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Kohler KG2204 Engine

The Kohler KG2204 is a 2.2 L 4-cylinder natural aspiration engine rated at 1800 rpm, producing up to 30 kW. It powers generator sets from Kohler, including the 24RCL and 30RCLH. It holds 4.2 L (1.1 gal) of oil and 12.4 L (3.3 gal) of coolant.

Also known as: Kohler KG2204

Part of the Kohler KG2204 engine family — 2 variants share parts & fitment.

2.2 L

Displacement

Cylinders

1800 rpm

Rated speed

30 kW

Gross power

On this pageSpecs Generator sets Maintenance FAQ Service intervals Torque & specs Fluids Fault codes Procedures Wiring

Engine specifications

Oil capacity	4.2 L
Coolant capacity	12.4 L
Displacement	2.2 L
Cylinders	4
Aspiration	Natural Aspiration
Rated speed	1800 rpm
Gross power	30 kW

Generator sets powered by this engine

Kohler 24RCLKohler 30RCLH

How to read your Kohler engine serial & model number →

Troubleshooting

Symptoms & remedies

Symptom	Cause	Remedy
Will Not Start	No fuel	Check fuel supply.
Will Not Start	Incorrect fuel	Make sure fuel system is configured properly for LPG or NG supply.
Will Not Start	Dirty/restricted fuel system	Check fuel system and clean components as needed.
Will Not Start	Incorrect oil level	Check engine oil level; add as needed.
Will Not Start	Engine overloaded	Disconnect or reduce loads.
Will Not Start	Faulty spark plug	Inspect, adjust, or replace as needed.
Hard Starting	No fuel	Check fuel supply.
Hard Starting	Incorrect fuel	Make sure fuel system is configured properly for LPG or NG supply.
Hard Starting	Restricted fuel flow	Make sure fuel supply valves are open; check for air intake system leakage.
Hard Starting	Dirty/restricted fuel system	Check fuel system and clean components as needed.
Hard Starting	Incorrect oil level	Check engine oil level; add as needed.
Hard Starting	Engine overloaded	Disconnect or reduce loads.
Hard Starting	Faulty spark plug	Inspect, adjust, or replace as needed.
Stops Suddenly	No fuel	Check fuel supply.
Stops Suddenly	Dirty/restricted fuel system	Check fuel system and clean components as needed.
Stops Suddenly	Incorrect oil level	Check engine oil level; add as needed.
Stops Suddenly	Engine overloaded	Disconnect or reduce loads.
Lacks Power	Incorrect fuel	Make sure fuel system is configured properly for LPG or NG supply.
Lacks Power	Low fuel pressure	Check and adjust fuel pressure.
Lacks Power	Incorrect oil level	Check engine oil level; add as needed.
Lacks Power	Engine overloaded	Disconnect or reduce loads.
Lacks Power	Faulty spark plug	Inspect, adjust, or replace as needed.
Lacks Power	Dirty/restricted fuel system	Check fuel system and clean components as needed.
Lacks Power	Air induction system leak	Inspect air induction system.
Lacks Power	Damaged turbocharger	Inspect turbocharger compressor and turbine blades for damage and/or contact against housing.
Operates Erratically or Unevenly	Incorrect fuel	Make sure fuel system is configured properly for LPG or NG supply.
Operates Erratically or Unevenly	Dirty/restricted fuel system	Check fuel system and clean components as needed.
Operates Erratically or Unevenly	Low fuel supply pressure	Check and adjust.
Operates Erratically or Unevenly	Engine overloaded	Disconnect or reduce loads.
Operates Erratically or Unevenly	Loose wiring at shut-off valve(s)	Check wiring and repair connections.
Operates Erratically or Unevenly	Faulty spark plug	Inspect, adjust, or replace as needed.
Operates Erratically or Unevenly	Dirty air filter	Inspect and replace as needed.
Knocks or Pings	Incorrect fuel	Make sure fuel system is configured properly for LPG or NG supply.
Knocks or Pings	Engine overloaded	Disconnect or reduce loads.
Knocks or Pings	Faulty spark plug	Inspect, adjust, or replace as needed.
Knocks or Pings	Dirty/restricted fuel system	Check fuel system and clean components as needed.
Knocks or Pings	Dirty air filter	Inspect and replace as needed.
Knocks or Pings	Boost pressure too high	Check for stuck wastegate, check for leak in wastegate boost line.
Knocks or Pings	Excessive intake manifold temperature	Check charge air cooler for debris and clean as needed.
Skips or Misfires	Incorrect fuel	Make sure fuel system is configured properly for LPG or NG supply.
Skips or Misfires	Faulty spark plug	Inspect, adjust, or replace as needed.
Skips or Misfires	Dirty/restricted fuel system	Check fuel system and clean components as needed.
Skips or Misfires	Dirty air filter	Inspect and replace as needed.
Backfires	Incorrect fuel	Make sure fuel system is configured properly for LPG or NG supply.
Backfires	Faulty spark plug	Inspect, adjust, or replace as needed.
Backfires	Dirty/restricted fuel system	Check fuel system and clean components as needed.
Backfires	Dirty air filter	Inspect and replace as needed.
Overheats	Incorrect fuel	Make sure fuel system is configured properly for LPG or NG supply.
Overheats	Dirty/restricted fuel system	Check fuel system and clean components as needed.
Overheats	Incorrect oil level	Check engine oil level; add as needed.
Overheats	Engine overloaded	Disconnect or reduce loads.
Overheats	Faulty spark plug	Inspect, adjust, or replace as needed.
Consumes Excess Fuel	Faulty spark plug	Inspect, adjust, or replace as needed.
Consumes Excess Fuel	Dirty/restricted air cleaner element	Clean or replace.
Consumes Excess Fuel	Incorrect fuel pressure	Check and adjust fuel pressure.
ECM Does Not Store DTC	Faulty electrical connections, components, or wiring	Contact Rehlko service.
Erratic operation	Air induction system leak	Inspect air induction system.

Fault codes and symptom→remedy steps extracted from this engine’s service/owner documentation; verify against the official manual before servicing.

Common problems

Generator set stops suddenly.
Cause: Low oil pressure shutdown.
Fix: Check for oil leaks. Check the oil level and add oil if necessary.
The generator set cranks but does not start, starts hard, lacks power, or operates erratically.
Cause: Air cleaner clogged.
Fix: Clean and/or replace the air cleaner.
The generator set does not crank.
Cause: Battery weak or dead.
Fix: Recharge or replace the battery.
No AC output.
Cause: AC circuit breaker in the OFF position.
Fix: Place the circuit breaker in the ON position.
Loss of communication to accessory modules.
Cause: Bad connections.
Fix: Check wiring and connections. Verify that cable size and length of run comply with the instructions in the Installation manual.
Load management relays do not operate.
Cause: Bad connections.
Fix: Check wiring and connections. Verify that cable size and length of run comply with the instructions in the Installation manual.
Verify Date Time Setting — The time and date have not been set on the generator controller. Chk DateTime
Fix: Enter the date and time using the RDC2 controller. See Figure 3-8 and Figure 3-16.
Unavailable Genset Serial Number — Generator set serial number is unavailable. Genset S/N Unaval
Fix: Contact an authorized distributor/dealer for service. See section 3.11.
Speed Sensor Fault — Engine speed sensor has failed or engine stalled. ECM is no longer reporting valid speed. Spd Sens Flt
Fix: Contact an authorized distributor/dealer for service.
Primary Loop Shorted — Ignition coil 1 voltage is abnormal. PrimLoopSht
Fix: Check the battery voltage.; Contact an authorized distributor/dealer for service and provide the fault code.
Primary Loop Open — Ignition coil 1 voltage is below normal or there is an open circuit. PrimLoopOpn
Fix: Check the battery voltage.; Contact an authorized distributor/dealer for service and provide the fault code.
Over Crank — Three unsuccessful starting attempts. Over Crank
Fix: Check the fuel supply, spark plug, and battery.; Check for loose connections.; Contact an authorized distributor/dealer for service.
Not In Auto — The generator set is not in Automatic (standby) mode. Remote start and stop commands from a transfer switch or remote switch will be ignored. Not in Auto
Fix: Press AUTO to place the generator set in Automatic mode, when appropriate.
Maintenance Required Warning — Engine maintenance is due. Maint Req’d
Fix: Check the maintenance schedule in the operation manual for tasks such as changing the oil, spark plugs or the air filter.
Main Power Overload — Main power overload. An over current fault on the 70 controller power output (short circuit). MainPwrOverL
Fix: Check for shorted run relay. Check wiring for short circuits.; Contact an authorized distributor/dealer for service.

Compiled from service & troubleshooting documentation across every generator set that uses the Kohler KG2204.

Maintenance schedule

Item	Spec	Capacity	Part #
Air filter	Dry		—
Oil filter			—
Battery	BCI group 24 size, 12-volt, minimum 630 cold cranking amps (CCA) at 0°F		—
Belt	5–7 mm (0.20–0.28 in.)		—
Coolant	50% ethylene glycol-based long-life coolant / 50% clean, softened water	12.4 L (13.1 gal.)	—
Oil		3.3 L	—
Spark plug	0.7–0.8 mm (0.028–0.031 in.)		GM100158	Amazon eBay $49.00

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

Service intervals

Item	Action	Hours	Months	Notes
Air cleaner element	Clean	20 hr	3 mo	Replace at 3 years or 400 hours
Bolts and nuts for tightness	Check	20 hr	3 mo	Quarterly or 20 hours
Battery cables	Clean	120 hr	12 mo
Battery charge	Check	120 hr	12 mo
Battery fluid level	Check	120 hr	12 mo
Battery for cracks and corrosion	Check	120 hr	12 mo
Belts and belt tension	Check	120 hr	12 mo	See engine O/M
Engine oil and filter	Change	120 hr	12 mo
Fuel regulator pressure	Check	120 hr	12 mo
Radiator exterior	Check	120 hr	12 mo
Brushes and collector ring	Other	300 hr	12 mo	Authorized distributor/dealer only
Air induction for leaks	Check	500 hr	36 mo
Engine coolant	Change	500 hr	36 mo	Long-life coolant: 5000 hours or 5 years
Hoses, condition	Check	500 hr	36 mo	Replace as necessary
Intake manifold for vacuum leaks	Check	500 hr	36 mo
Secondary ignition coil wires	Check	500 hr	36 mo	Replace as necessary
Spark plug wires for cuts, abrasions, or hardening	Check	500 hr	36 mo	Replace as necessary
Spark plugs	Change	500 hr	36 mo
Exhaust manifold for leaks	Check	2000 hr	60 mo	Replace as necessary
Exhaust piping for leaks	Check	2000 hr	60 mo
Fuel shutoff valve operation	Check	2000 hr	60 mo
HEGO (oxygen) sensor connections and wires	Check	2000 hr	60 mo	See engine O/M
Fuel lines and connections	Check		3 mo	Quarterly
Vacuum lines and fittings	Inspect		60 mo	5 years
Wiring for cuts, abrasions, or corrosion	Inspect		60 mo	5 years

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

Type	Item	Value	Unit	Condition
Gap	Spark plug gap	0.51	mm (0.02 in.)
Gap	Spark plug gap	0.7--0.8	mm (0.028--0.030 in.)
Gap	Spark plug gap	0.7-0.8	mm (0.028-0.030 in.)
Gap	Spark plug gap	0.76	mm (0.03 in.)
Gap	Spark plug gap	0.8--0.9	mm (0.03--0.04 in.)
Gap	Spark plug gap	0.89	mm (0.035 in.)
Gap	Spark plug gap	0.9--1.0	mm (0.036--0.04 in.)
Gap	Spark plug gap	0.9-1.0	mm (0.036-0.040 in.)
Pressure	Fuel supply test pressure	6-8	ounces per square inch (10-14 inches water column)	leak test with soap and water solution
Pressure	Radiator pressure cap rating	97	kPa (14 psi)
Torque	Oil filter	25	Nm (18.4 ft. lbs.)	after hand-tight plus 3/4 turn
Torque	Spark plug	18	Nm (13.3 ft. lbs.)	plus additional 1/4 turn
Torque	Spark plug	25	Nm (18.4 ft. lbs.)	plus additional 1/4 turn
Torque	Spark plug torque	15	Nm (11 ft. lb.)
Torque	Spark plug torque	18	Nm (13.3 ft. lb.)
Torque	Spark plug torque	24.4--29.8	Nm (18--22 ft. lb.)
Torque	Spark plug torque	25	Nm (18 ft. lb.)
Torque	Terminal connector, socket size 12.7mm (1/2 in)	56.5	Nm (500 in. lb.)	internal-drive socket-head screw
Torque	Terminal connector, socket size 14.3mm (9/16 in)	67.8	Nm (600 in. lb.)	internal-drive socket-head screw
Torque	Terminal connector, socket size 3.2mm (1/8 in)	5.1	Nm (45 in. lb.)	internal-drive socket-head screw
Torque	Terminal connector, socket size 4.0mm (5/32 in)	11.4	Nm (100 in. lb.)	internal-drive socket-head screw
Torque	Terminal connector, socket size 4.8mm (3/16 in)	13.8	Nm (120 in. lb.)	internal-drive socket-head screw
Torque	Terminal connector, socket size 5.6mm (7/32 in)	17.0	Nm (150 in. lb.)	internal-drive socket-head screw
Torque	Terminal connector, socket size 6.4mm (1/4 in)	22.6	Nm (200 in. lb.)	internal-drive socket-head screw
Torque	Terminal connector, socket size 7.9mm (5/16 in)	31.1	Nm (275 in. lb.)	internal-drive socket-head screw
Torque	Terminal connector, socket size 9.5mm (3/8 in)	42.4	Nm (375 in. lb.)	internal-drive socket-head screw
Voltage	Undervoltage dropout (ATS source availability)	90	% of pickup
Voltage	Undervoltage pickup (ATS source availability)	90	% of nominal

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
Coolant	50% ethylene glycol-based long-life coolant / 50% clean, softened water		37°C to 149°C	12.4 L (13.1 gal.)	Freezing protection to -37C (-34F), overheating protection to 149C (300F); do not mix long-life and conventional coolants, no alcohol/methanol antifreeze
Engine oil	SAE 5W-30 (cold environments); 10W-30 (hot environments, never below 0C/32F)	API Starburst certification, service class SJ or higher (gasoline engines)		4.2 L (4.4 qt.)	CC/CD classification oils not acceptable

Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.

Fault codes

Code	Name	Meaning	Severity	Action
AC Sens Loss	AC Sensing Lost	AC sensing lost in Auto mode; warning after 1 sec if no output after crank disconnect, shutdown after 3 sec if voltage was present then lost	Warning	Contact an authorized distributor/dealer for service
Accy PwrOver	Accessory Power Overload	Over current fault (short circuit) on the accessory controller power output	Warning	Contact an authorized distributor/dealer for service
ATS ComError	ATS Communication Error	RXT interface connection is lost	Warning	Check communication wiring between transfer switch interface board and generator set
ATS PhaseRot	ATS Phase Rotation Mismatch	Transfer switch phase rotation does not match; ATS will not transfer	Warning	Correct the ATS connection per installation manual, wiring diagrams, and labels
Aux Input	Auxiliary Input	An optional customer-connected input is closed (digital input from optional PIM)	Shutdown	Check customer-supplied equipment
Battery CrLo	Critically Low Battery Voltage	Battery voltage falls below 11V for more than 10 seconds; inhibited during crank	Warning	Check battery rating/condition and charger operation; charge or replace battery
Battery High	High Battery Voltage	Battery voltage rises above 133% (16V) of the battery voltage setting for more than 10 seconds	Warning	Check battery rating/condition and charger operation
Battery Low	Low Battery Voltage	Battery voltage falls below the battery voltage setting (typically 12.5V) for more than 90 seconds when engine is not running	Warning	Check battery rating/condition and charger operation; charge or replace battery
Chk DateTime	Verify Date Time Setting	The time and date have not been set on the generator controller	Warning	Enter the date and time using the RDC2 controller
Coolant Lvl Low	Low Coolant Level Shutdown	The coolant level switch input has been activated	Shutdown	Check coolant level; check radiator hoses for leaks; contact dealer
CoolntTemp 0	Coolant Temp 0 Shutdown	ECM reported coolant temperature sensor problem: 0 = high temperature	Shutdown	Check coolant level and radiator/fans; contact dealer with fault code
CoolntTemp 3	Coolant Temp 3 Shutdown	ECM reported coolant temperature sensor problem: 3 = high voltage	Shutdown	Contact an authorized distributor/dealer for service and provide the fault code
CoolntTemp 4	Coolant Temp 4 Shutdown	ECM reported coolant temperature sensor problem: 4 = low voltage	Shutdown	Contact an authorized distributor/dealer for service and provide the fault code
CoolntTemp 5	Coolant Temp 5 Shutdown	ECM reported coolant temperature sensor problem: 5 = open circuit	Shutdown	Contact an authorized distributor/dealer for service and provide the fault code
CoolTemp Vhi	Ect Higher Than Expected 2	Coolant temperature is extremely high	Shutdown	Check coolant level; check radiator/fans for obstruction; contact dealer with fault code
CoolTempHigh	Ect Higher Than Expected 1	Coolant temperature is too high	Warning	Check coolant level; check radiator/fans for obstruction; contact dealer with fault code
Crank Lost	Crank Signal Lost	Crankshaft Position Sensor (CPS) timeout error occurred	Warning	Contact an authorized distributor/dealer for service and provide the fault code
ECM warnings	ECM warnings (any warning with ECM in the fault name)	Group of faults that originate from the engine ECM and contain ECM in the fault name	Warning	Contact an authorized distributor/dealer for service and provide the fault code
Emerg Stop	Emergency Stop Shutdown	The emergency stop switch has been activated, or there has been an open circuit in the wiring	Shutdown	Contact an authorized distributor/dealer for service
Eng Speed High	High Engine Speed	Engine speed exceeds 115% of normal running speed for more than 0.3 seconds	Shutdown	Contact an authorized distributor/dealer for service
Eng Speed Low	Low Engine Speed	Engine speed drops below 85% of normal running speed for more than 3 seconds	Shutdown	Reduce the load; contact an authorized distributor/dealer for service
Exer Not Sch	ATS Exercise Not Scheduled	No exercise has been scheduled on the RDC2 controller	Warning	Set the exerciser per Section 2.5
Frequency High	High Frequency	Governed frequency exceeds 110% of system frequency setpoint for more than 10 seconds (10 sec inhibit after start)	Shutdown	Contact an authorized distributor/dealer for service
Frequency Low	Low Frequency	Governed frequency falls below 90% of system frequency setting for more than 10 seconds, or 1 Hz below setting for more than 60 seconds	Shutdown	Reduce the load and restart; contact dealer
Genset S/N Unaval	Unavailable Genset Serial Number	Generator set serial number is unavailable	Warning	Contact an authorized distributor/dealer for service
Ground Fault	Ground Fault Warning	The digital input for Ground Fault Warning is active (low); PIM required	Warning	Check customer equipment connected to the PIM
IAT High 1	Iat Higher Than Expected 1	Engine manifold air temperature is too high	Warning	Contact an authorized distributor/dealer for service and provide the fault code
IAT Volt Lo	Iat Low Voltage	ECM reported an Engine Air Temperature/Manifold Absolute Pressure Sensor (TMAP) error	Warning	Contact an authorized distributor/dealer for service and provide the fault code
Lo Crank Vlt	Low Cranking Voltage	Battery voltage falls below 60% of system battery voltage for more than 6 seconds while the starter is engaged	Warning	Charge or replace the battery
Locked Rotor	Locked Rotor	No engine rotation is sensed during cranking; shuts down 3 seconds after fault detected	Shutdown	Check battery, connections, and for obstruction of alternator or engine; contact dealer
MainPwrOverL	Main Power Overload	Over current fault on the controller power output (short circuit)	Shutdown	Check for shorted run relay; check wiring for short circuits; contact dealer
Maint Req'd	Maintenance Required Warning	Engine maintenance is due	Warning	Check the maintenance schedule in the operation manual
Not in Auto	Not In Auto	The generator set is not in Automatic (standby) mode; remote start/stop commands will be ignored	Warning	Press AUTO to place the generator set in Automatic mode
Oil Pres Low	Low Oil Pressure	The engine ECM indicates low oil pressure	Shutdown	Check for leaks in the lubrication system; check oil level; check oil pressure switch and wiring
Over Crank	Over Crank	Three unsuccessful starting attempts	Shutdown	Check fuel supply, spark plug, battery, and connections; contact dealer
PrimLoopOpn	Primary Loop Open	Ignition coil 1 voltage is below normal or there is an open circuit	Warning	Check the battery voltage; contact dealer with fault code
PrimLoopSht	Primary Loop Shorted	Ignition coil 1 voltage is abnormal	Warning	Check the battery voltage; contact dealer with fault code
Spd Sens Flt	Speed Sensor Fault	Engine speed sensor has failed or engine stalled; ECM no longer reporting valid speed	Shutdown	Contact an authorized distributor/dealer for service
Volts L1-L2 High	High Generator Voltage L1-L2	Output voltage exceeds 120% of system nominal voltage for more than 2 seconds	Shutdown	Contact an authorized distributor/dealer for service
Volts L1-L2 Low	Low Generator Voltage L1-L2	Output voltage falls below 80% of nominal system voltage for more than 10 seconds	Shutdown	Reduce the load and restart; contact dealer
Volts L2-L3 High	High Generator Voltage L2-L3	Output voltage exceeds 120% of system nominal voltage for more than 2 seconds	Shutdown	Contact an authorized distributor/dealer for service
Volts L2-L3 Low	Low Generator Voltage L2-L3	Output voltage falls below 80% of nominal system voltage for more than 10 seconds	Shutdown	Reduce the load and restart; contact dealer
Volts L3-L1 High	High Generator Voltage L3-L1	Output voltage exceeds 120% of system nominal voltage for more than 2 seconds	Shutdown	Contact an authorized distributor/dealer for service
Volts L3-L1 Low	Low Generator Voltage L3-L1	Output voltage falls below 80% of nominal system voltage for more than 10 seconds	Shutdown	Reduce the load and restart; contact dealer

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-Lead Generator Reconnection Procedure adjustment

⚠ Verify that voltage ratings of transfer switch, line breakers, and accessories match the selected line voltage

Tools: digital multimeter, voltmeter

Press the OFF button on the RDC2 controller
Disconnect engine starting battery, negative lead first
Disconnect utility power to the generator set
Select desired voltage connection and connect leads according to the diagram
Reconnect engine starting battery, negative lead last
Enter the RDC2 Genset System menu and check/change system voltage, frequency, phase settings
Connect a digital multimeter (DVM) to the generator set output
Press RUN to start the generator set
Use a voltmeter to check output voltage and calibrate if necessary
Press OFF to stop the generator set
Reconnect utility power to the generator set
Press AUTO to place the generator set in automatic mode

Fuel Conversion: Reset Regulator for NG adjustment

Push up on the adjusting cap and rotate counterclockwise, release upward pressure, and lock into place
Disconnect wire N20 and wire 45

Fuel Conversion: Set Regulator for LPG adjustment

⚠ Do not adjust the IEPR or the air/fuel mixer

Push the adjusting cap to its upper stop and rotate clockwise, release upward pressure, and lock into place
For LPG fuel only, use the quick-connect adapters to connect wire N20 from the fuel pressure regulator to wire 45 from the ECM wiring harness

RDC2 Voltage Calibration Using SiteTech adjustment

Tools: digital voltmeter, personal computer, SiteTech software

Connect PC to controller via USB
With generator off, connect multimeter across L1/L2 (AC volts)
Start generator set
Compare voltmeter reading to controller display
Calculate new Genset Calibration Factor Voltage using (Vmeter / Vcontrol) x Fold = Fnew
Enter new value into SiteTech and click Apply Changes
Verify voltmeter matches controller display
Repeat for L2-L3 and L3-L1 if three-phase
Press OFF to stop generator set

RDC2 Voltage Calibration Using the Controller Keypad adjustment

Tools: digital voltmeter

With generator off, connect digital multimeter across L1 and L2, set to AC volts
Start generator set with RUN button
Navigate to Generator Metering menu, press Select; Volts L1-L2 displayed
Press Select; voltage number flashes
Use up/down arrows to match voltmeter reading
Press Select to confirm
Step to Return screen
Press OFF to stop generator set

VSC Current (Load) Calibration Using the Controller Keypad adjustment

Tools: clamp-on DC current probe or DC current meter

Connect DC current probe/clamp meter to measure generator current
Start generator with RUN button
Adjust system voltage to obtain rated current output with battery bank attached (or use load bank)
Trip output breaker
Navigate to Generator Metering menu, select Generator Load
Press and hold Select for No-Load Calibration; verify breaker open, confirm Yes
Close output breaker; verify rated output current, confirm Yes
Verify displayed load is correct; recalibrate if necessary
Press OFF to stop generator set

Voltage Calibration Using RDC2 Controller Keypad and Menus adjustment

Tools: digital multimeter

With the generator set off, connect a digital multimeter to measure output voltage across L1 and L2
Start the generator set by pressing RUN
Navigate to the Generator Metering menu
Press Select to display Volts L1-L2 and compare to the voltmeter reading
If incorrect, press Select, use up/down arrows to adjust voltage to match the voltmeter, press Select to save
Wait 30-60 seconds for the reading to stabilize
For three-phase models, repeat for L2-L3 and L3-L1
Step to Return and exit the Generator Metering menu
Press OFF to stop the generator set

Obtain DC2 Controller Password and Serial Number diagnostic

Press OFF and verify that the generator set is not running.
Press and hold the Exercise button until Press Again to Reset OnCue Plus PW is displayed.
Release the Exercise button and press it again within 5 seconds.
Write down the serial number (S/N) and password.

Obtain RDC/DC Controller Password diagnostic

Press OFF to place the controller into OFF mode.
Press the down arrow button (RDC) or exercise button (DC) 5 times.
Note the four-digit code displayed on the controller; this is the controller password.
Write down the password and press OFF to clear the display.

Obtain RDC2 or VSC Controller Password and Serial Number diagnostic

Press the controller down arrow button to navigate to the Networking Information menu.
Follow the reset password procedure shown in Figure 1-3.
Write down the serial number (S/N) and password displayed for 10 seconds.

Power Cycle the Controller diagnostic

Disconnect all input power for two minutes to allow capacitors to discharge.
Remove the battery negative cable or disconnect P1 from the back of the controller.
Disconnect the battery charger 120 VAC input power supply or disconnect P5 from the back of the controller.
Unplug the USB mini-B connector from the front of the controller if plugged in.
Wait two minutes, then reconnect power, hooking up battery power (P1) first.

Resetting the Controller after a Fault Shutdown diagnostic

⚠ Always identify and correct the cause of a fault shutdown before resetting

Press the Select button to go to the Overview menu
Press Select again to display the active fault
Press Select; Confirm Clear Fault: NO is displayed
Press the Up arrow button; Confirm Clear Fault: YES is displayed
Press Select to enter YES and clear the fault
Press Select to return to the Overview menu
Press AUTO to put the generator set into automatic mode

Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.

Voltage reconnection

Voltage	Phase	Connection	Leads	Notes
	Three-phase (12-lead)	Reconnectable to voltages/phases per generator set specification sheet	12-lead	See Figure 3-2, 24RCL and 30RCLH
100/200	1	Single
100/200	3	Delta
110/220	1	Single
110/220	3	Delta
115/230	1	Single
120	1	Single		Genset System Voltage/Frequency/Phase table for controller setup
120/208	3	4D5.0	12, Reconnectable	Three-phase
120/208	3	Wye
120/240	1	4E5.0	4	Single-phase
120/240	1	Single
120/240	3	Delta
120/240 V	Single-phase (four-lead)	Factory connection, not reconnectable	4-lead	60 Hz; see Figure 3-1
127/220	3	4D5.0	12, Reconnectable	Three-phase
127/220	3	Wye
220	1	Single
220/380	3	Wye
230	1	Single
230/400	3	Wye
240	1	Single
240/416	3	Wye
277/480	3	Wye

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 KG2204 family

Part #	Description	Category
GM103786	Battery heater wrap	Battery heater wrap
GM104701	Battery heater wrap	Battery heater wrap
GM104708	Battery heater wrap	Battery heater wrap
GM103784	Battery heater wrap	Service part / kit
GM104699	Battery heater wrap	Service part / kit
GM104703-KP1	Battery heater kit, 120 Volts, heater wrap rating 50 Watts, battery wrap length 864 mm (34 in.), power cord length 483 mm (19 in.), plug cord length 75 mm (3 in.)	Service part / kit

Parts cataloged across all variants of this engine family — verify the exact part fits your specific variant and serial number before ordering.

Common questions

What is the oil capacity of the Kohler KG2204?

The Kohler KG2204 engine has an oil capacity of 4.2 liters.

What is the displacement of the Kohler KG2204?

The Kohler KG2204 has a displacement of 2.2 liters with 4 cylinders.

Which generators use the Kohler KG2204 engine?

The Kohler KG2204 powers 2 generator set(s), including Kohler 24RCL, Kohler 30RCLH.

What is a common problem with the Kohler KG2204 engine?

A commonly reported issue on generators using the Kohler KG2204 is: Generator set stops suddenly.. Cause: Low oil pressure shutdown.. Fix: Check for oil leaks. Check the oil level and add oil if necessary..

Kohler KG2204 Engine

Engine specifications

Generator sets powered by this engine

Troubleshooting

Symptoms & remedies

Common problems

Maintenance schedule

Repair guides

Service intervals

Service specifications

Recommended fluids

Fault codes

Procedures

Voltage reconnection

Parts cataloged across the Kohler KG2204 family

Common questions