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Kohler KG2204/KG2204T Engine

Name: Kohler KG2204/KG2204T Engine
Brand: Kohler

The Kohler KG2204/KG2204T is a 2.2 L 4-cylinder naturally aspirated (kg2204); turbocharged (kg2204t) engine rated at 1800 rpm, producing up to 30 kW. It powers generator sets from Kohler, including the 24RCL, 25CCL, 30CCL and 30RCL. It holds 4.2 L (1.1 gal) of oil and 13.2 L (3.5 gal) of coolant.

Also known as: Kohler KG2204/KG2204T, KG2204/KG2204T

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

Real-unit nameplate

Kohler KG2204/KG2204T engine engine nameplate / data tag

Nameplate from a real Kohler KG2204/KG2204T engine — photo from a surplusrecord.com listing. How to read one →

Engine specifications

Oil capacity	4.2 L
Coolant capacity	13.2 L
Displacement	2.2 L
Cylinders	4
Aspiration	Naturally aspirated (KG2204); Turbocharged (KG2204T)
Rated speed	1800 rpm
Gross power	30 kW

Generator sets powered by this engine

Kohler 24RCL Kohler 25CCL Kohler 30CCL Kohler 30RCL Kohler 36CCL Kohler 38RCLB

How to read your Kohler engine serial & model number →

Common problems

Relé de falla común DCB2 DCB2
Relé de falla común DCB1 DCB1
Fix: Llene el sistema de enfriamiento antes de encender el calentador de bloque. Ponga en marcha el motor hasta que este se caliente y llene el radiador para purgar el aire del sistema antes de energizar el calentador de bloque.
Battery short circuits.
Fix: Disconnect or reconnect generator before servicing the equipment. Jewelry should be removed before servicing the equipment. Use tools with insulated handles. Remove the negative (-) lead first when disconnecting the battery. Reconnect the negative (-) lead last when reconnecting the battery. Never connect the negative (-) battery cable to the positive (+) connection terminal of the starter solenoid.
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.
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.
The generator set does not crank.
Cause: Battery weak or dead, Battery connections reversed or poor, Blown fuse(s)
Fix: Recharge or replace the battery, Check the connections, Replace the fuse. Contact an authorized Kohler distributor/dealer for service if fuse blows repeatedly
The generator set cranks but does not start, starts hard, lacks power, or operates erratically.
Cause: Air cleaner clogged, Battery weak or dead, Battery connection poor, Spark plug wire connection loose
Fix: Clean and/or replace the air cleaner, Recharge or replace the battery, Clean and tighten the battery connections, Check the spark plug wires
The engine ECM indicates low oil pressure. Oil Pres Low
Fix: Note: The low oil pressure shutdown does not protect against low oil level. Check the engine oil level regularly as recommended in Section 4. Check for leaks in the lubrication system. Check the oil level and add oil if the level is low. Check the oil pressure switch and wiring.
The emergency stop switch has been activated, or there has been an open circuit in the wiring. Emerg Stop
Fix: Contact an authorized distributor/dealer for service.
The ECM reported an Engine Air Temperature/Manifold Absolute Pressure Sensor (TMAP) error. IAT Volt Lo
Fix: Contact an authorized distributor/dealer for service and provide the fault code.
The ECM reported a problem with the coolant temperature sensor reading: 5 = open circuit. CoolntTemp 5
Fix: Contact an authorized distributor/dealer for service and provide the fault code.
The ECM reported a problem with the coolant temperature sensor reading: 4 = low voltage. CoolntTemp 4
Fix: Contact an authorized distributor/dealer for service and provide the fault code.
The ECM reported a problem with the coolant temperature sensor reading: 3 = high voltage. CoolntTemp 3
Fix: Contact an authorized distributor/dealer for service and provide the fault code.
Remote stop command received from a remote switch, ATS, or OnCuer Plus.
Fix: Check the remote switch position
Overspeed shutdown.
Fix: Reset the controller. If the overspeed fault occurs again, contact an authorized Kohler distributor/dealer

Compiled from service & troubleshooting documentation across every generator set that uses the Kohler KG2204/KG2204T.

Maintenance schedule

Item	Spec	Capacity	Part #	Interval
Air filter			—	400 hr
Oil filter			—	120 hr
Battery	Check charge, electrolyte level, cracks/corrosion; clean cables		—	120 hr
Belt	Deflection new 5-7 mm; used 7-8 mm at 98 N (22 lb.) applied pressure		—	120 hr
Coolant	50% ethylene glycol long-life coolant / 50% clean, softened water	13.2 L (3.5 gal.) (13.7 L / 3.6 gal. with block heater)	—	500 hr
Oil	SAE 5W-30 (cold) or 10W-30 (hot), API service class SJ or higher, multi-viscosity synthetic	4.2 L	—	120 hr
Spark plug	Gap 0.7-0.8 mm (0.028-0.031 in.); torque 25 Nm (18.4 ft. lb.)		GM100158	500 hr	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
Battery connections	Check	10 hr		Weekly or every 10 hours; tightness and corrosion
Coolant system hoses and clamps	Check	10 hr		Weekly or every 10 hours
Fuel system leaks	Check	10 hr		Weekly or every 10 hours; hissing sounds, gas odor
Fuel system leaks, hissing sounds, gas odor	Check	10 hr		Weekly or every 10 hours of operation
Oil and coolant leaks	Check	10 hr		Weekly or every 10 hours of operation
Wiring and electrical connections	Check	10 hr		Weekly or every 10 hours of operation; repair or replace loose/damaged components
Air cleaner element	Clean	20 hr	3 mo	Replace at 3 years or 400 hours
Air filter	Clean	20 hr	3 mo	Quarterly or every 20 hours; refer to equipment Operation Manual
All fasteners	Check	20 hr	3 mo	Quarterly or every 20 hours
Battery voltage	Check	20 hr	3 mo	Quarterly or every 20 hours; charge or replace as needed
Bolts and nuts for tightness	Check	20 hr	3 mo	Quarterly or 20 hours
Fasteners	Check	20 hr		Quarterly or every 20 hours of operation
Battery	Inspect	120 hr	12 mo	Yearly or every 120 hours; check for cracks, damaged electrodes, corrosion
Battery (cracks, electrodes, corrosion)	Inspect	120 hr		Yearly or every 120 hours of operation
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
Drive belt tension	Adjust	120 hr	12 mo	Yearly or every 120 hours; adjust or replace if necessary
Drive-belt tension	Adjust	120 hr		Yearly or every 120 hours of operation; replace if necessary
Engine oil and filter	Change	120 hr	12 mo
Engine oil and oil filter	Change	120 hr
Engine oil and oil filter	Replace	120 hr	12 mo	Yearly or every 120 hours of operation
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 filter element(s)	Change	400 hr	36 mo	3 years or every 400 hours; see equipment Operation Manual
Air filter element(s)	Replace	400 hr	36 mo	3 years or every 400 hours of operation
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 condition and electrode gap	Check	500 hr	36 mo	3 years or every 500 hours of operation; adjust gap or replace if discolored/damaged
Spark plug condition and gap	Check	500 hr	36 mo	Adjust gap if necessary; replace if discolored or damaged
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

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
Clearance	Drive belt deflection - new	5–7	mm (0.20–0.28 in.)	98 N (22 lb.) applied test pressure
Clearance	Drive belt deflection - new belt	5-7	mm (0.20-0.28 in.)	Applied test pressure 98 N (22 lb.) at belt midpoint
Clearance	Drive belt deflection - used	7–8	mm (0.28–0.31 in.)	98 N (22 lb.) applied test pressure
Clearance	Drive belt deflection - used belt	7-8	mm (0.28-0.31 in.)	Applied test pressure 98 N (22 lb.) at belt midpoint
Clearance	Drive-Belt Tension Deflection - New	5–7	mm (0.20–0.28 in.)	Applied Test Pressure 98 N (22 lb.)
Clearance	Drive-Belt Tension Deflection - Used	7–8	mm (0.28–0.31 in.)	Applied Test Pressure 98 N (22 lb.)
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	0.7–0.8	mm (0.028–0.030 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.)
Gap	Spark plug gap	0.9–1.0	mm (0.036–0.040 in.)
Gap	Spark plug gap - KG2204	0.9-1.0	mm (0.036-0.040 in.)
Gap	Spark plug gap - KG2204T	0.7-0.8	mm (0.028-0.031 in.)
Other	Battery wrap length	1067 (42)	mm (in.)
Other	Battery wrap length	864 (34)	mm (in.)
Other	Compression ratio	10.5:1
Other	Electric Starter	1.2	kW, speed reduction type
Other	Heater wrap rating	50	Watts
Other	Heater wrap rating	65	Watts
Other	Plug cord length	75 (3)	mm (in.)
Other	Power cord length	1677 (66)	mm (in.)
Other	Power cord length	1830 (72)	mm (in.)
Other	Power cord length	483 (19)	mm (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	LPG maximum fuel pressure, engine OFF no load	2.74	kPa (11.0 in. H2O)
Pressure	LPG minimum fuel pressure, engine ON full load	1.7	kPa (7.0 in. H2O)
Pressure	NG maximum fuel pressure, engine OFF no load	2.74	kPa (11.0 in. H2O)
Pressure	NG minimum fuel pressure, engine ON full load	1.7	kPa (7.0 in. H2O)
Pressure	Radiator pressure cap rating	97	kPa (14 psi)
Speed	Rated engine speed	1800	rpm
Speed	Rated speed	1800	rpm
Temperature	Thermostat off temperature	27	C (80 F)
Temperature	Thermostat on temperature	16	C (60 F)
Temperature	Thermostat valve fully open temperature	88	°C (190°F)
Temperature	Thermostat valve lift fully open	88	°C (190°F)
Temperature	Thermostat valve open	76	°C (169°F)
Temperature	Thermostat valve open temperature	76	°C (169°F)
Torque	Oil Filter Tightening	25	N•m (18.4 ft.lbs.) - additional 3/4 turn
Torque	Oil Pan Drain Plug Torque	20–25	N•m (14.8–18.4 ft.lb.)
Torque	Oil cooler adapter nut	40	Nm (29.5 ft. lb.)
Torque	Oil cooler adapter nut torque	40	Nm (29.5 ft. lb.)
Torque	Oil filter	25	Nm (18.4 ft. lb.)	tighten additional 3/4 turn after hand-tight
Torque	Oil filter torque	25	Nm (18.4 ft. lb.)
Torque	Oil pan drain plug	20–25	Nm (14.8–18.4 ft. lb.)
Torque	Oil pan drain plug torque	20-25	Nm (14.8-18.4 ft. lb.)
Torque	Spark Plugs - KG2204 (standard torque table)	18	N•m (13.3 ft.lb.)
Torque	Spark Plugs - KG2204T (standard torque table)	25	N•m (18.4 ft.lb.)
Torque	Spark plug	18	Nm (13.3 ft. lb.)
Torque	Spark plug	25	Nm (18.4 ft. lb.)
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	Spark plug torque - KG2204	18	Nm (13.3 ft. lb.)
Torque	Spark plug torque - KG2204T	25	Nm (18.4 ft. lb.)

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% long life coolant / 50% clean, softened water		above -37°C		Overheating protection to 149°C (300°F); do not mix long-life and conventional coolants or different colors of long-life coolant
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	5W-30 (cold), 10W-30 (hot), API service class SJ or higher	API Starburst certification mark for gasoline engines		4.2 L (4.4 qt.)	CC or CD classification oils (even labeled HEAVY DUTY or For Natural Gas Engines) are not acceptable
Engine oil	SAE 5W-30 (cold environments) / SAE 10W-30 (hot environments), API service class SJ or higher	API Starburst certification mark for gasoline engines		4.2 L	Do not mix different brands or types of oil; do not use straight-weight industrial/CC/CD oils
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
Engine oil	SAE 5W-30, API service class SJ or higher (colder environments); SAE 10W-30, API SJ or higher (hot environments)	API SJ	below 0°C	4.2 L (4.4 qt.)	Do not mix different brands or types of oil; multi-viscosity synthetic oils recommended
Grease	High-quality lithium-based automotive grease				For alternator and starter bearings
Grease	high-quality lithium-based automotive grease				For alternator and starter bearings

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
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
Accy PwrOver	Accessory Power Overload	Over current fault (short circuit) on the accessory controller power output	Warning	Contact an authorized distributor/dealer for service
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
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
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
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

NG to LPG Conversion adjustment

⚠ Accidental starting can cause severe injury or death

⚠ Risk of fire near fuels or fuel system

⚠ Explosive fuel vapors can cause fires and severe burns

Disconnect battery cables, negative lead first, before working on engine
Push the regulator adjusting cap to its upper stop and rotate clockwise for LPG, release and lock into place
For LPG only, connect wire N20 from the regulator to wire 45 from the ECM harness using quick-connect adapters
To reset for NG, push up the adjusting cap and rotate counterclockwise, release and lock
Disconnect wire N20 and wire 45 to reset for NG

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

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

Engine Starting Battery Installation installation

⚠ Sulfuric acid in batteries can cause severe injury or death

Ensure the starting battery is fully charged before placing in service
Clean the battery posts and/or adapters if necessary
Install battery post adapters if needed
Place the battery on the battery rack on the skid
Connect the red battery cable to the positive (+) battery terminal
Connect the black battery cable to the negative (-) battery terminal
Place the boots over the battery terminals

Fill the Cooling System installation

⚠ Hot coolant and steam can cause severe injury or death

⚠ Do not add coolant to a hot engine

Close the radiator's coolant drain valve and tighten the hose clamps
Fill the radiator with the recommended coolant mixture of 50% ethylene glycol-based long-life coolant and 50% clean, softened water
Check the oil level before operating the engine
Operate the engine with the radiator's pressure cap removed until the thermostat opens and the upper hose becomes hot
Stop the engine and allow it to cool
Add coolant to the radiator to just below the overflow tube on the filler neck
Replace the radiator's pressure cap
Maintain the coolant level in the overflow bottle between the Hot and Cold markings

Generator Installation installation

⚠ Minimum clearances required per NFPA 37

⚠ Local codes may require greater distances

Exhaust must be aimed away from or parallel to the structure.
Do not direct exhaust at play areas, patios, or congregation areas.
Place nearest window, vent, door at least 5 feet from exhaust end.
Install minimum 18 inches from structure per NFPA 37 (verify local codes).
Keep windows and doors on adjacent walls closed.
Place furnace and similar intakes at least 10 feet from exhaust.
Install 4-inch thick concrete pad extending 6 inches beyond genset.
Remove plants, shrubs, combustibles from minimum 8-foot clearance area.
Position sensitive plants and furniture at least 8 feet from exhaust.

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
		LPG conversion (set regulator for LPG)	Connect wire N20 from fuel pressure regulator to wire 45 from ECM wiring harness using quick-connect adapters	Reverse (disconnect wire N20 and wire 45) to reset for NG
	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	4D8.3	12, Reconnectable	Three-phase
120/208	3	Wye
120/240	1	4E5.0	4	Single-phase
120/240	1	4E8.3	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
24RCL	KOHLER 24RCL generator	other_service
256984	Battery, 12 volt wet-charged, BCI group size 24, 650 CCA at -18 C, 120 min. reserve capacity	other_service
30RCL	KOHLER 30RCL generator	other_service
GM100209	Maintenance Service Kit	other_service
GM104032-S1	Service kit with two L-shaped metal shields and U-channel edging for shielding the RDC2 controller from EMI interference.	other_service
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.)	other_service
GM62348-SKP1-QS	Maintenance Kit	other_service
GM83718-SKP1-QS	Maintenance Kit	other_service
GM86771-SKP1-QS	Maintenance Kit	other_service
GM88832	Flywheel adapter	other_service
GM89020-KP1	Battery kit, wet-charged, contains 1 battery, BCI group size 24, 650 CCA, 120 min. reserve capacity (loose kit only)	other_service
GM89979-SKP1-QS	Maintenance Kit	other_service
GM90230	Figure 1-23 Coolant Fill (24RCL shown)	other_service
GM92075	Figure 1-24 Coolant Fill (30RCL and 38RCLB shown)	other_service
GM93396	Maintenance Service Kit	other_service
GM93396-SKP1-QS	Maintenance Kit	other_service
GM100158	Spark Plug (use only genuine Kohler service parts)	spark_plug
GM92785	Spark plug, screw thread M14 x 1.25 (KG2204 only)	spark_plug

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/KG2204T?

The Kohler KG2204/KG2204T engine has an oil capacity of 4.2 liters.

What is the displacement of the Kohler KG2204/KG2204T?

The Kohler KG2204/KG2204T has a displacement of 2.2 liters with 4 cylinders.

Which generators use the Kohler KG2204/KG2204T engine?

The Kohler KG2204/KG2204T powers 6 generator set(s), including Kohler 24RCL, Kohler 25CCL, Kohler 30CCL, Kohler 30RCL, Kohler 36CCL.

How often should you change the oil in the Kohler KG2204/KG2204T?

The Kohler KG2204/KG2204T oil change interval is every 120 hours.

What is a common problem with the Kohler KG2204/KG2204T engine?

A commonly reported issue on generators using the Kohler KG2204/KG2204T is: Relé de falla común DCB2.