Kohler KDW 1003 Generator Set

Tools: Torque wrench, Nippon Denso tension measuring instrument, Belt preload tool 7107-1460-049

1. Insert torque wrench in the tool with axis A of the key at 90° to axis B of the tool.
2. Tighten clockwise at 20 Nm.
3. Remount the drive pulley.
4. Maintaining belt tension, tighten nut 3 with another torque wrench at 40 Nm.
5. Rotate crankshaft a few times and recheck tension.

Tools: Vacuum pressure gauge 1 bar (or 1 m mercury column), T-branch

1. Mount T-branch on vacuum valve - E.G.R. valve connection pipe and connect a 1 bar vacuum gauge.
2. Adjust accelerator lever position so internal adjusting nut 2 is about 5 mm from the thread end.
3. Accelerate to 3.600 rpm with valve closed; gauge must read 0.
4. With brake at N=constant load engine down to 2.800 rpm.
5. Find the E.G.R. valve closing point (vacuum = zero).
6. Measure consumption; if less than 18.8 mm3/stroke adjust nut closer to rod 3.
7. Tighten the adjusting nuts when 18.8 mm3/stroke (about 7 kW) is reached.

⚠ Each time a pump/injector is replaced it is necessary to balance the deliveries.

Tools: Instrument 7104-1460-127, Test head B

1. If balancing error exceeds 2 cm³/min adjust injection pump deliveries.
2. Loosen screws 1 and 2 that block plate 4 and rod 3.
3. Move plate 4 rightwards relative to rod 3 to increase delivery.
4. Moving leftwards decreases delivery; make very small movements.
5. Tighten screws 1 and 2 at 1.1 Nm.

1. Fill engine with oil, fuel and coolant; start and warm up 10 minutes.
2. Turn screw 1 to adjust idle speed at 850 to 900 rpm; tighten locknut.
3. Turn screw 2 and regulate idle maximum at 3800 rpm; block locknut.

Tools: Dial gauge, Tool 7107-1460-048, Tester and special coupling

1. Fill the tank and operate the fuel pump.
2. Set pump/injector delivery control rod at half-stroke.
3. Bring piston to top dead centre of compression.
4. Prime the injection pump by turning the advance screw lock nut wrench forth and back.
5. Operate lever 2 to bring drain valve into contact with piston; reset dial gauge.
6. Go back ¼ turn anticlockwise, then turn forward slowly until fuel level changes.
7. Check piston lowering against the conversion table.

Tools: Pressure gauge 0-2 bar, Dial gauge, Pressure reducer, T-joint

1. Disconnect waste gate tube from turbocharger compressor side.
2. Connect a 0-2 bar pressure gauge with T-joint to air network via reducer.
3. Set network air supply pressure 1.5 to 2 bar.
4. Make a 1.55 mm hole B in the pressure gauge pipe.
5. Set dial gauge feeler on terminal 2; feed air until terminal 2 moves A = 1 mm.
6. Read pressure; must be 830÷890 mm Hg (1.11÷1.19 bar).
7. If low: unscrew locknut 1, remove split pin 9, disconnect rod 8 and adjust terminal 2.
8. Keep rod steady and do not allow torsion during rotation.

Tools: Feeler gauge

1. Perform setting with the engine cold.
2. Bring each cylinder piston to top dead centre on compression stroke.
3. Set clearance A at 0.20 mm for both intake and exhaust valves.
4. Alternatively use clearance check B; in this case the value is 0.15 mm.

⚠ The lifting point brackets are designed to lift the engine only, not additional weights.

Tools: Lifting beam, Protective gloves

1. Disconnect power supply, fuel and coolant supply and all mechanical connections.
2. Attach engine to a suitable lifting device (lifting beam).
3. Hook the lifting device in the engine lifting points.
4. Before lifting check weight is balanced by checking its barycentre.
5. Close all engine openings, wash outside and dry with compressed air.

⚠ Never clean the filtering element with highly flammable solvents - danger of explosion.

Tools: Compressed air supply

1. Blow compressed air crossways over the external part and inside the cartridge.
2. Do not exceed a pressure of 5 atm.
3. If necessary knock the front of the cartridge repeatedly against a flat surface.
4. Never clean the element with highly flammable solvents.

Tools: Protective sheet

1. Pour AGIP RUSTIA C protective oil in the engine housing up to maximum level.
2. Fill up with fuel containing 10% AGIP RUSTIA NT.
3. Check coolant up to maximum level.
4. Start engine and keep at minimum idle for some minutes.
5. Bring engine to ¾ maximum speed for 5÷10 minutes, then switch off.
6. Empty the fuel tank completely.
7. Spray SAE 10W on exhaust and intake manifolds.
8. Seal exhaust and intake ducts, clean external parts, treat non-painted parts, loosen alternator/fan belt, cover with 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.

1. Check that the positive pole of the battery is insulated.
2. Remove belt tensioner 1.
3. Remove the timing belt off the timing pulley.

1. Remove toothed belt from its protective wrapping only when mounting it.
2. Fit belt connections to pulley reference marks.
3. Insert the belt observing the direction of arrows A (direction of rotation).
4. Tighten nut 1 by hand until the belt tightener rests on the crankcase surface.
5. Mount camshaft pulley belt first, then crankshaft pulley.
6. Do not mount driven belts.