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: 116
Issued: june 2012
Bookmarks: Yes
Searchable: Yes
Wiring Diagrams: Yes
Model
Kohler Engine
KDW702
KDW1003
KDW1404
Contents
-MANUFACTURER AND ENGINE IDENTIFICATION
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
California Emission Control Warranty Statement
Your Warranty Rights And Obligations
Explanation Of The Safety Pictograms That Can Be Found On The Engine Or In The Operation And Maintenance Handbook
Indications Regarding The Points On The Engine Where The Safety Pictograms Are Placed
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
Troubleshooting
-TECHNICAL INFORMATION
Trouble Shooting
Technical Specifications
Performance Diagrams
Overall Dimension
-MAINTENANCE – RECOMMENDED OIL TYPE – REFILLING
Routine Engine Maintenance
Ordinary Maintenance
Extraordinary Maintenance
Lubricant
Prescribed Lubricant
Coolant
Fuel Recommendations
REGULATIONS FOR LIFTING THE ENGINE
-DISASSEMBLY/REASSEMBLY
Recommendations For Disassembling And Assembling
Recommendations For Overhauls And Tuning
Dry Type Air Filter
Air Restriction Switch
Oil Bath Air Cleaner (On Request)
Air Filter Support
Intake Manifold – Remote Air Filter
EGR Circuit (Components)
EGR Circuit
Vacuum Pump And Vacuum Pump Flange
Exhaust Manifold
Exhaust Manifold – Engines With EGR
Cooling Fan
Alternator/Cooling Fan Belt Drive
Fuel Tank (Optional)
Flywheel
Return Pulley
Driving Pulley
Ringfeder-Type Rings On Kdw 1404
Ringfeder-Type Rings On Kdw 1404 – Assembly
Timing Belt Cover
Timing Belt / Timing Pulley Arrangement
Timing Belt Removal
Tightening Pulley
Crankshaft Timing Pulley
Camshaft Timing Pulley
Camshaft Timing
Valve Timing Check
Valve Timing – Angles
Speed Governor
Speed Governor Components
Governor Springs
Speed Governor
Oil Pump
Rocker Arm Cover
Rocker Arm Cover Gasket
Crankcase Vacuum Regulator Valve
Crankcase Breather
Valve / Rocker Arm Clearance
Injection Pump Control Rod
Fuel Rail
Pump/Injector Unit
Rocker Arm Pivot, Dismounting And Remounting
Camshaft
Camshaft Journals And Housings – Dimensions (Mm)
Camshaft Lobe Measurement
Intake / Exhaust / Injection Camshaft Lobe Height
Cylinder Head, Removal
Valves
Valve Stem Sealing Rings – Reassembly
Valve Springs
Valve, Specifications
Valve Guides And Valve Guide Housings
Valve Guide Insertion
Valve Seats And Housings – Dimensions
Valve Recess And Seat Sealing Width
Pre-Combustion Chamber
Pre-Combustion Chamber Ring Nut Removal
Pre-Combustion Chamber, Removal
Pre-Combustion Chamber, Installation
Oil Pan, Removal
Piston
Stop Pin Rings, Dismounting And Remounting
Piston, Disassembly And Inspection
Piston, Class
Piston, Weight
Piston Rings – End Gaps (Mm)
Piston Ring, Clearance Between Grooves (Mm)
Piston Ring, Mounting Order
Piston, Assembly
Piston Clearance
Head Gasket
Cylinder Head Assembly
Cylinder Head Tightening Procedure KDW 1003
Cylinder Head Tightening Procedure KDW 1404
Connecting Rod
Big End Bearing
Connecting Rod, Weight
Connecting Rod With Bearings And Pin
Connecting Rod Alignment
Cylinders
Cylinder, Class
Cylinder Roughness
Central Main Bearing Caps
Rear And Forward Main Bearing Caps
Check The Clearances Between The Bearings And The Journal
Piston Coolant Nozzles
Shoulder Half Rings
Crankshaft Axial Clearance
Shoulder Half Rings, Oversized Elements
Crankshaft Front And Back Oil Seal Rings
Crankshaft, Lubrication Lines
Crankshaft, Check Journals And Crank
Journal And Connecting Rod Pins Diameters
Main Bearings And Connecting Rod Big Ends Diameters
Clearances Between The Bearings And Corresponding Pins
Hydraulic Pump Drive
Third Drive, Components
-TURBOCHARGER
Turbo Charger
Turbocharger Components
Turbocharger Pressure Testing
-LUBRIFICATION CIRCUIT
Lubrication Circuit
Internal Oil Filter And Oil Sump Return Pipe
Oil Pump
Oil Pump, Clearance Between Rotors
Oil Pressure Regulating Valve
Oil Filter Cartridge
Oil Pressure Check
-COOLANT CIRCUIT
Coolant Circuit
Radiator And Compensation, Check And Seal Tank Cap
Coolant Circulation Pump, Components
Thermostatic Valve
-FUEL SYSTEM
Fuel Feeding / Injection Circuit
Fuel Filter Detached From The Tank (On Request)
Fuel Lift Pump
Fuel Pump Drive Rod Projection
Pump/Injector Unit
Pump/Injector Unit, Components
Plunger Barrel Ring Nut Assembly/Disassembly
Injection Pump Assembly/Disassembly
Plunger Injection Pump Reassembly
Pumping Element (Old-Type Injection Pump)
Pumping Element
Pump/Injector Unit See No. 6590285 Control Data
Injector, Setting (Old Type)
Setting Of Injector According To Current Pump/Injector Unit
Injector, Nozzle Projection
Injector, Spark Arrester
Injection Advance Control And Regulation
Injection Advance For Currently Used Pump/Injector Unit
Static Injection Advance Tuning
Injection Advance References On Timing Belt Protector
TDC (Top Dead Center) References
Tester And Special Coupling For Injection Advance Control (Old-Type Injection Pump)
Static Injection Advance Regulation
Preliminary Steps To Pump/Injector Unit Delivery Balancing Test
Closing The Oil Hole
Test Head B Assembly
Instrument Connection
Injection Pumps Delivery Balancing
Electric Control Panel With Automatic Engine Stop (Upon Request)
-ELECTRIC SYSTEM
Alternator, 14V 33A
Alternator, 14V 33A – Performance Curve
Electric Starting Layout (12V) With Alternator 14V 33A
Alternator 14V 45A – 65A
Alternator, 14V 45A – Performance Curve
Alternator, 14V 65A – Performance Curve
Electric Starting Layout 12V 33A – 45A – 65A
Flywheel Alternator
Alternator Battery Charger Curve 12V 30A
Electric Starting Layout (12V) With Flywheel Alternator
Voltage Regulator Connections
Starter Motor – Bosch Dw 12V 1,1 Kw
Starter Motor, Bosch Dw 12V 1,1 Kw – Performance Curve
Starter Motor, Bosch 12V 1,6 Kw
Starter Motor, Bosch Dw 12V 1,6 Kw – Performance Curve
Pre-Heating Glow Plug
Pre-Heating Plug Control Unit With Coolant Temperature Sensor
Temperature Sensor For Control Unit
Oil Pressure Switch (Fig 215)
Pre-Heating Water Temperature Thermistor And Water Temperature Indicator Thermal Contact
-SETTINGS
Speed Settings
Setting The Idle Minimum (Standard)
Setting The Idle Maximum (Standard)
Pump Injection Delivery Standard Setting Without Dynamometric Brake
Injection Pump Flow Limiter And Engine Torque Gearing Device
Pump/Injector Unit Timing With Speed Governor
Pump/Injector Unit Delivery Setting With Braked Engine
EGR Calibration
-STORAGE
Engine Storage
Protective Treatment
Preparing The Engine For Operation After Protective Treatment
What you get
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