Kohler KDI Series Workshop Manual
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Kohler KDI Series Workshop Manual

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KDI 1903 TCR - KDI 2504 TCR
WORKSHOP MANUAL
TP-6916 04/16

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Summary of Contents for Kohler KDI Series

  • Page 1 KDI 1903 TCR - KDI 2504 TCR WORKSHOP MANUAL TP-6916 04/16...
  • Page 2 ED0053029590 51273 10/2013 04/2016 TRANSLATED FROM THE ORIGINAL MANUAL IN ITALIAN LANGUAGE. Data reported in this issue can be modified at any time by KOHLER. Important • Connect to http://iservice.lombardini.it > KDI KOHLER DIESEL section > "TECHNICAL DOCUMENTATION" > select "KDI 1903 TCR" or "KDI 2504 TCR" and download the latest version of this manual onto your device.
  • Page 3 NOTES ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ED0053029590...
  • Page 4 INDEX GENERAL INFORMATION Useful information Manufacturer and engine identification Name plate for EPA regulations Identification of main internal components of the engine and operating references Identification of external components of the engine TECHNICAL INFORMATION Engine specifications Engine dimensions (mm) Performance diagrams 2.4.1 SAE classification 2.4.2...
  • Page 5 INDEX 2.15 Electrical components 2.15.1 Alternator 2.15.2 Poly-V belt alternator (optional) 2.15.3 Starter Motor 2.15.4 EGR valve 2.15.5 Cold starting device 2.15.6 Fuel intake regulating valve (SCV) 2.15.7 Electric fuel pump (optional) 2.16 Timing system and tappets 2.16.1 Components identification 2.16.2 Timing system phasing angles 2.16.3...
  • Page 6 INDEX High-pressure fuel injection pump replacement 6.2.1 High pressure fuel tube disassembly (from injection pump to Common Rail) 6.2.2 Timing system carter oil filling flange disassembly 6.2.3 High-pressure fuel injection pump disassembly 6.2.4 High-pressure fuel injection pump assembly 6.2.5 High-pressure line assembly (injection pump / Common Rail) 6.2.6 Timing system carter oil filling flange assembly EGR cooler unit replacement...
  • Page 7 INDEX Crankshaft and target wheel pulley disassembly Lubrication circuit disassembly 7.8.1 Oil pressure valve 7.8.2 Timing system carter oil filling cover 7.8.3 Timing system carter 7.8.4 Oil pump 7.8.5 Oil Cooler Unit and lub. oil filter 7.8.6 Oil steam separator unit Intake manifold disassembly 7.10 Fuel system disassembly...
  • Page 8 INDEX Connecting rod-piston 8.5.1 Connecting rod dimension check 8.5.2 Checking the gudgeon pin-pin axes are parallel 8.5.3 Piston rings check 8.5.4 Piston dimension check Cylinder head 8.6.1 Flatness check 8.6.2 Valve seats check 8.6.3 Valve springs 8.6.4 Valve guides check 8.6.5 Valve guides replacement 8.6.6...
  • Page 9 INDEX 9.11 Lubrication circuit assembly 9.11.1 Oil steam separator unit 9.11.2 Oil Cooler unit and lub. oil filter 9.11.3 Oil pump 9.11.4 Timing system carter 9.11.5 Timing system carter oil filling flange 9.11.6 Oil pressure valve 9.12 Crankshaft and phonic wheel pulley unit assembly 9.13 Coolant circuit assembly 9.13.1...
  • Page 10 INDEX 11.12 Oil sump with supporting structure 11.12.1 Flywheel disassembly 11.12.2 Plate/flange housing disassembly 11.12.3 Oil sump disassembly 11.12.4 Oil sump assembly 11.12.5 Flange plate / housing assembly 11.12.6 Flywheel assembly INFORMATION REGARDING REGULATIONS 12.1 Waste Gate opening valve regulation 12.2 Air filter check 12.3...
  • Page 11 NOTES ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ED0053029590...
  • Page 12 Therefore, the information in this manual is subject to change without notice. • 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 13 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 Engine serial number Engine type Manufacturer identification Engine version Approval data and...
  • Page 14 GENERAL INFORMATION 1.3 Name plate for EPA regulations Fig. 1.4 POS. DESCRIPTION Model year in compliance with the rules Power category (kW) Engine displacement (Lt.) 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 15: Table Of Contents

    GENERAL INFORMATION 1.4 Identification of the main internal components of the engine and operating reference (BASE CONFIGURATION) VIEW OF EXHAUST SIDE Fig. 1.5 The following chapters contain operating references in order Tab. 1.2 to clearly understand the engine. This paragraph illustrates REF.

  • Page 16: General Information

    GENERAL INFORMATION VIEW OF FLYWHEEL SIDE Fig. 1.6 VIEW OF TIMING SYSTEM SIDE Fig. 1.7 ED0053029590...
  • Page 17 GENERAL INFORMATION 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 - INTAKE Fig. 1.9 ED0053029590...

  • Page 18: Crankshaft Pulley (2 Nd Pto)

    GENERAL INFORMATION This paragraph illustrates all external components that are NOTE: The illustrated components may differ from those present in the base configuration of the engine. illustrated; the illustration is only as an example. For components present on engines that differ from those represented in these illustrations, refer to Chap.
  • Page 19 TECHNICAL INFORMATION 2.1 Engine specifications Tab. 2.1 MANUFACTURER SPECIFICATIONS AND OPERATION UNIT OF GENERAL INFORMATION KDI 1903 TCR KDI 2504 TCR MEASURE Operating cycle diesel - 4-stroke Cylinders Bore x stroke 88x102 Displacement 1861 2482 Compression ratio 17.4:1 Intake Supercharged with Turbocharger Cooling Liquid Crankshaft rotation (view from flywheel side)
  • Page 20 TECHNICAL INFORMATION LUBRICATION CIRCUIT UNIT OF GENERAL INFORMATION KDI 1903 TCR KDI 2504 TCR MEASURE Lubrication see Par. 2.4 Recommended oil Circuit forced Lobe pump Oil sump capacity (MAX) 11,5 Oil pressure switch Intervention pressure (MIN) 0.8±0.1 Oil filter Maximum operating pressure Degree of filtration 17 ±2 µm...
  • Page 21 TECHNICAL INFORMATION 2.2 Engine dimensions (mm) NOTE: Dimensions vary according to engine configuration. 545.3 593.3 KDI 1903 TCR 537.5 704.3 KDI 2504 TCR Fig. 2.2 ED0053029590...
  • Page 22 N = Power NM = Torque C = Specific consumption curve NOTE: Refer to KOHLER for power curves, torque curves and specific consumptions at speeds other than those given above. Fig. 2.3 Power (ISO TR 14396 - SAE J1995 - CE 97/68) = Power curve.
  • Page 23 TECHNICAL INFORMATION 2.4 Oil Important Danger • The engine may be damaged if operated with improper oil • Prolonged skin contact with the exhausted engine oil can level. cause cancer of the skin. • Do not exceed the MAX level because a sudden increase in •...
  • Page 24 TECHNICAL INFORMATION 2.5 Fuel 2.5.1 Fuel for low temperatures • When operating the engine in ambient temperatures lower Important than 0 degrees C, use use suitable low temperature fuel • Use the same type of diesel fuel as used in cars (EN 590 for normally available from fuel distributors and corresponding E.U.
  • Page 25 2.6 Coolant Tab. 2.6 TECHNICAL SPECIFICATIONS 50% ETHYLENEGLYCOL and 50% DECALCIFIED WATER 50% PROPYLENE GLYCOL and 50% DECALCIFIED WATER 2.7 Battery features Battery not supplied by Kohler Tab. 2.7 RECOMMENDED BATTERIES AMBIENT TEMPERATURE BATTERY TYPE ≥ - 15°C 100 Ah - 800 CCA/SAE <...
  • Page 26 TECHNICAL INFORMATION 2.8 Periodic maintenance The intervals of preventive maintenance in Tab. 2.8 and Tab. 2.9 with fuel and oil meeting the recommended specifications. refer to the engine operating under normal operating conditions Tab. 2.8 CLEANING AND CHECKING PERIODICITY (HOURS) OPERATION DESCRIPTION 1000 1500...
  • Page 27 TECHNICAL INFORMATION 2.9 Fuel system 2.9.1 Injection circuit (pressure 2000 bar) (Fig. 2.4) The materials of the fuel system components (pipes, tank, The most critical chemical element is Zinc (Zn), therefore it is forbidden to use galvanised components. filters, etc.) and any surface treatments must be free from Other damaging elements are indicated in the table below.
  • Page 28 Common Rail to the electronic injectors Electronic injectors NOTE: The representation of fuel tank is purely indicative. Component not necessarily supplied Fig. 2.4 by KOHLER. 2.9.2 Fuel return circuit The fuel return circuit is under low pressure. Tab. 2.12 POS. DESCRIPTION...
  • Page 29 TECHNICAL INFORMATION 2.9.3 High-pressure injection pump (2000 bar) Important • DO NOT use the cylinder connecting pipe (item 5) to carry the pump during movement as this may cause damage resulting in fuel leakag; to handle the injection pump, refer to Par.
  • Page 30 TECHNICAL INFORMATION 2.9.4 Electronic injector The electronic injector is equipped with an integral solenoid valve which, when excited electronically, manages a valve controlled from inside the electronic injector to commence fuel injection. The ECU output signal is digital. Important • The electronic injector is NOT repairable. •...
  • Page 31 TECHNICAL INFORMATION 2.9.5 Common rail Important Fuel is injected under pressure into the Common Rail (Pos. 3), from the high-pressure fuel injection pump. • Common Rail is NOT repairable. - The internal volume of the Common Rail is optimised to obtain •...
  • Page 32 TECHNICAL INFORMATION 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. Tab. 2.16 POS. COMPONENTS DESCRIPTION Fuel filter support Fuel system filling button Cartridge Water in fuel sensor Wing nut, filter drainage Cartridge characteristics...
  • Page 33 TECHNICAL INFORMATION 2.9.7 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 injection pump; 2 - Insert a pre-filter between the tank and the electric pump; 3 - The electric pump may be assembled on application at a maximum height of 500 mm from the position of the fuel tank.
  • Page 34 TECHNICAL INFORMATION 2.9.8 Guards for fuel injection circuit components ST_26 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 35 TECHNICAL INFORMATION 2.10 Lubrication circuit 2.10.1 Lubrication circuit diagram The oil pump is driven by the crankshaft on the timing system side. 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 36 TECHNICAL INFORMATION 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 37 TECHNICAL INFORMATION 2.10.3 Oil filter and Oil Cooler NOTE: unscrewing the cartridge holder cover makes the oil in support 7 flow towards the oil sump by means of the drain duct 4. Fig. 2.18 Tab. 2.22 POS. DESCRIPTION Oil arriving from the pump Oil cooling Oil filtering Oil drain duct (oil sump return)
  • Page 38 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 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) Vent line to expansion vase (to 15)
  • Page 39 TECHNICAL INFORMATION 2.11.2 Coolant pump Tab. 2.25 POS. DESCRIPTION Coolant pump control pulley Coolant intake fitting Coolant return hose from the Oil Cooler Fig. 2.22 2.11.3 Radiator with Intercooler (optional) Tab. 2.26 POS. DESCRIPTION Radiator with intercooler Coolant refill cap Radiator coolant vent tube or return Air hose (from Intercooler to manifold) Intercooler air delivery hose...
  • Page 40 It contains precious metals (platinum, palladium, iridium). NOTE: The image is indic ative only. The installation of the catalyst must be approved by KOHLER, for each application. Important • In order to prevent breakage on the connection flange, the catalyst must be connected via a flexible exhaust tube.
  • Page 41 TECHNICAL INFORMATION 2.12.3 Intake and exhaust circuit diagram with EGR Air in intake Gas in recycle Gas in exhaust Fig. 2.28 Fig. 2.29 ED0053029590...
  • Page 42 2.12.4 Air filter (optional) Tab. 2.32 POS. DESCRIPTION NOTE: Component not necessarily supplied by KOHLER. Air filter cartridge Air filter safety cartridge Important • The air filter is a dry type of filter with a paper filtering element; Filter cover elements H and L are replaceable (refer to Tab.
  • Page 43 TECHNICAL INFORMATION 2.13 Electric system 2.13.1 ECU input and output signals diagram Electronic injector 1 Power relay Engine revolutions sensor Electronic injector 2 Engine phase sensor Electronic injector 3 Coolant temperature sensor Common Rail pressure sensor Electronic injector 4 Oil pressure switch EGR valve control EGR valve position Fuel intake adjustment valve...
  • Page 44 300 mm) from one of the ECU fixing • The ECU must only be used with the configuration defined points to a plate of mass, taking care to ensure perfect by KOHLER, for each individual engine. electrical contact. Fig. 2.31 Tab. 2.33 ECU AND ENGINE IDENTIFICATION PLATES POS.
  • Page 45 TECHNICAL INFORMATION 2.13.3 Engine electrical wiring Fig. 2.33 Tab. 2.34 RIF. DESCRIPTION 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 Common Rail pressure sensor connector Injectors connectors Fig.
  • Page 46 TECHNICAL INFORMATION 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 or unblock the retainers B, as illustrated from Fig. 2.34c to Fig. 2.34r. Fig. 2.34c Fig.
  • Page 47 TECHNICAL INFORMATION Fig. 2.34l Fig. 2.34m Fig. 2.34n Fig. 2.34o Fig. 2.34p Fig. 2.34q Fig. 2.34r ED0053029590...

  • Page 48: Tab. 2.35

    TECHNICAL INFORMATION 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 - 2 teeth) situated on the crankshaft pulley. It sends it to the ECU as an analogical signal.

  • Page 49: Tab. 2.36

    TECHNICAL INFORMATION 2.14.5 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 50 TECHNICAL INFORMATION 2.14.9 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 51 TECHNICAL INFORMATION 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 52: Tab. 2.37

    TECHNICAL INFORMATION 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. Tab. 2.38 indicates the pumps' features.
  • Page 53 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. 2.51 Tab. 2.39 POS. DESCRIPTION Crankshaft Camshaft Camshaft tappets Rocker arm control rod...
  • Page 54 TECHNICAL INFORMATION 2.16.2 Timing system phasing angles VIEW OF TIMING SYSTEM SIDE - 2 Important Crankshaft rotation • For information purposes, Tab. 2.40 reports the timing system diagram phasing angle values. Intake cicle • It should be noted that the said values may be verified by Exhaust cicle rotating the crankshaft (Pos.
  • Page 55 TECHNICAL INFORMATION 2.16.5 Hydraulic tappets Tab. 2.43 POS. DESCRIPTION Low pressure chamber Hight pressure chamber Hydraulic tappets oil refill pipe Retaining ring Piston Unidirectional valve 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 56 TECHNICAL INFORMATION 2.17 Balancer device (optional - only KDI 2504) 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.
  • Page 57 TECHNICAL INFORMATION 2.18 Components handling 2.18.1 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. 2.59 2.18.2 Electronic injector - Only handle by means of the points marked by Y. - It is forbidden to handle using the points marked by N.
  • Page 58 • Do not apply additives to the lubricating oil and fuel, unless • Check the engine oil level. instructed to do so by Kohler. • Before switching it off after it has been used, make the engine • Do not increase engine speed, or apply loads, immediately run idle, or without a load, for approximately 1 minute.
  • Page 59 TECHNICAL INFORMATION 2.19.3 Before installing a new turbocharger Important • Do not lift the turbocharger with one hand from the FG box. • Do not lift turbocharger from Comp hsg side. • Lift the turbocharger with both hands from FG box. •...
  • Page 60 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 61 Any use of the • In the event KOHLER does not approve the type of machine other than that described cannot be considered as modification, KOHLER shall not be held responsible for any...
  • Page 62 • The oil must be drained whilst the engine is hot. Particular care is required to prevent burns. Do not allow oil to come into • Only use the eyebolts A installed by KOHLER to move the contact with the skin because of the health hazards involved.
  • Page 63 SAFETY INFORMATION 3.4 Safety signal description • To ensure safe operation please read the following statements • This manual contains safety precautions which are explained and understand their meaning. below. • Also refer to your equipment manufacturer's manual for other •...
  • Page 64 State of California to cause cancer, birth defects, or other reproductive harm. 3.6 Safety and environmental impact In order to minimise the impact on the environment, KOHLER Every organisation has a duty to implement procedures to provides some indications to be followed by all those handling identify, assess and monitor the influence of its own activities the engine, for any reason, during its expected lifetime.
  • Page 65 SAFETY INFORMATION 3.7 Location of safety signals on engine KDI 1903 TCR KDI 2504 TCR ED0053029590...
  • Page 66 NOTES ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ED0053029590...
  • Page 67 STORAGE INFORMATION 4.1 Product preservation 11 - When cleaning the engine, if using a pressure washer or steam cleaning device, avoid directing the nozzle on Important electrical components, cable connections and sealed rings (oil seals etc). • If the engines are not to be used for 6 months, they must If cleaning engine with a pressure washer or steam be protected by carrying out the operations described in Engine storage (up to 6 months) (Par.
  • Page 68 NOTES ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ED0053029590...
  • Page 69 INFORMATION REGARDING DISCHARGE OF LIQUIDS 5.1 Coolant NOTE: Component not necessarily supplied by KOHLER. The representation of the radiator is purely indicative. Warning • Before proceeding with operation, carefully read Par. 3.3.2. • Presence of steam pressurized coolant danger of burns.
  • Page 70 INFORMATION REGARDING DISCHARGE OF LIQUIDS 5.2 Engine oil Important • Before proceeding with operation, carefully read Par. 3.3.2. • 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 71 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS Important • After disassembly, protect the sensor against shocks, • Before proceeding with operation, carefully read Par. 3.3.2 dampness and any high temperature sources. • In the event of the electronic injectors being disassembled (not •...
  • Page 72 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 6.1.2 High pressure fuel pipes disassembly (Common Rail/electronic injectors) Danger • The fuel injection circuit is under 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 one of the nuts H.
  • Page 73 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 6.1.5 High pressure fuel pipes assembly Important • Always replace the pipes N after each assembly. 1 - Position tube N in the Common Rail seat of the electronic injector; correct the position of the electronic injector by means of the entrance of the electronic injector unions F and Common Rail L.
  • Page 74 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 6.2 High-pressure fuel injection pump replacement Danger • The fuel injection circuit undergoes high pressure, use safety protections as described in Para 3.4.3. • Ensure that the Common Rail is not under pressure by slowly and carefully unscrewing nut A.
  • Page 75 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 6.2.2 Timing system carter oil filling flange disassembly 1 - Remove starter motor (Par. 7.3.2) and assemble special tool ST_34 (Par. 7.7 point 2). 2 - Undo the screws G (ST_06), remove the clamp E and the flange H.
  • Page 76 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 6.2.4 High-pressure fuel injection pump assembly Important • Before assembling, carefully read Par. 2.18.1. • Always replace the gasket V after each assembly. The gasket V can only be fitted in one direction. • Remove the tool ST_04 from the pump control gear (Ref. M of Par.
  • Page 77 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 7 - Fit the connector T on the sensor J. 8 - Fit the connector S on the sensor Y. 9 - Remove the protection caps. 10 - Fit the pipe Q on the fitting AA. 11 - Fit the pipe P on the fitting AB.
  • Page 78 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 6.3 Unit EGR Cooler replacement 6.3.1 Disassembly NOTE: Perform the operations described in Par. 5.1. 1 - Undo the screws B of pipe C. Fig. 6.28 2 - Undo screws D and E. 3 - Remove pipe F and the relevant metal gaskets. 4 - Release the clamps G and remove the sleeve M.
  • Page 79 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 5 - Insert the gasket N between the hose B and the EGR Cooler L and fix the screws A (tightening torque at 25 Nm) Fig. 6.32 6 - Insert the hose E in its housing on the manifold S inserting the gasket R.
  • Page 80 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 3 - Fit the connector A on the valve C. NOTE: Perform the operations described in Par. 10.2. Fig. 6.36 6.5 Coolant pump replacement 6.5.1 Disassembly NOTE: Perform the operations described in Par. 5.1. Important •...
  • Page 81 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 6.5.2 Assembly Important • Always replace the gaskets L, at each disassembly. • Always replace the belt E after each assembly. • If the engine is fitted with the Poly-V belt, perform the operations described in Par. 11.3. 1 - Fit the pump N with the screws H interposing the new gasket L (tightening torque at 25 Nm).
  • Page 82 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 3 - Disassemble the starting motor. 4 - Mount the tool ST_34 in the seat of the starter motor C and fit it with the two starter motor fixing screws. ST_34 Fig. 6.44 6 - Disconnect the connector L. 7 - Undo the screw M and remove the revolution sensor N and its respective spacer.
  • Page 83 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 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. 3 - Position the phonic wheel S on the pulley V respecting the reference of the pin U.
  • Page 84 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 2 - Remove the rotors F and G from the oil pump crankcase E. Fig. 6.52 6.7.5 Oil pump assembly Important • Carry out the checks described in Par. 8.7 prior to assembly. 1 - Check that all surfaces in contact between F, G, H, E and C are free from impurities - scratches - dents.
  • Page 85 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 5 - Lubricate and insert the gasket P in the seat of the oil pump Q. 6 - Tighten the tool ST_10 on the crankshaft. 7 - Position the crankcase C on the base, using the reference pins N, inserting the oil pump Q on the crankshaft.
  • Page 86 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 7 - Mount the bracket Z with the screws AA (tightening torque at 10 Nm). 8 - Perform the operations described in Par. 9.12. 9 - Insert the shim AB on the sensor AC. 10 - Clamp the sensor AC on the bracket Z with the screw AD (tightening torque at 10 Nm).
  • Page 87 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 6.9 Oil vapour separator replacement Important • Before proceeding with operation, carefully read Par. 3.3.2. 6.9.1 Disassembly 1 - Release the clamp AA and remove the pipe D. 2 - Release the clamps F. 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 88 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 6.10 Oil cooler unit and oil filter replacement 6.10.1 Oil Cooler unit disassembly Important • Perform the operations described in Par. 5.1 and Par. 5.2. • Oil Cooler unit E is not repairable. 1 - Release the clamps A. 2 - Remove the pipes B out of the Oil Cooler unit E.
  • Page 89 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 5 - Lubricate and insert gaskets L, M and N in the L1, M1 and N1 seats of element holder cover H. 6 - Insert element P into element holder cover H. Fig. 6.71 6.10.2 Oil Cooler unit assembly Important...
  • Page 90 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 6.11 Fuel filter replacement 6.11.1 Disassembly Warning • Before proceeding with operation, carefully read Par. 3.3.2. • 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 F.
  • Page 91 NOTES ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ED0053029590...
  • Page 92 • Where necessary, reference to special tools to use during disassembly operations is indicated (e.g. ST_05), refer to • Before disassembly, perform the operation described in KOHLER diesel special tools. Chap. 5. 7.2 EGR circuit disassembly 7.2.1...
  • Page 93 INFORMATION FOR DISASSEMBLY 7.2.2 EGR Valve 1 - Disconnect the connector P. 2 - Undo the screws Q and remove the EGR valve R with the relevant gasket. NOTE: The EGR valve is not a serviceable item, and damaged/worn, it should be replaced with a new one. Fig.
  • Page 94 INFORMATION FOR DISASSEMBLY 5 - Disconnect the connectors K and L. Fig. 7.8 6 - Disconnect the connectors M and P. 7 - Release the clamp Q. Fig. 7.9 8 - Disconnect the connectors R. 9 - Undo the screws S and remove the wiring support T (ST_06).
  • Page 95 INFORMATION FOR DISASSEMBLY 7.3.3 Belt and alternator 1 - Loosen the screws Z and W. 2 - Push the alternator AA in the direction of the arrow AB. 3 - Remove the belt AC from the pulleys AR. Important • The belt must always be replaced every time it is disassembled, even if it has not reached the scheduled hours for replacement.
  • Page 96 INFORMATION FOR DISASSEMBLY 7.3.4.4 Camshaft phase sensor 1 - Undo the screw AM and remove the sensor AN with the relative spacer (ST_06). Fig. 7.16 7.3.4.5 T-MAP sensor ( 1 - Undo the screw AP and remove the sensor AQ (ST_06). Fig.
  • Page 97 INFORMATION FOR DISASSEMBLY 2 - Unscrew the fittings D and remove the pipe E with the relative gaskets G. 3 - Undo the screws F. 4 - Release clamp M. Fig. 7.20 5 - Undo the nuts H and remove the turbocharger L. 6 - Remove tube N.
  • Page 98 INFORMATION FOR DISASSEMBLY 3 - Release the clamp K and remove hoses AA. Fig. 7.24 7.6.2 Coolant pump Important • The pump B is not repairable. 1 - Undo the screws A and remove the water pump unit B with its gasket C.
  • Page 99 INFORMATION FOR DISASSEMBLY 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.
  • Page 100 INFORMATION FOR DISASSEMBLY 7.8.4 Oil pump ( Important • The oil pump is not repairable. 1 - Undo the screws L and remove the pump unit M from the timing system carter H. Fig. 7.31 2 - Remove the rotors N and P from oil pump carter M. Fig.
  • Page 101 INFORMATION FOR DISASSEMBLY 7.8.6 Oil vapour separator unit 1 - Release the clamps AA. 2 - Remove the manifolds AB, AC and AD. 3 - Remove the clamp AE by carefully cutting it at the point indicated and remove the oil separator. Fig.
  • Page 102 INFORMATION FOR DISASSEMBLY 7.10 Fuel system disassembly 7.10.1 Fuel return pipes 1 - Release the clips A. Warning • After removing the unions, the clips A must automatically return to their initial position; otherwise they must be replaced. 2 - Undo the B distributor return fixing capscrew. 3 - Release the clamp D.
  • Page 103 INFORMATION FOR DISASSEMBLY 7.10.4 Common rail 1 - 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. The internal parts of the rail cannot be repaired. Important •...
  • Page 104 INFORMATION FOR DISASSEMBLY 7.10.7 High-pressure fuel injection pump ST_04 Important • Before disassembling, carefully read Par. 2.18.1. • The injection pump is not repairable. • Should the fuel feeding pump need to be replaced, after assembly, it is necessary to perform the Pump Learning procedure by means of instrument ST_01.
  • Page 105 INFORMATION FOR DISASSEMBLY 7.12 Flange unit disassembly 7.12.1 Flywheel Important • Leave the special tool ST_34 for blocking the flywheel (Par. 7.7). 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 106 INFORMATION FOR DISASSEMBLY 7.13.2 Rocker arm pin 1 - Undo the screws D. 2 - Remove the rocker arm pin unit E. Fig. 7.54 7.13.2.1 Rocker arm ( 1 - Remove the retainer ring F. 2 - Remove the shoulder rings G. 3 - Remove the rocker arms H.
  • Page 107 • The cylinder head fastening bolts P must be replaced every time they are disassembled. • 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 head Q and crankcase J against impacts..
  • Page 108 INFORMATION FOR DISASSEMBLY Important • Before removing the valves, make some marks to record their original position, in order to avoid confusing them when re- assembling (if they are not replaced). 4 - Remove the valves V. Fig. 7.62 7.13.4.2 Electronic injector sleeves ( 1 - Unscrew and remove the sleeves Z from the head Q.
  • Page 109 INFORMATION FOR DISASSEMBLY 7.14 Oil sump unit disassembly 7.14.1 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. 7.66 7.14.2 Oil suction pipe 1 - Undo the screws C and remove the oil pipe D.
  • Page 110 INFORMATION FOR DISASSEMBLY 7.15 Engine block disassembly 7.15.1 Crankshaft gasket flange 1 - 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 111 INFORMATION FOR DISASSEMBLY 3 - Pull out the connecting rod - piston assembly from position 2 and 3 by manually applying pressure on the connecting rod M 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 112 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. 7.74 7.15.4 Crankshaft Remove:...
  • Page 113 INFORMATION FOR DISASSEMBLY 7.15.5.1 Rings ( 1 - Remove the rings S. Fig. 7.77 7.15.6 Oil spray nozzles ( 1 - Undo the screws T and remove the spray nozzles U from the upper semi-crankcase AB. Fig. 7.78 7.15.7 Camshaft 1 - Remove the lock ring V.
  • Page 114 INFORMATION FOR DISASSEMBLY 7.15.9 Crankshaft bushings 1 - Remove the crankshaft bushings AC from the upper crankcase AB. Important • The crankshaft half-bearings AC are made of special material. Therefore, they must be replaced every time they are removed to prevent seizures. Fig.
  • Page 115 NOTES ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ED0053029590...
  • Page 116 INFORMATION ABOUT OVERHAULING 8.1 Recommendations for overhauls and tuning • The information is laid out in sequence, according to • Do not wash the components with steam or hot water. Use operational requirements, and the intervention methods have suitable products only. been selected, tested and approved by the manufacturer's •...
  • Page 117 EPA name plate (refer to Par. 1.3). The grinding involved is of +0.20, +0.50 and + 1 mm. • Cylinder grinding operations must observe KOHLER • SPECIFICATIONS - cod. ED0035612500. Grinding must be strictly performed on all cylinders F.
  • Page 118 INFORMATION ABOUT OVERHAULING 8.2.3 4-cylinder camshaft housing check Tab. 8.2 Housing and camshaft gudgeon dimensions. The camshaft housings only contain the timing system side CLEARANCE REF. DIMENSIONS (mm) bushing Q. VALUE (mm) Use an internal dial gauge to measure the diameters of housings 44.000 - 44.025 - Z.
  • Page 119 INFORMATION ABOUT OVERHAULING 8.2.5 Camshaft housing check for 3 cylinder engine Tab. 8.3a Housing and camshaft gudgeon dimensions. The camshaft housings only contain the timing system side CLEARANCE VALUE bushing Q. REF. DIMENSIONS (mm) (mm) Use an internal dial gauge to measure the diameters of housings - Z.
  • Page 120 INFORMATION ABOUT OVERHAULING 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 121 INFORMATION ABOUT OVERHAULING 8.4 Crankshaft Measure the crank pins with a micrometer, and using a 8.4.1 Dimensional check and overhauling dial gauge measure the internal diameter of the connecting rod half-bearings A2. Wash the crankshaft thoroughly using suitable detergent. Measure the main journals B1, with a micrometer, and using Insert the pipe cleaner into all lubrication ducts and blow a dial gauge measure the internal diameter of the crankshaft...
  • Page 122 INFORMATION ABOUT OVERHAULING 8.4.2 Checking the axial clearance of the crankshaft Perform the operations described in Par. 9.3.5 e 9.3.6. Using a dial gauge, measure the axial shift of crankshaft E. Axial shift must be a MIN of 0.18 mm and MAX 0.38 mm. If the values measured do not correspond, replace shoulder rings D.
  • Page 123 INFORMATION ABOUT OVERHAULING 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. The parallelism deviation (value V) measured at the tip of the gudgeon pin, must be a MIN of 0,015 and MAX of 0,030 mm.
  • Page 124 INFORMATION ABOUT OVERHAULING Important • With a feeler gauge, measure the clearance of the seal ring in the respective seat (value L1, e L3). • If the clearance does not comply with the values shown in the table (Tab. 8.8), replace the seal rings and the piston. Fig.
  • Page 125 INFORMATION ABOUT OVERHAULING 8.6.2 Valve seats check Thoroughly clean the valves and their seats with. Measure indentation of each valve with regard to the cylinder head surface C, which is to be a MIN of 0.60 mm and MAX of 0.85 mm. MAX indentation allowed on worn components is 1.10 If the measured value does not correspond with the values indicated, replace the worn component.
  • Page 126 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 127: Fig. 8.29

    INFORMATION ABOUT OVERHAULING 8.7 Oil pump check 8.7.1 Dimensional and visual check Perform the operations described in Par 7.8.1 and 7.8.4. Measure clearance value between the rotor teeth, the value of allowable wear is MAX 0.28 mm. Clean all the components thoroughly, check that the work surfaces C of the rotors and pump body are not worn.

  • Page 128: Tab. 8.14

    INFORMATION ABOUT OVERHAULING Fig. 8.32 Fig. 8.32a Important • Replace carter R complete with its oil pump, if there are signs of wear in area of surface Q (Fig. 8.32 - 8.32a). 8.7.3 Oil pressure valve check Measure the free length F of spring D, which must be 47.91 mm. If the measured value does not correspond to the value indicated, replace spring D.
  • Page 129 • 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. • Where necessary, reference to special tools during assembly operations refer to KOHLER diesel special tools. • Hereinafter in Tab. 9.1 an example of a special tool (ST_05).

  • Page 130: H (Tab. 8.10)

    ASSEMBLY INFORMATION 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 prevent seizures.
  • Page 131 ASSEMBLY INFORMATION 9.3.4 Oil spray nozzles 1 - Insert the sprayers V onto the upper crankcase E manually screwing the screw fittings U. 2 - Direct the sprayers V as shown Z and tighten the connecting screws U (tightening torque of 10 Nm). Fig.
  • Page 132 ASSEMBLY INFORMATION 3 CYLINDERS Important • Failure to adhere to the bolt fixing procedures may compromise the functionality of the engine, and may also cause damage to persons and property. 6 - Tighten the fastening screws strictly following the sequence and the tightening torque indicated. Tightening sequence for 3 cylinders Tightening Screws Torx M12x1,25 (from the n°...
  • Page 133 ASSEMBLY INFORMATION 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. 5 - Perform the operations described in Par.
  • Page 134 ASSEMBLY INFORMATION 9.3.9 Piston and connecting rod assembly Important • Before assembling the piston and connecting rod assemblies, execute the controls described in Par. 8.5. 1 - Rotate the crankshaft W by moving the crankpin BG to a TDC position of the affected cylinder. Fig.
  • Page 135 ASSEMBLY INFORMATION Important • Leave the ring compressor assembled on the piston 6 - Push piston AQ downwards without introducing segments in the cylinder, rotate piston AQ by 10° in a clockwise direction (value – correct assembly position). Fig. 9.20 7 - Push the piston AQ downwards by centering the crankpin BG with the connecting rod AZ.
  • Page 136 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 at each assembly. 1 - Check that there are bushings BT on the crankcase E. 2 - Lubricate the oil seal lip BU.
  • Page 137 ASSEMBLY INFORMATION 9.4 Oil sump unit assembly 9.4.1 Oil vapour pipes 1 - 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 •...
  • Page 138 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 reference pins B on the base C.
  • Page 139 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.
  • Page 140 ASSEMBLY INFORMATION 9.6.2 High-pressure injection pump 1 - Check that the surface V is free from impurities (Fig. 9.38). Important • Always replace gasket U with every assembly. • The seal gasket U can only be fitted in one direction (Fig. 9.38). •...
  • Page 141 ASSEMBLY INFORMATION 9.7 Cylinder head unit assembly 9.7.1 Valve stem gasket Important • Carry out the checks described in Par. 8.6.4 before proceeding with the following operations. • Always replace gasket A with every assembly. • Lubricate the gaskets A on the inside. 1 - Fit the gaskets A on the valve guides B using the tool ST_08.
  • Page 142 ASSEMBLY INFORMATION 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 - Position the disk S on the spring Y centering the valve X.
  • Page 143 ASSEMBLY INFORMATION 2 - Position the piston P at the TDC. 3 - Position the tool ST_03 on the crankcase surface of the head and measure the piston protrusion P from head level K in 4 diametrically opposed points R. Repeat the operation for all pistons P and take note of the highest average value, determining value S (Tab.
  • Page 144 ASSEMBLY INFORMATION Tab. 9.3 4 CYLINDERS CYCLE TORQUE 40 Nm 70 Nm 100 Nm 90° 90° 90° Fig. 9.53 9.7.6 Rods and valve bridges 1 - Insert the rocker control rods AA into the niches of the head F. Important •...
  • Page 145 ASSEMBLY INFORMATION 9.7.7 Rocker arms Important • To correctly position the rocker arms, turn the rocker arm pin AH with the lower height towards the timing system side as in Fig.9.57. • The discharge rocker arm AT is shorter than the suction arm 1 - Fit the lock ring AM into the seat AN of the rocker arm pin 2 - Position the pin AH with the screw support surface AP facing upwards and insert the 2 shoulder rings AQ.
  • Page 146 ASSEMBLY INFORMATION BP = -90° Fig. 9.60a Fig. 9.60b 9.7.9 Assembly Rocker arm cover Important • Replace gasket BF, BL and BM with each assembly (ST_11 - ST_12). • Observe the order of tightening illustrated in Fig. 9.62 - 9.63. 1 - Position tool ST_17 onto the head in correspondence with the two fastening holes and 6.
  • Page 147 ASSEMBLY INFORMATION 2 - Insert the tube K on the fitting coming out of the filter holder R and on the fuel inlet fitting of the injection pump M and secure it with the clamps N. Fig. 9.65 9.8.2 Common Rail 1 - Secure the rail AA on the head AB with the screws AC (tightening torque at 10 Nm).
  • Page 148 ASSEMBLY INFORMATION 9.8.4 High pressure fuel pipes Important • Always replace the pipes AQ and tube E after each assembly. 1 - Position the pipes AQ on the Common Rail AA and on the electronic injectors AM, adjust the position of electronic injectors AM via the fitting inlets with the pipes AQ.
  • Page 149 ASSEMBLY INFORMATION 2 - 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). 3 - Mount the fittings BG (Fig. 9.74) on the injectors AM and lock them with the clips BH.
  • Page 150 ASSEMBLY INFORMATION 9.9.2 External half-manifold ST_18 Important • Check that the contact surfaces between the two semi collectors C and D are free from impurities. 1 - Fit the screws L on the semi-collector M freeing the holes Q indicated in Fig. 9.78. 2 - Mount the gaskets N on the semi-collector by interposing the separation sheet P.
  • Page 151 ASSEMBLY INFORMATION 4 - Fit the pipes F and G on the holder C. 5 - Insert the bleeder H attaching it to the pipes F and G. Secure the pipe F with the clamps J. 6 - Secure the bleeder H onto the holder C with the clamp K. Fig.
  • Page 152 ASSEMBLY INFORMATION 9.11.3 Oil pump NOTE: Carry out the checks described in Par. 8.7 before proceeding with the following operations. 1 - Check that all contact surfaces between AL, AH, AF, AG and AN are free of impurities – scratches - dents. 2 - When assembling, do not use any type of gasket between AG and AN.
  • Page 153 ASSEMBLY INFORMATION 7 - Fasten capscrews AW observing the indicated clamping sequence (tightening torque of 25 Nm). Fig. 9.89 9.11.5 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 - Fasten the flange BB on the crankcase BC with the screws BD (tightening torque of 8 Nm - ST_06).
  • Page 154 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 head C (detail D).
  • Page 155 ASSEMBLY INFORMATION 9.14 Turbocharger Assembly Important • Before proceeding, perform the operation described in Par. 2.19. • 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. Important •...
  • Page 156 ASSEMBLY INFORMATION 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 157 ASSEMBLY INFORMATION 5 - Measure the distance from the coupling surface AD to the tooth surface on the phonic wheel (X1). 6 - Measure the distance between the coupling surface AD and the sensor surface R (Y1). 7 - The difference between the 2 measurements determines the air gap value (Z1).
  • Page 158 ASSEMBLY INFORMATION 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 159 ASSEMBLY INFORMATION 9.15.3 Starter Motor Important • Remove the ST_34 tool if it remains in position on the engine. 1 - Fit the engine BQ with the screws BR on to the flange bell BS (tightening torque of 45 Nm). Fig.
  • Page 160 ASSEMBLY INFORMATION 9 - Fit the connector C6 on the sensor S6. 10 - Fit the connector C7 on the sensor S7. 11 - Insert the clamps H2 on the thermostat cover DB and H3 on the lateral oil intake flange DC. 12 - Fit the connector C8 on the sensor S8.
  • Page 161 ASSEMBLY INFORMATION 6 - Fit the connector H on the valve L. 7 - Tighten the clamp J with the screw K on the flange B. Fig. 9.121 9.16.2 EGR Cooler 1 - Insert the fitting N of EGR Cooler M in the sleeve P of the EGR valve unit.
  • Page 162 ASSEMBLY INFORMATION 9.17 Tightening torques and the use of sealants Tab. 9.4 Alternatively to the capscrew replacements, with "Dri-loc" BASE CONFIGURATION SHORT BLOCK Component Thread (mm) Torque (Nm) Sealer Oil sprays fastening capscrew M6x1 Lower crankcase fastening capscrew M12x1.25 3 Torque cycles 1st Cycle 2nd Cycle 3rd Cycle...
  • Page 163 ASSEMBLY INFORMATION Alternatively to the capscrew replacements, with "Dri-loc" Injector side injection tube nuts M12x1.5 Injection pump side injection tubes nuts M12x1.5 Common Rail side injection tubes nuts M14x1.5 Injection pump fastening capscrew M8x1.25 Loctite 270* INTAKE MANIFOLD Component Thread (mm) Torque (Nm) Sealer Internal semi-manifold fastening capscrew (on cylinder head)
  • Page 164 ASSEMBLY INFORMATION Alternatively to the capscrew replacements, with "Dri-loc" ELECTRICAL COMPONENTS Component Thread (mm) Torque (Nm) Sealer MAP sensor fastening capscrew Coolant temperature sensor M12x1.5 20 max. Oil pressure switch M12x1.5 Phase sensor fastening capscrew Speed sensor fastening capscrew Sensor for water presence in fuel Alternator bracket fastening capscrew M8x1.25 Alternator fastening capscrew...
  • Page 165 ASSEMBLY INFORMATION Alternatively to the capscrew replacements, with "Dri-loc" REMOTE OIL FILTER Component Thread (mm) Torque (Nm) Sealer Head fastening and Oil Cooler union on crankcase M20x1.5 Loctite 2701 Crankcase head nipple and oil filter support M14x1.5 Tube union on crankcase head G3/8 Tube union on filter support G3/8...
  • Page 166 FLUIDS FILLING INFORMATION 10.1 Engine oil Warning • Before proceeding with operation, carefully 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 (Par. 2.2). Fig.
  • Page 167 FLUIDS FILLING INFORMATION 3 - Refill the radiator with coolant (refer to Par. 2.6 for the liquid specifications). 4 - Top liquid up until the pipes inside the radiator are covered by about 5 mm. 5 - For engines equipped with separate expansion tank, pour in fluid until reaching the max level mark.
  • Page 168 INFORMATION ABOUT OPTIONAL COMPONENTS Warning • Before proceeding with operation, carefully read Par. 3.3.2. 11.1 Oil dipstick in cylinder head 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 169 INFORMATION ABOUT OPTIONAL COMPONENTS NOTE: Check the integrity of the gaskets J. 4 - Insert the dipstick B inside the hose E. Fig. 11.5 11.2 Heater (replacement) 11.2.1 Disassembly 1 - Undo the screws A and the relevant washers and remove the earth cable B.
  • Page 170 INFORMATION ABOUT OPTIONAL COMPONENTS 11.3 Poly-V alternator belt (replacement and adjustment) 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 2 - Untighten the screw B by around 32mm (A). 3 - Untighten the screw C.
  • Page 171 INFORMATION ABOUT OPTIONAL COMPONENTS 11.4 Tightening pulley and alternator for Poly-V belt 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 172 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 - Insert the spacer R on the screw H (between the alternator and crankcase).
  • Page 173 INFORMATION ABOUT OPTIONAL COMPONENTS 11.5 Idler gear (for 3 PTO) 11.5.1 Disassembly 1 - Undo the screw A and remove the gear unit B. Fig. 11.20 2 - Remove the retainer ring C from the seat of the pin D. 3 - Remove the shoulder washer E, the gear B, the shoulder ring F and the bushing G from the pin D.
  • Page 174 INFORMATION ABOUT OPTIONAL COMPONENTS 11.6 3 PTO (replacement) Fig. 11.24 11.6.1 Disassembly 1 - Undo the screws A and remove the pump B. Fig. 11.25 2 - Remove the centring ring C and the relative gaskets. 3 - Undo the screws N. Fig.
  • Page 175 INFORMATION ABOUT OPTIONAL COMPONENTS 4 - Remove the flange F with the components D, E, G and H in the direction of the arrow P. 5 - Remove the gasket J. Fig. 11.27 6 - Remove the retainer ring D and the shoulder washer E. 7 - Remove the gear H and the shoulder ring G from the flange F in the direction of the arrow Q.
  • Page 176 INFORMATION ABOUT OPTIONAL COMPONENTS 4 - Secure the flange F using the screws N (tightening torque at 25 Nm). Fig. 11.31 Important • Always replace the gaskets P and Q at each assembly. 5 - Insert the centring ring C in the flange F up to the stop. 6 - Position the pump B on the flange F engaging the gear H.
  • Page 177 INFORMATION ABOUT OPTIONAL COMPONENTS 11.7.1 Disassembly 1 - Undo the screws A and remove the pump B. Fig. 11.34 2 - Undo the screws C and remove the flange D. Fig. 11.35 3 - Undo the screws E and remove the cover F. Fig.
  • Page 178 INFORMATION ABOUT OPTIONAL COMPONENTS 5 - Remove the retainer ring H and the shoulder ring J from the flange K. 6 - Remove the gear N and the shoulder ring M from the flange Fig. 11.38 11.7.2 Assembly Important • Always replace the gasket P at each assembly. •...
  • Page 179 INFORMATION ABOUT OPTIONAL COMPONENTS Important • Always replace the gasket V after each assembly. 5 - Insert gasket V on cover F, insert and position the cover F on flange K. 6 - Secure the cover F using the screws E on the flange K (tightening torque at 25 Nm).
  • Page 180 INFORMATION ABOUT OPTIONAL COMPONENTS 11.8 3 PTO (configurations) Fig. 11.45 11.8.1 Information Hydraulic pumps on the 3 and 4 PTO can be installed at the same time. In some configurations, there is also the centering ring C on the 4 PTO.
  • Page 181 INFORMATION ABOUT OPTIONAL COMPONENTS 11.9 Balancer device (replacement) 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 3 - Undo the screws C and remove the hose D. Fig.
  • Page 182 INFORMATION ABOUT OPTIONAL COMPONENTS 6 - 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 183 INFORMATION ABOUT OPTIONAL COMPONENTS 5 - Manually tighten the retainer screw ST_15 on the box F by slightly rotating the shaft K, centring the hole on it using the ST_15, to lock the device. ST_15 Fig. 11.55 6 - Rotate the crankshaft and clamp it on the TDC (Ref. P upwards) using the tool ST_34 secured in place of the starter motor (detail Q).
  • Page 184 INFORMATION ABOUT OPTIONAL COMPONENTS 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 • The safety cartridge E (if present) must always be replaced if it is dirty or damaged.
  • Page 185 INFORMATION ABOUT OPTIONAL COMPONENTS 11.11.2 Assembly Important • Always replace the gaskets P, Q, R and U at each assembly. • Lubricate the gaskets P, Q and R with oil before assembling them. 1 - Insert the gasket P on the seat of the fitting K. 2 - Insert flange head J on the union K and the gasket Q in the seat of head J.
  • Page 186 INFORMATION ABOUT OPTIONAL COMPONENTS 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.
  • Page 187 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 - Place flange housing or plate L onto crankcase H, complying with centring tap pins M.
  • Page 188 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. 11.74 11.12.5 F l a n g e p l a t e / h o u s i n g assembly 1 - Execute the operations described in point 6 of Par.
  • Page 189 INFORMATION ON ADJUSTMENTS Warning • Before proceeding with operation, carefully read Par. 3.3.2. 12.1 Waste Gate opening valve regulation Important • Regulation must not be carried out with the engine running. During the procedure in point 5, pay special attention not to bend rod H.
  • Page 190 INFORMATION ON ADJUSTMENTS 12.2 Air filter check 1 - All manifolds connected to the turbo must be fully clean and not damaged. 2 - Clean the inside components A and D with a damp cloth. 3 - Do not use compressed air, repeatedly tap the front side E on a flat surface.
  • Page 191 INFORMATION ON ADJUSTMENTS 12.5 Oil leak check 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 - It is anyhow necessary to also check the seals of all main components and their surface contact, such as: - crankcase and gasket (side 1a PTO)
  • Page 192 NOTE ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ED0053029590...
  • Page 193 TOOLS INFORMATION 13.1 Information regarding specific tools For reference check the specific tools manual, cod. ED0053030770-S, to be found at: http://iservice.lombardini.it ED0053029590...
  • Page 194 INFORMATION ABOUT FAILURES 14.1 Possible causes and trouble shooting IMMEDIATELY STOP THE ENGINE WHEN: Tab. 14.1 contains the possible causes of some failures, which may occur during operation. 1 - Engine rpm increases and decreases suddenly without Always perform these simple checks before removing or being able to control them;...
  • Page 195 INFORMATION ABOUT FAILURES TROUBLES POSSIBLE CAUSE Oil level too high Oil level low Dirty or blocked pressure regulating valve Worn oil pump Air in the oil suction pipe Oil suction hose clogged Oil steam exhaust pipe clogged Damaged electronic injectors Damaged injection pump Wrong injector IMA codes Insufficient coolant...
  • Page 196 Alternator: electrical energy. Authorised service station: KOHLER authorised workshop. Authorised workshop: Kohler authorised service centre. A device that reduces vibrations caused by movement of the Balancer device: alternating weights (Crankshaft - Connecting rods - Pistons). Base configuration: Engine having components represented in Par. 1.4 - 1.5.
  • Page 197 GLOSSARY A group of maintenance actions that have the sole objective to control and replace elements on their expiry, without modifying Maintenance - periodic: or improving the functions carried out by the system, neither increasing the value nor improving performance. MAX: Maximum.
  • Page 198 GLOSSARY Torque: Force applied to an object that rotates on an idler shaft. Trochoid: Rounded toothed profile (also known as "lobes"). Device that compresses air intake by sending it to the intake Turbocharger: manifold by means of a turbine. Oil altered by operation or time, which is no longer compliant Used oil: for correct lubrication of the components.
  • Page 199 GLOSSARY TAB. 15.1 SYMBOLS AND UNITS OF MEASUREMENT SYMBOL UNIT OF MEASUREMENT DESCRIPTION EXAMPLE α degree Rotation/inclination angle 1° square centimetre Area 1 cm millimetre Circumference Ø Ø 1 mm newton-metre Torque 1 Nm millimetre 1 mm Dimension 1/1000 of a millimetre μm 1 μm (micron)
  • Page 200 TP-6916 04/16 Lombardini s.r.l. is a part of Kohler Group. E U R O P E U S A & C A N A D A F R A N C E Lombardini has manufacturing facilities Lombardini Srl Kohler Co.

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