Related Manuals for Kohler KDI 3404TCR-SCR
Summary of Contents for Kohler KDI 3404TCR-SCR
- Page 1 KDI 3404TCR-SCR OWNER MANUAL ED0053032140_Rev_03.3 Confidential Communication: Information is for use only by approved users.
- Page 2 INDEX...
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Page 3: Table Of Contents
INDEX General Information ......................5 Manual's Purpose ..........................5 Glossary and Definitions ......................... 5 Emission-Related Installation Instructions ................... 6 Service request ..........................6 Manufacturer and engine identification ..................7 Engine component identification ....................8 Cooling circuit ..........................10 AdBlue circuit ..........................12 Intake and exhaust circuit ...................... - Page 4 INDEX Periodic maintenance ........................38 Oil level check ..........................39 Air filter check ..........................40 Check of the radiator heat - exchanger surface ................ 41 Rubber hoses check ........................41 Check coolant level ........................41 Check Poly-V alternator belt ......................42 Filter cartridge and fuel pre-filter check ..................
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Page 5: General Information
However, development on the engines is continuous. Therefore, the information within this manual is subject to change without notice and without obligation. • KOHLER reserves the right to make, at any time, changes in the engines for technical or commercial reasons. •... -
Page 6: Emission-Related Installation Instructions
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 7: Manufacturer And Engine Identification
GENERAL INFORMATION 1.5 Manufacturer and engine identification... -
Page 8: Engine Component Identification
GENERAL INFORMATION 1.6 Engine component identification... - Page 9 GENERAL INFORMATION Some components are for illustrative purposes only and may vary. NOTE: Components in Pos. 8, 10 are not supplied by Kohler. POS. DESCRIPTION EGR Cooler High-pressure fuel injection pump Oil cooler Fuel filter Oil filler side cap Oil dipstick AC compressor Lub.
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Page 10: Cooling Circuit
GENERAL INFORMATION 1.7 Cooling circuit... - Page 11 GENERAL INFORMATION 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. POS. DESCRIPTION Radiator Intake sleeve Intake return tube Intake return tube...
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Page 12: Adblue Circuit
GENERAL INFORMATION 1.8 AdBlue circuit... - Page 13 GENERAL INFORMATION Some components are for illustrative purposes only and may vary. NOTE: Components in Pos. 4, 5, 6 are not supplied by Kohler. POS. DESCRIPTION SCR system control unit AdBlue tank AdBlue pump AdBlue intake tube AdBlue delivery tube to AdBlue injector...
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Page 14: Intake And Exhaust Circuit
GENERAL INFORMATION 1.9 Intake and exhaust circuit... - Page 15 GENERAL INFORMATION Some components are for illustrative purposes only and may vary. NOTE: Components in Pos. 1, 2, 4, 5, 6 are not supplied by Kohler. POS. DESCRIPTION Air filter Air intake sleeve Turbocharger Air delivery tube to Intercooler Intercooler...
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Page 16: Homologation Labels
GENERAL INFORMATION 1.10 Homologation labels 1.10.1 Label for EPA rules (compilation example) 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 Electronic injector opening pressure (bar) Production date (example: 2013.JAN) - Page 17 GENERAL INFORMATION 1.10.2 Label for China Standards (compilation example) POS. DESCRIPTION Manufacturer Engine model Manufactoring date Certificate N° Power range (kW) Emission level Rated power Aftertreat system...
- Page 18 GENERAL INFORMATION 1.10.3 Label for Korea Standards (compilation example) POS. DESCRIPTION Tier 4 Final Engine model Manufactoring date and manufacturer code N° Korea emission certificate...
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Page 19: Technical Information
TECHNICAL INFORMATION 2 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; - Turbocharger with Waste-gate valve; - Common rail - Direct injection. 2.2 Engine specifications UNIT OF TECHNICAL DATA MEASURE... -
Page 20: Oil
TECHNICAL INFORMATION 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. -
Page 21: Fuel
TECHNICAL INFORMATION (*1) NOTA : Do NOT use fuel with sulphur content above 15ppm. (*2) - On all engines compliant with Stage-V emission regulation (engines with DPF device), the oil to use must comply with the specification API CJ-4 Low S.A.P.S or ACEA E6 Low S.A.P.S. (*3) - NOTE : Do NOT use fuel with sulphur content above 500ppm. - Page 22 TECHNICAL INFORMATION is guaranteed by the appropriate additives in low-sulfur (‹50 mg/kg) or sulfur-free (‹10 mg/kg or ‹15 mg/kg) diesel fuels according to EN 590 and ASTM D 975. In low-sulpur and sulfur-free diesel fuels which do not comply with this standard, the lubricating capacity may have to be guaranteed by additives. The parameter for sufficient lubricating capacity is a maximum wear spot of 460 micrometers in the HFRR test (EN ISO 12156-1).
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Page 23: 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 ®... -
Page 24: Coolant Recommendation
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 ≥... -
Page 25: 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: •... -
Page 26: Safety Information
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. •... - Page 27 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.
- Page 28 SAFETY INFORMATION Important • Only use the eyebolts A installed 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.
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Page 29: Safety Signal Description
SAFETY INFORMATION 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. •... -
Page 30: Information And Safety Signals
SAFETY INFORMATION Warning This indicates that failure to comply with it can cause minor damage or injury. 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. - Page 31 SAFETY INFORMATION Never operate the engine with heat shields or guards removed. Never use fuel as a cleaning agent. ROTATING PARTS EXPLOSIVE GAS Rotating Parts can Explosive Gas can cause fires and severe acid cause severe injury. burns. Stay away while engine is in Charge battery only in a well ventilated area.
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Page 32: Safety And Environmental Impact
- 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. -
Page 33: Information About Use
INFORMATION ABOUT USE 4 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 34: Starting And Turning Off
INFORMATION ABOUT USE 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 Par. 4.6 2. Put the ignition key in the ignition switch (if supplied). 3. -
Page 35: Refuelling
Tab. 2.3 • In those countries where fuel 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 36: Oil Filling
INFORMATION ABOUT USE 4.5 Oil filling Important • For safety precautions see Par. 2.4 • Before proceeding with operation, read Par. 3.2.2 1. Loosen the oil filler cap A. 2. Add the type oil recommended ( Tab. 2.2 3. Before checking oil engine needs to be level. 4. -
Page 37: Information About Maintenance
INFORMATION ABOUT MAINTENANCE 5 INFORMATION ABOUT MAINTENANCE 5.1 Useful information about maintenance Important • This chapter shows all operations • Before proceeding with operation, described in the Tab. 5.1 and Tab. 5.2 if read Par. 3.2.2 you have the skills appropriate may be directly carried out by the user. -
Page 38: Periodic Maintenance
5000 (4) (8) Engine oil level (8)(9) Coolant level Cartridge dry-type air filter Components not supplied by KOHLER . Refer to the technical documentation of the vehicle Radiator heat-exchange surface and Intercooler Alternator belt Rubber hose (intake air / coolant) -
Page 39: Oil Level Check
The air filter must be cleaned and replaced more frequently under very dusty conditions. 6 - Contact authorized KOHLER workshops. 7 - The replacement interval is only an indication, it strongly depends from environmental condition and hose status detected during regular visual inspection. -
Page 40: Air Filter Check
INFORMATION ABOUT MAINTENANCE 5.4 Air filter check NOTA: 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 41: Check Of The Radiator Heat - Exchanger Surface
INFORMATION ABOUT MAINTENANCE 5.5 Check of the radiator heat - exchanger surface NOTE : Components not supplied by KOHLER . Refer to the technical documentation of the vehicle.. 5.6 Rubber hoses check Danger • For safety precautions see Cap. 3. -
Page 42: Check Poly-V Alternator Belt
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. Refer to the technical documentation of the vehicle.. 5.9 Filter cartridge and fuel pre-filter check Important •... -
Page 43: Product Preservation
INFORMATION ABOUT MAINTENANCE 5.10 Product preservation Important: • If the engines are not to be used for 6 months, they must be protected by carrying out the operations described in Engine storage (up to 6 months) ( Par. 5.11 • If the engine is still not in use after the first 6 months, it is necessary to carry out a further operation to extend the protection period (more than 6 months) ( Par. -
Page 44: Engine Starting After Storage
6. Proceed with the disposal of the AdBlue contained in the tank; replace the AdBlue pump filter and wash the AdBlue tank/circuit with hot distilled water. 7. Check the AdBlue injector at an authorized Kohler workshop. 8. Start the engine and keep it idle at minimum speed for a two about minutes. -
Page 45: Unused Machine
INFORMATION ABOUT MAINTENANCE 5.14 Unused machine If the machine is not used for a certain amount of time, follow the operations below: Operations for the engine POINT PERIOD OPERATION • The place must be dry and fresh throughout the period in which the machine is not used. - Page 46 Consult the machine’s manual to connect the battery. 9+ months • 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.
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Page 47: Information About Replacements
INFORMATION ABOUT REPLACEMENTS 6 INFORMATION ABOUT REPLACEMENTS 6.1 Engine oil replacement Danger: • Disconnect the negative wire (-) from the battery to avoid accidental engine starting. Important: • Before proceeding with operation, read Cap. 3 Important : • Place engine on level surface to ensure accurate measurement of oil level. -
Page 48: Oil Filter Cartridge Replacement
INFORMATION ABOUT REPLACEMENTS 6.2 Oil filter cartridge replacement Important • Before proceeding with operation, read Par. 3.2.2 Warning: • Oil filter cartridge replacement (Par. 6.2) and fuel filter replacement ( Par. 6.3 • In case of low use replace it 12 months. •... -
Page 49: Filter Cartridge And Fuel Pre-Filter Replacement
INFORMATION ABOUT REPLACEMENTS 6.3 Filter cartridge and fuel pre-filter replacement NOTE: The fuel filter is situated on the crankcase of the engine or it may be assembled on the frame of the vehicle. Important • Before proceeding with operation, read Par. -
Page 50: Air Filter Cartridge Replacement
Important • Before proceeding with operation, read Par. 3.2.2 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. 4. Fit cartridges G and B. -
Page 51: Replacement Of Adblue® Filter
INFORMATION ABOUT REPLACEMENTS 6.5 Replacement of AdBlue® filter Warning • Par. 3.2.2 Before proceeding with operation, read • Do not lubricate gaskets A with oil or fuel. • Filter D includes gaskets A in the package. • Avoid any type of contamination during replacement. •... -
Page 52: Disposal And Scrapping
INFORMATION ABOUT REPLACEMENTS 6.6 Disposal and scrapping • In case of scrapping, the engine shall be disposed of in appropriate locations, in conformity with the law in force. • Before scrapping, it is necessary to separate the rubber or plastic parts from the rest of the components. -
Page 53: Information About Failures
Colour the exhaust fumes suddenly darkens TROUBLES POSSIBLE CAUSE SOLUTION PAR. Warning YELLOW Engine ECU has detect Contact KOHLER authorised workshops light turn on a malfunctions Sulphated battery Clean the battery terminals terminals corroded Battery voltage too low Recharge the battery or replace it... - Page 54 High oil sump level Engine overheats Contact KOHLER authorised workshops Clean the radiator; if the problem persists, Clogged radiator contact KOHLER authorised workshops In the event that the solutions proposed in Tab. 7.2 do not eliminate the trouble, contact a KOHLER authorized workshop...
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Page 55: Information About Warranty
KOHLER DIESEL ENGINES GLOBAL WARRANTY TERMS 1. WARRANTY PERIOD Kohler Co. warrants to the End User that each Diesel engine will be free from manufacturing defects in materials or workmanship in normal service for the applicable coverage period or operating hours (whichever comes first) set forth below, provided the engine is operated and maintained in accordance with Kohler Co.’s instructions and... - Page 56 Use & 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 57 You are responsible for initiating the warranty process. The ARB & US EPA suggests that you present your off-road & Marine engine to a Kohler Co. dealer as soon as a problem exists. The warranty repairs should be completed by the dealer as expeditiously as possible.
- Page 58 INFORMATION ABOUT WARRANTY When a warrantable condition exists, Kohler Co. will repair your heavy-duty off-road & marine engine at no cost to you including diagnosis, parts and labor. The owner shall not be charged for diagnostic labor that leads to the determination that a warranted part is in fact defective, provided that such diagnostic work is performed at a warranty station.
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Page 59: Glossary
9 GLOSSARY 9.1 Glossary Alternator A component that transforms mechanical energy into AC 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) inside a combustion Combustion chamber. - Page 60 Air-cooling element under pressure from the turbo situated between the turbine and Intercooler intake manifold. "Kohler Direct Injection" A group of maintenance actions that have the sole objective to control and replace Maintenance - elements on their expiry, without modifying or improving the functions carried out by periodic the system, neither increasing the value nor improving performance.
- Page 61 GLOSSARY Par. Paragraph. Paraffin Fatty and solid substance that may form inside the diesel. "Poly-V", the name associated with a service belt, which derives from the profile of its Poly-V section that is constructed with joined Vs. Ref. Reference. Selective Catalytic Reduction "Serial number"...
- Page 62 GLOSSARY SYMBOLS AND UNITS OF MEASUREMENT SYMBOL UNIT OF MEASUREMENT DESCRIPTION EXAMPLE α degree Rotation/inclination angle 1° square centimetre Area 1 cm Ø millimetre Circumference Ø 1 mm newton-metre Torque 1 Nm millimetre 1 mm µm 1/1000 of a millimetre (micron) 1 µm Length hour...
- Page 63 GLOSSARY...