Factory Workshop Manual For Kohler Engine. Manual Contains Illustrations, Instructions, Diagrams For Step By Step Remove And Install, Assembly And Disassembly, Service, Inspection, Repair, Troubleshooting, Tune-Ups.
Format: PDF
Language: English
Pages: 108
Number: 0053029180 (february 2011)
Searchable: Yes
Model
Kohler Engine
KDW1603
KDW2204
KDW2204T
Contents
-MANUFACTURER AND MOTOR IDENTIFICATION DATA
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
-GENERAL REMARKS AND SAFETY INFORMATION
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
-TECHNICAL INFORMATION
Possible Causes And Trouble Shooting
Technical Data
Performance Diagrams
Overall Dimensions
-MAINTENANCE – RECOMMENDED OIL TYPE – REFILLING
Routine Engine Maintenance
Ordinary Maintenance
Extraordinary Maintenance
Lubricant
Prescribed Lubricant
Coolant
Specifications Fuel
-REGULATIONS FOR LIFTING THE ENGINE
Regulations For Lifting The Engine
-DISASSEMBLY/REASSEMBLY
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 PTO)
Tank
Flywheel
Rocker Arm Cover With Vent Into The Air
Rocker Arm Cover With Vent Into The Air
Rocker Arm Cover For Engines With Recirculating Vent
Rocker Arm Assembly
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
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 Adjustment
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/T
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 PTO
GR 1 And GR 2 Hydraulic Pump 3Rd PTO
-TURBOCHARGER
Turbocharger
Turbocharger Components
Turbocharger Testing
Checking Actuator Setting – “Waste Gate” Valve Control Rod Stroke Adjustment
-LUBRICATION SYSTEM
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
-COOLING SYSTEM
Expansion Tank And Cap
Checking For Cooling System Leaks
Coolant Circulating Pump
Thermostat
-FUEL SYSTEM
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
-ELECTRIC SYETEM
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
Characteristic Voltage Curve For Regulator Type RTT 119 AC
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 22 KW
Wiring Diagram 24V With Alternator 35A
Recommended Batteries
Alternator Type Iskra, Type AAK3570 28V 35A – (For 24 V Outfits)
Characteristic Curves For Alternator Type Aak3570 28V 35A (For 24 V Outfits)
Characteristic Voltage Curve For Regulator Type AER 1528
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
-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
-ENGINE STORAGE
Engine Storage
Protective Treatment
Preparing The Engine For Operation After Protective Treatment
-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)
SPECIAL TOOLS
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