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Summary of Contents for Kohler KD 500
- Page 1 WORKSHOP MANUAL KD 500...
- Page 2 ED0053029390 51267 04/07/2012 04/07/2012 KD 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. 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;...
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Page 3: Warranty Certificate
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 19≤kW<37 and rated speed less than 3,000 rpm, all variable speed engines with maximum power 19≤kW<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 19≤kW<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 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. -
Page 4: Table Of Contents
INDEX INDEX WARRANTY CERTIFICATE ............................. 3 Limited 3 year kohler ® diesel engine warranty ........................3 California emission control warranty statement ......................... 3 TROUBLE SHOOTING .............................. 7 POSSIBLE CAUSES AND TROUBLE SHOOTING ......................7 GENERAL REMARKS AND SAFETY INFORMATION ................... 8 SAFETY REGULATIONS ..............................8 GENERAL SAFETY DURING OPERATING PHASES ...................... 9 SAFETY AND ENVIRONMENTAL IMPACT ........................9 MODEL NUMBER AND IDENTIFICATION ......................10 The identification plate shown in the figure can be found directly on the engine. .............10 Approval data . - Page 5 Index INJECTION EQUIPMENT ............................25 Fuel circuit ..................................25 Injection pump .................................. 25 Injection pump calibration ..............................26 Injection pump assembly ..............................26 Leak test.................................... 27 Injector inspection and calibration ............................ 27 ELECTRICAL EQUIPMENT ............................ 29 Characteristics of the system ............................29 Checking the system ................................ 29 Checking the alternator..............................30 Ring gear ..................................30 ENGINE ASSEMBLY ............................... 31 Preparing the engine block ..............................31 Injection pump tappets ..............................31 Timing system cover pre-assembly ..........................
- Page 6 Index - 6 - Workshop Manual KD500 _ cod. ED0053029390 - 1° ed_rev. 00...
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Page 7: Trouble Shooting
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 simple checks before removing or replacing any part. TROUBLE POSSIBLE CAUSE Clogged pipes Clogged fuel filter Air inside fuel circuit Clogged tank breather hole Faulty fuel pump Injector jammed Jammed injection pump delivery valve Wrong injector setting Excessive plunger blow-by Jammed injection pump delivery control Wrong injection pump setting Oil level too high Jammed pressure relief valve Worn oil pump Air inside oil suction pipe Faulty pressure gauge or switch Clogged oil suction pipe Battery discharged Wrong or inefficient cable connection Defective ignition switch Defective starter motor 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 speed too low Worn or jammed piston rings... -
Page 8: General Remarks And Safety Information
GENERAL NOTES . Children and animals must be kept at a sufficient distance . Kohler engines are built to provide safe and longlasting from the machine to prevent any danger resulting from its performances, but in order to obtain these results it is operation. -
Page 9: General Safety During Operating Phases
. 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. -
Page 10: Model Number And Identification
MODEL NUMBER AND IDENTIFICATION 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). - 10 - Workshop Manual KD500 _ cod. ED0053029390 - 1° ed_rev. 00... -
Page 11: Technical Data
TECHNICAL DATA ENGINE TYPE KD 500 N° Number of cylinders Bore Stroke Swept volume 19:1 Compression ratio N 80/1269/CEE-ISO 1585 9 (12.24) 9 (12,24) Power kW (HP) NB ISO 3046 - 1 IFN 8.4 (11.42) 8,4 (11,42) NA ISO 3046 - 1 ICXN 7.6 (10.34) 7,6 (10,34) 3600 Crankshaft PTO ratio 3000 Camshaft PTO ratio left* Crankshaft main PTO rotation right* Camshaft main PTO rotation Nm (@ rpm) 31 (2000) Max. torque g/kWh Fuel consumption (@ max. torque) kg/h 0,0055 Oil consumption Capacity of standard oil sump Ah - A 50Ah-255A DIN Recommended battery 12V in standard start conditions... -
Page 12: Characteristics
CHARACTERISTICS CHARACTERISTICS POWER, TORQUE AND SPECIFIC FUEL CONSUMPTION CURVES KD 500 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 constant load. -
Page 13: Overall Dimensions
OVERALL DIMENSIONS 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 Note: Dimensions in mm Workshop Manual KD500 _ cod. ED0053029390 - 1° ed_rev. 00 - 13 - - 13 -... -
Page 14: Special Tools
SPECIAL TOOLS TOOL CODE DESCRIPTION Failure Flywheel puller 00365R0020 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... -
Page 15: Maintenance - Recommended Oil Type - Refilling
MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING Failure to carry out the operations described in the table may lead to technical damage to the machine and/or system MAINTENANCE INTERVAL (HOURS) OPERATION 2500 5000 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 (1) After the first 50 working hours (2) In case 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. -
Page 16: Recommended Oil
Maintenance - Recommended oil type - Refilling 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 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 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. ESSO ULTRA 10W40 specification API SJ/CF ACEA A3-96 MIL- L-46152 D/E. SAE 10W 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 SAE 30... -
Page 17: Disassembly Of The Engine
DISASSEMBLY OF THE ENGINE 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. -
Page 18: Demounting The Piston
Disassembly of the engine 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. 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 Main bearing 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). -
Page 19: Checks And Overhaul
CHECKS AND OVERHAUL Head Parts indicated in fig. 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. -
Page 20: Valve Springs
Checks and overhaul 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. -
Page 21: Piston Rings - Piston - Pin
Checks and overhaul 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: Piston ring Fitting mm Max. wear mm Compression 0,30 ÷ 0,50 0,80 Oil scrapper 0,25 ÷ 0,50 0,80 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: Piston ring Max. wear mm... -
Page 22: Crankshaft
Checks and overhaul 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 proceeding 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). -
Page 23: Checking The Oil Pump
Checks and overhaul Checking the oil pump 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 Measurement Dimensions mm Max. wear mm Ø 25,97 ÷ 25,99 Ø 25,92 Ø 34,96 ÷ 34,99 Ø 34,87 26,205 ÷ 26,27 26,31 Rotor A... -
Page 24: Tapets And Rocker Arms
Checks and overhaul 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: Max. wear mm Fitting mm 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). -
Page 25: Injection Equipment
INJECTION EQUIPMENT 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. -
Page 26: Injection Pump Calibration
Injection equipment 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/cm² 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. -
Page 27: Leak Test
Injection equipment 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. - Page 28 Injection equipment heck the time it takes to drop. The pressure must drop to 150 to 100 Kg/cm² 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 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.
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Page 29: Electrical Equipment
ELECTRICAL EQUIPMENT Characteristics of the system Starter motor: lh 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 - 60Ah/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. -
Page 30: Checking The Alternator
Electrical equipment 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. -
Page 31: Engine Assembly
ENGINE ASSEMBLY The instructions refer to engines updated at the time 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. -
Page 32: Timing System Cover Pre-Assembly
Engine assembly Timing system cover pre-assembly Prepare the cover of the timing system in the following way: 1. Mount the main bearing as indicated at page 18. 2. Fit in the pin and drive shaft bearing ring (fig 52). 3. 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) 4. 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. -
Page 33: Removal And Assembly Of The Drive Shaft Gear
Engine assembly 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. -
Page 34: Camshaft
Engine assembly 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. -
Page 35: Counter-Shaft Float (Optional)
Engine assembly 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 Spread liquid seal of the AREXON D 0036 MOTORSIL type on the retention surface of the timing system cover (fig.65). -
Page 36: Piston
Engine assembly Piston 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 rings through 120°, one in relation to the other, with the first compression ring pointing with its ends on a level with the pin axis. -
Page 37: Valve Clearance
Engine assembly Insert 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: 4 kgm (39,2 Nm) NOTE: To prevent oil leaks, apread sealant (Motorsil) on 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): 0,20 mm (intake/exhaust) 0,20 mm cold (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. -
Page 38: Mounting The Injection Pump On The Engine
Engine assembly 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 39: Engine Testing
ENGINE TESTING 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 Time (min) -
Page 40: Temporary Protection (1/6 Months)
STORAGE 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 • Remove fuel tube and empty the tank • Remove fuel filter, replace cartridge if dirty and refit • Carefully clean cylinder fins, heads and fan • Seal all openings with tape. • 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. • Store in a dry place, 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. -
Page 41: Quick Reference Charts
QUICK REFERENCE CHARTS Couplings Spiel (mm) Grezen (mm) Camshaft and plugs 0,032 ÷ 0,061 0,030 ÷ 0,050 Compression ring opening Oil scraper ring opening 0,025 ÷ 0,050 0,023 ÷ 0,038 0,04 Connecting rod and piston pin Injection pump tappets and housing 0,021 ÷ 0,059 0,005 ÷ 0,029 Tappets and housing Pin and piston 0,003 ÷ 0,013 0,04 0,030 ÷ 0,050 Intake guide and valve Exhaust guide and valve 0,045 ÷ 0,065 MIN (mm) MAX (mm) Adjustments 0,25 Camshaft float 0,25 Countershaft float Crankshaft float Connecting rod float 0,15 (0,20) 0,15 (0,20) Valve clearance hot [cold] Valve recessing... - Page 42 Quick reference charts (Nm) kgm Tightening torques 2,7 ÷ 2,8 26,5 ÷ 27,5 Timing system cover 4,6 ÷ 5,6 45 ÷ 55 Injector ring nut 2 ÷ 2,5 19,6 ÷ 24,5 Injection tube unions 0,8 ÷ 0,9 7,8 ÷ 8,8 Injector bracket 19,6 Injection pump bracket 39,2 Head 18 ÷ 20 176,5 ÷ 196,1 Flywheel 3,8 ÷ 3,9 37,3 ÷ 38,2 Connecting rod Standard screw tightening torques = 8.8 = R10 = 10.9 = R12 = 12.9 Denomination R ≥...
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Page 43: Service
SERVICE 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. - Page 44 Translated from the original manual in Italian language. Data reported in this issue can be modified at any time by KOHLER. FOR SALES AND SERVICE INFORMATION IN U.S. AND CANADA, CALL 1-800-544-2444 FORM NO. ED0053029390 KohlerEngines.com ISSUED 04/07/2012 ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044 REVISED DATE 04/07/2012...
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