Kohler KDI 2504TM Instruction manual

KDI 2504TM
WORKSHOP MANUAL
TP-6971 3/23

INDEX
REGISTRATION OF MODIFICATIONS TO THE DOCUMENT
Any modifications to this document must be registered by the drafting body, by completing the
following table.
Released by Document code Revision Issue date Review date Edited by Endorsed
Technical
Documentation ED00530303507.6 04/2015 03/2023 M.
SILVESTRONE V. MANINI
Translated from the original manual in Italian language.
Data reported in this issue can be modified at any time by KOHLER.

INDEX
EN
1General information...............................................................................................................7
1.1 Useful information ........................................................................................................................... 7
1.2 Manufacturer and engine identification ....................................................................................... 8
1.3 Identification of the main internal components of the engine and operating reference
(BASE CONFIGURATION) ............................................................................................................................... 9
1.4 Identification of the external components of the engine (BASE CONFIGURATION)............. 11
2Technical information.......................................................................................................... 13
2.1 Engine specifications .................................................................................................................... 13
2.2 Engine dimensions (mm) .............................................................................................................. 15
2.3 Performance................................................................................................................................... 15
2.4 Oil .................................................................................................................................................... 16
2.5 Fuel.................................................................................................................................................. 17
2.6 Coolant recommendation ............................................................................................................. 19
2.7 Battery recommendation.............................................................................................................. 19
2.8 Periodic maintenance ................................................................................................................... 20
2.9 Fuel system .................................................................................................................................... 21
2.10 Lubrication circuit.......................................................................................................................... 26
2.11 Coolant circuit................................................................................................................................ 29
2.12 Intake and exhaust circuit ............................................................................................................ 30
2.13 Electric system............................................................................................................................... 33
2.14 Sensors and switches ................................................................................................................... 36
2.15 Electrical components .................................................................................................................. 38
2.16 Timing system and tappets .......................................................................................................... 42
2.17 Components handling................................................................................................................... 45
2.18 Turbocharger ................................................................................................................................. 45
2.19 Balancer device (optional) ............................................................................................................ 49
3Safety information ............................................................................................................... 50
3.1 Before start-up .............................................................................................................................. 50
3.2 Safety precautions ........................................................................................................................ 50
3.3 General remarks ............................................................................................................................ 50
3.4 Safety signal description .............................................................................................................. 53
3.5 Information and safety signals..................................................................................................... 55
3.6 Safety and environmental impact................................................................................................ 56
3.7 Location of safety labels on engine............................................................................................. 57
4Storage information............................................................................................................. 58
4.1 Product preservation..................................................................................................................... 58
4.2 Engine storage (up to 6 months).................................................................................................. 58
4.3 Engine storage (over 6 months) ................................................................................................... 58

INDEX
4.4 Engine starting after storage ....................................................................................................... 59
5Information regarding discharge of liquids ....................................................................... 60
5.1 Coolant ........................................................................................................................................... 60
5.2 Engine oil........................................................................................................................................ 61
6Information for replacing the functional units ................................................................... 62
6.1 Injectors and injection pump replacement ................................................................................. 62
6.2 Coolant pump replacement.......................................................................................................... 70
6.3 Replace the crankshaft pulley...................................................................................................... 71
6.4 Oil pump replacement................................................................................................................... 72
6.5 Oil pressure valve replacement.................................................................................................... 75
6.6 Oil cooler unit and oil filter replacement..................................................................................... 76
6.7 Fuel filter replacement .................................................................................................................. 78
6.8 Oil vapour separator replacement ............................................................................................... 79
7Information for disassembly ............................................................................................... 81
7.1 Recommendations for disassembly ............................................................................................ 81
7.2 Electric components disassembly ............................................................................................... 81
7.3 Turbocharger disassembly ........................................................................................................... 83
7.4 Exhaust manifold disassembly..................................................................................................... 83
7.5 Coolant recirculation components disassembly ........................................................................ 83
7.6 Crankshaft pulley disassembly .................................................................................................... 84
7.7 Lubrication circuit disassembly ................................................................................................... 85
7.8 Intake manifold disassembly........................................................................................................ 86
7.9 Fuel system disassembly .............................................................................................................. 87
7.10 Timing system gear disassembly................................................................................................. 89
7.11 Flange unit disassembly ............................................................................................................... 90
7.12 Cylinder head unit disassembly ................................................................................................... 90
7.13 Oil sump unit disassembly............................................................................................................ 93
7.14 Engine block disassembly ............................................................................................................ 94
8Information about overhauling ........................................................................................... 99
8.1 Recommendations for overhauls and tuning ............................................................................. 99
8.2 Crankcase..................................................................................................................................... 100
8.3 Tappets and tappet housings..................................................................................................... 103
8.4 Crankshaft.................................................................................................................................... 103
8.5 Connecting rod - piston assembly............................................................................................. 105
8.6 Cylinder head ............................................................................................................................... 108
8.7 Oil pump check ............................................................................................................................ 111
9Assembly information ....................................................................................................... 113
9.1 Information on engine configuration......................................................................................... 113
9.2 Assembly recommendations ...................................................................................................... 113

INDEX
EN
9.3 Engine block assembly ............................................................................................................... 114
9.4 Oil sump unit assembly............................................................................................................... 121
9.5 Flange unit assembly .................................................................................................................. 122
9.6 Timing system gear assembly and injection pump.................................................................. 123
9.7 Cylinder head unit assembly ...................................................................................................... 125
9.8 Fuel system assembly ................................................................................................................. 130
9.9 Intake manifold assembly ........................................................................................................... 132
9.10 Exhaust manifold assembly........................................................................................................ 133
9.11 Lubrication circuit assembly ...................................................................................................... 133
9.12 Crankshaft pulley assembly ....................................................................................................... 135
9.13 Turbocharger Assembly.............................................................................................................. 136
9.14 Coolant circuit assembly ............................................................................................................ 137
9.15 Electric component assembly .................................................................................................... 139
9.16 Tightening torques and the use of sealants............................................................................. 141
10 Fluids filling information ................................................................................................... 147
10.1 Engine oil...................................................................................................................................... 147
10.2 Coolant ......................................................................................................................................... 148
11 Information about optional components.......................................................................... 150
11.1 Oil dipstick in cylinder head ....................................................................................................... 150
11.2 Heater (replacement) .................................................................................................................. 151
11.3 Idler gear (for 3rd / 4th PTO) ...................................................................................................... 152
11.4 3rd PTO (replacement) ................................................................................................................ 153
11.5 4th PTO (replacement) ................................................................................................................ 156
11.6 3rd + 4th PTO (configurations) ................................................................................................... 159
11.7 Air filter (cartridge replacement)................................................................................................ 160
11.8 Remote oil filter (disassembly and assembly) .......................................................................... 160
11.9 Poly-V alternator belt (replacement and adjustment) ............................................................. 162
11.10 Tightening pulley and alternator for Poly-V belt ...................................................................... 163
11.11 Oil sump with supporting structure........................................................................................... 165
12 Information on adjustments.............................................................................................. 169
12.1 Air filter check.............................................................................................................................. 169
12.2 Rubber hose and manifold control ............................................................................................ 169
12.3 Oil leak check............................................................................................................................... 170
12.4 Oil pressure check....................................................................................................................... 171
13 Tools information............................................................................................................... 172
13.1 Information regarding specific tools ......................................................................................... 172
14 Information about failures................................................................................................. 174
14.1 Possible causes and trouble shooting ...................................................................................... 174
15 Glossary ............................................................................................................................. 176

INDEX
15.1 Glossary ........................................................................................................................................ 176

GENERAL INFORMATION 1
7 EN
1GENERAL 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.
•The information, descriptions and illustrations contained in this manual reflect the basic
configuration of the engines (Par. 1.3 and Par. 1.4).
•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 (underlined).
•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 engine, you should read Chap. 3 in its entirity, which
contains important information regarding procedures to follow with regard to safety and the
environment.

1GENERAL INFORMATION
EN 8
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

GENERAL INFORMATION 1
9 EN
1.3 Identification of the main internal components of the engine and operating reference
(BASE CONFIGURATION)
VIEW OF EXHAUST SIDE
Fig 1.4
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.
NOTE : it is advisable to keep this page visible
during disassembly and assembly operations.
Tab 1.1
REF.
DESCRIPTION
A View of timing system side (2 nd PTO)
B View of flywheel side (1
st
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)
6
Gear timing system
7
Thermostatic valve
8
Oil pump
9
Oil suction hose
10
Crankshaft
11
Exhaust manifold
12
Intake manifold

1GENERAL INFORMATION
EN 10
13
Camshaft
14
Gears adaptor for 3
a
/4
a
PTO (optional)
15
Flywheel (1
st
PTO)
16
Injector
VIEW OF FLYWHEEL SIDE
Fig 1.5
VIEW OF TIMING SYSTEM SIDE
Fig 1.6

GENERAL INFORMATION 1
11 EN
1.4 Identification of the external components of the engine (BASE CONFIGURATION)
VIEW OF TIMING SYSTEM SIDE – EXHAUST
Fig 1.7
VIEW OF FLYWHEEL SIDE
Fig 1.8

1GENERAL INFORMATION
EN 12
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 1.2
POS.
DESCRIPTION
1
Oil filler cap
2
Oil pressure switch
3
Starter motor
4
Oil drain plug
5
Engine identification name plate
6
Alternator
7
Coolant pump
8
Coolant temperature sensor
9
Oil filler cap side
10
Thermostatic valve
11
High-pressure fuel injection pump
12
Lub. oil filter
13
Oil dipstick
14
Fuel filter
15
Crankshaft pulley (2 nd PTO)
16
Flywheel (1
st
PTO)
17
Intake manifold
POS.
DESCRIPTION
18
Exhaust manifold
19
Flange bell
20
Injectors
21
Turbocharger
22
Oil steam separator
23
Oil Cooler
24
Waste Gate valve control actuator
25
Air intake hose
UPPER VIEW
Fig 1.9

TECHNICAL INFORMATION 2
13 EN
2TECHNICAL INFORMATION
2.1 Engine specifications
MANUFACTURER SPECIFICATIONS AND OPERATION
GENERAL INFORMATION
UNIT OF
MEASURE
KDI 2504 TM
Operating cycle diesel - 4 stroke
Cylinders
N°
4
Bore x stroke
mm
88x102
Displacement
cm 3
2482
Compression ratio
17.4:1
Intake
Supercharged with Turbocharger
Cooling
Liquid
Crankshaft rotation (view from flywheel side) Counterclockwise
Combustion sequence
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
Engine dry weight
Kg
244
MAX inclination 30' continuous operation
(min./a)
25°
MAX inclination 1' continuous operation
(min./a)
35°
Volume of aspirated air (2600 rpm)
Kg/h
2.9
POWER AND TORQUE
GENERAL INFORMATION
UNIT OF
MEASURE
KDI 2504 T M
MAX operating speed
Rpm
2600
MAX operating power (ISO TR 14396 - SAE
J1995 - CE 97/68)
kW 41
Maximum torque (at 1500 rpm)
Nm
170
Admissible axial load on crankshaft
Kg
300
CONSUMPTIONS
GENERAL INFORMATION
UNIT OF
MEASURE
KDI 2504 T M
Specific fuel consumption (best point)
g/kWh
210
Oil consumption
%Fuel
< 0.05

2TECHNICAL INFORMATION
EN 14
FUEL SUPPLY SYSTEM
GENERAL INFORMATION
UNIT OF
MEASURE
KDI 2504 T M
Type of fuel Diesel UNI-EN590 - ASTM D975
High-pressure fuel injection pump
STANADYNE - DB
Fuel supply
Low pressure electric pump
Fuel filter
Filtering surface
cm 2
2300
Degree of filtration
µm
5
Maximum pressure at injection pump inlet
bar
< 0.5
LUBRICATION CIRCUIT
GENERAL INFORMATION
UNIT OF
MEASURE
KDI 2504 T M
Fuel
Lubrication
See Par. 2.4
Circuit forced Lobe pump
Oil sump capacity (MAX)
Lt.
11,5
Oil pressure switch
Intervention pressure (MIN)
bar
0.8±0.1
Oil filter
Maximum operating pressure
bar
7.0
Degree of filtration
µm
17±2
Filtering surface
cm 2
1744
COOLING CIRCUIT
GENERAL INFORMATION
UNIT OF
MEASURE
KDI 2504 T M
Coolant %
See Par. 2.6
Water pump
Lt./min
75
Thermostatic valve
Opening temperature
°C
+79
Stroke at 91°C
mm
7.50
Liquid recirculation
Lt./h
9
ELECTRICAL SYSTEM - ELECTRIC FAN
GENERAL INFORMATION
UNIT OF
MEASURE KDI 2504 T M
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
W24

TECHNICAL INFORMATION 2
15 EN
motor
Coolant temperature indicator light
Indicator light operating temperature
°C
+100/+110
2.2 Engine dimensions (mm)
2.3 Performance
50 Hz @ 1500 rpm
KDI 2504 TM-30
KDI 2504 TM-40 EU
KDI 2504 TM-40
POWER
Stand-by power (kW/HP)
31,0 / 41,5
36,4 / 48,8
41,0 / 54,9
Prime power (kW/HP)
28,2 / 37,8
33,1 / 44,3
37,3 / 49,9
FUEL CONSUMPTION (g/kWh)
Fuel consumption 100% load
226,8
228,7
225,0
Fuel consumption 75% load
238,0
235,7
228,0
Fuel consumption 50% load
252,9
252,2
235,0
Fuel consumption 25% load
280,6
278,4
265,0
Fuel consumption 10% load
420,9
398,4
376,0
60 Hz @ 1800 rpm
KDI 2504 TM
POWER
Stand-by power (kW/HP)
36,4 / 48,8
Prime power (kW/HP)
33,1 / 44,3
FUEL CONSUMPTION (g/kWh)
Fuel consumption 100% load
226,6
Fuel consumption 75% load
236,5

2TECHNICAL INFORMATION
EN 16
Fuel consumption 50% load
256,8
Fuel consumption 25% load
299,8
Fuel consumption 10% load
470,7
2.4 Oil
Important
•The engine may be damaged if operated with improper oil level.
•Do not exceed the MAX level because a sudden increase in engine rpm could be caused by its
combustion.
•Use only the recommended oil to ensure adequate protection, efficiency and service life of the
engine.
•The use of lubricants other than recommended may shorten the engine life.
•Viscosity must be appropriate to the ambient temperature to which the engine is to be exposed.
Danger
•Prolonged skin contact with the exhausted engine oil can cause cancer of the skin.
•If contact with oil cannot be avoided, thoroughly wash your hands with soap and water as soon as
possible.
•For the exhausted oil disposal, refer to the Par. DISPOSAL and SCRAPPING.
2.4.1 SAE oil classification
•In the SAE classification, oils are identified according to viscosity without considering any other
qualitative characteristic.
•The code is composed of two numbers, which indicate, and must correspond to, the ambient
temperature in which the engine operates, the first number refers to the viscosity when cold, for use
during winter (" W"), while the second number is for viscosity at high temperatures.
2.2
RECCOMENDED OIL
VISCOSITY SAE
10w-30 (-25°C ÷ +40°C)
10w-40 (-25°C ÷ +50°C)
5w-30 (-30°C ÷ +40°C)
0w-40 (-40°C ÷ +50°C)
WITH SPECIFICATIONS
API
CI-4 Plus CI-4
CH-4
ACEA
E7
E5
•Low S.A.P.S. oils, sulfate ashes <1% may not be used with fuels with a sulfur content >50ppm.
•Filtration of oils is critical to proper operation and lubrication; always change filters regularly as
specified in this manual.

TECHNICAL INFORMATION 2
17 EN
2.5 Fuel
Important
•Use of other types of fuel could damage the engine. Do not use dirty diesel fuel or mixtures of
diesel fuel and water since this will cause serious engine faults.
•Any failures resulting from the use of fuels other than recommended will not be warranted.
Warning
•Clean fuel prevents the fuel injectors from clogging. Immediately clean up any spillage during
refuelling.
•Never store diesel fuel in galvanized containers (i.e. coated with zinc). Diesel fuel and the galvanized
coating react chemically to each other, producing flaking that quickly clogs filters or causes fuel
pump and/or injector failure.
2.3
FUEL COMPATIBILITY
EN 590 (biodiesel content max. 7% (V/V))
ASTM D 975 Grade 1-D S15
ASTM D 975 Grade 2-D S15
NATO F-54, equivalent to diesel fuel in accordance with EN 590
EN 590 or ASTM D 975 Grade 1, 2 -D S15 Arctic Diesel
JIS K 2204 No. 1, No. 2
NOTE : In a warranty case the customer must prove by a certificate from the fuel supplier that an allowed
fuel was used.
KDI Mechanical Injection Tier 3,Tier 4 Final – Stage IIIA, Stage IIIB, Stage V certified Engines (w and
w/o EGR)
•Those engines are designed for fuels in accordance with EN 590 and ASTM D975 for a cetane
number of at least 45. Since those engines are not equipped with exhaust gas after-treatment, they
can be operated with diesel fuels with sulfur content up to 500 mg/kg (ppm). Compliance with the
emission requirements is guaranteed only with sulfur content up to 15 mg/kg (ppm).
Engines operated with fuels as per EN 590 and ASTM D975 with sulfur content < 15mg/kg have an
oil changing interval of 500hrs. Fuels with a sulfur content > 500 mg/kg demand a shorter
lubricating oil change interval. This is set at 250hrs. However, the engine oil must be changed when
the Total Base Number TBN is reduced to 6.0 mgKOH/g test method ASTM D4739. With high fuel
sulfur content fuel this may happen at 125hrs. Do not use low SAPS oils.
KDI Mechanical Injection Uncertified Engines (no EGR Engines)
•Those engines are designed for fuels in accordance with EN 590 and ASTM D975 for a cetane
number of at least 45. Since those engines are not equipped with exhaust gas after-treatment, they
can be operated with diesel fuels with sulfur content up to 2000 mg/kg (ppm).Engines operated
with fuels as per EN 590 and ASTM D975 with sulfur content < 15mg/kg have an oil changing
interval of 500hrs. Fuels with a sulfur content > 500 mg/kg demand a shorter lubricating oil change
interval. This is set at 250hrs. However, the engine oil must be changed when the Total Base
Number TBN is reduced to 6.0 mgKOH/g test method ASTM D4739
2.5.1 Fuel for low temperatures
•When operating the engine in ambient temperatures lower than 0 degrees C, use suitable low
temperature fuel normally available from fuel distributors and corresponding to the specifications of
Tab. 2.3.

2TECHNICAL INFORMATION
EN 18
•These fuels reduce the formation of paraffin in diesel at low temperatures.
•When paraffin forms in the diesel, the fuel filter becomes blocked interrupting the flow of fuel.
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.
2.4
BIODIESEL COMPATIBILITY
Biodiesel according to EN 14214 (only permissible for mixture with diesel fuel at max. 10% (V/V))
US biodiesel according to ASTM D6751 – 09a (B100) (only permissible for mixtures with diesel fuel at 10%
(V/V))
2.5.3 Synthetic fuels: GTL, CTL, BTL, HV
It is a well-known fact that engines which are operated for longer periods with conventional diesel fuel and
then converted to synthetic fuels suffer shrinkage of polymer seals in the injection system and thus fuel
leaks. The reason for this behavior is that the aromatic-free synthetic fuels can lead to a change in the
sealing behavior of polymer seals.
Therefore, conversion from diesel fuel to synthetic fuel may only be done after changing the critical seals.
The problem of shrinkage does not occur when an engine was operated with synthetic fuel from the start.
2.5.4 Non-Road Fuels
Other non-road fuels may be used if they comply with all the limit values of EN 590 except for the fuel
density, the cetane number and the sulfur content.
The following limits apply for these parameters:
2.5
FUEL PARAMETER
UNIT
LIMIT VALUE
Cetane number
Min. 49
Fuel density at 15°C
Kg/m 3
820 - 860
Sulfur content
mg/kg or ppm
max. 500
2.5.5 Jet Fuels
Only for KDI Mechanical Injection Uncertified Engines (no EGR Engines).
The following jet fuels can be used but only adopting an additional fuel filter with lubricity doser:
2.6
FUEL
F-34/F-35 (kerosene, NATO designation)
JP-8 (kerosene, US military
designation)
F-44 (kerosene, NATO designation
JP-5 (kerosene, US military
designation)
F-63 (kerosene, NATO designation, equivalent to F-34/F-35 with
additives)
Jet A (kerosene for civil aviation)
F-65 (kerosene, NATO designation, 1:1 mixture of F-54 and F-34/F-
35)
Jet A1 (kerosene for civil aviation)
2.5.6 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.

TECHNICAL INFORMATION 2
19 EN
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.
2.6 Coolant recommendation
A mixture of 50% demineralized water and 50% low silicate ethylene glycol based coolant liquid must be
used. Use a Long Life or Extended Life Heavy Duty OAT coolant free of: silicates, phosphates, borates,
nitrites and amines.
The following ethylene-glycol based engine coolant for all models within KDI engine family may be used:
•OAT (Organic Acid Technology) Low Silicate: ASTM D-3306 D-6210
•HOAT (Hybrid Organic Acid Technology) Low Silicate: ASTM D-3306 D-6210
The above coolants in concentrated formulation must be mixed with distilled, deionized, or demineralized
water. A pre-mixed formulation (40-60% or 50-50%) can be used directly when available.
Important
•Do not mix ethylene glycol and propylene glycol based coolants. Do not mix OAT and HOAT based
coolant. OAT performance life can be drastically reduced if contaminated with nitrite-containing
coolants.
•Never use automotive-type coolants. These coolants do not contain the correct additives to protect
heavy – duty diesel engines.
OAT coolants are maintenance free up to 6 years or 6000hrs of operation, provided that the cooling system
is topped up using the same type of coolant. Do not mix different coolant types. Test the coolant condition
annually with coolant test strips.
HOAT are not all maintenance free and it is recommended to have SCA (Supplemental Coolant Additives)
added at the first maintenance interval.
2.7 Battery recommendation
Battery not supplied by Kohler
Tab. 2.7
RECOMMENDED BATTERIES
AMBIENT TEMPERATURE
BATTERY TYPE
>- 15°C
12V 100 Ah - 800 CCA/SAE
-15°C ÷ -25°C
12V 110 Ah - 950 CCA/SAE
< -25°C
12V 120 Ah - 1000 CCA/SAE

2TECHNICAL INFORMATION
EN 20
2.8 Periodic maintenance
The intervals of preventive maintenance in Tab. 2.8, Tab. 2.9, Tab. 2.10 and Tab. 2.11 refer to the engine
operating under normal operating conditions with fuel and oil meeting the recommended specifications.
2.8
CLEANING AND CHECKING
OPERATION DESCRIPTION
PERIOD (HOURS)
100
250
500
5000
Engine oil level (8)
Coolant level (8) (9)
Water presence in fuel filter
Cartridge dry-type air filter (2)
Radiator heat-exchange surface and Intercooler (2) (8)
Standard alternator belt (8)
Poly-V alternator belt (8)
Rubber hose (intake air / coolant)
Fuel hose
Starter Motor
Alternator
2.9
REPLACEMENT
OPERATION DESCRIPTION
PERIOD (HOURS)
500
2000
5000
Cartridge dry-type air filter (2)
Intake manifold hose (air filter - intake manifold) (7)
Coolant hoses
(7)
Fuel line hose (7)
Alternator belt
Standard alternator belt (trapezoidal)
(3)
Poly-V belt heavy environmental condition
Poly-V belt standard condition
Coolant
OAT
HOAT (10)