ENGINE SERVICE MANUAL

Engines:

A1000 - Branson 2200

A1100 - Branson 2500
A1100T - Branson 2900
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1. ENGINE APPEARANCE, SPECIFICATION AND NAMES OF PARTS

1.1. ENGINE APPEARANCE
1.1.1. Natural Aspirated E/G and Turbo engine

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1.1.2. TURBO CHARGER ENGINE

1.2. Engine specification
1.2.1. Small engines

‫ٻڄۈۋۍڋڋڑڍڊۋۃڏڍڃڋڋڌڌڜڊڄۈۋۍڋڋڑڍڊۋۃڌڍڃڋڋڋڌڜ‬ ‫ٻڄۈۋۍڋڋڑڍڊۋۃړڍڃگڋڋڌڌڜ‬

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 Full capacity ℓ 2.9 2.9 3

Capacity
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.

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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.

‫ٻ‬
Exhaust side Intake side ‫ٻ‬
G
(for Natural Aspirated E/G) (for Natural Aspirated E/G) 4
1. Exhaust manifold 1. Intake manifold
2. Generator 2. Oil inlet
3. Oil dipstick 3. Cooling fan
4. Starter motor 4. Fuel injection pump
5. Oil filter 5. Feed pump
6. Coolant pump 6. Crank-axis pulley

‫ٻ‬ ‫ٻ‬
G

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Exhaust side ‫ٻ‬ Intake side ‫ٻ‬

G (for turbo charger) (for turbo charger)

1. Turbo charger 1. Intake manifold

2. Exhaust manifold 2. Intake hose
3. Turbo lubricant pipe (IN) 3. Oil inlet
4. Generator 4. Coolant pump
5. Oil filter 5. Cooling fan
6. Turbo lubricant pipe(OUT) 6. Fuel injection pump
7. Oil dipstick 7. Feed pump
8. Starter motor 8. Crank-axis pulley

‫ٻ‬ ‫ٻ‬
G

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2. MAIN FUNCTIONALITY CHECKS AND REGULAR INSPECTIONS

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.

every every every 1000 hrs. 2000 hrs.

Category Item Inspection
50 hrs 250 hrs 500 hrs or 1 year Or 2 years

Check & add fuel ○

Fuel tank cleaning ○

Check fuel filter & coolant hose ○

Fuel Fuel filter de-oiler oil drain ○
related
Fuel filter (element) change ◎
Fuel injection Check & adjust
●
valve pressure
Fuel injection Injection timing
●
pump adjustment
Check engine oil amount ○
Lubricant ◎
Engine oil change ◎
related (initial)
◎
Oil filter change ◎
(initial)
4
Check coolant amount ○

Check radiator for blocking ○ ○

Coolant Coolant change ◎
related
○
Fan belt tension adjust ○
(initial)
Coolant tubing cleaning, inspection
●
& maintenance
Fuel & coolant pipe inspection &
○ ●
change
Air cleaner cleaning,
Intake ○ ◎
element change
related
Turbo charger blower cleaning ●
●
Bolt retightening (retight
Engine ening)
parts Valve gap adjustment ●

Intake valve wrapping ●

Electrical Warning lights inspection ○

devices Battery fluid check ○

※ ○: customer inspection/ ◎: part replacement /●: inspection at authorized shop

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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"& 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.

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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 After three or four days, insert the fuel
container for three or four days intake pipe to the middle of the container
undisturbed for sediments to collect (not to disturb sediments collected at
at the bottom. 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.

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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. 4
● Please use genuine V-belt parts. Change if damaged or old.

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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.
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.

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.
2.2.9. 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

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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 4
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.

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3. TROUBLE SHOOTING AND SOLUTION

Trouble Cause Solution

1) Charge or change if discharged.

2) Slowly heat if insufficiency caused
1) insufficient battery capacity
by cold weather, recharge or
change
2) Cut in a wire harness, or bad
connection in battery and switch Modify
terminals
1. trouble starting
(1) Starter is turned on but 3) Faulty spline engaged with pinion
Modify spline
no pinion of armature shaft

4) Bad magnetic switch plunger, or

Modify or change
cut or short coil

5) Starter switch malfunctioning Modify or change

Disassemble and clean, or change

6) Starter brush malfunctioning
broken parts

1) insufficient battery capacity Same as 1- 1)

2) Cut in the cable connecting the

4
battery with the magnetic switch,
or Connecting wire between the Modify
(2) Pinion is engaged magnetic switch and motor terminal
with a ring gear but starter is not tight enough.
is not turning 3) Bad fit between the pinion and
Modify or change pinion
ring gear

4) Faulty starter Modify or change

5) Battery code connection is not

Tighten more
tight enough.

1) Starter not installed properly. Reinstall

(3) Pinion turns without 2) incorrect plunger ＆ measurement

Adjust
engaging with the ring gear adjustment

3) Bad pinion sleeve spring Change

1) Over running clutch fault Change

(4) Pinion is engaged with the
ring gear and starter turns
but engine does not turn. 2) Internal fault of the engine Repair

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Trouble Cause Solution

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

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Trouble Cause Solution

9) Blocked fuel pipe system Modify
10) Air mixed in fuel Remove air
11) Water mixed in fuel Fuel change
3. Insufficient engine Place in a warm garage until it
12) Frozen or hard wax in fuel line
power is thawed or soft and remove air
Replace with new fuel
13) Faulty fuel injection pump
injection pump
14) Bad turbo charger Repair or replace
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

4. Engine overheat 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 4

1) Increased clearance due to worn metal Replace metal or grind
or crank shaft crank shaft
5. Engine noise
1) Crank shaft metal 2) Uneven wear in crank shaft Grind crank shaft or change

3) Scorched metal Change metal and grind crank

1) Worn crank pin metal Change metal

2) Abrasion in crank pin parts Change crank shaft

2) Connecting rod
3) Bent connecting rod Change
metal
4) Scorched crank pin metal Change metal and polish crank

5) Insufficient oil due to blocked path Clean oil path

1) Increased piston clearance due to

Change piston & piston ring
worn piston and piston ring

2) Worn piston pins Change

3) Piston, piston pin
& piston ring 3) Scorched piston Change

4) Worn or bad piston Change

5) Damaged piston ring Change

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Trouble Cause Solution

1) Worn crank shaft and thrust bearing Change thrust bearing

2) Excessive timing gear back lash Change timing gear

5. Engine noise 3) Excessive valve clearance Adjust valve clearance

4) others 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

Inspect and change pipes
1) Fuel leak if necessary. Retighten every
connections.
- Inspect if return line is twist-
ed or crushed. Replace dam-
aged parts.
2) Blocked return pipe or hose
- If line is blocked, use pres-
surized air to remove air.
6. Excessive fuel con-
sumption 3) Improper injection timing Modify

4) Compression pressure inspection Modify or change

5) Bad fuel injection valve
Modify or change
(injection or pressure)
6) Bad injection pump
Modify or change
(excessive injection)
7) Head gasket inspection Change
1) Excessive clearance between the
Change
cylinder and piston

7. Excessive oil 2) Worn piston ring and ring groove Change piston ring
consumption 3) Improper positioning of piston ring inlet Modify position
1) Oil up
4) Blocked air breather Wash

5) Excessive oil supply Modify

1) Loose valve stem and valve guide Change

2) Oil down 2) Bad cylinder head gasket Change gasket

3) Bad valve stem seal Change

1) Loose connections Tighten

3) Oil leak
2) Bad packing of parts Change packing
3) Bad oil seal Change oil seal

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Trouble Cause Solution

1) Improper oil quality Change to specified oil

2) Bad pressure control valve Change

8. Decrease in lubricant 3) Worn oil pump Change
pressure
4) Bad oil pipe Modify or change

5) Worn crank metal & crank pin metal Change metal

1) Incorrect injection timing Adjust

2) Incorrect injection pressure Adjust

3) Bad injection function Disassemble to modify

9. Engine knocking 4) Insufficient air intake Clean the air cleaner

5) Engine oil in combustion chamber

- Oil up Modify
- Oil down Modify
- Low oil viscosity Change to proper oil 4

6) Low engine temperature Operate in warm place

1) Late injection timing Adjust

2) Decreased compression pressure Modify

10. Excessive exhaust gas
3) Water mixed in the fuel Change
1) white exhaust gas

4) Not enough air intake Modify

5) Engine oil in the combustion chamber Modify

1) Late injection timing Adjust

2) Over loaded Adjust to proper load

3) Excessive injection rate Bad injection control spring

2) black exhaust gas
4) Irregular injection Adjust

5) Bad injection from fuel injection valve Modify or change

6) Insufficient air intake Clean the air cleaner

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4. ENGINE MAINTENANCE
4.1. ENGINE INSPECTION
4.1.1 Cylinder compression pressure inspection

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 4
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 Tu 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) Location of Exhaust
Piston NO. Intake valve
no. 1 piston valve
※CAUTION
a. The TDC mark “T”of the rear plate only NO.1 * *
applies to no. 1 cylinder. TDC NO.2 *
b. Measure the gaps two or three times for
better accuracy. NO.3 *
c. Order of the cylinder is 1, 2, and 3 referencing NO.1
to gear case shaft.
OverLap NO.2 *
(1) Adjusting bolt NO.13 *
(2) Fastening nut
Table 4.1.2_1
(3) Gap
Proper limit 0.15 ~ 0.20mm

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4.1.3 Top Clearance measurement

① Remove the cylinder head. But do not

remove the cylinder head gasket.
② Turn the crank shaft so that piston will be at
the top inside the cylinder.
③ Assemble the cylinder head. Comply with
required torque when assembling the head bolt.
④ Turn the crank shaft so as to pass the TDC
mark of the piston.
⑤ Measure the fuse thickness after
disassembling the cylinder head.
⑥ If measurement is out of range, measure
oil clearance of crank pin, crank pin bearing,
piston pin and Small end Bushing.

※CAUTION
a. Use a new cylinder head gasket when re-
measuring the Top Clearance.
(1) Fuse

allowance 0.55 ~ 0.75 mm

4.1.4 Oil pressure inspection

① Remove the oil pressure switch that is

mounted on the block and mount the oil
pressure gage.
② Measure the oil pressure when idling after
engine is warmed up and oil pressure is
nominal.
③ If the oil pressure is out of proper range or
outside of allowance, check whether the engine
is normal or not.
• Check if there is enough oil.
• Check the oil pump.
• Check for foreign objects within the oil intake pipe.
• Check for foreign objects within the oil filter.
Proper IDEL 1.5kgf/㎠
• Check for foreign objects within the oil gallery.
Engine oil pressure
• Check the Oil Clearance. RATED 2.0~3.5kgf/㎠
pressure
• Check if the Relief valve is normal. Allowance RATED 3.0kgf/㎠

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4.2. Engine disassembly

General caution
● Please select a clean place without dust or foreign objects.
● Pay attention not to have the disassembled parts contaminated or damaged. Prepare a storage container
for parts.
● Prepare cleaning agent and pressurized air for washing parts in advance.
● Please have appropriate tools to disassemble and assemble engine. Use them properly according to
degree of disassembly and location.
● If disassembly is very complex and there are numerous parts, mark them with identifications so assembly
process is easier.

4.2.1. Engine oil

① Open the drain bolt of the oil pan and

discharge the engine oil.

CAUTION :
② Please avoid touching the
hot oil.

WARNING :
③ Please comply with discarding
unusable oil according to legal 4
requirements.

4.2.2. Muffler, generator, cooling fan

① Disassemble the generator and fan belt. DRAIN PLUG

② Disassemble the cooling fan and fan pulley.
③ Disassemble the muffler.

※CAUTION
a. Check abnormality in disassembled muffler,
generator and cooling fan.
b. Check the status of fan belt.
c. If the fan belt is worn beyond the specification,
replace with a new belt.

(1) muffler (2) cooling fan (3) generator

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4.2.3. Turbo charger

① Disassemble the intake hose.
② Disassemble the turbo charger lubricant
supply pipe and discharge pipe.
③ Disassemble the turbo charger.

※CAUTION
a. Make sure there is no oil leak within the turbo.
b. Turn the fan with your hand to check for
damaged bearing or fan interference.
(1)Intake hose
(2)Lubricant supply pipe and discharge pipe
(3)Turbo charger assembly

4.2.4. Cylinder head cover

① Remove the head cover cap nut.
② Remove the head cover.

※CAUTION
a. Check for damage on the head cover and
abnormality of the breather valve.
b. Replace the head cover gasket if it is
excessively damaged.

4.2.5. Fuel supply line

① Remove the pipe clamp.
② Remove high pressure lines in order.

※CAUTION
a. Clean dust with air inside the fuel supply lines.
(1) pipe clamp (3) fuel supply line 2
(2) fuel supply line 1 (4) fuel supply line 3

4.2.6. injection nozzle & glow plug

① Disassemble the over flow pipe assembly.
② Disassemble the injection nozzle.
③ Disassemble the copper packing & nozzle
spacer.
④ Disassemble the glow plug assembly.

※ CAUTION
a. Use new packing and nozzle spacer.

(1) Over flow pipe assembly (4) Nozzle spacer

(2) Injection nozzle (5) Glow plug
(3) Copper packing

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4.2.7. Fuel injection pump & speed control panel

① Remove the fuel injection pump fastening bolt & nut.
② Remove the fuel injection pump.
③ Remove the speed control panel.

※ CAUTION
a. Be careful not to damage the starter spring and
speed control spring while removing the fuel injection
pump and speed control panel.
b. When assembling the injection pump, make sure
the control lock pin is place inside the thrust lever of
fork lever.
(1) Fuel injection pump (2) Adjusting shaft
(3) Speed control panel assembly (4) Gasket

4.2.8. Exhaust manifold

① Disassemble the exhaust manifold fastening bolt.
② Remove the exhaust manifold.

※ CAUTION
a. If a new exhaust manifold is used in reassembly,
make sure it is in a right place.
(1)Exhaust manifold
(2) Exhaust manifold gasket 4

4.2.9. Intake manifold

① Disassemble the intake manifold fastening bolt.
② Remove the intake manifold.

※ CAUTION
a. Make sure the intake manifold gasket is in the right
place.
(1)Intake manifold gasket
(2) Intake manifold

4.2.10. Rocker arm & push rod

① Disassemble the rocker arm fastening nut.
② Remove the rocker arm.
③ Disassemble the push rod.

※ CAUTION
a. Check the valve gap before disassembling the
rocker arm. Make sure the push rod assembly is in
good condition. (valve gap: 0.15 ~ 0.20)
b. Check if the push rod is deformed or not after the
disassembly.
(1) Lock arm assembly (2) Push rod
(3) Tappet (4) Valve gap

KUKJE RGO 60 4-25

RGO 60

4.2.11. Cylinder head

① Disassemble the cylinder head bolt in
descending order from 14 to 1.
② Remove the cylinder head.

※ CAUTION
a. Be careful not to damage the bottom and
block sides while disassembling the cylinder
head.
b. Use a new head gasket when reassembling.
c. Assemble the head bolts in the order from 1to 14.
d. Check the head bolt torque again after
operating for 30 minutes when assembled.
(1) Head bolt
(2) Cylinder head
(3) Gasket (Cylinder head)

4.2.12. Tappet
① Remove the tappet from the crank case.
② Mark on the tappet according to
disassembling order and piston position not to
have the order confused.

※ CAUTION
a. Make sure the bottom the tappet is worn
evenly in circular motion.
b. Pay attention not to confuse the order of
tappets while assembling and apply oil on the
surfaces that come in contact.

4.2.13. Valve
① Remove the valve cap.
② Push down the valve spring retainer with a
zig and remove the valve spring cotter.
③ Remove the valve spring retainer, valve
spring and valve stem seal, in that order.
④ Remove the valve.

※ CAUTION
a. Check the status of the stem seal before
removing the valve stem seal and check for oil
leak.
b. Replace the valve if necessary.
c. Make sure the order of valve is correct when
assembling.
(1) Valve spring puller (2) Valve cap
(3) Valve spring cotter (4) Valve spring retainer
(5) Valve spring (6) Valve stem seal
(7) Valve

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 Small Engine

4.2.14. V-pulley
① Remove the V-pulley bolt on the crank shaft.
② Remove the V-pulley.
③ Remove the parallel pin mounted on the
crank shaft.

※ CAUTION
a. Use the dedicated zig to remove the
V-pulley. Do not stand in front of the pulley
since it might pop out.

4.2.15. Cooler pump

① Disassemble the coolant returning hose, then
the coolant pump fastening bolt.
② Disassemble the coolant pump.

※ CAUTION
a. Do not reuse the coolant pump gasket.
(1) Coolant pump assembly
(2) Gasket

4.2.16. Gear case

① Disassemble the fuel tube connected to the
injection pump first, and remove the feed pump. 4
② Remove the gear cast fastening bolt, and
remove the gear case.

※ CAUTION
a. Pay attention not to damage the oil seal when
removing the gear case.
b. Replace four O rings on the rear side of the
gear case appropriately when reassembling.
c. Remove gasket remaining on the rear side of
gear case and cylinder block completely and
replace with a new gasket in reassembly.
d. Assemble the feed pump after the gear case
is assembled first to prevent damage to the feed
pump.
(1) Gear case (2) Gear case gasket
(3) Oil seal (4) Feed pump
(5) O -ring

※ Length of bolts (mm)

A. 45 E. 65
B. 50 F. 68
C. 55 G. 너트
D. 60

KUKJE RGO 60 4-27

RGO 60

4.2.17. Idle gear

① Disassemble the snap ring using the snap ring puller.
② Remove the idle gear collar.
③ Remove the idle gear.

※ CAUTION
a. While assembling the gear, check the steering angle
of cam shaft gear, crank shaft gear and fuel cam shaft
gear.
(1) Idle gear (2) Idle gear bush
(3) Snap ring

4.2.18. Cam shaft and fuel cam shaft

① Turn the cam shaft gear until the fastening bolt inside
is visible. Then disassemble the bolt.
② Remove the cam shaft.
③ Disassemble the fuel cam shaft stopper.
④ Remove the fuel cam shaft.
(1)Cam shaft (2)Fuel cam shaft
(3)Fuel cam shaft stopper

4.2.19. Fork lever

① Remove the starter spring.
② Remove the fork lever shaft cover.
③ Remove the fork lever shaft using the tool shown in
the diagram.

※ CAUTION
a. Reassemble in correct order.
b. Use a new gasket.
c. Assemble so that the mark “UP” on the lever shaft
cover is pointing upward.
(1)For lever A (2) For lever B
(3)Governor spring (4)Starter spring
(5) Fork lever shaft cover (6)Fork lever shaft

4.2.20. Governor
① Disassemble the snap ring with the snap ring
remover.
② Remove the governor in the direction of the arrow.

※ CAUTION
a. Be careful not to damage the ball bearing while
removing the governor.
(1) Snap ring (2) Governor shaft
(3) Ball bearing (4) Stop bolt

4.2.21. Oil pan and oil inlet

① Remove the oil pan fastening bolt.
② Tap the oil pan with a rubber mallet to remove.
③ Remove the oil inlet bolt.
④ Remove the oil inlet.

※ CAUTION
a. Use a new oil pan gasket when reassembling.
b. Make sure the magnet is located on the oil inlet.
(1)Oil pan (2)Oil inlet
(3)Oil pan gasket (4)magnet

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 Small Engine

4.2.22. Connecting rod and piston

① Remove the connecting rod cap.
② Tap with a rubber mallet to remove the piston
and connection rod.

※ CAUTION
a. Ba careful to align the mark and number on
the connecting rod when reassembling.(Figure
4.2.22_5)
b. Use the dedicated zig to assemble the piston
and check the position of the piston ring.
c. Direct the piston clover toward the nozzle.

KUKJE RGO 60 4-29

RGO 60

4.2.23. Piston and piston ring

① Remove the piston pin snap ring and piston
pin.
② Disassemble in order after removing the
piston.

※ CAUTION
a. Assemble the piston ring in the order of the
Oil Ring, Second Ring and Top.
b. Make sure the “Y” mark on the top side of
the piston ring is facing upward (Figure 4.2.23_2).
c. While assembling the Oil Ring, spring joint
and the oil gap should face opposite of each
other.
e. Assemble with piston gaps separated by 120°.
(Figure 4.2.23_4)
(1) TOP Ring (2) Second Ring
(3) Oil Ring (4) Piston snap ring +PJOU
(5) Piston (6) Connecting rod
(7) Piston pin 0SJOH
HBQ

Assemble so that the maker

engraving faces upward

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 Small Engine

4.2.24. Fly wheel

① Disassemble the fly wheel bolt.
② Remove the fly wheel.

※ CAUTION
a. While assembling the fly wheel, fly pin hole
should be aligned with crank shaft pin.

Pin hole Parallel pin

4.2.25. Main bearing case cover

① Remove the bearing case cover bolt.
② Remove the bearing case cover.

※ CAUTION
a. Be careful not to damage the oil seal when
removing the bearing case cover.
b. Use a new gasket when reassembling. Place
the gasket and bolt hole accurately.
c. Be careful there are two types of bear case
cover bolt: block fastening bolt and bearing
case fastening bolt.

(1) Main bearing case cover

(2) Gasket (bearing case cover) 4
(3) Gasket (bearing case)

4.2.26. Crank shaft & main bearing case

① Remove two main bearing case bolts.
② Remove the crank shaft.

※ CAUTION
a. Be careful not to damage the main bearing
case when removing the crank shaft.
b. Adjust the main bearing case location so that
the bolt holes of the cylinder block and bearing
case coincide when assembling.
(1) Main bearing case bolt_2

KUKJE RGO 60 4-31

RGO 60

4.2.27. Main bearing case

① Remove the bearing case bolt 1.
② Separate the bearing case top and bottom to
remove.

※ CAUTION
a. There are A, B and C types of bearing cases. Be
careful not to mix them up.
b. Make sure the engraved number on the bearing
case and “FLYWHEEL” marking are aligned when
assembling.
(1) Main bearing case A (2) Main bearing case B
(3) Main bearing case C (4) Thrust bearing
(5) Crank shaft metal (6) Mark
(7) Main bearing case bolt 1

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MEMO
RGO 60

4.3. MAJOR PARTS INSPECTION AND MAINTENANCE

4.3.1. CYLINDER HEAD

1) Cylinder head

(1) Before washing the cylinder head, check for

any leaks, damage or crack.
● Check the cracks on the combustion side of
the head using the color check.
(2) Inspect with hydrostatic test or magnetic
particle testing for any invisible cracks.
(3) If there is gas leak on the cylinder head
gasket, measure the flatness of the bottom side.
● Replace the cylinder head if it is misaligned
more than the allowance.

Allowance Over 0.15 mm

2) Intake & exhaust valve and valve guide

(1) Valve
● Measure the outer circumference of the valve
stem. Replace the valve if it is worn more than the
allowance.
Standardv Allowance
6.95 ~ 6.96 mm 6.9 mm

(2) Valve seat contact side

● Inspect the valve seat contact side and polish
or replace as needed.
(3) Measure the margin (or valve head thickness)
and replace if it is less than the allowance.

Standard Allowance
1.2 mm 0.5 mm

(4) Valve guide

● Measure the gap between the valve guide
and valve stem. Replace either or both if the
valve gap is more than the allowance.

Standard Allowance
7.015 ~ 7.000 mm 7.1 mm

● The valve guide and valve seat have to be

processed at the same time. (Assemble the valve
guide using a press.)
● Protrusion from the valve guide head: 9 mm

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 Small Engine

(5) Valve seat

● Measure the valve difference. If the indentation
if more than the allowance, change the valve.

Standard Allowance
0.05~0.15 mm 0.40 mm

● Valve seat modification

-> When modifying the valve seat, change the
valve guide if necessary.
-> Modify the seat width and angle according
to specification using a special tool or the valve
grinder.

Intake valve seat angle Exhaust valve seat angle

120° 90°

(6) Valve spring

● Make sure the check the valve spring
perpendicular angle, free field or deformation
when disassembling since it is a direct cause to
valve stem uneven wear or damage. 4
● C h a n g e i f i t d o e s n ot c o m p ly w i th th e
specifications.
Category Standard Allowance
Fee field(A) 37.25 mm -
Inclination(B) - 1.0 mm
Spring load 12.0 kgf/31.0 mm

4.3.2. CYLINDER BLOCK

1) Cylinder block inspection

(1) Crack inspection in each part

● Visually check damages by freezing or turn
over and perform the color check if damaged.
● Check cylinder head bolt and screw for
cracks.
● Change the cylinder block if the damage is
severe or modify for lesser damage.
● Perform a pressure test to check for cracks or
water leak.
● Apply adhesive on the exterior surface of the
plug when changing plug to prevent freezing.
(Three Bond 1194 of better products)

KUKJE RGO 60 4-35

RGO 60

(2) Cylinder inner circumference measurement

● Measure the cylinder inner circumference and
change if it is more than the allowance.
(mm)
Category Standard Allowance
cylinder inner 88.20
circumference 78.015 ~ 78.025
Cylinder 0.0 ~ 0.01 0.03
roundness
Cylindericity 0.015 0.03
● Measurement locations: within 20mm of upper
part (A), Middle (B) and lower (C) part of engine
front and thrust. (average value)
4.3.3. Valve device

Valve rocker arm is directly related to opening

and closing of the valve and the timing affects the
engine power and performance. Please maintain
it accurately.
1) Rocker arm
(1) Rocker arm shaft outer circumference & rocker
arm inner circumference
● Measure the shaft outer circumference and
rocker arm inner circumference and change if
they are more than the allowances.
(mm)
Category Standard Allowance
Shaft outer 11.973 ~ 11.984 0.10
circumference
Rocker
arm inner 12.000 ~ 12.018
circumference
clearance 0.020 ~ 0.070 0.14
(2) Tappet
● Measure the tappet outer circumference and
cylinder block tappet hole and change if they are
more than the allowances.
(mm)
Category Standard Allowance
Tappet outer 19.959 ~ 19.980 0.070
circumference
Guide inner
circumference 20.000 ~ 20.021
clearance 0.020 ~ 0.062 0.12
● Contact of cam shaft of the tappet: Replace if
wear or deformation is excessive.
(3) Push rod
● Measure the push rod place on a flat surface
and using a gap gauge and replace if it is bent
more than the allowance.

Allowance 0.25 mm

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 Small Engine

4.3.4. Piston and piston ring

1) 1) Piston inspection
(1) Piston outer circumference
● Measure each major parts and change if any
of them are more than the allowance.
● Change if there is any damage or scar on the
outer surface.
● Piston outer circumference

Category Standard Allowance

Piston outer 77.90 mm
circumference 77.953~77.972 mm
Minimum
gap to the 0.041 ~ 0.059 mm -
cylinder
(2) Piston ring
● Clean the ring groove when changing the
piston ring and assemble with the maker mark
facing toward top of the piston. Check if it is
moving smoothly.
● When assembling the piston ring, misalign
about120 degrees so that the cut is not placed on
the side pressure point.
● Measure each major parts and change if any 4
of them are more than the allowance.
● Measure the piston ring gap.
(mm)
Category Standard Allowance
No. 1 ring 0.15 ~ 0.30 1.5
No. 2 ring 0.30 ~ 0.50 1.5
Oil ring 0.20 ~ 0.40 1.5
● Measure the piston ring and ring groove gap.
(mm)
Category Standard Allowance
No. 1 ring 0.15 ~ 0.30 -
No. 2 ring 0.085 ~ 0.112 0.20
Oil ring 0.020 ~ 0.055 0.15
(3) Piston pin
● Measure the major parts and change if any of
them worn more than the allowance or unevenly
worn. (mm)
Category Standard Allowance
Piston pin outer
circumference
21.999 ~ 22.005 21.90
Pin bush
inner 22.002 ~ 22.007 22.02
circumference
Gap 0.003 ~ 0.008 0.10

KUKJE RGO 60 4-37

RGO 60

(4) Connecting rod

● Measure the twist and parallel of the large and
small section and change if they are more than
the allowances. twist
parallel
Category Standard Allowance
twist 100 mm
0.05 mm
parallel 0.03 mm

● Connecting rod large section inspection

(mm)
Category Standard Allowance
Large
section inner 43.0 ~ 43.016 -
circumference
Metal
1.487 ~ 1.500 -
thickness
Crank
pin outer 39.959 ~ 39.975 39.89
circumference
Oil gap 0.025 ~ 0.087 0.15

● Measure and change the pin bearing if it is

more that the allowance. Change the connecting
rod if needed.

2) Piston change
A. Keep it clean while assembling the piston ring
and connecting rod.
B. Make sure the piston is moving smoothly after
the piston ring is assembled.
C. Assemble the piston pin stopper ting on one
side of the piston.
D. Apply oil on the piston pin and assemble the
connecting rod.
E. Assemble the piston pin stopper ring.
F. When changing the piston, change the piston
pin.

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 Small Engine

4.3.5. Crank shaft

1) Crank shaft inspection

(1) Crank shaft journal inspection
● Change if there is crack or damage.
● Measure each major parts and change main
bearing if it is more than the allowance. Change
the crank shaft if necessary.
(mm)
Category Standard Allowance
Crank
journal outer 51.921 ~ 51.940 51.91
circumference
Metal
2.002 ~ 2.015 -
thickness
Oil gap 0.020 ~ 0.081 0.10

(2) Crank shaft bend inspection

● Measure the crank shaft bend. Dial gauge
Place both ends of crank shaft journal on V
block on top of a flat surface and turn the crank crank shaft
shaft to measure with a dial gauge. Change if the roundness

straightness of center of the crank shaft is more

straightness
than the allowance.
4
Bend standard 0.02 mm or less

(3) Crank shaft side clearance inspection

● Measure the crank shaft side clearance.
Install a magnetic base at the end of the crank
shaft and mount a dial gauge on top. Measure the
crank shaft-wise side clearance and change the
thrust bearing or crank shaft if the measurement
is more than the allowance.

Category Standard
Thrust gap 0.15 ~ 0.31 mm

KUKJE RGO 60 4-39

RGO 60

4.3.6. Cam shaft

1) Cam shaft inspection Dial gauge

(1) Cam shaft exterior inspection
● Check for wear between the tappet and cam
or for damage to cam gear.
(2) Can shaft bend measurement
● Measure the can shaft bend.
Place both ends of cam shaft journal on V block
on top of a flat surface and turn the cam shaft
to measure the cam journal shaking with a dial
gauge. One half of the journal shaking is the
bend.
V-block
Category Standard Allowance
Cam shaft
0.02 mm or less 0.05 mm
bend

(3) Cam shaft journal inspection

● Measure the cam shaft outer circumference
using a micrometer. Measure the cylinder block
can shaft inner circumference with a cylinder
gauge, then calculate the oil gap from the difference
with the cam shaft outer circumference.

Category Standard Standard

35.934 ~ fly wheel side
Cam shaft outer
35.89
Gear circumference 35.950 middle
gear side
side
Oil gap 0.050 ~ 0.091 -

Cam shaft outer 35.934 ~

circumference 35.89
35.950
middle
Oil gap 0.050 ~ 0.091 -

Cam shaft 34.934 ~

Fly outer 35.89
circumference 35.950
wheel
side Oil gap 0.050 ~ 0.091 -

Cam height
(4) Intake and exhaust cam height inspection

category Standard Allowance

Cam intake 28.80 28.75

height exhaust 29.00 28.95

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 Small Engine

4.3.7. Gear

1) Gear inspection
(1) Gear inspection
● Inspect the gear teeth and change if there is
damage or excessive wear.

(2) Gear back lash

Item Standard Note

Crank gear ~ idle gear 0.032~0.115

idle gear ~ injection pump gear 0.032~0.115

Back
idle gear ~ cam gear 0.032~0.115
lash
cam gear ~ compression
0.036~0.114
pump gear
Crank gear ~ oil pump gear 0.032~0.115

(3) Gear train

● When assembling the gear, make sure of the
contact mark.
- The contact marks can be confirmed by
cam shaft gear 4
number of points. fuel cam shaft gear

a. 1 point b. 2 points c. 3 points

idle gear

governor gear
crank shaft gear

KUKJE RGO 60 4-41

MEMO
 Small Engine

4.4. ENGINE OPERATION

4.4.1. Preparation before the operation

1) Add new engine oil in the oil tank.
2) Connect the cooling hose and add coolant.
3) Connect the fuel hose to the fuel tank.
4) Remove air from the fuel line.

4.4.2. Engine operation

Please pay attention to the following since the oil film on the unbroken new engine may be overloaded
due to over-speed which shortens the engine longevity.

First 50 hours
1) Drive within the range of 1200 ~ 1500rpm without any load until the engine temperature reaches
normal condition.
2) Avoid overloading or continuous over speeding.
3) Avoid over speeding without load.
4) Avoid sudden acceleration or braking.
5) Performa the inspections and tests.
4
4.4.3. To break the engine in
Please comply with the following while driving to break in the engine.
1) Check the engine oil level often. (Maintain the oil level between the maximum and the minimum.)
2) Check the oil pressure warning lamp.
If the lamp is on, check for insufficient oil or problem in lubricating system.
3) Make sure the coolant circulation is normal by observing the engine coolant gauge.

Change engine oil and oil filter at the end of the first 50 hours of driving.
(Use appropriate engine oil for local weather)

KUKJE RGO 60 4-43

RGO 60

5. MAJOR ENGINE PART MAINTENANCE

5.1. FUEL DEVICE
● The fuel system consists of the fuel tank, fuel supply feed pump, fuel filter, fuel injection pump,
fuel연injection valve and parts to connect all these devices.

(1). Fuel tank (5). Injection pump

(2). Fuel over flow pipe (6). Fuel feed pump
(3). Injection nozzle (7). Fuel filter
(4). Injection pipe

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 Small Engine

5.1.1. Fuel injection pump

● The fuel injection pump is a distributing type (VE) and mounted on the gear cover plate. It is
operated by the injection pump gear.
As a plunger rotates, fuel is distributed to each piston. Fuel is sent to the injection pump through the
fuel filter coming from the fuel tank by the external feed pump and built-in feed pump. Fuel with low
pressure is adjusted by the regulating valve when it enters the pump chamber. Fuel reaches the
high pressure chamber passing the barrel intake port through the injection pump head path from
the pump chamber. Pressurized fuel by the plunger is injected through the fuel injection valve in the
injection order. Any excessive fuel within the injection pump is returned to the fuel tank through the
overflow valve and fuel returning hose. Through such fuel circulation, the fuel injection pump is cooled
and lubricated. Any remaining fuel left in the fuel injection valve is returned to the fuel tank through
the overflow hose after collected in the injection pump. Any moisture in the fuel causes short pump
longevity, so please be careful and maintain the fuel system not to be contaminated with moisture or
dust.

Names of the fuel injection pump

(1) Fuel injection pump housing

(2) Control rod
(3) Pin
(4) Tappet
(5) Roller
(6) Plunger spring 4
(7)Control sleeve
(8) pion
(9) Plunger assembly
(10) Delivery assembly
(11) Delivery valve spring
(12) Delivery valve holder

● Specification
Item Specification Note
Fuel filter specification Cartridge filtering type
Type PFR
Injection sequence 1-2-3
Fuel injection pump
Governor type All Speed
Fuel blocking solenoid 12V / 8Ω
Nozzle type Semi-Throttle Type
Fuel injection valve
Holder type Screw insert type M20 X 1.5

KUKJE RGO 60 4-45

RGO 60

5.1.2. Fuel injection valve

● The injection type of the fuel injection valve is very important in the performance of the diesel engine.
Please adjust and maintain properly.

1) Nozzle injection check

Adjust the nozzle injection pressure to 140±5kg/㎠, mount it on the nozzle tester, operate the lever for
four to six times per second and check the injection. If there is abnormality, clean or change the nozzle.
(1) Check if the injection is normal.
(2) If not good, disassemble the fuel injection valve to change the nozzle tube or the assembly.
(3) Check for residual after the injection has stopped.
(4) If not good, disassemble the fuel injection valve to change the nozzle tube or the assembly.

Good No good

2) Nozzle inspection and adjustment: Initial injection pressure inspection and adjustment
(1) Mount the nozzle holder on the nozzle tester.
(2) Operate the nozzle tester handle once per second.
(3) Indicating needle of the pressure measure slowly rises and the needle may shake during the
injection. Read the needle indication at the moment the needle begins to shake and check if that initial
pressure is within the standard range.

Altered pressure 140 kg/cm2

Standard pressure
Adjusting pressure 145 ~ 155 kg/cm2 A1000, A1100(T)

Upper limit 140kg/cm2 이상

CAUTION : Avoid dust while disassembling the nozzle holder.

(4) If the initial injection pressure is not adjusted with a different thickness, change the assembly.

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 Small Engine

Nozzle holder body

Retaining nut

spring seat

space

nozzle

3) Nozzle oil-tightness inspection

(1) After injecting several times with the nozzle tester lever, wipe fuel off the injecting head and check if
there is any fuel leak from the nozzle tube while increasing the pressure from 20kg/㎠ to 130kg/㎠.
(2) If no good, disassemble the fuel injection valve and change the nozzle tube or the assembly.
4

4) Combustion chamber insulation packing

● Insulation inspection is necessary since the swirl type combustion chamber is equipped with
insulation packing on the nozzle valve to improve the nozzle durability.
● Clean the cylinder head fuel injection valve hole and use a new gasket.
(Replace used or damaged ones.)

KUKJE RGO 60 4-47

RGO 60

5) Nozzle holder
● Disassembly
(1) Lightly secure the retaining nut using a cushion bracket.
(2) Secure the retaining nut with a box wrench and disassemble the nozzle holder body with a deep socket wrench.

● Nozzle tip inspection

(1) Check if carbon is attached on the nozzle tip. If so, remove the carbon, clean the parts with cleaning
oil and soak in diesel. Be careful not to damage the needle valve nozzle tip.
(2) Soak the nozzle tip in diesel and check if the needle valve operates smoothly. Change it, if not.
Wash new nozzle tip in diesel before using it.

deep socket wrench

needle

nozzle tip

● Retaining nut assembly

(1) Tighten the nozzle holder body firmly with a hand.
(2) Lightly secure the retaining nut using a vice with a cushion plate.
(3) Secure the retaining nut with a box wrench and assemble the nozzle holder body with a deep socket
wrench to required torque.

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 Small Engine

5.2. LUBRICATING DEVICE

● Engine oil is pumped in through the oil suction pipe by the oil pump, moved through the oil filter and
supplied to each lubricating parts.

(1). Rocker arm (10). Relief valve

(2). Oil pressure switch (11). Push rod
(3). Rocker arm shaft (12). Tappet
(4). Valve (13). Cam shaft
(5). Governor shaft (14). Piston
(6). Idle gear (15). Connecting rod
(7). Crank shaft (16). Oil filter
(8). Oil pump
(9). Oil suction pipe

KUKJE RGO 60 4-49

RGO 60

1) Oil pump
● The oil pump is a trochoid type pump which is operated by the crank shaft gear. It is compact, has
less pressure fluctuation and delivers 3.5kg/㎠ of pressure to each parts.
● Check the oil amount if the lubricant pump output pressure is low. Inspect the lubricant pump in the
following ways if there is nothing wrong.

● Gap between the outer rotor and inner rotor

Measure the gap between the outer rotor and inner
rotor using a gap gauge.

division standard allowance

gap (mm) 0.07 0.15

● Gap between the pump and outer rotor, or inner rotor

Measure the gap between the outer rotor and pump
body using a gap gauge.

division standard allowance

gap (mm) 0.100 0.180

● Gap between the inner rotor shaft and oil pump cover
Measure the gap between the rotor and oil pump
cover.

division standard allowance

gap (mm) 0.030 0.0.085

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 Small Engine

2) Oil pressure switch

● Connect a tester between the terminal and
body to check the electricity. It is normal if there is
electricity. If not, change the switch.

● Lightly press in the oil hole with a thin stick. It is

normal to have no electricity. If there is, change the
switch.
thin stick

● It is normal to have no electricity with 0.5 kg/cm2

of air pressure in the oil hole.
Check if there is air leak. If there is, change the
switch since this indicates a damaged diaphragm.

KUKJE RGO 60 4-51

RGO 60

5.3. TURBO CHARGER

● The turbo charger is operated using the exhaust gas. It pressurizes the air intake to supply to the
combustion chamber so that engine power is increased.

(1) Actuator (5) Compressing wheel (9) snap ring (13) Thrust sleeve
(2) Turbine housing (6) turbine wheel (10) snap ring (TD025) (14) O-ring
(3) snap ring (7) piston ring (11) piston ring (15) thrust bearing
(4) Locking nut (8) bearing (12) oil diffracter (16) thrust ring

1) Turbo charger operation summary

a. Air intake comes in through the air cleaner.
b. Revolving pressure wheel pushed air into the
engine
c. Pressurized air is mixed with injector fuel to taken
into the combustion chamber.
d. Pressurized and charged gas mixture generates
more horse power in the combustion process.
e. Exhaust gas goes out to the exhaust manifold
through the turbine.
f. As the intake manifold pres sure reaches the
appropriate pressure, part of exhaust gas bypasses
through open valve of the west gate.
g. Turbine wheel is turned by the exhaust pressure
and high heat energy. The pressure wheel is also
turned.
h. Cold and expanded exhaust gas leave through the
exhaust system by the turbine housing.

4-52 KUKJE RGO 60

 Small Engine

2) Turbo charger oil schematic

(1). Lubricant moves into the turbo charger from the
cylinder block through the lubricant tubing.
(2). It lubricates within the turbo charger.
(3). It returns to the cylinder block through the return
tubing from the turbo charger.

a. This is the turbo charger lubricant inlet.

b. This is the pressurizer oil route.
c. It directly lubricates though the center housing
bearing.
d. There is a hole to aid in the bearing oil circulation.
e. This is pressurizer end bearing.
f. A piston ring seal is used at the end of the turbine
wheel shaft to prevent engine oil leak into the turbine
wheel housing. 4
g. Carbon seal is used at the end of the pressurizer
wheel shaf t to prevent engine oil leak into the
pressurizer wheel housing.
h. Oil drain from the turbo charger is done through the
return hole in the center housing.

KUKJE RGO 60 4-53

RGO 60

5.4. COOLING PROCESS

● This engine is water cooled. The coolant absorbs the combustion heat and engine oil heat and
dissipates to the outside for a normal engine operation.
The cooling system supplies coolant through the coolant pump and circulates the oil cooler to absorb
the oil heat through the cooling hose. Combustion heat is also absorbed while it goes through the
cylinder block coolant jacket and cylinder coolant tubing.
The coolant that absorbed oil heat and combustion heat moves to the thermostat. If the coolant is cooler
than the valve opening temperature, coolant recirculates to cylinder. If the coolant is hotter, then it flows
into the radiator. The radiator cools the coolant by dissipating heat and the coolant recirculates to the
coolant pump.

(1). Radiator (5). Cylinder head water jacket

(2). Cooling fan (6). Cylinder block water jacket
(3). Thermostat
(4). Coolant pump

4-54 KUKJE RGO 60

 Small Engine

1) Auxiliary tank (Coolant time extended)

pressurizing valve
vapor
negative pressure valve
When the coolant becomes hot from the engine
operation, it is cooled in the radiator by the
sucked in air. However, overload or long driving
will increase the water temperature and vapor maxi
mum
pressure within the radiator. If the vapor pressure
is more than 0.9kg/㎠, the pressure valve is
opened to discard the steam at which time the
coolant is consumed.
the
lowest
The auxiliary tank prevents the consumption of limit

coolant by collecting the vapor in it to liquefy.

If engine is not running or there is no load,
radiator pressure becomes negative so coolant
in the tank is sucked into the radiator. This is the
reason for long driving without adding coolant.

When inspecting the coolant amount, there is

to auxiliary tank
no need to remove the radiator cap. Just check
the level of the auxiliary tank, which eliminates a
danger of burn from the hot steam.

vapor into the 4

auxiliary tank

to
auxiliary
tank

2) Cooling pump inspection

● Inspect the coolant pump and the followings. If abnormal, change the coolant pump with assembly.
1) Coolant leak (check if there is leak from the pump body while driving)
2) Coolant pump bodily damage or crack
3) Impeller damage or crack
4) Bearing damage (Turn the pump shaft lightly to check if it turns smoothly without wobbling.)

KUKJE RGO 60 4-55

RGO 60

3) Coolant temperature sensor inspection

● Leave the sensor in water and add heat slowly to measure the resistance. (Resistance between the
terminal and body)
temperature (℃) 80 115

resistance (Ω) 118 42

4) Glow plug control sensor inspection

● Measure the sensor resistance. (Resistance between the terminal and body)

temperature (℃) -15 20

resistance (Ω) 9.6 2.4

5) Over heat warning sensor inspection

● Heat engine oil and check if sensor is turned on when the engine oil reached certain temperature.

ON OFF

110 ± 2℃ 100℃ 이상

6) 써모스탯
● Thermostat maintains the coolant temperature
at proper level and prevent heat loss to improve water
the engine heat effectiveness. thermometer

● Check the valve opening temperature while

heating the thermostat in water.

Valve opening 72 ± 2℃ (starts to open)

temperature 85 ± 2℃ (completely open)

● valve deploy lift: 8mm or more

7) Over Heat
● If engine is stopped when it is over heated, coolant circulation also stops which may temporarily
increase the over heat. If engine is cooled in short time, block could develop cracks. Do not panic. Let
the engine operate in low revolution to cool the coolant naturally.

4-56 KUKJE RGO 60

 Small Engine

5.5. ELECTRICAL SYSTEM

5.5.1. Starter
● Circuit diagram

● Specification 4

item detail note

output 12V / 2.2kW
Number of pinion
15
teeth
Electricity without
12.5V
load

● Inspection
1) Pull in coil test of the magnetic switch (solenoid)
The pull-in coil is normal if plunger is sucked in and
pinion pops out with the battery in contact between
battery
the magnetic switch S-M terminals. If not, change 12V
the magnetic switch.
connector separated
starter motor
CAUTION
- While the inspection, remove the M terminal from the connector.
- Do not leave in contact more than 10 seconds.

KUKJE RGO 60 4-57

RGO 60

2) Holding coil of the magnetic switch test

Manually pull the pinion to the stopper location
while the battery is in contact between the magnetic
switch S terminal and body. The hold in winding is battery
12V
normal, if it returns when let go.

connector separated starter motor

CAUTION
Do not leave in contact more than 10 seconds.

3) magnetic switch return test

Manually pull the pinion to the stopper location
while the battery is in contact between the magnetic
switch M terminal and body. Both coil are normal if battery
they return when let go. 12V

CAUTION connector separated starter motor

Do not leave in contact more than 10 seconds.

4) No loading test
1. As shown in diagram, connect the starter motor,
variable resistance
battery, voltmeter, ammeter and variable resistance.
2. The starter motor is normal, if it turns smoothly ammeter

with maximum resistance and switch ON. Adjust the

voltmeter to be 11.5V. If voltage and revolution are
starter motor battery
not within the standard values, estimate the cause voltmeter
12V
according to the following table and repair.

Trouble Cause
- metal stained, oil polluted
High voltage, fast turning
- worn armature core pole piece
(torque is not that strong.)
- armature coil short
- Electronic switch grounding
High voltage, no turning - armature coil, field coil grounding
- Scorched metal
- armature coil, field coil short
- Brush and pig tail short
No voltage, no turning
- commutator soiled, bad contact between brush and commutator due
to Biotite (Highmica)
Weak voltage, slow turning - bad contact of field coil ( shunt coil short or bad contact cause fast
(torque is not that strong.) turning.)
High voltage, fast turning - Field coil short
(torque is not that strong)

4-58 KUKJE RGO 60

 Small Engine

● Starter parts cleaning

1) Do not soak parts in solvent. When yoke, field coil assembly or commutator is soaked in solvent, their
insulation will be damaged. When these parts are dirty, wipe then with cloth.
2) Do not soak the driver unit in detergent since washing in detergent will clean out the clutch oil of the
over running clutch which is oiled at the manufacturer.
3) Clean the driver unit with a brush wet with cleaning liquid and dry with cloth.
● Commutator inspection
1) Place the commutator on a set of V block and
check the roundness with a dial gauge.

standard 0 ~ 0.03 mm

allowance 0.1 mm

2) Check the undercut depth between segments.

standard 0.5 mm

allowance 0.2 mm Undercut

segment

3) Field coil conductivity test

This is to test conductivity between the field
brushes. It is normal if it is not conductive.

yoke

4) File coil grounding test

This is to test conductivity between the field coil
brush and yoke. It is normal if it is not conductive. field brush

yoke

KUKJE RGO 60 4-59

RGO 60

5) Brush holder
This is to test conductivity between the brush holder
and plate holder. It is normal if it is not conductive. brush holder

6) Over running clutch

1. Check if the pinion is locked when turned to left
and turns smoothly when turned to right.
2. Inspect wear and damage to pinion.

● Brush inspection
1. Check roughness of commutator and brush
length.

standard Wear allowance

2. Modify the commutator contact surface with wear

sandpaper when the contact surface is modified or allowance
brush is changed.
3. Be careful not to damage the pig tail when
remaining brush is removed with a flyer.
4. Polish the pig tail with a sandpaper to induce
better soldering. new brush
5. Solder a pigtail in the new brush hole. Make sure pig tail Solder (Make
sure there is no
there is no lead left on the brush. lead left on the
brush.)

mark
2) Commutator coil short test
1. Install the commutator on the growler. Growler
2. Place a thin plate parallel to the commutator. Turn
the commutator slowly. It is normal if the plate is not
sucked in or vibrates.

CAUTION
Remove all attachment on the commutator and test again

4-60 KUKJE RGO 60

 Small Engine

3) Commutator coil grounding test Growler

Check bet ween the commutator segment
and armature coil cores. It is normal if it is not
conductive.

4) Armature coil short

Check the conductivity between each segment. It is
normal if it is conductive.

KUKJE RGO 60 4-61

RGO 60

5.5.2. Generator (alternator)

● Basic circuit diagram

● Specification

Item detail Remarks

Type AC generating rectifier-type
Output 12V / 50A
Motor speed 1,000~18,000 rpm
Regulator setting voltage 14.7 ± 0.3V
Temperature compensation -7 ± 3mV/℃

● Inspection

1) Generator output measurement while the engine

is running
(1) Connect the positive (+) terminal of the voltmeter
to the output (B+) terminal of the generator and
ground the negative (-) terminal of the voltmeter.

(2) The measurement should be between 13.4 and

15.7 V while the engine is running in 1500ERPM
with all the devices turned on.

(3) If the measurement is not obtainable or the

voltage is not regular, check for output circuit
damage, loose or dirty.

(4) If above condition persists, check for the brush

or slip ring wear, foreign objects or damage.

(5) If the brush and slip ring are normal, the failure
is due to internal damage to the generator.

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 Small Engine

2) Lamp circuit test while the engine is on

(1) Connect the positive (+) terminal of the voltmeter
to the lamp line and ground the negative (-) terminal
of the voltmeter.

(2) If the lamp is not on or there is no output while

the engine is running, then lamp line or lamp may
be short.

(3) If the output is very weak, then regulator circuit

or rotating magnetic field coil may be short.

3) Lamp circuit test while the engine is running

(1) Connect the positive (+) terminal of the voltmeter
to the lamp line and ground the negative (-) terminal
of the voltmeter.

(2) If the lamp is not on or there is no output,

then regulator circuit, rotating magnetic field coil or
commutator diode may be short.

(3) Remove the cover, connect the positive (+)

terminal of the voltmeter to F(+) terminal of brush
and regulator assembly and ground the negative
(-) terminal of the voltmeter to the generator. If there 4
is no measurement from the battery, then there is a
problem with regulator or commutator. The regulator
or commutator has to be replaced.

4) Starter circuit test while the engine is on

(1) Unplug the ignition plug from the voltage
regulator.

(2) Connect the positive (+) terminal of the voltmeter

to the ignition line of the ignition wiring harness and
ground the negative (-) terminal of the voltmeter.

(3) T here should b e a measurement on the

voltmeter. If not, check whether the ignition circuit is
dirty or damaged.

KUKJE RGO 60 4-63

RGO 60

5) Rotor
1. This is a rotor coil conductivity test to check the
conductivity between the slip rings. Measure the
resistance of the rotor. If the resistance is very low,
that means it is shorted. If there is no conductivity
or a short, replace the rotor assembly.

standard Approx. 27.5Ω / 20℃

2. Check the rotor coil grounding. Check for

conductivity between the slip ring and grounding. If
there is, replace the rotor assembly.

6) Stator
1. Test the stator conductivity. Check for the
conductivity between the coil and lead. If not,
replace the stator assembly.

2. Check for the coil grounding. Check for the

conductivity between the coil and core. If not,
replace the stator assembly.

4-64 KUKJE RGO 60

 Small Engine

● Disassembled diagram and parts

1. nut 8. rotor assembly 14. separating plate

2. pulley 9. stator assembly 15, 16, 19. insulation
3, 6. spacer 10. bearing (rear) 17. brush, adjustor combination
4. moving frame 11. gap ring 18, 20, 21. screws
5. bearing (front) 12. rotating frame 22. brush fastening rubber
7. fan (front) 13. bolt (4EA) 23. cover

KUKJE RGO 60 4-65

RGO 60

● Regulating voltage inspection of the IC regulator (with no load)

1) Specialty wiring connector, voltmeter and ammeter are set as shown in diagram below.

Load
Ignition
switch Altenator

Red

Voltmeter Yellow Ammeter

Battery

2) Inspect in the order shown in the table below.

determination
order Inspection item operation cause treatment
normal failure
Ignition switch : Voltage gen- Modify wiring
0V Bad wiring or
OFF erated or repair the
Voltage between alternator
1 L terminal and 0V alternator
grounding Ignition switch: ON 2~5V
Battery voltage Bad ALTR Repair ALTR

Ignition switch: Modify wiring

Voltage between OFF Battery Wiring or fus- or replace
2 S terminal and 0V
voltage ible ling short link
grounding Ignition switch: ON

Over the
IC regulator Repair the
standard in
fault alternator
excess
Voltage between Turn the engine 14.4±0.5 Use fully
In case of more
3 S terminal and on and maintain V charged bat-
than 5A output
grounding 2000~3000rpm. (at 20℃) Less than the tery .
standard Bad alternator
Repair alter-
if less than 5A
nator
output

4-66 KUKJE RGO 60

 Small Engine

5.5.3. ELECTRICAL WIRING

5.5.3.1. Electrical wiring diagram
● The following electrical wiring is a representative example.

KUKJE RGO 60 4-67

RGO 60

5.4.3.2. Electrical wiring connector

Fuel cut wiring

Korea Union Machine

Fuel stopping solenoid

Starter wiring Controller wiring

Engine control unit

starter

Generator wiring

generator

4-68 KUKJE RGO 60

 Small Engine

5.5.3.3. Electrical wiring

1) Generator (alternator)

● Do not connect the battery in opposite terminals.

If plus and minus terminals of battery cable are connected in reverse, generator diode may be damaged
and the battery will not be charged. The stator coil will also be damaged. To prevent the reverse
connection, adjust the battery cable length or there should be solution to prevent it from the manufacturer.

● Do not use the charging output voltage for the purpose of control since the engine revolution and the
output voltage do not proportionally related to each other.

● Lamp control
After fully charged and charging lamp is off, the lamp will not come on since the engine revolution is
decreased. If the charging circuit is normal, the lamp will not be turned on again. If the lamp comes on,
check for damaged V-belt.

● Use only specified V-belt.

● Do not use pressurized washer to clean.

Any moisture in the brush due to high pressure will cause insufficient charge.

2) Starter (starting motor)

● Use specified battery. 4

Engine starting up depends mainly on the battery. The battery performance is influenced by
temperature and its operational period. Therefore, use only battery required for the conditions.

● Battery cable (+,-) line resistance should be less than 2/1000Ω.

If excessive, it may cause lost function or failure of the starter motor.

● If the starter motor circuit line resistance is in excess of the specification

Round trip line resistance between the starter motor and Key switch (or power relay, safety relay:
when used) should be less than 5/100Ω.

● If there is no Safety relay

Main reason of the starter motor failure is overrun time (energized too long). Overrun causes armature
coil burn out or clutch failure. Please be careful.

● Do not use pressurized washer to clean.

Do not leave the starter motor in water and use a pressurized washer to clean since the starter motor
is waterproofed for only general rain or water.

3) Current limiter

● Do not used over-discharged (8V or less) battery. If used, other electronic devices may be damaged
by its high voltage ability. Do not recharge the over-discharged battery to use.

● Do not remove the battery while driving. It may cause a current limiter failure depending on the
electronic devices which causes control failure. It might generate high voltage to damage other electronic
devices.

KUKJE RGO 60 4-69

MEMO
 Small Engine

6. MAINTENANCE STANDARD TABLE

6.1. MAIN PARTS TIGHTENING TORQUE
Width of hexagonal Clamping torque
Item Size Remarks
side(mm) (kgf・m)
M10×
Cylinder head bolt 14 6.75±0.25
1.25
Connecting rod bolt M8×1.0 13 4.5±0.2
M10×
Fly wheel mounting bolt 14 6.75±0.25
1.25
Metal cap mounting bolt M8×1.25 12 3.25±0.25
Crank shaft V-pulley
M22×1.5 32 17.5±0.5
mounting bolt
M10×
Glow plug 12 1.75±0.25
1.25
Fuel injection valve M20×1.5 22 7.5±0.5

6.2. GENERAL BOLT TIGHTENING TORQUE TABLE

(unit: kgf•m)
4T 7T 9T
dimension
Division Subdivision Division Subdivision Division Subdivision
M5 40±5 60±10 90±10
M6 60±10 130±10 135±10
M8 150±20 270±30 330±20 4
M 10 300±50 240±40 530±70 420±60 690±30 550±30
M 12 530±70 420±60 900±100 720±80 1130±70 900±60
M 14 780±70 620±60 1350±150 1080±120 1850±150 1480±120
M 16 1250±150 1000±120 1900±200 1520±160 2580±220 2060±220
M 18 1750±150 1400±120 2650±250 2120±200 3800±300 3040±240
M 20 2450±250 1960±200 3700±400 2960±320 5400±400 4320±320

dimension 1/8 1/4 3/8 1/2 3/4

PT plug aluminum 150±20 200±30 250±30 350±50 460±50
Casting type 200±20 250±30 360±30 560±50 770±50

M8 M 12 M 14 M 16
Hollow bolt
150±20 300±50 450±50 550±50

KUKJE RGO 60 4-71

RGO 60

6.3. ENGINE ASSEMBLY TOLERANCE

6.3.1. Cylinder head

Model A1000, A1100, A1100T Remarks

Item standard allowance

Cylinder head combustion surface bent 0.03 or less 0.15

Intake 120° -
Belt seat angle
Exhaust 90° -
Intake 1.6±0.1 2.23
Belt seat width
Exhaust 1.6±0.1 2.62

valve stem outer cir- φ7 -0.040

φ6.9
cumference -0.050

Intake valve valve guide inner cir- φ7 +0.015

φ7.1
cumference 0

Oil clearance 0.055 ~ 0.065 0.15

valve stem outer cir- φ7 -0.040

φ6.9
cumference -0.040

Exhaust valve valve guide inner cir- φ7 +0.015

φ7.1
cumference 0

Oil clearance 0.040 ~ 0.055 0.15

valve guide protrusion (from head surface) 13 -

valve depression Intake valve 0.4±0.1

0.7
depth Exhaust valve 0.4±0.1
Intake valve 1.9±0.15
valve head thickness 0.5
Exhaust valve 1.9±0.15
Open b. TDC 14°
intake valve timing
Close a. BDC 34°
-
Open b. BDC 58°
Exhaust valve timing
Close a. TDC 14°
Free field 37.25 -
valve spring inclination - 1.0
load(1mm pressure) 1.902 -
Intake ・ Exhaust valve gap ■0.15 ~ 0.05 - -

4-72 KUKJE RGO 60

 Small Engine

6.3.2 Cylinder block

Model A1000 A1100, A1100T

note
Item standard allowance standard allowance
Cylinder φ74 +0.020 φ78 +0.025 20mm below
L
block inner +0.015 +0.015 from the head
- -
circumfer- φ84 +0.015 φ78 +0.015 assembly within
S
ence 0 0 the cylinder
Cylinder block inner cir-
0 ~ 0.015 0 ~ 0.015 -
cumference roundness

6.3.3 Valve rocker arm

Model A1000, A1100, A1100T Note

Item Standard Allowance
Rocker arm shaft
φ13 -0.020
Intake and exhaust rocker arm outer circumfer- -0.045
φ12.95
Rocker arm inner circumfer- ence
ence φ13 +0.025
φ13.09
Oil clearance 0
0.020 ~ 0.070 0.14
Push rod bend 0.25 or less - - 4
φ20f7 -0.020
Tappet stem outer circumference φ14.18
-0.041
Tappet Tappet guide hole inner circumfer- φ20f7 +0.020
φ14.30
ence 0
Oil clearance 0.020 ~ 0.062 0.12

6.3.4 Piston

Model A1000 A1100, A1100T note

Item Standard Allowance Standard Allowance

Piston outer cir- φ73.966±

A φ73.9 φ77.966±0.009 φ77.90
cumference 0.009

Minimum gap between piston and

0.041 ~ 0.059 - 0.041 ~ 0.059 -
cylinder block
Top clearance ■0.66±0.15 - ■0.66±0.15 -
piston pin outer φ22 +0.005 φ22 +0.005
φ21.90 φ21.90
circumference -0.001 -0.001
Piston and piston pin hole in- φ22 +0.007 φ22 +0.007
φ22.02 φ22.02
piston pin ner circumference +0.002 +0.002
0.003 ~
Oil clearance 0.10 0.003 ~ 0.008 0.10
0.008

KUKJE RGO 60 4-73

RGO 60

6.3.5 Piston ring

Model A1000, A1100, A1100T note

Item standard allowance
Ring groove width 1.896±0.01 -
1.803 0
Ring width -
-0.024
Top ring
Gap between ring
0.15 ~ 0.30 -
and ring groove
End gap 0.15 ~ 0.30 1.5
1.5 +0.09
Ring groove width -
+0.07
1.5 -0.09
Ring width -
2nd ring -0.03
Gap between ring
0.080 ~ 0.120 -
and ring groove
End gap 0.30 ~ 0.50 1.5
3.0 +0.03
Ring groove width -
+0.01
3.0 -0.01
Ring width -
Oil ring -0.03
Gap between ring
0.020 ~ 0.060 -
and ring groove
End gap 0.20 ~ 0.40 1.5

6.3.6 Connecting rod

Model A1000, A1100, A1100T note

Item standard allowance
Crank pin inner φ43 0
-
circumference +0.016
Crank pin metal
1.487 ~ 1.500 -
Crank pin part thickness
Crank pin outer φ39.9 +0.059
φ39.89
circumference +0.075
Oil clearance 0.025 ~ 0.087 0.15
Piston pin bush
φ22 +0.005
inner circumfer- φ22.10
+0.001
ence
Piston pin part
Piston pin outer φ22 +0.040
φ21.90
circumference +0.025
Oil clearance 0.014 ~ 0.038 0.2
Large & small end parallelism
φ0.03/100mm or less φ0.05
(twisting)

4-74 KUKJE RGO 60

 Small Engine

6.3.7 Cam axis

Model A1000, A1100, A1100T note

Item standard allowance
Cam shaft journal
φ36 -0.050
outer circumfer- φ35.89
Gear side -0.066
ence
Oil clearance 0.050 ~ 0.091 -
Cam shaft journal
φ36 -0.050
outer circumfer- φ35.89
middle -0.066
ence
Oil clearance 0.050 ~ 0.091 -
Cam shaft journal
φ36 -0.050
outer circumfer- φ35.89
Fly wheel side -0.066
ence
Oil clearance 0.050 ~ 0.091 -

6.3.8 Cranking axis

Model A1000, A1100, A1100T note

Item standard allowance

Crank journal outer φ52 -0.060 4

φ51.91
circumference -0.079

Crank journal Bearing metal 2.0 +0.015

-
thickness +0.002

Oil clearance 0.020 ~ 0.081 0.10

Degree of bend 0.02 or less - -

KUKJE RGO 60 4-75

RGO 60

6.4 SPECIAL TOOLS

Tool Tool specification (unit: mm) diagram

Stem seal pressurizing zig

Flywheel oil seal

pressurizing zig

Gear case oil seal pressurizing

zig

Plate-type plug pressurizing

zig

Governor axis gear pressurizing

zig

4-76 KUKJE RGO 60

 Small Engine

ToolTool Tool specification (unit: mm) diagram

Available in regular retail market

Piston assembling zig (applicable to φ60 ~ φ125)

Piston ring assembling zig Available in regular retail market

Oil filter wrench Available in regular retail market

KUKJE RGO 60 4-77

MEMO