Kohler KDI 3404 TCR Owner's Manual

KDI 3404 TCR

OWNER MANUAL

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

Technical

Documentation

ED0053030050 51322 08 07 10/2014 05/2017

Data reported in this issue can be modified at any time by KOHLER.

Model

N°

Edition Revision Issue date

Review

date

Translated from the original manual in Italian language.

Edited by Endorsed

Technical

Documentation

Important

Connect to http://iservice.lombardini.it > KDI KOHLER DIESEL section > login a s a guest "Enter a s a guest" > "TECHNICAL
DOCUMENTATION" > select "KDI 3404 TCR" and download the latest version of this manual onto your device.

NOTE: you can select the desired language before downloading the manual, as shown in the figure below.

The online manuals are provided with hyperlinks which direct you to each individual chapter. By clicking on;

- The analytic index titles you can go directly to the selected subject.

- The blue underlined words you can go directly to a paragraph, a table or a picture.

- The chapter titles (headings) you come back automatically to the chapter initial page.

- Clicking next to the bottom page number you come back to the analytic index.

2

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INDEX

1 - GENERAL INFORMATION

1.1 Manual's Purpose ................................................................. 6

1.2 Glossary and Definitions

1.3 Emission-Related Installation Instructions

1.4 Service request

...............................................................6

1.5 Engine component identification

1.6 Manufacturer and engine identification

1.7 Homologation labels

1.7.1 Label for EPA rules ................................................................ 9

1.7.2 Label for China Standards

1.7.3 Label for Korea Standards

................................................6

..................6

..................................7

.......................8

.......................................................9

................................................. 10

................................................. 10

2 - TECHNICAL INFORMATION

2.1 General description of the engine ..............................12

2.2 Engine specifications

2.3 Engine dimensions (mm)

2.4 Oil....................................................................................13

2.4.1 SAE oil classification .......................................................... 13

2.5 Fuel ................................................................................. 13

2.5.1 Fuel for low temperatures .................................................. 13

2.5.2 Biodiesel fuel

2.5.3 Emission-Related Installation Instructions

2.6 Coolant recommendation ............................................15

2.7 Battery recommendation

2.8 Control panel

.................................................................15

...................................................12

..............................................12

....................................................................... 14

.................... 14

.............................................15

4 - INFORMATION ABOUT USE

4.1 Pre-start check .............................................................21

4.2 Running-in period

4.3 Starting and turning off

4.3.1 Starting .................................................................................21

4.3.2 After starting

4.3.3 Turning off

.........................................................21

...............................................21

...................................................................... 21

........................................................................... 21

4.4 Refuelling .......................................................................22

4.5 Oil filling

4.6 Coolant filling

.........................................................................22

................................................................23

5 - INFORMATION ABOUT MAINTENANCE

5.1 Useful information about maintenance ......................24

5.2 Periodic maintenance

5.3 Oil level check

5.4 Air filter check

...............................................................25

...............................................................25

5.5 Check of the radiator heat - exchanger surface

5.6 Rubber hoses check

5.7 Check coolant level.......................................................26

5.8 Check Poly-V alternator belt

5.9 Filter cartridge and fuel pre-filter check

5.10 Product preservation

5.11 Engine storage up to 6 months

5.12 Engine storage over 6 months

5.13 Engine starting after storage.....................................28

..................................................24

.......26

.....................................................26

.......................................27

....................27

..................................................28

..................................28

...................................28

3 - SAFETY INFORMATION

3.1 Safety information ........................................................16

3.2 General remarks

3.2.1 Note for OEM ....................................................................... 16

3.2.2 Note for end user

3.3 Safety signal description .............................................18

3.3.1 Adhesive safety plates ....................................................... 18

3.3.2 Safety guards

3.3.3 Warnings

3.4 Information and safety signals .................................... 19

3.5 Safety and environmental impact

3.6 Location of safety labels on engine

...........................................................16

................................................................ 16

...................................................................... 18

.............................................................................. 18

.................................... 19

............................20

6 - INFORMATION ABOUT REPLACEMENTS

6.1 Engine oil replacement ................................................29

6.2 Oil filter cartridge replacement...................................30

6.3 Filter cartridge and fuel pre-filter replacement

6.4 Air filter cartridge replacement

..................................31

........31

6.5 Disposal and scrapping................................................32

7 - INFORMATION ABOUT FAILURES

7.1 Useful information about failures ................................33

8 - INFORMATION ABOUT WARRANTY

8.1 Info ..................................................................................34

9 - GLOSSARY

9.1 G lossary .........................................................................37

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ANALYTICAL INDEX

A

Adhesive safety plates .......................................................18

After starting
Air filter cartridge replacement
Air filter check

.......................................................................21

.........................................31

.....................................................................25

B

Battery recommendation ...................................................15

Biodiesel fuel

.......................................................................14

C

Check coolant level .............................................................26

Check of the radiator heat - exchanger surface
Check Poly-V alternator belt
Control panel
Coolant filling
Coolant recommendation

.......................................................................15

......................................................................23

..............................................27

..................................................15

.............26

D

Disposal and scrapping ......................................................32

H

Homologation labels .............................................................9

I

Info ........................................................................................34

Information and safety signals

..........................................19

L

Label for China Standards .................................................10

Label for EPA rules
Label for Korea Standards
Location of safety labels on engine

...............................................................9

.................................................10

..................................20

M

Manual's Purpose .................................................................6

Manufacturer and engine identification

.............................8

N

Note for end user ................................................................16

Note for OEM

.......................................................................16

O

E

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

Emission-Related Installation Instructions
Engine component identification
Engine dimensions (mm)
Engine oil replacement
Engine specifications
Engine starting after storage
Engine storage over 6 months
Engine storage up to 6 months

....................................................12

......................................................29

.........................................................12

........................................7

............................................28

...........................................28

.........................................28

......................14

F

Filter cartridge and fuel pre-filter check ..........................27

Filter cartridge and fuel pre-filter check

.......................................................................................13

Fuel
Fuel for low temperatures

..................................................13

..........................31

G

General description of the engine ....................................12

General remarks
Glossary
Glossary and Definitions

...............................................................................37

..................................................................16

......................................................6

Oil ..........................................................................................13

Oil filling
Oil filter cartridge replacement
Oil level check

...............................................................................22

.........................................30

.....................................................................25

P

Periodic maintenance .........................................................24

Pre-start check
Product preservation

...................................................................21

..........................................................28

R

Refuelling .............................................................................22

Rubber hoses check
Running-in period

...........................................................26

...............................................................21

EN

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ANALYTICAL INDEX

S

SAE oil classification ..........................................................13

Safety and environmental impact
Safety guards
Safety information
Safety signal description
Service request
Starting
Starting and turning off

......................................................................18

..............................................................16

...................................................18

.....................................................................6

................................................................................21

......................................................21

T

Turning off ............................................................................21

U

Useful information about failures .....................................33

Useful information about maintenance

.....................................19

............................24

W

Warnings .............................................................................. 18

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Index

1.1 Manual's purpose

GENERAL INFORMATION

- 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
proper ty of KOHLER. As such, no rep roduction or replic ation
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.
Ex: 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.

1.4 Service request

- The complete and updated list of authorized Kohler Co. service centers can be found on websites:

www.kohlerengines.com & www.lombardinigroup.it/dealer-locator.

- 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).

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1.5 Engine component identification

Index

GENERAL INFORMATION

1

Side view A

Turbocharger

Valve EGR

Thermostatic valve

Coolant

temperature

sensor

Alternator

Coolant

pump

Fuel filter

Nameplate

Oil drain plug

Oil steam separator

EGR Cooler

Oil pressure sensor

High injection pump

Oil cooler

Oil filter

Oil dipstick

Prefilter (type B)

Side view B

EGR Cooler

Oil steam separator

Electric fuel pump

Prefilter (type A)

Oil filler cap

Turbocharger

Alternator

Nameplate

Starter motor

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Oil drain plug

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Index

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

Peak

rpm

Engine type

Engine serial number

Manufacturer identification

Engine

version

Approval data and

"EC" directives

EN

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1.7 Homologation labels

Index

1.7.1 Label for EPA rules

GENERAL INFORMATION

1

1

2

3

8

9

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 (*BTDC)
9 Injector opening pressure (bar)

Production date (example: 2013.JAN)

10

4

5

6

7

10

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Index

1.7.2 Label for China Standards

GENERAL INFORMATION

1

3

5

7

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

2

4

6

8

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1.7.3 Label for Korea Standards

Index

GENERAL INFORMATION

1

1 4

2

POS. DESCRIPTION

1 Tier 4 Final
2 Engine model
3 Date of manufacture and manufacturer code
4 Korea emission certification no.

3

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Index

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

2.1

TECHNICAL DATA

ENGINE TYPE
CYLINDERS n. 4
BORE mm 96
STROKE mm 116
DISPLACEMENT cm

MAX INCLINATION DURING OPERATION
(EVEN IN COMBINED)

OIL CAPACITY
(MA X LEVEL.)
INCLUDING OIL
FILTER

DRY WEIGHT Kg 394

standard version lt. 15.6

UNIT

OF MEASURE

3

a

a

KDI 3404 TCR

3359

40° max. 30 minutes

45° max.1 minute

2.3 Engine dimensions (mm)

579.5

726

816

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2.4 Oil

Index

TECHNICAL INFORMATION

2

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 (Par. 2.4.1).

2.4.1 SAE oil classification

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

2.2

RECOMMENDED OIL

VISCOSITY SAE

WITH

SPECIFICATIONS

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 Par. 6.5 DISPOSAL

and SCRAPPING.

• The code is made up of two numbers. The first number
refers to the viscosity when cold, for use during winter
("W"= winter), while the second number is for viscosity at
high temperatures.

5W-30 (≥ -25°C)
0W-30 (< -25°C)

API CJ-4

ACEA

E6 - E7 - E9

LOW S.A.P.S.

N. B.: Low S.A.P.S. technology (fuel with low Sulphate, Phosphorous, Sulphur content) keeps catalyst

in working conditions. The presence of sulfate, phosphorus and sulfur ashes causes with time the
catalyst clogging and its consequent inefficiency.

CLASSIFICATION DESCRIPTION ACEA SPECIFICATION

E6 Long drain LOW S.A.P.S.
E7 High power over long distances (Euro 4 - 5 engines)
E9 Long drain MID S.A.P.S.

2.5 Fuel

Important

• Use the same type of diesel fuel as used in cars (EN 590 for
E.U. - ASTM D975 regulation - S 15 for U.S). 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.

• 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.

Warning

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.

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Index

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.

2.3

EN 590, DIN 51628 (S = 10 ppm)
Military NATO Fuel F-54 (S = 10 ppm)

TECHNICAL INFORMATION

FUEL COMPATIBILITY

ENGINE VERSION

TCR TCR/D TIERIII

Compatible Compatible

yes no yes no

Bio Fuels EN 14214 B10 (10% methyl ester)

Arctic Fuel (EN 590, ASTM D 975)

No 1 Diesel (US) ASTM D 975 Grade 1-D S 15 (S = 15 ppm)
No 1 Diesel (US) ASTM D 975 Grade 1-D S 500 (S = 500 ppm)
No 2 Diesel (US) ASTM D 975 Grade 2-D S 15 (S = 15 ppm)
No 2 Diesel (US) ASTM D 975 Grade 2-D S 1500 (S = 1500 ppm)

High Sulphur Fuel S < 2000 ppm (< 0,2%)
High Sulphur Fuel S > 2000 ppm (> 0,2%)

Civil Jet Fuels Jet A/A1 (kerosene)
Military Nato Fuel F-35 (kerosene)
Military Nato Fuel F-34 + additives (JP8)
Civil Jet Fuels Jet B
Military Nato Fuel F-40 – JP4

(1) With lubricity doser

(1)

2.5.3 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.

EN

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TECHNICAL INFORMATION

Index

2.6 Coolant recommendation

2.4

TECHNICAL SPECIFICATIONS

50% ETYLENGLYCOL E 50% DECALCIFIED WATER

50% PROPYLENGLYCOL E 50% DECALCIFIED WATER

OAT/HIBRID TECHNOLOGY (ASTM 3306)

2.7 Battery recommendation

Battery not supplied by Kohler

2.5

RECOMMENDED BATTERIES

AMBIENT TEMPERATURE BAT TERY TYPE

≥ - 15°C

< -15°C

120 Ah/20 h - 1000 CCA /SAE

130 Ah/20 h - 1100 CCA/SAE

2

2.8 Control panel

Tab. 2.6 shows the control panel components.

2.6

POS. DESCRIPTION

A Switch key to start the panel and motor
B Engine data or errors display
C Top navigation menu arrow push button
D Bottom navigation menu arrow push button
E Data selection or entry push button

F

: if LED F is red, contact authorised

NOTE

Tab. 2.7 shows data that can be consulted on display B by
pressing push buttons C or D.

: data described in Tab. 2.7 can differ,

NOTE

Engine operating status

(green = no problem detected)

KOHLER workshops to know what
type of problem it is. Certain problems
automatically switch off the engine.

therefore, consult the machine's manual.

F

B

C

A

D

E

2.7

DESCRIPTION

Operating hours

Hours left for maintenance

Engine rpm

Engine oil pressure

Coolant temperature

Torque used @ rpm (% used)

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Index

3.1 Safety information

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.

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 app roval to a modification is not gra nted, KOHLER
shall not be deemed responsible for any consequential
failures or damages to the engine.

• The engine may only be assembled on a machine by

3.2.2 Note for end user

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

personnel specifically trained by KOHLER and who work in
compliance with the existing documentation.

• The engine has been built to the specifications of a machine
manufacturer, and it is his responsibility to ensure that all
necessary action is taken to meet the essential and legally
prescribed health and safety requirements. Any use of the
machine other than that described cannot be considered
as complying with its intended purpose as specified by
KOHLER, which therefore declines all responsibility for
accidents caused by such operations.

• 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 200 mm bet ween the su rfa ce to be washe d and the noz zle.
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.

• Make sure that no soundproofing panels and the ground or
floor on which the machine is standing have not soaked up
any fuel.

• Fuel vapour is highly toxic. Only refuel outdoors or in a well
ventilated place.

• Do not smoke or use open flames when refuelling.

• During operation, the surface of the engine can become
dangerously hot. Avoid touching the exhaust system in
particular.

• Before proceeding with any operation on the engine, stop it
and allow it to cool.

• Always open the radiator plug or expansion chamber with
the utmost caution, wearing protective garments and
goggles.

• The coolant fluid is under pressure. Never carry out any
inspections until the engine has cooled.

• If there is an electric fan, do not approach the engine when
it is still hot as the fan could also start operating when the
engine is at a standstill.

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SAFETY INFORMATION

Index

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 parts of
the engine and/or removal of rotating guards, disconnect
and insulate the negative wire (-) of the battery to prevent
accidental short-circuits and to stop the starter motor from
being energized.

• Check belt tension only when the engine is off.

• Fully tighten the tank cap each time after refuelling. Do not
fill the tank right to the top but leave an adequate space for
the fuel to expand.

• To start the engine follow the specific instructions provided
in the engine and/or machine operating manual. Do not
use auxiliary starting devices not originally installed on the
machine (e.g. Startpilot).

• Before starting, remove any tools that were used to service
the engine and/or machine. Make sure that all guards have
been refitted.

• Do not mix fuel with elements such as oil or kerosene.
Failure to comply with this prohibition will cause the non­operation of the catalyst and non-observance of the
emissions declared by KOHLER.

• Pay attention to the temperature of the oil filter when the
filter itself is replaced.

3

• Only check, top up and change the coolant fluid when
the engine is off and reached the ambient temperature.
Coolant fluid is polluting, it must therefore be disposed of
in the correct way.

• Do not use air and water jets at high pressures on cables,
connectors and injectors.

Important

• Only use the eyebolts A installed by KOHLER to move the
engine (Fig. 3.1).

• The angle between each lifting chain and the eyebolts shall
not exceed 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.

α ≤ 15°

A

α ≤ 15°

A

3.1

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Index

3.3 Safety signal description

SAFETY INFORMATION

• To ensure safe operation please read the following
statements and understand their meaning.

• Also refer to your equipment manufacturer's manual for
other important safety information.

3.3.1 Adhesive safety plates

The following is a list of the adhesive safety plates that may
be found on the engine, which indicate potential points of
danger to the operator (Par. 3.6).

Read the Operation and Maintenance handbook before
performing any operation on the engine.

Hot Parts.
Danger of burns.

Presence of rotating parts.
Danger of jamming or cutting.

• This manual contains safety precautions which are
explained below.

• Please read them carefully.

3.3.2 Safety guards

Hereunder is a list of safety guards that must be worn prior
to carrying out any type of operation and to avoid potential
harm to the operator.

Use protecti ve gloves before carr ying out the operati on.

Use protective glasses before carrying out the
operation.

Use sound absorbing protections before carrying out
the operation.

Presence of explosive fuel.
Danger of fire or explosion.

Presence of steam and pressurized coolant.
Danger of burns.

Lifting point.

Electrical shock.
Danger of severe scalding or death.

High pressure fluid.
Danger of fluid penetration.

Lethal Exhaust Gases.
Danger of poisoning or death.

3.3.3 Warnings

Hereunder is a list of safety warnings that may be found in
the manual, which advise you to pay attention when carrying
out particular procedures that may be potentially dangerous
to the operator or things.

Danger

• This indicates situations of grave danger which, if ignored,

may seriously threaten the health and safety of individuals.

Important

• This indicates particularly important technical information

that should not be ignored.

EN

18

Warning

• This indicates that failure to comply with it can cause minor

damage or injury.

ED0053030050

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3.4 Information and safety signals

Index

SAFETY INFORMATION

3

ACCIDENTAL START

Accidental Starts can cause

Before working on the engine or equipment, disconnect the
batter y negative (-) wire.

Engine components can get extremely hot from operation.
Do not touch engine while operating or just after stopping.
Never operate the engine with heat shields or guards
removed.

Stay away while engine is in operation. Keep hands, feet,
hair, and clothing away from all moving parts to prevent
injury.
Never operate the engine with covers, shrouds, or guards
removed.

LETHAL EXHAUST GASES

Avoid inhaling exhaust fumes and never run the engine in a
closed building or confined area.
Carbon monoxide is toxic, odorless, colorless, and can
cause death if inhaled.

Do not touch wires while engine is running.

severe injury or death.

HOT PARTS

Hot Parts can cause severe
burns.

ROTATING PARTS

Rotating Parts can cause
severe injury.

Carbon Monoxide can cause
severe nausea, fainting or
death.

ELECTRICAL SHOCK

Electrical Shock can cause
injury.

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 hazardous.
If an injury occurs, seek immediate medical attention.

EXPLOSIVE FUEL

Explosive fuel can cause fires
and severe burns.

Fuel is flammable and its vapours can ignite.
Store fuel only in approved containers, in well ventilated,
unoccupied buildings.
Do not fill the fuel tank while the engine is hot or running,
since spilled fuel could ignite if it comes in contact with hot
parts or sparks from ignition.
Do not start the engine near spilled fuel.
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 of children.
Remove all jewelry when servicing batteries. Before
disconnecting the negative (-) ground cable, make sure all
switches are OFF.
If ON, a spark will occur at the ground cable terminal which
could cause an explosion.

CALIFORNIA

WARNING - DECLARATION 65

Engine exhaust f rom this product con tains chemicals k nown
to the State of California to cause cancer, birth defects, or
other reproductive harm.

3.5 Safety and environmental impact

Every organisation has a duty to implement procedures to
identify, assess and monitor the influence of its own activities
(products, services, etc.) on the environment.
Procedures for identifying the extent of the impact on the
environment must consider the following factors:

- Liquid waste.

- Waste management.

- Soil contamination.

- Atmospheric emission.

- Use of raw materials and natural resources.

- Regulations and directives regarding environmental impac t.

ED0053030050

_07

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 compo nents and fluids must b e disposed of in acc ordance
with the laws of the country in which disposal is ta king place.

- Keep the fuel and engine control systems and the exhaust
pipes in efficient working order to limit environmental and
noise pollution.

- When discontinuing use of the engine, select all compone nts
according to their chemical characteristics and dispose of
them separately.

19

EN

3

Index

SAFETY INFORMATION

3.6 Location of safety labels on engine

EN

20

ED0053030050

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INFORMATION ABOUT USE

Index

4

4.1 Pre-start check

Important

• Read carefully the following pages and carry out the operations described below in accordance with the instructions specified.

• 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.

• Increase the frequency of maintenance operations in heavy working conditions (engine starts but stops, very dusty and hot

environments, etc...).

4.2 Running-in period

NOTE: For the first 50 hours of engine operation, it is advisable not to exceed 75% of the maximum power

supplied.

4.3 Starting and turning off

4.3.1 S tarti ng

1. Check the level of the engine oil, fuel and coolant and fill if necessary (Par. 4.5 and Par. 4.6).

2. Put the ignition key in the ignition switch (if supplied).

3. Tu n the key to ON position.

4. Tu rn the key beyond the ON position and release it when the engine starts (the key will return into ON position automatically).

Important

• Do not actuate the starter for more than 15 seconds at a time. If the engine does not start, wait for one minute before repeating

attempt.

• If engine does not start after two attempts see Tab. 7.1 and Tab. 7.2, to locate 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).

AMBIENT TEMPERATURE TIME

≤ -20°C 2 minutes

from -20° C to -10°C 1 minutes

from -10° C to -5° C 30 seconds

from -5° C to 5° C 20 seconds

≥ 5° C 15 seconds

4.3.3 Turning off

1. Do not turn off the engine when it is running at the maximum rotation speed (except constant speed engine).

2. Before turning it off, keep it idle at minimum speed for about 1 minute.

3. Tu rn the key to OFF position.

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21

EN

4

Index

INFORMATION ABOUT USE

4.4 Refuelling

Important

• Before proceeding with operation, read Par. 3.2.2.

Danger

• Fill the engine off.

• The only approved fuels are those listed in Tab. 2 .3.

• 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.

• 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.The fuel should also be filtered to prevent dust
or dirt from entering the tank.

• Do not overfill the fuel tank. Leave room for the fuel to expand.

NOTE: At the first fuelling or if the tank was empty filling the fuel system (Par. 6.3 point 8).

4.5 Oil filling

Important

• For safety precautions see Par. 2.4.

• Before proceeding with operation, read Par. 3.2.2.

1. Loosen the oil filler cap A.

2. Add the type oil recommended (Tab. 2 .1 and Tab. 2 .2 ).

3. Before checking oil engine needs to be level.

4. Remove the oil dipstick B and check that the level is up to

but does not exceed the

5. If level is not at the MAX. level, add additional oil.

MAX

.

4.1

A

B

B

6. Re-tighten the cap A.

Important

• Do not use the engine with the oil level below the minimum.

22

EN

4.2

MAX

MIN

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4.6 Coolant filling

Index

INFORMATION ABOUT USE

4

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 water.

• As well as lowering the freezing point, the antifreeze also

raises the boiling point.

• A 50% mixture is recommended to ensure a general level

at protection prevents the formation of rust, galvanic

currents and calcium deposits (Tab. 2.4).

ED0053030050

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23

EN

5

Index

INFORMATION ABOUT MAINTENANCE

5.1 Useful information about maintenance

• This chapter shows all operations described in the Tab.

5.1 and Tab. 5.2 if you have the skills appropriate may be
directly carried out by the user.

• Before proceeding with operation, read Par. 3.2.2.

Important

• Periodic inspection and maintenance operations must
be carried out as indicated in this manual and are the
responsability of the user.

• Failure to comply with these service and maintenance
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.

• Inspections must be made when the engine is off and cold.

• Place engine on level surface to ensure accurate
measurement of oil level.

• Before starting, to avoid spillages of oil make sure that:

- the oil dipstick is inserted correctly;

- also check that:

oil drain plug and; oil filler cap are tightened firmly.

Warning

5.2 Periodic maintenance

The intervals of preventive maintenance in Tab. 5.1, Tab. 5.2 and Tab. 5.3 refer to the engine operating under normal operating
conditions with fuel and oil meeting the recommended specifications.

5.1

OPERATION DESCRIPTION

Engine oil level
Coolant level /

Check of the radiator heat-exchanger surface
Cartridge dry-type air filter

(2)

Radiator heat-exchange surface and Intercooler
Alternator belt tension

(5) (8)

Rubber hose (intake air / coolant)
Fuel hose
Starter Motor
Alternator

(6)

(6)

5.2

OPERATION DESCRIPTION

Fuel prefilter Type A
Fuel prefilter Type B
Fuel filter cartridge
Coolant

(4) (6)

(1)

(1) (6 )

(1)

Intake manifold hose (air filter - intake manifold)
Coolant hoses
Fuel line hose

Alternator belt

(6) (7)

(6) (7)

Poly-V belt heavy environmental condition
Poly-V in condizioni normale

Dry air cleaner external cartridge

CLEANING AND CHECKING

PERIOD (HOURS)

10 250 500 1000 1500 5000

PAR.

5.3

(2)

Components not supplied by KOHLER.

Refer to the technical documentation of the

(2)

vehicle

5.7

5.5

5.4

5.5

5.8

5.6

--

--

--

REPLACEMENT

PERIOD (HOURS)

10 250 500 1000 1500 5000

PAR.

--

6.3

--

(6) (7)

--

--

--

(6)

(6)

(2)

After 6 checks with cleaning 6.4

--

EN

24

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INFORMATION ABOUT MAINTENANCE

Index

5

5.3

1. In case of low use: 12 months.

2. The period of time that must elapse before checking

the filter element depends on the environment in which
the engine operates. The air filter must be cleaned and
replaced more frequently under very dusty conditions.

3. In case of low use: 36 months.

4. In case of low use: 24 months.

ENGINE OIL AND OIL FILTER CARTRIDGE REPLACEMENT

ENGINE VERSION

(1)

TCR

TCR/D TIERIII

(1)

PERIOD (HOURS)

250 500

5. Not Poly-V type.

6. The replacement must be carried out by authorized

KOHLER workshops.

7. The replacement interval is only an indication, it strongly
depends from environmental condition and hose status
detected during regular visual inspection.

8. The first check must be done after 10 hours.

PAR.

6.1

6.2

5.3 Oil level check

1. Loosen the oil filler cap A.
Remove the oil dipstick B and check that the level is up
to MAX.

2. Pour in recommended oil until reaching the MAX level
mark.

3. Reinstall the oil dipstick B completely.

4. Re-tighten the cap A (Fig. 5.2).

Important

• Do not use the engine with the oil level below the minimum.

B B

MAX

MIN

5.1

A

5.2

5.4 Air filter check

NOTE: Component not supplied by KOHLER.
Refer to the technical documentation of the vehicle.

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25

EN

5

Index

INFORMATION ABOUT MAINTENANCE

Danger

• For safety precautions see Cap. 3.

5.5 Check of the radiator heat-exchanger surface

NOTE: Component not necessarily supplied by KOHLER.

5.6 Rubber hoses check

The check is carried out by exerting a slight deflection or
bending along the pipe and near the hose clamps.

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.

1. Check that the:

- Fuel system hoses A are intact.

-

- Cooling circuit hoses B.

-

- Vent system pipes C.

5.3

A

C

B

A

B

A

A

5.7 Check coolant level

NOTE: Component not supplied by KOHLER.
Refer to the technical documentation of the vehicle.

26

EN

5.4

ED0053030050

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5.8 Check Poly-V alternator belt

Index

INFORMATION ABOUT MAINTENANCE

5

NOTE: The poly-v belt is not adjustable.

1. Check the belt A condition, if worn out or deteriorated,
replace it.

NOTE: Make sure that the ribs of the belt A are

inserted correctly into the grooves of the
pulleys B (as shown in D1 and D2).

2. Start the engine and run it for some minutes, then turn
off it, and let it cool down at ambient 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.

B

B

P

A

B

5.5

D2

5.9 Filter cartridge and fuel pre-filter check

When turn on lights on control water filter cartridge fuel:

1. Gently loosen the wing screw A without removing it.

2. Drain the water if present.

3. Re-tighten the wing screw A as soon as the fuel begins

to flow.

5.6

5.7

D1

A

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27

EN

5

Index

INFORMATION ABOUT MAINTENANCE

5.10 Product preservation

Important

• If the engines are not to be used for 6 months, they must
be protected by carrying out the operations described in
Engine storage (up to 6 months) (Par. 5.11).

• If the engine is still not in use after the first 6 months, it
is necessary to carry out a further operation to extend the
protection period (more than 6 months) (Par. 5.12).

• If the engine is not to be used for an extended period, the
protective treatment procedure must be repeated within 24
months of the previous one.

5.11 Engine storage up to 6 months

Before storing the engine check that:

• The environments are not humid or exposed to bad weather.
Cover the engine with a proper protective sheet against
dampness and atmospheric contaminants.

• The place is not near electric panel.

• Avoid storing the engine in direct contact with the ground.

5.12 Engine storage over 6 months

Follow the steps described in Par. 5.11.

1. Engine oil replacement (Par. 6.1).

11. When cleaning the engine, if using a pressure washer

or steam cleaning device, avoid directing the nozzle on
electrical components, cable connections and sealed
rings (oil seals etc). 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 - avoiding absolutely
electrical components such as alternators, starter motors
and engine control units (ECU).

12. Treat non-painted parts with protective products.

If the engine protection is performed according to the
suggestions indicated no corrosion damage should occur.

5.13 Engine starting after storage

1. Remove the protective sheet.

2. Use a cloth soaked in degreasing product to remove the

protective treatment from the external parts.

3. Inject lubricating oil (no more than 2 cm3) into the intake
ducts.

4. Refill the tank with fresh fuel.

5. Make sure that the oil and the coolant are up to the

maximum level.

6. Start the engine and keep it idle at minimum speed for a
two about minutes.

2. Refuel with fuel additives for long storage.
The following additives are recommended:
DEFA Fluid Plus (Pakelo Lubricants),
Diesel Treatment (Green Star),
Top Diesel (Bardhal),
STP® Diesel Fuel Injector Treatment.

3. With expansion tank: make sure that the coolant is up to
the maximum 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 3/4 of the maximum speed for 5÷10
minutes.

7. Turn off the engine.

8. Completely empty the fuel tank.

9. Spray SAE 10W-40 on the exhaust and intake manifolds.

10. Seal the exhaust and intake ducts to prevent foreign

bodies from entering.

7. Bring the engine to 75% of maximum rated speed for 5 to
10 minute.

8. 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 is

important consider whether they need replacing, also based

on the criteria described in Tab. 5.2.

9. Replace the filters (air, oil, fuel) with original spare parts.

10. Pour new oil (Par. 4.5) up to the maximum level.

11. Empty the cooling circuit completely and pour in the new

coolant up to the maximum level (Par. 4.6).

EN

28

ED0053030050

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INFORMATION ABOUT REPLACEMENTS

Index

Danger

• Disconnect the negative wire (-) from the battery to avoid accidental engine starting.

Important

• Before proceeding with operation, read Par. 3.3.2.

6.1 Engine oil replacement

A

Important

• Place engine on level surface to ensure accurate
measurement of oil level.

• Before proceeding, perform the operation described in

Par. 6.2 - Point 1.

NOTE: Perform this operation with warm engine,

to get a better fluidity of the oil and get
a full discharge of oil and impurities
contained in it.

6.1

1. Loosen the oil filler cap A (Fig. 6.1).

E

D

6

B

2. Remove the oil 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. 6.5 DISPOSAL and SCRAPPING).

5. Replace gasket E.

6. Tighten the drain oil plug D (tightening torque at 35 Nm).

7. Perform the operation described in Par. 6.2 - point 2 to 5.

8. Add the type oil recommended (Tab. 2.1 and Tab. 2.2).

Important

• Do not exceed the MAX level on the dipstick.

D

6.2

A

C

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6.3

29

EN

6

Index

9. Fit and remove the oil dipstick B to check the level.
Pour in fluid until reaching the MAX level mark.

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.

• For disposal of oil filter cartridge and fuel filter refer to

Par. 6.5 DISPOSAL and SCRAPPING.

B B

MAX

MIN

6.4

6.2 Oil filter cartridge replacement

Important

• Electric/pneumatic screwdrivers are forbidden.

1. Unscrew cartridge holder cover A by performing three
complete 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 replace the gaskets C, D and E with new
ones.

A

A

B

F

6.5

D

C

B

EN

30

6.6

E

ED0053030050

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INFORMATION ABOUT REPLACEMENTS

Index

5. Fit and tighten the cover A on the oil filter support F,
tightening it with a torque wrench G (tightening torque of
25 Nm).

6.3 Filter cartridge and fuel pre-filter check

NOTE: The fuel filter is situated on the

crankcase of the engine or it may be
assembled on the frame of the vehicle.

1. Disconnect the cable A of the water presence sensor C.

6.7

6

A

F

G

C

2. Remove the water presence sensor C from its cartridge B.

3. Loosen the cartridge B using the appropriate wrench

(Fig. 6.9).

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. 6.9) 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 cartridge
B (tightening torque of 5 Nm).

7. Reconnect the cable A of the water presence sensor C.

NOTE: Bleeding.

8. Push repeatedly the button G in order to fill the circuit.

6.4 Air filter cartridge replacement

B

6.8

6.9

B

A

E

B

D

B

C

NOTE: Component not supplied by KOHLER.
Refer to the technical documentation of the vehicle.

ED0053030050

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31

EN

6

Index

INFORMATION ABOUT REPLACEMENTS

6.5 Disposal and scrapping

• In case of scrapping, the engine shall be disposed of in
appropriate locations, in conformity with the law in force.

• Before scrapping, it is necessary to 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 appropriate centers.

EN

32

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INFORMATION ABOUT FAILURES

Index

7

7.1 Useful information about failures

• This chapter contains information about the problems that may appear during engine operation with its causes and trouble
shooting Tab. 7.2.

• In some cases, you shall turn off the engine immediately to avoid further damage Tab. 7.1.

7.1

1 Warning RED light turn on
2 The oil pressure indicator light turns on while running
3 The engine rpms suddenly increase and decrease
4 A sudden and/or unusual noise is heard
5 Colour the exhaust fumes suddenly darkens

THE ENGINE MUST BE IMMEDIATELY TURNED OFF WHEN

7.2

TROUBLES POSSIBLE CAUSE SOLUTION PAR.

Warning YELLOW light
turn on

Engine ECU has detect a malfunctions Contact KOHLER authorised workshops

Sulphated 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

The engine does not
start

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
Open fuse Replace with a new fuse
Intake or exhaust system clogged Contact KOHLER authorised workshops
Inefficient electrical connections Clean the electrical contacts
Sulphated battery terminals Clean the battery terminals

Engine starts but stops

Clogged fuel filter

Replace with a new filter and clean the

tank
Clogged fuel pipes Contact KOHLER authorised workshops
Safety protocol in starting Wait some seconds

Engine doesn't rev up

RPM instability at idle
speed

Low
idle speed

Blue smoke

Excessive fuel
consumption

Throttle to MAX in starting

Clogged fuel pipes Contact KOHLER authorised workshops

Clogged fuel pipes Contact KOHLER authorised workshops
Poor quality fuel Clean the tank and refuel with quality fuel 2.5
High oil sump level Replace the engine oil
Clogged air filter Replace with a new filter 6.4
Clogged air filter Replace with a new filter
High oil sump level Replace the engine oil

Release the throttle and wait some

seconds

Clogged air filter Replace with a new filter

Engine lost its initial
performance

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

Slow acceleration Clogged fuel filter Replace the fuel filter 6.3
Engine jerking Clogged fuel pipes Contact KOHLER authorised workshops

Insufficient coolant level Fill up to the level

Engine overheats

High oil sump level Replace the engine oil

Clogged radiator Clean the radiator

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

--

6.4

--

6.3

--

--

--

--

4.6

--

--

- In the event that the solutions proposed in Tab. 7.2 do not eliminate the trouble, contact a KOHLER authorized workshop.

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33

EN

8

Index

INFORMATION ABOUT WARRANTY

WARRANTY INTERNATIONAL

3 YEAR LIMITED WARRANTY - KOHLER DIESEL ENGINES

Kohler Co. warrants to the original retail consumer that each new Diesel engine will be free from manufacturing defects in
materials or workmanship in normal service for the applicable coverage period set forth below beginning on the date of
purchase; provided the engine is operated and maintained in accordance with Kohler Co.’s instructions and manuals. If no hour
meter is installed as original equipment then 4 hours of use per day and 5 days per week will be used to calculate hours used.

ENGINE SERIES WARRANTY PERIOD OPERATING HOURS WARRANTY COVERAGE

Diesel (non KDI) 3 Years 0 – 2.000 100% Parts & Labor

0 – 2.000 100% Parts & Labor

KDI 3 Years

2.001 – 6.000 Major Components Only *

* Major component defects are failures related to a crankcase casting, cylinder head casting, crankshaft, crankshaft pulley,
camshaft, connecting rod, flywheel, and oil pump.

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.

EXCLUSIONS

The following items are not covered by this warranty.

• Damage caused by: (i) an accident or casualty; (ii) unreasonable use or neglect; (iii) normal wear; (iv) premature wear from
improper maintenance; (v) improper storage; (vi) old or contaminated fuel left within the fuel system, which includes but is not
limited to tanks, fuel lines, or fuel injection components.

• Failures caused by: (i) faulty repairs made by any party other than Kohler Co. or an authorized service facility designated by
Kohler Co.; (ii) use of non-Kohler replacement service parts; or (iii) an act beyond the control of Kohler Co., which includes but
is not limited to theft, vandalism, fire, lightning, earthquake, windstorm, hail, volcanic eruption, flood or tornado.

• Transportation charges in connection with the repair or replacement of defective parts.

• Engine accessories such as fuel tanks, clutches, transmissions, power drive assemblies, and batteries, unless supplied or
installed by Kohler Co.

• Rental of equipment during performance of warranty repairs.

• Fuel, lubricating oil, air filters, oil filters, or coolant/antifreeze

IMPLIED OR STATUTORY WARRANTIES, INCLUDING THOSE OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE, ARE EXPRESSLY LIMITED TO THE DURATION OF THIS WRITTEN WARRANTY. KOHLER CO. MAKES NO OTHER
EXPRESS WARRANTY, NOR IS ANYONE AUTHORIZED TO MAKE ANY ON KOHLER CO.’S BEHALF. KOHLER CO. AND/OR
THE SELLER SHALL NOT BE LIABLE FOR SPECIAL , INDIRECT, INCIDENTAL, OR CONSEQUENTIAL DAMAGES OF ANY KIND.

Some states or countries do not allow limitations on how long an implied warranty lasts, or the exclusion or limitation of
incidental or consequential damages, so the above limitation or exclusion may not apply to you. This warranty gives you
specific legal rights, and you may also have other rights which vary from country to country (www.kohlerengines.com), or
state to state within U.S.A.

TO OBTAIN WARRANTY SERVICE

Original retail purchaser must bring the engine to an authorized service facility designated by Kohler Co. found by visiting

www.kohlerengines.com or telephone [phone] (U.S.A. and Canada).

ENGINE DIVISION, Kohler Co., Kohler Wisconsin

EN

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INFORMATION ABOUT WARRANTY

Index

8

WARRANTY NORMS EPA

KOHLER CO.
CALIFORNIA AND FEDERAL EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND
OBLIGATIONS

The California Air Resources Board, U.S. Environmental Protection Agency (“EPA”) and Kohler Co. are pleased to explain the
emission control system warranty on your MY2014-2016 engine. In California (“the State”) and US EPA regulated applications,
new heavy-duty off-road engines must be designed, built and equipped to meet the State's and U.S EPA’s stringent anti-smog
standards. Kohler Co. must warrant the emission control system on your engine for the periods of time listed below provided
there has been no abuse, neglect or improper maintenance of your engine.

Your emission control system may include parts such as the fuel injection system and the air induction system. Also included
may be hoses, belts, connectors and other emission-related assemblies.

Where a warrantable condition exists, Kohler Co. will repair your heavy-duty off-road engine at no cost to you including
diagnosis, parts and labor.

MANUFACTURER'S WARRANTY COVERAGE

The MY2014-2016 heavy-duty off-road engines are warranted for the periods listed below. If any emission-related part on your
engine is defective, the part will be repaired or replaced by Kohler Co.

MY2014-2016 KD, KDW AND ALL TPEM ENGINES

ENGINE POWER DUR ATION

kW < 19 (hp < 25) 3 years or 2,000 hours
kW ≥ 19 (hp ≥ 25) 5 years or 3,000 hours

OWNER'S WARRANTY RESPONSIBILITIES

1. As the off-road engine owner, you are responsible for the performance of the required maintenance listed in your owner's
manual. Kohler Co. recommends that you retain all receipts covering maintenance on your off-road 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.

2. As the off-road engine owner, you should however be aware that Kohler Co. may deny you warranty coverage if your off­road engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.

3. Yo ur engine is designed to operate on diesel fuel only. Use of any other fuel may result in your engine no longer operating
in compliance with California's emissions requirements.

4. Yo u are responsible for initiating the warranty process. The ARB suggests that you present your off-road engine to a
Kohler Co. dealer as soon as a problem exists. The warranty repairs should be completed by the dealer as expeditiously
as possible.

If you have any questions regarding your warranty rights and responsibilities, you should contact Kohler Co., by visiting

www.kohlerengines.com or telephone [phone] (U.S.A. and Canada).

ENGINE POWER DUR ATION

kW < 19 (hp < 25) 3 years or 6,000 hours
kW ≥ 19 (hp ≥ 25) 5 years or 6,000 hours

MY2014-2016 KDI ENGINES

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8

Index

COVERAGE

Kohler Co. will repair or replace emission control system parts, components and sub-assemblies found to be defective with
respect to materials or workmanship at no cost to you including engine exhaust system related diagnosis, labor and parts.
The choice and responsibility of the decision to repair or replace an emission control system defect will be solely that of Kohler
Co. Emission control system parts/ components covered by the Federal and California Emission Control Systems Limited
Warranty are listed below

- Fuel injector(s) - Electronic control unit (ECU) if equipped

- Injection pump(s) - Sensors associated with ECU operation

- Exhaust manifold - Emission control information labels

- Intake manifold - Turbocharger (if equipped)

- Exhaust gas recirculation (EGR) tube - Fuel limiting device

- Crankcase ventilation valve

Parts/components that are scheduled to be replaced as part of the required maintenance schedule will be covered under
the warranty provisions for a period of time up to the first scheduled replacement point for the subject parts/ components.
Subseque nt damage to other engine co mponents as a direct re sult of a warrantable failure an exhaust emission par t/ component
will be covered under the warranty provisions described herein.

As the heavy-duty off-road engine owner, you should however be aware that Kohler may deny you warranty coverage if your
heavy-duty off-road engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.
Only due to the above reasons, the manufacturer may deny the warranty coverage.

INFORMATION ABOUT WARRANTY

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GLOSSARY

Index

9

A Alternator:

Authorised workshop: Kohler authorised service centre.

B Bore: Internal diameter of the cylinder in combustion engines.
C Catalyst: A device in charge of filtering exhausted gas.

Combustion:

Common Rail:

E EC: European Community.

ECS: Emission Control System

ECU:

EGR Cooler:

EGR:

Electronic injector:

EPA:

F Fig.: Figure.
G Galvanised: Material that has undergone surface protection treatment.

H Heavy conditions:

I Intercooler:

International lubricant specifications:

K KDI: Kohler Direct Injection

M Maintenance - periodic:

MAX: Maximum.

Methyl ester

Min.: Minutes.
MIN: Minimum.

Model:

O Oil Cooler: Small radiator used to cool the oil.
P Par.: Paragraph.

Paraffin: Fatty and solid substance that may form inside the diesel.

Poly-V:

R Ref.: Reference.

A component that transforms mechanical energy into AC
electrical energy.

Chemical reaction of a mixture composed of fuel and fuel (air)
inside a combustion chamber.

A high-pressure "Common Duct" that produces a constant
supply of fuel directly to the injectors.

Electronic Control Unit; an electronic device in charge of
electronically detecting and controlling othe r electronic c ontrol
devices.

Recirculated exhaust gas cooling; a system that is able to
cool recirculated gas (EGR) from the exhaust. This enables
the temperature to remain constant inside the intake manifold,
thus improving combustion inside the cylinders and breaking
down pollutants further.

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 it to break down a
part of the pollutants present in the exhaust gas.

An electronically activated component able to inject jets of
atomised fuel inside the cylinders.

Environmenta l Protection Agency. The United State s' au thority
that safeguards the environment; its duty is to govern and
control polluting emissions.

Type of extreme condition referred to the work environment
in which the engine is used (very dusty - dirty area, or in a
contaminated environment due to various types of gas).

Air-cooling element under pressure from the turbo situated
between the turbine and intake manifold.

A.P.I.: (American Petroleum Institute)
MIL: U.S.A. military engine oil specification
ACEA: European Automobile Manufacturers Association

A group of maintenance actions that have the sole objective to
control and r eplace elements on th eir expiry, without modif ying
or improving the functions carried out by the system, neither
increasing the value nor improving performance.

It is a mixture of products by means of a chemical conversion
of oils and animal and/or vegetable fat, which is used to
produce Biofuel.

Model, engine identification plate, which indicate s the engine's
model.

Poly-V, the name associated with a service belt, which derives
from the profile of its section that is constructed with joined Vs.

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Index

GLOSSARY

S s/n:

Spec.:

T Tab.: Table.

TCR: Turbo Common Rail.

Tightening torque:

T-MAP:

Turbocharger:

U Used oil:

W Waste-Gate valve:

Serial number (engine identification name plate) indicating the
engine identification series/chassis number.

Specification, (engine identification name plate) indicating the
engine version.

A term indicated for installation of threaded components and
which is determined by means of a unit of measurement Nm.

T-MAP (sensor), measures the temperature and absolute
pressure inside the intake collector.

Device that compresses air intake by sending it to the intake
manifold by means of a turbine.

Oil altered by operation or time, which is no longer compliant
for correct lubrication of the components.

A device, which is directly or automatically controlled, used to
limit the pressure of exhaust gas inside the turbine.

EN

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GLOSSARY

Index

SYMBOLS AND UNITS OF MEASUREMENT

SYMBOL UNIT OF MEASUREMENT DESCRIPTION EXAMPLE

α

2

cm

Ø millimetre Circumference Ø 1 mm
Nm newton-metre Torq ue 1 Nm
mm millimetre

μm

h hour Time 1 h

g/kWh

grammes per kilowatt per

kg/h kilogramme per hour Max. flow rate 1 kg/h

Lt./min. litres per minute

Lt./h litres per 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
kg kilogramme 1 kg

W Watt

kW kiloWatt 1 kW

pa pascal

KPa Kilopascal 1 KPa

bar barometric pressure 1 bar

mbar (1/1000 bar) barometric pressure 1 mbar

R Resistance

Ω ohm

Rpm revs per minute Rotation of an axis 1 Rpm

Ra

°C degree centigrade Temperature 1°C

V Volt Electrical voltage 1 V

Ã

3

cm

Lt. litre 1 Lt.

degree Rotation/inclination angle 1°

square centimetre Area 1 cm

1/1000 of a millimetre

Length

(micron)

hour

Specific consumption 1 g/kWh

Flow rate

1 Lt./min.

Weight

Power

Pressure

Resistance to electrical

current (referred to a

component)

Resistance of electrical

current

average roughness

expressed in microns

millimetre Hex-head capscrew

cubic centimetre

Roughness Ra = 1

à 1 mm

Volume

1 mm

1 μm

1 gr.

1 W

1 pa

1 Ω

1 Ω

1 cm

9

2

3

ED0053030050

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39

EN

Lombardini s.r.l. is a part of Kohler Group.
Lombardini has manufacturing facilities
in Italy, Slovakia and India and sales
subsidiaries in France, Germany, UK, Spain
and Singapore. Kohler/Lombardini reserves
the right to make modifications without prior

notice.

www.lombardini.it

DEUTSCHLAND

Lombardini Motoren GmbH

Fritz-Klatte-Str. 6, Bürogebäude 2
D – 65933 Frankfurt
Hessen, DEUTSCHLAND
T. [phone]
F. [phone]

EUROPE

Lombardini Srl

Via Cav. del lavoro
A. Lombardini n° 2
42124 Reggio Emilia, ITALY
T. [phone]
F. [phone]

UK

Lombardini U.K. Ltd

1, Rochester Barn - Eynsham Road
OX2 9NH
Oxford, UK
T. [phone]
F. [phone]

USA & CANADA

Kohler Co.

444 Highland Drive,
Kohler - Wisconsin (53044), US
T. [phone]
F. [phone]

ESPAÑA

Lombardini ESPAÑA, S.L.

P.I. Cova Solera 1-9
08191 - Rubí (Barcelona)
ESPAÑA
T. [phone]
F. [phone]

FRANCE

Lombardini France S.a.s.

47 Alléè de Riottier,
69400 Limas, FRANCE
T. [phone]
F. [phone]

CHINA & ROAPAC

Kohler China INVESTMENT Co. Ltd

no.158, Jiang Chang San Road,
200436, Zhabe, Shanghai
CHINA
Tel: [phone]
Fax: [phone]