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Related Manuals for Kohler LOMBARDINI MARINE KDI 1903TCR-MP
Summary of Contents for Kohler LOMBARDINI MARINE KDI 1903TCR-MP
- Page 1 KDI 1903TCR-MP KDI 2504TCR-MP OWNER MANUAL...
- Page 2 REGISTRATION OF MODIFICATIONS TO THE DOCUMENT Any modifications to this document must be registered by the drafting body, by completing the following table. Model Review Released by Document code Edition Revision Issue date Edited by Endorsed N° date Technical Technical ED0053032450 51567 03/2018...
- Page 3 INDEX 1 - GENERAL INFORMATION 4 - INFORMATION ABOUT USE 1.1 Manual's purpose ............6 4.1 Pre-start check .............19 1.2 Glossary and Definitions ..........6 4.2 Break-in running ............19 1.3 Emission ................6 4.3 Starting and turning off ..........19 1.4 Service request ...............6 4.3.1 Starting ...............19 1.5 Engine component identification ........7 4.3.2 After starting ..............19...
- Page 4 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...
- Page 5 NOTES ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ED0053032450...
- Page 6 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. ser vice centers can be found on websites: www.kohlerengines.com & www.lombardinigroup.it/dealer-locator.
- Page 7 GENERAL INFORMATION 1.5 Engine component identification SIDE VIEW A Thermostat Oil filler cap Coolant refill cap Riser Air filter Turbocharger Coolant pump Water pump Oil pressure switch and sensor Starter motor Alternator SIDE VIEW B Intercooler Coolant temperature sensor Radiator Fuel injection pump Reversing gear Oil filter...
- Page 8 GENERAL INFORMATION 1.6 Manufacturer and motor identification data The engine identification nameplate is located on side A or B as below. SIDE VIEW A SIDE VIEW B Manufacturer identification Engine serial number Engine type CE certificate (*1) Peak Engine version Approval data and "EC"...
- Page 9 2.1 General description of the engine - 4-stroke, in-line cylinders Diesel engine; - Liquid-cooling system; - 4 valves per cylinder with hydraulic tappets; - Turbocharger with Waste-gate valve; - Direct injection. 2.2 Engine specifications UNIT TECHNICAL DATA MEASURE KDI 1903 TCR-MP KDI 2504 TCR-MP ENGINE TYPE CYLINDERS...
- Page 10 2.4 Oil Danger Important • The engine may be damaged if operated with improper oil • Prolonged skin contact with the exhausted engine oil can cause cancer of the skin. level. • If contact with oil cannot be avoided, thoroughly wash your •...
- Page 11 2.5 Fuel Warning Important • Clean fuel prevents the fuel injectors from clogging. • Use of other types of fuel could damage the engine. Do not Immediately clean up any spillage during refuelling. use dirty diesel fuel or mixtures of diesel fuel and water since •...
- Page 12 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 2.7 Batteries reccomendation Batteries not supplied by Kohler Engines. RECOMMENDED BATTERIES BATTERY TYPE AMBIENT TEMPERATURE >...
- Page 13 2.8 Control panel Tab. 2.7 shows the control panel components. POS. DESCRIPTION Panel ignition switch with key switch Engine on push button Engine rpm indicator Engine data or errors display Engine data or errors push button Maintenance errors reset push button Engine off push button Tab.
- Page 14 • In case the approval to a modification is not granted, KOHLER necessary action is taken to meet the essential and legally shall not be deemed responsible for any consequential prescribed health and safety requirements.
- Page 15 Important being energized. • Check belt tension only when the engine is off. • Only use the eyebolts A installed by KOHLER to move the • Fully tighten the tank cap each time after refuelling. Do not engine (Fig. 3.1).
- Page 16 SAFETY INFORMATION 3.3 Safety signal description • To ensure safe operation please read the following • This manual contains safety precautions which are statements and understand their meaning. explained below. • Also refer to your equipment manufacturer's manual for • Please read them carefully. other important safety information.
- Page 17 State of California to cause cancer, birth defects, and other reproductive harm. 3.5 Safety and environmental impact In order to minimise the impact on the environment, KOHLER Every organisation has a duty to implement procedures to now provides a number of indications to be followed by...
- Page 18 SAFETY INFORMATION 3.6 Location of safety labels on engine ED0053032450...
- Page 19 INFORMATION ABOUT USE 4.1 Pre-start check • Read carefully the following pages and carry out the operations described below in accordance with the instructions specified. 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.
- Page 20 • 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.
- Page 21 INFORMATION ABOUT USE 4.6 Reversing gear oil top-up • Before proceeding with operation, read Par. 3.2.2. Important • Place engine on horizontal surface to ensure accurate • For safety precautions see Par. 2.4. measurement of filling. 1. Loosen the oil filler cap A. 2.
- Page 22 INFORMATION ABOUT USE 4.7 Coolant filling Important Warning • Before proceeding with operation, read Par. 3.2.2. • An anti-freeze protection liquid (ANTIFREEZE) - mixed with • Place engine on horizontal surface to ensure accurate decalcified water - must be used. measurement of filling.
- Page 23 9. Test the coolant condition annually with coolant test more frequently under very dusty conditions. 2. In case of low use: 36 months. strips. 3. Not supplied by Kohler Engines. 11. In case of low use: 24 months. 6. Contact Kohler Engines workshop. ED0053032450...
- Page 24 INFORMATION ABOUT MAINTENANCE 5.3 Oil level check Important • Place engine on horizontal surface to ensure accurate measurement of checking. 1. Loosen the oil filler cap A. Remove the oil dipstick B and check that the level is up to MAX. 2.
- Page 25 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.
- Page 26 INFORMATION ABOUT MAINTENANCE 5.5 Check coolant level NOTE: Before proceeding with any operation on the engine, stop it and allow it to cool. Important • Place engine on horizontal surface to ensure accurate measurement of checking. Warning • Presence of steam pressurized coolant danger of burns. 1.
- Page 27 INFORMATION ABOUT MAINTENANCE 4. Loosen the clamps E of manifolds F and G. 5. Remove the 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. 5.11 8.
- Page 28 INFORMATION ABOUT MAINTENANCE 10. Check the radiator P for any kind of encrustations and dirt. 11. Check all the holes on the surfaces P1, P2 for any kind of encrustations and dirt. NOTE: if the inner side of the hoses on the surfaces P1 and P2 are encrusted even after carrying out the cleaning in point 9, clean the hoses with specific mechanical...
- Page 29 INFORMATION ABOUT MAINTENANCE 17. Connect a suitable pump on the unions R to clean the ducts with a solution of distilled water and hydrochloric acid 10%, at a temperature of 50° C. 18. At the end of the cleaning operations in point 3, rinse with water only the inner side of the ducts using the pump as described in point 17.
- Page 30 INFORMATION ABOUT MAINTENANCE 23. Position the gasket Q4 on the intercooler U. 24. Insert the Intercooler U into the support V until it stops. 25. Insert the gasket Q5 on the intercooler U. 5.17 26. Fix the cap T1 on the support V with the screws M (tightening torque of 25 Nm).
- Page 31 4. Tighten in sequence the screw B (tightening torque of 25 Nm) and C (tightening torque of 40 Nm). 5. Perform the operations described in point 2 of Par. 5.7.1. NOTE: Contact KOHLER authorised workshops 5.23 for replacement. 5.8 Control water filter cartridge fuel...
- Page 32 INFORMATION ABOUT MAINTENANCE 11. When cleaning the engine, if using a pressure 5.9 Product preservation washer or steam cleaning device, avoid directing nozzle electrical components, cable connections sealed rings (oil seals etc). Important If cleaning engine with a pressure washer or steam •...
- Page 33 INFORMATION ABOUT MAINTENANCE 5.13 Unused machine If the machine is not used for a certain amount of time, follow the operations below: 5.13.1 Operations for the engine 5.12 POINT OPERATION - The place must be dry and fresh throughout the period in which the machine is not used. unused ma- - Consult the machine’s manual to disconnect the battery (before disconnecting the battery, chine up to 2...
- Page 34 INFORMATION ABOUT REPLACEMENTS Danger Disconnect the negative wire (-) from the battery to avoid accidental engine starting. Important Before proceeding with operation, read Par. 3.2.2 6.1 Engine oil replacement Important • Place engine on horizontal surface to ensure accurate measurement of oil level. •...
- Page 35 INFORMATION ABOUT REPLACEMENTS Warning • Oil filter cartridge replacement (Par. 6.2) fuel filter replacement (Par. 6.3) In case of low use replace it 12 months. 1. For disposal of oil filter cartridge and fuel filter refer 2. to Par. 6.8 DISPOSAL and SCRAPPING.
- Page 36 INFORMATION ABOUT REPLACEMENTS 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.
- Page 37 INFORMATION ABOUT REPLACEMENTS 6.5 Alternator belt replacement Important • Before proceeding with operation, carefully read Par. 3.3.2. 1. Loosen the screws A and B. 2. Push the alternator C in the direction of the arrow D and remove the belt E. 3.
- Page 38 INFORMATION ABOUT REPLACEMENTS 6.6 Coolant replacement 1. Undo cap A to drain all liquid from the system contained in the engine crankcase ducts into an appropriate container (Par. 3.5). Important • Perform the operations described in Par. 5.6 before proceeding. •...
- Page 39 Colour the exhaust fumes suddenly darkens 7.14 TROUBLES POSSIBLE CAUSE SOLUTION PAR. Engine ECU has detect a malfunctions Contact KOHLER authorised workshops Error code Sulphated battery terminals corroded Clean the battery terminals Battery voltage too low Recharge the battery or replace it Low fuel level...
- Page 40 INFORMATION ABOUT FAILURES 7.2 Error signals on the control panel Tab. 7.3 shows the errors that can be generated on the control panel. 7.15 POS. DESCRIPTION Engine oil pressure low High coolant temperature Disabled alternator (with engine rpm < 850 rpm) Maintenance service (*1) Insufficient battery voltage (flashing display...
- Page 41 8.1 Application and Validation process for marine engine Kohler Engines educates his sales and service network in order to carry out the installation and commissioning of the engine with functional checks in respect of the standards established over the years and the requirements set out in the technical documents (owner manuals).
- Page 42 APPLICATION AND VALIDATION PROCESS 8.2 Prescriptions to be respected During the installation operations, the following instructions must be observed: Compliance with the maximum inclinations permitted (owner manual) Engine below sea level with airvent valve installation scheme If sea water outlet is at height of less than 200 mm from the water line, fit an airvent system.
- Page 43 APPLICATION AND VALIDATION PROCESS Fuel circuit connection 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 APPLICATION AND VALIDATION PROCESS Connection and alignment to the axis line scheme Accurate alignment is done by adjusting the elastic 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.
- Page 45 Kohler Co.’s obligation under this warranty is expressly limited, at its option, to an appropriate adjustment, repair or replacement of such part or parts as found to be defective following an inspection by Kohler Co. or an authorized service facility designated by Kohler Co.
- Page 46 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.
- Page 47 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.
- Page 48 GLOSSARY A component that transforms mechanical energy into AC Alternator: electrical energy. Authorised workshop: Kohler authorised service centre. Bore: Internal diameter of the cylinder in combustion engines. Catalyst: A device in charge of filtering exhausted gas. Chemical reaction of a mixture composed of fuel and fuel Combustion: (air) inside a combustion chamber.
- Page 49 GLOSSARY Serial number (engine identification name plate) indicating s/n: the engine identification series/chassis number. Sec.: seconds Specification, (engine identification name plate) indicating Spec.: the engine version. Tab.: Table. A term indicated for installation of threaded components Tightening torque: and which is determined by means of a unit of measurement T-MAP (sensor), measures the temperature and absolute T-MAP: pressure inside the intake collector.
- Page 50 GLOSSARY SYMBOLS AND UNITS OF MEASUREMENT SYMBOL UNIT OF MEASUREMENT DESCRIPTION EXAMPLE degree Rotation/inclination angle 1° square centimetre Area 1 cm Ø millimetre Diameter Ø 1 mm newton-metre Torque 1 Nm millimetre 1 mm Length 1/1000 of a millimetre μm 1 μm (micron) hour...
- Page 51 NOTES ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ED0053032450...
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- Page 55 NOTES ......................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................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.
- Page 56 SALES OFFICE Kohler Engines is a division of Lombardini s.r.l., part of Kohler Group. Kohler Engines Lombardini has manufacturing facilities in Italy, Via Cav. del lavoro A. Lombardini n° 2 Slovakia and India and sales subsidiaries in 42124 Reggio Emilia, Italia France, Germany, UK, Spain and Singapore.