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KDW 1603 - 2204 - 2204/T WORKSHOP MANUAL

1. 12 General remarks safety information Mt 12 California emission control warranty lt 13 OUR warranty NOMS and SIAN MET EET OU 13 NN 14 Limited 3 year kohler diesel engine CMM ras EF benken edda 15 General service manual ET 15 Elec uarie e EEE EE eect TOO 15 rem regu 11 0 CNET T m 16 General safety during operating tase sceanatanaucnetseesyeaselessasanrcnacses 17 Safety and environmental impact T EP 17 3 TECHNICAL INFORMATION isa tvscisceacvesinnsecccabaascadexsaaspeadddesedenciusnusarnssanconsesbiobensedsneasatacssvenaseneasevamsnancdaieeavensxase 18 Possible causes and rouble SOOT Ju dewcsiiaalentyeadasmartasapratansnncsdandsbhamaseinsmeadoseseiolswestsadeunaaads 18 POC NC Al CUA RER NU NUN 21 Fa 19520 100 D EEE E to oom 22 ee 25 4 MAINTENANCE RECOMMENDED OIL TYPE 28 KOF ael caido RE m oe ee ee oe eT ee sne 28 TA WAVENEY US UNC 28 Extraordinary WMV 1 NET m 28 TNR Drea 29 FSSC MOC t
2. 89 Characteristic curves for alternator type Marelli AA 125 14V 65 89 Characteristic voltage curve for regulator type RTT 119 ACG rrrrrnnnnnnnnnnnnnnnennannrnrnnnenrnnnenrnnnrnrrnnennnnernnnanennnnneennnsnennaseennnsee 89 Alternator type Iskra AAK3139 14V 80A ssssssessseeeeeeen ssa ansa 90 Characteristic curves for alternator type Iskra AAK3139 14V 80A 90 Characteristic voltage curve for regulator type AER 1528 rrrnrnnnnrnnnrnnnrrnrnnnnrvnrnnnnrnnnnnsnrnrnnnnsrnnrnnnnrnnnnnsernrnnnnsnnnnnsnsnnsnnsee 90 16 M H 91 Characteristic curves for starting motor type Bosch EV 12V 2 2 KW r rrrnrannnnnnnnnnnnnnnnnnnnnennnnnnnnnnernnnnnennnnnennnnnennnnnennnnsene 91 Wiring diagram 24V with alternator 35A EEE NE EE 92 Recommended batteries EE E 93 Alternator type Iskra type AAK3570 28V 35A for 24 V 94 Characteristic curves for alternator type AAK3570 28V 354A for 24 V outfits 94 Characteristic voltage curve for regulator type AER 1528 94 cidem rT ER 95 Characteristic curves for starting motor Iskra type AZE 4598 24V KW
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4. 30 Coola RPM T 31 E E 31 5 REGULATIONS FOR LIFTING THE ENGINE esnnnnnnrnnnrnnnnnnnnnnnnnnnnnnnnnnnnnnnnnsnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnunnnnennnr 32 Regulations for lifting the GING ING saci PT 32 6 5 5 55 1 34 Recommendations for disassembling and assembling 34 Recommendations Tor overhauls and tuning 34 MATET 35 PETN 35 BE NE DET 35 COMPOR SEE EEE TP 36 eee eee es EEE EEE 36 ne VA OVO EE EE EEE EE EE 9f EET 37 Ve 9f Ko 37 BEE G EEE E EE EEE 38 TOM REE 38 EE MEE EN EE EA E E 38 Rocker arm cover with vent into the air RE ERR TE EE 39 Workshop Manual KDW 1603_2204_2204 T _ cod ED0053029180 1 ed_rev 00 5 Chapter index KOHLER Rocker arm cover with vent Into the air vassere
5. Piston cooling sprayer This is assembled on turbo engines KDW 2204 T Blow on it with compressed air and check that there are no impurities inside Reassemble it back into place making sure you maintain axis alignment A of the spray with respect to axis B shown in the figure 67 Anyway the correct position is ensured by the fixing screw 66 67 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 f ed rev 00 51 6 Disassembly Reassembly KOHLER Center main bearings The main bearing caps and the crankcase have reference holes marked on them one two or three A 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 Follow the same procedure
6. 55 Checking main journals and crank PI Svarene eee lid e Sum Hi dide sun on 56 Main bearing and connecting rod big bearing inside diameter 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 SI Front cover before the serial number 7366305 cccccccsseccccceseececeeeceecceeececeueeeeecsuceesseeeeesseeeeessusucesssageeeessagsessssaes 58 Front cover after the serial number 7366306 cccccccssssccceceeeeccceeceeccesececsceeeeecseuseesseeeeesseegeeessuausessuaueeeessgeesssaags 58 jeep EE TE omm 58 2 WR S NE EEE NN 59 Dimensions for injection pump delivery control yoke 59 Camshaft gear Speed governor counter weights 60 oped governor se mE m c 60 Frame with idling Speed governor 60 Summary tables of the governor equipment according to the speed 61 Spring for extra fuel supply at SUMING
7. AN 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 Good quality or poor quality of the lubricating oil has an affect on engine performance and life If inferior oil is used or if your engine oil is not changed regularly the risk of piston seizure piston ring sticking and accelerated wear of the cylinder liner bearing and other moving components increases significantly Always use oil with the right viscosity for the ambient temperature in which your engine is being operated Use the chart when chosing your engine oil AN Danger Attention The used engine oil can cause skin cancer if kept frequently in contact for prolonged periods If contact with oil cannot be avoided wash carefully your hands with water and soap as soon as possible Do not disperse the oil in the ambient as it has a high pollution power LUBRICATION SYSTEM LAYOUT F an mL i ep e F RS M ES 10 11 S 2 12 6 13 125 Components 1 Oil fill cap 6 Oil dipstick 11 Oil pump 2 Rocker arm shaft 7 Drain plug 12 Crankshaft 3 Oil filter 8 Breather 13 Oil pressure adjusting valve 4 Main journal 9 Camshaft 14 Oil pick up screen 5 Connecting rod
8. Intake side Support clump 151 a 35 TESA pu O y AI f3 NE S A SE 7 BS Fl EN at Io 152 153 Electric fuel pump 24V The use of the electric pump is foreseen for certain applications where the engine has to be started at very low temperatures Assembly notes When the electric fuel pump is installed in a diesel engine it is necessary to 1 Remove the filter fitted at the pump intake intake side 2 Insert the prefilter upstream of the pump intake side 3 The electric pump on the application must be at such a height from the minimum tank level that it generates a maximum pressure drop equal to a column of 500 mm of water 4 Avoidrunning dry due to emptying of the intake pipeline inserting a non return valve Features Pressure 0 44 0 56 bars Max capacity 100 I 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 All high pressure tubes between injector and pump A feature the same shape and dimensions Features 1603 2204 2204 T erm Sealing Volume 25 mm Volume 25 mm valve 1
9. 95 Spacer ilange for Starter MOTOT Emm 95 Connection diagram for preheating control unit eene nnne nnne nn nnne nnn nenne nnn nnn nnns 96 Glow plug controller relay with coolant temperature sensor sseessessssssssssssesnenenen enne enne enne nnns nnns 96 Pre h eating UN 96 Temperature sensor 97 Coolant high temperature lamp 5 ass saa nnn 97 Thermistor for electric thermometer Lus TED TETTE 98 Thermistor for preheating water temperature Thermal contact for water temperature indicator light 98 pci P 100 Idling speed setting in no load conditions 100 Full speed setting in no load conditions 5 100 Standard injection pump delivery setting without torque 100 Injection pump delivery limiting and torque adjusting device rrrrnnnnvnnnnnvrnnnvvrnnnevnnnnnvnnnnnnnvnnnnnvnnsrnnnnnnnnnnnennnnnennnanennnnnen 100 Fuel limiting device fig al AP P T H H HQ 101 Fuel limiting device adjustment
10. KOHLER 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 mme at the fuse holder box 3 Cable cross section 1 5 mm at the earth 4 Cable cross section 1 mm atthe 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 mme at the fuse 194 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 a I v 464 Trasducer Heating time in seconds Resistance Temperature Pre heating Pre heating Starting control Q 12V 24V andPost 30 30 20 7000 23 5 29 5 19 23 0 2400 13 5 16 5 9 5 12 5 s Pre heating glow plug Components 1 Sheath 2 Regulation filament 3 Heating filament O Installation torque 20 Nm E24 NV V RST Glow plug Type XM Y A Nominal voltage 11 5 V LE 12 14 after5 12 14 after 5 Sheath surface afters 12 14 A atter 5 y temperature 12 14 A after 5 j d 22 Note The glow plug is not damaged in any way due
11. erre 61 EEE 61 Camshaft MOV AL Sene 61 Checking camshaft bushing internal diameter 62 Camshaft journals and bushings in Model KDW 1603 ccccccccceecseeeeeeeeeeeeeeeeeeeeeeeeaeeeeeseeeeeeeseeeseesaaeeeeeseeaeeeeeseeeesesaaees 62 Camshaft journals and bushings in models KDW 2204 22047 7 62 Workshop Manual KDW 1603 2204 2204 T _ cod ED0053029180 1 ed rev 00 KOHLER Chapter index RENN 62 Intake exhaust and injection cam height for engine with hydraulic tappets 63 NNN 64 Valve timing without considering timing MAPKS vsssicieseciasssscactvcictadasiceverdondncensudeideieediseadaansdeecbanessteciaveniwersaedelduedidassiannisnotana 64 VIENNE band 64 hydraulic NAOT ETR EE NE NE TE 65 ENE NE EN EE T E A E EN EE NER 66 P No EE NE EE EE EN EE Y 66 GR 1and GR 2 hydraulic pump PT eee 66 hr 68 TUS OC o RN T T m UU UU Mm 68 HE eo e Melo aeo gt NT OO TEE 68 Trpo hargar TSS UNG NR UI 68 Checking actuator setting Waste Gate valve control rod stroke 69 oa LUBRICATION SSEM he 70 NTN NENNE 71 Oil press re adj sting RERO 71 TPT TAMU CS RE Eom 71 I TS Ss SU E
12. 3 NIELS NSA 5 Uk i 10 7 4 8 140 Components 1 Coolant fill cap 2 Expansion tank 3 Cylinder block 4 Circulating pump 6 Thermostat 7 Fan 8 Radiator 9 Temperature sensor 5 Coolant temperature warning lamp 10 Heat exchanger KDW 2204T 74 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 KOHLER Cooling system 9 141 145 146 Expansion tank and cap The expansion tank is separated from the radiator and is fitted with a coolant fill cap The cap comes with vacuum valve 1 and pressure relief valve 2 The pressure relief valve opens at a pressure of 0 7 bar Checking for cooling system leaks Remove the cap from the expansion tank and check coolant level Replace the cap with one fitted with portable hand air pump coupling as shown in the figure 142 Compress air at a pressure of 1 bar for approximately 2 minutes Check that no leaks occur MW Caution Warning 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 t
13. Do not disperse the oil in the ambient as it has a high pollution power 30 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 KOHLER Maintenance Recommended oil type Refilling 4 COOLANT 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 Coolant fluid is polluting it must therefore be disposed of in the correct way Do not litter 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 KDW KDW KDW 50 AGIP ANTIFREEZE 1603 2204 2204 T mM CAPACITY L itres 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
14. N NIRS T 7 P HN LNG N WAAAAAASARAN 1152140 LT SAA ANAM N S N SSN SSS M NN ASSESS N NNNNNNNNNNNNNNRNNNNRNSNNNNNNNNNNNN EN LONG ANNAN ASA EIE AAAI NN TEN 45 46 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 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 AN Important Do not manually hone the cylinder bore surfaces with emery cloth or other means The inclination of the cross hatched marks left by machining should range between 115 140 they should be uniform and clearly visible in both directions Average roughness should range between 0 5 and 1 mm The cylinder surface which comes into contact with the piston rings should be machine honed with the plateau system Piston Remove circlips and piston pin Remove piston rings and clean grooves Measure diameter Q at the A distance from t
15. Components 2 2 Ay 1 Pump body Zz Hh unger NN 4 Plunging blade WS K Note Barrel 2 forms an integral part of the pump body 1 27 Yas For this reason both the barrel and plunger 3 should not replaced dd Checking injection pump delivery Components 1 Delivery adjustment rod 2 Rod 1 stop position 3 Rod 1 max delivery position 18 5 19 5 mm rod max stroke 66 rod max rotation Test data of injection pump KDW pede rod Rod as from Camshaft KDW 1603 2204 2204 max force max elivery rpm Delivery Delivery Newton point mm mm stroke mm stroke 1500 31 41 40 48 Workshop Manual KDW 1603 2204 2204 cod ED0053029180 f ed rev 00 61 10 KOHLER 167 1603_2204_2204 T mm The same operation must be carried out on each pump The difference in adjustment must be limited to about 1 Checking low pressure injection timing for engines with hydraulic tappets To verify the delivery starting point the first operation to carry out is to disconnect the nylon tubes at the inlet 4 and outlet 3 of every injection pump Then disassemble the air filter the intake manifold and the rocker arm cap Now disassemble the whole rocker arm pin and after removing the push rods reassemble it Screw the special tool 1 serial number 7107 1460 075 fig
16. Idle frame Anti hunting Spring for extra fuel supply at starting The device is operated automatically when the engine is stopped spring 1 acts on the injection pump control lever 2 providing maximum fuel delivery until the governor starts operating CAMSHAFT Camshaft removal To remove camshaft first remove valve tappets 1 injection pump follower 2 bearing stop plate 3 and fuel pump control rod 5 Note To remove follower 2 loosen screw 4 by three or four turns Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 f ed rev 00 61 6 Disassembly Reassembly KOHLER 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 fe Camshaft journals and bushings in model KDW 1603 Clearance Worn limit mm mm A B C D A B C D Dimensions 43 000 43 025 B 42 940 42 960 0 040 0 085 42 000 42 025 41 940 41 960 Note A and C values refer to driven in and bored bushings Camshaft journals and bushings in models KDW 2204 2204 T Clearance Worn limit mm mm mm A 44 000 44 025 B 43 940 43 960 43 000 43 025 0 040 0 085 D 42 940 42 960 42 000 42 025 41 940 41 96
17. LEVEL ENGINE LUBRICANT COOLANT LEVEL DRY AIR CLEANER Engine oilreplacement Oil filter replacement OIL BATH AIR CLEANER RADIATOR EXCHANGE SURFACE BELT FAN ALTERNATOR STRETCH SLEEVES SETTING AND INJECTORS CLEANING FUEL PIPES RUBBER INTAKE HOSE AIR FILTER MANIFOLD INTERIOR RADIATOR CLEANING ALTERNATOR AND STARTER MOTOR _ ENGINE LUBRICANT OIL FILTER FUEL FILTER ALTERNATOR FAN BELT COOLANT LEVEL PARTIAL OVERHAUL TOTAL OVERHAUL FUEL PIPES RUBBER INTAKE HOSE AIR FILTER MANIFOLD REPLACEMENT INTAKE SLEEVES DRY AIR CLEANER EXTERNAL CARTRIDGE AFTER 6 CHECKS WITH CLEANING gt STANDARD OIL SUMP ENHANCED OIL SUMP DRY AIR CLEANER INTERNAL CARTRIDGE AFTER 3 CHECKS WITH CLEANING In case of low use every year In case of low use every 2 years The period of time that must elapse before cleaning or replacing the filter element depends on the environment in which the engine operates The air filter must be cleaned and replaced more frequently in very dusty conditions 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 28 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 KO
18. 3W Maximum thermal contact power The max torque is 30 Nm 98 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 KOHLER Electric system 11 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 99 12 SETTINGS KOHLER dop eu 7 TSS HO UDE eas Gf LLL LL LLL GN M R o BKS 20 TONG XD 1 Hun Y yr Emi e N N 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 Example of adjustment of an engine at 3000 rpm After setting idle speed turn screw 2 and set full speed in no load conditions at 3200 rpm then tighten lock nut When the engine reaches the pre set power full soeed stabilize
19. A Worn ooo i Damaged cylinder head gasket IP l L T1 PER Bentrods CC TT Tt dL Faulty hydraulic tappets EE ET J jj TT SYSTEM _ LLL L LL LLL LLL we smore f oenas 5 of 2 D e eg gt 2 E _ Wo seceteratio ELECTRIC MAINTE NANCE o 15 LLI 14 o Z LLI o 18 Workshop Manual KDW 1603 2204 2204 T _ cod ED0053029180 1 ed rev 00 KOHLER Technical information 3 TROUBLE POSSIBLE CAUSE Inadequate perfor Excessive oil con Er High noise level sumption Damaged injector White smoke Too low oil pressure Non uniform speed EE Black smoke Injection pump valve damaged HEG No acceleration njector not adjusted Faulty fuel feeding pump Hardened pump control rod Broken or loose supplementary start up spring INJECTION 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 5 O Faulty pressure gauge or pressure switch H l Blocked draining pipe
20. Tension adjustment Loosen alternator fixing bolts C Stretch belt so that a 100 Nm load located half way between the two pulleys causes a 10 15 mm flexure Pull strongly alternator externally and tighten fixing bolts C The final torque must be 40 Nm If you use the belt tension gauge type DENSO BTG 2 the correct value of tension must be from 35 40 Nm Cooling fan AN Danger Attention Before disassembling the cooling fan isolate the positive battery cable to prevent accidental short circuiting and consequently activation of the starter motor Take off the fan and check that all blades are not damaged if any are damaged replace the entire fan Depending on the type of application the cooling fans can be suction or blower fans and can differ in diameter O Tighten the fastening screws to 10 Nm Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 37 6 Disassembly Reassembly KOHLER ES ne ES 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 i consequently the cooling fan Bolt D can be loosened by turning clockwise When refitting lubricate the bolt with Molyslip and tighten it a
21. environments The internal combustion process generates carbon monoxide an odourless and highly toxic gas so spending too long a time in an environment where the engine discharges its exhaust products freely can lead to loss of consciousness and even death The engine may not be used in environments containing flammable materials explosive atmospheres or easily combustible powders unless adequate specific precautions have been taken and are clearly stated and certified for the machine To prevent the risk of fire keep the machine at a distance of at least one metre from buildings or other machines During operation Children and animals must be kept at a sufficient distance from the machine to prevent any danger resulting from its operation Fuel is flammable so the tank must be filled only when the engine is turned off Dry carefully any fuel that may have spiled remove the fuel container and any cloths soaked in fuel or oil check that any sound absorbing panels made of porous material are not soaked with fuel or oil and make sure that the ground on which the machine is located has not absorbed fuel or oil Before starting remove any tools that have been used for carrying out maintenance work to the engine and or the machine and check that any guards removed have been replaced In cold climates it is possible to mix kerosene with the diesel fuel to make the engine easier to start The liquids must
22. Faulty spray nozzles Turbo engines only Blocked draining pipe EHHH HEN Alternator fan belt loose orton Clogged radiator exchange surface Insufficient coolant P j t Ld LL Fault fan radiator or radiator plug Faulty thermostatic valve _________________ SSS Blockage inside the radiator or the coolant ducts Coolant leaking from radiator hoses the crankcase or from the water pump B B Gg Faulty or worn water pump ttt ELL ET TT COOLING CIRCUIT Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 19 3 Technical information KOHLER 20 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 KOHLER Technical information 3 TECHNICAL DATA ENGINE TYPE Cylindres Bore Stroke Displacement Compression ratio N 80 1269 CEE ISO 1585 DIN 70020 Power KW NB ISO 3046 1 IFN DIN 6270 NA ISO 3046 1 ICXN DIN 6270 Max torque Max torque 3rd 4th p t o KDW EE NE 3 oz 221 om 3000 3000 3000 300 380 492 276 5 4 320 423 4 Oil consumption 0 025 Dry weight Combustion air volume at 3000 r p m Cooling air volume at 3000 r p m mmm 96 128 180 Max permissible driving shaft axial load in both directions Max 60seconds 35 35 35 Maxindination Lastingupto30seconds 25 25 25
23. c N lt e gt LLI to O INAN LO Oz N c T 2 LO gt lt lt lt co 67 X o 9 lt x OW ow OOOO 5 X gt c a 45 0010 MM Nol lt C m x gt GC OOO lt LE D a eo d 4 E c 5 E E E a E 5 2 oe ama 0 8 ES E E N tof og g O 2 0 e C o ol o i c a OL N AE ME fv o LO Do D PR PRP Be gO 3 EC Lo rod To og x lt 1111 Fee gt S mg lt Pie PE REG 2 L0 x a JE ERES co oC c o IG es SN 2 ope 5 2 2 3 33 Liigi ogg 5 o i 225 xXx tS o m Q amp cQ _ 6 S e X O gt N e O D O v BL SR 56520 6 So 33 on 1958 110592 oS wo 2 59 o gt du D DO o gt gt gt Oo Oo E a e O 5 2 es SBOlSodnMPODSE SES 0 N Ww o c oO OS o 9 2 N oe 5 gt 5 2 gt GOoOo5 c EoS9Sc 2uooc tgg
24. gt LL 08 132 esa Referred to max N power i At NA power d Depending on the application KDW 1603 KDW 2204 T KDW 2204 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 f ed rev 00 21 3 Technical information KOHLER PERFORMANCE DIAGRAMS CHARACTERISTICS POWER TORQUE AND SPECIFIC FUEL CONSUMPTION CURVES ar a Ed i E SK EX ai Z z TOT 1 7 Fra F A LA LIT 4 KDW 1603 Pale EE OR CA ee a EH tT ALT ALT ALT TJA Say ae TATT EE oie MITTE LISTET LLL LI 7 19 BENE EN I NN Ea TT N EA N k iN E E an AE CRE 8 110 12 102 104 838 5 3 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 NA ISO 3046 1 ICXN CONTINUOUS RATING WITH OVERLOAD CAPABILITY continuous heavy duty with constant speed variable load and constant load MN Torque curve N curve MB NB curve MA NA curve C Specific fuel consumption curve NB curve Max power tolerance is 5 Power decreases by approximately
25. 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 Em Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 KOHLER Technical information 3 CHARACTERISTICS POWER TORQUE AND SPECIFIC FUEL CONSUMPTION CURVES KDW 2204 KDW 2204 T mum 1 11 LT STS LI TET 52 TT T TT aoe 49 LT 48 TT Lt HAH FIIIT 43 a a 40 7 37 EREN an 4 431 2 LITT BE ODESSAN ANHEE EE E E ESS 22 80 1269 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 MN Torque curve N curve MB NB curve MA NA curve 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 AN Important Non approval by Kohler for any modifications r
26. 12 020 12 038 12 048 12 058 Valve guides with outside diameter F increased by 0 5 mm are available in such case valve guide bore E should also be increased by 0 5 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 f ed rev 00 41 6 Disassembly Reassembly KOHLER Valve guide insertion after driving Press guides considering the L distance from the head plane X Dimensions mm 7 020 7 035 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 42 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 KOHLER Valve seats and bore 41 500 41 520 mm B 41 575 41 590 mm 365 5 3859 a 44 53 45 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 mm ZEE Workshop Manual KDW 1603 2204 2204 T cod ED0053029180
27. 2 5 2 waa s 760 1000 1200 1000 220 2700 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 105 15 SPECIAL TOOLS KOHLER 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 02 1 Static timing tool 7271 1460 024 T D C determination fixture 7107 1460 075 Pliers for injection pump feeding tubes 1 Fortube diam 6 mm 1 7104 1460 022 2 Fortube diam 8 mm 2 7104 1460 023 Tool for replacement of injection pump outlet union 7107 1460 212 1 For extraction 2 For driving 106 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 KOHLER Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 f ed rev 00 107 Translated from the original manual in Italian language Data reported in this issue can be modified at any time by KOHLER KOHLER FOR SALES AND SERVICE INFORMATION IN U S AND CANADA CALL 1 800 544 2444 KohlerEngines com ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 REVISED 00 DATE 02 15 2011
28. 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 PRESCRIBED LUBRICANT Fuel with low sulphur content API CF4 CG4 Fuel with high sulphur content API CF FUEL TYPE For best results use only clean fresh commercial grade diesel fuel Diesel fuels that satisfy the following specifications are suitable for use in this engine ASTM D 975 1D or 2D EN590 or equivalent FUELS FOR LOW TEMPERATURES It is possible to run the engine at temperatures below O C using special winter fuels These fuels reduce the formation of paraffin in diesel at low temperatures If paraffin forms in the diesel the fuel filter becomes blocked interrupting the flow
29. 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 e Take the engine to the setting speed and power e Loosen the lock nut 2 e Unscrew the screw 1 to bring lever 4 close up to rod 5 until the engine speed tends to decrease e 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 e 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 e Unscrew the screw 2 e Move rod 1 fully to the left e Screw down screw 2 to touch rod 1 e Continue screwing screw 2 by 1 2 turn e Lock nut 3 Note In these conditions the injection pump delivery control limit stops cannot be damaged by violent impact caused by operation of any electro stops that may be fitted Application diagram for tampering system adjustment screw and torque gearing device for EPA approved engines Components 1 Br
30. Inner seal ring Gasket Cover Cap clamp Cap Centrifugal pre filter 10 Centrifugal pre filter clamp 11 Oil level mark 12 Upper filtering element polyurethan sponge OAOANOaRWND Note Centrifugal pre filter 9 is fitted upon request Dry air cleaner AN Danger Attention Never clean the filtering element using solvents with a low flash point This could cause an explosion A Fitting to accomodate clogging indicator See page 22 for periodic dry air cleaner check and replacement and the rubber intake hose air filter intake manifold Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 35 6 Disassembly Reassembly KOHLER ag 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 Use a lamp to check that the filter element is not damaged or inspect it against the light while slanted In ca
31. S E o YT ob Pink Black 9 15 54 7 9 ks 50 Black BC Em R LIN x d i 173 66 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 KOHLER Electric system 11 Wiring diagram with alternator 12V 45A 65 80A 1 Alternator 2 Starter Motor 3 Battery See below for sizing details 4 Glow Plugs 5 Thermistor Glow Plug Controller Circuit 6 Glow Plug Controller Timer 7 Key Switch 8 System Fuse 9 Fuse Accessory 10 Fuel Valve 11 Glow Plug Indicator Lamp 12 Coolant High Temperature Lamp 13 Coolant High Temperature Switch N O 14 Oil Pressure Low Lamp 15 Oil Pressure Switch N C 16 Alternator Charging Lamp Off if Charging 17 Diode 18 Air Filter High Restriction Indicator 19 Air Filter Restriction Switch N O 20 Low Fuel Level Lamp 21 Low Fuel Level Switch N O 22n 2 100 ohm resistances in parallel A Accessory B Off Position C On Position D Starting Position Battery 3 is not supplied by KOHLER A 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 12 V 92 Ah 880 A EN 12 V 110 Ah 980 A EN 12 V 92 Ah 715 A SAE 12 V 110 Ah 790 A SAE Key switch electrical layout A Accessory B Off position C On position D S
32. The user should read these instructions carefully and get to know the operations described By not doing so he may place at risk his own health and safety and that of anyone else in the vicinity of the machine The engine may be used or mounted on a machine only by personnel suitably trained in its operation and aware of the dangers involved This is particularly true for standard and above all special maintenance work For special maintenance contact personnel trained specifically by Kohler This work should be carried out in accordance with existing literature Kohler declines all responsibility for accidents or for failure to comply with the requirements of law if changes are made to the engine s functional parameters or to the fuel flow rate adjustments and speed of rotation if seals are removed or if parts not described in the operating and maintenance manual are removed and reassembled by unauthorized personnel A WARNING In addition to all other machine specifications ensure that the engine is in a near horizontal position when starting If starting manually ensure that the necessary operations can be performed without any risk of striking against walls or dangerous objects Rope starting except for recoil rope starting is not permitted even in emergencies Check that the machine is stable so that there is no risk of it overturning Get to know the engine speed adjustment and machine stop operations
33. a 8 before S y 36 before 2400 r p m 28 after 5 8 after S upper a 12 before S 8 before I 2400 r p m 36 after I 2 after S under upper a 12 before S 8 before I 2400 r p m 2204 T B 48 after I 4 after S Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 f ed rev 00 65 6 Disassembly Reassembly KOHLER 117 118 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 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 GR 1 and GR 2 hydraulic pump 3rd p t o 1 O R 2 O R 3 Center ring 4 Circlip 5 Thrust washer 6 GR 2 hydraulic pump flange 7 GR 1 hydraulic pump flange 8 Bushing 9 Trust washer 10 GR 2 hydraulic pump drive gear 11 GR 1 hydraulic pump drive gear 12 Control gear 66 Workshop Manual KDW 1603 2204 2204
34. and smoothness of the mechanical parts Refill the tank with fresh fuel Make sure that the oil and the coolant are up to the ma ximum level Start the engine and after some minutes bring it to of the maximum speed for 5 10 minutes Turn off the engine Remove the oil drain plug see Oil replacement and discharge the AGIP RUSTIA NT protective oil while the engine is hot Pour new oil see Table of lubricants up to the maxi mum level 14 Replace the filters air oil fuel with original spare parts 15 Empty the cooling circuit completely and pour in the new coolant up to the maximum level Caution Warning Over time a number of engine components and lubricants lose their properties so it is important considering whether they need replacing also based on age see Replacement table A Important Maximum every 24 months of inactivity the engine must be started up by repeating all Engine Storage operations Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 103 14 TORQUE SPECIFICATIONS AND USE OF SEALANT MAIN TORQUE SPECIFICATIONS KOHLER Reference fig and pitch Torque Type of POSITION N and page mm Nm sealant Alternator fixing bolt fig 8 pag 29 10x1 5 40 Diesel fuel union
35. be mixed in the tank by pouring in first the kerosene and then the diesel fuel Consult Kohler technical office for mixture proportions Petrol may not be used because of the risk of it forming flammable vapours the surface of the engine reaches temperatures that may be dangerous Avoid in particular all contact with the exhaust system The liquid cooling circuit is under pressure Do not carry out any checks before the engine has cooled down and even then open the radiator cap or the expansion tank cautiously Wear protective clothing and glasses If there is an electric fan do not approach the engine while it is still hot as the fan may come on even when the engine is not running Clean the cooling system with the engine turned off While cleaning the oil bath air filter check that the oil is disposed of in such a way as not to harm the environment Any filtering sponges in the oil bath air filter should not be soaked with oil The cyclone pre filter cup must not be filled with oil Since the oil must be emptied out while the engine is still hot approx 80 C particular care should be taken in order to avoid burns In any case make sure that oil does not come into contact with your skin because of the health hazards involved Fuel vapours are highly toxic so fill up only in the open air or in well ventilated environments During operations which involve access to moving parts of the engine and or removal of the rotary guar
36. bolts 14x1 5 40 Flywheel housing 10x1 5 50 Preheating glow plug fig 197 pag 81 12x1 25 20 Roker arm cover fig 13 15 pag 30 8x1 25 20 Main bearing cap 12x1 25 120 Cap vent 6x1 10 Intake manifold fig 6 pag 28 8x1 25 25 Exhaust manifold fig 7 pag 28 8x1 25 29 Throttle cover 6x1 10 Camshaft cover 6x1 10 Timing cover fig 93 pag 48 8x1 25 25 1P hydraulic pump flange cover 6x1 10 Hydraulic pump gear support cover 8x1 25 25 Oil pump top cover 6x1 10 Loctite 270 Oil pump bottom cover 6x1 10 Loctite 518 Thermostat cover 8x1 25 25 Oil sump 8x1 25 25 Water pump case and pump support 8x1 25 25 Flange for flywheel control oil sealing ring 6x1 10 Nozzle clamping ring nut fig 172 pag 72 24x2 70 90 Rod support ring nut 18x1 5 40 Equalizer unit 10x1 5 60 Loctite 242 Oil pressure indicator 12x1 5 35 Camshaft gear 10x1 100 Injector fig 171 pag 72 24x2 70 Starting motor 10x1 5 45 Intermediate pin 8x1 25 25 Front engine foot 16x1 5 200 Engine foot on bell 10x1 5 40 Fuel pump 8x1 25 25 Loctite 270 Injection pump fig 164 pag 69 8x1 25 25 Feed pump stud bolts 8x1 25 10 Drive puly fig 10 pag 29 16x1 5 360 Oil filter nipple UNF 3 4 Loctite 270 Fuel pump and solenoid valve union 10x1 12 Injection pump union fig 154 pag 68 12x1 5 35 Intermediate thrust block union 22x1 5 150 Loctite 270 Injection pump union 12x1 5 25 Water recirculation unions in brass 14x1 5 Loctite 554 Revolution counter driving gear 5x0 8 5 Alte
37. 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 MADE IN SLOVAKIA KOHLER Model XX XX XXXX rom XXXX D sin XX XX XXXX Spec XXXXXX E 9 97 68 CE 00 000xx xxxx xx Q XX 000 10 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 KOHLER Manufacturer and motor identification data 1 Name plate for EPA rules applied on rocker arm cap Compilation example 1 10 4 5 6 T 8 9 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 f ed rev 00 11 2 GENERAL REMARKS AND SAFETY INFORMATION General remarks and safety information KOHLER 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 AN Dan
38. 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 Remove throttle cover 2 and release spring 3 When refiting replace gasket 4 and 5 O Tighten front cover 1 to 25 Nm Idler gear and hub YV AL f V M e NBA AL Components 2 1 7 1 Idle wheel 4 Fitting jd ay 2 Hub 5 Oil seal ring lt 3 Thrust washer 6 Bushing lubrication hole 7 Thrust washer Note Unscrew fitting 4 clockwise and when refitting it to 150 Nm Dimensions Play Worn limit mm A B mm A B mm 95 777 36 000 36 020 0 025 0 061 0 120 B 35 959 35 975 Axial play Worn limit mm mm 1 950 2 050 0 100 0 300 0 600 D 0 960 1 000 98 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 KOHLER Disassembly Reassembly 6 Speed governor A 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 4 Bolt 5 Throttle control rod 6 Governor spring 7 Injection pump delivery rod 8 Yoke 9 adjustement eccentric 9 Control yoke for in
39. f ed rev 00 43 6 Disassembly Reassembly KOHLER e Precombustion chamber The precombustion chamber can be extracted from the head banging with a punch into the hole from the injector housing 2 4 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 Hydraulic tappet valve control Dimensions mm Clearance mm Limit value mm 23 000 23 021 0 040 0 046 0 10 B 22 960 22 975 Nota f tappet is worn out along diameter B replace it No oversize tappets are available If tappet camshaft surface is worn replace 2 Hydraulic diagram for feeding the tappets Y 1 Rocker arm E 2 Rocker arm 1 9 3 Push rod n S 4 Oil drainage M 4 5 Hydraulic tappet og I 35 Hydraulic tappet components H a Tappet body _ e b Plunger a 22 WY c Non retur
40. four M10 screws to the crankcase provisionally tightening it to 40 Nm Don t remove screw B By making the driving shaft turn check the clearance between the ring gear A and the gear of mass D set a comparator with the feeler on one tooth of the timing system control gear G by turning the driving shaft a little way check the clearance which must be 0 026 0 067 If the clearance measured does not come within the values given repeat the operation placing the 0 05 mm shims provided for adjustment between the support C and the crankcase When mounting the balancer lubricate the bushings with Molikote then couple the two masses taking into account the references H and I Permanently fix the support C to the crankcase by tightening the screws to 50 Nm plus one turn of the wrench clockwise through 45 The four screws will have to be mounted with a few drops of Loctite 242 Remove screw B 92 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 f ed rev 00 57 6 Disassembly Reassembly KOHLER Front cover before the serial number 7366305 To remove front cover 1 bring the 1st cylinder to the top dead 2 WS MMOH e Remove throttle cover 2 and release spring 3 When refiting replace gasket 4 and 5 275 imme O Tighten front cover 1 to 25 Nm pr U MA IZA Front
41. hole 0 81 3 holes 1 5 Injection pump disassembly Release the spring from the cap and remove the plunger Two pins keep the upper cap connected to the pump body pry with a tool between the pump body and the cap Injection pump components 1 Delivery union 8 Spring 2 Spacer 9 Upper cap 3 Spring 10 Plunger pumping 4 Gasket 11 Lever 5 Delivery valve 12 Pin 6 Gasket 13 Body 7 Cap A Fuel feed union B Fuel dischrge union C Pump flange D Barrel pumping E Fuel control helix Note Union A and B flange C and barrel D form an integral part of the pump body 78 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 KOHLER 10 Fuel system 154 7 Sr SANN 3 155 Tool serial number 7107 1460 212 156 159 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 O Tighten delivery union to 35 Nm it is essential to use a torque wrench Injection pump non return valve The discharge union is fitted
42. in engine oil for approximately half an hour e Fill the inside with grease and lubricate and sealing lip with thick oil e Drive the seal into its seal exerting a uniform pressure over the entire front area Warning n case of room temperature below 35 C seals could become damaged Crankshaft timing gear If gear A has to be replaced use a bearing puller to remove it To reassemble it you need to heat it up to a temperature of 180 200 C and then fit it snugly Crankshaft lubrication ducts AN Important During repair operations when using compressed air wear eye protection Dip crankshaft into a bath use a cleaning product Remove plugs and clean ducts A B and C with a pointed tool Finally blow with compressed air Re place plugs using a calking tool and check for sealing Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 55 6 Disassembly Reassembly KOHLER Checking main journals and crank pins Use an outside micrometer gauge Main journal and connecting rod big end journal diameter KDW 1603 2204 2204 T Dimensions mm 59 981 60 000 B 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 g
43. journal 10 Oil pressure switch 15 Hydraulic tappet 16 Turbocharger KDW 2204 T 70 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 KOHLER Lubrication system 8 126 127 131 132 ah a amp OON 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 Oil pump capacity 24 5 litres min at a pressure of 4 5 4 75 bar engine speed 3000 rpm oil temperature 38 42 C Oil pump rotor clearance Measure clearance A between the teeth located along the axis of the keyway as shown in the figure 129 its value is 0 150 mm worn limit clearance 0 280 mm Oil pressure adjusting valve Components 1 Valve 2 Spring 3 Gasket 4 Plug Length of spring 45 5 46 0 mm Blow compressed air into the valve seat and carefully clean all components using a caliper measure the length of spring A Oil filter cartridge Components 1 Gasket 4 Blade 2 Plate 5 Filtering material 3
44. lowest levels in the tubes is not more than 2 cm At this point it is possible to either reduce the delivery of the pump that consumes most tube with the lowest level or increase 164 the delivery of the pump that consumes the least tube with the highest level To vary the delivery of the pumps rotate slightly in one direction or the other at the injection pumps Unscrew the fastening screws of the pump to be adjusted by a quarter of a turn Rotating clockwise the delivery is increased anti clockwise the delivery is reduced O Once adjustment is finished tighten the fastening screws to 25 Nm A Important Whenever an injection pump is disassembled or replaced delivery balancing must be carried out Note A reference notch is located between the pump flange and its mounting on the crankcase If one or more pumps are disassembled and reassembled do as follows Make a reference marking on the fastening flanges of the injection pumps and on the base planes of the crankcase Leave the shims for injection timing setting under each pump unchanged Each pump should be reassembled in its own housing Align the delivery reference notches located on the pump flange with those on the crankcase 80 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 KOHLER Fuel system 10 Injection pump P No 6590 249 Plunger and barrel assembly
45. oOSB 008 Of IF T x 5 FEL o gt x ex S9 32 6 o JE Gorg E 5 S gt gt ou 029r o xXAIIES ox lt II Ho O Sova Cr O Ka CC qe oOomcmcoazcturzcrozce Om Fa 2 FF m cod ED0053029180 1 ed_rev 00 3 2204 2204 T 5000 6000 7000 n g min 4000 3000 Rd elle e 2000 1000 0 A 189 188 11 Electric system Workshop Manual KDW 160 40 30 20 10 0 10 20 30 40 50 60 70 80 90 100 110 190 94 KOHLER Electric system 11 Starting Motor 24V Iskra type AZE 4598 24V 3 kW RH direction of rotation Characteristic curves for starting motor Iskra type AZE 4598 24V 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 193 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 f ed rev 00 95 11 Electric system
46. of fuel Fuel can be Summer up to 0 C Winter upto 10 C Alpine up to 20 C Arctic up to 30 C BIODIESEL FUEL Fuels containing less than 20 methyl ester or B20 are suitable for use in this engine Biodiesel fuels meeting the specification of BQ 9000 or equivalent are recommended DO NOT use vegetable oil as a biofuel for this engine Any failures resulting from the use of fuels other than recommended will not be EMISSION CONTROL INFORMATION LOW SULFUR FUEL OR warranted ULTRA LOW SULFUR FUEL ONLY AVIATION FUEL Aviation fuels suitable for use in this engine include JP5 JP4 JP8 and JET A if EPA CARB emission label must be 5 percent oil is added attached near the fuel inlet Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 31 5 REGULATIONS FOR LIFTING THE ENGINE KOHLER Regulations for lifting the engine AN 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 Hook the lifting device in the engine lifting points as shown in the figure Before lifting make sure the weight is correctly balanced by checking its barycentre Close all engine openings accurately exhaust intake etc then wash the outside and dry with a jet of compressed air AN Im
47. on control side 6203 2z Bearing on manifold side 6201 2z C3 Voltage regulator RTT 119 AC RH direction of rotation O 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 P1 Power in kW Current in Ampere T Alternator efficiency Note The alternator rpm is equal to the rpm shown in the table multiplied by 1000 Ratio between engine alternator rpm 1 1 8 Characteristic voltage curve for regulator type RTT 119 AC The electronic voltage regulator is built into the alternator The curve changes depending on temperature A Max voltage curve B Min voltage curve Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 89 cod ED0053029180 1 ed_rev 00 3 2204 2204 T o co 9 d v 3 D 0 0 2 D e OY Y c c E N cc NANI D Q I LO O gt LLI av o lt gt m gt oooo O o Q TOM 20 gt x rooodc x O o oe gt 0 0 OG 5 og lt
48. others not containing these compounds as this may give rise to the formation of nitrosamines which are a health hazard The cooling liquid is polluting so dispose of in a manner that does not damage the environment 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 GENERAL SAFETY DURING OPERATING PHASES procedures contained in this manual have been tested and selected by the manufacturer s technical experts and hence are to be recognised as authorised operating methods Some tools are normal workshop ones while others are special tools designed by the Manufacturer of the engine All tools must be in good working condition so that engine components are not damaged and that operations are carried out properly and safely Itis important to wear the personal safety devices prescribed by work safety laws and also by the standards of this manual Holes must be lined up methodically and with the aid of suitable equipment Do not use your fingers to carry out this operation to avoid the risk of amputation SAFETY AND ENVIRONMENTAL IMPACT Every organisation has a duty to implement procedures to identify assess and monitor the influence of its own activities products services etc on the environment Procedures for identifying the exte
49. pin and put back the push rods in their seats Then re assemble the rocker arm pin Rotate the crankshaft so as to position the pistons at half stroke for three cylinder engines For four cylinder engines place the piston of cylinder number one at 150 after the top dead centre in crossover stage The rocker arm pin must be fastened in different stages so as to allow the oil inside the tappets to be drained thus allowing them to position themselves correctly Oil density and ambient temperature are important factors that will affect the waiting time about 10 between successive fastening operations Hurried fastening can cause serious damage to the engine As a guideline to each fastening operation make sure that the cup of the upper spring bearing ring does not touch the valve stem oil sealing ring fitted on the guide The final torque of the rocker arm pin is 50 Nm Reassemble the rocker arm cap and the intake manifold tightening the screws to the indicated torque 82 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 KOHLER Fuel system 10 Engine aming Injection timing value type r p m gt D for r p m x 2400 KDW 1603 2204 13 41 11 7 Checking low pressure injection timing for engines with mechanical tappets The check of the advance on engines with mechanical tappets is carried out using the same procedu
50. rod tappet cam system The tappet body moves away from the plunger creating a slight vacuum in chamber B and causing the valve 2 to open thus allowing the oil in chamber A to flow into chamber B re establishing the quantity of oil required for optimal running conditions ype 37 Difficult operating conditions For correct functioning of the hydraulic tappets the pressure chamber of plunger 3 must always be filled with oil However this is not possible in some conditions in that when the engine is not running oil leakages may cause partial emptying of the tappets This situation will cause excessive clearance which will make itself apparent through an unusual ticking sound that is not to be confused with the normal ticking of the injectors 1 Starting from cold the engine has not been used for some time and oil may have leaked out of the pressure chamber of the tappets Moreover lubricant flows with greater difficulty at low temperatures and hence several seconds may go by before the tappets are once again supplied with oil 2 Engine very hot at minimum speed the oil pressure is low and tiny air bubbles may form inside it more than 5 of its volume This causes the lubricant to become compressible and the tappet is squeezed slightly creating clearance and thus making a noise 3 Starting and stopping the engine repeatedly very rare in this situation the tappets may empty temporarily 4 An oil
51. uu 47 PENE EINE RT RTT 47 Piston rings Clearance between 47 Piston rings Fitting sequence REE 47 micis NHI METTE EE Om 48 Pist n position and Er 48 C VIIder EEE EEE EEE 48 Cylinder head tightening for engines without hydraulic 1 49 Cylinder head tightening steps E TE m 49 Assembling and tightening the cylinder head on engines with hydraulic 49 oe 50 Connecting rod weights NTC NR RR H 50 Connecting rod and piston pin MNT TO m 50 Connecting rod Ge Ag EE Tm 51 1900 NEN m mE 51 Connecting rod piston assemblies 51 Center ae go PR e 52 Main bearing caps timing side flywheel SIGC ccccccsseecccceeecececeuseeecceueeeccsauuceeecsuseeesseuseeessusseessuuecessuaueeeessgeessssass 52 Check clearance between main bearings and journals 53 Thrust bearing oversizes CEPR OTT PEPL 54 NNN ro H P P 54 Crankshaft front and rear oil Seal TEEN NN 55 Oi ele Sn e EEE EEE sm 55 Crankshaft llegeuemee E E
52. 0 Camshaft bushing replacement Tool part No 7104 1460 021 Components d 1 Mandrel 2 Centering bushing T 3 Bushing diam 44 mm 1 5 4 Bushing diam 43 mm 5 Bushing diam 42 mm AN Important Before driving in the bushing position it in such a way that the lubricating hole maiches with the hole in the crankcase 109 110 62 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 KOHLER Disassembly Reassembly 6 Intake exhaust and injection cam height for engine with hydraulic tappets S 35 44 35 50 35 14 35 20 33 95 34 00 1 1 cyl intake cam A2 2 cyl intake cam 3 cyl intake cam A4 4 cyl intake cam 51 19 cyl exhaust cam 1 1 cyl injection cam 52 2 cyl exhaust cam 12 2 cyl injection cam 53 3 cyl exhaust cam I3 3 cyl injection cam S4 4 cyl exhaust cam 14 4 cyl injection cam Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 63 6 Disassembly Reassembly KOHLER 115 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 mar
53. 14 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 KOHLER General remarks and safety information 2 LIMITED 3 YEAR KOHLER DIESEL ENGINE WARRANTY Kohler Co warrants to the original retail consumer that each new KOHLER Diesel engine sold by Kohler Co will be free from manufacturing defects in materials or workmanship in normal service for a period of three 3 years or 2000 hours whichever occurs first from the date of purchase provided it is operated and maintained in accordance with Kohler Co s instructions and manuals If no hour meter is installed as original equipment then 8 hours of use per day and 5 days per week will be used to calculate hours used Our obligation under this warranty is expressly limited at our option to the replacement or repair at Kohler Co Kohler Wisconsin 53044 or at a service facility designated by us of such parts as inspection shall disclose to have been defective This warranty does not apply to defects caused by unreasonable use including faulty repairs by others and failure to provide reasonable and necessary maintenance The following items are not covered by this warranty Engine accessories such as fuel tanks clutches transmissions power drive assemblies and batteries unless supplied or installed by Kohler Co These are subject to the warranties if any of their manufacturers KOHLER CO AND OR THE SELLER SHALL NOT BE LIABLE FOR SPECIAL INDI
54. 167 onto the head making sure the dial indicator tracer 5 sets against the upper spring bearing ring of the intake valve Use a provisional fuel tank e g delivery balancing tool to gravity feed the injection pump connecting it to the inlet union 4 on the outlet union 3 fit the transparent nylon tube 6 by the means of which we measure the overflow Place the pump control rod in the stop position Operate the lever 2 of the tool to rotate the crankshaft until the valve touches the piston crown This procedure determines the exact TDC top dead centre of the piston of the cylinder in question reset the dial indicator in this position Then rotate clockwise the crankshaft on the flywheel side until diesel fuel begins to flow out of the small hose on the pump outlet Now change the rotation direction to anticlockwise The flow diminishes As soon as it stops flowing the delivery starting pointis determined Then lower the tool lever to make contact between the valve and the piston crown and using the dial indicator 5 measure how much lower the piston is with respect to the TDC top dead centre in mm Use the transformation chart mm to degrees to find out the correspondence between mm measured with the dial indicator 5 and degrees Example KDW 1603 2204 2204 T an advance of a 15 corresponds to a lowering of the piston with respect to the TDC top dead centre of 2 00 mm Disassemble the various equipment remove the rocker arm
55. 3029180 1 ed rev 00 Disassembly Reassembly 6 7 Wz I oM S97 AL EIN M de N DNG T 14 15 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 AN 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 2 Gasket AN Important Every time the rocker arm cap is removed replace the gasket 2 Rocker arm cover for engines with recirculating vent Components 1 Recirculating vent system 2 Oil refilling plug 3 Rubber hose for the passage of the oil vapours 4 Intake manifold Inthe rocker arm cap we find most ofthe recirculating vent system 1 This device is used to separate the oil vapours and to convey them via a rubber hose 3 into the intake manifold 4 The vapours are then recirculated inside the engine and notreleased into the air as they can be polluting Aclogged up air filter and a consequent increase in suction vacuum could cause the oil to be sucked into the combustion chamber and the engine over revving This is in any case avoided as the diaphr
56. 3029180 1 ed rev 00 KOHLER Electric system 11 Wiring diagram 24 V with alternator 35A 1 Alternator 2 Starter Motor 3 Battery See below for sizing details 4 Glow Plugs 5 Thermistor Glow Plug Controller Circuit 6 Glow Plug Controller Timer 7 Key Switch 8 System Fuse 9 Fuse Accessory 10 Fuel Valve 11 Glow Plug Indicator Lamp 12 Coolant High Temperature Lamp 13 Coolant High Temperature Switch N O 14 Oil Pressure Low Lamp 15 Oil Pressure Switch N C 16 Alternator Charging Lamp Off if Charging 17 Diode 18 Air Filter High Restriction Indicator 19 Air Filter Restriction Switch N O 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 LN 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 12 V 92 Ah 880 A EN 12 V 110 Ah 980 A EN 12 V 92 Ah 715 A SAE 12 V 110 Ah 790 A SAE Key switch electrical layout A Accessory B Off position C On position D Starting position 187 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 93 um c 9 E Qo co O O s 5 N gt O 2 ONN oc e lt Y Y
57. EES S UH os TT JUR TR 100 120 m ram C F 20 40 60 80 Workshop Manual KDW 160 90 2 n N FOG VE Me Ti 1 2 JET TET TETTE S quem Poo er FTT ud E LE EE TEE ERR ee ee eee eee eee eee ee eee eee KOHLER Electric system 11 185 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 A Absorbed current in Ampere P Power in kW M Torque in Nm Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 f ed rev 00 91 11 Electric system KOHLER Wiring diagram 24V with alternator 35A Pink S me WT pp t 17 1 1 6 E Black Green Ram 14 T White 15 NE Soe imm Sr TIE Black Blue 12 RS NS de DD amp R 2 F 5 Black Black e 186 92 Workshop Manual KDW 1603 2204 2204 T cod ED005
58. G W X ar Y Z A1 Note Dimensions shown in mm 26 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 KOHLER Technical information 3 KDW 2204 T So s 77 TET Note Dimensions shown in mm BMENSONSmm C r 30 e al 25 m 20 15 fe 20 m R 231 w e s0 n n s x ut 1 1 r as v 1s e uv z Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 f ed rev 00 27 4 MAINTENANCE RECOMMENDED OIL TYPE REFILLING KOHLER ROUTINE ENGINE MAINTENANCE MD 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 HOURS EXTRAORDINARY MAINTENANCE
59. Gasket 6 By pass valve Specifications Max working pressure 7 bar Max explosion pressure 20 bar Low temperature limit 35 C By pass valve setting 2 1 2 8 bar Total filtering surface 2000 cm2 Degree of filtration 19 um Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 71 KOHLER 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 ake 1 3 bed NE 60 80 90 100 120 90 100 120 134 135 Oil pressure curve for KDW 2204 Fig 136 The curve is obtained at the oil filter level constant engine epeed of 850 rpm in no load conditions ar bar 5 7 Fig 137 The curve is obtained at the oil filter level wit
60. HLER Maintenance Recommended oil type Refilling 4 LUBRICANT SAE Classification In the SAE classification oils differ on the basis of their ee tot viscosity no other qualitative characteristic is taken into account The first number refers to the viscosity when the engine is cold Symbol W winter while the second considers viscosity with the engine at regime The criteria for choosing must consider during winter the lowest outside temperature to which the engine will be subject and the highest functioning temperature during summer Single degree oils are normally used when the running temperature varies scarcely Multi degree oil is less sensitive to temperature changes 40 35 30 25201510 5 0 5 1015 20 25 30 35 40 45 50 Mineral base SAE Grade Semi synthetic base Synthetic base International specifications They define testing performances and procedures that the lubricants need to successfully respond to in several engine testing and laboratory analysis so as to be considered qualified and in conformity to the regulations set for each lubrication kind A P I American Petroleum Institute MIL Engine oil U S military specifications released for logistic reasons ACEA European Automobile Manufacturers Association Tables shown on this page are of useful reference when buying a kind of oil Codes are u
61. I ETT uu 72 Oil pressure curve for KDW 1003 72 Oil pressure curve for KDW 2204 T 72 NESE c rve f r KDW TN 72 ING STS TE 74 Expansion tank and Ca METTRE 75 Checking for cooling System eakS EE NE 75 cio Enge pet La fe EEE EE 75 TRENO fo gs sO Sy ene ee E ne eee ee ere ee ree 76 SEG taeda KEEPER 4 FINN 77 Fuel feeding pump drive rod protrusion NN E E OT ME 77 led T 76 Me 78 Injection pump disassembly vau eNEAN RENERE EE 78 How to reassemble injection pump COMPONENMGS ccccccsccccececseeeceececseeceueeseueeceueeseueeseueesseesaueesaeeeseessaeesseeesseeenseeeas 79 injection pump NONE TR mm 79 nen NNN 79 How to remove injection pump feeding WUD CS arrest 79 How to reassemble injection pump feeding 80 Instrument for equalizing injection pump delivery Part No 7104 1460 090 80 Injection pump
62. L 2104 C 46152 D KDW CHD ENGINES OIL CAPACITY KDW 1603 2204 2204 T OIL VOLUME AT MAX LEVEL Sheet STD oil sump OIL FILTER INCLUDED Litres ENHANCED aluminium oil sump OIL VOLUME AT MAX LEVEL Sheet STD oil sump WITHOUT OIL FILTER Litres ENHANCED aluminium oil sump With dynamic balancer AN 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 AN 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 Good quality or poor quality of the lubricating oil has an affect on engine performance and life If inferior oil is used or if your engine oil is not changed regularly the risk of piston seizure piston ring sticking and accelerated wear of the cylinder liner bearing and other moving components increases significantly Always use oil with the right viscosity for the ambient temperature in which your engine is being operated AN Danger Attention The used engine oil can cause skin cancer if kept frequently in contact for prolonged periods If contact with oil cannot be avoided wash carefully your hands with water and soap as soon as possible
63. RECT INCIDENTIAL OR CONSEQUENTIAL DAMAGES OF ANY KIND including but not limited to labor costs or transportation charges in connection with the repair or replacement of defective parts IMPLIED OR STATUTORY WARRANTIES INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FORA PARTICULAR PURPOSE ARE EXPRESSLY LIMITED TO THE DURATION OF THIS WRITTEN WARRANTY We make no other express warranty nor is any one authorized to make any on our behalf Some states do not allow limitations on how long an implied warranty lasts or the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state To obtain warranty service Purchaser must bring the engine to an authorized Kohler service facility To locate the nearest facility visit our website www kohlerengines com and use the locator function consult your Yellow Pages or telephone 1 800 544 2444 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 cu
64. T cod ED0053029180 1 ed rev 00 KOHLER Disassembly Reassembly 6 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 f ed rev 00 67 7 TURBOCHARGER KOHLER 122 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 Turbocharger components 1 Flexible hose 2 Actuator 3 Collar 4 Turbine body 5 Snap ring 6 Compressor volute 7 Thickness 8 Nut 9 Lock nut 10 Shaft with turbine 11 Segment 12 Flame shield 13 Bearing 14 Snap ring 15 Thickness 16 Segment 17 Oil deflector 18 Thrust block sleeve 19 O ring 20 Thrust block bearing 21 Thrust block ring 22 Bearing 23 Snap ring 24 Snap ring 25 Bearing support Turbocharger Testing Get a pressure gauge with scale from zero to 2 bar connect it according to fig 120 and 121 Start up the engine warm it up for a few minutes then take it to 3000 rpm at the power NB The supercharge air pressure value to be measured is 89 93 KPa 0 89 0 93 bar If the setting pressure does not come within the required value it is necessary t
65. T engines the head gasket is metal 1603 2204 2204 T 1603 2204 2204 T 1603 2204 2204 T 0 68 0 81 0 83 0 98 0 81 0 94 0 98 1 10 0 94 1 07 0 67 0 82 0 69 0 82 0 67 0 82 0 66 0 79 Note The notches shown above protrude from the cylinder head plane you can thus determine the gasket thickness before taking down the head 48 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 KOHLER Disassembly Reassembly 6 1 5 1 3 9 mes ASP seii 0 N IA ON TL 2 S 200 A KDW 1603 B KDW 2204 2204 T L IN IR Vi 2222 27027207 KK 58 27 NN S ZL NNN OOS L cnn F Cylinder head tightening for engines without hydraulic tappets Use a torque wrench fitted with tool for angular tightening It is recommended to replace the screws whenever the head is disassembled AN Important The cylinder head must never be retightened 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 tightene
66. __ WORKSHOP MANUAL KOHLER KDW 1603 2204 2204 T KOHLER ENGINES KDW 1603 2204 2204 T 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 well as emp
67. agm valve 7 by winning the resistance of spring 6 properly calibrated closes duct 5 and stops the oil from reaching manifold 4 via hose 3 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 39 6 Disassembly Reassembly KOHLER N YX J di ACAN 48 BI gt Ej am 4 VN Rocker arm assemly Loosen the screws which fasten the assembly to the head When refitting apply a drop of Loctite 270 onto the threads O 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 mm mm Limit value mm 14 032 14 050 A B 13 989 14 000 0 043 0 050 With bushing fitted to the rocker arm and reamed Cylinder head MWD Caution Warning Do not demount when hot or the part could become deformed Do not remove when hot to avoid deformation Check cylinder head plane using a metal straight edge and thickness gauge if warpage exceeds 0 10 mm le
68. aired 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 Please review the document titled Kohler Co Federal and California Emission Control Systems Limited Warranty Off Road Diesel Engines for complete details of your heavy duty off road engine warr
69. ake 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 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 f ed rev 00 75 10 FUEL SYSTEM KOHLER AN 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 fa
70. anty If you have any questions regarding your warranty rights and responsibilities or the location of the nearest Kohler Co authorized service location you should contact Kohler Co at 1 800 544 2444 or access our website at www kohlerengines com Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 f ed rev 00 13 2 General remarks and safety information KOHLER 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 Presence of rotating parts Danger of entangling and cutting Electric shock Danger of severe scalding or death 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 FLI 7 Fo 2 Jo A rn P on 7 Palin 1 ELR RELSE E
71. bic centimeters cc and pressure is presented in barometric units bar GLOSSARY AND TERMINOLOGY Cylinder number one is the piston timing belt side viewed from the flywheel side of the engine Rotation direction anticlockwise viewed from the flywheel side of the engine For clarity here are the definitions of a number of terms used recurrently in the manual Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 f ed rev 00 15 2 General remarks and safety information KOHLER SAFETY REGULATIONS GENERAL NOTES Kohler engines are built to provide safe and longlasting performances but in order to obtain these results it is essential that the maintenance requirements described in the manual are observed along with the following safety recommendations The engine has been built to the specifications of a machine manufacturer and it is his responsibility to ensure that all necessary action is taken to meet the essential and legally prescribed health and safety requirements Any use of the machine other than that described cannot be considered as complying with its intended purpose as specified by Kohler which therefore declines all responsibility for accidents caused by such operations The following instructions are intended for the user of the machine in order to reduce or eliminate risks especially those concerning the operation and standard maintenance of the engine
72. can cause fires and severe burns Do not fill the fuel tank while the engine is hot or running Explosive Fuel Fuel is flammable and its vapors can ignite Store fuel only in approved containers well ventilated unoccupied buildings Do not fill the fuel tank while the engine is hot or running since spilled fuel could ignite If it comes in contact with hot parts or sparks from ignition Do not start the engine near spilled fuel Never use fuel as a cleaning agent A DANGER Carbon Monoxide can cause severe nausea fainting or death Avoid inhaling exhaust fumes and never run the engine in a closed building or confined area Lethal Exhaust Gases Engine exhaust gases contain poisonous carbon monoxide Carbon monoxide is odorless colorless and can cause death if inhaled Avoid inhaling exhaust fumes and never run the engine in a closed building or confined area DANGER Explosive Gas can cause fires and severe acid burns Charge battery only in a well ventilated area Keep sources of ignition away Explosive Gas Batteries produce explosive hydrogen gas while being charged To prevent a fire or explosion charge batteries only in well ventilated areas Keep sparks open flames and other sources of ignition away from the battery at all times Keep batteries out of the reach of children Remove all jewelry when servicing batteries Before disconnecting the negative ground cable make s
73. d in four susequent steps with the following 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 steps 90 90 For bolts 12 R present only in the TURBO engines perform a rotation of the key of 270 in three steps 90 90 90 Assembling and tightening the cylinder head on engines with hydraulic tappets AN Important Before re assembling the cylinder head the tappets must be removed from their housing and released This operation must be carried out using a pin 1 Insert pin 1 inside the tappet and open the non return valve The excess oil is released by turning the tappet upside down Rotate the crankshaft so as to position the pistons at half stroke for three cylinder engines For four cylinder engines place the piston of cylinder number one at 150 after the top dead centre in crossover stage Fit the head insert the fastening screws and tighten them in the order shown in figure 57 and to their respective torques see Cylinder Head Tightening Stage Reassemble the complete pin inserting the seats of the rocker arms on their respective rods and screw up the fastening screws of the supports by hand AN Important To avoid bending the push rods or damaging the tappets the fastening screws of the rocker arm pin supports must be tightened gradually before reaching the final torque This procedure will give time for the excess
74. d up for the first time Remove oil pan and oil pump suction pipe Disconnect the connecting rod from the engine shaft and perform the subsequent checks When refitting both centering notches A and B should be located on the same side O Tighten the connecting rod big end bolts to 70 Nm Connecting rod weights Connecting rod piston and piston pin can also be weighed in a preassembled state but the difference in weigt should not exceed 14 g in order to avoid unbalance Connecting rod and piston pin The connecting rod big end shell bearings are supplied in either standard or with this value decreased by 0 25 and 0 50 mm respectively AN Important The fastening screws must be tightened by hand until the beginning of the tightening stage and then pre tightened to 10 15 Nm O Final tightening is to 70 Nm 50 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 KOHLER Disassembly Reassembly 6 1603 2204 2204 T EJ 65 Valueto measure With driven and bored bearing Re Clearance mm Limit value mm With cap fitted and screws tightened to a torque of 70 Nm Connecting rod alignment Use a surface plate and a dial gauge as shown in the figure 65 Check the alignment of the axes using the wrist pin of the piston deviation A 0 02 mm limit 0 05 mm Moderate warpage may be corrected by gradually working with a press
75. delivery equalization 2 2 m 80 ETNE 81 Injection pump P No 6590 249 Plunger and barrel 5 81 Checking injection pump dalivery STE m 81 Checking low pressure injection timing for engines with hydraulic tappets 82 Checking low pressure injection timing for engines with mechanical 83 Injection timing correction by changing the pad 83 Ne UR T tm 84 e a E Uu TURPE 84 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 f ed rev 00 7 Chapter index KOHLER UV a Be gd Sg geo BR ee ae se eee ee ee eee eee eee eee 86 Wiring diagram with alternator 12V 45A 65A 80A rrrnnrnnnrrnvnnnnnrnrnnnnrnnrnnnnrnnnnnnnrnnrnnnnsnnrnnnnsnnrnnnnrnnrnnnsrnnrnnnnsnnnnsnernnnnnnsen 86 Recommended batteries 87 Alternator type Marelli 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 88 Alternator type Marelli AA 125 R 14V 65
76. ds disconnect and insulate the positive cable of the battery so as to prevent accidental short circuits and activation of the starter motor Check the belt tension only when the engine is turned off AN Do not start the machine in closed or poorly ventilated IMPORTANT To start the engine follow the specific instructions provided in the engine and or machine operating manual Do not use auxiliary starting devices not originally installed on the machine e g Startpilot systems which utilise ether etc Before carrying out any work on the engine turn it off and allow it to cool down Do not perform any operation while the engine is running Check that the discharged oil the oil filter and the oil contained in the oil filter are disposed of in such a way as not to harm the environment Close the fuel tank filler cap carefully after each filling operation Do not fill the tank right up to the top but leave sufficient space to allow for any expansion of the fuel Do not smoke or use naked flames while filling 16 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 KOHLER General remarks and safety information Take care when removing the oil filter as it may be hot The operations of checking filling up and replacing the cooling liquid must be carried out with the engine turned off and cold Take particular care if liquids containing nitrites are mixed with
77. e State s stringent anti smog standards Kohler Co must warrant the emission control system on your engine for the time period listed below provided there has been no abuse neglect or improper maintenance of your engine Your emission control system may include parts such as the fuel injection system and the air induction system Also included may be hoses connectors and other emission related assemblies Where a warrantable condition exists Kohler Co will repair your heavy duty off road engine at no cost to you including diagnosis parts and labor MANUFACTURER S WARRANTY COVERAGE 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 19XkW 37 and rated speed less than 3 000 rpm all variable speed engines with maximum power 19SkW lt 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 19xkW 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 rep
78. e 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 fastening parts in a criss cross or alternating pattern Assemblies and or components with a specific tightening torque must initially be fastened at a level lower than the assigned value and then subsequently tightened to the final torque RECOMMENDATIONS FOR OVERHAULS AND TUNING AN Important To locate specific topics the reader should refer to the index 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 The operator must comply with the specific measures described in order to avoid errors that might cause damage to the engine Before carrying out any operation clean the assemblies and or components thoroughly and eliminate any deposits or residual material Wash the components with special detergent and do not use steam or hot water not use flammable products petrol diesel etc to degrease or wash components Use special products Dry all washed surfaces and components thoroughly with a jet of air or special cloths before reassembling them Apply a layer of lubricant
79. eaking nut 2 STEI screw 3 Rivets No 2 4 TCEI screw 5 Special cover fixing screw 6 Lower plate 7 Upper plate 211 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 101 a2 KOHLER 102 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 KOHLER 13 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 Awoid 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 AN 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 PROTECTIVE TREATMENT 1 2 3 4 5 6 7 8 9 10 Pour in the engine housing AGIP RUSTIA protective oil up to the maximum level Fill up with fuel containing 10 AGIP RUSTIA NT Make sure that the coolant is up to the maximum level Start the engine and keep it idle at minimum sp
80. eed for some minutes Bring the engine to of the maximum speed for 5 10 minutes Turn off the engine Empty out completely the fuel tank Spray SAE 10W on the exhaust and intake manifolds Seal the exhaust and intake ducts to prevent foreign bodies from entering Thoroughly clean all external parts of the engine using suitable products 11 Treat non painted parts with protective products AGIP RUSTIA NT 12 Loosen the alternator fan belt 13 Cover the engine with a proper protective sheet MD Caution Warning In countries in which AGIP products are not available find an equivalent product with specifications MIL L 21260C AN Important Maximum every 24 months of inactivity the engine must be started up by repeating all Engine Storage operations PREPARING THE ENGINE FOR OPERATION AFTER PROTECTIVE TREATMENT After the storage period and before starting up the engine and preparing it for operation you need to perform certain opera tions to ensure maximal efficiency conditions 1 2 3 8 9 10 11 12 13 Remove the protective sheet Remove any sealing devices from the exhaust and inta ke ducts Use a cloth soaked in degreasing product to remove the protective treatment from the external parts Inject lubricating oil no more than 2 cm3 into the intake ducts Adjust the alternator fan belt tension Turn the engine manually to check the correct movement
81. ekte und 39 Rocker arm cover for engines with recirculating 39 Rocker arm ES Es LL PRISES 40 e sein ene 40 EGO M 40 SS o giao EN 41 Valve spring check under load EE EE NE m 41 VENTS LE LET PPTTTERPPTT 41 Valve guides and cylinder Ev deemed 41 Valve guide insertion after NN 42 Oil seal in the valves guides intake and 42 Valve sedis Ag DOE e er 43 Valve recess and sealing surfaces rene 43 ge JA eV HON CHAMO EEE EEE EE ENER 44 Hydraulic tappet valve 44 Hydraulic diagram for feeding the appels caos uaria oer p Eo etae bici ehe Reb ero bx Le UI h 44 Hydraulic tappet Tr 44 Pl 45 Injection pump ee EEE EEE ENE 45 S nel c r Pt TT H se 46 diesel dcc EE EE E MES 46 xo 46 Piston avalaDilty TT H 46 PIS WOR WG e MET
82. eleases 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 3 Technical information KOHLER 24 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 KOHLER Technical information 3 OVERALL DIMENSIONS KDW 1603 3D Leth LESE ce all PE 4 7 Ea en ie ia E M 5 p rm gt d gt 4 4 S a a LL F f i mw uma DA F Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 25 3 Technical information KOHLER KDW 2204 FEL P A JT IF j D ae E NUT i OMTAPPO SCARICO ACQUA WATER DRAIN PLUG SCARICO OLIO 1 ae OIL DRAIN PLU
83. elect all components according to their chemical characteristics and dispose of them separately Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 17 3 TECHNICAL INFORMATION KOHLER POSSIBLE CAUSES AND TROUBLE SHOOTING THE ENGINE MUST BE STOPPED IMMEDIATELY WHEN 1 The engine rpms suddenly increase and decrease 2 Asudden 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 Engine starts but stops sumption ELI LLL He noise eve Obstructed fuel line Fuel filter clogged Air or water leaks in fuel system The tank cap vent hole is clogged No fuel E Discharged battery Cable connection uncertain or incorrect _ Fautystartngswin Faulty staring motor Faulty glow plugs Faulty glow plug control relay EE Clogged air filter J LLL LL LLL LA Excessive idle operation ae Incomplete run in Bl M Overloaded BIS deese ese _ Governor spring broken or unhooked o o A
84. eplace the seal ring 1 Introduce seal ring 1 into the injector housing with the sealing surface facing upwards see figure 171 See page 22 for maintenance intervals O Fix injector to the head tightening to 70 Nm Injector setting Connect the injector to a injection test stand and check that the pressure setting is 140 150 bar Adding the shims 9 increases the pressure setting reducing their number lowers it Eleven spare setting shims are included their measurements range from 1 to 2 mm When spring 10 is replaced calibration must be carried out at a pressure 10 bars higher than the nominal pressure 160 bar to counterbalance bedding in the operation Check needle valve sealing by slowly moving the hand pump until approximately 120 bar per 10 seconds Replace nozzle 12 in case of dripping O The torque of the injector ring nut is 70 90 Nm 84 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 KOHLER Fuel system Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 f ed rev 00 11 ELECTRIC SYSTEM KOHLER Wiring diagram with alternator 12V 45A 65 80A Pink SS IE N 1mm L E 14 White 15 EN Nr E 1 Wr T Black XY Blue 12 13 VEE Iz 2 5mm 200 11 SS SS TE 10 F Black 3 s y at ag Y
85. exerting pressure and using special pliers and a plastic hammer The nylon tubes can no longer be used after disassembly Replace them every time they are removed Instrument for equalizing injection pump delivery Part No 7104 1460 090 Components 1 Tank 2 Test tube 3 Support 4 Switching lever 5 Injection pump discharge tube cut off valve 6 Injection pump intake tube off valve A Tube for connection to injection pump intake union B Tube for connection to injection pump discharge union Remove feed tubes from all injection pumps and fit the instrument tubes making sure that each pump has its own intake and discharge tubes Connect the instrument A with the engine A and the instrument B with the engine B Proceed in a similar manner with the other pumps m N 4 Injection pump delivery equalization R RI AN Op N o a After checking the injection advance go ahead with the delivery balancing of the pumps Before connecting the tool serial number 7104 1460 090 to the pumps and refilling tank 1 with fuel set it to a higher level of at least 200 mm than that of the pumps themselves Open taps 5 and 6 and start the engine set the engine to an idling speed of 2000 rpm Switch the engine feed from tank 1 to the tubes 2 using the switching lever 4 fig 163 After the first minute minimum testing time verify that the level between the highest and
86. fig 208 209 usiein ia rotos era ne dx nx dap peu bas kan 101 0 M T 101 Application diagram for tampering system adjustment screw and torque gearing device for EPA approved engines 101 13 ENGINE STORAGE c C 103 ENE NE 103 Peer MNT RERO 103 Preparing the engine for operation after protective treatment 103 14 TORQUE SPECIFICATIONS AND USE OF SEALANT eene nennen sns annuas 104 Main torque specifications PONERET B 104 Table of tightening torques for standard screws coarse 105 Table of tightening torques for standard screws fine 105 VB FC TOOLS e 106 8 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 KOHLER Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 EB MANUFACTURER AND MOTOR IDENTIFICATION DATA KOHLER The identification plate shown in the figure can be found directly on the engine It
87. for the timing side main bearing cap To introduce the supports complete with silicone rubber seals 2 into the crankcase place two plates C and D measuring 0 1 mm in thickness between the surfaces O Tighten the screws to 120 Nm 52 Workshop Manual KDW 1603 2204 2204 T _ cod ED0053029180 1 ed rev 00 KOHLER Disassembly Reassembly 6 C _ INS B 73 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 O Tighten bolts to 120 Nm Determine clearance by measuring the squeezed portion of the plastigage with the indexed scale supplied gt For clearance between main journals connecting rod big end journals and the corresponding bearings fig 79 AN Important When replacing bearings make sure that the lower half is kept separate from the upper one Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 53 6 Disassembly Reassembly KOHLER 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 beari
88. ger Attention This indicates situations of grave danger which if ignored may seriously threaten the health and safety of individuals AK 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 AN Important This indicates particularly important technical information that should not be ignored DANGER Accidental Starts can cause severe injury or death Disable engine by disconnecting negative battery cable Accidental Starts Disabling engine Accidental starting can cause severe injury or death Before working on the engine or equipment disable the engine as follows 1 Disconnect negative battery cable from battery DANGER Hot Parts can cause severe burns Do not touch engine while operating or just after stopping Hot Parts Engine components get extremely hot from operation To prevent severe burns do not touch these areas while the engine is running or immediately after it is turned off Never operate the engine with heat shields or guards removed SAFETY REGULATIONS DANGER Rotating Parts can cause severe injury Stay away while engine is in operation Rotating Parts Keep hands feet hair and clothing away from all moving parts to prevent injury Never operate the engine with covers shrouds or guards removed DANGER Fuel
89. h engine working at 3000 rpm at the N power 3 5 2 4 3 7 1 1 3 3 60 70 80 90 100 120 60 70 80 90 100 120 ec 136 137 Oil pressure curve for KDW 2204 T Fig 138 The curve is obtained at the oil filter level constant engine epeed of 850 rpm in no load conditions ar ba 5 7 Fig 139 The curve is obtained the oil filter level with engine working at 3000 rpm at the N power 3 5 2 4 Note The max lubrication oil temperature must be lower than 12 3 5 the sum ambient temperature 95 C 9 60 70 80 90 100 120 2 60 70 80 90 100 120 SC 138 139 72 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 KOHLER Lubrication system 8 Notes Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 f ed rev 00 73 O COOLING SYSTEM KOHLER AN 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 Coolant fluid is polluting it must therefore be disposed of in the correct way Do not litter COOLING SYSTEM LAYOUT 1 5 9 2 ES I ON 1 0 9 rah ors a
90. he bottom of the skirt A 12 mm In case of diameter wear exceeding 0 05 mm of the minimum given value replace piston and rings Nota The oversizes are 0 50 and 1 00 mm The TURBO piston differs from that of the NATURALLY ASPIRATED in its cooling sprayer passage niche and an insert in the slot of the first ring Piston availability The pistons oversized by 0 5 and 1 0 mm have the uprating reference on the crown fig 45 46 Class 9 Cylinder Piston Clearance mm mm mm 88 00 88 01 87 960 87 967 0 033 0 050 46 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 KOHLER Disassembly Reassembly 6 51 Piston weight Weigh the pistons when replacing them in order to avoid unbalance The difference in weight should not exceed 6 g Piston rings End gaps Place piston rings into the cylinder and measure end gap A Piston rings Clearance between grooves 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 Asse
91. jection pump delivery rod 10 Bushing 11 Lever 12 Adjusting screw Yoke 9 is pre set through screw 12 and eccentric 8 Do not unscrew O When refitting camshat gear 1 tighten bolt 4 to 100 Nm Dimensions for injection pump delivery control yoke adjustement Components 9 Control yoke for injection pump delivery rod 10 Bushing 11 Lever 12 Adjusting screw 13 Reference and mounting plane for support 14 14 Lever Support Re op Note f when adjusting screw 12 is unintentionally loosened adjust yoke 9 considering the dimensions A C and D In case of replacement lever 11 is supplied complete with preset yoke 9 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 f ed rev 00 59 6 Disassembly Reassembly KOHLER HEAVY FLYWEIGHT 100 LIGTH FLYWEIGHT L 101 gana i mmm X c OK puit pa SY Ls cx JE OG 102 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 se
92. ks 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 Mark the idler gear with camshaft and timing gear Valve timing check Check valve timing at the crankshaft The values shown are checked at the flywheel circumference with flywheel diameter of 290 each degree corresponds to 2 53 mm Set valve clearance at 0 65 0 70 mm after checking reset the value to 0 15 mm Set dial gauge on intake valve to a zero value by rotating the crankshaft according to its direction of rotation you can measure intake valve opening advance referred to top dead center S and D intake valve closing delay referred to bottom dead center I Follow the same procedure for exhaust valves checking y exhaust valve opening advance and 6 exhaust valve closing delay 64 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 KOHLER Disassembly Reassembly 6 Legend S piston at top dead centre piston at bottom dead centre a intake valve open intake valve closed y exhaust valve open 6 exhaust valve closed 116 Engines with hydraulic tappets Timing belt operating angles with valve clearance set to zero under
93. loying 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 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 f ed rev 00 3 m KOHLER 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 body code N Revision Issue date den Endorsed 7 ID p 0053029180 51223 0 02 15 2011102 15 2011 HO 4 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 KOHLER CHAPTER INDEX CHAPTER INDEX 1 MANUFACTURER AND MOTOR IDENTIFICATION DATA cernere nennen nnn nnn 10 The identification plate shown in the figure can be found directly on the 10 RM I E T m 10 Name plate for EPA rules applied on rocker arm cap 11 Compilaton example ER EEE E E 11 2 GENERAL REMARKS AND SAFETY INFORMATION
94. mble the segments with the TOP marking facing the piston crown Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 47 KOHLER 6 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 Warning Remove the head gasket from its protective wrapping only when ready for fitting At B the gasket shows small semi circular notches indicating thickness Choose the proper head gasket considering that for each value of A maximum projection of the piston from the cylinder surface there is a matching gasket among the three available with no notch one notch or two notches to achieve a clearance volume between 0 66 and 0 90 mm In the LDW 1603 engines the head gasket is made of fibre while in the LDW 2204 2204
95. n valve 244 d Spring Push rod VN A f Low pressure chamber N oN V f g High pressure chamber IN NA The hydraulic tappet is a device that enables elimination of 2 2 clearance between timing system components and provides the following advantages d g Reduces noise levels during operation 7A Reduces wear of the timing system components thanks to there being no collisions at the opening with consequent breaking of 29 the oil film No maintenance 44 Workshop Manual KDW 1603_2204_2204 T _ cod ED0053029180 1 ed_rev 00 KOHLER 6 Hydraulic tappet operation The operating principle of the hydraulic tappet is based on the incompressibility of the liquids and on controlled leakage 2 lt 4 PY Through push rod 1 the pressurised oil gets into the tappet in GN Z chamber A low pressure chamber maintaining a constant flow of 7 Lad nz oil inthe above chamber as well as in the high pressure chamber aN NG The oil can only enter chamber B through the non return valve 2 Y and leave through the clearance between the plunger 3 and the JAN tappet body 4 controlled leakage IRS SS 2 Chamber is refilled when the tappet is the bottom of the cam WZ NY NNN WSS NL SSS base and spring 5 keeps plunger 3 pressed thus eliminating the clearance in the entire valve rocker arm push
96. ng oversizes Grinding B according to the above table following half rings can be assembled 1 Oversize Half rings 1 and 2 on both the support sides 0 10 mm 2 9 Oversize Half rings 1 and 2 on one support side 0 10 mm and on the other side 0 20 mm 39 Oversize Half rings 1 and 2 on both the support sides 0 20 mm fig 82 A fig 81 STD 27 TT 28 00 27 92 28 05 28 12 28 25 28 07 28 30 Seu uds 2nd Oversize 28 22 28 35 28 17 28 40 3rd versize 28 32 28 45 Crankshaft end play After tightening main bearings measure the end play A between the crankshaft shoulder on the flywheel side and main bearing halves Rif Clearance mm If the end play does not fall within the given values check B and possibly fit the oversize thrust bearings 82 54 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 KOHLER Disassembly Reassembly 6 AA oN eR 86 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 e Carefully clean the seat e Soak the seal
97. nt of the impact on the envi ronment must consider the following factors Liquid waste Waste management Soil contamination Atmospheric emissions Use of raw materials and natural resources Regulations and directives regarding environmental impact Some phases may require the assistance of more than one operator If so it is important to inform and train them regarding the type of activity they will be performing in order to prevent risks to the health and safety of all persons involved Do not use flammable liquids petrol diesel etc to degrease or wash components Use special products Use the oils and greases recommended by the manufacturer Do not mix different brands or combine oils with different characteristics Discontinue use of the engine if any irregularities arise particularly in the case of unusual vibrations Do not tamper with any devices to alter the level of performance guaranteed by the manufacturer Inorderto minimise the impact on the environment the manufacturer now provides a number of indications to be followed by all persons handling the engine for any reason during its expected lifetime All packaging components must be disposed of in accordance with the laws of the country in which disposal is taking place Keep the fuel and engine control systems and the exhaust pipes in efficient working order to limit environmental and noise pollution When discontinuing use of the engine s
98. o adjust the stroke of the valve control rod C Waste gate 68 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 KOHLER turbocharger 7 Checking actuator setting Waste gate valve control rod stroke adjustment A 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 Use the reduction unit 5 to send air to the actuator so as to make terminal 2 of A move forward A 1 mm Position a comparator 6 so that the feeler rests on the terminal 2 The pressure read on the pressure gauge must be 830 890 mm Hg 1 11 1 19 bar If the pressure is lower than the given value proceed as follows Unscrew the lock nut 1 Remove the split pin 9 and disconnect the rod 8 Keeping the rod stationary screw the terminal 2 to reach the setting pressure While the terminal is rotating the rod must undergo no twisting Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 69 8 LUBRICATION SYSTEM KOHLER
99. oil in the tappets to drain away Each time you start to tighten up the fastening screws of the supports you can use the upper spring support cup of the valve spring as an indicator to know how far to screw them up The cup must never be compressed so much that it touches the valve stem oil sealing ring fitted on the guide Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 f ed rev 00 49 6 Disassembly Reassembly KOHLER 3 1 et i le F LA w ha ry c A e eo iS is fy ex AQ NOM ji KDW 1603 KDW 2204 2204 T 62 KDW 1603 2204 2204 T 63 KDW 2204 T KDW 64 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 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 Connecting rod AN Important When remounting the big end bearings remember to thoroughly clean the parts and generously lubricate them to prevent seizure when the engine is starte
100. over all surfaces to protect them against oxidation Check all components for intactness wear and tear seizure cracks and or faults to be sure that the engine is in good working condition Some mechanical parts must be replaced en bloc together with their coupled parts e g valve guide valve etc as specified in the spare parts catalogue AN Danger Attention During repair operations when using compressed air wear eye protection 34 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 KOHLER Disassembly Reassembly 6 Oil bath air cleaner AN Danger Attention Never clean the filtering element 6 using solvents with a highly flash point This could cause an explosion A Caution Warning During repair operations when using compressed air wear eye protection Check gaskets and replace if necessary Check that flange welds are free of porosity or defective spots Carefully clean bowl and filtering element with Diesel fuel and dry with compressed air Top up engine oil to the mark see below When refitting tighten nuts to 25 Nm See page 22 for periodic cleaning and oil replacement Oil bath air cleaner components AN Important Check the sealing rings regularly Replace the sealing rings if hardening or damage is noted Bowl Outer seal ring Lower filtering element
101. portant The bracket of the lifting points have been designed to lift the engine only They are not intended nor approved to lift additional weights Do not use different methods to lift the engine than those described herein In case different methods are used no warranty shall be granted for any consequential damage Use protective gloves when handling the engine 2 Workshop Manual KDW 1603 2204 2204 T _ cod ED0053029180 1 ed rev 00 KOHLER Regulations for lifting the engine 5 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 33 6 DISASSEMBLY REASSEMBLY KOHLER RECOMMENDATIONS FOR DISASSEMBLING AND ASSEMBLING AN 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 ar
102. re as that described for the hydraulic tappets the only difference is in the disassembly and reassembly of the rocker arm pin and of the push rods which is not necessary Injection timing correction by changing the pad thickness Should it be necessary to correct the injection static advance remove the injection pump from the engine block and replace pad B inside the injection tappets with one of a different thickness to extract pad B use a magnet C Its value is printed on the lower part of the pad Twelve spare pads are supplied for the advance variations and their thickness can vary from 4 to 5 1 mm The gasket A between the injection pump flange and the engine block is only one with the only task of preventing any possible oil leaks Previously to vary the injection advance gaskets of different thicknesses were used between the injection pump surface and the engine block surface in effect gasket A without sealing rubber border 47 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 83 KOHLER 170 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 r
103. rnator bracket 8x1 25 25 Engine mounting bracket 12x1 75 50 Bracket of the oil suction hose with equalizer 6x1 10 Bracket of the oil suction hose without equalizer 8x1 25 Loctite 242 Alternator support 8x1 25 25 Injection pump control rod support 6x1 10 Rocker arm assembly fig 16 pag 31 10x1 5 50 Loctite 270 Governor lever support 6x1 10 Tank bracket 8x1 25 30 Thermostat support 8x1 25 25 Loctite 242 Crankcase lubrication port plug 14x1 25 Loctite 554 Plug for oil pressure regulating valve 16x1 5 50 Water drain plug 14x1 5 40 Loctite 242 Oil drain plug 18x1 5 50 Air bleed plug under oil sump 12x1 5 35 Loctite 242 Head fig 57 59 pag 39 40 Connecting rod big end fig 61 64 pag 40 10x1 5 70 Oil suction hose 6x1 10 Air bleed tube under oil sump 12x1 5 35 Loctite 518 Water pump control fan and pulley 6x1 10 Flywheel fig 12 pag 30 12x1 25 140 Loctite 270 104 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 KOHLER Torque specifications and use of sealant 14 Table of tightening torques for standard screws coarse thread Resistance class R Quality Dimensions me 79 15 og 14 210 205 os mo tsa 18 26 ao so 69 sa eo eo 2000 20 Table of tightening torques for standard screws fine thread Resistance class R Quality Dimensions Diameter a
104. s at 3000 rpm Nota Speed increases when loosening screw 2 and decreases when tightening it Standard injection pump delivery setting without torque dynamometer This adjustment must only be carried if necessary and if there is no dynamometric brake since this type of adjustment is very approximate Loosen delivery limiting device C by 5 turns Bring engine to max rpm in no load conditions i e 3200 rpm Tighten limiting device C until the engine rpm decreases Unscrew limiting device C by 1 1 2 turn Tighten lock nut Note f the engine at full load generates too much smoke tighten C loosen C if no smoke is observed at the exhaust and if the engine cannot deliver its full power Injection pump delivery limiting and torque adjusting device Limiting device C has the function of limiting the injection pump maximum delivery The same device acts as torque adjusting device since springs N act on lever L and thus oppose the resistance of spring M contained in the barrel The torque limiting device allows lever L to have a stroke H of 1 0 1 1 mm this increases the injection pump delivery while torque reaches its peak Note In application for generating sets and motor welding units the torque adjusting device only acts as delivery limiting device without spring M and stroke H 100 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 KOHLER Settings 12 By
105. se of doubt install a new cartridge Air filter clogging indicator AN Important The indicator has to be tightened to mounting 4 as shown in fig 5 B Due to space requirements it can be assembled by using special fastener 3 fig A and by creating a hole of 14 15 mm in the rubber hose see fig 4 1 Air filter restriction switch 2 Turbo adapter 3 Fastener 4 Mounting for clogging indicator Note There are two types one for an aspirated engine and one for a supercharged engine Setting for aspirated engine KDW 1603 2204 635 mm column of water Setting for supercharged engine KDW 2204 T 380 mm column of water 36 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 KOHLER Disassembly Reassembly 6 Intake manifold The sealing surface should be clean smooth and free of any strains and scoring When reassembly replace gasket A O Tighten the fastening screws to 25 Nm RM e Exhaust manifold B m FN Danger Attention X 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 When refitting replace gaskets B O Tighten nuts to 25 Nm V belt AN Danger Attention Check the belt tension only when the engine is not running
106. sually printed out on the oil container and the understanding of their meaning is useful for comparing different brands and choosing the kind with the right characteristics Usually a specification showing a following letter or number is preferable to one with a preceding letter or number An SF oil for instance is more performing than a SE oil but less performing than a SG one ACEA Regualtions ACEA Sequences PETROL HEAVY DUTY DIESEL ENGINES SLow viscosity for frictions reduction OBSOLETE A2 Standard AS High performances E2 Standard Heavy conditions Euro 1 Euro 2 engines LIGHT DUTY DIESEL ENGINES 4 Heavy conditions Euro 1 Euro 2 Euro engines 5 performances in heavy conditions Euro 1 Euro 2 Euro B1 9Low viscosity for frictions reduction 3 engines B2 sStandard High performances indirect injection High quality direct injection API MIL Sequences DIESEL PETROL r4 49 DIE 1 LI IL IL IL LI Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 f ed rev 00 29 4 Maintenance Recommended oil type Refilling KOHLER PRESCRIBED LUBRICANT API CF SH ae 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
107. t 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 KDW 1603 2204 2204 T Dimensions 50 035 50 066 59 04 59 969 Limit 0 035 0 077 0 150 0 031 0 096 0 200 56 Workshop Manual KDW 1603_2204_2204 T _ cod ED0053029180 1 ed_rev 00 KOHLER Disassembly Reassembly 6 1 Crankshaft for engines with dynamic equalizer only four cylinder engines 1 LM 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 Ret 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 Screw the screw B into support C taking care to centre the hole in the mass of the gear D to lock it Fit the mass assembly under the crankcase so that the tooth with reference E goes between the teeth with references F of Control gear dynamic balancer Fix the mass assembly with the
108. t 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 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 Remove fuel line and loosen clamp screws Completely empty the tank and check that no impurities are found inside Check that cap breather hole is not clogged Flywheel MD Caution Warning During the demounting phases pay particular attention to prevent the flywheel from dropping as this could seriously injure the operator Wear protective goggles when removing the flywheel ring Remove the bolts which attach the flywheel to the crankshaft when refitting tighten to 140 Nm after checking that the locating pin is in its seat To remove the starter ring gear it is recommended to cut it into several portions with an iron hacksaw and then use a chisel To remove the starter rim it is advisable to cut it into several parts with a hacksaw and to then use a chisel To replace slowly heat for 15 20 minutes to a temperature of 300 C max Fit the rim into the flywheel housing make sure that it rests evenly against the support of the housing itself Allow it to slowly cool 38 Workshop Manual KDW 1603 2204 2204 T cod ED005
109. t to run at low rpm 1500 1800 rpm and agricultural applications light weights for engines set to run at high rpm 2200 3000 rpm Speed governor counter springs Besides the weights used according to the speed rate and application type differenttypes of springs with differentfeatures 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 For engines used on generating sets it is preferable to fit a single spring 6 to act against the heavy governor weights to avoid hunting with variations in the load and to achieve a more constant frequency over time Frame with idling speed governor spring Engines for applications requiring a certain power capacity at low speeds are fitted with the frame 2 complete with the idling speed spring which allows satsifying the above described requirements without the engine tending to stop Components 1 Rocker arm with speed governor springs 2 Frame for idling speed spring 60 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 KOHLER Disassembly Reassembly 6 Summary tables of the governor equipment according to the speed variation KDW 2204 2204 T 1500 5655370 1500 5655154 5655 156 1800 5655369 Spring serial number
110. tarting position L 174 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 f ed rev 00 67 11 Electric system KOHLER 175 Je In NEE EEE aE EERE EERE BE EE PR ER Eee SURES AR EROR UR JIN 1141413 1418 41 EI EI I LIII LIT LLL LI grad H R PET TT TT GET TT do zT 5 LLLIT LTTE EILELTIELIBWIJIIICcLEITIILLELLE TITLE PIT N ITA A TN E 1111402 4 TT et II I KE JSR RRR REESE IL TL LIS EL Br GO a J He d 9 10 42 13 14 r p n T mi U mi 176 40 20 O 20 40 60 80 Alternator type Marelli AA 125 R 14V 45A Characteristics Rated voltage 14V Rated current 45A lt 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 O Tighten the nut 1 to 60 Nm Note Lube the two bearings with high temperature grease The al
111. ternator 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 P1 Power in kW Current in Ampere T Alternator efficiency Note The alternator rpm is equal to to the rpm shown in the table multiplied by 1000 Ratio between engine alternator rpm 1 1 8 Characteristic voltage curve for regulator type RTT 119 AC The electronic voltage regulator is built into the alternator The curve changes depending on temperature A Max voltage curve B Min voltage curve 88 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 KOHLER Electric system 11 178 Alternator type Marelli AA 125 R 14V 65A Characteristics Rated voltage 14V Rated current 65A 14 000 giri 1 Peak speed max 15 min 15 000 rpm Bearing
112. to the prolonged 196 197 activation time 96 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 KOHLER Electric system 11 198 M14x1 5 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 9790 13940 Features of heavy duty 6300 7700 start sensor 4900 3600 Temperature Resistance Q 2160 2640 C 900 1100 Coolant high temperature lamp switch Characteristics Single pole circuit normally open Supply voltage 6 24V Absorbed power 3W Circuit closing temperature 107 113 C O When refitting tighten to 25 Nm Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 97 11 KOHLER Thermistor for electric thermometer 0 Mi4xl 5 85 87 201 Thermistor for preheating water temperature Thermal contact for water temperature indicator light Temperature C T2 0 92 705 Thermal contact T2 features
113. ults FUEL SYSTEM 147 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 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 KOHLER Fuel system 10 148 Fuel filter Components 1 Drain screw 2 Cover 3 Seal 4 Fitting 5 Cartridge Cartridge specifications 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 If features an external lever for manual operation Fuel feeding pump drive rod protrusion Push rod 2 shows a protrusion A of 1 5 1 9 mm from the crankcase plane Check this value with eccentric 1 at the lowest point on the bottom of the cam base of the camshaft Push rod length 32 5 32 7 mm Check push rod length and replace push rod if inadequate size is Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 775 10 KOHLER
114. ure all switches are OFF If ON a spark will occur at the ground cable terminal which could cause an explosion if hydrogen gas or fuel vapors are present 12 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 KOHLER General remarks and safety information 2 CAUTION r DANGER High Pressure Fluids puncture skin and cause severe injury or death Do not work on fuel system without proper training or safety equipment Electrical Shock can cause injury Do not touch wires while engine is running Electrical Shock Never touch electrical wires or High Pressure Fluid Puncture components while the engine is Fuel system is to be serviced only by running They can be sources of properly trained personnel wearing electrical shock protective safety equipment Fluid puncture injuries are highly toxic and hazardous If an injury occurs seek immediate medical attention California Proposition 65 WARNING Engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board and Kohler Co are pleased to explain the emission control system warranty on your 2012 engine In California new heavy duty off road engines must be designed built and equipped to meet th
115. vel off by removing a maximum 0 20 mm See pictures 56 59 pages 39 40 for cylinder head tightening Valve removal Components 1 Valve 2 Lower spring seat 3 Valve guide seal for intake only 4 Spring 5 Spring cap 6 Cotters To remove the cotters firmly press down as shown in the figure 20 40 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 KOHLER Disassembly Reassembly 6 NOMINAL LENGHTS WITHA WEIGHT OF WITH A WEIGHT OF A 52 00mm 205N 20 2KG 315N 32 1KG 34 8 mm C 25 8mm Permissible tollerance on weights and lenghts 5 22 23 24 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 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 B 3530 35 50mm 40 30 40 50 mm a 46 30 45 45 Valve guides and cylinder head Intake and exhaust valve guides are both made of gray cast iron with pearlitic and phosphoric matirx Re Dimensions mm
116. with a non return valve A this valve improves injection by bleeding the air inside the fuel and stops the engine immediately after the stop device is operated To replace the outlet union with non return ball valve on QLC type injection pumps having inlet and outlet unions pressure fitted on the pump case use the special tool serial number 7107 1460 212 Tool B is required for removal of valve A tool C for driving Injection pump control rod A Caution Warning Do not unscrew ring nut 2 before removing rod 1 Control rod 1 operated by the throttle and governed by the speed governor controls the injection pump Ring nut 2 keeps rod 1 in the required position by means of groove 3 How to remove injection pump feeding tubes A Caution Warning Cutting the pipe in the opposite direction to the arrow A horizontally damages the pump coupling with consequent leakage of fuel Cut the nylon tube at A Remove the portion left inside the union using pliers Remove the nylon tube without damaging the union seals as shown in the figure 159 Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 1 ed rev 00 79 KOHLER How to reassemble injection pump feeding tubes 1 Pliers for 6 mm diam tubes intake Part No 7104 1460 022 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
117. with a viscosity not adequate to the environmental conditions of the engine may affect the proper functioning of the hydraulic tappets For the determination of the adequate viscosity of oil referred to page 29 In all four cases the ticking should not last too long If this is not the case the problem is definitely due to a manufacturing fault wear and tear or dirt which can be drawn in by the oil and get between the non return valve and its seat inside the plunger thus compromising the functioning of the tappets In this case the hydraulic tappets must be replaced Injection pump follower Introduce the follower into its housing and manually turn screw 3 until it matches with notch 2 Before locking screw 3 use your finger to check that the follower is allowed to move upwards freely Space 1 should be introduced into the pushrod with the flat surface facing upwards Note The screws 3a can be fitted without distinction in each cylinder Screw 3b however which is shorter than the others has to be fitted on the timing side of the cylinder inside the stop lever cover Workshop Manual KDW 1603 2204 2204 T cod ED0053029180 f ed rev 00 45 6 Disassembly Reassembly KOHLER 7 7 S L NNNN 2 AN p NES N ANNAN DII NANANAAAANN NS ASN

KDW 1603 - 2204 - 2204/T WORKSHOP MANUAL

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