Lombardini i-service - SPECIAL TOOLS...KDW 702 / 1003 / 1404 corresponds to Lombardini FOCS LDW 702 / 1303 / 1404 KD 330 / 425 corresponds to Lombardini 25 LD 330-2 / 425-2 KD 477-2

KOHLER DIESEL

SPECIAL TOOLS

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KOHLER DIESEL SPECIAL TOOLS

ED0053030770EN

Important

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REGISTRATION OF MODIFICATIONS TO THE DOCUMENT

Any modifications to this document must be registered by the drafting body, by completing the following table.

Translated from the original manual in Italian language.

Data reported in this issue can be modified at any time by KOHLER.

Released by Document codeModel

N°Edition Revision Issue date

Review date

Edited by Endorsed

Technical Documentation

ED0053030770 51394 7 6 11/2015 04/2019Technical

Documentation

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ED0053030770 EN

INFORMATION REGARDING SPECIAL TOOLS KDI SERIES PAG. 4Special tools for disassembly and assembly PAG. 4Special equipment to protect components of the injection circuit PAG. 8Special tools for diagnostic procedure PAG. 9Spare parts for special KDI equipment PAG. 10

INFORMATION REGARDING SPECIAL TOOLS KD-KDW-LD-LDW SERIES PAG. 11

INFORMATION REGARDING SPECIAL TOOLS LDW 442 - LDW 492 SERIES PAG. 17

INDEX

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INFORMATION REGARDING SPECIAL TOOLS KDI SERIES

In Tab. there is a list of all the specific tools that are required and approved to carry out operations of disassembly - assembly - regulations - settings - repairs on engine series KDI, correctly and safely.

Warning• KOHLER declines all responsibility for any damage to the engine, persons, or things caused by the use of different types of

tools to those indicated in Tab., where referred to them in the manual.

SPECIAL TOOLS FOR DISASSEMBLY AND ASSEMBLY

"ST" PICTURE/DRAW DESCRIPTION PART NUMBER3404 TCR

3404 TM

1903 / 2504 TCR

1903 / 2504

M

2504 TM

ST_03

Piston protrusion - electronic injectors

cylinder head surface control tool

ED0014602980-S

ST_05Spanner for capscrews

Six nicks SN 8ED0014603650-S

ST_06Spanner for capscrews

Six nicks SN 5ED0014603640-S

ST_07Tool for disassembling /

reassembling valvesED0014603720-S

ST_08 Tool for gasket valve stem ED0014603660-S

ST_17Rocker arm cover mounting studs

ED0014603730-S

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3404 TM

1903 / 2504 TCR

1903 / 2504

M

2504 TM

ST_18Intake and oil sump

manifold mounting studsED0014603740-S

ST_34 Crankshaft blocking tool ED0014604270-S

ST_04High-pressure fuel

injection pump puller gearED0014603680-S

ST_09Tool for flywheel

assembling / disassembling

ED0014603610-S

ST_10Crankshaft gasket assembling tool

ED0014603670-S

ST_14Buffer insertion of a

crankshaft gasket onto a timing system carter

ED0014603750-S

ST_15Locking screw balance

shaftsED0097301980-S

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3404 TM

1903 / 2504 TCR

1903 / 2504

M

2504 TM

ST_11Rocker arm cover

gasket assembling tool (electronic injector seat)

ED0014603620-S

ST_12

Rocker arm cover gasket assembling tool (rocker arm capscrew gudgeon seat - electronic injector

fastening capscrew brace seat)

ED0014603630-S

ST_30Piston n°1 tool positioning

prior to injection pump assembly.

ED0014603940-S

ST_36Assembling tool for a

gasket on a rocker arm cover (injector seat)

ED0014603830-S

ST_13High-pressure fuel

injection pump puller gearED0014604050-S

ST_43 Flywheel lifting tool ED0014604030-S

ST_44 Flange bell lifting tool ED0014604010-S

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3404 TM

1903 / 2504 TCR

1903 / 2504

M

2504 TM

ST_45 Flange bell placing tool ED0014604020-S

ST_46 Flywheel placing tool ED0014604040-S

ST_47Tool for sealing ring

insertion flywheel side and pulley side

ED0014604340-S

ST_51 Injectors placing tool ED0014604310-S

ST_52 Injectors placing tool ED0014604320-S

ST_41Spacers for crankshaft

gears lockingED0014604070-S

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SPECIAL EQUIPMENT TO PROTECT COMPONENTS OF THE INJECTION CIRCUIT


3404 TM

1903 / 2504 TCR

1903 / 2504

M

2504 TM

ST_40

Complete box with caps to close holes and unions for high-

pressure injection circuit components.

ED0082051380-S

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SPECIAL TOOLS TO TEST THE ENGINE ON THE TEST BENCH - DIAGNOSTIC PROCEDURE


3404 TM

1903 / 2504 TCR

1903 / 2504

M

2504 TM

ST_51 KIRA VCI / 3 years licence ED0014604490-S

ST_52KIRA VCI / 3 years licence

Tablet Panasonic MK4ED0014604500-S

ST_01Complete instrument Kit

for diagnostics "POLAR XL"

ED0014603690-S

ST_49Complete instrument Kit

for diagnostics "DIAGBOX"

ED0014604210-S

ST_50Complete instrument Kit for engines bench test

ED0014604110-S

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SPARE PARTS FOR SPECIAL KDI EQUIPMENT

PICTURE/DRAW DESCRIPTION PART NUMBER REPLACEMENT TOOL (PART NUMBER)

Diagnostic tool for test bench

ED0014604100-S

Complete instrument Kit for engines bench test

(ED0014604110-S)

Box with set of wiring, instrument bench testing

ED0014604240-S

Engine wiring/ECU engine test stand

ED0014604250-S

Engine test stand power supply wiring

ED0014604260-S

Wiring adapter KDI Molex-Deutsch second

seriesED0014604520-S OPTIONAL

Wiring KDI Molex-Deutsch

ED0014604230-S

Wiring adapter KDI Molex-Deutsch second series

(ED0014604520-S)

Adapter KDI Molex second series

ED0014604510-S

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PICTURE/DRAW DESCRIPTION PART NUMBER REPLACEMENT TOOL (PART NUMBER)

OBD II connector ED0014603520-S

Complete instrument Kit for diagnostics "POLAR XL"

(ED0014603690-S)---

Complete instrument Kit for diagnostics "DIAGBOX"

(ED0014604210-S)DEUTSCH connector ED0014603950-S

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INFORMATION REGARDING SPECIAL TOOLS KD-KDW-LD-LDW SERIES

In Tab. there is a list of all the specific tools that are required and approved to carry out operations of disassembly - assembly - regulations - settings - repairs on engine series KD-KDW-LD-LDW, correctly and safely.



PICTURE/DRAW DESCRIPTION PART NUMBER

KDW 1603 / 2204 / 2204/T

KDW 702 /

1003 / 1404

KD 330 / 425

KD 477-2

KD 625-3

KD 625-2

Piston protrusion - injectors cylinder head

surface control toolED0014602980-S

Injection pump static injection advance tester

ED0014600240-S

Valve guide gasket assembly tool

ED0014600470-S

Valve lowering tool for static injection timing

checkED0014602850-S

Injection pumps delivery balancing instrument

ED0014601270-S

Crankshaft blocking tool ED0014600510-S

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KDW 1603 / 2204 / 2204/T

KDW 702 /

1003 / 1404

KD 330 / 425

KD 477-2

KD 625-3

KD 625-2

Metal sheet for insertion of main bearings in the

crankcaseED0014600530-S

Universal puller ED00365R0010-S

Valve guide rubber fitting tool

ED00365R0930-S

Flywheel puller ED00365R0020-S

Flywheel puller ED0014601190-S

Pliers for injection pump feeding tubes Ø 6 mm

ED0014600220-S

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KDW 1603 / 2204 / 2204/T

KDW 702 /

1003 / 1404

KD 330 / 425

KD 477-2

KD 625-3

KD 625-2

Pliers for injection pump feeding tubes Ø 8 mm

ED0014600230-S


checkED0014600750-S

Replacement of injection pump outlet union tool

ED0014602120-S

Precombustion chamber wrench

ED0014600270-S

Ring nut wrench for fastening pump/injector

pumping elementED0014600290-S

Precombustion chamber puller

ED0014600300-S

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KDW 1603 / 2204 / 2204/T

KDW 702 /

1003 / 1404

KD 330 / 425

KD 477-2

KD 625-3

KD 625-2

Precombustion chamber adjusting rod

ED0014600310-S


checkED0014600480-S

Timing belt tightening tool

ED0014600490-S

Tool for injection advance control and setting of

injector for pump/injector unit: se.no. 6590-272

(outdated)

ED0014600560-S

Tool for injection advance control and setting of

injector for pump/injector unit: se.no. 6590-285, 6590-307, 6590-290

ED0014600740-S


checkED0014602830-S

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KDW 1603 / 2204 / 2204/T

KDW 702 /

1003 / 1404

KD 330 / 425

KD 477-2

KD 625-3

KD 625-2

Cranckshaft gear puller ED00365R0890-S

Main bearing puller ED00365R0900-S

Central bearing assembly tool

ED00365R0910-S

Spring on tappet rod protection pipe assembly/

disassembly toolED0014600090-S

Blower control pulley puller

ED0014602000-S

KDW 1603 /2204 / 2204/T corresponds to Lombardini CHD LDW 1503 / 1603 / 2004 / 2004/T / 2204 / 2204/T KDW 702 / 1003 / 1404 corresponds to Lombardini FOCS LDW 702 / 1303 / 1404KD 330 / 425 corresponds to Lombardini 25 LD 330-2 / 425-2KD 477-2 corresponds to Lombardini 12 LD 477-2KD 625-3 corresponds to Lombardini 11 LD 625-3 / 626-3KD 625-2 corresponds to Lombardini 9 LD 561-2 / 561-2/L / 625-2 /626-2 / 625-2EPA / 626-2 NR/CE

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NOTES

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PICTURE/DRAW DESCRIPTION PART NUMBER LDW 442 CRS LDW 492 DCI

Camshaft seal ring protection sleeve ED0014603190-S

Protection sleeve for assembling the gear cover oil seal ring

ED0014602960-S

Piston protrusion - injectors cylinder head surface control tool

ED0014602980-S

Gear cover centring tool ED0014602990-S

Flywheel locking tool ED0014603010-S

Timing belt tensioning tool ED0014603250-S

INFORMATION REGARDING SPECIAL TOOLS LDW 442 - LDW 492 SERIES

In Tab. there is a list of all the specific tools that are required and approved to carry out operations of disassembly - assembly - regulations - settings - repairs on engine series LDW 442 CRS - LDW 492 DCI, correctly and safely.



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PICTURE/DRAW DESCRIPTION PART NUMBER LDW 442 CRS LDW 492 DCI

Valve guide gasket assembly tool ED0014600470-S

Diagnostic tool ED0014603220-S

Camshaft Pulley tightening tool ED0014603900-S

Camshaft blocking tool ED0014603910-S

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NOTES

Lombardini s.r.l. is a part of Kohler Group.Lombardini has manufacturing facilities in Italy, Slovakia and India and sales subsidiaries in France, Germany, UK, Spain and Singapore. Kohler/Lombardini reserves the right to make modifications without prior

notice.

www.lombardini.it

EUROPELombardini SrlVia Cav. del lavoro A. Lombardini n° 2 42124 Reggio Emilia, ITALYT. +39-(0)522-389-1 F. +39-(0)522-389-503

UKLombardini U.K. Ltd1, Rochester Barn - Eynsham RoadOX2 9NHOxford, UKT. +44-(0)1865-863858F. +44-(0)1865-861754

FRANCELombardini France S.a.s.47 Alléè de Riottier,69400 Limas, FRANCET. +33-(0)474-626500F. +33-(0)474-623945

ESPAÑALombardini ESPAÑA, S.L.P.I. Cova Solera 1-908191 - Rubí (Barcelona)ESPAÑAT. +34-(0)9358-62111F. +34-(0)9369-71613

USA & CANADAKohler Co.444 Highland Drive, Kohler - Wisconsin (53044), UST. +1 920 457 4441F. +1 920 459 1570

CHINA & ROAPACKohler China INVESTMENT Co. Ltdno.158, Jiang Chang San Road,200436, Zhabe, ShanghaiCHINATel: +86 400-0120-648Fax: +86 21 61078904

DEUTSCHLANDLombardini Motoren GmbHFritz-Klatte-Str. 6, Bürogebäude 2 D – 65933 FrankfurtHessen, DEUTSCHLANDT. +49-(0)69-9508160 F. +49-(0)69-950816-30

Documents

Lombardini i-service - SPECIAL TOOLS...KDW 702 / 1003 / 1404 corresponds to Lombardini FOCS LDW 702 / 1303 / 1404 KD 330 / 425 corresponds to Lombardini 25 LD 330-2 / 425-2 KD 477-2