Kohler KD425-2 SM275-19 Engine Workshop Manual – PDF DOWNLOAD
DESCRIPTION:
Kohler KD425-2 SM275-19 Engine Workshop Manual – PDF DOWNLOAD
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;
2 – The person or people performing service work on KOHLER series engines possesses adequate hand and KOHLER special
tools to safely and professionally perform the subject service operation;
3 – The person or people performing service work on KOHLER series engines has read the pertinent information regarding the
subject service operations and fully understands the operation at hand.
– This manual was written by the manufacturer to provide technical and operating information to authorised KOHLER after-sales
service centres to carry out assembly, disassembly, overhauling, replacement and tuning operations.
– As well as employing good operating techniques and observing the right timing for operations, operators must read the
information very carefully and comply with it scrupulously.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Kohler KD425-2 SM275-19 Engine Workshop Manual – PDF DOWNLOAD
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…………………………………………………………….. 8
Safety regulations……………………………………………………………………………………………………………………………………………. 8
General safety during operating phases…………………………………………………………………………………………………………….. 9
Safety and environmental impact ……………………………………………………………………………………………………………………… 9
III – MODEL NUMBER AND IDENTIFICATION…………………………………………………………………………………………. 10
The identification plate shown in the figure can be found directly on the engine……………………………………………………..10
Approval data………………………………………………………………………………………………………………………………………………….10
IV – TECHNICAL DATA…………………………………………………………………………………………………………………………. 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
Manutenance………………………………………………………………………………………………………………………………………………….15
Fuel……………………………………………………………………………………………………………………………………………………………….15
Recommended oil……………………………………………………………………………………………………………………………………………16
Acea sequences……………………………………………………………………………………………………………………………………………..16
IX – DISASSEMBLY OF THE ENGINE…………………………………………………………………………………………………….. 17
Extracting fuel injectors……………………………………………………………………………………………………………………………………17
Removing the flywheel…………………………………………………………………………………………………………………………………….17
Extraction of flywheel side main bearing……………………………………………………………………………………………………………17
Extraction of crankshaft gear……………………………………………………………………………………………………………………………17
Extraction of the camshaft gear………………………………………………………………………………………………………………………..18
Extracting crankcase bushes……………………………………………………………………………………………………………………………18
Extracting the oil pressure indicator plug…………………………………………………………………………………………………………..18
X – CHECKS AND OVERHAUL………………………………………………………………………………………………………………. 19
Cylinders heads………………………………………………………………………………………………………………………………………………19
Valves – Guides – Seats……………………………………………………………………………………………………………………………………19
Valves and springs………………………………………………………………………………………………………………………………………….21
Rocker arms…………………………………………………………………………………………………………………………………………………..21
Cylinders………………………………………………………………………………………………………………………………………………………..21
Piston rings – Pistons – Piston pins…………………………………………………………………………………………………………………… 22
Connecting rods……………………………………………………………………………………………………………………………………………. 22
Crankshaft……………………………………………………………………………………………………………………………………………………. 23
Checking crankshaft dimensions…………………………………………………………………………………………………………………….. 23
Oil seal rings…………………………………………………………………………………………………………………………………………………. 24
Camshaft……………………………………………………………………………………………………………………………………………………… 24
Tappets and push rods…………………………………………………………………………………………………………………………………… 25
KD 425-2 Workshop Manual_cod. ED0053029360_1° ed_ rev. 00 – 5 –
INDEX
Injection pump plug nuts and control rods………………………………………………………………………………………………………… 25
Fuel pump push-rod………………………………………………………………………………………………………………………………………. 25
Oil pump………………………………………………………………………………………………………………………………………………………. 25
Governor lever and spring………………………………………………………………………………………………………………………………. 26
XI – INJECTION EQUIPMENT…………………………………………………………………………………………………………………. 27
Fuel circuit……………………………………………………………………………………………………………………………………………………. 27
Injection pumps…………………………………………………………………………………………………………………………………………….. 27
Checking injection pumps………………………………………………………………………………………………………………………………. 27
Injection pump setting……………………………………………………………………………………………………………………………………. 27
Assembly of injection pumps…………………………………………………………………………………………………………………………… 27
Testing air tightness……………………………………………………………………………………………………………………………………….. 28
Injectors……………………………………………………………………………………………………………………………………………………….. 29
Checking and setting the injectors…………………………………………………………………………………………………………………… 29
Disassembly and re-assembly of injectors………………………………………………………………………………………………………… 29
XII – ELECTRICAL EQUIPMENT…………………………………………………………………………………………………………….. 30
Plant specifications ……………………………………………………………………………………………………………………………………….. 30
Checking electrical equipment………………………………………………………………………………………………………………………… 30
Checking the alternator………………………………………………………………………………………………………………………………….. 30
XIII – ENGINE ASSEMBLY……………………………………………………………………………………………………………………… 31
Preparing the crankcase………………………………………………………………………………………………………………………………….31
Central main bearings……………………………………………………………………………………………………………………………………..31
Crankshaft……………………………………………………………………………………………………………………………………………………. 32
Main bearings – flywheel side………………………………………………………………………………………………………………………….. 32
Crankshaft end float………………………………………………………………………………………………………………………………………. 32
Camshaft……………………………………………………………………………………………………………………………………………………… 33
Governor tie rod adjustment……………………………………………………………………………………………………………………………. 33
Oil pump………………………………………………………………………………………………………………………………………………………. 34
Timing cover…………………………………………………………………………………………………………………………………………………. 34
Pulley and flywheel………………………………………………………………………………………………………………………………………… 34
Pistons…………………………………………………………………………………………………………………………………………………………. 35
Connecting rods……………………………………………………………………………………………………………………………………………. 35
Cylinders………………………………………………………………………………………………………………………………………………………. 35
Checking injector protrusion……………………………………………………………………………………………………………………………. 36
Cylinder heads………………………………………………………………………………………………………………………………………………. 36
Valve clearance…………………………………………………………………………………………………………………………………………….. 36
Injection pumps…………………………………………………………………………………………………………………………………………….. 36
Injection check………………………………………………………………………………………………………………………………………………. 37
Injectors and injector pipes……………………………………………………………………………………………………………………………… 38
Oil filter…………………………………………………………………………………………………………………………………………………………. 38
Feed pump……………………………………………………………………………………………………………………………………………………. 38
Electric shut off……………………………………………………………………………………………………………………………………………… 38
XIV – ENGINE TESTING………………………………………………………………………………………………………………………… 39
Speed adjustment …………………………………………………………………………………………………………………………………………. 39
Checking oil pressure…………………………………………………………………………………………………………………………………….. 39
Checking for oil leaks…………………………………………………………………………………………………………………………………….. 39
Dyno testing of engine……………………………………………………………………………………………………………………………………. 39
Running-in table……………………………………………………………………………………………………………………………………………. 40
XV – STORAGE…………………………………………………………………………………………………………………………………….. 41
Storage………………………………………………………………………………………………………………………………………………………….41
How to prepare the engine for operation…………………………………………………………………………………………………………….41
XVI – QUICK REFERENCE CHARTS………………………………………………………………………………………………………. 42
Couplings……………………………………………………………………………………………………………………………………………………….42
Adjustments……………………………………………………………………………………………………………………………………………………42
Tightening torques…………………………………………………………………………………………………………………………………………. 43
PLEASE NOTE:
- This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
- You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
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