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Index
Workshop Manual KD500 _ cod. ED0053029390 -
1° ed
_rev.
00
INJECTION EQUIPMENT ....................................................................................................................................... 25
Fuel circuit ......................................................................................................................................................................... 25
Injection pump .................................................................................................................................................................. 25
Injection pump calibration ................................................................................................................................................. 26
Injection pump assembly .................................................................................................................................................. 26
Leak test............................................................................................................................................................................ 27
Injector inspection and calibration .................................................................................................................................... 27
ELECTRICAL EQUIPMENT .................................................................................................................................... 29
Characteristics of the system ........................................................................................................................................... 29
Checking the system ........................................................................................................................................................ 29
Checking the alternator..................................................................................................................................................... 30
Ring gear .......................................................................................................................................................................... 30
ENGINE ASSEMBLY ............................................................................................................................................... 31
Preparing the engine block ................................................................................................................................................31
Injection pump tappets ......................................................................................................................................................31
Timing system cover pre-assembly .................................................................................................................................. 32
Removal and assembly of the drive shaft gear ................................................................................................................ 33
Drive shaft assembly ........................................................................................................................................................ 33
Connecting rod - drive shaft connection .......................................................................................................................... 33
Counter-shaft .................................................................................................................................................................... 33
Camshaft ........................................................................................................................................................................... 34
Play adjustment ................................................................................................................................................................ 34
Crankshaft float: ................................................................................................................................................................ 34
Camshaft float: .................................................................................................................................................................. 34
Counter-shaft float (optional): ........................................................................................................................................... 35
Cover on timing system side ............................................................................................................................................. 35
Oil retention rings .............................................................................................................................................................. 35
Flywheel ............................................................................................................................................................................ 35
Piston ................................................................................................................................................................................ 36
Cylinder ............................................................................................................................................................................. 36
Head.................................................................................................................................................................................. 36
Valve clearance ................................................................................................................................................................ 37
Injection lead ..................................................................................................................................................................... 37
Mounting the injection pump on the engine ...................................................................................................................... 38
Injector and injector tube .................................................................................................................................................. 38
ENGINE TESTING ................................................................................................................................................... 39
Rpm regulation ................................................................................................................................................................. 39
Braked engine test ............................................................................................................................................................ 39
Temporary protection (1/6 months) ................................................................................................................................... 40
Permanent protection (over 6 months) ............................................................................................................................. 40
How to prepare the engine for operation .......................................................................................................................... 40
STORAGE ...............................................................................................................................................................40
QUICK REFERENCE CHARTS .............................................................................................................................. 41
SERVICE ................................................................................................................................................................. 43
SUGGESTIONS ON HOW TO TIME THE INJECTION PUMP WHEN THE LEAD PUNCH MARKS ON THE
FLYWHEEL ARE DIFFICULT TO REACH. ...................................................................................................................... 43
