Kohler KDI 3404TCR-SCR, Owner'S Manual

Page 1: ...Confidential Communication Information is for use only by approved users ED0053032140_Rev_03 3 KDI 3404TCR SCR OWNER MANUAL ...

Page 2: ...INDEX EN ...

Page 3: ... 2 2 Engine specifications 19 2 3 Engine dimensions mm 19 2 4 Oil 20 2 5 Fuel 21 2 6 AdBlue 23 2 7 Coolant recommendation 24 2 8 Battery recommendation 24 2 9 Inducement strategy of SCR system 25 3 Safety information 26 3 1 Safety information 26 3 2 General remarks 26 3 3 Safety signal description 29 3 4 Information and safety signals 30 3 5 Safety and environmental impact 32 3 6 Location of safet...

Page 4: ... months 43 5 12 Engine storage over 6 months 43 5 13 Engine starting after storage 44 5 14 Unused machine 45 6 Information about replacements 47 6 1 Engine oil replacement 47 6 2 Oil filter cartridge replacement 48 6 3 Filter cartridge and fuel pre filter replacement 49 6 4 Air filter cartridge replacement 50 6 5 Replacement of AdBlue filter 51 6 6 Disposal and scrapping 52 7 Information about fai...

Page 5: ... 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...

Page 6: ...s 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 ...

Page 7: ...GENERAL INFORMATION 1 7 EN 1 5 Manufacturer and engine identification 1 1 ...

Page 8: ...1 GENERAL INFORMATION EN 8 1 6 Engine component identification ...

Page 9: ...GR Cooler 3 High pressure fuel injection pump 4 Oil cooler 5 Fuel filter 6 Oil filler side cap 7 Oil dipstick 8 AC compressor 9 Lub oil filter 10 Brake compressor 11 Thermostatic valve 12 EGR valve 13 Turbocharger 14 Air inlet valve 15 Oil steam separator 16 Alternator 17 Coolant pump 18 Starter motor 19 Oil sump 20 Flywheel 21 Oil drain plug 22 Wiring 23 Oil filler cap ...

Page 10: ...1 GENERAL INFORMATION EN 10 1 7 Cooling circuit ...

Page 11: ...TION 1 Radiator 2 Intake sleeve 3 Intake return tube 4 Intake return tube 5 Circuit for AdBlue heating 6 AdBlue tank 7 Coolant delivery tube in AdBlue tank 8 Coolant delivery tube to AdBlue injector 9 Electronic valve for coolant delivery to AdBlue tank 10 Coolant delivery tube to SCR system 11 Coolant to radiator return sleeve 12 Coolant pump 13 SCR system control unit ...

Page 12: ...1 GENERAL INFORMATION EN 12 1 8 AdBlue circuit ...

Page 13: ...e purposes only and may vary NOTE Components in Pos 4 5 6 are not supplied by Kohler POS DESCRIPTION 1 SCR system control unit 2 AdBlue tank 3 AdBlue pump 4 AdBlue intake tube 5 AdBlue delivery tube to AdBlue injector 6 Return tube in AdBlue tank 7 AdBlue injector ...

Page 14: ...1 GENERAL INFORMATION EN 14 1 9 Intake and exhaust circuit ...

Page 15: ...y NOTE Components in Pos 1 2 4 5 6 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 injector 10 SCR ...

Page 16: ...CRIPTION 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 ...

Page 17: ...TION 1 17 EN 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 ...

Page 18: ...1 GENERAL INFORMATION EN 18 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 ...

Page 19: ...rbocharger with Waste gate valve Common rail Direct injection 2 2 Engine specifications 2 1 TECHNICAL DATA UNIT OF MEASURE Engine type KDI 3404 TCR SCR 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 2 3 Engine dimensions...

Page 20: ...e 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 VISCOSITY SAE 10w 40 25 C 50 C 0w 40 40 C 50 C TCR STAGE V 1 2 TCR TIER IV FINAL 1 TCR D TIER III o...

Page 21: ...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 II...

Page 22: ...ble 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...

Page 23: ...her liquids including water and do not fill the fuel tank with AdBlue The presence of AdBlue inside the specific tank is required to start the engine Purchase in containers the container even if opened can be stocked with the same conditions of a sealed container Do not stock the container with a temperature higher than 35 C as this could alter the AdBlue In case of AdBlue freezing inside the cont...

Page 24: ...ed 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 OA...

Page 25: ...s are reset after 40h if the DCU does not detect any fault otherwise the hours are added to those already counted For low AdBlue level activation depends on the percentage of liquid inside the AdBlue tank and the fault hours are not counted The strategy for the different faults is listed below Low AdBlue level information activation on car panel 10 of MAX level Level 1 inducement 2 5 of MAX level ...

Page 26: ...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 caus...

Page 27: ...proach the engine when it is still hot as the fan could also start operating when the engine is at a standstill Important The oil must be drained whilst the engine is hot Particular care is required to prevent burns Do not allow oil to come into contact with the skin because of the health hazards involved It is recommended to use an oil intake pump During operations that involve access to moving p...

Page 28: ...ceed 15 inwards The correct tightening of the lifting screws is 25Nm Do not interpose spacers or washers between the eyebolts and engine head Provided that the above requirements are met if the lifting eyebolts are subject to permanent deformation inwards all subsequent lifting operations must be performed in order to prevent them from bending in the opposite direction 3 1 ...

Page 29: ...eration and Maintenance handbook before performing any operation on the engine Hot Parts Danger of burns Presence of rotating parts Danger of jamming or cutting Presence of explosive fuel Danger of fire or explosion Presence of steam and pressurized coolant Danger of burns Warnings Hereunder is a list of safety warnings that may be found in the manual which advise you to pay attention when carryin...

Page 30: ...tive wire HOT PARTS Hot Parts can cause severe burns Engine components can get extremely hot from operation Do not touch engine while operating or just after stopping HIGH PRESSURE FLUID RISK OF PUNCTURE High Pressure Fluids can puncture skin and cause severe injury or death Do not work on fuel system without proper training or safety equipment Fluid puncture injuries are highly toxic and hazardou...

Page 31: ...ical Shock can cause injury Do not touch wires while engine is running Never use fuel as a cleaning agent EXPLOSIVE GAS Explosive Gas can cause fires and severe acid burns Charge battery only in a well ventilated area Keep sparks open flames and other sources of ignition away from the battery at all times Batteries produce explosive hydrogen gas while being charged Keep batteries out of the reach ...

Page 32: ... 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 All components and fluids must be disposed of in accordance with the laws of the country in which disposal is taking place Keep the fuel and engine control systems and ...

Page 33: ...vehicle on which it is installed as well as personal and or property damage Increase the frequency of maintenance operations in heavy working conditions engine starts but stops very dusty and hot environments etc Check that the minimum required AdBlue quantity is present inside the AdBlue tank Refer also to the car documentation to check the AdBlue level required for engine correct operation 4 2 R...

Page 34: ...gine does not start after two attempts see Tab 7 1 and Tab 7 2 to found the cause 4 3 2 After starting Warning Make sure that all the warning lights on the control panel are off when the engine is running Run at minimum speed for a few minutes according to table except constant speed engine NOTE To avoid damaging the engine do not use it mostly at idle for a long time AMBIENT TEMPERATURE TIME 20 C...

Page 35: ...ot smoke or use open flames during the operations Fuel vapours are highly toxic Only carry out the operations outdoors or in a well ventilated place Keep your face well away from the fuel fill to prevent harmful vapours from being inhaled Dispose of fuel in the correct way and do not litter as it is highly polluting When refuelling it is advisable to use a funnel to prevent fuel from spilling out ...

Page 36: ...ck on the right to play the procedure https www youtube com embed HWCzK41Br1U rel 0 4 6 Coolant filling Important Before proceeding with operation read Par 3 2 2 NOTE Refer to the technical documentation of the vehicle Warning 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 wa...

Page 37: ...tenance intervals increases the risk of technical damage to the engine Any non compliance makes the warranty become null and void In order to prevent personal and property damage read carefully the instructions listed below before proceeding with any operation of the engine Important Before proceeding with operation read Par 3 2 2 Warning Inspections must be made when the engine is off and cold Pl...

Page 38: ...e Cartridge dry type air filter 2 Radiator heat exchange surface and Intercooler 2 Alternator belt 8 Rubber hose intake air coolant Fuel hose Starter Motor 6 Alternator 6 5 2 REPLACEMENT OPERATION DESCRIPTION PERIOD HOURS 500 2000 5000 Engine oil 1 Oil filter cartridge 1 Fuel filter and pre filter cartridge 1 AdBlue filter cartridge 1 6 11 Intake manifold hose air filter intake manifold 6 7 Coolan...

Page 39: ...ng regular visual inspection 8 The first check must be done after 10 hours 9 Test the coolant condition annually with coolant test strips 10 It is recommended to have SCA Supplemental Coolant Additives added at the first maintenance interval 11 If the AdBlue tank is not equipped with filtering system it must be replaced at 500h 5 3 Oil level check 1 Loosen the oil filler cap A Remove the oil dipst...

Page 40: ...e and remove cover A 3 clean the inside components A and D with a damp cloth 4 Do not use compressed air repeatedly tap the front side E on a flat surface 5 3 Important When the cartridge G is dirty do not clean it but replace cartridges B and G 5 Fit cartridges G and B 6 Fit cover A by performing the operations indicated in points 2 and 1 in the reverse order 5 4 5 5 ...

Page 41: ...ps Components must be replaced if they have clear signs of cracks tears cuts leaks and do not retain a certain degree of elasticity Important Before proceeding with operation read Par 3 2 2 If hoses are damaged contact an authorized KOHLER workshop For other pipes not illustrated refer to the technical documentation of the vehicle 5 3 1 Check that the Fuel system hoses A are intact Cooling circuit...

Page 42: ...nt temperature Check by the appropriate tool that at point p the tension value is between 135 and 178 Hz NOTE If the poly v belt tension results out of the above mentioned values contact KOHLER authorised workshops for replacement NOTE Belts A2 A3 are not supplied by KOHLER Refer to the technical documentation of the vehicle 5 5 5 6 5 9 Filter cartridge and fuel pre filter check Important Before p...

Page 43: ...atment Green Star Top Diesel Bardhal STP Diesel Fuel Injector Treatment 3 With expansion tank make sure that the coolant is up to the MAX level 4 Without expansion tank Top liquid up until the pipes inside the radiator are covered by about 5 mm Do not overfill the radiator but leave room for the fuel to expand 5 Start the engine and keep it idle at minimum speed for 2 minutes 6 Bring the engine to...

Page 44: ...ith hot distilled water 7 Check the AdBlue injector at an authorized Kohler workshop 8 Start the engine and keep it idle at minimum speed for a two about minutes 9 Bring the engine to 75 of MAX rated speed for 5 to 10 minute 10 Stop the engine while the oil is still hot Par 6 1 discharge the protective oil in a suitable container Warning Over time lubricants and filters lose their properties so it...

Page 45: ...tions described in point 1 Perform the operations described in Para 5 6 Start the engine at least every 4 months as per operations described in point 1a Avoid sudden accelerations for the first few minutes Bring the engine to the working temperature by pressing the accelerator 3 4 from MAX Leave the engine running at minimum speed for a few minutes and turning off the engine 2a Start up after 9 mo...

Page 46: ...lectrical or hydraulic connections 2a Start up after 9 months Before starting the engine check Para 5 2 for maintenance operations Consult the machine s manual to connect the battery and start the engine 3 over 9 months Perform the operations described in point 3 of Tab 5 3 Fill the AdBlue tank with AdBlue to the MAX level The ambient temperature must be kept between 40 and 25 C Do not disconnect ...

Page 47: ...dipstick B 3 Remove the oil drain plug D and the gasket E the oil drain plug is on both sides of the oil sump 4 Drain oil in an appropriate container For the exhausted oil disposal refer to Par 6 6 DISPOSAL and SCRAPPING 5 Replace gasket E 6 Tighten the drain oil plug D tightening torque at 50 Nm 7 Perform the operation described in Par 6 2 point 2 to 5 6 2 8 Add the type oil recommended Tab 2 1 a...

Page 48: ... turns and wait 1 minute NOTE This operation allows to oil contained in the support F to flow into the oil sump in the correct way 2 Unscrew cartridge holder cover A and check that the oil in the lub oil filter support F has flowed towards the oil sump 3 Remove the cap A as well as the oil cartridge B from the oil filter support 4 Remove and replace the oil cartridge B with a new one Remove and re...

Page 49: ...move the water presence sensor C from its cartridge B 3 Loosen the cartridge B using the appropriate wrench Fig 6 8 4 Lubricate the gasket D of the new cartridge B Important Do not fill the new cartridge B with fuel 5 Tighten the new empty cartridge B Fig 6 8 on the diesel fuel filter support E using the special wrench tightening torque of 17 Nm 6 Tighten the water presence sensor C on the new car...

Page 50: ...peration read Par 3 2 2 NOTE Component not necessarily supplied by KOHLER 1 Pull insert F to unlock cover A 2 Rotate counter clockwise and remove cover A 6 9 3 Remove the cartridges B and G 4 Fit cartridges G and B 5 Fit cover A by performing the operations indicated in points 2 and 1 in the reverse order 6 10 ...

Page 51: ...starting any operations make sure the key on the machine s panel is OFF and the AdBlue pump has executed the circuit emptying operation 1 Loosen cap B 6 11 2 Remove cap B and extract filter bracket C 3 Extract filter D 4 Use warm AdBlue to clean the seat of filter D on pump E if impurities are detected 5 Lubricate the A gaskets with AdBlue or distilled water 6 Place the filter bracket C together w...

Page 52: ...o separate the rubber or plastic parts from the rest of the components The parts only composed of plastic material aluminium and steel can be recycled if collected by the appropriate centers Waste oil must properly be recycled and disposed of in the correct way to safeguard the environment According to the laws in force it is classified as hazardous waste therefore it must be collected by the appr...

Page 53: ... battery terminals corroded Clean the battery terminals Battery voltage too low Recharge the battery or replace it Low fuel level Refuel 4 4 Frozen fuel Contact KOHLER authorised workshops Clogged fuel filter Replace with a new filter 6 3 Air suction in fuel system Contact KOHLER authorised workshops Clogged air filter Replace with a new filter 6 4 Clogged pipes Contact KOHLER authorised workshops...

Page 54: ...ntact KOHLER authorised workshops Engine lost its initial performance Clogged air filter Replace with a new filter 6 4 Clogged fuel pipes Contact KOHLER authorised workshops Cheap fuel Clean the tank and refuel with quality fuel High oil sump level Replace the engine oil if the problem persists Contact KOHLER authorised workshops Slow acceleration Clogged fuel filter Replace the fuel filter 6 3 En...

Page 55: ...imited 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 SPARE PARTS WARRANTY PERIOD OPERATING HOURS WARRANTY COVERAGE KOHLER and Lombardini Diesel Parts 2 Years 0 2 000 100 Parts Labor Parts components that are scheduled to be replaced as par...

Page 56: ...t of Authorized dealers can be found by visiting www kohlerengines com or telephone 1 800 544 2444 U S A and Canada ENGINE DIVISION Kohler Co Kohler Wisconsin EUROPE MIDDLE EAST AND ASIA List of Authorized dealers can be found by visiting dealers kohlerpower it CENTRAL AND SOUTH AMERICA List of Authorized dealers can be found by visiting dealers kohlerpower it CHINA AND ASIA PACIFIC List of Author...

Page 57: ... result of a warrantable failure an exhaust emission part component will be covered under the warranty provisions described herein 6 MAINTENANCE AND REPAIR REQUIREMENTS The owner is responsible for the proper use and maintenance of the engine Kohler Co recommends that all receipts and records covering the performance of regular maintenance be retained in case questions arise If the engine is resol...

Page 58: ...ated part on your engine is defective the part will be repaired or replaced by Kohler Co VARIABLE SPEED OR CONSTANT SPEED KW 19 ANY SPEED 1 500 HOURS OR TWO YEARS WHICHEVER COMES FIRST Constant speed 19 kW 37 3 000 rpm or higher 1 500 hours or two years whichever comes first Constant speed 19 kW 37 Less than 3 000 rpm 3 000 hours or five years whichever comes first Constant speed 19 kW 37 Any spee...

Page 59: ...the parameters detected by the different sensors E EC European Community ECS Emission Control System ECU Electronic Control Unit an electronic device in charge of electronically detecting and controlling other electronic control devices EGR Exhaust Gas Recirculation in internal combustion engines a system that enables recirculation of combusted gas by means of taking it in once again which enables...

Page 60: ... under pressure from the turbo situated between the turbine and intake manifold K KDI Kohler Direct Injection M Maintenance periodic A group of maintenance actions that have the sole objective to control and replace elements on their expiry without modifying or improving the functions carried out by the system neither increasing the value nor improving performance Max Maximum Methyl ester It is a ...

Page 61: ...indicating the engine version T Tab Table T MAP T MAP sensor measures the temperature and absolute pressure inside the intake collector TCR Turbo Common Rail Tightenin g torque A term indicated for installation of threaded components and which is determined by means of a unit of measurement Nm Turbocha rger Device that compresses air intake by sending it to the intake manifold by means of a turbin...

Page 62: ...er hour 1 Lt h ppm parts per million Percentage 1 ppm N newton Force 1 N A Ampere Intensity of electrical current 1 A gr gramme Weight 1 gr kg kilogramme 1 kg W Watt Power 1 W kW kiloWatt 1 kW pa pascal Pressure 1 pa KPa Kilopascal 1 KPa bar barometric pressure 1 bar mbar 1 1000 bar barometric pressure 1 mbar R Resistance Resistance to electrical current referred to a component 1 Ω Ω ohm Resistanc...

Page 63: ...GLOSSARY 9 63 EN ...

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