Kohler KD 500 Workshop Manual page 5

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 .................................................................................................................................. 32
Removal and assembly of the drive shaft gear ................................................................................................................ 33
Drive shaft assembly ........................................................................................................................................................ 33
Connecting rod - drive shaft connection . ......................................................................................................................... 33
Counter-shaft .................................................................................................................................................................... 33
Camshaft . .......................................................................................................................................................................... 34
Play adjustment ................................................................................................................................................................ 34
Crankshaft float: . ............................................................................................................................................................... 34
Camshaft float: . ................................................................................................................................................................. 34
Counter-shaft float (optional): ........................................................................................................................................... 35
Cover on timing system side . ............................................................................................................................................ 35
Oil retention rings . ............................................................................................................................................................. 35
Flywheel . ........................................................................................................................................................................... 35
Piston ................................................................................................................................................................................ 36
Cylinder . ............................................................................................................................................................................ 36
Head.................................................................................................................................................................................. 36
Valve clearance ................................................................................................................................................................ 37
Injection lead . .................................................................................................................................................................... 37
Mounting the injection pump on the engine . ..................................................................................................................... 38
Injector and injector tube .................................................................................................................................................. 38
ENGINE TESTING ................................................................................................................................................... 39
Rpm regulation ................................................................................................................................................................. 39
Braked engine test ............................................................................................................................................................ 39
Temporary protection (1/6 months) . .................................................................................................................................. 40
Permanent protection (over 6 months) ............................................................................................................................. 40
How to prepare the engine for operation .......................................................................................................................... 40
STORAGE ............................................................................................................................................................... 40
QUICK REFERENCE CHARTS .............................................................................................................................. 41
SERVICE ................................................................................................................................................................. 43
SUGGESTIONS ON HOW TO TIME THE INJECTION PUMP WHEN THE LEAD PUNCH MARKS ON THE
FLYWHEEL ARE DIFFICULT TO REACH. ...................................................................................................................... 43
Workshop Manual KD500 _ cod. ED0053029390 - 1° ed_rev. 00
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