Kohler KDI-1903TCR User manual

ED0053029490_Rev_19.1
KDI 1903 - TCR - TCRE5 – TC
KDI 2504 - TCR - TCRE5
OWNER MANUAL

INDEX
EN
1General Information...............................................................................................................4
1.1 Manual's Purpose ............................................................................................................................ 4
1.2 Glossary and Definitions................................................................................................................. 4
1.3 Emission-Related Installation Instructions................................................................................... 5
1.4 Service request ................................................................................................................................ 5
1.5 Engine component identification................................................................................................... 6
1.6 ATS (After Treatment System) ....................................................................................................... 7
1.7Manufacturer and motor identification data ................................................................................ 8
1.8 Homologation labels........................................................................................................................ 9
2Technical information.......................................................................................................... 12
2.1 General description of the engine ............................................................................................... 12
2.2 Engine specifications .................................................................................................................... 12
2.3 Engine dimensions (mm) .............................................................................................................. 12
2.4 Oil .................................................................................................................................................... 13
2.5 Fuel.................................................................................................................................................. 14
2.6 Coolant recommendation ............................................................................................................. 17
2.7 Battery recommendation.............................................................................................................. 17
2.8 Control panel.................................................................................................................................. 18
3Safety information ............................................................................................................... 19
3.1 Safety information ......................................................................................................................... 19
3.2 General remarks ............................................................................................................................ 20
3.3 Safety signal description .............................................................................................................. 22
3.4 Information and safety signals..................................................................................................... 24
3.5 Safety and environmental impact................................................................................................ 26
3.6 Location of safety labels on engine............................................................................................. 26
4Information about use ......................................................................................................... 27
4.1 Pre-start check .............................................................................................................................. 27
4.2 Running-in period.......................................................................................................................... 27
4.3 Starting and turning off ................................................................................................................ 27
4.4 Refuelling........................................................................................................................................ 28
4.5 Oil filling .......................................................................................................................................... 29
4.6 Coolant filling ................................................................................................................................. 30
4.7 ATS regeneration strategy (only for Stage V configurations) ................................................... 32
5Information about maintenance.......................................................................................... 34
5.1 Useful information about maintenance ...................................................................................... 34
5.2 Periodic maintenance ................................................................................................................... 35
5.3 Oil level check ................................................................................................................................ 37
5.4 Oil dipstick on cylinder head ........................................................................................................ 37

INDICE ANALITICO
EN
5.5 Air filter check................................................................................................................................ 38
5.6 Check of the radiator heat - exchanger surface ........................................................................ 38
5.7 Rubber hoses check...................................................................................................................... 39
5.8 Check coolant level ....................................................................................................................... 40
5.9 Check and setting alternator standard belt tension.................................................................. 41
5.10 Check Poly-V alternator belt ........................................................................................................ 42
5.11 Filter cartridge and fuel pre-filter check..................................................................................... 43
5.12 Product preservation..................................................................................................................... 43
5.13 Engine storage up to 6 months.................................................................................................... 43
5.14 Engine storage over 6 months ..................................................................................................... 44
5.15 Engine starting after storage ....................................................................................................... 45
5.16 Unused machine ............................................................................................................................ 46
6Information about replacements......................................................................................... 47
6.1 Engine oil replacement ................................................................................................................. 47
6.2 Oil filter cartridge replacement.................................................................................................... 48
6.3 Remote oil filter cartridge replacement (optional)..................................................................... 49
6.4 Filter cartridge and fuel pre-filter replacement.......................................................................... 50
6.5 Air filter cartridge replacement.................................................................................................... 51
6.6 Disposal and scrapping................................................................................................................. 51
7Information about failures................................................................................................... 52
7.1 Useful information about failures ................................................................................................ 52
8Information about warranty................................................................................................. 54
8.1 Warranty terms .............................................................................................................................. 54
9Glossary ...............................................................................................................................59
9.1 Glossary .......................................................................................................................................... 59

1GENERAL INFORMATION
EN 4
1GENERAL INFORMATION
1.1 Manual's Purpose
•
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.
•This manual is an integral part of the engine, in the event of transfer or sale, it must be attached
to it.
•Safety pictograms can be found on the engine and it is the operator's responsibility to keep them
in a perfectly visible place and replace them when they are no longer legible.
•Information, description and pictures in this manual reflect the state of the art at the time of the
marketing of engine.
•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.
•These changes do not require KOHLER to intervene on the marketed production up to that time
and not to consider this manual as inappropriate.
•Any additional section that KOHLER will deem necessary to supply some time after the main text
shall be kept together with the manual and considered as an integral part of it.
•The information contained within this manual is the sole property of KOHLER . As such, no
reproduction or replication in whole or part is allowed without the express written permission of
KOHLER .
1.2 Glossary and Definitions
The paragraphs, tables and figure are divided into chapter with their progressive numbers.
Es: Par. 2.3 - chapter 2 paragraph 3.
Tab. 3.4 - chapter 3 paragraph 4.
Fig. 5.5 - chapter 5 paragraph 5.
The references of the objects described in the text and in figure and number are indicated by letters,
which are always and only related to the paragraph you are reading unless there are specific references
to other figures or paragraphs.
NOTE: All data, measurements and relevant symbols are shown in the glossary section.

GENERAL INFORMATION
1
5 EN
1.3 Emission-Related Installation Instructions
Failing to follow the instructions in the applications guidebook when installing a certified engine in a piece
of nonroad equipment violates federal law (40 CFR 1068.105(b)), subject to fines or other penalties as
described in the Clean Air Act. OEM must apply a separate label with the following statement: “ULTRA
LOW SULFUR FUEL ONLY” near the fuel inlet.
Ensure you are installing an engine appropriately certified for your application. Constant speed engines
may only be installed on constant speed equipment for constant speed operation.
If you install the engine in a way that makes the engine's emission control information label hard to read
during normal engine maintenance, you must place a duplicate label on the equipment, as described in
40 CFR 1068.105.
1.4 Service request
•
The complete and updated list of authorized Kohler Co. service centers can be found on
websites:
www.kohlerengines.com & dealers.kohlerpower.it .
•If you have any questions regarding your warranty rights and responsibilities or the location of the
nearest Kohler Co. authorized service location, you should contact Kohler Co. at 1-800-544-
2444 or access our website at www.kohlerengines.com (USA and North American).

1GENERAL INFORMATION
EN 6
1.5 Engine component identification

GENERAL INFORMATION
1
7 EN
1.6 ATS (After Treatment System)
A: Turbocharger
B: Turbine exhaust pipe
NOTE: The ATS system is only present
for versions that conform to "Stage V"
emission regulations. The ATS system
can be mounted differently than the
figure.
•The ATS system reduces emissions because the DPF
eliminates the particulates generated by the
combustion of the diesel. The system starts automatic
regeneration cycles of the DPF based on the level of
clogging. The smell of the gases emitted by the
exhaust line is different from that of traditional gases of
diesel engines. Also, during the regeneration phases,
the exhaust gases could be temporarily white.
•The minimum engine speed increases during the
forced regeneration phases.
• See Par. 4.7 for the regeneration strategies of the DPF.

1GENERAL INFORMATION
EN 8
1.7 Manufacturer and motor identification data
The nameplate motor identification is find side Aor side B.

GENERAL INFORMATION
1
9 EN
1.8 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)

1GENERAL INFORMATION
EN 10
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