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KD 500 WORKSHOP MANUAL

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1. KOHLER Camshaft Insert the tappets into their housings on the casing Mount the camshaft matching the reference marks on the gears fig 60 Play adjustment Crankshaft float Place a calibrated bar on the casing on a level with the timing system cover retention surface and use a thickness gauge to check the distance between the gear and bar fig 61 Note down the value measured Place a calibrated bar on the cover of the timing system on a level with the engine casing retention surface and use a thickness gauge to check the distance between the bearing ring and bar fig 62 Note down the value measured The sum of the two measured values must be within 0 10 0 30 mm Camshaft float Place a calibrated bar on the casing on a level with the timing system retention cover and use a thickness gauge to check the distance between the gear and bar fig 63 The value must be between 0 10 0 25 mm Workshop Manual KD500 _ cod ED0053029390 1 ed rev 00 KOHLER Engine assembly 1 3 Counter shaft float optional Place a calibrated bar on a level with the timing system cover retention surface and use a thickness gauge to check the distance between the stop surface and bar fig 64 The measured value must be between 0 10 0 25 mm Cover on timing system side a 9 f 4 Spread liquid seal of the AREXON D 0036 MOTOR
2. 59 Removal and assembly of the drive shaft gear The gear on the timing system side can only be replaced To demount it use puller code 00365R0100 fig 56 or a puller available on the market To assemble preheat the gear to a temperature of about 180 to 200 C fit it on the shaft taking care to ensure that the chamfer points towards the internal part and use the tang as a reference Drive shaft assembly fig 57 Mount the drive shaft after having fixed the first shimming washer to the casing with Loctite 648 and after having inserted the needle bearing and the second shimming washer Connecting rod drive shaft connection After having fitted the bearings into the small end connect the connecting rod to the crank pin as shown in fig 58 Mount the connecting rod cap with the reference numbers matching those on the rod WARNING mount the connecting rod half bearing H with the positioning mark on the cap and that without positioning mark in the center of the rod in compliance with the dimensions indicated in fig 58 Evenly tighten the connecting rod bolts to the following value 3 8 3 9 kgm 37 3 38 2 Nm Counter shaft Insert the counter shaft matching the reference marks on the gears fig 59 Workshop Manual KD500 _ cod ED0053029390 1 ed rev 00 33 1 3 Engine assembly
3. TONER NEP 35 CG ver on ming System SIde ee m 35 OLTENII TIN NN a E E 35 35 xime S ERRORES 36 Apol e 36 om TE 36 NING Cle eA CG IER TETTE M eem 37 CUCM NGG MUTET CE c E oat gti NT 37 Mounting the injection pump on the engine pp 38 mMector and njector UDE Tr E 38 ENGINE TESTING criar I E AAE E E E ee 39 UN 39 Sela EE E R E cid ace TEE 39 Temporary protection 1 6 MONUNS 2ccccscacconsesasceuastencdenwsiasseenaentoociaenecdaeesanddanede cic ei eei aa Uode oci RE Rs esas 40 Permanent protection over 6 months pp 40 How to prepare the engine for operation pp 40 40 QUICK REFERENCE CHARIS er a ee eee 41 SERVICE e 43 SUGGESTIONS ON HOW TO TIME THE INJECTION PUMP WHEN THE LEAD PUNCH MARKS ON THE FLY WHEECGARE DIFFICULT TO REACH 43 Workshop Manual KD500 _ cod ED0053029390 1 ed_rev 00 5 Index KOHLER Workshop Manual KD500 _ cod ED0053029390
4. KOHLER INJECTION EQUIPMENT 11 Fuel circuit Fuel supply is the gravitational type An AC pump can be mounted on request Air bleeding is automatic Illustration in fig 30 1 Fuel tank 2 Fuel pipe 3 Fuel filter 4 Injection pump 5 Fuel return pipe 6 Injector 7 Injection pipe 8 Fuel pipe Injection pump Illustration in fig 31 1 Delivery union 2 Filler 3 Valve spring 4 Delivery valve 5 Washers 6 Monobloc pump casing 7 Adjuster seal 8 Flange 9 Pump seal 10 Plunger 11 Adjuster sleeve 12 Plug 13 Adjuster block 14 Spring 15 Lower cap Workshop Manual KD500 _ cod ED0053029390 1 ed_rev 00 25 11 Injection equipment 35 cB Checking the injection pump before demounting the injection pump make sure that the plunger unit enbloc pump casing and valve are pressure tight by proceeding in the following way 1 Connect a pressure gauge with scale up to 600 Kg cm to the fuel delivery pipe fig 32 2 Set the regulating sleeve fig 33 to the average delivery position 3 Slowly turn the flywheel to make the plunger make one compression stroke 4 Read the indication on the pressure gauge If it is lower than 300 Kg cm the complete pump must be changed During the test th
5. AT 3 Limited 3 year KONIEK diesel engine iaaiiai 3 California emission control warranty statement pp 3 TROUBLE SHOOTIN G 7 POS SIBLE CAUSES AND TROUBLE SHOOTING ERU opa RE E Rima 7 GENERAL REMARKS AND SAFETY INFORMATION ee 8 v wl al a oss 100 Oe ee eee eee 8 GENERAL SAFETY DURING OPERATING PHASES 4 9 SAFETY AND ENVIRONMENTAL IMPACT 9 MODEL NUMBER AND IDENTIFICATION ee 10 The identification plate shown in the figure can be found directly on the 10 APPO DO 10 De MILI T 11 Cubic T ee 11 CHARACTERISTIC c 12 CHARACTERISTICS POWER TORQUE AND SPECIFIC FUEL CONSUMPTION CURVES 12 OVERALL DIMENSIONS UNSER 13 T 14 MAINTENANCE RECOMMENDED OIL TYPE REFILLING _ nennen nnn nnn nennen nnn nnn 15 Jpn nic nie cq Q 15
6. 1000 2000 3000 RPM 44 Workshop Manual KD500 _ cod ED0053029390 1 ed_rev 00 29 12 Electrical equipment 47 Checking the alternator With the engine at a standstill disconnect the alternator wires from the regulator and check 1 using an ohmmeter that the windings fig 45 null resistance and the insulation between wires and ground fig 46 infinite resistance are unbroken Replace the stator if interruptions are discovered 2 with a voltmeter the voltage between the two yellow wires fig 47 Accelerate the engine to 3000 rpm The voltage must be 33V If the values are more than 10V less than this it means that the rotor is demagnetized and that the alternator must be replaced Warning H 1 the alternator does not deliver current when the yellow cables are isolated 2 the alternator burns out if the yellow wires are grounded 3 the regulator may be damaged if the ground connection or electrical connections are made in a slapdash way 4 the alternator and regulator will immediately burn out if the battery connections are inverted Ring gear Make sure that the teeth of the crown wheel are not worn or damaged Heat the starting ring gear to a temperature of 200 250 C before fitting it on to the flywheel 30 Workshop Manual KD500 _ cod ED0053029390 1 ed rev 00
7. 5 16 24UNF w profondita 7 x stan La 16 24UNF profondita 11 depth Note Dimensions in mm Workshop Manual KD500 _ cod ED0053029390 1 ed rev 00 13 7 SPECIAL TOOLS KOHLER DESCRIPTION 00365R0020 Failure Flywheel puller 00365R0900 Tool to mount and demount main bearings 00366R0220 Plug to mount and demount main bearings 00366R0230 Sleeve to insert main bearings 00365R0770 Piston mounting tool 00365R0100 Crankshaft gear puller 00366R0210 Punch to insert By pass valve 00365R0430 Injector test bench 00366R0240 Tool to stagger injection lead 00365R0940 Capillary tube for injection lead 14 Workshop Manual KD500 _ cod ED0053029390 1 ed rev 00 KOHLER Failure to carry out the operations described in the table may lead to technical damage to the machine and or system MAINTENANCE RECOMMENDED OIL TYPE REFILLING 8 MAINTENANCE INTERVAL INTERVAL HOURS OPERATION SUMP OIL LEVEL CHECK OIL BATH AIR CLEANER CLEANING DRY AIR CLEANER CHECKING OIL CARTER REPLACEMENT 4 OIL FILTER REPLACEMENT FUEL FILTER REPLACEMENT COOLING FINS CLEANING SETTING ROCKER ARMS CLEARANCE SETTING AND INJECTORS CLEANING OVERALL INSPECTION PARTIAL OVERALL INSPECTION COMPLETE eee 1 After the first 50 working hours 2 In cas
8. 15 RECOMMENDED M M Y V 16 PCER EOUENCE HC 16 DISASSEMBEY OF THE ENGINE se vate ale oe essen 17 DISASSBEMBEYTIANBDISEASSBENBDY i 17 NS MNS CUO NETT p 17 the Du 17 PVG NEN E OU Nr TTE 17 Removing the cover the TIMING system side pp 17 EG IO UIUC Me SI 18 Demounting and remounting the main bearings pp 18 GCGHECKS AND ee ee ee ee AE E eee ne 19 ES 19 Valves NECNON cise sc spt sone fae sa nc ce estan aes ace ae nee ere 19 bici SNS TO rive dua pass uae E E 20 el NR ONT 20 PRONTOS ME CUI iMd E EU 21 reins ie dew 21 Cash 22 O 22 POCORN II 22 Gheckng ine OlPUMD 23 23 Tapets and TOCker args 24 Tal clove gas Si yale tappet and PAUS NE Tm 24 mi ellus exo cie 07 gt eee tree me r x eee oer ee nee ee een ey mee een ee ee eee 24 4 Workshop Manual KD500 _ cod ED0053029390 1 ed_rev 00
9. KOHLER ENGINE ASSEMBLY 13 The instructions refer to engines updated at the time H of publication Check the technical circulars for any modifications Thoroughly clean the parts before remounting them Lubricate the moving parts to prevent seizures when the engine is first started Replace the seals whenever the parts are remounted Use torque wrenches to tighten to the correct values Preparing the engine block Remove all traces of sealant or impurities from the bearing surfaces with a copper plate or lapping stone then proceed in the following way 1 Fit on the oil drain plugs without tightening them too much max 2 Kgm to prevent damage to the threads 2 Mount the main bearing as indicated at page 18 3 Fit the benzing ring on to the pin of the regulator levers fig 48 A apply Loctite 648 to the zone where the pin touches the engine casing Insert the stop lever fig 48 B the accelerator lever fig 49 C and complete the assembly operations in compliance with the sequencies indicated in figures 48 and 49 4 Comply with the sequence indicated in fig 50 for the motorstop version Injection pump tappets Insert the tappet into the injection pump housing in the engine casing Fit the screw into the guide as shown in fig 51 Workshop Manual KD500 _ cod ED0053029390 1 ed rev 0
10. 26 Workshop Manual KD500 _ cod ED0053029390 1 ed rev 00 KOHLER Injection equipment 11 36 37 39 5 Insert the adjuster sleeve unit and plunger L into the pump casing A making sure that the helical profile is directed on a level with the return union with ball 6 Fit in the adjuster block M matching the reference marks applied during the demounting phase 7 Tighten the plug N to a 0 5 to 0 6 Nm torque locking it in place with Loctite 290 8 Insert the spring O and lower cap P 9 Compress the tappets in the various operating positions to check that the adjuster sleeve L slides perfectly Resistance or jamming will make the engine to hunt during operation Leak test Plug the fuel return union and let air in through the fuelling union at a pressure of 6 Kg cm Fully immerse the pump in a receptacle containing diesel fuel for about 50 60 seconds fig 37 and make sure that no bubbles appear NOTE the position of the pump adjuster sleeve is of no importance for this test Injector Details of fig 38 1 Filter 2 Fuel inlet union 3 Fuel return union 4 Nozzle holder 5 Calibration washer 6 Spring 7 Pressure rod 8 Spacer 9 Nozzle 10 Ring nut Injector inspection and calibration 1 Clean the nozzle holes with a thin steel w
11. KOHLER Index INJECTION EQUIP MEN T e 25 mu ejes et ese Shere Gene dere da os eam ta 25 WNC 25 ER 26 Tm 26 LEI 27 Injector inspection and calibration pp 27 ELECIRICAL EQUIPMENT E AEAEE EREE 29 Characteristics of the System a NETTE 29 ES 29 Ghecking the A I AON artes ETE 30 WU c c MH 30 ziehlzPtc lefe s 31 TNS DOCK ETE TU 31 OURO DCTS ER 31 Timing system COVER xa ape top ia 32 Removal and assembly of the drive shaft gear pe 33 Dive natas MO m 33 Connecting drive shaft connection pt 33 GUEST 33 34 E E E denaneeunadaneaeteesisans semanas tedimenencuaitead 34 RS TO 34 OS AIS ele HOA 34 SOUS Tas eT OAL optional MERE
12. if possible not directly on the soil and far from high voltage electric lines Permanent protection over 6 months The following is recommended apart from the above instructions For the lubrication and injection system as well as for moving parts use rustproof oil type MIL L 21260 P10 grade 2 SAE 30 Ex ESSO RUST BAN 623 AGIP RUSTIA C SAE 30 Let the engine run with rustproof oil and drain any excess Coat external unpainted surfaces with antirust type MIL C 16173D grade 3 Ex ESSO RUST BAN 398 AGIP RUSTIA 100 F How to prepare the engine for operation Clean engine outside Remove protections and covers Remove antirust with an appropriate solvent or degreaser Remove injector fill with standard oil turn crankshaft by a few revolutions remove oil pan and drain the protective oil 40 Workshop Manual KD500 _ cod ED0053029390 1 ed rev 00 KOHLER QUICK REFERENCE CHARTS 16 Couplings Grezen mm 0 032 0 061 Ot Compression ring opening Oil scraper ring opening Connecting rod and piston pin Injection pump tappets and housing Tappets and housing Pin and piston Intake guide and valve Exhaust guide and valve Camshaft float Countershaft float Crankshaft float Connecting rod float Valve clearance hot cold 1 2 2 2 7 0 1 0 4 Valve recessing Workshop Manual KD500 _ cod ED0053029390 1 ed_rev 00 41 16 Quick reference charts KOHLER
13. po 10 Workshop Manual KD500 _ cod ED0053029390 1 ed rev 00 KOHLER TECHNICAL DATA 4 ENGINE TYPE Number of cylinders Bore Stroke Swept volume Compression ratio N 80 1269 CEE ISO 1585 9 12 24 Power kW HP NB ISO 3046 1 IFN 8 4 11 42 NA ISO 3046 1 ICXN 7 6 10 34 Crankshaft PTO ratio Camshaft PTO ratio Crankshaft main PTO rotation Camshaft main PTO rotation Max torque Fuel consumption max torque Oil consumption Capacity of standard oil sump Recommended battery 12V in standard start conditions Recommended battery 12V in heavy duty start conditions Dry weight Combustion air volume Cooling air volume Max permissible driving shaft axial on crankshaft main PTO continuous instantaneous Flywheel site continuous instantaneous 30 35 Power take off site continuous instantaneous 35 45 Max inclination Bank angle right side continuous instantaneous EN 40 Bank angle left side continuous instantaneous 45 Viewed the engine from main Tee ee 703 o noh 120 300 Workshop Manual KD500 _ cod ED0053029390 1 ed rev 00 11 5 CHARACTERISTICS KOHLER CHARACTERISTICS POWER TORQUE AND SPECIFIC FUEL CONSUMPTION CURVES KD 500 230 210 190 170 r 1200 1600 2000 2400 2800 3200 3600 r p m N
14. Demounting and remounting the main bearings Use tool code 00365R0900 and plug code 00366R0220 fig 6 to demount the main bearings from the engine casing and cover on the timing system side To fit the main bearing back into the engine casing use tool code 00365R0900 with plug code 00366R0220 and sleeve code 00366R0230 side A fig 7 To mount the main bearing on the cover on the timing system side use tool code 00365R0900 with plug code 00366R0220 and sleeve code 00366R0230 side B fig 7 During the assembly operations make sure that the bearing holes match the oil ducts by making reference marks with a felt tip pen Make sure that the reference mark on the bearing edge points towards the casing interior the outer part of the timing system cover WARNING H Proceed with the following inspections after assembly Cover on timing system side The main bearing must project 1 7 to 2 mm in relation to the bearing surface of the bull ring inner side of cover Engine casing The main bearing must be flush with the bearing surface of the shimming ring inner side of casing 18 Workshop Manual KD500 _ cod ED0053029390 1 ed rev 00 KOHLER CHECKS AND OVERHAUL 10 1 intake 2 exhaust ER F1 F2 10 11 Parts indicated in fig
15. EXPRESSLY LIMITED TO THE DURATION OF THIS WRITTEN WARRANTY 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 Also included may be hoses connectors and ot
16. Information presented within this manual assumes the following 1 The person or people performing service work on KOHLER series engines is properly trained and equipped to safely and professionally perform the subject operation 2 The person or people performing service work on KOHLER series engines possesses adequate hand KOHLER special tools to safely and professionally perform the subject service operation 3 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 KOHLER WARRANTY CERTIFICATE LIMITED 3 YEAR KOHLER DIESEL ENGINE WARRANTY Kohler Co warrants to the original retail consumer that each new KOHLER Diesel engine sold by K
17. Injection tube unions s R10 10 9 o R12 12 9 7 27 2 800 N mm 2 1000 N mm 2 1200 N mm 4 Denomination 1 9 1 25 3 3 88 93 4 5 45 64 2 6 55 10 x 1 50 52 5 5 36 73 8 7 54 88 7 9 05 13 1 75 8 9 09 12 12 80 150 15 30 14 x 2 00 135 13 80 1 19 40 2 23 30 22 x 2 50 4 44 40 6 62 40 74 90 24 x 3 00 5 56 90 7 80 00 94 96 00 42 Workshop Manual KD500 _ cod ED0053029390 1 ed_rev 00 1 9 7 5 90 2 62 4 0 11 84 6 7 2 8 9 4 8 05 7 35 i 73 of 0 KOHLER SERVICE 17 SUGGESTIONS ON HOW TO TIME THE INJECTION PUMP WHEN THE LEAD PUNCH MARKS ON THE FLYWHEEL ARE DIFFICULT TO REACH Consult chapter Injection lead on page 37 for a description of the conventional adjustment Proceed in the following way 1 Remove the cover from the rocker arms 2 Demount the recoil and turn the drive shaft to the valve regulation position This operation is carried out by means of the fylwheel nut using a 32 socket wrench 3 Demount the intake or exhaust rocker arm the valve spring and caps 4 Rest the valve top on the crown of the T D C balanced piston fig 1 WARNING The valve slips from its guide if the piston is lowered by turning the drive shaft more than 1 4 of a pipe wrench turn 5 Position a comparator mounted on a magnetic pedestal or dummy injector and reset it on the valve stem fig 1 6 Slowly turn t
18. been used for a lengthy period of time valve knocking in their housings at high temperatures will harden the housing tracks and make manual milling difficult to carry out When this happens remove the hardened surface layer with a grinder at 45 Fig 11 The valve retention track will widen when the valve housing is machined Final adaptation of the valve in the housing must be carried out by smearing fine grain lapping compound in the housing and turning the valve with a light pressure and with an alternate movement until the surfaces bed perfectly fig 12 Comply with the valve embedding values as indicated in the table G fig 9 Warning when the valve embedding values are lower H than those prescribed the valves could interfere with the piston Workshop Manual KD500 _ cod ED0053029390 1 ed rev 00 19 1 0 Checks and overhaul KOHLER Grinding in must always be carried out when new valves or housings are mounted Valve housings oversized on the outside by 0 5 mm are available Thoroughly wash the valve and housing with petroleum or gasoline to eliminate lapping paste residues or swarf Proceed in the following way to make sure that the valve and seat are tight 1 Mount the valve on the head with cap string and cotters see fig 8 2 Overturn the head and pour a few drops of diesel fuel or oil on to the edge of the valve top 3 Blow compressed air into the head duct Plug the edges of
19. casing and cover on the timing system side The max xonstructional play is 0 032 to 0 061 mm INJECTION 917 973 17 984 1 EXHAUST INTAKE pins exceeds 0 1 mm injection cams and pins 0 3 mm intake and exhaust cams WARNING replace the shaft if the wear the cams 27 Workshop Manual KD500 _ cod ED0053029390 1 ed_rev 00 23 1 0 Checks and overhaul 3 216 8 217 2 07 986 7 995 4 29 921 959 21 979 4 45 4 55 218 9 19 Tapets and rocker arms Make sure that there is no wear scoring or signs of seizure on the surfaces of the tappets fig 28 Replace the parts if necessary Tapet and housing coupling play 0 16 0 215 0 345 The rods must be straight with ball shaped surfaces at the ends and in good conditions fig 28 Injection pump tappets and pads Replace the parts if the wear on their surfaces exceeds 0 1 mm fig 29 Coupling play between the tappet and relative housing in the crankcase Fuel pump optional Check the projection of the AC pump rod in relation to the engine casing surface with the canshaft eccentric in the non operative position Rod length Wear limit Rod projection mm m mm m WARNING the rod projection cannot be adjusted 24 Workshop Manual KD500 _ cod ED0053029390 1 ed rev 00
20. demounting operations or if a new one must be installed Injector and injector tube Mount the injector on the head inserting the copper retention seals see section Head page 36 Connect the injector to the pump with the injection pipe Warning always use two wrenches to slacken off or tighten injection pipes fig 78 38 Workshop Manual KD500 _ cod ED0053029390 1 ed_rev 00 KOHLER ENGINE TESTING 14 HUNTING RATE DIMINISHES 80 RATE DIMINISHES MORE SLOWLY 81 Rpm regulation Fill the engine with oil and diesel fuel and allow it to warm up for 10 minutes With the engine hot adjust the idling rate A fig 79 to 1 300 rpm and the peak no load rate B fig 79 to 3 150 rpm for engines set at 3 000 rpm on load 3 750 rpm for engines set at 3 600 rpm on load Braked engine test Carry out the following operations after having positioned the engine on the brake 1 Start the engine and allow it to idle 2 Allow the engine to run in before checking the maximum power Running in table Consult the power curves in chapter 5 There may be hunting problems slowness or misfiring if the injection pump is changed Correct these faults by turning the pump casing a few degrees in relation to the engine casing following the directions indicated in fig 80 Fuel limiter The fue
21. insufficient oil It is also dangerous to add too much oil as its A combustion could sharply increase the rotation speed Use a 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 or 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 A 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 5 40 specification API SJ CF ACEA A3 96 B3 96 MIL L 46152 D E SoS ESO GO OGE GEO p ESSO ULTRA 10W40 specification API 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 s
22. that fixes the nozzle using a torque wrench and as device like the one shown in fig 41 which relieves the pressure exercised by the spring on the ring nut 1 Visual inspection make sure that the needle housing is not deformed or excessively rough The nozzle body must not show signs of wear or damage The holes must be free from carbon residues 2 Smoothness test the nozzle needle which will have been previously immersed in impurity free fuel should be inserted into the body of the nozzle Noz extract it by up to a third of the guide length holding the nozzle in a vertical position The needle must drop back into its housing thanks to its actual weight alone 41 Remount the injection in compliance with the order indicated in fig 38 Make sure that the plugs and centering pins on the spacer N 8 fig 38 match the relative holes in the housings Tighten the ring nut that fixes the nozzle to a value of 4 6 5 6 kgm 45 55 Nm 28 Workshop Manual KD500 _ cod ED0053029390 1 ed_rev 00 KOHLER ELECTRICAL EQUIPMENT 12 Characteristics of the system Starter motor Ih rotation direction pinion side 12V voltage rating power 1 1 kW Internal alternator 12V 280W Voltage regulator electronic with controlled diodes and indicator connection for battery recharger Recommended battery In standard start conditions 12V 50Ah 255 A DIN In heavy duty start conditions 12V 60A
23. 0 31 13 Engine assembly KOHLER 55 9 Timing system cover pre assembly Prepare the cover of the timing system in the following way Mount the main bearing as indicated at page 18 Fit in the pin and drive shaft bearing ring fig 52 Mount the oil pump rotors as described at page 23 Insert the plug and driving pin as shown in fig 53 A Fix the oil pump cover in place by tightening the screws to the following torque value 0 8 1 0 kgm 7 8 9 8 Nm Insert the by pass valve using tool code 00366R0210 fig 54 mount the by pass check screw with Loctite 648 mount the bypass valve inspection plug on the outside of the cover on the timing system side Fit the retainer cap on the oil intake duct at the base of the cover on the timing system side using Loctite 648 fig 53 B Tighten the internal oil filter fig 53 Fit on the engine oil filter and relative plug including the O Ring fig 53 D Mount the rpm governor in compliance with the alphabetical sequence given in fig 55 Fit in the fuel flow limiter 10 Mount the oil retention ring as indicated on page 35 fig 66 32 Workshop Manual KD500 _ cod ED0053029390 1 ed rev 00 KOHLER Engine assembly 1 3 58
24. 1 ed_rev 00 TROUBLE SHOOTING 1 KOHLER POSSIBLE CAUSES AND TROUBLE SHOOTING The following table contains the possible causes of some failures which may occur during operation Always perform these simple checks before removing or replacing any part TROUBLE POSSIBLE CAUSE Excessive oil consumption Oil and fuel dripping from exhaust gt il o C O z o o E 4 c c 2 x E o 2 lt 2 o o Q Engine does not start Engine starts but stops ICogedtakbeaternde Faulty fuel pump Injector jammed CEE EET Jammed injection pumpdeliveryvave Wrong injector setting CT l Exesswepunerbowby Tc dT dT Jammes injection pump delivery control Wrong injection pump setting Oil evel too high CT ET Jammedpressurereliefvave S Womolpump CEE EET TT Air inside oil suction pipe Faulty pressure gauge or switeh SST Clogged oil suction pipe S Battery discharged CE TE Wrong or inefficient cable connection Defective ignition switch CE Defective startermotor CE ET Td TdT dT Clogged air filter HEH EM _ Excessive idle operation B BS Incomp
25. 8 1 Nut 2 Nut with ball 3 Rocker arm 4 Cotters 5 Rocker arm stud 6 Upper cap 7 Spring 8 Air relief valve 9 Lower cap 10 Valve guide 11 Rocker arm cover 12 Head 13 Valve housing 14 Exhaust valve 15 Intake valve 16 Rocker arm rod 17 Camshaft 18 Tappets The head is made of aluminium with valve guides and housings in faced cast iron Remove any carbon deposits from the head and check the cylinder bearing surface Level it off to a depth of no more than 0 3 mm if deformed The head must not be cracked or deformed If such faults are discovered replace the part after consulting the spare parts catalogue Do not demount the head when hot to avoid deformations Valves Guides Housings Clean the valves with a metal brush and replace them if the tops are deformed cracked or worn fig 9 0 c2 002 gec ert c 13 4 13 025 40 13 35 13 0 35 t 6 96 6 945 08 13 01 13 037 40 145 35 145 40 025 35 025 7 01 697 6995 1 with guide mounted measurements in mm Check the dimensions of the valve stem fig 10 and the play between the guide and valve Ream the guide to the dimensions indicated in the table Change the guide and valve if the play exceeds 0 1 mm The valve housings will always need to be ground when new guides are mounted Valve guides oversized on the outside by 0 10 mm are available After the engine has
26. 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 constant load MN Torque at N power MB Torque at NB power MA Torque at NA power C Specific fuel consumption at NB power The above power values refer to an engine fitted with air cleaner and standard muffler after testing and at the environmental conditions of 20 C 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 C Note Consult KOHLER for power torque curves and specific consumptions at rates differing from those given above 12 Workshop Manual KD500 _ cod ED0053029390 1 ed rev 00 OVERALL DIMENSIONS 6 KOHLER 239 LA LLL 343 y s 27 la EP Mn d 7 E V NC TAM EMT EN 211 aa a mS E Ah AUXILIARY P T O FOR HYDRAULIC GRAVITY CENTER OF THE ENGINE PUMPS STANDARD P T O WITH ANTICLOCKWISE DIRECTION OF OPTIONAL P T O ON CAMSHAFT WITH CLOCKWISE DIRECTION OF ROTATION ROTATION s gt D 0 lt Conicita 1 5 Taper
27. ARNING In addition to all other machine specifications ensure that the engine is in a 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 so spending too long a 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 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 During operation 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
28. D500 _ cod ED0053029390 1 ed rev 00 KOHLER Checks and overhaul 1 0 Checking the oil pump D Make sure that the oil pump cover is in a good condition After demounting examine the rotors and replace them if their lobes or centerings are damaged To check the degree of pump wear measure the dimensions of rotor A and rotor B fig 24 and compare them with the values in the following table OIL PUMP ROTOR DIMENSIONS AND PLAY Dimensions mm Max wear mm 25 97 25 99 25 92 26 205 26 27 26 31 7 97 7 99 7 93 The entire pump must be replaced if the wear is greater RotorA Rotor B D CY 23496 3499 34 87 24 The coupling play between the external oil pump rotor and the housing on the cover of the timing system is 0 16 0 215 0 345 Make sure that the oil pump recess in relation to the surface of the timing system cover fig 25 is between Make sure that there are no impurities in the by pass valve on the cover on the timing system side by unscrewing the inspection plug near the fuel flow limiter 40 85 40 90 35 95 36 00 Intake Injection Exhaust 26 Camshaft Make sure that the cams and bearing pins are not scored or worn Check the dimensions as indicated in fig 26 Check the dimensions of the camshaft pins D fig 27 and thecorresponding housings in the
29. SIL type on WA the retention surface of the timing system cover fig 65 S Place the cover on the casing o M Insert the cover fixing screws making sure that the five shorter SA ones 40 mm are mounted in the top part of the cover Tighten to the following torque value 2 7 2 8 kgm 26 5 27 5 Nm T Oil retention rings 1 Immerse the retention ring in oil for about 10 minutes 3 2 Clean the housing and insert the ring with a plug exercising an even pressure all over the surface fig 66 Flywheel Block the flywheel fig 67 and torque the nut to value 18 20 kgm 176 5 196 1 Nm 67 Workshop Manual KD500 _ cod ED0053029390 1 ed rev 00 35 1 3 Engine assembly KOHLER Mount the rings on the piston fig 68 in the following order 1 chromium plated compression retention ring stamped trademark pointing upwards 2 tapering retention ring stamped word TOP pointing upwards 3 oil Scraper ring stamped trademark pointing upwards Position the piston so that the central axis of the combustion chamber is aligned with the injector fig 69 Connect the piston to the connecting rod slightly pressing with the hand on the pin Cylinder Insert the cylinder into the engine casing after having inserted the 0 3 mm thick seal before mounting turn the r
30. 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 ow Review body code N Revision Issue date date Endorsed Y SZ prac ED0053029390 51267 0 04 07 2012 04 07 2012 2 500 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
31. ce to allow for any expansion of the fuel Do not smoke or use naked flames while filling Workshop Manual KD500 _ cod ED0053029390 1 ed rev 00 KOHLER General remarks and safety information 2 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 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 The 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 important to wear the personal
32. ceeding with the scraping operation fig 21 When the crankshaft is perfectly clean check with a micrometer to ascertain wear and main journal ovality in the two perpendicular positions fig 22 Grind the shaft if the wear exceeds the values in the table by 0 08 mm or more AC 41 97 41 99 41 72 41 74 B 39 98 40 39 73 39 75 NOTE crankshaft grinding operations of more than 0 25 mm should not be carried out Undersized bearings can be mounted without any reaming work required WARNING do not remove material from the main journal shims during the grinding operation as this would alter crankshaft float Also make sure that the grinder radii correspond to those indicated in fig 21 to prevent fracture sections from initiating on the shaft Oil retention rings Make sure that the rings have not hardened in the retention lip and that there is no sign of breakage or wear Lubrication circuit Lubrication of the main bearings and connecting rod big end is the forced type with a rotor oil pump Excessive pressure in the oil circuit is prevented by the by pass valve 3 fig 23 All the other parts are splash lubricated Oil vapours are eliminated from inside the casing by a diaphragm mounted in the rocker arm cover Illustration in fig 23 1 Internal intake oil filter in casing 2 Oil pump 3 By pass valve 4 Engine oil filter 5 Pressure switch 6 Main bearing T Big end bearing Workshop Manual K
33. 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 proportions Petrol may not be used because of the risk of it forming flammable vapours 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 If 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 cyc
34. e exact lead position This value must correspond to the one previously read on the comparator see point 7 If this is not the case add or remove seals to or from the injection pump according to the corrections indicated in the following table I sc bubble rm Lead IP 2 443 mm 17 2 735 mm T 3 043 mm RC Injection pump Capillary tube 0036580940 3 336 mm 4 058 mm 4 427 mm Fig 3 4 811 mm Workshop Manual KD500 _ cod ED0053029390 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
35. e 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 Workshop Manual KD500 _ cod ED0053029390 1 ed rev 00 3 INDEX KOHLER INDEX WARRANTY
36. e of low use every 6 months 3 In case of low use every 12 months 4 If you are using oil of a quality lower than the recommended one then you will have to replace it every 150 hours 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 during 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 5 0 Workshop Manual KD500 _ cod ED0053029390 1 ed_rev 00 15 8 Maintenance Recommended oil type Refilling KOHLER The engine could be damaged if allowed to operate with
37. e pressure gauge needle will show a progressive pressure increase until reaching a maximum value after which it will drop sharply back and stop at a lower pressure value Replace the valve if the pressure drop is more that 50 Kg and continues to slowly drop lower The pressure must drop from 200 Kg cm to 150 Kg cm in not less than 7 sec Injection pump calibration fig 34 When the adjuster sleeve is 10 5 mm from the stop position and the pump spins at 1 500 rpm the amount of fuel for 1 000 deliveries must be between Replace the pump if the values differ WARNING Check to make sure that plunger travel with the injection cams in the non operative position BDC at the start of delivery is Injection pump assembly fig 36 If the injection pump must be demounted use an electric pen to mark the adjuster block M with the enbloc pump casing A and loosen the plug N after having heated it to make the Loctite easier to release Comply with the following instructions when remounting the parts 1 Fit the washer B the delivery valve C the washer D the alve spring E the filler F into the enbloc pump casing A and torque the delivery union G to a value of 4 3 5 4 kgm 42 5 52 5 Nm 2 Insert the adjuster seal H 3 Insert the flange I 4 Insert the plunger with helical profile A fig 35 into the iner housing of the adjuster sleeve from the side opposite the sleeve pin B fig 35
38. etic thickness of the seals to insert under the injection pump NOTE if the flywheel or a crank component is replaced make sure that the punch mark on the flywheel TDC fig 75 the reference mark of the tool code 00366R0240 match when the piston is at top dead center Lead values in degrees and millimeters on the flywheel 3000 18 42 4 mm 3600 23 54 2 mm The punch marks on the flywheel indicate fig 75 TDC top dead center IP start of delivery Workshop Manual KD500 _ cod ED0053029390 1 ed rev 00 37 1 3 Engine assembly KOHLER Mounting the injection pump on the engine Lower the tappet in the innermost point of the engine by slightly turning the flywheel Insert a seal of adequate thickness see section Injection lead point 5 page 37 Turn the motor stop lever to the STOP position Set the adjuster sleeve of the injection pump about one millimeter from the stop position on the adjuster block fig 77 Fit the injection pump into the engine block and keeping it pressed down fix it in place by tightening the nut that holds the relative bracket Match the marks made during the demounting phase see section Removing the injection pump page 17 Warning consult section Braked engine test page 39 if the position of the injection pump in relation to the casing was not marked during the
39. h 300 A DIN Optional accessories control strip with remote control switch and OIL ALARM plant Illustration in fig 42 1 Ignition key 2 Voltage regulator 3 Starter motor 4 Battery 5 Alternator 6 Pressure switch 7 Low battery charge indicator 8 Low oil pressure indicator CABLES Colour x Section mm CABLE COLOURS B white M brown N black R red V green 42 Checking the system 1 make sure that the connections between the regulator and alternator are correct and in good conditions 2 detach the wire from the remote control switch from the terminal and fit on a d c amperometer A fig 43 3 connect a d c voltmeter to the battery terminals V fig 43 4 make a few no load starts or introduce a 80 100W lamp load at the battery lugs to keep the battery voltage below 13V 5 accelerate the engine to a 3000 rpm rate The current indicated on the amperometer must correspond to the values in fig 44 6 disconnect the load if any and keep the engine at the above mentioned rate for a few minutes The battery voltage must progressively increase until reaching about 14 2 V Meanwhile the charge voltage must drop to a minimum value of about 2A with a speed determined by the battery charge condition 7 if charge current is missing or is less than the given values check the alternator and replace the voltage regulator if necessary
40. he drive shaft in an anti clockwise direction and check the comparator to make sure that the piston drops Fig 1 about 5 mm in relation to TDC dimension h fig 2 7 Slowly turn the drive shaft in a clockwise direction and check the comparator to make sure that the piston rises by the values indicated in the following table in relation to TDC dimension h fig 2 8 Remove the injection tube and mount the capillary tube code 00365R0940 on the injection pump delivery fitting fig 3 9 Turn the accelerator lever to the MAX position and the stop lever to about half travel 10 Turn the drive shaft anti clockwise by no more than 1 4 of the pipe wrench turn 11 Pressurize the circuit by turning the drive shaft several times in an alternate clockwise anti clockwise way until fuel splashes out of the calibrated hole of the capillary tube 12 Turn the drive shaft and check the comparator to make sure that the piston drops about 10 mm in relation to TD Fig 2 dimension quota h fig 2 13 Shake the capillary tube until an air bubble forms inside it fig 3 14 Turn the drive shaft in a clockwise direction very slowly and TDC top dead center h extent of piston lowering in relation to TDC a angle corresponding to piston lowering in relation to T D C I P start of delivery check the position of the air bubble in the capillary tube A small movement of this bubble will indicate th
41. he manufacturer In order to minimise the impact on 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 65 WARNING Engine exhaust from chemicals known to the State of California to cause cancer birth defects or other reproductive harm this product contains Workshop Manual KD500 _ cod ED0053029390 1 ed rev 00 9 3 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 A MADE IN ITALY e KOHLER B Model XX XX XXXX mm XXXX D C sin XX XX XXXX Spec XXXXXX E egg E xxxx XX EXE EX C Go
42. her 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 19SkW lt 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 Kohler Co cannot deny warranty solely for th
43. ings through 120 one in relation to the other with the first compression ring pointing with its ends on a level with the pin axis There is a chamfer to allow ring insertion on the lower side of the cylinder The operation is simplified by using a normal ring mounting tool code 00365R0770 as indicated in fig 70 _ Move the piston to TDC top dead center and check that the mark stamped on the flywheel corresponds to the reference pointer of the tool code 00366R0240 fig 75 To obtain the correct clearance use a head seal of adequate thickness 1 check the piston projection as shown in fig 71 2 Choose the seal as indicated in the following table 0 00 0 10 0 10 0 20 0 20 0 30 0 30 0 40 NOTE The distance between piston crown the corresponding head surface must be 0 7 0 8 mm Head Before fixing the head to the cylinder fit the injector into its housing and after having temporarily fixed it check that the distance the nozzle projects from the surface of the head by fig 72 2 2 2 7 mm regulate by placing copper washers between the injector and the bearing surface on the head Consult page 19 and 20 for the relative inspections and overhauls 36 Workshop Manual KD500 _ cod ED0053029390 1 ed_rev 00 KOHLER Engine assembly 13 75 IP I
44. ire fig 39 with the following diameters Diameter of steel Number Diameter wire mm of holes of holes mm 2 Mount the injector on the test bench code 00365R0430 fig 40 Disconnect the pressure gauge and rapidly operate the lever The nozzle must make the characteristic trilling sound and inject with a good atomizing action 3 Connect the pressure gauge Slowly depress the level in a continuous way until injection occurs The injector needle must open at the pressure of 230 to 238 bar Vary the washer shims N 5 fig 38 to calibrate in the correct way 4 Leak test operate the test bench lever until the gauge pointer is 20 Kg cm below the injection pressure value Nozzle tightness is good if no fuel comes out within 10 sec 5 Checking for leaks on the nozzle return phase operate the test bench lever until the gauge pointer is 20 Kg cm below the injection pressure value Release the lever and Workshop Manual KD500 _ cod ED0053029390 1 ed_rev 00 27 11 Injection equipment KOHLER heck the time it takes to drop The pressure must drop to 150 to 100 Kg cm withinn 6 to 40 seconds replace the nozzle if it drops in less than 6 seconds if it takes longer than 40 seconds to drop make sure that there are no carbon deposits in the nozzle and that the return holes are not clogged Demounting and remounting Loosen the ring nut
45. is a ridge in zone X fig 15 of the cylinder and if tapering and ovality exceed the previously given values 15 20 Workshop Manual KD500 _ cod ED0053029390 1 ed rev 00 KOHLER 10 Checks and overhaul 16 EN gO WAT Y y a A T 19 Piston rings Piston Pin To gauge the wear on the piston rings put them into the cylinder from the bottom side and measure the distance between the free ends fig 16 which must be Oil scrapper 0 25 0 50 Make sure that the piston rings slide smoothly in the slots and use a thickness gauge to check the play between the slot and ring fig 17 Replace the piston and rings if the play exceeds 1st Compression A 0 22 2nd Compression B 0 19 3rd Oil scrapper C 0 16 WARNING it is advisable to replace the piston rings whenever the piston is demounted Checking the piston diameter the diameter of the piston must be measured at a distance from the base fig 18 of approximately 11 mm 86 915 86 835 Check the play between cylinder and piston Replace the parts if play exceeds 0 150 mm Play between pin and piston mm Pin mm Assy clearance mm Max wear mm 21 997 22 002 0 003 0 013 0 040 Connecting rod Coupling between the small e
46. l limiter has a torque corrector device fig 81 that consists of the following parts A Torque corrector cap B Maximum power flow rate adjuster C Spring load adjuster D Locking nuts The adjustments can only be made to the exhaust brake It is therefore inadvisable to tamper with the corrector adjuster C fig 81 The setting of adjuster B fig 81 can only be modified if work has been done on the injection pump or regulator if the engine produces a lot of smoke or has insufficient power Workshop Manual KD500 _ cod ED0053029390 1 ed_rev 00 39 15 STORAGE KOHLER Storage Prepare engines as follows for storage over 30 days Temporary protection 1 6 months 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 e Remove fuel tube and empty the tank e Remove fuel filter replace cartridge if dirty and refit Carefully clean cylinder fins heads and fan Seal all openings with 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 Wrap the engine in a plastic film e Store in a dry place
47. lete running in 36 Engine overloaded Advanoed injection CEE Po Delayedinjection CE EE ET PL 2 Incorrect governor linkage adjustment Broken or loose governor spring tate speed too low Wom or jammed piston rings Wom or scored oytinders TL bL p Wom valve guides CECT AST Jammed valves Cid TE ll lll Lo Wom Governorlinkagenotfreetoside S Drive shaft not free to slide Tc l Damaged cylinder nead gasket l lll Workshop Manual KD500 _ cod ED0053029390 1 ed rev 00 7 x O D x amp e FUEL CIRCUIT Clogged pipes m Clogged fuel filter Clogged fuel filter Air inside fuel circuit Air inside fuel circuit Z Q H ELECTRIC SYSTEM MAINTE NANCE 9 LLI o 2 E L LLI o 2 GENERAL REMARKS AND SAFETY INFORMATION 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 necessa
48. lone pre filter cup must not be filled with oil Since the oil must be emptied out while the engine is still hot approx 80 C 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 activation 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 spa
49. nd hole of the connecting rod and pin is made without a bearing Play between connecting rod small end and pin mm Pin mm Assy clearance mm Max wear mm 21 997 22 002 0 023 0 038 0 070 Check connecting rod axes parallelism in the following way 1 Insert the pin into the small end hole of the connecting rod and a calibrated plug into the big end with the bearing mounted 2 Rest the plug on two prisms arranged on a surface plate or between two centers fig 19 3 Use a centesimal comparator to check that the difference between the readings made at the ends of the pin does not exceed 0 02 mm square up the connecting rod if the deformation is greater max 0 05 mm Workshop Manual KD500 _ cod ED0053029390 1 ed rev 00 21 1 0 Checks and overhaul KOHLER The operation is carried out by applying a calibrated pressure to the convex side in the middle of the connecting rod stem set on surface plates fig 20 Crankshaft It is advisable to check the condition of the crankshaft whenever the engine is demounted and particularly when cylinders and pistons must be replaced following wear due to dust having been intaken Thoroughly clean inside the oil ducts using a shaped metal point If there are heavily caked incrustations immerse the crankshaft into a bath of petroleum or gasoline before pro
50. ng if this has not already been done Remove the injection tube and take out the fuel pipes The pump can only be removed when the stop lever has been turned to the stop position To do this the pump must be pressed towards the housing as shown in fig 2 Flywheel extraction Remove the fuel tank the air conveyor and flywheel nut Use extractor cod 00365R0020 as shown in figure 3 A During the demounting phases pay particular attention to prevent the flywheel from dropping as this could seriously injure the operator Wear protective goggles when removing the flywheel ring IMPORTANT Do not tap the end of the extractor when removing the flywheel Removing the cover on the timing system side Slacken off the screws around the perimeter of the cover on the timing system side Split the cover from the engine casing by levering with a screwdriver in the points indicated in fig 4 advisable to demount the cover from the timing system Yr Warning to prevent damage to the main bearings it is side with the engine cold Workshop Manual KD500 _ cod ED0053029390 1 ed rev 00 17 9 Disassembly of the engine Main bearing 00365R0900 Main bearing 00366R0220 Demounting the piston Take out the piston pin as shown in fig 5 Warning do not demount the head when hot or the retention surfaces could be damaged
51. nsert the rocker arm casings the partition A fig 74 the head seal and the head Tighten the head fixing nuts evenly and alternately fig 73 to the following value NOTE To prevent oil leaks apread sealant Motorsil on H the threads of the stud bolts and washer bearing surfaces in the rocker arm chamber before tightening the nuts Valve clearance Adjust the clearance between valves and rocker arms in either a hot or cold condition to the following values fig 74 me 020mm ntakelexhaust cold 0 20 mm intake exhaust Since the automatic decompression device opens the exhaust valve near TDC clearance must be adjusted during the expansion phase a few degrees after TDC Injection lead To ensure the injection lead is accurately adjusted it is advisable to define the shims to insert under the pump by measuring the dimension between the pump bearing surface and the tappet Proceed in the following way 1 turn the flywheel to the compression phase 2 insert the tappet pad into the housing in the engine block pointing the exhaust side towards the tappet roller see fig 29 page 24 3 align the dynamic lead punch mark IP on the flywheel with the reference mark of the tool code 00366R0240 fig 75 4 using a depth gauge fig 76 measure the dimension between the injection pump bearing surface and the tappet pad 5 subtract 51 6 mm from the dimension measured on the gauge the result represents the theor
52. ohler 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 MERCHANTABILITY OR FITNESS FORAPARTICULAR PURPOSE ARE
53. pecification MIL L 46152 D E OIL SUPPLY liters Standard oil sump filter included 1 51 SEQUENCES Gasoline Petrol BENZINA ESSENCE PETROL B Light Diesel fuels BENZIN GASOLINA DIESEL API CF CD 58 SC SD SE SG SH SJ E Heavy Diesel fuels Required levels CCMCG 2 1 CcMCG 3 A1 96 A2 96 4 CCMC D 2 A3 96 D 5 CCMC D 3 B1 96 B2 96 B3 96 E1 96 E2 96 E3 96 VW 505 00 VOLVO VDS MAN QC 13 017 16 Workshop Manual KD500 _ cod ED0053029390 1 ed rev 00 KOHLER DISASSEMBLY OF THE ENGINE 9 During repair operations when using compressed air wear eye protection DISASSEMBLY AND REASSEMBLY Besides disassembly and reassembly operations this chapter also includes checking and setting specifications dimensions repair and operating instructions Always use original KOHLER spare parts for repair operations Removing the injector Slacken off the fuel delivery pipe remove the fixing bracket and take out the tube Remove the injector by levering it out with a screwdriver as indicated in fig 1 Removing the injection pump Mark the position of the injection pump in relation to the engine casi
54. ry 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 may 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 W
55. 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 contamination 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 t
56. the duct itself to prevent air escaping If there are air leaks in the form of bubbles between the housing and valve demount the valve and grind in again Valve springs Check the length of the spring as indicated in fig 13 to identify any yielding Replace the springs if the values are different Rocker arms Make sure that there are no evident signs of wear on the contacting surfaces Replace the parts if necessary 42 3 43 7 Free length 28 3 28 5 18 7 18 9 y Cylinder In special cast iron with integral liner Use a bore gauge to check the two internal diameters C D perpendicular to each other and at different heights fig 14 Maximum tolerated taper error A B and ovality error C D 0 06 mm Cylinder diameter 87 87 020 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 14 Do not manually hone the cylinder bore surfaces with H emery 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 fig 15 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 Replace the cylinder and piston if there

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