Kohler KDI 1903 TCR Owner's Manual
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Kohler KDI 1903 TCR Owner's Manual

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KDI 1903 - TCR - TCRE5 – TC
KDI 2504 - TCR - TCRE5
OWNER MANUAL
ED0053029490_Rev_19.1

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  • Page 1 KDI 1903 - TCR - TCRE5 – TC KDI 2504 - TCR - TCRE5 OWNER MANUAL ED0053029490_Rev_19.1...

  • Page 2: Table Of Contents

    INDEX General Information ....................... 4 Manual's Purpose ..........................4 Glossary and Definitions ......................... 4 Emission-Related Installation Instructions ................... 5 Service request ..........................5 Engine component identification ....................6 ATS (After Treatment System) ....................... 7 Manufacturer and motor identification data ................8 Homologation labels ........................
  • Page 3 INDICE ANALITICO Air filter check ..........................38 Check of the radiator heat - exchanger surface ................ 38 Rubber hoses check ........................39 Check coolant level ........................40 Check and setting alternator standard belt tension ..............41 5.10 Check Poly-V alternator belt ......................42 5.11 Filter cartridge and fuel pre-filter check ..................

  • Page 4: General Information

    However, development on the engines is continuous. Therefore, the information within this manual is subject to change without notice and without obligation. • KOHLER reserves the right to make, at any time, changes in the engines for technical or commercial reasons. •...

  • Page 5: Emission-Related Installation Instructions

    40 CFR 1068.105. 1.4 Service request • The complete and updated list of authorized Kohler Co. service centers can be found on websites: www.kohlerengines.com &...

  • Page 6: Engine Component Identification

    GENERAL INFORMATION 1.5 Engine component identification...

  • Page 7: Ats (After Treatment System)

    GENERAL INFORMATION 1.6 ATS (After Treatment System) A: Turbocharger B: Turbine exhaust pipe • The ATS system reduces emissions because the DPF eliminates the particulates generated by the combustion of the diesel. The system starts automatic regeneration cycles of the DPF based on the level of NOTE: The ATS system is only present clogging.

  • Page 8: Manufacturer And Motor Identification Data

    GENERAL INFORMATION 1.7 Manufacturer and motor identification data The nameplate motor identification is find side A or side B .

  • Page 9: Homologation Labels

    GENERAL INFORMATION 1.8 Homologation labels Label for EPA rules (compilation example) Tab 1.1 POS. DESCRIPTION Model year in compliance with the rules Power category (kW) Engine displacement (L) Particulate emission limit (g/kWh) Engine family ID Emission Control System = ECS Fuel with low sulphur content Injection timing Electronic injector opening pressure (bar)
  • Page 10 GENERAL INFORMATION Label for China Standards (compilation example) Tab 1.2 DESCRIPTION Manufacturer Engine model Manufactoring date Certificate N° Power range (kW) Emission level Rated power Aftertreat system...
  • Page 11 GENERAL INFORMATION Label for Korea Standards (compilation example) Tab 1.3 DESCRIPTION Tier 4 Final Engine model Manufactoring date and manufacturer code N° Korea emission certificate...

  • Page 12: Technical Information

    - 4 valves per cylinder with hydraulic tappets; - Turbocharger with Waste-gate valve; - Common rail - Direct injection. 2.2 Engine specifications Tab. 2.1 UNIT OF TECHNICAL DATA MEASURE Engine type KDI 1903 TCR KDI 2504 TCR Cylinders Bore Stroke Displacement 1861 2482 α...

  • Page 13: Oil

    TECHNICAL INFORMATION 2.4 Oil Important • The engine may be damaged if operated with improper oil level. • Do not exceed the MAX level because a sudden increase in engine rpm could be caused by its combustion. • Use only the recommended oil to ensure adequate protection, efficiency and service life of the engine.

  • Page 14: Fuel

    TECHNICAL INFORMATION • For Mid S.A.P.S oil sequence the sulfated ash level is the same as API CJ-4 ≤ 1.0% but as per ACEA standardization those oils are referenced as mid SAPS. • Filtration of oils is critical to proper operation and lubrication; always change filters regularly as specified in this manual.
  • Page 15 TECHNICAL INFORMATION Insufficient lubricating capacity can lead to serious wear problems above all in common rail injection systems. Too low a lubricating capacity is particularly a problem in fuels with a low sulfur content (and in this respect sulfur contents ‹500 mg/kg can already be considered low). An adequate lubricating capacity is guaranteed by the appropriate additives in low-sulfur (‹50 mg/kg) or sulfur-free (‹10 mg/kg or ‹15 mg/kg) diesel fuels according to EN 590 and ASTM D 975.
  • Page 16 TECHNICAL INFORMATION 2.5.4 Non-Road Fuels Only for KDI De- Contented Electronic Injection Tier 3 – Stage IIIA emission equivalent certified Engines (EGR engines) and KDI De- Contented Electronic Injection Uncertified Engines (no EGR engines). Other non-road fuels may be used if they comply with all the limit values of EN 590 except for the fuel density, the cetane number and the sulfur content.

  • Page 17: Coolant Recommendation

    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 recommendation Battery not supplied by Kohler Tab. 2.7 RECOMMENDED BATTERIES AMBIENT TEMPERATURE BATTERY TYPE ≥...

  • Page 18: Control Panel

    Engine operating status (green = no problem detected) NOTE : if LED F is red, contact authorised KOHLER workshops to know what type of problem it is. Certain problems automatically switch off the engine. Tab. 2.9 shows data that can be consulted on display B by pressing push buttons C or D .

  • Page 19: Safety Information

    Any use of the machine other than that described cannot be considered as complying with its intended purpose as specified by KOHLER . • KOHLER declines all responsibility for any change to the engine not described in this manual made by unauthorized KOHLER personnel. •...

  • Page 20: General Remarks

    Any improvement must be verified at KOHLER testing laboratories before application of the engine. • In case the approval to a modification is not granted, KOHLER shall not be deemed responsible for any consequential failures or damages to the engine.
  • Page 21 Do not use air and water jets at high pressures on cables, connectors and injectors. Important • Only use the eyebolts A installed by KOHLER to move the engine (Fig. 3.1) . • The angle between each lifting chain and the eyebolts shall not exceed 15° inwards.

  • Page 22: Safety Signal Description

    SAFETY INFORMATION 3.3 Safety signal description • To ensure safe operation please read the following statements and understand their meaning. • Also refer to your equipment manufacturer's manual for other important safety information. • This manual contains safety precautions which are explained below. •...
  • Page 23 SAFETY INFORMATION Important This indicates particularly important technical information that should not be ignored. Warning This indicates that failure to comply with it can cause minor damage or injury. Safety guards Hereunder is a list of safety guards that must be worn prior to carrying out any type of operation and to avoid potential harm to the operator.

  • Page 24: Information And Safety Signals

    SAFETY INFORMATION 3.4 Information and safety signals ACCIDENTAL START HIGH PRESSURE FLUID RISK OF PUNCTURE High Pressure Fluids can puncture skin and cause severe injury or death. Accidental Starts can cause severe injury or Do not work on fuel system without proper training or safety death.
  • Page 25 SAFETY INFORMATION Carbon Monoxide can If ON, a spark will occur at the ground cable terminal which cause severe nausea, could cause an explosion. fainting or death. Avoid inhaling exhaust fumes and never run the engine in a closed CALIFORNIA WARNING - DECLARATION 65 building or confined area.

  • Page 26: Safety And Environmental Impact

    - Regulations and directives regarding environmental impact. In order to minimise the impact on the environment, KOHLER now provides a number of indications to be followed by all persons handling the engine, for any reason, during its expected lifetime. - All components and fluids must be disposed of in accordance with the laws of the country in which disposal is taking place.

  • Page 27: Information About Use

    INFORMATION ABOUT USE 4 INFORMATION ABOUT USE 4.1 Pre-start check • Read carefully the following pages and carry out the operations described below in accordance with the instructions specified. Important • 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 28: Refuelling

    The only approved fuels are those listed in • In those countries where fuel 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. •...

  • Page 29: Oil Filling

    INFORMATION ABOUT USE 4.5 Oil filling Important • Par. 2.4 For safety precautions see • Par. 3.2.2 Before proceeding with operation, read • Do not use the engine with the oil level below the minimum. 1. Loosen the oil filler cap A or the oil filler cap C if the cap A is not accessible.

  • Page 30: Coolant Filling

    INFORMATION ABOUT USE 4.6 Coolant filling Important • Before proceeding with operation, read Par. 3.2.2 Warning • An anti-freeze protection liquid (ANTIFREEZE) - mixed with decalcified water - must be used. • The freezing point of the refrigerant mixture depends on the amount concentration in water. •...
  • Page 31 INFORMATION ABOUT USE Fig. 4.5 - Fig. 4.6 https://www.youtube.com/embed/S79xPhTZMps?rel=0 NOTE : Click on the right to play the procedure.

  • Page 32: Ats Regeneration Strategy (Only For Stage V Configurations)

    • Stationary vehicle Flashing • No load applied to the engine *2 Contact an authorized KOHLER workshop. REGENERATION via Strong Engine Level 5 de-rate. Service Regeneration Kohler software Required Flashing *1: The warning lights be different – consult the machine manual.
  • Page 33 If the regeneration inhibition function is misused, the particulate accumulation level will increase within a short time. • The engine oil filter and oil must be changed after a Service Regeneration is completed via KOHLER software • (Level 5 Particulate accumulation). •...

  • Page 34: Information About Maintenance

    INFORMATION ABOUT MAINTENANCE 5 INFORMATION ABOUT MAINTENANCE 5.1 Useful information about maintenance • This chapter shows all operations described in the Tab. 5.1 and Tab. 5.2 . if you have the skills appropriate may be directly carried out by the user. •...

  • Page 35: Periodic Maintenance

    INFORMATION ABOUT MAINTENANCE 5.2 Periodic maintenance The intervals of preventive maintenance in Tab. 5.1, Tab. 5.2, Tab. 5.3 and Tab. 5.4 refer to the engine operating under normal operating conditions with fuel and oil meeting the recommended specifications. CLEANING AND CHECKING PERIOD (HOURS) OPERATION DESCRIPTION 5000...
  • Page 36 (4) - The inspection must be carried out every 50 hours or every week in engines with an ATS system ( Par. 1.6 (6) - Contact authorized KOHLER workshops. (7) - The replacement interval is only an indication, it strongly depends from environmental condition and hose status detected during regular visual inspection.

  • Page 37: Oil Level Check

    INFORMATION ABOUT MAINTENANCE 5.3 Oil level check Important • Par. 3.2.2 Before proceeding with operation, read • Do not use the engine with the oil level below the minimum. • Change the oil and oil filter if the level exceeds the MAX.

  • Page 38: Air Filter Check

    • When the cartridge G is dirty, do not clean it but replace cartridges B and G. NOTE: Components not necessarily supplied by KOHLER . Fig 5.5 1. Release the two clasps F of the cover A . 2. Remove the cartridges B and G .

  • Page 39: Rubber Hoses Check

    Important • Before proceeding with operation, read Par. 3.2.2 • If hoses are damaged contact an authorized KOHLER workshop. Check that the: - Fuel system hoses A are intact. - Cooling circuit hoses B . - Vent system pipes C .

  • Page 40: Check Coolant Level

    • Presence of steam pressurized coolant danger of burn. 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 41: 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.

  • Page 42: Check Poly-V Alternator Belt

    Check by the appropriate tool that at point p the tension value is between 149 and 196 Hz . NOTE : If the poly-v belt tension results out of the above mentioned values contact KOHLER authorised workshops for replacement.

  • Page 43: Filter Cartridge And Fuel Pre-Filter Check

    INFORMATION ABOUT MAINTENANCE 5.11 Filter cartridge and fuel pre-filter check Important • Par. 3.2.2 Before proceeding with operation, read Warning • For safety precautions see Chap. 3 Fig 5.16 When turn on lights on control water filter cartridge fuel: 1. Gently loosen the wing screw A without removing it. 2.

  • Page 44: Engine Storage Over 6 Months

    INFORMATION ABOUT MAINTENANCE 5.14 Engine storage over 6 months Follow the steps described in Par. 5.13 1. Engine oil replacement ( Par. 6.1 ) 2. Refuel with fuel additives for long storage. The following additives are recommended: DEFA Fluid Plus (Pakelo Lubricants), Diesel Treatment (Green Star), Top Diesel (Bardhal), Diesel Fuel Injector Treatment.

  • Page 45: Engine Starting After Storage

    INFORMATION ABOUT MAINTENANCE 5.15 Engine starting after storage 1. Remove the protective sheet. 2. Use a cloth soaked in degreasing product to remove the protective treatment from the external parts. 3. Inject lubricating oil (no more than 2 cm ) into the intake ducts. 4.

  • Page 46: Unused Machine

    INFORMATION ABOUT MAINTENANCE 5.16 Unused machine If the machine is not used for a certain amount of time, follow the operations below: 5.16.1 Operations for the engine POINT OPERATION • The place must be dry and fresh throughout the period in which the machine is not used.

  • Page 47: Information About Replacements

    INFORMATION ABOUT REPLACEMENTS 6 INFORMATION ABOUT REPLACEMENTS 6.1 Engine oil replacement Danger • Disconnect the negative wire (-) from the battery to avroid accidental engine stating. Important Fig. 6.1 • Before proceeding with operation, read Par. 3.2.2 • Place engine on level sur face to ensure accurate measurement of oil level.

  • Page 48: Oil Filter Cartridge Replacement

    INFORMATION ABOUT REPLACEMENTS 6.2 Oil filter cartridge replacement Important • Before proceeding with operation, read Par. 3.2.2 Warning • Electric/pneumatic screwdrivers are forbidden. Fig 6.5 • In case of low use replace il 12 months. • For disposal of oil filter cartridge and fuel filter refer to Par.

  • Page 49: Remote Oil Filter Cartridge Replacement (Optional)

    INFORMATION ABOUT REPLACEMENTS 1. Fit and tighten the cover A on the oil filter support F , tightening it with a torque wrench G (tightening torque of 25 Nm ). Fig 6.7 https://www.youtube.com/embed/jr0sXe8Cdro?rel=0 NOTE : Click on the right to play the procedure. 6.3 Remote oil filter cartridge replacement (optional) Important •...

  • Page 50: Filter Cartridge And Fuel Pre-Filter Replacement

    INFORMATION ABOUT REPLACEMENTS 6.4 Filter cartridge and fuel pre-filter replacement Important • Before proceeding with operation, read Par. 3.2.2 Warning • In case of low use replace il 12 months. • For disposal of oil filter cartridge and fuel filter refer to Par.

  • Page 51: Air Filter Cartridge Replacement

    Important • Par. 3.2.2. Before proceeding with operation, read NOTE : Component not necessarily supplied by KOHLER . 1. Release the two fastenings F of the cover A . 2. Remove the cartridges B and G. 3. Reinstall: - the new cartridges B and G .

  • Page 52: Information About Failures

    Tab 7.2 TROUBLES POSSIBLE CAUSE SOLUTION PAR. Warning YELLOW Engine ECU has detect Contact KOHLER authorised workshops light turn on a malfunctions Sulphated battery Clean the battery terminals terminals corroded Battery voltage too low Recharge the battery or replace it...
  • Page 53 Engine overheats Contact KOHLER authorised workshops Clean the radiator; if the problem persists, Clogged radiator contact KOHLER authorised workshops In the event that the solutions proposed in Tab. 7.2 do not eliminate the trouble, contact a KOHLER authorized workshop...

  • Page 54: Information About Warranty

    KOHLER DIESEL ENGINES GLOBAL WARRANTY TERMS 1. WARRANTY PERIOD Kohler Co. warrants to the End User that each Diesel engine will be free from manufacturing defects in materials or workmanship in normal service for the applicable coverage period or operating hours (whichever comes first) set forth below, provided the engine is operated and maintained in accordance with Kohler Co.’s instructions and manuals.
  • Page 55 Parts/components that are scheduled to be replaced as part of the required maintenance schedule will be covered under Kohler Co.’s warranty from date of purchase of the part up to the first scheduled replacement point for the subject parts/ components.
  • Page 56 2. As the off-road & marine engine owner, you should however be aware that Kohler Co. may deny you warranty coverage if your off-road & marine engine or a part shows signs of malfunction or failed due to abuse, neglect, improper maintenance or unapproved modifications.
  • Page 57 6. MAINTENANCE AND REPAIR REQUIREMENTS The owner is responsible for the proper use and maintenance of the engine. Kohler Co. recommends that all receipts and records covering the performance of regular maintenance be retained in case questions arise.
  • Page 58 Your emission control system may include parts such as the fuel injection system and the air-induction system. Also included maybe hoses, belts, connectors and other emission related assemblies. When a warrantable condition exists, Kohler Co. will repair your heavy-duty off-road & marine engine at no cost to you including diagnosis, parts and labor.

  • Page 59: Glossary

    9 GLOSSARY 9.1 Glossary Alternator A component that transforms mechanical energy into AC electrical energy. Authorised Kohler authorised service centre. workshop After Treatment System - Post-treatment system, referred to the exhaust gases produced by the engine. Bore Internal diameter of the cylinder in combustion engines.
  • Page 60 Air-cooling element under pressure from the turbo situated between the turbine and intake Intercooler manifold. "Kohler Direct Injection" A group of maintenance actions that have the sole objective to control and replace Maintenance - elements on their expiry, without modifying or improving the functions carried out by periodic the system, neither increasing the value nor improving performance.
  • Page 61 GLOSSARY Ref. Reference. "Serial number" (engine identification name plate) indicating the engine identification series/chassis number. Spec. "Specification", (engine identification name plate) indicating the engine version. Tab. Table. "T-MAP" (sensor), measures the temperature and absolute pressure inside the intake T-MAP collector. "Turbo Common Rail"...
  • Page 62 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 µm 1/1000 of a millimetre (micron) 1 µm Length hour...
  • Page 63 GLOSSARY...

This manual is also suitable for:

Kdi 1903 tcre5Kdi 1903 tcKdi 2504 tcrKdi 2504 tcre5

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