Kohler Diesel KDI 1903M-2504M Engines for JCB Workshop Manual PDF

This workshop manual is intended for the repair and maintenance of Kohler diesel engines of such KDI 1903M-2504M models.

The service manual helps to identify engine malfunctions, for which tables are provided for the main components and parts. It should be borne in mind that the data on the limiting wear of parts have approximate values ​​and should not be considered as the only criterion without taking into account the actual behavior of the part in the node or aggregate.
This repair manual contains detailed service information as well as detailed repair instructions necessary for the proper use and maintenance of the Kohler engine.

This workshop manual is an electronic PDF book. Which works with Adobe PDF reader and other analogs. This application helps to save, copy and print this manual and use it as a book. Therefore it must always be available, for future reference when required. You can view the manual and decide on the purchase option by clicking on the link 'Kohler pdf manual instant preview'.

This workshop manual is a guide for the repair and maintenance of Kohler 1903M-2504M engines installed on JCB equipment. It is intended for service stations, repair shops, and individual owners.

Form No. ED0053029610

Models covered:
1903M-2504M

Contents:

• 1. GENERAL INFORMATION
  • 1.1 Useful information
  • 1.2 Manufacturer and engine identification
  • 1.3 Identification of the main internal components of the engine and operating reference (BASE CONFIGURATION)
  • 1.4 Identification of the external components of the engine (BASE CONFIGURATION)
• 2. TECHNICAL INFORMATION
  • 2.1 Engine specifications
  • 2.2 Engine dimensions
  • 2.3 Performance diagrams
  • 2.4 Oil
  • 2.5 Fuel
  • 2.6 Coolant
  • 2.7 Battery features
  • 2.8 Periodic maintenance
  • 2.9 Fuel system
  • 2.10 Lubrication circuit
  • 2.11 Cooling circuit
  • 2.12 Intake and exhaust circuit
  • 2.13 Electric system
  • 2.14 Sensors and switches
  • 2.15 Electrical components
  • 2.16 Timing system and tappets
  • 2.17 Balancer device (optional - only KDI 2504)
  • 2.18 Components handling
• 3. SAFETY INFORMATION
  • 3.1 Before start-up
  • 3.2 Safety precautions
  • 3.3 General remarks
  • 3.4 Safety signal description
  • 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
  • 6.2 Coolant pump replacement
  • 6.3 Replace the crankshaft pulley
  • 6.4 Oil pump replacement
  • 6.5 Oil pressure valve replacement
  • 6.6 Oil filter replacement
  • 6.7 Fuel filter replacement
• DISASSEMBLY INFORMATION 72
  • 7.1 Recommendations for disassembly
  • 7.2 Electric components disassembly
  • 7.3 Exhaust manifold disassembly
  • 7.4 Coolant recirculation components disassembly
  • 7.5 Crankshaft pulley disassembly
  • 7.6 Lubrication circuit disassembly
  • 7.7 Intake manifold disassembly
  • 7.8 Fuel system disassembly
  • 7.9 Timing system gear disassembly
  • 7.10 Flange unit disassembly
  • 7.11 Cylinder head unit disassembly
  • 7.12 Oil sump unit disassembly
  • 7.13 Engine block disassembly
• 8. INFORMATION ABOUT OVERHAULING 90
  • 8.1 Recommendations for overhauls and tuning
  • 8.2 Crankcase
  • 8.4 Tappets and tapper housing
  • 8.5 Crankshaft
  • 8.6 Cylinder head
  • 8.7 Oil pump check
• 9. ASSEMBLY INFORMATION
  • 9.1 Information on engine configuration
  • 9.2 Assembly recommendations
  • 9.3 Engine block assembly
  • 9.4 Oil sump unit assembly
  • 9.5 Flange unit assembly
  • 9.6 Timing system gear assembly injection pump
  • 9.7 Cylinder head unit assembly
  • 9.8 Fuel system assembly
  • 9.9 Intake manifold assembly
  • 9.10 Exhaust manifold assembly
  • 9.11 Lubrication circuit
  • 9.12 Crankshaft pulley assembly
  • 9.13 Coolant circuit assembly
  • 9.14 Electric component assembly
  • 9.15 Summary table of tightening torques and the use of sealants
• 10. FLUIDS SUPPLY INFORMATION
  • 10.1 Engine oil
  • 10.2 Coolant
• 11. INFORMATION ABOUT OPTIONAL COMPONENTS
  • 11.1 Oil dipstick in the cylinder head
  • 11.2 Heater (replacement)
  • 11.3 Idler gear (for 3rd / 4th PTO)
  • 11.4 3rd PTO (replacement / installation)
  • 11.5 4th PTO (replacement / installation)
  • 11.6 3rd + 4th PTO (configurations)
  • 11.7 Balancer shafts (replacement)
  • 11.8 Air filter (cartridge replacement)
  • 11.9 Remote oil filter (disassembly and assembly)
  • 11.10 Intake circuit (replacement)
  • 11.11 Muffler (replacement)
  • 11.12 Cooling circuit (replacement)
  • 11.13 Engine feet (information)
• 12. INFORMATION ON ADJUSTMENTS and checks
  • 12.1 Air filter check
  • 12.2 Rubber hose and manifold control
  • 12.3 Oil leak check
  • 12.4 Oil pressure check
• 13. TOOLS INFORMATION
  • 13.1 Information regarding specific tools
• 14. INFORMATION about failures
  • 14.1 Possible causes and troubleshooting
• 15. GLOSSARY