Kohler KD 625/3, RD 626/3, KD 626/3 Workshop Manual

KD 625/3 - 626/3

WORKSHOP MANUAL

- 2 -

CUSE/ATLO

REGISTRATION OF MODIFICATIONS TO THE DOCUMENT

Any modications to this document must be registered by the drafting body, by completing the following table.

Drafting

body

Document

code

Edition Issue date

Review

date

Model

N°

Revision Endorsed

PREFACE

- Every attempt has been made to present within this service manual, accurate and up to date technical information.

However, development on the KOHLER series is continuous. Therefore, the information within this manual is subject to change without notice and without obligation.

- The information contained within this service manual is the sole property of KOHLER.

As such, no reproduction or replication in whole or part is allowed without the express written permission of

KOHLER.

Information presented within this manual assumes the following:

1 - The person or people performing service work on KOHLER series engines is properly trained and equipped to

safely and professionally perform the subject operation;

2 - The person or people performing service work on KOHLER series engines possesses adequate hand and

KOHLER special tools to safely and professionally perform the subject service operation;

3 - The person or people performing service work on KOHLER series engines has read the pertinent information

regarding the subject service operations and fully understands the operation at hand.

- This manual was written by the manufacturer to provide technical and operating information to authorised KOHLER

after-sales service centres to carry out assembly, disassembly, overhauling, replacement and tuning operations.

- As well as employing good operating techniques and observing the right timing for operations, operators must

read the information very carefully and comply with it scrupulously.

- Time spent reading this information will help to prevent health and safety risks and nancial damage.

Written information is accompanied by illustrations in order to facilitate your understanding of every step of the

operating phases.

02/07/20121° 0

ED0053029350

51261 02/07/2012

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 3 -

This manual contains the most important information for the repair of KOHLER air cooled, direct injection Diesel engines type KD 625/3 and 626/3. This information is current upto 02/07/2012

CHAPTER INDEX

California emission control warranty statement ................................................................................................................. 6

Your warranty rights and obligations

.................................................................................................................................. 6

GENERAL REMARKS AND SAFETY INFORMATION ........................................................................................... 7

Safety and warning decals ................................................................................................................................................. 7

Limited 3 year kohler® diesel engine warranty .................................................................................................................... 7

General service manual notes

............................................................................................................................................ 7

Glossary and terminology

................................................................................................................................................... 7

Safety regulations ............................................................................................................................................................... 8

General safety during operating phases ............................................................................................................................ 9

Safety and environmental impact ...................................................................................................................................... 9

TECHNICAL INFORMATION .................................................................................................................................. 10

Possible causes and trouble shooting ...............................................................................................................................10

Manufacturer and motor identication data .......................................................................................................................12

The identication plate shown in the gure can be found directly on the engine. .............................................................12

Approval data .....................................................................................................................................................................12

Techinical specications ....................................................................................................................................................13

Performance diagrams ......................................................................................................................................................14

Overall dimensions ............................................................................................................................................................16

MAINTENANCE - PRESCRIBED LUBRICANT - REFILLING ............................................................................. 17

Routine engine maintenance .............................................................................................................................................17

Extraordinary maintenance ...............................................................................................................................................17

Ordinary maintenance .......................................................................................................................................................17

Lubricant ............................................................................................................................................................................18

Prescribed lubricant ...........................................................................................................................................................19

Fuel specications ............................................................................................................................................................ 20

DISASSEMBLY/REASSEMBLY .............................................................................................................................. 22

Recommendations for disassembling and assembling .................................................................................................... 22

Recommendations for overhauls and tuning .................................................................................................................... 22

Oil-bath air cleaner ........................................................................................................................................................... 23

Oil-bath air cleaner components ...................................................................................................................................... 23

Exhaust manifold .............................................................................................................................................................. 23

Intake manifold .................................................................................................................................................................. 24

Blower belt alternator ........................................................................................................................................................ 24

Belt tension adjustment .................................................................................................................................................... 24

Half-pulley - Reassembly .................................................................................................................................................. 24

Blower belt alternator - Reassembly

................................................................................................................................. 25

Tension check

................................................................................................................................................................... 25

Air shroud and bafes - Disassembly ............................................................................................................................... 25

Blower assembly ............................................................................................................................................................... 25

Blower assembly components with 14 A alternator .......................................................................................................... 26

Blower assembly components with 21 A alternator

.......................................................................................................... 26

Blower control pulley - Disassembly

................................................................................................................................ 26

Crankshaft pulley .............................................................................................................................................................. 27

Blower control pulley diameter ......................................................................................................................................... 27

Timing cover ..................................................................................................................................................................... 27

Tank

.................................................................................................................................................................................. 28

Flywheel

............................................................................................................................................................................ 28

Valve / rocker arm clearance ............................................................................................................................................ 28

Compression release (optional) ........................................................................................................................................ 29

Rocker arm assembly ....................................................................................................................................................... 29

Disassembling size P injector

........................................................................................................................................... 29

Injector protrusion

..............................................................................................................................................................31

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 4 -

Chapter index

Cylinder Head ....................................................................................................................................................................31

Valves ................................................................................................................................................................................31

Valve stem sealing rings - Reassembly ........................................................................................................................... 32

Valve springs..................................................................................................................................................................... 32

Valve material .................................................................................................................................................................. 32

Valve guides and cylinder head housings ........................................................................................................................ 32

Valve guide insertion ........................................................................................................................................................ 33

Dimensions and clearance between guides and valves ................................................................................................. 33

Valve seats and housings ................................................................................................................................................. 33

Valve seat lapping ............................................................................................................................................................. 33

Pushrod tube spring tting ................................................................................................................................................ 34

Cylinder ............................................................................................................................................................................. 34

Checks and cyiinder roughness ....................................................................................................................................... 34

Piston ................................................................................................................................................................................ 34

Piston weight ..................................................................................................................................................................... 35

Metal snap rings - End gaps ........................................................................................................................................... 35

Metal snap rings - Piston grooves .................................................................................................................................. 35

Metal snap rings - Fitting sequence ................................................................................................................................. 35

Piston - Retting ............................................................................................................................................................... 36

Piston clearance ............................................................................................................................................................... 36

Connecting rod ................................................................................................................................................................. 36

Connecting rod small end bearing and pin ....................................................................................................................... 37

Connecting rod alignment ................................................................................................................................................. 37

Connecting rod weight ...................................................................................................................................................... 37

Connecting rod big end bearing ....................................................................................................................................... 37

Camshaft gear .................................................................................................................................................................. 38

Oil pump gear ................................................................................................................................................................... 38

Timing gear ....................................................................................................................................................................... 38

Main bearing support, gear side ...................................................................................................................................... 38

Main bearing support, ywheel side ................................................................................................................................. 39

Crankshaft ......................................................................................................................................................................... 39

Center main bearing support, locating bolts ..................................................................................................................... 39

Crankshaft removal ........................................................................................................................................................... 39

Crankshaft center main bearing supports ........................................................................................................................ 39

Crankshaft lubrication ducts ............................................................................................................................................. 40

Crankshaft journal radius .................................................................................................................................................. 40

Checking main journals and crank pins ............................................................................................................................ 40

Main journal and crank pin diameter ............................................................................................................................... 40

Diameter of main bearings .................................................................................................................................................41

Main bearing and connecting rod big end bearing inside diameter ..................................................................................41

Clearance between main journals/crank pins and connecting rod bearings ....................................................................41

Main bearing supports .......................................................................................................................................................41

Main bearing housings .......................................................................................................................................................42

Crankshaft end play ...........................................................................................................................................................42

Camshaft ............................................................................................................................................................................42

Camshaft removal ..............................................................................................................................................................42

How to measure camshaft bearing and journal inside diameter .......................................................................................42

Dimensions of camshaft journals and housings ............................................................................................................... 43

Checking intake/exhaust cam height ................................................................................................................................ 43

Intake/exhaust cam height ................................................................................................................................................ 43

Camshaft end play ............................................................................................................................................................ 43

Camshaft timing ................................................................................................................................................................ 44

Valve timing without considering timing marks ................................................................................................................. 44

Valve timing check ............................................................................................................................................................ 44

Hydraulic pump p.t.o. group 1 ........................................................................................................................................... 46

Hydraulic pump 3rd p.t.o., group 2 .................................................................................................................................... 46

Hydraulic pump 4th p.t.o., group 1 ................................................................................................................................... 46

Use of 3rd and 4th p.t.o. ................................................................................................................................................... 46

Mechanical speed governor ..............................................................................................................................................47

Mechanical speed governor components (standard) ........................................................................................................47

Mechanical speed governor operation (standard) .............................................................................................................47

Mechanical speed governor components for special generating sets ............................................................................. 48

Mechanical speed governor setting .................................................................................................................................. 48

Spring for extra fuel supply at starting ............................................................................................................................. 48

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 5 -

Chapter index

LUBRICATION SYSTEM ......................................................................................................................................... 49

Oil pump ............................................................................................................................................................................ 50

Oil pressure relief valve

.................................................................................................................................................... 50

Oil lter cartridge .............................................................................................................................................................. 50

Oil pressure check ............................................................................................................................................................ 50

Oil pressure curve at idling speed

.....................................................................................................................................51

Oil pressure curve at full speed .........................................................................................................................................51

FUEL SYSTEM ........................................................................................................................................................52

Fuel feeding/injection circuit ............................................................................................................................................. 52

Fuel lter ........................................................................................................................................................................... 52

Fuel feeding pump

............................................................................................................................................................ 52

Injection pump ................................................................................................................................................................. 52

Injection pump only for EPA engines

................................................................................................................................ 53

Injection pump only for standard and 97/68 Ce engines .................................................................................................. 53

Plunger .............................................................................................................................................................................. 54

How to check plunger and barrel for internal leakage

...................................................................................................... 54

How to check injection pump delivery valve sealing ........................................................................................................ 54

Test data for injection pump delivery at the test bench only for EPA engines

................................................................. 55

Test data for injection pump delivery at the test bench for standard and 97 / 68 CE engines ......................................... 55

Injection pump replacement ............................................................................................................................................. 56

Size S injector

................................................................................................................................................................... 56

Size S nozzle

................................................................................................................................................................... 57

Size P injector

................................................................................................................................................................... 57

Size P nozzle

................................................................................................................................................................... 57

Injector setting .................................................................................................................................................................. 58

(Static) Injection timing

..................................................................................................................................................... 58

ELECTRIC SYSTEM ................................................................................................................................................ 62

Standard electric equipment ............................................................................................................................................. 62

Electric starting layout without battery charging light

....................................................................................................... 62

Electrical starting layout with battery charging Iight ......................................................................................................... 62

12,5 V, 14 A Alternator

...................................................................................................................................................... 62

Alternator battery charger curve (12.5 V, 14A)

................................................................................................................. 63

12 V, 21 A Alternator

......................................................................................................................................................... 63

Alternator battery charger curve (12 V, 21 A)

................................................................................................................... 63

Magnetization checking tool (Part No. 7000-9727-001) ................................................................................................... 64

Checking for cable continuity

........................................................................................................................................... 64

Voltage regulator

............................................................................................................................................................... 64

How to check voltage regulator for proper operation

....................................................................................................... 65

Alternator type Bosch G1 14 V, 33 A

................................................................................................................................ 66

Alternator type Bosch Gil 14 V, 33 A layout ...................................................................................................................... 66

14 V, 33 A Bosch G1 alternator battery charger curve

..................................................................................................... 66

Starting motor type Bosch JF (R) 12 V, class 2.5 ............................................................................................................. 67

Characteristic curves for starting motor type Bosch JF (R) 12 V

..................................................................................... 67

Starting motor layout ......................................................................................................................................................... 67

SETTINGS ............................................................................................................................................................... 68

Settings ............................................................................................................................................................................. 68

Injection pump delivery setting ......................................................................................................................................... 68

Stop setting

....................................................................................................................................................................... 68

APPENDIX FOR ENGINE WITH ADVANCE VARIATOR ..................................................................................... 71

ADVANCE VARIATOR OPERATING PRINCIPLE ................................................................................................. 72

Injection timing device operation ...................................................................................................................................... 72

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 6 -

CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT

YOUR WARRANTY RIGHTS AND OBLIGATIONS

The California Air Resources Board and Kohler Co. are pleased to explain the emission control system warranty on your 2012 engine. In

California, new heavy-duty off-road engines must be designed, built and equipped to meet the State’s stringent anti-smog standards. Kohler Co. must warrant the emission control system on your engine for the time period listed below provided there has been no abuse, neglect or improper maintenance of your engine. Your emission control system may include parts such as the fuel-injection system and the air induction system. Also included may be hoses, connectors and other emission related assemblies. Where a warrantable condition exists, Kohler Co. will repair your heavy-duty off-road engine at no cost to you including diagnosis, parts and labor.

MANUFACTURER’S WARRANTY COVERAGE:

Your off-road, diesel engine emission control system is covered under warranty for a period of ve (5) years or 3,000 hours, whichever occurs rst, beginning on the date the engine or equipment is delivered to an ultimate purchaser for all constant speed engines with maximum power 19≤kW<37 and rated speed less than 3,000 rpm, all variable speed engines with maximum power 19≤kW<37, and all variable or constant speed engines with maximum power greater than 37 kW. Your off-road, diesel engine emission control system on variable or constant-speed engines with maximum power less than 19 kW, and for constant speed engines with maximum power 19≤kW<37 and rated speed equal to or greater than 3,000 rpm is covered under warranty for a period of two (2) years or 1,500 hours, whichever occurs rst. If any emission related part on your engine is defective, the part will be repaired or replaced by Kohler Co.

OWNER’S WARRANTY RESPONSIBILITIES:

As the heavy-duty off-road engine owner, you are responsible for the performance of the required maintenance listed in your Kohler Co. owner’s manual. Kohler Co. recommends that you retain all receipts covering maintenance on your heavy-duty off-road engine, but Kohler Co.

cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all recommended scheduled maintenance. As the heavy-duty off-road engine owner, you should however be aware that Kohler Co. may deny you warranty coverage if your heavy-duty offroad engine or emission control related component has failed due to abuse, neglect, improper maintenance or unapproved modications. Your engine is designed to operate on commercial diesel fuel (No. 1 or No. 2 low sulfur or ultra low sulfur diesel fuel) only. Use of any other fuel may result in your engine no longer operating in compliance with California’s emissions requirements. You are responsible for initiating the warranty process. The Air Resources Board suggests that you present your heavy-duty off-road engine to a Kohler Co. dealer as soon as a problem exists. The warranty repairs should be completed by the dealer as expeditiously as possible. Please review the document titled, “Kohler Co. Federal and California Emission Control Systems Limited Warranty Off-Road Diesel Engines”, for complete details of your heavy-duty off-road engine warranty. If you have any questions regarding your warranty rights and responsibilities or the location of the nearest Kohler Co. authorized service location, you should contact Kohler Co. at 1-800-544-2444 or access our website at www. kohlerengines.com.

Chapter index

DISASSEMBLY/REASSEMBLY .............................................................................................................................. 74

Solenoid valve assembly diagram .....................................................................................................................................74

Speed sensor and variator assembly diagram

................................................................................................................. 78

Blower belt alternator - Disassembly ................................................................................................................................ 80

Blower control pulley - Disassembly .................................................................................................................................81

Angular position sensor and AC pump assembly diagram

.............................................................................................. 88

Phase sensor assembly diagram ..................................................................................................................................... 90

Resetting the dial indicator

............................................................................................................................................... 92

Sensor test ........................................................................................................................................................................ 92

Resetting the dial indicator ............................................................................................................................................... 93

Measuring the depth between the sensor support and the camshaft

............................................................................. 93

Air gap adjustment ............................................................................................................................................................ 93

Example of adhesive plate on the control panel

............................................................................................................... 98

STORAGE ............................................................................................................................................................. 100

Storage ........................................................................................................................................................................... 100

External engine protection:

............................................................................................................................................. 100

Injection systems protection: .......................................................................................................................................... 100

External engine protection:

............................................................................................................................................. 100

Procedures to be carried out before start the engine ......................................................................................................101

MAIN TORQUE SPECIFICATIONS AND USE OF SEALANTS .......................................................................... 102

Main torque specications ...............................................................................................................................................102

Use of sealants only for engines with variator

.................................................................................................................103

Table of tightening torques for standard screws (coarse thread)

................................................................................... 104

Table of tightening torques for standard screws (ne thread)

........................................................................................ 104

SPECIAL TOOLS .................................................................................................................................................. 105

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 7 -

1

GENERAL REMARKS AND SAFETY INFORMATION

WARRANTY CERTIFICATE

GLOSSARY AND TERMINOLOGY

For clarity, here are the denitions of a number of terms used recurrently in the manual.

- Cylinder number one: is the piston timing belt side «viewed

from the ywheel side of the engine».

- Rotation direction: anticlockwise «viewed from the ywheel

side of the engine».

GENERAL SERVICE MANUAL NOTES

1

- Use only genuine Kohler repair parts.

Failure to use genuine Kohler parts could result in sub-

standard performance and low longevity.

2

- All data presented are in metric format. That is, dimensions are presented in millimeters (mm), torque is presented in Newton-meters (Nm), weight is presented in kilograms (Kg), volume is presented in liters or cubic centimeters (cc) and pressure is presented in barometric units (bar).

LIMITED 3 YEAR KOHLER® DIESEL ENGINE WARRANTY

Kohler Co. warrants to the original retail consumer that each new KOHLER Diesel engine sold by Kohler Co. will be free from manufacturing defects in materials or workmanship in normal service for a period of three (3) years or 2000 hours whichever occurs rst from the date of purchase, provided it is operated and maintained in accordance with Kohler Co.’s instructions and manuals. If no hour meter is installed as original equipment then 8 hours of use per day and 5 days per week will be used to calculate hours used.

Our obligation under this warranty is expressly limited, at our option, to the replacement or repair at Kohler Co., Kohler, Wisconsin 53044, or at a service facility designated by us of such parts as inspection shall disclose to have been defective.

This warranty does not apply to defects caused by unreasonable use, including faulty repairs by others and failure to provide reasonable and necessary maintenance.

The following items are not covered by this warranty: Engine accessories such as fuel tanks, clutches, transmissions, power-drive assemblies and batteries, unless supplied or installed by Kohler Co. These are subject to the warranties, if any, of their manufacturers.

KOHLER CO. AND/OR THE SELLER SHALL NOT BE LIABLE FOR SPECIAL, INDIRECT, INCIDENTIAL OR CONSEQUENTIAL DAMAGES OF ANY KIND, including but not limited to labor costs or transportation charges in connection with the repair or replacement of defective parts.

IMPLIED OR STATUTORY WARRANTIES, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE EXPRESSLY LIMITED TO THE DURATION OF THIS WRITTEN WARRANTY. We make no other express warranty, nor is any one authorized to make any on our behalf.

Some states do not allow limitations on how long an implied warranty lasts, or the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you.

This warranty gives you specic legal rights, and you may also have other rights, which vary from state to state.

To obtain warranty service

Purchaser must bring the engine to an authorized Kohler service facility. To locate the nearest facility, visit our website, www.kohlerengines.com, and use the locator function, consult your Yellow Pages or telephone 1-800-544-2444.

ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044

- Important remarks and features of the text are highlighted

using symbols, which are explained below:

 Danger – Attention This indicates situations of grave danger which, if ignored, may seriously threaten the health and safety of individuals.

SAFETY AND WARNING DECALS

Caution – Warning This indicates that it is necessary to take proper precautions to prevent any risk to the health and safety of individuals and avoid nancial damage.

Important This indicates particularly important technical information that should not be ignored.

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 8 -

1

GENERAL NOTES

.

Kohler engines are built to provide safe and longlasting

performances, but in order to obtain these results it is essential that the maintenance requirements described in the manual are observed along with the following safety recommendations.

. The engine has been built to the specications 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 complying with its intended purpose as specied by Kohler, which therefore declines all responsibility for accidents caused by such operations.

. The following instructions are intended for the user of the

machine in order to reduce or eliminate risks, especially those concerning the operation and standard maintenance of the engine.

. The user should read these instructions carefully and get

to know the operations described. By not doing so he may place at risk his own health and safety and that of anyone else in the vicinity of the machine.

. The engine may be used or mounted on a machine only

by personnel suitably trained in its operation and aware of the dangers involved. This is particularly true for standard and, above all, special maintenance work. For special maintenance contact personnel trained specically by Kohler. This work should be carried out in accordance with existing literature.

. Kohler declines all responsibility for accidents or for failure

to comply with the requirements of law if changes are made to the engine’s functional parameters or to the fuel ow rate adjustments and speed of rotation, if seals are removed, or if parts not described in the operating and maintenance manual are removed and reassembled by unauthorized personnel.

WARNING

. In addition to all other machine specications, ensure that

the engine is in a near horizontal position when starting. lf starting manually, ensure that the necessary operations can be performed without any risk of striking against walls or dangerous objects. Rope starting (except for recoil rope starting) is not permitted even in emergencies.

. Check that the machine is stable so that there is no risk of it

overturning.

. Get to know the engine speed adjustment and machine

stop operations.

. Do not start the machine in closed or poorly ventilated

environments. The internal combustion process generates carbon monoxide, an odourless and highly toxic gas, so spending too long a time in an environment where the engine discharges its exhaust products freely can lead to loss of consciousness and even death.

. The engine may not be used in environments containing

ammable materials, explosive atmospheres or easily combustible powders, unless adequate and specic precautions have been taken and are clearly stated and certied for the machine.

. To prevent the risk of re, keep the machine at a distance of

at least one metre from buildings or other machines.

SAFETY REGULATIONS

.

Children and animals must be kept at a sufcient distance

from the machine to prevent any danger resulting from its operation.

. Fuel is ammable, so the tank must be lled only when the

engine is turned off. Dry carefully any fuel that may have spilled, remove the fuel container and any cloths soaked in fuel or oil, check that any sound-absorbing panels made of porous material are not soaked with fuel or oil, and make sure that the ground on which the machine is located has not absorbed fuel or oil.

. Before starting, remove any tools that have been used for

carrying out maintenance work to the engine and/or the machine and check that any guards removed have been replaced. In cold climates it is possible to mix kerosene with the diesel fuel to make the engine easier to start. The liquids must be mixed in the tank by pouring in rst the kerosene and then the diesel fuel. Consult Kohler technical ofce for mixture proportions. Petrol may not be used because of the risk of it forming ammable vapours.

. During operation the surface of the engine reaches

temperatures that may be dangerous. Avoid in particular all contact with the exhaust system.

. The liquid cooling circuit is under pressure. Do not carry out

any checks before the engine has cooled down, and even then open the radiator cap or the expansion tank cautiously. Wear protective clothing and glasses. lf there is an electric fan, do not approach the engine while it is still hot as the fan may come on even when the engine is not running. Clean the cooling system with the engine turned off.

. While cleaning the oil bath air lter, check that the oil is

disposed of in such a way as not to harm the environment. Any ltering sponges in the oil bath air lter should not be soaked with oil. The cyclone pre-lter cup must not be lled with oil.

. Since the oil must be emptied out while the engine is still hot

(approx. 80°C), particular care should be taken in order to avoid burns. In any case make sure that oil does not come into contact with your skin because of the health hazards involved.

. Fuel vapours are highly toxic, so ll up only in the open air or

in well ventilated environments.

. During operations which involve access to moving parts of

the engine and/or removal of the rotary guards, disconnect and insulate the positive cable of the battery so as to prevent accidental short circuits and activation of the starter motor.

. Check the belt tension only when the engine is turned off.

IMPORTANT

.

To start the engine follow the specic 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 systems which utilise ether etc.)

. Before carrying out any work on the engine, turn it off and

allow it to cool down. Do not perform any operation while the engine is running.

.

Check that the discharged oil, the oil lter and the oil

contained in the oil lter are disposed of in such a way as not to harm the environment.

.

Close the fuel tank ller cap carefully after each fílling

operation. Do not ll the tank right up to the top, but leave sufcient space to allow for any expansion of the fuel.

.

Do not smoke or use naked ames while lling.

General remarks and safety information

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 9 -

1

GENERAL SAFETY DURING OPERATING PHASES

– The procedures contained in this manual have been

tested and selected by the manufacturer’s technical experts, and hence are to be recognised as authorised operating methods.

– Some tools are normal workshop ones, while others are

special tools designed by the Manufacturer of the engine.

– All tools must be in good working condition so that engine

components are not damaged and that operations are carried out properly and safely.

– It is important to wear the personal safety devices

prescribed by work safety laws and also by the standards of this manual.

– Holes must be lined up methodically and with the aid of

suitable equipment. Do not use your ngers to carry out this operation to avoid the risk of amputation.

SAFETY AND ENVIRONMENTAL IMPACT

Every organisation has a duty to implement procedures to identify, assess and monitor the inuence 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:

- Liquid waste;

- 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, the manufacturer now provides a number of indications to be followed by all persons handling the engine, for any reason, during its expected lifetime.

- All packaging components must be disposed of in accordance

with the laws of the country in which disposal is taking place.

- Keep the fuel and engine control systems and the exhaust

pipes in efcient working order to limit environmental and noise pollution.

- When discontinuing use of the engine, select all components

according to their chemical characteristics and dispose of them separately.

– Some phases may require the assistance of more than

one operator. If so, it is important to inform and train them regarding the type of activity they will be performing in order to prevent risks to the health and safety of all persons involved.

– Do not use ammable liquids (petrol, diesel, etc.) to

degrease or wash components. Use special products. – Use the oils and greases recommended by the manufacturer. Do not mix different brands or combine oils with different

characteristics. – Discontinue use of the engine if any irregularities arise,

particularly in the case of unusual vibrations. – Do not tamper with any devices to alter the level of

performance guaranteed by the manufacturer.

.

Take care when removing the oil lter as it may be hot.

. The operations of checking, lling up and replacing the

cooling liquid must be carried out with the engine turned off and cold. Take particular care if liquids containing nitrites are mixed with others not containing these compounds as this may give rise to the formation of nitrosamines which are a health hazard. The cooling liquid is polluting, so dispose of in a manner that does not damage the environment.

. In order to move the engine simultaneously use the

eyebolts tted for this purpose by Kohler. These lifting points are however not suitable for the entire machine, so in this case use the eyebolts tted by the manufacturer.

General remarks and safety information

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 10 -

2

FUEL

CIRCUIT

POSSIBLE CAUSE

ELECTRIC

SYSTEM

MAINTENANCE

SETTINGS REPAIRS

In adequat e

performance

High noise

level

Overheats

TROUBLE

Engine does

not start

Engine starts

but stops

No acceleration

Non -unif orm

speed

Black smoke

White smoke

Too low oil

pressure

Excessive oil

consumption

Obstructed fuel line

Fuel lter clogged

Air or water leaks in fuel system

The tank cap vent hole is clogged

No fuel

Discharged battery

Cable connection uncertain or incorrect

Faulty starting switch

Faulty starting motor

Clogged air lter

Excessive idle operation

Incomplete run-in

Overloaded engine

Non-conforming engine oil

Incorrect governor linkage adjustment

Governor spring broken or unhooked

Low idle speed

Rings worn or sticking

Worn cylinder

Worn main con rod-rocker arm

bearings

Badly sealed intake valve

Head tightening nuts loose

Damaged cylinder head gasket

Excessive valve-rocker arm clearance

No clearance between valves and rocker arms

Valves sticking

Defective timing system

Bent rods

POSSIBLE CAUSES AND TROUBLE SHOOTING

THE ENGINE MUST BE STOPPED IMMEDIATELY WHEN:

1) - The engine rpms suddenly increase and decrease

2) - A sudden and unusual noise is heard

3) - The colour of the exhaust fumes suddenly darkens

4) - The oil pressure indicator light turns on while running.

TABLE OF LIKELY ANOMALIES AND THEIR SYMPTOMS

The following table contains the possible causes of some failures which may occur during operation. Always perform these simple checks before removing or replacing any part.

TECHNICAL INFORMATION

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 11 -

2

INJECTION

LUBRICATION

CIRCUIT

COOLING

CIRCUIT

Damaged injector

Injection pump valve damaged

Injector not adjusted

Faulty fuel feeding pump

Hardened pump control rod

Broken or loose supplementary start-

up spring

Worn or damaged pumping element

Incorrect tuning of injection components

(delivery balancing advance)

Extra fuel control level sticking

Oil level too high

Oil level low

Oil pressure valve blocked or dirty

Oil pressure regulator not adjusted

Worm oil pump

Oil sump suction line clogged

Faulty pressure gauge or pressure switch

Blocked draining pipe

Worn or broken blower belt

Cooling circuit clogged

POSSIBLE CAUSE

In adequat e

performance

High noise

level

Overheats

TROUBLE

Engine does

not start

Engine starts

but stops

No acceleration

Non -unif orm

speed

Black smoke

White smoke

Too low oil

pressure

Excessive oil

consumption

Technical information

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 12 -

2

Technical information

EPA Label Shown on the Recoil Starter or on Air Shroud

MANUFACTURER AND MOTOR IDENTIFICATION DATA

The identication plate shown in the gure can be found directly on the engine.

It contains the following information:

A) Manufacturer’s identity B) Engine type C) Engine serial number D) Maximum operating speed E) Number of the customer version (form K) F) Approval data

Approval data

The approval reference directives EC are on the engine plate (F).

s/n

MADE IN ITALY

rpm

XX XX XXXX

XXXX

XXXXXX

e9 • 97/68/CE • 00/000xx • xxxx •xx

Xx

0.00

xxx xxx xx

Model

Spec.

C

A

F

D

E

B

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 13 -

2

ENGINE TYPE



Only for 97/68 CE and EPA approved engines * Referred to max. NB power ** At NA power *** Depending on the application

Technical information

TECHINICAL SPECIFICATIONS

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

3 95 88

1870

17:1

3000

28/38 26/35,4 24/32,7

104/10,6

@2000 13/17,7

7,98/10,8

190/258.5

15

0,017

5

170

2400

38000

300

35° 25°

****

1 - 3 - 2

N. mm mm

Cm³

kW/CV kW/CV kW/CV

Nm/kgm

kW/CV kW/CV

g/CV.h - g/kW.h

l.

kg/h

l.

kg

l./min' l./min'

kg

α α α

Number of cylinders Bore Stroke Displacement Compression ratio R.P.M. N (80/1269/CEE) ISO 1585 Power kW/HP NB ISO 3046 IFN NA ISO 3046 ICXN Max. torque

Max. torque at 3rd p.t.o. at 3200 r.p.m. Max. torque at 4th p.t.o. at 3200 r.p.m. Specic fuel consumption * Tank capacity Oil consumption ** Oil sump capacity Dry weight Combustion air volume at 3000 r.p.m. Cooling air volume at 3000 r.p.m. Max. permissible driving shaft axial load in both directions momentary Max. inclination lasting up to 1 h. permanent Firing Order

KD

625-3

- 14 -

2

Technical information

PERFORMANCE DIAGRAMS

KD 625-3 @ 3000 r.p.m.KD 626-3 @ 3000 r.p.m.

KD 626-3 NR @ 3000 r.p.m. KD 626-3 B2 NR @ 2800 r.p.m.

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 15 -

2

Technical information

N (80/1269/EEC - ISO 1585) - AUTOMOTIVE RATING: Intermittent operation with variable speed and variable load. NB (ISO 3046 - 1 IFN) - RATING WITH NO OWERLOAD CAPABILITY: continuos ligth duty operation with constant speed and

variable load.

NA (ISO 3046 - 1 ICXN) - CONTINUOS RATING WITH OVERLOAD CAPABILITY: continuos heavy duty with constant speed

and constant load.

MN Torque at N power. MB (NB curve) MA (NA curve). C Specic fuel consumption at NB power.

The above power values refer to an engine tted with air cleaner and standard mufer, after testing and at the environmental conditions of 20°C and 1 bar. Max. power tolerance is 5%. Power decreases by approximately 1% every 100 m di altitude and by 2% every 5°C above 25°C.

Important

Non-approval by KOHLER for any modications releases the company from any damages incurred by the engine.

Note: Consult KOHLER for power, torque curves and specic consumptions at rates differing from those given above.

KD 625 - 3 / 626 - 3 EPA @ 2400 r.p.m. @ 2600 r.p.m.

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 16 -

2

A

B

C

D

E

F

601

612

400

DIMENSIONI mm - MESURES mm - DIMENSION mm - EINBAUMAßE mm - DIMENSIONE mm - DIMENÇÕES (mm)

G

H

I

212

47

421

L

M

N

82

4

525

O

P

Q

247

278

110

R

S

T

110

45

132

U

V

Z

173

305

65

X

Y

230

65

46

X1

Y1

94

60

237

400

OVERALL DIMENSIONS

Note : Dimensions shown in mm

Technical information

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 17 -

10 125 250 500 1000 2500 5000

(***)

(*) (*) (*)

(**)

(***)

3

MAINTENANCE - PRESCRIBED LUBRICANT - REFILLING

Engine oilreplacement.

Oil lter replacement.

OPERATION DESCRIPTION

FREQUENCY x HOURS

LEVEL ENGINE LUBRICANT

DRY AIR CLEANER

OIL BATH AIR CLEANER

BLOWER BELT TENSION

VALV E/R OC KER A RM S CLE ARA NC E

ADJUSTMENT

SETTING AND INJECTORS CLEANING

FUEL PIPES

RUBBER INTAKE HOSE (AIR FILTER – IN-

TAKE MANIFOLD)

ENGINE OIL RADIATOR CLEANING (IN THE

APPLICATIONS WHERE IT IS PRESENT)

FUEL TANK CLEANING

COOLING SYSTEM CLEANING

ENGINE LUBRICANT

OIL FILTER

FUEL FILTER

BLOWER BELT

FUEL PIPES

RUBBER INTAKE HOSE (AIR FILTER – IN-

TAKE MANIFOLD)

DRY AIR CLEANER EXTERNAL CAR-

TRIDGE

DRY AIR CLEANER INTERNAL CARTRID-

GE

PARTIAL OVERHAUL

TOTAL OVERHAUL

Important

Failure to carry out the operations described in the table may lead to technical damage to the machine and/or system

AFTER THE FIRST 50 WORKING

HOURS

CHECK

REPLACEMENT

OVERHAUL

INSPECTION

(*) - In case of low use: every year. (**) - In case of low use: every 2 years. (***) - The period of time that must elapse before cleaning or replacing the lter element depends on the environment in which the

engine operates. The air lter must be cleaned and replaced more frequently in very dusty conditions.

AFTER 6 CHECKS WITH CLEANING

AFTER 3 CHECKS WITH CLEANING

ROUTINE ENGINE MAINTENANCE

EXTRAORDINARY MAINTENANCE

ORDINARY MAINTENANCE

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 18 -

3

SAE 20W*

SAE 30*

SAE 40*

SAE 10W-30**

SAE 10W-40**

SAE 10W-60**

SAE 15W-40 **

SAE 20W-60 **

SAE 5W-30 ***

SAE 0W-30 ***

-30-2520

-

15

-105

0+5+10+15+20

+

25

+30+

35

+40+

45

SAE 10W*

+

50

-35-

40

SAE 5W-40 ***

Maintenance - Prescribed lubricant - Relling

International specications

They dene testing performances and procedures that the lubricants need to successfully respond to in several engine testing and laboratory analysis so as to be considered qualied and in conformity to the regulations set for each lubrication kind. A.P.I : ( American Petroleum Institute ) MIL : Engine oil U.S. military specications released for logistic reasons ACEA : European Automobile Manufacturers Association Tables shown are of useful reference when buying a kind of oil. Codes are usually printed-out on the oil container and the understanding of their meaning is useful for comparing different brands and choosing the kind with the right characteristics. Usually a specication showing a following letter or number is preferable to one with a preceding letter or number. An SF oil, for instance, is more performing than a SE oil but less performing than a SG one.

PETROL

A1 = Low-viscosity, for frictions reduction A2 = Standard A3 = High performances

LIGHT DUTY DIESEL ENGINES

B1 = Low-viscosity, for frictions reduction B2 = Standard B3 =High performances (indirect injection) B4 = High quality (direct injection)

HEAVY DUTY DIESEL ENGINES

E1 = OBSOLETE

E2 = Standard E3 = Heavy conditions (Euro 1 - Euro 2 engines ) E4 = Heavy conditions (Euro 1 - Euro 2 - Euro 3 engines ) E5 = High performances in heavy conditions (Euro 1 - Euro 2 -

Euro 3 engines )

ACEA Regualtions - ACEA Sequences

LUBRICANT

SAE Classication

In the SAE classication, oils differ on the basis of their viscosity, and no other qualitative characteristic is taken into account. The rst number refers to the viscosity when the engine is cold (symbol W = winter), while the second considers viscosity with the engine at régime. The criteria for choosing must consider, during winter, the lowest outside temperature to which the engine will be subject and the highest functioning temperature during summer. Single-degree oils are normally used when the running temperature varies scarcely. Multi-degree oil is less sensitive to temperature changes.

* Mineral base ** Semi-synthetic base *** Synthetic base

SAE- Grade

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 19 -

CF CE CD CC CB CA SA SB SC SD SE SF SG

L - 2104 D / E

L - 46152 B / C / D / E

SH

API

SJ

SLCH-4 CG-4 CF-4 CF-2

MIL

5,5

5

DIESEL

AGIP SUPERDIE-

SEL

MULTIGRADE

15W40

API CF 4

ACEA B2 - E2

MIL - L-2104 D/E

3

Maintenance - Prescribed lubricant - Relling

Litres

API / MIL Sequences

OBSOLETE

PETROL

CURRENT

specications

PRESCRIBED LUBRICANT

In the countries where AGIP products are not available, use oil API SJ/CF for Diesel engines or oil corresponding to the military specication MIL-L-2104 D/E.

For a temperature of -10°C an oil with a 5W40 viscosity is recommended. For a temperature of -15°C an oil with a 0W30 viscosity is recommended.

OIL VOLUME AT MAX LEVEL (OIL FILTER INCLUDED)

OIL VOLUME AT MAX LEVEL (WITHOUT OIL FILTER)

Danger – Attention

- The engine may be damaged if operated with insufcient lube oil.

- It is also dangerous to supply too much lube oil to the engine because a sudden increase in engine rpm could be caused by its combustion.

- Use proper lube oil preserve your engine.

Good quality or poor quality of the lubricating oil has an affect on engine performance and life.

- If inferior oil is used, or if your engine oil is not changed regularly, the risk of piston seizure, piston ring sticking, and accelerated wear of the cylinder liner, bearing and other moving components increases signicantly.

- Always use oil with the right viscosity for the ambient temperature in which your engine is being operated.

Danger – Attention

- The used engine oil can cause skin-cancer if kept frequently in contact for prolonged periods.

- If contact with oil cannot be avoided, wash carefully your hands with water and soap as soon as possible.

- Do not disperse the oil in the ambient, as it has a high pollution power.

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 20 -

15

3

API CF4 - CG4

API CF - CD - CE

Fuels for low temperatures

It is possible to run the engine at temperatures below 0°C using special winter fuels. These fuels reduce the formation of parafn in diesel at low temperatures. If parafn forms in the diesel, the fuel lter becomes blocked interrupting the ow of fuel.

Fuel can be: - Summer up to 0°C

- Winter up to -10°C

- Alpine up to -20°C

- Arctic up to -30°C

For all fuel types, the cetane number cannot be lower than 51.

Aviation kerosene and RME fuels (biofuels)

The only Aviation fuels that may be used in this engine are: JP5, JP4, JP8 and JET-A if 5% oil is added. For more information on Aviation fuels and Biofuels (RME, RSME) please contact the KOHLER applications department.

Capacities standard fuel tank

Litres

Maintenance - Prescribed lubricant - Relling

Fuel with low sulphur content

Fuel with high sulphur content

PRESCRIBED LUBRICANT

FUEL SPECIFICATIONS

Danger – Attention

- To avoid explosions or re outbreaks, do not smoke or use naked ames during the operations.

- Fuel vapours are highly toxic. Only carry out the operations outdoors or in a well ventilated place.

- Keep your face well away from the plug to prevent harmful vapours from being inhaled.

- Dispose of fuel in the correct way and do not litter as it is highly polluting.

To achieve optimum performance of the engine, use good quality fuel with certain characteristics:

Cetane number (minimum 51): indicates the ignition quality. A fuel with a low cetane number may cause problems when starting from cold and have a negative

effect on combustion.

Viscosity

(2.0/4.5 centistokes at 40°C): this is the resistance to ow and performance may decline if not within the limits.

Density (0.835/0.855 Kg/litre): a low density reduces the power of the engine, and density that is too high increases performance

and opacity of the exhaust

Distillation (85% at 350°): this is an indication of the mixture of different hydrocarbons in the fuel.

A high ratio of light hydrocarbons may have a negative effect on combustion. Sulphur (maximum 0.05% of the weight): high sulphur content may cause engine wear. In those countries where diesel has a high sulphur content, it is advisable to lubricate the

engine with a high alkaline oil or alternatively to replace the lubricating oil recommended by the manufacturer more frequently.

The countries in which diesel normally has a low sulphur content are: Europe, North America and Australia.

As for lters, tanks and special crankcases please refer to KOHLER instructions.

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 21 -

3

........................................................................................................................................................

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 22 -

4

RECOMMENDATIONS FOR OVERHAULS AND TUNING

Important

To locate specic topics, the reader should refer to the index.

– Before any intervention, the operator should lay out all equipment and tools in such a way as to enable him to carry out ope-

rations correctly and safely.

– The operator must comply with the specic measures described in order to avoid errors that might cause damage to the engine.

– Before carrying out any operation, clean the assemblies and/or components thoroughly and eliminate any deposits or residual

material.

– Wash the components with special detergent and do not use steam or hot water.

– Do not use ammable products (petrol, diesel, etc.) to degrease or wash components. Use special products.

– Dry all washed surfaces and components thoroughly with a jet of air or special cloths before reassembling them.

– Apply a layer of lubricant over all surfaces to protect them against oxidation.

– Check all components for intactness, wear and tear, seizure, cracks and/or faults to be sure that the engine is in good working

condition.

– Some mechanical parts must be replaced en bloc, together with their coupled parts (e.g. valve guide/valve etc.) as specied

in the spare parts catalogue.

Danger - Attention

During repair operations, when using compressed air, wear eye protection.

RECOMMENDATIONS FOR DISASSEMBLING AND ASSEMBLING

DISASSEMBLY/REASSEMBLY

Important

To locate specic topics, the reader should refer to the index.

– Besides disassembly and reassembly operations this chapter also includes checking and setting specications, dimensions,

repair and operating instructions.

– Always use original KOHLER spare parts for proper repair operations.

– The operator must wash, clean and dry components and assemblies before installing them.

– The operator must make sure that the contact surfaces are intact, lubricate the coupling parts and protect those that are prone

to oxidation.

– Before any intervention, the operator should lay out all equipment and tools in such a way as to enable him to carry out ope-

rations correctly and safely.

–

For safety and convenience, you are advised to place the engine on a special rotating stand for engine overhauls.

– Before proceeding with operations, make sure that appropriate safety conditions are in place, in order to safeguard the operator

and any persons involved.

– In order to x assemblies and/or components securely, the operator must tighten the fastening parts in a criss-cross or alter-

nating pattern.

– Assemblies and/or components with a specic tightening torque must initially be fastened at a level lower than the assigned

value, and then subsequently tightened to the nal torque.

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 23 -

4

1

2

3

Disassembly / Reassembly

Oil-bath air cleaner

 Danger – Attention

Do not blow the paper lter element with compressed air to clean.

 Caution – Warning

Check gaskets and replace as necessary. Check that ange welds are free of defective spots.

 When reassembling, tighten the fastening nuts of the air lter to the

intake manifold to 25 Nm.

Exhaust manifold

 Danger – Attention

Allow the exhaust manifold to cool before demounting it in order to prevent scorching and burns.

Make sure that the inside is properly clean and is free from cracks or breakage. Always replace the seals between the manifold and the exhaust pipes.

 When assembling, tighten the nuts in sequence and gradually be-

fore the nal torque to 20 Nm.

Oil-bath air cleaner components

Caution – Warning

Replace if irreparably clogged.

1 Bowl 7 Cover clamp

2 External seal ring 8 Cap 3 Lower ltering element 9 Centrifugal pre-lter 4 Internal seal ring 10 Centrifugal pre-lter clamp 5 Gasket 11 Oil level mark 6 Cover 12 Upper ltering element (polyurethan sponge)

Note: Thoroughly clean the lower tank and the metal lter element

using diesel fuel then blow compressed air into them.

The upper lter element in polyurethane foam is cleaned by

washing it in soapy water; after washing, dry completely using compressed air.

After cleaning rell the engine oil tank up to the indicated level.

See page 17 for the maintenance or replacement instructions.

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 24 -

4

5

6

7

A

Intake manifold

Before reassembling the manifold check the levelness of the anges. Always replace the seals between the manifold and the intake pipes.

 Tighten the nuts gradually to 25 Nm.

Note: In case of low temperature starting we can supply a manifold

with provision for a glow plug for air preheating.

Disassembly / Reassembly

Half-pulley - Reassembly

 Important

The three stop nuts of the half-pulley should never be tightened simultaneously.

Turn the pulley so that, whenever you tighten a nut, this is in the position indicated A in the gure 7. Tightening should be carried out gradually.

Belt tension adjustment

 Danger – Attention

Check the belt tension only when the engine is not running

The belt tension is adjusted by adding (to reduce tension) or removing (to increase tension) spacers between the half-pulleys. Spacers are available in thicknesses of 0.5, 1 and 2 mm.

Blower belt alternator

Components:

1 Guard 2 Pulley 3 Spacers 4 'V'-belt

Unscrew the fastening screws of the belt guard and remove it, then take out the nuts on the three stud bolts on the half-pulley. Remove the V belt and check for wear.

See page 17 for periodic maintenance details.

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 25 -

4

8

9

10

11

Disassembly / Reassembly

Blower belt alternator - Reassembly

 The half-pulley fastening nuts must be tightened using the torque

wrench to a nal torque of 10 Nm.

Again during this phase the nut must be in position A when tightened as in g. 7 – page 22.

Blower assembly

 Danger – Attention

Before demounting the cooling fan, disconnect the positive battery cable to prevent accidental short-circuits which could consequently energize the starter motor.

The plate and tension regulator are xed to the outside of the blower fan stator. A 14 A or 21 A alternator is housed inside the stator.

See page 60 - 61 for the alternator technical data. See page 13 for the cooling air volume.

Air shroud and bafes - Disassembly

The air shroud 1 and the bafes 2, 3, 4, 5 are shaped in such a way as to direct the ow of air onto the cylinders in order to cool them. As the shroud is completely covered in noise-absorbent material, it also has the function of reducing the amount of noise generated by the blower fan and vibrations.

Tension check

A 4 Kg load located halfway between the pulleys should cause the belt to bend 5 ÷ 15 mm. The correct belt tension can also be checked with special tools that are available on sale.

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 26 -

4

12

14

13

Blower assembly components with 14 A alternator

1 Housing 2 14 A alternator 3 Key 4 Ball bearing 5 Washer 6 Nut 7 Shaft 8 Bolt 9 Fan

10 14 A alternator bell 11 Spacer

Disassembly / Reassembly

Blower control pulley - Disassembly

The blower control pulley is installed on and is driven by the crankshaft. To disassemble the pulley unscrew the left-handed bolt (clockwise) after blocking the crankshaft.

 When reassembling, tighten the bolt using a torque wrench to a

torque of 300 Nm.

Blower assembly components with 21 A alternator

1 Housing 2 21 A alternator 3 Key 4 Washer 5 Nut 6 Shaft 7 Bearing 8 Bolt 9 Fan

10 21 A alternator bell 11 Spacer

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 27 -

A = 142 mm A1 = 147 mm A2 = 163 mm

4

15

16

17

18

Crankshaft pulley

Remove the pulley using extractor serial no. 1460.200.

Disassembly / Reassembly

Timing cover

Loosen the screws and remove the cover.

 When retting tighten screws at 25 Nm.

Check oil seal ring 1 and replace if warped, hardened or worn-out. Replace gasket 2.

Blower control pulley diameter

There are three pulleys with different diameters A which take account of engine settings:

( from 2401 to 3000 r.p.m. ) ( from 2001 to 2400 r.p.m. ) ( from 1500 to 1800 r.p.m. )

Check S surface in contact with oil seal ring and, if necessary, rub with a ne grain emery cloth.

Components:

1 Left-handed bolt 2 Washer 3 Blower control pulley

Note:

It is only possible to check crankshaft axial clearance after

tightening the pulley.

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 28 -

4

19

20

21 22

Tank

 Danger – Attention

Do not smoke or use naked ames during the demounting operations as these could cause explosions or re outbreaks. Fuel fumes are highly toxic. Only carry out the operations outdoors or in a well ventilated place. Keep your face well away from the ller cap or you could inhale harmful fumes. Dispose of fuel in the correct way as it is highly polluting. Do not litter.

Remove fuel lter and loosen clamp screws. Completely empty the tank and check that no impurities are found inside. Check that cap breather is not clogged.

Disassembly / Reassembly

Flywheel

 Danger – Attention

During the demounting phases, pay particular attention to prevent the ywheel from dropping as this could seriously injure the operator. Wear protective goggles when removing the ywheel ring.

Remove the bolts which attach the ywheel to the crankshaft. To replace starter ring gear heat it up to 300°C for 15 ÷ 20 minutes. Drive it onto the ywheei caretully checking that it perfectly ts into its seat. Let it cool down slowly.

 When reassembling gradually tighten the fastening screws to 140

Nm on the crankshaft using a torque wrench.

Valve / rocker arm clearance

 Caution – Warning

Make settings when the engine is cold.

Remove the rocker arm covers and make sure the seals are intact, otherwise replace them. Bring the cylinder piston that is to be adjusted to the compression top dead centre. Loosen the fastening nut C, insert the thickness gauge D between the rocker arm and the top of the valve stem, then, using a cross-head screwdriver turn the adjusting screw B to set clearance. Tighten the fastening screw C and check valve clearance A again to ensure that it is between 0,15 and 0,2 mm for intake and 0,3 ÷ 0,35 mm for exhaust.

 When retting tighten cover screws to 20 Nm.

If necessary place a 0,30 or 0,40 mm shim at B.

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 29 -

4

24

25

27

28

26

A 18.032 ÷ 18.050 B 17.989 ÷ 18.000

Rocker arm assembly

Components: 1 Rocker arm axle lubrication hole 2 Lubrication tube

Replace the axle and the rocker arm if clearance (A-B) is greater than 0,135 mm. When retting check that lubrication tube 2 perfectly ts into centering bore 1.

 Tighten screws at 25 Nm.

Disassembly / Reassembly

To release the injector union from the high-pressure pipe, use two box wrenches (14 and 17 mm).

Disassembling size P injector

The injector is attached to the cylinder head via a forked bracket.

Compression release (optional)

Bring piston to top dead center on the compressìon stroke. Unscrew rocker arm cover side plug and measure clearance A should be 0,30 ÷ 0,40 mm.

Ref.

Dimensions

(mm)

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 30 -

4

29

30

31

32

Remove the forked bracket xing the injector to the cylinder head using a 5 mm hexagon screwdriver (see photo 29 - 30).

Disassembly / Reassembly

 The xing bracket screws must be tightened to 10 Nm using a tor-

que wrench.

These operations are necessary when checking injector calibration or when replacing it.

Unscrew the screw fastening the clamp of the high-pressure pipe using a 4 mm hexagon screwdriver.

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 31 -

4

33

34

35

36 37

 The high-pressure pipe union must be tightened to the injector

union to 20 ÷ 25 Nm using a torque wrench.

Disassembly / Reassembly

Valves

Components:

1 Intake valve 1a Exhaust valve 2 Lower spring collar 3 Valve stem sealing ring 4 Spring 5 Upper spring collar 6 Three-groove half collets

Te remove half collets rmly press down the special tool 1460 - 113 as shown in the gure 36.

Cylinder Head

 Caution – Warning

Do not demount or remount while hot as this could lead to deformations.

If the head surface is distorted, grind it by removing up to 0.3 mm thickness. When reassembling, before tightening, make sure that the rocker arm lubrication hose is rmly lodged into holes. The cylinder heads must be tightened with the exhaust or intake manifold mounted to keep them lined up. Always replace the copper seal between the cylinder head and the cylinder that determines clearance volume; see page 34 for the choice of thickness. See page 32 for how to mount the spring on the tappet rod protection pipe.

 The cylinder head fastening nuts must be tightened gradually to 55

Nm and in the sequence 1, 2, 3, 4; see g. 35.

Injector protrusion

It is only possible to check injector protrusion with the cylinder head disassembled. The end of the nozzle must be 3 ÷ 3,5 mm with respect to the head surface A. Protrusion is adjusted by adding or removing copper seals B which are supplied at a thickness of 0,5 and 1 mm.

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 32 -

4

38

40

41

43

39

42

A 42.00 B 48.00 C 14.00 ÷ 14.018 D 14.045 ÷ 14.056

Valve stem sealing rings - Reassembly

Lubricate the inside of the sealing ring with Molikote BR2 Plus and insert them all the way onto the guides using tool 1460 – 108. To prevent deformation of the sealing ring 1 as it is inserted onto the valve guide 2 insert it onto tool 3. Lubricate valve stem with the same type of grease; insert the valves into the guides rotating them particularly as they enter the sealing ring.

Disassembly / Reassembly

Valve guides and cylinder head housings

Intake and exhaust valve guides are both made of phosphoric cast iron.

Components: 1 = Exhaust valve guide 2 = Intake valve guide

Valve guides with outside diameter increased by 0,5 mm are also available; in such cases valve guide bore C should also be increased by 0,5 mm.

Valve material

Intake valves A

- Material: X 45 Cr Si 9 - 3 UNI EN 10090 1 = Chromium-plated portion α = 45°15' ÷ 45°25'

Exhaust valve B

Shaft and head are made of 2 different materials.

2 = Welded portion 3 = Chromium-plated portion 4 = Portion made of X 45 Cr Si 9 - 3 UNI EN 10090 5 = Portion made of X 53 Cr Mn Ni N 21 - 9 UNI EN 10090

α = 45°15' ÷ 45°25'

Valve springs

Measure free length with a gauge. Using a spring tester check that the spring length under two different loads corresponds to the values below:

Free length A = 52 mm Length B compressed by a 21 Kg weight = 34.8 mm Length C compressed by a 32 Kg weight = 25.8 mm.

Ref. Dimensions (mm)

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 33 -

4

44

45

46

47

A 30.80 ÷ 31.20 B 24.80 ÷ 25.20

A 8.025 ÷ 8.040

0.025 ÷ 0.055 1.15

B 7.985 ÷ 8.000

D 0.75 ÷ 1.25 1.65

A 40.000 ÷ 40.016 B 40.120 ÷ 40.140 A 34.000 ÷ 34.016 B 34.120 ÷ 34.140

Valve guide insertion

Heat cylinder head up to 160 ÷ 180°C. Thread guides considering the A e B distances from the head plane.

Note: If the guides are supplied with the housing for the lock ring C,

insert the ring, then drive the guides until the lock ring is stopped without worrying about A and B.

INTAKE

VALVE

EXHAUST

VALVE

Disassembly / Reassembly

Valve seat lapping

After cutting, lap valve seats with ne emery paste in oil suspension. The sealing surface S should not exceed 2 mm.

Valve recess after grinding

Valve seats and housings

Dimensions and clearance between guides and valves

Ref. Dimensions (mm)

Ref. Dimensions (mm) Clearance (mm) Limit value (mm)

Ref. Dimensions (mm) Limit value (mm)

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 34 -

4

49

51

53

54

50

52

55

Pushrod tube spring tting

Components:

1 Spring 2 Tool Part No 1460-009 3 Rocker arm lubrication tube 4 Gasket 5 Pushrod tube 6 Gasket

To mount the spring 1 on the tappet rod protection pipe 5 insert it into the tool 2 with the help of a vice. Make sure that the rocker arm lubrication hose 3 and the seals 4 and

6 are fully in place.

Disassembly / Reassembly

Piston

Remove the Sieger stop rings and extract the pin. After removing the snap rings from the piston, clean the grooves if necessary. Measure the diameter at 2 mm from the base using an external micrometer.

Replace the piston and the snap rings if the diameter of the wear is greater than 0,05 mm of the minimum value prescribed.

Note: Oversize pistons of 0,5 and 1,0 mm are available.

Checks and cyiinder roughness

The cylinder should show no blowholes or porosities. Seal both ends of cylinder and pressurize with compressed air at 4 bar for 30 sec. Fins must be intact. Cross hatch pattern must range between 115° ÷ 140°: they must be uniform and clear in both directions. Average roughness should range between 0,5 and 1 µm.

Cylinder

Measure diameter sìze between two diametrically opposed points at three different heights.

In case wear exceeds 0,10 mm, bore the cyIinder and t oversize piston and rings. In case of less wear replace piston rings only.

Ref. Ø Cylinder (mm)

Ref. Ø Piston (mm)

625/3 - 626/33 34.00 ÷ 34.016

625/3 - 626/33 94.90 ÷ 94.92

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 35 -

4

56

57

58

60

59

A 0,07 ÷ 0,11 0,20 B 0,05 ÷ 0,09 0,16 C 0,04 ÷ 0,08 0,15

Piston weight

Weigh pistons when replacing them in order to avoid unbalance. The difference in weight should not exceed 6 g.

Disassembly / Reassembly

Metal snap rings - Fitting sequence

A = Compression snap ring (chrome-plated) B = Snap ring (conical internal torsional) C = Ring (oil scraper)

Note: before inserting the piston in the cylinder, rotate snap rings so

that cuts are misaligned by 120° from one to the next.

 Important

Assemble the segments with TOP facing the piston crown.

Metal snap rings - Piston grooves

Metal snap rings - End gaps

Insert the snap rings in the lower part of the cylinder, then measure the distance between the tips.

Ref. Dimensions (mm) Limit value (mm)

KD 625/3-626/3 Limit value

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

1°

Compression snap ring

(chrome-plated)

A

0.40 ÷ 0.65 1 mm

2°

Snap ring

(conical internal

torsional)

A

3°

Ring (oil scraper)

A 0.25 ÷ 0.50

- 36 -

4

61

63

65

62

64

66

Piston - Retting

 Caution – Warning

Lubricate the following parts with oil before mounting: the piston pin, the piston, the cylinder and the big-end bearing

Connect piston to connecting rod in a way that the combustion chamber center b is under nozzle tip a. Lubricate piston pin and introduce it into the piston by exerting pressure with your thumb. Check that both circlips are well inside their seats.

Seal thickness

Position

Disassembly / Reassembly

Connecting rod

 Caution – Warning

When remounting the big-end bearings, remember to thoroughly clean the parts and generously lubricate them to prevent seizure when the engine is started up for the rst time

Remove the oil sump and internal oil lter. Remove connecting rocis and check as follows.

 Important

All connecting rod/piston units should be tted back into the corresponding cylinders; mark them to avoid mistakes.

 See page 35 g. 71 for specications as to the tightening of the

connecting rod big end bearing.

Piston clearance

A = Clearance volume is 0,65 ÷ 0,7 mm for size S injectors and 0,55 ÷ 0,6 mm for size P injectors B = Copper seal with various thicknesses

The piston crown in the TDC (top dead centre) position may vary, and extend or be short of the upper surface of the cylinder. Use a dial indicator to measure the positive or negative difference between the two surfaces (piston crown and upper cylinder surface) and use a suitable thickness copper gasket B for the cylinder head to adjust the clearance volume A between the cylinder head and the piston crown, and which must be between 0,65 and 0,7 mm for size S injectors and 0,55 ÷ 0,6 mm for size P injectors.

The table below shows how to choose the most suitable cylinder head copper seal according to the position of the piston in relation to the upper surface of the cylinder.

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 37 -

4

67

68

......6970 ......71

A 141.95 ÷ 142.05 B 25.020 ÷ 25.030

0.020 ÷ 0.035 0.070

C 24.995 ÷ 25.000

Connecting rod small end bearing and pin

* with driven and machined bearing. When retting the bearing of the connecting rod small end, as you drive in, make sure that the lubrication hole on the connecting rod coincides with the hole on the bearing.

Disassembly / Reassembly

Connecting rod big end bearing

Both centering notches A and B must be on the same side when retting.

 Tighten bolts at 40 Nm.

See page 39 for dimensions.

Connecting rod weight

Weight connecting rods when replacing them in order to avoid unbalance. The difference in weight should not exceed 10 g.

Connecting rod alignment

Check alignment of small end and big end bearing bores using tted mandrels; axial mis-alignment A = 0,02 mm; maximum limit 0,05 mm. Moderale warpage may be corrected by gradually working with a press.

Ref. Dimensions (mm)

Clearance

(C-D) (mm)

Limit value (C-D) (mm)

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 38 -

4

72

73

74

75

Camshaft gear

Remove nut 1 and washer 2. Then remove camshaft gear 3. The cylindrical type of coupling makes gear removal easier since no puller is required.

 Tighten nut 1 at 25 Nm.

See Page 42 for timing.

Disassembly / Reassembly

Main bearing support, gear side

Remove crankshaft key and thrust bearing. Loosen the three xing bolts and remove the main bearing support on gear side using two M 8x1,25 screws with fully threaded length of 60 mm.

Note: To avoid distortion it is not recommended to repiace the bea-

ring bushing.

Complete assemblies of bushing and support are available in

standard, 0,25 and 0,50 mm undersíze congurations as spare parts.

 When retting tighten screws at 25 Nm.

Timing gear

The timing gear can be easily pulled out thanks to the cylindrical type of coupling. However, if resistance is felt use a bearing puller.

Oil pump gear

Remove nut 1 and washer 2. Then remove oil pump gear using a puller with two M 8x1,25 bolts (length: 60 mm).

 Tighten the nut at 35 Nm.

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 39 -

4

76

77

78

79

Main bearing support, ywheel side

Loosen nuts and extract main bearing support using two M 8x1.25 screws with fully threaded length of 40 mm. Check oil seal ring and replace if warped, hardened or worn-out.

 When retting tighten nuts at 25 Nm.

See Page 40 for dimensions.

Disassembly / Reassembly

Crankshaft center main bearing supports

Main bearing supports 2 and 3 have a different diameter size (see page 40 for dimensions). When retting, both centering notches A and B must be located on the same side.

 Tighten screws at 30 Nm.

Crankshaft removal

To pull out the crankshaft tap lightly on the gear side end using a copperheaded hammer. When retting align center main bearing supports so that the locating bolt holes coincide with the crankcase holes.

Crankshaft

Center main bearing support, locating bolts

Before removing the crankshaft, straighten the safety stop 1 and unscrew the bolts 2 of the central main bearings.

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 40 -

4

80

81

82

83

A 80.781 ÷ 80.800 B 45.500 ÷ 45.516 C 55.350 ÷ 55.370 D 54.931 ÷ 54.950

Crankshaft lubrication ducts

Important

During repair operations, when using compressed air, wear eye protection.

Remove the caps, clean ducts A, B and C using a drill bit with the same diameter and blow with compressed air. After cleaning, replace the new caps in their seats and make sure they are sealed.

Disassembly / Reassembly

Main journal and crank pin diameter

Checking main journals and crank pins

Use an outside micrometer gauge.

Crankshaft journal radius

The radius R connecting journal to shoulders is 2,8 ÷ 3,2 mm.

Note:

When grinding main journals or crank pins restore the R value

to original specication.

Ref. Dimensions (mm)

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 41 -

4

84

85

86

87

E 80,870 ÷ 80,890 F 45,548 ÷ 45,578 G 55,430 ÷ 55,460 H 55,000 ÷ 55,020

E-A 0,070÷0,109 0,195 F-B 0,032÷0,078 0,150 G-C 0,060÷0,110 0,195 H-D 0,050÷0,089 0,180

I 85,785 ÷ 85,815

L 152,000 ÷ 152,020 M 60,000 ÷ 60,020 N 150,000 ÷ 150,020 * O 148,000 ÷ 148,020 * P 77,990 ÷ 78,010

Diameter of main bearings

Use an inside micrometer to measure the inside.

Disassembly / Reassembly

* with tightened bearing

Main bearing supports

1 Flywheei side 3 2nd central 2 1st central 4 Gear side

Clearance between main journals/crank pins and connecting rod bearings

Main bearing and connecting rod big end bearing inside diameter

The above dimensions refer to driven in or tightened bearings. Note: Both main bearings and connecting rod big end bearings are

available with inside diameter size measuring 0,25 and 0,50 less than the standard version.

Ref. Dimensions (mm)

Ref. Dimensions (mm) Limit value (mm)

Ref. Dimensions (mm)

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 42 -

4

88

89

91

92

90

93

A 150.000 ÷ 150.020 B 152.000 ÷ 152.020 C 148.000 ÷ 148.020 D 78.000 ÷ 78.020

A 48.200 ÷ 48.250 B 47.950 ÷ 48.000

A 44.000 ÷ 44.025

0.040 ÷ 0.085 0.170

B 43.940 ÷ 43.960

Crankshaft end play

Check crankshaft end play after retting the crankshaft pulley and tightening its nut at 300 Nm; the crankshaft end play is equal to 0,20 ÷ 0,30 mm and is not adjustable. lf this value cannot be obtained check

A and B, and possibly replace the parts whose size is inadequate.

Main bearing housings

Disassembly / Reassembly

How to measure camshaft bearing and journal inside diameter

Measure A using an internal dial indicator and B with an external micrometer. When repiacing the bearing make the lubrication hole 1 match with the corresponding crankcase bore.

Camshaft

Camshaft removal

To pull out the camshaft simply remove bell 1, gear 2, fuel feeding pump 3, injection pumps 4 and tilt the engine; in this position the cam followers is not in contact with the camshaft thus making its removal possible.

Ref. Dimensions (mm)

Ref. Dimensions (mm) Clearance (mm)

Limit value

(mm)

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 43 -

4

94

95

96

97

A 42.000 ÷ 42.025 B 41.000 ÷ 41.025 C 33.200 ÷ 33.220 D 41.940 ÷ 41.960 E 40.940 ÷ 40.960 F 33.140 ÷ 33.160

A-D

0.040 ÷ 0.085 0.170

B-E

C-F 0.040 ÷ 0.085 0.160

Dimensions of camshaft journals and housings

Disassembly / Reassembly

Camshaft end play

Check camshaft end play after removing cylinder head, injection pump and fuel feed pump from the engine.

 Check that the three cover 1 screws are tightened at 25 Nm.

Place the dial gauge on the camshaft gear outer part; push and pull same gear as required. Camshaft end play should be 0,15 ÷ 0,30 mm.

Intake/exhaust cam height

A1= 1st cylinder intake cam S1 = 1st cylinder exhaust cam A2 = 2nd cylinder intake cam S2 = 2nd cylinder exhaust cam A3 = 3rd cylinder intake cam S3 = 3rd cylinder exhaust cam H = 33,65 ÷ 33,55 for engines EPA 97/68 CE

Exhaust and intake cams feature the same height H. Replace camshaft if H is 0.1 mm below the given value.

Checking intake/exhaust cam height

Use an outside micrometer gauge to measure camshaft lobe height.

Ref. Dimensions (mm)

Ref.

Cleatance

(mm)

Limit value

(mm)

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 44 -

4

98

99

100

Camshaft timing

Fit camshaft gear by making timing mark 2 coincide with timing marks

1.

 Tighten camshaft bolt at 250 Nm.

Disassembly / Reassembly

Valve timing check

Check using an index plate suitable for reading angles, integral with the crankshaft. Readings are taken in degrees. Set valve clearance at 0,65 ÷ 0,70 mm (after checking restore the value al 0,15 ÷ 0,20 mm). Set dial gauge on intake valve to a zero value; by rotating the driving shaft according to its direction of rotation you can measure α (intake valve opening advance referred to top dead centre PMS) and ß (intake valve closing delay referred to bottom 1 dead centre).

Follow the same procedure for exhaust valves checking γ (exhaust valve opening advance) and δ (exhaust valve closing delay).

Valve timing without considering timing marks

Locate piston 1 (on ywheeI side) at the top dead center. Position two small cylinders A of the same height onto the tappets. Rotate camshaft stopping when cylinder 1 tappets are in overlap position (intake open, exhaust closed). By means of ruler B check that tappets are at the same height.

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 45 -

4

101

Value expressed in degrees of the timing angles. (valves clearance = 0.65 ÷ 0.70 mm)

α = open 2° before P.M.S. β = close 34° after P.M.I. γ = open 34° before P.M.I. δ = close 2° after P.M.S.

Disassembly / Reassembly

Legend

S =

piston at top dead center

I = piston at bottom dead center

α = intake valve open β = intake valve closed γ = exhaust valve open δ = exhaust valve closed

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 46 -

4

102

103

104

105

Hydraulic pump p.t.o. group 1

A hydraulic pump of group 1 or 2 can be installed on the gear side A, 3rd p.t.o. A group 1 hydraulic pump can be installed at the 4th p.t.o. B.

Disassembly / Reassembly

Use of 3rd and 4th p.t.o.

1 Hydraulic pump, group 2, mounted at 3rd p.t.o. 2 Hydraulic pump, group 1, mounted at 4th p.t.o.

Total power obtainable from 3rd and 4th plo. is 13 kW ( 17.7 HP). Ratio for both p.t.o. compared to the engine r.p.m. is 1:1 for 4th PTO is 1 : 1,067 for 3th PTO.

Hydraulic pump 4th p.t.o., group 1

Components:

1

Drive 7 Seal ring 2 Control shaft 8 Seal ring 3 Pin 9 Centering ring 4 Gear 10 Bracket 5 Washer 11 Gasket 6 Nut 12 Cover

A max. torque of 243 Nm can be obtained from this p.t.o.

Hydraulic pump 3rd p.t.o., group 2

Components:

1 Gear 2 Gear support 3 Bearing 4 Drive 5 Flange 6 Washer 7 Seal ring 8 Circlip

A max torque of 39,6 Nm can be obtained from this p.t.o.

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 47 -

4

106

108

109

106

Mechanical speed governor

The governor (with centrifugal weights) is housed inside the crankcase and is controlled by a camshaft gear. To remove speed governor 1 remove camshaft bell 2 and speed governor control gear 3.

Disassembly / Reassembly

Mechanical speed governor operation (standard)

Weights 1 are moved to the periphery by the centrifugal force and thus axially shift the washer 2 and the drive rod 3 which, by means of a linkage, move injection pump control lever 4. The governor springs 5 placed under tension by the accelerator control lever 6 offset the weights 1 centrifugal force. Balance between the two forces keeps speed at an almost constant level in spite of load variations.

Mechanical speed governor components (standard)

1

Drive rod 9 Key 2 Stop ring 10 Thrust washer 3 Bearing 11 Bearings 4 Washer 12 Shaft support 5 Pin 13 Gear 6 Weights 14 Spring washer 7 Weight support 15 Flat washer 8 Shaft 16 Nut

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 48 -

4

110

111

112

Mechanical speed governor components for special generating sets

1 Spring anchoring rocker arm 2 Governor springs 3 Journal 4 Governor control lever 5 Governor control lever ball bearing 6 Lever 7 Bearing 8 Plate

Note: Two types of governor springs 2 are available: one for full spe-

ed regulation at 1500 r.p.m. and the other for full speed regulation at 1800 r.p.m.; in this case governor weights are heavier.

Disassembly / Reassembly

Spring for extra fuel supply at starting

The device is operated automatically: when the engine is stopped spring 1 acts on injection pump control yoke 2 providing maximum fuel delivery, until the speed governor starts operating.

Mechanical speed governor setting

Lift nkage A. Loosen screw B. Push lever C to the right and check that speed governor weights are closed. Shift injection pump delivery control yoke D to the right (for maximum delivery). Tighten screw B.

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 49 -

5

113

Components:

1) Rocker arm shaft 6) Oil pump 11) Oil pressure relief valves

2) Connecting rod big end bearìng 7) Drain plug 12) Pump intake pipe

3) Oil dipstick 8) Crankshaft main journal 13) Internal strainer

4) Camshaft 9) Crankshaft 14) Drain plug

5) Crankshaft journal 10) Cartridge lter

 Danger – Attention The engine can be damaged if allowed to operate with insufcient oil. It is also dangerous to add too much oil because its combustion may lead to a sharp increase in the rotation speed. Use suitable oil in order to protect the engine. Nothing more than lubrication oil can inuence the performances and life of an engine. Use of an inferior quality oil or failure to regularly change the oil will increase the risk of piston seizure, will cause the piston rings to jam and will lead to rapid wear on the cylinder liner, the bearings and all other moving parts. Engine life will also be notably reduced. The oil viscosity must suit the ambient temperature in which the engine operates.

 Danger – Attention Old engine oil can cause skin cancer if repeatedly left in contact with the skin and for long periods of time. If contact with the oil is unavoidable, you are advised to wash your hands with soap and water as soon as possible. Dispose of old oil in the correct way as it is highly polluting.

LUBRICATION SYSTEM

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 50 -

5

114

116

118

119

115

117

Oil pump

Check that gear teeth are intact and that clearance between gear edge and pump body is 0,041 ÷ 0,053 mm with limit value 0,10 mm. Furthermore check that control shaft is tree to rotate with end oat of 0,040 ÷ 0,090 mm with limit value of 0,170 mm. Oil pump delivery at 3000 r.p.m. is 18 liters/min.

Lubrication system

Oil pressure check

Once the engine is tted ll with oil and fuel, connect a 10 bar pressure gauge to the oil lter tting. Start the engine and check pressure as a function of the oil temperature (see page. 49).

Oil lter cartridge

Components: 1 Retainer 6 Upper cover 2 Plate 7 Blade 3 Valve 8 Filtering element 4 Gasket 9 Assembly 5 Gasket 10 Belleville washer 11 Tank Characteristics:

Max. working pressure ....................................13 bar

Filtering area....................................................955 cm2

Type of ltration ...............................................20 µm

By-pass valve opening pressure .....................1,4 ÷ 1,8 bar.

Oil pressure relief valve

Components:

1 Plug 5 Rubber gasket 2 Copper gasket 6 Ring 3 Bushing 7 Hole for pressure switch connection 4 Piston 8 Spring

Note: Blow-by at an oil temperature of 40 ÷ 50°C and pressure of 3

bar should be less than 1 I/min. When retting screw bushing 3 so that it touches gasket 5. Do not tighten excessively since gasket 5 might break causing an oil pressure drop in the system.

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 51 -

5

120

121

Oil pressure curve at idling speed

The curve is obtained at the oil lter level with constant engine speed of 1200 r.p.m. in no-Ioad conditions and at a room temperature of + 25°C. Pressure is given in bar and temperature in centigrades.

Lubrication system

Oil pressure curve at full speed

The curve is obtained at the oil lter level with engine working al 3000 r.p.m. al the N power. Room temperature is +25°C. Lube oil peak temperature should be below 120°C for engines without oil cooler and below 110°C for engines with oil cooler. Pressure is given in bar and temperature in centigrades.

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 52 -

6

122

123

124

125

Injection pump

The Bosch injection system consists of three pumps each feeding one cylinder. The pumps mounted on the crankcase, corresponding to their proper cylinder, are directly operated by the camshaft.

Fuel feeding/injection circuit

Components:

1 Tank 2 Filter 3 Fuel feeding tube 4 Fuel feeding pump 5 Injection pump 6 Injection line 7 Injector 8 Injector leak off line and self bleeding system 9 Bowl

FUEL SYSTEM

Fuel feeding pump

The fuel feeding pump is of the diaphgragm type operated by a camshaft eccentric through a drive rod. It features an external lever for manual operation.

Components:

1 Drive rod : shelf 1,470 ÷ 2,070 mm 2 Gasket 3 Camshaft eccentric

Characteristics: when the control eccentric rotates at 1500 r.p.m. mini-

mum delivery is 64 l/h while self-regulation pressure is 4 ÷ 5 m water column.

Fuel lter

Components: 1 Bleeder 2 Cap 3 Seal element 4 Union 5 Cartridge

Cartridge characteristics:

Filtering paper......................PF 904

Filtering area........................5000 cm2

Degree of ltraon ...............2 ÷ 3 µm

Max.,working pressure:...... 4 bar

See page 17 for periodical maintenance details.

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 53 -

6

126

127

128

Fuel system

Injection pump only for standard and 97/68 Ce engines

1

Delivery union 2 Rubber ring 3 Delivery valve 4 Pump housing 5 Piston 6 Plunger 7 Rack rod 8 Spring 9 Tappet body 10 Roller 11 Journal 12 Pin 13 Spring retainer 14 Eccentric 15 Copper gasket 16 Spring 17 Filler

1 Delivery union 2 PRV valve 3 O-Ring 4 Pump housing 5 Pumping piston 6 Pumpung plunger 7 Elastic pin 8 Rack rod 9 Superior retainer 10 Spring tappet 11 Tappet body 12 Inferior retainer 13 Roller 14 Journal guide tappet 15 Elastic pin 16 Adjustment hose 17 Plunger stop pin 18 Cap

Injection pump only for EPA engines

19 Threaded plug 20 Adjustment rod locking device 21 Area in which the pump delivery class is stamped

In this engine the injection pumps are preset by the manufacturer who supplies them stamped with alphabetical classes (A, Ax, B, Bx, C, Cx or D) for standard and 97/68 EC engines, while for EPA2 engines the classes are numerical (5, 6, 7, 8, 9, 10, 11, 12, 13 and 14). The adjustment rod is locked via the bayonet device.

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 54 -

6

129

130

131

132

C 1,000 ÷ 1,100 D 7,445 ÷ 7,455 E 7,500 F 3,000 ÷ 3,025

G 7,225 ÷ 7,275

Fuel system

How to check plunger and barrel for internal leakage

This operation is only diagnostic since pressure changes depend on the pumping speed. Connect the delivery union with a 600 bar pressure gauge with safety valve. Adjust rack rod at half-stroke. Turn ywheeI according to its direction so that the plunger puts the circuit under pressure. Replace plunger if the displayed pressure is below 300 bar. Repeat the same operation for the other plungers.

Plunger

How to check injection pump delivery valve sealing

Components:

1 Valve 2 Seat

Adjust pump rack at half-stroke. Turn ywheeI according to its direction of rotation so that the plunger puts the circuit under pressure. During this operation the displayed pressure will gradually reach a peak followed by a sudden drop which corresponds to valve closing. Pressure drop should be 30 ÷ 50 bar. Replace the valve if pressure drop is below this value. Repeat the same operation for the other two pumps.

Ref. Dimensions (mm)

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 55 -

0,45

- 2

max

27,5 ÷ 30,5

90 ÷ 100

500

1500

150

3 ÷ 4

4 ÷ 5

5 ÷ 6

6 ÷ 7

7 ÷ 8

8 ÷ 9

9 ÷ 10

6

133

0,45

0

max

38 ÷ 40

90 ÷ 100

500

1500

150

3 ÷ 4

4 ÷ 5

5 ÷ 6

6 ÷ 7

7 ÷ 8

8 ÷ 9

9 ÷ 10

Fuel system

Test data for injection pump delivery at the test bench for standard and 97 / 68 CE engines

1 Rack rod lock to be removed after pump tting to the engine 2 Injection pump axis

Test data:

The above test data refer to pump with plunger dia. of 7,500 mm.

Test data for injection pump delivery at the test bench only for EPA engines

Test data:

The pump class is indicated by the full delivery value * at 1 mm

3

/ stroke from 5 to 14.

Plunger diameter size: 7,500 mm.

Note: All pumps are tested and set in order to obtain the same delivery at full speed.

After the tests carried out at idIe speed pumps are subdivided into classes marked with references in letters or numbers. These reference marks are very clearly stamped on the upper pump body. If replacing, make sure that the new pumps have the same references (letters or numbers) as the previous ones.

Camshaft

r.p.m.

Delivery

mm3/stroke

Rod stroke from pump axis (mm)

+ towards max

- towards stop

Control rod max. force

(N)

Camshaft

r.p.m.

Delivery

mm

3

/stroke

Rod stroke from pump axis (mm)

+ towards max

- towards stop

Control rod max. force

(N)

stamped A

stamped Ax

stamped B

stamped Bx

stamped C

stamped Cx

stamped D

stamped A

stamped Ax

stamped B

stamped Bx

stamped C

stamped Cx

stamped D

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 56 -

6

127

129

130

128

Injection pump replacement

1 Rack rod lock 2 Reference mark pump class

A = 82.80 mm C = Injection cam radius D = Injection pump support

 Important

Whe replacing this type of injection pump check that the new one has a same reference mark as the old one. The reference marks of injection pumps must be the same.

Replace as follows:

 Fit pump into the crankcase and tighten screws at 25 Nm.

Remove lock 1 and check that rack rod is free to move. If pump removal is required t lock 1 to its original position: the rack rod centre should coincide with the pump axis (see g. 126). When replacing the crankcase or the camshaft preserve the same distance A between D, injection pump support, and C, injection cam radius; add shims G on D to obtain the right A value if required. Seals G are supplied with different thicknesses: 0,05 – 0,1 – 0,3 and 0,5 mm.

Fuel system

Size S injector

Components:

1 Intake tting 2 Nozzle holder 3 Shim 4 Spring 5 Pressure rod 6 Intermediate ange 7 Nozzle 8 Needle valve 9 Fixing ange

10 Taper pin 11 Gasket 12 System duct 13 Sump 14 Cup

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 57 -

6

131

132

133

Size S nozzle

Features:

Hole number and diameter ........4x0,28 mm

Jet angles ..................................160°

Needle valve elevation ..............0,20 ÷ 0,22 mm

Hole length ................................0,7 mm

Sump diameter and length

........1x1,5 mm

Clean nozzle tip with a brass brush. Check that holes are not obstructed using a mandrel with steel wìre with 0,28 mm diam.

 When retting tighten ring nut at 70 Nm.

Fuel system

Size P nozzle

Features:

Hole number and diameter ............. 5 x 0,23 mm.

Jet angles ....................................... 150°.

Needle valve elevation ................... 0,200 ÷ 0,205 mm

Hole length ..................................... 1 mm

Sump diameter and length ............. 2 x 2,5 mm

Clean nozzle tip with a brass brush. Check that holes are not obstructed using a mandrel with steel wìre with 0,23 mm diam.

 When retting tighten ring nut at 55 ÷ 65 Nm.

Size P injector

Components:

1

Injector housing

2 Intake tting

3 Shim 4 Spring 5 Pressure rod 6 Taper pin 7 Nozzle 8 Cup 9 Needle valve

10 Sump 11 System duct 12 Overow pipe

 When retting tighten ring 8 nut at 50 Nm.

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 58 -

6

134

135

136

137

Injector setting

Connect injector to high pression pump and check that setting pressure is 210 ÷ 220 bar for size S injector and 245 ÷ 255 bar for size P injector. To change injector setting replace the shim over the spring. When replacing the spring, setting should be performed at a 10 bar greater pressure to allow for bedding during operation. Check needIe valve sealing by slowly moving hand pump until approximately 180 bar. Replace nozzle in case of dripping (only for size S injectors).

Fuel system

Use a 19 mm box wrench to lock the injection pump union and a 17 mm box wrench to loosen the union of the injector pump high-pressure pipe.

Use a 14 mm box wrench to lock the injector union and a 17 mm box wrench to loosen the union of the injector pump high-pressure pipe.

(Static) Injection timing

Remove the rocker arm cover.

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 59 -

6

138

139

140

141

Assemble tool serial no. 1460 - 266 made up of lever 2 serial no. 1460 - 275, of a dial indicator 1 serial no. 1460 - 274 inserted in a dial indicator holder serial no. 1460 - 270. The function of lever 2 is to reduce the effort required against the resistance of the spring when the valve lowers and comes into contact with the piston crown near the top dead centre. The dial indicator tracer 1 rests against the upper spring bearing ring of the valve. To sum up, as pressure is placed on lever 2 the valve goes into contact with the piston since the dial indicator 1 is applied to the valve, allowing to know precisely every movement of the piston from and towards the TDC, which is very important for the following operation.

Fuel system

Insert the capillary tester serial no. 1460 - 024 onto the injection pump union where the high-pressure pipe is usually connected from the pump to the injector.

To the injection pump connect the high-pressure pump serial no. 1460

- 273 supplied by a tank whose fuel level is at least 100 mm above the injection pump.

Unscrew the fuel supply union for the injection pump of the cylinder which is to be worked on.

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 60 -

6

142

143

144

145

Components:

1 Fuel supply pipe from the tank 2 High-pressure pipe 3 Capillary tester 4 Valve-lowering lever with dial indicator showing piston movement

Fuel system

Rotate the crankshaft anticlockwise until diesel starts to ow out from the capillary when the high-pressure lever is pressed. Change direction of rotation of the crankshaft to clockwise from the timing belt side. Press the high-pressure lever and rotate the crankshaft until fuel stops owing from the capillary.

Press the lever to bring the valve into contact with the piston crown. By joggling back and forth clockwise and anticlockwise, nd the dead centre via the dial indicator and then reset to zero.

Rotate the crankshaft clockwise on the timing belt side and position the relevant cylinder piston at top dead centre.

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 61 -

6

146

147

97-68 CE

2400 9° ± 1°

8° --> 0.56

9° --> 0.71

10° --> 0.87

2500 ÷ 2800 8° ± 1°

7° --> 0.43 8° --> 0.56

9° --> 0.71

3000 9° ± 1°

8° --> 0.56

9° --> 0.71

10° --> 0.87

EPA 2400 ÷ 2800 5° ± 1°

4° --> 0.14 5° --> 0.22 6° --> 0.32

1500 ÷ 2200 14° ± 1°

13° --> 1.47 14° --> 1.71 15° --> 1.96

2201 ÷ 3000 16° ± 1°

15° --> 1.47 16° --> 1.71 17° --> 1.96

α

(mm)

0° 0.00 1° 0.01 2° 0.04 3° 0.08 4° 0.14 5° 0.22 6° 0.32 7° 0.43 8° 0.56

9° 0.71 10° 0.87 11° 1.06 12° 1.26 13° 1.47 14° 1.71 15° 1.96 16° 2.22 17° 2.51 18° 2.81 19° 3.12 20° 3.45

The capillary tube shows when the fuel is owing out, thanks to its small transparent slot.

Table static advance values for engines with P size injectors

Fuel system

Table static advance values for engines with S size injectors

Conversion table from degrees

into millimetres

After nding the delivery start point (when fuel stops owing from the capillary), press the lever and use the dial indicator to check how many millimetres the piston has moved from the top dead centre. Check static injection advance using the conversion table from millimetres to degrees. If it is necessary to change static advance add the seals G in gure 129 (to delay) or remove the seals G in gure 129 (to advance) from between the injection pump surface and the crankcase surface. The same operation must be performed for each cylinder.

R.p.m.

α

Piston lowering (mm)

R.p.m.

α

Piston lowering (mm)

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 62 -

7

148

150

149

A 111,701 ÷ 111,788 B 31,000 ÷ 33,500 C 76,226 ÷ 76,300 D 77,400 ÷ 77,474

Standard electric equipment

Electric starting layout without battery charging light

Components:

1 Alternator 2 Starting motor 3 Voltage regulator 4 Battery 5 Pressure switch 6 Oil pressure warning light 7 Key switch

12,5 V, 14 A Alternator

Features a xed armature winding, housed in the bell inside the blower stator. The rotating permanent magnet inductor is located in the fan spindle. See page 24.

Note:

Clearance between armature winding and inductor (air gap)

should be 0,55 ÷ 0,63 mm.

ELECTRIC SYSTEM

Electrical starting layout with battery charging Iight

Components:

1 Alternator 2 Starting motor 3 Voltage regulator 4 Battery 5 Pressure switch 6 Oil pressure warning light 7 Key switch 8 Battery charging light

Ref. Dimensions (mm)

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 63 -

7

151

153

152

A 111,701 ÷ 111,788 B 49,500 ÷ 52,000 C 76,226 ÷ 76,300 D 77,400 ÷ 77,474

Alternator battery charger curve (12.5 V, 14A)

The curve was obtained at room temperature of + 25°C with 12.5V battery voltage.

Note: The r.p.m. shown in the table refers to the engine.

Electric system

Alternator battery charger curve (12 V, 21 A)

The curve was obtained at room temperature of + 25°C with 12.5V battery voltage.

Note: The r.p.m. shown in the table refers to the engine.

12 V, 21 A Alternator

Features a xed armature winding housed in the bell inside the blower stator.The rotating permanent magnet inductor is located in the fan spindle. See page 24.

Note: Clearance between armature winding and inductor (air gap)

should be 0,47 ÷ 0,63 mm.

Ref. Dimensions (mm)

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 64 -

~

R

+

LE

O O

6.25

9.50

4.75

6.25

0.8

1.12

0.5

0.8

7

154

155

156

157

Magnetization checking tool (Part No. 7000-9727-001)

Components:

1 Casing 2 Slider 3 Casing reference line 4 Slider reference line

Rest the tool end horizontally onto the magnetic poles. Hold sder so that its reference line coincides with the casing reference line. Release slider: if no attraction occurs the rotor is demagnetized; therefore replace alternator.

Electric system

Connection size (mm)

Width Thickness

Ref.

To avoid wrong connections 3 different sizes are supplied.

Voltage regulator

Supplied by SAPRISA : Voltage 12 V, max. current 26A.

Checking for cable continuity

Check that stator windings have no unsoldered connections, burnt areas or grounded wires. Using an ohmmeter check for continuity between the red cable and the two yellow ones. Furthermore, check that they are insulated from the ground.

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 65 -

7

158

Electric system

How to check voltage regulator for proper operation

Check that connections correspond to the layout. Disconnect the terminal from the battery positive poie. Connect a d.c. voltmeter between the two battery poles. Fit an ammeter between the positive pole and the corresponding cable 1 terminal. The ammeter should be suitabie for reading the required value (14 or 21 A) and for withstanding the starting motor peak absorption (400 ÷ 450 A). Start a couple of times until battery voltage drops below 13 V. When battery voltage reaches 14,5 V the ammeter current suddeniy drops down to almost zero. Replace regulator if recharge current is zero with voltage below 14 V.

 Important

When the engine is running do not disconnect battery cables or remove the key from the control panel. Keep regulator away from heat sources since temperatures above 75°C mmght damage it. No electric welding on engíne or application.

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 66 -

7

159

160

161

Alternator type Bosch G1 14 V, 33 A

The alternator is ot the claw-pole rotor type with built-in voltage reguiator. The rotating motion is conveyed by the engine through a 'V' belt and sheave.

Features: 12V rated voltage. Max. current 33A at 7000 alternator

r.p.m. RH direction of rotation.

Electric system

14 V, 33 A Bosch G1 alternator battery charger curve

The curve was obtained at room temperature of +25°C. Battery terminal voltage is 12.5 V. The r.p.m. shown on the table refers to the engine.

Alternator type Bosch Gil 14 V, 33 A layout

Components:

1 Alternator 2 Starting motor 3 Battery 4 Key switch 5 Pressure switch 6 Oil pressure warning light 7 Battery charging light

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 67 -

7

162

163

164

Starting motor type Bosch JF (R) 12 V, class 2.5

RH direction of rotation

A = 23 ÷ 24 mm B = Ring gear plane C = Flange plane

Vorsicht - Warnung

The ywheel should not project from ring gear plane B.

Note: Apply to Bosch Service Centers for any type of repair.

Electric system

Starting motor layout

A = Parking lights B = Stop C = Run D = Start

Characteristic curves for starting motor type Bosch JF (R) 12 V

Curves were obtained at room temperature of + 20°C with 88 Ah batteries.

V = Motor terminal voltage in Volt P = Power in kW C = Torque in N/m N = Motor speed in r.p.m. J (A) = Absorbed current in Ampere

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 68 -

8

165

166

167

168

SETTINGS

Settings

1 - ldling speed setting in no-load conditions (standard)

After lling with oil and fuel, start the engine and let it warm up for 10 minutes. Adjust idling speed at 800 ÷ 900 r.p.m. by turning setscrew

1; then tighten lock nut.

Stop setting

Remove fuel feeding pump and cover.

1) Loosen both bolts xing plate A.

2) Push injection pump B control rod to the right and keep it in this

position.

3) Push plate A to the right until it touches rod B and stop.

4) Release rod B and push plate A to the right so that rod B has a

stroke of 1 mm. Tighten both bolts.

Note: Under these conditions no damage can be caused to the injec-

tion pump rack rod stops by sudden impacts due to the available control solenoids.

Injection pump delivery setting

This setting should be performed at the torque dynamometer. lf not, setting is only approximate. The following steps are required: Loosen delivery limiting device C by 5 turns. Bring engine to full speed in no-load conditions i.e. 3200 r.p.m.. Tighten limiting device until the engine shows a drop in r.p.m.. Unscrew limiting device C by 1½ turn. Tighten lock nut.

Note: lf the engine, under full load, generates too much smoke tighten

C; if no smoke is observed at the exhaust and the engine can- not reach its full power unscrew C.

2 - Full speed setting in no-load conditions (standard)

After setting idle speed turn screw 2 and set full speed in no-load conditions at 3200 r.p.m.; then tighten lock nut.

Note: When the engine reaches the pre-set power full speed stabili-

zes at 3000 r.p.m.

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 69 -

........................................................................................................................................................

NOTES

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 70 -

........................................................................................................................................................

NOTES

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 71 -

APPENDIX FOR ENGINE WITH ADVANCE VARIATOR

KD 625/3 - 626/3 ENGINE

with advance variator

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 72 -

I

ADVANCE VARIATOR OPERATING PRINCIPLE

INJECTION TIMING DEVICE OPERATION

In order to meet EPA tier 2 limits, the engine KD 625-3 has been equipped with a variable injection timing device. The system consists of an electro–hydraulic actuated mechanical device, that allows changing the injection timing by rotating the camshaft against its driving gear. The change takes place using the oil whose pressure is regulated by a pair of electric valves, which allow a rotation between 0 and 4.5°. The maximum variation of the injection timing is 4.5° (camshaft degrees). Oil is taken from the engine oil circuit and its pressure acts on a sort of hydraulic piston that moves from one side to the other. The hydraulic plunger is attached on the inside by means of a straight groove and on the outside via a spiral-shaped groove. Thus movement from left to right (or vice versa) causes rotation from the driving gear and the camshaft. In other words, the plunger translates and, at the same time, rotates and thus varying the angular position of camshaft that is connected to it. The gear timing variation is managed by an ECU which receives electric signals from two speed sensors, the temperature sensor and the load sensor, which reads the position of the injection pump control. The ECU memory contains the maps of the injection timing variation strategies.

Fig. A_1. Injection timing device: in "Resting position"

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 73 -

I

Fig. A_2. Injection timing device: during actuation of an advance (max value 4.5°). The oil (yellow) goes into the system and moves the plunger (blue) that activates the camshaft anticlockwise.

Fig. A_3. Injection timing device: moving from actuation of an advance to resting position. The oil (yellow) goes out and releases the spring to move the plunger (blue), which in turn activates the camshaft

clockwise.

Our system is able to actuate any intermediate advance, regulating the oil pressure. When the set level is reached, the oil exerts the right force to compress the spring at the right height to move the plunger appropriately, thus achieving the required rotation (angular advance).

Advance variator operating principle

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 74 -

II

Solenoid valve assembly diagram

DISASSEMBLY/REASSEMBLY

COMPONENTS TABLE

1 Cylindrical 1/4" gas union 2 Union bolt M 12x1.5 3 Connection screw M 14x1.5 4 Nut M 5 5 Copper seal 13.5x19x2 6 Seal 7 Seal 14x19x1.5 8 Adjustable union d. 12 9 Screw TCEI M 5x65 10 Pressure switch 11 Spacer 12 Bolt for two adjustable unions M 12x1.5 13 OilSistem solenoid valve block 14 Variator lubrication jet 15 Pressure switch union 16 Solenoid valve block support 17 Solenoid valve block oil lter pipe 18 Variator oil loading pipe 19 Variator oil bypass pipe 20 Variator oil draining pipe 21 "OTECO clic 66" clamp

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 75 -

II

A_5

A_6

A_7

A_4

Disassembly / Reassembly

After loosening the screws, remove the alternator belt guard.

Components:

1 Variator oil loading pipe 2 Variator oil bypass pipe 3 Variator oil draining pipe 4 Solenoid valve block oil lter pipe

Components:

1 Pressure switch 2 Pressure switch union 3 Solenoid valve block oil lter pipe

Overall view of variator speed sensor and hydraulic circuit.

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 76 -

II

A_8

A_9

A_10

A_11

Components:

1 Variator load solenoid valve 2 Variator unload solenoid valve

 Important

Do not invert cables during reassembly.

Disassembly / Reassembly

On the opposite end of the block of pipe 19 is the variator lubrication jet attached to the pipe by a click clamp.

Refer to page 78 to identify the pipes.

Loosen the union screw of pipes 17 and 19.

To remove connectors, press the stop tabs and draw upwards.

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 77 -

II

A_12

A_13

A_14

A_15

Variator lubrication jet complete with banjo union.

Disassembly / Reassembly

View of the unassembled solenoid valve block with two spacers between the block and the bracket.

To remove the solenoid valve block from the support bracket, unscrew the two screws M 5.

Unscrew the union of variator oil discharge pipe 20.

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 78 -

II

Speed sensor and variator assembly diagram

COMPONENTS TABLE

1 Oil seal ring 20x30x7 2 Washer 6x12xSp1 3 Screw TCEI M 5x10 4 Screw TCEI UNI 5931 M 6x10 5 Screw TCEI UNI 5931 M 6x14 6 Lid seal (rev. counter) 7 Oil seal support ring 8 Variator oil bush 9 Special tab for variator 10 Advance variator device 11 Timing cover side cover for variator 12 Speed and phase sensors 13 Cylindrical pin 5x16 14 Speed sensor support

Disassembly / Reassembly

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 79 -

II

A_16

A_17

A_18

A_19

To remove the speed sensor cable connector press the spring as shown in gures A_16 and A_17 and draw upwards.

Disassembly / Reassembly

Loosen screw M6 to remove the speed sensor from its support.

Loosen the two screws M8 to disassemble the solenoid valve support bracket.

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 80 -

II

A_20

A_21

A_22

A_23

Draw he speed sensor outwards, being careful not to damage the rubber seal ring.

Disassembly / Reassembly

Blower belt alternator - Disassembly

See page 22 - 23.

View of speed sensor housing.

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 81 -

II

A_24

A_26

A_27

A_25

Blower control pulley - Disassembly

See page 24 - 25.

Disassembly / Reassembly

Pay attention to the oil seal support ring when disassembling the timing cover.

After loosening the screws, remove the timing cover.

Components:

1 Left-handed bolt 2 Washer 3 Blower control pulley

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 82 -

II

A_28

A_29

A_30

A_31

A

B

Remove the timing cover seal.

Disassembly / Reassembly

Remove the variator. The gure shows the camshaft pin for correct variator timing.

A Cylindrical pin Ø 5x16 B Pin housing

Remove screw M10.

Unscrew screws M10 on the variator to the camshaft.

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 83 -

II

A_32

A_33

View of the camshaft ends with pin inserted.

Disassembly / Reassembly

Remove the shoulder housing of the idle gear that drives the speed governor.

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 84 -

II

A_34

A_35

A_36

A_37

 After retting the housing tighten the screws to 20 Nm using a tor-

que wrench.

Disassembly / Reassembly

Assemble the timing control gear onto the crankshaft so that reference mark A is lined up with the two reference marks B on the idle gear installed on the camshaft.

Assemble the variator onto the end of the camshaft taking care to properly insert the timing pin into place and ensuring that the variator comes into contact with the surface of the speed governor idle gear.

 Tighten screw M10 to 65 Nm using a torque wrench.

Remove the distribution control gear from the crankshaft.

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 85 -

II

A_38

A_39

A_40

A_41

Replace the timing cover, placing a new seal and lining up with the two centring pins.

Disassembly / Reassembly

Replace the speed sensor taking care not to damage the O-ring.

Ret the oil feed bushing to the variator, placing the oil seal support ring in between. Replace the seal.

 Tighten the three screws M6 to an 8 Nm torque.

 Tighten the screws to a 25 Nm torque.

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 86 -

II

A_42

A_43

A_44

A_45

 Attach the sensor using screw M6 to a torque of 8 Nm.

Disassembly / Reassembly

Replace the variator circuit oil pipes. If in doubt consult the diagram on page 78.

Replace and check the belt tension (see page 22-23).

Reassemble the blower control pulley onto the crankshaft.

 Tighten the left-handed fastening bolts to torque of 300 Nm.

Components:

1 Left-handed bolt 2 Washer 3 Blower control pulley

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 87 -

II

A_46

A_47

Insert the solenoid valve connectors following the references (IN and OUT) shown on the cables and on the solenoid valve block.

Disassembly / Reassembly

 Replace the built guard and tighten to 15 Nm.

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 88 -

II

Angular position sensor and AC pump assembly diagram

Disassembly / Reassembly

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 89 -

II

COMPONENTS TABLE

1 Stud bolt M8x20 2 Silicone O-ring 3 Snap pin 2x10 4 Conical screw STEI M 10x1.5 5 Self-locking anged hex nut 6 Copper washer 7 Crinkled spring washer 8 Screw TCEI UNI 5931 M 4x35 9 Screw STEI M 8x20 10 Fuel supply pump

11 Screw TCEI M 8x18 12 Fuel supply pump seal 13 Sensor pump connection rod 14 AC pump and angular position sensor cover 15 Sensor control lever 16 Connecting pin between rod and sensor 17 Discharge stop plate 18 Angular position sensor 19 Flathead screw

Disassembly / Reassembly

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 90 -

II

COMPONENTS TABLE

1 Silicone O-ring 2 Washer 6x12xSp1 3 Screw TCEI UNI 5931 M 6x10 4 Screw TCEI UNI 5931 M 6x25 5 Speed and phase sensors 6 Phase sensor air gap adjustment shim 7 Phase sensor support

Phase sensor assembly diagram

Adjust with 0.2 mm shims

Disassembly / Reassembly

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 91 -

II

A_48

A_49

A_50

A_51

To assemble the phase sensor connector press the locking spring.

Disassembly / Reassembly

Remove the sensor from the support taking care not to damage the O-ring.

 Loosen screw M6. When retting, tighten to 8 Nm.

Remove the connector from the sensor.

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 92 -

II

A_52

A_53

A_54

A_55

30.24 ÷ 30.26 mm

Components:

1 Dial indicator 2 Support for dial indicator 3 Sensor control gauge measurement: 30,24 ÷ 30,26 mm 4 Control master measurement: 30,24 ÷ 30,26 mm for sensor

gauge

If replacing the phase sensor, check the length of the sensor pin using the tool in gure A_52. Check by measuring the distance between magnetic end and the sensor support surface (30,24 ÷ 30,26 mm).

The serial numbers of special tools are on page 103.

Disassembly / Reassembly

Sensor test

Remove the master 4 from the gauge 3; insert the phase sensor and check that the sensor falls within tolerance measurements of 30,015 ÷ 30,035 mm. See g. A_53 -A_ 54.

Resetting the dial indicator

Assemble the dial indicator 1 onto support 2. Attach the support with the dial indicator to the gauge 3. Insert the master 4 into the gauge 3 and reset the dial indicator.

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 93 -

II

1

4

2

3

5

30.24 ÷ 30.26 mm

6

A_56

A_57

A_58

A_59

Resetting the dial indicator

Components:

1 Dial indicator 2 Support for dial indicator 3 Camshaft sensor support surface control gauge

measurement: 30,24 ÷ 30,26 mm

4 Resetting master measure: 30,24 ÷ 30,26 mm for gauge 5 Resetting reference base

If replacing the sensor, camshaft or engine block via the tool see gure 56. Make sure that the support surface of the sensor on the camshaft support measures 30,24 ÷ 30,26 mm. Assemble the dial indicator 1 in the support 2. Insert the support 2 complete with dial indicator 1 into the gauge 3. Set the master 4 and reset the dial indicator while resting on the base 5 as in 6.

Disassembly / Reassembly

Example of where to insert the air gap adjustment shims.

Air gap adjustment

The air gap is adjusted using shims measuring 0,2 mm in thickness which are placed between the sensor surface and its support. The air gap must be between 0,3 and 0,5 mm (see phase sensor assembly diagram page 94). When adjusting the air gap with shims, it is important to consider any difference between the measurements taken (length of the sensor pin and depth between the sensor support surface and the camshaft) and specications.

Measuring the depth between the sensor support and the camshaft

Insert the gauge complete with dial indicator onto the sensor support and attach using the three screws. Make sure the measurements taken are within the specic tolerance limits 30.24 ÷ 30.26 mm.

 The three screws for the phase sensor support screws must be

tightened to 8 Nm using a torque wrench.

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 94 -

II

A_60

A_61

A_62

A_63

Remove the connector from the position sensor on the injection pump control rod.

Disassembly / Reassembly

When reassembling, replace the sealing gasket.

Unscrew the two screws to disassemble the fuel pump;

 when retting, tighten the athead screws, the nuts and hexagonal-

head screws to 25 Nm.

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 95 -

II

A_64

A_65

A_66

A_67

Remove the conical inspection plug.

Disassembly / Reassembly

Unscrew the last screw (athead) after rotating the sensor anticlockwise.

Remove the three anged nuts and the athead screw.

Unscrew the two screws to disassemble the injection pump rod position sensor.

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 96 -

II

A_68

A_69

A_70

A_71

Remove the cover supporting the sensor and the fuel pump.

Disassembly / Reassembly

Tighten only one screw on the position sensor to keep it in the right position.

Insert the fork into the slot in the support. Rotate the sensor body 180°, keeping the fork in the position shown in gure A _70.

Rotate the position sensor shaft to direct the fork on the side opposite the connector.

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 97 -

II

A_72

A_73

A_74

A_75

Set the cover against the crankcase so that the injection pump rod drive pin 1 is inserted between the two prongs of the fork 2.

Disassembly / Reassembly

Replace the screws and nuts in the cover in the opposite order to when they were removed and

 tighten to 25 Nm.

Operate the stop control lever repeatedly to make sure the system is running smoothly.

Look through the upper inspection hole on the cover to make sure that the pin 1 is correctly inserted into the fork 2.

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 98 -

II

A_76

A_77

A_78

Ret the fuel pump after replacing the seal; tighten the screws to 25 Nm.

Disassembly / Reassembly

Example of adhesive plate on the control panel

1 Engine type 2 Control panel serial number 3 Version number (form K) 4 SN plus engine serial number plus date

Correct assembly position of the control unit that runs the engine variator.

s/n

MADE IN ITALY

rpm

XX XX XXXX

XXXX

XXXXXX

e9 • 97/68/CE • 00/000xx • xxxx •xx

Xx

0.00

xxx xxx xx

Model

Spec.

1

3

4

2

XXXX XXX-X

XXXXXX

XXXX.XXX/X

XXXXXXX

XX/XXXX

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 99 -

........................................................................................................................................................

NOTES

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

- 100 -

13

169

170

171

STORAGE

When the engines are not used for more than 3 months, they must be protected by the measures described below:

STORAGE

External engine protection:

- Start the engine and heat it.

- Remove the drain plug and let the oil ow completely.

- Replace the oil lter with a new one (screw manually the new lter).

- Clean the oil drain plug and after having assembled a new gasket, tighten it.

- Carry out the oil relling to the upper level of the rod, using AGIP RUSTIA C (for Countries in which this product is not available nd an equivalent product on the market).

- Start for about 10 minutes and verify any possible oil leakage, then stop the engine.

External engine protection:

- Clean carefully cylinder cooling system ns and the blowing fan.

- Loosen the drive belt of the blowing fan.

- Protect the external non-painted surfaces with AGIP RUSTIA 100/F.

- Seal with adhesive tape the intake and exhaust systems

- Coat the engine with a nylon or plastic sheet.

- Keep in a dry place. If possible not in direct contact with the ground and away from high voltage electric lines.

Injection systems protection:

- Empty the fuel tank.

- Replace the fuel lter with a new one.

- Carry out the lling of fuel using 10% of AGIP RUSTIA NT special additives.

- After having performed the air bleeding, start the engine, verify any possible fuel leakage, then stop the engine.

KD Workshop Manual_cod. ED0053029350_1° ed_ rev. 00

Kohler KD 625/3, RD 626/3, KD 626/3 Workshop Manual

Specifications and Main Features

Frequently Asked Questions

User Manual