Specifications
| Fuel | Natural Gas or LPG |
|---|---|
| Frequency | 60.0 Hz |
| Standby power | 38 kW |
| Standby kVA | 47 |
| Controller | RDC2 |
| Oil capacity | 4.2 L |
| Alternator | 4-Pole, Rotating-Field (4-pole, Class Class H insulation) |
| Voltage options | 120/240 V, 120/208 V, 127/220 V, 277/480 V, 220/380 V, 230/400 V, 240/416 V |
| Rated current | 158 A |
| Power factor | 1.0 (single-phase), 0.8 (three-phase) |
| Battery group | 24 |
| Battery cranking | 630 CCA |
| Battery voltage | 12 V |
| Battery quantity | 1 |
| Coolant capacity | 13.2 L |
| Engine jacket water | 2.65 L |
| Max ambient | 45 °C |
| Dimensions (L×W×H) | 1880×836×1169 mm |
| Dry weight | 621 kg |
| Wet weight | 621 kg |
| Sound level | 61.0 dBA @ 7 m |
Engine
| Oil capacity | 4.2 L |
|---|---|
| Coolant capacity | 13.2 L |
| Displacement | 2.2 L |
| Aspiration | Turbocharged |
| Rated speed | 1800 rpm |
Maintenance & consumables
for the Kohler KG2204T| Item | Spec | Capacity | Part # | Interval | |
|---|---|---|---|---|---|
| Air filter | Clean quarterly or 20 hr.; replace at 3 years or 400 hr. | — | 400 hr | ||
| Oil filter | ×1 | — | 120 hr | ||
| Battery | Check charge, electrolyte level, cracks/corrosion; clean cables | — | 120 hr | ||
| Coolant | 50% ethylene glycol long-life coolant / 50% clean, softened water | — | 500 hr | ||
| Oil | 4.2 L | — | 120 hr | ||
| Spark plug | Gap: 24RCL 0.9-1.0 mm (0.036-0.040 in.); 30RCL and 38RCLB 0.7-0.8 mm (0.028-0.030 in.). Torque: 24RCL 18 Nm (13.3 ft. lbs.); 30RCL and 38RCLB 25 Nm (18.4 ft. lbs.), plus additional 1/4 turn | — | 500 hr |
Service intervals
25| 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
60| 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.) | |
| Other | Battery wrap length | 1067 (42) | mm (in.) | |
| Other | Battery wrap length | 864 (34) | mm (in.) | |
| 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 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 filter | 25 | Nm (18.4 ft. lbs.) | after hand-tight plus 3/4 turn |
| 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 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.) |
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) | |
| 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 | |
| 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
44| 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
12RDC2 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.
Air Cleaner Element and Precleaner maintenance
- Disable set: press OFF button, disconnect battery charger power, remove battery cables, negative (--) lead first.
- Loosen the cover retaining knob(s) or release the retaining clips and remove the cover.
- Remove and discard the old air cleaner element and precleaner (if equipped).
- Install the precleaner over the new air cleaner element.
- Install the paper element onto the air cleaner base, making sure it is flat and properly seated.
- Reinstall the element cover, element cover nut, and the air cleaner cover; secure with the knob(s) or clips.
- 15RES/30RES and RCL models: wipe cover and housing with a clean rag and make sure sealing surfaces fit correctly.
- Reconnect the battery cable, negative (--) lead last.
Filling Cooling System maintenance
⚠ Do not add coolant to a hot engine; cylinder block or head can crack
- Close the radiator coolant drain valve and tighten hose clamps
- Fill the radiator with 50% ethylene glycol / 50% clean softened water mixture
- Operate the engine with the radiator cap removed until the thermostat opens and upper hose is hot
- Stop the engine and allow it to cool
- Add coolant to just below the overflow tube on the filler neck
- Replace the radiator pressure cap
- Maintain the coolant overflow bottle level between Hot and Cold markings
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.
Common questions
What is the power rating of the Kohler 38RCLB?
The Kohler 38RCLB is rated 38 kW standby (47.0 kVA).
What engine does the Kohler 38RCLB use?
The Kohler 38RCLB is powered by the Kohler KG2204T engine.
What fuel does the Kohler 38RCLB use?
The Kohler 38RCLB runs on Natural Gas or LPG.
What's the oil capacity on a Kohler 38RCLB?
The Kohler KG2204T engine in the Kohler 38RCLB has an oil capacity of 4.2 liters.
How much coolant does the Kohler 38RCLB hold?
The Kohler 38RCLB cooling system holds 13.2 liters (3.5 US gallons) for the radiator system including the engine, per the manufacturer specification sheet.
What is the sound level of the Kohler 38RCLB?
The Kohler 38RCLB is rated at 61.0 dBA at 7 m, per the manufacturer specification sheet.
What is the dry weight of the Kohler 38RCLB?
The Kohler 38RCLB has a dry weight of 621 kg (1369 lb).
What voltage does the Kohler 38RCLB produce?
The Kohler 38RCLB is offered in 120/240 V, 120/208 V, 127/220 V, 277/480 V, 220/380 V, 230/400 V.
What battery does the Kohler 38RCLB use?
The Kohler 38RCLB uses 1 battery, 12 V each, 630 CCA, group 24, per the manufacturer specification sheet.
Which alternator is fitted to the Kohler 38RCLB?
The Kohler 38RCLB uses a 4-Pole, Rotating-Field alternator. It has 4 poles. Insulation class Class H.
Troubleshooting
6Fault codes
| Code | Meaning | Remedy |
|---|---|---|
| Auxiliary Input | Auxiliary Input — An optional customer-connected input is closed. (Digital input from optional PIM.) | Check customer-supplied equipment. |
| Battery CrLo | Critically Low Battery Voltage — Engine starting battery voltage falls below 11 V for more than 10 seconds. Inhibited during the engine crank cycle. Clears when the battery voltage returns to an acceptable level. | Check the battery rating and condition.; Check the battery charger operation.; Charge or replace the battery. |
| Battery High | High Battery Voltage — Engine starting battery voltage rises above 133% (16 V) of the battery voltage setting for more than 10 seconds. Inhibited during the engine crank cycle. Clears when the battery voltage returns to an acceptable level. | Check the battery rating and condition.; Check the battery charger operation. |
| Battery Low | Low Battery Voltage — Engine starting battery voltage falls below the battery voltage setting (typically 12.5 volts) for more than 90 seconds when the engine is not running. Inhibited during the engine crank cycle. Clears when the battery voltage returns to an acceptable level. | Check the battery rating and condition.; Check the battery charger operation.; Charge or replace the battery. |
| Chk DateTime | Verify Date Time Setting — The time and date have not been set on the generator controller. | Enter the date and time using the RDC2 controller. See Figure 3-8 and Figure 3-16. |
| Coolant Lvl Low | Low Coolant Level Shutdown — The coolant level switch input has been activated. | Check coolant level.; Check radiator hoses for leaks.; Contact an authorized distributor/dealer for service. |
Fault codes and symptom→remedy steps extracted from this model’s service/owner documentation; verify against the official manual before servicing. Full Kohler 38RCLB troubleshooting guide (72 entries) →
Parts
11| Part # | Description | Qty | System | |
|---|---|---|---|---|
| 256984 | Battery, 12 volt wet-charged, BCI group size 24, 650 CCA at -18 C, 120 min. reserve capacity | 1 | Battery | Amazon eBay |
| GM103786 | Battery heater wrap | 1 | Battery heater wrap | Amazon eBay |
| GM104701 | Battery heater wrap | 1 | Battery heater wrap | Amazon eBay |
| GM104708 | Battery heater wrap | 1 | Battery heater wrap | Amazon eBay |
| GM100209 | Maintenance Service Kit | 1 | Service part / kit | eBay |
| GM103784 | Battery heater wrap | 1 | Service part / kit | Amazon eBay |
| GM104032-S1 | Service kit with two L-shaped metal shields and U-channel edging for shielding the RDC2 controller from EMI interference. | 1 | Service part / kit | Amazon eBay |
| GM104699 | Battery heater wrap | 1 | Service part / kit | Amazon eBay $30.00 |
| 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.) | 1 | Service part / kit | Amazon eBay $105.00 |
| GM89020-KP1 | Battery kit, wet-charged, contains 1 battery, BCI group size 24, 650 CCA, 120 min. reserve capacity (loose kit only) | 1 | Service part / kit | Amazon eBay |
| GM92075 | Figure 1-24 Coolant Fill (30RCL and 38RCLB shown) | 1 | Service part / kit | Amazon eBay |
Service, wear & replacement parts referenced for this model and its engine — confirm the exact part for your serial number. See the full parts catalog to search and cross-reference.
Fuel consumption
| Rating | Load | L/h | gal/h |
|---|---|---|---|
| Standby | 3.4 | 0.9 | |
| Standby | 25% | 5.8 | 1.53 |
| Standby | 50% | 9.3 | 2.46 |
| Standby | 75% | 11.4 | 3.01 |
| Standby | 100% | 13.9 | 3.67 |
Available documents
Spec sheet (Kohler)Reference — g6130 (Kohler)Reference — g6132 (Kohler)Reference — tp6906 (Kohler)Owner's manual (Kohler)Owner's manual — tp6905 (Kohler)Parts manual (Kohler)Parts manual — kohlerpow datasheet stepid-2757002 (Kohler)Parts manual — tp6904 (Kohler)Parts manual — tp6908 (Kohler)Parts manual — tt1589 (Kohler)Service manual — 4f53249c-825d-4340-a887-aac9199ce897 (Kohler)Service manual — Controllers tt1589 (Kohler)Service manual — tp6878 4D 4E Alt (Kohler)Service manual — tp6878 (Kohler)Service manual — tp6878es (Kohler)Service manual — tp7007 (Kohler)Service manual — tt1445 (Kohler)Service manual — tt1584 (Kohler)Service manual — tt1633 (Kohler)Service manual — tt1691 (Kohler)Service manual — tt1742 (Kohler)
This page was generated from the 22 manufacturer documents above by automated extraction; every figure shown is copied from one of them. How the data is compiled.