Operation
Engine
Engine Model:
KG2204
Propane, Liquefied Petroleum Gas (LPG) /
Natural Gas (NG) Fueled
TP-6901 6/14
INTRODUCTION
WARNING
!
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 Imperial (U.S.) equivalent.
California Proposition 65
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Related Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Section 2 Safety Precautions
2.1 Safety Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Safety Information For This Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Section 3 Components and Maintenance Locations
3.1 Engine Side Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 Front and Rear Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Section 4 Operation
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.2 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
NG to LPG Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.3 Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.4 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.5 Cold Weather Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.6 Monitoring Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.7 Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Section 5 Maintenance
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.2 Fluid Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Oil Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Grease Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Coolant Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5.3 Periodic Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.4 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Check Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Change Engine Oil and Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Check and Clean the Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Replace the Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Check and Adjust the Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Replace the Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Ignition Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3
5.5 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Check Battery and Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Check and Adjust the Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Replace the Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Check Wiring and Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.6 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Check Coolant Level and Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Check Hoses and Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.7 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Check Fuel Supply Pipe and Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Check Fuel Level (LPG only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Section 6 Troubleshooting
6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Section 7 Storage
7.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8.2 Specifications of Main Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
8.3 Adjustment Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
8.4 Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
8.5 Standard Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4
ENGINE IDENTIFICATION AND TECHNICAL SUPPORT
Section 1 Engine Identification and
Technical Support
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.
1.3 SERVICE PARTS
Contact a KOHLER authorized distributor/dealer for all
maintenance, service, and engine parts. To find a
KOHLER authorized distributor/dealer, visit
KOHLERPower.com or call 1-800-544-2444 (U.S. and
Canada).
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
Service Manual
KOHLER Model KG2204
Service Manual / Troubleshooting /
Diagnostics
KOHLER Model KG2204
Service Parts Manual
TP-6902
TP-6903
TP-6904
TP-6901 6/14 Engine Identification and Technical Support 5
ENGINE IDENTIFICATION AND TECHNICAL SUPPORT
6 Engine Identification and Technical Support TP-6901 6/14
2.1 SAFETY ALERTS
NOTE:
!
DANGER
NOTICE
WARNING
!
!
CAUTION
WARNING
!
WARNING
!
!
CAUTION
WARNING
!
WARNING
!
SAFETY PRECAUTIONS
Section 2 Safety Precautions
Danger indicates the presence
of a hazard that will cause
severe personal injury, death, or
substantial property damage.
Notice communicates installation,
operation, or maintenance
information that is safety related
but not hazard
related.
Warning indicates the presence
of a hazard that can cause
severe personal injury, death, or
substantial property damage.
A Note is used to inform you of
important installation, operation, or
maintenance information.
Caution indicates the presence
of a hazard that will or can cause
minor personal injury or
property damage.
2.2 SAFETY INFORMATION FOR THIS ENGINE
Carbon
monoxide can
cause severe
nausea, fainting,
or death.
Avoid inhaling
exhaust fumes.
Engine exhaust gases contain
poisonous carbon monoxide.
Carbon monoxide is odorless,
colorless, and can cause death if
inhaled.
Keep hands, feet, hair, and clothing
away from all moving parts to
prevent injury. Never operate the
engine with covers, shrouds, or
guards removed.
Electrical shock
can cause injury.
Do not touch
wires while
engine is running.
Rotating parts
can cause
severe injury.
Stay away while
the engine is in
operation.
Never operate engine with heat
shields or guards removed.
Hot parts can
cause severe
burns.
Do not touch
engine while
operating or just
after stopping.
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
WARNING
!
WARNING
!
WARNING
!
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
the first stop to relieve pressure
before removing completely.
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.
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.
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.
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
decompose forming hydrofluoric
acid. Avoid inhalation or skin
contact. Do not incinerate-rings.
Dispose of O-ring waste material in
a responsible manner.
8 Safety Precautions TP-6901 6/14
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
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.
SAFETY PRECAUTIONS
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 shortly 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 9
SAFETY PRECAUTIONS
10 Safety Precautions TP-6901 6/14
Section 3 Components and Maintenance
2
3
4
5
7
1
8
9
1213
10
14
6
21
17
16
18
19
23
24
22
11
15
20
K0695 K0403
3.1 ENGINE SIDE VIEWS
COMPONENTS AND MAINTENANCE LOCATIONS
Locations
Figure 3-1:
Battery Charging
Alternator
1
15 Oil Pump Drive 21 Oil Pan Drain Plug
Crankshaft
Position Sensor
Oil Dipstick and
Tube
1 Rocker Arm Cover 7 Air-Fuel Mixer 13 Oil Pan 19
2 Rear Hanger 8 Throttle Body 14
3
Crankcase
Breather
9 TMAP Sensor
4 Spark Plug Wires 10 Intake Manifold 16 Ignition Coil 22
5 Oil Filler Cap 11 Flywheel 17
6 Front Hanger 12 Exhaust Manifold 18
1) Air Temperature / Manifold Absolute Pressure (TMAP)
TP-6901 6/14 Components and Maintenance Locations 11
Knock Sensor (if
equipped with
turbocharger)
Oil Cooler Adapter
20
(not included on
all models)
Oil Pressure
Sender
23 Oil Filter Base
24 Oil Filter
COMPONENTS AND MAINTENANCE LOCATIONS
2
3
4
5
7
1
8
9
14
15
10
17
6
21
22
11
1
12
13
19
16
23
24
26
K0693K0647
27
18
20
25
3.2 FRONT AND REAR VIEWS
Figure 3-2:
1 Air-Fuel Mixer 8 Ignition Coil 15
Crankshaft
Position Sensor
22 Flywheel
2 Throttle Body 9 Oil Dipstick 16 Timing Cover 23
3 TMAP Sensor 10 Fuel Control Valve 17 Oil Drain Plug 24 Oil Pan
Upper Intake
4
Manifold
5 PCV Valve 12
6 Rocker Arm Cover 13 Drive Belt 20
7 Oil Filter 14
11
Upper Coolant
Outlet
Coolant
Temperature
Sensor
Vibration
Dampener
Oil Pressure
18
19 Oil Filter Base 26
Sensor (PGS)
Oil Cooler Adapter
(not included on
21
all models)
Lower Intake
Manifold
25 Exhaust Manifold
27 Water Pump Inlet
Exhaust Manifold
Studs
Battery Charging
Alternator
12 Components and Maintenance Locations TP-6901 6/14
OPERATION
K0404
Section 4 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.
4.2 FUEL SYSTEM
Components
Fuel Shut-Off Valves
Figure4-3
The fuel supply contains two fuel shut-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.
TP-6901 6/14 Operation 13
OPERATION
K0692
K0379
NOTICE
K0380
Fuel Pressure Regulator
Figure4-4
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.
Air-Fuel Mixer
Figure4-6
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.
f
Fuel Control Valve
Figure4-5
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.
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 authorized
distributor/dealer.
14 Operation TP-6901 6/14
OPERATION
K0679
K0382
Throttle Body
Figure4-7
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.
Engine Control Module (ECM)
Figure4-8
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.
TP-6901 6/14 Operation 15
Loading...