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

USER MANUAL KD477-2 KOHLER

SAFETY PRECAUTIONS To ensure safe operation please read the following statements and understand their meaning. Also refer to your equipment manufacturers manual for other important safety information: This manual contains safety precautions which are explained below. PIN WARNING Waming is used to indicate the presence of a hazard that can cause severe personal injury, death, or substantial property damage ifthe warning is ignored. PIN CAUTION Caution is used to indicate the presence of a hazard that will or can cause minor personal injury or property damage NOTE This indicates particularly important technical information that should not be ignored. ifthe caution is ignored. À WARNING À WARNING À WARNING À VARNING PAS “hé, Accidental Starts can cause severe injury or death. Disconnect and ground spark plug lead before servicing. IRotating Parts can cause severe injury. Stay away while engine is in operation: Tarbon Monoxide can cause severe nausea, fainting or death. Avoid inhaling exhaust fumes, and never run the engine in a closed building or confined area. Hot Parts can cause severe burns. Do not touch engine while operating or just after stopping. 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, 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 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 à closed building or confined area. 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 itis tumed off. Never operate the engine with heat shields or guards removed

À WARNING PIN WARNING Fuel can cause fires and severe burns. Do not fill the fuel tank while the engine is hot or running. À WARNING À CAUTION

Explosive Gas can cause fires and severe acid burns. Charge battery only in a well ventilated area. Keep sources of ignition away. High Pressure Fluids can puncture skin and cause severe injury or death Do not work on fuel system without proper training or safety equipment. Electrical Shock can cause injury. Do nottouch wires while engine is 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 à cleaning agent. 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 ofignition away from the battery at all ümes. 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. IFON, a spark will occur at the ground cable terminal which could cause an explosion if hydrogen gas or fuel vapors are present. WARNING California Proposition 65 harm. Engine exhaust from is product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive 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. Electrical Shock! Never touch electrical wires or components while the engine is running. They can be sources of electrical shock.

KOHLER. 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. PREFACE The information contained within this manual is the sole property of Kohler Co. As such, no reproduction or replication in whole or partis 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 Koher 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.

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. Ib.) or inch pounds (in. Ib.) and Newton-meters (N-m); weight is expressed in pounds (Ib.) 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). The engine may be used or mounted on à machine only by personnel suitably trained in its operation and aware ofthe dangers involved. This is particular 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.

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.

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 American Petroleum Institute MI 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

(@ oeser Fuel FUEL RECOMMENDATIONS 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 overfll 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 frequentiy. The regions in which diesel normally has a low sulfur content are Europe, North America, and Australia. RECOMMENDED LUBRICANT Fuel With Low Sulphur Content APICF4-CG4 Fuel With High Sulphur Content APICF 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

Itis 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 fier becomes blocked interrupting the flow of fuel Fuel can be Summer upto. 0°C (32°F) Winter up tou. 10°C (14°F) Alpine up to…-20°C (-4°F) Arctic up to.

30°C (-22°F) EMISSION CONTROL

BIODIESEL FUEL INFORMATION 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 LOW SULFUR FUEL OR from the use of fuels other than recommended will not be warranted. ULTRA LOW SULFUR FUEL ONLY AVIATION FUEL Aviation fuels suitable for use in this engine include JP5, JP4, JP8 and, JET-A (if 5% oil is added). EPA/CARB emission label must be attached near the fuel inlet.

ENGINE STORAGE - Ifthe engine is notto be used for extensive periods, check the storage area conditions and the type of packaging to make sure they are suitable for correct storage Ifnecessary, cover the engine with a proper protective sheet. After the storage period and before starting up the engine and preparing it for operation, - Avoid storing the engine in direct contact with the ground, in environments that are humid | you need to perform certain operations to ensure maximal efficiency conditions. and exposed to bad weather, near high voltage electric lines, etc. Remove the protective sheeting. Remove any areas covered to keep dust and debris out. Use a cloth soaked in degreaser to remove applied protective coating, Remove intake manifold

NOTE: {fthe engine is still not in use after the first 6 months, it is necessary to carry outa | 3

5. Inject lubrication oil (no more than 2 cm°) into valves and reinstall intake manifold

further measure lo extend the protection period (see “Protective treatment”) Adjust alternator/fan belt tension. Turn fiywheel manually to check movement of mechanical parts. Refl tank with fresh fuel.

9. Start engine and run at # of maximum speed for 5-10 minutes.

10. Switch off engine.

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. 11. Remove protect oi to replace wi engine oil

3 Run engine atidle speed for 15 minutes. 12. Introduce new oil (see “Lubricants”) up to correct level marked on dipstick. 4 Switch of engine. 13. Replace filters (ai, oi, fuel) with original spare parts. 5 Dino 14. Empty cooling circuit completely and add new coolant up to correct level.

6. Refll sump with protective oi: AGIP RUSTIA.

7. Startengine and check for fuel and oil leaks. NOTE: Over time, a number of engine components and lubricants lose their properties, 8. Bring the engine to % of maximum speed for 5-10 minutes. so it is important to consider whether they need replacing, also based on age (see

9. Switch off engine. Replacement table),

10. Empty fuel tank completely.

11. Replace fuel filter. NOTE: After every 24 months of inactivity, the engine must be started up by repeating all

12. Spray SAE 10W oil on exhaust and intake manifolds. “Engine Storage" operations.

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

14. Thoroughly clean all extemal parts of the engine

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

16. Loosen alternator/fan belt.

17. lfnecessary, 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.

1) - The engine RPMs suddenly increase and decrease

- 1 giri del motore aumentano e diminuiscono improwvisamente - Les tours du moteur augmentent et diminuent tout à coup - Die Motordrehzahl plôtzlich steigt und sinkt - Las revoluciones del motor aumentan y disminuyen de repente - As voltas do motor aumentam e diminuem repentinamente

2) - A sudden and unusual noise is heard

4) - The oil pressure indicator lightturs on while running

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. 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.

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 partis 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 19SKW<37 and rated speed less than 3,000 rpm, all variable speed engines with maximum power 19SKW<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. wil repair or replace emission control system parts, components and sub-assemblies found to be defective with respect to materials or workmanship ätno 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) + Electronic Control Unit (ECU) if Equipped + Injection Pump(s) + Sensors Associated With ECU Operation « Exhaust Manifold + Emission Control Information Labels + Intake Manifold + Turbocharger (if equipped) + Exhaust Gas Recirculation (EGR) Tube + Fuel Limiting Device + Crankcase Ventilation Valve Parts/components that are scheduled to be replaced as part ofthe 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 heawy-duty off-road engine owner, you should however be aware that Kohler may deny you warranty coverage if your heawy-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. Ifthe 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 ofthe 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 à 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.

The Califomia 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 meetthe State's strngent anti-smog standards. Kohler Co. must warrantthe 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 à 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 19SKW<37 and rated speed less than 3,000 rpm, all variable speed engines with maximum power 19SKW<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 19SKW<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. owners 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 heawy-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 Califoria's emissions requirements. You are responsible for initiating the warranty process. The Air Resources Board suggests that you present your heawy-duty off-road engine to a Kohler Co. dealer as soon as à 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).

ISSUED: 4/09 REVISED