Kohler KDW 1603 User Manual

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Chapter index
Camshaftbushingreplacement........................................................................................................................................ 62
Intake,exhaustandinjectioncamheightforenginewithhydraulictappets.................................................................... 63
Camshafttiming................................................................................................................................................................ 64
Valvetimingwithoutconsideringtimingmarks................................................................................................................. 64
Valvetimingcheck............................................................................................................................................................ 64
Engineswithhydraulictappets......................................................................................................................................... 65
Camshaftendplay............................................................................................................................................................ 66
HydraulicpumpP.T.O........................................................................................................................................................ 66
GR1andGR2hydraulicpump3rdP.T.O........................................................................................................................ 66
7 - TURBOCHARGER ............................................................................................................................................. 68
Turbocharger..................................................................................................................................................................... 68
Turbochargercomponents................................................................................................................................................ 68
TurbochargerTesting........................................................................................................................................................ 68
Checkingactuatorsetting-"WasteGate"valvecontrolrodstrokeadjustment............................................................... 69
8 - LUBRICATION SYSTEM .................................................................................................................................... 70
Oilpump.............................................................................................................................................................................71
Oilpumprotorclearance...................................................................................................................................................71
Oilpressureadjustingvalve...............................................................................................................................................71
Oilltercartridge...............................................................................................................................................................71
Oilpressurecheck............................................................................................................................................................ 72
OilpressurecurveforKDW1603.................................................................................................................................... 72
OilpressurecurveforKDW2204.................................................................................................................................... 72
OilpressurecurveforKDW2204/T................................................................................................................................ 72
9 - COOLING SYSTEM ............................................................................................................................................ 74
Expansiontankandcap....................................................................................................................................................75
Checkingforcoolingsystemleaks....................................................................................................................................75
Coolantcirculatingpump...................................................................................................................................................75
Thermostat.........................................................................................................................................................................75
10 - FUEL SYSTEM ................................................................................................................................................. 76
Fuellter........................................................................................................................................................................... 77
Fuelfeedingpump............................................................................................................................................................ 77
Fuelfeedingpumpdriverodprotrusion............................................................................................................................ 77
Electricfuelpump(24V)................................................................................................................................................... 78
Injectionpump.................................................................................................................................................................. 78
Injectionpumpdisassembly............................................................................................................................................. 78
Howtoreassembleinjectionpumpcomponents.............................................................................................................. 79
Injectionpumpnon-returnvalve....................................................................................................................................... 79
Injectionpumpcontrolrod................................................................................................................................................ 79
Howtoremoveinjectionpumpfeedingtubes................................................................................................................... 79
Howtoreassembleinjectionpumpfeedingtubes............................................................................................................ 80
Instrumentforequalizinginjectionpumpdelivery-PartNo.7104-1460-090.................................................................. 80
Injectionpumpdeliveryequalization................................................................................................................................ 80
Testdataofinjectionpump...............................................................................................................................................81
InjectionpumpP.No.6590-249-Plungerandbarrelassembly.......................................................................................81
Checkinginjectionpumpdelivery......................................................................................................................................81
Checkinglowpressureinjectiontimingforengineswithhydraulictappets.................................................................... 82
Checkinglowpressureinjectiontimingforengineswithmechanicaltappets................................................................. 83
Injectiontimingcorrectionbychangingthepadthickness............................................................................................... 83
Injector(pintype).............................................................................................................................................................. 84
Injectorsetting.................................................................................................................................................................. 84
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