Kohler KDI-1903TCR Instruction manual

KDI 2504TCR / KDI 2504TCRE5
KDI 2504TCR / KDI 2504TCRE5
WORKSHOP MANUAL (REV. 17.4)

INDICE ANALITICO
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Sommario
1. TITOLO 1 ................................................................................................................................ 2
1.1. Asdfsdfsdf ........................................................................................................................................ 2
1.2. Asdfsdfsdfggg ................................................................................................................................. 2

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1 GENERAL INFORMATION
1.1 Useful information
This manual contains the instructions needed to carry out proper use and maintenance of the
engine, therefore it must always be available, for future reference when required.
Information, descriptions and pictures contained in this manual reflect the basic configuration of the
engines ( Par. 1.4 and Par. 1.5 ).
However, the development of engines is continuous. Therefore, the information in this manual is
subject to change without notice.
KOHLER reserves the right to make, at any time, changes on the engines for technical or
commercial reasons.
These changes do not require KOHLER to intervene on the production marketed up to that time and
nor to consider this manual as inappropriate.
The paragraphs, tables and figures are numbered by chapter and followed by the progressive
paragraph, table and/or figure number.
Es: Par. 1.3 - chapter 1paragraph 3.
Tab. 2.4 - chapter 2table 4.
Fig. 4.5 - chapter 4figure 5.
NOTE: The paragraphs may contain sub-paragraphs.
All technical terms, specific components and symbols ( Tab. 15.1 ) that are in the manual are listed
and described inside the glossary, which can be consulted in ( Chap. 15 ).
The references of the objects described in the text and in the figure are indicated by letters and
numbers, which are always and only related to the paragraph you are reading unless there are
specific references to other figures or paragraphs.
Reference to values are indicated by letters or numbers.

The mark ( ) after the title of a paragraph, indicates that the procedure is not required in order to
disassemble the engine, however the procedures are featured in order to illustrate the disassembly
of components.
Any additional section that KOHLER will deem necessary to supply at a later stage must be kept
with the manual and considered as an integral part of it.
The information contained in this manual is the sole property of KOHLER , therefore no partial or
total reproduction or replication is allowed without the express permission of KOHLER .
1.1.1 Useful Information - accident prevention - environmental impact
Before proceeding repair - handling the motor , read the entire chapter 3, which contains important
information about the procedures to be followed for safety and environment .

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1.2 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

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1.3 Homologation labels
Label for EPA rules (compilation example)
Tab 1.1
POS.
DESCRIPTION
1
Model year in compliance with the rules
2
Power category (kW)
3
Engine displacement (L)
4
Particulate emission limit (g/kWh)
5
Engine family ID
6
Emission Control System = ECS
7
Fuel with low sulphur content
8
Injection timing
9
Electronic injector opening pressure (bar)
10
Production date (example: 2013.JAN)

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Label for China Standards (compilation example)
Tab 1.2
POS
DESCRIPTION
1
Manufacturer
2
Engine model
3
Manufactoring date
4
Certificate N°
5
Power range (kW)
6
Emission level
7
Rated power
8
Aftertreat system

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Label for Korea Standards (compilation example)
Tab 1.3
POS
DESCRIPTION
1
Tier 4 Final
2
Engine model
3
Manufactoring date and manufacturer code
4
N° Korea emission certificate

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1.4 Identification of the main internal components of the engine and operating reference
(BASE CONFIGURATION)
WIEW OF EXHAUST SIDE
Fig 1.5
The following chapters contain operating references in order to clearly
understand the engine. This paragraph illustrates these references
that may be recognised by means of some main internal components.
Should you need to execute complex operations, always consult this
paragraph
Tab 1.2
REF.
DESCRIPTION
A
View of timing system
side (2 nd PTO)
B
View of flywheel side (1
nd PTO)
C
View of exhaust side
D
View of intake side
1
Cylinder/Piston N. 1
(KDI 1903 - KDI 2504)
2
Cylinder/Piston N. 2
(KDI 1903 - KDI 2504)
3
Cylinder/Piston N. 3
(KDI 1903 - KDI 2504)
4
Cylinder/Piston N. 4
(KDI 2504)
POS.
DESCRIPTION
5
Crankshaft pulley (2 nd
PTO)

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6
Gear timing system
7
Thermostatic valve
8
Oil pump
9
Oil suction hose
10
Crankshaft
11
Exhaust manifold
12
Intake manifold
13
Camshaft
14
Gears adaptor for 3 th
/4 th PTO (optional)
15
Flywheel (1 st PTO)
WIEW OF FLYWHEEL SIDE
Fig 1.6

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WIEW OF TIMING SYSTEM SIDE
Fig 1.7

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1.5 Identification of the external components of the engine (BASE CONFIGURATION)
VIEW OF TIMING SYSTEM SIDE - EXHAUST
Fig 1.8
VIEW OF FLYWHEEL SIDE

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Fig 1.9
This paragraph illustrates all external components
that are present in the base configuration of the
engine.
For components present on engines that differ from
those represented in these illustrations, refer to Chap.
11 .
NOTE: The illustrated components may differ from
those illustrated; the illustration is only as an
example.
Tab 1.3
POS.
DESCRIPTION
1
Oil filler cap
2
Wiring
3
ECU
4
Turbocharger
5
Oil pressure switch
6
Starter motor
7
Oil steam separator
8
Oil drain plug
9
Engine identification name plate
10
Alternator
11
Coolant pump
12
Coolant temperature sensor
13
Oil filler cap side
14
Thermostatic valve
15
Catalyst
16
EGR Cooler
17
High-pressure fuel injection pump
POS.
DESCRIPTION
18
Oil Cooler
19
Lub. oil filter
20
Oil dipstick
21
Fuel filter
22
EGR valve
23
Crankshaft pulley (2 nd PTO)
24
Flywheel (1 st PTO)
25
Intake manifold
26
Waste Gate valve control actuator
27
Exhaust manifold
28
Flange bell
29
Electronic injectors
30
Common Rail
31
Air intake hose

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UPPER VIEW
Fig 1.10

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1.6 ATS (After Treatment System)
1.6.1 ATS with DOC filter
NOTE: The ATS system can be installed in a different way than shown.
Fig 1.10
Tab 1.4
POS.
DESCRIZIONE
4
Turbocharger
5
Gas exhaust
flange
13
DOC
14
Flexible exhaust
tube
1.6.2 ATS with DOC+DPF filter
NOTE: the ATS system with DPF filter is only present for versions
compliant with "Stage V" emission regulations.
The ATS system can be installed in a different way than shown.
Tab 1.5
POS.
DESCRIZIONE
1
Turbocharger
2
Turbine exhaust
pipe
3
DOC
4
DPF
5
ETB

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Fig 1.11

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2 TECHNICAL INFORMATION
2.1 Engine specifications
MANUFACTURER SPECIFICATIONS AND OPERATION
GENERAL INFORMATION
UNIT OF
MEASURE
KDI 1903 TCR
KDI 2504 TCR
Operating cycle
diesel - 4 stroke
Cylinders
N°
3
4
Bore x stroke
mm
88x102
Displacement
cm 3
1861
2482
Compression ratio
17.4:1
Intake
Supercharged with Turbocharger
Cooling
Liquid
Crankshaft rotation (view from flywheel side)
Counterclockwise
Combustion sequence
1-3-2
1-3-4-2
Timing System
Valves per cylinder
N°
4
Timing System
Rods and rocker arms - Camshaft in
the crankcase
Tappets
Hydraulic
Injection
Direct - Common Rail
Engine dry weight
Kg
233
267
MAX inclination 30' continuous operation
α
25°
MAX inclination 1' continuous operation
α
35°
Volume of aspirated air (2600 rpm)
m 3/h
2.4
2.8
POWER AND TORQUE
GENERAL INFORMATION
UNIT OF
MEASURE
KDI 1903 TCR
KDI 2504 TCR
MAX operating speed
Rpm
2600
MAX operating power (ISO TR 14396 - SAE
J1995 - CE 97/68)
kW
42
55.4
Maximum torque (at 1500 rpm)
Nm
225
300
Admissible axial load on crankshaft
Kg
300
CONSUMPTIONS
GENERAL INFORMATION
UNIT OF
MEASURE
KDI 1903 TCR
KDI 2504 TCR
Specific fuel consumption (best point)
g/kWh
210
Oil consumption
%Fuel
< 0.05
FUEL SUPPLY SYSTEM
GENERAL INFORMATION
UNIT OF
MEASURE
KDI 1903 TCR
KDI 2504 TCR

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Type of fuel
Diesel UNI-EN590 - ASTM D975
High-pressure fuel injection pump
DENSO HP3
Fuel supply
Low pressure electric pump (if
necessary)
Fuel filter
Filtering surface
cm 2
2300
Degree of filtration
µm
5
Maximum pressure at injection pump inlet
bar
0,2
LUBRICATION CIRCUIT
GENERAL INFORMATION
UNIT OF
MEASURE
KDI 1903 TCR
KDI 2504 TCR
Lubrication
Recommended oil
See Par. 2.4
Circuit forced
Lobe pump
Oil sump capacity ( MAX )
Lt.
8,9
11,5
Oil pressure switch
Intervention pressure ( MIN )
bar
0.8±0.1
Oil filter
Maximum operating pressure
bar
4.0
Degree of filtration
µm
17±2
Filtering surface
cm 2
1744
COOLING CIRCUIT
GENERAL INFORMATION
UNIT OF
MEASURE
KDI 1903 TCR
KDI 2504 TCR
Coolant
%
See Par. 2.6
Coolant pump
Lt./min
75
Thermostatic valve
Opening temperature
°C
+79
Stroke at 91°C
mm
7.50
Liquid recirculation
Lt./h
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ELECTRICAL SYSTEM - ELECTRIC FAN
GENERAL INFORMATION
UNIT OF
MEASURE
KDI 1903 TCR
KDI 2504 TCR
Circuit rated voltage
V
12
External alternator (rated current)
A
80
Starter motor power
kW
2
System electrical consumption, excluding:
heater, electric pump, electric fan, starter
motor
W
25
Coolant temperature indicator light
Indicator light operating temperature
°C
+100/+110

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2.2 Engine dimensions (mm)
NOTE : Dimensions vary according to engine configuration.
Fig 2.1