Kohler D 200 Generator Set

1. Change belts that are saturated with oil, worn, or damaged.
2. Change belts working in pairs simultaneously.
3. Stretch the generator belts after loosening the alternator.
4. Set belts so they can be depressed approximately 10 mm (0.4 in.) midway between the belt pulleys.
5. Note the engine has an automatic belt tensioner for the fan belts.

⚠ Do not adjust the valves while the engine is running as the pistons may strike the valve disks.

⚠ Perform valve adjustment on a stationary, cold engine.

Tools: 9993590

1. Remove the valve covers.
2. Install rotation tool 9993590.
3. Turn the engine in the direction of rotation until piston 1 is at TDC after the compression stroke (0° on the flywheel).
4. Adjust valves 1, 2, 3, 6, 7, and 10.
5. Turn the engine one turn until piston 6 is at TDC after the compression stroke.
6. Adjust valves 4, 5, 8, 9, 11, and 12.
7. Change valve cover gaskets if necessary and reattach the valve covers.
8. Remove the rotation tool.

⚠ Never turn the flywheel against direction of rotation for fine adjustment; if turned too far, restart the process.

Tools: 9987057, 9993590

1. Remove the front valve cover.
2. Turn the flywheel in the direction of engine rotation until cylinder no. 1 is at its compression position (0° on flywheel).
3. Rotate the flywheel against direction of rotation approximately 1/4 turn, then in the direction of rotation to the correct setting angle.
4. Remove the pump coupling clamp bolt and turn the pump coupling approximately 1/4 turn in the direction of pump rotation.
5. Remove the plug in the governor housing and attach the measuring tool sensor.
6. Tighten the pump coupling clamp bolt so the coupling can be turned against rotation with considerable resistance.
7. Carefully turn the pump coupling against direction of rotation until both LEDs illuminate.
8. Torque the pump coupling clamp screw to 90 ±9 Nm (66 ±7 ft. lb.).
9. Remove the measuring instrument sensor and reinstall the plug; top off engine oil.

1. Make sure the thermostat is completely closed (no gap visible in the opening).
2. Heat water in a receptacle to 70°C (158°F) and immerse the thermostat.
3. Check that the thermostat is still closed after at least 30 seconds.
4. Heat the water to boiling point, 100°C (212°F).
5. After at least 30 seconds, check that the thermostat has opened a minimum of 7 mm (0.28 in.).
6. Replace the thermostat if it does not open.

Tools: 9998009, 9988539

1. Install adapter 9998009 with the injector attachment bracket and nut.
2. Connect compression tester 9988539 and perform a compression test.

1. Open the bleeder nipple on the fuel filter holder.
2. Pump fuel using the feed pump hand pump until the fuel is free from air bubbles.
3. Tighten the bleed screw while fuel is running out; keep pumping to attain a good feed pressure.
4. If necessary, loosen the union for the overflow valve and pump until fuel emerges without air bubbles.
5. Retighten the union while fuel is still running out.

1. Disconnect the pipe, if equipped, from the thermostat housing front cover and remove the cover retaining bolts.
2. Detach the pipe from the coolant pump.
3. Remove retaining bolts and lift the coolant pump out.
4. Remove the thermostat housing cover from the coolant pump and remove the pipe between cover and pump.
5. Clean all sealing surfaces.
6. Install new sealing rings on the pipe between the thermostat housing cover and the coolant pump.
7. Install new sealing rings for the coolant pump seal to the timing gear casing and cylinder head.
8. Install a new sealing ring on the thermostat housing cover, place the coolant pump, install and tighten the bolts.
9. Install the thermostat housing cover.
10. Attach the pipe onto the thermostat housing front cover and install the pipe on the coolant pump using new sealing rings.
11. Fill with coolant and check for leaks.

Tools: 9999179

1. Clean the filter bracket thoroughly.
2. Remove the fuel filter using tool 9999179.
3. Moisten seals on the new filters with oil and screw them in by hand until the seals contact the attachment.
4. Tighten the filter another half a turn.
5. Bleed the fuel system.
6. Start the engine and check for leaks around the filters.

Tools: 9999179

1. Place a receptacle beneath the filter.
2. Clean the filter attachment and remove the filter using tool 9999179.
3. Moisten the seals on the new filter with oil and screw in by hand until the seals contact the attachment.
4. Tighten the filter by hand another half a turn.
5. Fill with engine oil and rotate the engine with the starter motor until oil pressure is indicated.
6. Start the engine and check for oil leaks around the filter.

⚠ The fuel pipes must never be bent or reshaped; remove the entire pipe set when dismantling injectors or injection pump.

Tools: 9996643, 9812546

1. Clean the injector and pipe connections.
2. Remove the exhaust temperature sensor from the exhaust manifold.
3. Remove the fuel leakoff pipe between the injectors and plug the connections.
4. Remove fuel delivery pipes and plug connections (remove all pipes as one unit).
5. Remove the nuts from the injector attachment brackets and remove the brackets.
6. Remove the rubber seals from the injectors.
7. Turn the injectors with a wrench while pulling upward; use puller 9996643 if necessary.
8. Clean the copper sleeve surfaces in contact with the injectors.
9. Install the new injectors and new rubber seals.
10. Install the attachment brackets and torque the nuts to 50 ±5 Nm (37 ±4 ft. lb.).
11. Install the leakoff pipe with new copper washers.
12. Install the fuel delivery pipes and exhaust temperature sensor; start the engine and check for leaks.