Kohler KDI-1903TCR Owner'S Manual Download Page 7

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GENERAL INFORMATION

Engine component identification

SIDE VIEW A

SIDE VIEW B

Thermostat

Water temperature

sensor

Oil filler cap

Water pump

Alternator

Starter motor

Oil pressure sensor

Oil filler cap

Turbocharger

Oil steam separator

Nameplate

Oil drain plug

Fuel filter

Oil drain plug

Oil cooler

Valve EGR

High injection pump

EGR Cooler

Oil filter

Oil dipstick

UM KDI 1903TCR_2504TCR _ cod. ED0053029490 -

2° ed

_rev.

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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Kohler KDI-1903TCR, Owner'S Manual

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