Kohler KDI 1903M Workshop Manual
  1. Manuals
  2. Brands
  3. Kohler Manuals
  4. Portable Generator
  5. KDI 1903M
  6. Workshop manual
Kohler KDI 1903M Workshop Manual

Kohler KDI 1903M Workshop Manual

Hide thumbs Also See for KDI 1903M:
Table of Contents

Advertisement

Quick Links

Download this manual
KDI 1903M
KDI 2504M
WORKSHOP MANUAL
TP-6939 3/23

Advertisement

Table of Contents
loading

Related Manuals for Kohler KDI 1903M

Summary of Contents for Kohler KDI 1903M

  • Page 1 KDI 1903M KDI 2504M WORKSHOP MANUAL TP-6939 3/23...
  • Page 2 Released by Document code Revision Issue date Edited by Endorsed Review date Technical ED0053029610 04/2013 03/2023 V. MANINI Documentation SILVESTRONE Translated from the original manual in Italian language. Data reported in this issue can be modified at any time by KOHLER.

  • Page 3: Table Of Contents

    INDEX General information ....................... 8 Useful information ........................... 8 Manufacturer and engine identification ..................9 Identification of the main internal components of the engine and operating reference (BASE CONFIGURATION) ..........................10 Identification of the external components of the engine (BASE CONFIGURATION) ..... 12 Technical information ......................
  • Page 4 INDEX Information regarding discharge of liquids ............... 58 Coolant ............................58 Engine oil ............................59 Information for replacing the functional units ..............60 Injectors and injection pump replacement ................. 60 Coolant pump replacement ......................68 Replace the crankshaft pulley ...................... 69 Oil pump replacement ........................
  • Page 5 INDEX Timing system gear assembly and injection pump ..............120 Cylinder head unit assembly ...................... 122 Fuel system assembly ......................... 128 Intake manifold assembly ......................130 9.10 Exhaust manifold assembly ......................131 9.11 Lubrication circuit assembly ...................... 131 9.12 Crankshaft pulley assembly ....................... 133 9.13 Coolant circuit assembly ......................
  • Page 6 INDEX 14 Information about failures ....................182 14.1 Possible causes and trouble shooting ..................182 15 Glossary ..........................184 15.1 Glossary ............................184...
  • Page 7 GENERAL INFORMATION...

  • Page 8: General Information

    Reference to values are indicated by letters or numbers (underlined). • Any additional section that KOHLER will deem necessary to supply at a later stage must be kept with the manual and considered as an integral part of it. •...

  • Page 9: Manufacturer And Engine Identification

    GENERAL INFORMATION 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 10: Identification Of The Main Internal Components Of The Engine And Operating Reference (Base Configuration)

    GENERAL INFORMATION 1.3 Identification of the main internal components of the engine and operating reference (BASE CONFIGURATION) VIEW OF EXHAUST SIDE Fig 1.4 Tab 1.1 REF. DESCRIPTION View of timing system side (2 PTO) View of flywheel side (1 PTO) View of exhaust side The following chapters contain operating View of intake side...
  • Page 11 GENERAL INFORMATION Camshaft Gears adaptor for 3 PTO (optional) Flywheel (1 PTO) Injector VIEW OF FLYWHEEL SIDE Fig 1.5 VIEW OF TIMING SYSTEM SIDE Fig 1.6...

  • Page 12: Identification Of The External Components Of The Engine (Base Configuration)

    GENERAL INFORMATION 1.4 Identification of the external components of the engine (BASE CONFIGURATION) VIEW OF TIMING SYSTEM SIDE - EXHAUST Fig 1.7 VIEW OF FLYWHEEL SIDE Fig 1.8...
  • Page 13 GENERAL INFORMATION This paragraph illustrates all external components NOTE: The illustrated components may differ that are present in the base configuration of the from those illustrated; the illustration is only as an engine. example. For components present on engines that differ from those represented in these illustrations, refer Chap.
  • Page 14 GENERAL INFORMATION UPPER VIEW Fig 1.9...

  • Page 15: Technical Information

    TECHNICAL INFORMATION 2 TECHNICAL INFORMATION 2.1 Engine specifications MANUFACTURER SPECIFICATIONS AND OPERATION UNIT OF GENERAL INFORMATION KDI 1903 M KDI 2504 M MEASURE Operating cycle diesel - 4 stroke Cylinders N° Bore x stroke 88x102 Displacement 1861 2482 Compression ratio 18.4:1 Intake Atmospheric pressure...
  • Page 16 TECHNICAL INFORMATION Type of fuel Diesel UNI-EN590 - ASTM D975 High-pressure fuel injection pump STANADYNE - DB Fuel supply Low pressure electric pump Fuel filter Filtering surface 2300 Degree of filtration µm Maximum pressure at injection pump inlet < 0.5 LUBRICATION CIRCUIT UNIT OF GENERAL INFORMATION...

  • Page 17: Engine Dimensions (Mm)

    TECHNICAL INFORMATION 2.2 Engine dimensions (mm) NOTE: Dimensions vary according to engine configuration. Fig 2.1...

  • Page 18: Performance

    TECHNICAL INFORMATION 2.3 Performance Fig. 2.2 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.

  • Page 19: Oil

    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. 2.4 Oil Important •...

  • Page 20: Fuel

    TECHNICAL INFORMATION RECCOMENDED OIL 10w-30 (-25°C ÷ +40°C) 10w-40 (-25°C ÷ +50°C) VISCOSITY 5w-30 (-30°C ÷ +40°C) 0w-40 (-40°C ÷ +50°C) CI-4 Plus CI-4 CH-4 WITH SPECIFICATIONS ACEA • Low S.A.P.S. oils, sulfate ashes <1% may not be used with fuels with a sulfur content >50ppm. •...
  • Page 21 TECHNICAL INFORMATION change interval. This is set at 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. With high fuel sulfur content fuel this may happen at 125hrs. Do not use low SAPS oils. KDI Mechanical Injection Uncertified Engines (no EGR Engines) •...

  • Page 22: Coolant Recommendation

    TECHNICAL INFORMATION 2.5.5 Jet Fuels Only for KDI Mechanical 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 23: Battery Recommendations

    TECHNICAL INFORMATION HOAT are not all maintenance free and it is recommended to have SCA (Supplemental Coolant Additives) added at the first maintenance interval. 2.7 Battery recommendations Battery not supplied by Kohler Tab. 2.7 RECOMMENDED BATTERIES AMBIENT TEMPERATURE BATTERY TYPE >...
  • Page 24 TECHNICAL INFORMATION Fuel line hose Coolant (10) HOAT 2.10 ENGINE OIL AND OIL FILTER CARTRIDGE REPLACEMENT PERIOD (HOURS) ENGINE VERSION KDI Mechanical Injection Stage V KDI Mechanical Injection Tier 4 Final – Stage IIIB KDI Mechanical Injection Tier 3 – Stage IIIA (1) (11) KDI Mechanical Injection Uncertified Engines 2.11...

  • Page 25: Fuel System

    The fuel supply system is under low pressure from the 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 2.12 POS. DESCRIPTION Fuel tank...
  • Page 26 TECHNICAL INFORMATION Fuel tank Fuel return pipe to the tank 2.9.3 Injection pump Pressure into the injection pump must be positive in all operating conditions. The injection pump is operated by means of the pump control gear and sends high-pressure fuel to the injectors.
  • Page 27 TECHNICAL INFORMATION 2.9.4 Injector It is a device used to introduce fuel, in the form of one or more jets that are adequately pulverised and suitably oriented directly into the combustion chamber. They consist of a metallic body that internally provides a mobile element that acts on the needle: this, rising against the action of a calibrated spring, allows the release of fuel under high pressure.
  • Page 28 TECHNICAL INFORMATION 2.9.6 Electric fuel pump (optional) When the electric fuel pump is installed in a diesel engine, one must: 1. Remove any filters installed on the inlet of the electric fuel pump; 2. Insert a pre-filter between the tank and the electric pump;...

  • Page 29: Lubrication Circuit

    TECHNICAL INFORMATION Cap guards must be accurately washed after use and placed back in their housing (ST_40). Important • It is highly recommended to have this page visible during disassembly operations of the components of the fuel injection circuit. 2.10 Lubrication circuit 2.10.1 Lubrication circuit diagram The oil pump is driven by the crankshaft on the timing system side.
  • Page 30 TECHNICAL INFORMATION https://www.youtube.com/embed/5HuLfSg NOTE: Click by side to play the procedure. qz6s?rel=0 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 31 TECHNICAL INFORMATION 2.10.3 Oil filter Fig 2.16 Tab 2.23 POS. DESCRIPTION Oil cartridge Tab 2.22 Filter element DESCRIPTION VALUE Gasket Filtering surface 2.000 cm Safety valve Degree of filtration 15 µm Upper cranckcase Max operating pressure 7.0 Bar Inlet oil Oil filtering Output oil (sent to the circuit)

  • Page 32: Coolant Circuit

    TECHNICAL INFORMATION 2.11 Coolant circuit 2.11.1 Coolant circuit diagram Tab 2.24 POS. DESCRIPTION Coolant pump Coolant intake Coolant, cylinder Coolant, cylinder head Coolant to radiator Coolant into radiator Vent line from radiator (to 8) Compensation tank Thermostatic valve Return from compensation tank Fig 2.17 2.11.2 Coolant pump Tab 2.25...

  • Page 33: Intake And Exhaust Circuit

    TECHNICAL INFORMATION 2.11.4 Radiator (optional) NOTE: Component not necessarily supplied by Kohler. Tab 2.27 POS. DESCRIPTION Fig 2.20 Radiator group Coolant refill cap Vent tube or excess coolant return Coolant flow manifold Coolant intake manifold Protective grid Fig 2.21 2.12 Intake and exhaust circuit...
  • Page 34 Exhaust manifold Crankcase Exhaust muffler (optional) 2.12.1 Air filter (optional) Tab 2.29 POS. DESCRIPTION NOTE: Component not necessarily supplied by KOHLER. Air filter cartridge Filter cover Important Filter support Dust exhaust valve • The air filter is a dry-type one, with a replaceable paper...

  • Page 35: Electric System

    Tab 2.30 REF. DESCRIPTION Engine panel connector 2.13.1 Engine electrical wiring (opzional) interface (Fig. 2.26a) NOTE: Component not necessarily supplied by KOHLER. Accessories panel connector interface (Fig. 2.26b) Electrical wiring is supplied upon request, it interfaces with the panel by means of 19-way Deutsch connectors (female on Electrical fuel pump engine panel - male on accessories panel).
  • Page 36 TECHNICAL INFORMATION Air cleaner clogging sensor connector Earth connector Tab. 2.31 2.13.1.1 Connector panel on the PIN. INLET SIGNALS TO THE PANEL engine/machine Oil pressure switch The connector is a female 19-way Deutsch type. Alternator indicator light There is a list of all PIN connections in Tab. 2.31. Coolant temperature warning light Air cleaner clogging warning light Air cleaner clogging warning light...
  • Page 37 TECHNICAL INFORMATION The connector is a male 19-way Deutsch type. There is a list of all PIN connections in Tab. 2.32. Fig 2.26b 2.13.3.1 Wiring disconnection Some sensor connectors and electronic control devices are sealed. This tipe of connectors must be disconnected by means of pressure on tabs A or unblock the retainers B, as illustrated from Fig.

  • Page 38: Sensors And Switches

    TECHNICAL INFORMATION Fig 2.26g Fig 2.26f 2.14 Sensors and switches 2.14.1 Fuel filter water detection sensor (optional) The water presence sensor in the fuel filter serves to indicate the presence of water in the fuel. The sensor closes the electrical circuit and the warnin lamp in the panel board switches on the dashboard of the car on which the motor is mounted.
  • Page 39 TECHNICAL INFORMATION 2.14.3 Coolant temperature sensor connector The sensor has the dual function of a thermometer and thermal contact. The coolant/thermal contact P temperature probe is applied to the cylinder head on the side of the thermostatic valve. Sensor P1 or P2 (Fig. 2.29) can be assembled on the engine: P1 Characteristics indicated in Tab.

  • Page 40: Electrical Components

    TECHNICAL INFORMATION 2.14.4 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 41 TECHNICAL INFORMATION 2.15.4 Electric 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. Tab. 2.34 a-b-c-d indicates the pumps' features.
  • Page 42 TECHNICAL INFORMATION 2.15.5 Cold start advance The Cold Start Advance E device is part of injection pump D; it provides for advance injection modification to enable advance of the engine at low temperatures. The device is controlled by the ECU H. 2.15.6 Electro-Stop Fig 2.39 The electro-stop F device is part of injection pump D;...
  • Page 43 Device G is assembled on cylinder head P (flywheel side); it protects the electrical circuit in the event of an overload or short circuit. NOTE: Component not necessarily supplied by KOHLER. Fig 2.41 2.15.9 Control panel (optional) Panel L can be assembled on the engine or machine.

  • Page 44: Timing System And Tappets

    TECHNICAL INFORMATION 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 2.43 Tab 2.37 POS. DESCRIPTION Crankshaft Camshaft Camshaft tappets Rocker arm control rod...
  • Page 45 TECHNICAL INFORMATION 2.16.2 Rocker arm pin Tab 2.39 POS. DESCRIPTION Rocker arm pin Rocker arm distancing spring Rocker arm pin support Exhaust rocker arm Fig 2.47 Intake rocker arm 2.16.3 Rocker arms Tab 2.40 POS. DESCRIPTION Rocker arm body Hydraulic tappet oil refill line Valve tappet lubrication line Valve tappet Hydraulic tappet...
  • Page 46 TECHNICAL INFORMATION 3 against the valve stem, thus eliminating any system play. Thanks to the spring extension, the tappet extends", creating a small depression in the chamber B, making the non-return valve 4 open, and allowing the oil in the chamber A to pass to chamber B, restoring the proper amount of oil required to eliminate any play in the valves.

  • Page 47: Components Handling

    TECHNICAL INFORMATION 2.17 Components handling 2.17.1 Injection pump - Only handle by means of the points marked by Y. - It is forbidden to handle using the points marked by N. Fig 2.50 2.17.2 Injector - Only handle by means of the points marked by Y. - It is forbidden to handle using the points marked by N.

  • Page 48: Balancer Device (Optional)

    TECHNICAL INFORMATION 2.18 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 49: Safety Information

    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 50 Make sure that no soundproofing panels and the ground or floor on which the machine is standing • have not soaked up any fuel. The engine may only be assembled on a machine by personnel specifically trained by KOHLER and • who work in compliance with the existing documentation.
  • Page 51 Do not use jets of air and water at high pressure on the cables, connectors and injectors. • Important Only use the eyebolts A installed by KOHLER to move the engine (Fig. 3.1). • The angle between each lifting chain and the eyebolts shall not exceed 15° inwards.

  • Page 52: Safety Signal Description

    SAFETY INFORMATION 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 53: Information And Safety Signals

    SAFETY INFORMATION Warning This indicates that failure to comply with it can cause minor damage or injury. 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.
  • Page 54 SAFETY INFORMATION ROTATING PARTS EXPLOSIVE GAS Rotating Parts can cause Explosive Gas can cause fires and severe injury. severe acid burns. Stay away while engine is in operation. Charge battery only in a well ventilated area. Keep Keep hands, feet, hair, and clothing away sparks, open flames, and other sources of ignition from all moving parts to prevent injury.

  • Page 55: Safety And Environmental Impact

    - Use of raw materials and natural resources. - 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.

  • Page 56: Storage Information

    STORAGE INFORMATION 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 •...

  • Page 57: Engine Starting After Storage

    STORAGE INFORMATION 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. (Par.

  • Page 58: Information Regarding Discharge Of Liquids

    5.1 Coolant Important • Par. 3.3.2. Before proceeding with operation, read 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 59: Engine Oil

    INFORMATION REGARDING DISCHARGE OF LIQUIDS Fig 5.4 https://www.youtube.com/embed/wX NOTE: Click by side to play the procedure. Sb6sOYsD8?rel=0 5.2 Engine oil Important • 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.

  • Page 60: Information For Replacing The Functional Units

    INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 6 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 6.1 Injectors and injection pump replacement Important • Before proceeding with operation, read Par. 3.3.2. • Replace the high pressure pipes after two disassemblies. • Always replace the gaskets after each disassembly.
  • Page 61 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 6.1.2 Rocker arms cover disassembly 1. Loosen clamp G and disconnect hose H 2. Undo the screws L and remove the rocker arm cap C. Fig 6.4 6.1.3 Fuel return pipes disassembly 1. Undo the screws M and remove hose N. Fig 6.5 Fig 6.6 6.1.4 Injectors disassembly...
  • Page 62 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 2. Disassemble the starter motor. 3. Mount the tool ST_34 in the seat of the starter motor Y and fit it with the two starter motor fixing screws. 4. Rotate the crankshaft clockwise ST_34 tool bringing reference X upwards.
  • Page 63 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS ED0065905680-S 1,695 13° ED0065905760-S 1,695 13° ED0065905790-S 2,558 16° ED0065905970-S 0,815 9° ED0065905980-S 1,216 11° With reference X pointed upwards, find the Fig 6.11 TDC through tool ST_30, then bring the dial gauge indicator to 0. Having identified the value to lower the piston, rotate the crankshaft anti-clockwise by going beyond the value described in Tab.
  • Page 64 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS • Be careful that the nut AN does not fall into the timing cover. Screw the tool ST_04 on the gear AE. 14. Loosen the screws AF. 15. Tighten the screw of tool ST_04 to disconnect the injection pump AG from the high pressure pump control gear AE.
  • Page 65 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS a screwdriver to guide the nut AN on the shaft AP in order to avoid the fall of it into the timing cover AQ - tightening torque at 70 Nm). Undo the capscrew K and shift the slotted plate AB in the direction of arrow AA.
  • Page 66 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS Assemble the parts P, Q, R and fit the parts so assembled on the injector Z. Fig 6.22 Insert tool ST_51 on the injectors junctions Z (detail X1). Tighten the screw P (tightening torque to 20 Fig 6.23 https://www.youtube.com/embed/Kcv- NOTE: Click on the right to play the procedure.
  • Page 67 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS (KDI 1903 M) or Fig. 6.28 (KDI 2504 M) (tightening torque to 10 Nm). 4. Connect pipe H and tighten the clamp G. Important • Always replace the gaskets AK after each disassembly (ST_36). Fig 6.26 Fig 6.27 Fig 6.28...

  • Page 68: Coolant Pump Replacement

    INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 6.1.10 Installation of the fuel injector pipes (pump injector/injectors) 1. Position pipes D on the injectors and on the injector pump. Important Fig 6.29 • Tighten the nuts E and F manually, without clamping them. 2.

  • Page 69: Replace The Crankshaft Pulley

    INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 6.2.2 Assembly Important • Always replace the gaskets H, after each disassembly. • Always replace the belt E after each assembly. 1. Fit the coolant pump G with the screws F Fig 6.33 interposing the new gasket H (tightening torque at 25 Nm).

  • Page 70: Oil Pump Replacement

    INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 3. Undo the screw P (clockwise) and remove the pulley Fig 6.36 6.3.2 Assembly 1. Check that the pin U is mounted properly on the crankshaft V. 2. Insert the pulley Q on crankshaft V respecting the reference of the pin U.
  • Page 71 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 6.4.3 Timing system crankcase disassembly Important • Par. 5.2. Perform the operations described in 1. Make sure that the reference pin A is facing upwards. 2. Undo the screws B and remove the timing Fig 6.38 system crankcase C.
  • Page 72 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 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. 2.10.2). 5. Check that the 2 pins L are inserted properly in the timing system crankcase C.

  • Page 73: Oil Pressure Valve Replacement

    INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 8. Fit the timing system crankcase C with the screws R observing the indicated clamping sequence (tightening torque at 25 Nm). Fig 6.45 6.4.7 Crankshaft pulley assembly 1. Perform the operations described in 6.3.2. 6.4.8 Coolant pump assembly 1.

  • Page 74: Oil Filter Replacement

    INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 6.6 Oil filter replacement 6.6.1 Disassembly Important • Before proceeding with operation, read Par. 3.3.2. • Perform the operations described in Par. 5.2. 1. Unscrew the cartridge A. Fig 6.48 6.6.2 Assembly Important • In the event of mounting the fitting U on the crankcase S (tightening torque at 1 5 Nm + Loctite 2701).
  • Page 75 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 5. Loosen the air bleeding screw F on fuel filter bracket The air inside the circuit and the filter will begin to escape from the screw G. 6. Tighten the bleeding screw F (tightening torque of 1.5 Nm) when the fuel begins to flow.

  • Page 76: Information For Disassembly

    INFORMATION FOR DISASSEMBLY 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 77 INFORMATION FOR DISASSEMBLY • The belt must always be replaced every time it is disassembled, even if it has not reached the scheduled hours for replacement 4. Undo the screws C and D and remove the alternator E. 7.2.4 Sensors and switches Important •...

  • Page 78: Exhaust Manifold Disassembly

    INFORMATION FOR DISASSEMBLY 7.2.4.3 Fuel filter water detection sensor ( Warning • The fuel filter is not always installed in the engine. • When disassembling the sensor M, use a suitable container to recover the fuel contained in the cartridge N. Fig 7.5 1.

  • Page 79: Crankshaft Pulley Disassembly

    INFORMATION FOR DISASSEMBLY 7.4.2 Thermostatic valve 1. Undo the screws D and remove the thermostatic valve cover E. 2. Remove the thermostatic valve F and its gasket. Important • Always replace the gasket G every time it is Fig 7.8 disassembled.
  • Page 80 INFORMATION FOR DISASSEMBLY 7.6.2 Timing system semi-crankcase oil filling flange ( 1. Undo the screws G and remove the oil filling flange E (ST_06). 2. Remove the gasket F. Fig 7.11 7.6.3 Timing system 1. Make sure that the crankshaft with the 1st cylinder is at TDC.

  • Page 81: Intake Manifold Disassembly

    INFORMATION FOR DISASSEMBLY 7.6.5 Oil filter 1. Unscrew and remove the cartridge R. Warning • Use a suitable container to recover any residue oil. Fig 7.15 7.7 Intake manifold disassembly 1. Loosen clamp A and disconnect hose B. Fig 7.16 2.
  • Page 82 INFORMATION FOR DISASSEMBLY 7.8.1 Fuel injection pipes 1. Remove loking clips A from pipes B. 2. Loose nuts C and D and remove pipes B. Fig 7.18 7.8.2 Rocker arm cover 1. Undo the screws F and remove the rocker arm cap G.
  • Page 83 INFORMATION FOR DISASSEMBLY 7.8.5 Injection pump Important • Before disassembling, carefully read Par. 2.17. • The injector pump cannot be repaired. 1. Carry on operations described in steps 1-13 Fig 7.22 Par. 6.1.5. 2. Undo the nut S and remove it together with the washer.

  • Page 84: Timing System Gear Disassembly

    INFORMATION FOR DISASSEMBLY 7.9 Timing system gear disassembly 1. Unscrew screws C and remove camshaft gear D. 2. Remove lock ring A and the shoulder ring B. 3. Remove the intermediate gear L. Fig 7.26 4. Undo the screws F and remove the intermediate gear support G.

  • Page 85: Cylinder Head Unit Disassembly

    INFORMATION FOR DISASSEMBLY 7.10.2 Flange housing Undo the screws F and remove the engine housing Danger • The housing G is very heavy, pay utmost attention while removing in order to prevent it from falling, with Fig 7.29 serious consequences for the operator. 7.11 Cylinder head unit disassembly 7.11.1 Rocker arm pin 1.
  • Page 86 Fig 7.34 1. Undo the bolts M. 2. Remove the cylinder head N. Important • Only use the eyebolts AE installed by KOHLER to move the cylinder head Q. Remove the head gasket P. Fig 7.35 7.11.3.1 Valves ( 1.
  • Page 87 INFORMATION FOR DISASSEMBLY Important • Before removing the valves, make some marks in their original position, in order to prevent confusing them when they are re-assembled, if they are not replaced. 4. Remove the valves V. Fig 7.38 7.11.3.2 Injector sleeve ( 1.

  • Page 88: Oil Sump Unit Disassembly

    INFORMATION FOR DISASSEMBLY 7.12 Oil sump unit disassembly 7.12.1 Oil sump 1. Undo the screws A. 2. Remove the oil sump B by inserting a plate in the areas indicated by the arrow AA. Fig 7.42 7.12.2 Oil intake pipe 1.
  • Page 89 INFORMATION FOR DISASSEMBLY 7.13.2 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 Fig 7.46 assembly. Failure to do this may result in engine malfunctions.
  • Page 90 INFORMATION FOR DISASSEMBLY 3. 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. 4. Couple the connecting rod big end caps L with the relevant piston and connecting rod unit M.
  • Page 91 INFORMATION FOR DISASSEMBLY 4 Cylinders 4 CYLINDERS 1. 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. Fig 7.50 7.13.4 Crankshaft Remove: 1.
  • Page 92 INFORMATION FOR DISASSEMBLY 7.13.5.1 Rings ( 1. Remove the seal rings S. Fig 7.53 7.13.6 Breather room closing cover ( 1. Undo the screws AE and remove the cover AF. Fig 7.54 7.13.7 Camshaft 1. Remove the retainer ring V. 2.
  • Page 93 INFORMATION FOR DISASSEMBLY 7.13.9 Crankshaft bushings 1. Remove the crankshaft bushings AC from the upper semi-crankcase AB. Important • The crankshaft half-bearings AC are made of special material. Therefore, they must be replaced Fig 7.57 every time they are removed to prevent seizures. 2.

  • Page 94: Information About Overhauling

    INFORMATION ABOUT OVERHAULING 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 95 • 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 96 INFORMATION ABOUT OVERHAULING 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. Fig 8.2a 8.2.3 Block Surface Flatness Use a dial gauge to check if the cylinder head surface A1 is level.
  • Page 97 INFORMATION ABOUT OVERHAULING Tab 8.2a Housing and camshaft gudgeon 8.2.4 4-cylinder camshaft housing check dimensions. The camshaft housings only contain the timing system DIMENSIONS CLEARANCE REF. side bushing Q. (mm) VALUE (mm) Use an internal dial gauge to measure the diameters of 44.000 - 44.025 housings X - W - K - Y - Z.
  • Page 98 INFORMATION ABOUT OVERHAULING Fig 8.4 Tab 8.3a Housing and camshaft gudgeon 8.2.6 3 -cylinder camshaft housing check dimensions. The camshaft housings only contain the timing system DIMENSIONS CLEARANCE REF. side bushing Q. (mm) VALUE (mm) Use an internal dial gauge to measure the diameters of 44.000 - 44.025 housings X - W - K - Z.

  • Page 99: Tappets And Tappet Housings

    INFORMATION ABOUT OVERHAULING Tab 8.3b Camshaft 8.2.7 Camshaft control for 3 cylinder engine dimensions With a micrometer, measure the maximum dimensions of intake REF. DIMENSIONS (mm) camshaft R and exhaust camshaft S (Tab. 8.3b). 32.834 - 32.896 The MAX value of wear allowed is 0.1 mm. 33.335 - 33.397 Important •...

  • Page 100: Crankshaft

    INFORMATION ABOUT OVERHAULING NOTE: During the positioning phase of reference X, check that cylinder N° 1 is in compression phase (intake and exhaust valves of cylinder N° 1 must be in closing position). Tab. 8.4 T appets and t appet housing size. DIMENSIONS (mm) CLEARANCE VALUE (mm) REF.

  • Page 101: Connecting Rod - Piston Assembly

    INFORMATION ABOUT OVERHAULING Important Tab 8.5 Connecting rod and journal diameter DIMENSIONS CLEARANCE REF. • The crankshaft and connecting rod must be (mm) VALUE (mm) replaced every time they are assembled to prevent 53.981 - seizure, as they are made of special lead-free 54.000 material.
  • Page 102 INFORMATION ABOUT OVERHAULING 8.5.1 Connecting rod dimensions check Important • Before assembling the connecting rod and pistons Fig. 8.11 (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 103 INFORMATION ABOUT OVERHAULING Measure value A, C, D, E and F and confront them with those 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.
  • Page 104 INFORMATION ABOUT OVERHAULING +0.5 for a piston with an increased diameter of 0.50 mm; +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 •...

  • Page 105: Cylinder Head

    INFORMATION ABOUT OVERHAULING 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 The MAX removal allowed is 0.20 mm.
  • Page 106 INFORMATION ABOUT OVERHAULING Tab 8.9 WEIGHT (kg) LENGHT (mm) ED0057552810-S (*1) ED0057551850-S 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.
  • Page 107 INFORMATION ABOUT OVERHAULING 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 108: Oil Pump Check

    INFORMATION ABOUT OVERHAULING Fig. 8.26 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 109 INFORMATION ABOUT OVERHAULING Par. For assembly, carry out the operations described from 9.11.3 to Par. 9.11.4. Tab 8.13 REF. DIMENSIONS (mm) CLEARANCE VALUE (mm) 82.820 - 82.855 0.032 - 0.075 82.500 - 82.540 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...

  • Page 110: Assembly Information

    ASSEMBLY INFORMATION 9 ASSEMBLY INFORMATION 9.1 Information on engine configuration • In this chapter, the engine is represented as "BASE CONFIGURATION" (refer to Par 1.3 Par. 1.4). • For the assembly of components not described in this chapter refer to Chap.

  • Page 111: Engine Block Assembly

    ASSEMBLY INFORMATION Important • Par. 3.3.2. Before proceeding with operations, read • To easily locate specific topics, the reader should refer to the analytical index or chapter index. • The operator must check that: 1. the components, the assemblies, the coupling surfaces of the parts are washed, clean and thoroughly dried;...
  • Page 112 ASSEMBLY INFORMATION 9.3.2 Tappets 1. Lubricate the tappets G with oil. 2. Insert the tappets G into the housings H of the upper crankcase. Fig 9.3 9.3.3 Camshaft 1. 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.
  • Page 113 ASSEMBLY INFORMATION 4. Insert the 2 shoulder half-rings K, between the crankshaft W and the upper crankcase E (AB detail). 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 oil to keep them in their seat.
  • Page 114 ASSEMBLY INFORMATION 8. Check that crankshaft W rotates smoothly. NOTE: In the next illustrations of Par. 9.3 the coupled crankcase half will be indicated with the letter E. 4 Cylinders 9. Tightening sequence for 3 cylinders Tightening Screws Torx M12x1,25 (from the n°...
  • Page 115 ASSEMBLY INFORMATION 9.3.8 Piston and connecting rod Important • Before proceeding to the assembly of the piston and connecting rod, carry out the checks described in Par. 8.5.1. • Always replace the bearings CE after Fig 9.13 each assembly. 1. Loosen the screws AU and remove the connecting rod cap AV.
  • Page 116 ASSEMBLY INFORMATION 4. Check that the half-bearing AS is mounted correctly on the connecting rod cap AV. Important • As the rods are divided by breaking pay particular attention to the coupling of the cap on the connecting rod. • Check before you screw and tighten the bolts Fig 9.17 that the breaking surfaces are perfectly flush.

  • Page 117: Oil Sump Unit Assembly

    ASSEMBLY INFORMATION 9.3.10 Crankshaft gasket flange Important • Check that the contact surface between the flange and the crankcase is free of grit and dirt. • Always replace the gasket BS after each assembly. Fig 9.19 1. Check that there are bushings BT on the crankcase 2.
  • Page 118 ASSEMBLY INFORMATION 9.4.2 Oil suction pipe Important • It is mandatory to replace the gasket B after each assembly. • Always replace capscrews D with new ones or alternatively apply Loctite 2701. Fig 9.24 1. Insert the new gasket B in the seat of the oil suction hose flange D.

  • Page 119: Flange Unit Assembly

    ASSEMBLY INFORMATION 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. 1. Install the bell housing A in accordance with the Fig 9.27 reference pins B on the base C.

  • Page 120: Timing System Gear Assembly And Injection Pump

    ASSEMBLY INFORMATION 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 B. 2. Position the gear C on the camshaft B adhering to the key reference A. 3.
  • Page 121 ASSEMBLY INFORMATION 9.6.2 Injection pump Important • Always change screws T with new ones or alternatively apply Loctite 270 (Fig. 9.34) to the threads. 1. Perform the operations described in the warning in Fig 9.34 Par. 6.1.5. 2. Place a dial gauge to detect the TDC on piston N° 1, then bring the indicator of the dial gauge to 0.

  • Page 122: Cylinder Head Unit Assembly

    ASSEMBLY INFORMATION 7. Fix pump Z into housing V by means of screws T (Fig. 9.34 - tightening torque at 25 Nm). 8. Position the gear AC onto shaft AB of the pump. NOTE: You are not required to respect the reference Q gear AE (Fig.
  • Page 123 ASSEMBLY INFORMATION 9.7.3 Injectors projection 1. Insert the injector G inside the sleeve H. 2. Mount the injector fixing bracket M and secure it with the screw N, without performing the calibration. Fig 9.40 3. Check protrusion of injectors by means of the tool ST_03 (Fig.
  • Page 124 ASSEMBLY INFORMATION 6. Push the lever of the tool ST_07 downwards, in order to lower the valve disks S in the direction of the arrow AK, and insert the valve cotters AJ inside the disk S. 7. Check that the valve cotters AJ are properly mounted on the valve seats X and release the tool ST_07.
  • Page 125 ASSEMBLY INFORMATION 7. Check that the surface head W is free from impurities. 8. Position the head F on the crankcase Z with reference to the centering bushings J. Important • The fastening bolts V must be replaced every time they are assembled.
  • Page 126 ASSEMBLY INFORMATION 9.7.6 Rods and valve bridges 1. Insert the rocker control rods AA into the niches of the head F. Fig 9.51 Important • Properly centre the rods AA into the spherical housing of the camshaft tappets AB. 2. Mount the valve bridge AC on to the pairs of discharge and suction valves.
  • Page 127 ASSEMBLY INFORMATION 9.7.8 Rocker arm pin assembly Important • Position the rocker arm pin assembly BB on a level to align all the support surfaces. • Check that the pistons are positioned half way between the TDC and BDC. Rotate the crankshaft Fig 9.56 90°...

  • Page 128: Fuel System Assembly

    ASSEMBLY INFORMATION 9.8 Fuel system assembly Important • Replace the high pressure pipes after two disassemblies. • Remove the protective caps from all the components of the fuel circuit just before assembly (Par. 2.9.7). • When repaired, RSN-A injectors must be Fig 9.59 certified by a Stanadyne centre to check their correct operation - check the type of...
  • Page 129 ASSEMBLY INFORMATION 5. Insert tool ST_51 on the injectors junctions Z (detail X1). 6. Tighten the screw P (tightening torque to 20 Nm). Fig 9.63 9.8.2 Fuel injector ricicle pipe 1. Position the tube N on the injectors Z, and tighten screws M (coppia di serraggio a 14 Nm) and insert the gasket T.

  • Page 130: Intake Manifold Assembly

    ASSEMBLY INFORMATION 9.8.4 Installation of the fuel injector pipes (injection pump/injectors) Important • Replace the high pressure pipes after two disassemblies. 1. Position pipes D on the injectors and on Fig 9.68 the injector pump and tighten the nuts E and F manually, without clamping them.

  • Page 131: Exhaust Manifold Assembly

    ASSEMBLY INFORMATION 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 assembly. • In the event of mounting the studs C, fix (25 Nm tightening torque) with Loctite 2701 on the thread.
  • Page 132 ASSEMBLY INFORMATION 4. Insert, inside the seat AF, the 2 rotors (in sequence) AH and AL, respecting the reference BP as the picture. (or refer to Par. 2.10.2). 5. Check that the 2 pins AM are inserted properly in the crankcase timing system AN. 6.

  • Page 133: Crankshaft Pulley Assembly

    ASSEMBLY INFORMATION 7. Fasten the screws R (tightening torque of 25 Nm). Fig 9.77 9. 11.4 Crankcase oil filler flange Timing System Important • Always replace the gasket BA after each assembly. 1. Position the gasket BA in the seat on the flange BB. 2.

  • Page 134: Coolant Circuit Assembly

    ASSEMBLY INFORMATION 9.13 Coolant circuit assembly 9.13.1 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 Fig 9.81 head C (detail D).
  • Page 135 ASSEMBLY INFORMATION 9.14.1.2 Oil pressure switch 1. Clamp the oil pressure switch F on the crankcase G (tightening torque at 35 Nm). Fig 9.84 9.14.1.3 Fuel filter water detection sensor 1. Lubricate and insert the gasket AA on the fitting AB. Fix the sensor AB onto the cartridge AC (tightening torque of 5 Nm).

  • Page 136: Tightening Torques And The Use Of Sealants

    ASSEMBLY INFORMATION 9. Check the tension of the belt S with the instrument (DENSO BTG-2), positioning it in point P (the tension must be between 200 and 230 N). 10. If the tension values do not correspond, tighten screws A and D, then repeat operations 7, 8, 9 and 9.14.3 Starter Motor Important •...
  • Page 137 ASSEMBLY INFORMATION Coolant drain hole closing cap M16x1.5 OIL SUMP ASSEMBLY Thread Component Torque (Nm) Sealer (mm) Oil fumes tube M12x1,5 Loctite 648 Loctite Oil suction hose fastening capscrew M6x1 2701* Oil sump fastening capscrew M8x1.25 Oil drain cap M18x1.5 FLANGE ASSEMBLY (1st PTO) Thread Component...
  • Page 138 ASSEMBLY INFORMATION Waste line fastening drilled capscrew on injectors M10x1 Injector side injection tube nuts M12x1.5 Injection pump side injection tubes nuts M12x1.5 Loctite Injection pump fastening capscrew M8x1.25 2701* Fuel injection pump locking screw Fuel delivery fastening drilled capscrew (on injection pump) M10x1 Waste line fastening drilled capscrew (on injection pump) M10x1...
  • Page 139 ASSEMBLY INFORMATION Thread Component Torque (Nm) Sealer (mm) Thermostatic valve cover fastening capscrew M6x1 Coolant pump fastening capscrew M8x1.25 ELECTRICAL COMPONENTS Thread Component Torque (Nm) Sealer (mm) Coolant temperature sensor M12x1.5 20 max. Oil pressure switch M12x1.5 Sensor for water presence in fuel Alternator bracket fastening capscrew M8x1.25 Alternator fastening capscrew...
  • Page 140 ASSEMBLY INFORMATION Component Thread (mm) Torque (Nm) Sealer Pump support fastening capscrew M8x1.25 Loctite 2701* Pump fastening capscrew M8x1.25 Component Thread (mm) Torque (Nm) Sealer Grooved crankshaft support fastening capscrew M8x1.25 Loctite 2701* Cover fastening capscrew (3rd PTO side) M8x1.25 Sump support fastening capscrew Pump fastening capscrew M8x1.25...
  • Page 141 ASSEMBLY INFORMATION Upper brace fastening capscrew (on engine cylinder head) M8x1.25 Side bulkheads fastening capscrew M6x1 ENGINE SUPPORT Component Thread (mm) Torque (Nm) Sealer Side feet fastening capscrew (on flange bell or crankcase) M12x1.75 Rear feet fastening capscrew M16x1.5...

  • Page 142: Fluids Filling Information

    FLUIDS FILLING INFORMATION 10 FLUIDS FILLING INFORMATION 10.1 Engine oil Important • Before proceeding with operation, read Par. 3.3.2. • Do not use the engine with the oil level below the minimum. 1. Loosen the oil filler cap A or the oil filler cap C if the cap A is not accessible.
  • Page 143 FLUIDS FILLING INFORMATION 1. Screw the cap. G, replacing the copper gasket (Tightening torque of 50 Nm). Fig 10.3 2. Tighten the cap E, replacing the copper gasket D. Fig 10.4 3. Refill the radiator with coolant (refer to Par. 2.6 the liquid specifications).
  • Page 144 FLUIDS FILLING INFORMATION Warning • Before starting make sure that the radiator cap and expansion tank cap, if present, are installed correctly to avoid spillage of liquid or vapour at high temperatures. 13. After a few hours of operation stop the engine and allow it to cool.

  • Page 145: Information About Optional Components

    INFORMATION ABOUT OPTIONAL COMPONENTS 11 INFORMATION ABOUT OPTIONAL COMPONENTS 11.1 Oil dipstick in cylinder head Important • Par. 3.3.2. Before proceeding with operation, read 11.1.1 Check 1. Pull out the dipstick B in the direction of the arrow 2. Check that the mark left by the oil on the dipstick is between the MIN.

  • Page 146: Heater (Replacement)

    INFORMATION ABOUT OPTIONAL COMPONENTS Tighten the oil dipstick hose E using the screw D on the manifold L (Tightening torque of 10 Nm). Fig 11.4 NOTE: Check the integrity of the gaskets J. 4. Insert the dipstick B inside the hose E. Fig 11.5 11.2 Heater (replacement) Important...

  • Page 147: Poly-V Alternator Belt (Replacement And Adjustment)

    INFORMATION ABOUT OPTIONAL COMPONENTS 11.2.2 Assembly Important • Always replace gaskets F, with each assembly. 1. In sequence, fit the manifold G with the gasket F, the new heater E, the second gasket F, the flange C, the Fig 11.7 washers H, the screws A and the cable B.

  • Page 148: Tightening Pulley And Alternator For Poly-V Belt

    INFORMATION ABOUT OPTIONAL COMPONENTS Fig 11.9 4. 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).
  • Page 149 INFORMATION ABOUT OPTIONAL COMPONENTS 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. Fully undo the screw B and remove the tightening pulley C.
  • Page 150 INFORMATION ABOUT OPTIONAL COMPONENTS 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 2. Insert the screw H into the fixing hole on the alternator L. 3.

  • Page 151: Idler Gear (For 3Rd / 4Th Pto)

    INFORMATION ABOUT OPTIONAL COMPONENTS 11.5 Idler gear (for 3rd / 4th PTO) Important • Par. 3.3.2. Before proceeding with operation, read 11.5.1 Disassembly 1. Undo the screw A and remove the gear unit B. Fig 11.8 2. Remove the retainer ring C from the seat of the pin D. 3.

  • Page 152: 3Rd Pto (Replacement)

    INFORMATION ABOUT OPTIONAL COMPONENTS 3. Position the gear unit B on the hole J using the bushing G to centre. 4. Secure the gear B using the screw A inserting the washer H (tightening torque at see service letter 700019 - 700021). 11.6 3rd PTO (replacement) Fig 11.12 Important...
  • Page 153 INFORMATION ABOUT OPTIONAL COMPONENTS 2. Remove the centring ring C and the relative gaskets 3. Undo the screws N. Fig 11.14 4. Remove the flange F with the components D, E, G and H in the direction of the arrow P. 5.
  • Page 154 INFORMATION ABOUT OPTIONAL COMPONENTS 3. Position the flange F on the crankcase K inserting the gasket J, and inserting the gear H up to the stop on the bearing L (Fig. 11.31). Fig 11.18 4. Secure the flange F using the screws N (tightening torque at 25 Nm).

  • Page 155: 4Th Pto (Replacement)

    INFORMATION ABOUT OPTIONAL COMPONENTS 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 2. Undo the screws C and remove the flange D. Fig 11.23...
  • Page 156 INFORMATION ABOUT OPTIONAL COMPONENTS 3. Undo the screws E and remove the cover F. Fig 11.24 4. Undo the screws G and remove the flange K with the components H, J, M and N. Fig 11.25 5. Remove the retainer ring H and the shoulder ring J from the flange K.
  • Page 157 INFORMATION ABOUT OPTIONAL COMPONENTS 3. Position the flange K on the crankcase Q inserting the gasket P, and inserting the gear N up to the stop on the bearing R 11.41). (Fig. 4. Secure the flange K using the screws N (tightening torque at 25 Nm).

  • Page 158: 3Rd + 4Th Pto (Configurations)

    INFORMATION ABOUT OPTIONAL COMPONENTS 11.8 3rd + 4th PTO (configurations) Fig. 11.32 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.
  • Page 159 INFORMATION ABOUT OPTIONAL COMPONENTS 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 11.34 3. Undo the screws C and remove the hose D. Fig 11.35 4. Undo the screws E and remove the shaft support box F.
  • Page 160 INFORMATION ABOUT OPTIONAL COMPONENTS 6. Remove the shafts J and K in the direction of the arrow L from box F. Fig 11.38 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 161 INFORMATION ABOUT OPTIONAL COMPONENTS 5. Manually tighten the retainer screw ST_15 the box F by slightly rotating the shaft K, centring the hole on it using the ST_15, to lock the device. Fig 11.42 6. Rotate the crankshaft and clamp it on the TDC (Ref.

  • Page 162: Air Filter (Cartridge Replacement)

    INFORMATION ABOUT OPTIONAL COMPONENTS 11.10 Air filter (cartridge replacement) Important • Par. 3.3.2. Before proceeding with operation, read 1. Release the two hooks A and remove the cover B from the body C. 2. Remove the cartridges D. Fig 11.46 3.
  • Page 163 INFORMATION ABOUT OPTIONAL COMPONENTS lose together with the nuts A, with the consequent of oil leakage. 2. Undo the nuts A and remove the hoses B and C. 3. Unscrew and remove the fitting H with its copper gasket from the head J. 4.

  • Page 164: Intake Circuit (Replacement)

    INFORMATION ABOUT OPTIONAL COMPONENTS 5. Clamp the fitting K (tightening torque at 45 Nm + Loctite 2701). 6. Clamp the fitting H on the flange J inserting the gasket U (tightening torque at 65 Nm). 7. Connect the hose B to the central fitting of support M and of flange J.

  • Page 165: Muffler (Replacement)

    INFORMATION ABOUT OPTIONAL COMPONENTS 11.12.2 Manifold air filter disassembly 1. Release the clamp D. 2. Remove the manifold E. 3. Loosen capscrews G and remove plate H. Fig. 11.54 11.12.3 Air filter manifold assembly 1. Insert the fitting G on the flange H. 2.

  • Page 166: Cooling Circuit (Replacement)

    INFORMATION ABOUT OPTIONAL COMPONENTS 11.13.1 Disassembly 1. Undo the screw A. 2. Undo the nuts B. Remove the muffler C. Fig. 11.57 11.13.2 Assembly 1. Position the gasket D and the muffler C on the intake manifold E. 2. Position the muffler C on the bracket F and tighten the screws A (tightening torque at 25 Nm).
  • Page 167 INFORMATION ABOUT OPTIONAL COMPONENTS 3. Loosen the 4 capscrews C and capscrew E. Fig. 11.60 4. Remove guard D. Fig. 11.61 5. Release the clamp H. 6. Release the pipe L from the radiator M. Fig. 11.62 7. Undo nuts N and remove the radiator M. Fig.
  • Page 168 INFORMATION ABOUT OPTIONAL COMPONENTS 11.14.2 Fan disassembly 1. Undo the screws P and remove the plate Q from the fan R. Fig. 11.64 11.14.3 Fan assembly 1. Assemble the fan R on the pulley U. 2. Position the plate Q on the fan R. 3.

  • Page 169: Engine Feet (Information)

    Y. 9. Tighten the clamps A. Fig. 11.70 11.15 Engine feet (information) NOTE: Component not necessarily supplied by KOHLER. The representation of the engine is purely indicative. Important • The motor supports A can be installed on the bell B or on the crankcase C by using the screws D (tightening torque at 50 Nm).

  • Page 170: Oil Sump With Supporting Structure

    INFORMATION ABOUT OPTIONAL COMPONENTS 11.16 Oil sump with supporting structure 11.16.1 Flywheel (J) disassembly 1. Execute the operations described in Par. 7.10.1. 11.16.2 Plate/flange housing (L) disassembly 1. Loosen supplementary capscrews A and B. 2. Execute the operations described in Par.
  • Page 171 INFORMATION ABOUT OPTIONAL COMPONENTS 4. Apply capscrews E into the fastening holes and use torque at 10 Nm. 5. Loosen capscrews E, leaving approximately 1 mm leeway (position A) between the neck surface of capscrews E and oil sump F. 6.
  • Page 172 INFORMATION ABOUT OPTIONAL COMPONENTS 12. Insert gaskets N into seats P of bypass tube D. 13. Fasten bypass tube D onto oil sump F using capscrews C (tightening torque at 10 Nm). Fig. 11.79 11.16.5 Flange plate / housing assembly 1.

  • Page 173: Oil Sump 15L

    INFORMATION ABOUT OPTIONAL COMPONENTS 11.17 Oil sump 15L 11.17.1 Disassembly 1. Perform the operations indicated in Par. 5.2 2. Loosen the screws A and remove the oil sump B . 3. Loosen the screws A1 and remove the oil sump B1 flange.
  • Page 174 INFORMATION ABOUT OPTIONAL COMPONENTS 4. To fix the sump B1 , tighten the screws A1 by strictly following the order indicated in the Fig. 11.83 (tightening torque of 25 Nm ). 5. Loosen the screw 1 again and tighten it to 25 Nm . Fig.

  • Page 175: Crankcase Oil Filter - Lengthwise Assembly

    INFORMATION ABOUT OPTIONAL COMPONENTS 11.18 Crankcase oil filter - Lengthwise assembly 11.18.1 Disassembly 1. Perform the operations indicated in Par. 5.2. Important • Before performing the operation, check Par. 3.3.2 • To replace only the cartridge, refer to operations 2 ( Fig 11.86 Par.
  • Page 176 INFORMATION ABOUT OPTIONAL COMPONENTS 5. Fix the oil pressure switch B to the support E placing the gasket B1 in-between (tightening torque of 25 Nm ). Fig 11.89 6. Lubricate the gasket of the cartridge A and secure the cartridge A to the support E (tightening torque of 20 Nm ).

  • Page 177: Information On Adjustments

    INFORMATION ON ADJUSTMENTS 12 INFORMATION ON ADJUSTMENTS 12.1 Air filter check Important • Before proceeding with operation, read Par. 3.3.2. 1. Hose A must be completely clean and not damaged. 2. Air filter cartridge B and its housing C must be completely clean and free from impurities.

  • Page 178: Oil Leak Check

    INFORMATION ON ADJUSTMENTS 12.3 Oil leak check Important • Par. 3.3.2. Before proceeding with operation, read 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. It is anyhow necessary to also check the seals of all main components and their surface contact, such as: - crankcase and oil seal (side 1...
  • Page 179 INFORMATION ON ADJUSTMENTS Fig. 12.8 Fig. 12.7...

  • Page 180: Tools Information

    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, where referred to them in the manual.
  • Page 181 TOOLS INFORMATION ED0014603610- ST_09 Tool for flywheel assembling / disassembling ED0014603670- ST_10 Crankshaft gasket assembling tool Buffer insertion of a crankshaft gasket onto a ED0014603750- ST_14 timing system carter ED0097301980- ST_15 Locking screw balance shafts ED0014603730- ST_17 Rocker arm cover mounting studs ED0014603740- ST_18 Intake and oil sump manifold mounting studs...
  • Page 182 INFORMATION ABOUT FAILURES 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 183 INFORMATION ABOUT FAILURES...
  • Page 184 A component that transforms mechanical energy into AC electrical Alternator: energy. Authorised service KOHLER authorised workshop. station: Authorised workshop: KOHLER authorised service centre. A device that reduces vibrations caused by movement of the alternating weights Balancer device: (Crankshaft - Connecting rods - Pistons). Base Para. 1.3 - 1.4.
  • Page 185 Idle speed operation: Operation of a running engine with the vehicle stopped and on idle speed. 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 periodic by the system, neither increasing the value nor improving performance.
  • Page 186 GLOSSARY Normally Closed, referred to switches (oil-pressure switch). N/C: N/O: Normally Opened, referred to switches (Coolant temperature sensor) 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 Pipe similar to a brush and is used to clean areas that are not easily accessible manually cleaner:...
  • Page 187 GLOSSARY Trochoid: Rounded toothed profile (also known as "lobes"). Used Oil altered by operation or time, which is no longer compliant for correct lubrication of the components. oil: Warning A warning light (usually red) that indicates a serious anomaly during engine Lamp: operation.
  • Page 188 GLOSSARY average roughness expressed Roughness 1 Ra in microns °C degree centigrade Temperature 1°C Volt Electrical voltage millimetre Hex-head capscrew 1 mm cubic centimetre 1 cm Volume litre 1 Lt.
  • Page 192 TP-6939 3/23...

This manual is also suitable for:

Kdi 2504m

Table of Contents