Kohler KDI 1903M, Owner'S Manual

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

Page 2: ...ment code Model N Edition Revision Issue date Review date Edited by Endorsed Technical Documentation ED0053029510 51270 15 14 1 02 2013 05 2020 Technical Documentation Important Connect to http iservi...

Page 3: ...2 5 3 Synthetic fuels GTL CTL BTL HV 13 2 5 4 Non Road Fuels 13 2 5 5 Jet Fuels 13 2 5 6 Emission Related Installation Instructions 13 2 6 Coolant 14 2 7 Battery recommendations 14 3 SAFETY INFORMATI...

Page 4: ...eservation 28 5 12 Engine storage up to 6 months 28 5 13 Engine storage over 6 months 28 5 14 Engine starting after storage 29 5 15 Unused machine 29 5 15 1 Operations for the engine 29 6 INFORMATION...

Page 5: ...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 paragra...

Page 6: ...ication Fuel injection pump Thermostat Coolant temperature sensor Oil filler cap Coolant pump Alternator Oil filler cap Oil pressure switch Starter motor Oil drain plug Oil filter Fuel filter Nameplat...

Page 7: ...data Peak rpm Engine serial number Approval data and EC directives Engine type Engine version Manufacturer identification The engine identification nameplate is located on side A or B as below Side vi...

Page 8: ...NFORMATION 1 7 Homologation labels 1 7 1 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...

Page 9: ...1 4 3 2 1 EN GENERAL INFORMATION 1 7 2 Label for Korea Standards POS DESCRIPTION 1 Tier 4 Final 2 Engine model 3 Manufactoring date and manufacturer code 4 N Korea emission certificate ED0053029510 I...

Page 10: ...s per cylinder with hydraulic tappets Injection 2 3 Engine dimensions mm TECHNICAL DATA UNIT OF MEASURE ENGINE TYPE KDI 1903 M KDI 2504 M CYLINDERS n 3 4 BORE mm 88 STROKE mm 102 DISPLACEMENT cm3 1861...

Page 11: ...of the engine The use of lubricants other than recommended may shorten the engine life Viscosity must be appropriate to the ambient temperature to which the engine is to be exposed Par 2 4 1 Danger P...

Page 12: ...fuels with sulfur content up to 2000 mg kg ppm Engines operated with fuels as per EN 590 and ASTM D975 with sulfur content 15mg kg have an oil changing interval of 500hrs Fuels with a sulfur content...

Page 13: ...el fuel and then converted to synthetic fuels suffer shrinkage of polymer seals in the injection system and thus fuel leaks The reason for this behavior is that the aromatic free synthetic fuels can l...

Page 14: ...ve coolants in concentrated formulation must be mixed with distilled deionized or demineralized water A pre mixed formulation 40 60 or 50 50 can be used directly when available Important Do not mix et...

Page 15: ...vent 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 haza...

Page 16: ...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 non oper...

Page 17: ...er 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 the adhesive sa...

Page 18: ...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 in a well ven...

Page 19: ...3 _14 19 KDI 1903 M KDI 2504 M EN SAFETY INFORMATION 3 6 Location of safety labels on engine ED0053029510 Index...

Page 20: ...the tank was empty filling the fuel system Par 6 4 from point 4 to point 6 Do not actuate the starter for more than 15 seconds at a time If the engine does not start wait for one minute before repeat...

Page 21: ...way and do not litter as it 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...

Page 22: ...eeding with any operation on the engine stop it and allow it to cool Warning Presence of steam pressurized coolant danger of burn 1 Loosen the cap A and fill the radiator with coolant composed of 50 A...

Page 23: ...d Place engine on level surface to ensure accurate measurement of oil level Before starting to avoid spillages of oil make sure that the oil dipstick is inserted correctly also check that oil drain pl...

Page 24: ...e front side E on a flat surface 5 Reinstall cartridges B the cover A checking the right tightness of clasps D 1 In case of low use 12 months 2 The period of time that must elapse before checking the...

Page 25: ...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 26: ...cap A 2 Top liquid 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 c...

Page 27: ...ll the alternator outwards in direction of the arrow D to tension the belt 3 Tension the belt tightening the bolts B and C 4 Tighten bolts B tightening torque of 25 Nm and C tightening torque of 69 Nm...

Page 28: ...el additives for long storage The following additives are recommended DEFA Fluid Plus Pakelo Lubricants Diesel Treatment Green Star Top Diesel Bardhal STP Diesel Fuel Injector Treatment 3 With expansi...

Page 29: ...e machine is not used Consult the machine s manual to disconnect the battery before disconnecting the battery wait for minimum 5 mins after turning off the engine Make sure the engine is not exposed t...

Page 30: ...he 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 6 6 DISPOSAL and SCRAPPING 5 Replace gasket E 6 Tigh...

Page 31: ...h B torque to 15 Nm 10 Fit and remove the oil dipstick B to check the level Pour in fluid until reaching the MAX level mark 11 Upon completion reinstall the oil dipstick B completely 12 Tighten the ca...

Page 32: ...portant Do not fill the new cartridge A with fuel 4 Loosen the air bleeding screw F on fuel filter bracket B e la vite E posta sulla pompa iniezione G 5 Turn the key on the control panel to the ON pos...

Page 33: ...te the rubber or plastic parts from the rest of the components The parts only composed of plastic material aluminium and steel can be recycled if collected by the appropriate centers Waste oil must pr...

Page 34: ...d Clogged fuel pipes Contact KOHLER authorised workshops Low idle speed Clogged fuel pipes Contact KOHLER authorised workshops Poor quality fuel Clean the tank and refuel with quality fuel 2 5 Blue sm...

Page 35: ...anty from date of purchase of the part up to the first scheduled replacement point for the subject parts components All other Spare Parts items are covered by the above warranty provided that the repa...

Page 36: ...nance listed in your Use Maintenance Manual Kohler Co recommends that you retain all receipts covering maintenance on your off road marine engine but Kohler Co cannot deny warranty solely for the lack...

Page 37: ...d to meet the state s and US EPA anti smog standards The warranty period shall begin on the date the engine or equipment is delivered to an ultimate purchaser Kohler Co must warrant the emission contr...

Page 38: ...ontrolandreplaceelementsontheirexpiry withoutmodifying or improving the functions carried out by the system neither increasing the value nor improving performance MAX Maximum Methyl ester It is a mixt...

Page 39: ...trical current 1 A gr gramme Weight 1 gr kg kilogramme 1 kg W Watt Power 1 W kW kiloWatt 1 kW pa pascal Pressure 1 pa KPa Kilopascal 1 KPa bar barometric pressure 1 bar mbar 1 1000 bar barometric pres...

Page 40: ...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...