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WORKSHOP MANUAL

KD 477-2

Summary of Contents for KD477-2

Page 1: ...WORKSHOP MANUAL KD 477 2...

Page 2: ...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 p...

Page 3: ...isted below provided there has been no abuse neglect or improper maintenance of your engine Your emission control system may include parts such as the fuel injection system and the air induction syste...

Page 4: ...TA 11 V CHARACTERISTICS 12 Characteristics power torque and specific fuel consumption curves 12 VI OVERALL DIMENSIONS 13 VII SPECIAL TOOLS 14 VIII MAINTENANCE RECOMMENDED OIL TYPE REFILLING 15 Manuten...

Page 5: ...of crankcase 32 Camshaft preparation 32 Crankshaft preparation 33 Upper crankcase preparation 33 Timing cover assembly 34 Fitting of oil seal rings 35 Oil pump assembly 35 Feeding pump assembly 36 Pi...

Page 6: ...6 KD 477 2 Workshop Manual_cod ED0053029370_1 ed_ rev 00 INDEX XVI QUICK REFERENCE CHARTS 45 Couplings 45 Adjustments 45 End floats 45 Tightening torques 46 Standard screw tightening torques 46...

Page 7: ...e overloaded Advanced injection Delayed injection Incorrect governor linkage adjustment Broken or loose governor spring Idle speed too low Worn or jammed piston rings Worn or scored cylinders Worn val...

Page 8: ...chines SAFETY REGULATIONS 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 on...

Page 9: ...l packaging components must be disposed of in accordance with the laws of the country in which disposal is taking place Keep the fuel and engine control systems and the exhaust pipes in efficient work...

Page 10: ...n 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 custo...

Page 11: ...nsumption Oil consumption Capacity of standard oil sump Recommended battery 12V Dry weight Combustion air volume Cooling air volume Max permissible driving shaft axial continuous instantaneous Flywhee...

Page 12: ...continuos heavy duty with constant speed and constant load Mt N Torque at N power C Specific fuel consumption at N power U1 Standard utilization range of engines rated at 3000 rpm U2 Standard utilizat...

Page 13: ...13 KD 477 2 Workshop Manual_cod ED0053029370_1 ed_ rev 00 VI Note Dimensions in mm OVERALL DIMENSIONS...

Page 14: ...00365R0260 Oil seal protection cone 00365R0210 Injection pump spanner 00365R0450 Valve guide gauge 7 mm 0 27 inch 00365R0850 Valve guide grinder 7 mm 0 27 inch 00365R0540 Tool for valve seat 00365R05...

Page 15: ...your face well away from the plug to prevent harmful vapours from being inhaled Dispose of fuel in the correct way and do not litter as it is highly polluting FUEL When refuelling it is advisable to...

Page 16: ...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...

Page 17: ...ving the flywheel ring IMPORTANT Do not tap the end of the extractor when re moving the flywheel Crankshaft gear extraction Use extractor cod 00365R0010 and cod 00365R0100 fig 2 Camshaft gear extracti...

Page 18: ...operation the hammering of the val ves on their seats at high temperature causes the face of the seats to harden and hand grinding is made difficult It is thus necessary to re move the hardened surfa...

Page 19: ...hanged Fitting of new valves or seats always requires grinding After grinding wash valve and seat carefully with petrol or paraffin to eliminate any residual grinding paste or cuttings To check the wo...

Page 20: ...check internal diameters C D at three different heights fig 15 Maximum permitted taper A B and ovality C D is 0 06mm Diameter of cylinders fig 15 If the diameter of the cylinder does not exceed said v...

Page 21: ...s the values shown in the table renew the pi ston and the piston rings Piston rings must always be renewed after dismantling the piston Piston diameter check The diameter of the piston must be measure...

Page 22: ...n 2 prisms set out on a checking bench 3 Check with a comparator gauge that the discrepancy in the rea dings at the two ends of the gudgeon pin is not more than 0 05 mm Should the distortion exceed th...

Page 23: ...o clean the inside of the oil passages and the collection traps If the deposits are parti cularly resistant immerse the whole crankshaft in petrol or paraf fin before proceeding with the operations 3...

Page 24: ...use protective cone cod 00365R0260 Fit said cone over the ends of the crankshaft to avoid damage to the ring itself Tappet checking Make sure the tappet surfaces are not worn lined or present signs of...

Page 25: ...ts after con sulting the spare parts catalogue Supplement and governor spring dimensions fig 30 Supplement H Governor N Spring Load kg Nr of windings Lenght under load mm Lenght mm Oil pump checking T...

Page 26: ...Delivery connection Checking injection pump Before dismantling injection pump check pressure seal of the pum ping unit cylinder and valve as follows 1 Connect a pressure gauge graded up to 600 kg cm...

Page 27: ...fig 38 Make sure the bar moves freely on the guides Resistance and drag will cau se the engine to run unevenly 4 Marks b cut on the bar must coincide with marks a of the too thed quadrants Marks c on...

Page 28: ...of wire fig 42 of the same size as that of the nozzle holes indicated on the table 2 Set up injector on a test bench tool cod 00365R0430 3 Unscrew injector lock coupling No 3 fig 41 or nozzle ring nu...

Page 29: ...nt ammeter with a 20 Amp range between said free terminal and the detached wire 3 Connect a direct current voltmeter with a minimum range of 15 Volts fig 44 to the battery terminals 4 Insert starter k...

Page 30: ...sition the oil warning light and battery charging functions are excluded The voltage regulator will be damaged beyond repair if it is run with the battery cables disconnected or with unactiva ted batt...

Page 31: ...gulator 3 Alternator 4 Starter motor 5 Pressure gauge 6 Oil pressure warning light 7 Starter key 8 Battery char ging light ELECTRICAL EQUIPMENT Diagram of electric starting wiring system with external...

Page 32: ...e the seat of the valve ball in the casing is free of dirt or scores which could jeopardize the pressure seal 4 Insert cylinder studs and centering pins Camshaft preparation To prepare the camshaft un...

Page 33: ...roduced without applying force along the grooves inside the crankcase 4 Mount governor lever and insert lever fulcrum pin taking care not to damage the oil seal rings fig 55 The lever should be able t...

Page 34: ...ce returns to normal values fig 60 0 2 and 0 3 mm shims are available 7 Place crankshaft on previously housed shells making sure the ti ming references found on the gears coincide fig 57 8 Insert oil...

Page 35: ...il pump assembly For rotor checks see page 25 After tightening crankcase mount oil pump external rotor with the notch facing inwards fig 63 Make sure the O Ring on the oil pump cover is in perfect con...

Page 36: ...ngs The piston is coupled to the connecting rod by means of slight hand pressure on the gudgeon pin without heating the piston The clearance between the small end and the gudgeon pin is 0 023 to 0 038...

Page 37: ...linder mounting The lower end of the cylinder is chamfered for piston ring insertion fig 71 The operation can be carried out easily by using a standard piston ring compression tool tool 00365R0770 Pis...

Page 38: ...inder height adjustement Between the top face of the cylinder and the piston at top dead cen ter there must be a clearance of Checking valve head face depth When replacing valves check that the cleara...

Page 39: ...avoid oil leaks Align heads using a manifold or a metallic bar as shown in fig 78 Tighten down cylinder head nuts uniformly fig 78 increasing 1 kgm at every turn until a pressure is reached of Valve c...

Page 40: ...tie rod connection The injection pump tie rod length measured from the connecting centre of the rack bar to the centre of the ball joint must be mm 118 1 complete turn Careful operation will avoid une...

Page 41: ...start of static injec tion At this moment injection pimp delivery starts fig 86 and the top dead centre reference on the air conveyor must coincide with the IP mark punched cm the flywheel fig 87 If...

Page 42: ...revs to minimum The pressure should not fall to under 1 kg cm with the oil temperature exceeding 80 C Checking for oil leaks 1 Remove exhaust gas collection pipe from suction manifold and close with...

Page 43: ...xhaust fumes 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 94 Engine power c...

Page 44: ...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 possib...

Page 45: ...housing in crankcase External oil pump rotor and housing in engine crankcase Pistons and wrist pin Big end bearing and crankpin Valve guide and stem inlet Valve guide and stem exhaust Adjustments Val...

Page 46: ...2 Nm 3 6 7 12 19 8 29 6 38 52 5 89 135 205 257 358 435 557 kgm 0 37 0 72 1 23 2 02 3 02 3 88 5 36 9 09 13 80 21 00 26 30 36 60 44 40 56 90 4 x 0 70 5 x 0 80 6 x 1 00 7 x 1 00 8 x 1 25 9 x 1 25 10 x 1...

Page 47: ...47 KD 477 2 Workshop Manual_cod ED0053029370_1 ed_ rev 00 NOTE...

Page 48: ...SERVICE INFORMATION IN U S AND CANADA CALL 1 800 544 2444 KohlerEngines com FORM NO ED0053029370 ISSUED 05 07 2012 REVISED 00 DATE 05 07 2012 Translated from the original manual in Italian language Da...

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Kohler KD477-2, Workshop Manual

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