Kioti 4A200T, 4A220 Workshop Manual

Page 1
CHAPTER 2
ENGINE
Page 2
Page 3
1. GENERAL
1.1 APPEARANCE
ENGINE
The DAEDONG A series engines are vertical, water­cooled, 4-cycle, three or four cylinders diesel engines, they concentrate DAEDONG’s foremost technologies.
With swirl combustion chamber, bosch K type fuel in­jection pump, well-balanced designs, they feature greater power, low fuel consumption, less vibration and noise, and low emission.
632W201A
2-3
Page 4
ENGINE
1.2 SPECIFICATIONS
MODEL
Type
Number of cylinder Bore and stroke mm (in.) Total displacement
(in3.) Combustion chamber POWER (NET) PS/rpm (kW. rpm) Maximum idling speed rpm Minimum idling speed rpm Order of firing Direction of rotation
Injection pump Injection pressure
Injection timing (Before T.D.C) Compression ratio Fuel Lubricant Dimensions mm (length x width x height) (in.) Dry weight kg (kg, lbs.)
4A220
Vertical, water-cooled,
4-cycle diesel engine
4
87.0 x 92.4 (3.43 x 3.64)
2.197 (134.1)
vortex chamber
43/2,700 (30.9/2,700)
2,900
850 ~ 900
1-3-4-2
Counterclockwise
(viewed from flywheel side)
Bosch K TYPE mini pump
140 ~ 150 kgf/cm
2
(13.73 ~ 14.71 MPa, 1991 ~ 2133 psi)
18°
22 : 1
Diesel fuel
Engine oil SAE 15W-40
817.3 x 488.1 x 735.8 (32.2 x 19.2 x 29.0)
207 (456)
4A200T
Vertical, water-cooled,
4-cycle diesel engine (Turbo)
4
83.0 x 92.4 (3.27 x 3.64)
1.999 (122.0)
vortex chamber
47/2,600 (34.6/2,600)
2,800
850 ~ 900
1-3-4-2
Counterclockwise
(viewed from flywheel side)
Bosch K TYPE mini pump
140 ~ 150 kgf/cm
2
(13.73 ~ 14.71 MPa, 1991 ~ 2134 psi)
12°
22 : 1
Diesel fuel
Engine oil SAE 15W-40
817.3 x 542.0 x 735.8 (32.2 x 19.2 x 29.0)
211 (465)
* NOTE: Change of parts are not subject to advance notice.
2-4
Page 5
1.3 PERFORMANCE CURVE
ENGINE
632W204A 632W203A
2-5
Page 6
ENGINE
1.4 DIMENSIONS
632W205A
Sample/td Spec.
4A220
4A200T
4A220
4A200T
A
697.3 (27.45)
697.3 (27.45)
G
736 (28.98) 736 (28.98)
B
817.3 (32.18)
817.3 (32.18)
H
260 (10.24) 260 (10.24)
280 (11.02) 280 (11.02)
240 (9.45) 240 (9.45)
1.5 GENERAL WARNING
• When disassembling, arrange each part on a clean place. Do not mix them up. Replace bolts and nuts where they were.
• When connecting instruments to electrical equipment, first disconnect battery negative terminal.
• Replace gaskets or O-rings with new ones when reassembling, and apply grease on a O-rings and the oil seals when reassembling.
• When exchanging parts, use genuine DAEDONG parts to maintain engine performance and safety.
• To prevent oil and water leakage, apply non-drying adhesive to the gaskets according to this manual before reassembling.
• When hoisting up the engine, use the hook pro­vided on the cylinder head.
• When installing the engine, use the hook provided on the cylinder head.
• When installing external cir-clips or internal cir-clips, direct corner end to the non- loosening direction.
mm (in.)
C
I
D
φ
400 (15.75)
φ
400 (15.75)
J
φ
321 (12.64)
φ
321 (12.64)
E
502.6 (19.79) 519 (20.43)
K
104.5 (4.11) 104 (4.09)
F
262.5 (10.33)
282.4 (11.12)
L
-
542 (21.34)
2-6
Page 7
2. STRUCTURE AND FUNCTION
2.1 BODY
A . CYLINDER HEAD
The cylinder head is made of special alloy cast iron which can resist high temperature and pressure caused by combustion. The intake and exhaust ports are arranged cross-flow type to get high combustion efficiency by protecting the suction air from being heated and expanded by heated exhaust air.
The Daedong vortex type combustion chamber is de­signed for high efficiency combustion and reducing fuel consumption. The glow plugs assures easy engine starts even at (-) 15 °C (5 °F).
(1) Combustion Chamber (2) Inlet Port (3) Exhaust Port (4) Injection Nozzle (5) Glow Plug (6) Cylinder Head
ENGINE
632W206A
B. CYLINDER BLOCK
The engine has a high durability tunnel-type cylinder block. Furthermore, liner less type, allows effective cool­ing, less distortion, and greater wear-resistance using special material. The noise is reduced to a minimum because each cylinder had its chamber.
632W207A
632W208A
2-7
Page 8
ENGINE
C. CRANKSHAFT
The crankshaft is made of forged steel and the journals, the crankpins and the bearing surface for the oil seal are induction-hardened to increase wear resistance. Each crankshaft journal is supported by the main bear­ing case (3) having a bearing inside.
The front crankshaft bearing (2) is a solid type bushing and rear and intermediate bearings are a split type. The crankshaft’s bearings have oil holes for lubricant flow.
D. PIST ON AND PISTON RINGS
The piston are made of an aluminum alloy which is temperature and pressure resistant. Three rings in­stalled in grooves of the piston. The top ring (1) is a keystone type, which can withstand heavy loads, and the barrel face on the ring fits well to the cylinder wall. The second ring (2) is an undercut type, which pre­vents the oil from being carried up. The oil ring (3) has chambered contact faces and an expander ring, which increase the pressure of the oil ring against the cylin­der wall to scrape the oil. The top ring is plated with hard chrome to increase wear resistance (The ring of 4A200T engine is mode of a special steel).
632W209A
(1) Crankshaft (4) Crankshaft Bearing 2 (2) Crankshaft Bearing (5) Thrust Bearing (3) Main Bearing Case
E. CONNECTING ROD
The connecting rod (2), which converts the reciprocat­ing motion of the pistons caused by the fuel combus­tion into the rotating motion of the crankshaft, is made of harden forged steel. The connecting rod has bear­ings at both ends. The small end has a solid type bear­ing (small end bushing (2)) and the big end has a split type bearing (crankpin bearing (3)).
632W210A
(1) Top Ring (3) Oil Ring (2) Second Ring
632W211A
(1) Small End Bushing (3) Crankpin Bearing (2) Connecting Rod
2-8
Page 9
F. CAMSHAFT
The camshaft (3) is made of forged steel and it’s jour­nals and cams are hardened to increase wear resistance. The cams on the camshaft open and close the intake and exhaust valves with the push rods and rocker arms. The journals and their bearings are force­lubricated.
G. FUEL CAMSHAFT
This fuel camshaft is made of forged steel and its cams are hardened and tempered to increase wear resistance. The cams on the fuel camshaft (1) drive the injection pump and the fuel transfer pump. The governor balls are installed on the fuel camshaft to control the engine speed.
ENGINE
632W212A
(1) Cam Gear (3) Camshaft (2) Camshaft Stopper
H. ROCKER ARM ASSEMBLY
The rocker arm assembly includes the rocker arms (1) and an adjusting screw (3), which is at the end of rocker arm and rests on the push rod, rocker arm brackets (4) and rocker arm shaft (5). The rocker arms are activated by the reciprocating motion of the push rods and open or close the intake and exhaust valves. The rocker arm and other parts are lubricated through the drilled holes of the brackets and the rocker arm shaft.
632W213A
(1) Fuel Camshaft (2) Injection Pump Gear
632W214A
(1) Rocker Arm (4) Rocker Arm Bracket (2) Lock Nut (5) Rocker Arm Shaft (3) Adjusting Screw
2-9
Page 10
ENGINE
I. INTAKE AND EXHAUST V AL VES
The valve and its guide of the intake are different from those for the exhaust. Other parts, such as the spring, spring retainers, valve spring collets, valve stem seals are the same for both the intake and the exhaust. All contact or sliding surfaces are hardened to increase wear resistance.
J. TIMING GEARS
The crankshaft drives the oil pump and the idle gear engaged fuel camshaft and camshaft. The timing for opening and closing the valves is extremely important to achieve effective air intake and sufficient gas exhaust. The appropriate timing can be obtained by aligning the mark on the crankshaft gear (6) with one the idle gear (5), idle gear with camshaft gear, idle gear with injec­tion pump gear, when assembling.
632W215A
(1) Valve Spring Collet (4) Valve Stem Seal (2) Valve Spring Retainer (5) Exhaust Valve (3) Valve Spring (6) Intake Valve
K. FLYWHEEL
The flywheel is installed on the rear end of the crankshaft. Its inertia keeps the engine turning at a constant speed, while the crankshaft tends to speed up during the power stroke and to slow down during other stokes. The flywheel has a ring gear (1), which meshes with the drive pinion of the starter.
The flywheel has marks “TC” and “FI” on its outer rim. The mark TC shows the piston’s top dead center and the mark FI shows the fuel injection timing, when they are aligned with the mark of window on the clutch hous­ing.
632W216A
(1) Injection Pump Gear (5) Idle Gear (2) Fuel Camshaft (6) Crankshaft Gear (3) Camshaft Gear (7) Crankshaft (4) Camshaft
632W217A
(1) Ring Gear (3) Crankshaft (2) Flywheel
2-10
Page 11
2.2 LUBRICATING SYSTEM
A. FLOW OF LUBRICATING OIL
The lubricating oil is forced to each journal through the oil passages of the cylinder block, cylinder head and shafts. The oil, splashed by the crankshaft or thrown off from the bearings, lubricates other engine parts such as the push rods (11), tappets (12), piston pins and timing gears.
ENGINE
B. OIL PUMP
The oil pump is a gear type. Whose rotors have tro­choid lobes. The inner rotor (3) has 4 lobes and the outer rotor (4) has 5 lobes, and they are eccentrically engaged to each other. The inner rotor, which is driven by the crankshaft through the gears, rotates the outer rotor in the same direction, varying the space between the lobes.
While the rotors rotate from (A) to (B), the space lead­ing to the inlet port increases, which causes the oil to flow through the inlet port. When the rotors rotate to (C), the port to which the space leads is changed from inlet to outlet. At (D), the space decreases and oil is discharged though the outlet port.
632W218A
(1) Piston (9) Rocker Arm Shaft (2) Idle Gear (10) Rocker Arm (3) Oil Pump (11) Push Rod (4) Relief Valve (12) Tappet (5) Strainer (13) Oil Pressure Switch (6) Oil Filter Element (14) Camshaft (7) Bypass Valve (15) Crankshaft (8) Oil Pan
632W219A
(1) Inlet (3) Inner Rotor (2) Outlet (4) Outer Rotor
2-11
Page 12
ENGINE
C. OIL FILTER AND RELIEF V ALVE
The lubricating oil force-fed by the pump is filtered by the filter cartridge, passing through the filter element from the outside to the inside. When the filter element accumulates dirt and the pressure difference between the inside and the outside rises more than 98 kPa (1.0 kgf/cm allow the oil to flow from the inlet line to outlet line, bypassing the filter element. The relief valve ball (4) in the inlet line allows oil to prevent damage to the lubri­cating system, when the oil pressure rises more than 441 kPa (4.5 kgf/cm
2
, 14 psi), the bypass valve (1) opens to
2
, 64 psi).
632W220A
(1) Bypass Valve (2) Bypass Adjusting Spring (3) Filter Element (4) Relief Valve Ball (5) Relief Adjusting Spring
(a) To Idle Gear, Camshaft and Rocker Arm (b) From Oil Pump
(c) To Crankshaft Journal Crankpin
(d) Drain of Relief Valve
D. OIL PRESSURE SWITCH
The oil pressure switch is installed on the cylinder block and leads to the oil passage of the lubricating oil. When the oil pressure falls below the specified value, the contacts of the oil pressure switch closes to turn on the warning lamp (1).
632W221A
(A) At lower Oil Pressure
(49 kPa (0.5 kgf/cm
2
, 7 psi) or less)
(B) At Proper Oil Pressure
(1) Warning Lamp (6) Rubber washer (2 ) Battery (7 ) Oil Pressure (3) Contact Movable (8) Cylinder Block (4) Cintact Cup (9) Pressure (5) Diaphragm
2-12
Page 13
2.3 COOLING SYSTEM
A. FLOW OF COOLING WATER
The cooling system consists of a radiator (5), a cen­trifugal water pump (7), a cooling fan (6) and a thermo­stat (2). The water is cooled as it flows through the radiator core, and the fan behind the radiator pulls the cooling air through the radiator core. The water pump receives water from the radiator or from the cylinder head and forces it into cylinder block. The thermostat open or closes according to the water temperature. When the water temperature is high, the thermostat opens to allow the water to flow from the cylinder block to the radiator. When the water temperature is low, the thermostat closes and the flow stays within the block. The opening temperature of the thermostat is approx. 70 °C (160 °F).
ENGINE
632W222A
(1) Water Return Pipe (2) Thermostat (3) Cylinder Head Water Jacket (4) Cylinder Block Water Jacket (5) Radiator (6) Cooling Fan (7) Water Pump
B. WA TER PUMP
The water pump is driven with the fan drive pulley, which is on the water pump shaft and driven by the crankshaft with a belt. The water pump sucks the cooled water, forces into the cylinder block and draws out the hot water to the radiator repeatedly. The mechanical seal (3) prevents the water from entering the bearing (1).
632W223A
(a) From the Thermostat (b) To the Cylinder Block
(c) From the Radiator
(1) Bearing (3) Mechanical Seal (2) Pump Body (4 ) Pump Impeller
2-13
Page 14
ENGINE
C. THERMOSTAT
The thermostat is wax pellet type, which controls the flow of the cooling water to the radiator to keep the proper temperature. The case has a seat (1) and the pellet has a valve (2). The spindle attached to the case is inserted into the synthetic rubber in the pellet. The pellet is charged with wax.
(A) At low temperature (lower than 71 °C (160 °F)). The valve (2) is seated by the spring (7) and the cooling water circulates in the engine through the water return pipe but does not enter the radiator.
(B) At high temperature (higher than 71 °C (160° F)). As the water temperature rises, the wax in the pellet (3) turns liquid and expands, repelling the spindle. The pellet lowers and the valve (2) opens to send the cool­ing water to the radiator.
632W224A
(1) Seat (6) Wax (Solid) (2) Valve (7) Spring (3) Pellet (8) Leak Hole (4) Spindle (9) Wax (Liquid) (5) Synthetic Rubber
D. RADIATOR
The radiator core consists of water carrying tubes (2) with fins (3) at a right angle to it. The water in the radia­tor is cooled by the air flowing through between the tube wall and the fin.
E. RADIAT OR CAP
The pressure type cap is installed on the radiator, which prevents the pressure difference between the inside and the outside of the radiator from deforming the radia­tor.
(A) At high pressure Higher than 88 kPa (0.9 kgf/cm
ant temperature rises and the pressure in the radiator increase above the specified pressure, the pressure valve (1) opens to reduce the internal pressure.
(B) At low pressure When the coolant temperature falls and a vacuum is
formed in the radiator, the vacuum valve (2) opens to allow coolant stored in the over flow tank to enter the radiator.
2
, 13 psi) when the cool-
632W225A
(1) Cooling Air ( 3 ) Fin (2) Tube
632W226A
(1) Pressure Valve ( 2) Vacuum Valve
2-14
Page 15
2.4 FUEL SYSTEM
A. FLOW OF FUEL
The fuel is fed from the fuel tank (1) through the fuel feed pump (7) to the injection pump (3) thru the fuel filter (2). The injection pump force-feds the fuel through the injection nozzles (5), which inject the fuel into the cylinders for combustion. The excessive fuel from the injection pump to the injection nozzles is collected in the fuel overflow pipes (6) and returns to the fuel tank.
ENGINE
632W227A
(1) Fuel Tank (5) Injection Nozzle (2) Fuel Filter (6 ) Fuel Overflow Pipe (3) Injection Pump (7) Fuel Feed Pump (4) Injection Pipe
B. FUEL FILTER
The fuel filter removes dirt and water with its fine filter paper, which collects particles of 90 microns (0.0034 in.) at 20 kPa (0.2 kgf/cm2, 3 psi). The fuel from the fuel feed pump is filtered by the filter element (6), while flowing through the filter body (3). The air vent (2) re­turns the air in the fuel to the fuel tank to prevent the engine from stopping or running irregularly.
632W228A
(a) To Fuel Tank (b) From Fuel Feed Pump
(c) To Injection Pump
(1) Cock (4) Retainer Ring (2) Air Vent (5) Pot (3) Filter Body (6) Filter Element
2-15
Page 16
ENGINE
C. FUEL FEED PUMP
The diaphragm (6) is linked to the tappet (3) with a push rod (2). The tappet is reciprocated by the eccen­tric cam on the fuel camshaft (7).
(A) Inlet stroke When the diaphragm is pulled down by the spring,
vacuum in the chamber (5) causes the outlet valve (4) to close and the atmospheric pressure in the fuel tank forces the fuel into the chamber, opening the inlet valve (1).
(B) Discharge stroke When the diaphragm is pushed up by the cam, the
pressure in the chamber causes the inlet valve to close and forces out the fuel, opening the outlet valve.
632W229A
(a) From Fuel Tank (b) To Fuel Filter
(1) Inlet Valve (5) Chamber (2) Push Rod (6) Diaphragm (3) Tappet (7) Fuel Camshaft (4) Outlet Valve
D. FUEL INJECTION PUMP
The injection pump is bosch K type mini injection pump. It features a compact and light weight design.
632W230A
(a) To Injection Nozzle (b) From Fuel Filter
(1) Delivery Valve Holder (5) Plunger (2) Delivery Valve Spring (6) Control Rack (3) Delivery Valve (7) Plunger Spring (4) Cylinder (8) Tappet
2-16
Page 17
a. Pump Element
The pump element (1) consists of a plunger (3) and cylinder (2), their sliding surfaces are precision ma­chined to maintain fuel tightness. The plunger (3) fits in the control sleeve (5) at the driving surface (7). The sleeve is engaged with the control rack, which rotate the plunger in the cylinder to control the amount of fuel delivery.
ENGINE
632W231A
b. Operation of Pump Element
(A) Before delivery As the taper lowers, the plunger (2) lowers and fuel is
drawn into the delivery chamber (1) through the feed hole (4) from the fuel chamber (5).
(B) Beginning of delivery When the plunger is pushed up by the cam and the
head of the plunger closes the feed hole (4), the pres­sure in the delivery chamber (1) rises to push the deliv­ery valve (3) open.
(C) Delivery While the plunger (2) is rising, delivery of fuel continues. (D) End of delivery When the plunger rises further and the control groove
(6) on its periphery meets the feed hole, the fuel re­turns to the fuel chamber (5) from the delivery chamber (1) through the control groove (6) and the feed hole (4).
(1) Pump Element (5) Control Sleeve (2) Cylinder (6) Control Groove (3) Plunger (7) Driving Surface (4) Feed Hole
632W232A
(1) Delivery Chamber (4) Feed Hole (2) Plunger (5) Fuel Chamber (3) Delivery Valve (6) Control Groove
2-17
Page 18
ENGINE
c. Amount of Fuel Delivery
(A) No fuel delivery At the engine stop position of the control rack (3), the
lengthwise slot (1) on the plunger (2) aligns with the feed hole (5). The delivery chamber (4) is led to the feed hole during the entire stroke of the plunger. The pressure in the delivery chamber does not build up and no fuel is forced to the injection nozzle.
(B) Fuel delivery The plunger is rotated by the control rack and the feed
hole is not aligned with the lengthwise slot. When the plunger is pushed up, the feed hole is closed by the plunger. The pressure in the delivery chamber builds up and forces the fuel to the injection nozzle until the control groove (6) meets the feed hole. The amount of the fuel to be forced into the nozzle corresponds to distance A.
632W233A
d. Delivery Valve
The delivery valve prevents the fuel in the injection pipe from flowing back into the delivery chamber and the fuel in the injection nozzle from dribbling after injection.
(1) Slot (4) Delivery Chamber (2) Plunger (5) Feed Hole (3) Control Rack (6) Control Groove
2-18
632W234A
(1) Valve Spring (4) Fuel Chamber (2) Valve (5) Valve Face (3) V alve Seal (6) Relief Plunger
Page 19
E. FUEL INJECTION NOZZLE
The nozzle is a throttle-type. It features low fuel con­sumption and works well with DAEDONG combustion chamber. The nozzle valve opening pressure is about
13.7 to 14.7 MPa (140 to 150 kgf/cm psi), the pressure overcomes the counterforce of nozzle valve spring, and push the valve up instantly, the fuel is then injected in a proper quantity into the swirling air in the combustion chamber for combustion. Addition or reduction of adjusting shims can adjust the opening pressure. A washer of 0.1 mm corresponds to 980 kPa (10 kgf/cm
2
, 142 psi) change in opening pressure. The heat seal is employed to improve the durability and reliability of the nozzle.
2
, 1,991 to 2,134
ENGINE
632W235A
F. GOVERNOR AND IDLE COMPENSATING
a. Disassembled View
The governor serves to keep engine speed constant by automatically adjusting the amount of fuel supplied to the engine according to changes in the load. The en­gine employs an all-speed governor which is controlled by the centrifugal force of the steel ball (13) weights, produced by rotation of the fuel camshaft (9), and ten­sion of the governor spring 1 (2) and 2 (3) are balanced.
(1) Nozzle Holder Ass’y (6) Nozzle Body (2) Adjusting Washer (7) Needle Valve (3) Nozzle Spring (8 ) Heat Seal (4) Push Rod (9) Packing (5) Retaining Nut
632W236A
(1) Start Spring (8) Governor Lever (2) Governor Spring 1 (9) Fuel Camshaft (3) Governor Spring 2 (10) Governor Ball Case (4) Fork Lever 1 (11) Steel Ball (5) Fork Lever 2 (12) Governor Sleeve (6) Fork Lever Shaft (13) Steel Ball (7) Fork Lever Holder
2-19
Page 20
ENGINE
b. Operation of Governor a) At start
The steel balls (13) have no centrifugal force. As the fork lever 1 (4) is pulled by the start spring (1), the control rack (14) moves to the maximum injection posi­tion. At start, the sufficient injection of the fuel enables easy starting.
b) At idling
At the idling position of the speed control lever (15), the governor spring 1 (2) is free and the governor spring 2 (3) only acts slightly. The governor sleeve (12) is pushed leftward by a centrifugal force of steel ball (13). Therefore, the fork lever 1 (4) and control rack (14) are moved to the rear by the governor sleeve (12) and then the idling adjusting spring (16) is compressed by the control rack (14). As a result, the control rack (14) is kept at a position where the centrifugal force of steel ball (13) and forces of the start spring (1), governor spring 2 (3) and idling limit spring are balanced, pro­viding stable idling.
632W237A
(1) Start Spring (13) Steel Ball (4) Fork Lever 1 (14) Control Rack
IMPORTANT:
• The idling speed has been factory-set. The idling adjusting screw (20) and spring (16) should not be disassembled and readjusted.
2-20
632W238A
(1) Start Spring (13) Steel Ball (2) Governor Spring 1 (14) Control Rack (3) Governor Spring 2 (15) Speed Control Lever (4) Fork Lever 1 (16) Idle Adjusting Spring
(12) Governor Sleeve (20) Idle Adjusting Screw
Page 21
c) At High Speed Running with a Load
When a load is applied to an engine running at high speed, the engine speed drops and the centrifugal force of steel ball (13) becomes less, the fork lever 2 (5) is pulled forward by the governor spring 1 (2) and 2 (3), this increases the amount of fuel injected.
The fork lever 2 (5) becomes ineffective in increasing the fuel injection when it is stopped by the adjusting bolt (17). After that, when the force of torque spring (18) becomes greater than the centrifugal force of the steel balls, fork lever 1 (4) moves forward to increase fuel injection, causing the engine to run continuously at a high torque.
ENGINE
632W239A
(2) Governor Spring 1 (13) Steel Ball (3) Governor Spring 2 (17) Adjusting Bolt (4) Fork Lever 1 (18) Torque Spring (5) Fork Lever 2
d) To stop engine
When the stop lever (19) is moved to the STOP position, fork lever 1 (4) is moved rearward and the control rack (14) is moved to the non-injection position, causing the engine to stop.
632W240A
(4) Fork Lever 1 (19) Stop Lever
(14) Control Rack
2-21
Loading...