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Kontax KS90, Assembly Instructions Manual

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Kontax KS90 Assembly Instructions Manual Download Page 58

If your engine stops suddenly after a 
few revolutions the main axle ball-race 
bearings might need cleaning.  
 
Disassemble your engine (by following 
the assembly instructions backwards) 
until you gain access to the bearings. 
Remove them and rinse in Methylated 
spirit or Denatured alcohol. Then either 
blow dry with compressed air or allow 
to dry naturally on an absorbent cloth 
or paper towel.  
 
Follow the assembly instructions to 
reassemble your engine. 
 

Summary of Contents for KS90

Page 1: ...es KS90 instructions This document covers the following Tools required Parts list Assembly instructions Operating instructions Maintenance Contact details www stirlingengine co uk Kontax btconnect com...

Page 2: ...Tools you will need to assemble your KS90 Low Temperature Stirling Engine Cross point screwdriver Flat bladed screwdriver Elastic band coffee tea mug...

Page 3: ...Bottom plate x1 Top plate x1 75mm O ring x2 Chamber wall x1 Displacer x1 Flywheel x1...

Page 4: ...Main pillar x1 Ball race bearing x2 Crank x1 Piston x1 Cylinder x1 Gland x1 Hub axle x1...

Page 5: ...ring x2 M2x6mm roundhead x2 Conrod bush x2 M2x4mm roundhead x1 M3x6mm countersunk x2 M2x6mm countersunk x7 M2x4mm countersunk x3 Gland stem x1 Chamber pillar x7 7mm O ring x1 Note Pre assembled from l...

Page 6: ...e stem between the thumb and forefinger of your left hand and roll the gland along the side of your right hand forefinger As you roll it work the gland along the whole length of the stem This will rem...

Page 7: ...Fit one 7mm O ring into the groove in the bottom of the gland...

Page 8: ...less steel plates you will need to remove the protective film from the top plate now Once you have removed the film try to handle the plate by its edges this will minimise fingerprints Solar acrylic p...

Page 9: ...ighten you might need to wrap an elastic band around it for grip Make sure that the O ring does not become pinched or fall out of its groove If you have trouble with the O ring falling out you can tur...

Page 10: ...Fit one 13mm O ring into the groove in the bottom of the cylinder...

Page 11: ...ighten you might need to wrap an elastic band around it for grip Make sure that the O ring does not become pinched or fall out of its groove If you have trouble with the O ring falling out you can tur...

Page 12: ...Align the hole in the main pillar as shown in the diagram and push the pillar into the hole in the packing tray This will hold it still and upright while you perform the next few assembly stages...

Page 13: ...Insert one 13mm O ring into the groove in the bottom of the pillar...

Page 14: ...over the main pillar with the underside of the plate facing upwards Align the two countersunk holes in the plate with the two threaded holes in the main pillar and insert two M3x6mm countersunk screws...

Page 15: ...Screw the screws in until they both lightly touch the top plate then fully tighten...

Page 16: ...Remove the partially assembled engine from the packing tray...

Page 17: ...Place the partially assembled engine over the top of a coffee mug This will hold it still so that you can use both hands to perform the next few assembly stages...

Page 18: ...rs into the seven small holes in the plate they should all be an easy fit If you have solar plates the heads of the pillars will sit below the surface if you have polished black or blue plates the hea...

Page 19: ...Position the packing tray over the partially assembled engine and align the hole in the bottom of the tray with the main pillar gland and cylinder...

Page 20: ...lower the tray down until it sits on top of the brass chamber pillars the engine plate will fit inside the first step on the inside of the tray...

Page 21: ...llars do not fall out of the top plate Remove from the mug carefully turn upside down and place back on top of the mug with the main pillar inside the mug The packing tray will hold the chamber pillar...

Page 22: ...Wipe the chamber wall with a dry cloth to remove any fingerprints Stretch one 75mm O ring over the rebate on one end...

Page 23: ...Stretch another 75mm O ring over the rebate on the other end of the chamber wall...

Page 24: ...Carefully lower the chamber wall and fitted O rings onto the upturned top plate Make sure the O rings stay seated in their rebates and that you do not dislodge any of the chamber pillars...

Page 25: ...The top face of the displacer has been marked with a coloured dot near the centre...

Page 26: ...One end of the gland stem is plain and the other has a small through it The hole end should point upwards in the next assembly stage...

Page 27: ...land stem hole end upwards into the top face of the displacer it will be a reasonably tight fit You only need to push the stem in a quarter of the way for now final positioning will be completed at a...

Page 28: ...Lower the displacer and stem into the gland It should slide freely...

Page 29: ...nless steel plates you will need to remove the protective film from the bottom plate now Once you have removed the film try to handle the plate by its edges this will minimise fingerprints Solar acryl...

Page 30: ...derside facing upwards lower the bottom plate onto the engine Align the holes in the base plate with the chamber pillars and start inserting seven M2x6mm countersunk screws Screw each screw nearly all...

Page 31: ...h pillar with thumb and finger to stop it spinning while you tighten the screws Work around the screws in the order 1 3 5 7 2 4 and 6 Tighten the screws sufficient to hold the plate in place without a...

Page 32: ...The chamber pillars are deliberately short and will not touch the bottom plate This is so that they cannot conduct heat directly between the two plates and retard engine performance...

Page 33: ...Remove the engine from the packing tray...

Page 34: ...e three holes in the flywheel and hub are spaced so that there is only one way that they will all line up together This ensures the flywheel counterweight is in the correct position Note the three hol...

Page 35: ...Screw the three screws in until they all lightly touch the flywheel then fully tighten...

Page 36: ...Fit two ball race bearings into the recesses in the top of the main pillar The bearings have a dust shield on one side and are open on the other The shielded sides should face outwards after fitting...

Page 37: ...Slide the axle through the bearings The axle should be a good fit but not tight in the bearings...

Page 38: ...Screw one M2x4mm roundhead screw into the side of the crank a couple of turns...

Page 39: ...Slide the crank onto the end of the axle The crank should be a good fit but not tight on the axle Note the screw in the side of the crank must screw onto the small flat on the end of the axle...

Page 40: ...Make sure the crank screw is square on the axle flat then fully tighten...

Page 41: ...d there should be a small amount of movement here If there is not slacken the crank screw move the crank out a fraction and tighten Make sure that when tightening the crank screw again it stays locate...

Page 42: ...Give the flywheel a sharp spin it should keep spinning for several minutes If it does not then you will need to go back and move the crank out a fraction more...

Page 43: ...and secure with one M2x6mm roundhead screw The screw only needs screwing in a couple of turns at this stage Note the hook on the bottom of the conrod should be aligned as shown in the diagram Note Pr...

Page 44: ...screw in until it just touches the bush Do not over tighten or you could cause the bush to expand and pinch the conrod eye which could prevent your engine from running Note Pre assembled from late 201...

Page 45: ...Fit the hook on the conrod through the hole in the top of the gland stem...

Page 46: ...onrod screw into the hole in the front face of the crank Tighten only sufficient to lock over tightening will cause the conrod bush to expand and pinch the conrod eye which could prevent your engine f...

Page 47: ...on This will press the stem into the displacer and set the displacer to its correct position in the chamber There is a small amount of flex in the conrod you should be able to take advantage of this a...

Page 48: ...the displacer up and down in the chamber Check that it does not touch the bottom plate If it does touch you can go back and press the top of the gland stem some more Note the chamber wall and 75mm O r...

Page 49: ...and use it to pull the stem up in the displacer a small amount Be careful not to bend the hook on the bottom of the conrod when doing this Ideally the displacer should have an even gap at the top and...

Page 50: ...and secure with one M2x6mm roundhead screw The screw only needs screwing in a couple of turns at this stage Note the hook on the bottom of the conrod should be aligned as shown in the diagram Note Pr...

Page 51: ...screw in until it just touches the bush Do not over tighten or you could cause the bush to expand and pinch the conrod eye which could prevent your engine from running Note Pre assembled from late 201...

Page 52: ...Fit the hook on the conrod through the hole in the top of the piston...

Page 53: ...Slide the piston and conrod into the cylinder Some air pressure should be felt as you slide it in...

Page 54: ...conrod screw into the hole in the front face of the hub Tighten only sufficient to lock over tightening will cause the conrod bush to expand and pinch the conrod eye which could prevent your engine fr...

Page 55: ...t of resistance will be felt on rotation due to the air pressure inside the main chamber Check the piston does not bump into the bottom of the cylinder and re check the displacer does not bump into ei...

Page 56: ...been designed to run on hand heat but will run equally as well from a wide variety of heat sources including Digital TV box adsl modem table lamp hot water tea or coffee warm sunlight The engine will...

Page 57: ...NOT place it on any high temperature heat source cooker wood burning stove candle etc This will melt a number of parts on the engine If you wish to operate your engine on hot coffee or tea you must a...

Page 58: ...r engine by following the assembly instructions backwards until you gain access to the bearings Remove them and rinse in Methylated spirit or Denatured alcohol Then either blow dry with compressed air...

Page 59: ...of the cylinder Wipe the piston with a paper towel and clean the inside of the cylinder with a rolled up paper towel or cotton bud Make sure there are no stray fibres on the piston or in the cylinder...

Page 60: ...slower than usual you might need to clean the gland stem Rotate the flywheel until the displacer stem is at its highest point and wipe the stem with a cloth Make sure there are no stray fibres from yo...

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