Kohler KDI 1903M - Workshop Manual

192 pages

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KDI 1903M

KDI 2504M

WORKSHOP MANUAL

TP-6939 3/23

Main Page

Table of Contents3
General Information8
Useful Information8
Manufacturer and Engine Identification9
Identification of the Main Internal Components of the Engine and Operating Reference (BASE CONFIGURATION)10
Identification of the External Components of the Engine (BASE CONFIGURATION)12
Technical Information15
Engine Specifications15
Engine Dimensions (MM)17
Performance18
Oil19
Fuel20
Coolant Recommendation22
Battery Recommendations23
Periodic Maintenance23
Fuel System25
Lubrication Circuit29
Coolant Circuit32
Intake and Exhaust Circuit33
Electric System35
Sensors and Switches38
Electrical Components40
Timing System and Tappets44
Components Handling47
Balancer Device (Optional)48
Safety Information49
Before Start-Up49
Safety Precautions49
General Remarks49
Safety Signal Description52
Information and Safety Signals53
Safety and Environmental Impact55
Location of Safety Signals on Engine55
Storage Information56
Product Preservation56
Engine Storage (up to 6 Months)56
Engine Storage (over 6 Months)56
Engine Starting after Storage57
Information Regarding Discharge of Liquids58
Coolant58
Engine Oil59
Information for Replacing the Functional Units60
Injectors and Injection Pump Replacement60
Coolant Pump Replacement68
Replace the Crankshaft Pulley69
Oil Pump Replacement70
Oil Pressure Valve Replacement73
Oil Filter Replacement74
Fuel Filter Replacement74
Information for Disassembly76
Recommendations for Disassembly76
Electric Components Disassembly76
Exhaust Manifold Disassembly78
Coolant Recirculation Components Disassembly78
Crankshaft Pulley Disassembly79
Lubrication Circuit Disassembly79
Intake Manifold Disassembly81
Fuel System Disassembly81
Timing System Gear Disassembly84
Flange Unit Disassembly84
Cylinder Head Unit Disassembly85
Oil Sump Unit Disassembly88
Engine Block Disassembly88
Information about Overhauling94
Recommendations for Overhauls and Tuning94
Crankcase94
Tappets and Tappet Housings99
Crankshaft100
Connecting Rod - Piston Assembly101
Cylinder Head105
Oil Pump Check108
Assembly Information110
Information on Engine Configuration110
Assembly Recommendations110
Engine Block Assembly111
Oil Sump Unit Assembly117
Flange Unit Assembly119
Timing System Gear Assembly and Injection Pump120
Cylinder Head Unit Assembly122
Fuel System Assembly128
Intake Manifold Assembly130
Exhaust Manifold Assembly131
Lubrication Circuit Assembly131
Crankshaft Pulley Assembly133
Coolant Circuit Assembly134
Electric Component Assembly134
Tightening Torques and the Use of Sealants136
Fluids Filling Information142
Engine Oil142
Coolant142
Information about Optional Components145
Oil Dipstick in Cylinder Head145
Heater (Replacement)146
Poly-V Alternator Belt (Replacement and Adjustment)147
Tightening Pulley and Alternator for Poly-V Belt148
Idler Gear (for 3Rd / 4Th PTO)151
3Rd PTO (Replacement)152
4Th PTO (Replacement)155
3Rd + 4Th PTO (Configurations)158
Balancer Device (Replacement)158
Air Filter (Cartridge Replacement)162
Remote Oil Filter (Disassembly and Assembly)162
Intake Circuit (Replacement)164
Muffler (Replacement)165
Cooling Circuit (Replacement)166
Engine Feet (Information)169
Oil Sump with Supporting Structure170
Oil Sump 15L173
Crankcase Oil Filter - Lengthwise Assembly175
Information on Adjustments177
Air Filter Check177
Rubber Hose and Manifold Control177
Oil Leak Check178
Oil Pressure Check178
Tools Information180
Information Regarding Specific Tools180

Kohler KDI 1903M - Workshop Manual

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