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

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

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

MANUAL CONTENT: 
GENERAL INFORMATION 
1.1 Useful information 
1.2 Manufacturer and engine identification 
1.3 Name plate for EPA regulations 
1.4 Identification of main internal components of the engine and operating references 
1.5 Identification of external components of the engine

TECHNICAL INFORMATION
2.1 Engine specifications
2.2 Engine dimensions (mm)
2.3 Performance diagrams
2.4 Oil
2.4.1 SAE 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 Emissions - Regarding installation instructions
2.6 Coolant
2.7 Battery features
2.8 Scheduled maintenance
2.9 Fuel system
2.9.1 Injection circuit (2000 bar)
2.9.2 Fuel return circuit
2.9.3 High-pressure injection pump (2000 bar)
2.9.4 Electronic injector
2.9.5 Common rail
2.9.6 Fuel filter
2.9.7 Electric fuel pump (optional)
2.9.8 Guards for fuel injection circuit components
2.10 Lubrication circuit
2.10.1 Lubrication circuit diagram
2.10.2 Oil pump
2.10.3 Lub. oil filter and Oil Cooler
2.11 Coolant circuit
2.11.1 Coolant circuit diagram
2.11.2 Coolant pump
2.11.3 Radiator with intercooler (optional)
2.11.4 Thermostatic valve
2.11.5 EGR gas circuit cooling (EGR Cooler)
2.12 Intake and exhaust circuit
2.12.1 Turbocharger
2.12.2 Catalyst (optional)
2.12.3 Intake and exhaust circuit diagram with EGR
2.12.4 Air cleaner (optional)
2.13 Electric system
2.13.1 ECU input and output signals diagram
2.13.2 Control unit (ECU)
2.13.2.1 Installation rules
2.13.3 Engine electrical wiring
2.13.3.1 Wiring disconnection
2.14 Sensors and switches
2.14.1 Speed sensor on phonic wheel
2.14.2 Phase sensor indicator on camshaft
2.14.3 T-MAP sensor
2.14.4 Common Rail pressure sensor
2.14.5 Fuel filter water detection sensor
2.14.6 Fuel temperature sensor on fuel injection pump
2.14.7 Oil pressure switch
2.14.8 Coolant temperature sensor
2.14.9 Air cleaner clogging switch
2.15 Electrical components
2.15.1 Alternator
2.15.2 Poly-V belt alternator (optional)
2.15.3 Starter Motor
2.15.4 EGR valve
2.15.5 Cold starting device
2.15.6 Fuel intake regulating valve (SCV)
2.15.7 Electric fuel pump (optional)
2.16 Timing system and tappets
2.16.1 Components identification
2.16.2 Timing system phasing angles
2.16.3 Rocker arm gudgeon
2.16.4 Rocker arm
2.16.5 Hydraulic tappets
2.16.5.1 Hydraulic tappet operation
2.16.5.2 Difficult operating conditions
2.17 Balancer device
2.18 Components handling
2.18.1 High-pressure fuel injection pump
2.18.2 Electronic injector
2.18.3 Common Rail
2.18.4 Turbocharger
2.19 Turbocharger
2.19.1 What to do and what not to do
2.19.2 Practical operating rules
2.19.3 Before installing a new turbocharger
2.19.4 Installation instructions
2.19.5 Replacement instructions

SAFETY INFORMATION
3.1 Pre-start check
3.2 Safety precautions
3.3 General remarks
3.3.1 Manufacturer's notes
3.3.2 Notes for the end user
3.4 Safety label description
3.4.1 Adhesive safety plates
3.4.2 Warnings
3.4.3 Safety guards
3.5 Information and safety labels
3.6 Safety and environmental impact
3.7 Location of safety labels 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

LIQUID DRAINAGE INFORMATION
5.1 Coolant liquid
5.2 Engine oil

INFORMATION FOR REPLACING FUNCTIONAL UNITS
6.1 Electronic injector replacement
6.1.1 Fuel return tubes disassembly (Common Rail/electronic injectors)
6.1.2 High pressure fuel tubes disassembly (Common Rail/electronic injectors)
6.1.3 Electronic injector disassembly
6.1.4 Electronic injector assembly
6.1.5 High-pressure fuel lines assembly
6.1.6 Fuel return tubes assembly
6.2 High-pressure fuel injection pump replacement
6.2.1 High pressure fuel tube disassembly (from injection pump to Common Rail)
6.2.2 Timing system carter oil filling flange disassembly
6.2.3 High-pressure fuel injection pump disassembly
6.2.4 High-pressure fuel injection pump assembly
6.2.5 High-pressure line assembly (injection pump / Common Rail)
6.2.6 Timing system carter oil filling flange assembly
6.3 EGR cooler unit replacement
6.3.1 Disassembly
6.3.2 Assembly
6.4 EGR valve replacement
6.4.1 Disassembly
6.4.2 Assembly
6.5 Coolant pump replacement
6.5.1 Disassembly
6.5.2 Assembly
6.6 Target wheel replacement
6.6.1 Disassembly
6.6.2 Assembly
6.7 Oil pump replacement
6.7.1 Coolant pump disassembly
6.7.2 Crankshaft and phonic wheel pulley disassembly
6.7.3 Timing system carter disassembly
6.7.4 Oil pump disassembly
6.7.5 Oil pump assembly
6.7.6 Timing system carter assembly
6.7.7 CRANKSHAFT AND PHONIC WHEEL PULLEY ASSEMBLY
6.7.8 Coolant pump assembly
6.8 Oil pressure valve replacement
6.8.1 Disassembly
6.8.2 Assembly
6.9 Oil steam separator replacement
6.9.1 Disassembly
6.9.2 Assembly
6.10 Oil Cooler Unit and lub. oil filter replacement
6.10.1 Oil Cooler unit disassembly
6.10.2 Oil filter cartridge replacement
6.10.3 Oil Cooler unit assembly
6.11 Fuel filter replacement
6.11.1 Disassembly
6.11.2 Assembly

INFORMATION FOR DISASSEMBLY
7.1 Recommendations for disassembly
7.2 EGR circuit disassembly
7.2.1 EGR Cooler Unit
7.2.2 EGR Valve
7.3 Electric components disassembly
7.3.1 Electric wiring
7.3.2 Starter motor
7.3.3 Belt and alternator
7.3.4 Sensors and switches
7.3.4.1 Oil pressure switch
7.3.4.2 Coolant temperature sensor
7.3.4.3 Speed sensor
7.3.4.4 Camshaft phase sensor
7.3.4.5 T-MAP sensor
7.3.4.6 Fuel filter water detection sensor
7.4 Turbocharger disassembly
7.5 Exhaust manifold disassembly
7.6 Coolant recirculation components disassembly
7.6.1 Oil Cooler manifold
7.6.2 Coolant pump
7.6.3 Thermostatic valve
7.7 Crankshaft and target wheel pulley disassembly
7.8 Lubrication circuit disassembly
7.8.1 Oil pressure valve
7.8.2 Timing system carter oil filling cover
7.8.3 Timing system carter
7.8.4 Oil pump
7.8.5 Oil Cooler Unit and lub. oil filter
7.8.6 Oil steam separator unit
7.9 Intake manifold disassembly
7.10 Fuel system disassembly
7.10.1 Fuel return tubes
7.10.2 Fuel flow tubes
7.10.3 High-pressure fuel lines
7.10.4 Common rail
7.10.5 Electronic injectors
7.10.6 Fuel filter
7.10.7 High-pressure fuel injection pump
7.11 Timing system gear disassembly
7.12 Flange unit disassembly
7.12.1 Flywheel
7.12.2 Flange bell
7.13 Cylinder head unit disassembly
7.13.1 Rocker arm cover
7.13.2 Rocker arm gudgeon
7.13.2.1 Rocker arms
7.13.3 Valve rods and bridges
7.13.4 Cylinder head
7.13.4.1 Valves
7.13.4.2 Electronic injector sleeves
7.13.4.3 Valve stem gasket
7.13.4.4 Lifting eyebolts
7.14 Oil sump unit disassembly
7.14.1 Oil sump
7.14.2 Oil suction pipe
7.14.3 Oil steam tube
7.15 Short block disassembly
7.15.1 Crankshaft gasket flange
7.15.2 Piston unit / connecting rod and crankshaft
7.15.3 Lower crankcase
7.15.4 Crankshaft
7.15.5 Piston
7.15.5.1 Rings
7.15.6 Oil spray nozzles
7.15.7 Camshaft
7.15.8 Camshaft tappets
7.15.9 Crankshaft bushings
7.15.10 3rd PTO cover

INFORMATION ABOUT OVERHAULING AND TUNING
8.1 Recommendations for overhauls and tuning
8.2 Crankcase
8.2.1 Oil tubes check
8.2.2 Cylinders Check
8.2.3 4-cylinder camshaft housing check
8.2.4 4-cylinder camshaft check
8.2.5 3-cylinder camshaft housing check
8.2.6 3-cylinder camshaft check
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 Check the axial clearance of the crankshaft
8.5 Connecting rod-piston
8.5.1 Connecting rod dimension 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 Rocker arm check
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 Short block assembly
9.3.1 Crankshaft bushings
9.3.2 Tappets
9.3.3 Camshaft
9.3.4 Oil spray nozzles
9.3.5 Crankshaft
9.3.6 Lower crankcases
9.3.7 Rings
9.3.8 Piston
9.3.9 Piston and connecting rod unit
9.3.10 Crankshaft oil seal flange
9.3.11 3rd PTO cover
9.4 Oil sump unit assembly
9.4.1 Oil vapour pipes
9.4.2 Oil suction pipe
9.4.3 Oil Sump
9.5 Flange unit assembly
9.5.1 Flange bell
9.5.2 Flywheel
9.6 Timing system gear assembly and injection pump assembly
9.6.1 Timing system gears
9.6.2 High-pressure fuel injection pump
9.7 Cylinder head unit assembly
9.7.1 Valve stem gasket
9.7.2 Electronic injector sleeves
9.7.3 Electronic injector projection
9.7.4 Valves
9.7.5 Cylinder head
9.7.6 Valve rods and bridges
9.7.7 Rocker arm
9.7.8 Rocker arm gudgeon unit
9.7.9 Rocker arm cover
9.8 Fuel system assembly
9.8.1 Fuel filter
9.8.2 Common Rail
9.8.3 Electronic injectors
9.8.4 High-pressure fuel lines
9.8.5 Fuel return tubes
9.9 Intake manifold assembly
9.9.1 Internal half-manifold
9.9.2 External half-manifold
9.10 Exhaust manifold assembly
9.11 Lubrication circuit assembly
9.11.1 Oil steam separator unit
9.11.2 Oil Cooler unit and lub. oil filter
9.11.3 Oil pump
9.11.4 Timing system carter
9.11.5 Timing system carter oil filling flange
9.11.6 Oil pressure valve
9.12 Crankshaft and phonic wheel pulley unit assembly
9.13 Coolant circuit assembly
9.13.1 Thermostatic valve
9.13.2 Water pump
9.13.3 Oil Cooler Manifold
9.14 Turbocharger assembly
9.15 Electric components assembly
9.15.1 Sensors and switches
9.15.1.1 T-MAP sensor
9.15.1.2 Water temperature sensor
9.15.1.3 Oil pressure switch
9.15.1.4 Camshaft phase sensor
9.15.1.5 Speed sensor
9.15.1.6 Fuel filter water detection sensor
9.15.2 Alternator
9.15.3 Starter motor
9.15.4 Electric cabling
9.16 EGR circuit assembly
9.16.1 EGR valve
9.16.2 EGR Cooler Unit
9.17 Torque specifications and use of sealant

FLUIDS FILLING 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 Poly-V alternator belt (replacement or regulation)
11.4 Tightening pulley and alternator for Poly-V belt
11.4.1 Disassembly
11.4.2 Assembly
11.5 Idler gear (for 3rd / 4th PTO)
11.5.1 Disassembly
11.5.2 Assembly
11.6 3rd PTO (replacement)
11.6.1 Disassembly
11.6.2 Assembly
11.7 4th PTO (replacement)
11.7.1 Disassembly
11.7.2 Assembly
11.8 3rd+ 4th PTO (configurations)
11.8.1 Information
11.9 Balancer device (replacement)
11.9.1 Disassembly
11.9.2 Assembly
11.10 Air cleaner (cartridge replacement)
11.11 Remote lub. oil filter (disassembly and assembly)
11.11.1 Disassembly
11.11.2 Assembly
11.12 Oil sump with supporting structure
11.12.1 Flywheel disassembly
11.12.2 Plate/flange housing disassembly
11.12.3 Oil sump disassembly
11.12.4 Oil sump assembly
11.12.5 Flange plate / housing assembly
11.12.6 Flywheel assembly

INFORMATION REGARDING REGULATIONS
12.1 Waste Gate opening valve regulation
12.2 Air filter check
12.3 Oil steam separator check
12.4 Rubber hose and manifold control
12.5 Oil leak check
12.6 Oil pressure check

INFORMATION REGARDING TOOLS
13.1 Information regarding specific tools

INFORMATION REGARDING FAILURES
14.1 Possible causes and troubleshooting