Kohler KDI 3404TM Operation And Maintenance Manual
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Kohler KDI 3404TM Operation And Maintenance Manual

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Operation and maintenance manual
Engine
KDI 3404TM
KOHLER
Supplied by
33521021901_5_1
ED005303-012 - revision 10.1
01/02/2023

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Summary of Contents for Kohler KDI 3404TM

  • Page 1 Operation and maintenance manual Engine KDI 3404TM KOHLER Supplied by 33521021901_5_1 ED005303-012 - revision 10.1 01/02/2023...
  • Page 3 KDI 3404TM OWNER MANUAL Internal Communication: For internal & partner use only.
  • Page 4 Documentation Translated from the original manual in Italian language. Data reported in this issue can be modified at any time by KOHLER. Important The latest version of this manual is available on the i-Service website, connect to the following link https://iservice.lombardini.it, before downloading the manual, you can select the desired language from the top bar of the...

  • Page 5: Table Of Contents

    INDEX General Information ......................5 Manual's Purpose ..........................5 Glossary and Definitions ......................... 5 Emission-Related Installation Instructions ................... 6 Service request ..........................6 Engine component identification ....................7 Manufacturer and engine identification ..................8 Homologation labels ........................9 Technical information ......................12 General description of the engine ....................
  • Page 6 INDEX Check Poly-V alternator belt ......................34 Check fuel filter cartridge ......................34 5.10 Product preservation ........................35 5.11 Engine storage up to 6 months ....................35 5.12 Engine storage over 6 months ...................... 35 5.13 Engine starting after storage ......................36 5.14 Unused machine ..........................

  • Page 7: 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 8: 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 Errore. Riferimento a collegamento ipertestuale non valido. websites: &...

  • Page 9: Engine Component Identification

    GENERAL INFORMATION 1.5 Engine component identification Internal Communication: For internal & partner use only.

  • Page 10: Manufacturer And Engine Identification

    GENERAL INFORMATION 1.6 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 11: Homologation Labels

    GENERAL INFORMATION 1.7 Homologation labels 1.7.1 Label for EPA rules (compilation example) Tab. 1.1 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)
  • Page 12 GENERAL INFORMATION 1.7.2 Label for China Standards (compilation example) Tab 1.2 DESCRIPTION Manufacturer Engine model Manufactoring date Certificate N° Power range (kW) Emission level Rated power Aftertreat system...
  • Page 13 GENERAL INFORMATION 1.7.3 Label for Korea Standards (compilation example) Tab 1.3 DESCRIPTION Tier 4 Final Engine model Manufactoring date and manufacturer code N° Korea emission certificate Internal Communication: For internal & partner use only.

  • Page 14: 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; • Direct Injection. 2.2 Engine specifications Tab. 2.1 TECHNICAL DATA UNIT OF MEASURE Engine type KDI 3404 TM Cylinders...

  • Page 15: 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 16: Fuel

    Jet fuels, the certification primary filter must be with lubricity dosing capability. (*1) Contact Kohler for information about the approved filter for this purpose. Power and torque might be 1% to 5% lower due to low fuel 100% (EN density compared to standard diesel fuel.
  • Page 17 Jet fuels, the certificati primary filter must be with lubricity dosing capability. (*1) Contact Kohler for information about the approved filter for this purpose. Sulphur Fuel S < 500 ppm High Sulphur Fuel S <...

  • Page 18: 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. 2.7 RECOMMENDED BATTERIES AMBIENT TEMPERATURE BATTERY TYPE ≥...

  • Page 19: 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 20 • 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 21 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 80Nm.

  • 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 SAFETY INFORMATION Warnings Hereunder is a list of safety warnings that may be found in the manual, which advise you to pay attention when carrying out particular procedures that may be potentially dangerous to the operator or things. Danger This indicates situations of grave danger which, if ignored, may seriously threaten the health and safety of individuals.

  • Page 24: 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 cause Do not work on fuel system without proper training or severe injury or death.

  • 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. •...

  • Page 26: Location Of Safety Labels On Engine

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

  • Page 27: 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 28: 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 29: 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. • Do not use the engine with the oil level below the minimum. 1. Loosen the oil filler cap A. 2.
  • Page 30 INFORMATION ABOUT USE NOTE: Before proceeding with any operation on the engine, stop it and allow it to cool. Warning • Presence of steam pressurized coolant danger of burns. 1. Loosen the cap A and fill the radiator with coolant composed of: 50% ANTIFREEZE and 50% decalcified water.

  • 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

    INFORMATION ABOUT MAINTENANCE 5.2 Periodic maintenance The intervals of preventive maintenance in Tab. 5.1, Tab. 5.2, Tab. 5.3 and Tab. 5.4 refer to the engine operating under normal operating conditions with fuel and oil meeting the recommended specifications. CLEANING AND CHECKING PERIOD (HOURS) OPERATION DESCRIPTION PAR.

  • Page 33: Oil Level Check

    The air filter must be cleaned and replaced more frequently under very dusty conditions. (3) - In case of low use: 36 months. (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 34: Air Filter Check

    • Before proceeding with operation, read Par. 3.2.2. NOTE: Components not necessarily supplied by KOHLER. 1. Release the two clasps F of the cover A. 2. Remove the cartridge B. 3. Clean the inside components A and D with a damp cloth.

  • Page 35: Rubber Hoses Check

    Important Fig 5.5 • 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.

  • Page 36: Check Poly-V Alternator Belt

    Check by the appropriate tool that at point p the tension value is between 149 and 196 Hz. NOTE: If the poly-v belt tension results out of the above mentioned Fig 5.9 values contact KOHLER authorised workshops for replacement. 5.9 Check fuel filter cartridge Important • Before proceeding with operation, read Par.

  • Page 37: 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 38: 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 39: 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 40: 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 Fig. 6.1 • Place engine on level sur face to ensure accurate measurement of oil level.

  • Page 41: 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 42: Fuel Filter Cartridge Replacement

    INFORMATION ABOUT REPLACEMENTS 6.3 Fuel filter cartridge replacement Warning Important • In case of low use replace il 12 months. • Before proceeding with operation, read Par. • To replace the cartridge with Option B filter, it 3.2.2. is necessary to use the ST_55 tool cod. •...
  • Page 43 INFORMATION ABOUT REPLACEMENTS Option B 1. Unscrew the ring nut H using the ST_55 tool and remove the cartridge A. Fig 6.8a 2. Lubricate the gasket C of the new cartridge A. 3. Insert the ring nut H on the new cartridge A and mount the new cartridge A on the support 4.

  • Page 44: Air Filter Cartridge Replacement

    INFORMATION ABOUT REPLACEMENTS 6.4 Air filter cartridge replacement Important • Before proceeding with operation, read Par. 3.2.2. NOTE: Component not necessarily supplied by KOHLER. 1. Release the two fastenings F of the cover A. 2. Remove the cartridge B. 3. Reinstall: •...

  • Page 45: 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 terminals Clean the battery terminals corroded Battery voltage too low Recharge the battery or replace it...
  • Page 46 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 47: 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 48 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 49 4. 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 50 The [current model year – {2+ current model year}] heavy-duty off-road & marine engines are warranted for the periods listed below. If any emission-related part on your engine is defective, the part will be repaired or replaced by Kohler Co. VARIABLE SPEED OR 1,500 HOURS OR TWO YEARS, KW <19...

  • Page 51: Glossary

    9 GLOSSARY 9.1 Glossary and Definitions 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.
  • Page 52 GLOSSARY A group of maintenance actions that have the sole objective to control and replace elements Maintenance - on their expiry, without modifying or improving the functions carried out by the system, periodic neither increasing the value nor improving performance. Maximum.
  • Page 53 GLOSSARY Waste-Gate A device, which is directly or automatically controlled, used to limit the pressure of exhaust valve gas inside the turbine. SYMBOLS AND UNITS OF MEASUREMENT SYMBOL UNIT OF MEASUREMENT DESCRIPTION EXAMPLE α degree Rotation/inclination angle 1° square centimetre Area 1 cm Ø...

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