Table Of Contents - Kohler KD 625/2 Workshop Manual

This manual contains pertinent information regarding the repair of KOHLER air-cooled, direct injection Diesel engi-
nes type KD 625-2 - 625-2 EPA:
INDEX
California emission control warranty statement ................................................................................................................. 4
Your warranty rights and obligations .................................................................................................................................. 4
1 - GENERAL REMARKS AND SAFETY INFORMATION ...................................................................................... 9
Limited 3 year kohler ® diesel engine warranty .................................................................................................................. 9
General service manual notes ............................................................................................................................................ 9
Glossary and terminology ................................................................................................................................................... 9
Safety regulations ..............................................................................................................................................................10
General safety during operating phases ...........................................................................................................................11
Safety and environmental impact .....................................................................................................................................11
2 - TECHNICAL INFORMATION ............................................................................................................................. 12
Trouble shooting ................................................................................................................................................................12
Manufacturer and engine identification .............................................................................................................................14
The identification plate shown in the figure can be found directly on the engine. .............................................................14
Approval data .....................................................................................................................................................................14
Main components ..............................................................................................................................................................15
Techinical specifications ....................................................................................................................................................16
Fuel supply circuit ..............................................................................................................................................................17
Lubrication circuit ...............................................................................................................................................................17
Electrical system ................................................................................................................................................................17
Performance diagram ........................................................................................................................................................18
Overall dimension ............................................................................................................................................................. 20
3 - MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING ......................................................................... 22
Routine engine maintenance ............................................................................................................................................ 22
Extraordinary maintenance ............................................................................................................................................. 22
Ordinary maintenance ..................................................................................................................................................... 22
Lubricant ........................................................................................................................................................................... 23
Prescribed lubricant .......................................................................................................................................................... 24
Fuel recommendations ..................................................................................................................................................... 25
4 - DISASSEMBLY / REASSEMBLY ...................................................................................................................... 26
Recommendations for disassembling and assembling .................................................................................................... 26
Recommendations for overhauls and tuning .................................................................................................................... 26
Air cleaner ......................................................................................................................................................................... 26
Oil-bath air cleaner ........................................................................................................................................................... 26
Dry air cleaner .................................................................................................................................................................. 27
Dry air cleaner, donaldson type ........................................................................................................................................ 27
Clogging indicator ............................................................................................................................................................. 28
Oil vapour separator ........................................................................................................................................................ 28
Manifolds, intake/exhaust ................................................................................................................................................. 28
Intake manifold .................................................................................................................................................................. 28
Exhaust manifold .............................................................................................................................................................. 28
External alternator control belt (Only for engines with external alternator) ...................................................................... 29
External alternator blower control belt - disassembly ...................................................................................................... 29
External alternator blower control belt - tension check ................................................................................................... 29
External alternator blower control belt - reassembly ........................................................................................................ 29
Fuel tank ........................................................................................................................................................................... 29
Pulley guard - shroud - side plates ................................................................................................................................... 30
Cooling fan ........................................................................................................................................................................ 30
Hub .................................................................................................................................................................................... 30
Internal alternator .............................................................................................................................................................. 30
Shroud support (gear cover plate) .....................................................................................................................................31
Flywheel .............................................................................................................................................................................31
Rocker arms .......................................................................................................................................................................31
Valve / rocker arm clearance .............................................................................................................................................31
Compression release (optional) ........................................................................................................................................ 32
KD 625-2 Workshop Manual_cod. ED0053029380_1° ed_ rev. 00
updated 06/072012.
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CHAPTER INDEX
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