Kohler KDW 1603 Workshop Manual
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Kohler KDW 1603 Workshop Manual

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WORKSHOP MANUAL
KDW 1603 - 2204 - 2204/T

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Summary of Contents for Kohler KDW 1603

  • Page 1 WORKSHOP MANUAL KDW 1603 - 2204 - 2204/T...
  • Page 3 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.
  • Page 4 REGISTRATION OF MODIFICATIONS TO THE DOCUMENT Any modifications to this document must be registered by the drafting body, by completing the following table. Drafting Document Model Review Edition Revision Issue date Endorsed body code N° date CUSE/ATLO 0053029180 51223 1° 02_15_2011 02_15_2011 - 4 - - 4 - Workshop Manual KDW 1603_2204_2204/T _ cod. ED0053029180 - 1° ed_rev. 00...

  • Page 5: Table Of Contents

    The identification plate shown in the figure can be found directly on the engine. .............10 Approval data ..................................10 Name plate for EPA rules applied on rocker-arm cap .......................11 Compilation example .................................11 2 - GENERAL REMARKS AND SAFETY INFORMATION ..................12 General remarks and safety information ...........................12 California emission control warranty statement ........................13 Your warranty rights and obligations ..........................13 Safety ....................................14 Limited 3 year kohler diesel engine warranty........................15 General service manual notes ............................15 Glossary and terminology ..............................15 Safety regulations ................................16 General safety during operating phases ...........................17 Safety and environmental impact .............................17 3 - TECHNICAL INFORMATION ..........................18 Possible causes and trouble shooting ..........................18 Technical data .
  • Page 6 Chapter index 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 - Check ................................41 Valve spring - check under load ............................41 Valve material ..................................41 Valve guides and cylinder head ............................41 Valve guide insertion, after driving ............................42 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 .
  • Page 7 Chapter index 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 P.T.O. ............................... 66 GR 1 and GR 2 hydraulic pump 3rd P.T.O........................66 7 - TURBOCHARGER ............................. 68 Turbocharger..................................68 Turbocharger components ..............................68 Turbocharger Testing .
  • Page 8 Chapter index 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 12V ................................91 Characteristic curves for starting motor type Bosch EV 12V 2.2 kW ................91 Wiring diagram 24V with alternator 35A ...........................
  • Page 9 Workshop Manual KDW 1603_2204_2204/T _ cod. ED0053029180 - 1° ed_rev. 00 - 9 - - 9 -...

  • Page 10: Manufacturer And Motor Identification Data

    MANUFACTURER AND MOTOR IDENTIFICATION DATA The identification plate shown in the figure can be found directly on the engine. It contains the following information: A) Manufacturer’s identity B) Engine type C) Engine serial number D) Maximum operating speed E) Number of the customer version (form K) F) Approval data Approval data The approval reference directives EC are on the engine plate ( F ). - 10 - - 10 - Workshop Manual KDW 1603_2204_2204/T _ cod. ED0053029180 - 1° ed_rev. 00...

  • Page 11: Name Plate For Epa Rules Applied On Rocker-Arm Cap

    Manufacturer and motor identification data Name plate for EPA rules applied on rocker-arm cap Compilation example 1) Model year. 2) Engine displacement. 3) Power category, kW. 4) Particulate emission limit (g/kWh). 5) Engine family ID. 6) Kind of application i.e. 7) Injection timing (BTDC). 8) Injector opening pressure (bar). 9) Production date (example 2012_Jan). 10) Emission Control System = ECS. Workshop Manual KDW 1603_2204_2204/T _ cod. ED0053029180 - 1° ed_rev. 00 - 11 - - 11 -...

  • Page 12: General Remarks And Safety Information

    GENERAL REMARKS AND SAFETY INFORMATION General remarks and safety information To ensure safe operation please read the following statements and understand their meaning. Also refer to your equipment manufacturer's manual for other important safety information. This manual contains safety precautions which are explained below. Danger – Attention This indicates situations of grave danger which, if ignored, may seriously threaten the health and safety of individuals. Caution – Warning This indicates that it is necessary to take proper precautions to prevent any risk to the health and safety of individuals and avoid finan- cial damage.

  • Page 13: California Emission Control Warranty Statement

    Your off-road, diesel engine emission control system is covered under warranty for a period of five (5) years or 3,000 hours, whichever occurs first, beginning on the date the engine or equipment is delivered to an ultimate purchaser for all constant speed engines with maximum power 19≤kW<37 and rated speed less than 3,000 rpm, all variable speed engines with maximum power 19≤kW<37, and all variable or constant speed engines with maximum power greater than 37 kW. Your off-road, diesel engine emission control system on variable or constant-speed engines with maximum power less than 19 kW, and for constant speed engines with maximum power 19≤kW<37 and rated speed equal to or greater than 3,000 rpm is covered under warranty for a period of two (2) years or 1,500 hours, whichever occurs first. If any emission related part on your engine is defective, the part will be repaired or replaced by Kohler Co. OWNER’S WARRANTY RESPONSIBILITIES: As the heavy-duty off-road engine owner, you are responsible for the performance of the required maintenance listed in your Kohler Co. owner’s manual. Kohler Co. recommends that you retain all receipts covering maintenance on your heavy-duty off-road engine, but Kohler Co. cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all recommended scheduled maintenance. As the heavy-duty off-road engine owner, you should however be aware that Kohler Co. may deny you warranty coverage if your heavy-duty off- road engine or emission control related component has failed due to abuse, neglect, improper maintenance or unapproved modifications. Your engine is designed to operate on commercial diesel fuel (No. 1 or No. 2 low sulfur or ultra low sulfur diesel fuel) only. Use of any other fuel may result in your engine no longer operating in compliance with California’s emissions requirements. You are responsible for initiating the warranty process. The Air Resources Board suggests that you present your heavy-duty off-road engine to a Kohler Co. dealer as soon as a problem exists. The warranty repairs should be completed by the dealer as expeditiously as possible.

  • Page 14: Safety

    General remarks and safety information Safety Explanation of the safety pictograms that can be found on the engine or in the Operation and Maintenance handbook Read the Operation and Maintenance handbook before Use protective gloves before carrying out the operation performing any operation on the engine Use protective glasses before carrying out the operation High temperature components - Danger of scalding Use sound absorbing protections before carrying out the operation Electric shock - Danger of severe scalding or death Presence of rotating parts - Danger of entangling and cutting Fluids under high pressure - Danger of fluids penetration Presence of explosive fuel - Danger of fire or explosion Lethal exhaust gas - Danger of poisoning or death Presence of steam and pressurized coolant - Danger of scalding Indications regarding the points on the engine where the safety pictograms are placed - 14 - - 14 - Workshop Manual KDW 1603_2204_2204/T _ cod. ED0053029180 - 1° ed_rev. 00...

  • Page 15: Limited 3 Year Kohler Diesel Engine Warranty

    ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044 GENERAL SERVICE MANUAL NOTES 1 - Use only genuine Kohler repair parts. 2 - All data presented are in metric format. That is, dimensions Failure to use genuine Kohler parts could result in sub- are presented in millimeters (mm), torque is presented in standard performance and low longevity. Newton-meters (Nm), weight is presented in kilograms (Kg), volume is presented in liters or cubic centimeters (cc) and pressure is presented in barometric units (bar).

  • Page 16: Safety Regulations

    GENERAL NOTES . Children and animals must be kept at a sufficient distance . Kohler engines are built to provide safe and longlasting from the machine to prevent any danger resulting from its performances, but in order to obtain these results it is operation.

  • Page 17: General Safety During Operating Phases

    . In order to move the engine simultaneously use the eyebolts fitted for this purpose by Kohler. These lifting points are however not suitable for the entire machine, so in this case use the eyebolts fitted by the manufacturer.

  • Page 18: Technical Information

    TECHNICAL INFORMATION POSSIBLE CAUSES AND TROUBLE SHOOTING THE ENGINE MUST BE STOPPED IMMEDIATELY WHEN: 1) - The engine rpms suddenly increase and decrease 2) - A sudden and unusual noise is heard 3) - The colour of the exhaust fumes suddenly darkens 4) - The oil pressure indicator light turns on while running. TABLE OF LIKELY ANOMALIES AND THEIR SYMPTOMS The following table contains the possible causes of some failures which may occur during operation. Always perform these simple checks before removing or replacing any part. TROUBLE POSSIBLE CAUSE Obstructed fuel line Fuel filter clogged Air or water leaks in fuel system The tank cap vent hole is clogged No fuel Discharged battery Cable connection uncertain or incorrect Faulty starting switch Faulty starting motor...
  • Page 19 Technical information TROUBLE POSSIBLE CAUSE Damaged injector Injection pump valve damaged Injector not adjusted Faulty fuel feeding pump Hardened pump control rod Broken or loose supplementary start-up spring Worn or damaged pumping element Incorrect tuning of injection components (delivery balancing advance) Cracked or broken precombustion chamber Oil level too high Oil level low Oil pressure valve blocked or dirty Worn oil pump Oil sump suction line clogged Faulty pressure gauge or pressure switch Blocked draining pipe Faulty spray nozzles (Turbo engines only). Blocked draining pipe Alternator fan belt loose or torn Clogged radiator exchange surface Insufficient coolant Fault fan, radiator or radiator plug Faulty thermostatic valve Blockage inside the radiator or the coolant ducts Coolant leaking from radiator, hoses, the crankcase or from the water pump Faulty or worn water pump Workshop Manual KDW 1603_2204_2204/T _ cod. ED0053029180 - 1° ed_rev. 00 - 19 - - 19 -...
  • Page 20 Technical information ..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... - 20 - - 20 - Workshop Manual KDW 1603_2204_2204/T _ cod.

  • Page 21: Technical Data

    35° 35° Max. 60 seconds 25° 25° 25° Max inclination Lasting up to 30 seconds Permanent 1-3-2 1-3-4-2 1-3-4-2 Firing Order Referred to max. N power At NA power *** Depending on the application KDW 2204/T KDW 1603 KDW 2204 Workshop Manual KDW 1603_2204_2204/T _ cod. ED0053029180 - 1° ed_rev. 00 - 21 - - 21 -...

  • Page 22: Performance Diagrams

    Technical information PERFORMANCE DIAGRAMS CHARACTERISTICS POWER, TORQUE AND SPECIFIC FUEL CONSUMPTION CURVES KDW 1603 N (80/1269/CEE - ISO 1585) AUTOMOTIVE RATING: intermittent operation with variable speed and variable load. NB (ISO 3046 - 1 IFN) RATING WITH NO OVERLOAD CAPABILITY: Continuous light duty operation with constand speed and variable load. NA (ISO 3046 - 1 ICXN) CONTINUOUS RATING WITH OVERLOAD CAPABILITY: continuous heavy duty with constant speed and constant load.
  • Page 23 C: Specific fuel consumption curve (NB curve) Max. power tolerance is 5%. Power decreases by approximately 1% every 100 m altitude and by 2% every 5°C above 25°C. Engine power can be influenced by the type of coupling used with the cooling fan. Important Non-approval by Kohler for any modifications releases the company from any damages incurred by the engine. Note: Consult KOHLER for power, torque curves and specific consumptions at rates differing from those given above. Workshop Manual KDW 1603_2204_2204/T _ cod. ED0053029180 - 1° ed_rev. 00 - 23 - - 23 -...
  • Page 24 Technical information ..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... - 24 - - 24 - Workshop Manual KDW 1603_2204_2204/T _ cod.

  • Page 25: Overall Dimensions

    Technical information OVERALL DIMENSIONS KDW 1603 Note : Dimensions shown in mm DIMENSIONS mm 215.7 356.4 233 max 147.5 99.6 231.3 250.2 283.3 425.2 154.2 187.5 Workshop Manual KDW 1603_2204_2204/T _ cod. ED0053029180 - 1° ed_rev. 00 - 25 - - 25 -...
  • Page 26 Technical information KDW 2204 TAPPO SCARICO ACQUA WATER DRAIN PLUG TAPPO SCARICO OLIO OIL DRAIN PLUG Note : Dimensions shown in mm DIMENSIONS mm 187.5 233 156.5 356.3 231.3 154.2 215.7 99.6 425.2 283.3 - 26 - - 26 - Workshop Manual KDW 1603_2204_2204/T _ cod. ED0053029180 - 1° ed_rev. 00...
  • Page 27 Technical information KDW 2204/T Note : Dimensions shown in mm DIMENSIONS mm 166.7 186.3 224.8 233.1 156.5 153.5 386.1 168.7 373.2 452.5 133.5 190.5 468.1 Workshop Manual KDW 1603_2204_2204/T _ cod. ED0053029180 - 1° ed_rev. 00 - 27 - - 27 -...

  • Page 28: Maintenance - Recommended Oil Type - Refilling

    MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING ROUTINE ENGINE MAINTENANCE Caution – Warning Failure to carry out the operations described in the table may lead to technical damage to the machine and/or system. ORDINARY MAINTENANCE AFTER THE FIRST 50 WORKING Engine oilreplacement.

  • Page 29: Lubricant

    Maintenance - Recommended oil type - Refilling LUBRICANT SAE Classification n the SAE classification, oils differ on the basis of their viscosity, and no other qualitative characteristic is taken SAE 10W* into account. SAE 20W* The first number refers to the viscosity when the engine SAE 30* is cold (symbol W = winter), while the second considers viscosity with the engine at régime.

  • Page 30: Prescribed Lubricant

    Maintenance - Recommended oil type - Refilling PRESCRIBED LUBRICANT API CF - SH ACEA B3-B4 AGIP SINT 2000 TURBODIESEL 5W40 specifications MIL - L-2104 C MIL-L-46152 D In the countries where AGIP products are not available, use oil API CF/SH for Diesel engines or oil corresponding to the military specification MIL-L-2104 C/46152 D. CHD ENGINES OIL CAPACITY Sheet STD oil sump. ENHANCED aluminium oil sump. Sheet STD oil sump. ENHANCED aluminium oil sump. * With dynamic balancer Important If you are using oil of a quality lower than the prescribed one then you will have to replace it every 125 hours for the standard sump and every 150 hours for the enhanced sump.

  • Page 31: Coolant

    The anti-freeze protection liquid (AGIP ANTIFREEZE SPEZIAL) must be used mixed with water, preferably decalcified. The freezing point of the cooling mixture depends on the product concentration in water, it is therefore recommended to use a 50% diluted mixture which guarantees a certain degree of optimal protection. As well as lowering the freezing point, the permanent liquid also raises the boiling point. Prescribed coolant. Coolant refueling ENGINE TYPE 50% AGIP ANTIFREEZE SPEZIAL CAPACITY (Litres) Without radiator 50% Water For information concerning the capacity of Kohler radiators, please contact Kohler directly. The total volume for refilling the cooling liquid varies according to the type of engine and radiator. SPECIFICATIONS FUEL Purchase diesel fuel in small quantities and store in clean, approved containers. Clean fuel prevents the diesel fuel injectors and pumps from clogging. Do not overfill the fuel tank. Leave room for the fuel to expand. Immediately clean up any spillage during refueling. Never store diesel fuel in galvanized containers; diesel fuel and the galvanized coating react chemically to each other, producing flaking that quickly clogs filters or causes fuel pump or injector failure. High sulfur content in fuel may cause engine wear. In those countries where diesel has a high sufur content, its is advisable to lubricate the engine with a high alkaline oil or alternatively to replace the lubricating oil recommended by the manufacturer more frequently. The regions in which diesel normally has a low sulfur content are Europe, North America, and Australia.

  • Page 32: Regulations For Lifting The Engine

    REGULATIONS FOR LIFTING THE ENGINE Regulations for lifting the engine Important - Before removing the engine from the vehicle on which it is installed, disconnect the power supply, detach the fuel and coolant supply, and all connections including the mechanical ones. - Attach the engine to a suitable lifting device (lifting beam).
  • Page 33 Regulations for lifting the engine ..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

  • Page 34: Disassembly/Reassembly

    DISASSEMBLY/REASSEMBLY RECOMMENDATIONS FOR DISASSEMBLING AND ASSEMBLING Important To locate specific topics, the reader should refer to the index. – Besides disassembly and reassembly operations this chapter also includes checking and setting specifications, dimensions, repair and operating instructions. – Always use original KOHLER spare parts for proper repair operations. – The operator must wash, clean and dry components and assemblies before installing them. – The operator must make sure that the contact surfaces are intact, lubricate the coupling parts and protect those that are prone to oxidation. – Before any intervention, the operator should lay out all equipment and tools in such a way as to enable him to carry out operations correctly and safely. – For safety and convenience, you are advised to place the engine on a special rotating stand for engine overhauls. – Before proceeding with operations, make sure that appropriate safety conditions are in place, in order to safeguard the operator and any persons involved. – In order to fix assemblies and/or components securely, the operator must tighten the fastening parts in a criss-cross or alternating pattern.

  • Page 35: Oil-Bath Air Cleaner

    Disassembly / Reassembly Oil-bath air cleaner Danger – Attention Never clean the filtering element 6 using solvents with a highly flash point. This could cause an explosion ! Caution – Warning During repair operations, when using compressed air, wear eye protection. Check gaskets and replace if necessary.

  • Page 36: Dry Air Components

    Disassembly / Reassembly Dry air components 1 Main cartridge 2 Safety cartridge 3 Axial cover 4 Vacuator valve 5 Cap complete with clamp 6 Rubber connecting hose to the air filter - manifold or compressor. 7 Air filter restriction switch 8 Mounting for clogging indicator 9 Fastener Scavenging valve 4 must be positioned as in figure 4. The cartridge can be cleaned by blowing compressed air breadthways outside and inside the cartridge, at a pressure not greater than 5 atmospheres, or in necessity case by knocking the front of the cartridge several times against a flat surface.

  • Page 37: Intake Manifold

    Disassembly / Reassembly Intake manifold The sealing surface should be clean, smooth and free of any strains and scoring. When reassembly replace gasket A.  Tighten the fastening screws to 25 Nm. Exhaust manifold Danger – Attention Allow the exhaust manifold to cool before demounting it in order to prevent scorching and burns. Verify that the seal surfaces are free of distortions and scratches and that the manifold is not broken in any way.

  • Page 38: Driving Pulley (2A P.t.o.)

    Disassembly / Reassembly Driving pulley (2 P.T.O.) The maximum torque that can be drawn from the second power take-off must be at maximum 70 Nm. The driving pulley drives the alternator and the water pump and consequently the cooling fan. Bolt D can be loosened by turning clockwise. When refitting lubricate the bolt with Molyslip and tighten it at 360 Nm. Tank Danger – Attention To avoid explosions or fire outbreaks, do not smoke or use naked flames during the operations. Fuel vapours are highly toxic.

  • Page 39: Rocker Arm Cover With Vent Into The Air

    Disassembly / Reassembly Rocker arm cover with vent into the air Components: 1 - Decanting device 2 - Oil fill cap 3 - Gasket Inside the decanting device 1 there is a small metal skein that separates the oil from the bled vapours; before reassembling it, clean it and verify its intactness. Important Every time the rocker arm cap is removed replace the gasket 3. Rocker arm cover with vent into the air Components: 1 - Oil fill cap...

  • Page 40: Rocker Arm Assemly

    Disassembly / Reassembly Rocker arm assemly Loosen the screws which fasten the assembly to the head. When refitting apply a drop of Loctite 270 onto the threads.  When refitting tighten to 50 Nm. Inside the rocker arm pin flows the oil that lubricates the rocker arms and feeds the hydraulic tappets. To clean the rocker-arm pin inside, remove the two tightening screws C at the ends (fig. 17). To check the pin and the rocker-arm pin bearings for wear compare the measured values with the parameters in the table below. Table of pin-rocker arm dimensions Dimensions Clearance Ref. Limit value (mm) (mm) (mm) Ø A* 14,032 ÷ 14,050 ØA-ØB = 0,014...

  • Page 41: Valve Spring - Check

    Disassembly / Reassembly Valve spring - Check Check the overall state of the valve springs. Replace if damaged or if they have lost their original elasticity. First of all, use a gauge to check that the free length matches the measurements given below. A = 52 mm Valve spring - check under load Verify (with a dynamometer) that the length under load matches the nominal length. If it is shorter than that quoted in figure 22, replace the spring. Valve material Ref. Dimensions 6,985 ÷ 7,00 mm 35,30 ÷ 35,50 mm 40,30 ÷ 40,50 mm 45° 30' ÷ 45° 45' 60° 30' ÷ 60° 45' Valve guides and cylinder head Intake and exhaust valve guides are both made of gray cast iron with pearlitic and phosphoric matirx. Ref.

  • Page 42: Valve Guide Insertion, After Driving

    Disassembly / Reassembly Valve guide insertion, after driving Press guides considering the L distance from the head plane X. Dimensions Clearance Ref. Limit value Ref. (mm) (mm) (mm) 7,020 ÷ 7,035 0,020 ÷ 7,020 ÷ 7,035 0,100 0,050 36,8 ÷ 37,2 6,985 ÷ 7,00 The referred quote are used to control the X-Y concentricity between the valve seats and guides. Oil seal in the valves guides, (intake and exhaust) To prevent the seal 1 warping when mountig the valve guide 3 put it into the tool 2 part no. 7107-1460-047 and proceed as shown in the figure 27, making sure the seal 1 reaches its stop.

  • Page 43: Valve Seats And Bore

    Valve seats and bore Dimensions Ref. 41,500 ÷ 41,520 mm 41,575 ÷ 41,590 mm 36,500 ÷ 36,520 mm 36,575 ÷ 36,590 α 44° 53' ÷ 45° α 59° 53' ÷ 60° Valve recess and sealing surfaces Ss* = Sealing surface width on exhaust side Sa* = Sealing surface width on intake side H = Valve recess with reference to the head plane Dimensions Limit value Ref. (mm) (mm) S s* 1,27 ÷ 1,55 2,00 S a* 1,20 ÷ 1,60 0,75 ÷ 1,00 1,30 Workshop Manual KDW 1603_2204_2204/T _ cod. ED0053029180 - 1° ed_rev. 00 - 43 - - 43 -...

  • Page 44: Precombustion Chamber

    Disassembly / Reassembly Precombustion chamber The precombustion chamber can be extracted from the head banging with a punch into the hole from the injector housing. This procedure implies irreversible damages to the precombustion chamber which will have to be replaced. In the assembly stage line up the dowel 1 with the reference notch 2 located in the head. Driving must be carried out evenly The clearance allowance between the precombustion chamber and its bore on the cylinder head is equal to 0.05 mm. Using a depth gauge check that the precombustion chamber plane protrusion does not exceed 0.04 and does not receed over 0.02 mm from the head plane level.

  • Page 45: Hydraulic Tappet Operation

    Hydraulic tappet operation The operating principle of the hydraulic tappet is based on the incompressibility of the liquids and on controlled leakage. Through push rod 1, the pressurised oil gets into the tappet in chamber A (low-pressure chamber), maintaining a constant flow of oil in the above chamber as well as in the high-pressure chamber B. The oil can only enter chamber B through the non-return valve 2 and leave through the clearance between the plunger 3 and the tappet body 4 (controlled leakage). Chamber B is refilled when the tappet is on the bottom of the cam base and spring 5 keeps plunger 3 pressed, thus eliminating the clearance in the entire valve-rocker arm-push rod-tappet-cam system.

  • Page 46: Cylinders

    Disassembly / Reassembly Cylinders Reset dial gauge with a calibrated ring. Check diameter size D at 1, 2 and 3; repeat the same operation at the same places after turning the dial gauge by 90°. Check for wear in the X area where piston rings are located. D (mm) Limit value (mm) 88,00 ÷ 88,01 88,100 To check clearance with the matching piston measure the diameter size at Z along the axis which runs at right angles to the driving shaft. Cylinder roughness Important Do not manually hone the cylinder bore surfaces with emery cloth or other means.

  • Page 47: Piston Weight

    Place piston rings into the cylinder and measure end gap A. 1st ring A = 0,30 ÷ 0,50 mm 2nd ring A = 0,30 ÷ 0,50 mm 3rd ring A = 0,20 ÷ 0,50 mm Piston rings - Clearance between grooves Ref. KDW 2204 - 2204/T KDW 1603 0,07 ÷ 0,12 mm 0,02 ÷ 0,08 mm 0,06 ÷ 0,95 mm 0,05 ÷ 0,08 mm 0,05 ÷ 0,08 mm Piston rings - Fitting sequence A* = 1st chrome plated compression ring * B = 2nd tapered compression ring * C = 3rd spiral spring oil scraper ring * The first ring in the TURBO engine is different from the NA- TURALLY ASPIRATED version, it has a trapezoidal cross-sec- tion.

  • Page 48: Piston - Refitting

    Disassembly / Reassembly Piston - Refitting Connect piston to connecting rod after lubricating piston pin and introducing it by exerting pressure with your thumb. Position the two piston pin circlips and check that they are well inside their seats. Using a ring compressor introduce the piston into the cylinder with combustion chamber facing the injection pump side. Piston position and clearance To obtain a clearance of 0.67÷0.90 mm measure protrusion A of all pistons from the cylinder plane and consider the A value of the most protruding piston. Perform this measurement along the engine axis. Cylinder head gasket Caution –...

  • Page 49: Cylinder Head Tightening For Engines Without Hydraulic Tappets

    It is advisable to lubricate the lower part of the screws with anti-seize of the type MOLYSLIP AS COMPOUND 40. Cylinder head tightening steps Following the number sequence shown in the figure 57 bolts should be tightened in four susequent steps with the following KDW 1603 torque values: 1st step = 40 Nm 2nd step = 70 Nm 3rd step = 100 Nm 4th steps = For bolts 10 R: Rotate wrench by 180° (in two...

  • Page 50: Connecting Rod

    Disassembly / Reassembly Tightening must be carried out as shown in figure 59. Once the final torque 50 Nm is reached, wait thirty minutes before manually rotating the engine to verify that the pistons do not collide KDW 1603 with the valves, if the engine turns freely start the engine normally, otherwise wait another 30 minutes before repeating the operation. At first start-up the engine may run irregularly until all the air contained in the tappets has been drained. KDW 2204 2204/T Connecting rod Important When remounting the big-end bearings, remember to thoroughly clean the parts and generously lubricate them to prevent seizure when the engine is started up for the first time.

  • Page 51: Connecting Rod Alignment

    Dimensions Ref. α 3° α 28° 28 mm Connecting rod/piston assemblies The three connecting rod/piston assemblies should be fitted back into their original cylinders. Mark them with references to avoid mistake. Note: The custom at KOHLER is to consider the cylinder on the flywheel side as the first cylinder. Workshop Manual KDW 1603_2204_2204/T _ cod. ED0053029180 - 1° ed_rev. 00 - 51 - - 51 -...

  • Page 52: Center Main Bearings

    Disassembly / Reassembly Center main bearings The main bearing caps and the crankcase have reference holes marked on them (one, two or three). Important In the assembly stage make sure that the number of holes on the bearings matches those on the crankcase and that they are on the same side. Main bearing caps timing side - flywheel side When refitting rear flywheel side main bearing cap 1, replace the rubber gaskets 2 considering that A and B should protrude 0.5÷1.0 mm from the crankase; cut any excess portion.

  • Page 53: Check Clearance Between Main Bearings And Journals

    Disassembly / Reassembly Check clearance between main bearings and journals Use "Perfect Circle Plastigage" A and position it with a few drops of oil at the center of the half bearing.  Tighten bolts to 120 Nm. Determine clearance by measuring the squeezed portion of the plastigage with the indexed scale supplied.  For clearance between main journals, connecting rod big end journals and the corresponding bearings fig 79. Important When replacing bearings make sure that the lower half is kept separate from the upper one.

  • Page 54: Thrust Bearing, Oversizes

    Disassembly / Reassembly Grease the shoulder half-rings so that they will remain in their seats during assembly. Halves should be fitted with grooves A as shown in the figure 77-78. Thrust bearing thickness = 2.31÷2.36 mm; oversize halves with thickness increased by 0.1 and 0.2 mm are available as spares. Thrust bearing, oversizes Grinding B according to the above table, following half-rings can be assembled: Oversize: Half-rings 1 and 2, on both the support sides +0.10 mm. Oversize: Half-rings 1 and 2, on one support side +0.10 mm and on the other side +0.20 mm.

  • Page 55: Crankshaft Front And Rear Oil Seal

    Disassembly / Reassembly Crankshaft front and rear oil seal The front oil seal A is located in the oil pump cover while the rear oil seal ring B, is positioned in the flange on the flywheel side. Replace seals if warped, hardened or damaged. In case of replacement: • Carefully clean the seat. • Soak the seal in engine oil for approximately half an hour. • Fill the inside with grease and lubricate and sealing lip with thick oil.

  • Page 56: Checking Main Journals And Crank Pins

    Disassembly / Reassembly Checking main journals and crank pins Use an outside micrometer gauge. Main journal and connecting rod big end journal diameter Rif. 1603-2204-2204/T Dimensions (mm) 59,981÷60,000 49,984÷50,000 The crakshaft is made of spheroidal graphite cast iron hardened at the level of the oil seal rings 1 and 2. Hardness 55 hrc, hardening depth 0.5÷1.5 mm. Main bearing and connecting rod big bearing inside diameter (mm)  See fig. 73 and 74 for checking procedures. Note: Both main bearing and connecting rod big end bearings are available with inside diameter measuring 0.25 and 0.50 mm.

  • Page 57: Crankshaft For Engines With Dynamic Equalizer (Only Four-Cylinder Engines)

    Disassembly / Reassembly Crankshaft for engines with dynamic equalizer (only four-cylinder engines). The crankshaft comes with seat for the control gear of the counter-rotating shaft dynamic balancer. With centering hole (spring pin). Components: 1 Control gear for counter-rotating shafts 2 Seat for the control gear of counter-rotating shafts 3 Dowel pin Ref. Dimensions (mm) 132,00 ÷ 132,03 132,07 ÷ 132,09 To replace the gear heat it up to 180°÷200°C. Locate it into its seat so that the timing reference marks on the teeth are found on the flyweel side. Dynamic balancer (on request) - Adjustment of clearance between teeth D and ring gear A Follow figures 91 and 92.

  • Page 58: Front Cover (Before The Serial Number 7366305)

    Disassembly / Reassembly Front cover (before the serial number 7366305) To remove front cover 1 bring the 1st cylinder to the top dead center. Remove throttle cover 2 and release spring 3. When refiting replace gasket 4 and 5.  Tighten front cover 1 to 25 Nm. Front cover (after the serial number 7366306) To disassemble the cover 1 rotate the crankshaft until the plug 6 of centering pulley command alternator is located in the upward position.

  • Page 59: Speed Governor

    Disassembly / Reassembly Speed governor Important During reassembly, make sure the components are undamaged and verify they work properly. Malfunctioning of the speed governor can cause serious damage to the engine and to people in the vicinity of it. Components: 1 Gear 2 Bell 3 Counterweights...

  • Page 60: Camshaft Gear - Speed Governor Counter Weights

    Disassembly / Reassembly Camshaft gear - Speed governor counter weights Components: 1 Camshaft gear 2 Governor weights 3 Governor weight support 4 Governor weight pin The governor weights 2 are housed inside the camshaft gear 1. The weights 2 can be of two types: light or heavy, depending on the speed rate and the type of application. Heavy weights for engines set to run at low rpm (1500 - 1800 rpm LIGTH FLYWEIGHT and agricultural applications), light weights for engines set to run HEAVY FLYWEIGHT at high rpm (2200 - 3000 rpm). Speed governor counter springs Besides the weights used according to the speed rate and application type, different types of springs with different features are used as well. Components: 1 Camshaft gear 6 Speed governor springs Components: 1 Limiting device / torque gearing device 2 Maximum rpm adjustment screw 3 Minimum rpm adjustment screw 4 Camshaft gear 5 Governor weight 6 Speed governor spring...

  • Page 61: Summary Tables Of The Governor Equipment According To The Speed Variation

    Disassembly / Reassembly Summary tables of the governor equipment according to the speed variation. KDW 1603 KDW 2204_2204/T Weight type N.Spring Spring serial number Weight type N.Spring Spring serial number 1500 5655370 1500 5655370 Duty Duty 1500 5655154/5655156** 1500 5655154/5655156*...

  • Page 62: Checking Camshaft Bushing Internal Diameter

    Checking camshaft bushing internal diameter Use a bore gauge. If the diameter size does not correspond to the given value remove the bushings using the special tool (pic. 109 and 110) and replace. Camshaft journals and bushings in model KDW 1603 Clearance Worn limit Dimensions (mm) Rif.

  • Page 63: Intake, Exhaust And Injection Cam Height For Engine With Hydraulic Tappets

    Disassembly / Reassembly Intake, exhaust and injection cam height for engine with hydraulic tappets A (mm) S (mm) I (mm) 35,44 ÷ 35,50 35,14 ÷ 35,20 33,95 ÷ 34,00 A1 =1 cyl. intake cam S1 = 1 cyl. exhaust cam I1 = 1 cyl. injection cam A2 = 2 cyl intake cam S2 =2 cyl exhaust cam I2 = 2 cyl injection cam A3 = 3 cyl intake cam S3 = 3 cyl exhaust cam I3 = 3 cyl injection cam A4 = 4 cyl intake cam S4 = 4 cyl exhaust cam...

  • Page 64: Camshaft Timing

    Disassembly / Reassembly Camshaft timing Fit idler gear B by making timing mark 2 coincide with timing mark 1 on the camshaft control gear A and mark 3 with 4 on the timing gear C. Valve timing without considering timing marks Locate piston 1 (on flywheel) at the top dead center. Position two small rods A of the same length onto the tappets. Rotate camshaft stopping when cylinder 1 tappets are in overlap position (intake open exhaust closed). Using the straight edge B check that rods A are at the same length.

  • Page 65: Engines With Hydraulic Tappets

    Disassembly / Reassembly Legend S = piston at top dead centre l = piston at bottom dead centre = intake valve open β = intake valve closed γ = exhaust valve open δ = exhaust valve closed Engines with hydraulic tappets Timing belt operating angles (with valve clearance set to zero) r.p.m. Engine type Exhaust Intake under a = 8° before S γ...

  • Page 66: Camshaft End Play

    Disassembly / Reassembly Camshaft end play Check camshaft end play after removing the cylinder head, the injection and the fuel pumps from the engine. Check that plate 1 is tightened. Position the dial gauge on the camshaft front surface; push and pull the camshaft. Maximum end play should be 0,008 mm (ball bearing end play). Hydraulic pump p.t.o. A = 3rd p.t.o. with hydraulic pump Gr 2. B = 4th p.t.o. with hydraulic pump Gr 1 Hydraulic pumps of either GR 1 or GR 2 type can be fitted, even simultaneously, on the erd and 4th p.t.o. provided the resulting torque does not exceed 40 Nm. The gear ratio between engine r.p.m. and 3rd and 4th p.t.o. is 1:1.
  • Page 67 Disassembly / Reassembly ..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... Workshop Manual KDW 1603_2204_2204/T _ cod.

  • Page 68: Turbocharger

    TURBOCHARGER Turbocharger It is installed on the engine in two versions: with air intake on the flywheel side and with air intake on the fan side. To control the supercharge air pressure, screw the pressure gauge into the M8 holes A and B both for the version with air intake on flywheel side (fig. 120) and for air intake on fan side (fig.121).

  • Page 69: Checking Actuator Setting - "Waste Gate" Valve Control Rod Stroke Adjustment

    turbocharger Checking actuator setting. "Waste gate" valve control rod stroke adjustment Important This test must be done with the engine stationary. Disconnect pipe 7 from the compressor side. Using a T coupling, connect up with a pressure gauge 4 (scale from zero to 2 bar) and with the compressed air mains pipe complete with reduction unit 5. The mains air pressure must be 1.5÷2.0 bar. Make a hole B diameter 1.5 mm in the pressure gauge pipe where part of the air will escape which has the purpose of stabilizing the pressure in the pressure gauge.

  • Page 70: Lubrication System

    LUBRICATION SYSTEM Danger – Attention The engine may be damaged if operated with insufficient lube oil. It is also dangerous to supply too much lube oil to the engine because a sudden increase in engine rpm could be caused by its combustion. Use proper lube oil preserve your engine.

  • Page 71: Oil Pump

    Lubrication system Oil pump Components: 1 Suction port 5 External rotor 2 Delivery port 6 Internal rotor 3 Oil pressure adjusting Valve port 7 Key 4 Gasket The oil pump is driven by the crankshaft via key 7. Rotor 6 is locked in the circumferential but not in the axial direction. This allows the shaft to move axially while rotors 5 and 6 are prevented from damaging the pump sealing surfaces.

  • Page 72: Oil Pressure Check

    Oil pressure check On completing assembly, fill with engine oil and fuel; connect a 10 bar pressure gauge to the pressure switch fitting. Start the engine and check pressure as a function of the oil temperature. Oil pressure curve for KDW 1603 Fig. 134 - The curve is obtained at the oil filter level constant engine speed of 850 rpm in no-load conditions. Fig. 135 - The curve is obtained at the oil filter level with engine working at 3000 rpm at the N power. Oil pressure curve for KDW 2204 Fig. 136 - The curve is obtained at the oil filter level constant...
  • Page 73 Lubrication system Notes : ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................Workshop Manual KDW 1603_2204_2204/T _ cod.

  • Page 74: Cooling System

    COOLING SYSTEM Danger – Attention - The fluid coolant circuit is pressurized. - Inspections must only be made when the engine has cooled and even in this case, the radiator or expansion chamber plug must be unscrewed with the utmost caution. - If an electric fan is installed, do not approach a hot engine since the fan itself could start up even when the engine is at a standstill.

  • Page 75: Expansion Tank And Cap

    In very dusty working conditions verify and clean the outside of the radiator frequently.  Replace coolant as specified on page 22. Coolant circulating pump Impeller 3 and hub 5 are fitted to the shaft by press fit. To remove the impeller, screw the M 18x1.5 bolt into bore 2. To remove that shaft take 4 which locks the bearing to the pump body. A seal is located on the shaft between the bearing and the impeller. In case of worn-out seal, coolant leaks from hole 1. KDW 1603 - 2204: The ratio between the pump and engine rpm = 1:1.2 Pump delivery at 3000 rpm is 70 liters/min. KDW 2204/T: The ratio between the pump and engine rpm = 1:1.5 Pump delivery at 3000 rpm is 116 liters/min. Thermostat 1 - Air valve Specifications: Opening temperature: 77°/81°C Max. stroke at 94°C = 7.5 mm Coolant flow rate with thermostat and valve in closed position = 15 Liters/h.

  • Page 76: Fuel System

    FUEL SYSTEM Danger – Attention To avoid explosions or fire outbreaks, do not smoke or use naked flames during the operations. Fuel vapours are highly toxic. Only carry out the operations outdoors or in a well ventilated place. Keep your face well away from the plug to prevent harmful vapours from being inhaled. Dispose of fuel in the correct way and do not litter as it is highly polluting. When refuelling, it is advisable to use a funnel to prevent fuel from spilling out. The fuel should also be filtered to prevent dust or dirt from entering the tank. Use the same type of diesel fuel as used in cars. Use of other types of fuel could damage the engine. Do not use dirty diesel fuel or mixtures of diesel fuel and water since this would cause serious engine faults. FUEL SYSTEM Components: 1 - Tank 2 - Fuel feeding pump 3 - Fuel filter 4 - Fuel delivery tube 5 - Injector pumps overflow tube 6 - Injection pump 7 - High-pressure tube between pump and injector 8 - Injector 9 - Injector return tube 10 - Solenoid valve - 76 - - 76 - Workshop Manual KDW 1603_2204_2204/T _ cod. ED0053029180 - 1° ed_rev. 00...

  • Page 77: Fuel Filter

    Fuel system Fuel filter Components: 1 - Drain screw 2 - Cover 3 - Seal 4 - Fitting 5 - Cartridge Cartridge specifications Filtering paper:.....PF 904 Filtering area:.......5000 cm2 Filtering degree:....2/3 m Max. working pressure: ..4 bar  See page 22 for maintenance details. Fuel feeding pump Components: 1 - Feeding pump 2 - Push rod 3 - Seal ring The fuel feeding pump is of the diaphragm type operated by a camshaft eccentric through a push rod.

  • Page 78: Electric Fuel Pump (24V)

    Features: Pressure: 0.44 / 0.56 bars Max capacity: 100 l/h Injection pump The injection pump of a simplified Q type has been designed by KOHLER for installation on engines of the KDW 1603-2204- 2204/T series. The injection system includes three or four separate pumps each of which feeds a cylinder. Located on the crankcase at the level of the corresponding cylinder, pumps are directly operated by the camshaft.

  • Page 79: How To Reassemble Injection Pump Components

    Fuel system How to reassemble injection pump components Fit the plunger with helix E directed towards the discharge union B; if it is erroneously fitted with spiral facing the fuel feed union A the injection pump will not operate (thus the possibility of the engine overspeeding is completely ruled out); complete reas- sembly following fig. 154  Tighten delivery union to 35 Nm; it is essential to use a torque wrench. Injection pump non-return valve Tool serial number The discharge union is fitted with a non-return valve A; this 7107.1460.212 valve improves injection by bleeding the air inside the fuel and stops the engine immediately after the stop device is operated.

  • Page 80: How To Reassemble Injection Pump Feeding Tubes

    Fuel system How to reassemble injection pump feeding tubes 1 Pliers for 6 mm diam. tubes (intake) - Part No. 7104-1460- 2 Pliers for 8 mm diam. tubes (discharge) - Part No. 7104- 1460-023 Feeding and discharge tubes are made of nylon; they fit into the injection pump unions by exerting pressure and using special pliers and a plastic hammer.

  • Page 81: Test Data Of Injection Pump

    For this reason both the barrel and plunger 3 should not be replaced. Checking injection pump delivery Components: 1 Delivery adjustment rod 2 Rod 1 stop position 3 Rod 1 max. delivery position A =18.5÷19.5 mm (rod max. stroke) = 66° (rod max. rotation) Test data of injection pump Control rod Rod stroke from KDW 1603-2204 2204/T Camshaft max. force max. delivery Delivery Delivery Newton point (mm) /stroke /stroke 1500 31 ÷ 41...

  • Page 82: Checking Low Pressure Injection Timing For Engines With Hydraulic Tappets

    0,89 lower the piston is with respect to the TDC (top dead centre) in mm. 9° 0,72 Use the transformation chart (mm to degrees) to find out the 8° 0,57 correspondence between mm measured with the dial indicator 5 and degrees. 7° 0,43 Example KDW 1603-2204-2204/T: an advance of a=15° 6° 0,32 corresponds to a lowering of the piston with respect to the TDC 5° 0,22 (top dead centre) of 2,00 mm. 4° 0,14 3° 0,08 - The same operation must be carried out on each pump.

  • Page 83: Checking Low Pressure Injection Timing For Engines With Mechanical Tappets

    Fuel system Checking low pressure injection timing for engines with Injection timing Engine Injection timing value mechanical tappets value for type for r.p.m. ≤ 2400 r.p.m. ≥ 2400 The check of the advance on engines with mechanical tappets KDW 1603 is carried out using the same procedure as that described for the hydraulic tappets; the only difference is in the disassembly and 13° ± 1°...

  • Page 84: Injector (Pin Type)

    Fuel system Injector (pin type) Components: 1 Fuel inlet 7 Delivery union 2 Filter 8 Backflow union 3 Body 9 Setting shims 4 Delivery duct 10 Pressure spring 5 Pad 11 Pressure pin 6 Clamping ring nut 12 Nozzle 13 Fireproof bulkhead Whenever maintenance operations are carried out on the injector replace the seal ring 1. Introduce seal ring 1 into the injector housing with the sealing surface facing upwards (see figure 171).
  • Page 85 Fuel system ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................Workshop Manual KDW 1603_2204_2204/T _ cod. ED0053029180 - 1° ed_rev. 00 - 85 - - 85 -...

  • Page 86: Electric System

    ELECTRIC SYSTEM Wiring diagram with alternator 12V 45A / 65A / 80A Black Pink Black Green White Black Blue Grey Black Black Brown Pink/Black Black Black - 86 - - 86 - Workshop Manual KDW 1603_2204_2204/T _ cod. ED0053029180 - 1° ed_rev. 00...

  • Page 87: Recommended Batteries

    21 Low Fuel Level Switch (N.O.) 22 n. 2 100 ohm resistances in parallel A Accessory B Off Position C On Position D Starting Position Battery 3 is not supplied by KOHLER. Battery not supplied. Ground rubber mounted engines. RECOMMENDED BATTERIES In Standard Start Conditions In Heavy-Duty Start Conditions 12 V - 92 Ah/450 A/DIN 12 V - 110 Ah/500 A/DIN...

  • Page 88: Alternator Type Marelli Aa 125 R 14V 45A

    Electric system Alternator type Marelli AA 125 R 14V 45A Characteristics: Rated voltage ......14V Rated current ......45A Max. speed ........14000 giri/1' Peak speed (max 15 min)..15000 rpm Bearing on control side ....6203.2z Bearing on manifold side ...6201-2z/C3 Voltage regulator .......RTT 119 AC RH direction of rotation.  Tighten the nut 1 to 60 Nm. Note: Lube the two bearings with high temperature grease. The alternator has a W terminal for a speed indicator. Characteristic curves for alternator type Marelli AA 125 R 14V 45A The curves have been detected with electronic voltage regulator after thermal stabilization at 25°C; test voltage 13.5 V.

  • Page 89: Alternator Type Marelli Aa 125 R 14V 65A

    Electric system Alternator type Marelli AA 125 R 14V 65A Characteristics: Rated voltage ......14V Rated current ......65A Max. speed ........14.000 giri/1' Peak speed (max 15 min) ..15.000 rpm Bearing on control side ....6203.2z Bearing on manifold side ...6201-2z/C3 Voltage regulator .......RTT 119 AC RH direction of rotation.  Tighten the nut 1 to 60 Nm. Note: Lube the two bearings with high temperature grease. The alternator has a W terminal for a speed indicator. Characteristic curves for alternator type Marelli AA 125 R 14V 65A The curves have been detected with electronic voltage regulator after thermal stabilization at 25°C; test voltage 13.5 V.

  • Page 90: Alternator Type Iskra, Aak3139 14V 80A

    Electric system Alternator type Iskra, AAK3139 14V 80A Characteristics: Rated voltage ...........14V Rated current ............80A Speed of the load starting point ......1350 rpm Maximum permanent intermittent speed (max. 15') ......13000 -15000 rpm Front bearing ............6303 - 2RS - C3 Rear bearing .............6201 - 2RS - C3 Max. force on the bearing ........ 600 N Voltage regulator ..........AER 1528 RH direction of rotation.  Tighten the nut 1 to 60÷70 Nm. Note: Lube the two bearings with high temperature grease. The alternator has a W terminal for a speed indicator. Characteristic curves for alternator type Iskra, AAK3139 14V 80A The curves have been detected with electronic voltage regulator after thermal stabilization at23 ± 5°C; test voltage 13 V.

  • Page 91: Starting Motor 12V

    Electric system Starting Motor 12V Bosch type EV 12V 2.2 Kw RH direction of rotation. Note: Apply to a Bosch service center for any tipe of repair. Characteristic curves for starting motor type Bosch EV 12V 2.2 kW The solid lines were obtained at a temperature of +20°C; the dotted lines were obtained at a temperature of -20°C.Battery type 110 Ah 450A. U = Motor terminal voltage in Volt n = Motor speed in rpm.

  • Page 92: Wiring Diagram 24V With Alternator 35A

    Electric system Wiring diagram 24V with alternator 35A Black Pink Black Green White Black Blue Grey Black Black Brown Pink/Black Black Black - 92 - - 92 - Workshop Manual KDW 1603_2204_2204/T _ cod. ED0053029180 - 1° ed_rev. 00...

  • Page 93: Recommended Batteries

    20 Low Fuel Level Lamp 21 Low Fuel Level Switch (N.O.) A Accessory B Off Position C On Position D Starting Position Battery 3 is not supplied by KOHLER. Battery not supplied. Ground rubber mounted engines. RECOMMENDED BATTERIES In Standard Start Conditions In Heavy-Duty Start Conditions 12 V - 92 Ah/450 A/DIN 12 V - 110 Ah/500 A/DIN...

  • Page 94: Alternator Type Iskra, Type Aak3570 28V 35A (For 24 V Outfits)

    Electric system Alternator type Iskra, type AAK3570 28V 35A (for 24 V outfits) Characteristics: Rated voltage ..........28V Rated current ..........35A Speed of the load starting point ...... 1140 rpm Maximum permanent intermittent speed (max. 15') ......13000 -15000 rpm Front bearing ..........6303 - 2RS - C3 Rear bearing ........... 6201 - 2RS - C3 Max. force on the bearing ......600 N Voltage regulator ..........AER 1528 RH direction of rotation.  Tighten the nut 1 to 60 ÷ 70 Nm.

  • Page 95: Starting Motor 24V

    Electric system Starting Motor 24V Iskra type AZE 4598 24V 3 kW RH direction of rotation. Characteristic curves for starting motor Iskra type AZE 4598 24V 3 kW The thick lines were obtained at a temperature of +20°C; the thin lines were obtained at a temperature of -20°C. Battery type 55 Ah 300A. U = Motor terminal voltage in Volt n = Motor speed in rpm. A =Absorbed current in Ampere P =Power in kW M = Torque in Nm Spacer flange for starter motor The 24V starter motor requires the assembling of the spacer flange.

  • Page 96: Connection Diagram For Preheating Control Unit

    Electric system Connection diagram for preheating control unit Components: 1 Cable cross-section 2.5 mm at point “50” of the key panel 2 Cable cross-section 6 mm at the fuse holder box 3 Cable cross-section 1.5 mm at the earth 4 Cable cross-section 1 mm at the spark plug warning light (max. 2 W) 5 Cable cross-section 6 mm at point “30” of the key panel 6 Cable cross-section 1 mm at the water temperature sensor 7 Cable cross-section 1.5 mm at the fuse Glow plug controller relay with coolant temperature sensor To avoid white smoke generation at cold start-up, post-heating is maintained for approximately 5 sec. after starting. Trasducer Heating time in seconds Resistance Temperature Pre-heating Pre-heating Starting control Ω...

  • Page 97: Temperature Sensor (Thermistor)

    Electric system Temperature sensor (Thermistor) The thermistor is located on the thermostat housing, adjacent to the high coolant temperature switch. The thermistor must be installed in the thermostat housing in the port located nearest to the cylinder head. (See the figure to the left). Characteristic: Voltage: 6/24 V Max. installation torque: 30 Nm. Features of standard sensor Temperature °C Resistance Ω - 30 9790 ÷ 13940 - 20 6300 ÷ 7700 Features of heavy-duty start sensor - 10 4900 ÷ 3600 2160 ÷ 2640 Temperature Resistance Ω °C + 20 900 ÷ 1100 + 37.7 1125 + 37.7 448 ÷ 672 + 65.5 + 65.5...

  • Page 98: Thermistor For Electric Thermometer

    Electric system Thermistor for electric thermometer Thermistor features Temperature °C Resistance Ω 73806 ÷ 53983 52941 ÷ 39229 20825 ÷ 18006 8929 ÷ 7095 2040 ÷ 1718 589 ÷ 521 205 ÷ 189 +120 85 ÷ 87 Thermistor for preheating water temperature Thermal contact for water temperature indicator light Thermal contact T1 features Temperature °C Resistance Ω 73806 ÷ 53983 52941 ÷ 39229 20825 ÷ 18006 8929 ÷ 7095 2040 ÷ 1718 589 ÷ 521...
  • Page 99 Electric system ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................Workshop Manual KDW 1603_2204_2204/T _ cod. ED0053029180 - 1° ed_rev. 00 - 99 - - 99 -...

  • Page 100: Settings

    SETTINGS Idling speed setting in no-load conditions (standard) After filling with oil, fuel and coolant, start the engine and warm up for 10 minutes. Adjust idling speed at 850÷950 rpm by turning screw 1 then tighten lock nut. Note: Speed decreases when loosening screw 1 and increases when tightening it. Full speed setting in no-load conditions (standard) Before carrying out this operation, make sure that the engine adjustment is standard; i.e. corresponding to one of the power curve diagrams shown on pages 20- 21.

  • Page 101: Fuel Limiting Device (Fig. 208-209)

    Settings Fuel limiting device (fig. 208-209) When starting up the engine the fuel limiting device has the aim of preventing excessive smoke at the exhaust. Use the delivery adjustment rod of the injection pumps 5 Fig.209 in a constant manner when ambient temperature is above 15°C. As the temperature gradually falls, this device gradually lessens its action to then exclude it at 0°C. Fuel limiting device adjustment (fig208-209) • Take the engine to the setting speed and power • Loosen the lock nut 2. • Unscrew the screw 1 (to bring lever 4 close up to rod 5) until the engine speed tends to decrease. • Screw the screw down by at most 1/2, 3/4 of a turn so as to distance lever 4 from rod 5 by 1.2/1.8 mm. Screw down the lock nut 2. • When the temperature falls under 0°C, lever A turns (pin 6 of the thermostat 3 comes back in) to go into position B thereby allowing rod 5 to go into the supplement position. Stop setting • Unscrew the screw 2 •...
  • Page 102 ............................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................- 102 - - 102 - Workshop Manual KDW 1603_2204_2204/T _ cod.

  • Page 103: Engine Storage

    ENGINE STORAGE ENGINE STORAGE - When the engines are not for more than 6 months, they have to be protected performing the operations described in the following pages. If the engine is not to be used for extensive periods, check the storage area conditions and the type of packaging and make sure that these are suitable for correct storage. If necessary, cover the engine with a proper protective sheet. Avoid storing the engine in direct contact with the ground, in environments that are humid and exposed to bad weather, near high voltage electric lines, etc. Important If, after the first 6 months, the engine is still not used, it is necessary to carry out a further measure to extend the pro- tection period (see “Protective treatment”).

  • Page 104: Torque Specifications And Use Of Sealant

    TORQUE SPECIFICATIONS AND USE OF SEALANT MAIN TORQUE SPECIFICATIONS Reference (fig. Ø and pitch Torque Type of POSITION N° and page) sealant Alternator fixing bolt fig. 8 - pag. 29 10x1,5 Diesel fuel union bolts 14x1.5 Flywheel housing 10x1.5 fig. 197 - pag. 81 Preheating glow plug 12x1.25 fig. 13 ÷ 15 - pag. 30 Roker arm cover 8x1.25 Main bearing cap 12x1.25 Cap vent Intake manifold fig. 6 - pag. 28 8x1.25 Exhaust manifold fig. 7 - pag. 28...

  • Page 105: Table Of Tightening Torques For Standard Screws (Coarse Thread)

    Torque specifications and use of sealant Table of tightening torques for standard screws (coarse thread) Resistance class (R) 10.9 12.9 Quality/ Dimensions R>400N/mm R>500N/mm R>600N/mm R>800N/mm R>1000N/mm R>1200N/mm Diameter 1000 1200 1050 1500 1800 1088 1450 2000 2400 Table of tightening torques for standard screws (fine thread) Resistance class (R) 10.9 12.9...

  • Page 106: Special Tools

    SPECIAL TOOLS SPECIAL TOOLS DESCIPTION Part No. Fuel delivery equalization tool. Allows the adjustment of individual unit injector fuel 7104-1460-090 delivery. Glass column for fuel delivery equalization tool. 7104-1460-072 Camshaft bushing replacement tool 7104-1460-021 Static timing tool 7271-1460-024 T.D.C. determination fixture. 7107-1460-075 Pliers for injection pump feeding tubes 1 7104-1460-022 1 For tube diam. 6 mm 2 7104-1460-023 2 For tube diam. 8 mm Tool for replacement of injection pump outlet union: 7107-1460-212 1 For extraction 2 For driving - 106 - - 106 - Workshop Manual KDW 1603_2204_2204/T _ cod.

  • Page 107: Workshop Manual Kdw 1603_2204_2204/T _ Cod. Ed0053029180 - 1° Ed_Rev

    ..................................Notes : ..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................Workshop Manual KDW 1603_2204_2204/T _ cod. ED0053029180 - 1° ed_rev. 00 - 107 - - 107 -...
  • Page 108 Translated from the original manual in Italian language. Data reported in this issue can be modified at any time by KOHLER. FOR SALES AND SERVICE INFORMATION IN U.S. AND CANADA, CALL 1-800-544-2444 FORM NO. ED0053029180 KohlerEngines.com ISSUED 02/15/2011 ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044 REVISED DATE 02/15/2011...

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