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

Kohler KDI 2504TM Workshop Manual

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KDI 2504TM
WORKSHOP MANUAL
TP-6971 3/23

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  • Page 1 KDI 2504TM WORKSHOP MANUAL TP-6971 3/23...
  • Page 2 Released by Document code Revision Issue date Edited by Endorsed Review date Technical ED0053030350 04/2015 03/2023 V. MANINI SILVESTRONE Documentation Translated from the original manual in Italian language. Data reported in this issue can be modified at any time by KOHLER.

  • Page 3: Table Of Contents

    INDEX General information ....................... 7 Useful information ........................... 7 Manufacturer and engine identification ..................8 Identification of the main internal components of the engine and operating reference (BASE CONFIGURATION) ..........................9 Identification of the external components of the engine (BASE CONFIGURATION) ..... 11 Technical information ......................
  • Page 4 INDEX Engine starting after storage ....................... 59 Information regarding discharge of liquids ............... 60 Coolant ............................60 Engine oil ............................61 Information for replacing the functional units ..............62 Injectors and injection pump replacement ................. 62 Coolant pump replacement ......................70 Replace the crankshaft pulley ......................
  • Page 5 INDEX Engine block assembly ....................... 114 Oil sump unit assembly ....................... 121 Flange unit assembly ........................122 Timing system gear assembly and injection pump ..............123 Cylinder head unit assembly ...................... 125 Fuel system assembly ......................... 130 Intake manifold assembly ......................132 9.10 Exhaust manifold assembly ......................
  • Page 6 INDEX 15.1 Glossary ............................176...

  • Page 7: General Information

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

  • Page 8: Manufacturer And Engine Identification

    GENERAL INFORMATION 1.2 Manufacturer and engine identification The engine identification name plate is situated in the lower part of the crankcase; it is visible from the intake or exhaust side. Fig 1.1 - Fig 1.2 Fig 1.3...

  • Page 9: Identification Of The Main Internal Components Of The Engine And Operating Reference (Base Configuration)

    GENERAL INFORMATION 1.3 Identification of the main internal components of the engine and operating reference (BASE CONFIGURATION) VIEW OF EXHAUST SIDE Fig 1.4 Tab 1.1 REF. DESCRIPTION View of timing system side (2 PTO) View of flywheel side (1 PTO) View of exhaust side View of intake side The following chapters contain operating...
  • Page 10 GENERAL INFORMATION Camshaft Gears adaptor for 3 PTO (optional) Flywheel (1 PTO) Injector VIEW OF FLYWHEEL SIDE Fig 1.5 VIEW OF TIMING SYSTEM SIDE Fig 1.6...

  • Page 11: Identification Of The External Components Of The Engine (Base Configuration)

    GENERAL INFORMATION 1.4 Identification of the external components of the engine (BASE CONFIGURATION) VIEW OF TIMING SYSTEM SIDE – EXHAUST Fig 1.7 VIEW OF FLYWHEEL SIDE Fig 1.8...
  • Page 12 GENERAL INFORMATION This paragraph illustrates all external components NOTE: The illustrated components may differ from that are present in the base configuration of the those illustrated; the illustration is only as an engine. example. For components present on engines that differ from those represented in these illustrations, refer to Chap.

  • Page 13: Technical Information

    TECHNICAL INFORMATION 2 TECHNICAL INFORMATION 2.1 Engine specifications MANUFACTURER SPECIFICATIONS AND OPERATION UNIT OF GENERAL INFORMATION KDI 2504 TM MEASURE Operating cycle diesel - 4 stroke Cylinders N° Bore x stroke 88x102 Displacement 2482 Compression ratio 17.4:1 Intake Supercharged with Turbocharger Cooling Liquid Crankshaft rotation (view from flywheel side)
  • Page 14 TECHNICAL INFORMATION FUEL SUPPLY SYSTEM UNIT OF GENERAL INFORMATION KDI 2504 T M MEASURE Type of fuel Diesel UNI-EN590 - ASTM D975 High-pressure fuel injection pump STANADYNE - DB Fuel supply Low pressure electric pump Fuel filter Filtering surface 2300 Degree of filtration µm Maximum pressure at injection pump inlet...

  • Page 15: Engine Dimensions (Mm)

    TECHNICAL INFORMATION motor Coolant temperature indicator light Indicator light operating temperature °C +100/+110 2.2 Engine dimensions (mm) 2.3 Performance 50 Hz @ 1500 rpm KDI 2504 TM-30 KDI 2504 TM-40 EU KDI 2504 TM-40 POWER Stand-by power (kW/HP) 31,0 / 41,5 36,4 / 48,8 41,0 / 54,9 Prime power (kW/HP)

  • Page 16: Oil

    TECHNICAL INFORMATION Fuel consumption 50% load 256,8 Fuel consumption 25% load 299,8 Fuel consumption 10% load 470,7 2.4 Oil Important • The engine may be damaged if operated with improper oil level. • Do not exceed the MAX level because a sudden increase in engine rpm could be caused by its combustion.

  • Page 17: Fuel

    TECHNICAL INFORMATION 2.5 Fuel Important • Use of other types of fuel could damage the engine. Do not use dirty diesel fuel or mixtures of diesel fuel and water since this will cause serious engine faults. • Any failures resulting from the use of fuels other than recommended will not be warranted. Warning •...
  • Page 18 TECHNICAL INFORMATION • These fuels reduce the formation of paraffin in diesel at low temperatures. • When paraffin forms in the diesel, the fuel filter becomes blocked interrupting the flow of fuel. 2.5.2 Biodiesel fuel • Fuels containing 10% methyl ester or B10, are suitable for use in this engine provided that they meet the specifications listed in the Tab.

  • Page 19: Coolant Recommendation

    HOAT are not all maintenance free and it is recommended to have SCA (Supplemental Coolant Additives) added at the first maintenance interval. 2.7 Battery recommendation Battery not supplied by Kohler Tab. 2.7 RECOMMENDED BATTERIES AMBIENT TEMPERATURE BATTERY TYPE >...

  • Page 20: Periodic Maintenance

    TECHNICAL INFORMATION 2.8 Periodic maintenance The intervals of preventive maintenance in Tab. 2.8, Tab. 2.9, Tab. 2.10 and Tab. 2.11 refer to the engine operating under normal operating conditions with fuel and oil meeting the recommended specifications. CLEANING AND CHECKING PERIOD (HOURS) OPERATION DESCRIPTION 5000...

  • Page 21: Fuel System

    TECHNICAL INFORMATION 2.10 ENGINE OIL AND OIL FILTER CARTRIDGE REPLACEMENT PERIOD (HOURS) ENGINE VERSION KDI Mechanical Injection Tier 3 – Stage IIIA (1) (11) KDI Mechanical Injection Uncertified Engines 2.11 FUEL FILTER AND PREFILTER CARTRIDGE REPLACEMENT PERIOD (HOURS) ENGINE VERSION KDI Mechanical Injection Tier 3 –...
  • Page 22 The fuel supply system is under low pressure from the tank 1 to the high-pressure fuel injection pump 5. NOTE : The representation of fuel tank is purely indicative. Component not necessarily supplied by KOHLER. Tab 2.12 POS. DESCRIPTION Fuel tank...
  • Page 23 TECHNICAL INFORMATION POS. COMPONENTS DESCRIPTION Accelerator lever Min Adjustment Max Adjustment Torque adjustment High pressure delivery to injectors Return to fuel tank Inlet suction fuel Fig 2.7 Cold starting device Gasket Shaft Advance settings (locked) Pump identification label Air bleeding screw Pump control shaft blocking device.
  • Page 24 TECHNICAL INFORMATION 2.9.5 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 cartridge Air bleeding screw Cartridge Water in fuel sensor Hole water drainage Tab 2.17 Cartridge characteristics...
  • Page 25 TECHNICAL INFORMATION 2.9.7 Guards for fuel injection circuit components High-pressure injection circuit components are particularly sensitive to impurities. To prevent impurities, even microscopic ones, from accessing the fuel input or output unions, you are required to close these accesses by means of specific caps as soon as the various tubes are disassembled and disconnected.

  • Page 26: Lubrication Circuit

    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 27 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 28 TECHNICAL INFORMATION 2.10.3 Oil filter and Oil Cooler Fig 2.1 6 NOTE : unscrewing the cartridge holder cover makes the oil in support 7 flow towards the oil sump by means of the drain duct 4. Tab 2.22 POS. DESCRIPTION Oil arriving from the pump Oil cooling Oil filtering...

  • Page 29: Coolant Circuit

    TECHNICAL INFORMATION 2.11 Coolant circuit 2.11.1 Coolant circuit diagram Tab 2.24 POS. DESCRIPTION Coolant pump Coolant intake Coolant, cylinder Coolant, cylinder head Coolant to radiator Coolant into radiator Vent line from radiator (to 8) Compensation tank Thermostatic valve Return from compensation tank Fig 2.18 2.11.2 Coolant pump Tab 2.25...

  • Page 30: Intake And Exhaust Circuit

    TECHNICAL INFORMATION 2.11.4 Radiator (optional) NOTE: Component not necessarily supplied by Kohler. Tab 2.27 POS. DESCRIPTION Fig 2.21 Radiator group Coolant refill cap Vent tube or excess coolant return Coolant flow manifold Coolant intake manifold Protective grid Fig 2.22 2.12 Intake and exhaust circuit...
  • Page 31 TECHNICAL INFORMATION Fig 2.23 Tab 2.28 Important POS. DESCRIPTION Air in air filter • The air temperature inside the intake manifold must Air in compression in the never exceed that of the environment by 10°C. turbocharger Air in head intake Clean air is sucked by the turbocharger, which compresses it in the intake manifold and via ducts in the cylinder head, enters the Air in cylinder intake...
  • Page 32 TECHNICAL INFORMATION POS. DESCRIPTION NOTE: Component not necessarily supplied by KOHLER. Air filter cartridge Filter cover Important Filter support Dust exhaust valve • The air filter is a dry-type one, with a replaceable paper Dust exhaust valve filter cartridge •...

  • Page 33: Electric System

    Accessories panel connector interface (Fig. 2.13.1 Engine electrical wiring (opzional) 2.26b) Electrical fuel pump NOTE : Component not necessarily supplied by KOHLER. connector Cold Start Advance Electrical wiring is supplied upon request, it interfaces with the connector (on injection panel by means of 19-way Deutsch connectors (female on pump - Fig.
  • Page 34 TECHNICAL INFORMATION Tab. 2.31 2.13.1.1 Connector panel on the engine/machine PIN. INLET SIGNALS TO THE PANEL Oil pressure switch The connector is a female 19-way Deutsch Alternator indicator light type. There is a list of all PIN connections in Tab. 2.31. Coolant temperature warning light Air cleaner clogging warning light Air cleaner clogging warning light...
  • Page 35 TECHNICAL INFORMATION 2.13.3.1 Wiring disconnection Some sensor connectors and electronic control devices are sealed. This tipe of connectors must be disconnected by means of pressure on tabs A or unblock the retainers B, as illustrated from Fig. 2.26c to Fig. 2.26g. Fig 2.26c Fig 2.26e Fig 2.26d...

  • Page 36: Sensors And Switches

    TECHNICAL INFORMATION 2.14 Sensors and switches 2.14.1 Fuel filter water detection sensor (optional) The water presence sensor in the fuel filter serves to indicate the presence of water in the fuel. The sensor closes the electrical circuit and the warnin lamp in the panel board switches on the dashboard of the car on which the motor is mounted.
  • Page 37 TECHNICAL INFORMATION Thermal contact N/O with closing temperature at +110 °C ±3°C, re-opening +88 °C / +100 °C. P2 Characteristics indicated in Tab. 2.33B (white connector). Thermal contact N/O with closing temperature at +110 °C ±3°C, re-opening +88 °C / +100 °C. NOTE : R indicates the pin where it is possible to measure electrical resistance.

  • Page 38: Electrical Components

    TECHNICAL INFORMATION 2.14.4 Air cleaner clogging switch NOTE: Component not necessarily supplied by KOHLER. The switch is assembled on the air cleaner. When the filter is clogged, it sends a signal to the panel. Features: • Operating temperature: -30 °C / +100°C •...
  • Page 39 Tipo Hidria GH + CSA 12 V 2.15.4 Electric pump (optional) NOTE: Component not necessarily supplied by KOHLER. The electric pump is located before the fuel filter. One of the following pumps can be assembled A1 - A2 - A3 - A4.
  • Page 40 TECHNICAL INFORMATION Fig 2.38 2.15.5 Cold start advance The Cold Start Advance E device is part of injection pump D; it provides for advance injection modification to enable advance of the engine at low temperatures. The device is controlled by the ECU H. Fig 2.39a 2.15.6 Electro-Stop The electro-stop F device is part of injection pump D;...
  • Page 41 Device G is assembled on cylinder head P (flywheel side); it protects the electrical circuit in the event of an overload or short circuit. NOTE: Component not necessarily supplied by KOHLER. Fig 2.41 2.15.9 Control panel (optional) Panel L can be assembled on the engine or machine.

  • Page 42: Timing System And Tappets

    TECHNICAL INFORMATION 2.16 Timing system and tappets The timing system is equipped with hydraulic tappets that automatically recover the operation of the rocker rods assembly. No registration is therefore required. 2.16.1 Components identification Fig 2.43 Tab 2.37 POS. DESCRIPTION Crankshaft Camshaft Camshaft tappets Rocker arm control rod...
  • Page 43 TECHNICAL INFORMATION 2.16.2 Rocker arm pin Tab 2.39 POS. DESCRIPTION Rocker arm pin Rocker arm distancing spring Rocker arm pin support Exhaust rocker arm Fig 2.47 Intake rocker arm 2.16.3 Rocker arms Tab 2.40 POS. DESCRIPTION Rocker arm body Hydraulic tappet oil refill line Valve tappet lubrication line Valve tappet Hydraulic tappet...
  • Page 44 TECHNICAL INFORMATION The operating principle of the hydraulic tappet is based on the incompressibility of the liquids and on controlled leakage. The oil under pressure enters the tappet chamber A, providing a constant supply of oil in the low-pressure chamber. Through the non-return valve, 4 the oil can only access the high-pressure chamber B and exit via the clearance between the piston 3 and the tappet body 5 (controlled leakage).

  • Page 45: Components Handling

    TECHNICAL INFORMATION 2.17 Components handling 2.17.1 Injection pump - Only handle by means of the points marked by Y. - It is forbidden to handle using the points marked by N. Fig 2.56 2.17.2 Injector - Only handle by means of the points marked by Y. - It is forbidden to handle using the points marked by N.
  • Page 46 Do not apply additives to the lubricating make the engine run idle, or without a load, for oil and fuel, unless instructed to do so approximately 1 minute. by Kohler. • Ensure that controls and maintenance intervals • Do not increase engine speed, or apply of the engine are observed as specified in Tab.
  • Page 47 TECHNICAL INFORMATION idle speed or without a load for at least 2 minutes, thus allowing the turbocharger to cool. 5. Engine at idle speed Avoid using the engine at idle speed or without a load for long periods (more than 20-30 minutes).
  • Page 48 2.18.5 Replacement instructions Always understand the cause of the breakage of the turbocharger before replacing it. Correct the cause of the breakage before replacing it with a new turbocharger. If in doubt, contact KOHLER service department. Important • Failure to comply with these instructions can cause damage to the turbocharger and void the warranty.

  • Page 49: Balancer Device (Optional)

    TECHNICAL INFORMATION 2.19 Balancer device (optional) The balancer device is composed of a special crankshaft that activates 2 additional shafts (balancers). Rotation of the balancers, which have counterweights that oppose the movement of alternating weights (crankshaft - connecting rods - pistons), reduces vibrations caused by them.

  • Page 50: Safety Information

    Any improvement must be verified at KOHLER testing laboratories before application of the engine. • In case the approval to a modification is not granted, KOHLER shall not be deemed responsible for any consequential failures or damages to the engine.
  • Page 51 Do not mix fuel with elements such as oil or kerosene. Failure to comply with this prohibition will cause the non-operation of the catalyst and non-observance of the emissions declared by KOHLER. • Pay attention to the temperature of the oil filter when the filter itself is replaced.
  • Page 52 SAFETY INFORMATION Important • Only use the eyebolts A installed by KOHLER to move the engine (Fig. 3.1). • The angle between each lifting chain and the eyebolts shall not exceed 15° inwards. • The correct tightening of the lifting screws is 25Nm.

  • Page 53: Safety Signal Description

    SAFETY INFORMATION 3.4 Safety signal description • To ensure safe operation please read the following statements and understand their meaning. • Also refer to your equipment manufacturer's manual for other important safety information. • This manual contains safety precautions which are explained below. •...
  • Page 54 SAFETY INFORMATION Warning This indicates that failure to comply with it can cause minor damage or injury. Safety guards Hereunder is a list of safety guards that must be worn prior to carrying out any type of operation and to avoid potential harm to the operator. Use suitable protective gloves before carrying out any type of operation.

  • Page 55: Information And Safety Signals

    SAFETY INFORMATION 3.5 Information and safety signals ACCIDENTAL START HIGH PRESSURE FLUID RISK OF PUNCTURE Accidental Starts can High Pressure Fluids can puncture skin and cause severe injury or death. cause severe injury or death. Work on the injection system must be carried out by suitably trained staff wearing protection equipment.

  • Page 56: Safety And Environmental Impact

    - Use of raw materials and natural resources. - Regulations and directives regarding environmental impact. In order to minimise the impact on the environment, KOHLER provides some indications to be followed by all those handling the engine, for any reason, during its expected lifetime.

  • Page 57: Location Of Safety Labels On Engine

    SAFETY INFORMATION 3.7 Location of safety labels on engine...

  • Page 58: Storage Information

    STORAGE INFORMATION 4 STORAGE INFORMATION 4.1 Product preservation Important • If the engines are not to be used for 6 months, they must be protected by carrying out the operations described in Engine storage (up to 6 months) (Par. 4.2). •...

  • Page 59: Engine Starting After Storage

    STORAGE INFORMATION 4.4 Engine starting after storage 1. Remove the protective sheet. 2. Use a cloth soaked in degreasing product to remove the protective treatment from the external parts. 3. Inject lubricating oil (no more than 2 cm3) into the intake ducts. (Par.

  • Page 60: Information Regarding Discharge Of Liquids

    LIQUIDS 5.1 Coolant Important • Before proceeding with operation, read Par. 3.3.2. NOTE: Component not necessarily supplied by KOHLER. The representation of the radiator is purely indicative. Warning Fig 5.1 • Presence of steam pressurized coolant danger of burns. 1. Undo the cap A carefully (circuit under pressure).

  • Page 61: Engine Oil

    INFORMATION REGARDING DISCHARGE OF LIQUIDS 5.2 Engine oil Important • This operation should be carried out with vacuum pump. The oil must be drained whilst the engine is hot, which requires particular care to prevent burns. Do not allow oil to come into contact with the skin because of the health hazards involved.

  • Page 62: Information For Replacing The Functional Units

    INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 6 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 6.1 Injectors and injection pump replacement Important • Before proceeding with operation, read Par. 3.3.2. • Replace the high pressure pipes after two disassemblies. • Always replace the gaskets after each disassembly.
  • Page 63 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 6.1.2 Rocker arms cover disassembly 1. Undo the screws AR. 2. Loosen clamp G and disconnect hose H 3. Undo the screws L and remove the rocker arm cap C. Fig 6.4 6.1.3 Fuel return pipes disassembly 1.
  • Page 64 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 6.1.5 Injection pump disassembly Important • Before proceeding with the disassembly, identify the pump code from its identifying name plate (Pos. 12 - Tab. 2.12). • Alternatively, you can identify the pump from the online spare parts catalogue Fig 6.8 (https://partners.lombardini.it/App/Spare partCatalogue/Default/Catalogue.aspx).
  • Page 65 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS ED0065905540-S 1,006 10° ED0065905550-S 1,695 13° ED0065905950-S 0,815 9° 5. With reference X pointed upwards, find the TDC through tool ST_30, then bring the dial gauge indicator to 0. 6. Having identified the value to lower the piston, rotate the crankshaft anti-clockwise by going beyond the value described in Tab.
  • Page 66 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 15. Tighten the screw of tool ST_04 to disconnect the injection pump AG from the high pressure pump control gear AE. 16. Undo the screws AF and extract the injection pump AG. 17. Undo and remove the tool ST_04. Fig 6.15 https://www.youtube.com/embed/NaOHNXyU03c?r NOTE : Click on the right to play the procedure.
  • Page 67 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 4. Undo the capscrew K and shift the slotted plate AB in the direction of arrow AA. 5. Tighten screw K (tightening torque to 5.5 Nm). The injection pump is unlocked. 6. Remove the tool ST_30 and ST_34.
  • Page 68 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 3. Assemble the parts P, Q, R and fit the parts so assembled on the injector Z. Fig 6.22 4. Insert tool ST_51 on the injectors junctions Z (detail X1). 5. Tighten the screw P (tightening torque to 20 Nm) Fig 6.23 6.1.8 Assembly of the injector return pipes 1.
  • Page 69 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 6.1.9 Assembly Rocker arm cover Important • The gasket AM between the rocker arm cover and the cylinder head must always be Fig 6.25 replaced every time it is disassembled. 1. Position the two guide pins ST_17 before mounting the rocker arm cover.

  • Page 70: Coolant Pump Replacement

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

  • Page 71: Replace The Crankshaft Pulley

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

  • Page 72: Oil Pump Replacement

    INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 3. Undo the screw P (clockwise) and remove the pulley Q. Fig 6.36 6.3.2 Assembly 1. Check that the pin U is mounted properly on the camshaft V. 2. Insert the pulley Q on camshaft V respecting the reference of the pin U.
  • Page 73 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 6.4.4 Oil pump disassembly Fig 6.39 1. Undo the screws D and remove the group pump E from the timing system crankcase C. 2. Remove the rotors F and G from the oil pump crankcase E.
  • Page 74 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 6.4.6 Timing system crankcase assembly Important • Always replace the oil seal J after each assembly. • Always replace the gasket P after each assembly. • To prepare the surface of the K plane for the new application of the sealant, it must be cleaned Fig 6.43 through the use of:...

  • Page 75: Oil Pressure Valve Replacement

    INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 6.4.8 Coolant pump assembly 1. Perform the operations described in 6.2.2. 6.5 Oil pressure valve replacement 6.5.1 Disassembly Important • Par. 3.3.2. Before proceeding with operation, read 1. Undo the cap A. 2. From the crankcase D, remove the spring B. Fig 6.46 3.

  • Page 76: Oil Cooler Unit And Oil Filter Replacement

    INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 6.6 Oil cooler unit and oil filter replacement 6.6.1 Oil Cooler unit disassembly Important • Before proceeding with operation, read Par. 3.3.2. • Perform the operations described in Par 5.1 5.2. • Oil Cooler unit E is not repairable. Fig 6.67 1.
  • Page 77 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 6.6.2 Oil filter cartridge replacement 1. Remove gaskets L, M and N from element holder cover 2. Remove cartridge P from element holder cover H. Fig 6.70 1. Lubricate and insert gaskets L, M and N in the L1, M1 and N1 seats of element holder cover H.

  • Page 78: Fuel Filter Replacement

    INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 5. Insert and tighten the cartridge support H on the filter support E (tightening torque at 25 Nm). 6. Fit the pipes B on the support E and secure the pipes B with the clamps A. 6.7 Fuel filter replacement Important •...

  • Page 79: Oil Vapour Separator Replacement

    INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 4. Screw the new filter G onto the pump Q (tightening torque 20 Nm). 5. Connect the hose E to the filter G and fasten with the clamp D. 6.8 Oil vapour separator replacement 6.8.1 Disassembly Important •...
  • Page 80 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 2. Position flange H inserting hose K onto the flange union H, being careful not to bend tube E. 3. Insert the gasket M between the flange H and the crankcase N. 4. Secure the flange H using the screws B on the crankcase N (tightening torque at 10 Nm).

  • Page 81: Information For Disassembly

    INFORMATION FOR DISASSEMBLY 7 INFORMATION FOR DISASSEMBLY 7.1 Recommendations for disassembly Important • The mark ( ) after the title of a paragraph, indicates that the procedure is not required in order to disassemble the engine, however the procedures are featured in order to illustrate the disassembly of components.
  • Page 82 INFORMATION FOR DISASSEMBLY 7.2.4 Sensors and switches Important • After disassembly, protect the sensors suitably against knocks, dampness and any high temperature sources. • The sensors and switches cannot be repaired, therefore they must be replaced in the event of anomalies. 7.2.4.1 Oil pressure switch disassembly ( 1.

  • Page 83: Turbocharger Disassembly

    INFORMATION FOR DISASSEMBLY 7.3 Turbocharger disassembly 1. Follow operations 1 and 2 of Par. 6.1.2. 2. Release the clamps A and B and remove the manifold C. 3. Unscrew the fittings D and remove the pipe E with the relative gaskets G. 4.

  • Page 84: Crankshaft Pulley Disassembly

    INFORMATION FOR DISASSEMBLY 7.5.2 Thermostatic valve 1. Undo the screws D and remove the thermostatic valve cover E. 2. Remove the thermostatic valve F and its gasket. Important Fig 7.10 • Always replace the gasket G every time it is disassembled.

  • Page 85: Lubrication Circuit Disassembly

    INFORMATION FOR DISASSEMBLY 7.7 Lubrication circuit disassembly 7.7.1 Oil overpressure valve ( 1. Undo the cap A. 2. Remove the spring B. 3. Remove the valve piston C using a magnet. Fig 7.13 7.7.2 Timing system semi-crankcase oil filling flange ( 1.

  • Page 86: Intake Manifold Disassembly

    INFORMATION FOR DISASSEMBLY 2. Remove the rotors P and Q. Fig 7.17 7.7.5 Gruppo Oil Cooler e filtro olio 1. Follow operations of Par. 6.6.1. Warning • Use a suitable container to recover any residue oil. 7.7.6 Oil vapour separator unit Par.

  • Page 87: Fuel System Disassembly

    INFORMATION FOR DISASSEMBLY 7.9 Fuel system disassembly Important • Seal all injection component unions as illustrated in Par. 2.9.7. • The fuel injection circuit undergoes high pressure, use 3.4.3. safety protections as described in 7.9.1 Fuel injection pipes 1. Remove loking clips A from pipes B. 2.
  • Page 88 INFORMATION FOR DISASSEMBLY 7.9.4 Injector 1. Undo the screws P and remove the washers Q and 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 (∅ 11 mm), by applying small rotations to unblock the component.

  • Page 89: Timing System Gear Disassembly

    INFORMATION FOR DISASSEMBLY 7.9.6 Fuel filter ( NOTE: to disassemble the fuel cartridge, refer to operations and 2 of Par. 6.7.1. 1. Undo the screws V and remove the filter support W. Fig 7.26 7.10 Timing system gear disassembly 1. Unscrew screws C and remove camshaft gear D. 2.

  • Page 90: Flange Unit Disassembly

    INFORMATION FOR DISASSEMBLY 7.11 Flange unit disassembly 7.11.1 Flywheel Important • Leave the special tool ST_34 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 91 Fig 7.34 1. Undo the bolts M. 2. Remove the cylinder head N. Important • Only use the eyebolts AE installed by KOHLER to move the cylinder head Q. 3. Remove the head gasket P. Fig 7.35...
  • Page 92 INFORMATION FOR DISASSEMBLY 7.12.3.1 Valves ( 1. Mount the tool ST_07 on the head Q fixing it on one of the holes for fixing the rocker arm cover. NOTE: change the fixing hole according to the position of the valves to be removed. 2.

  • Page 93: Oil Sump Unit Disassembly

    INFORMATION FOR DISASSEMBLY 7.12.3.3 Valve steam gasket ( 1. Remove the oil seals AC. Fig 7.40 7.12.3.4 Lifting eyebolts ( 1. Undo the screws AD and remove the eyebolts AE. 2. Make the thorough washing the cylinder head Q. Fig 7.41 7.13 Oil sump unit disassembly 7.12.1 Oil sump 1.

  • Page 94: Engine Block Disassembly

    INFORMATION FOR DISASSEMBLY 7.12.3 Oil vapour pipes ( 1. Unscrew and removethe pipes E. Fig 7.44 7.14 Engine block disassembly 7.14.1 Crankshaft gasket flange 1. Undo the screws A. 2. Remove the flange B and the gasket C. Fig 7.45 7.14.2 Piston unit/connecting rod Important •...
  • Page 95 INFORMATION FOR DISASSEMBLY NOTE : coupling cap F1 on the connecting rod can be carried out with centring taper pins (Fig. 7.46b) or broken (Fig. 7.46c - without centring taper pins). Fig. 7.46b Fig 7.46a Fig. 7.46c 3. Pull out the connecting rod - piston assembly from position 2 and 3 by manually applying pressure on the connecting rod big end L in the direction of arrow AK.
  • Page 96 INFORMATION FOR DISASSEMBLY 7.14.3 Lower semi-crankcase 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 7.49 7.14.4 Crankshaft Remove: 1.
  • Page 97 INFORMATION FOR DISASSEMBLY 7.14.5.1 Rings ( 1. Remove the seal rings S. Fig 7.53 7.14.6 Oil spray nozzles ( 1. Undo the screws T and remove the spray nozzles U from the upper semi-crankcase AM. Fig 7.54 7.14.7 Camshaft 1. Remove the retainer ring V. 2.
  • Page 98 INFORMATION FOR DISASSEMBLY 7.14.9 Crankshaft bushings 1. Remove the crankshaft bushings AC from the upper semi-crankcase AB. Important • The crankshaft half-bearings AC are made of special material. Therefore, they must be replaced every time Fig 7.57 they are removed to prevent seizures. 2.

  • Page 99: Information About Overhauling

    INFORMATION ABOUT OVERHAULING 8 INFORMATION ABOUT OVERHAULING 8.1 Recommendations for overhauls and tuning • The information is laid out in sequence, according to operational requirements, and the intervention methods have been selected, tested and approved by the manufacturer's technicians. • This chapter describes procedures for checking, overhauling and tuning units and/or individual components.

  • Page 100: Crankcase

    Important • The grinding involved is of +0.20. • Cylinder grinding operations must observe KOHLER SPECIFICATIONS - cod. ED0035612500. • Grinding must be strictly performed on all cylinders F. • Tab. 8.1a details the dimensional values of new components only.
  • Page 101 INFORMATION ABOUT OVERHAULING PISTON Ø CILINDER (± 0.007 mm) Ø PISTON (± 0.007 mm) CLEARANCE VALUE (mm) 88.010 87.950 0.046 - 0.074 +0.20 88.210 88.150 Fig 8.2 N.B.: if removing the Z2 hole closing cap, the new cap must comply with the MAX measurement of 1.5 mm from the surface G1 Fig 8.2a 8.2.3 Block Surface Flatness...
  • Page 102 INFORMATION ABOUT OVERHAULING Grinding of surface A1 is not permitted Tab 8.2a Housing and camshaft gudgeon 8.2.4 4-cylinder camshaft housing check dimensions. DIMENSIONS CLEARANCE The camshaft housings only contain the timing system REF. side bushing Q. (mm) VALUE (mm) Use an internal dial gauge to measure the diameters of 44.000 - 44.025 housings X - W - K - Y - Z.

  • Page 103: Tappets And Tappet Housings

    INFORMATION ABOUT OVERHAULING Fig 8.4 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 104 INFORMATION ABOUT OVERHAULING Insert the pipe cleaner into all lubrication ducts B and blow compressed air to free them completely from any dirt residues. Check the state of wear and integrity of journals C and connecting rod D. Perform the operations described in Par.

  • Page 105: Connecting Rod - Piston Assembly

    INFORMATION ABOUT OVERHAULING and B1, observing the clearance indicated in Tab. 8.5. • La Tab. 8.5 riporta i valori dimensionali solo per i componenti nuovi. 8.4.2 Checking the axial clearance of the crankshaft Perform the operations described in Par. 9.3.5 and 9.3.6.
  • Page 106 INFORMATION ABOUT OVERHAULING Tab 8.6 REF. DIMENSIONS (mm) CLEARANCE VALUE (mm) 169.980 - 170.020 30.020 - 30.030 0.025 - 0.030 29.995 - 30.000 54.035 - 54.066 67.700 - 68.000 29.750 - 29.790 Important • Tab. 8.6 details the dimensional values of new components only.
  • Page 107 INFORMATION ABOUT OVERHAULING • Seal rings cannot be replaced separately. NOTE: refer to Fig. 8.19 to locate the rings. Tab. 8.7 RINGS H (mm) 0.100 - 0.300 0.250 - 0.500 0.250 - 0.400 8.5.4 Piston dimension check Clean the piston thoroughly. Measure the diameter of the piston at 12 mm (quota L) from the base of the skirt in correspondence with the graphite lubrication windows M.

  • Page 108: Cylinder Head

    INFORMATION ABOUT OVERHAULING Important • With a feeler gauge, measure the clearance of the seal ring in the respective seat (value L1, L2 e L3). • If the clearance does not comply with the values shown in the Tab. 8.8, replace the seal rings and the piston. Tab 8.8 SEAL RINGS CLEARANCE VALUE (mm)
  • Page 109 INFORMATION ABOUT OVERHAULING 8.6.2 Valve seats check Thoroughly clean the valves and their seats with. Measure indentation B 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.
  • Page 110 INFORMATION ABOUT OVERHAULING 8.6.4 Valve guides check Measure the diameters D and E of the rods and guides valve (Tab. 8.10). If the diameters don't correspond to the values indicated, replace the valves or guides. The MAX allowed value of wear for D and E is 0.10 mm. Observe values G from surface F when assembling guides H (Tab.

  • Page 111: Oil Pump Check

    INFORMATION ABOUT OVERHAULING 8.6.6 Rocker arm check Measure values W1 in correspondence with holes M located on rocker arm gudgeon L (seen from B in Fig. 8.25). Measure values W2 (Fig. 8.27). Based on the values measured, calculate the clearance between W1 and W2, which is to observe the values in Tab.
  • Page 112 INFORMATION ABOUT OVERHAULING 8.7.2 Check rotors clearance Important Replace carter R complete with its oil pump, if there are signs of wear in area P of surface Q (Fig. 8.32 - 8.32a). Measure values G and H (Fig. 8.30). Measure values L, M and N (Fig. 8.31). According to the values measured, calculate the clearance between G and H, L and M and L and N which are to observe Fig 8.30...

  • Page 113: Assembly Information

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

  • Page 114: Engine Block Assembly

    ASSEMBLY INFORMATION the components, the assemblies, the coupling surfaces of the parts are washed, clean and thoroughly dried; the coupling surfaces are undamaged; the equipment and tools are ready so that all work can be carried out correctly and safely; ensure that the working environment is safe.
  • Page 115 ASSEMBLY INFORMATION Fig 9.3 9.3.3 Camshaft 1. Check that the bushing Q is correctly fitted. 2. Lubricate the pins L, the cams M of the camshaft N, all the housing P (Par. 8.2.4 and Par. 8.2.6) and the bushing Q with oil. 3.
  • Page 116 ASSEMBLY INFORMATION 1. Check that the crankshaft half-bearings are mounted correctly on the lower crankcase F (AC detail). 2. Assemble the 2 shoulder half-rings AD onto the lower crankcase F applying two drops of oil to keep them in their seat. 3.
  • Page 117 ASSEMBLY INFORMATION Fig 9.10 5. Perform the operations described in Par. 8.5.4. 6. Position the segment openings with a 120° angle between them (Y). NOTE: do not use the segment opening with the pin hole (N) 7. Lubricate the piston skirt and piston rings with oil. Fig 9.11 9.3.8 Piston Important...
  • Page 118 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 Fig 9.14 TDC position of the affected cylinder. 2.
  • Page 119 ASSEMBLY INFORMATION Important • Leave the ring compressor assembled on the piston 6. Push piston AQ downwards without introducing the segments in the cylinder, rotate piston AQ by 10° in a clockwise direction (value BR – correct assembly position). Fig 9.18 7.
  • Page 120 ASSEMBLY INFORMATION • Failure to adhere to the assembly procedures may compromise the functionality of the engine, and also cause damage to persons and property. Tighten the screws AU, alternately, strictly following the tightening torques indicated. Tightening sequence of screws Torx M10x1: 1°...

  • Page 121: Oil Sump Unit Assembly

    ASSEMBLY INFORMATION Fig 9.22 inserting the gasket CD (tightening torque 25 Nm). 9.4 Oil sump unit assembly 9.4.1 Oil fume pipes 1. Apply Loctite 648 on the pipe threads A. 2. Screw and tighten the pipes A (tightening torque of 15 Nm).

  • Page 122: Flange Unit Assembly

    ASSEMBLY INFORMATION 5. Remove the two studs Fig 9.26 ST_18 with the appropriate screws (tightening torque 25 Nm) 6. After tightening all of the screws, loosen screw n°1 and retighten it to the torque value specified in step 4. 7. Check that the oil drain plugs M are tight (tightening torque 35 Nm).

  • Page 123: Timing System Gear Assembly And Injection Pump

    ASSEMBLY INFORMATION 9.6 Timing system gear assembly and injection pump 9.6.1 Timing system gear assembly 1. Check that the key A is correctly fitted on the camshaft 2. Position the gear C on the camshaft B adhering to the key reference A. 3.
  • Page 124 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, Fig 9.34 then bring the indicator of the dial gauge to 0.

  • Page 125: Cylinder Head Unit Assembly

    ASSEMBLY INFORMATION 9.7 Cylinder head unit assembly 9.7.1 Valve stem gasket Important • Par. 8.6.4 Carry out the checks described in before proceeding with the following operations. • Always replace gasket A with every assembly • Lubricate the gaskets A on the inside. 1.
  • Page 126 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 Par. 7.11.3.1. the reference marks made in 2. Position the spring Y on the seat of the head F. 3.
  • Page 127 ASSEMBLY INFORMATION 0.251 - 0.375 4. Based on the value detected at point 3, select the relevant gasket T as shown in the Tab. 9.2 (Fig. 9.47 detail U). 5. Check that the crankcase surface K and the gasket T are completely free of dirt and grit.
  • Page 128 ASSEMBLY INFORMATION 9.7.6 Rods and valve bridges 1. Insert the rocker control rods AA into the niches of the head F. Fig 9.51 Important • Properly centre the rods AA into the spherical housing of the camshaft tappets AB. 2. Mount the valve bridge AC on to the pairs of discharge and suction valves.
  • Page 129 ASSEMBLY INFORMATION 9.7.8 Rocker arm pin assembly Important • Position the rocker arm pin assembly BB on a level to align all the support surfaces. • Check that the pistons are positioned half way between the TDC and BDC. Rotate the crankshaft 90° Fig 9.56 counterclockwise with regard to the 1st cylinder TDC, positioning the crankshaft pin BP as shown in Fig...

  • Page 130: Fuel System Assembly

    ASSEMBLY INFORMATION 9.8 Fuel system assembly Important • Replace the high pressure pipes after two disassemblies. • Remove the protective caps from all the components of the fuel circuit just before assembly (Par. 2.9.7). • When repaired, RSN-A injectors must be Fig 9.59 certified by a Stanadyne centre to check their correct operation - check the type of engine...
  • Page 131 ASSEMBLY INFORMATION 5. Insert tool ST_51 on the injectors junctions Z (detail X1). 6. Tighten the screw P (tightening torque to 20 Nm) Fig 9.63 9.8.2 Fuel injector ricicle pipe 1. Position the tube N on the injectors Z, and tighten screws M (coppia di serraggio a 14 Nm) and insert the gasket T.

  • Page 132: Intake Manifold Assembly

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

  • Page 133: Exhaust Manifold Assembly

    ASSEMBLY INFORMATION 9.10 Exhaust manifold assembly Important • Replace the self-locking nuts B and the metal gaskets D between the manifold and the cylinder head every time they are assembly. • In the event of mounting the studs C, fix (25 Nm tightening torque) with Loctite 2701 on the thread.
  • Page 134 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 AM. 7. Fasten the oil pump cover AG with the screws AH (tightening torque 10 Nm).

  • Page 135: Crankshaft Pulley Assembly

    ASSEMBLY INFORMATION 7. Fasten the screws R (tightening torque of 25 Nm). Fig 9.77 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.

  • Page 136: Turbocharger Assembly

    ASSEMBLY INFORMATION 9.13 Turbocharger Assembly Important • Before proceeding, perform the operation described in Par. 2.18. • Ensure that tube B is not clogged. 1. Fasten the connecting sleeve A to the pipe B with the clamp C onto the flange fitting D. Important •...

  • Page 137: Coolant Circuit Assembly

    ASSEMBLY INFORMATION - Q and R; - Q and S; - Q and H. Fasten the fuel outlet pipe Q with the fittings R on the turbo-compressor H and on the crankcase S (tightening torque of 15 Nm). 9. Follow operations 4 and 5 of Par. 6.1.9. 9.14 Coolant circuit assembly 9.14.1 Thermostatic valve Important...
  • Page 138 ASSEMBLY INFORMATION 9.14.3 Oil Cooler hoses 1. Fit hose Q1 onto coolant pump G and Oil Cooler M. 2. Fit hose Q2 onto crankcase R and Oil Cooler M. 3. Secure the sleeve Q on Oil Cooler M and to the pump G with the clamps K. 4.

  • Page 139: Electric Component Assembly

    ASSEMBLY INFORMATION 9.15 Electric component assembly 9.15.1 Sensors and switches 9.15.1.1 Coolant temperature sensor 1. Secure the sensor D onto the head E (tightening torque of 20 Nm). Fig 9.87 9.15.1.2 Oil pressure switch 1. Clamp the oil pressure switch F on the crankcase G (tightening torque at 35 Nm).
  • Page 140 ASSEMBLY INFORMATION Important • The belt S must always be replaced every time it is assembled, even if it has not reached the scheduled hours for replacement. 6. Insert the belt E on the pulleys T. Fig 9.91 7. Push the alternator C in the direction of the arrow J.

  • Page 141: Tightening Torques And The Use Of Sealants

    ASSEMBLY INFORMATION 9.16 Tightening torques and the use of sealants Tab. 9.4 - * Alternatively to the capscrew replacements, with "Dri-loc" BASE CONFIGURATION SHORT BLOCK Thread Component Torque (Nm) Sealer (mm) Breather room closing cover fastening capscrew (EXHAUST M6x1 SIDE) 3 Torque Lower crankcase fastening capscrew M12x1.25...
  • Page 142 ASSEMBLY INFORMATION Intermediate gear gudgeon fastening screw M8x1.25 Camshaft gear control fastening capscrew M10x1 Fastening nut on fuel injection pump gear M14x1.5 ENGINE CYLINDER HEAD ASSEMBLY Thread Component Torque (Nm) Sealer (mm) Air bleeding cap M6x1 Lifting brace fastening capscrew M8x1.25 Injector manifold M12x1...
  • Page 143 ASSEMBLY INFORMATION EXHAUST MANIFOLD Thread Component Torque (Nm) Sealer (mm) Exhaust manifold fixing stud M8x1.25 Exhaust manifold fixing nut M8x1.25 Exhaust flange/muffler fixing nut M8x1.25 LUBRICATION CIRCUIT Thread Component Torque (Nm) Sealer (mm) Loctite Oil filter fastening union M20x1.5 2701* Oil filter M20x1.5 Oil pump carter fastening capscrew...
  • Page 144 ASSEMBLY INFORMATION Thread Component Torque (Nm) Sealer (mm) Accelerator bracket fastening capscrew M6x1 * Alternatively to the capscrew replacements, with "Dri-loc" OPTIONAL COMPONENTS (CHAP. 11) OIL DIPSTICK ON CYLINDER HEAD Thread Component Torque (Nm) Sealer (mm) Oil dipstick tube fastening capscrew M6x1 HEATER Thread...
  • Page 145 ASSEMBLY INFORMATION BALANCE DEVICE (4 CYLINDERS) Thread Component Torque (Nm) Sealer (mm) Housing closing panel fastening capscrew M6x1 Shafts support fastening capscrew M10x1.5 REMOTE OIL FILTER Thread Component Torque (Nm) Sealer (mm) Loctite Head fastening and Oil Cooler union on crankcase M20x1.5 2701* Crankcase head nipple and oil filter support...
  • Page 146 ASSEMBLY INFORMATION Thread Component Torque (Nm) Sealer (mm) Side feet fastening capscrew (on flange bell or M12x1.75 crankcase) Rear feet fastening capscrew M16x1.5 OIL SUMP WITH SUPPORTING STRUCTURE Thread Component Torque (Nm) Sealer (mm) Flange bell fastening capscrew M10x1.5 Flange bell fastening capscrew M16x2 Oil sump fastening capscrew M8x1.25...

  • Page 147: Fluids Filling Information

    FLUIDS FILLING INFORMATION 10 FLUIDS FILLING INFORMATION 10.1 Engine oil Important • Before proceeding with operation, read Par. 3.3.2. • Do not use the engine with the oil level below the minimum. 1. Loosen the oil filler cap A or the oil filler cap C if the cap A is not accessible.

  • Page 148: Coolant

    FLUIDS FILLING INFORMATION 10.2 Coolant Important • Before proceeding with operation, read Par. 3.3.2. 1. Tighten the cap E, replacing the copper gasket D (Tightening torque of 2 Nm). Fig 10.3 2. Refill the radiator with coolant (refer to Par. 2.6 for the liquid specifications).
  • Page 149 FLUIDS FILLING INFORMATION 12. After a few hours of operation stop the engine and allow it to cool. Check and top up the coolant liquid. Fig 10.6 https://www.youtube.com/embed/XuR1t NOTE: Click on the right to play the procedure. lU2zmo?rel=0...

  • Page 150: Information About Optional Components

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

  • Page 151: Heater (Replacement)

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

  • Page 152: Idler Gear (For 3Rd / 4Th Pto)

    INFORMATION ABOUT OPTIONAL COMPONENTS washers H, the screws A and the cable B. 2. Secure the flange H with the screws A (tightening torque at 22 Nm). 3. Secure the earth cable B with the nut J and the relevant washer on the heater E.

  • Page 153: 3Rd Pto (Replacement)

    INFORMATION ABOUT OPTIONAL COMPONENTS Important • Always replace the washer H every time it is disassembled. Modified component, see service letter 700019 - 700021. • Check that the perforated screw A is free from impurities inside it. Fig 11.11 3. Position the gear unit B on the hole J using the bushing G to centre.
  • Page 154 INFORMATION ABOUT OPTIONAL COMPONENTS Important • Before proceeding with operation, read Par. 3.3.2. 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 11.14 4.
  • Page 155 INFORMATION ABOUT OPTIONAL COMPONENTS 11.4.2 Assembly Important • Always replace the gasket J after each assembly. • Lubricate the gear H with oil. • It is mandatory to replace the screws N or apply a few Fig 11.17 beads of Loctite 2701. 1.

  • Page 156: 4Th Pto (Replacement)

    INFORMATION ABOUT OPTIONAL COMPONENTS 11.5 4th PTO (replacement) Fig 11.21 Important • Before proceeding with operation, read Par. 3.3.2. 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...
  • Page 157 INFORMATION ABOUT OPTIONAL COMPONENTS 3. Undo the screws E and remove the cover F. Fig 11.24 4. Undo the screws G and remove the flange K with the components H, J, M and N. Fig 11.25 5. Remove the retainer ring H and the shoulder ring J from the flange K.
  • Page 158 INFORMATION ABOUT OPTIONAL COMPONENTS 3. Position the flange K on the crankcase Q inserting the gasket P, and insert gear N in crankcase Q. 4. Secure the flange K using the screws N (tightening torque at 25 Nm). Fig 11.28 Important •...

  • Page 159: 3Rd + 4Th Pto (Configurations)

    INFORMATION ABOUT OPTIONAL COMPONENTS 11.6 3rd + 4th PTO (configurations) Fig. 11.32 11.6.1 Information Hydraulic pumps on the 3rd and 4th PTO can be installed at the same time. In some configurations, there is also the centering ring C on the 4th PTO.

  • Page 160: Air Filter (Cartridge Replacement)

    INFORMATION ABOUT OPTIONAL COMPONENTS 11.7 Air filter (cartridge replacement) Important • Par. 3.3.2. Before proceeding with operation, read 1. Release the two hooks A and remove the cover B from the body C. 2. Remove the cartridges D. Fig 11.34 3.
  • Page 161 INFORMATION ABOUT OPTIONAL COMPONENTS with a tool the fittings K, H (Fig. 11.37) and L (Fig. 11.38) in order to prevent their lose together with the nuts A, with the consequent of oil leakage. 2. Undo the nuts A and remove the hoses B and C. 3.

  • Page 162: Poly-V Alternator Belt (Replacement And Adjustment)

    INFORMATION ABOUT OPTIONAL COMPONENTS 2701 on thread) as positioned in Fig. 11.39. 7. Clamp union H on flange J inserting gasket U (tightening torque at 40 Nm). 8. Connect the hose B to the central fitting of support M and of flange J. 9.

  • Page 163: Tightening Pulley And Alternator For Poly-V Belt

    INFORMATION ABOUT OPTIONAL COMPONENTS 4. Remove the V-Belt H and install the new one. NOTE: Ensure that the internal profile of belt H is properly inserted into the grooves of the pulley A (as illustrated in D1 e D2). Fig 11.43 5.
  • Page 164 INFORMATION ABOUT OPTIONAL COMPONENTS 5. Undo the screws D and remove the plate E and the pin Fig 11.46 6. Undo the screws G and H remove the alternator L. Fig 11.47 7. Undo the screws M and remove the bracket N. Fig 11.48 11.4.2 Assembly 1.

  • Page 165: Oil Sump With Supporting Structure

    INFORMATION ABOUT OPTIONAL COMPONENTS 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). 4. Tighten the screw manually H onto the crankcase Q. 5.
  • Page 166 INFORMATION ABOUT OPTIONAL COMPONENTS 11.11.3 Oil sump disassembly 1. Execute the operations described in Par. 5.2. 2. Loosen capscrews C and remove bypass tube D. 3. Loosen capscrews E and remove oil sump F. Fig. 11.54 11.11.4 Oil sump assembly 1.
  • Page 167 INFORMATION ABOUT OPTIONAL COMPONENTS Fig. 11.58 9. Fasten oil sump F by tightening capscrews E and strictly following the order shown in Fig. 11.59 (tightening torque at 20 Nm). 10. Loosen capscrews A and remove housing or plate L (Fig. 11.58). 11.
  • Page 168 INFORMATION ABOUT OPTIONAL COMPONENTS 11.11.5 Flange plate / housing assembly 1. Execute the operations described in point 6 of Par. 11.11.4. 2. Fasten housing or plate L by using capscrews A and strictly following the order shown in Fig. 11.61 (tightening torque at 85 Nm).

  • Page 169: Information On Adjustments

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

  • Page 170: Oil Leak Check

    INFORMATION ON ADJUSTMENTS 12.3 Oil leak check Important • Before proceeding with operation, read Par. 3.3.2. Check that there are no leakages next to area A. 1. Start the engine at idle speed or without a load and check whether there are any leakages next to area A. It is anyhow necessary to also check the seals of all main components and their surface contact, such as: - crankcase and oil seal (side 1...

  • Page 171: Oil Pressure Check

    INFORMATION ON ADJUSTMENTS 12.4 Oil pressure check 1. Insert a thermocouple instead of the oil dipstick A. 2. Unscrew and remove the oil pressure switch B and screw on a 10 bar pressure gauge in its seat (Fig. 12.8). 3. Start the engine at idle speed and without a load, check the oil pressure value according to the oil temperature (Fig.

  • Page 172: Tools Information

    Warning • KOHLER declines all responsibility for any damage to the engine, persons, or things caused by the use of different types of tools to those indicated in Tab 13.1 - 13.2, where referred to them in the manual.
  • Page 173 TOOLS INFORMATION 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 ST_17 Rocker arm cover mounting studs ED0014603730-S ST_18 Intake and oil sump manifold mounting studs...

  • Page 174: Information About Failures

    INFORMATION ABOUT FAILURES 14 INFORMATION ABOUT FAILURES 14.1 Possible causes and trouble shooting IMMEDIATELY STOP THE ENGINE WHEN: 1. Engine rpm increases and decreases suddenly without being able to control them; 2. A sudden and unusual noise is heard; 3. The colour of the exhaust fumes suddenly darkens or turns white; 4.
  • Page 175 INFORMATION ABOUT FAILURES...

  • Page 176: Glossary

    A component that transforms mechanical energy into AC electrical energy. Authorised service station: KOHLER authorised workshop. Authorised workshop: KOHLER authorised service centre. A device that reduces vibrations caused by movement of the alternating weights Balancer device: (Crankshaft - Connecting rods - Pistons).
  • Page 177 Idle speed operation: Operation of a running engine with the vehicle stopped and on idle speed. KDI: "Kohler Direct Injection" A group of maintenance actions that have the sole objective to control and replace Maintenance - elements on their expiry, without modifying or improving the functions carried out by periodic the system, neither increasing the value nor improving performance.
  • Page 178 GLOSSARY N/C: Normally Closed, referred to switches (oil-pressure switch). N/O: Normally Opened, referred to switches (Coolant temperature sensor) Small radiator used to cool the oil. Oil Cooler: 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.
  • Page 179 GLOSSARY Tab.: Table. TDC: Top Dead Centre; a moment in which the piston is at the end of its stroke. Thermostatic A valve that adjusts the flow of coolant liquid; it is able to operate by means of valve: temperature variation. Torque: Force applied to an object that rotates on an idler shaft.
  • Page 180 GLOSSARY 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 Length µm 1/1000 of a millimetre (micron) 1 µm hour Time...
  • Page 184 TP-6971 3/23...

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