Kohler KD 425-2 Workshop Manual
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Kohler KD 425-2 Workshop Manual

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WORKSHOP MANUAL
KD 425-2

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Summary of Contents for Kohler KD 425-2

  • Page 1 WORKSHOP MANUAL KD 425-2...
  • Page 2 KOHLER, who therefore refuses all responsibility for any injury arising from such an operation.

  • Page 3: Warranty Certificate

    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.

  • Page 4: Table Of Contents

    INDEX INDEX WARRANTY CERTIFICATE ............................. 3 Limited 3 year kohler ® diesel engine warranty ........................3 California emission control warranty statement ......................... 3 Your warranty rights and obligations ..........................3 I - TROUBLE SHOOTING ............................7 Possible causes and trouble shooting ..........................7 II - SAFETY AND WARNING DECALS - SAFETY INSTRUCTIONS ...............
  • Page 5 How to prepare the engine for operation ...........................41 XVI - QUICK REFERENCE CHARTS ........................42 Couplings ...................................42 Adjustments ..................................42 Tightening torques ................................43 Standard screw tightening torques ........................... 43 - 5 - KD 425-2 Workshop Manual_cod. ED0053029360_1° ed_ rev. 00...
  • Page 6 INDEX - 6 - KD 425-2 Workshop Manual_cod. ED0053029360_1° ed_ rev. 00...

  • Page 7: I - Trouble Shooting

    Worn or jammed piston rings Worn or scored cylinders Worn valve guides Jammed valves Worn bearings Governor linkage not free to slide Drive shaft not free to slide Damaged cylinder head gasket - 7 - KD 425-2 Workshop Manual_cod. ED0053029360_1° ed_ rev. 00...

  • Page 8: Safety And Warning Decals - Safety Instructions

    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

    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 - KD 425-2 Workshop Manual_cod. ED0053029360_1° ed_ rev. 00...

  • Page 11: Technical Data

    Max.permissible driving shaft axial: continuous (instantaneous) 100(300) Flywheel site: continuous (instantaneous) 25°(30°) Max. inclination Power take off site: continuous (instantaneous) 25°(35°) Lateral: continuous (instantaneous) 25°(40°) Referred to N power Consumption at max torque - 11 - KD 425-2 Workshop Manual_cod. ED0053029360_1° ed_ rev. 00...

  • Page 12: Characteristics

    Max. power tolerance is 5%. 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 -...

  • Page 13: Overall Dimensions

    OVERALL DIMENSIONS Note: Dimensions in mm - 13 - KD 425-2 Workshop Manual_cod. ED0053029360_1° ed_ rev. 00...

  • Page 14: Special Tools

    00365R0890 Gear extractor 00365R0910 Central bearing assembly tool 00365R0930 Valve guide rubber fitting tool 00365R0770 Cylinder collar Ø 80/85 mm 00365R0940 Injection advance control tool 00365R0430 Injector test bench - 14 - KD 425-2 Workshop Manual_cod. ED0053029360_1° ed_ rev. 00...

  • Page 15: Maintenance - Recommended Oil Type - Refilling

    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: lt. 4,0 - 15 - KD 425-2 Workshop Manual_cod. ED0053029360_1° ed_ rev. 00...

  • Page 16: Recommended Oil

    MIL - L- 46152 D/E MB 226.1 MB 226.5 E1-96 MB 227.1 MB 227.5 E2-96 228.3 MB 228.1 E3-96 VW 500.00 VW 501.01 VW 505.00 VOLVO VDS MAN QC 13-017 - 16 - KD 425-2 Workshop Manual_cod. ED0053029360_1° ed_ rev. 00...

  • Page 17: Disassembly Of The Engine

    Withdraw the bearing using two M8 screws taking care to tighten them evenly; alternatively use a commercial extractor, as shown in fi- gure 3. Extraction of crankshaft gear Use extractor tool number 00365R0890 (fig.4). - 17 - KD 425-2 Workshop Manual_cod. ED0053029360_1° ed_ rev. 00...

  • Page 18: Extraction Of The Camshaft Gear

    Loosen the plug securing screw, and remove circlip, spring and ball. Cut a thread on the inside of the plug body and then withdraw it using a commercial extractor tool (fig. 8). - 18 - KD 425-2 Workshop Manual_cod. ED0053029360_1° ed_ rev. 00...

  • Page 19: Checks And Overhaul

    Renew both guide and valve if the clearance is greater than 0.1mm. It is always necessary to grind the valve seats when new guides are fitted. Oversize valve guides with external diameter increased by 0.10 are available. - 19 - KD 425-2 Workshop Manual_cod. ED0053029360_1° ed_ rev. 00...
  • Page 20 (fig.15). Should air bubbles form between the seat and the valve remove the valve and regrind the seat. - 20 - KD 425-2 Workshop Manual_cod. ED0053029360_1° ed_ rev. 00...

  • Page 21: Valves And Springs

    The cylinder surface which comes into contact with piston rings should be machined with the plateau method. If the taper and ovality of the cylinder exceed the values indicated, then the cylinder and piston must be renewed. - 21 - KD 425-2 Workshop Manual_cod. ED0053029360_1° ed_ rev. 00...

  • Page 22: Piston Rings - Pistons - Piston Pins

    (fig.23): 1. Fit the wrist pin in the hole in the small end of the connecting rod and fit a calibrated pin into the big end (with bush fitted). - 22 - KD 425-2 Workshop Manual_cod. ED0053029360_1° ed_ rev. 00...

  • Page 23: Crankshaft

    39,994 39,744 39,494 39,244 ÷ ÷ ÷ ÷ 40,010 39,760 39,510 39,260 Undersize bearing bushes are already available at the necessary si- zes without requiring any adjustment by boring. - 23 - KD 425-2 Workshop Manual_cod. ED0053029360_1° ed_ rev. 00...

  • Page 24: Oil Seal Rings

    ÷ 0,065 F aluminium crankcase 0,07 ÷ 0,105 F cast iron crankcase 0,04 ÷ 0,075 Renew the camshaft if the cams or journals show wear in excess of 0.1mm. - 24 - KD 425-2 Workshop Manual_cod. ED0053029360_1° ed_ rev. 00...

  • Page 25: Tappets And Push Rods

    Check the extent of pump wear by taking the measurements indica- ted in figure 35. Measurement Dimensions mm Max. wear mm 29,72 ÷ 29,77 29,65 40,551 ÷ 40,576 40,45 17,92 ÷ 17,94 17,89 - 25 - KD 425-2 Workshop Manual_cod. ED0053029360_1° ed_ rev. 00...

  • Page 26: Governor Lever And Spring

    Supplement and governor spring dimensions (fig.37): Lenght Lenght under Load Nr of Spring load mm windings Governor (N) ÷ 14,75 Supplement (H) 38,7 25,5 25,75 ÷ 26,25 - 26 - KD 425-2 Workshop Manual_cod. ED0053029360_1° ed_ rev. 00...

  • Page 27: Injection Equipment

    With the control sleeve at 10mm from the stop position and the pump running at 1,500 rpm, the quantity of fuel for 1,000 shots must be between: 23 ÷ 25 cc 20 ÷ 22 cc (BOSCH) - 27 - KD 425-2 Workshop Manual_cod. ED0053029360_1° ed_ rev. 00...

  • Page 28: Testing Air Tightness

    (fig.45); check that no air bubbles are released. N.B.: Tightness can be checked by compressing the springs to 52.8 ÷ 54.4 mm, which corresponds to the bottom dead centre wor- king position of the pump. - 28 - KD 425-2 Workshop Manual_cod. ED0053029360_1° ed_ rev. 00...

  • Page 29: Injectors

    46; during reassembly make sure that the locating elements on di- stance ring 5 (fig.46) are correctly inserted to the corresponding ho- les. Torque the nozzle securing ring nut to: kgm 3,5 (Nm 34,3) - 29 - KD 425-2 Workshop Manual_cod. ED0053029360_1° ed_ rev. 00...

  • Page 30: Electrical Equipment

    3. The voltage regulator may be damaged if the ground connection or other circuit connections are not made properly. 4. The alternator and the voltage regulator will burn out instantly if the battery connections are inverted. - 30 - KD 425-2 Workshop Manual_cod. ED0053029360_1° ed_ rev. 00...

  • Page 31: Engine Assembly

    The reference numbers (fig.58) must be aligned on each half-shell, making sure that the oil passages match the corresponding openings in the crankcase. Torque the bearing assembly bolts (fig. 59) to: kgm 2,2 (Nm 21,6) - 31 - KD 425-2 Workshop Manual_cod. ED0053029360_1° ed_ rev. 00...

  • Page 32: Crankshaft

    (fig. 65), which must be within the range: 0,10 ÷ 0,20 mm 0,20 ÷ 0,30 mm (cast iron crankcase) - 32 - KD 425-2 Workshop Manual_cod. ED0053029360_1° ed_ rev. 00...

  • Page 33: Camshaft

    5. Check that the timing marks on the camshaft and crankshaft ge- ars are correctly aligned with respect to each other (fig. 69). - 33 - KD 425-2 Workshop Manual_cod. ED0053029360_1° ed_ rev. 00...

  • Page 34: Oil Pump

    2,2 ÷ 2,4 (Nm 21,6 ÷ 23,8) Pulley and flywheel Tighten the pulley and flywheel nut (fig.72) to: kgm 18 ÷ 22 (Nm 176,5 ÷ 215,7) - 34 - KD 425-2 Workshop Manual_cod. ED0053029360_1° ed_ rev. 00...

  • Page 35: Pistons

    0,10 ÷ 0,20 mm This distance is adjusted with special shims that are inserted between the bottom surface of the cylinder and the crankcase 0.1 - 0.2 - 0.3 mm. - 35 - KD 425-2 Workshop Manual_cod. ED0053029360_1° ed_ rev. 00...

  • Page 36: Checking Injector Protrusion

    (B, fig.81) 4. Secure the injection pumps to the crankcase, taking care to turn the first injection pump around through approximately 3/4 of a turn in a clockwise direction. - 36 - KD 425-2 Workshop Manual_cod. ED0053029360_1° ed_ rev. 00...

  • Page 37: Injection Check

    Should the flywheel need changing, determine TDC and mark the start of static and dynamic injection as shown in the table: Version I.P. 22° 44 mm 17° 34 mm standard 20° 40 mm 12° 24 mm whisper quiet - 37 - KD 425-2 Workshop Manual_cod. ED0053029360_1° ed_ rev. 00...

  • Page 38: Injectors And Injector Pipes

    O-ring on the cover are in good condition. On request or KD 425-2 engines can mount an external filter cartrid- ge that can be screwed onto the crankcase (fig.88). Oil the seal befo- re assembly.

  • Page 39: Engine Testing

    1. Check the oil level (fig.95). 2. Start the engine and let it idle. 3. Check the oil pressure on the pressure gauge (fig.92) 4. Run in engine before testing it at full power. - 39 - KD 425-2 Workshop Manual_cod. ED0053029360_1° ed_ rev. 00...

  • Page 40: Running-In Table

    Delivery of diesel fuel is correctly calibrated when the exhaust gas is slightly coloured by smoke; change the adjustment if necessary by turning the adjustment screw (fig.96). - 40 - KD 425-2 Workshop Manual_cod. ED0053029360_1° ed_ rev. 00...

  • Page 41: Storage

    • 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. - 41 - KD 425-2 Workshop Manual_cod. ED0053029360_1° ed_ rev. 00...

  • Page 42: Quick Reference Charts

    Rocker arm end float 0,05 ÷ 0,130 Valve clearance 0,15 0,15 Valve depth from cylinder head 0,8 ÷ 1,0 Injector protrusion 1,75 ÷ 2,25 2,25 Piston protrusion 0,10 ÷ 0,20 - 42 - KD 425-2 Workshop Manual_cod. ED0053029360_1° ed_ rev. 00...

  • Page 43: Tightening Torques

    29,50 35,40 16 x 2,00 26,30 37,00 44,40 18 x 2,50 36,60 51,50 61,80 20 x 2,50 44,40 62,40 74,90 22 x 2,50 56,90 80,00 96,00 24 x 3,00 - 43 - KD 425-2 Workshop Manual_cod. ED0053029360_1° ed_ rev. 00...
  • 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. ED0053029360 KohlerEngines.com ISSUED 04/07/2012 ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044...

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