Kohler KDI 2504TM Owner's Manual
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Kohler KDI 2504TM Owner's Manual

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KDI 2504TM
OWNER MANUAL
Internal Communication: For internal & partner use only.

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Peter ava
February 25, 2025

My Genset Kohler KD12504TM S/N 511341770 Plz help me for Fuel Filter P/N Oil Filter P/N Air Filter P/N Weter Separator Filter P/N

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1 comments:
Peter ava
February 25, 2025

can you get all the fuel filters number for me please send to me

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Summary of Contents for Kohler KDI 2504TM

  • Page 1 KDI 2504TM OWNER MANUAL Internal Communication: For internal & partner use only.
  • Page 2 Documentation Translated from the original manual in Italian language. Data reported in this issue can be modified at any time by KOHLER. Important The latest version of this manual is available on the i-Service website, connect to the following link https://iservice.lombardini.it, before downloading the manual, you can select the desired language from the top bar of the...

  • Page 3: Table Of Contents

    INDEX General Information ......................5 Manual's Purpose ..........................5 Glossary and Definitions ......................... 5 Emission-Related Installation Instructions ................... 6 Service request ..........................6 Engine component identification ....................7 Manufacturer and engine identification ..................8 Technical information ......................9 General description of the engine ....................9 Engine specifications ........................
  • Page 4 INDEX Check and setting alternator standard belt tension ..............33 5.10 Check Poly-V alternator belt ......................35 5.11 Check fuel filter cartridge ......................35 5.12 Product preservation ........................36 5.13 Engine storage up to 6 months ....................36 5.14 Engine storage over 6 months ...................... 36 5.15 Engine starting after storage ......................

  • Page 5: 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 6: 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 Errore. Riferimento a collegamento ipertestuale non valido. websites: &...

  • Page 7: Engine Component Identification

    GENERAL INFORMATION 1.5 Engine component identification Internal Communication: For internal & partner use only.

  • Page 8: Manufacturer And Engine Identification

    GENERAL INFORMATION 1.6 Manufacturer and engine identification The engine identification name plate is situated in the lower part of the crankcase; it is visible from the intake or exhaust side. Fig 1.1 - Fig 1.2 Fig 1.3...

  • Page 9: Technical Information

    TECHNICAL INFORMATION 2 TECHNICAL INFORMATION 2.1 General description of the engine • 4-stroke, in-line cylinders Diesel engine; • Liquid-cooling system; • valves per cylinder with hydraulic tappets; • Direct Injection. 2.2 Engine specifications Tab. 2.1 UNIT OF TECHNICAL DATA MEASURE KDI 2504 TM Engine type Cylinders...

  • Page 10: Engine Dimensions (Mm)

    TECHNICAL INFORMATION 2.3 Engine dimensions (mm) 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.
  • Page 11 TECHNICAL INFORMATION 2.4.1 SAE oil classification • In the SAE classification, oils are identified according to viscosity without considering any other qualitative characteristic. • The code is composed of two numbers, which indicate, and must correspond to, the ambient temperature in which the engine operates, the first number refers to the viscosity when cold, for use during winter ("W"), while the second number is for viscosity at high temperatures.

  • Page 12: Fuel

    Jet fuels, certificatio the primary filter must be with lubricity dosing n (*1) capability. Contact Kohler for information about the approved filter for this purpose. Power and torque might be 1% to 5% lower due to 100% (EN low fuel density compared to standard diesel fuel.
  • Page 13 Jet fuels, certificati the primary filter must be with lubricity dosing (*1) capability. Contact Kohler for information about the approved filter for this purpose. Sulphur Fuel S < 500 ppm High Sulphur Fuel S <...

  • Page 14: 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 15: Safety Information

    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 16 Do not mix fuel with elements such as oil or kerosene. Failure to comply with this prohibition will cause the non-operation of the catalyst and non-observance of the emissions declared by KOHLER . • Pay attention to the temperature of the oil filter when the filter itself is replaced.
  • Page 17 SAFETY INFORMATION 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. • The correct tightening of the lifting screws is 25Nm.

  • Page 18: 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 19 SAFETY INFORMATION Warnings Hereunder is a list of safety warnings that may be found in the manual, which advise you to pay attention when carrying out particular procedures that may be potentially dangerous to the operator or things. Danger This indicates situations of grave danger which, if ignored, may seriously threaten the health and safety of individuals.

  • Page 20: Information And Safety Signals

    SAFETY INFORMATION 3.4 Information and safety signals HIGH PRESSURE FLUID RISK OF PUNCTURE ACCIDENTAL START High Pressure Fluids can puncture skin and cause severe injury or death. Accidental Starts can cause severe injury or death. Do not work on fuel system without proper training or safety equipment.
  • Page 21 SAFETY INFORMATION Carbon Monoxide can cause Remove all jewelry when servicing batteries. severe nausea, fainting or Before disconnecting the negative (-) ground cable, make sure all switches are OFF. death. If ON, a spark will occur at the ground cable Avoid inhaling exhaust fumes and never run terminal which could cause an explosion.

  • Page 22: 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. •...

  • Page 23: Location Of Safety Labels On Engine

    SAFETY INFORMATION 3.6 Location of safety labels on engine Internal Communication: For internal & partner use only.

  • Page 24: 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 25: Refuelling

    2.3. • 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. • To avoid explosions or fire outbreaks, do not smoke or use open flames during the operations.

  • Page 26: Oil Filling

    INFORMATION ABOUT USE 4.5 Oil filling Important • For safety precautions see Par. 2.4. • Before proceeding with operation, read Par. 3.2.2. • 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 27 INFORMATION ABOUT USE NOTE: Before proceeding with any operation on the engine, stop it and allow it to cool. Warning • Presence of steam pressurized coolant danger of burns. 1. Loosen the cap A and fill the radiator with coolant composed of: 50% ANTIFREEZE and 50% decalcified water.

  • Page 28: 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 29: 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 PAR.

  • Page 30: Oil Level Check

    The air filter must be cleaned and replaced more frequently under very dusty conditions. (3) - In case of low use: 36 months. (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 31: Oil Dipstick On Cylinder Head

    • Before proceeding with operation, read Par. 3.2.2. NOTE: Components not necessarily supplied by KOHLER. 1. Release the two clasps F of the cover A. 2. Remove the cartridge B. 3. Clean the inside components A and D with a damp cloth.

  • Page 32: Rubber Hoses Check

    Important • Before proceeding with operation, read Par. 3.2.2. • If hoses are damaged contact an authorized KOHLER workshop. 1. Loosen the capscrews E and remove guard F. 2. Check that the: • Fuel system hoses A are intact.

  • Page 33: Check Coolant Level

    Fig 5.8 Warning • 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 34 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 35: Check Poly-V Alternator Belt

    Check by the appropriate tool that at point p the tension value is between 149 and 196 Hz. Fig 5.15 NOTE : If the poly-v belt tension results out of the above mentioned values contact KOHLER authorised workshops for replacement. 5.11 Check fuel filter cartridge Important •...

  • Page 36: Product Preservation

    INFORMATION ABOUT MAINTENANCE 5.12 Product preservation Important • If the engines are not to be used for 6 months, they must be protected by carrying out the (Par. 5.13). operations described in Engine storage (up to 6 months) • If the engine is still not in use after the first 6 months, it is necessary to carry out a further operation to extend the protection period (more than 6 months) (Par.

  • Page 37: 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 38: 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 • Before proceeding with operation, read Par. 3.2.2 • Place engine on level sur face to ensure accurate measurement of oil level.

  • Page 39: 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. • In case of low use replace il 12 months. • For disposal of oil filter cartridge and fuel filter refer to Par.

  • Page 40: Fuel Filter Cartridge Replacement

    INFORMATION ABOUT REPLACEMENTS 6.3 Fuel filter cartridge replacement Warning Important • In case of low use replace il 12 months. • Before proceeding with operation, read • To replace the cartridge with Option B Par. 3.2.2. filter, it is necessary to use the ST_55 tool •...

  • Page 41: Air Filter Cartridge Replacement

    6.4 Air filter cartridge replacement Important • Before proceeding with operation, read Par. 3.2.2. NOTE: Component not necessarily supplied by KOHLER. 1. Release the two fastenings F of the cover A. 2. Remove the cartridge B. 3. Reinstall: •...

  • Page 42: Information About Failures

    Frozen fuel Contact KOHLER authorised workshops Clogged fuel filter Replace with a new filter The engine does not Air suction in fuel system Contact KOHLER authorised workshops start Clogged air filter Replace with a new filter Clogged pipes Contact KOHLER authorised workshops Replace with a new fuse;...
  • Page 43 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 Internal Communication: For internal & partner use only.

  • Page 44: 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 45 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 46 4. You are responsible for initiating the warranty process. The ARB & US EPA suggests that you present your off-road & Marine engine to a Kohler Co. dealer as soon as a problem exists. The warranty repairs should be completed by the dealer as expeditiously as possible.
  • Page 47 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 48: Glossary

    9 GLOSSARY 9.1 Glossary and Definitions Alternator A component that transforms mechanical energy into AC 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.
  • Page 49 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 50 GLOSSARY 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. Tightening A term indicated for installation of threaded components and which is determined by torque means of a unit of measurement Nm.
  • Page 51 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 1/1000 of a millimetre µm 1 µm Length (micron)

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