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Workshop Manual KD 441_cod. 1.5302.865_2

ed_ rev.

01.

30-01-2009

28-05-2009

CUSE/ATLO

2°

REGISTRATION OF MODIFICATIONS TO THE DOCUMENT

Any modifications 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

Summary of Contents for RD 441

Page 1: ...15 LD 441 KD 441 SERVICE MANUAL cod 1 5302 865 _ 2nd ed _rev 01 HORIZONTAL CRANKSHAFT...

Page 2: ......

Page 3: ...e 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 infor...

Page 4: ...09 CUSE ATLO 2 01 REGISTRATION OF MODIFICATIONS TO THE DOCUMENT Any modifications to this document must be registered by the drafting body by completing the following table Drafting body Document code...

Page 5: ...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 oper...

Page 6: ...embly 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 Remov...

Page 7: ...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 p...

Page 8: ...s 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 a...

Page 9: ...turning 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 insufficient ventilation GENERAL SAFETY DURING OPERATING PH...

Page 10: ...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 TR...

Page 11: ...placement 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 A...

Page 12: ...wer 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...

Page 13: ...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 C D E F G H I J K L M N O P Q S R T OVERALL DIME...

Page 14: ...first 1000 km ORDINARY MAINTENANCE CLEANING CHECK REPLACEMENT Dry air cleaner Cylinder cooling fins Fuel filter primary Lube oil level Valves gap Water presence in the fuel filter Fuel lines pipes In...

Page 15: ...pecification 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...

Page 16: ...roper 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 regula...

Page 17: ...only clean fresh commercial grade diesel fuel Diesel fuels that satisfy the following specifications are suitable for use in this engine ASTM D 975 1D or 2D EN590 IS 1460 or equivalent FUELS FOR LOW...

Page 18: ...every variations to functional system Optimisation must be carried out beforehand at KOHLER testing centres Non approval by KOHLER of any modifications releases the company from any damages incurred...

Page 19: ...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 g...

Page 20: ...omponents 1 Fuel filter return tube 2 Fuel filter 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 tub...

Page 21: ...ystem Disassembly Loosen the outlet union of the injection pump and remove it Remove the injector exhaust pipe from the main fuel overflow pipe Disconnect the diesel fuel filter exhaust pipe and remov...

Page 22: ...ump Loosen the fastening screw between the diesel fuel filter and the so lenoid valve Remove the fuel supply circuit complete with solenoid valve filter and fuel pump Injector Loosen screw A and remov...

Page 23: ...y removing up to 0 2 mm thickness Always replace the seal see fig 130 131 on page 55 for the correct thickness For overhaul and cylinder head checks see page 33 Connecting rod Loosen the 4 fastening s...

Page 24: ...e the piston to the B D C Loosen the screws of the cap on the connecting rod big end In T D C position the cylinder and the piston will be lifted as shown in the figure Insert the two nylon bars F und...

Page 25: ...ankshaft 7 Rotate the crankshaft to release the connecting rod 8 Using a nylon bar keep the connecting rod shaft lifted and move the bar of the special tool from the upper hole to the lower hole Conne...

Page 26: ...the bar outwards so as to place the connecting rod shaft on the crankshaft and make the upper connecting rod half bearing accessible 10 Using the nylon bar push on a half bearing side and disconnect...

Page 27: ...tes to a temperature of 300 C max Fit the rim into the flywheel housing make sure that it rests evenly against the support of the housing itself Allow it to slowly cool Timing cover Disassemble the oi...

Page 28: ...or gear Components 1 Spool spacer 2 Spool 3 Weights 4 Spool guide 5 Gear 6 Oil pump driving shaft 7 Circlip 8 Thrust ring Remove drive rod 2 forcing the clamping teeth on rod collar 4 and the clearanc...

Page 29: ...3 2 1 1 9 Disassembly Loosen the fastening screws and remove oil pump cover 1 Oil pump Components 1 Cover 2 Oil pump driving shaft 3 Key 4 Pin 5 Internal rotor 6 External rotor Remove governor lock te...

Page 30: ...op Manual KD 441_cod 1 5302 865_2nd ed_ rev 01 4 49 48 4 2 3 50 5 Disassembly Remove oil pump drive shaft 2 with pin 3 Remove internal rotor 4 Remove outside rotor 5 For overhaul and oil pump checks s...

Page 31: ...31 Workshop Manual KD 441_cod 1 5302 865_2nd ed_ rev 01 Notes...

Page 32: ...use steam or hot water Do not use flammable products petrol diesel etc to degrease or wash components Use special products Dry all washed surfaces and components thoroughly with a jet of air or specia...

Page 33: ...d press down firmly as indicated in the figure Valves characteristics Intake valve A Weld Joint Chrome Plated Chrome Plated Base Material X 70 Cr Mn Ni N21 6 UNI 3992 Base Material X 45 Cr Si 8 UNI 39...

Page 34: ...lation to the block surface Dimensions mm Valves guides and housings Dimensions mm 1 Intake guide 2 Exhaust guide Note Valve guides with outer diameters increased by 0 5 mm are also available as spare...

Page 35: ...and remove the valve guides Legend 1 Exhaust valve seat 2 Intake valve seat 3 Exhaust valve guide 4 Intake valve guide B Valve guide valve seat pressing tool intake valve p n 1460 338 C Valve guide v...

Page 36: ...mponents 1 Valve stem 2 Oil seal 3 Spring washer set 4 Spring 5 Cap 6 Half collets Caution Warning To reassembly half collets place a suitable plate under the valve head and press down firmly as indic...

Page 37: ...ld be machined with the plateau method Piston Remove circlips and piston pin Measure diameter Q at the A distance from the skirt bottom A 12 mm Replace the piston and piston rings if wear on the diame...

Page 38: ...ing oil scraper Piston rings play between the slots mm Replace the piston or piston rings if the value exceeds the maximum limit Piston rings assembly order A 1st Nitrided plated piston ring B 2nd pis...

Page 39: ...to prevent the drive shaft from breaking Radius R that joins the crankpin to the supports is 3 3 3 7 mm Radius R1 that joins the main journal to the timing gear is 1 5 mm Crankshaft lubrication ducts...

Page 40: ...in and main journal are 0 25 0 50 and 1 mm Crankshaft Main bearing big end and crankshaft bearing inter nal diameters and relevant clearances Caution Warning The gears must be mounted with the right t...

Page 41: ...hrust washer re placement Legend 1 Thrust washer on timing cover side 2 Thrust washer on crankcase side 3 Bearing on timing cover side 4 Bearing on crankcase side D Assembly extraction tool for timing...

Page 42: ...on tool D on bearing 4 Operate the press remove bearing 4 and then thrust washer 2 pla ced inside the crankcase Crankcase bearing Reassembly Caution Warning Thoroughly wash the crankcase thrust washer...

Page 43: ...eal pressing tool flyweel side p n 1460 328 K Oil seal pressing tool PTO side gearbox extension p n 1460 346 H Roller bearing assembly disassembly and PTO side oil seal pres sing tool gearbox extensio...

Page 44: ...the reference ridge on the gearbox extension Place oil seal ring assembly tool K on oil seal ring 2 Operate the press to assemble the oil seal ring Repeat these operations for the second oil seal ring...

Page 45: ...haft pin housing dia meters Limit Limit Camshaft cam height mm Note Replace camshaft if cam wear exceeds the minimum given va lue of H H1 and H2 by 0 1 mm Camshaft pin and housing dimensions and relev...

Page 46: ...e 21 before S 58 after I 80 before I 33 after S Timing valve angles for checking To check the timing valve angles set the valve clearance to 0 zero measure the angles achieved when the valve lift is 2...

Page 47: ...47 Workshop Manual KD 441_cod 1 5302 865_2nd ed_ rev 01 Notes...

Page 48: ...d assemblies before installing them The operator must make sure that the contact surfaces are intact lubricate the coupling parts and protect those that are prone to oxidation RECOMMENDATIONS FOR REAS...

Page 49: ...ricating generously in order to avoid risks of seizure at the first start When reassembling make sure pins A on the connecting rod big end cap are in line with holes B on the connecting rod shaft Ring...

Page 50: ...ete with gasket po sitioning flow control 1 in the fork of lever 5 which should be in the maximum flow position Caution Warning When removing the injection pump from its housing make sure that spacer...

Page 51: ...t Caution Warning Lubricate the camshaft bearing on the crankcase Match the reference tip on crankshaft gear A with the 2 ones on camshaft gear B see circled area 1 Insert the camshaft Equalizer shaft...

Page 52: ...spacer 2 Spool 3 Weights 4 Spool guide 5 Gear 6 Oil pump driving shaft 7 Circlip 8 Thrust ring Assemble oil pump cover 1 and tighten the screws alternately to 10 Nm Insert oil pump drive shaft 2 toget...

Page 53: ...liquid sealant Loctite 5205 Carefully clean the two sealing surfaces and spread the sealant uniformly Tighten screws to 23 Nm Caution Warning Wait 3 hours before starting again the engine Assemble gov...

Page 54: ...the crankshaft Push and pull the driving shaft on the flywheel side End play should be 0 05 0 25 mm it is not adjustable In case of excessive clearance replace the clearance shims Gearbox extension in...

Page 55: ...f these four readings to get the precise measurement of the protrusion between the piston and the cylinder head base plane Choose the appropriate gasket according to the following table Assessing head...

Page 56: ...nuts in the same order to 30Nm 4th phase tighten all nuts in the same order with further rotation of 90 Tighten the 2 side nuts M6 to 10 Nm Flywheel Danger Attention During the assembly phase pay par...

Page 57: ...on at the TDC Loosen lock nut A while locking lock nut B in its position as shown in the figure Rocker arm cover Replace the seal and assemble the rocker arm cover by tightening the 3 screws A to a to...

Page 58: ...rication oil can influence the performances and life of an engine Use of an inferior quality oil or failure to regularly change the oil will increase the risk of piston seizure will cause the piston r...

Page 59: ...nternal strainer Placed inside the bottom cap see figure Oil pressure regulation valve Components 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...

Page 60: ...essure curve at full rotation speed The curve is obtained with engine running at 3600 r p m at the N po wer pressure is given in bar and temperature in centigrades The curve represents the minimum pre...

Page 61: ...61 Workshop Manual KD 441_cod 1 5302 865_2nd ed_ rev 01 Notes...

Page 62: ...hile the automatic adjustment pressure is 0 5 0 7 bars FUEL SYSTEM Fuelling injection circuit Components 1 Fuel filter return tube 2 Fuel filter 3 Injection pump 4 Injector pump exhaust pipe 5 High pr...

Page 63: ...west point of travel Protrusion A of drive rod 3 is 1 5 1 9 mm it is not adjustable Replace the drive rod if it does not comply with tolerance Drive rod length 70 8 80 0 mm Fuel system Fuel lift pump...

Page 64: ...plete with gasket po sitioning flow control 1 in the fork of lever 5 which should be in the maximum flow position Caution Warning When removing the injection pump from its housing make sure that space...

Page 65: ...g 4 Gasket 5 Delivery valve 6 Gasket 7 Spring retainer 8 Spring 9 Sleeve 10 Rack 11 Piston pumping element 12 Pin A Fuel exhaust union screw with non return valve B Fuel inlet union screw C Fastening...

Page 66: ...ipe from injection pump outlet 1 2 In its place assemble a clear nylon hose 2 as shown in the figure 3 Insert a metal wire protruding about 10 mm into the hose to allow an easier check of fuel leaks 4...

Page 67: ...ywheel Reference in degrees between B and C recorded to 3600 rpm Injection advance adjustment To alter the value of injection advance the pad must be replaced with another of a suitable thickness see...

Page 68: ...edle valve 10 Tip 11 Duct 12 Return hole After re assembly tighten ring nut 8 to a 50 Nm torque value Fuel system Bar filter Bar filter A is a filter inside the injector inlet union If obstructed repl...

Page 69: ...een the needle and the guide must leave the needle free to fall and merely as a result of its own weight when lifted 7mm from its seat and rotated in different directions with the nozzle kept at a 45...

Page 70: ...ity of not less than 44 Ah 210 Amp of fast discharge intensity Alternator charger graph 12V 17A This test has been carried out after thermal stabilization at 20 C for 2 minutes at 3000 r p m with cons...

Page 71: ...he tabs are in different sizes to prevent incorrect connections Caution Warning When the engine is running do not disconnect battery cables or switch key to off position Do not place the governor near...

Page 72: ...from the battery positive pole Connect a d c voltmeter between the battery poles Fit an ammeter between the positive pole and the B on voltage regu lator Start and stop the engine a several times unt...

Page 73: ...eel rim surface to starter motor flange surface Note Contact Bosch service centers for repair operations Ignition switch positions A Accessory B Off C On D Start Characteristic curves for starting mot...

Page 74: ...on the pin With a special fork tool matr 1460 341 take the min max assembly as shown in the front and top figure pin lock ring Accelerator lever for speed governor with min max speed system A Interna...

Page 75: ...ting the slow idle standard rotation speed After having filled the engine with oil and fuel start it and allow it to warm up for 10 minutes Using adjuster screw 1 regulate the idling rate at 1000 1250...

Page 76: ...means of nut A and conse quently the injection pump delivery will increase under the specified set torque value Injection pump delivery approximate setting This regulation must be carried out by means...

Page 77: ...pecifications see below If consumption is not as indicated change balance conditions at the torque dynamometer by varying the load and adjusting the governor Under stable engine conditions check consu...

Page 78: ...otective treatment 1 Pour in the engine housing AGIP RUSTIA C protective oil up to the maximum level 2 Fill up with fuel containing 10 AGIP RUSTIA NT 3 Start the engine and keep it idle at minimum spe...

Page 79: ...movement and smoothness of the mechanical parts 7 Refill the tank with fresh fuel 8 Make sure that the oil is up to the maximum level 9 Start the engine and after some minutes bring it to of the maxim...

Page 80: ...over M8 fixing screws for air filter support and intake manifold Rocker arm fulcrum screws Stator screws Base coupling surface cover Tappet contact cam TYPE OF SEALANT MAIN TORQUE SPECIFICATIONS Re co...

Page 81: ...1 5 M 14x1 5 M 16x1 5 M 18x1 5 M 18x2 M 20x1 5 M 20x2 M 22x1 5 M 24x2 M 27x2 M 30x2 R 400N mm2 R 500N mm2 R 600N mm2 R 800N mm2 R 1000N mm2 R 1200N mm2 Nm 10 21 20 36 38 56 84 122 117 173 164 229 293...

Page 82: ...clamping tool SPECIAL TOOLS DESCRIPTION Part N SPECIAL TOOLS Flywheel puller Timing tool Gasket selection tool Bancer shaft bearing pressing tool Bancer shaft bearing extractor tool Oil seal pressing...

Page 83: ...bly Special tools Oil seal protection tool flywheel side Fuel pipe assembly tool SPECIAL TOOLS DESCRIPTION Part N Nylon bars Assembly extraction tool for timing cover side bearing and for crankcase si...

Page 84: ...L Plot No J 2 1 MIDC Industrial Area Chikaltana AURANGABAD 431210 Maharashtra INDIA Tel 91 240 2471415 Fax 91 0240 2486234 E MAIL marketing lombardini it FORM NO 1 5302 865 ISSUED 30 01 2009 REVISED...

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