JCB Kohler KDI 1903 M, 2504 M Diesel Engine Service Manual
166 pages · Publication 9806-6850
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- Models
- Kohler KDI 1903 M, 2504 M Diesel
- Manual type
- Service Manual
- Pages
- 166
- Publication
- 9806-6850
- Condition
- Brand new
What's inside
From the manual's own table of contents: 9 sections, 231 entries. See sample pages (PDF, 468 KB)
GENERAL INFORMATION4 topics
- Useful information
- Useful Information -accident prevention - environmental impact
- Manufacturer and engine identification
- Identification of the external components of the engine (BASE CONFIGURATION)
TECHNICAL INFORMATION85 topics
- Engine specifications
- Engine dimensions (mm)
- Performance diagrams
- SAE oil classification
- International lubricant specifications
- Fuel
- Fuel for low temperatures
- Biodiesel fuel
- Emission-Related Installation Instructions
- Coolant
- Battery features
- Periodic maintenance
- Fuel system
- Supply system
- Fuel return circuit
- Injection pump
- Injector
- Fuel filter
- Electric fuel pump (optional)
- Guards for fuel injection circuit components
- Lubrication circuit
- Lubrication circuit diagram
- Oil pump
- Oil filter
- Coolant circuit
- Coolant circuit diagram
- Coolant pump
- Thermostatic valve
- Radiator (optional)
- Intake and exhaust circuit
- Air filter (optional)
- Electric system
- Engine electrical wiring (opzional)
- Sensors and switches
- Fuel filter water detection sensor
- Oil pressure switch
- Coolant temperature sensor
- Air cleaner clogging switch
- Electrical components
- Alternator
- Starter motor
- Cold starting device (Heater)
- Electric fuel pump (optional)
- Cold Start Advance
- Electro-Stop
- Fuse
- Control panel (optional)
- Timing system and tappets
- Components identification
- Timing system phasing angles
- Rocker arm pin
- Rocker arms
- Hydraulic tappets
- Balancer device (optional - only KDI 2504)
- Components handling
- Injection pump
- Injector
- SAFETY INFORMATION
- Before start-up
- Safety precautions
- General remarks
- Safety signal description
- Information and safety signals
- Safety and environmental impact
- Location of safety signals on engine
- STORAGE INFORMATION
- Product preservation
- Engine storage (up to 6 months)
- Engine storage (over 6 months)
- Engine starting after storage
- INFORMATION REGARDING DISCHARGE OF LIQUIDS
- Engine oil
- INFORMATION FOR REPLACING THE FUNCTIONAL UNITS
- Injector and injection pump replacement
- Installation of the fuel injector pipes (pump injector/injectors)
- Coolant pump replacement
- Replace the crankshaft pulley
- Oil pump replacement
- Oil pressure valve replacement
- Oil filter replacement
- Disassembly
- Assembly
- Fuel filter replacement
- Disassembly
- Assembly
DISASSEMBLY INFORMATION90 topics
- Recommendations for disassembly
- Electric components disassembly
- Electric wiring
- Starter motor
- Belt and alternator
- Sensors and switches
- Exhaust manifold disassembly
- Coolant recirculation components disassembly
- Coolant pump
- Thermostatic valve
- Crankshaft pulley disassembly
- Lubrication circuit disassembly
- Oil pressure valve
- Timing system carter oil filling flange
- Timing system
- Oil pump
- Oil cooler unit
- Intake manifold disassembly
- Fuel system disassembly
- Fuel injection pipes
- Rocker arm cover
- Fuel return pipes
- Injector
- Injection pump
- Fuel filter
- Timing system gear disassembly
- Flange unit disassembly
- Flywheel
- Flange housing
- Cylinder head unit disassembly
- Rocker arm pin
- Valve rods and bridges
- Cylinder head
- Oil sump unit disassembly
- Oil sump
- Oil intake pipe
- Oil vapour pipe
- Engine block disassembly
- Crankshaft gasket flange
- Piston unit / connecting rod
- Lower semi-crankcase
- Crankshaft
- Piston
- Breather room closing cover
- Camshaft
- Camshaft tappets
- Crankshaft bushings
- Cover 3at PTO
- INFORMATION ABOUT OVERHAULING
- Recommendations for overhauls and tuning
- Crankcase
- Tappets and tappet housings
- Crankshaft
- Connecting rod - piston assembly
- Cylinder head
- Oil pump check
- ASSEMBLY INFORMATION
- Information on engine configuration
- Assembly recommendations
- Engine block assembly
- Crankshaft gasket flange
- Cover 3rd PTO
- Oil sump unit assembly
- Flange unit assembly
- Timing system gear assembly and injection pump
- Cylinder head unit assembly
- Rocker arms
- Rocker arm pin assembly
- Fuel system assembly
- Injector
- Fuel injector ricicle pipe
- Rocker arm cover
- Installation of the fuel injector pipes (injection pump/injectors)
- Fuel filter
- Intake manifold assembly
- Exhaust manifold assembly
- Oil filter
- Oil pump
- Timing system crankcase
- Crankcase oil filler flange Timing System
- Oil pressure relief valve
- Crankshaft pulley assembly
- Coolant circuit assembly
- Thermostatic valve
- Coolant pump
- Electric component assembly
- Sensors and switches
- Alternator
- Starter Motor
- Summary table of tightening torques and the use of sealants
INFORMATION ABOUT OPTIONAL COMPONENTS37 topics
- Oil dipstick in cylinder head
- Check
- Replacement
- Heater (replacement)
- Disassembly
- Assembly
- Idler gear (for 3rd / 4th PTO)
- Disassembly
- Assembly
- 3rd PTO (replacement)
- Disassembly
- Assembly
- 4th PTO (replacement)
- Disassembly
- Assembly
- 3rd + 4th PTO (configurations)
- Balancer device (replacement)
- Disassembly
- Assembly
- Air filter (cartridge replacement)
- Remote oil filter (disassembly and assembly)
- Disassembly
- Assembly
- Intake circuit (replacement)
- Air filter disassembly
- Manifold air filter disassembly
- Air filter manifold assembly
- Air filter assembly
- Muffler (replacement)
- Disassembly
- Assembly
- Cooling circuit (replacement)
- Radiator disassembly
- Fan disassembly
- Fan assembly
- Radiator assembly
- Engine feet (information)
INFORMATION ON ADJUSTMENTS and checks4 topics
- Air filter check
- Rubber hose and manifold control
- Oil leak check
- Oil pressure check
tools information1 topic
- Information regarding specific tools
INFORMATION about failures1 topic
- Possible causes and trouble shooting
Inside this manual
Real pages from this service manual (166 pages). Open the sample pages (PDF, 467 KB)
- Diagram, page 31: TECHNICAL INFORMATION
- Specifications, page 97: INFORMATION ABOUT OVERHAULING
- Troubleshooting, page 161: INFORMATION ABOUT FAILURES
- Color page, page 130: ASSEMBLY INFORMATION
- Color page, page 19: TECHNICAL INFORMATION
This is a service manual
Here's how it compares to the other manual types.
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 166 pages
Quantity one is the manual described above.
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Other editions and similar models
Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).