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Home›Engines›Kohler KDI 3404TM

Kohler KDI 3404TM Engine

The Kohler KDI 3404TM is a 3.36 L 4-cylinder turbo engine rated at 1500 rpm, producing up to 72 kW. It powers generator sets from Kohler, including the 40REOZK, 50REOZK, 60REOZK and KDI 3404 TM. It holds 15.6 L (4.1 gal) of oil and 4.5 L (1.2 gal) of coolant.

Also known as: Kohler KDI 3404TM, KDI 3404TM

Part of the Kohler KDI3404TM engine family — 2 variants share parts & fitment.

3.359 L
Displacement
4
Cylinders
1500 rpm
Rated speed
72 kW
Gross power
On this pageSpecsGenerator setsMaintenanceFAQService intervalsTorque & specsFluidsProcedures

Engine specifications

Oil capacity15.6 L
Coolant capacity4.5 L
Displacement3.359 L
Cylinders4
AspirationTurbo
Rated speed1500 rpm
Gross power72 kW

Common problems

15
  • Emergency Stop 32A
    Fix: Reset the emergency stop switch.
  • Pre Low Oil Pressure 41
    Fix: Check and adjust oil level or replace oil pump.
  • Pre High Coolant Temp. 40
  • Low Fuel 63
    Fix: Refuel the generator set.
  • Low Battery Volts 62
  • High Coolant Temperature 32
  • Warning YELLOW light turn on
    Cause: Engine ECU has detect a malfunctions
    Fix: Contact KOHLER authorised workshops
  • Throttle to MAX in starting
    Fix: Release the throttle and wait some seconds
  • The engine does not start
    Cause: Sulphated battery terminals corroded
    Fix: Clean the battery terminals
  • Sulphated battery terminals
    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
  • Intake or exhaust system clogged
    Fix: Replace with a new fuse; if the problem persists, Contact KOHLER authorised workshops
  • High oil sump level
    Fix: Replace the engine oil; if the problem persists, Contact KOHLER authorised workshops

Compiled from service & troubleshooting documentation across every generator set that uses the Kohler KDI 3404TM.

Maintenance schedule

ItemSpecCapacityPart #Interval
Air filterDry air cleaner external cartridge—5000 hr
Fuel filter—250 hr
Oil filter—250 hr
BatteryOne, 650 CCA—
BeltAlternator belt—1500 hr
Coolantinterior radiator cleaning—1000 hr
Oil15.6 L—250 hr
Spark plug—

Pooled from every document that names this exact engine — confirm the interval and part number against your unit's serial number.

Service intervals

1
ItemActionHoursMonthsNotes
oilChange500 hrMinimum 500 hours oil change interval

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

50
TypeItemValueUnitCondition
GapSpeed sensor air gap0.36- 0.71mm
Other10 in. weld flange bolt circle diameter B361.95mm (14.25 in.)
Other10 in. weld flange outside diameter C406.4mm (16.0 in.)
Other10 in. weld flange quantity of bolts / bolt hole diameter D12, 25.40mm (1.00 in.)
Other12 in. weld flange bolt circle diameter B431.80mm (17.00 in.)
Other12 in. weld flange outside diameter C482.6mm (19.0 in.)
Other12 in. weld flange quantity of bolts / bolt hole diameter D12, 25.40mm (1.00 in.)
Other14 in. weld flange bolt circle diameter B476.25mm (18.75 in.)
Other14 in. weld flange outside diameter C533.4mm (21.0 in.)
Other14 in. weld flange quantity of bolts / bolt hole diameter D12, 28.58mm (1.13 in.)
Other16 in. weld flange bolt circle diameter B539.75mm (21.25 in.)
Other16 in. weld flange outside diameter C596.9mm (23.5 in.)
Other16 in. weld flange quantity of bolts / bolt hole diameter D16, 28.58mm (1.13 in.)
Other18 in. weld flange bolt circle diameter B577.85mm (22.75 in.)
Other18 in. weld flange outside diameter C635.0mm (25.0 in.)
Other18 in. weld flange quantity of bolts / bolt hole diameter D16, 31.75mm (1.25 in.)
Other20 in. weld flange bolt circle diameter B635.00mm (25.00 in.)
Other20 in. weld flange outside diameter C698.5mm (27.5 in.)
Other20 in. weld flange quantity of bolts / bolt hole diameter D20, 31.75mm (1.25 in.)
Other5 in. weld flange bolt circle diameter B215.90mm (8.50 in.)
Other5 in. weld flange outside diameter C241.30mm (9.50 in.)
Other5 in. weld flange quantity of bolts / bolt hole diameter D8, 22.23mm (0.88 in.)
Other6 in. weld flange bolt circle diameter B254.0mm (10.0 in.)
Other6 in. weld flange outside diameter C279.4mm (11.0 in.)
Other6 in. weld flange quantity of bolts / bolt hole diameter D8, 22.23mm (0.88 in.)
Other8 in. weld flange bolt circle diameter B298.45mm (11.75 in.)
Other8 in. weld flange outside diameter C342.9mm (13.5 in.)
Other8 in. weld flange quantity of bolts / bolt hole diameter D8, 22.23mm (0.88 in.)
OtherWeld flange angle A (10, 12, 14 in. nominal pipe size)30deg.
OtherWeld flange angle A (16, 18, 20 in. nominal pipe size)22.5deg.
OtherWeld flange angle A (5, 6, 8 in. nominal pipe size)45deg.
PressureBattery equalizer input voltage (24 volts nominal)20- 35volts
PressureBattery equalizer output voltage(input voltage/2) ±2%volts
PressurePressure switch 364345483 ±14kPa
ResistancePressure sender 264390 value A240 +17/- 15ohms at 0 psi
ResistancePressure sender 264390 value B153 +12/- 15ohms at 25 psi
ResistancePressure sender 264390 value C33.5ohms at 100 psi
ResistancePressure sender 365624 value A241 ±16ohms at 0 psi
ResistancePressure sender 365624 value B152 ±13ohms at 50 psi
ResistancePressure sender 365624 value C33.5ohms at 200 psi
ResistanceTemperature sender 226717 value A123.8 +7.2/- 7.8ohms at 90.6 C (195 F)
ResistanceTemperature sender 226717 value B35.6 +3.4/- 3.6ohms at 137.8 C (280 F)
ResistanceTemperature sender 226919 value A942 ±22ohms at 37.7 C (100 F)
ResistanceTemperature sender 226919 value B35ohms at 115.6 C (240 F)
SpeedOverspeed shutdown70Hz60 Hz models
TemperatureBattery equalizer operating temperature- 40 to 71C (- 40 F to 160 F)
TemperatureTemperature switch 241308107 ±4C (225 F ±7 F)normally open to close on temp. rise
TemperatureTemperature switch 290090/GM5170516 ±3C (60 F ±5 F)normally open to close on temp. fall
VoltageSpeed sensor voltage, wire 2 (black) & 16 (white)3- 6volts DC
VoltageSpeed sensor voltage, wire 2 (black) & 24 (red)8- 10volts 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

FluidGradeStandardAmbientCapacityNotes
FuelNo 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 onlyASTM 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

12
Overfrequency Adjustment (Over/Underfrequency Relay, Decision-Maker 3+) adjustment
  1. Turn the overfrequency adjustment potentiometer fully clockwise (CW).
  2. Place master switch in RUN to start the generator set.
  3. Adjust governor per engine operation manual, engine service manual, or governor section of this manual.
  4. Slowly turn overfrequency potentiometer counterclockwise (CCW) until the LED starts flashing; after about 10 seconds the set shuts down on auxiliary fault.
  5. Place master switch to OFF/RESET to reset the controller.
  6. Place master switch to RUN to start the generator set.
  7. Readjust the governor to the desired frequency as required.
  8. 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.

  1. Disconnect generator set from load by opening line circuit breaker or disconnecting and taping output leads.
  2. Determine overvoltage shutdown value based on user requirement; factory setting is 15% above nominal line-to-neutral voltage.
  3. Remove the controller cover.
  4. Place master switch in RUN to start the generator set.
  5. Observe AC voltmeter; turn voltage adjustment potentiometer CW until generator set shuts down.
  6. If the shutdown point is correct, go to step 12; otherwise continue.
  7. Turn controller circuit board R42 adjustment potentiometer fully CW.
  8. Place master switch to OFF/RESET to reset; then to RUN to start.
  9. Observe AC voltmeter while turning voltage adjustment potentiometer to desired overvoltage shutdown point.
  10. Turn R42 adjustment potentiometer slowly CCW until the generator set shuts down.
  11. Turn controller voltage adjustment potentiometer slightly CCW.
  12. Place master switch OFF/RESET then RUN to start; adjust for correct voltage and phase.
  13. Place master switch OFF/RESET to stop.
  14. Disconnect battery negative lead first; reconnect generator set to load; reconnect battery negative lead last.
Reactive Droop Compensator Adjustment Procedure adjustment

Tools: Voltmeter, Wattmeter

  1. Remove any load; start each generator set with master switch in RUN.
  2. 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.
  3. Repeat for generator set no. 2.
  4. Compare readings; adjust voltage within 1 volt and speed within 3 rpm (or 0.1 Hz) at each load step.
  5. Check droop compensation on each unit with an inductive load 1/2 to full load.
  6. Adjust rheostat to approximately 4% below rated voltage at full load.
  7. Repeat for unit no. 2.
Reactive Droop Compensator Alternate Adjustment Procedure adjustment

Tools: Voltmeter

  1. Turn reactive droop compensator rheostat on generator set no. 1 to minimum setting.
  2. Remove controller cover; move voltage sensing lead from V7 to V9 at the AC fuse terminal block.
  3. Remove any load connected to the generator set.
  4. Start the generator set with master switch in RUN.
  5. Use controller or remote voltage adjusting potentiometer to fine adjust voltage.
  6. Apply resistive load (1.0 power factor) until reaching rated current.
  7. Adjust reactive droop compensator rheostat to achieve a 4% droop in voltage.
  8. Remove the resistive load and stop the generator set.
  9. Return voltage sensing lead from V9 to V7 at the AC fuse terminal block.
  10. Replace the controller cover and repeat for generator set no. 2.
Underfrequency Adjustment (Over/Underfrequency Relay, Decision-Maker 3+) adjustment
  1. Turn underfrequency adjustment potentiometer fully clockwise (CW).
  2. Place master switch in RUN to start the generator set.
  3. Adjust governor per engine operation manual, engine service manual, or governor section of this manual.
  4. Slowly turn underfrequency potentiometer counterclockwise (CCW) until LED starts flashing; after about 10 seconds the set shuts down on auxiliary fault.
  5. Place master switch to OFF/RESET to reset the controller.
  6. Place master switch to RUN to start the generator set.
  7. Readjust the governor to the desired frequency as required.
  8. 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

  1. Measure DC voltage between lead 31A (+) and ground (- ) with sender submerged in coolant; voltmeter indicates approximately 12.5 VDC.
  2. 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

  1. Measure resistance between lead 31 and ground with sender submerged in coolant; ohmmeter indicates a high resistance reading.
  2. 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

  1. Remove the ground (GND) connections from the battery equalizer; do not allow contact with other connections.
  2. 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.
  3. Connect the test light between the +12 volt and GND terminals; the light will illuminate on a functional unit.
  4. With the test light connected, measure and record the voltage between the +12 volt and +24 volt terminals.
  5. With the test light connected, measure and record the voltage between the +12 volt and GND terminals.
  6. Remove the test light.
  7. 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

  1. Disconnect the oil pressure sender lead 7C.
  2. Check the sender resistance with an ohmmeter.
  3. Compare resistance values when the generator set is shut down and when running at operating temperature to Section 1, Specifications.
  4. Use a mechanical oil pressure gauge to further verify correct readings.
Overcrank Test (Typical) diagnostic
  1. On gas-fueled sets, disconnect the coil wire at the distributor cap and ground it or disconnect the ignition system.
  2. On diesel-fueled sets, unplug the fuel injector harness from ECM or disconnect wire no. 70 from the injector pump solenoid.
  3. Place unit in RUN mode; observe 15-second on-off cranking cycles and maximum 75-second elapsed time to overcrank shutdown.
  4. Observe controller fault lamp and display for an overcrank shutdown.
  5. Place unit in OFF/RESET mode.
  6. 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

  1. 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.
  2. Place master switch in RUN to start the generator set.
  3. 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.
  4. Place master switch in OFF/RESET to stop the generator set.
  5. If sensor emits a signal, check continuity of speed sensor leads (wires 2, 16, 24) between controller P1 connector and sensor terminals.
Speed Sensor Test with Separate 12 VDC Source diagnostic

Tools: DC voltmeter, 12-volt battery or DC power supply, Flat piece of iron or steel

  1. Place master switch in OFF/RESET position.
  2. Disconnect the speed sensor leads.
  3. Connect speed sensor, DC voltmeter, and DC voltage source as shown.
  4. Touch sensing surface with a flat piece of iron or steel at least 4.1 cm (1/4 cu. in.) in size.
  5. DC voltmeter reading should equal the source voltage, approximately 12 VDC.
  6. Remove the iron or steel piece and observe a voltmeter reading of 0 VDC.
  7. If the sensor passes, it is functional; replace if it fails.
  8. Connect the speed sensor leads and adjust the air gap.

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 KDI3404TM family

5
Part #DescriptionCategory
F-44kerosene, NATO designationFuel
F-63kerosene, NATO designation, equivalent to F-34/F-35 with additivesFuel
ED0010101730-SCamshaftService part / kit
ED0010101820-SCamshaftService part / kit
ED0014603650-SSix Nicks SN8Service part / kit

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

1
ED0021750010-S Amazon eBay $109.95 FridayParts $19.50

Parts 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 3404TM?

The Kohler KDI 3404TM engine has an oil capacity of 15.6 liters.

What is the displacement of the Kohler KDI 3404TM?

The Kohler KDI 3404TM has a displacement of 3.359 liters with 4 cylinders.

Which generators use the Kohler KDI 3404TM engine?

The Kohler KDI 3404TM powers 5 generator set(s), including Kohler 40REOZK, Kohler 50REOZK, Kohler 60REOZK, Kohler KDI 3404 TM, Kohler KDI 3404 TM E.PACK 60 kVA.

How often should you change the oil in the Kohler KDI 3404TM?

The Kohler KDI 3404TM oil change interval is every 250 hours.

What is a common problem with the Kohler KDI 3404TM engine?

A commonly reported issue on generators using the Kohler KDI 3404TM is: Emergency Stop. Fix: Reset the emergency stop switch..