Kohler Diesel KDI 1903TCR-2504TCR for JCB Workshop Manual PDF

This workshop manual contains the instructions needed to carry out proper use and maintenance of the Kohler engine. Therefore it must always be available, for future reference when required. The service information, description, and pictures in this manual reflect the state of the art at the time of the marketing of the engine.

Form No. ED0053029590

Models covered:
1903TCR-2504TCR

Contents:

• 1. General Information
  • 1.1 Manufacturer and engine identification
  • 1.2 Nameplate for EPA regulations
• 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 Configurations with balancer shafts (optional)
  • 2.18 Components handling
  • 2.19 Turbocharger
• 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 Safety signals
• 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. Liquid Drainage Information
  • 5.1 Coolant
  • 5.2 Engine oil
• 6. Information For Replacing The Functional Units
  • 6.1 Electronic injector replacement
  • 6.2 High-pressure pump replacement
  • 6.3 Unit EGR cooler replacement
  • 6.4 EGR valve replacement
  • 6.5 Water pump replacement
  • 6.6 Phonic wheel replacement
  • 6.7 Oil pump replacement
  • 6.8 Oil pressure valve replacement
  • 6.9 Oil vapor separator replacement
  • 6.10 Oil cooler unit and filter replacement
  • 6.11 Fuel filter replacement
• 7. Disassembly Information
  • 7.1 Recommendations for disassembly
  • 7.2 Exhaust fumes recycle circuit disassembly (EGR)
  • 7.3 Electric components disassembly
  • 7.4 Turbocharger disassembly
  • 7.5 Exhaust manifold disassembly
  • 7.6 Water recirculation components disassembly
  • 7.7 Engine pulley and phonic wheel disassembly
  • 7.8 Lubrication circuit disassembly
  • 7.9 Intake manifold disassembly
  • 7.10 Injection circuit disassembly
  • 7.11 Timing system gear disassembly
  • 7.12 Flange unit disassembly
  • 7.13 Cylinder head unit disassembly
  • 7.14 Oil sump unit disassembly
  • 7.15 Engine block disassembly
• 8. Information About Overhauling and Tuning
  • 8.1 Recommendations for overhauls and tuning
  • 8.2 Crankcase
  • 8.4 Tappets and tapper housing
  • 8.5 Crankshaft
  • 8.6 Connecting rod - piston assembly
  • 8.7 Cylinder head
  • 8.8 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 and high-pressure pump
  • 9.7 Cylinder head unit assembly
  • 9.8 Fuel system assembly
  • 9.9 Intake manifold assembly
  • 9.10 Exhaust manifold assembly
  • 9.11 Assembly lubrication circuit
  • 9.12 Engine pulley and phonic wheel assembly
  • 9.13 Water circuit assembly
  • 9.14 Turbo-compressor assembly
  • 9.15 Electric component assembly
  • 9.16 EGR circuit assembly
  • 9.17 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 Poly-V alternator belt (replacement and adjustment)
  • 11.4 Tightening pulley and alternator for Poly-V belt
  • 11.5 Idler gear (for 3rd/4th PTO)
  • 11.6 3rd PTO (replacement / installation)
  • 11.7 4th PTO (replacement / installation)
  • 11.8 Balancer shafts (replacement)
  • 11.9 Air filter (cartridge replacement)
  • 11.10 Remote oil filter (disassembly and assembly)
• 12. Information On Adjustments
  • 12.1 Adjustment to "WASTE GATE" valve
• 13. Tools Information
  • 13.1 Special tools
  • 13.2 Commercial tools
• 14. Information About Failures
  • 14.1 Possible causes and troubleshooting
• 15. Diagnostic Information
  • 15.1 Diagnostic tool error list
  • 15.2 Information on resources used in graphics software POLAR-XL

The workshop manual discusses the main malfunctions and in accordance with each case gives step-by-step instructions on how to fix the damage from the very beginning. This guide helps beginners and experienced professionals.

Features of the Manual
Format: PDF
Language: English
Pages: 204
Compatible with all versions of Windows, Mac, Linux, iPhone, iPad, and Android
The repair service manual is a rather narrowly specialized section of technical literature. This technical service manual presents detailed operating instructions, which are fully illustrated. Separately, the rules for maintenance of Kohler engines, taking into account the frequency of all preventive procedures. Carrying out the necessary inspections, checks, and adjustments, you can be calm for the excellent working condition of the equipment.

FAQs
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Yes, all pages are printable.

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