Thank you for purchasing Kipor KD388、KD488 series … · Thank you for purchasing Kipor KM2V80...

Thank you for purchasing Kipor KM2V80 series diesel engine. In order to ensure proper

operation, reliable running and good economic benefit of your machine, it is especially important

for you to operate correctly and maintain carefully. This manual will tell you how to operate and

maintain the machine correctly, it will also give you detail instruction about the main technical

specification, configuration and troubleshooting.

Content

Instruction of products……………………………………………………………………………..1

1. Brief instruction of products……………………………………………………………....1

2. Composition of model and its meaning………………….………………………………1

3. External installation drawings and names of parts……………………………………. 2

4. Specification………………………………………………………………………………. 6

5. Main adjusting parameter………………………………………………………………… 7

6. Tighten torque values of main bolts and nuts……………………………………………7

7. Fit clearance and interference table………………………………………………………8

Technical maintenance………………………………………………………………………………9

1. Daily check and periodic check …………………………………………………….9

2. Procedure of periodic maintenance………………………………………………………..9

Disassembly and reassembly…………………………………………………………………….. 13

1. Basic procedure of disassembly…………………………………………………………..13

2. Basic procedure of reassembly……………………………………………………………18

Check and maintenance……………………………………………………………………………22

1. Cylinder cover…………………………………………………………………………….. 22

2. Camshaft...............................………………………………………………………………23

3. Piston and piston pin……………………………………………………………………… 24

4. Crankshaft………………………………………………………………………………… 25

5. Cylinder block and cylinder cover................................................................................

6. Lubrication system……………………………………………………………………….. 27

7. Cooling system…………………………………………………………………………… 27

8. Fuel system……………………………………………………………………………… 28

The electrical system…………………………………………………………………………… 29

1. Starter motor……………………………………………………………………………… 29

2. Heater plug............…………………………………………………………………… .31

Troubleshooting and remedy of engine………………………………………………………...35

Preliminary run...........................................................................................................….........39

Instruction of products

1. Brief instruction of products

This model is double cylinder, V-type, four strokes, water cooled, and swirl type diesel engines.

This model will be exploited into multi-purpose engine with vertical or horizontal shaft.

This model is simple in structure, convenient in disassembly or reassembly, and have smart

size, short axial length, light weight, good performance, reliable quality, long running time. They

will meet various demands for each customer, and are ideal complementary power for

generating sets, construction machinery, ship, combined harvester, agricultural machine etc.

Welcome you to purchase.

2. Composition of model and its meaning

KM 2 V 80

Cylinder bore (mm)

V-type

Cylinder No.

Kipor

Introduction of products

3. External installation drawings and name of parts

Please refer to picture 1, picture 2, picture 3 and picture 4 for details.

Picture1 Vertical section view for KM2V80 diesel engine

Picture 2 Horizontal section view for KM2V80 diesel engine

Picture 3 Vertical figuration view for KM2V80 diesel engine

Picture 4 Horizontal figuration view for KM2V80 diesel engine

4. Specification

Table 1 Main specification table of KM2V80 diesel engine

Model KM2V80

Type Double cylinder, V-type, water-cooled, 4 stroke,

swirl type

Bore×Stroke mm 80×79

Displacement L 0.794

Compression ratio 23

Rated output/Rated speed

kW/r/min 12.5/3000 14.5/3600

Max. torque N·m 49/1600～1800

Min. speed (zero load) r/min ≤900

Lubricating system Pressure splashed

Starting system Electric starter

Output terminal direction (face

to the flywheel) Anticlockwise

Fuel type 0#(summer), -10# or -20#(winter), -35#(chillness)

Fuel consumption ratio g/(kW·h) 285 297

Lube oil type SAE 10W－30、20W－40 or L－ECD Grade

Lube oil capacity L 2.27

oil consumption ratio g/(kW·h) ≤5

Starting motor capacity V，kW 12V 1.4 kW

Charging generator capacity

(V,A) 12V 20A

Battery capacity (V,AH) 12V 60AH

Overall dimension （L×W×H） mm 616×486×528

Net weight kg 58

5. Main adjusting specification

Table 2 Main adjusting specification of KM2V80 diesel engine

Item Standard value

Cylinder compression clearance height

mm

0.88～1.2

Advanced angle of fuel supply BTDC 18.5°±1°

Fuel spraying pressure Mpa 13°±0.5°

Valve timing Inlet valve Open at BTDC 22°

Close at ABDC 56°

Exhaust valve Open at BTDC 61°

Close at ATDC 26°

Valve clearance mm (cooled state) 0.10～0.15

Valve sunk volume mm 0.5±0.10

Oil pressure Mpa 0.25～0.5

6. Tighten torque of main bolt and nut

Table 3 Tighten torque of main bolts and nuts

Value

Item Thread

Tighten torque

（N·m ） Remark

Cylinder cover bolt M9×1.25 60±5

Connection rod bolt M7×1 28±2

Flywheel bolt M10×1.25 75～80

Crankcase cover bolt M8×1.25 22～25

Fuel injector bolt M20×1.5 50±5

Heater plug M10×1.25 12±2

General bolt: mechanical performance

is 8.8 grade

M6×1.0 8～12

M8×1.25 17～23

M10×1.5 40～50

M12×1.75 85～100

M14×1.5 130～150

M16×1.5 220～240

7. Fit clearance and interference table

Table 4 Fit clearance and interference table

No. Name Standard dimension（mm） Fitting clearance

（mm） Remark

1 Cylinder inner diameter/

Piston top outer diameter

φ80H7(+0.03

0 )／d-0.515±0.01 0.565～0.635


Piston skirt upper part

φ80H7(+0.03

0 )／d-0.125±0.01 0.175～0.245


Piston skirt diameter

φ80H7(+0.03

0 )／φ80-0.06

-0.08 0.06～0.110

4. Piston pin hole/Piston pin φ20-0.002

-0.008 ／φ20 0 -

0.006 0.004～－0.008

5 The width of ring groove /

The height of 1st ring 1.2

+0.060

+0.040 ／1.2-0.01

-0.02 0.05～0.08


The height of 2nd ring

1.5+0.040

+0.020 ／1.5-0.01

-0.02 0.03～0.06


The height of 3rd ring

3.0+0.030

+0.010 ／3-0.01

-0.02 0.02～0.05

8 Open clearance of 1st ring 0.25～0.35

9 Open clearance of 2nd ring 0.20～0.35

10 Open clearance of 3rd ring 0.15～0.30

11 Connection rod bushing/

Piston pin diameter

φ20+0.025

+0.015 ／φ20 0 -

0.006 0.015～0.031

12 Connection rod bush hole diameter/

Connection rod journal φ40

+0.032

0 ／φ40f5(-0.025

-0.036) 0.025～0.062

13 Main bearing bushing hole diameter/

Main journal

φ50+0.035

+0.015 ／φ50f5(-0.025

-0.036) 0.040～0.071

14 Crankshaft axial clearance 120.7+0.10

0 ／108.6+12=120.6 0 -

0.10 0.10～0.30

15 Crankshaft axial open split/

The width of connection rod big head

40+0.25

+0.10／20-0.15

-0.20 ×2=40-0.30

-0.40 0.40～0.65

16

(Crankshaft center line to the tank

top)/(piston + connection rod + crank

radius) 13.01.1935.395.1251.28

03.054.193

0.28～0.60

17 Camshaft hole diameter/

Camshaft journal

φ18H7(+0.018

0 )／φ18e6(-0.032

-0.043) 0.032～0.061

18 Side cover camshaft hoe diameter/

Camshaft journal

φ24H7(+0.021

0 )／φ24f6(-0.040

-0.053) 0.040～0.074

19 Camshaft axial clearance 176.5+0.10

0 /164.1+12.2=176.3±0.05 0.035～0.15

20 Valve tappet hole/

Tappet diameter

φ10H7(+0.015

0 )／φ10e7(-0.025

-0.040) 0.025～0.055

21 Fuel pump tappet hole/

Fuel pump tappet

φ21H7(+0.021 )(

0)／φ21-0.047

-0.080 0.047～0.101

22 Valve pipe/ Inlet valve φ6H7(+0.012

0 )／φ6-0.030

-0.045 0.03～0.057

23 Valve pipe/ Exhaust valve φ6H7(+0.012

0 )／φ6-0.035

-0.050 0.035～0.062

24 Cylinder cover pipe hole/

Valve pipe

φ10H7(+0.015

0 )／φ10+0.055

+0.045 -0.03～-0.055

25 Cylinder cover housing washer hole/

Inlet valve housing washer

φ33.5H7(+0.025

0 )／φ33.5+0.12

+0.09 -0.065～-0.012

26 Cylinder cover housing washer hole/

Exhaust valve housing washer

φ28H7(+0.021

0 )／φ28+0.11

+0.09 -0.069～-0.11

27 Cylinder cover insert/

Combustion chamber insert

φ32.5H7(+0.021

0 )／32.5p6(+0.042

+0.026) -0.005～-0.042

28 Cylinder cover rocker shaft hole/

Rocker shaft diameter

φ12H7(+0.018

0 )／φ12f6(-0.016

-0.027) 0.016～0.045

29 Rocker arm hole/

Rocker shaft diameter

φ12H7(+0.018

0 )／φ12f6(-0.016

-0.027) 0.016～0.045

30 Timing gear hole/

Camshaft journal

φ24H7(+0.021

0 )／φ25s6(+0.048

+0.035) -0.014～-0.048

31 Crankshaft gear hole/

Crankshaft journal

φ50H6(+0.016

0 )／φ50p5(+0.037

+0.026) -0.010～-0.037

32 Flywheel gear ring hole/

Flywheel stop ring

φ214H7(+0.046

0 )／φ214u7(+0.364

+0.258) -0.212～-0.304

33

Connection rod small head hole/

Connection rod bushing outer

diameter

φ22H7(+0.013

0 )／φ22r6(+0.041

+0.028)

-0.015～-0.041

34 Connection rod bolt hole/

Bolt location diameter

φ7.5H7(+0.015

0 )／φ7.5f6(-0.013

-0.022) 0.013～0.037

35 Side cover outer rotor diameter/

Outer rotor diameter

φ41H7(+0.025

0 )／φ41-0.075

-0.115 0.075～0.14

36 Side cover oil pump shaft diameter/

Shaft diameter

φ11H7(+0.018

0 )／φ11f6(-0.016

-0.027) 0.016～0.045

37 Inner/outer rotor hole depth/

Inner/outer rotor axial depth

12+0.08

+0.04／12 0 -

0.020 0.04～0.10

Technical maintenance

1. Daily check and periodic check

Engine’ performance will be deteriorated if the operation condition becomes worse or time

prolongs, such as: fuel and oil consumption increase, exhaust harmful substance increases, or

vibratory and noise increase. Please strengthen the maintenance service of engine, insist on

daily check and periodic maintenance, which will prove efficiency and prevent fault.

Check can be divided into daily check and periodic check.

Daily check: Do daily check before starting engine, and operate it as a rule.

Periodic check: Suggest you make a running diary, writing down results of everyday operation

and check, accumulating total running time. Start your periodic check and maintenance

according to below table (table 5).

Periodic check can be divided into: 50h、250h、500h、1000h、2000h(h: hours)

Time interval of periodic check can be properly advanced or delayed according to the engine’s

purpose, location condition, fuel or lube oil’s quality and other using conditions.

Table 5 Periodic check table of engine

System Checking item Everyday 50h 250h 500h 1000h 2000h

Fuel

Check and refill fuel oil ○

Check for oil leakage ○

Drain out fuel oil ○

Replace the oil filter element ◎

Lube oil

Check and refill lube oil ○

Check for oil leakage ○

Replace lube oil ◎first

time

◎seco

nd time

Replace lube filter element

Cooling

water

Check and refill cooling water ○

Clean radiator element ○

Replace cooling water ◎

Wash and maintain cooling

system

●

Robber

pipe

Replace fuel pipe and cooling

water tube

○ ◎

Operation

system

Speed regulator operation ○

Idle adjust ●

Inlet

system

Clean and replace air cleaner

element

○clean ◎

Electric

parts

Check alarm ○

Check electrolyte and charge

the battery

○

Cylinder

cover

Adjust clearance of

intake/exhaust valve

○first

time

○seco

nd

time

Wear of intake/exhaust valve

sealing ring belt

●

○：check ◎：replace ●：Contact with Kipor

agent

2. Procedure of periodic check

2.1 First 50h operation check

At the beginning time of operation, the inner parts wear

mutually and the lube oil is polluted soon, so please replace

the lube oil and oil filter element. Oil draining is much easier and quicker when the engine is hot.

Notice: Prevent be scalded when draining out the hot oil, and don’t let the hot oil splash on you.

2.1.1 Drain out lube oil: Prepare an oil basin to store oil before draining, loosen the drain screw

with a spanner, and then begin to drain oil. Make sure you have tightened the drain screw after

draining to prevent be dropped out.

Danger: Indicate that severe damage will result if you haven’t tightened the drain screw.

2.1.2 Replace oil filter element: Revolve down the oil filter element with a filter element spanner

in anticlockwise direction, clean the oil filter seat, smear a thin lube oil on the filter element

sealing gasket before replacing, revolve hard with hand in clockwise direction, then revolve 3/4

circle with filter element spanner.(Tighten torque valve20-23N.m)

2.1.3 Refill fuel, about 6.9L.

Run the engine 5 minutes to preheat the engine, and check for oil leakage. Recheck fuel after

stop running 10 minutes, and refill to the upper limit line.

After the initial maintenance, replace fuel and oil filter element regularly per 250h interval.

2.2 Check per 50h operation

2.2.1 Drain out fuel tank: Prepare an oil basin; revolve down the drain screw, drain out water and

other foreign matter in the fuel tank; install drain screw and tighten up, check for oil leakage.

2.2.2 Check battery: Disconnect battery negative electrode earth wire when checking the electric

appliance system, or fire will result by short circuit; Make sure to be well-ventilated, or hydrogen

caused during charging will burn; Check battery electrolyte and refill to the upper limit location if

it is gong to reach the lower one, otherwise life of battery will be shorten, or even explosion will

be caused. You should always check and refill distilled water since electrolyte lever drops down

quickly in summer. Please recharge the battery if rotation speed of crankshaft is slower than

normal and starting is failure. If you still can’t start the engine after recharging, replace the battery.

2.2.3 Clean air filter: Air filter element will easily be polluted by dust, oil mist or steam, which will

result in increase of intake resistance, decrease of intake volume, and black smoke of engine,

so you should always check and clean the oil filter element, or even replace it; Cleaning should

be more frequent if operating at

Fuel

injector

and fuel

injection

pump

Check and adjust fuel injection

pressure

○

Timing check and adjust of fuel

injection

○

Maintenance of fuel injector

and fuel injection pump

●

Picture 6 Clean air filter places full of dust(such as quarrying plant, coal yard

or road building plant), foreign matter inside the oil filter should be cleaned; Take out filter

element parts from air filter shell, blow dust down with compression air. Please replace filter

element parts if papery filter element is broken. Clean oil sludge inside the air filter; cover the air

inlet port with cloth to prevent some other matter dropping into the air inlet manifold.

2.2.4 Install the air filter, pay attention to the sealing condition between filter element and

connecting pipe to prevent air entering into cylinder not through filter element.


2.3.1 Replace lube oil and filter element inside the oil filter, replace once per 250h operation from

the second time.

2.3.2 Check and clean radiator element: Dust and dirt adhesion on the radiator element will

reduce radiator’s cooling performance and result in engine’ overheat, you can advance the

cleaning according to special condition, or even clean it everyday; Flow down dust and dirt

around the radiator element with 196kPa(2kgf/cm2 ）compression air or even the lower air

pressure compression air. If there is still dirt, clean completely with detergent and water; Wear

protecting grasses to prevent dust or floating matter hurting your eyes before using compression

air; don’t try to clean radiator element with high pressure water tap and high pressure air, or try

to clean with brush, which will damage radiator element.

2.3.3 Replace air filter element: Damaged filter element will bring air enter into cylinder without

filtering, and accelerates wear of valve, cylinder, piston and piston ring. Dusty air filter element

will result in hard starting, power decrease and black smoke of engine.


2.4.1 Replace fuel filter: Regularly replace diesel filter element before it is blocked by oil mist.

(1) Close oil tank switch, disassemble inlet/exhaust pipe, take out diesel filter element, and then

clean the fuel filter seat.

(2) Replace filter element, install the fuel filter.

(3) Install the fuel inlet/exhaust pipe, turn on oil tank switch, and drain out air in fuel line,

otherwise hard starting or stop running after starting will be resulted.

2.4.2 Replace cooling water: Drain out water after the cooling water is cooled down, in order to

prevent be scalded by the splashing hot water.

(1) Cooling water which contains iron rust or incrustation will deduce cooling performance, as

well as refrigerating fluid.

(2) Cooling water should be replaced at least once per year. Fill in soft water only after draining

out the cooling water.

2.4.3 Check and adjust valve clearance

Make sure that the valve is off, because only in that condition there will be valve clearance.

Notice: This single cylinder/double cylinder engine is marked from flywheel terminal to gearing

box terminal, which is different from the normal way. Upper dead point line for each cylinder is

marked on the flywheel; you can see them from the dead point view port hole on flywheel cover

（φ30）. Upper dead point line for single cylinder is marked on engine body.

(1) Adjust valve clearance

a) Make sure the 1st cylinder piston is at the compression upper dead point, you can then

adjust the inlet/exhaust air clearance of the 1st cylinder 0.1mm；

b) Revolve flywheel 280° in anticlockwise direction after regulation, and adjust the

inlet/exhaust air clearance of 2nd cylinder 0.1mm;

Notice: Do remember tighten the adjusting screw cap tightly after regulation, otherwise it will

loosen soon and cause engine fail to work.

2.4.4 Check and adjust fuel injector: Check and regulation of fuel injecting pressure and injecting

mist quality should be operated on the fuel injecting experiment table.

(1) If the fuel injecting pressure is incorrect, please revolve down the fuel injecting parts fasten

cap, take out adjusting gasket and replace for a new one , so that the fuel injecting pressure

can attach to the correct valve（13±0.5）MPa.

(2)If the fuel injecting pressure is correct while the quality of injecting mist is poor, please clean

the injecting hole or replace the fuel injector parts;

(3)When installing fuel injector into the cylinder cover, please use the original fuel injecting

washer to make sure the fuel injecting head extend 2.2-2.3mm. Too big mistake will affect power,

fuel consumption or exhaust smoke of diesel engine.


2.5.1 Check and adjust the injection advance angle (please leave it to specialist, for this task

needs special tools, knowledge and skill).

a. Concrete steps

(1) Refill the fuel injection pump with fuel, and revolve the flywheel in clockwise direction to the

compression upper dead centre. Resolve the flywheel for several times until there is fuel flowing

out.

(2) Install the high pressure oil pipe tie which is used for measuring the oil supplying advance

angle, then resolve the flywheel to drain out the air inside. Stop the flywheel at 30° BTDC.

(3) Resolve the flywheel slowly in clockwise direction and check the oil level, stop the flywheel

immediately when oil begins fluctuating. The oil supplying advance angle is supposed to be 18.5°

±1°, if not, you should disassemble the fuel injection pump assembly, replace the adjust gasket,

check and adjust for another time until the value gets to 18.5°±1°.

(4) Screw on the fuel injection pump fixed bolt after adjusting and install the high pressure oil

pipe parts in turn.

Notice: Drain out the air in the high pressure oil pipe.

The rust and scale in the cooling system will worsen the heat abstraction performance and

increase the cooling water temperature. So please clean the rust and scale in the cooling system

by professional.

2.6 Check per 2000h running

2.6.1 Check and replace fuel、lube oil、cooling water and rubber hose. Check each kind of rubber

hose regularly; replace them if there is damage or aging.

2.6.2 Check and grind sealing ring belt of intake/exhaust valve. Please consult with the specialist

because professional skill is needed. You should check the sinking quantity of air door, width of

sealing ring belt and clearance between valve stem and valve pipe.

2.6.3 Check performance of fuel injection pump, this job needs oil pump experiment table, so

please consult with the specialist to maintain. You should check aiming point oil supply quantity,

starting oil quantity, oil supply uniformity of each cylinder, governor, maximum and minimum

stable rotation limit.

Disassembly and reassembly of diesel engine

1. Basic procedure of disassembly

(1) Prepare necessary room or container to store parts before disassembly, put each kind of bolt

and screw as well as related parts together, in order to prevent possible mistaken.

(2) Make sure what problem there is before disassembling; avoid mistaken disassembly.

1.1 Disassemble muffler weldment

(1) Loosen the four M8 nuts which fix the muffler weldment.

(2) Remove the muffler weldment from the cylinder cover.

Refer to picture 11

picture 11

1.2 Disassembly the air filter assembly

(1) Loosen the two M8 nuts which fix the air filter seat.

(2) Loosen the hoop of the connection hose.

(3) Remove the air filter assembly.

Refer to picture 12

picture 12

1.3 Disassemble the heat abstraction water tank and overflow tank parts

(1) Loosen the four M8X10 bolts and nuts which fix the heat abstraction water tank parts

(2) Loosen the hoop which fixes the inlet/outlet hose of heat abstraction water tank

(3) Remove the heat abstraction water tank parts

(4) Remove the overflow tank.

Refer to picture 13

picture 13

1.4 Disassemble fan gasket、fan impeller and fan seat

(1) Loosen the four M6×25 bolts, which fix fan impeller and fan gasket and then remove the fan

impeller and fan gasket.

(2) Loosen the three M6×16 bolts which fix fan seat and then remove the fan seat.

Refer to picture 14

picture 14

1.5 Disassembly the air conduct cover parts

(1) Loosen the three M10X20 bolts which fix the air conduct cover parts on the flywheel end.

(2) Loosen the four M6X16 bolts which fix the air conduct cover parts on the engine seat.

(3) Remove the air conduct cover parts

Refer to picture 15

picture 15

1.6 Disassemble the inlet pressurizer tank

(1) Loosen the four M6X18 bolts which fix the inlet pressurizer tank parts on the cylinder cover

inlet flange end.

(2) Remove the inlet pressurizer tank parts.

Refer to picture 16

picture 16

1.7 Disassemble the water pipe weldment

(1) Loosen the M8X10 bolt which fixes the water pipe weldment on the crankcase cover

(2) Loosen the hoop which connects the thermostat connection pipe and water outlet pipe.

(3) Remove the water outlet pipe weldment.

Refer to picture 17

picture 17

1.8 Disassemble the thermostat parts, water outlet pipe seat and water outlet connection pipe.

(1) Loosen the two M6X40 bolts which fix the thermostat parts.

(2) Loosen the two M6X20 bolts which fix the water outlet pipe seat.

(3) Remove the thermostat parts, water outlet pipe seat and water outlet connection pipe.

Refer to picture 18

picture 18

1.9 Disassemble the rear support plate parts of starting motor and starting motor parts

(1) Loosen the M10X20 bolt which fixes the rear support plate of starting motor on the engine

side cover.

(2) Loosen the two M10X30 bolts which fix the starting motor parts.

(3) Remove the starting motor parts and rear support plate of starting motor.

Refer to picture 19

picture 19

1.10 Disassemble the cylinder cover parts

(1) Loosen the four M6X25 bolts which fix the cylinder cover.

(2) Remove the cylinder cover parts

Refer to picture 20

picture 20

1.11 Disassemble the high pressure oil pipe parts and fuel injector assembly

(1) Loosen the tie of high pressure oil pipe which connects the fuel injection pump and fuel

injector. Remove the high pressure oil pipe parts.

(2) Loosen the fuel injector of the 1st cylinder, take out the fuel injector, two washer and heat

insulation sleeve from the cylinder cover.

(3) Disassemble the fuel injector of 2nd cylinder in the same way.

Refer to picture 21

picture 21

1.12 Disassemble the cylinder cover parts, valve push rod and cylinder cover gasket

(1) Loosen the four cylinder cover bolts which fix the cylinder cover parts

(2) Remove the cylinder cover parts, two valve push rods and cylinder cover gasket

(3) Disassemble the cylinder cover parts in the same way.

Refer to picture 22

picture 22

1.13 Disassemble the governor assembly, fuel injection pump assembly and fuel pump tappet.

(1) Loosen the seven M6X70 bolts, one M6X85 bolt and four M6X20 bolts which fix the governor

assembly.

(2) Remove the governor assembly and fuel injection pump assembly.

(3) Take out the two fuel pump tappet assembly.

(4) Pay attention to the adjusting gasket label in the fuel pump tappet. Make sure the reassembly

is correct.

Refer to picture 23

picture 23

1.14 Disassemble the flywheel parts and electromagnetic rotor parts

(1) Loosen the four M10X32 flywheel bolts which fix the flywheel on the crankshaft.

(2) Remove the flywheel parts and electromagnetic rotor parts.

Refer to picture 24

picture 24

1.15 Disassemble the stator coil parts

(1) Loosen the three M6X25 bolts and one bolt which fix the stator coil parts on the engine rear

end.

(2) Remove the stator coil parts

Refer to picture 25

picture 25

1.16 Disassemble the crankcase cover parts

(1) Loosen the seventeen M8X40 bolts which fix the crankcase cover.

(2) Remove the crankcase cover parts.

Refer to picture 26

picture 26

1.17 Disassemble the camshaft bearing cover and oil supplying camshaft.

(1) Loosen the two M6X16 inner hexagonal bolts which fix the camshaft bearing cover

(2) Remove the camshaft bearing cover and oil supplying camshaft.

(3) Screw on the bearing cover.

Refer to picture 27

picture 27

1.18 Disassemble the camshaft and valve tappet

(1) Draw out the camshaft parts from the crankcase.

(2) Take out the four valve tappets.

Refer to picture 28

picture 28

1.19 Disassemble the oil filter baffler weldment and oil filter parts

(1) Loosen the two M6X12 bolts which fix the oil filter baffler weldment and remove the oil filter

baffler weldment.

(2) Loosen the oil filter parts with a special spanner and remove the oil filter parts.

Refer to picture 29

picture 29

1.20 Disassemble the piston connection rod assembly

(1) Loosen the connection rod bolts of 1st cylinder and 2nd cylinder to remove the connection rod

cover.

(2) Take out the two piston connection rod assembly.

(3) Reassemble the connection rod cover and connection rod bolt immediately after taking out

the piston connection rod.

(4) Mark the piston connection rod assembly of 1st cylinder and 2nd cylinder.

Refer to picture 30

picture 30

1.21 Disassemble the crankshaft parts

Draw out the crankshaft parts from the crankcase.

Refer to picture 31

picture 31

2. Basic procedure of reassemble

Notice items before reassembling

(1) Clean thoroughly and check all parts.

(2) Lubricate moving parts and revolving parts with fresh oil.

(3)Use new gasket、O-style seal ring、oil seal and rubber pipe.

(4)Use liquid sealing glue to prevent oil leakage.

(5)Make sure clearance between each part (oil film, thrust plate etc) is correct.

2.1 Reassemble crankshaft parts

(1)Smear oil on the surface of sliding bearing and crankshaft main journal.

(2)Install the crankshaft parts vertically into the sliding bearing hole.

2.2 Reassemble piston connecting rod assembly

(1)Smear fresh oil on piston ring、piston pin、cylinder cover and connecting rod big-end hole.

(2)The opening of piston ring should be staggered: the 1st ring and the 2nd ring staggered 180°,

the 2nd ring and the 3rd ring staggered 100°. Avoid piston main pushing side, lean piston skirt

flute on the side of main oil duct. Refer to picture 32

Picture 32

(3)Install disassembled piston connecting rod parts into cylinder cover according to original

cylinder number, clamp piston ring with special tools, push piston into cylinder, then close the

connecting rod cover. Notice that connecting rod body and bush locating skirt of connecting rod

cover should be on the same side, never turnaround.

(4)Smear thread fasten glue on thread of connecting rod bolt, tighten uniformly to stipulate

tighten torque for three times (28±2)N·m

(5)Rock connecting rod cover with hands, it should move smoothly and can’t be seized.

2.3 Reassemble the oil filter parts and oil filter baffler weldment

(1) Smear fresh oil on the oil filter parts seal ring and screw it on the connection turnbuckle.

(2) Screw on the oil filter parts with special spanner (for about 3/4 circuit)

(3) Reassemble the oil filter baffler weldment and fix it with two M6X12 bolts.

2.4 Reassemble valve tappet and camshaft parts

(1) Smear little fresh oil on the surface of valve tappet, and install them into the upper valve

tappet hole.

(2) Smear little fresh oil on the camshaft and install it into the camshaft hole, make sure the

joggle label on the camshaft timing gear matches with that of the crankshaft timing gear.

(3) Revolve the crankshaft and check the joggle of two timing gears.

2.5 Reassemble the oil supplying camshaft and camshaft bearing cover

(1) Smear little fresh oil on the oil supplying camshaft and install it into the camshaft hole.

(2) Install the camshaft bearing cover on the bearing seat and fix it with two M6X16 inner

hexagonal bolts.

2.6 Reassemble the crankcase cover parts

(1) Smear little seal gum on the crankcase cover.

(2) Install the crankcase cover and fix it with seventeen M8X40 bolts.

2.7 Reassemble the stator coil parts

(1) Install the stator coil parts on the flywheel end.

(2) Fix it with three M6X25 bolts.

2.8 Reassemble the oil seal, flywheel and electromagnetic rotor parts

(1) Smear little fresh oil on the oil seal lips and install it vertically into the crankcase cover oil

seal hole. Pay attention not to roll or lean it.

(2) Install the flywheel and electromagnetic rotor parts on the crankshaft flywheel end.

(3) Fix the flywheel on the crankshaft end with four M10X32 flywheel bolts.

2.9 Reassemble the fuel pump tappet, governor assembly and fuel injection pump assembly

(1) Smear little fresh oil on the two tappets and install them into the tappet hole on the engine

top.

(2) Smear seal gum on the governor installation face.

(3) Fix the governor assembly and fuel injection pump assembly on the engine top with seven

M6X70 bolts, one M6X85 bolt and two M6X20 bolts.

2.10 Reassemble the cylinder cover gasket, valve push rod and cylinder cover assembly.

(1) Smear little seal gum on both sides of cylinder cover gasket, install it on the engine top.

(2) Smear little fresh oil on the valve push rod and Install it the valve tappet hole.

(3) Install the 1st cylinder cover assembly on the cylinder cover, screw on the two cylinder cover

long bolts and cylinder cover short bolts, the torque is (60±5)N·m.

(4) Reassemble the 2nd cylinder cover assembly in the same way.

2.11 Reassemble the fuel injector assembly and high pressure oil pipe parts

(1) Install the two fuel injector washers and one fuel injector heat insulation sleeve into the fuel

injector hole and then screw on the fuel injector assembly. The torque is (50±5)N·m.

(2) Reassemble the other fuel injector assembly in the same way.

(3) Install the high pressure oil pipe parts on the fuel injection pump assembly and fuel injector

assembly. Fix them securely.

2.12 Reassemble the cylinder cover parts

(1) Install the cylinder coverⅠ, and fix it with four M6X24 bolts.

(2) Install the cylinder coverⅡ in the same way.

2.13 Reassemble the support plate parts and starting motor parts

(1) Install the rear support plate on the starting motor rear end.

(2) Install the starting motor into the motor hole and fix it with two M10X30 bolts.

(3) Fix the rear support plate with one M10X20 bolt.

2.14 Reassemble the thermostat parts, water outlet pipe seat and water outlet connection pipe

(1) Install the thermostat parts on the water outlet flange face of 1st cylinder cover and fix it with

two M6X40 bolts.

(2) Install the water outlet pipe seat on the water outlet flange face of 2nd cylinder cover and fix

it with two M6X20 bolts.

(3) Check the hoop of water outlet connection pipe which connects the thermostat parts and

water outlet pipe seat.

2.15 Reassemble the water outlet pipe weldment

(1) Fix the water outlet pipe weldment with one M8X10 bolt.

(2) Connect the thermostat and water outlet pipe weldment with a hose and lock it with hoop 40.

2.16 Reassemble the inlet pressurizer tank parts

(1) Install the 0-seal ring 40X2.65 on the inlet flange groove of pressurizer tank.

(2) Install the flange face of inlet pressurizer tank on the cylinder cover inlet port and fix it with

two M6X18 bolts.

2.17 Reassemble the air conduct cover parts

(1) Install the air conduct cover parts on the flywheel end and fix it with three M10X20 bolts.

(2) Fix the air conduct cover seat and engine seat with four M6X18 bolts.

2.18 Reassemble the fan seat, fan gasket and fan impeller

(1) Install the fan seat on the flywheel end and fix it with three M6X16 bolts.

(2) Fix the fan gasket and fan impeller on the fan seat with four M6X20 bolts.

2.19 Reassemble the heat abstraction tank and overflow tank parts

(1) Install the heat abstraction tank and fix it with four M8X110 bolts and nuts.

(2) Install the overflow tank.

(3) Connect the water inlet port and outlet pipe weldment with a water tank connection hose and

lock it with hoop 40.

(4) Connect the water outlet port and water pump inlet port with a water pump inlet hose and

lock it with hoop 40.

2.20 Reassemble the air filter assembly

(1) Fix the installation seat of air filter with two M8 nuts and washers.

(2) Connect the connection hose of pressurizer tank with the inlet port of air filter, and lock it with

hoop.

2.21 Reassemble the muffler weldment

(1) Install the muffler weldment on the cylinder cover and fix it with four M8 nuts.

Check and maintain

1. Cylinder cover

1.1 Combustion chamber surface of cylinder cover

Disassemble fuel injector、 inlet valve and exhaust valve, clean the surface of combustion

chamber and see whether there is any crack or other damage. Use smear infiltration to check

minute crack.

1.2 Inlet/exhaust valve seat

(1) Clean cylinder cover、valve and valve sealing cone, insert valve into valve pipe, measure

valve sunk mete with deep vernier caliper, refer to picture 33. If the valve sunken mete or valve

ring width exceeds much, please adjust it by changing valve or valve seat gasket.

Table 6 Valve sunken mete

Model

Item

KM2V80

Standard

Valve sunken

mete

0.5～0.7

Picture 33 Measure valve sunken mete

(2) Check the seal conical surface of inlet/exhaust valve seat and observe the seal ring strip on

the valve panel and valve seat ring.

1.3 Inlet/exhaust valve and valve pipe

(1) Clean the gathered carton inside valve pipe; measure the valve pipe hole with inside diameter

level meter.

(2)Check outside diameter of valve rod with outside micrometer.

(3)Account the fitting clearance, if it exceeds the limitation valve, please change valve. If it still

can’t attach to the limitation valve after changing valve, please change valve pipe. Refer to

picture 34.

Picture 34 Check inlet/exhaust valve and valve pipe

Table 7 Fitting clearance between valve pipe and inlet/exhaust valve rod

Model

Item

KM2V80

Fitting clearance

between valve

pipe and inlet

valve rod

0.03-0.057

(standard)

0.12

(maintenance

limitation)

Fitting clearance

between valve

0.035-0.062

(standard)

0.12

(maintenance

pipe and

exhaust valve

rod

limitation)

1.4 Valve spring

(1)Measure the free length of valve spring with vernier caliper, and change the valve spring if the

free length exceeds limitation valve.

(2)Measure the valve spring verticality; revolve valve spring to see whether the whole side of

valve spring is connected with the square ruler. Change valve spring if the measured verticality

exceeds the limitation valve.

Refer to picture 35

Table 8 Free length and verticality of valve spring

Model

Item

KM2V80

Standard

Valve spring free

length

39.5

Valve spring

verticality

0.5

Picture 35 Measure valve spring

(3)Check whether there is any crack or corrosion on the valve spring surface, if there is any,

please change it.

1.5 Lube oil clearance between rockshaft and valve rocker hole

Measure the outside diameter of rockshaft with outside micrometer; measure the aperture of

valve rockshaft hole with inside lever meter. Then account lube oil clearance, if the measured

lube oil clearance exceeds limitation value, please change rockshaft and valve rocker arm. Refer

to picture 36

Table 9 Fitting clearance of valve rocker arm hole and rockshaft diameter

Model

Item

KM2V80

Standard Service

limitation

Valve rocker arm hole and 0.016～ 0.12

rockshaft diameter 0.045

Picture 36 Measure lube oil clearance between rockshaft and valve rocker arm hole

1.6 Adjust valve clearance

Adjust valve clearance when the generator is at cooling state. Refer to picture 37

Table 10 Clearance of inlet and exhaust valve

Model

Item

KM2V80

Standard

Inlet valve clearance 0.10～0.15

Exhaust valve clearance 0.10～0.15

Picture 37 Adjust valve clearance

1.7 Measure cylinder compression clearance height

(1)Disassemble cylinder cover, put fuse ф1.5×10mm of the same height on the four points of

piston top, reassemble cylinder cover, screw on cylinder cover bolts according to the stipulated

order and torque.

(2)Revolve crankshaft in anticlockwise direction, flat fuse, disassemble cylinder cover and take

out the flat fuse, and measure its thickness. Take the average valve of four fuses as cylinder

compression clearance. Refer to picture 38.

Table 11 Piston top clearance

Model

Item

KM2V80

Standard

Piston top

clearance

0.88～1.20

Picture 38 Measure piston top clearance

2 Camshaft parts

2.1 Lube oil clearance of camshaft axial diameter

Measure the camshaft journal with outside micrometer, measure inside diameter of camshaft

hole with inside diameter lever meter, account the lube oil clearance. If the measured valve

exceeds the limitation valve, please change camshaft. Refer to picture 39.

Table 12 Fitting clearance between camshaft aperture and camshaft axial diameter

Model

Item

KM2V80

Standard Service

limitation

Camshaft aperture and

camshaft axle diameter

0.032-

0.061

0.15

Picture 39 Measure lube oil clearance of camshaft axial diameter

2.2 Height of cam

Measure the height of cam at its top point with outside micrometer, if the measured height

exceeds the limitation valve, please change for a new camshaft. (Height for inlet/exhaust cam is

31.13+0.03

-0.50 ). Refer to picture 40.

Picture 40 Measure the height of cam

2.3 Lube oil clearance of camshaft axial diameter

Measure camshaft journal with outside micrometer, measure inside diameter of camshaft hole

with inside diameter lever meter; account the lube oil clearance. If the measured clearance

exceeds the limitation valve, please change the camshaft. Refer to picture 41.

Picture 41 Measure fitting clearance of camshaft aperture and axial diameter of oil supplying

camshaft

Model

Item

KM2V80

Standard Service

limitation

Camshaft aperture and

axial diameter of oil

supplying camshaft

0.032～

0.061

0.15

2.4 Valve tappet

(1) Check the upper part of tappet. The tappet center line is supposed to be off-centering to the

camshaft center, so that to avoid uneven wearing. Change the tappet if it wears severely.

(2) Check the tappet surface. Change the tappet if it is damaged or worn.

3. Piston and piston pin

3.1 Piston

(1) Check piston top surface, clear up the gathered carton on it, please be careful and don’t hurt

the surface.

(2) Check piston outside diameter, if damage of piston surface or ring groove exceeds the

limitation value, please change for a new piston.

(3) Check inside diameter of piston pin hole, if the value of it exceeds the limitation value, please

change for a new piston. Refer to picture 42.

Picture 42 Check the inside diameter of piston pin hole

3.2 Piston ring

(1) Use special tools to assemble or disassemble piston ring, don’t separate piston ring too hard.

(2) Clear up the gathered carton in the ring groove; use thickness gauge or depth gauge to

measure the clearance between piston ring and ring groove. If the measured value exceeds the

limitation value, please replace piston ring or piston. If the clearance is too big, air leakage will

be caused, and then result in leakage of lube oil. Refer to picture 43.

Table 14 Clearance between piston ring and ring groove

Model

Item

KM2V80

Standard Service

limitation

Height of ring groove and

thickness of the 1st ring

0.05～

0.08

0.15


thickness of the 2nd ring

0.03～

0.06

0.15


thickness of the 3rd ring

0.02～

0.065

0.15

Picture 43 Check clearance between piston ring and ring groove

(3) Assemble piston ring to damage parts of cylinder cover, measure piston ring gap clearance

with thickness gauge. If the measured value exceeds the limitation value, replace piston ring or

cylinder cover. Refer to picture 44

Table 15 Gap clearance of piston ring

Model

Item

KM2V80

Standard

Gap clearance of the 1st ring 0.25～0.35

Gap clearance of the 2nd ring 0.20～0.35

Gap clearance of the 3rd ring 0.15～0.30

Picture 44 Measure the gap clearance of piston ring

3.3 Piston pin

Measure the outside diameter of piston pin, if the measured value exceeds the maintenance

limitation, or has been grinded severely into echelon form, then you should replace the piston

pin. Refer to picture 45.

Table 16 Fitting clearance between piston pin hole diameter and piston pin diameter

Model

Item

KM2V80

Standard Service

limitation

Piston pin hole diameter

and piston pin diameter

0.004～

0.008

0.025

Picture 45 Measure outside diameter of piston pin and diameter of connection rod bushing hole

3.4 Connecting rod

(1) Check parallelism and torsion deformation of connection rod big head and small head. Clamp

measurement in the big head hole and small head hole to check the its depth of parallelism and

distortional deformation. If the depth of parallelism exceeds promised limitation, please replace

connecting rod. Refer to picture 46.

Table 17 Parallelism of connection rod big head hole and small head hole

Model

Item

KM2V80

Standard

Parallelism of

connection rod

big head and

0.04/100

small head

Picture 46 Measure the parallelism of connecting rod big head and small head

(2)Check the surface of connecting rod bushing to see whether there is any gaffing、melting or

seizure, if there is gaffing or damage , please change the bushing.

3.5 Lube oil clearance between piston pin and connecting rod small head bushing

Measure the outside diameter of piston pin which connects with connecting rod bushing with

outside micrometer, measure inside diameter of connecting rod small head bushing with inside

diameter lever meter; account the lube oil clearance. If the measured valuve exceeds the

limitation value, please replace the piston pin and bushing.

Table 18 Fitting clearance between connecting rod bushing hole diameter and piston pin

diameter

Model

Item

KM2V80

Standard Service

limitation

Connecting rod bushing

hole diameter and piston

pin diameter

0.015～

0.031

0.06

4. Crankshaft

4.1 Lube oil clearance of crankshaft、connecting rod big head hole and main bearing hole

(1) Painting check of journal neck

Clean crankshaft, check whether there is crack by painting infiltrating or magnetic inspection. If

there is crack or severe damage, please replace the crankshaft.

(2) Measure diameter of crankshaft crank pin (connecting rod journal) with outside micrometer;

measure connecting rod big head hole diameter with inside lever meter, then account the lube

oil clearance. If the measured value exceeds the limitation value, please replace crankshaft or

connecting rod bushing. Refer to picture 47.

Table 19 Fitting clearance of connecting rod bushing aperture and crankshaft connecting rod

axial diameter.

Model

KM2V80

Standard Service

Item limitation

Connecting rod bushing aperture

and crankshaft connecting rod

axial diameter

0.025～

0.062

0.15

Picture 47 Check the connecting rod axial diameter

(3) Check crankshaft main journal diameter with outside micrometer, measure main bearing hole

diameter with inside lever meter, then account the lube oil clearance. If the measured value

exceeds limitation value, please replace crankshaft or main bushing. Refer to picture 48.

Table 20 Fitting clearance of main bearing hole and main axial diameter

Model

Item

KM2V80

Standard Service

limitation

Main bearing hole and main axial

diameter

0.040～

0.071

0.15

Picture 57 Measure main bearing hole and main axial diameter

5. Cylinder block and cylinder cover

Measure the inner diameter of cylinder cover. If the measured value exceeds the limitation value,

please bore the cylinder again and use the bigger size piston. Refer to picture 49

Table 21 Cylinder cover diameter

Model

Item

KM2V80

Standard

Cylinder cover

diameter

80.00～80.03

Picture 49

6. Lubricating system

6.1 Clearance between outer rotor hole and outer rotor

Measure the axial diameter of outer rotor with outside micrometer, and measure the oil pump

outer rotor hole on the crankcase cover with inner level meter, account the lube oil clearance. If

the measured value exceeds the limitation value, please change the oil pump parts. Refer to

picture 50.

Table 22 Clearance between outer rotor hole and outer rotor

Model

Item

KM2V80

Standard Maintenance

limitation

Clearance

between outer

rotor hole and

outer rotor

0.075～0.14 0.20

Picture 50 Clearance between outer rotor hole and outer rotor

6.2 Clearance between rotor pump shaft hold and rotor pump shaft

Measure the rotor pump shaft diameter with outside micrometer and measure the rotor pump

shaft hole diameter with level meter, account the lube oil clearance. If the measured value

exceeds the limitation value, please change the oil pump rotor parts. Refer to picture 51.

Table 23 Clearance between rotor pump shaft hole and rotor pump shaft

Model

Item

KM2V80


limitation

Clearance

between rotor

pump shaft

hole and rotor

pump shaft

0.016～0.045 0.10

Picture 51 Measure the clearance between rotor pump shaft hole and rotor pump shaft

6.3 Axial clearance of oil pump

(1) Measure the depth of oil pump hole on the crankcase cover with depth meter.

(2) Measure the axial thickness of inner/outer rotor with outside micrometer.

(3) Account the axial clearance. If the measured value exceeds the limitation value, please

change the oil pump rotor parts. Refer to picture 52.

Table 24 Axial clearance of oil pump

Model

Item

KM2V80


limitation

Axial clearance of

oil pump

0.04～0.10 0.15

Picture 52 Axial clearance of oil pump

7. Cooling system

7.1 Opening temperature of thermostat

Add a piece of line between valves of thermostat, put thermostat and a temperature gauge into

a barrel. Heat the water in barrel gradually, hold on the line and hang thermostat in air.

Thermostat will open as the water temperature increases, please read the temperature. Go on

heating, when the thermostat opens for about 6mm, then read again the temperature. If the

temperature is not in the leaving factory range, you should replace thermostat. Refer to picture

53.

Table 25 Temperature of thermostat

Model

Item

KM2V80

Standard

Opening

temperature of

thermostat

69.5◎～72.5◎

Complete opening

temperature of

thermostat

85◎

Picture 53 Measure the temperature of thermostat

7.2 Check water leakage of radiator

Fill some water into radiator, install radiator tester, and increase water pressure to 137kPa.

Check the water leakage of radiator, if the water leakage is too much, please replace radiator. If

the water leak hole is small, please adjust with radiator filling agent. Refer to picture 54.

Picture 54 Check water leakage of radiator

8 Fuel system

8.1 Check fuel injection pressure

Install fuel injector on fuel injector tester, remove test handle of fuel injector slowly, and check

the instant pressure when fuel is ejected out. If the measured valve is not within the limitation

range, please replace fuel injection gasket.

8.2 Check spray of fuel injector

Install fuel injector on fuel injector tester, and check the spray of fuel injector. If the quality of

spray is not good, please replace fuel injector parts. Refer to picture 55.

Picture 55 Check the spray of fuel injector

8.3 Check the sealing of fuel injector seat

Install fuel injector on fuel injector tester, raise the fuel pressure, and keep it at 12.7MPa for 10s.

If there is oil leakage, please replace fuel injector parts. Refer to picture 56.

Picture 56 Check the sealing of fuel injector seat

Starting System

1. Starter motor

1.1Check starter motor Refer to Fig 57

（1）Remove the motor excitation & armature winding outlet line from starter motor C wiring

terminal

（2）Connecting the motor case to battery anode with conducting wire.

（3）When connecting the motor case to battery cathode with conducting wire, the motor should

revolve, if not, please check the two windings of the motor.

Fig 57

1.2 Check electromagnetic switch Refer to Fig 58

（1）Disassemble the starter motor from the base-frame of starter motor, and prepare a 6V

battery.

（2）Connect the electromagnetic switch case and C wiring terminal to battery cathode with two

conducting wires.

（3）Connect the battery anode and receptacle S with another conducting wire, now the gear

shaft breaks cover suddenly. If coming away the C wiring terminal, the gear shaft should be on

the position protruding, this means the electromagnetic switch is in working order.

（4）While testing, please pay special attention that the turn-on time should be only 3 to 5

seconds, if not, the windings will be burnt out.

Fig 58

1.3 Motor disassembly Refer to Fig 59

（1）Disassemble the leading-out wire terminal from the electromagnetic switch wiring terminal.

（2）Loose the transfixion screw and the setscrew of carbon brush holder

（3）Take off the rear shield, stator, carbon brush holder, and armature in turn.

（4）Assembly sequence and disassembly sequence are opposite, smear some lubricant grease

on the end B of armature spline while assembling.

Fig 59

1 magnet switch 2.armature 3.leading-out wire terminal of winding 4.stator

5. carbon brush holder 6.rear shield 7.transfixion screw 8. setscrew of carbon brush holder

1.4 Electromagnetic switch dismounting Refer to Fig 60

（1）Loose the three screws of end cover

（2）Take off end cover 1 and magnet iron core.

Fig 60

1.5 Decelerating clutch dismounting Refer to Fig 61

（1）Loose three bolts which tighten the driving shell ,(two are outside of motor, one is inside of

motor),

（2）Take off driving shell, clutch subassembly, steel ball, return spring and drive gear in turn.

（3）When assembling, please smear some fresh lube oil.

1. driving shell 2.decelerating clutch 3.steel ball 4. return spring

5. electromagnetic switch 6.driving gear 7.idler gear 8. drive gear

Fig 61

1.6 Starter motor inspection and maintenance

1.6.1Commutator inspection and maintenance

（1）Check wearing of the commutator, if slightly worn, burnishing and polishing with fine rubber

（Refer to Fig 62），

Fig 62 Fig 63

（2）Measure diameter of commutator with outside micrometer, if the measured value is smaller

than the limitation size, please change armature. (Refer Fig 63)

（3） If there is much difference between excircle wire harness of commutator and axes

parallelism, while the minimum size limitation of axial diameter is in the allowable range. Please

modify to the specified value on the lathe. Refer to Fig 64 ，

Fig (a) is good, Fig (b) is bad.

Fig 64

1.6.2 Check the electric brush wear Refer to Fig 65

（1）If there is soil and dust on the wearing surface, please burnish with abrasive cloth.

（2）Measure the electric brush height with slide gauge. If A is abrasive (means A’s size is

smaller), please replace the electric brush.

Fig 65

1.6.3 Check electric brush holder Refer to Fig 66

Check the insulating property between the insulating electric brush holder and supporting plate,

if it is current conducting, please replace the electric brush holder.

Fig 66

1.6.4 Check armature Refer to Fig 67

Check the electric conductivity with ohmmeter between the commutator copper sheet and the

armature core or armature winding:

（1）If the commutator copper sheet and armature core are current conducting, please replace

armature.

（2）If commutator copper sheet and armature winding are not current conducting, please

replace armature.

（3）If the commutator copper sheet is current conducting each other, please replace armature.

（Refer to Fig 68）

Fig 67 Fig 68

Engine electrical system

1.6.5 Check stator winding

(1) Test electricity of stator winding outgoing line with an ohmmeter, if no conductivity, please

replace stator. Refer to Fig. 69

(2) Test insulatibity between stator winding and stator shell with an ohmmeter, if it is conductive,

please replace stator. Refer to Fig.70.

Fig. 69 Fig. 70

1.6.6 Check armature roll bearing

Small radial and axial clearance, smooth running of roll bearing. If big vibration, clagging or

damages happen, please replace the roll bearing.

1.6.7 Check retarder clutch. Refer to Fig.71

(1) Check all gears of retarder clutch, if severe aging or damage happens, please replace

retarder clutch or related gear.

(2) Check flexibility of retarder clutch. Smooth radial operation and rotation must be secured.

No skid when given a force, normal performance maintained, otherwise please replace.

Fig.71

1.6.8 Check electromagnetic switch. Refer to Fig.72

Test electricity conductivity of contact disc in electromagnetic switch. Hold magnetic core with

your thumb (Refer to Fig.68), test electricity conductivity between wire holder C and B. If no

conductivity, please check contact and fastening between two wire holders and inner copper

sheet.

Fig.72

2. Glow plug

(1) Check the resistance between center screw and installation thread, resistance of 0.9~1.2Ω

indicates good performance of glow plug. Refer to picture 73

(2) Resistance of 0Ωindicates short circuit between center screw and outer shell. Please change

the glow plug.

(3) If the measured value is not the standard value, please change the glow plug.

Picture 73

Engine Troubleshooting (see Table26～Table33)

Table 26 Fault of Alarm System

Fault symptom Cause Remedy

Oil Alarm １.Low oil level

２.Oil filter is blocked

Add oil

Replace oil filter element

Temperature

indicator lamp of

cooling water

１ .Low cooling water level in

radiator

２.Dirty radiator element

3.Cooling water leak, cooling

water pipe is polluted

4. Fan, Water pump

transmission V belt is loosening.

５.Fault cooling water pump

Add cooling water

Clean radiator element

Check the leakage part of cooling water,

clean or replace cooling water pipe

Tighten or replace

Repair or replace water pump

Charging indicator

lamp

１.Fault battery

２.Fault wiring

３.Fault AC alternator

Check electrolyte, and recharge or

replace battery

Check, repair or replace

Repair or replace alternator

Table 27 Fault Starting

Fault

sympt

om

Cause Remedy

Fault

Fuel

supply

syste

m

１.No fuel in fuel tank

２ .Air existed in the fuel supply

system

３ . Electron magnetic stop valve

does not work

４.Unqualified fuel

５.Dirty air filter

６.Low environmental temperature

７.Fuel filter is blocked

８.Incorrect fuel supply timing

９.Blocked nozzle

10. Incorrect air intake and outlet

valve clearance

11. Poor inside compress of Cylinder

（1）Leakage of air valve

（2）Cylinder, piston, piston rings are

worn out

12.Starting fuel supply is not enough

for fuel pump

Add fuel

Eliminate air

Check the function of electron magnetic stop valve

with electricity, then repair or replace

Replace fuel with correct specification

Replace air filter element

Use air heater

Replace fuel filter element

Check and adjust fuel supply advanced angle

Check or replace nozzle

Check and adjust valve clearance

Check the cylinder inside compress pressure standard

value 3.1Mpa, with lowest value 2.2Mpa

Check or skive air valve

Repair by professional technician

Check and adjust the fuel pump on the test table

Fault

circuit

1. Battery without enough electricity

or loosen connector

2. Starter does not work properly,

only run idle

3. Hard meshing for starter

4.Low running speed of starter

Check the wiring connector or the electrolyte level and

proportion in the battery and recharge the battery

Adjust the joggle position between starter and flywheel

gear ring surface

Battery pressure is heavy in winter or the battery cable

is slightness

Low air intake

pressure indicator

lamp

Dirty air filter element Clean the filter element through

compressive air or replace

Table 28 Abnormal smoke of exhaust air


Black smoke

1.Overload for diesel engine

2.Blocked air filter

3.Unqualified fuel

4.Large air valve clearance

5.Blocked nozzle or leaked nozzle

6.Incorrect fuel supply timing

7.Air valve without good seal

8. Cylinder, piston, piston rings are

worn

Reduce the load

Clean or replace air filter element

Use fuel with correct specification

Check and adjust air valve clearance

Check the injected fuel pressure and

injected frog quality

Check and adjust fuel supply advance

angle

Check the seal ring, repair and rubbing

Replace or repair

Blue smoke

1.High oil level

2.Breather with too much oil frog

3.Ineffective air valve oil seal, large

clearance of air valve rod

4.Opposite position of the second ring

Check the oil level in the oil base pan by

oil dip stick, and release oil

Check seal of the breather valve plate

and check if the oil return hole is smooth

Replace air valve oil seal or repair air

valve and conduit

Check and modify (Oil fleecing part is

undersurface)

White smoke

1. For it is cold in winter, it is normal to

exhaust white smoke at the beginning.

As the temperature becomes higher,

the white smoke will disappear.

2. The fuel is mixed with water, and

there is water steam exhausted

3. The injected fuel is not atomized,

and the fuel steam is exhausted.

4. The fuel injection advance angle is

too late, the fuel gas is exhausted.

5. There is leakage in cylinder, cylinder

head and cylinder gasket.

Drain the water by the fuel drain plug of

the fuel tank

Check fuel injection pressure and

injection frog quality

Check and adjust fuel supply advance

angle

Find the reason that cooling water flow

into the cylinder and repair the problem

Table 29 Insufficient Power of Engine


Insufficient

power of engine

1. Air filter element is too dirty, and the

air intake is not smooth

2. Fuel filter element is too dirty, and

the Fuel supply is unsmooth

3. Fuel pipe is blocked, the fuel supply

Clean or replace air filter element

Clean or replace fuel filter element

Check and clean or replace fuel pipe

is unsmooth.

4. There is leakage of fuel suction pipe

connector, and air goes into the pipe.

5. The timing spring is softening, and

the running speed lower down.

6. The fuel supply limit is too low, no

inefficient fuel volume

7. Fuel supply is not enough in the fuel

pump

8.Fuel supply advance angle is

incorrect

9.Fuel injection pressure and injection

frog is unqualified.

10.Incorrect air valve clearance

11.Fuel with poor quality

12. The vent hole on the fuel tank cap

is blocked

13. Insufficient compress pressure in

cylinder

（1）Air valve leak

（2）Cylinder gasket leak

（3）Cylinder, piston, piston ring are

worn and tear

（4）Installation hole of fuel injector

leak

Check the leakage and air exhaust

Check and adjust the running speed of

engine

Make the fuel volume limit larger

Check the fuel supply in the fuel pump

Check and adjust

Check and adjust

Check and adjust

Use the qualified fuel

Check and dredge

The compress pressure in cylinder

should be around 3.1Mpa

Check, rubbing air valve or replace air

valve, air valve seat ring

Tighten the cylinder head bolt or

replace cylinder gasket

Replace relative parts

Tighten or replace fuel injector washer

Table 30 Unstable operation


Unstable

operation

１. There is air in fuel system

２ . Accelerograph pull rod is not

flexible or the clearance is too large

３.Timing is not flexible

４ . The fuel supply of fuel injection

pump to each cylinder is not balanced

Exhaust air, check the leak of fuel

suction pipe connector

Check on the fuel pump test table



Table 31 Overheat of Engine

Table 32 Sudden Stop

５. The injected frog of fuel injector is

in poor quality with fuel drop



High

temperature of

supplied water

１. Insufficient cooling water in water

tank

２. Air existed in the cooling water tank

３.Overload of engine

４ . Fan belt is loosen to make the

running speed lower

５.Blocked cooling water pipe

６.Too late to inject fuel

７.Combustion is abnormal

８.Dirty water tank surface

９ . There is begrime in the cooling

system

10. Damaged thermostat

11.Water pump does not work properly

12.Water temperature meter does not

work

Add cooling water

Add cooling water or exhaust air

Deduce the load

Tighten or replace the belt

Check or replace

Adjust fuel supply advance angle

Check the injected frog quality

Clean the water tank radiator element

Clean the furring and rust in

professional way

Replace thermostat

Check or replace water pump

Replace

High oil

temperature

1.Higher or lower oil level

2.Poor oil quality

3. Air leak in the piston ring

4.High temperature of cooling water

5.Overload of diesel engine

6.Fault water temperature meter

Check the oil level by oil dip stick

Use the oil with correct specification

Check if cylinder, piston ring are worn,

clip and the connecting rod of cylinder

Check as showed above

Deduce the load

Replace

Fault

symptom

Cause Remedy

Sudden

stop

１. No fuel in the fuel tank

２. There is leak in the fuel pipe, and air

goes into the fuel pipe

Add fuel

Check the leak, and exhaust air

Table 33 Abnormal noise in engine while running

３. Blocked fuel filter element

４ .No electricity of fuel pump electron

magnetic stop valve, and cut the fuel

supply

５. Fuel pump does not work properly

６. Damaged fuel injection pump

７.No rotation of crankshaft

（1）Broken plain journal bearing of piston,

blocked cylinder

（2）Low oil pressure or broken bearing

and plain journal bearing

（3）Fault oil pump

（4）Air valve head missed, broken piston,

cylinder cover, cylinder head

Replace fuel filter element

Check circuit and electron magnetic stop

valve

Replace fuel pump

Replace fuel injection pump

Disassemble and check the engine

Check and repair by professional

technician


technician


technician


technician

Fault

symptom

Cause Remedy

Abnormal

noise in

engine

while

running

１. Large air valve clearance, with knock

２ .Large clearance between piston and

cylinder, with knock noise

３ .Large radial clearance between main

bearing and connecting rod bearing, with

knock noise

４.Large clearance between piston pin and

head bushing hole of connecting rod

５ .Large clearance between piston ring

and ring slot

６ .Large clearance of crankshaft axial

direction, crankshaft is loosen in portrait

direction

７. Air valve touches piston

Check and adjust air valve clearance

Check and replace worn out parts, keep

regular clearance

Check the crankshaft, and replace

bearing

Check and replace connecting rod

bushing and piston pin

Replace piston and piston ring

Replace thrust plate

８. Large gear clearance, with knock noise

９. Fuel injection is too early, and the noise

of hitting cylinder

10.Blocked nozzle

Check the air valve clearance and valve

timing and cylinder compress

Replace gear

Check and adjust fuel supply timing

Clean or replace nozzle

Preliminary operation

Both new engine and repaired engine have to do preliminary operation.

1.1 Preparing work before starting

Check all the bolts and nuts to make sure they are tightened.

1.2 Check and add fuel

Check the left fuel level in the fuel tank, and add fuel if necessary.

1.3 Check and add oil

Check the oil level in the oil base pan by oil dip stick, and add the same grade oil to the up limit

if necessary. Pay attention not to overfill the oil more than up limit.

1.4. Check and add cooling water

Check the cooling water level in the radiator and overflow bucket. Add soft water if the cooling

water level is too low. Daily check and adding cooling water can only be operated in the overflow

bucket. If the cooling water level is lower than the lower limit in the overflow bucket, then check

the cooling water in radiator.

1.5 Check the flexibility of governing handle.

The governing handle should be flexible and easy to operate. If there is any block, please

eliminate the problem. If operate each pivot remotely, please add oil. Please adjust the clearance

if it is large.

1.6 Check the alarm system

Make sure the alarms of cooling water, oil pressure are in normal condition. It will cause severe

result if alarm system does not work properly.

Thank you for purchasing Kipor KD388、KD488 series … · Thank you for purchasing Kipor KM2V80...

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Transcript of Thank you for purchasing Kipor KD388、KD488 series … · Thank you for purchasing Kipor KM2V80...