Kohler KDI Series Instruction manual

KDI 1903 TCR - KDI 2504 TCR
WORKSHOP MANUAL
TP-6916 04/16

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Ente
compilatore Codice
documento Edizione Data emissione Data
revisione
Revisione
Modello
n° Visto
Redatto
DICOM/ATLO 04/20168 7 10/2013
ED0053029590
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
ED0053029590 51273
TRANSLATED FROM THE ORIGINAL MANUAL IN ITALIAN LANGUAGE.
Data reported in this issue can be modied at any time by KOHLER.
Important
•Connect to http://iservice.lombardini.it > KDI KOHLER DIESEL section > "TECHNICAL DOCUMENTATION"
> select "KDI 1903 TCR" or "KDI 2504 TCR" 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 gure below.

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INDEX
1GENERAL INFORMATION 12
1.1 Useful information 12
1.2 Manufacturer and engine identication 13
1.3 Name plate for EPA regulations 14
1.4 Identication of main internal components of the engine and operating references 15
1.5 Identication of external components of the engine 17
2 TECHNICAL INFORMATION 19
2.1 Engine specications 19
2.2 Engine dimensions (mm) 21
2.3 Performance diagrams 22
2.4 Oil 23
2.4.1 SAE classication 23
2.4.2 International lubricant specications 23
2.5 Fuel 24
2.5.1 Fuel for low temperatures 24
2.5.2 Biodiesel fuel 24
2.5.3 Emissions - Regarding installation instructions 25
2.6 Coolant 25
2.7 Battery features 25
2.8 Scheduled maintenance 26
2.9 Fuel system 27
2.9.1 Injection circuit (2000 bar) 27
2.9.2 Fuel return circuit 28
2.9.3 High-pressure injection pump (2000 bar) 29
2.9.4 Electronic injector 30
2.9.5 Common rail 31
2.9.6 Fuel lter 32
2.9.7 Electric fuel pump (optional) 33
2.9.8 Guards for fuel injection circuit components 34
2.10 Lubrication circuit 35
2.10.1 Lubrication circuit diagram 35
2.10.2 Oil pump 36
2.10.3 Lub. oil lter and Oil Cooler 37
2.11 Coolant circuit 38
2.11.1 Coolant circuit diagram 38
2.11.2 Coolant pump 39
2.11.3 Radiator with intercooler (optional) 39
2.11.4 Thermostatic valve 39
2.11.5 EGR gas circuit cooling (EGR Cooler) 39
2.12 Intake and exhaust circuit 40
2.12.1 Turbocharger 40
2.12.2 Catalyst (optional) 40
2.12.3 Intake and exhaust circuit diagram with EGR 41
2.12.4 Air cleaner (optional) 42
2.13 Electric system 43
2.13.1 ECU input and output signals diagram 43
2.13.2 Control unit (ECU) 44
2.13.2.1 Installation rules 44
2.13.3 Engine electrical wiring 45
2.13.3.1 Wiring disconnection 46
2.14 Sensors and switches 48
2.14.1 Speed sensor on phonic wheel 48
2.14.2 Phase sensor indicator on camshaft 48
2.14.3 T-MAP sensor 48
2.14.4 Common Rail pressure sensor 48
2.14.5 Fuel lter water detection sensor 49
2.14.6 Fuel temperature sensor on fuel injection pump 49
2.14.7 Oil pressure switch 49
2.14.8 Coolant temperature sensor 49
2.14.9 Air cleaner clogging switch 50

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INDEX
2.15 Electrical components 50
2.15.1 Alternator 50
2.15.2 Poly-V belt alternator (optional) 50
2.15.3 Starter Motor 50
2.15.4 EGR valve 51
2.15.5 Cold starting device 51
2.15.6 Fuel intake regulating valve (SCV) 51
2.15.7 Electric fuel pump (optional) 52
2.16 Timing system and tappets 53
2.16.1 Components identication 53
2.16.2 Timing system phasing angles 54
2.16.3 Rocker arm gudgeon 54
2.16.4 Rocker arm 54
2.16.5 Hydraulic tappets 55
2.16.5.1 Hydraulic tappet operation 55
2.16.5.2 Difcult operating conditions 55
2.17 Balancer device 56
2.18 Components handling 57
2.18.1 High-pressure fuel injection pump 57
2.18.2 Electronic injector 57
2.18.3 Common Rail 57
2.18.4 Turbocharger 57
2.19 Turbocharger 58
2.19.1 What to do and what not to do 58
2.19.2 Practical operating rules 58
2.19.3 Before installing a new turbocharger 59
2.19.4 Installation instructions 60
2.19.5 Replacement instructions 60
3SAFETY INFORMATION 61
3.1 Pre-start check 61
3.2 Safety precautions 61
3.3 General remarks 61
3.3.1 Manufacturer's notes 61
3.3.2 Notes for the end user 61
3.4 Safety label description 63
3.4.1 Adhesive safety plates 63
3.4.2 Warnings 63
3.4.3 Safety guards 63
3.5 Information and safety labels 64
3.6 Safety and environmental impact 64
3.7 Location of safety labels on engine 65
4STORAGE INFORMATION 67
4.1 Product preservation 67
4.2 Engine storage (up to 6 months) 67
4.3 Engine storage (over 6 months) 67
4.4 Engine starting after storage 67
5LIQUID DRAINAGE INFORMATION 69
5.1 Coolant liquid 69
5.2 Engine oil 70
6INFORMATION FOR REPLACING FUNCTIONAL UNITS 71
6.1 Electronic injector replacement 71
6.1.1 Fuel return tubes disassembly (Common Rail/electronic injectors) 71
6.1.2 High pressure fuel tubes disassembly (Common Rail/electronic injectors) 72
6.1.3 Electronic injector disassembly 72
6.1.4 Electronic injector assembly 72
6.1.5 High-pressure fuel lines assembly 73
6.1.6 Fuel return tubes assembly 73

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INDEX
6.2 High-pressure fuel injection pump replacement 74
6.2.1 High pressure fuel tube disassembly (from injection pump to Common Rail) 74
6.2.2 Timing system carter oil lling ange disassembly 75
6.2.3 High-pressure fuel injection pump disassembly 75
6.2.4 High-pressure fuel injection pump assembly 76
6.2.5 High-pressure line assembly (injection pump / Common Rail) 77
6.2.6 Timing system carter oil lling ange assembly 77
6.3 EGR cooler unit replacement 78
6.3.1 Disassembly 78
6.3.2 Assembly 78
6.4 EGR valve replacement 79
6.4.1 Disassembly 79
6.4.2 Assembly 79
6.5 Coolant pump replacement 80
6.5.1 Disassembly 80
6.5.2 Assembly 81
6.6 Target wheel replacement 81
6.6.1 Disassembly 81
6.6.2 Assembly 83
6.7 Oil pump replacement 83
6.7.1 Coolant pump disassembly 83
6.7.2 Crankshaft and phonic wheel pulley disassembly 83
6.7.3 Timing system carter disassembly 83
6.7.4 Oil pump disassembly 83
6.7.5 Oil pump assembly 84
6.7.6 Timing system carter assembly 84
6.7.7 CRANKSHAFT AND PHONIC WHEEL PULLEY ASSEMBLY 85
6.7.8 Coolant pump assembly 86
6.8 Oil pressure valve replacement 86
6.8.1 Disassembly 86
6.8.2 Assembly 86
6.9 Oil steam separator replacement 87
6.9.1 Disassembly 87
6.9.2 Assembly 87
6.10 Oil Cooler Unit and lub. oil lter replacement 88
6.10.1 Oil Cooler unit disassembly 88
6.10.2 Oil lter cartridge replacement 88
6.10.3 Oil Cooler unit assembly 89
6.11 Fuel lter replacement 90
6.11.1 Disassembly 90
6.11.2 Assembly 90
7 INFORMATION FOR DISASSEMBLY 92
7.1 Recommendations for disassembly 92
7.2 EGR circuit disassembly 92
7.2.1 EGR Cooler Unit 92
7.2.2 EGR Valve 93
7.3 Electric components disassembly 93
7.3.1 Electric wiring 93
7.3.2 Starter motor 94
7.3.3 Belt and alternator 95
7.3.4 Sensors and switches 95
7.3.4.1 Oil pressure switch 95
7.3.4.2 Coolant temperature sensor 95
7.3.4.3 Speed sensor 95
7.3.4.4 Camshaft phase sensor 96
7.3.4.5 T-MAP sensor 96
7.3.4.6 Fuel lter water detection sensor 96
7.4 Turbocharger disassembly 96
7.5 Exhaust manifold disassembly 97
7.6 Coolant recirculation components disassembly 97
7.6.1 Oil Cooler manifold 97
7.6.2 Coolant pump 98
7.6.3 Thermostatic valve 98

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INDEX
7.7 Crankshaft and target wheel pulley disassembly 99
7.8 Lubrication circuit disassembly 99
7.8.1 Oil pressure valve 99
7.8.2 Timing system carter oil lling cover 99
7.8.3 Timing system carter 99
7.8.4 Oil pump 100
7.8.5 Oil Cooler Unit and lub. oil lter 100
7.8.6 Oil steam separator unit 101
7.9 Intake manifold disassembly 101
7.10 Fuel system disassembly 102
7.10.1 Fuel return tubes 102
7.10.2 Fuel ow tubes 102
7.10.3 High-pressure fuel lines 102
7.10.4 Common rail 103
7.10.5 Electronic injectors 103
7.10.6 Fuel lter 103
7.10.7 High-pressure fuel injection pump 104
7.11 Timing system gear disassembly 104
7.12 Flange unit disassembly 105
7.12.1 Flywheel 105
7.12.2 Flange bell 105
7.13 Cylinder head unit disassembly 105
7.13.1 Rocker arm cover 105
7.13.2 Rocker arm gudgeon 106
7.13.2.1 Rocker arms 106
7.13.3 Valve rods and bridges 106
7.13.4 Cylinder head 107
7.13.4.1 Valves 107
7.13.4.2 Electronic injector sleeves 108
7.13.4.3 Valve stem gasket 108
7.13.4.4 Lifting eyebolts 108
7.14 Oil sump unit disassembly 109
7.14.1 Oil sump 109
7.14.2 Oil suction pipe 109
7.14.3 Oil steam tube 109
7.15 Short block disassembly 110
7.15.1 Crankshaft gasket ange 110
7.15.2 Piston unit / connecting rod and crankshaft 110
7.15.3 Lower crankcase 111
7.15.4 Crankshaft 112
7.15.5 Piston 112
7.15.5.1 Rings 113
7.15.6 Oil spray nozzles 113
7.15.7 Camshaft 113
7.15.8 Camshaft tappets 113
7.15.9 Crankshaft bushings 114
7.15.10 3rd PTO cover 114
8INFORMATION ABOUT OVERHAULING AND TUNING 116
8.1 Recommendations for overhauls and tuning 116
8.2 Crankcase 116
8.2.1 Oil tubes check 116
8.2.2 Cylinders Check 117
8.2.3 4-cylinder camshaft housing check 118
8.2.4 4-cylinder camshaft check 118
8.2.5 3-cylinder camshaft housing check 119
8.2.6 3-cylinder camshaft check 119
8.3 Tappets and tappet housings 120
8.3.1 Tappets check 120
8.3.2 Tappet housing check 120
8.4 Crankshaft 121
8.4.1 Dimensional check and overhauling 121
8.4.2 Check the axial clearance of the crankshaft 122

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INDEX
8.5 Connecting rod-piston 122
8.5.1 Connecting rod dimension check 122
8.5.2 Checking the gudgeon pin-pin axes are parallel 123
8.5.3 Piston rings check 123
8.5.4 Piston dimension check 123
8.6 Cylinder head 124
8.6.1 Flatness check 124
8.6.2 Valve seats check 125
8.6.3 Valve springs 125
8.6.4 Valve guides check 125
8.6.5 Valve guides replacement 126
8.6.6 Rocker arm check 126
8.7 Oil pump check 127
8.7.1 Dimensional and visual check 127
8.7.2 Rotors clearance check 127
8.7.3 Oil pressure valve check 128
9ASSEMBLY INFORMATION 129
9.1 Information on engine conguration 129
9.2 Assembly recommendations 129
9.3 Short block assembly 130
9.3.1 Crankshaft bushings 130
9.3.2 Tappets 130
9.3.3 Camshaft 130
9.3.4 Oil spray nozzles 131
9.3.5 Crankshaft 131
9.3.6 Lower crankcases 131
9.3.7 Rings 133
9.3.8 Piston 133
9.3.9 Piston and connecting rod unit 134
9.3.10 Crankshaft oil seal ange 136
9.3.11 3rd PTO cover 136
9.4 Oil sump unit assembly 137
9.4.1 Oil vapour pipes 137
9.4.2 Oil suction pipe 137
9.4.3 Oil Sump 137
9.5 Flange unit assembly 138
9.5.1 Flange bell 138
9.5.2 Flywheel 138
9.6 Timing system gear assembly and injection pump assembly 139
9.6.1 Timing system gears 139
9.6.2 High-pressure fuel injection pump 140
9.7 Cylinder head unit assembly 141
9.7.1 Valve stem gasket 141
9.7.2 Electronic injector sleeves 141
9.7.3 Electronic injector projection 141
9.7.4 Valves 142
9.7.5 Cylinder head 142
9.7.6 Valve rods and bridges 144
9.7.7 Rocker arm 145
9.7.8 Rocker arm gudgeon unit 145
9.7.9 Rocker arm cover 146
9.8 Fuel system assembly 146
9.8.1 Fuel lter 146
9.8.2 Common Rail 147
9.8.3 Electronic injectors 147
9.8.4 High-pressure fuel lines 148
9.8.5 Fuel return tubes 148
9.9 Intake manifold assembly 149
9.9.1 Internal half-manifold 149
9.9.2 External half-manifold 150
9.10 Exhaust manifold assembly 150

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INDEX
9.11 Lubrication circuit assembly 150
9.11.1 Oil steam separator unit 150
9.11.2 Oil Cooler unit and lub. oil lter 151
9.11.3 Oil pump 152
9.11.4 Timing system carter 152
9.11.5 Timing system carter oil lling ange 153
9.11.6 Oil pressure valve 153
9.12 Crankshaft and phonic wheel pulley unit assembly 153
9.13 Coolant circuit assembly 154
9.13.1 Thermostatic valve 154
9.13.2 Water pump 154
9.13.3 Oil Cooler Manifold 154
9.14 Turbocharger assembly 155
9.15 Electric components assembly 156
9.15.1 Sensors and switches 156
9.15.1.1 T-MAP sensor 156
9.15.1.2 Water temperature sensor 156
9.15.1.3 Oil pressure switch 156
9.15.1.4 Camshaft phase sensor 156
9.15.1.5 Speed sensor 157
9.15.1.6 Fuel lter water detection sensor 157
9.15.2 Alternator 158
9.15.3 Starter motor 159
9.15.4 Electric cabling 159
9.16 EGR circuit assembly 160
9.16.1 EGR valve 160
9.16.2 EGR Cooler Unit 161
9.17 Torque specications and use of sealant 162
10 FLUIDS FILLING INFORMATION 166
10.1 Engine oil 166
10.2 Coolant 166
11 INFORMATION ABOUT OPTIONAL COMPONENTS 168
11.1 Oil dipstick in cylinder head 168
11.1.1 Check 168
11.1.2 Replacement 168
11.1.2.1 Disassembly 168
11.1.2.2 Assembly 168
11.2 Heater (replacement) 169
11.2.1 Disassembly 169
11.2.2 Assembly 169
11.3 Poly-V alternator belt (replacement or regulation) 170
11.4 Tightening pulley and alternator for Poly-V belt 170
11.4.1 Disassembly 171
11.4.2 Assembly 172
11.5 Idler gear (for 3rd / 4th PTO) 173
11.5.1 Disassembly 173
11.5.2 Assembly 173
11.6 3rd PTO (replacement) 174
11.6.1 Disassembly 174
11.6.2 Assembly 175
11.7 4th PTO (replacement) 176
11.7.1 Disassembly 177
11.7.2 Assembly 178
11.8 3rd+ 4th PTO (congurations) 180
11.8.1 Information 180
11.9 Balancer device (replacement) 181
11.9.1 Disassembly 181
11.9.2 Assembly 182
11.10 Air cleaner (cartridge replacement) 184
11.11 Remote lub. oil lter (disassembly and assembly) 184
11.11.1 Disassembly 184
11.11.2 Assembly 185

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INDEX
11.12 Oil sump with supporting structure 186
11.12.1 Flywheel disassembly 186
11.12.2 Plate/ange housing disassembly 186
11.12.3 Oil sump disassembly 186
11.12.4 Oil sump assembly 186
11.12.5 Flange plate / housing assembly 188
11.12.6 Flywheel assembly 188
12 INFORMATION REGARDING REGULATIONS 186
12.1 Waste Gate opening valve regulation 186
12.2 Air lter check 187
12.3 Oil steam separator check 187
12.4 Rubber hose and manifold control 187
12.5 Oil leak check 188
12.6 Oil pressure check 188
13 INFORMATION REGARDING TOOLS 193
13.1 Information regarding specic tools 193
14 INFORMATION REGARDING FAILURES 194
14.1 Possible causes and troubleshooting 194
15 GLOSSARY 196

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GENERAL 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.
•Information, description and pictures in this manual reflect the
state of the art at the time of the marketing of engine (Par.
1.4 e Par. 1.5).
•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.
E.g.: Par. 1.3 - chapter 1 paragraph 3.
Tab. 2.4 - chapter 2 table 4.
Fig. 4.5 - chapter 4 gure 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 (in
red and underlined).
•Other important references are highlighted in red.
•The mark ( ) after the title of a paragraph, indicates that the
procedure is not required in order to disassemble the engine,
however the procedures are featured in order to illustrate the
disassembly of components.
•The pictures are based on model KDI 2504 TCR, where
necessary KDI 1903 TCR model is illustrated.
•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 motor, read the entire
Chap. 3, which contains important information about the
procedures to be followed for safety and environment.

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Fig. 1.3
Fig. 1.1 Fig. 1.2
ED0053029590
GENERAL INFORMATION
Max
rpm
Engine serial number
Approval data and
"EC" directives
Manufacturer identicationEngine type
Engine
version
1.2 Manufacturer and engine identication
The engine identication name plate is situated in the lower part of the crankcase; it is visible from the intake or exhaust side.

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1
4
5
10
2
3
8
9
6
7
Fig. 1.4
ED0053029590
GENERAL INFORMATION
1.3 Name plate for EPA regulations
POS. DESCRIPTION
1Model year in compliance with the rules
2Power category (kW)
3Engine displacement (Lt.)
4Particulate emission limit (g/kWh)
5Engine family ID
6Emission Control System = ECS
7Fuel with low sulphur content
8Injection timing
9Electronic injector opening pressure (bar)
10 Production date (example: 2013.JAN)

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1
AB
4
5
6
7
8
9
15
10
23
Fig. 1.5
ED0053029590
GENERAL INFORMATION
1.4 Identication of the main internal components of the engine and operating reference (BASE CONFIGURATION)
REF.DESCRIPTION
AView of timing system side (2nd PTO)
BView of ywheel side (1st PTO)
CView of exhaust side
DView of intake side
1Cylinder/Piston N. 1 (KDI 1903 - KDI 2504)
2Cylinder/Piston N. 2 (KDI 1903 - KDI 2504)
3Cylinder/Piston N. 3 (KDI 1903 - KDI 2504)
4Cylinder/Piston N. 4 (KDI 2504)
POS. DESCRIPTION
5Crankshaft pulley (2nd PTO)
6Gear timing system
7Thermostatic valve
8Oil pump
9Oil suction hose
10 Crankshaft
11 Exhaust manifold
12 Intake manifold
13 Camshaft
14 Gears adaptor for 3rd/4th PTO (optional)
15 Flywheel (1st PTO)
Tab. 1.2
VIEW OF EXHAUST SIDE
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 keepthis page visible during disassembly
and assembly operations.

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C
D
D
C
11
12
14
13
10
12
11
6
10
Fig. 1.6
Fig. 1.7
ED0053029590
GENERAL INFORMATION
VIEW OF TIMING SYSTEM SIDE
VIEW OF FLYWHEEL SIDE

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Fig. 1.8
Fig. 1.9
14
12
13
23
11
10 6
5
1
4
3
7
8
21
18
17
22
15
16
25
19
20
2
2324 28
9
9
8
ED0053029590
GENERAL INFORMATION
VIEW OF TIMING SYSTEM SIDE - EXHAUST
VIEW OF FLYWHEEL SIDE - INTAKE
1.5 Identication of the external components of the engine (BASE CONFIGURATION)

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Fig. 1.10
29
28
27
14
11
12
25
16
30
4 115
22 2
26
31
ED0053029590
GENERAL INFORMATION
POS. DESCRIPTION
1Oil filler cap
2Wiring
3ECU
4Turbocharger
5Oil pressure switch
6Starter motor
7Oil steam separator
8Oil drain plug
9Engine identication name plate
10 Alternator
11 Coolant pump
12 Coolant temperature sensor
13 Oil filler cap side
14 Thermostatic valve
15 Catalyst
16 EGR Cooler
17 High-pressure fuel injection pump
Tab. 1.3
This paragraph illustrates all external components that are
present in the base conguration 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.
POS. DESCRIPTION
18 Oil Cooler
19 Lub. oil lter
20 Oil dipstick
21 Fuel lter
22 EGR valve
23 Crankshaft pulley (2nd PTO)
24 Flywheel (1st PTO)
25 Intake manifold
26 Waste Gate valve control actuator
27 Exhaust manifold
28 Flange bell
29 Electronic injectors
30 Common Rail
31 Air intake hose
UPPER VIEW

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TECHNICAL INFORMATION
MANUFACTURER SPECIFICATIONS AND OPERATION
GENERAL INFORMATION
UNIT OF
MEASURE
KDI 1903 TCR KDI 2504 TCR
Operating cycle diesel - 4-stroke
Cylinders No. 3 4
Bore x stroke mm 88x102
Displacement cm31861 2482
Compression ratio 17.4:1
Intake Supercharged with Turbocharger
Cooling Liquid
Crankshaft rotation (view from ywheel side) Counterclockwise
Combustion sequence 1-3-2 1-3-4-2
Timing System
Valves per cylinder 4
Timing System Rods and rocker arms - Camshaft in the crankcase
Tappets Hydraulic
Injection Direct - Common Rail
Engine dry weight Kg 233 267
MAX inclination 30' continuous operation α 25°
MAX inclination 1' continuous operation α 35°
Volume of aspirated air (2600 rpm) m3/h 2.4 2.8
POWER AND TORQUE
GENERAL INFORMATION
UNIT OF
MEASURE
KDI 1903 TCR KDI 2504 TCR
MAX. operating speed Rpm 2600
MAX. operating power
(ISO TR 14396 - SAE J1995 - CE 97/68) kW 42 55.4
Maximum torque (at 1500 rpm) Nm 225 300
Admissible axial load on crankshaft Kg 300
CONSUMPTIONS
GENERAL INFORMATION
UNIT OF
MEASURE
KDI 1903 TCR KDI 2504 TCR
Specic fuel consumption (best point) g/kWh 210
Oil consumption %Fuel < 0.05
FUEL SUPPLY SYSTEM
GENERAL INFORMATION
UNIT OF
MEASURE
KDI 1903 TCR KDI 2504 TCR
Type of fuel Diesel UNI-EN590 - ASTM D975
High-pressure fuel injection pump DENSO HP3
Fuel supply Low pressure electric pump (if necessary)
Fuel lter
Filtering surface cm22300
Degree of ltration µm 5
Maximum pressure at injection pump inlet bar 0.2
2.1 Engine specications
Tab. 2.1

20
2
_07ED0053029590
TECHNICAL INFORMATION
LUBRICATION CIRCUIT
GENERAL INFORMATION
UNIT OF
MEASURE
KDI 1903 TCR KDI 2504 TCR
Lubrication
Recommended oil see Par. 2.4
Circuit forced Lobe pump
Oil sump capacity (MAX) Lt. 8,9 11,5
Oil pressure switch
Intervention pressure (MIN) bar 0.8±0.1
Oil lter
Maximum operating pressure bar 4.0
Degree of ltration µm 17 ±2
Filtering surface cm21744
COOLING CIRCUIT
GENERAL INFORMATION
UNIT OF
MEASURE
KDI 1903 TCR KDI 2504 TCR
Coolant %see Par. 2.6
Coolant 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 1903 TCR KDI 2504 TCR
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 motor W 25
Coolant temperature indicator light
Indicator light operating temperature °C +100 / +110