Kohler KD2500-4 Operating instructions

Service and Repair Manual

Original Instructions

Diesel engine

KD62V12

From serial number 2019730018

EN_US

33525088601_6_1

02-2019

Service and Repair Manual

For United States only

WARNING: This product can expose you to chemicals,

including carbon monoxide and benzene, which are known to

the State of California to cause cancer and birth defects or

other reproductive harm.

For more information go to www.p65warnings.ca.gov/

WARNING: Breathing diesel engine exhaust exposes you

to chemicals known to the State of California to cause cancer

and birth defects or other reproductive harm.

- Always start and operate the engine in a well-ventilated area.

- If in an enclosed area, vent the exhaust to the outside.

- Do not modify or tamper with the exhaust system.

- Do not idle the engine except as necessary.

For more information go to www.p65warnings.ca.gov/diesel

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Service Assistance

For professional advice on generator set power requirements and conscientious service, please

contact your nearest Kohler distributor or dealer.

– Visit the KOHLER Co. website at KOHLERPower.com.

– Look at the labels and decals on your KOHLER product or review the appropriate literature or

documents included with the product.

– Call toll free in the US and Canada 1-800-544-2444.

– Outside the US and Canada, call the nearest regional office.

Headquarters Europe, Middle East, Africa

(EMEA)

Kohler EMEA Headquarters

Netherlands B.V.

Kristallaan 1

4761 ZC Zevenbergen

The Netherlands

Phone: (31) 168 331630

Fax: (31) 168 331631

China

East China Regional Office, Shanghai

Phone: (86) 21 6288 0500

Fax: (86) 21 6288 0550

Asia Pacific

Kohler Asia Pacific Headquarters

Singapore, Republic of Singapore

Phone: (65) 6264-6422

Fax: (65) 6264-6455

India, Bangladesh, Sri Lanka

India Regional Office

Bangalore, India

Phone: (91) 80 3366208

(91) 80 3366231

Fax: (91) 80 3315972

China

North China Regional Office, Beijing

Phone: (86) 10 6518 7950

(86) 10 6518 7951

(86) 10 6518 7952

Fax: (86) 10 6518 7955

Japan, Korea

North Asia Regional Office

Tokyo, Japan

Phone: (813) 3440-4515

Fax: (813) 3440-2727

To order special tools, please refer to the cross reference list in the appendix.

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Service and Repair Manual

For KOHLER-SDMO power generating sets:

– Visit the website the site of KOHLER-SDMO at www.kohlersdmo.com.

– Pay attention to the labels and stickers on your KOHLER-SDMO product or check the corre-

sponding literature or documents included with the product's scope of delivery.

– Call the nearest regional office.

SALES OFFICE FRANCE

WEST

SDMO BREST

Tel.: +33 (0) 2 98 41 13 48

Fax: +33 (0) 2 98 41 13 57

SOUTHWEST

SDMO TOULOUSE

Tel.: +33 (0) 5 61 24 75 75

Fax: +33 (0) 5 61 24 75 79

BRANCH OFFICES

SOUTH AFRICA

SDMO SOUTH AFRICA

Tel.: +27 (0) 8 32 33 55 61

Fax: +33 (0) 1 72 27 61 51

MID-WEST

SDMO CHOLET

Tel.: +33 (0) 2 41 75 96 70

Fax: +33 (0) 2 41 75 96 71

SUBSIDIARIES

GERMANY

SDMO GMBH

Tel.: +49 (0) 63 32 97 15 00

Fax: +49 (0) 63 32 97 15 11

ALGERIA

SDMO ALGIERS

Tel.: +213 (0) 21 68 12 12

Fax: +213 (0) 21 68 14 14

PARIS/NORTH & NORMANDY

SDMO ARRAS

Tel.: +33 (0) 3 21 73 38 26

Fax: +33 (0) 3 21 73 14 59

SDMO GENNEVILLIERS

Tel.: +33 (0) 1 41 88 38 00

Fax: +33 (0) 1 41 88 38 37

LATIN AMERICA & CARRIBEAN

Tel.: +1 (305) 863 0012

Fax: +1 (954) 432 8330

DUBAI

SDMO MIDDLE EAST

Tel.: +971 4 458 70 20

Fax: +971 4 458 69 85

BELGIUM

SDMO NV/SA

Tel.: +32 36 46 04 15

Fax: +32 36 46 06 25

EGYPT

SDMO KAIRO

Tel./Fax: +20 (2) 22 67 12 78

EAST

SDMO METZ

Tel.: +33 (0) 3 87 37 88 50

Fax: +33 (0) 3 87 37 88 59

BRAZIL

KOHLER MAQUIGERAL

Tel.: +55 (11) 37 89 60 00

KENYA

SDMO NAIROBI

Tel./Fax: +25 (47) 07 60 54

00

SOUTH ESAT

SDMO AIX-EN-PROVENCE

Tel.: +33 (0) 4 42 52 51 60

Fax: +33 (0) 4 42 52 51 61

SDMO VALENCE

Tel.: +33 (0) 4 75 81 31 00

Fax: +33 (0) 4 75 81 31 10

SPAIN

SDMO INDUSTRIES IBERICA

Tel.: +34 (9) 35 86 34 00

Tel./Fax: +34 (9) 35 80 31 36

RUSSIA

SDMO MOSCOW

Tel./Fax: +7 495 665 16 98

UK

SDMO ENERGY LTD.

Tel.: +44 (0) 16 06 83 81 20

Fax: +44 (0) 16 06 83 78 63

TOGO

SDMO WEST AFRICA

Tel.: +228 22 22 65 65

TURKEY

SDMO ISTANBUL

Tel.: +90 53 07 35 09 10

Please consult the cross-reference list in the appendix when ordering special tools.

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Revision history

Version Author Modification Date

05 MUA California Proposal 65,

Service assistance,

Maintenance plan,

Lubricants and operating fluids,

Error code

Spelling mistakes

30

th

of July 2018

06 MUA First 3.02 engine version,

Spelling mistakes,

22

th

of February 2019

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Service and Repair Manual

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Preface

About this document

This repair and service manual is dedicated for the mechanics and the workshop personnel of the

Kohler Co. dealers and subsidiaries.

This repair manual provides information regarding the assembly, disassembly, and adjustment

tasks for KOHLER Diesel engines.

Information

Information for the United States

Failing to follow these instructions when installing a certified engine in a piece of nonroad equip-

ment violates federal law (40 CFR 1068.105(b)), subject to fines or other penalties as described in

the Clean Air Act.

If you install the engine in a way that makes the engine's emission control information label hard to

read during normal engine maintenance, you must place a duplicate label on the equipment, as

described in 40 CFR 1068.105.

Some sections of this manual do not apply to all engines.

Some illustrations in this repair and service manual show details and implements that may be

different from your engine and machinery.

Protective devices and covers have been removed to provide a clearer representation in some

illustrations.

KOHLER engines are subject to continuous development and improvement. This may result in

modifications to your engine which may not be referred to in this repair and service manual.

If you require further explanations or information, please contact your nearest authorized Kohler

service representative. See “Service Assistance” section.

Spare parts

Only original KOHLER spare parts, or spare parts purchased by Kohler Co. should be used for

repairing KOHLER Diesel engines.

Kohler Co. will declare all possible undertakings carried out by Kohler Co. and/or their dealers,

such as guarantees, service orders, etc. null and void without advance notice, if spare parts other

than original KOHLER spare parts or spare parts purchased by Kohler Co. are used for mainte-

nance or repair.

Fuels, lubricants and coolants

Only fuels, lubricants and coolants approved by Kohler Co. may be used for the operation of

KOHLER Diesel engines.

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Preface Service and Repair Manual

About this document

Kohler Co. will declare all possible undertakings carried out by Kohler Co. and/or their dealers,

such as guarantees, service orders, etc. null and void without advance notice, if fuel, lubricants and

coolants other than fuel, lubricants and coolants approved by Kohler Co. are used for maintenance

or repair.

Liability and warranty

Due to the wide variety of products offered by other manufacturers (e.g. service products, lubri-

cants, tool attachments and spare parts), Kohler Co. cannot examine the general suitability and

absence of defects in third-party products which are used in or on KOHLER products. The same

applies to possible interactions between third-party products and products approved by Kohler Co.

Third-party products are used in or on KOHLER engines at the user's own discretion. Kohler Co.

does not offer any warranty or accept any liability for losses of any kind caused by failures of or

damage to KOHLER engines attributable to the use of third-party products.

Furthermore, Kohler Co. will not recognize any warranty claims attributable to incorrect operation,

inadequate or insufficient maintenance or use of unapproved operating fluids or non-compliance

with safety regulations.

Kohler Co. will cancel any obligations entered into by Kohler Co. and/or its dealers, such as guar-

antees, service contracts etc., without advance notice if any parts other than original KOHLER

parts or spare parts purchased from Kohler Co. are used for maintenance and repairs.

The aforementioned provisions do not extend the warranty and liability conditions in the general

terms and conditions of business of Kohler Co.

Modifications, conditions, copyright

Kohler Co. reserves the right to make modifications in the course of technical development, without

issuing prior notification.

The aforementioned provisions do not extend the warranty and liability conditions in the general

terms and conditions of business of Kohler Co.

Copyright - Proprietary notice ISO16016

The reproduction, distribution and utilization of this document as well as the communication of its

contents to others without express authorization is prohibited

Offenders will be held liable for the payment of damages.

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Service and Repair Manual Preface

Other applicable documents

Document Application

Operation and Maintenance Manual Operator's manual for the engine operation

KODIA Operation Manual Description of KODIA, diagnosis software

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Preface Service and Repair Manual

General information

Manual structure

Information

Read and understand this manual before performing any service or maintenance procedures on

any component.

The procedures described in this manual are based on the following structure:

1. Product description. (For more information see: 1 Product description, page 21) .

2. Safety. (For more information see: 2 Safety, page 39) .

3. Repair. (For more information see: 3 Repair, page 61) .

4. Tools and devices. (For more information see: 4 Tools and devices, page 195) .

5. Appendix. (For more information see: 5 Appendix, page 201) .

Task layout

Information

Prior to any intervention, read the complete task procedure through to the end. Various symbols

are used and explained in chapter (For more information see: 2.1.2 Additional identifications,

page 39) .

Each task in this manual have the following structure:

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Service and Repair Manual Preface

General information

Task layout description

1. Chapter heading

2. Previous work with details of the chapter

3. Specific safety instructions which complete the general safety instructions

4. Special tools and consumables which are needed to fulfill the task

5. One or more overview(s) of the assembly with list of components

6. Instructions to remove and install the components, with additional directives

7. Setting values spreadsheet to check the nominal and tolerances values of critical components

8. Tightening specifications table for specific fastener

9. Tightening sequence table if required

10. Data recording sheet, if required, to inform the engine manufacturer.

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Preface Service and Repair Manual

General information

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Contents

1 Product description

21

1.1 Technical description

21

1.1.1 Cylinder designation, direction of rotation

23

1.1.2 Nameplates

24

1.2 Function description

33

1.2.1 Fuel system

33

1.2.2 Lubricating system

35

1.2.3 Cooling system

36

1.2.4 Charge air system

37

2 Safety

39

2.1 Identification of the warnings

39

2.1.1 Warnings

39

2.1.2 Additional identifications

39

2.1.3 Additional rules and directives

40

2.2 Target audience

41

2.2.1 Responsibility of machinery owner

41

2.2.2 International standard classification of occupations

41

2.2.3 Occupational references

41

2.2.4 Unauthorized personnel - servicing

42

2.3 Intended use

43

2.4 Limitation of liability

43

2.5 Safety instructions

45

2.5.1 General safety instructions

45

2.5.2 Safety while commissioning

45

2.5.3 Safety when starting

46

2.6 Preventing injuries

48

2.6.1 Preventing bruising

48

2.6.2 Preventing burns

48

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Contents Service and Repair Manual

2.6.3 Preventing fires and explosion hazards

49

2.6.4 Preventing intoxication and poisoning hazards

50

2.6.5 Preventing electrical hazards

50

2.6.6 Preventing noise hazards

50

2.6.7 Preventing vibrations hazards

51

2.6.8 Preventing electro-magnetic hazards

51

2.6.9 Preventing falling risks

51

2.7 Personal Protective Equipment (PPE)

51

2.8 Accessible areas

53

2.8.1 Engine ready for use or in operation

53

2.8.2 Engine in commissioning — test-run

54

2.8.3 Emergency stop

54

2.8.4 Signage recommendations

55

2.9 Prevent property damages

56

2.9.1 Safety instructions for engine control unit (ECU)

56

2.9.2 Alarm conditions

56

2.9.3 Safety instructions for the fuel system

57

2.9.4 Cleanliness standards and safety

58

2.10 Disposal and environment protection

59

3 Repair

61

3.1 Prevent property damages

61

3.2 Covers

62

3.2.1 Vibration damper cover removal and installation

62

3.2.2 Battery charging alternator & PTO cover removal and installation

63

3.2.3 Cylinder head cover removal and installation

67

3.3 Rocker arms - Valve clearance set (SL 204)

71

3.3.1 Previous work

71

3.3.2 Safety

71

3.3.3 Special tools

72

3.3.4 Consumables

72

3.3.5 Overview

72

3.3.6 Valve set order

73

3.3.7 Checking valve clearance

75

3.3.8 Setting valve clearance

75

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Service and Repair Manual Contents

3.3.9 Setting values

75

3.3.10 Tightening specifications

77

3.4 Rocker arms housing

78

3.4.1 Inlet and outlet rocker arms removal and installation

78

3.4.2 Rocker arms housing removal and installation

83

3.5 Cylinder head (SL 224)

91

3.5.1 Cylinder head removal and installation

91

3.6 Driving gear

97

3.6.1 Power unit

97

3.7 Fuel system

100

3.7.1 Venting pipes removal and installation

100

3.7.2 High pressure pipes removal and installation

103

3.7.3 Fuel supply pipes removal and installation

106

3.7.4 Injector removal and installation (SL 205)

107

3.7.5 Fuel filters removal and installation

117

3.7.6 Leakage fuel block removal and installation

119

3.7.7 Fuel pump HP and LP removal and installation (SL 209)

120

3.8 Charge air system

125

3.8.1 Charge air line removal and installation

125

3.8.2 Charge air cooler removal and installation (SL 220)

131

3.9 Exhaust gas system

134

3.9.1 Admission pipes to turbocharger removal and installation

134

3.9.2 Exhaust pipes to turbocharger removal and installation

136

3.9.3 Turbocharger removal and installation (SL 213)

139

3.9.4 Oil supply – turbocharger removal and installation

143

3.9.5 Turbocharger brackets removal and installation

149

3.10 Lubricating system

155

3.10.1 Oil cooler inspection (removal and installation) (SL 221)

155

3.10.2 Oil cooler by-pass valve (SL 212)

157

3.11 Cooling system

160

3.11.1 Venting line removal and installation

160

3.11.2 Turbocharger cooling lines removal and installation

165

3.11.3 Thermostat HT and housing removal and installation (SL 217)

172

3.11.4 Thermostat LT and housing removal and installation (SL 217)

174

3.11.5 Water pump HT removal and installation (SL 216)

176

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Contents Service and Repair Manual

3.11.6 Water pump LT removal and installation (SL 215)

179

3.12 Electrical system

182

3.12.1 Power take-off (PTO) and battery charging alternator removal and

installation (SL 218, SL 223) 182

3.12.2 Starter removal and installation

190

3.12.3 Engine Control Unit (ECU)

192

4 Tools and devices

195

4.1 Tools

195

4.1.1 Special tools

195

4.1.2 Turning device

198

5 Appendix

201

5.1 Technical design documents

201

5.2 Cleaning agents, thread-locking adhesives and greases

202

5.2.1 Cleaning agents and thread-locking adhesives

202

5.2.2 Greases

202

5.3 Standard tightening torques

203

5.3.1 Screws pre-tightening, reuse and marking

203

5.3.2 Standard torques for hexagonal / socket / flange screws

205

5.3.3 Standard torques for internal drive pipe plug with conical thread

206

5.3.4 Standard torques for locking screws and banjo bolts

207

5.3.5 Standard torques for metric flange joints

208

5.3.6 Standard torques for metric thread unions L series (up to 500 bar/7252

Psi) 208

5.3.7 Standard torques for metric thread unions S series (up to 800 bar/

11603 Psi) 209

5.3.8 Standard torques for imperial thread unions L series (up to 500 bar/

7252 Psi) 210

5.3.9 Standard torques for imperial thread unions S series (up to 800 bar/

11603 Psi) 211

5.3.10 Standard torques for metric thread unions L series (up to 500 bar/7252

Psi) for aluminum 211

5.3.11 Standard torques for cutting ring flange joints

212

5.3.12 Standard torques for triple lock flange joints

213

5.3.13 Standard torques for VSTI screw plugs

214

5.4 Abbreviations - Acronyms

217

5.5 Unit conversion tables

219

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Service and Repair Manual Contents

5.5.1 Length conversion factors

219

5.5.2 Mass conversion factors

219

5.5.3 Pressure conversion factors

219

5.5.4 Volume conversion factors

219

5.5.5 Power conversion factors

220

5.5.6 Moment of inertia and torque conversion factors

220

5.5.7 Fuel consumption conversion factors

220

5.5.8 Flow conversion factors

220

5.5.9 Temperature conversion factors

220

5.5.10 Density conversion factors

220

5.6 Prefix

222

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Contents Service and Repair Manual

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Kohler KD2500-4 Operating instructions

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