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
ڜڌڋڋڋڃڍڌۃۋڊڍڑڋڋۍۋۈڄڊڜڌڌڋڋڃڍڏۃۋڊڍڑڋڋۍۋۈڄٻ ڜڌڌڋڋگڃڍړۃۋڊڍڑڋڋۍۋۈڄٻ
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.
4"&
(SBEFDBUFHPSZ
GPSBMMTFBTPOT
GPSXJOUFS
GPSFYUSFNFMZ
DPMEXFBUIFS
● 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.

KUKJE RGO 60
4-12
RGO 60
2.2.6. AIR CLEANER
● Contaminated air cleaner may not only reduce the engine output, but also increase the fuel
consumption or produce black exhaust gas.
● Change air cleaner if there is any deformation, damage or cracks.
● If it is used in excessively dusty area, clean the dust collector every day, and inspect and clean the
element every 50 hours or more often. If it is cleaned with pressurized air (5 ~ 7kgf/cm2), clean it from
inside of the element and blowing outwards.
● When assembling the dust collector, make sure “TOP”is facing upwards.
2.2.7. RADIATOR
● Check for blocked radiator pin:
If the radiator pin is blocked, remove any foreign objects by blowing with pressurized air or wash with
water.
● Radiator coolant amount inspections should be done when the engine is completely cooled.
● If the engine is not in use for extended period, drain coolant completely since it may cause freezing
of cylinder interior of cracks.
WARNING : Do not check the amount of coolant while the radiator is
hot. If the cap is open immediately after the engine has stopped, hot
steam or coolant may cause burns.
WARNING:
1. Please be careful not to come in contact with electrolyte with skin or clothing
since it is strong sulfuric acid.
2. When charging, do it in a well-ventilated area since it produces explosive
gas. Do not smoke and prohibit sparks around it.
3. If the electrolyte comes in contact with skin, wash immediately and contact a
medical institute.
2.2.8. Battery
● Check the level of electrolyte and add distilled water if insufficient.
●
Measure the specific gravity of the electrolyte. If it is below the required level (1.12 ~ 1.28), please add.
● Separate the negative terminal first when removing the battery. (The negative terminal should be
attached later when assembled.)
● Check if terminal is tight, and clean if there is dirt or corrosion.
2.2.9. Inspections every 50 hours
(1) Engine and oil filter change: Change after first 50 hours of engine operation.
(2) Drain water from the fuel filter de-oiler
(3) Battery inspection
(4) Cooler V-belt tension inspection
2.2.10. Inspections every 250 hours
(1) Engine and oil filter change: Change every 250 hours after the initial change in 50 hours
(2) Radiator pin inspection and cleaning
(3) Air cleaner cleaning
(4) Cooler V- belt tension inspectio

KUKJE RGO 60 4-13
Small Engine
4
2.2.11. INSPECTIONS EVERY 500 HOURS
(1) Engine fuel filter change: Change the fuel filter every 500 hours after the initial change in 50 hours
(2) Coolant anti-freeze change
(3) Element of the air cleaner change
2.2.12. INSPECTIONS EVERY 1000 HOURS
(1) TURBO CHARGER BLOWER WASHING
● If engine revolution is decreased or exhaust gas is darker, it may be caused by dirty turbo
charger blower blades. Please wash with a blower washer.
● How to wash:
1) Inject specified amount of blower washer into the air inlet while the engine is loaded with 3/4 to
4/4 of its capacity. (20cc per each time)
2) Inject clean water (20cc) three to five minutes after the blower washer injection.
CAUTION : Do not inject excessive amount of blower washer or coolant into the turbo
charger in short time may cause serious accident.
3) Repeat the washing in 10 minutes if there are no changes in air pressure or temperature after
the initial washing. If there are still no changes after three or four washings, disassemble since it
may require other repairs.
4) Operate the engine for 15 minutes after the washing to dry.
(2) Fuel injection valve injecting pressure and condition inspection and adjustment (Please refer
to the Section 5.1.2.)
(3) Valve gap adjustment (Please refer to the Section 4.3.23)
2.2.13. Inspections every 2000 hours
(1) Coolant path cleaning & maintenance: related to coolant path such as radiator, coolant pump,
cylinder block & head and oil cooler
Parts should be cleaned and maintained due to reduced cooling ability when used for a long period
(2) Fuel oil pipe and coolant pipe inspection and change: Inspect the fuel oil pipe or coolant pipe and
change if there are any flaws or deteriorated parts. Please change hoses in every 2 years even if
they seem normal.
(3) Intake and exhaust wrapping: Maintain to ensure the tightness of cylinder heads.
(4) Fuel injection timing adjustment and fuel injection pump inspection & adjustment: Please refer to the
Section 4.3.11.

MEMO

KUKJE RGO 60 4-15
Small Engine
4
3. TROUBLE SHOOTING AND SOLUTION
Trouble Cause Solution
1. trouble starting
(1) Starter is turned on but
no pinion
1) insufficient battery capacity
1) Charge or change if discharged.
2) Slowly heat if insufficiency caused
by cold weather, recharge or
change
2) Cut in a wire harness, or bad
connection in battery and switch
terminals
Modify
3) Faulty spline engaged with pinion
of armature shaft Modify spline
4) Bad magnetic switch plunger, or
cut or short coil Modify or change
5) Starter switch malfunctioning Modify or change
6) Starter brush malfunctioning Disassemble and clean, or change
broken parts
(2) Pinion is engaged
with a ring gear but starter
is not turning
1) insufficient battery capacity Same as 1- 1)
2) Cut in the cable connecting the
battery with the magnetic switch,
or Connecting wire between the
magnetic switch and motor terminal
is not tight enough.
Modify
3) Bad fit between the pinion and
ring gear Modify or change pinion
4) Faulty starter Modify or change
5) Battery code connection is not
tight enough. Tighten more
(3) Pinion turns without
engaging with the ring gear
1) Starter not installed properly. Reinstall
2) incorrect plunger ＆ measurement
adjustment Adjust
3) Bad pinion sleeve spring Change
(4) Pinion is engaged with the
ring gear and starter turns
but engine does not turn.
1) Over running clutch fault Change
2) Internal fault of the engine Repair

KUKJE RGO 60
4-16
RGO 60
Trouble Cause Solution
1. Trouble starting
(5) Engine turns but
does not start.
1) No fuel in the fuel tank. Add fuel.
2) Air present in fuel system. Remove air.
3) Fuel element blocked Wash or change
4) Air mixture at the injection pump Remove air
5) No electricity at the fuel blocking so-
lenoid valve of the fuel injection pump
Inspect whether there is pow-
er with the Key switch on ON
position.
Inspect fuse or wiring if neces-
sary.
6) Lose or bad fuel blocking solenoid
valve of the fuel injection pump
Tighten the solenoid valve.
Check the operation sound with
Key switch on ON and Off.
Change bad solenoid.
7) Bad fuel injection pump Repair or replace
8) Loose connection of the
pressurized pipe Retighten
9) Fused fuel injection valve Modify or change
10) Insufficient injection from the fuel in-
jection valve Modify or change
11) Improper injection pressure Adjust
12) Bad glow plug Inspect and replace if necessary
13) Insufficient compression pressure
- Valve not closing properly
- Cylinder head gasket packing fault
- Worn piston, piston ring, and cylinder
Inspect valve and valve seat
Modify
Change
Change
(6) Engine starts up
but dies immediately.
1) Fuel pipe blocked or filter contaminated Wash
2) Air mixed in the fuel Remove air
3) Vent blocked in fuel tank cap Modify
2. Bad idling
1) Accelerating lever adjustment fault Adjust accelerating lever or cable
2) Air mixed at the injection pump Remove air
3) Bad fuel injecting valve Modify or change
4) Bad injection timing Adjust
5) Injection pump not working Replace with a new pump or
disassemble to repair
3. Insufficient engine
power
1) Improper valve clearance Adjust
2) Bad valve engaging Inspect valve & valve seat
3) Gas leak at the cylinder head gasket Change gasket
4) Abrasion, adhesion or damage to the
piston ring Change piston ring
5) Insufficient air intake Air cleaner element cleaning
6) Bad fuel injection timing Adjust
7) Insufficient fuel injection rate Adjust pump output
8) Bad injection pressure or scorched Adjust or change the fuel injec-
tion valve

KUKJE RGO 60 4-17
Small Engine
4
Trouble Cause Solution
3. Insufficient engine
power
9) Blocked fuel pipe system Modify
10) Air mixed in fuel Remove air
11) Water mixed in fuel Fuel change
12) Frozen or hard wax in fuel line Place in a warm garage until it
is thawed or soft and remove air
13) Faulty fuel injection pump Replace with new fuel
injection pump
14) Bad turbo charger Repair or replace
4. Engine overheat
1) Insufficient coolant or water slime present Add or wash
2) Loose, abrasion or damage to fan belt Adjust or replace
3) Reduced cooling pump function Modify or change
4) Improper valve clearance Adjust
5) Reduced resistance to exhaust system Clean or change
6) Air way blocked in the radiator Clean
7) Improper injection timing Adjust injection timing
8) Damaged cylinder head gasket Change head gasket
9) Insufficient or bad engine oil Add or change
5. Engine noise
1) Crank shaft metal
1) Increased clearance due to worn metal
or crank shaft
Replace metal or grind
crank shaft
2) Uneven wear in crank shaft Grind crank shaft or change
3) Scorched metal Change metal and grind crank
2) Connecting rod
metal
1) Worn crank pin metal Change metal
2) Abrasion in crank pin parts Change crank shaft
3) Bent connecting rod Change
4) Scorched crank pin metal Change metal and polish crank
5) Insufficient oil due to blocked path Clean oil path
3) Piston, piston pin
& piston ring
1) Increased piston clearance due to
worn piston and piston ring Change piston & piston ring
2) Worn piston pins Change
3) Scorched piston Change
4) Worn or bad piston Change
5) Damaged piston ring Change

KUKJE RGO 60
4-18
RGO 60
Trouble Cause Solution
5. Engine noise
4) others
1) Worn crank shaft and thrust bearing Change thrust bearing
2) Excessive timing gear back lash Change timing gear
3) Excessive valve clearance Adjust valve clearance
4) Wear in valve parts Modify or change
5) Bad coolant pump bearing Change coolant pump
6) Internal damage in turbo charger Repair or change
6. Excessive fuel con-
sumption
1) Fuel leak
Inspect and change pipes
if necessary. Retighten every
connections.
2) Blocked return pipe or hose
- Inspect if return line is twist-
ed or crushed. Replace dam-
aged parts.
- If line is blocked, use pres-
surized air to remove air.
3) Improper injection timing Modify
4) Compression pressure inspection Modify or change
5) Bad fuel injection valve
(injection or pressure) Modify or change
6) Bad injection pump
(excessive injection) Modify or change
7) Head gasket inspection Change
7. Excessive oil
consumption
1) Oil up
1) Excessive clearance between the
cylinder and piston Change
2) Worn piston ring and ring groove Change piston ring
3) Improper positioning of piston ring inlet Modify position
4) Blocked air breather Wash
5) Excessive oil supply Modify
2) Oil down
1) Loose valve stem and valve guide Change
2) Bad cylinder head gasket Change gasket
3) Bad valve stem seal Change
3) Oil leak
1) Loose connections Tighten
2) Bad packing of parts Change packing
3) Bad oil seal Change oil seal

KUKJE RGO 60 4-19
Small Engine
4
Trouble Cause Solution
8. Decrease in lubricant
pressure
1) Improper oil quality Change to specified oil
2) Bad pressure control valve Change
3) Worn oil pump Change
4) Bad oil pipe Modify or change
5) Worn crank metal & crank pin metal Change metal
9. Engine knocking
1) Incorrect injection timing Adjust
2) Incorrect injection pressure Adjust
3) Bad injection function Disassemble to modify
4) Insufficient air intake Clean the air cleaner
5) Engine oil in combustion chamber
- Oil up
- Oil down
- Low oil viscosity
Modify
Modify
Change to proper oil
6) Low engine temperature Operate in warm place
10. Excessive exhaust gas
1) white exhaust gas
1) Late injection timing Adjust
2) Decreased compression pressure Modify
3) Water mixed in the fuel Change
4) Not enough air intake Modify
5) Engine oil in the combustion chamber Modify
2) black exhaust gas
1) Late injection timing Adjust
2) Over loaded Adjust to proper load
3) Excessive injection rate Bad injection control spring
4) Irregular injection Adjust
5) Bad injection from fuel injection valve Modify or change
6) Insufficient air intake Clean the air cleaner

MEMO

KUKJE RGO 60 4-21
Small Engine
4
4.1. ENGINE INSPECTION
4.1.1 Cylinder compression pressure inspection
4. ENGINE MAINTENANCE
① Warm up the engine enough then stop the
engine.
② Disassemble the air cleaner, muffler and
injection nozzle.
③ Pull the engine stop lever to block the fuel
supply.
④ Install the pressure gage in the nozzle.
⑤ Crank so that each cylinder would turn six or
seven times and measure the pressure within
the cylinder.
⑥ If the cylinder pressure is less than allowed,
check the assembly of the gage and measure
again.
⑦ If the result is same, check the cylinder head
assembly, valve gap and piston top clearance.
※CAUTION
a. Make sure the engine stop lever is fastened
properly when cranking.
b. Fill the battery to its full capacity before the
inspection.
c. Pressure within the cylinder should be less
than 10%.
d. The injection nozzle tap specification is
M20xP1.5.
4.1.2 Valve gap inspection
① Remove the cylinder head cover.
② Turn the fly wheel so that the no. 1 piston
is at TDC and then coincide the“1”mark of fly
wheel with“T” mark of rear plate.
③ Check the gaps in the order shown in Table
4.1.2_1.(TDC No.1 Piston)
④ T u r n t h e f l y w h e e l o n e t u r n i n
counterclockwise to coincide the“1”mark of fly
wheel and“T”mark of rear plate.
⑤ Check the gaps in the order shown in Table
4.1.2_1.(OverLap No.1 Piston)
※CAUTION
a. The TDC mark “T”of the rear plate only
applies to no. 1 cylinder.
b. Measure the gaps two or three times for
better accuracy.
c. Order of the cylinder is 1, 2, and 3 referencing
to gear case shaft.
(1) Adjusting bolt
(2) Fastening nut
(3) Gap
Location of
no. 1 piston Piston NO. Intake valve Exhaust valve
TDC
NO.1 * *
NO.2 *
NO.3 *
OverLap
NO.1
NO.2 *
NO.13 *
Proper limit 0.15 ~ 0.20mm
Table 4.1.2_1