Kohler KDI 2504 TM Workshop Manual
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Kohler KDI 2504 TM Workshop Manual

Kohler KDI 2504 TM Workshop Manual

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1903 TCR -2504 TCR
KDI 2504 TM
WORKSHOP MANUAL
MANUALE OFFICINA

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  • Page 1 1903 TCR -2504 TCR KDI 2504 TM WORKSHOP MANUAL MANUALE OFFICINA...
  • Page 2 REGISTRATION OF MODIFICATIONS TO THE DOCUMENT Any modifications to this document must be registered by the drafting body, by completing the following table. Drafting Code Date Model Date Written by Endorsed Edition Revision body document issue N° Review 512352 1° 10/2014 10/2014 DICOM/ATLO...
  • Page 3 MO KDI 2504TM_code ED0053030350 - 1st ed_rev. 00...
  • Page 4 ANALYTICAL INDEX 3rd + 4th PTO (configurations) ........143 control, Rubber hose and manifold ......154 3rd PTO (replacement) ............ 137 Coolant (chapter technical information) ......25 4th PTO (replacement) ............. 139 Coolant (chapter fluids supply) ........132 Coolant (chapter liquid drainage) ........56 Coolant circuit (chapter technical information) ....
  • Page 5 ANALYTICAL INDEX Electric component assembly ........126 Handling, Components ............. 49 Electric components disassembly ........72 Heater (replacement) ............135 Electric system ..............38 Electrical components ............42 Identification of the external components of the engine (BASE CONFIGURATION) ..........16 Engine block assembly ...........
  • Page 6 ANALYTICAL INDEX Safety signals description ..........52 Sensors and switches ............41 Oil filter replacement ............71 Signals description, Safety ..........52 Oil (chapter technical information) ........23 specific tools, Information regarding ......156 Oil dipstick in cylinder head ........... 134 Specifications, Engine ............
  • Page 7 NOTES ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................MO KDI 2504TM_code ED0053030350 - 1st ed_rev. 00...
  • Page 8 CHAPTER INDEX GENERAL INFORMATION 2.15 Electrical components Useful information 2.15.1 Alternator 1.1.1 Useful Information -accident prevention 2.15.2 Starter motor - environmental impact 2.15.3 Cold starting device (Heater) 2.15.4 Electric fuel pump (optional) Manufacturer and engine identification 2.15.5 Cold Start Advance Identification of the main internal 2.15.6 Electro-Stop...
  • Page 9 CHAPTER INDEX (injection pump/injectors) 7.6.3 Timing system 6.1.2 Rocker arms cover disassembly 7.6.4 Oil pump 6.1.3 Fuel return pipes disassembly 7.6.5 Oil cooler unit 6.1.4 Injectors disassembly 6.1.5 Injection pump disassembly Intake manifold disassembly 6.1.6 Injection pump assembly Fuel system disassembly 6.1.7 Injector assembly 7.8.1...
  • Page 10 CHAPTER INDEX 9.7.9 Rocker arm pin assembly Crankshaft 8.4.1 Dimensional check and overhauling Fuel system assembly 8.4.2 Checking the axial clearance of the 9.8.1 Injector crankshaft 9.8.2 Fuel injector ricicle pipe 9.8.3 Rocker arm cover Connecting rod - piston assembly 9.8.4 Installation of the fuel injector pipes 8.5.1...
  • Page 11 CHAPTER INDEX 11.5.1 Disassembly 11.5.2 Assembly 11.6 PTO (configurations) 11.6.1 Information 11.7 Balancer device (replacement) 11.7.1 Disassembly 11.7.2 Assembly 11.8 Air filter (cartridge replacement) 11.9 Remote oil filter (disassembly and assembly) 11.9.1 Disassembly 11.9.2 Assembly 11.10 Intake circuit (replacement) 11.10.1 Air filter disassembly 11.10.2 Manifold air filter disassembly...

  • Page 12: General Information

    Therefore, the information in this manual is subject to change safety and the environment. 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 nameplate is located on side find timing system or flywheel as below. Fig. 1.1 Fig. 1.2 Engine type Engine serial number Manufacturer identification Engine version Approval data and "EC" directives Fig.
  • Page 14 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 The following chapters contain operating references in order Tab. 1.1 to clearly understand the engine. This paragraph illustrates REF.
  • Page 15 GENERAL INFORMATION VIEW OF FLYWHEEL SIDE Fig. 1.5 VIEW OF TIMING SYSTEM SIDE Fig. 1.6 MO KDI 2504TM_code ED0053030350 - 1st ed_rev. 00...
  • Page 16 GENERAL INFORMATION 1.4 Identification of the external components of the engine (BASE CONFIGURATION) VIEW OF TIMING SYSTEM SIDE EXHAUST Oil filler cap Turbocharger Thermostat Oil pressure sensor Water coolant sensor Oil filler cap Starter motor Coolant pump Oil steam separator Nameplate Alternator Oil drain plug...
  • Page 17 NOTES ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................MO KDI 2504TM_code ED0053030350 - 1st ed_rev. 00...
  • Page 18 NOTES ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................MO KDI 2504TM_code ED0053030350 - 1st ed_rev. 00...

  • Page 19: Technical Information

    TECHNICAL INFORMATION 2.1 Engine specifications Tab. 2.1 MANUFACTURER SPECIFICATIONS AND OPERATION UNIT OF GENERAL INFORMATION KDI 2504 TM MEASURE Operating cycle diesel - 4-stroke Cylinders Bore x stroke 88x102 Displacement 2482 Compression ratio 17:1 Intake Atmospheric pressure Cooling Liquid Crankshaft rotation (view from flywheel side)
  • Page 20 TECHNICAL INFORMATION LUBRICATION CIRCUIT UNIT OF GENERAL INFORMATION KDI 2504 TM MEASURE Lubrication Recommended oil see Par. 2.4 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 µm...
  • Page 21 TECHNICAL INFORMATION 2.2 Engine dimensions (mm) 734.4 Fig. 2.1 MO KDI 2504TM_code ED0053030350 - 1st ed_rev. 00...
  • Page 22 NOTES ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................MO KDI 2504TM_code ED0053030350 - 1st ed_rev. 00...
  • 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 Important • For the operation of the engine at temperatures lower than 0 ° C suitable for use fuels normally distributed by • Use the same type of diesel fuel as used in cars (EN the oil companies and in any case corresponding to the 590 for E.U.

  • Page 25: Technical Specifications

    2.6 Coolant Tab. 2.6 TECHNICAL SPECIFICATIONS 50% ETYLENGLYCOL e 50% DECALCIFIED WATER 50% PROPYLENGLYCOL e 50% DECALCIFIED WATER 2.7 Battery features Battery not supplied by Kohler Tab. 2.7 RECOMMENDED BATTERIES AMBIENT TEMPERATURE BATTERY TYPE 100Ah/20h - 424 A/DIN from 0°C to -10°C...
  • 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 PERIOD (HOURS) OPERATION DESCRIPTION 1000 1500...
  • Page 27 TECHNICAL INFORMATION 2.9 Fuel system 2.9.1 Supply system (Fig. 2.4) Important • If the engine is cleaned with high pressure washer, then the • The high pressure supply injection system is highly susceptible nozzle must be kept at a minimum distance of 200mm from to damage if the fuel is contaminated.

  • Page 28: Components Description

    TECHNICAL INFORMATION 2.9.2 Fuel return circuit The fuel return circuit is under low pressure. Tab. 2.11 POS. DESCRIPTION Injectors Injectors fuel return pipe Injection pump Fuel tank Fuel return pipe to the tank Fig. 2.5 2.9.3 Injection pump Pressure into the injection pump must be positive in all operating conditions.
  • Page 29 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 30 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 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 31 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. On the parts of the systems shown in green on In the parts in green, the oil is in intake, in the parts in red, the oil is under pressure and in those in yellow the oil is returning towards the oil sump 2 (not under pressure).
  • Page 32 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 visible by the operator.
  • Page 33 TECHNICAL INFORMATION 2.10.3 Oil filter Fig. 2.16 Tab. 2.20 POS. DESCRIZIONE Oil cartridge Filter element Gasket Safety valve Upper cranckcase Inlet oil Oil filtering Output oil (sent to the circuit) Tab. 2.21 Cartridge characteristics DESCRIPTION VALUE Filtering surface 2.000 cm Degree of filtration 15 µm Max operating pressure...
  • Page 34 TECHNICAL INFORMATION 2.11 Coolant circuit 2.11.1 Coolant circuit diagram Tab. 2.22 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.
  • Page 35 Tab. 2.25 POS. DESCRIPTION Radiator Coolant refill cap Vent tube or excess coolant return Coolant flow manifold Coolant intake manifold Protective grid Fig. 2.20 Fig. 2.21 NOTE: Component not necessarily supplied by KOHLER. MO KDI 2504TM_code ED0053030350 - 1st ed_rev. 00...
  • Page 36 TECHNICAL INFORMATION 2.12 Intake and exhaust circuit Air in intake Gas in exhaust Fig. 2.22 Fig. 2.23 MO KDI 2504TM_code ED0053030350 - 1st ed_rev. 00...
  • Page 37 Exhaust muffler (optional) 2.12.1 Air filter (optional) Tab. 2.27 POS. DESCRIPTION NOTE: Component not necessarily supplied by KOHLER. Air filter cartridge Important Filter cover • The air filter is a dry-type one, with a replaceable paper filter Filter support cartridge H (refer to Tab. 2.8 and Tab. 2.9 for procedure Dust exhaust valve frequency on components).
  • Page 38 TECHNICAL INFORMATION 2.13 Electric system 2.13.1 Engine electrical wiring (opzional) Tab. 2.28 NOTE: Component not necessarily supplied by KOHLER. DESCRIPTION REF. Electrical wiring is supplied upon request, it interfaces with Engine panel connector interface (Fig. 2.26a) the panel by means of 19-way Deutsch connectors (female Accessories panel connector interface (Fig.
  • Page 39 TECHNICAL INFORMATION 2.13.1.1 Connector panel on the engine/machine Tab. 2.29 INLET SIGNALS TO THE PANEL PIN. The connector is a female 19-way Deutsch type. There is a list of all PIN connections in Tab. 2.29. Oil pressure switch Alternator indicator light Coolant temperature warning light Air cleaner clogging warning light Outlet indicator general alarm...
  • Page 40 TECHNICAL INFORMATION 2.13.1.3 Wiring disconnection Some sensor connectors and electronic control devices are sealed. This tipe of connectors must be disconnected by means of pressure on tabs or unblock the retainers B, as illustrated from Fig. 2.26c to Fig. 2.26g. Fig.

  • Page 41: Oil Pressure Switch

    TECHNICAL INFORMATION 2.14 Sensors and switches 2.14.1 Fuel filter water detection sensor 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 warning lamp in the panel board switches on the dashboard of the car on which the motor is mounted.
  • Page 42 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 43 TECHNICAL INFORMATION 2.15.4 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. 2.33 indicates the pumps' features.

  • Page 44: Control Panel (Optional)

    Fuse 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 2.15.8 Control panel (optional) Panel L can be assembled on the engine or machine.

  • Page 45: Components Identification

    TECHNICAL INFORMATION 2.16 Timing system and tappets The distribution 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. 2.35 POS. DESCRIPTION Crankshaft Camshaft Camshaft tappets Rocker arm control rod...
  • Page 46 TECHNICAL INFORMATION 2.16.2 Timing system phasing angles VIEW OF TIMING SYSTEM SIDE Important Crankshaft rotation • For information purposes, Tab. 2.36 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 47 TECHNICAL INFORMATION 2.16.5 Hydraulic tappets Tab. 2.39 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 48 TECHNICAL INFORMATION 2.17 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.
  • Page 49 TECHNICAL INFORMATION 2.18 Components handling 2.18.1 Injection pump - Only handle by means of the points marked by Y. - It is forbidden to handle using the points marked by N. Fig. 2.51 2.18.2 Injector - Only handle by means of the points marked by Y. - It is forbidden to handle using the points marked by N.

  • Page 50: Safety Information

    • In the event KOHLER does not approve the type of prescribed health and safety requirements. Any use of the modification, KOHLER shall not be held responsible for any...
  • Page 51 • 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 52: Safety Signal Description

    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 53 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 54 SAFETY INFORMATION 3.7 Location of safety signals on engine MO KDI 2504TM_code ED0053030350 - 1st ed_rev. 00...

  • Page 55: Storage Information

    STORAGE INFORMATION 4.1 Product preservation With a high-pressure flushing or steam it is important to keep a minimum distance of at least 200 mm between the surface to be washed and the nozzle. Important Avoid absolutely parts such as alternator, starter motor and control unit.
  • Page 56 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 57 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 58 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 6.1 Injector and injection pump replacement Important • Before proceeding with operation, carefully read Par. 3.3.2. • Replace the high pressure pipes after two disassemblies. • The injectors cannot be repaired but must be replaced. •...

  • Page 59: Injection Pump Disassembly

    INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 6.1.3 Fuel return pipes disassembly 1 - Undo the screws M and remove hose N. Fig. 6.5 6.1.4 Injectors disassembly 1 - Undo the screw P and remove washer Q and then bracket 2 - Remove the injector Z. NOTE: Should you be unable to remove the electronic injector (acting only on point BC), use an open-ended spanner (Ã...
  • Page 60 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 2 - Disassemble the starter motor. 3 - Mount the tool ST_02 in the seat of the starter motor fit it with the two starter motor fixing screws. 4 - Rotate the crankshaft clockwise (as seen from the timing system side - Ref.
  • Page 61 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 10 - Undo and remove the nut AN fixing the injection pump control gear AE. Important • After removing the nut AN, ensure that the correct advance value has remained unchanged on ST_30. • Be careful that the nut AN does not fall into the timing cover. Fig.
  • Page 62 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 6.1.6 Injection pump assembly Important • Before assembling the new pump AG, make sure that plate AB can move freely and that fastening capscrews K are not loose (the pump sold as a spare part is supplied with the cylinder injection timing blocked N°...
  • Page 63 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 6.1.7 Injector assembly Important • To prevent damaging the injection system, the protection caps (Par. 2.9.7) must be removed during assembly. 1 - Lubricate the gaskets U, T, S, and fit them on the injector Fig.
  • Page 64 3 - Attach the rocker arm cover C on the head AL with the screw L adhering to the tightening sequence shown in Fig. 6.28 (KDI 2504 TM) (tightening torque to 10 Nm). 4 - Connect pipe H and tighten the clamp G. Warning •...
  • Page 65 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 6.1.10 I nst allat ion of t he fue l inje ct o r p i p e s (pump injector/injectors) 1 - Position pipes D on the injectors and on the injector pump. Important •...
  • Page 66 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 6.2 Coolant pump replacement 6.2.1 Disassembly 1 - Perform the operations described in Par. 5.1. Importante • Before proceeding with operation, carefully read Par. 3.3.2. • The coolant pump is not repairable. 2 - Loosen the screws A and B. 3 - Push the alternator C in the direction of the arrow D and remove the belt E.
  • Page 67 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 6.3 Replace the crankshaft pulley 6.3.1 Disassembly NOTE: Perform the operations described in Par. 6.1.5, steps 2 and 3. 1 - Position the crankshaft with the 1st cylinder in PMS, reference upwards. 2 - Remove the alternator belt following steps 2 and 3 (Par.
  • Page 68 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 6.4 Oil pump replacement Important • Before proceeding with operation, carefully read Par. 3.3.2. • The oil pump is not repairable. 6.4.1 Coolant pump disassembly 1 - Perform the operations described in Par 6.2.1. 6.4.2 Engine pulley disassembly 1 - Perform the operations described in Par 6.3.1...
  • Page 69 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 6.4.5 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. 2 - When assembling, do not use any type of gasket between E and C.
  • Page 70 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 Par 6.3.2. 6.4.8 Coolant pump assembly 1 - Perform the operations described in Par 6.2.2.
  • Page 71 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 •...

  • Page 72: Disassembly Information

    DISASSEMBLY INFORMATION 7.1 Recommendations for disassembly • Before proceeding with operation, carefully read Chap. 3. Important • In order to operate safely and easily, we recommend positioning the engine on a rotating stand for engine • To locate specific topics, the reader should refer to the index. overhauling.
  • Page 73 DISASSEMBLY INFORMATION 7.2.4.2 Coolant temperature sensor ( 1 - Unscrew and remove the sensor L. Fig. 7.4 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.
  • Page 74 DISASSEMBLY INFORMATION 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 disassembled. 3 - Check that the air bleeding hole is not clogged or blocked (Par.
  • Page 75 DISASSEMBLY INFORMATION 7.6.3 Timing system 1 - Ensure that the crankshaft with the 1st cylinder is at the TDC (taper pin W must be facing upwards). 2 - Undo the screws X. 3 - Remove the timing system crankcase H. Fig.
  • Page 76 DISASSEMBLY INFORMATION 7.7 Intake manifold disassembly 1 - Loosen clamp A and disconnect hose B. Fig. 7.16 2 - Undo the screws C and remove the manifold D together with the washer E. Fig. 7.17 7.8 Fuel system disassembly Important •...

  • Page 77: Injection Pump

    DISASSEMBLY INFORMATION 7.8.3 Fuel return pipes 1 - Undo the screws L and remove hose H. Fig. 7.20 7.8.4 Injector 1 - Undo the screws P and remove the washers Q and then the brackets M. 2 - Pull out the injectors N. NOTE: Should you be unable to remove the injector (acting only on point BC), use an open-ended spanner (Ã...
  • Page 78 DISASSEMBLY INFORMATION 5 - Tighten the screw U of the unit in order to separate the injector pump S from the high pressure pump control gear Fig. 7.24 7.8.6 Fuel filter ( NOTE: to disassemble the fuel cartridge, refer to operations 3 and 4 of Par.
  • Page 79 DISASSEMBLY INFORMATION 7.10 Flange unit disassembly 7.10.1 Flywheel Important • Leave the special tool ST_02 for blocking the flywheel. 1 - Only undo the screw C located upwards. 2 - Insert the tool ST_09 in the seat of the screw C tightening it all the way.
  • Page 80 DISASSEMBLY INFORMATION 7.11 Cylinder head unit disassembly 7.11.1 Rocker arm pin 1 - Undo the screws D. 2 - Remove the rocker arm pin unit E. Fig. 7.30 7.11.1.1 Rocker arm ( 1 - Remove the retainer snap ring C. 2 - Remove the shoulder rings D.

  • Page 81: Cylinder Head

    1 - Undo the bolts M. Important • Only use the eyebolts AE installed by KOHLER to move the cylinder head Q (refer to Fig. 7.41). Fig. 7.34 • When removing the cylinder head Q and subsequent...
  • Page 82 DISASSEMBLY INFORMATION 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 - Unscrew and remove the sleeves Z from the head Q.
  • Page 83 DISASSEMBLY INFORMATION 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 - Undo the screws C and remove the oil pipe D.
  • Page 84 DISASSEMBLY INFORMATION 7.13 Engine block disassembly 7.13.1 Crankshaft gasket flange 1 - Undo the screws A. 2 - Remove the flange B and the gasket C. Fig. 7.45 7.13.2 Piston unit / connecting rod Important • Mark some references on the connecting rods, caps F, pistons and gudgeon pins to prevent unintentionally confusing the components during reassembly.
  • Page 85 DISASSEMBLY INFORMATION 7.13.3 Lower semi-crankcase 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 container suitable for washing. Fig. 7.50 MO KDI 2504TM_code ED0053030350 - 1st ed_rev. 00...
  • Page 86 DISASSEMBLY INFORMATION 7.13.4 Crankshaft Remove: 1 - Crankshaft G. 2 - The four shoulder semi-rings H. Fig. 7.51 7.13.5 Piston ( 1 - Remove the retainer ring N. 2 - Remove the pin P to separate the piston Q from the connecting rod R.
  • Page 87 DISASSEMBLY INFORMATION 7.13.7 Camshaft 1 - Remove the retainer ring V. 2 - Extract the camshaft W from the upper crankcase AB. Fig. 7.55 7.13.8 Camshaft tappets 1 - With a magnet, remove the tappets AA from the upper semi-crankcase AB. Fig.
  • Page 88 DISASSEMBLY INFORMATION 7.13.10 Cover 3 PTO ( 1 - Undo the screws AG. 2 - Remove the cover AH and the gasket AL. Fig. 7.59 MO KDI 2504TM_code ED0053030350 - 1st ed_rev. 00...
  • Page 89 NOTES ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................MO KDI 1903M_2504M_code ED0053029610 - 2 ed_rev. 02...
  • Page 90 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 91 INFORMATION ABOUT OVERHAULING 8.2 Crankcase 8.2.1 Oil line check Use a pipe cleaner in access points A, B, C, D, to clean the Replace and assemble the conical cap in hole B (B1 if present oil ducts of crankcase G. - tightening torque at 30 Nm) and caps in holes D, after having Use compressed air to eliminate any residues.
  • Page 92 Importante • T he grinding involved is of +0.20, +0.50 and + 1 mm. • C ylinder grinding operations must observe KOHLER SPECIFICATIONS - cod. ED0035612500. • G rinding must be strictly performed on all cylinders F. Tab. 8.1a details the dimensional values of new components only.
  • Page 93 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 94 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 95 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 96 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 97 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 98 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 99: Seal Rings

    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 100 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 101 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 102 INFORMATION ABOUT OVERHAULING 8.7.2 Rotors clearance check Important • Replace carter R complete with its oil pump, if there are signs of wear in area of surface Q (Fig. 8.29 - 8.29a). Measure values (Fig. 8.27). Measure values L, (Fig. 8.28). According to the values measured, calculate the clearance between and H,...
  • Page 103 ....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................MO KDI 2504TM_code ED0053030350 - 1st ed_rev. 00...

  • Page 104: Assembly Information

    ASSEMBLY INFORMATION 9.1 Information on engine configuration • In this chapter, the engine is represented as "BASE CONFIGURATION" (refer to Par 1.4 - 1.5). • For the assembly of components not described in this chapter refer to Chapter 11. • The following are the components described in Chapter 11. 11.1 Oil dipstick in cylinder head 11.2 Heater (replacement) 11.3 Idler gear (for 3rd / 4th PTO)
  • Page 105 ASSEMBLY INFORMATION 9.3 Engine block assembly 9.3.1 Semi main bearings 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 106 ASSEMBLY INFORMATION 9.3.4 Breather room closing cover 1 - With the screws CF tighten the cover CG and the gasket CH (tightening torque to 10 Nm). Fig. 9.5 9.3.5 Crankshaft Important • Carry out the checks described in Par. 8.4.1 and Par. 8.4.2. 1 - Check that the crankshaft half-bearings are mounted correctly on the upper crankcase E.
  • Page 107 ASSEMBLY INFORMATION Important • Failure to follow the bolting procedures compromises the functionality of the engine and can cause damage to people and property. 6 - Tighten the fastening screws strictly following the sequence and the tightening torque indicated. Tightening sequence for 4 cylinders Tightening Screws Torx M12x1,25 (from the n° 1 to the n° 10): CYCLE 1 - with a torque of 40 Nm; CYCLE 2 - with a torque of 70 Nm; CYCLE 3 - with a torque of 120 Nm.
  • Page 108 ASSEMBLY INFORMATION 9.3.7 Piston rings 1 - Perform the operations described in Par. 8.5.3. 2 - Put the oil control ring AP onto the piston AQ. 3 - Put the 2° compression ring AR on the piston AQ. 4 - Put the 1° compression ring AS onto the piston AQ. Fig.

  • Page 109: Piston And Connecting Rod Assembly

    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. 2 - Push the piston AQ downwards by centering the crankpin BG with the connecting rod AZ.
  • Page 110 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 M after each assembly. 1 - Check that there are bushings BT on the crankcase E . 2 - Lubricate the oil seal lip BU.
  • Page 111 ASSEMBLY INFORMATION 9.4 Oil sump unit assembly 9.4.1 Oil vapour pipe 1 - Apply Loctite 648 on the pipe threads A. 2 - Screw and tighten the pipe A tightening torque of 15 Nm). Fig. 9.23 9.4.2 Oil suction pipe Important •...
  • Page 112 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 A adhering to the reference pins B on the base C.
  • Page 113 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 114 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 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 115 ASSEMBLY INFORMATION 9.7 Cylinder head unit assembly 9.7.1 Valve stem gasket ST_08 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 116 ASSEMBLY INFORMATION 9.7.4 Valves 1 - Lubricate the valve stem and insert the valves X inside the head F in the same positions of origin, based on the marks made in Par. 7.11.3.1. 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 117 Important • Failure to follow the bolting procedures compromises the functionality of the engine and can cause damage to people and property. • Tighten capscrews V observing the cycles, tightening, and subsequent rotation as indicated in Tab. 9.3. • For engine KDI 2504 TM: 10 screws Torx M12x1,25 (Fig. 9.50). MO KDI 2504TM_code ED0053030350 - 1st ed_rev. 00...
  • Page 118 ASSEMBLY INFORMATION Tab. 9.3 4 CYLINDERS CYCLE TORQUE 40 Nm 70 Nm 100 Nm 90° 90° 90° Fig. 9.50 9.7.6 Rods and valve bridges 1 - Insert the rocker control rods AA into the niches of the head F. Important •...
  • Page 119 ASSEMBLY INFORMATION 9.7.8 Rocker arms Important • To correctly position the rocker arms, turn the rocker arms pin AH with the lower height towards the timing system side as in Fig.9.54. • 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 120 ASSEMBLY INFORMATION BP = -90° BQ = -90° Fig. 9.58a Fig. 9.58b 9.8 Fuel system assembly Important • Replace the high pressure pipes after two disassemblies. • The injectors cannot be repaired but must be replaced. • Remove the protective caps from all the components of the fuel circuit just before assembly (Par.
  • Page 121 ASSEMBLY INFORMATION 3 - Assemble parts P, Q, R. 4 - Fit the parts so assembled on the injector Z. Fig. 9.62 5 - Perform the operations 1 and 2 described in Par. 9.8.3 and the operation 1 in Par 9.8.4.

  • Page 122: Fuel Filter

    ASSEMBLY INFORMATION 3 - Fit the rocker arm cap C on the head AL via the screws L observing the clamping sequence illustrated in Fig. 9.67b (KDI 2504 TM) (tightening torque at 10 Nm). 4 - With vaseline lubricate the gaskets AK. Fig. 9.66 Fig. 9.67b 9.8.4 I nst allat ion of t he fue l inje ct o r p i p e s...
  • Page 123 ASSEMBLY INFORMATION 9.9 Intake manifold assembly ST_18 Important • Check that the contact surfaces between the collector C and the head D are free from impurities. 1 - Insert ST_18 special tool into market point. 2 - Mount the gasket A on the head D. 3 - Mount the manifold C on the head D.
  • Page 124 ASSEMBLY INFORMATION 5 - Check that the 2 pins AM are inserted properly in the crankcase timing system AN. 6 - Position the oil pump assembly AG using the pin marks 7 - Fasten the oil pump cover AG with the screws AH (tightening torque 10 Nm).
  • Page 125 ASSEMBLY INFORMATION 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 - Clamp the flange BB on the crankcase BC with the screws BD (tightening torque of 10 Nm - ST_06).
  • Page 126 ASSEMBLY INFORMATION 9.13.2 Coolant pump Important • Always replace the gasket L every time it is assembled. 1 - Fit the pump G with the screws H interposing the gasket L (tightening torque of 25 Nm). Fig. 9.82 9.14 Electric component assembly 9.14.1 Sensors and switches 9.14.1.1 Coolant temperature sensor...
  • Page 127 ASSEMBLY INFORMATION 9.14.2 Alternator 1 - Mount the bracket G on the head using the screw H and relative washer, without clamping it. 2 - Fit the alternator with the screw A with the relative washer and spacer B. 3 - Mount the alternator C on the crankcase F tightening the nut E up to the stop without clamping it.

  • Page 128: Base Configuration

    ASSEMBLY INFORMATION 9.15 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 Breather room closing cover fastening capscrew (EXHAUST SIDE) M6x1 Lower crankcase fastening capscrew M12x1.25 3 Torque cycles 1st Cycle...
  • Page 129 ASSEMBLY INFORMATION Alternatively to the capscrew replacements, with "Dri-loc" INJECTION SYSTEM Component Thread (mm) Torque (Nm) Sealer Injector brace fastening capscrew M8x1.25 Waste line fastening drilled capscrew/nipple on Cyl. head M8x1 Waste line fastening drilled capscrew on injectors M6x1 Injector side injection tube nuts M12x1.5 Injection pump side injection tubes nuts M12x1.5...
  • Page 130 ASSEMBLY INFORMATION Alternatively to the capscrew replacements, with "Dri-loc" OPTIONAL COMPONENTS (CHAP. 11) OIL DIPSTICK ON CYLINDER HEAD Component Thread (mm) Torque (Nm) Sealer Oil dipstick tube fastening capscrew M6x1 HEATER Component Thread (mm) Torque (Nm) Sealer Flange intake with heater fastening capscrew M8x1.25 IDLE GEAR (FOR 3TH /4TH PTO) Component...
  • Page 131 ....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................MO KDI 2504TM_code ED0053030350 - 1st ed_rev. 00...
  • Page 132 FLUIDS SUPPLY 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 of oil recommended (Par. 2.4). Fig.
  • Page 133 FLUIDS SUPPLY INFORMATION 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 134 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.
  • Page 135 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 136 INFORMATION ABOUT OPTIONAL COMPONENTS 11.3 Idler gear (for 3 PTO) 11.3.1 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 - Remove the shoulder washer E, the gear B, the shoulder ring F and the bushing G from the pin D.
  • Page 137 INFORMATION ABOUT OPTIONAL COMPONENTS 11.4 3 PTO (replacement) Fig. 11.12 11.4.1 Disassembly 1 - Undo the screws A and remove the pump B. Fig. 11.13 2 - Remove the centring ring C and the relative gaskets. 3 - Undo the screws N. Fig.
  • Page 138 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. 11.15 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 139 INFORMATION ABOUT OPTIONAL COMPONENTS 4 - Secure the flange F using the screws N (tightening torque at 25 Nm). 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 140 INFORMATION ABOUT OPTIONAL COMPONENTS 11.5.1 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 3 - Undo the screws E and remove the cover F. Fig.
  • Page 141 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. 11.26 11.5.2 Assembly Important • Always replace the gasket P at each assembly. •...
  • Page 142 INFORMATION ABOUT OPTIONAL COMPONENTS Important • Always replace the gasket T after each assembly. 7 - Position and secure the flange D using the screws C on the crankcase S (tightening torque 10 Nm - ST_06). Fig. 11.30 Important • Always replace the gasket U after each assembly. Position the gasket U on the flange D.
  • Page 143 INFORMATION ABOUT OPTIONAL COMPONENTS 11.6 3 PTO (configurations) Fig. 11.32 11.6.1 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 144 INFORMATION ABOUT OPTIONAL COMPONENTS 11.7 Balancer device (replacement) 11.7.1 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.
  • Page 145 INFORMATION ABOUT OPTIONAL COMPONENTS 6 - Remove the shafts J and K in the direction of the arrow L from box F. Fig. 11.38 11.7.2 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 146 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. 11.42 6 - Rotate the crankshaft and clamp it on the TDC (Ref.
  • Page 147 INFORMATION ABOUT OPTIONAL COMPONENTS 11.8 Air filter (cartridge replacement) 1 - Release the two hooks A and remove the cover B from the body C. 2 - Remove the cartridges D. Fig. 11.46 3 - Insert the new cartridge D and both of them inside the filter body C.
  • Page 148 INFORMATION ABOUT OPTIONAL COMPONENTS 5 - Unscrew the fittings L and remove the copper gaskets from the support M. 6 - Unscrew the cartridge N with gasket from the support M. Fig. 11.50 11.9.2 Assembly Important • Always replace the gaskets P, Q, V and U at each assembly. •...

  • Page 149: Air Filter Disassembly

    INFORMATION ABOUT OPTIONAL COMPONENTS 11.10 Intake circuit (replacement) 11.10.1 Air filter disassembly 1 - Release the clamp B. 2 - Untighten the screws A and remove the filter C. Fig. 11.53 11.10.2 Manifold air filter disassembly 1 - Release the clamp D. 2 - Remove the manifold E.
  • Page 150 INFORMATION ABOUT OPTIONAL COMPONENTS 11.11 Muffler (replacement) 11.11.1 Disassembly 1 - Undo the screw A. 2 - Undo the nuts B. 3 - Remove the muffler C. Fig. 11.57 11.11.2 Assembly 1 - Position the gasket D and the muffler C on the intake manifold E.
  • Page 151 INFORMATION ABOUT OPTIONAL COMPONENTS 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 - Loosen nuts N and remove radiator M. Fig. 11.63 11.12.2 Fan disassembly 1 - Undo the screws P and remove the plate Q from the fan R.
  • Page 152 INFORMATION ABOUT OPTIONAL COMPONENTS 11.12.3 Fan assembly 1 - Assemble the fan R on the pulley U. 2 - Position the plate Q on the fan R. 3 - Fasten the fan R by using the screws P and interposing washers S (tightening torque at 10 Nm).
  • Page 153 9 - Tighten the clamps A. Fig. 11.70 11.13 Engine feet (information) NOTE: Component not necessarily supplied by KOHLER. The representation of the radiator 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 154 INFORMATION ON ADJUSTMENTS AND CHECKS Warning • Before proceeding with operation, carefully read Par. 3.3.2. 12.1 Air filter check 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 155 INFORMATION ON ADJUSTMENTS AND CHECKS 12.3 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 oil seal (side 1a PTO)
  • Page 156 13.1 Information regarding specific tools Warning • KOHLER declines all responsibility for any damage to the In Tab 13.1 - 13.2 there is a list of all the specific tools that are engine, persons, or things caused by the use of different types required and approved to carry out operations of disassembly of tools to those indicated in Tab 13.1 - 13.2, , where referred...
  • Page 157 TOOLS INFORMATION Tab. 13.1 SPECIAL TOOLS FOR DISASSEMBLY AND ASSEMBLY "ST" Picture/Draw DESCRIPTION PART NUMBER ST_09 Tool for flywheel assembling / disassembling ED0014603610-S ST_10 Crankshaft gasket assembling tool ED0014603670-S Buffer insertion of a crankshaft gasket onto a ST_14 ED0014603750-S timing system carter ST_15 Locking screw balance shafts ED0097301980-S...
  • Page 158 TOOLS INFORMATION Tab. 13.2 SPECIFIC EQUIPMENT TO PROTECT COMPONENTS OF THE INJECTION CIRCUIT "ST" Picture/Draw DESCRIPTION PART NUMBER Box complete with caps to close holes and ST_40 unions for high-pressure injection circuit ED0082051380-S components. ST_25 Cap Ø6x20 (cap on the injector nozzle) ST_32 Cap M12x1.5 (fuel input union closure on injector) ST_33...
  • Page 159 NOTES ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................MO KDI 2504TM_code ED0053030350 - 1st ed_rev. 00...

  • Page 160: Information About Failures

    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 161 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 injectors Damaged injection pump Wrong injector IMA codes Insufficient coolant Defective fan, radiator, or radiator cap...
  • Page 162 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 Para. 1.4 - 1.5.
  • Page 163 GLOSSARY Par.: Paragraph. Paraffin: Fatty and solid substance that may form inside the diesel. An instrument having a metal cylindrical body with bristles that jut outwards. It is similar to a brush and is used to clean Pipe cleaner: areas that are not easily accessible manually (e.g. oil ducts inside an engine).
  • Page 164 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 Ø millimetre Circumference Ø 1 mm newton-metre Torque 1 Nm millimetre 1 mm Dimension 1/1000 of a millimetre μm 1 μm (micron)
  • Page 165 NOTES ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................MO KDI 2504TM_code ED0053030350 - 1st ed_rev. 00...
  • Page 166 Original instructions Data reported in this issue can be modified at any time by KOHLER. FORM NO. ED0053030350 ISSUED 10/2014 REVISED DATE 10/2014 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...

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