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2

14

SAFETY INFORMATION

EN

2.1 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.  

2.2 General remarks

2.2.1 

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. 

2.2.2 

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.

• 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.

• The  engine  may  only  be  assembled  on  a  machine  by 

personnel specifically trained by 

KOHLER

 and who work in 

compliance with the existing documentation. 

• The engine has been built to the specifications of a machine 

manufacturer,  and 

it  is  his  responsibility  to  ensure  that  all 

necessary action is taken to meet the essential and legally 

prescribed health and safety requirements. Any use of the 

machine other than that described cannot be considered as 

complying with its intended purpose as specified by 

KOHLER

which  therefore  declines  all  responsibility  for  accidents 

caused by such operations.

• 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.  

 

Important

• This operation should be carried out with vacuum pump.
• The oil must be drained whilst the engine is hot. Particular care 

is required to prevent burns.  Do not allow the oil to come into 

contact with the skin because of the health hazards involved.

• 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.

UM KDI 1903TCR_2504TCR _ cod. ED0053029490 - 

2° ed

_rev. 

01

Index

Summary of Contents for KDI-1903TCR

Page 1: ...KDI 1903TCR KDI 2504TCR OWNER MANUAL...

Page 2: ...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 wo...

Page 3: ...t level check 25 Coolant filling 21 D Definitions and Glossary 6 Dimensions engine 10 Disposal and scrapping 33 E Emission Related Installation Instructions 6 Engine dimensions 10 Engine component ide...

Page 4: ...uct preservation 28 Purpose Manual 6 INDEX R Recommendations Battery 13 Radiator heat exchange surface Check of the 24 Refuelling 20 Remarks General 14 Remote oil filter cartridge replacement optional...

Page 5: ...seful information about maintenance 22 W Warranty responsibilities Owner s 35 Water filter cartridge fuel Control 27 Y Your warranty rights and obligations California emission control warranty stateme...

Page 6: ...the paragraph you are reading unless there are specific references to other figures or paragraphs The figure are based on model 2504 TCR where necessary the version 1903 TCR is illustrated All data me...

Page 7: ...r Oil filler cap Water pump Alternator Starter motor Oil pressure sensor Oil filler cap Turbocharger Oil steam separator Nameplate Nameplate Oil drain plug Fuel filter Oil drain plug Oil cooler Valve...

Page 8: ...data Peak rpm Engine serial number Approval data and EC directives Engine type Engine version Manufacturer identification The nameplate motor identification is find side A or side B SIDE VIEW A SIDE V...

Page 9: ...e 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 BTDC 9 Inject...

Page 10: ...ngine specifications TECHNICAL DATA UNIT OF MEASURE ENGINE TYPE KDI 1903 TCR KDI 2504 TCR CYLINDERS n 3 4 BORE mm 88 STROKE mm 102 DISPLACEMENT cm3 1861 2482 MAX INCLINATION DURING OPERATION even in c...

Page 11: ...or U S 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...

Page 12: ...that they meet the specifications listed in the Tab 1 3 DO NOT USE vegetable oil as a biofuel for this engine Any failures resulting from the use of fuels other than recommended will not be warranted...

Page 13: ...EN 90 Ah 20 h 855 CCA SAE from 15 C to 25 C 110 Ah 20 h 500 A DIN 110 Ah 20 h 980 A EN 110 Ah 20 h 950 CCA SAE TECHNICAL SPECIFICATIONS 50 ETHYLENEGLYCOL e 50 WATER 50 PROPYLENE GLYCOL e 50 WATER ANTI...

Page 14: ...or 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...

Page 15: ...ion 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 p...

Page 16: ...This indicates that failure to comply with it can cause minor damage or injury ReadtheOperationandMaintenancehandbookbefore performing any operation on the engine Hot Parts Danger of burns Presence of...

Page 17: ...s 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 HIGH PRESSUR...

Page 18: ...replace them with original ones if they are deteriorated and illegible Ask for new safety signals to the manufacturer Position them as shown in Par 2 7 Clean with a cloth water and soap 2 6 Safety pr...

Page 19: ...oil fuel and coolant and fill if necessary Par 3 5 and Par 3 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...

Page 20: ...a well ventilated place Keep your face well away from the fuel fill to prevent harmful vapours from being inhaled Dispose of fuel in the correct way and do not litter as it is highly polluting When re...

Page 21: ...vel mark 4 Bleeding the cooling circuit as indicated in the Par 4 8 5 Re tighten the cap A 6 After a few hours of operator stop the engine and allow the liquid to cool returns to a ambient temperature...

Page 22: ...of the engine 4 1 Useful information about maintenance Warning Inspections must be made when the engine is off and cold Place engine on level surface to ensure accurate measurement of oil level Befor...

Page 23: ...ck on cylinder head 4 5 Air filter check NOTE Components not necessarily supplied by KOHLER 1 Release the two clasps F of the cover A 2 Remove the cartridges B and G 3 Remove the cap C 4 Clean the ins...

Page 24: ...cial detergent if it is clogged 4 7 Rubber hoses check The check is carried out by exerting a slight deflection or bending along the pipe and near the hose clamps Components must be replaced if they h...

Page 25: ...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...

Page 26: ...propriate 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 to check the corresponding value in Newtons w...

Page 27: ...tridge fuel see Par 5 4 1 Gently loosen the wing screw A without removing it 2 Drain the water if present 3 Re tighten the wing screw A as soon as the fuel begins to flow NOTE If the poly v belt tensi...

Page 28: ...t 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...

Page 29: ...ove the oil drain plug D and the gasket E 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 5 6 DISPOSAL and SCRAP...

Page 30: ...e gaskets C D and E with new ones Warning Oil filter cartridge replacement Par 5 2 and fuel filter replacement Par 5 4 In case of low use replace it 12 months For disposal of oil filter cartridge and...

Page 31: ...rque wrench G tightening torque of 25 Nm 5 3 Remote oil filter cartridge replacement optional 1 Unscrew and remove the cartridge A using the appropriate wrench 2 Lubricate the gasket and screw on the...

Page 32: ...new cartridge B Important Do not fill the new cartridge B with fuel 5 Tighten the new empty cartridge B Fig 5 10 on the diesel fuel filter support E using the special wrench F tightening torque of 17...

Page 33: ...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 compos...

Page 34: ...s Inefficient electrical connections Clean the electrical contacts if the problem persists contact KOHLER authorised workshops Sulphated battery terminals Clean the battery terminals Clogged fuel filt...

Page 35: ...equired maintenance listed in your Kohler Co owner s manual Kohler Co recommends that you retain all receipts covering maintenance on your heavy duty off road engine Kohler Co cannot deny warranty sol...

Page 36: ...36 EN NOTES UM KDI 1903TCR_2504TCR _ cod ED0053029490 2 ed_rev 01 Index...

Page 37: ...37 NOTES EN UM KDI 1903TCR_2504TCR _ cod ED0053029490 2 ed_rev 01 Index...

Page 38: ...38 NOTES EN UM KDI 1903TCR_2504TCR _ cod ED0053029490 2 ed_rev 01 Index...

Page 39: ...39 NOTES EN UM KDI 1903TCR_2504TCR _ cod ED0053029490 2 ed_rev 01 Index...

Page 40: ...522 389 503 UK Lombardini U K Ltd 1 Rochester Barn Eynsham Road OX2 9NH Oxford UK T 44 0 1865 863858 F 44 0 1865 861754 FRANCE Lombardini France S a s 47 All de Riottier 69400 Limas FRANCE T 33 0 474...

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