3404 tm workshop
- 1. KDI 3404 TM WORKSHOP MANUAL
- 2. 2 - _01 Ente compilatore Codice documento Edizione Data emissione Data revisione Revisione Modello n° Visto Redatto DICOM/ATLO 12/2015 2 01 09/2015 ED0053030410 REGISTRATION OF MODIFICATIONS TO THE DOCUMENT Any modifications to this document must be registered by the drafting body, by completing the following table. Drafting body Code document Edition Date issue Date Review Revision Model N° Endorsed Written by ED0053030410 51358 TRANSLATED FROM THE ORIGINAL MANUAL IN ITALIAN LANGUAGE. Data reported in this issue can be modified at any time by KOHLER.
- 3. 3 - _01 ED0053030410 1 GENERAL INFORMATION 12 1.1 Useful information 12 1.1.1 Useful Information -accident prevention - environmental impact 12 1.2 Manufacturer and engine identification 13 1.3 Name plate for EPA regulations 13 1.4 Identification of the main internal components of the engine and operating reference (BASE CONFIGURATION) 14 1.5 Identification of the external components of the engine (BASE CONFIGURATION) 16 2 TECHNICAL INFORMATION 18 2.1 Engine specifications 18 2.2 Engine dimensions (mm) 20 2.3 Performance 21 2.4 Oil 22 2.4.1 SAE oil classification 22 2.4.2 International lubricant specifications 22 2.5 Fuel 23 2.5.1 Fuel for low temperatures 23 2.5.2 Biodiesel fuel 23 2.5.3 Emission-Related Installation Instructions 24 2.6 Coolant 24 2.7 Battery features 24 2.8 Periodic maintenance 25 2.9 Fuel system 26 2.9.1 Supply system 26 2.9.2 Fuel return circuit 27 2.9.3 Injection pump 27 2.9.4 Injector 28 2.9.5 Fuel filter 28 2.9.6 Electric fuel pump (optional) 29 2.9.7 Guards for fuel injection circuit components 29 2.10 Lubrication circuit 30 2.10.1 Lubrication circuit diagram 30 2.10.2 Oil pump 31 2.10.3 Oil filter and Oil Cooler 32 2.11 Coolant circuit 33 2.11.1 Coolant circuit diagram 33 2.11.2 Coolant pump 34 2.11.3 Thermostatic valve 34 2.11.4 Radiator (optional) 35 2.12 Intake and exhaust circuit 36 2.12.1 Intake and exhaust circuit diagram with Intercooler 36 2.12.2 Intake and exhaust circuit diagram without Intercooler 37 2.12.3 Turbocharger 37 2.12.4 Air filter (optional) 38 2.12.5 Internal EGR 38 2.13 Electric system 39 2.13.1 Engine electrical wiring (opzional) 39 2.13.1.1 Connector panel on the engine/machine 40 2.13.1.2 Accessories panel connector 40 2.13.1.3 Wiring disconnection 41 2.14 Sensors and switches 42 2.14.1 Fuel filter water detection sensor 42 2.14.2 Oil pressure switch 42 2.14.3 Coolant temperature sensor 42 2.14.4 Air cleaner clogging switch 43 2.15 Electrical components 43 2.15.1 Alternator 43 2.15.2 Starter motor 43 2.15.3 Cold starting device (Heater) 43 2.15.4 Electric fuel pump (optional) 44 2.15.5 Cold Start Advance 45 2.15.6 Electro-Stop 45 2.15.7 Starting Relay 45 INDEX OF CHAPTERS
- 4. 4 - _01 ED0053030410 INDEX OF CHAPTERS 2.15.8 Fuse 45 2.15.9 Control panel (optional) 45 2.16 Timing system and tappets 46 2.16.1 Components identification 46 2.16.2 Timing system phasing angles 47 2.16.3 Rocker arm pin 47 2.16.4 Rocker arms 47 2.16.5 Hydraulic tappets 48 2.16.5.1 Hydraulic tappet operation 48 2.16.5.2 Difficult operating conditions 48 2.17 Components handling 49 2.17.1 Injection pump 49 2.17.2 Injector 49 2.17.3 Turbocharger 49 2.18 Turbocharger 50 2.18.1 What to do and what not to do 50 2.18.2 Practical operating rules 50 2.18.3 Before installing a new turbocharger 51 2.18.4 Installation instructions 52 2.18.5 Replacement instructions 52 3 SAFETY INFORMATION 53 3.1 Before start-up 53 3.2 Safety precautions 53 3.3 General remarks 53 3.3.1 Note for OEM 53 3.3.2 Note for end user 53 3.4 Safety signal description 55 3.4.1 Adhesive safety plates 55 3.4.2 Warnings 55 3.4.3 Safety guards 55 3.5 Information and safety signals 56 3.6 Safety and environmental impact 56 3.7 Location of safety signals on engine 57 4 STORAGE INFORMATION 58 4.1 Product preservation 58 4.2 Engine storage (up to 6 months) 58 4.3 Engine storage (over 6 months) 58 4.4 Engine starting after storage 58 5 INFORMATION REGARDING DISCHARGE OF LIQUIDS 60 5.1 Coolant 60 5.2 Engine oil 61 6 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 62 6.1 Injector and injection pump replacement 62 6.1.1 Injection fuel pipes disassembly(injection pump/injectors) 62 6.1.2 Rocker arms cover disassembly 62 6.1.3 Fuel return pipes disassembly 63 6.1.4 Injectors disassembly 63 6.1.5 Injection pump disassembly 63 6.1.6 Injection pump assembly 66 6.1.7 Injector assembly 67 6.1.8 Assembly of the injector return pipes 68 6.1.9 Assembly Rocker arm cover 69 6.1.10 Installation of the fuel injector pipes (pump injector/injectors) 69 6.2 Coolant pump replacement 70 6.2.1 Disassembly 70 6.2.2 Assembly 71
- 5. 5 - _01 ED0053030410 INDEX OF CHAPTERS 6.3 Oil vapour separator replacement 72 6.3.1 Disassembly 72 6.3.2 Assembly 72 6.4 Oil cooler unit and oil filter replacement 73 6.4.1 Oil Cooler unit disassembly 73 6.4.2 Oil filter cartridge replacement 73 6.4.3 Oil Cooler unit assembly 74 6.5 Fuel filter replacement 75 6.5.1 Disassembly 75 6.5.2 Assembly 75 7 DISASSEMBLY INFORMATION 77 7.1 Recommendations for disassembly 77 7.2 Turbocharger disassembly 77 7.3 Coolant recirculation components disassembly 78 7.3.1 Oil Cooler manifold 78 7.3.2 Thermostatic valve 78 7.3.3 Coolant pump 78 7.4 Electric components disassembly 79 7.4.1 Electric wiring 79 7.4.2 Starter motor 79 7.4.3 Belt and alternator 79 7.4.3.1 Oil pressure switch disassembly 79 7.4.3.2 Coolant temperature sensor 79 7.5 Exhaust manifold disassembly 79 7.6 Fuel system disassembly 80 7.6.1 Fuel injection pipes 80 7.6.2 Rocker arm cover 80 7.6.3 Fuel return pipes 80 7.6.4 Injector 80 7.6.5 Injection pump 80 7.6.6 Fuel filter 80 7.7 Crankshaft pulley disassembly 80 7.8 Flange unit disassembly 81 7.8.1 Flywheel 81 7.8.2 Flange housing 81 7.9 Lubrication circuit disassembly 81 7.9.1 Oil pump 81 7.9.2 Oil pressure valve 81 7.10 Cylinder head unit disassembly 82 7.10.1 Rocker arm pin 82 7.10.1.1 Rocker arm 82 7.10.2 Valve rods and bridges 82 7.10.3 Cylinder head 83 7.10.3.1 Valves 83 7.10.3.2 Injector sleeve 84 7.10.3.3 Valve stem gasket 84 7.10.3.4 Lifting eyebolts 84 7.11 Oil sump unit disassembly 85 7.11.1 Oil sump 85 7.11.2 Oil intake pipe 85 7.11.3 Oil drain pipe 85 7.12 Engine block disassembly 86 7.12.1 Piston unit / connecting rod 86 7.12.2 Timing system gear disassembly 87 7.12.3 Lower semi-crankcase 88 7.12.4 Crankshaft 89 7.12.5 Piston 89 7.12.5.1 Rings 89 7.12.6 Oil spray nozzles 89 7.12.7 Camshaft 90 7.12.8 Camshaft tappets 90 7.12.9 Crankshaft bushings 90
- 6. 6 - _01 ED0053030410 8 INFORMATION ABOUT OVERHAULING 91 8.1 Recommendations for overhauls and tuning 91 8.2 Crankcase 91 8.2.1 Oil line check 91 8.2.2 Cylinder check 92 8.2.3 Camshaft housing check 93 8.2.4 Camshaft control 93 8.2.5 Camshaft control with internal EGR 93 8.3 Tappets and tappet housings 94 8.3.1 Tappets check 94 8.3.2 Tappet housing check 94 8.4 Crankshaft 95 8.4.1 Dimensional check and overhauling 95 8.4.2 Checking the axial clearance of the crankshaft 96 8.5 Connecting rod - piston assembly 96 8.5.1 Connecting rod dimensions check 96 8.5.2 Checking the gudgeon pin-pin axes are parallel 97 8.5.3 Piston rings check 97 8.5.4 Piston dimension check 97 8.6 Cylinder head 98 8.6.1 Flatness check 98 8.6.2 Valve seats check 99 8.6.3 Valve springs 99 8.6.4 Valve guides check 99 8.6.5 Valve guides replacement 100 8.6.6 Valve guides replacement 100 8.7 Oil pump check 101 8.7.1 Dimensional and visual check 101 8.7.2 Oil pressure valve check 101 9 ASSEMBLY INFORMATION 102 9.1 Information on engine configuration 102 9.2 Assembly recommendations 102 9.3 Engine block assembly 103 9.3.1 Semi main bearings 103 9.3.2 Tappets 103 9.3.3 Oil spray nozzles 103 9.3.4 Crankshaft 104 9.3.5 Lower crankcase 104 9.3.6 Camshaft 106 9.3.7 Timing system gear assembly 106 9.3.8 Piston rings 107 9.3.9 Piston 107 9.3.10 Piston and connecting rod assembly 108 9.4 Oil sump unit assembly 110 9.4.1 Oil drain pipe 110 9.4.2 Oil suction pipe 110 9.4.3 Oil Sump 110 9.5 Cylinder head unit assembly 111 9.5.1 Valve stem gasket 111 9.5.2 Injector sleeves 111 9.5.3 Injectors projection 112 9.5.4 Valves 112 9.5.5 Cylinder head 113 9.5.6 Rods and valve bridges 114 9.5.7 Rocker arms 115 9.5.8 Rocker arm pin assembly 115 9.6 Lubrication circuit assembly 116 9.6.1 Oil pressure relief valve 116 9.6.2 Oil pump 116 INDEX OF CHAPTERS
- 7. 7 - _01 ED0053030410 9.7 Flange unit assembly 117 9.7.1 Flange housing 117 9.7.2 Flywheel 117 9.8 Fuel system assembly 118 9.8.1 High-pressure injection pump 118 9.8.2 Injector 118 9.8.3 Fuel injector ricicle pipe 118 9.8.4 Rocker arm cover 118 9.8.5 Installation of the fuel injector pipes (injection pump/injectors) 118 9.8.6 Fuel filter 118 9.9 Crankshaft pulley assembly 118 9.10 Coolant circuit assembly 119 9.10.1 Thermostatic valve 119 9.10.2 Coolant pump 119 9.10.3 Oil Cooler hoses 119 9.11 Exhaust manifold assembly 120 9.12 Turbocharger Assembly 120 9.13 Electric component assembly 121 9.13.1 Sensors and switches 121 9.13.1.1 Water temperature sensor 121 9.13.1.2 Oil Pressure Switch 121 9.13.2 Alternator 121 9.13.3 Starter Motor 121 9.14 Summary table of tightening torques and the use of sealants 122 10 FLUIDS SUPPLY INFORMATION 126 10.1 Engine oil 126 10.2 Coolant 126 11 INFORMATION ABOUT OPTIONAL COMPONENTS 129 11.1 Heater (replacement) 129 11.1.1 Disassembly 129 11.1.2 Assembly 129 11.2 Air filter (cartridge replacement) 129 11.3 Cooling circuit (replacement) 130 11.3.1 Radiator disassembly 130 11.3.2 Fan disassembly 131 11.3.3 Fan assembly 131 11.3.4 Radiator assembly 131 12 INFORMATION ON ADJUSTMENTS and checks 133 12.1 Waste Gate opening valve regulation 133 12.2 Air filter check 134 12.3 Oil steam separator check 134 12.4 Rubber hose and manifold control 134 12.5 Oil leak check 135 12.6 Oil pressure check 135 13 TOOLS INFORMATION 137 13.1 Information regarding specific tools 137 14 INFORMATION ABOUT FAILURES 138 14.1 Possible causes and trouble shooting 138 15 GLOSSARY 140 INDEX OF CHAPTERS
- 11. 11 1 _01 ED0053030410 GENERAL INFORMATION 1.1 Useful information • This manual contains the instructions needed to carry out proper use and maintenance of the engine, therefore it must always be available, for future reference when required. • Information, description and pictures in this manual reflect the state of the art at the time of the marketing of engine (Par. 1.4 e Par. 1.5). • However, the development of engines is continuous. Therefore, the information in this manual is subject to change without notice. • KOHLER reserves the right to make, at any time, changes on the engines for technical or commercial reasons. • These changes do not require KOHLER to intervene on the production marketed up to that time and nor to consider this manual as inappropriate. • The paragraphs, tables and figures are numbered by chapter and followed by the progressive paragraph, table and/or figure number. E.g.: Par. 1.3 - chapter 1 paragraph 3. Tab. 2.4 - chapter 2 table 4. Fig. 4.5 - chapter 4 figure 5. NOTE: The paragraphs may contain sub-paragraphs. • All technical terms, specific components and symbols (Tab. 15.1) that are in the manual are listed and described inside the glossary, which can be consulted in (Chap. 15). • The references of the objects described in the text and in the figure are indicated by letters and numbers, which are always and only related to the paragraph you are reading unless there are specific references to other figures or paragraphs. • Reference to values are indicated by letters or numbers (in red and underlined). • Other important references are highlighted in red. • 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. • 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. • The information contained in this manual is the sole property of KOHLER, therefore no partial or total reproduction or replication is allowed without the express permission of KOHLER. 1.1.1 Useful Information -accident prevention - environmental impact • Before proceeding repair - handling the motor, read the entire Chap. 3, which contains important information about the procedures to be followed for safety and environment.
- 12. 12 1 _01 Fig. 1.1 Fig. 1.2 Fig. 1.3 ED0053030410 GENERAL INFORMATION Max rpm Engine serial number Approval data and "EC" directives Manufacturer identification Engine type Engine version 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.
- 13. 13 1 _01 1 4 5 10 2 3 8 9 6 7 Fig. 1.4 Tab. 1.1 ED0053030410 GENERAL INFORMATION 1.3 Name plate for EPA regulations POS. DESCRIPTION 1 Model year in compliance with the rules 2 Power category (kW) 3 Engine displacement (Lt.) 4 Particulate emission limit (g/kWh) 5 Engine family ID 6 Emission Control System = ECS 7 Fuel with low sulphur content 8 Injection timing 9 Electronic injector opening pressure (bar) 10 Production date (example: 2013.JAN)
- 14. 14 1 _01 1 A B 4 5 6 7 8 9 15 10 2 3 Fig. 1.5 Tab. 1.2 ED0053030410 GENERAL INFORMATION 1.4 Identification of the main internal components of the engine and operating reference (BASE CONFIGURATION) REF. DESCRIPTION A View of crankshaft pulley (2nd PTO) B View of flywheel side (1st PTO) C View of exhaust side D View of intake side 1 Cylinder/Piston N. 1 2 Cylinder/Piston N. 2 3 Cylinder/Piston N. 3 4 Cylinder/Piston N. 4 VIEW OF INTAKE SIDE The following chapters contain operating references in order to clearly understand the engine. This paragraph illustrates these references that may be recognised by means of some main internal components. Should you need to execute complex operations, always consult this paragraph. NOTE: itisadvisabletokeepthispagevisibleduringdisassembly and assembly operations. POS. DESCRIPTION 5 Crankshaft pulley (2nd PTO) 6 Gear timing system 7 Thermostatic valve 8 Oil pump 9 Oil suction hose 10 Crankshaft 11 Exhaust manifold 12 Intake manifold 13 Camshaft 14 Flywheel (1st PTO)
- 15. 15 1 _01 D C 11 8 13 10 12 6 Fig. 1.6 9 ED0053030410 GENERAL INFORMATION VIEW OF FLYWHEEL SIDE
- 16. 16 1 _01 Fig. 1.7 Fig. 1.8 14 23 11 10 13 6 5 5 16 1 1 4 3 7 8 21 18 17 22 15 19 20 2 9 12 ED0053030410 GENERAL INFORMATION VIEW OF PULLEY SIDE - INTAKE VIEW OF FLYWHEEL SIDE - EXHAUST 1.5 Identification of the external components of the engine (BASE CONFIGURATION)
- 17. 17 1 _01 Fig. 1.9 5 22 14 12 16 19 11 23 1 10 2 8 Tab. 1.3 ED0053030410 GENERAL INFORMATION POS. DESCRIPTION 1 Oil filler cap 2 Turbocharger 3 Oil pressure switch 4 Starter motor 5 Oil steam separator 6 Oil drain plug 7 Engine identification name plate 8 Alternator 9 Coolant pump 10 Coolant temperature sensor 11 Thermostatic valve 12 Fuel injection pump This paragraph illustrates all external components that are present in the base configuration of the engine. For components present on engines that differ from those represented in these illustrations, refer to Chap. 11. NOTE: The illustrated components may differ from those illustrated; the illustration is only as an example. POS. DESCRIPTION 13 Oil Cooler 14 Lub. oil filter 15 Oil dipstick 16 Fuel filter 17 Crankshaft pulley (2nd PTO) 18 Flywheel (1st PTO) 19 Intake manifold 20 Waste Gate valve control actuator 21 Exhaust manifold 22 Flange bell 23 Injectors UPPER VIEW
- 18. 18 2 _01 Tab. 2.1 ED0053030410 TECHNICAL INFORMATION MANUFACTURER SPECIFICATIONS AND OPERATION GENERAL INFORMATION UNIT OF MEASURE KDI 3404 TM Operating cycle diesel - 4-stroke Cylinders No. 4 Bore x stroke mm 96x116 Displacement cm3 3359 Compression ratio 17:1 Intake Supercharged with Turbocharger Cooling Liquid Crankshaft rotation (view from flywheel side) Counterclockwise Combustion sequence 1-3-4-2 Timing System Valves per cylinder 4 Timing System Rods and rocker arms - Camshaft in the crankcase Tappets Hydraulic Injection Direct Engine dry weight Kg 394 MAX inclination 30' continuous operation α 40° MAX inclination 1' continuous operation α 45° POWER AND TORQUE GENERAL INFORMATION UNIT OF MEASURE KDI 3404 TM MAX. operating speed Rpm 2400 MAX. operating power (ISO TR 14396 - SAE J1995 - CE 97/68) kW 100 Maximum torque (at 1500 rpm) Nm 500 CONSUMPTIONS GENERAL INFORMATION UNIT OF MEASURE KDI 3404 TM Specific fuel consumption (best point) g/kWh 205 Oil consumption %Fuel < 0.1 FUEL SUPPLY SYSTEM GENERAL INFORMATION UNIT OF MEASURE KDI 3404 TM 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 cm2 2300 Degree of filtration µm 5 Maximum pressure at injection pump inlet bar 0.2 LUBRICATION CIRCUIT 2.1 Engine specifications
- 19. 19 2 _01 ED0053030410 TECHNICAL INFORMATION GENERAL INFORMATION UNIT OF MEASURE KDI 3404 TM Lubrication Recommended oil see Par. 2.4 Circuit forced Lobe pump Oil sump capacity (MAX) Lt. 15,6 Oil pressure switch Intervention pressure (MIN) bar 0.6±0.1 Oil filter Maximum operating pressure bar 7.0 Degree of filtration µm 17 ±2 Filtering surface cm2 1744 COOLING CIRCUIT GENERAL INFORMATION UNIT OF MEASURE KDI 3404 TM Coolant % see Par. 2.6 Coolant pump Lt./min 155 Thermostatic valve Opening temperature °C +83 Stroke at 95°C mm 7.50 Liquid recirculation Lt./h 9 ELECTRICAL SYSTEM - ELECTRIC FAN GENERAL INFORMATION UNIT OF MEASURE KDI 3404 TM Circuit rated voltage V 12 External alternator (rated current) A 90 Starter motor power kW 2 System electrical consumption, excluding: heater, electric pump, electric fan, starter motor W Coolant temperature indicator light Indicator light operating temperature °C +100 / +110
- 20. 20 2 _01 734.4 Fig. 2.1 579.5 816 ED0053030410 TECHNICAL INFORMATION 2.2 Engine dimensions (mm) NOTE: Dimensions vary according to engine configuration.
- 21. 21 2 _01 ED0053030410 TECHNICAL INFORMATION 2.3 Performance with AFTER COOLER without AFTER COOLER 70HZ @1800 RPM 60HZ @1800 RPM 50HZ @1800 RPM 63HZ @1500 RPM 63HZ @1500 RPM POWER Stand-by power (kW/HP) 70 / 95.2 60 / 81.6 50 / 68 63 / 85.7 63 / 85.7 Prime power (kW/HP) 63 / 85.7 54 / 73.4 45 / 61.2 56.7 / 77.1 56.7 / 77.1 FUEL CONSUMPTION (g/kWh) Fuel consumption 100% load 229.0 241.6 240.8 223,2 219 Fuel consumption 75% load 242.8 260.8 255.4 232.5 228 Fuel consumption 50% load 242.4 265.1 272 248.5 238 Fuel consumption 25% load 274.2 298.4 325.1 263.1 261 Fuel consumption 10% load 425.3 452.1 510.8 366.6 380
- 22. 22 2 _01 Tab. 2.2 Tab. 2.3 Tab. 2.4 ED0053030410 TECHNICAL INFORMATION 2.4.2 International lubricant specifications • They define performances, procedures and laboratory tests that lubricants must pass successfully to be considered suitable and in compliance with the type of lubrication required. • Check the code on the oil container to understand and compare the characteristics of the lubricant to be chosen. 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. • Use only the recommended oil to ensure adequate protection, efficiency and service life of the engine. • The use of lubricants other than recommended may shorten the engine life. • Viscosity must be appropriate to the ambient temperature to which the engine is to be exposed Par. 2.4.1). Danger • Prolonged skin contact with the exhausted engine oil can cause cancer of the skin. • If contact with oil cannot be avoided, thoroughly wash your hands with soap and water as soon as possible. • For the exhausted oil disposal, refer to the Par. 3.6. 2.4.1 SAE oil classification • In the SAE classification, oils are identified according to viscosity without considering any other qualitative characteristic. • The code is made up of two numbers. The first number refers to the viscosity when cold, for use during winter ("W"= winter), while the second number is for viscosity at high temperatures. A.P.I (American Petroleum Institute). MIL U.S.A. military engine oil specification. ACEA European Automobile Manufacturers Association. • A specification with a greater number or letter is preferable to one with a lower number or letter. • For the purchase of oil refer to Tab. 2.2. RECOMMENDED OIL VISCOSITY SAE 5W-40 (≥ -25°C) 0W-30 (< -25°C) WITH SPECIFICATIONS API CI-4, CH-4, CG-4 ACEA E4 - E5 - E7 CLASSIFICATION DESCRIPTION ACEA SPECIFICATION E4 High performance (Euro 1 - 2 - 3 Engines) heavy duty E5 High performance (Euro 1 - 2 Engines) heavy duty E7 High power over long distances (Euro 4 - 5 engines)
- 23. 23 2 _01 Tab. 2.5 ED0053030410 TECHNICAL INFORMATION Important • Use the same type of diesel fuel as used in cars (EN 590 for E.U. - ASTM D975 regulation - S 15 for U.S). 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 would cause serious engine faults. • Any failures resulting from the use of fuels other than recommended will not be warranted. Warning • Clean fuel prevents the fuel injectors from clogging. Immediately clean up any spillage during refuelling. • Never store diesel fuel in galvanized containers (i.e. coated with zinc). Diesel fuel and the galvanized coating react chemically to each other, producing flaking that quickly clogs filters or causes fuel pump and/or injector failure. 2.5.1 Fuel for low temperatures • For the operation of the engine at temperatures lower than 0 ° C suitable for use fuels normally distributed by the oil companies and in any case corresponding to the specifications of Tab. 2.5. • 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 less than 10% methyl ester or B10, are suitable for use in this engine provided that they meet the specifications listed in the Tab. 2.5. • DO NOT USE vegetable oil as a biofuel for this engine. 2.5 Fuel (1) Without adding oil. (2) Stage 3A. (3) EPA TIER III. (4) Max. 10% in fuel. FUEL COMPATIBILITY Compatible Warranty coverage Engine waste Certification emission yes no yes no yes no yes no EN 590, DIN 51628 - Military NATO fuel F-54 (S=10 ppm) (2) Bio Fuels (EN14214) (4) (4) (4) (4) ARCTIC (EN 590/ASTM D 975) (1) No 1 Diesel (US) - ASTM D 975 - Grade 1-D S 15 (S=15 ppm) (3) No 1 Diesel (US) - ASTM D 975 - Grade 1-D S 500 (S=500 ppm) No 2 Diesel (US) - ASTM D 975 - Grade 2-D S 15 (3) No 2 Diesel (US) - ASTM D 975 - Grade 2-D S 1500 High sulfur fuel < 5000 ppm (<0.5%) High sulfur fuel > 5000 ppm (>0.5%) High sulfur fuel > 10000 ppm (>1%) Civil Jet Fuels Jet A/A1 (1) Civil Jet Fuels Jet B
- 24. 24 2 _01 Tab. 2.6 Tab. 2.7 ED0053030410 TECHNICAL INFORMATION Battery not supplied by Kohler 2.7 Battery features 2.6 Coolant TECHNICAL SPECIFICATIONS 50% ETYLENGLYCOL e 50% DECALCIFIED WATER 50% PROPYLENGLYCOL e 50% DECALCIFIED WATER 2.5.3 Emission-Related Installation Instructions Failing to follow the instructions in the applications guidebook when installing a certified engine in a piece of nonroad equipment violates federal law (40 CFR 1068.105(b)), subject to fines or other penalties as described in the Clean Air Act. OEM must apply a separate label with the following statement: “ULTRA LOW SULFUR FUEL ONLY” near the fuel inlet. Ensure you are installing an engine appropriately certified for yourapplication.Constantspeedenginesmayonlybeinstalled on constant speed equipment for constant speed operation. If you install the engine in a way that makes the engine's emission control information label hard to read during normal engine maintenance, you must place a duplicate label on the equipment, as described in 40 CFR 1068.105. RECOMMENDED BATTERIES AMBIENT TEMPERATURE BATTERY TYPE ≥ - 15°C 100 Ah - 800 CCA/SAE < -15°C 120 Ah - 1000 CCA/SAE
- 25. 25 2 _01 Tab. 2.8 Tab. 2.9 Tab. 2.10 ED0053030410 TECHNICAL INFORMATION DESCRIPTION PERIOD MAX Engine oil 12 months Oil filter cartridge 12 months Fuel filter cartridge 12 months Dry air filter cartridge 12 months Coolant 24 months Fan/alternator belt 36 months TheintervalsofpreventivemaintenanceinTab.2.8andTab.2.9 refertotheengineoperatingundernormaloperatingconditions with fuel and oil meeting the recommended specifications. 2.8 Periodic maintenance Important • In the event one does not reach the times scheduled for maintenance, one must in any case replace the components described in Tab. 2.10. (*)Onceremoved,thefan/alternatorbeltmustbereplaced,even if it has not completed the hours required or the MAX period. CLEANING AND CHECKING OPERATION DESCRIPTION PERIODICITY (HOURS) 10 250 500 1000 1500 5000 Engine oil level Coolant level / Radiator check (2) Water presence in fuel filter Dry-type air filter (1) Alternator belt tension (8) Radiator heat-exchange surface (2) Rubber hoses Fuel hose Starter Motor Alternator (1) - In case of low use: 12 months. (2) - The period of time that must elapse before checking the filter element depends on the environment in which the engine operates. The air filter must be cleaned and replaced more frequently under very dusty conditions. (3) - In case of low use: 36 months. (4) - In case of low use: 24 months. (7) - The replacement interval is only an indication, it strongly depends from environmental condition and hose status detected during regular visual inspection. (8) - The first check must be done after 10 hours. (9) - 250hrs for Stage IIIA or Tier 3 engine with CE homologation (Par. 1.2) or EPA label (Par. 1.3). REPLACEMENT OPERATION DESCRIPTION PERIODICITY (HOURS) 10 250 500 1000 1500 5000 Engine oil (1) (9) Oil filter cartridge (1) (9) Fuel filter cartridge (1) Coolant (4) (interior radiator cleaning) Intake manifold sleeve (air filter - intake manifold) (7) Coolant hoses (7) Fuel hose (7) Alternator belt Poly-V belt heavy environmental condition Poly-V belt not heavy environmental condition Dry air cleaner external cartridge (2) After 6 checks with cleaning
- 26. 26 2 _01 5 6 4 6 7 3 Fig. 2.2 2 2 1 Tab. 2.11 ED0053030410 TECHNICAL INFORMATION 2.9 Fuel system 2.9.1 Supply system (Fig. 2.3) The fuel supply system is under low pressure from the tank 1 to the injection pump 5. NOTE: The representation of fuel tank is purely indicative. Component not necessarily supplied by KOHLER. Important • Thehighpressuresupplyinjectionsystemishighlysusceptible to damage if the fuel is contaminated. • It is crucial that all components of the injection circuit are thoroughly cleaned before the components are removed. • Thoroughly wash and clean the engine before maintenance. • Contamination in the fuel supply injection system may cause a reduction in effectiveness / operation of engine fault indication. • If the engine is cleaned with high pressure washer, then the nozzle must be kept at a minimum distance of 200mm from the surface, and not directed at electrical components and connectors. POS. DESCRIPTION 1 Fuel tank 2 Fuel supply hose from the tank to the injection pump 3 Fuel filter 4 Electrical fuel feed pump 5 Injection pump 6 Injector high-pressure hose from the injection pump to the injectors 7 Injectors
- 27. 27 2 _01 1 2 14 12 6 13 3 4 5 7 8 10 11 Fig. 2.4 9 Fig. 2.5 2 5 4 3 1 Tab. 2.12 Tab. 2.13 Fig. 2.3 ED0053030410 TECHNICAL INFORMATION 2.9.3 Injection pump Pressureintotheinjectionpumpmustbepositiveinalloperating conditions. The injection pump is operated by means of the pump control gear (Tab. 2.40 - Pos. 7) and sends high-pressure fuel to the injectors. NOTE: In the event of leakage from the high pressure circuit do not intervene with the engine running, but turn it off and wait 5 - 10 minutes before checking the leak. 2.9.2 Fuel return circuit The fuel return circuit is under low pressure. POS. DESCRIPTION 1 Injectors 2 Injectors fuel return pipe 3 Injection pump 4 Fuel tank 5 Fuel return pipe to the tank POS. COMPONENTS DESCRIPTION 1 Accelerator lever 2 Max adjustment 3 Min Adjustment 4 Torque adjustment 5 High pressure delivery to injectors 6 Return to fuel tank 7 Inlet suction fuel 8 Cold Start Advance 9 Gasket 10 Shaft 11 Advance settings (locked) 12 Pump identification label 13 Air bleeding screw 14 Pump control shaft blocking device NOTE: The representation of fuel tank is purely indicative. Component not necessarily supplied by KOHLER.
- 28. 28 2 _01 1 2 3 4 5 Fig. 2.6 OUT IN 2 3 4 1 5 Tab. 2.14 Tab. 2.15 Tab. 2.16 Fig. 2.7 ED0053030410 TECHNICAL INFORMATION POS. COMPONENTS DESCRIPTION 1 Inlet fuel 2 Gasket 3 Gasket 4 Nozzle 5 Hole for fuel return to fuel tank 2.9.4 Injector It is a device used to introduce fuel, in the form of one or more jetsthatareadequatelypulverisedandsuitablyorienteddirectly 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. Important • The injectors are calibrated individually. • Fuel contamination causes serious damage to the injection system. 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. POS. COMPONENTS DESCRIPTION 1 Fuel filter support cartridge 2 Air bleeding screw 3 Cartridge 4 Water draining device 5 Hole water drainage Cartridge characteristics. DESCRIPTION VALUE Filtering surface 2,300 cm2 Degree of filtration 5 µm Max operating pressure 2.0 Bar
- 29. 29 2 _01 Fig. 2.9 ST_35 ST_32 Fig. 2.10 ST_33 ST_32 ST_25 5 2 4 1 3 6 Fig. 2.8 Tab. 2.17 ED0053030410 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. 4 - Insert a shut-off valve to prevent dry operation due to the emptying of the intake manifold; 5 - The supply pressure given from the electric pump must not exceed the pressure of 0.2 bar to the input of injection pump. POS. DESCRIZIONE 1 Fuel tank 2 Arrival pipe from the tank 3 Prefilter 4 Electric pump 5 Flow pipe to the fuel filter 6 Fuel filter 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. Disassembly of any component of the injection circuit must not occur in dusty environments. Cap guards must remain closed in their housing (ST_40) until the moment they are to be used. Pay special attention when using the caps and avoid any contamination of dust or dirt of any kind. Even after using the caps illustrated in this paragraph, all components of the injection circuit must be placed with care in environments that are free of any type of impurity. Fig. 2.10, and 2.11 illustrate the caps that must be used on components of the injection circuit. Cap guards must be accurately washed after use and placed back in their housing ST_40. Important • It is highly recommended to have this page visible during disassembly operations of the components of the fuel injection circuit.
- 30. 30 2 _01 1 4 4 11 3 3 6 9 8 7 10 2 2 5 12 13 Fig. 2.11 Fig. 2.12 Tab. 2.18 Tab. 2.19 ED0053030410 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). COLOUR DESCRIPTION Oil in intake Oil under pressure Oil returning to the oil sump POS. DESCRIPTION 1 Oil pump rotors 2 Oil sump 3 Crankshaft 4 Camshaft 5 Turbocharger 6 Rocker arm pin 7 Hydraulic tappets 8 Rocker arm cover 9 Cylinder head 10 Upper crankcase 11 Lower crankcase 12 Oil filter 13 Oil Cooler
- 31. 31 2 _01 Tab. 2.20 5 4 1 3 2 Fig. 2.13 Fig. 2.14 A ED0053030410 TECHNICAL INFORMATION 2.10.2 Oil pump Theoilpumprotorsaretrochoidal(withlobes)andareactivated 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. POS. DESCRIPTION 1 Internal rotor 2 External rotor 3 Oil pump crankcase 4 Oil pump control gear 5 Crankshaft gear
- 32. 32 2 _01 10 14 15 8 7 9 11 16 5 4 1 6 3 5 1 1 2 2 12 13 Fig. 2.15 Fig. 2.16 5 Tab. 2.21 Tab. 2.22 ED0053030410 TECHNICAL INFORMATION 2.10.3 Oil filter and Oil Cooler POS. DESCRIPTION 1 Oil arriving from the pump 2 Oil cooling 3 Oil filtering 4 Oil drain duct (oil sump return) 5 Oil returning into the circuit 6 Outgoing fitting from filter 7 Oil filter support 8 Cartridge holder cover 9 Oil filter cartridge 10 Oil Cooler 11 Crankcase 12 Oil flowing to the cartridge 13 Coolant 14 Oil drain duct closure gasket 15 Oil filtering chamber closure gasket 16 Cartridge holder cover gasket DESCRIPTION VALUE Filtering surface 2,300 cm2 Degree of filtration 2 µm Max operating pressure 4.0 Bar Max flow rate 190 litres/hour Cartridge characteristics. NOTE: unscrewing the cartridge holder cover makes the oilinsupport7flowtowardstheoilsumpbymeans of the drain duct 4.
- 33. 33 2 _01 1 2 6 17 7 7 6 12 4 3 Fig. 2.17 Fig. 2.18 16 15 15 Tab. 2.23 9 10 11 14 14 ED0053030410 TECHNICAL INFORMATION POS. DESCRIPTION 1 Coolant pump 2 Coolant intake 3 Coolant, cylinder 4 Coolant, cylinder head 5 EGR gas coolant 6 Coolant to radiator 7 Coolant into radiator 9 Coolant in the Oil Cooler 10 Coolant input into the Oil Cooler 11 Coolant output from the Oil Cooler 12 Vent line from radiator (to 15) 13 Vent line to expansion vase (to 15) 14 Return from compensation tank 15 Compensation tank 16 Thermostatic valve 17 Coolant drain cap from crankcase 2.11 Coolant circuit 2.11.1 Coolant circuit diagram
- 34. 34 2 _01 1 2 3 4 5 2 1 Fig. 2.20 Tab. 2.24 Tab. 2.25 Fig. 2.19 ED0053030410 TECHNICAL INFORMATION 2.11.2 Coolant pump POS. DESCRIPTION 1 Coolant pump control pulley 2 Coolant intake fitting 2.11.3 Thermostatic valve POS. DESCRIZIONE 1 Cylinder head 2 Coolant outlet cover 3 Thermostatic valve 4 Gaskets 5 Air bleeding hole Opening temperature +89° ± 3°C.
- 35. 35 2 _01 1 8 3 6 10 5 2 Fig. 2.21 Fig. 2.22 4 Tab. 2.26 7 1 5 9 ED0053030410 TECHNICAL INFORMATION 2.11.4 Radiator (optional) POS. DESCRIPTION 1 Radiator 2 Coolant refill cap 3 Vent tube or excess coolant return 4 Coolant flow manifold 5 Coolant intake manifold 6 Fan 7 Protective grid 8 Air hose (from Intercooler to manifold - Fig. 2.23) 9 Intercooler air delivery hose (Fig. 2.23) 10 Compressed air delivery hose to the intake manifold (Fig. 2.22) NOTE: NellaFig.2.22illustratestheradiatorwithoutIntercooler (the differences in POS. 10). Fig. 2.23 illustrates the radiator with Intercooler (the differences in POS. 8 - 9). Component not necessarily supplied by KOHLER.
- 36. 36 2 _01 1 1 3 7 8 2 9 7 B 10 C D 4 5 1 Fig. 2.23 Fig. 2.24 4 6 A Tab. 2.27 ED0053030410 TECHNICAL INFORMATION 2.12 Intake and exhaust circuit Air in intake Gas in exhaust Important • The air temperature inside the intake manifold must never exceed that of the environment by 10°C. Clean air is sucked by means of an intake manifold and via ducts in the cylinder head, enters the cylinders. Compressed air inside the cylinders and mixed with the fuel transforms into Gas after combustion. Gas is expelled from the cylinders and sent to the exhaust manifold, which expels the gas towards the exhaust muffler. POS. DESCRIPTION 1 Air in intake from air filter 2 Air in compression 3 Air in intercooler flow 4 Air cooling 5 Air in intake manifold flow 6 Cylinder head air intake 7 Air in cylinder intake 8 Gas in cylinder outlet 9 Cylinder head gas outlet 10 Exhaust gas from the turbocharger A Diagram, intake and exhaust circuit without Intercooler B Exhaust manifold C Crankcase D Radiator/intercooler 2.12.1 Intake and exhaust circuit diagram with Intercooler
- 37. 37 2 _01 1 7 6 8 4 5 3 11 10 9 2 Fig. 2.25 Tab. 2.28 Fig. 2.26 Tab. 2.29 1 A 8 3 2 4 5 7 6 B C ED0053030410 TECHNICAL INFORMATION POS. DESCRIPTION 1 Air intake hose 2 Air compression volute 3 Turbo charger central body 4 Turbine housing with Waste Gate valve 5 Gas exhaust flange 6 Waste Gate control valve hose 7 Waste Gate valve control actuator 8 Waste Gate control valve linkage 9 Air compressed flow pipe to intercooler 10 Oil drain pipe 11 Turbo charger lubrication pipe 2.12.3 Turbocharger The turbocharger is controlled by means of exhaust gas that activates the turbine. Important • See Par. 2.19. Air in intake Gas in exhaust POS. DESCRIPTION 1 Air in intake from air filter 2 Air in compression 3 Air in intake manifold flow 4 Air in head intake 5 Air in cylinder intake 6 Gas in cylinder outlet 7 Gas in head outlet 8 Exhaust gas from the turbocharger A Intake manifold B Exhaust manifold C Crankcase 2.12.2 Diagram, intake and exhaust circuit without Intercooler
- 38. 38 2 _01 H M Q R N Fig. 2.27 Tab. 2.30 F F K J B Fig. 2.27 A ED0053030410 TECHNICAL INFORMATION POS. DESCRIPTION H Air filter cartridge M Filter cover N Filter support Q Dust exhaust valve R Filter cover hook 2.12.4 Air filter (optional) NOTE: Component not necessarily supplied by KOHLER. Important • The air filter is a dry-type one, with a replaceable paper filter cartridge H (refer to Tab. 2.8 and Tab. 2.9 for procedure frequency on components). • The filter intake must be positioned in a cool area. • Should a hose be used, the length must not exceed 400 mm and is to be as straight as possible. 2.12.5 Internal EGR TheinternalEGRisonlyonStageIIIAorTier3enginesprovided with "CE" approval (Par. 1.2) or "EPA" name plate (Par. 1.3). It is a system that enables breakdown of pollutants through recirculationofcombustedgasbyreintegratingitinthecylinder during the intake stage. This process occurs through the use of cam J on the profile of exhaust cam K of camshaft F. Cam J slightly opens the exhaust valves during opening of the intake valves.
- 39. 39 2 _01 7 8 3 4 14 6 10 13 11 12 5 9 1 2 Fig. 2.28 Tab. 2.31 Fig.27/28 ED0053030410 TECHNICAL INFORMATION 2.13 Electric system 2.13.1 Engine electrical wiring (opzional) NOTE: Component not necessarily supplied by KOHLER. Electrical wiring is supplied upon request, it interfaces with the panel by means of 19-way Deutsch connectors (female on engine panel - male on accessories panel). The connectors are described in Tab. 2.31. REF. DESCRIPTION 1 Engine panel connector interface (Fig. 2.27) 2 Accessories panel connector interface (Fig. 2.28) 3 Electrical fuel pump connector 4 Cold Start Advance connector (on injection pump - Fig. 2.46) 5 Fuse connector 6 Electro-Stop connector (on injection pump) 7 "L" alternator connector (Iskra) 8 "W" alternator connectors (Iskra) 9 Coolant temperature sensor connector 10 Oil pressure switch connector 11 Starter motor connector "+ 50" 12 Starter motor connector "+ 30" 13 Air cleaner clogging sensor connector 14 Earth connector
- 40. 40 2 _01 2 1 1 2 3 4 5 6 7 19 18 17 16 15 14 13 12 11 10 9 8 Fig. 2.29 Fig. 2.30 Tab. 2.32 Tab. 2.33 ED0053030410 TECHNICAL INFORMATION 2.13.1.1 Connector panel on the engine/machine The connector is a female 19-way Deutsch type. There is a list of all PIN connections in Tab. 2.32. 2.13.1.2 Accessories panel connector The connector is a male 19-way Deutsch type. There is a list of all PIN connections in Tab. 2.33. PIN. INLET SIGNALS TO THE PANEL 2 Fuel filter (water detection sensor) 4 Radiator (coolant level sensor) 7 Outlet indicator general alarm 9 External Stop 15 Inlet indicator general alarm 19 Fuel tank (fuel level sensor) PIN. OUTLET SIGNALS FROM THE PANEL 5 Earth 6 Relay with 5A fuse (+ 15 wrench) 10 Grid heater (Relay) 13 Alternator (W) 17 Coolant temperature warning light PIN. INLET SIGNALS TO THE PANEL 1 Oil pressure switch 2 Alternator indicator light 3 Coolant temperature warning light 4 Air cleaner clogging warning light 7 Outlet indicator general alarm 9 Electro-Stop 13 Alternator (W) 14 Starter motor (+ 30) 15 Inlet indicator general alarm PIN. OUTLET SIGNALS FROM THE PANEL 5 Earth 6 IG excitation alternator (+15 wrench) 8 Starter motor (+ 50) 10 Grid heater (Relay) 11 Electric pump 18 Injection pump (Cold Start Advance - Fig. 2.46)
- 41. 41 2 _01 Fig. 2.31 B B B A B 12 3 4 1 11 Fig. 2.34 Fig. 2.35 Fig. 2.33 Fig. 2.32 ED0053030410 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 A or unblock the retainers B, as illustrated from Fig. 2.29 to Fig. 2.33.
- 42. 42 2 _01 Fig. 2.36 H N P R P1 P2 Fig. 2.37 Fig. 2.38 Tab. 2.34 Tab. 2.35 ED0053030410 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. Water, if present in the fuel, because of its greater specific weight separates and settles in the lower part of the filter where there is a drain plug. Gently loosen the water drain plug without removing it and spill out the water if present. Re-tighten the water drain plug H as soon as the fuel spills. 2.14.2 Oil pressure switch Oil pressure switch N is situated on the crankcase. It is a N/C switch, calibrated at 0.8 bar ± 0.1 bar. The switch closes the electrical circuit and the warning lamp in the panel board switches on the dashboard of the application on which the motor is mounted. 2.14.3 Coolant temperature sensor The coolant temperature sensor P of the cooling circuit is situated on the engine head. Sensor P1 or P2 (Fig. 2.39) can be assembled on the engine: P1 Characteristics indicated in Tab. 2.34 (blue connector). Thermal contact N/O with closing temperature at +110 °C ±3°C, re-opening +88 °C / +100 °C. P2 Characteristics indicated in Tab. 2.35 (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. SENSOR P1 CHARACTERISTICS °C R min Ω R max Ω -35 53.983 73.806 -30 39.229 52.941 -15 18.006 20.825 0 7.095 8.929 30 1.717 2.039 60 0.520 0.589 90 0.188 0.204 120 0.076 0.084 SENSOR P2 CHARACTERISTICS °C R min Ω R max Ω -36 11.835 15.724 -30 8.258 10.834 -16 3.721 4.753 0 1.611 2.003 30 414,1 493 60 132 151,7 90 50,27 56,11 120 21,6 24,29
- 43. 43 2 _01 A Fig. 2.39 Fig. 2.40 Fig. 2.41 H Fig. 2.42 C ED0053030410 TECHNICAL INFORMATION 2.15.2 Starter motor (C) Characteristics: • Type Bosch 12 V • Power 3,2 kW • Direction of rotation anticlockwise (seen from timing system side) 2.15 Electrical components 2.15.1 Alternator (A) Externally controlled by the crankshaft by means of a belt. Characteristics: • Ampere: 90 A • Volt: 12 V 2.15.3 Cold starting device (Heater) The cold starting device consists of a resistance, managed by the pre-heater timer H, which is activated when the ambient temperature is ≤-16° C. The intake air is heated through the resistance and facilitates starting the engine. Characteristics cold starting device: • Type Hidria AET 12 V • Power 550 W 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 • Contact usually open. • Contact closed by vacuum: -50 mbar.
- 44. 44 2 _01 Fig. 2.43 B C A OUT IN Tab. 2.36 ED0053030410 TECHNICAL INFORMATION 2.15.4 Electric fuel pump (optional) NOTE: Component not necessarily supplied by KOHLER. The electric pump A is located before the fuel filter. Characteristics: • Delivery: 60.56 L/h @ 0.41 bar • Volt: 12 V POS. DESCRIPTION 1 Electrical connection 2 Prefilter pump IN Ingoing fitting (IN) from tank OUT Outgoing fitting (OUT) to fuel filter
- 45. 45 2 _01 Fig. 2.44 Fig. 2.46 E D G P L W1 W2 W3 W4 W5 Fig. 2.47 M S Tab. 2.37 H D F Tab. 2.38 Tab. 2.39 °C HEATER CSA ≤ 20 ÷ -15 0" 120" -16 16" -21 21" -26 26" ≤ -32 32" Fig. 2.45 ED0053030410 TECHNICAL INFORMATION 2.15.5 Cold Start Advance The Cold Start Advance E device is part of injection pump D; it provides for advance injection modification to enable advance of the engine at low temperatures. 2.15.6 Electro-Stop The electro-stop F device is part of injection pump D; it turns off the engine by blocking the flow of fuel into pump D. 2.15.7 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. 2.15.9 Control panel (optional) Panel L can be assembled on the engine or machine. In Tab. 2.39, are described the main functions are illustrated. POS. DESCRIPTION M Hour-meter indicator S Control switch to start the engine W1 Panel ignition indicator W2 Warning Light - battery not charging W3 Warning Light - engine oil not pressurised W4 Warning Light - high coolant temperature W5 Warning Light - alarm general indicator NOTE: Component not necessarily supplied by KOHLER. NOTE: Component not necessarily supplied by KOHLER. POS. CONNECTED TO: 1 Heater 2 50 - ignition 3 15 - ignition 4 CSA 5 30 - battery 6 ... 7 Earth 8 Control panel indicator 2.15.8 Start-up relay The H device assists cold engine ignition controlling the "cold starting device" (Heater) and the "Cold Start Advance" (CSA). Tab. 2.37 indicates the activation times based on the ambient temperature.
- 46. 46 2 _01 5 4 10 6 11 12 7 8 1 9 8 1 2 3 4 5 6 7 9 8 Fig. 2.48 Fig. 2.49 Fig. 2.50 Tab. 2.40 ED0053030410 TECHNICAL INFORMATION 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 2.16 Timing system and tappets POS. DESCRIPTION 1 Crankshaft 2 Camshaft 3 Camshaft tappets 4 Rocker arm control rod 5 Rocker arms 6 Valves 7 Fuel injection gear pump control 8 Camshaft control gear 9 Crankshaft gear 10 Valve control bridge 11 Articulation control valves 12 Hydraulic tappets
- 47. 47 2 _01 Fig. 2.51 Tab. 2.41 Tab. 2.42 Tab. 2.43 1 1 5 4 3 2 6 2 3 4 5 Fig. 2.52 Fig. 2.53 ED0053030410 TECHNICAL INFORMATION 2.16.3 Rocker arm pin 2.16.4 Rocker arms POS. DESCRIPTION 1 Rocker arm pin 2 Rocker arm distancing spring 3 Rocker arm pin support 4 Exhaust rocker arm 5 Intake rocker arm POS. DESCRIPTION 1 Rocker arm body 2 Hydraulic tappet oil refill line 3 Valve tappet lubrication line 4 Valve tappet 5 Hydraulic tappet 6 Oil flow line 2.16.2 Timing system phasing angles Important • For information purposes, Tab. 2.41 reports the timing system diagram phasing angle values. • It should be noted that the said values may be verified by rotating the crankshaft (Pos. 1 of Fig. 2.50), by means of handling the rocker arm control rod (Pos. 4 of Fig. 2.49). NOTE: Detecting the value by means of handling the rocker arm/valves may not be correct due to the hydraulictappets,whichmaycompressandcreate clearances that alters the actual value. Intake cicle Crankshaft rotation Exhaust cicle INTAKE OPENING T.D.C. B.D.C. EXHAUST CLOSURE INTAKE CLOSURE EXHAUST OPENING VIEW OF FLYWHEEL SIDE (1ST PTO) INTAKE EXHAUST opens 12° before TDC opens 22° before BDC closes 36° after BDC closes 8° after TDC
- 48. 48 2 _01 Fig. 2.54 A B 1 2 3 4 5 Tab. 2.44 ED0053030410 TECHNICAL INFORMATION 2.16.5 Hydraulic tappets POS. DESCRIPTION A Low pressure chamber B Hight pressure chamber 1 Hydraulic tappets oil refill pipe 2 Retaining ring 3 Piston 4 Unidirectional valve 5 Tappet body 6 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. 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). The chamber B is filled when the rocker arm is on the base radius of the cam and the spring 6 keeps the piston 3 against the valve stem, thus eliminating any system play. Thanks to the spring extension, the tappet "extends", creating a small depression in the chamber B, making the non-return valve 4 open, and allowing the oil in the chamber A to pass to chamber B, restoring the proper amount of oil required to eliminate any play in the valves. 2.16.5.2 Difficult operating conditions: For proper operation of the hydraulic tappets is essential that the low pressure chamber of the piston 3 is always full of oil. In some conditions this may not occur (due to the fact that oil leaks, when the engine is switched off, can also partially drain the tappets): this situation will result in play that will occur with a typical noise similar to ticking, not to be confused with the normal ticking of the injectors. 1 - When the engine is cold, the tappet filling time could be very long if the oil used is not suitable for the specific environmental conditions (Tab. 2.2). 2 - If the engine is very hot: at idle speed, oil pressure may be low, and small air bubbles could form in the circuit. Because of this, this compressing the tappet slightly and producing valve play which is responsible for the ticking sound. On account of this, the tappet compresses slightly giving rise to a valve clearance, thus generating a slight ticking sound, which however disappears rapidly (MAX 10 seconds) once normal operating conditions have been restored. Anyway the duration of ticking Anyway the duration of ticking sound must be MAX 30 seconds. If not, the problem is surely due to the poor quality of the oil, wear or impurities that, transported by the oil, can infiltrate between the ball valve and its seat inside the piston, compromising the operation of the tappet itself; In these cases, the only solution is to replace the oil or hydraulic tappets. The prolonged persistence of the ticking sound or abnormal noisemustbeinvestigatinginordertopreventanymalfunctions; if necessary, replace the hydraulic tappets and engine oil.
- 49. 49 2 _01 N N Y Y N Fig. 2.56 Fig. 2.55 N N N N N N N N N N N N Y Y Y Y Y N N N N N N Y Y N N Fig. 2.57 ED0053030410 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. 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. 2.17.4 Turbocharger - Only handle by means of the points marked by Y. - It is forbidden to handle using the points marked by N. Important • Refer to Par. 2.18.
- 50. 50 2 _01 B A Fig. 2.58 Fig. 2.59 D E C ED0053030410 TECHNICAL INFORMATION 2.18 Turbocharger 2.18.1 What to do and what not to do What to do: • Before assembling the turbocharger, make sure that the protection caps are fitted on all openings of the turbo. • Ensure pre-lubrication of the turbocharger. • Periodically check that the joints are sealed against oil and air. • Use lubricating oil according to the specifications described in Par. 2.4. • Check the engine oil level. • Before switching it off after it has been used, make the engine run idle, or without a load, for approximately 1 minute. • Ensure that controls and maintenance intervals of the engine are observed as specified in Tab. 2.8 and 2.9. • Make sure that the engine and equipment are used correctly so as not to compromise the life of the turbocharger. What not to do: • Do not store turbocharges in damp, wet places if they are not in their original packaging. • Do not expose the turbocharger to dust and dirt if it is not in its original packaging. • Do not lift of hold the turbocharger from the actuator rod if it is not in its original packaging. • Do not apply additives to the lubricating oil and fuel, unless instructed to do so by Kohler. • Do not increase engine speed, or apply loads, immediately after start-up. • Do not intervene on the actuator settings A (Fig. 2.79). • Do not let the vehicle / engine run at idle speed for more than 20-30 minutes at a time. 5 - Engine at idle speed Avoid using the engine at idle speed or without a load for long periods (more than 20-30 minutes). When operating at idle speed or without a load, the turbocharger is at low pressure in the exhaust chamber C and air supply D; this may cause oil leaks from seals E to the extremity of the shaft. Even if this does not cause damage, it can cause blue smoke from the exhaust when the engine speed and load are increased. 2.18.2 Practical operating rules Users can help to maximise the duration of their turbocharger by following the rules described below. 1 - Start-up Start the engine at idle speed, or without a load, for approximatelyoneminute.Oiloperatingpressureisreached within a few seconds and enables the moving parts to warm up and be lubricated. Immediately increasing the engine speed upon start-up means making the turbocharger run at high speed with suboptimal lubrication, which may compromise the life of the turbocharger. 2 - After maintenance or a new installation Proceed with pre-lubrication by filling new oil into the oil supply duct B until filling it completely. Start the engine at idle speed, or without a load, for a few minutes in order to ensure that the oil and bearings system operate satisfactorily. 3 - Low temperature air or engine inactivity If the engine has been inactive for some time, or the air temperature is very low, start the engine at idle speed or without a load for a few minutes. 4 - Engine shutdown Before switching the engine off after intense activity, one must allow the turbocharger to cool down. One must therefore let the engine run at idle speed or without a load for at least 2 minutes, thus allowing the turbocharger to cool.
- 51. 51 2 _01 Fig. 2.60 F G Fig. 2.61 F H Fig. 2.62 Fig. 2.63 ED0053030410 TECHNICAL INFORMATION 2.18.3 Before installing a new turbocharger Important • Do not lift the turbocharger with one hand from the FG box. • Do not lift turbocharger from Comp hsg side. • Lift the turbocharger with both hands from FG box. • Make sure to use clean gloves. • Handle the turbocharger as indicated in Par. 2.17.4. 1 - Avoid lifting from the intake side G. 2 - Remove cap guard F and check that there is no excessive shaft axial and radial clearances. 3 - Check for any signs of friction of the turbine on the turbocharger body. 4 - Check for any traces of oil leaks on the turbocharger body. 5 - After having check everything, reapply cap F on intake opening H of the turbocharger and do not remove it until assembly has been completed. 6 - Check the correct assembly of the capscrews and the presence of paint on them.
- 52. 52 2 _01 Fig. 2.64 ED0053030410 TECHNICAL INFORMATION 2.18.4 Installation instructions 1 - Remove the cap guards with care only when assembling. Handle carefully avoiding erratic movements. 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. • Modifying the calibration of the turbocharger damages the turbocharger/engine. • Always use the correct gaskets, and fit carefully to avoid blocking holes when mounting. • Refer to the manual of the engine / vehicle, for: the correct type and quantity of oil, the correct tightening of components, instructions and installation. • It is forbidden to use liquid gaskets or sealants, particularly for the oil inlet/outlet. • Avoid dirt / debris while installing the turbocharger. • Before mounting the turbocharger, check that the code of the component is correct for the type of engine, as mounting the wrong turbocharger can damage the turbo / engine and void the warranty.
- 53. 3 53 _01 ED0053030410 SAFETY INFORMATION 3.2 Safety precautions • The intended use of the engine is in conformity with the machine on which it is mounted. • Any use of the machine other than that described cannot be considered as complying with its intended purpose as specified by KOHLER . • KOHLER declines all responsibility for any change to the engine not described in this manual made by unauthorized KOHLER personnel. • A proper use of the engine, a strict observance of the rules listed below and the rigorous application of all these precautions will avoid the risk of accidents or injuries. • Those who carry out the use and maintenance on the engine must wear the safety equipment and the accident-prevention guards Par. 3.4.3. • KOHLER declines all direct and indirect liability for failure to comply with the standards of conduct contained in this manual. • KOHLER cannot consider every reasonably unforeseeable misuse that may cause a potential danger. 3.1 Before start-up • Read the manual carefully and carry out the operations described below in compliance with the instructions specified. • Periodic inspection and maintenance operations must be carried out as indicated in this manual and under the user's responsibility. Important • Only use original spare parts and accessories. • The use of non-original parts, as well as voiding the warranty, affects the life and performance of the engine, and may be dangerous. • Non compliance with the operations described in the following pages may result damage to the engine and vehicle on which it is installed, as well as to people and/or property. 3.3 General remarks 3.2.1 Note for OEM • When installing the KDI engines, always bear in mind that any variation to the functional systems may involve serious failures to the engine. • Any improvement must be verified at KOHLER testing laboratories before application of the engine. • In the event KOHLER does not approve the type of modification, KOHLER shall not be held responsible for any consequential operation anomalies that the engine may undergo and any damage the engine may cause to persons and things. • The engine may only be assembled on a machine by 3.2.2 Note for end user • The following indications are dedicated to the user of the machine in order to reduce or eliminate risks concerning engine operation and the relative routine maintenance work. • The user must read these instructions carefully. Failure to do this could lead to serious danger for his personal safety and health and that of any persons who may be in the vicinity of the machine. • On starting, make sure that the engine is as horizontal as possible, unless the machine specifications differ. • Make sure that the machine is stable to prevent the risk of overturning. • Theenginemustnotoperateinplacescontaininginflammable materials, in explosive atmospheres, where there is dust that can easily catch fire unless specific, adequate and clearly indicated precautions have been taken and have been certified for the machine. • To prevent fire hazards, always keep the machine at least one meter from buildings or from other machinery. • Children and animals must be kept at a due distance from operating machines in order to prevent hazards deriving from their operation. personnel specifically trained by KOHLER and who work in compliance with the existing documentation. • The engine has been built to the specifications of a machine manufacturer, and it is his responsibility to ensure that all necessary action is taken to meet the essential and legally prescribed health and safety requirements. Any use of the machine other than that described cannot be considered as complyingwithitsintendedpurposeasspecifiedbyKOHLER, which therefore declines all responsibility for accidents caused by such operations. • Thoroughly wash and clean all the external parts of the engine before performing any operation, in order to avoid the accidental introduction of impurities/foreign bodies. Useonlywaterand/orappropriateproductstocleantheengine. If cleaning engine with a pressure washer or steam cleaner, it is important to maintain a minimum distance of at least 200mm between the surface to be washed and the nozzle. Avoid directing the nozzle on electrical components, cable connections and sealed rings (oil seals etc). Thoroughly wash and clean the area surrounding the engine following the instructions provided by machine manufacturer. • Fuelandoilareinflammable.Thetankmustonlybefilledwhen the engine is off. Before starting, dry any spilt fuel. • Make sure that no soundproofing panels and the ground or floor on which the machine is standing have not soaked up any fuel. • Fuel vapour is highly toxic. Only refuel outdoors or in a well ventilated place. • Do not smoke or use open flames when refuelling. • During operation, the surface of the engine can become dangerously hot. Avoid touching the exhaust system in particular.
- 54. 3 54 _01 α ≤ 15° α ≤ 15° A A Fig. 3.1 ED0053030410 SAFETY INFORMATION • Before proceeding with any operation on the engine, stop it and allow it to cool. • Always open the radiator plug or expansion chamber with the utmost caution, wearing protective garments and goggles. • The coolant fluid is under pressure. Never carry out any inspections until the engine has cooled. • If there is an electric fan, do not approach the engine when it is still hot as the fan could also start operating when the engine is at a standstill. Important • The oil must be drained whilst the engine is hot. Particular care is required to prevent burns. Do not allow oil to come into contact with the skin because of the health hazards involved. It is recommended to use an oil intake pump. • During operations that involve access to moving parts of the engine and/or removal of rotating guards, disconnect and insulate the negative wire (-) of the battery to prevent accidental short-circuits and to stop the starter motor from being energized. • Check belt tension only when the engine is off. • Fully tighten the tank cap each time after refuelling. Do not fill the tank right to the top but leave an adequate space for the fuel to expand. • To start the engine follow the specific instructions provided in the engine and/or machine operating manual. Do not use auxiliary starting devices not originally installed on the machine (e.g. Startpilot). • Before starting, remove any tools that were used to service the engine and/or machine. Make sure that all guards have been refitted. • 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. • Only check, top up and change the coolant fluid when the engine is off and reached the ambient temperature. Coolant fluid is polluting, it must therefore be disposed of in the correct way. • Do not use jets of air and water at high pressure on the cables, connectors and electronic injectors. Important • Only use the eyebolts A installed by KOHLER to move the engine (Fig. 3.1). • The angle bet ween each lif ting chain and the eyebolts shall not exceed 15° inwards. NOTE: the lifting chain must be vertical for engines equipped with the radiator with Intercooler. • • The correct tightening of the lifting brace capscrews is 80Nm. • Do not interpose spacers or washers between the eyebolts and engine head.
- 55. 3 55 _01 ED0053030410 SAFETY INFORMATION 3.4 Safety signal description • Toensuresafeoperationpleasereadthefollowingstatements 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. • Please read them carefully. Danger • This indicates situations of grave danger which, if ignored, may seriously threaten the health and safety of individuals. Important • This indicates particularly important technical information that should not be ignored. Warning • This indicates that failure to comply with it can cause minor damage or injury. ReadtheOperationandMaintenancehandbookbefore performing any operation on the engine. Hot Parts. Danger of burns. Presence of rotating parts. Danger of jamming or cutting. Presence of explosive fuel. Danger of fire or explosion. Presence of steam and pressurized coolant. Danger of burns. Use suitable protective gloves before carrying out any type of operation. Use protective goggles before carrying out any type of operation. Useearmuffsbeforecarryingoutanytypeofoperation. 3.4.1 Adhesive safety plates The following is a list of the adhesive safety plates that may be found on the engine, which indicate potential points of danger to the operator (Par. 3.7). 3.4.3 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. 3.4.2 Warnings Hereunder is a list of safety warnings that may be found in the manual, which advise you to pay attention when carrying out particular procedures that may be potentially dangerous to the operator or things.
- 56. 3 56 _01 ED0053030410 SAFETY INFORMATION 3.6 Safety and environmental impact Every organisation has a duty to implement procedures to identify, assess and monitor the influence of its own activities (products, services, etc.) on the environment. Procedures for identifying the extent of the impact on the environment must consider the following factors: - - Disposal of liquids. - - Waste management. - - Soil contamination. - - Atmospheric emissions. - - 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. - - Allcomponentsandfluidsmustbedisposedofinaccordance with the laws of the country in which disposal is taking place. - - Keeptheinjectionsystemaswellasenginemanagementand exhaustpipesinefficientworkingordertolimitenvironmental and noise pollution. - - When decommissioning the engine, select all components according to their chemical characteristics and dispose of them separately. 3.5 Information and safety signals ACCIDENTAL START Accidental Starts can cause severe injury or death. Before working on the engine or equipment, disconnect the battery negative (-) wire. ROTATING PARTS Rotating Parts can cause severe injury. Stay away while engine is in operation. Keep hands, feet, hair, and clothing away from all moving parts to prevent injury. Never operate the engine with covers, shrouds, or guards removed. LETHAL EXHAUST GASES Carbon Monoxide can cause severe nausea, fainting or death. Avoid inhaling exhaust fumes and never run the engine in a closed building or confined area. Carbon monoxide is toxic, odorless, colorless, and can cause death if inhaled. EXPLOSIVE GAS Explosive Gas can cause fires and severe acid burns. Charge battery only in a well ventilated area. Keep sparks, open flames, and other sources of ignition away from the battery at all times. Batteries produce explosive hydrogen gas while being charged. Keep batteries out of the reach of children. Remove all jewelry when servicing batteries. Before disconnecting the negative (-) ground cable, make sure all switches are OFF. If ON, a spark will occur at the ground cable terminal which could cause an explosion. HOT PARTS Hot Parts can cause severe burns. Engine components can get extremely hot from operation. Do not touch engine while operating or just after stopping. Never operate the engine with heat shields or guards removed. EXPLOSIVE FUEL Explosive fuel can cause fires and severe burns. Fuel is flammable and its vapours can ignite. Store fuel only in approved containers, in well ventilated, unoccupied buildings. Do not fill the fuel tank while the engine is hot or running, since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition. Do not start the engine near spilled fuel. Never use fuel as a cleaning agent. HIGH PRESSURE FLUID RISK OF PUNCTURE High Pressure Fluids can puncture skin and cause severe injury or death. Work on the injection system must be carried out by suitably trained staff wearing protection equipment. Injuries caused by fluid penetration are highly toxic and dangerous. If an injury occurs, seek immediate medical attention. ELECTRICAL SHOCK Electrical Shock can cause injury. Do not touch wires while engine is running. CALIFORNIA WARNING - DECLARATION 65 Engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
- 57. 3 57 _01 Fig. 3.2 ED0053030410 SAFETY INFORMATION 3.7 Location of safety signals on engine
- 58. 58 4 _01 ED0053030410 STORAGE INFORMATION 4.1 Product preservation Important • If the engines are not to be used for 6 months, they must be protected by carrying out the operations described in Engine storage (up to 6 months) (Par. 4.2). • If the engine is still not in use after the first 6 months, it is necessary to carry out a further procedure to extend the protection period (more than 6 months) (Par. 4.3). • If the engine is not to be used for an extended period, the protective treatment procedure must be repeated within 24 months of the previous one. 4.2 Engine storage (up to 6 months) Before storing the engine check that: • The environments are not humid or exposed to bad weather. Cover the engine with a proper protective sheet against dampness and atmospheric contaminants. • The place is not near electric panel. • Avoid storing the engine in direct contact with the ground. 4.3 Engine storage (over 6 months) Follow the steps described in Par. 4.2. 1 - Pour protective oil in the carter up to the MAX level. 2 - Refuel with fuel additives for long storage. The following additives are recommended: DEFA Fluid Plus (Pakelo Lubricants), Diesel Treatment (Green Star), Top Diesel (Bardhal), STP® Diesel Fuel Injector Treatment. 3 - With expansion tank: make sure that the coolant is up to the maximum level. 4 - Without expansion tank: Top liquid up until the pipes inside the radiator are covered by about 5 mm. Do not overfill the radiator, but leave room for the fuel to expand. 5 - Start the engine and run it at idle speed for around 2 minutes. 6 - Bring the engine to 75% of maximum rated speed for 5 to 10 minutes. 7 - Turn off the engine. 8 - Empty out completely the fuel tank. 9 - Spray SAE 10W-40 on the exhaust and intake manifolds. 10 - Seal the exhaust and intake ducts to prevent foreign bodies from entering. 11 - When cleaning the engine, if using a pressure washer or steam cleaning device, avoid directing the nozzle on electrical components, cable connections and sealed rings (oil seals etc). If cleaning engine with a pressure washer or steam cleaner, it is important to maintain a minimum distance of at least 200mm between the surface to be washed and the nozzle - avoiding absolutely electrical components such as alternators, starter motors and engine control units (ECU). 12 - Treat non-painted parts with protective products. 13 - Loosen the alternator belt Par. 6.2.1 point 1 e 2. If the engine protection is performed according to the suggestions indicated no corrosion damage will be found. 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. 4 - Adjust the alternator belt tension or replace if there are signs of deterioration. 5 - Refill the tank with fresh fuel. Warning • Over time, lubricants and filters lose their properties, so it is important to consider whether they need replacing, also based on the criteria described in Tab. 2.9. 6 - Make sure that the oil and the coolant are up to the maximum level. 7 - Start the engine and run it at idle speed for around 2 minutes. 8 - Bring the engine to 75% of maximum rated speed for 5 to 10 minutes. 9 - Stop the engine and while the oil still hot, perform the operation in Par. 5.2. 10 - Replace the filters (air, oil, fuel) with original spare parts. 11 - Perform the operations described in Par. 10.1. 12 - Perform the operations described in Par. 5.1 e Par. 10.2.
- 60. 60 5 _01 F H A Fig. 5.1 Fig. 5.2 ED0053030410 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. 1 - Undo the cap A carefully (circuit under pressure). 2 - Loosen clamp F and remove hose H to drain all liquid from the system contained in the engine crankcase ducts into an appropriate container and refer to Par. 3.6.
- 61. 61 5 _01 C C F B D E A Fig. 5.3 Fig. 5.4 ED0053030410 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. It is recommended to use an oil suction pump via the oil dipstick hole B. • Electric/pneumatic screwdrivers are forbidden. 1 - Unscrew cartridge holder cover C by performing three complete turns and wait 1 minute. NOTE: this operation allows to oil contained in the support G to flow into the oil sump in the correct way. 2 - Unscrew cartridge holder cover C and check that the oil in the lub. oil filter bracket G has flowed towards the oil sump (refer to NOTE in Par. 2.10.3). 3 - Undo the oil filler cap A. 4 - Remove the oil dipstick B. 5 - Remove the oil drain plug D and the gasket E. (the oil drain plug is on both sides of the oil sump). 6 - Drain oil in to an appropriate container. (For used oil disposal refer to the Par. 3.6). 7 - Replace gasket E. 8 - Tighten the drain oil plug D (tightening torque at 50 Nm). 9 - Perform the operations described in par. 6.4.2 and the operation 5 par. 6.4.3.
- 62. 6 62 _01 A B E C D G H N P L M F H Fig. 6.1 Fig. 6.2 Fig. 6.4 Fig. 6.3 H1 H2 ED0053030410 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. • Seal all injection component unions as illustrated in Par. 2.9.7 during disassembly. • Always replace the gaskets after each disassembly. • Handle the components as described in Par. 2.18. • Refer to Par. 1.3 for operating references when assembling and disassembling. 6.1.1 I n j e c t i o n f u e l p i p e s d i s a s s e m b l y (injection pump/injectors) 1 - Undo the screws A. 2 - Undo the screws B. 3 - Remove quick fitting C. 4 - Undo the screws D and remove the manifold E. 5 - Undo capscrews H1 and remove clamps H2 and the rubber element. 6 - Undo the nuts F. 7 - Undo the nuts G. 8 - Remove the tube H. 6.1.2 Rocker arms cover disassembly 1 - Undo the screw L. 2 - Undo the screw M. 3 - Undo the screws N and remove the rocker arm cap P.
- 63. 6 63 _01 ST_30 ST_30 X K J Fig. 6.6 Fig. 6.7 Fig. 6.8 Q R J X K Z BC Z S S V Fig. 6.5 ED0053030410 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) and remove the cylinder injector 1 (Par. 1.4 - 6.1.1 - 6.1.2 - 6.1.3 - 6.1.4). • Alternatively, you can identify the pump from the online spare parts catalogue (https://partners.lombardini.it/App/ SparepartCatalogue/Default/Catalogue.aspx). 1 - Insert the tool ST_30 into the injector N°1 and fix it with the fixing brace X, capscrew J and washer K. NOTE: Do not tighten the capscrew J. 6.1.3 Fuel return pipes disassembly 1 - Undo the screws Q and remove hose R. 6.1.4 Injectors disassembly 1 - Undo the screw J and remove washer K and then bracket X. 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 11 mm), by applying small rotations to unblock the component. 3 - Seal all injection component unions as illustrated in Par. 2.9.7. 4 - Ensure that gasket S has remained in the correct position (Fig. 6.7). Otherwise, recover the gasket from inside the electronic injector V manifold.
- 64. 6 64 _01 ST_02 Fig. 6.9 Fig. 6.10 X1 W ST_30 Y A1 B1 Fig. 6.11 Tab. 6.1 ST_02 ED0053030410 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 5 - With reference X pointed upwards, find the TDC through tool ST_30, then bring the dial gauge indicator to 0. 2 - Disassemble the starter motor. 3 - Mount the tool ST_02 in the seat of the starter motor Y and fit it with the two starter motor fixing screws. 4 - Rotate the crankshaft clockwise (Ref. A Par. 1.4) through the ST_02 tool bringing reference X upwards. NOTE: When positioning reference X, make sure cylinder N° 1 is in compression phase (the valves on piston N° 1 must all be closed). 6 - By means of the identified pump code, refer to Tab. 6.1 to know the advance degrees and the corresponding value to lower the piston. 7 - Having identified the value to lower the piston, rotate the crankshaft anti-clockwise by going beyond the value described in Tab. 6.1, once again, rotate the crankshaft clockwise, stopping at the correct advance value by using tool ST_30 (Ref. A Par. 1.4). NOTE: The value indicated in Tab. 6.1 must be reached by rotating the shaft with the piston in compression phase. Use the ST_02 tool to totate the crankshaft. 8 - Lock the ST_02 tool through J screws and ensure that the crankshaft does not rotate, which would alter the correct advance value. If this happens, repeat the instructions described in points 4, 5, 6, 7 and 8. 9 - Undo the screws A1, remove the plate B1. PUMP CODE PISTON LOWERING (mm) ADVANCE a ED0065905290-S 0,733 8° ED0065905430-S 0,562 7° ED0065905440-S 0,828 8,5° ED0065905690-S 0,413 6°
- 65. 6 65 _01 G1 F1 E1 E1 ST_13 J1 P1 D1 ST_13 D1 D1 C1 Fig. 6.13 Fig. 6.14 Fig. 6.15 J2 N1 K2 K1 L1 M1 Fig. 6.12 ED0053030410 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 11 - Undo the capscrew E1 and shift the slotted plate F1 in the direction of arrow G1. 12 - Tighten screw E1 to block the pump (tightening torque to 12 Nm). 13 - Screw the tool ST_13 on the gear D1. 18 - Undo the screw P1. 19 - Tighten the screw of tool ST_13 to disconnect the injection pump J1 from the high pressure pump control gear D1. 20 - Undo the screws J2 and extract the injection pump J1. 21 - DO NOT remove the tool ST_13. 10 - Undo and remove the nut C1 fixing the injection pump control gear D1. Important • After removing the nut C1, ensure that the correct advance value has remained unchanged on ST_30. • Be careful that the nut C1 does not fall into the timing cover. 14 - Perform the operations of point 1 of Par. 5.2. 15 - Remove quick fitting N1. 16 - Loosen capscrews K1 and K2 and detach Oil Cooler unit L1 from crankcase M1. 17 - Loosen the screws J2.
- 66. 6 66 _01 Fig. 6.16 J1 J2 Q1 M1 G2 E1 F1 E1 Fig. 6.17 M1 Fig. 6.18 D1 S1 C1 Fig. 6.19 R1 R2 K1 K2 L1 ED0053030410 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 6.1.6 Injection pump assembly Important • Before assembling the new pump J1, make sure that plate F1 can move freely and that fastening capscrews E1 are not loose (the pump sold as a spare part is supplied with the cylinder injection timing blocked N° 1). • Ensure that the coupling surfaces on shaft Q1 and gear D1 are free from impurities and lubrication residues. • Remove the guard cap only when the pipes are reconnected. • Do not remove the tool ST_30. 1 - Mount the injection pump J1, inserting the shaft Q1 in the gear D1. Important • Always change screws J2 with new ones or apply Loctite 2701 to the threads. 2 - Clamp the screws J2 on the crankcase M1 (tightening torque at 25 Nm). 3 - Remove the tool ST_13. 4 - Ensure that the correct advance value has remained unchanged, tighten nut C1 on shaft Q1 (as shown in Fig. 6.17, you are allowed to use a screwdriver to guide nut C1 onto shaft Q1 in order to prevent it from accidentally falling inside carter S1 - tightening torque at 140 Nm). 5 - Undo the capscrew E1 and shift the slotted plate F1 in the direction of arrow G2. 6 - Tighten screw E1 (tightening torque to 5.5 Nm). The injection pump is unlocked. 7 - Remove the tool ST_30 and ST_02. 8 - Assemble Oil Cooler L1 onto crankcase M1 by means of capscrews K1 and K2. NOTE: Always replace the gasket R1, R2 at each assembly.
- 67. 6 67 _01 Fig. 6.20 Fig. 6.21 N1 P1 T1 U1 J1 A1 B1 V1 S1 Fig. 6.22 Z W1 W2 Z V Fig. 6.23 S ED0053030410 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 W1, W2, S, and fit them on the injector Z. 2 - Fit the injector Z in the sleeve V. 9 - Secure tube U1 by means of capscrew P1, inserting gasket T1. 10 - Fit quick coupling N1 onto pump J1. 11 - Secure plate B1 by means of capscrews A1, inserting gasket V1 onto carter S1 (tightening torque at 10 Nm).
- 68. 6 68 _01 Z J K X Fig. 6.24 Y1 H Fig. 6.25 Q R Z Fig. 6.26 ED0053030410 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 3 - Assemble the parts P, Q, R. and fit the parts so assembled on the injector Z. 4 - Follow operations 1 and 2 of Par. 6.1.9, operations 1 of Par. 6.1.10. NOTE: By following these operations, the injector union is perfectly centred with gasket Y1. 5 - Remove tubes H, cap P and gasket. NOTE: be careful not to compromise orientation of the injector when removing components H, P. 6 - Tighten the screw J (tightening torque to 20 Nm - Fig. 6.24). 6.1.8 Assembly of the injector return pipes 1 - Position the tube N on the injectors Z and tighten screws M (tightening torque to 14 Nm).
- 69. 6 69 _01 Y1 E2 H6 A B H F G C D2 E P Z1 M M1 M2 L B2 A2 N D E C2 A2 ST_17 ST_17 Fig. 6.28 Fig. 6.29 Fig. 6.27 Fig. 6.30 Fig. 6.31 1 3 7 5 8 9 4 2 6 10 H H3 H4 H5 H2 M3 ED0053030410 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 6.1.10 Installation of the fuel injector pipes (pump injector/injectors) 1 - Position pipes H on the injectors and on the injector pump. Important • Tighten the nuts F and G manually, without clamping them. 2 - Tighten the nuts F and G (tightening torque at 25 Nm). 3 - Secure tubes H by means of clamps H2, assembling: - H3 rubber element; - clamp H2 on element H3; - secure clamp H2 by means of capscrew H4 and nut H5 (tightening torque at 10 Nm). 4 - Secure manifold E onto cylinder head A2 by means of capscrews D, inserting gasket C2. 5 - Secure suction line E2 onto manifold E by means of capscrews A, inserting gasket D2. 6 - Fit quick coupling C onto manifold E. 7 - Fasten the pipe H6 on the manifold E with the screws B. 6.1.9 AssemblyRockerarm cover Important • The gasket Z1 between the rockerarmcoverandthecylinder head must always be replaced every time it is disassembled. 1 - Position tool ST_17 onto the head in correspondence with the two fastening holes 9 and 10. 2 - Position gasket Z1 and cap P on cylinder head A2 matching the holes of fastening capscrews N with the aid of the gudgeon guides ST_17. 3 - Attach the rocker arm cover P on the head A2 with the screw N adhering to the tightening sequence shown in Fig. 6.28 (tightening torque to 10 Nm). 4 - Secure the hose M2 with the screw L. 5 - Clamp the fitting M3 with the screw M inserting the gasket B2.
- 70. 6 70 _01 F E Fig. 6.34 G H G C D B A Fig. 6.33 Fig. 6.32 ED0053030410 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 6.2 Coolant pump replacement 6.2.1 Disassembly NOTE: Perform the operations described in Par. 5.1. Important • Before proceeding with operation, carefully read Par. 3.3.2. • The coolant pump is not repairable. 1 - Loosen the screws A and B. 2 - Loosen capscrew C and disconnect voltage from belt D and remove belt D. 3 - Undo the screws E and remove the pulley F. 4 - Undo the screws G and remove the pump H with the relevant gasket.
- 71. 6 71 _01 E F Fig. 6.35 H G J A C M D Fig. 6.37 K P Fig. 6.36 ED0053030410 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 6.2.2 Assembly Important • Always replace the gaskets J, at each disassembly. • Always replace the belt D after each assembly. 1 - Fit the pump H with the screws G interposing the new gasket J (tightening torque at 25 Nm). 2 - By means of capscrews E, secure pulley F to crankcase K (tightening torque at 25 Nm). 3 - Insert the belt D on the pulleys M. 4 - Tighten capscrew C, bringing capscrew A to its stop on the slot of support. 5 - Fit the screw A (tightening torque at 25 Nm). 6 - Fit the screw B (Fig. 6.32 - tightening torque at 45 Nm). 7 - Start the engine and run it for some minutes, then turn off it and let it cool down at ambient temperature. Check by the appropriate tool that at point P the tension value is between 135 and 178 Hz. NOTE: If the belt does not comply with the pre-set voltage values, replace it.
- 72. 6 72 _01 A B F F B C E D D E E Fig. 6.40 Fig. 6.39 Fig. 6.38 ED0053030410 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 6.3 Oil vapour separator replacement Important • Before proceeding with operation, carefully read Par. 3.3.2. 6.3.1 Disassembly 1 - Remove quick fitting A. 2 - Release the clamps B and C. 3 - Remove hose D from breather body E. 4 - Remove capscrews F and remove breather body E. 6.3.2 Assembly 1 - Secure breather body E by means of capscrews F. 2 - Fit hose D onto breather body E (Fig. 6.38). 3 - Secure the clamps B and C (Fig. 6.38).
- 73. 6 73 _01 Fig. 6.43 Fig. 6.44 Fig. 6.41 Fig. 6.42 B B A C E D H N1 F G N M L P H E A ED0053030410 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 6.4 Oil cooler unit and oil filter replacement 6.4.1 Oil Cooler unit disassembly Important • Perform the operations described in Par. 5.1 and Par. 5.2. • Oil Cooler unit E is not repairable. 1 - Release the clamps A. 2 - Remove the hoses B out of the Oil Cooler unit E. Warning • Electric/pneumatic screwdrivers are forbidden. • Use a suitable container to recover any residue oil. 3 - Unscrew cartridge holder cover H by performing three complete turns and wait 1 minute. NOTE: this operation allows to oil contained in the support E to flow into the oil sump in the correct way. 4 - Unscrew cartridge holder cover H and check that the oil in the lub. oil filter support E has flowed towards the oil sump. 5 - Remove quick fitting N1. 6 - Undo the screws C and D and remove the Oil Cooler unit E. 7 - Remove the gaskets F and G from the Oil Cooler unit E. 6.4.2 Oil filter cartridge replacement 1 - Remove gaskets L, M and N from element holder cover H. 2 - Remove cartridge P from element holder cover H.
- 74. 6 74 _01 Fig. 6.45 Fig. 6.46 T G F1 G1 F Q S E U C D Q E H A A B N1 J1 B P L N L1 M H M1 N1 Fig. 6.47 ED0053030410 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 5 - Lubricate and insert gaskets L, M and N in the L1, M1 and N1 seats of element holder cover H. 6 - Insert element P into element holder cover H. 6.4.3 Oil Cooler unit assembly Important • In the event of assembly of union U on crankcase S, (manual tightening torque with Loctite 2701 on the thread). 1 - Check that the surface Q on the support E and on the crankcase S are free from impurities. 2 - Lubricate and insert the gasket T on the fitting U. 3 - Lubricate and insert the gaskets on the support E: F in seat F1; G in seat G1. 4 - Fit the support R with the screws C and D (tightening torque at 10 Nm). 5 - Insert and tighten the cartridge support H on the filter support E (tightening torque at 25 Nm). 6 - Fit the hoses B on the support E and secure the hoses B with the clamps A. 7 - Fit quick coupling N1 onto pump J1.
- 75. 6 75 _01 N1 C F H A B H N F H L M P B A C Fig. 6.50 Fig. 6.51 Fig. 6.49 Fig. 6.48 N1 ED0053030410 INFORMATION FOR REPLACING THE FUNCTIONAL UNITS 6.5 Fuel filter replacement 6.5.1 Disassembly Warning • Before proceeding with operation, carefully read Par. 3.3.2. • The fuel filter is not always mounted in the engine. • When disassembling, use a suitable container to recover the fuel contained in the cartridge F. 1 - Remove quick fitting N1. 2 - Release the clamps A and pull the pipes B out of the support H. 3 - Unscrew the cartridge F from the support H. 4 - Undo the screws C and remove the support H. 4 - Lubricate the gasket N with fuel. 5 - Tighten the cartridge F on the support H (tightening torque at 17 Nm). 6 - Fit quick coupling N1 onto support H. 6.5.2 Assembly 1 - Secure fuel filter bracket H with capscrews C onto crankcase M, inserting spacer L between M and H and washer P between H and C (tightening torque at 25 Nm). 2 - Fit the pipes B on the support H. 3 - Secure the pipes B with the clamps A.
- 77. 7 77 _01 D E B A C C A Fig. 7.1 Fig. 7.2 Fig. 7.3 G F ED0053030410 INFORMATION FOR DISASSEMBLY 7.1 Recommendations for disassembly Important • To locate specific topics, the reader should refer to the index. • 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. • The operator should prepare all equipment and tools in order to enable him to carry out the operations correctly and safely. • Before disassembly, perform the operation described in Chap. 5. • Before proceeding with operation, carefully read Chap. 3. • In order to operate safely and easily, we recommend positioning the engine on a rotating stand for engine overhauling. • Seal all injection component unions as illustrated in Par. 2.9.8 during disassembly • Protect all disassembled components and coupling surfaces subject to oxidation with lubricant. • Where necessary, reference to special tools to use during disassembly operations is indicated (e.g. ST_05), refer to KOHLER diesel special tools. 7.2 Turbocharger disassembly 1 - Unscrew the fittings A and remove the pipe B with the relative gaskets C. 2 - Undo the screws D and remove pipe E and the relevant gaskets. 3 - Undo the nuts F and remove the turbocharger G.
- 78. 7 78 _01 C B A G F Fig. 7.6 D E Fig. 7.4 D C B A A Fig. 7.5 Fig. 7.7 ED0053030410 INFORMATION FOR DISASSEMBLY 7.3 Coolant recirculation components disassembly 7.3.1 Oil Cooler manifold 1 - Release the clamps A. 2 - Undo the screws B and remove hoses C. 7.3.2 Coolant pump Important • The pump B is not repairable. 1 - Perform the operations described in Par. 6.2.1. 2 - Undo capscrews F and remove flange G with the relative gasket. 7.3.3 Thermostatic valve 1 - Undo the screws A and remove the thermostatic valve cover B. 2 - Remove the thermostatic valve C and its gasket. Important • Always replace the gasket D every time it is disassembled. 3 - Check that the air bleeding hole is not clogged or blocked (Par. 2.11.3). 3 - Release the clamps D and remove hoses E.
- 79. 7 79 _01 B1 A1 C1 Fig. 7.10 Fig. 7.9 Fig. 7.8 Fig. 7.11 G1 F1 D C E B ED0053030410 INFORMATION FOR DISASSEMBLY 7.4 Electric components disassembly 7.4.1 Starter motor Important • The motor is not repairable. 1 - Perform the operations from point 2 to 3 of Par. 6.1.5. 7.4.2 Alternator 1 - Undo the screws A1 and B1 and remove the alternator C1. 7.4.3.2 Coolant temperature sensor ( ) 1 - Unscrew and remove the coolant temperature sensor G1. 7.4.3 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. 7.4.3.1 Oil pressure switch ( ) 1 - Unscrew and remove the oil pressure switch F1. 7.5 Exhaust manifold disassembly 1 - Remove capscrews B and spacers C, manifold D and gaskets E. 2 - Close the openings and manifolds to prevent foreign bodies from entering.
- 80. 7 80 _01 Fig. 7.12 Fig. 7.13 A A B B C ED0053030410 INFORMATION FOR DISASSEMBLY 7.6 Fuel system disassembly Important • Seal all injection component unions as illustrated in Par. 2.9.8 during disassembly. 7.6.1 Injection fuel pipes 1 - Perform the operations of Par. 6.1.1. 7.6.2 Rocker arms cover 1 - Perform the operations of Par. 6.1.2. 7.6.3 Fuel return pipes 1 - Perform the operations of Par. 6.1.3. 2 - Perform the operations of point 18 of Par. 6.1.5. 3 - Loosen union A from cylinder head B and remove return line C. 7.6.4 Injectors 1 - Perform the operations of Par. 6.1.4. 7.6.5 Injection pump 1 - Perform the operations of Par. 6.1.5. 7.6.6 Fuel filter ( ) 1 - Perform the operations of Par. 6.5.1. 7.7 Crankshaft pulley disassembly 4 - Undo the screws A and remove the pulley B.
- 81. 7 81 _01 E D Fig. 7.15 16 15 14 13 12 18 7 6 5 11 10 9 17 2 3 4 8 1 B C A B ST_41 Fig. 7.14 A B Fig. 7.16 D E F Fig. 7.17 C ED0053030410 INFORMATION FOR DISASSEMBLY 7.8 Flange unit disassembly 7.8.1 Flywheel Danger • The flywheel A is very heavy. Pay the utmost attention while removing it in order to prevent it dropping or falling, as this may have serious consequences for the operative. 1 - Undo the screws B and remove the flywheel A by means of tool ST_43. 2 - Secure tool ST_41 onto gear C by means of capscrews B. 7.8.2 Flange housing Danger • The flange housing D is very heavy. Pay the utmost attention while removing it in order to prevent it dropping or falling, as this may have serious consequences for the operative. 1 - Undo capscrews E by following the order indicated in the figure. 2 - Remove the engine housing D by means of tool ST_44. 7.9 Lubrication circuit disassembly 7.9.1 Oil pump ( ) Important • The oil pump is not repairable. 1 - Undo the screws A and remove the pump unit B. 7.9.2 Oil pressure valve ( ) 1 - Remove cotter pin C. 2 - Remove disk D, spring E, piston valve F using a magnet.
- 82. 7 82 _01 Fig. 7.20 M N Fig. 7.18 Fig. 7.19 D E H G F ED0053030410 INFORMATION FOR DISASSEMBLY 7.10.2 Valve rods and bridges 1 - Remove the valve bridges M. 2 - Remove the rocker arm control rods N. 7.10.1.1 Rocker arm ( ) 1 - Remove the retainer ring F. 2 - Remove the shoulder rings G. 3 - Remove the rocker arms H. 7.10 Cylinder head unit disassembly 7.10.1 Rocker arm pin 1 - Undo the screws D. 2 - Remove the rocker arm pin unit E.
- 83. 7 83 _01 Fig. 7.22 R J W Fig. 7.21 P Q 4 6 10 8 2 1 5 9 7 3 Fig. 7.23 S U T Fig. 7.24 Q ST_07 ED0053030410 INFORMATION FOR DISASSEMBLY 7.10.3 Cylinder head Important • The capscrews P must be replaced every time they are disassembled. • Do NOT remove the capscrews completely, first loosen them by turning them a whole cycle following the order shown in the figure. 1 - Loosen fastening screws P, turning them by one turn following the order shown in the figure.. 2 - Undo capscrews P by following the order indicated in the figure. Important • To lift cylinder head Q, only use both eyebolts Y provided by KOHLER (refer to Fig. 7.28). • When removing the cylinder head Q and subsequent disassembly, control, and assembly operations, it is necessary to protect the contact surface W of cylinder head Q and crankcase J against impacts.. 3 - Remove the cylinder head Q. 4 - Remove the head gasket R. 7.10.3.1 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 - Position the tool ST_07 on the valve as shown in the figure. 3 - Push the lever of the tool ST_07 downwards, in order to lower the valve plates S in the direction of the arrow T, remove cotters U using a magnet. NOTE: Repeat all the operations for all the valves concerned.
- 84. 7 84 _01 Fig. 7.27 Fig. 7.28 W X Y X Q Fig. 7.25 Fig. 7.26 V Z Z Q J K ED0053030410 INFORMATION FOR DISASSEMBLY 7.10.3.3 Valve stem gasket ( ) 1 - Remove the gaskets W. 7.10.3.4 Lifting eyebolts ( ) 1 - Undo the screws X and remove the eyebolts Y. 2 - Thoroughly wash the cylinder head Q. 7.10.3.2 Electronic injector sleeves ( ) 1 - Unscrew and remove the sleeves Z from the head Q. 2 - Remove the gaskets J, K. Important • Before removing the valves, make some marks to record their original position, in order to avoid confusing them when re- assembling (if they are not replaced). 4 - Remove the valves V.
- 85. 7 85 _01 Fig. 7.31 H Fig. 7.30 F F G L Fig. 7.29 A E C D B ED0053030410 INFORMATION FOR DISASSEMBLY 7.11 Oil sump unit disassembly Important • For the following operation, turn the engine by bringing the cylinder head surface downwards. 7.11.1 Oil sump 1 - Undo the screws A. 2 - Remove the oil sump B by inserting a plate between surface C of crankcase D and oil sump B. 3 - Remove the oil dipstick E. 7.11.2 Oil suction pipe 1 - Undo the screws F and remove the pipe G. 7.11.3 Oil drain pipe ( ) 1 - Undo the screws H and remove the pipe L.
- 86. 7 86 _01 Fig. 7.32 4 3 2 1 Fig. 7.33 Fig. 7.34 Fig. 7.35 L M K1 K2 N ED0053030410 INFORMATION FOR DISASSEMBLY 7.12 Engine block disassembly 7.12.1 Piston unit / connecting rod Important • Mark some numerical references (cylinder n°) on the connecting rods, connecting rod caps N, pistons and gudgeon pins to prevent unintentionally confusing the components not replaced during assembly. Failure to do this may result in engine malfunctions. • References on connecting rod M and cap N must only be carried out on a side in correspondence with K1 and K2 , as illustrated in Fig. 7.33. 1 - Unsrew bolts M and remove the connecting rod caps N. NOTE: coupling cap N on the connecting rod can be carried out with centring taper pins (Fig. 7.34) or broken (Fig. 7.35 - without centring taper pins).
- 87. 7 87 _01 L X N P L Fig. 7.37 Fig. 7.36 Fig. 7.39 B C A D E Fig. 7.38 ED0053030410 INFORMATION FOR DISASSEMBLY Warning • The connecting rod half-bearings Z are made of special material. Therefore, they must be replaced every time they are removed to prevent seizures. 2 - Pull out the connecting rod - piston assembly from position 2 and 3 by manually applying pressure on the connecting rod M in the direction of arrow AK. 3 - Couple the connecting rod big end caps L with the relevant piston and connecting rod unit M. 4 - Rotate the crankshaft by 180°. 5 - Repeat points 2 to 5 to disassemble the connecting rod - piston assembly to position 1 and 4. 7.12.2 Timing system gear disassembly 1 - Unscrew screws A and remove the gear B. 2 - Remove the gear C. 3 - Unscrew screws D and remove the gear E.
- 88. 7 88 _01 D1 R 1 7 9 5 3 2 8 10 6 4 Fig. 7.41 Q 18 17 6 5 4 3 2 1 16 15 14 13 12 7 8 9 11 10 Fig. 7.40 ED0053030410 INFORMATION FOR DISASSEMBLY Important • The capscrews R must be replaced every time they are disassembled. • Do NOT remove the capscrews completely, first loosen them by turning them a whole cycle following the order shown in the figure. 1 - Loosen fastening screws R, turning them by one turn following the order shown in the figure. 2 - Undo capscrews R by following the order indicated in the figure. 3 - Remove the lower semi-crankcase D1 and store it in a suitable container for washing. 7.12.3 Lower semi-crankcase Important • The capscrews Q must be replaced every time they are disassembled. • Do NOT remove the capscrews completely, first loosen them by turning them a whole cycle following the order shown in the figure. 1 - Loosen fastening screws Q, turning them by one turn following the order shown in the figure. 2 - Undo capscrews Q by following the order indicated in the figure.
- 89. 7 89 _01 Fig. 7.44 K Fig. 7.45 X D2 W Fig. 7.42 S T U Fig. 7.43 V Z J L ED0053030410 INFORMATION FOR DISASSEMBLY 7.12.5.1 Rings ( ) 1 - Remove the rings K. 7.12.6 Oil spray nozzles ( ) 1 - Undo the screws W and remove the spray nozzles X from the upper semi-crankcase D2. 7.12.4 Crankshaft Remove: 1 - Crankshaft S. 2 - The shoulder semi-rings T. 3 - Remove gasket U from crankshaft S. 7.12.5 Piston ( ) 1 - Remove the retainer ring V. 2 - Remove the pin Z to separate the piston J from the connecting rod L. Important • If they are not replaced, keep the components together (connecting rod - piston - gudgeon pin) by using references in order to prevent them from getting mixed up during assembly.
- 90. 7 90 _01 D2 A1 Fig. 7.48 B1 D1 C F Y D2 D2 Fig. 7.46 Fig. 7.49 Fig. 7.47 ED0053030410 INFORMATION FOR DISASSEMBLY 7.12.9 Crankshaft bushings 1 - Remove the crankshaft bushings A1 from the upper crankcase D2. Important • The crankshaft half-bearings A1, B1 are made of special material. Therefore, they must be replaced every time they are removed to prevent seizures. 2 - Remove the crankshaft bushings B1 from the lower semi- crankcase D1. 7.12.7 Camshaft 1 - Remove the lock ring C. 2 - Extract the camshaft F from the upper semi-crankcase D2. 7.12.8 Camshaft tappets 1 - With a magnet, remove the tappets Y from the upper semi- crankcase D2.
- 91. 91 8 _01 Fig. 8.1 A B1 D C B B1 G A1 A2 A3 A3 ED0053030410 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. NOTE: To easily locate specific topics, the reader should refer to the analytical index or chapter index. • Before any intervention, the operator should lay out all equipment and tools in such a way as to enable him to carry out operations correctly and safely. • The operator must comply with the specific measures described in order to avoid errors that might cause damage to the engine. • Before carrying out any operation, clean the units and/or components thoroughly and eliminate any deposits. • Do not wash the components with steam or hot water. Use suitable products only. • Do not use flammable products (petrol, diesel, etc.) to degrease or wash components. Use suitable products only. • Apply a layer of lubricant over all surfaces of all disassembled components to protect them against oxidation. • Check the integrity and state of wear of all disassembled components in order to ensure good working condition of the engine. • When indicated, some components are to be replaced in pairs or together with other parts (e.g. crankshaft half-bearings/ connecting rod, piston complete with rings and gudgeon pin, etc.). • When indicated, some grinding operations are to be carried out in series (e.g. grinding of cylinders, crankpins, journals, etc.). 8.2 Crankcase 8.2.1 Oil line check Important • Replace and assemble the conical cap A3 in hole B, B1 (tightening torque at 30 Nm), after having performed cleaning operations. 1 - Remove capscrews A1 and remove plate A2 with its gasket. Use a pipe cleaner in access points A, B, B1, C, D to clean the oil ducts of crankcase G. Use compressed air to eliminate any residues.
- 92. 92 8 _01 J M N F G H L Fig. 8.2 Tab. 8.1 ED0053030410 INFORMATION ABOUT OVERHAULING 8.2.2 Cylinder check Position crankcase G onto a workbench. With a dial gauge, measure the diameter in correspondence to points J-M-N (Fig. 8.2) lengthwise and diagonally with regard to axis H of the crankshaft. If ovalisation or wear detected in a single point in J-M-N is greater than +0.05 mm with regard to the value in Tab. 8.1, you are required to perform grinding operations on all cylinders F. Refer to Tab. 8.1 to establish the clearance value of cylinders subjected to grinding operations. Important • Grinding is prohibited before 10000 h of operation on all engines provided with an EPA name plate (refer to Par. 1.3). • The grinding involved is of +0.20, +0.50 and + 1 mm. • Cylinder grinding operations must observe KOHLER SPECIFICATIONS - cod. ED0035612500. • Grinding must be strictly performed on all cylinders F. Tab.8.1 detailsthedimensionalvaluesofnewcomponentsonly. (1) The increase of +0.20 mm, may already be present on the engine. Grinding values PISTON Ø CYLINDER (± 0.007 mm) Ø PISTON (± 0.007 mm) CLEARANCE VALUE (mm) STD 96.010 95.950 0.046 - 0.074 +0.20 (1) 96.210 96.150 +0.50 96.510 96.450 +1.00 97.010 96.950
- 93. 93 8 _01 Z Fig. 8.3 K W X Z1 W1 X1 K1 Y1 Fig. 8.4 R Y S Tab. 8.2 Tab. 8.3 S1 P B ED0053030410 INFORMATION ABOUT OVERHAULING 8.2.3 Camshaft housing check Useaninternaldialgaugetomeasurethediametersofhousings W - K - Y - Z. With a micrometer, measure the diameters of gudgeon pins W1 - K1 - Y1 - Z1 (Fig. 8.4). According to the values measured, calculate the clearance between the housing and gudgeon, which is to observe the values in Tab. 8.2. The MAX value of wear allowed is 0.120 mm. Important • Tab. 8.2 details the dimensional values of new components only. REF. DIMENSIONS (mm) CLEARANCE VALUE (mm) W 47.500 - 47.525 0.060 - 0.105 W1 47.420 - 47.440 K 47.000 - 47.025 0.060 - 0.105 K1 46.920 - 46.940 Y 46.500 - 46.525 0.060 - 0.105 Y1 46.420 - 46.440 Z 35.000 - 36.025 0.060 - 0.105 Z1 34.920 - 35.940 8.2.4 Camshaft control Withamicrometer,measurethemaximumdimensionsofintake camshaft R and exhaust camshaft S (Tab. 8.3). The MAX value of wear allowed is 0.1 mm. Important • Tab. 8.3 details the dimensional values of new components only. 8.2.5 Camshaft control with internal EGR The internal EGR is available only for Stage IIIA or Tier 3 engines provided with "CE" approval (Par. 1.2) or "EPA" name plate (Par. 1.3). With a micrometer, measure the dimensions of the S1 quota (Tab. 8.3) on all of cams S (the S1 quota varies according to the code of camshaft P - refer to the spare parts cataloguetoidentifythecodeofcamshaftP).Replacecamshaft P if the S1 quota does not comply with the value on Tab. 8.3. Housing and camshaft gudgeon dimensions. REF. CODE (P) DIMENSIONS (mm) R 40.495 - 40.433 S 39.175 - 39.113 S1 P = ED0010101820-S 35.666 - 35.616 S1 P = ED0010101730-S 35.564 - 35.514 Camshaft dimensions
- 94. 94 8 _01 A Fig. 8.5 Fig. 8.6 B C D D X Tab. 8.4 ED0053030410 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. 8.5. 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. With a gauge, check the length of value A and B (Tab. 8.4). The MAX value of wear allowed is 0.08 mm 8.3.2 Tappet housing check Use an internal dial gauge to measure the diameter of the tappet housings X. value of A detected (Par. 8.3.1) calculate the clearance value (Tab. 8.4). If the clearance values are not observed, replace the worn component. Important • Tab. 8.4 details the dimensional values of new components only. Tappets and tappet housing dimensions. REF. DIMENSIONS (mm) CLEARANCE VALUE (mm) A 14.984 - 14.966 0.016 - 0.052 X 15.000 - 15.018 B 47.5 ...
- 95. 95 8 _01 Fig. 8.7 B1 A1 D C B2 A2 B Tab. 8.5 ED0053030410 INFORMATION ABOUT OVERHAULING 8.4 Crankshaft 8.4.1 Dimensional check and overhauling Wash the crankshaft thoroughly using suitable detergent. 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. 9.3.1 and Par. 9.3.5 - except points 2, 3, 5, 9 and 10. Tighten capscrews J (Fig. 9.9) and K (Fig. 9.10) observing the cycles, tightening, and subsequent rotation. Cycle 1 - Screw J - Torx M14x1,5 - Torque 60 Nm. (Fig. 9.9) Cycle2-ScrewK-TorxM10x1.25-Torque30Nm.(Fig.9.10). Measure the crank pins A1 with a micrometer, and using a dial gauge measure the internal diameter of the connecting rod half-bearings A2. Measure the main journals B1, with a micrometer, and using a dial gauge measure the internal diameter of the crankshaft half-bearings B2. If the values describedinTab.8.5donotcorrespond,proceedwithgrinding all gudgeon pins A1 e B1. Important • The crankshaft and connecting rod must be replaced every time they are assembled to prevent seizure, as they are made of special lead-free material. • The MAX allowed value of wear for A1 e A2 is 0.120 mm. • The MAX allowed value of wear for B1 e B2 is 0.120 mm. • To grind the crankshaft, a decrease in diameter of the half- bearings and connecting rod is provided for at 0.25 mm and 0.50 mm, to grind gudgeon pins A1 and B1, measure the values of diameters A2 and B2 by assembling the decreased half-bearings, define the diameter to grind of pins A1 and B1, observing the clearance indicated in Tab. 8.5. • Tab. 8.5 details the dimensional values of new components only. REF. DIMENSIONS(mm) CLEARANCE VALUE (mm) A1 60.980 - 61.000 0.034 - 0.09 A2 61.034 - 61.069 B1 79.978 - 80.000 0.036 - 0.104 B2 80.036 - 80.082 Connecting rod and journal diameter
- 96. 96 8 _01 Fig. 8.8 B C F D Q R T S P Fig. 8.10 A E E Fig. 8.11 D Tab. 8.6 Fig. 8.9 ED0053030410 INFORMATION ABOUT OVERHAULING 8.5 Connecting rod - piston assembly 8.5.1 Connecting rod dimensions check Important • Before assembling the connecting rod and pistons (Par. 9.3.7 and 9.3.8), check that the difference in weight between the complete connecting rod and piston units do not exceed 15 gr to prevent weight imbalances during rotation of the crankshaft and consequent damage. • Mark some references on the connecting rods, caps Q, pistons and gudgeon pins to prevent unintentionally confusing the components during assembly. Failure to do this may result in engine malfunctions.. • Connecting rod half-bearings S must be replaced at each assembly. Check that the contact surfaces are perfectly clean and intact. Assemble the connecting rod cap Q to the connecting rod with the half-bearings S and tighten capscrews P (tightening torque at 28 Nm). With a dial gauge, measure diameters B and D. The MAX allowed value of wear for B and D is 0.06 mm. Important • Tab. 8.6 details the dimensional values of new components only. • Check that the connecting rod and crankshaft half-bearings are coupled properly. • Refer to the warnings in Par. 8.4.1 for value D decreased. • If the clearance value between B and D is not observed, you are required to replace bearing R (Fig. 8.10). 8.4.2 Checking the axial clearance of the crankshaft Perform the operations described in Par. 9.3.1, 9.3.4 and. Par. 9.3.5 - except points 2, 3, 5, and 10. Tighten capscrew J (Fig. 9.9) observing the cycles, tightening, and subsequent rotation. Cycle 3 - Screw J - Torx M14x1,5 - Torque 45°. (Fig. 9.9) Cycle 4 - Screw J - Torx M14x1,5 - Torque 45°. (Fig. 9.9) 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. Measure value A, C, D, E and F and confront them with those described in Tab. 8.6. If the measured values do not follow those described in Tab. 8.6, replace connecting rod T. REF. DIMENSIONS (mm) CLEARANCE VALUE (mm) A 192.980 - 193.020 B 37.025 - 37.015 0.015 - 0.030 C 36.995 - 37.000 D 61.034 - 61.069 E 74.000 - 74.300 F 33.950 - 33.990
- 97. 97 8 _01 Fig. 8.12 Fig. 8.15 Fig. 8.13 L Fig. 8.14 T A U M H W1 W2 H V Tab. 8.7 Tab. 8.8 ED0053030410 INFORMATION ABOUT OVERHAULING 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. Refer to Tab. 8.8 to establish the clearance value of the pistons with a decreased diameter. In correspondence with point W, there are: 3 digits for the STD piston; 3digitsfollowedbyRforapistonwithanincreaseddiameterof0.20mm; +0.5 for a piston with an increased diameter of 0.50 mm +1 for a piston with an increased diameter of 1.00 mm; If clearance between cylinder and piston is greater than 0,074 mm, the piston and seal rings must be replaced. Important • Tab. 8.8 details the dimensional values of new components only. 8.5.3 Piston rings check Insert ring U into the cylinder, measure value H (distance between the points of ring U). Repeat for all the seal rings. If the measured value H does not correspond to the values indicated in the table (Tab. 8.7), replace the seal rings U. Important • Seal rings cannot be replaced separately. NOTE: refer to Fig. 8.17 to locate the rings. 8.5.2 Checking the gudgeon pin-pin axes are parallel Lubricate gudgeon pin A and bearing R (Fig. 8.10). Insert the gudgeon pin into bearing R. Useadialgaugetochecktheaxisparallelismoftheconnecting 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. If the parallelism values do not comply with the specified ones, replace the connecting rod T. PISTON Ø CYLINDERS (± 0.007 mm) Ø PISTON (± 0.007 mm) CLEARANCE VALUE (mm) STD 96.010 95.950 0.046 - 0.074 +0.20 96.210 96.150 +0.50 96.510 96.450 +1.00 97.010 96.950 RINGS H (mm) U1 0.30 - 0.15 U2 0.50 - 0.70 U3 0.20 - 0.40
- 98. 98 8 _01 Fig. 8.16 L1 L2 L3 U2 U1 U3 Fig. 8.17 C A Fig. 8.19 Fig. 8.18 Tab. 8.9 ED0053030410 INFORMATION ABOUT OVERHAULING SEAL RINGS CLEARANCE VALUE (mm) U1 (L1) 0.110 - 0.150 U2 (L2) 0.070 - 1.115 U3 (L3) 0.030 - 0.070 8.6 Cylinder head 8.6.1 Flatness check Put the cylinder head on a surface plate and, with a dial gauge, check the flatness of surface C. The MAX value of allowable irregularity of surface C is 0.10 mm. Ifthevalueisnotobserved,youarerequiredtogrindsurface C. The MAX removal allowed is 0.20 mm. Important • Grinding is to be performed with sleeves A of the injectors assembled. • Grinding is prohibited on all engines provided with an EPA name plate (refer to Par 1.3). 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 table (Tab. 8.9), replace the seal rings and the piston.
- 99. 99 8 _01 Z Z1 Z2 B C Fig. 8.21 Fig. 8.22 D E G F H Fig. 8.20 Tab. 8.10 Tab. 8.11 ED0053030410 INFORMATION ABOUT OVERHAULING 8.6.2 Valve seats check Thoroughly clean the valves and their seats with. Measureindentation Bofeachvalvewithregardtothecylinder head surface C, which is to be a MIN of 0.50 mm and MAX of 0.53 mm. The B MAX indentation allowed on worn components is 0.90 mm. If the measured value does not correspond with the values indicated, replace the worn component. Important • The seats must be worked after driving to reach value B, go to a rectification workshop for such operations. 8.6.3 Valve springs Use a gauge to measure the free length Z. Using a dynamometer, subject the spring to two different forces and check that the length of the spring corresponds to the values indicated in the Tab. 8.10. WEIGHT (kg) LENGTH (mm) 0 Z 42.50 20,4 Z1 33.00 42,8 Z2 23.80 8.6.4 Valve guides check Measure the diameters D and E of the rods and guides valve (Tab. 8.11). 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. 8.11). Important • Carry out the measurements in different points to detect any ovalisation and/or concentrated wear. • Tab. 8.11 details the dimensional values of new components only. REF. DIMENSIONS (mm) CLEARANCE VALUE (mm) D 5.978 - 5.990 0.040 - 0.064 E 6.030 - 6.042 G 38.300 - 38.700 Valve stem - valve guide dimensions
- 100. 100 8 _01 Fig. 8.23 M L A A B B N L M M N M N N Fig. 8.24 Fig. 8.26 Fig. 8.25 W1 W2 Tab. 8.12 Tab. 8.13 ED0053030410 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. 8.12. Observe values G from surface F when assembling guides H (Tab. 8.11 - Fig. 8.22). Important • The guides must be worked for value E (Tab. 8.11 - Fig. 8.22) after driving. Contact a rectification workshop for such operations. Guide valve - guide seat valves dimensions REF. DIMENSIONS (mm) PRESS-FIT VALUE (mm) L 10.000 - 10.015 0.030 - 0.054 M 10.045 - 10.054 REF. DIMENSIONS (mm) CLEARANCE VALUE (mm) W1 22.005 - 22.015 0.025 - 0.056 W2 22.040 - 22.061 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. 8.26). Based on the values measured, calculate the clearance between W1andW2,whichistoobservethevaluesinTab.8.13. Check that all oil pipes N and M are free from impurities or obstructions.
- 101. 101 8 _01 B Fig. 8.27 F B A D E Fig. 8.28 Tab. 8.14 ED0053030410 INFORMATION ABOUT OVERHAULING 8.7 Oil pump check 8.7.1 Dimensional and visual check Measure clearance value B between the rotor teeth, the value of allowable wear is MAX 0.28 mm. Important • Should the results from checks carried out not be in accordance with the conditions described, replace the oil pump A. 8.7.2 Oil pressure valve check Measure the free length F of spring D, which must be 47.5 mm. If the measured value does not correspond to the value indicated, replace spring D. POS. DESCRIPTION B Plug C Gasket D Spring E Piston
- 102. 9 102 _01 Tab. 9.15 ED0053030410 ASSEMBLY INFORMATION 9.2 Assembly recommendations • The information is laid out in sequence, the intervention methods have been selected, tested and approved by the manufacturer's technicians. • This chapter describes the installation procedures for the assemblies and/ or individual components which have already been checked, overhauled or possibly replaced with original spare parts. • Where necessary, reference to special tools during assembly operations refer to KOHLER diesel special tools. Here in after in Tab. 9.1 an example of a special tool (ST_05). Important • To easily locate specific topics, the reader should refer to the analytical index or chapter index. • Before proceeding with operation, carefully read Chap. 3. • The operator must check that: - 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. • The operator must: - carry out the procedures smoothly and safely. It is thus recommended to install the engine on a special rotating stand used when servicing engines to ensure the safety of the operator and the other individuals involved. - tighten the assemblies and / or components in a criss-cross or alternating pattern, initially with a value lower than that pre- set, and then subsequently, with the tightening torque specified in the procedure. - replace all seal gaskets after each assembly for all components on which they are provided. 9.1 Information on engine configuration • In this chapter, the engine is represented as "BASE CONFIGURATION" (refer to Para 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 Heater (replacement) 11.2 Air filter (cartridge replacement) 11.3 Cooling circuit (replacement) SPECIAL TOOLS "ST" Picture/Draw DESCRIPTION PART NUMBER ST_05 Six Nicks SN8 ED0014603650-S
- 103. 9 103 _01 Fig. 9.2 C B1 A2 Fig. 9.4 Fig. 9.3 Fig. 9.1 C F A1 D B1 B1 E B1 L H G ED0053030410 ASSEMBLY INFORMATION 2 - Fit the new half-bearings A2 onto the lower crankcase B2 using the reference notches C. 3 - Lubricate the half-bearings A1 and A2 with oil. 9.3.2 Tappets 1 - Lubricate the tappets E with oil. 2 - Insert the tappets E into the housings F of the upper crankcase B1. 9.3 Engine block assembly 9.3.1 Crankshaft bushings Important • Execute the procedure in Par. 8.2.1 and 8.2.2, before proceeding with assembly. • The crankshaft half-bearings are made of special material. Therefore, they must be replaced every time they are assembled to prevent seizures. 1 - Fit the new half-bearings A1 onto the crankcase upper half B1 adhering to the reference notches C. Important • After the half-bearings are fitted, check that the lubrication holes D correspond with the crankcase grooves B1. • The lower and upper half bearings CANNOT be singularly replaced, and both halves must be replaced together. 9.3.3 Oil spray nozzles 1 - Insert the sprayers G onto the upper crankcase B1 manually screwing the screw fittings H. 2 - Ensure that the spray nozzles G are inserted correctly in their seat, as shown in detail L and tighten the connecting screws H (tightening torque of 10 Nm).
- 104. 9 104 _01 B1 S N2 A2 Fig. 9.7 M N1 J B1 Q B2 X X Y P P B2 P Fig. 9.5 Fig. 9.6 Fig. 9.8 T R LOCTITE 5660 B1 B1 LOCTITE 5660 ED0053030410 ASSEMBLY INFORMATION 9.3.4 Crankshaft Important • Carry out the checks described in Par. 8.4.1 and Par. 8.4.2. 1 - Check that the crankshaft half-bearings A1 are mounted correctly on the upper crankcase B1. 2 - Lubricate the main journal and crankpin J, with oil. 3 - Insert the crankshaft M into its seat on the upper crankcase B1. 4 - Insert the 2 shoulder half-rings N1, between the crankshaft M and the upper crankcase B1 (Q detail). 4 -Check that the crankshaft half-bearings A2 are mounted correctly on the lower crankcase B2. 5 - Assemble the 2 shoulder half-rings N2 onto the lower crankcase B2 applying two drops of grease to keep them in their seat. 6 - Join the two crankshaft halves B1 and B2 observing the guide pins T. 9.3.5 Lower semi-crankcase 1 - Check that the coupling surfaces P are free from dirt and grit. 2 - Spread a bead of Loctite 5660 of approx 1,5 mm thickness on the surface P of the upper crankshaft half B1 being careful not to block the oil feed grooves X and the return oil sump Y. 3 - Insert gasket S into the seat of crankcase B1.
- 105. 9 105 _01 K 1 2 13 14 15 16 17 18 3 4 5 6 7 12 11 10 8 9 B2 J 10 4 2 6 8 9 3 1 5 7 Fig. 9.11 Fig. 9.9 Fig. 9.10 W M B Tab. 9.16 ED0053030410 ASSEMBLY INFORMATION CYCLE SCREWS TORQUE 1 J - Torx M14x1,5 60 Nm 2 K - Torx M10x1.25 30 Nm 3 J - Torx M14x1,5 45° 4 J - Torx M14x1,5 45° Important • The fastening bolts J, K must be replaced every time they are assembled. • Failure to adhere to the bolt fixing procedures may compromise the functionality of the engine, and also may cause damage to persons and property. • Tighten capscrews J, K observing the cycles, tightening, and subsequent rotation as indicated in Tab. 9.2. 7 - Apply "Molyslip AS COMPOUND 40" on the threads and under the head of capscrews J and K and manually tighten them until their stop. 8 - Tightening the screws J, K strictly following the sequence indicated in the Fig. 9.9 or Fig. 9.10 and the tightening torque indicated in the Tab. 9.2. 9 - Check that crankshaft M rotates smoothly. 10 - Insert gasket W into the seat of crankcase B.
- 106. 9 106 _01 Fig. 9.12 Fig. 9.14 Fig. 9.13 P1 M M1 M1 Q1 B S1 S4 R1 R2 ST_41 N1 S3 S2 T1 ED0053030410 ASSEMBLY INFORMATION 9.3.6 Camshaft 1 - Lubricate the pins S2, the cams S3 of the camshaft S1, all the housing Q1 with oil. 2 - Insert the camshaft S1 all the way into its housing Q1. 3 - Fit the lock ring S4 on to the crankcase B to hold the position of the camshaft S1. 9.3.7 Timing system gear assembly 1 - Check that the pin P1 is correctly fitted on the crankshaft M. 2 - Position the gear M1 on the crankshaft M respecting the reference with pin P1. 3 - Fully tighten the screw N1 interposing tool ST_41 between N1 and M1. 4 - Position the gear R1 on the camshaft S1 observing the marks T1 of the gear M1. Important • Failure to comply with the marks T1 on the gears M1 and R1 causes engine malfunction and serious damage. • Fastening capscrew R2 must be replaced every time it is assembled. 5 - Assemble gear R1 by means of capscrew R2 (tightening torque 100 Nm). 6 - Check that crankshaft M rotates smoothly.
- 107. 9 107 _01 Fig. 9.15 Z1 Z2 Z3 Z3 Z2 Z1 Z Fig. 9.16 Z3 Z2 C1 Z Z1 Fig. 9.17 F2 F1 E1 Fig. 9.18 L1 H1 Z L1 G2 Z L1 F2 G1 D1 ED0053030410 ASSEMBLY INFORMATION 9.3.8 Piston rings 1 - Perform the operations described in Par. 8.5.3. 2 - Put the scraper ring Z3 onto the piston Z. 3 - Put the 2° seal ring Z2 on the piston Z. 4 - Put the 1° seal ring Z1 onto the piston Z. 5 - Perform the operations described in Par. 8.5.4. 6 - Align the piston rings with the opening of the centre of the hole for the gudgeon pin C1. 7 - Lubricate the piston skirt and piston rings with oil. 9.3.9 Piston Important • The fastening bolts E1 must be replaced every time they are assembled. • Before proceeding to the assembly of the piston and connecting rod, carry out the checks described in Par. 8.5.1, • Always replace the bearings D1 after each assembly. • Mate components respecting references at Par. 7.12.5. 1 - Loosen the screws E1 and remove the connecting rod cap F1. 2 - Insert the connecting rod F2 into the piston Z and align the seats G1. 3 - Insert the gudgeon pin H1 into the seat G1 for the assembly of the connecting rod and piston unit. 4 - Insert the lock rings L1 inside the seat G2 of the piston Z to lock the gudgeon pin H1.
- 108. 9 108 _01 Fig. 9.20 F2 G Z F2 V1 U1 T2 Fig. 9.22 Fig. 9.23 W1 T3 Z Z Z Fig. 9.21 J1 M K1 G Fig. 9.19 ED0053030410 ASSEMBLY INFORMATION 2 - Lubricate the piston skirt and rings Z. 3 - Check that the half-bearing U1 is mounted correctly and lubricate it thoroughly. 4 - Using the piston ring compression pliers, insert the piston inside the cylinder W1 by around 10mm (height T2). Important • Make sure you are at the stage described in Point 1. • Piston Z must be assembled with notch K1 on the side of the skirt facing oil spray nozzles G. 5 - Rotate the piston Z by 10° counter-clockwise with respect to its correct assembly position (Fig. 9.21 - height T3). NOTE: Doing this prevents the impact between the connecting rod F2 and the sprayer G. 9.3.10 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 M by moving the crankpin J1 to a TDC position of the affected cylinder.
- 109. 9 109 _01 T3 Z Fig. 9.24 Fig. 9.27 F1 F2 E1 E1 Fig. 9.26 M F2 J1 J1 U1 F2 Fig. 9.25 Tab. 9.17 ED0053030410 ASSEMBLY INFORMATION Important • Leave the ring compressor assembled on the piston. 6 - Push piston Z downwards without introducing the segments in the cylinder, rotate piston Z by 10° in a clockwise direction (value T3 – correct assembly position). 7 - Push the piston Z downwards by centering the crankpin J1 with the connecting rod F2. 8 - Rotate the crankshaft M by moving the crankpin J1 to a BDC position of the affected cylinder. 9 - Push the piston Z downwards by centering the crankpin J1 with the connecting rod F2. 10 - Turn the crankcase on support to assemble the con rod capp F1. 11 - Check that the half-bearing U1 is mounted correctly on the connecting rod cap F1. Important • Check that the break levels of connecting rod cap F1 coincide perfectly onto connecting rod F2 before screwing on and tightening capscrews E1. 12 - Couple the connecting rod cap F1 to the connecting rod F2 using the marks made at disassembly Par. 7.12.1). 13 - Apply "Molyslip AS COMPOUND 40" on the threads and under the head of capscrew E1 and manually tighten them until their stop. Important • Failure to adhere to the assembly procedures may compromise the functionality of the engine, and also cause damage to persons and property. 14 - Tighten the screws E1, alternately, strictly following the tightening torques indicated (Tab. 9.3). 15 - Repeat the operations from 1 to 14 for each cylinder. 16 - Check that the connecting rods have axial play and the crankshaft M rotates smoothly. NOTE: After the check carried out at point 16, position the shaft M with the first cylinder to TDC. CYCLE SCREWS TORQUE 1 E1 28 Nm 2 E1 30° 3 E1 30°
- 110. 9 110 _01 Fig. 9.28 A B B D C Fig. 9.29 C C G F E B ST_18 ST_18 B Fig. 9.31 Fig. 9.30 LOCTITE 5660 H ED0053030410 ASSEMBLY INFORMATION 9.4.2 Oil suction pipe Important • It is mandatory to replace the gasket F after each assembly. • Always replace capscrews B with new ones or alternatively apply Loctite 2701. 1 - Secure the hose E on the crankcase C with the screws B (tightening torque 10 Nm) fitting the gasket F. 9.4 Oil sump unit assembly 9.4.1 Oil drain pipe Important • It is mandatory to replace the gasket D after each assembly. • Always replace capscrews B with new ones or alternatively apply Loctite 2701. 1 - Secure the hose A on the crankcase C with the screws B inserting the gasket D (tightening torque 10 Nm). 9.4.3 Oil Sump 1 - Ensure that the contact surfaces G of the oil sump H and the crankcase C are completely clean. 2 - Apply a bead of approx. 2.5 mm of sealant (Loctite 5660) on the surface G of the crankcase C. 3 - Position the oil sump H on the crankcase C in line with the fastening holes (use the aid of tool ST_18).
- 111. 9 111 _01 A B C F E D E G D Fig. 9.32 Fig. 9.33 Fig. 9.34 2 1 11 12 10 9 18 17 3 4 5 6 7 8 13 14 15 16 L ED0053030410 ASSEMBLY INFORMATION Important • Tighten the screws L, strictly following the sequence and tightening torque indicated. 4 - Fix oil sump H by means of the screws L following the sequence indicated (tightening torque 25 Nm). 5 - After tightening of the screw n° 10, loosen screw n°1 and re-tighten it to the torque value specified in step 4. 9.5 Cylinder head unit assembly 9.5.1 Valve stem gasket Important • CarryoutthechecksdescribedinPar.8.6.4beforeproceeding 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. 9.5.2 Injector sleeves ( ) 1 - Insert the seals C in the seats of the sleeve D. 2 - Insert the seal E with the convex side facing upward at the base of the sleeve D. 3 - Lubricate the gaskets C. 4 - Insert and carefully screw the sleeve D into the seat of the head F. NOTE: The sleeve D must not protrude above the surface of the head G. 5 - Clamp the sleeve D (tightening torque at 30 Nm).
- 112. 9 112 _01 F ST_07 ST_03 L Q Fig. 9.38 Fig. 9.35 Fig. 9.36 Fig. 9.37 X Y F S F ED0053030410 ASSEMBLY INFORMATION 9.5.3 Injectors projection 1 - Assemble the rocker arm shaft fastening screw L until it stops on cylinder head P. 2 - Perform the operations of point 1, 2 Par. 6.1.4. 3 - Perform the operations of point 3, 4 Par. 6.1.5. 4 - Check, using ST_03 tool (Fig. 9.36), the projection of the injector, which must range between 1.68 ÷ 2.42 mm. NOTE: if the value detected does not correspond, replace gasket Q with a different thickness 9.5.4 Valves 1 - Pre-lubricate and insert the valves X into the head F taking care to fit them in the original positions as per the reference marks made in Par. 7.12.4.1. 2 - Position the spring Y on the seat of the head F. 3 - Position the disk S on the spring Y centering the valve X. 4 - Mount the tool ST_07 on the head F fixing it on one of the holes for securing the rocker arm cover. NOTE: Change the fixing hole according to the position of the valves to be fitted. 5 - Position the tool ST_07 on the valve as shown in Fig. 9.38.
- 113. 9 113 _01 AX AW F AJ AJ X AK S Fig. 9.39 Fig. 9.42 R P K K J T K U Fig. 9.40 Fig. 9.41 Tab. 9.18 ED0053030410 ASSEMBLY INFORMATION 9.5.5 Cylinder head 1 - Fix the eyebolts AW with the screws AX onto the head F (tightening torque of 80 Nm). 6 - Push the lever of the tool ST_07 downwards, in order to lower the valve disks S in the direction of the arrow AK, and insert the valve cotters AJ inside the disk S. 7 - Check that the valve cotters AJ are properly mounted on the valve seats X and release the tool ST_07. NOTE: repeat all the steps for the relevant valves and remove the tool ST_07. 2 - Position the piston P at the TDC. 3 - Position the tool ST_03 on the crankcase surface of the head and measure the piston protrusion P from head level K in 4 diametrically opposed points R. Repeat the operation for all pistons P and take note of the highest average value, determining value S (Tab. 9.4). 4 - Based on the value detected at point 3, select the relevant gasket T as shown in the Tab. 9.4 (Fig. 9.42 detail U). 5 - Check that the crankcase surface K and the gasket T are completely free of dirt and grit. Important • The head gasket must be replaced for each assembly. 6 - Position the gasket T on the surface K with reference to the centering bushings J. S (mm) Hole number 0.030 - 0.126 1 0.127 - 0.250 2 0.251 - 0.375 3
- 114. 9 114 _01 5 4 7 V 8 1 2 3 9 6 10 Fig. 9.46 Fig. 9.45 F W Z J J Fig. 9.43 Fig. 9.44 AC AC AB F AA Tab. 9.19 ED0053030410 ASSEMBLY INFORMATION 7 - Check that the surface head W is free from impurities. 8 - Position the head F on the crankcase Z with reference to the centering bushings J. Important • The fastening bolts V must be replaced every time they are assembled. • Failure to adhere to the bolt fixing procedures may compromise the functionality of the engine, and also may cause damage to persons and property. • Tighten capscrews V observing the cycles, tightening, and subsequent rotation as indicated in Tab. 9.5. 9 - Apply "Molyslip AS COMPOUND 40" on the threads and under the head of capscrew V and manually tighten them until their stop. 10 - Secure the head F by tightening the screws V strictly following the sequence indicated in the Fig. 9.44 and the tightening torque and pauses between cycles indicated in the Tab. 9.5. CYCLE TORQUE PAUSE 1 28 Nm 3" 2 30° 3" 3 30° 10" 3 30° ... 2 - Mount the valve bridge AC on to the pairs of discharge and suction valves. 9.5.6 Rods and valve bridges 1 - Insert the rocker control rods AA into the niches of the head F. Important • Properly centre the rods AA into the spherical housing of the camshaft tappets AB.
- 115. 9 115 _01 Fig. 9.47 BB BF F BD Fig. 9.48 AN AP Fig. 9.50 AU AV BC AH AR AT AS AM AH AQ BP = -90° BP = -90° Fig. 9.49 ED0053030410 ASSEMBLY INFORMATION 9.5.8 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. As seen from A (Par. 1.4) turn the crankshaft anticlockwise by 90°, complying with TDC of the 1st cylinder, positioning taper pin BP of the crankshaft as shown in Fig. 9.49. 1 - Position rocker arm shaft unit BB on cylinder head F, complying with the taper pin BC reference with hole BF of cylinder head F. 2 - Check the correct positioning of all the rocker arms and the u-bolt control valves (detail BD). House the tappet in the seat of the rocker arms control rod. 9.5.7 Rocker arms Important • The suction rocker arm AT is shorter than the discharge arm AR. 1 - Fit the lock ring AM into the seat AN of the rocker arm pin AH. 2 - Position the pin AH with the surface AP facing upwards and insert the 2 shoulder rings AQ. 3 - Insert in sequence the suction rocker arm AR, the holder AS and the discharge rocker arm AT in the pin AH. 4 - Insert the spring AU in the pin AH. 5 - Repeat points 3, 4 for all the rocker arms. NOTE: Support AV, which contains taper pin BV, must be assembled in correspondence with cylinder n° 3. 6 - Insert 2 shoulder rings AQ and the lock ring AN to lock all the components inserted in the pin AH. NOTE: The spring AU ensures that the supports AS and AV are kept in place .
- 116. 9 116 _01 BB BE 1 2 3 4 Fig. 9.51 R N P T T V T X U Q S S Fig. 9.52 Fig. 9.53 Fig. 9.54 ED0053030410 ASSEMBLY INFORMATION 3 - Secure the rocker arm pin BB tightening the screws BE (tightening torque to 40 Nm). Adhere to the screw tightening sequence BE as shown in Fig. 9.51. 9.6 Assembly lubrication circuit 9.6.1 Oil pressure relief valve 1 - Lubricate the piston N and fully insert it in the seat P. 2 - Insert the spring Q in the piston N. 3 - Insert disk R onto spring Q. 4 - Insert cotter pin S in the provided seat of oil pump T to lock components N, Q, and R. 9.6.2 Oil pump NOTE: Carry out the checks described in Par. 8.7 before proceeding with the following operations. 1 - Check that all contact surfaces between T, V are free of impurities – scratches - dents. 2 - When assembling, do not use any type of gasket between T and V. 3 - Thoroughly lubricate the seat of the rotors on oil pump T. 4 - Make sure the external rotor is assembled correctly with Ref. U visible, as shown in the picture (or refer to Par. 2.10.2). 5 - Fasten the oil pump cover T on the crankcase V with the screws X (tightening torque 10 Nm).
- 117. 9 117 _01 C E E D G G F F B A A F 1 13 12 14 15 16 17 2 3 4 5 6 7 8 10 9 11 18 G L G ST_41 H LOCTITE 5660 Fig. 9.55 Fig. 9.56 Fig. 9.57 ED0053030410 ASSEMBLY INFORMATION 9.7 Flange unit assembly 9.7.1 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 - Apply a bead of approx. 2.5 mm of sealant (Loctite 5660) on the surface B of the bell A. 2 - Assemble bell A onto crankcase D, complying with reference taper pins E. 9.7.2 Flywheel Danger • Flywheel H is very heavy; pay special attention during assembly operations to avoid dropping and causing serious risks to the operator. 1 - Loosen capscrews G and remove tool ST_41. 2 - Position flywheel H onto crankshaft L by means of tool ST_43. 3 - Apply "Molyslip AS COMPOUND 40" on the threads and under the head of capscrews G and manually tighten them until their stop. 4 - Secure flywheel H with capscrews G (tightening torque 60 Nm). 5 - Once again, tighten capscrews G (2 cycles with tightening torque 130 Nm). Important • Failure to adhere to the assembly procedures may compromise the functionality of the engine, and also cause damage to persons and property. • Always replace and lubricate the gasket C with oil, every time they are assembled (the gasket C is to be mounted after the operation at point 4). 3 - Apply the screws F by hand without tightening them. 4 - Tighten the screws F following the tightening sequence indicated (tightening torque 75 Nm).
- 118. 9 118 _01 A A C D B B Fig. 9.58 Fig. 9.59 ED0053030410 ASSEMBLY INFORMATION 9.8 Fuel system assembly Important • Remove the protective caps from all the components of the fuel circuit just before assembly just before assembly (Par. 2.9.8). 9.8.1 High-pressure injection pump 1 - Follow operations 1, 2, 3, 4, 5, 6, 7 and 8 of Par. 6.1.5. 2 - Follow operations 1, 2, 3, 4, 5, 6, 7 and 10 of Par. 6.1.6. 9.8.6 Fuel filter 1 - Perform the operations of Par. 6.5.2. 9.8.2 Injectors Important • To prevent damaging the injection system, the protection caps (Par. 2.9.7) must be removed during assembly. 1 - Follow operations of Par. 6.1.7. 9.8.3 Fuel return pipes 1 - Tighten union A onto cylinder head B, inserting the relative gasket. 2 - Perform the operations of point 18 of Par. 6.1.5. 9.8.4 Rocker arms cover 1 - Perform the operations of Par. 6.1.9. 9.8.5 Injection fuel pipes 1 - Perform the operations of Par. 6.1.10. 9.9 Crankshaft pulley assembly 1 - Check that the pin A is mounted properly on the crankshaft B. 2 - Position the pulley C on the crankshaft B using the pin mark A. 3 - Apply "Molyslip AS COMPOUND 40" grease onto the thread and under the head of capscrew D. 4 - Fix the pulley C with the screw D (tightening torque of 100 Nm) and remove special tool ST_02.
- 119. 9 119 _01 S M T V R U X S R P A C B F E L G H M Q P N M Fig. 9.60 Fig. 9.61 Fig. 9.62 Fig. 9.63 ED0053030410 ASSEMBLY INFORMATION 9.10.2 Coolant pump Important • Always replace the gasket L every time it is assembled. 1 - Secure the flange G with the screws H interposing the gasket L onto the crankcase M (tightening torque of 25 Nm). 2 - Perform the operations 1 and 2 of Par. 6.2.2. 9.10 Coolant circuit assembly 9.10.1 Thermostatic valve Important • Always replace the gasket A after each assembly. 1 - Check the condition of the seal gasket A and fit it on the thermostatic valve B. 2 - Position the thermostatic valve B in the seat on the head C (detail D). 3 - Secure the cover E with the screws F on the head C (tightening torque of 10 Nm). 9.10.3 Oil Cooler hoses 1 - Secure hose N on Oil Cooler P and on crankcase M by means of clamps Q. 2 - Position and secure hose R by means of clamp S on Oil Cooler P and on crankcase M. 3 - Secure clamps T on manifold U by means of capscrews V in points X (tightening torque 10 Nm - ST_06)..
- 120. 9 120 _01 G E F H Fig. 9.64 H G E A C M P N C B D F Q S E P R S Q R Fig. 9.65 Fig. 9.66 Fig. 9.67 ED0053030410 ASSEMBLY INFORMATION 9.11 Exhaust manifold assembly Important • Replace the metal gaskets A every time they are assembled. 1 - Check that the contact surfaces D are free from impurities. 2 - Position manifold E onto cylinder head G by manually tightening capscrews F, inserting: - gaskets A between cylinder head G and manifold E; - spacers H between capscrews F and manifold E.. 3 - Secure manifold E onto cylinder head G by means of capscrews F (tightening torque 25 Nm). 9.12 Turbocharger Assembly Important • Before proceeding, perform the operation described in Par. 2.18. • Ensure that tube C is not clogged. • Always replace the gaskets A, B, Q at each assembly. • Remove the plastic or foam caps from the turbo compressor before assembling. 1 - Check that the contact surfaces D are free from impurities deformations or cracks, otherwise replace damaged component. 2 - Position the turbo-compressor E on the bolts F on the manifold G. 3 - Fasten the turbo-compressor E with the nuts H (tightening torque of 25 Nm). 4 - Fasten the pipe C with the screws M to the turbo- compressor E. 5 - Fasten the pipe C with the screws N on the crankcase P. Important • Always replace the gasket Q after each assembly. • Before assembly of the tube R, perform the operation described in Par. 2.18.2 - Point 2. • Ensure that tube R is not clogged. 6 - Fasten the pipe R with the fittings S on the turbo-compressor E and on the crankcase P (tightening torque of 15 Nm). Insert the gaskets Q between: - S and R; - E and R; - P and R.
- 121. 9 121 _01 A N B P C D Fig. 9.68 Fig. 9.69 Fig. 9.71 E G M F L H Fig. 9.70 ED0053030410 ASSEMBLY INFORMATION 9.13 Electric component assembly 9.13.1 Sensors and switches 9.13.1.2 Coolant temperature sensor 1 - Secure the sensor A onto the head B (tightening torque of 20 Nm). 9.13.1.3 Oil Pressure Switch 1 - Clamp the oil pressure switch C on the crankcase D (tightening torque at 35 Nm). 9.13.2 Alternator 1 - Insert the washer E onto the screw F. 2 - Insert the screw F onto the alternator G. 3 - Secure the bracket H and the alternator G using the screws L, F onto the crankcase M. 4 - Follow operations 3, 4, 5, 6 and 7 of Par. 6.2.2. 9.13.3 Starter Motor 1 - Secure motor N by means of capscrews P (tightening torque at 45 Nm).
- 122. 9 122 _01 Tab. 9.20 ED0053030410 ASSEMBLY INFORMATION 9.14 Tightening torques and the use of sealants BASE CONFIGURATION SHORT BLOCK Component Thread (mm) Torque (Nm) Sealer Oil sprays fastening capscrew M6x1 10 Lower crankcase fastening capscrew M14x1.5 3 cycles 1st Cycle 60 2nd Cycle +45° 3rd Cycle +45° Lower crankcase fastening capscrew M10x1.25 30 Connecting rod screw M11x1 3 cycles 1st Cycle 28 2nd Cycle +30° 3rd Cycle +30° Coolant drain hole closing cap M16x1.5 50 Main oil delivery line closing plate M6x1 15 Intermediate idle gear cap fastening screw M8x1 25 Camshaft gear fastening screw M10x1 100 DRI LOC 2040 OIL SUMP ASSEMBLY Component Thread (mm) Torque (Nm) Sealer Oil suction hose fastening capscrew M6x1 10 Loctite 2701* Oil return pipe fastening screw M6x1 10 Loctite 2701* Oil sump fastening capscrew M8x1 25 Oil drain cap M18x1.5 30 ENGINE CYLINDER HEAD ASSEMBLY Component Thread (mm) Torque (Nm) Sealer Air bleeding cap (Rev. 00) M6x1 6 Air bleeding cap (Rev. 01) M14x1,5 50 Lifting brace fastening capscrew M8x1.25 80 Injector manifold M12x1 30 Cylinder head fastening capscrew M12x1.25 4 cycles 1st Cycle 75 2nd Cycle +90° 3rd Cycle +90° 4th Cycle +90° Rocker arm gudgeon fastening capscrew M8x1,25 40 Rocker arm cover fastening capscrew M6x1 10 LUBRICATION CIRCUIT Component Thread (mm) Torque (Nm) Sealer Oil vapour separator support fastening capscrew TG8 22 Oil steam separator return tube drilled fastening screw (on crankcase) M16x1.5 Oil filter fastening union M20x1.5 15 Loctite 2701* Oil cooler fastening capscrew M6x1 10 Cartridge-holder cover ... 25 Oil pump fastening screw M6x1 10 FLANGE ASSEMBLY (1ST PTO) Component Thread (mm) Torque (Nm) Sealer Flange bell fastening capscrew M12x1,75 75 Flywheel fastening capscrew M12x1,25 3 cycles 1st Cycle 60 2nd Cycle 130 3rd Cycle 130 * Alternatively to the capscrew replacements, with "Dri-loc" * Alternatively to the capscrew replacements, with "Dri-loc"
- 123. 9 123 _01 ED0053030410 ASSEMBLY INFORMATION INJECTION SYSTEM Component Thread (mm) Torque (Nm) Sealer Fuel filter fastening capscrew M8x1.25 25 Injector brace fastening capscrew M8x1.25 20 Injector side injection tube nuts M12x1.5 25 Injection pump side injection tubes nuts M12x1.5 25 Injection pump fastening capscrew M8x1.25 25 Loctite 2701* Gear fastening nut on fuel injection pump M14x1.5 140 Screw for cover over injection pump shaft nut (on bell housing) M6x1 10 INTAKE MANIFOLD Component Thread (mm) Torque (Nm) Sealer Manifold fastening screw M8x1.25 25 Intake flange fastening capscrew M8x1.25 25 CRANKSHAFT PULLEY ASSEMBLY (2ND PTO) Component Thread (mm) Torque (Nm) Sealer Crankshaft pulley fastening capscrew M12x1.75 100 Molyslip COOLANT CIRCUIT Component Thread (mm) Torque (Nm) Sealer Coolant tube clamp fastening capscrew (Oil Cooler return) TG8 22 Thermostatic valve cover fastening capscrew M6x1 10 Coolant pump fastening capscrew M8x1.25 25 Blower fastening capscrew M8x1.25 25 EXHAUST MANIFOLD Component Thread (mm) Torque (Nm) Sealer Exhaust manifold fastening screw M10x1.5 50 TURBO COMPRESSOR Component Thread (mm) Torque (Nm) Sealer Oil return tube fastening capscrew M6x1 10 Oil supply tube fastening capscrew M10x1 15 Turbine fastening stud (on manifold) M10x1.5 30 Exhaust fastening stud (on turbine) M8x1.25 25 Exhaust flange fastening stud (on turbine) M10x1.5 30 Exhaust flange fastening nut (on turbine) M8x1.25 25 ELECTRICAL COMPONENTS Component Thread (mm) Torque (Nm) Sealer Coolant temperature sensor M12x1.5 20 max. Oil pressure switch M12x1.5 35 Alternator fastening capscrew M10x1.5 45 Alternator fastening capscrew M8x1.25 25 Alternator brace fastening screw M12x1.75 75 Starter motor fastening capscrew M10x1.5 45 Supply cable fastening nut (starter motor) M10x1.5 15 * Alternatively to the capscrew replacements, with "Dri-loc" * Alternatively to the capscrew replacements, with "Dri-loc"
- 124. 9 124 _01 ED0053030410 ASSEMBLY INFORMATION * Alternatively to the capscrew replacements, with "Dri-loc" * Alternatively to the capscrew replacements, with "Dri-loc" OPTIONAL COMPONENTS (CHAP. 11) HEATER Component Thread (mm) Torque (Nm) Sealer Flange intake with heater fastening capscrew M8x1.25 25 COOLING CIRCUIT Component Thread (mm) Torque (Nm) Sealer Blower fastening capscrew M6x1 10 Radiator support fastening capscrew (on crankcase) M12x1.75 Shroud radiator fastening capscrew M6x1 10 Radiator central brace fastening screw M10x1.5 Radiator on anti-vibrating M8x1.25 25 Vibration-damping nut fixing (on radiator support) M8x1.25 25 Anti-vibrating and brace fastening capscrew (upper) M8x1.25 25 Upper brace fastening capscrew (on engine cylinder head) M8x1.25 25 Side bulkheads fastening capscrew M6x1 10
- 126. 126 10 _01 B MIN MAX Fig. 10.1 B Fig. 10.2 Fig. 10.3 Fig. 10.4 A A B C ED0053030410 FLUIDS FILLING INFORMATION 10.1 Engine oil Warning • Before proceeding with operation, carefully read Par. 3.3.2. 1 - Loosen the oil filler cap A. 2 - Add the type and amount of oil recommended (Tab. 2.2). 3 - Remove the oil dipstick B and check that the level is up to but does not exceed the MAX. Important • Do not use the engine with the level of oil below MIN or above MAX. 4 - If the oil level is not at MAX, insert more oil until the MAX level is reached as indicated on the dipstick. 5 - Re-tighten the cap A. 10.2 Coolant Warning • Before proceeding with operation, carefully read Par. 3.3.2. 1 - Fit tube A onto radiator B and secure it with clamp C. 2 - Refill the radiator with coolant (refer to Par. 2.6 for the liquid specifications). 3 - Top liquid up until the pipes inside the radiator are covered by about 5 mm. 4 - For engines equipped with separate expansion tank, pour in fluid until reaching the max level mark.
- 127. 127 10 _01 Fig. 10.5 Fig. 10.6 D Fig. 10.7 F H ED0053030410 FLUIDS FILLING INFORMATION 5 - Loosen the screw F on the head G, release any air and tighten the screw (Fig. 10.7); Tightening torque: - 8 Nm for screw M6 (Rev. 00); - 30 Nm for screw M12 (Rev. 01). 6 - Start the engine without the radiator cap D or the expansion tank cap B. 7 - Keep the engine at idle speed or without a load until the cooling liquid level goes down and becomes steady (the waiting times varies according to the ambient temperature). 8 - Turn off the engine and allow it to cool. 9 - If there is an expansion tank top liquid up to the mark MAX. 10 - Without expansion tank top liquid up until the pipes inside the radiator are covered by 5 mm. Do not overfill the radiator, but leave room for the fuel to expand. 11 - Tighten the radiator cap D or the expansion tank cap B. Warning • Before starting make sure that the radiator cap and expansion tank cap, if present, are installed correctly to avoid loss of liquid or vapour at high temperatures. 12 - After a few hours of operation stop the engine and allow it to cool. Check and top up the coolant liquid.
- 129. 129 11 _01 Fig. 11.1 Fig. 11.2 A C F E C G F E A H B A C D C B A A B Fig. 11.3 Fig. 11.4 ED0053030410 INFORMATION ABOUT OPTIONAL COMPONENTS 11.1 Heater (replacement) 11.1.1 Disassembly 1 - Undo the screws A and the relevant washers. 2 - Remove the flange C. 3 - Remove the heater E and the relevant gaskets F. 11.1.2 Assembly Important • Always replace gaskets F, with each assembly. 1 - In sequence, fit the manifold G with the gasket F, the new heater E, the second gasket F, the flange C, the washers H, the cable B and the screws A. 2 - Secure the flange C with the screws A (tightening torque at 22Nm). 11.2 Air filter (cartridge replacement) 1 - Release the two hooks A and remove the cover B from the body C. 2 - Remove the cartridges D. 3 - Insert the new cartridge D and both of them inside the filter body C. 4 - Secure the cover B via the hooks A.
- 130. 130 11 _01 A2 C C A4 A1 A3 B D H1 J1 H2 J2 E1 G1 G2 E2 E3 F C Fig. 11.5 Fig. 11.7 Fig. 11.9 Fig. 11.8 Fig. 11.6 K ED0053030410 INFORMATION ABOUT OPTIONAL COMPONENTS 11.3 Cooling circuit (replacement) 11.3.1 Radiator disassembly 1 - Release the clamp A1, A2. 2 - Disconnect hose B from radiator C. 3 - Release the clamp A3, A4. 4 - Disconnect hose D from radiator C. 5 - Loosen all capscrews E1, E2 and E3. 6 - Release nut F. 7 - Remove floodgates G1 and G2. 8 - Loosen capscrews K. 9 - Disconnect radiator C from hoses H1 and H2, being careful not to deform tubes J1 and J2.
- 131. 131 11 _01 R P U P R C Fig. 11.10 Fig. 11.11 Fig. 11.12 C H2 J2 V C V K ED0053030410 INFORMATION ABOUT OPTIONAL COMPONENTS 11.3.2 Fan disassembly 1 - Undo the screws P and remove the fan R. 11.3.3 Fan assembly 1 - Assemble the fan R on the pulley U. 2 - Fasten the fan R by using the screws P (tightening torque at 10 Nm). 11.3.4 Radiator assembly 1 - Fit radiator C onto hose H2, being careful not to deform tube J2. 2 - Centre radiator C onto v i b r a t i o n - d a m p e n i n g devices V. 3 - Secure radiator C onto v i b r a t i o n - d a m p e n i n g devices V by means of capscrews K (tightening torque at 25 Nm).
- 132. 132 11 _01 Fig. 11.13 Fig. 11.14 Fig. 11.15 G1 G2 C E1 E2 E3 H1 C S S F V2 V2 F1 J1 ED0053030410 INFORMATION ABOUT OPTIONAL COMPONENTS 4 - Position floodgate G1 onto radiator C. 5 - Secure all capscrews E1. 6 - Place floodgate G2 onto radiator C. 7 - Secure all capscrews E3 and E2. 8 - Fit hose H1 onto radiator C, being careful not to deform tube J1. NOTE: Make sure vibration-dampening device V2 is correctly installed in its place on brace S. 9 - Secure vibration-dampening device V2 onto brace S by means of nut F, inserting washer F1 (tightening torque at 25 Nm). 10 - Secure hoses B and D by means of clamps A2 and A3 (Fig. 11.5 - 11.6). 11 - Secure hoses H1 and H2 by means of clamps A1 and A4 (Fig. 11.5 - 11.6).
- 133. 133 12 _01 A L D C F M M G H F E M Fig. 12.1 ED0053030410 INFORMATION ON ADJUSTMENTS 12.1 Waste Gate opening valve regulation Important • Regulation must not be carried out with the engine running. During the procedure in point 5, pay special attention not to bend rod H. 1 - Disconnect the hose A from the turbocharger. 2 - Connect a pressure reducer C to the network of compressed air. The air pressure in the network must be set to 2.0 bar. 3 - Position dial gauge D in such a way that feeler F rests on the Waste Gate rod control valve extremity H (point E). 4 - By using reduction gear C send air to the Waste Gate actuator control L in order to move rod H forward by 1 mm (value M to check on dial gauge D D). Pressure read on reduction gear C must be: 2500 mbar. 5 - If pressure is less or more than the indicated value, proceed as follows: - Undo lock nut G from rod H. - Remove the retainer cotter pin (point E) and disconnect rod H from the Waste Gate control lever. - Tighten to increase or loosen to decrease (the pressure) of the ring nut of rod H until reaching the corrected calibration. - Redo lock nut G. - Reconnect rod H and assemble the cotter pin point E. Fig. 12.1 Warning • Before proceeding with operation, carefully read Par. 3.3.2.
- 134. 134 12 _01 A A1 A2 A D B B Fig. 12.4 Fig. 12.5 A C B C Fig. 12.2 Fig. 12.3 ED0053030410 INFORMATION ON ADJUSTMENTS 12.3 Oil steam separator check 1 - Loosen clamp B and remove hose C from separator A. 2 - Remove rapid fitting D from separator A. 3 - Start the engine at idle speed or without a load and check if air comes out from unions A1 and A2. NOTE: If what is described in Point 3 does not occur, proceed with cleaning or replacing oil separator A and all connecting hoses. Repeat the operation from point 3. 12.4 Rubber hoses and manifolds check The check is carried out by applying slight deflection or bending along the tube/hose and next to the hose clamps. Componentsmustbereplacediftheyhaveclearsignsofcracks, tears, cuts, leaks, or do not retain a certain degree of elasticity. 1 - Check the condition of all hoses and rubber tubes highlighted in red in Fig. 12.4 - 12.5. 2 - Check whether there are any leakages of air, coolant, oil or fuel next to their connections. NOTE: Refer to the technical documentation of the machine for components that are not shown in the figure. 12.2 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.
- 135. 135 12 _01 A A A A Fig. 12.6 Fig. 12.7 A B C 3,1 0,9 0,6 0 0,5 1 1,5 2 2,5 3 3,5 40 100 110 bar °C @1000 RPM Fig. 12.8 Fig. 12.9 Fig. 12.10 ED0053030410 INFORMATION ON ADJUSTMENTS 12.5 Oil leak check Check that there are no leakages next to area A. 1 - Start the engine at idle speed or without a load and check whether there are any leakages next to area A. 2 - It is anyhow necessary to also check the seals of all main components and their surface contact, such as: - crankcase and gasket (side 2a PTO) - oil sump and exhaust caps - cylinder head and its assembled components - rocker arm cover - flange and gasket (side 1a PTO) - oil dipstick housing or rod support tube. NOTE: Perform the checks described in Points 1 and 2 periodically and during maintenance procedures. It is also necessary to check for leakages on the components that are not listed. If necessary,disassemblethecomponentsthathavealeakage and investigate the possible cause. The components must be replaced otherwise they do not guarantee their sealing. 12.6 Oil pressure check 1 - Replace the oil dipstick A with a thermocouple B (Fig. 12.8). 2 - Unscrew and remove the oil pressure switch C and screw on a 10 bar pressure gauge in its seat (Fig. 12.10). 3 - Start the engine at idle speed and without a load, check the oil pressure value according to the oil temperature (Fig. 12.9). NOTE: The graph in Fig. 12.9 illustrates the pressure line with speed of 1000 Rpm. 4 - If the pressure values are below the values indicated in Fig. 12.9, check to identify the cause of the problem.
- 137. 137 13 _01 ED0053030470 TOOLS INFORMATION 13.1 Information regarding specific tools For reference check the specific tools manual, cod. ED0053030770-S, to be found at: http://iservice.lombardini.it
- 138. 138 14 _01 Tab. 14.1 ED0053030470 INFORMATION ABOUT FAILURES 14.1 Possible causes and trouble shooting POSSIBLE ANOMALIES ACCORDING TO THEIR SYMPTOMS POSSIBLE CAUSE TROUBLES Engine does not start It starts and stops No acceleration Variable speed Black smoke White smoke Low oil pressure Oil level increase Excessive oil consumption Oil and fuel leak- ing out from the exhaust Engine overheats Inadequate performance High noise level The Warning Lamp switches on FUEL CIRCUIT Clogged fuel line Clogged fuel filter Air or water in the fuel system The fuel tank cap air bleeding hole is clogged Faulty fuel feeding pump No fuel ELECTRIC SYSTEM Cable connection uncertain or incorrect Faulty starting motor Defective heater (optional) MAINTE- NANCE Clogged air filter Excessive idle operation Incomplete run-in SETTINGS REPAIRS Rings worn or sticking Worn cylinder Worn out valve guides Badly sealed intake valve Crankshaft/Connecting rod bearings worn out Damaged cylinder head gasket Defective timing system 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 - The oil pressure warning light or a Warning Lamp turns on during operation; 5 - The coolant temperature warning light turns on during operation. Tab. 14.1 contains the possible causes of some failures, which may occur during operation. Always perform these simple checks before removing or replacing any part. Warning • Search for a topic and the operations to carry out from the analytical index or chapter index found at the beginning of the manual. • Do not carry out any checks or operations on the engine when it is running.
- 139. 139 14 _01 ED0053030470 INFORMATION ABOUT FAILURES POSSIBLE CAUSE TROUBLES Engine does not start Engine starts but stops No acceleration Variable speed Black smoke White smoke Low oil pressure Oil level increase Excessive oil consumption Oil and fuel leak- ing out from the exhaust Engine overheats Inadequate performance High noise level The Warning Lamp switches on LUBRICATION CIRCUIT 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 INJECTION Damaged electronic injectors Damaged injection pump Wrong injector IMA codes COOLING CIRCUIT Insufficient coolant Defective fan, radiator, or radiator cap Blockage inside the radiator or the coolant ducts Heat exchange surface of the radiator clogged Defective thermostatic valve Coolantleakingfromtheradiator,manifolds, crankcase or from the coolant pump Defective or worn coolant pump
- 140. 140 15 _01 ED0053030410 GLOSSARY A Air gap: Distance to respect between a fixed component and one in movement. Alternator: A component that transforms mechanical energy into AC electrical energy. Authorised service station: KOHLER authorised workshop. Authorised workshop: Kohler authorised service centre. Base configuration: Engine having components represented in Para. 1.4 - 1.5. BDC: Bottom Dead Centre; a moment in which the piston is at the start of its stroke. Bore: Internal diameter of the cylinder in combustion engines. C Cold Start Advance: thedeviceprovidesforadvanceinjectionmodificationtoenable advance of the engine at low temperatures. Combustion: Chemical reaction of a mixture composed of fuel and fuel (air) inside a combustion chamber. Crankshaft: A component that transforms straight operation into rotary operation, and vice-versa. E EC: European Community. F Fig.: Figure. Functional units: Component, or group of main components, able to carry out specific functions on the engine. G Galvanised: Material that has undergone surface protection treatment. Grinding (valves and seats): Cleaning operation of the valves and seats carried out with an abrasive paste (refer to an authorised service station for this type of operation). H Heater: A device that heats the intake air by means of an electrical resistor. Heavy conditions: Type of extreme condition referred to the work environment in which the engine is used (very dusty - dirty area, or in a contaminated environment due to various types of gas). I Idle speed operation: Operation of a running engine with the vehicle stopped and on idle speed. K KDI: Kohler Direct Injection M Maintenance - periodic: A group of maintenance actions that have the sole objective to controlandreplaceelementsontheirexpiry,withoutmodifying or improving the functions carried out by the system, neither increasing the value nor improving performance. MAX: Maximum. Methyl ester It is a mixture of products by means of a chemical conversion of oils and animal and/or vegetable fat, which is used to produce Biofuel. Min.: Minutes. MIN: Minimum. Model: Model,engineidentificationplate,whichindicatestheengine's model. N N/C: Normally Closed, referred to switches (oil-pressure switch). N/O: Normally Opened, referred to switches (Coolant temperature sensor) O Oil Cooler: Small radiator used to cool the oil.
- 141. 141 15 _01 ED0053030410 GLOSSARY P Par.: Paragraph. Paraffin: Fatty and solid substance that may form inside the diesel. Pipe cleaner: An instrument having a metal cylindrical body with bristles that jut outwards. It is similar to a brush and is used to clean areas that are not easily accessible manually (e.g. oil ducts inside an engine). Power operation: Operation of the engine at high speeds. PTO: Power Take Off - a point provided to take advantage of alternative operation transmission. R Ref.: Reference. Rpm: Rounds per minute. S s/n: Serial number (engine identification name plate) indicating the engine identification series/chassis number. Spec.: Specification, (engine identification name plate) indicating the engine version. STD: (Standard), base configuration of a component, or a group of components. T Tab.: Table. TDC: Top Dead Centre; a moment in which the piston is at the end of its stroke. Thermostatic valve: A valve that adjusts the flow of coolant liquid; it is able to operate by means of temperature variation. Tightening torque: A term indicated for installation of threaded components and which is determined by means of a unit of measurement Nm. Torque: Force applied to an object that rotates on an idler shaft. Trochoid: Rounded toothed profile (also known as "lobes"). U Used oil: Oil altered by operation or time, which is no longer compliant for correct lubrication of the components. W Warning Lamp: A warning light (usually red) that indicates a serious anomaly during engine operation. Waste-Gate valve: A device, which is directly or automatically controlled, used to limit the pressure of exhaust gas inside the turbine.
- 142. 142 15 _01 Tab. 15.1 ED0053030410 GLOSSARY SYMBOLS AND UNITS OF MEASUREMENT SYMBOL UNIT OF MEASUREMENT DESCRIPTION EXAMPLE α degree Rotation/inclination angle 1° cm2 square centimetre Area 1 cm2 Ø millimetre Circumference Ø 1 mm Nm newton-metre Torque 1 Nm mm millimetre Dimension 1 mm μm 1/1000 of a millimetre (micron) 1 μm h hour Quantity 1 h g/kWh grammes per kilowatt per hour 1 g/kWh kg/h kilogramme per hour 1 kg/h L/min. litres per minute 1 L/min. L/h litres per hour 1 L/h ppm parts per million 1 ppm N newton Force 1 N A Ampere Intensity of electrical current 1 A L litre Liquids 1 L gr. gramme Weight 1 gr. kg kilogramme 1 kg W Watt Power 1 W kW kiloWatt 1 kW pa pascal Pressure 1 pa KPa Kilopascal 1 KPa bar barometric pressure 1 bar mbar (1/1000 bar) barometric pressure 1 mbar R Resistance Resistance to electrical current (referred to a compo- nent) 1 Ω Ω ohm Resistance of electrical cur- rent 1 Ω Rpm revs per minute Rotation of an axis 1 Rpm Ra average roughness ex- pressed in microns Roughness Ra = 1 °C degree centigrade Temperature 1°C V Volt Electrical voltage 1 V à millimetre Hex-head capscrew à 1 mm cm3 cubic centimetre Volume 1 cm3 L litre 1 L
- 143. Lombardini s.r.l. is a part of Kohler Group. Lombardini has manufacturing facilities in Italy, Slovakia and India and sales subsidiaries in France, Germany, UK, Spain and Singapore. Kohler/Lombardini reserves the right to make modifications without prior notice. www.lombardini.it DEUTSCHLAND Lombardini Motoren GmbH Silostr. 41, 65929 FRANKFURT Hessen, DEUTSCHLAND T. +49-(0)69-9508160 F. +49-(0)69-950816-30 EUROPE Lombardini Srl Via Cav. del lavoro A. Lombardini n° 2 42124 Reggio Emilia, ITALY T. +39-(0)522-389-1 F. +39-(0)522-389-503 UK Lombardini U.K. Ltd 1, Rochester Barn - Eynsham Road OX2 9NH Oxford, UK T. +44-(0)1865-863858 F. +44-(0)1865-861754 FRANCE Lombardini France S.a.s. 47 Alléè de Riottier, 69400 Limas, FRANCE T. +33-(0)474-626500 F. +33-(0)474-623945 ESPAÑA Lombardini ESPAÑA, S.L. P.I. Cova Solera 1-9 08191 - Rubí (Barcelona) ESPAÑA T. +34-(0)9358-62111 F. +34-(0)9369-71613 USA & CANADA Kohler Co. 444 Highland Drive, Kohler - Wisconsin (53044), US T. +1 920 457 4441 F. +1 920 459 1570 CHINA & ROAPAC Kohler China INVESTMENT Co. Ltd no.158, Jiang Chang San Road, 200436, Zhabe, Shanghai CHINA Tel: +86 400-0120-648 Fax: +86 21 61078904