KOHLER KDI 1903 M 2504 M Engine Workshop Manual ED0053029610

KOHLER KDI 1903 M 2504 M Engine Workshop Manual ED0053029610
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TECHNICAL SPECIFICATIONS:
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Size: 105.44 MB
Pages: 166
Format: PDF
Language: English
Brand: KOHLER

CONTENTS (Table of Contents):
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1 GENERAL INFORMATION
1.1 Useful information
1.1.1 Useful Information -accident prevention - environmental impact
1.2 Manufacturer and engine identification
1.4 Identification of the external components of the engine (BASE CONFIGURA TION)
2 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
3 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
4 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
5 INFORMATION REGARDING DISCHARGE OF LIQUIDS
5.1 Coolant
5.2 Engine oil
6 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
7 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

PLEASE NOTE:
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This is a digital manual - no physical copy will be shipped.
The manual is available for immediate download after purchase.