Kohler KDW 702 Workshop Manual
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Kohler KDW 702 Workshop Manual

Water-cooled, indirect injection
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WORKSHOP MANUAL
KDW 702 - 1003 - 1404

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  • Page 1 WORKSHOP MANUAL KDW 702 - 1003 - 1404...
  • Page 2 - 2 - KD 702_1003_1404 Workshop Manual_cod. ED0053029340_1° ed_ rev. 00...
  • Page 3 KOHLER, who therefore refuses all responsibility for any injury arising from such an operation.
  • Page 4 REGISTRATION OF MODIFICATIONS TO THE DOCUMENT Any modifications to this document must be registered by the drafting body, by completing the following table. Drafting Document Model Review Edition Revision Issue date Endorsed body code N° date CUSE/ATLO 51262 1° 20/06/2012 20/06/2012 ED0053029340 - 4 -...

  • Page 5: Table Of Contents

    CHAPTER INDEX This manual contains pertinent information regarding the repair of Kohler water-cooled, indirect injection Diesel engines type KDW 702-1003-1404: updated 20/06/2012. CHAPTER INDEX 1 - MANUFACTURER AND ENGINE IDENTIFICATION ..................10 The identification plate shown in the figure can be found directly on the engine..............10 Approval data ..................................10...
  • Page 6 Chapter index 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 ................................
  • Page 7 Chapter index Piston clearance ................................65 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 ..............................
  • Page 8 Chapter index 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 ..............................
  • Page 9 Chapter index 14 - TORQUE SPECIFICATIONS AND USE OF SEALANT ................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 - 9 - KD 702_1003_1404 Workshop Manual_cod.

  • Page 10: Manufacturer And Engine Identification

    MANUFACTURER AND ENGINE IDENTIFICATION The identification plate shown in the figure can be found directly on the engine. It contains the following information: A) Manufacturer’s identity B) Engine type C) Engine serial number D) Maximum operating speed E) Number of the customer version (form K) F) Approval data Approval data The approval reference directives EC are on the engine plate (F).

  • Page 11: Name Plate For Epa Rules Applied On Rocker-Arm Cap

    MANUFACTURER AND ENGINE IDENTIFICATION Name plate for EPA rules applied on rocker-arm cap Compilation example USE IN CONSTANT-SPEED APPLICATIONS ONLY 1) Model year. 2) Engine displacement. 3) Power category, kW. 4) Particulate emission limit (g/kWh). 5) Engine family ID. 6) Kind of application i.e. 7) Injection timing (BTDC).

  • Page 12: General Remarks And Safety Information

    GENERAL REMARKS AND SAFETY INFORMATION To ensure safe operation please read the following statements and understand their meaning. Also refer to your equipment manufacturer's manual for other important safety information. This manual contains safety precautions which are explained below. Danger – Attention This indicates situations of grave danger which, if ignored, may seriously threaten the health and safety of individuals.

  • Page 13: California Emission Control Warranty Statement

    Your emission control system may include parts such as the fuel-injection system and the air induction system. Also included may be hoses, connectors and other emission related assemblies. Where a warrantable condition exists, Kohler Co. will repair your heavy-duty off-road engine at no cost to you including diagnosis, parts and labor. MANUFACTURER’S WARRANTY COVERAGE: Your off-road, diesel engine emission control system is covered under warranty for a period of five (5) years or 3,000 hours, whichever occurs first, beginning on the date the engine or equipment is delivered to an ultimate purchaser for all constant speed engines with maximum power 19≤kW<37...

  • Page 14: Explanation Of The Safety Pictograms That Can Be Found On The Engine Or In The Operation And Maintenance Handbook

    General remarks and safety information Explanation of the safety pictograms that can be found on the engine or in the Operation and Maintenance handbook Use protective gloves before carrying out the operation Read the Operation and Maintenance handbook before performing any operation on the engine Use protective glasses before carrying out the operation High temperature components - Danger of scalding Use sound absorbing protections before carrying out the operation...

  • Page 15: Limited 3 Year Kohler ® Diesel Engine Warranty

    8 hours of use per day and 5 days per week will be used to calculate hours used. Our obligation under this warranty is expressly limited, at our option, to the replacement or repair at Kohler Co., Kohler, Wisconsin 53044, or at a service facility designated by us of such parts as inspection shall disclose to have been defective.

  • Page 16: Safety Regulations

    GENERAL NOTES . Children and animals must be kept at a sufficient distance . Kohler engines are built to provide safe and longlasting from the machine to prevent any danger resulting from its performances, but in order to obtain these results it is operation.

  • Page 17: General Safety During Operating Phases

    . In order to move the engine simultaneously use the eyebolts fitted for this purpose by Kohler. These lifting points are however not suitable for the entire machine, so in this case use the eyebolts fitted by the manufacturer.

  • Page 18: Trouble Shooting

    TECHNICAL INFORMATION TROUBLE SHOOTING THE ENGINE MUST BE STOPPED IMMEDIATELY WHEN: 1) - The engine rpms suddenly increase and decrease; 2) - A sudden and unusual noise is heard; 3) - The colour of the exhaust fumes suddenly darkens; 4) - The oil pressure indicator light turns on while running. TABLE OF LIKELY ANOMALIES AND THEIR SYMPTOMS The following table contains the possible causes of some failures which may occur during operation.

  • Page 19: Technical Information

    Technical information TROUBLE POSSIBLE CAUSE High oil level Low oil level Dirty or blocked pressure regulation valve Worn oil pump Air to the oil suction hose Faulty manometer or pressure switch Oil in sump suction hose blocked Oil in sump drainage pipe blocked Faulty spray nozzles (Turbo engines only) Damaged injector Damaged injection pump valve...
  • Page 20 Technical information ..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... - 20 - KD 702_1003_1404 Workshop Manual_cod.

  • Page 21: Techinical Specifications

    Max tilt Intermittent operation (up to 30 min) 25° 25° 25° Permanent operation **** **** **** KDW 702 At NB power Referred to NB power Measured at NA power **** Depends on application • At 3600 Rpm •• Measured at NB power...
  • Page 22 Technical information ..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... - 22 - KD 702_1003_1404 Workshop Manual_cod.
  • Page 23 Technical information ..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... - 23 - KD 702_1003_1404 Workshop Manual_cod.

  • Page 24: Performance Diagrams

    Mt : Torque at N. a : Range of application for continuous operation. In case of application outside this range please contact KOHLER. The above power values refer to an engine fitted with air cleaner and standard muffler, after testing and at the environmental conditions of 20°C and 1 bar.
  • Page 25 Technical information ..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... - 25 - KD 702_1003_1404 Workshop Manual_cod.
  • Page 26 Technical information ..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... - 26 - KD 702_1003_1404 Workshop Manual_cod.
  • Page 27 Technical information ..................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................... - 27 - KD 702_1003_1404 Workshop Manual_cod.

  • Page 28: Overall Dimension

    Technical information OVERALL DIMENSION KDW 702 DIMENSIONS mm (in.) - DIMENSIONI mm - MESURES mm - EINBAUMAßE mm - DIMENSIONE mm - DIMEN0ÇÕES mm 359 (14.13) 186 (7.32) 418 (16.46) 169.5 (6.67) 204 (8.03) 515.5 (20.3) 269.2 (10.6) 165 (6.5) 367 (14.45)
  • Page 29 Technical information LDW 1003 COPPA OLIO STANDARD IN LAMIERA - CARTER D’HUILE EN TÔLE STANDARD - SHEET METAL STANDARD OIL SUMP - STANDARD BLECHÖLWANNE - CÁRTER DE ACEITE STANDARD EN PLANCHA - CÁRTER DE ÓLEO STANDARD EM CHAPA DIMENSIONS mm (in.) - DIMENSIONI mm - MESURES mm - EINBAUMAßE mm - DIMENSIONE mm - DIMENÇÕES mm 169.5 (6.67) 359 (14.13) 204 (8.03)
  • Page 30 Technical information KDW 1003 with EGR circuit, Gear-box and CVT (Continuous Variable Transmission) DIMENSIONI mm - MESURES mm - DIMENSION mm - EINBAUMAßE mm - DIMENSIONE mm - DIMENÇÕES (mm) 350,2 152,9 168,4 236,4 361,8 129,3 641,8 703,5 534,5 54,8 701,7 151,5 300,5...
  • Page 31 Technical information 1404 COPPA OLIO STANDARD IN LAMIERA - CARTER D’HUILE EN TÔLE STANDARD - SHEET METAL STANDARD OIL SUMP - STANDARD BLECHÖLWANNE - CÁRTER DE ACEITE STANDARD EN PLANCHA - CÁRTER DE ÓLEO STANDARD EM CHAPA DIMENSIONS mm (in.) - DIMENSIONI mm - MESURES mm - EINBAUMAßE mm - DIMENSIONE mm - DIMEN0ÇÕES (mm) 186 (7.32) 593 (23.35) 359 (14.13)

  • Page 32: Maintenance - Recommended Oil Type - Refilling

    MAINTENANCE - RECOMMENDED OIL TYPE - REFILLING ROUTINE ENGINE MAINTENANCE Important Failure to carry out the operations described in the table may lead to technical damage to the machine and/or system. ORDINARY MAINTENANCE AFTER THE FIRST Engine oil replacement. Oil filter replacement. 50 WORKING HOURS EXTRAORDINARY MAINTENANCE FREQUENCY x HOURS...

  • Page 33: Lubricant

    Maintenance - Recommended oil type - Refilling LUBRICANT SAE Classification n the SAE classification, oils differ on the basis of their viscosity, and no other qualitative characteristic is taken into account. SAE 10W* The first number refers to the viscosity when the engine SAE 20W* is cold (symbol W = winter), while the second considers SAE 30*...

  • Page 34: Prescribed Lubricant

    Maintenance - Recommended oil type - Refilling PRESCRIBED LUBRICANT API SJ/CF AGIP SINT 2000 specifications ACEA A3-96 B3-96 5W40 MIL - L-46152 D/E In the countries where AGIP products are not available, use oil API CF/SH for Diesel engines or oil corresponding to the military specification MIL-L-2104 C/46152 D.

  • Page 35: Coolant

    1,75 50 % Water Without radiator For information concerning the capacity of KOHLER radiators, please contact KOHLER directly. The total volume for refilling the cooling liquid varies according to the type of engine and radiator. FUEL RECOMMENDATIONS Purchase diesel fuel in small quantities and store in clean, approved containers. Clean fuel prevents the diesel fuel injectors and pumps from clogging.

  • Page 36: Regulations For Lifting The Engine

    REGULATIONS FOR LIFTING THE ENGINE Important - Before removing the engine from the vehicle on which it is installed, disconnect the power supply, detach the fuel and coolant supply, and all connections including the mechanical ones. - Attach the engine to a suitable lifting device (lifting beam). - Hook the lifting device in the engine lifting points, as shown in the figure.

  • Page 37: Disassembly / Reassembly

    – Besides disassembly and reassembly operations this chapter also includes checking and setting specifications, dimensions, repair and operating instructions. – Always use original KOHLER spare parts for proper repair operations. – The operator must wash, clean and dry components and assemblies before installing them.

  • Page 38: Dry Type Air Filter

    Components: 1 Reset buttione 2 .25" Tab connection Note: The indicator is calibrated at 600÷650 mm of water co- lumn for KDW 702, 1003, 1404. Oil bath air cleaner (on request) Important Check the sealing rings regularly. Replace the sealing rings if hardening or damage is noted...

  • Page 39: Air Filter Support

    Disassembly / Reassembly Air filter support The support for air filter 1 incorporates the intake manifold and the accelerator control box. Remove all bolts that secure the air filter support 1 to the cylinder head. Carefully pull the air filter support from the cylinder head.

  • Page 40: Circuit (Components)

    Disassembly / Reassembly E.G.R. Circuit Components: 1. Exhaust manifold 2. E.G.R. Pipe 3. E.G.R. Valve 4. Vacuum pump 5. Three way union 6. Vacuum pump pipe 7. Thermovalve – vacuum pump con- nection pipe 8. Vacuum valve – thermovalve con- nection pipe 9.

  • Page 41: E.g.r. Circuit

    Disassembly / Reassembly E.G.R. Circuit Disassembly: Disengage the control rod catch 1 with a screwdriver from the accelerator control rod 2. Disconnect the accelerator control rod 2 from the accelerator control lever 3 . Disconnect the thermovalve – vacuum pump connection pipes (7, fig.

  • Page 42: Vacuum Pump And Vacuum Pump Flange

    Disassembly / Reassembly Vacuum pump and vacuum pump flange Unscrew the three fastening screws 1 that fix the vacuum pump to the flange and remove the vacuum pump. Unscrew the fastening screws that fix the flange to the engine crankcase and remove it. Components: 1.

  • Page 43: Cooling Fan

    Disassembly / Reassembly Cooling fan Danger - Attention Carry out the cooling fan disassembly, only after isolating the positive battery cable to prevent accidental short- circuiting and, consequently, the activation of the starter motor. Carefully clean and check all blades. Replace the fan even if there is only a single damaged blade.

  • Page 44: Flywheel

    Disassembly / Reassembly Flywheel Danger - Attention During dismounting be particularly careful not to let the flywheel fall, as this can be very dangerous for the operator. Use protective goggles while removing the starter ring gear. Unscrew the screws that fasten it to the crankshaft. In order to replace the ring gear, it is necessary to disassemble the flywheel.

  • Page 45: Ringfeder-Type Rings On Kdw 1404

    Disassembly / Reassembly Ringfeder-type rings on KDW 1404 It is possible to draw ¾ of the power from the second drive of KDW 1404 engines. If you want to draw the entire power it is necessary to mount the Ringfeder rings on the crankshaft handle. Components: 1 Puleggia appropriata 6 Ringfeder external ring...

  • Page 46: Timing Belt / Timing Pulley Arrangement

    Disassembly / Reassembly Timing belt / Timing pulley arrangement Components: 1 Camshaft pulley 2 Timing belt 3 Crankshaft pulley 4 Coolant pump pulley 5 Belt tensioner pulley Timing belt removal Caution – Warning When you remove the distributor belt replace it even if its prescribed operation time has not expired yet.

  • Page 47: Camshaft Timing Pulley

    Disassembly / Reassembly Camshaft timing pulley Camshaft timing pulley - Disassembly/Assembly Unscrew screw 1 and remove the pulley. No extractor is needed.  When refitting tighten the screw at a torque of 80 Nm. Note: Assess any wear caused by the lip of the seal ring on the pulley tang.

  • Page 48: Camshaft Timing - Belt Tightening Tool

    Disassembly / Reassembly Camshaft timing - Belt tightening tool Position belt preload tool 7107-1460-049 1 over the timing belt idler adjustment ear 2. See "Camshaft timing - Belt Tightening and Fastening". Camshaft timing - Belt Tightening and Fastening Insert the torque wrench in the suitable tool so that the A axis of the key fig.

  • Page 49: Valve Timing - Angles

    Disassembly / Reassembly Valve timing - Angles The angle values are determined by turning the driving shaft clockwise. S = Piston at top dead centre I = Piston at bottom dead centre = Intake valve open β = Intake valve closed γ...

  • Page 50: Speed Governor

    Disassembly / Reassembly Speed governor The weight-type mechanical governor, is driven directly by the camshaft and is housed with the cylinder head. Components: 1 Thrust washer 2 Spool 3 Flyweight assembly Note: In engines with the minimum/maximum (see fig. 49) the weights are lightened by 25%.

  • Page 51: Speed Governor - Limiting Speed Governor

    Disassembly / Reassembly Speed governor - Limiting speed governor With applications for the automotive sector the regulator spring (C fig. 45) is replaced by a device (plunger barrel) that only enables a constant speed at the minimum and maximum rpm rating.

  • Page 52: Oil Pump

    Disassembly / Reassembly Oil pump Oil pump - disassembly KOHLER therefore recommends that the oil pump be handled as an assembly from a service standpoint KOHLER does not recommend that the oil pump be disassembled, then reassembled for purposes of installation on the engine except during emergency situations.

  • Page 53: Rocker Arm Cover Gasket

    Disassembly / Reassembly Rocker arm cover gasket The rocker arm cover gasket A ensures the seal of the lubrication circuit for the camshaft and rocker arm shaft. Always replace it and mount it with especial care above all in zones 1 and 2 where, for greater safety, it is advisable to apply a few drops of silicon sealant.

  • Page 54: Crankcase Breather

    Disassembly / Reassembly Crankcase breather For KDW 702-1003-1404 engines, the exhaust gases exit from the cylinder head cover (see Fig. 53, 54). Remove the cover, check the integrity of the air valve and oil decanting wire gauze. Valve / Rocker arm clearance Important Setting should be performed when the engine is cold.

  • Page 55: Pump/Injector Unit - Non-Return Valve

    Disassembly / Reassembly Pump/injector unit - non-return valve Non-return valve A immediately stops the engine whenever the stop is activated. Note: If the value of B is not achieved, the two rings C are not subject to enough compression to ensure the seal; any fuel loss would contaminate the lubrication oil and consequently damage the engine, F = metal gasket.

  • Page 56: Rocker Arm Pivot, Dismounting And Remounting

    Disassembly / Reassembly Rocker arm pivot, dismounting and remounting To remove pivot 1 from the support 2 it's necessary to drill out pin 3 using a 4mm drill bit. On remounting insert a new pin and reinsert it in bearing surface A (0 to 1 mm).

  • Page 57: Camshaft Journals And Housings - Dimensions (Mm)

    Disassembly / Reassembly Camshaft journals and housings - Dimensions (mm) limit value 37,035÷37,060 36,975÷37,000 0,035÷0,085 0,170 Note: The camshaft journal and cylinder head camshaft bore dimensions are identical for all KDW-FOCS series engi- Camshaft lobe measurement Use an outside micrometer gauge. Intake / Exhaust / Injection camshaft lobe height All engines in the series have intake exhaust and injection cams with the same height of H and H1.

  • Page 58: Cylinder Head, Removal

    Disassembly / Reassembly CYLINDER HEAD, removal Important Do not remove the cylinder head when hot to avoid deformation. lf cylinder head is deformed by more than 0.10 mm, level it off by removing a maximum of 0.20 mm.  For the cylinder head tightening procedure see page 67. Valves To remove the valves it is necessary to remove the collets;...

  • Page 59: Valve, Specifications

    Disassembly / Reassembly Valve, specifications Exhaust valve A Shaft and head are made of 2 different materials. 2 Welded joint 3 Chromium-plated joint 4 Portion made of: ..X 45 Cr Si 8 UNI 3992 5 Portion made of: ..X 70 Cr Mn NI N 216 UNI 3992 702-1003-1404 30,20 45°...

  • Page 60: Valve Seats And Housings - Dimensions

    Disassembly / Reassembly Valve seats and housings - Dimensions KDW 702-1003-1404 α α1 35,220÷35,245 35,306÷35,315 44° 53' ÷ 45° 59° 53' ÷ 60° 31,220÷31,241 31,308÷31,316 Press valve seats into the housings Note: Valve seatsare supplied in finished form, further machining is prohibited.

  • Page 61: Pre-Combustion Chamber

    Note: There are many types of precombustion chambers for the various engines described as follows. - KDW 702-1003-1404. Pre-combustion chamber, installation The pre-combustion chamber has a hole on the side where the pre-heating glow plug 2 must be inserted.

  • Page 62: Oil Pan, Removal

    Remove the connecting rod big end cap. Remove the piston-connecting rod assembly. Note: The Ricardo type of combustion chamber is used for KDW 702-1003-1404 engines. Stop pin rings, dismounting and remounting Extract the ring inserting a pointed tool in hollow A.

  • Page 63: Piston, Disassembly And Inspection

    Pistons at the nominal diameter are only supplied in category A. Pistons oversized by 0.50 and 1.00 mm are supplied with reference to the increased level on the piston crown: Ø 75.5 – 76.0 for KDW 702-1003-1404 engines. - 63 -...

  • Page 64: Piston, Weight

    Disassembly / Reassembly Piston, weight Weigh pistons when replacing them in order to avoid unbalance. Important The difference in weight should not exceed 4 g. Piston rings - End gaps (mm) Place piston rings squarely into the unworn part of the lower cylinder and measure the end gap A.

  • Page 65: Piston Ring, Mounting Order

    Disassembly / Reassembly Piston ring, mounting order A = 1° ring (internal tapered and torsional) B = 2° ring (internal tapered and torsional) C = 3° Oil control ring D = Chrome-plated area E = Chrome-plated area Note: When there is writing on the surface of a piston ring, mount that surface with face upward.

  • Page 66: Kd 702_1003_1404 Workshop Manual_Cod. Ed0053029340_1° Ed_ Rev

    1404 one notch, two notches, three notches. The A value relates to figure 111. Each time you dismount the head you must replace the gasket. KDW 702-1003 N° of holes A(mm) Piston clearance 0,82÷0,91...

  • Page 67: Cylinder Head Assembly

    Once the head has been correctly tightened, it should not be retightened except if it is disassembled again. A = For KDW 702 models B = For KDW 1003 models Following the numerical order shown in the diagram, the bolts...

  • Page 68: Connecting Rod

    14 g. Connecting rod with bearings and pin Dimensions (mm): A = 126,48÷126,52 ..(for KDW 702-1003-1404) B = 20,015÷20,025 ..(for KDW 702-1003-1404) C = 40,021÷40,050 ..(bearing tightened at 40 Nm) D = 19,996÷20,000 ..(for KDW 702-1003-1404) E = 54,000÷55,100 ..

  • Page 69: Connecting Rod Alignment

    Check any wear in zone X where the piston rings operate and if it is greater than the 0.05 mm max limit given adjust the cylinder to the next increased value. 75,000 mm for KDW 702-1003-1404 engines. Cylinder, class The pistons (A, B, C) locations are shown on the piston crown while those for the cylinders are found on the crankcase in the points shown by the arrows, see picture.

  • Page 70: Central Main Bearing Caps

    Disassembly / Reassembly Central main bearing caps The central support caps are marked with locations that can be numbers as in the diagram or dots. The same locations are given on the crankcase. Couple the caps with the same references and on the same side.

  • Page 71: Piston Coolant Nozzles

    Disassembly / Reassembly Piston coolant nozzles Caution – Warning The piston has a recess so that during up-down movements and vice versa it cannot come into contact with the nozzle. When remounting the nozzle be careful that it is placed so that when the piston goes past it is in the centre of the recess.

  • Page 72: Shoulder Half Rings, Oversized Elements

    Disassembly / Reassembly Shoulder half rings, oversized elements Dimensions (mm): 22,787÷22920 23,050÷23,100 22,987÷23,120 23,250÷23,300 0,130÷0,313 23,087÷23,220 23,350÷23,400 23,187÷23,320 23,450÷23,500 * A of Fig. 134. ** B of Fig. 135. Grinding B as per relevant table, you can mount the following half rings: Oversized element Half rings 1 and 2 + 0.10 mm on both sides of the bearing...

  • Page 73: Crankshaft, Lubrication Lines

    During repairs, when compressed air is used it is important to wear protective goggles. B = Crankshaft KDW 702 Put the crankshaft in a bath of crude oil. Remove the caps and clean lines 1 and 2 or 3 and 4 with a bit;...

  • Page 74: Main Bearings And Connecting Rod Big Ends Diameters

    Disassembly / Reassembly Main bearings and connecting rod big ends diameters Dimensions (mm): KDW 702-1003-1404 Limit value Ref. Tolerance C (mm) 51,023÷51,059 51,098 D (mm) 40,021÷40,050 40,100 The dimensions given refer to tightened bearings.  For tightening torque see figures 116 e 126.

  • Page 75: Hydraulic Pump Drive

    Disassembly / Reassembly Hydraulic pump drive A = Third drive You can mount a 2P hydraulic pump on the third drive with Bosch flanging, or a 1 PD type one. You can draw 7 KW of power from the third drive corresponding to a 37 Nm torque at 3600 rpm (engine revolutions).

  • Page 76: Turbocharger

    TURBOCHARGER TURBO CHARGER Turbocharger components 1 Waste gate tube 2 Attuatore 3 Collare 4 Corpo turbina 5 Anello seeger 6 Chiocciola compressore 7 Spessore 8 Dado 9 Controdado 10 Albero con turbina 11 Segmento 12 Parafiamma 13 Cuscinetto 14 Seeger 15 Spessore 16 Segmento 17 Deflettore olio...

  • Page 77: Turbocharger West Gate Adjustment - Regolazione Corsa Asta Comando Valvola " Waste Gate

    Turbocharger Turbocharger west gate adjustment - Regolazione corsa asta comando valvola " Waste gate " Disconnect westgate tube 7 from the turbocharger compressor side. Using a T-joint connect a pressure gauge 4 (scale 0 to 2 bar) and with the compressed air network pipe complete with reducer The network air supply pressure must be from 1.5 to 2 bar.

  • Page 78: Lubrification Circuit

    LUBRIFICATION CIRCUIT Danger – Attention - The engine can be damaged if allowed to operate with insufficient oil. It is also dangerous to add too much oil because its combustion may lead to a sharp increase in the rotation speed. - Use suitable oil in order to protect the engine.

  • Page 79: Internal Oil Filter And Oil Sump Return Pipe

    Lubrification circuit Internal oil filter and oil sump return pipe Clean with petrol the internal oil filter 1 and oil sump return pipe 2, blow also some compressed air. Replace sealing rings 3 and 4. Tighten oil drain plug at a torque of 40 Nm. ...

  • Page 80: Oil Pressure Regulating Valve

    Lubrification circuit Oil pressure regulating valve Components: 1 Valve 2 Spring 3 Gasket 4 Screw cap Spring length = 27.50÷27.75 mm Blow the valve’s seating with compressed air and carefully clean all the components before remounting them. Nota: The valve begins to open at a pressure of 4.5÷5.5 bar. Oil filter cartridge Components: 1 Gasket...
  • Page 81 Lubrification circuit ....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................- 81 - KD 702_1003_1404 Workshop Manual_cod. ED0053029340_1° ed_...

  • Page 82: Coolant Circuit

    COOLANT CIRCUIT Danger – Attention - The coolant circuit is pressurised. Do not check it before the engine has cooled down and, also in that case, open the radiator cap or expansion tank plug with caution. - When there is an electric fan do not approach a hot engine because it could also come on with the engine off. - The liquid coolant is a pollutant and therefore must be disposed of with care according to environmental provisions.

  • Page 83: Radiator And Compensation, Check And Seal Tank Cap

    Coolant circuit Radiator and compensation, check and seal tank cap. Remove the cap from compensation tank cap and check that the liquid is at the correct level. Replace the cap with a new one provided with hand air pump socket. Compress air at a pressure of 1 bar for about two minutes.

  • Page 84: Fuel System

    FUEL SYSTEM Fuel feeding / injection circuit Components: 1 Fuel Tank 2 Fuel filter 3 Fuel feeding tube 4 Fuel lift pump 5 lnjection pump 6 Injector 7 Fuel rail passage rubber joint 8 Injector exhaust pipe 9 Fuel tank cap 10 Solenoid valve Note: The tank complete with filter is supplied on request.

  • Page 85: Pump/Injector Unit

    Fuel system Pump/injector unit Designed by KOHLER, the pump/injector is exclusive to KDW 702-1003-1404 series engines. The injection system includes two, three, four identical pumps/ injector units, each one of which feeds a cylinder. Note: On pumps/injector units of recent construction (for serial numbers and references see the table on page 88) the pump has been modified (see fig.

  • Page 86: Plunger Barrel Ring Nut Assembly/Disassembly

    Fuel system Plunger barrel ring nut assembly/disassembly To disassemble ring nut (9 fig. 169) use the suitable wrench A se.no. 7107-1460-029  When refitting tighten it a torque of 34 Nm. Injection pump assembly/disassembly Disassemble the unit following the progressive order of fig. 169. Reassemble following the same steps in reverse order.

  • Page 87: Pumping Element (Old-Type Injection Pump)

    Fuel system Pumping element (old-type injection pump) 1 Plunger 2 Upper plunger section 3 Plunger barrel 4 Delay notch 5 Control slot Dimensions (mm): nominal value 2,00÷2,03 inlet hole diameter 1,50÷1,53 outlet hole diameter 10,00 Pumping element 1 Plunger 2 Upper plunger section 3 Plunger barrel 4 Delay notch 5 Control slot...
  • Page 88 CURRENT PUMP INJECTOR OLD TYPE INJECTOR PUMP KOHLER injection system is being steadily implemented, seeking the best performance of its engines. For this reason the pump injector body has been modified three times in the course of its evolution. Three different pump injectors are shown in the top figure.

  • Page 89: Injector, Setting (Old Type)

    Fuel system Injector, setting (old type) Connect the injector to a hand pump after removing cap screw (20 fig. 169). By means of the tool - se.no. 7107-1460-028 - check that the setting pressure is 130÷145 bar. Adjust, if necessary, by changing the spacer located under the spring.

  • Page 90: Injection Advance Control And Regulation

    Fuel system Injection advance control and regulation - Dismount the rocker arm cover (see page 52). - Position the device on the head, in contact with cylinder no. 1. - Mount the dial gauge on the valve controlled by tool ref. 1460.048.

  • Page 91: Static Injection Advance Tuning

    KDW1404. E coincides with A = TDC of the 2 cylinder KDW 1003. F coincides with A = TDC of 2 cylinder KDW 702, of 3 cylinder KDW 1404. G coincides with A = TDC of 3 cylinder KDW 1003.

  • Page 92: Static Injection Advance Regulation

    Fuel system Static injection advance regulation Fill the tank and operate the fuel pump. Set the pump/injector delivery control rod (ref. A fig. 187) at half- stroke. Bring the piston to the top dead centre of compression. Fit a 13 mm hexagon wrench on the injection advance adjusting screw lock nut.

  • Page 93: Instrument Connection

    Fuel system Instrument connection Place the instrument 1, se.no. 7104-1460-127 at least 20 cm above the pump/injector level. Connect pipe A (outlet from every instrument test piece) with pipe A (inlet of every pump/injector) and pipe B (return to the instrument) with pipe B (outlet from the pump/injector).

  • Page 94: Electric Control Panel With Automatic Engine Stop (Upon Request)

    ELECTRIC SYSTEM ELECTRIC CONTROL PANEL WITH AUTOMATIC ENGINE STOP (UPON REQUEST) AUXILIARY TERMINALS Brown-black = Signal for H2O temperature instrument (6.3) Orange = Signal for electric rev. indicator (6.3) White = Oil pressure ON/OFF signal (6.3) Purple = (+) Positive under key (6.3) Yellow-green = (-) Negative - Earth (6.3) Yellow = Protected socket available for engine stop in an emergen- cy (6.3)

  • Page 95: Alternator, 14V 33A

    Electric System Alternator, 14V 33A Nominal voltage ....14V Nominal current output ..33A Maximum Rpm ....12.000 giri/1' Maximum peak Rpm....13.000 giri/1' Voltage regulator AER 1503 Rotation (viewed at puley end): Clockwise  Tighten nut 1 at a torque of 35÷45 Nm. Alternator, 14V 33A - Performance Curve The curve was obtained at room temperature of +25°C with 13 V battery voltage.

  • Page 96: Electric Starting Layout (12V) With Alternator 14V 33A

    4 Glow Plugs 5 Coolant temperature thermistor 6 Glow Plug Controller / Timer 7 Key Switch 8 System Fuse, 30A for KDW 702; 50 A for KDW 1003; 80 A for KDW 1404. 9 Fuse (Accessory)- 5A 10 Fuel Solenoid Valve...

  • Page 97: Alternator 14V 45A - 65A

    Electric System Alternator 14V 45A - 65A Characteristics: Nominal voltage ..........= 14V Nominal current output .......= 45A - 65A Maximum Rpm ...........= 14000 giri/1' Maximum peak Rpm (for 15') .....= 15000 giri/1' Bearing, Pulley End ........= 6203-2Z Bearing, Voltage Regulator End ....= 6201-2Z/C3 Voltage regulator ........= RTT 119 A Rotation (viewed at puley end): Clockwise Note: Use only high temperature grease when servicing...

  • Page 98: Electric Starting Layout 12V 33A - 45A - 65A

    21 Low Fuel Level Switch A Accessory Position B Off Position C On Position D Starting Position Note: Battery 3 not supplied by KOHLER, for battery characteristics see page 96. Flywheel Alternator 12V 30A with two cables at output 1 Flywheel...

  • Page 99: Alternator Battery Charger Curve 12V 30A

    Electric System Alternator battery charger curve 12V 30A (two cables at output) This curve is obtained at 20°C. The statistical charging output of the flywheel alternator is +10% to -5% of the values shown. - 99 - KD 702_1003_1404 Workshop Manual_cod. ED0053029340_1° ed_...

  • Page 100: Electric Starting Layout (12V) With Flywheel Alternator

    20 Low Fuel Level Lamp 21 Low Fuel Level Switch A Accessory Position B Off Position C On Position D Starting Position Note: Battery 3 not supplied by KOHLER, for battery characteristics see page 96. Voltage regulator connections AETSA Conncetion dimensions...

  • Page 101: Starter Motor - Bosch Dw 12V 1,1 Kw

    Electric System STARTER MOTOR - Bosch DW 12V 1,1 KW Rotation: Clockwise A = 17,5÷19,5 mm (distance from starter mounting flange to ring gear face) Note: Please refer to your local BOSCH distributor for service parts, repair criterion and warranty service. Starter motor, Bosch DW 12V 1,1 KW - Performance Curve The curve was obtained at room temperature of -20°C with a fully charged 66Ah battery.

  • Page 102: Starter Motor, Bosch Dw 12V 1,6 Kw - Performance Curve

    Electric System Starter motor, Bosch DW 12V 1,6 KW - Performance Curve The curve was obtained at room temperature of -20°C with a fully charged 88 Ah battery. U = Starter Motor Voltag n = Armature r/min I = Absorbed Amperage P = Starter Output Power (KW) M = Starter Output Torque (Nm) Pre-heating glow plug...

  • Page 103: Temperature Sensor For Control Unit

    Electric System Temperature sensor for control unit In engines fitted with the above-mentioned type of control unit, the introduction of the glow plugs depends on a temperature sensor that varies preheating temperature in relation to the coolant temperature. Characteristics: Temperature range ....-30 ÷ +50°C Voltage range ......

  • Page 104: Settings

    SETTINGS SPEED SETTINGS Setting the idle minimum (standard) After filling the engine with oil, fuel and coolant, start it and let it warm up for 10 minutes. Turn the screw 1 to adjust the idle speed at 850 to 900 rpm. Tighten then the locknut.

  • Page 105: Injection Pump Flow Limiter And Engine Torque Gearing Device

    Settings Injection pump flow limiter and engine torque gearing device Flow limiter C has the function of limiting the injection pump’s maximum delivery. The same mechanism acts also as a torque gearing device. Indeed, under torque, spring N operating lever L overcomes the resistance of spring M located in the plunger barrel.

  • Page 106: Pump/Injector Unit Delivery Setting With Braked Engine

    Settings Pump/injector unit delivery setting with braked engine 1) Run the engine to the maximum speed. 2) Screw flow limiter C (see fig. 219). 3) Load the engine up to the power and number of revs required by the application’s manufacturer. 4) Check that consumption is within the values allowed for in the settings table (see below).

  • Page 107: E.g.r. Calibration

    Settings E.G.R. calibration Mount a T-branch on vacuum valve - E.G.R. valve connection pipe 1, and connect it to a vacuum pressure gauge with 1 bar bottom scale so as to be able to read the degree of vacuum within the pipe. Note: It is also possible to use a mercury column, 1 metre long, since the maximum suction pressure exerted by the vacuum pump is 720 mmHg.

  • Page 108: Storage

    STORAGE ENGINE STORAGE - When the engines are not for more than 6 months, they have to be protected performing the operations described in the following pages. If the engine is not to be used for extensive periods, check the storage area conditions and the type of packaging and make sure that these are suitable for correct storage.

  • Page 109: Preparing The Engine For Operation After Protective Treatment

    Storage PREPARING THE ENGINE FOR OPERATION AFTER PROTECTIVE TREATMENT After the storage period and before starting up the engine and preparing it for operation, you need to perform certain operations to ensure maximal efficiency conditions. 1 - Remove the protective sheet. 2 - Remove any sealing devices from the exhaust and intake ducts.

  • Page 110: Torque Specifications And Use Of Sealant

    TORQUE SPECIFICATIONS AND USE OF SEALANT Table of tightening torques for the main components Torque Riference Diam. & pitch Sealant POSITION ( Nm ) (figure and page n°) ( mm ) Injection pump control rod 62÷63 - p. 54 M 3 spec. Connecting rod **** 116 - p.

  • Page 111: Table Of Tightening Torques For Standard Screws (Coarse Thread)

    Torque specifications and use of sealant Table of tightening torques for standard screws (coarse thread) Resistance class (R) 10.9 12.9 Quality/ Dimensions R>400N/mm R>500N/mm R>600N/mm R>800N/mm R>1000N/mm R>1200N/mm Diameter 1000 1200 1050 1500 1800 1088 1450 2000 2400 Table of tightening torques for standard screws (fine thread) Resistance class (R) Quality/ Dimensions...

  • Page 112: Special Tools

    SPECIAL TOOLS SPECIAL TOOLS DESCIPTION Part N°. 7107.1460.127 Injection pumps delivery balancing instrument Precombustion chamber extractor 7107.1460.030 Injection pump static injection advance 7271.1460.024 tester(old type) Sheet metal for insertion of main bearings in 7107.1460.053 the crankcase Ring nut wrench for fastening pump/injector 7107.1460.029 pumping element Precombustion chamber wrench...
  • Page 113 Notes ....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................- 113 - KD 702_1003_1404 Workshop Manual_cod. ED0053029340_1° ed_...
  • Page 114 Notes ....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................- 114 - KD 702_1003_1404 Workshop Manual_cod. ED0053029340_1° ed_ rev. 00...
  • Page 115 Notes ....................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................- 115 - KD 702_1003_1404 Workshop Manual_cod. ED0053029340_1° ed_...
  • Page 116 Translated from the original manual in Italian language. Data reported in this issue can be modified at any time by KOHLER. FOR SALES AND SERVICE INFORMATION IN U.S. AND CANADA, CALL 1-800-544-2444 FORM NO. ED0053029340 KohlerEngines.com ISSUED 06/20/2012 ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044...

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