Kohler KDW 702 troubleshooting: 108 symptom-cause-remedy entries from the manufacturer's own service documentation.
Kohler KDW 702 — full specs, parts & maintenance.
| Symptom | Cause | Remedy |
|---|---|---|
| The engine does not start | Sulphated battery terminals corroded, Battery voltage too low, Low fuel level, Frozen fuel, Clogged fuel filter, Air suction in fuel system, Clogged air filter, Clogged pipes, Open fuse, Intake or exhaust system clogged | Clean the battery terminals, Recharge the battery or replace it, Refuel, Contact KOHLER authorised workshops, Replace with a new filter, Contact KOHLER authorised workshops, Replace with a new filter, Contact KOHLER authorised workshops, Clean the tank and refuel with quality fuel, Replace the engine oil; if the problem persists, contact KOHLER authorised workshops, Replace with a new fuse; if the problem persists, contact KOHLER authorised workshops |
| Engine starts but stops | Inefficient electrical connections, Sulphated battery terminals, Clogged fuel filter, Clogged fuel pipes | Clean the electrical contacts; if the problem persists, contact KOHLER authorised workshops, Clean the battery terminals, Replace with a new filter and clean the tank, Contact KOHLER authorised workshops |
| RPM instability at idle speed | Clogged fuel pipes | Contact KOHLER authorised workshops |
| Low idle speed | Clogged fuel pipes | Contact KOHLER authorised workshops |
| Poor quality fuel | Clean the tank and refuel with quality fuel | |
| Blue smoke | High oil sump level | Replace the engine oil; if the problem persists, contact KOHLER authorised workshops |
| Excessive fuel consumption | High oil sump level | Replace the engine oil; if the problem persists, contact KOHLER authorised workshops |
| Engine lost its initial performance | Clogged air filter, Clogged fuel pipes | Replace with a new filter, Contact KOHLER authorised workshops |
| Slow acceleration | Clogged fuel filter | Replace the fuel filter |
| Engine jerking | Clogged fuel pipes | Contact KOHLER authorised workshops |
| Engine does not start | Clogged fuel pipes | |
| Engine does not start | Clogged fuel filter | |
| Engine does not start | Air or water in the fuel circuit | |
| Engine does not start | Tank cap breather blocked | |
| Engine does not start | Faulty fuel pump | |
| Engine does not start | Lack of fuel | |
| Engine does not start | Glow plug fuse burned | |
| Engine does not start | Faulty glow plug control relay | |
| Engine does not start | Flat battery | |
| Engine does not start | Unclear or mistaken cable connection | |
| Engine does not start | Faulty starter switch | |
| Engine does not start | Faulty starting motor | |
| Engine does not start | Faulty glow plugs | |
| Engine starts but stops | Clogged fuel pipes | |
| Engine starts but stops | Clogged fuel filter | |
| Engine starts but stops | Air or water in the fuel circuit | |
| Engine starts but stops | Tank cap breather blocked | |
| Engine starts but stops | Faulty fuel pump | |
| Engine starts but stops | Lack of fuel | |
| Engine starts but stops | Glow plug fuse burned | |
| Engine starts but stops | Faulty glow plug control relay | |
| Engine starts but stops | Flat battery | |
| Engine starts but stops | Unclear or mistaken cable connection | |
| Engine starts but stops | Faulty starter switch | |
| Engine starts but stops | Faulty starting motor | |
| Engine starts but stops | Faulty glow plugs | |
| Inadequate performance | Clogged air filter | |
| Inadequate performance | Prolonged operation at idle | |
| Inadequate performance | Incomplete run-in | |
| Inadequate performance | Overloaded engine | |
| Inadequate performance | Excessive valve clearances | |
| Inadequate performance | Absence of valve clearances | |
| Inadequate performance | Incorrect speed governor leverages | |
| Inadequate performance | Speed governor spring broken or disengaged | |
| Inadequate performance | Idle low | |
| Inadequate performance | Worn out or stuck rings | |
| Inadequate performance | Worn out cylinders | |
| Inadequate performance | Worn out valve guides | |
| Inadequate performance | Bad valve seal | |
| Inadequate performance | Bearing shells of bearing cap - piston rod - rocker worn out | |
| Inadequate performance | E.G.R. valve blocked open | |
| Inadequate performance | Governor leverages not running | |
| Inadequate performance | Cylinder head gasket damaged | |
| Inadequate performance | Faulty timing system | |
| Inadequate performance | Supplementary starter spring broken or disengaged | |
| High noise level | Excessive valve clearances | |
| High noise level | Absence of valve clearances | |
| High noise level | Incorrect speed governor leverages | |
| High noise level | Speed governor spring broken or disengaged | |
| High noise level | Bearing shells of bearing cap - piston rod - rocker worn out | |
| High noise level | Faulty timing system | |
| No acceleration | Clogged air filter | |
| No acceleration | Incorrect speed governor leverages | |
| No acceleration | Speed governor spring broken or disengaged | |
| No acceleration | Governor leverages not running | |
| No acceleration | Faulty timing system | |
| Non-uniform speed | Air or water in the fuel circuit | |
| Non-uniform speed | Incorrect speed governor leverages | |
| Non-uniform speed | Speed governor spring broken or disengaged | |
| Non-uniform speed | Governor leverages not running | |
| Non-uniform speed | Faulty timing system | |
| Black smoke | Clogged air filter | |
| Black smoke | Overloaded engine | |
| Black smoke | Faulty spray nozzles (Turbo engines only) | |
| Black smoke | Damaged injector | |
| Black smoke | Damaged injection pump valve | |
| Black smoke | Incorrectly calibrated injector | |
| Black smoke | Worn or damaged pumping element | |
| Black smoke | Incorrect injection pump delivery setting (delivery equalisation) | |
| Black smoke | Hardened pump/injector control rod | |
| Black smoke | Cracked or broken pre-combustion chamber | |
| Black smoke | Incorrect adjustment of the injection systems (delivery equalisation advance) | |
| White smoke | Faulty spray nozzles (Turbo engines only) | |
| White smoke | Damaged injector | |
| White smoke | Incorrectly calibrated injector | |
| White smoke | Cracked or broken pre-combustion chamber | |
| White smoke | Incorrect adjustment of the injection systems (delivery equalisation advance) | |
| Oil preassure too low | High oil level | |
| Oil preassure too low | Low oil level | |
| Oil preassure too low | Dirty or blocked pressure regulation valve | |
| Oil preassure too low | Worn oil pump | |
| Oil preassure too low | Air to the oil suction hose | |
| Oil preassure too low | Faulty manometer or pressure switch | |
| Oil preassure too low | Oil in sump suction hose blocked | |
| Oil preassure too low | Oil in sump drainage pipe blocked | |
| Oil level increase | High oil level | |
| Oil level increase | Dirty or blocked pressure regulation valve | |
| Oil and fuel dripping from the exhaust | Faulty spray nozzles (Turbo engines only) | |
| Oil and fuel dripping from the exhaust | Damaged injector | |
| Oil and fuel dripping from the exhaust | Incorrectly calibrated injector | |
| Engine overheats | Insufficient refrigerant fluid | |
| Engine overheats | Defective fan, radiator, or radiator cap | |
| Engine overheats | Defective thermostatic valve | |
| Engine overheats | Loss of refrigerant fluid from the radiator, hoses, engine crankshaft or water pump. | |
| Engine overheats | Inside of radiator or coolant lines obstructed. | |
| Engine overheats | Defective or worn water pump | |
| Engine overheats | Alternator fan drive belt loose or torn | |
| Engine overheats | Heat exchange surface of the radiator clogged |
Fault codes and symptom→remedy steps extracted from this model’s service/owner documentation; verify against the official manual before servicing.
Documented causes: Clogged air filter; Prolonged operation at idle; Incomplete run-in; Overloaded engine. See the table for the matching fixes.
Documented causes: Inefficient electrical connections, Sulphated battery terminals, Clogged fuel filter, Clogged fuel pipes; Clogged fuel pipes; Clogged fuel filter; Air or water in the fuel circuit. See the table for the matching fixes.
Documented causes: Clogged fuel pipes; Clogged fuel filter; Air or water in the fuel circuit; Tank cap breather blocked. See the table for the matching fixes.