Kohler KD4000 Generator Set

⚠ Hazardous voltage. Moving parts. Operate only when all guards and electrical enclosures are in place.

Tools: sonic tension meter, wrench

1. Disable generator set and remove from service.
2. Remove fan guard rear face panel; inspect fan drive belt and replace if damaged or worn.
3. Check fan belt tension using sonic tension meter or belt deflection method.
4. Loosen four 3/4 in. undercarriage bolts.
5. Adjust tensioner pulley along tensioner slots via lead screw.
6. Adjust until belt tension falls into range listed in Figure 24.
7. Check pulley alignment on fan shaft; adjust fan sheaves and tensioner sheaves.
8. Tighten 3/4 in. undercarriage bolts; reinstall belt guards; reconnect battery; test run.

1. Disable generator set and remove from service.
2. For standard-duty filters: loosen clamp, remove element from air intake elbow, replace, tighten clamp.
3. For heavy-duty filters: release cover clips (KD2000-KD2500) or remove wingnut (KD2800-KD4000), remove cover.
4. Remove filter element.
5. Clean internal components with damp cloth.
6. Install new element.
7. Replace cover; for KD2000-KD2500 point dust ejector downward.

⚠ Sulfuric acid in batteries. Wear protective goggles and clothing.

Tools: wire brush

1. Clean battery and cables and tighten terminals according to service schedule.
2. Wipe battery with damp cloth; keep connections dry and tight.
3. If corrosion exists, disconnect cables and remove corrosion with wire brush.
4. Clean battery and cables with baking soda and water solution; do not allow solution to enter cells.
5. Flush with clean water and wipe with dry cloth.
6. After reconnecting cables, coat terminals with petroleum jelly, silicon grease, or other nonconductive grease.

⚠ Hot coolant and steam. Stop generator set and allow to cool before removing pressure cap.

1. Disable generator set and remove from service.
2. Allow engine to cool.
3. Remove pressure cap to allow system to drain and prevent air pockets.
4. Open radiator and/or engine block coolant drain valve(s) and allow system to drain.
5. On KD2000-KD4000, use engine drainage ports to drain coolant from water pumps and oil cooler.
6. If radiator has mineral deposits or coolant contains dirt/grease, flush and clean cooling system.
7. Otherwise proceed to refill cooling system.

⚠ Hot coolant and steam. Do not add coolant to a hot engine.

1. Remove pressure cap.
2. Close radiator and/or engine block coolant drain valve(s) and tighten hose clamps.
3. Fill cooling system with recommended coolant/antifreeze mixture.
4. Fill coolant expansion tank to middle of sight glass.
5. For KD2000-KD4000, use manual engine venting ports to bleed trapped air.
6. Leave radiator cap off and run for 5 minutes with no load.
7. Stop engine and allow to cool; check and repair leaks.
8. Add coolant to just below overflow tube opening; replace pressure cap; operate until thermostat opens.

⚠ Handling diesel exhaust fluid. Can cause skin, eye, respiratory irritation.

Tools: strap wrench or filter wrench, anti-static gloves, goggles

1. Disable generator set and remove from service; wear anti-static gloves and goggles.
2. Disconnect wiring harness from sleeve.
3. Remove three screws and loosen and remove sleeve.
4. Remove filter; use strap wrench or filter wrench if needed.
5. Clean surrounding surfaces of DEF filter and manifold.
6. Replace O-ring on filter manifold; lubricate with P80 or DEF.
7. Lubricate seal of new filter with DEF or distilled water; fill new filter about 2/3 full with DEF; thread onto manifold.
8. Tighten filter to 30 Nm (22 ft. lbs.) then additional 120°; reinstall sleeve; reconnect harness; reset run time in Kodia; run 30 minutes.

⚠ Explosive fuel vapors. Use extreme care when handling fuels.

1. Disable generator set and remove from service.
2. Hold suitable container beneath fuel/water separator.
3. Open vent plug and manually operated drain.
4. Close drain when fuel free of water flows from separator.
5. Use manual primer pump to prime filter until fuel flows from vent plug.
6. Close vent plug.

⚠ Hazardous voltage. Moving parts. Operate only when all guards and electrical enclosures are in place.

Tools: grease gun

1. Disable generator set and remove from service.
2. Inject grease at remotely located grease fittings on left-hand side of radiator.
3. Grease slowly to prevent over-greasing.
4. Remove any excess grease.
5. Reconnect engine starting battery(ies), negative lead last, and return to service.

⚠ Explosive fuel vapors. Use extreme care when handling fuels.

Tools: strap wrench or filter wrench

1. Disable generator set and remove from service.
2. Close fuel shut-off valve if present.
3. Disconnect fuel-in-water sensor.
4. Open vent plug and remove water drain plug to drain fuel.
5. Remove element from mounting head by twisting counterclockwise.
6. Remove bowl from element; inspect components; lubricate O-ring with clean diesel fuel.
7. Install bowl onto new element; lubricate and install assembly onto mounting head.
8. Replace drain plug; connect sensor; open fuel valve; prime with manual primer pump.

⚠ Hazardous voltage. Moving parts. Operate only when all guards and electrical enclosures are in place.

1. Operate generator set under load for 30–60 minutes maintaining exhaust temperature at rated kW.
2. Apply voltage and check for alarms or faults.
3. Check for leaks, vibrations, or abnormal noises.
4. Ensure exhaust gas color is normal.
5. Check engine parameters (oil pressure, coolant temperature).
6. Check electrical parameters (voltage, frequency, current, rotating magnetic field).
7. If fitted, check automatic filling devices (fuel or oil).

⚠ Hazardous voltage. Moving parts. Operate only when all guards and electrical enclosures are in place.

1. Operate generator set for minimum 10 minutes under no-load or low-load conditions.
2. If faults are indicated, correct and acknowledge them.
3. If fitted, check pre-heating system works properly.
4. Check for leaks, vibrations, or abnormal noises.
5. Ensure exhaust gas color is normal.
6. Check engine parameters (oil pressure, coolant temperature).
7. Check electrical parameters (voltage, frequency, current, rotating magnetic field).
8. If fitted, check automatic filling devices (fuel or oil).

⚠ Handling diesel exhaust fluid. Can cause skin, eye, respiratory irritation.

⚠ Hot engine and exhaust system. Do not work until it cools.

Tools: anti-static gloves, goggles, torque wrench

1. Disable generator set and remove from service; wear anti-static gloves and goggles.
2. Disconnect DEF supply line by disengaging connector clip; disconnect wiring harness.
3. Unbolt and remove nuts and washers securing DEF injector and plate to SCR module.
4. Remove DEF injector and plate.
5. Disconnect DEF return line by pressing both buttons and pulling.
6. Remove gasket from SCR surface; clean debris from plate, injector, and SCR surfaces.
7. Install new injector: position gasket, mounting plate, align holes, apply anti-seize to studs, tighten nuts to 17 Nm (12.5 ft. lbs.).
8. Connect supply and return lines; enter slope and offset data into KODIA; reset run time; run 30 minutes.