Jcb Engines Kohler Kdi 1903m & 2504m Workshop Manual

KDI 1903 M - 2504 M WORKSHOP MANUAL

REGISTRATION OF MODIFICATIONS TO THE DOCUMENT Any modifications to this document must be registered by the drafting body, by completing the following table.

Drafting body

Code document

DICOM/ATLO ED0053029610

2

Model N°

Edition

Revision

Date issue

Date Review

51275

4°

3

10/2013

04/2015

Written by

Endorsed

MO KDI 1903M_2504M_code ED0053029610 - 4th ed_rev. 03

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NOTES

-

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MO KDI 1903M_2504M_code ED0053029610 - 4st ed_rev. 03

3

INDEX

1

1.1 1.2 1.3 1.4

2

2.1 2.2 2.3 2.4 2.5

2.6 2.7 2.8 2.9

2.10

2.11

2.12 2.13

2.14

2.15

2.16

4

1.1.1

2.4.1 2.4.2 2.5.1 2.5.2 2.5.3

2.9.1 2.9.2 2.9.3 2.9.4 2.9.5 2.9.6 2.9.7 2.10.1 2.10.2 2.10.3 2.11.1 2.11.2 2.11.3 2.11.4 2.12.1 2.13.1

2.14.1 2.14.2 2.14.3 2.14.4 2.15.1 2.15.2 2.15.3 2.15.4 2.15.5 2.15.6 2.15.7 2.15.8 2.16.1 2.16.2

GENERAL INFORMATION Useful information Useful Information -accident prevention - environmental impact Manufacturer and engine identification Identification of the main internal components of the engine and operating reference (BASE CONFIGURATION) Identification of the external components of the engine (BASE CONFIGURATION) TECHNICAL INFORMATION Engine specifications Engine dimensions (mm) Performance diagrams Oil SAE oil classification International lubricant specifications Fuel Fuel for low temperatures Biodiesel fuel Emission-Related Installation Instructions Coolant Battery features Periodic maintenance Fuel system Supply system Fuel return circuit Injection pump Injector Fuel filter Electric fuel pump (optional) Guards for fuel injection circuit components Lubrication circuit Lubrication circuit diagram Oil pump Oil filter Coolant circuit Coolant circuit diagram Coolant pump Thermostatic valve Radiator (optional) Intake and exhaust circuit Air filter (optional) Electric system Engine electrical wiring (opzional) 2.13.1.1 Connector panel on the engine/machine 2.13.1.2 Accessories panel connector 2.13.1.3 Wiring disconnection Sensors and switches Fuel filter water detection sensor Oil pressure switch Coolant temperature sensor Air cleaner clogging switch Electrical components Alternator Starter motor Cold starting device (Heater) Electric fuel pump (optional) Cold Start Advance Electro-Stop Fuse Control panel (optional) Timing system and tappets Components identification Timing system phasing angles

12 12 12 13 14 16 19 19 21 22 23 23 23 24 24 24 25 25 25 26 27 27 28 28 29 29 30 30 31 31 32 33 34 34 34 34 35 36 37 38 38 39 39 40 41 41 41 41 42 42 42 42 42 43 44 44 44 44 45 45 46

MO KDI 1903M_2504M_code ED0053029610 - 4th ed_rev. 03

INDEX 2.16.3 2.16.4 2.16.5 2.17 2.18

3

50 50 50 50 50 50 52 52 52 52 53 53 54

4.1 4.2 4.3 4.4

STORAGE INFORMATION Product preservation Engine storage (up to 6 months) Engine storage (over 6 months) Engine starting after storage

55 55 55 55 55

5.1 5.2

INFORMATION REGARDING DISCHARGE OF LIQUIDS Coolant Engine oil

56 56 57

INFORMATION FOR REPLACING THE FUNCTIONAL UNITS Injector and injection pump replacement Injection fuel pipes disassembly(injection pump/injectors) Rocker arms cover disassembly Fuel return pipes disassembly Injectors disassembly Injection pump disassembly Injection pump assembly Injector assembly Assembly of the injector return pipes Assembly Rocker arm cover Installation of the fuel injector pipes (pump injector/injectors) Coolant pump replacement Disassembly Assembly Replace the crankshaft pulley Disassembly Assembly Oil pump replacement Coolant pump disassembly Engine pulley disassembly Timing system crankcase disassembly Oil pump disassembly Oil pump assembly Timing system crankcase assembly Crankshaft pulley assembly Coolant pump assembly Oil pressure valve replacement 6.5.1 Disassembly 6.5.2 Assembly

58 58 58 58 59 59 59 62 63 64 64 65 66 66 66 67 67 67 68 68 68 68 68 69 69 70 70 70 70 70

3.5 3.6 3.7

5

6

46 46 47 47 47 48 49 49 49

SAFETY INFORMATION Before start-up Safety precautions General remarks Note for OEM Note for end user Safety signal description Adhesive safety plates Warnings Safety guards Information and safety signals Safety and environmental impact Location of safety signals on engine

3.1 3.2 3.3 3.4

4

2.18.1 2.18.2

Rocker arm pin Rocker arms Hydraulic tappets 2.16.5.1 Hydraulic tappet operation 2.16.5.2 Difficult operating conditions Balancer device (optional - only KDI 2504) Components handling Injection pump Injector

-

6.1

6.2 6.3 6.4

6.5

3.3.1 3.3.2 3.4.1 3.4.2 3.4.3

6.1.1 6.1.2 6.1.3 6.1.4 6.1.5 6.1.6 6.1.7 6.1.8 6.1.9 6.1.10 6.2.1 6.2.2 6.3.1 6.3.2 6.4.1 6.4.2 6.4.3 6.4.4 6.4.5 6.4.6 6.4.7 6.4.8

MO KDI 1903M_2504M_code ED0053029610 - 4th ed_rev. 03

5

INDEX

6.6 6.7

7

7.1 7.2

7.3 7.4 7.5 7.6

7.7 7.8

7.9 7.10 7.11

6.6.1 6.6.2 6.7.1 6.7.2

7.2.1 7.2.2 7.2.3 7.2.4

7.4.1 7.4.2 7.6.1 7.6.2 7.6.3 7.6.4 7.6.5 7.8.1 7.8.2 7.8.3 7.8.4 7.8.5 7.8.6 7.10.1 7.10.2 7.11.1 7.11.2 7.11.3

7.12

7.13

7.11.1.1 7.11.3.1 7.11.3.2 7.11.3.3 7.11.3.4

7.12.1 7.12.2 7.12.3 7.13.1 7.13.2 7.13.3 7.13.4 7.13.5 7.13.6 7.13.7 7.13.8 7.13.9 7.13.10

6

7.2.4.1 7.2.4.2 7.2.4.3

7.13.5.1

Oil filter replacement Disassembly Assembly Fuel filter replacement Disassembly Assembly

71 71 71 71 71 71

DISASSEMBLY INFORMATION Recommendations for disassembly Electric components disassembly Electric wiring Starter motor Belt and alternator Sensors and switches Oil pressure switch disassembly Coolant temperature sensor Fuel filter water detection sensor Exhaust manifold disassembly Coolant recirculation components disassembly Coolant pump Thermostatic valve Crankshaft pulley disassembly Lubrication circuit disassembly Oil pressure valve Timing system carter oil filling flange Timing system Oil pump Oil cooler unit Intake manifold disassembly Fuel system disassembly Fuel injection pipes Rocker arm cover Fuel return pipes Injector Injection pump Fuel filter Timing system gear disassembly Flange unit disassembly Flywheel Flange housing Cylinder head unit disassembly Rocker arm pin Rocker arm Valve rods and bridges Cylinder head Valves Injector sleeve Valve stem gasket Lifting eyebolts Oil sump unit disassembly Oil sump Oil intake pipe Oil vapour pipe Engine block disassembly Crankshaft gasket flange Piston unit / connecting rod Lower semi-crankcase Crankshaft Piston Rings Breather room closing cover Camshaft Camshaft tappets Crankshaft bushings Cover 3at PTO

72 72 72 72 72 72 72 72 73 73 73 73 73 74 74 74 74 74 75 75 75 76 76 76 76 77 77 77 78 78 79 79 79 80 80 80 80 81 81 82 82 82 83 83 83 83 84 84 84 85 86 86 87 87 87 87 88 88

MO KDI 1903M_2504M_code ED0053029610 - 4th ed_rev. 03

INDEX 8

8.1 8.2

8.3 8.4 8.5

8.6

8.7

9

9.1 9.2 9.3

9.4

9.5 9.6 9.7

8.2.1 8.2.2 8.2.3 8.2.4 8.2.5 8.2.6 8.3.1 8.3.2 8.4.1 8.4.2 8.5.1 8.5.2 8.5.3 8.5.4 8.6.1 8.6.2 8.6.3 8.6.4 8.6.5 8.6.6 8.7.1 8.7.2 8.7.3

9.3.1 9.3.2 9.3.3 9.3.4 9.3.5 9.3.6 9.3.7 9.3.8 9.3.9 9.3.10 9.3.11 9.4.1 9.4.2 9.4.3 9.5.1 9.5.2 9.6.1 9.6.2 9.7.1 9.7.2 9.7.3 9.7.4 9.7.5 9.7.6

-

INFORMATION ABOUT OVERHAULING Recommendations for overhauls and tuning Crankcase Oil line check Cylinder check 4-cylinder camshaft housing check Camshaft control for 4 cylinder engine Camshaft housing check for 3 cylinder engine Camshaft control for 3 cylinder engine Tappets and tappet housings Tappets check Tappet housing check Crankshaft Dimensional check and overhauling Checking the axial clearance of the crankshaft Connecting rod - piston assembly Connecting rod dimensions check Checking the gudgeon pin-pin axes are parallel Piston rings check Piston dimension check Cylinder head Flatness check Valve seats check Valve springs Valve guides check Valve guides replacement Valve guides replacement Oil pump check Dimensional and visual check Rotors clearance check Oil pressure valve check

90 90 91 91 92 93 93 94 94 95 95 95 96 96 97 97 97 98 98 98 99 99 100 100 100 101 101 102 102 102 103

ASSEMBLY INFORMATION Information on engine configuration Assembly recommendations Engine block assembly Semi main bearings Tappets Camshaft Breather room closing cover Crankshaft Lower crankcase Piston rings Piston Piston and connecting rod assembly Crankshaft gasket flange Cover 3rd PTO Oil sump unit assembly Oil vapour pipe Oil suction pipe Oil Sump Flange unit assembly Bell housing Flywheel Timing system gear assembly and injection pump Timing system gear assembly Injection pump Cylinder head unit assembly Valve stem gasket Injector sleeves Injectors projection Valves Cylinder head Rods and valve bridges

104 104 104 105 105 105 105 106 106 106 108 108 109 110 110 111 111 111 111 112 112 112 113 113 114 115 115 115 115 116 116 118

MO KDI 1903M_2504M_code ED0053029610 - 4th ed_rev. 03

7

INDEX

9.8

9.9 9.10 9.11

9.12 9.13 9.14

9.15 10

11

9.8.1 9.8.2 9.8.3 9.8.4 9.8.5

9.11.1 9.11.2 9.11.3 9.11.4 9.11.5 9.13.1 9.13.2 9.14.1

9.14.2 9.14.3

11.1

11.3 11.4 11.5

11.7 11.8 11.9 11.10

Rocker arms Rocker arm pin assembly Fuel system assembly Injector Fuel injector ricicle pipe Rocker arm cover Installation of the fuel injector pipes (injection pump/injectors) Fuel filter Intake manifold assembly Exhaust manifold assembly Lubrication circuit Oil filter Oil pump Timing system crankcase Crankcase oil filler flange Timing System Oil pressure relief valve Crankshaft pulley assembly Coolant circuit assembly Thermostatic valve Coolant pump Electric component assembly Sensors and switches 9.14.1.1 Water temperature sensor 9.14.1.2 Oil Pressure Switch 9.14.1.3 Fuel filter water detection sensor Alternator Starter Motor Summary table of tightening torques and the use of sealants FLUIDS SUPPLY INFORMATION Engine oil Coolant

10.1 10.2

11.2

8

9.7.7 9.7.8

11.1.1 11.1.2

11.2.1 11.2.2 11.3.1 11.3.2 11.4.1 11.4.2 11.5.1 11.5.2 11.6 11.7.1 11.7.2 11.9.1 11.9.2 11.10.1 11.10.2 11.10.3 11.10.4

119 119 120 120 121 121 122 122 123 123 123 123 123 124 125 125 125 125 125 126 126 126 126 126 126 127 127 128 132 132 132

INFORMATION ABOUT OPTIONAL COMPONENTS Oil dipstick in cylinder head Check Replacement 11.1.2.1 Disassembly 11.1.2.2 Assembly Heater (replacement) Disassembly Assembly Idler gear (for 3rd / 4th PTO) Disassembly Assembly 3rd PTO (replacement) Disassembly Assembly 4th PTO (replacement) Disassembly Assembly 3rd + 4th PTO (configurations) 11.6.1 Information Balancer device (replacement) Disassembly Assembly Air filter (cartridge replacement) Remote oil filter (disassembly and assembly) Disassembly Assembly Intake circuit (replacement) Air filter disassembly Manifold air filter disassembly Air filter manifold assembly Air filter assembly

134 134 134 134 134 134 135 135 135 136 136 136 137 137 138 139 140 141 143 143 144 144 145 147 147 147 148 149 149 149 149 149

MO KDI 1903M_2504M_code ED0053029610 - 4th ed_rev. 03

INDEX 11.11

Muffler (replacement) Disassembly Assembly Cooling circuit (replacement) Radiator disassembly Fan disassembly Fan assembly Radiator assembly Engine feet (information)

150 150 150 150 150 151 152 152 153

12.1 12.2 12.3 12.4

INFORMATION ON ADJUSTMENTS and checks Air filter check Rubber hose and manifold control Oil leak check Oil pressure check

154 154 154 155 155

13.1

tools information Information regarding specific tools

156 165

14.1

INFORMATION about failures Possible causes and trouble shooting

160 160

GLOSSARY

162

11.12

11.13 12

13 14 15

-

11.11.1 11.11.2 11.12.1 11.12.2 11.12.3 11.12.4

MO KDI 1903M_2504M_code ED0053029610 - 4th ed_rev. 03

9

-

NOTES

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10

MO KDI 1903M_2504M_code ED0053029610 - 4st ed_rev. 03

NOTES

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MO KDI 1903M_2504M_code ED0053029610 - 4st ed_rev. 03

11

1

GENERAL INFORMATION

1.1 Useful information • This manual contains the instructions needed to carry out proper use and maintenance of the engine, therefore it must always be available, for future reference when required.

• Information, description and pictures in this manual reflect the state of the art at the time of the marketing of engine.

• However, the development of engines is continuous.

Therefore, the information in this manual is subject to change without notice.

1.1.1

Useful Information -accident prevention environmental impact

• Before proceeding repair - handling the engine, you should read chapter 3 in its entirity, which contains important information regarding procedures to follow with regard to safety and the environment.

• KOHLER reserves the right to make, at any time, changes on the engines for technical or commercial reasons.

• These changes do not require KOHLER to intervene on the production marketed up to that time and nor to consider this manual as inappropriate.

• The paragraphs, tables and figures are numbered by chapter and followed by the progressive paragraph, table and/or figure number.

E.g.: Par. 1.3 - chapter 1 paragraph 3.

Tab. 2.4 - chapter 2 table 4.

Fig. 4.5 - chapter 4 figure 5.

Note: The paragraphs may contain sub-paragraphs.

• The references of the objects described in the text and in the figure are indicated by letters and numbers, which are always and only related to the paragraph you are reading unless there are specific references to other figures or paragraphs.

• Reference to values are indicated by letters or numbers (in red and underlined).

• Other important references are highlighted in red.

• The pictures are based on model KDI 2504 M, where necessary KDI 1903 M model is illustrated.

• All technical terms, specific components and symbols (Tab. 15.1) that are in the manual are listed and described inside the glossary, which can be consulted in (Chap. 15).

• Any additional section that KOHLER will deem necessary to supply at a later stage must be kept with the manual and considered as an integral part of it.

• The information contained in this manual is the sole property of KOHLER, therefore no partial or total reproduction or replication is allowed without the express permission of KOHLER.

12

MO KDI 1903M_2504M_code ED0053029610 - 4th ed_rev. 03

GENERAL INFORMATION

1

1.2 Manufacturer and engine identification The engine identification nameplate is located on side find timing system or flywheel as below.

Fig. 1.1

Fig. 1.2 Engine type

Engine serial number Manufacturer identification

Max rpm

Engine version Approval data and "EC" directives

Fig. 1.3

MO KDI 1903M_2504M_code ED0053029610 - 4th ed_rev. 03

13

GENERAL INFORMATION

1

1.3 Identification of the main internal components of the engine and operating reference (BASE CONFIGURATION) VIEW OF EXHAUST SIDE 4

7

3

2

1

6

5

15

A

B

8 10 9 Fig. 1.4 The following chapters contain operating references in order to clearly understand the engine. This paragraph illustrates these references that may be recognised by means of some main internal components.

Tab. 1.1 A

View of timing system side (2nd PTO)

Should you need to execute complex operations, always consult this paragraph.

B

View of flywheel side (1st PTO)

C

View of exhaust side

D

View of intake side

NOTE: it is advisable to keepthis page visible during disassembly and assembly operations.

REF.

1

Cylinder/Piston N. 1 (KDI 1903 - KDI 2504)

2

Cylinder/Piston N. 2 (KDI 1903 - KDI 2504)

3

Cylinder/Piston N. 3 (KDI 1903 - KDI 2504)

4

Cylinder/Piston N. 4 (KDI 2504)

POS.

14

DESCRIPTION

DESCRIPTION

5

Crankshaft pulley (2nd PTO)

6

Gear timing system

7

Thermostatic valve

8

Oil pump

9

Oil suction hose

10

Crankshaft

11

Exhaust manifold

12

Intake manifold

13

Camshaft

14

Gears adaptor for 3rd/4th PTO (optional)

15

Flywheel (1st PTO)

16

Injector

MO KDI 1903M_2504M_code ED0053029610 - 4th ed_rev. 03

GENERAL INFORMATION

1

VIEW OF FLYWHEEL SIDE

16 12

C

D

11

13

10

Fig. 1.5 VIEW OF TIMING SYSTEM SIDE 12 11 C

D

6

14

10

Fig. 1.6 MO KDI 1903M_2504M_code ED0053029610 - 4th ed_rev. 03

15

GENERAL INFORMATION

1

1.4 Identification of the external components of the engine (BASE CONFIGURATION) VIEW OF TIMING SYSTEM SIDE - EXHAUST

1

10

8

18

9

2 3

7 5

15

4 6 Fig. 1.7 VIEW OF FLYWHEEL SIDE - INTAKE

20 17

11

16

12 13

14

Fig. 1.8 16

MO KDI 1903M_2504M_code ED0053029610 - 4th ed_rev. 03

GENERAL INFORMATION This paragraph illustrates all external components that are present in the base configuration of the engine.

1

NOTE: The illustrated components may differ from those illustrated; the illustration is only as an example.

For components present on engines that differ from those represented in these illustrations, refer to Chap. 11.

Tab. 1.2 POS.

DESCRIPTION

POS.

DESCRIPTION

1

Oil filler cap

18

Exhaust manifold

2

Oil pressure switch

19

Flange bell

3

Starter motor

20

Injectors

4

Oil drain plug

5

Engine identification name plate

6

Alternator

7

Coolant pump

8

Coolant temperature sensor

9

Oil filler cap side

10

Thermostatic valve

11

Fuel injection pump

12

Lub. oil filter

13

Oil dipstick

14

Fuel filter

15

Crankshaft pulley (2nd PTO)

16

Flywheel (1st PTO)

17

Intake manifold

UPPER VIEW

17

20

9

10

8

6 18

1

3

19

Fig. 1.9 MO KDI 1903M_2504M_code ED0053029610 - 4th ed_rev. 03

17

-

NOTES

........................................................................................................................................................ ........................................................................................................................................................ ........................................................................................................................................................ ........................................................................................................................................................ ........................................................................................................................................................ ........................................................................................................................................................ ........................................................................................................................................................ ........................................................................................................................................................ ........................................................................................................................................................ ........................................................................................................................................................ ........................................................................................................................................................ ........................................................................................................................................................ ........................................................................................................................................................ ........................................................................................................................................................ ........................................................................................................................................................ ........................................................................................................................................................ ........................................................................................................................................................ ........................................................................................................................................................ ........................................................................................................................................................ ........................................................................................................................................................ ........................................................................................................................................................ ........................................................................................................................................................ ........................................................................................................................................................ ........................................................................................................................................................ ........................................................................................................................................................ ........................................................................................................................................................ ........................................................................................................................................................ ........................................................................................................................................................ ........................................................................................................................................................ ........................................................................................................................................................

18

MO KDI 1903M_2504M_code ED0053029610 - 3st ed_rev. 02

TECHNICAL INFORMATION

2

2.1 Engine specifications Tab. 2.1 MANUFACTURER SPECIFICATIONS AND OPERATION GENERAL INFORMATION

UNIT OF MEASURE

KDI 1903 M

Operating cycle

KDI 2504 M

diesel - 4-stroke

Cylinders

No.

Bore x stroke

mm

Displacement

cm3

3

4 88x102

1861

2482

Compression ratio

17:1

Intake

Atmospheric pressure

Cooling

Liquid

Crankshaft rotation (view from flywheel side)

Counterclockwise

Combustion sequence

1-3-2

1-3-4-2

Timing System Valves per cylinder

4

Timing System

Rods and rocker arms - Camshaft in the crankcase

Tappets

Hydraulic

Injection

Direct

Engine dry weight

Kg

210

244

MAX inclination 30' continuous operation

α

25°

MAX inclination 1' continuous operation

α

35°

Volume of aspirated air (2600 rpm)

m /h 3

2.2

2.9

KDI 1903 M

KDI 2504 M

POWER AND TORQUE GENERAL INFORMATION MAX. operating speed

UNIT OF MEASURE Rpm

2600

MAX. operating power (ISO TR 14396 - SAE J1995 - CE 97/68)

kW

31

41

Maximum torque (at 1500 rpm)

Nm

133

170

Admissible axial load on crankshaft

Kg

300

CONSUMPTIONS GENERAL INFORMATION

UNIT OF MEASURE

KDI 1903 M

KDI 2504 M

Specific fuel consumption (best point)

g/kWh

210

Oil consumption

%Fuel

< 0.05

FUEL SUPPLY SYSTEM GENERAL INFORMATION

UNIT OF MEASURE

Type of fuel

KDI 1903 M

KDI 2504 M

Diesel UNI-EN590 - ASTM D975

High-pressure fuel injection pump

STANADYNE - DB

Fuel supply

Low pressure electric pump Fuel filter

Filtering surface

cm2

2300

Degree of filtration

µm

5

Maximum pressure at injection pump inlet

bar

0.2

MO KDI 1903M_2504M_code ED0053029610 - 4th ed_rev. 03

19

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL