JCB Kohler KDW 1603, 2204, 2204/T Engine Service Manual
108 pages · Publication 9806-4065
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- Models
- Kohler KDW 1603, 2204, 2204/T
- Manual type
- Service Manual
- Pages
- 108
- Publication
- 9806-4065
- Condition
- Brand new
What's inside
From the manual's own table of contents: 119 sections, 206 entries. See sample pages (PDF, 493 KB)
1 - MANUFACTURER AND MOTOR IDENTIFICATION DATA4 topics
- The identification plate shown in the figure can be found directly on the engine
- Approval data
- Name plate for EPA rules applied on rocker-arm cap
- Compilation example
2 - GENERAL REMARKS AND SAFETY INFORMATION10 topics
- General remarks and safety information
- California emission control warranty statement
- Your warranty rights and obligations
- Safety
- Limited 3 year kohler diesel engine warranty
- General service manual notes
- Glossary and terminology
- Safety regulations
- General safety during operating phases
- Safety and environmental impact
3 - TECHNICAL INFORMATION4 topics
- Possible causes and trouble shooting
- Technical data
- Performance diagrams
- Overall dimensions
4 - MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING7 topics
- Routine engine maintenance
- Ordinary maintenance
- Extraordinary maintenance
- Lubricant
- Prescribed lubricant
- Coolant
- Specifications fuel
5 - REGULATIONS FOR LIFTING THE ENGINE1 topic
- Regulations for lifting the engine
6 - DISASSEMBLY/REASSEMBLY15 topics
- Recommendations for disassembling and assembling
- Recommendations for overhauls and tuning
- Oil-bath air cleaner
- Oil-bath air cleaner components
- Dry air cleaner
- Dry air components
- Air filter clogging indicator
- Intake manifold
- Exhaust manifold
- V" belt
- Cooling fan
- Driving pulley (2a P.T.O.)
- Tank
- Flywheel
- Rocker arm cover with vent into the air
Rocker arm cover for engines with recirculating vent
Rocker arm assemly
Cylinder head
Valve removal
Valve spring - Check
Valve spring - check under load
Valve material
Valve guides and cylinder head
Valve guide insertion, after driving
Oil seal in the valves guides, (intake and exhaust)
Valve seats and bore
Valve recess and sealing surfaces
Precombustion chamber
Hydraulic tappet valve control
Hydraulic diagram for feeding the tappets
Hydraulic tappet components
Hydraulic tappet operation
Injection pump follower
Show all 119 sections
Cylinders
Cylinder roughness
Piston
Piston availability
Piston weight
Piston rings - End gaps
Piston rings - Clearance between grooves
Piston rings - Fitting sequence
Piston - Refitting
Piston position and clearance
Cylinder head gasket
Cylinder head tightening for engines without hydraulic tappets
Cylinder head tightening steps
Assembling and tightening the cylinder head on engines with hydraulic tappets
Connecting rod
Connecting rod weights
Connecting rod and piston pin
Connecting rod alignment
Piston cooling sprayer
Connecting rod/piston assemblies
Center main bearings
Main bearing caps timing side - flywheel side
Check clearance between main bearings and journals
Thrust bearing, oversizes
Crankshaft end play
Crankshaft front and rear oil seal
Crankshaft timing gear
Crankshaft lubrication ducts
Checking main journals and crank pins
Main bearing and connecting rod big bearing inside diameter (mm)
Crankshaft for engines with dynamic equalizer (only four-cylinder engines)
Dynamic balancer (on request) - Adjustment of clearance between teeth D and ring gear A
Front cover (before the serial number 7366305)
Front cover (after the serial number 7366306)
Idler gear and hub
Speed governor
Dimensions for injection pump delivery control yoke adjustement
Camshaft gear - Speed governor counter weights
Speed governor counter springs
Frame with idling speed governor spring
Summary tables of the governor equipment according to the speed variation
Spring for extra fuel supply at starting
Camshaft
Camshaft removal
Checking camshaft bushing internal diameter
Camshaft journals and bushings in model KDW 1603
Camshaft journals and bushings in models KDW 2204-2204/T9 topics
- Camshaft bushing replacement
- Intake, exhaust and injection cam height for engine with hydraulic tappets
- Camshaft timing
- Valve timing without considering timing marks
- Valve timing check
- Engines with hydraulic tappets
- Camshaft end play
- Hydraulic pump P.T.O
- GR 1 and GR 2 hydraulic pump 3rd P.T.O
7 - TURBOCHARGER4 topics
- Turbocharger
- Turbocharger components
- Turbocharger Testing
- Checking actuator setting - "Waste Gate" valve control rod stroke adjustment
8 - LUBRICATION SYSTEM8 topics
- Oil pump
- Oil pump rotor clearance
- Oil pressure adjusting valve
- Oil filter cartridge
- Oil pressure check
- Oil pressure curve for KDW 1603
- Oil pressure curve for KDW 2204
- Oil pressure curve for KDW 2204/T
9 - COOLING SYSTEM4 topics
- Expansion tank and cap
- Checking for cooling system leaks
- Coolant circulating pump
- Thermostat
10 - FUEL SYSTEM21 topics
- Fuel filter
- Fuel feeding pump
- Fuel feeding pump drive rod protrusion
- Electric fuel pump (24V)
- Injection pump
- Injection pump disassembly
- How to reassemble injection pump components
- Injection pump non-return valve
- Injection pump control rod
- How to remove injection pump feeding tubes
- How to reassemble injection pump feeding tubes
- Instrument for equalizing injection pump delivery - Part No. 7104-1460-090
- Injection pump delivery equalization
- Test data of injection pump
- Injection pump P. No. 6590-249 - Plunger and barrel assembly
- Checking injection pump delivery
- Checking low pressure injection timing for engines with hydraulic tappets
- Checking low pressure injection timing for engines with mechanical tappets
- Injection timing correction by changing the pad thickness
- Injector (pin type)
- Injector setting
11 - ELECTRIC SYSTEM
Wiring diagram with alternator 12V 45A / 65A / 80A
Recommended batteries
Alternator type Marelli AA 125 R 14V 45A
Characteristic curves for alternator type Marelli AA 125 R 14V 45A
Characteristic voltage curve for regulator type RTT 119 AC
Alternator type Marelli AA 125 R 14V 65A
Characteristic curves for alternator type Marelli AA 125 R 14V 65A
Alternator type Iskra, AAK3139 14V 80A
Characteristic curves for alternator type Iskra, AAK3139 14V 80A
Characteristic voltage curve for regulator type AER 1528
Starting Motor 12V
Characteristic curves for starting motor type Bosch EV 12V 2.2 kW
Wiring diagram 24V with alternator 35A
Alternator type Iskra, type AAK3570 28V 35A - (for 24 V outfits)
Characteristic curves for alternator type AAK3570 28V 35A (for 24 V outfits)
Starting Motor 24V
Characteristic curves for starting motor Iskra type AZE 4598 24V 3 kW
Spacer flange for starter motor
Connection diagram for preheating control unit
Glow plug controller relay with coolant temperature sensor
Pre-heating glow plug
Temperature sensor (Thermistor)
Coolant high temperature lamp switch
Thermistor for electric thermometer
Thermistor for preheating water temperature - Thermal contact for water temperature indicator light
12 - SETTINGS
Idling speed setting in no-load conditions (standard)
Full speed setting in no-load conditions (standard)
Standard injection pump delivery setting without torque dynamometer
Injection pump delivery limiting and torque adjusting device
Fuel limiting device (fig. 208-209)
Fuel limiting device adjustment (fig. 208-209)
Stop setting
Application diagram for tampering system adjustment screw and torque gearing device for EPA-approved engines
13 - ENGINE STORAGE
Engine storage
Protective treatment
Preparing the engine for operation after protective treatment
14 - TORQUE SPECIFICATIONS AND USE OF SEALANT
Main torque specifications
Table of tightening torques for standard screws (coarse thread)
Table of tightening torques for standard screws (fine thread)
15 - SPECIAL TOOLS
Inside this manual
Real pages from this service manual (108 pages). Open the sample pages (PDF, 492 KB)
- Troubleshooting, page 18: TECHNICAL INFORMATION
- Specifications, page 60: Camshaft gear - Speed governor counter weights
- Diagram, page 93: 12 V - 92 Ah/450 A/DIN
- Color page, page 14: General remarks and safety information
This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 108 pages
Quantity one is the manual described above.
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Other editions and similar models
Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).