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15

3

18

EN

SAFETY INFORMATION

3.1 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.  

3.2 General remarks

3.2.1 

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. 

• The engine may only be assembled on a machine by 

3.2.2 

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.

• 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 surface to be washed and the nozzle.  
Avoid directing the nozzle on electrical components, 
cable connections and sealed rings (oil seals etc). 

 

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.

Thoroughly wash and clean the area surrounding the 
engine following the instructions provided by machine 
manufacturer.

• 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.

• 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.

Summary of Contents for KDI-2504TCR

Page 1: ...KDI 2504 TCR MGWI TP 7110 4 18 OWNER MANUAL...

Page 2: ...s 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...

Page 3: ...fety and environmental impact 20 4 INFORMATION ABOUT USE 4 1 Pre start check 21 4 2 Running in period 21 4 3 Starting and turning off 21 4 3 1 Starting 21 4 3 2 After starting 21 4 3 3 Turning off 21...

Page 4: ...Fuel filter cartridge replacement 36 Fuel for low temperatures 14 G General description of the engine 13 General remarks 17 Glossary SYMBOLS AND UNITS OF MEASUREMENT 42 Glossary and Definitions 6 H Ho...

Page 5: ...5 1 EN ANALYTICAL INDEX U Useful information about failures 38 Useful information about maintenance 24 W Warnings 19 Water pump impeller replacement 37 Z Zinc anode and radiator check 28...

Page 6: ...umbers Ex Par 2 3 chapter 2 paragraph 3 Tab 3 4 chapter 3 table 4 Fig 5 5 chapter 5 figure 5 The references of the objects described in the text and in figure and number are indicated by letters which...

Page 7: ...ntification data The nameplate motor identification is find side A or side B Peak rpm Engine serial number Approval data and EC directives Engine type Engine version Manufacturer identification GENERA...

Page 8: ...8 6 7 5 10 11 8 14 14 1 8 1 3 2 16 19 18 17 4 4 9 12 13 13 1 EN 1 6 Engine component identification Side view A Side view B GENERAL INFORMATION...

Page 9: ...3 Oil cooler 4 Oil filler cap 5 Oil dipstick 6 Lub oil filter 7 Thermostatic valve 8 Turbocharger 9 Oil steam separator 10 Coolant pump 11 Starter motor 12 Flywheel 13 Oil drain plug 14 Cooled inlet m...

Page 10: ...N 1 Engine displacement L 2 Emission Control System ECS 3 Application type 4 Injection timing BTDC 5 Injector opening pressure bar 6 Model year in compliance with the rules 7 Power category kW 8 Engin...

Page 11: ...N GENERAL INFORMATION 1 7 2 Label for China Standards POS DESCRIPTION 1 Manufacturer 2 Engine model 3 Date of manufacture 4 China emission certification no 5 Power range kW 6 Emission level 7 Power 8...

Page 12: ...12 1 4 3 2 1 EN GENERAL INFORMATION 1 7 3 Label for Korea Standards POS DESCRIPTION 1 Tier 4 Final 2 Engine model 3 Date of manufacture and manufacturer code 4 Korea emission certification no...

Page 13: ...ppets 2 2 Engine specifications Liquid cooled turbocharger Common Rail Direct injection TECHNICAL DATA UNIT OF MEASURE ENGINE TYPE KDI 2504 TCR MGWI CYLINDERS n 4 BORE mm 88 STROKE mm 102 DISPLACEMENT...

Page 14: ...osity must be appropriate to the ambient temperature to which the engine is to be exposed Par 2 4 1 Danger Prolonged skin contact with the exhausted engine oil can cause cancer of the skin If contact...

Page 15: ...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 certified for your application Constant speed...

Page 16: ...y Kohler 2 6 Coolant recommendation TECHNICAL SPECIFICATIONS 50 ETYLENGLYCOL E 50 DECALCIFIED WATER 50 PROPYLENGLYCOL E 50 DECALCIFIED WATER OAT HIBRID TECHNOLOGY ASTM 3306 RECOMMENDED BATTERIES AMBIE...

Page 17: ...17 2 TECHNICAL INFORMATION EN...

Page 18: ...e 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 du...

Page 19: ...e used to service the engine and or machine Make sure that all guards have been refitted Do not mix fuel with elements such as oil or kerosene Failure to comply with this prohibition will cause the no...

Page 20: ...al shock Danger of severe scalding or death High pressure fluid Danger of fluid penetration Lethal Exhaust Gases Danger of poisoning or death 3 3 1 Adhesive safety plates The following is a list of th...

Page 21: ...in a closed building or confined area Carbon monoxide is toxic odorless colorless and can cause death if inhaled EXPLOSIVE GAS Explosive Gas can cause fires and severe acid burns Charge battery only...

Page 22: ...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 Impor...

Page 23: ...is highly polluting When refuelling it is advisable to use a funnel to prevent fuel from spilling out The fuel should also be filtered to prevent dust or dirt from entering the tank Do not overfill t...

Page 24: ...Fig 4 5 3 Re tighten the cap A C 4 After a few minutes of operator stop the engine and allow the liquid to cool returns to a ambient temperature and check the coolant level again 4 6 Coolant filling...

Page 25: ...rted correctly also check that oil drain plug and oil filler cap are tightened firmly CLEANING AND CHECKING OPERATION DESCRIPTION PERIOD HOURS PAR 100 250 500 5000 Engine oil level 8 4 5 3 Coolant lev...

Page 26: ...check 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 complete...

Page 27: ...slight deflection or bending along the pipe and near the hose clamps Components must be replaced if they have clear signs of cracks tears cuts leaks and do not retain a certain degree of elasticity Im...

Page 28: ...on the cooled exhaust manifold B 2 Undo capscrew C and refill the cooled exhaust manifold B until coolant leaks out of capscrew C NOTE The MAX filling level for exhaust manifold B is in correspondence...

Page 29: ...ake sure that radiator F is free from deposits and dirt of any kind 8 Make sure that all the holes in surfaces F1 F2 are free from deposits and dirt of any kind NOTE If the inside of the pipes on surf...

Page 30: ...D1 H4 G G B H5 F 5 10 5 11 EN INFORMATION ABOUT MAINTENANCE 14 Clamp capscrew B on cap E1 inserting gasket H5 tightening torque 30 Nm 15 Screw union A onto manifold G 16 Perform the operations describ...

Page 31: ...as specified in point 3 5 Loosen capscrews A and remove caps B1 and B2 6 Remove Intercooler C from intake manifold E 7 Perform the cleaning operations immerse components B1 B2 and C in a solution of d...

Page 32: ...d stop 12 Put gasket F on intercooler C 13 Fasten cap B1 onto manifold E using capscrews A 14 Insert gasket F on intercooler C until it comes into contact with manifold E 15 Insert flange G on interco...

Page 33: ...to the technical documentation of the vehicle 5 10 Fuel filter cartridge check When turn on lights on control water filter cartridge fuel 1 Gently loosen the wing screw A without removing it 2 Drain...

Page 34: ...e 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 engin...

Page 35: ...appropriate container For the exhausted oil disposal refer to Par 6 7 DISPOSAL and SCRAPPING 5 Replace gasket E 6 Tighten the drain oil plug D tightening torque at 35 Nm 7 Perform the operations from...

Page 36: ...that the oil in the lub oil filter support F has flowed towards the oil sump 3 Remove the cap A as well as the oil cartridge B from the oil filter support 4 Remove and replace the oil cartridge B with...

Page 37: ...using the appropriate wrench 4 Lubricate the gasket D of the new cartridge B Important Do not fill the new cartridge B with fuel 5 Tighten the new empty cartridge B Fig 6 9 on the diesel fuel filter s...

Page 38: ...y the appropriate centers Waste oil must properly be recycled and disposed of in the correct way to safeguard the environment According to the laws in force it is classified as hazardous waste therefo...

Page 39: ...ev up Safety protocol in starting Wait some seconds Throttle to MAX in starting Release the throttle and wait some seconds RPM instability at idle speed Clogged fuel pipes Contact KOHLER authorised wo...

Page 40: ...ired or replaced by Kohler Co OWNER S WARRANTY RESPONSIBILITIES 1 As the off road engine owner you are responsible for the performance of the required maintenance listed in your owner s manual Kohler...

Page 41: ...mission control information labels Intake manifold Turbocharger if equipped Exhaust gas recirculation EGR tube Fuel limiting device Crankcase ventilation valve Parts components that are scheduled to b...

Page 42: ...ontaminated environment due to various types of gas I Intercooler Air cooling element under pressure from the turbo situated between the turbine and intake manifold International lubricant specificati...

Page 43: ...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...

Page 44: ...r 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 pasca...

Page 45: ..._01 45 EN NOTES...

Page 46: ..._01 46 EN NOTES...

Page 47: ..._01 47 EN NOTES...

Page 48: ...NH 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 626500 F 33 0 474 623945 ESPA A Lombardini ESPA A S L P I Cova Solera...

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