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

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OWNER MANUAL
KDI 1903M - KDI 2504M

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Summary of Contents for Kohler KDI 1903M

  • Page 1: Um Kdi 1903M_2504M _ Cod. Ed0053029510 - 2° Ed_Rev

    OWNER MANUAL KDI 1903M - KDI 2504M...
  • Page 2 REGISTRATION OF MODIFICATIONS TO THE DOCUMENT Any modifications to this document must be registered by the drafting body, by completing the following table. Drafting Code Date Model Date Written by Endorsed Edition Revision body document N° issue Review 51270 2° 30/07/2013 30/07/2013 DICOM/ATLO ED0053029510...

  • Page 3: Table Of Contents

    INDEX Air filter cartridge replacement ..........33 Emission-Related Installation Instructions ......6 Air filter check..............23 Engine component identification .........7 Alternator standard belt tension, check and setting ..26 Engine dimensions ..............10 Engine, General description of the ........10 Engine oil replacement ............29 Battery recommendations ..........13 Engine, Location of safety signals on .......18 Break-in, Running ..............19 Engine specifications............10...
  • Page 4 INDEX Replacement, Oil filter cartridge ........30 Level check, Coolant ............25 Request, Service..............6 Level check, Oil ..............23 Rubber hoses check ............24 Location of safety signals on engine ........18 Running, Break-in ..............20 Maintenance, Periodic............22 Manual's purpose ..............6 Safety information ...............14 Manufacturer and motor identification data .......8 Safety signals, Information and .........17 Manufacturer’s warranty coverage ........35 Safety signal description ............16...
  • Page 5 NOTES ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

  • Page 6: Definitions, Glossary And

    Service request • Authorized service centers can be found in the service handbook (received with the product purchased). • The complete and updated list of authorized Kohler Co. ser vice centers can be found on our web site: http://www.lombardinigroup.it/dealer-locator. • If you have any questions regarding your warranty rights and responsibilities or the location of the nearest Kohler Co.

  • Page 7: Component Identification, Engine

    GENERAL INFORMATION Engine component identification SIDE VIEW A Thermostat Oil filler cap Water temperature sensor Oil pressure sensor Oil filler cap Starter motor Water pump Nameplate Oil drain plug Alternator SIDE VIEW B High pressure pump Oil filter Nameplate Oil drain plug Fuel filter UM KDI 1903M_2504M _ cod.

  • Page 8: Identification Data, Manufacturer And Motor

    GENERAL INFORMATION 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 type Engine serial number Manufacturer identification Peak Engine version Approval data and "EC" directives Fig.
  • Page 9 NOTES ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................UM KDI 1903M_2504M _ cod. ED0053029500 - 2° ed_rev. 01 Index...

  • Page 10: Dimensions, Engine

    TECHNICAL INFORMATION 1.1. General description of the engine - 4-stroke, in-line cylinders Diesel engine; - Liquid-cooling system; - 4 valves per cylinder with hydraulic tappets; - Injection. 1.2 Engine specifications Tab. 1.1 UNIT TECHNICAL DATA MEASURE ENGINE TYPE KDI 1903 M KDI 2504 M CYLINDERS BORE...

  • Page 11: Fuel

    TECHNICAL INFORMATION 1.4 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 TECHNICAL INFORMATION 1.5.2 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. 1.3. • DO NOT USE vegetable oil as a biofuel for this engine. •...

  • Page 13: Battery Recommendations

    FREECOR DSC TEXACO REVKOGEL 2000 PARAFLU LLC L255A LLC A432 1.7 Battery recommendations Battery not supplied by Kohler RECOMMENDED BATTERIES AMBIENT TEMPERATURE BATTERY TYPE 110Ah/20h - 500 A/DIN from 0°C to -15°C 110Ah/20h - 980 A/EN 110Ah/20h - 950 CCA/SAE 120Ah/20h - 560 A/DIN from -15°C to -25°C...

  • 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 • Fully tighten the tank cap each time after refuelling. Do not Important fill the tank right to the top but leave an adequate space for • Only use the eyebolts A installed by KOHLER to move the the fuel to expand. engine (Fig. 2.1).

  • Page 16: Description, Safety Signal

    SAFETY INFORMATION 2.3 Safety signal description • To ensure safe operation please read the following statements • This manual contains safety precautions which are explained and understand their meaning. below. • Also refer to your equipment manufacturer's manual for other •...

  • Page 17: 2.4 Information And Safety Signals

    State of California to cause cancer, birth defects, or other reproductive harm. 2.5 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: Engine, Location Of Safety Signals On

    SAFETY INFORMATION 2.6 Safety precautions • Position them as shown in Par. 2.7. • Check the good condition of safety signals. • Clean with a cloth, water and soap. • The user must replace them with original ones if they are deteriorated and illegible.

  • Page 19: Break-In, Running

    INFORMATION ABOUT USE 3.1 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. hot environments, etc...). 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. 3.2 Break-in running NOTE: For the first 50 hours of engine operation, it is advisable not to exceed 75% of the maximum power supplied. 3.3 Starting and turning off 3.3.1 Starting 1 -...

  • 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 3.6 Coolant filling 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. • A 50% mixture is recommended to ensure a general level at •...

  • Page 22: Maintenance, Periodic

    Coolant hoses After 6 checks with cleaning Dry air cleaner external cartridge The replacement must be carried out by authorized KOHLER workshops The replacement must be carried out by authorized Fuel line hose KOHLER workshops (1) - In case of low use: 12 months.

  • Page 23: Air Filter Check

    Fig. 4.3 Fig. 4.4 4.5 Air filter check NOTE: Components not necessarily supplied by KOHLER. 1 - Release the two clasps D of the cover A. 2 - Remove the cartridges B. 3 - Clean the inside components A and C with a damp cloth.

  • Page 24: 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 - 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 Standard Belt Tension, Check And Setting

    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. 40 Nm NOTE: Contact KOHLER authorised workshops replacement. 40 Nm Fig. 4.13 UM KDI 1903M_2504M _ cod.

  • Page 27: Control Water Filter Cartridge Fuel

    INFORMATION ABOUT MAINTENANCE 4.10 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. Fig.

  • Page 28: Engine Starting After Storage

    INFORMATION ABOUT MAINTENANCE 4.11 Product preservation If cleaning engine with a pressure washer or steam cleaner, it is important to maintain a minimum distance of at least 200mm between the surface to be washed and the Important nozzle - avoiding absolutely electrical components. •...

  • Page 29: Engine Oil Replacement

    INFORMATION ABOUT REPLACEMENTS Danger Disconnect the negative wire (-) from the battery to avoid accidental engine starting. 5.1 Engine oil replacement Important • Place engine on level sur face to ensure accurate measurement of oil level. NOTE: Perform this operation with warm engine, to get a better fluidity of the oil and get a full discharge of oil and impurities contained in it.

  • Page 30: Cartridge Replacement, Oil Filter

    INFORMATION ABOUT REPLACEMENTS 9 - Fit and remove the oil dipstick B to check the level. Pour in fluid until reaching the MAX level mark. 10 - Upon completion, reinstall the oil dipstick B completely. 11 - Tighten the cap A or C. Fig.

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

    INFORMATION ABOUT REPLACEMENTS NOTE: Click on the icon ( ) to play the procedure. 5.3 Remote oil filter cartridge replacement (optional) 1 - Unscrew and remove the cartridge A using the appropriate wrench. 2 - Lubricate the gasket and screw on the new cartridge A using the appropriate wrench. Fig. 5.7 UM KDI 1903M_2504M _ cod. ED0053029510 - 2° ed_rev. 01 Index...

  • Page 32: Fuel Filter Cartridge Replacement

    INFORMATION ABOUT REPLACEMENTS 5.4 Fuel filter cartridge replacement 1 - Unscrew the filter cartridge A from the holder B. 2 - Unscrew the fuel water sensor D. 3 - Replace the gasket C. 4 - Lubricate the gasket E. 5 - Screw the new filter cartridge A. Important •...

  • Page 33: Air Filter Cartridge Replacement

    INFORMATION ABOUT REPLACEMENTS 5.5 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 34: Useful Information About Failures

    Cheap fuel Clean the tank and refuel with quality fuel performance Replace the engine oil; if the problem persists, High oil sump level contact KOHLER authorised workshops Slow acceleration Clogged fuel filter Replace the fuel filter Engine jerking Clogged fuel pipes Contact KOHLER authorised workshops Insufficient coolant level Fill up to the level Replace the engine oil; if the problem persists, High oil sump level Engine overheats contact KOHLER authorised workshops Clean the radiator; if the problem persists, contact Clogged radiator KOHLER authorised workshops - In the event that the solutions proposed in Tab. 6.2 do not eliminate the trouble, contact a KOHLER authorized workshop. UM KDI 1903M_2504M _ cod. ED0053029510 - 2° ed_rev. 01 Index...

  • Page 35: Manufacturer's Warranty Coverage

    • The Air Resources Board suggests that you present your heavy-duty off-road engine to a Kohler Co. dealer as soon • Kohler Co. cannot deny warranty solely for the lack of as a problem exists. receipts or for your failure to ensure the performance of all recommended scheduled maintenance.
  • Page 36 NOTES ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................UM KDI 1903M_2504M _ cod. ED0053029510 - 1° ed_rev. 00 Index...
  • Page 37 NOTES ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................UM KDI 1903M_2504M _ cod. ED0053029510 - 1° ed_rev. 00 Index...
  • Page 38 Translated from the original manual in Italian language. Data reported in this issue can be modified at any time by KOHLER. FORM NO. ED0053029510 ISSUED 30/07/2013 REVISED DATE 30/07/2013 Lombardini s.r.l. is a part of Kohler Group. E U R O P E U S A &...

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