Kohler KDI 1903M Owner's Manual
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Kohler KDI 1903M Owner's Manual

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KDI 1903M - KDI 2504M
OWNER MANUAL

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Summary of Contents for Kohler KDI 1903M

  • Page 1 KDI 1903M - KDI 2504M OWNER MANUAL...
  • Page 2 05/2020 Documentation Documentation Translated from the original manual in Italian language. Data reported in this issue can be modified at any time by KOHLER. Important • Connect to http://iservice.lombardini.it and download the latest version of this manual onto your device.

  • Page 3: Table Of Contents

    INDEX 1 - GENERAL INFORMATION 3 - SAFETY INFORMATION 1.1 Manual's purpose ............5 3.1 Safety information ............15 1.2 Glossary and Definitions ..........5 3.2 General remarks ............15 1.3 Emission-Related Installation Instructions ....5 3.2.1 Note for OEM ..............15 1.4 Service request ...............5 3.2.2 Note for end user ............15 1.5 Engine component identification ........6 3.3 Safety signal description ..........17...
  • Page 4 INDEX 5 - INFORMATION ABOUT MAINTENANCE 7 - INFORMATION ABOUT FAILURES 5.1 Useful information about maintenance ......23 7.1 Useful information about failures ........34 5.2 Periodic maintenance ..........23 8 - INFORMATION ABOUT WARRANTY 5.3 Oil level check ...............24 5.4 Oil dipstick on cylinder head ........24 Warranty terms ............35 5.5 Air filter check ...............24 9 - GLOSSARY...

  • Page 5: General Information

    40 CFR 1068.105. 1.4 Service request - The complete and updated list of authorized Kohler Co. ser vice centers can be found on websites: www.kohlerengines.com & dealers.kohlerpower.it.

  • Page 6: Engine Component Identification

    GENERAL INFORMATION 1.5 Engine component identification Side view A Thermostat Oil filler cap Coolant temperature sensor Oil pressure switch Oil filler cap Starter motor Coolant pump Nameplate Oil drain plug Alternator Side view B Fuel injection pump Oil filter Nameplate Oil drain plug Fuel filter ED0053029510...

  • Page 7: Manufacturer And Motor Identification Data

    GENERAL INFORMATION 1.6 Manufacturer and motor identification data The engine identification nameplate is located on side A or B as below. Side view A Side view B Engine Engine serial number type Manufacturer identification Peak Engine version Approval data and "EC" directives ED0053029510 Index...

  • Page 8: Homologation Labels

    GENERAL INFORMATION 1.7 Homologation labels 1.7.1 Label for China Standards POS. DESCRIPTION Manufacturer Engine model Manufactoring date Certificate N° Power range (kW) Emission level Rated power Aftertreat system ED0053029510 Index...

  • Page 9: Label For Korea Standards

    GENERAL INFORMATION 1.7.2 Label for Korea Standards POS. DESCRIPTION Tier 4 Final Engine model Manufactoring date and manufacturer code N° Korea emission certificate ED0053029510 Index...

  • Page 10: Technical Information

    TECHNICAL INFORMATION 2.1. General description of the engine - 4-stroke, in-line cylinders Diesel engine; - Liquid-cooling system; - 4 valves per cylinder with hydraulic tappets; - Injection. 2.2 Engine specifications UNIT TECHNICAL DATA MEASURE ENGINE TYPE KDI 1903 M KDI 2504 M CYLINDERS BORE STROKE...

  • Page 11: Oil

    TECHNICAL INFORMATION 2.4 Oil Important Danger • The engine may be damaged if operated with improper oil • Prolonged skin contact with the exhausted engine oil can level. cause cancer of the skin. • Do not exceed the MAX level because a sudden increase in •...

  • Page 12: Fuel

    TECHNICAL INFORMATION 2.5 Fuel Warning Important • Clean fuel prevents the fuel injectors from clogging. • Use of other types of fuel could damage the engine. Do not Immediately clean up any spillage during refuelling. use dirty diesel fuel or mixtures of diesel fuel and water since •...

  • Page 13: Fuel For Low Temperatures

    TECHNICAL INFORMATION 2.5.1 Fuel for low temperatures • When operating the engine in ambient temperatures lower than 0 degrees C, use suitable low temperature fuel normally available from fuel distributors and corresponding to the specifications of Tab. 2.3. • These fuels reduce the formation of paraffin in diesel at low temperatures. •...

  • Page 14: Coolant

    Do not mix different coolant types. Test the coolant condition annually with coolant test strips. HOAT are not all maintenance free and it is recommended to have SCA (Supplemental Coolant Additives) added at the first maintenance interval 2.7 Battery recommendations Battery not supplied by Kohler RECOMMENDED BATTERIES AMBIENT TEMPERATURE BATTERY TYPE >...

  • Page 15: Safety Information

    • In case the approval to a modification is not granted, KOHLER necessary action is taken to meet the essential and legally shall not be deemed responsible for any consequential prescribed health and safety requirements.
  • Page 16 Important accidental short-circuits and to stop the starter motor from being energized. • Only use the eyebolts A installed by KOHLER to move the • Check belt tension only when the engine is off. engine (Fig. 3.1). • Fully tighten the tank cap each time after refuelling. Do not •...

  • Page 17: Safety Signal Description

    SAFETY INFORMATION 3.3 Safety signal description • To ensure safe operation please read the following • This manual contains safety precautions which are statements and understand their meaning. explained below. • Also refer to your equipment manufacturer's manual for • Please read them carefully. other important safety information.

  • Page 18: Information And Safety Signals

    State of California to cause cancer, birth defects, and other reproductive harm. 3.5 Safety and environmental impact In order to minimise the impact on the environment, KOHLER Every organisation has a duty to implement procedures to now provides a number of indications to be followed by...

  • Page 19: Location Of Safety Labels On Engine

    SAFETY INFORMATION 3.6 Location of safety labels on engine KDI 1903 M KDI 2504 M ED0053029510 Index...

  • Page 20: Information About Use

    INFORMATION ABOUT USE 4.1 Pre-start check Important • Read carefully the following pages and carry out the operations described below in accordance with the instructions specified. • Non compliance with the operations described in the following pages involves the risk of damages to the engine and vehicle on which it is installed as well as personal and/or property damage.

  • Page 21: Refuelling

    • In those countries where diesel has a high sulphur content, its is advisable to lubricate the engine with a high alkaline oil or alternatively to replace the lubricating oil recommended by KOHLER more frequently. • To avoid explosions or fire outbreaks, do not smoke or use open flames during the operations.

  • Page 22: Coolant Filling

    INFORMATION ABOUT USE 4.6 Coolant filling Warning Important • An anti-freeze protection liquid (ANTIFREEZE) - mixed with • Before proceeding with operation, read Par. 3.2.2. decalcified water - must be used. • The freezing point of the refrigerant mixture depends on the amount concentration in water.

  • Page 23: Information About Maintenance

    INFORMATION ABOUT MAINTENANCE 5.1 Useful information about maintenance • This chapter shows all operations described in the Tab. 5.1, Tab. 5.2, Tab. 5.3 and Tab. 5.4 if you have the skills appropriate may be directly carried out by the user. Important •...

  • Page 24: Oil Level Check

    Additives) added at the first maintenance interval. 3. In case of low use: 36 months. 11. Read Cap. 2.5, "KDI Mechanical Injection Uncertified 6. Contact authorized KOHLER workshops. Engines (no EGR Engines)" 7. The replacement interval is only an indication, it strongly depends from environmental condition and hose status detected during regular visual inspection.

  • Page 25: Check Of The Radiator Heat-Exchanger Surface

    Components must be replaced if they have clear signs of cracks, tears, cuts, leaks and do not retain a certain degree of elasticity. Important • If hoses are damaged contact an authorized KOHLER workshop. 1. Loosen the four capscrews E. Remove guard F. 2. Check that the: - Fuel system hoses A are intact.

  • Page 26: Check Coolant Level

    • Presence of steam pressurized coolant danger of burns. NOTE: Component not necessarily supplied by KOHLER. 1. Start the engine without the radiator cap A. 2. Top liquid up until the pipes inside the radiator are covered by about 5 mm.

  • Page 27: Check And Setting Alternator Standard Belt Tension

    Let the engine run for some minutes, then let it cool down at ambient temperature and repeat the operations 2, 3, 4 and 5 in case the belt tension results out of the above mentioned values. NOTE: Contact KOHLER authorised workshops for replacement. 5.13 ED0053029510 _14.1...

  • Page 28: Control Water Filter Cartridge Fuel

    INFORMATION ABOUT MAINTENANCE 5.10 Control water filter cartridge fuel 1. Gently loosen the water drain plug A without removing it. 2. Spill out the water if present. 3. Re-tighten the water drain plug A as soon as the fuel spills. 5.14 5.11 Product preservation 5.13 Engine storage over 6 months...

  • Page 29: Engine Starting After Storage

    INFORMATION ABOUT MAINTENANCE 5.14 Engine starting after storage 1. Remove the protective sheet. 2. Use a cloth soaked in degreasing product to remove the Warning protective treatment from the external parts. • Over time, lubricants and filters lose their properties, so it is important consider whether they need replacing, also based 3.

  • Page 30: Information About Replacements

    INFORMATION ABOUT REPLACEMENTS Danger Disconnect the negative wire (-) from the battery to avoid accidental engine starting. • Important Before proceeding with operation, read Par. 3.3.2. • 6.1 Engine oil replacement Important • Place engine on level surface to ensure accurate measurement of oil level.

  • Page 31: Oil Filter Cartridge Replacement

    INFORMATION ABOUT REPLACEMENTS 10. Fit and remove the oil dipstick B to check the level. Pour in fluid until reaching the MAX level mark. 11. Upon completion, reinstall the oil dipstick B completely. 12. Tighten the cap A or C. Warning Oil filter cartridge replacement (Par.

  • Page 32: Remote Oil Filter Cartridge Replacement (Optional)

    1.5 Nm) when the fuel begins to flow. 6.5 Air filter cartridge replacement NOTE: Component not necessarily supplied by KOHLER. 1. Release the two fastenings F of the cover A. 2. Remove the cartridge B. 3. Reinstall: - the new cartridges B.

  • Page 33: Disposal And Scrapping

    INFORMATION ABOUT REPLACEMENTS 6.6 Disposal and scrapping • In case of scrapping, the engine shall be disposed of in • The parts only composed of plastic material, aluminium appropriate locations, in conformity with the law in force. and steel can be recycled if collected by the appropriate •...

  • Page 34: Information About Failures

    Fill up to the level High oil sump level Replace the engine oil Engine overheats Clogged radiator Clean the radiator - In the event that the solutions proposed in Tab. 7.2 do not eliminate the trouble, contact a KOHLER authorized workshop. ED0053029510 Index...

  • Page 35: Information About Warranty

    Kohler Co.’s obligation under this warranty is expressly limited, at its option, to an appropriate adjustment, repair or replacement of such part or parts as found to be defective following an inspection by Kohler Co. or an authorized service facility designated by Kohler Co.
  • Page 36 Maintenance Manual. Kohler Co. recommends that you retain all receipts covering maintenance on your off-road & marine engine, but Kohler Co. cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.
  • Page 37 US EPA anti-smog standards. The warranty period shall begin on the date the engine or equipment is delivered to an ultimate purchaser. Kohler Co. must warrant the emission control system on your engine for the periods of time listed in the section below, provided there has been no abuse, neglect or improper maintenance of your engine.

  • Page 38: Glossary

    GLOSSARY A component that transforms mechanical energy into AC Alternator: electrical energy. Authorised workshop: Kohler authorised service centre. Bore: Internal diameter of the cylinder in combustion engines. Catalyst: A device in charge of filtering exhausted gas. Chemical reaction of a mixture composed of fuel and fuel (air) Combustion: inside a combustion chamber.

  • Page 39: Symbols And Units Of Measurement

    GLOSSARY SYMBOLS AND UNITS OF MEASUREMENT SYMBOL UNIT OF MEASUREMENT DESCRIPTION EXAMPLE α degree Rotation/inclination angle 1° square centimetre Area 1 cm Ø millimetre Circumference Ø 1 mm newton-metre Torque 1 Nm millimetre 1 mm Length 1/1000 of a millimetre μm 1 μm (micron)
  • Page 40 Lombardini s.r.l. is a part of Kohler Group. E U ROPE US A & C ANA DA FRA NCE Lombardini has manufacturing facilities Lombardini Srl Kohler Co. Lombardini France S.a.s. in Italy, Slovakia and India and sales Via Cav. del lavoro 444 Highland Drive, 47 Alléè...

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Kdi 2504m

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