KMW MINT 5 P User manual

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Operator Manual cum Parts Catalogue for
KMW –MIN T 5 PETROL

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FOREWORD
KIRLOSKAR OIL ENGINES, LIMITED (KOEL) congratulates you for becoming a prestigious customer of
KOEL by purchasing the MINT 5 P
Read, Understand and follow all instructions on the machine and in the manual before attempting to
operate.
The Operator Manual covers important usage instructions & guidelines on machine operating
procedures, safety instructions, warranty policy, Dos and Don’ts, troubleshooting, periodic service
maintenance schedule and Parts catalogue.
Register your product warranty by submitting duly filled warranty registration Card to KOEL dealer.
We are providing three labor free Services within six month of purchase, requested to utilize our
services according to the service maintenance schedule mentioned in the operator manual.
This Manual Cover’s all variants of MINT 5 P Power Weeder. Please refer relevant details only
applicable for your Machine.
C O N T E N T S
1. MINT Warranty Period, Policy Guide Lines & WRC ………………………………………….3-4
2. Technical Specifications –MINT 5 P……….. ……………………………………………………….4-5
3. Safety Precaution and Do’s & Don’ts ……………………………………………………..……….5-7
4. Controls & Equipment’s ……….…………………………..…………………...........................7-8
5. Operating instruction……………………………………………………………………………………..9-13
6. Maintenance & Service ……………....………………………………………………………………..13-24
7. Troubleshooting …………………………………………………………………………………………….24-26
8. Wiring Diagrams …………………………………………………………………………………………….26
9. Parts Catalogue ……………………………………………………………………………………………..27-47
10. Service Coupons and Check List ……………………………………………………………………..48-49
11. PDI Check List ………………………………………………………………………………………………..50

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1. MINT 5 P Warranty Period and Warranty Policy Guide Lines
1.1 Warranty Period
Sl. No.
Product
Warranty Coverage
1
Machine ( Engine,
Transmission)
6 months or 250 operational hours whichever is earlier from
Date of Sale to First Purchaser
2
Proprietary parts, Like:
Carburetor, Spark plug, Tyre,
etc.
Warranties for Proprietary parts are subject to respective
manufactures as per their warranty policy and guidelines.
3
Accessories / Implements
Will not be covered
1.2 Warranty Policy Guide Lines
1. The warranty period shall start from the date of purchase of product and applicable to the
first purchaser on receipt of the warranty Registration Card.
2. The warranty only covers the manufacturing defect or defective part within the specified
warranty timeframe only.
3. The warranty will cease if Service maintenance is not carried out as per periodical
maintenance schedule.
4. Warranty voids if KOEL genuine parts or approved blades are not used on machine during
periodical maintenance.
5. The warranty will not cover for normal wear & tear of parts such as clutch plate, rubber parts,
plastic parts, electrical parts.
6. Under warranty period, only repair or replacement of defective parts will be considered,
replacement of the machine is not warranted.
7. Warranty is not transferable to the second and subsequent owners.
8. The warranty ceases if the machine is serviced or repaired by unauthorized persons or at any
Local workshop.
9. The warranty will not cover for any accidental damage, fire, collision, improper usage,
tampering, customer abuse and external modifications/fabrications done by the customer.
KOEL reserves the right to refuse warranty if the product was found not to be carried periodical
maintenance & installed as per our installation instructions.

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1.3 WARRANTY REGISTRATION CARD / Sales Intimation Card
MINT 5P Details
Model
Invoice No.
Invoice Date
Engine No.
Frame No.
Warranty Start Date
Warranty End Date
Use of MINT
1) Forest Professionals 2) Orchard 3) Vegetable Crops
4) Hill Area 5) House Garden
Customer Details
Name
Village
PIN
District
City
State
Country
Mobile / mail ID
Date of Birth
Customer Signature
(I acknowledge that I have read, understood and I accept the
warranty policy and terms.)
Dealer's Seal & Signature
Dealer has to maintain the photo copy of the WRC (Company Copy)
2. Technical Specifications
Power Weeder Specifications
Product
MIN T 5 P
Engine
Model
CCP196
Bore X Stroke
68mm x 54mm
Displacement
196cc
Compression Ratio
8.5:1
Type
Single Cylinder, 4 Stroke, Air cooled, Petrol engine
Power
5 HP
Rated rpm
3600 rpm
High Idle rpm
3800 rpm
Max Torque(rpm)
12.4Nm @ 2500 rpm
Type of Starting
Recoil Type Manual
Lubrication System
Splash Lubrication
Ignition System
Spark Ignition
P.T.O. Shaft Rotation
Anti-Clockwise
Air Cleaner
Oil bath type
Fuel Tank Capacity
3.5 liters
Fuel Consumption
< 395 g/kWh

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Transmission
No. of Speeds
3 (2 forward + 1 reverse)
Working speed
0.38 –1.08 kmph
Clutch
Frictional multi disc
Rotary Tiller
Rotation
120 rpm(Fast) & 70 rpm(Slow)
Blades (nos.)
32
Tilling Width
1050 mm.
Tilling depth
≥100 mm
Tyre size
4.00 –8, 2 Ply
Dimension L * W * H (mm)
1450 X 1000 X 1050
Weight
65 kgs
3. Safety Precautions Do’s and Don’ts
3.1 Safety Precautions of MINT 5 P
1. Read and follow the owner’s manual and safety instructions carefully before operating.
2. Don’t allow children to use the machine.
3. In general all moving parts particular shafts & blades shall be treated as dangerous
3.2 DOs
Training
1. Read, Understand and follow all instructions on the machine and in the manual before
attempting to operate. Keep this manual in a safe place for future and regular
reference and for ordering replacement for parts.
2. Be familiar with all controls and their proper operations, know how to stop the
machine and disengage them quickly.
A. Check the General Condition of the Engine
Look around and underneath the engine for signs of oil or gasoline leaks. Remove any
excessive dirt or debris, especially around the muffler and recoil starter. Look for signs of
damage. Check that all shields and covers are in place, and all nuts, bolts, and screws are
tightened.
B. Check the Engine
Check the engine oil level. Running the engine with a low oil level can cause engine damage.
The Low Oil Alert System will automatically stop the engine before the oil level falls below
safe limits. However, to avoid the inconvenience of an unexpected shutdown, always check
the engine oil level before startup.
Check the air filter. A dirty air filter will restrict the flow of air to the carburetor, thereby
reducing engine performance. Check the fuel level. Starting with a full tank will help to
eliminate or reduce operating interruptions for refueling.

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C. General - Operator should:
a) Be in good health, sound mind and be not under the influence of any sort of
intoxicants;
b) Be adequately trained on MINT 5 P and when required;
c) Obtain and read the operator’s manual before using the MINT 5 P for the first time;
and when required.
d) Wear suitable non slip footwear, suitable hearing protection and comfortable clothing.
D. Before Starting MINT 5 P - Operator should:
a) Inspect the machine and make certain that it is properly adjusted and in good working
condition;
b) Keep all controls in neutral before starting.
c) Check the oil level of engine and fuel level in tank.
d) Check the transmission oil level
e) Clear the work area of objects that might jam or wrap around the tines such as glass,
large sticks, stones, metal objects, wire, rope, and string-like materials.
E. Maintenance & Storage - Operator should:
a) Only use genuine spare parts/accessories approved by MINT 5 P.
b) Keep machine, attachment and accessories in safe working order.
c) Apply Grease/Oil to all link, pins and rivets.
d) Check for tightness of all fasteners.
g) Wash and clean the machine periodically.
i) Keep Machine in level platform.
j) Store the machine in a well-ventilated place, protected from dampness and the weather.
k) Always store gasoline in an approved container. If fuel spills, make sure the area is dry
before starting the engine.
l) Provide adequate ventilation for stationary equipment applications; keep the engine at
least 1 meter away from building walls and other equipment during operation.
3.3 Don’ts
1. Do not put hands or feet near or under rotating parts.
2. Don’t operate the MINT 5 P without any Demonstration training.
3. Do not operate if you found any leakage of Fuel or lubricants.
4. Never place your hands, feet, or any part of your body near or under any moving part
while the MINT 5 P engine is running.
5. Do not touch the muffler and engine when the machine is in use.
6. Do not use this machine around large roots and surface rocks.
7. Do not use this machine around underground pipes and wiring.
8. Do not use machine when fuel leakage is observed near FIP, Injector and Fuel lines.

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9. Do not operate the machine without good visibility.
10.Do not tamper with any safety devices or fittings.
11.Do not use unapproved attachments.
12.Don’t use non recommended blades.
13.Disengage clutch before shifting gear.
14.Ensure gears are aligned properly during shifting and if not release clutch to align the
gear.
15. Do not wear open-toed sandals or go barefoot when operating the machines.
16. Do not wear loose fitting, scarf, ties or jewels which might caught in the machine while
operating.
17. Do not operate the MINT 5 P on terrain.
18. Do not store the fuel in Closed (Unventilated atmosphere) and in area where source of
flames or sharks are there. Don’t smoke while fueling.
19. Don’t place flammable objects close to the engine.
20. Don’t fuel a running or hot engine. Don’t loosen the fuel cap while engine is running.
21. Don’t smoke near gasoline, and keep other flames and sparks away.
22. Don’t make any adjustment when the engine is in use.
23. Handle LH/RH and other levers to be used only for controlling the machine.
24. Do not inhale exhaust gas.
35. Never run the engine in a closed garage or confined area.
3.4 Recognize Decals Information’s
An important safety incorporated into MINT 5 P is the warning and information decals
found in various parts of the machine.
4. Control & Equipment

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ACCELERATOR
CLUTCH LEVER
FORWARD LEVER
REVERSE LEVER
HANDLEBAR HEIGHT ADJUSTER
RESISTANCE BAR
TRANSMISSION OIL FILLER CAP
PROTECTING FENDER
TOOL BOX
FRONT STAND

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5. Operating Instruction
5.1 Engine Controls
Fuel Valve Lever
The fuel valve opens and closes the passage
between the fuel tank and the carburettor. The
fuel valve lever must in the ON position for the
engine to run. When the engine is not in use,
leave the fuel valve lever
in the OFF position to prevent carburettor
flooding and to reduce them possibility of the
fuel leakage.
Throttle Lever
The throttle lever controls engine THROTTLE
LEVER speed. Moving the throttle lever in the
directions shown makes the engine run faster
or slower
Engine Switch
The engine switch enables and disables the
ignition system. The engine switch must be in
the ON position for the engine to run. Turning
the engine switch to the OFF position stops the
engine.
Choke Lever
The choke lever opens and closes the choke
valve in the carburettor. The CLOSE position
enriches the fuel mixture for starting a cold
engine. The OPEN position provides the correct
fuel mixture for operation after starting, and
for restarting a warm engine.
Recoil Starter Grip
Pulling the starter grip operates the recoil
starter to crank the engine.

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5.2 Starting The Engine
1. Move the fuel valve lever to the ON position.
2. To start a cold engine, move the choke lever
to the CLOSE position. To restart a warm
engine, leave the choke lever in the OPEN
position.
3. Move the throttle lever away from the SLOW
position, about 1/3 of the way toward the
FAST position.
4. Turn the engine switch to the ON position.
5. Operate the starter by pulling the starter
grip lightly until you feel resistance, then
pull briskly. Return the starter grip gently.
6. If the choke lever has been moved to the
CLOSE position to start the engine, gradually
move it to the OPEN position as the engine
warms up.

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5.3 Stopping the Engine
To stop the engine in an emergency, simply turn the engine switch to the OFF position. Under
normal conditions, use the following procedure.
1. Move the throttle lever to the SLOW
position.
2. Turn the engine switch to the OFF position.
3. Turn the fuel valve lever to the OFF position.
5.4 Setting Engine Speed
Position the throttle lever for the desired engine
speed. For engine speed recommendations, refer
to the instructions provided with the equipment
powered by this engine

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5.5 Transmission controls
Accelerator (Throttle) Control Lever
The throttle lever controls the engine speed
and tine rotations. Moving the throttle lever
in the direction shown, run the engine faster
or slower. To increase engine RPM, pull the
lever to anti clockwise direction. To decrease
engine RPM, push the lever to clockwise
direction.
Main clutch Lever
The main clutch lever engages and
disengages the transmission that drives
the blades. It is located on left hand side
to handlebar.
Lever for Forward Speed
The transmission offers a choice of fast & slow
speed in forward direction.
Lever for Reverse Speed
Reverse speed lever with reverse lock located on
right hand side of handlebar with identification
sticker. To operate the reverse lever, reverse lock
should be pressed along with reverse lever to operate
in reverse gear.
Handlebar Height Adjuster
Handlebar height can be adjusted to match
operator height. For normal tilling, most
comfortable operator height is with the
handlebars at waist height.

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Resistance Bar
Resistance Bar controls tilling depth and
should always be used when tilling. It enables
you to compensate for the hardness of the
soil. Ideal resistance bar height will depend on
the type of soil being tilled and soil conditions
at the time of tilling. In general, the resistance
bar should be adjusted so that the tiller is
tilted slightly backward
6. Maintenance
The purpose of the maintenance schedule is to keep the tiller in the best operating
condition. Inspect or service as scheduled in the table below. Remember that your
service dealer knows your tiller best and is fully equipped to maintain and repair it.
To ensure the best quality and reliability, use only new, KOEL genuine parts for repair
and replacement.
6.1 The Importance of Maintenance
Good maintenance of the engine is essential for safe, economical, and trouble-free
operation. It will also help reduce air pollution.
To help you properly care for your engine,
the following pages include a maintenance
schedule, routine inspection procedures,
and simple maintenance procedures using
basic hand tools. Other service tasks that
are more difficult, or require special tools,
are best handled by professionals and are
normally performed by a technician or
other qualified mechanic. The maintenance
schedule applies to normal operating
conditions. If you operate your engine under unusual conditions, such as sustained high-load
or high-temperature operation, or use in unusually wet or dusty conditions, consult your
servicing dealer for recommendations applicable to your individual needs and use.
6.2 Maintenance Safety
Some of the most important safety precautions are as
follows: However, we cannot warn you of every
conceivable hazard that can arise in performing
maintenance. Only you can decide whether or not
you should perform a given task.

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6.3 Safety Precautions
Make sure the engine is off before you begin any maintenance or repairs.
This will eliminate several potential hazards such as:
Carbon monoxide poisoning from engine exhaust. Be sure there is adequate
ventilation whenever you operate the engine.
Burns from hot parts. Let the engine and exhaust system cool before touching.
Injury from moving parts. Do not run the engine unless instructed to do so.
Read the instructions before you begin, and make sure you have the tools and skills
required.
To reduce the possibility of fire or explosion, be careful when working around gasoline. Use
only a nonflammable solvent, not gasoline, to clean parts. Keep cigarettes, sparks and flames
away from all fuel-related parts.
Remember that your servicing dealer knows your engine best and is fully equipped to
maintain and repair it. To ensure the best quality and reliability, use only new, genuine parts
or their equivalents for repair and replacement.
6.4 Torque Values
SL. No.
DESCRIPTION
TORQUE VALUE
1
Cylinder Head Bolt
26-28 Nm
2
Crankcase Gear Casing Cover Bolts
24-26 Nm
3
Connecting Rod Big End Bolts
12 Nm
4
Flywheel Assembly Bolt
65 Nm
5
Rocker Arm Pivot Lock Nut
10 Nm
6
Rocker arm pivot bolt/stud
24 Nm
7
Ignition Coil Bolts
8 - 10 Nm
6.5 Assembly Clearance
SL. No.
DESCRIPTION
CLEARANCE
1
Gap between Ignition Coil & Flywheel
0.4 mm
2
Valve Clearance
2.1
Intake/ Inlet
0.10 –0.12 mm
2.2
Exhaust
0.15 –0.17 mm
3
Electrode gap of spark plug
0.7 –0.8 mm

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6.6 Maintenance Chart
Free Service Period
(from date of delivery)
Frequency
Item
Each
Use
1st Month
/ 20 hrs.
Each Month
/ 50 hrs.
Every Month
/ 100 hrs.
Every year/
300 hrs.
Clean Crank Case
CLEAN
C
C
C
C
Engine Oil
INSPECT LEVEL
I
CHANGE
R
I/R
R
Valve Clearance
(adjust if necessary)
CHECK-ADJUST
I/A
I/A
I/A
I/A
Air cleaner
INSPECT
I
CLEAN
C
C
C
REPLACE
R
Sediment Cup
CLEAN
C
Spark Plug
INSPECT -
CLEAN
I/C
REPLACE
R
Spark
Arrester(Optional)
CLEAN
C
Idle Speed
INSPECT -
ADJUST
I/A
Fuel Tank and
strainer
CLEAN
C
Combustion
Chamber
CLEAN
C
Fuel Line
INSPECT
Every 2 years (Replace if necessary)
Cylinder Head Bolts
INSPECT
I/T
I/T
I/T
I/T
Main Gear Box Oil
INSPECT -
REPLACE
R
I/F
Decompression lever
INSPECT
I
Blade fitting Nuts
and Bolts
INSPECT
I/T
Injector Pressure
and timing
INSPECT
I
I
Main Clutch free
play
INSPECT -
ADJUST
I/A
I/A
I/A
I/A
C - Clean I - Inspect R –Replace T –Torque A –Adjust F –Fill/Top-up
* Service more frequently when used in dusty areas

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6.7 Assembly of Engine
6.7.1 Assembly of Piston and Connecting Rod
6.7.2 Assembly of Crankcase

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6.7.3 Assembly of Cylinder Head and Valve Assembly
6.7.4 Assembly of Cylinder Head 6.7.5 Assembly of Governor

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6.8 Refueling
CCP196 fuel tank capacity: 3.5 Liters
With the engine stopped, remove the fuel tank cap and
check the fuel level. Refill the tank if the fuel level is low.
Refuel in a well-ventilated area before starting the
engine. If the engine has been running, allow it cool.
Refuel carefully to avoid spilling fuel. Do not fill above
the fuel strainer shoulder. After refueling,
tighten the fuel tank cap securely.
Never refuel the engine inside a building
where gasoline fumes may reach flames or
sparks. Keep gasoline away from appliance
pilot lights, barbecues, electric appliances,
power tools, etc.
.
Spilled fuel is a fire hazard. Wipe up spills
immediately.
6.9 Fuel Recommendations
USE UNLEADED GASOLINE WITH A PUMP OCTANE RATING OF 86 OR HIGHER.
These engines are certified to operate on unleaded gasoline. Use of unleaded gasoline leads
to fewer engine and spark plug deposits and extends the exhaust system life.
Never use stale or contaminated gasoline or an oil/gasoline mixture. Avoid getting dirt or
water in the fuel tank.
Occasionally you may hear a light "spark knock" or "pinging" (metallic rapping noise) while
operating under heavy loads. This is no cause for concern.
If spark knock or pinging occurs at a steady engine speed, under normal load, change brands
of gasoline. If spark knock or pinging persists, see an authorized servicing dealer.

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6.10 Engine Oil Level Check
Check the engine oil level with the engine stopped and in a
level position.
1. Remove the filler cap/dipstick and wipe it clean.
2. Insert and remove the dipstick without screwing it into the
filler neck. Check the oil level shown on the dipstick.
3. If the oil level is low, fill to the edge of the oil filler hole
with the recommended oil.
4. Screw in the filler cap/dipstick securely.
The Low Oil Alert System will automatically stop the engine
before the oil level falls below the safe limit. However, in
order to avoid the inconvenience of an unexpected
shutdown, always check the engine oil level before startup.
6.11 Engine Oil Change
Drain the used oil while the engine is warm. Warm oil drains
quickly and completely.
1. Place a suitable container below the engine to catch the
used oil, and then remove the filler cap/dipstick and the drain
plug.
2. Allow the used oil drain completely, and then reinstall the
drain plug, and tighten it securely. Please dispose of used
motor oil in a manner that is compatible with the
environment. We suggest you take your used oil in a sealed
container to your local recycling center or service station for
reclamation. Do not throw it in the trash; pour it on the
ground; or down a drain.
3. With the engine in a level position, fill to the outer edge of
the oil filler hole with the recommended oil.
CCP196 Engine oil capacity: 0.6 Liters
Running the engine with a low oil level can cause engine
damage. The Low Oil Alert System will automatically stop the
engine before the oil level falls below the safe limit. However,
in order to avoid the inconvenience of an unexpected
shutdown, fill oil to the upper limit, and check the oil level
regularly.
4. Screw in the filler cap/dipstick securely.

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6.12 Servicing Your Engine
Engine Oil Recommendations
Oil is a major factor affecting performance and service life.
Use 4- stroke automotive detergent oil. SAE 10W-30 is
recommended for general use. Other viscosities shown in the
chart may be used when the average temperature in your
area is within the recommended range.
The SAE oil viscosity and service classification are in the API
label on the oil container. We recommended that you use
API SERVICE Category SE or SF oil.
6.13 Air Filter Inspection
Remove the air cleaner cover and inspect the filter.
Clean or replace dirty filter elements. Always
replace damaged filter elements. If equipped with
an oil-bath air cleaner, also check the oil level.
6.14 Air Filter Service
A dirty air filter restricts air-flow to the carburetor,
thereby reducing engine performance.
If you operate the engine in very dusty areas, clean
the air filter more often than specified in the
MAINTENANCE SCHEDULE.
6.14.1 Oil-Bath Type Air Filter
1. Remove the wing nut, and remove the air filter
cap and cover.
2. Remove the air filter from the cover, wash the
cover and filter in warm, soapy water, rinse, and
allow drying thoroughly. Or clean in
nonflammable solvent and allow drying.
3. Dip the filter in clean engine oil, and then
squeeze out all excess oil. The engine will smoke
if too much oil is left in the foam.
4. Empty the used oil from the air cleaner case, wash out any accumulated dirt with
nonflammable solvent, and dry the case.