KDI 3404TCR-SCR
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
ED0053032140 51534 3 2 06/2017 11/2018
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 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.
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INDEX
1 - GENERAL INFORMATION
1.1 Manual's Purpose ............................................................4
1.2 Glossary and Definitions
1.3 Emission-Related Installation Instructions
1.4 Service request
1.5 Manufacturer and engine identification
1.6 Engine component identification
1.7 Cooling circuit
1.8 AdBlue circuit
1.9 Intake and exhaust circuit............................................10
1.10 Homologation labels
1.10.1 Label for EPA rules
1.10.2 Label for China Standards
1.10.3 Label for Korea Standards
...............................................................4
.................................................................8
..................................................................9
................................................4
..................4
.......................5
..................................6
...................................................11
................................................... 11
......................................12
......................................13
2 - TECHNICAL INFORMATION
2.1 General description of the engine ..............................14
2.2 Engine specifications
2.3 Engine dimensions (mm)
2.4 Oil....................................................................................15
2.5 Fuel
2.5.1 Fuel for low temperatures.........................................17
2.5.2 Biodiesel fuel
2.5.3 Synthetic fuels: GTL, CTL, BTL, HV
2.5.4 Emission-Related Installation Instructions
2.6 AdBlue
2.7 Coolant recommendation
2.8 Battery recommendation
2.9 Inducement strategy of SCR system
.................................................................................16
............................................................................18
...................................................14
..............................................14
.............................................................17
.........................17
............17
............................................19
.............................................19
..........................20
4 - INFORMATION ABOUT USE
4.1 Pre-start check .............................................................26
4.2 Running-in period
4.3 Starting and turning off
4.3.1 Starting
4.3.2 After starting
4.3.3 Turning off
4.4 Refuelling
4.5 Oil filling
4.6 Coolant filling
4.7 AdBlue® filling
.......................................................................26
.......................................................................27
.........................................................................27
.........................................................26
...............................................26
.............................................................26
..................................................................26
................................................................28
..............................................................28
5 - INFORMATION ABOUT MAINTENANCE
5.1 Useful information about maintenance ......................29
5.2 Periodic maintenance
5.3 Oil level check
5.4 Air filter check
5.5 Check of the radiator heat - exchanger surface
5.6 Rubber hoses check
5.7 Check coolant level.......................................................32
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.....................................34
5.14 Unused machine..........................................................35
5.14.1 Operations for the engine
5.14.2 Operations for the SCR system
...............................................................30
...............................................................31
..................................................29
.......32
.....................................................32
.......................................33
....................33
..................................................34
..................................34
...................................34
.......................................35
..............................35
3 - SAFETY INFORMATION
3.1 Safety information ........................................................21
3.2 General remarks
3.2.1 Note for OEM
3.2.2 Note for end user
3.3 Safety signal description
3.3.1 Adhesive safety plates
3.3.3 Warnings
3.3.2 Safety guards
3.4 Information and safety signals
3.5 Safety and environmental impact
3.6 Location of safety labels on engine
...........................................................21
..............................................................21
.......................................................21
.............................................23
..............................................23
.....................................................................23
.............................................................23
....................................24
...............................24
............................25
6 - INFORMATION ABOUT REPLACEMENTS
6.1 Engine oil replacement ................................................36
6.2 Oil filter cartridge replacement...................................37
6.3 Fuel filter and pre-filter cartridge replacement
6.4 Air filter cartridge replacement
6.5 Replacement of AdBlue® filter
6.6 Disposal and scrapping
................................................39
..................................38
...................................39
........38
7 - INFORMATION ABOUT FAILURES
7.1 U seful information about failures ................................40
8 - INFORMATION ABOUT WARRANTY
Warranty terms ....................................................................41
9 - GLOSSARY
Glossary .............................................................................. 44
Symbols and units of measurement
.................................46
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1
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 property of KOHLER. As such, no reproduction or
replication in whole or part is allowed without the express
written permission of KOHLER.
1.2 Glossary and Definitions
The paragraphs, tables and figure are divided into chapter with their progressive numbers.
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 & dealers.kohlerpower.it
• If you have any questions regarding your warranty rights and responsibilities or the location of the nearest
Kohler Co. authorized service location, you should contact Kohler Co. at 1-800-544-2444 or access our website at
www.kohlerengines.com (USA and North American).
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GENERAL INFORMATION
Index
1.5 Manufacturer and motor identification data
1
Peak
rpm
Engine type
Engine serial number
Manufacturer identification
Engine
version
Approval data and
"EC" directives
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1
Index
GENERAL INFORMATION
1.6 Engine component identification
SIDE VIEW A
10
11 12 13 14
2
3
9
4
678 5
19
1
21
SIDE VIEW B
1
15 13 12 1014
22
16
EN
16
20
6
1819
17
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GENERAL INFORMATION
Index
1
1.1
POS. DESCRIPTION
1 ECU
2 EGR 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
Some components are for illustrative purposes only and
may var y.
NOTE: Components in Pos. 8, 10 are not
supplied by Kohler
SIDE VIEW C
10
1513
2023
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142 22
1
7
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1
Index
1.7 Cooling circuit
GENERAL INFORMATION
SIDE VIEW A
8
3
2
1
11
12
10
79
4 56
13
1.2
POS. DESCRIPTION
1 Radiator
2 Intake sleeve
3 Intake return tube
4 Intake return tube
5 Circuit for AdBlue heating
8
7
6 AdBlue tank
Coolant delivery tube in
7
AdBlue tank
Coolant delivery tube to
8
AdBlue injector
Electronic valve for
9
coolant delivery to AdBlue
tank
Coolant delivery tube to
10
SCR system
Coolant to radiator return
11
sleeve
12 Coolant pump
13 SCR system control unit
SIDE VIEW B
13
111098
7
12
45 4 2
8
3
1
Some components are for illustrative purposes only and may vary.
NOTE: Components in Pos. 1, 2, 3, 4, 7, 8, 10, 11 are not supplied by Kohler
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1.8 AdBlue circuit
Index
GENERAL INFORMATION
1
1.3
POS. DESCRIPTION
SCR system control
1
unit
2 AdBlue tank
3 AdBlue pump
4 AdBlue intake tube
AdBlue delivery
5
tube to AdBlue
injector
Return tube in
6
AdBlue tank
7 AdBlue injector
4
5
SIDE VIEW A
2
3
1
4
6
5
7
6
SIDE VIEW B
7 5
1
4
5
32
Some components are for illustrative purposes only and may vary.
NOTE: Components in Pos. 4, 5, 6 are not supplied by Kohler
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1
Index
1.9 Intake and exhaust circuit
SIDE VIEW A
9
4
GENERAL INFORMATION
10 1 7
1.4
POS. DESCRIPTION
1 Air filter
2 Air intake sleeve
3 Turbocharger
4 Air delivery tube to Intercooler
5 Intercooler
Air delivery tube to intake
6
manifold
7 Air inlet valve
8 Exhaust gas delivery hose to SCR
9 AdBlue injector
10 SCR
Some components are for illustrative
purposes only and may vary.
5
SIDE VIEW B
10
NOTE: Components in Pos. 1, 2,
4, 5, 6 are not supplied by
Kohler
6
3
9
4 1 6
EN
10
8 2 5
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1.10 Homologation labels
Index
1.10.1 Label for EPA rules
GENERAL INFORMATION
1
1
2
3
8
9
1.5
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
1.10.2 Label for China Standards
GENERAL INFORMATION
1
3
5
7
1.6
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
2
4
6
8
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1.10.3 Label for Korea Standards
Index
GENERAL INFORMATION
1
1 4
2
1.7
POS. DESCRIPTION
1 Tier 4 Final
2 Engine model
3 Manufactoring date and manufacturer code
4 N° Korea emission certificate
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 UNIT OF MEASURE
ENGINE TYPE
CYLINDERS n. 4
BORE mm 96
STROKE mm 116
DISPLACEMENT cm
MAX INCLINATION DURING OPERATION
(even in combined)
OIL CAPACITY (MAX LEVEL.)
including oil filter
DRY WEIGHT kg 394
standard version lt. 15.6
3
a
a
KDI 340 TCR-SCR
3359
40° max. 30 minutes
45° max.1 minute
2.3 Engine dimensions (mm)
659.7
996.1
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
VISCOSITY SAE
RECOMMENDED OIL
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. 6.6 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.
15W-40 (-15°C ÷ +50°C)
10W-30 (-25°C ÷ +40°C)
10W-40 (-25°C ÷ +50°C)
5W-30 (-30°C ÷ +40°C)
0W-40 (-40°C ÷ +50°C)
WITH
SPECIFICATIONS
• Low S.A.P.S. technology (fuel with low Sulfated Ash, Phosphorus, Sulfur content) keeps catalyst in good working conditions.
The presence of sulfated ash, phosphorus and sulfur causes with time the catalyst clogging and its consequent inefficiency.
• For Mid S.A.P.S oil sequence the sulfated ash level is the same as API CJ-4 ≤ 1.0% but as per ACEA standardization those
oils are referenced as mid SAPS.
• Filtration of oils is critical to proper operation and lubrication; always change filters regularly as specified in this manual.
API CJ-4 Low S. A . P.S
ACEA
E9 Mid S.A.P.S.
E6 Low S.A.P.S.
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