Kohler KG2204 manual

Operation Engine Engine Model: KG2204 Propane, Liquefied Petroleum Gas (LPG) / Natural Gas (NG) Fueled TP-6901 6/14[...]

INTRODUCTION This manual provides operat ing an d ma intenance instruct ions for KOHLER Engi ne Model KG2204. Keep this manual with the equipm ent for future re ference. Refer to th e KG2204 Service Manual for detaile d information on adjusting a nd servicing t he engine. Information in this pu blication represents data available at the time of pr [...]

3 Section 1 Engine Identification and Technical Support 1.1 Know Your Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Purchase Da te . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1.2 Rel ated L[...]

4 5.5 Elect rical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Check Batte ry and Con nections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Check and Adjust the Dr ive Belt . . . . . . . . . . . . . . . . . . . . . [...]

ENGINE IDENTIFICATION AND TECHNICAL SUPPORT TP-6901 6/14 Engine Identification and Technical Support 5 Section 1 Engine Identification and Technical Support 1.1 KNOW YOUR ENGINE Product identifica tion numbers determin e service parts. Record the product identif ication numbers in the spaces below immediately after unpacking the products so that th[...]

ENGINE IDENTIFICATION AND TECHNI CAL SUPPORT 6 Engine Identification an d Technical Support TP-6901 6/14[...]

SAFETY PRECAUTIONS TP-6901 6/14 Safety Precautions 7 Section 2 Safety Precautions 2.1 SAFETY ALERTS NO TE: A Note is used to inform y ou of important installat ion, operation, or maintenance information. 2.2 SAFETY INFORMATION FOR THIS ENGINE ! DANGER Danger indi cates the presence of a hazard that will cause severe personal injury , death , or sub[...]

SAFETY PRECAUTIONS 8 Safety Precauti ons TP-6901 6/14 WARNING ! Hot liquid can cause severe burns. Do not loosen radiator cap while engine is operating o r warm to touch. Liquid coolant can be extremely hot from operati on. Turning radiator cap when engine is hot can allow steam and scalding liquid to blow out and burn you severely. Shut o ff machi[...]

SAFETY PRECAUTIONS TP-6901 6/14 Safety Precautions 9 WARNING ! 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 fue l system for leakag e by[...]

SAFETY PRECAUTIONS 10 Safety Precautions TP-6901 6/14[...]

COMPONENTS AND MA INTENANCE LOCATIONS TP-6901 6/14 Components and Maintenan ce Locations 11 Section 3 Components and Maintenance Locations 3.1 ENGINE SIDE VIEWS Figure 3-1: 1 Rocker Arm Cover 7 Air-Fuel Mixer 13 Oil Pan 19 Knock Sensor (if equipped with turbocharger) 2 Rear Hanger 8 Throttle Body 14 Battery Charging Alternator 20 Oil Cooler Adapter[...]

COMPONENTS AND MAIN TENANCE LOCATIONS 12 Components an d Maintenance Loca tions TP-6901 6/14 3.2 FRONT AND REAR VIEWS Figure 3-2: 1 Air-Fuel Mi xer 8 Ig nition Coil 15 Cranks haft Position Sensor 22 Flywheel 2 Throttle Body 9 Oil Dipstick 16 Timing Cover 23 Exhaust Manifold Studs 3 TMAP Sensor 10 Fuel Control Valve 17 Oil Drain Plug 24 Oil Pan 4 Up[...]

OPERATION TP-6901 6/14 Operation 13 Section 4 Operation 4.1 INTRODUCTION The KG2204 is a four-stro ke internal combustion engine certified to op erate on either Prop ane, Liquid Petroleum Gas (LPG) or Na tural Gas ( NG). System configuration is factory preset for NG. Instru ctions for switching to LPG are provided withi n this section. The fuel sys[...]

OPERATION 14 Oper ation TP-6901 6/14 Fuel Pressure Regulator Figure  4-4 The fuel pressure regu lator modulates the pressure of the LPG/NG vapor to th e air-fuel mixe r. The fuel pressure regulat or is not adjustable. However, a selector at the base of the regulator is rot ated when switching from NG to LPG and back. See “NG to LPG Conversion?[...]

OPERATION TP-6901 6/14 Operation 15 Throttle Body Figure  4-7 The throttle body cont rols the operating spee d of the engine according to input from the ECM. Defaults programmed into the EC M softwar e, along with throttle position sensors, allow the ECM to control th e overall operation of the eng ine in respo nse to ch anging speeds and loads.[...]

OPERATION 16 Oper ation TP-6901 6/14 Sensors Heated Exhaust Gas Oxygen (HEGO) Sensor The Heat ed Exhaust G as Oxygen ( HEGO) sens or measur es the a mount of oxygen present in the exhaust stream to dete rmine whether the ai r–fuel ratio is too rich or too lean. Air Temperature / Ma nifold Absolute Pressur e (TMAP) Sensor The Air Temperature / Ma [...]

OPERATION TP-6901 6/14 Operation 17 Fuel Specifications NOTICE Natural gas and propane installations mus t be installed in accordance with app licable federa l, state, and loca l law, and with th e National Fire Protection Associ ation (NFPA) Pamphlet #58, standard for storage and handling of Liquefied Petroleum Gases, to the extent that t hese sta[...]

OPERATION 18 Oper ation TP-6901 6/14 NG to LPG Conversion The KG2204 engine is easily configurable for use with either NG or LPG. System con figuration for NG or LPG requires a mechanical setting on the fuel pressure regulator and an electrical setting ch ange at the ECM. These adjustments will ensure that the proper fuel and spark timing is supp l[...]

OPERATION TP-6901 6/14 Operation 19 To set the regulator for LPG: 1. Push the adjusting ca p to its upper stop an d rotate clockwise, rele ase upward pressure, and lock into place. See Figu re 4-7. 2. For LPG fuel only, co nnect wire N20 from th e fuel pressure reg ulator to wir e 45 from the ECM wiring harness using the quick- connect adapters. Se[...]

OPERATION 20 Oper ation TP-6901 6/14 — Che ck and clea n cooling area s, air intake areas, and external surfac es of the engine , particularl y if the eng ine has been st ored for a long period of ti me. — Check to make sure that air cleaner components, shrouds, equ ipment covers, and guards are in plac e and securely fastene d. — Check all e[...]

OPERATION TP-6901 6/14 Operation 21 4.5 COLD WEATHER STARTING Cold weather put s added stress o n the engine d uring start up. To start t he engine in cold weather: 1. Make sure t hat the engine oil is appropr iate for the ambient operat ing temperature. See “Fluid Specifications” in Section 5. Drain and replace th e engine oil if ne cessary. 2[...]

OPERATION 22 Oper ation TP-6901 6/14 4.6 MONITORING ENGINE OPERATION Check for the fo llowing items as the engine run s. • Gas/ai r leaks : check for leakage from fuel pipes, cooling pipes, or air pipes. • Exhaust: check for detonation , backfire, or knocking. Watch fo r excessive smoke or abnor mal color. • Noise: listen f or rattles or othe[...]

MAINTENANCE TP-6901 6/14 Maintenance 23 Section 5 Maintenance 5.1 INTRODUCTION Preventive maintenance is cr itical to prolonging th e life of the KG22 04 engine an d keeping it in optimum working condition. As the e ngine runs, fasteners may loosen, part s may become worn, clearances change, and oil picks up dirt and contaminan ts. The engine may e[...]

MAINTENANCE 24 Maintenance TP-6901 6/14 5.2 FLUID SPECIFICATIONS Oil Recommendations NO TE: • Do not mix differ ent brands or types of oil. • Do not overfill or underfill the engine’s lubrication system. See “Engine Specif ications” in Section 8. Use oil that displays the American Petr oleum Institute (API) Starbrus t certificat ion mark [...]

MAINTENANCE TP-6901 6/14 Maintenance 25 5.3 PERIODIC MAINTENANCE SCHEDULE Engine parts experien ce wear at differ ent rates. Technical ma intenance tasks, there fore, are require d at several different int ervals throughout the life of the engine : • Daily • Weekly or every 10 hours of oper ation • Quarterly or every 20 hours of operation •[...]

MAINTENANCE 26 Maintenance TP-6901 6/14 5.4 ENGINE Check Engine Oil Check the engine oil le vel daily be fore startin g the engine. Inspect the oil fo r signs of deteriorati on, discoloration, thinning, or water contamination. If any of these conditions exist, the oil quality has been compromised and sh ould be replace d. Required materials: • Cl[...]

MAINTENANCE TP-6901 6/14 Maintenance 27 Required materials: • Fresh engine oil (See “Oil Recommen dations” on page 24.) • Collection co ntainer for drain ed oil—minimu m 8 liter (2.1 gal.) ca pacity • Replacement oil filter • Oil filter wrench • Clean, dry clot h • Drop cl oth to prot ect work su rface Change the engine oil and oi[...]

MAINTENANCE 28 Maintenance TP-6901 6/14 Figure  5-15 4. Using an oil filt er wrench , remove the old oil filter (D). See Figure 5- 15. NO TE: After  removing  the  oil  filter,  ensure  that  the  oil  cooler  adapter  nut  is  tightened  to  specification,  40  N•m  (29.5  ft.lbs.), [...]

MAINTENANCE TP-6901 6/14 Maintenance 29 Check and Clean the Air Filter Refer to the Equip ment Operation Ma nual using this engine installation. Replace the Air Filter Refer to the Equip ment Operation Ma nual using this engine installation. Check and Adjust the Spark Plugs Damaged, loose, or improperly adju sted spark plugs can overheat or cause e[...]

MAINTENANCE 30 Maintenance TP-6901 6/14 Figure  5-19 2. Use a cloth to wip e dirt and oil away from th e area around e ach of the four spa rk plug wires (A). See Figure 5-19. 3. Disconnect the sp ark plug wires. 4. Wipe the inter ior of the spark plug tubes. 5. Use a spark plug wrench to remove the spark plugs. Figure  5-20 6. Inspect the ele[...]

MAINTENANCE TP-6901 6/14 Maintenance 31 Replace the Spark Plugs Spark plugs should be replaced at the r ecommended intervals specified at the begi nning of this section. Use only the recommended sp ark plug or an equivale nt. See “Specificat ions of Main Components” in Se ction 8. Required materials: • Replacement spark plu gs (4) • Spark p[...]

MAINTENANCE 32 Maintenance TP-6901 6/14 5.5 ELECTRICAL SYSTEM Check Battery and Connections Check th e condition of the batt ery and c onnections according to the interv als specified in “Periodic Maintenance Sch edule” on page 25. Specific ite ms to look for are: • Loose or missing f asteners on the b attery hold-down . • Loose cable conn [...]

MAINTENANCE TP-6901 6/14 Maintenance 33 Figure  5-25 3. Inspect the drive belt . Look for signs of cracking, separation , cuts, or ot her dam age. See Figure 5-25. 4. If any abn ormality is found, replace the dr ive belt. Figure  5-26 Check drive belt tension: 5. The drive belt tension should be checke d at the midpoint (B) betwee n the pulle[...]

MAINTENANCE 34 Maintenance TP-6901 6/14 Replace the Drive Belt Required materials: • Replacement drive belt. • Belt tension gauge or straig htedge and steel rule. Figure  5-28 1. Loosen the two altern ator mou nting bolts (A) on the alternat or and moun ting bracket . See Figure 5-28. 2. Remove and discard th e old drive belt. Figure  5-2[...]

MAINTENANCE TP-6901 6/14 Maintenance 35 4. Set drive belt tensio n to specification. See Figure 5-30. • Apply specified pressure to the drive belt at its midpoint. At the same time, meas ure the amount of deflectio n of the drive belt at its midpoint (D) . Deflection should be within specification. DRIVE BELT TENSION Applied Test Pressure 98 N (2[...]

MAINTENANCE 36 Maintenance TP-6901 6/14 Check Hoses and Clamps Check the condition of the coola nt system h oses and clamps every 10 hours of operation. Hoses: • Inspect the hoses f or cracks, abrasions, cuts, bulges, swo llen ends, o r leaks. • Squeeze the hoses. T hey should yield slightly to moderate pressu re and not feel too hard, too so f[...]

MAINTENANCE TP-6901 6/14 Maintenance 37 Check Fuel Supply Pipe and Connections With the fuel valve fully op ened and the engine stopped, check all fuel system connecti ons and lines for leaks using a soapy water soluti on. Correct any leaks before restar ting the engine. Do not st art the engine if you can smell leaking gas . Have any necessary se [...]

MAINTENANCE 38 Maintenance TP-6901 6/14[...]

TROUBLESHOOTING TP-6901 6/14 Troubleshooting 39 Section 6 Troubleshooting 6.1 INTRODUCTION The following chart will help you to ident ify and solve some of t he basic operating problems that may occur while operating t his engine. Do not attempt to service or re place major engine component s, or any items that require sp ecial timing or adjustment[...]

TROUBLESHOOTING 40 Troubleshooti ng TP-6901 6/14 Operates Erratically or Unevenly 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 n eeded. Low fuel supply pressure Check and adjust. Engine overloaded Disconnect or reduce loads. Loose wiring at s[...]

STORAGE TP-6901 6/14 Storage 41 Section 7 Storage 7.1 PREPARATION If you plan to take the en gine out of service for an extended period of time, prepare th e engine according to the tasks de scribed in this section . These preventive measures will help to prot ect your engine from the cumulative effects of rust and deterioration while it is not bei[...]

STORAGE 42 Storag e TP-6901 6/14 7.5 REMOVAL FROM STORAGE • Remove protective cloth s, covers, and caps from the engine. • Clean protectant from exposed met al parts and electrical components. • Tighten the altern ator belt. • Check fluid levels and fill as needed. • Connect the batte ry. • Connect the fuel supply and open fuel valves. [...]

SPECIFICATIONS TP-6901 6/14 Specifications 43 Section 8 Specifications 8.1 ENGINE SPECIFICATIONS Item Specific ations Engine Model KG2204 Block Type I-4 Number of Cy linder s 4 Cylinder Bor e 91 mm (3.5 in .) Piston Strok e 86 mm (3.4 in .) Displacem ent 2.2 L (1 34.25 in. 3 ) Rated Output 61 kW (81.8 HP) @ 3600 rp m Fuel Type Propane, Liqu id Petr[...]

SPECIFICATIONS 44 Specifications TP-6901 6/14 8.2 SPECIFICATIONS OF MAIN COMPONENTS 8.3 ADJUSTMENT SPECIFICATIONS 8.4 TORQUE SPECIFICATIONS Item Specifications Oil Filter/ Breather Paper, Rock er Arm Covers, Top Oil Filter Oil Pump Rotor type Water Pump Centrifuga l type; no fan Flywheel Flywheel with att achment provisions for flywheel adapter (KO[...]

SPECIFICATIONS TP-6901 6/14 Specifications 45 8.5 STANDARD TORQUE SPECIFICATIONS NO TE: 1. The torque values abov e are gene ral guideline s. Always us e the torq ue values sp ecified in the service manuals an d/or assembly drawings wh en they di ffer from a bove torque values. 2. The torque values above are based on new pla ted threads. In crease [...]

SPECIFICATIONS 46 Specifications TP-6901 6/14 NO TE: 1. The torque va lues above are general gu idelines. A lways use the torq ue values specified in the service manuals and/or assembly drawings wh en they differ from above to rque values. 2. The torque va lues above are based on n ew plated threads. Increase t orque values by 15% if non-plate d th[...]

Notes NOTES[...]

TP-690 1 6/14 ® Kohler Pow er Systems Asia Pacif ic Headquar ters 7 Jurong Pier Road Singapor e 619159 Phone (65) 62 64-6422, Fax (65) 6244 -6455 2014 by Kohler Co. All Rights R eserved. Kohler CO. Kohler, Wi sconsin 53 044 Phone 920- 457-4441, Fa x 920-459 -1646 For the nea rest sales/se rvice outlet i n the US and Canada, ph one 1-800-5 44-2444 [...]