Foreword
The Operator's Manual
You and others can be killed or seriously injured if you operate or maintain the machine without first studying the Operator's Manual. You must understand and follow the instructions in the Operator's Manual. If you do not understand anything, ask your employer or JCB dealer to explain it.
Do not operate the machine without an Operator's Manual, or if there is anything on the machine you do not understand.
Treat the Operator's Manual as part of the machine. Keep it clean and in good condition. Replace the Operator's Manual immediately if it is lost, damaged or becomes unreadable.
00 - General
Introduction
This section contains information about the complete engine assembly. For specific engine technical information refer to the technical data section.
Make sure that the correct engine service tools, consumables and torque figures are used when you perform service procedures.
Replacement of oil seals, gaskets, etc., and any component that show signs of wear or damage, is expected as a matter of course.
It is expected that components will be cleaned and lubricated where required, and that any opened hose or pipe connections will be blanked to prevent excessive loss of hydraulic fluid, engine oil and ingress of dirt.
Basic Description
The Kohler KDI engine is a 4 cylinder diesel engine in which the fuel is ignited by compression ignition (C.I.). The engine operates on a four stroke cycle.
Theengineisstartedbyanelectricstartermotor.The starter motor turns the engine via a pinion and teeth on the engine flywheel.
When the engine runs the crankshaft drives the camshaft though the gears. The camshaft opens and closes the inlet and exhaust valves and through push rods in time with the four stroke cycle. The engine has 16 valves, 2 inlet and 2 exhaust valves for each cylinder.
The crankshaft also drives a mechanical high pressure fuel pump via gears. The pump is part of the electronically controlled common rail fuel injection system.
Air is drawn into the engine through the inlet manifold and exhaust gases exit through the exhaust manifold. The engine uses a variable geometry turbocharger which pressurises the air at the inlet manifold.
A mechanical lubrication oil pump is driven by the crankshaft through gears. The pump pressurises and circulates oil for engine lubrication and cooling purposes.
A drive belt again driven by the crankshaft, drives a coolant circulation pump and alternator.
Internal
Thefollowingidentifiesthemaininternalcomponents of a typical engine assembly. Some variants may differ in detail.
A Crankshaft
C Intermediate gear
B Crankshaft gear
D Camshaft gear
E Camshaft F Tappet
G Push rod H Valve
A Crankshaft
B Crankshaft gear
C Intermediate gear
D Camshaft control gear
J Camshaft phonic wheel
K Intermediate gear pin
L Phonic wheel positioning reference pin on camshaft
G Rocker arm push rod
H Valve
M Articulation control valve
N Valve control bridge
P Hydraulic tappet
Q Rocker arm
Health and Safety
Hot Components
Touching hot surfaces can burn skin. The engine and machine components will be hot after the unit has been running. Allow the engine and components to cool before servicing the unit.
Turning the Engine
Do not try to turn the engine by pulling the fan or fan belt.Thiscouldcauseinjuryorprematurecomponent failure.
Notice: The engine and other components could be damaged by high pressure washing systems. Special precautions must be taken if the machine is to be washed using a high pressure system.Make sure that the alternator, starter motor and any other electrical components are shielded and not directly cleaned by the high pressure cleaning system. Do not aim the water jet directly at bearings, oil seals or the engine air induction system.
WARNING! To bleed the injectors you must turn the engine. When the engine is turning, there are parts rotating in the engine compartment.Before starting this job make sure that you have no loose clothing (cuffs, ties etc) which could get caught in rotating parts.When the engine is turning, keep clear of rotating parts.
Notice: Clean the engine before you start engine maintenance. Obey the correct procedures. Contamination of the fuel system will cause damage and possible failure of the engine.
Notice: Do not exceed the correct level of engine oil in the sump. If the maximum is exceeded, the excess must be drained to the correct level. An excess of engine oil could cause the engine speed to increase rapidly without control.
WARNING! The engine has exposed rotating parts. Switch off the engine before working in the engine compartment. Do not use the machine with the engine cover open.
WARNING! Hot oil and engine components can burn you. Make sure the engine is cool before doing this job.Used engine crankcase lubricants contain harmful contaminants. In laboratory tests it was shown that used engine oils can cause skin cancer.
Notice: A drive belt that is loose can cause damage to itself and/or other engine parts.
WARNING! Do not open the high pressure fuel system with the engine running. Engine operation causes high fuel pressure. High pressure fuel spray can cause serious injury or death.
CAUTION! It is illegal to pollute drains, sewers or the ground. Clean up all spilt fluids and/or lubricants.Used fluids and/or lubricants, filters and contaminated materials must be disposed of in
accordance with local regulations. Use authorised waste disposal sites.
Technical Data
Description
Engine Type
Table 46.
KDI 2504 TCR
Emission compliance US-EPA Tier 4 final, EU Stage IIIB
Max. operating speed 2200 RPM (Revolutions Per Minute)
Power Output 55kW at 2200 RPM
Weight (Dry) 233kg
Number of cylinders 4
Nominal bore size 88mm
Stroke 102mm
Cylinder arrangement In line
Combustion Cycle 4-stroke
Firing order 1-3-4-2
Displacement 2.482L
Compression ratio 17: 1
Direction of rotation (viewed from flywheel end)
Counterclockwise
Valves 4 per cylinder
Tappets Hydraulic
Lubricating oil pressure (Dependent on engine temperature and speed)
Filter type
1–2.8bar (14.5–40.6psi)
Screw-on canister
Pressure to open bypass valve 2.5 ± 0.5bar
(36.2 ± 7.2psi)
Oil pressure switch setting 0.8 ± 0.1bar
Oil pump(1)
(11.6 ± 1.4psi) falling
Integral unit with relief valve
Combustion system Common rail direct Injection
High pressure fuel pump High pressure with electronically controlled fuel metering
(1) The oil pump is a non-serviceable part
Component Identification
External
The following identifies the main components of a typical engine assembly visible from the exterior. Some variants may differ in detail.
A Flywheel housingRefer to: PIL 15-54-03.
C Fuel filterRefer to: PIL 18-09-00.
E DipstickRefer to: PIL 15-45-09.
G Oil coolerRefer to: PIL 15-69-00.
J High pressure fuel pumpRefer to: PIL 18-18-15.
L Catalytic converterRefer to: PIL 18-24-18.
N Engine harness
B FlywheelRefer to: PIL 15-54-00.
D Fuel filter drain plugRefer to: PIL 18-09-00.
F Oil filterRefer to: PIL 15-21-00.
H PTO (Power Take-Off) cover (If installed)
K Inlet manifoldRefer to: PIL 18-24-03.
M EGR (Exhaust Gas Recirculation) valveRefer to: PIL 18-27-06.
P ECM (Engine Control Module)
A ThermostatRefer to: PIL 21-12-00.
C Cooling pumpRefer to: PIL 21-09-00.
E Crankshaft phonic wheelRefer to: PIL 15-12-15.
G Timing gear caseRefer to: PIL 15-51-21.
J Oil sump drain plugRefer to: PIL 15-45-03.
L BedplateRefer to: PIL 15-09-00.
N Starter motorRefer to: PIL 15-75-00.
Q Cylinder headRefer to: PIL 15-06-00.
B Oil filler capRefer to: PIL 15-57-00.
D Drive beltRefer to: PIL 15-18-03.
F Oil sumpRefer to: PIL 15-45-00.
H AlternatorRefer to: PIL 15-72-00.
K CrankcaseRefer to: PIL 15-03-00.
M Crankcase ventilation filterRefer to: PIL 15-27-00.
P Oil pressure sensorRefer to: PIL 15-84-21.
R Outlet manifoldRefer to: PIL 18-24-04.
A InjectorRefer to: PIL 18-18-03.
C Turbocharger actuatorRefer to: PIL 18-35-00.
E Turbocharger linkRefer to: PIL 18-35-00.
G Low pressure fuel return pipesRefer to: PIL 18-96-06.
J High pressure fuel pipesRefer to: PIL 18-96-03.
B Rocker coverRefer to: PIL 15-42-06.
D TurbochargerRefer to: PIL 18-35-00.
F Oil filler capRefer to: PIL 15-57-00.
H EGR coolerRefer to: PIL 18-27-09.
K Fuel railRefer to: PIL 18-18-12.
Operation
The Four Cylinder Cycle
This section describes the cycle sequence for the 4 cylinder engine.
With the crankshaft positioned as shown, the pistons in numbers 1 and 4 cylinders are at top dead centre and pistons in numbers 2 and 3 cylinders are at bottom dead centre.
It is important to note that number 1 cylinder is firing and about to start its Power stroke. Rotating the crankshaft a further full rotation would position the pistons as described but the engine would be at a different stage in its four stroke cycle, with number 1 cylinder about to start its Induction stroke.
Firing Order
Acylinderissaidtobefiring,whenthefuel/airmixture ignites and the piston is about to start its power stroke.
From the stages described, it can be seen that number 1 cylinder will be next to fire. Number 3 cylinder is starting its compression stroke and is next in the cycle, followed by cylinders 4 and 2. The firing order is therefore; 1, 3, 4, 2.
The stages in the four stroke cycle for each cylinder are as follows:
Cylinder number
Piston operation
1 The piston is at the top of its Compression stroke and is about to start its Power stroke.
2 The piston is at the bottom of its Power stroke and is about to start its Exhaust stroke.
3 The piston is at the bottom of its Induction stroke and is about to start its Compression stroke.
4 The piston is at the top of its Exhaust stroke and is about to start its Induction stroke.
Valve operation
Inlet and exhaust valves closed
Inlet valves closed, exhaust valves about to open
Exhaust valves closed, inlet valves about to close.
Valve Operation Exhaust valves about to close, inlet valves about to open
Four Stroke Cycle Induction
As the piston travels down the cylinder, it draws filtered air at atmospheric pressure and ambient temperature through an air filter and inlet valves into the cylinder.
Compression
When the piston reaches the bottom of its stroke, the inletvalvesclose.Thepistonthenstartstoriseupthe cylinder compressing the air trapped in the cylinder. This causes the temperature and pressure of the air to rise. Fuel is injected into the cylinder when the piston is near to TDC (Top Dead Centre)
Power
The piston continues to rise after the start of fuel injection, causing a further increase in pressure and temperature.
The temperature rises to a point at which the fuel/air mixture ignites. A cylinder is said to be firing when the fuel/air mixture ignites.
This combustion causes a very rapid rise in both temperature and pressure. The high pressure generated propels the piston downwards turning the crankshaft and producing energy.
Exhaust
Once the piston has reached the bottom of its travel, the exhaust valves open and momentum stored in the flywheel forces the piston up the cylinder expelling the exhaust gases.
In a running engine, these four phases are continuously repeated. Each stroke is half a revolution of the crankshaft, thus, in one cycle of a four stroke engine, the crankshaft revolves twice.
Diagram
Electrical Operation and Schematics
The schematic diagram shows a typical system. For machine specific schematics, refer to electrical system- general, refer to (PIL 33-00).
The schematic is shown with the ignition switch set to position III and the transmission set to N. A
signal will be sent between the Transmission ECU (Electronic Control Unit) and Engine ECU via the CAN (Controller Area Network)bus to tell the Engine ECU that the transmission is in Neutral.
The engine ECU provides power to the engine compartment fusebox to energise the start relay, the fuel pump relay, the starter motor and the fuel pump.
A Alternator B Battery
C Ignition switch
E Primary fuse
D Starter motor
F RHC/LMS (Loadall Monitoring System) display
G Engine compartment fusebox H Start signal relay
J Fuel pump relay K Fuel pump L Engine ECU
Drain and Fill Oil
Oil is toxic. If you swallow any oil, do not induce vomiting, seek medical advice. Used engine oil contains harmful contaminants which can cause skin cancer. Do not handle used engine oil more than necessary. Always use barrier cream or wear gloves to prevent skin contact. Wash skin contaminated with oilthoroughlyinwarmsoapywater.Donotusepetrol, diesel fuel or paraffin to clean your skin.
CAUTION! It is illegal to pollute drains, sewers or the ground. Clean up all spilt fluids and/or lubricants.Used fluids and/or lubricants, filters and contaminated materials must be disposed of in accordance with local regulations. Use authorised waste disposal sites.
Engine oil replacement must be completed in accordance with the service schedules. Failure to replace the oil replacement at the recommended interval could cause serious engine failure.
Drain the oil when the engine is warm as contaminants held in suspension will then be drained with the oil.
1.Make the machine safe. Refer to: PIL 01-03-27.
2.Park the machine on a hard level surface for accurate measurement of the oil level.
3.Get access to the engine.
4.Place a container of suitable size beneath the drain plug.
5.Remove the oil filler cap.
A
CAUTION! Oil will gush from the hole when the drain plug is removed. Keep to one side when you remove the plug.
6.Remove the oil dipstick.
7.Remove the oil sump drain plug and O-ring from both sides of the oil sump.
8.Drain the engine oil into an suitable container.
9.Clean and install the drain plug with a new Oring. Tighten the plug to the correct torque value.
10.Throughoneofthefillerpoints,filltheenginewith the recommended oil to the MAX mark on the dipstick.
E Maximum level mark
F Minimum level mark
11.Wipe off any spilt oil, install the filler cap and make sure it is secure.
12.Operate the engine, until the oil pressure low warning light has extinguished.
13.Check for oil leakage.
14.When the oil has cooled, check the oil level again, and if necessary top up with clean engine oil.
Clean
Notice: Clean the engine before you start engine maintenance. Obey the correct procedures. Contamination of the fuel system will cause damage and possible failure of the engine. Notice: The engine and other components could be damaged by high pressure washing systems. Special precautions must be taken if the machine is to be washed using a high pressure system. Make sure that the alternator, starter motor and any other electrical components are shielded and not directly cleaned by the high pressure cleaning system. Do not aim the water jet directly at bearings, oil seals or the engine air induction system.
Before carrying out any service procedures that require components to be removed, the engine must be properly cleaned.
Cleaning must be carried out either in the area of components to be removed or, in the case of major work, or work on the fuel system, the whole engine and surrounding machine must be cleaned.
Stop the engine and allow it to cool for at least one hour. DO NOT attempt to clean any part of the engine while it is running.
1.Make sure that the electrical system is isolated.
2.Make sure that all electrical connectors are correctly connected. If connectors are open install the correct caps or seal with water proof tape.
3.Cover the alternator with a plastic bag to prevent water ingress.
4.Seal the engine air intake, exhaust and breather system.
5.Make sure that the oil filler caps and dipstick are correctly installed.
6.Use a low pressure water jet and brush to soak off mud or dirt.
7.Apply an approved cleaning and degreasing agent with a brush. Obey the manufacturers instructions.
8.Use a pressure washer to remove the soft dirt and oil. Important: DO NOT aim the water jet directly at oil seals or electrical and electronic components such as the engine electronic controlunit(ECU),alternatororfuelinjectors.DO NOTplacethejetnozzlecloserthanthespecified distance to any part of the engine.
Distance: 600mm
9.When the pressure washing is complete, move the machine away from the wash area, or alternatively, clean away the material washed from the machine.
10.Before working on specific areas of the engine, use a compressed air jet to dry off any moisture. When the area is dry, use a soft clean brush to remove any sand or grit particles that remain.
11.When removing components, be aware of any dirt or debris that may be exposed. Cover any open ports and clean away the deposits before proceeding.
Additional cleaning must be carried out prior to working on the high pressure fuel system. Refer to Fuel System, General, Clean.
Check (Pressure)
Remove and Install
Lifting Equipment
1.Make the machine safe with the excavator/lift arm lowered.
Refer to: PIL 01-03-27.
2.Make sure that the engine oil and fuel are at the correct level.
3.Remove the pressure switch.
Refer to: PIL 15-84-21.
4.Connect a pressure gauge to the pressure switch fitting.
SpecialTool:PressureGauge(0-40Bar)(Qty.:1)
Figure 148.
You can be injured if you use incorrect or faulty lifting equipment.Youmustidentifytheweightoftheitemto be lifted then choose lifting equipment that is strong enough and suitable for the job. Make sure that lifting equipment is in good condition and complies with all local regulations.
The lifting equipment used must be an approved type and capable of lifting the engine safely. The recommended lifting equipment is shown. Use a spreader bar when lifting the engine. Never attempt to manually lift heavy components on your own. Always use lifting equipment, or obtain the help of an assistant. Inspect the lifting brackets for signs of damage. The brackets must be correctly torqued to the crankcase. Make sure the lifting equipment does not damage any of the engine dressing and the rocker cover.
There will be some component differences dependingonthemachinevariant.Beforeattempting to remove the engine ensure that all the necessary components have either been removed, or safely disconnected from the engine.
Before Removal
1.Make sure that the engine is safe to work on. If the engine has been running, let it cool before you start the service work.
2.Position the machine on firm level ground. Make the machine safe. Refer to: PIL 01-03-27.
5.Start the engine.
6.Monitor the oil pressure with respect to the oil temperature.
7.The oil pressure should be more than the specified value.
Pressure: 1.5bar (21.7psi)
8.Stop the engine and allow it to cool.
9.Remove the pressure gauge and install the pressure switch.
3.Get access to the engine. Refer to: PIL 06-06-06.
Remove
1.Disconnect and remove the battery. Refer to: PIL 33-03-00.
2.Drain the engine oil. Refer to: PIL 15-00-00.
3.Drain the engine cooling system. Refer to: PIL 21-00-00.
4.Remove the cooling pack.
5.Discharge the hydraulic pressure. Refer to: PIL 30-00-00.
6.Drain the hydraulic tank. Disconnect and plug the hydraulic pipes. Label the hoses to help installation.
7.Disconnect and plug the hydraulic cooler hoses. Label the hoses to help installation.
8.Disconnect the exhaust system.
9.Label the cab heater hoses at the engine crankcase. Release the hose clips and remove the hoses.
10.Disconnect the wiring connections from the starter motor.
Refer to: PIL 15-75-00.
11.Disconnect the wiring connections from the alternator.
Refer to: PIL 15-72-00.
12.Disconnect the wiring connections from the engine sensors and actuators.
Refer to: PIL 15-84.
13.Disconnect the fuel supply line at the fuel lift pump and the spill line at the fuel injection pump. Cap all hoses and ports to prevent ingress of dirt.
14.Disconnect the electrical harness at the engine harness.
15.Uncouple the electrical harness at the ECM (Engine Control Module) machine side connector. Important: DO NOT touch the connector pins on the ECM or harness connectors. Cover the connectors to prevent contamination.
16.Ensure that all relevant harnesses and hoses are unclippedfromtheengineandtiedoutoftheway.
17.Disconnect and plug the hoses at the hydraulic pump.
18.Disconnect the wiring to the hydraulic pump.
19.Attach slings to the engine lifting eyes.
B Sling
20.Take the weight of the engine on the hoist and remove the engine mounting bolts.
21.Withdraw the engine in a level attitude until it is clear of the chassis. Raise the engine to lift it clear of the machine.
22.Lower the engine into a suitable stand that is capable of supporting the weight of the engine.
Install
1.Replacement is a reversal of the removal procedure. Note the following:
2.Fill the cooling system with the correct mix of coolant fluid.
Refer to: PIL 75-00-00.
3.Fill and Check the hydraulic fluid level. Refer to: PIL 30-00-00.
4.Fill and Check the engine oil level. Refer to: PIL 15-00-00.
5.On completion, check the hydraulic and cooling system for leakage and levels.
6.Check the function of the drive and hydraulic services. Table
Store and Recommission
Engine Storage (up to 6 months)
Before you store the engine make sure that:
•The environment is not humid or exposed to bad weather.
•The storage place is not near an electrical panel.
•Prevent storing the engine in direct contact with the ground.
1.Cover the engine with a proper protective sheet to prevent it from dampness and atmospheric contaminants.
Engine Storage (over 6 months)
1.Follows the precautions mentioned in the above procedure.
2.Fill the engine housing with protective oil up to the maximum level.
3.Refuel the machine with fuel additives for long storage.
4.For machines with expansion tank:
4.1.Make sure that the coolant is up to the maximum level.
5.For machines without expansion tank:
5.1.Fill the coolant until the pipes inside the radiator are covered by specified distance.
Distance: 5mm
5.2.Do not overfill the radiator, but leave sufficient space for the fuel to expand.
6.Start the engine and run it at idle speed for the specified duration.
Duration: 2min
7.Bring the engine to 75% of the maximum rated speed for the specified duration.
Duration: 5–10min
8.Turn off the engine.
9.Drain the fuel tank completely.
10.Spray engine oil (SAE 10W40) on the exhaust and intake manifolds.
11.Seal the exhaust and intake ducts to prevent contamination.
12.Clean the engine. Refer to: PIL 15-00-00.
13.Apply protective paints on non-painted parts.
14.Loosen the alternator belt.
15.Cover the engine with a proper protective sheet to prevent it from dampness and atmospheric contaminants.
Engine Starting After Storage
1.Remove the protective sheet.
2.Use a cloth soaked in degreasing fluid to remove the protective treatment from the external parts.
Consumable: Cleaner/Degreaser - General purpose solvent based parts cleaner
3.Inject lubricating oil (not more than 2cm³) into the intake ducts.
4.Adjust the alternator belt tension. Refer to: PIL 15-18-00.
5.Refuel the machine.
6.Make sure that the oil and the coolant are up to the maximum level.
7.Start the engine and run it at idle speed for the specified duration.
Duration: 2min
8.Bring the engine to 75% of the maximum rated speed for the specified duration.
Duration: 5–10min
9.Stop the engine.
10.While the oil is still hot, drain the protective oil in a suitable container.
11.Put new oil up to the maximum level.
12.Replace the filters (air, oil, fuel).
13.Drain the cooling circuit completely and put new coolant up to the maximum level.
Important: Over time, lubricants and filters lose their properties, so it is important to consider whether they need replacing, also based on the criteria mentioned in the maintenance schedules.
If the engine is not to be used for an extended period, the protective treatment procedure must be repeated within 730d of the previous one.
00 - General
Introduction
The crankcase is the housing for the crankshaft. The enclosure forms the largest cavity in the engine and is located below the cylinders. It is integral with the cylinder bank and forms an engine block. It has an opening in the bottom to which an oil sump is attached with a gasket and bolted joint.
The crankcase protects the crankshaft and connecting rods from foreign objects it also keeps the engine oil contained and allows the oil to be pressurised and also provide the rigid structure with which to join the engine to the transmission.
Technical Data
Table 71. Crankcase and Bedplate Data
Main bearing bolts
torque(1)
First stage 40N·m
Second stage 70N·m
Third stage 120N·m
Peripheral bolts
Fourth stage 20N·m
Fifth stage 35N·m
(1) Torque information must be used in conjunction with recommended procedures contained in this manual. Failure to use the appropriate and correct removal, replacement, dismantle and assembly procedures may result in an engine failure in service. Refer also to the procedures for the correct bolt tightening sequence.
Table 72. Cylinder bore Data
(1) This table shows the reference values and their classification applicable for new engines only
Suggest:
If the above button click is invalid.
Please download this document first, and then click the above link to download the complete manual.
Thank you so much for reading
Clean Oil pipes
Important: Make sure you keep a safe distance from all of the open ports.
1.Remove all the plugs.
2.Put a pipe cleaner in all the open ports to clean the oil pipes,as shown.
3.Use a compressed air line to remove any remaining oil.
4.Install all the plugs with Loctite.
