Table Of Contents - Kohler RD 441 Service Manual

This manual contains pertinent information regarding the repair of KOHLER water-cooled, indirect injection Diesel engines type
20-04-2009
KD 441: updated

TABLE OF CONTENTS

1 GENERAL REMARKS AND SAFETY INFORMATION ................................................................................................... 8-9
General safety during operating phases ............................................................................................................................. 9
Safety and environmental impact ........................................................................................................................................ 9
Safety and warning decals .................................................................................................................................................. 8
Safety regulations ............................................................................................................................................................... 8
2 TECHNICAL INFORMATION ...................................................................................................................................... 10-13
Manufacturer and engine identifications ............................................................................................................................11
Overall dimensions ............................................................................................................................................................ 13
Technical data ................................................................................................................................................................... 12
Trouble shooting................................................................................................................................................................ 10
3 MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING ................................................................................... 14-17
ACEA Regualtions - ACEA Sequences ............................................................................................................................. 15
API / MIL Sequences ..................................................................................................................................................... 15
Engines oil capacity .......................................................................................................................................................... 16
Extraordinary maintenance ............................................................................................................................................... 14
Fuel recommendations ...................................................................................................................................................... 17
International specifications ................................................................................................................................................ 15
Lubricant ........................................................................................................................................................................... 15
Ordinary maintenance ....................................................................................................................................................... 14
Prescribed lubricant .......................................................................................................................................................... 16
Routine engine maintenance ............................................................................................................................................ 14
SAE Classification ............................................................................................................................................................ 15
4 DISASSEMBLY ............................................................................................................................................................ 18-31
Camshaft ........................................................................................................................................................................... 27
Connecting rod .................................................................................................................................................................. 23
Connecting rod - upward replacement of the connecting rod half bearings ...................................................................... 25
Crankshaft ......................................................................................................................................................................... 28
Cylinder ............................................................................................................................................................................. 25
Cylinder head ................................................................................................................................................................... 22
Decompression lever, operation check ............................................................................................................................. 18
Engine starting by means of a rope (emergency starting) ................................................................................................ 18
Equalizer shaft .................................................................................................................................................................. 28
Flywheel ............................................................................................................................................................................ 26
Fuel overflow system, Disassembly ................................................................................................................................. 21
Fuelling/injection circuit ..................................................................................................................................................... 20
Injector .............................................................................................................................................................................. 22
Oil pump ............................................................................................................................................................................ 29
Recommendations for disassembly .................................................................................................................................. 18
Rocker arm cover .............................................................................................................................................................. 19
Rocker arm cover - Breather ricirculation .......................................................................................................................... 19
Rocker arm cover breather system ................................................................................................................................... 19
Shroud ............................................................................................................................................................................... 20
Speed governor gear ........................................................................................................................................................ 28
Start pulley ........................................................................................................................................................................ 20
Timing cover ...................................................................................................................................................................... 27
5 OVERHAULS AND CHECKING .................................................................................................................................. 32-47
Availability of bearings ...................................................................................................................................................... 40
Camshaft ........................................................................................................................................................................... 44
Camshaft journals and bore .............................................................................................................................................. 45
Camshaft, cam height (mm) .............................................................................................................................................. 45
Camshaft, pin and housing dimensions, and relevant clearances (mm) .......................................................................... 45
Connecting rod alignement ............................................................................................................................................... 39
Connecting rod, piston pin ................................................................................................................................................ 38
Crankcase bearing - Extraction ......................................................................................................................................... 42
Crankcase bearing - Reassembly ..................................................................................................................................... 42
Crankshaft - journal diameter (mm) .................................................................................................................................. 40
Crankshaft - Main bearing, big end, and crankshaft bearing internal diameters, and relevant clearances. ...................... 40
Workshop Manual KD 441_cod. 1.5302.865_2
nd
ed_ rev. 01.
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INDEX
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