Kohler KDW 502 User Manual

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KD 702_1003_1404 Workshop Manual_cod. ED0053029340_1° ed_
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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
CHAPTER INDEX
1 - MANUFACTURER AND ENGINE IDENTIFICATION ........................................................................................ 10
The identication plate shown in the gure 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
Trouble shooting ................................................................................................................................................................18
Techinical specications ....................................................................................................................................................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 lter................................................................................................................................................................ 38
Air restriction switch .......................................................................................................................................................... 38
Oil bath air cleaner (on request) ....................................................................................................................................... 38
Air lter support................................................................................................................................................................. 39
Intake manifold – remote air lter ..................................................................................................................................... 39
E.G.R. Circuit (Components) ............................................................................................................................................ 40
E.G.R. Circuit .....................................................................................................................................................................41
Vacuum pump and vacuum pump ange ..........................................................................................................................42
Exhaust manifold
...............................................................................................................................................................42
Exhaust manifold - engines with egr
..................................................................................................................................42
Cooling fan ........................................................................................................................................................................ 43
Alternator/cooling fan belt drive ........................................................................................................................................ 43

Kohler KDW 502 Specifications

General

Brand	Kohler
Model	KDW 502
Category	Engine
Language	English