Kohler LOMBARDINI MARINE KDI 1903TCR-MP User manual

KDI 1903TCR-MP
KDI 2504TCR-MP
OWNER MANUAL

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EN ED0053032450
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 gure below.
REGISTRATION OF 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 ED0053032450 51567 5 5 03/2018 05/2021 Technical Documentation

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INDEX
1 - GENERAL INFORMATION
1.1 Manual's purpose............................................................6
1.2 Glossary and Definitions................................................6
1.3 Emission...........................................................................6
1.4 Service request ...............................................................6
1.5 Engine component identification..................................7
1.6 Manufacturer and motor identification data ...............8
2 - TECHNICAL INFORMATION
2.1 General description of the engine ................................9
2.2 Engine specifications.....................................................9
2.3 Engine dimensions (mm) - with TMC 260 reversing gear ... 9
2.4 Oil....................................................................................10
2.4.1 SAE oil classification .................................................10
2.5 Fuel .................................................................................11
2.5.1 Fuel for low temperatures.........................................11
2.5.2 Biodiesel fuel .............................................................11
2.5.3 Synthetic fuels: GTL, CTL, BTL, HV.........................11
2.5.4 Non-Road Fuels .........................................................12
2.5.5 Emission-Related Installation Instructions ............12
2.6 Coolant recommendation ............................................12
2.7 Battery recommendation.............................................12
2.8 Control panel.................................................................13
3 - SAFETY INFORMATION
3.1 Safety information ........................................................14
3.2 General remarks ...........................................................14
3.2.1 Note for OEM/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
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
5.2 Periodic maintenance ..................................................23
5.3 Oil level check ...............................................................24
5.4 Rubber hoses check.....................................................25
5.5 Check coolant level ......................................................26
5.6 Zinc anode, intercooler and radiator check ..............26
5.7 Check and setting alternator standard belt tension.31
5.8 Control water filter cartridge fuel ...............................31
5.9 Product preservation ...................................................32
5.10 Engine storage (up to 6 months) ...............................32
5.11 Engine storage (over 6 months).................................32
5.12 Engine starting after storage.....................................32
5.13 Unused machine .........................................................33
5.13.1 Operations for the engine .......................................33
6 - INFORMATION ABOUT REPLACEMENTS
6.1 Engine oil replacement ................................................34
6.2 Oil filter cartridge replacement...................................35
6.3 Fuel filter cartridge replacement................................36
6.4 Water pump impeller replacement .............................36
6.5 Alternator belt replacement ........................................37
6.6 Coolant replacement....................................................38
6.7 Air cleaner replacement...............................................38
6.8 Disposal and scrapping ...............................................38
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INDEX
7 - INFORMATION ABOUT FAILURES
7.1 Useful information about failures................................39
7.2 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
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EN
NOTES
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EN
GENERAL INFORMATION
1.1 Manual's purpose
• This manual contains the instructions needed to carry out
proper use and maintenance of the engine, therefore it must
always be available, for future reference when required.
• This manual is an integral part of the engine, in the event of
transfer or sale, it must be attached to it.
• Safety pictograms can be found on the engine and it is the
operator's responsibility to keep them in a perfectly visible
place and replace them when they are no longer legible.
• Information, description and pictures in this manual reflect
the state of the art at the time of the marketing of engine.
• However, development on the engines is continuous.
Therefore, the information within this manual is subject to
change without notice and without obligation.
• Kohler Engines reserves the right to make, at any time,
changes in the engines for technical or commercial reasons.
• These changes do not require Kohler Engines to intervene
on the marketed production up to that time and not to
consider this manual as inappropriate.
• Any additional section that Kohler EnginesRwill deem
necessary to supply some time after the main text shall be
kept together with the manual and considered as an integral
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 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 figures or paragraphs.
The figure are based on model 2504 TCR-MP, where necessary the version 1903 TCR-MP is illustrated.
NOTE: All data, measurements and relevant symbols are shown in the glossary section.
1.3 Emission
The power of propulsion engines for marine use is measured in compliance with Directive 2013/53/EU.
1.4 Service request
-The complete and updated list of authorized Kohler Co. service centers can be found on websites:
www.kohlerengines.com & www.lombardinigroup.it/dealer-locator.
-If you have any questions regarding your warranty rights and responsibilities or the location of the nearest
Kohler Co. authorized service location, you should contact Kohler Co. at 1-800-544-2444 or access our website at
www.kohlerengines.com (USA and North American).
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1.1
1.2
EN
SIDE VIEWA
SIDE VIEW B
1.5 Engine component identification
GENERAL INFORMATION
Thermostat Oil filler cap
Coolant pump
Alternator
Water pump
Starter motor
Coolant rell cap
Riser
Coolant temperature
sensor
Oil pressure
switch and sensor
Fuel lter
Fuel injection pump
Oil lter
Air lter
Engine oil
extraction pump
Reversing gear
Intercooler
Radiator
Turbocharger
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1.3
1.4
EN
GENERAL INFORMATION
1.6 Manufacturer and motor identification data
Peak
rpm
Engine serial number
Approval data and
"EC" directives
Engine type (*1)
Engine
version
Manufacturer identication
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 certicate
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618
775
1021
908 (KDI 1903 TCR MP)
2.1
EN
2.1 General description of the engine
2.2 Engine specifications
2.3 Engine dimensions (mm) - with TMC 260 reversing gear
TECHNICAL DATA
UNIT
OF
MEASURE
ENGINE TYPE KDI 1903 TCR-MP KDI 2504 TCR-MP
CYLINDERS n. 3 4
BORE mm 88 88
STROKE mm 102 102
DISPLACEMENT cm31861 2482
MAX INCLINATION DURING
OPERATION (EVEN IN COMBINED)
TRANSVERSAL a35° MAX 35° MAX
LONGITUDINAL a15° 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;
- Turbocharger with Waste-gate valve;
- Direct injection.
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2.2
EN
2.4 Oil
Important
• The engine may be damaged if operated with improper oil
level.
• Do not exceed the MAX level because a sudden increase in
engine rpm could be caused by its combustion.
• Use only the recommended oil to ensure adequate protection,
efficiency and service life of the engine.
• The use of lubricants other than recommended may shorten
the engine life.
• Viscosity must be appropriate to the ambient temperature to
which the engine is to be exposed (Par. 2.4.1).
Danger
• Prolonged skin contact with the exhausted engine oil can
cause cancer of the skin.
• If contact with oil cannot be avoided, thoroughly wash your
hands with soap 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 is for viscosity at high
temperatures.
2.4.2 Reversing gear oil
NOTE: Refer to the technical documentation of the reversing gear supplied with the engine.
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)
0W-40 (-40°C ÷ +50°C)
WITH
SPECIFICATIONS
API
CI-4 Plus
CI-4
CH-4
ACEA E7
E5
• Filtration of oils is critical to proper operation and lubrication; always change filters regularly as specified in this manual.
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2.3
2.4
EN
Those engines are designed for fuels in accordance with EN 590 and ASTM D975 for a cetane number of at least 45. Since
those engines are not equipped with exhaust gas after-treatment, they can be operated with diesel fuels with sulfur content up
to 500 mg/kg (ppm). Compliance with the emission requirements is guaranteed only with sulfur content up to 350 mg/kg (ppm).
Fuels with a sulfur content > 50 mg/kg demand a shorter lubricating oil change interval. This is set at 250hrs. However, the
engine oil must be changed when the Total Base Number TBN is reduced to 6.0 mgKOH/g test method ASTM D4739. Do not
use low SAPS engine oils.
NOTE: In a warranty case the customer must prove by a certificate from the fuel supplier that an allowed
fuel was used.
2.5 Fuel
Important
• Use of other types of fuel could damage the engine. Do not
use dirty diesel fuel or mixtures of diesel fuel and water since
this will cause serious engine faults.
• Any failures resulting from the use of fuels other than
recommended will not be warranted.
Warning
• Clean fuel prevents the fuel injectors from clogging.
Immediately clean up any spillage during refuelling.
• Never store diesel fuel in galvanized containers (i.e. coated
with zinc). Diesel fuel and the galvanized coating react
chemically to each other, producing flaking that quickly
clogs filters or causes fuel pump and/or injector failure.
FUEL COMPATIBILITY
EN 590 (biodiesel content max. 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 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 fuel filter becomes blocked interrupting the flow of fuel.
BIODIESEL COMPATIBILITY
Biodiesel according to EN 14214 (only permissible for mixture with diesel fuel at max. 10% (V/V))
US biodiesel according to ASTM D6751 – 09a (B100) (only permissible for mixtures with diesel fuel at 10% (V/V))
2.5.3 Synthetic fuels: GTL, CTL, BTL, HV
It is a well-known fact that engines which are operated for longer periods with conventional diesel fuel and then converted
to synthetic fuels suffer shrinkage of polymer seals in the injection system and thus fuel leaks. The reason for this behavior is
that the aromatic-free synthetic fuels can lead to a change in the selling behavior of polymer seals.
Therefore, conversion from diesel fuel to synthetic fuel may only be done after changing the critical seals. The problem of
shrinkage does not occur when an engine was operated with synthetic fuel from the start.
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2.5
2.6
EN
FUEL PARAMETER UNIT LIMIT VALUE
Cetane number Min. 49
Fuel density at 15°C Kg/m3 820 - 860
Sulfur content mg/kg or ppm max. 500
2.5.4 Non-Road Fuels
Other non-road fuels may be used if they comply with all the limit values of EN 590 except for the fuel density, the cetane
number and the sulfur content.
The following limits apply for these parameters:
2.5.5 Emission-Related Installation Instructions
Failing to follow the instructions in the applications guidebook when installing a certified engine in a piece of nonroad equipment
violates federal law (40 CFR 1068.105(b)), subject to fines or other penalties as described in the Clean Air Act.
OEM must apply a separate label with the following statement: “ULTRA LOW SULFUR FUEL ONLY” near the fuel inlet.
Ensure you are installing an engine appropriately certified for your application. Constant speed engines may only be installed
on constant speed equipment for constant speed operation.
If you install the engine in a way that makes the engine's emission control information label hard to read during normal engine
maintenance, you must place a duplicate label on the equipment, as described in 40 CFR 1068.105.
2.6 Coolant recommendation
A mixture of 50% demineralized water and 50% low silicate ethylene glycol based coolant 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 concentrated formulation must be mixed with distilled, deionized, or demineralized water. A pre-mixed
formulation (40-60% or 50-50%) can be used directly when available.
Important
• Do not mix ethylene glycol and propylene glycol based coolants. Do not mix OAT and HOAT based coolant. OAT performance
life can be drastically reduced if contaminated with nitrite-containing coolants.
• Never use automotive-type coolants. These coolants do not contain the correct additives to protect heavy – duty diesel
engines.
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
Batteries not supplied by Kohler Engines.
2.7 Batteries reccomendation
RECOMMENDED BATTERIES
AMBIENT TEMPERATURE BATTERY T YPE
> - 15°C 12V 100 AH - 800 CCA/SAE
-15°C ÷ -25°C 12V 110 AH - 950 CCA/SAE
< - 25°C 12V 120 AH - 1000 CCA/SAE
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C
E
B
A
D
F
2.7
2.8
G
EN
POS. DESCRIPTION
APanel ignition switch with key switch
BEngine on push button
CEngine rpm indicator
DEngine data or errors display
EEngine data or errors push button
FMaintenance errors reset push button
GEngine o󰀨 push button
POS. DESCRIPTION
Coolant temperature (°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 Eand Ffor 3seconds
Hours left for maintenance (h)
Backlighting adjustment
- Press push button Efor 3seconds
- Press push button Eto decrease
brightness or Fto increase it
Turbocharger pressure
Fault code
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SAFETY INFORMATION
EN
3.1 Safety information
• The intended use of the engine is in conformity with the
machine on which it is mounted.
• Any use of the machine other than that described cannot
be considered as complying with its intended purpose as
specified by KOHLER .
• KOHLER declines all responsibility for any change to the
engine not described in this manual made by unauthorized
KOHLER personnel.
• A proper use of the engine, a strict observance of the
rules listed below and the rigorous application of all these
precautions will avoid the risk of accidents or injuries.
• Those who carry out the use and maintenance on the
engine must wear the safety equipment and the accident-
prevention guards.
• KOHLER declines all direct and indirect liability for failure
to comply with the standards of conduct contained in this
manual.
• KOHLER cannot consider every reasonably unforeseeable
misuse that may cause a potential danger.
3.2 General remarks
3.2.1 Note for OEM
• When installing the KDI engines, always bear in mind that
any variation to the functional systems may result in serious
failures to the engine.
• Any improvement must be verified at KOHLER testing
laboratories before application of the engine.
• In case the approval to a modification is not granted, KOHLER
shall not be deemed responsible for any consequential
failures or damages to the engine.
3.2.2 Note for end user
• The following indications are dedicated to the user of the
machine in order to reduce or eliminate risks concerning
engine operation and the relative routine maintenance work.
• The user must read these instructions carefully. Failure to do
this could lead to serious danger for his personal safety and
health and that of any persons who may be in the vicinity of
the machine.
• On starting, make sure that the engine is as horizontal as
possible, unless the machine specifications differ.
• Make sure that the machine is stable to prevent the risk of
overturning.
• The engine must not operate in places containing
inflammable materials, in explosive atmospheres, where
there is dust that can easily catch fire unless specific,
adequate and clearly indicated 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 operation, in order to avoid
the accidental introduction of impurities/foreign bodies.
Use only water and/or appropriate products to clean the
engine. If cleaning engine with a pressure washer or steam
cleaner, it is important to maintain a minimum distance of at
least200mmbetweenthesurfacetobewashedandthenozzle.
• The engine may only be assembled on a machine by
personnel specifically trained by KOHLER and who work in
compliance with the existing documentation.
• The engine has been built to the specifications of a machine
manufacturer, and it is his responsibility to ensure that all
necessary action is taken to meet the essential and legally
prescribed health and safety requirements. Any use of the
machine other than that described cannot be considered
as complying with its intended purpose as specified by
KOHLER, which therefore declines all responsibility for
accidents caused by such operations.
Avoid directing the nozzle on electrical components,
cable connections and sealed rings (oil seals etc).
Thoroughly wash and clean the area surrounding the
engine following the instructions provided by machine
manufacturer.
• Fuel and oil are inflammable. The tank must only be filled
when the engine is off. Before starting, dry any spilt fuel.
• Make sure that no soundproofing panels and the ground or
floor on which the machine is standing have not soaked up
any fuel.
• Fuel vapour is highly toxic. Only refuel outdoors or in a well
ventilated place.
• Do not smoke or use open flames when refuelling.
• During operation, the surface of the engine can become
dangerously hot. Avoid touching the exhaust system in
particular.
• Before proceeding with any operation on the engine, stop it
and allow it to cool.
• Always open the radiator plug or expansion chamber with
the utmost caution, wearing protective garments and
goggles.
• The coolant fluid is under pressure. Never carry out any
inspections until the engine has cooled.
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A
A
3.1
α ≤ 15° α ≤ 15°
SAFETY INFORMATION
EN
• If there is an electric fan, do not approach the engine when
it is still hot as the fan could also start operating when the
engine is at a standstill.
Important
• The oil must be drained whilst the engine is hot. Particular
care is required to prevent burns. Do not allow oil to come
into contact with the skin because of the health hazards
involved. It is recommended to use an oil intake pump.
• During operations that involve access to moving parts of
the engine and/or removal of rotating guards, disconnect
and insulate the negative wire (-) of the battery to prevent
accidental short-circuits and to stop the starter motor from
being energized.
• Check belt tension only when the engine is off.
• Fully tighten the tank cap each time after refuelling. Do not
fill the tank right to the top but leave an adequate space for
the fuel to expand.
• To start the engine follow the specific instructions provided
in the engine and/or machine operating manual. Do not
use auxiliary starting devices not originally installed 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 oil filter when the
filter itself is replaced.
• Only check, top up and change the coolant fluid when
the engine is off and reached the ambient temperature.
Coolant fluid is polluting, it must therefore be disposed of
in the correct way.
• Do not use air and water jets at high pressures on cables,
connectors and injectors.
Important
• Only use the eyebolts Ainstalled by KOHLER to move the
engine (Fig. 3.1).
• The angle between each lifting chain and the eyebolts shall
not exceed 15° inwards.
• The correct tightening of the lifting screws is 25Nm.
• Do not interpose spacers or washers between the eyebolts
and engine head.
• Provided that the above requirements are met, if the lifting
eyebolts are subject to permanent deformation (inwards), all
subsequent lifting operations must be performed in order to
prevent them from bending in the opposite direction.
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SAFETY INFORMATION
EN
3.3 Safety signal description
• To ensure safe operation please read the following
statements and understand their meaning.
• Also refer to your equipment manufacturer's manual for
other important safety information.
• This manual contains safety precautions which are
explained below.
• Please read them carefully.
Danger
• This indicates situations of grave danger which, if ignored,
may seriously threaten the health and safety of individuals.
Important
• This indicates particularly important technical information
that should not be ignored.
Warning
• This indicates that failure to comply with it can cause minor
damage or injury.
Read the Operation and Maintenance handbookbefore
performing any operation on the engine.
Hot Parts.
Danger of burns.
Presence of rotating parts.
Danger of jamming or cutting.
Presence of explosive fuel.
Danger of fire or explosion.
Presence of steam and pressurized coolant.
Danger of burns.
Use protective gloves before carrying out the operation.
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 Exhaust Gases.
Danger of poisoning or death.
3.3.1 Adhesive safety plates
The following is a list of the adhesive safety plates that may
be found on the engine, which indicate potential points of
danger to the operator (Par. 3.6).
3.3.2 Safety guards
Hereunder is a list of safety guards that must be worn prior
to carrying out any type of operation and to avoid potential
harm to the operator.
3.3.3 Warnings
Hereunder is a list of safety warnings that may be found in
the manual, which advise you to pay attention when carrying
out particular procedures that may be potentially dangerous
to the operator or things.
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SAFETY INFORMATION
EN
3.4 Information and safety signals
ACCIDENTAL START
Accidental Starts can cause
severe injury or death.
Before working on the engine or equipment, disconnect
the battery negative (-) wire.
ROTATING PARTS
Rotating Parts can cause
severe injury.
Stay away while engine is in operation. Keep hands, feet,
hair, and clothing away from all moving parts to prevent
injury.
Never operate the engine with covers, shrouds, or guards
removed.
LETHAL EXHAUST GASES
Carbon Monoxide can cause
severe nausea, fainting or
death.
Avoid inhaling exhaust fumes and never run the engine in a
closed building or confined area.
Carbon monoxide is toxic, odorless, colorless, and can
cause death if inhaled.
EXPLOSIVE GAS
Explosive Gas can cause
res and severe acid burns.
Charge battery only in a well ventilated area.
Keep sparks, open flames, and other sources of ignition
away from the battery at all times.
Batteries produce explosive hydrogen gas while being
charged.
Keep batteries out of the reach of children.
Remove all jewelry when servicing batteries. Before
disconnecting the negative (-) ground cable, make sure all
switches are OFF.
If ON, a spark will occur at the ground cable terminal which
could cause an explosion.
HOT PARTS
Hot Parts can cause severe
burns.
Engine components can get extremely hot from operation.
Do not touch engine while operating or just after stopping.
Never operate the engine with heat shields or guards
removed.
EXPLOSIVE FUEL
Explosive fuel can cause
res and severe burns.
Fuel is flammable and its vapours can ignite.
Store fuel only in approved containers, in well ventilated,
unoccupied buildings.
Do not fill the 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.
Fluid puncture injuries are highly toxic and hazardous.
If an injury occurs, seek immediate medical attention.
ELECTRICAL SHOCK
Electrical Shock can cause
injury.
Do not touch wires while engine is running.
3.5 Safety and environmental impact
Every organisation has a duty to implement procedures to
identify, assess and monitor the influence of its own activities
(products, services, etc.) on the environment.
Procedures for identifying the extent of the impact on the
environment must consider the following factors:
-Liquid waste.
-Waste management.
-Soil contamination.
-Atmospheric emission.
-Use of raw materials and natural resources.
-Regulations and directives regarding environmental impact.
In order to minimise the impact on the environment, KOHLER
now provides a number of indications to be followed by
all persons handling the engine, for any reason, during its
expected lifetime.
-All components and fluids must be disposed of in accordance
with the laws of the country in which disposal is taking place.
-Keep the fuel and engine control systems and the exhaust
pipes in efficient working order to limit environmental and
noise pollution.
-When discontinuing use of the engine, select all components
according to their chemical characteristics and dispose of
them separately.
CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
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SAFETY INFORMATION
EN
3.6 Location of safety labels on engine
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4.9
INFORMATION ABOUT USE
EN
• Read carefully the following pages and carry out the
operations described below in accordance with the
instructions specified.
4.1 Pre-start check
Important
• Non compliance with the operations described in the
following pages involves the risk of damages to the engine
and vehicle on which it is installed as well as personal and/
or property damage.
• Increase the frequency of maintenance operations in heavy
working conditions (engine starts but stops, very dusty and
hot environments, etc...).
4.2 Break-in running
NOTE: For the first 50 hours of engine operation, it is advisable not to exceed 75% of the maximum power supplied.
4.3 Starting and turning off
4.3 .1 Star ting
1. Check the level of the engine oil, fuel and coolant and fill
if necessary (Par. 4.5 and Par. 4.6).
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 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 warning lights on the control panel are off when the engine is running.
• Check for any leakages from the pipes on first start-up
1. Run at minimum speed for a few minutes according to table.
AMBIENT TEMPERATURE TIME
≤ -20°C 2 minutes
from -20° C to -10°C 1 minutes
from -10° C to -5° C 30 seconds
from -5° C to 5° C 20 seconds
≥ 5° C 15 seconds
4.3.3 Turning off
1. Do not turn off the engine with a full load or when it is running at the maximum rotation speed. Leave it running at idle speed
without a load for approximately 1 minute.
2. Press the Stop push button (the engine turns off) and turn the key to position 0.
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MIN
MAX
B
B
4.2
C
A
4.1
INFORMATION ABOUT USE
EN
4.4 Refuelling
Importan
• Before proceeding with operation, read Par. 3.2.2.
Danger
• Fill the engine off.
• The only approved fuels are those listed in Tab. 2 .3.
• In those countries where diesel has a high sulphur content, its is advisable to lubricate the engine with a high alkaline oil or
alternatively to replace the lubricating oil recommended by Kohler Engines more frequently.
• To avoid explosions or fire outbreaks, do not smoke or use open flames during the operations.
• Fuel vapours are highly toxic.Only carry out the operations outdoors or in a well ventilated place.
• Keep your face well away from the fuel fill to prevent harmful vapours from being inhaled.
• Dispose 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 accessible.
2. Add the type oil recommended (Tab. 2.1 and Tab. 2.2).
3. Remove the oil dipstick B and check that the level is up to
but does not exceed the MAX .
4. If level is not at the MAX. level, add additional oil.
5. Re-tighten the cap A or C.
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 ensure accurate
measurement of filling.
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