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Kohler KG2204 Service

Propane, liquefied petroleum gas (lpg) and natural gas (ng) fueled
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Service
Engine Fuel System and
Diagnostic Code Troubleshooting
Engine Models:
KG2204
KG2204T
Propane, Liquefied Petroleum Gas (LPG)
and Natural Gas (NG) Fueled
TP-6903 5/16a

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Summary of Contents for Kohler KG2204

  • Page 1 Service Engine Fuel System and Diagnostic Code Troubleshooting Engine Models: KG2204 KG2204T Propane, Liquefied Petroleum Gas (LPG) and Natural Gas (NG) Fueled TP-6903 5/16a...

  • Page 2: Product Identification Information

    California Proposition 65 WARNING Engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Product Identification Information Product identification numbers determine service Engine Identification parts. Record the product identification numbers in Record the product identification information from the spaces below immediately after unpacking the products so that the numbers are readily available for...

  • Page 3: Table Of Contents

    Table of Contents   Product Identification Information ............................2   Table of Contents ..................................3   Safety Precautions and Instructions ............................5   Introduction ..................................9   Service Assistance................................... 10     Section 1 Fuel System Overview ..........................11 1.1.  ...
  • Page 4 4.3.   Coolant Temperature Sensor Troubleshooting ................. 62       4.4. Crankshaft Position (CKP) Sensor Troubleshooting ................. 64 4.5.   Electrical System Intermittent Problems .................... 66   4.6.   Fuel Control Valve Troubleshooting ....................67       4.7. Heated Exhaust Gas Oxygen (HEGO) Sensor Troubleshooting ............

  • Page 5: Safety Precautions And Instructions

    Safety Precautions and Instructions Read and follow all safety precautions Accidental Starting Engine Backfire/Flash instructions. SAVE THESE Fire INSTRUCTIONS. WARNING This manual has several types of safety precautions and instructions: Danger, WARNING Warning, Caution, and Notice. DANGER Danger indicates the presence of a hazard that will cause severe personal Accidental starts...
  • Page 6 Exhaust System Hazardous WARNING Voltage/Moving Parts WARNING WARNING Carbon monoxide cause Explosive fuel can cause fires and severe nausea, fainting, or death. severe burns. Avoid inhaling exhaust fumes. If a gaseous odor is detected, Engine exhaust gases contain Electrical shock can cause injury. ventilate the area and contact an poisonous carbon...
  • Page 7 Hot Parts WARNING WARNING WARNING Spring-loaded parts. Can cause severe personal injury or property damage. Wear protective goggles when servicing spring-loaded parts. Hold Hot parts can cause severe burns. parts securely during disassembly. touch engine while operating or just after stopping. Never operate engine with heat Handling caustic engine fluids WARNING...
  • Page 8 Notes Safety Precautions and Instructions TP-6903 5/16a...

  • Page 9: Introduction

    Section 5, Installation and Removal Procedures. 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.

  • Page 10: Service Assistance

    Visit the Kohler Power Systems website at Fax: (86) 10 6518 7955 KOHLERPower.com. East China Regional Office, Shanghai  Look at the labels and decals on your Kohler Phone: (86) 21 6288 0500 product or review the appropriate literature or Fax: (86) 21 6288 0550 documents included with the product.

  • Page 11: Fuel System Overview

    Crankshaft position sensor Exhaust Ignition coil 10. Oil pressure sender 11. Fuel pressure regulator 12. Fuel shut-off valve 13. ECM 14. Air cleaner 15. Air intake Figure 1-1 Fuel System Overview, KG2204 Naturally Aspirated Engine TP-6903 5/16a Fuel System Overview...
  • Page 12 Fuel pressure regulator Air-fuel mixer Turbocharger TMAP sensor HEGO sensor Throttle body Additional MAP sensor Coolant temperature sensor Crankshaft position sensor 10. Ignition coil Note: Air Cleaner removed for clarity. 11. Oil cooler adapter 12. ECM 13. Fuel control valve 14.

  • Page 13: Air-Fuel Mixer

    1.3. Charge Air Cooler 1.2. Air-Fuel Mixer (KG2204T only) Figure 1-3 Air-Fuel Mixer The air-fuel mixer is an air-fuel metering device and is completely self-contained. The mixer is an air valve Figure 1-4 Charge Air Cooler design, utilizing a relatively constant pressure drop to draw fuel into the mixer from cranking to full load.

  • Page 14: Crankshaft Position (Ckp) Sensor

    1.5. Crankshaft Position (CKP) 1.6. Electronic Control Module Sensor Figure 1-7 Electronic Control Module To obtain maximum and accurate control of the air fuel ratio, the engine is equipped with an onboard computer Figure 1-6 Crankshaft Position Sensor or Electronic Control Module (ECM). The ECM The crankshaft position (CKP) sensor measures the receives input data from sensors mounted to the rotary speed and crankshaft turning angle.

  • Page 15: Fuel Control Valve

    (FCV), which is used as a fuel trim device and is located at the intake manifold. 1.8. Fuel Pressure Regulator KG2204 Figure 1-9 Fuel Pressure Regulator The fuel pressure regulator ensures that the fuel enters the system at a consistent and usable pressure. The...

  • Page 16: Fuel Shut-Off Valves

    1.9. Fuel Shut-Off Valves 1.10. Heated Exhaust Gas Oxygen (HEGO) Sensor Figure 1-10 Fuel Solenoid Valve Figure 1-12 HEGO Sensor The heated exhaust gas oxygen (HEGO) sensor mounts to the exhaust system and is composed of a sensor and an internal heating element. During operation, heat from the exhaust increases the temperature of the heating element and activates the sensor.

  • Page 17: Ignition System

    1.11. Ignition System 1.12. MAP and TMAP Sensors 1.12.1. Manifold Air Temperature and Manifold Absolute Pressure (TMAP) Sensor Figure 1-13 Ignition Coil TMAP sensor The ignition system is a wasted spark system. In a Wire harness connector wasted spark system, spark is provided to two cylinders simultaneously.

  • Page 18: Oil Pressure Sender

    1.12.2. Up-stream Throttle Manifold Air 1.13. Oil Pressure Sender Pressure (MAP) Sensor (KG2204T only) The up-stream throttle manifold air pressure sensor on the KG2204T turbocharged engine monitors the absolute pressure (boost pressure) in the air induction system up-stream of the throttle. Data returned by the MAP sensor prompts the ECM to adjust the air-fuel mixture as needed.

  • Page 19: Throttle Body

    1.14. Throttle Body 1.15. Throttle Position (TP) Sensor Figure 1-17 Throttle Body The throttle body controls the amount of fuel that enters Throttle position sensor the engine and is composed of a throttle blade, electric throttle motor, and a throttle position (TP) sensor. Engine speed control is maintained by the ECM.

  • Page 20: Turbocharger (Kg2204T Only)

    1.16. Turbocharger (KG2204T only) 1.17. Turbocharger Oil Lines (KG2204T only) Turbocharger oil line Turbocharger oil line Figure 1-21 Turbocharger oil lines Figure 1-19 Turbocharger The turbocharger bearings require oil for lubrication and cooling. Oil is fed to the turbocharger bearings The turbocharger utilizes exhaust gas flowing through from the oil supply line on the top side of the bearing the turbine to spin a compressor.

  • Page 21: Diagnostic Troubleshooting Codes

    DTC. Use Spectrum software and a Kvaser cable to retrieve logged DTCs from the ECM. Note: When the KG2204 or KG2204T engine is paired with a Kohler generator set, the diagnostic port is located on the side of the connection box.
  • Page 22 P-Code Description Possible Cause Corrective Action  Problem with the fuel  Check the fuel shutoff valve P0006 Fuel Shutoff Valve A shutoff valve or leads. Control Circuit Low leads.  Replace fuel shutoff valve.  Problem with the fuel ...
  • Page 23 P-Code Description Possible Cause Corrective Action  Problem with the  Troubleshoot the TMAP sensor P0102 Mass or Volume Air TMAP sensor or leads. Refer to Section 4.10. Flow Circuit Low Input leads.  Replace the TMAP sensor. Refer to Section 5.10. ...
  • Page 24 P-Code Description Possible Cause Corrective Action  Problem with the CT  Check CT sensor leads. Refer to P0125 Insufficient Coolant sensor or leads. Temperature for Closed Section 4.3.  Replace CT sensor. Refer to Loop Fuel Control Section 5.2. ...
  • Page 25 P-Code Description Possible Cause Corrective Action  Not applicable  Not applicable P0154 3256 O2 Sensor No Activity Detected (B2S1)  Not applicable  Not applicable P0157 3266 O2 Sensor Circuit Low Voltage (B2S2)  Not applicable  Not applicable P0158 3266 O2 Sensor Circuit High...
  • Page 26 P-Code Description Possible Cause Corrective Action  Low coolant, high  Check coolant level, clean the P0217 Engine Coolant ambient, plugged radiator from debris. Temperature High radiator, bad CT  Check Coolant outlet temp with IR Shutdown sensor. Gun.  Troubleshoot the CT sensor. Refer to Section 4.3.
  • Page 27 P-Code Description Possible Cause Corrective Action  Not applicable  Not applicable P0261 Cylinder 1 Injector Circuit Low  Not applicable  Not applicable P0262 Cylinder 1 Injector Circuit High  Not applicable  Not applicable P0263 Cylinder 1 Contribution/Balance ...
  • Page 28 P-Code Description Possible Cause Corrective Action  Not applicable  Not applicable P0300 1322 Random/Multiple Cylinder Misfire Detected  Not applicable  Not applicable P0301 1323 Cylinder 1 Misfire Detected  Not applicable  Not applicable P0302 1324 Cylinder 2 Misfire Detected ...
  • Page 29 P-Code Description Possible Cause Corrective Action  Problem with the TP  Troubleshoot the TP sensor P0506 Idle Air Control System sensor in the throttle leads. Refer to Section 4.11. RPM Lower Than body or the leads.  Replace the throttle body. Refer Expected to Section 5.1.
  • Page 30 P-Code Description Possible Cause Corrective Action  Problem with  Check harness, engine, and P0562 System Voltage Low charging system. equipment grounds.  Problem with  Check the battery fluid levels and charging system or for corrosion on the battery posts. battery not ...
  • Page 31 P-Code Description Possible Cause Corrective Action  Problem with 5 V  Check electrical connection at P0642 3509 Sensor Reference sensor power supply ECM for sensor power supply Voltage A Circuit Low circuit. Power supply circuit. is less than 4.6 V. ...
  • Page 32 P-Code Description Possible Cause Corrective Action  Not applicable  Not applicable P0656 Fuel Level Output Circuit Fault  Problem with the  Check the relay coil and leads for P0657 Actuator Power Supply actuator power power and continuity. Voltage A Circuit Open voltage circuit.
  • Page 33 P-Code Description Possible Cause Corrective Action  Problem with 5 V  Check the ECM leads. P0699 3511 Sensor Reference sensor power supply.  Check for sensor shorts for Voltage C Circuit High sensors using 5 V sensor power supply by disconnecting all sensors and then connecting back one at a time.
  • Page 34 P-Code Description Possible Cause Corrective Action  Not applicable  Not applicable Vehicle Antitheft P1502 1196 triggered  Bad throttle body or  Troubleshoot the TP sensor P1518 3464 Throttle Actuator Zero leads. leads. Refer to Section 4.11. Cycle Incomplete ...
  • Page 35 P-Code Description Possible Cause Corrective Action  Not applicable  Not applicable P1690 Maintenance Reminder  Not applicable  Not applicable P2096 3227 Post Catalyst Fuel Trim System Too Lean  Not applicable  Not applicable P2097 3227 Post Catalyst Fuel Trim System Too Rich ...
  • Page 36 P-Code Description Possible Cause Corrective Action  Problem with throttle  Check for smooth throttle P2113 3464 Throttle Position Sensor body or leads. operation. B Minimum Stop  Troubleshoot the TP sensor Performance leads. Refer to Section 4.11.  Perform manual throttle zero process using the scan tool.
  • Page 37 P-Code Description Possible Cause Corrective Action  Problem with throttle  Check for smooth throttle P2163 3464 Throttle Position Sensor movement. operation. A Maximum Stop  Troubleshoot the TP sensor Performance leads. Refer to Section 4.11.  Check for proper throttle position voltage readings.
  • Page 38 P-Code Description Possible Cause Corrective Action  Problem with the  Check for misfires. P2177 1695 System Too Lean Off closed-loop feedback  Check fuel quality. Idle control.  Check fuel pressure regulator and outlet pressure.  Check for exhaust leaks. ...
  • Page 39 P-Code Description Possible Cause Corrective Action  Problem with the  Check for misfires. P2192 1695 System Too Rich at closed-loop feedback  Check fuel quality. Higher Load. control.  Check fuel pressure regulator and outlet pressure.  Check for exhaust leaks. ...
  • Page 40 P-Code Description Possible Cause Corrective Action  Only supported with  Check the post pressure sensor P2263 1127 Turbocharger Boost the turbo version of connection. Pressure System the engine.  Check the air ducting for secure Performance  Insufficient boost connections.
  • Page 41 P-Code Description Possible Cause Corrective Action  No spark detected by  Troubleshoot the ignition coil and P2306 1270 Ignition Coil C Primary the ECM. leads. Refer to Section 4.8. Control Circuit Low  Check for a disconnected spark plug lead. ...
  • Page 42 P-Code Description Possible Cause Corrective Action  No spark detected by  Troubleshoot the ignition coil and P2311 1396 Ignition Coil D the ECM. leads. Refer to Section 4.8. Secondary Circuit  Check for a disconnected spark plug lead.  Check the spark plug lead continuity.
  • Page 43 P-Code Description Possible Cause Corrective Action  Not applicable  Not applicable P2428 2433 Exhaust Overheat  Not applicable  Not applicable P2560 2430 Engine Coolant Level  Problem with the  Troubleshoot the HEGO sensor P2626 3217 HEGO sensor Pumping HEGO sensor.
  • Page 44 Notes Diagnostic Troubleshooting Codes TP-6903 5/16a...

  • Page 45: Fuel System Troubleshooting

    Section 3 Fuel System Troubleshooting Introduction WARNING The following symptom tables contain groups of possible causes for each symptom. If no diagnostic troubleshooting codes (DCTs) are recorded by the ECM, then check for the most likely cause first. Before using this section, you should determine that: ...
  • Page 46 Used engine oil. Contact with used engine oil may WARNING 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 shortly after handling used engine oil.

  • Page 47: Fuel System Intermittent Problems

    3.1. Fuel System Intermittent 3.2. Fuel System Basic Checks Problems When checking for air or fuel delivery problems, keep the process simple and check the basics. Make sure that air and fuel are being delivered to the fuel WARNING regulator. Use a manometer to verify fuel pressure at the fuel pressure port.
  • Page 48 To check the outlet pressure, connect a manometer to the outlet port of the fuel pressure regulator. See Figure 3-3.  NG = 1–3 inches of water pressure  LPG = 1–4 inches of water vacuum Verify air intake system is intact. If the generator has hoses, couplers or tubing, make sure all connections are secure and there are no cracks.

  • Page 49: No Start

    3.3. No Start Definition: The engine cranks but does not start. Checks Action Preliminary Checks None  Use Spectrum to : ECM Checks o Check for proper communication with the ECM o Check battery power, ignition power and ground circuits to the ECM. ...

  • Page 50: Hard Start

    3.4. Hard Start Definition: The engine cranks but does not start for a long time. The engine does eventually run, or may start but immediately stalls. Checks Action  Make sure the engine’s operator is using the correct starting procedure. Preliminary Checks ...

  • Page 51: Cuts Out And Misses

    3.5. Cuts Out and Misses Definition: A surging or jerking that follows engine speed, usually more pronounced as the engine load increases, but normally felt below 1500 rpm. The exhaust has a steady spitting sound at low speed or hard acceleration resulting from fuel starvation that can cause the engine to cut-out.

  • Page 52: Hesitation, Sag, Or Stumble

    3.6. Hesitation, Sag, or Stumble Definition: The engine has a momentary lack of response when accelerating. The condition can occur at any engine speed. The condition may cause the engine to stall if it’s severe enough. Checks Action Preliminary Checks None.

  • Page 53: Backfire

    3.7. Backfire WARNING Definition: The fuel ignites in the intake manifold, or in the exhaust system, making a loud popping noise. WARNING Electrical shock can cause injury. Do not touch wires while engine is running. Risk of Fire. Can cause severe injury or death. Do not smoke or permit flames or sparks near fuels or the fuel system.

  • Page 54: Lack Of Power Or Sluggishness

    3.8. Lack of Power or Sluggishness Definition: The engine delivers less than expected power. There is little or no increase in speed when increasing the engine throttle. Checks Action  Use Spectrum to check the ECM for stored DTC codes. Preliminary Checks ...

  • Page 55: Poor Fuel Economy

    3.9. Poor Fuel Economy Definition: Fuel economy, as measured by refueling records, is noticeably lower than expected. Also, the economy is noticeably lower than it was on this engine at one time, as previously shown by refueling records. Checks Action ...

  • Page 56: Rough, Unstable, Or Incorrect Engine Speed And Stalling

    3.10. Rough, Unstable, or Incorrect Engine Speed and Stalling Definition: The engine runs unevenly when under no load. If severe enough, the engine may shake. The engine speed may vary in rpm. Either condition may be severe enough to stall the engine. Definition: Checks Action Preliminary Check...

  • Page 57: Hunting And Surging

    3.11. Hunting and Surging Definition: The engine has a power variation under a steady throttle. The engine feels as if it speeds up and slows down with no change to the throttle. Checks Action Preliminary Checks None. Sensor Checks Check the Heated Exhaust Gas Oxygen Sensor (HEGO) performance. ...
  • Page 58 Notes Fuel System Troubleshooting TP-6903 5/16a...

  • Page 59: Electrical System And Sensor Troubleshooting

    Section 4 Electrical System and Sensor Troubleshooting WARNING WARNING Rotating parts can cause severe injury. Stay away while the engine is in operation. Accidental starts can cause severe injury or death. Keep hands, feet, hair, and clothing away from all moving Disconnect and ground spark plug leads before parts to prevent injury.
  • Page 60 WARNING WARNING Risk of Fire. Can cause severe injury or death. Do not smoke or permit flames or sparks near fuels or the fuel system. Troubleshooting and/or repairing the sensors or the Explosive fuel can cause fires and severe burns. If a gaseous odor is detected, ventilate the area and ECM.

  • Page 61: Introduction

    These instructions explain how to turn the ECM power 4.1. Introduction on and off on generator sets equipped with the Kohler® RDC2 generator set controller. Many of the troubleshooting steps require the use of a digital Volt-Ohm meter (DVOM) when checking for To turn the ECM power ON and OFF using Kohler®...

  • Page 62: Coolant Temperature Sensor Troubleshooting

    4.3. Coolant Temperature Sensor Troubleshooting P26-55, Coolant temperature CT sensor P26-51, Sensor ground HEGO sensor Figure 4-3 Coolant Temperature Sensor Wiring Diagram Temp (°C) Temp (°F) Ohms 57.50 144.25 186.50 243.25 322.50 435.75 595.50 Figure 4-2 Coolant Temperature Sensor 987.50 WARNING 1707.00 4712.00...
  • Page 63 Action  Turn the ECM power OFF.  Disconnect the CT sensor connector.  Using a DVOM, check the resistance between terminals A and B of Go to the next step. Replace the sensor. the CT sensor and compare the resistance reading to the chart, Figure 4-4.

  • Page 64: Crankshaft Position (Ckp) Sensor Troubleshooting

    4.4. Crankshaft Position (CKP) WARNING Sensor Troubleshooting 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.
  • Page 65 Action  Check the battery connections, the battery, and engine grounds. Repair the circuit as Go to the next step. necessary. Are the power ground terminals clean and tight?  Turn the ECM power OFF.  Disconnect ECM connector.  Disconnect Crankshaft Position Sensor (CKP) connector. Repair the open circuit ...

  • Page 66: Electrical System Intermittent Problems

    Definition: The problem is not always observable and 4.5. Electrical System Intermittent may or may not store a Diagnostic Trouble Code Problems (DTC). Use the plot function in the Spectrum software to troubleshoot intermittent electrical problems. Set up WARNING the plot for the sensor code that is stored in the ECM. For example: If an intermittent Intake Air Temperature (IAT) code is set, tag the IAT voltage and watch the plot.

  • Page 67: Fuel Control Valve Troubleshooting

    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 4-10 Fuel Control Valve, KG2204 Power from the controller P26-65, Power Fuel...
  • Page 68 Action  Turn the ECM power OFF.  Disconnect the Fuel Control Valve (FCV) connector.  Using a DVOM, check the resistance between the two pins of the Replace the FCV. Go to the next step. FCV solenoid Does the DVOM show a resistance value greater than 42 Ohms? Does the DVOM show a resistance value of less than 30 Ohms? ...

  • Page 69: Heated Exhaust Gas Oxygen (Hego) Sensor Troubleshooting

    4.7. Heated Exhaust Gas Oxygen WARNING (HEGO) Sensor Troubleshooting Risk of Fire. Can cause severe injury or death. Do not smoke or permit flames or sparks near fuels or the fuel system. Troubleshooting and/or repairing the sensors or the ECM. A backfire due to an open fuel shut-off valve can cause severe injury or death.
  • Page 70 Action  Check the air-fuel mixer for vacuum leaks.  Check that air can flow through the air intake duct and that the air intake duct is undamaged and unrestricted.  Check that the air filter is clean and undamaged. ...
  • Page 71 Action  Replace the HEGO sensor. Refer to Section 5.7. Go to the next step. Is the replacement complete? Verify that the HEGO sensor is working properly:  Connect any disconnected components.  Clear DTC information from the ECM. Restart HEGO ...

  • Page 72: Ignition Coil Troubleshooting

    4.8. Ignition Coil Troubleshooting WARNING 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. P27-116, Cylinder 1 P27-117, Cylinder 2 Figure 4-17 Ignition Coil...
  • Page 73  Before diagnosing no spark ignition issues, 4.8.1. Ignition System and No Spark make sure the ECM is receiving the initialization signal on P26-3 and P26-65 and WARNING the crank position sensor is working.  If spark is present, the ignition coil is likely good.
  • Page 74 Action  Turn the ECM power ON.  Connect Spectrum in system Data Mode.  Crank the engine. Troubleshoot as an Go to the next step. intermittent problem. Does the DTC reset?  Turn the ECM power OFF.  Disconnect the ignition module connector. ...

  • Page 75: Oil Pressure Sender Troubleshooting

    4.9. Oil Pressure Sender Troubleshooting pressure sender P26-31, Oil pressure switch Figure 4-21 Oil Pressure Sender Wiring Diagram If an oil pressure fault occurs, always verify the oil pressure before checking for an electrical malfunction. If there are no problems with the oil pressure level (indicating a problem with the sensor), proceed with the following oil pressure sender troubleshooting.
  • Page 76 Action  Verify that the engine has oil pressure using a mechanical oil pressure gauge before proceeding with this chart. Oil pressure must Repair faulty Go to the next step. remain above 6 psi. lubrication system Does the engine have oil pressure above 6 psi? ...

  • Page 77: Temperature Manifold Pressure (Tmap) And Map Sensor Troubleshooting

    P26-40, Sensor +5V 1. TMAP sensor TMAP 2. Wire harness connector Sensor P26-74, IAT sensor signal Figure 4-23 TMAP Sensor, KG2204 and KG2204T P26-70, Sensor ground To TP sensor Figure 4-25 TMAP Sensor Wiring Diagram P26-13 MAP sensor signal P26-40 Sensor +5V...
  • Page 78 Action  Turn the ECM power ON.  Connect Spectrum in the data stream mode.  Clear the diagnostic code. Troubleshoot as an Go to the next step.  Turn the ECM power OFF. intermittent problem.  Turn the ECM power ON. Does the diagnostic troubleshooting code (DTC) re-set? ...

  • Page 79: Throttle Position (Tp) Sensor Troubleshooting

    WARNING 4.11. Throttle Position (TP) Sensor Troubleshooting 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. Servicing the exhaust system. Hot parts can cause severe injury or death.
  • Page 80 Figure 4-29 TP Sensor Wiring Diagram To TMAP The ECM monitors feedback from the electronic sensor throttle control (ETC) through leads TPS1 and TPS2. P27-104, ETC– The ECM controls the signal through leads ETN and ETP to adjust the throttle position and maintain the programmed engine speed.
  • Page 81 Action  Turn the ECM power ON.  Connect Spectrum to the ECM in data stream mode. Troubleshoot as an  Clear the diagnostic troubleshooting code (DTC). Go to the next step. intermittent problem.  Start the engine. Does DTC re-set? ...
  • Page 82 Action  Remove all test equipment except Spectrum.  Connect any disconnected components.  Using Spectrum, clear DTC information from the ECM.  Turn the ECM power OFF and wait 30 seconds. The system is OK. Go to the next step. ...

  • Page 83: Installation And Removal Procedures

    Section 5 Installation and Removal Procedures The following section includes the installation and WARNING removal procedures for fuel system components and sensors. If the troubleshooting steps determine that a component is damaged and replacement is needed, use the following procedures to remove and replace that component.
  • Page 84 WARNING 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 Explosive fuel can cause fires and severe burns. removed. If a gaseous odor is detected, ventilate the area and contact an authorized service technician.

  • Page 85: Air-Fuel Mixer, Adapter, And Throttle Body Assembly

    NG (Natural Gas) is extremely flammable, is lighter than air, and rises. Do not start or operate this engine in Figure 5-1 Component Exploded View, KG2204 a poorly ventilated area where leaking gas could accumulate and endanger the safety of persons in the Note: To loosen the four mounting bolts securing the area.
  • Page 86 Place tape or a clean cloth over the intake to prevent items from falling inside the engine. 5.1.2. Throttle Body and Air-Fuel Mixer Installation, KG2204 Install the throttle body adapter plate to the upper intake manifold. Secure with four socket head cap Disconnect wire harness.
  • Page 87 5.1.4. Throttle Body Installation, KG2204 5.1.5. Air-Fuel Mixer Removal, KG2204T Note: For turbocharger removal and installation Position the throttle body gasket between the instructions, refer to the engine service adapter and the upper intake manifold. manual. Install the throttle body adapter plate to the upper intake manifold.

  • Page 88: Coolant Temperature (Ct) Sensor

    To separate the air-fuel mixer from the 5.2. Coolant Temperature (CT) turbocharger, use a rotational motion while pulling Sensor the two components apart. Use caution not to damage the O-rings. Remove four socket head cap screws securing air-fuel mixer to the air-fuel mixer adapter and then remove the adapter and the mixer gasket.
  • Page 89 5.2.1. Removal Procedure WARNING Make sure that the engine is off. If the engine is used as part of a generator set, disconnect AC power to the generator set by opening the upstream circuit breaker. Disconnect the engine starting battery, negative (-) lead first.

  • Page 90: Crankshaft Position (Ckp) Sensor

    5.3. Crankshaft Position (CKP) 5.3.1. Removal Procedure Make sure that the engine is off. Sensor If the engine is used as part of a generator set, disconnect AC power to the generator set by opening the upstream circuit breaker. Disconnect the engine starting battery, negative (-) lead first.

  • Page 91: Electronic Control Module (Ecm)

    21° C – 38° C (70° F – 100° F) and the minimum temperature requirement is 10° C (50° F). Apply black bonding tape, Kohler part number 32000 00110, to the back of the ECM. Press and hold the ECM onto the mounting bracket for 1 minute.

  • Page 92: Fuel Control Valve

    Observe federal, state, and local laws governing LPG/NG fuel, storage, and systems. Figure 5-5 Fuel Control Valve, KG2204 5.5.1. Removal Procedure Make sure that the engine is off. If the engine is used as part of a generator set, disconnect AC power to the generator set by opening the upstream circuit breaker.

  • Page 93: Fuel Pressure Regulator

    5.6.1. Removal Procedure 5.6. Fuel Pressure Regulator Make sure that the engine is off. If the engine is used as part of a generator set, disconnect AC power to the generator set by opening the upstream circuit breaker. Disconnect the engine starting battery, negative (-) lead first.
  • Page 94 5.6.2. Installation Procedure To install the hose connector into the fuel pressure regulator, place the fuel pressure regulator in a vice. Add a PTFE (Polytetrafluoroethylene) paste that is appropriate for NG or LPG applications onto the male threads of the hose connector and thread the hose connector with a wrench.

  • Page 95: Heated Exhaust Gas Oxygen Sensor (Hego)

    5.7.1. Removal Procedure 5.7. Heated Exhaust Gas Oxygen Make sure that the engine is off. Sensor (HEGO) If the engine is used as part of a generator set, disconnect AC power to the generator set by opening the upstream circuit breaker. Disconnect the engine starting battery, negative (-) lead first.

  • Page 96: Ignition Coil

    5.8. Ignition Coil 5.8.1. Removal Procedure Make sure that the engine is off. If the engine is used as part of a generator set, disconnect AC power to the generator set by opening the upstream circuit breaker. Disconnect the engine starting battery, negative (-) lead first.

  • Page 97: Oil Pressure Sender

    Used engine oil. Contact with used engine oil may cause 5.9. Oil Pressure Sender 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 shortly after handling used engine oil.

  • Page 98: Temperature Manifold Pressure (Tmap) Sensor

    5.10. Temperature Manifold 5.10.2. Installation Procedure Lightly apply petroleum jelly to the O-ring on the Pressure (TMAP) Sensor TMAP sensor. Install the TMAP sensor and secure with the retaining screw. Torque the retaining screw to 9.9 Nm (7.3 ft. lb.). Reconnect the wire harness.

  • Page 99: Manifold Pressure (Map) Sensor, Kg2204T

    5.11. Manifold Pressure (MAP) 5.11.2. Installation Procedure Lightly apply petroleum jelly to the O-ring on the Sensor, KG2204T MAP sensor. Install the MAP sensor and secure with the retaining screw. Tighten the retaining screw to 9.9 Nm (7.3 ft. lb.). Reconnect the wire harness.
  • Page 100 Notes TP-6903...

  • Page 101: Appendix A Torque Specifications

    Appendix A Torque Specifications American Standard Fasteners Torque Specifications Assembled into Cast Iron or Steel Assembled into Torque Aluminum, Grade Grade 2 Grade 5 Grade 8 Size Measurement 2 or 5 See Note 3 8-32 N•m (in. lb.) 1.8 (16) 2.3 (20) —...
  • Page 102 Metric Fasteners Torque Specifications Assembled into Assembled into Cast Iron or Steel Torque Aluminum Grade Size Measurement Grade 5.8 Grade 8.8 Grade 10.9 5.8 or 8.8 See Note 3 M6 x 1.00 N•m (ft. lb.) 6.2 (4.6) 12 (9) 13.6 (10) M8 x 1.25 N•m (ft.

  • Page 103: Appendix B Abbreviations

    (2 bytes) cold cranking amps est. estimated ccw. counterclockwise KBus Kohler communication protocol E‐Stop emergency stop Canadian Electrical Code kilogram etc. et cetera (and so forth) cert. certificate, certification, certified kg/cm kilograms per square centimeter exh.
  • Page 104 kilojoule National Electrical Code remote terminal unit kilometer NEMA National Electrical Manufacturers room temperature vulcanization kOhm, k kilo‐ohm Association read/write NFPA National Fire Protection Society of Automotive Engineers kilopascal Association scfm standard cubic feet per minute kilometers per hour newton meter silicon controlled rectifier kilovolt normally open...
  • Page 105 Notes...
  • Page 106 Notes...
  • Page 108 7 Jurong Pier Road Singapore 619159 Phone (65) 6264‐6422, Fax (65) 6264‐6455 For the nearest KOHLER authorized installation, service, and sales dealer in the US and Canada: TP-6903 5/16a Call 1‐800‐544‐2444 or visit KOHLERPower.com © 2015, 2016 by Kohler Co. All rights reserved.

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