LOMBARDINI MARINE Kohler KDI 1903TCR-MP, Owner'S Manual

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

Page 2: ...F MODIFICATIONS TO THE DOCUMENT Any modifications to this document must be registered by the drafting body by completing the following table Translated from the original manual in Italian language Data reported in this issue can be modified at any time by Lombardini Marine Released by Document code Model N Edition Revision Issue date Review date Edited by Endorsed Technical Documentation ED0053032...

Page 3: ...ental impact 17 3 6 Location of safety labels on engine 18 4 INFORMATION ABOUT USE 4 1 Pre start check 19 4 2 Break in running 19 4 3 Starting and turning off 19 4 3 1 Starting 19 4 3 2 After starting 19 4 3 3 Turning off 19 4 4 Refuelling 20 4 5 Engine oil filling 20 4 6 Reversing gear oil top up 21 4 7 Coolant filling 22 5 INFORMATION ABOUT MAINTENANCE 5 1 Useful information about maintenance 23...

Page 4: ... Error signals on the control panel 40 8 APPLICATION AND VALIDATION PROCESS 8 1 Application and Validation process for marine engine 41 8 2 Prescriptions to be respected 42 9 INFORMATION ABOUT WARRANTY Warranty terms 45 10 GLOSSARY Glossary 48 Symbols and units of measurement 50 ED0053032450 ...

Page 5: ..._04 1 5 EN NOTES ED0053032450 ...

Page 6: ...egral part of it The information contained within this manual is the sole property of Kohler Engines As such no reproduction or replication in whole or part is allowed without the express written permission of Kohler Engines 1 2 Glossary and Definitions 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 ...

Page 7: ...Thermostat Oil filler cap Coolant pump Alternator Water pump Starter motor Coolant refill cap Riser Coolant temperature sensor Oil pressure switch and sensor Fuel filter Fuel injection pump Oil filter Air filter Engine oil extraction pump Reversing gear Intercooler Radiator Turbocharger ED0053032450 ...

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 ED0053032450 ...

Page 9: ...TCR 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 DRY WEIGHT kg 277 300 4 stroke in line cylinders Diesel engine Liquid cooling system 4 valves per cylinder with hydraulic tappets Turbocha...

Page 10: ...oap and water as soon as possible For the exhausted oil disposal refer to Par 6 8 DISPOSAL and SCRAPPING 2 4 1 SAE oil classification In the SAE classification oils are identified according to viscosity without considering any other qualitative characteristic The code is made up of two numbers The first number refers to the viscosity when cold for use during winter W winter while the second number...

Page 11: ... 7 V V ASTM D 975 Grade 1 D S15 ASTM D 975 Grade 2 D S15 NATO F 54 equivalent to diesel fuel in accordance with EN 590 EN 590 or ASTM D 975 Grade 1 2 D S15 Arctic Diesel JIS K 2204 No 1 No 2 2 5 2 Biodiesel fuel Fuels containing 10 methyl ester or B10 are suitable for use in this engine provided that they meet the specifications listed in the Tab 2 3 DO NOT USE vegetable oil as a biofuel for this ...

Page 12: ...oolant liquid must be used Use a Long Life or Extended Life Heavy Duty OAT coolant free of silicates phosphates borates nitrites and amines The following ethylene glycol based engine coolant for all models within KDI engine family may be used OAT Organic Acid Technology Low Silicate ASTM D 3306 D 6210 HOAT Hybrid Organic Acid Technology Low Silicate ASTM D 3306 D 6210 The above coolants in concent...

Page 13: ...C Oil pressure bar Battery voltage V Consumption per hour 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 press push buttons E and F for 3 seconds Hours left for maintenance h Backlighting adjustment Press push but...

Page 14: ...ated precautions have been taken and have been certified for the machine To 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 op...

Page 15: ...led on the machine e g Startpilot Before starting remove any tools that were 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 oi...

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: ..._04 3 18 SAFETY INFORMATION EN 3 6 Location of safety labels on engine ED0053032450 ...

Page 19: ... 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 fuelling or if the tank was empty filling the fuel system Par 6 3 point 7 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 war...

Page 20: ...ose 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 ac...

Page 21: ...ot exceed 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 ...

Page 22: ...p 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 ANTIFREEZE mixed with decalcified water must be used T...

Page 23: ...ug 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 Zinc anode intercooler and radiator surface 2 5 6 Standard alternator belt 8 5 7 Rubber hose intake air coolant 5 4 Fuel hose Starter Motor 6 Alternator 6 REPLACEMENT OPERATION...

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 ED0053032450 ...

Page 25: ...tion 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 Kohler Engines workshop 1 Check that the Fuel system hoses A are intact Hoses for the cooling circuit B1 B2 Manifolds for the air circuit C Hoses for the oil circ...

Page 26: ... MAX filling level for the tank B is indicated by the LEVEL mark 3 Reinstall 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 intercooler and radiator check Warning Protect the starter motor adequately against cont...

Page 27: ...e manifolds from the components J and K 6 Unscrew the screws H remove the unit J and K 7 Unscrew the screws L separate the components J and K 8 Unscrew the screws M remove the cap N1 N2 and remove the radiator P from the support K 9 Clean immerse the components P N1 N2 in a solution of distilled water with hydrochloric acid 10 at a temperature of 50 C ED0053032450 ...

Page 28: ...arrying out the cleaning in point 9 clean the hoses with specific mechanical tools Important Replace all the gaskets 12 Insert the gasket Q2 on the radiator P 13 Insert the radiator P into the support K until it stops 14 Fix the cap N1 on the support K with the screws M interposing the gasket Q1 between N1 and P the gasket Q3 between N2 and K tightening torque MIN 8 Nm MAX 10 Nm 15 Insert the gask...

Page 29: ...cap T1 T2 and remove the intercooler U from the support V 20 Clean immerse the components T1 T2 U in a solution of distilled water with the addition of an alkaline soap compatible with aluminium 21 Check the intercooler U for any kind of encrustations and dirt wash with water mixed with alkaline soap suitable for aluminum material 22 Check all the holes on the surfaces U1 U2 for any kind of encrus...

Page 30: ...tening torque of 25 Nm 27 Insert the gasket Q6 on the intercooler U until it touches the support V and fix the cap T2 on the support V with the screws M tightening torque of 25 Nm 28 Fix the component J to the component K using the screws L and the washers W tightening torque of 25 Nm 29 Fix the unit J and K on the plate X with the screws H and the washers W 30 Fit the manifolds F and G on the com...

Page 31: ...G of approx 10kg on the point p When correctly tensioned the belt must show a movement of less than 10 mm If not adjus it 5 7 2 Adjustment 1 Loosen the fastening screws B and C 2 Pull the alternator outwards in direction of the arrow D to tension the belt 3 Keeping the belt tensed tighten the screws B and C 4 Tighten in sequence the screw B tightening torque of 25 Nm and C tightening torque of 40 ...

Page 32: ...y the fuel tank 9 Spray SAE 10W 40 on the exhaust and intake manifolds 10 Seal the exhaust and intake ducts to prevent foreign bodies from entering 11 When cleaning the engine if using a pressure washer or steam cleaning device avoid directing the nozzle on electrical components cable connections and sealed rings oil seals etc If cleaning engine with a pressure washer or steam cleaner it is import...

Page 33: ...ated to unused machine described in point 1 Perform the operations described in Par 5 6 Start the engine at least every 4 months as per operations described in point 1 Avoid sudden accelerations for the first few minutes Bring the engine to the working temperature by pressing the accelerator 3 4 from MAX Leave the engine running at minimum speed for a few minutes and turning off the engine Startin...

Page 34: ...appropriate container For the exhausted oil disposal refer to Par 6 8 DISPOSAL and SCRAPPING 6 Tighten the drain oil plug D tightening torque at 10 Nm 7 Perform the operation described in Par 6 2 point 2 to 5 8 Add the type oil recommended Tab 2 1 and Tab 2 2 9 If the plug A is not accessible use the oil filler cap C 10 Fit and remove the oil dipstick B to check the level Pour in fluid until reach...

Page 35: ...en 1 Unscrew cartridge holder cover A by performing three complete turns and wait 1 minute NOTE this operation allows to oil contained in the support F to flow into the oil sump in the correct way 2 Unscrew cartridge holder cover A and check that the oil in the lub oil filter support F has flowed towards the oil sump 3 Remove the cap A as well as the oil cartridge B from the oil filter support 4 R...

Page 36: ...n cover B and pump body D 6 3 Fuel filter cartridge replacement Important Do not fill the new cartridge B with fuel Replace the gaskets D and dampen them with oil 1 Disconnect the cable A of the water presence sensor C 2 Remove the water presence sensor C from its cartridge B 3 Unscrew the cartridge B 4 Tighten the new cartridge B on the fuel filter bracket E tightening torque of 17 Nm 5 Tighten t...

Page 37: ...irection of the arrow G 6 While tensioning the alternator C first clamp screw A tightening torque at 25 Nm and then screw B tightening torque at 41 Nm 7 Check the tension of the belt E with the instrument DENSO BTG 2 positioning it in point P the tension must be between 350 and 450 N Should the correct tool not be available the belt tension can be checked by applying a force in the direction of ar...

Page 38: ...osed of in the correct way to safeguard the environment According to the laws in force it is classified as hazardous waste therefore it must be collected by the appropriate centers 6 7 Air cleaner replacement 1 Loosen clamp A and remove filter B from support C 2 Fasten the new air cleaner B onto support C using clamp A 6 6 Coolant replacement 1 Undo cap A to drain all liquid from the system contai...

Page 39: ... KOHLER authorised workshops Engine starts but stops Inefficient electrical connections Clean the electrical contacts Sulphated battery terminals Clean the battery terminals Clogged fuel filter Replace with a new filter and clean the tank Clogged fuel pipes Contact KOHLER authorised workshops Engine doesn t rev up Safety protocol in starting Wait some seconds Throttle to MAX in starting Release th...

Page 40: ... flashing display with battery 9 V Fault code 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 Simulta...

Page 41: ...engine are observed owner manual installation manual provided on request in case of non observance of the instructions the warranty is to be considered as not applicable The warranty is activated from the sales invoice date to the final customer Below you can find some examples of the types of application of a marine engine for propulsion a the classical transmission in line with the shaft connect...

Page 42: ...s the following instructions must be observed Compliance with the maximum inclinations permitted owner manual 8 2 Prescriptions to be respected Exhaust line with muffler and terminal siphon installation scheme If the exhaust line is ascending and the sea water exit from the engine is under the waterline install a muffler and a non return siphon Muffler must hold a large volume of water included be...

Page 43: ...onnection scheme 1 Fuel supply shut off valve on the tank 2 Fuel return shut off valve on the tank 3 Fuel prefilter with water separator 10 micron 4 Fuel cooler interposed on fuel return pipe on the tank Supports anti vibration position and adjustment scheme ED0053032450 ...

Page 44: ...astic supports and locking them when the correct position has been found Engine and inverter must be aligned with the propeller shaft in two ways The traditional measurement is made using a thickness gauge and the alignment can be considered correct when the measured value is within 0 125 mm Extraction and ventilation engine room scheme ED0053032450 ...

Page 45: ...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 46: ...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 47: ...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 48: ...omised fuel inside the cylinders EPA Environmental Protection Agency The United States authority that safeguards the environment its duty is to govern and control polluting emissions F Fig Figure G Galvanised Material that has undergone surface protection treatment H Heavy conditions Type of extreme condition referred to the work environment in which the engine is used very dusty dirty area or in ...

Page 49: ...MAP T MAP sensor measures the temperature and absolute pressure inside the intake collector Turbocharger Device that compresses air intake by sending it to the intake manifold by means of a turbine U Used oil Oil altered by operation or time which is no longer compliant for correct lubrication of the components W Waste Gate valve A device which is directly or automatically controlled used to limit...

Page 50: ...rts 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 curr...

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Page 55: ..._04 10 55 NOTES EN CALIFORNIA PROPOSITION 65 WARNING Dieselengineexhaustandsomeofitsconstituentsareknown to the State of California to cause cancer birth defects and other reproductive harm ED0053032450 ...

Page 56: ...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 Kohler Engines 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 ...