brb-2800 machine manual - amazon s3...throttle for 20 minutes. if noise persists, take engine to...

BRB-2800 MACHINE MANUAL

BLASTPRO MANUFACTURING, INC. ~ WARRANTY & REGISTRATION CARD ONE YEAR LIMITED WARRANTY

(1-877-495-6464) A COPY OF THE WARRANTY CARD ON THE FOLLOWING PAGE, TOGETHER WITH PROOF OF PAYMENT, MUST BE SUBMITTED WITH ANY SERVICE REQUEST. THIS WARRANTY CARD MUST BE RETURNED TO: BLASTPRO MANUFACTURING, INC., 6021 MELROSE LANE, OKLAHOMA CITY, OK 73127, WITHIN TEN (10) DAYS OF ACQUIRING BLASTPRO PRODUCTS IN ORDER TO QUALIFY FOR THE ONE YEAR LIMITED WARRANTY CONTAINED IN THE SALES AGREEMENT.

BlastPro provides as a limited warranty to Original Purchasers of BlastPro equipment, purchased within and situated within the United States of America, who notify BlastPro in writing through completion of the BlastPro Equipment Warranty Card within ten (10) days of acquiring BlastPro Equipment, the following limited warranty. Subject to the exclusions, limitations and conditions stated above and below, BlastPro will warrant its products against defects in materials and workmanship, provided the Original Purchaser uses such equipment under normal and proper use, for a period of one year or 1,000 hours, whichever occurs first, from the date of delivery to the Original Purchaser. During the applicable limited warranty period and subject to the exclusions, limitations and conditions contained herein, BlastPro shall, within a reasonable period of time, repair or replace, at its option, any defective components of the equipment. The limited warranty does not cover wear parts, including but not limited to, tires, magnets, seals, casters, liners, wear plates, bearings, cages, blast wheels, blades, belts, electrical wiring components and items of a similar nature. This limited warranty does not cover damage to BlastPro equipment caused by any of the following: the use of the equipment for purposes other than which the equipment was designed and intended, all external causes such as (without limitation) acts of God, accidents, dropping, collision, fire, water damage, freezing, striking other objects, misuse or otherwise using the equipment contrary to the instructions and warnings contained in the User Manual; altering or modifying BlastPro equipment or accessories; exposure to environmental conditions beyond reasonable limits and the limits stated in the equipment manual; failure to properly maintain and service the equipment; damage caused by the use of any non-BlastPro parts or attachments on the equipment. To obtain repair or replacement under this limited warranty, the Original Purchaser must contact BlastPro at 1-877-495-6464. The Original Purchaser must be prepared to describe any alleged problem, as well as provide proof of purchase and proof of date of delivery and return of the Equipment Warranty Card. Written authorization from BlastPro must be obtained prior to any BlastPro equipment being returned to BlastPro. Once BlastPro provides the Original Purchaser with a written authorization, then the Original Purchaser shall deliver the equipment as instructed by BlastPro. The Original Purchaser shall pay the cost of shipping and shall also bear any risk of loss during shipping. Providing the BlastPro equipment is defective and the limited warranty applies, BlastPro shall, within a reasonable period of time, repair or replace any defective components. The Original Purchaser shall be responsible for picking up the repaired equipment or may arrange for shipment at Original Purchaser’s expense. BlastPro’s repair or replacement of any defective parts on the equipment does not extend the term of this limited warranty, which shall expire on expiration of the period of one year from the date of Original delivery, subject to the further terms of this warranty.

THIS LIMITED WARRANTY IS THE ONLY WARRANTY APPLICABLE TO BLASTPRO EQUIPMENT. BLASTPRO DISCLAIMS ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING IMPLIED WARRANTIES OF MERCHANTABLILITY OR FITNESS FOR A PARTICULAR PURPOSE, OTHER THAN THOSE WARRANTIES IMPLIED AND INCAPABLE OF EXCLUSION, RESTRICTION OR MODIFICATION UNDER APPLICABLE LAW. ANY SUCH IMPLIED WARRANTIES WHICH MAY BE REQUIRED BY LAW AND ARE NOT DISCLAIMED HEREBY, ARE LIMITED TO THE EXTENT ALLOWED BY LAW TO THE APPLICABLE PERIOD OF THIS IMPLIED WARRANTY OR TO THE APPLICABLE TIME PERIOD PROVIDED BY THE APPLICABLE STATE LAW, WHICHEVER PERIOD IS SHORTER. UNDER NO CIRCUMSTANCES SHALL BLASTPRO BE LIABLE TO THE ORIGINAL PURCHASER OR ANY OTHER PERSON FOR ANY DIRECT, INDIRECT OR CONSEQUENTIAL DAMAGES RESULTING FROM THE USE OR MISUSE OF THE EQUIPMENT OR ARISING OUT OF ANY BREACH OF ANY WARRANTY OR FOR ANY SPECIAL OR CONSEQUENTIAL DAMAGES OF ANY CHARACTER, INCLUDING WITHOUT LIMITATION, DAMAGES FOR ANY LOSS OF GOODWILL, WORK STOPPAGE OR ANY AND ALL OTHER COMMERCIAL DAMAGES OR LOSSES. NO CHANGE TO OR ADDITIONAL WARRANTY, NO MATTER BY WHOM MADE OR WHEN MADE, SHALL APPLY TO ANY EQUIPMENT SOLD BY BLASTPRO.

Keep this top portion for your records

Delivery Date Machine Model No.

Delivering Distributors Name Machine Serial No.

and Address Modifications

Operating Manual Received Training Scheduled

(Please Print)

Company

Address

City State Zip

Phone Number

Contact Person

Purchase Date Delivery Date

Machine Model No.

Distributor Name

BlastPro Warranty Registration Card

NOTICE!

USER'S REFERENCE INFORMATION

WARRANTY REGISTRATION CARD

6021 Melrose Lane, Oklahoma City, OK 73127, or Fax to 405-495-1331

(All boxes must be checked or date filled in)

the attached card COMPLETELY and ACCURATELY and return to BlasPro Mfg.To ensure the proper warranty coverage is extended to the owner of this machine, fill out

IMPORTANT! To ensure that your BlastPro machine is covered under warranty, pleasefill in the following information and mail it to BlastPro Manufacturing, Inc.

Training Complete

CUT HERE

4 24 590 35 Rev. DKohlerEngines.com

Pre-Start Checklist1. Check oil level. Add oil if low. Do not overfi ll.2. Check fuel gauge (if equipped). If propane

tank is low, have it refi lled. Check fuel system components and lines for leaks.

3. Check and clean cooling areas, air intake areas and external surfaces of engine (particularly after storage).

4. Check that air cleaner components and all shrouds, equipment covers, and guards are in place and securely fastened.

5. Check spark arrestor (if equipped).

Starting

WARNINGCarbon 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.

WARNINGRotating Parts can cause severe injury.Stay away while engine is in operation.

Keep hands, feet, hair, and clothing away from all moving parts to prevent injury. Never operate engine with covers, shrouds, or guards removed.

NOTE: Do not crank engine continuously for more than 10 seconds. Allow a 60 second cool down period between starting attempts. Failure to follow these guidelines can burn out starter motor.

NOTE: Upon start-up, a metallic ticking may occur. Run engine for 5 minutes. If noise continues, run engine at mid throttle for 20 minutes. If noise persists, take engine to your local Kohler authorized dealer.

1. Place throttle control midway between slow and fast positions.

2. Slowly turn fuel valve on propane tank to full open position.

3. Turn key switch to START position. Release switch as soon as engine starts. If starter does not turn engine over, shut off key switch immediately. Do not make further attempts to start engine until condition is corrected. Do not jump start. See your Kohler authorized dealer for trouble analysis.

Cold Weather Starting Hints1. Use proper oil for temperature expected.2. Disengage all possible external loads.

Stopping1. If possible, remove load by disengaging all

PTO driven attachments.2. Turn fuel valve to full closed position and

allow engine to continue running until it runs out of fuel. Turn key switch to OFF position.

Angle of OperationRefer to operating instructions of equipment this engine powers. Do not operate this engine exceeding maximum angle of operation; see specifi cation table. Engine damage could result from insuffi cient lubrication.

Engine SpeedNOTE: Do not tamper with governor setting to

increase maximum engine speed. Overspeed is hazardous and will void warranty.

524 590 35 Rev. D KohlerEngines.com

Maintenance Instructions

WARNINGBefore working on engine or equipment, disable engine as follows: 1) Disconnect spark plug lead(s). 2) Disconnect negative (–) battery cable from battery.

Accidental Starts can cause severe injury or death.Disconnect and ground spark plug lead(s) before servicing.

Normal maintenance, replacement or repair of emission control devices and systems may be performed by any repair establishment or individual; however, warranty repairs must be performed by a Kohler authorized dealer found at KohlerEngines.com or 1-800-544-2444 (U.S. and Canada).For safety and health reasons, many states require special licensing or certifi cation for servicing propane fuel systems. Check local and state regulations before choosing a repair establishment to perform fuel system repairs.

Maintenance ScheduleEvery 25 Hours1

● Service/replace low-profi le precleaner (if equipped).Every 100 Hours1

● Check oil cooler fi ns, clean as necessary (if equipped). ● Change oil. ● Replace low-profi le air cleaner element (if equipped). ● Remove cooling shrouds and clean cooling areas.Every 150 Hours1

● Check heavy-duty fi lter minder. ● Inspect heavy-duty air fi lter paper element and inlet screen area.Every 200 Hours1

● Change oil fi lter. ● Replace unique EFI fuel fi lters.Every 300 Hours1

● Replace heavy-duty air cleaner element and check inner element.Every 500 Hours or Annually1

● Check all lines (high pressure/vacuum) including fi ttings for leaks. ● Drain vaporizer/regulator of accumulated fuel deposits. ● Replace spark plugs and set gap.Every 500 Hours or Annually1,2

● Inspect lock-off assembly for damage/leakage. ● Have combustion deposits removed if using non-synthetic oil.Every 600 Hours or Annually1

● Replace heavy-duty air cleaner inner element.Every 1500 Hours1,2

● Have vaporizer/regulator tested.1 Perform these procedures more frequently under severe, dusty, dirty conditions.2 Must be performed by a Kohler authorized dealer or qualifi ed propane personnel only.


Oil RecommendationsSynthetic oil is recommended for use in propane fueled engines. Non-synthetic oil must be low ash* rated oil. Oils (including synthetic) must meet API (American Petroleum Institute) service class SG, SH, SJ, or SL. Select viscosity based on air temperature at time of operation as shown in table below.*Low ash is defi ned as less than 1% sulfated ash.

°F -20 0 20 32 40 6050 80 100

°C -30 -20 -10 0 10 20 30 40

5W-30

10W-30

SAE 30

Check Oil LevelNOTE: To prevent extensive engine wear or

damage, never run engine with oil level below or above operating range indicator on dipstick.

Ensure engine is cool. Clean oil fi ll/dipstick areas of any debris.1. Remove dipstick; wipe oil off. a. Press-in cap: reinsert dipstick into tube;

press completely down.or

b. Thread-on cap: reinsert dipstick into tube; rest cap on tube, do not thread cap onto tube.

2. Remove dipstick; check oil level. Level should be at top of indicator on dipstick.

3. If oil is low on indicator, add oil up to top of indicator mark.

4. Reinstall and secure dipstick.

Change Oil and FilterChange oil while engine is warm.1. Clean area around oil fi ll cap/dipstick and

drain plug. Remove drain plug and oil fi ll cap/dipstick. Allow oil to drain completely.

2. Clean area around oil fi lter. Place a container under fi lter to catch any oil and remove fi lter. Wipe off mounting surface. Reinstall drain plug. Torque to 10 ft. lb. (13.6 N·m).

3. Place new fi lter in shallow pan with open end up. Fill with new oil until oil reaches bottom of threads. Allow 2 minutes for oil to be absorbed by fi lter material.

4. Apply a thin fi lm of clean oil to rubber gasket on new fi lter.

5. Refer to instructions on oil fi lter for proper installation.

6. Fill crankcase with new oil. Level should be at top of indicator on dipstick.

7. Reinstall oil fi ll cap/dipstick and tighten securely.

8. Start engine; check for oil leaks. Stop engine; correct leaks. Recheck oil level.

9. Dispose of used oil and fi lter in accordance with local ordinances.

Oil Sentry™ (if equipped)This switch is designed to prevent engine from starting in a low oil or no oil condition. Oil Sentry™ may not shut down a running engine before damage occurs. In some applications this switch may activate a warning signal. Read your equipment manuals for more information.


Fuel Recommendations

WARNINGExplosive Fuel can cause fi res and severe burns.If a gaseous odor is detected, ventilate area and contact an authorized service technician.

Propane is extremely fl ammable and is heavier than air and tends to settle in low areas where a spark or fl ame 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. To ensure personal safety, installation and repair of propane fuel supply systems must be performed only by qualifi ed propane system technicians. Improperly installed and maintained propane equipment could cause fuel supply system or other components to malfunction, causing gas leaks.Observe federal, state and local laws governing propane fuel, storage, and systems.

This engine is certifi ed to operate on commercial propane (per GPA STD 2140). If you have any questions, contact your propane supplier.Propane from an appropriate propane fuel tank (supplied separately) is required to operate this engine.

Vaporizer/RegulatorIn compliance with government emission standards, vaporizer/regulator is preset at factory to provide proper supply of fuel. No adjustment or resetting of vaporizer/regulator is to be made. All service relating to vaporizer/regulator must be performed by a Kohler authorized dealer or qualifi ed propane personnel only.Vaporizer/regulator can change propane from supply tank to a gaseous/vapor state.Lock-Off assembly opens and closes controlling fuel fl ow from supply tank before reaching vaporizer/regulator. Over time, fuel deposits can accumulate inside vaporizer/regulator. Removing these deposits is recommended. Follow steps below to drain vaporizer/regulators.1. Turn fuel supply valve off, run engine out of

fuel, and turn off ignition switch.2. Disconnect and ground spark plug leads.3. Remove drain plug from bottom of vaporizer/

regulator. Remove any accumulated deposits.

4. Reinstall plug and tighten securely. If required, a replacement plug can be found at KohlerEngines.com.

Fuel LineHigh pressure fuel line meeting a minimum of SAE R7 standard must be installed on Kohler Co. engines equipped with propane EFI system (from vaporizer/regulator to injectors).

Spark Plugs

CAUTIONElectrical Shock can cause injury.Do not touch wires while engine is running.

Clean out spark plug recess. Remove plug and replace.1. Check gap using wire feeler gauge. Adjust

gap, see specifi cation table for adjustment.2. Install plug into cylinder head.3. Torque plug to 20 ft. lb. (27 N·m).

Electronic Fuel Injection (EFI) SystemEFI is an electronically-controlled fuel management system which is monitored by an Electronic Control Unit (ECU). A Malfunction Indicator Light (MIL) will illuminate if problems or faults are detected. Servicing by a Kohler authorized dealer is necessary.

Fuel System ComponentsEngines are equipped with special EFI fuel fi lters. See Maintenance Schedule.

Fuse ReplacementThis engine has three (3) blade type automotive fuses. Replacement fuses must have same rating as blown fuse. Use fuse chart below to determine correct fuse.

Wire Color Fuse Rating

2 Solid Red Wires 10-amp Fuse

1 Red Wire with Black Stripe1 Red Wire with White Stripe

10-amp Fuse

2 Purple Wires 30-amp Fuse


Air CleanerNOTE: Operating engine with loose or

damaged air cleaner components could cause premature wear and failure. Replace all bent or damaged components.

NOTE: Paper element cannot be blown out with compressed air.

Low-Profi leLoosen knob and remove air cleaner cover.Precleaner:1. Remove precleaner from paper element.2. Replace or wash precleaner in warm water

with detergent. Rinse and allow to air dry.3. Saturate precleaner with new engine oil;

squeeze out excess oil.4. Reinstall precleaner over paper element.Paper Element:1. Clean area around element. Remove wing

nut, element cover, and paper element with precleaner.

2. Separate precleaner from element; service precleaner and replace paper element.

3. Check condition of rubber seal and replace if necessary.

4. Install new paper element on base; install precleaner over paper element; reinstall element cover and secure with wing nut.

Reinstall air cleaner cover and secure with knob.Heavy-Duty1. Unhook retaining clips and remove end

cap(s).2. Check and clean inlet screen (if equipped).3. Pull air cleaner element out of housing and

replace. Check condition of inner element; replace when dirty.

4. Check all parts for wear, cracks, or damage, and that ejector area is clean.

5. Install new element(s).6. Reinstall end cap(s) with dust ejector valve/

screen down; secure with retaining clips.

Breather Tube (if equipped)Ensure end of breather tube is properly connected.

Oil Cooler (if equipped)1. Clean fi ns with a brush or compressed air.2. Remove two screws securing oil cooler, and

tilt to clean back side.3. Reinstall oil cooler.

Air Cooling

WARNINGHot Parts can cause severe burns.Do not touch engine while operating or just after stopping.

Never operate engine with heat shields or guards removed.

Proper cooling is essential. To prevent over heating, clean screens, cooling fi ns, and other external surfaces of engine. Avoid spraying water at wiring harness or any electrical components. See Maintenance Schedule.

Repairs/Service PartsWe recommend that you use a Kohler authorized dealer for all maintenance, service, and engine parts. To fi nd a Kohler authorized dealer visit KohlerEngines.com or call 1-800-544-2444 (U.S. and Canada).

Leakage Check/TestingWith fuel valve fully opened, engine not running, turn key switch ON. Check all fuel system connections and lines for leaks using soapy water. Any leakage must be corrected before restarting engine. Have service performed by a Kohler authorized dealer or qualifi ed propane personnel only.

StorageIf engine will be out of service for 2 months or more follow procedure below.1. Change oil while engine is still warm from

operation. Remove spark plug(s) and pour about 1 oz. of engine oil into cylinder(s). Replace spark plug(s) and crank engine slowly to distribute oil.

2. Disconnect negative (-) battery cable.3. Separate propane tank from unit and store

separately in an area designated for safe propane tank storage.

4. Store engine in a clean, dry place.


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Engine Specifi cations

Model Bore Stroke Displacement Oil Capacity (Refi ll)

Spark Plug Gap

Maximum Angle of Operation

(@ full oil level)*

PCH680

3.27 in. (83 mm)

2.72 in. (69 mm)

45.6 cu. in. (747 cc)

1.7-2.0 U.S. qt. (1.6-1.9 L)

0.03 in. (0.76 mm) 25°

PCV680PCH740PCV740

*Exceeding maximum angle of operation may cause engine damage from insuffi cient lubrication.Additional specifi cation information can be found in service manual at KohlerEngines.com.Exhaust Emission Control System for propane EFI models PCH680, PCH740, and PCV680, PCV740 is EM, O2S, ECM, MPI for U.S. EPA, California, and Europe.Any and all horsepower (hp) references by Kohler are Certifi ed Power Ratings and per SAE J1940 & J1995 hp standards. Details on Certifi ed Power Ratings can be found at KohlerEngines.com.

Table of Contents SECTION 1.1: APPLICATIONS...........................................................................4 SECTION 1.2: SPECIFICATIONS .......................................................................4 SECTION 1.3: MANUFACTURER.......................................................................4 SECTION 2.1: GENERAL....................................................................................6 SECTION 2.2: MAINTENANCE AND WEAR PART REPLACEMENT MODES ..6 SECTION 2.3: WORK SITE ASSESSMENT AND INSPECTION ........................7 SECTION 2.4: PERSONAL PROTECTIVE EQUIPMENT (PPE) .........................9 SECTION 2.5: OPERATIONAL SAFETY...........................................................10 SECTION 3.1: START-UP .................................................................................12

FIGURE 3.1.1 ..............................................................................................13 SECTION 3.2: SHUT DOWN.............................................................................13 SECTION 3.3: BLADE SELECTION..................................................................14

FIGURE 3.3.1 ..............................................................................................14 FIGURE 3.3.2 ..............................................................................................14 FIGURE 3.3.3 ..............................................................................................15

SECTION 3.4: TRANSPORT.............................................................................15 SECTION 4.1: MAINTENANCE INTERVALS ....................................................17 SECTION 4.2: TROUBLESHOOTING ...............................................................18 SECTION 4.3: RECOMMENDED SPARE PARTS ............................................19 SECTION 4.4: RECOMMENDED TOOLS .........................................................19 SECTION 4.5: HYDRAULIC SCHEMATIC ........................................................20 SECTION 4.6: ELECTRIC SCHEMATIC ...........................................................22 SECTION 4.7: PARTS LIST ..............................................................................23 SECTION 4.8: ENGINE OWNER’S AND SERVICE MANUALS........................24

MACHINE MANUAL BRB-2800SPECIFICATIONS

© 2010 Blastpro Manufacturing Inc.®

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SECTION 1.1: APPLICATIONS SECTION 1.2: SPECIFICATIONS SECTION 1.3: MANUFACTURER

MACHINE MANUAL BRB-2800SPECIFICATIONS


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SECTION 1.1: APPLICATIONS The BRB-2800 is specifically designed to remove coatings and coverings from horizontal surfaces. Coatings may include glue, epoxies and cementitious overlays. Coverings may include carpet, ceramic tile, VCT and wood flooring. A wide variety of tools are available from Blastpro® for your specific application. In general, the BRB-2800 uses sharpened spring steel blades along with the weight of the machine itself to perform the scraping function. The variable angle of attack allows for a great deal of flexibility when dealing with different floor coatings. SECTION 1.2: SPECIFICATIONS Dimensions (L x W x H) 74” x 30” x 68” (1880mm x 762mm x 1727.5mm) Weight 2800 lbs (1270 kg) Fuel Liquid Propane Fuel Capacity 33 lb. Engine 27 HP Kohler Electrical System 12 VDC Blade Actuation Hydraulic Steering Hydraulic Ground Drive Hydraulic Blade Widths 2” through 36” SECTION 1.3: MANUFACTURER

Blastpro Manufacturing 6021 Melrose Lane

Oklahoma City, OK 73127 Toll free: 877-495-6464 Phone: 405-491-6464

Fax: 405-495-4994 Website: www.BlastProMfg.com

MACHINE MANUAL BRB-2800SAFETY


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SECTION 2.1: GENERAL

SECTION 2.2: MAINTENANCE AND WEAR PARTS REPLACEMENT MODES

SECTION 2.3: WORK SITE ASSESSMENT AND INSPECTION

SECTION 2.4: PERSONAL PROTECTIVE EQUIPMENT

SECTION 2.5: OPERATIONAL SAFETY



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SECTION 2.1: GENERAL Read and understand this Machine Manual prior to operating or performing maintenance on the BRB-2800. This Machine Manual has been developed as a guideline for machine operation. It is not a substitute for proper organizational training and management. All machine operators and maintenance personnel should be properly trained in operation and safety features of the BRB-2800. Make these operating instructions accessible to all operating and maintenance personnel. Never weld, modify, cut or grind components of the BRB-2800 without prior written consent from the manufacturer. Never use aggressive cleaning chemicals to clean the machine. All operators and maintenance personnel should receive training on the dangers of carbon monoxide, or CO. All personnel should be able to identify signs and symptoms of CO poisoning. Common signs associated with overexposure include headache, nausea, weakness, dizziness, lethargy, visual disturbances, and changes in personality and/or loss of consciousness. SECTION 2.2: MAINTENANCE AND WEAR PART REPLACEMENT MODES Maintenance mode is defined as placing the machine in a configuration, which minimizes potential electric, hydraulic or stored energy hazards. In general, the machine should be placed in Maintenance Mode prior to performing any maintenance and/or troubleshooting activities. MAINTENANCE MODE:

1. Move the machine to a level surface. 2. Reduce machine RPM to low idle. 3. Turn key switch to “OFF” position. 4. Remove key from switch to prevent accidental or unintended starting. 5. Block wheels to prevent the machine from moving. 6. Turn the LP bottle valve to “CLOSED” position. 7. Allow engine and exhaust tube to cool down prior to carrying out any

maintenance work.



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In general, the machine should be placed in Wear Parts Replacement Mode prior to changing the blade(s). WEAR PARTS REPLACEMENT MODE:

1. Move the machine to a level surface. 2. Raise the blade holder so the blade is off of the ground. 3. Reduce machine RPM to low idle. 4. Turn key switch to “OFF” position. 5. Remove key from switch to prevent accidental or unintended starting. 6. Loosen appropriate bolts and replace blade(s).

After performing any maintenance or repair work verify that all safety labels, guards, lids and bolted connections are properly and securely installed on the machine. SECTION 2.3: WORK SITE ASSESSMENT AND INSPECTION Before starting scrapping operations, a site assessment must be performed. During the site assessment verify the following:

Work area is flat, clean, and dry, free of debris, frost-free, and has no flammable liquids nearby. Also, make sure that the machine will be able to clear all obstructions. NEVER SCRAPE OVER BOLTS, NUTS, SCREWS, NAILS, OR OTHER DEBRIS AS THIS MAY RESULT IN SIGNIFICANT DAMAGE TO THE MACHINE AND SERIOUS INJURY TO THE OPERATOR.

Work area is well ventilated. IF WORK AREA IS ENCLOSED OR PARTIALLY ENCLOSED (WAREHOUSE, PARKING GARAGE, TUNNELS, ETC.), this is because carbon monoxide, which is a byproduct all internal combustion engines, can be extremely hazardous when allowed to accumulate in an area. An odorless, tasteless, and non-irritating gas, carbon monoxide can quickly become lethal. As a result, liquid propane must be used in all instances when the work area is enclosed or partially enclosed

Each worker has a carbon monoxide monitor on their persons. These carbon monoxide monitors should be calibrated, in working order, and should be equipped with audible alarms that will warn workers if carbon monoxide levels become too high. IF CARBON MONOXIDE LEVELS EXCEED 35 PARTS PER MILLION, ALL WORK MUST CEASE IMMEDIATELY! THIS REPRESENTS A POTENTIALLY DEADLY SITUATION WHICH NECESSITATES AN IMMEDIATE SHUTDOWN!

All workers have received training on the dangers of overexposure to carbon monoxide. Staff members must also be able to identify all of the



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signs and the symptoms associated with carbon monoxide poisoning. This training should ensure that work would stop immediately and emergency medical personnel would be notified promptly if one or more workers exhibited or complained of any of the common signs and symptoms associated with carbon monoxide overexposure, including: headache, nausea, weakness, dizziness, lethargy, visual disturbances, changes in personality, and/or loss of consciousness.

All operators and other personnel within the work area have received training on proper ventilation procedures and on proper operation procedures for the engine and for other types of equipment.

FLOORS HAVE BEEN THOROUGLY INSPECTED. SOME FLOOR OR DECK SURFACES MAY BE COATED WITH OR CONTAMINATED BY DANGEROUS MATERIALS SUCH AS:

o PCBs o LEAD o ASBESTOS o PESTICIDES o SOLVENTS o CLEANING FLUIDS o AND/OR OTHER HARMFUL CHEMICALS

DISTURBING SUCH SURFACES CAN CREATE A SERIOUS HEALTH THREAT TO THOSE WHO INHALE OR COME INTO CONTACT WITH THE DUST. THE WORK AREA MUST BE CHECKED FOR THESE MATERIALS BEFORE WORK CAN BEGIN. BLASTPRO MANUFACTURING, INC. DOES NOT WARRANT ITS EQUIPMENT TO BE SUITABLE FOR, OR APPROVED FOR, REMOVING DANGEROUS MATERIALS. IT IS THEREFORE THE RESPONSIBILITY OF THE CONTRACTOR TO CONFIRM THE SAFETY OF THE WORK AREA AND THE EQUIPMENT WITH THE PROPER AUTHORITIES. IT IS ALSO THE RESPONSIBILITY OF THE CONTRACTOR TO WARN ALL STAFF MEMBERS OF ALL THE POTENTIAL SHORT-TERM AND LONG-TERM HEALTH RISKS ASSOCIATED WITH INHALING AND COMING INTO CONTACT WITH DANGEROUS MATERIALS. THE CONTRACTOR IS RESPONSIBLE FOR PROTECTING ALL WORKERS FROM BEING EXPOSED TO DANGEROUS MATERIALS.

Operator and any other personnel in the work area are wearing safety glasses with side shields, dust masks, ear plugs, hard hats, steel toed work boots, long sleeved shirts, tight fitting clothing, and gloves. It is also imperative for staff to tie back long hair and to remove all jewelry.

Work area has been blocked off to pedestrians, unprotected personnel, and untrained personnel. In the event pedestrians, unprotected



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personnel, or untrained personnel enter the work area, blasting operations are to be stopped immediately.

Fire extinguishers are nearby. Also, take note of the location and the contact information of fire departments close to the work site.

Belt guards are in working order and are present on the machine where needed. All glass and equipment, including vehicles, are protected from debris. This can

be done by loosely hanging a sheet of visqueen or other protective material in front of the glass or equipment in a curtain-like fashion.

Plug or cover all floor drains to prevent steel shot from falling into the drains. The operator must be aware of their surroundings and use common sense. THE

OPERATOR IS NOT TO OPERATE THE EQUIPMENT IF HE IS TIRED, DISTRACTED, OR UNDER THE INFLUENCE OF DRUGS, ALCOHOL, OR MEDICATION THAT DECREASES AWARENESS!

SECTION 2.4: PERSONAL PROTECTIVE EQUIPMENT (PPE) All personnel working with, or in the vicinity of the BRB-2800 should, at a minimum, utilize the following PPE:

Protective boots or shoes Eye protection with side shields Hearing protection Appropriate respiratory protection Protective leather gloves for handling blades

Additionally, all personnel should utilize a carbon monoxide monitor while working indoors. The BRB-2800 utilizes an internal combustion engine, which produces carbon monoxide, or CO. CO can be fatal at high exposure levels. In addition to CO monitoring equipment, the work site should be properly ventilated to minimize exposure potential. All personnel should observe PPE requirements particular to each job site.



10

SECTION 2.5: OPERATIONAL SAFETY

Support personnel must keep a safe distance from the machine while it is in operation. Do not stand in front of, or behind the machine while in operation.

The blade should only be actuated up and down with the operator properly seated on the machine.

Do not drive the machine with the scraper blade more than ½” off of the floor.

Verify that the LP tank is properly seated on the brackets, with the alignment pin properly located in slot or hole on tank.

The operator must be aware of their surroundings. No personnel should operate or perform maintenance on the machine if they are tired, distracted or under the influence of drugs, alcohol or medication that decreases awareness.

Verify that all protective guards and covers are properly installed and secured.

Verify that there is sufficient light for the operator to view the work surface. The machine is equipped with headlights to provide additional lighting.

MACHINE MANUAL BRB-2800OPERATION


11

SECTION 3.1: START-UP

SECTION 3.2: SHUT DOWN

SECTION 3.3: BLADE SELECTION

SECTION 3.4: TRANSPORT



12

SECTION 3.1: START-UP

Only trained, authorized personnel should be allowed to run the BRB-2800. If training is needed, please consult with your Blastpro Manufacturing representative or authorized distributor.

Prior to start-up, the work surface should be inspected for hidden studs, electrical boxes, or any other hidden obstructions. These items should be removed or clearly marked so they can be avoided.

To move machine: 1. Verify that LP bottle is installed and has fuel in it.2. Verify that the LP bottle valve is turned to the “OPEN” position.3. Operator should be firmly seated in the operator’s seat.4. Verify that the left and right control levers are in the center position.5. Turn the key switch to start until the motor starts.6. Move the throttle knob down to full throttle. A detent will engage at the

proper setting.7. Push rocker switch on the left control lever to raise the blade.8. Push levers forward to move forward; pull backward to reverse. Varying

positions of the left and right control levers will turn the BRB-2800 left andright.

9. Move machine to desired location.

Normal Operation: 1. Verify LP bottle has fuel in it.2. Verify that the LP bottle valve is open.3. Insert selected blade into blade holder (see SECTION 3.3: BLADE

SELECTION). Always wear leather gloves and use caution whenhandling the blades.

4. Operator should be firmly seated in the operator’s seat5. Verify that the left and right control levers are in the center position.6. Turn the key switch to start until the motor starts.7. Move the throttle knob down to full throttle. A detent will engage at the

proper setting.8. Push rocker switch on left control lever to adjust the blade angle. Some

materials may require more pressure on blade for removal. This can beaccomplished with a higher angle on the blade holder.

9. Move control levers forward to start removal. It is recommended to makea single pass in one direction to expose an edge of the material to beremoved. Subsequent passes should be made perpendicular to the initialpass. See FIGURE 3.1.1.



13

1

2

3

4

5

6

7

8

9

FIGURE 3.1.1

SECTION 3.2: SHUT DOWN

At end of shift or work day: 1. Move machine to level ground for storage.2. Use the rocker switch in the left control lever to lower the cylinders until

the front caster lifts off of the ground.3. Pull throttle up to low idle.4. Turn key switch to “OFF” position.5. Remove key to protect against unauthorized operation.6. Turn the LP bottle valve to “CLOSED” position.

For long term storage: 1. Move machine to level ground in a secure location for storage.2. Lift blade to upper-most position.3. Pull throttle up to low idle.4. Turn key switch to off position.5. Remove the blade and/or the blade holder from the front of the machine.6. Turn key switch to start position until the motor starts.7. Use the rocker switch on the left control lever to lower the cylinders until

the front caster lifts off of the ground.8. Turn key switch to off position.9. Remove the key to protect against unauthorized operation.10. Turn the LP bottle valve to “CLOSED” position.11. Remove LP bottle and store in a secure location.12. Cover the BRB-2800 to protect it from dust and moisture.



14

SECTION 3.3: BLADE SELECTION

Selecting the proper blade for the application will have a dramatic effect on machine efficiency. If a blade is too wide for the application, there may not be enough pressure on the blade to stay under the material to be removed. If the blade is too narrow, the machine may not be removing the maximum material it is capable of in a single pass.

Based on information about a particular job, start with the widest blade that may be appropriate for removal. Make a test pass to determine if the blade will stay under the material. If so, continue with this selected blade. If removal of the material is relatively easy, consider moving to a larger blade. If it is difficult to stay under the material, move to a narrower blade.

Always wear leather gloves and use caution when handling blades.

In general, flat blades should be used for scraping glues, mastics, epoxies and thinsets. SEE FIGURE 3.3.1.

FIGURE 3.3.1

For carpet, rubberized and elastomeric coatings, a carpet blade should be utilized. The 90° wings on each end of the blade will help keep the removed material manageable. SEE FIGURE 3.3.2.

FIGURE 3.3.2



15

Blastpro offers a carbide tipped tool for tile removal. This can be inserted into the 3-hole tool adapter on the blade holder. SEE FIGURE 3.3.3

FIGURE 3.3.3

SECTION 3.4: TRANSPORT

Only use factory installed tie-down/lifting lugs when transporting or moving the equipment. These are located at the front of the machine, near the blade, and at the rear of the machine, under the motor mounting plate.

Never secure the machine with straps or chains across the hydraulic cylinders. This can result in damage to the cylinders or premature wear.

Verify that lifting straps or chains are rated for the weight of the machine.

Verify that trailer or truck bed is rated for the weight of the machine.

Remove scraper blade and/or pivoting blade holder prior to securing for transport.

Verify that the blade holder is lowered and that the front swivel caster is off of the truck or trailer bed.

Never allow personnel to stand under the machine when it is being lifted.

Verify that LP bottle valve is in “CLOSED” position and that the bottle is securely stored during transport.

MACHINE MANUAL BRB-2800MAINTENANCE


16

SECTION 4.1: MAINTENANCE INTERVALS

SECTION 4.2: TROUBLESHOOTING

SECTION 4.3: RECOMMENDED SPARE PARTS

SECTION 4.4: RECOMMENDED TOOLS

SECTION 4.5: HYDRAULIC SCHEMATIC

SECTION 4.6: ELECTRIC SCHEMATIC

SECTION 4.7: PARTS LIST

SECTION 4.8: ENGINE OWNER’S AND SERVICE MANUALS



17

SECTION 4.1: MAINTENANCE INTERVALS

Daily, or at the beginning of each shift

Never inspect a pressurized hydraulic system with your hand. Pinhole leaks can inject hydraulic fluid into the body, which can result in serious injury. If additional assistance is required consult your Blastpro representative, authorized Blastpro distributor, or qualified hydraulic systems professional.

Always wear leather gloves and use caution when handling blades.

1. Check engine oil.2. Check hydraulic oil level.3. Inspect hydraulic oil cooler for obstructions (dirt, paper, etc.).4. Inspect hydraulic components and hoses for leaks or abrasions.5. Inspect engine air filter*.6. Inspect belts for proper tension.7. Inspect blades for excessive wear.8. Check air intake and cooling areas*.9. Inspect drive wheels for wear.

Every 25 Hours

1. Service engine pre-cleaner element*.2. Grease all blade and cylinder pivot pins.

Every 50 Hours 1. Change hydraulic oil filter.2. Top off hydraulic oil tank.3. Tighten rear wheel nuts4. Grease front caster and inspect for wear or damage.5. Blow out hydraulic oil cooler fins.

Every 100 Hours

1. Replace engine air cleaner element*.2. Change engine oil*.3. Replace engine oil filter*.

*Perform these maintenance activities more frequently under extremely dusty,dirty conditions.



18

SECTION 4.2: TROUBLESHOOTING

PROBLEM POSSIBLE CAUSE REMEDYEngine will not start LP tank is empty

LP tank valve is closed

Battery is dead

Cold conditions

Incorrect oil level

Dirty air cleaner Faulty spark plug

Replace with a full tank Turn LP valve to “OPEN” position Jump start machine or replace battery Work throttle back and forth while turning key switch to “START” Check oil level and fill/remove as necessary Clean/replace air cleaner Replace/re-gap spark plug

Engine seems sluggish during operation

Throttle not set in high position Incorrect oil level

Dirty air cleaner

Move throttle to high position Check oil level and fill/remove as necessary Clean/replace air cleaner

Slow coating removal Blade is dull Blade is too wide

Incorrect blade angle

Flip or replace blade Replace with narrower blade Adjust blade angle up or down with hydraulic cylinders

Cylinder movement seems slow

Dirt in cylinder control spool valve

Damaged cylinder

Consult Blastpro representative or authorized distributor

Ground speed seems slow

Throttle not set in high position Damage to ground drive pump or motor

Move throttle to high position Consult Blastpro representative or authorized distributor



19

SECTION 4.3: RECOMMENDED SPARE PARTS

It is recommended that the machine owner/operator keep a minimum of spare parts with the machine while it is working. Down time due to part failure or lack of wear parts can far exceed the cost of the parts.

PART NUMBER DESCRIPTION QUANTITY BTP000451 6” CARPET REMOVAL BLADE Depends on size of job BTP000553 8” CARPET REMOVAL BLADE Depends on size of job BTP000554 10” CARPET REMOVAL BLADE Depends on size of job BTP000555 12” CARPET REMOVAL BLADE Depends on size of job BTP000853 6” TILE BLADE Depends on size of job BTP000854 8” TILE BLADE Depends on size of job BTP000855 12” TILE BLADE W/ BEVEL Depends on size of job BTP000886 10” TILE BLADE W/ BEVEL Depends on size of job

SECTION 4.4: RECOMMENDED TOOLS

“Recommended Tools” is a list of the minimum tools necessary to maintain and/or operate the BRB-2800 during normal operation. This list is not meant to be exhaustive or to indicate the tools required for more intensive maintenance.

Ratchet Sockets: 7/16”, 1/2”, 9/16” and 3/4” Combination wrench: 7/16”, 1/2”, 9/16” and 3/4” Utility knife Rubber mallet or dead blow hammer Leather gloves



20

SECTION 4.5: HYDRAULIC SCHEMATIC



21

ITEM PART NUMBER QTY DESCRIPTION 1 BP85000504 1 HYDRAULIC TANK2 BP85000012 1 JOYSTICK 3-POS SWITCH3 BP85000011 1 JOYSTICK – STANDARD4 BP85000007 1 PUMP – HYDRAULIC 5 BP85000003 2 GROUND DRIVE MOTOR6 SCR0003 2 HYRDAULIC CYLINDER7 1 PO CHECK VALVE 8 BP85000009 1 VALVE/LIFT CYLINDER9 BP85000010 1 EQUALING VALVE10 BP85000001 1 HYDRAULIC COOLER11 BP85000008 1 FILTER



22

SECTION 4.6: ELECTRIC SCHEMATIC



23

SECTION 4.7: PARTS LIST

PART NUMBER DESCRIPTION QTY BP85000001 HYDRAULIC COOLER 1 BP85000004 BANDED BELT 1 BP85000002 SPLINE COUPLING 1 BP85000003 GROUND DRIVE MOTOR 2 BP85000006 BLADE PIVOT PIN BRB-2800 1 BP85000007 PUMP-HYDRAULIC 1 BP85000008 FILTER 1 BP85000009 VALVE LIFT CYL. 1 BP85000011 JOYSTICK STANDARD 1 BP85000012 JOYSTICK 3 POS SWITCH 1 BP85000546 25HP MOTOR (VAPOR) 1 BTP001409-27HP 27HP MOTOR (LIQUID) 1 BT-07100007 TACH/HOUR METER 1 BTP003048 EXHAUST PURIFIER/W 1 1/2 INLET 1 BTP001409-13 REGULATOR 25HP/KOHLER 1 BTP001409-8 VAPORIZER ASSY/W FILTER 1 BP85000529 THROTTLE CABLE 1 SCR0038 WHEEL/TRACTION DRIVE 2 BTP000257 CASTER/SWIVEL 6.00X3.0 W/1.0 T 1 SCR0003 HYDRAULIC BLADE CYLINDER 2 ZT-00053 ENGINE SHEAVE 1 BT06300025 TAPERLOCK BUSHING 1 ZT-00024 12V LED WORK LIGHTS 2 SCR0031 PROPANE BOTTLE BRACKETS 1 SCR0016 UPPER CYLINDER PIN 2 SCR0015 LOWER CYLINDER PIN 2 BT03400013 E CLIP/FOR 1.0" OD SHAFT .822 12 BT06150031 PUMP SHEAVE 1 ZT-00056 TAPERLOCK BUSHING 1 ZT-00058 NEEDLE BEARING 1 BP80000504 HM IDLER BRACKET 1 ZT-00060 SO2 SHAFT 1 BTP002439 WIRING HARNESS 1 BP85000532 IDLER PULLEY 1



24

SECTION 4.8: ENGINE OWNER’S AND SERVICE MANUALS

BRB-2800 PARTS ILLUSTRATIONS

1

HIGH BACK SEAT #SCR0020

JOYSTICK 3 POS SWITCH #BP85000012

JOYSTICK STANDARD #BP85000011

12V LED WORK LIGHTS #ZT-00024

HYDRAULIC BLADE CYLINDER #SCR0003

UPPER CYLINDER PIN #SCR0016

LOWER CYLINDER PIN #SCR0015


2

HIGH BACK SEAT #SCR0020

JOYSTICK 3 POS SWITCH #BP85000012

JOYSTICK STANDARD #BP85000011

HYDRAULIC BLADE CYLINDER #SCR0003

HYDRAULIC HOSE KIT #BP85000526

HYDRAULIC PUMP #BP85000007

TRACTION DRIVE TIRE #SCR0038


3

HYDRAULIC COOLER #BP85000001

25HP VAPOR INJECTED ENGINE #BP85000546

SWIVEL CASTER #BTP000257

12” BLADE HOLDER #BT06-7050-12

EXHAUST PURIFIER #BTP003048


Owner's Manual

IMPORTANT: Read all safety precautions and instructions carefully before operating equipment. Refer to operating instruction of equipment that this engine powers.

Ensure engine is stopped and level before performing any maintenance or service.

Warranty coverage as outlined in warranty card and on KohlerEngines.com. Please review carefully as it provides you specifi c rights and obligations.

To maintain compliance with applicable emission regulations, exhaust system backpressure may not exceed limits which can be found on KohlerEngines.com. Search by Model No., select Read More, then select Specs tab.

Record engine information to reference when ordering parts or obtaining warranty coverage.

Engine Model

Specifi cation

Serial Number

Purchase Date

PCH680, PCH740PCV680, PCV740Propane Electronic Fuel Injection (EFI)


Safety Precautions WARNING: A hazard that could result in death, serious injury, or substantial property damage.

CAUTION: A hazard that could result in minor personal injury or property damage.

NOTE: is used to notify people of important installation, operation, or maintenance information.


Propane is extremely fl ammable and is heavier than air and tends to settle in low areas where a spark or fl ame 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.To ensure personal safety, installation and repair of propane fuel supply systems must be performed only by qualifi ed propane system technicians. Improperly installed and maintained propane equipment could cause fuel supply system or other components to malfunction, causing gas leaks.Observe federal, state and local laws governing propane fuel, storage, and systems.



WARNINGHigh Pressure Fluids can puncture skin and cause severe injury or death.Do not work on fuel system without proper training or safety equipment.

Fluid puncture injuries are highly toxic and hazardous. If an injury occurs, seek immediate medical attention.




California Proposition 65 WarningEngine exhaust from this product contains chemicals known to State of California to cause cancer, birth defects, or other reproductive harm.

WARNINGAccidental Starts can cause severe injury or death.Disconnect and ground spark plug lead(s)before servicing.

Before working on engine or equipment, disable engine as follows: 1) Disconnect spark plug lead(s). 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 ground cable terminal which could cause an explosion if hydrogen gas or propane fuel vapors are present.



California Proposition 65 WarningThis product contains chemicals known to State of California to cause cancer, birth defects, or other reproductive harm.


I

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F

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N

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D

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C

H

Q

Y

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Z

AB

U

WR

AC

VX

AD

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A End Cap B Element C Inner Element D Retaining Clip

E Inlet Screen F Air Cleaner Housing G Ejector Area H Heavy-Duty Air

Cleaner

I Air Cleaner Knob J Wing Nut K Air Cleaner

Cover L Element Cover

M Precleaner N Paper Element O Air Cleaner Base P Rubber Seal

Q Low-Profi le Air Cleaner R Debris Screen S Oil Filter T Vaporizer/

Regulator

UVaporizer/

Regulator Inlet Filter

VVaporizer/

Regulator Drain Plug

W Lock-Off X Unique EFI Fuel Filter

Y Spark Plug Z Oil Cooler AA Oil Fill/Dipstick AB Filter Minder

AC Oil Fill AD Oil Drain Plug AE DipstickVisit KohlerEngines.com for service parts information and purchasing options.


Pre-Start Checklist1. Check oil level. Add oil if low. Do not overfi ll.2. Check fuel gauge (if equipped). If propane

tank is low, have it refi lled. Check fuel system components and lines for leaks.

3. Check and clean cooling areas, air intake areas and external surfaces of engine (particularly after storage).

4. Check that air cleaner components and all shrouds, equipment covers, and guards are in place and securely fastened.

5. Check spark arrestor (if equipped).

Starting





NOTE: Do not crank engine continuously for more than 10 seconds. Allow a 60 second cool down period between starting attempts. Failure to follow these guidelines can burn out starter motor.

NOTE: Upon start-up, a metallic ticking may occur. Run engine for 5 minutes. If noise continues, run engine at mid throttle for 20 minutes. If noise persists, take engine to your local Kohler authorized dealer.

1. Place throttle control midway between slow and fast positions.

2. Slowly turn fuel valve on propane tank to full open position.

3. Turn key switch to START position. Release switch as soon as engine starts. If starter does not turn engine over, shut off key switch immediately. Do not make further attempts to start engine until condition is corrected. Do not jump start. See your Kohler authorized dealer for trouble analysis.

Cold Weather Starting Hints1. Use proper oil for temperature expected.2. Disengage all possible external loads.

Stopping1. If possible, remove load by disengaging all

PTO driven attachments.2. Turn fuel valve to full closed position and

allow engine to continue running until it runs out of fuel. Turn key switch to OFF position.

Angle of OperationRefer to operating instructions of equipment this engine powers. Do not operate this engine exceeding maximum angle of operation; see specifi cation table. Engine damage could result from insuffi cient lubrication.

Engine SpeedNOTE: Do not tamper with governor setting to

increase maximum engine speed. Overspeed is hazardous and will void warranty.


Maintenance Instructions

WARNINGBefore working on engine or equipment, disable engine as follows: 1) Disconnect spark plug lead(s). 2) Disconnect negative (–) battery cable from battery.

Accidental Starts can cause severe injury or death.Disconnect and ground spark plug lead(s) before servicing.

Normal maintenance, replacement or repair of emission control devices and systems may be performed by any repair establishment or individual; however, warranty repairs must be performed by a Kohler authorized dealer found at KohlerEngines.com or 1-800-544-2444 (U.S. and Canada).For safety and health reasons, many states require special licensing or certifi cation for servicing propane fuel systems. Check local and state regulations before choosing a repair establishment to perform fuel system repairs.

Maintenance ScheduleEvery 25 Hours1

● Service/replace low-profi le precleaner (if equipped).Every 100 Hours1

● Check oil cooler fi ns, clean as necessary (if equipped). ● Change oil. ● Replace low-profi le air cleaner element (if equipped). ● Remove cooling shrouds and clean cooling areas.Every 150 Hours1

● Check heavy-duty fi lter minder. ● Inspect heavy-duty air fi lter paper element and inlet screen area.Every 200 Hours1

● Change oil fi lter. ● Replace unique EFI fuel fi lters.Every 300 Hours1

● Replace heavy-duty air cleaner element and check inner element.Every 500 Hours or Annually1

● Check all lines (high pressure/vacuum) including fi ttings for leaks. ● Drain vaporizer/regulator of accumulated fuel deposits. ● Replace spark plugs and set gap.Every 500 Hours or Annually1,2

● Inspect lock-off assembly for damage/leakage. ● Have combustion deposits removed if using non-synthetic oil.Every 600 Hours or Annually1

● Replace heavy-duty air cleaner inner element.Every 1500 Hours1,2

● Have vaporizer/regulator tested.1 Perform these procedures more frequently under severe, dusty, dirty conditions.2 Must be performed by a Kohler authorized dealer or qualifi ed propane personnel only.


Oil RecommendationsSynthetic oil is recommended for use in propane fueled engines. Non-synthetic oil must be low ash* rated oil. Oils (including synthetic) must meet API (American Petroleum Institute) service class SG, SH, SJ, or SL. Select viscosity based on air temperature at time of operation as shown in table below.*Low ash is defi ned as less than 1% sulfated ash.

°F -20 0 20 32 40 6050 80 100

°C -30 -20 -10 0 10 20 30 40

5W-30

10W-30

SAE 30

Check Oil LevelNOTE: To prevent extensive engine wear or

damage, never run engine with oil level below or above operating range indicator on dipstick.

Ensure engine is cool. Clean oil fi ll/dipstick areas of any debris.1. Remove dipstick; wipe oil off. a. Press-in cap: reinsert dipstick into tube;

press completely down.or

b. Thread-on cap: reinsert dipstick into tube; rest cap on tube, do not thread cap onto tube.

2. Remove dipstick; check oil level. Level should be at top of indicator on dipstick.

3. If oil is low on indicator, add oil up to top of indicator mark.

4. Reinstall and secure dipstick.

Change Oil and FilterChange oil while engine is warm.1. Clean area around oil fi ll cap/dipstick and

drain plug. Remove drain plug and oil fi ll cap/dipstick. Allow oil to drain completely.

2. Clean area around oil fi lter. Place a container under fi lter to catch any oil and remove fi lter. Wipe off mounting surface. Reinstall drain plug. Torque to 10 ft. lb. (13.6 N·m).

3. Place new fi lter in shallow pan with open end up. Fill with new oil until oil reaches bottom of threads. Allow 2 minutes for oil to be absorbed by fi lter material.

4. Apply a thin fi lm of clean oil to rubber gasket on new fi lter.

5. Refer to instructions on oil fi lter for proper installation.

6. Fill crankcase with new oil. Level should be at top of indicator on dipstick.

7. Reinstall oil fi ll cap/dipstick and tighten securely.

8. Start engine; check for oil leaks. Stop engine; correct leaks. Recheck oil level.

9. Dispose of used oil and fi lter in accordance with local ordinances.

Oil Sentry™ (if equipped)This switch is designed to prevent engine from starting in a low oil or no oil condition. Oil Sentry™ may not shut down a running engine before damage occurs. In some applications this switch may activate a warning signal. Read your equipment manuals for more information.


Fuel Recommendations


Propane is extremely fl ammable and is heavier than air and tends to settle in low areas where a spark or fl ame 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. To ensure personal safety, installation and repair of propane fuel supply systems must be performed only by qualifi ed propane system technicians. Improperly installed and maintained propane equipment could cause fuel supply system or other components to malfunction, causing gas leaks.Observe federal, state and local laws governing propane fuel, storage, and systems.

This engine is certifi ed to operate on commercial propane (per GPA STD 2140). If you have any questions, contact your propane supplier.Propane from an appropriate propane fuel tank (supplied separately) is required to operate this engine.

Vaporizer/RegulatorIn compliance with government emission standards, vaporizer/regulator is preset at factory to provide proper supply of fuel. No adjustment or resetting of vaporizer/regulator is to be made. All service relating to vaporizer/regulator must be performed by a Kohler authorized dealer or qualifi ed propane personnel only.Vaporizer/regulator can change propane from supply tank to a gaseous/vapor state.Lock-Off assembly opens and closes controlling fuel fl ow from supply tank before reaching vaporizer/regulator. Over time, fuel deposits can accumulate inside vaporizer/regulator. Removing these deposits is recommended. Follow steps below to drain vaporizer/regulators.1. Turn fuel supply valve off, run engine out of

fuel, and turn off ignition switch.2. Disconnect and ground spark plug leads.3. Remove drain plug from bottom of vaporizer/

regulator. Remove any accumulated deposits.

4. Reinstall plug and tighten securely. If required, a replacement plug can be found at KohlerEngines.com.

Fuel LineHigh pressure fuel line meeting a minimum of SAE R7 standard must be installed on Kohler Co. engines equipped with propane EFI system (from vaporizer/regulator to injectors).

Spark Plugs


Clean out spark plug recess. Remove plug and replace.1. Check gap using wire feeler gauge. Adjust

gap, see specifi cation table for adjustment.2. Install plug into cylinder head.3. Torque plug to 20 ft. lb. (27 N·m).

Electronic Fuel Injection (EFI) SystemEFI is an electronically-controlled fuel management system which is monitored by an Electronic Control Unit (ECU). A Malfunction Indicator Light (MIL) will illuminate if problems or faults are detected. Servicing by a Kohler authorized dealer is necessary.

Fuel System ComponentsEngines are equipped with special EFI fuel fi lters. See Maintenance Schedule.

Fuse ReplacementThis engine has three (3) blade type automotive fuses. Replacement fuses must have same rating as blown fuse. Use fuse chart below to determine correct fuse.

Wire Color Fuse Rating

2 Solid Red Wires 10-amp Fuse

1 Red Wire with Black Stripe1 Red Wire with White Stripe

10-amp Fuse

2 Purple Wires 30-amp Fuse


Air CleanerNOTE: Operating engine with loose or

damaged air cleaner components could cause premature wear and failure. Replace all bent or damaged components.

NOTE: Paper element cannot be blown out with compressed air.

Low-Profi leLoosen knob and remove air cleaner cover.Precleaner:1. Remove precleaner from paper element.2. Replace or wash precleaner in warm water

with detergent. Rinse and allow to air dry.3. Saturate precleaner with new engine oil;

squeeze out excess oil.4. Reinstall precleaner over paper element.Paper Element:1. Clean area around element. Remove wing

nut, element cover, and paper element with precleaner.

2. Separate precleaner from element; service precleaner and replace paper element.

3. Check condition of rubber seal and replace if necessary.

4. Install new paper element on base; install precleaner over paper element; reinstall element cover and secure with wing nut.

Reinstall air cleaner cover and secure with knob.Heavy-Duty1. Unhook retaining clips and remove end

cap(s).2. Check and clean inlet screen (if equipped).3. Pull air cleaner element out of housing and

replace. Check condition of inner element; replace when dirty.

4. Check all parts for wear, cracks, or damage, and that ejector area is clean.

5. Install new element(s).6. Reinstall end cap(s) with dust ejector valve/

screen down; secure with retaining clips.

Breather Tube (if equipped)Ensure end of breather tube is properly connected.

Oil Cooler (if equipped)1. Clean fi ns with a brush or compressed air.2. Remove two screws securing oil cooler, and

tilt to clean back side.3. Reinstall oil cooler.

Air Cooling



Proper cooling is essential. To prevent over heating, clean screens, cooling fi ns, and other external surfaces of engine. Avoid spraying water at wiring harness or any electrical components. See Maintenance Schedule.

Repairs/Service PartsWe recommend that you use a Kohler authorized dealer for all maintenance, service, and engine parts. To fi nd a Kohler authorized dealer visit KohlerEngines.com or call 1-800-544-2444 (U.S. and Canada).

Leakage Check/TestingWith fuel valve fully opened, engine not running, turn key switch ON. Check all fuel system connections and lines for leaks using soapy water. Any leakage must be corrected before restarting engine. Have service performed by a Kohler authorized dealer or qualifi ed propane personnel only.

StorageIf engine will be out of service for 2 months or more follow procedure below.1. Change oil while engine is still warm from

operation. Remove spark plug(s) and pour about 1 oz. of engine oil into cylinder(s). Replace spark plug(s) and crank engine slowly to distribute oil.

2. Disconnect negative (-) battery cable.3. Separate propane tank from unit and store

separately in an area designated for safe propane tank storage.

4. Store engine in a clean, dry place.


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Engine Specifi cations

Model Bore Stroke Displacement Oil Capacity (Refi ll)

Spark Plug Gap

Maximum Angle of Operation

(@ full oil level)*

PCH680

3.27 in. (83 mm)

2.72 in. (69 mm)

45.6 cu. in. (747 cc)

1.7-2.0 U.S. qt. (1.6-1.9 L)

0.03 in. (0.76 mm) 25°

PCV680PCH740PCV740

*Exceeding maximum angle of operation may cause engine damage from insuffi cient lubrication.Additional specifi cation information can be found in service manual at KohlerEngines.com.Exhaust Emission Control System for propane EFI models PCH680, PCH740, and PCV680, PCV740 is EM, O2S, ECM, MPI for U.S. EPA, California, and Europe.Any and all horsepower (hp) references by Kohler are Certifi ed Power Ratings and per SAE J1940 & J1995 hp standards. Details on Certifi ed Power Ratings can be found at KohlerEngines.com.

brb-2800 machine manual - amazon s3...throttle for 20 minutes. if noise persists, take engine to...

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