Kohler KDI3404TCR Owner's manual

Brand: Kohler

Model: KDI3404TCR

Category: Engine

Type: Owner's manual

Internal Communication: For internal & partner use only.

KDI 3404TCR

KDI 3404 TCR HT

OWNER MANUAL

INDEX

REGISTRATION OF MODIFICATIONS TO THE DOCUMENT

Any modifications to this document must be registered by the drafting body, by completing the following table.

Released by Document code Revision Issue date Review date Edited by Endorsed

Technical

Documentation ED005303-005 11.8 10/2014 02/2023 C. ACCOTI V. MANINI

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

site as shown in the figure below.

INDEX

[Titolo] EN

Internal Communication: For internal & partner use only.

1 General Information .............................................................................................................. 5

1.1 Manual's Purpose ............................................................................................................................ 5

1.2 Glossary and Definitions ................................................................................................................. 5

1.3 Emission-Related Installation Instructions ................................................................................... 6

1.4 Service request ................................................................................................................................. 6

1.5 Engine component identification ................................................................................................... 7

1.6 ATS (After Treatment System) ........................................................................................................ 8

1.7 Manufacturer and engine identification ........................................................................................ 9

1.8 Homologation labels ...................................................................................................................... 10

2 Technical information ......................................................................................................... 13

2.1 General description of the engine ................................................................................................ 13

2.2 Engine specifications .................................................................................................................... 13

2.3 Engine dimensions (mm) ............................................................................................................... 14

2.4 Oil ..................................................................................................................................................... 14

2.5 Fuel .................................................................................................................................................. 16

2.6 Coolant recommendation.............................................................................................................. 18

2.7 Battery recommendation .............................................................................................................. 18

2.8 Control panel .................................................................................................................................. 18

3 Safety information ............................................................................................................... 20

3.1 Safety information.......................................................................................................................... 20

3.2 General remarks ............................................................................................................................. 20

3.3 Safety signal description ............................................................................................................... 24

3.4 Information and safety signals ..................................................................................................... 25

3.5 Safety and environmental impact ................................................................................................ 27

3.6 Location of safety labels on engine ............................................................................................. 28

4 Information about use ......................................................................................................... 29

4.1 Pre-start check ............................................................................................................................... 29

4.2 Running-in period .......................................................................................................................... 29

4.3 Starting and turning off ................................................................................................................. 29

4.4 Refuelling ........................................................................................................................................ 30

4.5 Oil filling .......................................................................................................................................... 30

4.6 Coolant filling.................................................................................................................................. 31

4.7 ATS regeneration strategy ............................................................................................................ 32

5 Information about maintenance ......................................................................................... 34

5.1 Useful information about maintenance ....................................................................................... 34

5.2 Periodic maintenance .................................................................................................................... 35

5.3 Oil level check ................................................................................................................................. 36

5.4 Air filter check ................................................................................................................................ 37

INDEX

5.5 Check of the radiator heat - exchanger surface ........................................................................ 37

5.6 Rubber hoses check ...................................................................................................................... 38

5.7 Check coolant level ........................................................................................................................ 38

5.8 Check Poly-V alternator belt ......................................................................................................... 39

5.9 Filter cartridge and fuel pre-filter check ..................................................................................... 39

5.10 Product preservation ..................................................................................................................... 40

5.11 Engine storage up to 6 months .................................................................................................... 40

5.12 Engine storage over 6 months ...................................................................................................... 40

5.13 Engine starting after storage ........................................................................................................ 40

5.14 Unused machine ............................................................................................................................ 41

6 Information about replacements ........................................................................................ 42

6.1 Engine oil replacement .................................................................................................................. 42

6.2 Oil filter cartridge replacement .................................................................................................... 43

6.3 Filter cartridge and fuel pre-filter replacement .......................................................................... 44

6.4 Air filter cartridge replacement .................................................................................................... 45

6.5 DPF filter replacement................................................................................................................... 45

6.6 Disposal and scrapping ................................................................................................................. 46

7 Information about failures .................................................................................................. 47

7.1 Useful information about failures ................................................................................................. 47

8 Information about warranty ................................................................................................ 49

8.1 Warranty terms ............................................................................................................................... 49

9 Glossary ............................................................................................................................... 53

9.1 Glossary ........................................................................................................................................... 53

GENERAL INFORMATION

5 EN

Internal Communication: For internal & partner use only.

1 GENERAL INFORMATION

1.1 Manual's Purpose

•

This manual contains the instructions needed to carry out proper use and maintenance of the engine,

therefore it must always be available, for future reference when required.

• This manual is an integral part of the engine, in the event of transfer or sale, it must be attached to it.

• Safety pictograms can be found on the engine and it is the operator's responsibility to keep them in a

perfectly visible place and replace them when they are no longer legible.

• Information, description and pictures in this manual reflect the state of the art at the time of the marketing

of engine.

• However, development on the engines is continuous. Therefore, the information within this manual is

subject to change without notice and without obligation.

• 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.

• Any additional section that KOHLER will deem necessary to supply some time after the main text shall be

kept together with the manual and considered as an integral part of it.

• The information contained within this manual is the sole property of KOHLER. As such, no reproduction

or replication in whole or part is allowed without the express written permission of KOHLER.

1.2 Glossary and Definitions

The paragraphs, tables and figure are divided into chapter with their progressive numbers.

Es:

• Par. 2.3 - chapter 2 paragraph 3.

• Tab. 3.4 - chapter 3 table 4.

• Fig. 5.5 - chapter 5 figure 5.

The references of the objects described in the text and in figure and number are indicated by letters, which are

always and only related to the paragraph you are reading unless there are specific references to other figures or

paragraphs.

NOTE: All data, measurements and relevant symbols are shown in the glossary section.

1 GENERAL INFORMATION

1.3 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. OEM must apply a separate label with the following statement: “ULTRA LOW SULFUR FUEL

ONLY” near the fuel inlet.

Ensure you are installing an engine appropriately certified for your application. Constant speed engines may only

be installed on constant speed equipment for constant speed operation.

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:Errore. Riferimento a collegamento ipertestuale non valido. &

dealers.kohlerpower.it.

• If you have any questions regarding your warranty rights and responsibilities or the location of the nearest

Kohler Co. authorized service location, you should contact Kohler Co. at 1-800-544-2444 or access our

website at www.kohlerengines.com (USA and North American).

GENERAL INFORMATION

7 EN

Internal Communication: For internal & partner use only.

1.5 Engine component identification

1 GENERAL INFORMATION

1.6 ATS (After Treatment System)

A: Turbocharger

B: Turbine exhaust pipe

NOTE: The ATS system is only present for

versions that conform to "Stage V"

emission regulations. The ATS system can

be mounted differently than the figure.

• 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 gases emitted by the exhaust line is different

from that of traditional gases of diesel engines. Also,

during the regeneration phases, the exhaust gases could

be temporarily white.

• The minimum engine speed increases during the forced

regeneration phases.

•

See Par. 4.7 for the regeneration strategies of the DPF.

GENERAL INFORMATION

9 EN

Internal Communication: For internal & partner use only.

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

1 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)

GENERAL INFORMATION

11 EN

Internal Communication: For internal & partner use only.

1.8.2 Label for China Standards (compilation example)

Tab 1.2

POS

DESCRIPTION

Manufacturer

Engine model

Date of manufacture

China emission certification no.

Power range (kW)

Emission level

Power

Post-treatment system

1 GENERAL INFORMATION

1.8.3 Label for Korea Standards (compilation example)

Tab 1.3

POS

DESCRIPTION

Tier 4 Final

Engine model

Date of manufacture and manufacturer code

Korea emission certification no.

TECHNICAL INFORMATION

13 EN

Internal Communication: For internal & partner use only.

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. 2.1

TECHNICAL DATA UNIT OF

MEASURE

Engine type

KDI 3404 TCR

Cylinders

Bore

Stroke

116

Displacement

cm 3

3359

MAX INCLINATION DURING OPERATION (even in combined)

40° max 30 min.

45° max 1 min.

OIL CAPACITY (MAX level.) including oil

filter

standard

version lt. 15.6

DRY WEIGHT

394

2 TECHNICAL INFORMATION

2.3 Engine dimensions (mm)

NOTE: Dimensions vary according to engine configuration.

Fig. 2.1 - Fig. 2.2

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.

• The use of lubricants other than recommended may shorten the engine life.

• Viscosity must be appropriate to the ambient temperature to which the engine is to be exposed.

Danger

• Prolonged skin contact with the exhausted engine oil can cause cancer of the skin.

• If contact with oil cannot be avoided, thoroughly wash your hands with soap and water as soon as possible.

• For the exhausted oil disposal, refer to the Par. DISPOSAL and SCRAPPING .

TECHNICAL INFORMATION

15 EN

Internal Communication: For internal & partner use only.

2.4.1 SAE oil classification

• In the SAE classification, oils are identified according to viscosity without considering any other qualitative

characteristic.

• The code is composed of two numbers, which indicate, and must correspond to, the ambient temperature in

which the engine operates, the first number refers to the viscosity when cold, for use during winter ("W"),

while the second number is for viscosity at high temperatures.

2.2

RECCOMENDED OIL

TCR STAGE-V (*1) (*2) TCR TIER IV FINAL (*1)

TCR/D TIER III o NON

CERTIFICATO (*3)

WITH

SPECIFICATIONS

API

CJ-4 Low S.A.P.S

CK-4 Low S.A.P.S

CJ-4 Low S.A.P.S

CK-4 Low S.A.P.S

CI-4 Plus

CI-4

CH-4

ACEA E6 Low S.A.P.S. E6 Low S.A.P.S.

VISCOSITY SAE

0w-40 (-40°C ÷ +50°C)

5w-40 (-30°C ÷ +50°C)

10w-40 (-25°C ÷ +50°C)

0w-40 (-40°C ÷ +50°C)

5w-40 (-30°C ÷ +50°C)

10w-40 (-25°C ÷ +50°C)

0w-40 (-40°C ÷ +50°C)

5w-40 (-30°C ÷ +50°C)

10w-40 (-25°C ÷ +50°C)

• Low S.A.P.S. technology (oil with low Sulfated Ash, Phosphorus, Sulfur content) keeps catalyst in good

working conditions. The presence of sulfated ash, phosphorus and sulfur causes with time the catalyst

clogging and its consequent inefficiency.

• For Mid S.A.P.S oil sequence the sulfated ash level is the same as API CJ-4 ≤ 1.0% but as per ACEA

standardization those oils are referenced as mid SAPS.

• Filtration of oils is critical to proper operation and lubrication; always change filters regularly as specified in

this manual.

(*1) NOTA: 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.

(*3) - NOTE: Low S.A.P.S. oils, sulfate ashes <1% may not be used with fuels with a sulfur content >50ppm.

2 TECHNICAL INFORMATION

2.5 Fuel

Important

• Use of other types of fuel could damage the

engine. Do not use dirty diesel fuel or

mixtures of diesel fuel and water since this

will cause serious engine faults.

Warning

• Clean fuel prevents the fuel injectors from

clogging. Immediately clean up any spillage

during refuelling.

• Never store diesel fuel in galvanized containers

(i.e. coated with zinc). Diesel fuel and the

galvanized coating react chemically to each other,

producing flaking that quickly clogs filters or

causes fuel pump and/or injector failure.

• Any failure resulting from the use of fuel other

than Tab. 2.3, 2.4 will not be covered

by warranty.

Cetane number of 40 minimum. Cetane number greater than 47 is preferred, especially for temperatures

below –20 °C (–4 °F) or elevations above 1675 m (5500 ft.).

2.3

Fuel Type

Certification

Remarks

Stage

Tier

(USA)

certification

(*1)

*1: the regions known as poor lubricity diesel fuel

quality or if the engine is operated with Jet fuels, the

primary filter must be with lubricity dosing capability.

Contact Kohler for information about the approved filter

for this purpose.

3A IVF III

HVO

100% (EN

15940)

Power and torque might be 1% to 5% lower due to low fuel

density compared to standard diesel fuel.

Military NATO

Fuel F-54 (S =

10 ppm)

JIS K 2204

No.1, No.2

(EN 590 - DIN

51628)

Do NOT USE vegetable oils as a biofuel not compliant with

EN590 prescription.

Grade 1-D S15

For ambient temperatures below 0°C (32°F) with no arctic

fuel available (Grade 1-D S15, Grade 2-D S15, ASTM D

975) use the following additives to prevent possible engine

damage with low engine load in cold weather:

• Power Service Diesel Fuel Supplement+Cetane

Boost

Different additives are not allowed.

The use of approved additives has no impact on the engine

maintenance schedule.

Do NOT USE vegetable oils as a biofuel not compliant with

ASTM D975 Grade1 and Grade2 prescription.

Grade 2-D S15

TECHNICAL INFORMATION

17 EN

Internal Communication: For internal & partner use only.

Fuel Type

Certification

Remarks

Stage

Tier

(USA)

certification

(*1)

*1: the regions known as poor lubricity diesel fuel

quality or if the engine is operated with Jet fuels, the

primary filter must be with lubricity dosing capability.

Contact Kohler for information about the approved filter

for this purpose.

3A IVF III

Sulphur Fuel S

< 500 ppm

High Sulphur

Fuel S < 2000

ppm

F-34/F-35

(kerosene,

NATO

designation)

Operations with Jet Fuels

The jet fuels can be used but only adopting an additional

fuel filter with lubricity doser.

Because of lower density and greater leak fuel volume due

to lower viscosity, depending on the engine speed and

torque, a power loss up to 10% is possible.

There are some problematical fuel proprieties amongst the

listed jet fuels (viscosity, lubricating capacities and low

boiling point). A slight increase in wear in the injection

system is to be expected which can lead to a statistically

shorter life of these components. Sulphur content must be

below 2000ppm.

F-44 (kerosene,

NATO

designation)

F-63 (kerosene,

NATO

designation,

equivalent to F-

34/F-35 with

additives)

JP-8

(kerosene, US

military

designation)

JP-5

(kerosene, US

military

designation)

Jet A (kerosene

for civil

aviation)

Jet A1

(kerosene for

civil aviation)

2.4

FUEL ADDITIVES

Remarks

Fuel additives with biocide/algaecide functions only are allowed in case of

storage of fuel in the tank for long periods (one year or more).

For suggested brands and

types contact Kohler staff

These additives must be diluted in the fuel following the product prescribed

percentages when filling the tank.

Additives with functions other than biocide / algaecide are not al-lowed.

2 TECHNICAL INFORMATION

2.6 Coolant recommendation

A mixture of 50% demineralized water and 50% low silicate ethylene glycol based coolant liquid must be used.

Use a Long Life or Extended Life Heavy Duty OAT coolant free of: silicates, phosphates, borates, nitrites and

amines.

The following ethylene-glycol based engine coolant for all models within KDI engine family may be used:

• OAT (Organic Acid Technology) Low Silicate: ASTM D-3306 D-6210

• HOAT (Hybrid Organic Acid Technology) Low Silicate: ASTM D-3306 D-6210

The above coolants in concentrated formulation must be mixed with distilled, deionized, or demineralized water.

A pre-mixed formulation (40-60% or 50-50%) can be used directly when available.

Important

• Do not mix ethylene glycol and propylene glycol based coolants. Do not mix OAT and HOAT

based coolant. OAT performance life can be drastically reduced if contaminated with nitrite-containing

coolants.

• Never use automotive-type coolants. These coolants do not contain the correct additives to protect

heavy – duty diesel engines.

OAT coolants are maintenance free up to 6 years or 6000hrs of operation , provided that the cooling system is

topped up using the same type of coolant. 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

Tab. 2.6

RECOMMENDED BATTERIES

AMBIENT TEMPERATURE

BATTERY TYPE

≥ - 15°C

120 Ah/20 h - 1000 CCA/SAE

< -15°C

130 Ah/20 h - 1100 CCA/SAE

2.8 Control panel

Tab. 2.8 shows the control panel components.

Tab 2.8

POS.

DESCRIPTION

Switch key to start the panel and motor

Engine data or errors display

Top navigation menu arrow push button

Bottom navigation menu arrow push button

Data selection or entry push button

Engine operating status (green = no problem detected)

Fig 2.1

TECHNICAL INFORMATION

19 EN

Internal Communication: For internal & partner use only.

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.

NOTE: data described in Tab. 2.9 can differ, therefore, consult the machine's manual.

Tab 2.9

DESCRIPTION

Operating hours

Hours left for maintenance

Engine rpm

Engine oil pressure

Coolant temperature

Torque used @ rpm (% used)

3 SAFETY INFORMATION

3.1 Safety information

•

The intended use of the engine is in conformity with the machine on which it is mounted.

• 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.

• A proper use of the engine, a strict observance of the rules listed below and the rigorous application of all

these precautions will avoid the risk of accidents or injuries.

• Those who carry out the use and maintenance on the engine must wear the safety equipment and the

accident-prevention guards.

• KOHLER declines all direct and indirect liability for failure to comply with the standards of conduct

contained in this manual.

• KOHLER cannot consider every reasonably unforeseeable misuse that may cause a potential danger.

3.2 General remarks

3.2.1 Note for OEM

• When installing the KDI engines, always bear in mind that any variation to the functional systems may result

in serious failures to the engine.

• 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.

• Those who carry out the use and maintenance on the engine must wear the safety equipment and the

accident-prevention guards.

• KOHLER declines all direct and indirect liability for failure to comply with the standards of conduct contained

in this manual.

• KOHLER cannot consider every reasonably unforeseeable misuse that may cause a potential danger.

3.2.2 Note for end user

• The following indications are dedicated to the user of the machine in order to reduce or eliminate risks

concerning engine operation and the relative routine maintenance work.

• The user must read these instructions carefully. Failure to do this could lead to serious danger for his

personal safety and health and that of any persons who may be in the vicinity of the machine.

• On starting, make sure that the engine is as horizontal as possible, unless the machine specifications differ.

• Make sure that the machine is stable to prevent the risk of overturning.

• The engine must not operate in places containing inflammable materials, in explosive atmospheres, where

there is dust that can easily catch fire unless specific, adequate and clearly indicated precautions have been

taken and have been certified for the machine.

• To prevent fire hazards, always keep the machine at least one meter from buildings or from other machinery.

• Children and animals must be kept at a due distance from operating machines in order to prevent hazards

deriving from their operation.

• Thoroughly wash and clean all the external parts of the engine before performing any operation, in order to

avoid the accidental introduction of impurities/foreign bodies. Use only water and/or appropriate products to

clean the engine. If cleaning engine with a pressure washer or steam cleaner, it is important to maintain a

minimum distance of at least 200mm between the surface to be washed and the nozzle. Avoid directing the

nozzle on electrical components, cable connections and sealed rings (oil seals etc). Thoroughly wash and

clean the area surrounding the engine following the instructions provided by machine manufacturer.

• Fuel and oil are inflammable. The tank must only be filled when the engine is off. Before starting, dry any spilt

fuel.

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Kohler KDI3404TCR Owner's manual

Brand: Kohler

Model: KDI3404TCR

Category: Engine

Type: Owner's manual

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Kohler KDI3404TCR Owner's manual

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