KT40 CPCB Ii - Alg

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T40 II
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Table of Contents

Table of Contents Page No
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Section A. ENGINE ASSEMBLY ......................................................................................................................... 1
1. Engine System......................................................................................................................................... 1
1.1 Complete Assembly ............................................................................................................................ 1
1.2 Half Block & Long Block ..................................................................................................................... 2
1.3 Gasket ................................................................................................................................................ 3
1.4 Cylinder Block ..................................................................................................................................... 7
1.5 Cylinder Head & Cover ..................................................................................................................... 11
1.6 Moving Parts .................................................................................................................................... 14
1.7 Engine Timing .................................................................................................................................. 21
1.8 Fuel Injector Equipment ................................................................................................................... 25
1.9 Injector .............................................................................................................................................. 27
1.10 Fuel Filter ....................................................................................................................................... 28
1.11 Air Compressor Cover .................................................................................................................... 29
1.12 Exhaust Manifold /EGR/Turbocharger ............................................................................................ 30
1.13 Alternator/Starter............................................................................................................................. 32
1.14 Engine Lubrication (Oil Pump/Filter) ............................................................................................... 33
1.15 Oil Cooler ........................................................................................................................................ 36
1.16 Water Pump .................................................................................................................................... 38
1.17 Air Intake System ............................................................................................................................ 43
1.18 Engine Suspension ......................................................................................................................... 44
Section B. GENSET ENGINE ASSEMBLY ........................................................................................................... 46

1. Accessories for Engine Assembly 40kVA............................................................................................. 46
1.1 Accessories for Engine Group STD ................................................................................................... 46
2. Alternator Group 40 kVA ........................................................................................................................ 47

2.1 Alternator Group 40 kVA 3 Phase ...................................................................................................... 47
2.2 Alternator Group 40 kVA 3 Phase ...................................................................................................... 48
3. Controller Assembly 63KVA ................................................................................................................... 50

3.1 Control Panel Assembly for 40 kVA 3 PHASE STD ........................................................................... 50
3.2 Exhaust System for 40 kVA ................................................................................................................ 52
4. Canopy Assembly ................................................................................................................................... 54

4.1 Radiator 40 kVA ................................................................................................................................. 54
4.2 Canopy Group 40 kVA ........................................................................................................................ 56
4.3 Canopy Group 40 kVA ....................................................................................................................... 57
5. INDEX……………………………………………………………………………………………………………....58
KOHLER POWER SYSTEM

MODIFICATIONS SUMMARY
Revision No. Document Number / Date Details of Modifications Page No

00 06/09/2015 New Release --
01 17/11/2015 Engine Group Added 1 TO 44
KOHLER POWER SYSTEM

ENGINE COMPLETE ASSEMBLY
Ref.
Part No. Part Name QTY. Remark
No.
1 ‐‐‐‐‐‐‐‐‐ ASSY ENGINE COMPLETE 1
KOHLER PAWER SYSTEM Page 1

HALF BLOCK AND LONG BLOCK
Ref.
No.
‐ KG252701990288 LONG BLOCK 1
1 KG252701990287 HALF BLOCK 1

GASKET KIT

Ref.
No.
‐ KG252701990101 GASKET KIT (ENGINE OVERHAUL) 1
1 ‐ ASSY GASKET OIL SUMP 1
4 ‐ GASKET (FLANGE) 2
5 ‐ GASKET (TIMING GEAR HSG TO CYL. BLOCK) 1
6 ‐ GASKET FOR TGH COVER 1
7 ‐ GASKET TOP COVER 1
8 ‐ GASKET PRC COVER 1
‐ ‐ GASKET FOR NOZZLE HOLDER 4
10 ‐ CYLINDER HEAD GASKET 1
11 ‐ GASKET CYL. HEAD COVER 1
‐ ‐ GASKET 1
13 ‐ GASKET (INTAKE ELBOW ) 1
14 ‐ RUBBER RING (BREATHER) 1
‐ ‐ GASKET RING (FOR CYL. HEAD) 5
17 ‐ GASKET CYLINDER SLEEVE CYL. BLOCK 1
18 ‐ GASKET (A/C CYL. HEAD) 1
21 ‐ GASKET EXH. MANIFOLD 1
22 ‐ GASKET (STRAINER HSG.) 1
‐ ‐ GASKET (OIL FILLER) 1
24 ‐ GASKET (ASSY COOLER ON CYL. BLK.) 2
25 ‐ GASKET (COOLER) 1
26 ‐ GASKET (W ATER PUMP) 1
27 ‐ GASKET 1
28 ‐ GASKET 2

GASKET KIT

Ref.
No.
‐ ‐ W ASHER 10X13.5 AL 1
‐ ‐ W ASHER 14X18 AL 16
‐ ‐ W ASHER 16X20CU 2
‐ ‐ W ASHER 18X22 AL 1
‐ ‐ W ASHER 10X13.5 CU 4
‐ ‐ W ASHER 14X18 CU 1
‐ ‐ SEALING W ASHER A 8X12 4
‐ ‐ SEALINGW ASHER8X11.5CU 12
‐ KG252701990102 DECARBONISING GASKET KIT 1
11 ‐ GASKET (CYL. HEAD COVER) 1
10 ‐ GASKET (CYLINDER HEAD) 1
‐ ‐ GASKET (FOR NOZZLE HOLDER) 4
21 ‐ GASKET (EXH. MANIFOLD) 1
‐ ‐ GASKET (EXH. PIPE) 1

CYLINDER BLOCK

Ref.
No.
1 KG252701100127 ASSY CYL.BLOCK W /O CLUTCH/FLYW HEL HSG 1
3 KG252701103727 CYLINDER LINER 4
‐ KG3520110335 SCREW PLUG 1
6 KG16220710282 W ASHER 18X22 CU 1
8 KG16081001808 SEALING PLUG AM18X1.5 TS16460 1
10 KG3121881135P SLEEVE 1
11 KG3219920025 CLAMPING SLEEVE 1
12 KG13050910304 CYL. PIN 12 H 8X30 2
‐ KG16220710258 W ASHER 16X22 1
22 KG3129910260 CYL. PIN (CYL. HEAD TO CYL. BLOCK) 2
24 KG13050508166 CYL. PIN 8 M 6X16 10
‐ KG3520110335 SCREW PLUG 1
35 KG252501159910 HEXAGONAL HEAD SCREW FOR M.B.CAP MTG. 10
‐ KG1869910055 LOCATING PIN 1
60 KG252401170112 ASSY TUBE (DIPSTICK) 1
61 KG252701170161 ASSY OIL DIPSTICK 1
62 KG252703113702 FLYW HEEL HOUSING 1
63 KG0422510004J CLUTCH COVER HOUSING UPPER 1
‐‐‐‐‐‐‐‐‐ TIMING GEAR HOUSING
72 KG252301140121 ASSY TIMING GEAR HOUSING W ITH COVER 1
72 KG252701140135 ASSY TGH W ITH THREAD INSERTS 1
74 KG13050508166 CYL. PIN 8 M 6X16 2
75 KG252501145302 GASKET (TIMING GEAR HSG TO CYL. BLOCK) 1
80 KG3129940310 LOCKING PLATE 3
83 KG11323998045 HEX SCREW M 10X25 3

CYLINDER BLOCK

Ref.
No.
84 KG3520150201 COVER FRONT (TGH) W /O OIL HOLE 1
84 KG252701143706 COVER FRONT TGH W ITH OUT OIL HOLE 1
86 KG253403107801 SEAL (CRANKSHAFT FRONT) 1
87 KG252701145305 GASKET (TGH COVER) 1
95 KG252301170122 ASSY BREATHER 1
‐‐‐‐‐‐‐‐‐ PUSH ROD CHAMBER COVER
105 KG252701140102 ASSY COVER PUSH ROD CHAMBER 1
107 KG252701145303 GASKET (PUSH ROD CHAMBER COVER) 1
‐‐‐‐‐‐‐‐‐ OIL SUMP
115 KG252701130125 ASSY OILSUMP W /O DIPSTICK FLANGES 1
117 KG16220710282 W ASHER 18X22 1
118 KG253401130111 ASSY MAGNETIC DRAIN PLUG 1
120 KG252301133702 RETAINING FLANGE (DIPSTICK) 1
121 KG12520698017 SPRING W ASHER B 6 2
122 KG11323998061 HEX. SCREW M 6X12 2
123 KG3520180380 GASKET (FLANGE) 2
124 KG252401133701 FLANGE OIL SUMP DIPSTICK 1
126 KG11342296035 HEX. SCREW M 8X20 2
127 KG16220510216 W ASHER 14X18 AL 1
128 KG252301178501 DOUBLE SOCKET 1
134 KG252701130169 ASSY OIL SUMP GASKET 1
138 KG252301130114 ASSY COMBI SCREW 12

CYLINDER HEAD AND COVER

1 KG253401150232 ASSY CYLINDER HEAD W ITH VALES 1
‐‐‐ KG253401150233 ASSY CYLINDER HEAD W ITHOUT VALES 1
3 KG16081803009 PLUG MC 30X1.5 3
5 KG16081803009 PLUG MC 30X1.5 1
8 KG16081802207 PLUG MC 24X1.5 2
12 KG253405153402 VALVE GUIDE INLET 4
12 KG253405153415 VALVE GUIDE EXHAUST 4
‐‐‐ KG253405159909 VALVE GUIDE SEAL INLET 4
‐‐‐ KG253405159910 VALVE GUIDE SEAL EXHAUST 4
‐‐‐ KG253405158701 VALVE SPRING (INNER) 8
‐‐‐ KG253405158702 VALVE SPRING (OUTER) 8
‐‐‐ KG3529902040 VALVE SPRING W ASHER 8
15 KG252501153433 VALVE SEAT RING INLET (STD) 4
16 KG252501153410 VALVE SEAT RING EXHAUST (STD) 4
22 KG252501159912 HEX COLLAR BOLT (W ITH RELIEF GROOVE) 17
25 KG252701155310 CYLINDER HEAD GASKET (MLS) 1
26 KG253401150184 ASSY CYLINDER HEAD COVER 1
36 KG279001159905 CAP (FOR CYL.HEAD COVER) 1
‐‐‐ KG254701155325 GASKET (FOR CYL.HEAD COVER) 1
45 KG253401155335 GASKET (CYL.HEAD COVER INJECTOR INSIDE) 1
47 KG16220710126 W ASHER 8X14CU 4
48 KG3229900019 STRETCH BOLT 3
49 KG11064096089 H EX BOLT M 8X125 1
‐‐‐ KG252505155102 LOCK RETAINER VALVE SPRING 8
‐‐‐ KG3120530127 VALVE SPRING LOCK HALF 16

CYLINDER HEAD AND COVER
Ref.
No.
‐‐‐ KG252701153867 AIR INTAKE ELBOW 1
‐‐‐ KG252701155315 GASKET (AIR INTAKE ELBOW ) 1
‐‐‐ KG252001168001 PRESSURE LOCK 1
‐‐‐ KG252701175808 HOSE (BREATHER) 1

MOVING PARTS

Ref.
No.
‐ CRANKSHAFT
1 KG252703100230 ASSY CRANKSHAFT 1
7 KG3520520003 CRANKSHAFT GEAR 1
8 KG13650510091 KEY 8X13 2
10 KG252703130104 ASSY PULLEYW ITH COVER (CRANKSHAFT) 1
‐ KG252503138201 OILSLINGER 1
‐ KG252703138603 SPACER (SUITABLE FOR OIL SLINGER) 1
25 KG252303138603 THRUST SPACER 1
20 KG252503123442 THRUST W ASHER UPPER HALF STD 1
21 KG252503123438 THRUST W ASHER LOW ER HALF STD 1
30 KG252303133202 VIBRATION DAMPER LOCK 1
31 KG252503107801 SEALING RING HALF 2
32 KG1869910055 LOCATING PIN 1
38 KG252503110130 ASSY FLYW HEEL W ITH RING GEAR 1
39 KG3520321105 RING GEAR 1
‐ KG252703113702 FLYW HEEL HSG.(W ITH 5/8THREAD HOLE) 1
57 KG252503150107 ASSY CON ROD (W ITHOUT BEARING SHELLS) 4
61 KG252503153204 CONNECTING ROD BOLT 8
65 KG885403432534 CONNECTING ROD BEARING SET STD 1
‐ ‐ CON. ROD BEARING HALF STD 8
65 KG885403452534 CONNECTING ROD BEARING SET R/S I1 1
‐ ‐ CON. ROD BEARING HALF R/S I 8
65 KG885403462534 CONNECTING ROD BEARING SET R/S II 1
‐ ‐ CON. ROD BEARING HALF R/S II 8
65 KG885403472534 CONNECTING ROD BEARING SET R/S III 1

MOVING PARTS

Ref.
No.
‐ ‐ CON. ROD BEARING HALF R/S III 8
65 KG885403482534 CONNECTING ROD BEARING SET R/S IV 1
‐ ‐ CON. ROD BEARING HALF R/S IV 8
106 KG885403402527 MAIN BEARING SET STD (88.00 MM DIA.) 1
34 ‐ MAIN BEARING HALF UPPER STD 5
35 ‐ MAIN BEARING HALF LOW ER STD 5
106 KG885403422527 MAIN BEARING SET RS I 1
34 ‐ MAIN BEARING HALF UPPER RS I 5
35 ‐ MAIN BEARING HALF LOW ER RS I 5
106 KG885403432527 MAIN BEARINGSET RS II 1
34 ‐ MAIN BEARING HALF UPPER RS II 5
35 ‐ MAIN BEARING HALF LOW ER RS II 5
106 KG885403452527 MAIN BEARING SET RS IV 1
34 ‐ MAIN BEARING HALF UPPER RS IV 5
35 ‐ MAIN BEARING HALF LOW ER RS IV 5
105 KG885403762525 SET OF THRUST W ASHER STD 1
37 ‐ THRUST W ASHER LOW ER HALF (116 MM DIA.) 2
36 ‐ THRUST W ASHER UPPER HALF (116 MM DIA.) 2
105 KG885403772525 SET OF THRUST W ASHER RS I 1
37 ‐ THRUST W ASHER LOW ER HALF RS I (116 MM DIA.) 2

MOVING PARTS

Ref.
No.
36 ‐ THRUST W ASHER UPPER HALF RS I (116 MM DIA.) 2
105 KG885403782525 SET OF THRUST W ASHER RS II 1
37 ‐ THRUST W ASHER LOW ER HALF RS II (116 MM DIA.) 2
36 ‐ THRUST W ASHER UPPER HALF RS II (116 MM DIA.) 2
100 KG885403502527 SET OF BARE PISTON (STD) W /O RINGS 1
70 ‐ PISTON 4
75 ‐ PIN 4
76 ‐ CIRCLIP 8
100 KG885403532527 SET OF BARE PISTON (STD) W /O RINGS 1
70 ‐ PISTON 4
75 ‐ PIN 4
76 ‐ CIRCLIP 8
101 KG885403742534 SET OF PISTON RINGS (STD) BS I & II 1
71 ‐ COMPRESSION RING GR‐I 4
72 ‐ INTERNALLY STEPPED RING GR ‐ II 4
73 ‐ OIL RING GR‐II 4
‐ KG885403522534 CON. ROD BUSH SET STD 1
58 ‐ CON. ROD BUSH STD 4
‐ KG885403082525 KIT, CRANKSHAFT SEALING RING HALF 1
31 ‐ SEALING RING HALF 2
32 ‐ LOCATING PIN 2

MOVING PARTS
Ref.
No.
31 ‐ SEALING RING HALF 2
32 ‐ LOCATING PIN 2

ENGINE TIMING

Ref.
No.
1 KG252705107922 CAMSHAFT 1
‐‐‐ KG252707130134 ASSY CAMSHAFT GEAR AND DRIVE GEAR(FIP) 1
2 KG252705115403 CAMSHAFT GEAR 1
17 KG252707135401 DRIVE GEAR (FIP) 1
12 KG3520520762 THRUSTW ASHER 1
15 KG3129900004 HEX. SCREW 4
19 KG3520510062 BUTTING RING 1
21 KG252305105901 PARALLEL KEY 1
27 KG3520750071 PIN (INJ.TIMERMTG.) 1
30 KG253405139902 VALVE TAPPET (STD) 8
32 KG3520540205 PUSH ROD 8
35 KG3520501033 ASSY ROCKER ARM LEFT W ITH BUSH 4
36 KG3520500634 ASSY ROCKER ARM RIGHT W ITH BUSH 4
37 KG3120550050 BUSH 4
38 KG252305146701 BALL END TAPPET ADJUSTER 4
42 KG3129900251 HEX NUT 4
44 KG3129930701 SPRING LONG 3
‐ KG253405140101 ASSY ROCKER ARM SHAFT W ITH ARMS 1
48 KG252705147901 ASSY ROCKER ARM SHAFT 1
49 KG17071001407 SEALING CAP 14 2
58 KG3520550610 ROCKER ARM SUPPORT NO. 1 1
60 KG3520550410 ROCKER ARM SUPPORT NO. 2,5,6 2
62 KG3520550510 ROCKER ARM SUPPORT NO. 3 & 4 1
65 KG3120550171 BOLT (ROCKER ARM) 3
67 KG11064012632 H EX BOLT M 12X75 1

ENGINE TIMING

Ref.
No.
69 KG11433206101 GRUB SCREW EM 6X10 1
72 KG3129930005 SPRING SHORT 2
73 ‐ SPRING CLIP 2
80 KG253405158701 VALVE SPRING (INNER) 8
81 KG253405158702 VALVE SPRING (OUTER) 8
83 KG3529902040 VALVE SPRING W ASHER 8
85 KG252505155102 LOCK RETAINER VALVE SPRING 8
86 KG3120530127 LOCK HALF (VALVE SPRING) 16
100 KG253405990122 VALVE SET 1
78 ‐ INLET VALVE 60DEG INDUCTION HARDENED M/S 4
80 ‐ EXHAUST VALVE 4
‐ KG885405032534 SET OF CAMSHAFT BEARING STD 1
5 ‐ CAMSHAFT BEARING NO. 1 1
7 ‐ CAMSHAFT BEARING NO. 2,3 2

FUEL INJECTOR EQUIPMENT

Ref.
No.
1 ‐‐‐‐‐‐‐‐‐ ASSY FIP (40 KVA CPCB II) 1
3 KG252307105401 INJECTION PUMP GEAR 1
4 KG252707123704 SUPPORT‐INJECTION PUMP 1
‐ KG252707125305 GASKET‐SUPPORT FIP 1
25 KG252707140103 ASSY FUEL LEAKAGE LINE 1
‐ KG252709125809 HOSE (FOR ASSY OVER FLOW LINE) 1
33 KG16220510216 SEALING W ASHER 14X18 8
26 KG252707140120 ASSY FUEL PRESSURE LINE BENT CYL NO.1 1
26 KG252707140121 ASSY FUEL PRESSURE LINE BENT CYL NO 2 1
26 KG252707140122 ASSY FUEL PRESSURE LINE BENT 1
26 KG252707140124 ASSY FUEL PRESSURE LINE(BENT) CYL.NO.4 1
‐ KG252707140102 ASSY CLAMP LOW ER 2
‐ KG252707148201 PIPE CLAMP UPPER 2
‐ KG3129970230 PLUG LOCKING SCREW (PRESSURE PIPE) 1
‐ KG3129970330 PLUG 1
‐ KG252707147501 RUBBER GROMMET 2

INJECTOR
Ref.
No.
1 KG252701160141 ASSY INJECTOR W ITH K‐FACTOR 4


FUEL FILTER
Ref.
No.
2 KG252709110124 ASSY FUEL FILTER 1
1 KG252509120239 FUEL ‐ W ATER SEPERATOR 1
‐‐‐ KG263254209945 W ATER IN FUEL SENSOR 1
4 KG252709110121 HEAD FUEL FILTER 1
5 KG252709113713 FUEL FILTER MOUNTING BRACKET 1
‐‐‐ KG252709120230 ASSY OVERFLOW LINE(COMBINED) 1
‐‐‐ KG257642914201 CLAMP 1
‐‐‐ KG252709110122 ASSY FUEL LINE (FEED PUMP TO FUEL FILTER) 1
‐‐‐ KG252709110123 ASSY FUEL LINE (FUEL FILTER TO FIP)
‐‐‐ KG252709118001 AIR VENT SCREW (ON FUEL FILTER BANJO) 1
‐‐‐ KG252709120230 ASSY OVERFLOW LINE(COMBINED) 1
‐‐‐ KG252709113201 PIPE UNION BOLT 1
‐‐‐ KG503054209912 W ATER IN FUEL INDICATOR 1

AIR COMPRESSOR COVER
Ref.
No.
1 KG253401177101 FLANGE 1
2 KG253401177801 O RING 1
3 KG11323999114 HEX SCREW M8X18 3
4 KG12520698025 SPRING W ASHER B8 3

EXHAUST MANIFOLD/EGR/TURBOCHARGER

Ref.
No.
1 KG252714113752 EXHAUST MANIFOLD 1
2 KG252514115313 GASKET (EGR PIPE FLANGE TO EGR VALVE) 3
3 KG252714110188 ASSY EGR PIPE W ITH SUPPORT 1
4 KG278601174213 CLAMP (FOR DIPSTICK TUBE) 1
5 KG252714110191 ASSY EGR VALVE CPCB II 1
6 KG252754200111 W IRING HARNESS 1
7 KG252754209908 ECU‐40KVA (EGR) 1
8 KG571407100120 ECU MOUNTING BRACKET 1
‐‐‐ KG252714115306 GASKET (T.C. TO EXH.MANIFOLD) 1
‐‐‐ KG253414115306 GASKET (TC TO INT PIPE) 1
‐‐‐ KG252714510163 ASSY TURBOCHARGER‐CPCB II GENSET 1
‐‐‐ KG252714603804 PIPE‐ TURBOCHARGER TO INTERCOOLER 1
‐‐‐ KG252714603820 PIPE INTERCOOLER TO AIR INTAKE 1
‐‐‐ KG252514605801 RUBBER HOSE (50 I.D. x 80 LONG) 3
‐‐‐ KG11632608308 STUD BM8X30 4
‐‐‐ KG254714116503 CLINCH NUT 1
‐‐‐ KG252714605803 HOSE (TC OUTLET) 1
‐‐‐ KG254709134210 HOSE CLAMP (75 DIA.) 1
‐‐‐ KG254714604215 HOSE CLAMP (65 DIA.) 6
‐ KG278914115304 GASKET‐EGR VALVE TO EGR COOLER 3
‐ KG252714119904 MAGNETIC PICKUP (DUAL COIL) 1

ALTERNATOR/STATER
Ref.
No.
2 KG265415409933 ALTERNATOR 12V 40A 1
3 KG252715143702 ASSY BRACKET (ALTERNATOR MTG.) 1
6 KG252415140110 ASSY CLAMPING ROD 1
‐‐‐ KG254015404201 CLAMPING PIECE 1
‐ KG252415146501 CLAMPING NUT 1
9 KG12080896024 HEX.THIN NUT M12 1
1 KG265115100130 STARTER MOTOR 1
‐‐‐ KG252715108601 SPACER 1
‐‐‐ KG11063896057 HEX. BOLT (M10X60) 1
‐‐‐ KG3121550174 BOLT 1
14 KG3129932801 SPRING 1
‐‐‐ KG206754610101 EARTH STRAP W ITH CU TUBE 1

ENGINE LUBRICATION (OIL PUMP/FILTER)

Ref.
No.
‐ OIL PUMP
1 KG252718100111 ASSY OIL PUMP W ITHOUT STRAINER 1
3 KG3521810401 OIL PUMP HOUSING 1
10 KG252718150115 ASSY STRAINER (OIL PUMP). 1
11 KG252318107901 SHAFT DRIVEN GEAR 1
12 KG252318105409 OIL PUMP GEAR (DRIVEN) 1
13 KG252718107901 DRIVE SHAFT OIL PUMP 1
14 KG252318105410 OIL PUMP GEAR DRIVESHAT 1
15 KG13650505055 W OODRUFF KEY 3X6.5 2
16 KG3121810308 DRIVE GEAR OIL PUMP 1
‐ KG3521840329 VALVE HOUSING OIL PR RELIEF VALVE 1
18 KG3269930401 SPRING PRESSURE RELIEF VALVE 1
19 KG3211810042 PLUNGER (FOR OIL PRESSURE RELIEF VALVE) 1
20 KG252718107201 PLUG (RELIEF VALVE ‐OIL PUMP) 1
21 KG3121860080 GASKET 1
‐ KG885418012523 KIT, OIL PUMP GEAR 1
‐‐‐‐‐‐‐‐‐ CONSISTS OF:
12 ‐ GEAR (DRIVEN) 1
14 ‐ GEAR (DRIVE SHAFT) 1
‐‐‐‐‐‐‐‐‐ OIL FILTER
22 KG252718130176 ASSY OIL FILTER COMPLETE 1
23 KG252718130145 CARTRIDGE LUB. OIL FILTER 1
‐‐‐ KG252718130177 OIL FILTER HEAD 1
17 KG252518135306 GASKET OIL FILTER 1
‐‐‐ KG252718170212 ASSY.OIL LINE (OIL FILTER TO FIP) 1

ENGINE LUBRICATION (OIL PUMP/FILTER)
Ref.
No.
‐‐‐ KG265454509913 OIL PRESSURE SW ITCH 1
‐‐‐ KG257654209930 PRESSURE TRANSDUCER 1

OIL COOLER

Ref.
No.
1 KG252718170164 ASSY OIL COOLER‐AL(M/S POSH) 1
1 KG252718170165 ASSY OIL COOLER‐AL (M/S PN‐NJ) 1
2 KG252118175302 GASKET (CYL. BLOCK) 1
3 KG11071708405 HEX FL BOLT M8X40 27
‐‐‐ KG252718130165 ASSY OIL SUPPLY LINE (FLEXIBLE) 1
‐‐‐ KG252718175821 HOSE‐TC OIL OUTLET TO CYLINDER BLOCK 1
7 KG14280500357 HOSE CLAMP 35 2
‐‐‐ KG16531999031 PIPE UNION BOLT 8 M12X1.5 1
‐‐‐ KG16220510186 SEALING W ASHER 12X16 2
‐‐‐ KG16531999049 PIPE UNION BOLT 10 M14X1.5 1
‐‐‐ KG16220710215 SEALING W ASHER 14X18 6
‐‐‐ KG252718175821 HOSE‐TC OIL OUTLET TO CYLINDER BLOCK 1
16 KG254720124214 HOSE CLAMP ( 32 DIA.) 1
‐‐‐ KG11064010672 HEX BOLT M10X95 1
‐‐‐ KG16220710169 SEALING W ASHER 10X16 IS3175 CU 1
‐‐‐ KG3529900163 HOLLOW SCREW 1
‐‐‐ KG16531999022 PIPE UN BOLT 6 M10X1 1
‐‐‐ KG252718177210 CONNECTOR (OIL COOLER) 1

WATER PUMP

Ref.
No.
1 KG252420100103 ASSY W ATER PUMP 1
2 KG571420105301 GASKET‐W ATER PUMP 1
3 KG3129940330 LOCK PLATE (PULLEY) 3
4 KG11067008351 BOLT M 8X16 6
5 KG252520147009 W ATER PUMP PULLEY 1
28 KG260020600111 FAN 1
32 KG252720156305 V‐BELT (COGGED) 1
‐ KG252520143812 FAN INTERMEDIATE RING 1
33 KG253420120104 ASSY THERMOSTAT 1
36 KG252720125804 RUBBER HOSE (THERMOSTAT TO W ATER PUMP) 1
37 KG14280500357 HOSE CLIP 35 1
45 KG14280500501 HOSE CLAMP 50 3
38 KG253420120108 ASSY.UPPER COOLING W ATER LINE 1
39 KG252720125302 GASKET (UPPER COOLING W ATER LINE) 2
40 KG11342296035 SCREW M 8X20 2
43 KG253450005801 RUBBER HOSE (COOLING W ATER LINE TO THERMOSTAT) 1
‐‐‐ KG252550005812 RUBBER HOSE 1
‐‐‐ KG264154509910 THERMOSTAT SW ITCH ‐100DEG 1
‐‐‐ KG263254209903 TEMPERATURE TRANSDUCER 1
‐‐‐ KG252520100119 W ATER PUMP REPAIR KIT (MAJOR) 1
6 ‐ SEALING MEMBER 1
5 ‐ SLIDING RING 1
7 ‐ AXLE SLIDE RING SEAL 1
7 ‐ CYCLAM SLIDE RING SEAL 1

WATER PUMP

Ref.
No.
8 ‐ RUBBER SEAL RING 1
9 ‐ TAPER ROLLER BEARING 1
10 ‐ TAPER ROLLER BEARING 1
4 ‐ IMPELLER, PLASTIC 1
3 ‐ SHAFT 1
13 ‐ OIL SEAL 1
‐ ‐ GASKETW ATER PUMP 1
15 ‐ SHIM 0.05 MM THICK AR
20 ‐ GASKET 1
25 ‐ GASKET 1
‐ ‐ CIRCLIP A 28X2 (HEAVY DUTY) 1
‐ ‐ HUB 1
‐ KG252520100118 W ATER PUMP REPAIR KIT (MINOR) 1
‐‐‐‐‐‐‐‐‐ CONSISTING OF:
6 ‐ SEALING MEMBER 1
5 ‐ SLIDING RING 1
7 ‐ SEAL SLIDING RING 1
13 ‐ OIL SEAL 1
‐ ‐ GASKETW ATER PUMP 1
20 ‐ GASKET 1
25 ‐ GASKET CLUTCH 1

WATER PUMP
Ref.
No.
‐ ‐ CIRCLIP A 28X2 1

ENGINE SUSPENSION
Ref.
No.
1 252722120115 ASSY SUPPORT ENG.FRONT‐LH 1
‐ 252722120114 ASSY SUPPORT ENG.FRONT‐RH 1
‐ 11064199023 HEX BOLT M1 2X1.5X60 IS13726‐10.9 2
‐ 12520696014 SPRINGW ASHERB12 6
‐ 12460501308 BRIGHT W ASHER 13 IS2016 STSS8451‐8C 6
3 252722120111 ASSY BRACKET‐REAR 2
8 252322107101 LIFTING HOOK FRONT 1
9 252722107107 LIFTING HOOK‐REAR 1

AIR INTAKE SYSTEM FOR 40-63kVA
Ref.
No.
KGI151387 AIR INTAKE SYSTEM 40‐63kVA ALGANDHI 1
1 KGI103045 HEAVY DUTY AIR CLEANER FOR KT40‐63 1
2 KGI118276 AIR FILTER MOUNTING BRACKET FOR KT40‐KT63 CPCB‐II 1

ACCESSORIES FOR ENGINE GROUP 40kVA
Ref.
No.
KGI151503 ENGINE GROUP FOR 40 KVA ‐ CPCB‐II 1
KGI101090 ENGINE TATA 497TCIC FOR 40KVA –CPCB II 1
1 KG272701 VALVE OIL DRAIN 1
2 KGX‐582‐1 CONNECTOR HOSE ADAPTOR 1
3 KGI115042 ADAPTOR FOR OPS 1
4 KGI232005 OIL PRESSURE SENSOR 1
5 KGI232056 COOLANT TEMPERATURE SENSOR 1
6 KG324389 MOUNT VIBRO 2
7 KGI115015 OIL DRAIN ADAPTOR BUSHING M18X1/2 NPT
‐ KG811377 DRAIN PLUG FOR OIL & FUEL & COOLANT
KGI151388 FINAL STAGE FOR 40‐63 KVA ALGANDHI PRO 1
7 KGI118018 OIL DRAIN HOSE 1
8 KGI115016 BUSHING ADAPTER CTS KT40‐63 & KT75/82 1
9 KGI115008 FUEL FILING HOSE 1
10 KG811372 HOSE CLAMP FOR OIL DRAIN 2
11 KG811370 HOSE CLAMP FOR FUEL FILLING 2
‐ KGI105054 KOHLER NAME PLATE 1
‐ KGI232020 RIVET FOR GENSET NAME PLATE 4

Alternator Group for 40 kVA 3 Phase
Ref.
No.
KGI151204 ALTERNATOR ASSEMBLY GROUP FOR KT40 1
- KGI102011 ALTERNATOR 40 KVA ECO32 WITH SAE 3/10 1
1 KG324075 MOUNT, VIBRO 2

Alternator Group for 40 kVA 3 Phase

Ref.
No.
‐ KG6110611950 DIODE FOR EXCITER ARMATURE 1
X KG9911190388 SECURING STUD ECP 3‐L B9/30 1
X KG9911190582 SECURING STUD ECP 3‐L B9/25.4 1
‐ KG7502212040 RING SPACER 1
‐ KG4505005600 DL1 FOR DSR/DER1+CABLR DL1/REG. 1
1 KG8500611200 TERMINAL BOX LID 1
5 KG9909915061 TERMINAL BOARD 76X36 M5 1
7 KG6102204165 NON DRIVE END BRACKET 1
8 KG3501568405 FRAME AND STATOR 3L/4 1
9 KG6102312035 DRIVE END BRACKET MD35/3 1
10 KG4500478657 EXCITER STATOR H‐40 1
13 KG4500568151 EXCITER ARMATURE H‐40 6P + DIODES 1
14 KG2001018010 ROTOR ASSY. 3L/4 MD35 1
14 KG2001018005 ROTOR ASSY. 3L/4 B14 1
15 KG9909514076 FAN MD35‐D50 1
15 KG9909514075 FAN B14 B9‐D40 1
17 KG9900905110 FRONT BEARING 6308‐2RS C3 1
19 KG9900905095 REAR BEARING 6305‐2RS C3 1
23 KG4505005091 ELECTRONIC REGULATOR SR7/2‐G 1
23 KG4505005560 ELECTRONIC REGULATOR DSR 1
28 KG9911190297 COVER STAY BOLT ECP 3‐L 1
39 KG8500626096 PROTECTION SCREEN B14 B9 MD35 1
60 KG6110611150 COUPLING DISC PLATE SAE 6,5 1
75 KG9909509105 CABLE GLAND 1
99 KG6110611508 DISC LOCKING RING‐SPACER 1
107 KG9909505006 NUT‐COVER RUBBER CAP FOR LID 1

Control Panel Group 40kVA 3 Phase STD

Ref.
No.
KGI151581 CONTROLLER GROUP FOR KT 40 II‐3PHASE STD ‐ ALGANDHI 1
1 KGI116590 CONTROL PANEL KE15 TO KT40 ALGANDHI ‐CPCB‐II 1
2 KGI116143 ADC 2203 THREE PHASE STD CONTROLLER 1
3 KGI116592 MCB FOR KT40 II ‐ CSMBS4C63 ‐ 4 POLE 63AMP 1
4 KGI116584 ENGINE HARNESS KT40 TO KT63 CPCB‐II ‐ALGANDHI 1
5 KGI110001 P TYPE CLAMP 2
6 KGI116463 POWER CABLE FOR KT40‐ALGANDHI PRO 1
7 KGI116161 FLEXIBLE CONDUIT PES 22B(22 MM DIA) BLACK 0.4
8 KGI116169 CT 100/5A,2.5VA 21 MM WINDOW DIAMETER(NER21) 3
9 KGI116157 BATTERY CABLE FOR 40‐63 KVA 1
10 KGX‐6046‐5 GROUND STRAP 1
11 KGI118069 FUEL LEVEL INDICATOR 12 VOLT(FOR OCTA) 1
12 KGI116290 EMERGENCY STOP WITH NO ELEMENT 1
‐ KGI116359 BATTERY TERMINAL CAP +VE 1
‐ KGI116360 BATTERY TERMINAL CAP ‐VE 1
13 KGI101006 WATER SEPARATOR ASSEMBLY(D10035000) 1
14 KGI116583 STOP SOLENOID PUSH TYPE12V ‐ ENERGIZE TO STOP 1

Exhaust System for 40kVA

Ref.
No.
KGI151578 EXHAUST SYSTEM KT 40 TO KT63 CPCB‐II ALGANDHI 1
1 KGI218081 EXHAUST PIPE KT 40II TO KT63 II ALGANDHI 1
2 KGI218059 EXHAUST BELLOW KT 40‐63 NEW 1
3 KGI218093 EXHAUST SILENCER KT40‐KT63 ‐RVE 1
4 KGI224005 GASKET EXHAUST PIPE TO SILENCER FOR KT40 50 & 63 3
5 KGI224004 GASKET EXHAUST SILENCER FOR KT40 50 & 63 2
6 KGI224006 GASKET TURBO EXHAUST TO EXHAUST PIPE 1
7 KGI105046 TAIL PIPE FOR KT40‐63 1

KT40 TO KT63Kva RADIATOR

Ref.
No.
KGI151577 RADIATOR ASSEMBLY FOR KT 40 TO KT63 ‐CPCB‐II ALGANDHI 1
1 KGI103024 40‐63 KVA ALUMINIUM TUBE RADIATOR ASSEMBLY EM 1
‐ KG826534 PAD RADIATOR / SILENCER SUPPORT 8
2 KGI103033 TOP HOSE FOR 63 KVA 1
3 KGI103011 BOTTOM HOSE FOR KT63 1
4 KGI103064 CAC OUT (LOW CARBON STEEL) FOR KT40‐KT63 1
5 KGI103065 HOSE CAC‐OUT FOR KT40‐KT63 ‐ A 1
6 KGI103066 HOSE CAC‐OUT FOR KT40‐KT63 ‐ B 1
7 KGI110007 TUBE CAC INLET FOR 62.5KVA TATA ENGINE 1
8 KGI101024 HOSE ELBOW FOR KT63 1
9 KGI101025 HOSE INTERCOOLER PIPE FOR KT63 1
10 KG826809 HOSE CLAMP 50MM KLIPCO SIZE ‐ 2A 3
11 KG811371 HOSE CLAMP FOR FUEL FILLING (40MM TO 60MM) KLIPCO SIZE ‐ 2X 10
12 KGI115059 HOSE CLAMP 6 TO 16MM 2
13 KGI103038 RECOVERY BOTTLE FOR KE15‐30 & KT 40‐ 63 & KT82.5‐KZA125 1
14 KGI118265 BRACKET GROUP RECOVERY BOTTLE MOUNTING KT GENSET 1

Canopy
Ref.
No.
KGI151438 SKID PREPARATION FOR 40kVA CANOPY ALGANDHI PRO 1
- KGI118243 CANOPY FOR KE15 ALGANDHI 1
1 KGI105031 COMBO FUEL GAUGE UNIT OCTA 1
2 KG811377 DRAIN PLUG FOR OIL & FUEL & COOLANT 2
- KGX‐582‐1 CONNECTOR HOSE ADAPTOR 1

CANOPY
Ref.
No.
1 ALTERNATOR END PANEL 1
2 DOOR BV- RHS 1
3 SKID 1
4 DOOR AR- RHS 1
5 SIDE FRAME RHS 1
6 RADIATOR END PANEL 1
7 DOOR BV- LHS 1
8 DOOR BV-LHS 1
9 ROOF 1

Index
Description Page No

A
Air Compressor covers 29
Alternator & Starter 32
Air Intake System ‐1 43
Air Intake System ‐2 45
Accessories for Engine Accessories 46
Alternator Group for 40 kVA 3 Phase 47
Alternator Group for 40 kVA 3 Phase 48, 49
C
Complete Engine Assembly 1
Cylinder Block Assembly 7, 10
Cylinder Head & Cover 11, 13
Control Panel Assembly for 40 kVA 3 PHASE STD 50, 51
Canopy KT 40 kVA 56
Canopy KT 40 kVA Assembly 57
E
Engine Timing 21, 24
Exhaust Manifold /EGR/Turbocharger 30, 31
Engine Lubrication (Oil Pump/Filter) 33, 35
Engine Suspension 44
Exhaust System for 40 kVA 52, 53
F
Fuel Injector Equipment 25, 26
Fuel filter 28

G
Gas kit 3, 6
H
Half Block & Long Block 2

KOHLER POWER SYSTEM

Index
Description Page No

I
Injector 27

M
Moving Parts 14, 20

O
Oil Cooler 36, 37

R
Radiator 54, 55

W
Water Pump 38, 42
KOHLER POWER SYSTEM

KT40 CPCB Ii - Alg

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Section B. GENSET ENGINE ASSEMBLY ........................................................................................................... 46

2. Alternator Group 40 kVA ........................................................................................................................ 47

3. Controller Assembly 63KVA ................................................................................................................... 50

4. Canopy Assembly ................................................................................................................................... 54

Revision No. Document Number / Date Details of Modifications Page No

KOHLER POWER SYSTEM

ENGINE COMPLETE ASSEMBLY

KOHLER PAWER SYSTEM Page 1

HALF BLOCK AND LONG BLOCK

KOHLER PAWER SYSTEM Page 2

KOHLER PAWER SYSTEM Page 3

KOHLER PAWER SYSTEM Page 4

KOHLER PAWER SYSTEM Page 5

KOHLER PAWER SYSTEM Page 6

KOHLER PAWER SYSTEM Page 7

KOHLER PAWER SYSTEM Page 8

KOHLER PAWER SYSTEM Page 9

KOHLER PAWER SYSTEM Page 10

CYLINDER HEAD AND COVER

KOHLER PAWER SYSTEM Page 11

KOHLER PAWER SYSTEM Page 12

CYLINDER HEAD AND COVER

KOHLER PAWER SYSTEM Page 13

KOHLER PAWER SYSTEM Page 14

KOHLER PAWER SYSTEM Page 15

KOHLER PAWER SYSTEM Page 16

KOHLER PAWER SYSTEM Page 17

KOHLER PAWER SYSTEM Page 18

KOHLER PAWER SYSTEM Page 19

KOHLER PAWER SYSTEM Page 20

KOHLER PAWER SYSTEM Page 21

KOHLER PAWER SYSTEM Page 22

KOHLER PAWER SYSTEM Page 23

KOHLER PAWER SYSTEM Page 24

FUEL INJECTOR EQUIPMENT

KOHLER PAWER SYSTEM Page 25

KOHLER PAWER SYSTEM Page 26

KOHLER PAWER SYSTEM Page 27

KOHLER PAWER SYSTEM Page 28

AIR COMPRESSOR COVER

KOHLER PAWER SYSTEM Page 29

KOHLER PAWER SYSTEM Page 30

KOHLER PAWER SYSTEM Page 31

KOHLER PAWER SYSTEM Page 32

ENGINE LUBRICATION (OIL PUMP/FILTER)

KOHLER PAWER SYSTEM Page 33

KOHLER PAWER SYSTEM Page 34

ENGINE LUBRICATION (OIL PUMP/FILTER)

KOHLER PAWER SYSTEM Page 35

KOHLER PAWER SYSTEM Page 36

KOHLER PAWER SYSTEM Page 37

KOHLER PAWER SYSTEM Page 38

KOHLER PAWER SYSTEM Page 39

KOHLER PAWER SYSTEM Page 40

KOHLER PAWER SYSTEM Page 41

KOHLER PAWER SYSTEM Page 42

KOHLER PAWER SYSTEM Page 43