Kohler engines are built to provide safe and longlasting performances but in order to obtain these results. It is essential that the maintenance requirements described in the manual are observed along with the following safety recommendations.
This workshop manual covers repair and service information, technical maintenance instructions, lots of circuits and schematics for Kohler Engines KDW 1603-2204-2204/T, installed on JCB equipment.
The procedures contained in this repair manual have been tested and selected by the manufacturer’s technical experts, and hence are to be recognized as authorized operating methods.
This PDF workshop manual works with Adobe PDF reader and other analogs. With the help of this application, you can easily save, copy and print this manual. Therefore it must always be available, for future reference when required.
This manual was written by the manufacturer to provide technical and repair information to authorized KOHLER after-sales service centers to carry out assembly, disassembly, overhauling, replacement and tuning operations.
Form No. ED0053029180
Models covered:
KDW 1603-2204-2204/T
CHAPTER INDEX
- 1 - MANUFACTURER AND MOTOR IDENTIFICATION DATA
- The identification plate shown in the figure can be found directly on the engine
- Approval data
- Nameplate for EPA rules applied on rocker-arm cap
- Compilation example
- 2 - GENERAL REMARKS AND SAFETY INFORMATION
- General remarks and safety information
- California emission control warranty statement
- Your warranty rights and obligations
- Safety
- Limited 3-year Kohler diesel engine warranty
- General service manual notes
- Glossary and terminology
- Safety regulations
- General safety during operating phases
- Safety and environmental impact
- 3 - TECHNICAL INFORMATION
- Possible causes and troubleshooting
- Technical data
- Performance diagrams
- Overall dimensions
- 4 - MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING
- Routine engine maintenance
- Ordinary maintenance
- Extraordinary maintenance
- Lubricant
- Prescribed lubricant
- Coolant
- Specifications fuel
- 5 - REGULATIONS FOR LIFTING THE ENGINE
- Regulations for lifting the engine
- 6 - DISASSEMBLY/REASSEMBLY
- Recommendations for disassembling and assembling
- Recommendations for overhauls and tuning
- Oil-bath air cleaner
- Oil-bath air cleaner components
- Dry air cleaner
- Dry air components
- Air filter clogging indicator
- Intake manifold
- Exhaust manifold
- "V" belt
- Cooling fan
- Driving pulley (2a P.T.O.)
- Tank
- Flywheel
- Rocker arm cover with vent into the air
- Rocker arm cover with vent into the air
- Rocker arm cover for engines with recirculating vent
- Rocker arm assembly
- Cylinder head
- Valve removal
- Valve spring - Check
- Valve spring - check under load
- Valve material
- Valve guides and cylinder head
- Valve guide insertion, after driving
- Oil seal in the valves guides, (intake and exhaust)
- Valve seats and bore
- Valve recess and sealing surfaces
- Precombustion chamber
- Hydraulic tappet valve control
- Hydraulic diagram for feeding the tappets
- Hydraulic tappet components
- Hydraulic tappet operation
- Injection pump follower
- Cylinders
- Cylinder roughness
- Piston
- Piston availability
- Piston weight
- Piston rings - End gaps
- Piston rings - Clearance between grooves
- Piston rings - Fitting sequence
- Piston - Refitting
- Piston position and clearance
- Cylinder head gasket
- Cylinder head tightening for engines without hydraulic tappets
- Cylinder head tightening steps
- Assembling and tightening the cylinder head on engines with hydraulic tappets
- Connecting rod
- Connecting rod weights
- Connecting rod and piston pin
- Connecting rod alignment
- Piston cooling sprayer
- Connecting rod/piston assemblies
- Center main bearings
- Main bearing caps timing side - flywheel side
- Check clearance between main bearings and journals
- Thrust bearing, oversizes
- Crankshaft endplay
- Crankshaft front and rear oil seal
- Crankshaft timing gear
- Crankshaft lubrication ducts
- Checking main journals and crankpins
- Main bearing and connecting rod big bearing inside diameter (mm)
- Crankshaft for engines with a dynamic equalizer (only four-cylinder engines)
- Dynamic balancer (on request) - Adjustment of clearance between teeth D and ring gear
- Front cover (before the serial number 7366305)
- Front cover (after the serial number 7366306)
- Idler gear and hub
- Speed governor
- Dimensions for injection pump delivery control yoke adjustment
- Camshaft gear - Speed governor counterweights
- Speed governor counter springs
- Frame with idling speed governor spring
- Summary tables of the governor equipment according to the speed variation
- Spring for extra fuel supply at starting
- Camshaft
- Camshaft removal
- Checking camshaft bushing internal diameter
- Camshaft journals and bushings in model KDW 1603
- Camshaft journals and bushings in models KDW 2204-2204/T
- Camshaft bushing replacement
- Intake, exhaust and injection cam height for the engine with hydraulic tappets
- Camshaft timing
- Valve timing without considering timing marks
- Valve timing check
- Engines with hydraulic tappets
- Camshaft endplay
- Hydraulic pump P.T.O.
- GR 1 and GR 2 hydraulic pump 3rd P.T.O.
- 7 - TURBOCHARGER
- Turbocharger
- Turbocharger components
- Turbocharger Testing
- Checking actuator setting - "Waste Gate" valve control rod stroke adjustment
- 8 - LUBRICATION SYSTEM
- Oil pump
- Oil pump rotor clearance
- Oil pressure adjusting valve
- Oil filter cartridge
- Oil pressure check
- Oil pressure curve for KDW 1603
- Oil pressure curve for KDW 2204
- Oil pressure curve for KDW 2204/T
- 9 - COOLING SYSTEM
- Expansion tank and cap
- Checking for cooling system leaks
- Coolant circulating pump
- Thermostat
- 10 - FUEL SYSTEM
- Fuel filter
- Fuel feeding pump
- Fuel feeding pump drive rod protrusion
- Electric fuel pump (24V)
- Injection pump
- Injection pump disassembly
- How to reassemble injection pump components
- Injection pump non-return valve
- Injection pump control rod
- How to remove injection pump feeding tubes
- How to reassemble injection pump feeding tubes
- The instrument for equalizing injection pump delivery - Part No. 7104-1460-090
- Injection pump delivery equalization
- Test data of injection pump
- Injection pump P. No. 6590-249 - Plunger and barrel assembly
- Checking injection pump delivery
- Checking low-pressure injection timing for engines with hydraulic tappets
- Checking low-pressure injection timing for engines with mechanical tappets
- Injection timing correction by changing the pad thickness
- The injector (pin type)
- Injector setting
- 11 - ELECTRIC SYSTEM
- Wiring diagram with alternator 12V 45A / 65A / 80A
- Recommended batteries
- Alternator type Marelli AA 125 R 14V 45A
- Characteristic curves for alternator type Marelli AA 125 R 14V 45A
- Characteristic voltage curve for regulator type RTT 119 AC
- Alternator type Marelli AA 125 R 14V 65A
- Characteristic curves for alternator type Marelli AA 125 R 14V 65A
- Characteristic voltage curve for regulator type RTT 119 AC
- Alternator type Iskra, AAK3139 14V 80A
- Characteristic curves for alternator type Iskra, AAK3139 14V 80A
- Characteristic voltage curve for regulator type AER 1528
- Starting Motor 12V
- Characteristic curves for starting motor type Bosch EV 12V 2.2 kW
- Wiring diagram 24V with alternator 35A
- Recommended batteries
- Alternator type Iskra, type AAK3570 28V 35A - (for 24 V outfits)
- Characteristic curves for alternator type AAK3570 28V 35A (for 24 V outfits)
- Characteristic voltage curve for regulator type AER 1528
- Starting Motor 24V
- Characteristic curves for starting motor Iskra type AZE 4598 24V 3 kW
- Spacer flange for starter motor
- Connection diagram for preheating control unit
- Glow plug controller relay with coolant temperature sensor
- Pre-heating glow plug
- Temperature sensor (Thermistor)
- Coolant high-temperature lamp switch
- Thermistor for an electric thermometer
- Thermistor for preheating water temperature - Thermal contact for water temperature indicator light
- 12 - SETTINGS
- Idling speed setting in no-load conditions (standard)
- Full speed setting in no-load conditions (standard)
- Standard injection pump delivery setting without torque dynamometer
- Injection pump delivery limiting and torque adjusting device
- Fuel limiting device (fig. 208-209)
- Fuel limiting device adjustment (fig. 208-209)
- Stop setting
- Application diagram for tampering system adjustment screw and torque gearing device for EPA-approved engines
- 13 - ENGINE STORAGE
- Engine storage
- Protective treatment
- Preparing the engine for operation after protective treatment
- 14 - TORQUE SPECIFICATIONS AND USE OF SEALANT
- Main torque specifications
- Table of tightening torques for standard screws (coarse thread)
- Table of tightening torques for standard screws (fine thread)
- 15 - SPECIAL TOOLS
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