Kohler Diesel Engine KDI 1903 M - KDI 2504 M workshop service manual

Description Kohler Diesel Engine KDI 1903 M - KDI 2504 M workshop service manual

Kohler Diesel Engines KDI 1903 M - KDI 2504 M pdf workshop service & repair manual + owner manual 

MANUAL CONTENT: 
GENERAL INFORMATION 
1.1 Useful information 
1.1.1 Useful Information -accident prevention - environmental impact 
1.2 Manufacturer and engine identification 
1.3 Identification of the main internal components of the engine and operating reference (BASE CONFIGURATION) 
1.4 Identification of the external components of the engine (BASE CONFIGURATION)

TECHNICAL INFORMATION
2.1 Engine specifications
2.2 Engine dimensions (mm)
2.3 Performance diagrams
2.4 Oil
2.4.1 SAE oil classification
2.4.2 International lubricant specifications
2.5 Fuel
2.5.1 Fuel for low temperatures
2.5.2 Biodiesel fuel
2.5.3 Emission-Related Installation Instructions
2.6 Coolant
2.7 Battery features
2.8 Periodic maintenance
2.9 Fuel system
2.9.1 Supply system
2.9.2 Fuel return circuit
2.9.3 Injection pump
2.9.4 Injector
2.9.5 Fuel filter
2.9.6 Electric fuel pump (optional)
2.9.7 Guards for fuel injection circuit components
2.10 Lubrication circuit
2.10.1 Lubrication circuit diagram
2.10.2 Oil pump
2.10.3 Oil filter
2.11 Coolant circuit
2.11.1 Coolant circuit diagram
2.11.2 Coolant pump
2.11.3 Thermostatic valve
2.11.4 Radiator (optional)
2.12 Intake and exhaust circuit
2.12.1 Air filter (optional)
2.13 Electric system
2.13.1 Engine electrical wiring (opzional)
2.13.1.1 Connector panel on the engine/machine
2.13.1.2 Accessories panel connector
2.13.1.3 Wiring disconnection
2.14 Sensors and switches
2.14.1 Fuel filter water detection sensor
2.14.2 Oil pressure switch
2.14.3 Coolant temperature sensor
2.14.4 Air cleaner clogging switch
2.15 Electrical components
2.15.1 Alternator
2.15.2 Starter motor
2.15.3 Cold starting device (Heater)
2.15.4 Electric fuel pump (optional)
2.15.5 Cold Start Advance
2.15.6 Electro-Stop
2.15.7 Fuse
2.15.8 Control panel (optional)
2.16 Timing system and tappets
2.16.1 Components identification
2.16.2 Timing system phasing angles
2.16.3 Rocker arm pin
2.16.4 Rocker arms
2.16.5 Hydraulic tappets
2.16.5.1 Hydraulic tappet operation
2.16.5.2 Difficult operating conditions
2.17 Balancer device (optional - only KDI 2504)
2.18 Components handling
2.18.1 Injection pump
2.18.2 Injector

SAFETY INFORMATION
3.1 Before start-up
3.2 Safety precautions
3.3 General remarks
3.3.1 Note for OEM
3.3.2 Note for end user
3.4 Safety signal description
3.4.1 Adhesive safety plates
3.4.2 Warnings
3.4.3 Safety guards
3.5 Information and safety signals
3.6 Safety and environmental impact
3.7 Location of safety signals on engine

STORAGE INFORMATION
4.1 Product preservation
4.2 Engine storage (up to 6 months)
4.3 Engine storage (over 6 months)
4.4 Engine starting after storage

INFORMATION REGARDING DISCHARGE OF LIQUIDS
5.1 Coolant
5.2 Engine oil

INFORMATION FOR REPLACING THE FUNCTIONAL UNITS
6.1 Injector and injection pump replacement
6.1.1 Injection fuel pipes disassembly(injection pump/injectors)
6.1.2 Rocker arms cover disassembly
6.1.3 Fuel return pipes disassembly
6.1.4 Injectors disassembly
6.1.5 Injection pump disassembly
6.1.6 Injection pump assembly
6.1.7 Injector assembly
6.1.8 Assembly of the injector return pipes
6.1.9 Assembly Rocker arm cover
6.1.10 Installation of the fuel injector pipes (pump injector/injectors)
6.2 Coolant pump replacement
6.2.1 Disassembly
6.2.2 Assembly
6.3 Replace the crankshaft pulley
6.3.1 Disassembly
6.3.2 Assembly
6.4 Oil pump replacement
6.4.1 Coolant pump disassembly
6.4.2 Engine pulley disassembly
6.4.3 Timing system crankcase disassembly
6.4.4 Oil pump disassembly
6.4.5 Oil pump assembly
6.4.6 Timing system crankcase assembly
6.4.7 Crankshaft pulley assembly
6.4.8 Coolant pump assembly
6.5 Oil pressure valve replacement
6.5.1 Disassembly
6.5.2 Assembly
6.6 Oil filter replacement
6.6.1 Disassembly
6.6.2 Assembly
6.7 Fuel filter replacement
6.7.1 Disassembly
6.7.2 Assembly

DISASSEMBLY INFORMATION
7.1 Recommendations for disassembly
7.2 Electric components disassembly
7.2.1 Electric wiring
7.2.2 Starter motor
7.2.3 Belt and alternator
7.2.4 Sensors and switches
7.2.4.1 Oil pressure switch disassembly
7.2.4.2 Coolant temperature sensor
7.2.4.3 Fuel filter water detection sensor
7.3 Exhaust manifold disassembly
7.4 Coolant recirculation components disassembly
7.4.1 Coolant pump
7.4.2 Thermostatic valve
7.5 Crankshaft pulley disassembly
7.6 Lubrication circuit disassembly
7.6.1 Oil pressure valve
7.6.2 Timing system carter oil filling flange
7.6.3 Timing system
7.6.4 Oil pump
7.6.5 Oil cooler unit
7.7 Intake manifold disassembly
7.8 Fuel system disassembly
7.8.1 Fuel injection pipes
7.8.2 Rocker arm cover
7.8.3 Fuel return pipes
7.8.4 Injector
7.8.5 Injection pump
7.8.6 Fuel filter
7.9 Timing system gear disassembly
7.10 Flange unit disassembly
7.10.1 Flywheel
7.10.2 Flange housing
7.11 Cylinder head unit disassembly
7.11.1 Rocker arm pin
7.11.1.1 Rocker arm
7.11.2 Valve rods and bridges
7.11.3 Cylinder head
7.11.3.1 Valves
7.11.3.2 Injector sleeve
7.11.3.3 Valve stem gasket
7.11.3.4 Lifting eyebolts
7.12 Oil sump unit disassembly
7.12.1 Oil sump
7.12.2 Oil intake pipe
7.12.3 Oil vapour pipe
7.13 Engine block disassembly
7.13.1 Crankshaft gasket flange
7.13.2 Piston unit / connecting rod
7.13.3 Lower semi-crankcase
7.13.4 Crankshaft
7.13.5 Piston
7.13.5.1 Rings
7.13.6 Breather room closing cover
7.13.7 Camshaft
7.13.8 Camshaft tappets
7.13.9 Crankshaft bushings
7.13.10 Cover 3at PTO

INFORMATION ABOUT OVERHAULING
8.1 Recommendations for overhauls and tuning
8.2 Crankcase
8.2.1 Oil line check
8.2.2 Cylinder check
8.2.3 4-cylinder camshaft housing check
8.2.4 Camshaft control for 4 cylinder engine
8.2.5 Camshaft housing check for 3 cylinder engine
8.2.6 Camshaft control for 3 cylinder engine
8.3 Tappets and tappet housings
8.3.1 Tappets check
8.3.2 Tappet housing check
8.4 Crankshaft
8.4.1 Dimensional check and overhauling
8.4.2 Checking the axial clearance of the crankshaft
8.5 Connecting rod - piston assembly
8.5.1 Connecting rod dimensions check
8.5.2 Checking the gudgeon pin-pin axes are parallel
8.5.3 Piston rings check
8.5.4 Piston dimension check
8.6 Cylinder head
8.6.1 Flatness check
8.6.2 Valve seats check
8.6.3 Valve springs
8.6.4 Valve guides check
8.6.5 Valve guides replacement
8.6.6 Valve guides replacement
8.7 Oil pump check
8.7.1 Dimensional and visual check
8.7.2 Rotors clearance check
8.7.3 Oil pressure valve check

ASSEMBLY INFORMATION
9.1 Information on engine configuration
9.2 Assembly recommendations
9.3 Engine block assembly
9.3.1 Semi main bearings
9.3.2 Tappets
9.3.3 Camshaft
9.3.4 Breather room closing cover
9.3.5 Crankshaft
9.3.6 Lower crankcase
9.3.7 Piston rings
9.3.8 Piston
9.3.9 Piston and connecting rod assembly
9.3.10 Crankshaft gasket flange
9.3.11 Cover 3rd PTO
9.4 Oil sump unit assembly
9.4.1 Oil vapour pipe
9.4.2 Oil suction pipe
9.4.3 Oil Sump
9.5 Flange unit assembly
9.5.1 Bell housing
9.5.2 Flywheel
9.6 Timing system gear assembly and injection pump
9.6.1 Timing system gear assembly
9.6.2 Injection pump
9.7 Cylinder head unit assembly
9.7.1 Valve stem gasket
9.7.2 Injector sleeves
9.7.3 Injectors projection
9.7.4 Valves
9.7.5 Cylinder head
9.7.6 Rods and valve bridges
9.7.7 Rocker arms
9.7.8 Rocker arm pin assembly
9.8 Fuel system assembly
9.8.1 Injector
9.8.2 Fuel injector ricicle pipe
9.8.3 Rocker arm cover
9.8.4 Installation of the fuel injector pipes (injection pump/injectors)
9.8.5 Fuel filter
9.9 Intake manifold assembly
9.10 Exhaust manifold assembly
9.11 Lubrication circuit
9.11.1 Oil filter
9.11.2 Oil pump
9.11.3 Timing system crankcase
9.11.4 Crankcase oil filler flange Timing System
9.11.5 Oil pressure relief valve
9.12 Crankshaft pulley assembly
9.13 Coolant circuit assembly
9.13.1 Thermostatic valve
9.13.2 Coolant pump
9.14 Electric component assembly
9.14.1 Sensors and switches
9.14.1.1 Water temperature sensor
9.14.1.2 Oil Pressure Switch
9.14.1.3 Fuel filter water detection sensor
9.14.2 Alternator
9.14.3 Starter Motor
9.15 Summary table of tightening torques and the use of sealants

FLUIDS SUPPLY INFORMATION
10.1 Engine oil
10.2 Coolant

INFORMATION ABOUT OPTIONAL COMPONENTS
11.1 Oil dipstick in cylinder head
11.1.1 Check
11.1.2 Replacement
11.1.2.1 Disassembly
11.1.2.2 Assembly
11.2 Heater (replacement)
11.2.1 Disassembly
11.2.2 Assembly
11.3 Idler gear (for 3rd / 4th PTO)
11.3.1 Disassembly
11.3.2 Assembly
11.4 3rd PTO (replacement)
11.4.1 Disassembly
11.4.2 Assembly
11.5 4th PTO (replacement)
11.5.1 Disassembly
11.5.2 Assembly
11.6 3rd + 4th PTO (configurations)
11.6.1 Information
11.7 Balancer device (replacement)
11.7.1 Disassembly
11.7.2 Assembly
11.8 Air filter (cartridge replacement)
11.9 Remote oil filter (disassembly and assembly)
11.9.1 Disassembly
11.9.2 Assembly
11.10 Intake circuit (replacement)
11.10.1 Air filter disassembly
11.10.2 Manifold air filter disassembly
11.10.3 Air filter manifold assembly
11.10.4 Air filter assembly
11.11 Muffler (replacement)
11.11.1 Disassembly
11.11.2 Assembly
11.12 Cooling circuit (replacement)
11.12.1 Radiator disassembly
11.12.2 Fan disassembly
11.12.3 Fan assembly
11.12.4 Radiator assembly
11.13 Engine feet (information)

INFORMATION ON ADJUSTMENTS and checks
12.1 Air filter check
12.2 Rubber hose and manifold control
12.3 Oil leak check
12.4 Oil pressure check
13 tools information
13.1 Information regarding specific tools

INFORMATION about failures
14.1 Possible causes and trouble shooting