Kohler KD 626-3 Generator Set

Tools: 1460-266, 1460-275, 1460-274, 1460-270, 1460-024, 1460-273

1. Remove the rocker arm cover.
2. Assemble tool 1460-266 (lever 1460-275, dial indicator 1460-274 in holder 1460-270).
3. Insert capillary tester 1460-024 onto the injection pump union.
4. Connect high-pressure pump 1460-273 supplied by a tank at least 100 mm above the injection pump.
5. Unscrew the fuel supply union for the injection pump of the cylinder to be worked on.
6. Rotate the crankshaft anticlockwise until diesel starts to flow out from the capillary.
7. Change direction of rotation clockwise from the timing belt side.
8. Press the high-pressure lever and rotate until fuel stops flowing from the capillary.
9. Press the lever to bring the valve into contact with the piston crown; find dead centre and reset dial indicator to zero.
10. Rotate the crankshaft clockwise and position the cylinder piston at top dead centre.
11. Read piston lowering in mm and convert to degrees with the conversion table.
12. Adjust static advance by adding seals G (to delay) or removing seals G (to advance); repeat for each cylinder.

⚠ Check the belt tension only when the engine is stopped

Tools: Spacers 0.5, 1 and 2 mm

1. Check the belt tension only when the engine is not running.
2. Add spacers (to reduce tension) or remove spacers (to increase tension) between the half-pulleys.
3. Spacers are available in thicknesses of 0.5, 1 and 2 mm.
4. Check with a 4 Kg load halfway between the pulleys: bend should be 5 ÷ 15 mm.

1. Fill with oil and fuel, start the engine and let it warm up for 10 minutes.
2. Adjust idling speed at 800 ÷ 900 r.p.m. by turning setscrew 1; tighten lock nut.
3. Turn screw 2 and set full speed in no-load conditions at 3200 r.p.m.; tighten lock nut.

1. Perform setting at the torque dynamometer; otherwise it is only approximate.
2. Loosen delivery limiting device C by 5 turns.
3. Bring engine to full speed in no-load conditions, i.e. 3200 r.p.m.
4. Tighten limiting device until the engine shows a drop in r.p.m.
5. Unscrew limiting device C by 1½ turn.
6. Tighten lock nut.

Tools: 0,2 mm shims, Torque wrench

1. The air gap is adjusted using shims measuring 0,2 mm placed between the sensor surface and its support.
2. The air gap must be between 0,3 and 0,5 mm.
3. Consider any difference between measured sensor pin length and depth between sensor support surface and camshaft and specifications.

1. Remove fuel feeding pump and cover.
2. Loosen both bolts fixing plate A.
3. Push injection pump B control rod to the right and keep it in this position.
4. Push plate A to the right until it touches rod B and stop.
5. Release rod B and push plate A to the right so that rod B has a stroke of 1 mm.
6. Tighten both bolts.

⚠ Make settings when the engine is cold

Tools: Thickness gauge, Cross-head screwdriver, Torque wrench

1. Make settings when the engine is cold.
2. Remove the rocker arm covers and check that seals are intact, otherwise replace.
3. Bring the cylinder piston to be adjusted to the compression top dead centre.
4. Loosen the fastening nut C, insert the thickness gauge D between rocker arm and valve stem.
5. Turn adjusting screw B with a cross-head screwdriver to set clearance.
6. Tighten fastening screw C and recheck clearance.
7. Refit cover, tighten screws to 20 Nm.

Tools: 10 bar pressure gauge

1. Once the engine is fitted, fill with oil and fuel.
2. Connect a 10 bar pressure gauge to the oil filter fitting.
3. Start the engine and check pressure as a function of the oil temperature.

Tools: Dial indicator, Support for dial indicator, Gauge, Master

1. Assemble dial indicator 1 onto support 2.
2. Attach the support with dial indicator to gauge 3.
3. Insert master 4 into gauge 3 and reset the dial indicator.
4. Remove the master from the gauge; insert the phase sensor.
5. Check that the sensor falls within tolerance measurements of 30,015 ÷ 30,035 mm.

⚠ When the engine is running do not disconnect battery cables or remove the key from the control panel

⚠ Keep regulator away from heat sources (above 75°C may damage it)

⚠ No electric welding on engine or application

Tools: d.c. voltmeter, Ammeter (14 or 21 A, withstand 400 ÷ 450 A)

1. Check that connections correspond to the layout.
2. Disconnect the terminal from the battery positive pole.
3. Connect a d.c. voltmeter between the two battery poles.
4. Fit an ammeter between the positive pole and the corresponding cable 1 terminal.
5. Start a couple of times until battery voltage drops below 13 V.
6. When battery voltage reaches 14,5 V the ammeter current suddenly drops to almost zero.
7. Replace regulator if recharge current is zero with voltage below 14 V.

⚠ Do not blow the paper filter element with compressed air to clean

⚠ Check gaskets and replace as necessary

⚠ The cyclone pre-filter cup must not be filled with oil

Tools: Compressed air

1. Thoroughly clean the lower tank and the metal filter element using diesel fuel, then blow compressed air into them.
2. Clean the upper polyurethane foam filter element by washing it in soapy water.
3. Dry completely using compressed air.
4. After cleaning refill the engine oil tank up to the indicated level.

1. Remove all protections and coverings.
2. Remove the rust preventer from the external part of the engine with solvent or degreaser.
3. Tension the blower timing belt.
4. Disassemble the injectors and introduce motor oil on the piston crown (no more than 2 cc for every cylinder).
5. Remove valve covers, spray motor oil on the valves and turn the crankshaft manually for a few revolutions.
6. Start the engine and heat it for about 10 minutes.
7. Remove the drain plug and let the protective oil flow completely.
8. Reinsert the drain plug.
9. Refill motor oil to the upper level of the rod using the recommended oil.