Kohler KD 626/3 Workshop Manual Download Page 88

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Angular position sensor and AC pump assembly diagram

Disassembly / Reassembly

KD Workshop Manual_cod. ED0053029350_

1° ed

_ rev.

Summary of Contents for KD 626/3

Page 1: ...KD 625 3 626 3 WORKSHOP MANUAL...

Page 2: ...rform 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 se...

Page 3: ...Overall dimensions 16 MAINTENANCE PRESCRIBED LUBRICANT REFILLING 17 Routine engine maintenance 17 Extraordinary maintenance 17 Ordinary maintenance 17 Lubricant 18 Prescribed lubricant 19 Fuel specif...

Page 4: ...cation 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 bearin...

Page 5: ...ic 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...

Page 6: ...f 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 warran...

Page 7: ...e 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...

Page 8: ...ent distance from the machine to prevent any danger resulting from its operation Fuel is flammable so the tank must be filled only when the engine is turned off Dry carefully any fuel that may have sp...

Page 9: ...is taking place Keep the fuel and engine control systems and the exhaust pipes in efficient working order to limit environmental and noise pollution When discontinuing use of the engine select all com...

Page 10: ...oken 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 v...

Page 11: ...el 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...

Page 12: ...e 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 refe...

Page 13: ...CV Nm kgm kW CV kW CV g CV h g kW h l kg h l kg l min l min kg 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...

Page 14: ...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...

Page 15: ...cific fuel consumption at NB power The above power values refer to an engine fitted with air cleaner and standard muffler after testing and at the environmental conditions of 20 C and 1 bar Max power...

Page 16: ...AUMA E mm DIMENSIONE mm DIMEN ES 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...

Page 17: ...E 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 tech...

Page 18: ...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 red...

Page 19: ...with insufficient 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 e...

Page 20: ...ful 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 characteri...

Page 21: ...21 3 KD Workshop Manual_cod ED0053029350_1 ed_ rev 00...

Page 22: ...n using compressed air wear eye protection RECOMMENDATIONS FOR DISASSEMBLING AND ASSEMBLING DISASSEMBLY REASSEMBLY Important To locate specific topics the reader should refer to the index Besides disa...

Page 23: ...embling tighten the nuts in sequence and gradually be fore the final torque to 20 Nm Oil bath air cleaner components Caution Warning Replace if irreparably clogged 1 Bowl 7 Cover clamp 2 External seal...

Page 24: ...ut this is in the position indicated A in the figure 7 Tightening should be carried out gradually Belt tension adjustment Danger Attention Check the belt tension only when the engine is not running Th...

Page 25: ...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 baffles Disassembly The air shr...

Page 26: ...control pulley is installed on and is driven by the cran kshaft To disassemble the pulley unscrew the left handed bolt clockwise af ter blocking the crankshaft When reassembling tighten the bolt using...

Page 27: ...ce 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...

Page 28: ...flywheel to the crankshaft To replace starter ring gear heat it up to 300 C for 15 20 minutes Drive it onto the flywheei caretully checking that it perfectly fits into its seat Let it cool down slowl...

Page 29: ...ering 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 at...

Page 30: ...Disassembly Reassembly The fixing 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 s...

Page 31: ...e rocker arm lubrication hose is firmly 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...

Page 32: ...st 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...

Page 33: ...ing C insert the ring then drive the guides until the lock ring is stop ped without worrying about A and B INTAKE VALVE EXHAUST VALVE Disassembly Reassembly Valve seat lapping After cutting lap valve...

Page 34: ...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 blow...

Page 35: ...rting 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 groo...

Page 36: ...into the corresponding cylinders mark them to avoid mistakes See page 35 fig 71 for specifications as to the tightening of the connecting rod big end bearing Piston clearance A Clearance volume is 0...

Page 37: ...Both centering notches A and B must be on the same side when re fitting Tighten bolts at 40 Nm See page 39 for dimensions Connecting rod weight Weight connecting rods when replacing them in order to a...

Page 38: ...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...

Page 39: ...erent diameter size see page 40 for dimensions When refitting 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...

Page 40: ...ow 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...

Page 41: ...ith 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 r...

Page 42: ...equate 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 mi crometer When repia...

Page 43: ...e 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...

Page 44: ...o its direction of rotation you can measure intake valve opening advance referred to top dead centre PMS and intake valve closing delay referred to bottom 1 dead centre Follow the same procedure for e...

Page 45: ...2 before P M S close 34 after P M I open 34 before P M I close 2 after P M S Disassembly Reassembly Legend S piston at top dead center I piston at bottom dead center intake valve open intake valve clo...

Page 46: ...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 S...

Page 47: ...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 con trol lever 6 offset the weights 1 ce...

Page 48: ...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...

Page 49: ...fluence 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 wil...

Page 50: ...ee page 49 Oil filter 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 pr...

Page 51: ...perature in centigrades Lubrication system Oil pressure curve at full speed The curve is obtained at the oil filter level with engine working al 3000 r p m al the N power Room temperature is 25 C Lube...

Page 52: ...el 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...

Page 53: ...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...

Page 54: ...f 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...

Page 55: ...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 o...

Page 56: ...mp removal is required fit lock 1 to its original position the rack rod centre should coincide with the pump axis see fig 126 When replacing the crankcase or the camshaft preserve the same di stance A...

Page 57: ...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...

Page 58: ...during operation Check needIe valve sealing by slowly moving hand pump until appro ximately 180 bar Replace nozzle in case of dripping only for size S injectors Fuel system Use a 19 mm box wrench to l...

Page 59: ...er 2 the valve goes into con tact with the piston since the dial indicator 1 is applied to the valve allowing to know precisely every movement of the piston from and to wards the TDC which is very imp...

Page 60: ...of rotation of the crankshaft to clockwise from the timing belt side Press the high pressure lever and rotate the crankshaft until fuel stops flowing from the capillary Press the lever to bring the v...

Page 61: ...system Table static advance values for engines with S size injectors Conversion table from degrees into millimetres After finding the delivery start point when fuel stops flowing from the capillary p...

Page 62: ...a fixed armature winding housed in the bell inside the blo wer stator The rotating permanent magnet inductor is located in the fan spindle See page 24 Note Clearance between armature winding and indu...

Page 63: ...ery 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 fixed a...

Page 64: ...ttraction occurs the rotor is demagnetized the refore replace alternator Electric system Connection size mm Width Thickness Ref To avoid wrong connections 3 different sizes are supplied Voltage regula...

Page 65: ...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 d...

Page 66: ...or 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 sh...

Page 67: ...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 obtai...

Page 68: ...ue to the availa ble 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 Lo...

Page 69: ...69 NOTES KD Workshop Manual_cod ED0053029350_1 ed_ rev 00...

Page 70: ...70 NOTES KD Workshop Manual_cod ED0053029350_1 ed_ rev 00...

Page 71: ...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...

Page 72: ...ts 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...

Page 73: ...e 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...

Page 74: ...ble 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 Sol...

Page 75: ...ariator oil loading pipe 2 Variator oil bypass pipe 3 Variator oil draining pipe 4 Solenoid valve block oil filter pipe Components 1 Pressure switch 2 Pressure switch union 3 Solenoid valve block oil...

Page 76: ...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 u...

Page 77: ...assembly 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...

Page 78: ...931 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...

Page 79: ...ess the spring as shown in figures 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 solenoi...

Page 80: ...raw 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_c...

Page 81: ...4 25 Disassembly Reassembly Pay attention to the oil seal support ring when disassembling the ti ming cover After loosening the screws remove the timing cover Components 1 Left handed bolt 2 Washer 3...

Page 82: ...Disassembly Reassembly Remove the variator The figure shows the camshaft pin for correct variator timing A Cylindrical pin 5x16 B Pin housing Remove screw M10 Unscrew screws M10 on the variator to th...

Page 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_ re...

Page 84: ...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 vari...

Page 85: ...sembly Reassembly Replace the speed sensor taking care not to damage the O ring Refit the oil feed bushing to the variator placing the oil seal support ring in between Replace the seal Tighten the thr...

Page 86: ...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...

Page 87: ...olenoid 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_...

Page 88: ...88 II Angular position sensor and AC pump assembly diagram Disassembly Reassembly KD Workshop Manual_cod ED0053029350_1 ed_ rev 00...

Page 89: ...CEI 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 l...

Page 90: ...w 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 Disas...

Page 91: ...nector press the locking spring Disassembly Reassembly Remove the sensor from the support taking care not to damage the O ring Loosen screw M6 When refitting tighten to 8 Nm Remove the connector from...

Page 92: ...tic 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 senso...

Page 93: ...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 ga...

Page 94: ...njection pump control rod Disassembly Reassembly When reassembling replace the sealing gasket Unscrew the two screws to disassemble the fuel pump when refitting tighten the flathead screws the nuts an...

Page 95: ...mbly Reassembly Unscrew the last screw flathead after rotating the sensor anti clockwise Remove the three flanged nuts and the flathead screw Unscrew the two screws to disassemble the injection pump r...

Page 96: ...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 figure A _70 Rotate the...

Page 97: ...ssembly 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 smoot...

Page 98: ...trol 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 va riator s n MADE IN ITALY rpm XX XX XXXX...

Page 99: ...99 NOTES KD Workshop Manual_cod ED0053029350_1 ed_ rev 00...

Page 100: ...es and verify any possible oil leakage then stop the engine External engine protection Clean carefully cylinder cooling system fins and the blowing fan Loosen the drive belt of the blowing fan Protect...

Page 101: ...of a bowl motor oil on the piston crown no more than 2 cc for every cylinder Remove valve covers and spray motor oil on the valves then turn the crankshaft manually for a few revolutions Start the en...

Page 102: ...ntake manifold Exhaust manifold Air shroud Throttle control cover Rocker arm cover Timing cover Cover hydraulic pump flange 1P Oil pump casing Blower pulley nuts Oil pump nut or union Oil pump gear th...

Page 103: ...fastening screws Speed sensor support fastening screws Oil sump Belt guard Blower crankshaft pulley Fan pulley Fuel filter union Fuel pump union Radiator union Injector high pressure pipe union Speed...

Page 104: ...0x2 M 22x1 5 M 24x2 M 27x2 M 30x2 R 400N mm2 R 500N mm2 R 600N mm2 R 800N mm2 R 1000N mm2 R 1200N mm2 Nm 10 21 20 36 38 56 84 122 117 173 164 229 293 431 600 Nm 14 28 26 48 45 75 113 163 157 230 218 3...

Page 105: ...phase sensor 1 Dial indicator 2 Dial indicator support 3 Gauge 4 Master Only for engines with advance variator Tool for measuring air gap 1 Dial indicator 2 Dial indicator support 3 Gauge 4 Master 5 B...

Page 106: ...SERVICE INFORMATION IN U S AND CANADA CALL 1 800 544 2444 KohlerEngines com FORM NO ED0053029350 ISSUED 02 07 2012 REVISED 00 DATE 06 20 2012 Translated from the original manual in Italian language Da...

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