KEM GMG-857 Generator Set

⚠ To be performed by qualified personnel only.

1. Check GAIN and STABILITY controls, and external SPEED TRIM control, are set to mid-position.
2. Crank the engine with D.C. battery power applied to the governor system.
3. If engine is unstable after starting, turn GAIN and STABILITY counterclockwise until stable.
4. Rotate the GAIN adjustment clockwise until instability develops, then counterclockwise until stability returns, then 1/8 turn counterclockwise.
5. Rotate the STABILITY adjustment clockwise until instability develops, then counterclockwise until stability returns, then 1/8 turn counterclockwise.
6. Adjust dead time compensation using posts E1, E2, E3 as required.

⚠ Connecting the initial timing connector to B+ before starting may damage the ignition control module (ICM).

Tools: timing light with inductive pick-up

1. Do not use a timing light that requires piercing of the secondary insulation; use inductive pick-up or jumper type.
2. Install timing light at #1 spark plug lead per manufacturer's instructions.
3. Do not connect the alligator clip of the initial timing connector to a B+ source until after the engine is started.
4. Start the engine and warm to operating temperature.
5. Connect alligator clip on long lead of the initial timing connector to a convenient B+ source to remove all advance.
6. Loosen distributor clamp screw just enough to rotate distributor and set base timing to specification.
7. Secure distributor with clamp screw and tighten clamp screw to torque specified.
8. Recheck timing and disconnect the initial timing connector from B+ source.
9. Label the initial timing connector by folding the adhesive label over one of the wires.

⚠ Only in rare instances should the sensitivity adjustment be changed.

1. Remove the plug covering the sensitivity adjusting screw by drilling a 1/8 diameter hole and prying it out.
2. If engine is too sensitive, turn the SENSITIVITY SCREW 1/4 turn clockwise and readjust the MAIN ADJUSTMENT.
3. End each adjustment with a clockwise turn of the screw; repeat as needed.
4. If engine speed drops excessively when loaded, turn SENSITIVITY SCREW 1/2 turn counter-clockwise, then 1/4 turn clockwise.
5. Readjust MAIN ADJUSTMENT and repeat as needed.
6. Seal the adjusting screws using HOOF SEAL KIT 200-940 or force silicone sealer into the cavity.

⚠ The actuator must be rigidly mounted as close as possible to the engine throttle lever.

1. Drill the actuator mounting holes in a pre-fabricated mounting bracket.
2. Affix the actuator bracket to the selected location on the engine.
3. Attach the actuator securely to the mounting bracket.
4. Adjust and secure the linkage rod and rod end bearings.
5. Fabricate a cable harness to connect the speed control unit to the actuator.
6. Connect A and D of the military connector or the 2 pin connector harness to the speed control unit.
7. Push the actuator lever to the maximum full fuel position and verify smooth return to minimum fuel.

⚠ Do not attempt to measure gas pressure with a mercury manometer.

Tools: water manometer

1. Measure gas inlet pressures at idle and full load with a water manometer.
2. Remove the air valve cover and lift out the spring and air-gas valve with diaphragm.
3. Inspect diaphragm for holes, charring or stiffness.
4. Check inside diameter of the air valve cup and fins of the gas jet for wear.
5. Inspect the inside diameter of the gas jet and O.D. of the small tapered gas valve for wear.
6. Wash all parts thoroughly in kerosene or equivalent (water and detergent for digester gas).
7. Reassemble cleaned or replaced parts in the bowl, centering the spring on the air valve.
8. Replace and fasten the cover; lift valve several times to assure free travel.

⚠ If left loose, dust will be drawn in and the air cleaner will fail to function properly.

1. Remove the dust cup and withdraw the element.
2. On double element type, do not remove the inner element when cleaning the outer element.
3. Remove inner element only when the outer element is replaced; replace both at the same time.
4. Clean the inside of the case and dust cup before installation.
5. Slowly insert the element; if horizontal, install dust cup with direction mark face upward.
6. Ensure element and dust cup are securely installed.

⚠ The element cannot be washed and reused.

⚠ Wipe away spilt fuel as it could start a fire.

1. Remove the element, using care not to spill fuel.
2. Install the new element.
3. Bleed the fuel system and check for fuel leaks.

⚠ The element cannot be washed and reused.

Tools: filter wrench

1. Remove the element by turning counterclockwise; use a filter wrench if hard to loosen.
2. Apply a thin coat of engine oil to the packing of the new element.
3. Tighten the element fully with a filter wrench.
4. If only the element was replaced, replenish oil to proper level.
5. Wipe away spilt oil, start the engine and check for leaks from the packing.

⚠ Use soft water; well or river water may cause scaling or rusting.

1. Open the radiator cap and drain cocks of engine crankcase and radiator to remove coolant.
2. Close drain cocks, pour coolant into radiator, run engine until coolant is heated to about 80°C.
3. If considerable scale or rust, pour in cleaning solution and heat to about 80°C.
4. Continue to idle the engine for about 30 minutes.
5. Stop engine, open drain cocks and drain coolant completely.
6. Close cocks, pour in coolant and rinse until dirty water no longer runs out.
7. Fill until coolant flows out from the overflow pipe.
8. Run engine, stop, check and replenish coolant level.

⚠ A badly contaminated or deteriorated oil should be replaced regardless of the replacement intervals.

1. After shutdown, remove the oil while it is still hot; replace the oil filter at the same time.
2. Install the drain plug and pour in fresh engine oil up to the FULL mark on the level gauge.
3. After running the engine at idle for several minutes, recheck the oil level.