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Kohler KDI 2504 TCR MGWI User Manual

Kohler KDI 2504 TCR MGWI
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KDI 2504 TCR MGWI
TP-7110 4/18
OWNER MANUAL

Table of Contents

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Kohler KDI 2504 TCR MGWI Specifications

General IconGeneral
Engine ModelKDI 2504 TCR MGWI
Displacement2482 cc
Number of Cylinders4
Bore x Stroke88 mm x 102 mm
Compression Ratio17.5:1
Fuel SystemCommon Rail Direct Injection
Emission ComplianceEU Stage V, EPA Tier 4 Final
Cooling SystemLiquid cooled
Lubrication SystemForced lubrication with gear pump
Engine Type4-stroke
AspirationTurbocharged
Max Torque300 Nm
Fuel Consumption210 g/kWh

Summary

GENERAL INFORMATION

1.1 Manual's purpose

Instructions for proper use and maintenance of the engine.

1.2 Glossary and Definitions

Explains how paragraphs, tables, and figures are referenced in the manual.

1.3 Emission-Related Installation Instructions

Guidance on installing certified engines to comply with air quality regulations.

1.4 Service request

Information on how to contact authorized service centers for support.

1.5 Manufacturer and motor identification data

Details on locating and understanding the engine's identification nameplate.

1.6 Engine component identification

Visual guide to identify major components of the engine with numbered labels.

HOMOLOGATION LABELS

1.7.1 Label for EPA rules

Explanation of the emission control label for EPA compliance.

1.7.2 Label for China Standards

Details the emission certification label for engines compliant with China standards.

1.7.3 Label for Korea Standards

Describes the emission certification label for engines compliant with Korea standards.

TECHNICAL INFORMATION

2.1 General description of the engine

Overview of the engine's key characteristics and design features.

2.2 Engine specifications

Technical data including engine type, displacement, bore, stroke, and oil capacity.

2.3 Engine dimensions (mm)

Graphical representation and physical measurements of the engine.

2.4 Oil

Information on recommended oil types, specifications, and viscosity classifications.

2.5 Fuel

Guidance on approved diesel fuels, low-temperature options, and biodiesel compatibility.

2.6 Coolant recommendation

Specifies the recommended coolant mixtures and types for engine cooling.

2.7 Battery recommendation

Provides guidelines for selecting appropriate batteries based on ambient temperature.

SAFETY INFORMATION

3.1 Safety information

General safety precautions and disclaimer regarding engine use and modifications.

3.2 General remarks

Notes for OEMs and end-users regarding engine installation and operation safety.

3.3 Safety signal description

Explains various safety plates, guards, and warning symbols used in the manual.

3.4 Information and safety signals

Details critical safety signals related to accidental starts, hot parts, and electrical hazards.

3.5 Safety and environmental impact

Discusses responsibilities for minimizing environmental impact and proper waste disposal.

INFORMATION ABOUT USE

4.1 Pre-start check

Checklist for essential operations to perform before starting the engine.

4.2 Running-in period

Guidelines for the initial operation period to ensure engine longevity.

4.3 Starting and turning off

Step-by-step instructions for safely starting and stopping the engine.

4.4 Refuelling

Procedures and safety warnings for refueling the engine with appropriate fuels.

4.5 Oil filling

Instructions for checking and filling engine oil to the correct level.

4.6 Coolant filling

Steps for filling the engine's cooling system with the correct coolant.

INFORMATION ABOUT MAINTENANCE

5.1 Useful information about maintenance

General advice on performing maintenance tasks and warranty compliance.

5.2 Periodic maintenance

Schedule for routine cleaning, checking, and replacement of engine parts.

5.3 Oil level check

Detailed steps for checking the engine oil level using the dipstick and filler caps.

5.4 Air filter check

Guidance on inspecting the engine's air filter, referring to vehicle documentation.

5.5 Rubber hoses check

Procedure for inspecting fuel, cooling, and vent system hoses for damage.

5.6 Coolant level check

Instructions for checking the coolant level in the engine's cooling system.

5.7 Zinc anode and radiator check

Steps for inspecting and cleaning the zinc anode and radiator for deposits.

5.8 Checking Intercooler

Procedure for inspecting and cleaning the engine's intercooler for deposits.

5.9 Alternator belt check

Guidance on checking the alternator belt, referring to vehicle documentation.

5.10 Fuel filter cartridge check

Steps for checking the fuel filter cartridge for water and tightening.

5.11 Product preservation

Instructions for protecting engines not in use for extended periods.

5.12 Engine storage up to 6 months

Procedures for preparing the engine for storage for periods up to six months.

5.13 Engine storage over 6 months

Procedures for extending engine protection for storage longer than six months.

5.14 Engine starting after storage

Steps to follow to restart an engine after a period of storage.

INFORMATION ABOUT REPLACEMENTS

6.1 Engine oil replacement

Step-by-step guide for draining old oil and refilling with new oil.

6.2 Oil filter cartridge replacement

Instructions for removing and replacing the engine oil filter cartridge.

6.3 Fuel filter cartridge replacement

Procedure for replacing the fuel filter cartridge and bleeding the system.

6.4 Air filter cartridge replacement

Guidance on replacing the air filter cartridge, referring to vehicle documentation.

6.5 Coolant replacement

Instructions for replacing the engine coolant, referencing another section.

6.6 Water pump impeller replacement

Steps for removing and replacing the water pump impeller.

6.7 Disposal and scrapping

Guidelines for the proper disposal and scrapping of the engine and components.

INFORMATION ABOUT FAILURES

7.1 Useful information about failures

Troubleshooting guide for common engine problems, causes, solutions, and paragraphs.

INFORMATION ABOUT WARRANTY

Owner's Warranty Responsibilities

Outlines owner's duties for warranty coverage and proper engine use.

GLOSSARY

Symbols and units of measurement

Table defining various symbols and units of measurement used in the manual.

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