The Kohler KDW1003 is a 1.03 L 3-cylinder liquid-cooled with axial fan engine rated at 3600 rpm. It powers generator sets from Kohler and SDMO, including the KDW 1003, K9U, XP-K6M-ALIZE and XP-K9-ALIZE. It holds 4.7 L (1.2 gal) of oil and 4.5 L (1.2 gal) of coolant.
Also known as: KDW 1003, Kohler KDW1003
Part of the Kohler KDW1003 engine family — 2 variants share parts & fitment.
| Oil capacity | 4.7 L |
|---|---|
| Coolant capacity | 4.5 L |
| Displacement | 1.028 L |
| Cylinders | 3 |
| Aspiration | Liquid-cooled with axial fan |
| Rated speed | 3600 rpm |
Shared across brands: Kohler, SDMO
Compiled from service & troubleshooting documentation across every generator set that uses the Kohler KDW1003.
| Item | Spec | Capacity | Part # | Interval | |
|---|---|---|---|---|---|
| Air filter | — | ||||
| Fuel filter | — | ||||
| Oil filter | — | ||||
| Battery | — | ||||
| Belt | — | ||||
| Coolant | 4.5 | — | |||
| Oil | 2.4 | — | |||
| Spark plug | — |
Pooled from every document that names this exact engine — confirm the interval and part number against your unit's serial number.
| Item | Action | Hours | Months | Notes |
|---|---|---|---|---|
| Engine oil | Change | 50 hr | First service — After the first 50 working hours | |
| Oil filter | Replace | 50 hr | First service — After the first 50 working hours |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
| Type | Item | Value | Unit | Condition |
|---|---|---|---|---|
| Clearance | Camshaft journal to housing clearance A-B | 0.035÷0.085 (limit 0.170) | mm | |
| Clearance | Clearance between connecting rod big end and pin D-B | 0.021÷0.066 (limit 0.130) | mm | bearings tightened |
| Clearance | Clearance between main bearings and journals C-A | 0.023÷0.078 (limit 0.200) | mm | bearings tightened |
| Clearance | Connecting rod alignment gap A | 0.015 (limit 0.030) | mm | |
| Clearance | Crankshaft axial clearance A | 0.130÷0.313 (limit 0.5) | mm | main bearings tightened |
| Clearance | Oil pump clearance between rotors A | max 0.171 (wear limit 0.250) | mm | delivery test at 3600 rpm, oil temperature 120°C |
| Gap | Piston ring end gap (1st, 2nd, 3rd ring) | 0.25÷0.45 (limit 1.0) | mm | ring placed squarely in unworn part of lower cylinder |
| Injection timing | Injection advance (current pump/injector unit) | 12°÷14° | deg | 3000÷3600 rpm |
| Injection timing | Injection advance (current pump/injector unit) | 8°÷10° | deg | 1500÷2999 rpm |
| Injection timing | Static injection advance | 11° to 13° | deg | adjustments from 1500/3600 rpm |
| Other | Cylinder bore | 75 | mm | |
| Other | Displacement | 686 / 1028 / 1372 | cm3 | |
| Other | Stroke | 77.6 | mm | |
| Pressure | Injector setting pressure (current pump/injector unit) | 140÷155 | bar | |
| Pressure | Injector setting pressure (old type) | 130÷145 | bar | |
| Pressure | Oil pressure | not less than 1 | bar | maximum operating temperature 120°C at 900 rpm |
| Pressure | Oil pressure regulating valve opening pressure | 4.5÷5.5 | bar | |
| Pressure | Turbocharger boost pressure | 0.87-0.91 (655÷685 mm Hg) | bar | full speed, full Nb load |
| Pressure | Turbocharger waste gate calibration pressure | 1.11÷1.19 (830÷890 mm Hg) | bar | actuator terminal pushed forward by A = 1 mm |
| Resistance | Pre-heating water temperature thermistor (T2) | -30°C=12000; -20°C=7000; 0°C=2800; +20°C=1350; +40°C=750; +60°C=490; +80°C=360; +100°C=300; +120°C=270 | ohm | |
| Speed | Idle maximum (standard) | 3800 | rpm | stabilises at 3600 rpm at setting power |
| Speed | Idle minimum (standard) | 850 to 900 | rpm | |
| Temperature | Flywheel ring gear heating temperature | 300 | °C | hold for 15÷20 minutes |
| Temperature | Thermostatic valve opening temperature | 83÷87 | °C | |
| Torque | Alternator 14V 45A/65A nut 1 | 60 | Nm | |
| Torque | Camshaft lift pump drive eccentric screw | 80 | Nm | |
| Torque | Camshaft timing pulley screw | 80 | Nm | |
| Torque | Connecting rod big end (aluminium connecting rod) | 35 | Nm | |
| Torque | Connecting rod big end cap screws (tighten simultaneously) | 40 | Nm | |
| Torque | Cylinder head tightening (3 phases) | 50 Nm, then 90° clockwise, then 90° clockwise | Nm/deg | |
| Torque | Driving pulley central screw 1 (left-handed) | 360 | Nm | |
| Torque | Exhaust manifold nuts | 25 | Nm | |
| Torque | Flywheel screws | 80 | Nm | |
| Torque | Fuel lift pump fastening nuts | 24 | Nm | |
| Torque | Fuel rail holder screws | 4 | Nm | |
| Torque | Glow plug | 20 | Nm | |
| Torque | Hydraulic pump drive pinion 2 | 45 | Nm | |
| Torque | Injection pump control rod screws 1 and 2 | 1.1 | Nm | |
| Torque | Injector spark arrester nuts | 20 | Nm | |
| Torque | Main bearing cap screws | 60 | Nm | |
| Torque | Oil drain plug | 40 | Nm | |
| Torque | Oil pan screws | 10 | Nm | |
| Torque | Oil pressure switch | 25 | Nm | |
| Torque | Oil pump fastening screws to crankcase | 25 | Nm | |
| Torque | Oil pump plate screws | 10 | Nm | |
| Torque | Piston coolant nozzle joint 4 | 12 | Nm | |
| Torque | Plunger barrel ring nut 9 | 34 | Nm | |
| Torque | Pre-combustion chamber ring nut (1st and 2nd tightening) | 100 then 180 | Nm | |
| Torque | Pump/injector injector ring nut A | 70 | Nm | |
| Torque | Return pulley bolt 1 | 25 | Nm | |
| Torque | Ringfeder screws 3 (M16 x 1,5) | 360 | Nm | |
| Torque | Rocker arm assembly support nuts | 40 | Nm | |
| Torque | Rocker arm cover screws | 9 | Nm | |
| Torque | Speed governor three screws | 10 | Nm | |
| Torque | Terminal 2 / alternator 14V 33A nut 1 | 35÷45 | Nm | |
| Torque | Timing belt cover screws | 10 | Nm | |
| Torque | Timing belt tensioner nut 3 | 40 | Nm | |
| Torque | Vacuum pump fixing screws 9 | 15 | Nm | |
| Torque | Vacuum pump flange screws 8 | 10 | Nm | |
| Valve clearance | Valve / rocker arm clearance A (intake and exhaust) | 0.20 | mm | engine cold, piston at TDC compression stroke |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
| Fluid | Grade | Standard | Ambient | Capacity | Notes |
|---|---|---|---|---|---|
| Coolant | 50% AGIP ANTIFREEZE SPEZIAL + 50% water (preferably decalcified) | Capacities without radiator: KDW 702 = 0.90 L; KDW 1003 = 1.30 L; KDW 1404 = 1.75 L. Total refill volume varies with engine and radiator type. | |||
| Engine oil | AGIP SINT 2000 5W40 (semi-synthetic base oils also listed: SAE 10W-30, 10W-40, 10W-60, 15W-40, 20W-60; synthetic: SAE 5W-30, 0W-30, 5W-40) | API SJ/CF; ACEA A3-96 B3-96; MIL-L-46152 D/E | In countries where AGIP products are not available use oil API CF/SH for Diesel engines or MIL-L-2104 C/46152 D. If oil of lower quality than prescribed is used, replace every 125 h (standard sump) / 150 h (enhanced sump). Select viscosity by ambient temperature per SAE chart (page 33). | ||
| Fuel | Commercial diesel No. 1 or No. 2 low sulfur or ultra low sulfur diesel; ASTM D-975 1D or 2D, EN590 or equivalent | ASTM D-975 1D/2D; EN590; BQ-9000 for biodiesel | Winter fuels: summer up to 0°C, winter up to -10°C, alpine up to -20°C, arctic up to -30°C. Biodiesel with less than 20% methyl ester (B20) suitable; do not use vegetable oil as biofuel. Aviation fuels JP5, JP4, JP8 and JET-A (with 5% oil added). |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Tools: Torque wrench, Nippon Denso tension measuring instrument, Belt preload tool 7107-1460-049
Tools: Vacuum pressure gauge 1 bar (or 1 m mercury column), T-branch
⚠ Each time a pump/injector is replaced it is necessary to balance the deliveries.
Tools: Instrument 7104-1460-127, Test head B
Tools: Dial gauge, Tool 7107-1460-048, Tester and special coupling
Tools: Pressure gauge 0-2 bar, Dial gauge, Pressure reducer, T-joint
Tools: Feeler gauge
⚠ The lifting point brackets are designed to lift the engine only, not additional weights.
Tools: Lifting beam, Protective gloves
⚠ Never clean the filtering element with highly flammable solvents - danger of explosion.
Tools: Compressed air supply
Tools: Protective sheet
⚠ When you remove the distributor belt replace it even if its prescribed operation time has not expired yet.
⚠ Always check that the positive pole of the battery is insulated.
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
| Part # | Description | Category |
|---|---|---|
| ED0053029340 | Rocker arm cover gasket | Gasket |
| 12-041 | Glow plug | Glow plug |
| 12-046 | Impeller | Impeller |
| 12-048 | Sensor | Sensor |
Parts cataloged across all variants of this engine family — verify the exact part fits your specific variant and serial number before ordering.
Parts listed by aftermarket suppliers as fitting this engine — leads compiled from supplier catalogs; verify the exact part for your serial number.
The Kohler KDW1003 engine has an oil capacity of 4.7 liters.
The Kohler KDW1003 has a displacement of 1.028 liters with 3 cylinders.
The Kohler KDW1003 powers 4 generator set(s), including Kohler KDW 1003, SDMO K9U, SDMO XP-K6M-ALIZE, SDMO XP-K9-ALIZE.
A commonly reported issue on generators using the Kohler KDW1003 is: The engine rpms suddenly increase and decrease. Fix: THE ENGINE MUST BE STOPPED IMMEDIATELY.