Kohler KDI 3404TCR Engine
The Kohler KDI 3404TCR is a 3.36 L 4-cylinder turbo+ charge after cooler engine rated at 1800 rpm, producing up to 55.4 kW. It powers generator sets from Kohler, Lombardini and Valdinoci, including the 48REOZK4, 55REOZT4, KDI 3404 TCR and KDI 3404 TCR. It holds 15.6 L (4.1 gal) of oil and 12 L (3.2 gal) of coolant.
Also known as: Kohler KDI 3404TCR, KDI 3404TCR
Part of the Kohler KDI3404TCR engine family — 2 variants share parts & fitment.
Engine specifications
| Oil capacity | 15.6 L |
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| Coolant capacity | 12.0 L |
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| Displacement | 3.359 L |
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| Cylinders | 4 |
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| Aspiration | Turbo+ Charge After Cooler |
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| Rated speed | 1800 rpm |
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| Gross power | 55 kW |
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Common problems
15- Emergency Stop 32A
Fix: Reset the emergency stop switch. - Warning YELLOW light turn on ED0053030050
Cause: Engine ECU has detect a malfunctions
Fix: Contact KOHLER authorised workshops - Warning RED light turn on
Fix: The engine must be immediately turned off when this occurs. - The oil pressure indicator light turns on while running
Fix: The engine must be immediately turned off when this occurs. - The engine starts but stops
Cause: Inefficient electrical connections
Fix: Clean the electrical contacts - The engine rpms suddenly increase and decrease
Fix: The engine must be immediately turned off when this occurs. - The engine does not start
Cause: Sulphated battery terminals corroded
Fix: Clean the battery terminals - RPM instability at idle speed
Cause: Clogged fuel pipes
Fix: Contact KOHLER authorised workshops - Poor quality fuel
Fix: Clean the tank and refuel with quality fuel - Numero dei giri al minimo basso
Cause: Clogged fuel pipes
Fix: Contact KOHLER authorised workshops - Low idle speed
Cause: Clogged fuel pipes
Fix: Contact KOHLER authorised workshops - High oil sump level
Fix: Replace the engine oil - Excessive fuel consumption
Cause: Clogged air filter
Fix: Replace with a new filter - Engine starts but stops
Cause: Inefficient electrical connections
Fix: Clean the electrical contacts; if the problem persists, Contact KOHLER authorised workshops - Engine overheats
Cause: Insufficient coolant level
Fix: Fill up to the level
Compiled from service & troubleshooting documentation across every generator set that uses the Kohler KDI 3404TCR.
Maintenance schedule
| Item | Spec | Capacity | Part # | Interval | |
|---|
| Air filter | Replace air filter cartridge | | — | 12000 hr | |
| Fuel filter | Replace fuel pre-filter and filter cartridge | | — | 12000 hr | |
| Oil filter | Replace oil filter cartridge | | — | 12000 hr | |
| Battery | | | — | 2000 hr | |
| Belt | check tension when off | | — | 5000 hr | |
| Coolant | | | — | 40000 hr | |
| Coolant filter | An anti-freeze protection liquid (ANTIFREEZE) - mixed with decalcified water - must be used. | | — | 500 hr | |
| Oil | Change engine oil and filter | 15.6 l | — | 2000 hr | |
| Spark plug | Before proceeding with operation, read Par. 3.2.2. | | — | 5000 hr | |
Pooled from every document that names this exact engine — confirm the interval and part number against your unit's serial number.
Service intervals
3| Item | Action | Hours | Months | Notes |
|---|
| oil | Change | 500 hr | | Minimum 500 hours oil change interval |
| Paralleling box | Inspect | | 12 mo | Annually by a Kohler authorized distributor/dealer, or when wear, damage, deterioration, or malfunction is evident or suspected. |
| Paralleling box internal components | Inspect | | 1 mo | Monthly or when a condition noticed during external inspection may have affected internal components; enclosure cover must be removed by trained personnel. |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Service specifications
26| Type | Item | Value | Unit | Condition |
|---|
| Gap | Speed sensor air gap | 0.36- 0.71 | mm | |
| Other | Engine speed adjustment | 50 | | default setting; settings between 40 and 60 acceptable; 52 increases speed by 2 RPM, 49 decreases by 1 RPM |
| Other | Generator to bus phase angle | -10 to 10 | degrees | verify with contactor closed |
| Other | Reactive droop | 1 | % | default setting; range 0.5 - 2% |
| Pressure | Battery equalizer input voltage (24 volts nominal) | 20- 35 | volts | |
| Pressure | Battery equalizer output voltage | (input voltage/2) ±2% | volts | |
| Pressure | Pressure switch 364345 | 483 ±14 | kPa | |
| Resistance | Pressure sender 264390 value A | 240 +17/- 15 | ohms at 0 psi | |
| Resistance | Pressure sender 264390 value B | 153 +12/- 15 | ohms at 25 psi | |
| Resistance | Pressure sender 264390 value C | 33.5 | ohms at 100 psi | |
| Resistance | Pressure sender 365624 value A | 241 ±16 | ohms at 0 psi | |
| Resistance | Pressure sender 365624 value B | 152 ±13 | ohms at 50 psi | |
| Resistance | Pressure sender 365624 value C | 33.5 | ohms at 200 psi | |
| Resistance | Temperature sender 226717 value A | 123.8 +7.2/- 7.8 | ohms at 90.6 C (195 F) | |
| Resistance | Temperature sender 226717 value B | 35.6 +3.4/- 3.6 | ohms at 137.8 C (280 F) | |
| Resistance | Temperature sender 226919 value A | 942 ±22 | ohms at 37.7 C (100 F) | |
| Resistance | Temperature sender 226919 value B | 35 | ohms at 115.6 C (240 F) | |
| Speed | Overspeed shutdown | 70 | Hz | 60 Hz models |
| Temperature | Battery equalizer operating temperature | - 40 to 71 | C (- 40 F to 160 F) | |
| Temperature | Temperature switch 241308 | 107 ±4 | C (225 F ±7 F) | normally open to close on temp. rise |
| Temperature | Temperature switch 290090/GM51705 | 16 ±3 | C (60 F ±5 F) | normally open to close on temp. fall |
| Torque | PGEN terminal block connections | 0.5 | Nm | |
| Torque | PGEN terminal block connections | 4.4 | in. lbs. | |
| Voltage | Controller measurement accuracy | 2 | % | without calibration; requires a calibrated multimeter for calibration |
| Voltage | Speed sensor voltage, wire 2 (black) & 16 (white) | 3- 6 | volts DC | |
| Voltage | Speed sensor voltage, wire 2 (black) & 24 (red) | 8- 10 | volts DC | |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Recommended fluids
| Fluid | Grade | Standard | Ambient | Capacity | Notes |
|---|
| Fuel | No 1 Diesel (US) - ASTM D 975-09 B - Grade 1-D S 15 and No 2 Diesel (US) - ASTM D 975-09 B - Grade 2-D S 15, S 500 for mechanical models only | ASTM D 975-09 B | | | |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Procedures
12Calibration adjustment
⚠ Copying personality profiles from one controller to another can overwrite calibration coefficients and requires re-calibration.
Tools: Calibrated multimeter with recent calibration verification
- Use a calibrated multimeter to measure the generator voltage and enter the correct value in the CONTROLLER CONFIG -> CALIBRATION screen.
- Use a calibrated multimeter to measure the bus voltage and enter the correct value in the CONTROLLER CONFIG -> CALIBRATION screen.
Overfrequency Adjustment (Over/Underfrequency Relay, Decision-Maker 3+) adjustment
- Turn the overfrequency adjustment potentiometer fully clockwise (CW).
- Place master switch in RUN to start the generator set.
- Adjust governor per engine operation manual, engine service manual, or governor section of this manual.
- Slowly turn overfrequency potentiometer counterclockwise (CCW) until the LED starts flashing; after about 10 seconds the set shuts down on auxiliary fault.
- Place master switch to OFF/RESET to reset the controller.
- Place master switch to RUN to start the generator set.
- Readjust the governor to the desired frequency as required.
- Place master switch to OFF/RESET to stop the generator set.
Overvoltage Feature Testing and Adjustment (Decision-Maker 3+) adjustment
⚠ Hazardous voltage. Moving parts. Will cause severe injury or death. Operate the generator set only when all guards and electrical enclosures are in place.
⚠ Disconnecting the electrical load. Hazardous voltage will cause severe injury or death.
- Disconnect generator set from load by opening line circuit breaker or disconnecting and taping output leads.
- Determine overvoltage shutdown value based on user requirement; factory setting is 15% above nominal line-to-neutral voltage.
- Remove the controller cover.
- Place master switch in RUN to start the generator set.
- Observe AC voltmeter; turn voltage adjustment potentiometer CW until generator set shuts down.
- If the shutdown point is correct, go to step 12; otherwise continue.
- Turn controller circuit board R42 adjustment potentiometer fully CW.
- Place master switch to OFF/RESET to reset; then to RUN to start.
- Observe AC voltmeter while turning voltage adjustment potentiometer to desired overvoltage shutdown point.
- Turn R42 adjustment potentiometer slowly CCW until the generator set shuts down.
- Turn controller voltage adjustment potentiometer slightly CCW.
- Place master switch OFF/RESET then RUN to start; adjust for correct voltage and phase.
- Place master switch OFF/RESET to stop.
- Disconnect battery negative lead first; reconnect generator set to load; reconnect battery negative lead last.
Reactive Droop Compensator Adjustment Procedure adjustment
Tools: Voltmeter, Wattmeter
- Remove any load; start each generator set with master switch in RUN.
- Set reactive droop compensator rheostat on generator set no. 1 to minimum CCW; record rpm/frequency and voltage at 1/4 load steps to full load.
- Repeat for generator set no. 2.
- Compare readings; adjust voltage within 1 volt and speed within 3 rpm (or 0.1 Hz) at each load step.
- Check droop compensation on each unit with an inductive load 1/2 to full load.
- Adjust rheostat to approximately 4% below rated voltage at full load.
- Repeat for unit no. 2.
Reactive Droop Compensator Alternate Adjustment Procedure adjustment
Tools: Voltmeter
- Turn reactive droop compensator rheostat on generator set no. 1 to minimum setting.
- Remove controller cover; move voltage sensing lead from V7 to V9 at the AC fuse terminal block.
- Remove any load connected to the generator set.
- Start the generator set with master switch in RUN.
- Use controller or remote voltage adjusting potentiometer to fine adjust voltage.
- Apply resistive load (1.0 power factor) until reaching rated current.
- Adjust reactive droop compensator rheostat to achieve a 4% droop in voltage.
- Remove the resistive load and stop the generator set.
- Return voltage sensing lead from V9 to V7 at the AC fuse terminal block.
- Replace the controller cover and repeat for generator set no. 2.
Underfrequency Adjustment (Over/Underfrequency Relay, Decision-Maker 3+) adjustment
- Turn underfrequency adjustment potentiometer fully clockwise (CW).
- Place master switch in RUN to start the generator set.
- Adjust governor per engine operation manual, engine service manual, or governor section of this manual.
- Slowly turn underfrequency potentiometer counterclockwise (CCW) until LED starts flashing; after about 10 seconds the set shuts down on auxiliary fault.
- Place master switch to OFF/RESET to reset the controller.
- Place master switch to RUN to start the generator set.
- Readjust the governor to the desired frequency as required.
- Place master switch to OFF/RESET to stop the generator set.
2-Wire Low Water Level Sender Test diagnostic
⚠ Hot engine and exhaust system can cause severe injury or death. Do not work on the generator set until it cools.
⚠ Hazardous voltage. Moving parts. Will cause severe injury or death. Operate the generator set only when all guards and electrical enclosures are in place.
Tools: DC voltmeter
- Measure DC voltage between lead 31A (+) and ground (- ) with sender submerged in coolant; voltmeter indicates approximately 12.5 VDC.
- Measure DC voltage between lead 31A (+) and ground (- ) with sender removed from coolant for at least 5-15 seconds; voltmeter indicates a drop to approximately 7 VDC.
3-Wire Low Water Level Sender Test diagnostic
⚠ Hot engine and exhaust system can cause severe injury or death. Do not work on the generator set until it cools.
⚠ Hazardous voltage. Moving parts. Will cause severe injury or death.
Tools: Ohmmeter
- Measure resistance between lead 31 and ground with sender submerged in coolant; ohmmeter indicates a high resistance reading.
- Measure resistance between lead 31 and ground with sender removed from coolant for at least 5-15 seconds; ohmmeter indicates a low resistance reading.
Battery Equalizer Troubleshooting diagnostic
⚠ To prevent reverse polarity damage to the battery equalizer, remove the ground (GND) connection first and attach the ground connection last when disconnecting the battery equalizer.
Tools: 12-volt test light with alligator clips, Voltmeter with 0.01 volt resolution, Battery load tester
- Remove the ground (GND) connections from the battery equalizer; do not allow contact with other connections.
- Verify a differential of 12 volts between the +12 volt and +24 volt terminals using a 12-volt test light; the light will illuminate on a functional unit. Remove the test light.
- Connect the test light between the +12 volt and GND terminals; the light will illuminate on a functional unit.
- With the test light connected, measure and record the voltage between the +12 volt and +24 volt terminals.
- With the test light connected, measure and record the voltage between the +12 volt and GND terminals.
- Remove the test light.
- Compare the values from steps 4 and 5; the difference should be - 0.5 and +0.13 volts on a functional unit.
Oil Pressure Sender Testing diagnostic
Tools: Ohmmeter, Mechanical oil pressure gauge
- Disconnect the oil pressure sender lead 7C.
- Check the sender resistance with an ohmmeter.
- Compare resistance values when the generator set is shut down and when running at operating temperature to Section 1, Specifications.
- Use a mechanical oil pressure gauge to further verify correct readings.
Overcrank Test (Typical) diagnostic
- On gas-fueled sets, disconnect the coil wire at the distributor cap and ground it or disconnect the ignition system.
- On diesel-fueled sets, unplug the fuel injector harness from ECM or disconnect wire no. 70 from the injector pump solenoid.
- Place unit in RUN mode; observe 15-second on-off cranking cycles and maximum 75-second elapsed time to overcrank shutdown.
- Observe controller fault lamp and display for an overcrank shutdown.
- Place unit in OFF/RESET mode.
- Reconnect the ignition coil wire/ignition system, or reconnect the fuel injector harness/wire no. 70.
Speed Sensor Test with Generator Set Running diagnostic
⚠ Keep leads connected to the speed sensor terminals during the test; do not disconnect the leads.
Tools: DC voltmeter
- Connect a DC voltmeter between positive (+) lead (wire 24) at the speed sensor and ground (wire 2) with master switch OFF/RESET; read approximately 8- 12 volts DC.
- Place master switch in RUN to start the generator set.
- Connect DC voltmeter negative probe to 0 terminal (wire 16 white) and positive probe to positive (+) terminal (wire 24 red); read approximately 7- 12 volts DC.
- Place master switch in OFF/RESET to stop the generator set.
- If sensor emits a signal, check continuity of speed sensor leads (wires 2, 16, 24) between controller P1 connector and sensor terminals.
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Parts cataloged across the Kohler KDI3404TCR family
44| Part # | Description | Category |
|---|
| ED0053030050 | Air filter cartridge | Air filter |
| GM93824 | Air Cleaner Assy | Air filter |
| GM93996 | Element, Air Cleaner Primary | Air filter |
| GM93997 | Element, Air Cleaner Secondary | Air filter |
| 8080710050 | AIR INLET MANIFOLD / AIR FILTER | Air inlet manifold filter |
| 8045710050 | BREATHER SYSTEM | Breather system |
| 8079710010 | FITTING FOR CAB HEATING | Cabin heating fitting |
| 8035710090 | CAMSHAFT | Camshaft |
| 8020710090 | CRANKCASE | Crankcase |
| 8010710020 | CRANKSHAFT | Crankshaft |
| 8021710070 | CYLINDER HEAD | Cylinder head |
| 8025710010 | ENGINE MOUNTS | Engine mounts |
| 8085710090 | EXHAUST GAS MANIFOLD | Exhaust gas manifold |
| 8086710020 | EXHAUST MUFFLER | Exhaust muffler |
| 8012710050 | FLYWHEEL | Flywheel |
| 8061710010 | FUEL FILTER | Fuel filter |
| 8061710020 | FUEL FILTER | Fuel filter |
| 8022710080 | HEAD COVER | Head cover |
| 8068710070 | HOSES FOR WATER COOLER | Hoses water cooler |
| 8030710150 | INJECTION SYSTEM | Injection system |
| 8043710020 | OIL DIPSTICK | Oil dipstick |
| 10W-40 | 0o F to 80o F (-18o C to 27o C) | Oil filter |
| 5W-40 | Oil, SAE 5w-40 (-30°C ÷ +50°C) | Oil filter |
| 8041710040 | OIL PAN | Oil pan |
| 8040710030 | OIL PUMP | Oil pump |
| 8011710040 | PISTON / CONNECTING ROD | Service part / kit |
| 8020710100 | CRANKCASE | Service part / kit |
| 8021710080 | CYLINDER HEAD | Service part / kit |
| 8022710070 | HEAD COVER | Service part / kit |
| 8030710130 | INJECTION SYSTEM | Service part / kit |
| 8035710120 | CAMSHAFT | Service part / kit |
| 8036710080 | ROCKER ARMS / VALVES | Service part / kit |
| 8038710040 | TIMING GEAR | Service part / kit |
| 8045710070 | BREATHER SYSTEM | Service part / kit |
| 8047710030 | OIL COOLER | Service part / kit |
| 8064710030 | FUEL PIPING | Service part / kit |
| ED0014603650-S | Six Nicks SN8 | Service part / kit |
| 8011710030 | PISTON / CONNECTING ROD | Piston connecting rod |
| 8014710050 | PULLEYS / BELT | Pulleys belt |
| 8036710070 | ROCKER ARMS / VALVES | Rocker arms valves |
| 8074710030 | THERMOSTAT UNIT | Thermostat unit |
| 8038710050 | TIMING GEAR | Timing gear |
| 8083710060 | TURBOCHARGER | Turbocharger |
| 8077710030 | WATER PUMP | Water pump |
Parts cataloged across all variants of this engine family — verify the exact part fits your specific variant and serial number before ordering.
Aftermarket parts that fit this engine
3Parts listed by aftermarket suppliers as fitting this engine — leads compiled from supplier catalogs; verify the exact part for your serial number.
Common questions
What is the oil capacity of the Kohler KDI 3404TCR?
The Kohler KDI 3404TCR engine has an oil capacity of 15.6 liters.
What is the displacement of the Kohler KDI 3404TCR?
The Kohler KDI 3404TCR has a displacement of 3.359 liters with 4 cylinders.
Which generators use the Kohler KDI 3404TCR engine?
The Kohler KDI 3404TCR powers 5 generator set(s), including Kohler 48REOZK4, Kohler 55REOZT4, Kohler KDI 3404 TCR, Lombardini KDI 3404 TCR, Valdinoci Power Pack KDI 3404 TCR.
How often should you change the oil in the Kohler KDI 3404TCR?
The Kohler KDI 3404TCR oil change interval is every 2000 hours.
What is a common problem with the Kohler KDI 3404TCR engine?
A commonly reported issue on generators using the Kohler KDI 3404TCR is: Emergency Stop. Fix: Reset the emergency stop switch..