KUKJE MACHINERY A1000 User manual

ENGINE SERVICE MANUAL
Engines:
A1000 - Branson 2200
A1100 - Branson 2500
A1100T - Branson 2900

KUKJE RGO 60 4-3
Small Engine
4
1.1. ENGINE APPEARANCE
1.1.1. Natural Aspirated E/G and Turbo engine
1. ENGINE APPEARANCE, SPECIFICATION AND NAMES OF PARTS

KUKJE RGO 60
4-4
RGO 60
1.1.2. TURBO CHARGER ENGINE
1.2. Engine specification
1.2.1. Small engines
G
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Engine MODEL 단위/Unit A1000 A1100 A1100T
Type Vertical Water-Cooled 4Cycle Diesel Engine
No. of Cylinders 3 3 3
Bore×Stroke mm 74×82 78×82 78×82
Displacement cc 1,056 1,175 1,175
Combustion System Swirl chamber system
Intake System Natural Aspirated Turbo Charger
Direction of Rotation CCW from Flywheel Side
Cooling System Pressurized Radiator
Lubricant
Capacity
Full capacity ℓ 2.9 2.9 3
Valid capacity ℓ 1.6 1.6 1.8
Starter Capacity V-kW 12 - 2.2
Alternator V-A 12 – 45
Dimension(L×W×H) mm 487x414x612 494x417x655
Dry Weight kg 115 115 120
※ These specification may change for improvements without notice.

KUKJE RGO 60 4-5
Small Engine
4
1.3. NAMES OF PARTS
These diagrams are to show external parts, filter and for maintenance. Some of the parts may be different
depending on engines.
ٻٻ
G
ٻٻ
G
Exhaust side
(for Natural Aspirated E/G)
1. Exhaust manifold
2. Generator
3. Oil dipstick
4. Starter motor
5. Oil filter
6. Coolant pump
Intake side
(for Natural Aspirated E/G)
1. Intake manifold
2. Oil inlet
3. Cooling fan
4. Fuel injection pump
5. Feed pump
6. Crank-axis pulley

KUKJE RGO 60
4-6
RGO 60
ٻٻ
G
ٻٻ
G
Exhaust side
(for turbo charger)
1. Turbo charger
2. Exhaust manifold
3. Turbo lubricant pipe (IN)
4. Generator
5. Oil filter
6. Turbo lubricant pipe(OUT)
7. Oil dipstick
8. Starter motor
Intake side
(for turbo charger)
1. Intake manifold
2. Intake hose
3. Oil inlet
4. Coolant pump
5. Cooling fan
6. Fuel injection pump
7. Feed pump
8. Crank-axis pulley

KUKJE RGO 60 4-7
Small Engine
4
2.1. REGULAR INSPECTION LIST
Regular inspections are very important to main the best engine condition. Please adhere to the inspection
list shown below for inspection details and periods.
2. MAIN FUNCTIONALITY CHECKS AND REGULAR INSPECTIONS
Category Item Inspection every
50 hrs
every
250 hrs
every
500 hrs
1000 hrs.
or 1 year
2000 hrs.
Or 2 years
Fuel
related
Check & add fuel ○
Fuel tank cleaning ○
Check fuel filter & coolant hose ○
Fuel filter de-oiler oil drain ○
Fuel filter (element) change ◎
Fuel injection
valve
Check & adjust
pressure ●
Fuel injection
pump
Injection timing
adjustment ●
Lubricant
related
Check engine oil amount ○
Engine oil change ◎
(initial) ◎
Oil filter change ◎
(initial) ◎
Coolant
related
Check coolant amount ○
Check radiator for blocking ○ ○
Coolant change ◎
Fan belt tension adjust ○
(initial) ○
Coolant tubing cleaning, inspection
& maintenance ●
Fuel & coolant pipe inspection &
change ○ ●
Intake
related
Air cleaner cleaning,
element change ○ ◎
Turbo charger blower cleaning ●
Engine
parts
Bolt retightening
●
(retight
ening)
Valve gap adjustment ●
Intake valve wrapping ●
Electrical
devices
Warning lights inspection ○
Battery fluid check ○
※ ○: customer inspection/ ◎: part replacement /●: inspection at authorized shop

MEMO

KUKJE RGO 60 4-9
Small Engine
4
2.2. MAIN FUNCTIONALITY CHECKS
● Main functionality checks are the best for the performance and longevity of the engine.
Please pay attention to the followings for the engine maintenance.
2.2.1. Visual inspections while in use
● Visual inspections around the engine: Check for oil or water leaks of fuel, lubricant and coolant.
Please check each hoses and V-belt. Check the tightness of climp.
Check for damaged parts or loose bolts and nuts.
● If any abnormality is found in visual inspection, please repair prior to using it again.
2.2.2. Engine oil
● Please make sure to use proper engine oil since diesel engines usually operate under worse
conditions that gasoline engines.
● Using low grade engine oil or regular engine oil change is not done, it will be causes for rapid wear
and tear or short engine life.
● Please use engine oil of SAE 10W-30 and API CD grade or better.
※ Please refer to diagram below for proper oil selection.
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● Check the oil level with the oil level gage. It is normal if the oil level is between“H(high)”and “L(low)”of
the oil dipstick.
Add oil into the inlet if oil is insufficient. Check for contamination and viscosity to determine to change.
1) Stop the engine before the oil inspection.
2) Check before starting the engine. Please wait three minutes, if checking after driving.
3) Check for oil level again in five to six minutes after adding engine oil.
● Please change oil and oil filter after first 50 hours of operation and every 250 hours thereafter.
If the engine is being operated in exceptionally dusty area, check more frequently and change engine oil
and filter.

KUKJE RGO 60
4-10
RGO 60
2.2.3. FUEL
● The property of fuel for diesel engine (cetane number, specific gravity, viscosity and etc.) influences
the engine starting, output power, fuel consumption, fuel system performance, knocking or exhaustion
gas. Please use 45 or higher cetane number. Be sure to use lower viscosity fuel in low temperature.
● Always use clean fuel since fuel containing excessive moisture and dust may cause serious failure.
1) Please leave the fuel container for three or four days without disturbance for sediments to collect at
the bottom. Insert the fuel intake pipe to the middle of the fuel container to use fuel in the midsection of
the container.
When fuel is purchased, leave the
container for three or four days
undisturbed for sediments to collect
at the bottom.
After three or four days, insert the fuel
intake pipe to the middle of the container
(not to disturb sediments collected at
the bottom)
2) Check the integrated filter for sediments of water or foreign matters. If there is any, drain the sediments
completely through the drain valve at the bottom.
● Fuel filter change: Change every 500 hours.
If there is excessive moisture or dust, change more often.
● Air vent: The fuel system consists of fuel filter, fuel injection pump and pressurized pump. The fuel is
provided through the fuel system to fuel injection valve. If there is air within the fuel system, fuel injection
will not work. Please vent air as the following.
1) Open the air vent bolt located on upper part of the fuel filter and wait until no more air bubble is
present. Place absorbent fabric around the air vent bolt to prevent fuel leak.
2) If there is no air in the fuel, tighten the air vent bolt.
3) Continue pushing until the pump is very tight.
4) Check for fuel leaks.
WARNING : Do not leave flammable or smoke cigarette around the engine.

KUKJE RGO 60 4-11
Small Engine
4
2.2.4. COOLANT
● Use soft water such as tap water for the coolant. Hard water such as well water may leave deposits
in the cooling system which may cause the piston scorching due to decreased cooling effect and hot
coolant temperature. Use anticorrosive in summer to prevent rusting and antifreeze in winter to prevent
freezing.
● Coolant change: Change every 500 hours or 2 years.
Contaminated coolant may cause the piston scorching due to decreased cooling effect and hot coolant
temperature.
● Check the amount of coolant in the secondary tank before starting the engine. Check the amount of
coolant in the radiator at least once every week.
Insufficient coolant may cause the piston scorching due to decreased cooling effect and hot coolant
temperature.
2.2.5. V-BELT
● Adjust fan belt tension since high fan belt tension causes excessive belt wear while low fan belt
tension causes overheat and discharge due to not enough revolution in fan pulley and generator.
Adjust fan belt tension.
● Proper belt tension is 7~8mm.
● Check the tension by pressing down on the middle of the belt with your finger. Check for
contamination of oil or grease contamination or harmful damage on the belt.
● Visually inspect the belt for cracks in both lengthwise or widthwise directions and replace immediately
if there are any intersecting cracks.
● Please use genuine V-belt parts. Change if damaged or old.