Kohler KDI 2504 TCR MGWI Owner's Manual
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Kohler KDI 2504 TCR MGWI Owner's Manual

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KDI 2504 TCR MGWI
OWNER MANUAL
TP-7110 4/18

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Summary of Contents for Kohler KDI 2504 TCR MGWI

  • Page 1 KDI 2504 TCR MGWI OWNER MANUAL TP-7110 4/18...
  • Page 2 Translated from the original manual in Italian language. Data reported in this issue can be modified at any time by KOHLER. The online manuals are provided with hyperlinks which direct you to each individual chapter. By clicking on; - The analytic index titles you can go directly to the selected subject.

  • Page 3: Table Of Contents

    INDEX 4.4 Refuelling ...............22 1 - GENERAL INFORMATION 4.5 Oil filling .................22 1.1 Manual's purpose ..............6 4.6 Coolant filling ..............23 1.2 Glossary and Definitions ..........6 5 - INFORMATION ABOUT MAINTENANCE 1.3 Emission-Related Installation Instructions ....6 1.4 Service request ...............6 5.1 Useful information about maintenance ......24 1.5 Manufacturer and motor identification data ....7 5.2 Periodic maintenance ..........24...
  • Page 4 ANALYTICAL INDEX Adhesive safety plates ............19 Information and safety signals ..........20 After starting ...............21 Air filter cartridge replacement .........36 Air filter check ..............25 Label for China Standards ..........11 Alternator belt check ............32 Label for EPA rules .............10 Label for Korea Standards ..........12 Battery recommendation ...........16 Biodiesel fuel ...............15 Manual's purpose ..............6...
  • Page 5 ANALYTICAL INDEX Useful information about failures ........38 Useful information about maintenance ......24 Warnings ................19 Water pump impeller replacement ........37 Zinc anode and radiator check ..........28...

  • Page 6: 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 & www.lombardinigroup.it/dealer-locator.

  • Page 7: Manufacturer And Motor Identification Data

    GENERAL INFORMATION 1.5 Manufacturer and motor identification data The nameplate motor identification is find side A or side B. Side view A Side view B Manufacturer identification Engine serial number Engine type Peak Engine version Approval data and "EC" directives...

  • Page 8: Engine Component Identification

    GENERAL INFORMATION 1.6 Engine component identification Side view A Side view B...
  • Page 9 GENERAL INFORMATION Side view C POS. DESCRIPTION Cooled exhaust manifold High-pressure fuel supply pump Oil cooler Oil filler cap Oil dipstick Lub. oil filter Thermostatic valve Turbocharger Oil steam separator Coolant pump Starter motor Flywheel Oil drain plug Cooled inlet manifold Coolant refill cap Water pump Fuel pre-filter...

  • Page 10: Homologation Labels

    GENERAL INFORMATION 1.7 Homologation labels 1.7.1 Label for EPA rules POS. DESCRIPTION Engine displacement (L) Emission Control System = ECS Application type Injection timing (*BTDC) Injector opening pressure (bar) Model year in compliance with the rules Power category (kW) Engine family ID Particulate emission limit (g/kWh) Fuel with low sulphur content Production date (example: 2017.Oct)

  • Page 11: Label For China Standards

    GENERAL INFORMATION 1.7.2 Label for China Standards POS. DESCRIPTION Manufacturer Engine model Date of manufacture China emission certification no. Power range (kW) Emission level Power Post-treatment system...

  • Page 12: Label For Korea Standards

    GENERAL INFORMATION 1.7.3 Label for Korea Standards POS. DESCRIPTION Tier 4 Final Engine model Date of manufacture and manufacturer code Korea emission certification no.

  • Page 13: Technical Information

    - Liquid-cooled turbocharger; - Liquid-cooling system; - Common Rail - Direct injection. - 4 valves per cylinder with hydraulic tappets; 2.2 Engine specifications UNIT TECHNICAL DATA OF MEASURE KDI 2504 TCR MGWI ENGINE TYPE CYLINDERS BORE STROKE DISPLACEMENT 2482 25°...

  • Page 14: 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 15: Biodiesel Fuel

    TECHNICAL INFORMATION 2.5.2 Biodiesel fuel • Fuels containing 10% methyl ester or B10, are suitable for use in this engine provided that they meet the specifications listed in the Tab. 2.3. • DO NOT USE vegetable oil as a biofuel for this engine. FUEL COMPATIBILITY Compatible EN 590, DIN 51628 - Military NATO Fuel F-54 (S=10 ppm)

  • Page 16: Coolant Recommendation

    TECHNICAL SPECIFICATIONS 50% ETYLENGLYCOL E 50% DECALCIFIED WATER 50% PROPYLENGLYCOL E 50% DECALCIFIED WATER OAT/HIBRID TECHNOLOGY (ASTM 3306) 2.7 Battery recommendation Battery not supplied by Kohler RECOMMENDED BATTERIES AMBIENT TEMPERATURE BATTERY TYPE 120 Ah/20 h - 1000 CCA/SAE ≥ - 15°C 130 Ah/20 h - 1100 CCA/SAE <...
  • Page 17 TECHNICAL INFORMATION ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

  • Page 18: 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 19 It is recommended to use an oil intake pump. • During operations that involve access to moving parts of • Only use the eyebolts A installed by KOHLER to move the the engine and/or removal of rotating guards, disconnect engine (Fig.

  • Page 20: 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 21: Information And Safety Signals

    State of California to cause cancer, birth defects, or 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 22: 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 23: 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 24: 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. • Place engine on horizontal surface to ensure accurate •...

  • Page 25: Information About Maintenance

    6. The operation must be carried out by authorized depends on the environment in which the engine operates. KOHLER workshops or skilled personnel. Cleaned and replace more frequently under very dusty 7. The replacement interval is only an indication, it strongly conditions.

  • Page 26: Oil Level Check

    INFORMATION ABOUT MAINTENANCE 5.3 Oil level check 1. Loosen the oil filler cap A. Remove the oil dipstick B and check that the level is up to MAX. 2. Pour in recommended oil until reaching the MAX level mark. 3. Reinstall the oil dipstick B completely. 4.

  • Page 27: Rubber Hoses Check

    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. Check that the: - Fuel system hoses A are intact.

  • Page 28: Coolant Level Check

    INFORMATION ABOUT MAINTENANCE 5.6 Coolant level check NOTE: Before proceeding with any operation on the engine, stop it and allow it to cool. Important • Place engine on horizontal surface to ensure accurate measurement of checking. Warning • Presence of steam pressurized coolant danger of burns. 1.

  • Page 29: Zinc Anode And Radiator Check

    INFORMATION ABOUT MAINTENANCE 5.7 Zinc anode and radiator check Warning • Protect the starter motor adequately against contact with liquids before starting operations. 1. Undo capscrew B. 2. Replace component B if value C is below 15 mm. 3. Slightly undo union A to drain the coolant into an appropriate container...
  • Page 30 INFORMATION ABOUT MAINTENANCE 14. Clamp capscrew B on cap E1, inserting gasket H5 (tightening torque 30 Nm). 15. Screw union A onto manifold G. 16. Perform the operations described in Par. 4.6. 5.10 5.11...

  • Page 31: Checking Intercooler

    INFORMATION ABOUT MAINTENANCE 5.8 Checking Intercooler 1. Release clamp 2. Disconnect hose from cap B1. 3. Connect suitable pump onto the infeed outfeed unions of cap B1 in order to clean the pipes with a solution 5.12 distilled water with 10% hydrochloric acid at a temperature of 50°...
  • Page 32 INFORMATION ABOUT MAINTENANCE 11. Insert Intercooler C in manifold E until its end stop. 12. Put gasket F on intercooler C. 5.15 13. Fasten cap B1 onto manifold E using capscrews A. 5.16 14. Insert gasket intercooler C until it comes into contact with manifold 15.

  • Page 33: Alternator Belt Check

    INFORMATION ABOUT MAINTENANCE 5.9 Alternator belt check NOTE: Refer to the technical documentation of the vehicle. 5.10 Fuel filter cartridge check When turn on lights on control water filter cartridge fuel: 1. Gently loosen the wing screw A without removing it. 2.

  • Page 34: Product Preservation

    INFORMATION ABOUT MAINTENANCE 11. When cleaning the engine, if using a pressure washer 5.11 Product preservation or steam cleaning device, avoid directing the nozzle on electrical components, cable connections and sealed rings (oil seals etc). If cleaning engine with a pressure washer or steam cleaner, it is important to maintain a minimum distance of at least 200mm between the Important...

  • Page 35: 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 36: Oil Filter Cartridge Replacement

    INFORMATION ABOUT REPLACEMENTS Warning Oil filter cartridge replacement (Par. 6.2) and fuel filter replacement (Par. 6.4) • In case of low use replace it 12 months. • For disposal of oil filter cartridge and fuel filter refer to • Par. 6.6 DISPOSAL and SCRAPPING. 6.2 Oil filter cartridge replacement Important •...

  • Page 37: Fuel Filter Cartridge Replacement

    INFORMATION ABOUT REPLACEMENTS 6.3 Fuel filter cartridge replacement NOTE: The fuel filter is situated on the crankcase of the engine or it may be assembled on the frame of the vehicle. 1. Disconnect the cable A of the water presence sensor C. 2.

  • Page 38: Coolant Replacement

    INFORMATION ABOUT REPLACEMENTS 6.5 Coolant replacement 1. Perform the operation described in Par. 5.7. 6.6 Water pump impeller replacement Important • Replace gasket G. 1. Loosen capscrews A and remove cover B. 2. Remove impeller C from pump body D. 3.

  • Page 39: 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.
  • Page 40 Co. cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance. 2. As the off-road engine owner, you should however be aware that Kohler Co. may deny you warranty coverage if your off- road engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.

  • Page 41: Information About Warranty

    The choice and responsibility of the decision to repair or replace an emission control system defect will be solely that of Kohler Co.

  • Page 42: Glossary

    GLOSSARY 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 Combustion: (air) inside a combustion chamber.
  • Page 43 GLOSSARY Serial number (engine identification name plate) indicating s/n: the engine identification series/chassis number. Sec.: seconds Specification, (engine identification name plate) indicating Spec.: the engine version. Tab.: Table. A term indicated for installation of threaded components Tightening torque: and which is determined by means of a unit of measurement Device that compresses air intake by sending it to the intake Turbocharger: manifold by means of a turbine.

  • Page 44: 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 45 NOTES ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
  • Page 46 NOTES ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
  • Page 47 NOTES ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
  • Page 48 Lombardini s.r.l. is a part of Kohler Group. EU RO PE U S A & C ANADA FR ANC E 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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