Kohler KD 625/2 Workshop Manual Download

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WORKSHOP MANUAL

KD 625/2

Summary of Contents for KD 625/2

Page 1: ...WORKSHOP MANUAL KD 625 2 ...

Page 2: ...07 2012 06 07 2012 ED0053029380 51266 Drafting body Document code Edition Issue date Review date Model N Revision REGISTRATION OF MODIFICATIONS TO THE DOCUMENT Any modifications to this document must be registered by the drafting body by completing the following table Endorsed ...

Page 3: ...wed 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...

Page 4: ...under warranty for a period of two 2 years or 1 500 hours whichever occurs first 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...

Page 5: ...it 17 Electrical system 17 Performance diagram 18 Overall dimension 20 3 MAINTENANCE RECOMMENDED OIL TYPE REFILLING 22 Routine engine maintenance 22 Extraordinary maintenance 22 Ordinary maintenance 22 Lubricant 23 Prescribed lubricant 24 Fuel recommendations 25 4 DISASSEMBLY REASSEMBLY 26 Recommendations for disassembling and assembling 26 Recommendations for overhauls and tuning 26 Air cleaner 2...

Page 6: ... side 41 Crankshaft 42 Center main bearing support locating screw 42 Crankshaft removal 42 Crankshaft center main bearing support 42 Crankshaft lubrication ducts 42 Crankshaft journal radius 43 Checking main journals and crank pins 43 Main journal and crank pin diameter 43 How to measure main bearing inside diameter 43 Main bearing and connecting rod big end bearing inside diameter 44 Clearance be...

Page 7: ... How to check plunger and barrel for internal leakage 59 How to check injection pump delivery valve sealing 60 Test data for injection pump delivery 60 How to reassemble injection pump components 61 How to mount injection pump on the engine 61 Injection pump mechanical speed governor timing 62 Static injection timing 62 Injection static advance adjustment 62 Injection advance adjustment 63 Injecto...

Page 8: ...ction pump delivery setting 76 Lnjection pump delivery limiting and extra fuel device 76 Injection pump delivery setting with dynamometric brake 77 Lnjection pump delivery setting without dynamometric brake 77 Setting the stop limit stop 78 9 STORAGE 80 Engine storage 80 Protective treatment 80 Preparing the engine for operation after protective treatment 81 10 TORQUE SPECIFICATIONS AND USE OF SEA...

Page 9: ...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 clutch...

Page 10: ...uildings or other machines SAFETY REGULATIONS Children and animals must be kept at a sufficient 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 spilled remove the fuel container and any cloths soaked in fuel or oil check that any sound absorbing panels m...

Page 11: ...king 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 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 ...

Page 12: ...OMS 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 PROBLEM Engine does not start Engine starts but stops No acceleration Non uniform speed Black smoke White smoke Oil preassure too low Excessive oil consumption COOLING CIRCUIT Incorrect governor linkage adjustment Governor s...

Page 13: ...xcessive oil consumption Excessive idle operation Incomplete run in Overloaded engine Non conforming engine oil Damaged blocked or dirty injector Injection pump valve damaged Injector not adjusted Hardened pump control rod Broken or loose supplementary start up spring Worn or damaged pumping element Incorrecttuningofinjectioncomponents delivery balancing advance Extra fuel control level sticking O...

Page 14: ...tion plate shown in the figure 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 C A F D E B ...

Page 15: ...4 5 6 7 8 9 10 11 12 Technical information MAIN COMPONENTS Components 1 Fuel tank 2 Injectors 3 Air cleaner 4 Starting motor 5 Oil filter 6 Rocker arm cover 7 Oil dipstick 8 Throttle and stop controls 9 Oil drain plug 10 Fuel feeding pump 11 Flywheel 12 Injection pump ...

Page 16: ...filter or dry air cleaner Air fan integral to the flywheel Counter clockwise from flywheel side 2 in line Four stroke diesel POWER AND TORQUE CONSUMPTION AT MAXIMUM POWER GENERAL DETAILS Operating cycle Cylinders Bore x stroke Displacements Compression rate Intake Cooling Crankshaft rotation Combustion sequence Timing system Valves Shaft Tappets Fuel injection Dry weight of engine Maximum tilt whi...

Page 17: ...lternator Internal Optional nominal voltage Alternator External Optional nominal voltage Alternator Internal Standard nominal current Alternator Internal Optional nominal current Alternator External Optional nominal current Starter motor power Bosh GF Starter motor power Bosh DW R Type of lubrication Circuit supply Maximum oil quantity Maximum oil quantity Oil pressure at min speed oil temperature...

Page 18: ... 18 KD 625 2 Workshop Manual_cod ED0053029380_1 ed_ rev 00 2 Technical information PERFORMANCE DIAGRAM KD 625 2 EPA 3000 r p m KD 625 NR 2800 r p m KD 625 3000 r p m ...

Page 19: ... 19 KD 625 2 Workshop Manual_cod ED0053029380_1 ed_ rev 00 2 Technical information ...

Page 20: ...0053029380_1 ed_ rev 00 2 A B C D 198 425 E F 434 397 I L 340 168 G H O P 421 178 207 542 599 633 557 217 DIMENSIONI mm MESURES mm DIMENSION mm EINBAUMAßE mm DIMENSIONE mm DIMENÇÕES mm M N OVERALL DIMENSION Technical information KD 625 2 ...

Page 21: ... 21 KD 625 2 Workshop Manual_cod ED0053029380_1 ed_ rev 00 2 Technical information ...

Page 22: ...XTERNAL CARTRIDGE PARTIAL TOTAL Engine oil replacement Oil filter replacement EXTRAORDINARY MAINTENANCE AFTER THE FIRST 50 WORKING HOURS ORDINARY MAINTENANCE OPERATION DESCRIPTION FREQUENCY x HOURS CHECK REPLACEMENT OVERHAUL AFTER 6 CHECKS WITH CLEANING 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 filter element...

Page 23: ...er An SF oil for instance is more performing than a SE oil but less performing than a SG one API MIL Sequences 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 Hea...

Page 24: ...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 ...

Page 25: ... fuel Diesel fuels that satisfy the following specifications are suitable for use in this engine ASTM D 975 1D or 2D EN590 or equivalent 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 paraffin in diesel at low temperatures If paraffin forms in the diesel the fuel filter becomes blocked interruptin...

Page 26: ...e of porosity or defective spots Carefully clean bowl and filtering element with Diesel oil and blow through with compressed air Top up with engine oil to the mark When refitting tighten nuts at 25 Nm See page 22 for periodic maintenance details RECOMMENDATIONS FOR DISASSEMBLING AND ASSEMBLING Important To locate specific topics the reader should refer to the index Besides disassembly and reassemb...

Page 27: ...ing valve 5 Cap complete with clamp Scavenging valve 4 must be positioned as in figure 4 Danger Attention During repair operations when using compressed air wear eye protection The cartridge can be cleaned by blowing compressed air breadthways outside and inside the cartridge at a pressure not greater than 5 atmospheres or in necessity case by knocking the front of the cartridge several times agai...

Page 28: ...ke manifold To avoid flange breakage check that heads are in line before tightening nuts Check flange surface for warpage and correct if necessary Replace gaskets Tighten nuts at 25 Nm Note In case of low temperature starting we can supply a manifold with possibility of fitting a glow plug with air preheating Oil vapour separator Fitted on engines with dry air cleaner Screw it out of the air conve...

Page 29: ...g a pressure of 10 kg External alternator blower control belt Reassembly Install the belt and the belt guard Force the alternator outwards and temporarily tighten the fastening bolts Make sure that the belt tension is within the required parameters see External alternator blower control belt Tension check Fig 11 Tighten the fastening bolts to a final torque of 30 Nm 8x1 25 and 50 Nm 10x1 50 FUEL T...

Page 30: ... and stator bolts at 10 Nm See page 67 69 for alternator characteristics Cooling fan Carefully clean and check all blades and inserts Replace the fan even if there is only a single damaged blade or only a single released insert See page 16 for cooling air flow Tighten the fan s fixing screws at a torque of 10 Nm Pulley guard Shroud Side plates Components 1 Pulley guard 2 Shroud 3 Side plates The p...

Page 31: ... hot surfaces Insert the ring gear into its seat and place it carefully on the rim of the flywheel Leave to the ring gear to cool gently before reassembling the flywheel Disassembly Reassembly Shroud support Gear cover plate Loosen screws and remove shroud support very carefully to avoid damage to the oil seal ring When refitting check that gaskets A and oil seal ring B are well inside their housi...

Page 32: ...ctly matches with the journal bore On slow engines which are set to 1 500 1 800 rpm the rocker arms differ from the standard version in the upper part of the lubrication channel Tighten the rocker arm shaft fastening screws to the head at a torque of 25 Nm Compression release optional Bring piston to top dead center on the compression stroke Unscrew rocker arm cover side plug and measure clearance...

Page 33: ...d that the rubber seals of the tappet hose are assembled and inserted correctly into their seats Always replace copper head gasket see page 39 for choosing the right thickness Progressively tighten nuts in the 1 2 3 4 sequence at 55 Nm Injector projection The end of nozzle A should project 3 0 3 5 mm from the cylinder head plane Adjust injector projection by means of copper shims B measuring 0 5 1...

Page 34: ... with the same type of grease insert the valves into the guides rotating them particularly as they enter the sealing ring Valve springs Measure free length with a gauge Using a dynamometer check that the spring length under two dìfferent loads corresponds to the values below Free length A 52 mm Length B compressed by a 210 6 N 35 8 mm Length C compressed by a 340 6 N 25 8 mm Replace spring if leng...

Page 35: ...lve 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 shouid also be increased by 0 5 mm Valve guide insertion Heat cylinder head up to 160 180 C Press guides considering the A and B distances from the head plane Dimensions and clearance between guides and valves with driven guide Disassembly Reassembly Ref Dimensi...

Page 36: ...d tube When refitting cheek that gaskets A and rocker arm lubricatíon tube C are well inside their seats Valve seat grinding After cutting grind valve seats with fine emery paste in oil suspension The sealing surface S should not exceed 2 mm Valve recess after grinding D 0 75 1 25 mm maximum worn limit 1 65 mm CYLINDER Checks and cylinder roughness Fins must be intact Cross hatch pattern must rang...

Page 37: ...In case wear exceeds 0 10 mm bore the cylinder and fit oversize piston and rings In case of less wear replace piston rings only Note Oversize pistons of 0 5 and 1 0 mm are available only for standard and 97 68 CE engines Important The cylinder heads must be tightened with the exhaust or intake manifold mounted to keep them lined up The cylinder and piston must be replaced with a new cylinder and p...

Page 38: ...m Dimensions mm Ref Piston rings Fitting sequence A 1 Chromium plated ring B 2 Torsional internal tapered ring C 3 Oil control ring Important Before fitting the piston into the cylinder stagger the ring gaps at 120 Pistons ringis Clearance between grooves mm Piston rings End gaps mm Place piston rings squarely into the unworn part of the lower cylinder and measure the end gap Piston weight Weigh p...

Page 39: ...Piston clearance Piston clearance 0 65 0 70 mm for standard engines 0 55 0 60 mm for 97 68 CE and EPA engines The piston in the TDC top dead centre position may extend or be short of the upper surface of the cylinder Use a dial indicator to measure the difference between the two sur faces piston crown and upper cylinder surface and use a suitable thickness copper gasket B for the cylinder head to ...

Page 40: ...nnecting rod weight Weigh connecting rods when replacing them in order to avoid unbalance Important The difference in weight should not exceed 10 g Connecting rod alignment Check alignment of small end and big end bearing bores using fitted mandrels axial mis alignment A 0 02 mm maximum limit 0 05 mm Connecting rod small end bushing Dimensions and clearance mm C 25 020 25 030 with machined bushing...

Page 41: ...t N 7271 1460 119 Note To avoid deformation it is not recomended to replace the bearing bushing complete assembly s of bushing and support are availa ble in standard 0 25 mm and 0 50 mm undersize configurations as spare parts When refitting tighten the screws at 30 Nm See page 44 45 for dimensions Crankshaft timing gear Disassembly Use tool 1 Part N 7560 4000 052 and puller 2 Part N 7271 1460 119 ...

Page 42: ...ing compressed air wear eye protection Remove plugs clean duct A with a pointed tool and blow in compressed air Screw plugs again and check for sealing Crankshaft removal To pull out the crankshaft tap lightfy on the timing side end using a copper headed hammer When refitting align center main bearing support so that the locating screw hole coincides with the crankcase hole CRANKSHAFT Center main ...

Page 43: ... bearing inside diameter Use an inside micrometer gauge Disassembly Reassembly Dimensions mm Ref Main journal and crank pin diameter Checking main journals and crank pins Use an outside micrometer gauge Crankshaft journal radius The radius R connecting journals to shoulders is 2 8 3 2 mm Important When grinding external main journals restore the R value to ori ginal specification ...

Page 44: ...9 5 O 0 1 0 6 7 0 9 9 5 7 P 0 2 0 0 6 0 0 0 0 6 Q 5 0 4 2 5 9 3 2 R 0 2 1 3 0 1 1 3 Disassembly Reassembly Limit value mm Clearance mm Ref Clearance between main journals crank pins and connecting rod bearings Main bearíng supports Dimensions 1 Flywheel side 2 Central 3 Gear side Dimensions mm Ref Dimensions mm Ref Main bearing housings Main bearing and connecting rod big end bearing inside diamet...

Page 45: ...journals Clearance mm Limit value mm Dimensions mm Ref Dimensions of camshaft journals and housings Crankshaft end play When refitting crankshaft check end play by means of a thickness gau ge this value should be 0 08 0 38 mm and can be set by changing the thickness of gasket A which is located on the flywheel side main bearings Gaskets with thickness of 0 30 and 0 50 mm can be supplied Important ...

Page 46: ...are at the same height Engage camshaft gear with crankshaft gear CAMSHAFT TIMING Fit camshaft gear by making timing mark 1 coincide with timing mark 2 on the crankshaft timing gear Tighten camshaft boll at 60 Nm Camshaft end play End play should be 0 10 0 25 mm check by means of a dial gauge pushing or pulling camshaft as required How to measure intake exhaust cam height A1 1 st cylinder intake ca...

Page 47: ...oup 1 1P or 2 2P can be installed on the gear side 3rd p t o Valve timing check Check valve timing at the crankshaft The values shown are checked at the flywheel circumference with flywheel of 291 mm diameter each degree corresponds to 2 5 mm Set valve clearance at 0 65 0 70 mm after checking restore the value at 0 15 0 20 mm Set dial gauge on intake valve to a zero value by rotating the driving s...

Page 48: ...ump rack control lever by a linkage Aspring placed under tension by the accelerator control offset the weight centrifugal force Balance between the two forces keeps speed at an almost constant level in spite of load variations See page 62 for timing MECHANICAL SPEED GOVERNOR Weight type governor housed inside the camshaft drive gear Hydraulic pump components 1 P 1 Seal ring 2 Centering ring 3 Coup...

Page 49: ...ing it on the reference pins and make sure that the injection pump rack rod pin is inside lever 1 Fix the plate by using the specific screws for its model Governor springs with rocker arm system The system features two springs anchored to a rocker arm and allows for minimal r p m changes at low speed levels The device is operated automatically when the engine is stopped spring 6 acts on injection ...

Page 50: ...make sure that the plunger has moved In this case you will hear the typical activated magnet sound 3 Feed actuator 6 with a tension of 12V put between the actuator and the 12V a 10 Amp fuse the actuator tension will cause the pump delivery control lever to move to the right 4 By the eccentric screw 3 place and check by sight that the lever in Max position is at the extreme right from this position...

Page 51: ... 51 KD 625 2 Workshop Manual_cod ED0053029380_1 ed_ rev 00 4 Disassembly Reassembly ...

Page 52: ...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 ...

Page 53: ...float not exceeding 0 15 mm Oil pump delivery at 3000 r p m is 9 liters min Lubrication system Components 1 Oil pressure gauge 2 Breather 3 Connecting rod big end bearing 4 Crankshaft main bearing on gear side 5 Cartridge filter 6 Oíl pressure relief valve 7 Oil pump 8 Internal filter 9 Oil fill plug 10 Rocker arm shafts 11 Pushrod protection tube 12 Hydraulic pump gear 13 Camshaft joumal on fiywh...

Page 54: ... element 6 Bypass valve 7 Spring For characteristics see page 17 Disassembly Before removing the oil pressure regulating valve remove the oil filter by using an appropriate wrench Remove the regulating valve using a hammer puller equipped with a M9x1 threaded terminal Reassembly Make sure that the valve seat is free of scratches and scores which could reduce the pressure seal Insert the entire oil...

Page 55: ...urve with engine at full speed The curve is obtained at the oil filter level with engine working at 3000 r p m and max power at 25 C room temperature Pressure is given in bar and temperature in centigrades If the oil pressure value is below the indicated one please check all components indicated on page 52 53 Oil pressure check Once the engine is fitted fill with oil and fuel connect a 10 bar pres...

Page 56: ... feeding tube 3 Fuel filter 4 Fuel lift pump 5 lnjection pump 6 High pressure pipe 7 Injector 8 Injector exhaust pipe Fuel feeding injection circuit with external fuel filter and double solenoid valve Components 1 Fuel tank 2 Solenoid valve 3 Fuel filter 4 Fuel lift pump 5 Solenoid valve 6 lnjection pump 7 High pressure pipe 8 Injector 9 Injector exhaust pipe 10 Non return valve Fuel feeding injec...

Page 57: ... by a camshaft eccentric through a drive rod It features an external lever for manual operation Fuel filter external 1 Air relief valve 2 Support 3 Cartridge 4 Gasket 5 Filtering element For characteristics see page 17 For maintenance see page 22 Fuel feeding injection circuit with external fuel filter and QSD Quick Stop System Components 1 Fuel tank 2 Fuel feeding tube 3 Fuel filter 4 Fuel lift p...

Page 58: ...r 12 Tappet spring 5 Shim 13 Upper retainer 6 Valve spring 14 Lower retainer 7 Delivery valve 15 Tappet 8 Plunger and barrel assembly 16 Tappet roller INJECTION PUMP The injection system consists of a single body pump with plungers featuring constant stroke and feeding one cylinder each The pump mounted on the crankcase is directly operated by the camshaft Speed governor extra fuel and stop device...

Page 59: ... valve assembly How to check plunger and barrel for internal leakage This operation is only indicative since pressure changes depending on the pumping speed Connect the delivery union with a 600 bar pressure gauge with safety valve Adjust rack rod at half stroke Turn flywheel according to its direction of rotation so that the plunger puts the circuit under pressure Replace plunger if the displayed...

Page 60: ... 9 5 500 13 18 3 Test data for injection pump delivery Check only maximum plunger difference by positioning rack rod accor ding to the indicated delivery value How to check injection pump delivery valve sealing Components 1 Valves 2 Seat Adjust pump rack at half stroke Turn flywheel according to its direction of rotation so that the plunger puts the circuit under pressure During this operation the...

Page 61: ...ng them at 35 40 Nm Fit plungers by making reference points E match with the sector gear D points Fix retainers and springs lock tappet with special stop Check that both plungers have the same delivery by performing the necessary measurements at the test bed if delivery is not the same set screw F Tighten screws at 25 Nm Check that rack rod slides smoothly if not the engine may fail to start or hu...

Page 62: ...acer is correctly placed on the intake valve collar 5 Place the auxiliary tank at a higher height than the one of the in jection pump 30 40 cm 6 Connect the tank to the injection pump fuel supply hole 7 Slowly rotate the crankshaft clockwise keeping lever 1 lowered and the valve positioned on the piston crown until the dial indica tor 2 shows the maximum measurement 8 Set the maximum measurement d...

Page 63: ... one indicated in the Table Conversion for establishing advance 2 Advanced Injection Advance add shims under the pump until the detected value corresponds to the one indicated in the Table Conversion for establishing advance Note By removing or adding a 0 1 mm shim under the pump it is possible to advance or delay the injection by about 1 Table Conversion for establishing advance Check values 13 T...

Page 64: ...20 0 22 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 refitting tighten ring nut at 60 Nm INJECTOR Size S Injector only for standard engines Components 1 Intake fitting 2 Nozzle holder 3 Shim 4 Spring 5 Pressure rod 6 Intermediate flange 7 Nozzle 8 Needle valve 9 Fixing flange 10 Taper pin 11 Gasket 12 System duct ...

Page 65: ...ressure for 10 seconds Chek that setting pressure is 210 220 bar for standard engines 245 230 bar for EPA e CE engines make the required adjustments if any by modifying the adjusting shim height When replacing the spring setting should be performed at a 10 bar greater pressure 255 265 bar to allow for bedding during operation Replace nozzle in case of dripping Size P nozzle for 97 68 CE and EPA en...

Page 66: ...gulator 4 Battery 5 Pressure switch 6 Oil pressure warning light 7 Key switch 8 Battery charging light Note Battery which is not supplied by Kohler should feature 12 V voltage and capacity not below 70 Ah Components 1 Alternator 2 Starting motor 3 Battery 4 Key switch 5 Pressure switch 6 Oil pressure warning light 7 Battery charging light Note Battery which is not supplied by Kohler should feature...

Page 67: ...arance between armature wìnding and inductor air gap must b 0 48 0 60 mm Alternator battery charger curve 12 V 18 A This curve is obtained at 25 C with 12 5 V battery voltage Alternator 24 V 6 A Features a fixed armature winding mounted on the air shroud bracket The rotating permanent magnet inductor is located in the fan spindle There are the two yellow cables and one red cable at output Dimensio...

Page 68: ...cides with the casing refe rence line Release slider if no attraction occurs the rotor is demagnetized in this case replace alternator Alternator 12 V 14 A Features a fixed armature winding mounted on the air shroud bracket The rotating permanent magnet inductor is located in the fan spindle There are the two yellow cables and one red cable at output Dimensions mm A 158 80 159 20 B 27 50 27 90 Not...

Page 69: ...ulated from the ground Alternator external 12 V 33 A The alternator is of the claw pole rotor type with built in voltage regu lator The rotating motion is conveyed by the engine through a V belt and sheave Features Rated voltage 12V Max current 33 A at 7000 alternator r p m min RH direction of rotation Tighten the nut 1 at a torque of 70 Nm Alternator battery charger curve external 12 V 33 A The c...

Page 70: ...rt a couple of times until battery voltage drops below 13 V When battery voltage reaches 14 5 V the ammeter current suddenly drops down to almost zero Replace regulator if recharge current is zero with voltage below 14V Caution Warning 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 ...

Page 71: ...V 30 A The voltage regulator is of the bridge type See page 70 for tag dimensions Voltage regulator 12V 26A with W terminal W pole tab Width 4 75 mm Thickness 0 5 mm See page 70 for tag dimensions Voltage regulator 12V 30A with W terminal W pole tab Width 4 75 mm Thickness 0 5 mm See page 70 for tag dimensions ...

Page 72: ... V Motor terminal voltage in Volt P Power in kW C Torque in N m N Motor speed in r p m6 J A Absorbed current in Ampere STARTING MOTOR Important Made by MARELLI and BOSCH Apply to their distributors for any type of repair Bosch starting motor type GIF 12 V 1 7 kW RH direction of rotation A 29 5 31 5 mm B Ring gear plane C Flange plane Caution Warning Flywheel should not project from ring gear plane...

Page 73: ... 31 5 mm B Ring gear plane C Flange plane Caution Warning Flywheel should not project from ring gear plane B Characteristic curves of the 24 V 1 6 kW starting motor The curves have been measured at a 20 C temperature with an 88 Ah battery V Voltage to the motor terminals in Volt P Power in kW C Torque in N m N Motor speed in rpm J A Absorbed current in Amperes ...

Page 74: ...al joint 7 Electromagnet 8 Stop control lever 9 Axial joint 10 Stop control electromagnet support Adjustment Carry out the adjustments by screwing and unscrewing the joints Adjust the device so as to make the electromagnet get to the end of the stroke before the STOP lever reaches its limit stop after perfor ming the operation stroke When the electromagnet is excited put the stop lever at about 1 ...

Page 75: ...g tension 12V Power coil absorption 41 A Hold coil absorption 0 5 A Setting Screw drive rod 1 to the end of the thread on the electromagnet piston Excite the electromagnet and leave the stop lever in normal opera tion position Bring drive rod 1 in contact with the stop lever and tighten lock nut 2 Electric System ...

Page 76: ...ting device C limits the injection pump maximum delivery It also acts as a torque setting device since spring N opposes the resi stence of spring M inside the cylinder through lever L The torque setting device allows lever L to move over stroke H corre sponding to 0 15 0 25 mm This consequently increases injection pump delivery with torque rea ching its peak value Note In generator sets and power ...

Page 77: ...starts decrea sing 7 Lock screw C using a lock nut 8 Carry out the fuel consumption check again 9 Release the dynamometric brake and detect the rotation speed of the stabilized engine maximum idle speed 10 Bring the engine to minimum idle speed Carry out engine setting when the engine is stabilized 11 Switch off the engine and let it cool down 12 Check the valve rocker arm clearance see Setting va...

Page 78: ...ely turn lever C counter clockwise and keep it in this position Retainer F should not be in contact with lever C 2 Unscrew nut G and bring retainer F in contact with lever C 3 Push retainer F so that lever C is moved backwards clockwise by 1 0 mm 4 Lock retainer F by screwing nut G Note In this condition the limit stops of the injection pump adjustment rod will not be damaged by the violent impact...

Page 79: ... 79 KD 625 2 Workshop Manual_cod ED0053029380_1 ed_ rev 00 8 Settings ...

Page 80: ...engine housing AGIP RUSTIA C protective oil up to the maximum level 2 Fill up with fuel containing 10 AGIP RUSTIA NT 3 Start the engine and keep it idle at minimum speed for some minutes 4 Bring the engine to of the maximum speed for 5 10 minutes 5 Turn off the engine 6 Empty out completely the fuel tank 7 Spray SAE 10W on the exhaust and intake manifolds 8 Seal the exhaust and intake ducts to pre...

Page 81: ...check the correct movement and smoothness of the mechanical parts 8 Refill the tank with fresh fuel 9 Make sure that the oil is up to the maximum level 10 Start the engine and after some minutes bring it to of the maximum speed for 5 10 minutes 11 Turn off the engine 12 Remove the oil drain plug see Oil replacement and discharge the AGIP RUSTIA NT protective oil while the engine is hot 13 Pour new...

Page 82: ... Accelerator cover Governor control cover Air conveyor shroud Alternator cable clamp High pressure fuel line clamp Air cleaner Hydraulic pump flange Air conveyor shroud gasket Head injector Camshaft gear Oil pump gear Air conveyor sheet Internal oil filter pierced plate Breather sheet Starting motor Blower hub Nippl radiator Rocker arm shaft Injection pump control lever pivot Speed governor extern...

Page 83: ...25 14x1 5 10x1 5 6x1 0 16x1 5 20x1 5 15 40 55 10 160 300 Loctite 270 Loctite 270 Crankase lubrification plug Oil drain plug Cylinder head Blower Cooling fan hub fixing screw Flywheel Torque specifications and use of sealant POSITION Diam and pitch mm Torque Nm Sealant ...

Page 84: ...25 M 12x1 5 M 14x1 5 M 16x1 5 M 18x1 5 M 18x2 M 20x1 5 M 20x2 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 75 113 163 157 230 218 305 390 575 800 Nm 13 26 24 45 42 70 105 153 147 213 204 287 367 533 750 Nm 17 35 33 59 56 94 141 203 196 288 273 381 488 719 1000 Nm 20 42 39 ...

Page 85: ...052 SPECIAL TOOLS SPECIAL TOOLS DESCIPTION Part N Special tools and equipment for maintenance Valve lowering tool for static injection timing check 1 Spacers h 40mm 2 Dial gauge indicator 3 Dial gauge extension Static timing tool Tool for valve stem O ring assembly Flywheel puller Timing control gear extractor fork ...

Page 86: ... 86 KD 625 2 Workshop Manual_cod ED0053029380_1 ed_ rev 00 ...

Page 87: ... 87 KD 625 2 Workshop Manual_cod ED0053029380_1 ed_ rev 00 ...

Page 88: ... SERVICE INFORMATION IN U S AND CANADA CALL 1 800 544 2444 KohlerEngines com FORM NO ED0053029380 ISSUED 06 07 2012 REVISED 00 DATE 06 07 2012 Translated from the original manual in Italian language Data reported in this issue can be modified at any time by KOHLER ...

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