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Kohler KDI-2504TCR, Owner'S Manual

The Kohler KDI-2504TCR is a powerful and reliable engine designed for various industrial and agricultural applications. For easy maintenance and troubleshooting, make sure to download the free Owner's Manual from our website. Stay informed and keep your engine running smoothly with the help of the comprehensive manual.manualshive.com.

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_01

45

EN

NOTES

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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