Kohler KD425-2, Workshop Manual

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1 General remarks and safety information
This manual contains safety precautions which are explained
below.
Danger
Warning is used to indicate the presence of a hazard that can
cause severe personal injury, death, or substantial property
damage if the warning is ignored.
Warning
Caution is used to indicate the presence of a hazard that will or
can cause minor personal injury or property damage if the caution
is ignored.
Important
This indicates particularly important technical information that
should not be ignored.
Safety regulation
KD425-2 Workshop Manual_cod. ED0053031750_
1° ed
_ rev.
00
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
necessary 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.
Danger
• In addition to all other machine specifications, ensure that
the engine is in a near horizontal position when starting.
lf 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.
• Do not start the machine in closed or poorly ventilated
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 and 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.
• 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 spilled, remove
the fuel container and any 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.
• During operation 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. lf 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 cyclone 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.