Kohler KD225 Workshop Manual
Water-cooled, indirect injection
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Summary of Contents for Kohler KD225
- Page 1 WORKSHOP MANUAL KD225 - KD315 - KD350 KD400 - KD440...
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Page 2: Preface
KOHLER. Information presented within this manual assumes the following: 1 - The person or people performing service work on KOHLER series engines is properly trained and equipped to safely and professionally perform the subject operation; 2 - The person or people performing service work on KOHLER series engines possesses adequate hand and KOHLER special tools to safely and professionally perform the subject service operation; 3 - The person or people performing service work on KOHLER series engines has read the pertinent information regarding the subject service operations and fully understands the operation at hand. This manual was written by the manufacturer to provide technical and operating information to authorised KOHLER after-sales service centres to carry out assembly, disassembly, overhauling, replacement and tuning operations. -
Page 3: Warranty Certificate
Your off-road, diesel engine emission control system is covered under warranty for a period of five (5) years or 3,000 hours, whichever occurs first, beginning on the date the engine or equipment is delivered to an ultimate purchaser for all constant speed engines with maximum power 19≤kW<37 and rated speed less than 3,000 rpm, all variable speed engines with maximum power 19≤kW<37, and all variable or constant speed engines with maximum power greater than 37 kW. Your off-road, diesel engine emission control system on variable or constant-speed engines with maximum power less than 19 kW, and for constant speed engines with maximum power 19≤kW<37 and rated speed equal to or greater than 3,000 rpm is covered under warranty for a period of two (2) years or 1,500 hours, whichever occurs first. If any emission related part on your engine is defective, the part will be repaired or replaced by Kohler Co. OWNER’S WARRANTY RESPONSIBILITIES: As the heavy-duty off-road engine owner, you are responsible for the performance of the required maintenance listed in your Kohler Co. owner’s manual. Kohler Co. recommends that you retain all receipts covering maintenance on your heavy-duty off-road engine, but Kohler Co. cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all recommended scheduled maintenance. As the heavy-duty off-road engine owner, you should however be aware that Kohler Co. may deny you warranty coverage if your heavy-duty off- road engine or emission control related component has failed due to abuse, neglect, improper maintenance or unapproved modifications. Your engine is designed to operate on commercial diesel fuel (No. 1 or No. 2 low sulfur or ultra low sulfur diesel fuel) only. Use of any other fuel may result in your engine no longer operating in compliance with California’s emissions requirements. You are responsible for initiating the warranty process. The Air Resources Board suggests that you present your heavy-duty off-road engine to a Kohler Co. dealer as soon as a problem exists. The warranty repairs should be completed by the dealer as expeditiously as possible. -
Page 4: Table Of Contents
INDEX This manual contains pertinent information regarding the repair of KOHLER water-cooled, indi- rect injection Diesel engines type KD 225_315_350_400_440: updated June 20, 2012. INDEX PREFACE .................................. 2 WARRANTY CERTIFICATE ............................. 3 Limited 3 year kohler ® diesel engine warranty ........................3 California emission control warranty statement ......................... 3 Your warranty rights and obligations ..........................3 1 - TROUBLE SHOOTING ............................7 Possible causes and trouble shooting ..........................7 2 - GENERAL REMARKS AND SAFETY INFORMATION ..................8 Safety regulations ................................8 General safety during operating phases .......................... - Page 5 INDEX Cylinder head ..................................27 Injector projection ................................27 Valves - Disassembly ................................ 28 Valves - Oil seal in valve guide ............................28 Valve, springs..................................28 Valves, characteristics ..............................29 Valves, guides and housings ............................29 Valves, guide insertion ..............................29 Dimensions and clearance between guides and valve stems (mm) ................30 Valves seats and valve seat bores ........................... 30 Valve seat lapping ................................30 Cylinder ....................................31 Cylinder roughness ................................31 Piston ....................................31 Dimensions of pistons and cylinders, Logo ........................31 Piston rings, distance between the tips (mm) ........................33 Piston rings, play between the slots (mm) ........................
- Page 6 INDEX 10 - FUEL SYSTEM ..............................52 Fuel filter KD 225-315-350-400-440 ..........................52 Fuel filter KD 225 (version with internal filter in tank) ....................... 52 Feed pump (optional) ................................ 52 Fuel pump, drive rod protrusion ............................53 Injection pump .................................. 53 Injection pump fitting in the crankcase ..........................53 Injection pump components and disassembly ......................... 54 Injection pump, body, plunger and delivery valve ......................54 Injection pump refitting ..............................54 Injection pump non-return valve ............................55 Outlet fitting components for 315-350 EPA E 400-440 engines ..................55 Injection pump, Rilsan tube removal ..........................55 Injection pump, Rilsan tube refitting ..........................55 Injection pump delivery check on test bench ........................56 Static injection timing .
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Page 7: Trouble Shooting
TROUBLE SHOOTING POSSIBLE CAUSES AND TROUBLE SHOOTING THE ENGINE MUST BE STOPPED IMMEDIATELY WHEN: 1) - The engine rpms suddenly increase and decrease 2) - A sudden and unusual noise is heard 3) - The colour of the exhaust fumes suddenly darkens 4) - The oil pressure indicator light turns on while running. TABLE OF LIKELY ANOMALIES AND THEIR SYMPTOMS The following table contains the possible causes of some failures which may occur during operation. Always perform these simple checks before removing or replacing any part. TROUBLE POSSIBLE CAUSE Clogged pipes Clogged fuel filter Air inside fuel circuit Clogged tank breather hole Faulty fuel pump Injector jammed Jammed injection pump delivery valve Wrong injector setting Excessive plunger blow-by... -
Page 8: General Remarks And Safety Information
GENERAL NOTES . Children and animals must be kept at a sufficient distance . Kohler engines are built to provide safe and longlasting from the machine to prevent any danger resulting from its performances, but in order to obtain these results it is operation. -
Page 9: General Safety During Operating Phases
. In order to move the engine simultaneously use the eyebolts fitted for this purpose by Kohler. These lifting points are however not suitable for the entire machine, so in this case use the eyebolts fitted by the manufacturer. - Page 10 NOTE - 10 - KD 225_315_350_400_440 Workshop Manual_cod. ED0053029330_1° ed_ rev. 00...
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Page 11: Model Number And Identification
MODEL NUMBER AND IDENTIFICATION MANUFACTURER AND MOTOR IDENTIFICATION DATA The identification plate shown in the figure can be found directly on the engine. It contains the following information: MADE IN ITALY A) Manufacturer’s identity XX XX XXXX XXXX Model B) Engine type XX XX XXXX XXXXXX C) Engine serial number Spec. e9 • 97/68/CE • 00/000xx • xxxx •xx D) Maximum operating speed 0.00 xxx xxx xx E) Number of the customer version (form K) F) Approval data Approval data... -
Page 12: Technical Data
TECHNICAL DATA CHARACTERISTICS KD 225_315_350 ENGINE TYPE Number of cylinders Bore Stroke Swept volume Compression ratio 20,3:1 21:1 20,3:1 R.P.M. 3600 3600 3600 N 80/1269/EEC-ISO 1585 3,5(4,8) 5,0(6,8) 5,5(7,5) Power kW (HP) NB ISO 3046 - 1 IFN 3,3(4,5) 4,6(6,2) 5,1(7,0) NA ISO 3046 - 1 ICXN 3,1(4,2) 4,1(5,6) 4,7(6,4) Max. torque * 15@2400 10,4@2400 16,6@2400 Fuel consumption ** g/kW.h Oil consumption 0,0021 0,0035 0,0038 Capacity of standard oil sump Recommended battery... -
Page 13: Characteristics Kd 400_440
TECHNICAL DATA CHARACTERISTICS KD 400_440 ENGINE TYPE Number of cylinders Bore Stroke Swept volume Compression ratio 20,3:1 20,3:1 R.P.M. 3600 3600 N 80/1269/EEC-ISO 1585 7,0(9,5) 7,7(10,5) Power kW (HP) NB ISO 3046 - 1 IFN 6,4(8,7) 7,0(9,6) NA ISO 3046 - 1 ICXN 5,8(7,9) 6,4(8,7) Max. torque * 21,3@2400 23,5@2400 Fuel consumption ** g/kW.h Oil consumption 0,005 0,0055 Capacity of standard oil sump Recommended battery V/Ah 12/44 12/44 Dry weight Combustion air volume at 3600 r.p.m. -
Page 14: Characteristics
MN Torque at N power. C Specific fuel consumption at NB power. The above power values refer to an engine fitted with air cleaner and standard muffler, after testing and at the environmental conditions of 20°C and 1 bar. Max. power tolerance is 5%. Power decreases by approximately 1% every 100 m di altitude and by 2% every 5°C above 25°C. Note: Consult KOHLER for power, torque curves and specific consumptions at rates differing from those given above. - 14 - KD 225_315_350_400_440 Workshop Manual_cod. ED0053029330_1° ed_ rev. 00... - Page 15 MN Torque at N power. C Specific fuel consumption at NB power. The above power values refer to an engine fitted with air cleaner and standard muffler, after testing and at the environmental conditions of 20°C and 1 bar. Max. power tolerance is 5%. Power decreases by approximately 1% every 100 m di altitude and by 2% every 5°C above 25°C. Note: Consult KOHLER for power, torque curves and specific consumptions at rates differing from those given above. - 15 - KD 225_315_350_400_440 Workshop Manual_cod. ED0053029330_1° ed_ rev. 00...
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Page 16: Overall Dimensions
OVERALL DIMENSIONS KD 225 KD 315 KD 350 Note : Dimensions shown in mm - 16 - KD 225_315_350_400_440 Workshop Manual_cod. ED0053029330_1° ed_ rev. 00... - Page 17 OVERALL DIMENSIONS KD 400 KD 440 Note: Dimensions shown in mm. - 17 - KD 225_315_350_400_440 Workshop Manual_cod. ED0053029330_1° ed_ rev. 00...
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Page 18: Maintenance - Recommended Oil Type - Refilling
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 10 50 250 500 OIL-BATH AIR CLEANER (*) HEAD AND CYLINDER FINS CLEANING INJECTOR... -
Page 19: Recommended Oil
MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING The engine could be damaged if allowed to operate with insufficient oil. It is also dangerous to add too much oil as its com- bustion could sharply increase the rotation speed. Use a suitable oil in order to protect the engine. The lubrication oil influences the performances and life of the engine in an incredible way. The risk of piston seizure, jammed piston rings and rapid wear of the cylinder liner, the bearings and all moving parts in- creases if oil whose characteristics differ from the recommended type is used, or if the oil is not regularly changed. All this notably reduces engine life. Oil viscosity must suit the ambient temperature in which the engine operates. Old oil can cause skin cancer if repeatedly left in contact with the skin and for long periods of time. If contact with the oil is inevitable, you are advised to thoroughly wash your hands with soap and water as soon as possible. Appropriate protective gloves etc should be wore during this operation. Old oil is highly polluting and must be disposed of in the correct way. Do not litter. RECOMMENDED OIL AGIP SUPERDIESEL MULTIGRADE 15W40 specifications API CF-4/ SG ACEA E2,B2 MIL-L-46152 D/E. ESSO SPECIAL PKW-UNI- FLO DIESEL 15W40 specifications API CF-4/SG ACEA E2,B2 MIL- GRADE L-46152 D/E. In the countries where AGIP and ESSO products are not available, use oil API SJ/CF for Diesel engines or oil correspon- ding to the military specification MIL-L-46152 D/E. -
Page 20: Disassembly/Reassembly
Besides disassembly and reassembly operations this chapter also includes checking and setting specifications, dimensions, repair and using compressed air, wear eye operating instructions. Always use original KOHLER spare parts for protection. repair operations. Clean the filtering element with air blast. Air must be blown from inside to outside the cartridge at a distance of at least 15 cm from the paper. -
Page 21: Dry Air Cleaner For Kd 400-440
DISASSEMBLY/REASSEMBLY Clean the filtering element with air blast. Air must be blown from inside to outside the cartridge at a distance of at least 15 cm from the paper. Lightly and repeatedly tap the element on a hard surface to eliminate all excess dirt. Dry air cleaner for KD 400-440 Open air cleaner (fig. 4). Unscrew the wing nut 1 (fig. 4a) and remove the filter element (fig. 5). Check the rubber seal is undamaged A (fig. 5a) Clean the filtering element with air blast. If the filtering element has been already cleaned other times, or if it is irreparably clogged, throw it away and replace . Refit the air filter and make sure the seal A is properly inserted, then tighten the wing nut 1. Make sure that the filter is mounted in the correct way other- wise dust and other impurities could ilfiltrate into the intake ducts. -
Page 22: Oil-Bath Air Cleaner (Optional)
DISASSEMBLY/REASSEMBLY Never clean the filtering element 6 using solvents with a low flash point. This could cause an explosion ! Make sure that the retention rings 4 - 5 are in a good condition and replace them if they are damaged. Oil-bath air cleaner (optional) Components: 1 Upper shell 1A Upper unit with separator pre-filter 2 Secondary filter element 3 Primary polyurethane 4 Internal seal ring 5 External rubber gasket 6 Lower metal filter element 7 Lower cup 8 Oil level gauge Characteristics of filter element 2: made of Viledon synthetic fabric, porosity 120 gr/m , resin-covered. -
Page 23: Rocker Arm Cover - Breather Ricirculation
DISASSEMBLY/REASSEMBLY Always check the the spring and valve to make sure they are in a good conditions. Rocker arm cover - Breather ricirculation Crankcase vapor recirculation occurs through duct 4. If the air filter clogs, the increased intake vacuum could suck oil throu- gh duct 4 into the combustion chamber, causing the engine to operate at a runaway rate. This is prevented by valcuum valve 2 which, when the vacuum increases, overcomes the resistance of spring 3 and shuts the duct 4. Make sure that oil plug 5 is correctly closed. Refit cover 1 and tighten rocker arm cover to 10 Nm. Valve/rocker arm clearance ( KD 225-315-350 ) Set valve/rocker arm clearance when the engine is cold: bring piston to top dead center on the compression stroke and set clearance at 0.10-0.15 mm using a thickness gauge. Tighten lock nut. -
Page 24: Hydraulic Tappets Kd 400-440
DISASSEMBLY/REASSEMBLY Hydraulic tappets KD 400-440 Distribution uses hydraulic tappets for automatic adjustment of valve clearance. The figure shows the tappet used in KD 400 engines. Caption 1- Lock ring 2- Upper collar 3- Oil inlet holes 4- Low-pressure chamber 5- Piston 6- Play-recovery spring 7- Case 8- Area to be lubricated 9- High-pressure chamber 10- Check valve 11- Identification marks Fill the low-pressure chamber through the oil inlet holes. If clearance occurs while running, as the tappet returns to the base of the camshaft, the play-recovery spring stretches out, keeping all timing system parts close together. -
Page 25: Tank
DISASSEMBLY/REASSEMBLY To avoid explosions or fire outbreaks, do not smoke or use na- ked flames during the operations. Fuel vapours are highly toxic. Only carry out the operations out- doors or in a well ventilated place. Keep your face well away from the plug to prevent harmful va- pours from being inhaled. Dispose of fuel in the correct way and do not litter as it is highly polluting. Tank Unscrew the upper and lower studs and remove the washers, which otherwise might make removal of the tank difficult. Next disconnect the fuel and air bleeding tubes. -
Page 26: Re-Coil Starting
DISASSEMBLY/REASSEMBLY Re-coil starting Operation: When pulling handle 10, thanks to the action of friction spring 12, te- eth 4 protrude from cap 3. After starting these teeth go back to the initial position because the cap rotates. Rope 9 is re-wound around pulley 6 by means of spring 7. Components: 1 Retainer 7 Spring 2 Washer 8 Guard 3 Cap 9 Rope 4 Flyweights 10 Handle 5 Spring... -
Page 27: Cylinder Head
DISASSEMBLY/REASSEMBLY Do not demount when hot or the part could become deformed. Cylinder head If the surface of the cylinder head is deformed, flatten it by removing 0.2 mm of material at most. Always replace the seal. See figs 46-47-48-49-50 when selecting the thickness. The bolts must be tightened in different phases for the va- rious engines, in compliance with the order shown in the figure: First tighten the 4 screws M10, then the 2 side screws M6. Lubricate the shanks of the bolts, under their heads and the washers with engine oil. Do not use too much oil. Oil that deposits in the thre- aded hole on the cylinder block could become pressurized during the tightening phase, sensibly diminishing the driving force. Always make sure that the holes on the cylinder block are dry and clean. Engine KD 225 Engine KD 350 1st phase: tighten all the bolts to a 30 Nm torque value in a 1st phase: tighten all the bolts to a 30 Nm torque value in a crossed fashion. -
Page 28: Valves - Disassembly
DISASSEMBLY/REASSEMBLY Valves - Disassembly Components: 1 Valve stem 2 Oil seal 3 Spring washer/set 4 Spring 5 Cap 6 Half collets Note: To remove half collets place a suitable plate under the valve head and press down firmly as indicated in the figure. Valves - Oil seal in valve guide To prevent seal 2 from being deformed when the valve guide is mounted, fit it into tool 1 serial N° 7107-1460-047 after having thorou- ghly lubricated it, then proceed as indicated in the figure. -
Page 29: Valves, Characteristics
DISASSEMBLY/REASSEMBLY Valves, characteristics Intake valve A 315 - 350 400 - 440 Base Material Chrome Plated ÷ ÷ ÷ ÷ a a a a a ° ÷ Exhaust valve B - Stem and head are of two different materials 225 - 315 - 350 - 400 - 440 Weld Joint Chrome Plated Base Material > - Base Material > - °... -
Page 30: Dimensions And Clearance Between Guides And Valve Stems (Mm)
DISASSEMBLY/REASSEMBLY Dimensions and clearance between guides and valve stems (mm) 315-350 400-440 ÷ ÷ ÷ ÷ ÷ Clearance ÷ ÷ Limit Valves seats and valve seat bores Dimensions (mm) 400-440 315-350 ÷ ÷ ÷ ÷ ÷ ÷ ÷ ÷ ÷ ÷... -
Page 31: Cylinder
DISASSEMBLY/REASSEMBLY Cylinder Set a bore gauge to zero with a calibrated ring. Check diameter at 1, 2 and 3; repeat the operation at the same points after turning the bore gauge 90°. If wear exceeds the max. given value by 0.05, bore the cylinder and fit oversize piston and rings. See fig. 40 and 41 for cylinder diameter values. Do not manually hone the cylinder bore surfaces with emery cloth or other means. Cylinder roughness The cross-hatch pattern should be at an angle of 45°-55°; lines should be uniform and clear in both directions. Average roughness must range between 0.5 mm 1 µm. The cylinder surface which comes into contact with piston rings should be machined with the plateau method. Piston Being of low expansion type, the piston allows small clearances between piston and cylinder and, thus, oil consumption is reduced. Remove circlips and piston pin. Remove piston rings and clean grooves. - Page 32 DISASSEMBLY/REASSEMBLY - 32 - KD 225_315_350_400_440 Workshop Manual_cod. ED0053029330_1° ed_ rev. 00...
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Page 33: Piston Rings, Distance Between The Tips (Mm)
DISASSEMBLY/REASSEMBLY Piston rings, distance between the tips (mm) Fit the piston ring into the top part of the cylinder and measure the distance between the tips. Value Piston rings Engine stamped - GOE stamped - ko stamped - N ÷ 1st piston ring (nitrided) ÷ ÷ 2nd piston ring * ÷... -
Page 34: Piston Rings, Play Between The Slots (Mm)
DISASSEMBLY/REASSEMBLY Piston rings, play between the slots (mm) 350-400 ÷ ÷ ÷ ÷ ÷ ÷ ÷ ÷ ÷ ÷ ÷ ÷ Replace the piston or piston rings if the value exceeds the maximum limit. Piston rings, assembly order A = 1st Chromium plated piston ring (nitrided for 225-350-400) B = 2nd piston ring (torsional) C = 3rd piston ring (oil scraper) (nitrided for 225-350-400) D = Chromium plated zone Note: If a word (top, or some other word) is written on the surface of a piston ring, mount that surface upwards. Before inserting the piston into the cylinder, oil and turn the pi- ston rings so that the cuts are staggered 120° to each other. In KD 350 and KD 225 engines, the second piston ring is not torsional, while the first and third piston rings do not have chro- mium plated zones but are nitrided. -
Page 35: Piston Protrusion Check
DISASSEMBLY/REASSEMBLY Piston protrusion check To calculate the right thickness for the gasket, the protrusion between the piston and the cylinder head surface must be measured. Use a dial indicator with base plate. Reset to zero while resting on a surface plate, then position against the cylinder head base plane as shown in the diagram, so that the dial indicator rod rests against the piston. Now take the reading. Repeat the operation in the other three points (going crosswise) and take the readings. Calculate the average of these four readings to get the precise measurement of the protrusion between the piston and the cylinder head base plane. -
Page 36: Connecting Rod
DISASSEMBLY/REASSEMBLY When remounting the big-end bearings, remember to thorou- ghly clean the parts and generously lubricate them to prevent seizure when the engine is started up for the first time Connecting rod Demount the connecting rod and proceed with the following inspec- tions. The big-end cap and big-end bear the same numbers. When remounting, mount the cap from the same side as in C of the figure. Tighten the KD 225 bolts to a 23 Nm torque value. Tighten the bolts to a 30 Nm torque value for KD 315-350-400-440. Connecting rod, piston pin 400-440 ÷ ÷ ÷ ÷ ÷ ÷ ÷... -
Page 37: Drive Shaft Oil Seals
DISASSEMBLY/REASSEMBLY A warped oil retainer may allow the introduction of air into the engine thus causing crankcase ventilation problems. Use genuine oil retainers with the KOHLER logo (see B). Drive shaft oil seals Oil retainer 1 is located in the gear cover on the timing side while re- tainer 2 is located in the crankcase on the flywheel side. Arrows a point to the crankshaft direction of rotation. Press them into their seats by exerting uniform pressure throughout their front surface. Drive shaft, lubrication ducts, bore thread on flywheel side and p.t.o. -
Page 38: Crankshaft - Journal Diameter (Mm)
DISASSEMBLY/REASSEMBLY Crankshaft - journal diameter (mm) 315-350 400-440 ÷ ÷ ÷ oil seal working area ÷ ÷ ÷ ÷ ÷ ÷ ÷ ÷ ÷ ÷ ÷ ÷ ÷ ÷ ÷ oil seal working area The undersizes for the crankpin and main journal are 0.25, 0.50 and 1 mm. -
Page 39: Camshaft
DISASSEMBLY/REASSEMBLY Camshaft Components: 1 Journal, gear cover on timing side 2 Gear 3 Exhaust lobe 4 Injection lobe 5 Fuel pump eccentric 6 Intake lobe 7 Journal, crankcase side Camshaft journals and bore Use a comparator for interiors Dimensions of camshaft journals and bore (mm) 315-350 400-440 ÷ ÷ ÷ ÷ ÷ ÷ ÷ ÷ ÷ ÷ ÷ Limit ÷ Limit Cam height (mm) 315-350 350 EPA... -
Page 40: Camshaft Timing
DISASSEMBLY/REASSEMBLY Camshaft timing Fit camshaft by aligning marks' A with mark D on the crankshaft. Camshaft – Antireverse system KD 400-440 it consists of a device on the camshaft which lifts the intake valve in case of a startup in reverse direction with respect to normal rotation. During normal operation, the tappet overcomes the spring resistance while passing on the system and decompression does not operate. In case of a startup in reverse direction, the antireverse system lifts the valve as the tappet passes by. Startup is thus inhibited. Note: Check the antireverse system for wear, and make sure it is kept in the rest position by the return spring, as shown in picture 68c. Verify that in this condition the clearance between weight A and surface B is 1 mm. -
Page 41: Automatic Decompression
DISASSEMBLY/REASSEMBLY Automatic decompression With the engine at a standstill and up to a rate of about 300 RPM, spring 1, acting on weights 2 and 3 via lever 4 and pin 5, keeps the exhaust valve open during the compression phase also. Once the engine exceeds the 300 RPM rate, weights 1 and 2 keep pin 5 in the hold position owing to the action of the centrifugal force. In this position, cam 6 can regularly control the exhaust valve thanks to a ridge on the pin itself. - Page 42 DISASSEMBLY/REASSEMBLY - 42 - KD 225_315_350_400_440 Workshop Manual_cod. ED0053029330_1° ed_ rev. 00...
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Page 43: Dinamic Balancer Timing
DISASSEMBLY/REASSEMBLY Dinamic balancer timing Position crankshaft as shown in the figure. Introduce the dynamic balancer so that timing mark 1 engages between teeth 2 of the crankshaft gear. Valve timing check Remove the tank and conveyor to access the flywheel. Carry out the inspections on the drive shaft. The values given are measured on the circumference of the flywheel. Adjust the valve play as indicated on the next page. Reset the comparator on the cap of intake valve 1. Turn the drive α... -
Page 44: Timing Angles For Operation (0.15 Valve Play)
DISASSEMBLY/REASSEMBLY Timing angles for operation (0.15 valve play). For KD 225 α = 6° before A corresponding to 12 mm β = 22° after B corresponding to 44 mm γ = 58° before B corresponding to 116 mm δ = 10° after A corresponding to 20 mm. Values measured on the circumference of the flywheel D = 230 (one degree corresponds to 2 mm). For KD 315 - 350 α = 10° before A corresponding to 20.09 mm β = 42° after B corresponding to 87.78 mm γ... -
Page 45: Speed Governor
DISASSEMBLY/REASSEMBLY Speed governor Components: 1 Spool spacer 2 Spool 3 Weights 4 Spool guide 5 Gear 6 Oil pump driving shaft 7 Circlip 8 Thrust ring Speed governor removal Spool guide 1 has retainers one end which prevent spool 2 from slip- ping out. To remove the speed governor use a suitable tool to slightly widen the two teeth. Refitting gear cover on timing side Proper sealing between gear cover and crankcase is ensured by the liquid sealant "Loctite 5205". Carefully clean the two sealing surfaces and spread the sealant uniformly. Tighten screws to 23 Nm. -
Page 46: Lubrication System
LUBRICATION SYSTEM The engine can be damaged if allowed to operate with insufficient oil. It is also dangerous to add too much oil because its combustion may lead to a sharp increase in the rotation speed. Use suitable oil in order to protect the engine. Nothing more than lubrication oil can influence the performances and life of an engine. Use of an inferior quality oil or failure to regularly change the oil will increase the risk of piston seizure, will cause the piston rings to jam and will lead to rapid wear on the cylinder liner, the bearings and all other moving parts. Engine life will also be notably reduced. The oil viscosity must suit the ambient temperature in which the engine operates. Old engine oil can cause skin cancer if repeatedly left in contact with the skin and for long periods of time. Wear protective gloves to avoid touching used oil. If contact with the oil is unavoidable, you are advised to wash your hands with soap and water as soon as possible. Dispose of old oil in the correct way as it is highly polluting. KD 225 - 315 - 350 LUBRICATION SYSTEM AND BREATHER RECIRCULATION SYSTEM Components: 1) Oil fill cap 6) Oil drain plug 11) Oil intake filter 2) Safety valve 7) Metal filter element 3) Rod journal 8) Main journal 4) Pressure control valve 9) Oil filter 5) Pressure switch 10) Oil pump - 46 - KD 225_315_350_400_440 Workshop Manual_cod. -
Page 47: Kd 400-440 Lubrication System And Breather Recirculation System
LUBRICATION SYSTEM KD 400-440 LUBRICATION SYSTEM AND BREATHER RECIRCULATION SYSTEM Components: 1) Oil fill cap 6) Oil drain plug 11) Oil intake filter 2) Safety valve 7) Metal filter element 12) Pushrods 3) Rod journal 8) Main journal 13) Hydraulic tappets 4) Pressure control valve 9) Oil filter 14) Calibrated union 5) Pressure switch 10) Oil pump - 47 - KD 225_315_350_400_440 Workshop Manual_cod. ED0053029330_1° ed_ rev. 00... -
Page 48: Oil Pump
LUBRICATION SYSTEM Oil pump Components: 1 Cover 2 Shaft 3 Key 4 Pin 5 Internal rotor 6 External rotor Oil pump delivery at 3000 rpm is 5.8 l/min. Oil pump - Clearance between rotors Measure clearance as shown in the figure; the max. value is 0.13 mm; wear limit 0.25 mm. Oil pressure regulation valve Components for KD 315 and KD 350: 1 Spring 2 Valve 3 Plug Free length A of the spring is 27.50-27.75 mm. Components for KD 225: 4 Ball 5 Spring... -
Page 49: Oil Filter
LUBRICATION SYSTEM Oil filter Filter components: KD 315/350 1 Seal 2 Adhesive 3 End cap 4 Filtering material 5 Plate Dimension mm: A = 26.5 B = 18 C = 88.5 D = 67.5 E = 8.5 Characteristics: Useful filtering area = 75 cm Degree of filtration = 50 µm. The by-pass valve is set at 0.6-0.8 bar. Filter components: KD 225 7 Rubber pad 8 Upper cover 9 Filter element 10 Lower cover Dimension mm: A = 19.0-19.3 B = 12.5 C = 83.0-83.5 Characteristics: Useful filtering area ≥ 75 cm Degree of filtration = 40-60 µm. See page 18 for the replacement frequencies. Oil pressure check When assembly operations are completed fill engine with oil and fuel; connect a 10 bar pressure gauge to the oil filter fitting. -
Page 50: Oil Pressure Curve At Idle Speed
LUBRICATION SYSTEM Oil pressure curve at idle speed The curve is obtained at the oil filter port with engine running at a con- stant speed of 1200 r.p.m. in no-load conditions; pressure is given in bar and temperature in centigrades. The curve represents the minimum pressure value while the maxi- mum value is 5 bar. Oil pressure curve at full speed The curve is obtained at the oil filter port with engine running at 3000 r.p.m. at the N power; pressure is given in bar and temperature in centigrades. -
Page 51: Fuelling/Injection Circuit For Kd 315-350-400-440
LUBRICATION SYSTEM Fuelling/injection circuit for KD 315-350-400-440 Components: 1 Tank 2 Return tube 3 Fuel filter 4 Injection pump 5 Injector leak-off line 6 Injector 7 High pressure line 8 Return tube Fuelling/injection circuit for KD 225 1 Tank 2 Injector leak-off line 3 Injector 4 High pressure line 5 Return tube 6 Return tube 7 Diesel fuel filter 8 Fuel pipe 9 T-connector 10 Reduction... -
Page 52: Fuel System
FUEL SYSTEM Fuel filter KD 225-315-350-400-440 A = 7.3 B = 3.8 C = 1.5 D = 42 H = 75 Characteristics: Filtering area ≥ 390 cm² Filtration level ≤ 7 µm See page 18 for fuel filter replacement Fuel filter KD 225 (version with internal filter in tank) 1 Rubber retention ring 2 PRV cover 3 SCP radial unit 4 PRV cover 5 Segment Characteristics: Filtering area 215 cm 2 Filtration level 7 µm See page 18 for fuel filter replacement Feed pump (optional) A feed pump is usually requested when the tank is not supplied in conjunction with the engine. -
Page 53: Fuel Pump, Drive Rod Protrusion
FUEL SYSTEM Fuel pump, drive rod protrusion Components: 1 Fuel pump 2 Crankcase 3 Drive rod 4 Eccentric Check while eccentric 4 is at rest (lowest point of travel). Protrusion A of drive rod 3 is 1.5-1.9 mm; it is not adjustable. Drive rod length = 58-58.2 mm for KD 225 Drive rod length = 65.8-66.0 mm for KD 315/350 Drive rod length = 61,4÷61,6 mm for KD 400/440 Injection pump This is of the simplified QLC type; it is housed in the crankcase and is controlled by the camshaft via tappets. Injection pump fitting in the crankcase Fit tappets 3 so that screw 6 is introduced into guide 4. Tighten screw 6 to 9 Nm and check that the tappet is free to move downwards. -
Page 54: Injection Pump Components And Disassembly
FUEL SYSTEM Injection pump components and disassembly 1 Delivery union 2 Filler 3 Spring 4 Gasket 5 Valve 6 Gasket 7 Spring retainer 8 Spring 9 Spring plate 10 Rack 11 Plunger 12 Pin A = Fuel outlet union B = Fuel intake union C = Fastening D = Barrel E = RH helix Demount in compliance with the numeric order. Plate 9 is held firm by pins 12. Lever up by inserting a tool between the plate and the body of the pump. The volume shifted by delivery valve 5 is 15 in the pump of KD 315-350 and 25 mm³ in the pump of KD 225 is 21 mm in the pump of... -
Page 55: Injection Pump Non-Return Valve
FUEL SYSTEM Injection pump non-return valve The exhaust union has a non-return valve A. The purpose of this val- ve is to improve the injection phase by expelling the air in the fuel and 225-315-350 preventing it from being sucked in by the pump during the intake pha- se. This also ensures that the engine stops promptly as soon as the stopping device is activated by means of the solenoid valve. Outlet fitting components for 315-350 EPA E 400-440 engines 1) Outlet fitting 315-350 EPA 400-440 2) Ball Ø1/8" 3) Threaded dowel Do not cut the tube longitudinally because you might damage the union. Injection pump, Rilsan tube removal Cut nylon tube at A. Remove the portion of the tube which is still connected to the union using common pliers. Pinch the nylon tube without impairing the sea- ling properties of union (see figure). -
Page 56: Injection Pump Delivery Check On Test Bench
FUEL SYSTEM Injection pump delivery check on test bench 1 Delivery control rack rod 2 Rack rod 1 in stop position 3 Rack rod 1 in max. delivery position A = 18-19 mm (max.rack rod stroke) α = 66° Static injection timing Disconnect pipe 1 from injection pump and close it, to avoid fuel lea- kages. Mount in its place a nylon pipe 2 as shown in the picture. Insert in this pipe an iron wire and let it project by approximately 10 mm: in this way any drop in fuel can easily be checked. - 56 - KD 225_315_350_400_440 Workshop Manual_cod. ED0053029330_1° ed_ rev. 00... -
Page 57: Static Injection Lead Test On Flywheel
FUEL SYSTEM Static injection lead test on flywheel Fill the tank and make sure that the fuel is not more than 10-15 cm above the tester. Set the flow governor lever of the injection pump in the stop position and lock it there. Turn the flywheel in the engine rotation direction. proceed slowly du- ring the compression phase. The fuel that flows from tube 2 will tend to diminish. Stop as soon as it creases to drip (one drop of fuel every 30-40 seconds is tolerated): this is the static injection lead. Make sure that B coincides with A. See fig. 117-118 if B does not coincide with A. Use a temporary tank if the engine is not fitted with one. Here again, it is essential to make sure that the fuel level is no more than 10-15 cm above the injectionm pump. References on the flywheel A = Reference of fixed TDC on crankcase B = Injection lead reference on the flywheel C = TDC reference on flywheel α = Reference in degrees between B and C. When B coincides with A, the piston is in the static injection lead position. When C coincides with A, the piston is at top dead center. α... -
Page 58: Injection Advance Adjustment
FUEL SYSTEM Injection advance adjustment Injection advance beyond the thickness of gasket A is determined by the thickness of the pad inside the injection tappet. To alter the value of injection advance the pad must be replaced with another of a suitable thickness (see fig. 117-118). To extract pad B, use a rod with a suction cap or magnet at one end. The replacement pads supplied have 10 different thicknesses (between 4.0 and 4.9mm). To alter the value of injection advance the pad must be replaced with another of a suitable thickness (see fig. 117-118). If reference point B does not coincide with A follow the examples in fig. 117-118. 1) Example of delayed injection advance (fig. 117): to make B match up with A, replace the pad with a thicker one (fig. 116). 2) Example of early injection advance (fig. 118): to make B match up with A, replace the pad with a thinner one (fig. 116). -
Page 59: Leakage Time (Waste)
FUEL SYSTEM Nozzles The set-up between the needle and the guide must leave the needle free to fall and merely as a result of its own weight, when lifted 7mm from its seat and rotated in different directions, with the nozzle kept at a 45° angle. Rotation of the needle must be completely smooth and uninhibited by obstacles and malformations. Moreover, on being squeezed against its seat, it must fall freely, when the nozzle is inverted. The test must be carried out after rinsing both the needle and nozzle with trichloroethane and wetting with filtered SHELL CALIBRATION FLUID “C” oil. n° and Ø of holes hole lenght a a a a a ° ° ° ° ° ° ° ° ° ÷ ÷ ÷ ÷... - Page 60 FUEL SYSTEM - 60 - KD 225_315_350_400_440 Workshop Manual_cod. ED0053029330_1° ed_ rev. 00...
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Page 61: 12V, 12A Electric Ignition Diagram
12V, 12A electric ignition diagram Components: 1 Alternator 2 Starter motor 3 Voltage regulator 4 Battery 5 Pressure switch 6 Oil pressure light 7 Key switch 8 Battery charging light Note: The battery, which is not supplied by KOHLER, should have 12V nominal voltage rating and a capacity of not less than 44 Ah / 210 Amp. of fast discharge intensity. Alternator Components: 1 Ring gear 2 Flywheel 3 Rotor 4 Stator Fixing screws must be tightened to 1.2 Nm. Note: The rotor is made up by a plastoferrite ring which is fixed to flywheel while the stator is mounted on the crankcase. -
Page 62: Electrical System
ELECTRICAL SYSTEM 24V, 9A alternator battery recharging curve 12V, 30A alternator battery recharging curve The test was conducted after heat stabilizing at 20°C. The value of the current delivered in relation to the curve may be subjected to a variation of between +10 % and -5%. Voltage regulator 12V, 12A: for standard alternators with 3 output wires 12V, 30A: for 12V, 20A alternators with 2 output wires 24V, 9A: for 24V, 9A alternators with two output wires Tab dimensions mm Width Thickness 6.35 0.80 9.50 1.12 The tabs are in different sizes to prevent incorrect connections. -
Page 63: Electric Starter Diagram With Voltage Regulator Built Into The Ignition Panel
Components: 1 Alternator 2 Starter motor 4 Battery 5 Pressure switch 6 Solenoid valve 7 Ignition switch Note: The battery, which is not supplied by KOHLER, should have 12V nominal voltage rating and a capacity of not less than 44 Ah / 210 Amp. of fast discharge intensity. 12V electric ignition layout with motor protection (optional) Components: 1 Alternator 2 Starter motor... -
Page 64: Diagram Of Electric Starter Motor Protection With Sole Self-Winding Starter - Without Battery - (Optional)
ELECTRICAL SYSTEM Diagram of electric starter motor protection with sole self- winding starter - without battery - (optional) Components: 1 Alternator 2 Solenoid valve 3 Pressure switch 4 Thermostat 5 A.c. motor stop device - 64 - KD 225_315_350_400_440 Workshop Manual_cod. ED0053029330_1° ed_ rev. 00... -
Page 65: Testing Voltage Regulator For Proper Operation
ELECTRICAL SYSTEM Testing voltage regulator for proper operation Check that connections correspond to the schematic. Disconnect the terminal from the battery positive pole. Connect a d.c. voltmeter between the battery poles. Fit an ammeter between the positive pole and the B+ on voltage re- gulator. Start and stop the engine a several times until battery voltage drops below 13V. When battery voltage reaches 14.5V the ammeter current should sud- denly drop down to almost zero. Replace regulator if recharge current is zero with voltage below 12,5V. When the engine is running do not disconnect battery cables or switch key to "off" position. Keep regulator away from heat sources above 75°C. Do no electric welding on engine or application. Starting motor Bosch type DW (L) 12V, 1.1 KW for KD 315-350-400-440 Bosch type DW (L) 12V, 0.9 KW for KD 225 Anti-clockwise rotation direction (viewed from pinion side) A = 17.5-19.5 mm (distance from flywheel rim surface to starter motor... -
Page 66: Characteristic Curves Of Bosch Starter Motor Type Dw (L) 12V, 0.9 Kw
ELECTRICAL SYSTEM Characteristic curves of Bosch starter motor type DW (L) 12V, 0.9 kW The curves were measured at a temperature of -20°C with a 55 Ah battery. U = Voltage on motor terminals in Volts. n = Motor speed in rpm M = Torque in Nm I (A) = Power draw in Amperes. Characteristic curves of Bosch starter motor type DW (L) 24V, 1.6 kW The curves were measured at a temperature of -20°C with a 36 Ah battery. -
Page 67: Adjustments - Kd 315-350
ELECTRICAL SYSTEM ADJUSTMENTS - KD 315-350 Idling speed setting in no-load conditions (standard) After filling with oil and fuel, start the engine and let it warm up for 10 minutes. Adjust idling speed to 1000-1250 rpm by turning set screw 1; then tighten lock nut. Washer 2 assures sealing and prevents possible oil leaks. Idle speed adjustment, for small car versions The idle speed adjusting spring (C) for small cars must be hooked in the speed governor lever hole D ( fig.140). Completely unscrew the std idle speed adjusting screw 1 (fig.137). Loosen nut B by one half of a turn. Turn the screw A anticlockwise until lever G touches cover. Start the engine: turning clockwise screw A , set idle speed at 1050 rpm ; tighten the lock nut B tighten the screw 1 (fig. 137) until touching lever H (fig. 141); when the screw touches the lever, the speed increases; at this point unloose screw 1/4 of a turn and lock the lock nut of screw 1. The controls cover screws must be tightened to 10Nm. Note: By this way idle speed on hot engine could diminish of 80 rpm max. -
Page 68: Settings / Adjustments
SETTINGS / ADJUSTMENTS ADJUSTMENTS - KD 225-400-440 No-load idling adjustment (standard) After having filled the engine with oil and fuel, start it and allow it to warm up for 10 minutes. Using adjuster screw 1, regulate the idling rate at 1000-1250 rpm. Tighten the check nut. No-load top rate adjustment (standard) After having adjusted the idling rate, use screw 2 and regulate the top rate at 3800 rpm (for engines set at 3600 rpm on load). Tighten the check nut. Injection pump flow rate adjustment for KD 225-315-350-400-440 This regulation must be carried out by means of a water brake, other-... -
Page 69: Injection Pump Delivery Setting
SETTINGS / ADJUSTMENT Injection pump delivery setting 1) Bring engine to idling speed 2) Unscrew delivery limiting device C ( see fig. 145) 3) Bring the engine to the power and rpm required by the manufactu- rer of the device. 4) Check that fuel consumption falls within the table specifications (see below). If consumption is not as indicated change balance conditions at the torque dynamometer by varying the load and adjusting the gover- nor.Under stable engine conditions check consumption again. 5) Tighten limiting device C until the engine rpm decreases. Lock the limiting device by means of lock nut. 6) Release brake completely and check at what speed the engine becomes stable Speed governor should comply with the requirements of the class indicated by the manufacturer of the device. -
Page 70: Storage
STORAGE When the engines are not used for more than 3 months, they must be protected by the measures described below: STORAGE Internal engine protection: - Start the engine and allow it to heat up. - Remove the drain plug and let the oil flow out completely. - Replace the oil filter with a new one. - Clean the oil drain plug and after inserting a new gasket, tighten it. -
Page 71: Procedures To Be Carried Out Before Start The Engine
STORAGE PROCEDURES TO BE CARRIED OUT BEFORE START THE ENGINE - Remove all protections and coverings. - Remove the protective oil from the outside of the engine using suitable products (solvent or degreaser). - Remove the injector and, using a flask, pour engine oil on the piston crown (no more than 2 cc). - Remove rocker arm cover and spray engine oil on the valves, then turn the crankshaft manually a few revolutions. - Start the engine and allow it to heat up for about 10 minutes. - Remove the drain plug and let the protective oil flow out completely. - Replace the drain plug. - Fill up with engine oil as far as the upper level of the dipstick using the oil recommended by the manufacturer for normal engine operation. -
Page 72: Torque Specifications
TORQUE SPECIFICATIONS MAIN TORQUE SPECIFICATIONS Reference ( fig. Diam. and pitch Torque ( Nm ) Torque ( Nm ) Torque ( Nm ) POSITION ( mm ) N° and page) 400-440 315-350 Re-coil starting fig. 18 - p. 25 Connecting rod, aluminium fig. 51 - p. 36 Connecting rod, steel fig. 13 - p. 23 Rocker arm adjusting screw lock nut 6x0,5 fig. 13 - p. 23 Rocker arm adjusting screw pin 8x1,25... -
Page 73: Table Of Tightening Torques For Standard Screws (Coarse Thread)
TORQUE SPECIFICATIONS Table of tightening torques for standard screws (coarse thread) Resistance class (R) 10.9 12.9 Quality/ Dimensions R>400N/mm R>500N/mm R>600N/mm R>800N/mm R>1000N/mm R>1200N/mm Diameter 1000 1200 1050 1500 1800 1088 1450 2000 2400 Table of tightening torques for standard screws (fine thread) Resistance class (R) 10.9 12.9... - Page 74 Translated from the original manual in Italian language. Data reported in this issue can be modified at any time by KOHLER. FOR SALES AND SERVICE INFORMATION IN U.S. AND CANADA, CALL 1-800-544-2444 ED0053029330 FORM NO. KohlerEngines.com ISSUED 25/06/2012 ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044 REVISED DATE 25/06/2012...
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Questions and answers
KD225 lost prime to/from injector pump. Need instructions for re-priming the curcuit. Help
To re-prime the injector pump circuit for the Kohler KD225, use the optional feed pump if the tank is not supplied with the engine. The feed pump is a diaphragm type operated by a camshaft eccentric through a drive rod. It helps supply fuel to the injection pump, allowing the circuit to be filled and primed.
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