Home
Kohler
Engine
KDW 702
Kohler KDW 702 User Manual
4
of 1
of 1 rating
116 pages
Give review
Manual
Specs
To Next Page
To Next Page
Loading...
WORKSHOP
MANUAL
KDW 702 - 1003 - 1404
2
Table of Contents
Default Chapter
5
Table of Contents
5
1 Manufacturer and Engine Identification
10
The Identification Plate Shown in the Figure Can be Found Directly on the Engine
10
Approval Data
10
Name Plate for EPA Rules Applied on Rocker-Arm Cap
11
Compilation Example
11
2 General Remarks and Safety Information
12
California Emission Control Warranty Statement
13
Your Warranty Rights and Obligations
13
Explanation of the Safety Pictograms that Can be Found on the Engine or in the Operation and Maintenance Handbook
14
Indications Regarding the Points on the Engine Where the Safety Pictograms Are Placed
14
Limited 3 Year Kohler ® Diesel Engine Warranty
15
General Service Manual Notes
15
Glossary and Terminology
15
Safety Regulations
16
General Safety During Operating Phases
17
Safety and Environmental Impact
17
Trouble Shooting
18
3 Technical Information
18
Technical Information
19
Techinical Specifications
21
Performance Diagrams
24
Overall Dimension
28
4 Maintenance - Recommended Oil Type - Refilling
32
Routine Engine Maintenance
32
Ordinary Maintenance
32
Extraordinary Maintenance
32
Lubricant
33
Prescribed Lubricant
34
Coolant
35
Fuel Recommendations
35
5 Regulations for Lifting the Engine
36
6 Disassembly / Reassembly
37
Recommendations for Disassembling and Assembling
37
Recommendations for Overhauls and Tuning
37
Dry Type Air Filter
38
Air Restriction Switch
38
Oil Bath Air Cleaner (on Request)
38
Air Filter Support
39
Intake Manifold - Remote Air Filter
39
Circuit (Components)
40
E.G.R. Circuit
41
Vacuum Pump and Vacuum Pump Flange
42
Exhaust Manifold
42
Exhaust Manifold - Engines with Egr
42
Cooling Fan
43
Alternator/Cooling Fan Belt Drive
43
Fuel Tank (Optional)
43
Flywheel
44
Return Pulley
44
Driving Pulley
44
Ringfeder-Type Rings on Kdw 1404
45
Ringfeder-Type Rings on Kdw 1404 - Assembly
45
Timing Belt Cover
45
Timing Belt / Timing Pulley Arrangement
46
Timing Belt Removal
46
Tightening Pulley
46
Crankshaft Timing Pulley
46
Camshaft Timing Pulley
47
Camshaft Timing Pulley - Disassembly/Assembly
47
Camshaft Timing Pulley - Reference Marks
47
Camshaft Timing
47
Camshaft Timing - Belt Reassembly
47
Camshaft Timing - Belt Tightening Tool
48
Camshaft Timing - Belt Tightening and Fastening
48
Valve Timing Check
48
Valve Timing - Angles
49
Speed Governor
50
Speed Governor Components
50
Governor Springs
50
Governor Springs for Gensets
50
Speed Governor - Limiting Speed Governor
51
Speed Governor - Reassembly
51
Oil Pump
52
Oil Pump - Disassembly
52
Oil Pump - Reassembly
52
Rocker Arm Cover
52
Rocker Arm Cover Gasket
53
Crankcase Vacuum Regulator Valve
53
Crankcase Breather
54
Valve / Rocker Arm Clearance
54
Injection Pump Control Rod
54
Fuel Rail
54
Pump/Injector Unit - Non-Return Valve
55
Pump/Injector Unit - Disassembly
55
Rocker Arm Pivot, Dismounting and Remounting
56
Camshaft, Disassembly
56
Camshaft, Journal and Housing Measurement
56
Camshaft Journals and Housings - Dimensions (MM)
57
Camshaft Lobe Measurement
57
Intake / Exhaust / Injection Camshaft Lobe Height
57
Cylinder Head, Removal
58
Valves
58
Valve Stem Sealing Rings - Reassembly
58
Valve Springs
58
Valve, Specifications
59
Valve Guides and Valve Guide Housings
59
Valve Guide Insertion
59
Valve Seats and Housings - Dimensions
60
Valve Recess and Seat Sealing Width
60
Pre-Combustion Chamber
61
Pre-Combustion Chamber Ring Nut Removal
61
Pre-Combustion Chamber, Removal
61
Pre-Combustion Chamber, Installation
61
Oil Pan, Removal
62
Piston
62
Stop Pin Rings, Dismounting and Remounting
62
Piston, Disassembly and Inspection
63
Piston, Class
63
Piston, Weight
64
Piston Rings - End Gaps (MM)
64
Piston Ring, Clearance between Grooves (MM)
64
Piston Ring, Mounting Order
65
Piston, Assembly
65
Piston Clearance
65
KD 702_1003_1404 Workshop Manual_Cod. ED0053029340_1° Ed_ Rev
66
Head Gasket
66
Cylinder Head Assembly
67
Cylinder Head Tightening Procedure KDW 1003
67
Cylinder Head Tightening Procedure KDW 1404
67
Connecting Rod
68
Big End Bearing
68
Connecting Tod, Weight
68
Connecting Rod with Bearings and Pin
68
Connecting Rod Alignment
69
Cylinders
69
Cylinder, Class
69
Cylinder Roughness
69
Central Main Bearing Caps
70
Rear and Forward Main Bearing Caps
70
Check the Clearances between the Bearings and the Journal
70
Piston Coolant Nozzles
71
Shoulder Half Rings
71
Crankshaft Axial Clearance
71
Shoulder Half Rings, Oversized Elements
72
Crankshaft Front and Back Oil Seal Rings
72
Crankshaft, Lubrication Lines
73
Crankshaft, Check Journals and Crank
73
Journal and Connecting Rod Pins Diameters
73
Main Bearings and Connecting Rod Big Ends Diameters
74
Clearances between the Bearings and Corresponding Pins
74
Hydraulic Pump Drive
75
Third Drive, Components
75
7 Turbocharger
76
Turbocharger Components
76
Turbocharger Pressure Testing
76
Turbocharger West Gate Adjustment - Regolazione Corsa Asta Comando Valvola " Waste Gate
77
8 Lubrification Circuit
78
Internal Oil Filter and Oil Sump Return Pipe
79
Oil Pump
79
Oil Pump, Clearance between Rotors
79
Oil Pressure Regulating Valve
80
Oil Filter Cartridge
80
Oil Pressure Check
80
9 Coolant Circuit
82
Radiator and Compensation, Check and Seal Tank Cap
83
Coolant Circulation Pump, Components
83
Thermostatic Valve
83
10 Fuel System
84
Fuel Feeding / Injection Circuit
84
Fuel Filter Detached from the Tank (on Request)
84
Fuel Lift Pump
84
Fuel Pump Drive Rod Projection
84
Pump/Injector Unit
85
Pump/Injector Unit, Components
85
Plunger Barrel Ring Nut Assembly/Disassembly
86
Injection Pump Assembly/Disassembly
86
Plunger Injection Pump Reassembly
86
Pumping Element (Old-Type Injection Pump)
87
Pumping Element
87
Pump/Injector Unit Se.no. 6590.285 Control Data
87
Injector, Setting (Old Type)
89
Setting of Injector According to Current Pump/Injector Unit
89
Injector, Nozzle Projection
89
Injector, Spark Arrester
89
Injection Advance Control and Regulation
90
Injection Advance for Currently Used Pump/Injector Unit
90
Static Injection Advance Tuning
91
Injection Advance References on Timing Belt Protector
91
Tdc (Top Dead Center) References
91
Tester and Special Coupling for Injection Advance Control (Old-Type Injection Pump)
91
Static Injection Advance Regulation
92
Preliminary Steps to Pump/Injector Unit Delivery Balancing Test
92
Closing the Oilhole
92
Test Head B Assembly
92
Instrument Connection
93
Injection Pumps Delivery Balancing
93
Electric Control Panel with Automatic Engine Stop (Upon Request)
94
11 Electric System
94
Alternator, 14V 33A
95
Alternator, 14V 33A - Performance Curve
95
Electric Starting Layout (12V) with Alternator 14V 33A
96
Alternator 14V 45A - 65A
97
Alternator, 14V 45A - Performance Curve
97
Alternator, 14V 65A - Performance Curve
97
Electric Starting Layout 12V 33A - 45A - 65A
98
Flywheel Alternator
98
Alternator Battery Charger Curve 12V 30A
99
(Two Cables at Output)
99
Electric Starting Layout (12V) with Flywheel Alternator
100
Voltage Regulator Connections
100
Starter Motor - Bosch Dw 12V 1,1 Kw
101
Starter Motor, Bosch Dw 12V 1,1 Kw - Performance Curve
101
Starter Motor, Bosch 12V 1,6 Kw
101
Starter Motor, Bosch Dw 12V 1,6 Kw - Performance Curve
102
Pre-Heating Glow Plug
102
Pre-Heating Plug Control Unit with Coolant Temperature Sensor
102
Temperature Sensor for Control Unit
103
Oil Pressure Switch (Fig. 215)
103
Pre-Heating Water Temperature Thermistor and Water Temperature Indicator Thermal Contact
103
12 Settings
104
Speed Settings
104
Setting the Idle Minimum (Standard)
104
Setting the Idle Maximum (Standard)
104
Pump Injection Delivery Standard Setting Without Dynamometric Brake
104
Injection Pump Flow Limiter and Engine Torque Gearing Device
105
Pump/Injector Unit Timing with Speed Governor
105
Pump/Injector Unit Delivery Setting with Braked Engine
106
E.G.R. Calibration
107
13 Storage
108
Engine Storage
108
Protective Treatment
108
Preparing the Engine for Operation after Protective Treatment
109
14 Torque Specifications and Use of Sealant
110
KD 702_1003_1404 Workshop Manual_Cod. ED0053029340_1° Ed_ Rev
110
Table of Tightening Torques for the Main Components
110
Table of Tightening Torques for Standard Screws (Coarse Thread)
111
Table of Tightening Torques for Standard Screws (Fine Thread)
111
15 Special Tools
112
Other manuals for Kohler KDW 702
Use & Maintenance
188 pages
4
Based on 1 rating
Ask a question
Give review
Questions and Answers:
Need help?
Do you have a question about the Kohler KDW 702 and is the answer not in the manual?
Ask a question
Kohler KDW 702 Specifications
General
Governor Type
Mechanical
Lubrication System
Forced Lubrication
Engine Type
Diesel
Cooling System
Liquid Cooled
Starting System
Electric
Related product manuals
Kohler KDW 502
116 pages
Kohler KDW 1404
116 pages
Kohler KDW 1603
108 pages
Kohler KD225
140 pages
Kohler KD27V12
112 pages
Kohler KD 477-2
48 pages
Kohler KD 625/2
88 pages
Kohler KDI Series
200 pages
Kohler KDI 2504TM
52 pages
Kohler KDI-1903TCR
40 pages
Kohler KDI 1903 TCR
64 pages
Kohler KDI 3404 TCR
40 pages
Need help?
General
To Next Page
