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KD 625/3 - 626/3 WORKSHOP MANUAL

1. 102 Main torque 102 Use of sealants only for engines with nennen nn 103 Table of tightening torques for standard screws coarse 104 Table of tightening torques for standard screws fine thread sees 104 c 105 CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board and Kohler Co are pleased to explain the emission control system warranty on your 2012 engine In California new heavy duty off road engines must be designed built and equipped to meet the State s stringent anti smog standards Kohler Co must warrant the emission control system on your engine for the time period listed 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 system Also included may be hoses connectors and other emission related assemblies Where a warrantable condition exists Kohler Co will repair your heavy duty off road engine at no cost t
2. 200 1000 1400 1800 RN 400 800 1200 1600 2000 2400 T min U min 2200 2600 3000 2 Alternator type Bosch G1 14 V 33 A The alternator is ot the claw pole rotor type with built in voltage re guiator The rotating motion is conveyed by the engine through a V belt and sheave Features 12V rated voltage Max current 33A at 7000 alternator r p m RH direction of rotation Alternator type Bosch Gil 14 V 33 A layout Components 1 Alternator 2 Starting motor 3 Battery 4 Key switch 5 Pressure switch 6 Oil pressure warning light 7 Battery charging light 14 V 33 A Bosch G1 alternator battery charger curve The curve was obtained at room temperature of 25 C Battery terminal voltage is 12 5 V The r p m shown on the table refers to the engine 66 KD Workshop Manual cod ED0053029350_1 ed_ rev 00 KOHLER Electric system 7 P n v Kw 164 Starting motor type Bosch JF R 12 V class 2 5 RH direction of rotation 23 24 mm B Ring gear plane C Flange plane Vorsicht Warnung The flywheel should not project from ring gear plane B Note Apply to Bosch Service Centers for any type of repair Characteristic curves for starting motor type Bosch JF R 12 V Curves were obtained at room tempe
3. Resetting dial indicator Components 1 Dial indicator 2 Support for dial indicator 3 Camshaft sensor support surface control gauge measurement 30 24 30 26 mm 4 Resetting master measure 30 24 30 26 mm for gauge 5 Resetting reference base If replacing the sensor camshaft or engine block via the tool see figu re 56 Make sure that the support surface of the sensor on the camshaft support measures 30 24 30 26 mm Assemble the dial indicator 1 in the support 2 Insert the support 2 complete with dial indicator 1 into the gauge 3 Set the master 4 and reset the dial indicator while resting on the base 5 as in 6 Measuring the depth between the sensor support and the camshaft Insert the gauge complete with dial indicator onto the sensor support and attach using the three screws Make sure the measurements taken are within the specific tolerance limits 30 24 30 26 mm The three screws for the phase sensor support screws must be tightened to 8 Nm using a torque wrench Air gap adjustment The air gap is adjusted using shims measuring 0 2 mm in thickness which are placed between the sensor surface and its support The air gap must be between 0 3 and 0 5 mm see phase sensor as sembly diagram page 94 When adjusting the air gap with shims it is important to consider any difference between the measurements taken length of the sensor pin and depth between the sensor suppor
4. 34 TOUS SS __ _____ RC EE 34 34 PST WG MTMHMENCHHH 35 PINGS End NN OO OE 35 Metal snap rings Piston grooves __ __ 35 Metal snap rings Fitting Sedul 6 PAN E Mu bU UM Eii 35 miei po OT E 36 ANO MATER m m _ ne 36 onines a E 36 Connecting rod small end bearing and aikaisia 37 Connecting rod io nuts IN 37 Co nnecung Tod W ClO OU PRI ERR em 37 COMMECTING 37 OE ee cg ce E EE E AT 38 Gein EE ETE AEE OEE EEE 38 TGO e A E E R 38 Main bearing support gear side METTE 38 Main bearing support flywheel 6 PP 39 OOA 39 Center main bearing Support locating DONS vac 39 Crankshaft RG MO eM M TT 39 Crankshaft center main bearing
5. _ _ 44 NES CNE O e 44 pump 000 eres o s 46 Hydraulic p mp srd GOUD 2 46 Hydraulic pump 410 06 46 Wire ae ime 10 and Neo 46 Mechanical speed governor 47 Mechanical speed governor components nnn nna nns 47 Mechanical speed governor operation 47 Mechanical speed governor components for special generating 48 Mechanical speed governor 48 Spring for extra fuel supply at starting 48 KD Workshop Manual_cod ED0053029350_1 ed_ rev 00 KOHLER Chapter index LUBRICATNON SYSTEM em T UU T 49 8 1 10
6. Intake exhaust cam height A1 1st cylinder intake cam 51 1st cylinder exhaust cam A2 2nd cylinder intake cam Y 2 2nd cylinder exhaust cam A3 3rd cylinder intake cam Exhaust and intake cams feature the same height H A 53 3rd cylinder exhaust cam 33 65 33 55 for engines EPA 97 68 CE 3 S3 A2 S2 Ai Si Replace camshaft if H is 0 1 mm below the given value 96 Camshaft end play Check camshaft end play after removing cylinder head injection pump and fuel feed pump from the engine Check that the three cover 1 screws are tightened at 25 Nm Place the dial gauge on the camshaft gear outer part push and pull z same gear as required Camshaft end play should be 0 15 0 30 mm KD Workshop Manual cod ED0053029350_1 ed_ rev 00 43 4 Disassembly Reassembly KOHLER ZA a a 50 6 ge Camshaft timing Fit camshaft gear by making timing mark 2 coincide with timing marks 1 Tighten camshaft bolt at 250 Nm Valve timing without considering timing marks Locate piston 1 on flywheel side at the top dead center Position two small cylinders A of the same height onto the tappets Rotate camshaft stopping when cylinder 1 tappets are in ov
7. P 28 dz e 28 Valve rocker arm clearance __ _____ 28 Compression relgase oie Tc 29 NETT cT 29 P MECO E mm 29 SCION qe Te TETTE 31 KD Workshop Manual cod ED0053029350_1 ed_ rev 00 3 Chapter index KOHLER initio E c re 31 Um 31 stem sealing rings IREASSEMDIY Rada Ce tuo P CER 32 vl xeu gt 32 IMS BL MEN c T 32 Valve guides and cylinder head housings TIR 32 Valve guide insertion 33 Dimensions and clearance between guides and valves 33 Valve seats and ROS uU 33 33 Pushrod tube spring RT TR 34 Sn lr
8. NSSCE ENE EEE N 5 amp amp S amp amp 2 z z cod ED0053029350_1 ed rev 00 KD Workshop Manua 14 Technical information 2 KOHLER KD 625 3 626 3 EPA 2400 r p m 2600 r p m EXIIT v ET ee 808 20 2 62410 D a a 4 20 30 28 28 24 18 20 16 24 20 14 A 18 29 46 12 14 10 12 14 N 80 1269 EEC ISO 1585 AUTOMOTIVE RATING Intermittent operation with variable speed and variable load NB ISO 3046 1 IFN RATING WITH NO OWERLOAD CAPABILITY continuos ligth duty operation with constant speed and variable load NA ISO 3046 1 ICXN CONTINUOS RATING WITH OVERLOAD CAPABILITY continuos heavy duty with constant speed and constant load MN Torque at N power MB NB curve MA curve C Specific fuel consumption at NB power The above power values refer to an engine fitted with air cleaner and standard muffler after testing and at the environmental conditions of 20 and 1 bar Max power tolerance is 5 Power decreases by approximately 1 every 100 m di altitude and by 2 every 5 C above 25 A Important Non approva
9. 50 Oil pressure relief valve Ne 50 REED 50 Nec meg __ _ _______ eae wot sees eee eee 50 Oil pressure c rvye at idling SPESO a ee ey oe eer ee ees 51 Oil pressure curve at full speed ssssesesssesssssessesseenene nennen nnn ss as esa nsn 51 SYSTEM _______________ 52 eese T 52 I Ris A EENAA 52 UT 52 Ag T a eee 52 Injection pump only for nid eos cO ere eer ey meee PTS 53 Injection pump only for standard and 97 68 Ce nene emnes 53 milio ______ ___ __ 54 How to check plunger and barrel for internal 54 How to check injection pump delivery valve sealing 54 Test data for injection pump delivery test bench only for EPA 55 Test data for
10. AW D lt Q EZ B The high pressure pipe union must be tightened to the injector union to 20 25 Nm using a torque wrench Injector protrusion It is only possible to check injector protrusion with the cylinder head disassembled The end of the nozzle must be 3 3 5 mm with respect to the head surface A Protrusion is adjusted by adding or removing copper seals B which are supplied at a thickness of 0 5 and 1 mm Cylinder Head Caution Warning Do not demount or remount while hot as this could lead to defor mations If the head surface is distorted grind it by removing up to 0 3 mm thickness When reassembling before tightening make sure that the rocker arm lubrication hose is firmly lodged into holes The cylinder heads must be tightened with the exhaust or intake manifold mounted to keep them lined up Always replace the copper seal between the cylinder head and the cylinder that determines clearance volume see page 34 for the choice of thickness See page 32 for how to mount the spring on the tappet rod protection pipe The cylinder head fastening nuts must be tightened gradually to 55 Nm and in the sequence 1 2 3 4 see fig 35 Valves Components Intake valve a Exhaust valve Lower spring collar Valve stem sealing ring Spring Upper spring collar Three groove half
11. Disassembly Reassembly KOHLER Attach the sensor using screw to a torque of 8 Nm Reassemble the blower control pulley onto the crankshaft O Tighten the left handed fastening bolts to torque of 300 Nm Components 1 Left handed bolt 2 Washer 3 Blower control pulley 2 Replace and check the belt tension see page 22 23 Replace the variator circuit oil pipes If in doubt consult the diagram on page 78 66 KD Workshop Manual cod ED0053029350 1 ed rev 00 KOHLER Disassembly Reassembly Insert the solenoid valve connectors following the references IN and OUT shown on the cables and on the solenoid valve block O Replace the built guard and tighten to 15 Nm a EI v A 47 KD Workshop Manual cod ED0053029350_1 ed_ rev 00 67 I Disassembly Reassembly KOHLER Angular position sensor and AC pump assembly diagram 7 JEE ff 88 KD Workshop Manual_cod ED0053029350_1 ed_ rev 00 KOHLER Disassembly Reassembly wx 4 N T mm M 5 lm om uw o m ON 7 f A 2 7 4 AIE YM UY VA 2 AN COMPONENTS
12. p Ta mA Me Use an inside micrometer to measure the inside 21411 S VES g lt SN NS 5 A AUI z 9 e NM mA un Main bearing and connecting rod big end bearing inside diameter Re Bimensions The above dimensions refer to driven in or tightened bearings Note Both main bearings and connecting rod big end bearings are available with inside diameter size measuring 0 25 and 0 50 less than the standard version 85 Clearance between main journals crank pins and connecting rod bearings Ret Dimensions mm Limit value rm __ 0 070 0 109 050009 Main bearing supports 3 2nd central 4 Gear side 1 Flywheei side 2 1st central Re Bimensions mm wf 60 000 60 020 150 000 150 020 o S 14 00 148 020 p __ 87 with tightened bearing KD Workshop Manual cod ED0053029350 1 rev 00 41 4 Disassembly Reassembly KOHLER Main bearing housings Rer Dimensions mm A 8 LB 152 000 152 020 78 000 78 020 Crankshaft end play Ret Dimensions mm _ 48 200 48 250 B 47 950 48 000 Check crankshaft end play after refitting the crankshaft pulley and tightening its nut at 300 Nm the crankshaft end play is equal to 0 20 0 30 mm and is not ad
13. Number of cylinders Displacement Compression ratio 3000 N 80 1269 CEE ISO 1585 kW CV 28 38 Power kW HP NB ISO 3046 IFN kW CV 26 35 4 ISO 3046 ICXN kW CV 24 32 7 Max torque Nm kgm 104 10 6 2000 Max torque at 3rd p t o at 3200 r p m kW CV TOT Max torque at 4th p t o at 3200 r p m kW CV 7 98 10 8 Specific fuel consumption g CV h g kW h 190 258 5 Tank capacity 15 Oil consumption kg h 0 017 Oil sump capacity 9 Dry weight kg 170 Combustion air volume at 3000 r p m 2400 Cooling air volume at 3000 r p m 38000 Max permissible driving shaft axial load in both directions kg 300 momentar Max inclination lasting up to 1 h 35 permanent Firing Order Only for 97 68 CE and EPA approved engines Referred to max NB power A At NA power Depending on the application KD Workshop Manual cod ED0053029350_1 ed_ rev 00 2 Technical information PERFORMANCE DIAGRAMS 3 B2 2800 r p m KD 626 KD 626 3 NR 3000 r p m KD 625 3 3000 r p m KD 626 3 3000 r p m 555 25 g ped 3 Hapa E T
14. X WN 72 KD Workshop Manual cod ED0053029350_1 ed_ rev 00 KOHLER Advance variator operating principle Fig A 2 Injection timing device during actuation of an advance max value 4 5 The oil yellow goes into the system and moves the plunger blue that activates the camshaft anticlockwise home Fig A 3 Injection timing device moving from actuation of an advance to resting position The oil yellow goes out and releases the spring to move the plunger blue which in turn activates the camshaft clockwise Our system is able to actuate any intermediate advance regulating the oil pressure When the set level is reached the oil exerts the right force to compress the spring at the right height to move the plunger appropriately thus achieving the required rotation angular advance KD Workshop Manual cod ED0053029350 1 ed rev 00 73 DISASSEMBLY REASSEMBLY KOHLER Solenoid valve assembly diagram COMPONENTS TABLE Cylindrical 1 4 gas union Union bolt M 12x1 5 Connection screw M 14x1 5 Nut M 5 Copper seal 13 5x19x2 Seal Seal 14x19x1 5 Adjustable union d 12 Screw TCEI M 5x65 Pressure switch Spacer Bolt for two adjustable unions M 12x1 5 OilSistem solenoid valve block Variator lubrication jet Pressure switch union Solenoid valve block support Solenoid valve block oil filter pipe Varia
15. Take care when removing the oil filter as it may be hot The operations of checking filling up and replacing the cooling liquid must be carried out with the engine turned off and cold Take particular care if liquids containing nitrites are mixed with others not containing these compounds as this may give rise to the formation of nitrosamines which are a health hazard The cooling liquid is polluting so dispose of in a manner that does not damage the environment In order to move the engine simultaneously use the eyebolts fitted for this purpose by Kohler These lifting points are however not suitable for the entire machine so in this case use the eyebolts fitted by the manufacturer GENERAL SAFETY DURING OPERATING PHASES procedures contained in this manual have been tested and selected by the manufacturer s technical experts and hence are to be recognised as authorised operating methods Some tools are normal workshop ones while others are special tools designed by the Manufacturer of the engine All tools must be in good working condition so that engine components are not damaged and that operations are carried out properly and safely Itis important to wear the personal safety devices prescribed by work safety laws and also by the standards of this manual Holes must be lined up methodically and with the aid of suitable equipment Do not use your fingers to carry out this operation to avoid the r
16. Components 1 Fuel supply pipe from the tank 2 High pressure pipe 3 Capillary tester 4 Valve lowering lever with dial indicator showing piston movement Rotate the crankshaft clockwise on the timing belt side and position the relevant cylinder piston top dead centre Press the lever to bring the valve into contact with the piston crown By joggling back and forth clockwise and anticlockwise find the dead centre via the dial indicator and then reset to zero 144 Rotate the crankshaft anticlockwise until diesel starts to flow out from the capillary when the high pressure lever is pressed Change direction of rotation of the crankshaft to clockwise from the timing belt side Press the high pressure lever and rotate the crankshaft until fuel stops flowing from the capillary 60 KD Workshop Manual cod ED0053029350 1 ed rev 00 KOHLER Fuel system 6 The capillary tube shows when the fuel is flowing out thanks to its small transparent slot 4 After finding the delivery start point when fuel stops flowing from the capillary press the lever and use the dial indicator to check how many millimetres the piston has moved from the top dead centre Check static injection advance using the conversion table from milli metres to degrees If it is necessary t
17. Overall Tool for checking phase sensor AEOS AN 1 Dial indicator Mp 1 1460 274 d support 2 1460 270 VETE M 3 2003 020 4 1460 267 KD Workshop Manual cod ED0053029350 1 ed rev 00 105 Translated from the original manual in Italian language Data reported in this issue can be modified at any time by KOHLER KOHLER FOR SALES AND SERVICE INFORMATION IN U S AND CANADA CALL 1 800 544 2444 KohlerEngines com ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 oo DATE 06 20 2012
18. 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 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 If 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 particular care should be taken in order to avoid burns In any case make sure that oil does not
19. 10 15 20 25 30 35 40 45 50 viscosity and no other qualitative characteristic is taken into account The first number refers to the viscosity when the engine is cold symbol W winter while the second considers viscosity with the engine at r gime The criteria for choosing must consider during winter the lowest outside temperature to which the engine will be subject and the highest functioning temperature during summer Single degree oils are normally used when the running temperature varies scarcely Multi degree oil is less sensitive to temperature changes SAE 0W 30 Mineral base SAE Grade Semi synthetic base Synthetic base International specifications They define testing performances and procedures that the lubricants need to successfully respond to in several engine testing and laboratory analysis so as to be considered qualified and in conformity to the regulations set for each lubrication kind American Petroleum Institute MIL Engine oil U S military specifications released for logistic reasons ACEA European Automobile Manufacturers Association Tables shown are of useful reference when buying a kind of oil Codes are usually printed out on the oil container and the understanding of their meaning is useful for comparing different brands and choosing the kind with the right characteristics Usually a specification showing a following letter or n
20. 7 Key switch 8 Battery charging light 149 12 5 V 14 A Alternator Features a fixed armature winding housed in the bell inside the blo a p wer stator The rotating permanent magnet inductor is located in the fan spindle See page 24 oN Dimensions mm __ 50 Note Clearance between armature winding and inductor air gap should be 0 55 0 63 mm 62 KD Workshop Manual cod ED0053029350 1 rev 00 KOHLER Electric system 7 __ KNE LL LIN __ __ __ _ _ ___ _ r p m T min U min 1400 151 Giri 1 1200 1600 2000 2400 2800 3 E lt E O y 152 ENNNLNWE FENE N LLL tT PIN MERN Giri T 1200 16 r p m 1400 T min U min 1800 2200 153 NL BN 2600 Alternator battery charger curve 12 5 V 14A The curve was obtained at room temperature of 25 with 12 5V battery voltage Note The r p m shown in the table refers to the engine 12 V 21 A Alternator Features a fixed armature winding housed in the bell inside the blo wer stator The rotating perma
21. This indicates that it is necessary to take proper precautions using symbols which are explained below to prevent any risk to the health and safety of individuals and avoid financial damage This indicates situations of grave danger which if ignored may seriously threaten the health and safety of individuals This indicates particularly important technical information that should not be ignored Danger Attention A Important LIMITED 3 YEAR KOHLER DIESEL ENGINE WARRANTY Kohler Co warrants to the original retail consumer that each new KOHLER Diesel engine sold by Kohler Co will be free from manufacturing defects in materials or workmanship in normal service for a period of three 3 years or 2000 hours whichever occurs first from the date of purchase provided it is operated and maintained in accordance with Kohler Co s instructions and manuals If no hour meter is installed as original equipment then 8 hours of use per day and 5 days per week will be used to calculate hours used Our obligation under this warranty is expressly limited at our option to the replacement or repair at Kohler Co Kohler Wisconsin 53044 or at a service facility designated by us of such parts as inspection shall disclose to have been defective This warranty does not apply to defects caused by unreasonable use including faulty repairs by others and failure to provide reasonable and necessary maintenance The following items are not covered by this wa
22. Version number form K 4 SN plus engine serial number plus date 98 KD Workshop Manual cod ED0053029350_1 ed_ rev 00 KOHLER NOTES KD Workshop Manual cod ED0053029350_1 ed_ rev 00 99 13 STORAGE KOHLER When the engines are not used for more than 3 months they must be protected by the measures described below STORAGE FI 7 V na c 4 wei nem nt AD VIE reri ae gt lt A External engine protection Start the engine and heat it Remove the drain plug and let the oil flow completely Replace the oil filter with a new one screw manually the new filter Clean the oil drain plug and after having assembled a new gasket tighten it Carry out the oil refilling to the upper level of the rod using AGIP RUSTIA C for Countries in which this product is not available find an equivalent product on the market Start for about 10 minutes and verify any possible oil leakage then stop the engine Injection systems protection Empty the fuel tank Replace the fuel filter with a new one Carry out the filling of fuel using 10 of AGIP RUSTIA NT special additives After having performed the air bleeding start the engine verif
23. are numerical 5 6 7 8 9 10 11 12 13 and 14 The adjustment rod is locked via the bayonet device Injection pump only for EPA engines 1 Delivery union 2 PRV valve 3 O Ring 4 Pump housing 5 Pumping piston 6 Pumpung plunger 7 Elastic pin 8 Rack rod 9 Superior retainer 10 Spring tappet 11 Tappet body 12 Inferior retainer 13 Roller 14 Journal guide tappet 15 Elastic pin 16 Adjustment hose 17 Plunger stop pin 18 Cap Injection pump only for standard and 97 68 Ce engines 1 Delivery union 2 Rubber ring 3 Delivery valve 4 Pump housing 5 Piston 6 Plunger 7 Rack rod 8 Spring 9 Tappet body 10 Roller 11 Journal 12 Pin 13 Spring retainer 14 Eccentric 15 Copper gasket 16 Spring 17 Filler KD Workshop Manual cod ED0053029350_1 ed_ rev 00 53 Fuel system KOHLER 131 132 Plunger dimensions mm p 7451455 Eg x89 s mmssnms 0 How to check plunger and barrel for internal leakage This operation is only diagnostic since pressure changes depend on the pumping speed Connect the delivery union with a 600 bar pressure gauge with safety valve Adjust rack rod at half stroke Turn flywheel according to its direction so that the plunger puts the circuit under pressure Replace plunger if the displayed pressure is below 300 bar Repeat the sa
24. be below 120 C for engines without oil cooler and below 110 C for engines with oil cooler Pressure is gi ven in bar and temperature in centigrades KD Workshop Manual cod ED0053029350 1 ed rev 00 51 6 FUEL SYSTEM KOHLER 123 emm e Fuel feeding injection circuit Components 1 Tank 2 Filter 3 Fuel feeding tube 4 Fuel feeding pump 5 Injection pump 6 Injection line 7 Injector 8 Injector leak off line and self bleeding system 9 Bowl Fuel filter Components 1 Bleeder 2 Cap 3 Seal element 4 Union 5 Cartridge Cartridge characteristics Filtering paper PF 904 Filtering area 2000 cm2 Degree of filtrafion 2 3 um 4 bar gt 17 for periodical maintenance details Fuel feeding pump The fuel feeding pump is of the diaphgragm type operated by a camshaft eccentric through a drive rod It features an external lever for manual operation Components 1 Drive rod shelf 1 470 2 070 mm 2 Gasket 3 Camshaft eccentric Characteristics when the control eccentric rotates at 1500 r p m mini mum delivery is 64 I h while self regulation pressure is 4 5 m water column Injection pump C The Bosch injection system consists of three pu
25. compression stroke Unscrew rocker arm cover side plug and measure clearance A should be 0 30 0 40 mm Rocker arm assembly Components 1 Rocker arm axle lubrication hole 2 Lubrication tube Dimensions mm A 1 032 18 050 B 1789 18 000 Replace the axle and the rocker arm if clearance A B is greater than 0 135 mm When refitting check that lubrication tube 2 perfectly fits into centering bore 1 O Tighten screws at 25 Nm Disassembling size P injector The injector is attached to the cylinder head via a forked bracket To release the injector union from the high pressure pipe use two box wrenches 14 and 17 mm KD Workshop Manual cod ED0053029350_1 ed_ rev 00 29 4 Disassembly Reassembly KOHLER Unscrew the screw fastening the clamp of the high pressure pipe using a 4 mm hexagon screwdriver Remove the forked bracket fixing the injector to the cylinder head using a 5 mm hexagon screwdriver see photo 29 30 These operations are necessary when checking injector calibration or when replacing it N The fixing bracket screws must be tightened to 10 Nm using a tor que wrench KD Workshop Manual cod ED0053029350_1 ed_ rev 00 KOHLER Disassembly Reassembly 4 T Q Jf A y NOS Cu
26. drives the speed governor KD Workshop Manual cod ED0053029350 1 rev 00 83 Disassembly Reassembly KOHLER O After refitting the housing tighten the screws to 20 Nm using a tor que wrench Remove the distribution control gear from the crankshaft Assemble the variator onto the end of the camshaft taking care to properly insert the timing pin into place and ensuring that the variator comes into contact with the surface of the speed governor idle gear O Tighten screw M10 to 65 Nm using a torque wrench Assemble the timing control gear onto the crankshaft so that referen ce mark A is lined up with the two reference marks B on the idle gear installed on the camshaft 64 KD Workshop Manual cod ED0053029350 1 ed rev 00 KOHLER Disassembly Reassembly Replace the timing cover placing a new seal and lining up with the ay two centring pins O Tighten the screws to a 25 Nm torque Refit the oil feed bushing to the variator placing the oil seal support ring in between Replace the seal O Tighten the three screws M6 to an 8 Nm torque Replace the speed sensor taking care not to damage the O ring KD Workshop Manual cod ED0053029350_1 ed_ rev 00 85
27. 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 To achieve optimum performance of the engine use good quality fuel with certain characteristics Cetane number minimum 51 indicates the ignition quality Afuel with a low cetane number may cause problems when starting from cold and have a negative effect on combustion Viscosity 2 0 4 5 centistokes at 40 this is the resistance to flow and performance may decline if not within the limits Density 0 835 0 855 Kg litre a low density reduces the power of the engine and density that is too high increases performance and opacity of the exhaust Distillation 85 at 350 this is an indication of the mixture of different hydrocarbons in the fuel A high ratio of light hydrocarbons may have a negative effect on combustion Sulphur maximum 0 05 of the weight high sulphur content may cause engine wear In those countries where diesel has a high sulphur content it is advisable to lubricate the engine with a high alkaline oil or alternatively to replace the lubricating oil recommended by the manufacturer more frequently PRESCRIBED LUBRICANT Fuel with low sulphur content API 4 CG4 Fuel with high sulphur content API CF CD CE The countries in which diesel normally has a low sulphur content are Europe North America and Australia Fuels for low temperatures is possible
28. go vernor control gear 3 Mechanical speed governor components standard 1 Drive rod 9 Key 2 Stop ring 10 Thrust washer 3 Bearing 11 Bearings 4 Washer 12 Shaft support 5 Pin 13 Gear 6 Weights 14 Spring washer 7 Weight support 15 Flat washer 8 Shaft 16 Nut Mechanical speed governor operation standard Weights 1 are moved to the periphery by the centrifugal force and thus axially shift the washer 2 and the drive rod 3 which by means of a linkage move injection pump control lever 4 The governor springs 5 placed under tension by the accelerator con trol lever 6 offset the weights 1 centrifugal force Balance between the two forces keeps speed at an almost constant level in spite of load variations KD Workshop Manual cod ED0053029350_1 rev 00 47 4 Disassembly Reassembly KOHLER NO l S N Aime m B S 7 N A N Fox 51 BAY Uu par EF las i E Mechanical speed governor components for special generating sets 1 Spring anchoring rocker arm 2 Governor springs 3 Journal 4 Governor control lever 5 Governor control lever ball bearing 6 Lever 7 Bearing 8 Plate Note Two types of governor springs 2 are available one for full spe ed regulation at 1500 r p m and the other for full speed regu
29. high Oil level low Oil pressure valve blocked or dirty Oil pressure regulator not adjusted Worm oil pump LUBRICATION CIRCUIT Oil sump suction line clogged Faulty pressure gauge or pressure switch Blocked draining pipe Worn or broken blower belt Cooling circuit clogged COOLING CIRCUIT KD Workshop Manual cod ED0053029350_1 ed_ rev 00 11 2 Technical information KOHLER MANUFACTURER AND MOTOR IDENTIFICATION DATA The identification plate shown 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 customer version form K F Approval data Approval data The approval reference directives EC are on the engine plate F MADE IN ITALY KOHLER Model XX XX XXXX rom XXXX D sn XX XX XXXX Spec e9 97 68 CE 00 000 xx Q Xx 0 00 XXX XXX XX O EPA Label Shown on the Recoil Starter or on Air Shroud ___ __ EMISSION CONTROL INFORMATION THIS ENGINE COMPLIES WITH U S EPA CALIFORNIA REGULATIONS FOR 2011 NONROAD DIESEL ENGINES POWER CATEGORY 19 12 KD Workshop Manual cod ED0053029350_1 rev 00 KOHLER Technical information TECHINICAL SPECIFICATIONS
30. iam y 4 72 Pus pma 2 5 GL LL Ll Jf RE ial 6 Emme 2 2 2 2 FABIA 13 Blower assembly components with 14 A alternator 1 Housing 2 14 A alternator 3 Key 4 Ball bearing 5 Washer 6 Nut 7 Shaft 8 Bolt 9 Fan 10 14 A alternator bell 11 Spacer Blower assembly components with 21 A alternator 1 Housing 2 21 A alternator 3 Key 4 Washer 5 Nut 6 Shaft 7 Bearing 8 Bolt 9 Fan 10 21 A alternator bell 11 Spacer Blower control pulley Disassembly The blower control pulley is installed on and is driven by the cran kshaft To disassemble the pulley unscrew the left handed bolt clockwise af ter blocking the crankshaft O When reassembling tighten the bolt using a torque wrench to a torque of 300 Nm KD Workshop Manual cod 0053029350 1 rev 00 KOHLER Disassembly Reassembly EID iT S CCP UNE e al AC j ub 27 17 Vas 17 Crankshaft pulley Remove the pulley using extractor serial no 1460 200 Components 1 Left handed bolt 2 Washer 3 Blower control pulley Note It is only possible to check crankshaft axial clearance after tightening the pulley Blower control pulley diameter There are three pul
31. in metric format That is dimensions Failure to use genuine Kohler parts could result in sub are presented in millimeters mm torque is presented in standard performance and low longevity Newton meters Nm weight is presented in kilograms Kg volume is presented in liters or cubic centimeters cc and pressure is presented in barometric units bar GLOSSARY AND TERMINOLOGY Cylinder number one is the piston timing belt side viewed from the flywheel side of the engine Rotation direction anticlockwise viewed from the flywheel side of the engine For clarity here are the definitions of a number of terms used recurrently in the manual KD Workshop Manual_cod ED0053029350_1 ed_ rev 00 1 General remarks and safety information KOHLER SAFETY REGULATIONS 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 Kohl
32. nozzle Features Hole number and diameter 5 x 0 123 mm Jet angles ravi ma Su cd e DE laa 150 Needle valve elevation 0 200 0 205 mm Hole length 1 mm Sump diameter and length 2 2 5 mm Clean nozzle tip with a brass brush Check that holes are not obstructed using a mandrel with steel wire with 0 23 mm diam When refitting tighten ring nut at 55 65 Nm KD Workshop Manual cod ED0053029350_1 ed_ rev 00 57 Fuel system KOHLER Injector setting Connect injector to high pression pump and check that setting pres sure is 210 220 bar for size S injector and 245 255 bar for size P injector To change injector setting replace the shim over the spring When replacing the spring setting should be performed at a 10 bar greater pressure to allow for bedding during operation Check needle valve sealing by slowly moving hand pump until appro ximately 180 bar Replace nozzle in case of dripping only for size S injectors Static Injection timing Remove the rocker arm cover Use a 14 mm box wrench to lock the injector union and a 17 mm box wrench to loosen the union of the injector pump high pressure pipe Use a 19 mm box wrench to lock the injection pump union and a 17 mm box wrench to loosen the union of the injector pump high pr
33. owner you should however be aware that Kohler Co may deny you warranty coverage if your heavy duty off road engine or emission control related component has failed due to abuse neglect improper maintenance or unapproved modifications Your engine is designed to operate on commercial diesel fuel No 1 or No 2 low sulfur or ultra low sulfur diesel fuel only Use of any other fuel may result in your engine no longer operating in compliance with California s emissions requirements You are responsible for initiating the warranty process The Air Resources Board suggests that you present your heavy duty off road engine to a Kohler Co dealer as soon as a problem exists The warranty repairs should be completed by the dealer as expeditiously as possible Please review the document titled Kohler Co Federal and California Emission Control Systems Limited Warranty Off Road Diesel Engines for complete details of your heavy duty off road engine warranty If you have any questions regarding your warranty rights and responsibilities or the location of the nearest Kohler Co authorized service location you should contact Kohler Co at 1 800 544 2444 or access our website at www kohlerengines com 6 KD Workshop Manual cod ED0053029350 1 ed rev 00 KOHLER GENERAL REMARKS AND SAFETY INFORMATION 1 SAFETY AND WARNING DECALS MD Caution Warning Important remarks and features of the text are highlighted
34. supports so that the locating bolt holes coincide with the crankcase holes Crankshaft center main bearing supports Main bearing supports 2 and 3 have a different diameter size see page 40 for dimensions When refitting both centering notches A and B must be located on the same side Tighten screws at 30 Nm 39 KD Workshop Manual cod ED0053029350_1 ed_ rev 00 Disassembly Reassembly KOHLER Crankshaft lubrication ducts A Important During repair operations when using compressed air wear eye protection Remove the caps clean ducts A B and C using a drill bit with the same diameter and blow with compressed air After cleaning replace the new caps in their seats and make sure they are sealed Crankshaft journal radius The radius R connecting journal to shoulders is 2 8 3 2 mm Note When grinding main journals or crank pins restore the R value to original specification Checking main journals and crank pins Use an outside micrometer gauge Main journal and crank pin diameter Dimensions mm B 45 00 45 316 83 D 54 931 54 950 40 KD Workshop Manual cod ED0053029350_1 ed_ rev 00 KOHLER Disassembly Reassembly Diameter of main bearings d
35. 05 0 1 0 3 and 0 5 mm G NO 129 Size S injector Components 1 Intake fitting 2 Nozzle holder A 9 3 Shim 10 re rod EWN Ew 7 7 6 Intermediate flange 11 7 Nozzle 2 GY HA 8 Needle valve 3 ALG 212 9 Fixing flange 4 V 7 10 Taper pin 11 Gasket 1 f 12 System duct 5 Ca 1 13 Sump lt th 14 Cup 6 ASDA a 14 Bi Ae T A 8 d 13 130 56 KD Workshop Manual cod ED0053029350 1 rev 00 KOHLER Fuel system 6 9 11 7 8 9 10 132 a NSN NN SS TR IN N WA 133 Size S nozzle Features Hole number and diameter 4x0 28 mm Jet 160 Needle valve elevation 0 20 0 222 mm Hole length 0 7 mm Sump diameter and length 1x1 5 mm Clean nozzle tip with a brass brush Check that holes are not obstructed using a mandrel with steel wire with 0 28 mm diam When refitting tighten ring nut at 70 Nm Size P injector Components 1 Injector housing 2 Intake fitting 3 Shim 4 Spring 5 Pressure rod 6 Taper pin 7 Nozzle 8 Cup 9 Needle valve 10 Sump 11 System duct 12 Overflow pipe When refitting tighten ring 8 nut at 50 Nm Size P
36. 4 Main torque specifications and use of sealants KOHLER Table of tightening torques for standard screws coarse thread Resistance class R Quality Dimensions EAM MN SR EUN NUN 1 4 A 8 Quality Dimensions a eUUETUEU ET M 8 mor 2 29 _ mois 3 26 mazs 96 48 mas 5 Mies 55 Midas a m meas 2 e Mio m er M 20x1 5 M 20x2 Eds m 305 1050 104 KD Workshop Manual cod ED0053029350 1 rev 00 KOHLER SPECIALTOOLS 19 SPECIAL TOOLS DESCRIPTION Part No Overall T 1460 266 1 Valve control lowering tool static injection dios 1 1460 275 2 Dial indicator support 2 1460 270 3 Dial indicator 3 1460 274 High pressure pump for static advance control 1460 273 Injection pump static injection advance tester 1460 024 a 1 OX Tool for fitting valve stem seal ring 1460 108 Blower control pulley extractor 1460 200 Tool for assembling removing valve half collets 1460 113 Tool for mounting the spring on the tappet rod 1460 009 protection pipe Only for engines with advance variator Overall 1460 272 Tool for measuring air gap 1 Dial indicator 1 1460 274 2 Dial indicator support 2 1460 270 3 Gauge 3 2003 021 4 Master 4 1460 269 5 Base 5 1460 268 Only for engines with advance variator
37. 42 05 B 25 020 25 030 0 020 0 035 0 070 24 995 25 000 with driven and machined bearing When refitting the bearing of the connecting rod small end as you dri ve in make sure that the lubrication hole on the connecting rod coin cides with the hole on the bearing Connecting rod alignment Check alignment of small end and big end bearing bores using fitted mandrels axial mis alignment A 0 02 mm maximum limit 0 05 mm Moderale warpage may be corrected by gradually working with a press Connecting rod weight Weight connecting rods when replacing them in order to avoid unba lance The difference in weight should not exceed 10 g Connecting rod big end bearing Both centering notches A and B must be on the same side when re fitting O Tighten bolts at 40 Nm See page 39 for dimensions KD Workshop Manual cod ED0053029350_1 ed_ rev 00 37 Disassembly Reassembly KOHLER Nun IL TUN Camshaft gear Remove nut 1 and washer 2 Then remove camshaft gear 3 The cylindrical type of coupling makes gear removal easier since no puller is required O Tighten nut 1 at 25 Nm z V See Page 42 for timing Oil pump gear Remove nut 1 and washer 2 Then remove oil pump gear using a pul ler with two M 8x1 25 bolts length 60 mm O Tighten the nut at 35 Nm Timing gea
38. 64 Voltage Te D i TON RM 64 How to check voltage regulator for proper operation nnne nnns easet 65 Alternator type Bosch G1 14 V _ 66 Alternator type Bosch Gil 14 V 33 Fay U 66 14 V 33 A Bosch G1 alternator battery charger curve sssssssssssssssssee nennen nennen 66 Starting motor type Bosch JF 12 V class 29 biis euet iota eeiam 67 Characteristic curves for starting motor type Bosch JF 12 67 gh RR 67 IN ee cette ce see __ 68 SEMAN MN i een ses oe enue act 68 injection pump delivery Seting Emm 68 PAE EASA 68 APPENDIX FOR ENGINE WITH ADVANCE T1 ADVANCE VARIATOR OPERATING PRINCIPLE 72 Injection timing device operation NR ETT TETTE 72 KD Workshop Manual cod ED0053029350_1 ed_ rev 00 5 Chapter index KOHLER DISASSEMBEYTREASSEMBLY enu ams a Cc qain 74 Solenoid valve assembly diagram ysis 74 Speed sensor and variator assembly diagram eene nn nnn nenne nnns n
39. 80 keeping the fork in the position shown in figure A 70 A 70 Tighten only one screw on the position sensor to keep it in the right position A 71 96 KD Workshop Manual cod ED0053029350 1 ed rev 00 KOHLER Disassembly Reassembly cover against the crankcase so that the injection pump rod drive pin 1 is inserted between the two prongs of the fork 2 Look through the upper inspection hole on the cover to make sure that the pin 1 is correctly inserted into the fork 2 Operate the stop control lever repeatedly to make sure the system is running smoothly Replace the screws and nuts in the cover in the opposite order to when they were removed and O tighten to 25 Nm KD Workshop Manual cod ED0053029350_1 ed_ rev 00 97 Disassembly Reassembly KOHLER Refit the fuel pump after replacing the seal tighten the screws to 25 Z Nm Correct assembly position of the control unit that runs the engine va riator MADE IN ITALY KOHLER Type XXXX sin KXXXXXX Sofiwore oad SN XXXXXXX calibrotioa A 78 Example of adhesive plate on the control panel 1 Engine type 2 Control panel serial number 3
40. RIPTION 250 500 1000 LEVEL ENGINE LUBRICANT DRY AIR CLEANER OIL BATH AIR CLEANER BLOWER BELT TENSION VALVE ROCKER ARMS CLEARANCE ADJUSTMENT SETTING AND INJECTORS CLEANING FUEL PIPES RUBBER INTAKE HOSE AIR FILTER IN TAKE MANIFOLD ENGINE OIL RADIATOR CLEANING IN THE APPLICATIONS WHERE IT IS PRESENT FUEL TANK CLEANING COOLING SYSTEM CLEANING ENGINE LUBRICANT OIL FILTER FUEL FILTER BLOWER BELT FUEL PIPES REPLACEMENT RUBBER INTAKE HOSE AIR FILTER IN TAKE MANIFOLD DRY AIR CLEANER EXTERNAL CAR TRIDGE AFTER 6 CHECKS WITH CLEANING DRY AIR CLEANER INTERNAL CARTRID GE AFTER 3 CHECKS WITH CLEANING OVERHAUL PARTIAL OVERHAUL INSPECTION TOTAL OVERHAUL In case of low use every year In case of low use every 2 years The period of time that must elapse before cleaning or replacing the filter element depends on the environment in which the engine operates The air filter must be cleaned and replaced more frequently in very dusty conditions KD Workshop Manual_cod ED0053029350_1 ed_ rev 00 17 3 Maintenance Prescribed lubricant Refilling KOHLER LUBRICANT SAE Classification In the SAE classification oils differ on the basis of their X 40 35 30 25201510 5 0 5
41. Reassembly KOHLER Draw he speed sensor outwards being careful not to damage the rubber seal ring View of speed sensor housing yy Blower belt alternator Disassembly gt Seepage 22 23 A 23 80 KD Workshop Manual cod ED0053029350 1 ed rev 00 KOHLER Disassembly Reassembly Blower control pulley Disassembly Seepage 24 25 Components 1 Left handed bolt 2 Washer 3 Blower control pulley After loosening the screws remove the timing cover 7 E ig 4 HN Pay attention to the oil seal support ring when disassembling the ti ming cover KD Workshop Manual cod ED0053029350_1 ed_ rev 00 61 Disassembly Reassembly KOHLER Remove the timing cover seal Unscrew screws M10 on the variator to the camshaft SN Remove screw M10 Remove the variator The figure shows the camshaft pin for correct variator timing A Cylindrical pin 5x16 B Pin housing KD Workshop Manual_cod ED0053029350_1 ed_ rev 00 KOHLER Disassembly Reassembly w3 View of the camshaft ends with pin inserted Remove the shoulder housing of the idle gear that
42. Supports uia pepe 39 Crankshaft lubrication EENAA ENS quU 40 Crankshaft 40 Checking main journals and crank 40 Main journal and crank pin diameter mmm 40 Diameter of main D6 ANOS NR ERENT 41 Main bearing and connecting rod big end bearing inside diameter 41 Clearance between main journals crank pins and connecting rod bearings e 41 Main Dearing gs 2 DEN 41 Main bearing NIGMS PE 42 Sca VL ERREUR 42 _ ___ __ 42 42 How to measure camshaft bearing and journal inside 42 Dimensions of camshaft journals and Ee teta a Rie Fe 43 Checking intake exhaust cam n a IE nnn dese ex C aano aen Ge val eve auus a De daga 43 amp cam a o Inm 43 Camshait end play 43 44 Valve timing without considering timing
43. TABLE 1 Stud bolt M8x20 11 Screw M 8x18 2 Silicone O ring 12 Fuel supply pump seal 3 Snap pin 2x10 13 Sensor pump connection rod 4 Conical screw STEI M 10x1 5 14 AC pump and angular position sensor cover 5 Self locking flanged hex nut 15 Sensor control lever 6 Copper washer 16 Connecting pin between rod and sensor 7 Crinkled spring washer 17 Discharge stop plate 8 Screw TCEI UNI 5931 M 4x35 18 Angular position sensor 9 Screw STEI M 8x20 19 Flathead screw 1 Fuel supply pump KD Workshop Manual_cod ED0053029350_1 ed_ rev 00 89 I Disassembly Reassembly KOHLER Phase sensor assembly diagram I T Mosca ex li el eC 22 OL O CRUS Em Pe EAS ur 7 4 a LU lt 1 3 X 2 es A NA a 22 ST A Yj 74 xL EES V MN VON A S 0 4 0 1 Adjust with 0 2 mm shims COMPONENTS TABLE 1 Silicone O ring 2 Washer 6x12xSp1 3 Screw TCEI UNI 5931 M 6x10 4 Screw TCEI UNI 5931 M 6x25 5 Speed and phase sensors 6 Phase sensor air gap adjustment shim 7 Phase sensor support 90 KD Workshop Manual cod ED0053029350 1 ed rev 00 Disassembly Reassembly To assemble the phase sensor connector press the locking spring Remove the connector from the sensor O Loosen screw M6 When
44. THOUT OIL FILTER AN Danger Attention The engine may be damaged if operated with insufficient lube oil It is also dangerous to supply too much lube oil to the engine because a sudden increase in engine rpm could be caused by its combustion Use proper lube oil preserve your engine Good quality or poor quality of the lubricating oil has an affect on engine performance and life If inferior oil is used or if your engine oil is not changed regularly the risk of piston seizure piston ring sticking and accelerated wear of the cylinder liner bearing and other moving components increases significantly Always use oil with the right viscosity for the ambient temperature in which your engine is being operated Danger Attention The used engine oil can cause skin cancer if kept frequently in contact for prolonged periods If contact with oil cannot be avoided wash carefully your hands with water and soap as soon as possible Do not disperse the oil in the ambient as it has a high pollution power KD Workshop Manual cod ED0053029350_1 ed_ rev 00 19 3 Maintenance Prescribed lubricant Refilling KOHLER FUEL SPECIFICATIONS Danger Attention To avoid explosions or fire outbreaks do not smoke or use naked flames during the operations Fuel vapours are highly toxic Only carry out the operations outdoors or in a well ventilated place Keep your face well away
45. WORKSHOP MANUAL KOHLER o 6253 626 3 ENGINES KOHLER REGISTRATION OF MODIFICATIONS TO THE DOCUMENT Any modifications to this document must be registered by the drafting body by completing the following table Drafting Document Model Review pody code N Revision Issue date date Endorsed M PREFACE Every attempt has been made to present within this service manual accurate and up to date technical informa tion However development on the KOHLER series is continuous Therefore the information within this manual is subject to change without notice and without obligation 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 he 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 h
46. and 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 Time spent reading this information will help to prevent health and safety risks and financial damage Written information is accompanied by illustrations in order to facilitate your understanding of every step of the operating phases 2 KD Workshop Manual cod ED0053029350_1 ed_ rev 00 KOHLER CHAPTER INDEX This manual contains the most important information for the repair of KOHLER air cooled direct injection Diesel engines type KD 625 3 and 626 3 This information is current upto 02 07 2012 CHAPTER INDEX California emission control warranty 6 Your warranty rights and Obligations TD TUN 6 GENERAL REMARKS AND SAFETY INFORMATION cccccscceeeeceeceeeseceseeeneseeseseneeeaaseaseeaasseasseneeonseseneseases T nye Deis And warning decals ERE 7 Limited 3 year kohler diesel engine WAllAINY rt ewe adeb care ci ER T General service manual NOIES a ut E eA E leta E EE E T Glo
47. and cylinder head housings Intake and exhaust valve guides are both made of phosphoric cast iron Components 1 Exhaust valve guide 2 Intake valve guide Ref Dimensions mm no _ B 4800 14 00 14 018 D 14 045 14 056 Valve guides with outside diameter increased by 0 5 mm are also available in such cases valve guide bore C should also be increased by 0 5 mm KD Workshop Manual cod 0053029350_ 1 rev 00 KOHLER 46 EXHAUST INTAKE VALVE VALVE KD Workshop Manual cod ED0053029350_1 ed_ rev 00 Disassembly Reassembly Valve guide insertion Heat cylinder head up to 160 180 C Thread guides considering the A e B distances from the head plane Ref Dimensions 30 80 31 20 24802520 Note f the guides are supplied with the housing for the lock ring C insert the ring then drive the guides until the lock ring is stop ped without worrying about A and B Dimensions and clearance between guides and valves Ret Dimensions mm Clearance mm Limit value mm 8 025 8 040 B 7 985 8 000 0 025 0 055 Valve seats and housings Dimensions mm 40 000 40 016 B 40 120 40 140 34 000 34 016 B 34 120 34 140 Valve seat lapping After cutting lap valve seats with fine emery paste in oi
48. arge pipe 20 View of the unassembled solenoid valve block with two spacers between the block and the bracket KD Workshop Manual cod ED0053029350 1 ed rev 00 77 I Disassembly Reassembly KOHLER Speed sensor and variator assembly diagram a COMPONENTS TABLE 1 Oil seal ring 20x30x7 2 6 12 5 1 al 3 Screw TCEI M 5x10 4 Screw TCEI 5931 M 6x10 5 Screw TCEI UNI 5931 M 6x14 SC 6 Lid seal rev counter 8 7 Oil seal support ring 8 Variator oil bush 9 Special tab for variator 10 Advance variator device 11 Timing cover side cover for variator 12 Speed and phase sensors 13 Cylindrical pin 5x16 14 Speed sensor support 78 KD Workshop Manual cod ED0053029350 1 ed rev 00 KOHLER Disassembly Reassembly To remove the speed sensor cable connector press the spring as _ h shown in figures 16 and 17 and draw upwards Loosen the two screws 8 to disassemble the solenoid valve support bracket Loosen screw M6 to remove the speed sensor from its support KD Workshop Manual cod ED0053029350 1 ed rev 00 79 Disassembly
49. arting switch Faulty starting motor MAINTENANCE ELECTRIC Clogged air filter Excessive idle operation Incomplete run in Overloaded engine Non conforming engine oil SETTINGS REPAIRS Incorrect governor linkage adjustment Governor spring broken or unhooked Low idle speed Rings worn or sticking Worn cylinder Worn main con rod rocker arm bearings Badly sealed intake valve Head tightening nuts loose Damaged cylinder head gasket Excessive valve rocker arm clearance No clearance between valves and rocker arms Valves sticking Defective timing system Bent rods 10 KD Workshop Manual cod ED0053029350 1 ed rev 00 KOHLER Technical information POSSIBLE CAUSE Damaged injector Injection pump valve damaged o Engine not start Engine starts but stops No acceleration Non uniform Black smoke TROUBLE White smoke Too low oil pressure Overheats Inadequate performance Excessive oil consumption High noise level Injector not adjusted Faulty fuel feeding pump Hardened pump control rod Broken or loose supplementary start up spring Worn or damaged pumping element INJECTION Incorrect tuning of injection components delivery balancing advance Extra fuel control level sticking Oil level too
50. collets NM Te remove half collets firmly press down the special tool 1460 113 as shown in the figure 36 KD Workshop Manual cod ED0053029350_1 ed_ rev 00 31 4 Disassembly Reassembly KOHLER Valve stem sealing rings Reassembly Lubricate the inside of the sealing ring with Molikote BR2 Plus and in sert them all the way onto the guides using tool 1460 108 To prevent deformation of the sealing ring 1 as it is inserted onto the valve guide 2 insert it onto tool 3 Lubricate valve stem with the same type of grease insert the valves into the guides rotating them particularly as they enter the sealing ring Valve springs Measure free length with a gauge Using a spring tester check that the spring length under two different loads corresponds to the values below Free length A 52 mm Length B compressed by 21 Kg weight 34 8 mm Length C compressed by a 32 Kg weight 25 8 mm Valve material Intake valves A Material X 45 Cr Si 9 3 UNI EN 10090 1 Chromium plated portion a 45 15 45 25 Exhaust valve B Shaft and head are made of 2 different materials 2 Welded portion 3 Chromium plated portion 4 Portion made of X 45 Cr Si 9 3 UNI EN 10090 5 Portion made of X 53 Cr Mn Ni N 21 9 UNI EN 10090 a 45 15 45 29 Valve guides
51. come into contact with your skin because of the health hazards involved Fuel vapours are highly toxic so fill up only in the open air or in well ventilated environments During operations which involve access to moving parts of the engine and or removal of the rotary guards disconnect and insulate the positive cable of the battery so as to prevent accidental short circuits and activation of the starter motor Check the belt tension only when the engine is turned off AN Do not start the machine in closed or poorly ventilated IMPORTANT To start the engine follow the specific instructions provided in the engine and or machine operating manual Do not use auxiliary starting devices not originally installed on the machine e g Startpilot systems which utilise ether etc Before carrying out any work on the engine turn it off and allow it to cool down Do not perform any operation while the engine is running Check that the discharged oil the oil filter and the oil contained in the oil filter are disposed of in such a way as not to harm the environment Close the fuel tank filler cap carefully after each filling operation Do not fill the tank right up to the top but leave sufficient space to allow for any expansion of the fuel Do not smoke or use naked flames while filling KD Workshop Manual cod ED0053029350_1 ed_ rev 00 KOHLER General remarks and safety information 1
52. contact with the skin and for long periods of time If contact with the oil is unavoidable you are advised to wash your hands with soap and water as soon as possible Dispose of old oil in the correct way as it is highly polluting 8 1 2 9 3 10 4 11 5 12 13 6 14 7 113 Components 1 Rocker arm shaft 6 Cil pump 11 Oil pressure relief valves 2 Connecting rod big end bearing 7 Drain plug 12 Pump intake pipe 3 Oil dipstick 8 Crankshaft main journal 13 Internal strainer 4 Camshaft 9 Crankshaft 14 Drain plug 5 Crankshaft journal 10 Cartridge filter KD Workshop Manual_cod ED0053029350_1 ed_ rev 00 49 9 Lubrication system KOHLER Oil pump Check that gear teeth are intact and that clearance between gear edge and pump body is 0 041 0 053 mm with limit value 0 10 mm Furthermore check that control shaft is tree to rotate with end float of 0 040 0 090 mm with limit value of 0 170 mm Oil pump delivery at 3000 r p m is 18 liters min Oil pressure relief valve Components 1 Plug 5 Rubber gasket 2 Copper gasket 6 Ring 3 Bushing 7 Hole for pressure switch connection 4 Piston 8 Spring Note Blow by at an oil temperature of 40 50 and pressure of 3 bar should be less than 1 l min When refitting screw bushing 3 so that it touches
53. dations for overhauls and 22 0 e tmm 29 Oil bath air cleaner components T ET 23 E 6 23 E AEE E 24 6 dici e PEE ED m 24 __ _ _____ __ ____ _ _ __ _ __ 24 wi ges Erica E T T T mm 24 Blower belt alternator I eassemiDly 25 gH 25 Air shroud and baffles DiSaS __________ _6_ _____ __ _ _ 25 BEIOWel assBIDD _____ _ ______ __ ________________ 25 Blower assembly components with 14 A 26 Blower assembly components with 21 nennen nennen nennen nennen nnns nnns annia nns 26 Blower control pulley DISASSOMMONY uassscenedndeitiuve mere phu ____ ______ ____ Dna 26 SVU I 27 Blower control pulley diameter __ __ _________ _ 27 oea S 27 rec
54. e supplied Connection size mm Thickness 64 KD Workshop Manual cod ED0053029350_1 ed_ rev 00 KOHLER Electric system 7 158 LB AMARILLO How to check voltage regulator for proper operation Check that connections correspond to the layout Disconnect the terminal from the battery positive poie Connect a d c voltmeter between the two battery poles Fit an ammeter between the positive pole and the corresponding ca ble 1 terminal The ammeter should be suitabie for reading the required value 14 or 21 A and for withstanding the starting motor peak absorption 400 450 A Start a couple of times until battery voltage drops below 13 V When battery voltage reaches 14 5 V the ammeter current suddeniy drops down to almost zero Replace regulator if recharge current is zero with voltage below 14 V A Important When the engine is running do not disconnect battery cables or remove the key from the control panel Keep regulator away from heat sources since temperatures abo ve 75 C mmght damage it No electric welding on eng ne or application KD Workshop Manual cod ED0053029350_1 ed_ rev 00 65 7 Electric system KOHLER 7 GRUN SSRN W E 1mm NERO NOIR SCHWARZ NEGRO BIANCO c 161
55. er 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 A WARNING In addition to all other machine specifications ensure that the engine is in a near horizontal position when starting If starting manually ensure that the necessary operations can be performed without any risk of
56. erlap posi tion intake open exhaust closed By means of ruler B check that tappets are at the same height Valve timing check Check using an index plate suitable for reading angles integral with the crankshaft Readings are taken in degrees Set valve clearance at 0 65 0 70 mm after checking restore the va lue al 0 15 0 20 mm Set dial gauge on intake valve to a zero value by rotating the driving shaft according to its direction of rotation you can measure q intake valve opening advance referred to top dead centre PMS and intake valve closing delay referred to bottom 1 dead centre Follow the same procedure for exhaust valves checking y exhaust valve opening advance and 6 exhaust valve closing delay 44 KD Workshop Manual cod ED0053029350_1 ed_ rev 00 KOHLER Disassembly Reassembly Legend S piston at top dead center l piston at bottom dead center intake valve open intake valve closed y exhaust valve open 6 exhaust valve closed Value expressed in degrees of the timing angles valves clearance 0 65 0 70 mm open 2 before P M S close 34 after P M I open 34 before P M I close 2 after P M S O3 WE H Hn H M 101 KD Workshop Manual cod ED0053029350_1 ed_ rev 00 45 4 Disassembly Reassembly KOHLER Hydraulic pump p t o group 1 A hydraulic pump of
57. ery value at 1 mm stroke from 5 to 14 Plunger diameter size 7 500 mm Note All pumps are tested and set in order to obtain the same delivery at full speed After the tests carried out at idle speed pumps are subdivided into classes marked with references in letters or numbers These reference marks are very clearly stamped on the upper pump body If replacing make sure that the new pumps have the same references letters or numbers as the previous ones KD Workshop Manual cod ED0053029350 1 ed rev 00 55 6 Fuel system KOHLER Injection pump replacement 1 Rack rod lock 2 Reference mark pump class 82 80 mm C Injection cam radius D Injection pump support A Important Whe replacing this type of injection pump check that the new one has a same reference mark as the old one The reference marks of injection pumps must be the same 127 128 Replace as follows Fit pump into the crankcase and tighten screws at 25 Nm Remove lock 1 and check that rack rod is free to move O O If pump removal is required fit lock 1 to its original position the rack rod centre should coincide with the pump axis see fig 126 When replacing the crankcase or the camshaft preserve the same di stance A between D injection pump support and C injection cam ra dius add shims G on D to obtain the right A value if required Seals G are supplied with different thicknesses 0
58. essu re pipe KD Workshop Manual cod ED0053029350_1 ed_ rev 00 KOHLER Fuel system 6 Assemble tool serial no 1460 266 made up of lever 2 serial no 1460 275 of a dial indicator 1 serial no 1460 274 inserted in a dial indicator holder serial no 1460 270 The function of lever 2 is to reduce the effort required against the re J sistance of the spring when the valve lowers and comes into contact with the piston crown near the top dead centre The dial indicator tracer 1 rests against the upper spring bearing ring of the valve sum up as pressure is placed on lever 2 the valve goes into tact with the piston since the dial indicator 1 is applied to the valve allowing to know precisely every movement of the piston from and to wards the TDC which is very important for the following operation Unscrew the fuel supply union for the injection pump of the cylinder which is to be worked on To the injection pump connect the high pressure pump serial no 1460 1 273 supplied by a tank whose fuel level is at least 100 mm above the injection pump Insert the capillary tester serial no 1460 024 onto the injection pump union where the high pressure pipe is usually connected from the pump to the injector KD Workshop Manual cod ED0053029350_1 ed_ rev 00 59 6 Fuel system KOHLER
59. g stud 10x1 5 Loctite 270 Main bearing support fixing stud bolt flywheel side 8 Loctite 270 Head stud 12 Loctite 270 Crankcase stud bolt 9x1 25 8 10 Loctite 270 Injection pump 8 25 Loctite 270 102 KD Workshop Manual cod ED0053029350 1 ed rev 00 KOHLER Main torque specifications and use of sealants 14 COMPONENT Oil sump MAIN TORQUE SPECIFICATIONS Diameter and pitch mm 10 Sealants Loctite 270 Belt guard 8x1 25 Blower crankshaft pulley 16x1 5 Fan pulley 12X 1 9 Fuel filter union 14x1 5 Fuel pump union 10x1 Radiator union 14x1 5 Injector high pressure pipe union Speed governor support shaft 12X1 5 8x1 25 Main bearing support gear case side 8x1 25 Main bearing support flywheel side 8x1 25 Center main bearing support 10x1 5 Hydraulic pump gear support 8x1 25 Governor control internal lever support 8x1 25 Fuel tank bracket 8x1 25 Drain plug 14x1 5 Cylinder head 10x1 5 Camshaft axle housing screws Flywheel 12 1 25 USE OF SEALANTS ONLY FOR ENGINES WITH VARIATOR POSITION SEALANTS Pump cover C Loctite 5205 Speed sensor support Loctite 209079 Phase sensor support fastening screws Loctite 242 Speed sensor support fastening screws Loctite 242 KD Workshop Manual cod ED0053029350 1 rev 00 103 1
60. gasket 5 Do not tighten excessively since gasket 5 might break causing an oil pressure drop in the system Oil filter cartridge Components 1 Retainer 6 Upper cover 2 Plate 7 Blade 3 Valve 8 Filtering element 4 Gasket 9 Assembly 5 Gasket 10 Belleville washer 11 Tank Characteristics Max working pressure 13 bar Filtering E 121 955 of aT 20 By pass valve opening pressure 1 4 1 8 bar Oil pressure check Once the engine is fitted fill with oil and fuel connect a 10 bar pressu re gauge to the oil filter fitting Start the engine and check pressure as a function of the oil tempera ture see page 49 KD Workshop Manual cod ED0053029350_1 ed_ rev 00 KOHLER Lubrication system 9 bar N Aa o gt 60 70 80 90 100 120 C 121 bar C A Oo si 60 70 80 90 100 120 C Oil pressure curve at idling speed The curve is obtained at the oil filter level with constant engine speed of 1200 r p m in no load conditions and at a room temperature of 25 Pressure is given in bar and temperature in centigrades Oil pressure curve at full speed The curve is obtained at the oil filter level with engine working al 3000 r p m al the N power Room temperature is 25 C Lube oil peak temperature should
61. group 1 or 2 can be installed the gear side GI 3rd p to e A group 1 hydraulic pump can be installed at the 4th p t o B Hert AA gt 3 Hydraulic pump 3rd p t o group 2 Components 1 Gear 2 Gear support 3 Bearing 4 Drive 5 Flange 6 Washer 7 Seal ring 8 Circlip A max torque of 39 6 Nm can be obtained from this p t o Hydraulic pump 4th p t o group 1 Components 1 Drive 7 Seal ring 2 Control shaft 8 Seal ring 3 Pin 9 Centering ring 4 Gear 10 Bracket 5 Washer 11 Gasket 6 Nut 12 Cover A max torque of 243 Nm can be obtained from this p t o Use of 3rd and 4th p t o 1 Hydraulic pump group 2 mounted at 3rd p t o 2 Hydraulic pump group 1 mounted at 4th p t o Total power obtainable from 3rd and 4th plo is 13 kW 17 7 HP Ratio for both p t o compared to the engine r p m is 1 1 for 4 PTO is 1 1 067 for 3 PTO 46 KD Workshop Manual cod ED0053029350 1 ed rev 00 KOHLER Disassembly Reassembly 4 9 8 7 65 43 2 ec 16 15 14 13 12 1 10 108 109 Mechanical speed governor The governor with centrifugal weights is housed inside the crankca se and is controlled by a camshaft gear To remove speed governor 1 remove camshaft bell 2 and speed
62. hop Manual cod ED0053029350 1 ed rev 00 101 14 MAIN TORQUE SPECIFICATIONS AND USE OF SEALANTS KOHLER MAIN TORQUE SPECIFICATIONS Diameter and pitch Tank bracket vibration dampers 8x1 25 Sealants Loctite 270 Connecting rod 8x1 Injection pump delivery valve union 18x1 5 Bell flywheel side 10x1 5 Central support collar 8x1 25 Intake manifold 8x1 25 Exhaust manifold 8x1 25 Air shroud 8x1 25 Throttle control cover 8x1 25 Rocker arm cover 8x1 25 Timing cover 8x1 25 Cover hydraulic pump flange 1P 8 1 25 Oil pump casing 8x1 25 Blower pulley nuts 6x1 Oil pump nut or union 8x5 Loctite 270 Oil pump gear threading Loctite 270 Tank bracket gasket LoctitelS 495 Air filter Oil filter Internal oil filter Hydraulic pump flange Nozzle cup Camshaft gear 250 Oil pump gear 35 Timing gear 40 10 Injector cylinder head fastening nuts for S size screw for P size Injection pump control lever 8x1 25 Starting motor 10x1 5 Oil radiator nipple 16x1 5 Loctite 270 Oil filter cartridge nipple 8x1 25 Loctite 270 Rocker arm pin 8x1 25 Governor control external lever pin 8x1 25 Stop control external lever pin 8x1 25 Engine mounting foot 10x1 5 Injector stud bolt 8x1 25 Starter motor stud bolt 8x1 25 Fuel feeding pump 8x1 25 Blower housin
63. imiting device until the engine shows a drop in r p m Un screw limiting device C by 175 turn Tighten lock nut Note If the engine under full load generates too much smoke tighten C if no smoke is observed at the exhaust and the engine can not reach its full power unscrew C S ADI AS C Stop setting Remove fuel feeding pump and cover 1 Loosen both bolts fixing plate A 2 Push injection pump B control rod to the right and keep it in this position 3 Push plate A to the right until it touches rod B and stop 4 Release rod B and push plate A to the right so that rod B has a stroke of 1 mm Tighten both bolts Note Under these conditions no damage can be caused to the injec tion pump rack rod stops by sudden impacts due to the availa ble control solenoids 168 66 KD Workshop Manual cod ED0053029350 1 ed rev 00 KOHLER NOTES KD Workshop Manual cod ED0053029350_1 ed_ rev 00 69 NOTES KOHLER 70 KD Workshop Manual cod ED0053029350_1 ed_ rev 00 KOHLER APPENDIX FOR ENGINE WITH ADVANCE VARIATOR KD 625 3 626 3 ENGINE with advance variator KD Workshop Manual cod ED0053029350_1 ed_ rev 00 71 ADVANCE VARIATOR OPERATING PRINCIPLE KOHLER INJECTION TIMING DEVICE OPERATION In order to
64. injection pump delivery at the test bench for standard and 97 68 CE 55 Injection pump replacement seus artes esse acu y aces u xy den ____________ ___ KH 56 Ris oia EEE EE A E ere 56 c M A 57 MEER RR 57 qe E ee gee eee eee aes 57 Nm tome 58 Static Injection miig 58 ELECTRIC TE 62 Standard electi 21610119194 62 Electric starting layout without battery charging 62 Electrical starting layout with battery charging ach MUSEI dl adt 62 MAR MEE ee 62 Alternator battery charger curve 12 5 V 14A LL ie eee ette er t rr need eo nux testeur a rares Ure 63 12 V 21 A Alternator 63 Alternator battery charger curve 12 V 21 A usce ht dte rotae 63 Magnetization checking tool Part No 7000 9727 001 nnne nnne enne nnne n nnns nnn nennen 64 Checking tor cable Ug 611 MN RET
65. isk of amputation SAFETY AND ENVIRONMENTAL IMPACT Every organisation has a duty to implement procedures to identify assess and monitor the influence of its own activities products services etc on the environment Procedures for identifying the extent of the impact on the envi ronment must consider the following factors Liquid waste Waste management Soil contamination Atmospheric emissions Use of raw materials and natural resources Regulations and directives regarding environmental impact Some phases may require the assistance of more than one operator If so it is important to inform and train them regarding the type of activity they will be performing in order to prevent risks to the health and safety of all persons involved Do not use flammable liquids petrol diesel etc to degrease or wash components Use special products Use the oils and greases recommended by the manufacturer Do not mix different brands or combine oils with different characteristics Discontinue use of the engine if any irregularities arise particularly in the case of unusual vibrations Do not tamper with any devices to alter the level of performance guaranteed by the manufacturer In order to minimise the impact on the environment the manufac turer now provides a number of indications to be followed by all persons handling the engine for any reason during its expected lifetime All packaging components must be dispo
66. justable If this value cannot be obtained check A and B and possibly replace the parts whose size is inadequate Camshaft Camshaft removal To pull out the camshaft simply remove bell 1 gear 2 fuel feeding pump 3 injection pumps 4 and tilt the engine in this position the cam followers is not in contact with the camshaft thus making its removal possible How to measure camshaft bearing and journal inside diameter Ref Dimensions mm Clearance mm SERIE A 44 000 44 025 0 040 0 085 0 170 B 43 940 43 960 Measure A using an internal dial indicator and B with an external mi crometer When repiacing the bearing make the lubrication hole 1 match with the corresponding crankcase bore 42 KD Workshop Manual cod ED0053029350 1 ed rev 00 KOHLER Disassembly Reassembly 4 Dimensions of camshaft journals and housings pce pep sur 42 000 42 025 unm om 5 SAX B 41 000 41 025 0 040 0 085 0 170 33 200 33 220 D E F 41940 41 960 C F 0 040 0 085 0160 D E 40 940 40 960 F 33 140 33 160 Checking intake exhaust cam height Use an outside micrometer gauge to measure camshaft lobe height p D LD D LD L L LD L NLU LUDA NN e e a T A T T ee DE D SE E r 95 m E
67. l by KOHLER for any modifications releases the company from any damages incurred by the engine Note Consult KOHLER for power torque curves and specific consumptions at rates differing from those given above KD Workshop Manual_cod ED0053029350_1 ed_ rev 00 15 2 Technical information KOHLER OVERALL DIMENSIONS JIPPE i I 4 gt Ue TAR Ae AAT H S al m maa ISJ LII Laut DIMENSIONI mm MESURES mm DIMENSION mm EINBAUMARE mm DIMENSIONE mm DIMENC ES mm 2 e s t 27 ms eo x w m B 62 47 H 4 276 45 5 35 V 6 fyf e c r a i ws n w e z 9 Note Dimensions shown in mm 16 KD Workshop Manual cod ED0053029350 1 ed rev 00 KOHLER MAINTENANCE PRESCRIBED LUBRICANT REFILLING 3 ROUTINE ENGINE MAINTENANCE A Important Failure to carry out the operations described in the table may lead to technical damage to the machine and or system EXTRAORDINARY MAINTENANCE AFTER THE FIRST 50 WORKING HOURS Engine oilreplacement Oil filter replacement ORDINARY MAINTENANCE FREQUENCY x HOURS OPERATION DESC
68. l suspension The sealing surface S should not exceed 2 mm Valve recess after grinding Limit value mm Disassembly Reassembly KOHLER J 3 _ _ 77 s a EA Pushrod tube spring fitting Components 1 Spring 2 Tool Part No 1460 009 3 Rocker arm lubrication tube 4 Gasket 5 Pushrod tube 6 Gasket To mount the spring 1 on the tappet rod protection pipe 5 insert it into the tool 2 with the help of a vice Make sure that the rocker arm lubrication hose 3 and the seals 4 and 6 are fully in place Cylinder Measure diameter size between two diametrically opposed points at three different heights Ref Cylinder mm _ 625 3 626 33 34 00 34 016 In case wear exceeds 0 10 mm bore the cylinder and fit oversize pi ston and rings In case of less wear replace piston rings only Checks and cyiinder roughness The cylinder should show no blowholes or porosities Seal both ends of cylinder and pressurize with compressed air at 4 bar for 30 sec Fins must be intact Cross hatch pattern must range between 115 140 they must be uniform and clear in both directions Average roughness should range between 0 5 and 1 um Piston Rem
69. la tion at 1800 r p m in this case governor weights are heavier Mechanical speed governor setting Lift finkage A Loosen screw B Push lever C to the right and check that speed governor weights are closed Shift injection pump delivery control yoke D to the right for maximum delivery Tighten screw B Spring for extra fuel supply at starting The device is operated automatically when the engine is stopped spring 1 acts on injection pump control yoke 2 providing maximum fuel delivery until the speed governor starts operating KD Workshop Manual cod ED0053029350_1 ed_ rev 00 KOHLER LUBRICATION SYSTEM 2 AN Danger Attention The engine can be damaged if allowed to operate with insufficient oil It is also dangerous to add too much oil because its combustion may lead to a sharp increase in the rotation speed Use suitable oil in order to protect the engine Nothing more than lubrication oil can influence the performances and life of an engine Use of an inferior quality oil or failure to regularly change the oil will increase the risk of piston seizure will cause the piston rings to jam and will lead to rapid wear on the cylinder liner the bearings and all other moving parts Engine life will also be notably reduced The oil viscosity must suit the ambient temperature in which the engine operates AN Danger Attention Old engine oil can cause skin cancer if repeatedly left in
70. leys with different diameters A which take account of engine settings from 2401 to 3000 r p m from 2001 to 2400 r p m from 1500 to 1800 r p m A Check S surface in contact with oil seal ring and if necessary rub with a fine grain emery cloth Timing cover Loosen the screws and remove the cover When refitting tighten screws at 25 Nm Check oil seal ring 1 and replace if warped hardened or worn out Replace gasket 2 KD Workshop Manual cod ED0053029350_1 ed_ rev 00 27 I Disassembly Reassembly KOHLER 4 0 c RM ws Tank AN Danger Attention Do not smoke or use naked flames during the demounting ope rations as these could cause explosions or fire outbreaks Fuel fumes are highly toxic Only carry out the operations outdo ors or in a well ventilated place Keep your face well away from the filler cap or you could inhale harmful fumes Dispose of fuel in the correct way as it is highly polluting Do not litter Remove fuel filter and loosen clamp screws Completely empty the tank and check that no impurities are found in side Check that cap breather is not clogged Flywheel AN Danger Attention During the demounting phases pay particular attention to pre vent the flywheel from droppi
71. me operation for the other plungers How to check injection pump delivery valve sealing Components 1 Valve 2 Seat Adjust pump rack at half stroke Turn flywheel according to its direction of rotation so that the plunger puts the circuit under pressure During this operation the displayed pressure will gradually reach a peak followed by a sudden drop which corresponds to valve closing Pressure drop should be 30 50 bar Replace the valve if pressure drop is below this value Repeat the same operation for the other two pumps 54 KD Workshop Manual cod ED0053029350_1 ed_ rev 00 KOHLER Fuel system 6 Test data for injection pump delivery at the test bench for standard and 97 68 CE engines 1 Rack rod lock to be removed after pump fitting to the engine 2 Injection pump axis Test data Rod stroke from pump axis mm Camshaft Delivery towards max r p m mm stroke towards stop stamped A stamped Ax stamped B stamped Bx stamped C stamped Cx 0 stamped D 399 785738 7 The above test data refer to pump with plunger dia of 7 500 mm Test data for injection pump delivery at the test bench only for EPA engines Test data Rod stroke from pump axis mm Camshaft Delivery towards max r p m mm stroke towards stop stamped A stamped Ax stamped B stamped Bx stamped C stamped Cx 0 stamped D The pump class is indicated by the full deliv
72. meet EPA tier 2 limits the engine KD 625 3 has been equipped with a variable injection timing device The system consists of an electro hydraulic actuated mechanical device that allows changing the injection timing by rotating the camshaft against its driving gear The change takes place using the oil whose pressure is regulated by a pair of electric valves which allow a rotation between 0 and 4 5 The maximum variation of the injection timing is 4 5 camshaft degrees Oil is taken from the engine oil circuit and its pressure acts on a sort of hydraulic piston that moves from one side to the other The hydraulic plunger is attached on the inside by means of a straight groove and on the outside via a spiral shaped groove Thus movement from left to right or vice versa causes rotation from the driving gear and the camshaft In other words the plunger translates and at the same time rotates and thus varying the angular position of camshaft that is connected to it The gear timing variation is managed by an ECU which receives electric signals from two speed sensors the temperature sen sor and the load sensor which reads the position of the injection pump control The ECU memory contains the maps of the injection timing variation strategies Fig A 1 Injection timing device in Resting position 72 77 ups SS z LL T ctp eem EE 7 297 A 42222 ae 2 RE HEJ
73. mps each feeding one cylinder The pumps mounted on the crankcase corresponding to their proper cylinder are directly operated by the camshaft KD Workshop Manual cod ED0053029350_1 ed_ rev 00 KOHLER Fuel system 6 MENNT NH _ ___ OIG 127 S SS ANV SS NS gt N D or d WSS mud NS ____ 22 EN SN TWO AN EE N NEN SS S 727 t d r N zu mmm gt N SH VN NI f mm 1 T jj NS N SS 5 2 ER s 1b AGG SA y e 5 15 Ce Xe Cu S 128 e amp E TES is bods NS c 24 SN AN poo Ses 4 ANANA ES 3 Y YES Dg ji aE ly ES 1 ECC 74 d 22 v oc E r tat E SMS 22 A 72 NS BS gt 2 5 19 Threaded plug 20 Adjustment rod locking device 21 Area in which the pump delivery class is stamped In this engine the injection pumps are preset by the manufacturer who supplies them stamped with alphabetical classes A Ax B Bx C Cx or D for standard and 97 68 EC engines while for EPA2 engines the classes
74. n case of low temperature starting we can supply a manifold with provision for a glow plug for air preheating Blower belt alternator Components c 1 Guard 2 Pulley zu 3 Spacers zu 4 V belt Unscrew fastening screws of the belt guard and remove it then take out the nuts on the three stud bolts on the half pulley Remove the V belt and check for wear gt See page 17 for periodic maintenance details arara Belt tension adjustment A Danger Attention Check the belt tension only when the engine is not running The belt tension is adjusted by adding to reduce tension or remo ving to increase tension spacers between the half pulleys Spacers are available in thicknesses of 0 5 1 and 2 mm Half pulley Reassembly A Important The three stop nuts of the half pulley should never be tightened simultaneously Turn the pulley so that whenever you tighten a nut this is in the position indicated A in the figure 7 Tightening should be carried out gradually 24 KD Workshop Manual cod ED0053029350 1 ed rev 00 KOHLER Disassembly Reassembly 4 Blower belt alternator Reassembly The half pulley fastening nuts must be tightened using the torque wrench to a final torque of 10 Nm Again during this phase the nut must be in position A when tigh
75. nent magnet inductor is located in the fan spindle See page 24 Red Dimensions __ B 49500 52000 c 782 6 76300 p monna __ Note Clearance between armature winding and inductor air should be 0 47 0 63 mm Alternator battery charger curve 12 V 21 A The curve was obtained at room temperature of 25 with 12 5V battery voltage Note The r p m shown in the table refers to the engine KD Workshop Manual cod ED0053029350_1 ed_ rev 00 263 Electric system KOHLER 155 156 157 Magnetization checking tool Part No 7000 9727 001 Components 1 Casing 2 Slider 3 Casing reference line 4 Slider reference line Rest the tool end horizontally onto the magnetic poles Hold sfider so that its reference line coincides with the casing referen ce line Release slider if no attraction occurs the rotor is demagnetized the refore replace alternator Checking for cable continuity Check that stator windings have no unsoldered connections burnt areas or grounded wires Using an ohmmeter check for continuity between the red cable and the two yellow ones Furthermore check that they are insulated from the ground Voltage regulator Supplied by SAPRISA Voltage 12 V max current 26A To avoid wrong connections 3 different sizes ar
76. ng as this could seriously injure the operator Wear protective goggles when removing the flywheel ring Remove the bolts which attach the flywheel to the crankshaft To replace starter ring gear heat it up to 300 C for 15 20 minutes Drive it onto the flywheei caretully checking that it perfectly fits into its seat Let it cool down slowly O When reassembling gradually tighten the fastening screws to 140 Nm on the crankshaft using a torque wrench Valve rocker arm clearance Caution Warning Make settings when the engine is cold Remove the rocker arm covers and make sure the seals are intact otherwise replace them Bring the cylinder piston that is to be adju sted to the compression top dead centre Loosen the fastening nut C insert the thickness gauge D between the rocker arm and the top of the valve stem then using a cross head screwdriver turn the adjusting screw B to set clearance Tighten the fastening screw C and check valve clearance A again to ensure that it is between 0 15 and 0 2 mm for intake and 0 3 0 35 mm for exhaust When refitting tighten cover screws to 20 Nm If necessary place a 0 30 or 0 40 mm shim at B 28 KD Workshop Manual cod ED0053029350_1 ed_ rev 00 KOHLER Disassembly Reassembly 4 Compression release optional Bring piston to top dead center on the
77. ngs so that cuts are misaligned by 120 from one to the next A Important Assemble the segments with TOP facing the piston crown KD Workshop Manual_cod ED0053029350_1 ed_ rev 00 35 Disassembly Reassembly KOHLER n y A WW o Ec uen E 00 pru y LL ear ee EN enn Ee f S QD pP eU 5074 A oe de 63 64 Piston Caution Warning Lubricate the following parts with oil before mounting the piston pin the piston the cylinder and the big end bearing Connect piston to connecting rod in a way that the combustion cham ber center b is under nozzle tip a Lubricate piston pin and introduce it into the piston by exerting pres sure with your thumb Check that both circlips are well inside their seats Piston clearance Clearance volume is 0 65 0 7 mm for size S injectors and 0 55 0 6 mm for size P injectors B Copper seal with various thicknesses The piston crown in the TDC top dead centre position may vary and 4 extend or be short of the upper surface of the cylinder Use a dial indicator to measure the positive or negative difference between the two surfaces piston crown and upper cylinder surface and use a suitable thicknes
78. nne nnne nean nnns 78 Blower belt alternator Disassembly menm 80 Blower control pulley 2 81 Angular position sensor AC pump assembly diagram 88 Phase sensor assembly DUMP NR 90 Resetting the dial INGICAION ____ IAEE a Ea inan ii rra Ssi 92 SEET PE NE E AE E E a ee te sere en A EAE N A S 92 UNG WGC ANON gm _________ 93 Measuring the depth between the sensor support and the 93 go 8 ipai TI T d eere 93 Example of adhesive plate on the control panel lseeesssessssssssseesseesee nennen nennen nnn 98 100 so M 100 External engine Protector Tro CTETUR 100 A tmm 100 External engine protection NNNM TREES 100 Procedures to be carried out before start the CNGING ccccccsseeecccsseeeccesececceueeecscesseeeseusececseeueeesseeseestseeeessneeseseas 101 MAIN TORQUE SPECIFICATIONS AND USE OF SEALANTS
79. o change static advance add the seals G in figure 129 to delay or remove the seals G in figure 129 to advance from between the injection pump surface and the crankcase surface The same operation must be performed for each cylinder Conversion table from degrees into millimetres 8 gt 0 56 9 gt 0 71 10 gt 0 87 7 gt 0 43 97 68 CE 2500 2800 8 gt 0 56 9 gt 0 71 8 gt 0 56 9 gt 0 71 10 gt 0 87 4 gt 0 14 2400 2800 5 gt 0 22 6 gt 0 32 Table static advance values for engines with S size injectors 13 gt 1 47 1500 2200 14 12 14 gt 1 71 15 gt 1 96 15 gt 1 47 2201 3000 16 12 16 gt 1 71 17 gt 1 96 KD Workshop Manual_cod ED0053029350_1 ed_ rev 00 61 ELECTRIC SYSTEM KOHLER 148 35mm AZZURRO AZUR BLUE BLAU Standard electric equipment Electric starting layout without battery charging light Components 1 Alternator 2 Starting motor 3 Voltage regulator 4 Battery 5 Pressure switch 6 Oil pressure warning light 7 Key switch Electrical starting layout with battery charging light Components 1 Alternator 2 Starting motor 3 Voltage regulator 4 Battery 5 Pressure switch 6 Oil pressure warning light
80. o you including diagnosis parts and labor MANUFACTURER S WARRANTY COVERAGE Your off road diesel engine emission control system is covered under warranty for a period of five 5 years or 3 000 hours whichever occurs first beginning on the date the engine or equipment is delivered to an ultimate purchaser for all constant speed engines with maximum power 19XkW 37 and rated speed less than 3 000 rpm all variable speed engines with maximum power 19SkW lt 37 and all variable or constant speed engines with maximum power greater than 37 kW Your off road diesel engine emission control system on variable or constant speed engines with maximum power less than 19 kW and for constant speed engines with maximum power 19xkW 37 and rated speed equal to or greater than 3 000 rpm is covered under warranty for a period of two 2 years or 1 500 hours whichever occurs first If any emission related part on your engine is defective the part will be repaired or replaced by Kohler Co OWNER S WARRANTY RESPONSIBILITIES As the heavy duty off road engine owner you are responsible for the performance of the required maintenance listed in your Kohler Co owner s manual Kohler Co recommends that you retain all receipts covering maintenance on your heavy duty off road engine but Kohler Co cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all recommended scheduled maintenance As the heavy duty off road engine
81. osits or residual material Wash the components with special detergent and do not use steam or hot water not use flammable products petrol diesel etc to degrease or wash components Use special products Dry all washed surfaces and components thoroughly with a jet of air or special cloths before reassembling them Apply a layer of lubricant over all surfaces to protect them against oxidation Check all components for intactness wear and tear seizure cracks and or faults to be sure that the engine is in good working condition Some mechanical parts must be replaced en bloc together with their coupled parts e g valve guide valve etc as specified in the spare parts catalogue AN Danger Attention During repair operations when using compressed air wear eye protection 22 KD Workshop Manual cod ED0053029350 1 ed rev 00 KOHLER Disassembly Reassembly 4 Oil bath air cleaner AN Danger Attention Do not blow the paper filter element with compressed air to clean Caution Warning Check gaskets and replace as necessary Check that flange welds are free of defective spots When reassembling tighten the fastening nuts of the air filter to the intake manifold to 25 Nm Oil bath air cleaner components MWD Caution Warning Replace if irreparably clogged 1 Bowl 7 Cover clamp 2 External seal ring 8 Cap 3 Lower filte
82. ove the Sieger stop rings and extract the pin After removing the snap rings from the piston clean the grooves if necessary Measure the diameter at 2 mm from the base using an external mi crometer Ref GPiston mm 625 3 626 33 94 90 94 92 Replace the piston and the snap rings if the diameter of the wear is greater than 0 05 mm of the minimum value prescribed Note Oversize pistons of 0 5 and 1 0 mm are available KD Workshop Manual cod ED0053029350_1 ed_ rev 00 KOHLER Disassembly Reassembly 4 58 60 Piston weight Weigh pistons when replacing them in order to avoid unbalance The difference in weight should not exceed 6 g Metal snap rings End gaps Insert the snap rings in the lower part of the cylinder then measure the distance between the tips KD 625 3 626 3 Compression snap ring A chrome plated Snap ring 0 40 0 65 conical internal torsional Ring oil scraper A 0 25 0 50 Metal snap rings Piston grooves FRet Dimensions mm Limit value _ 00 00 016 __ 055 Metal snap rings Fitting sequence A Compression snap ring chrome plated B Snap ring conical internal torsional C Ring oil scraper Note before inserting the piston in the cylinder rotate snap ri
83. r The timing gear can be easily pulled out thanks to the cylindrical type of coupling However if resistance is felt use a bearing puller 1 Main bearing support gear side Remove crankshaft key and thrust bearing Loosen the three fixing bolts and remove the main bearing support on gear side using two M 8x1 25 screws with fully threaded length of 60 mm Note To avoid distortion it is not recommended to repiace the bea ring bushing Complete assemblies of bushing and support are available in standard 0 25 and 0 50 mm unders ze configurations as spare parts When refitting tighten screws at 25 Nm 38 KD Workshop Manual cod ED0053029350_1 ed_ rev 00 KOHLER Disassembly Reassembly 4 Main bearing support flywheel side Loosen nuts and extract main bearing support using two M 8x1 25 screws with fully threaded length of 40 mm Check oil seal ring and replace if warped hardened or worn out When refitting tighten nuts at 25 Page 40 for dimensions Crankshaft Center main bearing support locating bolts Before removing the crankshaft straighten the safety stop 1 and un screw the bolts 2 of the central main bearings Crankshaft removal To pull out the crankshaft tap lightly on the gear side end using a cop perheaded hammer When refitting align center main bearing
84. rature of 20 C with 88 Ah bat teries V Motor terminal voltage in Volt P Power in kW C Torque in N m N Motor speed in r p m J A Absorbed current in Ampere Starting motor layout A Parking lights B Stop C Run D Start KD Workshop Manual cod ED0053029350_1 ed_ rev 00 67 8 sETTINGS KOHLER Settings 1 Idling speed setting in no load conditions standard After filling with oil and fuel start the engine and let it warm up for 10 minutes Adjust idling speed at 800 900 r p m by turning setscrew 1 then tighten lock nut n OT 2 Full speed setting in no load conditions standard EX H QE e JEN After setting idle speed turn screw 2 and set full speed in no load con ate 12 ditions at 3200 r p m then tighten lock nut NS T7 HO ES Y gt 4 Note When the engine reaches the pre set power full speed stabili U cad zes at 3000 r p m E D 0 gt t 9 lt gt 166 Injection pump delivery setting EN This setting should be performed torque dynamometer If not setting is only approximate E The following steps are required Loosen delivery limiting device C by 5 turns Bring engine to full speed in no load conditions i e 3200 r p m Tighten l
85. re installing them The operator must make sure that the contact surfaces are intact lubricate the coupling parts and protect those that are prone to oxidation Before any intervention the operator should lay out all equipment and tools in such a way as to enable him to carry out ope rations correctly and safely For safety and convenience you are advised to place the engine on a special rotating stand for engine overhauls Before proceeding with operations make sure that appropriate safety conditions are in place in order to safeguard the operator and any persons involved n order to fix assemblies and or components securely the operator must tighten the fastening parts in a criss cross or alter nating pattern Assemblies and or components with a specific tightening torque must initially be fastened at a level lower than the assigned value and then subsequently tightened to the final torque RECOMMENDATIONS FOR OVERHAULS AND TUNING A Important To locate specific topics the reader should refer to the index Before any intervention the operator should lay out all equipment and tools in such a way as to enable him to carry out ope rations correctly and safely The operator must comply with the specific measures described in order to avoid errors that might cause damage to the engine Before carrying out any operation clean the assemblies and or components thoroughly and eliminate any dep
86. refitting tighten to 8 Nm Remove the sensor from the support taking care not to damage the amp O ring KD Workshop Manual cod ED0053029350_1 ed_ rev 00 91 Disassembly Reassembly KOHLER 30 24 30 26 mm A 53 Components 1 Dial indicator 2 Support for dial indicator 3 Sensor control gauge measurement 30 24 30 26 mm 4 Control master measurement 30 24 30 26 mm for sensor gauge If replacing the phase sensor check the length of the sensor pin using the tool in figure A 52 Check by measuring the distance between magnetic end and the sensor support surface 30 24 30 26 mm serial numbers of special tools are on page 103 Resetting the dial indicator Assemble the dial indicator 1 onto support 2 Attach the support with the dial indicator to the gauge 3 Insert the master 4 into the gauge 3 and reset the dial indicator Sensor test Remove the master 4 from the gauge 3 insert the phase sensor and check that the sensor falls within tolerance measurements of 30 015 30 035 mim See fig A 53 A 54 92 KD Workshop Manual cod ED0053029350_1 ed_ rev 00 KOHLER Disassembly Reassembly 30 24 30 26 56
87. ring element 9 Centrifugal pre filter 4 Internal seal ring 10 Centrifugal pre filter clamp 5 Gasket 11 Oil level mark 6 Cover 12 Upper filtering element polyurethan sponge Note Thoroughly clean the lower tank and the metal filter element using diesel fuel then blow compressed air into them The upper filter element in polyurethane foam is cleaned by washing it in soapy water after washing dry completely using compressed air After cleaning refill the engine oil tank up to the indicated level See page 17 for the maintenance or replacement instructions Exhaust manifold AN Danger Attention Allow the exhaust manifold to cool before demounting it in order to prevent scorching and burns Make sure that the inside is properly clean and is free from cracks EN breakage E Always replace the seals between the manifold and the exhaust pi E T aL a m 22 When assembling tighten the nuts in sequence and gradually be lt fore the final torque to 20 Nm Op e ra PLA KD Workshop Manual cod ED0053029350_1 ed_ rev 00 23 4 Disassembly Reassembly KOHLER Intake manifold Before reassembling the manifold check the levelness of the flanges Always replace the seals between the manifold and the intake pipes O Tighten the nuts gradually to 25 Nm Note I
88. rranty Engine accessories such as fuel tanks clutches transmissions power drive assemblies and batteries unless supplied or installed by Kohler Co These are subject to the warranties if any of their manufacturers KOHLER CO AND OR THE SELLER SHALL NOT BE LIABLE FOR SPECIAL INDIRECT INCIDENTIAL OR CONSEQUENTIAL DAMAGES OF ANY KIND including but not limited to labor costs or transportation charges in connection with the repair or replacement of defective parts IMPLIED OR STATUTORY WARRANTIES INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FORA PARTICULAR PURPOSE ARE EXPRESSLY LIMITED TO THE DURATION OF THIS WRITTEN WARRANTY We make no other express warranty nor is any one authorized to make any on our behalf Some states do not allow limitations on how long an implied warranty lasts or the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state To obtain warranty service Purchaser must bring the engine to an authorized Kohler service facility To locate the nearest facility visit our website www kohlerengines com and use the locator function consult your Yellow Pages or telephone 1 800 544 2444 ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 GENERAL SERVICE MANUAL NOTES 1 Use only genuine Kohler repair parts 2 All data presented are
89. s copper gasket B for the cylinder head to adjust the clearance volume A between the cylinder head and the piston crown and which must be between 0 65 and 0 7 mm for size S injectors and 0 55 0 6 mm for size P injectors The table below shows how to choose the most suitable cylinder head copper seal according to the position of the piston in relation to the upper surface of the cylinder Seal thickness 045 050 055 060 065 070 075 0 80 085 090 0 95 1 00 0 25 0 15 0 05 0 05 0 15 0 25 0 35 0 20 0 10 0 0 10 0 20 0 30 Position Connecting rod Caution Warning When remounting the big end bearings remember to thoroughly clean the parts and generously lubricate them to prevent seizure when the engine is started up for the first time Remove the oil sump and internal oil filter Remove connecting rocis and check as follows A Important All connecting rod piston units should be fitted back into the corresponding cylinders mark them to avoid mistakes 2 See page 35 fig 71 for specifications as to the tightening of the connecting rod big end bearing KD Workshop Manual cod ED0053029350_1 ed_ rev 00 KOHLER Disassembly Reassembly 4 d Connecting rod small end bearing and pin Clearance Limit value meom Bu Vm 141 95 1
90. sed 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 working order to limit environmental and noise pollution When discontinuing use of the engine select all components according to their chemical characteristics and dispose of them separately KD Workshop Manual cod ED0053029350_1 ed_ rev 00 2 TECHNICAL INFORMATION KOHLER POSSIBLE CAUSES AND TROUBLE SHOOTING THE ENGINE MUST BE STOPPED IMMEDIATELY WHEN 1 The engine rpms suddenly increase and decrease 2 Asudden and unusual noise is heard 3 The colour of the exhaust fumes suddenly darkens 4 The oil pressure indicator light turns on while running TABLE OF LIKELY ANOMALIES AND THEIR SYMPTOMS The following table contains the possible causes of some failures which may occur during operation Always perform these simple checks before removing or replacing any part FUEL CIRCUIT POSSIBLE CAUSE Obstructed fuel line TROUBLE Engine starts but stops No acceleration Non uniform consumption Black smoke White smoke Too low oil pressure Overheats Inadequate performance Excessive oil High noise Fuel filter clogged Air or water leaks in fuel system The tank cap vent hole is clogged No fuel SYSTEM Discharged battery Cable connection uncertain or incorrect Faulty st
91. ssary and terminology PM omm 7 LAO a cece Sree tc 8 General safety during operating phases 9 engen ar 9 TECHNICAL INFORMATION Qr psa UN 10 Possible causes and trouble shooting tert TOT TT NT 10 Manufacturer and motor identification data NE o mo Rm 12 The identification plate shown in the figure can be found directly on the 12 PO AN OM iudei ieu stt dene ets ERIS nU EE 12 Heel e ENTE UU 13 dao _______________ _ _________ eee 14 OV c 16 MAINTENANCE PRESCRIBED LUBRICANT REFILLING eene nnne nennen nnne nnn nnn nnns 17 Roume enpdine dralnterelie Ena idum cetur sire cad d saext cus cetus CU E desde 17 Extraordinary maintenance 17 NC 17 CUDO 18 POS COSC WE TIC it TO T Oo Tm 19 gi USS AON e UNT 20 DISASSEMBLIREASSEMBLYseeciuEs us vRRU SERERE sae ERU cain ______ ______ 22 Recommendations for disassembling and assembling c cccecccccceeceecceesecccceusececeueceeecseececsusseeessseeecssaeeesseseesssaaes 22 Recommen
92. 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 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 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 During operation 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 spiled 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
93. t surface and the camshaft and specifications Example of where to insert the air gap adjustment shims KD Workshop Manual cod ED0053029350 1 rev 00 93 Disassembly Reassembly KOHLER Remove the connector from the position sensor on the injection pump control rod Unscrew the two screws to disassemble the fuel pump when refitting tighten the flathead screws the nuts and hexagonal head screws to 25 Nm When reassembling replace the sealing gasket 94 KD Workshop Manual cod ED0053029350_1 ed_ rev 00 KOHLER Disassembly Reassembly Remove the conical inspection plug Unscrew the two screws to disassemble the injection pump rod posi tion sensor Remove the three flanged nuts and the flathead screw Unscrew the last screw flathead after rotating the sensor anti clockwise KD Workshop Manual cod ED0053029350_1 ed_ rev 00 95 Disassembly Reassembly KOHLER Remove the cover supporting the sensor and the fuel pump Rotate the position sensor shaft to direct the fork on the side opposite the connector Insert the fork into the slot in the support Rotate the sensor body 1
94. tened as in fig 7 page 22 Tension check A 4 Kg load located halfway between the pulleys should cause the belt to bend 5 15 mm The correct belt tension can also be checked with special tools that are available on sale Air shroud and baffles Disassembly The air shroud 1 and the baffles 2 3 4 5 are shaped in such a way as to direct the flow of air onto the cylinders in order to cool them As the shroud is completely covered in noise absorbent material it also has the function of reducing the amount of noise generated by the blower fan and vibrations Blower assembly AN Danger Attention Before demounting the cooling fan disconnect the positive bat tery cable to prevent accidental short circuits which could con sequently energize the starter motor The plate and tension regulator are fixed to the outside of the blower fan stator A 14 A or 21 A alternator is housed inside the stator gt page 60 61 for the alternator technical data page 13 for the cooling air volume KD Workshop Manual cod ED0053029350_1 ed_ rev 00 25 Disassembly Reassembly KOHLER 1 77 2222202 2 10 de 3 11 m J2 4 4 miis 6 7 8 227277777774 Yiu 12 Lam c t 1 9 77 rez 2 9 CS 3 7 n y
95. to run the engine at temperatures below O C using special winter fuels These fuels reduce the formation of paraffin in diesel at low temperatures If paraffin forms in the diesel the fuel filter becomes blocked interrupting the flow of fuel Fuel can be Summer up to 0 C Winter up to 10 Alpine up to 20 C Arctic up to 30 C For all fuel types the cetane number cannot be lower than 51 Aviation kerosene and RME fuels biofuels The only Aviation fuels that may be used in this engine are JP5 JP4 JP8 and JET A if 5 oil is added For more information on Aviation fuels and Biofuels RME RSME please contact the KOHLER applications department Capacities standard fuel tank Litres 15 As for filters tanks and special crankcases please refer to KOHLER instructions 20 KD Workshop Manual cod ED0053029350 1 ed rev 00 KOHLER 3 KD Workshop Manual cod ED0053029350 1 ed rev 00 21 4 DISASSEMBLY REASSEMBLY KOHLER RECOMMENDATIONS FOR DISASSEMBLING AND ASSEMBLING Important To locate specific topics the reader should refer to the index Besides disassembly and reassembly operations this chapter also includes checking and setting specifications dimensions repair and operating instructions Always use original KOHLER spare parts for proper repair operations The operator must wash clean and dry components and assemblies befo
96. tor oil loading pipe Variator oil bypass pipe Variator oil draining pipe OTECO clic 66 clamp 74 KD Workshop Manual cod 0053029350_ 1 ed rev 00 KOHLER Disassembly Reassembly After loosening the screws remove the alternator belt guard Components 1 Pressure switch 2 Pressure switch union 3 Solenoid valve block oil filter pipe Components 1 Variator oil loading pipe 2 Variator oil bypass pipe 3 Variator oil draining pipe 4 Solenoid valve block oil filter pipe KD Workshop Manual cod ED0053029350_1 ed_ rev 00 75 Disassembly Reassembly KOHLER Components 1 Variator load solenoid valve 2 Variator unload solenoid valve AN Important Do not invert cables during reassembly remove connectors press the stop tabs and draw upwards gt Refer to page 78 to identify the pipes Loosen the union screw of pipes 17 and 19 On the opposite end of the block of pipe 19 is the variator lubrication jet attached to the pipe by a click clamp 76 KD Workshop Manual cod ED0053029350 1 ed rev 00 KOHLER Disassembly Reassembly Variator lubrication jet complete with banjo union Unscrew the union of variator oil disch
97. umber is preferable to one with a preceding letter or number An SF oil for instance is more performing than a SE oil but less performing than a SG one ACEA Regualtions ACEA Sequences PETROL HEAVY DUTY DIESEL ENGINES A1 Low viscosity for frictions reduction A2 Standard performances 2 Standard Heavy conditions Euro 1 Euro 2 engines LIGHT DUTY DIESEL ENGINES 4 Heavy conditions Euro 1 Euro 2 Euro engines E5 High performances in heavy conditions Euro 1 Euro 2 B1 Low viscosity for frictions reduction Euro 3 engines B2 Standard High performances indirect injection quality direct injection 18 KD Workshop Manual cod ED0053029350 1 ed rev 00 KOHLER Maintenance Prescribed lubricant Refilling 3 API MIL Sequences DIESEL PETROL L 2104 D E L 46152 B C D E PRESCRIBED LUBRICANT AGIP SUPERDIE API CF 4 SEL specifications ACEA B2 E2 MULTIGRADE MIL L 2104 D E 15W40 In the countries where AGIP products are not available use oil SJ CF for Diesel engines or oil corresponding to the military specification MIL L 2104 D E For a temperature of 10 C an oil with a 5W40 viscosity is recommended For a temperature of 15 C an oil with a OW30 visco sity is recommended OIL VOLUME AT MAX LEVEL OIL FILTER INCLUDED OIL VOLUME AT MAX LEVEL WI
98. y any possible fuel leakage then stop the engine External engine protection Clean carefully cylinder cooling system fins and the blowing fan Loosen the drive belt of the blowing fan Protect the external non painted surfaces with AGIP RUSTIA 100 F Seal with adhesive tape the intake and exhaust systems Coat the engine with a nylon or plastic sheet Keep in a dry place If possible not in direct contact with the ground and away from high voltage electric lines KD Workshop Manual cod ED0053029350 1 ed rev 00 KOHLER Storage 13 PROCEDURES TO BE CARRIED OUT BEFORE START THE ENGINE Remove all protections and coverings Remove the rust preventer from the external part of the engine by means of adequate products solvent or degreaser Tension the blower timing belt Disassemble the injectors and introduce by means of a bowl motor oil on the piston crown no more than 2 cc for every cylinder Remove valve covers and spray motor oil on the valves then turn the crankshaft manually for a few revolutions Start the engine and heat it for about 10 minutes Remove the drain plug and let the protective oil flow completely Reinsert the drain plug Carry out motor oil refilling to the upper level of the rod using the oil recommended by the manufacturer for a normal engine operation KD Works

KD 625/3 - 626/3 WORKSHOP MANUAL

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