Kohler Kdi 2504tm User manual

KDI 2504TM

OWNER MANUAL

TP-6970 5/20

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REGISTRATION OF MODIFICATIONS TO THE DOCUMENT

Any modiﬁcations to this document must be registered by the drafting body, by completing the following table.

The online manuals are provided with hyperlinks which direct you to each individual chapter. By clicking on;

-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.

-Clicking next to the bottom page number you come back to the analytic index.

Translated from the original manual in Italian language.

Data reported in this issue can be modiﬁed at any time by KOHLER.

Released by Document code Model

N° Edition Revision Issue date Review

date Edited by Endorsed

Technical

Documentation ED0053030260 51343 7 8.1 10/2014 05/2020 Technical

Documentation

Important

Connect to http://iservice.lombardini.it and download the latest version of this manual onto your device.

NOTE: you can select the desired language before downloading the manual, as shown in the ﬁgure below.

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INDEX

1 - GENERAL INFORMATION

1.1 Manual's Purpose............................................................6

1.2 Glossary and Deﬁnitions................................................6

1.3 Emission-Related Installation Instructions..................6

1.4 Service request ...............................................................6

1.5 Engine component identiﬁcation..................................7

1.6 Manufacturer and motor identiﬁcation data ...............8

2 - TECHNICAL INFORMATION

2.1 General description of the engine ..............................10

2.2 Engine speciﬁcations...................................................10

2.3 Engine dimensions (mm)..............................................10

2.4 Oil.................................................................................... 11

2.4.1 SAE oil classiﬁcation .................................................11

2.5 Fuel .................................................................................12

2.5.1 Fuel for low temperatures.........................................13

2.5.2 Biodiesel fuel .............................................................13

2.5.3 Synthetic fuels: GTL, CTL, BTL, HV.........................13

2.5.4 Non-Road Fuels .........................................................13

2.5.5 Emission-Related Installation Instructions ............13

2.6 Coolant recommendation ............................................14

2.7 Battery recommendation.............................................14

3 - SAFETY INFORMATION

3.1 Safety information ........................................................15

3.2 General remarks ...........................................................15

3.2.1 Note for OEM..............................................................15

3.2.2 Note for end user.......................................................15

3.3 Safety signal description .............................................17

3.3.1 Adhesive safety plates ..............................................17

3.3.2 Warnings.....................................................................17

3.3.3 Safety guards.............................................................17

3.4 Information and safety signals....................................18

3.5 Safety and environmental impact...............................18

3.6 Location of safety labels on engine ............................19

4 - INFORMATION ABOUT USE

4.1 Pre-start check .............................................................20

4.2 Running-in period.........................................................20

4.3 Starting and turning off ...............................................20

4.3.1 Star ting .......................................................................20

4.3.2 After starting..............................................................20

4.3.3 Turning off ..................................................................20

4.4 Refuelling.......................................................................21

4.5 Oil ﬁlling .........................................................................21

4.6 Coolant ﬁlling ................................................................22

5 - INFORMATION ABOUT MAINTENANCE

5.1 Useful information about maintenance......................23

5.2 Periodic maintenance ..................................................23

5.3 Oil level check ...............................................................24

5.4 Oil dipstick on cylinder head .......................................24

5.4 Air ﬁlter check...............................................................24

5.5 Check of the radiator heat - exchanger surface .......25

5.6 Rubber hoses check .....................................................25

5.7 Check coolant level.......................................................26

5.9 Check and setting alternator standard belt tension 26

5.9.1 Check ..........................................................................27

5.9.2 Adjustment .................................................................27

5.10 Check Poly-V alternator belt......................................28

5.11 Control water ﬁlter cartridge fuel..............................28

5.12 Product preservation..................................................29

5.13 Engine storage up to 6 months .................................29

5.14 Engine storage over 6 months...................................29

5.15 Engine starting after storage ....................................29

5.16 Unused machine .........................................................29

5.16.1 Operations for the engine .......................................29

6 - INFORMATION ABOUT REPLACEMENTS

6.1 Engine oil replacement ................................................30

6.2 Oil ﬁlter cartridge replacement...................................31

6.3 Filter cartridge and fuel check ....................................32

6.4 Air ﬁlter cartridge replacement ..................................32

6.5 Disposal and scrapping................................................33

7 - INFORMATION ABOUT FAILURES

7.1 Useful information about failures................................34

8 - INFORMATION ABOUT WARRANTY

Warranty terms..............................................................35

9 - GLOSSARY

9.1 Glossary .........................................................................38

Symbols and units of measurement ...........................40

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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.

GENERAL INFORMATION

1.2 Glossary and Deﬁnitions

The paragraphs, tables and gure are divided into chapter with their progressive numbers.

Ex: Par. 2.3 - chapter 2 paragraph 3.

Tab. 3.4 - chapter 3 table 4.

Fig. 5.5 - chapter 5 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.

NOTE: All data, measurements and relevant symbols are shown in the glossary section.

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).

1.3 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.

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Index

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GENERAL INFORMATION

1.5 Engine component identiﬁcation

SIDE VIEWA

SIDE VIEW B

Thermostat

Coolant

sensor

Oil filler cap

Coolant pump

Alternator

Starter motor

Oil pressure sensor

Turbocharger

Oil steam separator

Oil drain plug

Fuel lter

Oil cooler

Injection pump

Oil lter

Nameplate

Oil drain plug

Oil dipstick

Oil filler cap

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GENERAL INFORMATION

1.6 Manufacturer and motor identiﬁcation 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 VIEWA SIDE VIEW B

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735

734.4

2.1

TECHNICAL INFORMATION

EN

2.1 General description of the engine

-4-stroke, in-line cylinders Diesel engine;

-Liquid-cooling system;

-4 valves per cylinder with hydraulic tappets;

-Turbocharger with Waste-gate valve;

-Common Rail - Direct injection.

2.2 Engine speciﬁcations

TECHNICAL DATA UNIT

OF MEASURE

Engine type KDI 2504 TM

cylinders n. 4

bore mm 88

stroke mm 102

displacement cm32482

max inclination during operation

(even in combined)

degree 30° max. 30 minutes

degree 35° max.1 minute

oil capacity (MAX

level.)

including oil ﬁlter

standard version

lt.

11.5

with balancer device 9

dry weight Kg 300

2.3 Engine dimensions (mm)

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Index

Kohler KDI 2504TM User manual

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