JCB Engines Agco Sisu Kohler KDW 1603 – 2204 – 2204T Workshop Manual
FILE DETAILS:
JCB Engines Agco Sisu Kohler KDW 1603 – 2204 – 2204T Workshop Manual
Fomat: PDF
Language: English
Brand: JCB
Type of machine: Engines Agco Sisu Kohler KOW 1603 – 2204 – 2204/T
Type of document: Workshop Manual
Model: 9806-4065
Page of number: 108
VIDEO PREVIEW OF THE MANUAL:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
JCB Engines Agco Sisu Kohler KDW 1603 – 2204 – 2204T Workshop Manual
PREFACE:
- Every attempt has been made to present within this service manual, accurate and up to date technical information. However, development on the KOHLER series is continuous. Therefore, the information within this manual is subject to change without notice and without obligation.
- The information contained within this service manual is the sole property of KOHLER. As such, no reproduction or replication in whole or part is allowed without the express written permission of KOHLER.
Information presented within this manual assumes the following:
1 – The person or people performing service work on KOHLER series engines is properly trained and equipped to safely and professionally perform the subject operation;
2 – The person or people performing service work on KOHLER series engines possesses adequate hand and KOHLER 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 information regarding the subject service operations and fully understands the operation at hand.
- This manual was written by the manufacturer to provide technical and operating information to authorised KOHLER after-sales service centres to carry out assembly, disassembly, overhauling, replacement and tuning operations.
- As well as employing good operating techniques and observing the right timing for operations, operators must read the information very carefully and comply with it scrupulously.
- Time spent reading this information will help to prevent health and safety risks and financial damage. Written information is accompanied by illustrations in order to facilitate your understanding of every step of the operating phases.
TABLE OF CONTENTS:
JCB Engines Agco Sisu Kohler KDW 1603 – 2204 – 2204T Workshop Manual
1 – MANUFACTURER AND MOTOR IDENTIFICATION DATA 10
The identification plate shown in the figure can be found directly on the engine10
Approval data10
Name plate for EPA rules applied on rocker-arm cap11
Compilation example11
2 – GENERAL REMARKS AND SAFETY INFORMATION 12
General remarks and safety information12
California emission control warranty statement13
Your warranty rights and obligations13
Safety14
Limited 3 year kohler
diesel engine warranty15
General service manual notes15
Glossary and terminology15
Safety regulations16
General safety during operating phases17
Safety and environmental impact 17
3 – TECHNICAL INFORMATION18
Possible causes and trouble shooting18
Technical data21
Performance diagrams 22
Overall dimensions 25
4 – MAINTENANCE – RECOMMENDED OIL TYPE – REFILLING 28
Routine engine maintenance 28
Ordinary maintenance 28
Extraordinary maintenance 28
Lubricant 29
Prescribed lubricant 30
Coolant31
Specifications fuel31
5 – REGULATIONS FOR LIFTING THE ENGINE 32
Regulations for lifting the engine 32
6 – DISASSEMBLY/REASSEMBLY34
Recommendations for disassembling and assembling 34
Recommendations for overhauls and tuning 34
Oil-bath air cleaner 35
Oil-bath air cleaner components 35
Dry air cleaner 35
Dry air components 36
Air filter clogging indicator 36
Intake manifold 37
Exhaust manifold 37
“V” belt 37
Cooling fan 37
Driving pulley (2a PTO) 38
Tank 38
Flywheel 38
Rocker arm cover with vent into the air 39
Workshop Manual KDW 1603_2204_2204/T _ cod ED0053029180 – 1° ed_rev 00
Rocker arm cover with vent into the air 39
Rocker arm cover for engines with recirculating vent 39
Rocker arm assemly 40
Cylinder head 40
Valve removal 40
Valve spring – Check41
Valve spring – check under load41
Valve material41
Valve guides and cylinder head41
Valve guide insertion, after driving42
Oil seal in the valves guides, (intake and exhaust)42
Valve seats and bore 43
Valve recess and sealing surfaces 43
Precombustion chamber 44
Hydraulic tappet valve control 44
Hydraulic diagram for feeding the tappets 44
Hydraulic tappet components: 44
Hydraulic tappet operation 45
Injection pump follower 45
Cylinders 46
Cylinder roughness 46
Piston 46
Piston availability 46
Piston weight47
Piston rings – End gaps 47
Piston rings – Clearance between grooves47
Piston rings – Fitting sequence47
Piston – Refitting 48
Piston position and clearance 48
Cylinder head gasket 48
Cylinder head tightening for engines without hydraulic tappets 49
Cylinder head tightening steps 49
Assembling and tightening the cylinder head on engines with hydraulic tappets 49
Connecting rod 50
Connecting rod weights 50
Connecting rod and piston pin 50
Connecting rod alignment51
Piston cooling sprayer51
Connecting rod/piston assemblies51
Center main bearings 52
Main bearing caps timing side – flywheel side 52
Check clearance between main bearings and journals 53
Thrust bearing, oversizes 54
Crankshaft end play 54
Crankshaft front and rear oil seal 55
Crankshaft timing gear 55
Crankshaft lubrication ducts 55
Checking main journals and crank pins 56
Main bearing and connecting rod big bearing inside diameter (mm) 56
Crankshaft for engines with dynamic equalizer (only four-cylinder engines) 57
Dynamic balancer (on request) – Adjustment of clearance between teeth D and ring gear A 57
Front cover (before the serial number 7366305) 58
Front cover (after the serial number 7366306) 58
Idler gear and hub 58
Speed governor 59
Dimensions for injection pump delivery control yoke adjustement 59
Camshaft gear – Speed governor counter weights 60
Speed governor counter springs 60
Frame with idling speed governor spring 60
Summary tables of the governor equipment according to the speed variation61
Spring for extra fuel supply at starting61
Camshaft61
Camshaft removal61
Checking camshaft bushing internal diameter 62
Camshaft journals and bushings in model KDW 1603 62
Camshaft journals and bushings in models KDW 2204-2204/T 62
Workshop Manual KDW 1603_2204_2204/T _ cod ED0053029180 – 1° ed_rev 00
Camshaft bushing replacement 62
Intake, exhaust and injection cam height for engine with hydraulic tappets 63
Camshaft timing 64
Valve timing without considering timing marks 64
Valve timing check 64
Engines with hydraulic tappets 65
Camshaft end play 66
Hydraulic pump PTO 66
GR 1 and GR 2 hydraulic pump 3rd PTO 66
7 – TURBOCHARGER 68
Turbocharger 68
Turbocharger components 68
Turbocharger Testing 68
Checking actuator setting – “Waste Gate” valve control rod stroke adjustment 69
8 – LUBRICATION SYSTEM 70
Oil pump71
Oil pump rotor clearance71
Oil pressure adjusting valve71
Oil filter cartridge71
Oil pressure check 72
Oil pressure curve for KDW 1603 72
Oil pressure curve for KDW 2204 72
Oil pressure curve for KDW 2204/T 72
9 – COOLING SYSTEM 74
Expansion tank and cap75
Checking for cooling system leaks75
Coolant circulating pump75
Thermostat75
10 – FUEL SYSTEM 76
Fuel filter 77
Fuel feeding pump 77
Fuel feeding pump drive rod protrusion 77
Electric fuel pump (24V) 78
Injection pump 78
Injection pump disassembly 78
How to reassemble injection pump components 79
Injection pump non-return valve 79
Injection pump control rod 79
How to remove injection pump feeding tubes 79
How to reassemble injection pump feeding tubes 80
Instrument for equalizing injection pump delivery – Part No 7104-1460-090 80
Injection pump delivery equalization 80
Test data of injection pump81
Injection pump P No 6590-249 – Plunger and barrel assembly81
Checking injection pump delivery81
Checking low pressure injection timing for engines with hydraulic tappets 82
Checking low pressure injection timing for engines with mechanical tappets 83
Injection timing correction by changing the pad thickness 83
Injector (pin type) 84
Injector setting 84
Workshop Manual KDW 1603_2204_2204/T _ cod ED0053029180 – 1° ed_rev 00
11 – ELECTRIC SYSTEM 86
Wiring diagram with alternator 12V 45A / 65A / 80A 86
Recommended batteries 87
Alternator type Marelli AA 125 R 14V 45A 88
Characteristic curves for alternator type Marelli AA 125 R 14V 45A 88
Characteristic voltage curve for regulator type RTT 119 AC 88
Alternator type Marelli AA 125 R 14V 65A 89
Characteristic curves for alternator type Marelli AA 125 R 14V 65A 89
Characteristic voltage curve for regulator type RTT 119 AC 89
Alternator type Iskra, AAK3139 14V 80A 90
Characteristic curves for alternator type Iskra, AAK3139 14V 80A 90
Characteristic voltage curve for regulator type AER 1528 90
Starting Motor 12V91
Characteristic curves for starting motor type Bosch EV 12V 22 kW91
Wiring diagram 24V with alternator 35A 92
Recommended batteries 93
Alternator type Iskra, type AAK3570 28V 35A – (for 24 V outfits) 94
Characteristic curves for alternator type AAK3570 28V 35A (for 24 V outfits) 94
Characteristic voltage curve for regulator type AER 1528 94
Starting Motor 24V 95
Characteristic curves for starting motor Iskra type AZE 4598 24V 3 kW 95
Spacer flange for starter motor 95
Connection diagram for preheating control unit 96
Glow plug controller relay with coolant temperature sensor 96
Pre-heating glow plug 96
Temperature sensor (Thermistor) 97
Coolant high temperature lamp switch 97
Thermistor for electric thermometer 98
Thermistor for preheating water temperature – Thermal contact for water temperature indicator light 98
12 – SETTINGS 100
Idling speed setting in no-load conditions (standard) 100
Full speed setting in no-load conditions (standard) 100
Standard injection pump delivery setting without torque dynamometer 100
Injection pump delivery limiting and torque adjusting device 100
Fuel limiting device (fig 208-209)101
Fuel limiting device adjustment (fig 208-209)101
Stop setting101
Application diagram for tampering system adjustment screw and torque gearing device for EPA-approved engines101
13 – ENGINE STORAGE 103
Engine storage 103
Protective treatment103
Preparing the engine for operation after protective treatment103
14 – TORQUE SPECIFICATIONS AND USE OF SEALANT 104
Main torque specifications 104
Table of tightening torques for standard screws (coarse thread) 105
Table of tightening torques for standard screws (fine thread) 105
15 – SPECIAL TOOLS 106
PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.