Related Manuals for Kohler KG2204T
Summary of Contents for Kohler KG2204T
- Page 1 Operation Engine Engine Models: KG2204 Naturally Aspirated KG2204T Turbocharged Liquefied Petroleum Gas (LPG)/Propane/ Natural Gas (NG) Fueled TP-6901 3/16a...
- Page 2 This manual provides operating and maintenance instructions for KOHLER Engine Models KG2204 and KG2204T. Keep this manual with the equipment for future reference. Refer to the KG2204 and KG2204T Service Manual for detailed information on adjusting and servicing the engine.
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Page 3: Table Of Contents
3.4 Model KG2204T Front and Rear Views ........ - Page 4 5.5 Electrical System ............34 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 and KG2204T engines. Only trained and qualified personnel should install or service this engine. Literature Type... - Page 6 ENGINE IDENTIFICATION AND TECHNICAL SUPPORT 6 Engine Identification and Technical Support TP-6901 3/16a...
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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 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. 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...
- Page 10 SAFETY PRECAUTIONS 10 Safety Precautions TP-6901 3/16a...
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Page 11: Section 3 Components And Maintenance Locations
COMPONENTS AND MAINTENANCE LOCATIONS Section 3 Components and Maintenance Locations 3.1 MODEL KG2204 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... -
Page 12: Model Kg2204 Front And Rear Views
COMPONENTS AND MAINTENANCE LOCATIONS 3.2 MODEL KG2204 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... -
Page 13: Model Kg2204T Engine Side Views
COMPONENTS AND MAINTENANCE LOCATIONS 3.3 MODEL KG2204T ENGINE SIDE VIEWS idGM88249 Figure 3-3 Regulator to FCV Hose Throttle Body Oil Pump Drive FCV to Mixer Hose TMAP Sensor Crankshaft Position Sensor Fuel Control Valve (FCV) Intake Manifold Ignition Coil Rear Hanger... -
Page 14: Model Kg2204T Front And Rear Views
COMPONENTS AND MAINTENANCE LOCATIONS 3.4 MODEL KG2204T FRONT AND REAR VIEWS idGM88249 Figure 3-4 Coolant Temperature Throttle Body Crankshaft Position Sensor Sensor Upper Intake Manifold Lower Intake Manifold Timing Cover Fuel Control Valve Turbo Oil Feed Line Oil Pressure Sensor... -
Page 15: Section 4 Operation
OPERATION Section 4 Operation 4.1 INTRODUCTION 4.2 FUEL SYSTEM The KG2204 and KG2204T are four-stroke internal Components combustion engines certified to operate on either Propane, Liquid Petroleum Gas (LPG) or Natural Gas Fuel Shut-Off Valves (NG). System configuration is factory preset for NG. - Page 16 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 or dealer. K0379 Figure 4-3 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 17 Turbocharger idGM92075 Figure 4-8 The Model KG2204T engine is equipped with a charge air cooler. The charge air cooler (A) cools the compressed air/fuel mixture before it enters the intake manifold. The cooler intake manifold charge helps maintain emissions at the high power level of the turbocharged engine.
- Page 18 Figure 4-10 Up-Stream Throttle Manifold Air Pressure (MAP) Sensor (KG2204T) The Up-stream Thr ottle Manifold Air Pressure sensor monitors the absolute 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.
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Page 19: Fuel Specifications
Petroleum Gases, to the extent that these standards are not in violation of federal, state, or local law. Table 4-1: Fuel Specifications Specification Fuel Type Item KG2204 KG2204T Liquid Propane Type HD-5 or HD-10 Gas (LPG) Maximum fuel pressure 11.0" W.C. (engine OFF, no load) Minimum fuel pressure 5.0"... -
Page 20: Ng To Lpg Conversion
OPERATION NG to LPG Conversion WARNING The KG2204 and KG2204T engines are 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 Explosive fuel can cause fires and setting change at the ECM. -
Page 21: 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 4-10. 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 22: 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 23: 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 24: 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 25: Section 5 Maintenance
5.1 INTRODUCTION WARNING Preventive maintenance is critical to prolonging the life of the KG2204 and KG2204T engines and keeping them in optimum working condition. As the engine Handling caustic engine fluids and runs, fasteners may loosen, parts may become worn,... -
Page 26: 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 27: 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 28: 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 29 MAINTENANCE Required materials: WARNING • Fresh engine oil (See “Oil Recommendations” on page 26.) • 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 30 MAINTENANCE K0706 K0706 Figure 5-7 Figure 5-5 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 5-5. tighten the filter an additional 3/4 turn , 25 N•m...
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Page 31: 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 32 Adjust the gap to specification. See Figure 5-11. Spark Plug Gap KG2204 0.9–1.0 mm (0.036–0.040 in.) KG2204T 0.7–0.8 mm (0.028–0.031 in.) NOTE: Ensure that the spark plug tubes are seated before installing the spark plugs. If the tubes were removed, reinstall the tubes before installing the spark plugs.
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Page 33: Replace The Spark Plugs
Spark plug wires MUST be KG2204 0.9–1.0 mm (0.036–0.040 in.) installed in proper order. KG2204T 0.7–0.8 mm (0.028–0.031 in.) 2. Use a cloth to wipe dirt and oil away from the area around each of the four spark plug wires (A). See 7. -
Page 34: Ignition Timing
MAINTENANCE Ignition Timing 5.5 ELECTRICAL SYSTEM The KG2204 and KG2204T engines have an electronic Check Battery and Connections ignition system. All functions of the ignition system, including timing, are controlled by the ECM and cannot Check the condition of the battery and connections be adjusted. - Page 35 MAINTENANCE WARNING Accidental starts can cause severe injury or death. Disconnect and ground spark plug leads before servicing. K0707 Before working on engine or equipment, disable Figure 5-15 engine as follows: 1) Disconnect spark plug leads. 3. Inspect the drive belt. Look for signs of cracking, 2) Disconnect negative (–) battery cable from battery.
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Page 36: Replace The Drive Belt
MAINTENANCE Replace the Drive Belt Check drive belt tension: 5. The drive belt tension should be checked at the midpoint (B) between the pulleys. See Figure WARNING 5-16. • 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. -
Page 37: Check Wiring And Electrical Connections
MAINTENANCE 4. Set drive belt tension to specification. See Figure 5-20. • 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. -
Page 38: Cooling System
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. 38 Maintenance... -
Page 39: Fuel System
Explosive fuel can cause fires and engine if you can smell leaking gas. Have any severe burns. necessary service performed by a KOHLER authorized If a gaseous odor is detected, distributor/dealer or qualified LPG/NG technician only. ventilate the area and contact an authorized service technician. - Page 40 MAINTENANCE 40 Maintenance TP-6901 3/16a...
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Page 41: 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 42 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 Knocks or Pings Boost pressure too high Check for stuck wastegate, check for leak in wastegate boost line.
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Page 43: 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 44: 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 45: 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 46: Specifications Of Main Components
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... -
Page 47: 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 48 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 49 NOTES Notes...
- Page 52 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 3/16a Singapore 619159 Phone (65) 6264-6422, Fax (65) 6244-6455 ® 2014, 2016 by Kohler Co. All Rights Reserved.
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