Kohler KDI1903TCR Owner's Manual

KDI 1903 TCR - KDI 2504 TCR OWNER MANUAL

_15 2 EN Important Connect to http://iservice.lombardini.it > KDI KOHLER DIESEL section > login as a guest "Enter as a guest" > "TECHNICAL DOCUMENTATION" > select "KDI 1903 TCR" or "KDI 2504 TCR" and download the latest version of this manual onto your device. NOTE: you can select the desired language before downloading the manual, as shown in the figure below. REGISTRATION OF MODIFICATIONS TO THE DOCUMENT Any modifications to this document must be registered by the drafting body, by completing the following table. Translated from the original manual in Italian language. Data reported in this issue can be modified at any time by KOHLER. ED0053029490 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 words you can go directly to a paragraph, a table or a picture. - The chapter titles (headings) you come back automatically to the chapter initial page. - Clicking next to the bottom page number you come back to the analytic index. Released by Document code Model N° Edition Revision Issue date Review date Edited by Endorsed Technical Documentation ED0053029490 51269 16 15 09/2013 07/2017 Technical Documentation

_15 3 EN INDEX 1 - GENERAL INFORMATION 1.1 Manual's purpose.................................................................. 6 1.2 Glossary and Definitions ................................................ 6 1.3 Emission-Related Installation Instructions.................. 6 1.4 Service request ............................................................... 6 1.5 Engine component identification .................................. 7 1.6 Manufacturer and motor identification data ............... 8 1.7 Homologation labels ....................................................... 9 1.7.1 Label for EPA rules ................................................................ 9 1.7.2 Label for China Standards ................................................. 10 1.7.3 Label for Korea Standards ................................................. 11 2 - TECHNICAL INFORMATION 2.1 General description of the engine .............................. 12 2.2 Engine specifications ................................................... 12 2.3 Engine dimensions (mm).............................................. 12 2.4 Oil.................................................................................... 13 2.4.1 SAE oil classification .......................................................... 13 2.5 Fuel ................................................................................. 13 2.5.1 Fuel for low temperatures.................................................. 13 2.5.2 Biodiesel fuel ....................................................................... 14 2.5.3 Emission-Related Installation Instructions ..................... 14 2.6 Coolant recommendation ............................................ 15 2.7 Battery recommendation ............................................. 15 2.8 Control panel ................................................................. 15 3 - SAFETY INFORMATION 3.1 Advertencias sobre seguridad..................................... 16 3.2 General remarks ........................................................... 16 3.2.1 Note for OEM ....................................................................... 16 3.2.2 Note for end user ................................................................ 16 3.3 Safety signal description ............................................. 18 3.3.1 Adhesive safety plates ....................................................... 18 3.3.2 Safety guards ...................................................................... 18 3.3.3 Warnings .............................................................................. 18 3.4 Information and safety signals .................................... 19 3.5 Safety and environmental impact.................................... 19 3.6 Location of safety labels on engine ............................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 4.4 Rifornimento carburante .............................................22 4.5 Oil filling .........................................................................22 4.6 Coolant filling ................................................................23 5 - INFORMATION ABOUT MAINTENANCE 5.1 Useful information about maintenance ......................24 5.2 Periodic maintenance ..................................................24 5.3 Oil level check ...............................................................25 5.4 Oil dipstick on cylinder head .......................................25 5.5 Air filter check ...............................................................26 5.6 Check of the radiator heat-exchanger surface .........26 5.7 Rubber hoses check .....................................................26 5.8 Check coolant level ......................................................27 5.9 Check and setting alternator standard belt tension ...28 5.10 Check Poly-V alternator belt ......................................28 5.11 Filter cartridge and fuel pre-filter check ..................29 5.12 Product preservation ..................................................30 5.13 Engine storage up to 6 months .................................30 5.14 Engine storage over 6 months ...................................30 5.15 Engine starting after storage ....................................30 6 - INFORMATION ABOUT REPLACEMENTS 6.1 Engine oil replacement ................................................ 31 6.2 Oil filter cartridge replacement...................................32 6.3 Remote oil filter cartridge replacement (optional)....33 6.4 Filter cartridge and fuel pre-filter replacement .........33 6.5 Air filter cartridge replacement ..................................34 6.6 Disposal and scrapping................................................34 7 - INFORMATION ABOUT FAILURES 7.1 Useful information about failures ................................35 8 - INFORMATION ABOUT WARRANTY 8.1 Information about warranty .........................................36 9 - GLOSSARY 9.1 Glossary .........................................................................39 ED0053029490

_15 4 EN INDEX A Adhesive safety plates ....................................................... 18 Advertencias sobre seguridad .......................................... 16 After starting ....................................................................... 21 Air filter cartridge replacement.........................................34 Air filter check .....................................................................26 B Battery recommendation ................................................... 15 Biodiesel fuel ....................................................................... 14 C Check and setting alternator standard belt tension .......28 Check coolant level.............................................................27 Check of the radiator heat-exchanger surface ...............26 Check Poly-V alternator belt..............................................28 Control panel ....................................................................... 15 Coolant filling ......................................................................23 Coolant recommendation .................................................. 15 D Disposal and scrapping ......................................................34 E Emission-Related Installation Instructions........................ 6 Emission-Related Installation Instructions...................... 14 Engine component identification ........................................ 7 Engine dimensions (mm) .................................................... 12 Engine oil replacement ...................................................... 31 Engine specifications ......................................................... 12 Engine starting after storage ............................................30 Engine storage over 6 months...........................................30 Engine storage up to 6 months .........................................30 F Filter cartridge and fuel pre-filter check ..........................29 Filter cartridge and fuel pre-filter replacement ..............33 Fuel ....................................................................................... 13 Fuel for low temperatures.................................................. 13 G General description of the engine .................................... 12 General remarks.................................................................. 16 Glossary ...............................................................................39 Glossary and Definitions ...................................................... 6 H Homologation labels ............................................................. 9 I Information about warranty ...............................................36 Information and safety signals .......................................... 19 L Label for China Standards ................................................. 10 Label for EPA rules ............................................................... 9 Label for Korea Standards ................................................. 11 Location of safety labels on engine ..................................20 M Manual's purpose.................................................................. 6 Manufacturer and motor identification data ..................... 8 N Note for end user ................................................................ 16 Note for OEM ....................................................................... 16 O Oil .......................................................................................... 13 Oil dipstick on cylinder head .............................................25 Oil filling ...............................................................................22 Oil filter cartridge replacement .........................................32 Oil level check .....................................................................25 P Periodic maintenance.........................................................24 Pre-start check ................................................................... 21 Product preservation..........................................................30 ED0053029490

_15 5 EN INDEX R Remote oil ﬁlter cartridge replacement (optional) ..........33 Rifornimento carburante....................................................22 Rubber hoses check ...........................................................26 Running-in period ............................................................... 21 S SAE oil classiﬁcation .......................................................... 13 Safety and environmental impact ..................................... 19 Safety guards ...................................................................... 18 Safety signal description ................................................... 18 Service request ..................................................................... 6 Starting ................................................................................ 21 Starting and turning off...................................................... 21 T Turning off............................................................................ 21 U Useful information about failures .....................................35 Useful information about maintenance ............................24 W Warnings .............................................................................. 18 ED0053029490

_15 6 1 EN 1.1 Manual's purpose - This manual contains the instructions needed to carry out proper use and maintenance of the engine, therefore it must always be available, for future reference when required. - This manual is an integral part of the engine, in the event of transfer or sale, it must be attached to it. - Safety pictograms can be found on the engine and it is the operator's responsibility to keep them in a perfectly visible place and replace them when they are no longer legible. - Information, description and pictures in this manual reflect the state of the art at the time of the marketing of engine. - However, development on the engines is continuous. Therefore, the information within this manual is subject to change without notice and without obligation. - KOHLER reserves the right to make, at any time, changes in the engines for 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 sole property of KOHLER. As such, no reproduction or replication in whole or part is allowed without the express written permission of KOHLER. 1.2 Glossary and Definitions The paragraphs, tables and figure are divided into chapter with their progressive numbers. 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 are always and only related to 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. NOTE: All data, measurements and relevant symbols are shown in the glossary section. 1.4 Service request - The complete and updated list of authorized Kohler Co. service centers can be found on websites: www.kohlerengines.com & www.lombardinigroup.it/dealer-locator . - If you have any questions regarding your warranty rights and responsibilities or the location of the nearest Kohler Co. authorized service location, you should contact Kohler Co. at 1-800-544-2444 or access our website at www.kohlerengines.com (USA and North American). 1.3 Emission-Related Installation Instructions Failing to follow the instructions in the applications guidebook when installing a certified engine in a piece of nonroad equipment violates federal law (40 CFR 1068.105(b)), subject to fines or other penalties as described in the Clean Air Act. OEM 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 engines 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. GENERAL INFORMATION ED0053029490

_15 7 1 EN 1.5 Engine component identiﬁcation Side view A Thermostat Coolant temperature sensor Oil filler cap Coolant pump Alternator Starter motor Oil pressure switch Oil ﬁller cap Turbocharger Oil steam separator Nameplate Nameplate Oil drain plug Fuel filter Oil drain plug Oil cooler EGR Valve High injection pump EGR Cooler Oil filter Oil dipstick GENERAL INFORMATION Side view B Prefilter (type A) Prefilter (type B) Electric fuel pump ED0053029490

_15 8 1 EN 1.6 Manufacturer and motor identification 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 view B GENERAL INFORMATION ED0053029490

_15 9 1 4 5 10 2 3 8 9 6 7 1 EN 1.7 Homologation labels 1.7.1 Label for EPA rules GENERAL INFORMATION POS. DESCRIPTION 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 (*BTDC) 9 Injector opening pressure (bar) 10 Production date (example: 2013.JAN) ED0053029490

_15 10 1 6 8 7 5 3 1 4 2 EN 1.7.2 Label for China Standards 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 GENERAL INFORMATION ED0053029490

Kohler KDI1903TCR Owner's Manual

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