Kohler KDI 3404TM Owner's Manual
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Kohler KDI 3404TM Owner's Manual

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KDI 3404TM
OWNER MANUAL

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Summary of Contents for Kohler KDI 3404TM

  • Page 1 KDI 3404TM OWNER MANUAL...
  • Page 2 11/2020 Documentation Documentation Translated from the original manual in Italian language. Data reported in this issue can be modified at any time by KOHLER. Important • Connect to http://iservice.lombardini.it and download the latest version of this manual onto your device.
  • Page 3 INDEX 1 - GENERAL INFORMATION 4 - INFORMATION ABOUT USE 1.1 Manual's Purpose ............4 4.1 Pre-start check .............20 1.2 Glossary and Definitions ..........4 4.2 Running-in period ............20 1.3 Emission-Related Installation Instructions ....4 4.3 Starting and turning off ..........20 1.4 Service request ...............4 4.3.1 Starting ...............20 1.5 Engine component identification ........5 4.3.2 After starting .............20...

  • Page 4: General Information

    If you install the engine in a way that makes the engine's emission control information label hard to read during normal engine maintenance, you must place a duplicate label on the equipment, as described in 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 5 GENERAL INFORMATION 1.5 Engine component identification SIDE VIEW A Oil steam separator Turbocharger Oil filler cap Thermostat Oil pressure sensor Coolant temperature sensor Fuel injection pump Alternator Oil cooler Oil filter Coolant pump Oil dipstick Nameplate Oil drain plug Fuel filter SIDE VIEW B Oil filler cap Turbocharger...
  • Page 6 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 ED0053030120 Index...

  • Page 7: 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 8 GENERAL INFORMATION 1.7.2 Label for China Standards POS. DESCRIPTION Manufacturer Engine model Manufactoring date Certificate N° Power range (kW) Emission level Rated power Aftertreat system ED0053030120 Index...
  • Page 9 GENERAL INFORMATION 1.7.3 Label for Korea Standards POS. DESCRIPTION Tier 4 Final Engine model Manufactoring date and manufacturer code N° Korea emission certificate ED0053030120 Index...

  • Page 10: Technical Information

    TECHNICAL INFORMATION 2.1 General description of the engine - Turbocharger with Waste-gate valve; - 4-stroke, in-line cylinders Diesel engine; - Common Rail - Direct injection. - Liquid-cooling system; - 4 valves per cylinder with hydraulic tappets; 2.2 Engine specifications UNIT TECHNICAL DATA OF MEASURE KDI 3404 TM...

  • Page 11: Recommended 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 12 TECHNICAL INFORMATION 2.5 Fuel Warning Important • Clean fuel prevents the fuel injectors from clogging. • Use of other types of fuel could damage the engine. Do not Immediately clean up any spillage during refuelling. use dirty diesel fuel or mixtures of diesel fuel and water •...

  • Page 13: Limit Value

    TECHNICAL INFORMATION 2.5.1 Fuel for low temperatures • When operating the engine in ambient temperatures lower than 0 degrees C, use suitable low temperature fuel normally available from fuel distributors and corresponding to the specifications of Tab. 2.3. • These fuels reduce the formation of paraffin in diesel at low temperatures. •...

  • Page 14: 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 TEMPERATURE BATTERY TYPE ≥...

  • Page 15: General Remarks

    • 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 16: Safety Information

    Important being energized. • Check belt tension only when the engine is off. • Only use the eyebolts A installed by KOHLER to move the • Fully tighten the tank cap each time after refuelling. Do not engine (Fig. 3.1).

  • Page 17: 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 18 Do not touch wires while engine is running. 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 19 SAFETY INFORMATION 3.6 Location of safety labels on engine ED0053030120 Index...

  • Page 20: Information About Use

    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 21 • 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 22: Coolant Filling

    INFORMATION ABOUT USE 4.6 Coolant filling Important Warning Par. 3.2.2. • Before proceeding with operation, read • 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 23: Information About Maintenance

    INFORMATION ABOUT MAINTENANCE 5.1 Useful information about maintenance • This chapter shows all operations described in the Tab. 5.1, Tab. 5.2, Tab. 5.3 and Tab. 5.4 if you have the skills appropriate may be directly carried out by the user. Warning •...
  • Page 24 Additives) added at the first maintenance interval. 3. In case of low use: 36 months. 11. Read Cap. 2.5, "KDI Mechanical Injection Uncertified 6. Contact authorized KOHLER workshops. Engines (no EGR Engines)" 7. The replacement interval is only an indication, it strongly depends from environmental condition and hose status detected during regular visual inspection.
  • Page 25 Components must be replaced if they have clear signs of cracks, tears, cuts, leaks and do not retain a certain degree of elasticity. Important • If hoses are damaged contact an authorized KOHLER workshop. 1. Check that the: Fuel system hoses A are intact.

  • Page 26: Check Coolant Level

    • Presence of steam pressurized coolant danger of burns. 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 27: Control Water Filter Cartridge Fuel

    149 and 196 Hz. NOTE: If the poly-v belt tension results out of the above mentioned values contact KOHLER authorised workshops for replacement. 5.9 Control water filter cartridge fuel 1. Gently loosen the wing screw A without removing it.

  • Page 28: Engine Starting After Storage

    INFORMATION ABOUT MAINTENANCE 5.12 Engine storage over 6 months 5.13 Engine starting after storage Follow the steps described in Par. 5.11. 1. Remove the protective sheet. 1. Engine oil replacement (Par. 6.1). 2. Use a cloth soaked in degreasing product to remove the 2.
  • Page 29 INFORMATION ABOUT REPLACEMENTS Danger Disconnect the negative wire (-) from the battery to avoid accidental engine starting. • Important Before proceeding with operation, read Par. 3.2.2 • 6.1 Engine oil replacement Important • Place engine on level surface to ensure accurate measurement of oil level.

  • Page 30: Information About Replacements

    INFORMATION ABOUT REPLACEMENTS 10. Upon completion, reinstall the oil dipstick B completely. 11. Tighten the cap A. 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 31: Air Filter Cartridge Replacement

    1.5 Nm) when the fuel begins to flow. 6.4 Air filter cartridge replacement NOTE: Component not necessarily supplied by KOHLER. 1. Release the two fastenings F of the cover A. 2. Remove the cartridge B. 3. Reinstall: - the new cartridge B.

  • 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

    Engine overheats KOHLER authorised workshops Clean the radiator; if the problem persists, contact KOHLER Clogged radiator authorised workshops - In the event that the solutions proposed in Tab. 7.2 do not eliminate the trouble, contact a KOHLER authorized workshop. ED0053030120 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 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 36: Warranty Period

    US EPA anti-smog standards. 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 37 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 Tab.: Table. A term indicated for installation of threaded components Tightening torque: and which is determined by means of a unit of measurement Nm. Turbo Mechanical Device that compresses air intake by sending it to the Turbocharger: intake manifold by means of a turbine. Oil altered by operation or time, which is no longer Used oil: compliant for correct lubrication of the components.
  • Page 39 GLOSSARY SYMBOLS AND UNITS OF MEASUREMENT SYMBOL UNIT OF MEASUREMENT DESCRIPTION EXAMPLE 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) hour...
  • Page 40 NOTES ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
  • Page 41 ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
  • Page 42 NOTES ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

  • Page 43: California Proposition

    CALIFORNIA PROPOSITION 65 ED0053030120 ED0053030120 Index...
  • Page 44 Lombardini s.r.l. is a part of Kohler Group. E U R OP E U SA & C AN ADA FR ANC 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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