WORKSHOP MANUAL KD 425-2
Contents
1. 39 Checking NE 39 Des NTN re 39 BOLUM ao EEE EE EE E EETA 40 AN STORAGE 41 cis REE E EEA EEA ETIE E T VEE 41 How to prepare the engine for ODGFaLtlOFi u sicuro a auo pa no dura or xao iu xa corn nuo des cU esses d kae ex 41 QUICK REFERENCE CHARTS Lune 42 Von MRTRHH 42 FEN AM Ende 42 HOME UR Tm 43 Standard screw tightening tOrgUOS ee 43 KD 425 2 Workshop Manual cod ED0053029360_1 ed rev 00 5 INDEX KOHLER KD 425 2 Workshop Manual cod ED0053029360 1 ed rev 00 KOHLER TROUBLE SHOOTING POSSIBLE CAUSES AND TROUBLE SHOOTING The following table contains the possible causes of some failures which may occur during operation Always perform these sim ple checks before removing or replacing any part TROUBLE POSSIBLE CAUSE Non uniform speed Oil and fuel dripping Engine starts but from exhaust Q gt 8 I O P D und No acceleration Too low oil pressure Excessive oil consumption Clogged air filter Excessive idle operation Incomplete running in Engine overloaded Advanced injection Delayed injection Incorrect governor linkage adjustment Broken or loose governor spring Idle spe2. Description fig 50 51 Cables color fig 50 51 Ignition key optional M Brown Voltage regulator Black Engine starter White Battery not included Green Alternator Red Pressure switch Battery recharge warning light optional Oil pressure warning light optional Checking electrical equipment 1 Make sure that the connections between the voltage regulator and alternator are correctly made and in good condition 2 Disconnect the starter motor wire from the battery terminal and connect a dc ammeter fig 50 and 51 3 Connect a dc voltmeter to the battery terminals fig 50 and 51 4 Turn over the engine a few times without load or connect an 80 100W lamp load across the battery to restrict voltage to lower than 13V 5 Accelerate the engine to 3000 rpm The current shown by the ammeter must be in line with the values indicated in figure 52 6 Disconnect the load from the battery if it was previously connec ted and keep the engine running at the above indicated speed for a few minutes the battery voltage should slowly increase until it reaches approximately 14 2V At the same time the charge cur rent should drop to around 2A in a period of time that depends on the whether the battery is fully charged or not 7 If the charging current is absent is lower than
3. EEE EEE EEE 16 IX DISASSEMBLY OF THE ENGINE spaden 17 s UO EEE OQ 17 Removing Me EEE EE EE NE 17 Extraction of flywheel side main 17 Extraction of crankshaft GOO ARR PER ORRR m 17 Extraction of the camshaft RENEE 18 Extracting crankcase DENE M E H 18 Extracting the oil pressure indicator plug Lasse kerk ME RS zu 18 As GHECKS AND HR 19 DE TEN 19 E n T 19 Ste 10 c Re 21 KO EE RE NE RE 21 e I are SS 21 Piston rings Pistons Piston UNS RE EE TT 22 EEE 22 See EEE 23 Che king crankshaft Rc NNMERO 25 ENE 24 Ga EEE EEE ENE EEE 24 Tappets and push 005 PERPE PRERERRERC E 25 4 KD 425 2 Workshop Manual cod ED0053029360 1 ed rev 00 KOHLER Injection pump plug nuts control ped 25 FEN 25 NN 25 Governor lever Spring EE
4. XIII ENGINE ASSEMBLY KOHLER Checking injector protrusion Before mounting the heads to the cylinders fit the injectors into their housings and after having secured them temporarily check the protrusion of the nozzles from the head faces fig 77 Protrusion S should be 1 75 2 25 mm This value is adjusted by inserting copper washers between the injec tors and the injector supporting faces on the heads fig 77 Cylinder heads For checking and overhaul of the cylinder heads refer to page 19 Fit the push rods and oil sealing O rings on the cover pipes and pro ceed to install the cylinder heads with the relative gaskets on the fa cing surfaces Make sure that the oil seal rings are correctly seated in the heads to avoid the risk of oil leaks Align the heads using a metal bar or the exhaust manifold fig 78 Following a cross pattern tighten the head nuts fig 78 in increments of 1 kgm until you reach the value 4 kgm Nm 39 2 Valve clearance The clearance between valves and rockers with the engine cold fig 79 is 0 15 mm intake exhaust This clearance is to be adjusted with the pistons at their respective TDC compression positions Injection pumps 1 Insert the injection pump tappet D and spacer C into the hou sings in the crankcase fig 80 2 Assemble the injection pumps A fig 80 on the crankcase and secure them on the adjustment sleeve by means of the appro pri
5. KOHLER INDEX WARRANTY NG 3 Limited 3 year Kohler es diesel ENGINE NATTEN aa sy E a aaa 3 California emission control warranty uo Haee e uota Lain d ente som Ve CoU Gea Hb ad Pea rH RUE GU 3 Your warranty rights and obligations EE EE 3 TROUBLE SHOOTING Calc ufa T Possible causes and trouble shooting Lavvo andres Cu MEUM VUE Ride T SAFETY AND WARNING DECALS SAFETY 8 NNN E E O AE E A E AS 8 General safety during operating phases 2 2 9 Safety and environmental impact 2 9 MODEL NUMBER AND IDENTIFICATION 10 The identification plate shown in the figure can be found directly the 10 FP AMG erem 10 IV TECHNICAL DAE EAEAN 11 HEST 12 Characteristics power torque and specific fuel consumption 12 VES OVERALL DIMENSIONS 13 VI due Is sl 14 VIII MAINTENANCE RECOMMENDED OIL TYPE REFILLING 15 JE LGT IE REE EE EE NN 15 Fe 15 Recommended Ol ERR EE 16
6. MIL L 46152C B3 96 E1 96 E2 96 E3 96 VW 505 00 VOLVO VDS MAN QC 13 017 16 KD 425 2 Workshop Manual cod ED0053029360 1 rev 00 KOHLER DISASSEMBLY OF THE ENGINE IX During repair operations when using compressed air wear eye protection P D av AW ON Ki 222 7 i E Extracting fuel injectors Unscrew the fuel feeding pipes Removing the flywheel Use the extractor number 00365R0020 as shown in figure 2 injure the operator During the demounting phases pay particular attention to prevent the flywheel from dropping as this could seriously Wear protective goggles when removing the flywheel ring i IMPORTANT Do not tap the end of the extractor when re n moving the flywheel Extraction of flywheel side main bearing Withdraw the bearing using two M8 screws taking care to tighten them evenly alternatively use a commercial extractor as shown in fi gure 3 Extraction of crankshaft gear Use extractor tool number 00365R0890 fig 4 KD 425 2 Workshop Manual cod ED0053029360 1 ed rev 00 217 IX DISASSEMBLY OF THE ENGINE KOHLER Extraction of the camshaft gear Use the extractor number 00365R0010 fig 5 Extracting crankcase bushes From crankcase fig 6 From main bearing fig 7 Use extractor number 00365R0900 Extracting the o
7. Endgapofoiscraperrngs 025 050 08 0 07 0 041 Oil pump rotor and housing QOz7 047 06 Adjustments MIN mm MAX mm Crankshaft end float 0 10 0 20 0 2 Rocker arm end float 0 05 0 130 0 5 Valve depth from cylinder head 0 8 1 0 Injector protrusion 1 75 2 25 2 25 Piston protrusion 0 10 0 20 42 KD 425 2 Workshop Manual cod ED0053029360 1 ed rev 00 KOHLER QUICK REFERENCE CHARTS XVI Ni 3 5 22 es 22 es 082 R10 10 9 12 12 9 C M R 2 1000 N mm R 2 1200 N mm Diameter x pitch mm Nm kgm 3 Denomination 7 22 x 2 50 435 44 40 611 62 40 3 74 90 24 x 3 00 557 56 90 784 80 00 9 96 00 28 47 4 40 KD 425 2 Workshop Manual cod ED0053029360 1 ed rev 00 43 Translated from the original manual in Italian language Data reported in this issue can be modified at any time by KOHLER KOHLER FOR SALES AND SERVICE INFORMATION IN U S AND CANADA CALL 1 800 544 2444 KohlerEngines com ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 REVISED 00 DATE 04 07 2012
8. ds fig 45 check that no air bubbles are released N B Tightness can be checked by compressing the springs to 52 8 54 4 mm which corresponds to the bottom dead centre wor king position of the pump 26 KD 425 2 Workshop Manual cod ED0053029360 1 ed rev 00 KOHLER INJECTION EQUIPMENT XI Injectors Details of fig 46 1 Injector casing 2 Adjusting shim 3 Spring 4 Rod 5 Distance ring with locating pin 6 Nozzle 7 Ring nut Checking and setting the injectors 1 Clean the nozzle holes with 0 25mm gauge steel wire fig 47 2 Place the injector on the test bench p n 00365R0430 fig 48 bypass the pressure gauge and operate the lever rapidly The nozzle should chatter audibly and spray correctly 3 Connect the pressure gauge while pressing the lever slowly and steadily until injection occurs The opening pressure registered on the gauge should be 230 Kg cm 200 Kg cm on silenced versions Change the adjusting shims nr 2 fig 46 in order to achieve correct adjustment 4 Testing fortightness Operate test bench hand lever until the pressure gauge reads 20 Kg cm below the opening pressure of the needle valve The nozzle can be considered well sealed if there no Diesel fuel accumulates at the nozzle tip after 10 secon ds Disassembly and re assembly of injectors Unscrew the ring nut on the injector nozzle using a ring wrench and a special tool as illustrated in fi
9. Also included may be hoses connectors and other emission related assemblies Where a warrantable condition exists Kohler Co will repair your heavy duty off road engine at no cost to you including diagnosis parts and labor MANUFACTURER S WARRANTY COVERAGE Your off road diesel engine emission control system is covered under warranty for a period of five 5 years or 3 000 hours whichever occurs first beginning on the date the engine or equipment is delivered to an ultimate purchaser for all constant speed engines with maximum power 19XkW 37 and rated speed less than 3 000 rpm all variable speed engines with maximum power 19SkW lt 37 and all variable or constant speed engines with maximum power greater than 37 kW Your off road diesel engine emission control system on variable or constant speed engines with maximum power less than 19 kW and for constant speed engines with maximum power 19xkW 37 and rated speed equal to or greater than 3 000 rpm is covered under warranty for a period of two 2 years or 1 500 hours whichever occurs first If any emission related part on your engine is defective the part will be repaired or replaced by Kohler Co OWNER S WARRANTY RESPONSIBILITIES As the heavy duty off road engine owner you are responsible for the performance of the required maintenance listed in your Kohler Co owner s manual Kohler Co recommends that you retain all receipts covering maintenance on your heavy duty off road engine but
10. Information presented within this manual assumes the following T 2 The person or people performing service work on KOHLER series engines is properly trained and equipped to safely and professionally perform the subject operation The person or people performing service work on KOHLER series engines possesses adequate hand and KOHLER special tools to safely and professionally perform the subject service operation The person or people performing service work on KOHLER series engines has read the pertinent information regarding the subject service operations and fully understands the operation at hand This manual was written by the manufacturer to provide technical and operating information to authorised KOHLER after sales service centres to carry out assembly disassembly overhauling replacement and tuning operations As well as employing good operating techniques and observing the right timing for operations operators must read the information very carefully and comply with it scrupulously Time spent reading this information will help to prevent health and safety risks and financial damage Written information is accompanied by illustrations in order to facilitate your understanding of every step of the operating phases 2 KD 425 2 Workshop Manual_cod ED0053029360_1 ed_ rev 00 KOHLER WARRANTY CERTIFICATE LIMITED 3 YEAR KOHLER DIESEL ENGINE WARRANTY Kohler Co warrants to the original retail consu
11. Renew both guide and valve if the clearance is greater than 0 1mm It is always necessary to grind the valve seats when new guides are fitted Oversize valve guides with external diameter increased by 0 10 are available KD 425 2 Workshop Manual cod ED0053029360 1 ed rev 00 19 CHECKS AND OVERHAUL KOHLER After prolonged running of the engine the hammering of the valves on their seats at high temperature tends to harden the faces of the se ats and makes manual grinding difficult It is necessary to remove the hardened surface with 45 cutter fig 12 Grinding of valve seats causes widening of the valve seat face P fig 13 Final lapping of the valve on the seat must be carried out by coating the seat with fine lapping compound and rotating the valve in clockwise and counterclockwise direction with slight pressure until perfect surface finish is obtained fig 14 Observe the valve seating clearances indicated in the following table fig 10 d 0 8 1 0 d 1 3 In the case of values in excess of 1 3 mm the valve seat In the case of lower values the valve may strike the piston 1 rings must be replaced Fitting of new seats or valves always requires preparatory grinding Valves are available with the external diameter increased by 0 5 mm After grinding wash the valve and seat carefully with petrol or paraffin in order to remove residual grinding paste and chip
12. avoid changing the crankshaft end float also ensure that the grinding wheel radii are as specified in figure 28 so as not to create crack initiation sections on the crankshaft 117 99 118 01 Oil seal rings Check that the rings have not hardened around the internal contact edge and that they show no signs of cracks or wear Camshaft Check the cams and bearing journals for scoring and wear Measure the dimensions and compare them to the values in the table below and shown if figures 30 31 inlet exhaust injection feeding pump Camshaft dimensions fig 30 Fuel pump 25 50 25 70 Assembly clearance between the journals and their housings should be fig 31 13 960 13 975 42 95 42 96 24 KD 425 2 Workshop Manual cod ED0053029360 1 rev 00 Renew the camshaft if the cams or journals show wear in excess of 0 1mm KOHLER CHECKS AND OVERHAUL X Tappets and push rods Make sure that the tappet surfaces fig 32 are free from wear and present no signs of scoring or seizure otherwise renew Assembly clearance between tappets and their housings should be 0 07 0 041 0 10 The push rods must be straight and with the spherical surfaces at ei ther end in good condition fig 32 Make sure that the lubrication holes inside the tappets and push rods are free of dirt 11 977 11 993 Injection pump plug nuts and control
13. 17 34 mm 20 40mm 12 24 mm KD 425 2 Workshop Manual cod ED0053029360 1 ed rev 00 37 XIII ENGINE ASSEMBLY KOHLER Connect the injectors to the pumps by way of the injection lines lt De s Injectors and injector pipes 5 Mount injectors to heads placing copper gaskets in between see rs pag 36 ES me is 2 QU LD Important always use two wrenches to loosen or tighten NAS H the unions on the injector pipes fig 86 thereby ensuring that the position of the delivery valve holder on the pumps is not changed see pag 27 Oil filter Fit the mesh type oil filter cartridge into the crankcase fig 87 and check that the rubber seals and the O ring on the cover are in good condition On request or KD 425 2 engines can mount an external filter cartrid ge that can be screwed onto the crankcase fig 88 Oil the seal befo re assembly i gt gt F FI lt Feed pump 1 Insert the fuel feed pump tappet into its housing and make sure that it moves freely 2 Fit the 0 2 and 1mm adjustment gaskets 3 With the fuel pump excenter in rest position the tappet should protrude from the gasket surface fig 89 by 1 3 1 7 mm 4 With the fuel feed pump cam in the rest position mount the pump and actuate it manually Electric shut off If the engine is equipped with an electric shut off inse
14. Kohler Co cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all recommended scheduled maintenance As the heavy duty off road engine owner you should however be aware that Kohler Co may deny you warranty coverage if your heavy duty off road engine or emission control related component has failed due to abuse neglect improper maintenance or unapproved modifications Your engine is designed to operate on commercial diesel fuel No 1 or No 2 low sulfur or ultra low sulfur diesel fuel only Use of any other fuel may result in your engine no longer operating in compliance with California s emissions requirements You are responsible for initiating the warranty process The Air Resources Board suggests that you present your heavy duty off road engine to a Kohler Co dealer as soon as a problem exists The warranty repairs should be completed by the dealer as expeditiously as possible Please review the document titled Kohler Co Federal and California Emission Control Systems Limited Warranty Off Road Diesel Engines for complete details of your heavy duty off road engine warranty If you have any questions regarding your warranty rights and responsibilities or the location of the nearest Kohler Co authorized service location you should contact Kohler Co at 1 800 544 2444 or access our website at www kohlerengines com KD 425 2 Workshop Manual cod ED0053029360 1 ed rev 00 3
15. be turned to face the injector nozzle side Mount the connecting rod big end cap ensuring that the reference numbers are aligned with those punched on the connecting rod itself fig 74 Torque the bolts to 3 6 3 8 Nm 35 3 37 3 Now fit the oil pan after first inserting the appropriate gasket between the facing surfaces Cylinders Before fitting the cylinders turn the piston rings so that the end gaps are arranged at intervals of 120 with the end gap of the first com pression ring aligned with the axis of the wrist pin The lower face of the cylinders are chamfered to permit the easy insertion of the piston rings The operation can be simplified however using a normal pi ston ring compressor p n 00365R0770 as shown in figure 75 Mount the cylinders to the crankcase as shown in figure 76 and then bring the pistons up to their respective TDC top dead centre posi tions The following must now be checked 1 that the dots punched on the flywheel TDC correspond to the reference mark on the flywheel housing 2 that the pistons protrude over the top surface of the cylinders fig 76 by a distance of 0 10 0 20 mm This distance is adjusted with special shims that are inserted between the bottom surface of the cylinder and the crankcase O 1 0 2 0 3 mm lt lt lt AN UA 7 a TE LY KD 425 2 Workshop Manual cod ED0053029360 1 ed rev 00 35
16. must be changed During the test the reading on the gauge will show a progressive pressure increase to a maximum value and then will fall suddenly and stop at a lower pressure Replace the valve if the fall in pressure ex ceeds 50 Kg cm and continues to fall slowly The pressure drop from 200 Kg cm to 150 Kg cm must occur in a time interval of no less than 7 seconds Injection pump setting fig 41 Set the maximum quantity delivered by the pump by turning the ec centric pin using a screwdriver nr 16 fig 39 With the control sleeve at 10mm from the stop position and the pump running at 1 500 rpm the quantity of fuel for 1 000 shots must be between 23 25 06 20 22 cc BOSCH KD 425 2 Workshop Manual cod ED0053029360 1 ed rev 00 27 XI INJECTION EQUIPMENT KOHLER The difference between the deliveries of the two pumps when locked must exceed 0 5 cc Also check 1 That the distance between the injection cams in the rest position bottom dead centre and the pump supporting face is between 52 8 and 54 4 mm as shown on the data plate 2 That the stroke of the piston with injection cams in the rest po sition bottom dead centre to the start of delivery is between 2 and 2 1 mm Assembly of injection pumps If it proves necessary to disassemble the injection pumps they must be reassembled following the instructions listed below 1 Insert barrel into pump casing with t
17. perform the following 1 Check the oil level fig 95 2 Start the engine and let it idle 3 Check the oil pressure on the pressure gauge fig 92 4 Run in engine before testing it at full power KD 425 2 Workshop Manual cod ED0053029360 1 ed rev 00 39 XIV ENGINE TESTING KOHLER Running in table Time rity rem icd 3000 3600 3000 3600 30 3000 3600 50 3000 3600 70 3000 3600 100 Engine power curves are reported at page 12 In order to check that the setting is correct without tools accelerate the engine few times with no load and check the exhaust fumes Delivery of diesel fuel is correctly calibrated when the exhaust gas is slightly coloured by smoke change the adjustment if necessary by turning the adjustment screw fig 96 40 KD 425 2 Workshop Manual cod ED0053029360 1 ed rev 00 KOHLER STORAGE XV Prepare engines as follows for storage over 3 months Storage Let engine run at idling speed in no load conditions for 15 minutes Fill crankcase with protection oil MIL 1 644 P9 and let engine run at 3 4 full speed for 5 10 minutes When engine is warm empty oil pan and fill with standard new oil fig 97 e Remove fuel tube and empty the tank e Remove fuel filter replace cartridge if dirty and refit fig 98 e Carefully clean cylinder fins heads and fan e Seal all openings with
18. tape e Remove injectors pour a spoonful of oil type SAE 30 into the cylinders and rotate manualy to distribute the oil Refit injectors Spray oil type SAE 10W into exhaust and intake manifolds rocker arms valves tappet etc Grease all unpainted parts Loosen belt e Wrap the engine in a plastic film e Store in a dry place if possible not directly on the soil and far from high voltage electric lines For the lubrication and injection system as well as for moving VS parts use rustproof type MIL L 21260 P10 grade 2 SAE 30 W ESSO RUST 623 AGIP RUSTIA SAE 30 Let the SX engine run with rustproof oil and drain any excess F e Coat external unpainted surfaces with antirust type MIL C v 17 161730 grade 3 Ex ESSO RUST 398 RUSTIA y gt 100 F 3 How to the engine for operation Clean engine outside e Remove protections and covers e Remove antirust with an appropriate solvent or degreaser e Remove injector fill with standard oil turn crankshaft by a few revolutions remove oil pan and drain the protective oil KD 425 2 Workshop Manual_cod ED0053029360_1 ed_ rev 00 41 XVI QUICK REFERENCE CHARTS KOHLER Spiel mm Camshaft and central bearings aluminium crankcase 0 070 0 105 Camshaft and central bearings cast iron crankcase 0 040 0 075 End gap of compression rings 030 050 08
19. 2nd Compression B 0 18 3rd Oil scrapper C 0 16 E Piston rings must always be renewed after dismantling the piston Piston diameter check The diameter of the piston must be measured at approximately 18 mm from the base fig 22 Check the clearance between cylinder and piston if it is greater than 0 120 mm both cylinder and piston must be replaced Assembly clea rance between piston pin and piston in millimetres 0 003 0 013 0 050 Connecting rods The connection between the connecting rod small end and the wri st pin is without a bushing Assembly clearance between connecting rod small end and piston pin in millimetres Piston pin Assy mm mm 21 997 22 002 0 023 0 038 0 070 Checking parallelism between the two axes of the connecting rod fig 23 1 Fit the wrist pin in the hole in the small end of the connecting rod and fit a calibrated pin into the big end with bush fitted 22 KD 425 2 Workshop Manual cod ED0053029360 1 ed rev 00 KOHLER CHECKS AND OVERHAUL X 2 Position the calibrated pin on two prisms arranged check surface 3 Use a dial gauge to check that the discrepancy between readings at the ends of the calibrated pin is no more than 0 05 mm should deformation exceed this value max 0 10mm the connecting rod must be straightened This operation is performed by placing the connecting rod on p
20. 65 WARNING Engine exhaust from chemicals known to the State of California to cause cancer birth defects or other reproductive harm this product contains KD 425 2 Workshop Manual cod ED0053029360 1 ed rev 00 MODEL NUMBER AND IDENTIFICATION KOHLER The identification plate shown in the figure can be found directly on the engine It contains the following information A Manufacturer s identity B Engine type C Engine serial number D Maximum operating speed E Number of the customer version form K F Approval data Approval data The approval reference directives EC are on the engine plate F MADE IN ITALY KOHLER B Model mm AXXX D C sin XX XX XXXX Spec E eg OF B8 CE ox XXX 10 KD 425 2 Workshop Manual cod ED0053029360 1 ed rev 00 KOHLER TECHNICAL DATA IV CHARACTERISTICS 2 Number of cylinders Bore 85 Stroke 9 Swept volume 851 Compression ratio 19 1 Power kW HP NB ISO 3046 1 IFN 80 1269 CEE ISO 1585 3000 RPM 12 5 17 3600 RPM 3000 RPM 11 4 15 5 3600 RPM 13 17 7 NA ISO 3046 1 ICXN 3000 RPM 10 5 14 3 3600 RPM 12 16 5 Max torque Nm 40 5 2400 Fuel consumption g kW h 246 Oil consump
21. BILITY OR FITNESS FORA PARTICULAR PURPOSE ARE EXPRESSLY LIMITED TO THE DURATION OF THIS WRITTEN WARRANT Y We make no other express warranty nor is any one authorized to make any on our behalf Some states do not allow limitations on how long an implied warranty lasts or the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state To obtain warranty service Purchaser must bring the engine to an authorized Kohler service facility To locate the nearest facility visit our website www kohlerengines com and use the locator function consult your Yellow Pages or telephone 1 800 544 2444 ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board and Kohler Co are pleased to explain the emission control system warranty on your 2012 engine In California new heavy duty off road engines must be designed built and equipped to meet the State s stringent anti smog standards Kohler Co must warrant the emission control system on your engine for the time period listed below provided there has been no abuse neglect or improper maintenance of your engine Your emission control system may include parts such as the fuel injection system and the air induction system
22. E EE EE 26 As INJEC TON EQUIPMENT x m 27 Fen 27 NN 27 Gy Gea see WEE E 27 HET Ne 27 FEN 27 TESTING a EE OE EE 28 TR IIR EE SR NE EE 29 Checking and setting the injectors ETE DONI 29 Disassembly and re assembly of 29 AIl ELECTRICAL EQUIPMENT Lur 30 Plant specifications 30 Checking electrical equipment REDE 30 TENNENE 30 FA ENGINE ASSEMBLY en 31 Preparing EL ENE 31 00718101839 22 0 EEE ETER ER 31 SEILE pe EEE 32 Main dere 106 SpA gt EEE EE EEE 32 Sec 32 EE NE RE ENE ENE NE 33 Governor ue NNN 33 MN 34 dE ag OOM EEE EE EE NE 34 P ley and TIS see 34 PN 35 T m 35 UNE nr 35 Te NL 36 Gale EE QM 36 ENKE Tm 36 Injection PUMPS EEE ENE EE EE 36 SCHON COCK EEE Et 37 injectors NTN TEENS 38 SE EEE 38 FEN eden 38 BG Ss E TTE TM 38 AY ENGINE TESTING AEE SEE MAE DEREN NIHU EN ENSURE NN 39 NNN 39 Checking oil pressure
23. WORKSHOP MANUAL KOHLER KOHLER ENGINES REGISTRATION OF MODIFICATIONS TO THE DOCUMENT Any modifications to this document must be registered by the drafting body by completing the following table Drafting Document Model body code A n PU ED0053029360 51264 0 04 07 2012 04 07 2012 MO bx Review Revision Issue date iens Endorsed KD 425 2 PREFACE Every attempt has been made to present within this service manual accurate and up to date technical information However development on the KOHLER series is continuous Therefore the information within this manual is subject to change without notice and without obligation The materials used by KOHLER to construct the engine s components undergo strict quality controls and the engine s assembly guarantees reliability and long life The engine has been built to the machine manufacturer s specifications and it was its responsibility to adopt all the measures needed to meet the essential health and safety requirements as provided for by the laws in force use of the engine for uses other than the one defined shall not be considered as compliant with the use intended by KOHLER who therefore refuses all responsibility for any injury arising from such an operation The information contained within this service manual is the sole property of KOHLER As such no reproduction or replication in whole or part is allowed without the express written permission of KOHLER
24. arallel surface and applying slight pressure mid way along the convex side of the stem fig 24 Crankshaft Whenever the engine is dismantled particularly for the replacement of cylinders and pistons due to wear caused by the aspiration of dust itis good practice to check the condition of the crankshaft 1 Remove the plugs A from the oil passages fig 25 2 Use an appropriately shaped steel punch to clean the inside of the oil passages and the collection traps If the deposits are parti cularly resistant immerse the whole crankshaft in petrol or paraf fin before proceeding with the operations 3 When the oil passages and traps have been throughly cleaned close the openings with new plugs fig 26 Checking crankshaft dimensions Once the crankshaft has been thoroughly cleaned use a micrometer to check the wear and ovality of the main journals and crank journals across two sections at right angles to each other fig 27 If wear exceeds 0 08 mm fig 28 grind the crankshaft to the dimen sions shown in the table 39 904 39 744 39 94 39244 40 010 39760 39 510 39260 Undersize bearing bushes are already available at the necessary si zes without requiring any adjustment by boring KD 425 2 Workshop Manual cod ED0053029360 1 ed rev 00 2429 X CHECKS AND OVERHAUL KOHLER During grinding take care not to remove the shim adjustment material from the main journal thrust face to
25. ate pins E or H fig 80 on PF30 BOSCH pumps Then place the advance adjustment shims B fig 80 between the crankca se and the pump 3 Fix the injection pump connection rod A fig 81 to the speed go vernor lever tie rod B fig 81 4 Secure the injection pumps to the crankcase taking care to turn the first injection pump around through approximately 3 4 of a turn in a clockwise direction 36 KD 425 2 Workshop Manual cod ED0053029360 1 ed rev 00 KOHLER ENGINE ASSEMBLY XIII 5 Release the control sleeves on the traditional pumps by loosening the pins E fig 80 and inserting the appropriate distance collars F fig 80 on the BOSCH type PF30 pumps by removing the pins H fig 80 and closing the hole on the pump body using plug G Important injection pumps should be released only after they have been connected to the governor tie and secured to the crankcase If one or both pumps must be L5 m 2 changed in order to guarantee the same fuel delivery for E E each pump the pump remaining on the crankcase must TVG be locked using the pins E or H fig 80 Alternatively the rif mr above steps must be performed in their entirety 81 1 Injection check 1 Connect the fuel tank to the injection pumps 2 Set the speed control lever to Max fig 83 and the piston to the start of compression cylinder nr 1 on timing gear side 3 To eliminate the inj
26. ay place at risk his own health and safety and that of anyone else in the vicinity of the machine The engine may be used or mounted on a machine only by personnel suitably trained in its operation and aware of the dangers involved This is particularly true for standard and above all special maintenance work For special maintenance contact personnel trained specifically by Kohler This work should be carried out in accordance with existing literature Kohler declines all responsibility for accidents or for failure to comply with the requirements of law if changes are made to the engine s functional parameters or to the fuel flow rate adjustments and speed of rotation if seals are removed or if parts not described in the operating and maintenance manual are removed and reassembled by unauthorized personnel A WARNING In addition to all other machine specifications ensure that the engine is in near horizontal position when starting If starting manually ensure that the necessary operations can be performed without any risk of striking against walls or dangerous objects Rope starting except for recoil rope starting is not permitted even in emergencies Check that the machine is stable so that there is no risk of it overturning Get to know the engine speed adjustment and machine stop operations environments The internal combustion process generates carbon monoxide an odourless and highly toxic gas
27. between the contact surfaces fig 63 Torque the screws to 2 2 2 4 Nm 21 6 23 5 Crankshaft end float Install an 0 15 mm feeler gauge betwen the crankshaft shoulder and the crankcase flywheel side Use a screwdriver to force the crankshaft against its shoulder as shown in figure 64 Pre heat the timing gear to a temperature of 180 200 and fit it onto the crankshaft pressing it down until it comes into contact with the crankcase Wait until the timing gear has cooled down and then withdraw the feeler gauge and the screwdriver and check end float fig 65 which must be within the range 0 10 0 20 mm 0 20 0 30 mm cast iron crankcase _ 32 KD 425 2 Workshop Manual cod ED0053029360 1 ed rev 00 KOHLER ENGINE ASSEMBLY XIII Camshaft Prepare the camshaft assembly fig 66 as described below 1 Fit adjustment shim nr 3 and governor washer nr 4 onto the camshaft 2 Fit snap ring nr 5 and key nr 7 into their respective seats 3 Preheat 180 200 gear nr 6 complete with flyweights and mount it to the camshaft making sure that it is snugly fitted against the retaining ring 4 Insert the governor driving plate retaining ring nr 2 The speed governor is of the centrifugal type with flyweights keyed directly onto the end of the camshaft gear fig 67 Flyweights A impelled outward by centrifugal force cause a moving plate P to shift axially The plate
28. cooling liquid is polluting so dispose of in a manner that does not damage the environment In order to move the engine simultaneously use the eyebolts fitted for this purpose by Kohler These lifting points are however not suitable for the entire machine so in this case use the eyebolts fitted by the manufacturer GENERAL SAFETY DURING OPERATING PHASES procedures contained in this manual have been tested and selected by the manufacturer s technical experts and hence are to be recognised as authorised operating methods Some tools are normal workshop ones while others are special tools designed by the Manufacturer of the engine All tools must be in good working condition so that engine components are not damaged and that operations are carried out properly and safely Itis important to wear the personal safety devices prescribed by work safety laws and also by the standards of this manual Holes must be lined up methodically and with the aid of suitable equipment Do not use your fingers to carry out this operation to avoid the risk of amputation SAFETY AND ENVIRONMENTAL IMPACT Every organisation has a duty to implement procedures to identify assess and monitor the influence of its own activities products services etc on the environment Procedures for identifying the extent of the impact on the envi ronment must consider the following factors Liquid waste Waste management Soil c
29. ctivation of the starter motor Check the belt tension only when the engine is turned off AN Do not start the machine in closed or poorly ventilated IMPORTANT To start the engine follow the specific instructions provided in the engine and or machine operating manual Do not use auxiliary starting devices not originally installed on the machine e g Startpilot systems which utilise ether etc Before carrying out any work on the engine turn it off and allow it to cool down Do not perform any operation while the engine is running Check that the discharged oil the oil filter and the oil contained in the oil filter are disposed of in such a way as not to harm the environment Close the fuel tank filler cap carefully after each filling operation Do not fill the tank right up to the top but leave sufficient space to allow for any expansion of the fuel 8 KD 425 2 Workshop Manual cod ED0053029360 1 ed rev 00 KOHLER SAFETY AND WARNING DECALS SAFETY INSTRUCTIONS I Do not smoke or use naked flames while filling Take care when removing the oil filter as it may be hot The operations of checking filling up and replacing the cooling liquid must be carried out with the engine turned off and cold Take particular care if liquids containing nitrites are mixed with others not containing these compounds as this may give rise to the formation of nitrosamines which are a health hazard The
30. e ball seat is free of dirt that could reduce the effectiveness of the pressure seal Secure the oil pressure valve with the relative screw B fig 57 5 Insert the cylinder studs and the centring pins the engine thus causing crankcase ventilation problems Use genuine oil retainers warped oil retainer may allow the introduction of air into Central main bearings Fit the shells into their seats and coat with a thin film of oil The reference numbers fig 58 must be aligned on each half shell making sure that the oil passages match the corresponding openings in the crankcase Torque the bearing assembly bolts fig 59 to kgm 2 2 Nm 21 6 KD 425 2 Workshop Manual cod ED0053029360 1 ed rev 00 31 XIII ENGINE ASSEMBLY KOHLER Crankshaft Fit the crankshaft into the crankcase using tool p n 00365R0910 as shown in figure 60 make sure that the bearing oil passages are matched to the crankcase oil passages Torque the bearing screws fig 61 to kgm 2 2 Nm 21 6 Main bearings flywheel side Fit the bush to the bearing carriern using a special tool of appropriate diameter as shown in figure 62 Insert the bush arranging the groove so that it is facing the internal side of the bearing and positioned ver tically Fit the oil seal ring to the bearing using a suitable diameter tubular punch Fit the bearing into the crankcase after having first interposed an O ring
31. e to fill the oil suction pipe in order to aid pump priming when the engine is started up for the first time Timing cover Check that the timing markeson the camshaft and crankshaft gears are aligned fig 69 Fit the oil seal onto the cover using a normal tubular punch of appro priate diameter Mount the cover to the crankcase fig 71 after first inserting a gasket between the mating surfaces tighten the screws to kgm 2 2 2 4 Nm 21 6 23 8 Pulley and flywheel Tighten the pulley and flywheel nut fig 72 to 18 22 Nm 176 5 215 7 34 KD 425 2 Workshop Manual cod ED0053029360 1 ed rev 00 KOHLER ENGINE ASSEMBLY XIII Pistons Lubricate the following parts with oil before mounting the piston pin piston the cylinder and the big end bearing Fit the piston rings onto the pistons fig 73 in the following order 1 Chromed compression ring 2 Torsional compression ring with internal bevel facing upward 3 Expander oil scraper ring external bevel facing upward Install the piston to the connecting rod by pushind the wrist pin in without heading the piston Connecting rods After having fitted the bearings into the big ends mount the connec ting rods to the crank journals pins note that the pistons are marked with an arrow showing the direction of rotation of the engine The combustion chamber which is offset with respect to the central axis of the piston must
32. eck internal diameters C D at three different heights fig 18 Maximum permitted taper A B and ovality C D is 0 06mm Diameter of cylinders fig 18 If the diameter of the cylinder does not exceed said values or if there are slight surface scores on the cylinder it will be sufficient to change the piston rings Do not manually the cylinder bore surfaces with eme n ry cloth or other means The cross hatch pattern should be at an angle of 90 120 lines should be uniform and clear in both directions Average roughness must range between 0 5 mm 1 um The cylinder surface which comes into contact with piston rings should be machined with the plateau method 2 f If the taper and ovality of the cylinder exceed the values indicated then the cylinder and piston must be renewed RD N KD 425 2 Workshop Manual_cod ED0053029360_1 ed_ rev 00 21 CHECKS AND OVERHAUL KOHLER Piston rings Pistons Piston pins Check the wear of piston rings by fitting them into the cylinder throu gh the lower end and measuring the end gap fig 20 The values should be Compression 0 30 0 50 080 Oil scrapper 0 25 0 50 Check that the rings move freely in the grooves and check the ring groove clearance using a feeler gauge fig 21 If the clearance exceeds the values shown in the table renew the pi ston and the piston rings 1st Compression 0 22
33. ection delay caused by the milling on the pumping elements bring the injection pump connection rod A fig 81 to a position mid way between minimum and maximum 4 Fit the special tool p n 00365R0940 to the delivery valve hol der timing case side as shown in figure 82 5 Turn the flywheel slowly until the column of diesel fuel inside the special tool starts to move This indicates the start of static injection For variable advance pumps the reference mark on the flange bell fig 85 must match the intermediate point between TDC and IP start of dynamic injection punched onto the flywheel On traditional pumps the static start of injection is the same as the start of dynamic injection IP Should the reference mark or IP fall short of the notch on the flange bell this indicates that injection is too advanced so that the injection pump must be removed and then reassembled with shims gaskets between the pump and the crankcase fig 84 Should the reference mark or IP fall after the TDC reference mark this indicates that injection is too retarded In this case proce ed as above but this time removing shims Now repeat the injection timing check for all injection pumps Note that every 0 1mm shim inserted beneath the pump correspon ds to 2 75mm rotation of the flywheel Should the flywheel need changing determine TDC and mark the start of static and dynamic injection as shown in the table 22 44 mm
34. ed too low Worn or jammed piston rings Worn or scored cylinders Worn valve guides Jammed valves Worn bearings Governor linkage not free to slide Drive shaft not free to slide Damaged cylinder head gasket LUBRICATION FUEL CIRCUIT SETTINGS REPAIRS KD 425 2 Workshop Manual cod ED0053029360 1 ed rev 00 7 SAFETY AND WARNING DECALS SAFETY INSTRUCTIONS KOHLER SAFETY REGULATIONS GENERAL NOTES Kohler engines are built to provide safe and longlasting performances but in order to obtain these results it is essential that the maintenance requirements described in the manual are observed along with the following safety recommendations The engine has been built to the specifications of a machine manufacturer and it is his responsibility to ensure that all necessary action is taken to meet the essential and legally prescribed health and safety requirements Any use of the machine other than that described cannot be considered as complying with its intended purpose as specified by Kohler which therefore declines all responsibility for accidents caused by such operations The following instructions are intended for the user of the machine in order to reduce or eliminate risks especially those concerning the operation and standard maintenance of the engine The user should read these instructions carefully and get to know the operations described By not doing so he m
35. gure 49 serving to release the pressure exerted by the spring on the ring nut 1 Visual check make sure that the seat of the needle shows no signs of hammering or excess roughness that the needle is not worn or damaged and that the holes are free of carbon deposits 2 Smoothness test the needle previously immersed in diesel and inserted into the nozzle casing must be pulled out to a third of the length of the guide while holding the nozzle in a vertical po sition When the needle is released it should return freely to its seat by the effect of its own weight Reassemble the injector following the assembly order shown in figure 46 during reassembly make sure that the locating elements on di stance ring 5 fig 46 are correctly inserted to the corresponding ho les Torque the nozzle securing ring nut to kgm 3 5 Nm 34 3 KD 425 2 Workshop Manual cod ED0053029360 1 ed rev 00 29 XII ELECTRICAL EQUIPMENT KOHLER Internal built in alternator Plant specifications jose Starter motor Left rotation 12V power from 1 25 to 1 4 kW Built in alternator 280W Voltage regulator Electronic with controlled diodes and connection for battery charge indicator light External alternator 12V 400W Recommended battery Refer to tables in chapters 4 Flywheel ring gear Check teeth for wear or damage Fit crown whe el to flywheel by pre heating to 200 250 C
36. he fuel inlet hole aligned with the feeding connection fig 42 This is the only possible position because of the stud on the pump body Make sure that the sea ting face between the barrel and the pump are free of dirt 2 Insert delivery valve copper gasket spring washer filler O ring and temporarily tighten the delivery connection 3 Insert plunger with helical profile A fig 43 on the opposite side of the sleeve pin B fig 43 into the internal groove of the control sleeve make sure the helical profile is turned towards the fuel inlet and eccentric pin C fig 43 4 Complete pump assembly with plunger a fig 44 control sleeve b upper washer c retaining ring d spring f and secure all with the spring holder washer g 5 Tighten delivery valve holder h fig 44 to 4 5 5 torque 6 Check by compressing the spring through its various work posi tions that the control sleeve b fig 44 turns freely and does not stick or encounter resistance throughout its full stroke any irregu lar movement will give rise to hunting of engine speeds 7 Secure the control sleeve using the pin n fig 44 screwed into pump housing Always check the injection pump calibration after the deli very connection h fig 44 has been dismantled 1 Testing air tightness Feed pressurized air at 6 Kg cm into the fuel sullpy union and com 6 Kg cm pletely inmerse the pump in oil or diesel fuel for about 20 30 secon
37. il pressure indicator plug Loosen the plug securing screw and remove circlip spring and ball Cut a thread on the inside of the plug body and then withdraw it using a commercial extractor tool fig 8 18 KD 425 2 Workshop Manual cod ED0053029360 1 ed rev 00 KOHLER CHECKS AND OVERHAUL X I Cylinders heads Parts shown in figure 9 1 Head 2 Tappets 3 Valves 4 Seats 5 Guides 6 Seals 7 Lo wer washers 8 Springs 9 Top washers 10 Valve locking split co nes 11 Rocker arms 12 Rocker pins 13 Gaskets 14 Push rods 15 Cover tube 16 0 ring 17 Camshaft The heads are made off aluminium with valve guides and seats are made of cast iron Do not disassemble the head when the engine is hot to avoid deformation Clean heads of carbon deposits and check the cylinder mating sur faces if they are deformed they must be ground to a maximum of 0 3 mm Check that there are no cracks or other imperfections in the heads If defects are encountered the heads must be renewed In this case consult the spare parts catalogue Valves Guides Seats Clean the valves with a wire brush and renew them if the valve heads are deformed cracked or worn 6 960 6 970 7 00 7 01 13 025 13 037 0 8 1 0 13 13 01 Check the dimensional conformity of the valve stems fig 11 and the clearance between valve and guide bore out the guides to the dimensions indicated in the table fig 10
38. ion range of engines rated at 3000 rpm U2 Standard utilization range of engines rated at 3600 rpm The above power values refer to an engine fitted with air cleaner and standard muffler after testing and at the environmental conditions of 20 and 1 bar Max power tolerance is 596 Power decreases by approximately 1 every 100 m di altitude and by 2 every 5 C above 25 Note Consult Kohler for power torque curves and specific consumptions at rates differing from those given above 12 KD 425 2 Workshop Manual_cod ED0053029360_1 ed_ rev 00 KOHLER OVERALL DIMENSIONS VI NES D L j f Ag Sas lt DN Note Dimensions in mm KD 425 2 Workshop Manual cod ED0053029360 1 ed rev 00 13 VII SPECIAL TOOLS KOHLER TOOL CODE DESCRIPTION 00365R0020 Flywheel puller 00365R0010 Universal puller 00365R0900 Main bearing extractor 00365R0890 Gear extractor 00365R0910 Central bearing assembly tool 00365R0930 Valve guide rubber fitting tool 00365R0770 Cylinder collar 80 85 mm 00365R0940 Injection advance control tool 00365R0430 Injector test bench 14 KD 425 2 Workshop Manual cod ED0053029360 1 ed rev 00 KOHLER MAINTENANCE RECOMMENDED OIL TYPE REFILLING VIII H Failure to carry out the operations described in the table may lead to technical damage to the machine a
39. mer that each new KOHLER Diesel engine sold by Kohler Co will be free from manufacturing defects in materials or workmanship in normal service for a period of three 3 years or 2000 hours whichever occurs first from the date of purchase provided it is operated and maintained in accordance with Kohler Co s instructions and manuals If no hour meter is installed as original equipment then 8 hours of use per day and 5 days per week will be used to calculate hours used Our obligation under this warranty is expressly limited at our option to the replacement or repair at Kohler Co Kohler Wisconsin 53044 or at a service facility designated by us of such parts as inspection shall disclose to have been defective This warranty does not apply to defects caused by unreasonable use including faulty repairs by others and failure to provide reasonable and necessary maintenance The following items are not covered by this warranty Engine accessories such as fuel tanks clutches transmissions power drive assemblies and batteries unless supplied or installed by Kohler Co These are subject to the warranties if any of their manufacturers KOHLER CO AND OR THE SELLER SHALL NOT BE LIABLE FOR SPECIAL INDIRECT INCIDENTIAL OR CONSEQUENTIAL DAMAGES OF ANY KIND including but not limited to labor costs or transportation charges in connection with the repair or replacement of defective parts IMPLIED OR STATUTORY WARRANTIES INCLUDING WARRANTIES OF MERCHANTA
40. nd or system MANUTENANCE 3 50 200 300 400 2500 OIL BATH AIR CLEANER HEAD AND CYLINDER FINS CLEANING INTERNAL OIL FILTER FUEL TANK INJECTOR AIR CLEANER OIL OIL SUMP BATTERY FLUID VALVE ROCKER ARM CLEARANCE INJECTOR SETTING AIR CLEANER SUMP INTERNAL OIL FILTER CARTRIDGE REPLACEMENT EXTERNAL OIL FILTER CARTRIDGE FUEL FILTER CARTRIDGE DRY AIR CLEANER CARTRIDGE First replacement Under severe working conditions clean daily Under extremely dusty conditions change every 4 5 hours See recommended oil type x The partial overhaul includes the following operations valve and seat lapping injector and injection pump overhaul injector projection check fuel injection spark advance check check of the harmful area between head and piston camshaft and crankshaft end float check tightening of bolts xx general overhaul includes in addition to all partial overhaul the following procedures cylinder and piston repla cement seat guide and valve refacing crankshaft replacement or grinding bench bearing and connecting rod replace ment The maintenance operations listed above refer to an engine operating in normal conditions temperature degree of humidity dust in the working environment They may vary significantly according to the type of use To avoid explosions or fire outbreaks do not smoke or use naked flames duri
41. ng the operations A Fuel vapours are highly toxic Only carry out the operations outdoors or in a well ventilated place Keep your face well away from the plug to prevent harmful vapours from being inhaled Dispose of fuel in the correct way and do not litter as it is highly polluting FUEL When refuelling it is advisable to use a funnel to prevent fuel from spilling out The fuel should also be filtered to prevent dust or dirt from entering the tank Use the same type of diesel fuel as used in cars Use of other types of fuel could damage the engine The cetane rating of the fuel must be higher than 45 to prevent difficult starting Do not use dirty diesel fuel or mixtures of diesel fuel and water since this would cause serious engine faults The capacity of the standard tank is It 4 0 KD 425 2 Workshop Manual_cod ED0053029360_1 ed_ rev 00 15 MAINTENANCE RECOMMENDED OIL TYPE REFILLING KOHLER The engine could be damaged if allowed to operate with insufficient oil It is also dangerous to add too much oil as its combustion could sharply increase the rotation speed Use suitable oil in order to protect the engine The lubrication oil influences the performances and life of the engine in an incredible way The risk of piston seizure jammed piston rings and rapid wear of the cylinder liner the bearings and all moving parts increases if oil whose characteristics differ from the recommended type is used o
42. ns Petrol may not be used because of the risk of it forming flammable vapours During operation the surface of the engine reaches temperatures that may be dangerous Avoid in particular all contact with the exhaust system The liquid cooling circuit is under pressure Do not carry out any checks before the engine has cooled down and even then open the radiator cap or the expansion tank cautiously Wear protective clothing and glasses there is an electric fan do not approach the engine while it is still hot as the fan may come on even when the engine is not running Clean the cooling system with the engine turned off While cleaning the oil bath air filter check that the oil is disposed of in such a way as not to harm the environment Any filtering sponges in the oil bath air filter should not be soaked with oil The cyclone pre filter cup must not be filled with oil Since the oil must be emptied out while the engine is still hot approx 80 particular care should be taken in order to avoid burns In any case make sure that oil does not come into contact with your skin because of the health hazards involved Fuel vapours are highly toxic so fill up only in the open air or in well ventilated environments During operations which involve access to moving parts of the engine and or removal of the rotary guards disconnect and insulate the positive cable of the battery so as to prevent accidental short circuits and a
43. od ED0053029360_1 ed_ rev 00 KOHLER INJECTION EQUIPMENT XI Fuel circuit Fuel feeding can be either gravity type or forced with a mechanical double diaphragm pump operated a cam located on the camshaft Fuel is filtered by a filter in the fuel tank or through an external filter cartridge The fuel circuit is bled of air automatically Components of figure 38 1 Fuel tank 2 Fuel filter 3 Fuel supply lines 4 Fuel injection pumps 5 Bleed off connection 6 Fuel injectors 7 Injection lines 8 Fuel return lines 9 Fuel sully pump Injection pumps Components of figure 39 1 Delivery connection 2 O ring 3 Filler 4 Washer 5 Valve spring 6 Delivery valve 7 Injection plunger 8 Lower plate 9 Spring 10 Top plate 11 Retaining ring 12 Adjustment slee ve 13 Pump body 14 Sleeve securing pin 15 Distance ring 16 Eccentric pin 17 Cap 18 Clip for BOSCH pump type PF30 Checking injection pumps Before dismantling the injection pumps check for pressure leak of the pumping unit plunger and valve as follows 1 Connect a pressure gauge with 600 Kg cm full scale to the die sel delivery line fig 40 2 Set the control sleeve nr 12 fig 39 to a mid point delivery posi tion 3 Turn the flywheel slowly until the plunger has completed a full compression stroke 4 Take the pressure gauge reading If it is below 300 Kg cm the complete plunger unit
44. ontamination Atmospheric emissions Use of raw materials and natural resources Regulations and directives regarding environmental impact Some phases may require the assistance of more than one operator If so it is important to inform and train them regarding the type of activity they will be performing in order to prevent risks to the health and safety of all persons involved Do not use flammable liquids petrol diesel etc to degrease or wash components Use special products Use the oils and greases recommended by the manufacturer Do not mix different brands or combine oils with different characteristics Discontinue use of the engine if any irregularities arise particularly in the case of unusual vibrations Do not tamper with any devices to alter the level of performance guaranteed by the manufacturer Inorderto minimise the impacton the environment the manufacturer now provides a number of indications to be followed by all persons handling the engine for any reason during its expected lifetime All packaging components must be disposed of in accordance with the laws of the country in which disposal is taking place Keep the fuel and engine control systems and the exhaust pipes in efficient working order to limit environmental and noise pollution When discontinuing use of the engine select all components according to their chemical characteristics and dispose of them separately California Proposition
45. operates a lever R which is con nected through tie rods T to the control sleeves E of the injection pumps Spring N placed under tension by speed control lever C contrasts the action of the centrifugal force of the governor The balance between the two forces keeps the engine speed virtually constant with respect to load variations mm 36 5 1 turn The accuracy of this setting will serve to eliminate hunting of engine speed difficulty in starting and power fall off Assembly 1 Fit the tappets into their housings in the crankcase 2 Fit the governor lever and tie rod simultaneously with the camshaft into the crankcase fig 68 3 Insert the governor lever fulcrum pin from the outside of the cran kcase and secure it with the relative screw fig 68 The lever must be free to effect its full stroke without sticking 4 Insert the spring between the governor lever and the accelerator making sure that it is correctly installed 5 Check that the timing marks on the camshaft and crankshaft ge ars are correctly aligned with respect to each other fig 69 KD 425 2 Workshop Manual cod ED0053029360 1 ed rev 00 33 ENGINE ASSEMBLY KOHLER Oil pump See pag 25 if you wish to check the rotors Fit the external oil pump rotor with the bevel toward the inside of the cover fig 70 Torque the bolts to 0 5 0 6 Nm 4 9 5 9 It is good practiv
46. r if the oil is not regularly changed All this notably reduces engine life Oil viscosity must suit the ambient temperature in which the engine operates Old oil can cause skin cancer if repeatedly left in contact with the skin and for long periods of time If contact with the oil is inevitable you are advised to thoroughly wash your hands with soap and water as soon as possible Appropriate protective gloves etc should be wore during this operation Old oil is highly polluting and must be disposed of in the correct way Do not litter RECOMMENDED OIL GRADE AGIP SINT 2000 5W40 specification API SJ CF ACEA A3 96 B3 96 MIL L 46152 D E OW Go OE GEO ESSO ULTRA 10W40 specification SJ CF ACEA A3 96 MIL 40 35 30 25 20 1510 5 0 5 10 15 20 25 30 35 40 45 50 L 46152 D E SA In countries where AGIP and ESSO products are not available SAE 20W use API SJ CF oil for gasoline fuelled engines or oil that complies with military specification MIL L 46152 D E OIL SUPPLY liters Standard oil sump filter included 1 8 I ACEA SEQUENCES Gasoline Petrol BENZINA ESSENCE PETROL B Light Diesel fuels BENZIN GASOLINA DIESEL NN CD SC SD SE SG SH SJ Required levels COMCG 2 CCcMCG 3 A1 96 A2 96 4 CCMC D 2 A3 96 B1 96 B2 96
47. rkshop Manual cod ED0053029360 1 ed rev 00 KOHLER ENGINE ASSEMBLY XIII Notice These instructions are valid for engines up dated prior to the publication of this manual Any modifications must be checked on the technical circulars Before assembling the engine carefully clean all parts and dry them with compressed air Lubricate moving parts to prevent seizing when starting up Replace the gaskets with new ones each time the engine is assembled Use torque wrenches to ensure that the correct tightening torques are applied Preparing the crankcase Clean the mating surfaces of sealing compound residues or other fo reign material using copper scraper or fine emery stone Make sure that the oil passages are open and free of built up deposits 1 Fit the plugs A fig 55 in their holes 2 Insert the internal accelerator lever B fig 55 into the crankcase with its spring taking care to protect the oil seal O ring from da mage Complete the external assembly with plate spring lever etc as shown in figure 55 3 Mount the bearing bush gear train side using either standard press or a made to measure punch as shown in figure 56 F i t the bush by matching the hole with the passage on the crankca se Bushes with standard or smaller internal diameters can be or dered as required 4 Insert the complete oil pressure relief valve A fig 57 into its housing C fig 57 Make sure that the valv
48. rods Renew the parts if the surface wear is greater than 0 10mm fig 33 Assembly clearance between control rods and their housings in the crankcase 27 959 27 980 18 9 19 0 0 02 0 059 0 10 3 45 3 55 Fuel pump push rod Check that the surfaces of the fuel pump push rod fig 34 are free of 9 986 9 996 wear scoring or signs of seizure otherwise renew Assembly clearance between fuel pump push rod and its housing in the crankcase 0 05 0 098 0 120 38 9 39 1 Oil pump Check the rotors and renew them if they have worn lobes or centres Check the extent of pump wear by taking the measurements indica ted in figure 35 Measurement Dimensions mm wear _ 29 72 29 77 29 65 BB 40 551 40 576 40 45 KD 425 2 Workshop Manual cod ED0053029360 1 ed rev 00 25 CHECKS AND OVERHAUL KOHLER The clearance between the external rotor of the oil pump and the co ver facing surface must be 0 27 0 47 060 End float of rotors fig 36 0 01 0 06 0 10 Governor lever and spring Check that the shoes S fig 37 are level and that the springs have not lost their elasticity Renew any excessively worn parts after con sulting the spare parts catalogue Supplement and governor spring dimensions fig 37 L ht L ht und Load Nr of sm Supplement 2575 2023 387 08 288 596 KD 425 2 Workshop Manual_c
49. rt the electro ena 50 magnet into the crankcase taking care to position the engine shut off lever in the STOP position make sure that the injection pump con KEYSWITCH nection lever moves freely along its entire stroke BATTERIA BLUE Make the electrical connections as shown in diagram 90 BATTERY AZZURRO CHIAVE KEY SWITCH terminal 5 54 38 KD 425 2 Workshop Manual cod ED0053029360 1 ed rev 00 KOHLER ENGINE TESTING XIV Speed adjustment fig 91 When the engine is hot set idle speed at 1000 rpm and maximum no load speed at 3750 rpm for engines KD 425 2 Checking oil pressure 1 Remove the bolt from the hole in the crankcase and fit a pressure gauge with 0 to 10 kg cm full scale fig 92 2 Start the engine accelerate to 3000 rpm and wait for the oil to reach a temperature of 70 to 80 3 The pressure reading must be between 2 5 and 4 kg cm 4 Reduce engine speed to minimum the pressure should not fall below 1 1 5 Kg cm with oil temperature of 80 C Checking for oil leaks 1 Remove the exhaust gas collection pipe from the inlet manifold and close the connection with a plug fig 93 2 Start the engine and let it run for a few minutes The high pressu re generated in the crankcase will show up any oil leaks 3 Reconnect the exhaust gas collection pipe to the inlet manifold s di LR Dyno testing of engine After you have placed the engine on the brake fig 94
50. s Once you have finished grinding check the efficiency of the seal between the valve and seat as outlined below 1 Fit the valve on the head with spring washers and split cones fig 9 2 Invert the head and pour in a few drops of diesel fuel or oil around the edges of the valve head 3 Blow compressed air into the inlet of the cylinder head taking care to seal the edges so that the air does not escape fig 15 Should air bubbles form between the seat and the valve remove the valve and regrind the seat 20 KD 425 2 Workshop Manual cod ED0053029360 1 ed rev 00 KOHLER CHECKS AND OVERHAUL X Valves and springs In order to check the springs for possible failure measure the lengths under load as shown in figure 16 The permissible tolerance for loads and lengths is 10 If the fi gures measured do not fall within these values the springs must be renewed free length Rocker arms 15 03 15 05 Make sure that the facing surfaces between rocker and pin are not scored and show no signs of seizure If such marks are encountered renew rocker and pin Rocker pin clearance fig 17 0 03 0 06 0 15 Rocker axial play fig 17 um 0 05 0 130 Make sure that the rocker arm adjusting screw is not worn and that the lubrication hole is free of dirt 9 03 9 06 14 99 15 00 Cylinders Air cooled with cylinder barrels in special cast iron with integral liners Use a dial gauge to ch
51. so spending too long time in an environment where the engine discharges its exhaust products freely can lead to loss of consciousness and even death The engine may not be used in environments containing flammable materials explosive atmospheres or easily combustible powders unless adequate and specific precautions have been taken and are clearly stated and certified for the machine To prevent the risk of fire keep the machine at a distance of at least one metre from buildings or other machines Children and animals must be kept at a sufficient distance from the machine to prevent any danger resulting from its operation Fuel is flammable so the tank must be filled only when the engine is turned off Dry carefully any fuel that may have spiled remove the fuel container and any cloths soaked in fuel or oil check that any sound absorbing panels made of porous material are not soaked with fuel or oil and make sure that the ground on which the machine is located has not absorbed fuel or oil Before starting remove any tools that have been used for carrying out maintenance work to the engine and or the machine and check that any guards removed have been replaced In cold climates it is possible to mix kerosene with the diesel fuel to make the engine easier to start The liquids must be mixed in the tank by pouring in first the kerosene and then the diesel fuel Consult Kohler technical office for mixture proportio
52. the value indica ted above proceed by checking the alternator and if necessary renewing the voltage regulator cables Color x Section mm Checking the alternator Check 1 with motor stopped the continuity of the windings fig 53 by con necting an ohmmeter and ensuring that resistance is zero and the insulation between the windings and ground fig 54 by en suring that the ohmmeter gives a reading of infinite resistance If these readings are not obtained the stator must be renewed 2 with motor running use a multitester to check the charge current 1000 1500 2000 2500 3000 3500 between the two yellow wires Bring the engine up to 3000 rpm RPM the multitester should give a reading of 35V If the values are more than 10V below this value the rotor is de magnetized and the alternator must be renewed Important 1 The alternator will not deliver current when the yellow wires are disconnected 2 The alternator will burn out if the yellow wires are connected to ground 3 The voltage regulator may be damaged if the ground connection or other circuit connections are not made properly 4 The alternator and the voltage regulator will burn out instantly if the battery connections are inverted 30 KD 425 2 Wo
53. tion g kW h 0 8 Capacity of standard oil sump 1 8 Recommended battery 12V 66 300 Dry weight Combustion air volume Cooling air volume Max permissible driving shaft axial continuous instantaneous Flywheel site continuous instantaneous Max inclination Power take off site continuous instantaneous Lateral continuous instantaneous Referred to N power ai Consumption at max torque KD 425 2 Workshop Manual cod ED0053029360 1 ed rev 00 11 V CHARACTERISTICS KOHLER CHARACTERISTICS POWER TORQUE AND SPECIFIC FUEL CONSUMPTION CURVES kW CV m 42 40 Mt N 4 0 38 14 19 N 13 18 NB 17 12 1 NA 11 15 14 10 13 9 12 8 11 10 7 9 U1 g CV h g kW h 6 U2 190 260 C N 250 180 g min 1600 2000 2400 2800 3200 3600 rpm N 80 1269 EEC ISO 1585 AUTOMOTIVE RATING Intermittent operation with variable speed and variable load NB ISO 3046 1 IFN RATING WITH NO OWERLOAD CAPABILITY continuos ligth duty operation with constant speed and variable load NA ISO 3046 1 ICXN CONTINUOS RATING WITH OVERLOAD CAPABILITY continuos heavy duty with constant speed and con stant load Mt N Torque at N power C Specific fuel consumption at N power U1 Standard utilizat
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