Kohler KD420 [2/74] _315_350_400_440
![Kohler KD420 [2/74] _315_350_400_440](/views2/1597550/page2/bg2.png)
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,developmentontheKOHLERseriesiscontinuous.
Therefore,theinformationwithinthismanualissubjecttochangewithoutnoticeandwithoutobligation.
- TheinformationcontainedwithinthisservicemanualisthesolepropertyofKOHLER.
As such, no reproduction or replication in whole or part is allowed without the express written permission of
KOHLER.
Informationpresentedwithinthismanualassumesthefollowing:
1- ThepersonorpeopleperformingserviceworkonKOHLERseriesenginesisproperlytrainedandequippedto
safelyandprofessionallyperformthesubjectoperation;
2- The person or people performing service work on KOHLER series engines possesses adequate hand and
KOHLERspecialtoolstosafelyandprofessionallyperformthesubjectserviceoperation;
3- ThepersonorpeopleperformingserviceworkonKOHLERseriesengineshasreadthepertinentinformation
regardingthesubjectserviceoperationsandfullyunderstandstheoperationathand.
- This manual was written by the manufacturer to provide technical and operating information to authorised
KOHLERafter-salesservicecentrestocarryoutassembly,disassembly,overhauling,replacementandtuning
operations.
- Aswellasemployinggoodoperatingtechniquesandobservingtherighttimingforoperations,operatorsmust
readtheinformationverycarefullyandcomplywithitscrupulously.
- Timespentreadingthisinformationwillhelptopreventhealthandsafetyrisksandnancialdamage.
Writteninformationisaccompaniedbyillustrationsinordertofacilitateyourunderstandingofeverystepofthe
operatingphases.
Содержание
- _315_350_400_440 2
- California emission control warranty statement 3
- Kd 225_315_350_400_440 workshop manual_cod ed0053029330_ 1 ed _ rev 00 3
- Limited 3 year kohler diesel engine warranty 3
- Manufacturer s warranty coverage 3
- Owner s warranty responsibilities 3
- Warranty certificate 3
- Your warranty rights and obligations 3
- Characteristics 4
- Characteristics 14 4
- Disassembly reassembly 4
- Disassembly reassembly 20 4
- General remarks and safety information 4
- General remarks and safety information 8 4
- Maintenance recommended oil type refilling 4
- Maintenance recommended oil type refilling 18 4
- Model number and identification 4
- Model number and identification 11 4
- Overall dimensions 4
- Overall dimensions 16 4
- Preface 4
- Preface 2 4
- Technical data 4
- Technical data 12 4
- Thismanualcontainspertinentinformationregardingtherepairofkohlerwater cooled indi rectinjectiondieselenginestype kd 225_315_350_400_440 updatedjune20 2012 4
- Trouble shooting 4
- Trouble shooting 7 4
- Warranty certificate 4
- Warranty certificate 3 4
- Lubrication system 5
- Lubrication system 46 5
- Electrical system 6
- Electrical system 2 6
- Fuel system 6
- Fuel system 52 6
- Settings adjustments 6
- Settings adjustments 8 6
- Storage 6
- Storage 70 6
- Torque specifications 6
- Torque specifications 72 6
- Fuel circuit 7
- Possible cause 7
- Settings repairs 7
- Trouble 7
- Trouble shooting 7
- General remarks and safety information 8
- General remarks and safety information 9
- Model number and identification 11
- 350 225 12
- Dependingontheapplication 12
- Enginetype 12
- Kd 225 12
- Kd 315 12
- Kd 350 12
- Referredtonbpower 12
- Referredtonpower 12
- Dependingontheapplication 13
- Enginetype 13
- Kd 400 13
- Kd 440 13
- Referredtonbpower 13
- Referredtonpower 13
- Characteristics 14
- Characteristics power torque and specific fuel consumption curves 14
- Kd 225 14
- Kd 225_315_350_400_440 workshop manual_cod ed0053029330_ 1 ed _ rev 00 14
- Kd 315 kd 350 14
- Characteristics 15
- Characteristics power torque and specific fuel consumption curves 15
- Kd 225_315_350_400_440 workshop manual_cod ed0053029330_ 1 ed _ rev 00 15
- Kd 400 kd 440 15
- Kd 225 16
- Kd 315 16
- Kd 350 16
- Overall dimensions 16
- Kd 400 17
- Kd 440 17
- Overall dimensions 17
- Failure to carry out the operations described in the table may lead to technical damage to the machine and or system 18
- Maintenance recommended oil type refilling 18
- A gasoline petrol b lightdieselfuels e heavydieselfuels 19
- A1 96 a1 96 19
- A2 96 a2 96 19
- A3 96 a3 96 19
- Acea sequences 19
- Agipsuperdieselmultigrade15w40specificationsapicf 4 sg acea e2 b2 mil l 46152 d e esso special pkw uni flodiesel15w40specificationsapicf 4 sgaceae2 b2mil l 46152d e inthecountrieswhereagipandessoproductsare notavailable useoilapisj cffordieselenginesoroilcorrespon dingtothemilitaryspecificationmil l 46152d e 19
- B1 96 b1 96 19
- B2 96 b2 96 19
- B3 96 b3 96 19
- Benzin gasolina 19
- Cf ce cd cc cb ca sa sb sc sd se sf sg 19
- Diesel benzina essence petrol 19
- E1 96 e1 96 19
- E2 96 e2 96 19
- E3 96 e3 96 19
- Filter included 0 19
- Filter included 1 19
- Kd 225_315_350_400_440 workshop manual_cod ed0053029330_ 1 ed _ rev 00 19
- Maintenance recommended oil type refilling 19
- Oil supply liters kd 225 standard oil sump 19
- Oil supply liters kd 315 standard oil sump 19
- Oil supply liters kd 350 standard oil sump 19
- Oil supply liters kd 400 440 standard oil sump 19
- Oldoilcancauseskincancerifrepeatedlyleftincontactwiththeskinandforlongperiodsoftime ifcontactwiththeoilis inevitable youareadvisedtothoroughlywashyourhandswithsoapandwaterassoonaspossible appropriateprotectiveglovesetcshouldbeworeduringthisoperation oldoilishighlypollutingandmustbedisposedofinthecorrectway donotlitter 19
- Recommended oil 19
- Requiredlevels 19
- Sh api 19
- Theenginecouldbedamagedifallowedtooperatewithinsufficientoil itisalsodangeroustoaddtoomuchoilasitscom bustioncouldsharplyincreasetherotationspeed useasuitableoilinordertoprotecttheengine thelubricationoilinfluencestheperformancesandlifeoftheengineinanincredibleway theriskofpistonseizure jammedpistonringsandrapidwearofthecylinderliner thebearingsandallmovingpartsin creasesifoilwhosecharacteristicsdifferfromtherecommendedtypeisused oriftheoilisnotregularlychanged allthis notablyreducesenginelife oilviscositymustsuittheambienttemperatureinwhichtheengineoperates 19
- Disassembly reassembly 20
- During repair operations when using compressed air wear eye protection 20
- Warnings 20
- Disassembly reassembly 21
- Disassembly reassembly 22
- Disassembly reassembly 23
- Disassembly reassembly 24
- Disassembly reassembly 25
- Disassembly reassembly 26
- Disassembly reassembly 27
- Disassembly reassembly 28
- 315 350 400 440 29
- 350 315 350 400 440 225 29
- A 23 24 b 28 29 29
- A 25 26 b 34 35 29
- A 35 b 30 c 10 00 10 20 d 10 40 10 55 29
- A 40 b 31 c 11 00 11 18 d 11 40 11 55 29
- Alsoavailableasspares inthiscase housing c mustbein creasedby0 mmforassemblypurposes 29
- Basematerial 29
- Chromeplated 29
- Dimensions mm for kd 225 29
- Dimensions mm for kd 315 350 400 440 29
- Disassembly reassembly 29
- Exhaustvalve b stemandheadareoftwodifferentmaterials 29
- Heattheblocktoatemperatureof160 180 forcetheguides consideringdistance a and b inrelationtotheblock surface 29
- Intakeguide 2 exhaustguide 29
- Intakevalvea 29
- Kd 225_315_350_400_440 workshop manual_cod ed0053029330_ 1 ed _ rev 00 29
- Note valve guides with outer diameters increased by 0 mm are 29
- Valves characteristics 29
- Valves guide insertion 29
- Valves guides and housings 29
- Weldjoint 29
- 315 350 400 440 30
- 440 225 315 350 30
- A 5 3 0 6 0 2 0 6 0 4 0 7 5 2 0 7 30
- Aftercuttingvalveseats lapvalveseatswithfinelappingcompound thesealingsurface s shouldnotexceed2mm loweringvalveforkd225 315 350 d 0 5 0 5mm loweringvalveforkd400 440 d 0 5 0 5mm wearlimit1 mm 30
- B 0 0 0 6 5 8 9 5 0 0 0 7 5 8 9 6 0 0 0 7 5 8 9 6 30
- B a 0 5 0 0 0 2 0 0 5 5 0 0 5 2 0 0 30
- B a 4 1 0 30
- Clearance 30
- Dimensions and clearance between guides and valve stems mm 30
- Dimensions mm 30
- Disassembly reassembly 30
- Kd 225_315_350_400_440 workshop manual_cod ed0053029330_ 1 ed _ rev 00 30
- Machinedafterhavingbeeninserted 30
- Note since the seats are supplied pre finished they must not be 30
- Valve seat lapping 30
- Valves seats and valve seat bores 30
- 350epa 31
- 440epa 31
- Being of low expansion type the piston allows small clearances betweenpistonandcylinderand thus oilconsumptionisreduced removecirclipsandpistonpin removepistonringsandcleangrooves measurediameter q atthe a distancefromtheskirtbottom a 12 mm replace the piston and piston rings if wear on the diameter is 0 5 mmmorethantheminimumvaluegiven seetableinfig 0 41 31
- Clearance ø piston ø cilinders 31
- Cylinder 31
- Cylinder roughness 31
- Dimensions of pistons and cylinders logo 31
- Disassembly reassembly 31
- Do not manually hone the cylinder bore surfaces with emery clothorothermeans 31
- Kd 225_315_350_400_440 workshop manual_cod ed0053029330_ 1 ed _ rev 00 31
- Logo can be found inside the piston 31
- Note oversizepistonsof0 0and1 0mmareavailable 31
- Piston 31
- Setaboregaugetozerowithacalibratedring checkdiameterat 1 2 and 3 repeattheoperationatthesamepoints afterturningtheboregauge90 ifwearexceedsthemax givenvalueby0 5 borethecylinderandfit oversizepistonandrings seefig 0and41forcylinderdiametervalues 31
- Thecross hatchpatternshouldbeatanangleof45 55 linesshould beuniformandclearinbothdirections averageroughnessmustrangebetween0 mm1µm thecylindersurfacewhichcomesintocontactwithpistonringsshould bemachinedwiththeplateaumethod 31
- Disassembly reassembly 32
- Disassembly reassembly 33
- 315 350 400 440 34
- A 1stchromiumplatedpistonring nitridedfor225 350 400 b 2ndpistonring torsional c 3rdpistonring oilscraper nitridedfor225 350 400 d chromiumplatedzone 34
- A clearance c headgasket thethicknessofgasket c determinestheclearance a whichmustbe 0 5 0 5mmforkd315withinjectionpumpserialn 6590 259 itis 0 0 0 0mmwithinjectionpumpserialn 6590 281 theclearanceis0 5 0 5mmforkd225inallcases theclearanceis0 0 0 0mmforkd350 400 440inallcases forthecorrectthicknessofgasket c seetableinfig 9 50 there are gaskets with inner diameters oversized by 1 mm for kd 315andkd350 requiredifthecylindersareground 34
- Apistonring mountthatsurfaceupwards 34
- Beforeinsertingthepistonintothecylinder oilandturnthepi beforeinsertingthepistonintothecylinder oilandturnthepi stonringssothatthecutsarestaggered120 toeachother 34
- Clearance 34
- Connectpistontoconnectingrod lubricatepistonpinandintroduce itintothepiston connectingrodassemblybyexertingpressurewith yourthumb fitbothpistonpincirclipsandcheckthattheyarewellseated when introducing both the connecting rod and the piston into the cylindermakesurethatthelargercrownsurface a ifcomparedtothe combustionchamber isonthesamesideasthepushrodopening b 34
- Disassembly reassembly 34
- Inkd350andkd225engines thesecondpistonringisnot inkd350andkd225engines thesecondpistonringisnot torsional whilethefirstandthirdpistonringsdonothavechro miumplatedzonesbutarenitrided 34
- Kd 225_315_350_400_440 workshop manual_cod ed0053029330_ 1 ed _ rev 00 34
- Lubricatethefollowingpartswithoilbeforemounting thepi stonpin thepiston thecylinderandthebig endbearing 34
- Note ifaword top orsomeotherword iswrittenonthesurfaceof 34
- Piston refitting 34
- Piston rings assembly order 34
- Piston rings play between the slots mm 34
- Replacethepistonorpistonringsifthevalueexceedsthemaximum limit 34
- Disassembly reassembly 35
- For kd 225 for kd 350 35
- For kd 315 with injection pump p no 6590 59 35
- For kd 315 with injection pump p no 6590 81 for kd 440 35
- For kd 400 35
- Gasket 35
- Havingchosentherequiredthickness mountthegasketasshownin thefigure seeletter a findthenumberofnotchesinzone b tofindthethicknessofthega sketwhenthecylinderheadismounted thegasketthicknessgiveninthetableistheoneobtainedwiththe gasketmountedandtheheadtorqued 35
- Head gasket mm 35
- Kd 225_315_350_400_440 workshop manual_cod ed0053029330_ 1 ed _ rev 00 35
- Notches 35
- Number 35
- Ofnotches 35
- Onlyremovetheheadgasketfromitsprotectivewrappingjust beforeassembly 35
- Piston 35
- Piston protrusion check 35
- Protusion 35
- See page 26 when tightening the cylinder head 35
- Thickness 35
- Tocalculatetherightthicknessforthegasket theprotrusionbetween thepistonandthecylinderheadsurfacemustbemeasured useadialindicatorwithbaseplate resettozerowhilerestingona surfaceplate thenpositionagainstthecylinderheadbaseplaneas showninthediagram sothatthedialindicatorrodrestsagainstthe piston nowtakethereading repeattheoperationintheotherthreepoints goingcrosswise and takethereadings calculate the average of these four readings to get the precise measurement of the protrusion between the piston and the cylinder headbaseplane choosetheappropriategasketaccordingtothefollowingtable 35
- 315 350 400 440 36
- Clearance 36
- Connecting rod 36
- Connecting rod alignement 36
- Connecting rod piston pin 36
- Connectingrodbigenddiameter 36
- Crankshaft end play 36
- Demounttheconnectingrodandproceedwiththefollowinginspec tions thebig endcapandbig endbearthesamenumbers whenremounting mountthecapfromthesamesideasin c ofthe figure tightenthekd225boltstoa23nmtorquevalue tightentheboltstoa30nmtorquevalueforkd315 350 400 440 36
- Disassembly reassembly 36
- Kd 225_315_350_400_440 workshop manual_cod ed0053029330_ 1 ed _ rev 00 36
- Note the connecting rod has no insert bearings see fig 62 for 36
- Securetheenginetoametalbaseortable useadialindicatorwith columnandmagneticbaseplate placethestylusonthecrankshaft movethedrivingshaftbackandforthontheflywheelside endplayshouldbe0 5 0 5mm itisnotadjustable 36
- Useadialgaugeasshowninthefigure checkthataxesarealignedusingthepistonpin axialmisalignment a 0 15 limit0 3mm 36
- Whenremountingthebig endbearings remembertothorou ghlycleanthepartsandgenerouslylubricatethemtoprevent seizurewhentheengineisstartedupforthefirsttime 36
- Disassembly reassembly 37
- 400 440 315 350 38
- Availability of bearings 38
- Clearance mm 38
- Crankshaft journal diameter mm 38
- Dimensions mm see also fig 61 38
- Disassembly reassembly 38
- Drive shaft main bearing inside diameter connecting rod big end crankshaft bearing and timing control gear and balancer clearance and interference between the corresponding journals 38
- Interference mm 38
- Kd 225_315_350_400_440 workshop manual_cod ed0053029330_ 1 ed _ rev 00 38
- Main bearings are available at their nominal value or undersized0 5 0 0and1 mm connectingrodsareavailablewithbigendatnominal valueorundersized0 5and0 0mm 38
- The undersizes for the crankpin and main journal are 0 5 0 0and1mm 38
- Thegearsmustbemountedwiththerighttoolssothatthey canbecorrectlytimed thegearsshouldnotthereforebedemounted onlythecompleteshaftisavailableasaspare 38
- 315 350 350 epa 400 440 39
- 400 440 315 350 39
- 7 3 3 5 6 3 3 0 1 5 3 5 0 5 3 0 7 3 3 5 6 3 3 5 1 5 3 0 1 5 3 39
- 8 5 3 5 7 5 3 0 8 5 3 5 7 5 3 0 8 5 3 5 7 5 3 5 1 6 3 0 1 6 3 39
- Cam height mm 39
- Camshaft 39
- Camshaft journals and bore 39
- Components 1 journal gearcoverontimingside 2 gear 3 exhaustlobe 4 injectionlobe 5 fuelpumpeccentric 6 intakelobe 7 journal crankcaseside 39
- Dimensions of camshaft journals and bore mm 39
- Disassembly reassembly 39
- H 0 3 0 3 5 2 0 3 0 3 0 3 5 2 0 3 0 0 2 3 5 9 1 3 5 0 2 3 0 0 2 3 39
- Kd 225_315_350_400_440 workshop manual_cod ed0053029330_ 1 ed _ rev 00 39
- Lueofh h1andh2by0 mm 39
- Note replacecamshaftifcamwearexceedstheminimumgivenva 39
- Useacomparatorforinteriors 39
- Disassembly reassembly 40
- Disassembly reassembly 41
- Disassembly reassembly 42
- Disassembly reassembly 43
- Disassembly reassembly 44
- Disassembly reassembly 45
- Lubrication system 46
- Lubrication system 47
- Lubrication system 48
- Lubrication system 49
- Lubrication system 50
- Lubrication system 51
- Fuel system 52
- Fuel system 53
- Fuel system 54
- Fuel system 55
- Fuel system 56
- Fuel system 57
- Fuel system 58
- Kd 225 58
- Kd 315 350 400 440 58
- Connect the injector to a hand pump and adjust if necessary modifyingthethicknessabovethespring when the spring is replaced calibration must be carried out at a pressure higher than 10 bars to counterbalance adjustments while running 59
- Fuel system 59
- Injector calibration 59
- Kd 225_315_350_400_440 workshop manual_cod ed0053029330_ 1 ed _ rev 00 59
- Leakage time waste 59
- Nozzles 59
- Nozzletipwet pressuremustbekept20barsbelowtheopeningpressurefor10seconds afterthistime dampnessonthenozzletipisacceptable andmaybeidentifiedbytouchingwithadryfinger onlyadropof dampnessisacceptableandnotalargethickpatchwhichwouldindicatealeak 59
- Pressuremustdropfrom150to100barsinaspanofnotlessthan8secondsandnotmorethan30 59
- Seatseal 59
- Spraying and opening pressure 59
- Theset upbetweentheneedleandtheguidemustleavetheneedle freetofallandmerelyasaresultofitsownweight whenlifted7mm fromitsseatandrotatedindifferentdirections withthenozzlekeptat a45 angle rotationoftheneedlemustbecompletelysmoothanduninhibitedby obstaclesandmalformations moreover onbeingsqueezedagainstitsseat itmustfallfreely when thenozzleisinverted thetestmustbecarriedoutafterrinsingboththeneedleandnozzle with trichloroethane and wetting with filtered shell calibration fluid c oil 59
- Thesevaluesapplytonewinjectorandallowforlooseningofupto10 afterbreaking inperiod 59
- With the pressure gauge closed press hard on the hand pump at least10times openthepressuregaugeandpressdownonthepumponceevery second whilekeepingacheckonthesprayingprocessandpressure theopeningpressuremustliebetweenthetwovaluesgiveninthe table jetsmustbeuniformandwelldistributed 59
- Fuel system 60
- Electrical system 61
- Electrical system 62
- Kd 225_315_350_400_440 workshop manual_cod ed0053029330_ 1 ed _ rev 00 62
- Thetabsareindifferentsizestoprevent incorrectconnections 62
- Thetestwasconductedafterheatstabilizingat20 c the value of the current delivered in relation to the curve may be subjectedtoavariationofbetween 10 and 5 62
- V 12a forstandardalternatorswith3outputwires 12v 30a for12v 20aalternatorswith2outputwires 24v 9a for24v 9aalternatorswithtwooutputwires 62
- V 30a alternator battery recharging curve 62
- V 9a alternator battery recharging curve 62
- Voltage regulator 62
- Electrical system 63
- Electrical system 64
- Electrical system 65
- Electrical system 66
- Electrical system 67
- Settings adjustments 68
- Settings adjustment 69
- Storage 70
- When the engines are not used for more than 3 months they must be protected by the measures described below 70
- Storage 71
- Torque specifications 72
- Torque specifications 73
- Data reported in this issue can be modified at any time by kohler 74
- Ed0053029330 74
- Enginedivision kohlerco kohler wisconsin53044 74
- Forsalesandserviceinformation inu s andcanada call 1 800 544 2444 74
- Kohlerengines com 74
- Translated from the original manual in italian language 74
Похожие устройства
- Kohler KD420 Руководство пользователя
- Kohler KDW 502 Руководство по эксплуатации
- Kohler KDW702 Руководство по обслуживанию
- Kohler KDW702 Руководство пользователя
- Kohler KD425-2 Руководство по ремонту
- Kohler KD425-2 Руководство пользователя
- Kohler KD477-2 Руководство по ремонту
- Kohler KD477-2 Руководство пользователя
- Kohler KDW1003 Руководство по ремонту
- Kohler KDW1003 Руководство пользователя
- Kohler KDW1404 Руководство по ремонту
- Kohler KDW1404 Руководство пользователя
- Kohler KD625-2 Руководство по ремонту
- Kohler KD625-2 Руководство пользователя
- Kohler KDI1903M Руководство пользователя
- Kohler KDW2204 Руководство по ремонту
- Kohler KDW2204 Руководство пользователя
- Autonics LP-A104-T9D9-C6T Инструкция по эксплуатации
- Autonics LP-A104-T9D9-C6R Инструкция по эксплуатации
- Autonics LP-A104-T9D8-C6T Инструкция по эксплуатации