Kohler KDI-TCP 3404 E5 User manual

ED0053033030_Rev.00
KDI-TCP 3404 E5
KDI-TCP 3404 E5 OWNER MANUAL
(REV. 00)

INDEX
EN
1General Information...............................................................................................................4
1.1 Manual's Purpose ............................................................................................................................ 4
1.2 Glossary and Definitions ................................................................................................................. 4
1.3 Emission-Related Installation Instructions................................................................................... 4
1.4 Service request ................................................................................................................................ 5
1.5 Manufacturer and engine identification ....................................................................................... 5
1.6 Engine component identification................................................................................................... 6
1.7 Cooling circuit .................................................................................................................................. 8
1.8 AdBlue®/DEF circuit ..................................................................................................................... 10
1.9 Intake and exhaust circuit ............................................................................................................ 11
1.10 Homologation labels...................................................................................................................... 13
1.11 ATS (After Treatment System) ..................................................................................................... 16
2Technical information.......................................................................................................... 17
2.1 General description of the engine ............................................................................................... 17
2.2 Engine specifications .................................................................................................................... 17
2.3 Oil .................................................................................................................................................... 18
2.4 Fuel.................................................................................................................................................. 19
2.5 AdBlue®/DEF ................................................................................................................................. 21
2.6 Coolant recommendation ............................................................................................................. 22
2.7 Battery recommendation.............................................................................................................. 22
2.8 Inducement strategy of ATS system ........................................................................................... 23
2.9 Control panel.................................................................................................................................. 25
3Safety information ............................................................................................................... 26
3.1 Safety information ......................................................................................................................... 26
3.2 General remarks ............................................................................................................................ 26
3.3 Safety signal description .............................................................................................................. 28
3.4 Information and safety signals..................................................................................................... 30
3.5 Safety and environmental impact................................................................................................ 32
4Information about use ......................................................................................................... 33
4.1 Pre-start check .............................................................................................................................. 33
4.2 Running-in period.......................................................................................................................... 33
4.3 Starting and turning off ................................................................................................................ 33
4.4 Refuelling........................................................................................................................................ 34
4.5 Oil filling .......................................................................................................................................... 35
4.6 Coolant filling ................................................................................................................................. 36
4.7 AdBlue®/DEF filling ...................................................................................................................... 36
4.8 Inducement SCR............................................................................................................................ 37
4.9 ATS regeneration strategy............................................................................................................ 38

INDEX
EN
5Information about maintenance.......................................................................................... 39
5.1 Useful information about maintenance ...................................................................................... 39
5.2 Periodic maintenance ................................................................................................................... 40
5.3 Oil level check ................................................................................................................................ 41
5.4 Air filter check................................................................................................................................ 42
5.5 Check of the radiator heat - exchanger surface ........................................................................ 42
5.6 Rubber hoses check...................................................................................................................... 43
5.7 Check coolant level ....................................................................................................................... 44
5.8 Filter cartridge and fuel pre-filter check ..................................................................................... 44
5.9 Product preservation..................................................................................................................... 45
5.10 Engine storage up to 6 months.................................................................................................... 45
5.11 Engine storage over 6 months ..................................................................................................... 46
5.12 Engine starting after storage ....................................................................................................... 46
5.13 Unused machine ............................................................................................................................ 47
6Information about replacements......................................................................................... 49
6.1 Engine oil replacement ................................................................................................................. 49
6.2 Oil filter cartridge replacement.................................................................................................... 50
6.3 Filter cartridge and fuel pre-filter replacement.......................................................................... 51
6.4 Air filter cartridge replacement.................................................................................................... 52
6.5 Replacement of AdBlue®/DEF filter............................................................................................ 53
6.6 Disposal and scrapping................................................................................................................. 53
7Information about failures................................................................................................... 54
7.1 Useful information about failures ................................................................................................ 54
8Information about warranty................................................................................................. 56
8.1 Warranty terms .............................................................................................................................. 56
9Glossary ...............................................................................................................................60
9.1 Glossary .......................................................................................................................................... 60

1GENERAL INFORMATION
EN 4
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 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.
1.3 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.

GENERAL INFORMATION
1
5 EN
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 Manufacturer and engine identification
1.1

1GENERAL INFORMATION
EN 6
1.6 Engine component identification

GENERAL INFORMATION
1
7 EN
NOTE: Some
components are for
illustrative purposes only
and may vary or they are
not supplied by Kohler.
POS.
DESCRIPTION
1
ECU
2
Air filter
3
Air inlet valve
4
Oil filler cap
5
High-pressure fuel injection pump
6
Lub. oil filter
6a
Oil cooler
7
Fuel filter
8
Oil sump
9
Oil drain plug
10
Oil dipstick
11
Radiator/Intercooler
12
Coolant filler cap
13
ATS
14
Turbocharger
15
Alternator
16
Starter motor
17
Oil steam separator
18
Flywheel
19
Coolant pump
20
Thermostatic valve

1GENERAL INFORMATION
EN 8
1.7 Cooling circuit

GENERAL INFORMATION
1
9 EN
NOTE: Some components are for illustrative purposes only and may vary or they are not supplied by Kohler.
POS.
DESCRIPTION
1
Radiator
2
Intake sleeve
3
Intake return tube
4
Intake return tube
5
Circuit for AdBlue®/DEF heating
6
AdBlue®/DEF tank
7
Coolant delivery tube in AdBlue®/DEF tank
8
Coolant delivery tube to AdBlue®/DEF injector
9
Electronic valve for coolant delivery to AdBlue®/DEF tank
10
Coolant delivery tube to SCR system
11
Coolant to radiator return sleeve
12
Coolant pump
13
SCR system control unit
14
AdBlue®/DEF Injector
15
ATS

1GENERAL INFORMATION
EN 10
1.8 AdBlue®/DEF circuit
NOTE: Some components are for illustrative purposes only and may vary or they are not supplied by Kohler.
POS.
DESCRIPTION
1
SCR system control unit
2
AdBlue®/DEF tank
3
AdBlue®/DEF pump
4
AdBlue®/DEF intake tube
5
AdBlue®/DEF delivery tube to AdBlue injector
6
Return tube in AdBlue®/DEF tank
7
AdBlue®/DEF injector

GENERAL INFORMATION
1
11 EN
1.9 Intake and exhaust circuit

1GENERAL INFORMATION
EN 12
NOTE: Some components are for illustrative purposes only and may vary or they are not supplied by Kohler.
POS.
DESCRIPTION
1
Air filter
2
Air intake sleeve
3
Turbocharger
4
Air delivery tube to Intercooler
5
Intercooler
6
Air delivery tube to intake manifold
7
Air inlet valve
8
Exhaust gas delivery hose to SCR
9
AdBlue®/DEF injector
10
ATS

GENERAL INFORMATION
1
13 EN
1.10 Homologation labels
1.10.1 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
Electronic injector opening pressure (bar)
10
Production date (example: 2013.JAN)

1GENERAL INFORMATION
EN 14
1.10.2 Label for China Standards (compilation example)
POS.
DESCRIPTION
1
Manufacturer
2
Engine model
3
Manufactoring date
4
Certificate N°
5
Power range (kW)
6
Emission level
7
Rated power
8
Aftertreat system

GENERAL INFORMATION
1
15 EN
1.10.3 Label for Korea Standards (compilation example)
POS.
DESCRIPTION
1
Tier 4 Final
2
Engine model
3
Manufactoring date and manufacturer code
4
N° Korea emission certificate

1GENERAL INFORMATION
EN 16
1.11 ATS (After Treatment System)
ATS with DOC+DPF+SCR filter
NOTE: the ATS system with DPF filter is only present for versions compliant with
"Stage V" emission regulations.
The ATS system can be installed in a different way than shown.
Tab 1.5
POS.
DESCRIZIONE
1
Turbocharger
2
Turbine exhaust
pipe
3
DOC
4
DPF
5
SCR
6
ETB

TECHNICAL INFORMATION
2
17 EN
2TECHNICAL 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
2.1
TECHNICAL DATA UNIT OF MEASURE
Engine type
KDI-TCP 3404 E5
Cylinders
n.
4
Bore
mm
96
Stroke
mm
116
Displacement
cm 3
3359
MAX INCLINATION DURING OPERATION (even in combined)
α
40° max 30 min.
α
45° max 1 min.
OIL CAPACITY (MAX level.) including oil filter
standard version
lt.
15.6
DRY WEIGHT
394

2TECHNICAL INFORMATION
EN 18
2.3 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 .
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.
E7
E4
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.

TECHNICAL INFORMATION
2
19 EN
2.4 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.
•Any failures resulting from the use of fuels
other than recommended will not be
warranted.
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.
2.3
FUEL COMPATIBILITY
EN 590 (biodiesel content max. 7% (V/V))
ASTM D 975 Grade 1-D S15
ASTM D 975 Grade 2-D S15
NATO F-54, equivalent to diesel fuel in accordance with EN 590
EN 590 or ASTM D 975 Grade 1, 2 -D S15 Arctic Diesel
JIS K 2204 N. 1, N. 2
NOTE: In a warranty case the customer must prove by a certificate from the fuel supplier that an allowed fuel
was used.
KDI Electronic Injection Tier 4 final – Stage IIIB – Stage IV- Stage V certified Engine
Those engines are designed for fuels in accordance with EN 590 and ASTM D975 for a cetane number of at least 45.
Since those engines are equipped with exhaust gas after-treatment such as Diesel Oxidation Catalyst (DOC), Diesel
Particulate Filter (DPF), Selective Catalytic Reduction (SCR), they may only be operated with sulfur-free diesel fuels
(EN 590, DIN 5168, ASTM D975 Grade 2-D S15, ASTM D975 Grade 1-D S15). Otherwise, compliance with the
emission requirements and durability are not guaranteed.
Insufficient lubricating capacity can lead to serious wear problems above all in common rail injection 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. In low-sulpur and sulfur-free diesel fuels which do not comply with this standard, the lubricating capacity may
have to be guaranteed by additives. The parameter for sufficient lubricating capacity is a maximum wear spot of 460
micrometers in the HFRR test (EN ISO 12156-1).
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.
•When paraffin forms in the diesel, the fuel filter becomes blocked interrupting the flow of fuel.
2.5.2 Biodiesel fuel
•Fuels containing 10% methyl ester or B10, are suitable for use in this engine provided that they meet the
specifications listed in the Tab. 2.3.
•DO NOT USE vegetable oil as a biofuel for this engine.
2.4

2TECHNICAL INFORMATION
EN 20
BIODIESEL COMPATIBILITY
Biodiesel according to EN 14214 (only permissible for mixture with diesel fuel at max. 10% (V/V))
US biodiesel according to ASTM D6751 – 09a (B100) (only permissible for mixtures with diesel fuel at 10% (V/V))
2.5.3 Synthetic fuels: GTL, CTL, BTL, HV
It is a well-known fact that engines which are operated for longer periods with conventional diesel fuel and then
converted to synthetic fuels suffer shrinkage of polymer seals in the injection system and thus fuel leaks. The reason
for this behavior is that the aromatic-free synthetic fuels can lead to a change in the sealing behavior of polymer seals.
Therefore, conversion from diesel fuel to synthetic fuel may only be done after changing the critical seals. The
problem of shrinkage does not occur when an engine was operated with synthetic fuel from the start.
2.5.4 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 1068.105.5.