KM376 SERVICE MANUAL

WUXI KIPOR POWER CO.,LTD.

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 Pre-maintenance Attention

For successful and effective maintenance, please carry out preparations prior to maintenance as

following:

1. Enquire your user

（1） When your engine was maintained last time

（2） What about your engine was maintained last time

2. Storage of spare parts

（1） Keep appropriate quantity of spare parts and materials required for engine

maintenance in stock;

（2） Keep one complete catalogue of spare parts in hand

3. Keep one accurate maintenance record (work book, note and etc.)

（1） Work Sheet

（2） Check record including record for repair parts

（3） Measurement of spare parts

Condition of performance and quality
（4） Handling

4. Required apparatuses

（1） Tool

（2） Measure and instrument

（3） Others

5. Safety precaution

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 Content
Thank you for purchasing KIPOR KM376 series diesel engine. It is extremely important to
operate and maintain unit appropriately for long-term good running conditions, reliable operation
and best economic benefits. This manual describes in details correct operation and
maintenance, main technical specification and parameters and troubleshooting for KM376 unit.

Product introduction
1. Brief information
2. Designation and code meaning
3. Installation drawing and names of certain parts
4. Main specification and parameters
5. Adjustment of main parameters
6. Torque requirement for important bolts and nuts
Technical maintenance
1. Routine check
2. Scheduled check
3. Technical maintenance after 1000H
Removal &assembly
1. Basic removal procedure
2. Re-assembly procedure
3. Cylinder cover assy.
Check &maintenance
1. Cylinder cover
2. Piston connecting rod
3. Crankshaft and staff
4. Cylinder body
5. Check of camshaft
6. Check of lubricant pump component
7. Timing belt, tension pulley of timing belt and timing pulley
8. Sprayer
9. Check spray timing
10. Adjustment of engine-related parameters
Problem and remedy
Trial start-up

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1. Product introduction

1. General information
This series are single, straight, four-stroke, water-cooling, turbine combustion chamber and three-
cylinder diesel engines.
Units in the type of waste-gas turbine charge and charge inter-cooling are available from us.
Unit boasts several characteristics, such as simple structure, easy removal, small size, short axial
length, light weight, good performance, reliable and stable quality as well as long life. Therefore it
can meet requirements of various customers. It is the ideal power equipment for generator set,
construction machinery, logistic machinery, ship machine, combine harvester and agriculture
machinery. You can choose it for almost all applications.

2. Designation and code meaning

K M 3 76 Z

No－universal, natural suction

Structure code Z－Charge type

Cylinder diameter (mm)

Cylinder qty.
Code of diesel engine
Code of company

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3．Installation and name of certain parts
Refer to fig.1 and fig.2 for details.

Evenly distributed

Fig.1 KD376 Outlook and Spare Parts

Thru-
hole

P direction

P direction

Centerline of crankshaft

3-M10×1.25-6HDepth 16 Depth 22

Engine bottom

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 KD376 Outlook and spare Parts
Fig.2
Rear and surface of machine body

3-M10×1.25-6H Depth16 Depth 22

Engine bottom Q direction
Centerline of crankshaft

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4. Main specification and parameters
Table 1 Main Specification

Model
No. KM376G KM376AG
Item
Straight, water-cooling, four-stroke,
1 Type
natural suction
2 Type of combustion chamber Turbine
3 Cylinder diameter X stroke 76×73 76×77
4 Cylinder qty. 3
5 Total output of piston（L） 0.993 1.048

6 Ignition sequence（free end first） 1-2-3

7 Compression ratio 21.5

1500 7.7 8.1

Rated rotation
speed (r/min) and 1800 9.2 9.6
8
continuous rated 3000 13.5 15.5
power（kW） 15.5 17.3
3600
18.2kW/3000rpm 19.5kW/3000rpm
9 15 min Max. rotation speed（kW）
20.6kW/3600rpm 23.0kW/3600rpm
10 Max. torque / rotation speed N. m/（r/min） 49/2200 55/2200
Min. fuel consumption of outside
11 300
characteristic（g/ kW.h）
12 Idle speed（r/min） 950±50
Speed For generator set（%） ≤5%
13 regulation
Universal ≤8%
ratio（%）
Percentage of lubricant consumption to
14 ≤0.8%
fuel consumption at full-load and speed
15 Exhaust smoke FSN 4.4
16 Rotation direction (view against flywheel) Anti-clockwise
17 Start type 12VAC start
18 Lubrication Pressure and spray
19 Dimension（L×W×H）（㎜ ） 594×451×623
20 Net weight（㎏） ≤110

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 Table2 Specification and Parameters of Important Parts

Specification & Specification &

Item Item
parameters parameters
Type VE dispensing Silicon rectification
pump Type
excitation generator
Injection Model VE3/9F2500LND Generator Voltage 14V
pump Plunger Dia. 9㎜ Rated 40A（45A at cold
Speed current area）
Mechanical global
regulator Type Series AC motor
S series, (P series)
Model Starter Voltage 12V
thread splice
Dual-action Power 1.4KW
Sprayer Nozzle type throttling pintaux Working
Initial injection 11V
13.5-14.5MPa voltage
pressure
Glow plug Cycle time 7-8sec
Operating
2500r/min Working
rotation speed >750℃
Lubrican Operating temperature
t pump pressure 249KPa Economizer Mineral wax
Flowrate 20L/min Paper filter
(with oil/water
Type Centrifugal Diesel filter
separator and
Cooling
portable pump)
water Rotation speed 5000r/min
pump Lubricant filter Rotary-mounted
Flowrafe 55L/min

5. Adjustment of main parameters

Table3 Adjustment of Main Parameters
Name
Item Correct value Limit value

Compression clearance of
0.85－1.05 ㎜
cylinder
Supply timing Oil pump plunger distance when piston is at upper
compression limit 0.97±0.03 ㎜ or 0.86±0.03 ㎜
Injection pressure (2 types) 13.23～13.73MPa(Green), 13.74～14.22 MPa（Pink）
Open 16°± 5°before upper limit, close 40°± 5°
Inlet valve
Port after lower limit
timing Open 52°±5°before lower limit, close 14°±5°°
Outlet valve
after upper limit
Valve clearance （ at cold Inlet: 0.20-0.25 ㎜, outlet: 0.3-0.35 ㎜
state）
Width of valve seal ring Inlet& outlet valve: 1.2-1.6 ㎜
Valve sinkage Inlet valve: 0.9-1 ㎜, outlet valve: 0.8-0.9 ㎜
Belt tension Compress 6-7 ㎜ with 10kg force ( 5-6 ㎜ for new belt)
Lubricant pressure 0.4-0.6 Mpa, Idle speed ≥0.15MPa
Lubricant temperature 80℃-115℃
Water drainage ≤98℃
temperature
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 Exhaust temperature ≤700℃ (≤520℃ for KM376G generator)

6. Torque of important bolts and nuts

Table 4 Torque of Important Bolts and Nuts

Item
Thread spec. Torque（N.m） Bolt qty.
Name
Bolt on cylinder cover M12×1.25 90+10 8
Bolt on camshaft bearing M8 16±1 8
Bolt on main bearing M10×1.25 60±5 8
Bolt on oil sump M6 5.5±1.5 20
Bolt on connecting rod M9×1.0 47±5 6
Bolt on flywheel M10×1.25 55±5 6
Thread of sprayer body M20×1.25 60±10 3
Thread of glow plug M10×1.25 12±2 3
Other common bolts and nuts
M6 7.5±1.5
M8 18.5±3.5
M10×1.25 37.5±7.5
M12×1.25 60±10

2. Technical Maintenance

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1. Routine check
（1）Check if actual lubricant level in the oil sump is between upper limit and lower limit on the
lubricant staff gauge and more near to upper limit. If the engine is new or stored for long term, run
the engine at low speed for 5-10min then stop after lubricant is filled up to upper limit. Later re-
measure the level with lubricant gauge.
（2）Check the water in the radiator.
（3）Check reliability and fastness of lead plugs.
（4）Check engine leakages (water, oil and gas)
（5）Check connection fastness of engine support and of other driven equipments.
（6） Keep engine clean. Remove oil contamination and dust with dry cloth or rag with detergent.
Pay special attention to dryness and cleanness of electrical equipments.
（7）Resolve all found problems and abnormalities.
2. Scheduled check
Daily check is very important for long-term good running conditions. Table 5 clearly states how
and when to carry out checks.
Table 5 Engine Scheduled Check
Schedule
System Item Every Every Every Remark
100h 200h 500h
Replace sump lubricant ○
Lubrication
Clean or replace filter element ○
Check initial injection pressure ○
Check VE
Check spray quality ○
pump at
Fuel Clean or replace element of diesel
○ pump repair
filter station
Check VE pump ○
Replace cooling water ○ Check
sufficiency of
Cooling
Clean economizer ○ refrigeration
water
liquid (if used
Check fan belt tension ○ for cooling)
Clean element of air filter ○
Inlet duct
and air filter Remove dust deposit in the inlet ○
duct
Inlet& Check clearance of inlet and outlet ○
outlet Check port timing ○
Bolt on
Check fastness of bolt on cylinder
cylinder ○
cover
cover
Check voltage of storage battery
○
Electrical and specific gravity of electrolyte
starter Check switch-on of electrical
○
starter contactors
Note: ○ indicates parts to be checked.
（1）Replace lubricant and clean element of lubricant filter. Replace engine lubricant once every
100h. Attention: Prevent scalding during drainage of hot lubricant. Avoid hot lubricant contacting

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operator caused by spray. Remove filter element with wrench anticlockwise. Clean the filter base.
Apply one layer of thin lubricant on the element seal washer upon installation of new filter element.
Tighten it by hand clockwise. Refer to fig.3.
（2）Clean or replace element of diesel filter. Clean the element of diesel filter once every 100h.
Empty the water collection in the settling cup. If filter is found damage or cannot be cleaned
effectively, replace it immediately.
（3）Check and adjust valve clearance. Check the valve clearance once every 100h. Refer to fig.4.

Front

Fig.3 Replace lubricant filter element Fig.5 Sequence to fasten bolts on the cylinder cover
Fig. 4 Check and adjust valve clearance

（4）Check fastness of bolts on the cylinder cover. Check fastness of bolts on the cylinder cover
every 100h with tension wrench. Carry out the check following the sequence indicated in the fig. 5.
Refer to fig. 5. Torque shall be 70+5N.m.
（5）Check electrolyte level in the storage battery. Check the level every month. If level is below the
lower limit, refill distilled water up to the upper limit. Warning: Lock out power supply of storage
battery and remove the earth terminal before circuit check. If circuit is short, fire accident will be
caused. Charge the battery in the well-ventilated place. Keep away from fire source because
hydrogen in the battery is easily for combustion. Electrolyte is thin vitriol. Contacting eye or skin
can cause blindness and scalding as well as other personal injury. Therefore operator must be
provided with goggle and rubber glove. If contact occurs carelessly, please wash it with great
amount of water and consult physician.
Attention: Work on the storage battery at insufficient electrolyte can cause damage. Please check
the level of electrolyte as schedule. Fill the electrolyte if it is below the limit. Check more times in
summer as temperature is high. As it cannot be started even with accelerated rotation, measure
the specific gravity of electrolyte. Specific gravity shall be more than 1.27 (20hours) when battery

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is completely charged. If it is less than 1.24, battery requires to be charged. Replace the storage
battery in the case that specific gravity does not become higher after charging.
（6）Check the air filter. Air filter element is easily contaminated by airborne dust, oil mist and
moisture, leading to increase of inlet resistance, reduction of air flow and black fume from engine.
Regularly check and clean the air filter element and replace it if necessary. Check more times if air
filter operates in the dusty condition.
Remove the filter element component from housing. Blow off dust by compressed air through
center of filter element (as shown on fig. 6). Replace the damaged paper element. Eliminate the
oil sludge in the housing. Cover the inlet with cloth to avoid foreign matters falling into inlet
manifold. Pay attention to the airtight seal between filter element and connection rubber hose
during filter installation so that air not be filtered is prevented from the cylinder directly.
（7）Check injection pressure and mist quality of sprayer. Check injection pressure and mist quality
of sprayer once every 200hours as shown on fig. 7. If mist is found bad, or oil leakage occurs, or
nozzle needle valve is blocked, remove the sprayer for cleaning or replace the sprayer. If injection
pressure is incompliance with specification, place the steel spacer on the pressure-regulating
spring for adjustment.

Filter element

Fig.6 Clean air filter Fig.7 Check injection pressure and mist quality of sprayer

3. Technical maintenance after 1000H

Check following items besides those required for technical maintenance after 500h:
（1）Fastness of bolts of connecting rod and main bearing.
（2）Airtight seal of inlet and outlet valves. Correct and grind seat of inlet or outlet valves if
necessary.
（3）Remove start motor and generator out and apply the lubricant to bearing.
（4）Components of diesel engine
（5） Re-assemble all parts removed during maintenance. Run the diesel engine at the idle speed
to eliminate potential errors. Put it into use if it runs normally.

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3. Removal & assembly

1. Basic removal steps

（ 1 ） Prepare necessary tools, clamps and measures. （ 2 ） Prepare one note for recording
maintenance. （3）Take detergent for parts into the cleaning tray.（4）Prepare the location and
container for dispose of parts.（5）Empty residue lubricant in the engine.（6）Place bolts and nuts
with related parts to avoid mistake during re-assembly.（7）Determine existing problems before
removal in order to not remove unnecessary parts.
1.1 Assy. of inlet and outlet manifold as shown regulating arm.
on fig. 8 4）Remove securing bolts of generator frame
1）Remove locking nuts.
2）Remove securing bolts.
3）Remove exhaust manifold and take out the
washer in inlet and outlet manifold.

Fig. 8
1.2 Fan assy. (Fig. 9)
1）Remove securing bolts of fan
2）Remove the fan and take out the block.
Fig. 9
1.3 Generator assy., belt and pulley of water
pump (Fig. 10)
1）Loosen regulating bolts of generator. Adjust
the location of generator and remove the belt out
2）Remove the pulley of water pump.
3 ） Remove securing bolts of generator
Fig.10
1.4 High-pressure oil pipe and injection pump
assy. (Fig. 11)
1) Loosen oil-inlet nut on sprayer in high-
pressure oil pipe and end bolt on distributor.
Disconnect high-pressure oil pipe.
2）Remove the coverof tooth-belt of injection pump.
3）Remove the tension pulley of timing tooth-belt.
4）Remove the timing tooth-belt.
5）Remove gear of injection pump.
6 ） Remove securing nuts of injection pump
and securing bolts on the support plate at the
rear. Take out the injection pump.
7）Remove the weldment of support plate and
lug of injection pump.

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 Fig .11
1.5 Fuel filter assy. (Fig. 12)
1）Turn and remove the element of fuel filter.
2）Remove connection pipe of fuel filter.
3）Remove the seat of fuel cooler.
4）Remove the seat of fuel filter.
Fig. 12
1.6 Cylinder cover enclosure (Fig. 13)
1）Remove components of fill cover.
2） Remove enclosure nut and cylinder cover
enclosure.
3）Remove washer of cylinder cover enclosure
Fig. 13
14
1.7 Crankshaft pulley and tooth-belt enclosure
(Fig. 14)
1 ） Fix the ring gear of flywheel with special
tools so that crankshaft cannot be rotated.
2）Remove bolts on crankshaft and pulley.
3 ） Remove the upper enclosure of timing
tooth-belt.
4）Remove the lower enclosure of timing tooth-
belt.
Fig. 14
1.8 Connection section of tension pulley of
timing tooth-belt, timing tooth-belt of camshaft
and timing pulley of crankshaft (Fig. 15)
1) Remove regulating extension spring from
the pin.
2）Remove the tension pulley of timing tooth-
belt.
3）Remove timing tooth-belt of camshaft
4 ） Remove the baffle of timing pulley of
crankshaft
5）Remove timing pulley of crankshaft
Fig. 15

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1.9 Cylinder cover assy. and cylinder gasket 1.11 Water pump (Fig. 19)
(Fig. 16) Remove securing bolts on the water pump and
1）Remove bolts on the cylinder cover in the take out water pump.
manner shown on fig. 17.
2）Remove the cylinder cover assy.
3）Remove the cylinder gasket
· Place combustion end of cylinder cover
upward.

Front

Fig. 19

Fig. 16 Fig .17

1.12 Flywheel case and oil sump (Fig. 20)

1.10 Start motor and flywheel (Fig. 18)
1） Remove securing bolts of start motor and
start motor.
2）Remove bolts on flywheel.
3）Remove flywheel.
1 ） Remove securing bolts on flywheel case
and flywheel case.
2 ） Remove securing bolts on oil sump, oil
sump and gasket.

Fig. 20
Fig. 18

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1.13 Gear chamber cover and front/ rear oil
seal (Fig. 21)
1）Remove seat and rear oil seal. 1.16 Balance axis assy. (Fig. 24)

2）Remove securing bolts, gear chamber cover 1）Remove securing bolts on balance weight.

and oil seal. 2 ） Remove bolt gasket of balance axis and

balance weight.
3）Remove driving chain-wheel of fuel pump
4）Remove rear casing plate of balance axis.
5）Remove balance axis assy.

Fig. 21
1.14 Fuel pump (Fig. 22)
1 ） Remove chain wheel and chain of fuel
pump.
2）Remove securing bolts of fuel pump
3 ） Remove securing bolts on oil-outlet pipe
weldment of fuel pump
4）Remove fuel pump assy.
Fig. 24

1.17 Crankshaft assy. (Fig. 25)

1）Remove bolts on main bearing.
2）Remove casing of main bearing.
3）Take below bearing bush and thrust washer

Fig. 22 out.
1.15Piston connecting rod (Fig. 23) 4）Take crankshaft assy. out.
1）Remove locking nut on connecting rod.
2）Take out big end cover of connecting rod.
3）Turn crankshaft to distance limit and pull out
piston.
·Re-assemble big end of connecting rod and
piston connecting rod and place them in
position as original configuration.

Fig. 25
Fig. 23

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2. Re-assembly steps
Preparations prior to re-assembly:
（1）Completely clean and check all spare parts.（2）Lubricate moving parts and rotation parts with
new lubricant.（3）Use new washer and O ring.（4）Use liquid seal glue to avoid fuel leakage.（5）
Ensure correct clearance between all spare parts such as lubricant membrane and thrust washer.
（6）Mark corresponding parts upon re-assembly.（7）Use correct bolts, nuts and washers. Fasten
key bolts and nuts with specified torque. (Pay special attention to aluminum-alloy parts due to its
nature of easy damage.)（8）Apply lubricant on the threaded parts and flange connections before
key bolts is fastened with specified torque.
2.1 Crankshaft
1）Open main bearing cover of crankshaft.
2）Sufficiently apply clean lubricant on the required bearing bush.
3）Mount the upper bush with oil grove of crankshaft main bearing bush into the corresponding
hole. Direct oil hole on the engine body. Mount the lower bush without oil grove on the main
bearing cover. Insert the positioning bulge of bearing bush into notch of bearing casing.
4）Apply lubricant to the main bearing bush and crankshaft
journal. Place crankshaft assy. into main bearing bush
stably. Place the crankshaft to one side first to create
space. Insert one piece of thrust washer into the third
groove of main bearing in the manner that the side with oil
groove faces towards crankshaft. Then place the
crankshaft to the other side and insert the thrust washer at
the same direction.
5）Place main bearing covers as per marked number, 1,2, 3
Fig. 26
and 4, on the top of cover. Ensure direction marked with
arrow on the cover faces the front.
6 ） Mount bolts on main bearing covers and fasten bolts as shown on fig. 26 in three times.
Fastening torque is 60 ± 5 N.m. Lightly rotate the crankshaft after bolts are fastened to check
smooth rotation.
7）Check axial clearance of crankshaft. Keep clearance within 0.10-0.20 ㎜. If actual clearance
exceeds mentioned range, replace thrust washer or crankshaft.

2.2 Balance axis assy.

1 ） Apply lubricant to rear and front balance axis journal. Match engagement marks on the
balance axis gear with those on crankshaft gear. Mount the balance axis into engine.
2）Mount the thrust washer on balance axis.
3）Measure axial clearance of balance axis and keep it within 0.13-0.25 ㎜.
4）Mount driving chain wheel of lubricant pump on the balance axis with tooth end outward.
5) Mount the balance weight and ensure engagement of teeth.
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6）Apply glue on the rear cover of balance axis before rear cover is mounted.
2.3 Assy. of piston connecting rod
1）Select appropriate piston and big end bush of connecting rod as per sizes of cylinder body and
crank pin. Assemble them with connecting rod and piston ring to form the assy. of piston
connecting rod in compliance with cylinder requirements.
2）Separate connecting rod covers. Avoid mistaking them.
3 ） Apply CD15W40 lubricant to inner wall of cylinder, round outside of piston, piston ring,
connecting rod bearing bush and crankshaft journal.
4）Turn the crankshaft to the position that journal just faces big end bush of connecting rod to be
mounted on.
5）Place three air rings and oil rings of piston ring with included 120°. Side marked with Front on
the top of piston faces body front. Clamp piston ring with special fixture. Push piston into cylinder
till it reaches crankshaft journal at the rear of big end seat of connecting rod.
6）Mount the connecting rod cover as per marks. Apply thread sealant to bolts on connecting rod.
Fasten bolts twice with 47±5 N.m.
7） Turn crankshaft and check rotation of crankshaft after bolts on connecting rod are fastened.
Keep clearance between big end of connecting rod and crank pin journal within 0.15-0.33 ㎜.
2.4 Assy. of lubricant pump
1）Overturn the engine with bottom upward.
2）Mount positioning sleeve on lubricant pump.
3）Mount assy. of lubricant pump.
4）Mount chain wheel and chain of lubricant pump. Keep side with CB and OUT. SIDE outward.
Check flexibility of mounted chain. Compression of chain shall be 3-5mm by thumb. If flexibility is
excessive, it is allowed to insert proper washer under lubricant pump.
5）Mount the drainage pipe of lubricant pump.
2.5 Gear chamber cover and front/ rear oil seal
1 ） Mount the positing sleeve of gear chamber in the front of
engine.
2 ）Mount the positing sleeve of rear oil seal seat at the rear of
engine.
3）Compress front and rear oil seal of crankshaft into engine and
rear oil seal seat with special tool.
4）Mount spring securing pin on the gear chamber.
5Apply glue on the both sides of washer of gear chamber cover
and attach the washer to proper position on cover. Fig. 27
6）Mount the gear chamber cover.
7）Mount washer and rear oil seal seat.
2.6 Oil sump
1）Apply liquid sealant on the engine bottom, gear chamber cover and bottom of rear oil seal seat
of crankshaft. Liquid sealant is applied on part of stud bolt where is no more than 3mm away from
outside diameter of bolt.

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2）Mount the oil sump gasket.
3 ） Temporarily fasten stud bolts first upon mounting oil sump. Then fasten bolts in specified
sequence as shown on fig. 27. Fasten torque is 5.5 ± 1.5 N.m. Digitals in the bracket indicate
fastening sequence.
2.7 Flywheel casing and flywheel components Fig. 28
1）Overturn engine 180°till engine top upward.
2 ） Mount the positioning pin of flywheel casing on the rear end of
engine.
3）Mount the flywheel casing.
4）Mount the flywheel corresponding to positioning pin. Apply thread
Fig. 28
sealant on flywheel bolts and fasten flywheel as shown on fig. 29
twice evenly with 55±5 N.m.
5）Check run-out tolerance of 314 hole on flywheel casing to crankshaft is
no more than 0.12 when flywheel components are assembled.
6）Mark upper limit. Rotate flywheel to place first cylinder piston to upper
limit. Match upper limit mark on the flywheel with that on the casing.
2.8 Start motor and water pump Fig. 30
1）Mount the start motor.
2）Apply glue on the water pump washer. Fig. 29
3）Place water pump assy. and washer closely against front of engine.
2.9 Cylinder gasket and cylinder cover assy.
1) Compress the positioning sleeve of cylinder cover into the engine top.
2）Check the projection of piston with dial gauge. Determine proper thickness of cylinder washer
according to projection height of piston.
3）Apply little lubricant on the plane of cylinder gasket and engine top. Ensure the side marked with
letter of cylinder gasket upward and against positioning sleeve of engine. Then place the cylinder
gasket on the engine plane.
4 ） Rotate the flywheel till first cylinder piston at upper compression limit. Mount the planar
positioning sleeve against engine. Then place assembled cylinder cover assy. on it.
5） Mount and fasten bolts on cylinder cover in three times evenly
with 90±5 N.m.
2.10 Connection of tension pulley of timing tooth-belt, timing pulley
of crankshaft and timing tooth-belt of camshaft
1 ） Place one end of extension spring of tension pulley on the
bracket. Mount the tension pulley and place the other end of
Fig. 30
extension spring on the pin.
2） Insert the dust-proof block into gaps on connections of water pump with cylinder cover and
water pump with gear chamber cover.
3）Insert the semi-round key of timing pulley into crankshaft journal by compression. Mount the
baffle of timing pulley. Then mount the timing pulley. Pay attention to direct timing mark on gear to
that on the gear chamber cover.
4 ） As mounting timing tooth-belt of crankshaft, first ensure match holes on timing pulleys

20
respectively of crankshaft and camshaft in alignment with mark on the timing tooth-belt. Then
insert the belt.
2.11 Tooth-belt casing and crankshaft pulley
1 ） Mount another baffle to the outside of crankshaft timing pulley in the manner that inclined
surface in external edge of baffle faces tooth-belt.
2）Insert the dust-proof fillet into lower dust-proof case of timing tooth-belt and bolt it on the gear
chamber cover.
3 ） Insert the dust-proof fillet into upper dust-proof case of timing tooth-belt and bolt it on the
cylinder cover and water pump.
4）Mount the crankshaft pulley on the journal and fasten it on the crankshaft with securing bolts
(with washer). Securing torque is 95±5 N.m.
2.12 Cylinder cover casing
1）Insert the rubber washer into the groove on cylinder cover casing.
2）Apply silicon sealant to elbows of 1# and 4# bearing covers of cylinder cover.
3）Mount and fasten cylinder cover casing on the cylinder cover with four securing nuts. Securing
torque is 10±1 N.m.
4）Mount the fill-in cover.
2.13 Lubricant filter assy.
1）Mount the gasket and seat of lubricant filter.
2）Place O ring into annular groove in the seat of lubricant filter.
3）Connect the lubricant cooler seat to the filter seat with filter tube. Securing torque for filter tube
is 30±5 N.m.
4）Apply little lubricant on the rubber ring in filter element and fasten it on the cooler seat by hand.
2.14 Injection pump assy. and high-pressure oil pipe
1）Mount the support plate and lug of injection pump at the rear of cylinder cover.
2）Mount tension pulley of timing tooth-belt and extension spring of tension pulley.
3） Pre-fasten the injection pump on the support plate weldment. Insert the semi-round key into
axis of injection pump by hammer. Mount the pulley and pay attention to conical side of tooth belt.
Adverse mounting is not allowed. Fix the gear with special tool and secure oil pump with 65± 5
N.m.
4 ） Mount the timing tooth-belt of injection pump and ensure mark in the back of tooth-belt in
alignment with that on driving pulley and pulley of injection pump.
5 ） Adjust tension of tooth-belt. Turn tooth-belt 90° by hand for optimum tension. Then fasten
tension pulley bolts with 37.5±7.5 N.m.
6）Mount the tooth-belt casing with dust-proof fillet.
7）Mount the rear support plate of injection pump.
8）Mount high-pressure oil pipes of cylinders and return pipe of injection pump.
2.15 Water pump pulley, water pump belt and generator assy.

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1）Bolt the water pump pulley on the axis.
2）Pre-fasten regulating arm of generator on the engine body. Final securing shall be done when
V belt of generator is positioned tightly. Securing torque is 18.5±3.5 N.m.
3）Mount the frame of generator assy.
4）Place water pump belt on the generators of generator, water pump and crankshaft respectively.
Adjust tension of V belt to 5-6 ㎜/10 ㎏ based on nominal flexibility of belt. Fasten the regulating
arm and generator.
2.16 Mount fan block and fan assy.
2.17 Inlet and outlet pipes assy.
1）Mount the washer of inlet manifold.
2）Mount and bolt inlet manifold.
3）Mount the washer of outlet manifold.
4）Mount and bolt outlet manifold.
3. Cylinder cover assy.
In order to facilitate dismantle complete engine, assemble camshaft assy.,
glow plug assy. and sprayer in the same step during cylinder cover assembly.
3.1 Remove cylinder cover assy.
1）Remove securing nuts on return pipe and pipe weldment of sprayer
2 ） Remove sprayer assy. and take out sprayer gasket and heat insulation
gasket.
3）Remove nuts, conducting strip and connecting sheet of glow plug.
4）Remove glow plug and limiting resistor.
5）Remove bolts and stud bolts on bearing cover of camshaft.
6）Remove the bearing cover of camshaft.
7）Remove camshaft assy.
3.2 Assemble cylinder cover assy. (Fig. 31, Fig. 32 and Fig. 33)
Fig. 31
1）Mount the combustion chamber and direct pin hole on block of combustion
chamber to position pin on cylinder cover.
2）Height range of combustion chamber: -0.06-0.04 ㎜
3）Mount the steel balls in the main oil duct opening with special punch.
4 ） Mount the bottom seat of valve spring and oil seal with
compression. Keep 0.76±0.009 ㎜ clearance of valve oil seal.
5） Mount inlet valves and outlet valves of cylinders, valve spring,
elastic upper seat of valve and valve lock.
6）Check seal performance of valves with valve leakage indicator.
7）Mount valve lifter.
8）Open bearing cover of camshaft and mount the camshaft. Fig. 32
9）Mount bearing cover of camshaft. Apply liquid sealant to elbows
of 1# and 4# bearings during assembly.

22
10）Fasten bearing cover of camshaft with17.5±2.5N.m from inside first.
11）Mount oil seal of camshaft bearing.
12）Check clearance of inlet and outlet valves.
13）Mount the glow plug and limiting resistor. Fasten glow plug and limiting resistor on cylinder
cover with12±2N.m and 35±5N.m respectively.
14）Insert conducting strip into glow plug with 22.5±7.5N.m torque.
15）Insert connecting sheet into glow plug and limiting resistor with 2.5±1N.m torque.
16） Place heat insulation gasket into all sprayer orifices and seal
ring on the cylinder covers.
17）Mount the sprayer with 60±10N.m torque. Ensure identification
color for sprayer pressure same on one engine.
18）Remove return pipe nut and place aluminum washer.
19）Mount and fasten return pipe with 22.5±2.5 N.m torque.
20）Mount one return hose from return pipe to injection pump and fix
hose with clamps. Fig. 33
21）Bolt the inlet and outlet manifold with 37.5±7.5 N.m.
22）Turn the camshaft after assembly to check if valve lifter moves smoothly.

23
4. Check & maintenance

1. Cylinder cover
1.1 Inlet and outlet valves and valve seats
1）Check wearing of valve stem and replace it if necessary (Fig. 34)
① Diameter of valve stem: Inlet valve 6.945～6.960 ㎜
Outlet valve 6.940～6.955 ㎜ Total length
② Total length of valve: Inlet valve 104.9 ㎜
Outlet valve 105.1 ㎜
③ Measure thickness of valve end base (Fig. 35) Fig. 34 Fig. 35
Specification: Inlet valve: 1.1～1.3 ㎜; Outlet valve: 1.4～1.6 ㎜
Limit：Inlet valve: 1.0 ㎜；Outlet valve: 1.3 ㎜ Center of valve
contact position
④ Check contact of valve and valve seat (Fig. 36) Specified
Defined contact: contact width
Width: Central part of circumference
Specification: Inlet valve: 1.2～1.6 ㎜， Outlet: 1.2～1.6 ㎜ Fig. 36
2）Check and re-grind valve seat (Fig. 37)
① Apply red lead film on the valve seat. Make valve to
sit on the seat by gravity 2 or 3 times in order to check contact width
and location. Do not turn valves when contact is checked. Air inlet Exhaust
② Re-grind valve seat in following order: Fig. 37
First grind coarse face of valve seat with 45 °blade. Check contact location of valve and valve
seat. Keep contact at the center of valve face with 15°, 60° and 70° blades. Manually grind
valve with grinding paste after contact width meets with defined specification and valve seat is
grinded with blade at the center. Fig. 37
Perpendicularity
Note: Check wearing of valve guides prior to re-grinding valve
seat. If wearing exceeds specification, replace worn guides then
go on re-grinding operation.
1.2 Check valve spring (Fig. 38)
Free length
Check free length and perpendicularity of spring.
Specification: Free length: 43.3 ㎜，Limit: 42.0 ㎜
Perpendicularity limit: 1.5 ㎜ Fig. 38
1.3 Check valve guides (Fig. 39)
Check clearance of valve and valve seat
Specification: Inlet valve: 0.040～0.070 ㎜, Outlet valve: 0.045～0.075 ㎜
Limit: Inlet valve: 0.09 ㎜, Outlet valve: 0.10 ㎜
Note: Oil seal of valve stem on the inlet and outlet guides cannot be reused
after maintenance. Replace new oil seal. Fig. 39

24
1.4 Check cylinder cover (Fig. 40)
1）Check deformation
① Contact of cylinder Limit: 0.10 ㎜
Replace cylinder cover if measured value exceeds limit.
② Contact of inlet and outlet manifold Limit: 0.10 ㎜
Fig. 40
2）Measure clearance between cylinder cover and valve stem (Fig. 41)
Specification: 0.020～0.065 ㎜, Limit: 0.09 ㎜
3）Combustion chamber
① Check bugle with micrometer.
Specification: -0.03～0.04
② Visually check damage or rupture of combustion chamber.
2 Piston connecting rod Fig. 41
2.1 Piston and piston ring
1）Check piston OD (Fig. 42): Measure OD in
the position 13.0mm from piston bottom and in
the direction vertical to pin hole. Specification:
13mm
75.94-75.97 ㎜ . Calculate piston clearance
with piston OD and cylinder ID. Specification:
0.05-0.07 ㎜. Limit: 0.12 ㎜ Fig. 42 Fig. 43

2）Check side clearance of piston ring (Fig. 43)

① Check side clearance of piston ring with thickness gauge around the circumference of piston
ring groove.
Piston ring Specification (mm) Limit（㎜）
1st air ring ————— 0.16
2nd air ring 0.05～0.08 0.12
Oil ring 0.03～0.065 0.12
② 1st piston ring is in conical shape. Measure the side clearance and position piston ring as
shown.
3）Check gap of piston pin
① Match piston pin and connecting rod: Apply thin engine lubricant to the piston pin at normal
temperature to smoothly insert and slide piston pin.
② Match piston pin and piston: Heat piston to 80℃ and apply engine
lubricant on the piston ring. Then insert pin into piston. Ensure
resistance to piston pin can be removed compression with thumb.
4）Check end clearance of piston ring (Fig. 44)
Insert piston ring into cylinder with piston to the position below slide
Fig. 44
face of ring, i.e. about 110mm from the cylinder top. Measure the end
clearance of piston ring.

25
 Item Specification
Limit（㎜）
Part （㎜）
1st air ring 0.23～0.38
2nd air ring 0.20～0.40 0.70
Oil ring 0.20～0.40

2.2 Check cylinder ID and wearing Axial direction

1）Check cylinder ID and wearing (Fig.45) of cylinder
① Measure cylinder ID at six points shown with cylinder bore gauge Axial direction
of crankshaft
and calculate difference between maximum value and minimum value.
Limit: 0.10 ㎜, Basic cylinder ID: 76.00-76.03 ㎜
10mm
2.3 Connecting rod
Center point
1）Check axial clearance of connecting rod (Fig. 46) 10mm
Check axial clearance of connecting rod with thickness gauge.
Fig. 45
Specification: 0.150～0.330 ㎜
Limit: 0.40 ㎜
2）Check bush clearance of small end of
connecting rod (Fig. 47)
Measure bush ID and piston pin OD. Then
calculate the clearance.
Specification: 0.004～0.014 ㎜，
Limit: 0.05 ㎜ Fig. 46 Fig. 47

3. Crankshaft and balance axis

3.1 Check radial runout of crankshaft (Fig. 48)
1 ） Mount the micrometer at the proper position. Turn the
crankshaft one cycle. Pay attention to deflection of micrometer
during turning.
Specification: 0.05 ㎜. Half of maximum deflection of micrometer is
radial runout of crankshaft.
2 ） If measured value is larger than specification, replace the Fig. 48
crankshaft.
3.2 Check wearing of journal of main bearing and crankshaft
Two
connecting rod (Fig. 49) directions
1）Measure wearing of journal of main bearing and crankshaft
connecting rod at shown points. For KM376AG OD specification:
Two points
Journal of main bearing: 47.976 ～ 48.000 ㎜ , Journal of
crankshaft connecting rod: 44.926～45.000
2）If wearing exceeds specification, replace the crankshaft.
Fig. 49
3.3 Check axial clearance of crankshaft (Fig. 50)

26
1）Check axial clearance of crankshaft with micrometer.
KM376AG specification: 0.06～0.26 ㎜
2）If axial clearance exceeds specification, replace thrust washer or crankshaft. Then re-check the
axial clearance.
3.4 Check axial clearance of balance axis (Fig. 51)
Check the axial clearance with micrometer. Specification: 0.13-0.25 ㎜

Fig. 50 Fig. 51

4. Cylinder body
1）Check gasket flexibility of cylinder cover at the top (Fig. 52)
Specification: 0.05 ㎜
If measured flexibility exceeds specification, replace the cylinder body.
2）Check cylinder wearing with reference to 4.2.2. If cylinder body is replaced, it is necessary to
measure bulge of piston. Then select proper cylinder gasket as per measured bulge.

Fig. 52
5. Check camshaft
1）Check radial runout (Fig. 53)
Specification: 0.05
Contact the micrometer with camshaft and turn micrometer one cycle. Half of maximum deflection
of micrometer is radial runout of crankshaft.

2）Check bulge of cam (Fig. 54)

27
 Item
Specification ㎜ Limit ㎜
Cam
Inlet 44.150～44.250 43.85
Outlet 44.750～44.850 44.45
3）Measure axial clearance
Measure the axial clearance at the 2nd bearing cover.
Specification: 0.15～0.35 ㎜, Limit: 0.45 ㎜。
4）Measure clearance
Measure clearance at bearing covers.
Carry out measurement according to 3) and 4) after bearing cover is fastened with 16±1 N.m.

Item
Specification
Bearing cover
1st 0.035-0.076 0.13
2nd 0.055-0.096 0.15
3rd 0.055-0.096 0.15
4th 0.035-0.076 0.13

Fig. 53 Fig. 54

6. Check lubricant pump assy.

1）Visually check disassembled parts and replace any damaged one.
① Check crack, deformation and damage of pre-filter on lubricant pump.
② Check crack, wearing and deformation of lubricant pump cover.
③ Check wearing of driving rotors and driven rotors in lubricant pump.
2）Check crack and damage of lubricant pump and chain wheel of driving
axis.
3）Check damage of chains and crack and damage at connection of chain
wheel and chain.
4）Check clearance between lubricant pump axis and lubricant pump (Fig.
Fig. 55
55)
Specification: 0.045～0.085 ㎜, Limit: 0.10 ㎜
5）Check top clearance (i.e. between tooth of driving rotor and driven rotor) (Fig. 56)
Specification: ≤0.15 ㎜, Limit: 0.25 ㎜。

28
6 ） Check side clearance (i.e. between rotor and lubricant pump
cover) (Fig. 57)
Specification: 0.03～0.09 ㎜, Limit: 0.20 ㎜
7）Check pump clearance (i.e. between driving rotor and pump) (Fig.
58)
Specification: 0.10～0.16 ㎜, Limit: 0.30 ㎜
8）Check and ensure pressure limiting valve at normal condition for
assembly. Check damage of lubricant tube or sliding face. If any
Fig. 56
damage is found, replace the pressure limiting valve. If spring is
found damage or fails, replace the spring.

Fig. 57 Fig. 58
7. Timing belt, tension pulley of timing belt and timing pulley
7.1 Check timing belt
1）Check tooth missing, deformation or crack of timing belt.
Note: ①Carefully handle timing belt to avoid damaging it.
2 ）If there is any lubricant drop or water on the timing belt, belt bulge is shown due to rubber
nature. Therefore prevent timing belt from lubricant or water.
3）If water leaked from water pump continuously sprays on the timing belt, immediately replace
belt.
7.2 Check tension pulley of timing belt
Turn the tension pulley and check abnormal noise of bearing. In addition check scratch or damage
at connection with belt.
7.3 Timing pulley
Check wearing of timing pulley.
Check all mentioned part and replace damaged one.
8. Sprayer: Check sprayer and replace defective nozzle.
1）Check injection pressure (Fig. 59)
① Load nozzle on the testing equipment. Rapidly move handle of
testing equipment for 2 -3 injections, which can blow off any carbon
deposit in the nozzle.
② Then slowly move handle of testing equipment to increase pressure.
Measure the pressure when pointer of pressure meter indicates one Vibration
sudden fall. buzz
Fig. 59

29
Specified injection pressure: 13.5～14MPa(Green) and 14.1～14.5Mpa
(Pink)
2) Adjust injection pressure (Fig. 60) Regulating gasket
Disassemble the nozzle and change washer if measured value Fig. 60
is incompliant with specification.
3）Check fuel tension (Fig. 61)
① Slowly compress handle of pressure measure till pressure reaches to 100kg/cm3. Then hold it
under such pressure for 10sec to check any fuel leakage from injection chamber of nozzle or
retaining nut.
4）Check vibration buzz and mist (Fig.60)
① Operate testing equipment at 30-60 travel per minute for
new nozzle while 15-60 travel per minute for used nozzle.
Ensure vibration buzz is heard during each travel.
② Make sure fuel is injected in the form of conical mist and
center of cone is in alignment with center of nozzle when
Fig. 61
vibration buzz is heard.
③ Ensure nozzle does not drop.
9. Check injection timing
1) Remove high-pressure injection pipe and clamp
2）Remove bolts on distributor cover.
3）Use one micrometer.
4）Fix piston of 1st cylinder at the upper compression limit. Align mark on the flywheel with that on
flywheel casing.
5 ） Turn crankshaft in adverse direction, meaning pointer of micrometer indicates maximum
deflection first.
6）Zero micrometer.
7）Turn crankshaft in normal direction. As piston reaches to upper limit at 5°, gently rotate turning
part of crankshaft by hand and crankshaft. Pay attention to reading on micrometer when piston on
1st cylinder is at upper limit.
Specification: 0.97～1.00 ㎜。
8）If reading on micrometer is within specification range, disconnect the meter and mount bolts on
distributor.
9）Mount high-pressure pipe and clamp.
10 Adjust engine-related parameters
10.1 Adjust valve clearance (Fig. 62)
Valve clearance indicates travel of camshaft cam surface before it works on the valve. At the cold
state, inlet valve clearance is 0.25mm and outlet valve clearance is 0.30mm. At the hot state, inlet
valve clearance is 0.30mm and outlet valve clearance is 0.35mm. If clearance is improper, adjust

30
the thickness of washer.
1）Measure clearance
Measure clearance with feeler gauge as shown
（1）Measurement at the cold state
（2）Keep small end of cam upward during measurement.
2）Select clearance washer: Fig. 62
T2=T 1+（A ′-A）
T2：Thickness of replaced washer
T1：Thickness of washer during measurement
A′：Measured value A：Specified value

3）Replace adjusting washer

Press valve stem down with special tool. Take out washer used in the measurement. Replace it
with proper washer and make it to original position.
10.2 Adjust injection timing
For economic fuel consumption and good performance, injection advance angle shall be adjusted
properly. For KM376 engine VE injection pump, advance angle is worked as following:
(1) Turn the crankshaft till it is at the position 30°in front of upper limit of 1st cylinder, i.e. timing
mark on pump pulley is at the place just one tooth before mark of pump support plate.
(2) Loose securing nuts and bolts on rear support till injection pump can do rotation. And place
injection pump to the most inside of engine.
(3) Mount lever micrometer in the front of injection pump and zero the meter.
(4) Turn the crankshaft till engine 1st cylinder at upper limit.
(5) Turn injection pump towards outside of engine slowly till reading on micrometer is 0.97±0.03 ㎜.
(6) Check one more time. Turn crankshaft to 1 position and check reading on centimeter is 0. Then
turn crankshaft to upper limit and check reading on centimeter is 0.97±0.03 ㎜. If check results
are good, adjustment is finished. Otherwise repeat mentioned steps.
(7) Fasten bolts and nuts loosened in above steps.
10.3 Adjust sprayer
Test and adjust sprayer on the tester so that pressure of injection pump is adjusted. Check
atomization and resolve any problem.
(1) Manually pump oil till pressure at 14±0.5MPa. Check condition of sprayer and atomization as
per injection requirements. Remove sprayer pairs for cleaning or replacement, if any drop or
leakage.
(2) Manually pump oil. If startup pressure cannot reach 13 MPa, remove sprayer pairs. Adjust
injection pressure by increasing thickness of regulating washer till specified reading is gained. If
pressure is below specification, reduce thickness of regulating washer.
10.4 Adjust injection pump
Injection pump has been adjusted and check before delivery. If re-adjustment is necessary, please

31
follow operation introduction on the standard testing table. Regularly only qualification person is
allowed for re-adjustment.
10.5 Adjust V belt (Fig. 63)
Check tension in the arrow direction as shown. For new V belt, apply 100 N.m and relaxation is 4-
5 ㎜. Normally apply 100 N.m on V belt and relaxation is 6-7 ㎜ . If relaxation is more than 9 ㎜
(inclusive) with same force, replace V belt.

Generator Water pump

Crankshaft

Fig. 63

32
5. Problem and Remedy
Table 6 Difficult or no start
Error cause
1. Low startup rotation speed
1 ） Insufficient power supply by storage
battery or loose contact
2 ） Bad contact between carbon brush of
start motor and commutater
3） Gear of start motor cannot match with
gear ring of flywheel.
4 ） Thin and long battery line and great
voltage drop
2. Abnormal fuel system
A. No fuel injection
1）Fuel is empty in the fuel tank
2）Failure of solenoid valve of injection pump
（1）Broken lead or loose terminal
（2）Damage of solenoid valve winding
（3）Core of solenoid valve is blocked.
（4）Failure of start switch
3）Air existence in injection pump
4）Element of fuel filter is blocked
5 ） Injection pump plunger is broken or
blocked
6) Driving pin on the planar cam of
injection pump is broken.
7）Fuel drainage ring in the injection pump
is blocked.
B Abnormal operation of pre-heating system
1）Abnormality of glow plug relay
2）Abnormality of pre-heating timer
C Abnormality of water-temperature sensor
D Sprayer does not inject fuel or mist is bad.
1）Sprayer pairs are blocked.
2）Bad mist from nozzle
3）Broken of regulating spring
4）Leakage of high-pressure seal side
Remedy
1）Charge the storage battery and fasten contact.
Replace terminal if necessary.
2）Repair or replace carbon brush
3）Turn flywheel to certain degree. Adjust location
of small gear relative to gear ring
4）Replace battery line
1）Fill fuel and exhaust air
（1）Replace lead or fasten terminal
（2）Replace solenoid valve
（3）Replace solenoid valve
（4）Check or replace
3）Exhaust air and fasten joints of related oil piping
4）Clean or replace element of fuel filter
5）Replace distributor components of injection pump
6) Replace driving pin on the planar cam
7）Replace distributor components of injection pum
1）Check and repair or replace
2）Check and repair or replace
Check and repair or replace
1）Replace nozzle pairs
2）Replace nozzle pairs
3）Replace pressure regulation spring
4）Replace sprayer assy.
33
 Table 7 Excess Fume and Abnormal Fume Color
Error cause Remedy
1. Excess fume
1) Bad injection timing 1）Adjust injection timing
2）Limited fuel filter 2）Replace fuel filter
3）Abnormality of nozzle pairs of injection pump 3）Clean and repair
2. Black fume
1）Sprayer is blocked by carbon accumulation. 1）Check and repair or replace
Or needle valve is blocked.
2）Overload 2）Adjust the load to specified range
3 ） Delayed fuel injection and certain fuel 3）Adjust injection timing of injection pump
combusts in the exhaust.
4）Incorrect air valve clearance and bad seal 4）Check air valve
5 ） Uneven fuel supply by injection pump to 5 ） Authorized qualified personnel to adjust
cylinders supply volume to cylinders
6 ） Inlet pipe and air filter is blocked and air 6）Remove and clean air filter
intake is not smooth.
2. White fume
1 ） Lower pressure of injection pump. Bad 1）Check, adjust, repair or replace nozzle pairs
atomization. Fuel is dripped.
2）Lower temperature of cooling water 2）Increase temperature of cooling water
3）Moisture into cylinder 3）Check cylinder cover gasket
3. Blue fume
1）Great wearing of piston ring, or bad elasticity 1）Clean or replace piston ring
due to carbon accumulation, or lubricant blow-
by into combustion chamber of cylinder
2）Higher lubricant level 2) Drain off excess lubricant
3）Conical ring is installed adversely. 3）Place the side marked T upward
4）Oil seal of air valve is damaged. 4）Replace oil seal of air valve
Table 8 Excess Fuel Consumption

Error cause Remedy

1）Fuel leakage 1 ） Replace or re-fasten with upper limit of
fastening torque
2）Higher idle 2）Adjust idle
3 ） Maximum rotation speed of engine at no- 3）Check securing bolts of maximum speed on
load state is too quick. injection pump
4）Abnormal injection timing 4）Adjust injection timing
5）Abnormal sprayer or nozzle pairs 5）Clean and adjust

34
 Table 9 Insufficient Power
Error cause
1 ） Dirty element of fuel filter or unsmooth fuel 1）Clean or replace
supply
2）Inflexible operation of throttle wire
3 ） Fuel pipe is blocked and fuel supply is not
smooth.
4）Fuel leakage or air into fuel system
5 ） Regulating spring turns soft and rotation
speed falls down.
6）Incorrect timing of fuel supply
7）Failure of sprayer
8）Dirty air filter
9 ） Incorrect distribution phase or air valve
clearance
10）Insufficient compression pressure of cylinder
① Leakage of air valve
② Leakage of cylinder gasket
③ Wearing of cylinder, piston ring and piston
④ Leakage of sprayer
⑤ Loose bolts on the cylinder cover
Table 10 Unstable Running
Error cause
1. Air into fuel system
2. Inflexible operation of speed-regulation slide
bushing of injection pump
3. Inflexible operation or wearing of speed
regulating bar of injection pump
4. Uneven supply by injection pump to cylinders
5. Bad mist of one sprayer
Table 11 Engine not stop after solenoid valve shutoff of injection pump
Error cause
1. Failure of solenoid valve
2. Connection of solenoid valve on the injection
pump is not airtight.
3. Failure of solenoid valve switch
35
Remedy
2）Adjust throttle wire
3）Check and clean
4 ） Re-fasten and eliminate air in the fuel
system
5 ） Adjust limit screw for maximum rotation
speed
6) Adjust as per specification
7）Check pressure and mist of sprayer
8）Clean or replace filter element
9）Check and adjust
① Grind or replace air valve or seat ring
② Replace cylinder gasket
③ Replace related parts or grind cylinder
④ Replace seal washer or nozzle heat
insulation sleeve
⑤ Re-fasten bolts with specified torque
Remedy
1. Clear air and check leakage of fuel system.
Resolve problems if any.
2. Send to fuel pump maintenance station for
repair
3. Send to fuel pump maintenance station for
repair
4. Send to fuel pump maintenance station for
repair
5. Check and replace bad nozzle
Remedy
1. Replace solenoid valve or clean valve core
2. Send to fuel pump maintenance station for
repair.
3. Repair or replace
Table 12 Sudden Stop
Error cause
1. Fuel in fuel tank is empty.
2. Air in the fuel piping
3. Fuel filter is blocked
4. Plunger of injection pump or fuel drainage
ring is blocked.
5. Broken spring of injection pump plunger
6. Power failure of socket of solenoid valve of
injection pump
7. Broken tooth-belt
8. Rotation failure of crankshaft
1）Piston rubbing or blocking cylinder
2） Crankshaft combines bearing bush due to
lower fuel pressure or lack of lubricant
Remedy
1. Fill in fuel.
2. Remove air in the piping
3. Clean or replace filter element
4. Send to fuel pump maintenance station for
repair
5. Send to fuel pump maintenance station for
repair
6. Check and replace wiring
7. Replace and carry out debugging
8. Replace and carry out debugging
1）Send to maintenance station for repair
2）Send to maintenance station for repair and
check lubrication system

Table 13 Overheating engine

Error cause Remedy

1. Higher temperature of outlet water
1） Insufficient water in the water tank and air 1）Fill water and exhaust air
resistance in the water pipe
2）Contamination on the heat radiation fin and 2）Clean with compressed air
copper tube in water tank
3 ）Bad radiation due to thick scale in cooling 3）Clean scale
system
4 ） Leakage and broken shaft of water pump. 4）Remove, check and repair
Impeller does not work.
5）Broken or loose fan belt 5. Replace belt or adjust belt tension force
6 ） Cooling water pipe and water duct of fuel 6) Clear piping
cooler are blocked.
7）Damage of economizer 7）Replace
8）Overload of diesel engine 8）Reduce load
2. Excess fuel temperature
1）Insufficient or excess fuel 1) Replace fuel as per specification
2）Contamination in fuel cooler 2）Clean
3）Bad quality of fuel 3）Replace fuel as per specification
4）Great blow-by in the crankshaft case 4）Check blow-by of piston ring
5）Higher temperature of cooling water 5）Remove as mentioned
6）Overload of diesel engine 6）Reduce load

36
7）Failure of fuel temperature meter 7）Replace

37
 Table 14 Abnormal Fuel Pressure of Engine
Error cause
1. Lack of or insufficiency of fuel pressure
1）Less fuel in the oil sump
2）Thin fuel
3 ） Broken oil pipe or loose/ leakage of pipe
connection
4）Too much clearance of fuel pump
5）Plunger on pressure limiting valve of fuel pump
is not flexible. Or spring is deformed or broken.
6）Broken driving pin of fuel pump
7）Too much clearance between main bearing and
connecting rod bearing
8）Main oil duct is blocked or loose
9）Fuel filter is blocked by foreign matters.
10）Fuel filter is too dirty
11 ） Short-circuit of fuel filter or fuel cooler and
leakage inward
12）Damage of fuel pressure meter
2.Too high fuel pressure
1 ） Abnormality of pressure limiting valve of fuel 1）Check and adjust
pump. Fuel return is not smooth.
2）Lower temperature and excess fuel viscosity
3）Bad lubrication at camshaft journal
Table 15 Excess Lubricant Consumption
Error cause
1.Lower viscosity of lubricant and incorrect brand
2. Too much clearance between piston and cylinder
body. Or lubricant return hole on piston ring grove
is blocked.
3. Cementation of piston ring blocks ring grove.
Ring is installed adversely. Or wearing is serious.
4 ） Leakage at front/ rear oil seal of crankshaft,
connection interface of oil sump and seal
connection of gear chamber casing
5. Excess temperature and pressure of lubricant
6. Leakage of valve oil seal
38
Remedy
1）Fill fuel to the specified limit
2）Replace with specified fuel
3）Replace and fasten
4）Replace
5）Replace
6）Replace
7）Check, adjust or replace
8）Check if it is blocked
9）Check and clean fuel filter
10）Clean or replace filter element
11）Check and replace
12）Replace
2 ） Use specified fuel. Viscosity reduces
automatically after engine is warmed.
3）Eliminate foreign matters in the fuel limit
plug and clean oil duct of cylinder cover
Remedy
1. Replace with specified lubricant
2. Replace and clean lubricant return hole
3. Clean or replace
4. Check or replace related parts
5. Reduce the temperature. Check and
regulate pressure limiting valve of lubricant
pump
6. Replace oil seal of air valve
 Table 16 Abnormal Operation Sound
Error cause Remedy
1. Too much clearance between piston and 1. Replace piston ring and piston. Bore
cylinder cylinder if necessary.
2. Too much clearance between piston pin and 2. Replace worn parts and keep specified
small end bushing of connecting rod clearance
3. Too much clearance between main bearing 3. Replace main bearing bush and bearing
bush and bearing bush of connecting rod bush of connecting rod. Keep specified radial
clearance
4. Too much clearance between piston ring and 4. Replace piston ring and piston if necessary
ring grove
5. Too much clearance between crankshaft 5. Replace thrust washer of crankshaft and
thrust side and thrust washer keep specified clearance
6. Piston contacts air valve 6. Check compression clearance and
distribution phase and make adjustment as per
specification
7. Greatly wearing of gear, too much clearance 7. Replace worn gears
between teeth, impact sound upon immediate
reduction of rotation speed
8. Advance supply timing 8. Check and calibrate supply timing
9. Sprayer pairs are blocked. 9. Clean or replace nozzle pairs

Table 17 Rise of Fuel level

Error cause Remedy

1. Leakage of cylinder cover gasket 1. Replace the gasket
2.Leakge of cylinder cover or engine body 2. Check and replace

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6. Trial Startup

Prior to startup
1）Check fastness of anchor bolts of engine and connection of driven machinery.
2）Check flexibility of operation system and connection fastness.
3）Fill specified lubricant to the level between upper and lower limits on lubricant gauge of engine.
4）Fill specified fuel to the level. Avoid diesel overflow in fuel tank. Fill amount is approximately
90% of tank volume.
5）Check if there is any air in the fuel system and high-pressure fuel pipe.
6）Fill enough cooling water. Exhaust air in the water pipe during
filling. Check the leakage of cooling water tank and pipe
connection.
7) Check if negative ground and electrical wiring are correct and
power supply by storage battery is sufficient as connecting storage
battery.
Startup (Fig. 64)
Insert the key into start switch hole and turn the key to ON
clockwise. Then indication lamp of pre-heating plug is on and off Fig. 64
after about 7sec. Turn the key to STAR clockwise to drive engine
with starter. At last release manual switch that returns to ON position automatically. By then
startup operation finishes.
Running
1）Pre-heat the engine for 5min after startup.
2）Check pressure and temperature of lubricant, temperature of cooling water and charging meter
indication regularly during normal running of engine. Pay attention to fume color and listen to
running sound.
3）Do not increase or reduce rotation speed and load suddenly when engine runs normally.
6.4 Stop running (Fog. 64)
1）As engine stops, decrease running speed slowly to idle condition and run at idle state for about
5min.
2）Key the key to OFF when stop is required.
3）Prevent engine frozen when it stops in winner.

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