Kohler KD15-441 User manual

Kohler
Brand
Kohler
Model
KD15-441
Category
Engine
Type
User manual
15 LD 441
KD 441 SERVICE MANUAL
cod. 1-5302-865 _ 2nd ed._rev.01.
HORIZONTAL CRANKSHAFT
Danger – Attention Caution – Warning
Important
PREFACE
- Every attempt has been made to present within this service manual, accurate and up to date technical informa-
tion.
However, development on the KOHLER series is continuous.
Therefore, the information within this manual is subject to change without notice and without obligation.
- The information contained within this service manual is the sole property of KOHLER.
As such, no reproduction or replication in whole or part is allowed without the express written permission of KO-
HLER.
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 KO-
HLER 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 KO-
HLER after-sales service centers to carry out assembly, disassembly, overhauling, replacement and tuning
operations.
- As well as employing good operating techniques and observing the right timing for operations, operators must
read the information very carefully and comply with it scrupulously.
- Timespentreadingthisinformationwillhelptopreventhealthandsafetyrisksandnancialdamage.
Written information is accompanied by illustrations in order to facilitate your understanding of every step of the
operating phases.
KD 441
Engine Series
Workshop Manual KD 441_cod. 1.5302.865_2nd ed_ rev. 01.
- 4 - Workshop Manual KD 441_cod. 1.5302.865_2nd ed_ rev. 01.
-
30-01-2009 28-05-2009
CUSE/ATLO 2° 01
REGISTRATION OF MODIFICATIONS TO THE DOCUMENT
Anymodicationstothisdocumentmustberegisteredbythedraftingbody,bycompletingthefollowingtable.
Drafting
body Document
code Edition Issue date Review
date
Model
N° Revision Endorsed
1-5302-865 51203
- 5 -
Workshop Manual KD 441_cod. 1.5302.865_2nd ed_ rev. 01.
-
This manual contains pertinent information regarding the repair of KOHLER water-cooled, indirect injection Diesel engines type
KD 441: updated 20-04-2009
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identications ............................................................................................................................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specications ................................................................................................................................................ 15
Lubricant ........................................................................................................................................................................... 15
Ordinary maintenance ....................................................................................................................................................... 14
Prescribed lubricant .......................................................................................................................................................... 16
Routine engine maintenance ............................................................................................................................................ 14
SAEClassication ............................................................................................................................................................ 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overow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
INDEX
- 6 - Workshop Manual KD 441_cod. 1.5302.865_2nd ed_ rev. 01.
-
Crankshaft, connection radius ........................................................................................................................................... 39
Crankshaft, journal/crankpin diameter check, timing cover bearing internal diameters and crankshaft and big end bearing
support .............................................................................................................................................................................. 39
Crankshaft,lubricationducts,borethreadonywheelsideandp.t.o. .............................................................................. 39
Cylinder ............................................................................................................................................................................. 37
Cylinder head .................................................................................................................................................................... 33
Cylinder roughness ........................................................................................................................................................... 37
Dimensions and clearance between guides and valve stems (mm) ................................................................................. 34
Dynamic balancer (on request) ......................................................................................................................................... 45
Gearbox extension, bearing and oil seal replacement ...................................................................................................... 43
Injector protusion ............................................................................................................................................................... 37
Oil seal ring - Reassembly ................................................................................................................................................ 44
Oil seal ring on crankcase - Reassembly .......................................................................................................................... 43
Piston ................................................................................................................................................................................ 37
Piston rings, assembly order ............................................................................................................................................. 38
Piston rings, distance between the tips (mm) ................................................................................................................... 38
Piston rings, play between the slots (mm) ........................................................................................................................ 38
Recommendations for overhauls and checking ................................................................................................................ 32
Roller bearing - Disassembly ............................................................................................................................................ 43
Roller bearing - Reassembly ............................................................................................................................................. 43
Shaft seals ........................................................................................................................................................................ 32
Timing cover bearing - Disassembly ................................................................................................................................. 41
Timing cover bearing - Reassembly .................................................................................................................................. 41
Timing cover bearing, crankshaft bearing, and clearance shims replacement ................................................................. 41
Valve guides - Reassembly ............................................................................................................................................... 35
Valve guides - Removal .................................................................................................................................................... 35
Valve seat lapping ............................................................................................................................................................. 36
Valve seats - Reassembly ................................................................................................................................................. 36
Valve seats - Removal ...................................................................................................................................................... 35
Valve timing - Angles ......................................................................................................................................................... 46
Valve, springs .................................................................................................................................................................... 33
Valves - Disassembly ........................................................................................................................................................ 33
Valves - Oil seal in valve guide ......................................................................................................................................... 36
Valves - Reassembly ......................................................................................................................................................... 36
Valves seats and valve seat bores .................................................................................................................................... 34
Valves, characteristics ....................................................................................................................................................... 33
Valves, guide insertion ...................................................................................................................................................... 34
Valves, guides and housings ............................................................................................................................................. 34
6 REASSEMBLY .............................................................................................................................................................48-57
Assessing head gasket thickness ..................................................................................................................................... 55
Camshaft ........................................................................................................................................................................... 51
Camshaft end play ............................................................................................................................................................ 54
Connecting rod big end cap .............................................................................................................................................. 49
Connecting rod, tightening ................................................................................................................................................ 50
Crankshaft ........................................................................................................................................................................ 48
Crankshaft end play .......................................................................................................................................................... 54
Cylinder ............................................................................................................................................................................. 49
Equalizer shaft .................................................................................................................................................................. 51
Flywheel ............................................................................................................................................................................ 56
Gear cover on timing side ................................................................................................................................................. 53
Gearbox extension ............................................................................................................................................................ 54
Gearboxextension,intermediateange ........................................................................................................................... 54
Head gasket (mm) ............................................................................................................................................................. 55
Head tightening ................................................................................................................................................................. 56
Injectionpumpandtappetttinginthecrankcase ........................................................................................................... 50
Injector .............................................................................................................................................................................. 57
Oil pump ............................................................................................................................................................................ 51
Oil seals, crankshaft - Replacement ................................................................................................................................. 55
Piston ................................................................................................................................................................................ 48
Piston protrusion check ..................................................................................................................................................... 55
Recommendations for reassembling ................................................................................................................................. 48
Rings ................................................................................................................................................................................. 49
Rocker arm cover .............................................................................................................................................................. 57
Speed governor gear ........................................................................................................................................................ 52
Valve tappets ..................................................................................................................................................................... 50
Valve/rocker arm clearance ............................................................................................................................................... 57
Index
- 7 -
Workshop Manual KD 441_cod. 1.5302.865_2nd ed_ rev. 01.
-
Index
7 LUBRICATION SYSTEM .............................................................................................................................................58-61
Internal strainer ................................................................................................................................................................. 59
Lubrication system ............................................................................................................................................................ 58
Oil pressure check ............................................................................................................................................................ 60
Oil pressure curve at full rotation speed ............................................................................................................................ 60
Oil pressure curve at idle rotation speed .......................................................................................................................... 60
Oil pressure regulation valve ............................................................................................................................................. 59
Oil pump ............................................................................................................................................................................ 59
Oil pump - Clearance between rotors ............................................................................................................................... 59
8 FUEL SYSTEM ............................................................................................................................................................62-69
Barlter ............................................................................................................................................................................. 68
Conversion table from millimetres into degrees ................................................................................................................ 67
Fuellter ........................................................................................................................................................................... 62
Fuel lift pump ..................................................................................................................................................................... 62
Fuel lift pump - Filter cleaning ........................................................................................................................................... 63
Fuel pump, drive rod protrusion ........................................................................................................................................ 63
Fuelling/injection circuit ..................................................................................................................................................... 62
Injection advance adjustment ............................................................................................................................................ 67
Injectionadvancespeciedvalue ..................................................................................................................................... 67
Injection pump ................................................................................................................................................................... 64
Injection pump components and disassembly .................................................................................................................. 65
Injectionpumpttinginthecrankcase .............................................................................................................................. 64
Injection pump non-return valve ........................................................................................................................................ 66
Injectionpumpretting ...................................................................................................................................................... 65
Injection pump, body, plunger and delivery valve ............................................................................................................. 65
Injector .............................................................................................................................................................................. 68
Injector calibration ............................................................................................................................................................. 69
Nozzles ............................................................................................................................................................................. 69
Referencesontheywheel ............................................................................................................................................... 67
Solenoid valve ................................................................................................................................................................... 64
Static injection timing ........................................................................................................................................................ 66
9 ELECTRICAL SYSTEM ...............................................................................................................................................70-73
12V, 17A electric ignition diagram ..................................................................................................................................... 70
Alternator ........................................................................................................................................................................... 70
Alternator charger graph (12V, 17A) ................................................................................................................................. 70
Characteristic curves for starting motor type BOSCH DW (L) 12V, 1.2 KW..................................................................... 73
Connection Diagram ......................................................................................................................................................... 71
Ignition switch positions .................................................................................................................................................... 73
Starting motor - BOSCH ................................................................................................................................................... 73
Testing voltage regulator for proper operation .................................................................................................................. 72
Voltage regulator ............................................................................................................................................................... 71
10 ADJUSTMENTS ..........................................................................................................................................................74-77
Accelerator lever for speed governor with min/max speed system ................................................................................... 74
Assembly procedure for accelerator lever of speed governor with min/max speed system ............................................. 74
Injection pump delivery approximate setting ..................................................................................................................... 76
Injection pump delivery limiting and torque adapter .......................................................................................................... 76
Injection pump delivery setting for engines with dynamometric brake .............................................................................. 77
Required settings (the most common ones) ..................................................................................................................... 77
Setting the fast idle (standard) rotation speed .................................................................................................................. 75
Setting the slow idle (standard) rotation speed ................................................................................................................. 75
11 STORAGE ...................................................................................................................................................................78-79
Engine storage .................................................................................................................................................................. 78
Preparing the engine for operation after protective treatment ........................................................................................... 79
Protective treatment .......................................................................................................................................................... 78
12 MAIN TORQUE SPECIFICATIONS AND USE OF SEALANTS .................................................................................80-81
Maintorquespecications ................................................................................................................................................. 80
Table of tightening torques for standard screws (coarse thread) ...................................................................................... 81
Tableoftighteningtorquesforstandardscrews(nethread) ........................................................................................... 81
Use of sealant ................................................................................................................................................................... 80
13 SPECIAL TOOLS ........................................................................................................................................................82-83
- 8 - Workshop Manual KD 441_cod. 1.5302.865_2nd ed_ rev. 01.
1
Combustion creates carbon monoxide, an odourless and highly poisonous gas.
Lengthy stays in places where the engine freely exhausts this gas can lead to unconsciousness and death.
−Theenginemustnotoperateinplacescontaininginammablematerials,inexplosiveatmospheres,wherethereisdustthat
caneasilycatchreunlessspecic,adequateandclearlyindicatedprecautionshavebeentakenandhavebeencertiedfor
the machine.
−Topreventrehazards,alwayskeepthemachineatleastonemeterfrombuildingsorfromothermachinery.
− Children and animals must be kept at a due distance from operating machines in order to prevent hazards deriving from their
operation.
−Fuelisinammable.
 Thetankmustonlybelledwhentheengineisoff.
Thoroughly dry any spilt fuel and move the fuel container away along with any rags soaked in fuel or oil.
 Makesurethatnosoundproongpanelsmadeofporousmaterialaresoakedinfueloroil.
 Makesurethatthegroundorooronwhichthemachineisstandinghasnotsoakedupanyfueloroil.
− Fully tighten the tank plug each time after refuelling.
 Donotllthetankrighttothetopbutleaveanadequatespaceforthefueltoexpand.
− Fuel vapour is highly toxic.
Only refuel outdoors or in a well ventilated place.
−Donotsmokeorusenakedameswhenrefuelling.
−Theenginemustbestartedincompliancewiththespecicinstructionsintheoperationmanualoftheengineand/ormachine
itself.
Do not use auxiliary starting aids that were not installed on the original machine (e.g. Startpilot’).
− Before starting, remove any tools that were used to service the engine and/or machine.
 Makesurethatallguardshavebeenretted.
− During operation, the surface of the engine can become dangerously hot.
Avoid touching the exhaust system in particular.
− Before proceeding with any operation on the engine, stop it and allow it to cool.
Never carry out any operation whilst the engine is running.
−Thecoolantuidcircuitisunderpressure.
Never carry out any inspections until the engine has cooled and even in this case, only open the radiator plug or expansion
chamber with the utmost caution, wearing protective garments and goggles. If there is an electric fan, do not approach the en-
gine whilst it is still hot as the fan could also start operating when the engine is at a standstill.
Only clean the coolant system when the engine is at a standstill.
−Whencleaningtheoil-cooledairlter,makesurethattheoldoilisdisposedofinthecorrectwayinordertosafeguardtheen-
vironment.
 Thespongylteringmaterialinoil-cooledairltersmustnotbesoakedinoil.
 Thereservoiroftheseparatorpre-ltermustnotbelledwithoil.
− The oil must be drained whilst the engine is hot (oil T ~ 80°C).
Particular care is required to prevent burns.
Do not allow the oil to come into contact with the skin.
−Payattentiontothetemperatureoftheoillterwhenthelteritselfisreplaced.
− Onlycheck,topupandchangethecoolantuidwhentheengineisoffandcold.
 Takecaretopreventuidscontainingnitritesfrombeingmixedwithothersthatdonotcontainthesesubstancessince"Nitro-
samine",dangerousforthehealth,canform.
 Thecoolantuidispollutingandmustthereforebedisposedoffinthecorrectwaytosafeguardtheenvironment.
− During operations that involve access to moving parts of the engine and/or removal of rotating guards, disconnect and insula-
te the positive wire of the battery to prevent accidental short-circuits and to stop the starter motor from being energized.
− Only check belt tension when the engine is off.
− Only use the eyebolts installed by KOHLER to move the engine.
These lifting points are not suitable for the entire machine; in this case, the eyebolts installed by the manufacturer should be
used.
- Important remarks and features of the text are highlighted
using symbols, which are explained below:
Danger – Attention
This indicates situations of grave danger which, if igno-
red, may seriously threaten the health and safety of indi-
viduals.
SAFETY AND WARNING DECALS
Caution – Warning
This indicates that it is necessary to take proper precau-
tions to prevent any risk to the health and safety of indivi-
duals and avoid nancial damage.
Important
This indicates particularly important technical information
that should not be ignored.
SAFETY REGULATIONS
GENERAL REMARKS AND SAFETY INFORMATION
- 9 -
Workshop Manual KD 441_cod. 1.5302.865_2nd ed_ rev. 01.
1
General remarks and safety information
− KOHLER Engines are built to supply their performances in a safe and long-lasting way.
To obtain these results, it is essential for users to comply with the servicing instructions given in the relative manual along with
the safety recommendations listed below.
−Theenginehasbeenmadeaccordingtoamachinemanufacturer'sspecicationsandallactionsrequiredtomeettheessential
safety and health safeguarding requisites have been taken, as prescribed by the current laws in merit.
 Allusesoftheenginebeyondthosespecicallyestablishedcannotthereforebeconsideredasconformingtotheusedened
by KOHLER which thus declines all liability for any accidents deriving from such operations.
− The following indications are dedicated to the user of the machine in order to reduce or eliminate risks concerning engine ope-
ration in particular, along with the relative routine maintenance work.
− The user must read these instructions carefully and become familiar with the operations described.
Failure to do this could lead to serious danger for his personal safety and health and that of any persons who may be in the
vicinity of the machine.
• The engine may only be used or assembled on a machine by technicians who are adequately trained about its operation and
the deriving dangers.
This condition is also essential when it comes to routine and, above all, extraordinary maintenance operations which, in the
lattercase,mustonlybecarriedoutbypersonsspecicallytrainedbyKOHLER and who work in compliance with the existing
documentation.
−Variationstothefunctionalparametersoftheengine,adjustmentstothefuelowrateandrotationspeed,removalofseals,
demountingandrettingofpartsnotdescribedintheoperationandmaintenancemanualbyunauthorizedpersonnelshallrelieve
KOHLER from all and every liability for deriving accidents or for failure to comply with the laws in merit.
−Onstarting,makesurethattheengineisashorizontalaspossible,unlessthemachinespecicationsdiffer.
In the case of manual start-ups, make sure that the relative actions can take place without the risk of hitting walls or dangerous
objects, also considering the movements made by the operator.
Pull-starting with a free cord (thus excluding self-winding starting only), is not permitted even in an emergency.
− Make sure that the machine is stable to prevent the risk of overturning.
− Become familiar with how to adjust the rotation speed and stop the engine.
−Neverstarttheengineinaclosedplaceorwherethereisinsufcientventilation.
GENERAL SAFETY DURING OPERATING PHASES
– The procedures contained in this manual have been tested and selected by the manufacturer’s technical experts, and hence
are to be recognised as authorised operating methods.
– A number of procedures must be carried out with the aid of equipment and tools that simplify and improve the timing of
operations.
– All tools must be in good working condition so that engine components are not damaged and that operations are carried out
properly and safely.
It is important to wear the personal safety devices prescribed by work safety laws and also by the standards of this manual.
– Holes must be lined up methodically and with the aid of suitable equipment. Do not use your ngers to carry out this
operation to avoid the risk of amputation.
– Some phases may require the assistance of more than one operator. If so, it is important to inform and train them regarding
the type of activity they will be performing in order to prevent risks to the health and safety of all persons involved.
– Donotuseammableliquids(petrol,diesel,etc.)todegreaseorwashcomponents.Usespecialproducts.
– Use the oils and greases recommended by the manufacturer.
Do not mix different brands or combine oils with different characteristics.
– Discontinue use of the engine if any irregularities arise, particularly in the case of unusual vibrations.
– Do not tamper with any devices to alter the level of performance guaranteed by the manufacturer.
SAFETY AND ENVIRONMENTAL IMPACT
Every organisation has a duty to implement procedures to
identify, assess and monitor the inuence 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 on the environment, the manu-
facturer now provides a number of indications to be followed
by all persons handling the engine, for any reason, during its
expected lifetime.
- All packaging components must be disposed off in accor-
dance with the laws of the country in which disposal is ta-
king place.
- Keep the fuel and engine control systems and the exhaust
pipes in efcient working order to limit environmental and
noise pollution.
- When discontinuing use of the engine, select all compo-
nents according to their chemical characteristics and dispo-
se of them separately.
- 10 - Workshop Manual KD 441_cod. 1.5302.865_2nd ed_ rev. 01.
2
Clogged pipes
Cloggedfuellter
Air inside fuel circuit
Clogged tank breather hole
Faulty fuel pump
Fuelpumplterclogged
Injector jammed
Jammed injection pump delivery valve
Wrong injector setting
Excessive plunger blow-by
Jammed injection pump delivery control
Wrong injection pump setting
Oil level too high
Jammed pressure relief valve
Worn oil pump
Air inside oil suction pipe
Faulty pressure gauge or switch
Clogged oil suction pipe
Battery discharged
Wrongorinefcientcableconnection
Defective ignition switch
Defective starter motor
Cloggedairlter
Excessive idle operation
Incomplete running-in
Engine overloaded
Advanced injection
Delayed injection
Incorrect governor linkage adjustment
Broken or loose governor spring
Idle speed too low
Worn or jammed piston rings
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
SYSTEM
POSSIBLE CAUSE
FUEL SYSTEM
ELECTRIC
SYSTEM
MAINTE-
NANCE
DISASSEMBLY/REASSEMBLY
SETTINGS
Engine does not
start
No acceleration
Black smoke
Excessive oil
consumption
Too low oil pres-
sure
Engine starts but
stops
Non-uniform
speed
White smoke
oil and fuel drip-
ping from exhaust
Increase oil level
TECHNICAL INFORMATION
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.
- 11 -
Workshop Manual KD 441_cod. 1.5302.865_2nd ed_ rev. 01.
2
Technical information
Model R.P.M.
Displacement (cc) Engine Serial
Diesel
KOHLER
K version
MANUFACTURER AND ENGINE IDENTIFICATION
Customer code
Production year (last two digits)
Production month (alphabetically) A January
B February
C March
D April
E May
F June
G July
H August
J September
K October
L November
M December
Month codication
- 12 - Workshop Manual KD 441_cod. 1.5302.865_2nd ed_ rev. 01.
1
86
76
441
20.5:1
3600
6.8
6.6(9.0)
6.2(8.4)
21@2200
273
0.0044
1.5
12/44
51
580
5500
200
25°
35°
***
N.
mm
mm
Cm3
Nm
g/kW.h
l/h
lt
V/Ah
kg
l./min
l./min
kg.
KD 441
2
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 up to 30 min.
Max. inclination discontinuous service for about 1 min.
permanent service
* Referred to N power
** Referred to NB power
*** Depending on the application
ENGINE TYPE
Technical information
TECHNICAL DATA
- 13 -
Workshop Manual KD 441_cod. 1.5302.865_2nd ed_ rev. 01.
2
135.8
73
296
254
159.5
1.5
150
35
42.4
235.5
193
77
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
165.5
151
172.2
243
106
135.5
139
85.5
B
A
CD
E
F G
H
IJ
K
L M N
O
P
QSR
T
OVERALL DIMENSIONS
Technical information
DIMENSIONS mm
- 14 - Workshop Manual KD 441_cod. 1.5302.865_2nd ed_ rev. 01.
100.000
70.00020.00010.0001.000 5.000
3
30.000
Caution – Warning
Failure to carry out the operations described in the table may lead to technical damage to the machine and/or system
Check the valves gap
Oillter
Engine oil
Interval Km
OPERATION
CHECK
REPLACEMENT
ITEM Aftertherst1000km
ORDINARY MAINTENANCE
CLEANING
CHECK
REPLACEMENT
Dry air-cleaner
Cylindercoolingns
Fuellter-primary
Lube oil level
Valves gap
Waterpresenceinthefuellter
Fuel lines pipes
Injector and fuel injection pump
Idling speed
Lube oil
Oillter
Fuellterprimary
Fuellter-secondary
Dryairltercartridge
General overhaul
Maintenance interval at Km
OPERATION
OVERHAUL
EXTRAORDINARY MAINTENANCE
ITEM
MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING
ROUTINE ENGINE MAINTENANCE
Check the valves gap
Oillter
Engine oil
- 15 -
Workshop Manual KD 441_cod. 1.5302.865_2nd ed_ rev. 01.
3
CF CE CD CC
API CH-4 CG-4 CF-4
MIL
CF-2
OBSOLETI
DIESEL
CORRENTI OBSOLETE CURRENT
L- 46152 D / E
SAE 20W*SAE 30*
SAE 40*
SAE 10W-30**
SAE 10W-40**
SAE 10W-60**
SAE 15W-40 **
SAE 15W-40 **
SAE 20W-60 **
SAE 5W-30 ***
SAE 0W-30 ***
-
30 -
25 -
20 -
15 -
10 -
50+
5+
10 +
15 +
20 +
25 +
30 +
35 +
40 +
45
SAE 10W*
+
50
-
35
-
40
SAE 5W-40 ***
Maintenance - Recommended oil type - Relling
International specications
Theydenetestingperformancesandproceduresthatthelubricantsneedtosuccessfullyrespondtoinseveralenginetesting
andlaboratoryanalysissoastobeconsideredqualiedandinconformitytotheregulationssetforeachlubricationkind.
A.P.I : ( American Petroleum Institute )
MIL :EngineoilU.S.militaryspecicationsreleasedforlogisticreasons
ACEA : European Automobile Manufacturers Association
Tables shown on this page are of useful reference when buying a kind of oil.
Codes are usually printed-out on the oil container and the understanding of their meaning is useful for comparing different
brands and choosing the kind with the right characteristics.
Usuallyaspecicationshowingafollowingletterornumberispreferabletoonewithaprecedingletterornumber.
An SF oil, for instance, is more performing than a SE oil but less performing than a SG one.
LIGHT DUTY DIESEL ENGINES
B1 = Low-viscosity, for frictions reduction
B2 = Standard
B3 =High performances (indirect injection)
B4 = High quality (direct injection)
HEAVY DUTY DIESEL ENGINES
E1 = OBSOLETE
E2 = Standard
E3 = Heavy conditions (Euro 1 - Euro 2 engines )
E4 = Heavy conditions (Euro 1 - Euro 2 - Euro 3 engines )
E5 =High performances in heavy conditions (Euro 1 - Euro 2 - Euro
3 engines )
ACEA Regualtions - ACEA Sequences
LUBRICANT
SAE Classication
In the SAE classication, oils differ on the basis of their
viscosity, and no other qualitative characteristic is taken
into account.
The rst number refers to the viscosity when the engine
is cold (symbol W = winter), while the second considers
viscosity with the engine at régime.
The criteria for choosing must consider, during winter, the
lowest outside temperature to which the engine will be
subject and the highest functioning temperature during
summer.
Single-degree oils are normally used when the running
temperature varies scarcely.
Multi-degree oil is less sensitive to temperature changes.
API / MIL Sequences
* Mineral base
** Semi-synthetic base
*** Synthetic base
SAE- Grade
- 16 - Workshop Manual KD 441_cod. 1.5302.865_2nd ed_ rev. 01.
3
AGIP SUPERDIE-
SEL
MULTIGRADE
15W40
API CF- 4
ACEA B2 - E2
MIL - L-46152 D/E
1.5
Maintenance - Recommended oil type - Relling
specications
PRESCRIBED LUBRICANT
In the countries where AGIP products are not available, use oil API CF/SH for Diesel engines or oil corresponding to the military
specicationMIL-L-2104C/46152D.
Danger – Attention
- The engine may be damaged if operated with insufcient lube oil. It is also dangerous to supply too much lube oil to
the engine because a sudden increase in engine rpm could be caused by its combustion.
- Use proper lube oil preserve your engine. Good quality or poor quality of the lubricating oil has an affect on engine
performance and life.
- If inferior oil is used, or if your engine oil is not changed regularly, the risk of piston seizure, piston ring sticking, and
accelerated wear of the cylinder liner, bearing and other moving components increases signicantly.
- Always use oil with the right viscosity for the ambient temperature in which your engine is being operated.
Danger – Attention
- The used engine oil can cause skin-cancer if kept frequently in contact for prolonged periods.
- If contact with oil cannot be avoided, wash carefully your hands with water and soap as soon as possible.
- Do not disperse the oil in the ambient, as it has a high pollution power.
Litres
OIL VOLUME AT MAX LEVEL
ENGINES OIL CAPACITY
- 17 -
Workshop Manual KD 441_cod. 1.5302.865_2nd ed_ rev. 01.
3
API CF4 - CG4
API CF
Purchase diesel fuel in small quantities and store in clean, approved containers. Clean fuel prevents the diesel fuel injectors and
pumpsfromclogging.Donotoverllthefueltank.
Leave room for the fuel to expand. Immediately clean up any spillage during refueling.
Never store diesel fuel in galvanized containers; diesel fuel and the galvanized coating react chemically to each other, producing
akingthatquicklyclogsltersorcausesfuelpumporinjectorfailure.
High sulfur content in fuel may cause engine wear. In those countries where diesel has a high sufur content, its is advisable to
lubricate the engine with a high alkaline oil or alternatively to replace the lubricating oil recommended by the manufacturer more
frequently. The regions in which diesel normally has a low sulfur content are Europe, North America, and Australia.
FUEL TYPE
Forbestresults,useonlyclean,fresh,commercial-gradedieselfuel.Dieselfuelsthatsatisfythefollowingspecicationsare
suitable for use in this engine: ASTM D-975 - 1D or 2D, EN590, IS 1460 or equivalent.
FUELS FOR LOW TEMPERATURES
It is possible to run the engine at temperatures below 0°C using special winter fuels. These fuels reduce the formation of
parafnindieselatlowtemperatures.Ifparafnformsinthediesel,thefuellterbecomesblockedinterruptingtheowoffuel.
Fuel can be: - Summer up to 0°C
- Winter up to -10°C
- Alpine up to -20°C
- Arctic up to -30°C
BIODIESEL FUEL
Fuelscontaininglessthan20%methylesterorB20,aresuitableforuseinthisengine.Biodieselfuelsmeetingthespecication
of BQ-9000, EN 14214 or equivalent may be used. DO NOT use vegetable oil as a biofuel for this engine.
Any failures resulting from the use of fuels other than recommended will not be warranted.
AVIATION FUEL
Aviation fuels suitable for use in this engine include JP5, JP4, JP8 and, JET-A (if 5 percent oil is added).
FUEL RECOMMENDATIONS
Fuel with low sulphur content
Fuel with high sulphur content
PRESCRIBED LUBRICANT
Maintenance - Recommended oil type - Relling
- 18 - Workshop Manual KD 441_cod. 1.5302.865_2nd ed_ rev. 01.
2
1
3
A
B
4DISASSEMBLY
Important
To locate specic topics, the reader should refer to the
index.
- Before any intervention, the operator should lay out
all equipment and tools in such a way as to enable
him to carry out operations correctly and safely.
- Before proceeding with operations, make sure that
appropriate safety conditions are in place, in order to
safeguard the operator and any persons involved.
- For safety and convenience, you are advised to place the
engine on a special rotating stand for engine overhauls.
RECOMMENDATIONS FOR DISASSEMBLY
Caution – Warning
Please remember that any variation in the intake system
during the application phase of KD 441 engines involves
series anomalies tothe engines for every variations to
functional system.
Optimisation must be carried out beforehand at KOHLER
testing centres. Non-approval by KOHLER of any
modications, releases the company from any damages
incurred by the engine.
Decompression lever, operation check
Manually rotate the pulley clockwise up to the compression point.
Operate the decompression lever by moving it up to position B.
Check the proper functioning of the decompression lever as descri-
bed in the following operations:
After bringing the engine at the T.D.C., check that the lever is in posi-
tion B. The semiautomatic decompression lever should automatically
return to resting position A by manually rotating the engine clockwise.
Engine starting by means of a rope (emergency starting)
Manually rotate the pulley clockwise up to the compression point.
Operate the decompression lever by moving it up to position B.
Placetheknotoftheropeintheappropriatespace(seegure).
Wind the rope on the pulley clockwise.
- 19 -
Workshop Manual KD 441_cod. 1.5302.865_2nd ed_ rev. 01.
4
4
6
5
4
2
1
6
8
3
7
7
5
A
Disassembly
Holdthegripandrmlypullouttheropetostart.
Rocker arm cover breather system
The crankcase breather system is located inside the rocker arm cover
1. Check that diaphragm 2 is intact ; wash with Diesel oil and blow
through the small mesh element 4 with compressed air.
When reassembling x box 3 with Loctite " Form-a- gasket  No. 6"
and screw plate 5.
To assemble decompression lever 7, insert spring 6 (positioned as in
gure)ontheleverpin,consideringthatthespringclipshouldbein-
serted in hole 8.
Rocker arm cover - Breather recirculation
Caution – Warning
Always check the the spring 3 and valve 2 to make sure they are
in a good conditions.
Crankcase vapor recirculation occurs through duct 4.
Iftheairlterclogs,theincreasedintakevacuumcouldsuckoilthrou-
gh duct 4 into the combustion chamber, causing the engine to ope-
rate 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.
Retcover1 and tighten rocker arm cover to 10 Nm.
Rocker arm cover
Loosen fastening screws A and remove the rocker arm cover.
- 20 - Workshop Manual KD 441_cod. 1.5302.865_2nd ed_ rev. 01.
4
8
9
10
1
2
4
3
5
6
8
8
9
11
10
11
12
13
7
Disassembly
Shroud
Loosen the fastening screws and remove the conveyor.
Whenrettingtightenshroudscrewsto10Nm.
Fuelling/injection circuit
Components:
1  Fuellterreturntube
2  Fuellter
3 Injection pump
4 Injector pump exhaust pipe
5 High pressure line
6 Fuel lift pump
7 Fuel pump suction (to be connected to the tank)
8 Fuel feeding tubes
9 Solenoid valve
10 Injector
11 High pressure line
12 Injector leak-off line
13Mainfueloverowpipe(tobeconnectedtothetank)
Start pulley
Loosen the 3 fastening screws and remove the pulley.
When reassembling, tighten the screws to 23 Nm.
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Kohler KD15-441 User manual

Kohler
Brand
Kohler
Model
KD15-441
Category
Engine
Type
User manual
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