Kohler KDI 3404 TCR Owner's Manual
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Kohler KDI 3404 TCR Owner's Manual

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KDI 3404 TCR
OWNER MANUAL

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Summary of Contents for Kohler KDI 3404 TCR

  • Page 1 KDI 3404 TCR OWNER MANUAL...
  • Page 2 > KDI KOHLER DIESEL section > login as a guest "Enter as a guest" > "TECHNICAL DOCUMENTATION" > select "KDI 3404 TCR" and download the latest version of this manual onto your device. NOTE: you can select the desired language before downloading the manual, as shown in the figure below.

  • Page 3: Table Of Contents

    INDEX 1 - GENERAL INFORMATION 4 - INFORMATION ABOUT USE 1.1 Manual's Purpose ..............6 4.1 Pre-start check .............21 1.2 Glossary and Definitions ..........6 4.2 Running-in period ............21 1.3 Emission-Related Installation Instructions ....6 4.3 Starting and turning off ..........21 1.4 Service request ...............6 4.3.1 Starting .................
  • Page 4 ANALYTICAL INDEX Adhesive safety plates ............18 Homologation labels .............9 After starting ...............21 Air filter cartridge replacement .........31 Air filter check ..............25 Info ..................34 Information and safety signals ..........19 Battery recommendation ...........15 Label for China Standards ..........10 Biodiesel fuel ...............14 Label for EPA rules ...............9 Label for Korea Standards ..........10 Location of safety labels on engine ........20 Check coolant level .............26...
  • Page 5 ANALYTICAL INDEX SAE oil classification ............13 Safety and environmental impact ........19 Safety guards ..............18 Safety information ..............16 Safety signal description ...........18 Service request ..............6 Starting ................21 Starting and turning off ............21 Turning off ................21 Useful information about failures ........33 Useful information about maintenance ......24 Warnings ................18 ED0053030050...

  • Page 6: General Information

    40 CFR 1068.105. 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: Engine Component Identification

    GENERAL INFORMATION 1.5 Engine component identification Side view A Turbocharger Oil steam separator Valve EGR Thermostatic valve EGR Cooler Coolant temperature Oil pressure sensor sensor Alternator High injection pump Oil cooler Coolant pump Oil filter Oil dipstick Prefilter (type B) Fuel filter Nameplate Oil drain plug...

  • Page 8: Manufacturer And Engine Identification

    GENERAL INFORMATION 1.6 Manufacturer and motor identification data The nameplate motor identification is find side A or side B. Side view A Side view B Engine type Engine serial number Manufacturer identification Peak Engine version Approval data and "EC" directives ED0053030050 Index...

  • Page 9: Homologation Labels

    GENERAL INFORMATION 1.7 Homologation labels 1.7.1 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 10: Label For China Standards

    GENERAL INFORMATION 1.7.2 Label for China Standards POS. DESCRIPTION Manufacturer Engine model Date of manufacture China emission certification no. Power range (kW) Emission level Power Post-treatment system ED0053030050 Index...

  • Page 11: Label For Korea Standards

    GENERAL INFORMATION 1.7.3 Label for Korea Standards POS. DESCRIPTION Tier 4 Final Engine model Date of manufacture and manufacturer code Korea emission certification no. ED0053030050 Index...

  • Page 12: Technical Information

    - Common Rail - Direct injection. - Liquid-cooling system; - 4 valves per cylinder with hydraulic tappets; 2.2 Engine specifications UNIT TECHNICAL DATA OF MEASURE ENGINE TYPE KDI 3404 TCR CYLINDERS BORE STROKE DISPLACEMENT 3359 40° max. 30 minutes MAX INCLINATION DURING OPERATION (EVEN IN COMBINED) 45°...

  • Page 13: 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 in •...

  • Page 14: Biodiesel Fuel

    TECHNICAL INFORMATION 2.5.2 Biodiesel fuel • Fuels containing 10% methyl ester or B10, are suitable for use in this engine provided that they meet the specifications listed in the Tab. 2.3. • DO NOT USE vegetable oil as a biofuel for this engine. FUEL COMPATIBILITY ENGINE VERSION TCR/D TIERIII...

  • Page 15: Coolant Recommendation

    TECHNICAL SPECIFICATIONS 50% ETYLENGLYCOL E 50% DECALCIFIED WATER 50% PROPYLENGLYCOL E 50% DECALCIFIED WATER OAT/HIBRID TECHNOLOGY (ASTM 3306) 2.7 Battery recommendation Battery not supplied by Kohler RECOMMENDED BATTERIES AMBIENT TEMPERATURE BATTERY TYPE 120 Ah/20 h - 1000 CCA/SAE ≥ - 15°C 130 Ah/20 h - 1100 CCA/SAE <...

  • Page 16: 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 17 Important accidental short-circuits and to stop the starter motor from being energized. • Only use the eyebolts A installed by KOHLER to move the • Check belt tension only when the engine is off. engine (Fig. 3.1). • Fully tighten the tank cap each time after refuelling. Do not •...

  • Page 18: 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 19: Information And Safety Signals

    State of California to cause cancer, birth defects, or 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 20: Location Of Safety Labels On Engine

    SAFETY INFORMATION 3.6 Location of safety labels on engine ED0053030050 Index...

  • Page 21: 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 22: 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 23: 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 24: Information About Maintenance

    PAR. 1000 1500 5000 Engine oil level Coolant level / Components not supplied by KOHLER. Check of the radiator heat-exchanger surface Refer to the technical documentation of the Cartridge dry-type air filter vehicle Radiator heat-exchange surface and Intercooler Alternator belt tension...

  • Page 25: Oil Level Check

    4. Re-tighten the cap A (Fig. 5.2). Important • Do not use the engine with the oil level below the minimum. 5.4 Air filter check NOTE: Component not supplied by KOHLER. Refer to the technical documentation of the vehicle. ED0053030050 Index...

  • Page 26: 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 27: Check Poly-V Alternator Belt

    135 and 178 Hz. NOTE: If the poly-v belt tension results out of the above mentioned values contact KOHLER authorised workshops for replacement. 5.9 Filter cartridge and fuel pre-filter check When turn on lights on control water filter cartridge fuel: 1.

  • Page 28: Product Preservation

    INFORMATION ABOUT MAINTENANCE 11. When cleaning the engine, if using a pressure washer 5.10 Product preservation or steam cleaning device, avoid directing the nozzle on electrical components, cable connections and sealed rings (oil seals etc). If cleaning engine with a pressure washer or steam cleaner, it is important to maintain a minimum distance of at least 200mm between the Important...

  • Page 29: 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 30: Oil Filter Cartridge Replacement

    INFORMATION ABOUT REPLACEMENTS 9. Fit and remove the oil dipstick B to check the level. Pour in fluid until reaching the MAX level mark. 10. Upon completion, reinstall the oil dipstick B completely. 11. Tighten the cap A. Warning Oil filter cartridge replacement (Par.

  • Page 31: Filter Cartridge And Fuel Pre-Filter Replacement

    7. Reconnect the cable A of the water presence sensor C. NOTE: Bleeding. 8. Push repeatedly the button G in order to fill the circuit. 6.4 Air filter cartridge replacement NOTE: Component not supplied by KOHLER. Refer to the technical documentation of the vehicle. ED0053030050 Index...

  • Page 32: Disposal And Scrapping

    INFORMATION ABOUT REPLACEMENTS 6.5 Disposal and scrapping • In case of scrapping, the engine shall be disposed of in • The parts only composed of plastic material, aluminium appropriate locations, in conformity with the law in force. and steel can be recycled if collected by the appropriate •...

  • Page 33: 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. ED0053030050 Index...

  • Page 34: 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 35 Co. cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance. 2. As the off-road engine owner, you should however be aware that Kohler Co. may deny you warranty coverage if your off- road engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.
  • Page 36 The choice and responsibility of the decision to repair or replace an emission control system defect will be solely that of Kohler Co.

  • Page 37: 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 38 GLOSSARY 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.
  • Page 39 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 Length 1/1000 of a millimetre μm 1 μm (micron)
  • Page 40 Lombardini s.r.l. is a part of Kohler Group. E U ROP E U SA & C AN AD A FRAN C E Lombardini has manufacturing facilities Lombardini Srl Kohler Co. Lombardini France S.a.s. in Italy, Slovakia and India and sales Via Cav.

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