A TIPS To protect and improve the quality of the enviranment, do fallow the below structions while running the engine: @ Fill the proper amount of fuel to the tank, Do not overfill to avoid the fuel overflow. @ Keep the engine out of “three kinds of leakages"(oil leakage, water leakage, alr leakage). Keep the cutlook of engine clean and good tadiation, @ Refill the proper amount of engine oil to the oil sump. Do not refill too much to avoid overflow, Mf Regularly replace the engine ail, engine oil filter element, fuel filter element and air cleaner element. To prevent the engine from exhaust ing black smoke, replace these parts more frequently when run the engine under dusty cenditions §@ Do not run the engine at overload, Reduce the load cornespondly when run the engine at high altiude, high temperature and high humidy areas. @ To keep the engine under the best working condition, regularly Inspect and adjust the air clearance, fuel delivery advance and injection pressure etc.CONTENTS Preface Preparation fer maintenance Safety precautions Chapter1. Main specifications and data... essa 4.4 Main technical specifications --..--.--------:ccsecccesnatnseesetenaeenennien 1.2 Name of diesel engine outer parts 1-1-1... Chapter. Technical maintenance of diesel engine 1... 2.1 Daily inspection and maintemance cscs 2.2 Perlodic inspection and maintenamee «0. 2.3 Long-term storages: cusses esas Chapter3. Disassembling and reassembling of diesel engine - 3.1 General procedures of disassembling © .)---.--..200-..0 3.2 General procedures of reassembling 061, 2 3.3 Recod starter assettibly.... sc... AB Chapter4 Inspection and maintenance .---.--.---0 oe 4.1 Cylinder head «..- 4.2 Piston and piston pin = 4.3 Connecting rod «..... wit 4.4 Crankshaft and flywheel ---..------.--.- 8d 4.5 Camshaft and tappet =... weak 4.6 Timing gear»... wl4.7 Crankcase cover --..- 4.8 Cylinder barrel and cylinder block 4.9 Lubricating system »-~ 4.10 Fuel oil system -- 4.11 Governor device ---. 4,12 Accumulator 4.13 Adjustment > Chapter5. Malfunction analysis -... 5,1 Fault analysis... sig 5,2 Unexpected reverses while starting --+--r-sr 5.3 Over-speed of the engine --..- 5,4 Unsteady rotating speed of the engine soseeneeneencennens hE 5,5 Drop-dead halt of engine ChapterS.Trial running ----. 6.1 Pre-checks before starting -- 6.2 Starting 6.3 Running »\------+--- 6,4 Shutdown Appendix! The parts difference between F type and S type engine «51A. To correctly service your engine are for your own safety, be sure to read this manual carefully, otherwise the accident will result, Hf you have problem about your engine, please contact with KAMA sales company or the authorized agent. PREFACE: WE This manual guides you how In service KAMA air-cooled diesel engine comectly, as well ae the warnings. Be sute to read this manual before operating, to keep your engine al the best warkng canditian. MB Should thie manual missing or destroyed, please male an order from your agent. If you have arpthing unclear about this manual, please contact your agent KAMA air-cooled diene! engine vil meel your requirement ifyou operate if acearding ta the manual inefrublion, Gthecwise the fire, snaid elt wecinue accident wi reeult. @ 50, KAMA reconfirm that you must to master this manual before operating the engine. Indicates that the serous personal injury even death wal result if the in- structions ara nat followed Indicates that the seious personal injury even death will result if the i structions are nat followed Indicates that the serious personal injury or equpment damage wil resu® if the instructions are nat fallawed, HG indicates Wak you Muel give sect! Benton while Servicing Ie engine. (Cthenvise the engine performance will decreabed even tre Maul will reeuit. Be sure to Iollow inePREPARATION FOR MAINTENANCE TO PERFORM MAINTENANCE SMOOTHLY AND EFFECTIVELY, YOU MUST GARRY OUT THE FOLLOWING PREPARATION: BB Investigating your users A Wher the last maintenance performed? 8. What about the maintenance performance of last time? 1 Storage of spare parts: A Spare parts and materials for maintenance must be in goad storage conditian B. You must have a full parts list in hand. @ Make a correct maintenance record: A. Working table B. Inspection record including parts record ©, Parts testing record; D. Working data { Holding of performance and quality Bf Tools and equipment needed: A. Tools B Measuring implement and appliance S. OthersSAFETY INFORMATION (To aperate the engine safely, pleae follow these dere strictly) To prevent the fire, please pay attention to the folhwing items: fogs, Mite anol le te into the engin she fe wl em, ae ety the Tuel tyae and mode! before remling Mé Be sure to stop the engine before refiling HE Woe off the cverfiowed uel cil, @ Keep the engine lar away Irom olher Nammable ails and goede. Be careful when use the battery: 8 The battery will exhaust hydrogen while charging. Oo charge the battery al the well verdilated place. Meanwtife, flare and spark are not allowed — while charging, ee WW The electrolyte it heavy acid solution, be sure skin and eyes do mot touch it, otherwise, rings with vrater immediately. 9 The exhaust is harmful io the health, de not run the engine at the con: fined rooms or uventiated places. Ifyou hawe to run the engine indoors, be sure there is. good ventilation equipment “e The exhaust is poisonous, pay attention to the following Be care no to be involved: 1 Do not touch the moving parts while the engine Ie running, mosrwhila, when the engine js linked to the load, please cover the coupler and bel ste parts which have potential danger before running Be care of the hot parts: The mnulfer and the engine body will ba very het during rur afier running, do not touch these parts ing ar just Other safety information: 1 Do pal operate the engine afer drinking MB Be sure that the eurrcunding is safe before starting the enigne. I Puton the uniform and arti-slippery shoes1, MAIN TECHNICAL SPECIFICATIONS AND DATA 1-1 Main technical specifications ther Technical specifications and data Model KMT7OF! FS KMITEFIFS KIA16FIFS Tyre Single-cylinder vertical, 4-stroke, air-cooled, ditect-injection engine Bore x strokeimm) 70» 55 7B x 62 86 = 70 Displacement(L) 2 0.296 0,406 Rated epeedirpm) ‘BoC01806) aeonetaod| 90001 00500 BOHONG TSAO seO0r BON Rated power Max. |23(3.6)] 3.10425) 4(5.4) | 4.408) [6.48.5)| G89) KVWPS) Cont (243.4)) 2.4/4.8)/3.7(5.0}) 4(5.4) |5.7(7.8)/6.9/8.6) Rotation direction | Counterclockewite viewed from the output shaft end, Valve clearance(mm) 0.1 = 0.15{cold state) Injection pressure | 200(19.6) Fuel Kgticm’{Mpa} ; Delivery advance wt Fuel tank capacity{L) 25 3.6 55 Specifications [Oa{summar|t GA winter} Lube [Lubricating system [Pressure and flashing oi | Specifications [SAE 10WV30 above CC grade Lube cil capacity(L) | O76 w 1.62 Staring system [Recoil sterter of electric starter Net weight( kes} fu <3 <44 IB Specifications and data may be vary with the improvement of the enigne, so the contents in the above table only for reference.not as the standard.1-2. Name of diesel engine outer parts Fussinjecten naan 2. TECHNICAL MAINTENANCE OF DIESEL ENGINE 2.1 Daily inspection and maintenance @ Check and tgnten the nuts and bolts; I Check the engine ail level which should between the high and low ling; @ Check whether there's fueUall leakage: IB Viipe off the dirty from the oil diesel engine and it's parts to keep the whale engine body clean; I Shoot any fault found during the operation.2.2 Periodic inspection and maintenance Periodic inspection and maintenance are very important for keeping the diesel en- gine in good working cendition with good durability, The following table indicates what is necessary and when to check the engine. Black remarks show that special teal or technique is required for maintenance. Any problem happened, please con- tact with your local Geaber Interval aa ee 20 hours = |100hours or |S00hoursar | 1000 hours her or 1_manth_jevery 3 months avery 6 months) or every year | Checkandtighten | nuts end balls Check and refuel | © Replace engine ol) fe a 1 (second time arsthmel | and later) Clean and replace Oo e fuibe od filter (Replace) Check fuel leakage CO Intervals of check and man- Renters sit tenance will be shortened oO cleaner alament at dirty place. Clean fuel tank Every month Clean or replace Go oO fuel ail filter {Clean} (Replaca) Checknozzlo | s | ‘Check injection pump oe Check fuel pipe eviee " Adjust the inletier- . e aust valve charance| (First time) Grind the imleter~ aus! valve seat e Replace piston ting e Check sccurnula-| Every manth tor electrolyte Bd Clean air cleaner j O ; element Every manth| ar 50 hoursMCLEAN AND CHANGETHE FUEL FILTER The fuel filter must be kept clean to guarantee max output af the engine. A Take the filter out of fue! tank and clean it Clean [Every’6 months or £00 hrs Replace Every year or 1000 hee We cise sc! Lesbo rut re thes ou the py J z Famove the high Loosen fecha bait reese aur and Drarinut fhe fuel water and dusty a @ REPLACE LUBE SIL FILTER [lean [Every 500hrs [Repleoe Every 1000hrs or whan sarvioe the engine ee M REPLACE LUBE OIL | [EMTFOE KMITTEF | BMT88F | Lube oil capaciy 075 wt | 165 | Lube oil type | SAE 10K angie ci, over Cora) and Low ei Replace Lube ail Running time ved First time First month ot after 20hrs Secand time and fale Every 3 month or 100hrs Fi te rch cl rr theEvery 6 months or 500 hours Replace air cleaner element st (earlier if necessary) Do notwash air cleaner element with detergent, @ Wipe the dirty off the element outer face with soft brush, Wi Do not operate the engine without element or with a bad one, [NOTE] i Clogged element will reduce the air in combustion chamber, accordingly, the output power of diesel engine will decrease furthermore, the consumption of lube oil and fue! ail will Increase and starting became aifheult 2.3 Long-term storage Please carry out the belaw preparation for lang- term storage. @ Run the engine for three minutes then stop it BE Drain cut lube ofl while the engine is hot, then refill new lube oil decompressian kevay 1B Cisasserble the filler cap on the cylinder head cover to add 2CC lube ail, then tighten the capWi Recoil starting Prese down and hold the decompression lever at the nan-conpressisn piont, pull the receil starter two or three times simultaneously until you feel resistance (Do not start the diesel engine} Electric starting Keep the decompression lever atnon-compression point, run the angine 2-3 sec- onds while the starting key is at"START® position (Do not start the diesal engine}. 1 Pull the decompression lover upward and pull the recoil starter slowly until you feel resistance (thus the inlet and exhaust valve ara closed at comoression posi- tion to prevent from rust). @ Drain cut engine oil and the dirty, then put the engine ata dry place. 3. DISASSEMBLING AND REASSEMBLING OF DIESEL ENGINE 2.1 General procedures of disassembling WW Propare the necessary tools clips and gauges Il Prepare a notebook for recording maintenance details. Il Prepare detergent for clearing the parts. IB Prepare the container or place for storing the parts BB Drain cut the used engine oil from the engine. Put all kinds of bolts, nuts and related parts together to avoid confusing Confirm exactly what the problemis before disassembling, Do not remove unnac- eseary parte.3.4.4 Fuel tank @ Release the joint between the oil return pipe and fuel tank. Bf Release the hese clamp of the fuel pipeline on the pump side. @ Disassemble the upper parts of the tank support, @ Disassemble the fuel tank (Pull the fuelpipe upward on the puimp side.) Release the hose clamp on tee pump sic 3.1.2 Exhaust Muffier @ Remove the flange nut W Remeve the set bolt 3.1.3 Air cleaner 1 Disassemble the air cleaner cover. @ Pull out the element @ Disassemble the cleaner bottem case. 3.1.4 Receil starter unit Its not necessary to disassemble recoil starter unit every time except its necessary. Remove alr cleanar3.1.5 Dissasemble the airfoil Remove the airfoil. Remaye the atos 3.1.8 Starter pulley Disassemble the starter pulley. 3.17 Air inlet pipe Disassemide the air inet pipe Remove air inlet pipe 3.1.8 Start mator (ealy for the models equipped with start rretar) Disassemble the stact mator 3.1.9 Cylinder head cover Disassemble it 3.1. 10 Valve rocker arm seat (1) Disassemble the valve rocker arm. (2) Remore the valve adjusting separator Remove valve rocker arm seat3.1. 11 Push rads Pull out the push rod 3.1.12 Fuel injector I Remove the high-pressure fuel pipe, i Disassemble fuel injector i Fool injection inpcor washar FU Injection waive figure |_¢mtition ster INOTE] Ifthe injacter ie tightened, looeen the fuel exraying lecking nut with @ spanner clipping the end of the high-pressure pipe, Be careful not to damage the nozzle washer and injector washer, 3.1.13 Cynder head Remove cylinder head ot Remove the cyinder head3.1.14 Fuel injection pump @ Remove the fuel injection pure, A. Remove the pump together with the base, B. Make sure the hooking part of cantel lever at mesh- ing position before disassembling, G. Pull out the ftat tappet remaining inside 3.1.15 Crankease cover i Remove the engine cil injaction pump cover i Remove the engine oil fitter cover IB Remove crankcase caver. A, Taka the first and second step only its necessary Bi, Be careful nat to damage the ail seal. 3.1.16 Camshaft i Take out camshaft A. Check the timing mark. B. Store inlet and exhaust tappets separately. To avoid confusing inlet and exhaust tappets if bath af them fall down while pulling out the camshaft, 3.1.17 Balance shaft Pull out balance shaft. “10+3.1.18 Pisten and connecting red assembly @ Oismount the forcing nut of connecting red. Remove the big end cap ef connecting red, i Turn the crankshaft to the top of stroke and take out the piston, A. Wipe the carbon from the upper inner surface of cylinger barrel before take out tie pistan, B. Be sure the main bearing is at normal position Remove the bolts and nuts of connecting rods, 3.1.19 Flywheel @ Loose the flywheel nut. Bf Cismount the flywheel. 4, Use Mywtee! extractorispecial taal) B, Securely thread in the extractor bolts 3.1.20 Crankshaft IB Remove the flywheel key. 1 Dismount the main bearing thrust plate. @ Pull out the crankehaft A. Be careful nat to damage the ail seal Feemova the main baaring thrust plate Pullout the crankehatt ole3.1.21 Governor or speed control device @ Remove the governor of speed control device if necessary, Damaged or scratched governor lever will cause engine hunting of other malfunction. Be sure the governor spring in the proper positian before disassembling 3.2 General procedures of reassembling Preparation before reassemiting, @ Thoroughly before and clean all parts WE Apply the fresh engine ail to the maving and rotating parts Use new washers and O rings. Bl Apply liquid sealant for preventing fram ail leakage @ Ge sure the clearance among parts(ail film, thrust, etc} are correct BF Align with the matching remarks while reassembling. 8 Use right bolts, nuts and washers. Screw the key bolts and nuts to the specified terque, (Be careful far aluminum allay parts, for these are easily damaged ) @ Apply lube oll to the thread parts and flange surface before tightening the major balts to the specified torque. 3.2.1 Assemble gavemer or spead contra! davice @ Reassertte the governor or speed control device if it has been removed, 3.2.2 Crankshaft i Insert the crankshaft. ff [nstall the main bearing thrust plate. Attach the flywheel key to crankshaft A, Be sure crankshaft is in proper position, B. Apply grease to the oil seal lips. C. Apply lube oil to the crankshaft journal and crank pin (he main bearing thrust plates 12>3.2.3 Flywheel Tightening torque of flywheel nut Nim KMI7OF | 100-120 KM17aE 100-120 KM186F 130-150 Tighten the flywheel nut with special tool after in- stalled it, 3.2.4 Piston and connecting rod I Move the crankshaft to the upper dead point, then install piston and connecting rod. Align the remarks on the top surface of the piston with the crankcase cover side. i install connecting rod big end cap. (There's a washer at forcing nut) 4. Apply lube oil ta crank pin 6, Be cure every piston ring should be at correct cirection . Apply lube oil to the piston outer surface and the cylinder inner surface D. Be cure the main bearing is st proper position E. Check whether the rod bolts retainer is at proper position Connecting rad nut tightening torque Nm KM170F 121 KM17aF KM186F 38-42 -13- Ingtal the cormedting rod big-end cap3.2. § Camshaft and balance shaft i insort the tappets. i Insert the camshaft. IB Insert the balance shaft. ‘A. Do not confuse the intake and exhaust tappets. B. Check whether the matching remarks of gear are aligned correctly. 3.2.6 Crankease cover @ Piece an aluminum washer between the sur- face of crankease and the caver. IB Reassermble the crenkease cover. (Tighten bolts in the sequence in the figure. Tighten the baits diagonally.) A. To protect the ail seal, attach the jig for insert- ing the oil seal to the shaft prior ta insertion. 6. Apply grease to the ail seal lips. C. Make gure that the engine oil pump drive gears are property engaged. Tightening torque of crankease caver bolts Nim KM TOF 1 Add the stiffener bolts te the crankcase cover for reducing vibration and noise, which should be tightened after other balts around crankcase cover lightened, Tightening torque of the stiffener bolts KM17OF/KM1TBF/KM138F 20-23 14. Inaert balance ehalt Install the crankcase cover and tighten the bolts42.7 Reassemble the fuel injection pump { sssemble it in temporary position) Aligning with the oll level remarks on the injection pump, insert the governor lever into the fork groove of the governor lever. Install only one bocating nut to the fuel injection pump. Se cure the quantity and thickness of spacer shims are correct. 3.2.8 Aseemble the fuel injection pump {tinal assembling) Tighten the set boit of the fual injection pump. Tightening torque of fual injection pump set bolts him KMIFOPRMITBFIKMIG6F | 10-12 3.2.9 Cylinder head @ Pisce the cylinder head washer on the cylinder block. Wf Install the sheet gasket . @ Reassemble the cylinder head. A. Check whether the nazzle washer and the fuel injection valve washer(radiation sheathjare in sorrect position, 5. Face the section with white remarks of the air valve spring to the cylinder head before reas- seme the spring, (forall models of ciesel engines) Tightening the cylinder head bolts should be performed at ta steps. Tightening torque of cylinder head bolts Num | MODEL | FIRST TORQUE [LAST TORQUE [ KMI7OF 15 ade KN Fae BR 42-46 KMBGE » 24-58 -15- Tighten the bolts of the cylinder head3.2.10 Push rod Insert the push rod and check whether itis in proper position 3.2.11 Air valve rocker arm assembly @ Reassemiie the ar valve adjusting cushion and air valve rocker arm assembly. 1 Adjust the air valve clearance. The clearance between the inlet and exhaust valve is 0.15mm. (0.008 incold state) A, Go not miss any parts or damage the locaton pin. Tightening torque of the air valve rocker arm seat Naty KMT7ORKMTTEF | 20-23 ) KM186F 43-47 f 3.2.12 Cylinder head cover Install it and be sure the position of the washer is right 3.2.13 Fuel injection vaive Fuel injection vale 1B install the fue! injection valve assembly @ Tighten the set bolts of fuel injecton valve, I install the high-pressure oil pipe. 4, Be sure the installation direction of fuel injec- fon vale ic cormact B. Replace the fuel injection vatve washer while assembling. Tightening torque of the fuel injection vaive ineeal| fuel gection vale: Nm KT FOREN T?BFIKM186F -16-3.2.14 Air inlet pipe Install the air iniet pipe and check whether the washer is in proper pasition. 2.15 Airfoil Bi Inctall the starter pulley. @ Install the airfoil ( Raassembie the recoil starter assembly if it has baen removed } 4. Apply the seal rubber to the end face of airfoil 6. Be sure the collar and the airfoil supporting rubber re in right pastion Bea rudsben 3.2.16 Air cleaner ff Install the air cleaner bottom case. BB install the element. i install the air cleaner cover. A. Check whether the inlet pipe and washers are in proper position. Powe] & ld, Packing Air cleaner Inlet pipe Act inlet pigne 17+3.2.47 Staring moter Install the starting motor (Only for electric staring type.) 3.2.18 Exhauet muffler Install the exhaust muffler I its not necessary to dismount the muffler screen case 8 There's no muffler screen case on KM 186F- 3.2.18 Fuel tank I Joint (uel ofl pipe and the fuel injectian pump Fix the fuel tank with the upper support ME Connect the fuel return-pipe to the fuel tank. 4, Check whether the fuel tank supporting mubber (damping rubber} is in proper position, 3.3 Recoil starter assembly The recoil starter willnat have faultin normal usage. However, if the recoil starter damaged or need re- lubricating, disassemble and reassemble it as per the below procedures, 18 litall fuel Bare3.3.1 Disassembling procedures §§ Dissesembla the recoil startar acsembly from the angine with a kay wrench. I Pull the rope out shout 30cm, When the gap of starter reel reaches the exit of the ‘starter ropa, stop the reel with your finger and pull the rope outwith the awl 3s per the below figure (a), Then, put your finger on the gap to push the real for returning the rope until the reel stop running. IB Disassemble all kinds parts as per the below figure (b} ~ (a). Hold the shaft with pincers and twist the elastic collar till you can take it out. IB Disassemble the starter reel from the case as per below figure (a), and take it out slowly, then take out the spring. [NOTE] De not take the reel out suddenly, otherwise the spring will jump from the case. (Place the spring back if kemped from it's origin position as per figure {fh} Rowbon drecton tor sspec | Staner pe oekin Lewis nut Lock mt gpongiwather g-~ Washer3.3.2 Re-assembling procedures Check whether the spring is in proper position inside the case. Adjust the shape of inner end of the spring to engage it with the reel's hook mark correctly at the position 4mm away from starter ree! shaft. (The fOmmang inner end of the spring: can be simply reshaped with pliers} @ Wind the starter rope around the reel as per figure (g). Take the rope aut from the gap after two and half circles and engage te spring's inner end with the real's hook Then place the reel into the case. (Be careful net to assemble the reel as false a6 showed in figure (f), for the hookis invisible while reassembling the starter reel.) Spring cutee endl Rotating cirection for O apes ponirgcteaent see / ke) * Saner stan SPera rer end n @ Hold the starter rope as shown in figure (h). Securely hold the reel so that the rope may not reverse and wind the starter rope 4 circles in the srrow direction showed in figure (h). Cross the rope from the inside to outside. Run the reel slowly in an opposite direction of the sraw. 1 Re-sssemile the removed parts as figure (g} in.an opposite order af disassembling. Firat te pull return spring a little high while assembling the friction plate, then insert itinto the holes of friction plate respectively #3 figure (h), (i). Run the friction plate in the arrow direction. When the bulged part of ratchet wheel \s aligned with the guidance part press the friction plate into the starter reel. Then sscemble the lock pin and elastic caller. (Regarding KM178 and other supanor models, the elastic collar ia replaced by the nut) (First put the elastic collar in the groove of the reel shaft by hand, then tighten It with pincers. } 20Rotating drection tor F spec’ Hote for natura Roatairg ‘tection for Piaitnet guido 5 spec on) KAMPF (i) Kat 78 KMAIBBF 3.3.3 Inspection after re-assembling @ Pull out the starter rope alittle two or three times, A. Ifyou pull the handle hardly, its necessary to check whether the parts are in proper position B. ifthe ratchet wheel dees not mave, check whether the spring is in proper position. @ Pull out te starter rope completely. A. ifthe rope blocks the starter reel orit could not return back, which indicates that the epring received abnormal pressure, Conceming such situation, wind the rope ‘one of two circles more a= per the procedures showed in figure (a). Bi. ifthe returning power of the starter rope is too small or the handle dropped in half way, it's necessary to drop same lube oil to the friction parts. If the foregoing mesures failed, wind the rape one or two circias mara, (Check whether the sping received abnormal pressure as par the procedure (1),) C. Ifthe rope could not wind around! the starter reel after the epring disengaged fram the reel's hook, disassemble the recall starter assembly for re-essembling. 21+4 INSPECTION AND MAINTENANCE 4.1 Cylinder head 4.1.1 Combustion chamber surface Disassemble the uel injector valve, the air inlet valve and exhaust valve. Clean the combustion chamber surface and check whether there's any crack or ather damage. Check the faint crack by coating oamasis, 4.1.2 Inlet and exhaust valve seats Freeze the valve seat deeply with liquid nitrogen for improving the durability, then insert it into the cylinder head. Wipe off the caraon deposit tram the valve seat, for carbon deposit and excessive Wearing and corrosion will cause insuflicient compres- sion pressure, MODEL KMA7OF, KMI7EF, KMAB6F ITEM a Standard Maintenance limit Seat surface angle “ac i Seat surface wicth 1530 = Seat width = i ia KM TOF/KMI78F/KM1 BSF InictExhaust valve aesambly 4.1.3 inlevexhaust valve and valve conduit WW Check the wearing and distortion af the valve lever, replace itif necessary. Do nat confuse the iniet and exhaust valve, WW Check the valve sinking. Replace the wam out valves. r [NOTE] + There's a sealing partin the inletlexhaust valve conduit Replace it when main- taining the conduit Lubricate the surface of valve lever before insert it into the inlatiechaust valve conduit. 22>4.1.4 Air valve sping M@ Check whether there's crack or corracion on the spring. @ Measure the titing angle of the valve spring. W@ Test the rigidity of spring. [NOTE] _ There's an identity remarks (white coating) on one side of spring, be sure to face this side to the cylinder head, 4.1.5 Measure the top clearance of the piston 1 Remove the cylinder head, then place threee 1.2% 10mm fuses with same length at three points on the upper limit level of the pisten @ Re-assemble the cylinder head and the gaskets, fen tighten the nuts at the speci- fied tightening torque and in specified order 1 Turn the crankshaft at normal direction to fatten the fuse, @ Remove the cylinder head and take ouf the flattened fuse, then measure the thick- ness ofthe fuse. On the other side, you can te three fuses with three threads respectively then crass them auf fram the nozzle hole as per the below figure, thus its notnecessary to remove the cylinder head, Then, measure the thickness of the flattened fuses as from (3) 1B The top clearance of the piston is the average value of three measured thickness values. -23-Eis is KMI7OF, KMI7BF, KMABSE TEM Standard Top clearance of piston l 05-07 KH TOFKM 178K BSF Inet Exhaust valve assombly 4.1.6 inlevexnaust valve rocker arm and push rod I Valve rocker arm pivot Measure the outer diameter of the valve rocker arm and the inner chameter of the valve rocker arm hole. If the dimension exceed the mainte- nance limit, replace the valve rocker arm or the valve rocker @ Push rod Check the langth end distortion of the push rod. Inlevexhaust valve rocker arm nnd KMI7OF, KM178F KM 186F Standard |Weimanerealimt| Standard |Mantenance Imt! MODEL ITEM Outer diameter of the} inletiexhaust valve! 11989-1200 11.90 14.988-15 000) 14.90 Focker arm pivot Inner diameter af the inletfexhaust valve rocker arm hole 12.016-12.034 12.10 15.016-15.004 15.10 24.4.1.7 Adjust the valve clearance @ The clearance must be adjusted whila the an- gina is cooled. Aung te | The valve clearance ITEM ‘Standard Os I The below table is the correct valve timing Valve timing [ee Kmivor | KMI7aF | KMT85F ITEM Standard ae On 185° porte TOG) 185° prarto TOG | t4° prorto TOC | Of [455° laterto ADC) 46" laterin BDC | SO° laterto BOC afer, LOM LERET eaters BOE oat itor BO 6A per be BOG] Off | 85° laterto TDG | 12° tater TOC 10° later to TOC 4.2 Piston and piston pin 4.2.1 Piston (NOTE) 2 Conceming the pistons applied to KMITOF, KM17BF etc models engine, a dent of the inletiexhaust valve was added to the top surface of the piston after the camshaft changed design. Be careful the interchangeability of the parts while changing the piston, @ Check the top of piston and the surface of combustion chamber. To wipe off the carbon from the top of piston and the surface of combustion chamber with care nat to scratch the surface, therefore to check whether there's any damage on the surface of combustion chamber. Mi Check the cuter diameter of the piston Ifthe outer surface of piston and ring groave wear out beyond the kmiL replace the piston, -25-I Piston and pisten pin To disassemble the piston pin, heat the piston to 70-C-80 0, repeat this heating precedure while reassembling the piston pin, 4.2.2 Piston pin Measure the piston pin cuter diameter, (fit worn sul bayond the maintenance limit or already distorted inte ladder shape, it should be replaced Outer diameter of the pisten pir MpOEE KM 170F KM178F KM186F ITEM Standard 18.992-19,000 20.991-21.000 | 22991-23000 Maintenance limit 18.92 20.91 22.04 4.2.5 Check the hole of piston pin fl ifthe hole is damaged or the color changed, it must be replaced @ Measure the inner diameter of the hole, replace it ifthe inner diameter exceed the maintenance ‘iru. @ Replacing procedures of the piston Heat the piston to 700-8077, than align with the hole of piston pin and insert the pin. 4.2.4 Piston ring @ Assemble and disassemble the piston ring with special tools instead of pull it by force. Face the sechon with the remarks upward while sscembling the pisten ring. I Be cure that piston ring rotates smovthly after installstion. @ When insert the helical elastic collar into the oil ring, be sure the joint of the helical clastic is st the opposite of the opening of ail ring. @ Space the open points of the piston rings 120 degrees apart each other. -26-4.3 Connecting rod 4.3.1 Gheck the connecting roc I Check the parallelity and distortion of the large and small and holes, Pass the measuring jigs through the large end and small end holes of the canneting red to measure the parallelity or distortion of the connecting rod. Replace the conneeting rod fit distarted beyond the permit- ted limit distort ITEM KM TOF KM 7aP M1 86F | Parallelism or distortion, 0.05 4.3.2 Gheck the bush of crankshaft @ Check whether the surface of bush between the connecting rod and the connect- ingrod neck peeled, melted, stuck. Replce the bush f peeling or dsmage occurrad. fl Insert the connecting red to the shaft neck, and tighten the connecting rod nut with the specified tightening torque. ‘Adjust the piston position and align the top mark of the piston with the mark of the connecting rad as per the below figure, As the result, the top mark of the piston will align with the section of the crank- case cover (gear case] when insert the piston into the cylinder sheath. 4.3.3 Connect the piston and the connecting rod [Farcnitap mark — 9 —~ = : } Matcring ‘ark Posh belt ‘Augn piston wth connecting red vate4.4 Crankshaft and flywheel 4.4.1 Crankshaft @ Coating check for the neck journal Clesn the crankshaft then check whether it cracked by coating osmosis or by magnaflux, replace itif there's crack or serious damage. IB Measure the crank pin and the main journal Check the wearing condition of the crank pin and the main journal. Replace the crankshatt assembly if the wearing condition exceed the permitted limit. @ The ball bearing on the fywheel side has been pressed into the cranksheft (Replace the crank- shaft assembly if the ball bearing ts loose ) 4.4.2 Flywheel Bi Timing mark There are measuring marks at the edge of the flywheel far measuring the fuel injection timing FiDispacengine £ ape ingne @ Ring gear —— Heat the ring gearte 180°C then install it to the Fang gesr Sramter sie flywheel. i Ly Fiypwheed —f “284.5 Camshaft and tappet 4.5.1 Camshaft @ Check the thrust clearance af the camshaft (eylinder block side), The crankshaft bear- Ing has been pressed inte the cylinder block. Maintain the sinking clearance between the end face of the pressed bearing and the thrust surface of the eylinder body af 1.4-1, Sm, (Camshet thrust dlearance: 4.5.2 Tappet WW Check the condition of the tappet contact The tapget offsets from the cam center and rotales @ufing operation te prevent from uneven wearing, If the tappet wom seriously or the contact with the cam is uneven, the tappet must be replaced Check the cuter surface of tappet, replace itif the outer surface already wor aut or damaged. [NOTE] Store the inlet tappet and the exhaust tappet separately while disassembling and re-assembling. 4.6 Timing gear 4.8.1 Check the timing gear —aee WE Check every gear and replace if wram out Align wath the timing mark of every gear while Engrs ot pump | fe-assembling, La 29.4.7 Crankcase cover Be careful of the aluminum gasket while disassembling, replace it if it damaged or distorted. Furthermere, be sure to bghten the crankcase cover bolt with the specified tightening torque showed in below fable, Tightening torque MODEL © KM POF KM ITEP, KM 186F Crankease caver 10-12 20-23 Stiflener bolts 20-23 4.7.1 Cleaning and inspection Rinse the cylinder body while overhauling. Claan every ail hole to ensure there's no clog. (lfit's not necessary to replace the cylinder body, keep the plug in the origin position to praventthe leakage of the plug.) Biug Lube oil er Rotating direction of $ spec engine and that of F spec engine are different. In arder to maintain the crankease cover, pull out the lube oil filter -30-Lube of fiter Lube oil filler exist Luteal Marcigmet lant Luce ell fitor sera LO flow path LO flow path LO filter + LO pump + Main bearing! — Intak pipe + LO filter + LO pump Crank neck journal = Connectingrod Main bearing — Crank neck journal — shaft journal Connecting rod shaft journal 4.7.2 Replace the crankshaft oll seal and the camshaft oil seal Replace the oil seal with special tools, Push the crankshaft oil seal into the crankcase cover until the and face of the seal is deeper 4mm than that of the crankshaft. Accordingly. push the rear od seal of the crankshaft into the cylinder body, the both end faces must ba level too, -a1-4.8 Cylinder barrel and cylinder block 4.8.1 Cylinder barrel Measure the inner diameter of cyiindar barrel, bora if it exceads the permitted limit and use an oversized piston. 025 0.50 4.9 Lubricating system The lubricating system of this engine is the forced-ubricating system driven by the cycloid rotator pump. Regarding the lube oil route, please see the below figure, but the air valve rocker chamber is lubricated by the storrizing. Lube oil filter + Cycloid rotater pump Crankshaft -+ Bush of the connecting rad shaft journal -32- Inder block and cylinder barre! Lube of route4.9.1 Lube oil pump Mf Measure the clearance between the outer rotator af the lube oil pump and the lube ail pump body(on the crankcase cover), Replace the lube ail cump if the clearance exceeds the permitted lirrit I Measure the clearance between the outer rotator and the Inner rotator of the lube ail purng with feeler gauge, and replace the full set af lube of pump if the clearance exceeds the permitted lirrut WF Assemble the lube oll pump, A. Insert the lube oi] pump @ from the outside of the crankcase cover, B. Insert the pin @ into the lube oil pump shaft Sat the governor flying block qh onthe paar. Insert the spindle into the weight, then push the spindle into the shaft Once in place, the Installation of angina of pump: spindle can not be removed. = _ -_ =. a 5 4.10 Fuel oll system 4,104 Fuel injection pump Bf Identifying mark of the fuel injection pump is located on it's construction flange. WW The fuel injection pumps of different model generating sets have no interchangeability. 8 Differentiate the fuel injection pure of the diesel engine from that of the generating set, forthe @recton of the oil iniets of them are different. | ——— | KM TOF KAT TBF, KM 1S6F Standard thickness ‘Construction Nange of fuel injection punts of the spacer shim (while assembling Osmrn at the factory) -33-4.10.2 Fuel injection valve I Chack the identifying mark which matching the engina model as per tha upper figure while replacing the fuel injection valve. Every fuel injection valve at least must be identified from the outtook, @ Clean the nozzle orifice when disassemble the fuel injection valve, what more, do not place the injection nozzle on the dirty ground. i Inspection A. Carbon deposit (Flowenng) The carbon on the injection nozzia will seriously reduce the combustion efficiency, 50 do avord any polluten of the injection nezzie. B. Shape of the spray Put the fuel injection valve on the fuel injection vatve tester and run the handle of the tector atthe speed of approx. 1.2 times/second tn check the spray pattern. 1 Normal shape of injection spray A The injection spray angle injected from four orifices should be same. 6. Sprayed olf shoubd be like the fine mist. C. Injection spray from four orifices should be steady and smooth. D. Take the following items into consideration while assemining the fue injection valve. 1. Tighten the fuel injection valve to the specified torque. 2 Clean the sleeve of the fuel injection valve and replace the nozzle gasket (NOTE] . Ifthe gasket blocked in the cylinder while disassembling the fel injection valve, insert a Ma or M9 stud balt longer than 100mm into the orifice, thus pull out the nozzle gasket and the bolt together, Tightening torque Ning a MODEL KMA70F.KMI78E,KM186F eM Injection nozzle locking nut 40-45 a8.WW Disassembling and reassembling Disassemble the fuel injection valve lacking nut with @ 15mm box spanner, thus all the parts can be removed. In most cases, it's not necessary to dissssemble the locating pin of the fuel injection wave. Bi Adjusting The beginning fuel spraying prassure is 200kg, but the fuel spraying pressure can be adjusted by adding or reducing the spacer shims. The fuel spraying pressure will change 20ko! om? when add or reduce one spacer shim O.1mm_The following is the thickness of the spacer shim 0.1mm, 0.3mm, 0.4mm, 0.5mm and 0.6mm. JKMI7OF AMI TSF AMT BEF Standard thickness ef spacer shim o5 4.10.3 Fuel filter Fualinesen valve gaaioat Fuel injection nozzle Check the element whather it cracked, degummad, shelled or clogged etc during the periodic check, and replace itif any fault found. Concerning disassembling the fuel filter, first to pull out the filter screen cup, then take aut the fuel filtar fram the filler of the fuel tank; however, that should be took aut fram the bottom of the fuel tank re- garding FG model (generating set). 4.11 Governor device The installation positions af governar spang vary with madels and rated speed a per the following tablé and diagram. One thing more, be sure to check the position of the governar spring befere cenfirrn the fuel injection tirving lint, -35-The position ef the governor spring instaiistion holes. Modelaspeed The position of governor spring in: ~_KMATOF, KAN 78F | 3600q—em | 2000emm | a60dpm | 3000rpm Govemor type (60Hz) (S0Hz) (60Hz) (S0Hz} A changeable speed, fixed adjusting handle 2b 2c cad cas (remote contrel optien) B stable speed locked adjusting handle ‘2 se 2 as Stop Bun | V8.) pmeganior nana | 5 4.12 Accumulator Be sure to charge the accumulator before start the engine, do not use uncharged accumulator to avaid the specified starting speed unattainable at low temperature: 4.12.1 Accurmutstor capacity and accumulator cable Bi Accumulater capacity Regarding the recommend accumulator capacity(20 hra rated value) and the arn- bient temperature, refer to the following table 40H ] / KMTTOF - KMI?aF “101 or higher | -300 or higher KM1a6F = — | — | a0 orhigner | BOE or higher | -36-Accumulator cable Be eure te apply the thick and short accumulator cable to connect the aceurnutator and engine, otherwise the following fault will result, The wire is thiner than the specified) Lead with copper core ‘ [The wire is longer than the specified . The resistance of wire is too large | 4 Broken cirault caused by vibraban The current is too small | Starting full ‘Charging fault 4.12.2 Check the accumulator i Check the electrolyte in every grid and add some distilled water till the upper level limit if necessary, Check the electrolyte every 7-19 days, be sure to keep it's level 10-20mm higher than the top of the electrode plate. Fioper Teo tow Tea high i Cheek the case of the accurnulator whether any part lost er it racked ete fault Bf Check whether the terminal ef ecoumulater loose or corroded, W Check whether the air hele on the secumulater cover clogged @ Suck some electrolyte from every grid to test the specific weight, WF Specified cpecific waight i 1 27-1.29) 0 type) 1,26-4,28{ 1 type) “37+[NOTE] Do not overflow the electrolyte fram the accumulator, wipe off and rinsa if it happened. Replace the accumulator if there’s serious carrosion. If there's sedimentin every grid, do replace the accumulator. 1 Be careful ta prevent tre body and cloth from touching the electrolyte whic comprises thin sulfuric acid solution, for it can harm the skin and eyes, De seq the doctor immediately if any injury happened I Check the terminal voltage of the accurnulator when the flywheel generator and relay combination installed, (Fthe terminal valtage is too law, the charging gen: erator can not supply the necessary voltage (V or higher) while the relay i working, resulted the accumulator charging is becoming necessary. 4.92.3 Charging the accumulator IB Disconnect the wiring of the accumulator and open the caver of every grid @ Connect the positive and negative winng of the charger to the postive and nega- tive terminal ef the battery respectively. Charging current Accumulator rated 20 hours capacity value to rated 10 hours capacity value Example Rated 20 hours capacity valua is 45 Avhr, so the changing current of the accumula- toris (45 © 20)~ (45 © 10)-2.254~4.54.- IB Go sure to remove the cover of every grid before charging. HI Do keep the accumuistor avray from the flame and spark while charging 1 Switch power on/off from the charger instead from of the accurnulator terminal 38+4.13 Adjustment 4.13.1 Adjust the fuel injection timing Fuel injection timing must be correct, athenvise many faults will result, such as ciffi- cult starting, output power decreased, axhaust black smoke. On the other side, first do adjust the connecting parts of the governor and the fuel injection pressure before adjust the fuel injecbon timing. Generally speatang, the plug of the fuel mjection pump will worn aut after long time operation, so replace the plug and readjust the fuel injection timing if fuel injection timing changed or the plug already worn out. How to check fuel injection tming 4. Set the governor fever oa "RUN" position, B. Disassemble the high-pressure oil pipe, replace with the pipe used for testing the fuel injectisn timing C. Tum the flywheel til the upper dead point mark aligned with “V" scale mark on the radiating fin of cylinder, D. First tum the flywheel clockwise, then turn 30 degrees anti-clockwise from the upper dead point mark to ensure spraying the fuel oil, (If there's no oil sprayed, turn the flywheel cre tur more) E, Turn the flywheel slowly until the fuel ed flow out frem the teeting pipe, Then imene- diately check the mark angle of the flywheel with which the scale mark of cylinder aligned F. Repeat the foregoing steps three to four times to ensure the validity of the final value, ‘Tap dead posroan mark on ce eunterance.of the tywheal Top dead position mark -a9-Bt How to adjust the fuel injectian timing A, Disassemble the fuel injection purnp and the construction flange. B. Add spacer shims if the fuel injection timing is too early otherwise reduce the shims, The fuel injection timing will change one degree every 0.1mm spacer shim thickness changed 4.13.2 Drain eut the air rem the fuel oll system Because the air will enter the fuel oil system on disassembling the fuel oil way, drain itout as the below steps: I Set the governor lever on "RUN" pasitian Switch on all the switches of the fuel olf system. MB Set the decompression handle on decompression position Pull the recoil starter to. cenfirm that the fuel oll can spray out Irom injection nozzle by hearing the oll injection sound, Loose the drain valve lock bolt to drain aut the air, after that tighten the bolt with 40-45 Nin tecque: 4.13.3 Adjust the claarance of the inletfexhaust valve Check the valve clearance every time efter disassembling or after 500 hours operation, readjust it if necessary with feeler gauge: [NOTE] First do confirm that the cylinder is at the upper dead point position before ad- lusting the valve clearance.| IF the cylinder is af the upper dead point position, the inlefiexhaust valve rocker arm won't remowe no matter the pivot turn clock+ wise or counterclockwise.) 40+§. MALFUNCTION ANALYSIS §.1 Fault analysis 514 No fuel oil spraying sound (Engine can rotate easily) Set the governor lever insufficient com- sun'o on “RUN pasition a pression pressure ee el Ne fuel injection eouned Fault Possible cause Remedy VY | 1-Fuel tank is empty. No tial oil flew 2. Fuel oil switch on the tank is off. to the fuel injec- 3. Fuel filtar is claggad tion pump 4 There's air inside the fuel injection pump Push the decompression lever and pull the recoil starter several times, what more, check whether there's ail injection vibration by touching the high pressure oil pipe. Refuel ail and drain out the air a Disageemble the high pressure oll pipe. b, Loose the drain valve set bolt ¢, Switch on the feel tank switch tolletthe ail flaw aut from the drain valve Steps) (Turn the flywheel half turn if there's no fuel flow out) d Tighten and check the fuel cock (Test the tightening torque of the fuel cock.) 41+Disassemble the high pressure fuel pipe * Replace full set of drain valve (including drain valve gasket) No fuel off flow out from the fuel cock 2.The drain vaive is dirty or has fault (>) Clean the crain vaive No ail spray out ar oil injaction abnormal Gil injection pressure 4 nozzle erifices Final step 3.Abnormal adjustment of the governor contact. Adjust the govemor contact (refer to the operation manual 4.Fuel injection pump stud worn out Feeplace fuel injection pump 1. Injection nazale clagged Wash or replace it >! How to test the nection nozzie a, Wash it with light diesel. b. Put needle valve into it's body. & Ifthe needle valve can slide down the hole under it's. self gravity, it indicates that there's no fault. 2. Gil injection pressure is not correct Adjust it by adjusting The pressure the spacer shim is too high Check the tightening There's strike sound and torque of the nozzle nut the nozzle wom too feat. 3. Fuel injaction nozzle worn aut Replace Wash the fuel filter while replacing the nazzle Realign with the locating pin while replacing the nozzle. 4. Assembling the nozzle is nat right.(realign with the Locating pin) 5.The nozzle hole clogged Wash or replace “42>5.1.2 Compression pressure is tao low Fault Possible cause Remedy 1 (nietiexhaust valve leaking Valve clearance ‘Adjust til the proper — nat right ——} | valve clearance — [Method {inketexhaust valve} &. Tum the flywhaal til the upper dead point sligns with the cylinder mark. b. Adjust the valve clearance with adjusting scraw * Adjust 0.15mm while the engine is under cold state "Check and adjust every 500 operating hours Valve clearance nat right — | Replace inletiexhaust valve seat * The seat surface angle is 90°, * The seat surface width is 1.5-3.0mm * Store the inlevexhaust valve separately < 2. Thete’s leakage around the fuel injectian nozzle Assembling torque of the injac- 3 i a o = J & 3 & a = e oylinder head is insufficient pp | crease the tion nozzle is false tightening torque * Check the front and back side of the fuel injection valve pressure plate. Replace the The fuel inject azz ket fuel injection nezie gasket —pe | Pelee has fault 3 Thare’s leakage of cylinder head gasket [Tighten it] Check the Improper Sightening torque | of the cylinder head equally | tightening torque | The cylinder head gasket damaged > | Replace the insulation gasket -43-There's leak- age inside the crankcase, ‘The final step "Replace the gasket whan tha cylinder heeds tightenad equally 1.The engine oil's quality is poor —4 Replace the engine ail The engine ail deteriorated or the wiscosity is tao low. 2.Piston ring clogged — “Replace the engine ail every 100 hours. Please use CC or CD grade engine ail classfied by API. Please use SAE-20 engine oil in warm seasons and use SAE TOW-30 en gine ail in winter. Make ‘Wash or —+ | replacement replace ft record a. Wipe off the carbon fromthe ring groove. b. Place the manufacturer mark upward which on the end face of the piston ring c. Do not confuse the first and second ring. 3. Replace the piston ring if it wer out or cracked, 4. The piston ring groave worn out ot ring Replace pistan or Heating the piston before insert the piston pin, ote