KDI 1903M - KDI 2504M: Owner Manual

KDI 1903M - KDI 2504M
OWNER MANUAL
REGISTRATION OF MODIFICATIONS TO THE DOCUMENT
Any modifications to this document must be registered by the drafting body, by completing the following table.
Model Review
Released by Document code Edition Revision Issue date Edited by Endorsed
N° date
Technical Technical
Documentation
ED0053029510 51270 15 14.1 02/2013 05/2020
Documentation
Translated from the original manual in Italian language.
Data reported in this issue can be modified at any time by KOHLER.
Important
• Connect to http://iservice.lombardini.it 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.
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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EN 2 ED0053029510 _14
INDEX
1 - GENERAL INFORMATION 3 - SAFETY INFORMATION
1.1 Manual's purpose.............................................................5 3.1 Safety information.........................................................15
1.2 Glossary and Definitions.................................................5 3.2 General remarks............................................................15
1.3 Emission-Related Installation Instructions...................5 3.2.1 Note for OEM...............................................................15
1.4 Service request................................................................5 3.2.2 Note for end user........................................................15
1.5 Engine component identification...................................6 3.3 Safety signal description..............................................17
1.6 Manufacturer and motor identification data ...............7 3.3.1 Adhesive safety plates...............................................17
1.7 Homologation labels........................................................8 3.3.2 Safety guards..............................................................17
1.7.1 Label for China Standards............................................8 3.3.3 Warnings......................................................................17
1.7.2 Label for Korea Standards ..........................................9 3.4 Information and safety signals.....................................18
3.5 Safety and environmental impact................................18

2 - TECHNICAL INFORMATION
3.6 Location of safety labels on engine.............................19
2.1 General description of the engine...............................10
2.2 Engine specifications....................................................10 4 - INFORMATION ABOUT USE
2.3 Engine dimensions (mm)...............................................10

4.1 Pre-start check..............................................................20
2.4 Oil....................................................................................11
4.2 Running-in period..........................................................20
2.4.1 SAE oil classification..................................................11
4.3 Starting and turning off................................................20
2.5 Fuel..................................................................................12
4.3.1 Starting........................................................................20
2.5.1 Fuel for low temperatures.........................................13
4.3.2 After starting...............................................................20
2.5.2 Biodiesel fuel..............................................................13
4.3.3 Turning off...................................................................20
2.5.3 Synthetic fuels: GTL, CTL, BTL, HV..........................13
4.4 Refuelling........................................................................21
2.5.4 Non-Road Fuels..........................................................13
4.5 Oil filling..........................................................................21
2.5.5 Jet Fuels......................................................................13
4.6 Coolant filling.................................................................22
2.5.6 Emission-Related Installation Instructions.............13
2.6 Coolant............................................................................14
2.7 Battery recommendations............................................14
ED0053029510 _14 3 EN
INDEX
5 - INFORMATION ABOUT MAINTENANCE 7 - INFORMATION ABOUT FAILURES
5.1 Useful information about maintenance.......................23 7.1 Useful information about failures.................................34
5.2 Periodic maintenance...................................................23

8 - INFORMATION ABOUT WARRANTY
5.3 Oil level check................................................................24
5.4 Oil dipstick on cylinder head........................................24 Warranty terms.............................................................35

5.5 Air filter check................................................................24
9 - GLOSSARY
5.6 Check of the radiator heat-exchanger surface..........25
5.7 Rubber hoses check......................................................25 9.1 Glossary..........................................................................38

5.8 Check coolant level.......................................................26 Symbols and units of measurement............................39
5.9 Check and setting alternator standard belt tension....27
5.9.1 Check...........................................................................27 10 - CALIFORNIA PROPOSITION 65
5.9.2 Adjustment..................................................................27
10.1 California Proposition 65.............................................43
5.10 Control water filter cartridge fuel..............................28
5.11 Product preservation...................................................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 ABOUT REPLACEMENTS
6.1 Engine oil replacement.................................................30
6.2 Oil filter cartridge replacement...................................31
6.3 Remote oil filter cartridge replacement (optional)....32
6.4 Fuel filter cartridge replacement ................................32
6.5 Air filter cartridge replacement...................................32
6.6 Disposal and scrapping.................................................33
EN 4 ED0053029510 _14
GENERAL INFORMATION 1
1.1 Manual's purpose

-- This manual contains the instructions needed to carry out -- These changes do not require KOHLER to intervene on the
proper use and maintenance of the engine, therefore it must marketed production up to that time and not to consider
always be available, for future reference when required. this manual as inappropriate.
-- This manual is an integral part of the engine, in the event of -- Any additional section that KOHLER will deem necessary to
transfer or sale, it must be attached to it. supply some time after the main text shall be kept together
-- Safety pictograms can be found on the engine and it is the with the manual and considered as an integral part of it.
operator's responsibility to keep them in a perfectly visible -- The information contained within this manual is the sole
place and replace them when they are no longer legible. property of KOHLER. As such, no reproduction or replication
-- Information, description and pictures in this manual reflect in whole or part is allowed without the express written
the state of the art at the time of the marketing of engine. permission of KOHLER.
-- 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.
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 M, where necessary the version 1903 M is illustrated.
NOTE: All data, measurements and relevant symbols are shown in the glossary section.
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.
1.4 Service request

-- The complete and updated list of authorized Kohler Co. ser vice centers can be found on websites:
www.kohlerengines.com & dealers.kohlerpower.it.
-- 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).
Index ED0053029510 _14 5 EN

1 GENERAL INFORMATION 1
1.5 Engine component identification
Side view A
Thermostat
Oil filler cap
Coolant temperature
sensor
Oil pressure switch
Oil filler cap

Starter motor
Coolant pump
Nameplate
Oil drain plug
Alternator
Side view B
Fuel injection pump
Oil filter
Nameplate
Oil drain plug
Fuel filter
EN 6 ED0053029510 _14 Index

1 GENERAL INFORMATION 1
1.6 Manufacturer and motor identification data

The engine identification nameplate is located on side A or B as below.
Side view A Side view B
Engine Engine serial number

type
Manufacturer identification
Peak
rpm Engine
version
Approval data and "EC"

directives
Index ED0053029510 _14 7 EN

1 GENERAL INFORMATION
1.7 Homologation labels
1.7.1 Label for China Standards
1 2
3 4
5 6
7 8
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
EN 8 ED0053029510 _14 Index

GENERAL INFORMATION 1
1.7.2 Label for Korea Standards
1 4
POS. DESCRIPTION
1 Tier 4 Final
2 Engine model
3 Manufactoring date and manufacturer code
4 N° Korea emission certificate
Index ED0053029510 _14 9 EN

2 TECHNICAL INFORMATION
2.1. General description of the engine

-- 4-stroke, in-line cylinders Diesel engine;
-- Liquid-cooling system;
-- 4 valves per cylinder with hydraulic tappets;
-- Injection.
2.2 Engine specifications
2.1
UNIT
TECHNICAL DATA OF
MEASURE
ENGINE TYPE KDI 1903 M KDI 2504 M
CYLINDERS n. 3 4
BORE mm 88
STROKE mm 102
DISPLACEMENT cm3 1861 2482
MAX INCLINATION DURING OPERATION a 30° max. 30 minutes
(even in combined) a 35° max 1 minute
OIL CAPACITY standard version 8.9 11.5
(MAX level.) lt.
including oil filter with balancer device ... 9
DRY WEIGHT kg 210 244
2.3 Engine dimensions (mm)
475.1 598.3
KDI 1903 M
670.1
475.1 704.3
KDI 2504 M
670.1
EN 10 ED0053029510 _14 Index

TECHNICAL INFORMATION 2
2.4 Oil
Important Danger
• The engine may be damaged if operated with improper oil • Prolonged skin contact with the exhausted engine oil can
level. cause cancer of the skin.
• Do not exceed the MAX level because a sudden increase in • If contact with oil cannot be avoided, thoroughly wash your
engine rpm could be caused by its combustion. hands with soap and water as soon as possible.
• Use only the recommended oil to ensure adequate • For the exhausted oil disposal, refer to Par. 6.6 DISPOSAL
protection, efficiency and service life of the engine. and SCRAPPING.
• 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).
2.4.1 SAE oil classification

• In the SAE classification, oils are identified according • The code is made up of two numbers. The first number
to viscosity without considering any other qualitative refers to the viscosity when cold, for use during winter
characteristic. ("W"= winter), while the second number is for viscosity at
high temperatures.
2.2
RECOMMENDED OIL
10W-30 (-25°C ÷ +40°C)
10W-40 (-25°C ÷ +50°C)
VISCOSITY SAE 5W-30 (-30°C ÷ +40°C)
0W-40 (-40°C ÷ +50°C)
CI-4 Plus
API CI-4
WITH
CH-4
SPECIFICATIONS
E7
ACEA
E5
• Low S.A.P.S. oils, sulfate ashes <1% may not be used with fuels with a sulfur content >50ppm.
• Filtration of oils is critical to proper operation and lubrication; always change filters regularly as specified in this manual.
Index ED0053029510 _14.1 11 EN

2.5 Fuel
Important Warning
• Use of other types of fuel could damage the engine. Do not • Clean fuel prevents the fuel injectors from clogging.
use dirty diesel fuel or mixtures of diesel fuel and water since Immediately clean up any spillage during refuelling.
this will cause serious engine faults. • Never store diesel fuel in galvanized containers (i.e. coated
• Any failures resulting from the use of fuels other than with zinc). Diesel fuel and the galvanized coating react
recommended will not be warranted. chemically to each other, producing flaking that quickly
clogs filters or causes fuel pump and/or injector failure.
2.3 FUEL COMPATIBILITY

EN 590 (biodiesel content max. 7% (V/V))
ASTM D 975 Grade 1-D S15
ASTM D 975 Grade 2-D S15
NATO F-54, equivalent to diesel fuel in accordance with EN 590
EN 590 or ASTM D 975 Grade 1, 2 -D S15 Arctic Diesel
JIS K 2204 No. 1, No. 2
NOTE: In a warranty case the customer must prove by a certificate from the fuel supplier that an allowed
fuel was used.
KDI Mechanical Injection Tier 3 – Stage IIIA certified Engines (w and w/o EGR)
Those engines are designed for fuels in accordance with EN 590 and ASTM D975 for a cetane number of at least 45. Since
those engines are not equipped with exhaust gas after-treatment, they can be operated with diesel fuels with sulfur content up
to 500 mg/kg (ppm). Compliance with the emission requirements is guaranteed only with sulfur content up to 15 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 > 500 mg/kg demand a shorter lubricating oil change interval. This is set at 250hrs. However,
the engine oil must be changed when the Total Base Number TBN is reduced to 6.0 mgKOH/g test method ASTM D4739. With
high fuel sulfur content fuel this may happen at 125hrs. Do not use low SAPS oils.
KDI Mechanical Injection Uncertified Engines (no EGR Engines)
Those engines are designed for fuels in accordance with EN 590 and ASTM D975 for a cetane number of at least 45. Since
those engines are not equipped with exhaust gas after-treatment, they can be operated with diesel 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 > 500 mg/kg demand a shorter lubricating oil change interval. This is set at 250hrs. However,
the engine oil must be changed when the Total Base Number TBN is reduced to 6.0 mgKOH/g test method ASTM D4739.
EN 12 ED0053029510 _14 Index

TECHNICAL INFORMATION 2
2.5.1 Fuel for low temperatures
• When operating the engine in ambient temperatures lower than 0 degrees C, use suitable low temperature fuel normally
available from fuel distributors and corresponding to the specifications of Tab. 2.3.
• 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.
2.5.2 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. 2.3.
• DO NOT USE vegetable oil as a biofuel for this engine.
2.4 BIODIESEL COMPATIBILITY

Biodiesel according to EN 14214 (only permissible for mixture with diesel fuel at max. 10% (V/V))
US biodiesel according to ASTM D6751 – 09a (B100) (only permissible for mixtures with diesel fuel at 10% (V/V))
2.5.3 Synthetic fuels: GTL, CTL, BTL, HV
It is a well-known fact that engines which are operated for longer periods with conventional diesel 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 lead to a change in the selling behavior of polymer seals.
Therefore, conversion from diesel fuel to synthetic fuel may only be done after changing the critical seals. The problem of
shrinkage does not occur when an engine was operated with synthetic fuel from the start.
2.5.4 Non-Road Fuels
Other non-road fuels may be used if they comply with all the limit values of EN 590 except for the fuel density, the cetane
number and the sulfur content.
The following limits apply for these parameters:
2.5 FUEL PARAMETER UNIT LIMIT VALUE
Cetane number Min. 49
Fuel density at 15°C Kg/m3 820 - 860
Sulfur content mg/kg or ppm max. 500
2.5.5 Jet Fuels
Only for KDI Mechanical Injection Uncertified Engines (no EGR Engines).
The following jet fuels can be used but only adopting an additional fuel filter with lubricity doser:
2.6 FUEL
F-34/F-35 (kerosene, NATO designation) JP-8 (kerosene, US military designation)
F-44 (kerosene, NATO designation JP-5 (kerosene, US military designation)
F-63 (kerosene, NATO designation, equivalent to
Jet A (kerosene for civil aviation)
F-34/F-35 with additives)
F-65 (kerosene, NATO designation, 1:1 mixture of F-54
Jet A1 (kerosene for civil aviation)
and F-34/F-35)
2.5.6 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.
Index ED0053029510 _14.1 13 EN

2.6 Coolant
A mixture of 50% demineralized water and 50% low silicate ethylene glycol based coolant liquid must be used.
Use a Long Life or Extended Life Heavy Duty OAT coolant free of: silicates, phosphates, borates, nitrites and amines.
The following ethylene-glycol based engine coolant for all models within KDI engine family may be used:
• OAT (Organic Acid Technology) Low Silicate: ASTM D-3306 D-6210

• HOAT (Hybrid Organic Acid Technology) Low Silicate: ASTM D-3306 D-6210
The above 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 ethylene glycol and propylene glycol based coolants. Do not mix OAT and HOAT based coolant. OAT performance
life can be drastically reduced if contaminated with nitrite-containing coolants.
• Never use automotive-type coolants. These coolants do not contain the correct additives to protect heavy – duty diesel
engines.
OAT coolants are maintenance free up to 6 years or 6000hrs of operation , provided that the cooling system is topped up using
the same type of coolant. Do not mix different coolant types. Test the coolant condition annually with coolant test strips.
HOAT are not all maintenance free and it is recommended to have SCA (Supplemental Coolant Additives) added at the first
maintenance interval
2.7 Battery recommendations

Battery not supplied by Kohler
2.7
RECOMMENDED BATTERIES
AMBIENT TEMPERATURE BATTERY TYPE
> - 15°C 12V 100 AH - 800 CCA/SAE
-15°C ÷ -25°C 12V 110 AH - 950 CCA/SAE
< - 25°C 12V 120 AH - 1000 CCA/SAE
EN 14 ED0053029510 _14 Index

SAFETY INFORMATION 3
3.1 Safety information
• The intended use of the engine is in conformity with the • Those who carry out the use and maintenance on the
machine on which it is mounted. engine must wear the safety equipment and the accident-
• Any use of the machine other than that described cannot prevention guards.
be considered as complying with its intended purpose as • KOHLER declines all direct and indirect liability for failure
specified by KOHLER . to comply with the standards of conduct contained in this
• KOHLER declines all responsibility for any change to the manual.
engine not described in this manual made by unauthorized • KOHLER cannot consider every reasonably unforeseeable
KOHLER personnel. misuse that may cause a potential danger.
• 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.
3.2 General remarks
3.2.1 Note for OEM
• When installing the KDI engines, always bear in mind that • The engine may only be assembled on a machine by
any variation to the functional systems may result in serious personnel specifically trained by KOHLER and who work in
failures to the engine. compliance with the existing documentation.
• Any improvement must be verified at KOHLER testing • The engine has been built to the specifications of a machine
laboratories before application of the engine. manufacturer, and it is his responsibility to ensure that all
• In case the approval to a modification is not granted, KOHLER necessary action is taken to meet the essential and legally
shall not be deemed responsible for any consequential prescribed health and safety requirements. Any use of the
failures or damages to the engine. 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.
3.2.2 Note for end user
• The following indications are dedicated to the user of the Thoroughly wash and clean the area surrounding the
machine in order to reduce or eliminate risks concerning engine following the instructions provided by machine
engine operation and the relative routine maintenance work. manufacturer.
• The user must read these instructions carefully. Failure to do • Fuel and oil are inflammable. The tank must only be filled
this could lead to serious danger for his personal safety and when the engine is off. Before starting, dry any spilt fuel.
health and that of any persons who may be in the vicinity of • Make sure that no soundproofing panels and the ground or
the machine. floor on which the machine is standing have not soaked up
• On starting, make sure that the engine is as horizontal as any fuel.
possible, unless the machine specifications differ. • Fuel vapour is highly toxic. Only refuel outdoors or in a well
• Make sure that the machine is stable to prevent the risk of ventilated place.
overturning. • Do not smoke or use open flames when refuelling.
• The engine must not operate in places containing • During operation, the surface of the engine can become
inflammable materials, in explosive atmospheres, where dangerously hot. Avoid touching the exhaust system in
there is dust that can easily catch fire unless specific, particular.
adequate and clearly indicated precautions have been • Before proceeding with any operation on the engine, stop it
taken and have been certified for the machine. and allow it to cool.
• To prevent fire hazards, always keep the machine at least • Always open the radiator plug or expansion chamber with
one meter from buildings or from other machinery. the utmost caution, wearing protective garments and
• Children and animals must be kept at a due distance from goggles.
operating machines in order to prevent hazards deriving • The coolant fluid is under pressure. Never carry out any
from their operation. inspections until the engine has cooled.
• Thoroughly wash and clean all the external parts of the • If there is an electric fan, do not approach the engine when
engine before performing any operation, in order to avoid it is still hot as the fan could also start operating when the
the accidental introduction of impurities/foreign bodies. engine is at a standstill.
Use only water and/or appropriate products to clean the
engine. 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.
Avoid directing the nozzle on electrical components,
cable connections and sealed rings (oil seals etc).
Index ED0053029510 _14 15 EN

3 SAFETY INFORMATION
• Only check, top up and change the coolant fluid when

the engine is off and reached the ambient temperature.
Important Coolant fluid is polluting, it must therefore be disposed of
• The oil must be drained whilst the engine is hot. Particular in the correct way.
care is required to prevent burns. Do not allow oil to come • Do not use air and water jets at high pressures on cables,
into contact with the skin because of the health hazards connectors and injectors.
involved. It is recommended to use an oil intake pump.
• 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
Important
accidental short-circuits and to stop the starter motor from
being energized. • Only use the eyebolts A installed by KOHLER to move the
• Check belt tension only when the engine is off. engine (Fig. 3.1).
• Fully tighten the tank cap each time after refuelling. Do not • The angle between each lifting chain and the eyebolts shall
fill the tank right to the top but leave an adequate space for not exceed 15° inwards.
the fuel to expand. • The correct tightening of the lifting screws is 25Nm.
• To start the engine follow the specific instructions provided • Do not interpose spacers or washers between the eyebolts
in the engine and/or machine operating manual. Do not and engine head.
use auxiliary starting devices not originally installed on the • Provided that the above requirements are met, if the lifting
machine (e.g. Startpilot). eyebolts are subject to permanent deformation (inwards), all
• Before starting, remove any tools that were used to service subsequent lifting operations must be performed in order to
the engine and/or machine. Make sure that all guards have prevent them from bending in the opposite direction.
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-observance of the
emissions declared by KOHLER.
• Pay attention to the temperature of the oil filter when the
filter itself is replaced.
α ≤ 15° α ≤ 15°
A A
3.1
EN 16 ED0053029510 _14 Index

3.3 Safety signal description
• To ensure safe operation please read the following • This manual contains safety precautions which are
statements and understand their meaning. explained below.
• Also refer to your equipment manufacturer's manual for • Please read them carefully.
other important safety information.
3.3.1 Adhesive safety plates 3.3.2 Safety guards
The following is a list of the adhesive safety plates that may Hereunder is a list of safety guards that must be worn prior
be found on the engine, which indicate potential points of to carrying out any type of operation and to avoid potential
danger to the operator (Par. 3.6). harm to the operator.
Read the Operation and Maintenance handbook before Use protective gloves before carrying out the operation.
performing any operation on the engine.
Hot Parts. Use protective glasses before carrying out the

Danger of burns. operation.
Presence of rotating parts. Use sound absorbing protections before carrying out
Danger of jamming or cutting. the operation.
Presence of explosive fuel.

Danger of fire or explosion.
Presence of steam and pressurized coolant.

3.3.3 Warnings
Danger of burns.
Hereunder is a list of safety warnings that may be found in
the manual, which advise you to pay attention when carrying
out particular procedures that may be potentially dangerous
to the operator or things.
Lifting point.
Electrical shock.
Danger
Danger of severe scalding or death.
• This indicates situations of grave danger which, if ignored,
may seriously threaten the health and safety of individuals.
High pressure fluid.

Danger of fluid penetration.
Important
• This indicates particularly important technical information
that should not be ignored.
Lethal Exhaust Gases.
Danger of poisoning or death.
Warning
• This indicates that failure to comply with it can cause minor
damage or injury.
Index ED0053029510 _14 17 EN

3 SAFETY INFORMATION
3.4 Information and safety signals
ACCIDENTAL START HIGH PRESSURE FLUID

RISK OF PUNCTURE
Accidental Starts can cause High Pressure Fluids can
severe injury or death. puncture skin and cause
severe injury or death.
Before working on the engine or equipment, disconnect the
Do not work on fuel system without proper training or safety
battery negative (-) wire.
equipment.
Fluid puncture injuries are highly toxic and hazardous.
HOT PARTS If an injury occurs, seek immediate medical attention.
Hot Parts can cause severe
burns. EXPLOSIVE FUEL
Engine components can get extremely hot from operation.
Do not touch engine while operating or just after stopping. Explosive fuel can cause fires
Never operate the engine with heat shields or guards and severe burns.
removed. Fuel is flammable and its vapours can ignite.
Store fuel only in approved containers, in well ventilated,
unoccupied buildings.
ROTATING PARTS
Do not fill the fuel tank while the engine is hot or running,
Rotating Parts can cause since spilled fuel could ignite if it comes in contact with hot
severe injury. parts or sparks from ignition.
Do not start the engine near spilled fuel.
Stay away while engine is in operation. Keep hands, feet, Never use fuel as a cleaning agent.
hair, and clothing away from all moving parts to prevent
injury.
Never operate the engine with covers, shrouds, or guards EXPLOSIVE GAS
removed.
Explosive Gas can cause
LETHAL EXHAUST GASES fires and severe acid burns.
Carbon Monoxide can cause Charge battery only in a well ventilated area.
severe nausea, fainting or Keep sparks, open flames, and other sources of ignition
death. away from the battery at all times.
Batteries produce explosive hydrogen gas while being
Avoid inhaling exhaust fumes and never run the engine in a
charged.
closed building or confined area.
Keep batteries out of the reach of children.
Carbon monoxide is toxic, odorless, colorless, and can
Remove all jewelry when servicing batteries. Before
cause death if inhaled.
disconnecting the negative (-) ground cable, make sure all
switches are OFF.
If ON, a spark will occur at the ground cable terminal which
ELECTRICAL SHOCK could cause an explosion.
Electrical Shock can cause
injury.
Do not touch wires while engine is running.
3.5 Safety and environmental impact
Every organisation has a duty to implement procedures to In order to minimise the impact on the environment, KOHLER
identify, assess and monitor the influence of its own activities now provides a number of indications to be followed by
(products, services, etc.) on the environment. all persons handling the engine, for any reason, during its
Procedures for identifying the extent of the impact on the expected lifetime.
environment must consider the following factors:
-- All components and fluids must be disposed of in accordance
-- Liquid waste. with the laws of the country in which disposal is taking place.
-- Waste management. -- Keep the fuel and engine control systems and the exhaust
-- Soil contamination. pipes in efficient working order to limit environmental and
-- Atmospheric emission. noise pollution.
-- Use of raw materials and natural resources. -- When discontinuing use of the engine, select all components
-- Regulations and directives regarding environmental impact. according to their chemical characteristics and dispose of
them separately.
EN 18 ED0053029510 _14 Index

3.6 Location of safety labels on engine
KDI 1903 M
KDI 2504 M
Index ED0053029510 _14 19 EN

4 INFORMATION ABOUT USE
4.1 Pre-start check
Important
• Read carefully the following pages and carry out the operations described below in accordance with the instructions specified.
• 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.
• Increase the frequency of maintenance operations in heavy working conditions (engine starts but stops, very dusty and hot
environments, etc...).
4.2 Running-in period

NOTE: For the first 50 hours of engine operation, it is advisable not to exceed 75% of the maximum power
supplied.
4.3 Starting and turning off

4.3.1 Starting
1. Check the level of the engine oil, fuel and coolant and fill if necessary (Par. 4.5 and Par. 4.6).
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
• At the first fuelling or if 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 repeating
attempt.
• If engine does not start after two attempts see Tab. 7.1 and Tab. 7.2, to found the cause.
Panel L can be assembled on the engine or machine.

In Tab. 4.1, are described the main functions are illustrated. L M
4.1
W1
POS. DESCRIPTION
M Hour-meter indicator W2
S Control switch to start the engine
W3
W1 Panel ignition indicator
W2 Warning Light - battery not charging W4
W3 Warning Light - engine oil not pressurised
W5
W4 Warning Light - high coolant temperature S
W5 Warning Light - alarm general indicator 4.1
4.3.2 After starting

4.2
AMBIENT TEMPERATURE TIME
≤ -20°C 2 minutes
Warning from -20° C to -10°C 1 minutes
• Make sure that all the warning lights on the control panel are
from -10° C to -5° C 30 seconds
off when the engine is running.
• Run at minimum speed for a few minutes according to table from -5° C to 5° C 20 seconds
(except constant speed engine). ≥ 5° C 15 seconds
4.3.3 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.
EN 20 ED0053029510 _14 Index

INFORMATION ABOUT USE 4
4.4 Refuelling
Important
• Before proceeding with operation, read Par. 3.2.2.
Danger
• Fill the engine off.
• The only approved fuels are those listed in Tab. 2.3.
• 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 overfill the fuel tank. Leave room for the fuel to expand.
NOTE: At the first fuelling or if the tank was empty filling the fuel system (Par 6.4 from point 4 to point 6).
4.5 Oil filling
Important
• For safety precautions see Par. 2.4.
1. Loosen the oil filler cap A or the oil filler cap C if the cap
A is not accessible. C
2. Add the type oil recommended (Tab. 2.1 and Tab. 2.2).
4.2
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. B
5. If level is not at the MAX. level, add additional oil. B
6. Re-tighten the cap A or C. MAX
Important
MIN
• Do not use the engine with the oil level below the minimum.
4.3
Index ED0053029510 _14 21 EN

4 INFORMATION ABOUT USE
4.6 Coolant filling
Important Warning
• Before proceeding with operation, read Par. 3.2.2. • 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.
• 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.
NOTE: Before proceeding with any operation on

the engine, stop it and allow it to cool.
A
Warning
• Presence of steam pressurized coolant danger of burn.
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 overfill the radiator, but leave room
for the coolant to expand.
4.4
3. For engines equipped with expansion tank, pour in fluid
until reaching the max level mark.
4. Loosen the screw C, release any air and tighten the screw
C (Tightening torque of 8 Nm - Fig. 4.7).
5. Re-tighten the cap A.
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.
4.5
4.6 4.7
EN 22 ED0053029510 _14 Index

INFORMATION ABOUT MAINTENANCE 5
5.1 Useful information about maintenance

• This chapter shows all operations described in the Tab.
5.1, Tab. 5.2, Tab. 5.3 and Tab. 5.4 if you have the skills
appropriate may be directly carried out by the user.
Important
• Periodic inspection and maintenance operations must • Before proceeding with operation, read Par. 3.2.2.
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 Warning
engine. Any non compliance makes the warranty become • Inspections must be made when the engine is off and cold.
null and void. • Place engine on level surface to ensure accurate
• In order to prevent personal and property damage read measurement of oil level.
carefully the instructions listed below before proceeding • Before starting, to avoid spillages of oil make sure that:
-- the oil dipstick is inserted correctly;
with any operation of the engine.
-- also check that:
oil drain plug and; oil filler cap are tightened firmly.
5.2 Periodic maintenance
The intervals of preventive maintenance in Tab. 5.1, Tab. 5.2, Tab. 5.3 and Tab. 5.4 refer to the engine operating under normal
operating conditions with fuel and oil meeting the recommended specifications.
5.1 CLEANING AND CHECKING
PERIOD (HOURS)
OPERATION DESCRIPTION PAR.
100 250 500 5000
Engine oil level (8) 5.3
Coolant level (8) (9)
5.8
Water presence in fuel filter 5.10
Cartridge dry-type air filter (2) 5.5
Radiator heat-exchange surface (2) (8)
5.6
Alternator belt (8)
5.9
Rubber hose (intake air / coolant) 5.7
Fuel hose --
Starter Motor (6) --
Alternator (6)
--
5.2 REPLACEMENT
PERIOD (HOURS)
OPERATION DESCRIPTION PAR.
500 5000 6000
Alternator belt (3) (6) --
Cartridge dry-type air filter (2)
6.5
Intake manifold hose (air filter - intake manifold) (6) (7) --
Coolant hoses (6) (7)
--
Fuel line hose (6) (7) --
OAT (6)
Coolant --
HOAT (6) (10)
5.3 ENGINE OIL AND OIL FILTER CARTRIDGE REPLACEMENT

PERIOD (HOURS)
ENGINE VERSION PAR.
250 500
KDI Mechanical Injection Tier 3, Tier 4 Final
Stage IIIA, Stage IIIB, Stage V (1) 6.1
6.2
KDI Mechanical Injection Uncertified Engines (1) (11)
5.4 FUEL FILTER AND PREFILTER CARTRIDGE REPLACEMENT

PERIOD (HOURS)
ENGINE VERSION PAR.
250 500
KDI Mechanical Injection Tier 3, Tier 4 Final
Stage IIIA, Stage IIIB, Stage V (1) 6.4
KDI Mechanical Injection Uncertified Engines (1)
Index ED0053029510 _14.1 23 EN

5 INFORMATION ABOUT MAINTENANCE
1. In case of low use: 12 months. 8. The first check must be done after 10 hours.
2. The period of time that must elapse before checking 9. Test the coolant condition annually with coolant test
the filter element depends on the environment in which strips.
the engine operates. The air filter must be cleaned and 10. It is recommended to have SCA (Supplemental Coolant
replaced more frequently under very dusty conditions. Additives) added at the first maintenance interval.
3. In case of low use: 36 months. 11. Read Cap. 2.5, "KDI Mechanical Injection Uncertified
6. Contact authorized KOHLER workshops. Engines (no EGR Engines)"
7. The replacement interval is only an indication, it strongly
depends from environmental condition and hose status
detected during regular visual inspection.
5.3 Oil level check

1. Loosen the oil filler cap A. Remove the oil dipstick B and
check that the level is up to MAX. B
2. Pour in recommended oil until reaching the MAX level B

mark.
MAX
3. Reinstall the oil dipstick B completely.
4. Re-tighten the cap A and/or C.

MIN
Important 5.1
• Do not use the engine with the oil level below the minimum.
5.4 Oil dipstick on cylinder head
C
A B
B
MAX
MIN
5.2
5.3 5.4
5.5 Air filter check

NOTE: Components not necessarily supplied by
KOHLER.
A D E C
1. Release the two clasps D of the cover A.
2. Remove the cartridge 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 flat surface.
5. Reinstall: B
-- cartridges B.
-- the cover A checking the right tightness of clasps D. 5.5
EN 24 ED0053029510 _14 Index

Danger
• For safety precautions see Cap. 3.
5.6 Check of the radiator heat-exchanger surface

NOTE: Component not necessarily supplied by
KOHLER.
Important A
• 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 A.
2. Clean the surface with a brush soaked in special detergent

if it is clogged. 5.6
5.7 Rubber hoses check

F
The check is carried out by exerting a 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.
E
F
Important
• If hoses are damaged contact an authorized KOHLER
workshop.
1. Loosen the four capscrews E. Remove guard F.
2. 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. B1
-- Vent system pipes C.
-- Air system ducts D.

B2
D
When the control is finished the safe guard F mount and
tighten the four screws E. C
5.7
Index ED0053029510 _14.1 25 EN

5.8 Check coolant level

NOTE: Before proceeding with any operation on A
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 5.8
by about 5 mm.
3. Top up if necessary.
4. Do not overfill the radiator, but leave room for the coolant
B
to expand.
MAX C
5. Reinstall radiator cap A.
6. F
or engines equipped with expansion tank (B), check that
the fluid is until reaching the max level mark.
NOTE: For coolant filling see Par. 4.6.
Warning
• Before starting make sure that the radiator cap and cap, if 5.9
present, are installed correctly to avoid spillage of liquid or
vapour at high temperatures.
EN 26 ED0053029510 _14 Index

5.9 Check and setting alternator standard belt

tension
5.9.1 Check
A p
1. Check the belt condition A if worn out or deteriorated,
replace it.
P
2. 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 (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 F
for V-belt of 9 mm and 350 and 450 N for V-belt of 17 mm (H). 5.10
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 A must show a movement of less than 10 mm.
If not adjust it.
5.9.2 Adjustment
H
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 (tightening torque of 25 Nm) and C 5.11

(tightening torque of 69 Nm) in sequence with a torque
wrench E.
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
17mm (Fig. 5.10) (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 10 m
Newton, (which should be) included between 200 and 230 N m
p
for V-belt of 9 mm and 350 and 450 N for V-belt of 17 mm (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
G
approx' 10kg on the point p. When correctly tensioned the
belt A must show a movement of less than 10 mm.
5.12
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 E
values.
B
NOTE: Contact KOHLER authorised workshops
for replacement.
C
E B
5.13
Index ED0053029510 _14.1 27 EN

5.10 Control water filter 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.
5.14
5.11 Product preservation

5.13 Engine storage over 6 months
Follow the steps described in Par. 5.12.
Important 1. Engine oil replacement (Par. 6.1).

• If the engines are not to be used for 6 months, they must
be protected by carrying out the operations described in 2. Refuel with fuel additives for long storage.
Engine storage (up to 6 months) (Par. 5.12). The following additives are recommended:
DEFA Fluid Plus (Pakelo Lubricants),
• If the engine is still not in use after the first 6 months, it
Diesel Treatment (Green Star),
is necessary to carry out a further operation to extend the Top Diesel (Bardhal),
protection period (more than 6 months) (Par. 5.13). STP® Diesel Fuel Injector Treatment.
• If the engine is not to be used for an extended period, the
protective treatment procedure must be repeated within 24 3. With expansion tank: make sure that the coolant is up to
months of the previous one. the maximum level.
5.12 Engine storage up to 6 months 4. Without expansion tank: Top liquid up until the pipes
inside the radiator are covered by about 5 mm. Do not
Before storing the engine check that: overfill the radiator, but leave room for the fuel to expand.
• The environments are not humid or exposed to bad weather. 5. Start the engine and keep it idle at minimum speed for 2
Cover the engine with a proper protective sheet against minutes.
dampness and atmospheric contaminants.
• The place is not near electric panel. 6. B
ring the engine to 3/4 of the maximum speed for 5÷10
• Avoid storing the engine in direct contact with the ground. 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 such as alternators, starter motors
and engine control units (ECU).
12. Treat non-painted parts with protective products.
If the engine protection is performed according to the

suggestions indicated no corrosion damage should occur.
EN 28 ED0053029510 _14 Index

5.14 Engine starting after storage

1. Remove the protective sheet.
2. Use a cloth soaked in degreasing product to remove the Warning

protective treatment from the external parts. • Over time, lubricants and filters lose their properties, so it is
important consider whether they need replacing, also based
3. Inject lubricating oil (no more than 2 cm3) into the intake on the criteria described in Tab. 5.3 and Tab. 5.4.
ducts.
9. Replace the filters (air, oil, fuel) with original spare parts.
4. Refill the tank with fresh fuel.
10. Pour new oil (Par. 4.5) up to the maximum level.
5. Make sure that the oil and the coolant are up to the
maximum level. 11. Empty the cooling circuit completely and pour in the new
coolant up to the maximum level (Par. 4.6).
6. Start the engine and keep it idle at minimum speed for a
two about minutes.
7. Bring the engine to 75% of maximum rated speed for 5 to

10 minute.
8. Stop the engine while the oil is still hot

(Par. 6.1), discharge the protective oil in a suitable
container.
5.15 Unused machine

If the machine is not used for a certain amount of time, follow the operations below:
5.15.1 Operations for the engine
POINT OPERATION
-- The place must be dry and fresh throughout the period in which the machine is not used.
unused ma- -- Consult the machine’s manual to disconnect the battery (before disconnecting the battery,
chine up to 2 wait for minimum 5 mins after turning off the engine).
1 months -- Make sure the engine is not exposed to direct sunlight.
-- Make sure the engine is not near any heat sources.
-- Before starting the engine, check Par. 5.2 for maintenance operations.
Starting
-- Consult the machine’s manual to connect the battery and start the engine.
-- Perform the operations related to unused machine described in point 1.
-- Perform the operations described in Par. 5.6.
unused machi-
-- Start the engine at least every 4 months as per operations described in point 1:
ne from 2 to 9
-- Avoid sudden accelerations for the first few minutes.
months
2 Bring the engine to the working temperature by pressing the accelerator 3/4 from MAX.
Leave the engine running at minimum speed for a few minutes and turning off the engine.
-- Before starting the engine, check Par. 5.2 for maintenance operations.
Starting -- Consult the machine’s manual to connect the battery and start the engine.
unused ma-
chine over 9 -- Perform the operations related to unused machine described in point 1 and 2.
months
3 -- Before starting the engine, check Par. 5.2 for maintenance operations.
-- Check the quality of coolant from the relative testing strips.
Starting
-- Consult the machine’s manual to connect the battery and start the engine.
Index ED0053029510 _14.1 29 EN

6 INFORMATION ABOUT REPLACEMENTS
Danger
• Disconnect the negative wire (-) from the battery to avoid accidental engine starting.
Important
6.1 Engine oil replacement
A
B
Important
• Place engine on level surface to ensure accurate
measurement of oil level.
NOTE: Perform this operation with warm engine,

to get a better fluidity of the oil and get E
a full discharge of oil and impurities
contained in it. D
1. Loosen the oil filler cap A (Fig. 6.1).

6.1
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. 6.6 DISPOSAL and SCRAPPING).
D
5. Replace gasket E.
6. Tighten the drain oil plug D (tightening torque at 35 Nm).
7. Perform the operation described in Par. 6.2.
8. Add the type oil recommended (Tab. 21 and Tab. 2.2).

6.2
9. If the plug A is not accessible, use the oil filler cap C.
C
A
Important
• Do not exceed the MAX level on the dipstick.
6.3
EN 30 ED0053029510 _14 Index

INFORMATION ABOUT REPLACEMENTS 6
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. B

B
12. Tighten the cap A or C.
MAX
MIN
6.4
Warning
• Oil filter cartridge replacement (Par. 6.2) and fuel filter replacement (Par. 6.4)
• In case of low use replace it 12 months.
• For disposal of oil filter cartridge and fuel filter refer to
Par. 6.6 DISPOSAL and SCRAPPING.
6.2 Oil filter cartridge replacement

1. Unscrew the oil filter A with appropriate wrench.
6.5
2. Assembly and tighten the new oil filter cartridge

A tightening it with torque wrench B (torque to
15 Nm).
6.6
Index ED0053029510 _14 31 EN

6 INFORMATION ABOUT REPLACEMENTS
6.3 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.
6.7
6.4 Fuel filter cartridge replacement

1. Procure a suitable container to collect the fuel.
2. Rotate the filter A to take it to the unlocked position and B

remove it.
3. Lubricate the gasket C of the new cartridge.Assemble the C

new filter A on the support B and rotate it until reaches
the lock position.
A
Important
• Do not fill the new cartridge A with fuel.
6.8
4. Loosen the air bleeding screw F on fuel filter bracket B e la
vite E posta sulla pompa
iniezione G. G E
5. Turn the key on the control
panel to the ON position.
The electric pump D sends
fuel to the filter and then
the injection pump E. The
air inside the circuit and the
filter will begin to escape
from the screw F and E.
6. Tighten the bleeding screw

F and E (tightening torque of F G
1.5 Nm) when the fuel begins
D
to flow F (tightening torque of
1.5 Nm) when the fuel begins 6.9
to flow.
6.5 Air filter cartridge replacement
NOTE: Component not necessarily supplied by A F
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.
6.10
EN 32 ED0053029510 _14 Index

INFORMATION ABOUT REPLACEMENTS 6
6.6 Disposal and scrapping
• In case of scrapping, the engine shall be disposed of in • The parts only composed of plastic material, aluminium
appropriate locations, in conformity with the law in force. and steel can be recycled if collected by the appropriate
• Before scrapping, it is necessary to separate the rubber or centers.
plastic parts from the rest of the components. • 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.
Index ED0053029510 _14 33 EN

7 INFORMATION ABOUT FAILURES
7.1 Useful information about failures
• This chapter contains information about the problems that may appear during engine operation with its causes and trouble
shooting Tab. 7.2.
• In some cases, you shall turn off the engine immediately to avoid further damage Tab. 7.1.
7.1 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
7.2 TROUBLES POSSIBLE CAUSE SOLUTION PAR.

Sulphated battery terminals corroded Clean the battery terminals --
Battery voltage too low Recharge the battery or replace it --
Low fuel level Refuel 4.4
Frozen fuel Contact KOHLER authorised workshops --
The engine does not Clogged fuel filter Replace with a new filter 6.4
start Air suction in fuel system Contact KOHLER authorised workshops --
Clogged air filter Replace with a new filter 6.5
Clogged pipes Contact KOHLER authorised workshops --
Open fuse Replace with a new fuse --
Intake or exhaust system clogged Contact KOHLER authorised workshops --
Inefficient electrical connections Clean the electrical contacts --
Sulphated battery terminals Clean the battery terminals --
Engine starts but stops Replace with a new filter and clean the
Clogged fuel filter --
tank
Clogged fuel pipes Contact KOHLER authorised workshops --
RPM instability at idle
Clogged fuel pipes Contact KOHLER authorised workshops --
speed
Low Clogged fuel pipes Contact KOHLER authorised workshops --
idle speed Poor quality fuel Clean the tank and refuel with quality fuel 2.5
High oil sump level Replace the engine oil --
Blue smoke
Excessive fuel Clogged air filter Replace with a new filter 6.5
consumption High oil sump level Replace the engine oil --
Engine lost its initial Clogged fuel pipes Contact KOHLER authorised workshops --
performance Cheap fuel Clean the tank and refuel with quality fuel --
High oil sump level Replace the engine oil --
Slow acceleration Clogged fuel filter Replace the fuel filter 6.4
Engine jerking Clogged fuel pipes Contact KOHLER authorised workshops --
Insufficient coolant level Fill up to the level 4.6
Engine overheats High oil sump level Replace the engine oil --
Clogged radiator Clean the radiator --
-- In the event that the solutions proposed in Tab. 7.2 do not eliminate the trouble, contact a KOHLER authorized workshop.
EN 34 ED0053029510 _14 Index

INFORMATION ABOUT WARRANTY 8
KOHLER DIESEL ENGINES GLOBAL WARRANTY TERMS

1. WARRANTY PERIOD
Kohler Co. warrants to the End User that each Diesel engine will be free from manufacturing defects in materials or workmanship
in normal service for the applicable coverage period or operating hours (whichever comes first) set forth below, provided the
engine is operated and maintained in accordance with Kohler Co.’s instructions and manuals.
ENGINE SERIES WARRANTY PERIOD OPERATING HOURS WARRANTY COVERAGE
KOHLER Diesel (non KDI) 3 Years 0 – 2.000 100% Parts & Labor
0 – 2.000 100% Parts & Labor

KOHLER KDI 3 Years
2.001 – 6.000 Major Components Only*
Lombardini Diesel 2 Years 0 – 2.000 100% Parts & Labor
*Major component defects are failures related to crankcase casting, cylinder head casting, crankshaft, crankshaft pulley,
camshaft, connecting rod, flywheel, oil pump.
For the Warranty Period stated above, the period begins on the date of purchase of the finished equipment on which the engine
is installed. If no hour meter is installed on the application, the Operating Hours will be calculated as 4 hours of use per day
for 5 days per week beginning on the date of purchase.
Kohler Co.’s obligation under this warranty is expressly limited, at its option, to an appropriate adjustment, repair or replacement
of such part or parts as found to be defective following an inspection by Kohler Co. or an authorized service facility designated
by Kohler Co.
SPARE PARTS WARRANTY PERIOD OPERATING HOURS WARRANTY COVERAGE
KOHLER and Lombardini

2 Years 0 – 2.000 100% Parts & Labor
Diesel Parts
Parts/components that are scheduled to be replaced as part of the required maintenance schedule will be covered under Kohler
Co.’s warranty 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 repairs have been executed by Kohler Co or
by an Authorized Kohler Service Dealer.
2. EXCLUSIONS
The following items are not covered by this warranty.

• Damage caused by: (i) an accident or casualty; (ii) unreasonable use or neglect; (iii) normal wear; (iv) premature wear from
improper maintenance; (v) improper storage; (vi) old or contaminated fuel left within the fuel system, which includes but is not
limited to tanks, fuel lines, or fuel injection components; (vii) unapproved modifications.
• Failures caused by: (i) faulty repairs made by any party other than Kohler Co. or an authorized service facility designated by
Kohler Co.; (ii) use of non-Kohler replacement service parts; or (iii) additional damages caused by a lack of prescribed actions
as a result of an alarm light activation, either caused by fault or negligence or un-attended use of the engine; (iv) an act
beyond the control of Kohler Co., which includes but is not limited to theft, vandalism, fire, lightning, earthquake, windstorm,
hail, volcanic eruption, flood or tornado.
• Transportation charges or travel expenses in connection with the repair or replacement of defective parts on the engine.
• Engine accessories such as fuel tanks, clutches, transmissions, power drive assemblies, and batteries, unless supplied or
installed by Kohler Co.
• Engines installed in an application not formally reviewed by Kohler.
• Rental of other equipment during performance of warranty repairs All items subject to wear and to periodical maintenance
such as listed in the Use & Maintenance Manual (such as air, oil or fuel filters, belts etc.) are warranted for a period equal to
the prescribed interval of replacement as listed in the Manual.
• Fuel, lubricating oil, coolant/antifreeze.
Index ED0053029510 _14 35 EN

8 INFORMATION ABOUT WARRANTY
IMPLIED OR STATUTORY WARRANTIES, INCLUDING THOSE OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE, ARE EXPRESSLY LIMITED TO THE DURATION OF THIS WRITTEN WARRANTY. KOHLER CO. MAKES NO OTHER
EXPRESS WARRANTY, NOR IS ANYONE AUTHORIZED TO MAKE ANY ON KOHLER CO.’S BEHALF. KOHLER CO. AND/OR
THE SELLER SHALL NOT BE LIABLE FOR SPECIAL, INDIRECT, INCIDENTAL, OR CONSEQUENTIAL DAMAGES OF ANY KIND.
3. TO OBTAIN WARRANTY SERVICE
The repair shall be executed by a KOHLER Authorized Service Dealer designated by Kohler.
USA & CANADA:

List of Authorized dealers can be found by visiting www.kohlerengines.com or telephone 1-800-544-2444 (U.S.A. and Canada)
ENGINE DIVISION, Kohler Co., Kohler Wisconsin
EUROPE, MIDDLE EAST, AND ASIA

List of Authorized dealers can be found by visiting dealers.kohlerpower.it.
CENTRAL AND SOUTH AMERICA:

CHINA AND ASIA PACIFIC

INDIA
Note: Specific Warranty Terms and conditions do apply to engines directly sold in India.
4. OWNER'S WARRANTY RESPONSIBILITIES
1. As the off-road engine owner, you are responsible for the performance of the required maintenance 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 of receipts or for your failure to ensure the performance of
all scheduled maintenance.
2. As the off-road & marine engine owner, you should however be aware that Kohler Co. may deny you warranty coverage if
your off-road & marine engine or a part shows signs of malfunction or failed due to abuse, neglect, improper maintenance
or unapproved modifications.
3. Your engine is designed to operate on diesel fuel only. Diesel fuel an all other fluids used shall comply with the recommendation
listed in the Use & Maintenance Manual. Use of any other fuel or fluids may result in your engine breakage, premature wear
or no longer operating in compliance with the California & US EPA emissions requirements.
4. You are responsible for initiating the warranty process. The ARB & US EPA suggests that you present your off-road &
Marine 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.
5. COVERAGE
Kohler Co. will repair or replace emission control system parts, components and sub-assemblies found to be defective with
respect to materials or workmanship at no cost to you including engine exhaust system related diagnosis, labor and parts,
provided that no un-authorized modification of any kind has been executed on the engine, and its parts, components and
sub-assemblies.
The choice and responsibility of the decision to repair or replace an emission control system defect will be solely that of Kohler
Co. Emission control system parts/ components covered by the Federal and California Emission Control Systems Limited
Warranty are listed below
engine is defective, the part will be repaired or replaced by Kohler Co.
Fuel injector(s) Electronic control unit (ECU) if equipped

Injection pump(s) Sensors associated with ECU operation
Exhaust manifold Emission control information labels
Intake manifold Turbocharger (if equipped)
Exhaust gas recirculation (EGR) tube Fuel limiting device
Aftertreatment Systems if equipped and other components
Crankcase ventilation valve
when present
EN 36 ED0053029510 _14 Index

INFORMATION ABOUT WARRANTY 8
Parts/components that are scheduled to be replaced as part of the required maintenance schedule will be covered under
the warranty provisions for a period of time up to the first scheduled replacement point for the subject parts/ components.
Subsequent damage to other engine components as a direct result of a warrantable failure an exhaust emission part/ component
will be covered under the warranty provisions described herein.
6. MAINTENANCE AND REPAIR REQUIREMENTS
The owner is responsible for the proper use and maintenance of the engine. Kohler Co. recommends that all receipts and
records covering the performance of regular maintenance be retained in case questions arise. If the engine is resold during the
warranty period, the maintenance records should be transferred to each subsequent owner. Kohler Co. may not deny warranty
repairs solely because of the lack of repair, maintenance or failure to keep maintenance records.
Normal maintenance, replacement or repair of emission control devices and systems may be performed by any repair
establishment or individual; however, warranty repairs must be performed by a Kohler authorized service center.
7. CALIFORNIA AND FEDERAL EMISSION CONTROLWARRANTY STATEMENT, OFF-ROAD & MARINE DIESEL
ENGINES (USA ONLY)
The California Air Resources Board (CARB), U.S. environmental protection agency (EPA), and Kohler Co. are pleased to
explain the emission control system warranty on your [current model year – {2+ current model year}] off-road compression
ignition and marine (diesel) engine. In California (“the state”) and US EPA regulated region, new heavy-duty off-road & marine
engines must be designed, built and equipped 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
control system on your engine for the periods of time listed in the section below, provided there has been no abuse, neglect
or improper maintenance of your engine.
Your emission control system may include parts such as the fuel injection system and the air-induction system. Also included
maybe hoses, belts, connectors and other emission related assemblies.
When a warrantable condition exists, Kohler Co. will repair your heavy-duty off-road & marine engine at no cost to you including
diagnosis, parts and labor.
The owner shall not be charged for diagnostic labor that leads to the determination that a warranted part is in fact defective,
provided that such diagnostic work is performed at a warranty station.
MANUFACTURER’S WARRANTY COVERAGE:
The [current model year – {2+ current model year}] heavy-duty off-road & marine engines are warranted for the periods listed
below. If any emission-related part on your engine is defective, the part will be repaired or replaced by Kohler Co.
1,500 HOURS OR TWO

VARIABLE SPEED OR
KW <19 ANY SPEED YEARS, WHICHEVER
CONSTANT SPEED
COMES FIRST.
1,500 hours or two years,
Constant speed 19 ≤kW <37 3,000 rpm or higher
whichever comes first.
3,000 hours or five years,
Constant speed 19 ≤kW <37 Less than 3,000 rpm
3,000 hours or five years,
Variable speed 19 ≤kW <37 Any speed
Variable speed or constant 3,000 hours or five years,
kW ≥37 Any speed
speed whichever comes first.
MARINE DIESEL ENGINE
ENGINE POWER WARRANTY PERIOD
kW < 19 1,500 hours or 2,5 years, whichever comes first.
19 ≤ kW < 37 2,500 hours or 3,5 years, whichever comes first.
37 ≤ kW < 75 5,000 hours or 5 years, whichever comes first.
Index ED0053029510 _14 37 EN

9 GLOSSARY
A component that transforms mechanical energy into AC

A Alternator:
electrical energy.
Authorised workshop: Kohler authorised service centre.
B Bore: Internal diameter of the cylinder in combustion engines.
C Catalyst: A device in charge of filtering exhausted gas.
Chemical reaction of a mixture composed of fuel and fuel (air)

Combustion:
inside a combustion chamber.
E EC: European Community.

F Fig.: Figure.
G Galvanised: Material that has undergone surface protection treatment.
Type of extreme condition referred to the work environment

H Heavy conditions: in which the engine is used (very dusty - dirty area, or in a
contaminated environment due to various types of gas).
K KDI: Kohler Direct Injection

A group of maintenance actions that have the sole objective to
control and replace elements on their expiry, without modifying
M Maintenance - periodic:
or improving the functions carried out by the system, neither
increasing the value nor improving performance.
MAX: Maximum.
It is a mixture of products by means of a chemical conversion

Methyl ester of oils and animal and/or vegetable fat, which is used to
produce Biofuel.
Min.: Minutes.
MIN: Minimum.
Model, engine identification plate, which indicates the engine's

Model:
model.
P Par.: Paragraph.
Paraffin: Fatty and solid substance that may form inside the diesel.
R Ref.: Reference.
Serial number (engine identification name plate) indicating the
S s/n:
engine identification series/chassis number.
Specification, (engine identification name plate) indicating the

Spec.:
engine version.
T Tab.: Table.
A term indicated for installation of threaded components and

Tightening torque:
which is determined by means of a unit of measurement Nm.
Oil altered by operation or time, which is no longer compliant

U Used oil:
for correct lubrication of the components.
EN 38 ED0053029510 _14 Index

GLOSSARY 9
SYMBOLS AND UNITS OF MEASUREMENT

SYMBOL UNIT OF MEASUREMENT DESCRIPTION EXAMPLE
α degree Rotation/inclination angle 1°
cm 2
square centimetre Area 1 cm2
Ø millimetre Circumference Ø 1 mm
Nm newton-metre Torque 1 Nm
mm millimetre 1 mm
1/1000 of a millimetre Length
μm 1 μm
(micron)
h hour Time 1h
grammes per kilowatt per
g/kWh Specific consumption 1 g/kWh
hour
kg/h kilogramme per hour Max. flow rate 1 kg/h
Lt./min. litres per minute 1 Lt./min.
Flow rate
Lt./h litres per hour 1 Lt./h
ppm parts per million Percentage 1 ppm
N newton Force 1N
A Ampere Intensity of electrical current 1A
gr. gramme 1 gr.
Weight
kg kilogramme 1 kg
W Watt 1W
Power
kW kiloWatt 1 kW
pa pascal 1 pa
KPa Kilopascal 1 KPa
Pressure
bar barometric pressure 1 bar
mbar (1/1000 bar) barometric pressure 1 mbar
Resistance to electrical
R Resistance current (referred to a 1Ω
component)
Resistance of electrical
Ω ohm 1Ω
current
Rpm revs per minute Rotation of an axis 1 Rpm
average roughness
Ra Roughness Ra = 1
expressed in microns
°C degree centigrade Temperature 1°C
V Volt Electrical voltage 1V
Ã millimetre Hex-head capscrew Ã 1 mm
cm3 cubic centimetre 1 cm3
Volume
Lt. litre 1 Lt.
Index ED0053029510 _14 39 EN

9 NOTES
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_07
ENEN 40 ED0053029510 _14 Index
NOTES 9
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Index ED0053029510 _14 41 EN

9 NOTES
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_07
ENEN 42 ED0053029510 _14 Index
CALIFORNIA PROPOSITION 65 10
Index ED0053029510 _14 43 EN

Lombardini s.r.l. is a part of Kohler Group. E U RO PE U S A & C AN AD A FR AN C E
Lombardini has manufacturing facilities
Lombardini Srl Kohler Co. Lombardini France S.a.s.
in Italy, Slovakia and India and sales
Via Cav. del lavoro 444 Highland Drive, 47 Alléè de Riottier,
subsidiaries in France, Germany, UK, Spain
A. Lombardini n° 2 Kohler - Wisconsin (53044), US 69400 Limas, FRANCE
and Singapore. Kohler/Lombardini reserves
the right to make modifications without prior
42124 Reggio Emilia, ITALY T. +1 920 457 4441 T. +33-(0)474-626500
T. +39-(0)522-389-1 F. +1 920 459 1570 F. +33-(0)474-623945
notice.
F. +39-(0)522-389-503
www.lombardini.it
D E U T SCHLAND UK ES PAÑ A C H I N A & R O APAC

Lombardini Motoren GmbH Lombardini U.K. Ltd Lombardini ESPAÑA, S.L. Kohler China INVESTMENT Co. Ltd
Fritz-Klatte-Str. 6, Bürogebäude 2 1, Rochester Barn - Eynsham Road P.I. Cova Solera 1-9 no.158, Jiang Chang San Road,
D – 65933 Frankfurt OX2 9NH 08191 - Rubí (Barcelona) 200436, Zhabe, Shanghai
Hessen, DEUTSCHLAND Oxford, UK ESPAÑA CHINA
T. +49-(0)69-9508160 T. +44-(0)1865-863858 T. +34-(0)9358-62111 Tel: +86 400-0120-648
F. +49-(0)69-950816-30 F. +44-(0)1865-861754 F. +34-(0)9369-71613 Fax: +86 21 61078904

KDI 1903M - KDI 2504M: Owner Manual

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KDI 1903M - KDI 2504M

Translated from the original manual in Italian language.

Data reported in this issue can be modified at any time by KOHLER.

1 - GENERAL INFORMATION 3 - SAFETY INFORMATION

1.1 Manual's purpose.............................................................5 3.1 Safety information.........................................................15

1.2 Glossary and Definitions.................................................5 3.2 General remarks............................................................15

1.3 Emission-Related Installation Instructions...................5 3.2.1 Note for OEM...............................................................15

1.4 Service request................................................................5 3.2.2 Note for end user........................................................15

1.5 Engine component identification...................................6 3.3 Safety signal description..............................................17

1.7 Homologation labels........................................................8 3.3.2 Safety guards..............................................................17

1.7.1 Label for China Standards............................................8 3.3.3 Warnings......................................................................17

3.5 Safety and environmental impact................................18

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

2.2 Engine specifications....................................................10 4 - INFORMATION ABOUT USE

2.3 Engine dimensions (mm)...............................................10

2.7 Battery recommendations............................................14

5 - INFORMATION ABOUT MAINTENANCE 7 - INFORMATION ABOUT FAILURES

5.2 Periodic maintenance...................................................23

5.4 Oil dipstick on cylinder head........................................24 Warranty terms.............................................................35

5.7 Rubber hoses check......................................................25 9.1 Glossary..........................................................................38

5.9.1 Check...........................................................................27 10 - CALIFORNIA PROPOSITION 65

5.11 Product preservation...................................................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 ABOUT REPLACEMENTS

6.1 Engine oil replacement.................................................30

6.2 Oil filter cartridge replacement...................................31

6.3 Remote oil filter cartridge replacement (optional)....32

6.4 Fuel filter cartridge replacement ................................32

6.5 Air filter cartridge replacement...................................32

6.6 Disposal and scrapping.................................................33

1.1 Manual's purpose

1.2 Glossary and Definitions

1.3 Emission-Related Installation Instructions

1.4 Service request

Index ED0053029510 _14 5 EN

1.5 Engine component identification

Oil pressure switch

Oil filler cap

Oil drain plug

Fuel injection pump

Oil drain plug

EN 6 ED0053029510 _14 Index

1.6 Manufacturer and motor identification data

Side view A Side view B

Engine Engine serial number

Approval data and "EC"

Index ED0053029510 _14 7 EN

1.7 Homologation labels

1.7.1 Label for China Standards

EN 8 ED0053029510 _14 Index

1.7.2 Label for Korea Standards

Index ED0053029510 _14 9 EN

2.1. General description of the engine

2.2 Engine specifications

2.3 Engine dimensions (mm)