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KDI 1903 TCR
Kohler KDI 1903 TCR Workshop Manual
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Table of Contents
1 General information
4
1.1 Useful information
4
1.2 Manufacturer and engine identification
5
1.3 Homologation labels
6
1.4 Identification of the main internal components of the engine and operating reference (BASE CONFIGURATION)
9
1.5 Identification of the external components of the engine (BASE CONFIGURATION)
12
1.6 ATS (After Treatment System)
15
2 Technical information
17
2.1 Engine specifications
17
2.2 Engine dimensions (mm)
20
2.3 Performance
21
2.4 Oil
23
2.5 Fuel
25
2.6 Coolant recommendation
28
2.7 Battery recommendation
29
2.8 Periodic maintenance
30
2.9 Fuel system
32
2.10 Lubrication circuit
40
2.11 Cooling circuit
44
2.12 Intake and exhaust circuit
47
2.13 Electric system
54
2.14 Sensors and switches
60
2.15 Electrical components
67
2.16 Timing system and tappets
72
2.17 Components handling
76
2.18 Turbocharger
79
2.19 Balancer device (optional)
82
3 Safety information
83
3.1 Before start-up
83
3.2 Safety precautions
84
3.3 General remarks
85
3.4 Safety signal description
88
3.5 Information and safety signals
90
3.6 Safety and environmental impact
92
3.7 Location of safety signals on engine
93
4 Storage information
94
4.1 Product preservation
94
4.2 Engine storage (up to 6 months)
95
4.3 Engine storage (over 6 months)
96
4.4 Engine starting after storage
97
5 Information regarding discharge of liquids
98
5.1 Coolant
98
5.2 Engine oil
100
6 Information for replacing the functional units
101
6.1 Electronic injector replacement
101
6.2 High-pressure fuel injection pump replacement
106
6.3 Unit EGR Cooler replacement
111
6.4 EGR valve replacement
113
6.5 Coolant pump replacement
115
6.6 Target wheel replacement
118
6.7 Oil pump replacement
120
6.8 Oil pressure valve replacement
125
6.9 Oil vapour separator replacement
126
6.10 Oil cooler unit and oil filter replacement
128
6.11 Fuel filter replacement
130
6.12 Replacement of SCV valve
132
7 Information for disassembly
134
7.1 Recommendations for disassembly
134
7.2 EGR circuit disassembly
135
7.3 Electric components disassembly
137
7.4 Turbocharger disassembly
141
7.5 Exhaust manifold disassembly
142
7.6 Coolant recirculation components disassembly
143
7.7 Crankshaft and target wheel pulley disassembly
145
7.8 Lubrication circuit disassembly
146
7.9 Intake manifold disassembly
149
7.10 Fuel system disassembly
150
7.11 Timing system gear disassembly
153
7.12 Flange unit disassembly
154
7.13 Cylinder head unit disassembly
155
7.14 Oil sump unit disassembly
158
7.15 Engine block disassembly
159
8 Information about overhauling
166
8.1 Recommendations for overhauls and tuning
166
8.2 Crankcase
167
8.3 Tappets and tappet housings
173
8.4 Crankshaft
174
8.5 Connecting rod - piston assembly
176
8.6 Cylinder head
179
8.7 Oil pump check
183
9 Assembly information
185
9.1 Information on engine configuration
185
9.2 Assembly recommendations
186
9.3 Engine block assembly
187
9.4 Oil sump unit assembly
196
9.5 Flange unit assembly
198
9.6 Timing system gear assembly and injection pump
199
9.7 Cylinder head unit assembly
201
9.8 Fuel system assembly
208
9.9 Intake manifold assembly
212
9.10 Exhaust manifold assembly
213
9.11 Assembly lubrication circuit
214
9.12 Crankshaft and phonic wheel pulley unit assembly
218
9.13 Coolant circuit assembly
219
9.14 Turbocharger Assembly
221
9.15 Electric component assembly
223
9.16 EGR Circuit Assembly
228
9.17 Tightening torques and the use of sealants
230
10 Fluids filling information
236
10.1 Engine oil
236
10.2 Coolant
238
11 Information about optional components
241
11.1 Oil dipstick in cylinder head
241
11.2 Heater (replacement)
243
11.3 Poly-V alternator belt (replacement and adjustment)
244
11.4 Tightening pulley and alternator for Poly-V belt
246
11.5 Idler gear (for 3rd / 4th PTO)
248
11.6 3rd PTO (replacement)
250
11.7 4th PTO (replacement)
253
11.8 3rd + 4th PTO (configurations)
257
11.9 Balancer device (replacement)
258
11.10 Air filter (cartridge replacement)
262
11.11 Remote oil filter (disassembly and assembly)
263
11.12 Oil sump with supporting structure
272
11.13 ETB (replacement)
277
11.14 ACACT (replacement)
278
11.15 EGTS (Black | Yellow - replacement)
279
11.16 DPF & DOC filter (replacement)
280
11.17 Oil dipstick on timing gears side
288
12 Information on adjustments
294
12.1 'Waste Gate' opening valve regulation
294
12.2 Air filter check
296
12.3 Oil steam separator check
297
12.4 Rubber hoses and manifolds check
298
12.5 Oil leak check
299
12.6 Oil pressure check
300
13 Tools information
302
13.1 Information regarding specific tools
302
14 Information about failures
305
14.1 Possible causes and trouble shooting
305
15 Glossary
308
15.1 Glossary
308
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Kohler KDI 1903 TCR Specifications
General
Brand
Kohler
Model
KDI 1903 TCR
Category
Engine
Language
English
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