Kohler KDI Series Gebrauchsanweisung

KDI 1903 TCR - KDI 2504 TCR

WORKSHOP MANUAL

TP-6916 04/16

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Ente

compilatore Codice

documento Edizione Data

emissione Data

revisione

Revisione

Modello

n° Visto

Redatto

DICOM/ATLO 04/20168 7 10/2013

ED0053029590

REGISTRATION OF MODIFICATIONS TO THE DOCUMENT

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

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ED0053029590 51273

TRANSLATED FROM THE ORIGINAL MANUAL IN ITALIAN LANGUAGE.

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

Important

•Connect to http://iservice.lombardini.it > KDI KOHLER DIESEL section > "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 gure below.

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ED0053029590

NOTES

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INDEX

1GENERAL INFORMATION 12

1.1 Useful information 12

1.2 Manufacturer and engine identication 13

1.3 Name plate for EPA regulations 14

1.4 Identication of main internal components of the engine and operating references 15

1.5 Identication of external components of the engine 17

2 TECHNICAL INFORMATION 19

2.1 Engine specications 19

2.2 Engine dimensions (mm) 21

2.3 Performance diagrams 22

2.4 Oil 23

2.4.1 SAE classication 23

2.4.2 International lubricant specications 23

2.5 Fuel 24

2.5.1 Fuel for low temperatures 24

2.5.2 Biodiesel fuel 24

2.5.3 Emissions - Regarding installation instructions 25

2.6 Coolant 25

2.7 Battery features 25

2.8 Scheduled maintenance 26

2.9 Fuel system 27

2.9.1 Injection circuit (2000 bar) 27

2.9.2 Fuel return circuit 28

2.9.3 High-pressure injection pump (2000 bar) 29

2.9.4 Electronic injector 30

2.9.5 Common rail 31

2.9.6 Fuel lter 32

2.9.7 Electric fuel pump (optional) 33

2.9.8 Guards for fuel injection circuit components 34

2.10 Lubrication circuit 35

2.10.1 Lubrication circuit diagram 35

2.10.2 Oil pump 36

2.10.3 Lub. oil lter and Oil Cooler 37

2.11 Coolant circuit 38

2.11.1 Coolant circuit diagram 38

2.11.2 Coolant pump 39

2.11.3 Radiator with intercooler (optional) 39

2.11.4 Thermostatic valve 39

2.11.5 EGR gas circuit cooling (EGR Cooler) 39

2.12 Intake and exhaust circuit 40

2.12.1 Turbocharger 40

2.12.2 Catalyst (optional) 40

2.12.3 Intake and exhaust circuit diagram with EGR 41

2.12.4 Air cleaner (optional) 42

2.13 Electric system 43

2.13.1 ECU input and output signals diagram 43

2.13.2 Control unit (ECU) 44

2.13.2.1 Installation rules 44

2.13.3 Engine electrical wiring 45

2.13.3.1 Wiring disconnection 46

2.14 Sensors and switches 48

2.14.1 Speed sensor on phonic wheel 48

2.14.2 Phase sensor indicator on camshaft 48

2.14.3 T-MAP sensor 48

2.14.4 Common Rail pressure sensor 48

2.14.5 Fuel lter water detection sensor 49

2.14.6 Fuel temperature sensor on fuel injection pump 49

2.14.7 Oil pressure switch 49

2.14.8 Coolant temperature sensor 49

2.14.9 Air cleaner clogging switch 50

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INDEX

2.15 Electrical components 50

2.15.1 Alternator 50

2.15.2 Poly-V belt alternator (optional) 50

2.15.3 Starter Motor 50

2.15.4 EGR valve 51

2.15.5 Cold starting device 51

2.15.6 Fuel intake regulating valve (SCV) 51

2.15.7 Electric fuel pump (optional) 52

2.16 Timing system and tappets 53

2.16.1 Components identication 53

2.16.2 Timing system phasing angles 54

2.16.3 Rocker arm gudgeon 54

2.16.4 Rocker arm 54

2.16.5 Hydraulic tappets 55

2.16.5.1 Hydraulic tappet operation 55

2.16.5.2 Difcult operating conditions 55

2.17 Balancer device 56

2.18 Components handling 57

2.18.1 High-pressure fuel injection pump 57

2.18.2 Electronic injector 57

2.18.3 Common Rail 57

2.18.4 Turbocharger 57

2.19 Turbocharger 58

2.19.1 What to do and what not to do 58

2.19.2 Practical operating rules 58

2.19.3 Before installing a new turbocharger 59

2.19.4 Installation instructions 60

2.19.5 Replacement instructions 60

3SAFETY INFORMATION 61

3.1 Pre-start check 61

3.2 Safety precautions 61

3.3 General remarks 61

3.3.1 Manufacturer's notes 61

3.3.2 Notes for the end user 61

3.4 Safety label description 63

3.4.1 Adhesive safety plates 63

3.4.2 Warnings 63

3.4.3 Safety guards 63

3.5 Information and safety labels 64

3.6 Safety and environmental impact 64

3.7 Location of safety labels on engine 65

4STORAGE INFORMATION 67

4.1 Product preservation 67

4.2 Engine storage (up to 6 months) 67

4.3 Engine storage (over 6 months) 67

4.4 Engine starting after storage 67

5LIQUID DRAINAGE INFORMATION 69

5.1 Coolant liquid 69

5.2 Engine oil 70

6INFORMATION FOR REPLACING FUNCTIONAL UNITS 71

6.1 Electronic injector replacement 71

6.1.1 Fuel return tubes disassembly (Common Rail/electronic injectors) 71

6.1.2 High pressure fuel tubes disassembly (Common Rail/electronic injectors) 72

6.1.3 Electronic injector disassembly 72

6.1.4 Electronic injector assembly 72

6.1.5 High-pressure fuel lines assembly 73

6.1.6 Fuel return tubes assembly 73

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INDEX

6.2 High-pressure fuel injection pump replacement 74

6.2.1 High pressure fuel tube disassembly (from injection pump to Common Rail) 74

6.2.2 Timing system carter oil lling ange disassembly 75

6.2.3 High-pressure fuel injection pump disassembly 75

6.2.4 High-pressure fuel injection pump assembly 76

6.2.5 High-pressure line assembly (injection pump / Common Rail) 77

6.2.6 Timing system carter oil lling ange assembly 77

6.3 EGR cooler unit replacement 78

6.3.1 Disassembly 78

6.3.2 Assembly 78

6.4 EGR valve replacement 79

6.4.1 Disassembly 79

6.4.2 Assembly 79

6.5 Coolant pump replacement 80

6.5.1 Disassembly 80

6.5.2 Assembly 81

6.6 Target wheel replacement 81

6.6.1 Disassembly 81

6.6.2 Assembly 83

6.7 Oil pump replacement 83

6.7.1 Coolant pump disassembly 83

6.7.2 Crankshaft and phonic wheel pulley disassembly 83

6.7.3 Timing system carter disassembly 83

6.7.4 Oil pump disassembly 83

6.7.5 Oil pump assembly 84

6.7.6 Timing system carter assembly 84

6.7.7 CRANKSHAFT AND PHONIC WHEEL PULLEY ASSEMBLY 85

6.7.8 Coolant pump assembly 86

6.8 Oil pressure valve replacement 86

6.8.1 Disassembly 86

6.8.2 Assembly 86

6.9 Oil steam separator replacement 87

6.9.1 Disassembly 87

6.9.2 Assembly 87

6.10 Oil Cooler Unit and lub. oil lter replacement 88

6.10.1 Oil Cooler unit disassembly 88

6.10.2 Oil lter cartridge replacement 88

6.10.3 Oil Cooler unit assembly 89

6.11 Fuel lter replacement 90

6.11.1 Disassembly 90

6.11.2 Assembly 90

7 INFORMATION FOR DISASSEMBLY 92

7.1 Recommendations for disassembly 92

7.2 EGR circuit disassembly 92

7.2.1 EGR Cooler Unit 92

7.2.2 EGR Valve 93

7.3 Electric components disassembly 93

7.3.1 Electric wiring 93

7.3.2 Starter motor 94

7.3.3 Belt and alternator 95

7.3.4 Sensors and switches 95

7.3.4.1 Oil pressure switch 95

7.3.4.2 Coolant temperature sensor 95

7.3.4.3 Speed sensor 95

7.3.4.4 Camshaft phase sensor 96

7.3.4.5 T-MAP sensor 96

7.3.4.6 Fuel lter water detection sensor 96

7.4 Turbocharger disassembly 96

7.5 Exhaust manifold disassembly 97

7.6 Coolant recirculation components disassembly 97

7.6.1 Oil Cooler manifold 97

7.6.2 Coolant pump 98

7.6.3 Thermostatic valve 98

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INDEX

7.7 Crankshaft and target wheel pulley disassembly 99

7.8 Lubrication circuit disassembly 99

7.8.1 Oil pressure valve 99

7.8.2 Timing system carter oil lling cover 99

7.8.3 Timing system carter 99

7.8.4 Oil pump 100

7.8.5 Oil Cooler Unit and lub. oil lter 100

7.8.6 Oil steam separator unit 101

7.9 Intake manifold disassembly 101

7.10 Fuel system disassembly 102

7.10.1 Fuel return tubes 102

7.10.2 Fuel ow tubes 102

7.10.3 High-pressure fuel lines 102

7.10.4 Common rail 103

7.10.5 Electronic injectors 103

7.10.6 Fuel lter 103

7.10.7 High-pressure fuel injection pump 104

7.11 Timing system gear disassembly 104

7.12 Flange unit disassembly 105

7.12.1 Flywheel 105

7.12.2 Flange bell 105

7.13 Cylinder head unit disassembly 105

7.13.1 Rocker arm cover 105

7.13.2 Rocker arm gudgeon 106

7.13.2.1 Rocker arms 106

7.13.3 Valve rods and bridges 106

7.13.4 Cylinder head 107

7.13.4.1 Valves 107

7.13.4.2 Electronic injector sleeves 108

7.13.4.3 Valve stem gasket 108

7.13.4.4 Lifting eyebolts 108

7.14 Oil sump unit disassembly 109

7.14.1 Oil sump 109

7.14.2 Oil suction pipe 109

7.14.3 Oil steam tube 109

7.15 Short block disassembly 110

7.15.1 Crankshaft gasket ange 110

7.15.2 Piston unit / connecting rod and crankshaft 110

7.15.3 Lower crankcase 111

7.15.4 Crankshaft 112

7.15.5 Piston 112

7.15.5.1 Rings 113

7.15.6 Oil spray nozzles 113

7.15.7 Camshaft 113

7.15.8 Camshaft tappets 113

7.15.9 Crankshaft bushings 114

7.15.10 3rd PTO cover 114

8INFORMATION ABOUT OVERHAULING AND TUNING 116

8.1 Recommendations for overhauls and tuning 116

8.2 Crankcase 116

8.2.1 Oil tubes check 116

8.2.2 Cylinders Check 117

8.2.3 4-cylinder camshaft housing check 118

8.2.4 4-cylinder camshaft check 118

8.2.5 3-cylinder camshaft housing check 119

8.2.6 3-cylinder camshaft check 119

8.3 Tappets and tappet housings 120

8.3.1 Tappets check 120

8.3.2 Tappet housing check 120

8.4 Crankshaft 121

8.4.1 Dimensional check and overhauling 121

8.4.2 Check the axial clearance of the crankshaft 122

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INDEX

8.5 Connecting rod-piston 122

8.5.1 Connecting rod dimension check 122

8.5.2 Checking the gudgeon pin-pin axes are parallel 123

8.5.3 Piston rings check 123

8.5.4 Piston dimension check 123

8.6 Cylinder head 124

8.6.1 Flatness check 124

8.6.2 Valve seats check 125

8.6.3 Valve springs 125

8.6.4 Valve guides check 125

8.6.5 Valve guides replacement 126

8.6.6 Rocker arm check 126

8.7 Oil pump check 127

8.7.1 Dimensional and visual check 127

8.7.2 Rotors clearance check 127

8.7.3 Oil pressure valve check 128

9ASSEMBLY INFORMATION 129

9.1 Information on engine conguration 129

9.2 Assembly recommendations 129

9.3 Short block assembly 130

9.3.1 Crankshaft bushings 130

9.3.2 Tappets 130

9.3.3 Camshaft 130

9.3.4 Oil spray nozzles 131

9.3.5 Crankshaft 131

9.3.6 Lower crankcases 131

9.3.7 Rings 133

9.3.8 Piston 133

9.3.9 Piston and connecting rod unit 134

9.3.10 Crankshaft oil seal ange 136

9.3.11 3rd PTO cover 136

9.4 Oil sump unit assembly 137

9.4.1 Oil vapour pipes 137

9.4.2 Oil suction pipe 137

9.4.3 Oil Sump 137

9.5 Flange unit assembly 138

9.5.1 Flange bell 138

9.5.2 Flywheel 138

9.6 Timing system gear assembly and injection pump assembly 139

9.6.1 Timing system gears 139

9.6.2 High-pressure fuel injection pump 140

9.7 Cylinder head unit assembly 141

9.7.1 Valve stem gasket 141

9.7.2 Electronic injector sleeves 141

9.7.3 Electronic injector projection 141

9.7.4 Valves 142

9.7.5 Cylinder head 142

9.7.6 Valve rods and bridges 144

9.7.7 Rocker arm 145

9.7.8 Rocker arm gudgeon unit 145

9.7.9 Rocker arm cover 146

9.8 Fuel system assembly 146

9.8.1 Fuel lter 146

9.8.2 Common Rail 147

9.8.3 Electronic injectors 147

9.8.4 High-pressure fuel lines 148

9.8.5 Fuel return tubes 148

9.9 Intake manifold assembly 149

9.9.1 Internal half-manifold 149

9.9.2 External half-manifold 150

9.10 Exhaust manifold assembly 150

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INDEX

9.11 Lubrication circuit assembly 150

9.11.1 Oil steam separator unit 150

9.11.2 Oil Cooler unit and lub. oil lter 151

9.11.3 Oil pump 152

9.11.4 Timing system carter 152

9.11.5 Timing system carter oil lling ange 153

9.11.6 Oil pressure valve 153

9.12 Crankshaft and phonic wheel pulley unit assembly 153

9.13 Coolant circuit assembly 154

9.13.1 Thermostatic valve 154

9.13.2 Water pump 154

9.13.3 Oil Cooler Manifold 154

9.14 Turbocharger assembly 155

9.15 Electric components assembly 156

9.15.1 Sensors and switches 156

9.15.1.1 T-MAP sensor 156

9.15.1.2 Water temperature sensor 156

9.15.1.3 Oil pressure switch 156

9.15.1.4 Camshaft phase sensor 156

9.15.1.5 Speed sensor 157

9.15.1.6 Fuel lter water detection sensor 157

9.15.2 Alternator 158

9.15.3 Starter motor 159

9.15.4 Electric cabling 159

9.16 EGR circuit assembly 160

9.16.1 EGR valve 160

9.16.2 EGR Cooler Unit 161

9.17 Torque specications and use of sealant 162

10 FLUIDS FILLING INFORMATION 166

10.1 Engine oil 166

10.2 Coolant 166

11 INFORMATION ABOUT OPTIONAL COMPONENTS 168

11.1 Oil dipstick in cylinder head 168

11.1.1 Check 168

11.1.2 Replacement 168

11.1.2.1 Disassembly 168

11.1.2.2 Assembly 168

11.2 Heater (replacement) 169

11.2.1 Disassembly 169

11.2.2 Assembly 169

11.3 Poly-V alternator belt (replacement or regulation) 170

11.4 Tightening pulley and alternator for Poly-V belt 170

11.4.1 Disassembly 171

11.4.2 Assembly 172

11.5 Idler gear (for 3rd / 4th PTO) 173

11.5.1 Disassembly 173

11.5.2 Assembly 173

11.6 3rd PTO (replacement) 174

11.6.1 Disassembly 174

11.6.2 Assembly 175

11.7 4th PTO (replacement) 176

11.7.1 Disassembly 177

11.7.2 Assembly 178

11.8 3rd+ 4th PTO (congurations) 180

11.8.1 Information 180

11.9 Balancer device (replacement) 181

11.9.1 Disassembly 181

11.9.2 Assembly 182

11.10 Air cleaner (cartridge replacement) 184

11.11 Remote lub. oil lter (disassembly and assembly) 184

11.11.1 Disassembly 184

11.11.2 Assembly 185

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INDEX

11.12 Oil sump with supporting structure 186

11.12.1 Flywheel disassembly 186

11.12.2 Plate/ange housing disassembly 186

11.12.3 Oil sump disassembly 186

11.12.4 Oil sump assembly 186

11.12.5 Flange plate / housing assembly 188

11.12.6 Flywheel assembly 188

12 INFORMATION REGARDING REGULATIONS 186

12.1 Waste Gate opening valve regulation 186

12.2 Air lter check 187

12.3 Oil steam separator check 187

12.4 Rubber hose and manifold control 187

12.5 Oil leak check 188

12.6 Oil pressure check 188

13 INFORMATION REGARDING TOOLS 193

13.1 Information regarding specic tools 193

14 INFORMATION REGARDING FAILURES 194

14.1 Possible causes and troubleshooting 194

15 GLOSSARY 196

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