Kohler KD440

KD225
KD315
KD350
KD400
KD420
KD440
OWNER’S MANUAL
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Kohler KD440 Specifications

General

Brand	Kohler
Model	KD440
Category	Engine
Language	English

Summary

SAFETY PRECAUTIONS

Accidental Starts

Warning about accidental engine starts causing severe injury or death.

Rotating Parts

Warning about rotating parts causing severe injury.

Lethal Exhaust Gases

Warning about exhaust fumes (CO) causing severe health effects or death.

Hot Parts

Warning about hot engine parts causing severe burns.

Explosive Fuel

Warning about fuel being flammable and its vapors causing explosions.

Explosive Gas

Warning about battery charging producing explosive gas.

High Pressure Fluid Puncture

Warning about high-pressure fluids causing severe injury or death.

Electrical Shock

Warning about electrical components causing shock.

California Proposition 65 Warning

Warning about chemicals in exhaust causing cancer, birth defects, etc.

OVERVIEW OF PERIODIC MAINTENANCE OPERATIONS

AFTER FIRST 50 HOURS OF OPERATION

Maintenance for the initial 50 hours of operation.

Change Oil

Procedure for changing engine oil.

Change Oil Bath Filter

Procedure for changing the oil bath air filter.

ORDINARY MAINTENANCE

Check Oil Level

How to check the engine oil level.

Check Oil Bath Filter

How to check the oil bath air filter.

Check Dry Air Cleaner

How to check the dry air cleaner.

Fuel Tank Cleaning

Procedure for cleaning the fuel tank.

Cleaning Cooling Fins

Procedure for cleaning cooling fins.

REPLACEMENT

Replace Engine Oil

Instructions for replacing engine oil.

Replace Oil Filter

Instructions for replacing the oil filter.

Replace Engine Oil (Large Capacity Oil Sump)

Oil replacement for engines with large capacity oil sump.

Fuel Filter Replacement

Instructions for replacing the fuel filter.

Fuel Filter Replacement (Engines Equipped with Oil Alert System)

Fuel filter replacement for engines with oil alert system.

ENGINE IDENTIFICATION

Model Number

Information about the engine model number.

Serial Number

Information about the engine serial number.

EPA LABEL

EMISSION CONTROL INFORMATION

Details on the engine's emission control information.

PREFACE

GENERAL SERVICE MANUAL NOTES

Notes on using genuine parts, measurement systems, and safety.

SPECIFICATIONS KD225-350

ENGINE MODEL

Technical specifications by engine model.

Oil Capacity

Engine oil capacity specifications.

Dry Weight

Engine dry weight specifications.

ENGINE DIMENSIONS

KD225

Engine dimensions diagram for KD225 model.

KD315 KD350

Engine dimensions diagram for KD315/KD350 models.

SPECIFICATIONS KD400-440

ENGINE MODEL

Technical specifications by engine model (KD400-440).

Oil Capacity

Engine oil capacity specifications.

ENGINE DIMENSIONS

KD400 KD420 KD440

Engine dimensions diagram for KD400/KD420/KD440 models.

PRE-START CHECK

FOR THE FIRST 50 HOURS OF OPERATION, DO NOT EXCEED 70% OF MAXIMUM POWER

Operating limit for the first 50 hours of use.

SAE CLASSIFICATION

SAE Oil Classification Explanation

Explains the SAE oil classification system and its meaning.

ACEA REGULATIONS

GASOLINEDIESEL ENGINE OIL

ACEA classifications for gasoline/diesel engine oil.

LIGHT DUTY DIESEL ENGINE OIL

ACEA classifications for light-duty diesel engines.

HEAVY DUTY DIESEL ENGINE OIL

ACEA classifications for heavy-duty diesel engines.

OIL CLASSIFICATIONS

SAE VISCOSITY GRADE

Chart for SAE viscosity grades based on temperature.

OIL RECOMMENDATIONS

AGIP SUPERDIESEL MULTIGRADE 15 W-40

Recommended AGIP oil for specific models.

AGIP MULTIGRADE 5 W-40

Recommended AGIP oil for specific models.

ENGINE OIL CAPACITY

OIL VOLUME AT MAX LEVEL

Engine oil volume at maximum level.

MAXIMUM OIL VOLUME

Maximum engine oil volume.

FUEL WARNING - REFUELING

DIESEL FUEL

FUEL TYPE

Specifies approved diesel fuel types.

FUELS FOR LOW TEMPERATURES

Recommendations for using fuel in low temperatures.

BIODIESEL FUEL

Guidance on using biodiesel fuel.

AVIATION FUEL

Information on using aviation fuel.

EMPTY FUEL SYSTEM

STARTING

Recoil Starting

Procedure for starting the engine using the recoil starter.

Electric Starting

Procedure for starting the engine using electric start.

INDICATORS DESCRIPTION

Indicator OK

Description of the OK indicator light.

Oil pressure indicator

Description of the oil pressure indicator.

Battery recharge indicator

Description of the battery recharge indicator.

Air filter obstruction indicator

Description of the air filter obstruction indicator.

Oil or cylinder over-temperature indicator

Indicator for engine over-temperature.

Plugs indicator

Indicator for pre-heating/plug status.

Control unit indicator

Indicator for control unit status.

Hour counter display

Information about the hour counter display.

POST START-UP

BREAK-IN PERIOD

Guidelines for the engine break-in period.

PRE-SHUTDOWN

Steps to take before shutting down the engine.

SHUTDOWN

Procedure for shutting down the engine.

SINGLE-LEVER CONTROL STOP MODELS

SNAP SINGLE-LEVER THROTTLE CONTROL MODELS

Throttle control procedures for specific models.

MAINTENANCE

Use only genuine Kohler repair parts.

Emphasizes using genuine Kohler parts for repairs.

Every 250 Hours

Change Oil (Models with Standard Oil Sump)

Oil change procedure for standard oil sump models.

PRESCRIBED LUBRICANT

Recommended lubricants for engine oil.

Every 500 Hours

Replace Internal Oil Filter

Procedure for replacing the internal oil filter.

Change Oil (Models With a Large Capacity Oil Sump)

Oil change for engines with large capacity oil sump.

Fuel Filter Replacement

Fuel Filter Replacement (Engine Models Equipped With Oil Pressure Alert System)

Fuel filter replacement for engines with oil alert system.

Cleaning Fuel Tank

Cleaning Cooling Fins

500-HOUR MAINTENANCE

Adjust KD225-315-350 Rocker Arm Clearance

Adjusting rocker arm clearance for specific engine models.

Clean and Set Injectors

Procedure for cleaning and setting fuel injectors.

Engine Storage

PROTECTIVE TREATMENT

Steps for applying protective treatment for engine storage.

TROUBLESHOOTING

THE ENGINE MUST BE STOPPED IMMEDIATELY WHEN:

Conditions requiring immediate engine shutdown.

The Engine Does Not Start

Troubleshooting steps when the engine does not start.

Starts and Stops

Troubleshooting for intermittent engine operation.

Poor Acceleration

Troubleshooting for poor engine acceleration.

Black Smoke

Troubleshooting for black smoke from exhaust.

White Smoke

Troubleshooting for white smoke from exhaust.

Low Oil Pressure

Troubleshooting for low engine oil pressure.

ELECTRICAL

RECOMMENDED BATTERIES

Recommended battery types and specifications.

Fuel System

Oil Alert System

LIMITED 3 YEAR KOHLER DIESEL ENGINE WARRANTY

MANUFACTURERS WARRANTY COVERAGE

Details on warranty coverage for emission control systems.

OWNERS WARRANTY RESPONSIBILITIES

Owner's responsibilities regarding warranty.

COVERAGE

ORDERING PARTS

Service

Information for obtaining service and spare parts.