THREE-CYLINDER

WATER-COOLED
DIESEL
KM376 SERIES

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 PREFACE

Thank you for purchasing KAMA KM376 series three-cylinder water-cooled diesel
engine.

This manual describes safe information, operation instruction and maintenance of

KM376 series diesel engine. Be sure to read this manual carefully before
operation, for keeping your engine at the best working condition.

Keep this manual at hand for easy checking up. Contact with your agent if it
destroyed or missed.

This manual is considered a permanent part of the engine, and it must stay with
the engine if resold.

Any question or suggestion happened, contact with our After-service Dept.

Indicates a strong possibility of severe personal injury or

DANGER death if instructions are not followed.

Indicates personal injury of equipment damage will result if

WARNING instructions are not followed.

Indicates the severe personal injury will result if instructions

CAUTION are not followed. To prevent you from injury, be sure to read
the safety marks and correctly operate engine.

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 Electric Wiring Diagram Contents
1. Safety Information 1
1.1 Safety Mark 1
1.2 Safety Caution 1
2. Product Instructions 4
2.1 Main Specifications and Data 4
2.2 Specifications and Data of Key Parts 5
2.3 Main Adjusting Data Table 6
2.4 Tightening Torque of Main Bolts and Nuts 7
2.5 Operation Control Device 8
3. Preparation before Operation 10
3.1 Prepare the Fuel, Lubricating Oil and Cooling Water 10
3.2 Preparation before Starting 12
4. Operation Instruction 15
4.1 Starting 15
4.2 Running 16
4.3 Check Engine during the Running 18
4.4 Stop the Engine 19
5. Break-in Period and Trial Run 20
6. The Storage for a Long time 21

7. The Method of the Maintenance and Service 22

7.1 Daily Technical Maintenance 22

7.2 Periodically Check and Service 22

8. The Adjustment of the Technical Data 29

(1) The alternator (8) The grow plug 8.1 The Adjustment of Valve clearance 29
(2) The voltage regulator. (9) The current sensor
8.2 The Adjustment of the Injection Timing 30
(3) The CHG indication lamp. (10) The warm-up timer
(4) The hot insulation indication lamp (11) The grow plug resistance 8.3 The Adjustment of the Fuel Injector 31
(5) The Current meter (10A) (12) The grow plug relay 8.4 The Adjustment of the Injection Pump 31
(6) The generator (15A) (13) The water temperature sensor 8.5 The Adjustment of the V Belt 31
(7) The starter motor (14) The battery

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 11. APPENDIX
9. The Engine Fault and the Elimination Method 32
9.1 Starting hard or can't start 32
The outline of the tilt-position engine
9.2 The Exhaust Gas is Excessive and Its Color is Abnormal 33
9.3 Fuel Consumption is Too Large 34
9.4 The Power is Not Enough 34
9.5 The Running is Not Stable 35
9.6 Stopping the Engine Suddenly 35
9.7 The Engine Can't Stop When the solenoid is Cut Off 35
9.8 The Engine Temperature is Over High 36
9.9 Engine Oil Pressure is Abnormal 36
9.10 Engine Oil Consumption is Over Large 38
9.11 There is Abnormal Sound When Running the Engine 38
9.12 The Engine Oil Level rises 39
10. Storage 40
10.1 Storage 40
11. Appendix 41
The Outline of the Tilt-type engine 41
Electric Wiring Diagram 42

To the oil pump MAX. height position The center of the exhaust export
The center line of the crankcase. The center of the inlet
The center line of the engine. To oil pipe MAX height
Supercharger

NOTE: According to actral requirement, the dimension and dimension can

be deduced further.

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 10. STORAGE 1. SAFETY INFORMATION

10.1 Storage 1.1 Safety Marks

10.1.1 The diesel and spare parts and tools leaved from the factory should be Be sure to read and follow the instructions on the manual and safety marks.
wrapped in the water-proof plastic cover. The bottom bracket should be mounted Operating the engine without proper training or instruction is not allowed.
at the casing box bottom. And the casing box should closed and clenched firmly. CAUTION: Many accidents are resulted from false operating. For your safety,
please obey to the following instructions:
10.1.2 The casing box should be put the dry and ventilated room. Forbid putting it
the open air, and putting it with the chemical (such as pesticide and chemical
fertilizer). [OPERATING NOTICE]

10.1.3 The effective period of the oil seal is one year. Check the corrosion of the Covers important safe information. Be sure to pay special attention to and
diesel after one year. Store the engine after coating it with oil seal if necessary. follow it, otherwise the engine performance will decrease or the engine fault
and parts damage will result.

1.2 Safety Caution

Be sure to pay attention to the following safety cautions while running the engine:

DANGER

CAUTION: To avoid being scalded with vapor.

Do not open the radiator cap while the engine is running, otherwise the
vapor scald will result. Be sure to open the radiator cap with cloth covered it
after the engine temperature decreased, and tighten the radiator cap while
the engine is running.

DANGER

CAUTION: To provide well ventilation for the battery.

To keep the battery at well-ventilated place and far away from the fire,
otherwise hydrogen explosive will result.

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 DANGER 9.12 The engine oil level rises

CAUTION: To avoid fire resulted from improper operating. The cause of the fault Elimination method
Use the recommended grade diesel oil. Other fuels such as gasoline and 1. There is water leakage at the cylinder 1. Repalce the cylinder head gasket
kerosene will cause engine rough running, fuel injection system fault even head gasket
the fire or explosive. Be sure to use the recommended fuel described in this
2. There is water leakage in the cylinder 2. Check and repair, or replace
manual.
head or engine body
Refuel in a well-ventilated area with the engine stopped. Keep flames and
sparks away. If the fuel spilled, immediately clean up the overflowed fuel with
rag.
Keep the engine far away from gasoline, kerosene, match and other
explosive or flammable materials, otherwise will result fire.

WARNING

CAUTION: To avoid inhale the poisonous exhaust.

The exhaust contains poisonous content. Do not run the engine at poor
ventilated places, such as confined rooms, tunnels, tents and cabins. Be
sure run the engine at well-ventilated place.

WARNING

CAUTION: To avoid being caught into the moving parts.

When the engine is running, keep your hands, body and clothes away
from rotary parts such as cooling fan, V-type belt and starter axle.

CAUTION

CAUTION: To avoid touching the hot parts to prevent from scald.

Be careful not to be scaled with hot engine body when the engine just
stopped. Keep hands, body and clothes far away from muffler, exhaust pipe
and radiator etc parts.
Do not operate the engine after drinking alcoholic beverage.

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 9.10 Engine oil consumption is over large Safety information about inspection and maintenance:

The cause of the fault Elimination method DANGER

1. The engine oil viscosity is too low, and 1. Replace the engine oil brand
CAUTION: To avoid touching the battery electrolyte.
its brand isn't proper
The electrolyte contains diluted sulphuric acid, which can cause blindness
2. The gap between piston and cylinder 2. Clean or replace the oil hole
is too large, and the oil hole in the piston and burn if eyes or skin contacted with it. If electrolyte splash into your eyes,
circle groove is clogged. flush thoroughly with water immediately and call a physician.
3. The piston ring is clogged circuit groove 3. Clean, repair or replace
or the installation position of the
4. There isoil leakage in the front seal and 4. Check and replace the relative parts WARNING
rear seal of the crankcase
CAUTION: To avoid short circuit to prevent from fire.
5. The engine oil temperature and 5. Decrease the temperature, check and
pressure is excessive regulate the pressure-limited valve Do not confuse the earth terminals while checking electric system;
otherwise the fire will result from short circuit.
6. There is oil leakage in the air valve seal 6. Replace the air valve seal

9.11 There is abnormal sound when running the engine

WARNING
The cause of the fault Elimination method
CAUTION: To avoid being caught into the rotary parts.
1. The gap between piston and cylinder 1. Replace the piston ring, piston, and
Be sure to carry out maintenance with the engine stopped.
is too large bore the cylinder if necessary.
Do not remove the cover of rotary parts.
2. The gap between piston pin and small- 2. Repalce the worn parts, keep the
end bush of connecting rod is too large specified gap

3. The gap between main bush and the 3. Replace main bush, connecting rod CAUTION
connecting rod bush is too large bush, keep the radial gap specified
Do not rebuild product without permission.
4 The gap between the piston ring and 4. Replace the piston ring, and replace Do not release the control the high-speed limiting screw and oil level
piston ring circuit groove is too large the piston if necessary limiting bolt, otherwise the engine life will be shortened. Any rebuilding or
disassembling of the engine will decrease safety even cause severe
5. The gap between pressure surface 5. Replace the thrust piece, and keep the
accident. If necessary, contact your local KAMA agents for replacing the
and thrust piece is too large specified gap
genuine parts or technical support.
6.The piston bumps into the air valve 6. Check the clearance height
7. The abrasion of the gears is serious, 7. Judge whether replace the gear or not
and the gap between the gears is according to the abrasion degree
excessively large. There is a clash bump
when reducing the speed suddenly
8. The timing of oil supply is too early 8. Check and regulate the timing of oil supply
9.The oil injector assembly is snapped 9. Clean or replace the nozzle assembly

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 9.9 Engine oil pressure is abnormal
2. PRODUCT INSTRUCTION
The cause of the fault Elimination method
1. The engine oil lack of pressure or the pressure is too low
2.1 Main Specifications and Data
(1) The engine oil in the oil sump is not (1) Refill the engine oil up to the specified
Model enough level
KM376QC KM376G KM376AG
Item (2) The engine oil becomes thin (2) Choose the specified fuel type

Type In-line,
In-line,4-stroke, Tilt, 4-stroke, (3) The oil pipe is broken, pipe connector (3) Replace or tighten it
4-stroke, water-cooled water-cooled
water-cooled is loosened, and there is oil leakage in the
oil pipe
Combustion chamber type Swirl type
Bore cycle(mm) 76 73 76 77 (4) The gap of the engine oil pump is too large (4) Replace it
Cylinder no. 3
(5) The plunger of pressure-limited valve (5) Replace it
Piston displacement (L) 0.993 1.048 isn't quick and the spring is broken or
Fire order (from the free end) distorted
1-2-3
Compression ratio 21.5 (6) The drive pin of engine oil pump is broken (6) Replace it
Rated power (kW) 25 18.7/20.6 19.5/23 (7) The fit clearance between the main (7) Check, adjust or replace
Rated speed(r/min) (15 minutes power) 5000 3000/3600 3000/3600 bearing and connecting rod is too large

Max torque/speed (N.m/r/min) 54/ 3200 56/ 3000 62.5/ 3000 (8) The plug of the oil pipe is loosened (8) Check the plug
Min fuel consumption at max throttle (g/kW.h) 312 300 300 (9) The engine oil air filter is clogged by
(9) Check and clean air filter
Max steady speed at zero-load(r/min) 5800 150 the dirt.

Idle speed(r/min) 900 50 (10)The engine oil filter is too dirty (10) Clean or replace the element
Lube oil/fuel consumption ratio at full speed and full load 0.8% (11) (11) Check and replace
Exhaust smoke FSU 4.4 (12) The engine oil manomenter is broken (12) Replace
Rotation direction (in the face of flywheel) Counterclockwise 2. The engine oil pressure is over high
Starting system 12V DC electric start
(1) The adjustment of the pressure-limited (1) Check and adjust
Lubricating system Pressure and splash valve is not right, and the engine oil can't
return
Overall dimension (L W H) mm 594 451 623
Net weight (kg) 110 110 110 (2) The air temperature is over low, and (2) Use the specified fuel type, its
the oil viscosity is too large viscosity will fall automatically
after warming up

(3) The lubrication at the camshaft neck is (3) Eliminate the dirt that restricts the eng-
not good ine oil, and clean the oil passage of the
cylinder head.

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 9.8 The engine temperature is over high 2.2 Specifications and Data of Key Parts
The cause of the fault Elimination method Item Specifications and Data
1. The water temperature of exhausted is over high Type VE distributor pump

(1) The water in the reservoir is not (1) Add water, and eliminate the air Fuel injection Model VE3/9F2500LND
enough pump Plunger diameter 9mm
(2) The dirt clings to the surface of the (2) Clean the dirt with the compressed air Governor Mechanical full length
radiator pieces and copper pipes Model S series; (P series) thread coupling
(3) The scale deposit in the cooling sys- (3) Clean the scale deposit. Fuel injector Nozzle type Dual function throttling pintle nozzle
tem is too thick to cool the system down Fuel delivery pressure 13.5~14.5Mpa

(4) There is water leakage in the pump or (4) Disassemble, check and repair Working speed 2500r/min
the shaft of pump is broken, the impeller Lube oil pump Working pressure 249Kpa
can't rotate Flow volume Above 20L/min

(5) The fan belt is broken or too loosened (5) Replace the belt or adjust the belt Type Centrifugal
tension Cooling water
pump Speed 5000r/min
(6) The cooling water line pipe or engine (6) Clean the water line Flow volume 55L/min
cooler is clogged Screw-in type
Lube oil filter
(7) The thermoregulator is damaged (7) Replace it
(8) The diesel runs under over load (8) Reduce the load Item Specifications and Data

2. The engine oil temperature is over high Type Silicon rectifying, parallel excitation
Generator Voltage 14V
(1)The engine oil is insufficient or (1) Add the engine oil as specified
excessive Rated current 40A (45A in cold area)

(2) The engine cooler is clogged by dirt (2) Clean it Type DC motor

(3) The quality of the engine oil is bad (3) Replace the engine oil as specified Starter motor Voltage 12V
Power 1.4kW
(4) The amount of air flee is excessive in (4) Check the air flee for the piston ring
crankcase Working voltage 11V
Glow plug Working seconds 7-8 seconds
(5) The cooling water temperature is over (5)Reduce the temperature as described
high above Working temperature Above 750

(6) The diesel runs under over load (6) Reduce the load Thermoregulator Paraffin type

(7)The engine oil temperature meter doen't work (7) Replace it Paper element (with fuel/water
Diesel oil filter
separator and portable pump)

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 2.3 Main Adjusting Data Table 9.5 The running is not stable
Item 1. Check the air leakage and remedy the
Normal adjusting data value Limit value 1.There is some air in the fuel
fault then eliminate the air in the fuel
Specification system
system
Non-compression space 2.The speed-regulating slide cushion lost 2. Send the oil pump to the service station
0.7-1.0mm
height inside the cylinder its flexility
3.The speed-regulating level is worn or 3. Send the oil pump to the service station
When the piston is at the upper dead
not flexible
Fuel delivery timing point, the stroke of fuel pump plunger is:
0.97 0.03mm or 0.89 0.03mm 4.The fuel distributed to each cylinder is 4. Send the oil pump to the service station
not even
Fuel spraying pressure 13.5-14Mpa(green) and 5.One of the nozzles is bad 5.Check and replace the bad nozzle
(two bundle) 14.1-14.5Mpa(pink)
9.6 Stopping the engine suddenly
Open at BTDC16 10 ;
Valve close Intake valve The cause of the fault Elimination method
close at ABDC 40 10
and open 1.The fuel in the tank is used out 1. Add fuel to the fuel tank
phase Open at BBDC52 10 ; 2.There is some air in the fuel line 2. Exliminate the air in the fuel line
Exhaust valve
close at ATDC 14 10 3.The fuel filter is clogged 3. Clean or replace the element
4. The plunger and inner oil ring is snapped 4. Send the oil pump to the service station
Valve clearance Intake 0.25 0.05mm;
(cold state) 5. The plunger spring is broken 5. Send the oil pump to the service station
exhaust 0.3 0.05mm
6. The solenoid plug of fuel pump is not 6. Check the circuit
Valve (intake&exhaust) electrified
1.2-1.6mm
joint ring width 7. The denticulate belt is broken 7. Replace and test
Valve sunk volume 0.7-1mm 8. The crankcase can't crank 8. Replace and test
a) The piston sticks to the cylinder a) Send it to the service station
Press the belt down 6-7mm with
b) The oil pressure is too low and the lube b) Send it to the service station and
Belt tension 10kg pressure oil is not enough to cause the crankshaft check the lubricating system.
(New belt: press down 5-6mm) sticking to cylinder.

Lube oil pressure 0.4-0.6Mpa, idle speed 0.15Mpa

9.7 The engine can't stop when the solenoid is cut off
Lube oil temperature 60 ~110
The cause of the fault Elimination method
Drained water temperature 95
Exhaust temperature 1. There is some fault about the solenoid 1. Replace the solenoid and clean the
750
element

2. The seal surface of the solenoid loses 2. Send the oil pump to the service station
its seal function

3. The switch of the solenoid doesn't work 3. Replace or repair

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 9.3 Fuel consumption is too large 2.4 Tightening Torque of Main Bolts and Nuts
The cause of the fault Elimination method Thread Tightening
(1) Fuel leakage (1) replace or tighten securely Bolt qty.
specification torque (Nm)
(2) idle speed is too high (2) regulate idle speed
Cylinder head bolt M12 1.25 90+10 8
(3) the max rotation speed is too high (3) check the max speed set bolt of the
at the no load injector pump Camshaft bearing bolt M8 16 1 8
(4) injection timing is abnormal (4) regulate the injecting timing Main bearing bolt*) M10 1.25 60 5 8
(5) injector or nozzle assembly doesn't (5) Clean, regulate
Oil sump bolt M6 5.5 1.5 20
work normally
Connecting rod bolt M9 1.0 47 5 6
9.4 The power is not enough Flywheel bolt M10 1.25 55 5 6
The cause of the fault Elimination method Thread of fuel injector body M20 1.25 60 10 3
(1)The air cleaner is too dirty and the (1) Clean and replace Glow plug thread M10 1.25 12 2 3
fuel is restricted
Other bolts and nuts
(2) The throttle doesn't work normally (2) Regulate the throttle
M6 7.5 1.5
(3) Fuel pipe is clogged, (3) Check and clean
M8 18.5 3.5
(4) There is leakage or there is some air (4) Tighten it again, eliminate the air in
in the fuel system the system M10 1.25 37.5 7.5

(5) The speed-regulation spring is slack (5) Regulate the max speed limited screw M12 1.25 60 10

(6)The timing of the supplying fuel is not (6) Regulate it as specified Note: *Turbocharger-type: main bearing bolt M12 1.25;
correct. tightening torque 85 5N.m.
(7) There are some faults in the injector (7) Check the pressure of oil injection
and atomization condition
(8)The air cleaner is too dirty (8) Clean and replace the element

(9) Mix air phase or valve clearance isn't (9) Check and regulate it
correct
(10) The compression pressure of the cylinder is not enough
There is air leakage at the valve Abrade the surface or replace the
valve and valve base ring

There is air leakage at the cylinder Replace the cylinder cushion

cushion

The cylinder, piston ring or piston is Replace the relative parts and abrade
worn out the cylinder surface

There is air leakage when install the Replace the seal gasket or adiabatic
injector line of the nozzle
The bolt of the cylinder is loosened Tighten the bolt again as required

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 2.5 Operation Control Device 9.2 The exhaust gas is excessive and its color is abnormal.
The operation control device connected to warm-up unit, electric starter and fuel The cause of the fault Elimination method
pump solenoid valve respectively. 1. The smoke exhausted is too thick
The electric wiring of the control device is as below figure 2-1. (1) the injecting timing is improper (1) Adjust the injecting timing
(2) the fuel filter is restricted (2) Replace the fuel filter
The electric wiring of the starting motor is as below figure2-2.
(3) the assembly in injector nozzle (3) clean, repair
Recommended voltage is DC 12V. doesn't work normally.
Recommended current is less than 90A. 2.the exhaust gas is black smoke

The electric wiring of the glow plug is as below figure 2-3. (1) Fuel injector is clogged by the carbon cumu- (1) Check, repair or replace
lated and the needle valve is blocked up
The resistance of the glow plug is 0.4~0.6Ohm.
(2) The load is too large (2) Reduce the load to the specified range
The function and operation of the electric starting switch is as below. (3) Fuel injection is too late, part of fuel a) Replace the cable or tight connection
is burnt in the exhausting course
Rotary 3-position switch (4) The clearance is not accurate and (4) Check the valve clearance and seal
it's seal is not effective. surface of valve
The key can be pulled out when the switch is on
OFF position. Meanwhile, the current is cut off at (5) The distribution of the fuel to each (5) Regulate the fuel distribution of each
this position. cylinder isn't even cylinder

When the switch is on ON position: (6) The inlet pipe and air cleaner is (6) Remove the air cleaner and clean it
clogged, so the air is restricted
(1) the warm-up indicating lamp of glow plug will
3. the exhaust gas is white smoke
keep light for 7~8 seconds, and then goes out
(1) Injection pressure is too low, atomi- (1) Check, regulate, repair or replace
automatically.
zation isn't good, and there is oil leakage the nozzle assembly
(2) The solenoid of fuel injection pump is acted.
(2) The temperature of the cooling water (2) Increase the temperature of
When the switch is on START position, release is too low cooling water
The operation procedure the key and let it automatically return back to ON (3) The cylinder is penetrated by water (3) Check the cylinder head shim
Of the switch is: position. The solenoid of fuel injection pump is 4. The exhaust gas is blue smoke
OFF ON START ON acted, however the glow plug is still unconnected.
(1) The piston ring is worn excessively or (1) Clean or replace the piston ring
engine oil enters into the combustion
chamber in cause of the spring of the
carbon clogged is not enough.
(2) The engine oil level is too high (2) Drain out the excessive engine oil
(3) The installation of the air ring is (3) Make the surface marked
converse in up and down direction with "T" toward up
(4) Valve seal is damaged (4) Replace the valve seal

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 9. THE ENGINE FAULT AND THE ELIMINATION METHOD

The cause of the fault Elimination method

1. Starting speed is low.
(1) Battery electric amount isn't enough (1) Charge the battery; tighten the connec-
or the connection is loosened. tion and repair the terminal if necessary.
(2)The contact of between the carbon (2) Repair or replace the carbon brush
brush and rectifier is poor.
(3)The gear of the starter engine can't (3) Revolve the flying wheel until the small re-
be embedded into flying wheel circle gulating gear levels with the denticulate circuit
(4) The electric battle cable is too long, (4) Replace the electrical battle cable
too thick; voltage decrease is too large.
2.the fuel system doesn't work normally.
A. There is no fuel injected. 1. The solenoid of fuel injection pump 4. Starter motor 7. Glow plug relay
(1) The fuel in the tank is used up. (1) refuel the fuel and drain out the air 2. Warm-up indicating lamp 5. Glow plug 8. Warm-up timer
(2) There is fault in the solenoid Injection pump 3. Voltmeter (10A) 6. Glow plug resistance 9. Battery
a) The cable is cut and the connection is loosened a) Replace the cable or tight connection
Figure 2-1 The electric wiring diagram of control device
b) The winding of the solenoid is damaged b) Replace solenoid
c) The solenoid element is snapped c) Replace solenoid
d) There is fault in the starter switch d) Check or replace
(3)There is some air in the injector pump (3) Drain out the air, tighten the connection of the oil pipe
(4) Fuel filter element is clogged (4) Clean or replace fuel filter element 1. Housing ground
(5) The plunger of the injection pump is (5) Replace the parts of the injector 2.Terminal 50
broken or snapped pump distributor. 3. Terminal 30
(6) The transmission bolt in the plane (6) Replace the transmission bolt in the
cam of the injector pump is broken plane cam of the injector pump
(7) The inner oil ring of the injector (7) Replace the parts of the injector
pump is snapped pump distributor. Figure 2-2 Electric wiring diagram of starter motor
B the warm-up system doesn't work normally
(1) The grow plug relay doesn't work normally (1) check and repair, or replace
(2) Warm-up timer doesn't work normally (2) check and repair, or replace
C Water temperature sensor doesn't work normally C check and repair, or replace
1.To the solenoid of fuel injection pump
D Injector doesn't inject fuel or atomization quality is too bad 2.To warm-up indicating lamp
(1) Nozzle is snapped (1) Replace the nozzle assembly 3. To voltmeter (10A)
(2) The atomization quality of nozzle is too bad (2) Replace the nozzle assembly
(3) Pressure-regulating spring is broken (3) Replace pressure-regulating spring
(4)There is oil leakage at the (4) Replace the fuel injector assembly.
high-pressure oil seal Figure2-3 Electric wiring of glow plug

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 8.3 The adjustment of the fuel injector
3. PREPARATION BEFORE OPERATION The test and regulation of the injector should be done on the fuel injector test bed.
Its purpose is regulating the oil pressure and watching the atomization quality and
3.1 Prepare the Fuel, Lubricating Oil and Cooling Water eliminating the fault.
1. Pump the oil by using the hand pump unit the injection pressure is 14 0.5Mpa,
3.1.1 Fuel
check the Injection condition and atomization quality whether accords with
(1) To keep the engine in best working condition, be sure to use the recommend-
injection requirement. If there is oil leakage or dropping in the injector, you should
ed fuel: light diesel oil JIS K2204 (GB252-87)
remove the fuel injecting assembly to clean or repair it until make injection up to
However, be sure to choose the appropriate brand for the light diesel oil
requirement.
according to actual ambient temperature.
2. The adjustment of injection pump.
Light diesel oil brand: Pump the oil by using the hand pump. When the reading of the fuel injection
starting pressure can't reach 13Mpa, you can remove the injection assembly by
increasing the thickness of the adjustment shims to improve the injection pressure
until the pressure reading is up to standard. If the reading is over 13Mpa, you
Temperature: should reduce the thickness of the adjustment shims.

(2) Fuel usage 8.4 The adjustment of the injection pump

The fuel with water or dust contaminated will cause the rough running of the
engine. Be sure to use the clean container for storing the fuel, meanwhile, the Injection pump has been tested and adjusted before leaving from the factory. If
container must be stored at a clean and dry place. Then suck out the upper level you need to readjust it, you should perform the adjustment on the test bed
clean fuel with a pump as below figure. according to relative regulations.

[OPERATION NOTE] 8.5 The adjustment of the V belt

As shown in the figure, make the tension check in the arrowhead direction. As to
The improper fuel cannot make the engine new products, put a 100N force on the it and loosen the belt until looseness
achieve the best performance, and even degree reaches 4 5 mm. Under the normal condition, put on a 100N force until
cause the fault of the part. the looseness degree is 6 7mm. If you put on a 100N force but the looseness is
no less than 9mm, replace the V belt.
Only use the upper level clean fuel. Do not
use the lower deposited fuel.

Generator Water
pump

3.1.2 Lubricating oil

(1) Do use L-ECD grade oil; the quality index is 15W/30 or 15W/40.
(2) The usage of lubricating oil:
A. Carefully store and use the lubricating oil. Avoid any dust and impurity in the oil.
Crankshaft
B. Do not mix two different type lubricating oil, otherwise the lubrication
performance will be decreased.

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 8.2 The adjustment of the injection timing [OPERATION NOTE]
In order to obtain the most economical fuel consumption ratio and better running Using the improper type lubricating oil will burn out the inner part of the
performance, the injecting ahead angle should be set properly. The adjustment engine, even cause the engine to wear rapidly. And the service life of the
method of KM376QC/ KM376ZQC ahead angle should be as followed: engine will be also shortened.
(1) Crank the crankshaft to make crankshaft lies on the 30 spot NO.1 cylinder (In
other word, it's the injection pump bolt fan mark)
3.1.3 Cooling water
(2) Loosen the mounting nuts in the fuel injection pump and the bolts in the
Be sure to adopt tap water as cooling water.
supporting plate of the fuel injector rear end until the fuel injection pump can
revolve. Then keep the fuel injection pump toward the inner surface to the bottom. [OPERATION NOTE]
(3) Install the lever-type micrometer calipers in the front end of the fuel injection Be sure to add anti-rusting or anti-freeze solution to the cooling water.
pump, and let the pointer needle point at naught. Add anti-freezing solution to the cooling water in winter, otherwise, the
(4) Crank the crankcase to make NO.1 cylinder of the engine stay at upper dead frozen water may damage the cooling water system.
center of the compression stroke.
(5) Turn the injection pump toward outside surface slowly until the reading of the A. Anti-rusting solution:
meter is 0.97 0.03mm. Be sure to use the superior quality anti-rusting solution. But do not use it in winter
(6) Check the meter again. (Crank the crankcase to position 1, watch the reading because it may freeze when the air temperature is low. Its standard mixing ratio is
of meter whether reset to naught position. Then crank the crankcase until it 6%.
reaches the upper dead center, check the meter reading whether is 0.97 B. Anti-freezing solution:
0.03mm. If the reading is right, the adjustment is completed. If the reading isn't Be sure to use the superior quality anti-freezing solution. However, it's not
right, repeat the above adjusting steps.) necessary to use it with anti-rusting solution simultaneously. This kind of solution
(7) Tighten loosened nuts and bolts above mentioned. can be added to cooling water in all seasons. Its mixing ratio is 30%~55%.

[OPERATION NOTE]

If the mixing ratio of anti-freezing solution is too low, cooling water will
freeze in low temperature, which causes damage or rust to the water pipe.
If the mixing ratio of it is too high, the engine performance will be
decreased.

The lowest temp -15 -20 -24 -29

Mixing ratio % 30 35 40 45

Use the commercial available anti-freezing solution with the mixing ratio
recommended by manufacturer, meanwhile, it must be replaced every year.

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 3.2 Preparation before starting
3.2.1 Add the lubricating oil
8. THE ADJUSTMENT OF THE TECHNICAL DATA
(1) The amount of the lubricating oil added should flush with height of the
lubricating oil level in the oil sump. Put the engine on a level surface at first, then KM376 series engines are different from the general-use diesels in the structure.
check the oil level. In order to ensure maintenance quality, please read this additional section
carefully.
(2) The lubricating oil level in the oil sump should between the lower and upper
marked line of the oil stick.
8.1 The adjustment of valve clearance
[OPERATION NOTE] The valve clearance refers to the cam surface the clearance of inlet valve should
The lubricating oil level in the oil sump should between the lower and be 0.25 mm in cold condition, and that of the exhaust valve should be 0.30 mm. In
upper marked line of the oil stick. If the lubricating oil is not enough, it will hot condition, the clearance of inlet valve should be 0.30 mm, and that of the
damage the engine easily. However, if excessive, the lubricating oil will spill exhaust valve should be 0.35mm. If the clearance is improper, make it reach to
over from the air opening hole. the standard by adjusting the shim thickness.

8.1.1 The measurement of the clearance

3.2.2 Refill the fuel tank Measure the clearance using the ruler as shown in the figure 8-1
(1) Add the fuel to the fuel tank. (1) Measure the clearance in cold condition.
Add the fuel without containing dirt and water. To prevent the fuel from overfilling (2) The rabbet in the cam should be toward up.
during the running course, the amount of the refilled fuel should be 90% of the fuel
8.1.2 The selection of the adjusting shim clearance
tank capacity.
T2= T1 +(A'-A)
DANGER T2: the thickness of the shim replaced
Make certain whether the type of the fuel refilled is right or not. If improper T1: the thickness of the shim measured
fuel is added, it will cause the fire. If the fuel is overfilled, wipe it up at once. A': the metrical value A: the standard value

8.1.3 The replacement of the adjusting shim

(2) Eliminate the air in the fuel system Press the valve tappet down using the special tools, and get out the shim used for
When refill the fuel at first time or refuel the tank normally as required, you should the measurement, then replace the shims that need to install to primary position.
eliminate the air in the fuel line which begins from the fuel tank, though water-oil
separator or fuel filter or primary oil delivery pump, to the fuel injection pump.
If the air mixes with the fuel in the fuel line, the fuel injection pump won't provide
the high-pressure fuel for the fuel injector, and the engine can't start also.
This product adopts the VE distributor pump, and the lubricating and cooling of the
VE distributor pump relies on the fuel. So if the fuel is cut off, it will result in
damage of VE distributor pump.

Fig. 8-1 Check the valve clearance

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 (7) Check the air cleaner The fuel line of the engine fuel system is as shown in figure 3.2.2 followed:
If the dust is drawn into the air cleaner and clings to air cleaner parts, it will affect To eliminate the air in the low-pressure fuel line, loosen the connector of the intake
the output of the engine sooner or later. When the combustion chamber draws the pipe in the VE dispensing pump at first, then expel the air from the fuel.
dust in, it will accelerate the worn of the moving parts and cause the engine not to Inspect the connector of the VE pump return pipe. If there is a lot of fuel
run normally. When you run the engine in the dusty place, the service interval overflowed and no air bubble occur, It indicates that there is no air in the low-
should be shortened as possible as you can, paper air cleaner element. pressure fuel line.
Loosen the wing nuts in center of air cleaner, remove the air cleaner cap, then get
out the paper element inside the air cleaner.
Blow and clean the inner surface of the parts using the compressured air (below
0.2 Mpa). Clean the dirt and dust clinging to the surface.
If the elements are dirty or broken always, replace them with new elements.
Reinstall the paper element after cleaning the dirt and dust clinging to the air
cleaner and chassis.
primary oil delivery pump
diesel fuel filter
Oil return tube
solenoid valve
fuel injector
fuel tank
oil-water separator
VE distributor pump

3.2.3 Eliminate the air in the high-pressure fuel line.

7.3 The technical maintenance after the engine works 1000 hours
The high-pressure fuel line begins from VE dispensing pump, through high-
Repeat those items as technical maintenance after working 500 hours , then
pressure fuel pipe, to the fuel Injector.
perform the following maintenance items:
Method of the treatment: loosen the connector where the high-pressure fuel pipe
1. Check the tightness degree of the bolt in the connecting rod and main bearing.
connects with fuel injector, then start the starter motor and let it run at low speed
2. Check the seal of the inlet and exhaust valve. If necessary, machining the until the fuel overflows around the connector, finally tighten it. If there is still some
surface of the valve seat over again. air in the high-pressure fuel-pipe, the engine won't start.
3. Check the starter motor and generator. If necessary, add the lubricating oil, and
run the engine at idle speed after reinstalling it. Add grease to the bearing before
putting the engine to use.
4. Check each part of the diesel engine.
5. Reinstall the parts removed in the maintenance course to primary position,
eliminating the potential fault.

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 3.2.4 Add the cooling water. (6) Check the battery electrolyte
(1) The water in the radiator water tank should be sufficient. Expel the air from the When check the electric circuit, you must close the battery switch, disconnect the
water line when adding the water. At the same time, check the water tank and ground terminal. If there is a shortcut in the circuit, it may result in fire.
connector of pipes for leakage, and remedy if in time. Please recharge the battery in a good ventilated place. Keep all fire sources away,
(2) After adding water, tighten the radiator water tank cap. Otherwise it will cause because the hydrogen produced in the battery causes fire easily.
scald for the hot water. The electrolyte contains a mount of sulfuric acid. It could cause burnt injury even
(3) If there is some air in the water line, it will cause the restriction of cooling water, blind, if the eyes and skin contact with it.
even engine damage because of the excessive high temperature in the engine. Please wear the glasses and rubber gloves when you handle the battery
3.2.5 Check the all operation control systems, and the operation reliability of each electrolyte.
connection. Remedy the fault as soon as find it. If you touch the electrolyte without precaution, use a large quantity of water to
wash it and see the physician as soon as you can.
3.2.6 Check the connection of the bolt mounted to ground and the driven
machinery. If loosened, tighten it securely at once. Check the electrolyte level every month. If the level is lower than the lower limit
mark, refill the distilled water to the upper limit mark.
3.2.7 Before connecting the battery, make sure that the connection of the negative
lapping iron and the electrical diagram is right and electric capacity of the battery
is sufficient.
Upper limit mark
Lower limit mark

[OPERATION NOTICE]

1) If you continue to use the battery when the electrolyte is not enough, you
will cause the damage of the battery. Periodically check the electrolyte
capacity. If the electrolyte level is below the standard specified, please refill
the electrolyte in time.

In hot summer, the electrolyte tends to be vaporized. So check it ahead of

the specified time.

2) If the engine can't start using the accelerating return, use the gravity
meter to measure the density. When charged fully, the density should be
above the 1.27 g/ml(20 hours).

If the density is below to 1.24 g/ml, it indicates that the battery needs to be
charged.

If the density doesn't increase after charging, please replace the battery.

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 (4) Check and adjust the valve clearance

Check the valve clearance every 100 running hours 4. OPERATION INSTRUCTION
method: check valve clearance by removing the cylinder head according to the
method described in figure 8-1 of section 8.1. If you want replace the adjusting WARNING
shim, use the professional tools for the engine. Then get out the shims according
Provide the engine with good ventilation condition for its running.
to figure 7-5, and replace the shims you need to install.
When running the engine, your hands, body, clothes shouldn't close to or
contact with such moving parts as radiator fan, belt, drive shaft and so on.
When check and service the engine near these parts, be sure that the
Max. height engine is stopped. Before running it, make sure that there isn't anything left
on these moving parts.
Nice
When the engine is running or stopped not for a long time, your hands,
Tappet
body and clothes should not contact with the muffler, exhaust pipe and
radiator.
Fig. 7-5

4.1 Starting
(5) Check the tightness of the bolt in the cylinder
4.1.1 Start the engine under no load.
Check the tightness of the bolt in the cylinder by using the torque wrench every
100 hours. Check the bolts in sequence as described in figure 7-6. The tightening When starting the engine on the vehicle, let the vehicle to stop before.
torque should be 90+10N.m. 4.1.2 Set the throttle lever at the half-open position when you start the engine.

4.1.3 Insert the key to the engine switch hole, then

turn it to the ON position clockwise. At this time, the
grow plug indicator lamp is on. After it last about 7
seconds, it goes out soon. The next step, turn the
Front side
key to the START position clockwise, let the starter
motor to start the engine. Finally, release the key,
and it will return to ON position automatically. This
is completing the engine start.

[OPERATING NOTICE]
Fig. 7-6
Don't use the start switch over 15 seconds each time. If you can't start the
engine, wait for 1 minute, then restart the engine. Otherwise, the long-time
running with electricity overheats the engine to cause fault.

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 [OPERATING NOTICE] (3) Check the injecting pressure and the atomization quality of the fuel
Injector
When put the key at the ON position, 12V DC voltage will open the
Check the injecting pressure and the atomization quality of the fuel Injector every
solenoid valve in the VE pump. If the electrical bottle voltage is lower than
100 hours. (Refer to the figure 7-3)
8V or the cable isn't connected as required, the solenoid valve won't be
If you find there is oil leakage, atomization quality is bad and needle valve of the
opened and the engine won't start, even sudden stop will happen.
nozzle is blocked, please remove and clean the injector or replace the injecting
nozzle.
If you find the oil pressure isn't up to specified value, you can adjust the pressure
[OPERATING NOTICE]
regulating spring by adding the steel shims. Refer to figure 7-4 for the structure of
After starting, the starter switch key shouldn't be pulled out, but placed at the fuel injector.
ON position. If placed at the OFF position, the battery won't be charged.

[OPERATING NOTICE]

After starting, the handling lever should be put at idle or middle-low speed Resonance
position for running several minutes. Then check the all meters whether are
normal or not whether there is abnormal sound of engine. If either of them Fig. 7-3
is abnormal, stop the engine to check and remedy it right away.
[OPERATION NOTICE]

4.1.4 When the ambient temperature is below 5 C, it may be difficult to start the Fuel nozzle is a couple of exact assembly, don't replace the any of the parts
engine. Warm up the intake gas, fuel, cooling water, lube oil or use some solvent solely when clean them. Don't damage the surface of the injector lower body,
to make engine start easy. two terminal surfaces of the middle gasket, and main surface of the nozzle.
Otherwise, oil leakage will occur, affecting the quality of atomization.
4.2 Running
4.2.1 After starting the engine, keep it at idle state about 5 minutes then change it
into medium-speed, small-load running state. Increase the load and rotary speed
gradually along with the temperature of the cooling water and engine oil becoming
higher and higher.
Regulation shim of injection pressure
[OPERATING NOTICE]
Pressure-regulation spring
After starting the engine, shouldn't increase the rotary speed to high speed Needle valve
or run the engine under the large load suddenly. Otherwise, it will cause the Needle valve body
damage of them even shorten the parts' service lives.

Fig. 7-4

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 (1) Replace the engine oil, and clean the lubricating oil filter element 4.2.2 When the engine is running normally, inspect the engine oil pressure and
Replace the engine oil every 100 hours. temperature, cooling water temperature and the working condition of the charging
Clean or replace the lubricating oil filter element. (Refer to figure 7-1) indicator frequently
Be careful to observe the color of exhaust gas and listen to the working sound
during the operation.
bypass valve
cooling water 4.2.3 In the normal run course, shouldn't increase or decrease the rotary speed
bypass valve and load suddenly.

To main oil passage

WARNING
The oil pump troops
bypass passage If you find one of the phenomena that the engine oil pressure is over low and
to the pump the temperature of cooling water is over high (It's over the specified range in
the chart 2.4); dense smoke exhausting from the engine; and there is knock
sound in the normal run course, stop the engine as soon as possible and
Fig. 7-1
check the reason of these symptoms. Otherwise, the fault will lead to
damage of the engine.
(2) Clean and replace the diesel oil filter element
Clean the diesel oil filter element every 100 hours and drain out the water in the
sedimentation cup (refer to figure 7-2). If you find the element is broken or can't be 4.2.4 Provide the adequate heat preservation measure for running the engine in
clean, please replace it at once. the winter to prevent the temperature of the cooling water and engine oil is over
low. However, Provide the adequate cooling measure for running the engine in the
summer to prevent the temperature of the cooled water and engine oil is over high.
The sedimentation cup
WARNING

Never keep the engine running under overload for long time. Otherwise it will
result in fault and shortening the service life.

Filter element

Fig. 7-2

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 4.3 Check engine during the running

check the antifreeze

It's an additional
is added to water,
pump to service
Make sure there is no abnormal case during the running referring to following

If the antifreeze
Remark

KM376ZQC
Send the VE

item for the

items.

if sufficient.
station for
checking
1. Whether the color of the exhaust gas is normal or not.
If the engine exhausts black smoke continuously, stop to check it at once. If ignore
this symptom, it leads to engine run in a bad condition.

Per100 hrs Per200 hrs Per300 hrs

It will shorten the service life of the engine under the overload.

Periodically check interval

2. The abnormal working sound during the running
If there is abnormal working sound during the running, stop the engine right away.
If you continue to run the engine, it will result in serious damage accidents.
Check all the bolts and nuts if loosened or not. Find out the reason of the fault and
eliminate the trouble.

3. Avoid running the engine in the resonance range

Due to the intrinsic structure factor, the working machinery may resonate this
product in certain rotary speed range. It will make the vibration of the engine

Check the battery voltage and density of the electrolyte

Check the connection condition of every contact spot.
become very incredible. So avoid running the engine near this rotary speed. If

Clean the dirt from impeller and engine inner surface

Check the clearance of the exhaust and inlet valve
continue to run the engine at this case, it will result in serious damage accidents.

Clean the dirt on the surface of air compressor

Check the initial pressure of the fuel injector

Check the tightness of the bolt In the cylinder

4. A. Add the cooling water to the cooling water tank
Inspect the cooling water whether is enough or not during the running. And
Check and Service items

supply the cooling water to the water tank in time.

Clean or replace fuel cleaner element

B. Check the amount of the cooling water at the export hole whether reduced
Clean or replace cleaner element

or not.
Replace engine oil in the sump

Check the phase of gas mixed

Clean the air cleaner element
Clean dust from the inlet pipe
Check the tension of fan bolt
If the exported cooling water decreases, stop to check the engine.
Replace the cooling water
Check atomization quality

Clean the thermoregulator

C. Check the cooled water whether injected or leaked?

Check the inner rotator

If there is an abnormal case, stop to check the engine right away.
Check the VE pump

If continue to run the engine lacking of the cooled water, it will cause the
engine over hot to burn out the inside parts.

5. Check the oil pressure lamp whether is on and the oil pressure sign is red
If the oil pressure sign is red, stop to check the engine.
If continue to run the engine at the no-oil state it will result in burning out the inside
parts.
Bolts and cylinder cap
& Air cleaner
Air inlet pipe
Lubricating

exhaust air

6. Check the charging indication lamp is on.

System

Inlet and
Cooling

charger
If the charging indication lamp is on, it indicates that you can't charge the battery.
Electric
Starter

Turbo-
Water
Fuel

7. If there is burn or funk or smoke, please add the lubricating oil in time. You must
stop the engine when add the lubricating oil. If there is an abnormal case, but you
can't determine the reason, stop the engine and send to the dealer's shop to Note: " " Indicates that it's a necessary item or content

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 4.4 Stop the engine
7. THE METHOD OF THE MAINTENANCE AND SERVICE
4.4.1 If the engine needs to be stopped, decrease the engine speed to the idle
state gradually. Let the engine stop only when the temperature of the cooling
In order to make the engine work normally and reliably, proper technical water is below 70 C.
maintenance should be given to the diesel engine. And the technical maintenance
includes following kinds: the daily technical maintenance, the periodical 4.4.2 When you need to stop the engine, only turn the starter switch key to OFF
maintenance and the maintenance after working 1000 hours. position (refer to 4.1.1)

7.1 Daily technical maintenance 4.4.3 After you stop the engine in winter, you need to make antifreezing
(1) Check the lubricating oil level in the oil sump whether is between the upper preparative.
mark line and lower mark line of the oil dipstick and near the upper mark line. If it
is a new engine or an old engine stored for a long time, add the lubricating oil up
to the upper mark line and run it at low speed for 5 10 minutes before stopping it.
Then measure the height of the oil level with the oil dipstick.
(2) Check the water amount in the radiator.
(3) Check the reliability and degree of tightness of cables connection.
(4) Check the leakage of water, oil, and gas.
(5) Check the degree of tightness of the supporting connection or other driven
machinery.
(6) Keep the engine clean. Clean the oil and dust using dry rags or rags with
detergent. Keep the electric appliance connected to the engine dry and clean
especialy.
(7) Eliminate the fault and abnormal symptoms that have been found.

7.2 Periodically check and service

In order to keep the engine at good running state, the daily check is necessary.
The following table specifies the rules about when and how to check and repair
the engine.
Check the engine usage, load, fuel used, lube oil quality and operation state when
make the periodically maintenance. The following table describes the common
cases about the maintenance.

[OPERATION NOTICE]

According to use condition, set down periodically maintenance schedule.

Perform the rules to check the engine without missing as the schedule
specified. In case of missing the necessary item, it will affect the durability of
engine parts. As to the parts marked with (*) specially, the owner should
have the proper tools and be mechanically proficient. Otherwise, please
send your products to your KAMA dealers and consult with them.

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 5. BREAK-IN PERIOD AND TRIAL RUN 6. THE STORAGE FOR A LONG TIME

5.1 A new engine needs a break-in period and a trial-run course. And this course [OPERATION NOTICE]
should not be less than 45 hours or 2800 km.
If you don't drain out the cooling reserved in the engine, it will be frozen,
5.2 During the break-in period, don't let the engine stay at the high-speed state which will damage the parts.
with the fuel valve open fully. And you should increase the engine load slowly, at In order to reuse the engine normally, the following measurements should be
the same time inspect the engine's running data measured by the all kinds of carried out when you store the engine for a long time.
meters.

(1) When stored for a long time in winter, the water in the engine should be
[OPERATION NOTICE]
drained out. (If antifreeze is used, the water needn't be drained out). Drain out the
To make your engine run reliably and use for a long time, provide a new water by opening the draining water valve in the engine lower body. At the same
engine with a break-in period. time, open the radiator cap to drain the water.
During the break-in period, you should inspect all kinds of meters whether (2) Clean the dirt, dust and oil clinging to engine body.
work normally. After the break-in period, please replace the engine oil in the
(3) Periodically check and replace the engine oil.
oil sump.
(4) To prevent the fuel vapor changing into moisture in the fuel tank, you can drain
out the all of the fuel in the tank or refuel the fuel tank fully.
5.3 After break-in and trial-run course, replace the engine oil in the oil
(5) Remove the negative terminal of the battery at the ground cable. In order to
sump.
makeup the wastage that caused by discharging of battery itself. Charge the
Clean the engine oil filter and fuel filter. Check the tightening torques of the battery every month in the storage course.
cylinder head bolt and the others connecting bolts. These torques should meet the
(6) Add the lubricating oil to the acceleration coils and system.
requirement as specified.
(7) Coat the muffler, air cleaner, electric parts with the plastic cover to prevent the
water moisture and dust entering into those parts. The places in which the engine
stores should be dry and free of dust.

[OPERATION NOTICE]

When reuse the engine after storing for a long time, make the preparations
as using a new engine at first.

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