Kohler KDI 3404TCR User manual

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

INDEX
EN

INDEX
[Titolo] EN
Confidential Communication: Information is for use only by approved users.
1General Information...............................................................................................................5
1.1 Manual's Purpose ............................................................................................................................ 5
1.2 Glossary and Definitions ................................................................................................................. 5
1.3 Emission-Related Installation Instructions................................................................................... 5
1.4 Service request ................................................................................................................................ 6
1.5 Engine component identification................................................................................................... 6
1.6 ATS (After Treatment System) ....................................................................................................... 7
1.7Manufacturer and engine identification ....................................................................................... 8
1.8 Homologation labels........................................................................................................................ 9
2Technical information.......................................................................................................... 12
2.1 General description of the engine ............................................................................................... 12
2.2 Engine specifications .................................................................................................................... 12
2.3 Engine dimensions (mm) .............................................................................................................. 12
2.4 Oil .................................................................................................................................................... 13
2.5 Fuel.................................................................................................................................................. 14
2.6 Coolant recommendation ............................................................................................................. 17
2.7 Battery recommendation.............................................................................................................. 17
2.8 Control panel.................................................................................................................................. 18
3Safety information ...............................................................................................................19
3.1 Safety information ......................................................................................................................... 19
3.2 General remarks ............................................................................................................................ 20
3.3 Safety signal description .............................................................................................................. 22
3.4 Information and safety signals..................................................................................................... 23
3.5 Safety and environmental impact................................................................................................ 25
3.6 Location of safety labels on engine............................................................................................. 25
4Information about use ......................................................................................................... 26
4.1 Pre-start check .............................................................................................................................. 26
4.2 Running-in period.......................................................................................................................... 26
4.3 Starting and turning off ................................................................................................................ 26
4.4 Refuelling........................................................................................................................................ 27
4.5 Oil filling .......................................................................................................................................... 27
4.6 Coolant filling ................................................................................................................................. 28
4.7 ATS regeneration strategy (only for KDI 3404TCR HT configurations) ................................... 29
5Information about maintenance.......................................................................................... 31
5.1 Useful information about maintenance ...................................................................................... 31
5.2 Periodic maintenance ................................................................................................................... 32
5.3 Oil level check ................................................................................................................................ 33

INDEX
EN
5.4 Air filter check................................................................................................................................ 33
5.5 Check of the radiator heat - exchanger surface ........................................................................ 33
5.6 Rubber hoses check...................................................................................................................... 34
5.7 Check coolant level ....................................................................................................................... 34
5.8 Check Poly-V alternator belt ........................................................................................................ 35
5.9 Filter cartridge and fuel pre-filter check ..................................................................................... 35
5.10 Product preservation..................................................................................................................... 36
5.11 Engine storage up to 6 months.................................................................................................... 36
5.12 Engine storage over 6 months ..................................................................................................... 36
5.13 Engine starting after storage ....................................................................................................... 37
6Information about replacements......................................................................................... 38
6.1 Engine oil replacement ................................................................................................................. 38
6.2 Oil filter cartridge replacement.................................................................................................... 39
6.3 Filter cartridge and fuel pre-filter replacement.......................................................................... 40
6.4 Air filter cartridge replacement.................................................................................................... 40
6.5 DPF filter replacement .................................................................................................................. 40
6.6 Disposal and scrapping................................................................................................................. 41
7Information about failures................................................................................................... 42
7.1 Useful information about failures ................................................................................................ 42
8Information about warranty................................................................................................. 44
8.1 Warranty terms .............................................................................................................................. 44
9Glossary ...............................................................................................................................49
9.1 Glossary .......................................................................................................................................... 49
10 California Proposition 65..................................................................................................55
10.1 California Proposition 65.............................................................................................................. 55

GENERAL INFORMATION 1
5 EN
1GENERAL 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 paragraph 4.
Fig. 5.5 - chapter 5 paragraph 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.
1.3 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.

1GENERAL INFORMATION
EN 6
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. 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).
1.5 Engine component identification

GENERAL INFORMATION
1
7 EN
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.

1GENERAL INFORMATION
EN 8
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

GENERAL INFORMATION
1
9 EN
1.8 Homologation labels
1.8.1 Label for EPA rules (compilation example)
POS.
DESCRIPTION
1
Model year in compliance with the rules
2
Power category (kW)
3
Engine displacement (L)
4
Particulate emission limit (g/kWh)
5
Engine family ID
6
Emission Control System = ECS
7
Fuel with low sulphur content
8
Injection timing
9
Injector opening pressure (bar)
10
Production date (example: 2013.JAN)

1GENERAL INFORMATION
EN 10
1.8.2 Label for China Standards (compilation example)
Tab 1.2
POS
DESCRIPTION
1
Manufacturer
2
Engine model
3
Date of manufacture
4
China emission certification no.
5
Power range (kW)
6
Emission level
7
Power
8
Post-treatment system