Kohler KDI-1903TCR User manual

KDI 1903TCR - KDI 2504TCR
OWNER MANUAL

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UM KDI 1903TCR_2504TCR _ cod. ED0053029490 - 2° ed_rev. 01
24/07/201324/07/2013
DICOM/ATLO 2° 1 DICOM/ATLO ED0053029490
REGISTRATION OF MODIFICATIONS TO THE DOCUMENT
Any modications to this document must be registered by the drafting body, by completing the following table.
Drafting
body
Code
document Edition Date issue
Date
Review
Revision
Model
N° Endorsed
Written by
51269
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- The analytic index titles you can go directly to the selected subject.
- The blue underlined words you can go directly to a paragraph, a table or a picture.
- The chapter titles (headings) you come back automatically to the chapter initial page.
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- Clicking next to the bottom page number you come back to the analytic index.

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INDEX
A
Air lter cartridge replacement ..........................................33
Air lter check......................................................................23
Alternator belt, Check Poly-V ............................................26
Alternator standard belt tension, Check and setting .......26
B
Battery recommendations ..................................................13
Belt tension, Check and setting alternator standard .......25
C
California emission control warranty statement.
Your warranty rights and obligations ................................35
Cartridge replacement, Air lter .........................................33
Cartridge replacement, Oil lter .........................................30
Cartridge replacement (optional), Remote oil lter ..........31
Check and setting, Alternator standard belt tension .......26
Check, Air lter ....................................................................23
Check, Coolant level ...........................................................25
Check, Oil level ....................................................................23
Check of the radiator heat-exchange surface...................24
Check Poly-V alternator belt...............................................26
Check, Rubber hoses ..........................................................24
Check, Pre-start ...................................................................19
Control water lter cartridge fuel .......................................27
Coolant recommendations .................................................13
Coolant level check .............................................................25
Coolant lling .......................................................................21
D
Denitions, and Glossary .....................................................6
Dimensions, engine.............................................................10
Disposal and scrapping ......................................................33
E
Emission-Related Installation Instructions .........................6
Engine dimensions ..............................................................10
Engine component identication .........................................7
Engine oil replacement .......................................................29
Engine storage over 6 months ...........................................28
Engine storage up to 6 months ..........................................28
Engine starting after storage..............................................28
Engine, General description of the ....................................10
Engine specications..........................................................10
EPA rules, Label for ...............................................................9
F
Filling, Coolant .....................................................................21
Filling, Oil .............................................................................20
Filter cartridge replacement, Air ........................................33
Filter cartridge fuel, Control water .....................................27
Filter, Check air ....................................................................23
Filter cartridge replacement, Oil ........................................30
Filter cartridge replacement (optional), Remote oil .........31
Filter cartridge replacement, Fuel ......................................32
Fuel, Control water lter cartridge .....................................27
Fuel lter cartridge replacement ........................................32
Fuel .......................................................................................11
G
General description of the engine .....................................10
General remarks ..................................................................14
Glossary and Denitions ......................................................6
H
Heat-exchange surface, Check of the radiator check ......24
INDEX
UM KDI 1903TCR_2504TCR _ cod. ED0053029490 - 2° ed_rev. 01

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INDEX
I
Identication, Engine component ........................................7
Identication data, Manufacturer and motor ......................8
Information and safety signals...........................................17
Information, safety ..............................................................14
L
Label for EPA rules ...............................................................9
Level check, Oil ...................................................................23
Location of safety signals on engine ................................18
M
Maintenance, Periodic.........................................................22
Maintenance, Useful information about ............................22
Manual’s purpose ..................................................................6
Manufacturer and motor identication data .......................8
Manufacturer's warranty coverage ...................................35
Motor identication data, Manufacturer and .......................8
O
Oil ..........................................................................................11
Oil dipstick on cylinder head..............................................23
Oil lling ...............................................................................20
Oil lter cartridge replacement ..........................................30
Oil filter cartridge replacement, Remote ..........................31
Oil level check......................................................................23
Oil replacement, Engine......................................................29
Owner’s warranty responsibilities .....................................35
P
Period, Running-in ..............................................................19
Periodic maintenance .........................................................22
Poly-V alternator belt, Check .............................................26
Precautions, Safety .............................................................14
Pre-start check.....................................................................19
Product preservation ..........................................................28
Purpose, Manual ....................................................................6
INDEX
R
Recommendations, Battery ................................................13
Radiator heat-exchange surface, Check of the ...............24
Refuelling .............................................................................20
Remarks, General ................................................................14
Remote oil filter cartridge replacement (optional) ..........31
Replacement, Engine oil .....................................................29
Replacement, Fuel lter cartridge......................................32
Replacement, Oil lter cartridge ........................................30
Replacement (optional), Remote oil lter cartridge .........31
Request, Service....................................................................6
Rubber hoses check ...........................................................24
Rules, Label for EPA .............................................................9
Running-in period ................................................................19
S
Safety and environmental impact ......................................17
Safety signals, Information and .........................................17
Safety labels on engine, Location of .................................18
Safety signals description ..................................................16
Safety information ...............................................................14
Safety precautions ..............................................................18
Scrapping and, disposal .....................................................33
Service request ......................................................................6
Specications, Engine ........................................................10
Starting after storage, Engine ............................................28
Starting and turning off .......................................................19
Storage over 6 months, Engine..........................................28
Storage up to 6 months, Engine ........................................28
Storage, Engine starting after ............................................28
T
Tension, Check and setting alternator standard belt .......26
Turning off, Starting and .....................................................19
UM KDI 1903TCR_2504TCR _ cod. ED0053029490 - 2° ed_rev. 01

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INDEXINDEX
U
Useful information about failures ......................................34
Useful information about maintenance .............................22
W
Warranty responsibilities, Owner’s ...................................35
Water lter cartridge fuel, Control .....................................27
Y
Your warranty rights and obligations,
California emission control warranty statement ..............35
UM KDI 1903TCR_2504TCR _ cod. ED0053029490 - 2° ed_rev. 01

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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.
GENERAL INFORMATION
Glossary and Denitions
The paragraphs, tables and gure are divided into chapter with their progressive numbers.
Ex: Par. 1.3 - chapter 1 paragraph 3.
Tab. 2.4 - chapter 2 table 4.
Fig. 4.5 - chapter 4 gure 5.
The references of the objects described in the text and in gure and number are indicated by letters, which are always and only
related to the paragraph you are reading unless there are specic references to other gures or paragraphs.
The gure are based on model 2504 TCR, where necessary the version 1903 TCR is illustrated.
All data, measurements and relevant symbols are shown in the table below.
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. service 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. 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).
DATA MEASUREMENT SYMBOL EXAMPLE
Distance millimeter mm 1 mm
Torque newton-meter Nm 1 Nm
Force newton N 1 N
Mass Kilogram Kg 1 kg
Volume cubic centimeter cm31 cm3
Pressure pascal Pa 1 Pa
Volume liter L 1 L
Angle Degree a1°
Power kiloWatt kW 1 kW
Temperature centrigrade degree °C 1°C
Emission-Related Installation Instructions
Failing to follow the instructions in the applications guidebook when installing a certied engine in a piece of nonroad equipment
violates federal law (40 CFR 1068.105(b)), subject to nes 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 certied 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.
UM KDI 1903TCR_2504TCR _ cod. ED0053029490 - 2° ed_rev. 01
Index

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GENERAL INFORMATION
Engine component identication
SIDE VIEW A
SIDE VIEW B
Thermostat
Water temperature
sensor
Oil filler cap
Water pump
Alternator
Starter motor
Oil pressure sensor
Oil filler cap
Turbocharger
Oil steam separator
Nameplate
Nameplate
Oil drain plug
Fuel lter
Oil drain plug
Oil cooler
Valve EGR High injection pump
EGR Cooler
Oil lter
Oil dipstick
UM KDI 1903TCR_2504TCR _ cod. ED0053029490 - 2° ed_rev. 01
Index

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GENERAL INFORMATION
Manufacturer and motor identication data
Peak
rpm
Engine serial number
Approval data and
"EC" directives
Engine type
Engine
version
Manufacturer identication
The nameplate motor identication is nd side A or side B.
SIDE VIEW A SIDE VIEW B
UM KDI 1903TCR_2504TCR _ cod. ED0053029490 - 2° ed_rev. 01
Index

9
1
4
5
10
2
3
8
9
6
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GENERAL INFORMATION
Label for EPA rules
POS. DESCRIPTION
1Model year in compliance with the rules
2Power category (kW)
3Engine displacement (L)
4Particulate emission limit (g/kWh)
5Engine family ID
6Emission Control System = ECS
7Fuel with low sulphur content
8Injection timing (*BTDC)
9Injector opening pressure (bar)
10 Production date (example: 2013.JAN)
UM KDI 1903TCR_2504TCR _ cod. ED0053029490 - 2° ed_rev. 01
Index

1
10
Tab. 1.1
KDI 1903 TCR
KDI 2504 TCR
TECHNICAL INFORMATION
ENEN
1.1. General description of the engine
 
 
 
 
 
1.2 Engine specications
TECHNICAL DATA
UNIT
OF
MEASURE
ENGINE TYPE KDI 1903 TCR KDI 2504 TCR
CYLINDERS   
BORE  
STROKE  
DISPLACEMENT  
MAX INCLINATION DURING OPERATION
(even in combined)
 
 
OIL CAPACITY
(MAX level.)
including oil lter
standard version   
with dynamic balancer
(optional)  
DRY WEIGHT   
1.3 Engine dimensions (mm)
UM KDI 1903TCR_2504TCR _ cod. ED0053029490 - 2° ed_rev. 01
Index