Kohler KDI 2504TM

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TP-6971 3/23

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Table of Contents3
General Information7
Useful Information7
Manufacturer and Engine Identification8
Identification of the Main Internal Components of the Engine and Operating Reference (BASE CONFIGURATION)9
Identification of the External Components of the Engine (BASE CONFIGURATION)11
Technical Information13
Engine Specifications13
Engine Dimensions (MM)15
Performance15
Oil16
Fuel17
Coolant Recommendation19
Battery Recommendation19
Periodic Maintenance20
Fuel System21
Lubrication Circuit26
Coolant Circuit29
Intake and Exhaust Circuit30
Electric System33
Sensors and Switches36
Electrical Components38
Timing System and Tappets42
Components Handling45
Turbocharger45
Balancer Device (Optional)49
Safety Information50
Before Start-Up50
Safety Precautions50
General Remarks50
Safety Signal Description53
Information and Safety Signals55
Safety and Environmental Impact56
Location of Safety Labels on Engine57
Storage Information58
Product Preservation58
Engine Storage (up to 6 Months)58
Engine Storage (over 6 Months)58
Engine Starting after Storage59
Information Regarding Discharge of Liquids60
Coolant60
Engine Oil61
Information for Replacing the Functional Units62
Injectors and Injection Pump Replacement62
Coolant Pump Replacement70
Replace the Crankshaft Pulley71
Oil Pump Replacement72
Oil Pressure Valve Replacement75
Oil Cooler Unit and Oil Filter Replacement76
Fuel Filter Replacement78
Oil Vapour Separator Replacement79
Information for Disassembly81
Recommendations for Disassembly81
Electric Components Disassembly81
Turbocharger Disassembly83
Exhaust Manifold Disassembly83
Coolant Recirculation Components Disassembly83
Crankshaft Pulley Disassembly84
Lubrication Circuit Disassembly85
Intake Manifold Disassembly86
Fuel System Disassembly87
Timing System Gear Disassembly89
Flange Unit Disassembly90
Cylinder Head Unit Disassembly90
Oil Sump Unit Disassembly93
Engine Block Disassembly94
Information about Overhauling99
Recommendations for Overhauls and Tuning99
Crankcase100
Tappets and Tappet Housings103
Crankshaft103
Connecting Rod - Piston Assembly105
Cylinder Head108
Oil Pump Check111
Assembly Information113
Information on Engine Configuration113
Assembly Recommendations113
Engine Block Assembly114
Oil Sump Unit Assembly121
Flange Unit Assembly122
Timing System Gear Assembly and Injection Pump123
Cylinder Head Unit Assembly125
Fuel System Assembly130
Intake Manifold Assembly132
Exhaust Manifold Assembly133
Lubrication Circuit Assembly133
Crankshaft Pulley Assembly135
Turbocharger Assembly136
Coolant Circuit Assembly137
Electric Component Assembly139
Tightening Torques and the Use of Sealants141
Fluids Filling Information147
Engine Oil147
Coolant148
Information about Optional Components150
Oil Dipstick in Cylinder Head150
Heater (Replacement)151
Idler Gear (for 3Rd / 4Th PTO)152
3Rd PTO (Replacement)153
4Th PTO (Replacement)156
3Rd + 4Th PTO (Configurations)159
Air Filter (Cartridge Replacement)160
Remote Oil Filter (Disassembly and Assembly)160
Poly-V Alternator Belt (Replacement and Adjustment)162
Tightening Pulley and Alternator for Poly-V Belt163
Oil Sump with Supporting Structure165
Information on Adjustments169
Air Filter Check169
Rubber Hose and Manifold Control169
Oil Leak Check170
Oil Pressure Check171
Tools Information172
Information Regarding Specific Tools172
Information about Failures174
Possible Causes and Trouble Shooting174
Glossary176

Kohler KDI 2504TM

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