Injection Check - Kohler KD 425-2 Workshop Manual

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82
83
85
KD 425-2 Workshop Manual_cod. ED0053029360_1° ed_ rev. 00
84
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 rod and
secured to the crankcase. If one or both pumps must be
changed, in order to guarantee the same fuel delivery for
each pump the pump remaining on the crankcase must
be locked using the pins (E or H, fig.80). Alternatively the
above steps must be performed in their entirety.

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 injection 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:
Version
22°
standard =
20°
whisper quiet =
ENGINE ASSEMBLY
I.P. (*)
44 mm 17°
=
40 mm 12°
=
XIII
34 mm
24 mm
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