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Kohler KG2204T Engine

The Kohler KG2204T is a 2.2 L 4-cylinder turbocharged engine rated at 1800 rpm, producing up to 47.8 kW. It powers generator sets from Kohler, including the 25CCL, 30CCL, 30RCL and 36CCL. It holds 4.2 L (1.1 gal) of oil and 13.2 L (3.5 gal) of coolant.

Also known as: Kohler KG2204T

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

2.2 L

Displacement

Cylinders

1800 rpm

Rated speed

47 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	13.2 L
Displacement	2.2 L
Cylinders	4
Aspiration	Turbocharged
Rated speed	1800 rpm
Gross power	47 kW

Generator sets powered by this engine

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

How to read your Kohler engine serial & model number →

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 KG2204T.

Maintenance schedule

Item	Spec	Capacity	Part #	Interval
Oil filter	Cartridge		—	120 hr
Oil		3.3 L	—	120 hr

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 of operation. Check for tightness and signs of corrosion.
Engine	Test	10 hr		Weekly or every 10 hours of operation. Start engine and listen for abnormal noises.
Fuel system leaks	Check	10 hr		Weekly or every 10 hours of operation. Check for fuel system leaks, hissing sounds, or gas odor.
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 or damaged components.
Air cleaner element	Clean	20 hr	3 mo	Replace at 3 years or 400 hours
Air filter	Clean	20 hr		Quarterly or every 20 hours of operation. See equipment Operation Manual.
Battery voltage	Check	20 hr		Quarterly or every 20 hours of operation. 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. Check all fasteners for tightness.
Battery	Check	120 hr		Yearly or every 120 hours of operation. Check for cracks, damaged electrodes, and corrosion.
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	Check	120 hr		Yearly or every 120 hours of operation. Adjust or replace drive belt if necessary.
Engine oil and filter	Change	120 hr	12 mo
Engine oil and oil filter	Replace	120 hr		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 of operation. See equipment Operation Manual.
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	Check	500 hr	36 mo	3 years or every 500 hours of operation. Check condition and electrode gap; 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
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	0.7-0.8	mm (0.028-0.030 in.)
Gap	Spark Plug Gap	0.9-1.0	mm (0.036-0.040 in.)
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	0.76	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.)
Other	Battery wrap length	1067 (42)	mm (in.)
Other	Battery wrap length	864 (34)	mm (in.)
Other	Drive Belt Tension	Deflection of a new belt is 5-7 mm (0.20-0.28 in.); Deflection of a used belt is 7-8 mm (0.28-0.31 in.)	mm	at pressure of 98 N (22 lb)
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	Radiator pressure cap rating	97	kPa (14 psi)
Resistance	Cold stator resistance, main windings 1--4, 2--5, 3--6	0.40	ohms	6-Lead, 600 V; cold
Resistance	Cold stator resistance, main windings 1--4, 2--5, 3--6	0.45	ohms	6-Lead, 600 V; cold
Resistance	Cold stator resistance, main windings 1--4, 2--5, 3--6	0.52	ohms	6-Lead, 600 V; cold
Resistance	Cold stator resistance, main windings 1--4, 2--5, 3--6	0.60	ohms	6-Lead, 600 V; cold
Resistance	Cold stator resistance, main windings 1--4, 2--5, 3--6	1.0	ohms	6-Lead, 600 V; cold
Resistance	Cold stator resistance, main windings 1--4, 2--5, 3--6, 7--10, 8--11, 9--12	0.04	ohms	12-Lead; cold
Resistance	Cold stator resistance, main windings 1--4, 2--5, 3--6, 7--10, 8--11, 9--12	0.08	ohms	12-Lead; cold
Resistance	Cold stator resistance, main windings 1--4, 2--5, 3--6, 7--10, 8--11, 9--12	0.09	ohms	12-Lead; cold
Resistance	Cold stator resistance, main windings 1--4, 2--5, 3--6, 7--10, 8--11, 9--12	0.11	ohms	12-Lead; cold
Resistance	Cold stator resistance, main windings 1--4, 2--5, 3--6, 7--10, 8--11, 9--12	0.12	ohms	12-Lead; cold
Resistance	Cold stator resistance, main windings 1--4, 2--5, 3--6, 7--10, 8--11, 9--12	0.20	ohms	12-Lead; cold
Resistance	Exciter armature insulation resistance	1.5	MOhms	Megohmmeter applied 500 VDC; approximately 1.5 MOhms and higher indicates functional
Resistance	Exciter field insulation resistance	1.5	MOhms	Megohmmeter applied 500 VDC; approximately 1.5 MOhms and higher indicates functional
Resistance	Exciter field winding resistance (cold)	6.0	ohms	All models except 4D8.3/4E8.3; @ 20 C (68 F)
Resistance	Exciter field winding resistance (cold)	7.2	ohms	4D8.3/4E8.3; @ 20 C (68 F)
Resistance	Main field (rotor) insulation resistance	1.5	MOhms	Megohmmeter applied 500 VDC; approximately 1.5 MOhms and higher indicates functional
Resistance	Main field (rotor) resistance (cold)	3.2	ohms	12-Lead; @ 20 C (68 F)
Resistance	Main field (rotor) resistance (cold)	3.5	ohms	12-Lead; @ 20 C (68 F)
Resistance	Main field (rotor) resistance (cold)	3.8	ohms	12-Lead; @ 20 C (68 F)
Resistance	Main field (rotor) resistance (cold)	4.0	ohms	12-Lead; @ 20 C (68 F)
Resistance	Main field (rotor) resistance (cold)	4.3	ohms	12-Lead; @ 20 C (68 F)
Resistance	Main field (rotor) resistance (cold)	5.3	ohms	12-Lead; @ 20 C (68 F)
Resistance	Stator insulation resistance	1.5	MOhms	Megohmmeter applied 500 VDC; approximately 1.5 MOhms and higher indicates functional
Temperature	Thermostat Settings	Valve open at 76C (169F); Valve lift fully open at 88C (190F)	C
Temperature	Thermostat off temperature	27	C (80 F)
Temperature	Thermostat on temperature	16	C (60 F)
Torque	Alternator fan to rotor assembly bolts	10	Nm	M6--1.0 Class 8.8; apply Loctite 242 Blue or equivalent to bolt threads
Torque	Drive discs to flywheel bolts	43	Nm	M8--1.25 Class 12.9; apply Loctite 242 Blue or equivalent to bolt threads
Torque	Drive discs to rotor shaft bolts	33	Nm	M8--1.25 Class 10.9; apply Loctite 242 Blue or equivalent to bolt threads
Torque	End bracket to generator adapter studs/nuts	30	Nm	M10--1.5
Torque	Exciter armature lead to rectifier board screws	1.8	Nm	#8--32
Torque	Exciter armature retaining bolt	65	Nm	M10--1.50 Class 10.9
Torque	Exciter field bolts	5.8	Nm	M5--0.8 Class 8.8
Torque	Leads A, B, C, F1, and F2 to spacer studs	1.3	Nm	Five stainless steel hex nuts
Torque	Oil Cooler Adapter Nut	40	N.m (29.5 ft.lbs.)
Torque	Oil Drain Plug	20-25	N.m (14.8-18.4 ft.lb.)
Torque	Oil Filter	25	N.m (18.4 ft.lbs.)	tighten the filter an additional 3/4 turn by hand until resistance
Torque	Rectifier board to exciter field screws	4.0	Nm	#10--24
Torque	Rotating rectifier board to spacer studs	1.3	Nm	Five stainless steel nylock nuts
Torque	Rotor lead to rectifier board screws	1.8	Nm	#8--32
Torque	Spacer to exciter armature screws	3.9	Nm	X-67-135 qty. 3
Torque	Spark Plugs - KG2204	18	N.m (13.3 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% ethylene glycol-based long-life coolant / 50% clean, softened water		above -37°C	13.2 L (3.5 gal.)	13.7 L (3.6 gal.) with block heater; freeze protection to -37C (-34F), overheat protection to 149C (300F)
Coolant	50% long life coolant and 50% clean, softened water		-37°C to 149°C		Provides freezing protection to -37C (-34F) and overheating protection to 149C (300F). Do not mix long life coolants and conventional coolants.
Engine oil	SAE 5W-30	API service class SJ or higher		4.2 L	Multi-viscosity synthetic oil recommended. For best performance in colder environments (such as the United States and Canada). Oil dry fill capacity 4.2 L (4.4 qt.).
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 10W-30 (synthetic)	API service class SJ or higher	above 0°C	4.2 L	For extremely hot environments where temperatures are never or rarely below 0C (32F).
Fuel	LPG: HD-5 or HD-10		below 105°C		Maximum fuel pressure (engine OFF, no load) 11.0 in. W.C.; Minimum fuel pressure (engine ON, full load) 5.0 in. W.C. Operating temperature range -20C (-4F) to 105C (221F).
Fuel	Natural Gas (NG): standard pipeline	UL 2200	-20°C to 105°C		Approximate supply volume 37.257 kJ/m3 (1000 BTU/ft.3). Minimum flow KG2204 11.9 m3/hr. (420 SCFH) @ 5.0 in. W.C.; KG2204T 19.6 m3/hr. (690 SCFH) @ 5.0 in. W.C. Allowable water vapor less than 112.3 kg per 1 million m3 (7 lb. per 1 million ft.3).
Grease	high-quality lithium-based automotive grease				Alternator and starter bearings must be lubricated with this grease.
Grease	multi-purpose				Apply to O-ring and end bracket bearing bore during reassembly.

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

NG to LPG Conversion adjustment

⚠ Disconnect and ground spark plug leads before servicing. Disconnect negative (-) battery cable.

⚠ Do not smoke or permit flames or sparks near fuels or the fuel system.

Push the adjusting cap to its upper stop and rotate clockwise, release upward pressure, and lock into place.
For LPG fuel only, connect wire N20 from the fuel pressure regulator to wire 45 from the ECM wiring harness using the quick-connect adapters.
To reset for NG, reverse the procedure: push up on the adjusting cap and rotate counterclockwise, release, and lock.
Disconnect wire N20 and wire 45.

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

Exciter Armature Test Procedure diagnostic

⚠ Hazardous voltage

⚠ Hot parts

Tools: Ohmmeter, Megohmmeter

Disassemble the alternator.
Disconnect exciter armature leads from rectifier module AC terminals.
Set ohmmeter to R x 1 and check resistance across exciter armature leads.
No continuity indicates an open exciter armature winding.
Use a megohmmeter to apply 500 volts DC to either armature lead and the exciter armature frame.
A reading of approximately 1.5 MOhms and higher indicates a functional armature.

Exciter Field Test Procedure diagnostic

⚠ Hazardous voltage

⚠ Hot parts

Tools: Ohmmeter, Megohmmeter

Stop generator set and disconnect starting battery, negative (--) lead first.
Disconnect FP/FN connector between controller/activator board and exciter field.
Measure resistance across exciter field FN and FP leads with an ohmmeter.
A low reading indicates an internal short; a high reading indicates an open winding.
Use a megohmmeter to apply 500 volts DC from FN or FP lead to exciter field frame.
A reading of approximately 1.5 MOhms and higher indicates a functional field.

Generator Main Field (Rotor) Test Procedure diagnostic

⚠ Hazardous voltage

⚠ Hot parts

Tools: Ohmmeter, Megohmmeter

Disassemble generator and disconnect main field (rotor) windings at rectifier module terminals F+ and F--.
Measure main field (rotor) resistance across F+ and F-- leads with ohmmeter.
A low reading indicates an internal short; a high reading indicates an open winding.
Use megohmmeter to apply 500 volts DC to either field lead and main field frame.
A reading of 1.5 MOhms and higher indicates the main field is functional.

Rectifier Module Test Procedure diagnostic

⚠ Hazardous voltage

⚠ Hot parts

Tools: Multimeter with diode check, Ohmmeter

Disconnect exciter armature and main field leads from rectifier module.
Perform a diode check on all six rectifier board diodes.
Use multimeter diode check or ohmmeter on R x 100 scale.
Ohmmeter should show low resistance in one direction and high resistance with leads reversed.
Replace rectifier module if any diode tests differently than described.

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

Separate Excitation diagnostic

⚠ Accidental starting

⚠ Hazardous voltage

Tools: Ohmmeter, DC ammeter (0--10 A), 10-amp fuse, 12-volt battery, Voltmeter

Stop the generator set and disconnect the FP/FN connector.
Measure exciter field winding resistance with an ohmmeter and record the reading.
Connect a DC ammeter, 10-amp fuse, and 12-volt battery to FP and FN exciter leads.
Start the generator set and note the ammeter reading.
An increasing reading indicates a shorted exciter field; a decreasing or unstable reading suggests a running open.
If stable, check AC output across stator main windings and compare with Section 1 specifications.
Stop the generator set.

Stator Test Procedure diagnostic

⚠ Hazardous voltage

⚠ Hot parts

Tools: Ohmmeter, Megohmmeter

Press OFF on generator set controller.
Disconnect generator set engine starting battery, negative (--) lead first.
Check generator output lead connections and note voltage connection for reassembly.
Disconnect all stator leads to isolate windings.
Set ohmmeter to R x 1 and check stator continuity using single- or three-phase figures.
Check cold resistance of stator windings and compare with Section 1 values.
Use megohmmeter to apply 500 volts DC to any stator lead from each winding and stator frame.
A reading of 1.5 MOhms and higher indicates the stator is functional.

Installation Guidelines installation

⚠ Minimum 8 feet clearance from exhaust end

⚠ Verify state and local codes for installation distance requirements

Position exhaust aimed away from or parallel to structure
Do not direct exhaust at play areas or gathering spaces
Maintain minimum 5 feet distance from windows, vents, doors or openings
Install minimum 18 inches from structure per NFPA 37
Close windows and doors on adjacent walls
Keep furnace and intakes at least 10 feet from exhaust end
Provide 4 inch thick concrete pad extending 6 inches beyond genset
Maintain clear area with no combustibles within 8 feet of exhaust
Keep sensitive plants and patio 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
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	4D8.3	12, Reconnectable	Three-phase
120/208	3	Wye
120/240	1	4E8.3	4	Single-phase
120/240	1	Single
120/240	3	Delta
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 KG2204T?

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

What is the displacement of the Kohler KG2204T?

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

Which generators use the Kohler KG2204T engine?

The Kohler KG2204T powers 6 generator set(s), including Kohler 25CCL, Kohler 30CCL, Kohler 30RCL, Kohler 36CCL, Kohler 38RCLB.

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

The Kohler KG2204T oil change interval is every 120 hours.

What is a common problem with the Kohler KG2204T engine?

A commonly reported issue on generators using the Kohler KG2204T is: Generator set stops suddenly.. Cause: Low oil pressure shutdown.. Fix: Check for oil leaks. Check the oil level and add oil if necessary..