NOTE
These are SAMPLE instructions for kits designed to convert gasoline engines to LPG and
natural gas. Actual instructions will vary with engine type and size.
CONVERSION KIT SAMPLE INSTALLATION INSTRUCTIONS
GENERAL INFORMATION
PLEASE READ THE ENTIRE INSTRUCTION PROCEDURE BEFORE
ATTEMPTING TO COMPLETE THE INSTALLATION
The gaseous fuel conversion kits have been designed to provide a basic set of
equipment to convert an internal combustion engine to gaseous fuel. Most of the
conversions can be accomplished in 30-40 minutes using common hand tools. There are a few
instances where an electric drill or threading equipment are needed.
As an aid to installation, this procedure is divided into four parts. The first
section concerns the actual conversion of the carburetor. The next section concerns proper
placement of the zero governor. This is followed by a series of diagrams showing the
recommended piping for various types of systems. The last section details a procedure for
first time starting and normal operation.
Although most of the kits are designed for a particular engine model, there is
always a chance that because of the specific engine application the conversion cannot be
installed as the instructions show. If There appears to be no alternate way to install the
kit, either write or call us as we may be able to recommend how to modify the kit or
suggest another set of equipment.
! WARNING !
THE STANDARD KITS AS SHIPPED CONFORM TO THE NATIONAL FIRE PROTECTION ASSOCIATION
(NFPA) PAMPHLET 58 REQUIREMENTS FOR USE OF GASEOUS FUELS AS A MOTOR FUEL OUTDOORS. IF THE
CONVERTED ENGINE IS TO BE HOUSED IN AN ENCLOSURE OR USED INDOORS, ADDITIONAL EQUIPMENT IS
REQUIRED TO POSITIVELY SHUT OFF THE FUEL SUPPLY IF THE ENGINE SHOULD FAIL WHILE
UNATTENDED.
ADDITIONALLY, IF ANY MODIFICATION OF THE PIPING SYSTEM FROM THE ZERO GOVERNOR TO
THE FUEL SUPPLY IS REQUIRED, CONSULT THE LOCAL GAS SUPPLIER OR THE MOST RECENT COPY OF
NFPA PAMPHLET 58.
FOR A COPY Of PAMPHLET 58, WRITE THE NATIONAL FIRE PROTECTION ASSOCIATION,
BATTERY-MARCH PARK, QUINCY, MA 02269 |
! CAUTION !
(1) Thread sealing compound should be used on all pipe thread fittings between
the zero governor and the fuel supply, being careful not to get any inside the fittings.
This could allow excess compound to collect on valve seats and orifices and cause
hazardous leakage and poor performance.
(2) If copper Tubing is used, it should be "K" or "L" having
a minimum wall thickness of 0.032 inches.
(3) After piping is complete, turn on the fuel supply and use a soap solution to
check all fittings for leaks. |
CARBURETOR CONVERSION
The installation procedure for the carburetor section is detailed on an enclosed
sheet. After completion of this procedure continue with the next section.
ZERO GOVERNOR MOUNTING
PLEASE READ THE FRONT PAGE WARNINGS
The Zero Governor should be located according to the recommendations included
with it. If this sheet is not available, please follow the following suggestions.
The Zero Governor should be mounted as close to the carburetor as possible with
the diaphragm oriented in a vertical plane. This helps to minimize the effects of gravity
on diaphragm travel. The unit should also be placed for easy access to the lock-off
adjusting screw and primer if provided.
Refer to the piping diagram for the recommended piping system; and before
installing the fuel supply line, be sure that the gas pressure is no more than the maximum
inlet pressure shown on the cover of the zero governor. If the pressure is greater,
leakage could result in a fire hazard and or hard starting.
Flexible piping to the inlet should be used to prevent cracking from vibration
if the zero governor is mounted on the engine or other vibrating surface. Also piping to
the inlet should be of sufficient size to allow full flow to the zero governor. This is
very important in natural gas installations as any restrictions smaller than the zero
governor orifice can affect engine performance. If a solenoid valve is used ahead of the
zero governor in the low pressure line, it should have an orifice at least as big as the
orifice in the zero governor.
When an electric solenoid primer is used, follow the wiring and adjusting
instructions furnished separately.
Select and install the outlet fitting into the zero governor taking care not to
allow any dirt to enter the outlet. Some zero governors may already have a fitting
installed at the factory.
After installation of the fuel hose between the zero governor and the
carburetor, turn on the fuel supply and test the system for leaks at the pipe joints using
a soap bubble solution or suitable gas detection device.
MODEL KN
INSTALLATION & OPERATION
GENERAL
The KN is designed for sensitivity and simple operation, It is used with low
pressure vaporized gaseous fuels, where dependable starting is a requirement. Because of
its extreme sensitivity, the KN offers excellent results in most remote starting
applications (standby power generators, etc.). With proper installation and maintenance,
the KN will provide years of trouble free service.
! WARNING !
The KN should be installed and maintained per instructions and all applicable
federal, state, local laws and codes, and NFPA Pamphlet 58. SPECIAL NOTE: For indoor
installations by NFPA definition, an atmospheric zero governor is not considered a
positive shut-off valve and an approved automatic shut-off device shall be installed to
assure that the flow of fuel will be stopped should the engine fail while unattended. For
or a copy of Pamphlet 58, write the National Fire Protection Association, 470 Atlantic
Ave., Boston, Mass. 02110. |
OPERATION
The KN is an atmosphere zero governor which acts like the float and needle valve
in a gasoline carburetor. Air flow through a venturi in the carburetor creates a vacuum
which acts through the outlet of the KN on the diaphragm. Atmospheric pressure then forces
the diaphragm toward the vacuum, depressing the lever and pulling the valve seat away from
the orifice which allows fuel to flow as long as the demand persists. When the vacuum
ceases, a spring force pushes on the lever and forces the valve seat against the orifice
shutting off the fuel flow. It is important to remember that fuel should not flow
through the KN when the engine is not running.
A properly adjusted KN requires a vacuum of only 0.25" to 0.35" of
water column to start the opening sequence. Due to this sensitivity, most installations do
not need priming to start unless low cranking speeds or restricted and lengthy piping are
required. If priming is necessary and a manual primer is installed, use only 1 or 2 second
bursts of fuel and immediately try to start the engine. If there is a choke on the
carburetor, do not use it as this will probably cause flooding and hard starting. As you
can see, the operation of this unit is simple and basic. If you are having trouble
operating the engine, in most cases the fuel controller is NOT malfunctioning. There is
generally a problem with the engine or fuel supply so do not make adjustments or attempt
to service the KN until you are sure it is needed.
SERVICE
The KN should be periodically checked for leakage past the valve seat and the
vents on the cover kept clean and free of obstructions. If the KN needs service we suggest
you take it to a qualified serviceman. If that help is not available we will furnish you a
list of repair shops or the proper service information.
INSTALLATION
The KN should be mounted as close to the carburetor as possible with the arrow
on the cover pointing up and the diaphragm in a vertical position. This helps to minimize
the effects of gravity on diaphragm travel. The unit should also be placed for easy access
to the primer if provided.
There are two sets of mounting holes provided. Either set of mounts will
adequately support the KN. The bottom set of holes have a 1-3/4" bolt spacing for use
with all universal mounting brackets. The mounting bosses on the cover are spaced
(5-3/4") apart for use with 5/16 bolts.
Before installing the fuel supply line, be sure that the gas pressure is no more
than the maximum inlet pressure shown on the front of the KN. If the pressure is greater,
leakage could result in a fire hazard and or hard starting. The piping to the inlet should
be of sufficient size to allow full flow to the KN. This is very important in natural gas
installations as any restrictions can effect engine performance. If a solenoid is used
ahead of the KN in the low pressure line, it should have an orifice at least as big as the
orifice in the KN. Flexible piping to the inlet should be used to prevent cracking from
vibration if the KN is mounted on the engine or other vibrating surface.
NOTE: Thread sealing compound should be used on all pipe thread fittings between
the KN and the fuel supply tank, being careful not to get any inside the inlet or
fittings. Excess compound could collect on the seat and orifice and cause hazardous
leakage, resulting in poor performance. After piping is complete, turn on the gas and use
a soap solution to check all fittings for leaks.
If an electric solenoid primer is used, follow the wiring and adjusting
instructions furnished separately.
The KN outlet is 3/8 NAT and I an outlet fitting has not been provided, select
and insert a suitable vapor fitting taking care not to allow any chips or dirt to enter
the outlet. Use of street ells or conventional pipe fittings in the fuel line between the
KN and the carburetor is not recommended as they may restrict the flow of fuel.
After installation of a properly sized fuel hose between the KN and carburetor,
it you are installing a complete conversion return to the instructions. For field
replacement applications the unit is ready for service.
SETTING POWER ADJUSTMENT
The following are the steps needed to set the power adjustment.
The power adjustment is like the main jet on a gasoline engine but is
adjustable. It is located on a elbow with an adjusting bolt and a lock nut. The power
adjustment is best placed near the adapter but if there is no room then it can be placed
on the outlet of the regulator.
Start by turning it in till it bottoms then turning it out 2 turns and try to
start engine. Turn screw out (1/4) turn at a time until the unit starts. Once engine
starts place a load the engine that equals the load that will be placed on engine under
hard use.
While engine is now running and under hard load perform the following to set the
power adjustment.
A. Turn the power adjustment screw counter clock wise until there is a power loss
or drop in RPM.
B. Turn the power adjustment screw clock wise until power or RPM is regained,
continue to turn the power adjustment screw clock wise until you again have a power or RPM
loss.
C. Turn the power adjustment screw counter clockwise until you regain the lost
power or RPM.
D. The power adjustment is now set and should not need further adjustment.
