Lombardini marine Kdi 1903m-mp User manual

KDI 1903M-MP

KDI 2504M-MP

OWNER MANUAL

1

2_03

EN ED0053030870

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

1

3

_03 EN

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

ED0053030870

1

4_03

EN

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

ED0053030870

1

5

_03

........................................................................................................................................................

EN

NOTES

........................................................................................................................................................

ED0053030870

1

6_03

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.

• 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.

ED0053030870

1

7

_03 EN

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

ED0053030870

1

8_03

1.1

1.2

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

ED0053030870

2

9

_03

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

ED0053030870

2

10 _03

2.2

TECHNICAL INFORMATION

EN

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

2

11

_03

2.3

2.4

2.5

TECHNICAL INFORMATION

EN

KDI Mechanical Injection Tier 3 – Stage IIIA certiﬁed Engines (w and w/o EGR)

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 15 mg/kg (ppm).

Engines operated with fuels as per EN 590 and ASTM D975 with sulfur content < 15mg/kg have an oil changing interval of

500hrs. Fuels with a sulfur content > 500 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. With

high fuel sulfur content fuel this may happen at 125hrs. Do not use low SAPS oils.

NOTE: In a warranty case the customer must prove by a certiﬁcate from the fuel supplier that an allowed fuel was

used.

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.

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:

ED0053030870

2

12 _03

TECHNICAL INFORMATION

EN

2.6 Coolant

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

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.

ED0053030870

2

13

_03

C

E

B

A

D

F

2.8

2.6

2.7

TECHNICAL INFORMATION

EN

Battery not supplied by Lombardini Marine

2.7 Battery recommendation

RECOMMENDED BATTERIES

AMBIENT TEMPERATURE BATTERY TYPE

> - 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

POS. DESCRIPTION

A Panel ignition switch with key switch

BEngine on/off push button

CEngine rpm indicator

D Engine data or errors 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 press

push buttons E and F for 3 seconds

Hours left for maintenance (h)

Backlighting adjustment

- Press push button E for 3 seconds

- Press push button E to decrease brightness or

F to increase it

ED0053030870

3

14 _03

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.

• 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.

ED0053030870

3

15

_03

A

3.1

α ≤ 15° α ≤ 15°

SAFETY INFORMATION

EN

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.

ED0053030870

3

16 _03

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 Operationand 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.

ED0053030870

3

17

_03

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.

ED0053030870

3

18 _03

SAFETY INFORMATION

EN

3.6 Location of safety labels on engine

ED0053030870

4

19

_03

4.1

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 Starting

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 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 Ta b. 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.

ED0053030870

4

20 _03

MIN

MAX

B

4.1

4.2

C

A

INFORMATION ABOUT USE

EN

4.4 Refuelling

Important

• 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 Lombardini Marine 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 overll 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.

ED0053030870

LOMBARDINI MARINE KDI 1903M-MP User manual

Popular Engine manuals by other brands