Kohler KG2204 Instrucciones de montaje

TP-6903 5/16a

Engine Fuel System and

Diagnostic Code Troubleshooting

Engine Models:

KG2204

KG2204T

Propane, Liquefied Petroleum Gas (LPG)

and Natural Gas

(

)

Fueled

Service

2 Product Identification Information TP-6903 5/16a

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

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. Record field-installed kit numbers

after installing the kits.

Engine Identification

Record the product identification information from

the engine nameplate.

Manufacturer_______________________________

Model Designation___________________________

Serial Number ______________________________

TP-6903 5/16a 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.Introduction .......................................................................................................................................11

1.2.Air-Fuel Mixer....................................................................................................................................13

1.3.Charge Air Cooler (KG2204T only) ..................................................................................................13

1.4.Coolant Temperature Sensor ............................................................................................................13

1.5.Crankshaft Position (CKP) Sensor ....................................................................................................14

1.6.Electronic Control Module .................................................................................................................14

1.7.Fuel Control Valve.............................................................................................................................15

1.8.Fuel Pressure Regulator ...................................................................................................................15

1.9.Fuel Shut-Off Valves .........................................................................................................................16

1.10.Heated Exhaust Gas Oxygen (HEGO) Sensor..................................................................................16

1.11.Ignition System..................................................................................................................................17

1.12.MAP and TMAP Sensors ..................................................................................................................17

1.13.Oil Pressure Sender..........................................................................................................................18

1.14.Throttle Body.....................................................................................................................................19

1.15.Throttle Position (TP) Sensor ............................................................................................................19

1.16.Turbocharger (KG2204T only) ..........................................................................................................20

1.17.Turbocharger Oil Lines (KG2204T only) ...........................................................................................20

Section 2Diagnostic Troubleshooting Codes...........................................................................................................21

2.1.Introduction .......................................................................................................................................21

2.2.Spectrum Diagnostic Scan Tool (DST) .............................................................................................21

Section 3Fuel System Troubleshooting ....................................................................................................................45

3.1.Fuel System Intermittent Problems ...................................................................................................47

3.2.Fuel System Basic Checks................................................................................................................47

3.3.No Start.............................................................................................................................................49

3.4.Hard Start..........................................................................................................................................50

3.5.Cuts Out and Misses.........................................................................................................................51

3.6.Hesitation, Sag, or Stumble...............................................................................................................52

3.7.Backfire .............................................................................................................................................53

3.8.Lack of Power or Sluggishness .........................................................................................................54

3.9.Poor Fuel Economy...........................................................................................................................55

3.10.Rough, Unstable, or Incorrect Engine Speed and Stalling ................................................................56

3.11.Hunting and Surging .........................................................................................................................57

Section 4Electrical System and Sensor Troubleshooting .......................................................................................59

4.1.Introduction .......................................................................................................................................61

4.2.Powering the ECM ............................................................................................................................61

4 Table of Contents TP-6903 5/16a

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 .......................................................69

4.8.Ignition Coil Troubleshooting.............................................................................................................72

4.9.Oil Pressure Sender Troubleshooting ...............................................................................................75

4.10.Temperature Manifold Pressure (TMAP) and MAP Sensor Troubleshooting ....................................77

4.11.Throttle Position (TP) Sensor Troubleshooting .................................................................................79

Section 5Installation and Removal Procedures........................................................................................................83

5.1.Air-Fuel Mixer, Adapter, and Throttle Body Assembly.......................................................................85

5.2.Coolant Temperature (CT) Sensor....................................................................................................88

5.3.Crankshaft Position (CKP) Sensor ....................................................................................................90

5.4.Electronic Control Module (ECM)......................................................................................................91

5.5.Fuel Control Valve.............................................................................................................................92

5.6.Fuel Pressure Regulator ...................................................................................................................93

5.7.Heated Exhaust Gas Oxygen Sensor (HEGO)..................................................................................95

5.8.Ignition Coil .......................................................................................................................................96

5.9.Oil Pressure Sender..........................................................................................................................97

5.10.Temperature Manifold Pressure (TMAP) Sensor ..............................................................................98

5.11.Manifold Pressure (MAP) Sensor, KG2204T.....................................................................................99

Appendix A Torque Specifications......................................................................................................................................101

Appendix B Abbreviations ...................................................................................................................................................103

TP-6903 5/16a Safety Precautions and Instructions 5

Safety Precautions and Instructions

Read and follow all safety precautions

and instructions. SAVE THESE

INSTRUCTIONS.

This manual has several types of safety

precautions and instructions: Danger,

Warning, Caution, and Notice.

DANGER

Danger indicates the presence of a

hazard that will cause severe personal

injury, death, or substantial property

damage.

WARNING

Warning indicates the presence of a

hazard that can cause severe personal

injury, death, or substantial property

damage.

CAUTION

Caution indicates the presence of a

hazard that will or can cause minor

personal injury or property damage.

NOTICE

Notice communicates installation,

operation, or maintenance information

that is safety related but not hazard

related.

Safety decals affixed to the equipment in

prominent places alert the operator or

service technician to potential hazards

and explain how to act safely. The

decals are shown throughout this

publication to improve operator

recognition. Replace missing or

damaged decals.

Accidental Starting

WARNING

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.

Engine Backfire/Flash

Fire

WARNING

Risk of Fire. Can cause severe

injury or death.

Do not smoke or permit flames or

sparks near fuels or the fuel system.

Servicing the fuel system. A flash

fire can cause severe injury or

death. Do not smoke or permit

flames or sparks near the

carburetor, fuel line, fuel filter, fuel

pump, or other potential sources of

spilled fuels or fuel vapors. Catch

fuels in an approved container when

removing the fuel line or carburetor.

Servicing the air cleaner. A

sudden backfire can cause severe

injury or death. Do not operate the

engine with the air cleaner removed.

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. If power is supplied to the

shut-off valve during ECM or sensor

troubleshooting, fuel may enter the

air intake manifold or the air cleaner

and cause a backfire. Make sure that

the fuel supply is turned OFF and

that the fuel shut-off valves are

DISCONNECTED from the power

source BEFORE turning the ECM

power on.

6 Safety Precautions and Instructions TP-6903 5/16a

Exhaust System

WARNING

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.

Fuel System

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.

WARNING

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 area

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.

Hazardous

Voltage/Moving Parts

WARNING

Electrical shock can cause injury.

Do not touch wires while engine is

running.

WARNING

Avoid possible death or serious

injury! Pinch and entanglement

hazards!

Never check drive belt tension while

the engine is running.

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.

TP-6903 5/16a Safety Precautions and Instructions 7

WARNING

Spring-loaded parts. Can cause

severe personal injury or property

damage.

Wear protective goggles when

servicing spring-loaded parts. Hold

parts securely during disassembly.

WARNING

Airborne particles. Can cause

severe injury or blindness.

Wear protective goggles and

clothing when using power tools,

hand tools, or compressed air.

Hot Parts

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 removed.

Servicing the exhaust system. Hot

parts can cause severe injury or

death.

Do not touch hot engine parts. The

engine and exhaust system

components become extremely hot

during operation.

WARNING

Hot coolant and steam. Can cause

severe injury or death.

Before removing the pressure cap,

stop the engine and allow it to cool.

Then loosen the pressure cap to

relieve pressure.

WARNING

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, rustproofing

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.

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 accordance with

applicable laws and regulations.

Contact your local recycling center

for disposal information and

locations.

8 Safety Precautions and Instructions TP-6903 5/16a

Notes

TP-6903 5/16a Introduction 9

Introduction

This manual applies to the Kohler Model

KG2204/KG2204T 2.2L engine. The purpose of this

manual is to provide an understanding of the fuel

system and instructions to troubleshoot the fuel system

and sensors.

To troubleshoot the fuel system using the instructions

in this manual, use the following steps:

Connect to the ECM, electronic control module, to

read any logged Diagnostic Troubleshooting

Codes (DTC).

a. A laptop with Spectrum software and a

Kvaser® cable are required to connect to the

ECM.

Note: Spectrum is a diagnostic scan tool (DST)

software program from IMPCO® Technologies,

Inc. Refer to the software instruction manual for

installation and operation. See Section 2.2 for

more information.

Refer to Section 2, Diagnostic Troubleshooting

Codes in this manual to look up the

recommended troubleshooting steps for a DTC.

The DTC chart lists the components that are most

likely causing the DTC fault and the corrective

actions.

In Section 3, Fuel System Troubleshooting , and

Section 4, Electrical System and Sensor

Troubleshooting, follow the troubleshooting steps

indicated in the DTC chart.

If the troubleshooting steps require a component

to be replaced, refer to 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.

Read this manual and carefully follow all procedures

and safety precautions to ensure proper equipment

operation and to avoid bodily injury. Read and follow

the Safety Precautions and Instructions section at the

beginning of this manual. Keep this manual with the

equipment for future reference.

Unless otherwise specified, all units of measurement

are metric, followed by the Imperial (U.S.) equivalent.

IMPCO is a registered trademark brand of IMPCO Technologies,

Inc.

KVASER is a registered trademark of TIMEGALACTIC AB.

List of Related Materials

Figure 1-1 identifies related literature available for the

KG2204/KG2204T engine covered in this manual.

Figure 1-1 Related Literature

Literature Type

Part Number

Operation Manual,

KG2204/KG2204T Engine

TP-6901

Service Manual,

KG2204/KG2204T Engine

Mechanical

TP-6902

Parts Catalog,

KG2204/KG2204T Engine TP-6904

10 Service Assistance TP-6903 5/16a

Service Assistance

For professional advice

and conscientious service,

please

contact your nearest Kohler distributor or dealer.

Consult the Yellow Pages under the

heading Generators–Electric.

Visit the Kohler Power Systems website at

KOHLERPower.com.



Look

the labels and

decals

on your Kohler

product or review the appropriate literature or

documents included with the product.

Call toll free in the US and Canada 1-800-

544-2444.



Outside

the US and

Canada,

call the

nearest

regional office.

Headquarters Europe, Middle East,

Africa

(EMEA)

Kohler Power Systems Netherlands B.V.

Kristallaan 1

4761 ZC Zevenbergen

The Netherlands

Phone: (31) 168 331630

Fax: (31) 168 331631

Asia

Pacific

Power Systems Asia Pacific Regional Office

Singapore, Republic of Singapore

Phone: (65) 6264-6422

Fax: (65) 6264-6455

China

North China Regional Office, Beijing

Phone: (86) 10 6518 7950

(86) 10 6518 7951

(86) 10 6518 7952

Fax: (86) 10 6518 7955

East China Regional Office, Shanghai

Phone: (86) 21 6288 0500

Fax: (86) 21 6288 0550

India, Bangladesh, Sri Lanka

India Regional Office

Bangalore, India

Phone: (91) 80 3366208

(91) 80 3366231

Fax: (91) 80 3315972

Japan, Korea

North Asia Regional Office

Tokyo, Japan

Phone: (813) 3440-4515

Fax: (813) 3440-2727

Latin America

Latin America Regional Office

Lakeland, Florida, USA

Phone: (863) 619-7568

Fax: (863) 701-7131

Fax: (65) 6264-6455

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