Related Manuals for Kohler KG2204
Summary of Contents for Kohler KG2204
- Page 1 Operation Engine Engine Model: KG2204 Propane, Liquefied Petroleum Gas (LPG) / Natural Gas (NG) Fueled TP-6901 6/14...
- Page 2 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.
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Page 3: Table Of Contents
Section 1 Engine Identification and Technical Support 1.1 Know Your Engine ............5 Purchase Date . - Page 4 5.5 Electrical System ............32 Check Battery and Connections .
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Page 5: Section 1 Engine Identification And Technical Support
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... - Page 6 ENGINE IDENTIFICATION AND TECHNICAL SUPPORT 6 Engine Identification and Technical Support TP-6901 6/14...
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Page 7: Section 2 Safety Precautions
SAFETY PRECAUTIONS Section 2 Safety Precautions 2.1 SAFETY ALERTS CAUTION WARNING DANGER 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... -
Page 8: Safety Precautions
SAFETY PRECAUTIONS WARNING WARNING WARNING Hot liquid can Explosive fuel cause severe can cause fires Handling caustic burns. and severe engine fluids burns. and chemical Do not loosen products can radiator cap while If a gaseous odor cause severe engine is is detected, chemical burns, operating or warm... - Page 9 SAFETY PRECAUTIONS WARNING Explosive fuel vapors. Can cause severe injury or death. Use extreme care when handling, storing, and using fuels. vapors Gas fuel leaks. Explosive fuel 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...
- Page 10 SAFETY PRECAUTIONS 10 Safety Precautions TP-6901 6/14...
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Page 11: Engine Side Views
COMPONENTS AND MAINTENANCE LOCATIONS Section 3 Components and Maintenance Locations 3.1 ENGINE SIDE VIEWS K0695 K0403 Figure 3-1: Knock Sensor (if Rocker Arm Cover Air-Fuel Mixer Oil Pan equipped with turbocharger) Oil Cooler Adapter Battery Charging Rear Hanger Throttle Body (not included on Alternator all models) -
Page 12: Front And Rear Views
COMPONENTS AND MAINTENANCE LOCATIONS 3.2 FRONT AND REAR VIEWS K0647 K0693 Figure 3-2: Crankshaft Air-Fuel Mixer Ignition Coil Flywheel Position Sensor Exhaust Manifold Throttle Body Oil Dipstick Timing Cover Studs TMAP Sensor Fuel Control Valve Oil Drain Plug Oil Pan Upper Intake Upper Coolant Oil Pressure... -
Page 13: Section 4 Operation
OPERATION Section 4 Operation 4.1 INTRODUCTION 4.2 FUEL SYSTEM The KG2204 is a four-stroke internal combustion Components engine certified to operate on either Propane, Liquid Petroleum Gas (LPG) or Natural Gas (NG). System Fuel Shut-Off Valves configuration is factory preset for NG. Instructions for switching to LPG are provided within this section. -
Page 14: Fuel Control Valve
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 authorized distributor/dealer. K0379 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. -
Page 15: Throttle Body
OPERATION Throttle Body Engine Control Module (ECM) K0679 Figure 4-7 The throttle body controls the operating speed of the K0382 engine according to input from the ECM. Defaults programmed into the ECM software, along with throttle Figure 4-8 position sensors, allow the ECM to control the overall The ECM is a digital controller that oversees the operation of the engine in response to changing various operating parameters of the engine. - Page 16 OPERATION Sensors Throttle Position Sensor (TPS) The electronic throttle control device incorporates an Heated Exhaust Gas Oxygen (HEGO) Sensor internal Throttle Position Sensor (TPS), which provides The Heated Exhaust Gas Oxygen (HEGO) sensor output signals to the ECM as to the location of the measures the amount of oxygen present in the exhaust throttle shaft and blade.
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Page 17: Fuel Specifications
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. -
Page 18: Ng To Lpg Conversion
OPERATION NG to LPG Conversion WARNING 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. -
Page 19: Before Starting
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 WARNING place. See Figure 4-7. 2. For LPG fuel only, connect wire N20 from the fuel pressure regulator to wire 45 from the ECM wiring harness using the quick-connect adapters. -
Page 20: Starting
OPERATION — Check and clean cooling areas, air intake WARNING 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 Explosive fuel can cause fires and components, shrouds, equipment covers, and severe burns. -
Page 21: Cold Weather Starting
OPERATION 4.5 COLD WEATHER WARNING STARTING WARNING Explosive fuel can cause fires and severe burns. If a gaseous odor is detected, ventilate the area and contact an Handling caustic engine fluids and authorized service technician. chemical products can cause severe chemical burns, nausea, fainting, or death. -
Page 22: Monitoring Engine Operation
OPERATION 4.6 MONITORING ENGINE 4.7 STOPPING OPERATION 1. Disconnect all applied loads if possible, along with Power Take-Off (PTO) attachments, before stopping the engine. WARNING 2. If the engine has been running under a heavy load, reduce engine speed and allow it to run for an Carbon monoxide can cause additional 2–3 minutes before stopping. -
Page 23: Section 5 Maintenance
5.1 INTRODUCTION WARNING 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 Handling caustic engine fluids and loosen, parts may become worn, clearances change, chemical products can cause and oil picks up dirt and contaminants. -
Page 24: Fluid Specifications
MAINTENANCE Multi-viscosity synthetic oils are recommended. For WARNING 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 Explosive fuel can cause fires and temperatures are never or rarely below 0°C (32°F), use severe burns. -
Page 25: Periodic Maintenance Schedule
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 •... -
Page 26: Engine
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: •... - Page 27 MAINTENANCE Required materials: WARNING • Fresh engine oil (See “Oil Recommendations” on page 24.) • Collection container for drained oil—minimum 8 liter (2.1 gal.) capacity Explosive fuel can cause fires and severe burns. • Replacement oil filter If a gaseous odor is detected, •...
- Page 28 MAINTENANCE K0706 K0706 Figure 5-17 Figure 5-15 7. Lightly screw in the new oil filter by hand until you 4. Using an oil filter wrench, remove the old oil filter feel resistance. Using the oil filter wrench (F), (D). See Figure 5-15. tighten the filter an additional 3/4 turn , 25 ...
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Page 29: Check And Clean The Air Filter
MAINTENANCE Check and Clean the Air Filter Check and Adjust the Spark Plugs Refer to the Equipment Operation Manual using this Damaged, loose, or improperly adjusted spark plugs engine installation. can overheat or cause engine problems such as misfiring, hesitation, or knocking. Check the spark plugs after each 500 hours of operation. - Page 30 MAINTENANCE K0384 Figure 5-19 2. Use a cloth to wipe dirt and oil away from the area around each of the four spark plug wires (A). See K0390 Figure 5-19. Figure 5-21 3. Disconnect the spark plug wires. 4. Wipe the interior of the spark plug tubes. 7.
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Page 31: Replace The Spark Plugs
Spark plug wires MUST be installed in proper order. 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. -
Page 32: Electrical System
2) Disconnect negative (–) battery cable from battery. equivalent to the original equipment. Contact your Before disconnecting negative (–) ground cable, make KOHLER authorized distributor/dealer for assistance. sure all switches are OFF. If ON, a spark will occur at the ground cable terminal which could cause an... - Page 33 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.
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Page 34: Replace The Drive Belt
MAINTENANCE Replace the Drive Belt WARNING Accidental starts can cause severe injury or death. Disconnect and ground spark plug leads before servicing. K0395 Figure 5-28 1. Loosen the two alternator mounting bolts (A) on the alternator and mounting bracket. See Figure 5-28. 2. -
Page 35: Check Wiring And Electrical Connections
• Melted or scorched wiring, insulation, or radiator. Oil in the coolant indicates a leak somewhere connectors. in the lubrication system. Contact a KOHLER Repair or replace faulty electrical components before authorized distributor/dealer if either of these operating the machine. -
Page 36: Check Hoses And Clamps
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. 36 Maintenance TP-6901 6/14... -
Page 37: Check Fuel Supply Pipe And Connections
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. - Page 38 MAINTENANCE 38 Maintenance TP-6901 6/14...
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Page 39: 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... - Page 40 Faulty spark plug Inspect, adjust, or replace as needed. Dirty/restricted air cleaner element Clean or replace. Incorrect fuel pressure Check and adjust fuel pressure. ECM Does Not Store DTC Faulty electrical connections, Contact KOHLER service. components, or wiring 40 Troubleshooting TP-6901 6/14...
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Page 41: Section 7 Storage
STORAGE Section 7 Storage 7.2 SHORT-TERM STORAGE CAUTION (LESS THAN 30 DAYS) • Disconnect and remove the battery. Electrical shock can cause injury. • Cover or cap all intake and exhaust ports, including Do not touch wires while engine is fuel lines, air filter, and engine exhaust. -
Page 42: Removal From Storage
STORAGE 7.5 REMOVAL FROM STORAGE • Remove protective cloths, covers, and caps from the engine. • Clean protectant from exposed metal parts and electrical components. • Tighten the alternator belt. • Check fluid levels and fill as needed. • Connect the battery. •... -
Page 43: Section 8 Specifications
Propane, Liquid Petroleum Gas (LPG) or Natural Gas (NG). See “Fuel Specifications” in Section 4. Oil Type / Weight 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.) -
Page 44: Specifications Of Main Components
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... -
Page 45: Standard Torque Specifications
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 2 or 5 8-32 N•m (in.lb.) 1.8 (16) 2.3 (20) — 10-24 N•m (in.lb.) 2.9 (26) -
Page 46: Specifications
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 N•m (ft.lb.) 6.2 (4.6) 12 (9) 13.6 (10) M8 x 1.25 N•m (ft.lb.) 15.0 (11) 29.6 (22) - Page 47 NOTES Notes...
- Page 48 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 TP-6901 6/14 Singapore 619159 Phone (65) 6264-6422, Fax (65) 6244-6455 ® 2014 by Kohler Co. All Rights Reserved.