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Related Manuals for Kohler KDI 3404TCR-SCR
Summary of Contents for Kohler KDI 3404TCR-SCR
- Page 1 KDI 3404TCR-SCR OWNER MANUAL...
- Page 2 06/2017 11/2018 Documentation Documentation Translated from the original manual in Italian language. Data reported in this issue can be modified at any time by KOHLER. Important Connect to http://iservice.lombardini.it and download the latest version of this manual onto your device.
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Page 3: Table Of Contents
INDEX 1 - GENERAL INFORMATION 4 - INFORMATION ABOUT USE 1.1 Manual's Purpose ............4 4.1 Pre-start check .............26 1.2 Glossary and Definitions ..........4 4.2 Running-in period ............26 1.3 Emission-Related Installation Instructions ....4 4.3 Starting and turning off ..........26 1.4 Service request ...............4 4.3.1 Starting ...............26 1.5 Manufacturer and engine identification .......5 4.3.2 After starting .............26... -
Page 4: General Information
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 • The complete and updated list of authorized Kohler Co. service centers can be found on websites: www.kohlerengines.com &... -
Page 5: Manufacturer And Engine Identification
GENERAL INFORMATION 1.5 Manufacturer and motor identification data Engine type Engine serial number Manufacturer identification Peak Engine version Approval data and "EC" directives ED0053032140 Index... -
Page 6: Engine Component Identification
GENERAL INFORMATION 1.6 Engine component identification SIDE VIEW A SIDE VIEW B ED0053032140 Index... - Page 7 Some components are for illustrative purposes only and POS. DESCRIPTION may vary. EGR Cooler NOTE: Components in Pos. 8, 10 are not supplied by Kohler High-pressure fuel injection pump Oil cooler Fuel filter Oil filler side cap Oil dipstick AC compressor Lub.
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Page 8: Cooling Circuit
Coolant to radiator return sleeve Coolant pump SCR system control unit SIDE VIEW B Some components are for illustrative purposes only and may vary. NOTE: Components in Pos. 1, 2, 3, 4, 7, 8, 10, 11 are not supplied by Kohler ED0053032140 Index... -
Page 9: Adblue Circuit
AdBlue delivery tube to AdBlue injector Return tube in AdBlue tank AdBlue injector SIDE VIEW B Some components are for illustrative purposes only and may vary. NOTE: Components in Pos. 4, 5, 6 are not supplied by Kohler ED0053032140 Index... -
Page 10: Intake And Exhaust Circuit
Air inlet valve Exhaust gas delivery hose to SCR AdBlue injector Some components are for illustrative purposes only and may vary. NOTE: Components in Pos. 1, 2, 4, 5, 6 are not supplied by Kohler SIDE VIEW B ED0053032140 Index... -
Page 11: Homologation Labels
GENERAL INFORMATION 1.10 Homologation labels 1.10.1 Label for EPA rules POS. DESCRIPTION Model year in compliance with the rules Power category (kW) Engine displacement (L) Particulate emission limit (g/kWh) Engine family ID Emission Control System = ECS Fuel with low sulphur content Injection timing (*BTDC) Injector opening pressure (bar) Production date (example: 2013.JAN) -
Page 12: Label For China Standards
GENERAL INFORMATION 1.10.2 Label for China Standards POS. DESCRIPTION Manufacturer Engine model Manufactoring date Certificate N° Power range (kW) Emission level Rated power Aftertreat system ED0053032140 Index... -
Page 13: Label For Korea Standards
GENERAL INFORMATION 1.10.3 Label for Korea Standards POS. DESCRIPTION Tier 4 Final Engine model Manufactoring date and manufacturer code N° Korea emission certificate ED0053032140 Index... -
Page 14: Technical Information
TECHNICAL INFORMATION 2.1 General description of the engine - Turbocharger with Waste-gate valve; - 4-stroke, in-line cylinders Diesel engine; - Common Rail - Direct injection. - Liquid-cooling system; - 4 valves per cylinder with hydraulic tappets; 2.2 Engine specifications TECHNICAL DATA UNIT OF MEASURE ENGINE TYPE KDI 340 TCR-SCR... -
Page 15: Oil
TECHNICAL INFORMATION 2.4 Oil Important Danger • The engine may be damaged if operated with improper oil • Prolonged skin contact with the exhausted engine oil can level. cause cancer of the skin. • Do not exceed the MAX level because a sudden increase •... -
Page 16: Fuel
TECHNICAL INFORMATION 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 17: Fuel For Low Temperatures
TECHNICAL INFORMATION 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. •... -
Page 18: Adblue
4. During the refilling operations prevent any impurity from entering the tank. 5. At tank inlet there is a filter that must be periodically cleaned or replaced (see maintenance and replacement table - for tank supplied by Kohler only). 6. AdBlue quality must comply with the specifications described in Table 2.5. -
Page 19: Coolant Recommendation
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. 2.8 Battery recommendation Battery not supplied by Kohler RECOMMENDED BATTERIES AMBIENT TEMPERATURE BATTERY TYPE 120 Ah/20 h - 1000 CCA/SAE ≥... -
Page 20: Inducement Strategy Of Scr System
TECHNICAL INFORMATION 2.9 Inducement strategy of SCR system The inducement is the operation aimed at reducing the engine performance due to a malfunction or tampering with the SCR system detected by the DCU. The inducement degree is decided by the ECU according to the error detected by the DCU. The inducement can have the following 2 levels: - Level 1: 25% reduction of the MAX available torque. -
Page 21: Safety Information
• 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 22 (-) of the battery to prevent Important accidental short-circuits and to stop the starter motor from • Only use the eyebolts A installed by KOHLER to move the being energized. engine (Fig. 3.1). • Check belt tension only when the engine is off.
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Page 23: Safety Signal Description
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 24: Information And Safety Signals
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 25: Location Of Safety Labels On Engine
SAFETY INFORMATION 3.6 Location of safety labels on engine ED0053032140 Index... -
Page 26: Information About Use
INFORMATION ABOUT USE 4.1 Pre-start check Important • Read carefully the following pages and carry out the 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. -
Page 27: Refuelling
• 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 more frequently. • To avoid explosions or fire outbreaks, do not smoke or use open flames during the operations. -
Page 28: Coolant Filling
INFORMATION ABOUT USE 4.6 Coolant filling Warning Important • An anti-freeze protection liquid (ANTIFREEZE) - mixed with • Before proceeding with operation, read Par. 3.2.2. decalcified water - must be used. • The freezing point of the refrigerant mixture depends on NOTE: Refer to the technical documentation the amount concentration in water. -
Page 29: Information About Maintenance
OPERATION DESCRIPTION PAR. 5000 Engine oil level Coolant level Components not necessarily supplied by (8) (9) KOHLER. Cartridge dry-type air filter Refer to the technical documentation of the Radiator heat-exchange surface and Intercooler (2) (8) vehicle Alternator belt Rubber hose (intake air / coolant) -
Page 30: Oil Level Check
The air filter must be cleaned and replaced more frequently under very dusty conditions. 9. Test the coolant condition annually with coolant test 6. Contact authorized KOHLER workshops. strips. 10. It is recommended to have SCA (Supplemental Coolant Additives) added at the first maintenance interval. -
Page 31: Air Filter Check
INFORMATION ABOUT MAINTENANCE 5.5 Air filter check NOTE: Components not necessarily supplied by KOHLER. 1. Pull insert F to unlock cover A. 2. Rotate counter clockwise and remove cover A. 3. Clean the inside components A and D with a damp cloth. -
Page 32: Check Of The Radiator Heat-Exchanger Surface
Important • Before proceeding with operation, read Par. 3.2.2. • If hoses are damaged contact an authorized KOHLER workshop. • For other pipes not illustrated refer to the technical documentation of the vehicle. 1. Check that the: - Fuel system hoses A are intact. -
Page 33: Check Poly-V Alternator Belt
Check by the appropriate tool that at point p the tension value is between 135 and 178 Hz. NOTE: If the poly-v belt tension results out of the above mentioned values contact KOHLER authorised workshops for replacement. NOTE: Belts A2, A3 are not supplied by KOHLER. -
Page 34: Product Preservation
The following additives are recommended: AdBlue tank/circuit with hot distilled water. DEFA Fluid Plus (Pakelo Lubricants), Diesel Treatment (Green Star), 7. Check the AdBlue injector at an authorized KOHLER Top Diesel (Bardhal), workshop. STP® Diesel Fuel Injector Treatment. 8. Start the engine and keep it idle at minimum speed for a 3. -
Page 35: Unused Machine
• Consult the machine’s manual to connect the battery. • Start the engine. If faults are detected when starting the engine or during operation, turn off the engine and wait 5 mins before starting the engine. • If the fault persists, contact KOHLER authorised workshops. ED0053032140 Index... -
Page 36: Information About Replacements
INFORMATION ABOUT REPLACEMENTS Danger Disconnect the negative wire (-) from the battery to avoid accidental engine starting. • Important Before proceeding with operation, read Par. 3.3.2. • 6.1 Engine oil replacement Important • Place engine on level surface to ensure accurate measurement of oil level. -
Page 37: Oil Filter Cartridge Replacement
INFORMATION ABOUT REPLACEMENTS Warning Oil filter cartridge replacement (Par. 6.2) and 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 to • Par. 6.6 DISPOSAL and SCRAPPING. 6.2 Oil filter cartridge replacement Important •... -
Page 38: Fuel Filter And Pre-Filter Cartridge Replacement
8. Push repeatedly the button G in order to fill the circuit. 6.4 Air filter cartridge replacement NOTE: Component not necessarily supplied by KOHLER. 1. Pull insert F to unlock cover A. 2. Rotate counter clockwise and remove cover A. 3. Remove the cartridges B and G. -
Page 39: Replacement Of Adblue® Filter
INFORMATION ABOUT REPLACEMENTS 6.5 Replacement of AdBlue® filter Warning • Do not lubricate gaskets A with oil or fuel. • Filter D includes gaskets A in the package. • Avoid any type of contamination during replacement. • Before starting any operations, make sure the key on the machine’s panel is OFF and the AdBlue®... -
Page 40: Information About Failures
Fill up to the level High oil sump level Replace the engine oil Engine overheats Clogged radiator Clean the radiator - In the event that the solutions proposed in Tab. 7.2 do not eliminate the trouble, contact a KOHLER authorized workshop. ED0053032140 Index... -
Page 41: Information About Warranty
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 42 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 43 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.
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Page 44: Glossary
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 (air) Combustion: inside a combustion chamber. - Page 45 GLOSSARY Ref.: Reference. SCR: Selective Catalytic Reduction Serial number (engine identification name plate) indicating the s/n: engine identification series/chassis number. Specification, (engine identification name plate) indicating the Spec.: engine version. Tab.: Table. TCR: Turbo Common Rail. A term indicated for installation of threaded components and Tightening torque: which is determined by means of a unit of measurement Nm.
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Page 46: Symbols And Units Of Measurement
NOTES ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................ED005332140 Index... - Page 47 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 48 Lombardini s.r.l. is a part of Kohler Group. E U R O PE U S A & C ANADA FR AN C E Lombardini has manufacturing facilities Lombardini Srl Kohler Co. Lombardini France S.a.s. in Italy, Slovakia and India and sales Via Cav.