Kohler KDI 1903 TC Owner'S Manual Download Page 12

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TECHNICAL

INFORMATION

TECHNICAL INFORMATION

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

Tab. 2.1

TECHNICAL DATA

UNIT OF

MEASURE

Engine type

KDI 1903 TCR

KDI 2504 TCR

Cylinders

Bore

Stroke

102

Displacement

1861

2482

MAX INCLINATION DURING OPERATION
(even in combined)

30° max. 30 minutes

35° max.1 minute

OIL CAPACITY (MAX
level.) including oil filter

standard

version

lt.

8.9

11.5

with balancer

device

lt.

DRY WEIGHT

233

267

2.3

Engine dimensions (mm)

Summary of Contents for KDI 1903 TC

Page 1: ...ED0053029490_Rev_19 1 KDI 1903 TCR TCRE5 TC KDI 2504 TCR TCRE5 OWNER MANUAL ...

Page 2: ... 17 2 7 Battery recommendation 17 2 8 Control panel 18 3 Safety information 19 3 1 Safety information 19 3 2 General remarks 20 3 3 Safety signal description 22 3 4 Information and safety signals 24 3 5 Safety and environmental impact 26 3 6 Location of safety labels on engine 26 4 Information about use 27 4 1 Pre start check 27 4 2 Running in period 27 4 3 Starting and turning off 27 4 4 Refuelli...

Page 3: ... months 43 5 14 Engine storage over 6 months 44 5 15 Engine starting after storage 45 5 16 Unused machine 46 6 Information about replacements 47 6 1 Engine oil replacement 47 6 2 Oil filter cartridge replacement 48 6 3 Remote oil filter cartridge replacement optional 49 6 4 Filter cartridge and fuel pre filter replacement 50 6 5 Air filter cartridge replacement 51 6 6 Disposal and scrapping 51 7 I...

Page 4: ... 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...

Page 5: ...s 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 ...

Page 6: ...1 GENERAL INFORMATION EN 6 1 5 Engine component identification ...

Page 7: ... the DPF eliminates the particulates generated by the combustion of the diesel The system starts automatic regeneration cycles of the DPF based on the level of clogging The smell of the gases emitted by the exhaust line is different from that of traditional gases of diesel engines Also during the regeneration phases the exhaust gases could be temporarily white The minimum engine speed increases du...

Page 8: ...1 GENERAL INFORMATION EN 8 1 7 Manufacturer and motor identification data The nameplate motor identification is find side A or side B ...

Page 9: ...CRIPTION 1 Model year in compliance with the rules 2 Power category kW 3 Engine displacement L 4 Particulate emission limit g kWh 5 Engine family ID 6 Emission Control System ECS 7 Fuel with low sulphur content 8 Injection timing 9 Electronic injector opening pressure bar 10 Production date example 2013 JAN ...

Page 10: ...MATION EN 10 Label for China Standards compilation example Tab 1 2 POS DESCRIPTION 1 Manufacturer 2 Engine model 3 Manufactoring date 4 Certificate N 5 Power range kW 6 Emission level 7 Rated power 8 Aftertreat system ...

Page 11: ...GENERAL INFORMATION 1 11 EN Label for Korea Standards compilation example Tab 1 3 POS DESCRIPTION 1 Tier 4 Final 2 Engine model 3 Manufactoring date and manufacturer code 4 N Korea emission certificate ...

Page 12: ...mmon rail Direct injection 2 2 Engine specifications Tab 2 1 TECHNICAL DATA UNIT OF MEASURE Engine type KDI 1903 TCR KDI 2504 TCR Cylinders n 3 4 Bore mm 88 88 Stroke mm 102 102 Displacement cm 3 1861 2482 MAX INCLINATION DURING OPERATION even in combined α 30 max 30 minutes α 35 max 1 minute OIL CAPACITY MAX level including oil filter standard version lt 8 9 11 5 with balancer device lt 9 DRY WEI...

Page 13: ... 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 a...

Page 14: ...logging 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 NAT...

Page 15: ...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 Fuels with a sulfur content 15 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 Fu...

Page 16: ...sene 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 cert...

Page 17: ...ble 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 op...

Page 18: ...on F Engine operating status green no problem detected Fig 2 1 NOTE if LED F is red contact authorised KOHLER workshops to know what type of problem it is Certain problems automatically switch off the engine Tab 2 9 shows data that can be consulted on display B by pressing push buttons C or D NOTE data described in Tab 2 9 can differ therefore consult the machine s manual Tab 2 9 DESCRIPTION Opera...

Page 19: ...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 f...

Page 20: ...ving 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 surfa...

Page 21: ...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 Important Only use the eyebolts A insta...

Page 22: ...tial 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 Warnings Hereunder is a list of safety warnings that may be found in the manu...

Page 23: ...an 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 ...

Page 24: ...uel 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 ...

Page 25: ...odorless colorless and can cause death if inhaled ELECTRICAL SHOCK Electrical Shock can cause injury Do not touch wires while engine is running If ON a spark will occur at the ground cable terminal which could cause an explosion CALIFORNIA WARNING DECLARATION 65 Engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive ...

Page 26: ... directives regarding environmental impact In order to minimise the impact on the environment KOHLER now provides a number of indications to be followed by all persons handling the engine for any reason during its expected lifetime All components and fluids must be disposed of in accordance with the laws of the country in which disposal is taking place Keep the fuel and engine control systems and ...

Page 27: ...eck the level of the engine oil fuel and coolant and fill if necessary Par 4 5 e Par 4 6 2 Put the ignition key in the ignition switch if supplied 3 Tun the key to ON position 4 Turn the key beyond the ON position and release it when the engine starts the key will return into ON position automatically Important At the first fuelling or if the tank was empty filling the fuel system Par 6 4 point 8 ...

Page 28: ...able to lubricate the engine with a high alkaline oil or alternatively to replace the lubricating oil recommended by KOHLER more frequently To avoid explosions or fire outbreaks do not smoke or use open flames during the operations Fuel vapours are highly toxic Only carry out the operations outdoors or in a well ventilated place Keep your face well away from the fuel fill to prevent harmful vapour...

Page 29: ...the oil filler cap C if the cap A is not accessible 2 Add the oil of type recommended Tab 2 1 and Tab 2 2 Fig 4 1 1 Before checking oil engine needs to be level 2 Remove the oil dipstick B and check that the level is up to but does not exceed the MAX 3 If level is not at the MAX level add additional oil 4 Re tighten the cap A or C Fig 4 2 NOTE Click on the right to play the procedure https www you...

Page 30: ...h any operation on the engine stop it and allow it to cool Warning Presence of steam pressurized coolant danger of burns 1 Loosen the cap A and fill the radiator with coolant composed of 50 ANTIFREEZE and 50 decalcified water 2 Top liquid up until the pipes inside the radiator are covered by about 5 mm Do not overfill the radiator but leave room for the coolant to expand 3 For engines equipped wit...

Page 31: ...INFORMATION ABOUT USE 4 31 EN Fig 4 5 Fig 4 6 NOTE Click on the right to play the procedure https www youtube com embed S79xPhTZMps rel 0 ...

Page 32: ...ed in accordance with the machine instructions 4 11 SOOT LEVEL WARNING LAMPS 1 ENGINE DE RATE OPERATOR POSSIBLE ACTIONS OPERATING CONDITIONS Level 0 No condition Level 1 Level 2 Level 3 Fixed Forced Regeneration is Necessary Coolant temperature at 60 C Do not switch the engine off Stationary vehicle No load applied to the engine 2 Level 4 Flashing Engine de rate Forced Regeneration is Necessary Co...

Page 33: ...described in Par 5 3 or 5 4 must be executed after every forced regeneration If the regeneration inhibition function is misused the particulate accumulation level will increase within a short time The engine oil filter and oil must be changed after a Service Regeneration is completed via KOHLER software Level 5 Particulate accumulation Fuel contamination allowed in the engine oil is 3 MAX Any engi...

Page 34: ...reases the risk of technical damage to the engine Any non compliance makes the warranty become null and void In order to prevent personal and property damage read carefully the instructions listed below before proceeding with any operation of the engine Warning Inspections must be made when the engine is off and cold Place engine on level sur face to ensure accurate measurement of oil level Before...

Page 35: ...r 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 6 Alternator 6 5 2 REPLACEMENT OPERATION DESCRIPTION PERIOD HOURS 500 2000 5000 Cartridge dry type air filter 2 Intake manifold hose air filter intake manifold 6 7 Coolant hoses 6 7 Fuel line hose 6 7 Alternator belt Standard alternator b...

Page 36: ... must be cleaned and replaced more frequently under very dusty conditions 3 In case of low use 36 months 4 The inspection must be carried out every 50 hours or every week in engines with an ATS system see Par 1 6 6 Contact authorized KOHLER workshops 7 The replacement interval is only an indication it strongly depends from environmental condition and hose status detected during regular visual insp...

Page 37: ...eds the MAX Do not use the engine with the level of oil over MAX 1 Loosen the oil filler cap A Remove the oil dipstick B and check that the level is up to MAX 2 Pour in recommended oil until reaching the MAX level mark 3 Reinstall the oil dipstick B completely 4 Re tighten the cap A and or C Fig 5 2 Fig 5 1 Fig 5 2 5 4 Oil dipstick on cylinder head Important Before proceeding with operation read P...

Page 38: ...compressed air repeatedly tap the front side E on a flat surface 5 Reinstall cartridges G and B the cover A checking the right tightness of clasps F Fig 5 5 5 6 Check of the radiator heat exchanger surface Danger For safety precautions see Chap 3 NOTE Component not necessarily supplied by KOHLER Important Before proceeding with operation read Par 3 2 2 Wear safety goggles when using compressed air...

Page 39: ...clamps Components must be replaced if they have clear signs of cracks tears cuts leaks and do not retain a certain degree of elasticity Important Before proceeding with operation read Par 3 2 2 If hoses are damaged contact an authorized KOHLER workshop Fig 5 7 1 Check that the Fuel system hoses A are intact Cooling circuit hoses B Vent system pipes C Air system ducts D Oil return circuit hose E Fi...

Page 40: ...1 Start the engine without the radiator cap A 2 Top liquid up until the pipes inside the radiator are covered by about 5 mm 3 Top up if necessary 4 Do not overfill the radiator but leave room for the coolant to expand 5 Reinstall radiator cap A 6 For engines equipped with expansion tank B check that the fluid is until reaching the max level mark NOTE For coolant filling see Par 4 6 Warning Before ...

Page 41: ... alternator outwards in direction of the arrow D to tension the belt 3 Tension the belt tightening the bolts B e C 4 Tighten bolts B tightening torque of 25 Nm and C tightening torque of 69 Nm in sequence with a torque wrench E 5 Check by the appropriate tool that at point p the tension value is between 80 and 85 Hz Using the tool F DENSO BTG 2 or a similar one shown in the picture it is possible ...

Page 42: ...t NOTE Make sure that the ribs of the belt A are inserted correctly into the grooves of the pulleys B as shown in Fig 5 14 and Fig 5 15 2 Start the engine and run it for some minutes then turn off it and let it cool down at ambient temperature Check by the appropriate tool that at point p the tension value is between 149 and 196 Hz NOTE If the poly v belt tension results out of the above mentioned...

Page 43: ... carrying out the operations described in Engine storage up to 6 months Par 5 13 If the engine is still not in use after the first 6 months it is necessary to carry out a further operation to extend the protection period more than 6 months Par 5 14 If the engine is not to be used for an extended period the protective treatment procedure must be repeated within 24 months of the previous one 5 13 En...

Page 44: ...g the engine to 3 4 of the maximum speed for 5 10 minutes 7 Turn off the engine 8 Completely empty the fuel tank 9 Spray SAE 10W 40 on the exhaust and intake manifolds 10 Seal the exhaust and intake ducts to prevent foreign bodies from entering 11 When cleaning the engine if using a pressure washer or steam cleaning device avoid directing the nozzle on electrical components cable connections and s...

Page 45: ...ep it idle at minimum speed for a two about minutes 7 Bring the engine to 75 of maximum rated speed for 5 to 10 minutes 8 Stop the engine while the oil is still hot Par 6 1 discharge the protective oil in a suitable container Warning Over time lubricants and filters lose their properties so it is important consider whether they need replacing also based on the criteria described in Par 5 2 9 Repla...

Page 46: ...lated to unused machine described in point 1 Perform the operations described in Par 5 6 Start the engine at least every 4 months as per operations described in point 1 Avoid sudden accelerations for the first few minutes Bring the engine to the working temperature by pressing the accelerator 3 4 from MAX Leave the engine running at minimum speed for a few minutes and turning off the engine Starti...

Page 47: ...the oil drain plug is on both sides of the oil sump 4 Drain oil in an appropriate container For the exhausted oil disposal refer to Par 6 6 DISPOSAL and SCRAPPING 5 Replace gasket E 6 Tighten the drain oil plug D tightening torque at 35 Nm 7 Perform the operation described in Par 6 2 point 2 to 5 https iservice lombardini it jsp Template2 manuale jsp i d 84 parent 962 8 Add the type of oil recomme...

Page 48: ... 1 Unscrew cartridge holder cover A by performing three complete turns and wait 1 minute NOTE this operation allows to oil contained in the support F to flow into the oil sump in the correct way 1 Unscrew cartridge holder cover A and check that the oil in the lub oil filter support F has flowed towards the oil sump 2 Remove the cap A as well as the oil cartridge B from the oil filter support Fig 6...

Page 49: ... 6 7 NOTE Click on the right to play the procedure https www youtube com embed jr0sXe8Cdro rel 0 6 3 Remote oil filter cartridge replacement optional Important Before proceeding with operation read Par 3 2 2 1 Unscrew and remove the cartridge A using the appropriate wrench 2 Lubricate the gasket and screw on the new cartridge A using the appropriate wrench Fig 6 8 ...

Page 50: ... 3 Loosen the cartridge B using the appropriate wrench F Fig 6 10 4 Lubricate the gasket D of the new cartridge B Important Do not fill the new cartridge B with fuel 5 Tighten the new cartridge B Fig 6 10 on the diesel fuel filter support E using the special wrench F tightening torque of 17 Nm 6 Tighten the water presence sensor C on the new cartridge B tightening torque of 5 Nm 7 Reconnect the ca...

Page 51: ...l and scrapping In case of scrapping the engine shall be disposed of in appropriate locations in conformity with the law in force Before scrapping it is necessary to separate the rubber or plastic parts from the rest of the components The parts only composed of plastic material aluminium and steel can be recycled if collected by the appropriate centers Waste oil must properly be recycled and dispo...

Page 52: ...ated battery terminals corroded Clean the battery terminals Battery voltage too low Recharge the battery or replace it Low fuel level Refuel 4 4 Frozen fuel Contact KOHLER authorised workshops Clogged fuel filter Replace with a new filter 6 4 Air suction in fuel system Contact KOHLER authorised workshops Clogged air filter Replace with a new filter 6 5 Clogged pipes Contact KOHLER authorised works...

Page 53: ...ntact KOHLER authorised workshops Engine lost its initial performance Clogged air filter Replace with a new filter 6 5 Clogged fuel pipes Contact KOHLER authorised workshops Cheap fuel Clean the tank and refuel with quality fuel High oil sump level Replace the engine oil if the problem persists Contact KOHLER authorised workshops Slow acceleration Clogged fuel filter Replace the fuel filter 6 4 En...

Page 54: ...l 2 Years 0 2 000 100 Parts Labor Major component defects are failures related to crankcase casting cylinder head casting crankshaft crankshaft pulley camshaft connecting rod flywheel oil pump For the Warranty Period stated above the period begins on the date of purchase of the finished equipment on which the engine is installed If no hour meter is installed on the application the Operating Hours ...

Page 55: ...se of the engine iv an act beyond the control of Kohler Co which includes but is not limited to theft vandalism fire lightning earthquake windstorm hail volcanic eruption flood or tornado Transportation charges or travel expenses in connection with the repair or replacement of defective parts on the engine Engine accessories such as fuel tanks clutches transmissions power drive assemblies and batt...

Page 56: ... scheduled maintenance 2 As the off road marine engine owner you should however be aware that Kohler Co may deny you warranty coverage if your off road marine engine or a part shows signs of malfunction or failed due to abuse neglect improper maintenance or unapproved modifications 3 Your engine is designed to operate on diesel fuel only Diesel fuel an all other fluids used shall comply with the r...

Page 57: ...EPAIR REQUIREMENTS The owner is responsible for the proper use and maintenance of the engine Kohler Co recommends that all receipts and records covering the performance of regular maintenance be retained in case questions arise If the engine is resold during the warranty period the maintenance records should be transferred to each subsequent owner Kohler Co may not deny warranty repairs solely bec...

Page 58: ...ANUFACTURER S WARRANTY COVERAGE The current model year 2 current model year heavy duty off road marine engines are warranted for the periods listed below If any emission related part on your engine is defective the part will be repaired or replaced by Kohler Co VARIABLE SPEED OR CONSTANT SPEED KW 19 ANY SPEED 1 500 HOURS OR TWO YEARS WHICHEVER COMES FIRST Constant speed 19 kW 37 3 000 rpm or highe...

Page 59: ... engine DPF Diesel Particulate Filter A filter that captures particles of carbonaceous origin emitted by diesel engines E EC European Community ECS Emission Control System ECU Electronic Control Unit an electronic device in charge of electronically detecting and controlling other electronic control devices EGR Exhaust Gas Recirculation in internal combustion engines a system that enables recircula...

Page 60: ...e turbo situated between the turbine and intake manifold K KDI Kohler Direct Injection M Maintenance periodic A group of maintenance actions that have the sole objective to control and replace elements on their expiry without modifying or improving the functions carried out by the system neither increasing the value nor improving performance Max Maximum Methyl ester It is a mixture of products by ...

Page 61: ... collector TCR Turbo Common Rail Tightening torque A term indicated for installation of threaded components and which is determined by means of a unit of measurement Nm Turbocharger Device that compresses air intake by sending it to the intake manifold by means of a turbine U Used oil Oil altered by operation or time which is no longer compliant for correct lubrication of the components W Waste Ga...

Page 62: ...er hour 1 Lt h ppm parts per million Percentage 1 ppm N newton Force 1 N A Ampere Intensity of electrical current 1 A gr gramme Weight 1 gr kg kilogramme 1 kg W Watt Power 1 W kW kiloWatt 1 kW pa pascal Pressure 1 pa KPa Kilopascal 1 KPa bar barometric pressure 1 bar mbar 1 1000 bar barometric pressure 1 mbar R Resistance Resistance to electrical current referred to a component 1 Ω Ω ohm Resistanc...

Page 63: ...GLOSSARY 9 63 EN ...

Page 64: ......

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