Kohler KD 477-2

WORKSHOP MANUAL
KD 477-2

Kohler KD 477-2 Specifications

General

Brand	Kohler
Model	KD 477-2
Category	Engine
Language	English

Summary

Document Modification Registration

Preface and Introduction

Warranty Information

Limited 3-Year Diesel Engine Warranty

Details the manufacturer's warranty coverage for diesel engines.

California Emission Control Warranty

Explains emission control system warranty rights and obligations in California.

Trouble Shooting Guide

Safety Instructions and Warnings

Safety Regulations and General Notes

General safety rules for operating and maintaining the engine safely.

Safe Operating Procedures

Guidelines for safe operation during various phases and personnel training.

Environmental Impact and Safety

Minimizing environmental impact and adhering to safety protocols.

Model Number and Identification

Technical Data Overview

Engine Characteristics

Key engine specifications including bore, stroke, and displacement.

Engine Performance Characteristics

Power, Torque, and Fuel Consumption Curves

Graphical data on engine power, torque, and fuel efficiency at different speeds.

Overall Dimensions

Special Tools

Maintenance and Refilling Guidelines

Maintenance Schedule

Periodic maintenance tasks and intervals based on operating hours.

Fuel Recommendations

Guidance on fuel types, quality, and tank capacity.

Lubricant Specifications

Recommended oil types, grades, viscosity, and ACEA sequences.

Engine Disassembly Procedures

General Disassembly and Reassembly

Basic steps for engine disassembly and reassembly.

Flywheel Extraction

Procedure for safely removing the engine flywheel.

Gear Extraction (Crankshaft & Camshaft)

Steps for removing crankshaft and camshaft gears.

Oil Pressure Register Valve Extraction

Procedure for extracting the oil pressure register valve.

Component Checks and Overhaul

Cylinder Head and Valve Checks

Inspection of cylinder heads, valves, guides, and seats for wear.

Piston, Ring, and Connecting Rod Inspection

Checking pistons, rings, pins, connecting rods, and their clearances.

Crankshaft and Camshaft Condition

Inspection of crankshaft and camshaft journals for wear.

Auxiliary Component Checks

Inspection of oil seals, tappets, governor, and oil pump.

Injection Equipment

Fuel Circuit and Injection Pump Overview

Description of the fuel system and the injection pump.

Injection Pump Checks and Assembly

Procedures for checking, setting, and reassembling the injection pump.

Injector Checks and Setting

Testing and adjusting fuel injectors for proper opening pressure.

Electrical Equipment

Starting and Charging System

Characteristics of starter, alternator, and battery charging system.

Electrical Circuit Checks

Procedures for checking electrical circuits, alternator, and wiring.

Wiring Diagrams

Diagrams for electric starting systems with flywheel and external alternators.

Engine Assembly Procedures

Crankcase and Crankshaft Preparation

Preparing the crankcase and crankshaft for engine assembly.

Camshaft and Governor Assembly

Steps for assembling the camshaft, governor, and related parts.

Major Component Installation

Fitting oil seals, oil pump, feeding pump, and connecting rods.

Piston and Cylinder Assembly

Fitting piston rings, cylinders, and checking heights.

Cylinder Head and Injection System Fitting

Installing cylinder heads, checking valve clearance, and fitting injection pump.

Injection Timing and Start Check

Connecting injection pump tie rod and checking static injection timing.

Engine Testing Procedures

Speed Adjustment

Steps for adjusting engine minimum and maximum speeds.

Oil Pressure Checks

Procedure to measure and verify engine oil pressure.

Oil Leak Detection

Methods to detect oil leaks within the engine.

Brake Testing and Running-in

Procedures for testing engine performance and running-in.

Engine Storage and Preparation

Storage Procedures

Steps for preparing the engine for long-term storage.

Preparation for Operation After Storage

Instructions to ready the engine for use after it has been stored.

Quick Reference Charts

Component Clearances and Specifications

Tables for couplings, adjustments, and end float specifications.

Tightening Torque Specifications

Detailed tables for component and screw tightening torques.