Kohler KDI 1903M Owner's Manual

KDI 1903M - KDI 2504M

OWNER MANUAL

2

EN

UM KDI 1903M_2504M _ cod. ED0053029500 - 2° ed_rev. 01

30/07/2013

2° 1

30/07/2013

DICOM/ATLO

ED0053029510

51270

REGISTRATION OF MODIFICATIONS TO THE DOCUMENT

Any modications to this document must be registered by the drafting body, by completing the following table.

Drafting

body

Code

document

Edition

Date

issue

Date

Review

Revision

Model

N°

Endorsed

Written by

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.

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- Clicking next to the bottom page number you come back to the analytic index.

3

EN

A

Air lter cartridge replacement ..........................................33

Air lter check......................................................................23

Alternator standard belt tension, check and setting

........26

B

Battery recommendations ..................................................13

Break-in, Running

................................................................19

C

Cartridge replacement, Air lter .........................................33

Cartridge replacement, Oil lter

.........................................30

Cartridge replacement (optional), Remote oil lter

..........31

Check, Air lter

....................................................................23

Check and setting alternator standard belt tension

.........26

Check, Coolant level

...........................................................25

Check of the radiator heat-exchanger surface

.................24

Check, Oil level

....................................................................23

Check, Pre-start

...................................................................19

Check, Rubber hoses

..........................................................24

Cylinder head, Oil dipstick on

............................................23

Component identication, Engine

.......................................7

Control water lter cartridge fuel

.......................................27

Coolant level check

.............................................................25

Coolant

.................................................................................13

Coolant lling

.......................................................................21

D

Denitions, Glossary and .....................................................6

Description, Safety signal...................................................16

Dimensions, Engine

............................................................10

Disposal and scrapping

......................................................33

E

Emission-Related Installation Instructions .........................6

Engine component identication

.........................................7

Engine dimensions

..............................................................10

Engine, General description of the

....................................10

Engine oil replacement

.......................................................29

Engine, Location of safety signals on

...............................18

Engine specications..........................................................10

Engine starting after storage..............................................28

Engine storage (up to 6 months)

.......................................28

Engine storage (over 6 months)

.........................................28

F

Filter check, Air ....................................................................23

Filter cartridge replacement, Air

........................................33

Filter cartridge replacement (optional) replacement, Oil

.31

Filling, Coolant

.....................................................................21

Filling, Oil

.............................................................................20

Fuel

....................................................................................... 11

Fuel lter cartridge replacement

........................................32

G

General description of the engine .....................................10

General remarks

..................................................................14

Glossary and Denitions

......................................................6

H

Heat-exchanger surface, Check of the radiator ................24

Hoses check, Rubber

..........................................................24

I

Identication, Engine component ........................................7

Identication data, Manufacturer and motor

......................8

Information and safety signals...........................................17

Information, Safety

..............................................................14

INDEX

UM KDI 1903M_2504M _ cod. ED0053029510 - 2° ed_rev. 01

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EN

L

Level check, Coolant ...........................................................25

Level check, Oil

...................................................................23

Location of safety signals on engine

................................18

M

Maintenance, Periodic.........................................................22

Manual's purpose

..................................................................6

Manufacturer and motor identication data

.......................8

Manufacturer’s warranty coverage

....................................35

Motor identication data, Manufacturer and

.......................8

O

Oil .......................................................................................... 11

Oil dipstick on cylinder head..............................................23

Oil lter cartridge replacement (optional), Remote

..........31

Oil lter cartridge replacement

..........................................30

Oil lling

...............................................................................20

Oil level check......................................................................23

Oil replacement, Engine......................................................29

Owner’s warranty responsinilities

.....................................35

P

Periodic maintenance .........................................................22

Precautions, Safety

.............................................................18

Pre-start check.....................................................................19

Product preservation

..........................................................28

Purpose, Manual's

.................................................................6

R

Recommendations, Battery ................................................13

Refuelling

.............................................................................20

Remote oil lter cartridge replacement (optional)

...........31

Remarks, General

................................................................14

Replacement, Air lter cartridge

........................................33

Replacement, Engine oil

.....................................................29

Replacement, Fuel lter cartridge......................................32

Replacement, Oil lter cartridge ........................................30

Request, Service....................................................................6

Rubber hoses check

...........................................................24

Running, Break-in

................................................................20

S

Safety information ...............................................................14

Safety signals, Information and

.........................................17

Safety signal description

....................................................16

Safety signals on engine, Location of

...............................18

Safety precautions

..............................................................18

Safety and environmental impact

......................................17

Scrapping, Disposal and.....................................................33

Service request

......................................................................6

Specications, Engine

........................................................10

Starting after storage, Engine

............................................28

Starting and turning off

.......................................................19

Storage, Engine starting after

............................................28

Storage (up to 6 months), Engine

......................................28

Storage (over 6 months), Engine

.......................................28

T

Tension, check and setting alternator standard belt ......26

Turning off, Starting and

.....................................................19

U

Useful information about failures ......................................34

Useful information about maintenance

.............................22

W

Warranty coverage, Manufacturer’s ..................................35

Warranty responsinilities, Owner’s

...................................35

Water, Control lter cartridge fuel

.....................................27

INDEX

UM KDI 1903M_2504M _ cod. ED0053029510 - 2° ed_rev. 01

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........................................................................................................................................................

EN

NOTES

........................................................................................................................................................

UM KDI 1903M_2504M _ cod. ED0053029500 - 2° ed_rev. 01

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EN

GENERAL INFORMATION

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 necessar y 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.

Glossar y and Denitions

The paragraphs, tables and gure are divided into chapter with their progressive numbers. Ex: Par. 1.3 - chapter 1 paragraph 3. Tab. 2.4 - chapter 2 table 4. Fig. 4.5 - chapter 4 gure 5.

The references of the objects described in the text and in gure and number are indicated by letters, which are always and only related to the paragraph you are reading unless there are specic references to other gures or paragraphs.

The gure are based on model 2504 M, where necessary the version 1903 M is illustrated.

All data, measurements and relevant symbols are shown in the table below.

Emission-Related Installation Instructions

Failing to follow the instructions in the applications guidebook when installing a certied engine in a piece of nonroad equipment violates federal law (40 CFR 1068.105(b)), subject to nes 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 certied 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.

DATA MEASUREMENT SYMBOL EXAMPLE

Distance millimeter mm 1 mm

Torque newton-meter Nm 1 Nm

Force newton N 1 N

Mass Kilogram Kg 1 kg

Volume cubic centimeter cm

3

1 cm

3

Pressure pascal Pa 1 Pa

Volume liter L 1 L

Angle Degree

a

1°

Power kiloWatt kW 1 kW

Temperature centrigrade degree °C 1°C

Service request

• Authorized service centers can be found in the ser vice handbook (received with the product purchased).

• The com p lete an d up d ate d li s t o f au thori zed Kohl e r Co . s e r v ice c e nter s can be foun d on ou r we b site:

http://www.lombardinigroup.it/dealer-locator.

• If you have any que stions re garding your warrant y right s and responsibi lities or t he location of the nea rest 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).

UM KDI 1903M_2504M _ cod. ED0053029500 - 2° ed_rev. 01

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EN

SIDE VIEW A

SIDE VIEW B

Engine component identication

High pressure pump

GENERAL INFORMATION

Thermostat

Water temperature

sensor

Oil filler cap

Water pump

Alternator

Oil filler cap

Oil pressure sensor

Starter motor

Oil drain plug

Oil lter

Fuel lter

Nameplate

Oil drain plug

UM KDI 1903M_2504M _ cod. ED0053029510 - 2° ed_rev. 01

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Fig. 2.3

EN

GENERAL INFORMATION

Manufacturer and motor identication data

Peak

rpm

Engine serial number

Approval data and

"EC" directives

Engine type

Engine

version

Manufacturer identication

The engine identication nameplate is located on side A or B as below.

SIDE VIEW A SIDE VIEW B

UM KDI 1903M_2504M _ cod. ED0053029500 - 2° ed_rev. 01

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........................................................................................................................................................

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NOTES

UM KDI 1903M_2504M _ cod. ED0053029500 - 2° ed_rev. 01

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KDI 1903 M

KDI 2504 M

Tab. 1.1

TECHNICAL INFORMATION

EN

1.2 Engine specications

1.1. General description of the engine

- 4-stroke, in-line cylinders Diesel engine;

- Liquid-cooling system;

- 4 valves per cylinder with hydraulic tappets;

- Injection.

TECHNICAL DATA

UNIT

OF

MEASURE

ENGINE TYPE KDI 1903 M KDI 2504 M

CYLINDERS n. 3 4

BORE mm 88

STROKE mm 102

DISPLACEMENT cm

3

1861 2482

MAX INCLINATION DURING OPERATION (even in combined)

degree 30° max. 30 minuti

degree 35° max.1 minuto

OIL CAPACITY

(MAX level.)

including oil lter

standard version L 8.7 11.0

with dynamic balancer (optional)

L 10.7

DRY WEIGHT Kg 233 267

1.3 Engine dimensions (mm)

UM KDI 1903M_2504M _ cod. ED0053029510 - 2° ed_rev. 01

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TECHNICAL INFORMATION

EN

Tab. 1.2

RECOMMENDED OIL

VISCOSIT Y SAE 10W-40 / 5W-40

WITH SPECIFICATIONS

API CI-4, CH-4, CG- 4

ACEA E4 - E5 - E7

1.4 Oil

Important

• The engine may be damaged if operated with improper oil level.

• Do not exceed the MAX level because a sudden increase in engine rpm could be caused by its combustion.

• Use only the recommended oil to ensure adequate protection, efficiency and service life 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. 1.4.1).

Danger

• Prolonged skin contact with the exhausted engine oil can cause cancer of the skin.

• If contact with oil cannot be avoided, thoroughly wash your hands with soap and water as soon as possible.

• For the exhausted oil disposal, refer to Par. 5.6 DISPOSAL

and SCRAPPING.

1.5 Fuel

Important

• Use the same type of diesel fuel as used in cars (EN 590 for E.U. - ASTM D975-09B regulation - Grade 1e 2). 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 fuel injectors from clogging. Immediately clean up any spillage during refuelling.

• Never store diesel fuel in galvanized containers (i.e. coated with zinc). Diesel fuel and the galvanized coating react chemically to each other, producing flaking that quickly clogs filters or causes fuel pump and/or injector failure.

1.4.1 SAE oil classication

• In the SAE classification, oils are identified according to viscosit y without considering any other qualitative characteristic.

• The code is made up of two numbers. The first number refers to the viscosity when cold, for use during winter (" W"= winter), while the second number is for viscosity at high temperatures.

1.5.1 Fuel for low temperatures

• When operating the engine in ambient temperatures lower than 0 degrees C, use use suitable low temperature fuel normally available from fuel distributors and corresponding to the specifications of Tab. 1.3 pag. 12.

• These fuels reduce the formation of paraffin in diesel at low temperatures.

• When paraffin forms in the diesel, the fuel filter becomes blocked interrupting the flow of fuel.

CLASSIFICATION DESCRIPTION ACEA SPECIFICATION

E4 High performance (Euro 1 - 2 - 3 Engines) heavy duty

E5 High performance (Euro 1 - 2 Engines) heavy duty

E7 High power over long distances (Euro 4 - 5 engines)

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TECHNICAL INFORMATION

EN

(1) Without adding oil.

(2) Stage 3A.

(3) EPA TIER III.

1.5.2 Biodiesel fuel

• Fuels containing 10% methyl ester or B10, are suitable for use in this engine provided 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.

FUEL COMPATIBILITY

Compatible

Certication

emission

Warranty coverage

Engine waste

yes no yes no yes no yes no

EN 590, DI N 51628 - Militar y NATO fuel F- 54 (S=10 ppm)

(2)

No 1 Diese l (US) - ASTM D 975 -09 B - Grade 1-D S 15

(S=15 ppm)

(3)

No 1 Diese l (US) - ASTM D 975 -09 B - Grade 1-D S 500

(S=500 ppm)

No 2 Diese l (US) - ASTM D 975 -09 B - Grade 2- D S 15

(3)

No 2 Diese l (US) - ASTM D 975 -09 B - Grade 2- D S 1500

ARCTIC (EN 590/AST M D 975- 09 B)

(1) (3)

High sulf ur fuel < 5000 ppm (<0.5%)

High sulf ur fuel > 5000 ppm (>0.5%)

High sulf ur fuel > 10000 ppm (>1%)

Civil Jet Fuels Jet A/A1

(1)

Civil Jet Fuels Jet B

Bio Fuels (EN14214). Max. 30%

Bio Fuels (AST M D 6751-09a). Ma x. 30%

Tab. 1.3

1.5.3 Emission-Related Installation Instructions

Failing to follow the instructions in the applications guidebook when installing a certied engine in a piece of nonroad equipment violates federal law (40 CFR 1068.105(b)), subject to nes 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 certied 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.

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Tab. 1.4

TECHNICAL INFORMATION

EN

Battery not supplied by Kohler

1.7 Battery recommendations

1.6 Coolant

TECHNICAL SPECIFICATIONS

50% ETHYLENEGLYCOL e 50% WATER

50% PROPYLENE GLYCOL e 50% WATER

ANTIFREEZE TYPE

BASF

G05 G30 G33 G34 G40 G48 G50

VW

G13 G12++

ARTECO

XLC XLI LONG LIFE COOLANT FREECOR SPC FREECOR DSC

TEXACO

AFC XLC

REVKOGEL 2000

PARAFLU F02

CCI

LLC L255A LLC A432

RECOMMENDED BATTERIES

AMBIENT TEMPERATURE BATTERY TYPE

from 0°C to -15°C

110Ah/20h - 500 A/DIN

110Ah/20h - 980 A /EN

110Ah/20h - 950 CCA/SAE

from -15°C to -25°C

120Ah/20h - 560 A/DIN

120Ah/20h - 1100 A/EN

120Ah/20h - 1050 CCA/SAE

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SAFETY INFORMATION

EN

2.1 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.

2.2 General remarks

2.2.1 Note for OEM

• When installing the KDI engines, always bear in mind that any variation to the functional systems may result 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.

2.2.2 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.

• 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.

• The engine may only be assembled on a machine by 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.

• Do not smoke or use naked 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 whilst it is still hot as the fan could also start operating when the engine is at a standstill.

Important

• This operation should be carried out with vacuum pump.

• The oil must be drained whilst the engine is hot . Particular care is required to prevent burns. Do not allow the oil to come into contact with the skin because of the health hazards involved.

• During operations that involve access to moving parts of the engine and/or removal of rotating guards, disconnect and insulate the negative wire (-) of the battery to prevent accidental short-circuits and to stop the starter motor from being energized.

• Check belt tension only when the engine is off.

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15

Fig. 2.1

A A

α ≤ 15° α ≤ 15°

SAFETY INFORMATION

EN

• Fully tighten the tank cap each time after refuelling. Do not fill the tank right to the top but leave an adequate space for the fuel to expand.

• To star t the engine follow the specific instructions provided in the engine and/or machine operating manual. Do not use auxiliary starting devices not originally installed on the machine (e.g. Startpilot).

• Before starting, remove any tools that were 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 non-operation of the catalyst and non-obser vance of the emissions declared by KOHLER.

• Pay attention 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 polluting, it must therefore be disposed of in the correct way.

• Do not use air and water jets at high pressures on cables, connectors and injectors.

Important

• Only use the eyebolts A installed by KOHLER to move the engine (Fig. 2.1).

• The angle between each lifting chain and the eyebolts shall not exceed 15° inwards.

• The correct tightening of the lifting screws is 25Nm.

• Do not interpose spacers or washers between the eyebolts and engine head.

• Provided that the above requirements are met, if the lifting eyebolts are subject to permanent deformation (inwards), all subsequent lifting operations must be performed in order to prevent them from bending in the opposite direction.

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SAFETY INFORMATION

EN

2.3 Safety signal description

• To ensure safe operation please read the following statements and understand their meaning.

• Also refer to your equipment manufacturer's manual for other important safety information.

• This manual contains safety precautions which are explained below.

• Please read them carefully.

Danger

• This indicates situations of grave danger which, if ignored, may seriously threaten the health and safety of individuals.

Important

• This indicates particularly important technical information that should not be ignored.

Warning

• This indicates that failure to comply with it can cause minor damage or injury.

Read the Operation and Maintenance handbook before performing any operation on the engine.

Hot Parts. Danger of burns.

Presence of rotating parts. Danger of jamming or cutting.

Presence of explosive fuel. Danger of re or explosion.

Presence of steam and pressurized coolant. Danger of burns.

Use protective gloves before carrying out the operation.

Use protective glasses before carrying out the operation.

Use sound absorbing protections before carrying out the operation.

Lifting point.

Electrical shock. Danger of severe scalding or death.

High pressure uid. Danger of uid penetration.

Lethal Exhaust Gases. Danger of poisoning or death.

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SAFETY INFORMATION

EN

2.4 Information and safety signals

ACCIDENTAL START

Accidental Starts can cause severe injury or death.

Before working on the engine or equipment, disconnect the battery negative (-) wire.

ROTATING PARTS

Rotating Parts can cause severe injury.

Stay away while engine is in operation. Keep hands, feet, hair, and clothing away from all moving parts to prevent injury. Never operate the engine with covers, shrouds, or guards removed.

LETHAL EXHAUST GASES

Carbon Monoxide can cause severe nausea, fainting or death.

Avoid inhaling exhaust fumes and never run the engine in a closed building or conned area. Carbon monoxide is toxic, odorless, colorless, and can cause death if inhaled.

EXPLOSIVE GAS

Explosive Gas can cause res and severe acid burns.

Charge battery only in a well ventilated area. Keep sparks, open ames, and other sources of ignition away from the battery at all times. Batteries produce explosive hydrogen gas while being charged. Keep batteries out of the reach of children. Remove all jewelry when servicing batteries. Before disconnecting the negative (-) ground cable, make sure all switches are OFF. If ON, a spark will occur at the ground cable terminal which could cause an explosion.

HOT PARTS

Hot Parts can cause severe burns.

Engine components can get extremely hot from operation. Do not touch engine while operating or just after stopping. Never operate the engine with heat shields or guards removed.

EXPLOSIVE FUEL

Explosive fuel can cause res and severe burns.

Fuel is ammable and its vapours can ignite. Store fuel only in approved containers, in well ventilated, unoccupied buildings. Do not ll the fuel tank while the engine is 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 PRESSURE FLUID

RISK OF PUNCTURE

High Pressure Fluids can puncture skin and cause severe injury or death.

Do not work on fuel system without proper training or safety equipment. Fluid puncture injuries are highly toxic and hazardous.

If an injury occurs, seek immediate medical attention.

ELECTRICAL SHOCK

Electrical Shock can cause injury.

Do not touch wires while engine is running.

CALIFORNIA

WARNING - DECLARATION 65

Engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

2.5 Safety and environmental impact

Every organisation has a duty to implement procedures to identify, assess and monitor the inuence of its own activities (products, services, etc.) on the environment. Procedures for identifying the extent of the impact on the environment must consider the following factors:

- Liquid waste.

- Waste management.

- Soil contamination.

- Atmospheric emission.

- Use of raw materials and natural resources.

- Regulations and directives regarding environmental impact.

In order to minimise the impact on the environment, KOHLER now provides a number of indications to be followed by all persons handling the engine, for any reason, during its expected lifetime.

- All packaging components must be disposed of in accordance with the laws of the country in which disposal is taking place.

- Keep the fuel and engine control systems and the exhaust pipes in ef cient working order to limit environmental and noise pollution.

- When discontinuing use of the engine, select all components according to their chemical characteristics and dispose of them separately.

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KDI 1903 M

KDI 2504 M

SAFETY INFORMATION

EN

• Check the good condition of safety signals.

• The user must replace them with original ones if they are deteriorated and illegible. Ask for new safety signals to the manufacturer.

2.6 Safety precautions

2.7 Location of safety labels on engine

• Position them as shown in Par. 2.7.

• Clean with a cloth, water and soap.

UM KDI 1903M_2504M _ cod. ED0053029500 - 2° ed_rev. 01

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INFORMATION ABOUT USE

EN

•Read carefully the following pages and carr y out the op era tio ns des crib ed bel ow in accordanc e with the instructionsspecified.

Important

•Noncompliancewiththeoperationsdescribedinthefollowing pagesinvolvestheriskofdamagestotheengineandvehicle onwhich it isinstalled aswell as personal and/or property damage.

3.1 Pre-start check

•

Increasethefrequencyofmaintenanceoperationsinheavy workingconditions(enginestarts butstops,very dustyand hotenvironments,etc...).

3.2 Break-in running

NOTE:

Forthefirst50hoursofengineoperation,itisadvisablenottoexceed75%ofthemaximumpowersupplied.

3.3 Starting and turning off

3.3.1 Starting

1 - Checktheleveloftheengine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itwhentheenginestarts(thekeywillreturnintoONpositionautomatically).

Important

•Donotactuatethestarterformorethan15secondsatatime.Iftheenginedoesnotstart,waitforoneminutebeforerepeating attempt.

•IfenginedoesnotstartaftertwoattemptsseeTab. 6.1andTab. 6.2tofoundthecause.

3.3.2 After starting

Warning

•Makesurethatallthewarninglightsonthecontrolpanelareoffwhentheengineisrunning.

1 - Runatminimumspeedforafewminutesaccordingtotable(exceptconstantspeedengine).

AMBIENT TEMPERATURE TIME

≤ -20°C 2 minutes

from -20° C to -10°C 1 minutes

from -10° C to -5° C 30 seconds

from -5° C to 5° C 20 seconds

≥ 5° C 15 seconds

UM KDI 1903M_2504M _ cod. ED0053029510 - 2° ed_rev. 01

3

20

MIN

MAX

B

Fig. 3.2

Fig. 3.1

C

A

INFORMATION ABOUT USE

EN

3.3.3 Turning off

1 - Do not turn off the engine when it is running at the maximum rotation speed (except constant speed engine).

2 - Before turning it off, keep it idle at minimum speed for about 1 minute.

3 - Turn the key to OFF position.

3.4 Refuelling

Danger

• Fill the engine off.

• The only approved fuels are those listed in Tab. 1.3 page 12.

• In those countries where diesel has a high sulphur content, its is advisable to lubricate the engine with a high alkaline oil or alternatively to replace the lubricating oil recommended by KOHLER more frequently.

• To avoid explosions or fire outbreaks, do not smoke or use open flames during the operations.

• Fuel vapours are highly toxic.Only carry out the operations outdoors or in 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 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 overll the fuel tank. Leave room for the fuel to expand.

NOTE: At the rst fuelling or if the tank was empty bleeding the fuel system (Par 5.4 from point 6 to point 9).

3.5 Oil lling

Important

• For safety precautions see Par. 1.4.

1 - Loosen the oil filler cap A or the oil filler cap C if the cap A

is not accessible.

2 - Add the type and amount of oil recommended (Tab. 1.1

and Tab. 1.2).

3 -

Before checking oil engine needs to be level.

4 - Remove the oil dipstick B and check that the level is up to

but does not exceed the

MAX

.

5

-

If level is not at the MAX. level, add additional oil.

6 - Re-tighten the cap A or C.

UM KDI 1903M_2504M _ cod. ED0053029500 - 2° ed_rev. 01

3

21

Fig. 3.3

A

INFORMATION ABOUT USE

EN

NOTE: Before proceeding with any operation on the engine,

stop it and allow it to cool.

Warning

• Presence of steam pressurized coolant danger of burns.

1 - Loosen the cap A and fill the radiator with coolant

composed of:

50% ANTIFREEZE and 50% decalcified water.

2 - Top liquid up until the pipes inside the radiator are covered

by about 5 mm.

Do not overll the radiator, but leave room for the coolant

to expand.

3 - For engines equipped with expansion tank, pour in fluid

until reaching the max level mark.

4 - Re-tighten the cap A.

5 - Bleeding the cooling circuit as indicated in the Par. 4.8.

6 - After a few hours of operator, stop the engine and allow the

liquid to cool returns to a ambient temperature and check the coolant level again.

Warning

• An anti-freeze protection liquid (ANTIFREEZE) - mixed with decalcified water - must be used.

• The freezing point of the refrigerant mixture depends on the amount concentration in water.

3.6 Coolant lling

• As well as lowering the freezing point, the antifreeze also raises the boiling point.

• A 50% mixture is recommended to ensure a general level at protection prevents the formation of rust, galvanic currents and calcium deposits..

UM KDI 1903M_2504M _ cod. ED0053029500 - 2° ed_rev. 01

4

22

Tab. 4.1

Tab. 4.2

INFORMATION ABOUT MAINTENANCE

EN

(1) - In case of low use: 12 months.

(2) - The period of time that must elapse before checking the filter

element depends on the environment in which the engine operates.

The air filter must be cleaned and replaced more frequently under

very dusty conditions.

(3) - In case of low use: 36 months.

(4) - In case of low use: 24 months.

(5) - The replacement must be carried out by authorized

KOHLER workshops.

4.2 Periodic maintenance

The intervals of preventive maintenance in Tab. 4.1 and Tab. 4.2 refer to the engine operating under normal operating conditions with fuel and oil meeting the recommended specications.

• This chapter shows all operations described in the Tab. 4.1 and Tab. 4.2 that may be directly carried out by the user.

• Periodic inspection and maintenance operations must be carried out as indicated in this manual and are the responsability of the user.

• Failure to comply with these service and maintenance intervals increases the risk of technical damage to the engine. Any non compliance makes the warranty become null and void.

• In order to prevent personal and property damage read carefully the instructions listed below before proceeding with any operation of the engine.

4.1 Useful information about maintenance

Warning

• Inspections must be made when the engine is off and cold.

• Pla c e en g ine o n le vel sur face t o e n s ure accurat e 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 plug and oil ller cap are tightened rmly.

CLEANING AND CHECKING

OPERATION DESCRIPTION

PERIOD (HOURS)

PAR.

10 250 500 1000 5000

Engine oil level

4.3

Coolant level / Check of the radiator heat-exchanger surface

(2)

4.8

4.6

External cartridge dry-type air lter

(2)

4.5

Radiator heat-exchange surface

(2)

4.6

Alternator belt tension

(5)

4.9

Rubber hose (intake air / coolant)

4.7

Fuel hose --

REPLACEMENT

OPERATION DESCRIPTION

PERIOD (HOURS)

PAR.

10 250 500 1000 5000

Engine oil

(1)

5.1

Oil lter cartridge

(1)

5.3

Fuel lter cartridge

(1)

5.4

Alternator belt

(3) (5)

--

Coolant

(4)

--

Intake manifold hose (air lter - intake manifold)

(5)

--

Coolant hoses

(5)

--

Dry air cleaner external cartridge

(2)

After 6 checks with cleaning

The replacement must be carried out by

authorized KOHLER workshops

5.5

Fuel line hose

The replacement must be carried out by authorized

KOHLER workshops

UM KDI 1903M_2504M _ cod. ED0053029510 - 2° ed_rev. 01

4

23

MIN

MAX

B

Fig. 4.1

Fig. 4.2

A

C

B

Fig. 4.5

EA D C

Fig. 4.4

Fig. 4.3

MIN

MAX

B

INFORMATION ABOUT MAINTENANCE

EN

4.3 Oil level check

1 -

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 completely.

4 -

Re-tighten the cap A and/or C.

4.4 Oil dipstick on cylinder head

4.5 Air lter check

NOTE: Components not necessarily supplied by KOHLER.

1 -

Release the two clasps D of the cover A.

2 -

Remove the cartridges B.

3 -

Clean the inside components A and C with a damp cloth.

4 -

Do not use compressed air, repeatedly tap the front side

E on a at surface.

Important

• When the cartridge G is dirty, do not clean it but replace cartridges B and G.

5 -

Reinstall:

- cartridges G and B.

- the cover A checking the right tightness of clasps D.

UM KDI 1903M_2504M _ cod. ED0053029500 - 2° ed_rev. 01

4

24

Fig. 4.6

A

Fig. 4.7

E

F

B1

D

B2

C

A

INFORMATION ABOUT MAINTENANCE

EN

Danger

For safety precautions see Cap. 2.

4.6 Check of the radiator heat-exchanger surface

NOTE: Component not necessarily supplied by KOHLER.

Important

• Wear safety goggles when using compressed air.

• The radiator heat-exchange surface must be cleaned on both sides.

1 -

Check the radiator heat-exchange surface D.

2 -

Clean the surface with a brush soaked in special detergent

if it is clogged.

4.7 Rubber hoses check

The check is carried out by exerting a slight deection 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.

Important

• If hoses are damaged contact an authorized KOHLER workshop.

1

- Check that the:

- Fuel system hoses A are intact.

- Hoses for the cooling circuit B1 and B2.

To access the control of the cooling hoses B1

unscrew the four screws E and remove the safe guard F.

- Vent system pipes C.

- Air system ducts D.

When the control is nished the safe guard F mount and tighten the four screws E.

UM KDI 1903M_2504M _ cod. ED0053029500 - 2° ed_rev. 01

4

25

Fig. 4.9

Fig. 4.8

A

C

MAX

B

INFORMATION ABOUT MAINTENANCE

EN

4.8 Check coolant level

NOTE:

Before proceeding with any operation on the engine,

stop it and allow it to cool.

Warning

• Presence of steam pressurized coolant danger of burns.

NOTE: Component not necessarily supplied by KOHLER.

1 -

Start the engine without the radiator 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 cap A.

6 -

For engines equipped with expansion tank (B), check that

the fluid is until reaching the max level mark.

NOTE: For coolant lling see Par. 3.6.

Warning

• Before star ting make sure that the radiator cap and cap, if present, are installed correctly to avoid spillage of liquid or vapour at high temperatures.

UM KDI 1903M_2504M _ cod. ED0053029500 - 2° ed_rev. 01

4

26

Fig. 4.12

p

G

10 mm

Fig. 4.13

40 Nm

B

40 Nm

E

C

D

Fig. 4.10

Fig. 4.11

A p

p

F

H

INFORMATION ABOUT MAINTENANCE

EN

4.9 Check and setting alternator standard belt tension

4.9.1 Check

1 - Check the belt condition A if worn out or deteriorated,

replace it.

3 - Check that at point p the tension value is between 70 and

75 Hz for V-belt of 9 mm and 80 and 85 Hz for V-belt of 17

mm (Fig. 4.8) (H).

Using the tool F (DENSO BTG-2) shown in the picture

(or a similar one) it is possible to check the corresponding value in Newton, (which should be) included between 200 and 230 N for V-belt of 9 mm and 350 and 450 N for V-belt of 17 mm (Fig. 4.8) (H).

Should the correct tool not be available, the belt tension

can be checked by applying a force in the direction of arrow G of approx' 10kg on the point p. When correctly tensioned the belt must show a movement of less than 10 mm.

If not adjus it.

4.9.2 Adjustment

1 - Loosen the fastening bolts B and C.

2 -

Pull 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 and C in sequence with a torque wrench E

(tightening torque of 40 Nm).

5 -

Check that at point p the tension value is between 70 and

75 Hz for V-belt of 9 mm and 80 and 85 Hz for V-belt of 17

mm (Fig. 4.8) (H).

Using the tool F (DENSO BTG-2) shown in the picture

(or a similar one) it is possible to check the corresponding value in Newton, (which should be) included between 200 and 230 N for V-belt of 9 mm and 350 and 450 N for V-belt of 17 mm (Fig. 4.8) (H).

Should the correct tool not be available, the belt tension

can be checked by applying a force in the direction of arrow G of approx' 10kg on the point p. When correctly tensioned the belt must show a movement of less than 10 mm.

Let the engine run for some minutes, then let it cool down

at ambient temperature and repeat the operations 2, 3, 4 and 5 in case the belt tension results out of the above mentioned values.

NOTE: Contact KOHLER authorised workshops for

replacement.

UM KDI 1903M_2504M _ cod. ED0053029500 - 2° ed_rev. 01

4

27

Fig. 4.14

A

INFORMATION ABOUT MAINTENANCE

EN

4.10 Control water lter cartridge fuel

1 -

Gently loosen the water drain plug A without removing it.

2 - Spill out the water if present.

3 - Re-tighten the water drain plug A as soon as the fuel spills.

UM KDI 1903M_2504M _ cod. ED0053029500 - 2° ed_rev. 01

4

28

INFORMATION ABOUT MAINTENANCE

EN

4.11 Product preservation

Important

• If the engines are not to be used for 6 months, they must be protected by carrying out the operations described in Engine storage (up to 6 months) (Par. 4.12).

• If the engine is still not in use after the first 6 months, it is necessary to carry out a further operation to extend the protection period (more than 6 months) (Par. 4.13).

• If the engine is not to be used for an extended period, the protective treatment procedure must be repeated within 24 months of the previous one.

4.12 Engine storage (up to 6 months)

Before storing the engine check that:

• The environments are not humid or exposed to bad weather. Cover the engine with a proper protective sheet against dampness and atmospheric contaminants.

• The place is not near electric panel.

• Avoid storing the engine in direct contact with the ground.

4.13 Engine storage (over 6 months)

Follow the steps described in Par. 4.12.

1 -

Engine oil replacement (Par. 5.1).

2 -

Refuel with fuel 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 expansion tank: make sure that the coolant is up to the maximum level.

4 -

Without expansion tank: Top liquid up until the pipes inside the radiator are covered

by about 5 mm.

Do not overll the radiator, but leave room for the fuel to

expand.

5 - Start the engine and keep it idle at minimum speed for 2

minutes.

6 -

Bring the engine to 3/4 of the maximum speed for 5÷10

minutes.

7 - Turn off the 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 engine, if using a pressure washer

or steam cleaning device, avoid directing the nozzle on electrical components, cable connections and sealed rings (oil seals etc).

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 - avoiding absolutely electrical components.

12 - Treat non-painted parts with protective products.

13 - Loosen the alternator belt Par. 4.9.

If the engine protection is performed according to the suggestions indicated no corrosion damage should occur.

4.14 Engine starting after storage

1 -

Remove the protective sheet.

2 - Use a cloth soaked in degreasing product to remove the

protective treatment from the external parts.

3 - Inject lubricating oil (no more than 2 cm3) into the intake

ducts.

4 - Adjust the alternator belt tension (Par. 4.9).

5 - Refill the tank with fresh fuel.

Warning

• Over time, lubricants and filters lose their properties, so it is important consider whether they need replacing, also based on the criteria described in Tab. 4.2.

6 - Make sure that the oil and the coolant are up to the

maximum level.

7 - Start the engine and keep it idle at minimum speed for a

two about minutes.

8 - Bring the engine to 75% of maximum rated speed for 5 to

10 minutes.

9 - Stop the engine while the oil is still hot

(Par. 5.1), discharge the protective oil in a suitable container.

10 - Pour new oil (Par. 3.5) up to the maximum level.

11 - Replace the filters (air, oil, fuel) with original spare parts.

12 - Empty the cooling circuit completely and pour in the new

coolant up to the maximum level (Par. 3.6).

UM KDI 1903M_2504M _ cod. ED0053029500 - 2° ed_rev. 01

5

29

Fig. 5.2

50 Nm

D

Fig. 5.1

A

Fig. 5.3

A

C

B

D

E

INFORMATION ABOUT REPLACEMENTS

EN

5.1 Engine oil replacement

Important

• Pla c e e n gine on l eve l su r fa c e to en s ure accur a te measurement of oil level.

NOTE: Perform this operation with warm engine, to get a

better fluidity of the oil and get a full discharge of oil and impurities contained in it.

1 - Loosen the oil filler cap A (Fig. 5.1).

2 - Remove the oil dipstick B.

3 - Remove 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 SCRAPPING).

5 - Replace gasket E.

6 - Tighten the drain oil plug D (tightening torque at 50 Nm).

7 - Add the type and amount of oil recommended

(Tab. 1.1 and Tab. 1.2).

8 - If the plug A is not accessible, use the oil

filler cap C.

Important

• Do not exceed the MAX level on the dipstick.

Danger

Disconnect the negative wire (-) from the battery to avoid accidental engine starting.

UM KDI 1903M_2504M _ cod. ED0053029500 - 2° ed_rev. 01

5

30

A

B

Fig. 5.5

Fig. 5.6

B

Fig. 5.4

MIN

MAX

B

INFORMATION ABOUT REPLACEMENTS

EN

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 fuel filter refer

to Par. 5.6 DISPOSAL and SCRAPPING.

5.2 Oil lter cartridge replacement

1 -

Unscrew the oil filter A with appropriate wrench.

2 -

Assembly and tighten the new oil filter cartridge

A tightening it with torque wrench B (torque to

20 Nm).

9 -

Fit and remove the oil dipstick B to check the level.

Pour in fluid until reaching the MAX level mark.

10 - Upon completion, reinstall the oil dipstick B completely.

11 - Tighten the cap A or C.

UM KDI 1903M_2504M _ cod. ED0053029500 - 2° ed_rev. 01

5

31

Fig. 5.7

A

INFORMATION ABOUT REPLACEMENTS

EN

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 new cartridge A

usingtheappropriatewrench.

UM KDI 1903M_2504M _ cod. ED0053029510 - 2° ed_rev. 01

NOTE:Clickontheicon()toplaytheprocedure.

5

32

Fig. 5.9

A

C

D

B

Fig. 5.8

B

A

C

D

E

INFORMATION ABOUT REPLACEMENTS

EN

5.4 Fuel lter cartridge replacement

1 - Unscrew the filter cartridge A from the holder B.

2 - Unscrew the fuel water sensor D.

3 - Replace the gasket C.

4 - Lubricate the gasket E.

5 - Screw the new filter cartridge A.

Important

• Do not fill the new cartridge A with fuel.

6 - Turn the key on the control panel to the ON position.

The electric pump C sends fuel to the filter and then the

injection pump D.

7 - Procure a suitable container to collect the fuel.

8 - Loosen the air bleeding screw A on fuel filter bracket B.

The air inside the circuit and the filter will begin to escape

from the screw A.

9 - Tighten the bleeding screw A (tightening torque of 1.5 Nm)

when the fuel begins to flow.

UM KDI 1903M_2504M _ cod. ED0053029500 - 2° ed_rev. 01

NOTE: Click on the icon ( ) to play the procedure.

5

33

B

A F

Fig. 5.10

INFORMATION ABOUT REPLACEMENTS

EN

5.5 Air lter cartridge replacement

NOTE: Component not necessarily supplied by KOHLER.

1 -

Release the two fastenings F of the cover A.

2 -

Remove the cartridge B.

3 - Reinstall:

- the new cartridges B.

- the cover A checking the right tightness of fastenings F.

5.6 Disposal and scrapping

• In case of scrapping, the engine shall be 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 composed of plastic material, aluminium and steel can be recycled if collected by 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, therefore it must be collected by the appropriate centers.

UM KDI 1903M_2504M _ cod. ED0053029500 - 2° ed_rev. 01

6

34

INFORMATION ABOUT FAILURES

EN

Tab. 6.1

Tab. 6.2

6.1 Useful information about failures

•

Thischapter containsinformationabout the problemsthat mayappear duringengine operationwith its causesandtrouble shootingTab. 6.2.

•

Insomecases,youshallturnofftheengineimmediatelytoavoidfurtherdamage Tab. 6.1.

THE ENGINE MUST BE IMMEDIATELY TURNED OFF WHEN:

1

Theenginerpmssuddenlyincreaseanddecrease

2 Asuddenand/orunusualnoiseisheard

3 Thecolouroftheexhaustfumessuddenlydarkens

4 Theoilpressureindicatorlightturnsonwhilerunning

- IntheeventthatthesolutionsproposedinTab. 6.2donoteliminatethetrouble,contactaKOHLER authorizedworkshop.

TROUBLES POSSIBLE CAUSE SOLUTION PAR.

The engine does not start

Sulphatedbat teryterminalscorroded Cleanthebatteryterminals --

Batteryvoltagetoolow Rechargethebatteryorreplaceit --

Lowfuellevel Refuel 3.4

Frozenfuel ContactKOHLER authorisedworkshops --

Cloggedfuellter Replacewithanewlter 5.4

Airsuctioninfuelsystem ContactKOHLER authorisedworkshops --

Cloggedairlter Replacewithanewlter 5.5

Cloggedpipes ContactKOHLER authorisedworkshops --

Openfuse

Replacewithanewfuse;iftheproblempersists, contactKOHLER authorisedworkshops

--

Intakeorexhaustsystemclogged ContactKOHLER authorisedworkshops --

Enginestartsbutstops

Inefcientelectricalconnections

Cleantheelectricalcontacts;iftheproblempersists, contactKOHLER authorisedworkshops

--

Sulphatedbat teryterminals Cleanthebatteryterminals --

Cloggedfuellter Replacewithanewlterandcleanthetank --

Cloggedfuelpipes ContactKOHLER authorisedworkshops --

RPM instability at idle speed

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qualit yfuel 1.5

Bluesmoke

Highoilsumplevel

Replacetheengineoil;iftheproblempersists, contactKOHLER authorisedworkshops

--

Cloggedairlter Replacewithanewlter 5.5

Excessivefuel consumption

Cloggedairlter Replacewithanewlter 5.5

Highoilsumplevel

Replacetheengineoil;iftheproblempersists, contactKOHLER authorisedworkshops

--

Enginelostitsinitial performance

Cloggedairlter Replacewithanewlter 5.4

Cloggedfuelpipes ContactKOHLER authorisedworkshops --

Cheapfuel Cleanthetankandrefuelwithqualit yfuel --

Highoilsumplevel

Replacetheengineoil;iftheproblempersists, contactKOHLER authorisedworkshops

--

Slowacceleration

Cloggedfuellter Replacethefuellter 5.4

Enginejerking

Cloggedfuelpipes ContactKOHLER authorisedworkshops --

Engineoverheats

Insufcientcoolantlevel Filluptothelevel 3.6

Highoilsumplevel

Replacetheengineoil;iftheproblempersists, contactKOHLER authorisedworkshops

--

Cloggedradiator

Cleantheradiator;iftheproblempersists,contact KOHLER authorisedworkshops

--

UM KDI 1903M_2504M _ cod. ED0053029510 - 2° ed_rev. 01

7

35

INFORMATION ABOUT WARRANTY

EN

• Your of f-road diesel engine emission control system is covered under warranty for a period of five (5) years or 3,000 hours, whichever occurs first, beginning on the date the engine or equipment is delivered to an ultimate purchaser for all constant speed engines with maximum power 19≤kW<37 and rated speed less than 3,000 rpm, all variable speed engines with maximum power 19≤kW<37 and all variable or constant speed engines with maximum power greater than 37 kW.

• Your off-road diesel engine emission control system on variable or constant speed engines with maximum power less than 19 KW and constant speed engines with maximum power 19≤kW<37 and rated speed equal to or greater than

3.000 rpm is covered under warranty for a period of two (2) years or 1,500 hours, whichever occurs first.

• If any emission related part on your engine is defective, the part will be repaired or replaced by Kohler Co.

• As the heavy-duty off-road engine owner, you are responsible for the performance of the required 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 solely for the lack of receipts or for your failure to ensure the performance of all recommended scheduled maintenance.

• As the heavy-duty off-road engine owner, you should however be aware that Kohler Co. may deny you warranty coverage if your heavy-duty off-road engine or emission control related component has failed due to abuse, neglect, improper maintenance or unapproved modifications.

• Your engine is designed to operate on commercial diesel fuel (No. 1 or No. 2 low sulfur or ultra low sulfur diesel fuel) only.

• Use of any other fuel may result in your engine no longer op era ting i n c o mpl ian c e w ith Ca lif orni a’s emi ssio ns requirements.

• Requirements for emission directive in force in the Californian State.

• You are responsible for initiating the warranty process.

• The Air Resources Board suggests that you present your heavy-duty off-road engine to a Kohler Co. dealer as soon as a problem exists.

• The warranty repairs should be completed by the dealer as expeditiously as possible.

• Please review the document titled, “Kohler Co. Federal and California Emission Control Systems Limited Warranty OffRoad Diesel Engines”, for complete details of your heavy-duty off-road engine warranty.

• If you have any questions regarding your warranty rights and responsibilities or the location of the nearest Kohler Co. auth orized service locat ion, you sh ould contact Kohler Co. at 1-800-544-2444 or access our website at www.kohlerengines.com (USA and North American).

• Th e c o m p l et e a n d up d a te d l is t o f a u t h o r i z ed Kohler Co. service centers can be found on our web site:

http://ww w.lombardinigroup.it/dealer-locator.

OWNER’S WARRANTY RESPONSIBILITIES

MANUFACTURER’S WARRANTY COVERAGE

UM KDI 1903M_2504M _ cod. ED0053029500 - 2° ed_rev. 01

36

........................................................................................................................................................

NOTES

EN

UM KDI 1903M_2504M _ cod. ED0053029510 - 1° ed_rev. 00

37

........................................................................................................................................................

NOTES

EN

UM KDI 1903M_2504M _ cod. ED0053029510 - 1° ed_rev. 00

Lombardini s.r.l. is a part of Kohler Group. Lombardini has manufacturing facilities in Italy, Slovakia and India and sales subsidiaries in France, Germany, UK, Spain and Singapore. Kohler/Lombardini reserves the right to make modications without prior notice.

www.lombardini.it

DE UT SC HL AN D

Lombardini Motoren GmbH

Silostr. 41, 65929 FRANKFURT Hessen, DEUTSCHLAND T. +49-(0)69-9508160 F. +49-(0)69-5073410

EU RO PE

Lombardini Srl

Via Cav. del lavoro A. Lombardini n° 2 42124 Reggio Emilia, ITALY T. +39-(0)522-389-1 F. +39-(0)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

FR AN CE

Lombardini France S.a.s.

47 Alléè de Riottier, 69400 Limas, FRANCE T. +33-(0)474-626500 F. +33-(0)474-623945

RO APA C

Lombardini Singapore

26 Keong Saik Road (3rd oor) Asia Pacic Represent.Oces 089154- Singapore T. +65-(0)622-50556 F. +65-(0)622-50551

ES PAÑ A

Lombardini ESPAÑA, S.L.

P.I. Cova Solera 1-9 08191 - Rubí (Barcelona) ESPAÑA T. +34-(0)9358-62111 F. +34-(0)9369-71613

US A & CAN AD A

Kohler Co.

444 Highland Drive, Kohler - Wisconsin (53044), US T. +1 920 457 4441 F. +1 920 459 1570

Translated from the original manual in Italian language.

Data reported in this issue can be modied at any time by KOHLER.

FORM NO. ED0053029510

ISSUED 30/07/2013

REVISED 01 DATE 30/07/2013

Kohler KDI 1903M Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual