LOMBARDINI MARINE KDI 1903M-MP Owner'S Manual Download Page 1

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KDI 1903M-MP

KDI 2504M-MP

OWNER MANUAL

Summary of Contents for KDI 1903M-MP

Page 1: ...KDI 1903M MP KDI 2504M MP OWNER MANUAL ...

Page 2: ...ings you come back automatically to the chapter initial page Clicking next to the bottom page number you come back to the analytic index Important Connect to http iservice lombardini it and download the latest version of this manual onto your device NOTE you can select the desired language before downloading the manual as shown in the figure below TRANSLATED FROM THE ORIGINAL MANUAL IN ITALIAN LAN...

Page 3: ...s 14 3 2 1 Notes for the manufacturer installer 14 3 2 2 Note for end user 14 3 3 Safety signal description 16 3 3 1 Adhesive safety plates 16 3 3 2 Safety guards 16 3 3 3 Warnings 16 3 4 Information and safety signals 17 3 5 Safety and environmental impact 17 3 6 Location of safety labels on engine 18 4 INFORMATION ABOUT USE 19 4 1 Pre start check 19 4 2 Break in running 19 4 3 Starting and turni...

Page 4: ...mp impeller replacement 31 6 5 Coolant replacement 31 6 6 Alternator belt replacement 32 6 7 Coolant pump belt replacement 33 6 8 Air cleaner replacement 33 6 9 Disposal and scrapping 33 7 INFORMATION ABOUT FAILURES 34 7 1 Useful information about failures 34 7 2 Error signals on the control panel 36 8 INFORMATION ABOUT WARRANTY 37 Warranty terms 37 9 GLOSSARY 40 ED0053030870 ...

Page 5: ...1 5 _03 EN NOTES ED0053030870 ...

Page 6: ...nitions The paragraphs tables and figure are divided into chapter with their progressive numbers Ex Par 2 3 chapter 2 paragraph 3 Tab 3 4 chapter 3 table 4 Fig 5 5 chapter 5 figure 5 The references of the objects described in the text and in figure and number are indicated by letters which are always and only related to the paragraph you are reading unless there are specific references to other fi...

Page 7: ...il filler cap Coolant pump Water pump Starter motor Oil filler cap Coolant refill cap Raiser Cooled exhaust manifold Coolant tempera ture sensor Nameplate Alternator Coolant filler cap Cooled exhaust manifold Fuel injection pump Oil filter Nameplate Raiser Fuel filter Air filter Engine oil extraction pump Reversing gear ED0053030870 ...

Page 8: ...e 1 Engine version Manufacturer identification The engine identification nameplate is located on side A or B as below SIDE VIEWA SIDE VIEW B 1 the engine model reported on the name plate in Fig 1 3 is generic For a specific model refer to the engine model shown on the name place situated on the rocker arm cover as shown in Fig 1 4 CE certificate ED0053030870 ...

Page 9: ...s 2 3 Engine dimensions mm with TMC 260 reversing gear TECHNICAL DATA UNIT OF MEASURE Engine type KDI 1903 M MP KDI 2504 M MP cylinders n 3 4 bore mm 88 88 stroke mm 102 102 displacement cm3 1861 2482 max inclination during operation even in combined transversal a 35 MAX 35 MAX longitudinal a 15 MAX 15 MAX oil capacity MAX level including oil filter standard version lt 8 9 11 5 with balancer devic...

Page 10: ... soon as possible For the exhausted oil disposal refer to Par 6 6 DISPOSAL and SCRAPPING Low S A P S oils sulfate ashes 1 may not be used with fuels with a sulfur content 50ppm Filtration of oils is critical to proper operation and lubrication always change filters regularly as specified in this manual RECOMMENDED OIL VISCOSITY SAE 15W 40 15 C 50 C 10w 30 25 c 40 C 10w 40 25 C 50 C 5w 30 30 c 40 C...

Page 11: ...3 DO NOT USE vegetable oil as a biofuel for this engine 2 5 1 Fuel for low temperatures When operating the engine in ambient temperatures lower than 0 degrees C use suitable low temperature fuel normally available from fuel distributors and corresponding to the specifications of Tab 2 3 These fuels reduce the formation of paraffin in diesel at low temperatures When paraffin forms in the diesel the...

Page 12: ...ngines OAT coolants are maintenance free up to 6 years or 6000hrs of operation provided that the cooling system is topped up using the same type of coolant Do not mix different coolant types Test the coolant condition annually with coolant test strips HOAT are not all maintenance free and it is recommended to have SCA Supplemental Coolant Additives added at the first maintenance interval 2 5 5 Emi...

Page 13: ...rrors display E Engine data or errors push button F Maintenance errors reset push button POS DESCRIPTION Coolant temperature C Oil pressure bar Battery voltage V 2 8 Control panel Tab 2 7 shows the control panel components Tab 2 8 shows data that can be consulted on display D by pressing push button E POS DESCRIPTION Total and partial hours of operation h To reset partial hours simultaneously pres...

Page 14: ... prevent fire hazards always keep the machine at least one meter from buildings or from other machinery Children and animals must be kept at a due distance from operating machines in order to prevent hazards deriving from their operation Thoroughly wash and clean all the external parts of the engine before performing any operation in order to avoid the accidental introduction of impurities foreign...

Page 15: ...e used to service the engine and or machine Make sure that all guards have been refitted Do not mix fuel with elements such as oil or kerosene Failure to comply with this prohibition will cause the non operation of the catalyst and non observance of the emissions declared by KOHLER Pay attention to the temperature of the oil filter when the filter itself is replaced Only check top up and change th...

Page 16: ...ce of explosive fuel Danger of fire or explosion Presence of steam and pressurized coolant Danger of burns Useprotectiveglovesbeforecarryingouttheoperation Use protective glasses before carrying out the operation Use sound absorbing protections before carrying out the operation Lifting point Electrical shock Danger of severe scalding or death High pressure fluid Danger of fluid penetration Lethal ...

Page 17: ...fuel tank while the engine is hot or running since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition Do not start the engine near spilled fuel Never use fuel as a cleaning agent HIGH PRESSURE FLUID RISK OF PUNCTURE High Pressure Fluids can puncture skin and cause severe injury or death Do not work on fuel system without proper training or safety equipment Flui...

Page 18: ...3 18 _03 SAFETY INFORMATION EN 3 6 Location of safety labels on engine ED0053030870 ...

Page 19: ...2 Put the ignition key in the ignition switch 3 Tun the key to 1 position 4 Press the Start push button for it to start automatically Important At the first start up carry out the operations in point 4 5 and 6 of Par 6 3 RPM reading delay is normal If engine does not start after two attempts see Tab 7 1 and Tab 7 2 to found the cause 4 3 2 After starting Warning Make sure that all the warning ligh...

Page 20: ...e of fuel in the correct way and do not litter as it is highly polluting When refuelling it is advisable to use a funnel to prevent fuel from spilling out The fuel should also be filtered to prevent dust or dirt from entering the tank Do not overfill the fuel tank Leave room for the fuel to expand 4 5 Engine oil filling 1 Loosen the oil filler cap A or the oil filler cap C if the cap A is not acce...

Page 21: ...xceed the MAX 4 If level is not at the MAX level add additional oil and reinsert the dipstick correctly in the reversing gear seat C 5 Re tighten the cap A Important Do not exceed the MAX level on the dipstick Do not use the engine with the oil level below the MIN Important For safety precautions see Par 2 4 Before proceeding with operation read Par 3 2 2 Place engine on horizontal surface to ensu...

Page 22: ...aking out of capscrew C Fig 4 7 3 Re tighten the cap A 4 After a few minutes of operator stop the engine and allow the liquid to cool returns to a ambient temperature and check the coolant level again 4 7 Coolant filling Important Before proceeding with operation read Par 3 2 2 Place engine on horizontal surface to ensure accurate measurement of filling Warning An anti freeze protection liquid ANT...

Page 23: ...rain plug and oil filler cap are tightened firmly Important Before proceeding with operation read Par 3 2 2 CLEANING AND CHECKING OPERATION DESCRIPTION PERIOD HOURS PAR 100 250 500 5000 Engine oil level 8 5 3 Coolant level 8 9 5 5 Radiator heat exchange surface 2 8 5 6 Rubber hose 5 4 Fuel hose 5 4 Starter Motor 6 1 In case of low use 12 months 2 The period of time that must elapse before checking...

Page 24: ... of checking 1 Loosen the oil filler cap A Remove the oil dipstick B and check that the level is up to MAX 2 Pour in recommended oil until reaching the MAX level mark 3 Reinstall the oil dipstick B completely 4 Re tighten the cap A and or C Important Do not exceed the MAX level on the dipstick Do not use the engine with the oil level below the MIN ED0053030870 ...

Page 25: ...or bending along the pipe and near the hose clamps Components must be replaced if they have clear signs of cracks tears cuts leaks and do not retain a certain degree of elasticity Important If hoses are damaged contact an authorized Lombardini Marine workshop 1 Check that the Fuel system hoses A are intact Hoses for the cooling circuit B1 B2 B3 and B4 Vent system pipes C ED0053030870 ...

Page 26: ...nstall the cap A and capscrew C NOTE For coolant filling see Par 4 6 Warning Before starting make sure that the radiator cap and cap if present are installed correctly to avoid spillage of liquid or vapour at high temperatures 5 6 Zinc anode and radiator check Warning Protect the starter motor adequately against contact with liquids before starting operations 1 Slightly undo union A to drain the c...

Page 27: ...E1 inserting gasket H5 tightening torque 30 Nm 15 Screw union A onto manifold G 16 Perform the operations described in Par 4 6 5 7 Product preservation Important If the engines are not to be used for 6 months they must be protected by carrying out the operations described in Engine storage up to 6 months Par 5 8 If the engine is still not in use after the first 6 months it is necessary to carry ou...

Page 28: ...s and sealed rings oil seals etc If cleaning engine with a pressure washer or steam cleaner it is important to maintain a minimum distance of at least 200mm between the surface to be washed and the nozzle avoiding absolutely electrical components 12 Treat non painted parts with protective products If the engine protection is performed according to the suggestions indicated no corrosion damage shou...

Page 29: ...stick B Fig 6 3 3 Remove oil drain plug D from pump E 4 Start pump E and drain the oil in the engine 5 Drain oil in an appropriate container For the exhausted oil disposal refer to Par 6 9 DISPOSAL and SCRAPPING 6 Tighten the drain oil plug D tightening torque at 10 Nm 7 Perform the operation described in Par 6 2 8 Add the type oil recommended Tab 2 1 and Tab 2 2 9 If the plug A is not accessible ...

Page 30: ...l filter cartridge replacement 1 Procure a suitable container to collect the fuel 2 Loosen and remove cartridge A 3 Lubricate the gasket C of the new cartridge Tighten the new cartridge A onto support B tighten manually Important Do not fill the new cartridge A with fuel 4 Loosen the air bleeding screw F on fuel filter bracket B and screw E placed on the injection pump G 5 Turn the key on the cont...

Page 31: ...bed in Par 5 6 before proceeding Replace gasket C 2 Screw cap A onto crankcase B inserting gasket C tightening torque 50 Nm 3 Perform the operations described in Par 4 7 6 4 Water pump impeller replacement Important Replace gasket G 1 Loosen capscrews A and remove cover B 2 Remove impeller C from pump body D 3 Grease the new impeller C 4 Insert the new impeller C onto shaft E 5 Fasten cover B with...

Page 32: ...move the belt F 4 Perform the operations from point 2 to 6 of Par 6 7 5 Insert the new belt F on pulleys G 6 Move alternator E in the direction of arrow H tighten capscrew D followed by hollow stud C tightening torque at 40 Nm 7 Check the tension of belt F with a Clavis type of instrument positioning it in point P the value must be 392 N 8 Secure guard B with capscrews A tightening torque at 5 Nm ...

Page 33: ...ws in force it is classified as hazardous waste therefore it must be collected by the appropriate centers 6 7 Coolant pump belt replacement 1 Perform the operations from point 1 to 3 of Par 6 6 2 Remove belt A 3 Insert the new belt A onto pulley G1 and start fitting pulley G2 in point B making sure to channel the internal ribs of the belt into the ducts of pulley G2 as shown in detail B1 4 Start t...

Page 34: ...o low Recharge the battery or replace it Low fuel level Refuel 4 4 Frozen fuel Contact Lombardini Marine authorised workshops Clogged fuel filter Replace with a new filter 6 3 Air suction in fuel system Contact Lombardini Marine authorised workshops Clogged air filter Replace with a new filter Clogged pipes Contact Lombardini Marine authorised workshops Open fuse Replace with a new fuse if the pro...

Page 35: ...formance Clogged air filter Replace with a new filter 6 8 Clogged fuel pipes Contact Lombardini Marine authorised workshops Cheap fuel Clean the tank and refuel with quality fuel High oil sump level Replace the engine oil if the problem persists contact Lombardini Marine authorised workshops 6 1 Slow acceleration Clogged fuel filter Replace the fuel filter 6 3 Engine jerking Clogged fuel pipes Con...

Page 36: ...ltage flashing display with battery 9 V Besides visual signals acoustic errors are also transmitted from the panel Any errors disappear automatically once the anomaly has been solved 1 A maintenance service does not automatically carry out a reset it must be reset manually as follows 1 Press the E push button until the maintenance service page Service h is displayed on the screen D 2 Simultaneousl...

Page 37: ...warranty from date of purchase of the part up to the first scheduled replacement point for the subject parts components All other Spare Parts items are covered by the above warranty provided that the repairs have been executed by Kohler Co or by an Authorized Kohler Service Dealer 2 EXCLUSIONS The following items are not covered by this warranty Damage caused by i an accident or casualty ii unreas...

Page 38: ...intenance listed in your Use Maintenance Manual Kohler Co recommends that you retain all receipts covering maintenance on your off road marine engine but Kohler Co cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance 2 As the off road marine engine owner you should however be aware that Kohler Co may deny you warranty cover...

Page 39: ...ipped to meet the state s and US EPA anti smog standards The warranty period shall begin on the date the engine or equipment is delivered to an ultimate purchaser Kohler Co must warrant the emission control system on your engine for the periods of time listed in the section below provided there has been no abuse neglect or improper maintenance of your engine Your emission control system may includ...

Page 40: ... mixture of products by means of a chemical conversion of oils and animal and or vegetable fat which is used to produce Biofuel Min Minutes MIN Minimum Model Model engineidentificationplate whichindicatestheengine s model P Par Paragraph Paraffin Fatty and solid substance that may form inside the diesel R Raiser Mixing device that reduces the temperature of the exhaust gases by mixing them with th...

Page 41: ...ts per million Percentage 1 ppm N newton Force 1 N A Ampere Intensity of electrical current 1 A gr gramme Weight 1 gr kg kilogramme 1 kg W Watt Power 1 W kW kiloWatt 1 kW pa pascal Pressure 1 pa KPa Kilopascal 1 KPa bar barometric pressure 1 bar mbar 1 1000 bar barometric pressure 1 mbar R Resistance Resistance to electrical cur rent referred to a component 1 Ω Ω ohm Resistance of electrical curre...

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Page 47: ... 9 47 _03 NOTES EN CALIFORNIA PROPOSITION 65 WARNING Dieselengineexhaustandsomeofitsconstituentsareknown to the State of California to cause cancer birth defects and other reproductive harm ED0053030870 ...

Page 48: ...India and sales subsidiaries in France Germany UK Spain and Singapore Kohler Lombardini reserves the right to make modifications without prior notice www lombardinimarine com SALES OFFICE Lombardini Marine Via Cav del lavoro A Lombardini n 2 42124 Reggio Emilia Italia T 39 0522 389311 F 39 0522 389298 e mail sales lombardinimarine com ...

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