Wacker Neuson KOHLER®Diesel KOi 1903 TCR -2504 TCR Workshop Manual – PDF DOWNLOAD
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TABLE OF CONTENTS:
Wacker Neuson KOHLER®Diesel KOi 1903 TCR -2504 TCR Workshop Manual – PDF DOWNLOAD
Accident prevention, Regulations for safety and…………..3
Adjustment “WASTE GATE” valve……………………………..180
Air filter (cartridge replacement)………………………………..178
Alternator belt (replacement and adjustment), Poly-V..165
Assembly and high-pressure pump,
Timing system gear…………………………………………………..134
ASSEMBLY INFORMATION………………………………………..124
Assembly lubrication circuit……………………………………..145
Assembly recommendations……………………………………..124
Assembly, Electric component…………………………………151
Assembly, Cylinder head unit……………………………………136
Assembly, EGR Circuit………………………………………………155
Assembly, Engine block…………………………………………….125
Assembly, Exhaust manifold……………………………………..145
Assembly, Flange unit……………………………………………….133
Assembly, Fuel system……………………………………………..141
Assembly, Intake manifold…………………………………………144
Assembly, Oil sump unit……………………………………………132
Assembly, Turbo-compressor……………………………………150
Assembly, Water circuit…………………………………………….149
B
Balancer shafts (optional), Configurations with…………..48
Balancer shafts (replacement)…………………………………..175
Battery features………………………………………………………….20
Before start-up……………………………………………………………56
C
Check, Oil pump………………………………………………………..123
Circuit, Cooling…………………………………………………………..32
Circuit, Lubrication……………………………………………………..29
Components handling…………………………………………………49
Components, Identification of engine………………………….12
Components,Electrical………………………………………………..43
Configuration (chapter general configuration),
Information on engine………………………………………………..12
Configuration (chapter assembly),
Information on engine……………………………………………….124
Configurations with balancer shafts (optional)…………….48
Connecting rod – piston assembly…………………………….. 118
Coolant (chapter fluids supply)………………………………….161
Coolant (chapter liquid drainage information)……………..64
Coolant……………………………………………………………………….20
Cooling circuit…………………………………………………………….32
Crankcase………………………………………………………………… 112
Crankshaft……………………………………………………………….. 117
Cylinder head unit assembly……………………………………..136
Cylinder head unit disassembly…………………………………100
D
Definitions, Glossary and……………………………………………..9
DIAGNOSTIC INFORMATION……………………………………..191
Diagnostic tool error list……………………………………………192
Diagrams, Performance………………………………………………17
Dimensions, Engine…………………………………………………….16
Disassembly (EGR), Exhaust fumes recycle circuit……..87
Disassembly, Cylinder head unit……………………………….100
Disassembly, Electric components……………………………..88
Disassembly, Engine block………………………………………..105
Disassembly, Exhaust manifold…………………………………..92
Disassembly, Flange unit…………………………………………..100
Disassembly, Injection circuit……………………………………..97
Disassembly, Intake manifold……………………………………..96
Disassembly, Lubrication circuit…………………………………94
Disassembly, Oil sump unit……………………………………….104
Disassembly, Recommendations for……………………………87
Disassembly, Timing system gear……………………………….99
Disassembly, Turbocharger…………………………………………91
Disassembly, Water recirculation components……………92
E
EGR Circuit assembly……………………………………………….155
EGR valve replacement……………………………………………….74
Electric component assembly……………………………………151
Electric components disassembly………………………………88
CHAPTER INDEX
Electric system……………………………………………………………38
Electrical components………………………………………………..43
Electronic injector replacement…………………………………..66
Engine block assembly……………………………………………..125
Engine block disassembly…………………………………………105
Engine dimensions……………………………………………………..16
Engine identification, Manufacturer and………………………10
Engine oil (chapter liquid drainage information)…………65
Engine oil (chapter fluids supply)………………………………161
Engine pulley and phonic wheel assembly…………………148
Engine pulley and phonic wheel disassembly……………..93
Engine specifications………………………………………………….14
Engine starting after storage………………………………………62
Engine storage (over 6 months)…………………………………..62
Engine storage (up to 6 months)………………………………….62
Engine, Intended use of the…………………………………………..3
Environmental impact, Safety and……………………………….59
EPA regulations, Name plate for………………………………….11
Error list, Diagnostic tool………………………………………….192
Exhaust circuit, Intake and………………………………………….35
Exhaust fumes recycle circuit disassembly (EGR)……….87
Exhaust manifold assembly………………………………………145
Exhaust manifold disassembly……………………………………92
F
Features, Battery………………………………………………………..20
Filter (cartridge replacement), Air………………………………178
Flange unit assembly………………………………………………..133
Flange unit disassembly……………………………………………100
FLUIDS SUPPLY INFORMATION………………………………..161
Foreword, Introduction…………………………………………………3
Fuel…………………………………………………………………………….19
Fuel filter replacement………………………………………………..85
Fuel system………………………………………………………………..22
Fuel system assembly……………………………………………….141
G
Gear (for 3rd / 4th PTO), Idler……………………………………….168
GENERAL INFORMATION……………………………………………..9
General remarks………………………………………………………….56
Glossary and Definitions………………………………………………9
H
Handling, Components……………………………………………….49
Heater (replacement)…………………………………………………164
High-pressure pump replacement……………………………….69
High-pressure pump, Timing system gear
assembly and……………………………………………………………134
I
Identification of engine components……………………………12
Idler gear (for 3rd / 4th PTO)…………………………………………168
INFORMATION ABOUT FAILURES……………………………..188
INFORMATION ABOUT OPTIONAL COMPONENTS…….163
INFORMATION FOR REPLACING THE
FUNCTIONAL UNITS……………………………………………………66
INFORMATION ON ADJUSTMENTS……………………………180
Information on engine configuration
(chapter assembly)……………………………………………………124
Information on engine configuration
(chapter general configuration)……………………………………12
Information on resources used in graphics software
POLAR-XL…………………………………………………………………194
Information and safety signals…………………………………….59
Injection circuit disassembly………………………………………97
Injector replacement, Electronic………………………………….66
Intake and exhaust circuit……………………………………………35
Intake manifold assembly………………………………………….144
Intake manifold disassembly……………………………………….96
Intended use of the engine……………………………………………3
Introduction – Foreword………………………………………………..3
INTRODUCTION – FOREWORD……………………………………..3
L
LIQUID DRAINAGE INFORMATION………………………………64
Location of safety signals on engine…………………………..60
Lubrication circuit……………………………………………………….29
Lubrication circuit disassembly…………………………………..94
M
Maintenance, Periodic…………………………………………………21
Manufacturer and engine identification……………………….10
N
Name plate for EPA regulations…………………………………..11
O
Oil (chapter liquid drainage information), Engine………..65
Oil (chapter fluids supply), Engine…………………………….161
Oil……………………………………………………………………………….18
Oil cooler unit and oil filter replacement………………………83
Oil dipstick in cylinder head………………………………………163
Oil filter (disassembly and assembly), Remote…………..178
Oil filter replacement, Oil cooler unit and…………………….83
Oil pressure valve replacement…………………………………..81
Oil pump check…………………………………………………………123
Oil pump replacement…………………………………………………78
Oil sump unit assembly……………………………………………..132
Oil sump unit disassembly………………………………………..104
Oil vapour separator replacement……………………………….82
P
Performance diagrams………………………………………………..17
Periodic maintenance………………………………………………….21
Phonic wheel assembly, Engine pulley and………………..148
Phonic wheel disassembly, Engine pulley and…………..148
Phonic wheel replacement…………………………………………..76
Piston assembly, Connecting rod……………………………… 118
POLAR-XL, Information on resources used in graphics
software……………………………………………………………………194
Poly-V alternator belt (replacement and adjustment)….165
Poly-V belt, Tightening pulley and alternator for………..166
Possible causes and trouble shooting……………………….188
Precautions, Safety…………………………………………………….56
Preservation, Product…………………………………………………62
Product preservation…………………………………………………..62
R
Recommendations for disassembly…………………………….87
Recommendations for overhauls and tuning…………….. 111
Recommendations, Assembly…………………………………..124
Regulations for safety and accident prevention…………….3
Remarks, General……………………………………………………….56
Remote oil filter (disassembly and assembly)……………178
Replacement, Electronic injector…………………………………66
Replacement, Fuel filter………………………………………………85
Replacement, High-pressure pump……………………………..69
Replacement, Oil cooler unit and oil filter……………………83
Replacement, Oil pressure valve…………………………………81
Replacement, Oil pump……………………………………………….78
Replacement, Oil vapour separator……………………………..82
Replacement, Phonic wheel………………………………………..76
Replacement, Unit EGR cooler…………………………………….73
Replacement, Water pump…………………………………………..75
Rreplacement, EGR valve……………………………………………74
S
Safety and environmental impact………………………………..59
Safety signals, information and…………………………………..59
SAFETY INFORMATION………………………………………………56
Safety precautions………………………………………………………56
Safety signals……………………………………………………………..60
Safety signals description…………………………………………..58
Safety signals on engine, Location of………………………….60
Scrapping……………………………………………………………………..3
Sensors and switches…………………………………………………41
Shafts (replacement), Balancer………………………………….175
Signals description, Safety………………………………………….58
Signals, Safety……………………………………………………………60
MO KDI 1903_2504 TCR _ cod. ED0053029590 – 2° ed_rev. 01 7
EN
CHAPTER INDEX
Specifications, Engine………………………………………………..14
Start-up, Before…………………………………………………………..56
Storage (over 6 months), Engine………………………………….62
Storage (up to 6 months), Engine………………………………..62
STORAGE INFORMATION……………………………………………62
Summary table of tightening torques and
the use of sealants…………………………………………………….158
Switches, Sensors and………………………………………………..41
System, Electric………………………………………………………….38
System, Fuel……………………………………………………………….22
T
Tappet housings, Tappets and………………………………….. 116
Tappets and tappet housings……………………………………. 116
Tappets, Timing system and………………………………………..45
TECHNICAL INFORMATION…………………………………………14
Tightening pulley and alternator for Poly-V belt…………166
Timing system and tappets…………………………………………45
Timing system gear assembly and
high-pressure pump………………………………………………….134
Timing system gear disassembly………………………………..99
TOOLS INFORMATION………………………………………………182
Trouble shooting, Possible causes and……………………..188
Tuning, Recommendations for overhauls and…………… 111
Turbocharger disassembly………………………………………….91
Turbo-compressor………………………………………………………50
Turbo-compressor assembly…………………………………….150
U
Unit EGR cooler replacement………………………………………73
Use of sealants, Summary table of tightening
torques and the…………………………………………………………158
W
Water circuit assembly………………………………………………149
Water pump replacement…………………………………………….75
Water recirculation components disassembly……………..92
“WASTE GATE” valve, Adjustment…………………………….180
3rd PTO (replacement / installation)…………………………….169
4th PTO (replacement / installation)…………………………….171
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
S.M