KOHLER Flex™: integrated suite of engine systems

Kohler 2To facilitate the transition to Stage V, KDI engines are already available for development and validation tests. (Image source: Kohler)Kohler will present a new development of its platform of diesel engines, designed to meet the requirements of a market that demands more application flexibility and compliance with the various emissions limits, along with performance and productivity at the Middle East Electricity (MEE) 2018

Kohler’s Stage V solution is compact in design with best-in-class performance, reduced consumption, easy to install, and optimised solutions for every emissions regulation. With the Stage V development, Kohler adds another model to the line-up. KDI engines are characterised by extremely clean combustion and now, with the introduction of the DPF, Kohler takes full advantage of the efficiency of the combustion to deliver to its customers the most advanced technology and the most compact after-treatment system in the market. The company is proud of the DPF smart regeneration strategy, which was developed through extensive use of advanced simulation tools and testing.


KOHLER Flex™ is the range of solutions for emission control that Kohler has designed to enable each configuration of the KDI platform to comply with all emissions standards and regulations, worldwide.

At the heart of KOHLER Flex™ there is the clean combustion of KDI engines that enables the adoption of a compact, state-of-the-art DPF to meet the Stage V emission standard. KOHLER Flex™ combines the clean in-cylinder combustion of KDI engines, made possible by high-pressure common rail (2,000 bar), four valves head, turbocharger and cooled EGR, and the most compact after-treatment devices (DOC, DPF and SCR) to comply with all emission requirements.

KDI line-up extension

Kohler released two DPF versions. The first one reaches a maximum service interval of 10,000 hours, whereas the second is the most compact of the market and ensures a maintenance interval of 6,000 hours.

Kohler offers the after-treatment system mounted on the engine or separate, and thanks to the 360° rotation of the axial and radial inlet/outlet pipes it provides excellent adaptability for every application.

While complying with the new Stage V limits, the engines are also optimised for increased torque response and torque density. The KDI 3404 reaches 640 Nm at 1,400 rpm of maximum torque and 105kW of rated power. These new ratings improve productivity and efficiency of machines and give OEMs a great chance to adopt smaller and more compact engines.

For applications that require simple and compact solutions, the new KDI version without charge air cooling (CAC) offers OEMs an extremely cost-competitive solution.

This simplified non-CAC version is characterised by an upgraded fuel injection strategy that delivers the necessary torque and power and at the same time frees up space, reduces cooling load on the equipment and simplifies the engine installation.

Kohler is also extending the KDI engine line-up with new configurations for less regulated countries. These versions, with a 1,600 bar pressure common rail, no EGR and no DOC, will ensure the same performance of other configurations.

Introducing KDI Stage V

The Stage V models of KOHLER Flex™ enhance the strong points of the KDI range in terms of efficiency, compactness, power and torque delivery, simplified installation package, low operating costs and ease of maintenance, offering manufacturers and end users a complete and versatile engine platform. Cost competitiveness and superior performance are key advantages that are appreciated in every geographical area.

Up to now in the European Union (EU), the emissions standards only regulated the weight of the particulate matter emitted into the atmosphere. Stage V introduces the particle number (PN), which requires the use of a particulate filter system (DPF).

To facilitate the transition to Stage V, KDI engines are already available for development and validation tests.

Stand No: S1.A30

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