Kohler KDW 1603 User Manual

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Chapter index
Rockerarmcoverwithventintotheair............................................................................................................................ 39
Rockerarmcoverforengineswithrecirculatingvent....................................................................................................... 39
Rockerarmassemly......................................................................................................................................................... 40
Cylinderhead.................................................................................................................................................................... 40
Valveremoval................................................................................................................................................................... 40
Valvespring-Check..........................................................................................................................................................41
Valvespring-checkunderload........................................................................................................................................41
Valvematerial....................................................................................................................................................................41
Valveguidesandcylinderhead.........................................................................................................................................41
Valveguideinsertion,afterdriving....................................................................................................................................42
Oilsealinthevalvesguides,(intakeandexhaust)............................................................................................................42
Valveseatsandbore........................................................................................................................................................ 43
Valverecessandsealingsurfaces................................................................................................................................... 43
Precombustionchamber................................................................................................................................................... 44
Hydraulictappetvalvecontrol........................................................................................................................................... 44
Hydraulicdiagramforfeedingthetappets........................................................................................................................ 44
Hydraulictappetcomponents:.......................................................................................................................................... 44
Hydraulictappetoperation................................................................................................................................................ 45
Injectionpumpfollower..................................................................................................................................................... 45
Cylinders........................................................................................................................................................................... 46
Cylinderroughness........................................................................................................................................................... 46
Piston................................................................................................................................................................................ 46
Pistonavailability.............................................................................................................................................................. 46
Pistonweight......................................................................................................................................................................47
Pistonrings-Endgaps....................................................................................................................................................47
Pistonrings-Clearancebetweengrooves........................................................................................................................47
Pistonrings-Fittingsequence..........................................................................................................................................47
Piston-Retting............................................................................................................................................................... 48
Pistonpositionandclearance........................................................................................................................................... 48
Cylinderheadgasket........................................................................................................................................................ 48
Cylinderheadtighteningforengineswithouthydraulictappets....................................................................................... 49
Cylinderheadtighteningsteps......................................................................................................................................... 49
Assemblingandtighteningthecylinderheadonengineswithhydraulictappets............................................................ 49
Connectingrod................................................................................................................................................................. 50
Connectingrodweights.................................................................................................................................................... 50
Connectingrodandpistonpin.......................................................................................................................................... 50
Connectingrodalignment..................................................................................................................................................51
Pistoncoolingsprayer.......................................................................................................................................................51
Connectingrod/pistonassemblies....................................................................................................................................51
Centermainbearings....................................................................................................................................................... 52
Mainbearingcapstimingside-ywheelside.................................................................................................................. 52
Checkclearancebetweenmainbearingsandjournals................................................................................................... 53
Thrustbearing,oversizes................................................................................................................................................. 54
Crankshaftendplay.......................................................................................................................................................... 54
Crankshaftfrontandrearoilseal..................................................................................................................................... 55
Crankshafttiminggear...................................................................................................................................................... 55
Crankshaftlubricationducts............................................................................................................................................. 55
Checkingmainjournalsandcrankpins............................................................................................................................ 56
Mainbearingandconnectingrodbigbearinginsidediameter(mm)............................................................................... 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A........................................ 57
Frontcover(beforetheserialnumber7366305).............................................................................................................. 58
Frontcover(aftertheserialnumber7366306)................................................................................................................. 58
Idlergearandhub............................................................................................................................................................. 58
Speedgovernor................................................................................................................................................................ 59
Dimensionsforinjectionpumpdeliverycontrolyokeadjustement.................................................................................. 59
Camshaftgear-Speedgovernorcounterweights.......................................................................................................... 60
Speedgovernorcountersprings...................................................................................................................................... 60
Framewithidlingspeedgovernorspring.......................................................................................................................... 60
Summarytablesofthegovernorequipmentaccordingtothespeedvariation.................................................................61
Springforextrafuelsupplyatstarting...............................................................................................................................61
Camshaft............................................................................................................................................................................61
Camshaftremoval..............................................................................................................................................................61
Checkingcamshaftbushinginternaldiameter................................................................................................................. 62
CamshaftjournalsandbushingsinmodelKDW1603..................................................................................................... 62
CamshaftjournalsandbushingsinmodelsKDW2204-2204/T...................................................................................... 62
Workshop Manual KDW 1603_2204_2204/T _ cod. ED0053029180 - 1° ed_rev. 00

Kohler KDW 1603 Specifications

General

Brand	Kohler
Model	KDW 1603
Category	Engine
Language	English