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Kohler KD225, Workshop Manual

The Kohler KD225 Workshop Manual is the perfect companion for any KD225 engine user. Available for free download from our website, this comprehensive manual provides step-by-step instructions and essential tips for optimal performance and maintenance. Unlock the full potential of your engine with this indispensable manual. Download now from 88.208.23.73:8080.

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INDEX

KD 225_315_350_400_440 Workshop Manual_cod. ED0053029330_

1° ed

_ rev.

 

00

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 ............................................................................................................................ 9

Safety and environmental impact  ...................................................................................................................................... 9

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

Manufacturer and motor identification data .......................................................................................................................11

Approval data .....................................................................................................................................................................11

4 - TECHNICAL  DATA ............................................................................................................................................ 12

Characteristics kd 225_315_350 .......................................................................................................................................12

Characteristics kd 400_440 ...............................................................................................................................................13

5 - CHARACTERISTICS ......................................................................................................................................... 14

Characteristics power, torque and specific fuel consumption curves ...............................................................................14

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

7 - MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING  ........................................................................ 18

Maintenance ......................................................................................................................................................................18

Fuel ....................................................................................................................................................................................18

Recommended oil ..............................................................................................................................................................19

Acea sequences ................................................................................................................................................................19

8 - DISASSEMBLY/REASSEMBLY ........................................................................................................................ 20

Disassembly and reassembly ........................................................................................................................................... 20

Dry air cleaner for kd 315 and kd 350 ............................................................................................................................... 20

Dry air cleaner for kd 225 ................................................................................................................................................. 20

Dry air cleaner for kd 400-440 ..........................................................................................................................................21

Prefilter for dry air filter ......................................................................................................................................................21

Oil-bath air cleaner (optional) ........................................................................................................................................... 22

Muffler ............................................................................................................................................................................... 22

Rocker arm cover breather system ................................................................................................................................... 22

Rocker arm cover - breather ricirculation ......................................................................................................................... 23

Valve/rocker arm clearance (KD 225-315-350) ................................................................................................................ 23

The engines KD 400 and 440 have hydraulic tappets, therefore no adjustment is required ........................................... 23

Do not start the engine for approximately 4 hours to allow the hydraulic tappets to settle completely ........................... 23

Hydraulic tappets  KD 400-440 ........................................................................................................................................ 24

Tank .................................................................................................................................................................................. 25

Fuel filter KD 225-400-440 (version with internal filter) ................................................................................................... 25

Fuel filter for KD 225 - 315 - 350 - 400 - 440 (version with external filter) ........................................................................ 25

Re-coil starting.................................................................................................................................................................. 26

Shroud .............................................................................................................................................................................. 26

Flywheel ............................................................................................................................................................................ 26

Summary of Contents for KD225

Page 1: ...KD225 KD315 KD350 KD400 KD440 WORKSHOP MANUAL ...

Page 2: ...ce 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 tech...

Page 3: ...nsible 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 Please review the document titled Kohler Co Federal and California Emission Control Systems Limited Warranty Off Road Diesel Engines for comp...

Page 4: ...0_440 13 5 CHARACTERISTICS 14 Characteristics power torque and specific fuel consumption curves 14 6 OVERALL DIMENSIONS 16 7 MAINTENANCE RECOMMENDED OIL TYPE REFILLING 18 Maintenance 18 Fuel 18 Recommended oil 19 Acea sequences 19 8 DISASSEMBLY REASSEMBLY 20 Disassembly and reassembly 20 Dry air cleaner for kd 315 and kd 350 20 Dry air cleaner for kd 225 20 Dry air cleaner for kd 400 440 21 Prefil...

Page 5: ...diameter gear cover bearing inside diameter on timing side 37 Crankshaft journal diameter mm 38 Availability of bearings 38 Camshaft 39 Camshaft journals and bore 39 Dimensions of camshaft journals and bore mm 39 Cam height mm 39 Camshaft timing 40 Camshaft Antireverse system KD 400 440 40 Automatic decompression 41 Camshaft end play 41 Dynamic balancer on request 41 Dinamic balancer timing 43 Val...

Page 6: ...c ignition layout with motor protection optional 63 Diagram of electric starter motor protection with sole self winding starter without battery optional 64 Testing voltage regulator for proper operation 65 Starting motor 65 Characteristic curves for starting motor type DW L 12V 1 1 KW 65 Characteristic curves of Bosch starter motor type DW L 12V 0 9 kW 66 Characteristic curves of Bosch starter mot...

Page 7: ...Worn or scored cylinders Worn valve guides Jammed valves Worn bearings Governor linkage not free to slide Drive shaft not free to slide Damaged cylinder head gasket TROUBLE LUBRICATION POSSIBLE CAUSE FUEL CIRCUIT ELECTRIC SYSTEM MAINTE NANCE SETTINGS REPAIRS Engine does not start No acceleration Black smoke Excessive oil consumption Too low oil pressure Engine starts but stops Non uniform speed Wh...

Page 8: ...at least one metre from buildings or other machines Children and animals must be kept at a sufficient distance from the machine to prevent any danger resulting from its operation Fuel is flammable so the tank must be filled only when the engine is turned off Dry carefully any fuel that may have spilled remove the fuel container and any cloths soaked in fuel or oil check that any sound absorbing pa...

Page 9: ...d monitor the influence of its own activities products services etc on the environment Procedures for identifying the extent of the impact on the envi ronment must consider the following factors Liquid waste Waste management Soil contamination Atmospheric emissions Use of raw materials and natural resources Regulations and directives regarding environmental impact In order to minimise the impact o...

Page 10: ... 10 NOTE KD 225_315_350_400_440 Workshop Manual_cod ED0053029330_1 ed_ rev 00 ...

Page 11: ...tity B Engine type C Engine serial number D Maximum operating speed E Number of the customer version form K F Approval data Approval data The approval reference directives EC are on the engine plate MANUFACTURER AND MOTOR IDENTIFICATION DATA 1 Model year 2 Engine displacement 3 Power category kW 4 Particulate emission limit g kWh 5 Engine family ID 6 Kind of application i e 7 Injection timing BTDC...

Page 12: ...to NB power Depending on the application ENGINE TYPE Number of cylinders Bore Stroke Swept volume Compression ratio R P M N 80 1269 EEC ISO 1585 Power kW HP NB ISO 3046 1 IFN NA ISO 3046 1 ICXN Max torque Fuel consumption Oil consumption Capacity of standard oil sump Recommended battery Dry weight Combustion air volume at 3600 r p m Cooling air volume at 3600 r p m Max permissible driving shaft ax...

Page 13: ... Number of cylinders Bore Stroke Swept volume Compression ratio R P M N 80 1269 EEC ISO 1585 Power kW HP NB ISO 3046 1 IFN NA ISO 3046 1 ICXN Max torque Fuel consumption Oil consumption Capacity of standard oil sump Recommended battery Dry weight Combustion air volume at 3600 r p m Cooling air volume at 3600 r p m Max permissible driving shaft axial load in both directions continuous service for u...

Page 14: ...ed and variable load NA ISO 3046 1 ICXN CONTINUOS RATING WITH OVERLOAD CAPABILITY continuos heavy duty with constant speed and constant load MN Torque at N power C Specific fuel consumption at NB power The above power values refer to an engine fitted with air cleaner and standard muffler after testing and at the environmental conditions of 20 C and 1 bar Max power tolerance is 5 Power decreases by...

Page 15: ...nd variable load NA ISO 3046 1 ICXN CONTINUOS RATING WITH OVERLOAD CAPABILITY continuos heavy duty with constant speed and constant load MN Torque at N power C Specific fuel consumption at NB power The above power values refer to an engine fitted with air cleaner and standard muffler after testing and at the environmental conditions of 20 C and 1 bar Max power tolerance is 5 Power decreases by app...

Page 16: ...6 Note Dimensions shown in mm 16 KD 225 KD 315 KD 350 OVERALL DIMENSIONS KD 225_315_350_400_440 Workshop Manual_cod ED0053029330_1 ed_ rev 00 ...

Page 17: ...6 Note Dimensions shown in mm 17 KD 400 KD 440 OVERALL DIMENSIONS KD 225_315_350_400_440 Workshop Manual_cod ED0053029330_1 ed_ rev 00 ...

Page 18: ...gged KD 225_315_350_400_440 Workshop Manual_cod ED0053029330_1 ed_ rev 00 To avoid explosions or fire outbreaks do not smoke or use naked flames during the operations Fuel vapours are highly toxic Only carry out the operations outdoors or in a well ventilated place Keep your face well away from the plug to prevent harmful vapours from being inhaled Dispose of fuel in the correct way and do not lit...

Page 19: ... 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 gl...

Page 20: ...teristics media porosity 7 µm useful filtering area 1960 cm2 Polyurethane pre filter characteristic porosity 60 p p i front area 207 cm2 Note Pre filter 3 can undergo maintenance operations if dirty wash with soap and water and dry maximum 10 cleanings See page 18 for cartridge replacement Clean the filtering element with air blast Air must be blown from inside to outside the cartridge at a distan...

Page 21: ... 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 ...

Page 22: ...s can be washed with soap and water for a maxi mum of 10 times Wash the metal filter 6 with Diesel fuel Blow out excess fuel with com pressed air See pages 14 and 15 for periodic maintenance details and oil replacement Allow the exhaust manifold to cool before demounting it in order to prevent scorching and burns Muffler When reassembling replace the exhaust manifold gaskets Tighten nuts to 25 Nm ...

Page 23: ...p dead center on the compression stroke and set clearance at 0 10 0 15 mm using a thickness gauge Tighten lock nut N B Since an automatic decompression device is available on the exhaust lobe manualy rotate the engine until the tappets are at lowest point When replacing the rocket arms position the piston at the bottom dead centre and tighten the fixing screw gradually to adjust the hydraulic tapp...

Page 24: ... that air bubbles do not form The tappet may be supplied with the high pressure chamber full or empty The low pressure chamber is always empty The tappet should always be handled in an upright position to prevent the high pressure chamber from emptying The surface that comes into contact with the cam should be lubricated generously during assembly using AS COMPUND 40 type MOLYSLIP see figure This ...

Page 25: ...the fuel and air bleeding tubes Completely empty the tank to make sure that no impurities remain When reassembling tighten the upper nuts to 15 Nm 1 Fuel filter 2 Fuel tank 3 Filter sleeve 4 Filter cartridge 5 Flush ring 6 Nut 7 Union seal 8 Diesel fuel outlet union 9 Flat washer See page 18 for the frequency with which the fuel filter must be repla ced See fig 99 for the dimensions Loosen the cla...

Page 26: ... reducing to tal engine sound pressure levels When refitting tighten shroud screws to 10 Nm During the demounting phases pay particular attention to pre vent the flywheel from dropping as this could seriously injure the operator Wear protective goggles when removing the flywheel ring Flywheel Unscrew bolt 1 in a clockwise direction Remove the flywheel with a puller Make sure that the tapered surfa...

Page 27: ...all the bolts to a 30 Nm torque value in a crossed fashion 2nd phase unscrew all the bolts by 180 3rd phase tighten all the bolts to a 20 Nm torque value in a crossed fashion 4th phase make a 60 turn in the same order as the 3rd phase 5th phase tighten the 2 side bolts 5 to a 10 Nm torque value For KD 400 and 400 engines 1st phase tighten all screws crosswise to 20Nm 2nd phase tighten the screws i...

Page 28: ...l in valve guide To prevent seal 2 from being deformed when the valve guide is mounted fit it into tool 1 serial N 7107 1460 047 after having thorou ghly lubricated it then proceed as indicated in the figure Valve springs Measure the free length with a caliper Free length A 33 72 Free length A 34 88 Note Replace the spring if the free length A is 1 mm less than speci fied KD 225_315_350_400_440 Wo...

Page 29: ...D 11 040 11 055 A 35 B 30 C 10 000 10 020 D 10 040 10 055 Note Valve guides with outer diameters increased by 0 5 mm are also available as spares In this case housing C must be in creased by 0 5 mm for assembly purposes Valves guide insertion Heat the block to a temperature of 160 180 Force the guides considering distance A and B in relation to the block surface A 25 8 26 2 B 34 8 35 2 A 23 8 24 2...

Page 30: ... 3 0 1 5 3 225 315 350 400 440 DISASSEMBLY REASSEMBLY 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 they must not be machined after having been inserted KD 225_315_350_400_440 Workshop Manual_cod ED0053029330_1 ed_ rev 00 Valve seat lapping After cutting valve seats lap valve seats with fine...

Page 31: ...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...

Page 32: ...8 32 DISASSEMBLY REASSEMBLY KD 225_315_350_400_440 Workshop Manual_cod ED0053029330_1 ed_ rev 00 ...

Page 33: ...st piston ring nitrided 2nd piston ring 3rd piston ring oil scraper nitred 1st piston ring chromated 2nd piston ring torsional 3rd piston ring oil scraper 1st piston ring nitrided 2nd piston ring 3rd piston ring oil scraper nitred 1st piston ring nitrided 2nd piston ring 3rd piston ring oil scraper nitred 1st piston ring chromated 2nd piston ring torsional 3rd piston ring oil scraper Piston rings ...

Page 34: ...d piston rings do not have chro mium plated zones but are nitrided Lubricate the following parts with oil before mounting the pi ston pin the piston the cylinder and the big end bearing Piston Refitting Connect piston to connecting rod lubricate piston pin and introduce it into the piston connecting rod assembly by exerting pressure with your thumb Fit both piston pin circlips and check that they ...

Page 35: ...ween the piston and the cylinder head base plane Choose the appropriate gasket according to the following table Only remove the head gasket from its protective wrapping just before assembly See page 26 when tightening the cylinder head Having chosen the required thickness mount the gasket as shown in the figure see letter A Find the number of notches in zone B to find the thickness of the ga sket ...

Page 36: ... 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 Note The connecting rod has no insert bearings See fig 62 for connecting rod big end diameter Connecting rod aligne...

Page 37: ... M8x1 25 with standard shaft When the crankpin and main journal are ground values R and R1 must be obtained again to prevent the drive shaft from bre aking Drive shaft connection radius Radius R that joins the crankpin to the supports is 2 8 3 2 mm Radius R1 that joins the main journal to the timing gear is 0 5 mm Drive shaft main journal crankpin diameter gear cover bearing inside diameter on tim...

Page 38: ... 2 0 0 0 4 2 0 0 2 0 0 0 4 2 0 0 2 0 0 0 G F 6 5 0 0 5 1 0 0 6 5 0 0 5 1 0 0 6 5 0 0 5 1 0 0 I L 6 5 0 0 4 2 0 0 6 5 0 0 4 2 0 0 6 5 0 0 4 2 0 0 225 400 440 315 350 225 400 440 315 350 225 400 440 315 350 38 DISASSEMBLY REASSEMBLY oil seal working area oil seal working area Crankshaft journal diameter mm The undersizes for the crankpin and main journal are 0 25 0 50 and 1 mm The gears must be moun...

Page 39: ...7 5 3 0 8 5 3 5 7 5 3 5 1 6 3 0 1 6 3 H2 0 7 3 3 5 6 3 3 0 1 5 3 5 0 5 3 0 7 3 3 5 6 3 3 5 1 5 3 0 1 5 3 225 315 350 350 EPA 400 440 39 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 jour...

Page 40: ...esistance 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 a...

Page 41: ...r is used Camshaft end play Perform this check before fitting cylinder head and tappets including the injection tappets Temporarily fit camshaft 1 complete with washer tighten gear cover 2 to 25 Nm Check end play by moving the camshaft back and forth using a suita ble tool the end play value is 0 10 0 25 mm and is not adjustable Dynamic balancer on request The dynamic balancer is supported by two ...

Page 42: ...8 42 DISASSEMBLY REASSEMBLY KD 225_315_350_400_440 Workshop Manual_cod ED0053029330_1 ed_ rev 00 ...

Page 43: ...umference of the flywheel Adjust the valve play as indicated on the next page Reset the comparator on the cap of intake valve 1 Turn the drive shaft in the spinning direction and find α point at which the intake valve starts to open in relation to top dead center A and β point at which the intake valve shuts after bottom dead center B see fig 77 78 Proceed in a similar way with the exhaust valve c...

Page 44: ...ce of the flywheel D 240 one degree corresponds to 2 09 mm Timing angles for inspection 0 65 0 70 valve play α 7 after A corresponding to 14 mm β 9 after B corresponding to 18 mm γ 45 before B corresponding to 90 mm δ 3 before A corresponding to 6 mm Values measured on the circumference of the flywheel D 230 one degree corresponds to 2 mm α 1 after A corresponding to 2 09 mm β 31 after B correspon...

Page 45: ...ool 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 Wait 3 hours before starting the engine KD 225_315_350_400_440 Wor...

Page 46: ...e 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 o...

Page 47: ... 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 KD 225_315_350_400_440 Workshop Manual_cod ED0053029330_1 ed_ rev 00 KD 400 440 LUBRICATION SYSTEM AND BREATHER RECIRCULATION SYSTEM ...

Page 48: ...ure regulation valve Components for KD 315 and KD 350 1 Spring 2 Valve 3 Plug Free length A of the spring is 27 50 27 75 mm Components for KD 225 4 Ball 5 Spring 6 Plug Free length A of the spring is 23 50 24 50 mm Components for KD 400 440 7 Plunger 8 Spring 9 Washer 10 Cup 11 Snap ring Free length A of the spring is 25 50 25 75 mm Note If A is 1 mm less than the given value replace the valve Val...

Page 49: ...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 Start the engine and check pressure as a function of the oil tempera ture see below Calibrated pipe for lubrication of hydraulic tappets The pipe is fitted to the hydraulic tappets oil line see fig 83 ...

Page 50: ...ure 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 The curve represents the minimum pressure value while the maxi mum value is 5 bar Note After the running in period the lube max temperature should be less than the room temp...

Page 51: ... line 8 Return tube 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 11 Injection pump KD 225_315_350_400_440 Workshop Manual_cod ED0053029330_1 ed_ rev 00 Fuelling injection circuit for KD 315 350 400 440 Fuelling injection circuit for KD 225 ...

Page 52: ...acement Feed pump optional A feed pump is usually requested when the tank is not supplied in conjunction with the engine The pump is the diaphragm type and is operated by a camshaft ec centric through a drive rod Tighten screws to 15 Nm Characteristics At 2000 rpm of the camshaft the minimum delivery is 40 l h while the automatic adjustment pressure is 0 5 0 7 bars KD 225_315_350_400_440 Workshop ...

Page 53: ...6 to 9 Nm and check that the tappet is free to move downwards Fit pad 2 into the tappet so that recess B points downwards as shown in the figure Fit the injection pump into the crankcase complete with gasket C po sition8ing flow control 1 in the fork of lever 5 which should be in the maximum flow position When removing the injection pump from its housing make sure that spacer 2 is not dropped into...

Page 54: ...225 is 21 mm3 in the pump of KD 400 440 Injection pump body plunger and delivery valve Components Dimensions mm 1 Delivery valve A 5 50 nominal diam 225 315 350 2 Barrel A 7 00 nominal diam 400 440 3 Plunger A 6 00 nominal diam 315 350 EPA 4 Right helix B 2 00 2 03 5 Delay notch C 1 50 1 53 6 Pump body 7 Collar Note The injection pump installed in engines for small vehicles soundproof generating s...

Page 55: ...d 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 Re cycle the same feeding tube if the remaining length allows it re place if not Injection pump...

Page 56: ... 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 KD 225_315_350_400_440 Workshop Manual_cod ED0053029330_1 ed_ rev 00 ...

Page 57: ...rary 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 ...

Page 58: ...her 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 Note When the thickness of the pad varies by ...

Page 59: ...spring When the spring is replaced calibration must be carried out at a pressure higher than 10 bars to counterbalance adjustments while running Spraying and opening pressure With the pressure gauge closed press hard on the hand pump at least 10 times Open the pressure gauge and press down on the pump once every second while keeping a check on the spraying process and pressure The opening pressure...

Page 60: ...10 60 FUEL SYSTEM KD 225_315_350_400_440 Workshop Manual_cod ED0053029330_1 ed_ rev 00 ...

Page 61: ...ich is fixed to flywheel while the stator is mounted on the crankcase Alternator battery charger graph 12V 12A This test has been carried out after thermal stabilization at 20 C for 2 minutes at 3000 r p m with constant battery voltage of 12 5V The value of the power supplied with reference to the curve may change in a range between 10 and 5 KD 225_315_350_400_440 Workshop Manual_cod ED0053029330_...

Page 62: ...ted 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 The tabs are in different sizes to prevent incorrect connections Tab dimensions mm 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 KD 225_315_350_4...

Page 63: ... Alternator 2 Starter motor 4 Battery 5 Pressure switch 6 Solenoid valve 7 Ignition switch 8 Panel KD 225_315_350_400_440 Workshop Manual_cod ED0053029330_1 ed_ rev 00 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 Note The battery which is not supplied by KOHLER should have 12V nomin...

Page 64: ...c 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 KD 225_315_350_400_440 Workshop Manual_cod ED0053029330_1 ed_ rev 00 ...

Page 65: ...e 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 Anti clockwise rotation direction viewed from pinion side A 17 5 19 5 mm distance from flywheel rim surface to starter motor flange surface Note Contact Bosch service centers for repair operations Characteristic ...

Page 66: ...r 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 U Voltage on motor terminals in Volts n Motor speed in rpm M Torque in Nm I A Power draw in Amperes Ignition switch positions A Accessory B Off C On D Start KD 225_315_350_400_440 Workshop Manual_cod ED00530...

Page 67: ...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 t...

Page 68: ...gine tends to decelerate Loosen limiter C by one and a half turns Tighten the check nut Note Tighten C if the engine produces an excessive amount of exhaust in the maximum load condition loosen C if no smoke is exhausted and if the engine is unable to develop its maximum power Injection pump delivery limiting and torque adapter standard Delivery limiting device C has the function of limiting the i...

Page 69: ...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 Spe...

Page 70: ... fuel tank Replace the fuel filter with a new one Fill up with fuel containing 10 AGIP RUSTIA NT After bleeding air start the engine make sure there are no fuel leaks and then stop the engine External engine protection Carefully clean the cylinder cooling system fins and the flywheel fins Protect the external non painted surfaces with AGIP RUSTIA 68 F Seal the intake and exhaust systems with adhes...

Page 71: ...gine 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 PROCEDURES TO BE CARRIED OUT BE...

Page 72: ... bolt for dry air filter cover M6 fixing screws for side oil refilling union M6 screw for injection tappet guide M8 STEI screw for closing oil intake hole cover M8 STEI screw for closing crankcase lubrication hole M8 fixing screws for air filter support and intake manifold Rocker arm fulcrum screws Stator screws M8 stud bolts for tank Plastoferrite on flywheel Base coupling surface cover Coupling ...

Page 73: ...Nm Nm M 8x1 10 14 13 17 20 27 38 45 M 10x1 21 28 26 35 42 56 79 95 M 10x1 25 20 26 24 33 39 52 73 88 M 12x1 25 36 48 45 59 71 95 135 160 M 12x1 5 38 45 42 56 68 90 125 150 M 14x1 5 56 75 70 94 113 150 210 250 M 16x1 5 84 113 105 141 169 225 315 380 M 18x1 5 122 163 153 203 244 325 460 550 M 18x2 117 157 147 196 235 313 440 530 M 20x1 5 173 230 213 288 345 460 640 770 M 20x2 164 218 204 273 327 436...

Page 74: ...012 ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 FOR SALES AND SERVICE INFORMATION IN U S AND CANADA CALL 1 800 544 2444 KohlerEngines com Translated from the original manual in Italian language Data reported in this issue can be modified at any time by KOHLER ...

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