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

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OWNER MANUAL
KDI 1903 TCR - KDI 2504 TCR

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Summary of Contents for Kohler KDI 1903 TCR

  • Page 1 OWNER MANUAL KDI 1903 TCR - KDI 2504 TCR...
  • Page 2 • Connect to DOCUMENTATION" > select "KDI 1903 TCR" or "KDI 2504 TCR" and download the latest version of this manual onto your device. NOTE: you can select the desired language before downloading the manual, as shown in the figure below.

  • Page 3: Table Of Contents

    INDEX INDEX Air filter cartridge replacement ..........32 Emission-Related Installation Instructions ......6 Air filter check..............23 Engine dimensions ..............10 Alternator belt, Check Poly-V ..........26 Engine component identification .........7 Alternator standard belt tension, Check and setting ..26 Engine oil replacement ............29 Engine storage over 6 months ...........28 Battery recommendations ..........13 Engine storage up to 6 months ..........28 Belt tension, Check and setting alternator standard ..26...
  • Page 4 INDEX INDEX Identification, Engine component ........7 Recommendations, Battery ..........13 Identification data, Manufacturer and motor ......8 Radiator heat-exchange surface, Check of the ....24 Information and safety signals...........17 Refuelling ................20 Information, safety ..............14 Remarks, General ..............14 Remote oil filter cartridge replacement (optional) ..31 Replacement, Engine oil .............29 Replacement, Fuel filter cartridge........31 Label for EPA rules ...............9...
  • Page 5 INDEX INDEX Warranty international ............34 Warranty norms EPA ............35 ED0053029490...

  • Page 6: Definitions, And Glossary

    40 CFR 1068.105. 1.4 Service request • The c omplete and updated list of authorized Kohler Co. ser vice centers c an be found on websites: www.kohlerengines.com &...

  • Page 7: 1.5 Engine Component Identification

    GENERAL INFORMATION 1.5 Engine component identification SIDE VIEW A Oil filler cap Thermostat Turbocharger Oil filler cap Oil pressure switch Starter motor Coolant temperature sensor Oil steam separator Coolant pump Oil drain plug Nameplate Alternator SIDE VIEW B EGR Cooler High injection pump Valve EGR Oil cooler...

  • Page 8: Identification Data, Manufacturer And Motor

    GENERAL INFORMATION 1.6 Manufacturer and motor identification data The nameplate motor identification is find side A or side B. SIDE VIEW A SIDE VIEW B Engine type Engine serial number Manufacturer identification Peak Engine version Approval data and "EC" directives ED0053029490 Index...

  • Page 9: Epa Rules, Label For

    GENERAL INFORMATION 1.7 Label for EPA rules 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 (*BTDC) Injector opening pressure (bar) Production date (example: 2013.JAN) ED0053029490...

  • Page 10: Dimensions, Engine

    - Common Rail - Direct injection. - 4 valves per cylinder with hydraulic tappets; 2.2 Engine specifications Tab. 2.1 UNIT TECHNICAL DATA MEASURE ENGINE TYPE KDI 1903 TCR KDI 2504 TCR CYLINDERS BORE STROKE DISPLACEMENT 1861 2482 30° max. 30 minutes...

  • Page 11: Fuel

    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 cause cancer of the skin. level. • Do not exceed the MAX level because a sudden increase in •...
  • Page 12 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. Tab.

  • Page 13: Battery Recommendations

    Data selection or entry push button 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. 2.7 Tab.

  • Page 14: General Remarks

    • In case the approval to a modification is not granted, KOHLER prescribed health and safety requirements. Any use of the shall not be deemed responsible for any consequential machine other than that described cannot be considered as failures or damages to the engine.
  • Page 15 Important • Check belt tension only when the engine is off. • Only use the eyebolts A installed by KOHLER to move the • Fully tighten the tank cap each time after refuelling. Do not engine (Fig. 3.1).

  • Page 16: Safety Signals Description

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

  • Page 17: 3.4 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 18: Location Of Safety Signals On Engine

    SAFETY INFORMATION 3.6 Location of safety labels on engine KDI 1903 TCR KDI 2504 TCR ED0053029490 Index...

  • Page 19: Check, Pre-Start

    INFORMATION ABOUT USE 4.1 Pre-start check • Read carefully the following pages and carry out the • Increase the frequency of maintenance operations in heavy operations described below in accordance with the working conditions (engine starts but stops, very dusty and instructions specified.

  • Page 20: Filling, Oil

    • 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 21: Coolant Filling

    INFORMATION ABOUT USE 4.6 Coolant filling Important • Before proceeding with operation, read Par. 3.2.2. Warning • As well as lowering the freezing point, the antifreeze also • An anti-freeze protection liquid (ANTIFREEZE) - mixed with raises the boiling point. decalcified water - must be used.

  • Page 22: Maintenance, Periodic

    (2) - The period of time that must elapse before checking (6) - The replacement must be carried out by authorized KOHLER workshops. the filter element depends on the environment in which (7) - The replacement interval is only an indication, it strongly the engine operates.

  • Page 23: Air Filter Check

    Fig. 5.4 Fig. 5.3 5.5 Air filter check NOTE: Components not necessarily supplied by KOHLER. 1 - Release the two clasps F of the cover A. 2 - Remove the cartridges B and G. 3 - Clean the inside components A and D with a damp cloth.

  • Page 24: Check Of The Radiator Heat-Exchange 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. Fig. 5.7 1 - Check that the: - Fuel system hoses A are intact.

  • Page 25: Check, Coolant Level

    Warning • 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 26: Alternator Belt, Check Poly-V

    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 replacement. Fig. 5.13 5.10 Check Poly-V alternator belt...

  • Page 27: Control Water Filter Cartridge Fuel

    INFORMATION ABOUT MAINTENANCE NOTE: If the poly-v belt tension results out of the above mentioned values contact KOHLER authorised workshops for replacement. Fig. 5.15 5.11 Control water filter cartridge fuel NOTE: When turn on lights on control water filter cartridge fuel Par.

  • Page 28: Engine Storage Over 6 Months

    INFORMATION ABOUT MAINTENANCE 5.12 Product preservation 11 - When cleaning the engine, if using a pressure washer or steam cleaning device, avoid directing the nozzle on electrical components, cable connections and sealed Important rings (oil seals etc). If cleaning engine with a pressure washer or steam •...

  • Page 29: Engine Oil Replacement

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

  • Page 30: Cartridge Replacement, Oil Filter

    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. Fig.

  • Page 31: Cartridge Replacement (Optional), Remote Oil Filter

    INFORMATION ABOUT REPLACEMENTS 5- 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 6.3 Remote oil filter cartridge replacement (optional) 1 - Unscrew and remove the cartridge A using the appropriate wrench.

  • Page 32: Air Filter Cartridge Replacement

    INFORMATION ABOUT REPLACEMENTS 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 cartridges B and G. 3 - Reinstall: - the new cartridges B and G.

  • Page 33: 7.1 Useful 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. ED0053029490 Index...
  • Page 34 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 35: California And Federal Emission Control Warranty Statement Your Warranty Rights And Obligations

    Co. cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance. (b) 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 36 The choice and responsibility of the decision to repair or replace an emission control system defect will be solely that of Kohler Co.

  • Page 37: 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 38 GLOSSARY Serial number (engine identification name plate) indicating s/n: the engine identification series/chassis number. Specification, (engine identification name plate) indicating Spec.: the engine version. Tab.: Table. TCR: Turbo Common Rail. A term indicated for installation of threaded components and Tightening torque: which is determined by means of a unit of measurement Nm.
  • Page 39 GLOSSARY SYMBOLS AND UNITS OF MEASUREMENT SYMBOL UNIT OF MEASUREMENT DESCRIPTION EXAMPLE Rotation/inclination angle degree 1° square centimetre Area 1 cm Ø millimetre Circumference Ø 1 mm Torque newton-metre 1 Nm millimetre 1 mm Length 1/1000 of a millimetre μm 1 μm (micron) hour...
  • Page 40 Lombardini s.r.l. is a part of Kohler Group. Lombardini s.r.l. is a part of Kohler Group. E U R O P E E U R O P E U S A & CA N A DA U S A & CA N A DA...

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Kdi 2504 tcr

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