WORKSHOP MANUAL KD 477-2 REGISTRATION OF MODIFICATIONS TO THE DOCUMENT Any modifications to this document must be registered by the drafting body, by completing the following table. Drafting body CUSE/ATLO Document code Model N° Edition Revision Issue date Review date ED0053029370 51265 1° 0 05/07/2012 05/07/2012 Endorsed KD 477-2 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 materials used by KOHLER to construct the engine's components undergo strict quality controls and the engine's assembly guarantees reliability and long life. The engine has been built to the machine manufacturer's specifications, and it was its responsibility to adopt all the measures needed to meet the essential health and safety requirements as provided for by the laws in force; use of the engine for uses other than the one defined shall not be considered as compliant with the use intended by KOHLER, who therefore refuses all responsibility for any injury arising from such an operation. - 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 financial damage. Written information is accompanied by illustrations in order to facilitate your understanding of every step of the operating phases. -2- KD 477-2 Workshop Manual_cod. ED0053029370_1° ed_ rev. 00 WARRANTY CERTIFICATE 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 first 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 specific 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 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 five (5) years or 3,000 hours, whichever occurs first, 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 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 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 modifications. 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. KD 477-2 Workshop Manual_cod. ED0053029370_1° ed_ rev. 00 -3- INDEX INDEX WARRANTY CERTIFICATE...................................................................................................................................... 3 Limited 3 year kohler ® diesel engine warranty................................................................................................................... 3 California emission control warranty statement.................................................................................................................. 3 Your warranty rights and obligations................................................................................................................................... 3 I - TROUBLE SHOOTING.......................................................................................................................................... 7 Possible causes and trouble shooting................................................................................................................................ 7 II - SAFETY AND WARNING DECALS - SAFETY INSTRUCTIONS........................................................................ 8 Safety regulations................................................................................................................................................................ 8 General safety during operating phases............................................................................................................................. 9 Safety and environmental impact ....................................................................................................................................... 9 III - MODEL NUMBER AND IDENTIFICATION....................................................................................................... 10 The identification plate shown in the figure can be found directly on the engine...............................................................10 Approval data......................................................................................................................................................................10 IV - TECHNICAL DATA........................................................................................................................................... 11 V - CHARACTERISTICS.......................................................................................................................................... 12 Characteristics power, torque and specific fuel consumption curves................................................................................12 VI - OVERALL DIMENSIONS.................................................................................................................................. 13 VII - SPECIAL TOOLS.............................................................................................................................................. 14 VIII - MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING...................................................................... 15 Manutenance......................................................................................................................................................................15 Fuel.....................................................................................................................................................................................15 Recommended oil...............................................................................................................................................................16 Acea sequences.................................................................................................................................................................16 IX - DISASSEMBLY OF THE ENGINE..................................................................................................................... 17 Disassembly and reassembly.............................................................................................................................................17 Flywheel extraction.............................................................................................................................................................17 Crankshaft gear extraction.................................................................................................................................................17 Camshaft gear extraction...................................................................................................................................................17 Oil pressure register valve extraction.................................................................................................................................17 X - CHECKS AND OVERHAUL................................................................................................................................ 18 Cylinder heads....................................................................................................................................................................18 Valves - Guides - Seats......................................................................................................................................................18 Valves and springs............................................................................................................................................................. 20 Rocker arms....................................................................................................................................................................... 20 Cylinders............................................................................................................................................................................ 20 Piston rings - Pistons - Piston pins.....................................................................................................................................21 Connecting rods................................................................................................................................................................. 22 Crankshaft.......................................................................................................................................................................... 23 Checking crankshaft dimensions....................................................................................................................................... 23 Camshaft............................................................................................................................................................................ 24 Injection cam dimensions (fig. 28)..................................................................................................................................... 24 Oil seal rings...................................................................................................................................................................... 24 Tappet checking................................................................................................................................................................. 24 Governor lever and spring................................................................................................................................................. 25 Oil pump checking............................................................................................................................................................. 25 -4- KD 477-2 Workshop Manual_cod. ED0053029370_1° ed_ rev. 00 INDEX XI - INJECTION EQUIPMENT.................................................................................................................................. 26 Fuel circuit.......................................................................................................................................................................... 26 Injection pump................................................................................................................................................................... 26 Checking injection pump................................................................................................................................................... 26 Injection pump setting........................................................................................................................................................ 26 Injection pump assembly................................................................................................................................................... 27 Testing air tightness........................................................................................................................................................... 28 Injectors ............................................................................................................................................................................ 28 Injector checking and setting............................................................................................................................................. 28 XII - ELECTRICAL EQUIPMENT............................................................................................................................. 29 Electric starting with motor and alternator for battery re-charging.................................................................................... 29 Circuit checking................................................................................................................................................................. 29 Alternator checking (stator)................................................................................................................................................ 30 Wire checking.................................................................................................................................................................... 30 Method of use.................................................................................................................................................................... 30 Diagram of electric starting wiring system with flywheel alternator ..................................................................................31 Diagram of electric starting wiring system with external alternator ...................................................................................31 XIII - ENGINE ASSEMBLY....................................................................................................................................... 32 Preparation of crankcase................................................................................................................................................... 32 Camshaft preparation........................................................................................................................................................ 32 Crankshaft preparation...................................................................................................................................................... 33 Upper crankcase preparation............................................................................................................................................ 33 Timing cover assembly...................................................................................................................................................... 34 Fitting of oil seal rings........................................................................................................................................................ 35 Oil pump assembly............................................................................................................................................................ 35 Feeding pump assembly.................................................................................................................................................... 36 Piston-connection rod couplings....................................................................................................................................... 36 Connecting rod-crankshaft coupling................................................................................................................................. 36 Piston ring fitting................................................................................................................................................................ 37 Piston ring working position............................................................................................................................................... 37 Protective cap fitting.......................................................................................................................................................... 37 Cylinder mounting.............................................................................................................................................................. 37 Cylinder height adjustement.............................................................................................................................................. 38 Checking valve head face depth....................................................................................................................................... 38 Checking injector protrusion.............................................................................................................................................. 38 Fitting cylinder heads......................................................................................................................................................... 39 Valve clearance................................................................................................................................................................. 39 Injection pump fitting.......................................................................................................................................................... 40 Injection pump tie rod connection...................................................................................................................................... 40 Checking T.D.C.................................................................................................................................................................. 40 Checking start of injection..................................................................................................................................................41 XIV - ENGINE TESTING........................................................................................................................................... 42 Speed adjustment...............................................................................................................................................................42 Checking oil pressure.........................................................................................................................................................42 Checking for oil leaks..........................................................................................................................................................42 Testing engine on brake..................................................................................................................................................... 43 Running-in table................................................................................................................................................................. 43 XV - STORAGE........................................................................................................................................................ 44 Storage.............................................................................................................................................................................. 44 How to prepare the engine for operation........................................................................................................................... 44 KD 477-2 Workshop Manual_cod. ED0053029370_1° ed_ rev. 00 -5- INDEX XVI - QUICK REFERENCE CHARTS...................................................................................................................... 45 Couplings........................................................................................................................................................................... 45 Adjustments....................................................................................................................................................................... 45 End floats........................................................................................................................................................................... 45 Tightening torques............................................................................................................................................................. 46 Standard screw tightening torques.................................................................................................................................... 46 -6- KD 477-2 Workshop Manual_cod. ED0053029370_1° ed_ rev. 00 TROUBLE SHOOTING I POSSIBLE CAUSES AND TROUBLE SHOOTING 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. SETTINGS/REPAIRS MAINTE- ELECTRIC LUBRICATION NANCE SYSTEM FUEL CIRCUIT Oil and fuel dripping from exhaust Excessive oil consumption Increase oil level Too low oil pressure White smoke Black smoke Non-uniform speed No acceleration Engine starts but stops POSSIBLE CAUSE Engine does not start TROUBLE Clogged pipes Clogged fuel filter Air inside fuel circuit Clogged tank breather hole Faulty fuel pump Injector jammed Jammed injection pump delivery valve Wrong injector setting Excessive plunger blow-by Jammed injection pump delivery control Wrong injection pump setting Oil level too high Jammed pressure relief valve Worn oil pump Air inside oil suction pipe Faulty pressure gauge or switch Clogged oil suction pipe Battery discharged Wrong or inefficient cable connection Defective ignition switch Defective starter motor Clogged air filter Excessive idle operation Incomplete running-in Engine overloaded Advanced injection Delayed injection Incorrect governor linkage adjustment Broken or loose governor spring Idle speed too low Worn or jammed piston rings Worn or scored cylinders Worn valve guides Jammed valves Worn bearings Governor linkage not free to slide Drive shaft not free to slide Damaged cylinder head gasket KD 477-2 Workshop Manual_cod. ED0053029370_1° ed_ rev. 00 -7- II SAFETY AND WARNING DECALS - SAFETY INSTRUCTIONS SAFETY REGULATIONS 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 specifications of a machine manufacturer, and it is his responsibility to ensure that all necessary action is taken to meet the essential and legally prescribed health and safety requirements. Any use of the machine other than that described cannot be considered as complying with its intended purpose as specified 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 specifically 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 flow 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 specifications, 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 flammable materials, explosive atmospheres or easily combustible powders, unless adequate and specific precautions have been taken and are clearly stated and certified for the machine. . To prevent the risk of fire, keep the machine at a distance of at least one metre from buildings or other machines. -8- . 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 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 first the kerosene and then the diesel fuel. Consult Kohler technical office for mixture proportions. Petrol may not be used because of the risk of it forming flammable 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 filter, check that the oil is disposed of in such a way as not to harm the environment. Any filtering sponges in the oil bath air filter should not be soaked with oil. The cyclone pre-filter cup must not be filled 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 fill 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 specific instructions provided in the engine and/or machine operating manual. Do not use auxiliary starting devices not originally installed on the machine (e.g. Startpilot 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 filter and the oil contained in the oil filter are disposed of in such a way as not to harm the environment. . Close the fuel tank filler cap carefully after each fílling operation. Do not fill the tank right up to the top, but leave sufficient space to allow for any expansion of the fuel. KD 477-2 Workshop Manual_cod. ED0053029370_1° ed_ rev. 00 SAFETY AND WARNING DECALS - SAFETY INSTRUCTIONS II . Do not smoke or use naked flames while filling. . Take care when removing the oil filter as it may be hot. . The operations of checking, filling 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 fitted for this purpose by Kohler. These lifting points are however not suitable for the entire machine, so in this case use the eyebolts fitted by the manufacturer. 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 fingers to carry out this operation to avoid the risk of amputation. – 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 flammable 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. SAFETY AND ENVIRONMENTAL IMPACT Every organisation has a duty to implement procedures to identify, assess and monitor the influence of its own activities (products, services, etc.) on the environment. Procedures for identifying the extent of the impact on the environment must consider the following factors: - - - - - - 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. Liquid waste; - Keep the fuel and engine control systems and the exhaust Waste management; pipes in efficient working order to limit environmental and noise Soil contamination; pollution. Atmospheric emissions; - When discontinuing use of the engine, select all components Use of raw materials and natural resources; according to their chemical characteristics and dispose of them Regulations and directives regarding environmental impact. separately. California Proposition 65 WARNING Engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. KD 477-2 Workshop Manual_cod. ED0053029370_1° ed_ rev. 00 -9- III MODEL NUMBER AND IDENTIFICATION The identification 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). A D B E C F - 10 - KD 477-2 Workshop Manual_cod. ED0053029370_1° ed_ rev. 00 TECHNICAL DATA IV CHARACTERISTICS ENGINE TYPE KD 477-2 Number of cylinders N. Bore mm Stroke mm Swept volume cm³ Compression ratio @ 3000 RPM N 80/1269/CEE-ISO 1585 @ 3600 RPM @ 3000 RPM Power kW (HP) NB ISO 3046 - 1 IFN @ 3600 RPM @ 3000 RPM NA ISO 3046 - 1 ICXN @ 3600 RPM Max. torque * Nm Fuel consumption ** g/kW.h Oil consumption g/kW.h Capacity of standard oil sump lt Recommended battery 12V Ah -A Dry weight kg Combustion air volume m³/h Cooling air volume m³/h Max.permissible driving shaft axial: continuous (instantaneous) kg. Flywheel site: continuous (instantaneous) Max. inclination Power take off site: continuous (instantaneous) Lateral: continuous (instantaneous) 2 90 75 954 19:1 15(20,5) 17(23) 14(19) 15,7(21,4) 12,9(17,6) 14,5(19,8) [email protected] 236 0,8 3 66-300 78 90 950 100(350) 25°(35°) 25°(40°) 25°(40°) * ** Referred to N power Consumption at max torque KD 477-2 Workshop Manual_cod. ED0053029370_1° ed_ rev. 00 - 11 - V CHARACTERISTICS CHARACTERISTICS POWER, TORQUE AND SPECIFIC FUEL CONSUMPTION CURVES KD 477-2 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. Mt-N Torque at N power. C Specific fuel consumption at N power. U1: Standard utilization range of engines rated at 3000 rpm U2: Standard utilization range of engines rated at 3600 rpm 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 tolerance is 5%. Power decreases by approximately 1% every 100 m di altitude and by 2% every 5°C above 25°C. Note: Consult Kohler for power, torque curves and specific consumptions at rates differing from those given above. - 12 - KD 477-2 Workshop Manual_cod. ED0053029370_1° ed_ rev. 00 OVERALL DIMENSIONS VI Note: Dimensions in mm KD 477-2 Workshop Manual_cod. ED0053029370_1° ed_ rev. 00 - 13 - VII SPECIAL TOOLS TOOL - 14 - CODE DESCRIPTION 00365R0010 Extractor 00365R0940 Injection advance control tool 00365R0020 Flywheel extractor 00365R0040 Oil seal insertion tool 00365R0260 Oil seal protection cone 00365R0210 Injection pump spanner 00365R0450 Valve guide gauge Ø 7 mm (0.27 inch.) 00365R0850 Valve guide grinder Ø 7 mm (0.27 inch.) 00365R0540 Tool for valve seat 00365R0500 00365R0510 Cutter Ø 38 mm (1.50 inch.) Cutter Ø 40 mm (1.57 inch.) 00365R0430 Injector test bench 00365R0100 Bearing extractor 00365R0770 Cylinder collar Ø 80=85 mm (3.15=3.35 inch.) 00365R0880 Valve extractor KD 477-2 Workshop Manual_cod. ED0053029370_1° ed_ rev. 00 MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING VIII Failure to carry out the operations described in the table may lead to technical damage to the machine and/ or system MANUTENANCE OPERATION CLEANING CHECK REPLACEMENT OVERALL INSPECTION (*) (**) (***) (x) (xx) COMPONENT OIL-BATH AIR CLEANER HEAD AND CYLINDER FINS FUEL TANK INJECTOR AIR CLEANER OIL LEVEL OIL SUMP BATTERY FLUID VALVE/ROCKER ARM CLEARANCE INJECTOR SETTING AIR CLEANER OIL SUMP EXTERNAL OIL FILTER CARTRIDGE FUEL FILTER CARTRIDGE DRY AIR CLEANER CARTRIDGE PARTIAL COMPLETE INTERVAL (HOURS) 8 50 200 300 500 2500 5000 (*) (*) (**)(***) (x) (xx) First replacement Under severe working conditions, clean daily. Under extremely dusty conditions, change every 4-5 hours. See recommended oil type. The partial overhaul includes the following operations: valve and seat lapping, injector and injection pump overhaul, injector projection check, fuel injection spark advance check, check of the harmful area between head and piston, camshaft and crankshaft end float check, tightening of bolts. The general overhaul includes - in addition to all partial overhaul - the following procedures: cylinder and piston replacement, seat, guide and valve refacing, crankshaft replacement or grinding, bench bearing and connecting rod replacement. The maintenance operations listed above refer to an engine operating in normal conditions (temperature, degree of humidity, dust in the working environment). They may vary significantly according to the type of use. To avoid explosions or fire outbreaks, do not smoke or use naked flames 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. FUEL When refuelling, it is advisable to use a funnel to prevent fuel from spilling out. The fuel should also be filtered to prevent dust or dirt from entering the tank. Use the same type of diesel fuel as used in cars. Use of other types of fuel could damage the engine. The cetane rating of the fuel must be higher than 45 to prevent difficult starting. Do not use dirty diesel fuel or mixtures of diesel fuel and water since this would cause serious engine faults. The capacity of the standard tank is: lt. 7.0 KD 477-2 Workshop Manual_cod. ED0053029370_1° ed_ rev. 00 - 15 - VIII MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING The engine could be damaged if allowed to operate with insufficient oil. It is also dangerous to add too much oil as its combustion could sharply increase the rotation speed. Use a suitable oil in order to protect the engine. The lubrication oil influences the performances and life of the engine in an incredible way. The risk of piston seizure, jammed piston rings and rapid wear of the cylinder liner, the bearings and all moving parts increases if oil whose characteristics differ from the recommended type is used, or if the oil is not regularly changed. All this notably reduces engine life. Oil viscosity must suit the ambient temperature in which the engine operates. Old 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 inevitable, you are advised to thoroughly wash your hands with soap and water as soon as possible. Appropriate protective gloves etc should be wore during this operation. Old oil is highly polluting and must be disposed of in the correct way. Do not litter. GRADE RECOMMENDED OIL AGIP SINT 2000 5W40 specification API SJ/CF ACEA A3-96 B396 MIL-L-46152 D/E. ESSO ULTRA 10W40 specification API SJ/CF ACEA A3-96 MILL-46152 D/E. In countries where AGIP and ESSO products are not available, use API SJ/CF oil for gasoline-fuelled engines or oil that complies with military specification MIL-L-46152 D/E. - - - - - - - + + + + + + + + + + 40 35 30 25 20 15 10 5 0 5 10 15 20 25 30 35 40 45 50 SAE 10W SAE 20W SAE 30 SAE 40 SAE 10W-30 OIL SUPPLY ( liters ) Standard oil sump filter included SAE 10W-40 SAE 10W-60 3.0 l. SAE 15W-40 base minerale SAE 15W-40 base semi-sintetica SAE 20W-60 base semi-sintetica SAE 5W-30 base sintetica SAE 5W-40 base sintetica SAE 0W-30 base sintetica ACEA SEQUENCES A = Gasoline (Petrol) B = Light Diesel fuels E = Heavy Diesel fuels API CF CE CD CC CB CA SA SB SC SD SE SF SG SH SJ Required levels : A1-96 A2-96 A3-96 B1-96 B2-96 B3-96 E1-96 E2-96 E3-96 BENZINA - ESSENCE - PETROL BENZIN - GASOLINA DIESEL D- 4 D- 5 CCMC G- 2 CCMC G- 3 CCMC PD - 1 / PD - 2 CCMC D- 2 CCMC D- 3 G- 4 G- 5 MIL - L - 2104 D MIL - L - 2104 E MIL - L -46152 C MIL - L- 46152 D/E 228.3 MB 228.1 VW 505.00 MB 226.1 MB 227.1 MB 226.5 MB 227.5 VW 500.00 VW 501.01 VOLVO VDS MAN QC 13-017 - 16 - KD 477-2 Workshop Manual_cod. ED0053029370_1° ed_ rev. 00 IX DISASSEMBLY OF THE ENGINE During repair operations, when using compressed air, wear eye protection. DISASSEMBLY AND REASSEMBLY Besides disassembly and reassembly operations this chapter also includes checking and setting specifications, dimensions, repair and operating instructions. Always use original Kohler spare parts for repair operations. 1 Flywheel extraction Use extractor cod. 00365R0020, as shown in figure 1. During the demounting phases, pay particular attention to prevent the flywheel from dropping as this could seriously injure the operator. Wear protective goggles when removing the flywheel ring. IMPORTANT: Do not tap the end of the extractor when removing the flywheel. 2 Crankshaft gear extraction Use extractor cod. 00365R0010 and cod. 00365R0100 (fig. 2). Camshaft gear extraction Use extractor cod. 00365R0010 (fig. 3). 3 Oil pressure register valve extraction Use extractor cod. 00365R0880 (fig. 4). 4 KD 477-2 Workshop Manual_cod. ED0053029370_1° ed_ rev. 00 - 17 - IX CHECKS AND OVERHAUL Cylinder heads Details of fig. 5: 1. Cylinder head - 2. Pipe - 3. O-Ring - 4. Rockerarms - 5. Rockers 6. Cotters - 7. Plates - 8. Springs - 9. Guides - 10. Seats - 11. Valves - 12. Tappets - 13. Camshaft. The heads are of aluminium with inserted guides and valve seats in cast iron. Make sure there are no cracks or imperfections. Should it be so, replace according to the instructions given in the spare parts catalogue. Never remove head while still hot in order to avoid deformation. 5 Valves - Guides - Seats Clean the valves with a wire brush and renew them if the valve heads are deformed, cracked or worn. Check clearance between valve and guide with a micrometer on stem B (fig. 7) and with a go/no go gauge as shown in fig. 6 (tool cod. 00365R0450). Change the guide if the maximum gauge diameter passes through it, as it has passed the maximum permissible wear. After having fitted the new guide, check exact diameter using the “go” end of the gauge and if necessary grind it to the dimensions indicated in the table using the adjustable grinder (tool cod. 00365R0850). 6 Engine KD 477-2 Ø Guide mm Guide Inlet Outlet 7,000 ÷ 7,010 Ø Gauge mm go no go 7,000 7,079 Fitting of new guides always requires grinding of the valve seats (see page 19). Valve guides with an external diameter increased by 0.10 mm are available. If the inlet clearance between valve and guide is lower than 0.08 mm and the outlet clearance is lower than, 0.10 mm, the wear on B is less than 0.03 mm and A is more than 0.05 mm, recondition the valve by grinding face P to 45° (fig. 7). As a result of prolonged engine operation, the hammering of the valves on their seats at high temperature causes the face of the seats to harden and hand grinding is made difficult. It is thus necessary to remove the hardened surface with a 45° cutter mounted on a valve seat grinding tool (fig. 8). Final fitting can then be carried out manually with the cutters listed below. 7 Cut dimensions for valve seats Engine KD 477-2 Inlet Outlet Ø guide AxB Ø guide AxB 40 x 12 mm 7 mm 38 x 12 mm 7 mm 8 - 18 - KD 477-2 Workshop Manual_cod. ED0053029370_1° ed_ rev. 00 CHECKS AND OVERHAUL X Cutting of the valve seats involves the widening of the valve seat face P with a consequent reduction of seal of the valve itself, fig. 9 If face P is more than 2 mm wide, invert cutter and lower level Q of the seat, fig. 10, so as to restore the P level to the value of: 9 Fitting mm Max. wear mm 0,7 ÷ 1,2 2 Final lapping of the valve on the seat must be carried out by coating the seat with a fire grinding paste and rotating the valve backwards and forwards with a slight pressure until a perfect finish to the surface is obtained (fig. 11). Make sure the face of the valve head in relation to the face of the cylinder head is: Fitting mm Max. wear mm 0,9 ÷ 1,1 1,8 If the distance is less, the valve will strike the piston. If the distance is more than 1.8 mm the valve seat rings need to be changed. Fitting of new valves or seats always requires grinding. Valve seats with an external diameter increased by 0.2 mm, are available. 10 After grinding, wash valve and seat carefully with petrol or paraffin to eliminate any residual grinding paste or cuttings. To check the worthiness of the seal between valve and seat, after grinding has taken place, proceed as follows: 1. Fit valve on head with spring, plates and cotters (see fig. 5). 2.Invert head and pour a few drops of diesel or oil round the outside of the valve head. 3.Blow compressed air into the inlet of the cylinder head, taking care to seal the edges so that the air does not escape (fig. 12). 11 Should air bubbles form between the seat and the valve, remove the valve and regrind the seat. The fit can also be checked by pushing the valve upwards and letting it fall freely down onto its seat. If the resulting bounce is considerable and uniform, also when the valve is rotated, it means that the fit is good. If not, continue grinding until the conditions described above are achieved. 12 KD 477-2 Workshop Manual_cod. ED0053029370_1° ed_ rev. 00 - 19 - X CHECKS AND OVERHAUL Valves and springs In order to check the springs for possible failure measure the lengths under load as shown in figure 13. The permissible tolerance for loads and lengths is ± 10%. If the figures measured do not fall within these values, the springs must be renewed. 13 Rocker arms Make sure that the facing surfaces between rocker and pin are not scored and show no signs of seizure. If such marks are encountered, renew rocker and pin. Rocker / pin clearance (fig.14): Fitting mm Max. wear mm 0,030 ÷ 0,056 0,15 Rocker axial play (fig.14): 0,10 ÷ 0,50 14 Cylinders Air cooled with cylinder barrels in special cast iron with integral liners. Use a dial gauge to check internal diameters (C-D) at three different heights (fig.15). Maximum permitted taper (A-B) and ovality (C-D) is 0.06mm. Diameter of cylinders (fig.15): KD477-2 15 Ø 90 ÷ 90,015 If the diameter of the cylinder does not exceed said values or if there are slight surface scores on the cylinder, it will be sufficient to change the piston rings. Do not manually hone the cylinder bore surfaces with emery cloth or other means. The cross-hatch pattern should be at an angle of 90°÷120°; lines should be uniform and clear in both directions (fig. 16). Average roughness must range between 0.5 mm 1 µm. The cylinder surface which comes into contact with piston rings should be machined with the plateau method. If the taper and ovality of the cylinder exceed the values indicated, then the cylinder and piston must be renewed. 16 - 20 - KD 477-2 Workshop Manual_cod. ED0053029370_1° ed_ rev. 00 X CHECKS AND OVERHAUL Piston rings - Pistons - Piston pins Check the wear of piston rings by fitting them into the cylinder through the lower end and measuring the end gap (fig.17). The values should be: 17 Piston ring Fitting mm Max. wear mm Compression 0,30 ÷ 0,50 0,80 Oil scrapper 0,25 ÷ 0,50 0,80 Check that the rings move freely in the grooves and check the ring/ groove clearance using a feeler gauge (fig.18). If the clearance exceeds the values shown in the table, renew the piston and the piston rings. Piston ring Max. wear mm 1st Compression A = 0,22 2 - 3 Compression B -C= 0,18 4 Oil scrapper D = 0,16 nd rd th Piston rings must always be renewed after dismantling the piston. 18 Piston diameter check: The diameter of the piston must be measured at approximately 18 mm from the base (fig.19). Engine KD477-2 Diameter mm 89,919 ÷ 89,930 Check the clearance between cylinder and piston, if it is greater than 0.120 mm both cylinder and piston must be replaced. Assembly clearance between piston pin and piston in millimetres: 19 KD 477-2 Workshop Manual_cod. ED0053029370_1° ed_ rev. 00 Fitting mm Max. wear mm 0,001 ÷ 0,010 0,060 - 21 - X CHECKS AND OVERHAUL Connecting rods On the small end there is a groove (A, fig. 20) for the lubrication of the gudgeon pin. The small end and the gudgeon pin are coupled without a bush in between. Assembly clearance between connecting rod small end and piston pin in millimetres: Engine KD 477-2 Ø Piston pin mm Assy. clearance mm Max wear mm 21,997 ÷ 22,002 0,023 ÷ 0,038 0,070 20 If it is necessary to replace a complete connecting rod with bushes and bolts, make sure its weight is: Engine KD 477-2 Weight gr. 570 ± 10 21 Check parallelism between connecting rod axies (fig. 21) as follows: 1.Insert the gudgeon pin into the small end bush and a calibrated pin into the big end (with bearing fitted). 2.Place the ends of the pin on 2 prisms set out on a checking bench. 3.Check with a comparator gauge that the discrepancy in the readings at the two ends of the gudgeon pin is not more than 0.05 mm. Should the distortion exceed this value (max 0.10 mm), reset connecting rod as follows: Place connecting rod stem on checking bench and apply a calibrated pressure to the convex side of the stem (fig. 22). 22 - 22 - KD 477-2 Workshop Manual_cod. ED0053029370_1° ed_ rev. 00 X CHECKS AND OVERHAUL Crankshaft Whenever the engine is dismantled, particularly for the replacement of cylinders and pistons due to wear caused by the aspiration of dust, it is good practice to check the condition of the crankshaft. 1.Remove the plugs “A” from the oil passages (fig.23). 2.Use an appropriately shaped steel punch to clean the inside of the oil passages and the collection traps. If the deposits are particularly resistant, immerse the whole crankshaft in petrol or paraffin before proceeding with the operations. 23 3.When the oil passages and traps have been throughly cleaned, close the openings with new plugs (fig.24). Checking crankshaft dimensions Once the crankshaft has been thoroughly cleaned, use a micrometer to check the wear and ovality of the main journals and crank journals across two sections at right angles to each other (fig.25). If wear exceeds 0.08 mm (fig.26) grind the crankshaft to the dimensions shown in the table: STD mm -0,25 mm 45,005 ÷ 45,015 44,755 ÷ 44,765 44,505 ÷ 44,515 44,994 ÷ 45,010 44,744 ÷ 44,760 44,494 ÷ 44,510 Dimensions 24 A B -0,50 mm Undersize bearing bushes are already available at the necessary sizes without requiring any adjustment by boring. 25 Main bearing bushes with increased external diameters are also available. Table indicates the crankcase boring values. Bearing Ø of brush housingmm Standard 47,965 ÷ 47,985 + 1 mm 48,965 ÷ 48,985 During grinding take care not to remove the shim adjustment material from the main journal thrust face to avoid changing the crankshaft end float; also ensure that the grinding wheel radii are as specified in figure 26 so as not to create crack initiation sections on the crankshaft. 26 KD 477-2 Workshop Manual_cod. ED0053029370_1° ed_ rev. 00 - 23 - X CHECKS AND OVERHAUL exhaust inlet Camshaft Check cams and support pins for wear or scores. Check amount of wear by measuring points A and B shown in fig. 27 and 28 and comparing to the figures of the tables hereunder: Distribution cam dimensions (fig. 27). Engine Measurement Fitting mm Max. wear mm KD477-2 A-B 29,95 ÷ 30,00 29,70 27 Injection cam dimensions (fig. 28) Engine Measurement Fitting mm Max. wear mm KD477-2 A 28,39÷ 28,43 28,30 The coupling clearance between pins and respective housings should be: Fitting mm Max. wear mm 0,015 ÷ 0,048 0,100 Renew the camshaft if the cams or journals show wear in excess of 0.1mm. 28 Oil seal rings Make sure the oil seals have not hardened round the internal contact edge with the crankshaft and that they do not show signs of cracks or wear. If they do, replace them with new ones of the same size. Then re-fitting the oil seal, use protective cone cod. 00365R0260. Fit said cone over the ends of the crankshaft to avoid damage to the ring itself. Tappet checking Make sure the tappet surfaces are not worn, lined or present signs of seizure. If so, replace. Tappet and seat check in mm (fig. 29). Measurement Tappet Tappet seat Fitting mm 11,98 ÷ 11,99 12,00 ÷ 12,018 Max .assy.clearance mm 0,10 29 - 24 - KD 477-2 Workshop Manual_cod. ED0053029370_1° ed_ rev. 00 X CHECKS AND OVERHAUL Governor lever and spring Check that the shoes (S, fig. 30) are level and that the springs have not lost their elasticity. Renew any excessively worn parts after consulting the spare parts catalogue. Supplement and governor spring dimensions (fig. 30): Lenght mm Spring Supplement (H) Lenght under load mm Load kg Nr of windings 16,9 ÷ 17,4 35 0,3 18,5 53 69,2 2,5 13 Governor (N) 30 Oil pump checking The pump is of the lobed rotor type driven by the camshaft. Dismantle pump and check rotors. Check lobes and centers and if they are worn, replace rotors. Check the amount of pump wear, measure rotor A and rotor B (see fig. 31), and compare to the following table: 31 Measurement Dimensions mm Max. wear mm C 29,745 ÷ 29,770 29,700 D 40,551 ÷ 40,576 40,45 E 30,030 ÷ 30,60 30,10 F 17,920 ÷ 17,940 17,89 If wear exceed these figures, replace complete pump. The coupling clearance between oil pump external rotor and basement housing is: Fitting mm 0,094 ÷ 0,144 Max. wear mm 0,294 The axial clearance of the rotors (fig. 32) should be between: Fitting mm 0,010 ÷ 0,050 Max. wear mm 0,100 32 KD 477-2 Workshop Manual_cod. ED0053029370_1° ed_ rev. 00 - 25 - XI INJECTION EQUIPMENT Fuel circuit Feeding is carried out by a diaphram pump actuated by a camshaft eccentric coupled to a cap. See assembly on page 36 and consult spare parts catalogue for replacement. Details of fig. 33: 1.Tank - 2.Diesel filter - 3.Feeding pump - 4.Injection pump - 5.Injection pipes - 6.Injectors - 7.Diesel discharge pipe. Injection pump The injection pump is of the single casing type with two, constant stroke, separate pumping elements. Details of fig. 34. 1.Pump casing - 2.Pumping element - 3.Rack bar - 4.Eccentric dowel - 5.Adjusting bushing - 6.Spring - 7.Lower plate - 8.Tappet - 9.Upper plate - 10.Locking pin - 11.13.18.Gaskets - 12.Diesel intake connection - 14.Diesel exhaust screw - 15.Delivery valve - 16.O-ring 17.Valve spring - 19.Delivery connection. Checking injection pump Before dismantling injection pump check pressure seal of the pumping unit, cylinder and valve as follows: 33 1.Connect a pressure gauge graded up to 600 kg/cm² (fig. 35) to the diesel delivery pipe. 2.Set the rack bar in a half way position. 3.Rotate flywheel showly until the pumping element has completed a compression stroke. If the test is carried out on the bench, take care that the pumping element does not strike the delivery valve while pumping. 34 4.Take the pressure gauge reading. If the reading is less than 300 kg/cm² , the complete pumping unit must be replaced. During the test, the reading on the gauge will show a progressive pressure increase to a maximum value and will then fall suddenly and stop at a lower pressure. Replace valve if the fall in pressure exceeds 50 kg/cm² and continues to fall slowly. Injection pump setting Register eccentric dowel to the maximum capacity of the pumping elements (q, fig. 39). 35 - 26 - KD 477-2 Workshop Manual_cod. ED0053029370_1° ed_ rev. 00 INJECTION EQUIPMENT XI The quantity of diesel is in relation to 1000 deliveries with the rack bar at 8 mm from the stop position. Engine KD477-2 Ø Pumping element mm cc valve Valve Ø mm Capacity cc Pump RPM 6 15 4 24 ÷ 26 1500 36 Injection pump assembly After having dismantled the injection pump it should be reassembled in the following manner: 1.Insert cylinders into pump casing with diesel inlet opposite to feeding inlet connection (fig. 36). This position is necessary due to two eccentric dowels on the pump casing. Make sure the supporting faces of the cylinders and pumps are free of dirt. 2.Fix cylinders by inserting valves and temporarily tightening the delivery connections to stop the pumping elements from coming out. (fig. 37). 37 3.Insert rack bar and lock in a half way position (fig. 38). Make sure the bar moves freely on the guides. Resistance and drag will cause the engine to run unevenly. 4.Marks b cut on the bar must coincide with marks a of the toothed quadrants. Marks c on toothed quadrants must coincide with marks d on the flanges of the piston (fig. 39). 5.Insert piston into cylinder with groove turned towards the eccentric dowel on the pump casing. 6.Complete assembly of pump. IMPORTANT: The roller tappets (No 8 fig. 34) and the lower plates are not interchangeable as they determine the timing of the pumping elements. When replacing parts make sure that: 38 a.the distance between the injection cam in bottom dead centre position (PMI) and the pump supporting surface is 82.6 to 83 mm as stated on the plate. b.the piston stroke from the bottom dead centre position (PMI) of the injection cam to delivery commencement is 2.0 to 2.1 mm. 7.Check pressure seal again, as described in paragraph "Checking injection pump" page 26, to make sure the replaced parts are working properly. 39 KD 477-2 Workshop Manual_cod. ED0053029370_1° ed_ rev. 00 - 27 - XI INJECTION EQUIPMENT Testing air tightness Feed pressurized air at 6 kg/cm² into the fuel sullpy union and completely immerse the pump in oil or diesel fuel for about 20 ÷ 30 seconds (fig.40); check that no air bubbles are released. N.B.: Tightness can be checked by compressing the springs to 52.8 ÷ 54.4 mm, which corresponds to the bottom dead centre working position of the pump. 40 Injectors (fig. 41) 1.Body - 2.Nozzle - 3.Ring nut - 4.Plate - 5.Rod - 6.Spring 7.Adjustment shim. 41 Injector checking and setting 1.Clean out nozzle holes with a thin piece of wire (fig. 42) of the same size as that of the nozzle holes indicated on the table: Ø holes mm Engine KD477-2 0,25 2.Set up injector on a test bench (tool cod. 00365R0430). 42 3.Unscrew injector lock coupling (No 3 fig. 41) or nozzle ring nut and insert adjustment shim (7, fig. 41) until the pressure indicated in the table hereunder is reached on the pressure gauge while pumping. Engine Setting kg/cm2 KD477-2 225 ÷ 235 4.Tighten the nozzle ring nut (No 3 fig. 41) at: 5 kgm (49 Nm) 43 - 28 - 5.When setting is complete, while still at the test bench, run pumping elements a few times and check the amount of diesel that passes through the upper leak-off of the injector (fig. 43). KD 477-2 Workshop Manual_cod. ED0053029370_1° ed_ rev. 00 ELECTRICAL EQUIPMENT XII Electric starting with motor and alternator for battery re-charging Characteristics Starter motor: anticlockwise rotation. 12V - 1.5 HP (1.1 kW) Flywheel alternator: For re-charging 12V/280W batteries giving 17A charge at 3000 RPM. Regulator: Electronic with controlled diodes and preset for battery re-charging pilot light connection. 12V-24A Optional external alternator with belt control: For re-charging 12V/200W batteries giving 15.5A charge at 6000 RPM with 12V/26A voltage adjustor. Battery: 12V; 80 to 90 Ah To check starting system circuit see figures 47. 44 Circuit checking 1.Make sure the connections between regulator and alternator are correct and in good condition. 2.Detach from the terminal on the starter motor, the red wire coming from the alternator, and insert a direct current ammeter with a 20 Amp range between said free terminal and the detached wire. 3.Connect a direct current voltmeter with a minimum range of 15 Volts (fig. 44), to the battery terminals. 4.Insert starter key and start up a few times at no load or insert a lamp load of 80 to 100 W at the ends of the battery to keep the battery voltage under 13 Volts. 5.Run the engine up to the maximum of 3000 RPM. The charging current reading on the ammeter should be about: 17A with 12V/280W alternator For intermediate values see fig. 46. 6.Disconnect lamp load and keep engine running at A/m revs. for some time. The battery voltage will increase progressively until it reaches the setting limit of the regulator which is about 14.5 V. Simultaneously, the charging current will drop to about 2A. This will occur very quickly if the battery is charged and slowly if it is discharged. 7.If the charging current cuts out or is lower than the values given above, replace governor. If the performance does not improve after this replacement, the trouble must be locked for in the alternator. KD 477-2 Workshop Manual_cod. ED0053029370_1° ed_ rev. 00 - 29 - XII INJECTION EQUIPMENT Alternator checking (stator) Disconnect alternator cables from the regulator and check continuity between the windings with an Ohmmeter. Also check that there is good insulation between cables and earth (fig. 45). In the event of an open circuit, replace the stator. If the stator is in good working order but the values of the alternator charge are lower than those stated, the rotor is demagnetised and the entire alternator must be replaced. Insulation Continuity 45 Wire checking Examine condition of wires bearing the following in mind: 46 1.With one of the yellow wires open circuited, the alternator will not supply current. 2.With both yellow wires open circuited, the alternator will not supply current at all. 3.With one or both wires earthed, the rotor will demagnitize very quickly and the coils of the stator will burn out. 4.With red wire open circuited, the alternator will not supply current. 5.With red wire earthed the alternator will not supply current, the connection wires and warning circuit will burn out and the battery will discharge completely. 6.Avoid sparks between cables, as the alternator could burn out. 7.With an imperfect earth between the negative battery terminal and regulator casing, the charging current is irregular and the regulator could be damaged. 8.If the battery connections are inverted, the alternator and regulator will burn immediately. Method of use By turning the starter key to the first position, the battery charging circuit is started off, and thus: 47 1.With engine stationary the key must be kept on the off position. If it is left on the first position, the oil warning light could burn out, the battery could discharge and the regulator could be damaged. 2.With engine running turn key to first position. If it is left in the off position, the oil warning light and battery charging functions are excluded. The voltage regulator will be damaged beyond repair, if it is run with the battery cables disconnected or with unactivated batteries. - 30 - KD 477-2 Workshop Manual_cod. ED0053029370_1° ed_ rev. 00 ELECTRICAL EQUIPMENT XII Diagram of electric starting wiring system with flywheel alternator (fig. 47). 1.Battery - 2.Regulator - 3.Alternator - 4.Starter motor - 5.Pressure gauge - 6.Oil pressure warning light - 7.Starter key - 8.Battery charging light. Diagram of electric starting wiring system with external alternator (fig. 48). 1.Battery - 2.Regulator - 3.Alternator - 4.Starter motor - 5.Pressure gauge - 6.Oil pressure warning light - 7.Starter key - 8.Battery charging light. 48 KD 477-2 Workshop Manual_cod. ED0053029370_1° ed_ rev. 00 - 31 - XII ENGINE ASSEMBLY Notice: These instructions are valid for engines up-dated prior to the publication of this manual. Any modifications must be checked on the technical circulars. Before assembling the engine carefully clean all parts and dry them with compressed air. Lubricate moving parts to prevent seizing when starting up. Replace the gaskets with new ones each time the engine is assembled. Use torque wrenches to ensure that the correct tightening torques are applied. 49 Preparation of crankcase Clean support faces and remove seal residue and dirt with a copper plate or a fine emery stone to avoid damage to the contact surfaces (fig. 49). Lower crankcase (fig. 50) 1.Insert plugs (A) into relative seats. 2.Screw in oil filter cartridge connection (B). The connection should protude 11 to 13 mm. from the crankcase. 3.Insert complete oil pressure register valve into its seat (C). Make sure the seat of the valve ball in the casing is free of dirt or scores which could jeopardize the pressure seal. 4.Insert cylinder studs and centering pins. 50 51 Camshaft preparation To prepare the camshaft unit (fig. 51) proceed as follows: 1.Insert shim adjustment washer (No 3) and governor plate (No 4) on camshaft. 2.Fit snap ring (No 5) and tab (No 7) into respective housings. 3.Heat gear (No 6) complete with masses and insert onto camshaft making sure it rests against the locking snap ring. 4.Insert governor plate locking ring (No 2). The speed governor is of the centrifugal mass type splined directly onto the ends of the camshaft gear (fig. 52). Masses (A), pushed outwards by the centrifugal force, shift mobile plate (P) axially. Said plate actions lever (R) connected to injection pump rack bar (E) by means of tie rod (T). A spring (N) placed under tension by the accelerator (C), contrasts the action of the centrifugal force of the governor. The balance between the two forces keeps the revolutions practically constant when load is changed. For pre-load adjustment of the speed governor see paragraph on page 40 "Injection pump tie rod connection". 52 - 32 - KD 477-2 Workshop Manual_cod. ED0053029370_1° ed_ rev. 00 ENGINE ASSEMBLY XIII Crankshaft preparation The insertion of the main distribution gear onto the crankshaft must be carried out while hot. Heat by means of dry heating or an oil bath at 70/80 °C (fig. 53). 53 Upper crankcase preparation 1.Insert accelerator internal lever onto crankcase taking care not to damage the oil seal O-Ring. 2.Fit interchangeable tappets into housings on crankcase. 3.Camshaft assembly (fig. 54): in order to assemble the shaft correctly, the cams must be introduced, without applying force, along the grooves inside the crankcase. 54 4.Mount governor lever and insert lever fulcrum pin taking care not to damage the oil seal rings (fig. 55). The lever should be able to effect the complete stroke without strain. Insert spring between governor lever and accelerator. 5.Insert main bearings into respective housings and spread with oil slightly. The three main bearings are identical and interchangeable. 6.Fit rubber gaskets and O-Rings between crankcases taking care to insert same properly into respective grooves so as to prevent oil leaks between the contact surfaces (fig. 56). 55 It is advisable to spread a bit of rubber adhesive round the edges of the rubber gasket for better seal. 56 KD 477-2 Workshop Manual_cod. ED0053029370_1° ed_ rev. 00 - 33 - XIII ENGINE ASSEMBLY 7.Place crankshaft on previously housed shells making sure the timing references found on the gears coincide (fig. 57). 8.Insert oil seal rings on the drive side of the crankshaft (fig. 58). A warped oil retainer may allow the introduction of air into the engine thus causing crankcase ventilation problems. Use genuine oil retainers with the Kohler. 57 9.Mount lower crankcase complete with studs, centering pins and bearings. 10.Take care to insert the centering pins between crankcases into their respective housings without using force. 11.Tighten crankcase screws, to starting from the centre and alternating towards the outside at: kgm 1,3 (Nm 12,8) 58 Timing cover assembly Before mounting the timing cover check that between the gear shims and the crankcase surface (fig. 59) there is a maxi clearance of: 0,10 mm The axial clearance is measured at the timing cover gaskets and must be between: 59 0,10 ÷ 0,20 mm If the axial clearance of the crankshaft becomes excessive after a long working period, add adjustment shims to the engine shaft and camshaft gear until the clearance returns to normal values (fig. 60). 0.2 and 0.3 mm shims are available. 60 - 34 - KD 477-2 Workshop Manual_cod. ED0053029370_1° ed_ rev. 00 ENGINE ASSEMBLY XIII Fitting of oil seal rings To introduce oil seal ring, flywheel side, use an ordinary cylindrical plug of appropriate size as shown in fig. 61. A warped oil retainer may allow the introduction of air into the engine thus causing crankcase ventilation problems. Use genuine oil retainers with the Kohler. The oil seal rings are to be fitted with the arrow pointing in the same direction of the crankshaft rotation. 61 Final insertion of the oil seal ring, drive side, requires the use of special tool code 00365R0040 (fig. 62). 62 Oil pump assembly For rotor checks see page 25. After tightening crankcase, mount oil pump external rotor with the notch facing inwards (fig. 63). Make sure the O-Ring on the oil pump cover is in perfect condition. Tighten screws gradually to a pressure of: kgm 1 (Nm 9,8) 63 KD 477-2 Workshop Manual_cod. ED0053029370_1° ed_ rev. 00 - 35 - XIII ENGINE ASSEMBLY Feeding pump assembly 1.Insert fuel feeding pump cap into its housing and make sure it moves freely. The length of the cap is : 34 ÷ 34,2 mm 2.Fit gasket (0.5 mm and 0.2 mm thick). 3.With fuel pump control cams in a rest position the cap should protude from the gasket surface (fig. 64) for: 64 1,7 ÷ 2,1 mm 4.With fuel feeding pump control cams at bottom dead centre position mount feeding pump and action manually. There should still be a small suction stroke (fig. 65). If said checks are not carried out, the fuel feeding pump diaphram could be damaged due to the excessive stroke to which it will be subjected. 65 Piston-connection rod couplings The piston is coupled to the connecting rod by means of slight hand pressure on the gudgeon pin without heating the piston. The clearance between the small end and the gudgeon pin is: 0.023 to 0.038 mm and between gudgeon pin and piston: 0.002 to 0.008 mm. The lubrication groove (A, fig. 66) on the small end must be turned towards the engine rotation direction (injection pump side). 66 Connecting rod-crankshaft coupling After insertion of the bearings into the big end, attach connecting rods to crank pins, bearing in mind that an arrow, on the pistons, indicates the rotation direction of the engine (fig. 66). The combustion chamber, which is eccentric with respect to the axis, should be turned to the nozzle side. Mount connecting rod caps with reference numbers corresponding to those on the rod (fig. 67). The coupling clearance between big end bearing and pins is: 0.020 to 0.072 mm. Tighten up connecting rod bolts to: 67 - 36 - kgm 3,8 ÷ 4 (37,3 ÷ 39,3 Nm) KD 477-2 Workshop Manual_cod. ED0053029370_1° ed_ rev. 00 ENGINE ASSEMBLY XIII Piston ring fitting Fit rings onto pistons in the following order (fig. 68): 1.Chromed compression seal ring. 2.Torsional compression seal ring (with internal notch turned upwards). 3.Expander oil scraper ring. 68 Piston ring working position Before mounting cylinders, rotate rings 120° opposite to each (fig. 69) other with the ends of the 1st compression ring in line with the gudgeon pin axis. 69 Protective cap fitting To prevent the entrance of dust and water which could block the cylinder studs to the upper crankcase, insert protective caps on the studs themselves (fig. 70). To facilitate cap mounting, oil stud roots. Insert on crankcase, under the rocker shaft pipes, plates for the lubrication of the camshaft. 70 Cylinder mounting The lower end of the cylinder is chamfered for piston ring insertion (fig. 71). The operation can be carried out easily by using a standard piston ring compression tool (tool 00365R0770). 71 KD 477-2 Workshop Manual_cod. ED0053029370_1° ed_ rev. 00 - 37 - XIII ENGINE ASSEMBLY Cylinder height adjustement Between the top face of the cylinder and the piston at top dead center, there must be a clearance of: 0,25 ÷ 0,35 mm In order to carry out this operation correctly, make the check with the cylinder pressed well down on its crankcase (fig. 72). 72 The clearance is adjusted by means of shims inserted between the lower face of the cylinder and crankcase (fig. 73). Shim dimensions: 0.1 to 0.2 mm 73 Checking valve head face depth When replacing valves check that the clearance from the top of the head to the face (fig. 74) is of: Fitting mm Max. wear mm 0,9 ÷ 1,1 1,8 For different values see on pages 18-19. 74 Checking injector protrusion Before mounting the heads on the cylinders, insert injectors in their housings and after having secured them temporarily, check protusion of nozzles from head surface (fig. 75). Protusion S should be: 2,25 ÷ 2,75 mm 75 - 38 - KD 477-2 Workshop Manual_cod. ED0053029370_1° ed_ rev. 00 ENGINE ASSEMBLY XIII Adjustment is effected by inserting copper washers between the injector and injector supporting faces on the heads (fig. 76). Washer thickness 1 mm. 76 Fitting cylinder heads Insert oil seal O-rings on rocker arm housing and fit the cylinder head in place. Insert 0.5 mm copper gaskets between the surfaces. (fig. 77). Make sure the oil seal rings are housed properly in the heads to avoid oil leaks. 77 Align heads using a manifold or a metallic bar as shown in fig. 78. Tighten down cylinder head nuts uniformly (fig. 78) increasing 1 kgm at every turn until a pressure is reached of: 5 kgm (49 Nm) 78 Valve clearance The clearance between valves and rockers with the engine cold (fig. 79) is: 0,15 mm intake/exhaust The operation must be carried out with the pistons at their top dead center compression position. 79 KD 477-2 Workshop Manual_cod. ED0053029370_1° ed_ rev. 00 - 39 - XIII ENGINE ASSEMBLY Injection pump fitting Fit injection pump into timing case inserting adjusting shim between supporting flange and crankcase (fig. 80). To facilitate the insertion of the pump, rotate the flywheel so as to bring the actuating cam to rest position and set the rack bar in a half way position. 80 To facilitate tightening of pump nuts on the cylinder side, use the special key (tool od. 00365R0210) illustrated in fig. 81. 81 Injection pump tie rod connection - The injection pump tie rod length, measured from the connecting centre of the rack bar to the centre of the ball joint must be mm 118 ±1 complete turn. Careful operation will avoid uneven running, starting difficulties and power losses. - Connect tie rod to governor lever, engaging the ball joint to 90° (fig. 82), and to the injection pump rack bar and then insert split pin. 82 Checking T.D.C. With pistons in respective top dead center compression position check that the arrows on the air conveyor coincide with top dead center position indications on the flywheel (fig. 83). If the flywheel has to be replaced, transfer and punch the above mentioned indications on the new one. 83 - 40 - KD 477-2 Workshop Manual_cod. ED0053029370_1° ed_ rev. 00 ENGINE ASSEMBLY XIII Checking start of injection 1.Connect fuel tank to injection pump. 2.Bring accelerator lever to max. position and piston, flywheel side, at compression beginning (cylinder No 1) All operations are to be carried out with the rack bar in working position to annul the delay caused by the notch on the pumping element of the injection pump. 3. Fit the special tool, p.n. 00365R0940, to the delivery valve holder (flywheel side) as shown in figure 84. 84 4.Insert a band (fig. 85) to ease the tension of the spring. 5. Turn the flywheel slowly until the column of diesel fuel inside the special tool starts to move. This indicates the start of static injection. At this moment injection pimp delivery starts (fig. 86) and the top dead centre reference on the air conveyor must coincide with the IP mark punched cm the flywheel (fig. 87). If the IP mark falls short of the notch on the air conveyor, injection is too fast. The injection pimp must be disassembled and shims must be added between the pump flange and the crankcase. If the IP mark falls after the T.D.C. reference notch, injection is too slaw and the above operation is to be inverted. 85 Bear in mind that every 0.1 mm shim under the pimp corresponds to a 2.5 mm rotation of the flywheel. Repeat operation on second pumping element. Should the flywheel need to be replaced, the top dead center compression position of the pistons is to be determined as per page 40 and the start of injection according to the following table: 86 I.P. Ø flywheel 26° = 53,5 mm 236 mm 87 KD 477-2 Workshop Manual_cod. ED0053029370_1° ed_ rev. 00 - 41 - XIV ENGINE TESTING Speed adjustment 1.With engine hot set minimum speed at 1000 RPM (fig. 88) and maximum to idle (fig. 89) at: 3150 RPM for engines at 3000 rpm 3750 RPM for engines at 3600 rpm 2.Then stop the engine. 3.Remove injectors, clean nozzle holes carefully, check setting and re-fit. 4.Adjust clearance between valves and rockers, while engine is hot, to: 88 0,15 mm intake/exhaust 5.Re-fit rocker covers and sealing gaskets. 89 Checking oil pressure 1.Remove union from rocker oil hole and fit a pressure gauge graded from 0 to 8 kg/cm² (fig. 90). 2.Start engine and run up to 3000 RPM. Wait for the oil temperature to reach 70 to 80°C. 3.With engine idling at 3000 RPM the pressure gauge needle should be slightly over half way corresponding to a pressure of 3 to 4 kg/cm². Said pressure will stabilize at 2 to 3 kg/cm² when engine runs at full load and the oil temperature exceeds 70 to 80°C. 4.Reduce revs to minimum. The pressure should not fall to under 1 kg/cm² with the oil temperature exceeding 80°C. 90 Checking for oil leaks 1.Remove exhaust gas collection pipe from suction manifold and close with a plug (fig. 91). 2.Start engine and run for a few minutes. The pressure which forms inside the crankcase bring out any oil leaks. 3.Re-fit gas collection pipe to suction manifold. 91 - 42 - KD 477-2 Workshop Manual_cod. ED0053029370_1° ed_ rev. 00 ENGINE TESTING XIV Testing engine on brake After having placed the engine on the brake (fig. 92), proceed with the following operations: 1.Check oil level (fig. 93). 2.Start engine and run at minimum speed. 3.Check oil pressure on pressure gauge (fig. 90). 4.Run engine in before testing it at full power. 92 Running-in table 93 Time (min) RPM Load 5 2000 0 15 3000/3600 0 30 3000/3600 30% 30 3000/3600 50% 30 3000/3600 70% 5 3000/3600 100% Engine power curves are reported at page 12. In order to check that the setting is correct, without tools, accelerate the engine a few times with no load and check the exhaust fumes. Delivery of diesel fuel is correctly calibrated when the exhaust gas is slightly coloured by smoke; change the adjustment if necessary by turning the adjustment screw (fig. 94). 94 KD 477-2 Workshop Manual_cod. ED0053029370_1° ed_ rev. 00 - 43 - XV STORAGE Prepare engines as follows for storage over 3 months: Storage 95 • Let engine run at idling speed in no-load conditions for 15 minutes. • Fill crankcase with protection oil MIL-1-644-P9 and let engine run at 3/4 full speed for 5/10 minutes. • When engine is warm empty oil pan and fill with standard new oil (fig. 95) • Remove fuel tube and empty the tank • Remove fuel filter, replace cartridge if dirty and refit (fig. 96). • Carefully clean cylinder fins, heads and fan (fig. 97). • Seal all openings with tape. • Remove injectors, pour a spoonful of oil type SAE 30 into the cylinders (fig. 98) and rotate manualy to distribute the oil. Refit injectors. • Spray oil type SAE 10W into exhaust and intake manifolds, rocker arms, valves, tappet etc. Grease all unpainted parts. • Loosen belt • Wrap the engine in a plastic film. • Store in a dry place, if possible not directly on the soil and far from high voltage electric lines. • For the lubrication and injection system as well as for moving parts use rustproof oil type MIL-L-21260 P10 grade 2, SAE 30 (Ex. ESSO RUST - BAN 623 - AGIP, RUSTIA C. SAE 30) Let the engine run with rustproof oil and drain any excess. • Coat external unpainted surfaces with antirust type MIL-C16173D - grade 3 /Ex. ESSO RUST BAN 398 - AGIP, RUSTIA 100/F). 96 How to prepare the engine for operation • • • • Clean engine outside Remove protections and covers Remove antirust with an appropriate solvent or degreaser. Remove injector, fill with standard oil, turn crankshaft by a few revolutions, remove oil pan and drain the protective oil. 97 98 - 44 - KD 477-2 Workshop Manual_cod. ED0053029370_1° ed_ rev. 00 QUICK REFERENCE CHARTS XVI Spiel (mm) Grezen (mm) Camshaft journal and housing in timing cover 0,017÷ 0,047 0,1 Camshaft journal and housing in crankcase 0,015÷ 0,048 0,1 End gap of compression rings 0,30 ÷ 0,50 0,8 End gap of oil scraper rings 0,25 ÷ 0,40 0,7 Connecting rod and wrist pin 0,023 ÷ 0,038 0,07 Rockers and shaft 0,030 ÷ 0,056 0,15 Main journals and bearings bushes 0,010 ÷ 0,060 0,15 Oil pump drive gear spindle and housing in crankcase 0,030 ÷ 0,065 0,115 External oil pump rotor and housing in engine crankcase 0,094 ÷ 0,144 0,294 Pistons and wrist pin 0,002 ÷ 0,008 0,05 Big end bearing and crankpin 0,020 ÷ 0,072 0,17 Valve guide and stem: inlet 0,030 ÷ 0,050 0,1 Valve guide and stem: exhaust 0,045 ÷ 0,065 0,1 MIN (mm) MAX (mm) 0,15 0,15 0,9 ÷ 1,1 1,8 Dead space between cylinder face and piston 0,25 0,35 Protrusion of injector 2,25 2,75 End floats MIN (mm) MAX (mm) Crankshaft 0,10 0,20 Camshaft 0,10 0,20 Oil pump shaft 0,01 0,05 Couplings Adjustments Valves Valve depth from cylinder head KD 477-2 Workshop Manual_cod. ED0053029370_1° ed_ rev. 00 - 45 - XVI QUICK REFERENCE CHARTS Tightening torques kgm (Nm) Crankcase 1,3 (12,8) 3,8 ÷ 4,0 (37,3 ÷ 39,3) Bolt on power take off end 25 (245,5) Timing cover 1 (9,8) Oil sump 1,3 (12,8) Injectors 2,3 (22,6) Injection pump 2,3 (22,6) Oil pump cover 0,6 (5,9) Cylinder head 5 (49) Flywheel 28 (274,9) Connecting rod Standard screw tightening torques 8.8 Denomination = 8.8 R10 R ≥ 800 N/mm2 Diameter x pitch mm = R10 = 10.9 R12 R ≥ 1000 N/mm2 = R12 = 12.9 R ≥ 1200 N/mm2 Nm kgm Nm kgm Nm kgm 4 x 0,70 3,6 0,37 5,1 0,52 6 0,62 5 x 0,80 7 0,72 9,9 1,01 11,9 1,22 6 x 1,00 12 1,23 17 1,73 20,4 2,08 7 x 1,00 19,8 2,02 27,8 2,84 33 3,40 8 x 1,25 29,6 3,02 41,6 4,25 50 5,10 9 x 1,25 38 3,88 53,4 5,45 64.2 6,55 10 x 1,50 52,5 5,36 73,8 7,54 88.7 9,05 13 x 1,75 89 9,09 125 12,80 150 15,30 14 x 2,00 135 13,80 190 19,40 228 23,30 16 x 2,00 205 21,00 289 29,50 347 35,40 18 x 2,50 257 26,30 362 37,00 435 44,40 20 x 2,50 358 36,60 504 51,50 605 61,80 22 x 2,50 435 44,40 611 62,40 734 74,90 24 x 3,00 557 56,90 784 80,00 940 96,00 - 46 - KD 477-2 Workshop Manual_cod. ED0053029370_1° ed_ rev. 00 NOTE KD 477-2 Workshop Manual_cod. ED0053029370_1° ed_ rev. 00 - 47 - Translated from the original manual in Italian language. Data reported in this issue can be modified at any time by KOHLER. FOR SALES AND SERVICE INFORMATION IN U.S. AND CANADA, CALL 1-800-544-2444 KohlerEngines.com ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044 FORM NO. ED0053029370 ISSUED 05/07/2012 REVISED 00 DATE 05/07/2012
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