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

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KDI 3404TCR / KDI 3404 TCR HT
OWNER MANUAL
ED0053030050_Rev_11.2
Confidential Communication: Information is for use only by approved users.

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Summary of Contents for Kohler KDI 3404TCR

  • Page 1 KDI 3404TCR / KDI 3404 TCR HT OWNER MANUAL ED0053030050_Rev_11.2 Confidential Communication: Information is for use only by approved users.
  • Page 2 INDEX...

  • Page 3: Table Of Contents

    Starting and turning off ........................ 26 Refuelling............................27 Oil filling ............................27 Coolant filling ..........................28 ATS regeneration strategy (only for KDI 3404TCR HT configurations) ........29 Information about maintenance ..................31 Useful information about maintenance ..................31 Periodic maintenance ........................32 Oil level check ..........................
  • Page 4 INDEX Air filter check ..........................33 Check of the radiator heat - exchanger surface ................ 33 Rubber hoses check ........................34 Check coolant level ........................34 Check Poly-V alternator belt ......................35 Filter cartridge and fuel pre-filter check ..................35 5.10 Product preservation ........................

  • Page 5: 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 6: 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 7: Ats (After Treatment System)

    GENERAL INFORMATION 1.6 ATS (After Treatment System) A: Turbocharger B: Turbine exhaust pipe • The ATS system reduces emissions because the DPF eliminates the particulates generated by the combustion of the diesel. The system starts automatic regeneration cycles of the DPF based on the level of clogging. The smell of the NOTE: The ATS system is only present gases emitted by the exhaust line is different from that of for versions that conform to "Stage V"...

  • Page 8: Manufacturer And Engine Identification

    GENERAL INFORMATION 1.7 Manufacturer and engine identification The engine identification name plate is situated in the lower part of the crankcase; it is visible from the intake or exhaust side. Fig 1.1 - Fig 1.2 Fig 1.3...

  • Page 9: Homologation Labels

    GENERAL INFORMATION 1.8 Homologation labels 1.8.1 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 Injector opening pressure (bar) Production date (example: 2013.JAN)
  • Page 10 GENERAL INFORMATION 1.8.2 Label for China Standards (compilation example) Tab 1.2 DESCRIPTION Manufacturer Engine model Date of manufacture China emission certification no. Power range (kW) Emission level Power Post-treatment system...
  • Page 11 GENERAL INFORMATION 1.8.3 Label for Korea Standards (compilation example) Tab 1.3 DESCRIPTION Tier 4 Final Engine model Date of manufacture and manufacturer code Korea emission certification no.

  • Page 12: 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 Tab.

  • Page 13: 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 14: Fuel

    TECHNICAL INFORMATION (*1) NOTE : 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 15 TECHNICAL INFORMATION systems. Too low a lubricating capacity is particularly a problem in fuels with a low sulfur content (and in this respect sulfur contents ‹500 mg/kg can already be considered low). An adequate lubricating capacity 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.
  • Page 16 TECHNICAL INFORMATION FUEL PARAMETER UNIT LIMIT VALUE Cetane number Min. 49 Fuel density at 15°C 820 - 860 Kg/m Sulfur content mg/kg or ppm max. 500 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.

  • Page 17: Coolant Recommendation

    HOAT are not all maintenance free and it is recommended to have SCA (Supplemental Coolant Additives) added at the first maintenance interval. 2.7 Battery recommendation Battery not supplied by Kohler Tab. 2.6 RECOMMENDED BATTERIES AMBIENT TEMPERATURE BATTERY TYPE ≥...

  • Page 18: Control Panel

    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. Tab. 2.9 shows data that can be consulted on display B by pressing push buttons C or D .

  • Page 19: Safety Information

    Any use of the machine other than that described cannot be considered as complying with its intended purpose as specified by KOHLER . • KOHLER declines all responsibility for any change to the engine not described in this manual made by unauthorized KOHLER personnel. •...

  • Page 20: General Remarks

    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 21 Do not use air and water jets at high pressures on cables, connectors and injectors. 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.

  • Page 22: 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 23: 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 24 SAFETY INFORMATION Never operate the engine with heat Never use fuel as a cleaning agent. shields or guards removed. EXPLOSIVE GAS ROTATING PARTS Explosive Gas can cause fires and severe acid Rotating Parts can burns. cause severe injury. Charge battery only in a well ventilated area. Keep sparks, open Stay away while engine is in operation.

  • Page 25: 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 26: Information About Use

    INFORMATION ABOUT USE 4 INFORMATION ABOUT USE 4.1 Pre-start check • Read carefully the following pages and carry out the operations described below in accordance with the instructions specified. Important • 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 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 28: 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 29: Ats Regeneration Strategy (Only For Kdi 3404Tcr Ht Configurations)

    INFORMATION ABOUT USE 4.7 ATS regeneration strategy (only for KDI 3404TCR HT configurations) Only for Stage V configurations (see Par. ATS) You can intervene on the machine control panel for the DPF regeneration operations "only if requested by means of specific warning lights or messages on the control panel".
  • Page 30 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 31: Information About Maintenance

    INFORMATION ABOUT MAINTENANCE 5 INFORMATION ABOUT MAINTENANCE 5.1 Useful information about maintenance • This chapter shows all operations described in the Tab. 5.1 and Tab. 5.2 . if you have the skills appropriate may be directly carried out by the user. •...

  • Page 32: Periodic Maintenance

    OPERATION DESCRIPTION 5000 (4) (8) Engine oil level (8)(9) Coolant level Components not supplied by KOHLER . Cartridge dry-type air filter Refer to the technical documentation of the vehicle Radiator heat-exchange surface and Intercooler Alternator belt Rubber hose (intake air / coolant)

  • Page 33: Oil Level Check

    4. Re-tighten the cap A and/or C (Fig. 5.2) . Fig. 5.2 5.4 Air filter check NOTE : Components not supplied by KOHLER . Refer to the technical documentation of the vehicle.. 5.5 Check of the radiator heat - exchanger surface NOTE : Components not supplied by KOHLER .

  • Page 34: Rubber Hoses Check

    Important • Before proceeding with operation, read Par. 3.2.2 • If hoses are damaged contact an authorized KOHLER workshop. Check that the: - Fuel system hoses A are intact. - Cooling circuit hoses B . - Vent system pipes C .

  • Page 35: 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. 5.9 Filter cartridge and fuel pre-filter check Important •...

  • Page 36: 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 37: Engine Starting After Storage

    INFORMATION ABOUT MAINTENANCE 5.13 Engine starting after storage 1. Remove the protective sheet. 2. Use a cloth soaked in degreasing product to remove the protective treatment from the external parts. 3. Inject lubricating oil (no more than 2 cm ) into the intake ducts. 4.

  • Page 38: 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 Fig. 6.1 • Before proceeding with operation, read Par. 3.2.2 • Place engine on level sur face to ensure accurate measurement of oil level.

  • Page 39: 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 40: Filter Cartridge And Fuel Pre-Filter Replacement

    2. New or regenerated DPF KITS are available • The regenerated KITS are certified and covered by a specific KOHLER warranty. • Cleaning processes that are not certified by KOHLER could cause irreversible damage to the DPF filter or the ATS system.

  • Page 41: 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 42: Information About Failures

    Tab 7.2 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 43 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 44: 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 45 (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 46 2. As the off-road & marine engine owner, you should however be aware that Kohler Co. may deny you warranty coverage if your off-road & marine engine or a part shows signs of malfunction or failed due to abuse, neglect, improper maintenance or unapproved modifications.
  • Page 47 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 48 INFORMATION ABOUT WARRANTY MARINE DIESEL ENGINE ENGINE POWER WARRANTY PERIOD kW < 19 1,500 hours or 2.5 years, whichever comes first 19 ≤ kW < 37 2,500 hours or 3.5 years, whichever comes first 37 ≤ kW < 75 5,000 hours or 5 years, whichever comes first...

  • Page 49: 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 50 - 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 51 GLOSSARY 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. Ref. Reference. "Serial number" (engine identification name plate) indicating the engine identification series/chassis number.
  • Page 52 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 53 NOTES ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
  • Page 54 NOTES ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

  • Page 55: California Proposition 65

    CALIFORNIA PROPOSITION 65...

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