KAC conversion kit installation manual

-Vehicle InformationManufacturer : TOYOTA(Japan) Car Model : COSTER (MINI BUS) Passenger : 25 people Similar Model : Hyundai Chorus, Hyundai County, Kia Combi -Engine InformationEngine type 14B(with out TURBO) Displacement 3,660 cc Cylinder bore 102.0 mm Piston stroke 112.0 mm Compression ratio 18:01 Cylinder block alloy cast-iron Cylinder head alloy cast-iron Cylinder liner dry liner Valvetrain OHV HP 98 at 3,400RPM Torque 24kg f-m at 1,800RPM Injection type direct injection Fuel type diesel -Electrical Field Information- Generator 24v / 30A (assumption) Battery Capacity 65AH(2EA) CCA700A(assumption) This Install Manual is contributed to workers in order for them to understand rules and directions of converting diesel engine into CNG(Compressed Natural Gas) engine Matters that require attention 1) Workers ought to protect their own health during installation job Be careful of safety accidents all the time 2) Vehicles are very sensitive to heat, vibration, moisture, and etc more than general machines 3) This install manual recommends optimal installation, based on our know-how for conversion into CNG engine If installation job is followed by our recommendation, durability of engine and other parts can be extended However, installation job can be influenced by worker’s idea in accordance with environment or condition of work However, workers have to consider content 2) all the time Engine Checking Idling state of the Engine (Cylinder dissonance) Check all of the liquid condition flowing into the engine(rust, engine oil level) and check leak - If you need, cleanse or exchange it Visually inspect the exhausted gas if it emit different kind of gas, and expect the inside condition of the engine Check starting device Check HVAC system Problem of engine 4th piston and piston ring got damaged 4th cylinder liner got damaged Determine to replace them Over sized 14B 0.50mm piston Remove carbon from the piston Make the piston keep horizontal Measure water volume by using a shot or electronic scale as like the picture In the case of using an electronic scale, convert 1g into 1cc of water The level of water should be the same as the level of the piston surface ▣ Install Manual – Compression Ratio of Cylinder(1)  Calculate Cylinder Voulme VCyl  D π D H If D  12 Cm  H  14.5 Cm ,  π 12  14.5 Cm  1639.911 (cc) VCyl   H  1640 (cc) If Piston Water M easure Volume is 80 cc , Total Cylinder Volume  1640  80  1720 cc  BDC Piston Water Measure Volume TI-4 2/6 ▣ Install Manual – Compression Ratio of Cylinder(1)  Calculate Combustion Room Volume Head If Compression Ratio is 16.2 : 1, 16.2 :  1720 : Vcombustion 1720 Vcombustion  16.2  106.17 TDC Cylinder Piston  106 cc  Cobustion Room Volume except Piston Water Measure Volume Vresidual  106  80  26 cc  TI-4 3/6 Piston Water measure Volume ▣ Install Manual – Compression Ratio of Cylinder(1)  Calculate Combustion Room Volume Head If Compression Ratio is 16.2 : 1, 16.2 :  1720 : Vcombustion 1720 Vcombustion  16.2  106.17 TDC Cylinder Piston  106 cc  Cobustion Room Volume except Piston Water Measure Volume Vresidual  106  80  26 cc  TI-4 3/6 Piston Water measure Volume ▣ Install Manual – Compression Ratio of Cylinder(1)  Calculate Processing Diameter using Piston Precessing Volume If the depth of Piston Water Measure Volume is h  Cm,  d   138 cc  d  9.375 Cm  d h Attention : While processing piston, keep the depth of piston water measure volume If the depth of it is adjusted, oil line gets damaged TI-4 5/6 Draw up and work on machining the piston based on the calculation you’ve done Make the all edges be round (work for preventing hot spot) Make the water chamber be finished with soft sand paper Put some oil for preventing high temperature while machining 1.8mm 69.97cc R2 14B Diesel piston 14B CNG piston 101.44mm 6.88mm R8 Affix ECU and relay near fuse box of the car  Connect the wire of key box I/G key  Make a hole on the bottom of the vehicle and place wire harness through outside  Install engine room by using the structure of the vehicle  Protect from disconnection of wire which though the engine by differences in engine vibration  Connect wire harness to cylinder head ※ Electronics should be avoided moisture, source of heat and sharpened stuff ※ Install Manual – Ground Cable Make current flow of old vehicle be smooth by connecting engine part and chassis part with ground cable [Notice!] Install the ground cable away from exhaust manifold Install it after removing rust around installation area Do not install at driver’s will Connect Engine part and Chassis part with Ground Cable like the picture Fix CPS and MAP connector  Connect regulator power switch to pressure gauge wire and solder them  Place switch indicator where driver can find easily  Fix O2 sensor connector and be aware of not contacting with exhaust manifold ※ Electronics should be avoided moisture, source of heat and sharpened stuff ※ Install Manual – Level Indicator & Switch Install level indicator & switch where it can be seen easily by driver Connect the level indicator and wires of pressure gauge as shown in the picture [Notice!] Avoid the place where malfunction can be caused by driver 24v wire should be prevented from exposing to moisture  Check the battery and wire condition of an old vehicle, and replace or cleanse them as required ※ Electronics should be avoided moisture, source of heat and sharpened stuff ※ Fix MAP sensor to intake manifold  Place WTS sensor where cooling water is always flowing  Fix coil brocket to intake manifold (Equip it by using holes)  Place O2 sensor by using the sensor nuts that is supplied O2 sensor should be assembled from top to bottom (To prevent sensor malfunction caused by moisture) Assemble in the order of filter screen and then filter  Assemble pressure gauge and regulator  Place it where it is not affected by wind and rain drop (passenger seat)  Place nipple where cooling water is constantly flowing and connect hose (PT1/2-16Φ Nipple)  Make the bulk head to prevent influx of rain fall if you need ※ Santa Cruz downtown area may have 30~50 cm pools on rainy days so place regulator carefully ※ Cut the adjust bolt structure and equip it in order to secure flow rate of the valve, however there is not any improvement We worked on moving the valve outside because fuel setting is uncomfortable  Use PT3/8-16Φ (ㄱ)Nipple, expand the bore to 11Φ  equip nipple to the valve for connecting hose  Place it where fuel controlling is convenient The volume of equipped cylinder 100L (2EA), 60L (1EA)=260L As like the picture above, place two 100L containers under the back seat and fix them on the floor by using band  Connect the valves with pipe  Place 60L container under the left side of the center  Let the pipe of the valve be in series  Place charging entrance on the rear panel  connect pipe to regulator ※ Band 2-3 times on the CNG pipes in order to minimize the impact ※ Install Manual – Set up the fuel amount – Before starting the engine - Inspect gas leakage - Check engine oil and coolant - Set up TPS Output Voltage as a minimum of 0.7~0.8V - Open Fuel Adjustment Bolt(MAS 2way, 3way) in the right amount - Open the valve by over 1/3 of its total stroke(16mm) - Exchange Air Filter with new one (If the vehicle has dual filters, exchange all of them!) - After starting the engine, keep the engine idling until the temperature of coolant of the engine rises up by 60~80℃ - Inspect leakage of intake manifold - Connect KSCAN-1000 – Set up the fuel amount at the medium and high speed Open throttle valve slowly Maintain the engine RPM by 1,800~2,500rpm, which generates maximum output (Refer to specification of the engine.) While paying attention to the RPM data of SCANNER, open slowly fuel adjustment bolts (MAS 2way, 3way) at the same time When the RPM arrives at the highest, it means the fuel amount is adequate – Adjust Idle RPM - Adjust Idle RPM by changing TPS angles to meet the Target Idle RPM(600~700rpm) (Normal TPS signal voltage varies depending on engine displacement, but mostly it should be 0.5~0.8V.) – Adjust Idle AFR(Air & Fuel Ratio) - If the state of idling is unstable or rpm is too high, change TPS angles and control Idle AFR NI-20 The pictures above indicate that how air filter’s efficiency can be different in the same condition of valve Picture No.1 : diesel air filter AFR 17.7:1, gasoline air filter 19.5:1, removal air filter 20.4:1 As shown, there is difference in AFR based on filter specification Gasoline air filter should be used for 14B, 3B, 13B engine because the characteristic of mixer type of fuel system is that AFR is getting stronger as the resistance of air filter is getting higher In the case of diesel engine, it spray fuel to the combustion chamber directly by using nozzle, so we tell that there is not any specific problem ※ This part is directly related to fuel efficiency, so take notice ※ On the test driving after converting, output deficiency occurred Automatic transmission slipping problem happened in rapid acceleration situation The problem is solved after replacing clutch set ※ This part is directly related to fuel efficiency, so take notice ※ Thank you ... optimal installation, based on our know-how for conversion into CNG engine If installation job is followed by our recommendation, durability of engine and other parts can be extended However, installation. .. health during installation job Be careful of safety accidents all the time 2) Vehicles are very sensitive to heat, vibration, moisture, and etc more than general machines 3) This install manual recommends... Information- Generator 24v / 30A (assumption) Battery Capacity 65AH(2EA) CCA700A(assumption) This Install Manual is contributed to workers in order for them to understand rules and directions of converting