Name: Kohler RD 441
Brand: Kohler
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Workshop Manual KD 441_cod. 1.5302.865_2

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