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Details regarding the engine's approval references and directives.
Information on emissions compliance found on the engine's name plate.
Key safety rules and precautions for engine operation and maintenance.
Details on the warranty coverage for emission control systems in California.
Owner's responsibilities and rights related to the engine warranty.
Meaning and purpose of various safety symbols used in the manual and on the engine.
Diagram showing the location of safety pictograms on the engine components.
Kohler's warranty terms for diesel engines, covering defects in materials and workmanship.
Guidelines for using genuine parts and understanding metric specifications.
Definitions of key terms used throughout the service manual.
Guide to identifying and resolving common engine problems and anomalies.
Detailed specifications for KDW 702, 1003, and 1404 engine models.
Graphs illustrating engine power, torque, and fuel consumption curves.
Dimensional drawings and measurements for KDW 702 engine.
Basic maintenance tasks and their recommended frequencies.
Scheduled maintenance for routine operations like oil and filter changes.
Periodic checks and replacements based on operating hours.
Information on oil classification, SAE grades, and international specifications.
Recommended oil types and capacities for KDW engines.
Guidelines for coolant type, mixture, and safe handling procedures.
Specifications and advice for using diesel fuel, including low-temperature and biodiesel.
General advice and safety precautions for engine disassembly and assembly procedures.
Best practices for engine overhauling, cleaning, and component checks.
Procedure for inspecting and cleaning the dry type air filter.
Description and calibration of the air filter restriction indicator switch.
Instructions for checking and cleaning the oil bath air cleaner components.
Steps to remove and replace the air filter support, including gasket.
Procedure for removing the intake manifold and its connection to the remote air filter.
Explanation of the Exhaust Gas Recirculation system's function and components.
Detailed steps for disassembling the Exhaust Gas Recirculation system components.
Procedure for removing and replacing the vacuum pump and its flange.
Instructions for removing and reinstalling the exhaust manifold, including gasket replacement.
Specific procedure for removing the exhaust manifold on engines equipped with EGR.
Steps for disassembling and cleaning the engine cooling fan.
Procedure for adjusting the tension of the alternator and cooling fan belt.
Safety precautions and steps for removing the optional fuel tank.
Procedure for dismounting and replacing the flywheel, including safety warnings.
Steps for removing and remounting the return pulley.
Procedure for removing and installing the driving pulley, including torque specifications.
Description of Ringfeder rings for KDW 1404 engines and their purpose.
Instructions for assembling Ringfeder-type rings on KDW 1404 engines.
Procedure for removing and refitting the timing belt cover.
Diagram showing the timing belt and pulley configuration on the engine.
Step-by-step guide for removing the timing belt, including safety warnings.
Components and procedure for tightening the timing belt pulley.
Identification of timing marks on the crankshaft timing pulley and oil pump housing.
Procedure for disassembling and assembling the camshaft timing pulley.
Identification of timing reference marks for camshaft pulleys on various KDW engines.
Instructions for reassembling the timing belt onto the camshaft and crankshaft pulleys.
Description of the tool used for timing belt preload and adjustment.
Procedure for properly tightening and fastening the timing belt using specific tools.
Method for checking the valve timing alignment using dial indicators.
Specifications for valve timing angles during operation and checking procedures.
List and illustration of the components that make up the engine's speed governor.
Procedure for removing and reinstalling governor springs, including notes on spring types.
Information on governor springs used in generator set applications.
Details on the limiting speed governor used in automotive applications.
Step-by-step instructions for reassembling the speed governor components.
Recommended procedure for the disassembly of the engine oil pump.
Instructions for reassembling the engine oil pump, including torque specifications.
Description of the rocker arm cover's function and components.
Procedure for replacing the rocker arm cover gasket, including sealant application.
Components and function of the crankcase vacuum relief valve as an engine safety device.
Procedure for checking the crankcase breather valve and wire gauze.
Method and specifications for setting the valve and rocker arm clearance.
Description of the injection pump control rod linkage to injectors and governor.
Precautions for removing and refitting the fuel rail, including O-ring seating.
Function of the pump/injector unit's non-return valve and its role in stopping the engine.
Procedure for removing and reinstalling unit injectors without needing further adjustments.
Procedure for removing and tightening the rocker arm assembly to the cylinder head.
Steps for removing and remounting the rocker arm pivot, including pin drilling.
Procedure for removing the camshaft, including cover, gasket, and drive rod checks.
Methods for measuring camshaft journal and housing diameters using micrometers.
Specifications for camshaft journal and housing dimensions for KDW engines.
Procedure for measuring camshaft lobe height using an outside micrometer.
Specifications for intake, exhaust, and injection camshaft lobe height and wear limits.
Procedure for removing the cylinder head, with warnings about deformation.
Procedure for removing engine valves, including collets, springs, and caps.
Instructions for correctly installing valve stem sealing rings using specialized tools.
Method for measuring valve spring free height and replacement criteria.
Technical specifications for exhaust and intake valves, including material details.
Dimensions and specifications for valve guides and their housings.
Procedure for inserting valve guides into the cylinder head, noting dimensions.
Dimensions for valve seats and their housings for KDW engines.
Procedure for grinding valve seats and checking valve recess and sealing width.
Description of the pre-combustion chamber and its normal service requirements.
Procedure for removing the pre-combustion chamber ring nut using a special tool.
Steps for removing the pre-combustion chamber, including glow plug removal.
Procedure for installing the pre-combustion chamber, aligning holes, and tightening torque.
Procedure for removing the engine oil pan, including safety warnings and reassembly notes.
Details on piston components, specifications, and assembly procedures.
Procedure for dismounting and remounting piston stop pin rings.
Steps for disassembling and inspecting pistons, including measurement and replacement criteria.
Information on piston diameter classifications (A, B, C) and piston supply details.
Procedure for weighing pistons to ensure balance during replacement.
Method for measuring piston ring end gaps and their limit values.
Specifications for piston ring clearance within the piston grooves.
Correct order for installing piston rings onto the piston, including orientation notes.
Procedure for assembling pistons into the cylinder, including lubrication and connecting rod coupling.
Method for determining piston clearance and selecting the appropriate gasket.
Information on selecting and replacing the head gasket based on its thickness and engine model.
Procedure for assembling the cylinder head, including screw length check and tightening.
Step-by-step tightening sequence and torque values for KDW 1003 cylinder head.
Step-by-step tightening sequence and torque values for KDW 1404 cylinder head.
Procedures for connecting rod disassembly, reassembly, and measurement.
Procedure for checking and reassembling the connecting rod big end bearings.
Procedure for weighing connecting rods to ensure balance during replacement.
Dimensions and specifications for connecting rods, bearings, and pins.
Method for checking and correcting connecting rod alignment using a comparator.
Procedures for inspecting and measuring cylinders and their components.
Information on cylinder classifications and their location markings on the engine.
Specifications and precautions for cylinder internal surface roughness.
Procedure for installing central main bearing caps, including alignment and torque.
Procedure for installing rear and forward main bearing caps, with notes on gaskets and plates.
Method for checking bearing clearances using Plastigage, including torque and values.
Procedure for installing piston coolant nozzles, ensuring correct positioning.
Instructions for assembling shoulder half rings, including lubrication and thickness.
Method for measuring crankshaft axial clearance and fitting oversized half rings.
Details on oversized shoulder half rings and their dimensions.
Procedure for replacing crankshaft oil seal rings, with warnings and notes on tempered crankshafts.
Procedure for cleaning and checking crankshaft lubrication ducts.
Method for checking crankshaft journals and crank using a micrometer.
Dimensions for journal and connecting rod pins for KDW engines.
Diameters for main bearings and connecting rod big ends, with tightening torque references.
Specifications for clearances between bearings and pins for KDW engines.
Description of the hydraulic pump drive and its power output capabilities.
List of components for the third drive assembly, including the fuel pump control cam.
List and illustration of the components that make up the turbocharger assembly.
Procedure for testing turbocharger pressure and adjusting waste gate if needed.
Detailed steps for adjusting the turbocharger's waste gate control valve.
Diagram and component list of the engine's lubrication circuit.
Procedure for cleaning the internal oil filter and oil sump return pipe.
Tests and specifications for the engine oil pump's delivery and pressure.
Method for measuring rotor clearance in the oil pump and wear limits.
Components and function of the oil pressure regulating valve, including spring length.
Characteristics and specifications of the oil filter cartridge.
Procedure for checking engine oil pressure, including temperature and RPM considerations.
Diagram and component list of the engine's coolant circuit.
Procedure for checking the coolant level, radiator, and compensation tank cap.
List and illustration of the components of the coolant circulation pump.
Characteristics and function of the engine's thermostatic valve.
Diagram of the fuel feeding and injection circuit, with component identification.
Characteristics and specifications of the fuel filter when detached from the tank.
Description of the fuel lift pump, its drive mechanism, and performance characteristics.
Procedure for checking and replacing the fuel pump drive rod projection.
Detailed list and illustration of the components of the pump/injector unit.
Procedure for assembling and disassembling the plunger barrel ring nut.
Instructions for disassembling and reassembling the injection pump unit.
Specific steps for reassembling the plunger into the injection pump barrel.
Dimensions and description of the old-type injection pump's pumping element.
Dimensions for the pumping element of KDW 702-1003-1404 engines.
Control data and specifications for pump/injector units with serial number 6590.285.
Procedure for setting the injection pressure for old-type injectors.
Method for setting injectors according to current pump/injector unit specifications.
Procedure for checking and adjusting the injector nozzle projection.
Instructions for replacing the injector spark arrester, gaskets, and O-rings.
Procedure for controlling and regulating injection advance, including TDC references.
Table showing injection advance values for different engine RPM ranges.
Method for tuning static injection advance by adjusting screws.
Identification of Top Dead Center references for various KDW engine cylinders.
Using timing belt protector references to check injection advance.
Description of the tester and coupling for injection advance control on old-type pumps.
Detailed procedure for regulating static injection advance using a tester.
Preparatory steps for pump/injector unit delivery balancing, including oil hole closure.
Procedure for assembling test heads for pump/injector unit tests.
Instructions for connecting instruments for testing pump/injector unit deliveries.
Procedure for balancing injection pump deliveries and adjusting plate position.
Diagram and description of the electric control panel with automatic engine stop feature.
Description of auxiliary terminal connections and their functions.
Specifications and performance curve for the 14V 33A alternator.
Characteristics and performance curves for 14V 45A and 65A alternators.
Wiring diagram for the 12V electric starting system with 33A, 45A, and 65A alternators.
Description of the flywheel alternator and its output capabilities.
Performance curve for the 12V 30A flywheel alternator battery charger.
Wiring diagram for the 12V electric starting system using a flywheel alternator.
Details on voltage regulator connections and dimensions for various types.
Specifications and performance curve for the Bosch DW 12V 1.1 KW starter motor.
Specifications and performance curve for the Bosch DW 12V 1.6 KW starter motor.
Characteristics and components of the pre-heating glow plug.
Function and table for the pre-heating plug control unit with coolant temperature sensor.
Characteristics of the temperature sensor used for the control unit.
Characteristics and tightening torque for the oil pressure switch.
Characteristics and tightening torque for the coolant high temperature lamp sensor.
Features of the thermistor and thermal contact for water temperature indication.
Procedures for adjusting engine speed settings, including idle minimum and maximum.
Steps for setting the engine's idle speed to the standard minimum value.
Procedure for setting the engine's idle speed to the standard maximum value.
Method for adjusting pump injection delivery without a dynamometric brake.
Function of the injection pump flow limiter and its role as a torque gearing device.
Procedure for setting the engine stop mechanism, involving the rocker arm cover and push rod.
Procedure for timing pump/injector units in conjunction with the speed governor.
Procedure for setting pump/injector unit delivery using a braked engine and checking consumption.
Procedure for calibrating the Exhaust Gas Recirculation system using a vacuum gauge.
General guidelines for storing engines not in use for extended periods.
Steps for applying protective treatment to the engine for long-term storage.
Procedure for preparing a stored engine for operation, including removal of treatments and fluid checks.
List of main engine components with their specified tightening torques and sealant requirements.
Torque specifications for standard screws with coarse threads, categorized by resistance class.
Torque specifications for standard screws with fine threads, categorized by resistance class.
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