Kohler KDI 2504TM User manual

Internal Communication: For internal & partner use only.
KDI 2504TM
OWNER MANUAL

INDEX
EN
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 ED005303-026 10.1 10/2014 02/2023 C. ACCOTI V. MANINI
Translated from the original manual in Italian language.
Data reported in this issue can be modified at any time by KOHLER.
Important
The latest version of this manual is available on the i-Service website, connect to the following link
https://iservice.lombardini.it
, before downloading the manual, you can select the desired language from the top bar of the
site as shown in the figure below.

INDEX
[Titolo] EN
Internal Communication: For internal & partner use only.
1General Information .............................................................................................................. 5
1.1 Manual's Purpose ............................................................................................................................ 5
1.2 Glossary and Definitions ................................................................................................................. 5
1.3 Emission-Related Installation Instructions ................................................................................... 6
1.4 Service request................................................................................................................................. 6
1.5 Engine component identification ................................................................................................... 7
1.6 Manufacturer and engine identification ........................................................................................ 8
2Technical information ........................................................................................................... 9
2.1 General description of the engine.................................................................................................. 9
2.2 Engine specifications ...................................................................................................................... 9
2.3 Engine dimensions (mm) ............................................................................................................... 10
2.4 Oil..................................................................................................................................................... 10
2.5 Fuel .................................................................................................................................................. 12
2.6 Coolant recommendation.............................................................................................................. 14
2.7 Battery recommendation .............................................................................................................. 14
3Safety information ............................................................................................................... 15
3.1 Safety information.......................................................................................................................... 15
3.2 General remarks............................................................................................................................. 15
3.3 Safety signal description............................................................................................................... 18
3.4 Information and safety signals ..................................................................................................... 20
3.5 Safety and environmental impact ................................................................................................ 22
3.6 Location of safety labels on engine ............................................................................................. 23
4Information about use......................................................................................................... 24
4.1 Pre-start check............................................................................................................................... 24
4.2 Running-in period .......................................................................................................................... 24
4.3 Starting and turning off................................................................................................................. 24
4.4 Refuelling ........................................................................................................................................ 25
4.5 Oil filling .......................................................................................................................................... 26
4.6 Coolant filling.................................................................................................................................. 26
5Information about maintenance ......................................................................................... 28
5.1 Useful information about maintenance....................................................................................... 28
5.2 Periodic maintenance.................................................................................................................... 29
5.3 Oil level check................................................................................................................................. 30
5.4 Oil dipstick on cylinder head......................................................................................................... 31
5.5 Air filter check ................................................................................................................................ 31
5.6 Check of the radiator heat - exchanger surface ........................................................................ 31
5.7 Rubber hoses check ...................................................................................................................... 32
5.8 Check coolant level........................................................................................................................ 33

INDEX
EN
5.9 Check and setting alternator standard belt tension .................................................................. 33
5.10 Check Poly-V alternator belt......................................................................................................... 35
5.11 Check fuel filter cartridge ............................................................................................................. 35
5.12 Product preservation ..................................................................................................................... 36
5.13 Engine storage up to 6 months .................................................................................................... 36
5.14 Engine storage over 6 months...................................................................................................... 36
5.15 Engine starting after storage........................................................................................................ 37
6Information about replacements ........................................................................................ 38
6.1 Engine oil replacement.................................................................................................................. 38
6.2Oil filter cartridge replacement .................................................................................................... 39
6.3 Fuel filter cartridge replacement.................................................................................................. 40
6.4 Air filter cartridge replacement .................................................................................................... 41
6.5 Disposal and scrapping ................................................................................................................. 41
7Information about failures .................................................................................................. 42
7.1 Useful information about failures................................................................................................. 42
8Information about warranty ................................................................................................ 44
8.1 Warranty terms............................................................................................................................... 44
9Glossary............................................................................................................................... 48
9.1 Glossary and Definitions ............................................................................................................... 48

GENERAL INFORMATION
1
5 EN
Internal Communication: For internal & partner use only.
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 table 4.
•Fig. 5.5 - chapter 5 figure 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.

1GENERAL INFORMATION
EN 6
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:Errore. Riferimento a collegamento ipertestuale non valido. &
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).

GENERAL INFORMATION
1
7 EN
Internal Communication: For internal & partner use only.
1.5 Engine component identification

1GENERAL INFORMATION
EN 8
1.6 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

TECHNICAL INFORMATION
2
9 EN
Internal Communication: For internal & partner use only.
2TECHNICAL INFORMATION
2.1 General description of the engine
•4-stroke, in-line cylinders Diesel engine;
•Liquid-cooling system;
•valves per cylinder with hydraulic tappets;
•Direct Injection.
2.2 Engine specifications
Tab. 2.1
TECHNICAL DATA UNIT OF
MEASURE
Engine type
KDI 2504 TM
Cylinders
n.
4
Bore
mm
88
Stroke
mm
102
Displacement
cm
3
2482
MAX INCLINATION DURING OPERATION (even in
combined)
α
30° max 30 min
α
35° max 1 min
OIL CAPACITY (MAX level.) including oil
filter
standard
version lt. 11.5
DRY WEIGHT
300

2TECHNICAL INFORMATION
EN 10
2.3 Engine dimensions (mm)
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.

TECHNICAL INFORMATION
2
11 EN
Internal Communication: For internal & partner use only.
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.

2TECHNICAL INFORMATION
EN 12
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.
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.
•Any failure resulting from the use of fuel other than Tab. 2.3,
2.4 will not be covered by warranty.
Cetane number of 40 minimum. Cetane number greater than 47 is preferred, especially for
temperatures below –20 °C (–4 °F) or elevations above 1675 m (5500 ft.).
2.3
Fuel Type
|
|
V
Certification
Remarks
EU
Stage
Tier
(USA)
no
certificatio
n (*1)
*1: the regions known as poor lubricity diesel fuel
quality or if the engine is operated with Jet fuels,
the primary filter must be with lubricity dosing
capability. Contact Kohler for information about
the approved filter for this purpose.
5 3A III
HVO
100% (EN
15940)
Power and torque might be 1% to 5% lower due to
low fuel density compared to standard diesel fuel.
Military NATO
Fuel F-
54 (S =
10 ppm)
JIS K 2204
No.1, No.2
(EN 590 - DIN
51628)
Do NOT USE vegetable oils as a biofuel not compliant
with EN590 prescription.
Grade 1-D
S15 For ambient temperatures below 0°C (32°F) with no
arctic fuel available (Grade 1-D S15, Grade 2-D S15,
ASTM D 975) use the following additives to prevent
possible engine damage with low engine load in cold
weather:
Power Service Diesel Fuel Supplement+Cetane Boost
Different additives are not allowed.
The use of approved additives has no impact on the
engine maintenance schedule.
Do NOT USE vegetable oils as a biofuel not compliant
with ASTM D975 Grade1 and Grade2 prescription.
Grade 2-D
S15

TECHNICAL INFORMATION
2
13 EN
Internal Communication: For internal & partner use only.
Fuel Type
|
|
V
Certification Remarks
EU
Stage
Tier
(USA)
non
certificati
(*1)
*1: the regions known as poor lubricity diesel fuel
quality or if the engine is operated with Jet fuels,
the primary filter must be with lubricity dosing
capability. Contact Kohler for information about
the approved filter for this purpose.
53A III
Sulphur Fuel
S < 500 ppm
High Sulphur
Fuel S < 2000
ppm
F-34/F-35
(kerosene,
NATO
designation)
Operations with Jet Fuels
The jet fuels can be used but only adopting an
additional fuel filter with lubricity doser.
Because of lower density and greater leak fuel volume
due to lower viscosity, depending on the engine
speed and torque, a power loss up to 10% is
possible.
There are some problematical fuel proprieties
amongst the listed jet fuels (viscosity, lubricating
capacities and low boiling point). A slight increase in
wear in the injection system is to be expected which
can lead to a statistically shorter life of these
components. Sulphur content must be below
2000ppm.
F-44
(kerosene,
NATO
designation)
F-63
(kerosene,
NATO
designation,
equivalent to
F-34/F-35
with
additives)
JP-8
(kerosene, US
military
designation)
JP-5
(kerosene, US
military
designation)
Jet A
(kerosene for
civil aviation)
Jet A1
(kerosene for
civil aviation)
2.4
FUEL ADDITIVES
Remarks
Fuel additives with biocide/algaecide functions only are allowed in
case of storage of fuel in the tank for long periods (one year or more).
For suggested brands and
types contact Kohler staff
These additives must be diluted in the fuel following the product
prescribed percentages when filling the tank.
Additives with functions other than biocide / algaecide are not al-
lowed..

2TECHNICAL INFORMATION
EN 14
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

SAFETY INFORMATION
3
15 EN
Internal Communication: For internal & partner use only.
3SAFETY INFORMATION
3.1 Safety information
•
The intended use of the engine is in conformity with the machine on which it is mounted.
•Any use of the machine other than that described cannot be considered as complying with its
intended purpose as specified by KOHLER .
•KOHLER declines all responsibility for any change to the engine not described in this manual
made by unauthorized KOHLER personnel.
•A proper use of the engine, a strict observance of the rules listed below and the rigorous
application of all these precautions will avoid the risk of accidents or injuries.
•Those who carry out the use and maintenance on the engine must wear the safety equipment
and the accident-prevention guards.
•KOHLER declines all direct and indirect liability for failure to comply with the standards of
conduct contained in this manual.
•KOHLER cannot consider every reasonably unforeseeable misuse that may cause a potential
danger.
3.2 General remarks
3.2.1 Note for OEM
•When installing the KDI engines, always bear in mind that any variation to the functional systems
may result in serious failures to the engine.
•Any improvement must be verified at KOHLER testing laboratories before application of the engine.
•In case the approval to a modification is not granted, KOHLER shall not be deemed responsible for
any consequential failures or damages to the engine.
•Those who carry out the use and maintenance on the engine must wear the safety equipment and
the accident-prevention guards.
•KOHLER declines all direct and indirect liability for failure to comply with the standards of conduct
contained in this manual.
•KOHLER cannot consider every reasonably unforeseeable misuse that may cause a potential
danger.
3.2.2 Note for end user
•The following indications are dedicated to the user of the machine in order to reduce or eliminate
risks concerning engine operation and the relative routine maintenance work.
•The user must read these instructions carefully. Failure to do this could lead to serious danger for
his personal safety and health and that of any persons who may be in the vicinity of the machine.
•On starting, make sure that the engine is as horizontal as possible, unless the machine
specifications differ.
•Make sure that the machine is stable to prevent the risk of overturning.
•The engine must not operate in places containing inflammable materials, in explosive atmospheres,
where there is dust that can easily catch fire unless specific, adequate and clearly indicated
precautions have been taken and have been certified for the machine.
•To prevent fire hazards, always keep the machine at least one meter from buildings or from other
machinery.
•Children and animals must be kept at a due distance from operating machines in order to prevent
hazards deriving from their operation.
•Thoroughly wash and clean all the external parts of the engine before performing any operation, in
order to avoid the accidental introduction of impurities/foreign bodies. Use only water and/or
appropriate products to clean the engine. 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

3SAFETY INFORMATION
EN 16
be washed and the nozzle. Avoid directing the nozzle on electrical components, cable connections
and sealed rings (oil seals etc). Thoroughly wash and clean the area surrounding the engine
following the instructions provided by machine manufacturer.
•Fuel and oil are inflammable. The tank must only be filled when the engine is off. Before starting, dry
any spilt fuel.
•Make sure that no soundproofing panels and the ground or floor on which the machine is standing
have not soaked up any fuel.
•Fuel vapour is highly toxic. Only refuel outdoors or in a well ventilated place
•Do not smoke or use open flames when refuelling.
•During operation, the surface of the engine can become dangerously hot. Avoid touching the
exhaust system in particular.
•Before proceeding with any operation on the engine, stop it and allow it to cool.
•Always open the radiator plug or expansion chamber with the utmost caution, wearing protective
garments and goggles.
•The coolant fluid is under pressure. Never carry out any inspections until the engine has cooled.
•If there is an electric fan, do not approach the engine when it is still hot as the fan could also start
operating when the engine is at a standstill.
•The oil must be drained whilst the engine is hot. Particular care is required to prevent burns. Do not
allow oil to come into contact with the skin because of the health hazards involved. It is
recommended to use an oil intake pump.
•During operations that involve access to moving parts of the engine and/or removal of rotating
guards, disconnect and insulate the negative wire (-) of the battery to prevent accidental short-
circuits and to stop the starter motor from being energized.
•Check belt tension only when the engine is off.
•Fully tighten the tank cap each time after refuelling. Do not fill the tank right to the top but leave an
adequate space for the fuel to expand.
•To start the engine follow the specific instructions provided in the engine and/or machine operating
manual. Do not use auxiliary starting devices not originally installed on the machine (e.g. Startpilot).
•Before starting, remove any tools that were used to service the engine and/or machine. Make sure
that all guards have been refitted.
•Do not mix fuel with elements such as oil or kerosene. Failure to comply with this prohibition will
cause the non-operation of the catalyst and non-observance of the emissions declared by
KOHLER .
•Pay attention to the temperature of the oil filter when the filter itself is replaced.
•Only check, top up and change the coolant fluid when the engine is off and reached the ambient
temperature. Coolant fluid is polluting, it must therefore be disposed of in the correct way.
•Do not use air and water jets at high pressures on cables, connectors and injectors.

SAFETY INFORMATION
3
17 EN
Internal Communication: For internal & partner use only.
Important
•Only use the eyebolts Ainstalled by KOHLER to move the engine (Fig. 3.1).
•The angle between each lifting chain and the eyebolts shall not exceed 15° inwards.
•The correct tightening of the lifting screws is 25Nm.
•Do not interpose spacers or washers between the eyebolts and engine head.
•Provided that the above requirements are met, if the lifting eyebolts are subject to permanent
deformation (inwards), all subsequent lifting operations must be performed in order to prevent them
from bending in the opposite direction.
Fig 3.1

3SAFETY INFORMATION
EN 18
3.3 Safety signal description
•
To ensure safe operation please read the following statements and understand their meaning.
•Also refer to your equipment manufacturer's manual for other important safety information.
•This manual contains safety precautions which are explained below.
•Please read them carefully.
Adhesive safety plates
The following is a list of the adhesive safety plates that may be found on the engine, which indicate
potential points of danger to the operator.
Read the Operation and Maintenance handbook before performing any operation on
the engine.
Hot Parts.
Danger of burns.
Presence of rotating parts.
Danger of jamming or cutting.
Presence of explosive fuel.
Danger of fire or explosion.
Presence of steam and pressurized coolant.
Danger of burns.

SAFETY INFORMATION
3
19 EN
Internal Communication: For internal & partner use only.
Warnings
Hereunder is a list of safety warnings that may be found in the manual, which advise you to pay
attention when carrying out particular procedures that may be potentially dangerous to the operator
or things.
Danger
This indicates situations of grave danger which, if ignored, may seriously threaten the
health and safety of individuals.
Important
This indicates particularly important technical information that should not be ignored.
Warning
This indicates that failure to comply with it can cause minor damage or injury.
Safety guards Hereunder is a list of safety guards that must be worn prior to carrying out any type
of operation and to avoid potential
harm to the operator.
Use suitable protective gloves before carrying out any type of operation.
Use protective goggles before carrying out any type of operation.
Use earmuffs before carrying out any type of operation.

3SAFETY INFORMATION
EN 20
3.4 Information and safety signals
ACCIDENTAL START
Accidental Starts can cause
severe injury or death.
Before working on the engine or equipment,
disconnect the battery negative (-) wire.
HOT PARTS
Hot Parts can cause severe
burns.
Engine components can get extremely hot
from operation. Do not touch engine while
operating or just after stopping.
Never operate the engine with heat shields or
guards removed.
ROTATING PARTS
Rotating Parts can cause
severe injury.
Stay away while engine is in operation. Keep
hands, feet, hair, and clothing away from all
moving parts to prevent injury.
Never operate the engine with covers,
shrouds, or guards removed.
LETHAL EXHAUST GASES
HIGH PRESSURE FLUID RISK OF
PUNCTURE
High Pressure Fluids can
puncture skin and cause severe
injury or death.
Do not work on fuel system without proper
training or safety equipment. Fluid puncture
injuries are highly toxic and hazardous.
If an injury occurs, seek immediate medical
attention.
EXPLOSIVE FUEL
Explosive fuel can cause fires
and severe burns.
Fuel is flammable and its vapours can ignite.
Store fuel only in approved containers, in well
ventilated, unoccupied buildings. Do not fill the
fuel tank while the engine is hot or running,
since spilled fuel could ignite if it comes in
contact with hot parts or sparks from ignition.
Do not start the engine near spilled fuel.
Never use fuel as a cleaning agent.
EXPLOSIVE GAS
Explosive Gas can cause fires
and severe acid burns.
Charge battery only in a well ventilated area.
Keep sparks, open flames, and other sources
of ignition away from the battery at all times.
Batteries produce explosive hydrogen gas
while being charged.
Keep batteries out of the reach of children.