Home

KD225 - KD315 - KD350 KD400 - KD440

1. 41 Dynamic balancer on nnee 41 E mmm 43 UMN CGC MENT __ _ __ _ 43 Timing angles for operation 0 15 valve play 44 Timing angles for inspection 0 65 0 70 valve 44 OPEET OV 6 TNR 45 Speed governor removal 45 Refitting gear cover on timing Side Rm 45 9S LUBRICATION SYSTEM acerca irc es nese nce 46 225 315 350 lubrication system and breather recirculation system 46 KD 400 440 lubrication system and breather recirculation system 47 DINA Dam asian aga ak aa aaa ee eee ee ee 48 Oil pump clearance between rotors EET EET 48 Oil pressure regulation ai aa aa napa nan rawa hee aba 48 PTS A aE a E m 48 iE A EEE 49 Oil pressure CCCI 49
2. 49 Oil pressure curve at idle SPECO 50 50 Fuelling injection circuit for KD 315 350 400 440 51 Fuelling injection circuit for KD 225 E 51 KD 225 315 350 400 440 Workshop Manual cod ED0053029330_1 rev 00 9 KOHLER INDEX SUI 52 Fuel filter KD 225 315 350 400 440 52 Fuel filter KD 225 version with internal filter in mener 52 Feed pump Optional E Emm 52 F l pump drive DIOWUSION aaa kaka a m 53 ACON DUD _________ E E 53 Injection pump fitting in the 53 Injection pump components and disassembly aces dba 54 Injection pump body plunger and delivery 54 ITI STON pump UNS Emo 54 injection pump non feturn vale Lak Em 55 Outlet fitting components for 315 350 EPA E 400 440 55 Injection pump Rilsan tube removal Rete 29 Injection pump Rilsan tube refitting 55 Injection pump delivery check on test 29
3. 9 70 58416 s Ah 70 AMES UTA Proce EET 70 injection systems protecti ri M 70 External eio T T DE 70 Procedures to be carried out before start the 71 IS TORQUE SPECIFICATIONS 72 Maim torque e GG a A E mm 72 Rowe 21 NUNT ee ent GAE 72 Table of tightening torques for standard screws coarse aee 73 Table of tightening torques for standard screws fine 73 KD 225 315 350 400 440 Workshop Manual cod ED0053029330_1 rev 00 KOHLER TROUBLE SHOOTING 1 POSSIBLE CAUSES AND TROUBLE SHOOTING THE ENGINE MUST BE STOPPED IMMEDIATELY WHEN 1 The engine rpms suddenly increase and decrease 2 Asudden and unusual noise is heard 3 The colour of the exhaust fumes suddenly darkens 4 The oil pressure indicator light turns on while running TABLE OF LIKELY ANOMALIES AND THEIR SYMPTOMS The following table contains the possible causes of some failures which may occur during operation Always perform these simple checks before removing or replacing any part TROUBLE POSSIBLE CAUSE Engine starts but Non uniform speed oil and fuel d
4. dnndtideuntaeneceebetdeadapbhiauendadeedanntdoceseiieneaedeus 9 Safety and environmental impact 9 3 MODEL NUMBER AND IDENTIFICATION 2 000 0 0 00 11 Manufacturer and motor identification data iieri Ye PD Yn ga val Rex 11 ADPDFOVAL TINA ss MM A iMd pt A 11 A ies annA 12 oie phe leis kd 4 aan eee eee ere 12 0 L 13 ___ __ 14 Characteristics power torque and specific fuel consumption curves 2 14 6 OVERALL DIMENSIONS jasa inarang aan beka wai ____ ___ a a A NG 16 7 MAINTENANCE RECOMMENDED OIL TYPE REFILLING nnne 18 VMN MR 18 c ce 18 Recommended 19 Apoa 2 9 61 aaa KA AA Core 2 PER 19 8 DISASSEMBLYIREASSEMBIIUY apake uus gana RUE URS nan REESE 20 Disassembly Eom 20 Dry air cleaner for kd 315 and Kd oe uid utut pa
5. KOHLER TECHNICAL DATA 4 CHARACTERISTICS KD 400 440 ENGINE TYPE Number of cylinders Bore Stroke Swept volume Compression ratio 20 3 1 3600 80 1269 EEC ISO 1585 7 7 10 5 Power kW NB ISO 3046 1 IFN 7 0 9 6 NA ISO 3046 1 ICXN 6 4 8 7 Max torque Fuel consumption Oil consumption Capacity of standard oil sump Recommended battery Dry weight Combustion air volume at 3600 r p m Cooling air volume at 3600 r p m Max permissible driving shaft axial load in both directions continuous service for up to 30 min Max inclination discontinuous service for about 1 min permanent service Referred to power Referred to NB power Depending on application KD 225 315 350 400 440 Workshop Manual cod ED0053029330_1 rev 00 13 KOHLER 5 CHARACTERISTICS CHARACTERISTICS POWER TORQUE AND SPECIFIC FUEL CONSUMPTION CURVES KD 225 EUER Ep E EEE E E E aa ET EL ETAT m B ie p 4 T E AT COO 8 AC AZ E A A TE mE CECA T T i E T
6. Remove the drain plug and let the protective oil flow out completely Replace the drain plug Fill up with engine oil as far as the upper level of the dipstick using the oil recommended by the manufacturer for normal engine operation 175 KD 225 315 350 400 440 Workshop Manual cod 0053029330 1 ed 00 71 15 TORQUE SPECIFICATIONS KOHLER MAIN TORQUE SPECIFICATIONS POSITION Reference fig Diam and pitch Torque Nm Torque Torque XS ad mm 225 315 350 400 440 10 Re coil starting fig 18 p 25 Connecting rod aluminium fig 51 p 36 Connecting rod steel fig 13 p 23 Rocker arm adjusting screw lock nut fig 13 p 23 Rocker arm adjusting screw pin fig 19 p 25 Shroud fig 12 p 23 Rocker arm cover Control arm cover Enhanced engine oil sump Exhaust manifold Air cleaner support fig 3 p 20 Oil filter head fig 90 p 49 Injection tappet guide screw fig 103 104 p 53 Injector fixing onto the head Muffler on manifold fig 9 10 p 22 Fuel pump fig 100 p 52 Injection pump union Injection pump fastening screws fig 102 p 53 Oil pump support fig 84 p 48 Gear cover timing side fig 81 p 45 Calibrated fitting for hydraulic tappet lubrication Injection pump delivery union fig
7. m 2 ra TH de 1 8 is ora 11 10 16 48 1 8 7 14 44 7 8 1 16 9 12 12 14 1 4 6 2 8 5 4 6 44 W NAN E i 40 g kWh giCVh gikWh g CVh 4 3122 340 250 2 8 340 250 ZEE HERR es 0 230 3 FEES sanjan THE Bi 320 230 44 300 2 gan Ha zu 300 2 E uL LK HH A T AN THE 195 08 cS 260 190 12 H 260 190 HH Hri 1200 1600 2000 2400 2800 3200 3600 1200 1600 2000 2400 2800 3200 3600 r p m r p m N 80 1269 EEC ISO 1585 AUTOMOTIVE RATING Intermittent operation with variable speed and variable load NB ISO 3046 1 IFN RATING WITH NO OWERLOAD CAPABILITY continuos ligth duty operation with constant speed and variable load NA ISO 3046 1 ICXN CONTINUOS RATING WITH OVERLOAD CAPABILITY continuos heavy duty with constant speed and constant load MN Torque at N power C Specific fuel consumption at NB power The above power values refer to an engine fitted with air cleaner and standard muffler after testing and at the environmental conditions of 20 C and 1 bar Max power tolerance is 596 Power decreases by approximately 1 every 100 m di altitude and by 2 every 5 C ab
8. 56 _ _____ _______________ 56 Static injection lead test on Ty WHS E MUN pU NN 57 Mecon advance adjustmMmeN TONES mmm 58 ECTO E A 58 Leakage esdi a 59 ana EAE anga ngne doh 59 PIA SG COR CAR ARON e 59 ie ELECTRICAL 5 E 62 12V 12A electric ignition diagram TOO nnnenne 61 E E REE aa nag akan cS 61 Alternator battery charger graph 12V 12 5 ssa cx tae usan npa Hund eu Ene 61 24V 9A alternator battery recharging GUI VO 62 12V 30A alternator battery recharging CUIV 6 62 AIO 2 05 TD m AA iea a kaiaa Aan Aare ESR aiina inia 62 12V electric starter diagram with voltage regulator built into the ignition 63 12V electric ignition layout with motor protection 63 Diagram of electric starter motor protection with sole self winding starter without battery optional 64 Testing voltage regulator for proper operation cau cud Mess uU
9. Kohler declines all responsibility for accidents or for failure to comply with the requirements of law if changes are made to the engine s functional parameters or to the fuel flow rate adjustments and speed of rotation if seals are removed or if parts not described in the operating and maintenance manual are removed and reassembled by unauthorized personnel WARNING In addition to all other machine specifications ensure that the engine is in a near horizontal position when starting If starting manually ensure that the necessary operations can be performed without any risk of striking against walls or dangerous objects Rope starting except for recoil rope starting is not permitted even in emergencies Check that the machine is stable so that there is no risk of it overturning Get to know the engine speed adjustment and machine stop operations environments The internal combustion process generates carbon monoxide an odourless and highly toxic gas so spending too long a time in an environment where the engine discharges its exhaust products freely can lead to loss of consciousness and even death The engine may not be used in environments containing flammable materials explosive atmospheres or easily combustible powders unless adequate specific precautions have been taken and are clearly stated and certified for the machine To prevent the risk of fire keep the machine at a dis
10. 2nd piston ring 1 00 1 50 0 30 0 50 3rd piston ring oil scraper nitred 0 25 0 50 1st piston ring chromated 0 20 0 35 2nd piston ring torsional 0 30 0 50 3rd piston ring oil scraper 0 20 0 40 Wear limit 1 mm for the 2nd piston ring of 225 and KD 350 engines the wear limit is 2 0 mm KD 225 315 350 400 440 Workshop Manual cod ED0053029330_1 rev 00 33 KOHLER 8 DISASSEMBLY REASSEMBLY Piston rings play between the slots mm 350 400 OTOA 007 020 0 035 0 11 0 07 0 11 0 04 0 08 0 05 0 08 0 050 009 005 0 09 0 03 0 07 1004 0075 0030 0087 0 03 0 07 Replace the piston or piston rings if the value exceeds the maximum limit Piston rings assembly order A 1st Chromium plated piston ring nitrided for 225 350 400 B 2nd piston ring torsional C 3rd piston ring oil scraper nitrided for 225 350 400 D Chromium plated zone Note If a word top or some other word is written on the surface of a piston ring mount that surface upwards Before inserting the piston into the cylinder oil and turn the pi ston rings so that the cuts are staggered 120 to each other In KD 350 and KD 225 engines the second piston ring is not torsional while the first and third piston rings do not have chro mium plated zones but are nitrided T Lubricate the following parts with oil before mounting the pi ston pin the pisto
11. cv TEENETE Or m um 7 16 SERRA SSeS 1 6 He emt T Nun gt 5 45 27 rn LIT 8 cals NG AA End 56 PTT Ma T1 PTT TTT IT 1 3 ii 4 qe PTT 00017 EN 7 1 2 5 AY SERS ERRORS AAP 6 ak TT NYAN BEER LL Le aa 6 aa ee ee et a UC LLLLLLLLLLLLLLUZLEFLI M Uu uL 111111 5 LLL LE LEL LL LLLI Em EERE ERE RESEED PARP ABR LILLLELELELLEUA T A ag JATI T TITI YF ap 5 p PET p I 4 ap O 47 eee NANA NANDA A7 AUR T 4 T AAZ ee EN T 26 AATA TT 3 ET LLLLLLLLLLLLLLLLLLL AAZ 7 ee 2244 3 42 727 27 2 7232 err 2 BRERA ERA eae 2 pT eT se
12. 65 SUSIE TINO IEEE Es Hm 65 Characteristic curves for starting motor type DW L 12V 1 1 65 Characteristic curves of Bosch starter motor type DW L 12V 0 9 66 Characteristic curves of Bosch starter motor type DW L 24V 1 6 66 NILA SW E i DOS IMON m E mmm 66 AICS NG ea 92105902 67 Idling speed setting in no load conditions 67 Idle speed adjustment for small car 67 Full speed setting in no load conditions 67 12 SETTINGS ADJUSTMENTS ian aane ajun gag taa najana a A nanam SN a alan eaaa uic EE n E VERNON RYE ajaa kauh 68 Adjustments KD 225 400 440 68 No load idling adjustment i ERR T 68 No load top rate adjustment 1 20 68 Injection pump flow rate adjustment For KD 225 315 350 400 440 68 Injection pump delivery limiting and torque adapter 68 pump delivery Setting RETE m 69 Required settings most 5 sese ascertain ro erae tn erano enses bn ex ene e AEAEE aana Nana 69 M
13. The tappet is shortened by less than 0 1mm each cycle This allows the tappet to make up the reduction in play while the engine is running It is not necessary for the oil to reach the tappet on the downward stroke light pressure is enough to ensure that air bubbles do not form The tappet may be supplied with the high pressure chamber full or empty The low pressure chamber is always empty The tappet should always be handled in an upright position to prevent the high pressure chamber from emptying The surface that comes into contact with the cam should be lubricated generously during assembly using AS COMPUND 40 type MOLYSLIP see figure This operation is important to ensure correct lubrication right from the start The distribution system is assembled as follows Make sure that the piston is between the Bottom Dead Centre and the halfway point Insert the rods into position on the tappets Mount the rocker arm and the joint block then tighten the fixing nut to the specified torque DO NOT START THE ENGINE FOR AT LEAST 4 HOURS AFTER TIGHTENING THE ROCKER ARMS because the valve piston contact may be put at risk a b d The tappet is unloaded when it is possible to shift the internal part by 3 5 4 mm using a force of 30 Nm If the tappets are loaded for example if they have been left in a horizontal position the engine will be noisy during the first few minutes after switching on until the air has been completely drained o
14. 2 adim 210 ILL a 1 BR RE I LL LLLLLLLLLLLL BK rd 359 1 80 1269 ISO 1585 AUTOMOTIVE RATING Intermittent operation with variable speed and variable load NB ISO 3046 1 IFN RATING WITH OWERLOAD CAPABILITY continuos ligth duty operation with constant speed and variable load NA ISO 3046 1 ICXN CONTINUOS RATING WITH OVERLOAD CAPABILITY continuos heavy duty with constant speed and constant load MN Torque at N power C Specific fuel consumption at NB power The above power values refer to an engine fitted with air cleaner and standard muffler after testing and at the environmental conditions of 20 C and 1 bar Max power tolerance is 596 Power decreases by approximately 1 every 100 m di altitude and by 2 every 5 C above 25 C Note Consult KOHLER for power torque curves and specific consumptions at rates differing from those given above 14 KD 225 315 350 400 440 Workshop Manual cod ED0053029330_1 ed_ rev 00 KOHLER CHARACTERISTICS 5 CHARACTERISTICS POWER TORQUE AND SPECIFIC FUEL CONSUMPTION CURVES KD 400 KD 440 ive Nm kgm 5 21 12 UNE 2 TE _
15. ed_ rev 00 KOHLER DISASSEMBLY REASSEMBLY Always check the the spring and valve to make sure they are in a good conditions Rocker arm cover Breather ricirculation Crankcase vapor recirculation occurs through duct 4 If the air filter clogs the increased intake vacuum could suck oil throu gh duct 4 into the combustion chamber causing the engine to operate at a runaway rate This is prevented by valcuum valve 2 which when the vacuum increases overcomes the resistance of spring 3 and shuts the duct 4 Make sure that oil plug 5 is correctly closed Refit cover 1 and tighten rocker arm cover to 10 Nm Valve rocker arm clearance KD 225 315 350 Set valve rocker arm clearance when the engine is cold bring piston to top dead center on the compression stroke and set clearance at 0 10 0 15 mm using a thickness gauge Tighten lock nut N B Since an automatic decompression device is available on the exhaust lobe manualy rotate the engine until the tappets are at lowest point T The engines KD 400 and 440 have hydraulic tappets therefore no adjustment is required When replacing the rocket arms position the piston at the bottom dead centre and tighten the fixing screw gradually to adjust the hydraulic tappets While tightening make sure that A fits correctly into B fig 13a The adjusting screw pin should be tightened to 20 Nm H Do not start the engine for approximately 4
16. gulator Start and stop the engine a several times until battery voltage drops below 13V When battery voltage reaches 14 5V the ammeter current should sud denly drop down to almost zero Replace regulator if recharge current is zero with voltage below 12 5V BLACK BLUE When the engine is running do not disconnect battery cables or switch key to off position Keep regulator away from heat sources above 75 C Do no electric welding on engine or application 131 Starting motor Bosch type DW L 12V 1 1 KW for KD 315 350 400 440 Bosch type DW L 12V 0 9 KW for KD 225 Anti clockwise rotation direction viewed from pinion side A 17 5 19 5 mm distance from flywheel rim surface to starter motor flange surface Note Contact Bosch service centers for repair operations 132 Characteristic curves for starting motor type DW L 12V 1 1 KW n RPIM RE 30004 4 54 15 The curves were obtained at a temperature of 20 C with 66 Ah bat tery 2800 2600 2400 U Motor terminal voltage in Volts n Motor speed in r p m M Torque in Nm J A Absorbed current in Ampere 2200 2000 1800 1600 1400 1200 1000 ZT E et ST NY aN Im s KD 225 315 350 400 440 Workshop Manual cod 0053029330 1 ed 00 65 11 ELECTRIC
17. 105 p 54 Fuel tank bottom lower fixing Enhanced sump half shells fig 14 p 24 8x1 25 8x1 25 14x1 5 Fuel tank top fixing 20 Oil drain plug fig 21 p 26 Cylinder head 9 fig 21 p 26 6x1 10 Flywheel pulley fixing screws 8x1 25 Flywheel fig 20 p 25 14x1 5 sinistra USE OF SEALANT 150 POSITION TYPE OF SEALANT Loctite 648 BV Loctite Form a gasket N 6 Locking of adjustment lever box Air valve case M6 fixing screw for fuel filter Loctite 222 fixing screw for muffler bracket Loctite 222 MB fixing screws for fuel supply pump Loctite 222 M16 fixing screw for oil intake filter and cover Loctite 222 M6 finxing screws for air shroud Loctite 222 6 stud bolt for dry air filter cover Loctite 270 M6 fixing screws for side oil refilling union Loctite 270 M6 screw for injection tappet guide M8 STEI screw for closing oil intake hole cover Loctite 270 Loctite 270 M8 STEI screw for closing crankcase lubrication hole Loctite 270 MB fixing screws for air filter support and intake manifold Loctite 270 Rocker arm fulcrum screws Loctite 270 Stator screws Loctite 270 8 stud bolts for tank Loctite 270 Plastoferrite on flywheel Base coupling surface cover Coupling surface for enhanced engine oil sump Loctite 480 Loctite 5205 Loctite 5205 Coupling surface for enha
18. 107 Injection pump components and disassembly 1 Delivery union 2 Filler 3 Spring 4 Gasket 5 Valve 6 Gasket 7 Spring retainer 8 Spring 9 Spring plate 10 Rack 11 Plunger 12 Pin A Fuel outlet union B Fuel intake union C Fastening D Barrel E RH helix Demount in compliance with the numeric order Plate 9 is held firm by pins 12 Lever up by inserting a tool between the plate and the body of the pump The volume shifted by delivery valve 5 is 15 the pump of KD 315 350 and 25 mm in the pump of KD 225 is 21 the pump of KD 400 440 Injection pump body plunger and delivery valve Components Dimensions mm 1 Delivery valve A 5 50 nominal diam 225 315 350 2 Barrel A 7 00 nominal diam 400 440 3 Plunger A 6 00 nominal diam 315 350 EPA 4 Right helix B 2 00 2 03 5 Delay notch C 1 50 1 53 6 Pump body 7 Collar Note The injection pump installed in engines for small vehicles soundproof generating sets EPA and KD 400 440 engines are characterised by the inclusion of a collar 1 which contribu tes to noise reduction Injection pump refitting The plunger is fitted with helix E facing towards the outlet union A if it is mistakenly fitted with the helix facing the intake coupling B the injection pump no longer operates there is no danger of engine ru naway complete refitting following fig 107 54 KD 225 315 350 400 440 Workshop Manual cod ED00530
19. 225 35 30 10 000 10 020 D 10 040 10 055 Note Valve guides with outer diameters increased by 0 5 mm are also available as spares In this case housing C must be in creased by 0 5 mm for assembly purposes Valves guide insertion Heat the block to a temperature of 160 180 Force the guides considering distance A and B in relation to the block surface Dimensions mm for KD 315 350 400 440 A 25 8 26 2 B 34 8 35 2 A me EN MF ff E Dimensions mm for KD 225 A 23 8 24 2 B 28 8 29 2 KD 225 315 350 400 440 Workshop ED0053029330_1 rev 00 29 8 DISASSEMBLY REASSEMBLY KOHLER Dimensions and clearance between guides and valve stems mm A 6020 6235 B 54995 60 00015 255 7000 6285 7000 020280 055 Clearance 0020 0050 Limit Dimensions mm 3230 3231 0 14 Valves seats and valve seat bores 315 350 270052771 400 440 39 00539 01 32400 32762 37 10 37 12 39 0 39 L2 2820 2851 V N 3300 3301 28 60 28 62 22210522312 220222202 Since the seats supplied pre finished they must not be machined after having been inserted Note Valve seat lapping After cutting valve seats lap valve seats with fine lapping compound The sealing surface
20. See page 18 for the frequency with which the filtering material must be changed 20 KD 225 315 350 400 440 Workshop Manual cod ED0053029330_1 ed_ rev 00 KOHLER DISASSEMBLY REASSEMBLY Clean the filtering element with air blast Air must be blown from inside to outside the cartridge at a distance of at least 15 cm from the paper Lightly and repeatedly tap the element on a hard surface to eliminate all excess dirt Dry air cleaner for KD 400 440 Open air cleaner fig 4 Unscrew the wing nut 1 fig 4a and remove the filter element fig 5 Check the rubber seal is undamaged A fig 5a Clean the filtering element with air blast If the filtering element has been already cleaned other times or if it is irreparably clogged throw it away and replace Refit the air filter and make sure the seal A is properly inserted then tighten the wing nut 1 Make sure that the filter is mounted in the correct way other wise dust and other impurities could ilfiltrate into the intake ducts Prefilter for dry air filter Remove and clean the pre filter if clogged KD 225 315 350 400 440 Workshop Manual cod ED0053029330_1 rev 00 21 KOHLER 8 DISASSEMBLY REASSEMBLY Never clean the filtering element 6 using solvents with a low A flash point This could cause an explosion Make sure that the retention rings 4 5 are in a good condition and re
21. hours to allow the hydraulic tappets to settle completely 13a Once the tappets have settled tighten the bolt to 10Nm KD 225 315 350 400 440 Workshop Manual cod 0053029330 1 ed 00 23 KOHLER 8 DISASSEMBLY REASSEMBLY Hydraulic tappets KD 400 440 Distribution uses hydraulic tappets for automatic adjustment of valve clearance The figure shows the tappet used in KD 400 engines Caption 1 Lock ring 2 Upper collar 3 Oil inlet holes 4 Low pressure chamber 5 Piston 6 Play recovery spring 7 Case 8 Area to be lubricated 9 High pressure chamber 10 Check valve 11 Identification marks Fill the low pressure chamber through the oil inlet holes If clearance occurs while running as the tappet returns to the base of the camshaft the play recovery spring stretches out keeping all timing system parts close together While the play recovery spring is stretching the check valve lets oil into the high pressure chamber from the low pressure chamber to recover the increase in volume in the high pressure chamber caused by the stretching spring In this way since oil is practically uncontrollable when the valve is next opened play will be completely recovered During each cycle a small amount of oil is drawn from the high pressure chamber into the piston coupling wall with the case and then passing through the internal inlet hole flows into the low pressure chamber
22. play between the slots mm seis nacen Sama acc oaa surdi Nga 34 Pistontings assembly EEEn EEE Ri GA 34 UU MR 34 E MERERI 34 PISTON dm 35 OTIS CUNO 0 na wanan agan NE 36 GONNE ING FOC PRON PIN 36 Connecting r d algne MeNi RE m an Bada Sa KAN ak a aaa A a aia 36 Sys ia AY RERO mem 36 Drive shat C 37 Drive shaft lubrication ducts bore thread on flywheel side n aana 37 Dive shal SONGGON RE 37 Drive shaft main journal crankpin diameter gear cover bearing inside diameter on timing side 37 Crankshaft journal diameter mm 38 PAN ANI NR rS 38 i r cic kag AN Ba TE 39 Camshait journals and DOLG ETT m om 39 Dimensions of camshaft journals and bore 39 ANU NS NC ERR 39 C RAI ce E E E E E E 40 Camshaft Antireverse system KD 400 440 40 eke rele a aana agra eee ne 41 Camshaft end
23. pump flow rate adjustment for KD 225 315 350 400 440 This regulation must be carried out by means of a water brake other wise the adjustment will be approximate proceed in the following way Loosen flow rate limiter C by 5 turns Accelerate the engine to no load top rate i e to 3800 rpm Re tighten limiter C until the engine tends to decelerate Loosen limiter C by one and a half turns Tighten the check nut Note Tighten C if the engine produces an excessive amount of exhaust in the maximum load condition loosen C if no smoke is exhausted and if the engine is unable to develop its maximum power Injection pump delivery limiting and torque adapter standard Delivery limiting device C has the function of limiting the injection pump max delivery The same device also acts as torque adapter The speed governor spring acts on lever L with standing the resistance opposed by spring M inside the cylinder The stroke allowed by the torque device to lever L is 0 20 0 25 mm As a result of this pump delivery increases and torque reaces its peak value Note In generator sets and power welders the torque setting device acts as a delivery limiter only 68 KD 225 315 350 400 440 Workshop Manual cod ED0053029330 1 ed rev 00 KOHLER SETTINGS ADJUSTMENT 12 Injection pump delivery setting 1 Bring engine to idling speed 2 Unscrew delivery limiting device C see fig 145 3 Bring
24. the engine to the power and rpm required by the manufactu rer of the device 4 Check that fuel consumption falls within the table specifications see below If consumption is not as indicated change balance conditions at the torque dynamometer by varying the load and adjusting the gover nor Under stable engine conditions check consumption again 5 Tighten limiting device C until the engine rpm decreases Lock the limiting device by means of lock nut 6 Release brake completely and check at what speed the engine becomes stable Speed governor should comply with the requirements of the class indicated by the manufacturer of the device 7 Stop the engine 8 Check valve clearance when engine has cooled down 148 Required settings the most common ones KD 225 315 350 400 440 Workshop Manual cod 0053029330 1 ed 00 69 13 STORAGE KOHLER When the engines are not used for more than 3 months they must be protected by the measures described below STORAGE Internal engine protection Start the engine and allow it to heat up Remove the drain plug and let the oil flow out completely Replace the oil filter with a new one Clean the oil drain plug and after inserting a new gasket tighten it Fill up with oil to the upper level of the dipstick using AGIP RUSTIA C3
25. 0 for countries in which this product is available find an equivalent product on the market Start the engine for about 10 minutes check for oil leaks and then stop the engine Injection systems protection Empty the fuel tank Replace the fuel filter with a new one Fill up with fuel containing 10 AGIP RUSTIA NT After bleeding air start the engine make sure there are no fuel leaks and then stop the engine External engine protection Carefully clean the cylinder cooling system fins and the flywheel fins Protect the external non painted surfaces with AGIP RUSTIA 68 F Seal the intake and exhaust systems with adhesive tape Cover the engine with a nylon or plastic sheet Store in a dry place preferably not directly on the ground and away from high voltage electricity lines 70 KD 225 315 350 400 440 Workshop Manual cod ED0053029330_1 ed_ rev 00 KOHLER STORAGE 14 PROCEDURES TO BE CARRIED OUT BEFORE START THE ENGINE Remove all protections and coverings Remove the protective oil from the outside of the engine using suitable products solvent degreaser Remove the injector and using a flask pour engine oil on the piston crown no more than 2 cc Remove rocker arm cover and spray engine oil on the valves then turn the crankshaft manually a few revolutions Start the engine and allow it to heat up for about 10 minutes
26. 0 1 1 notch 0 510 0 600 1 1 notch 0 500 0 600 1 2 2 notches 0 610 0 700 12 2 notches 0 600 0 700 1 2 3 notches Having chosen the required thickness mount the gasket as shown in the figure see letter A Find the number of notches in zone B to find the thickness of the ga sket when the cylinder head is mounted The gasket thickness given in the table is the one obtained with the gasket mounted and the head torqued KD 225 315 350 400 440 Workshop Manual cod ED0053029330_1 rev 00 35 KOHLER 8 DISASSEMBLY REASSEMBLY When remounting the big end bearings remember to thorou ghly clean the parts and generously lubricate them to prevent seizure when the engine is started up for the first time Connecting rod Demount the connecting rod and proceed with the following inspec tions The big end cap and big end bear the same numbers When remounting mount the cap from the same side as in C of the figure Tighten the KD 225 bolts to a 23 Nm torque value Tighten the bolts to a 30 Nm torque value for KD 315 350 400 440 Connecting rod piston pin 400 440 9920 1400 03 109 9 705L10 05 124 97 125 03 2 01020 020 22 1022 020 23010 2 3 020 19 995 20 000 21 995 22 000 22 995 23 000 Clearance 0 010 0 025 Limit 0 05 Note The connecting rod has no insert bearings connecting rod big end diameter See fig 62 for Connecti
27. 00 27 KOHLER 8 DISASSEMBLY REASSEMBLY Valves Disassembly Components 1 Valve stem 2 Oil seal 3 Spring washer set 4 Spring 5 Cap 6 Half collets Note To remove half collets place a suitable plate under the valve head and press down firmly as indicated in the figure Valves Oil seal in valve guide To prevent seal 2 from being deformed when the valve guide is mounted fit it into tool 1 serial N 7107 1460 047 after having thorou ghly lubricated it then proceed as indicated in the figure Valve springs Measure the free length with a caliper Engine KD 225 315 350 Free length A 33 72 Engine KD 400 440 Free length A 34 88 Note Replace the spring if the free length A is 1 mm less than speci fied 28 KD 225 315 350 400 440 Workshop Manual cod ED0053029330_1 rev 00 KOHLER DISASSEMBLY REASSEMBLY Valves characteristics Intake valve A o Base Material X 45 Cr Si8 uni3992 Chrome Plated 91 1 31 6 35 8 36 0 37 6 37 8 21 92 0 92 4 45 35 45 65 Weld Joint Chrome Plated Base Material gt X45CrSi8UNI3992 Base Material gt X70CrMnNiN21 6 UNI3992 45 351 45 65 Valves guides and housings 1 Intake guide 2 Exhaust guide Dimensions mm for KD 315 350 400 440 40 31 11 000 11 018 D 11 040 11 055 Dimensions mm for
28. 29330_1 ed_ rev 00 KOHLER FUEL SYSTEM 10 Injection pump non return valve The exhaust union has a non return valve A The purpose of this val KD ve is to improve the injection phase by expelling the air in the fuel and 225 315 350 preventing it from being sucked in by the pump during the intake pha se This also ensures that the engine stops promptly as soon as the stopping device is activated by means of the solenoid valve Outlet fitting components for 315 350 EPA E 400 440 engines KD 315 350 EPA 1 Outlet fitting 400 440 2 Ball 1 8 3 Threaded dowel 108 Do not cut the tube longitudinally because you might damage the union Injection pump Rilsan tube removal Cut nylon tube at A Remove the portion of the tube which is still connected to the union using common pliers Pinch the nylon tube without impairing the sea ling properties of union see figure Re cycle the same feeding tube if the remaining length allows it re place if not Injection pump Rilsan tube refitting The outlet tube is made of nylon type Rilsan it is connected to the su itable injection pump union by means of special pliers Ser No 7104 1460 023 and a plastic head hammer see figure KD 225 315 350 400 440 Workshop Manual cod 0053029330 1 ed 00 55 KOHLER 10 FUEL SYSTEM Injection pump delivery check on test bench 1 Delivery control rack rod 2 Ra
29. 350 400 440 Workshop Manual cod ED0053029330_1 rev 00 25 KOHLER 8 DISASSEMBLY REASSEMBLY Re coil starting Operation When pulling handle 10 thanks to the action of friction spring 12 te eth 4 protrude from cap 3 After starting these teeth go back to the initial position because the cap rotates Rope 9 is re wound around pulley 6 by means of spring 7 Components 1 Retainer 7 Spring 2 Washer 8 Guard 3 Cap 9 Rope 4 Flyweights 10 Handle 5 Spring 11 Rope guide 6 Pulley 12 Spring Note there are two kinds of guards 8 one for engines with an rpm above 2000 and one with fewer cooling channels for engines with a lower rpm On reassembly tighten the screws to 10Nm Shroud The shroud and the metal sheeting outside the cylinder are made of special material ANTIPHON which absorbs noise thus reducing to tal engine sound pressure levels When refitting tighten shroud screws to 10 Nm During the demounting phases pay particular attention to pre A vent the flywheel from dropping as this could seriously injure the operator Wear protective goggles when removing the flywheel ring Flywheel Unscrew bolt 1 in a clockwise direction Remove the flywheel with a puller Make sure that the tapered surface that couples to the drive shaft is not damaged To remove the starter rim it is advisable to cut it into several parts with a hacksaw and to then use a chisel To replace slowly
30. 5 315 350 400 440 Workshop Manual cod ED0053029330_1 rev 00 KOHLER DISASSEMBLY REASSEMBLY Dinamic balancer timing Position crankshaft as shown in the figure Introduce the dynamic balancer so that timing mark 1 engages between teeth 2 of the crankshaft gear Valve timing check Remove the tank and conveyor to access the flywheel Carry out the inspections on the drive shaft The values given are measured on the circumference of the flywheel Adjust the valve play as indicated on the next page Reset the comparator on the cap of intake valve 1 Turn the drive shaft in the spinning direction and find point at which the intake valve starts to open in relation to top dead center A and p point at which the intake valve shuts after bottom dead center B see fig 77 78 Proceed in a similar way with the exhaust valve checking Y point at which the exhaust valve opens and 6 point at which the exhaust valve shuts KD 225 315 350 400 440 Workshop Manual cod 0053029330 1 ed 00 43 DISASSEMBLY REASSEMBLY KOHLER Timing angles for operation 0 15 valve play For KD 225 6 before A corresponding to 12 mm 22 after B corresponding to 44 mm y 58 before B corresponding to 116 mm 10 after A corresponding to 20 mm Values measured on the circumference of the flywheel D 230 one degree corre
31. 9330_1 ed rev 00 KOHLER FUEL SYSTEM 10 Fuel pump drive rod protrusion Components 1 Fuel pump 2 3 Drive rod 4 Eccentric Check while eccentric 4 is at rest lowest point of travel Protrusion A of drive rod 3 is 1 5 1 9 mm it is not adjustable Drive rod length 58 58 2 mm for KD 225 Drive rod length 65 8 66 0 mm for KD 315 350 Drive rod length 61 4 61 6 mm for KD 400 440 101 Injection pump This is of the simplified QLC type it is housed in the crankcase and is controlled by the camshaft via tappets 102 Injection pump fitting in the crankcase Fit tappets 3 so that screw 6 15 introduced into guide 4 Tighten screw 6 to 9 Nm and check that the tappet is free to move downwards Fit pad 2 into the tappet so that recess B points downwards as shown in the figure Fit the injection pump into the crankcase complete with gasket C po sition8ing flow control 1 in the fork of lever 5 which should be in the maximum flow position When removing the injection pump from its housing make sure that spacer 2 is not dropped into the oil sump injection pump operation will be impaired uf the spacer is not installed 103 104 KD 225 315 350 400 440 Workshop Manual cod ED0053029330_1 rev 00 53 10 FUEL SYSTEM KOHLER L 105
32. AL SYSTEM KOHLER Characteristic curves of Bosch starter motor type DW L 12V 0 9 kW avi 750 15 The curves were measured at a temperature of 20 C with a 55 Ah battery U Voltage on motor terminals in Volts n Motor speed in rpm M Torque in Nm A Power draw in Amperes E Ly E Z i __ NAT IN _ Characteristic curves of Bosch starter motor type DW L 24V 1 6 kW The curves were measured at a temperature of 20 C with a 36 Ah battery U Voltage on motor terminals in Volts n Motor speed in rpm M Torque in Nm A Power draw in Amperes Ignition switch positions A Accessory B Off C On D Start 136 66 KD 225 315 350 400 440 Workshop Manual cod ED0053029330_1 ed rev 00 KOHLER ELECTRICAL SYSTEM 11 ADJUSTMENTS KD 315 350 Idling speed setting in no load conditions standard After filling with oil and fuel start the engine and let it warm up for 10 minutes Adjust idling speed to 1000 1250 rpm by turning set screw 1 then tighten lock nut Washer 2 assures sealing and prevents possible oil leaks 137 Idle speed adjustment for small car versions The idle speed adjusting spring C for small cars must be hooked in the speed governor lever hole D fig 140 Completely unscrew the std idle speed adjustin
33. Drive shaft connection radius Radius R that joins the crankpin to the supports is 2 8 3 2 mm Radius R that joins the main journal to the timing gear is 0 5 mm E cl 5 Drive shaft main journal crankpin diameter gear cover bearing inside diameter on timing side Use an outside micrometer for the main journal and an inside bore gauge for the gear cover bearing on the timing side KD 225 315 350 400 440 Workshop Manual cod ED0053029330_1 rev 00 37 8 DISASSEMBLY REASSEMBLY KOHLER 62 Availability of bearings Main bearings are available at their nominal value or undersized 0 25 0 50 and 1 0 mm Connecting rods are available with big end at nominal value or undersized 0 25 and 0 50 mm Crankshaft journal diameter mm 315 350 34 959734 975 400 440 39 959 39 975 35 002 35 013 35 002 35 013 40 002 40 013 33 984 34 000 37 984 38 000 39 984 40 000 33 240 35 226 35 240 35 256 40 240 40 256 34 984 35 000 34 984 35 000 39 984 40 000 T 27 967 28 000 29 967 30 000 The undersizes for the crankpin and main journal are 0 25 0 50 and 1 mm The gears must be mounted with the right tools so that they can be correctly timed The gears should not therefore be demounted Only the complete shaft is available as a spare Drive shaft Main bearing inside diameter connecting rod big
34. Injection pump 5 Injector leak off line 6 Injector 7 High pressure line 8 Return tube Fuelling injection circuit for KD 225 1 Tank 2 Injector leak off line 3 Injector p S 4 High pressure line um IIS c 5 Return tube 6 Return tube 7 Diesel fuel filter 8 Fuel pipe 9 T connector 10 Reduction 11 Injection pump 97 KD 225 315 350 400 440 Workshop Manual cod ED0053029330_1 rev 00 51 KOHLER 10 FUEL SYSTEM Fuel filter KD 225 315 350 400 440 HoH Ig O V Characteristics Filtering area gt 390 cm Filtration level lt 7 um See page 18 for fuel filter replacement Fuel filter KD 225 version with internal filter in tank 1 Rubber retention ring 2 cover 3 SCP radial unit 4 PRV cover 5 Segment a JA L Characteristics Filtering area 215 cm Filtration level 7 um See page 18 for fuel filter replacement 1 1 Feed pump optional A feed pump is usually requested when the tank is not supplied in conjunction with the engine The pump is the diaphragm type and is operated by a camshaft ec centric through a drive rod Tighten screws to 15 Nm Characteristics At 2000 rpm of the camshaft the minimum delivery is 40 while the automatic adjustment pressure is 0 5 0 7 bars 100 52 KD 225 315 350 400 440 Workshop Manual cod ED005302
35. OBLIGATIONS The California Air Resources Board and Kohler Co are pleased to explain the emission control system warranty on your 2012 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 19xkW 37 and rated speed less than 3 000 rpm all variable speed engines with maximum power 19SkW lt 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 powe
36. Proper sealing between gear cover and crankcase is ensured by the liquid sealant Loctite 5205 Carefully clean the two sealing surfaces and spread the sealant uniformly Tighten screws to 23 Nm T Wait 3 hours before starting the engine KD 225 315 350 400 440 Workshop Manual cod ED0053029330_1 rev 00 45 KOHLER 9 LUBRICATION SYSTEM The engine can be damaged if allowed to operate with insufficient oil It is also dangerous to add too much oil because its A combustion may lead to a sharp increase in the rotation speed Use suitable oil in order to protect the engine Nothing more than lubrication oil can influence the performances and life of an engine Use of an inferior quality oil or failure to regularly change the oil will increase the risk of piston seizure will cause the piston rings to jam and will lead to rapid wear on the cylinder liner the bearings and all other moving parts Engine life will also be notably reduced The oil viscosity must suit the ambient temperature in which the engine operates Old engine oil can cause skin cancer if repeatedly left in contact with the skin and for long periods of time Wear protective A gloves to avoid touching used oil If contact with the oil is unavoidable you are advised to wash your hands with soap and water as soon as possible Dispose of old oil in the correct way as it is highly polluting KD 225 315 350 LUBRICATION SYSTEM AND BREATHE
37. R RECIRCULATION SYSTEM 82 Components 1 Oil fill cap 6 Oil drain plug 11 Oil intake filter 2 Safety valve 7 Metal filter element 3 Rod journal 8 Main journal 4 Pressure control valve 9 Oil filter 5 Pressure switch 10 Oil pump 46 KD 225 315 350 400 440 Workshop Manual cod ED0053029330_1 ed_ rev 00 KOHLER LUBRICATION SYSTEM 9 KD 400 440 LUBRICATION SYSTEM AND BREATHER RECIRCULATION SYSTEM Components 1 Oil fill cap 6 Oil drain plug 2 Safety valve 7 Metal filter element 3 Rod journal 8 Main journal 4 Pressure control valve 9 Oil filter 5 Pressure switch 10 Oil pump 11 Oil intake filter 12 Pushrods 13 Hydraulic tappets 14 Calibrated union KD 225 315 350 400 440 Workshop Manual cod 0053029330 1 ed 00 47 KOHLER 9 LUBRICATION SYSTEM Oil pump Components 1 Cover 2 Shaft 3 Key 4 Pin 5 Internal rotor 6 External rotor Oil pump delivery at 3000 rpm is 5 8 l min Oil pump Clearance between rotors Measure clearance as shown in the figure the max value is 0 13 mm wear limit 0 25 mm Oil pressure regulation valve Components for KD 315 and KD 350 1 Spring 2 Valve 3 Plug Free length A of the spring is 27 50 27 75 mm Components for KD 225 4 Ball 5 Spring 6 Plug Free length A of the spring is 23 50 24 50 mm Components for KD 400 440 7 Plunger 8 Spring 9 Washer 10 Cup 11 Sn
38. S should not exceed 2 mm Lowering valve for KD 225 315 350 D 0 55 0 85 mm Lowering valve for KD 400 440 D 0 35 0 65 mm Wear limit 1 5 mm 30 KD 225 315 350 400 440 Workshop Manual cod ED0053029330_1 rev 00 KOHLER DISASSEMBLY REASSEMBLY 8 Cylinder after turning the bore gauge 90 oversize piston and rings Do not manuall cloth or other means Cylinder roughness Piston Remove circlips and piston pin Set a bore gauge to zero with a calibrated ring Check diameter at 1 2 and 3 repeat the operation at the same points See fig 40 and 41 for cylinder diameter values Remove piston rings and clean grooves If wear exceeds the max given value by 0 05 bore the cylinder and fit hone the cylinder bore surfaces with emer The cross hatch pattern should be at an angle of 45 55 lines should be uniform and clear in both directions Average roughness must range between 0 5 mm 1 um The cylinder surface which comes into contact with piston rings should be machined with the plateau method Being of low expansion type the piston allows small clearances between piston and cylinder and thus oil consumption is reduced Measure diameter Q at the A distance from the skirt bottom A 12 mm 225 69 00 69 015 Dimensions of pistons and cylinders Logo Logo can be found inside the piston Piston 68 955 68 970 Replace t
39. WORKSHOP MANUAL KOHLER KD225 KD315 KD350 KD400 KD440 KOHLER ENGINES KD 225 315 350 400 440 PREFACE Every attempt has been made to present within this service manual accurate and up to date technical information However development on the KOHLER series is continuous Therefore the information within this manual is subject to change without notice and without obligation The information contained within this service manual is the sole property of KOHLER As such no reproduction or replication in whole or part is allowed without the express written permission of KOHLER Information presented within this manual assumes the following 1 The person or people performing service work on KOHLER series engines is properly trained and equipped to safely and professionally perform the subject operation 2 The person or people performing service work on KOHLER series engines possesses adequate hand and KOHLER special tools to safely and professionally perform the subject service operation The person or people performing service work on KOHLER series engines has read the pertinent information regarding the subject service operations and fully understands the operation at hand This manual was written by the manufacturer to provide technical and operating information to authorised KOHLER after sales service centres to carry out assembly disassembly overhauling replacement and tuning operations A
40. aa a a Ka KOE aka a a aa 26 gii aana a aa a EE AE 26 4 225 315 350 400 440 Workshop Manual_cod ED0053029330_1 ed_ rev 00 KOHLER INDEX EA H 27 ONG SC WOM I agan a a 27 28 Valves Oil seal in valve E 28 Ecl T MEC 28 Valves characteristiCs aaa 29 Valves guides am MOUS a ea M dup ad ERN 29 Valves guide kana naka aa kaa aan base kada KA Danan aa aaa da 29 Dimensions and clearance between guides and valve stems 30 Valves sedis valve seat 60755 cs esuresczxvxsnenipbeni stes UC Ed ERN aaa anana anaa ene 30 vave SO AU _ Tm m 30 ior auc 6 O are 31 um 31 aana aa aa 31 Dimensions of pistons and cylinders 00 31 Piston rings distance between the tips 39 Piston rings
41. ap ring Free length A of the spring is 25 50 25 75 mm Note If A is less than the given value replace the valve Valve setting is not adjustable Internal strainer The oil pick up strainer is made of nylon 66 Its degree of filtration is 500 um Dimensions mm M16x1 5 64 102 12 48 225 315 350 400 440 Workshop Manual cod ED0053029330_1 rev 00 KOHLER LUBRICATION SYSTEM 9 Oil filter y d OA Filter components KD 315 350 0 1 Seal 2 Adhesive 3 End cap 4 Filtering material 5 Plate Dimension 265 18 885 D 06075 85 Characteristics Useful filtering area 75 cm Degree of filtration 50 um The by pass valve is set at 0 6 0 8 bar Filter components KD 225 7 Rubber pad 8 Upper cover 9 Filter element 10 Lower cover Dimension mm 19 0 19 3 125 83 0 83 5 Characteristics Useful filtering area gt 75 cm Degree of filtration 40 60 um See page 18 for the replacement frequencies Oil pressure check When assembly operations are completed fill engine with oil and fuel connect a 10 bar pressure gauge to the oil filter fitting Start the engine and check pressure as a function of the oil tempera ture see below Calibrated pipe for lubrication of hydraulic tappets The pipe is fitted to the hydraulic tappets oil line see fig 83 detail 11 If the calibrated hole is cl
42. 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 INCIDENTIAL 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 FORA PARTICULAR PURPOSE ARE EXPRESSLY LIMITED TO THE DURATION OF THIS WRITTEN WARRANT Y 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 telephone 1 800 544 2444 ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND
43. at a standstill and up to a rate of about 300 RPM spring 1 acting on weights 2 and 3 via lever 4 and pin 5 keeps the exhaust valve open during the compression phase also Once the engine exceeds the 300 RPM rate weights 1 and 2 keep pin 5 in the hold position owing to the action of the centrifugal force In this position cam 6 can regularly control the exhaust valve thanks to a ridge on the pin itself Since there is then no compression in the cylinder the engine will ea sily start when the self winder is used Camshaft end play Perform this check before fitting cylinder head and tappets including the injection tappets Temporarily fit camshaft 1 complete with washer tighten gear cover 2 to 25 Nm Check end play by moving the camshaft back and forth using a suita ble tool the end play value is 0 10 0 25 mm and is not adjustable Dynamic balancer on request The dynamic balancer is supported by two identical ball bearings hou sed in the crankcase and in the gear cover on the timing side respec 1 tively 1 is the reference point for timing with the cranksaft gear see below 7 A Dimensions mm A 14 983 14 994 B 14 99 15 00 C 34 89 35 00 D 34 958 34 983 bearing housing diameter on crankcase and gear cover on timing side KD 225 315 350 400 440 Workshop Manual cod ED0053029330_1 rev 00 41 DISASSEMBLY REASSEMBLY KOHLER 42 KD 22
44. c SIN 2042 9930 30 209255505201 81 9952 00 320073205 35 9735 99 3971 9750 00 Saiba 35 022552101 336523552001 335 05353215 Note Replace camshaft if wear exceeds the minimum given lue of H H1 and H2 by 0 1 mm 55 My SS SS SS SS EN SS S 67 KD 225 315 350 400 440 Workshop Manual cod ED0053029330_1 rev 00 39 KOHLER 8 DISASSEMBLY REASSEMBLY Camshaft timing Fit camshaft by aligning marks A with mark D on the crankshaft Camshaft Antireverse system KD 400 440 it consists of a device on the camshaft which lifts the intake valve in case of a startup in reverse direction with respect to normal rotation 68a During normal operation the tappet overcomes the spring resistance while passing on the system and decompression does not operate 68b In case of a startup in reverse direction the antireverse system lifts the valve as the tappet passes by Startup is thus inhibited Note Check the antireverse system for wear and make sure it is kept in the rest position by the return spring as shown in picture 68c Verify that in this condition the clearance between weight A and surface B is 1 mm 68c 40 KD 225 315 350 400 440 Workshop Manual cod ED0053029330_1 ed_ rev 00 KOHLER DISASSEMBLY REASSEMBLY Automatic decompression With the engine
45. carried out after rinsing both the needle and nozzle with trichloroethane and wetting with filtered SHELL CALIBRATION FLUID C oil A B n and of holes hole lenght 0 5 0 6 0 6 0 5 0 5 160 160 160 160 160 DUELO 00 0 125 D IS gt 0 36mm 3 026 um 7 036mm 0 19mm 0 19mm sump volume pressure bar These values apply to new injector and allow for loosening of up to10 after breaking in period Injector calibration Connect the injector to a hand pump and adjust if necessary modifying the thickness above the spring When the spring is replaced calibration must be carried out at a pressure higher than 10 bars to counterbalance adjustments while running Spraying and opening pressure With the pressure gauge closed press hard on the hand pump at least 10 times Open the pressure gauge and press down on the pump once every second while keeping a check on the spraying process and pressure 121 The opening pressure must lie between the two values given in the table Jets must be uniform and well distributed Leakage time waste Pressure must drop from 150 to 100 bars in a span of not less than 8 seconds and not more than 30 Seat seal Nozzle tip wet Pressure must be kept 20 bars below the opening pressure for 10 seconds After this time dampness on the nozzle tip is acceptable and may be identified by touching with a dry f
46. ck rod 1 in stop position 3 Rack rod 1 in max delivery position A 18 19 mm max rack rod stroke a 66 113 Static injection timing Disconnect pipe 1 from injection pump and close it to avoid fuel lea kages Mount in its place a nylon pipe 2 as shown in the picture Insert in this pipe an iron wire and let it project by approximately 10 mm in this way any drop in fuel can easily be checked 114 56 KD 225 315 350 400 440 Workshop Manual cod ED0053029330_1 ed rev 00 KOHLER FUEL SYSTEM 10 Static injection lead test on flywheel Fill the tank and make sure that the fuel is not more than 10 15 cm above the tester Set the flow governor lever of the injection pump in the stop position and lock it there Turn the flywheel in the engine rotation direction proceed slowly du ring the compression phase The fuel that flows from tube 2 will tend to diminish Stop as soon as it creases to drip one drop of fuel every 30 40 seconds is tolerated this is the static injection lead Make sure that B coincides with A See fig 117 118 if B does not coincide with A Use a temporary tank if the engine is not fitted with one Here again it is essential to make sure that the fuel level is no more than 10 15 cm above the injectionm pump References on the flywheel A Reference of fixed TDC on crankcase B Injection lead reference on the flywheel C TDC reference on flywheel Refere
47. dentity B Engine type C Engine serial number D Maximum operating speed E Number of the customer version form K F Approval data Approval data The approval reference directives EC are on the engine plate 1 Model year 2 Engine displacement 3 Power category kW 4 Particulate emission limit g kWh 5 Engine family ID 6 Kind of application i e 7 Injection timing BTDC 8 Injector opening pressure bar 9 Production date example 2012 Jan 10 Emission Control System ECS KD 225 315 350 400 440 Workshop Manual cod 0053029330 1 ed 00 11 KOHLER 4 TECHNICAL DATA CHARACTERISTICS 225 315 350 LL Number of cylinders Compression ratio R P M 80 1269 EEC ISO 1585 Power kW NB ISO 3046 1 IFN NA ISO 3046 1 ICXN Max torque Fuel consumption Oil consumption Capacity of standard oil sump Recommended battery Dry weight Combustion air volume at 3600 r p m Cooling air volume at 3600 r p m Max permissible driving shaft axial load in both directions continuous service for up to 30 min Max inclination discontinuous service for about 1 min permanent service Referred to N power Referred to NB power Depending on the application 12 225 315 350 400 440 Workshop Manual cod ED0053029330_1 ed_ rev 00
48. described in the table may lead to technical damage to the machine and or system MAINTENANCE INTERVAL HOURS OPERATION COMPONENT OIL BATH AIR CLEANER HEAD AND CYLINDER FINS CLEANING REPLACEMENT OIL FILTER CARTRIDGE UEL FILTER CARTRIDGE DRY AIR CLEANER CARTRIDGE Under severe working conditions clean daily Under extremely dusty conditions change every 4 5 hours See recommended oil type After the polyurethane prefilter has been serviced 6 10 times see fig 2 for 315 350 engines when the clogging indicator if installed signals that the part must be replaced or if it is irreparably clogged To avoid explosions or fire outbreaks do not smoke or use naked flames during the operations A Fuel vapours are highly toxic Only carry out the operations outdoors or in a well ventilated place Keep your face well away from the plug to prevent harmful vapours from being inhaled Dispose of fuel in the correct way and do not litter as it is highly polluting FUEL When refuelling it is advisable to use a funnel to prevent fuel from spilling out The fuel should also be filtered to prevent dust or dirt from entering the tank Use the same type of diesel fuel as used in cars Use of other types of fuel could damage the engine The cetane rating of the fuel must be higher than 45 to prevent difficult starting Do not use dirty diesel fuel or mixtures of diesel fuel and water sinc
49. e 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 Co authorized service location you should contact Kohler Co at 1 800 544 2444 or access our website at www kohlerengines com KD 225 315 350 400 440 Workshop Manual cod 0053029330 1 ed 00 3 KOHLER INDEX This manual contains pertinent information regarding the repair of KOHLER water cooled indi rect injection Diesel engines type KD 225 315 350 400 440 updated June 20 2012 INDEX PREFACE Mu 2 WARRANTY CERTIFICATE e P 3 Limited 3 year kohlerg diesel engine eam 3 California emission control warranty 3 Your warranty rights and obligations usse coro Ux 3 Ts TROUBLE SHOOTING anaa aa gan nia Ding _____________ 7 Possible causes and trouble shooting 7 2 GENERAL REMARKS AND SAFETY INFORMATION 8 nie Njeng a AA MEA RA Ba ANAN m mE 8 General safety during operating phases
50. e this would cause serious engine faults The capacity of the standard tank is KD 225 3 0 KD 315 4 3 KD 350 4 3 KD 400 5 0 KD 440 5 0 18 KD 225 315 350 400 440 Workshop Manual cod ED0053029330_1 ed_ rev 00 KOHLER MAINTENANCE RECOMMENDED OIL TYPE REFILLING 7 The engine could be damaged if allowed to operate with insufficient oil It is also dangerous to add too much oil as its com bustion could sharply increase the rotation speed Use a suitable oil in order to protect the engine The lubrication oil influences the performances and life of the engine in an incredible way The risk of piston seizure jammed piston rings and rapid wear of the cylinder liner the bearings and all moving parts in creases if oil whose characteristics differ from the recommended type is used or if the oil is not regularly changed All this notably reduces engine life Oil viscosity must suit the ambient temperature in which the engine operates A Old oil can cause skin cancer if repeatedly left in contact with the skin and for long periods of time If contact with the oil is inevitable you are advised to thoroughly wash your hands with soap and water as soon as possible Appropriate protective gloves etc should be wore during this operation Old oil is highly polluting and must be disposed of in the correct way Do not litter RECOMMENDED OIL AGIP SUPERDIESEL MULTIGRADE 15WA0 spec
51. ectric fan do not approach the engine while it is still hot as the fan may come on even when the engine is not running Clean the cooling system with the engine turned off While cleaning the oil bath air filter check that the oil is disposed of in such a way as not to harm the environment Any filtering sponges in the oil bath air filter should not be soaked with oil The cyclone pre filter cup must not be filled with oil Since the oil must be emptied out while the engine is still hot approx 80 C particular care should be taken in order to avoid burns In any case make sure that oil does not come into contact with your skin because of the health hazards involved Fuel vapours are highly toxic so fill up only in the open air or in well ventilated environments During operations which involve access to moving parts of the engine and or removal of the rotary guards disconnect and insulate the positive cable of the battery so as to prevent accidental short circuits and activation of the starter motor Check the belt tension only when the engine is turned off AN Do not start the machine in closed or poorly ventilated IMPORTANT To start the engine follow the specific instructions provided in the engine and or machine operating manual Do not use auxiliary starting devices not originally installed on the machine e g Startpilot systems which utilise ether etc Before carrying out any work on the engine turn it
52. end crankshaft bearing and timing control gear and balancer Clearance and interference between the corresponding journals Dimensions mm see also fig 61 Clearance mm Interference mm 34 030 34 046 38 030 38 046 400 440 40 030 40 046 33 02025 050 25020 28 050 40 030 40 050 45 000 45 016 45 000 45 016 53 000 53 019 34 988 35 000 34 988 35 000 35 184 35 200 39 988 40 000 35 200 35 216 0 03 0 062 35 200 35 216 0030 0062 40 200 40 216 400 440 0 0300 062 0 120 0 120 0 120 0 03 0 066 0 002 0 025 0 080 0 066 0 002 0 024 0 0300 066 400 440 0 002 0 024 0 015 0 056 0 01550 0506 0015 0056 0024 0056 0 240 056 0024 0056 38 KD 225 315 350 400 440 Workshop Manual cod ED0053029330 1 rev 00 KOHLER DISASSEMBLY REASSEMBLY Camshaft Components 1 Journal gear cover on timing side 2 Gear 3 Exhaust lobe 4 Injection lobe 5 Fuel pump eccentric 6 Intake lobe 7 Journal crankcase side Camshaft journals and bore Use a comparator for interiors 219 2 17980 17 9667 984 15 957 15 984 16 000 16 018 19 900919 921 22 000922 021 18 00 18 018 0 02670 062 0 02090 0627 0 01670 0527 0 120 0 100 i CB 0 016 0 061 C 8 Limit 0 120 Cam height 315 350 350 EPA 400 440 u
53. erent thicknesses between 4 0 and 4 9mm To alter the value of injection advance the pad must be replaced with another of a suitable thickness see fig 117 118 116 If reference point B does not coincide with A follow the examples in fig 117 118 1 Example of delayed injection advance fig 117 to make B match up with A replace the pad with a thicker one fig 116 2 Example of early injection advance fig 118 to make B match up with A replace the pad with a thinner one fig 116 Note When the thickness of the pad varies by 0 1mm under the pump B is delayed or brought forward by 1 on the flywheel Injector Components 1 Body 2 Union 3 Adjusting shim 4 Spring 5 Pressure rod 6 Pin 7 Nozzle 8 Nozzle cup 9 Needle valve 10 Tip 11 Duct 12 Return hole After re assembly tighten ring nut 8 to a 50 Nm torque value 119 58 KD 225 315 350 400 440 Workshop Manual cod ED0053029330_1 ed rev 00 KOHLER FUEL SYSTEM 10 Nozzles The set up between the needle and the guide must leave the needle free to fall and merely as a result of its own weight when lifted 7mm from its seat and rotated in different directions with the nozzle kept at a 45 angle Rotation of the needle must be completely smooth and uninhibited by obstacles and malformations Moreover on being squeezed against its seat it must fall freely when the nozzle is inverted The test must be
54. f Pl 1 mm Yellow 1 rin NN circuit and YT Starting keyzwitch 128 12V electric ignition layout with motor protection optional Components Alternator Starter motor Battery Pressure switch Solenoid valve Ignition switch Panel Note The battery which is not supplied by KOHLER should have 12V nominal voltage rating and a capacity of not less than 44 Ah 210 Amp of fast discharge intensity CON OO RN tn Yell eu Green Red 0 5 mrn Inte grated circuit and voltage regulator Starting keyzwitch 129 KD 225 315 350 400 440 Workshop Manual cod ED0053029330_1 rev 00 63 KOHLER 11 ELECTRICAL SYSTEM Diagram of electric starter motor protection with sole self winding starter without battery optional Yellow 1 mm Yellow 1mm Components 1 Alternator 2 Solenoid valve 3 Pressure switch 4 Thermostat 5 A c motor stop device 130 64 225 315 350 400 440 Workshop Manual cod ED0053029330_1 ed_ rev 00 KOHLER ELECTRICAL SYSTEM 11 Testing voltage regulator for proper operation WHITE Check that connections correspond to the schematic Disconnect the terminal from the battery positive pole Connect a d c voltmeter between the battery poles Fit an ammeter between the positive pole and the B on voltage re
55. g screw 1 fig 137 Loosen nut B by one half of a turn Turn the screw A anticlockwise until lever G touches cover Start the engine turning clockwise screw A set idle speed at 1050 rpm tighten the lock nut B tighten the screw 1 fig 137 until touching lever H fig 141 whenthe screw touches the lever the speed increases at this point unloose screw 1 4 of a turn and lock the lock nut of screw 1 NI Ho The controls cover screws must be tightened to 10Nm 138 139 Note By this way idle speed on hot engine could diminish of 80 rpm max 2222272 Full speed setting no load conditions standard After setting idle speed turn screw 2 and set full speed in no load con ditions at 3800 rpm then tighten lock nut Washer 1 assures sealing and prevents possible oil leaks 142 KD 225 315 350 400 440 Workshop Manual cod ED0053029330_1 rev 00 67 KOHLER 12 SETTINGS ADJUSTMENTS ADJUSTMENTS KD 225 400 440 No load idling adjustment standard After having filled the engine with oil and fuel start it and allow it to warm up for 10 minutes Using adjuster screw 1 regulate the idling rate at 1000 1250 rpm Tighten the check nut No load top rate adjustment standard After having adjusted the idling rate use screw 2 and regulate the top rate at 3800 rpm for engines set at 3600 rpm on load Tighten the check nut Injection
56. he piston and piston rings if wear on the diameter is 0 05 mm more than the minimum value given see table in fig 40 41 Note Oversize pistons of 0 50 and 1 00 mm are available Clearance 0 03 0 06 315 78 00 78 15 TI 9507 0 03 0 06 350 350EPA 82 00 82 015 81 955 81 970 0 03 0 06 400 82 00 82 015 81 955 81 970 0 03 0 06 400EPA 82 00 82 015 81 925 81 940 0 06 0 09 440 440EPA 86 00 86 015 65 9007 0 03 0 06 KD 225 315 350 400 440 Workshop Manual cod ED0053029330_1 rev 00 31 DISASSEMBLY REASSEMBLY KOHLER 32 KD 225 315 350 400 440 Workshop Manual cod ED0053029330_1 rev 00 KOHLER DISASSEMBLY REASSEMBLY Piston rings distance between the tips mm Fit the piston ring into the top part of the cylinder and measure the distance between the tips Piston rings stamped stamped stamped 1st piston ring nitrided 0 20 0 40 2nd piston ring 1 002 1 50 0307050 3rd piston ring oil scraper nitred 25020 1st piston ring chromated 0 30 0 50 2nd piston ring torsional 0 30 0 50 3rd piston ring oil scraper 0 25 0 50 1st piston ring nitrided 0 20 0 35 2nd piston ring 1 00 1 50 0302050 3rd piston ring oil scraper nitred 0 25 0 50 1st piston ring nitrided 0 20 0 35
57. heat for 15 20 minutes to a temperature of 300 C max Fit the rim into the flywheel housing make sure that it rests evenly against the support of the housing itself Allow it to slowly cool When refitting tighten bolt 1 to 150 Nm See pages 34 and 35 for injection timing reference marks 26 KD 225 315 350 400 440 Workshop Manual cod ED0053029330_1 ed_ rev 00 KOHLER DISASSEMBLY REASSEMBLY Do not demount when hot or the part could become deformed Cylinder head If the surface of the cylinder head is deformed flatten it by removing 0 2 mm of material at most Always replace the seal See figs 46 47 48 49 50 when selecting the thickness The bolts must be tightened in different phases for the va rious engines in compliance with the order shown in the figure First tighten the 4 screws M10 then the 2 side screws M6 Lubricate the shanks of the bolts under their heads and the washers with engine oil Do not use too much oil Oil that deposits in the thre aded hole on the cylinder block could become pressurized during the tightening phase sensibly diminishing the driving force Always make sure that the holes on the cylinder block are dry and clean Engine KD 225 Engine KD 350 1st phase tighten all the bolts to a 30 Nm torque value 1st phase tighten all the bolts to a 30 Nm torque value in a crossed fashion crossed fashion 2nd phase unscrew all the bolts by 180 2
58. ifications CF 4 SG ACEA E2 B2 MIL L 46152 D E ESSO SPECIAL PKW UNI FLO DIESEL 15W40 specifications CF 4 SG ACEA E2 B2 MIL GRADE L 46152 D E In the countries where AGIP and ESSO products are not available use oil API SJ CF for Diesel engines or oil correspon SSE ding to the military specification MIL L 46152 D E 40 35 302520 1510 5 0 5 10 15 20 25 30 35 40 45 50 OIL SUPPLY liters KD 225 Standard oil sump SAE 20W_ SAE 30 SAE 40 SAE10W30 filter included 0 9 OIL SUPPLY liters KD 315 Standard oil sump filter included 1 2 OIL SUPPLY liters KD 350 Standard oil sump filter included 1 2 cinia gt 400 440 DIESEL BENZINA ESSENCE PETROL BENZIN GASOLINA filter included 1 5 A Gasoline Petrol B Light Diesel fuels E Heavy Diesel tucls Required levels 7 MIL L 4615220 ____ A1 96 A2 96 O 2274 A3 96 22887 MB2281 B1 96 B2 96 ds E1 96 E2 96 E3 96 KD 225 315 350 400 440 Workshop Manual cod 0053029330 1 ed rev 00 19 8 DISASSEMBLY REASSEMBLY KOHLER WARNINGS During repair operations when using compressed air wear eye protection DISASSEMBLY AND REASSEMBLY Besides disassembly and reassembly operations thi
59. influence of its own activities products services etc on the environment facturer now provides a number of indications to be followed by all persons handling the engine for any reason during its expected lifetime Procedures for identifying the extent of the impact on the envi ronment must consider the following factors z All packaging components must be disposed of in accor dance with the laws of the country in which disposal is ta king place Keep the fuel and engine control systems and the exhaust pipes in efficient working order to limit environmental and noise pollution When discontinuing use of the engine select all compo nents according to their chemical characteristics and dispo se of them separately Liquid waste Waste management Soil contamination Atmospheric emissions Use of raw materials and natural resources Regulations and directives regarding environmental impact In order to minimise the impact on the environment the manu KD 225 315 350 400 440 Workshop Manual cod 0053029330 1 ed rev 00 NOTE KOHLER 10 KD 225 315 350 400 440 Workshop Manual cod ED0053029330_1 ed_ rev 00 KOHLER MODEL NUMBER AND IDENTIFICATION 3 MANUFACTURER AND MOTOR IDENTIFICATION DATA The identification plate shown in the figure can be found directly B A D on the engine It contains the following information A Manufacturer s i
60. inger Only a drop of dampness is acceptable and not a large thick patch which would indicate a leak KD 225 315 350 400 440 Workshop Manual cod 0053029330 1 ed rev 00 59 10 FUEL SYSTEM KOHLER 60 KD 225 315 350 400 440 Workshop Manual cod ED0053029330_1 rev 00 KOHLER ELECTRICAL SYSTEM 11 12V 12A electric ignition diagram Components 1 Alternator 2 Starter motor 3 Voltage regulator 4 Battery 5 Pressure switch 6 Oil pressure light 7 Key switch 8 Battery charging light Note The battery which is not supplied by KOHLER should have 12V nominal voltage rating and a capacity of not less than 44 Ah 210 Amp of fast discharge intensity 122 Alternator Components 1 Ring gear 2 Flywheel 3 Rotor 4 Stator Fixing screws must be tightened to 1 2 Nm Note The rotor is made up by a plastoferrite ring which is fixed to flywheel while the stator is mounted on the crankcase 123 Alternator battery charger graph 12V 12A This test has been carried out after thermal stabilization at 20 C for 2 minutes at 3000 r p m with constant battery voltage of 12 5V The value of the power supplied with reference to the curve may change in a range between 10 and 5 E eee 1 __ TINI _ LL AI iris 1500 2000 2500 3000 3500 RPM imin Ll rmin 124 KD 225 315 350 400 440 Workshop Manual c
61. kaja ae anak 20 Dry air cleaner Tor 229 20 Dry air cleaner for kd 400 440 21 Prefilter for dry air filter MTT 21 OikDath air cleaner NE tms 22 MOOT e PH 22 GN 22 Rocker arm cover breather ricirculation da ab cu Gnd NES aper NEU aedi 23 Valve rocker arm clearance KD 225 315 350 000000 00 23 The engines KD 400 and 440 have hydraulic tappets therefore no adjustment is required 23 Do not start the engine for approximately 4 hours to allow the hydraulic tappets to settle completely 23 Hydraulic tappets KD 400 440 eee 24 E oe ees P e 25 Fuel filter 225 400 440 version with internal 25 Fuel filter for KD 225 315 350 400 440 version with external 25 GGO 21218 NN TR RU TR nag anaa anang an neg da Ban an ana da aan ngah agan nu Aa dg aa aa aa daa nag ak ngang 26 UO GN saa ate aaa KA aana a
62. ler engines are built to provide safe and longlasting performances but in order to obtain these results it is essential that the maintenance requirements described in the manual are observed along with the following safety recommendations The engine has been built to the specifications of a machine manufacturer and it is his responsibility to ensure that all necessary action is taken to meet the essential and legally prescribed health and safety requirements Any use of the machine other than that described cannot be considered as complying with its intended purpose as specified by Kohler which therefore declines all responsibility for accidents caused by such operations The following instructions are intended for the user of the machine in order to reduce or eliminate risks especially those concerning the operation and standard maintenance of the engine The user should read these instructions carefully and get to know the operations described By not doing so he may place at risk his own health and safety and that of anyone else in the vicinity of the machine 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
63. n the cylinder and the big end bearing Piston Refitting Connect piston to connecting rod lubricate piston pin and introduce it into the piston connecting rod assembly by exerting pressure with your thumb Fit both piston pin circlips and check that they are well seated When introducing both the connecting rod and the piston into the cylinder make sure that the larger crown surface A if compared to the combustion chamber is on the same side as the pushrod opening B Clearance A A Clearance C Head gasket 1 7 The thickness of gasket C determines the clearance A which must be A a 0 45 0 55 mm for KD 315 with injection pump serial N 6590 259 it is IDE lt 0 50 0 60 mm with injection pump serial N 6590 281 I lt The clearance is 0 45 0 55 mm for KD 225 in all cases The clearance is 0 50 0 60 mm for KD 350 400 440 in all cases For the correct thickness of gasket C see table in fig 49 50 There are gaskets with inner diameters oversized by 1 mm for KD 315 and KD 350 required if the cylinders are ground 34 225 315 350 400 440 Workshop Manual cod ED0053029330_1 ed_ rev 00 KOHLER DISASSEMBLY REASSEMBLY 5 Piston protrusion check To calculate the right thickness for the gasket the protrusion between the piston and the cylinder head surface must be measured Use a dial indicator with base plate Reset to zero while resting on a surface plate then po
64. nce in degrees between B and When B coincides with A the piston is in the static injection lead position When C coincides with A the piston is at top dead center BA mm Motor type with external with external with external with external flywheel flywheel flywheel flywheel 220 230 240 260 KD 225 standard 40 44 42 46 214 KD 225 recorded up to 1500 rpm 29 32 30 34 15 14 KD 225 recorded from 1500 to 2200 rpm 34 5738 36 40 18 20 KD 315 350 standard minivecture 46 50 46 952 299229 KD 315 350 Soundproof generating sets 20 44 42 46 20527 KD 315 350 recorded to 1500 rpm 36 40 38 42 18 20 KD 400 recorded to 3600 rpm 29 48 13 KD 400 recorded to 3000 rpm 24 95 11 400 EPA recorded to 3600 rpm 28 35 L2 KD 400 EPA recorded to 3000 rpm 24 95 11 KD 440 recorded to 3600 rpm 31 75 14 KD 440 recorded to 3000 rpm Doe 12 KD 225 315 350 400 440 Workshop Manual cod 0053029330 1 ed 00 57 KOHLER 10 FUEL SYSTEM Injection advance adjustment Injection advance beyond the thickness of gasket A is determined by the thickness of the pad inside the injection tappet To alter the value of injection advance the pad must be replaced with another of a suitable thickness see fig 117 118 To extract pad B use a rod with a suction cap or magnet at one end The replacement pads supplied have 10 diff
65. nced oil sump half shells Loctite 5205 Hydraulic tappet contact cam MOLYSLIP AS COMPOUND 40 72 225 315 350 400 440 Workshop Manual_cod ED0053029330_1 ed_ rev 00 KOHLER TORQUE SPECIFICATIONS 15 Table of tightening torques for standard screws coarse thread Resistance class R Quality Dimensions R gt 400N mm R gt 500N mm gt 600 R2800N mm R gt 1000N mm R 1200N mnr wem es e maf ts ta se at 3 28 3s 4s 6 10 es s 7 ea 75 0 4 2 5 M22 206 275 260 344 413 550 780 930 Table of tightening torques for standard screws fine thread Quality Dimensions 5 39 45 w 75 her c om pom m so 79 1000 1200 60 25 2700 KD 225 315 350 400 440 Workshop Manual_cod ED0053029330_1 rev 00 73 Translated from the original manual in Italian language Data reported in this issue can be modified at any time by KOHLER KOHLER FOR SALES AND SERVICE INFORMATION IN 0 5 AND CANADA CALL 1 800 544 2444 FORM NO ED0053029330 KohlerEngines com ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 REVISED 00 DATE 25 06 2012
66. nd phase unscrew all the bolts by 180 3rd phase tighten all the bolts to a 20 Nm torque value in a 3rd phase tighten all the bolts to a 20 Nm torque value crossed fashion crossed fashion Ath phase make 52 turn in the same order as the 3rd 4th phase make a 60 turn in the same order as the 3rd phase phase oth phase tighten the 2 side bolts 5 to a 10 Nm torque value 5th phase tighten 2 side bolts 5 to a 10 Nm torque value Engine KD 315 For KD 400 and 400 engines 1st phase tighten all the bolts to 30 Nm torque value in a 1 phase tighten all screws crosswise to 20Nm crossed fashion 2 phase tighten the screws in the same order to 40Nm 2nd phase unscrew all the bolts by 180 3 phase tighten all screws in the same order to 50Nm 3rd phase tighten all the bolts to a 20 Nm torque value in a 4 phase following the same order as in phase 3 rotate 60 crossed fashion 5 phase following the same order as in phase 4 rotate 60 4th phase make a 72 turn in the same order as the 3rd 6 phase tighten the 2 side screws 5 to 10 Nm phase 5th phase tighten the 2 side bolts 5 to a 10 Nm torque value Injector projection The end of nozzle A should project 2 5 mm for KD 225 315 350 and 3 0 3 5 mm for KD 400 440 from the cylinder head plane Adjust with copper gaskets B with thickness of 0 5 1 and 1 5 mm KD 225 315 350 400 440 Workshop Manual cod 0053029330 1 ed
67. ng rod alignement Use a dial gauge as shown in the figure Check that axes are aligned using the piston pin axial misalignment A 0 015 limit 0 03 mm Crankshaft end play Secure the engine to a metal base or table Use a dial indicator with column and magnetic base plate Place the stylus on the crankshaft Move the driving shaft back and forth on the flywheel side End play should be 0 05 0 25 mm it is not adjustable 36 KD 225 315 350 400 440 Workshop Manual cod ED0053029330_1 ed rev 00 KOHLER DISASSEMBLY REASSEMBLY A warped oil retainer may allow the introduction of air into the engine thus causing crankcase ventilation problems Use genuine oil retainers with the KOHLER logo see Drive shaft oil seals Oil retainer 1 is located in the gear cover on the timing side while re tainer 2 is located in the crankcase on the flywheel side Arrows a point to the crankshaft direction of rotation Press them into their seats by exerting uniform pressure throughout their front surface Drive shaft lubrication ducts bore thread on flywheel side and p t o Remove plug C and check that the lubrication duct is perfectly clean Close with a new plug checking for proper sealing A M14x1 5 turn counterclockwise B M8x1 25 with standard shaft When the crankpin and main journal are ground values R and R must be obtained again to prevent the drive shaft from bre aking
68. od 0053029330 1 ed 00 61 KOHLER 11 ELECTRICAL SYSTEM 24V 9A alternator battery recharging curve 3500 RPM 125 12V 30A alternator battery recharging curve The test was conducted after heat stabilizing at 20 C The value of the current delivered in relation to the curve may be subjected to a variation of between 10 and 5 1000 1500 2000 2500 3000 3500 4000 RPM Cgiri 17 126 Voltage regulator 12V 12 for standard alternators with output wires 12V 30A for 12V 20A alternators with 2 output wires 24V for 24V alternators with two output wires Tab dimensions mm Thickness 0 80 The tabs are in different sizes to prevent incorrect connections 127 62 KD 225 315 350 400 440 Workshop Manual cod ED0053029330_1 ed rev 00 KOHLER ELECTRICAL SYSTEM 11 12V electric starter diagram with voltage regulator built into the ignition panel Components Alternator Starter motor Battery Pressure switch Solenoid valve Ignition switch Note The battery which is not supplied by KOHLER should have 12V nominal voltage rating and a capacity of not less than 44 Ah 210 Amp of fast discharge intensity Blue 1 5 Red 0 5 mm c a Ge Zu
69. off and allow it to cool down Do not perform any operation while the engine is running Check that the discharged oil the oil filter and the oil contained in the oil filter are disposed of in such a way as not to harm the environment Close the fuel tank filler cap carefully after each filling operation Do not fill the tank right up to the top but leave sufficient space to allow for any expansion of the fuel Do not smoke or use naked flames while filling KD 225 315 350 400 440 Workshop Manual cod ED0053029330_1 ed_ rev 00 KOHLER GENERAL REMARKS AND SAFETY INFORMATION 2 Take care when removing the oil filter as it may be hot The operations of checking filling up and replacing the cooling liquid must be carried out with the engine turned off and cold Take particular care if liquids containing nitrites are mixed with others not containing these compounds as this may give rise to the formation of nitrosamines which are a health hazard The cooling liquid is polluting so dispose of in a manner that does not damage the environment In order to move the engine simultaneously use the eyebolts fitted for this purpose by Kohler These lifting points are however not suitable for the entire machine so in this case use the eyebolts fitted by the manufacturer GENERAL SAFETY DURING OPERATING PHASES The procedures contained in this manual have been tested and selected by the manufacturer
70. ogged the tappets are not sufficiently lubricated valve clearance is therefore increased and the engine may be noisier If the diameter of the calibrated pipe is larger than the ones given in picture 93 the pressure exerted by the hydraulic tappets may cause the valves to remain open even during the compression phase 93 KD 225 315 350 400 440 Workshop Manual cod 0053029330 1 ed 00 49 KOHLER 9 LUBRICATION SYSTEM Oil pressure curve at idle speed The curve is obtained at the oil filter port with engine running at a con stant speed of 1200 r p m in no load conditions pressure is given in bar and temperature in centigrades The curve represents the minimum pressure value while the maxi mum value is 5 bar Mee LETT EET Oil pressure curve at full speed The curve is obtained at the oil filter port with engine running at 3000 at the N power pressure is given in bar and temperature in centigrades The curve represents the minimum pressure value while the maxi mum value is 5 bar Note After the running in period the lube max temperature should be less than the room temperature 95 C 50 KD 225 315 350 400 440 Workshop Manual cod ED0053029330_1 ed rev 00 KOHLER LUBRICATION SYSTEM 9 Fuelling injection circuit for KD 315 350 400 440 Components 1 Tank 2 Return tube 3 Fuel filter 4
71. ove 25 C Note Consult KOHLER for power torque curves and specific consumptions at rates differing from those given above KD 225 315 350 400 440 Workshop Manual cod 0053029330 1 ed 00 15 6 OVERALL DIMENSIONS KOHLER 373 5 373 5 O ea ue gt d da Ww Note Dimensions shown in mm TI 11 911 d pac 6 fori a 6G sul 0135 328 25 EXC Dm 444 5 ij 3 2 4 1 444 5 133 5 p 43 Ib idl 12 CY 16 KD 225 315 350 400 440 Workshop Manual cod 0053029330 1 ed 00 KOHLER OVERALL DIMENSIONS 6 mM BI Tm m E a 5 muni E my MK ES E SW mmer EE es ERN O INI 011 45 14 de 1 54 Note Dimensions shown mm KD 225 315 350 400 440 Workshop Manual_cod ED0053029330_1 rev 00 17 KOHLER 7 MAINTENANCE RECOMMENDED TYPE REFILLING H Failure to carry out the operations
72. place them if they are damaged Oil bath air cleaner optional Components 1 Upper shell 1A Upper unit with separator pre filter 2 Secondary filter element 3 Primary polyurethane 4 Internal seal ring 5 External rubber gasket 6 Lower metal filter element 7 Lower cup 8 Oil level gauge Characteristics of filter element 2 made of Viledon synthetic fabric porosity 120 gr m resin covered Characteristics of filter element 3 open celled polyurethane foam porosity 45 P P I Both filter elements can be washed with soap and water for maxi mum of 10 times Wash the metal filter 6 with Diesel fuel Blow out excess fuel with com pressed air See pages 14 and 15 for periodic maintenance details and oil replacement Allow the exhaust manifold to cool before demounting it in order to prevent scorching and burns Muffler When reassembling replace the exhaust manifold gaskets Tighten nuts to 25 Nm The muffler design includes internal sound absorbing panels Tighten the bearing nuts and screw A to a 25 Nm torque value Rocker arm cover breather system The crankcase breather system is located inside the rocker arm cover Check that diaphragm 2 is intact wash with Diesel oil and blow throu gh the small mesh element 4 with compressed air When reassembling fix box 3 with Loctite Form a gasket No 6 and screw plate 5 Also see below 22 225 315 350 400 440 Workshop Manual_cod ED0053029330_1
73. r 19xkW 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 th
74. ripping from exhaust o c o o c LLI No acceleration Black smoke White smoke pressure Increase oil level Excessive oil consumption Clogged pipes Clogged fuel filter Air inside fuel circuit Clogged tank breather hole Faulty fuel pump Injector jammed ammed injection pump delivery valve Wrong injector setting Excessive plunger blow by Jammed injection pump delivery control Wrong injection pump setting Oil level too high Jammed pressure relief valve Worn oil pump Air inside oil suction pipe Faulty pressure gauge or switch Battery discharged Wrong or inefficient cable connection Defective ignition switch Defective starter motor Excessive idle operation Incomplete running in Engine overloaded Advanced injection Delayed injection Incorrect governor linkage adjustment Broken or loose governor spring Idle speed too low Worn or scored cylinders Worn valve guides Jammed valves Worn bearings Governor linkage not free to slide Drive shaft not free to slide Damaged cylinder head gasket FUEL CIRCUIT LUBRICATION SETTINGS REPAIRS N KD 225 315 350 400 440 Workshop Manual cod 0053029330 1 rev 00 2 GENERAL REMARKS AND SAFETY INFORMATION KOHLER SAFETY REGULATIONS GENERAL NOTES Koh
75. s chapter also includes checking and setting specifications dimensions repair and operating instructions Always use original KOHLER spare parts for repair operations Clean the filtering element with air blast Air must be blown from inside to outside the cartridge at a distance of at least 15 cm from the paper Lightly and repeatedly tap the element on a hard surface to eliminate all excess dirt Dry air cleaner for KD 315 and KD 350 Cartridge components 1 Seal 2 Metallic body 3 Polyurethane prefilter 4 outer mesh 5 Filter media 6 Blade 7 Inside envelope 8 Metallic body 9 Inner seal Cartridge characteristics media porosity 7 um useful filtering area 1960 Polyurethane pre filter characteristic porosity 60 p p i front area 207 Note Pre filter 3 can undergo maintenance operations if dirty wash with soap and water and dry maximum 10 cleanings See page 18 for cartridge replacement Clean the filtering element with air blast Air must be blown from inside to outside the cartridge at a distance of at least 15 cm from the paper Lightly and repeatedly tap the element on a hard surface to eliminate all excess dirt Replace if irreparably clogged Dry air cleaner for KD 225 Cartridge components 1 Complete cover 2 Filtering material 3 Support Characteristics of the filtering material paper porosity 3 um filtering area 4400 outer ring in open cell polyurethane
76. s technical experts and hence are to be recognised as authorised operating methods A number of procedures must be carried out with the aid of equipment and tools that simplify and improve the timing of operations All tools must be in good working condition so that engine components are not damaged and that operations are carried out properly and safely It is important to wear the personal safety devices prescribed by work safety laws and also by the standards of this manual Holes must be lined up methodically and with the aid of suitable equipment Do not use your fingers to carry out this operation to avoid the risk of amputation Some phases may require the assistance of more than one operator If so it is important to inform and train them regarding the type of activity they will be performing in order to prevent risks to the health and safety of all persons involved Do not use flammable liquids petrol diesel etc to degrease or wash components Use special products Use the oils and greases recommended by the manufacturer Do not mix different brands or combine oils with different characteristics Discontinue use of the engine if any irregularities arise particularly in the case of unusual vibrations Do not tamper with any devices to alter the level of performance guaranteed by the manufacturer SAFETY AND ENVIRONMENTAL IMPACT Every organisation has a duty to implement procedures to identify assess and monitor the
77. s well as employing good operating techniques and observing the right timing for operations operators must read the information very carefully and comply with it scrupulously Time spent reading this information will help to prevent health and safety risks and financial damage Written information is accompanied by illustrations in order to facilitate your understanding of every step of the operating phases KOHLER WARRANTY CERTIFICATE 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 service for a period of three 3 years or 2000 hours whichever occurs first from the date of purchase provided it is operated and maintained in accordance with Kohler Co s instructions and manuals If no hour meter is installed as original equipment then 8 hours of use per day and 5 days per week will be used to calculate hours used 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 This warranty does not apply to defects caused by unreasonable use including faulty repairs by others and failure to provide reasonable and necessary maintenance The following items
78. sition against the cylinder head base plane as shown in the diagram so that the dial indicator rod rests against the piston Now take the reading Repeat the operation in the other three points going crosswise and take the readings Calculate the average of these four readings to get the precise measurement of the protrusion between the piston and the cylinder head base plane Choose the appropriate gasket according to the following table Only remove the head gasket from its protective wrapping just before assembly ee page 26 when tightening the cylinder head Head gasket mm For KD 225 For KD 350 Piston Gasket Number Piston Gasket Number protusion Thickness of notches protusion Thickness of notches 0 351 0 450 0 9 0 0 365 0 500 1 0 0 450 0 550 1 1 notch 0 500 0 600 LA 1 notch 0 550 0 650 121 2 notches 0 600 0 700 L2 2 notches 0 650 0 750 12 3 notches For KD 315 with injection pump P no 6590 259 For KD 400 Piston Gasket Number Piston Gasket Number protusion Thickness of notches protusion Thickness of notches 0 365 0 450 0 9 0 0 410 0 500 1 0 0 450 0 550 1 1 notch 0 510 0 600 1 1 1 notch 0 550 0 650 Li 2 notches 0 610 0 700 L2 2 notches 0 650 0 750 1 2 3 notches For KD 315 with injection pump P no 6590 281 For KD 440 Piston Gasket Number Piston Gasket Number protusion Thickness of notches protusion Thickness of notches 0 365 0 400 0 9 0 0 410 0 500 1 0 0 400 0 50
79. sponds to 2 mm For KD 315 350 10 before A corresponding to 20 09 mm 42 after B corresponding to 87 78 mm y 58 before B corresponding to 121 22 mm 10 after A corresponding to 20 9 mm Values measured on the circumference of the flywheel D 240 one degree corresponds to 2 09 mm Timing angles for inspection 0 65 0 70 valve play For KD 225 7 after A corresponding to 14 mm p 9 after B corresponding to 18 mm y 45 before B corresponding to 90 mm 6 3 before A corresponding to 6 mm Values measured on the circumference of the flywheel D 230 one degree corresponds to 2 mm For KD 315 350 1 after A corresponding to 2 09 mm 31 after corresponding to 64 79 mm y 45 before B corresponding to 94 05 mm 3 before A corresponding to 6 27 mm Values measured on the circumference of the flywheel D 240 one degree corresponds to 2 09 mm 44 KD 225 315 350 400 440 Workshop Manual cod ED0053029330_1 ed_ rev 00 KOHLER DISASSEMBLY REASSEMBLY Speed governor Components 1 Spool spacer 2 Spool 3 Weights 4 Spool guide 5 Gear 6 Oil pump driving shaft 7 Circlip 8 Thrust ring Speed governor removal Spool guide 1 has retainers one end which prevent spool 2 from slip ping out To remove the speed governor use a Suitable tool to slightly widen the two teeth Refitting gear cover on timing side
80. tance of at least one metre from buildings or other machines During operation Children and animals must be kept at a sufficient distance from the machine to prevent any danger resulting from its operation Fuel is flammable so the tank must be filled only when the engine is turned off Dry carefully any fuel that may have spilled remove the fuel container and any cloths soaked in fuel or oil check that any sound absorbing panels made of porous material are not soaked with fuel or oil and make sure that the ground on which the machine is located has not absorbed fuel or oil Before starting remove any tools that have been used for carrying out maintenance work to the engine and or the machine and check that any guards removed have been replaced In cold climates it is possible to mix kerosene with the diesel fuel to make the engine easier to start The liquids must be mixed in the tank by pouring in first the kerosene and then the diesel fuel Consult Kohler technical office for mixture proportions Petrol may not be used because of the risk of it forming flammable vapours the surface of the engine reaches temperatures that may be dangerous Avoid in particular all contact with the exhaust system The liquid cooling circuit is under pressure Do not carry out any checks before the engine has cooled down and even then open the radiator cap or the expansion tank cautiously Wear protective clothing and glasses there is an el
81. ut of the inside of the tappets themselves 24 KD 225 315 350 400 440 Workshop Manual cod ED0053029330_1 ed_ rev 00 KOHLER DISASSEMBLY REASSEMBLY 8 To avoid explosions or fire outbreaks do not smoke or use na ked flames during the operations Fuel vapours are highly toxic Only carry out the operations out doors or in a well ventilated place Keep your face well away from the plug to prevent harmful va pours from being inhaled Dispose of fuel in the correct way and do not litter as it is highly polluting Tank Unscrew the upper and lower studs and remove the washers which otherwise might make removal of the tank difficult Next disconnect the fuel and air bleeding tubes Completely empty the tank to make sure that no impurities remain When reassembling tighten the upper nuts to 15 Nm Fuel filter KD 225 400 440 version with internal filter 1 Fuel filter 2 Fuel tank 3 Filter sleeve 4 Filter cartridge 5 Flush ring 6 Nut 7 Union seal 8 Diesel fuel outlet union 9 Flat washer See page 18 for the frequency with which the fuel filter must be repla ced See fig 99 for the dimensions Fuel filter for KD 225 315 350 400 440 version with external filter Loosen the clamps and disconnect the hoses Characteristics Filtering area gt 390 cm Paper porosity lt 7 um See page 18 for replacement See fig 98 for dimensions KD 225 315

KD225 - KD315 - KD350 KD400 - KD440

Contents

Download Pdf Manuals

Related Search

Related Contents