Engine Operation Manual
Contents
1. 21 4 6 Monitoring Engine Operation 22 4 7 Stopping 22 7 bee pos Ae Edw eee a a quede PL 22 Section 5 Maintenance 5 1 Introduction 2 copre PER peo erus dus T RC E P Ke oed 23 5 2 Fluid Specifications p r ees a Ree Yee ne REX A RE 24 Oil R corimendatioFis nasse hee tn Ee es eek eme sS PRO YT 24 Grease Recommendations 24 Coolant Recommendations 24 5 3 Periodic Maintenance Schedule 25 5 4 Enginie en es Exc ane RR Rd OU a C P CREER NUR Ur e ne a Date cx 26 Check Engine Qil eR RAS DUAE ET pee niea a pu ES 26 Change Engine Oil and Oil Filter 26 Check and Clean the Air Filler llli Ih 29 Replace the Air Filler 2 ernia eren IRI IIR 29 Check and Adjust the Spark Plugs 29 Replace the Spark Plugs 31 Ignition TIMING uses mk bet aede E eme Rom kn RH RO NUR dre ker eee et 31 5 5 Electrical System saiia eer aee AURA EUER VAR ee 32 Check Battery and lt 52. 10 Fuel Control Valve 17 Oil Drain Plug 24 Oil Pan Upper Intake Upper Coolant Oil Pressure Manifold H Outlet 18 Sensor PGS 79 Exnaust Manioid Coolant Battery Chargin PCV Valve 12 Temperature 19 Oil Filter Base 26 y ging Alternator Sensor Oil Cooler Adapter Rocker Arm Cover 13 Drive Belt 20 not included on 27 Water Pump Inlet all models ma Vibration Lower Intake 14 Dampener e Manifold 12 Components and Maintenance Locations TP 6901 6 14 OPERATION 4 1 INTRODUCTION The KG2204 is a four stroke internal combustion engine certified to operate on either Propane Liquid Petroleum Gas LPG or Natural Gas NG System configuration is factory preset for NG Instructions for switching to LPG are provided within this section The fuel system on this engine is a closed loop design As the engine runs sensors located at various points within the system provide continuous operating feedback to the Engine Control Module ECM The ECM adjusts the engine speed ignition timing and fuel supply in response to changes in the applied load surrounding air temperature operating temperature of the engine and amount of oxygen present in the exhaust Refer to the equipment Operation Manual for specific information on how fault codes are displayed TP 6901 6 14 Section 4 Operation 4 2 FUEL SYSTEM Components Fuel Shut Off Valves Figure 4 3 The fuel supply contains two fuel sh
3. leaking gas could accumulate and information found on the endanger the safety of persons in packaging Avoid inhalation and the area skin contact Use only in A WARNING NG Natural Gas is extremely well ventilated areas and use a flammable is lighter than air and protective mask when spraying rises Do not start or operate this Store engine fluids and chemical engine in a poorly ventilated are products in a locked cabinet where leaking gas could Contact your local recycling center Accidental starts accumulate and endanger the for disposal information and can cause safety of persons in the area locations severe injury or To ensure personal safety death installation and repair of LPG NG Disconnect and fuel supply systems must be ground spark plug performed only by qualified leads before LPG NG system technicians servicing Improperly installed and maintained LPG NG equipment could cause the fuel supply system or other components to malfunction causing gas leaks Observe federal state and local laws governing LPG NG fuel storage and systems the first stop to relieve pressure before removing completely Fire damaged or burned O rings may cause the formation of hydrofluoric acid Contact with hydrofluoric acid may cause severe skin irritation and chemical burns O rings and other fluoroelastomer seals exposed to fire or temperatures above 316 C 600 F i e during welding may d
4. SPECIFICATIONS 8 5 STANDARD TORQUE SPECIFICATIONS American Standard Fasteners Torque Specifications Assembled into Cast Iron or Steel Assembled into Torque Aluminum Grade Size Measurement Grade 2 Grade 5 Grade 8 20r5 8 32 Nem in Ib 1 8 16 2 3 20 10 24 Nem in IDb 2 9 26 3 6 32 10 32 Nem in Ib 2 9 26 3 6 32 1 4 20 Nem in Ib 6 8 60 10 8 96 14 9 132 1 4 28 Nem in Ib 8 1 72 12 2 108 16 3 144 5 16 18 Nem in Ib 13 6 120 21 7 192 29 8 264 5 16 24 Nem in Ib 14 9 132 23 1 204 32 5 288 3 8 16 Nem ft lb 24 0 18 38 0 28 53 0 39 3 8 24 Nem ft Ib 27 0 20 42 0 31 60 0 44 7 16 14 Nem ft Ib 39 0 29 60 0 44 85 0 63 7 16 20 Nem ft Ib 43 0 32 68 0 50 95 0 70 See Note 3 1 2 13 Nem ft Ib 60 0 44 92 0 68 130 0 96 1 2 20 Nem ft Ib 66 0 49 103 0 76 146 0 108 9 16 12 Nem ft Ib 81 0 60 133 0 98 187 0 138 9 16 18 Nem ft Ib 91 0 67 148 0 109 209 0 154 5 8 11 Nem ft Ib 113 0 83 183 0 135 259 0 191 5 8 18 Nem ft Ib 128 0 94 208 0 153 293 0 216 3 4 10 Nem ft Ib 199 0 147 325 0 240 458 0 338 3 4 16 Nem ft Ib 222 0 164 363 0 268 513 0 378 1 8 Nem ft ID 259 0 191 721 0 532 1109 0 818 1 12 Nem ft Ib 283 0 209 789 0 582 1214 0 895 NOTE 1 TP 6901 The torque values above are gene
5. LPG Liquefied Petroleum Gas is extremely flammable and tends to settle in low areas where a spark or flame could ignite the gas Do not start or operate this engine in a poorly ventilated area where leaking gas could accumulate and endanger the safety of persons in the area NG Natural Gas is extremely flammable is lighter than air and rises Do not start or operate this engine in a poorly ventilated are where leaking gas could accumulate and endanger the safety of persons in the area To ensure personal safety installation and repair of LPG NG fuel supply systems must be performed only by qualified LPG NG system technicians Improperly installed and maintained LPG NG equipment could cause the fuel supply system or other components to malfunction causing gas leaks Observe federal state and local laws governing LPG NG fuel storage and systems 5 2 FLUID SPECIFICATIONS Oil Recommendations NOTE e Do not mix different brands or types of oil e Do not overfill or underfill the engine s lubrication system See Engine Specifications in Section 8 Use oil that displays the American Petroleum Institute API Starbrust certification mark FOR GASOLINE ENGINES on the container Do not use straight weight oils recommended for industrial or stationary engines CC or CD classification oils even when labeled HEAVY DUTY or For Natural Gas Engines are not acceptable 24 Maintenance Multi viscosity synthetic oils
6. Operation Engine Engine Model KG2204 Propane Liquefied Petroleum Gas LPG Natural Gas NG Fueled Un KOHLER mum POWER SYSTEMS NATIONAL TERED KOHLER Power SystemS ma ena INTRODUCTION This manual provides operating and maintenance instructions for KOHLER Engine Model KG2204 Keep this manual with the equipment for future reference Refer to the KG2204 Service Manual for detailed information on adjusting and servicing the engine Information in this publication represents data available at the time of print KOHLER Co reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever This engine operates on either Propane Liquefied Petroleum Gas LPG or Natural Gas NG which are extremely flammable and explosive Installation and repair of LPG NG systems must be performed only by qualified LPG NG technicians Read this manual and carefully follow all procedures and safety precautions to ensure proper equipment operation and to avoid bodily injury Regular maintenance is necessary for safe and efficient operation Inspect the engine often and perform required maintenance at prescribed intervals Service work must be performed by appropriately skilled and suitably trained maintenance personnel who are familiar with engine diagnostics and repair Unless otherwise specified all units of measurement are metric followed by the Imperi
7. 2 Disconnect negative battery cable from battery KOHLER authorized distributor dealer for assistance Before disconnecting negative ground cable make sure all switches are OFF If ON a spark will occur at Check and Adjust the Drive Belt the ground cable terminal which could cause an explosion if hydrogen gas or LPG NG fuel vapors are A worn stretched or damaged drive belt may fail present especially under heavy loads Check the condition of _ the drive belt regularly and adjust belt tension as Required materials needed Belt tension gauge or straightedge and steel rule Check drive belt condition WARNING 1 Stop the engine and allow it to cool Rotating parts can cause severe injury Stay away while the engine is in operation Keep hands feet hair and clothing away from all moving parts to prevent injury Never operate the engine with covers shrouds or guards removed Figure 5 24 2 Locate the drive belt A See Figure 5 24 32 Maintenance TP 6901 6 14 MAINTENANCE Check drive belt tension 5 The drive belt tension should be checked at the midpoint B between the pulleys See Figure 5 26 Apply specified pressure to the drive belt at its midpoint At the same time measure the amount of deflection of the drive belt at its midpoint Deflection should be within specification DRIVE BELT TENSION Applied Test Pressure 98 N 22 Ib Belt Deflection New 5 7 mm 0
8. between the intake manifold and outside atmospheric pressure This sensor also measures the temperature of the incoming air Data returned by the TMAP sensor prompts the ECM to adjust the air fuel mixture as needed Knock Sensor if equipped with turbocharger NOTE On naturally aspirated engines the knock sensor is not connected to the ECM The Knock Sensor monitors vibrations caused by engine knock The ECM interprets the signals from the Knock Sensor and adjusts the ignition timing to prevent pre ignition damage Crankshaft Position Sensor Crankshaft Position Sensor CPS measures the rotary speed and crankshaft turning angle The ECM ensures the ignition timing for each cylinder depending on the turning signal The sensor which consists of a permanent magnet and coil is installed on the timing gear cover next to the crankshaft pulley When the crankshaft is turning the gear ring passes the sensor at different speeds and causes a change of magnet resistance at the sensor to produce a changeable signal 16 Operation Throttle Position Sensor TPS The electronic throttle control device incorporates an internal Throttle Position Sensor TPS which provides output signals to the ECM as to the location of the throttle shaft and blade The ECM will use the signal to monitor and adjust the engine speed Engine Coolant Temperature Sensor The engine coolant temperature sensor provides engine coolant temperature data to
9. both constraints Equipment Assemblies Operating temperature range 20 C 4 F to 105 C 221 F TP 6901 6 14 Operation 17 OPERATION NG to LPG Conversion The KG2204 engine is easily configurable for use with either NG or LPG System configuration for NG or LPG requires a mechanical setting on the fuel pressure regulator and an electrical setting change at the ECM These adjustments will ensure that the proper fuel and spark timing is supplied to the engine NOTE The fuel pressure regulator is factory preset for NG When using NG no mechanical adjustment is required A WARNING Accidental starts can cause severe injury or death Disconnect and ground spark plug leads before servicing Before working on engine or equipment disable engine as follows 1 Disconnect spark plug leads 2 Disconnect negative battery cable from battery Before disconnecting negative ground cable make sure all switches are OFF If ON a spark will occur at the ground cable terminal which could cause an explosion if hydrogen gas or LPG NG fuel vapors are present Fire Can cause severe injury or death Do not smoke or permit flames or sparks near fuels or the fuel system 18 Operation Explosive fuel can cause fires and severe burns If a gaseous odor is detected ventilate the area and contact an authorized service technician LPG Liquefied Petroleum Gas is extremely flammable and tends to
10. authorized distributor dealer visit KOHLERPower com or call 1 800 544 2444 U S and Canada Engine Identification and Technical Support 5 ENGINE IDENTIFICATION AND TECHNICAL SUPPORT 6 Engine Identification and Technical Support TP 6901 6 14 SAFETY PRECAUTIONS Section 2 Safety Precautions 2 1 SAFETY ALERTS warns Danger indicates the presence Warning indicates the presence Caution indicates the presence of a hazard that will cause of a hazard that can cause of a hazard that will or can cause severe personal injury death or severe personal injury death or minor personal injury or substantial property damage substantial property damage property damage NOTICE NOTE A Note is used to inform you of Notice communicates installation important installation operation or maintenance information operation or maintenance information that is safety related but not hazard related 2 2 SAFETY INFORMATION FOR THIS ENGINE Carbon Electrical shock Hot parts can monoxide can can cause injury cause severe cause severe Do riotto ch burns nausea fainting wires while s 4 engine is running engine while operating or just after stopping Engine exhaust gases contain WARNING Never operate engine with heat poisonous carbon monoxide Rotating parts shields or guards removed Carbon monoxide is odorless can cause colorless and can cause death if severe injury inhaled Sta
11. hours of operation Replace the engine oil and filter more often if the machine is being run in excessively dirty or dusty conditions A WARNING Handling caustic engine fluids and chemical products can cause severe chemical burns nausea fainting or death Most chemicals such as used engine oil antifreeze coolant rust proofing agent inhibiting oil degreasing agent spray paint and adhesives are hazardous to health Read and follow the user information found on the packaging Avoid inhalation and skin contact Use only in well ventilated areas and use a protective mask when spraying Store engine fluids and chemical products in a locked cabinet Contact your local recycling center for disposal information and locations TP 6901 6 14 MAINTENANCE A WARNING Explosive fuel can cause fires and severe burns If a gaseous odor is detected ventilate the area and contact an authorized service technician LPG Liquefied Petroleum Gas is extremely flammable and tends to settle in low areas where a spark or flame could ignite the gas Do not start or operate this engine in a poorly ventilated area where leaking gas could accumulate and endanger the safety of persons in the area NG Natural Gas is extremely flammable is lighter than air and rises Do not start or operate this engine in a poorly ventilated are where leaking gas could accumulate and endanger the safety of persons in the area To ensure pers
12. impact of these performance issues Keep the engine working reliably by performing all preventive maintenance tasks described in this section Accidental starts can cause severe injury or death Disconnect and ground spark plug leads before servicing Before working on engine or equipment disable the engine as follows 1 Disconnect spark plug leads 2 Disconnect negative battery cable from battery Before disconnecting negative battery cable make sure all switches are OFF If ON a spark will occur at the ground cable terminal which could cause an explosion if hydrogen gas or LPG NG fuel vapors are present TP 6901 6 14 Section 5 Maintenance Handling caustic engine fluids and chemical products can cause severe chemical burns nausea fainting or death Most chemicals such as used engine oil antifreeze coolant rust proofing agent inhibiting oil degreasing agent spray paint and adhesives are hazardous to health Read and follow the user information found on the packaging Avoid inhalation and skin contact Use only in well ventilated areas and use a protective mask when spraying Store engine fluids and chemical products in a locked cabinet Contact your local recycling center for disposal information and locations Maintenance 23 MAINTENANCE Explosive fuel can cause fires and severe burns If a gaseous odor is detected ventilate the area and contact an authorized service technician
13. settle in low areas where a spark or flame could ignite the gas Do not start or operate this engine in a poorly ventilated area where leaking gas could accumulate and endanger the safety of persons in the area NG Natural Gas is extremely flammable is lighter than air and rises Do not start or operate this engine in a poorly ventilated are where leaking gas could accumulate and endanger the safety of persons in the area To ensure personal safety installation and repair of LPG NG fuel supply systems must be performed only by qualified LPG NG system technicians Improperly installed and maintained LPG NG equipment could cause the fuel supply system or other components to malfunction causing gas leaks Observe federal state and local laws governing LPG NG fuel storage and systems Figure 4 9 TP 6901 6 14 OPERATION 4 3 BEFORE STARTING To set the regulator for LPG 1 Push the adjusting cap to its upper stop and rotate clockwise release upward pressure and lock into place See Figure 4 7 2 ForLPG fuel only connect wire N20 from the fuel pressure regulator to wire 45 from the ECM wiring harness using the quick connect adapters See Figure 4 8 To reset the regulator for NG Reverse the above procedure to reset for NG operation 1 Push up on the adjusting cap A and rotate counterclockwise Release upward pressure and lock into place See Figure 4 7 2 Disconnect wire N20 and wire 45 See Fig
14. the ECM The ECM uses this data to adjust for cold starting conditions and regulates various fuel and emission control functions Engine Oil Pressure Sender The engine oil pressure sender ensures sufficient lubrication throughout the engine The sender is a pressure valve that is monitored by the ECM A drop in pressure will trigger a fault code TP 6901 6 14 OPERATION Fuel Specifications NOTICE Natural gas and propane installations must be installed in accordance with applicable federal state and local law and with the National Fire Protection Association NFPA Pamphlet 58 standard for storage and handling of Liquefied Petroleum Gases to the extent that these standards are not in violation of federal state or local law Table 4 1 Fuel Specifications Fuel Type Item Specification Liquid Propane Type HD 5 or HD 10 Gas LPG i Maximum fuel pressure 13 85 W C engine OFF no load Minimum fuel pressure engine ON full load ep GS Natural Gas NG Supply Standard pipeline Approximate supply volume 37 257 kJ m 1000 BTU ft 3 Minmumflow 11 9 mhr 420 SCFH 6 0 W C Less than 112 3 kg per 1 million m water Less than 7 Ib per 1 million ft 3 Maximum fuel pressure engine OFF no load JOD Men Minimum fuel pressure 7 engine ON full load LPG and NG Fuel handling and supply component UL 2200 Standard for Stationary Engine
15. 20 0 28 in Belt Deflection Used 7 8 mm 0 28 0 31 in rigure 5 25 6 If the amount of deflection is out of specification 3 Inspect the drive belt Look for signs of cracking adjust the drive belt tension separation cuts or other damage See Figure 5 25 Adjust Drive Belt Tension 4 f any abnormality is found replace the drive belt Figure 5 26 Figure 5 27 7 Loosen the two alternator mounting bolts C See Figure 5 27 8 Toincrease tension move the alternator away from the engine To decrease tension move the alternator toward the engine 9 Tighten two alternator mounting bolts 10 Check the drive belt tension Repeat the adjustment procedure if necessary until the drive belt tension is within specification TP 6901 6 14 Maintenance 33 MAINTENANCE Replace the Drive Belt Accidental starts can cause severe injury or death Disconnect and ground spark plug leads before servicing Before working on engine or equipment disable engine as follows 1 Disconnect spark plug leads 2 Disconnect negative battery cable from battery Before disconnecting negative ground cable make sure all switches are OFF If ON a spark will occur at the ground cable terminal which could cause an explosion if hydrogen gas or LPG NG fuel vapors are present A WARNING Rotating parts can cause severe injury Stay away while the engine is in operation Keep hands feet hair and clothing a
16. 3 Adjustment Specifications 44 8 4 Torque Specifications cheer RS ET pA tempted panem due dett 44 8 5 Standard Torque Specifications 45 ENGINE IDENTIFICATION AND TECHNICAL SUPPORT Section 1 Engine Identification and 1 1 KNOW YOUR ENGINE Product identification numbers determine service parts Record the product identification numbers in the spaces below immediately after unpacking the products so that the numbers are readily available for future reference Engine Identification Record the product identification information from the engine nameplate Model Designation Serial Number Purchase Date Upon purchase of your KOHLER equipment record the purchase date for reference when communicating with your authorized KOHLER distributor dealer 1 2 RELATED LITERATURE Related Literature identifies related literature available for the KG2204 engine Only trained and qualified personnel should install or service this engine Literature Type Part Number KOHLER Model KG2204 TP 6902 Service Manual KOHLER Model KG2204 TP 6903 Service Manual Troubleshooting Diagnostics KOHLER Model KG2204 TP 6904 Service Parts Manual TP 6901 6 14 Technical Support 1 3 SERVICE PARTS Contact a KOHLER authorized distributor dealer for all maintenance service and engine parts To find a KOHLER
17. 32 Check and Adjust the Drive 32 Replace the Drive Belt 34 Check Wiring and Electrical Connections 35 5 6 Cooling System eve este Cae bee eS aetna es Sede AS aa 35 Check Coolant Level and Condition 35 Check Hoses and Clamps nreno de cece ett 36 5 7 Fuel System s oct eec be ve eb Re db as 36 Check Fuel Supply Pipe and Connections 37 Check Fuel Level LPG only 37 Section 6 Troubleshooting 6 1 Introduction etos eec IRE OQ Vile Eg I Eds 39 6 2 Troubleshooting 4x nl RED v AI a teal ah Nu eR es ERA 39 Section 7 Storage 7 1 Preparation e Ea Dee RR beg RU e UP 41 7 2 Short Term Storage Less than 30 days 41 7 3 Long Term Storage More than 30 days 41 7 4 Maintenance While In Storage 41 7 5 Removal From Storage 42 Section 8 Specifications 8 1 Engine Specifications 3 idesi 24 45 us LR NR EI CE beheld PAR 43 8 2 Specifications of Main Components 44 8
18. 97 201 0 148 287 0 212 M18 x 2 50 Nem ft Ib 179 0 132 273 0 201 390 0 288 M18 x 1 50 Nem ft Ib 189 0 140 289 0 213 413 0 305 NOTE 1 The torque values above are general guidelines Always use the torque values specified in the service manuals and or assembly drawings when they differ from above torque values 2 The torque values above are based on new plated threads Increase torque values by 15 if non plated threads are used 3 Hardware threaded into aluminum must have either two diameters of thread engagement or a 3096 or more reduction in the torque to prevent stripped threads 4 Torque values are calculated as equivalent stress loading on American hardware with an approximate preload of 90 of the yield strength and a friction coefficient of 0 125 46 Specifications TP 6901 6 14 NOTES Notes TP 6901 6 14 2014 by Kohler Co All Rights Reserved KOHLER Power Systems Kohler CO Kohler Wisconsin 53044 Phone 920 457 4441 Fax 920 459 1646 For the nearest sales service outlet in the US and Canada phone 1 800 544 2444 KOHLERPower com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone 65 6264 6422 Fax 65 6244 6455
19. Check the spark plugs after each 500 hours of operation Electrical shock can cause injury Do not touch wires while engine is running Hot parts can cause severe burns Do not touch engine while operating or just after stopping Required materials Spark plug wrench Torque wrench e Spark plug gap tool Clean dry cloth Procedure 1 Stop the engine and allow it to cool NOTICE Label or mark spark plug wires before disconnecting Spark plug wires MUST be reinstalled in proper order as removed Maintenance 29 MAINTENANCE Use a cloth to wipe dirt and oil away from the area around each of the four spark plug wires A See Figure 5 19 Disconnect the spark plug wires Wipe the interior of the spark plug tubes Use a spark plug wrench to remove the spark plugs Figure 5 20 Inspect the electrodes B on each spark plug See Figure 5 20 The electrodes should be light brown If the electrode appears to be burned covered with soot or fouled with oil replace the spark plug 30 Maintenance Figure 5 21 7 nspect the body of each spark plug for cracks damage or discoloration and check that the spark plug O ring is in good condition Replace as needed 8 Usea spark plug gap tool to measure the gap C on each spark plug Adjust the gap to specification See Figure 5 21 Spark Plug Gap 0 9 1 0 mm 0 036 0 040 in NOTE Ensure that the spark plug tubes are seated before instal
20. a To ensure personal safety installation and repair of LPG NG fuel supply systems must be performed only by qualified LPG NG system technicians Improperly installed and maintained LPG NG equipment could cause the fuel supply system or other components to malfunction causing gas leaks Observe federal state and local laws governing LPG NG fuel storage and systems NOTE Fuel system components are not adjustable and cannot be serviced Contact your authorized KOHLER authorized distributor dealer for replacements TP 6901 6 14 MAINTENANCE Check Fuel Supply Pipe and Connections With the fuel valve fully opened and the engine stopped check all fuel system connections and lines for leaks using a soapy water solution Correct any leaks before restarting the engine Do not start the engine if you can smell leaking gas Have any necessary service performed by a KOHLER authorized distributor dealer or qualified LPG NG technician only Check Fuel Level LPG only With the fuel valve on the LPG tank fully closed and the engine stopped check the fuel gauge on the LPG tank Make sure that the tank contains enough fuel for sustained operation If not refill the tank before restarting the engine Fully open the fuel valve on the LPG tank Check all fuel supply connections and lines for leaks using a soapy water solution Correct any leaks before restarting the engine Have any necessary service performed by a KOHLER aut
21. al U S equivalent California Proposition 65 A WARNING Engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Section 1 Engine Identification and Technical Support 1 1 Know Your Engine 5 Purchase Date e Sb ete tir d eb dus 5 1 2 Related Literature 5 1 3 Service orro reee 2440 ga DES E noted s 5 Section 2 Safety Precautions 2 1 Safety Alerts ssie Sx RUNS EM ve 7 2 2 Safety Information For This Engine 7 Section 3 Components and Maintenance Locations 3 1 Engine Side VIEWS dex RR ER nites wees daw s 11 3 2 Front and Rear Views 12 Section 4 Operation 4 1 Introduction sss eR Labeo epe eed s Bep me s 13 4 2 0 AO e OU ovv dust aee rbi UOS A tM c 13 Components MERE AE e 13 Fuel Specifications 2 2 se eder Estee en P etos t ed Ra ek 17 NG to LPG Conversion s orror er 18 4 3 Before Starting re pe eenia E ee oe ee In o ees 19 4 4 Starting o6 c oco m OO Aou e e 20 4 5 Cold Weather Starting
22. al components Tighten the alternator belt Check fluid levels and fill as needed Connect the battery Connect the fuel supply and open fuel valves Start the engine and allow it to run for several minutes without load Check for leaks and watch for signs of abnormal operation NOTE The engine may smoke when started for the first time after being taken out of storage This is normal and occurs as the engine burns away the protective oil coating inside the cylinders Check oil pressure and fuel pressure gauges to make sure that the engine is operating normally 42 Storage TP 6901 6 14 SPECIFICATIONS 8 1 ENGINE SPECIFICATIONS Section 8 Specifications Item Specifications Engine Model KG2204 Block Type l 4 Number of Cylinders 4 Cylinder Bore 91 mm 3 5 in Piston Stroke 86 mm 3 4 in Displacement 2 2 L 134 25 in 3 Rated Output 61 kW 81 8 HP 3600 rpm Fuel Type Oil Type Weight Propane Liquid Petroleum Gas LPG or Natural Gas NG See Fuel Specifications in Section 4 KOHLER synthetic engine oil SAE Class SJ or higher Variable per ambient temperature See Oil Recommendations in Section 5 Oil Dry Fill Capacity 4 2 L 4 4 qt Rotating Direction of Crankshaft Counterclockwise face to flywheel Compression Ratio 10 5 1 Cylinder Fire Order 1 3 4 2 Lubricating Style Pressurized Starting Style Electric Net W
23. are recommended For best performance in colder environments such as the United States and Canada use Society of Automotive Engineers SAE 5W 30 API service class SJ or higher In extremely hot environments where temperatures are never or rarely below 0 C 32 F use a synthetic oil with a viscosity designation of 10W 30 API service class SJ or higher Grease Recommendations The alternator and starter bearings on this engine must be lubricated with a high quality lithium based automotive grease Coolant Recommendations Use only a mixture of 50 long life coolant and 50 clean softened water to inhibit rust corrosion and prevent freezing A solution of 50 long life coolant provides freezing protection to 37 C 34 F and overheating protections to 149 C 300 F A coolant solution with less than 50 long life coolant may not provide adequate freezing and overheating protection Do not mix long life coolants and conventional coolants Do not mix different types and or colors of long life coolants TP 6901 6 14 MAINTENANCE 5 3 PERIODIC MAINTENANCE SCHEDULE Engine parts experience wear at different rates Technical maintenance tasks therefore are required at several different intervals throughout the life of the engine Daily Yearly or every 120 hours of operation Weekly or every 10 hours of operation Years or every 400 500 hours of operation Quarterly or every 20 hours of operation e Seasona
24. cumulate and endanger the safety of persons in the area To ensure personal safety installation and repair of LPG NG fuel supply systems must be performed only by qualified LPG NG system technicians Improperly installed and maintained LPG NG equipment could cause the fuel supply system or other components to malfunction causing gas leaks Observe federal state and local laws governing LPG NG fuel storage and systems Cold weather puts added stress on the engine during start up To start the engine in cold weather 1 Make sure that the engine oil is appropriate for the ambient operating temperature See Fluid Specifications in Section 5 Drain and replace the engine oil if necessary 2 Disconnect all applied loads and or equipment before cranking the starter 3 Allow the engine to run unloaded for about five minutes after cold weather start up Operation 21 OPERATION 4 6 MONITORING ENGINE 4 7 STOPPING OPERATION 1 Disconnect all applied loads if possible along with Power Take Off PTO attachments before WARNING stopping the engine 2 Ifthe engine has been running under a heavy load reduce engine speed and allow it to run for an additional 2 3 minutes before stopping This action will help to cool the engine slightly before Carbon monoxide can cause Severe nausea fainting or death Avoid inhaling exhaust fumes shutdown Engine exhaust gases contain poisonous carbon The specific engine stopp
25. d adjust fuel pressure ECM Does Not Store DTC 40 Troubleshooting Faulty electrical connections components or wiring Contact KOHLER service TP 6901 6 14 STORAGE Electrical shock can cause injury Do not touch wires while engine is running Handling caustic engine fluids and chemical products can cause severe chemical burns nausea fainting or death Most chemicals such as used engine oil antifreeze coolant rust proofing agent inhibiting oil degreasing agent spray paint and adhesives are hazardous to health Read and follow the user information found on the packaging Avoid inhalation and skin contact Use only in well ventilated areas and use a protective mask when spraying Store engine fluids and chemical products in a locked cabinet Contact your local recycling center for disposal information and locations 7 1 PREPARATION If you plan to take the engine out of service for an extended period of time prepare the engine according to the tasks described in this section These preventive measures will help to protect your engine from the cumulative effects of rust and deterioration while it is not being used Perform scheduled periodic maintenance tasks Make all necessary repairs and adjustments Close the fuel valves and disconnect the fuel supply Clean the outside of the engine Wipe away all visible dirt dust and oil e Remove the starting key TP 6901 6 14 S
26. de gap Adjust gap if necessary Replace spark plug s if discolored or damaged Seasonal Maintenance Check coolant concentration and replenish replace as needed Replace engine oil with a lower temperature grade in the winter if required TP 6901 6 14 Maintenance 25 MAINTENANCE 5 4 ENGINE Check Engine Oil Check the engine oil level daily before starting the engine Inspect the oil for signs of deterioration discoloration thinning or water contamination If any of these conditions exist the oil quality has been compromised and should be replaced Required materials Clean dry cloth Fresh engine oil See Oil Recommendations on page 24 Procedure 1 Stop the engine and allow it to cool NF DS Figure 5 11 2 Pull out the oil dipstick A See Figure 5 11 3 Wipe the end of the dipstick with a clean dry cloth 4 Insert the dipstick into the engine Figure 5 12 5 Pull out the dipstick again to check the oil level The oil level B should be maintained between the F full and L low marks See Figure 5 12 26 Maintenance Figure 5 13 6 Ifthe oil level is below L check for leaks If no leaks are found open the oil fill cap C Wipe the oil fill cap clean and add oil up to the F mark See Figure 5 13 7 If oil leaks are found repair them before operating the engine Change Engine Oil and Oil Filter Change the engine oil and filter every 120
27. e gap B on each new spark plug Adjust the gap to specification See Figure 5 23 Spark Plug Gap 0 9 1 0 mm 0 036 0 040 in 7 Install the new spark plugs in the cylinder head 8 Tighten the spark plugs to specification Spark Plug Torque 18 Nm 13 3 ft Ib Ignition Timing The KG2204 engine has an electronic ignition system All functions of the ignition system including timing are controlled by the ECM and cannot be adjusted Contact your KOHLER authorized distributor dealer for assistance with ignition related performance issues Maintenance 31 MAINTENANCE 5 5 ELECTRICAL SYSTEM Check Battery and Connections Check the condition of the battery and connections according to the intervals specified in Periodic Maintenance Schedule on page 25 Specific items to look for are Loose or missing fasteners on the battery hold down Loose cable connections Frayed cut or broken cables Cracks in battery cell cover or case Dirt oil or water contamination Corrosion at battery terminals Reduction in voltage or ability to hold a charge Repair or replace the battery and or components as needed Use only replacement parts that are equivalent to the original equipment Contact your Accidental starts can cause severe injury or death Disconnect and ground spark plug leads before servicing Before working on engine or equipment disable engine as follows 1 Disconnect spark plug leads
28. ecompose forming hydrofluoric acid Avoid inhalation or skin contact Do not incinerate rings Dispose of O ring waste material in a responsible manner Before working on engine or equipment disable engine as follows 1 Disconnect spark plug leads 2 Disconnect negative battery cable from battery Before disconnecting negative ground cable make sure all switches are OFF If ON a spark will occur at the ground cable terminal which could cause an explosion if hydrogen gas or LPG NG fuel vapors are present 8 Safety Precautions TP 6901 6 14 Explosive fuel vapors Can cause severe injury or death Use extreme care when handling storing and using fuels Gas fuel leaks Explosive fuel vapors can cause severe injury or death Fuel leakage can cause an explosion Check the LPG vapor or natural gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to 6 8 ounces per square inch 10 14 inches water column Do not use a soap solution containing either ammonia or chlorine because both prevent bubble formation A successful test depends on the ability of the solution to bubble Used engine oil Contact with used engine oil may cause severe skin irritation Repeated and prolonged skin exposure may have other health risks Used engine oil is a suspected carcinogen Avoid contact with skin Thoroughly wash your hands and nails with soap and water sh
29. ection 7 Storage 7 2 SHORT TERM STORAGE LESS THAN 30 DAYS Disconnect and remove the battery Cover or cap all intake and exhaust ports including fuel lines air filter and engine exhaust Cover the engine with a clean dry cloth Store the engine in a secure dry location away from trespassers children and animals 7 3 LONG TERM STORAGE MORE THAN 30 DAYS In addition to the short term tasks listed above perform these additional tasks before placing the engine in storage Change the engine oil and filter Loosen the drive belt Protect the cylinders from rust Disconnect the spark plug wires and remove the spark plugs Squirt approximately 30 ml 1 ounce of fresh engine oil into each cylinder Manually rotate the crankshaft 10 15 times to distribute the oil evenly in the cylinders Install the spark plugs and reconnect the spark plug wires Cover all exposed metal parts with a suitable protectant e Coat all electrical connectors with a suitable protectant 7 4 MAINTENANCE WHILE IN STORAGE Inspect the engine regularly at least once a month Check for signs of rust or leaks Periodically test the battery voltage and recharge as needed The battery may lose charge even when disconnected Storage 41 STORAGE 7 5 REMOVAL FROM STORAGE Remove protective cloths covers and caps from the engine Clean protectant from exposed metal parts and electric
30. eight Dry 145 kg 320 Ib Overall Dimensions L x W x H 826 x 547 x 647 mm 32 5 x 21 5 x 25 5 in TP 6901 6 14 Specifications 43 SPECIFICATIONS 8 2 SPECIFICATIONS OF MAIN COMPONENTS Item Specifications Cil Filter Breather Paper Rocker Arm Covers Top Oil Filter Oil Pump Rotor type Water Pump Centrifugal type no fan Flywheel Flywheel with attachment provisions for flywheel adapter KOHLER part number GM88832 Thermostat Settings Valve open at 76 C 169 F Valve lift fully open at 88 C 190 F Alternator Rated voltage 14 V rated current 90 A Electric Starter 1 2 kW speed reduction type Ignition System Electronic Spark Plug Bosch F6RTC or equivalent Screw thread M14 x 1 25 8 3 ADJUSTMENT SPECIFICATIONS Item Specifications Spark Plug Gap 0 9 1 0 mm 0 036 0 040 in Drive Belt Tension at pressure of 98 N 22 Ib 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 Fuel Pressure Regu lator Nonadjustable LPG or NG selectable Throttle Nonadjustable ECM controlled Air Fuel Mixer Tamper proof nonadjustable Fuel Control Valve Nonadjustable 8 4 TORQUE SPECIFICATIONS Item Nem ft Ib Spark Plugs 18 13 3 Oil Drain Plug 20 25 14 8 18 4 44 Specifications TP 6901 6 14
31. f it is dirty discolored or fouled with oil or rust particles Rusty coolant may indicate corrosion inside the radiator Oil in the coolant indicates a leak somewhere in the lubrication system Contact a KOHLER authorized distributor dealer if either of these conditions exist Maintenance 35 MAINTENANCE Check Hoses and Clamps Check the condition of the coolant system hoses and clamps every 10 hours of operation Hoses nspect the hoses for cracks abrasions cuts bulges swollen ends or leaks Squeeze the hoses They should yield slightly to moderate pressure and not feel too hard too soft or spongy e Replace faulty hoses before operating the engine Clamps Verify that all clamps are in place e Adjust and tighten clamps as needed 36 Maintenance 5 7 FUEL SYSTEM Explosive fuel can cause fires and severe burns If a gaseous odor is detected ventilate the area and contact an authorized service technician LPG Liquefied Petroleum Gas is extremely flammable and tends to settle in low areas where a spark or flame could ignite the gas Do not start or operate this engine in a poorly ventilated area where leaking gas could accumulate and endanger the safety of persons in the area NG Natural Gas is extremely flammable is lighter than air and rises Do not start or operate this engine in a poorly ventilated are where leaking gas could accumulate and endanger the safety of persons in the are
32. horized distributor dealer or qualified LPG NG technician only TP 6901 6 14 Maintenance 37 MAINTENANCE 38 Maintenance TP 6901 6 14 TROUBLESHOOTING 6 1 INTRODUCTION Section 6 Troubleshooting The following chart will help you to identify and solve some of the basic operating problems that may occur while operating this engine Do not attempt to service or replace major engine components or any items that require special timing or adjustment procedures This work should be performed only by a KOHLER authorized distributor dealer 6 2 TROUBLESHOOTING Problem Will Not Start Possible Cause No fuel Solution Check fuel supply Incorrect fuel Make sure fuel system is configured properly for LPG or NG supply Dirty restricted fuel system Check fuel system and clean components as needed Incorrect oil level Check engine oil level add as needed Engine overloaded Disconnect or reduce loads Faulty spark plug Inspect adjust or replace as needed Hard Starting No fuel Check fuel supply Incorrect fuel Make sure fuel system is configured properly for LPG or NG supply Restricted fuel flow Make sure fuel supply valves are open check for air intake system leakage Dirty restricted fuel system Incorrect oil level Check fuel system and clean components as needed Check engine oil level add as needed Engine overloaded Discon
33. ing sequence varies monoxide Carbon monoxide is odorless colorless depending on the equipment that this engine powers and can cause death if inhaled Refer to your equipment Operation Manual for more information Electrical shock can cause injury Do not touch wires while engine is running Check for the following items as the engine runs e Gas air leaks check for leakage from fuel pipes cooling pipes or air pipes Exhaust check for detonation backfire or knocking Watch for excessive smoke or abnormal color Noise listen for rattles or other abnormal noise Electrical check for burnt smell from hot electrical equipment Fluid leaks check for leaking oil or coolant Gauges check oil pressure coolant temperature and other operating parameters If any abnormal or unusual conditions are detected stop the engine immediately and perform troubleshooting diagnostics before resuming operation 22 Operation TP 6901 6 14 MAINTENANCE 5 1 INTRODUCTION Preventive maintenance is critical to prolonging the life of the KG2204 engine and keeping it in optimum working condition As the engine runs fasteners may loosen parts may become worn clearances change and oil picks up dirt and contaminants The engine may eventually become hard to start or may exhibit other symptoms such as decreased power output or increased fuel consumption Regularly scheduled maintenance will help to prevent or reduce the
34. installation surface E clean with a dry cloth Inspect the installation surface for damage See Figure 5 16 6 Apply a thin film of fresh oil to the gasket of the new oil filter 28 Maintenance Figure 5 17 Lightly screw in the new oil filter by hand until you feel resistance Using the oil filter wrench F tighten the filter an additional 3 4 turn 25 Nem 18 4 ft lbs See Figure 5 17 8 Install the oil drain plug Tighten to specification Pan Drain Plug Torque 20 25 Nem 14 8 18 4 9 Addfresh oil through the oil filler cap B N Figure 5 18 10 Check engine oil level making sure that the level lies between the L and F marks on the dipstick C See Figure 5 18 11 Install and tighten the oil filler cap 12 Start the engine and run it without load for approximately 5 minutes This will ensure that the fresh engine oil is distributed to each friction surface NOTE Dispose of used engine oil and oil filters in accordance with local environmental regulations TP 6901 6 14 MAINTENANCE Check and Clean the Air Filter Refer to the Equipment Operation Manual using this engine installation Replace the Air Filter Refer to the Equipment Operation Manual using this engine installation TP 6901 6 14 Check and Adjust the Spark Plugs Damaged loose or improperly adjusted spark plugs can overheat or cause engine problems such as misfiring hesitation or knocking
35. ling the spark plugs If the tubes were removed reinstall the tubes before installing the spark plugs 9 Install the spark plugs in the cylinder head 10 Tighten the spark plugs to specification Spark Plug Torque 18 Nem 13 3 ft Ib 11 Install spark plug wires to spark plugs TP 6901 6 14 MAINTENANCE Replace the Spark Plugs Spark plugs should be replaced at the recommended intervals specified at the beginning of this section Use only the recommended spark plug or an equivalent See Specifications of Main Components in Section 8 Electrical shock can cause injury Do not touch wires while engine is running Hot parts can cause severe burns Do not touch engine while operating or just after stopping Never operate engine with heat shields or guards removed Required materials Replacement spark plugs 4 e Spark plug wrench e Spark plug gap tool Torque wrench Clean dry cloth Procedure 1 Stop the engine and allow it to cool NOTICE Label or mark spark plug wires before disconnecting Spark plug wires MUST be installed in proper order Figure 5 22 TP 6901 6 14 2 Useacloth to wipe dirt and oil away from the area around each of the four spark plug wires A See Figure 5 22 3 Disconnect the spark plug wires 4 Wipe the interior of the spark plug tubes 5 Usea spark plug wrench to remove the old spark plugs Figure 5 23 6 Usea spark plug gap tool to measure th
36. lly The chart lists the required maintenance tasks at each designated intervals throughout the life of the engine For example a task performed after the first 10 hours of operation must be repeated after 20 hours 30 hours and so forth Daily before starting Check for loose or missing fasteners Tighten or replace as needed e Check the level of fuel coolant and oil Refill as needed Check coolant system hoses and clamps Weekly or every 10 hours of operation Check battery connections for tightness and signs of corrosion e Check for oil and coolant leaks Check wiring and electrical connections Repair or replace loose or damaged components e Start engine and listen for abnormal noises Check for fuel system leaks hissing sounds or gas odor Quarterly or every 20 hours of operation Check battery voltage charge or replace as needed Check and clean air filter See equipment Operation Manual Check all fasteners for tightness Yearly or every 120 hours of operation e Check the battery for cracks damaged electrodes and corrosion e Check the drive belt tension Adjust or replace drive belt if necessary Replace engine oil and oil filter 3 years or every 400 hours of operation Change air filter element s See equipment Operation Manual 3 years or every 500 hours of operation Check spark plug condition and electro
37. nect or reduce loads Faulty spark plug Inspect adjust or replace as needed Stops Suddenly No fuel Dirty restricted fuel system Check fuel supply Check fuel system and clean components as needed Incorrect oil level Check engine oil level add as needed Engine overloaded Disconnect or reduce loads Lacks Power Incorrect fuel Make sure fuel system is configured properly for LPG or NG supply Low fuel pressure Check and adjust fuel pressure Incorrect oil level Check engine oil level add as needed Engine overloaded Faulty spark plug Disconnect or reduce loads Inspect adjust or replace as needed TP 6901 6 14 Dirty restricted fuel system Check fuel system and clean components as needed Troubleshooting 39 TROUBLESHOOTING Problem Operates Erratically or Unevenly Possible Cause Incorrect fuel Solution Make sure fuel system is configured properly for LPG or NG supply Dirty restricted fuel system Check fuel system and clean components as needed Low fuel supply pressure Check and adjust Engine overloaded Disconnect or reduce loads Loose wiring at shut off valve s Check wiring and repair connections Faulty spark plug Inspect adjust or replace as needed Dirty air filter Inspect and replace as needed Knocks or Pings Incorrect fuel Make sure fuel system is configured
38. nections Electrical shock can cause injury Do not touch wires while engine is running Check the condition of the wiring and electrical connections after every 10 hours of operation Specific items to look for are Exposed bare wires Cuts or abrasions in wire insulation Loose connections at screw terminals Loose dirty or cracked electrical connectors Melted or scorched wiring insulation or connectors Repair or replace faulty electrical components before operating the machine TP 6901 6 14 5 6 COOLING SYSTEM Check Coolant Level and Condition The engine coolant level should be checked daily before starting the engine Insufficient coolant will cause the engine to overheat Hot coolant and steam Can cause severe injury or death Before removing the pressure cap stop the engine and allow it to cool Then loosen the pressure cap to relieve pressure Check coolant level 1 Openthe radiator cap slowly in order to release the pressure in the system 2 Maintain the coolant level in the coolant overflow bottle between the High and Low markings See Coolant Recommendations on page 24 NOTE Periodically check the coolant level by removing the radiator s pressure cap Do not rely solely on the level in the coolant overflow bottle 3 Install and tighten the radiator cap Check coolant condition Engine coolant should be uniformly colored and transparent Replace the coolant i
39. onal safety installation and repair of LPG NG fuel supply systems must be performed only by qualified LPG NG system technicians Improperly installed and maintained LPG NG equipment could cause the fuel supply system or other components to malfunction causing gas leaks Observe federal state and local laws governing LPG NG fuel storage and systems A WARNING Hot parts can cause severe burns Do not touch engine while operating or just after stopping Never operate engine with heat shields or guards removed TP 6901 6 14 Required materials Fresh engine oil See Oil Recommendations on page 24 Collection container for drained oil minimum 8 liter 2 1 gal capacity Replacement oil filter Oil filter wrench Clean dry cloth Drop cloth to protect work surface Change the engine oil and oil filter 1 Stop the engine and allow it to cool Figure 5 14 2 Placea drop cloth and collection container beneath the oil drain plug A See Figure 5 14 3 Remove the oil drain plug and allow the oil to drain into the container Maintenance 27 MAINTENANCE Figure 5 15 4 Using an oil filter wrench remove the old oil filter D See Figure 5 15 NOTE After removing the oil filter ensure that the oil cooler adapter nut is tightened to specification 40 Nem 29 5 ft lbs and that oil cooler adapter and gasket are seated properly Figure 5 16 5 Wipe the oil filter
40. ortly after handling used engine oil Wash or dispose of clothing or rags containing used engine oil Dispose of used engine oil in a responsible manner Contact your local recycling center for disposal information and locations TP 6901 6 14 SAFETY PRECAUTIONS Safety Precautions 9 SAFETY PRECAUTIONS 10 Safety Precautions TP 6901 6 14 COMPONENTS AND MAINTENANCE LOCATIONS Section 3 Components and Maintenance Locations 3 1 ENGINE SIDE VIEWS Figure 3 1 Knock Sensor if 1 Rocker Arm Cover 7 Air Fuel Mixer 13 Oil Pan 19 equipped with turbocharger Oil Cooler Adapter 2 Rear Hanger 8 Throttle Body 14 Battery Charging 20 not included on Alternator all models 3 crankcase 9 TMAP Sensor 15 Oil Pump Drive 21 Oil Pan Drain Plug Breather 4 Spark Plug Wires 10 Intake Manifold 16 Ignition Coil 22 CE PCosSure Sender 5 11 Flywheel 23 OilFilter Base Position Sensor 6 Front Hanger 12 Exhaust Manifold 18 s and 24 Filter 1 Air Temperature Manifold Absolute Pressure TMAP TP 6901 6 14 Components and Maintenance Locations 11 EXE Y PT EO AN ce wk d COMPONENTS AND MAINTENANCE LOCATIONS 3 2 FRONT AND REAR VIEWS Figure 3 2 f ES d Crankshaft Air Fuel Mixer 8 Ignition Coil 15 Position Sensor 22 Flywheel Throttle Body 9 Oil Dipstick 16 Timing Cover 23 ES
41. properly for LPG or NG supply Engine overloaded Disconnect or reduce loads Faulty spark plug Inspect adjust or replace as needed Dirty restricted fuel system Check fuel system and clean components as needed Dirty air filter Inspect and replace as needed Skips or Misfires Incorrect fuel Faulty spark plug Dirty restricted fuel system Dirty air filter Make sure fuel system is configured properly for LPG or NG supply Inspect adjust or replace as needed Check fuel system and clean components as needed Inspect and replace as needed Backfires Incorrect fuel Make sure fuel system is configured properly for LPG or NG supply Faulty spark plug Inspect adjust or replace as needed Dirty restricted fuel system Check fuel system and clean components as needed Dirty air filter Inspect and replace as needed Overheats Incorrect fuel Make sure fuel system is configured properly for LPG or NG supply Dirty restricted fuel system Check fuel system and clean components as needed Incorrect oil level Check engine oil level add as needed Engine overloaded Faulty spark plug Disconnect or reduce loads Inspect adjust or replace as needed Consumes Excess Fuel Faulty spark plug Inspect adjust or replace as needed Dirty restricted air cleaner element Clean or replace Incorrect fuel pressure Check an
42. r and clothing away from all moving parts to prevent injury Never operate the engine with covers shrouds or guards removed 20 Operation Explosive fuel can cause fires and severe burns If a gaseous odor is detected ventilate the area and contact an authorized service technician LPG Liquefied Petroleum Gas is extremely flammable and tends to settle in low areas where a spark or flame could ignite the gas Do not start or operate this engine in a poorly ventilated area where leaking gas could accumulate and endanger the safety of persons in the area NG Natural Gas is extremely flammable is lighter than air and rises Do not start or operate this engine in a poorly ventilated are where leaking gas could accumulate and endanger the safety of persons in the area To ensure personal safety installation and repair of LPG NG fuel supply systems must be performed only by qualified LPG NG system technicians Improperly installed and maintained LPG NG equipment could cause the fuel supply system or other components to malfunction causing gas leaks Observe federal state and local laws governing LPG NG fuel storage and systems If the engine does not start after 5 seconds of cranking wait at least 15 seconds before trying again Do not crank the starter longer than three crank cycles After three crank cycles the controller will display faults Longer crank times can overheat the starter and drain the batter
43. ral guidelines Always use the torque values specified in the service manuals and or assembly drawings when they differ from above torque values The torque values above are based on new plated threads Increase torque values by 15 if non plated threads are used Hardware threaded into aluminum must have either two diameters of thread engagement or a 30 or more reduction in the torque to prevent stripped threads Torque values are calculated as equivalent stress loading on American hardware with an approximate preload of 9096 of the yield strength and a friction coefficient of 0 125 6 14 Specifications 45 SPECIFICATIONS Metric Fasteners Torque Specifications Assembled into Cast Iron or Steel Assembled into Torque Aluminum Grade Size Measurement Grade 5 8 Grade 8 8 Grade 10 9 5 8 or 8 8 M6 x 1 00 Nem ft Ib 6 2 4 6 2 9 13 6 10 M8 x 1 25 Nem ft Ib 15 0 11 29 6 22 33 0 24 M8 x 1 00 Nem ft Ib 16 0 11 24 0 18 34 0 25 M10 x 1 50 Nem ft Ib 30 0 22 52 5 39 65 0 48 M10 x 1 25 Nem ft Ib 31 0 23 47 0 35 68 0 50 M12 x 1 75 Nem ft Ib 53 0 39 80 0 59 115 0 85 M12 x 1 50 Nem ft Ib 56 0 41 85 0 63 122 0 90 See Note 3 M14 x 2 00 Nem ft Ib 83 0 61 135 0 100 180 0 133 M14 x 1 50 Nem ft Ib 87 0 64 133 0 98 190 0 140 M16 x 2 00 Nem ft Ib 127 0 94 194 0 143 278 0 205 M16 x 1 50 Nem ft Ib 132 0
44. sion Check level of battery electrolyte and add fluid if necessary See Electrical System in Section 5 Operation 19 OPERATION Check and clean cooling areas air intake areas and external surfaces of the engine particularly if the engine has been stored for a long period of time Check to make sure that air cleaner components shrouds equipment covers and guards are in place and securely fastened Check all electrical connections to make sure that they are tight including those at the alternator starter spark plug and ignition coil Repair damaged or loose wires or connectors before starting the engine Check the fuel system Make sure that all connections are secure at the fuel supply line and at all fuel system components Do not start the engine if you can smell leaking gas LPG only check the fuel level in the fuel tank and refill if necessary 4 4 STARTING The specific engine starting sequence varies depending on the equipment that this engine powers Refer to your Equipment Operation Manual for more information A WARNING Carbon monoxide can cause severe nausea fainting or death Avoid inhaling exhaust fumes Engine exhaust gasses contain poisonous carbon monoxide Carbon monoxide is odorless colorless and can cause death if inhaled A WARNING Rotating parts can cause severe injury Stay away while the engine is in operation Keep hands feet hai
45. ure 4 8 P8 ENGINE INTERFACE CONNECT FOR LP FUEL K0839 Figure 4 10 TP 6901 6 14 Accidental starts can cause severe injury or death Disconnect and ground spark plug leads before servicing Before working on engine or equipment disable engine as follows 1 Disconnect spark plug leads 2 Disconnect negative battery cable from battery Before disconnecting negative ground cable make sure all switches are OFF If ON a spark will occur at the ground cable terminal which could cause an explosion if hydrogen gas or LPG NG fuel vapors are present To prevent possible injury or damage to equipment carefully read and understand all information in this Operation Manual before starting the engine Follow the checklist below prior to each start up Perform a walk around inspection checking for damage fluid leaks loose or missing fasteners or debris Check pipe and hose connections to make sure that they are tight Check drive belt tension and adjust as needed See Ignition Timing in Section 5 Check engine oil level add oil as needed Inspect engine oil for signs of deterioration or contamination See Check Engine Oil in Section 5 Check engine coolant level add coolant as needed Inspect coolant for contamination See Check Coolant Level and Condition in Section 5 Check battery connections to ensure that they are tight with no visible corro
46. ut off valves located upstream from the fuel connection point on the engine Each valve consists of a 12V solenoid and a normally closed port When energized the solenoid opens the valve and allows the LPG NG vapor to flow through the system The valves are open during the engine cranking and run cycles Voltage to the valves is controlled by the ECM Operation 13 OPERATION Fuel Pressure Regulator Air Fuel Mixer Figure 4 4 The fuel pressure regulator modulates the pressure of the LPG NG vapor to the air fuel mixer The fuel pressure regulator is not adjustable However a selector at the base of the regulator is rotated when switching from NG to LPG and back See NG to LPG Conversion on page 18 for instructions Fuel Control Valve Figure 4 5 The fuel control valve is an ECM controlled vacuum switch that adjusts the fuel pressure delivered from the fuel pressure regulator to the air fuel mixer 14 Operation Figure 4 6 The air fuel mixer is mounted in the air stream ahead of the throttle It is a nonadjustable metering device that combines LPG NG vapor with intake air for combustion NOTICE Avoid the possibility of component damage The air fuel mixer is an emission control device Components inside the mixer are specifically calibrated to meet the engine s emission requirements and should never be disassembled or rebuilt If the mixer fails to function correctly contact your KOHLER authori
47. way from all moving parts to prevent injury Never operate the engine with covers shrouds or guards removed Required materials Replacement drive belt Belt tension gauge or straightedge and steel rule NOTICE Do not replace a drive belt with one that is old or worn An old or worn replacement may not last as long as a new drive belt and may not hold consistent tension especially under load 34 Maintenance Figure 5 28 1 Loosen the two alternator mounting bolts A on the alternator and mounting bracket See Figure 5 28 2 Remove and discard the old drive belt B Correct C Incorrect Figure 5 29 3 Place the new drive belt on the pulleys Make sure that the belt is properly aligned with the grooves on each pulley See Figure 5 29 Figure 5 30 TP 6901 6 14 MAINTENANCE 4 Setdrive belt tension to specification See Figure 5 30 e Apply specified pressure to the drive belt at its midpoint At the same time measure the amount of deflection of the drive belt at its midpoint D Deflection should be within specification DRIVE BELT TENSION Applied Test Pressure 98 N 22 Ib Belt Deflection New 5 7 mm 0 20 0 28 in Belt Deflection Used 7 8 mm 0 28 0 31 in 5 Tighten the two alternator mounting bolts 6 Check the drive belt tension and adjust the alternator position as needed until correct drive belt tension is reached Check Wiring and Electrical Con
48. y If the engine does not start after three attempts discontinue the starting procedure Perform troubleshooting to locate the problem s and correct them before trying again TP 6901 6 14 OPERATION 4 5 COLD WEATHER STARTING Handling caustic engine fluids and chemical products can cause severe chemical burns nausea fainting or death Most chemicals such as used engine oil antifreeze coolant rust proofing agent inhibiting oil degreasing agent spray paint and adhesives are hazardous to health Read and follow the user information found on the packaging Avoid inhalation and skin contact Use only in well ventilated areas and use a protective mask when spraying Store engine fluids and chemical products in a locked cabinet Contact your local recycling center for disposal information and locations TP 6901 6 14 A WARNING Explosive fuel can cause fires and severe burns If a gaseous odor is detected ventilate the area and contact an authorized service technician LPG Liquefied Petroleum Gas is extremely flammable and tends to settle in low areas where a spark or flame could ignite the gas Do not start or operate this engine in a poorly ventilated area where leaking gas could accumulate and endanger the safety of persons in the area NG Natural Gas is extremely flammable is lighter than air and rises Do not start or operate this engine in a poorly ventilated are where leaking gas could ac
49. y away while the engine is in operation Keep hands feet hair and clothing away from all moving parts to prevent injury Never operate the engine with covers shrouds or guards removed Fire Can cause severe injury or death Do not smoke or permit flames or sparks near fuels or the fuel system TP 6901 6 14 Safety Precautions 7 SAFETY PRECAUTIONS A WARNING Hot liquid can cause severe burns Do not loosen radiator cap while engine is operating or warm to touch Liquid coolant can be extremely hot from operation Turning radiator cap when engine is hot can allow steam and scalding liquid to blow out and burn you severely Shut off machine Only remove radiator cap when cool enough to touch with bare hands Slowly loosen cap to LPG Liquefied Petroleum Gas is extremely flammable and tends to settle in low areas where a spark or flame could ignite the gas Do not start or operate this engine ina poorly ventilated area where Explosive fuel can cause fires and severe burns If a gaseous odor is detected ventilate the area and contact an authorized service technician A WARNING Handling caustic engine fluids and chemical products can cause severe chemical burns nausea fainting or death Most chemicals such as used engine oil antifreeze coolant rust proofing agent inhibiting oil degreasing agent spray paint and adhesives are hazardous to health Read and follow the user
50. zed distributor dealer TP 6901 6 14 OPERATION Throttle Body Figure 4 7 The throttle body controls the operating speed of the engine according to input from the ECM Defaults programmed into the ECM software along with throttle position sensors allow the ECM to control the overall operation of the engine in response to changing speeds and loads TP 6901 6 14 Engine Control Module ECM Figure 4 8 The ECM is a digital controller that oversees the various operating parameters of the engine The ECM receives input data from sensors mounted to the engine and fuel system and then outputs various signals to adjust engine operation The ECM also performs diagnostic functions on the fuel system If a malfunction occurs the ECM sends a fault signal to alert the operator to the problem A corresponding Diagnostic Trouble Code DTC is generated and stored in memory within the ECM A technician can then use a computerized diagnostic scan tool to retrieve the stored DTC number s and identify the problem Operation 15 OPERATION Sensors Heated Exhaust Gas Oxygen HEGO Sensor The Heated Exhaust Gas Oxygen HEGO sensor measures the amount of oxygen present in the exhaust stream to determine whether the air fuel ratio is too rich or too lean Air Temperature Manifold Absolute Pressure TMAP Sensor The Air Temperature Manifold Absolute Pressure TMAP sensor monitors the difference in pressure
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