Kohler KD 500 Workshop Manual - Page 26

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Injection equipment

- 26 -

Checking the injection pump

before demounting the injection pump, make sure that the

plunger unit, enbloc pump casing and valve are pressure tight by

proceeding in the following way:

1. Connect a pressure gauge with scale up to 600 Kg/cm² to the

fuel delivery pipe (fig. 32).

2. Set the regulating sleeve (fig. 33) to the average delivery

position.

3. Slowly turn the flywheel to make the plunger make one

compression stroke.

4. Read the indication on the pressure gauge. If it is lower than

300 Kg/cm², the complete pump must be changed.

During the test, the pressure gauge needle will show a

progressive pressure increase until reaching a maximum value,

after which it will drop sharply back and stop at a lower pressure

value. Replace the valve if the pressure drop is more that 50 Kg/

cm² and continues to slowly drop lower.

The pressure must drop from 200 Kg/cm² to 150 Kg/cm² in not

less than 7 sec.

Injection pump calibration (fig. 34)

When the adjuster sleeve is 10.5 mm from the stop position

and the pump spins at 1,500 rpm, the amount of fuel for 1,000

deliveries must be between:

Replace the pump if the values differ.

WARNING:

Check to make sure that plunger travel with the injection cams in

the non-operative position (BDC) at the start of delivery is:

Injection pump assembly (fig. 36)

If the injection pump must be demounted, use an electric pen to

mark the adjuster block (M) with the enbloc pump casing (A) and

loosen the plug (N) after having heated it to make the Loctite

easier to release.

Comply with the following instructions when remounting the

parts:

1. Fit the washer (B), the delivery valve (C), the washer (D), the

alve spring (E), the filler (F) into the enbloc pump casing (A)

and torque the delivery union (G) to a value of:

4,3 ÷ 5,4 kgm (42,5 ÷ 52,5 Nm)

2. Insert the adjuster seal (H).

3. Insert the flange (I).

4. Insert the plunger with helical profile (A, fig. 35) into the iner

housing of the adjuster sleeve from the side opposite the

sleeve pin (B, fig. 35).

Workshop Manual KD500 _ cod. ED0053029390 - 1° ed_rev. 00

25,5 ÷ 29 cc