists.
- Adjust the valve clearance corresponding to “
” of lower lists.
- After reinsuring the valve clearances, retighten if necessary.
z No. 1 Cylinder is located at the side where flywheel was installed.
Crankshaft pulley
125
Intake valve
Exhaust valve
Cylinder no.
Fly wheel
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z Adjusting Sequence of Valve Clearance (2 Type)
1 Type is the conventional and simple method, but if you have some problem to
adjust your engine, please try 2 type sequence. This is a precision method, but it
takes more times.
Valve overlapping on cylinder
(Intake & Exhaust valve)
1
5
3
6
2
4
Adjusting valves on cylinder
(Intake & Exhaust valve)
6
2
4
1
5
3
4.8.3. Method of adjusting the valve clearance
1) Loosen the lock-nuts ① using a
ring spanner.
2) Insert a thickness gauge of 0.3mm
between valve stem ② and rocker
arm ③.
3) Turn the adjusting bolts ④ using a
screw driver until the gauge can be
pulled out with some restriction.
4) After the adjustment fix the
adjusting bolt not to rotate and
tighten the lock-nut at the same
time.
5) Measure the clearance one more time and if necessary adjust again.
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4.9. Tightening the Cylinder Head Bolts
z The cylinder head bolts are to be
tightened in the sequence shown in
the illustrations, First tighten the
bolts slightly, then slightly more
again and finally tighten with a
torque wrench.
<Cylinder head bolts>
Bolt
Type
Specification
M14×1.5×146
1st : 6kg.m
Torque
2nd : 180°
3rd : 180°
(Angle torque)
z The tightening by excessive torque may cause the damages of the cylinder head
gaskets, the flanges of cylinder liners and the cylinder head bolts, therefore obey
the regular torque.
4.10. Cylinder Compression Pressure
z Stop the engine after warming it up,
then remove the spark plugs.
z Install a special tool (gauge
adapter) in spark plug hole and
connect the compression pressure
gauge to the adapter.
z Cut off fuel circulation, rotate the
starter, then measure compression
pressure of each cylinders.
Standard value
16 kg/cm2 over
Limit valve
13 kg/cm2
or less
Difference between
each cylinder
±10% or less
- Testing conditions:
At water temperature of 20°C
and speed of 200 rpm
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4.11. Belts
The tension of the belts should be checked after every 2,000 hours of operation.
1) Change the belts if necessary
If in the case of a multiple belt drive, wear or differing tensions are found, always
replace the complete set of belts.
2) Checking condition
Check belts for cracks, oil, overheating and wear.
3) Testing by hand
By the finger-pressure the belt is
pressed by 10-15mm between the
pulleys
in
normal
condition.(Pressed
mid-way
between the belt pulleys)
A more precise check of the V-belt
tension is possible only by using a
V-belt tension tester.
4) Measuring tension
① Lower indicator arm (1) into the
scale.
z Apply tester to belt at a point
midway between two pulleys
so that edge of contact
surface (2) is flush with the
V- belt.
z Slowly depress pad (3) until
the spring can be heard to
disengage. This will cause
the indicator to move
upwards.
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z If pressure is maintained after
the spring has disengaged a
false reading will be obtained.
② Reading of tension
z Read of the tensioning force
of the belt at the point where
the top surface of the
indicator arm (1) intersects
with the scale.
z Before taking readings make
ensure that the indicator arm
remains in its position.
z V-belt tension
Tensioning forces on the tester
Type
M
A
B
C
new installation
Drive belt width
9.5 mm
11.8 mm
15.5 mm
20.2 mm
Installation
After 10 min.
running time
50 kg
55 kg
75 kg
75 kg
45 kg
50 kg
70 kg
70 kg
When servicing after
long running time
40 kg
45 kg
60 kg
60 kg
5) Tensioning and changing belts
z Loosen fixing bolts and nuts.
z Adjust the alternator until belts
have correct tensions.
z Retighten fixing bolts and nuts.
To change the belts loosen
fixing bolts and nuts. Then push
the alternator toward water
pump pulley by hand.
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5. Maintenance of Major Components
5.1. Cooling System
5.1.1. General information
z This engine is water-cooling type. Heat from the combustion chamber and engine
oil heat are cooled down by coolant, resulting in the normal operation of the
engine.
z Looking into the cooling system, the water pumped up by the water pump
circulates around the oil cooler through the water pipe to absorb the oil heat, and
then flows through the water jacket of the cylinder block and water passage of the
cylinder head to absorb the heat of the combustion chamber.
5.1.2. Specification
Item
Type
Pump speed
Water pump
Delivery capacity
Operation pressure
Allowable back pressure
130
Specification
Centrifugal type
2,000 rpm
2,700 rpm
about 190 liter/min
about 280 liter/min
0.5 bar
0.8 bar
bellow 0.5 bar
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5.1.3. Diagnostics and troubleshooting
Complaints
1. Engine overheating
Possible causes
z
z
z
z
z
z
2. Lack of coolant
z
z
z
z
z
Replenish coolant
Adjust or replace fan belt
Replace fan belt
Repair or replace
Clean intercooler and water
passages
z
Adjust
correctly
Replace
gasket
Gases
leaking
into z
water jacket due to
broken cylinder head
gasket
z
z
Intercooler leaky
Intercooler
hoses
loosely connected or
damaged
Water pump leaky
Cylinder head gasket
leaky
Cylinder
head
or
cylinder block cracked
z
131
Lack of coolant
Belt loosened or broken
Belt fouled with oil
Water pump defective
Restrictions in water
passages
due
to
deposit of scales
Ignition timing incorrect
z
z
z
3. Cooling system
noisy
Corrections
z
Water pump
defective
ignition
cylinder
timing
head
z
z
Correct or replace
Retighten clamps or replace
hoses
z
z
Repair or replace
Replace
cylinder
head
gasket
Replace cylinder head or
block
z
bearing z
Replace bearing
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5.2. Lubricating System
5.2.1. General descriptions and specifications
z General descriptions
All the engine oil pumped up from the oil pan by the gear type oil pump is filtrated
through the oil cooler and oil filter, and this filtrated oil is forced through the main
oil gallery in the cylinder block from where it is distributed to lubricate the various
sliding parts in order to ensure normal engine performance.
z Specifications
Item
Lubricating system
Specifications
Item
Forced pressure Oil filter type
Specifications
Full flow
circulation
Oil pump type
Relief valve opening pressure
Gear type
Bypass for filter element
2
10±1.5 kg/cm
Bypass for oil cooler
Opening pressure
Valve opening pressure
1.8 ~ 2.3 kg/cm2
Bypass for entire oil filter
5+1 kg/cm
2
Valve opening pressure
4.0 ~ 4.8 kg/cm
2
Adjusting valve for spray nozzle
Opening pressure
1.5 ~ 1.8 kg/cm2
z Diagram of lubricating system
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5.2.2. Oil pump
z Disassembly
(1) Disassembly of oil pump drive
gear
a. Unscrew the screw and
disassemble the oil relief valve.
b. Unfold the washer for the oil
pump drive gear fixing nut and
remove the nut.
c. Disassemble the drive gear.
(2) Remove the oil pump cover
fixing nuts and disassemble the
oil pump cover.
The oil pump cover is fixed with
the two dowel pins.
(3) Disassemble the drive gear and
driven gear.
z Inspection and correction
(1) With steel rule and feeler gauge,
measure the axial end play of
the oil pump gear. Replace if the
measured value is beyond the
limit.
End play limit
0.025 ~ 0.089 mm
(2) With a feeler gauge, measure
the amount of backlash between
the oil pump drive gear and
driven gear. Replace if the
measured value is beyond the
limit.
Backlash limit
133
0.50 ~ 0.64 mm
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(3) Measuring clearance between
drive shaft and bushing
a. Measure
the
outside
diameters of the drive shaft
and driven shaft, and replace
if the measured values are
less
than
the
limit
(φ16.95mm)
Standard
φ16.95 ∼ φ16.968 mm
b. Measure the inside diameter
of the pump body bushing to
determine the clearance
between the bushing and
shaft, and compare the
measured value with the
standard value to determine
whether to replace or not.
Clearance
0.032 ~ 0.077 mm
z Reassembly
(1) For reassembly, reverse
disassembly sequence.
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the
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5.2.3. Diagnostics and troubleshooting
Complaints
1. Oil consumption
excessive
2. Oil pressure too low
Possible causes
z
Poor oil
z
z
Oil seal or packing leaky
z
Pistons or piston rings z
worn
z
Cylinder liner worn
z
Piston rings sticking
z
Valve guide oil seals or
valve guides, or valve stem z
worn
z
z
z
135
z
Use suggested oil
Replace
Replace pistons
piston rings
z
Replace cylinder liner
z
Replace pistons
piston rings
and/or
and/or
Replace
z
z
Use suggested oil
Replace
z
Clean strainer
z
z
z
Replace
Replace
Correct or replace
z
Correct or replace
z
Poor oil
Relief valve sticking
Restrictions in oil pump
strainer
Oil pump gear worn
Oil pump feed pipe cracked
Oil pump defective
Oil
pressure
gauge
defective
Various bearings worn
z
Replace
z
Restriction in oil filter
z
Replace filter element
z
Gases leaking
z
z
Wrong oil used
Replace piston rings and
cylinder liner
Use suggested oil
z
z
z
z
3. Oil deteriorates
quickly
Corrections
z
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5.3. Turbocharger
5.3.1. Main data and specifications
1) Main data and specifications
Specification
Turbocharger model
at maximum
output
Air pressure
at compressor outlet
GE08TIC
HX35G-8233AJ/J13S11
1.8 kg/cm
2
Air suction volume
16.8 m3/min
Speed of turbine revolution
80,000 rpm
Maximum allowable speed
130,000 rpm
Max. allowable temperature of exhaust gas
at turbine inlet
Lubricating system
720 °C
External oil supply
Weight
14 kg
2) Construction
1. Impeller casing
136
A. Air inlet
2. Turbine casing
B. Gas outlet
3. Bearing casing
C. Gas inlet
4. Impeller
D. Oil supply
5. Turbine
E. Oil return
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3) Construction
137
4
Bearing housing
32
O-ring
67
Hex bolt
5
Turbine housing
33
Oil baffle
74
Actuator ass`y
6
Turbine wheel ass`y
34
Inlet baffle
75
Hose clamp
7
Compressor wheel
36
Thrust collar
77
Actuator clip
8
Compressor housing
38
Heat protector cover
80
Cover plate
11
Journal bearing
43
Oil seal plate
81
Hose
12
Thrust bearing
46
Gasket
82
Elbow
13
Piston ring seal(turbine)
57
Hex bolt
83
Hex nut
16
Piston ring seal
61
Lock nut
88
Clamp plate
22
Retainer ring
64
Snap ring
91
Retaining ring
31
Oil stopper
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3) Operating principle
The turbocharger is a system designed to make use of the engine exhaust gas
energy to charge high-density air into the cylinders, thereby to increase the
engine output.
5.3.2. General descriptions
The engine output is determined by the fuel delivery volume and engine efficiency.
To burn the supplied fuel completely to change into effective power for the engine,
the volume of air enough to burn the fuel completely should be supplied into the
cylinders.
Therefore, the engine output is determined substantially by the cylinder capacity, and
a greater volume of compressed air is charged into cylinders of given capacity, the
greater engine output can be obtained as a greater volume of air charged into the
cylinders burns so much more fuel.
As explained, the compressing of air to supply into the cylinders is called
"Supercharging" and the making use of the energy of exhaust gas discharged from
the combustion chamber to charge the compressed air into the cylinders is called
"Turbocharging".
5.3.3. Functions
1) Turbine
Exhaust gas discharged from the combustion chamber distributes its own energy
to the turbine blades while passing the inside of the turbine housing, with the
result that the turbine shaft can get rotating force. This is the operating principle of
'turbine', which is mounted with seal rings and heat protector to prevent exhaust
gas from affecting the bearings adversely.
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2) Compressor
The compressor, which is connected to the turbine over the one and same shaft
to form a rotating body, takes in and compresses ambient air with rotating force
transmitted from the turbine shaft. Then, the compressed air is delivered to the
intake stake. This is the operating principle of the compressor.
3) Bearings
(1) Thrust bearing
The turbine wheel creates thrust force. Therefore, exercise care so that the
shaft is not deviated from its the original position due to this thrust.
(2) Journal bearing
This journal bearing of floating type forms a dual oil film on both the inside and
outside of the bearing so that the bearing can rotate independently. As the dual
oil film plays a role as a damper, the sliding speed of the bearing surface
becomes lower than the rotating speed of the shaft, resulting in assurance of
stability in its movement.
4) Sealing - Compressor shaft
The compressor is of a dual construction type composed of seal plate and seal
ring to prevent the leak of compressed air or lubricating oil.
5.3.4. Precautions for operation
1) Precautions for operation of engine
The following precautions should be observed when starting, operating, or
stopping the engine:
Operations
When starting
Precautions
Reasons
1) Check oil level
the engine
2) Crank the engine with starter to
check
the
increase
2) Abrupt starting of the engine
oil
causes the engine to rotate with
of
oil not being distributed not only
pressure gauge starts to move or
to each part but also to the
pressure
indicator
turbocharger,
actuated)
before
pressure(until
the
in
needle
lamp
starting
is
the
engine.
resulting
in
abnormal wear or seizure on the
bearing due to insufficient supply
of oil.
3) When having replaced oil, oil
3) In the case of the engine stopped
filter element, or lubricating parts,
for extended time or in a cold
or when having stopped the
place, oil fluidity within the pipes
engine for extended period of
can be deteriorated
time, or in a cold place, loosen
the oil pipe connections and
operate the starter motor until oil
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is discharged. After completing
the
operation,
be
sure
to
retighten the oil pipe connections
portion before starting the engine.
Immediately
after starting
1) Run the engine at idle for 5
1) Applying load abruptly If load is
minutes after starting off.
abruptly applied with the engine
and
turbocharger
rotating
unsmoothly, such parts that a
sufficient amount of oil has not
reached can be seized up.
2) Check each part for leakage of
2) Leakage of oil, gas, and air
oil, gas, and air, and take proper
(especially, oil leak) causes drop
measure.
in oil pressure and loss of oil
results in seizure of the bearing.
During operation
Check the followings:
1) Oil pressure At idle: 0.8 kg/cm2 or
1) Excessively low oil pressure
2
causes unusual wear or seizure
more At full load: 3.0~4.8 kg/cm
of the bearing. Too high pressure
causes oil leakage.
2) If unusual sound or vibration is
When stopping
the engine
2)
The
engine
Is
operated
heard or felt, reduce engine
continuously with unusual sound
revolutions slowly and locate the
or vibration not corrected, it can
cause.
be damaged beyond repair.
1) Run the engine at idle for 5
minutes before stopping.
1) If the engine is put to a stop after
being operated at high load, heat
from the red-hot turbine blades is
transmitted to the bearing portion
and burns oil to cause seizure of
the bearing metal and rotating
shaft.
5.3.5. Walk-around check and servicing
As the condition of turbocharger depends greatly on how well the engine is serviced,
it is very important to maintain the engine in accordance with the specified
maintenance procedure.
1) Intake system
Pay particular attention to the air cleaner when servicing the intake system.
In the case of wet-type air cleaner, if the level of oil surface is lower than specified,
cleaning effect is poor; if too high, the cleaner draws in oil to foul the case.
Especially, if the rotor is fouled, the sophisticatedly-tuned balance is broken to
create vibration and to cause seizure and unusual wear to the bearing.
Therefore, it is very important to use a good quality air cleaner all the time.
In the case of dry-type air cleaner, it is essential to clean it to reduce intake
resistance as much as possible.
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2) Exhaust system
Pay particular attention to prevent gas leaks and seizure when servicing the
exhaust system because leakage of exhaust gas from discharge pipes,
turbocharger fixing portions, etc. lowers charging effect.
As such components as turbine chamber that becomes red-hot during operation
use heat resisting steel nuts, do not interchange these nuts with ordinary steel
nuts. In addition, apply anti-seizure coating to fixing nuts on the portions as
designated.
3) Lubricating system
Pay particular attention to oil quality and oil filter change intervals when servicing
the lubricating system. Deteriorated engine oil affects adversely not only the
engine but torso the turbocharger. Suggested engine oils for the turbochargermounted engine are as follows:
Recommend oil
SAE No.
API No.
Sulfated ash
content
SAE 15W40
above CD or CE
Bellow 0.5 %
Engine model
GE08TIC
Recommend oil : TOTAL LMG-405
Mobil Delvac super GEO 15W40
5.3.6. Periodical checking and servicing
Make it a rule to check the turbocharger assembly for condition and contamination
periodically.
1) Guide for checking the rotor for rotating condition
The inspection of the rotor assembly for rotating condition should be performed by
the degree of unusual sound. If a sound detecting bar is used, install its tip on the
turbocharger housing and increase the engine revolutions slowly. If a high-pitch
sound is heard continuously, it means that the rotor assembly is not normal. In
this case, as the metal bearing and rotor are likely to be in abnormal conditions,
the turbocharger should be replaced or repaired.
2) Guide for checking rotor end play
Disassemble the turbocharger from the engine, then check the rotor axial play
and radial play.
When disassembling the turbocharger, be sure to plug the oil inlet and outlet ports
with taps, etc.
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(1) Rotor axial play
(2) Rotor radial play
(3) If the measured axial and radial plays are beyond the limit of wear, replace or
repair the turbocharger.
3) Guide for disassembling/cleaning and checking the turbocharger
First, disassemble the turbocharger from the engine and clean/check it with the oil
inlet and outlet plugged with tape and so on.
4) Precautions for reassembling the turbocharger onto the engine
For reassembly of the turbocharger or handling it after reassembly operation, be
sure to observe the following precautions:
Especially, exercise extreme care to prevent foreign matters from entering the
inside of the turbocharger.
(1) Lubricating system
z Before reassembling the turbocharger onto the engine, inject new oil in the
oil inlet port and lubricate the journal and thrust bearings by rotating them
with hand.
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z Clean not only the pipes installed between the engine and oil inlet port but
also the oil outlet pipe and check them for damage or foreign matters.
z Assemble each joint on oil pipes securely to prevent oil leaks.
(2) Intake system
z Check the inside of the intake system for foreign matters.
z Assemble each joint on the intake duct and air cleaner securely to prevent
air leaks.
(3) Exhaust system
z Check the inside of the exhaust system for foreign matters.
z Be sure to use heat resisting steel bolts and nuts. Do not interchange them
with ordinary steel bolts and nuts when performing reassembly operation.
Apply anti-seizure coating to the bolts and nuts.
z Assemble each joint on the exhaust pipes securely to prevent gas leaks.
5.3.7. Diagnostics and troubleshooting
Complaints
1. Excessive black smoke
Possible causes
Corrections
1) Air cleaner element clogged
Replace or clean
2) Restrictions in air duct
Check and correct
3) Leakage at intake manifold
Check and correct
4) Turbocharger seized up and not rotating
5) Turbine blades and compressor blades coming
in contact with each other or damaged
Disassemble/repair
1) Oil leak into turbine and compressor
or replace
wear of bearing
1) Gas leak at each part of exhaust system
Check and correct
2) Air cleaner element restricted
Replace or clean
Disassemble/repair
or replace
4) Leakage at discharge port on compressor side
vibration
1) Rotor assembly coming in contact
2) Unbalanced rotation of rotor
3) Seized up
4) Each joint loosened
143
Disassemble/repair
or replace
3) Turbocharger fouled or damaged
4. Unusual sound or
Disassemble/repair
Check and correct
2) Worn or damaged seal ring due to excessive
3. Low engine output
or replace
or replace
6) Exhaust piping deformed or clogged
2. Excessive white smoke
Disassemble/repair
Check and correct
Disassemble/repair
or replace
Disassemble/repair
or replace
Disassemble/repair
or replace
Check and correct
Maintenance of Major Components
Printed in May 2005 PS-MMG0416-E1A
GE08TIC
Operation and Maintenance Manual
5.4. Air Intake System
5.4.1. Maintenance
(only when engine is switched off)
Empty the dust bowl (7) regularly. The bowl should never be filled more than halfway
with dust.
On slipping off the two clamps (3), the dust bowl can be removed. Take off the cover
(6) of the dust bowl and empty.
Be careful to assemble cover and bowl correctly.
There is a recess in the cover rim and a lug on the collector which should register.
Where the filter is installed horizontally, watch for “top” mark on cleaner bowl.
1. Connection port,
fouling indicator
2. Cleaner housing
3. Clamp
4. Element
5. Hexagon nut
6. Cover
7. Dust bowl
5.4.2. Changing filter element
z On removing the hexagon nut, take
out the dirty cartridge and renew or
clean.
z Wipe the cleaner housing with a
damp cloth, in particular the sealing
surface for the element.
NOTE:
Do not allow dirt to get into the
clean air end.
144
Maintenance of Major Components
Printed in May 2005 PS-MMG0416-E1A
GE08TIC
Operation and Maintenance Manual
5.4.3. Cleaning filter elements
z By compressed air
(wear goggles)
- For the purpose, the air gun should
be fitted with a nozzle extension
which is bent 90° at the discharge
end and which is long enough to
reach down inside to the bottom of
the element.
- Moving the air gun up and down,
blow out the element from the
inside (maximum 500kPa - 5 bar)
until no more dust comes out of the filter pleats.
z By washing
- Before washing, the element should
be precleaned by means of
compressed air, as described
above.
- Then allow the element to soak in
lukewarm washing solvent for 10
minutes, and then move it to and
for in the solvent for about 5
minutes.
- Rinse thoroughly in clean water, shake out and allow drying at room temperature.
The cartridge must be dry before it is reinstalled.
- Never use steam sprayers, petrol (gasoline), alkalis or hot liquids etc. to clean
the filter elements.
z Knocking out dirt by hand
- In emergencies, when no compressed air or cleaning agent is available, it is
possible to clean the filter cartridge provisionally by hitting the end disk of the
cartridge with the ball of one's thumb.
- Under no circumstances should the element be hit with a hard object or knocked
against a hard surface to loosen dirt deposits.
z Checking the filter cartridge
- Before reinstalling the cartridge, it
must be checked for damage e.g.
to the paper pleats and rubber
gaskets, or for bulges and dents
etc. in the metal jacket.
- Cracks and holes in the paper
pleating can be established by
inspecting the cartridge with a
flashlight.
- Damaged cartridges should not be reused under any circumstances. In cases of
doubt, discard the cartridge and install a new one.
145
Maintenance of Major Components
Printed in May 2005 PS-MMG0416-E1A
GE08TIC
Operation and Maintenance Manual
6. Special Tool List
No.
Part no.
1
EF.123-173
Tool name
Descriptions
Applications
Oil seal insert ass’y(Front)
Tool
2
EF.123-184
Oil seal insert ass’y (Rear)
3
EF.123-052
Oil seal puller ass’y (Front)
4
EF.123-048
Oil seal puller ass’y (Rear)
5
EF.123-193
Cylinder pressure tester adapter
6
EF.123-365
Cylinder liner puller ass’y
Tool
7
EF.123-179
Valve stem seal punch
8
EU.2-0131
Valve clearance adjust ass’y
9
EF.123-065
Valve spring press
146
-
Special Tool List
Printed in May 2005 PS-MMG0416-E1A
GE08TIC
Operation and Maintenance Manual
No.
10
Part No.
EU.2-0647
Tool name
Descriptions
Applications
Crankshaft gear punch
Tool
EF.123-064
(GE08TIC only)
11
Piston sleeve
EF.120-208
(All engine)
12
60.99901-0027
Feeler gauge
13
65.98801-0001
Filter wrench
14
T7610001E
Snap ring plier
15
T7621010E
Piston ring plier
147
Special Tool List
Printed in May 2005 PS-MMG0416-E1A
GE08TIC
Operation and Maintenance Manual
Appendix
z Tightening torque for major parts
Screw
Major Parts
(Diameter x pitch)
Strength
Tightening torque Remarks
(grade)
1st : 6.0 kg.m
Cylinder head bolt
M14 x 1.5
2nd : 180。
10.9T
3rd : 150。
(Angle method)
1st : 10 kg.m
Connecting rod bearing cap bolt
M14 x 1.5
12.9T
2nd : 15 kg.m
3rd : 18 kg.m
1st : 15 kg.m
Crankshaft main bearing cap bolt
M16 x 1.5
12.9T
2nd : 25 kg.m
3rd : 30 kg.m
Balance weight fixing bolt
M12 x 1.5
10.9T
9.0 kg.m
Flywheel housing fixing bolt
M14 x 1.5
10.9T
8.0 kg.m
Flywheel fixing bolt
M14 x 1.5
10.9T
21.5 kg.m
Crankshaft pulley fixing bolt
M12 x 1.5
10.9T
13.4 kg.m
Oil spray nozzle
M14 x 1.5
-
7.0 kg.m
z Tightening torque for plug screw
Diameter
M10x1.0 M12x1.5 M14x1.5 M16x1.5 M18x1.5 M22x1.5 M26x1.5 M30x1.5
x pitch
Torque
(kg.m)
5.0
5.0
8.0
8.0
10.0
12.0
12.0
15.0
z Tightening torque for hollow screw(4-hole)
Material
SM25C
*
SUM22L
STS304
M8
0.8
0.8
M10
1.6
1.8
1.8
M12
2.5
3.0
3.0
M14
3.5
4.0
4.0
M16
4.5
5.5
5.5
M18
5.5
6.5
6.5
M22
9.0
11.0
11.0
M26
13.0
16.0
16.0
M30
18.0
20.0
20.0
M38
30.0
35.0
35.0
* : Adopted in DOOSAN’s engine
148
Appendix
Printed in May 2005 PS-MMG0416-E1A
GE08TIC
Operation and Maintenance Manual
z Standard bolt tightening torque table
Refer to the following table for bolts other then described above
Degree of strength
Diameter
x
pitch
(mm)
3.6
4.6
4.8
5.6
5.8
6.6
6.8
(4A)
(4D)
(4S)
(5D)
(5S)
(6D)
(6S)
6.9
8.8
10.9
12.9
(6G) (8G)
(10K)
(12K)
64
90
108
0.5
0.9
1.4
2.2
2.4
4.4
5
7.5
8
12
13
18
20
25
28
36
41
49
56
63
74
0.75
1.25
1.95
3.1
3.35
6.2
7
10.5
11.2
17
18.5
26
28
36
41
51
58
67
75
82
93
0.9
0.5
2.35
3.8
4.1
7.4
8.4
12.5
13.4
20
22
31
33
43
49
60
68
75
85
92
103
Limit value for elasticity (kg/mm2)
20
24
32
30
40
0.15
0.28
0.43
0.7
0.73
1.35
1.5
2.4
2.55
3.7
4.1
5.6
6.2
7.8
9.1
11.5
12.8
15.5
17
20.5
23
0.16
0.30
0.46
0.75
0.8
1.4
1.6
2.5
2.7
3.9
4.3
6
6.5
8.3
9.5
12
13.5
16
18.5
21.5
25
0.25
0.45
0.7
1.1
1.2
2.2
2.5
3.7
4
6
6.6
9
9.7
12.5
14.5
18
20.5
24.5
28
33
37
0.22
0.4
0.63
1
1.1
1.9
2.1
3.3
3.5
5.2
5.7
8
8.6
11
12.5
16
18
21
24
27
31
36
48
54
Tightening torque (kg.m)
M5
M6
M7
M8
M8x1
M10
M10x1
M12
M12x1.5
M14
M14x1.5
M16
M16x1.5
M18
M18x1.5
M20
M20x1.5
M22
M22x1.5
M24
M24x1.5
0.31
0.55
0.83
1.4
1.5
2.7
3.1
4.7
5
7.5
8.3
11.5
12.5
16
18.5
22
25
30
34
40
45
0.28
0.47
0.78
1.25
1.34
2.35
2.8
4.2
4.6
7
7.5
10.5
11.3
14.5
16.7
19
22.5
26
29
34
38
0.43
0.77
1.2
1.9
2.1
3.7
4.3
6.3
6.8
10
11.1
17.9
17
21
24.5
31.5
35
42
47
55
61
0.48
0.85
1.3
2.1
2.3
4.2
4.9
7.2
7.7
11.5
12.5
18.5
19.5
24.2
27.5
35
39.5
46
52
58
67
Others :
1. The above torque rating have been determined to 70% or so of the limit value
for bolt elasticity.
2. Tension is calculated by multiplying tensile strength by cross section of thread.
3. Special screws should be tightened to 85% or so of the standard value.
For example, a screw coated with MoS2 should be tightened to 60% or so of
the standard value.
149
Appendix
Printed in May 2005 PS-MMG0416-E1A
GE08TIC
Operation and Maintenance Manual
z Maintenance specification table
(Unit : mm)
Group
Part
Inspection Item
Stand value
for assembly
Limit
for use
Inside diameter of
φ111~φ111.022 φ111.122
cylinder liner for wear
Engine
body
Cylinder Amount of liner
block & projection
liner
The flatness of upper
surface of cylinder
block
Hydraulic test for 1
minute (kg/cm2)
Valve seat Intake
depression Exhaust
Cylinder
head & Cylinder head height
valve
Hydraulic test for 1
minute (kg/cm2)
Outer diameter of
piston
Clearance between
piston and liner
Piston
Width
of
piston ring
grooves
Major
moving
parts
Piston
ring
150
Replace liner
-
Need amount of
projection without
fail
0.05
-
Correct with a
surface grinder
4
-
Replace if leaky
0~0.3
0~0.3
0.55
0.55
109.9 ~110.1
108.4
Replace valve
seat
Replace cylinder
head
4
-
Top ring
-
-
2nd ring
3.06~3.08
-
Oil ring
4.04~4.06
-
0 ~ 0.12
Water temperature
70°C
Measure at 13mm
away from lower
surface of piston
Replace if leaky
Replace one worn
more
Replace piston if
groove width is
beyond specified
value
Measure unworn
portion beneath the
rim of the upper
side
Must exist
Permissible weight
difference of each
piston
Top ring
Piston ring 2nd ring
gap
Oil ring
±15 g
96 g↓
0.40~0.60
0.40~0.60
0.30~0.50
1.5
1.5
1.5
Top ring
2nd ring
Oil ring
0.07~0.102
0.05~0.085
0.15
0.15
-
-
φ41.994 ~ φ42.000
φ41.94
Replace piston pin
0.003~0.015
0.08
Replace one worn
more
Piston ring
side
clearance
Outer diameter of
piston pin
Clearance
between
piston pin and its bush
Measure unworn
portion beneath the
rim of the upper
side
Projection
difference between
adjacent liners :
0.15 ↓
Referenced length :
200mm
Replace liner
φ110.758~φ110.772
0.3
Direction of ring gap
Piston
pin
Remark
0.03~0.08
0.228~0.264
Piston projection from
cylinder block upper
surface
Correction
Replace piston
Standard
gauge
inside diameter :
φ108
Replace ring
Replace ring or
piston
Cross
120°
Install
Limit for use is if for
standard clearance
by
Appendix
Printed in May 2005 PS-MMG0416-E1A
GE08TIC
Operation and Maintenance Manual
(Unit : mm)
Group
Part
Stand value
for assembly
Limit
for use
-
0.01
Correct
with a grinder
φ83.966~φ83.988
φ83
φ70.971~φ70.990
φ70
Use under sized
bearings
respectively
(0.25,0.5,0.75,1.0)
0.008
0.025
0.01
0.03
0.02
0.03
0.052~0.122
0.25
Replace bearings
End play of crankshaft
0.15~0.325
0.5
Replace
thrust bearing
Run-out of crankshaft
0.06
0.1 ↓
Balance of crankshaft
(g.cm)
Torque value journal
bearing cap bolt
(kg.m)
60 ↓
Inspection Item
Radial run-out of
journal and pin
Crank
shaft
Outside diameter of
journal
Outside diameter of
pin
Ellipticity of journal
and pin
Concentricity of
journal and pin
Taper of journal and
pin
Clearance between
crankshaft
and
bearing
Crush
height
journal bearing
Oil seal for wear(crank
shaft rear)
End play of con-rod
Clearance
between
con-rod bearing and
crank pin
Clearance
between
small end bush &
piston pin
Major
moving
parts
Connecting
rod
Cam
shaft
Timing
gear
151
of
Crush height of conrod bearing
Correction
Adjust by a press
if bended
dynamic
60 or less Check
balance
Coat the bolt with
engine oil
30
-
0.08~0.110
-
-
-
0.170 ~ 0.248
0.50
Replace oil seal
if oil leaking
Replace con-rod
0.034 ~ 0.098
0.25
Replace bearing
0.050~0.081
0.12
0.04~0.07
-
Side clearance of bigend and small-end
Allowable weight
difference per con30 g ↓
rods
Torque value of
con-rod bearing cap
18
bolt (kg.m)
Diameter of cam shaft φ57.86~φ57.88
journal
Clearance
between
cam shaft and cam
0.12~0.17
bush
0.50
Measure in horizontal
and vertical directions
(against axial direction)
Measure at crown
part not parting line
Measure
at
No.4
bearing (No. 1 & 7
bearing supported)
Measure at 400 rpm
Clean out foreign
objects on joining
surface
Measure
after
tightening metal cap
and releasing one
stud
Measure after installing
the
bearing
and
releasing one bolt
Replace con-rod
-
Coat the bolt with
engine oil
Clean out foreign
objects on joining
surface
φ57.52
0.24
Replace cam bush
Replace
thrust
washer
Correct or replace
the cam shaft
End play of camshaft
0.28~0.43
0.6
Run-out of camshaft
0.05
0.2
0.025~0.091
0.15
0.043~0.167
0.3
Replace
collar
0.16~0.28
0.35
Correct or replace
gear
Clearance
between
idle shaft bush and
idle shaft
End play of idle gear
shaft
Back-lash between
gears(cam, idle, crank
and ignition timing)
Remark
thrust
Appendix
Printed in May 2005 PS-MMG0416-E1A
GE08TIC
Operation and Maintenance Manual
(Unit : mm)
Group
Part
Valve
Valve
system
Inspection Item
Stand value
for assembly
Diameter of intake φ8.950~φ8.970
valve stem
Diameter of
φ8.935~φ8.955
exhaust valve stem
Clearance
Intake
0.030~0.065
between
valve stem
and
valve Exhaust 0.045~0.080
guide
Thickness
Intake
2.7
of
valve
Exhaust
2.2
head
Clearance
Intake
2.0
between
valve guide
and
valve Exhaust
2.0
spring seat
Clearance
between
valve
guide
and -0.039~-0.010
cylinder head
(Press fit)
installing hole
Concentricity between
valve stem and valve
0.05
head
Free
length Approx. 64
(mm)
Tension force
Intake (when pressed
67~73
valve
to 41mm)kg
spring Squareness
(along
free
1.5°
length
direction)
Free
length
60
(mm)
Tension
force(when
Inner pressed to 26.9~30.3
38mm)kg
Squreness
(along free
1.5°
length
Exhaust
direction)
valve
spring
Free
71
length
Tension
force(when 62.7~69.3
Outer pressed to
41mm)kg
Squreness
(along free
1.5°
length
direction)
Valve
Intake
0.3
clearance
(at cold)
Exhaust
0.3
Joining surface of
valve stem and rocker
arm bush
-
Limit
for use
φ8.93
φ8.91
0.15
0.15
Max. 1
Remark
Replace
Valve &
guide
valve
When
replacing
valve, replace valve
guide alike
Replace
valve or
guide
valve
Replace one worn
more
Replace valve
Spread oil over
valve guide and
press it into the
hole
Without spring seat
66.5
Replace
valve spring
-
Replace
valve spring
-
Replace
valve spring
-
Clearance between
rocker arm shaft &
0.040~0.113
0.2
rocker arm bush
Diameter of rocker φ23.939~φ23.96 φ23.75
arm shaft for wear
Run-out of push rod
0.3
152
Correction
Adjust
Grind or replace if
severely pitted on
tip of rocker arm
and stem
Replace bush
or shaft
Replace
Replace
Appendix
Printed in May 2005 PS-MMG0416-E1A
GE08TIC
Operation and Maintenance Manual
(Unit : mm)
Group
Part
Valve
Tappet
system
Inspection Item
Clearance between
tappet & tappet hole
of cyl. block
Diameter of tappet
Tappet face in contact
with cam
Oil
pressure
Oil
temperature
Lubrica Oil
pump
ting
system
Oil pressure
(at normal speed)
kg/cm2
Oil pressure
2
(idling) kg/cm
Max. permissible
oil temperature °C
Permissible
oil temperature
in short time °C
Axial play
of oil pump gear
Clearance
between
gear shaft & oil pump
cover hole
Clearance
between
drive gear shaft and
cover hole
Diameter of gear shaft
Diameter of driving
gear bush
Between
crank
gear & idle
gear
Backlash
Between oil
pump drive
gear &
idle gear
Oil pressure control
2
valve (kg/cm )
By-pass valve for filter
element (kg/cm2 )
Valve
By-pass valve for full
opening
2
oil filter (kg/cm )
pressure
Relief valve for oil
2
pump (kg/cm )
Spray nozzle control
2
valve (kg/cm )
Damage of oil filter
Oil filter
cartridge
153
Stand value
for assembly
Limit
for use
0.035~0.077
0.15
φ19.944~φ19.965
-
-
-
4.8 or less
3.5
0.8~1.4
0.6
-
105
-
120
0.055 ~ 0.105
-
0.032 ~ 0.077
-
0.040 ~ 0.094
-
Correction
Remark
Replace tappet
Replace tappet
Replace
if severely worn or
deformed
Check oil leakage
and clearance
between each part
Use
recommended
oil
Must not
this value
Replace gear
or cover
Replace bush
or cover
φ16.950~φ16.968
Replace gear
shaft
φ17e7
φ28.000~φ28.033
Replace bush
φ28e7
0.15 ~ 0.25
exceed
0.8
Adjust back-lash
0.15 ~ 0.25
0.8
4.0 ~ 4.8
-
1.8 ~ 2.3
-
4.0 ~ 4.8
-
8.5 ~ 11.5
-
1.5 ~ 1.8
-
-
-
Replace valve
Replace valve
Clean or replace
Appendix
Printed in May 2005 PS-MMG0416-E1A
GE08TIC
Operation and Maintenance Manual
(Unit : mm)
Group
Part
Water
pump
Cooling
system
Cooling
water
temp
Ignition Spark
system plug
Inspection Item
Delivery volume l/min
- Engine speed
2,700rpm
- Water temp. 80°C
- Pressure : 0.8 kg/cm2
280
-
Clearance between
impeller & housing
0.35
-
Perpendicularity
of
pulley
Belt depression
(with thumb) mm
Operating temperature
(permissible temp.) °C
Permissible
temperature
in a short time °C
Gap of spark plug
Running-in the engine
Inspection
at
completion
154
Stand value
Limit
for assembly For use
Compression pressure
2
of cylinder (kg/cm )
Cylinder
Compression pressure
pressure
difference of each
cylinder
0.3
Approx. 15
-
79~95
-
Correction
Remark
Check the water
passage
For any restrictions
Replace if impeller
& housing are
damaged
Adjust by a bench
press
Adjust
Must not exceed
this value
-
105
0.39-0.40
-
Correct or replace
-
-
Refer to
supplement
“running-in”
16 or more
13 or
more
±10% or less
against
average
Correct
Correct
at 200rpm or more
(20°C)
Appendix
Printed in May 2005 PS-MMG0416-E1A
GE08TIC
Operation and Maintenance Manual
z
Engine Assembly
155
Appendix
Printed in May 2005 PS-MMG0416-E1A