KD 225-315-350-400-440

KD225 - KD315 - KD350 KD400 - KD440

WORKSHOP MANUAL

KD 225_315_350_400_440

PREFACE

- Every attempt has been made to present within this service manual, accurate and up to date technicalinformation.

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- ThepersonorpeopleperformingserviceworkonKOHLERseriesenginesisproperlytrainedandequippedtosafelyandprofessionallyperformthesubjectoperation;

2- The person or people performing service work onKOHLER series engines possesses adequate hand andKOHLERspecialtoolstosafelyandprofessionallyperformthesubjectserviceoperation;

3- ThepersonorpeopleperformingserviceworkonKOHLERseriesengineshasreadthepertinentinformationregardingthesubjectserviceoperationsandfullyunderstandstheoperationathand.

- This manual was written by the manufacturer to provide technical and operating information to authorisedKOHLERafter-salesservicecentrestocarryoutassembly,disassembly,overhauling,replacementandtuningoperations.

- Aswellasemployinggoodoperatingtechniquesandobservingtherighttimingforoperations,operatorsmustreadtheinformationverycarefullyandcomplywithitscrupulously.

- Timespentreadingthisinformationwillhelptopreventhealthandsafetyrisksandfinancialdamage. Writteninformationisaccompaniedbyillustrationsinordertofacilitateyourunderstandingofeverystepofthe

operatingphases.

- 3 -

WARRANTY CERTIFICATE

KD 225_315_350_400_440 Workshop Manual_cod. ED0053029330_1° ed_ rev.00

CALIFORNIA EMISSION CONTROL WARRANTY STATEMENTYOUR WARRANTY RIGHTS AND OBLIGATIONS

The California Air Resources Board andKohlerCo.arepleasedtoexplaintheemission control system warrantyonyour2012engine.InCalifornia,newheavy-dutyoff-roadenginesmustbedesigned,builtandequippedtomeettheState’sstringentanti-smogstandards.KohlerCo.mustwarranttheemissioncontrolsystemonyourengineforthetimeperiodlistedbelowprovidedtherehasbeennoabuse,neglectorimpropermaintenanceofyourengine.Youremissioncontrolsystemmay includepartssuchasthefuel-injectionsystemandtheair inductionsystem.Also includedmaybehoses,connectorsandotheremissionrelatedassemblies.Whereawarrantableconditionexists,KohlerCo.willrepairyourheavy-dutyoff-roadengineatnocosttoyouincludingdiagnosis,partsandlabor.

MANUFACTURER’S WARRANTY COVERAGE:

Youroff-road,dieselengineemissioncontrolsystemiscoveredunderwarrantyforaperiodoffive(5)yearsor3,000hours,whicheveroccursfirst,beginningonthedatetheengineorequipmentisdeliveredtoanultimatepurchaserforallconstantspeedengineswithmaximumpower19≤kW<37andratedspeedlessthan3,000rpm,allvariablespeedengineswithmaximumpower19≤kW<37,andallvariableorconstantspeedengineswithmaximumpowergreaterthan37kW.Youroff-road,dieselengineemissioncontrolsystemonvariableorconstant-speedengineswithmaximumpowerlessthan19kW,andforconstantspeedengineswithmaximumpower19≤kW<37andratedspeedequaltoorgreaterthan3,000rpmiscoveredunderwarrantyforaperiodoftwo(2)yearsor1,500hours,whicheveroccursfirst.Ifanyemissionrelatedpartonyourengineisdefective,thepartwillberepairedorreplacedbyKohlerCo.

OWNER’S WARRANTY RESPONSIBILITIES:

As theheavy-dutyoff-roadengineowner,youare responsible for theperformanceof the required maintenance listed in your Kohler Co. owner’s manual.KohlerCo.recommendsthatyouretainallreceiptscoveringmaintenanceonyourheavy-dutyoff-roadengine,butKohlerCo.cannotdenywarrantysolelyforthelackofreceiptsorforyourfailuretoensuretheperformanceofallrecommendedscheduledmaintenance.Astheheavy-dutyoff-roadengineowner,youshouldhoweverbeawarethatKohlerCo.maydenyyouwarrantycoverageifyourheavy-dutyoff-roadengineoremissioncontrolrelatedcomponenthasfailedduetoabuse,neglect,impropermaintenanceorunapprovedmodifications.Yourengineisdesignedtooperateoncommercialdieselfuel(No.1orNo.2lowsulfurorultralowsulfurdieselfuel)only.UseofanyotherfuelmayresultinyourenginenolongeroperatingincompliancewithCalifornia’semissionsrequirements.Youareresponsibleforinitiatingthewarrantyprocess.TheAirResourcesBoardsuggeststhatyoupresentyourheavy-dutyoff-roadenginetoaKohlerCo.dealerassoonasaproblemexists.Thewarrantyrepairsshouldbecompletedbythedealerasexpeditiouslyaspossible.Pleasereviewthedocumenttitled,“KohlerCo.FederalandCaliforniaEmissionControlSystemsLimitedWarrantyOff-RoadDieselEngines”,forcompletedetailsofyourheavy-dutyoff-roadenginewarranty.IfyouhaveanyquestionsregardingyourwarrantyrightsandresponsibilitiesorthelocationofthenearestKohlerCo.authorizedservicelocation,youshouldcontactKohlerCo.at1-800-544-2444oraccessourwebsiteatwww.kohlerengines.com.

LIMITED 3 YEAR KOHLER® DIESEL ENGINE WARRANTY

KohlerCo.warrantstotheoriginalretailconsumerthateachnewKOHLERDieselenginesoldbyKohlerCo.willbefreefrommanufacturingdefects inmaterialsorworkmanship innormal service for aperiodof three (3) yearsor2000hourswhicheveroccurs first from thedateofpurchase,provideditisoperatedandmaintainedinaccordancewithKohlerCo.’sinstructionsandmanuals.Ifnohourmeterisinstalledasoriginalequipmentthen8hoursofuseperdayand5daysperweekwillbeusedtocalculatehoursused.

Ourobligationunderthiswarrantyisexpresslylimited,atouroption,tothereplacementorrepairatKohlerCo.,Kohler,Wisconsin53044,orataservicefacilitydesignatedbyusofsuchpartsasinspectionshalldisclosetohavebeendefective.

Thiswarrantydoesnotapplytodefectscausedbyunreasonableuse,includingfaultyrepairsbyothersandfailuretoprovidereasonableandnecessarymaintenance.

Thefollowingitemsarenotcoveredbythiswarranty:Engineaccessoriessuchasfueltanks,clutches,transmissions,power-driveassembliesandbatteries,unlesssuppliedorinstalledbyKohlerCo.Thesearesubjecttothewarranties,ifany,oftheirmanufacturers.

KOHLERCO.AND/ORTHESELLERSHALLNOTBELIABLEFORSPECIAL,INDIRECT,INCIDENTIALORCONSEQUENTIALDAMAGESOFANYKIND,includingbutnotlimitedtolaborcostsortransportationchargesinconnectionwiththerepairorreplacementofdefectiveparts.

IMPLIEDORSTATUTORYWARRANTIES,INCLUDINGWARRANTIESOFMERCHANTABILITYORFITNESSFORAPARTICULARPURPOSE,AREEXPRESSLYLIMITEDTOTHEDURATIONOFTHISWRITTENWARRANTY.Wemakenootherexpresswarranty,norisanyoneauthorizedtomakeanyonourbehalf.

Somestatesdonotallowlimitationsonhowlonganimpliedwarrantylasts,ortheexclusionorlimitationofincidentalorconsequentialdamages,sotheabovelimitationorexclusionmaynotapplytoyou.

Thiswarrantygivesyouspecificlegalrights,andyoumayalsohaveotherrights,whichvaryfromstatetostate.

Toobtainwarrantyservice

PurchasermustbringtheenginetoanauthorizedKohlerservicefacility.Tolocatethenearestfacility,visitourwebsite,www.kohlerengines.com,andusethelocatorfunction,consultyourYellowPagesortelephone1-800-544-2444.

ENGINEDIVISION,KOHLERCO.,KOHLER,WISCONSIN53044

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INDEX


ThismanualcontainspertinentinformationregardingtherepairofKOHLERwater-cooled,indi-rectinjectionDieselenginestypeKD 225_315_350_400_440:updatedJune20,2012.INDEX

PREFACE .................................................................................................................................................................. 2

WARRANTY CERTIFICATE ..................................................................................................................................... 3Limited3yearkohler®dieselenginewarranty.................................................................................................................. 3Californiaemissioncontrolwarrantystatement................................................................................................................. 3Yourwarrantyrightsandobligations.................................................................................................................................. 3

1 - TROUBLE SHOOTING ........................................................................................................................................ 7Possiblecausesandtroubleshooting................................................................................................................................ 7

2 - GENERAL REMARKS AND SAFETY INFORMATION ...................................................................................... 8Safetyregulations............................................................................................................................................................... 8Generalsafetyduringoperatingphases............................................................................................................................ 9Safetyandenvironmentalimpact...................................................................................................................................... 9

3 - MODEL NUMBER AND IDENTIFICATION ....................................................................................................... 11Manufacturerandmotoridentificationdata.......................................................................................................................11Approvaldata.....................................................................................................................................................................11

4 - TECHNICAL DATA ............................................................................................................................................ 12Characteristicskd225_315_350.......................................................................................................................................12Characteristicskd400_440...............................................................................................................................................13

5 - CHARACTERISTICS ......................................................................................................................................... 14Characteristicspower,torqueandspecificfuelconsumptioncurves...............................................................................14

6 - OVERALL DIMENSIONS ................................................................................................................................... 16

7 - MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING ........................................................................ 18Maintenance......................................................................................................................................................................18Fuel....................................................................................................................................................................................18Recommendedoil..............................................................................................................................................................19Aceasequences................................................................................................................................................................19

8 - DISASSEMBLY/REASSEMBLY ........................................................................................................................ 20Disassemblyandreassembly........................................................................................................................................... 20Dryaircleanerforkd315andkd350............................................................................................................................... 20Dryaircleanerforkd225................................................................................................................................................. 20Dryaircleanerforkd400-440..........................................................................................................................................21Prefilterfordryairfilter......................................................................................................................................................21Oil-bathaircleaner(optional)........................................................................................................................................... 22Muffler............................................................................................................................................................................... 22Rockerarmcoverbreathersystem................................................................................................................................... 22Rockerarmcover-breatherricirculation......................................................................................................................... 23Valve/rockerarmclearance(KD225-315-350)................................................................................................................ 23TheenginesKD400and440havehydraulictappets,thereforenoadjustmentisrequired........................................... 23Donotstarttheengineforapproximately4hourstoallowthehydraulictappetstosettlecompletely........................... 23HydraulictappetsKD400-440........................................................................................................................................ 24Tank.................................................................................................................................................................................. 25FuelfilterKD225-400-440(versionwithinternalfilter)................................................................................................... 25FuelfilterforKD225-315-350-400-440(versionwithexternalfilter)........................................................................ 25Re-coilstarting.................................................................................................................................................................. 26Shroud.............................................................................................................................................................................. 26Flywheel............................................................................................................................................................................ 26

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INDEX


Cylinderhead.................................................................................................................................................................... 27Injectorprojection............................................................................................................................................................. 27Valves-Disassembly........................................................................................................................................................ 28Valves-Oilsealinvalveguide......................................................................................................................................... 28Valve,springs.................................................................................................................................................................... 28Valves,characteristics...................................................................................................................................................... 29Valves,guidesandhousings............................................................................................................................................ 29Valves,guideinsertion...................................................................................................................................................... 29Dimensionsandclearancebetweenguidesandvalvestems(mm)................................................................................ 30Valvesseatsandvalveseatbores................................................................................................................................... 30Valveseatlapping............................................................................................................................................................. 30Cylinder..............................................................................................................................................................................31Cylinderroughness............................................................................................................................................................31Piston.................................................................................................................................................................................31Dimensionsofpistonsandcylinders,Logo.......................................................................................................................31Pistonrings,distancebetweenthetips(mm)................................................................................................................... 33Pistonrings,playbetweentheslots(mm)........................................................................................................................ 34Pistonrings,assemblyorder............................................................................................................................................ 34Piston-Refitting............................................................................................................................................................... 34Clearance.......................................................................................................................................................................... 34Pistonprotrusioncheck.................................................................................................................................................... 35Connectingrod................................................................................................................................................................. 36Connectingrod,pistonpin................................................................................................................................................ 36Connectingrodalignement............................................................................................................................................... 36Crankshaftendplay.......................................................................................................................................................... 36Driveshaftoilseals........................................................................................................................................................... 37Driveshaft,lubricationducts,borethreadonflywheelsideandp.t.o.............................................................................. 37Driveshaft,connectionradius.......................................................................................................................................... 37Driveshaft,mainjournal/crankpindiameter,gearcoverbearinginsidediameterontimingside.................................... 37Crankshaft-journaldiameter(mm).................................................................................................................................. 38Availabilityofbearings...................................................................................................................................................... 38Camshaft........................................................................................................................................................................... 39Camshaftjournalsandbore............................................................................................................................................. 39Dimensionsofcamshaftjournalsandbore(mm)............................................................................................................. 39Camheight(mm)............................................................................................................................................................... 39Camshafttiming................................................................................................................................................................ 40Camshaft–AntireversesystemKD400-440................................................................................................................... 40Automaticdecompression.................................................................................................................................................41Camshaftendplay.............................................................................................................................................................41Dynamicbalancer(onrequest)..........................................................................................................................................41Dinamicbalancertiming................................................................................................................................................... 43Valvetimingcheck............................................................................................................................................................ 43Timinganglesforoperation(0.15valveplay)................................................................................................................... 44Timinganglesforinspection(0.65-0.70valveplay)......................................................................................................... 44Speedgovernor................................................................................................................................................................ 45Speedgovernorremoval.................................................................................................................................................. 45Refittinggearcoverontimingside................................................................................................................................... 45

9 - LUBRICATION SYSTEM .................................................................................................................................... 46KD225-315-350lubricationsystemandbreatherrecirculationsystem...................................................................... 46KD400-440lubricationsystemandbreatherrecirculationsystem..................................................................................47Oilpump............................................................................................................................................................................ 48Oilpump-clearancebetweenrotors............................................................................................................................... 48Oilpressureregulationvalve............................................................................................................................................ 48Internalstrainer................................................................................................................................................................. 48Oilfilter.............................................................................................................................................................................. 49Oilpressurecheck............................................................................................................................................................ 49Calibratedpipeforlubricationofhydraulictappets.......................................................................................................... 49Oilpressurecurveatidlespeed....................................................................................................................................... 50Oilpressurecurveatfullspeed........................................................................................................................................ 50Fuelling/injectioncircuitforKD315-350-400-440............................................................................................................51Fuelling/injectioncircuitforKD225...................................................................................................................................51

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INDEX


10 - FUEL SYSTEM ................................................................................................................................................. 52FuelfilterKD225-315-350-400-440................................................................................................................................ 52FuelfilterKD225(versionwithinternalfilterintank)....................................................................................................... 52Feedpump(optional)........................................................................................................................................................ 52Fuelpump,driverodprotrusion........................................................................................................................................ 53Injectionpump.................................................................................................................................................................. 53Injectionpumpfittinginthecrankcase............................................................................................................................. 53Injectionpumpcomponentsanddisassembly................................................................................................................. 54Injectionpump,body,plungeranddeliveryvalve............................................................................................................. 54Injectionpumprefitting..................................................................................................................................................... 54Injectionpumpnon-returnvalve....................................................................................................................................... 55Outletfittingcomponentsfor315-350EPAE400-440engines...................................................................................... 55Injectionpump,Rilsantuberemoval................................................................................................................................ 55Injectionpump,Rilsantuberefitting................................................................................................................................. 55Injectionpumpdeliverycheckontestbench................................................................................................................... 56Staticinjectiontiming........................................................................................................................................................ 56Staticinjectionleadtestonflywheel................................................................................................................................. 57Injectionadvanceadjustment........................................................................................................................................... 58Injector.............................................................................................................................................................................. 58Leakagetime(waste)........................................................................................................................................................ 59Nozzles............................................................................................................................................................................. 59Injectorcalibration............................................................................................................................................................. 59

11 - ELECTRICAL SYSTEM .................................................................................................................................... 6212V,12Aelectricignitiondiagram.....................................................................................................................................61Alternator...........................................................................................................................................................................61Alternatorbatterychargergraph(12V,12A)......................................................................................................................6124V,9Aalternatorbatteryrechargingcurve..................................................................................................................... 6212V,30Aalternatorbatteryrechargingcurve................................................................................................................... 62Voltageregulator............................................................................................................................................................... 6212Velectricstarterdiagramwithvoltageregulatorbuiltintotheignitionpanel............................................................... 6312Velectricignitionlayoutwithmotorprotection(optional)............................................................................................. 63Diagramofelectricstartermotorprotectionwithsoleself-windingstarter-withoutbattery-(optional)......................... 64Testingvoltageregulatorforproperoperation................................................................................................................. 65Startingmotor................................................................................................................................................................... 65CharacteristiccurvesforstartingmotortypeDW(L)12V,1.1KW.................................................................................. 65CharacteristiccurvesofBoschstartermotortypeDW(L)12V,0.9kW........................................................................... 66CharacteristiccurvesofBoschstartermotortypeDW(L)24V,1.6kW........................................................................... 66Ignitionswitchpositions.................................................................................................................................................... 66Adjustments-KD315-350................................................................................................................................................ 67Idlingspeedsettinginno-loadconditions(standard)....................................................................................................... 67Idlespeedadjustment,forsmallcarversions.................................................................................................................. 67Fullspeedsettinginno-loadconditions(standard).......................................................................................................... 67

12 - SETTINGS / ADJUSTMENTS .......................................................................................................................... 68Adjustments-KD225-400-440....................................................................................................................................... 68No-loadidlingadjustment(standard)................................................................................................................................ 68No-loadtoprateadjustment(standard)............................................................................................................................ 68InjectionpumpflowrateadjustmentForKD225-315-350-400-440............................................................................... 68Injectionpumpdeliverylimitingandtorqueadapter(standard)....................................................................................... 68Injectionpumpdeliverysetting........................................................................................................................................ 69Requiredsettings(themostcommonones)..................................................................................................................... 69

14 - STORAGE ........................................................................................................................................................ 70Storage............................................................................................................................................................................. 70Internalengineprotection:................................................................................................................................................ 70Injectionsystemsprotection:............................................................................................................................................ 70Externalengineprotection:............................................................................................................................................... 70Procedurestobecarriedoutbeforestarttheengine........................................................................................................71

15 - TORQUE SPECIFICATIONS ........................................................................................................................... 72Maintorquespecifications................................................................................................................................................ 72Useofsealant................................................................................................................................................................... 72Tableoftighteningtorquesforstandardscrews(coarsethread)..................................................................................... 73Tableoftighteningtorquesforstandardscrews(finethread).......................................................................................... 73

1

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POSSIBLE CAUSES AND TROUBLE SHOOTING

CloggedpipesCloggedfuelfilterAirinsidefuelcircuitCloggedtankbreatherholeFaultyfuelpumpInjectorjammedJammedinjectionpumpdeliveryvalveWronginjectorsettingExcessiveplungerblow-byJammedinjectionpumpdeliverycontrolWronginjectionpumpsettingOilleveltoohighJammedpressurereliefvalveWornoilpumpAirinsideoilsuctionpipeFaultypressuregaugeorswitchCloggedoilsuctionpipeBatterydischargedWrongorinefficientcableconnectionDefectiveignitionswitchDefectivestartermotorCloggedairfilterExcessiveidleoperationIncompleterunning-inEngineoverloadedAdvancedinjectionDelayedinjectionIncorrectgovernorlinkageadjustmentBrokenorloosegovernorspringIdlespeedtoolowWornorjammedpistonringsWornorscoredcylindersWornvalveguidesJammedvalvesWornbearingsGovernorlinkagenotfreetoslideDriveshaftnotfreetoslideDamagedcylinderheadgasket

TROUBLE

LUBR

ICAT

ION

POSSIBLE CAUSE

FUEL

CIR

CU

ITEL

ECTR

ICSY

STEM

MA

INTE

-N

AN

CE

SETT

ING

S/R

EPA

IRS

Enginedoesnot

start

Noacceleration

Blacksmoke

Excessiveoil

consum

ption

Too

low

oil

pressure

Enginestartsbut

stops

Non-uniformspeed

Whitesmoke

oilandfu

eldripping

fromexhaust

Increaseoillevel

THE ENGINE MUST BE STOPPED IMMEDIATELY WHEN:

1) -Theenginerpmssuddenlyincreaseanddecrease 2) -Asuddenandunusualnoiseisheard 3) -Thecolouroftheexhaustfumessuddenlydarkens 4) -Theoilpressureindicatorlightturnsonwhilerunning.

TABLE OF LIKELY ANOMALIES AND THEIR SYMPTOMS

Thefollowingtablecontainsthepossiblecausesofsomefailureswhichmayoccurduringoperation.Alwaysperformthesesimplechecksbeforeremovingorreplacinganypart.

TROUBLE SHOOTING


2

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SAFETY REGULATIONS

GENERAL REMARKS AND SAFETY INFORMATION


GENERAL NOTES

. Kohler engines are built to provide safe and longlastingperformances, but in order to obtain these results it isessential that the maintenance requirements described inthe manual are observed along with the following safetyrecommendations.

. The engine has been built to the specifications of amachinemanufacturer,anditishisresponsibilitytoensurethat all necessary action is taken to meet the essentialand legally prescribed health and safety requirements.Any use of themachine other than that described cannotbe considered as complying with its intended purposeas specified by Kohler, which therefore declines allresponsibilityforaccidentscausedbysuchoperations.

. The following instructions are intended for the user of themachine in order to reduce or eliminate risks, especiallythoseconcerning theoperationandstandardmaintenanceoftheengine.

. The user should read these instructions carefully and gettoknowtheoperationsdescribed.Bynotdoingsohemayplaceatriskhisownhealthandsafetyandthatofanyoneelseinthevicinityofthemachine.

. The enginemay be used ormounted on amachine onlybypersonnelsuitably trained in itsoperationandawareofthedangers involved.This is particularly true for standardand, above all, special maintenance work. For specialmaintenance contact personnel trained specifically byKohler.Thisworkshouldbecarriedoutinaccordancewithexistingliterature.

. Kohlerdeclinesallresponsibilityforaccidentsorforfailuretocomplywiththerequirementsoflawifchangesaremadetotheengine’sfunctionalparametersortothefuelflowrateadjustments and speed of rotation, if seals are removed,or ifpartsnotdescribed in theoperatingandmaintenancemanual are removed and reassembled by unauthorizedpersonnel.

WARNING

. Inaddition toall othermachinespecifications,ensure thattheengine is inanearhorizontalpositionwhenstarting. lfstarting manually, ensure that the necessary operationscanbeperformedwithoutanyriskofstrikingagainstwallsordangerousobjects.Ropestarting(exceptforrecoilropestarting)isnotpermittedeveninemergencies.

. Checkthatthemachineisstablesothatthereisnoriskofitoverturning.

. Get to know the engine speed adjustment and machinestopoperations.

. Do not start the machine in closed or poorly ventilatedenvironments.The internal combustion process generatescarbon monoxide, an odourless and highly toxic gas, sospending too long a time in an environment where theengine discharges its exhaust products freely can lead tolossofconsciousnessandevendeath.

. The engine may not be used in environments containingflammable materials, explosive atmospheres or easilycombustible powders, unless adequate and specificprecautions have been taken and are clearly stated andcertifiedforthemachine.

. Topreventtheriskoffire,keepthemachineatadistanceofatleastonemetrefrombuildingsorothermachines.

. Children and animals must be kept at a sufficient distancefrom the machine to prevent any danger resulting from itsoperation.

. Fuel is flammable, so the tankmust be filled only when theengine is turned off. Dry carefully any fuel that may havespilled, remove the fuel container and any cloths soakedin fuel or oil, check that any sound-absorbing panels madeofporousmaterial arenot soakedwith fueloroil, andmakesurethatthegroundonwhichthemachineislocatedhasnotabsorbedfueloroil.

. Before starting, remove any tools that have been used forcarrying out maintenance work to the engine and/or themachine and check that any guards removed have beenreplaced. Incoldclimates it ispossible tomixkerosenewiththediesel fuel tomaketheengineeasier tostart.Theliquidsmust be mixed in the tank by pouring in first the keroseneand then the diesel fuel. ConsultKohler technical office formixture proportions. Petrolmay not be used because of theriskofitformingflammablevapours.

. During operation the surface of the engine reachestemperatures thatmaybe dangerous. Avoid in particular allcontactwiththeexhaustsystem.

. The liquid cooling circuit is underpressure.Donot carryoutany checks before the engine has cooled down, and eventhenopen the radiator capor theexpansion tank cautiously.Wear protective clothing and glasses. lf there is an electricfan,donotapproachtheenginewhile it isstillhotasthefanmaycomeonevenwhentheengineisnotrunning.Cleanthecoolingsystemwiththeengineturnedoff.

. While cleaning the oil bath air filter, check that the oil isdisposed of in such a way as not to harm the environment.Any filtering sponges in the oil bath air filter should not besoakedwithoil. Thecyclonepre-filtercupmustnotbefilledwithoil.

. Sincetheoilmustbeemptiedoutwhiletheengineisstillhot(approx. 80°C), particular care should be taken in order toavoid burns. In any casemake sure that oil does not comeinto contact with your skin because of the health hazardsinvolved.

. Fuelvapoursarehighlytoxic,sofilluponlyintheopenairorinwellventilatedenvironments.

. During operations which involve access to moving parts ofthe engine and/or removal of the rotary guards, disconnectandinsulatethepositivecableofthebatterysoastopreventaccidentalshortcircuitsandactivationofthestartermotor.

. Checkthebelttensiononlywhentheengineisturnedoff.

IMPORTANT

. To start the engine follow the specific instructions providedin the engine and/or machine operating manual. Do notuse auxiliary starting devices not originally installed on themachine(e.g.Startpilotsystemswhichutiliseetheretc.)

. Before carrying out any work on the engine, turn it off andallowittocooldown.Donotperformanyoperationwhiletheengineisrunning.

. Check that the discharged oil, the oil filter and the oilcontainedintheoilfilteraredisposedofinsuchawayasnottoharmtheenvironment.

. Close the fuel tank filler cap carefully after each fíllingoperation. Do not fill the tank right up to the top, but leavesufficientspacetoallowforanyexpansionofthefuel.

. Donotsmokeorusenakedflameswhilefilling.

2

- 9 -

GENERAL SAFETY DURING OPERATING PHASES

– Theprocedurescontainedinthismanualhavebeentestedandselectedbythemanufacturer’stechnicalexperts,andhencearetoberecognisedasauthorisedoperatingmethods.

– Anumberof proceduresmustbe carriedoutwith theaidof equipmentand tools that simplify and improve the timingofoperations.

– Alltoolsmustbeingoodworkingconditionsothatenginecomponentsarenotdamagedandthatoperationsarecarriedoutproperlyandsafely.

Itisimportanttowearthepersonalsafetydevicesprescribedbyworksafetylawsandalsobythestandardsofthismanual.– Holes must be lined up methodically and with the aid of suitable equipment. Do not use your fingers to carry out this

operationtoavoidtheriskofamputation.– Somephasesmayrequiretheassistanceofmorethanoneoperator.Ifso,itisimportanttoinformandtrainthemregarding

thetypeofactivitytheywillbeperforminginordertopreventriskstothehealthandsafetyofallpersonsinvolved.– Donotuseflammableliquids(petrol,diesel,etc.)todegreaseorwashcomponents.Usespecialproducts.– Usetheoilsandgreasesrecommendedbythemanufacturer. Donotmixdifferentbrandsorcombineoilswithdifferentcharacteristics.– Discontinueuseoftheengineifanyirregularitiesarise,particularlyinthecaseofunusualvibrations.– Donottamperwithanydevicestoalterthelevelofperformanceguaranteedbythemanufacturer.

SAFETY AND ENVIRONMENTAL IMPACT

Every organisation has a duty to implement procedures toidentify,assessandmonitor the influenceof itsownactivities(products,services,etc.)ontheenvironment.Proceduresforidentifyingtheextentoftheimpactontheenvi-ronmentmustconsiderthefollowingfactors:

- Liquidwaste - Wastemanagement - Soilcontamination - Atmosphericemissions - Useofrawmaterialsandnaturalresources - Regulationsanddirectivesregardingenvironmentalimpact

Inordertominimisetheimpactontheenvironment,themanu-

facturer nowprovidesanumber of indications to be followedbyallpersonshandling theengine, forany reason,during itsexpectedlifetime.

- All packaging componentsmust be disposed of in accor-dancewiththelawsofthecountry inwhichdisposal ista-kingplace.

- Keepthefuelandenginecontrolsystemsandtheexhaustpipes in efficientworking order to limit environmental andnoisepollution.

- When discontinuing use of the engine, select all compo-nentsaccordingtotheirchemicalcharacteristicsanddispo-seofthemseparately.

GENERAL REMARKS AND SAFETY INFORMATION


. Takecarewhenremovingtheoilfilterasitmaybehot.

. The operations of checking, filling up and replacing thecoolingliquidmustbecarriedoutwiththeengineturnedoffandcold. Takeparticular care if liquids containingnitritesare mixed with others not containing these compoundsas this may give rise to the formation of nitrosamineswhichareahealthhazard. Thecooling liquid ispolluting,so dispose of in a manner that does not damage theenvironment.

. In order to move the engine simultaneously use theeyebolts fitted for this purpose by Kohler. These liftingpointsarehowevernotsuitable for theentiremachine,sointhiscaseusetheeyeboltsfittedbythemanufacturer.

- 10 -

NOTE


3

- 11 -

F EC

A DB

s/n

MADE IN ITALY

rpmXX XX XXXX

XX XX XXXX

XXXX

XXXXXXe9 • 97/68/CE • 00/000xx • xxxx •xx

Xx 0.00 xxx xxx xx

Model

Spec.

6

1

USE IN CONSTANT-SPEED APPLICATIONS ONLY

3 10

5

78

9

2 4

MODEL NUMBER AND IDENTIFICATION

Theidentificationplateshowninthefigurecanbefounddirectlyontheengine.Itcontainsthefollowinginformation:

A)Manufacturer’sidentityB)EnginetypeC)EngineserialnumberD) MaximumoperatingspeedE) Numberofthecustomerversion(formK)F)Approvaldata

Approval data

TheapprovalreferencedirectivesECareontheengineplate.

MANUFACTURER AND MOTOR IDENTIFICATION DATA

1)Modelyear.2)Enginedisplacement.3)Powercategory,kW.4)Particulateemissionlimit(g/kWh).5)EnginefamilyID.6)Kindofapplicationi.e.7)Injectiontiming(BTDC).8)Injectoropeningpressure(bar).9)Productiondate(example2012_Jan).10) EmissionControlSystem=ECS.


4

1786631520,3:13600

5,0(6,8)4,6(6,2)4,1(5,6)15@2400

2620,00351,212/4433480500020025°35°***

1826634920,3:13600

5,5(7,5)5,1(7,0)4,7(6,4)

16,6@2400260

0,00381,212/4433540500020025°35°***

N.mmmmCm3

Nmg/kW.h

l/hlt

V/Ahkg

l./minl./minkg.

1696022421:13600

3,5(4,8)3,3(4,5)3,1(4,2)

10,4@2400267

0,00210,912/3628350380015025°35°***

315 350225

- 12 -

KD 315

KD 350

KD 225

TECHNICAL DATA

* ReferredtoNpower** ReferredtoNBpower*** Dependingontheapplication

ENGINETYPENumberofcylindersBoreStrokeSweptvolumeCompressionratioR.P.M. N80/1269/EEC-ISO1585PowerkW(HP) NBISO3046-1IFN NAISO3046-1ICXNMax.torque*Fuelconsumption**OilconsumptionCapacityofstandardoilsumpRecommendedbatteryDryweightCombustionairvolumeat3600r.p.m.Coolingairvolumeat3600r.p.m.Max.permissibledrivingshaftaxialloadinbothdirections continuousserviceforupto30min.Max.inclination discontinuousserviceforabout1min. permanentservice


CHARACTERISTICS KD 225_315_350

4

1827640120,3:13600

7,0(9,5)6,4(8,7)5,8(7,9)

21,3@24002620,0051,512/4445580550020025°35°***

1867644220,3:13600

7,7(10,5)7,0(9,6)6,4(8,7)

23,5@2400260

0,00551,512/4445635550020025°35°***

N.mmmmCm3

Nmg/kW.h

l/hlt

V/Ahkg

l./minl./minkg.

400 440

- 13 -

KD 400

KD 440

TECHNICAL DATA

* ReferredtoNpower** ReferredtoNBpower*** Dependingontheapplication

ENGINETYPENumberofcylindersBoreStrokeSweptvolumeCompressionratioR.P.M. N80/1269/EEC-ISO1585PowerkW(HP) NBISO3046-1IFN NAISO3046-1ICXNMax.torque*Fuelconsumption**OilconsumptionCapacityofstandardoilsumpRecommendedbatteryDryweightCombustionairvolumeat3600r.p.m.Coolingairvolumeat3600r.p.m.Max.permissibledrivingshaftaxialloadinbothdirections continuousserviceforupto30min.Max.inclination discontinuousserviceforabout1min. permanentservice


CHARACTERISTICS KD 400_440

5

- 14 -

KD 225

KD 315 KD 350

CHARACTERISTICS

CHARACTERISTICS POWER, TORQUE AND SPECIFIC FUEL CONSUMPTION CURVES


N (80/1269/EEC - ISO 1585) AUTOMOTIVE RATING :Intermittentoperationwithvariablespeedandvariableload.NB (ISO 3046 - 1 IFN) RATING WITH NO OWERLOAD CAPABILITY:continuosligthdutyoperationwithconstantspeedandvariableload.NA (ISO 3046 - 1 ICXN) CONTINUOS RATING WITH OVERLOAD CAPABILITY:continuosheavydutywithconstantspeedandconstantload.MN TorqueatNpower.CSpecificfuelconsumptionatNB power.Theabovepowervalues refer toanenginefittedwithair cleanerandstandardmuffler,after testingandat theenvironmental conditionsof20°Cand1bar.Max.powertoleranceis5%.Powerdecreasesbyapproximately1%every100mdialtitudeandby2%every5°Cabove25°C.

Note:ConsultKOHLERforpower,torquecurvesandspecificconsumptionsatratesdifferingfromthosegivenabove.

5

- 15 -

KD 400 KD 440

CHARACTERISTICS

CHARACTERISTICS POWER, TORQUE AND SPECIFIC FUEL CONSUMPTION CURVES


N (80/1269/EEC - ISO 1585) AUTOMOTIVE RATING :Intermittentoperationwithvariablespeedandvariableload.NB (ISO 3046 - 1 IFN) RATING WITH NO OWERLOAD CAPABILITY:continuosligthdutyoperationwithconstantspeedandvariableload.NA (ISO 3046 - 1 ICXN) CONTINUOS RATING WITH OVERLOAD CAPABILITY:continuosheavydutywithconstantspeedandconstantload.MN TorqueatNpower.CSpecificfuelconsumptionatNB power.Theabovepowervalues refer toanenginefittedwithair cleanerandstandardmuffler,after testingandat theenvironmental conditionsof20°Cand1bar.Max.powertoleranceis5%.Powerdecreasesbyapproximately1%every100mdialtitudeandby2%every5°Cabove25°C.

Note:ConsultKOHLERforpower,torquecurvesandspecificconsumptionsatratesdifferingfromthosegivenabove.

6

Note :Dimensionsshowninmm

- 16 -

KD 225

KD 315

KD 350

OVERALL DIMENSIONS


6

Note:Dimensionsshowninmm.

- 17 -

KD 400

KD 440

OVERALL DIMENSIONS


7

10 50 250 500(*)(*)

(**)

(**)(***)

(°)

- 18 -

MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING

Failure to carry out the operations described in the table may lead to technical damage to the machine and/or system

MAINTENANCE INTERVAL (HOURS) OPERATION COMPONENT OIL-BATHAIRCLEANER HEADANDCYLINDERFINSCLEANING INJECTOR AIRCLEANEROIL LEVEL OILSUMPCHECK VALVE/ROCKERARMCLEARANCE INJECTORSETTING AIRCLEANER SUMP REPLACEMENT OILFILTERCARTRIDGE FUELFILTERCARTRIDGE DRYAIRCLEANERCARTRIDGE

(*) Undersevereworkingconditions,cleandaily.(**) Underextremelydustyconditions,changeevery4-5hours.(***) Seerecommendedoiltype.(°)Afterthepolyurethaneprefilterhasbeenserviced6-10times(seefig.2for315-350engines),whentheclogging

indicator(ifinstalled)signalsthatthepartmustbereplaced,orifitisirreparablyclogged.


Toavoidexplosionsorfireoutbreaks,donotsmokeorusenakedflamesduringtheoperations.Fuelvapoursarehighlytoxic.Onlycarryouttheoperationsoutdoorsorinawellventilatedplace.Keepyourfacewellawayfromtheplugtopreventharmfulvapoursfrombeinginhaled.Disposeoffuelinthecorrectwayanddonotlitterasitishighlypolluting.

FUEL

Whenrefuelling,itisadvisabletouseafunneltopreventfuelfromspillingout.Thefuelshouldalsobefilteredtopreventdustordirtfromenteringthetank.Usethesametypeofdieselfuelasusedincars.Useofothertypesoffuelcoulddamagetheengine.Thecetaneratingofthefuelmustbehigherthan45topreventdifficultstarting.Donotusedirtydieselfuelormixturesofdieselfuelandwatersincethiswouldcauseseriousenginefaults.

Thecapacityofthestandardtankis:

KD225 = l.3.0KD315 = l.4.3KD350 = l.4.3KD400 = l.5.0KD440 = l.5.0

7

-30

-25

-20

-15

-10

-5 0

+5

+10

+15

+20

+25

+30

+35

+40

+45

SAE 20WSAE 10W

+50

SAE 30SAE 40

SAE 10W-30SAE 10W-40

SAE 10W-60SAE 15W-40 base minerale

SAE 15W-40 base semi-sintetica

SAE 20W-60 base semi-sintetica

SAE 5W-30 base sintetica



-35

-40

CCMC G- 2

CF CE CD CC CB CA SA SB SC SD SE SF SG

DIESEL BENZINA - ESSENCE - PETROL BENZIN - GASOLINA

CCMC G- 3 G- 5CCMC PD - 1 / PD - 2

CCMC D- 2D- 4CCMC D- 3D- 5

MIL - L - 2104 DMIL - L - 2104 E

MIL - L -46152 CMIL - L- 46152 D/E

MB 226.1 MB 226.5MB 227.1 MB 227.5

228.3 MB 228.1

VW 501.01VW 500.00

SHAPIG- 4

SJ

VOLVO VDSMAN QC 13-017

VW 505.00

- 19 -

MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING

Theenginecouldbedamagedifallowedtooperatewithinsufficientoil.Itisalsodangeroustoaddtoomuchoilasitscom-bustioncouldsharplyincreasetherotationspeed.Useasuitableoilinordertoprotecttheengine.Thelubricationoilinfluencestheperformancesandlifeoftheengineinanincredibleway.Theriskofpistonseizure,jammedpistonringsandrapidwearofthecylinderliner,thebearingsandallmovingpartsin-creasesifoilwhosecharacteristicsdifferfromtherecommendedtypeisused,oriftheoilisnotregularlychanged.Allthisnotablyreducesenginelife.Oilviscositymustsuittheambienttemperatureinwhichtheengineoperates.

Oldoilcancauseskincancerifrepeatedlyleftincontactwiththeskinandforlongperiodsoftime.Ifcontactwiththeoilisinevitable,youareadvisedtothoroughlywashyourhandswithsoapandwaterassoonaspossible.Appropriateprotectiveglovesetcshouldbeworeduringthisoperation.Oldoilishighlypollutingandmustbedisposedofinthecorrectway.Donotlitter.

GRADE


RECOMMENDED OIL

AGIPSUPERDIESELMULTIGRADE15W40specificationsAPICF-4/SG ACEA E2,B2 MIL-L-46152 D/E. ESSO SPECIAL PKW-UNI-FLODIESEL15W40 specificationsAPICF-4/SGACEAE2,B2MIL-L-46152D/E. In the countrieswhereAGIPandESSOproducts arenotavailable,useoilAPISJ/CFforDieselenginesoroilcorrespon-dingtothemilitaryspecificationMIL-L-46152D/E.

OIL SUPPLY ( liters ) KD 225Standard oil sump

filter included 0.9


filter included 1.2


filter included 1.2

OIL SUPPLY ( liters ) KD 400 - 440Standard oil sump

filter included 1.5

ACEA SEQUENCES

A=Gasoline(Petrol)B=LightDieselfuelsE=HeavyDieselfuels

Requiredlevels:

A1-96 A2-96 A3-96

B1-96 B2-96 B3-96

E1-96 E2-96 E3-96

1 2

3

8

- 20 -

DISASSEMBLY/REASSEMBLY

WARNINGS!During repair operations, whenusing compressed air, wear eyeprotection.

DISASSEMBLY AND REASSEMBLY

Besides disassembly and reassembly operations this chapter alsoincludescheckingandsettingspecifications,dimensions, repairandoperating instructions.Always use original KOHLER spare parts forrepairoperations.

Clean the filtering element with air blast.Air must be blownfrominsidetooutsidethecartridgeatadistanceofatleast15cmfromthepaper.Lightly and repeatedly tap the element on a hard surface toeliminateallexcessdirt.

Cartridgecomponents: 1Seal 2 Metallicbody 3 Polyurethaneprefilter4 outermesh 5Filtermedia6 Blade7 Insideenvelope8 Metallicbody9Innerseal

Cartridge characteristics:mediaporosity7µm,usefulfilteringarea1960cm2.Polyurethane pre-filter characteristic:porosity60p.p.i.,frontarea207cm2.

Note: Pre-filter3canundergomaintenanceoperations;ifdirty,washwithsoapandwateranddry(maximum10cleanings).Seepage18forcartridgereplacement.

Clean the filtering element with air blast.Air must be blownfrominsidetooutsidethecartridgeatadistanceofatleast15cmfromthepaper.Lightly and repeatedly tap the element on a hard surface toeliminateallexcessdirt.Replaceifirreparablyclogged.

Cartridgecomponents:

1 Completecover2Filteringmaterial3Support

Characteristicsofthefilteringmaterial:paperporosity:3µmfilteringarea:4400cm²outerringinopen-cellpolyurethane

Seepage18for thefrequencywithwhichthefilteringmaterialmustbechanged.


Dry air cleaner for KD 315 and KD 350

Dry air cleaner for KD 225

8

4 4a

5 5a

6

7

- 21 -


Clean the filtering element with air blast.Air must be blownfrominsidetooutsidethecartridgeatadistanceofatleast15cmfromthepaper.Lightly and repeatedly tap the element on a hard surface toeliminateallexcessdirt.

Openaircleaner(fig.4).Unscrewthewingnut1(fig.4a)andremovethefilterelement(fig.5).ChecktherubbersealisundamagedA(fig.5a)Cleanthefilteringelementwithairblast.Ifthefilteringelementhasbeenalreadycleanedothertimes,orifitisirreparablyclogged,throwitawayandreplace.RefittheairfilterandmakesurethesealAisproperlyinserted,thentightenthewingnut1.

Makesure that thefilter ismounted in thecorrectwayother-wise dust and other impurities could ilfiltrate into the intakeducts.

Prefilter for dry air filter

Removeandcleanthepre-filterifclogged.


Dry air cleaner for KD 400-440

8

11

9 10A

8

- 22 -


Never clean the filtering element6 using solventswith a lowflashpoint.Thiscouldcauseanexplosion!

Makesurethattheretentionrings4 - 5 areinagoodconditionandreplacethemiftheyaredamaged.

Oil-bath air cleaner (optional)

Components:1 Uppershell1AUpperunitwithseparatorpre-filter2 Secondaryfilterelement3Primarypolyurethane4Internalsealring5Externalrubbergasket6 Lowermetalfilterelement7 Lowercup8Oillevelgauge

Characteristics of filter element 2:madeofViledonsyntheticfabric,porosity120gr/m2,resin-covered.

Characteristics of filter element 3:open-celledpolyurethanefoam;porosity45P.P.I..Bothfilterelementscanbewashedwithsoapandwaterforamaxi-mumof10times.Washthemetalfilter6 withDieselfuelBlowoutexcessfuelwithcom-pressed air. See pages 14 and 15 for periodic maintenance detailsandoilreplacement.

Allowtheexhaustmanifoldtocoolbeforedemountingitinordertopreventscorchingandburns.

Muffler

Whenreassemblingreplacetheexhaustmanifoldgaskets.Tightennutsto25Nm.Themufflerdesignincludesinternalsoundabsorbingpanels.TightenthebearingnutsandscrewAtoa25Nmtorquevalue.

Rocker arm cover breather system

Thecrankcasebreathersystemislocatedinsidetherockerarmcover.Checkthatdiaphragm 2isintact;washwithDieseloilandblowthrou-ghthesmallmeshelement 4withcompressedair.Whenreassemblingfixbox3withLoctite"Form-a-gasketNo.6"andscrewplate5.Alsoseebelow.


13

12

13a

13b

8

- 23 -


Alwayscheckthethespringandvalvetomakesuretheyareinagoodconditions.

Rocker arm cover - Breather ricirculation

Crankcasevaporrecirculationoccursthroughduct4.Iftheairfilterclogs,theincreasedintakevacuumcouldsuckoilthrou-ghduct4intothecombustionchamber,causingtheenginetooperateatarunawayrate.Thisispreventedbyvalcuumvalve2which,whenthe vacuum increases, overcomes the resistance of spring 3 andshutstheduct4.Makesurethatoilplug5iscorrectlyclosed.Refitcover1andtightenrockerarmcoverto10Nm.

Setvalve/rockerarmclearancewhentheengine iscold:bringpistonto top dead center on the compression stroke and set clearance at0.10-0.15mmusingathicknessgauge.Tightenlocknut.

N.B.: Since an automatic decompression device is available on theexhaustlobe,manualyrotatetheengineuntilthetappetsareatlowestpoint.

When replacing the rocket arms, position the piston at the bottomdead centre and tighten the fixing screw gradually to adjust thehydraulictappets.Whiletightening,makesurethatA fitscorrectlyintoB(fig.13a).Theadjustingscrewpinshouldbetightenedto20Nm.

Do not start the engine for approximately 4 hours to allow the hydraulic tappets to settle completely.

Oncethetappetshavesettled,tightentheboltto10Nm.


Valve/rocker arm clearance ( KD 225-315-350 )

The engines KD 400 and 440 have hydraulic tappets, therefore no adjustment is required.

8

- 24 -


Caption

1-Lockring2-Uppercollar3-Oilinletholes4-Low-pressurechamber5-Piston6-Play-recoveryspring7-Case8-Areatobelubricated9-High-pressurechamber10-Checkvalve11-Identificationmarks

Fillthelow-pressurechamberthroughtheoilinletholes.If clearanceoccurswhile running, as the tappet returns to thebaseof the camshaft, theplay-recovery spring stretchesout,keepingalltimingsystempartsclosetogether.While the play-recovery spring is stretching, the check valve lets oil into the high-pressure chamber from the low-pressurechamber,torecovertheincreaseinvolumeinthehigh-pressurechamber,causedbythestretchingspring.Inthisway,sinceoilispracticallyuncontrollable,whenthevalveisnextopened,playwillbecompletelyrecovered.Duringeachcycleasmallamountofoilisdrawnfromthehigh-pressurechamberintothepistoncouplingwallwiththecaseandthen,passingthroughtheinternalinlethole,flowsintothelow-pressurechamber.Thetappetisshortenedbylessthan0.1mmeachcycle.Thisallowsthetappettomakeupthereductioninplaywhiletheengineisrunning.Itisnotnecessaryfortheoiltoreachthetappetonthedownwardstroke:lightpressureisenoughtoensurethatairbubblesdonotform.Thetappetmaybesuppliedwiththehigh-pressurechamberfullorempty.Thelow-pressurechamberisalwaysempty.Thetappetshouldalwaysbehandledinanuprightpositiontopreventthehigh-pressurechamberfromemptying.Thesurface thatcomes intocontactwith thecamshouldbe lubricatedgenerouslyduringassemblyusingASCOMPUND40typeMOLYSLIP(seefigure).Thisoperationisimportanttoensurecorrectlubricationrightfromthestart.Thedistributionsystemisassembledasfollows:

a)MakesurethatthepistonisbetweentheBottomDeadCentreandthehalfwaypointb)Inserttherodsintopositiononthetappetsc)Mounttherockerarmandthejointblock,thentightenthefixingnuttothespecifiedtorqued)DONOTSTARTTHEENGINEFORATLEAST4HOURSAFTERTIGHTENINGTHEROCKERARMSbecausethevalve-pistoncontactmaybeputatrisk.

Thetappetisunloadedwhenitispossibletoshifttheinternalpartby3.5÷4mmusingaforceof30Nm.Ifthetappetsareloaded(forexampleiftheyhavebeenleftinahorizontalposition)theenginewillbenoisyduringthefirstfewminutesafterswitchingon,untiltheairhasbeencompletelydrainedoutoftheinsideofthetappetsthemselves.


Hydraulic tappets KD 400-440

Distributionuseshydraulictappetsforautomaticadjustmentofvalveclearance.ThefigureshowsthetappetusedinKD400engines.

14

16 17

15

8

- 25 -


Toavoidexplosionsorfireoutbreaks,donotsmokeorusena-kedflamesduringtheoperations.Fuelvapoursarehighlytoxic.Onlycarryouttheoperationsout-doorsorinawellventilatedplace.Keepyour facewellawayfromtheplug topreventharmfulva-poursfrombeinginhaled.Disposeoffuelinthecorrectwayanddonotlitterasitishighlypolluting.

Tank

Unscrewtheupperand lowerstudsandremove thewashers,whichotherwisemightmake removal of the tank difficult. Next disconnectthefuelandairbleedingtubes.Completelyemptythetanktomakesurethatnoimpuritiesremain.Whenreassemblingtightentheuppernutsto15Nm.

1Fuelfilter2Fueltank3Filtersleeve4Filtercartridge5Flushring6Nut7Unionseal8Dieselfueloutletunion9Flatwasher

Seepage18forthefrequencywithwhichthefuelfiltermustberepla-ced.Seefig.99forthedimensions.

Loosentheclampsanddisconnectthehoses.

Characteristics

Filteringarea≥390cm2

Paperporosity≤7µm.Seepage18forreplacementSeefig.98fordimensions.


Fuel filter for KD 225 - 315 - 350 - 400 - 440 (version with external filter)

Fuel filter KD 225-400-440 (version with internal filter)

18

19

20

8

- 26 -


Re-coil starting

Operation:Whenpullinghandle10,thankstotheactionoffrictionspring12,te-eth 4protrude fromcap3.Afterstarting these teethgoback to theinitial position because the cap rotates.Rope9 is re-woundaroundpulley6bymeansofspring7.

Components:1 Retainer 7Spring2 Washer 8Guard3Cap 9 Rope4Flyweights 10Handle5 Spring 11 Ropeguide6Pulley 12 Spring

Note: thereare twokindsofguards8,one forengineswithan rpmabove 2000 and onewith fewer cooling channels for engineswithalowerrpm

Onreassembly,tightenthescrewsto10Nm.

Shroud

Theshroudandthemetalsheetingoutsidethecylinderaremadeofspecialmaterial(ANTIPHON)whichabsorbsnoise,thusreducingto-talenginesoundpressurelevels.Whenrefittingtightenshroudscrewsto10Nm.

Duringthedemountingphases,payparticularattentiontopre-vent the flywheel from dropping as this could seriously injuretheoperator.Wearprotectivegoggleswhenremovingtheflywheelring.

Flywheel

Unscrewbolt1inaclockwisedirection.Removetheflywheelwithapuller.Makesurethat thetaperedsurfacethatcouplestothedriveshaft isnotdamaged.To remove the starter rim, it is advisable to cut it into several partswithahacksawandto thenuseachisel.Toreplace,slowlyheat for15-20minutestoatemperatureof300°Cmax.Fit the rim into the flywheel housing.make sure that it rests evenlyagainstthesupportofthehousingitself.Allowittoslowlycool.Whenrefittingtightenbolt1to150Nm.Seepages34and35forinjectiontimingreferencemarks.


21

22

8

- 27 -


Donotdemountwhenhotorthepartcouldbecomedeformed.

Cylinder head

If thesurfaceof thecylinderheadisdeformed,flatten itbyremoving0.2mmofmaterialatmost.Alwaysreplacetheseal.Seefigs46-47-48-49-50whenselectingthethickness.Theboltsmustbetightenedindifferentphasesfortheva-riousengines,incompliancewiththeordershowninthefigure:

Firsttightenthe4screwsM10,thenthe2sidescrewsM6.Lubricatetheshanksofthebolts,undertheirheadsandthewasherswithengineoil.Donotusetoomuchoil.Oilthatdepositsinthethre-adedholeonthecylinderblockcouldbecomepressurizedduringthetighteningphase,sensiblydiminishingthedrivingforce.Alwaysmakesurethattheholesonthecylinderblockaredryandclean.


Injector projection

TheendofnozzleAshouldproject2,5mmforKD225-315-350and3,0÷3,5mmforKD400-440fromthecylinderheadplane.AdjustwithcoppergasketsBwiththicknessof0.5,1and1.5mm

Engine KD 350

1stphase: tightenall thebolts toa30Nm torquevalue inacrossed fashion.

2ndphase:unscrewalltheboltsby180°.3rdphase: tightenall thebolts toa20Nm torquevalue ina

crossedfashion.4th phase: make a 60° turn in the same order as the 3rd

phase.5thphase:tightenthe2sidebolts(5)toa10Nmtorquevalue

For KD 400 and 400 engines

1stphase:tightenallscrewscrosswiseto20Nm.2ndphase:tightenthescrewsinthesameorderto40Nm.3rdphase:tightenallscrewsinthesameorderto50Nm.4thphase:followingthesameorderasinphase3,rotate60°.5thphase:followingthesameorderasinphase4,rotate60°.6thphase:tightenthe2sidescrews(5)to10Nm

Engine KD 225

1stphase: tightenall thebolts toa30Nmtorquevalue inacrossedfashion.

2ndphase:unscrewalltheboltsby180°.3rdphase: tightenall thebolts toa20Nmtorquevalue ina


phase.5thphase:tightenthe2sidebolts(5)toa10Nmtorquevalue.

Engine KD 315

1stphase: tightenall thebolts toa30Nmtorquevalue inacrossedfashion.

2ndphase:unscrewalltheboltsby180°.3rdphase: tightenall thebolts toa20Nmtorquevalue ina


phase.5thphase:tightenthe2sidebolts(5)toa10Nmtorquevalue.

25 26

27

23 24

8

- 28 -


Valves - Disassembly

Components:1Valvestem2 Oilseal3Springwasher/set4 Spring5Cap6 Halfcollets

Note: To remove half collets place a suitable plate under the valveheadandpressdownfirmlyasindicatedinthefigure.

Valves - Oil seal in valve guide

To prevent seal 2 from being deformed when the valve guide ismounted,fititintotool1serialN°7107-1460-047afterhavingthorou-ghlylubricatedit,thenproceedasindicatedinthefigure.

Valve, springs

Measurethefreelengthwithacaliper.

FreelengthA =33.72

FreelengthA =34,88

Note:ReplacethespringifthefreelengthA is1mmlessthanspeci-fied.


Engine KD 225-315-350

Engine KD 400-440

29

30

28

8

- 29 -

2993inu8iSrC54X

1

D 6,13÷4,13 0,63÷8,53 8,73÷6,73

L 8,18 19 4,29÷0,29

aaaaa '5654÷'53°54

2

3

4 2993INU8iSrC54X>--

5 2993INU6.12NiNnMrC07X>--

aaaaa '5654÷'53°54

225 - 315 - 350 - 400 - 440

315 - 350 400 - 440 225


Valves, characteristics

IntakevalveA

ExhaustvalveB-Stemandheadareoftwodifferentmaterials

Valves, guides and housings

1 Intakeguide2 Exhaustguide

A=40B=31C=11.000-11.018D =11.040-11.055

A=35B=30C=10.000-10.020D =10.040-10.055

Note: Valve guides with outer diameters increased by 0.5 mm arealsoavailableasspares. In thiscase,housingCmustbe in-creasedby0.5mmforassemblypurposes.

Valves, guide insertion

Heattheblocktoatemperatureof160°-180°Forcetheguides,consideringdistance Aand Binrelationtotheblocksurface.

A=25.8-26.2B=34.8-35.2

A=23.8-24.2B=28.8-29.2

WeldJoint

ChromePlated

ChromePlated

BaseMaterial

BaseMaterial

BaseMaterial


Dimensions (mm) for KD 315-350-400-440

Dimensions (mm) for KD 225

Dimensions (mm) for KD 315-350-400-440

Dimensions (mm) for KD 225

31

32

33 34

8

A 530,6÷020,6 040,7÷520,7

B 000,6÷589,5 000,7÷589,6 000,7÷589,6

)B-A( 050,0÷020,0 550,0÷520,0

)B-A( 41,0

400-440225 315-350

Clearance

Limit

- 30 -

A 15,23÷05,23 10,73÷00,73 10,93÷00,93

B 26,23÷06,23 21,73÷01,73 21,93÷01,93

C 15,82÷05,82 10,33÷00,33 10,53÷00,53

D 26,82÷06,82 21,33÷01,33 21,53÷01,53

225 315-350 400-440


Dimensions and clearance between guides and valve stems (mm)

Valves seats and valve seat bores

Dimensions (mm)

Note : Since the seats are supplied pre-finished, theymust not bemachinedafterhavingbeeninserted.


Valve seat lapping

Aftercuttingvalveseats,lapvalveseatswithfinelappingcompound.Thesealingsurface Sshouldnotexceed2mm.LoweringvalveforKD225-315-350(D=0.55÷0.85mm).LoweringvalveforKD400-440(D=0.35÷0.65mm).Wearlimit1.5mm.

37

35 36

38 39

40 41

8

510,96÷00.96 079,86÷559,86 60.0÷30.0

51.87÷00.87 079.77÷559.77 60.0÷30.0

510.28÷00.28 079.18÷559.18 60.0÷30.0

510,28÷00,28 079,18÷559,18 60.0÷30.0

510,28÷00,28 049,18÷529,18 90.0÷60.0

510,68÷00,68 079,58÷559,58 60.0÷30.0

225

315

350 - 350EPA

400

400EPA

440 - 440EPA

ClearanceØ PistonØ Cilinders

- 31 -


Cylinder

Setaboregaugetozerowithacalibratedring.Checkdiameterat1, 2and3;repeattheoperationatthesamepointsafterturningtheboregauge90°.Ifwearexceedsthemax.givenvalueby0.05,borethecylinderandfitoversizepistonandrings.Seefig.40and41forcylinderdiametervalues.

Do notmanually hone the cylinder bore surfaceswith emeryclothorothermeans.

Cylinder roughness

Thecross-hatchpatternshouldbeatanangleof45°-55°;linesshouldbeuniformandclearinbothdirections.Averageroughnessmustrangebetween0.5mm1µm.Thecylindersurfacewhichcomesintocontactwithpistonringsshouldbemachinedwiththeplateaumethod.

Piston

Being of low expansion type, the piston allows small clearancesbetweenpistonandcylinderand,thus,oilconsumptionisreduced.Removecirclipsandpistonpin.Removepistonringsandcleangrooves.MeasurediameterQat theAdistancefromtheskirtbottom(A=12mm).Replace the piston and piston rings if wear on the diameter is 0.05mmmorethantheminimumvaluegiven(seetableinfig.40-41).

Note:Oversizepistonsof0.50and1.00mmareavailable.

Dimensions of pistons and cylinders, Logo

Logo can be found inside the piston


8

- 32 -



42

8

04.0÷02.0

05.1÷00.1 05.0÷03.0

05.0÷52.0

05.0÷03.0

05.0÷03.0

05.0÷52.0

53.0÷02.0

05.1÷00.1 05,0÷03,0

05.0÷52.0

53.0÷02.0

05.1÷00.1 05.0÷03.0

05.0÷52.0

53.0÷02.0

05.0÷03.0

04.0÷02.0

- 33 -


Piston rings, distance between the tips (mm)

Fit the piston ring into the top part of the cylinder andmeasure thedistancebetweenthetips.

225

315

350

400

440

1stpistonring(nitrided)

2ndpistonring*

3rdpistonring,oilscraper(nitred)

1stpistonring(chromated)

2ndpistonring(torsional)

3rdpistonring,oilscraper


2ndpistonring*



2ndpistonring*


1stpistonring(chromated)

2ndpistonring(torsional)

3rdpistonring,oilscraper

Piston ringsEngine

Value

stamped - GOE stamped - ko stamped - N


Wearlimit1mm-forthe2ndpistonringofkD225andKD350engines,thewearlimitis2.0mm.

43 44

45

46

47

8

A 511.0÷70.0 01.0÷70.0 11.0÷530.0 11,0÷70,0

B 80.0÷40.0 80.0÷50.0 90.0÷050.0 90,0÷50,0

C 70.0÷30.0 570.0÷40.0 780.0÷030.0 70,0÷30,0

225 315 350-400 440

- 34 -



Piston rings, play between the slots (mm)

Replacethepistonorpistonringsifthevalueexceedsthemaximumlimit.

Piston rings, assembly order

A =1stChromiumplatedpistonring(nitridedfor225-350-400)B =2ndpistonring(torsional)C =3rdpistonring(oilscraper)(nitridedfor225-350-400)D =Chromiumplatedzone

Note: Ifaword(top,orsomeotherword)iswrittenonthesurfaceofapistonring,mountthatsurfaceupwards.

Beforeinsertingthepistonintothecylinder,oilandturnthepi-stonringssothatthecutsarestaggered120°toeachother.

InKD350andKD225engines,thesecondpistonringisnottorsional,whilethefirstandthirdpistonringsdonothavechro-miumplatedzonesbutarenitrided.

Lubricate the followingpartswithoil beforemounting: thepi-stonpin,thepiston,thecylinderandthebig-endbearing

Piston - Refitting

Connectpiston toconnecting rod, lubricatepistonpinand introduceit into thepiston/connecting rodassemblybyexertingpressurewithyourthumb.Fitbothpistonpincirclipsandcheckthattheyarewellseated.When introducing both the connecting rod and the piston into thecylindermakesurethatthelargercrownsurfaceA (ifcomparedtothecombustionchamber)isonthesamesideasthepushrodopeningB.

Clearance

A =ClearanceC =HeadgasketThethicknessofgasket Cdeterminestheclearance A,whichmustbe0.45-0.55mmforKD315withinjectionpumpserialN°6590-259;itis0.50-0.60mmwithinjectionpumpserialN°6590-281.Theclearanceis0.45-0.55mmforKD225inallcases.Theclearanceis0.50-0.60mmforKD350-400-440inallcases.ForthecorrectthicknessofgasketCseetableinfig.49÷50.There are gaskets with inner diameters oversized by 1mm for KD315andKD350,requiredifthecylindersareground.

49 50

48

8

054,0÷153,0 9,0 005,0÷563,0 1

055,0÷054,0 1 006,0÷005,0 1,1

056,0÷055,0 1,1 007,0÷006,0 2,1

057,0÷056,0 2,1

054,0÷563,0 9,0 005,0÷014,0 1

055,0÷054,0 1 006,0÷015,0 1,1

056,0÷055,0 1,1 007,0÷016,0 2,1

057,0÷056,0 2,1

004,0÷563,0 9,0 005,0÷014,0 1

005,0÷004,0 1 006,0÷015,0 1,1

006,0÷005,0 1,1 007,0÷016,0 2,1

007,0÷006,0 2,1

- 35 -


Piston protrusion check

Tocalculatetherightthicknessforthegasket,theprotrusionbetweenthepistonandthecylinderheadsurfacemustbemeasured.Useadialindicatorwithbaseplate.Resettozerowhilerestingonasurfaceplate, thenpositionagainst thecylinderheadbaseplaneasshowninthediagram,sothatthedial indicatorrodrestsagainstthepiston.Nowtakethereading.Repeattheoperationintheotherthreepoints(goingcrosswise)andtakethereadings.Calculate the average of these four readings to get the precisemeasurement of the protrusion between the piston and the cylinderheadbaseplane.Choosetheappropriategasketaccordingtothefollowingtable.

Onlyremovetheheadgasketfromitsprotectivewrappingjustbeforeassembly.

See page 26 when tightening the cylinder head

Havingchosentherequiredthickness,mountthegasketasshowninthefigure(seeletterA).FindthenumberofnotchesinzoneBtofindthethicknessofthega-sketwhenthecylinderheadismounted.Thegasket thicknessgiven in the table is theoneobtainedwith thegasketmountedandtheheadtorqued.

Head gasket (mm)

0

1notch

2notches

3notches

0

1notch

2notches

Pistonprotusion

GasketThickness

Numberofnotches

Numberofnotches

GasketThickness

Pistonprotusion

Pistonprotusion

GasketThickness

Numberofnotches

Numberofnotches

GasketThickness

Pistonprotusion

0

1notch

2notches

3notches

0

1notch

2notches

0

1notch

2notches

3notches

0

1notch

2notches

Numberofnotches

GasketThickness

Pistonprotusion

Numberofnotches

GasketThickness

Pistonprotusion


For KD 315 with injection pump P.no 6590.259

For KD 225 For KD 350

For KD 400

For KD 315 with injection pump P.no 6590.281 For KD 440

51

52

53

54

8

A 30,001÷079,99 30,011÷079,901 30,521÷79,421

B 020,02÷010,02 020,22÷010,22 020,32÷010,32

D 000,02÷599,91 000,22÷599,12 000,32÷599,22

)D-B( 520,0÷010,0

)D-B( 50,0

225 315 350 400-440

- 36 -


Clearance

Limit


When remounting thebig-endbearings, remember to thorou-ghlycleanthepartsandgenerously lubricatethemtopreventseizurewhentheengineisstartedupforthefirsttime

Connecting rod

Demount the connecting rodandproceedwith the following inspec-tions.Thebig-endcapandbig-endbearthesamenumbers.Whenremounting,mount thecapfromthesamesideas inCof thefigure.TightentheKD225boltstoa23Nmtorquevalue.Tightentheboltstoa30NmtorquevalueforKD315-350-400-440.

Connecting rod, piston pin

Note: The connecting rod has no insert bearings. See fig. 62 forconnectingrodbigenddiameter.

Connecting rod alignement

Useadialgaugeasshowninthefigure.Checkthataxesarealignedusingthepistonpin;axialmisalignmentA=0.015;limit0.03mm.

Crankshaft end play

Securetheenginetoametalbaseortable.Useadial indicatorwithcolumnandmagneticbaseplate.Placethestylusonthecrankshaft.Movethedrivingshaftbackandforthontheflywheelside.Endplayshouldbe0.05-0.25mm;itisnotadjustable.

57

55 56

58

59 60

8

- 37 -


Drive shaft oil seals

Oilretainer 1islocatedinthegearcoveronthetimingsidewhilere-tainer2 islocatedinthecrankcaseontheflywheelside.Arrowsapointtothecrankshaftdirectionofrotation.Press them into their seatsbyexertinguniformpressure throughouttheirfrontsurface.

Drive shaft, lubrication ducts, bore thread on flywheel side and p.t.o.

RemoveplugCandcheckthatthelubricationductisperfectlyclean.Closewithanewplugcheckingforpropersealing.A =M14x1.5(turncounterclockwise)B =M8x1.25(withstandardshaft)

Whenthecrankpinandmainjournalareground,valuesR andR1mustbeobtainedagaintopreventthedriveshaftfrombre-aking.

Drive shaft, connection radius

Radius R thatjoinsthecrankpintothesupportsis2.8-3.2mm.RadiusR1 thatjoinsthemainjournaltothetiminggearis0.5mm.

Drive shaft, main journal/crankpin diameter, gear cover bearing inside diameter on timing side

Use an outsidemicrometer for themain journal and an inside boregaugeforthegearcoverbearingonthetimingside.


Awarpedoil retainermayallowthe introductionofair into theenginethuscausingcrankcaseventilationproblems.UsegenuineoilretainerswiththeKOHLERlogo(see B).

61

62

8

M579,43÷959,43 579,43÷959,43 579,93÷959,93

A 310,53÷200,53 310,53÷200,53 310,04÷200,04

B 000,43÷489,33 000,83÷489,73 000,04÷489,93

L 652,53÷042,53 652,53÷042,53 652,04÷042,04

C 000,53÷489,43 000,53÷489,43 000,04÷489,93

D000,82÷769,72 000,82÷769,72 000,03÷769,92

225 400-440315-350

D 640,43÷030,43 640,83÷030,83 640,04÷030,04

E 050,53÷030,53 050,53÷030,53 050,04÷030,04

G 610,54÷000,54 610,54÷000,54 910,35÷000,35

H 000,53÷889,43 000,53÷889,43002,53÷481,53 000,04÷889,93

I 612,53÷002,53 612,53÷002,53 612,04÷002,04

)B-D( 260,0÷30,0 260,0÷030,0 260,0030,0

)B-D( 021,0 021,0 021,0

)C-E( 660,0÷30,0 660,0÷030,0 660,0030,0

)H-A( 520,0÷200,0 420,0÷200,0 420,0÷200,0

)G-F( 650,0÷510,0 650,0÷510,0 650,0÷510,0

)I-L( 650,0÷420,0 650,0÷420,0 650,0÷420,0

225 400-440315-350

225 400-440315-350

225 400-440315-350

- 38 -


oilsealworkingarea

oilsealworkingarea

Crankshaft - journal diameter (mm)

The undersizes for the crankpin and main journal are 0.25,0.50and1mm.

The gearsmust bemountedwith the right tools so that theycanbecorrectlytimed.Thegearsshouldnotthereforebedemounted.Onlythecompleteshaftisavailableasaspare.

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

Dimensions (mm) (see also fig. 61)

Clearance (mm)

Interference (mm)

Availability of bearings

Main bearings are available at their nominal value orundersized0.25,0.50and1.0mm.Connecting rodsareavailablewithbigendatnominalvalueorundersized0.25and0.50mm.

Limit


63

64 65

66

67

8

A 474,91÷954,91 089,12÷959,12 489,71÷669,71

B 489,51÷759,51

C 810,61÷000,61

D 125,91÷005,91 120,22÷000,22 810,81÷00,81

)A-D( 260,0÷620,0 260,0÷020,0 250,0÷610,0

)A-D( 021,0 001,0

)B-C( 160,0÷610,0

)B-C( 021,0

225 400-440315-350

H 03,03÷52,03 03,03÷52,03 00,23÷59,13 50,23÷00,23

H1 08,53÷57,53 08,53÷57,53 08,53÷57,53 51,63÷01,63

H2 07,33÷56,33 01,53÷50,53 07.33÷56,33 51,53÷01,53

225 315-350 350 EPA 400-440

- 39 -


Camshaft

Components:1 Journal,gearcoverontimingside2Gear3Exhaustlobe4Injectionlobe5Fuelpumpeccentric6 Intakelobe7Journal,crankcaseside

Camshaft journals and bore

Useacomparatorforinteriors

Dimensions of camshaft journals and bore (mm)

Cam height (mm)

Note:Replacecamshaftifcamwearexceedstheminimumgivenva-lueofH,H1andH2by0.1mm.

Limit

Limit


68

68b

68a

68c

A

B

8

- 40 -


Camshaft timing

Fitcamshaftbyaligningmarks'AwithmarkDonthecrankshaft.

itconsistsofadeviceonthecamshaftwhichliftstheintakevalveincaseofastartupinreversedirectionwithrespecttonormalrotation.

Duringnormaloperation,thetappetovercomesthespringresistancewhilepassingonthesystemanddecompressiondoesnotoperate.

Incaseofastartup in reversedirection, theantireversesystem liftsthevalveasthetappetpassesby.Startupisthusinhibited.

Note:Checktheantireversesystemforwear,andmakesureitiskeptin the rest position by the return spring, as shown in picture68c.Verifythat inthisconditiontheclearancebetweenweightAandsurfaceBis1mm.


Camshaft – Antireverse system KD 400-440

69 70

71

72

8

- 41 -


Automatic decompression

With the engine at a standstill and up to a rate of about 300RPM,spring1,actingonweights2and3via lever4andpin5,keeps theexhaustvalveopenduringthecompressionphasealso.Once the engine exceeds the 300RPM rate,weights1 and2 keeppin5intheholdpositionowingtotheactionofthecentrifugalforce.Inthisposition,cam6canregularlycontroltheexhaustvalvethankstoaridgeonthepinitself.Sincethereisthennocompressioninthecylinder,theenginewillea-silystartwhentheself-winderisused.

Camshaft end play

Perform this checkbeforefittingcylinderheadand tappets includingtheinjectiontappets.Temporarilyfitcamshaft1completewithwasher;tightengearcover2to25Nm.Checkendplaybymovingthecamshaftbackandforthusingasuita-bletool;theendplayvalueis0.10÷0.25mmandisnotadjustable.

Dynamic balancer (on request)

Thedynamicbalancerissupportedbytwoidenticalballbearingshou-sedinthecrankcaseandinthegearcoveronthetimingsiderespec-tively.1isthereferencepointfortimingwiththecranksaftgear(seebelow).

Dimensions(mm):A =14.983-14.994B =14.99-15.00C =34.89-35.00D=34.958-34.983(bearinghousingdiameteroncrankcaseandgear

coverontimingside).


8

- 42 -



74 75

73

8

- 43 -


Dinamic balancer timing

Positioncrankshaftasshowninthefigure.Introduce the dynamic balancer so that timing mark 1 engagesbetweenteeth2 ofthecrankshaftgear.

Valve timing check

Removethetankandconveyortoaccesstheflywheel.Carry out the inspections on the drive shaft. The values given aremeasuredonthecircumferenceoftheflywheel.Adjustthevalveplayasindicatedonthenextpage.Reset the comparator on the cap of intake valve 1. Turn the driveshaft in thespinningdirectionandfindα (pointatwhich the intakevalvestartstoopeninrelationtotopdeadcenterA)and β (pointatwhichtheintakevalveshutsafterbottomdeadcenter B)seefig.77-78.Proceed ina similarwaywith theexhaust valve, checkingγ (pointatwhichtheexhaustvalveopens)andδ (pointatwhichtheexhaustvalveshuts).


78

77

DISASSEMBLY/REASSEMBLY8

- 44 -

Timing angles for operation (0.15 valve play).

α = 6°beforeAcorrespondingto12mmβ = 22°after Bcorrespondingto44mmγ =58°beforeBcorrespondingto116mmδ =10°after Acorrespondingto20mm.

Valuesmeasuredonthecircumferenceof theflywheelD=230(onedegreecorrespondsto2mm).

α = 10°beforeAcorrespondingto20.09mmβ = 42°after Bcorrespondingto87.78mmγ =58°beforeBcorrespondingto121.22mmδ =10°after Acorrespondingto20.9mm.

Valuesmeasuredonthecircumferenceof theflywheelD=240(onedegreecorrespondsto2.09mm).

Timing angles for inspection (0.65-0.70 valve play).

α = 7°afterAcorrespondingto14mmβ = 9°after Bcorrespondingto18mmγ =45°beforeBcorrespondingto90mmδ =3°beforeAcorrespondingto6mm.

Valuesmeasuredonthecircumferenceof theflywheelD=230(onedegreecorrespondsto2mm).

α = 1°afterAcorrespondingto2.09mmβ = 31°after Bcorrespondingto64.79mmγ =45°beforeBcorrespondingto94.05mmδ =3°before Acorrespondingto6.27mm.

Valuesmeasuredonthecircumferenceof theflywheelD=240(onedegreecorrespondsto2.09mm).


For KD 225

For KD 315 - 350

For KD 225

For KD 315 - 350

79

80

81

DISASSEMBLY/REASSEMBLY 8

- 45 -

Speed governor

Components:1Spoolspacer2Spool3Weights4Spoolguide5Gear6 Oilpumpdrivingshaft7Circlip8Thrustring

Speed governor removal

Spoolguide1hasretainersoneendwhichpreventspool2fromslip-pingout.To remove the speed governor use a suitable tool to slightlywidenthetwoteeth.

Refitting gear cover on timing side

Propersealingbetweengearcoverandcrankcaseisensuredbytheliquidsealant"Loctite5205".Carefullycleanthetwosealingsurfacesandspreadthesealantuniformly.Tightenscrewsto23Nm.

Wait3 hoursbeforestartingtheengine.


82

9

- 46 -

LUBRICATION SYSTEM

Theenginecanbedamagedifallowedtooperatewithinsufficientoil.Itisalsodangeroustoaddtoomuchoilbecauseitscombustionmayleadtoasharpincreaseintherotationspeed.Usesuitableoilinordertoprotecttheengine.Nothingmorethanlubricationoilcaninfluencetheperformancesandlifeofanengine.Useofaninferiorqualityoilorfailuretoregularlychangetheoilwillincreasetheriskofpistonseizure,willcausethepistonringstojamandwillleadtorapidwearonthecylinderliner,thebearingsandallothermovingparts.Enginelifewillalsobenotablyreduced.Theoilviscositymustsuittheambienttemperatureinwhichtheengineoperates.

Oldengineoilcancauseskincancerifrepeatedlyleftincontactwiththeskinandforlongperiodsoftime.Wearprotectiveglovestoavoidtouchingusedoil.Ifcontactwiththeoilisunavoidable,youareadvisedtowashyourhandswithsoapandwaterassoonaspossible.Disposeofoldoilinthecorrectwayasitishighlypolluting.

Components:

1)Oilfillcap 6)Oildrainplug 11)Oilintakefilter2)Safetyvalve 7)Metalfilterelement3)Rodjournal 8)Mainjournal4)Pressurecontrolvalve 9)Oilfilter5)Pressureswitch 10)Oilpump


KD 225 - 315 - 350 LUBRICATION SYSTEM AND BREATHER RECIRCULATION SYSTEM

9

83

- 47 -

LUBRICATION SYSTEM

Components:

1)Oilfillcap 6)Oildrainplug 11)Oilintakefilter2)Safetyvalve 7)Metalfilterelement 12)Pushrods3)Rodjournal 8)Mainjournal 13)Hydraulictappets4)Pressurecontrolvalve 9)Oilfilter 14)Calibratedunion5)Pressureswitch 10)Oilpump


KD 400-440 LUBRICATION SYSTEM AND BREATHER RECIRCULATION SYSTEM

84

85

88 89

86 87

9

- 48 -

LUBRICATION SYSTEM


Oil pump

Components:

1 Cover2Shaft3Key4Pin5Internalrotor6Externalrotor

Oilpumpdeliveryat3000rpmis5.8l/min.

Oil pump - Clearance between rotors

Measureclearanceasshowninthefigure;themax.valueis0.13mm;wearlimit0.25mm.

Oil pressure regulation valve

Components for KD 315 and KD 350:1 Spring 2 Valve 3 PlugFreelengthA ofthespringis27.50-27.75mm.

Components for KD 225:4 Ball 5 Spring 6 PlugFreelengthA ofthespringis23.50-24.50mm.

Components for KD 400-440:7 Plunger 8 Spring 9 Washer10 Cup 11 SnapringFreelengthA ofthespringis25,50÷25,75mm.

Note: IfAis1mmlessthanthegivenvalue,replacethevalve. Valvesettingisnotadjustable.

Internal strainer

Theoilpick-upstrainerismadeofnylon66.Itsdegreeoffiltrationis500µm.

Dimensions(mm):A =M16x1.5B =64C=102D=12

92

90 91

93

9

- 49 -

LUBRICATION SYSTEM


Oil filter

Filtercomponents:KD 315/350

1 Seal2Adhesive3Endcap4 Filteringmaterial5 Plate

Dimensionmm:A =26.5B=18C=88.5D =67.5E =8.5

Characteristics:Usefulfilteringarea=75cm2

Degreeoffiltration=50µm.Theby-passvalveissetat0.6-0.8bar.

Filtercomponents:KD 225

7 Rubberpad8Uppercover9Filterelement10 Lowercover

Dimensionmm:A =19.0-19.3B=12.5C=83.0-83.5

Characteristics:Usefulfilteringarea≥75cm2

Degreeoffiltration=40-60µm.

Seepage18forthereplacementfrequencies.

Oil pressure check

Whenassemblyoperationsarecompletedfillenginewithoilandfuel;connecta10barpressuregaugetotheoilfilterfitting.Starttheengineandcheckpressureasafunctionoftheoiltempera-ture(seebelow).

Calibrated pipe for lubrication of hydraulic tappets

Thepipe is fitted to thehydraulic tappetsoil line (see fig. 83, detail11).If the calibrated hole is clogged, the tappets are not sufficientlylubricated,valveclearanceisthereforeincreasedandtheenginemaybenoisier.If thediameterof thecalibratedpipeis largerthantheonesgiveninpicture93, thepressureexertedbythehydraulic tappetsmaycausethevalvestoremainopenevenduringthecompressionphase.

94

95

9

- 50 -

LUBRICATION SYSTEM

Oil pressure curve at idle speed

Thecurveisobtainedattheoilfilterportwithenginerunningatacon-stantspeedof1200r.p.m.inno-loadconditions;pressureisgiveninbarandtemperatureincentigrades.The curve represents theminimumpressure value while themaxi-mumvalueis5bar.

Oil pressure curve at full speed

Thecurveisobtainedattheoilfilterportwithenginerunningat3000r.p.m. at theN power; pressure is given in bar and temperature incentigrades.The curve represents theminimumpressure valuewhile the maxi-mumvalueis5bar.

Note:Aftertherunning-inperiodthelubemax.temperatureshouldbelessthantheroomtemperature+95°C.


96

97

9

- 51 -

LUBRICATION SYSTEM

Components:

1 Tank2 Returntube3 Fuelfilter4 Injectionpump5 Injectorleak-offline6Injector7 Highpressureline8Returntube

1 Tank2 Injectorleak-offline3 Injector4 Highpressureline5 Returntube6 Returntube7Dieselfuelfilter8 Fuelpipe9T-connector10Reduction11Injectionpump


Fuelling/injection circuit for KD 315-350-400-440

Fuelling/injection circuit for KD 225

98

100

99

10

- 52 -

FUEL SYSTEM

A =7.3B=3.8C =1.5D=42H=75

Characteristics:Filteringarea≥390cm²Filtrationlevel≤7µmSeepage18forfuelfilterreplacement

1 Rubberretentionring2PRVcover3 SCPradialunit4PRVcover5Segment

Characteristics:Filteringarea215cm2

Filtrationlevel7µmSeepage18forfuelfilterreplacement

Feed pump (optional)

A feed pump is usually requested when the tank is not supplied inconjunctionwiththeengine.Thepumpisthediaphragmtypeandisoperatedbyacamshaftec-centricthroughadriverod.Tightenscrewsto15Nm.

Characteristics:At 2000 rpmof the camshaft, theminimumdeliveryis40l/h,whiletheautomaticadjustmentpressureis0.5÷0.7bars.


Fuel filter KD 225 (version with internal filter in tank)

Fuel filter KD 225-315-350-400-440

101

102

103 104

10

- 53 -

FUEL SYSTEM

Fuel pump, drive rod protrusion

Components:

1Fuelpump2Crankcase3Driverod4Eccentric

Checkwhileeccentric4isatrest(lowestpointoftravel).Protrusion A ofdriverod3is1.5-1.9mm;itisnotadjustable.

Injection pump

ThisisofthesimplifiedQLCtype;itishousedinthecrankcaseandiscontrolledbythecamshaftviatappets.

Injection pump fitting in the crankcase

Fittappets3 sothatscrew6 isintroducedintoguide4.Tighten screw6 to 9Nmand check that the tappet is free tomovedownwards.Fitpad 2intothetappetsothatrecessBpointsdownwardsasshowninthefigure.Fittheinjectionpumpintothecrankcasecompletewithgasket(C)po-sition8ingflowcontrol1 in the forkof lever5 whichshouldbe in themaximumflowposition.

Whenremovingtheinjectionpumpfromitshousingmakesurethatspacer2 isnotdroppedintotheoilsump; injectionpumpoperationwillbeimpairedufthespacerisnotinstalled.


Driverodlength=58-58.2mmforKD225Driverodlength=65.8-66.0mmforKD315/350Driverodlength=61,4÷61,6mmforKD400/440

107

105

106

10

- 54 -

FUEL SYSTEM


Injection pump components and disassembly 1 Deliveryunion 2Filler3 Spring 4Gasket5Valve6Gasket7Springretainer8Spring9 Springplate10Rack11Plunger12Pin

A=FueloutletunionB =FuelintakeunionC=FasteningD=BarrelE=RHhelix

Demountincompliancewiththenumericorder.Plate9 isheldfirmbypins 12.Leverupby insertingatoolbetweentheplateandthebodyofthepump.Thevolumeshiftedbydeliveryvalve5 is15mm3in thepumpofKD315-350and25mm³inthepumpofKD225is21mm3inthepumpofKD400/440

Injection pump, body, plunger and delivery valve

Components: Dimensionsmm:1 Deliveryvalve A=5.50(nominaldiam.)225-315-3502 Barrel A=7,00(nominaldiam.)400-4403Plunger A=6,00(nominaldiam.)315-350EPA4 Righthelix B=2.00/2.035Delaynotch C=1.50/1.536Pumpbody7 Collar

Note: The injection pump installed in engines for small vehicles,soundproof generating sets, EPA and KD 400-440 engines,arecharacterisedbytheinclusionofacollar1whichcontribu-testonoise-reduction.

Injection pump refitting

Theplunger is fittedwith helixE facing towards the outlet unionA;if it ismistakenlyfittedwiththehelixfacingtheintakecouplingBtheinjectionpumpnolongeroperates(there isnodangerofengineru-naway);completerefittingfollowingfig.107.

111 112

109 110

108

2 1

3

10

- 55 -

FUEL SYSTEM

Injection pump non-return valve

Theexhaustunionhasanon-returnvalveA.Thepurposeofthisval-veistoimprovetheinjectionphasebyexpellingtheairinthefuelandpreventingitfrombeingsuckedinbythepumpduringtheintakepha-se.Thisalsoensuresthattheenginestopspromptlyassoonasthestoppingdeviceisactivatedbymeansofthesolenoidvalve.

Outlet fitting components for 315-350 EPA E 400-440 engines

1) Outletfitting2) BallØ1/8"3) Threadeddowel

Donotcutthetubelongitudinallybecauseyoumightdamagetheunion.

Injection pump, Rilsan tube removal

CutnylontubeatA.Removetheportionof the tubewhich isstillconnected to theunionusingcommonpliers.Pinchthenylontubewithoutimpairingthesea-lingpropertiesofunion(seefigure).Re-cycle thesamefeeding tube if theremaining lengthallows it; re-placeifnot.

Injection pump, Rilsan tube refitting

TheoutlettubeismadeofnylontypeRilsan;itisconnectedtothesu-itableinjectionpumpunionbymeansofspecialpliers(Ser.No.7104-1460-023)andaplastic-headhammer(seefigure).


KD225-315-350

KD315-350 EPA

400-440

113

114

10

- 56 -

FUEL SYSTEM

Injection pump delivery check on test bench

1 Deliverycontrolrackrod2Rackrod1 instopposition3Rackrod1inmax.deliverypositionA=18-19mm(max.rackrodstroke)α=66°

Static injection timing

Disconnectpipe1frominjectionpumpandcloseit,toavoidfuellea-kages.Mountinitsplaceanylonpipe2asshowninthepicture.Insertinthispipeanironwireandletitprojectbyapproximately10mm:inthiswayanydropinfuelcaneasilybechecked.


115

10

mmC/B

44÷04 64÷24 32÷12

5,23÷92 43÷03 71÷51

83÷5,43 04÷63 02÷81

05÷64 25÷84 52÷32

44÷04 64÷24 22÷02

04÷63 24÷83 02÷81

84,92 31

59,42 11

53,82 5,21

59,42 11

57,13 41

12,72 21

α

- 57 -

FUEL SYSTEM

Static injection lead test on flywheel

Fill the tankandmakesure that the fuel isnotmorethan10-15cmabovethetester.Settheflowgovernorleveroftheinjectionpumpinthestoppositionandlockitthere.Turntheflywheelintheenginerotationdirection.proceedslowlydu-ringthecompressionphase.Thefuelthatflowsfromtube2willtendtodiminish.Stopassoonasitcreasestodrip(onedropoffuelevery30-40secondsistolerated):thisisthestaticinjectionlead.MakesurethatBcoincideswithA.Seefig.117-118ifB doesnotcoincidewithA.

Useatemporarytankiftheengineisnotfittedwithone.Hereagain,itisessentialtomakesurethatthefuellevelisnomorethan10-15cmabovetheinjectionmpump.

References on the flywheelA=ReferenceoffixedTDConcrankcaseB=InjectionleadreferenceontheflywheelC=TDCreferenceonflywheelα =Referenceindegreesbetween BandC.WhenB coincideswith A,thepistonisinthestaticinjectionleadposition.When C coincideswithA,thepistonisattopdeadcenter.

Motor type withexternalØflywheel

220

withexternalØflywheel

230


240


260


KD225standard

KD225recordedupto1500[rpm]

KD225recordedfrom1500to2200[rpm]

KD315/350standardandminivecture

KD315/350Soundproofgeneratingsets

KD315/350recordedto1500[rpm]

KD400recordedto3600[rpm]


KD400EPArecordedto3600[rpm]

KD400EPArecordedto3000[rpm]



116

117 118

10

119

- 58 -

KD315350400440

KD225

FUEL SYSTEM

Injection advance adjustment

InjectionadvancebeyondthethicknessofgasketA isdeterminedbythethicknessofthepadinsidetheinjectiontappet.Toalterthevalueofinjectionadvancethepadmustbereplacedwithanotherofasuitablethickness(seefig.117-118).ToextractpadB,usearodwithasuctioncapormagnetatoneend.The replacement pads supplied have 10 different thicknesses(between4.0and4.9mm).Toalterthevalueofinjectionadvancethepadmustbereplacedwithanotherofasuitablethickness(seefig.117-118).

If referencepointBdoesnotcoincidewithA follow theexamples infig.117-118.1)Exampleofdelayedinjectionadvance(fig.117):tomakeB match

upwithA,replacethepadwithathickerone(fig.116).2) Exampleofearlyinjectionadvance(fig.118):tomakeBmatchup

withA,replacethepadwithathinnerone(fig.116).

Note: When the thickness of the pad varies by 0.1mm under thepump,Bisdelayedorbroughtforwardby1°ontheflywheel.

Injector

Components:

1Body2 Union3 Adjustingshim4 Spring5 Pressurerod6Pin 7Nozzle8 Nozzlecup9 Needlevalve10Tip11Duct12Returnhole

Afterre-assembly,tightenringnut8toa50Nmtorquevalue.


121

120

10

A 5,4 5,4 5,4 5,4 5,4 5,4 5,4 5,4 5,4

B 71,0x4 02,0x4 141,0x5 22,0x4 141,0x5 951,0x5 051,0x5 661,0x5 561,0x5

5,0 6,0 8,0 6,0 8,0 5,0 8,0 5,0 8,0

aaaaa °061 °061 °551 °061 °541 °061 °061 °061 °551

÷01,051,0

÷01,051,0

÷571,0522,0

÷521,0571,0

÷571,0522,0

÷573,0524,0

÷573,0524,0

÷573,0524,0

÷573,0524,0

C³mm63,0 ³mm63,0 ³mm0 ³mm63,0 ³mm0 ³mm91,0 ³mm0 ³mm91,0 ³mm0

4±412 4±412 6±042 4±412 6±042 4±002 4±952 4±002 6±042

- 59 -

FUEL SYSTEM

Leakage time (waste)

Pressuremustdropfrom150to100barsinaspanofnotlessthan8secondsandnotmorethan30.

Seatseal

Nozzletipwet.Pressuremustbekept20barsbelowtheopeningpressurefor10seconds.After this time,dampnessonthenozzletip isacceptable,andmaybe identifiedbytouchingwithadryfinger.Onlyadropofdampnessisacceptableandnotalargethickpatchwhichwouldindicatealeak.

Injector calibration

Connect the injector to a hand pump and adjust if necessary,modifyingthethicknessabovethespring.When the spring is replaced, calibration must be carried out at apressure higher than 10 bars to counterbalance adjustments whilerunning.

Spraying and opening pressure

With the pressure gauge closed, press hard on the hand pump atleast10times.Open thepressuregaugeandpressdownon thepumponceeverysecond,whilekeepingacheckonthesprayingprocessandpressure.Theopeningpressuremust lie between the two valuesgiven in thetable.Jetsmustbeuniformandwelldistributed.

*Thesevaluesapplytonewinjectorandallowforlooseningofupto10%afterbreaking-inperiod

Nozzles

Theset-upbetweentheneedleandtheguidemust leavetheneedlefreetofallandmerelyasaresultof itsownweight,whenlifted7mmfromitsseatandrotatedindifferentdirections,withthenozzlekeptata45°angle.Rotationoftheneedlemustbecompletelysmoothanduninhibitedbyobstaclesandmalformations.Moreover,onbeingsqueezedagainstitsseat,itmustfallfreely,whenthenozzleisinverted.Thetestmustbecarriedoutafterrinsingboththeneedleandnozzlewith trichloroethane and wetting with filtered SHELL CALIBRATIONFLUID“C”oil.

n°andØofholes

holelenght

pinheight

sumpvolume

pressure(bar)*


10

- 60 -

FUEL SYSTEM


122

123

124

11

- 61 -

ELECTRICAL SYSTEM

12V, 12A electric ignition diagram

Components:1Alternator2Startermotor3 Voltageregulator4 Battery5 Pressureswitch6Oilpressurelight7Keyswitch8Batterycharginglight

Alternator

Components:1Ringgear2 Flywheel3Rotor4Stator

Fixingscrewsmustbetightenedto1.2Nm.

Note:The rotor ismade up by a plastoferrite ringwhich is fixed toflywheelwhilethestatorismountedonthecrankcase.

Alternator battery charger graph (12V, 12A)

Thistesthasbeencarriedoutafterthermalstabilizationat20°Cfor2minutesat3000r.p.m.withconstantbatteryvoltageof12.5V.The value of the power supplied with reference to the curve maychangeinarangebetween+10%and-5%.


Note: The battery,which is not supplied byKOHLER, should have12Vnominalvoltageratingandacapacityofnotlessthan44Ah/210Amp.offastdischargeintensity.

125

127

126

11

- 62 -

ELECTRICAL SYSTEM

24V, 9A alternator battery recharging curve

12V, 30A alternator battery recharging curve

Thetestwasconductedafterheatstabilizingat20°C.The value of the current delivered in relation to the curve may besubjectedtoavariationofbetween+10%and-5%.

Voltage regulator

12V,12A:forstandardalternatorswith3outputwires12V,30A:for12V,20Aalternatorswith2outputwires24V,9A:for24V,9Aalternatorswithtwooutputwires

Thetabsareindifferentsizestopreventincorrectconnections.

Tabdimensionsmm

Width Thickness

~ 6.35 0.80

R 9.50 1.12

+ 9.50 1.12

LE 4.75 0.50

0/0 6.35 0.80

W 4.75 0.50


128

129

11

- 63 -

ELECTRICAL SYSTEM

12V electric starter diagram with voltage regulator built into the ignition panel

Components:

1 Alternator2 Startermotor4 Battery5 Pressureswitch6 Solenoidvalve7 Ignitionswitch

12V electric ignition layout with motor protection (optional)

Components:

1 Alternator2 Startermotor4 Battery5 Pressureswitch6 Solenoidvalve7 Ignitionswitch8 Panel


Note: Thebattery,which is not supplied byKOHLER, should have12Vnominalvoltageratingandacapacityofnotlessthan44Ah/210Amp.offastdischargeintensity.

Note: Thebattery,which is not supplied byKOHLER, should have12Vnominalvoltageratingandacapacityofnotlessthan44Ah/210Amp.offastdischargeintensity.

130

11

- 64 -

ELECTRICAL SYSTEM

Diagram of electric starter motor protection with sole self-winding starter - without battery - (optional)

Components:

1 Alternator2 Solenoidvalve3 Pressureswitch4 Thermostat5 A.c.motorstopdevice


131

132

133

11

- 65 -

ELECTRICAL SYSTEM

Testing voltage regulator for proper operation

Checkthatconnectionscorrespondtotheschematic.Disconnecttheterminalfromthebatterypositivepole.Connectad.c.voltmeterbetweenthebatterypoles.FitanammeterbetweenthepositivepoleandtheB+onvoltagere-gulator.Startandstoptheengineaseveral timesuntilbatteryvoltagedropsbelow13V.Whenbatteryvoltagereaches14.5Vtheammetercurrentshouldsud-denlydropdowntoalmostzero.Replace regulator if recharge current is zero with voltage below12,5V.

Whentheengineisrunningdonotdisconnectbatterycablesorswitchkeyto"off"position.Keepregulatorawayfromheatsourcesabove75°C.Donoelectricweldingonengineorapplication.

Starting motor

Anti-clockwiserotationdirection(viewedfrompinionside)A =17.5-19.5mm(distancefromflywheelrimsurfacetostartermotor

flangesurface)

Note:ContactBoschservicecentersforrepairoperations.

Characteristic curves for starting motor type DW (L) 12V, 1.1 KW

Thecurveswereobtainedatatemperatureof-20°Cwith66Ahbat-tery.

U=MotorterminalvoltageinVoltsn =Motorspeedinr.p.m.M=TorqueinNmJ(A) =AbsorbedcurrentinAmpere.


Bosch type DW (L) 12V, 1.1 KW for KD 315-350-400-440Bosch type DW (L) 12V, 0.9 KW for KD 225

136

134

135

11

- 66 -

ELECTRICAL SYSTEM

Characteristic curves of Bosch starter motor type DW (L) 12V, 0.9 kW

Thecurvesweremeasuredata temperatureof -20°Cwitha55Ahbattery.

U=VoltageonmotorterminalsinVolts.n =MotorspeedinrpmM=TorqueinNmI (A) =PowerdrawinAmperes.

Characteristic curves of Bosch starter motor type DW (L) 24V, 1.6 kW

Thecurvesweremeasuredata temperatureof -20°Cwitha36Ahbattery.

U=VoltageonmotorterminalsinVolts.n =MotorspeedinrpmM=TorqueinNmI (A) =PowerdrawinAmperes..

Ignition switch positions

A=AccessoryB =OffC=OnD=Start


137

138 139

140 141

142

11

- 67 -

ELECTRICAL SYSTEM

Idling speed setting in no-load conditions (standard)

Afterfillingwithoilandfuel,starttheengineandletitwarmupfor10minutes.Adjustidlingspeedto1000-1250rpmbyturningsetscrew1;thentightenlocknut.Washer2assuressealingandpreventspossibleoilleaks.

Idle speed adjustment, for small car versions

Theidlespeedadjustingspring(C)forsmallcarsmustbehookedinthespeedgovernorleverhole D(fig.140).Completelyunscrewthestdidlespeedadjustingscrew1(fig.137).LoosennutBbyonehalfofaturn.Turnthescrew AanticlockwiseuntilleverGtouchescover.Starttheengine:turningclockwisescrewA ,setidlespeedat1050rpm;tightenthelocknutB tightenthescrew1(fig.137)untiltouchingleverH (fig.141);whenthescrewtouchesthelever,thespeedincreases;atthispointunloosescrew1/4ofaturnandlockthelocknutofscrew1.

Thecontrolscoverscrewsmustbetightenedto10Nm.

Note:Bythiswayidlespeedonhotenginecoulddiminishof80rpmmax.

Full speed setting in no-load conditions (standard)

Aftersettingidlespeedturnscrew2andsetfullspeedinno-loadcon-ditionsat3800rpm;thentightenlocknut.Washer 1assuressealingandpreventspossibleoilleaks.


ADJUSTMENTS - KD 315-350

145

146

143

144

12

- 68 -

SETTINGS / ADJUSTMENTS

No-load idling adjustment (standard)

Afterhavingfilled theenginewithoiland fuel,start itandallow it towarmupfor10minutes.Usingadjusterscrew1,regulatetheidlingrateat1000-1250rpm.Tightenthechecknut.

No-load top rate adjustment (standard)

Afterhavingadjustedtheidlingrate,usescrew2 andregulatethetoprateat3800rpm(forenginessetat3600rpmonload).Tightenthechecknut.

Injection pump flow rate adjustment

Thisregulationmustbecarriedoutbymeansofawaterbrake,other-wisetheadjustmentwillbeapproximate.proceedinthefollowingway.Loosenflowratelimiter Cby5turns.Acceleratetheenginetono-loadtoprate,i.e.to3800rpm.Re-tightenlimiterC untiltheenginetendstodecelerate.LoosenlimiterCbyoneandahalfturns.Tightenthechecknut.

Note:TightenCiftheengineproducesanexcessiveamountofexhaustinthemaximumloadcondition;loosen Cifnosmokeisexhaustedandiftheengineisunabletodevelopitsmaximumpower.

Injection pump delivery limiting and torque adapter (standard)

DeliverylimitingdeviceChasthefunctionoflimitingtheinjectionpumpmax.delivery.Thesamedevicealsoactsas torqueadapter. Thespeedgovernorspringactsonlever L withstandingtheresistanceopposedbyspringMinsidethecylinder.ThestrokeHallowedbythetorquedevicetoleverLis0.20/0.25mm.Asaresultofthispumpdeliveryincreasesandtorquereacesitspeakvalue.

Note:Ingeneratorsetsandpowerwelders,thetorquesettingdeviceactsasadeliverylimiteronly.


for KD 225-315-350-400-440

ADJUSTMENTS - KD 225-400-440

148

12

h.Wk/g

0063 05,3 892 782

0003 0,3 753 082

0063 0,5 242 572

0003 5,4 382 562

0063 5,5 891 572

0003 9,4 532 062

0063 3,7 151 572

0003 3,6 481 062

0063 0,8 731 572

0003 2,7 061 062

225

315

350

400

440

- 69 -

SETTINGS / ADJUSTMENT

Injection pump delivery setting

1)Bringenginetoidlingspeed2)UnscrewdeliverylimitingdeviceC (seefig.145)3)Bringtheenginetothepowerandrpmrequiredbythemanufactu-

rerofthedevice.4) Check that fuel consumption falls within the table specifications

(seebelow).Ifconsumptionisnotasindicatedchangebalanceconditionsatthetorquedynamometerbyvaryingthe loadandadjustingthegover-nor.Understableengineconditionscheckconsumptionagain.

5)TightenlimitingdeviceCuntiltheenginerpmdecreases.Lockthelimitingdevicebymeansoflocknut.

6) Release brake completely and check at what speed the enginebecomesstableSpeedgovernorshouldcomplywiththerequirementsoftheclassindicatedbythemanufacturerofthedevice.

7)Stoptheengine.8)Checkvalveclearancewhenenginehascooleddown.

Required settings (the most common ones)

Engine R.P.M. Power kW

Specific fuel consumption

Time (sec)pour 100 cc


13

5

5

5

- 70 -

STORAGE

Internal engine protection:

-Starttheengineandallowittoheatup.-Removethedrainplugandlettheoilflowoutcompletely.-Replacetheoilfilterwithanewone.- Clean the oil drain plug and after inserting a new gasket,tightenit.- Fill upwith oil to the upper level of the dipstick, usingAGIPRUSTIA C30 (for countries in which this product is notavailablefindanequivalentproductonthemarket).-Starttheengineforabout10minutes,checkforoilleaks,andthenstoptheengine.

Injection systems protection:

-Emptythefueltank.-Replacethefuelfilterwithanewone.-Fillupwithfuelcontaining10%AGIPRUSTIANT.-Afterbleedingair,starttheengine,makesuretherearenofuelleaksandthenstoptheengine.

External engine protection:

- Carefully clean the cylinder cooling system fins and theflywheelfins.-Protect theexternal non-painted surfaceswithAGIPRUSTIA68/F.-Sealtheintakeandexhaustsystemswithadhesivetape.-Covertheenginewithanylonorplasticsheet.-Storeinadryplace,preferablynotdirectlyonthegroundandawayfromhighvoltageelectricitylines.

STORAGE

When the engines are not used for more than 3 months, they must be protected by the measures described below:


14

174

175

- 71 -

STORAGE

-Removeallprotectionsandcoverings.

- Remove the protective oil from the outside of the engine usingsuitableproducts(solventordegreaser).

-Removetheinjectorand,usingaflask,pourengineoilonthepistoncrown(nomorethan2cc).

-Removerockerarmcoverandsprayengineoilonthevalves,thenturnthecrankshaftmanuallyafewrevolutions.

-Starttheengineandallowittoheatupforabout10minutes.

-Removethedrainplugandlettheprotectiveoilflowoutcompletely.

-Replacethedrainplug.

- Fill up with engine oil as far as the upper level of the dipstickusing the oil recommended by the manufacturer for normal engineoperation.

PROCEDURES TO BE CARRIED OUT BEFORE START THE ENGINE


15

fig.18-p.25fig.51-p.36

fig.13-p.23fig.13-p.23fig.19-p.25fig.12-p.23

---

fig.3-p.20fig.90-p.49

fig.103-104-p53-

fig.9-10-p.22fig.100-p.52

-fig.102-p.53fig.84-p.48fig.81-p.45

-

fig.105-p.54fig.14-p.24

--

fig.21-p.26fig.21-p.26

-fig.20-p.25

Loctite648BVLoctite“Form-a-gasketN.6”

Loctite222Loctite222Loctite222Loctite222Loctite222Loctite270Loctite270Loctite270Loctite270Loctite270Loctite270Loctite270Loctite270Loctite270Loctite480Loctite5205Loctite5205Loctite5205

MOLYSLIPASCOMPOUND40

1030--720101010--251099251540101023-

-15-20-10-

150

6x18x17x18x16x0,58x1,256x16x16x1

10x1,58x1,258x1,256x16x16x1

8x1,258x1,2514x1,56x16x1

8x1,2510x1,5

14x1,58x1,258x1,2514x1,5

-6x1

8x1,2514x1,5sinistra

10-23-720101010--2510912251540151023-

-15-20-10-

150

1030-35106101010402525109925154010102315

40151520-1025150

315-350225 400-440

- 72 -

POSITION

USE OF SEALANT

LockingofadjustmentleverboxAirvalvecaseM6fixingscrewforfuelfilterM8fixingscrewformufflerbracketM8fixingscrewsforfuelsupplypumpM16fixingscrewforoilintakefilterandcoverM6finxingscrewsforairshroudM6studboltfordryairfiltercoverM6fixingscrewsforsideoilrefillingunionM6screwforinjectiontappetguideM8STEIscrewforclosingoilintakeholecoverM8STEIscrewforclosingcrankcaselubricationholeM8fixingscrewsforairfiltersupportandintakemanifoldRockerarmfulcrumscrewsStatorscrewsM8studboltsfortankPlastoferriteonflywheelBasecouplingsurface-coverCouplingsurfaceforenhancedengineoilsumpCouplingsurfaceforenhancedoilsumphalf-shellsHydraulictappetcontact-cam

TYPE OF SEALANT

MAIN TORQUE SPECIFICATIONS

Re-coilstartingConnectingrod,aluminium

Connectingrod,steelRockerarmadjustingscrewlocknutRockerarmadjustingscrewpinShroudRockerarmcoverControlarmcoverEnhancedengineoilsumpExhaustmanifoldAircleanersupportOilfilterheadInjectiontappetguidescrewInjectorfixingontotheheadMuffleronmanifoldFuelpumpInjectionpumpunionInjectionpumpfasteningscrewsOilpumpsupportGearcover,timingsideCalibrated fitting for hydraulic tappetlubricationInjectionpumpdeliveryunionFueltankbottomlowerfixingEnhancedsumphalf-shellsFueltanktopfixingOildrainplugCylinderhead(*)FlywheelpulleyfixingscrewsFlywheel

POSITIONDiam. and pitch

( mm )Reference ( fig. N° and page)

Torque ( Nm ) Torque ( Nm ) Torque ( Nm )

TORQUE SPECIFICATIONS


15

R>400N/mm2 R>500N/mm2 R>600N/mm2 R>800N/mm2 R>1000N/mm2 R>1200N/mm2

Nm Nm Nm Nm Nm Nm Nm NmM3 0,5 0,7 0,6 0,9 1 1,4 1,9 2,3M4 1,1 1,5 1,4 1,8 2,2 2,9 4,1 4,9M5 2,3 3 2,8 3,8 4,5 6 8,5 10M6 3,8 5 4,7 6,3 7,5 10 14 17M8 9,4 13 12 16 19 25 35 41M10 18 25 23 31 37 49 69 83M12 32 43 40 54 65 86 120 145M14 51 68 63 84 101 135 190 230M16 79 105 98 131 158 210 295 355M18 109 145 135 181 218 290 405 485M20 154 205 193 256 308 410 580 690M22 206 275 260 344 413 550 780 930M24 266 355 333 444 533 710 1000 1200M27 394 525 500 656 788 1050 1500 1800M30 544 725 680 906 1088 1450 2000 2400

4.6 4.8 5.6 5.8 6.8 8.8 10.9 12.9

R>400N/mm2 R>500N/mm2 R>600N/mm2 R>800N/mm2 R>1000N/mm2 R>1200N/mm2

Nm Nm Nm Nm Nm Nm Nm NmM8x1 10 14 13 17 20 27 38 45M10x1 21 28 26 35 42 56 79 95M10x1,25 20 26 24 33 39 52 73 88M12x1,25 36 48 45 59 71 95 135 160M12x1,5 38 45 42 56 68 90 125 150M14x1,5 56 75 70 94 113 150 210 250M16x1,5 84 113 105 141 169 225 315 380M18x1,5 122 163 153 203 244 325 460 550M18x2 117 157 147 196 235 313 440 530M20x1,5 173 230 213 288 345 460 640 770M20x2 164 218 204 273 327 436 615 740M22x1,5 229 305 287 381 458 610 860 1050M24x2 293 390 367 488 585 780 1100 1300M27x2 431 575 533 719 863 1150 1600 1950M30x2 600 800 750 1000 1200 1600 2250 2700

4.6 4.8 5.6 5.8 6.8 8.8 10.9 12.9

Table of tightening torques for standard screws (fine thread)

- 73 -

Table of tightening torques for standard screws (coarse thread)

Resistanceclass(R)

Quality/Dimensions

Diameter

Quality/Dimensions

Resistanceclass(R)

Diameter

TORQUE SPECIFICATIONS


FORMNO. ED0053029330ISSUED 25/06/2012

REVISED 00 DATE 25/06/2012ENGINEDIVISION,KOHLERCO.,KOHLER,WISCONSIN53044

FORSALESANDSERVICEINFORMATIONINU.S.ANDCANADA,CALL 1-800-544-2444KohlerEngines.com

Translated from the original manual in Italian language.

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

KD 225-315-350-400-440

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Transcript of KD 225-315-350-400-440