Kohler KDI 1903 TCR Generator Set

⚠ Check belt tension only when engine is off.

Tools: DENSO BTG-2 or similar belt tension tool, torque wrench

1. Check belt A condition; replace if worn out or deteriorated.
2. Check at point p that tension is between 80 and 85 Hz.
3. Using DENSO BTG-2 or similar tool F, check corresponding value is between 350 and 450 N.
4. If no tool, apply approx. 10 kg force at point p; movement must be less than 10 mm.
5. If not correct, loosen fastening bolts B and C.
6. Pull alternator outwards in direction D to tension belt.
7. Tighten bolts B and C in sequence with torque wrench E at 40 Nm.
8. Check tension again; let engine run and cool, repeat adjustments if out of range.

1. Release two fastenings F of cover A.
2. Remove cartridges B and G.
3. Reinstall new cartridges B and G.
4. Reinstall cover A and check right tightness of fastenings F.

⚠ Do not use compressed air.

Tools: damp cloth

1. Release two clasps F of cover A.
2. Remove cartridges B and G.
3. Remove cap C.
4. Clean inside components A, C, and D with a damp cloth.
5. Do not use compressed air; repeatedly tap front side E on a flat surface.
6. When cartridge G is dirty, do not clean it but replace cartridges B and G.
7. Reinstall cartridges G and B, cap C, and cover A; check clasps F tightness.

1. Gently loosen wing screw A without removing it.
2. Drain water if present.
3. Re-tighten wing screw A as soon as fuel begins to flow.

⚠ Presence of steam and pressurized coolant; danger of burns.

1. Loosen cap A and fill radiator with 50% antifreeze and 50% decalcified water.
2. Top up until pipes inside radiator are covered by about 5 mm.
3. Do not overfill; leave room for coolant to expand.
4. For engines with expansion tank, pour fluid until max level mark.
5. Bleed cooling circuit as indicated in Par. 4.8.
6. Re-tighten cap A.
7. After a few hours, stop engine, allow to cool, and check coolant level again.

⚠ Presence of steam and pressurized coolant; danger of burns.

1. Stop engine and allow it to cool.
2. Start engine without radiator cap A.
3. Top liquid up until pipes inside radiator are covered by about 5 mm.
4. Top up if necessary.
5. Do not overfill radiator; leave room for coolant to expand.
6. Reinstall radiator cap A.
7. For engines with expansion tank B, check fluid reaches max level mark.

⚠ Disconnect negative battery wire to avoid accidental engine starting.

⚠ The oil must be drained whilst engine is hot; prevent burns.

Tools: container, torque wrench

1. Loosen oil filler cap A.
2. Remove oil dipstick B.
3. Remove oil drain plug D and gasket E.
4. Drain oil into appropriate container.
5. Replace gasket E.
6. Tighten oil drain plug D to 35 Nm.
7. Add recommended type and amount of oil.
8. Use oil filler cap C if plug A is not accessible.
9. Fit and remove oil dipstick B to check level; pour fluid to MAX.
10. Reinstall oil dipstick B completely.
11. Tighten cap A or C.

⚠ If cleaning with pressure washer or steam cleaner, maintain at least 200 mm distance and avoid electrical components.

Tools: protective products, SAE 10W-40 spray

1. Follow steps for engine storage up to 6 months.
2. Replace engine oil.
3. Refuel with fuel additives for long storage.
4. With expansion tank, ensure coolant is up to maximum level.
5. Without expansion tank, top coolant until radiator internal pipes are covered by about 5 mm.
6. Start engine and keep idle at minimum speed for 2 minutes.
7. Bring engine to 3/4 maximum speed for 5 to 10 minutes.
8. Turn off engine.
9. Completely empty fuel tank.
10. Spray SAE 10W-40 on exhaust and intake manifolds.
11. Seal exhaust and intake ducts to prevent foreign bodies entering.
12. Treat non-painted parts with protective products.
13. Loosen alternator belt.

Tools: protective sheet

1. Ensure environment is not humid or exposed to bad weather; cover engine with protective sheet against dampness and atmospheric contaminants.
2. Keep place away from electric panel.
3. Avoid storing engine in direct contact with ground.

⚠ Do not fill the new cartridge B with fuel.

Tools: appropriate wrench

1. Disconnect cable A of water presence sensor C.
2. Remove water presence sensor C from cartridge B.
3. Loosen cartridge B using appropriate wrench F.
4. Lubricate gasket D of new cartridge B.
5. Do not fill new cartridge B with fuel.
6. Tighten new empty cartridge B on fuel filter support E to 17 Nm.
7. Tighten water presence sensor C on new cartridge B to 5 Nm.
8. Reconnect cable A of water presence sensor C.
9. Push button G repeatedly to fill circuit and bleed.

⚠ Do not exceed MAX level; engine may be damaged with improper oil level.

1. Loosen oil filler cap A or oil filler cap C if A is not accessible.
2. Add recommended type and amount of oil.
3. Ensure engine is level before checking oil.
4. Remove oil dipstick B and check level is up to but not exceeding MAX.
5. If level is not at MAX, add additional oil.
6. Re-tighten cap A or C.

⚠ In case of low use replace oil filter cartridge at 12 months.

Tools: torque wrench

1. Loosen cap A.
2. Remove cap A and oil cartridge B from oil filter support.
3. Remove and replace oil cartridge B with a new one.
4. Remove and replace gaskets C, D, and E with new ones.
5. Fit and tighten cover A on oil filter support F to 25 Nm.