Lombardini marine Kdi 1903m-mp User manual

KDI 1903M-MP

KDI 2504M-MP

OWNER MANUAL

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REGISTRATION OF MODIFICATIONS TO THE DOCUMENT

Any modications to this document must be registered by the drafting body, by completing the following table.

The online manuals are provided with hyperlinks which direct you to each individual chapter. By clicking on;

- The analytic index titles you can go directly to the selected subject.

- The blue underlined words you can go directly to a paragraph, a table or a picture.

- The chapter titles (headings) 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 LANGUAGE.

Data reported in this issue can be modied at any time by Lombardini Marine.

Released by Document code Model

N° Edition Revision Issue date Review

date Edited by Endorsed

Technical

Documentation ED0053030870 51404 4 3 02/2016 11/2018 Technical

Documentation

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INDEX

1GENERAL INFORMATION 6

1.1 Manual's purpose 6

1.2 Glossary and Denitions 6

1.3 Emission-Related Installation Instructions 6

1.4 Service request 6

1.5 Engine component identication 7

1.6 Manufacturer and motor identication data 8

2TECHNICAL INFORMATION 9

2.1 General description of the engine 9

2.2 Engine specications 9

2.3 Engine dimensions (mm) 9

2.4 Oil 10

2.4.1 Engine oil 10

2.4.1.1 SAE oil classication 10

2.4.2 Olio inReversing gear oilvertitore di marcia 10

2.5 Fuel 10

2.5.1 Fuel for low temperatures 10

2.5.2 Biodiesel fuel 11

2.5.3 Synthetic fuels: GTL, CTL, BTL, HV 11

2.5.4 Non-Road Fuels 11

2.5.5 Emission-Related Installation Instructions 12

2.6 Coolant 12

2.7 Battery features 13

2.8 Control panel 13

3SAFETY INFORMATION 14

3.1 Safety information 14

3.2 General remarks 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

4INFORMATION ABOUT USE 19

4.1 Pre-start check 19

4.2 Break-in running 19

4.3 Starting and turning o󰀨 19

4.3.1 Starting 19

4.3.2 After starting 19

4.3.3 Turning o󰀨 19

4.4 Refuelling 20

4.5 Engine oil lling 20

4.6 Reversing gear oil top-up 21

4.7 Coolant lling 22

5INFORMATION ABOUT MAINTENANCE 23

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 Checking the zinc anode and radiator 26

5.7 Product preservation 28

5.8 Engine storage (up to 6 months) 28

5.9 Engine storage (over 6 months) 28

5.10 Engine starting after storage 28

5.11 Unused machine 28

5.11.1 Operations for the engine 28

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INDEX

6INFORMATION ABOUT REPLACEMENTS 29

6.1 Engine oil replacement 29

6.2 Oil lter cartridge replacement 30

6.3 Fuel lter cartridge replacement 30

6.4 Water pump 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

7INFORMATION ABOUT FAILURES 34

7.1 Useful information about failures 34

7.2 Error signals on the control panel 36

8INFORMATION ABOUT WARRANTY 37

Warranty terms 37

9GLOSSARY 40

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NOTES

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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.

• Lombardini Marine reserves the right to make, at any time,

changes in the engines for technical or commercial reasons.

• These changes do not require Lombardini Marine to

intervene on the marketed production up to that time and not

to consider this manual as inappropriate.

• Any additional section that Lombardini MarineR will 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 Lombardini Marine. As such, no reproduction

or replication in whole or part is allowed without the express

written permission of Lombardini Marine.

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 M, where necessary the version 1903 M is illustrated.

NOTE: All data, measurements and relevant symbols are shown in the glossary section.

1.3 Emission

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.

1.4 Service request

• Authorized service centers can be found on our web site: http://www.lombardinimarine.com

• If you have any questions regarding your warranty rights and responsibilities or the location of the nearest authorised service

location, contact +39 07462251 or go to http://www.lombardinimarine.com.

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SIDE VIEWA

SIDE VIEW B

1.5 Engine component identiﬁcation

GENERAL INFORMATION

Oil pressure

switch and

sensor

Thermostat

Oil filler cap

Coolant pump

Water pump

Starter motor

Oil filler cap

Coolant rell cap

Raiser

Cooled exhaust manifold

Coolant tempera-

ture sensor

Nameplate

Alternator

Coolant filler

cap

Cooled exhaust manifold

Fuel injection pump

Oil lter

Nameplate

Raiser

Fuel lter

Air lter

Engine oil

extraction pump

Reversing

gear

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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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620

687

992

2.1

TECHNICAL INFORMATION

EN

2.1 General description of the engine

- 4-stroke, in-line cylinders Diesel engine;

-Liquid-cooling system;

- 4 valves per cylinder with hydraulic tappets;

- Direct injection.

2.2 Engine speciﬁcations

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 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

with balancer device ... 9

dry weight kg 277 300

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TECHNICAL INFORMATION

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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 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. 6.6 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)

0w-40 (-40°c ÷ +50°C)

WITH

SPECIFICATIONS

API

CI-4 Plus

CI-4

CH-4

ACEA E7

E5

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.

2.4.2 Reversing gear oil

NOTE: Refer to the technical documentation of the reversing gear supplied with the engine.

2.5 Fuel

ED0053030870

LOMBARDINI MARINE KDI 1903M-MP User manual

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