Page 1 KDI 2504TCR / KDI 2504TCRE5 KDI 2504TCR / KDI 2504TCRE5 WORKSHOP MANUAL (REV. 17.4)
Page 2 INDICE ANALITICO Sommario TITOLO 1 ..........................2 1.1. Asdfsdfsdf ............................2 1.2. Asdfsdfsdfggg ..........................2...
Page 4 KOHLER reserves the right to make, at any time, changes on the engines for technical or commercial reasons.  These changes do not require KOHLER to intervene on the production marketed up to that time and nor to consider this manual as inappropriate. ...
Page 5 1.2 Manufacturer and engine identification The engine identification name plate is situated in the lower part of the crankcase; it is visible from the intake or exhaust side. Fig 1.1 - Fig 1.2 Fig 1.3...
Page 6 1.3 Homologation labels Label for EPA rules (compilation example) Tab 1.1 POS. DESCRIPTION Model year in compliance with the rules Power category (kW) Engine displacement (L) Particulate emission limit (g/kWh) Engine family ID Emission Control System = ECS Fuel with low sulphur content Injection timing Electronic injector opening pressure (bar) Production date (example: 2013.JAN)
Page 7 Label for China Standards (compilation example) Tab 1.2 DESCRIPTION Manufacturer Engine model Manufactoring date Certificate N° Power range (kW) Emission level Rated power Aftertreat system...
Page 8 Label for Korea Standards (compilation example) Tab 1.3 DESCRIPTION Tier 4 Final Engine model Manufactoring date and manufacturer code N° Korea emission certificate...
Page 9 1.4 Identification of the main internal components of the engine and operating reference (BASE CONFIGURATION) WIEW OF EXHAUST SIDE Fig 1.5 Tab 1.2 REF. DESCRIPTION View of timing system side (2 PTO) View of flywheel side (1 PTO) View of exhaust side The following chapters contain operating references in order to clearly understand the engine.
Page 10 Gear timing system Thermostatic valve Oil pump Oil suction hose Crankshaft Exhaust manifold Intake manifold Camshaft Gears adaptor for 3 PTO (optional) Flywheel (1 PTO) WIEW OF FLYWHEEL SIDE Fig 1.6...
Page 11 WIEW OF TIMING SYSTEM SIDE Fig 1.7...
Page 12 1.5 Identification of the external components of the engine (BASE CONFIGURATION) VIEW OF TIMING SYSTEM SIDE - EXHAUST Fig 1.8 VIEW OF FLYWHEEL SIDE...
Page 13 Fig 1.9 This paragraph illustrates all external components NOTE: The illustrated components may differ from that are present in the base configuration of the those illustrated; the illustration is only as an engine. example. For components present on engines that differ from those represented in these illustrations, refer to Chap.
Page 14 UPPER VIEW Fig 1.10...
Page 15 1.6 ATS (After Treatment System) 1.6.1 ATS with DOC filter Tab 1.4 POS. DESCRIZIONE NOTE: The ATS system can be installed in a different way than shown. Turbocharger Gas exhaust flange Flexible exhaust tube Fig 1.10 Tab 1.5 POS. DESCRIZIONE 1.6.2 ATS with DOC+DPF filter Turbocharger Turbine exhaust...
Page 16 Fig 1.11...
Page 17 2 TECHNICAL INFORMATION 2.1 Engine specifications MANUFACTURER SPECIFICATIONS AND OPERATION UNIT OF GENERAL INFORMATION KDI 1903 TCR KDI 2504 TCR MEASURE Operating cycle diesel - 4 stroke Cylinders N° Bore x stroke 88x102 Displacement 1861 2482 Compression ratio 17.4:1 Intake...
Page 18 Filtering surface 2300 Degree of filtration µm Maximum pressure at injection pump inlet LUBRICATION CIRCUIT UNIT OF GENERAL INFORMATION KDI 1903 TCR KDI 2504 TCR MEASURE Lubrication Recommended oil Par. 2.4 Circuit forced Lobe pump Oil sump capacity ( MAX )
Page 20 2.2 Engine dimensions (mm) NOTE : Dimensions vary according to engine configuration. Fig 2.1...
Page 21 N = Automotive rating curve MN = Torque curve C = Specific fuel consumption curve NOTE: Refer to KOHLER for power curves, torque curves and specific consumptions at speeds other than those given above.  N ( ISO TR 14396 - SAE J1995 - CE 97/68 ) AUTOMOTIVE RATING CURVE : Intermittent duty at...
Page 22 1 Bar and at a room temperature of +20°C  Maximum rating is guaranteed with a 5% tolerance. Warning  Non approval by KOHLER for any modification releases the company from liability for damage incurred on the engine.
Page 23 2.4 Oil Important  The engine may be damaged if operated with improper oil level.  Do not exceed the MAX level because a sudden increase in engine rpm could be caused by its combustion.  Use only the recommended oil to ensure adequate protection, efficiency and service life of the engine.
Page 24  Low S.A.P.S. technology (oil with low Sulfated Ash, Phosphorus, Sulfur content) keeps catalyst in good working conditions. The presence of sulfated ash, phosphorus and sulfur causes with time the catalyst clogging and its consequent inefficiency. For Mid S.A.P.S oil sequence the sulfated ash level is the same as API CJ-4 ≤ 1.0% but as per ...
Page 25 2.5 Fuel Important  Use of other types of fuel could damage the engine. Do not use dirty diesel fuel or mixtures of diesel fuel and water since this will cause serious engine faults.  Any failures resulting from the use of fuels other than recommended will not be warranted. Warning ...
Page 26 250hrs. However, the engine oil must be changed when the Total Base Number TBN is reduced to 6.0 mgKOH/g test method ASTM D4739. Do not use low SAPS engine oils. KDI Electronic Injection uncertified Engines (no EGR engines)  Those engines are designed for fuels in accordance with EN 590 and ASTM D975 for a cetane number of at least 45.
Page 27 2.5.5 Jet Fuels Only for KDI De- Contented Electronic Injection Uncertified Engines (no EGR engines). The following jet fuels can be used but only adopting an additional fuel filter with lubricity doser: FUEL JP-8 (kerosene, US military F-34/F-35 (kerosene, NATO designation) designation) JP-5 (kerosene, US military F-44 (kerosene, NATO designation...
Page 28 2.6 Coolant recommendation A mixture of 50% demineralized water and 50% low silicate ethylene glycol based coolant liquid must be used. Use a Long Life or Extended Life Heavy Duty OAT coolant free of: silicates, phosphates, borates, nitrites and amines. The following ethylene-glycol based engine coolant for all models within KDI engine family may be used: ...
Page 29 2.7 Battery recommendation Battery not supplied by Kohler Tab. 2.7 RECOMMENDED BATTERIES AMBIENT TEMPERATURE BATTERY TYPE ≥ - 15°C 100 Ah - 800 CCA/SAE < -15°C 120 Ah - 1000 CCA/SAE...
Page 30 2.8 Periodic maintenance The intervals of preventive maintenance in Tab. 2.8, Tab. 2.9, Tab. 2.10 and Tab. 2.11 refer to the engine operating under normal operating conditions with fuel and oil meeting the recommended specifications. CLEANING AND CHECKING PERIOD (HOURS) OPERATION DESCRIPTION 5000 Engine oil level...
Page 31 KDI TCR/D Tier 3 – Stage IIIA (1) (11) KDI TCR/D uncertified 2.11 FUEL FILTER AND PREFILTER CARTRIDGE REPLACEMENT PERIOD (HOURS) ENGINE VERSION KDI TCR Tier 4 final – Stage IIIB – Stage IV- Stage V KDI TCR/D Tier 3 – Stage IIIA KDI TCR/D uncertified (1) - In case of low use: 12 months.
Page 32 2.9 Fuel system 2.9.1 Injection circuit (pressure 2000 bar) (Fig 2.4) The materials of the fuel system components (pipes, tank, filters, etc.) and any surface treatments must be free from chemical elements that, transported in the fuel, compromise the operation of the injectors over time (hole clogging).
Page 33 The fuel supply system is under low pressure from fuel tank 1 to the high-pressure fuel injection pump 5 . NOTE : The representation of fuel tank is purely indicative. Component not necessarily supplied by KOHLER . Tab 2.13 POS. DESCRIPTION...
Page 34 2.9.2 Fuel return circuit The fuel return circuit is under low pressure. NOTE : The representation of fuel tank is purely indicative. Component not necessarily supplied by KOHLER . Tab 2.14 POS. DESCRIPTION Electronic injectors Common Rail Low-pressure fuel return tube from the...
Page 35 The inlet pressure to the high pressure pump must be between 300 mbar (suction pump without electric supply) and 200 mbar (with electric pump power) to the high pressure rail. The high pressure pump is operated via the pump control gear and sends high pressure fuel to the common rail.
Page 36  Fig 2.8 It is assembled on the engine; the new calibration code (QR code) must be inserted in Tab 2.16 the ECU by means of a diagnostics instrument (ST_01).  POS. COMPONENTS DESCRIPTION Do NOT fit new or different electronic injectors without the instruments required to enter the Connector for solenoid control injector calibration code.
Page 37 Fig 2.9 Tab 2.17 POS. DESCRIPTION Common Rail Pressure limit valve (return due to overpressure) Tube inlet union from high-pressure fuel injection pump Outlet fittings for supply pipes to electronic injectors Fuel pressure sensor 2.9.6 Fuel filter The fuel filter is situated on the crankcase of the engine or it may be assembled on the frame of the vehicle.
Page 38 Fig 2.11 3. The electric pump may be assembled on application at a maximum height of 500 mm from the position of the fuel tank. 4. Insert a shut-off valve to prevent dry operation due to the emptying of the intake manifold; 5.
Page 39 2.9.8 Guards for fuel injection circuit components High-pressure injection circuit components are particularly sensitive to impurities. To prevent impurities, even microscopic ones, from accessing the fuel input or output unions, you are required to close these accesses by means of specific caps as soon as the various tubes are disassembled and disconnected.
Page 40 2.10 Lubrication circuit 2.10.1 Lubrication circuit diagram The oil pump is driven by the crankshaft on the timing system side. On the parts of the systems shown in green on In the parts in green, the oil is in intake, in the parts in red, the oil is under pressure and in those in yellow the oil is returning towards the oil sump 2 (not under pressure).
Page 41 2.10.2 Oil pump The oil pump rotors are trochoidal (with lobes) and are activated from the crankshaft by means of the key. The pump body is situated inside the distribution guard. It is imperative to assemble the rotors with reference A visible by the operator.
Page 42 Fig 2.1 9 NOTE : unscrewing the cartridge holder cover makes the oil in support 7 flow towards the oil sump by means of the drain duct 4. Tab 2.24 POS. DESCRIPTION Oil arriving from the pump Oil cooling Oil filtering Oil drain duct (oil sump return) Oil returning into the circuit Outgoing fitting from filter...
Page 43 Degree of filtration 2 µm Max operating pressure 4.0 Bar Max flow rate 190 litres/hour...
Page 44 2.11 Cooling circuit 2.11.1 Cooling circuit diagram Tab 2.26 POS. DESCRIPTION Coolant pump Coolant intake Coolant, cylinder Coolant, cylinder head EGR gas coolant Coolant to radiator Coolant into radiator EGR valve coolant Coolant in the Oil Cooler Coolant input into the Oil Cooler Coolant output from the Oil Cooler Vent line from radiator (to 15) Fig 2.21...
Page 45 Fig 2.22 2.11.2 Water pump Tab 2.27 POS. DESCRIPTION Coolant pump control pulley Coolant intake fitting Coolant return hose from the Oil Cooler Fig 2.23 2.11.3 Radiator with Intercooler (optional) Tab 2.28 POS. DESCRIPTION Radiator with intercooler Coolant refill cap Radiator coolant vent tube or return Air hose (from Intercooler to manifold) Fig 2.24...
Page 46 Coolant intake manifold EGR Cooler coolant vent tube or return 2.11.4 Thermostatic valve Tab 2.29 POS. DESCRIPTION Cylinder head Coolant outlet cover Thermostatic valve Fig 2.25 Gaskets Air bleeding hole Starting opening temperature of +79° ± 2°C. 2.11.5 EGR gas circuit cooling (EGR Cooler) Device that cools exhaust gas Tab 2.30 POS.
Page 47 It contains precious metals (platinum, palladium, iridium). NOTE: The image is indicative only. The installation of the catalyst must be approved by KOHLER, for each application. In order to prevent breakage on the connection flange, the catalyst Fig 2.28 is normally connected via a hose.
Page 48 catalyst must be connected via a flexible exhaust tube. Tab 2.32a POS. DESCRIPTION Turbocharger Gas exhaust flange Flexible exhaust tube 2.12.2.2 Intake and exhaust circuit diagram with DOC Air in intake Gas in recycle Gas in exhaust Fig 2.29...
Page 49 Fig 2.30 Tab 2.32b POS. DESCRIPTION Important Air in intake from air filter Air in compression  Air in intercooler flow The diagrams in Fig. 2.29 and Fig. 2.30 do not have an air filter, which must always be present and connected by means of an Air cooling intake hose to the turbocharger.
Page 50 engines. Moreover, during regeneration stages, the exhaust gases could temporarily be white. NOTE: During regeneration, engine idling will increase. Fig 2.30a Tab 2.32c POS. DESCRIPTION turbocharger exhaust pipe from turbine EGTS (Black) EGTS (Yellow) Delta-P (Delta Pressure) 2.12.2.4 DPF regeneration strategy You can intervene on the machine control panel for the DPF regeneration operations "only if requested by means of specific warning lights or messages on the control panel".
Page 51 Necessary  Stationary Flashing vehicle  No load applied to the engine *2 Contact an authorized KOHLER workshop. REGENERATION via Strong Engine Level 5 de-rate Service Regeneration KOHLER software Required Flashing *1: The warning lights be different – consult the machine manual.
Page 52 If the regeneration inhibition function is misused, the particulate accumulation level will increase within a short time.  The engine oil filter and oil must be changed after a Service Regeneration is completed via KOHLER software  (Level 5 Particulate accumulation).
Page 53 Gas in oxidation Gas in recycle towards EGR valve Radiator/intercooler 2.12.3 Air filter Tab 2.33 POS. DESCRIPTION NOTE: Component not necessarily supplied by KOHLER . Air filter cartridge Air filter safety Important cartridge Filter cover  The air filter is a dry type of filter with a paper filtering element;...
Page 54 It is fitted on the frame of the vehicle, or in the cab (refer to the technical documentation of the vehicle). Important  The ECU must only be used with the configuration defined by KOHLER , for each individual engine.  To look up ECU errors, refer to the Help File manual...
Page 55 Fig 2.32 - Fig 2.33 Tab. 2.35 ECU AND ENGINE IDENTIFICATION PLATES POS. DESCRIPTION Engine model Validation code Engine specifications Bar Code of the engine chassis number Engine chassis number ECU identification code Connector A (ECU A) Connector B (ECU B) Barometric capsule Fastening points ...
Page 56 2.13.3 Engine electrical wiring...
Page 57 Fig 2.34 Tab. 2.36 RIF. DESCRIZIONE Vehicle interface connector (Fig. 2.34a) ECU Connector A (Fig. 2.34b) ECU Connector B (Fig. 2.34b) Fuel pressure regulating valve connector Fuel temperature sensor connector T-MAP sensor connector Fig 2.34a Common Rail pressure sensor connector Injectors connectors EGR valve connector Engine speed sensor connector...
Page 58 2.13.3.1 Wiring disconnection All sensor connectors and electronic control devices are sealed. The connectors must be disconnected by means of pressure on tabs A or unblock the retainers B , as illustrated from Fig. 2.34c to Fig. 2.34r. Fig 2.34c Fig 2.34d Fig 2.34e Fig 2.34f...
Page 59 Fig 2.34l Fig 2.34m Fig 2.34n Fig 2.34o Fig 2.34p Fig 2.34q Fig 2.34r...
Page 60 2.14 Sensors and switches 2.14.1 Revolution sensor on target wheel Speed sensor A is situated on the timing system carter. The sensor detects the signal from the target wheel B (60 - 2teeth) situated on the crankshaft pulley. It sends it to the ECU as an analogical signal.
Page 61 R ( Ω ) °C (°F) -30 (-22) 23475 - 25945 KDI TC 0 (32) 5370 - 5935 25 (77) 1900 - 2100 50 (122) 772 - 854 100 (212) 177 - 195 120 (248) 107 - 119 Fig 2.37 2.14.4 ACACT sensor (versions with DPF filter only) The ACACT sensor J is located on the intake manifold, before the T-Map sensor, and it measures the temperature of the air coming...
Page 62 2.14.5 EGTS sensor (yellow - black) The EGTS sensors K1 and K2 are placed on the ATS system, K1 with black wire before the DOC, K2 with yellow wire after the DOC. They are both needed for the DPF filter regeneration strategies. Tab.
Page 63 2.14.6 Delta-P sensor The Delta-P sensor J detects the clogging level of the DPF filter. Operating temperature: -30°C - +120°C. Fig 2.37c Important  Connect the J1 and J2 pipes to the Delta-P sensor exclusively as shown in Fig. 2.37d . Fig 2.37d 2.14.7 Common Rail pressure sensor Fuel pressure sensor G assembled on the Common Rail, detects...
Page 64 2.14.8 Fuel filter water detection sensor The water presence sensor H is situated in the fuel filter, which is there to indicate the presence of water in the fuel. Water, if present in the fuel, because of its greater specific weight separates and settles in the lower part of the filter where there is a specific sensor that, by means of the ECU activates an alarm signal on the dashboard.
Page 65 6.623 +140 0.067 0.076 2.14.12 Air cleaner clogging switch NOTE: Component not necessarily supplied by KOHLER. The switch is assembled on the air cleaner. When the filter is clogged, it sends a signal to the panel. Features :  Operating temperature: - 30 °C / +100°C ...
Page 66 2.14.14 EGR-T Sensor (KDI 1903 TC model only) The EGR-T R sensor is placed on the air intake manifold after the EGR gas inlet and measures the temperature of the air mixed with EGR gas coming from the turbocharger. Tab. 2.38b shows the electric resistance values based on the intake air temperature.
Page 67 2.15 Electrical components 2.15.1 Alternator (A) Externally controlled by the crankshaft by means of a belt.  Ampere 80 A  Volt 12V Fig 2.43 2.15.2 Alternator for Poly-V belt (optional) (B) Externally controlled by the crankshaft by means of a belt. ...
Page 68  Power 3.2 kW  Anticlockwise rotation (seen from timing system side) Fig 2.45b 2.15.4 EGR Valve (D) A device that provides for exhaust gas recovery that is controlled by ECU, which, according to acceleration parameters, RPM and power requested, varies the opening and closing of the valve. The device has an integrated ECU, which, on each start-up of the control panel, executes an operation self-check.
Page 69 Refer to Par 2.9.3 2.15.7 Electric fuel pump (optional) NOTE: Component not necessarily supplied by KOHLER. The electric pump is located before the fuel filter. One of the following pumps can be assembled A1 - A2 - A3 - A4.
Page 70 Tab. 2.39b Value Voltage 12 V Delivery 60.56 L/h @ 0.41 bar Fig 2.48a Tab. 2.39c Value Voltage 12 V Delivery 24 L/h @ 0.1 bar Fig 2.48b Tab. 2.39d Value Voltage 12 V Delivery 30 L/h @ 0.4 bar Fig 2.48c...
Page 71 Fig 2.48d 2.15.8 ETB (versions with DOC+DPF device - Stage V only) The ETB valve F is controlled by the ECU during the DPF filter regeneration strategies. Fig 2.48e...
Page 72 2.16 Timing system and tappets The timing system is equipped with hydraulic tappets that automatically recover the operation of the rocker rods assembly. No registration is therefore required. 2.16.1 Components identification Fig 2.49 Tab 2.40 POS. DESCRIPTION Crankshaft Camshaft Camshaft tappets Rocker arm control rod Rocker arms Valves...
Page 73 2.16.2 Timing system phasing angles Important  For information purposes, Tab. 2.41 reports the timing system diagram phasing angle values.  It should be noted that the said values may be verified by rotating the crankshaft (Pos. 1 of Fig. 2.49) , by means of handling the rocker arm control rod (Pos.
Page 74 Oil flow line 2.16.5 Hydraulic tappets Tab 2.44 POS. DESCRIPTION Hydraulic tappets Hight pressure chamber Hydraulic tappets oil refill pipe Retaining ring Piston Unidirectional valve Fig 2.55 Tappet body Spring 2.16.5.1 Hydraulic tappet operation The operating principle of the hydraulic tappet is based on the incompressibility of the liquids and on controlled leakage.
Page 75 the circuit. Because of this, this compressing the tappet slightly and producing valve play which is responsible for the ticking sound. On account of this, the tappet compresses slightly giving rise to a valve clearance, thus generating a slight ticking sound, which however disappears rapidly ( MAX 10 seconds) once normal operating conditions have been restored.
Page 76 2.17 Components handling 2.17.1 High-pressure fuel injection pump - Only handle by means of the points marked by Y . - It is forbidden to handle using the points marked by N . Fig 2.56 2.17.2 Electronic injector - Only handle by means of the points marked by Y . -It is forbidden to handle using the points marked by N .
Page 77: Only Handle By Means Of The Points Marked By Y
2.17.5 ACACT (versions with DOC+DPF device - Stage V only) - Only handle by means of the points marked by Y . - It is forbidden to handle using the points marked by N . NOTE: The sensor includes ceramic material. - Do not install sensors which suffered impacts or falls.
Page 78 Fig 2.59c...
Page 79: Fig 2.60
Before switching it off after it has been used, oil and fuel, unless instructed to do so make the engine run idle, or without a load, for by Kohler. approximately 1 minute.  Do not increase engine speed, or apply ...
Page 80: Fig 2.63
Before switching the engine off after intense activity, one must allow the turbocharger to cool down. One must therefore let the engine run at idle speed or without a load for at least 2 minutes, thus allowing the turbocharger to cool. 5.
Page 81 2.18.5 Replacement instructions Always understand the cause of the breakage of the turbocharger before replacing it. Correct the cause of the breakage before replacing it with a new turbocharger. If in doubt, contact KOHLER service department. Important  Failure to comply with these instructions can cause damage to the turbocharger and void the warranty.
Page 82 2.19 Balancer device (optional) The balancer device is composed of a special crankshaft that activates 2 additional shafts (balancers). Rotation of the balancers, which have counterweights that oppose the movement of alternating weights (crankshaft - connecting rods - pistons), reduces vibrations caused by them. The device is developed under the crankshaft, fixed on the crankcase, closed by the oil sump.
Page 83 3 SAFETY INFORMATION 3.1 Before start-up  Read the manual carefully and carry out the operations described below in compliance with the instructions specified.  Periodic inspection and maintenance operations must be carried out as indicated in this manual and under the user's responsibility.
Page 84 Any use of the machine other than that described cannot be considered as complying with its intended purpose as specified by KOHLER .  KOHLER declines all responsibility for any change to the engine not described in this manual made by unauthorized KOHLER personnel. ...
Page 85 Any improvement must be verified at KOHLER testing laboratories before application of the engine.  In the event KOHLER does not approve the type of modification, KOHLER shall not be held responsible for any consequential operation anomalies that the engine may undergo and any damage the engine may cause to persons and things.
Page 86  Do not mix fuel with elements such as oil or kerosene. Failure to comply with this prohibition will cause the non-operation of the catalyst and non-observance of the emissions declared by KOHLER  Pay attention to the temperature of the oil filter when the filter itself is replaced.
Page 87 Fig 3.1...
Page 88 3.4 Safety signal description  To ensure safe operation please read the following statements and understand their meaning.  Also refer to your equipment manufacturer's manual for other important safety information.  This manual contains safety precautions which are explained below. ...
Page 89 3.4.3 Safety guards Hereunder is a list of safety guards that must be worn prior to carrying out any type of operation and to avoid potential harm to the operator. Use suitable protective gloves before carrying out any type of operation. Use protective goggles before carrying out any type of operation.
Page 90 3.5 Information and safety signals ACCIDENTAL START HIGH PRESSURE FLUID RISK OF PUNCTURE High Pressure Fluids can puncture skin and cause severe injury or death. Accidental Starts can cause severe injury or death. Work on the injection system must be carried out by suitably trained staff wearing protection equipment.
Page 91 Avoid inhaling exhaust fumes and never run the engine in a closed building or confined area. CALIFORNIA WARNING - DECLARATION 65 Carbon monoxide is toxic, odorless, colorless, and can cause death if inhaled. Engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
Page 92 - Regulations and directives regarding environmental impact. In order to minimise the impact on the environment, KOHLER provides some indications to be followed by all those handling the engine, for any reason, during its expected lifetime. - All components and fluids must be disposed of in accordance with the laws of the country in which disposal is taking place.
Page 93 3.7 Location of safety signals on engine...
Page 94 4 STORAGE INFORMATION 4.1 Product preservation Important  If the engines are not to be used for 6 months, they must be protected by carrying out the operations described in Engine storage (up to 6 months) (Par. 4.2)  If the engine is still not in use after the first 6 months, it is necessary to carry out a further procedure to extend the protection period (more than 6 months) (Par.
Page 95 4.2 Engine storage (up to 6 months) Before storing the engine check that:  The environments are not humid or exposed to bad weather. Cover the engine with a proper protective sheet against dampness and atmospheric contaminants.  The place is not near electric panel. ...
Page 96 4.3 Engine storage (over 6 months) Follow the steps described in Par. 4.2. 1. Pour protective oil in the carter up to the MAX level. 2. Refuel with fuel additives for long storage.The following additives are recommended: DEFA Fluid Plus (Pakelo Lubricants), Diesel Treatment (Green Star), Top Diesel (Bardhal), STP®...
Page 97 4.4 Engine starting after storage 1. Remove the protective sheet. 2. Use a cloth soaked in degreasing product to remove the protective treatment from the external parts. 3. Inject lubricating oil (no more than 2 cm3) into the intake ducts. 4.
Page 98 5.1 Coolant Important  Before proceeding with operation, read Par. 3.3.2 NOTE: Component not necessarily supplied by KOHLER . The representation of the radiator is purely indicative. Fig 5.1 Warning  Presence of steam pressurized coolant danger of burns. 1. Undo the cap A carefully (circuit under pressure).
Page 99 Fig 5.3 1. Undo cap F to drain all liquid from the system contained in the engine crankcase ducts into an appropriate container and refer to ( Par. 3.6 Fig 5.4 NOTE : Click by side to play the procedure. https://www.youtube.com/embed/_s_qNZuOqQU?rel=0...
Page 100 5.2 Engine oil Important  Before proceeding with operation, read Par. 3.3.2  This operation should be carried out with vacuum pump. The oil must be drained whilst the engine is hot, which requires particular care to prevent burns. Do not allow oil to come into contact with the skin because of the health hazards involved.
Page 101 6 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 6.1 Electronic injector replacement Important  Before proceeding with operation, read Par. 3.3.2  In the event of the electronic injectors being disassembled (not necessarily replaced) their position with respect to individual cylinders must not be changed Fig 6.1 when re-assembled.
Page 102 6.1.1 Fuel return pipes disassembly (Common Rail/electronic injectors) 1. Disconnect the connector C . Fig 6.2 1. Remove clips E from the electronic injector 2. Disconnect the junction G from the electronic injector F . Warning  After removing the fittings, the clips E must Fig 6.3 automatically return to their initial position;...
Page 103 number from which they originate so as not to confuse them during re-assembly.  Seal all injection component unions as illustrated in Par. 2.9.8 6.1.3 Electronic injectors disassembly Undo and remove the screw P with the washer R e and then the bracket Q . Fig 6.5 Important ...
Page 104 injectors F (Fig. 6.7) . 2. Insert electronic injector F into manifold T , being extra careful not to damage gasket AB and direct it as indicated in Fig. 6.7 . 6.1.5 High pressure fuel pipes assembly Important  Always replace the pipes N after each assembly.
Page 105 1. Insert unions AF onto electronic injectors F and block them with clips E . 2. Mount the connectors C on the electronic injectors F . Warning Fig 6.11  Slightly move the wiring support to check that the electrical wire of connector C is not strained in correspondence with the outlet hole AF .
Page 106 6.2 High-pressure fuel injection pump replacement Danger  The fuel injection circuit undergoes high pressure, use safety protections as described in Par 3.4.3  Ensure that the Common Rail is not under pressure by slowly and carefully unscrewing nut A . Fig 6.12 Important ...
Page 107 1. Undo nut D from Common Rail E . Fig 6.14 1. Undo the nut B on the intake manifold C and remove the pipe F . Fig 6.15 6.2.2 Timing system carter oil filling flange disassembly 1. Remove starter motor ( Par.
Page 108 Important  Do NOT use the cylinder connection pipe W as a handle, to prevent damage or fuel leaks.  Before disassembling, carefully read Par. 2.17  Seal all injection component unions as Fig 6.18 Par. 2.9.8. illustrated in 1. Release the clamps N on the return pipe P and on the fuel inlet pipe Q .
Page 109 1. Check that the contact surfaces AA are free from impurities. 2. Insert the reference key K in the seat of the shaft Z . 3. Assemble the new gasket V on injection pump R . Insert injection pump R in its housing on crankcase AA making key K coincide with key seat AH of gear M .
Page 110 6.2.5 High-pressure line assembly (injection pump / Common Rail) 1. Remove the protection cap. 2. Position the pipe F . Important Fig 6.25  Manually tighten the nut A . 1. Manually tighten the nut D . 2. Fix clamp AC by means of capscrew B on intake manifold C (tightening torque 10 Nm ST_06 3.
Page 111 6.3 Unit EGR Cooler replacement 6.3.1 Disassembly Important  Par. 3.3.2 Before proceeding with operation, read  To handling components refer to Par. 2.17.  Always replace the gaskets (where are provided) Fig 6.28 after each disassembly. NOTE: Perform the operations described in Par.
Page 112 6.3.2 Assembly Insert the fitting U in the manifold M of the EGR valve unit. 2. Fit the EGR Cooler L with the screws H on the intake manifold S (tightening torque at 22 Nm - ST_05 ) 3. Insert the hose G on the fitting V . Fig 6.31 4.
Page 113 6.4 EGR valve replacement 6.4.1 Disassembly Important  Before proceeding with operation, read Par. 3.3.2 NOTE: Perform the operations described in Par. Fig 6.34 1. Disconnect the connector A from the valve 2. Undo the screws B and remove the EGR valve C with the relevant gasket.
Page 115 6.5 Coolant pump replacement 6.5.1 Disassembly NOTE: Perform the operations described in Par. Important  Fig 6.37 Before proceeding with operation, read Par. 3.3.2  If the engine is fitted with the Poly-V belt, perform the operations described in Par. 11.3 1.
Page 116 6.5.2 Assembly Important  Always replace the gaskets L , after each disassembly.  Always replace the belt E after each assembly. Fig 6.40  If the engine is fitted with the Poly-V belt, perform the operations described in Par. 11.3 ...
Page 118 6.6 Target wheel replacement 6.6.1 Disassembly Important  Before proceeding with operation, read Par. 3.3.2 1. Position the crankshaft with the 1st cylinder in TDC, reference A upwards. Fig 6.43 2. Remove the alternator belt following steps 1 and 2 ( Par.
Page 119 1. Undo the screws R and remove the target wheel S with the relevant sound-absorption disk T . Fig 6.47 6.6.2 Assembly 1. Check that the pin U is mounted properly on the pulley V . 2. Insert the disk T on the pulley V respecting the reference of the pin U .
Page 120 6.7 Oil pump replacement Important  Before proceeding with operations, read Par. 3.3.2  The oil pump is not repairable. 6.7.1 Refrigerant pump disassembly 1. Perform the operations described in Par 6.5.1 6.7.2 Crankshaft and target wheel pulley disassembly 1. Perform the operations described in Par 6.6.1 2.
Page 121 6.7.4 Oil pump disassembly Fig 6.51 1. Undo the screws D ( ST_06 ) and remove the group pump E from the timing system crankcase C . 2. Remove the rotors F and G from the oil pump crankcase E . Fig 6.52 6.7.5 Oil pump assembly NOTE: Carry out the checks described in...
Page 122 3. Thoroughly lubricate the seat of the rotors H on the oil pump crankcase E and the two rotors F and G . 4. Within housing H insert the 2 rotors (in sequence) G and F , observing the references BP as described in figure (or refer to Par.
Page 123 1. Fit the timing system crankcase C with the screws R observing the indicated clamping sequence (tightening torque at 25 Nm ). Fig 6.57 1. Assemble sensor S by means of capscrew T on carter C inserting gasket U (tightening torque at 10 Nm ST_06 Fig 6.58 6.7.7 Crankshaft and target wheel pulley assembly...
Page 124 1. Perform the operations described in Par 6.5.2...
Page 125 6.8 Oil pressure valve replacement 6.8.1 Disassembly Important  Before proceeding with operation, read Par. 3.3.2 1. Undo cap A . Fig 6.61 2. Remove spring B , check its condition and replace it if broken. 3. Remove the valve piston C using a magnet. 6.8.2 Assembly 1.
Page 126 6.9 Oil vapour separator replacement 6.9.1 Disassembly Important  Before proceeding with operation, read Par. 3.3.2 1. Release the clamp AA and remove the pipe D . 2. Release the clamps F . Fig 6.63 3. Remove the clamp P cutting it in the point indicated and remove the separator body C removing it from the hose AG and G .
Page 128 6.10 Oil cooler unit and oil filter replacement 6.10.1 Oil Cooler unit disassembly Important  Before proceeding with operation, read Par. 3.3.2  Perform the operations described in Par 5.1  Oil Cooler unit E is not repairable. Fig 6.67 1.
Page 129 6.10.2 Oil filter cartridge replacement 1. Remove gaskets L, M and N from element holder cover H . 2. Remove cartridge P from element holder cover H . Fig 6.70 1. Lubricate and insert gaskets L, M and N in the L1, M1 and N1 seats of element holder cover H .
Page 130 6.11 Fuel filter replacement 6.11.1 Disassembly Important  Par. 3.3.2 Before proceeding with operation, read Warning Fig 6.74  The fuel filter is not always mounted in the engine.  When disassembling the sensor E , use a suitable container to recover the fuel contained in the cartridge 1.
Page 131 6.11.2 Assembly Clamp the fuel filter support H with the screws C on the crankcase M (tightening torque at 25 Nm ). 2. Fit the pipes B on the support H . 3. Secure the pipes B with the clamps A . Fig 6.76 1.
Page 132 6.12 Replacement of SCV valve Important  Before starting any replacement operations, make sure the work area is free from dust (part X of valve B is extremely sensitive to micro-dust).  Pay the utmost attention to cleaning in order to prevent any type of contamination during replacement operations ...
Page 133 6.12.2 Assembly 1 - Insert studs E supplied with valve B in the fastening holes of pump A and insert gasket F in the seat of pump A . 2 - Assemble valve B on pump A using studs E as positioning guides.
Page 134 7 INFORMATION FOR DISASSEMBLY 7.1 Recommendations for disassembly Important  The mark ( ) after the title of a paragraph, indicates that the procedure is not required in order to disassemble the engine, however the procedures are featured in order to illustrate the disassembly of components.
Page 135 7.2 EGR circuit disassembly 7.2.1 EGR cooler unit 1. Undo the screws A ( ST_06 ) and B and remove the pipe C with the relative gaskets. Fig 7.1 1. Undo the screws D, E ( ST_06 ) and remove pipe F and the relevant gaskets.
Page 136 1. Undo capscrews S and remove flange T with the relative gasket. Fig 7.5...
Page 137 7.3 Electric components disassembly 7.3.1 Electric wiring Important  Par. 2.13 Refer to prior to proceeding with disassembly. 1. Disconnect the connectors A, B and C . Fig 7.6 2. Release the clamp D . 1. Disconnect the connectors E, F and G . 2.
Page 138 1. Disconnect the connectors R . 2. Undo the screws S and remove the wiring support T ( ST_06 Fig 7.10 7.3.2 Starter motor Important  The motor is not repairable. 1. Undo the screws U and remove the starter motor V . Fig 7.11 7.3.3 Belt and alternator Loosen the screws Z and W .
Page 139 7.3.4.1 Oil pressure switch ( Unscrew and remove the oil pressure switch AD . 7.3.4.2 Coolant temperature sensor ( Unscrew and remove the coolant temperature sensor AE Fig 7.14 7.3.4.3 Speed sensor ( Undo the screw AF and remove the sensor AG with the relative spacer ( ST_06 2.
Page 140 7.3.4.6 Fuel filter water detection sensor ( Warning  The fuel filter is not always mounted on the engine.  When disassembling the sensor A , use a suitable container to recover the fuel contained in the cartridge B . Fig 7.18 1.
Page 141 7.4 Turbocharger disassembly 1. Release the clamps A and B and remove the manifold C . Fig 7.19 1. Unscrew the fittings D and remove the pipe E with the relative gaskets G . 2. Undo the screws F . 3.
Page 142 7.5 Exhaust manifold disassembly 1. Undo the nuts A and remove the manifold B and the gaskets C . 2. Close the openings and manifolds to prevent foreign bodies from entering. Fig 7.22...
Page 143 7.6 Coolant recirculation components disassembly 7.6.1 Oil Cooler manifold 1. Release the clamps Z . 2. Undo the screw W and remove hoses J ( ST_05 Fig 7.23 1. Release the clamp K and remove hoses AA . Fig 7.24 7.6.2 Coolant pump Important ...
Page 144 1. Check that the air bleeding hole is not clogged or blocked Par. 2.11.4...
Page 145 7.7 Crankshaft and target wheel pulley disassembly 1. Position the crankshaft with the 1st cylinder at TDC,reference H . 2. Undo the screw C clockwise. 3. Remove the drive pulley unit and the target wheel D . Fig 7.27...
Page 146 7.8 Lubrication circuit disassembly 7.8.1 Oil pressure valve( 1. Undo the cap A . 2. Remove the spring B , check its condition and replace it if broken. 3. Remove the valve piston C using a magnet. Fig 7.28 7.8.2 Timing system carter oil filling flange ( 1.
Page 147 1. Remove the rotors N and P from oil pump carter M . Fig 7.32 7.8.5 Oil Cooler unit and lub. oil filter Screw the lid cartridge holder V . 2. Undo the screws Q, R and remove Oil Cooler group S . Warning Fig 7.33 ...
Page 148 1. Undo the screws AG . 2. Remove la flangia di supportoRemove flange support AH and the gasket seal AL . Fig 7.36...
Page 149 7.9 Intake manifold disassembly 1. Undo the screws A and remove the semi-manifold B ( ST_05 2. Remove the separation plate C and the gaskets H . Fig 7.37 1. Undo the screws D ( ST_06 ) and E . 2.
Page 150 7.10 Fuel system disassembly 7.10.1 Fuel return pipes Release the clip A . Warning Fig 7.39  After removing the union, the clip A must automatically return to its initial position; otherwise it must be replaced. 1. Undo the B distributor return fixing capscrew. 2.
Page 151 2. Fully undo the nuts S and T in sequence, and remove the high pressure pipes U and V . 7.10.4 Common Rail Undo the screws AB and remove the Common Rail AC . NOTE: Take care to protect te sensor AD from knocks, moisture and any high temperature source.
Page 152 7.10.6 Fuel filter ( Undo the fuel cartridge AW from support AP . 2. Undo the screws AN and remove the filter support AP . Fig 7.46 7.10.7 High-pressure fuel injection pump Important  Before disassembling, carefully read Par. 2.17 ...
Page 153 7.11 Timing system gear disassembly 1. Unscrew screws H and remove target wheel G . 2. Unscrew screws D and remove camshaft gear E . 3. Remove retainer ring A and the shoulder ring B . 4. Remove the intermediate gear C . Fig 7.49 1.
Page 154 7.12 Flange unit disassembly 7.12.1 Flywheel Important  ST_34 for blocking the flywheel ( Leave the special tool Par. 7.7 Fig 7.51 1. Only undo the screw C located uppermost. 2. Insert the tool ST_09 in the seat of the screw C tightening it all the way.
Page 155 7.13 Cylinder head unit disassembly 7.13.1 Rocker arms cover Undo the screws A . 2. Remove the rocker arms cover B . 3. Remove the gasket C . Fig 7.53 7.13.2 Rocker arm pin Undo the screws D . 2. Remove the rocker arm pin unit E . Fig 7.54 7.13.2.1 Rocker arm ( Remove the retainer ring F .
Page 156 1. Undo the bolts P . Important  To lift cylinder head Q , only use both eyebolts AE provided by KOHLER (refer to Fig. 7.66 ).  When removing the cylinder head Q and subsequent disassembly, control, and assembly operations, it is necessary to protect the contact surface W of cylinder Fig 7.59...
Page 157 Important  Before removing the valves, make some marks to record their original position, in order to avoid confusing them when reassembling (if they are not replaced). 1. Remove the valves V . Fig 7.62 7.13.4.2 Electronic injector sleeves ( Unscrew and remove the sleeves Z from the head Q .
Page 158 7.14 Oil sump unit disassembly 7.14.1 Oil sump Undo the screws A . 2. Remove the oil sump B by inserting a plate in the areas indicated by the arrow AA . Fig 7.66 7.14.2 Oil suction pipe Undo the screws C and remove the oil pipe D . Fig 7.67 7.14.3 Oil vapour pipes ( Unscrew and remove the pipes E .
Page 159 7.15 Engine block disassembly 7.15.1 Crankshaft gasket flange Undo the screws A . 2. Remove the flange B and the gasket C . Fig 7.69 7.15.2 Piston unit/connecting rod Important  Mark some numerical references (cylinder n°) on the connecting rods, connecting rod caps F1 , pistons and gudgeon pins to prevent unintentionally confusing the components not replaced during assembly.
Page 160 Fig. 7.70b Fig. 7.70c Fig 7.70a...
Page 161 1. Pull out the connecting rod - piston assembly from position 2 and 3 by manually applying pressure on the connecting rod big end L in the direction of arrow AK . 2. Couple the connecting rod big end caps L with the relevant piston and connecting rod unit M .
Page 162 Fig 7.73 4 CYLINDERS 4 Cylinders Undo capscrews E and F by following the order indicated in the figure. 2. Remove the lower semi-crankcase D and store it in a suitable container for washing.
Page 163 Fig 7.74 7.15.4 Crankshaft Remove: 1. Crankshaft G . 2. The shoulder semi-rings H . Fig 7.75...
Page 164 7.15.5 7.15.5 Piston ( Remove the retainer ring N . 2. Remove the pin P to separate the piston Q from the connecting rod R . Important Fig 7.76  If they are not replaced, keep the components together (connecting rod - piston - gudgeon pin) by using references in order to prevent them from getting mixed up during assembly.
Page 165 7.15.8 Camshaft tappets With a magnet, remove the tappets AA from the upper semi-crankcase AB . Fig 7.80 7.15.9 Crankshaft bushings 1. Remove the crankshaft bushings AC from the upper crankcase AB . Important Fig 7.81  The crankshaft half-bearings AC are made of special material.
Page 166 8 INFORMATION ABOUT OVERHAULING 8.1 Recommendations for overhauls and tuning  The information is laid out in sequence, according to operational requirements, and the intervention methods have been selected, tested and approved by the manufacturer's technicians.  This chapter describes procedures for checking, overhauling and tuning units and/or individual components.
Page 167  The grinding involved is of +0.20, +0.50 e + 1 mm .  Cylinder grinding operations must observe KOHLER SPECIFICATIONS - cod. ED0035612500.  Grinding must be strictly performed on all cylinders F . Tab. 8.1a details the dimensional values of new components only.
Page 168 Tab 8.1a Grinding values Ø CILINDER (± 0.007 mm) Ø PISTON (± 0.007 mm) CLEARANCE VALUE (mm) PISTON 88.010 87.950 88.210 88.150 +0.20 +0.50 88.510 88.450 0.046 - 0.074 +1.00 89.010 88.950 Fig 8.2 N.B.: if removing the Z2 hole closing cap, the new cap must comply with the MAX measurement of 1.5 mm from the surface G1.
Page 169 Fig 8.2a Tab 8.2a Housing and camshaft gudgeon 8.2.3 4-cylinder camshaft housing check dimensions. The camshaft housings only contain the timing system side bushing Q . DIMENSIONS CLEARANCE REF. Use an internal dial gauge to measure the diameters of (mm) VALUE (mm) housings X - W - K - Y - Z .
Page 170 8.2.3.1 Block Surface Flatness Use a dial gauge to check if the cylinder head surface A1 is level. The MAX value of allowable irregularity of surface A1 is:  0.10 mm on the entire area;  0.03 mm on an area of 100x100 mm. Fig 8.3b Grinding of surface A1 is not permitted 8.2.4 Camshaft control for 4 cylinder engine...
Page 171 values measured, calculate the clearance between the 43.000 - 43.025 0.060 - 0.105 housing and gudgeon, which is to observe the 42.920 - 42.940 42.000 - 42.025 values in Tab. 8.2a . 0.060 - 0.105 The MAX value of wear allowed is 0.120 mm 41.920 - 41.940 36.000 - 36.025 Important...
Page 172 Fig 8.6...
Page 173 8.3 Tappets and tappet housings 8.3.1 Tappets check Use a surface plate and a dial gauge as shown in Fig. 8.7 . Check the perpendicularity of the plate C , making the tappet D rotate in the direction of the arrow. The MAX value of wear allowed is 0.02 mm .
Page 174 8.4 Crankshaft 8.4.1 Dimensional check and overhauling Wash the crankshaft thoroughly using suitable detergent. Insert the pipe cleaner into all lubrication ducts B and blow compressed air to free them completely from any dirt residues. Check the state of wear and integrity of journals C and connecting rod D . Par.
Page 175  The MAX allowed value of wear for B1 and B2 is 63.981 - 0.120 mm. 64.000 0.035 - 0.102  To grind the crankshaft, a decrease in diameter of the 64.035 - halfbearings and connecting rod is provided for at 0.25 64.083 mm and 0.50 mm, to grind gudgeon pins A1 and B1 , measure the values of diameters A2 and B2 by...
Page 176 8.5 Connecting rod - piston assembly 8.5.1 Connecting rod dimensions check Important Fig 8.11  Before assembling the connecting rod and pistons ( Par. 9.3.7 e 9.3.8 ), check that the difference in weight between the complete connecting rod and piston units do not exceed 8 gr to prevent weight imbalances during rotation of the crankshaft and consequent damage.
Page 177 described in Tab.8.6 . If the measured values do not follow those described in Tab.8.6 , replace connecting rod T . 8.5.2 Checking the gudgeon pin-pin axes are parallel Lubricate gudgeon pin A and bearing R (Fig. 8.12) . Insert the gudgeon pin into bearing R . Use a dial gauge to check the axis parallelism of the connecting rod big end and small end.
Page 178 +1 for a piston with an increased diameter of 1.00 mm; If clearance between cylinder and piston is greater than 0,074 mm, the piston and seal rings must be replaced. Important  Tab. 8.1b details the dimensional values of new components only.
Page 179 8.6 Cylinder head 8.6.1 Flatness check Put the cylinder head on a surface plate and, with a dial gauge, check the flatness of surface C . The MAX value of allowable irregularity of surface C is 0.10mm. If the value is not observed, you are required to grind surface C . The MAX removal allowed is 0.20 mm.
Page 180 48.34 13.5 20.4 30.00 19.5 29.8 22.00 8.6.4 Valve guides check Measure the diameters D and E of the rods and guides valve (Tab. 8.10) . If the diameters don't correspond to the values indicated, replace the valves or guides. The MAX allowed value of wear for D and E is 0.10 mm.
Page 181 8.6.5 Valve guides replacement The intake and exhaust guides are both made out of grey iron with pearlitic phosphoric matrix and they have the same dimensions. The guides are press-fit assembled; assembly is possible by cooling the guides with the aid of liquid nitrogen. Before assembling a new guide, measure value L and M ,calculate the press-fit value, which must observe the values in Tab.
Page 182 Fig 8.25 Fig. 8.26 Fig 8.27...
Page 183 8.7 Oil pump check 8.7.1 Dimensional and visual check Perform the operations described in Par.7.8.1 and Par.7.8.4. Measure clearance value B between the rotor teeth, the value of allowable wear is MAX 0.28 mm. Clean all the components thoroughly, check that the work Fig 8.28 surfaces C of the rotors and pump body are not worn.
Page 184 Tab 8.13 REF. DIMENSIONS (mm) CLEARANCE VALUE (mm) 82.820 - 82.855 82.500 - 82.540 0.032 - 0.075 15.500 - 15.525 0.036 - 0.086 15.464 - 15.489 Fig 8.31 Fig 8.32 - Fig 8.32a 8.7.3 Oil pressure valve check Measure the free length F of spring D , which must be 47.91 mm .
Page 185 9 ASSEMBLY INFORMATION 9.1 Information on engine configuration  In this chapter, the engine is represented as "BASE CONFIGURATION" (refer to Par 1.4 Par. 1.5  For the assembly of components not described in this chapter refer to Chap. 11 ...
Page 186 9.2 Assembly recommendations  The information is laid out in sequence, the intervention methods have been selected, tested and approved by the manufacturer's technicians.  This chapter describes the installation procedures for the assemblies and/ or individual components which have already been checked, overhauled or possibly replaced with original spare parts. ...
Page 187 9.3 Engine block assembly 9.3.1 Crankshaft bushings Important  Execute the procedure in Par. 8.2.1 and 8.2.2 , before proceeding with assembly..  The crankshaft half-bearings are made of special material. Therefore, they must be replaced every time they are assembled to Fig 9.1 prevent seizures.
Page 188 9.3.3 Camshaft Check that the bushing Q is correctly fitted. 2. Lubricate the pins L , the cams M of the camshaft N , all the housing P and the bushing Q with oil. 3. Insert the camshaft N all the way into its Fig 9.4 housing P .
Page 189 9.3.6 Lower crankcase 1. Check that the crankshaft half-bearings are mounted correctly on the lower crankcase F ( AC detail). 2. Assemble the 2 shoulder half-rings AD onto the lower crankcase F applying two drops of grease to keep them in their seat. 3.
Page 190 Fig 9.9 1. Tightening sequence for 3 cylinders 4 Cylinders Tightening Screws Torx M12x1,25 (from the n° 1 to the n° 10 ): CYCLE 1 - with a torque of 40 Nm ; CYCLE 2 - with a torque of 70 Nm ; CYCLE 3 - with a torque of 120 Nm .
Page 191 Fig 9.10 9.3.7 Piston rings 1. Perform the operations described in Par. 8.5.3 2. Put the scraper ring AP onto the piston AQ . 3. Put the 2° seal ring AR on the piston AQ . 4. Put the 1° seal ring AS onto the piston AQ . Fig 9.11...
Page 192 1. Perform the operations described in Par. 8.5.4 2. Position the segment openings with a 120° angle between them ( Y ). NOTE: do not use the segment opening with the pin hole ( N ) Fig 9.12 1. Lubricate the piston skirt and piston rings with oil.
Page 193 1. Lubricate the piston skirt and rings AQ . 2. Check that the half-bearing AS is mounted correctly and lubricate it thoroughly. 3. Using the piston ring compression pliers, insert the piston inside the cylinder BQ by around Fig 9.17 10mm (height BM ).
Page 194 1. Push the piston AQ downwards by centering the crankpin BG with the connecting rod AZ . 2. Turn the crankcase on support to assemble the con rod capp on cylinder 1 and 4. 3. Check that the half-bearing AS is mounted correctly on the connecting rod cap AV .
Page 195 9.3.10 Crankshaft gasket flange Important  Check that the contact surface between the flange and the crankcase is free of grit and dirt. Fig 9.24  Always replace the gasket BS at each assembly. 1. Check that there are bushings BT on the crankcase E .
Page 196 9.4 Oil sump unit assembly 9.4.1 Oil vapour pipes Apply Loctite 648 on the pipe threads A . 2. Screw and tighten the pipes A (tightening torque of 15 Nm Fig 9.27 9.4.2 Oil suction pipe Important  It is mandatory to replace the gasket B after each assembly.
Page 198 9.5 Flange unit assembly 9.5.1 Bell housing Danger  Bell A is very heavy; pay special attention during assembly operations to avoid dropping and causing serious risks to the operator. Fig 9.31 1. Install the bell housing A in accordance with the reference pins B on the base C .
Page 199 9.6 Timing system gear assembly and injection pump 9.6.1 Timing system gear assembly 1. Check that the key A is correctly fitted on the camshaft 2. Position the gear C on the camshaft B adhering to the key reference A . 3.
Page 200 9.6.2 High-pressure injection pump 1. Check that the surface V is free from impurities ( Fig. 9.38 ). Important Fig 9.38  Always replace gasket U with every assembly.  The seal gasket U can only be fitted in one direction( Fig.
Page 201 9.7 Cylinder head unit assembly 9.7.1 Valve stem gasket Important  Par. 8.6.4 Carry out the checks described in before proceeding with the following operations.  Lubricate the oil seals A on the inside. Fig 9.41 1. Fit the oil seals A on the valve guides B using the tool ST_08 9.7.2 Electronic injector sleeves ( 1.
Page 202 9.7.4 Valves 1. Pre-lubricate and insert the valves X into the head F taking care to fit them in the original positions as per the reference marks made in Par. 7.13.4.1 2. Position the spring Y on the seat of the head F . 3.
Page 203 0.030 - 0.126 0.127 - 0.250 0.251 - 0.375 Fig 9.49 4. Based on the value detected at point 3 , select the relevant gasket T as shown in the Tab. 9.2 (Fig. 9.50 detail U ). 5. Check that the crankcase surface K and the gasket T are completely free of dirt and grit.
Page 204 Tighten capscrews V observing the cycles, tightening, and subsequent rotation as indicated in Tab. 9.3 .  For engine KDI 1903 TCR : 8 screws Torx M12x1,25 (Fig. 9.52) .  For engine KDI 2504 TCR : 10 screws Torx M12x1,25 (Fig.
Page 205 the camshaft tappets AB . 1. Mount the valve bridge AC on to the pairs of discharge and suction valves. Fig 9.55 9.7.7 Rocker arms Important  To correctly position the rocker arms, turn the rocker arm pin AH with the lower height AL towards the timing system side as in Fig.9.57 .
Page 206 not been removed, rotate the crankshaft positioning the reference BQ located on the target wheel in correspondence of the speed sensor, as shown in Fig. 9.60b .  If the engine is painted or protected with clear paint, replace the fastening screws BE . 1.
Page 207 Fig 9.62 Fig 9.63...
Page 208 9.8 Fuel system assembly Important  Do NOT mount new or different injectors without the required tool ( Chap. 13  Remove the protective caps from all the components of the fuel circuit just before assembly just before assembly. 9.8.1 Fuel filter Fig 9.64 1.
Page 209 9.8.3 Electronic injectors Important  Always replace and lubricate the gaskets AH and AL of the electronic injectors AM with fuel, every time they are assembled.  Pay attention when repositioning the electronic injectors, Fig 9.68 using the marks as described inl Par.
Page 210 Important Fig 9.71  Replace the pipes AQ (Fig. 9.69) if the screws AU do not rotate freely. 1. Tighten all the nuts AS (tightening torque at 30 Nm ). 2. Tighten the nuts AT (tightening torque at 25 Nm ). 3.
Page 211 1. Position the return pipes and fitting the distributor BE with the screw BC on the head BF ( Fig. 9.72 - tightening torque of 10 Nm ). 2. Mount the fittings BG ( Fig. 9.74 ) on the injectors AM and lock them with the clips BH .
Page 212 9.9 Intake manifold assembly 9.9.1 Semi-collettor external Important  Check that the contact surfaces between the semi- collector C and the head D are free from impurities. Fig 9.75 1. Insert the special tool ST_18 into indicated point. 2. Insert the screws A and the gasket B on the semi- collector C .
Page 213 9.10 Exhaust manifold assembly Important  Replace the self-locking nuts B and the metal gaskets D between the manifold and the cylinder head every time they are disassembled.  In the event of mounting the studs C , fix ( 25 Nm tightening torque) with Loctite 2701 on the thread.
Page 214 9.11 Assembly lubrication circuit 9.11.1 Assembly oil mist separator unit Important  Always replace the gasket B after each assembly.  Always carefully inspect the condition of the pipes, and replace them if there is any doubt regarding the integrity of their seal.
Page 215 Important  In the event of mounting the fitting P on the crankcase E (tightening torque of 15 Nm with Loctite 2701 on the thread). NOTE: To assemble the oil cartridge refer to operations 5 and 6 Par. 6.10.2 Important ...
Page 216 1. Distribute a bead of Loctite 5188 , of about 1mm Fig 9.87 thickness, on the surfaces AQ of the crankcase AN. 2. Make sure that the key AS (Fig. 9.88) is inserted properly on the crankshaft and that it is facing upwards. 3.
Page 217 1. Mount the gasket BH on cap BL . 2. Tighten the cap BL on the crankcase AN (tightening torque of 50 Nm ).
Page 218 9.12 Crankshaft and phonic wheel pulley unit assembly NOTE: To fit the target wheel refer to the operations in Par. 6.6.2 1. Check that the pin F is mounted properly on the crankshaft G . 2. Position the pulley unit H on the crankshaft G using the pin mark F (detail M ).
Page 219 9.13 Coolant circuit assembly 9.3.1 Thermostatic valve Important  Always replace the gasket A after each assembly. 1. Check the condition of the seal gasket A and fit it on the thermostatic valve B . 2. Position the thermostatic valve B in the seat on the head Fig 9.93 C (detail D ).
Page 220 4 . Secure the sleeve Q on Oil Cooler M and to the coolant pump T with the clamps K . 5. Fasten the clamp Y with the screw S (tightening torque of 22 Nm - ST_05 Fig 9.96...
Page 221 9.14 Turbocharger Assembly Important  Before proceeding, perform the operation described in Par. 2.18  Ensure that tube B is not clogged. 1. Fasten the connecting sleeve A to the pipe B with the clamp C onto the flange fitting D . Fig 9.97 Important ...
Page 222 1. Fasten the fuel outlet pipe Q with the fittings R on the turbocompressor H and on the crankcase S (tightening torque of 15 Nm ). Insert the gaskets P between: - Q and R ; - Q and S ; - Q and H .
Page 223 9.15 Electric component assembly 9.15.1 Sensors and switches 9.15.1.1 T-MAP Sensor 1. Fasten the sensor A with the screws B on the manifold C (tightening torque of 10 Nm - ST_06 Fig 9.101 9.15.1.2 Coolant temperature sensor 1. Secure the sensor D onto the head E (tightening torque of 20 Nm ).
Page 224 1. Measure the distance from the coupling surface AD to the tooth surface on the target wheel (X1) . 2. Measure the distance between the coupling surface AD and the sensor surface R (Y1) . 3. The difference between the 2 measurements determines the air gap value (Z1) .
Page 225 9.15.2 Alternator 1. Insert the screw BA onto the alternator BB . 2. Insert the washer BC onto the screw BA . 3. Manually fit the screw BA all of the way onto the crankcase BD without tightening. 4. Manually fit the screw BE all of the way onto the head BF without tightening.
Page 226 9.15.3 Starter Motor Important  Remove the ST_34 tool if it remains in position on the engine 1. Fit the starter BQ with the screws BR on to the flange bell Fig 9.113 BS (tightening torque of 45 Nm ). 9.15.4 Electric cabling 1.
Page 227 1. Fit the connector C6 on the sensor S6 . 2. Fit the connector C7 on the sensor S7 . 3. Insert the clamps H2 on the thermostat cover DB and H3 on the lateral oil intake flange DC . 4.
Page 228 9.16 EGR Circuit Assembly 9.16.1 EGR valve Important  Check that the contact surfaces between flange B and the head D are free from impurities.  Always replace the gasket A after each assembly. Fig 9.119 1. Mount the gasket A on the flange B . 2.
Page 229 1. Fasten the pipe T with the screws U on the EGR valve unit V inserting the gasket W (tightening torque of 10 Nm - ST_06 2. Fasten the pipe T with the screws AA on EGR Cooler M inserting the gasket AB (tightening torque of 25 Nm ). Fig 9.123 1.
Page 230 9.17 Tightening torques and the use of sealants Tab. 9.4 - *Alternatively to the capscrew replacements, with "Dri-loc" BASE CONFIGURATION SHORT BLOCK Thread Component Torque (Nm) Sealer (mm) Oil sprays fastening capscrew M6x1 3 Torque Lower crankcase fastening capscrew M12x1.25 cycles 1st Cycle 2nd Cycle...
Page 231 Intermediate gear gudgeon fastening screw M8x1.25 Camshaft gear control fastening capscrew M10x1 Gear fastening nut on high-pressure fuel injection pump M14x1.5 ENGINE CYLINDER HEAD ASSEMBLY Thread Component Torque (Nm) Sealer (mm) Air bleeding cap M6x1 Lifting brace fastening capscrew M8x1.25 Electronic injector manifold M12x1 6 Torque...
Page 232 Exhaust manifold fastening stud M8x1.25 Exhaust manifold fastening nut M8x1.25 Exhaust/manifold/muffler flange fastening nut M8x1.25 LUBRICATION CIRCUIT Thread Component Torque (Nm) Sealer (mm) Oil fumes support fastening capscrew (on crankcase) M6x1 Loctite Oil filter fastening union M20x1.5 2701* Oil cooler fastening capscrew M6x1 Cartridge-holder cover Oil pump carter fastening capscrew...
Page 233 Speed sensor fastening capscrew Sensor for water presence in fuel Alternator bracket fastening capscrew M8x1.25 Alternator fastening capscrew M8x1.25 Alternator fastening capscrew M10x1.5 Starter motor fastening capscrew M10x1.5 Supply cable fastening nut (starter motor) M8x1.25 Cabling support fastening capscrew EGR CIRCUIT Thread Component Torque (Nm)
Page 234 Thread Component Torque (Nm) Sealer (mm) Loctite Pump support fastening capscrew M8x1.25 2701* Pump fastening capscrew M8x1.25 Thread Component Torque (Nm) Sealer (mm) Loctite Grooved crankshaft support fastening capscrew M8x1.25 2701* M8x1.25 Cover fastening capscrew (3 PTO side) Sump support fastening capscrew Pump fastening capscrew M8x1.25 BALANCE DEVICE (4 CYLINDERS)
Page 235 Blower fastening capscrew M6x1 Radiator support fastening capscrew M16x1.5 Shroud radiator fastening capscrew M6x1 Radiator lower brace fastening capscrew M8x1.25 Radiator on anti-vibrating M8x1.25 Anti-vibrating radiator fastening nut (on lower brace) M8x1.25 Anti-vibrating and brace fastening capscrew (upper) M6x1 Upper brace fastening capscrew (on engine cylinder M8x1.25 head) Side bulkheads fastening capscrew...
Page 236 10 FLUIDS FILLING INFORMATION 10.1 Engine oil Important  Before proceeding with operation, read Par. 3.3.2 1. Loosen the oil filler cap A or the oil filler cap C if the cap A is not accessible. 2. Add the type and amount of oil recommended ( Tab.
Page 238 10.2 Coolant Important  Before proceeding with operation, read Par. 3.3.2 1. Tighten the cap G , replacing the copper gasket (Tightening torque of 50 Nm ). Fig 10.3 NOTE: A sealing plug or connecting pipe to the expansion tank may be present on the junction B , both should be secured with a strap.
Page 239 tighten the screw F Fig 10.5 (Tightening torque of 8 Nm - Fig. 10.7 ). 5. Start the engine without the radiator cap A or the expansion tank (C) cap B. 6. Keep the engine at idle speed or without a load until the coolant level goes down and becomes steady (the waiting times varies according to the...
Page 240 Fig. 10.7 NOTE : Click by side to play the https://www.youtube.com/embed/S79xPhTZMps?showinfo=0&rel=0 procedure.
Page 241 11 INFORMATION ABOUT OPTIONAL COMPONENTS 11.1 Oil dipstick in cylinder head Important  Before proceeding with operation, read Par. 3.3.2 11.1.1 Check 1. Pull out the dipstick B in the direction of the arrow A . 2. Check that the mark left by the oil on the dipstick is between the MIN and MAX notches.
Page 242 1. Secure the oil dipstick hose E using the screw D on the manifold L (tightening torque at 10 Nm ). Fig 11.4 NOTE: Check the integrity of the gaskets J . 1. Insert the dipstick B inside the hose E . Fig 11.5...
Page 243 11.2 Heater (replacement) Important  Before proceeding with operation, read Par. 3.3.2 11.2.1 Disassembly 1. Undo the screws A and the relevant washers and remove the earth cable B . 2. Remove the flange C and the manifold D . 3.
Page 244 11.3 Poly-V alternator belt (replacement and adjustment) Important  Before proceeding with operation, read Par. 3.3.2 1. Loosen the nut B and manually tighten the screw C until it just touches the pulley pin D (Fig. 11.9) . Fig 11.8 1.
Page 245 Fig 11.9 1. Remove the V-Belt H and install the new one. NOTE: Ensure that the internal profile of belt H is properly inserted into the grooves of the pulley A (as illustrated in D1 e D2 Fig 11.10 1. Tighten capscrew C , to shift gudgeon D fully to the bottom of the grooved guide.
Page 246 11.4 Tightening pulley and alternator for Poly-V belt Important  Before proceeding with operation, read Par. 3.3.2 11.4.1 Disassembly 1. Perform the operations from point 1 to 3 of Par. 11.3 2. Remove the belt H ( Fig. 11.10 3. Undo and remove the screw A . 4.
Page 247 11.4.2 Assembly 1. Secure the bracket N using the screws M on the cylinder head P (tightening torque at 25 Nm ). Fig 11.16 1. Insert the screw H into the fixing hole on the alternator L 2. Insert the spacer R on the screw H (between the alternator and crankcase).
Page 248 11.5 Idler gear (for 3rd / 4th PTO) Important  Before proceeding with operation, read Par. 3.3.2 11.5.1 Disassembly 1. Undo the screw A and remove the gear unit B . Fig 11.20 1. Remove the retainer ring C from the seat of the pin D 2.
Page 249 1. Position the gear unit B on the hole J using the bushing G to centre. 2. Secure the gear unit B using the screw A inserting the washer H (tightening torque at 85 Nm ).
Page 250 11.6 3rd PTO (replacement) Fig 11.12 Important  Par. 3.3.2 Before proceeding with operation, read 11.4.1 Disassembly 1. Undo the screws A and remove the pump B . Fig 11.13...
Page 251 1. Remove the centring ring C and the relative gaskets. 2. Undo the screws N . Fig 11.14 1. Remove the flange F with the components D, E, G and H in the direction of the arrow P . 2. Remove the gasket J . Fig 11.15 1.
Page 252 2. Insert the shoulder ring E on the flange F and clamp the gear H using the retainer ring D . 3. Position flange F on the crankcase K inserting the gasket J , and inser gear H in crankcase K . Fig 11.18 1.
Page 253 11.7 4th PTO (replacement) Fig 11.21 Important  Before proceeding with operation, read Par. 3.3.2 11.7.1 Disassembly 1. Undo the screws A and remove the pump B . Fig 11.22...
Page 254 1. Undo the screws C and remove the flange D . Fig 11.23 Undo the screws E and remove the cover F . Fig 11.24 Undo the screws G and remove the flange K with the components H, J, M, N and P . Fig 11.25 1.
Page 255 11..2 Assembly Important  Always replace the gasket J after each assembly.  Lubricate the gear H with oil. 1. Insert the gear N in the flange K in the direction of the Fig 11.27 arrow W inserting the shoulder ring M . 2.
Page 256 Fig 11.30 Important  Always replace the gasket U after each assembly. 1. Position the gasket U on the flange D . 2. Secure the pump B using the screws A (tightening torque at 25 Nm ) on the flange D . Fig 11.31...
Page 257 11.8 3rd + 4th PTO (configurations) Fig. 11.45 11.8.1 Information Hydraulic pumps on the 3rd and 4th PTO can be installed at the same time. In some configurations, there is also the centering ring C on the 4th PTO. Important ...
Page 258 11.9 Balancer device (replacement) Important  Before proceeding with operation, read Par. 3.3.2 11.9.1 Disassembly 1. Perform the operations described in Par. 5.2 2. Undo the screws A and remove the oil sump B . Fig 11.47 1. Undo the screws C and remove the hose D . Fig 11.48 1.
Page 259 1. Remove the shafts J and K in the direction of the arrow L from box F . Fig 11.51 11.9.2 Assembly 1. Lubricate the bushings V with Molikote grease. 2. Insert the shafts J and K inside the box F in the direction of the arrow M .
Page 260 1. Secure the plate H using the screws G on the box F (tightening torque at 8 Nm ). Fig 11.54 1. Manually tighten the retainer screw ST_15 on the box F by slightly rotating the shaft K , centring the hole on it using ST_15 , to lock the device.
Page 261 Fig 11.57 Important  Check that the retainer capscrew ST_15 (Fig. 11.55) is not present in point X on housing F .  Always replace the gasket W after each assembly.  Lubricate the gasket W with oil before assembling it. 1.
Page 262 11.10 Air filter (cartridge replacement) 1. Release the two hooks A and remove the cover B from the body C . 2. Remove the cartridges D and E . Important  Before proceeding with operation, read Par. 3.3.2  Fig 11.59 The safety cartridge E (if present) must always be replaced if it is dirty or damaged.
Page 263 11.11 Remote oil filter (disassembly and assembly) 11.11.1 Option A 11.11.1.1 Disassembly 1. Perform the operations described in Par. 5.2 Important Fig 11.60  Before proceeding with operation, read Par. 3.3.2  For the replace the cartridge, please refer to operation n°...
Page 264 11.11.1.2 Assembly Important  Always replace the gaskets P, Q, R and W at each assembly.  Lubricate the gaskets P, Q and R with oil before Fig 11.63 assembling them. 1. Insert the gasket P on the seat of the fitting K . 2.
Page 265  Before proceeding with operation, read Par. 3.3.2  The oil filter cartridge may not be supplied by KOHLER (in such cases, refer to the machine’s documentation)  To replace only the cartridge, refer to operations 5 ( Par. 11.11.1 ) and 7 ( Par. 11.11.2 ).
Page 266 Fig 11.68 Fig 11.69 Fig 11.70...
Page 267 Fig 11.71 1. Release the clamps D and remove the hoses E and F from Oil Cooler G . 2. Unscrew and remove the unions H together with the relevant copper gasket from the head J . 3. Unscrew and remove: - the union K with its gasket;...
Page 268 11.11.2.2 Assembly Importante  Replace the gaskets H1 , J1 , J2 , K1 , L1 , T1 and Z1 at every assembly.  Lubricate the gaskets J1 , J2 , K1 , T1 and Z1 with oil before performing the assembly. 1.
Page 269 Fig 11.75 1. Fix the unions H to the head J placing the gasket H1 in- between (tightening torque of 40 Nm ). Fig 11.76...
Page 270 1. Fix the unions L to the support M placing the gaskets L1 in-between (tightening torque of 40 Nm ). 2. Lubricate the gasket N1 and fix the cartridge N to the support M (tightening torque of 20 Nm ). Fig 11.77 Fig 11.78 1.
Page 272 11.12 Oil sump with supporting structure 11.12.1 Flywheel (J) disassembly 1. Execute the operations described in Par. 7.12.1 11.12.2 Plate/flange housing (L) disassembly 1. Loosen supplementary capscrews A and B . 2. Execute the operations described in Par. 7.12.2 3. Remove housing or plate L . Fig.
Page 273 11.12.4 Oil sump assembly 1. Make sure contact surfaces G of oil sump F and crankcase H have no impurities. 2. Apply a sealing bead of approximately 2.5 mm ( Loctite 5660 ) onto surface G of crankcase H . 3.
Page 274 1. Apply capscrews E into the fastening holes and use torque at 10 Nm . 2. Loosen capscrews E , leaving approximately 1 mm leeway ( position A ) between the neck surface of capscrews E and oil sump F . 3.
Page 275 1. Fasten oil sump F by tightening capscrews E and strictly following the order shown in Fig. 11.73 (tightening torque at 20 Nm ). 2. Loosen capscrews A and remove housing or plate L ( Fig. 11.72 ). 3. Fasten oil sump F by tightening capscrews E and strictly following the order shown in Fig.
Page 276 1. Insert gaskets N into seats P of bypass tube 2. Fasten bypass tube D onto oil sump F using capscrews C (tightening torque at 10 Nm ). Fig. 11.87 11.12.5 Flange plate / housing assembly 1. Execute the operations described in point 6 of Par.
Page 277 11.13 ETB (replacement) 1. Unscrew screws A and remove the ETB valve B with its gasket C . Important  Always replace the gasket C at each assembly. Fig. 11.89 1. Fix the ETB valve B and its gasket C by means of screws A (tightening torque 10 Nm ) Fig.
Page 278 11.14 ACACT (replacement) 1. Unscrew sensor A and its gasket B . Important  Before assembling the new sensor, see Par. 2.17.5  Always replace the gasket B at each assembly. Fig. 11.91 1. Fix sensor A and gasket B on their support C (tightening torque 20 Nm ).
Page 279 11.15 EGTS (Black | Yellow - replacement) 1. Unscrew sensors A . Important  Before assembling the new sensor, see Par. 2.17.6 Fig. 11.93 1. Fix sensors A on the ATS B (tightening torque 30 Nm ). Fig. 11.94...
Page 280 11.16 DPF & DOC filter (replacement) Danger  Highly carcinogenic material!  The dust contained inside the DPF is particularly fine and therefore classified as highly dangerous to living beings.  Before proceeding to any operation, wear: dust mask gloves goggles ...
Page 281 1. Loosen clamps E and remove manifold N . Fig. 11.96 1. Loosen clamp G and remove the DPF filter H . NOTE: do not remove clamp G . Inspect the DPF filter to detect any visible signs of oil contamination.
Page 282 1. Loosen the clamps Q and S and remove the manifold with DOC M from the flexible hose R . Fig. 11.98 1. Fit the new manifold with the DOC filter M on the support T , inserting the flexible hose R inside the inlet of the manifold M .
Page 283 Fig. 11.99...
Page 284 Important  Do not apply any tension during the assembly of components. 1. Before fastening the manifold M , it must be oriented in the same position as the previously installed DOC filter. 2. Tighten the clamp Q (tightening torque of 10 Nm ). 3.
Page 285 Important  Before fastening the DPF filter H , it must be oriented in the same position as the previous filter.  Do not apply any tension during the assembly of components. 1. Fasten the DPF filter H with clamp E (tightening torque 12 Nm ).
Page 286 1. Position support K in contact with support K1 and fasten clamp G (tightening torque 12 Nm ). Fig. 11.104 1. Screw unions J on the DPF filter H and position them about 20° away from the centre line (as in Fig. 11.90 ). Fig.
Page 287 3. Provide the machine owner with the warranty certificate of the new DPF filter KIT installed. 4. Perform the " DPF replacement " procedure to reset the ASH & SOOT through the relevant KOHLER diagnostic tool interfaced with the ECU. Fig. 11.107...
Page 288 11.17 Oil dipstick on timing gears side Important  Before proceeding with operation, read Par. 3.3.2 11.17.1 Check 1. Remove dipstick A . 2. Verificare che il segno lasciato dall'olio sull'asta sia tra le tacche MIN e MAX . NOTE: Check the condition of seal A1 every time dipstick A is inserted into dipstick tube D .
Page 289 Fig 11.108 11.17.2 Replacement 11.17.2.1 Disassembly 1. Unscrew screws B and C . 2. Remove the oil dipstick tube D from crankcase H along with support E. Unscrew screw F and remove the dipstick tube D from support E along with cable tie G .
Page 290 Fig 11.109 11.1.2.2 Assembly Important  Always replace O-ring D1 during every assembly. 1. Insert cable tie G on dipstick tube D. 2. Fit the clamp G onto support E using screw F . NOTE: Do not tighten screw F. 1.
Page 292 Fig 11.110 1. Secure support E using screws C onto crankcase H (tightening torque at 25 Nm ). 2. Secure the dipstick tube D to the crankcase H using screw B (tightening torque at 25 Nm ).
Page 293 Fig 11.111...
Page 294 H forward by 1 mm (value M to check on dial gauge D). Pressure read on gauge B must be: 1350 mbar for engine model KDI 2504 TCR and 1250 mbar for engine model KDI 1903 TCR. 5. If pressure is less or more than the indicated value, proceed as follows: - Undo lock nut G from rod - Remove the retainer cotter pin (point E ) and disconnect rod H from the Waste Gate control lever.
Page 295 Fig 12.1...
Page 296 12.2 Air filter check Important  Before proceeding with operation, read Par. 3.3.2  When the cartridge G is dirty, do not clean it but replace cartridges B and G . 1. All manifolds connected to the turbo must be fully clean and not damaged.
Page 297 12.3 Oil steam separator check Important  Before proceeding with operation, read Par. 3.3.2 1. Loosen clamp B and remove hose C from hose D . 2. Start the engine at idle speed or without a load; check if air comes out of hose C . NOTE: If what is described in Point 2 does not occur, proceed with cleaning or replacing oil separator A and accurately clean support flange F , all connecting...
Page 298 12.4 Rubber hoses and manifolds check Important  Before proceeding with operation, read Par. 3.3.2 The check is carried out by applying slight deflection or bending along the tube/hose and next to the hose clamps. Fig 12.4 Components must be replaced if they have clear signs of cracks, tears, cuts, leaks, or do not retain a certain degree of elasticity.
Page 299 12.5 Oil leak check Important  Before proceeding with operation, read Par. 3.3.2 Check that there are no leakages next to area A . 1. Start the engine at idle speed or without a load and check whether there are any leakages next to area A. 2.
Page 300 12.6 Oil pressure check Important  Before proceeding with operation, read Par. 3.3.2 1. Insert a thermocouple instead of the oil dipstick A . 2. Unscrew and remove the oil pressure switch and screw on a 10 bar pressure gauge in its seat (Fig. 12.10) . 3.
Page 301 Fig. 12.10...
Page 302 Warning  KOHLER declines all responsibility for any damage to the engine, persons, or things caused by the use of different types of tools to those indicated in Tab 13.1 - 13.2 - 13.3 , where referred to them in the manual.
Page 303 ED0014603660- ST_08 Tool for gasket valve stem ED0014603610- ST_09 Tool for flywheel assembling / disassembling ED0014603670- ST_10 Crankshaft gasket assembling tool Rocker arm cover gasket assembling tool ED0014603620- ST_11 (electronic injector seat) Rocker arm cover gasket assembling tool ED0014603630- ST_12 (rocker arm capscrew gudgeon seat - electronic injector fastening capscrew brace seat) Buffer insertion of a crankshaft gasket onto a...
Page 304 SPECIAL TOOLS TO TEST THE ENGINE ON THE TEST BENCH - DIAGNOSTIC PROCEDURE Complete instrument Kit for diagnostics ED0014603690- ST_01 "POLAR XL" Complete instrument Kit for diagnostics ED0014604210- ST_49 "DIAGBOX" ED0014604110- ST_50 Complete instrument Kit for engines bench test...
Page 305 14 INFORMATION ABOUT FAILURES 14.1 Possible causes and trouble shooting IMMEDIATELY STOP THE ENGINE WHEN: 1. Engine rpm increases and decreases suddenly without being able to control them; 2. A sudden and unusual noise is heard; 3. The colour of the exhaust fumes suddenly darkens or turns white; 4.
Page 308 Distance to respect between a fixed component and one in movement. Alternator: A component that transforms mechanical energy into AC electrical energy. Authorised workshop: KOHLER authorised service centre. Authorised service KOHLER authorised workshop. station: After Treatment System - Post-treatment system, referred to the exhaust gases ATS: produced by the engine.
Page 309 Diesel Oxidation Catalyst - Catalyst for diesel engines that reduces harmful exhaust gas emissions produced by the engine. Diesel Particulate Filter - A filter that captures particles of carbonaceous origin emitted by diesel DPF : engines. "European Community". ECS: Emission Control System Electronic Control Unit;...
Page 310 Air-cooling element under pressure from the turbo situated between the turbine and Intercooler: intake manifold. KDI: "Kohler Direct Injection" A group of maintenance actions that have the sole objective to control and replace Maintenance - elements on their expiry, without modifying or improving the functions carried out by the periodic: system, neither increasing the value nor improving performance.
Page 311 Oil Cooler: Small radiator used to cool the oil. Par.: Paragraph. Paraffin.: Fatty and solid substance that may form inside the diesel. An instrument having a metal cylindrical body with bristles that jut outwards. It is similar to a Pipe cleaner: brush and is used to clean areas that are not easily accessible manually (e.g.
Page 312 Tab.: Table. A wheel that is a part of a device to control angular operation by means of teeth placed Target Wheel: on the circumference, which enable to determine and transmit the speed and position of the crankshaft to a sensor. TCR: Turbo Common Rail.
Page 313 hour Time Specific consumption g/kW grammes per kilowatt per hour 1 g/kWh kg/h kilogramme per hour Max. flow rate 1 kg/h Lt./min. litres per minute 1 Lt./min. Flow rate Lt./h litres per hour 1 Lt./h parts per million Percentage 1 ppm newton Force Ampere...

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Kohler KDI 1903 TCR Workshop Manual

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Summary of Contents for Kohler KDI 1903 TCR

Page 77: Only Handle By Means Of The Points Marked By Y

Page 79: Fig 2.60

Page 80: Fig 2.63

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