KD477-2 - Internal combustion engine KOHLER - Free user manual and instructions

USER MANUAL KD477-2 KOHLER

Exterior view of a black industrial engine with visible fan and propeller (no text or symbols)

TABLE OF CONTENTS - INDICE - TABLE DES MATERIES - INHALTS/VERZEICHNIS - INDICE - INDICE

Safety Precautions 4-5
Norme Di Sicurezza....6-7
Précautions De Sécurité....8-9
Sicherheitsvorkehrungen....10-11
Precauciones De Seguridad 12-13
Precauções De Segurança ....14-15

Overview Of Periodic Maintenance Operations - Indice Riassuntivo Delle Operazioni Di Prima Manutenzione - Index Récapitulatif Des Opérations De Premier Entretien - Inhaltsverzeichnis Der Ersten Wartungsarbeiten - Indice Compendioso De Las Operaciones De Manutencion - Indice Resumidor Das Operações De Primeira Manutenção.... 16-18

Engine Identification Numbers - Identificazione Motore - Identification Moteur Identifizierungsdaten - Identificacion Del Motor - Identificação Do Motor ....19

Preface - Premessa - Preface - Einleitung - Premisa - Preâmbulo 20-25

Specifications - Caratteristiche - Caracteristiques - Technische Daten Carateristicas - Características ....26

Engine Dimensions - Dimensioni d'Ingombro - Mesures d'Encombrement Einbaumaße - Dimensione Exteriores - Dimenções Exteriores ....26

Oil Classifications (API/MIL) Sequences - Sequenze API/MIL - Sequences API/MIL API/MIL-Sequenzen - Secuencias API/MIL - Sequências API/MIL......34

SAE Viscosity Grade - Gradazione SAE - Viscosité SAE - SAE Viskositätsklasse Viscosidad SAE - Grsadação SAE....34

Oil Recommendations - Olio Prescritto - Huile - Vorgesschriebene Schmieröle Aceite Recomendado - Óleo Recomendado....35

Oil Capacity - Capacità Olio Motori - Capacité Huile Moteurs - Ölinhalt Motoren - Capacidad Aceite Motores - Capacidade De Oleo De Motores......36

Adding Oil - Rifornimento Olio Motore - Ravitaillement Huile Moteur - Öl-Aufüllen - Suministración Aceite Motor - Reabastecimento Óleo Motor....37

Engines With Oil Bath Air Cleaner - Per Motori con Filtro Aria a Bagno d'Olio - Pour Moteurs Avec Filtre à Air en Bain d'Huile - Für Motoren Mit Ölbadluftfilter - Para Motores con Filtro Aire a Baño de Aceite - Para Motores com Filtro ar e Banho de Óleo.... 38

Fuel Warning - Rifornimento Combustibile - Ravitaillement Combustible - Kraftstoff Einfüllen. Suministración Combustible.Reabastecimiento Combustivel....39

Diesel Fuel - Combustible - Combustible - Kraftstoff - Combustible - Combustível ..40-45

Refueling - Rifornimento Combustibile - Ravitaillement Combustible - Kraftstoff Einfullen - Suministración Combustible - Reabastecimiento Combustivel .... 46

To ensure safe operation please read the following statements and understand their meaning. Also refer to your equipment manufacturer's manual for other important safety information. This manual contains safety precautions which are explained below.

WARNING

Warning is used to indicate the presence of a hazard that can cause severe personal injury, death, or substantial property damage if the warning is ignored.

CAUTION

Caution is used to indicate the presence of a hazard that will or can cause minor personal injury or property damage if the caution is ignored.

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

WARNING

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Accidental Starts can cause severe injury or death.

Disconnect and ground spark plug lead before servicing.

Accidental Starts!

Disabling engine. Accidental starting can cause severe injury or death. Before working on the engine or equipment, disable the engine as follows: 1) Disconnect negative (-) battery cable from battery.

WARNING

Rotating Parts can cause severe injury.

Stay away while engine is in operation.

Rotating Parts!

Keep hands, feet, hair, and clothing away from all moving parts to prevent injury. Never operate the engine with covers, shrouds, or guards removed.

WARNING

Carbon Monoxide can cause severe nausea, fainting or death.

Avoid inhaling exhaust fumes, and never run the engine in a closed building or confined area.

Lethal Exhaust Gases!

Engine exhaust gases contain poisonous carbon monoxide. Carbon monoxide is odorless, colorless, and can cause death if inhaled. Avoid inhaling exhaust fumes, and never run the engine in a closed building or confined area.

WARNING

Hot Parts can cause severe burns.

Do not touch engine while operating or just after stopping.

Hot Parts!

Engine components can get extremely hot from operation. To prevent severe burns, do not touch these areas while the engine is running, or immediately after it is turned off. Never operate the engine with heat shields or guards removed.

WARNING

Fuel can cause fires and severe burns.

Do not fill the fuel tank while the engine is hot or running.

Explosive Fuel!

Fuel is flammable and its vapors can ignite. Store fuel only in approved containers, in well ventilated, unoccupied buildings. Do not fill the fuel tank while the engine is hot or running, since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition. Do not start the engine near spilled fuel. Never use fuel as a cleaning agent.

WARNING

Explosive Gas can cause fires and severe acid burns.

Charge battery only in a well ventilated area. Keep sources of ignition away.

Explosive Gas!

Batteries produce explosive hydrogen gas while being charged. To prevent a fire or explosion, charge batteries only in well ventilated areas. Keep sparks, open flames, and other sources of ignition away from the battery at all times. Keep batteries out of the reach of children. Remove all jewelry when servicing batteries. Before disconnecting the negative (-) ground cable, make sure all switches are OFF. If ON, a spark will occur at the ground cable terminal which could cause an explosion if hydrogen gas or fuel vapors are present.

WARNING

High Pressure Fluids can puncture skin and cause severe injury or death.

Do not work on fuel system without proper training or safety equipment.

High Pressure Fluid Puncture!

Fuel system is to be serviced only by properly trained personal wearing protective safety equipment. Fluid puncture injuries are highly toxic and hazardous. If an injury occurs, seek immediate medical attention.

CAUTION

Electrical Shock can cause injury.

Do not touch wires while engine is running.

Electrical Shock!

Never touch electrical wires or components while the engine is running. They can be sources of electrical shock.

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.

NORME DI SICUREZZA

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Three abstract black-and-white icons: a person running, a roller with a circular head, and a fan-like structure (no text or symbols)

Three black silhouette icons: a person in a wheelchair, a person in a wheel, and a helicopter (no text or symbols)

Three black-and-white pictograms: a person running, a person in a wheelchair, and a helicopter (no text or symbols)

Three black-and-white pictograms: a person in motion, a rollerblading wheel, and a fan-like object (no text or symbols)

Overview of Periodic Maintenance Operations

- Using the proper type and weight of oil in the crankcase is extremely important. So is checking oil daily and changing oil regularly. Failure to use the correct oil, or using dirty oil, causes premature engine wear and failure and void may warranty.

Every attempt has been made to present accurate and up-to-date technical information in this manual. However, since product development on this engine series is continuous, the information within is subject to change without notice, and without incurring obligation.

The information contained within this manual is the sole property of Kohler Co. As such, no reproduction or replication in whole or part is allowed without the express written permission of Kohler Co.

Information provided in this manual assumes the following:

1. The person(s) performing service work on Kohler diesel engines is properly trained and equipped to safely and professionally perform the operation;
2. The person(s) performing service work on Kohler diesel engines possesses the correct tools and equipment to safely and professionally perform the operation;
3. The person(s) performing service work on Kohler diesel engines has read the pertinent service information and fully understands the procedural requirements.

GENERAL SERVICE MANUAL NOTES

1. Use only genuine Kohler repair parts. Failure to use the correct replacement part could cause severe engine wear, or damage, and may void the warranty.
2. All data provided in this manual is expressed using both the English and metric measurement systems: Dimensions are given in inches (in.) and millimeters (mm); torque is expressed in foot pounds (ft. lb.) or inch pounds (in. lb.) and Newton-meters (N·m); weight is expressed in pounds (lb.) and kilograms (Kg); volume is expressed in quarts (qt.) and cubic inch (cu. in.), as well as liters (L) or cubic centimeters (cc); pressure is expressed in pounds per square inch (psi) and barometric units (bar).
3. 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.
4. In order to move the engine use the eyebolts fitted for this purpose by Kohler. These lifting points are however not suitable for the entire equipment.

KOHLER®

PREMESSA

Failure to follow the maintenance instructions and procedures outlined in this manual, may cause severe engine wear or damage, and will void the warranty. Use only genuine Kohler repair parts. Failure to use the correct replacement part may cause severe engine wear, or damage, and will void the warranty.

NOTE: NELLE PRIME 50 ORE NON SUPRARE IL 70% DEL CARICO TOTALE

NOTE: Using the proper type and weight of oil in the crankcase is extremely important. Check oil daily and change oil according to the maintenance schedules specified in this manual. Failure to use the correct oil type, or using dirty oil, will cause premature engine wear and failure, and will void the warranty.

To prevent extensive engine wear or damage, always maintain the proper oil level in the crankcase. Never operate the engine with the oil level below or above the recommended levels. Refer to page 34.

Avoid prolonged or repeated skin contact with used engine oil, or wear protective gloves. Used oil has been linked to skin cancer in laboratory animals. If contact cannot be avoided, thoroughly wash exposed areas with soap and water. Respect the environment; dispose of oil in accordance with local ordinances.

In the SAE classification, oils differ on the basis of their viscosity, and no other qualitative characteristic is taken into account.

The first number refers to the viscosity when the engine is cold (symbol W = winter), while the second considers viscosity with the engine at running temperature.

The criteria for choosing must consider, during winter, the lowest outside temperature to which the engine will be subject and the highest functioning temperature during summer.

Single-degree oils are normally used when the running temperature varies scarcely.

Multi-degree oil is less sensitive to temperature changes.

SAE CLASSIFICAZIONE

They define testing performances and procedures that the lubricants need to successfully respond to in several engine testing and laboratory analysis so as to be considered qualified and in conformity to the regulations set for each lubrication kind.

A.P.I.: American Petroleum Institute

MIL: Engine oil U.S. military specifications released for logistic reasons

ACEA: European Automobile Manufacturers Association

Tables shown on page 34 are of useful reference when buying a kind of oil.

Codes are usually printed-out on the oil container and the understanding of their meaning is useful for comparing different brands and choosing the kind with the right characteristics.

Usually a specification showing a following letter or number is preferable to one with a preceding letter or number.

An SF oil, for instance, is more performing than a SE oil but less performing than a SG one.

A.P.I.: American Petroleum Institute

A.P.I.: American Petroleum Institute

A.P.I.: American Petroleum Institute

A.P.I.: American Petroleum Institute

In the countries where AGIP products are not available, use oil API SJ/CF for Diesel engines or oil corresponding to the military specification MIL-L-46152 D/E.

NOTE: Make sure engine is stopped, level, and cool so oil has time to drain into sump.

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• Clean area around oil fill cap before removal. If necessary, add the correct type of oil and reinstall oil cap; tighten securely.
• Togliere il tappo rifornimento olio. Versare l'olio e rimettere il tappo.
• Dévisser le bouchon de remplissage d'huile. Verser l'huile et remettre le bouchon.
• Entfernen Sie die Öleinfüllschraube. Füllen Sie das Öl ein und schließen Sie den Öleinfüllstutzen wieder.
• Sacar el tapón llenado aceite. Poner aceite y montar el tapón
• Tirar o tampa reabastecimento óleo. Deitar óleo e repor o tampa.

MAX MIN

Engines With Oil Bath Air Cleaner Per Motori con Filtro Aria a Bagno d'Olio Pour Moteurs Avec Filtre à Air en Bain d'Huile Für Motoren Mit Ölbadluftfilter Para Motores con Filtro Air Baño de Aceite Para Motores com Filtro an Banho de Óleo

Air Cleaner Filling Rifornimento Olio Filtro Aria Ravitaillement huile filtre à Air Luftfilter Öl Einfüllen Suministración Aceite Filtro Aire Reabastecimento Óleo Filtro Ar

NOTE: Respect the environment; dispose of oil in accordance with local ordinances.

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Hand holding a lid placed inside a metal pot with decorative handles (no text or symbols visible)

• Fill oil bath canister with recommended oil up to level mark (see figure).
• Versare olio motore fino al livello indicato.
• Verser l'huile moteur jusqu'au repère.
• Füllen Sie Öl ein bis zur Niveau-Markierung.
• Poner aceite motor hasta en nivel.
• Deitar óleo motor até o sinal.

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• Reinstall filter. Install air cleaner housing.
• Montare la massa filtrante e il coperchio.
• Monter la masse filtrante et le couvercle.
• Das Filterelement einsetzen und den Deckel anbringen.
• Montar la masa filtrante y el tapón.
• Monte a massa filtrante e a tampa.

NOTE: Make sure that the filter is mounted correctly to prevent dust and other impurities from entering the intake ducts.
NOTE: Accertarsi che il filtro sia montato in modo corretto per evitare che polvere ed altro possono entrare nei condotti aspirazione.
NOTE: Vérifier que le filtre est monté correctement pour empêcher à la poussière ou autres saletés de pénétrer dans les conduits admission.
BEMERKUNG: Sicherstellen, daß der Filter korrekt montiert ist. Andernfalls können Staub und Fremdkörper in den saug leitungen.
NOTA: Cerciorarse que el filtro esté montado en modo correcto de lo contrario el polvo u otros elementos pueden entrar en los conductos aspiración.
NOTA: Verificar que o filtro esteja montado correctamente para evitar que a poeira possa entrar nos condutos de aspiração.

Fuel Warning Rifornimento Combustibile Ravitaillement Combustible Kraftstoff Einfüllen Suministración combustible Reabastecimiento Combustivel

WARNING: Explosive fuel vapors can cause severe injury or death. Vaporized fuels are highly explosive. Use extreme care when handling and storing fuels. Store fuels in a well-ventilated area away from spark producing equipment and out of the reach of children. Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts or from sparks. Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors. Keep the fuel lines and connections tight and in good condition.

Purchase diesel fuel in small quantities and store in clean, approved containers. Clean fuel prevents the diesel fuel injectors and pumps from clogging. Do not overfill the fuel tank. Leave room for the fuel to expand. Immediately clean up any spillage during refueling.

Never store diesel fuel in galvanized containers; diesel fuel and the galvanized coating react chemically to each other, producing flaking that quickly clogs filters or causes fuel pump or injector failure.

High sulfur content in fuel may cause engine wear. In those countries where diesel has a high sulfur content, it is advisable to lubricate the engine with a high alkaline oil or alternatively to replace the lubricating oil recommended by the manufacturer more frequently. The regions in which diesel normally has a low sulfur content are Europe, North America, and Australia.

RECOMMENDED LUBRICANT
Fuel With Low Sulphur Content	API CF4 - CG4
Fuel With High Sulphur Content	API CF

FUEL TYPE

For best results, use only clean, fresh, commercial-grade diesel fuel. Diesel fuels that satisfy the following specifications are suitable for use in this engine: ASTM D-975 - 1D or 2D, EN590, or equivalent.

FUELS FOR LOW TEMPERATURES

It is possible to run the engine at temperatures below 0^ C using special winter fuels. These fuels reduce the formation of paraffin in diesel at low temperatures. If paraffin forms in the diesel, the fuel filter becomes blocked interrupting the flow of fuel.

Fuel can be:	Summer	up to...... 0°C (32°F)
	Winter	up to...... -10°C (14°F)
	Alpine	up to...... -20°C (-4°F)
	Arctic	up to...... -30°C (-22°F)

BIODIESEL FUEL

Fuels containing less than 20% methyl ester or B20 are suitable for use in this engine. Biodiesel fuels meeting the specification of BQ-9000, EN 14214 or equivalent are recommended. DO NOT use vegetable oil as a biofuel for this engine. Any failures resulting from the use of fuels other than recommended will not be warranted.

AVIATION FUEL

Aviation fuels suitable for use in this engine include JP5, JP4, JP8 and, JET-A (if 5% oil is added).

EMISSION CONTROL INFORMATION

LOW SULFUR FUEL OR ULTRA LOW SULFUR FUEL ONLY

EPA/CARB emission label must be attached near the fuel inlet.

SPECIFICHE COMBUSTIBILE

NOTE: Do not overfill fuel tank. Leave room for fuel to expand. Clean up any spillage that occurs during refueling.

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• Add fuel and reinstall fuel tank cap.
• Versare il combustibile e rimettere il tappo.
• Verser le carburant et remettre le bouchon.
• Füllen Sie Kraftstoff ein und schließend.
• Poner el combustible y montar el tapón.
• Deitar o combustivel e repor o tampa.

Person pouring liquid from a container into a cup on a stove (no text or symbols visible)

NOTE: With low ambient temperatures (-5/8°C) add specific additives to diesel fuel, to avoid paraffin crystals solidification.

Throttle to maximum position.

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• Operate fuel pump with lever on mechanical feeding pump.
• Pompare il combustibile manualmente con la leva sulla pompa alimentazione meccanica.
• Pomper le carburant manuellement avec le levier sur la pompe d'alimentation mécanique.
• Den Kraftstoff durch manuelle Betätigung des Hebels auf der mechanischen Kraftstoffpumpe einpumpen.
• Bombear el combustible manualmente por medio de la palanca sobre la bomba de alimentación mecánica.
• Introduzir o combustível manualmente com a alavanca acima da bomba de alimentação mecânica.

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NOTE: Do NOT manually operate the fuel pump with the engine running.

NOTE: Do not actuate the starter for more than 20 seconds at a time. If engine does not start, wait 1 minute before repeating attempt. If engine does not start after two attempts, trace the cause according to Troubleshooting Chart (see page 76-87).

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• Return key to (1 ^st ) position when engine is running.
• Chiavetta libera - Motore in marcia.
• Clé en position de repos - Moteur en marche.
• Schlüssel in Stellung 1 wenn Motor läuft.
• Llave en 1ª posición - Motor en marcha.
• Chavina livre - Motor em marcha.

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NOTE: All the warning lights should be OFF when the engine is running. For engines equipped with an optional engine protection system, the ⏻ light remains on.

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NOTE: Do not stop the engine when operating at full load or high speed. Before shutting the engine down, let it run for a short time at low idle.
NOTE: Non spegnere il motore in condizioni di pieno carico o ad alta velocità di rotazione. Prima di spegnerlo, lasciarlo funzionare per breve tempo al minimo a vuoto.
NOTE: Ne pas arretér le moteur en conditions de plein charge ou de haute vitesse. A vant de l'arretér, le laisser fonctionner pour peu de temps au ralenti à vide.
BEMERKUNG: Den Motor nicht abstellen bei hoher Belastung oder hoher Geschwindigkeit. Vor den Motor abzustellen, bitte lassen ihn kurzzeitig im Leerlauf.
NOTA: No parar el motor en condicion de llena carga o alta velocidad. Antes de parar el motor dejar marchar poco tiempo en vacio.
NOTA: Não desligar o motor em condições de cargas pesadas ou de alta velocidade. Antes de desligar o motor, deixar funcionar durante pouco tempo no mínimo e em ponto morto.

MAINTENANCE MANUTENZIONE ENTRETIEN WARTUNG MANUTENCION MANUNTENAÇÃO

NOTE: Perform all maintenance procedures after engine has cooled.

NOTE: Use only genuine Kohler repair parts. Failure to use the correct replacement parts could cause severe engine wear or damage, and may void the warranty. Follow all procedures and recommendations in this document.

NOTE: Place engine on level surface to ensure accurate measurement of oil level.

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• Dry element carefully.
• Asciugare la massa filtrante superiore.
• Sécher la masse filtrante supérieure.
• Obere Filtereinsatz trocknen.
• Secar el elemento filtrante superior.
• Enxugar a massa filtrante superior.

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• Clean upper canister.
• Pulire la vaschetta superiore.
• Nettoyer la cuve supérieure.
• Oberen Filterbecher reinigen.
• Limpiar la taza superior.

• Limpiar o tanquezinho superior.

• Reinstall upper element.

• Rimontare la massa filtrante superiore.
• Remonter la masse filtrante supérieur.
• Den obere Filtereinsatz wieder montieren.
• Volver a montar la masa filtrante superior.

• Montar a masa de filtragem superior.

• Remove lower filter.

• Togliere la massa filtrante inferiore.
• Déposer la masse filtrante inférieure.
• Untere Filtereinsatz abmontieren.
• Quitar la masa filtrante inferior.
• Retirar a masa de filtragem inferior.

Hand holding a lid of a cylindrical container with decorative handles (no visible text or symbols)

• Never use solvents with a low flash point to clean filter, as this action could cause an explosion.
• Mai pulire l'elemento filtrante utilizzando solventi a basso punto di infiammabilità. Potrebbe verificarsi un'esplosione.
• Ne nettoyez jamais l'élément filtrant avec des solvants facilement inflammable. Risque d'explosion!
• Den Filtereinsatz nie mit Lösemitteln reinigen, die einen niedrigen Flammpunkt haben. Es besteht sonst Explosionsgefahr.
• Nunca limpiar el elemento filtrante usando solventes con bajo punto de inflamabilidad. Podría verificarse una explosión.

• Nunca limpar o elemento de filtragem usando solventes dotados de ponto baixo de inflamação porque podem provocar explosões.

• Clean and dry filter.

• Lavare e asciugare la massa filtrante.
• Nettoyer et essuyer la masse filtrante.
• Filtereinsatz reinigen und trocknen.
• Lavar y secar el elemento filtrante.
• Lavar e enxugar a massa filtrante.

Hand pouring liquid into a circular mechanical component (no text or symbols visible)

Close-up of a hand using a tool to adjust or install a circular mechanical component (no visible text or symbols)

• Respect the environment; dispose of used oil in accordance with local ordinances.
• Non disperdere l'olio esausto in ambiente in quanto altamente inquinante.
• Ne pas vidanger l'huile épuisée dans le milieu, car elle a un haut niveau de pollution.
• Wegen dem hohen Grad der Umweltverschmutzung, ist Sorge zu tragen, daß kein Öl ins Erdreich.
• Non dispersar o tirar el aceite usado: por ser de un alto nivel de contaminante.

• Não dispersar o óleo velho no ambiente porque é muito poluidor.

• Drain and clean lower canister.

• Vuotare e pulire la vaschetta.
• Vidanger et nettoyer la cuve du filtre.
• Reinigen und leeren Sie das Luftfilter unterteil.
• Vaciar y limpiar la taza.
• Esvaziar e limpar o tanquezinho.

Person pouring liquid from a black pot into a white pitcher (no text or symbols visible)

• Add engine oil up to mark indicated.
• Versare olio motore fino al segno.
• Verser l'huile moteur jusqu'au repère.
• Füllen Sie Öl ein bis zur Niveau-Markierung.
• Poner aceite motor hasta en nivel.
• Deitar óleo motor até o sinal.

Close-up of hands cleaning a black cylindrical container with a handle (no text or symbols visible)

• Reassemble oil bath system.
• Rimontare il filtro aria.
• Remonter le filtre à air.
• Setzen Sie den Luftfilter wieder zusammen.
• Montar el filtro aire.
• Remontar o filtro ar.

NOTE: Securely install filter and cover to prevent dust or other impurities from bypassing filtration system and damaging engine.

NOTE: Use only genuine Kohler repair parts.

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• Tap filter gently to dislodge debris. Do not wash paper filter or use pressurized air, as this will damage filter.
• Battere delicatamente il filtro per eliminare i residui. Per non danneggiare il filtro di carta, non lavarlo e non pulirlo con aria compressa.
• Tapoter doucement sur le filtre pour déloger les débris. Ne pas laver le filtre en papier ou utiliser d'air comprimé, car ceci abîmera le filtre.
• Klopfen Sie leicht auf den Filter, damit sich der Verschleißabrieb löst. Waschen Sie den Papierfilter nicht aus und setzen Sie keine Druckluft ein, denn dadurch wird der Filter beschädigt.
• Golpee suavemente el filtro para desprender la suciedad. No lave el filtro de papel ni use aire comprimido, ya que esto dañaría el filtro.

• Bata suavemente no filtro para fazer sair os resíduos. Não lave filtros de papel nem use ar comprimido uma vez que isto danificará o filtro.

• Do not reuse air filter or pre-cleaner if any damage or deterioration has occurred. Replace with new.

• Se la massa filtrante è stata pulita altre volte, o se è irrimediabilmente intasata gettarla e sostituirla.
• Si la masse filtrante a déjà été nettoyée plusieurs fois, ou bien si elle est irrémédiablement encrassée, la remplacer.
• Wenn das Element bereits mehrere Male gereinigt worden oder unwiederbringlich verstopft ist, wegwerfen und erneuern.
• Si la masa filtrante ya ha sido limpiada otras veces, o si está irremediablemente obstruida, tirarla o sustituirla.
• Se a massa filtrante já foi limpada outras vezes, ou se for irremediavelmente entupida, jogá-la substitui-la.

NOTE: Use only genuine Kohler repair parts.

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• Fit air filter back in position.
• Pulire e rimontare il filtro aria.
• Nettoyer et remonter le filtre à air.
• Reinigen und Luftfilter montieren.
• Limpiar y montar de nuevo el filtro de aire.
• Limpar e remontar o filtro ar.

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NOTE: Use only genuine Kohler repair parts.

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200 Hours h 200

Clean Cooling Fins

Pulizia Alette

Raffreddamento

Nettoyage Ailettes

Refroidissement

NOTE: When using compressed air, always wear protective goggles.

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Close-up of hands assembling or adjusting a black mechanical component (no visible text or symbols)

• Use compressed air on cylinder cooling fins and flywheel.
• Soffiare con aria compressa le alette cilindro e volano.
• Souffler de l'air comprimé sur les ailettes du cylindre et du volant.
• Die Rippen von Zylinder und Schwungrad mit Druckluft durchblasen.
• Insufle aire comprimido en las aletas del cilindro y en el volante.
• Soprar com ar comprimido as abas do cilindro e do volante.

Close-up of a hand using a screwdriver to adjust or install an internal combustion engine component (no visible text or symbols)

Close-up of a hand using a tool to adjust or install an internal combustion engine cylinder (no visible text or symbols)

• In case cooling fins are very dirty, clean with a brush soaked in detergent and blow clean with compressed air.
• Nel caso in cui le alette risultassero molto sporche pulire con un pennello imbibito con aqua e detersivo soffiare con aria compressa.
• Au cas où les ailettes étaient très sales, les nettoyer au moyen d'un pinceau imbibé de détersif, ensuite souffler avec de l'air comprimé.
• Sollten die Rippen stark verschmutzt sein, sind diese mit einem seifenwassergetränkten Pinsel zu reinigen und mit Druckluft zu durchblasen.
• Si las aletas están muy sucias límpielas con un pincel empapado de detergente e insufle aire comprimido.
• Caso as abas estejam muito sujas, limpar com um pincel embebido de detergente e soprar com ar comprimido.

Close-up of a hand using a wrench to adjust the engine block (no visible text or symbols)

Change Oil Sostituzione Olio Carter Remplacement Huile Carter Öl Wechsel Bei Motoren Sostitución Aceite Cárter Substituição Óleo Carter

NOTE: In case of low use: every 6 months.

NOTE: In dusty or dirty conditions, change oil and oil filter every 150 hours.

NOTE: Change the oil while the engine is still warm, the oil will flow more freely.

Close-up of a mechanical assembly with no visible text or symbols

Close-up of a hand pouring liquid from a fan into a white bucket (no text or symbols visible)

• Reinstall drain plug.
• Rimettere il tappo scarico olio.
• Revisser le bouchon de vidange.
• Abiaßschraube wieder einsetzen.
• Montar el tapon vaciado aceite.

• Repor o tampa descarregamento óleo.

• Reassemble oil drain cap, replace the copper seal and torque to 22 N·m (16 ft. lb.).

• Riavvitare il tappo scarico olio, sostituire la guarnizione in rame e serrarla a 22 N·m.
• Revisser le bouchon de vidange, remplacer le joint en cuivre et le serrer avec un couple de serrage de 22 N·m.
• Die Ölablassschraube wieder festschrauben, die Kupferdichtung auswechseln und auf 22 N·m anziehen.
• Volver a enroscar el tapón de vaciado, sustituir la junta de cobre y apretarlo a 22 N·m.

• Volte a aparafusar a tampa de descarga do óleo, substitua a guarnição de cobre e serrarla a 22 N·m.

• Remove oil fill cap.

• Togliere il tappo rifornimento olio.
• Dévisser le bouchon de remplissage d'huile.
• Entfernen Sie die Öleinfüllschraube.
• Quitar el tapón llenado aceite.
• Tirar o tampa reabastecimento óleo.

Close-up of a hand inspecting the engine compartment of a car (no visible text or symbols)

Close-up of a mechanical device with a white cylindrical component pouring liquid into a motor (no visible text or symbols)

• With engine on a level surface check that oil level is between the "min" and "max" marks on dipstick.
• Controllare che il livello sia al massimo, con il motore in piano.
• Verifier que le niveau soit au maximum avec le moteur en plan.
• Mit Motor auf ebene Fläche Kontrollieren dass Ölstand Maximum zeigt.
• Controlar que el nivel se encuentre al máximo, con el motor en plano.
• Verificar que o nível esteja no máximo, com o motor em posição horizontal.

NOTE: Before restarting, verify dipstick, drain, and fill cap have been correctly installed.

Close-up of hands operating a mechanical assembly with a tool (no visible text or symbols)

• Using a strap wrench, remove the oil filter.
• Tramite una chiave appropriata rimuovere il filtro olio.
• Enlever le filtre à huile avec une clé appropriée.
• Den Ölfilter mit einem geeigneten Schlüssel entfernen.
• Mediante una llave adecuada, quitar el filtro de aceite.
• Através de uma chave apropriada retire o filtro do óleo.

NOTE: Use only Kohler genuine parts.

NOTE: Dispose of used oil filter according to local ordinances.

Close-up of a hand operating a mechanical transmission device (no visible text or symbols)

Fuel Filter Replacement Sostituzione Filtro Combustibile Remplacement Filtre à Combustible. Wechsel-Brennstoffilter Sostitución Filtro Combustible Substituição Filtro Combustive

• Ensure fuel tank is completely empty of fuel. Disable engine by disconnecting negative (-) battery lead.
• Accerti che serbatoio di combustibile sia completamente vuoto di combustibile. Renda invalido il motore staccando (-) il cavo di batteria negativo
• Assurez que réservoir de carburant est complètement vide du carburant. Désactivez le moteur en déconnectant (-) le câble de batterie négatif.
• Stellen Sie sicher, dass Kraftstoffbehälter vom Kraftstoff vollständig leer ist. Sperren Sie Maschine, indem Sie negative (-) Batterieleitung trennen.
• Asegúrese que depósito de combustible sea totalmente vacío del combustible. Inhabilite el motor desconectando (-) el cable de batería negativo.

• Assegure-se de que tanque de combustível esteja completamente vazio do combustível. Incapacite o motor desconectando (-) o cabo de bateria negativo.

• Remove the fuel filter.

• Togliere il filtro combustibile.
• Démonter le filtre à gas-oil.
• Entfernen Sie den Kraftstofffilter.
• Quitar el filtro combustible.
• Tirar fora o filtro combustível.

Close-up of a hand operating a black engine pump assembly (no visible text or symbols)

NOTE: Respect the environment; dispose of used filter in accordance with local ordinances.

NOTE: Use only Kohler genuine parts.

NOTE: Adjust valve clearance only when the engine is cold.

Adjust Rocker Arm Clearance

Valve-Rocker Arm Clearance Setting: Remove rocker arm cover - Turn flywheel until piston reaches T.D.C. on compression stroke - Unlock adjusting screw nuts - Set feeler gauge (0.15 mm) after turning flywheel until pistoN reaches - Tighten adjusting screws locking nuts.

An injector pressure setting test pump with an adequate pressure gauge are required to clean and calibrate the injectors - Remove the injector – Connect it to the pump and pressure gauge – Operate the pump – Check to make sure that the injector atomizes and that the pressure setting is 220-230 Kg/cm ^2 . If the injector fails to atomize, unscrew the ring nut, clean the central hole and the needle pin with a brass brush, then thoroughly wash with gasoline. If it atomizes but the pressure setting is lower, increase the height of the shims under the calibrating spring. Lower the height of the shims if the pressure is excessive.

Replace Intake Manifold Hose

In addition to all items in Partial Overhaul, Complete Overhaul includes: Replace pistons and Rebore cylinders – Resurface or replace valves, valve seats, valve guides, crankshaft, and main bearings, if deemed necessary.

- If the engine is not to be used for extensive periods, check the storage area conditions and the type of packaging to make sure they are suitable for correct storage.

If necessary, cover the engine with a proper protective sheet.

- Avoid storing the engine in direct contact with the ground, in environments that are humid and exposed to bad weather, near high voltage electric lines, etc.

NOTE: If the engine is still not in use after the first 6 months, it is necessary to carry out a further measure to extend the protection period (see “Protective treatment”)

PROTECTIVE TREATMENT

1. Check that engine oil and coolant levels are up to the maximum.

2. Fill up with fuel containing 10% AGIP RUSTIA NT.

3. Run engine at idle speed for 15 minutes.

4. Switch off engine.

5. Drain oil.

6. Refill sump with protective oil: AGIP RUSTIA.

7. Start engine and check for fuel and oil leaks.

8. Bring the engine to 34 of maximum speed for 5-10 minutes.

9. Switch off engine.

10. Empty fuel tank completely.

11. Replace fuel filter.

12. Spray SAE 10W oil on exhaust and intake manifolds.

13. Cover all openings to prevent dust or debris from entering engine.

14. Thoroughly clean all external parts of the engine.

15. Treat non-painted parts with rust inhibitor (AGIP RUSTIA 100/F).

16. Loosen alternator/fan belt.

17. If necessary, cover engine with protective plastic sheeting.

NOTE: In countries in which AGIP products are not available, find an equivalent product (with specifications: MIL-L-21260C).

NOTE: Maximum every 24 months of inactivity, the engine must be started up by repeating all “Engine Storage” operations.

After the storage period and before starting up the engine and preparing it for operation, you need to perform certain operations to ensure maximal efficiency conditions.

1. Remove the protective sheeting.
2. Remove any areas covered to keep dust and debris out.
3. Use a cloth soaked in degreaser to remove applied protective coating.
4. Remove intake manifold.
5. Inject lubrication oil (no more than 2 cm^3 ) into valves and reinstall intake manifold.
6. Adjust alternator/fan belt tension.
7. Turn flywheel manually to check movement of mechanical parts.
8. Refill tank with fresh fuel.
9. Start engine and run at 34 of maximum speed for 5-10 minutes.
10. Switch off engine.
11. Remove protective oil to replace with engine oil.
12. Introduce new oil (see "Lubricants") up to correct level marked on dipstick.
13. Replace filters (air, oil, fuel) with original spare parts.
14. Empty cooling circuit completely and add new coolant up to correct level.

NOTE: Over time, a number of engine components and lubricants lose their properties, so it is important to consider whether they need replacing, also based on age (see Replacement table).

NOTE: After every 24 months of inactivity, the engine must be started up by repeating all "Engine Storage" operations.

STOCCAGGIO MOTORE

1) - The engine RPMs suddenly increase and decrease

2) - A sudden and unusual noise is heard

3) - The color of the exhaust fumes suddenly darkens

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

Battery not supplied. Ground rubber mounted engines.

In Standard Start Conditions

In Heavy-Duty Start Conditions

4 Battery (Not Included)

7 Battery Recharge Warning Light (Optional)

8 Oil Pressure Warning Light (Optional)

Cross-sectional technical drawing of a mechanical assembly (no visible text or labels)

3) Fuel System - Circuito Combustibile - Circuit de Graissage - Kraftstoffanlage - Circuito Combustibile - Circuito Combustivel

graph TD
    A["Tubo Rifiuto Inettori Injector Return Line Tuyau Rebut Injecteurs Leckölleitung Tubo Retorno Inyectores Tubo Refugo Injetor"] --> B["Fuel Tank Serbatoio Réservoir Kraftstofftank Deposito Tanque"]
    B --> C["Cartridge Filter Filtro a Cartuccia Filtre à Cartouche Patronenfilter Filtro de Cartucho Filtro a Cartucha"]
    C --> D["Fuel Feeding Pump Pompa Alimentazione Pompe d'Alimentation Kraftstoff-Förderpumpe Bomba Alimentacion Bomba Injeção"]
    D --> E["Injectors Inettori Injecteurs Einspritzdüsen Inyectores Injetor"]
    E --> F["Injection Pump Pompa Iniezione Pompe d'Injection Einspritzpumpe Bomba Inyeccion Bomba Injeção"]

NOTES - NOTE - BEMERKUNG - NOTAS

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 residential service for a period of three (3) years from date of purchase, provided it is operated and maintained in accordance with Kohler Co.'s instructions and manuals.

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.

EXCLUSIONS:

Mufflers on engines used commercially (non-residential) are warranted for one (1) year from date of purchase, except catalytic mufflers, which are warranted for two (2) years.

This warranty does not apply to defects caused by casualty or 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, INCIDENTAL, 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 call 1-800-544-2444.

ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044

KOHLER CO.

FEDERAL AND CALIFORNIA EMISSION CONTROL SYSTEMS

LIMITED WARRANTY OFF-ROAD DIESEL ENGINES

The U.S. Environmental Protection Agency (EPA), the California Air Resources Board (CARB), and Kohler Co. are pleased to explain the Federal and California Emission Control System Warranty on your 2008 and later off-road compression ignition (diesel) engine. Kohler Co. warrants that the engine is designed, built and equipped to meet the U.S. EPA and CARB off-road diesel regulations. The warranty period shall begin on the date the engine or equipment is delivered to an ultimate purchaser. The engine must be free of material or workmanship defects for the time period detailed in the manufacturer's warranty coverage section of this document below. Kohler Co. must warrant the emission control system on the engine for the period of time listed in the section below, provided there has been no abuse, neglect or improper maintenance. The owner shall not be charged for diagnostic labor that leads to the determination that a warranted part is in fact defective, provided that such diagnostic work is performed at a warranty station.

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.

OWNER'S WARRANTY RESPONSIBILITIES

(a) You are responsible for the performance of all required maintenance including the use of approved fluids as detailed in your operators/ owners manual. It is not necessary for replacement parts to be the same brand or by the same manufacturer as the original part sold with the engine. Such use shall not reduce the warranty obligations of the engine manufacturer.
(b) Be aware, however, that Kohler Co. may deny warranty coverage if the engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.
(c) You are responsible for initiating the warranty process. The CARB suggests that you present your heavy-duty off-road engine to a Kohler dealer as soon as a problem exists. To locate the nearest Kohler authorized service center, visit our web site, www.kohlerengines.com, and click on DEALER LOCATOR, or call 1-800-544-2444 (U.S. and Canada).

COVERAGE

Kohler Co. will repair or replace emission control system parts, components and sub-assemblies found to be defective with respect to materials or workmanship at no cost to you including engine exhaust system related diagnosis, labor and parts. The choice and responsibility of the decision to repair or replace an emission control system defect will be solely that of Kohler Co. Emission control system parts/components covered by the Federal and California Emission Control Systems Limited Warranty are listed below:

• Fuel Injector(s)
• Injection Pump(s)
• Exhaust Manifold
• Intake Manifold
• Exhaust Gas Recirculation (EGR) Tube
  • Crankcase Ventilation Valve

• Electronic Control Unit (ECU) if Equipped
- Sensors Associated With ECU Operation
- Emission Control Information Labels
- Turbocharger (if equipped)
- Fuel Limiting Device

Parts/components that are scheduled to be replaced as part of the required maintenance schedule will be covered under the warranty provisions for a period of time up to the first scheduled replacement point for the subject parts/components. Subsequent damage to other engine components as a direct result of a warrantable failure of an exhaust emission part/component will be covered under the warranty provisions described herein. As the heavy-duty off-road engine owner, you should however be aware that Kohler may deny you warranty coverage if your heavy-duty off-road engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications. Only due to the above reasons, the manufacturer may deny the warranty coverage.

MAINTENANCE AND REPAIR REQUIREMENTS

The owner is responsible for the proper use and maintenance of the engine. Kohler Co. recommends that all receipts and records covering the performance of regular maintenance be retained in case questions arise. If the engine is resold during the warranty period, the maintenance records should be transferred to each subsequent owner. Kohler Co. may not deny warranty repairs solely because of the lack of repair, maintenance or failure to keep maintenance records. Normal maintenance, replacement or repair of emission control devices and systems may be performed by any repair establishment or individual; however, warranty repairs must be performed by a Kohler authorized service center. Any replacement part or service that is equivalent in performance and durability may be used in non-warranty maintenance and repairs, and shall not reduce warranty obligations of the engine manufacturer.

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 2008 and later 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 off-road 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 authorized service center, you should access our web site at www.kohlerengines.com, and click on DEALER LOCATOR, or call Kohler Co. at 1-800-544-2444 (U.S. and Canada).

GARANZIA LIMITATA DI 3 ANNI, MOTORE DIESEL KOHLER®

For sales and service information go to KohlerEngines.com or call 1-800-544-2444 (U.S. and Canada).