Kohler KDI-TCP 3404 E5 Owner's Manual
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Kohler KDI-TCP 3404 E5 Owner's Manual

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KDI-TCP 3404 E5
KDI-TCP 3404 E5 OWNER MANUAL
(REV. 00)
ED0053033030_Rev.00

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Summary of Contents for Kohler KDI-TCP 3404 E5

  • Page 1 KDI-TCP 3404 E5 KDI-TCP 3404 E5 OWNER MANUAL (REV. 00) ED0053033030_Rev.00...

  • Page 2: Table Of Contents

    INDEX General Information ....................... 4 Manual's Purpose ..........................4 Glossary and Definitions ......................... 4 Emission-Related Installation Instructions ................... 4 Service request ..........................5 Manufacturer and engine identification ..................5 Engine component identification ....................6 Cooling circuit ..........................8 AdBlue®/DEF circuit ........................10 Intake and exhaust circuit ......................
  • Page 3 INDEX Information about maintenance ..................39 Useful information about maintenance ..................39 Periodic maintenance ........................40 Oil level check ..........................41 Air filter check ..........................42 Check of the radiator heat - exchanger surface ................ 42 Rubber hoses check ........................43 Check coolant level ........................

  • Page 4: General Information

    KOHLER reserves the right to make, at any time, changes in the engines for technical or commercial reasons. • These changes do not require KOHLER to intervene on the marketed production up to that time and not to consider this manual as inappropriate.

  • Page 5: Service Request

    GENERAL INFORMATION 1.4 Service request • The complete and updated list of authorized Kohler Co. service centers can be found on websites: www.kohlerengines.com dealers.kohlerpower.it & • If you have any questions regarding your warranty rights and responsibilities or the location of the nearest Kohler Co.

  • Page 6: Engine Component Identification

    GENERAL INFORMATION 1.6 Engine component identification...
  • Page 7 GENERAL INFORMATION NOTE: Some components are for illustrative purposes only and may vary or they are not supplied by Kohler. POS. DESCRIPTION Air filter Air inlet valve Oil filler cap High-pressure fuel injection pump Lub. oil filter Oil cooler Fuel filter...

  • Page 8: Cooling Circuit

    GENERAL INFORMATION 1.7 Cooling circuit...
  • Page 9 GENERAL INFORMATION NOTE: Some components are for illustrative purposes only and may vary or they are not supplied by Kohler. POS. DESCRIPTION Radiator Intake sleeve Intake return tube Intake return tube Circuit for AdBlue®/DEF heating AdBlue®/DEF tank Coolant delivery tube in AdBlue®/DEF tank Coolant delivery tube to AdBlue®/DEF injector...

  • Page 10: Adblue®/Def Circuit

    GENERAL INFORMATION 1.8 AdBlue®/DEF circuit NOTE: Some components are for illustrative purposes only and may vary or they are not supplied by Kohler. POS. DESCRIPTION SCR system control unit AdBlue®/DEF tank AdBlue®/DEF pump AdBlue®/DEF intake tube AdBlue®/DEF delivery tube to AdBlue injector Return tube in AdBlue®/DEF tank...

  • Page 11: Intake And Exhaust Circuit

    GENERAL INFORMATION 1.9 Intake and exhaust circuit...
  • Page 12 GENERAL INFORMATION NOTE: Some components are for illustrative purposes only and may vary or they are not supplied by Kohler. POS. DESCRIPTION Air filter Air intake sleeve Turbocharger Air delivery tube to Intercooler Intercooler Air delivery tube to intake manifold...

  • Page 13: 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 14 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 15 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...

  • Page 16: Ats (After Treatment System)

    GENERAL INFORMATION 1.11 ATS (After Treatment System) Tab 1.5 POS. DESCRIZIONE Turbocharger ATS with DOC+DPF+SCR filter Turbine exhaust pipe NOTE: the ATS system with DPF filter is only present for versions compliant with "Stage V" emission regulations. The ATS system can be installed in a different way than shown.

  • Page 17: Technical Information

    - 4 valves per cylinder with hydraulic tappets; - Turbocharger with Waste-gate valve; - Common rail - Direct injection. 2.2 Engine specifications TECHNICAL DATA UNIT OF MEASURE Engine type KDI-TCP 3404 E5 Cylinders Bore Stroke Displacement 3359 α 40° max 30 min.

  • Page 18: Oil

    TECHNICAL INFORMATION 2.3 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 19: Fuel

    TECHNICAL INFORMATION 2.4 Fuel Important Warning • • Clean fuel prevents the fuel injectors from clogging. Use of other types of fuel could Immediately clean up any spillage during refuelling. damage the engine. Do not use dirty diesel • fuel or mixtures of diesel fuel and water Never store diesel fuel in galvanized containers (i.e.
  • Page 20 TECHNICAL INFORMATION 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.

  • Page 21: Adblue®/Def

    During the refilling operations prevent any impurity from entering the tank. • 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). • ®...

  • Page 22: 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. 2.7 Battery recommendation Battery not supplied by Kohler RECOMMENDED BATTERIES AMBIENT STARTER BATTERY TYPE...

  • Page 23: Inducement Strategy Of Ats System

    TECHNICAL INFORMATION 2.8 Inducement strategy of ATS system The inducement is the operation aimed at reducing the engine performance due to a malfunction or tampering with the ATS system detected by the DCU. The inducement degree is decided by the ECU according to the error detected by the DCU. The information on the car panel or the activation of the inducement can occur for the following reasons: •...
  • Page 24 TECHNICAL INFORMATION Tampering with the monitoring systems of the ATS system • information activation on car panel: upon fault detection • Level 1 inducement: after 36h from fault detection • Level 2 inducement: after 100h from fault detection The strategy for the different faults is listed below (Tier 4 Final - USA): The inducement can have the following 3 levels: •...

  • Page 25: Control Panel

    Data selection or entry push button Engine operating status (green = no problem detected) NOTE : if LED F is red, contact authorised KOHLER workshops to know what type of problem it is. Certain problems automatically switch off the engine.

  • 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 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 29 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 30: Information And Safety Signals

    SAFETY INFORMATION 3.4 Information and safety signals HIGH PRESSURE FLUID RISK OF PUNCTURE ACCIDENTAL START High Pressure Fluids can puncture skin and cause severe injury or death. Accidental Starts can Do not work on fuel system without proper training or safety cause severe injury or equipment.
  • Page 31 SAFETY INFORMATION Carbon Monoxide can cause severe nausea, fainting or death. CALIFORNIA WARNING - DECLARATION 65 Avoid inhaling exhaust fumes and never Engine exhaust from this product contains chemicals known to the run the engine in a closed building or State of California to cause cancer, birth defects, or other confined area.

  • 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: Refuelling

    • 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 35: Oil Filling

    INFORMATION ABOUT USE 4.5 Oil filling Important • Par. 2.4 For safety precautions see • Par. 3.2.2 Before proceeding with operation, read 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 36: Coolant Filling

    INFORMATION ABOUT USE 4.6 Coolant filling Important • Before proceeding with operation, read Par. 3.2.2 Warning • An anti-freeze protection liquid (ANTIFREEZE) - mixed with decalcified water - must be used. • The freezing point of the refrigerant mixture depends on the amount concentration in water. •...

  • Page 37: Inducement Scr

    INFORMATION ABOUT USE 4.8 Inducement SCR Below is a list of the warning lights that may light up on the machine panel to indicate inducement levels Refer to the machine manual for the operations to be carried out according to the activated warning lights. CONDITION WARNING LIGHT DISPLAY...

  • Page 38: Ats Regeneration Strategy

    If the regeneration inhibition function is misused, the particulate accumulation level will increase within a short time. • The engine oil filter and oil must be changed after a Service Regeneration is completed via KOHLER software • (Level 5 Particulate accumulation).

  • Page 39: Information About Maintenance

    INFORMATION ABOUT MAINTENANCE 5 INFORMATION ABOUT MAINTENANCE 5.1 Useful information about maintenance Important • This chapter shows all operations described in the Tab. 5.1 and • Before proceeding with Tab. 5.2 if you have the skills appropriate may be directly carried Par.

  • Page 40: Periodic Maintenance

    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 41: Oil Level Check

    INFORMATION ABOUT MAINTENANCE 5.3 Oil level check 1. Loosen the oil filler cap A. Remove the oil dipstick B and check that the level is up to MAX. 2. Pour in recommended oil until reaching the MAX level mark. 3. Reinstall the oil dipstick B completely. 4.

  • Page 42: Air Filter Check

    5.5 Check of the radiator heat - exchanger surface Danger • For safety precautions see Chap. 3 NOTE: Component not necessarily supplied by KOHLER . Important • Before proceeding with operation, read Par. 3.2.2 • Wear safety goggles when using compressed air.

  • Page 43: Rubber Hoses Check

    • 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 the integrity of the pipes and hoses A.

  • Page 44: Check Coolant Level

    Warning • Presence of steam pressurized coolant danger of burn. NOTE : Component not necessarily supplied by KOHLER . 1. Start the engine without the radiator cap A . 2. Top liquid up until the pipes inside the radiator are covered by about 5 mm.

  • Page 45: Product Preservation

    INFORMATION ABOUT MAINTENANCE 5.9 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 46: Engine Storage Over 6 Months

    6. Proceed with the disposal of the AdBlue®/DEF contained in the tank; replace the AdBlue®/DEF pump filter and wash the AdBlue®/DEF tank/circuit with hot distilled water. 7. Check the AdBlue®/DEF injector at an authorized Kohler workshop. 8. Start the engine and keep it idle at minimum speed for a two about minutes.

  • Page 47: Unused Machine

    INFORMATION ABOUT MAINTENANCE 5.13 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 48 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.

  • Page 49: Information About Replacements

    INFORMATION ABOUT REPLACEMENTS 6 INFORMATION ABOUT REPLACEMENTS 6.1 Engine oil replacement Danger • Disconnect the negative wire (-) from the battery to avroid accidental engine stating. Important • Before proceeding with operation, read Par. 3.2.2 • Place engine on level sur face to ensure accurate measurement of oil level.

  • Page 50: Oil Filter Cartridge Replacement

    INFORMATION ABOUT REPLACEMENTS 6.2 Oil filter cartridge replacement Important • Before proceeding with operation, read Par. 3.2.2 Warning • Electric/pneumatic screwdrivers are forbidden. • In case of low use replace il 12 months. • For disposal of oil filter cartridge and fuel filter refer to Par.

  • Page 51: 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 52: Air Filter Cartridge Replacement

    Important • Par. 3.2.2 Before proceeding with operation, read 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 53: Replacement Of Adblue®/Def Filter

    INFORMATION ABOUT REPLACEMENTS 6.5 Replacement of AdBlue®/DEF 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 54: Information About Failures

    Colour the exhaust fumes suddenly darkens TROUBLES POSSIBLE CAUSE SOLUTION PAR. Warning YELLOW light Engine ECU has detect a Contact KOHLER authorised workshops turn on malfunctions Sulphated battery Clean the battery terminals terminals corroded Battery voltage too low Recharge the battery or replace it...
  • Page 55 High oil sump level Engine overheats Contact KOHLER authorised workshops Clean the radiator; if the problem persists, contact Clogged radiator KOHLER authorised workshops In the event that the solutions proposed in Tab. 7.2 do not eliminate the trouble, contact a KOHLER authorized workshop...

  • Page 56: Information About Warranty

    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 manuals.
  • Page 57 (iv) an act beyond the control of Kohler Co., which includes but is not limited to theft, vandalism, fire, lightning, earthquake, windstorm, hail, volcanic eruption, flood or tornado.
  • Page 58 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 59 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 60: Glossary

    9 GLOSSARY 9.1 Glossary Alternator A component that transforms mechanical energy into AC electrical energy. Authorised Kohler authorised service centre. workshop After Treatment System - Post-treatment system, referred to the exhaust gases produced by the engine. Bore Internal diameter of the cylinder in combustion engines.
  • Page 61 - dirty area, or in a contaminated environment due to various types of gas). Air-cooling element under pressure from the turbo situated between the turbine and intake manifold. Intercooler "Kohler Direct Injection" A group of maintenance actions that have the sole objective to control and replace elements on Maintenance -...
  • Page 62 GLOSSARY Oil Cooler Small radiator used to cool the oil. 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 section that is Poly-V constructed with joined Vs.
  • Page 63 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...

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