Engine Operation Manual
Contents
1. scting negative ound cable make sure all are OFF If ON a spark NG is extremely flammable is lighter than air and rises Do not start or operate this engine in a poorly ventilated area where leaking gas could accumulate h could cause an explosion drogen gas or LPG NG fuel A WARNING Hot Parts can cause severe burns oply systems must be EA d only by qualified LPG Do not touch engine 2m technicians Improperly cause injury while operating or d maintained LPG NG just after stopping Do not touch wires Never operate engine with heat components to while engine is shields or guards removed g gas leaks running storage and systems 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 TP 6901 7 13 3 Table of Contents Tabe OF R JUOS raer aE E E EE EEE folesicaseame needa EE ES 5 ENGINE MOGLA AIII occain o E E E T O vec eadeat aaataundton 6 PIC ah CCC IINGSE Derisinin E E E E EEE A AE E E T ERONC ODOTA orreee A E E E E E E EEO 8 Engine Maintenant o sissano en ean n aE e A E a AEAEE UIDMICATION SYSTERN sesrrssnrinso i ia E N ENGNG COON srera ea a E EE EEE EEE FSI SY O eenen E E AEE aaa Electmical SySteN sanieren E EEEE ATEENA ROlated SMU cossos E EE Troubleshooting Engine Specifications2. ccccccsseeccsseeeceeseeceseeesseeeeees Specifications of Main Components Adjustment Parameters ccccsecceeeeeeees Tightening Torque of Main Components 4 TP 6901 7 13 Table of Figures Figure 1 Front View of the Engine ccccccsccccssscecceseeecesececeuseeceaseeceaueeeceaeessuseccsaueeeseuseessegeecsageesssaeesssaeees 6 Figure 2 Top View of the Engine Figure 3 Right View of the Engine Figure 4 Left View of the Engine Figure 5 Maintenance Schedule Intervals cccccsscccceseccceesecceeeecseucecseueeeseueeessaueeeseueesseueeessaeeessaeeessags 9 Figure 6 Maintenance Schedule Figure 7 Check Oil Level ccccccceseececeeseeceesseceeaseeceeseecsegeesssaeeessaeees Figure 8 Oil Recommendations by Temperature Figure 9 Removing the Oil Filler Cap cccccccceeeeeseeeeeeseeeeeeaeeeeneeees Figure 10 Oil Filling Pipe and Filling Engine Oil Figure 11 Removing the Oil Filter 0 0 0 0 ceccccseeeeeeeeeeseeeesaeeeeeaeeeeesaees Figure 12 Cleaning a New Oil Filter Before Installation Figure 13 Installing the Oil Filter Figure 14 Check the V Belt Surface and Tension Figure 15 Removing the Spark Plugs and Tubes Figure 16 Inspecting the Spark Plug Gap Figure 17 Related Literature W Figure 18 General Troubleshooting Figure 19 Engi o ce IMI sec cececaececaeeeceececeuseseaecseueeseaeeseueeesseeesaeseneseneaeeneseeseneess T
3. 5 Check the connections on the battery for propper connection and corrosion 6 Check and clean cooling areas air intake area and external surfaces of engine particularly af storage 7 Check that air cleaner compone shrouds equipment covers and place and securely fastened 8 Check every connector on the starter spark T TP 6901 7 13 Engine Operation eck While the Engine Is Running A WARNING Carbon Monrorde can cauce cavers NOTE Check often for abnormal noise while the nausea fainting or death engine IS running NOTE Check for leakage from fuel pipes cooling pipes or air pipes If there is leakage stop the engine and repair Avoid inhaling exhaust fumes Engine exhaust gases contain poisonous carbon monoxide Carbon monoxide is odorless colorless and can cause death if inhaled 1 Check for det Re Rotating parts can cause severe injury P Stay away while engine is in operation l Keep hands feet hair and clothing away from all moving parts to prevent injury Never operate engine with covers shrouds or guards removed ation backfire knocking loose parts or con ns or other abnormal noise from hot electric system cooling rature and Starting Procedure NOTE Do not approach or attempt to disassemble disengaging all parts while the engine is running If adjustments must be made use caution NOTE Do not remove the radiator cap when it is for
4. Schedule Use only the recommended spark plug or an equivalent as described in Figure 20 Specifications of Main Components 1 Use a spark plug wrench to remove the spark plug s 4 See Figure 15 Removing the Spark Plugs and Tubes Clean out the spark plug recess Check each spark plug s gap using a wire feeler gauge See Figure 16 Inspecting the Spark Plug Gap 4 Adjust the spark gap if necessary See Figur 21 Adjustment Parameters Install spark plugs 4 into cylinder hea 6 Torque the spark plug s accordin g e Spark Plugs and Tightening Torque of Main Compo l ubes Figure 16 Inspecting the Spark Plug Gap Ignition Syste This engine has an ele 15 TP 6901 7 13 Related Literature Figure 17 Related Literature identifies related literature available for the model XXxxxx engine Only trained and qualified personnel should install or service this engine Literature Type Part Number Kohler Model XXxxxx Service Manual TP 6902 Kohler Model XXxxxx Service Manual Troubleshooting i TP 6903 Code Diagnostics Kohler Model XXxxxx Service Parts Manual TP 6904 Figure 17 Related Literature Troubleshooting v y items that rec pecial timing authorized dea NOTE Do not attempt to service or replace major engine componen or adjustment procedures This work should be performed b Fuel System Leakage Check and lines for leaks ervice performed With the fuel valve fully opened and the e
5. air temperature at time of operation as shown in Figure 8 OilRecommendations by Temperature Figure 8 Oil Recommendations by Temperature TP 6901 7 13 10 Replace With New Oil Lubrication System NOTE Each time you change the engine oil run the engine without load for a short time after to ensure that each friction surface has oil NOTE Change oil while engine is warm 1 Drain all used oil e Remove the oil filter cap from the top of the cylinder head cover See Figure 9 Removing the Oil Filler Cap Figure 9 Ren gy the OikFiller Cap e Prepare a drain pan for drained oil See Figure 11 Removing the Oil Filter e Remove the oil pan drain plug e Allow oil to drain e Replace the oil pan drain plug 2 Fill with new oil e Remove the oil filler cap See Figure Removing the Oil Filler Cap e Refill oil from oil filler cap See Fi Filling Pipe and Filling Engine e Replace the oil filler cap Jil Filling Pipe and Filling Engine Oil 11 TP 6901 7 13 Lubrication System Replace the Oil Filter The oil filter is a rotating type oil filter with whole body and paper filter element Tighten it at the seat using the appropriate wrench Oil Filter Wrench NOTE Do not reuse an oil filter do not use the same filter repeatedly Always use a new filter 1 Using the appropriate oil filter wrench remove the oil filter See Figure 11 Re
6. KOHLER Power Systems Engine Model XXxxxx Liquefied Petroleum Gas LPG or LPG Natural Gas NG Fueled Operation Manual TP 6901 Proprieta nd instructions carefully before operating equipment s of equipment that this engine powers fore performing any maintenance or service Rece ine Information to ref e when ordering parts or obtaining warranty coverage Serial Nu Purchase Date Safety Precautions A WARNING A hazard that could result in death serious injury or substantial property damage A CAUTION A hazard that could result in minor personal injury or property damage NOTE Used to notify people of important installation operation or maintenance information A WARNING A WARNING A WARNING Explosive Fuel can Carbon Monoxide cause fires and 7 can cause severe Accidental Starts severe burns nausea fainting or an cause severe death jury or death If a gaseous odor is detected ventilate i i Disconnect and area and contact an und spark plug authorized service Engine exhaust gases co before technician poisonous carbon monoxide LPG is extremely flammable and Carbon monoxide is _ odorles is heavier than air and tends to colorless and can cause deat settle in low areas where a spark inhaled or flame could ignite gas Do not start or operate this engine in a poorly ventilated area where leaking gas could accumulate and endanger safety of persons in area
7. P 6901 5 Engine Model XXxxxx 2 im a 10 Propria Prog oor O a i S un v of the Engine 6 Figure 2 Figure 1 Front View of the Engine fprietdry Pnoto Figure 4 Left View of the Engine Oil Filter Valve Cover 3 Gear Case ake Manifold MAP Sensor Coolant Temperature Sensor Water Inlet Oil Filler Cap Ignition Coil Oil Dipstick Rear Hanger Air Fuel Mixer Spark Plug Recesses Water Pump Spark Plug Wires V Belt Alternator Crankshaft Pulley Crankshaft Sensor Front Hanger Throttle Body Fuel Valve Exhaust Manifold Water Outlet Oil Pressure Switch Oil Pan Drain Plug TP 6901 7 13 6 Pre Start Checklist NOTE Operators must read this manual carefully before starting the engine Starting the engine according to this manual is important 1 Check all parts of the engine carefully 2 Tighten pipe connectors and check the tension of the fan belt See Figure 14 Check the V Belt Surface and Tension 3 Check oil level by using the oil dipstick and check oil for deterioration or aging See Figure 7 Check Oil Level NOTE The lower mark on the dipstick is the caution level not the use level fill with sufficient oil to avoid engine failure 4 Check the fuel level in the fuel tank LPG only and check the fuel pipe and connectors in the fuel supply system If LPG tank is low have it refilled
8. a engine For e hours require on a the maintenance the life of the ice every 8 s andeso Before disconnecting negative ground cable make sure all switches are OFF If ON a spark will occur at ground cable terminal which could cause an explosion if hydrogen gas or LPG NG fuel vapors are present after 16 hours Maintenance Schedule Every 10 Hours of Operation Check Check for Chet nections for tightness P id Every 20 Hours of Operation As the engine is used parts may become worn bolts may loosen clearances change and oil can become contaminated The condition of the Kohler model XXxxxX engine will change over time and issues suc as hard starting decreased power increased fue consumption etc may occur with wear According to the technical state and accumulative we ime of the engine some technical maintena ay be necessary In order to keep the engine injgood working order avoid or reduce issues and to f e life of the engine users mus olete the follo hnical c maintenance care f eck batter oltage nsthefair filter bolts for tightness Every 60 Hours of Operation e Check electrode of spark plug and adjust gap if necessary Replace air filter Every 120 Hours of Operation can you e Check the battery for cracking gt fluids e Check the alternator belt tension and adjust if necessary NOTE Ne ith water f you do it nd
9. ctrical setting for the ECM to insure proper fuel and spark timing is supplied to the engine The pressure regulator is pre set at the factory for NG so when using NG no mechanical adjustment is required TP 6901 7 13 To set the regulator for LPG 1 Lift the lower cylinder of the regulator 2 Turn the cylinder 1 4 turn tothe _ 3 Let go of the cylinder and allow it to settle into place To set the regulatorfor NG regulator e mixer is yressure to ontinue The 1 With a low speed mixture ined in a tamper proof housing e factory and should not require Never disa ble or rebuild the air fuel mixer The air fuel mixer is an emission control device Components inside the mixer are specifically calibrated to meet the engine s emissions requirements If the mixer fails to action correctly replace it LPG Regulator In compliance with government emission standards a fuel regulator is added to the engine at the factory to provide proper fuel supply to the engine Do not make adjustments to the fuel regulator A Kohler Authorized dealer or qualified LPG personnel must perform all service related to the fuel regulator 14 Electrical System A CAUTION Electrical shock can cause injury Do not touch wires while engine is running Spark Plugs Spark plugs should be replaced at the recommended intervals as described in Figure 6 Maintenance
10. ercharged e Replace oil and oil filter Seasonal Maintenance e Check the antifreeze concentration e Replace oil with cold temperature oil in the NOTE Do not mix di winter if required ands or grades of oil Figure 6 Maintenance Schedule Lubrication System Check Oil NOTE Use oil according to this manual NOTE Shorten the oil change interval if the engine is run continually in dirty places Regularly check the engine s oil If oil is deteriorating discoloring thinning or there is water present the quality of the oil has been compromised and it should be replaced Check Oil Level NOTE In addition to checking oil pressure also check the oil level before running the engine after certain periods of time See Figure 6 Maintenance Schedule Stop engine and wait for oil level to stabilize Pull out the oil dipstick Clean the oil dipstick with a dry clean cloth Re insert the oil dipstick into the engine ES Sy SS Oil Level Pull out the oil dipstick again to che level Maintain the oil level between the F full marks on the dipstick If the oil level not over or under fil ation system with oil Specifications engine s Figure 19 se in LPG NG J use of Kohler Figure 19 Engine Specifications Othe quality detergent oils including synthetic of API American Petroleum Institute service class SJ or higher are acceptable Select viscosity based on
11. justment Parameters adjust the v belt the following procedure Adjusting the V Belt 1 Loosen the retaining bolts o adjusting rod Figure 14 Check the V Belt Surface and Tension 13 TP 6901 7 13 Fuel System A WARNING Explosive Fuel can cause fires and severe burns If a gaseous odor is detected ventilate area and contact an authorized service technician LPG is extremely flammable and is heavier than air and tends to settle in low areas where a spark or flame could ignite gas Do not start or operate this engine in a poorly ventilated area where leaking gas could accumulate and endanger safety of persons in area NG is extremely flammable is lighter than air and rises Do not start or operate this engine in a poorly ventilated area where leaking gas could accumulate and endanger safety of persons in 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 fuel supply system or other components to malfunction causing gas leaks Observe federal state and local laws governing NG fuel storage and systems This engine is certified to operate on LPGio LPG Engines gt to the fuel ect the battery for safety The system configuration G or NG requires a mechanical setting on the pressure regulator and an ele
12. moving the Oil Filter 2 Check and clean the oil filter installation surface Apply clean engine oil to the gasket of a new oil filter See Figure 12 Cleaning a New Oil Filter Before Installation 3 Lightly screw in the oil filter by hand until you feel resistance Then using the appropriate oil filter wrench tighten it another turn See Figure 13 Installing the Oil Filter Figu saning a New Before nstallation A Oil Filter Wrench Figure 13 Installing the Oil Filter Addi Before refilling oil clean the oid impurities entering into Refill oil fra cover See Figure 10 Oil Fi e and Filling TP 6901 12 Engine Cooling A stk Gi 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 V Belt V belts are generally tensioned by adjusting the alternator or through a mechanical belt tensioner To check the tension of the v belt push the belt down at the midway between pulleys See Figure 14 Check the V Belt Surface and Tension and Figure 21 Adjustment Parameters Inspecting the V Belt 1 Inspect the belt visually for separation or damage If any abnormality is found replace the belt Check V Belt for Cracking and Seperation 2 Inspect belt tension and deflection If the flexur of the belt does not meet the standards in Fig 21 Ad
13. nder Head Oil Pan Drain Plug 20 25 14 8 18 4 Figure 22 Tightening Torque of Main Components TP 6901 7 13 18 4 ower Systems TP 6901 7 13 2013 by Kohler Co All Rights Reserved KOHLER Co Kohler Wisconsin 53044 Phone 920 457 4441 Fax 920 459 1646 Kohler Power Systems Asia Pacific Headquarters 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 Call 1 800 544 2444 or visit KOHLERPower com
14. ngine turned off using a soapy water solution Correct any leaks before resta Dirty Restricted Regulator Figure 18 General Trouk TP 6901 7 13 16 Engine Specifications Item Specifications Engine Model XXXXXX Block Type AIT K Number of Cylinders Cylinder Bore 91 mm 3 5 in Piston Stroke 86 mm 3 4 in Displacement 2 2 L 2 3 qts Oil Brand Rotating Direction of Crankshaft Compression Ratio Cylinder Fire Order Starting Styl R Net Weight Overall Dimension LxWxH 71 25 5 in A l fl lt f f T Ce C D Co m 5 Q ep ze D O O Q O a Specifications of Main Components op Oil Filer V ions for flywheel adapter GM88832 fully open at 88 C 190 F Item Oil Filter Breather Specifications Rompe N Centrifugal type No fa Flywheel withattachmert Valve open 76 0 169 F V Rated voltage A current 90 A 1 2 kW speed Electronic i arter bl TN d Figure 20 Specific f Main Compone 17 TP 6901 7 13 Adjustment Parameters Item Specifications Spark Plug Gap 0 7 0 8 mm 0 027 0 031 in At the pressure of 98 N the deflection of new belt is 5 7 mm 0 20 0 28 in an old belt is Fan Belt Tension 7 8 mm 0 28 0 31 in Figure 21 Adjustment Parameters Tightening Torque of Main Components Main Fastening Parts Nem ftelb Spark Plug Cyli
15. specific stopping hot as there is high pressure in t system sues such as low oil pressure ssure high coolant temperature Refer to operating instructions Imal noise stop the engine Cold Wea arti Engine Speed NOTE Do not tamper with the governor settings to increase the maximum engine speed doing so may result in engine overspeed Overspeed is hazardous and will void warranty Engine speed control is maintained by the engine s Angle of Ope Electronic Control Module ECM Defaults programmed into the ECM software and throttle position sensors of equipment allow the ECM to maintain safe operating control over srate this engine the engine while maintaining speed and load control of operation see damage could result this engine powe exceeding maxim specification table Eng from insufficient lubrication TP 6901 8 Engine Maintenance Viaintenance Schedule A WARNING Due to the wear that different parts accumulate at different speeds there are four grades of technical maintenance for this engine Accidental Starts can cause severe Injury or death Every 10 Hours of Operation E 20 H f i Disconnect and ground spark plug U eee P lead s before servicing Every 60 Hours of Operation Every 120 v AIS Figure 5 Mai Before working on engine or equipment disable engine as follows 1 Disconnect spark plug lead s Preform m 2 Disconnect negative battery cable from battery schedule
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