KM2V80
V-TWI N,
WATER-COOLED
DIESEL ENGINE
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CONTENTS
1. FOR YOUR SAFETY
1.1 Warning Symbols
1.2 Safety Precautions
2. PRODUCT OVERVIEW
2.1 Drive System and Applications
2.2 Specifications
2.3 External Views
2.4 Functions of Major Parts
2.5 Operation system
3. BEFORE OPERATION
3.1 Preparation of Fuel Oil, Lube Oil & Cooling Water
3.2 Supplying the Fuel Oil
3.3 Supplying the Lube Oil
3.4 Supplying the Cooling Water
3.5 Cranking (No-load)
3.6 Checking the Lube oil and cooling Water
4. OPERATION
4.1 Check Before Daily Operation
4.2 Starting
4.3 Adjusting the Speed
4.4 Precautions During Operation
4.5 Stopping the Engine
4.6 Taking Care During Long-term Storage
5. MAINTENANCE
5.1 Checking
5.2 Periodic Check Program
5.3 Periodic Check Procedure
6. TROUBLESHOOTING
Safety precautions and notices are described throughout this operation manual
for safe operation. Symbols used in this manual and their meanings are explained
below.
1.1 Warning Symbols
Following the precautions described in this manual will enable you to use this
engine with compete satisfaction. Failure to observe any of the rules and
precautions, however, may result in a scalding, injury, fire or engine damage.
Read this manual carefully and be sure you fully understand it before beginning
operation.
These are the warning signs which are used in this manual and the products.
Indicates an imminently hazardous situation which, if not
avoided, WILL result in death or serious injury.
Indicates a potentially hazardous situation which, if not
avoided, COULD result in death or serious injury.
Indicates a potentially hazardous situation which, if not
avoided, MAY result in minor or moderate injury.
The descriptions captioned by NOTICE are particularly important cautions
for handling. If you ignore them, the performance of your machine may be
deteriorated, leading to trouble.
Make sure to also observe warnings indicated on the driven machine and
instructions contained in the operation manual supplied from the driven machine
manufacturer.
1. FOR YOUR SAFETY
DANGER
WARNING
CAUTION
--
5.3.2 (2)
5.3.2(3)
3.1.1
3.1.1
SYMPTOM
Ref. Section
PROBABLE
CAUSEACTION
Self-starter not running
(hand turn possible)
(hand turn not possible)
Low battery voltage.
Poor contact of cable
terminals.
Faulty starter switch
Faulty starter
Faulty or burnt internal parts
Check battery fluid level.
Clean terminal off rust.
Fasten.
Call for repair.
Call for repair.
Call for repair.
Abnormal exhaust gas color
White smoke
Black smoke
Overloaded.
Clogged air cleaner.
Incorrect fuel oil.
Abnomal fuel injection
pattem.
Large clearance of
suction/exhaust valve
heads.
Reduce the load.
Replace or clean the
element.
Use the correct type of oil.
Call for repair.
Incorrect fuel oil.
Abnomal fuel injection
pattem.
Incorrect injection timing.
Lube oil burning.
Abnormally large amount
of lube oil consumption
Use the correct type of oil.
Call for repair.
Call for repair.
Call for repair.
Call for repair.
TROUBLESHOOTING INFORMATION
If your engine is not working normally, check it referring to the troubleshooting
section.
You can of course consult you KAMA dealer.
When asking the service, please give the following information to your KAMA
dealer;
Model name and serial number of your engine
Engine type number
Operating conditions. which speed or work has brought a problem.
How long have you used your engine?(Approximate area worked or hours of
operation)
Situation when a trouble is developed
(engine revolution, color of exhaust gas, fuel in use, lube oil type, engine sound,
etc.)
History of troubles
Any other information when a trouble has occurred.
--
1.2 Safety Precautions
Observe these instructions for your own safety.
Precautions for Operation
Burns from Scalding
Never open the radiator filler cap while the engine is hot. Steam and hot water will
spurt out and seriously burn you. Wait until the radiator is cooled down after the engine
has stopped, wrap the filler cap with a rag piece and slowly open the cap.
Securely tighten the filler cap after checking the radiator. Steam can spurt out during
operation, if the cap is tightened loose.
Proper Ventilation of the Battery Area
Keep the area around the battery well ventilated, paying attention to keep away any
fire source. During operation or charging, hydrogen gas is generated from the battery
and can be easily ignited.
Fires from Oil lgnition
Be sure to use the proper diesel fuel. Filling with gasoline or the like by mistake will
result in ignition.
Be sure to stop the engine before refueling.
If you spill fuel, wipe off such spillage completely.
Never place oils or other flammable materials close to engine, as this could result in
ignition.
Exhaust Gas Poisoning
Never block up windows, ventilation ports, or other ventilation equipment such as
ventilators of the engine room. Ensure good ventilation during engine operation.
Inhaling the exhaust gas is harmful.
Never operate the engine in a closed room, tunnel, underground room, manhole, or
ship's hold. It is dangerous since exhaust gas cannot get out.
Keep Away from Moving Parts
Pay sufficient attention so as not to touch rotating parts, or bring your hands or part
of your body or clothes close to rotating parts while the engine is operating. Otherwise,
you may get injured by being caught by the cooling fan, flywheel or PTO shaft. Never
operate the engine without covers on the rotating parts.
Check before starting the engine to see that any tools or cloths used in the
maintenance remains around the engine.
--
In case of an abnormality, stop the engine immediately and locate a problem by
referring to the following table.
6. TROUBLESHOOTING
3.3
5.3.1
3.4
5.3.2 (2)
5.3.2 (2)
3.2
3.2.2
3.1.1
4.2.2
5.3.4(1)
Cooling water
Temp. warning
lamp
SYMPTOM
Warning lamps
lighting during
operation
Lube oil
Pressure lamp
NOTICE
When a warning lamp lights, immediately stop the engine and
check and remove the cause
Low radiator cooling water
level.
Contaminated radiator lins.
Leak of cooling water.
Contaminated cooling water
piping.
Faulty cooling water pump.
Insufficient level of engine oil
Clogged lube oil filter
Replenish cooling water.
Clean the radiator fins.
Repair the leaking parts.
Call for service.
Call for service.
Replenish engine oil.
Replace the filter element .
Any of lamps not
lighting when starter
switch is turned ON
Charge lamp
Faulty warning lamp
Battery failure
Faulty alternator
Notice
If a warning lamp is faulty, do not continue operation.
Otherwise, faults will not be noticed, developing a serious accident.
Faulty sensor switches
Faulty lamp.
Faulty electrical wiring.
Faulty lamp.
selt-starter running
but the engine fails
to start
Any of lamps not
lighting when starter
switch is set from
START to ON
Failing to start
No fuel oil.
Air mixed in the fuel pipe.
Incorrect fuel oil.
Failure of ignition at low
temp.
Clogged fuel filter.
Low fuel injection sound.
Compression leak from
valves.
Recharge
Check battery fluid
Call for service
Repair the switches.
Replace relevant lamps.
Correct the wiring.
Replace the lamp.
Replenish the oil.
Bleed air.
Replace with correct oil.
Use the glow plug.
Replace the fuel filter.
Call for repair.
Call for repair.
Ref. Section
PROBABLE
CAUSEACTION
--
Scalds from Contact with Hot Engine Parts
Pay sufficient attention not to bring part of your hand and body or clothes in contact
with the silencer, exhaust pipe and engine body during operation or immediately after
stopping the engine.
The whole engine is hot any may cause scalding.
Never Operate the Engine while you are under the influence of alcohol
Also, never operate the engine when you are ill or feel unwell as this results in
unexpected accidents.
Safety Precautions for Inspection
Do not come in contact with battery electrolyte.
Pay sufficient attention to avoid your eyes or skin form being in contact with the
fluid. The battery electrolyte is dilute sulfuric acid and causes burns. Wash it off
immediately with a large amount of fresh water if you get any on you.
Fire due to Electric Short-Circuits
Make sure to turn off the battery switch or disconnect the negative cable ( )
before inspecting the electrical system. Failure to do so could cause short-
circuiting and fires.
Keep off Rotating Parts
Stop the engine before starting service operation. If you must inspect while the
engine is operating, never bring your hand, body or clothing in contact with or
close to rotating parts, as you may get injured by being caught by rotating parts.
Precautions to Prevent Scalds When Draining Hot Oil and Water
If lube oil must be drained from the engine while it is still hot, take care not to let
the oil splash on you to avoid scalding.
Wait until the temperature goes down before draining the coolant. Hot water
may splash to burn you.
Beware of dirt from air blowing
Wear protective equipment such as goggles to protect your eyes when blowing
compressed air. Dust or flying debris can hurt eyes.
--
5.3.5 Check every 1000 hours of operation
1. Cleaning the cooling system and checking cooling system parts
As this adjustment requires special knowledge and skill, consult with your dealer
or KAMA distributor. Rust and water scale will accumulate in the cooling water
system through many hours of operation. This lowers the engine cooling effect
and quickly deteriorates the lube oil. The following parts, especially, need
cleaning and maintenance each time the cooling water is replaced.
Cooling water system parts:
Radiator, cooling water pump, thermostat, cylinder blocks, cylinder heads, etc.
5.3.6 Check every 2000 hours of operation
1. Checking and replacing fuel hoses and cooling water hoses
As this adjustment requires special knowledge and skill, consult with your dealer
or KAMA distributor. Regularly check the rubber hoses of the fuel system and
cooling water system. If cracked or degraded, replace them with new ones.
2. Lapping intake and exhaust valves
As this adjustment requires special knowledge and skill, consult with your dealer
or KAMA distributor. The valves must be lapped to maintain air-tightness of
respective cylinders.
3. Checking and adjusting fuel injection timing
As this adjustment requires special knowledge and skill, consult with your dealer
or KAMA distributor. The fuel injection timing must be adjusted for best engine
performance.
--
Modification not authorized
Never modify this product or release the limit devices
(which limit engine speed, fuel injection quantity, etc.).
Such modification or release will impair the safety and
performance of the product and functions and result in
shorter engine life.
Disposal of waste materials
Put waste oil or drainage in a container. Never dispose of
waste oil or drainage to the outdoors, into a sewer, river,
or the sea.
Dispose of waste materials safely observing relevant
regulations and laws. Ask a specialized waste recovery
company for collection and disposal.
NOTICE
NOTICE
--
2. Replacing cooling water
Beware of scalding by hot water
Wait until the temperature goes down before draining the
cooling water. Otherwise, hot water may splash to cause
scalding.
Cooling water contaminated with rust or water scale reduces the cooling effect.
Even when antifreeze or anti-corrosive agent is mixed, the cooling water gets
contaminated due to deteriorated ingredients. Replace the cooling water at least
once a year.
(1) Draining cooling water: See 4.7.1 2 .
(2) Adding cooling water: See 3.4.
3. Checking and adjusting intake/exhaust valve head clearance
As this adjustment requires special knowledge and skill, consult with your dealer
or KAMA distributor.
This adjustment is needed to correct deviated intake/exhaust valve open/close
timing.
Negligence of this adjustment will cause noise generation from the engine and
poorer engine performance.
4. Checking and adjusting fuel injection valve
As this adjustment requires special knowledge and skill, consult with your dealer
or KAMA distributor. This adjustment is needed to obtain the optimum injection
pattern for full engine performance.
CAUTION
--
2. PRODUCT OVERVIEW
2.1 Drive System and Applications
This product is a vertical water-cooled small type muti-purpose diesel engine.
The power is transmitted downward from the engine to make the driven
machine structure simple. Since the engine requires a small mounting area,
compact driven machine can be designed.
Powerful and long-lasting torque characteristics are available for efficiency
improvement.
The engine is economical as it consumes extremely little fuel and lube oil.
The durability and reliability are increased by the forced water cooling (radiator)
and forced lubrication system.
The combustion performance is high and the engine is clean with little toxic
exhaust constituents. It is ecology oriented with significantly less vibration and
noise.
The structure facilitates operation and maintenance.
We are sure that you will be satisfied with the above feature.
The main engine specifications are standardized for multi-purpose application.
Options (fuel tank, remote controller, instruments, alarms, etc.) are provided to
meet various operating conditions.
Since installation and fitting of the engine require special knowledge and skill,
always consult with your dealer or KAMA distributor.
--
3. Replacing air cleaner element
Damaged air cleaner element admits suspended matters in the open air into the
combustion chamber to cause early engine wear and shortening of the engine
service life. The air cleaner element significantly clogged with dust also reduces
the engine output.
Replace the air cleaner element will a new one at regular intervals.
See section 5.3.2 3
5.3.4 Check every 400 hours of operation
1. Replacing fuel filter
Replace the filter at regular intervals before it is clogged with dust to adversely
affect the fuel flow.
(1) Close the cock of the fuel tank.
(2) Loosen the hose clips on the fuel filter inlet and outlet joints to remove the
fuel hose.
(3) Draw out the element assembly and remove it from the support.
(4) Press in a new fuel filter into the support until it is fixed in position.
(5) Connect the hoses to the inlet and outlet joints. Fix them with hose clips.
(6) After assembling, bleed air from the fuel system.
See section 3.2.2.
--
Clip
Fuel filter support
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