Kohler KD477-2 Workshop Manual Download Page 4

Page: 4 / 48

- 4 -

KD 477-2 Workshop Manual_cod. ED0053029370_

1° ed

_ rev.

INDEX

WARRANTY CERTIFICATE ..................................................................................................................................... 3

Limited 3 year kohler® diesel engine warranty .................................................................................................................. 3

California emission control warranty statement ................................................................................................................. 3

Your warranty rights and obligations .................................................................................................................................. 3

I - TROUBLE SHOOTING ......................................................................................................................................... 7

Possible causes and trouble shooting ............................................................................................................................... 7

II - SAFETY AND WARNING DECALS - SAFETY INSTRUCTIONS ....................................................................... 8

Safety regulations ............................................................................................................................................................... 8

General safety during operating phases ............................................................................................................................ 9

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

III - MODEL NUMBER AND IDENTIFICATION ...................................................................................................... 10

The identification plate shown in the figure can be found directly on the engine. .............................................................10

Approval data .....................................................................................................................................................................10

IV - TECHNICAL DATA .......................................................................................................................................... 11

V - CHARACTERISTICS ......................................................................................................................................... 12

Characteristics power, torque and specific fuel consumption curves ...............................................................................12

VI - OVERALL DIMENSIONS ................................................................................................................................. 13

VII - SPECIAL TOOLS ............................................................................................................................................. 14

VIII - MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING ..................................................................... 15

Manutenance .....................................................................................................................................................................15

Fuel ....................................................................................................................................................................................15

Recommended oil ..............................................................................................................................................................16

Acea sequences ................................................................................................................................................................16

IX - DISASSEMBLY OF THE ENGINE .................................................................................................................... 17

Disassembly and reassembly ............................................................................................................................................17

Flywheel extraction ............................................................................................................................................................17

Crankshaft gear extraction ................................................................................................................................................17

Camshaft gear extraction ..................................................................................................................................................17

Oil pressure register valve extraction ................................................................................................................................17

X - CHECKS AND OVERHAUL ............................................................................................................................... 18

Cylinder heads ...................................................................................................................................................................18

Valves - Guides - Seats .....................................................................................................................................................18

Valves and springs ............................................................................................................................................................ 20

Rocker arms ...................................................................................................................................................................... 20

Cylinders ........................................................................................................................................................................... 20

Piston rings - Pistons - Piston pins ....................................................................................................................................21

Connecting rods ................................................................................................................................................................ 22

Crankshaft ......................................................................................................................................................................... 23

Checking crankshaft dimensions ...................................................................................................................................... 23

Camshaft ........................................................................................................................................................................... 24

Injection cam dimensions (fig. 28) .................................................................................................................................... 24

Oil seal rings ..................................................................................................................................................................... 24

Tappet checking ................................................................................................................................................................ 24

Governor lever and spring ................................................................................................................................................ 25

Oil pump checking ............................................................................................................................................................ 25