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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 ED0053030870 51404 02/2016...
INDEX GENERAL INFORMATION Manual's purpose Glossary and Definitions Emission-Related Installation Instructions Service request Engine component identification Manufacturer and motor identification data TECHNICAL INFORMATION General description of the engine Engine specifications Engine dimensions (mm) Engine oil 2.4.1 2.4.1.1 SAE oil classification 2.4.2 Olio inReversing gear oilvertitore di marcia Fuel...
INDEX INFORMATION ABOUT REPLACEMENTS Engine oil replacement Oil filter cartridge replacement Fuel filter cartridge replacement Water pump impeller replacement Coolant replacement Alternator belt replacement Coolant pump belt replacement Air cleaner replacement Disposal and scrapping INFORMATION ABOUT FAILURES Useful information about failures Error signals on the control panel INFORMATION ABOUT WARRANTY Warranty terms...
GENERAL INFORMATION 1.1 Manual's purpose • Lombardini Marine reserves the right to make, at any time, • This manual contains the instructions needed to carry out changes in the engines for technical or commercial reasons. proper use and maintenance of the engine, therefore it must •...
GENERAL INFORMATION 1.5 Engine component identification SIDE VIEW A Oil filler cap Coolant refill cap Coolant tempera- ture sensor Cooled exhaust manifold Raiser Thermostat Oil pressure switch and sensor Oil filler cap Coolant pump Water pump Alternator Starter motor Nameplate SIDE VIEW B Coolant filler Cooled exhaust manifold...
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"...
TECHNICAL INFORMATION 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 UNIT TECHNICAL DATA MEASURE KDI 1903 M-MP KDI 2504 M-MP Engine type cylinders bore...
TECHNICAL INFORMATION 2.4 Oil Important Danger • Prolonged skin contact with the exhausted engine oil can • The engine may be damaged if operated with improper oil cause cancer of the skin. level. • If contact with oil cannot be avoided, thoroughly wash your •...
TECHNICAL INFORMATION 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.
TECHNICAL INFORMATION 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”...
• 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.
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Important • 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).
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.
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...
INFORMATION ABOUT USE 4.1 Pre-start check • Read carefully the following pages and carry out the Important operations described below in accordance with the instructions specified. • 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.
INFORMATION ABOUT USE 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.
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.
INFORMATION ABOUT USE 4.7 Coolant filling Important • Before proceeding with operation, read Warning Par. 3.2.2. • Place engine on horizontal surface to ensure accurate • An anti-freeze protection liquid (ANTIFREEZE) - mixed with measurement of filling. decalcified water - must be used. •...
INFORMATION ABOUT MAINTENANCE 5.1 Useful information about maintenance • This chapter shows all operations described in the Tab. 5.1 and Tab. 5.2 that may be directly carried out by the user. Warning • Periodic inspection and maintenance operations must • Inspections must be made when the engine is off and cold. •...
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.
INFORMATION ABOUT MAINTENANCE Danger For safety precautions see Cap. 3. 5.4 Rubber hoses check The check is carried out by exerting a slight deflection or bending along the pipe and near the hose clamps. Components must be replaced if they have clear signs of cracks, tears, cuts, leaks and do not retain a certain degree of elasticity.
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.
INFORMATION ABOUT MAINTENANCE NOTE: if the inside of the pipes on surfaces F1 and F2 (Fig. 5.7) are clogged with deposits even after having been cleaned as per step 6, the pipes must be cleaned using specific mechanical tools. Important •...
INFORMATION ABOUT MAINTENANCE 5.9 Engine storage (over 6 months) 5.10 Engine starting after storage Follow the steps described in Par. 5.8. 1. Remove the protective sheet. 1. Engine oil replacement 6.1). (Par. 2. Use a cloth soaked in degreasing product to remove the 2.
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. NOTE: Perform this operation with warm engine, to get a better fluidity of the oil and get...
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. For disposal of oil filter cartridge and fuel filter refer Par. 6.9 DISPOSAL and SCRAPPING. 6.2 Oil filter cartridge replacement 1.
INFORMATION ABOUT REPLACEMENTS 6.4 Water pump impeller replacement Important • Replace gasket G. 1. Loosen capscrews A and remove cover B. 2. Remove impeller C from pump body D. 3. Grease the new impeller C. 4. Insert the new impeller C onto shaft E. 5.
INFORMATION ABOUT REPLACEMENTS 6.6 Alternator belt replacement 1. Loosen capscrews A and remove guard B. 6.12 2. Loosen hollow stud C and capscrew D. 3. Remove the belt F. 4. Perform the operations from point 2 to 6 of Par. 6.7.
INFORMATION ABOUT REPLACEMENTS 6.7 Coolant pump belt replacement 1. Perform the operations from point 1 to 3 of Par. 6.6. 2. Remove belt A. 3. Insert the new belt A onto pulley G1 and start fitting pulley G2 in point B, making sure to channel the internal ribs of the belt into the ducts of pulley G2, as shown in detail B1.
INFORMATION ABOUT FAILURES 7.1 Useful information about failures • This chapter contains information about the problems that may appear during engine operation with its causes and trouble shooting Tab. 7.2. • In some cases, you shall turn off the engine immediately to avoid further damage Tab. 7.1. THE ENGINE MUST BE IMMEDIATELY TURNED OFF WHEN: The engine rpms suddenly increase and decrease A sudden and/or unusual noise is heard...
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INFORMATION ABOUT FAILURES RPM instability at idle Contact Lombardini Marine authorised Clogged fuel pipes speed workshops Contact Lombardini Marine authorised Clogged fuel pipes workshops idle speed Poor quality fuel Clean the tank and refuel with quality fuel Replace the engine oil; if the problem persists, High oil sump level contact Lombardini Marine authorised workshops...
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. POS. DESCRIPTION Engine oil pressure low High coolant temperature Disabled alternator (with engine rpm < 850 rpm) Maintenance service (*1) Insufficient battery voltage (flashing display with battery <...
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.
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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.
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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.
(very dusty - dirty area, or in a contaminated environment due to various types of gas). KDI: Kohler Direct Injection A group of maintenance actions that have the sole objective to control and replace elements on their expiry, without modifying...
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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...
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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.
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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. Kohler/Lombardini reserves the right to make T. +39 0522 389311 modifications without prior notice. F. +39 0522 389298 e-mail: sales@lombardinimarine.com...
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