TP-2474-H COMMAND SERIES CH18-26, CH730

TP-2474-H COMMAND SERIES CH18-26, CH730
0WNER's MANUAL
COMMAND S€R/€S
CHW.24 CH730=740
CRANKSHAFT
HOREONUL
60RUN'"
Safety Precautions
To insure safe operations please read the following statements and understand their meaning.
Also refer to your equipment owner's manual for other important safety information. This manual
contains safety precautions which are explained below. Please read carefully.
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WARNING
Warning is used to indicate the presence of a hazard that can cause severe personal injury, death,
or substantial property damage if the warning is ignored.
CAUTION
Caution is used to indicate the presence of a hazard that will or can cause minor personal injury or
property damage if the caution is ignored.
NOTE
Note is used to notify people of installation, operation, or maintenance information that is important
but not hazard-related.
For Your Safety!
These precautions should be followed at all times. Failure to follow these precautions could result
in injury to yourself and others.
a WARNING
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a WARNING
Explosive Fuel can cause fires and
severe burns.
Rotating Parts can cause severe
injury.
Stop engine before filling fuel tank.
Stay away while engine is in
operation.
Explosive Fuel!
Gasoline is extremely flammable
and its vapors can explode if
ignited. Store gasoline only in
approved containers, in well
ventilated, unoccupied buildings,
a way from sparks or flames. Do not
fill the fuel tank while the engine is
hot or running, since spilled fuel
could ignite if it comes in contact
with hot parts or sparks from
ignition. Do not start the engine near
spilled fuel. Never use gasoline as a
cleaning agent.
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Electrical Shock can cause injury.
Do not touch wires while engine is
running.
Electrical Shock!
Never touch electrical wires or
components while the engine is
running. They can be sources of
electrical shock.
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a WARNING
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Hot Parts can cause severe burns.
Do not touch engine while operating
or just after stopping.
Rotating Parts!
Keep hands, feet, hair, and clothing
a way from all moving parts to
prevent injuty Never operate the
engine with covers, shrouds, or
guards removed.
a CAUTION
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Hot Parts!
Engine components can get
extremely hot from operation. To
prevent severe burns, do not touch
these areas while the engine is
running, or immediately after it is
turned off. Never operate the engine
with heat shields or guards
removed.
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.
Safefy Precautions (Conf.)
WARNING
a WARNING
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Accidental Starts can cause severe
injury or death.
Disconnect and ground spark plug
leads before sewicing.
Accidental Starts!
Disabing engine. Accidents/
staring can cause severe injuv
or death. Before working on the
engine or equipment, disable the
engine as follows: 1) Disconnect the
spark plug lead(s). 2) Disconnect
negative (-)battery cable from
battery.
Carbon Monoxide can cause
severe nausea, fainting or death.
Do not operate engine in closed or
confined area.
Lethal Exhaust Gases!
Engine exhaust gases contain
poisonous carbon monoxide.
Carbon monoxide is odorless,
colorless, and can cause death if
inhaled. Avoid inhaling exhaust
fumes, and never run-the engine in
a closed building or confined area.
I Explosive Gas can cause fires and
severe acid burns.
Charge battey only in a well
ventilated area. Keep sources of
ianition awav.
Explosive Gas!
Batteries produce explosive
hydrogen gas while being charged.
To prevent a fire or explosion,
charge batteries only in well
ventilated areas. Keep sparks, open
flames, and other sources of
ignition away from the battery at all
times. Keep batteries out of the
reach of children. Remove all
jewelry when servicing batteries.
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Before disconnecting the 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
gasoline vapors are present.
Congratulations -You have selected a fine four-cycle, twin cylinder, air-cooled engine. Kohler designs long life
strength and on-the-job durability into each engine...making a Kohler engine dependable...dependability you can
count on. Here are some reasons why:
Efficient overhead valve design and full pressure lubrication provide maximum power, torque, and reliability
under all operating conditions.
Dependable, maintenance-free electronic ignition ensures fast, easy starts time after time.
Kohler engines are easy to service. All routine service areas like the dipstick, oil fill, air cleaner, and spark
plugs are easily and quickly accessible.
Parts subject to the most wear and tear (like the cylinder liner* and camshaft) are made from precision
formulated cast iron. Because the cylinder liner* can be rebored, these engines can last even longer.
*Some CH25/26 engines have POWER-BORETMCylinders. These cylinders are plated with nickel-silicon to
give increased power, virtually permanent cylinder life, superior oil control, and reduced exhaust emissions.
These cylinders cannot be rebored.
Every Kohler engine is backed by a worldwide network of over 10,000 distributors and dealers. Service
support is just a phone call away. Call 1-800-544-2444 (U.S. & Canada) for Sales & Service assistance.
To keep your engine in top operating condition, follow the maintenance procedures in this manual.
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Air Cleaner
Dipstick
Oil Fill,
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Side Oil Drain Plugs /
:igure I , Typical Command Horizontal Shaft Engine (CH18-25,CH730,740),
anifold
Coil
lnjecta
Oil
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Figure 2. CH26 Command Horizontal Shaft Engine,
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Rectifier-Regulafor
Oil Recommendations
Using the proper type and weight of oil in the
crankcase is extremely important. So is checking oil
daily and changing oil regularly. Failure to use the
correct oil, or using dirty oil, causes premature engine
wear and failure.
Oil Type
Use high quality detergent oil of API (American
Petroleum Institute) service class SC; SH, SJ or
higher. Select the viscosity based on the air
temperature at the time of operation as shown in the
following table.
R E C O M M E N D E D S A E V I S C O S I T Y GRADES
Fuel Recommendations
WARNING: Explosive Fuel!
Gasoline is extremely flammable and its vapors can
explode if ignited. Store gasoline only in approved
containers, in well ventilated, unoccupied buildings,
a way from sparks or flames. Do not fill the fuel tank
while the engine is hot or running, since spilled fuel
could ignite if it comes in contact with hot parts or
sparks from ignition. Do not start the engine near
spilled fuel. Never use gasoline as a cleaning agent.
General Recornmendations
Purchase gasoline in small quantities and store in
clean, approved containers. A container with a capacity
of 2 gallons or less with a pouring spout is
recommended. Such a container is easier to handle
and helps eliminate spillage during refueling.
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Do not use gasoline left over from the previous season,
to minimize gum deposits in fuel system and to insure
easy starting.
*Use of synthetic oil having 5W-20 or 5W-30 rating is
acceptable, up to 40°F.
**Syntheticoils will provide better starting in extreme
cold (below -10°F).
rigure 3. Viscosity Grades Table.
NOTE: Using other than service class SG, SH, SJ or
higher oil or extending oil change intervals
longer than recommended can cause engine
damage.
A logo or symbol on oil containers identifies the API
service class and SAE viscosity grade. See Figure 4.
Do not add oil to the gasoline.
Do not overfill the fuel tank. Leave room for the fuel to
expand.
Fuel Type
For best results use only clean, fresh, unleaded
gasoline with a pump sticker octane rating of 87 or
higher. In countries using the Research method, it
should be 90 octane minimum.
Unleaded gasoline is recommended as it leaves less
combustion chamber deposits and reduces harmful
exhaust emissions. Leaded gasoline is not
recommended and must not be used on CH26
engine, or on other models where exhaust emissions
are regulated.
Gasoline/Alcohol blends
Gasohol (up to 10% ethyl alcohol, 90% unleaded
gasoline by volume) is approved as a fuel for Kohler
engines. Other gasoline/alcohol blends are not
approved.
Figure 4. Oil Container Logo,
Refer to “Maintenance Instructions” beginning on
page 8 for detailed oil check, oil change, and oil
filter change procedures,
Gasoline/Ether blends
Methyl Tertiary Butyl Ether (MTBE) and unleaded
gasoline blends (up to a maximum of 15% MTBE by
volume) are approved as a fuel for Kohler engines.
Other gasoline/ether blends are not approved.
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Engine Identification Numbers
Model Designation
When ordering parts, or in any communication
involving an engine, always give the Model,
Specification, and Serial Numbers of the engine.
Model CH20S for example: C designates Command
engine, H designates horizontal crankshaft, and 20
designates horsepower. Some model numbers
(CH730) use the approximate displacement rather than
horsepower. A letter suffix designates a specific version
as follows:
Suffix
Designates
S
Electric Start
ST
Electric StarVRetractable Start
QS
Quiet ModeVElectric Start
EP
Electric Plant
cs
Clutch ModeVElectric Start
The engine identification numbers appear on a decal
affixed to the engine shrouding. Include letter suffixes,
if there are any.
Record your engine identification numbers on the
identification label below (Figure 5) for future reference.
IMPORTANT
- ENGINE INFORMATION
THIS ENGINE MEETS U.S. EPA 2004 AND
CALIFORNIA 2006 AND LATER EMISSION
CONTROL REGULATIONS FOR SI SORE*
FAMILY
DISPL, (CC)
MODEL NO,
SPEC. NO,
SERIAL NO,
Operating Instructions
Also read the operating instructions of the equipment
this engine powers.
Pre-Start Checklist
Check oil level. Add oil if low. Do not overfill.
eN11236
EMISSION COMPLIANCE PERIOD:
EPA:
CARB:
THIS ENGINE IS CERTIFIED TO OPERATE
ON:
REFER TO OWNER'S MANUAL FOR SAFETY,
MAINTENANCE SPECS AND ADJUSTMENTS.
Check fuel level. Add fuel if low.
Check cooling air intake areas and external
surfaces of engine. Make sure they are clean and
unobstructed.
FOR SALES/SERVICE IN US/CANADA, CALL:
1-800-544-2444
www. kohlerengines.com
Check that the air cleaner components and all
shrouds, equipment covers, and guards are in
place and securely fastened.
u
KOHLER CO. KOHLER, WISCONSIN USA
Check that any clutches or transmissions are
disengaged or placed in neutral. This is especially
important on equipment with hydrostatic drive. The
shift lever must be exactly in neutral to prevent
resistance which could keep the engine from starting.
*Small Off-Road Engines
7gure 5. Engine ldentification Label,
The Emission Compliance Period referred to on the
Emission Control or Air Index label indicates the
number of operating hours for which the engine has
been shown to meet Federal and CARB emission
requirements. The following table provides the Engine
Compliance Period (in hours) associated with the
category descriptor found on the certification label.
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WARNING: Lethal Exhaust Gases!
Engine exhaust gases contain poisonous carbon
monoxide. Carbon monoxide is odorless, colorless,
and can cause death if inhaled. Avoid inhaling exhaust
fumes, and never run the engine in a closed building or
confined area.
Emission Compliance Period (Hours)
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EPA
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Category C
250 hours
Moderate
125 hours
Category B
500 hours
Category A
1000 hours
Cold Weather Starting Hints
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Intermediate Extended
250 hours
500 hours
Refer to certification label for engine displacement.
Exhaust Emission Control System for models
CHI 8,20,22,23,25,730,740 is EM. Exhaust Emission
Control System for model CH26 is EM, 02S, ECM, MFI.
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1. Be sure to use the proper oil for the temperature
expected. See Figure 3 on page 5.
2. Disengage all possible external loads.
3. Be sure the battery is in good condition. A warm
battery has much more starting capacity than a
cold battery.
4. Use fresh winter grade fuel. NOTE: Winter grade
gasoline has higher volatility to improve starting.
Do not use gasoline left over from summer.
Starting
1. Place the throttle control midway between the
“slow” and “fast” positions. Place the choke
control (non-EFI engines only) into the “on”
Carbureted Engines Only:
3. For a Cold Engine -Gradually return the choke
control to the “off” position after the engine starts
and warms up.
position. See Figure 6.
The engine/equipment may be operated during
the warm-up period, but it may be necessary to
leave the choke partially on until the engine
warms up.
4. For a Warm Engine - Return choke to “off”
position as soon as engine starts.
Stopping
Figure 6, Optional Engine Mounted Throttle and
Choke Controls (CH18-25,CH730,740),
2. Start the engine by activating the key switch.
Release the switch as soon as the engine starts.
NOTE: Do not crank the engine continuously for
more than 10 seconds at a time. If the
engine does not start, allow a 60 second
cool down period between starting
attempts. Failure to follow these
guidelines can burn out, or permanently
damage, the starter motor.
NOTE: Upon start-up, a metallic ticking may
occur. This is caused by hydraulic lifter
leakdown during storage. Run the engine
for 5 minutes. The noise will normally
cease in the first minute. If noise
continues, run the engine at mid-throttle
for 20 minutes. If noise persists, take the
engine to your local authorized Kohler
Engine Service Dealer.
NOTE: If the engine develops sufficient speed to
disengage the starter but does not keep
running (a false start), engine rotation
must be allowed to come to a complete
stop before attempting to restart the
engine. If the starter is engaged while the
flywheel is rotating, the starter pinion and
flywheel ring gear may clash resulting in
damage to the starter.
If the starter does not turn the engine over, shut
off starter immediately. Do not make further
attempts to start the engine until the condition is
corrected. Do not jump start using another battery
(refer to “Battery” on this page). See your Kohler
Engine Service Dealer for service assistance.
1. Remove the load by disengaging all PTO driven
attachments.
2. For Carbureted Engines WithoutA Shutdown
Solenoid: Move the throttle to the “slow” or
“low”idle position. Allow the engine to run at idle
for 30-60 seconds; then stop the engine.
For Carbureted Engines Equipped With A
Shutdown Solenoid: Position the throttle control
somewhere between half and full throttle; then
stop the engine.
For EFl Engines: Move the throttle to the “slow”
or “idle” position; turn key “off” to stop engine.
Battery
A 12 volt battery is normally used. Refer to the
operating instructions of the equipment this engine
powers for specific battery requirements.
If the battery charge is not sufficient to crank the
engine, recharge the battery (see page 13).
Operating
Angle of Operation
This engine will operate continuously at angles up to
25”. Check oil level to assure crankcase oil level is at
the “F’ mark on the dipstick.
Refer to the operating instructions of the equipment
this engine powers. Because of equipment design or
application, there may be more stringent restrictions
regarding the angle of operation.
NOTE: Do not operate this engine continuously at
angles exceeding 25” in any direction. Engine
damage could result from insufficient
lubrication.
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Cooling
NOTE: If debris builds up on the grass screen or
other cooling air intake areas, stop the engine
immediately and clean. Operating the engine
with blocked or dirty air intake and cooling
areas can cause extensive damage due to
overheating.
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Engine Speed
NOTE: Do not tamper with the governor setting to
increase the maximum engine speed.
Overspeed is hazardous and will void the
engine warranty. The maximum allowable high
idle speed for these engines is 3750 RPM, no
load.
WARNING: Hot Parts!
Engine components can get extremely hot from
operation. To prevent severe burns, do not touch these
areas while the engine is running, or immediately after
it is turned off. Never operate the engine with heat
shields or guards removed.
Maintenance Instructions
Maintenance, repai5 or replacement of the emission control devices and systems, which are being done at
the customers expense, may be performed by any non-road engine repair establishment or individual,
Warranty repairs must be performed by an authorized Kohler service outlet,
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WARNING: Accidental Starts!
DisabHng engine. Accidenta/staHing can cause severe injury or death. Before working on the engine or
equipment, disable the engine as follows: I) Disconnect the spark plug [email protected]).2) Disconnect negative (-) battery
cable from battery.
Maintenance Schedule
These required maintenance procedures should be performed at the frequency stated in the table. They should
also be included as part of any seasonal tune-up.
Frequency
Daily or Before
Starting Engine
Every 2 5 Hours
Fill fuel tank.
Check oil level.
Check air cleaner for dirty’, loose, or damaged parts.
Check air intake and cooling areas, clean as necessary’.
Every250 Hours
Service precleaner element’.
Replace air cleaner element’.
Change oil. (More frequently under severe conditions.)
Remove cooling shrouds and clean cooling areas’,3.
Check oil cooler fins, clean as necessary (if equipped).
Check spark plug condition and gap.
Change oil filter.
Replace heavy-duty air cleaner element and check inner element’.
Annually or
Every 500 Hours
Have bendix starter drive serviced2.
Have solenoid shift starter disassembled and cleaned2.
Every 500 Hours
Have crankshaft spline lubricated2.
Every 7500 Hours
Replace fuel filter’ (EFI engines).
Every 700 Hours
Hours
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Maintenance Required
Check Oil Level
Change Oil and Filter, Service Oil Cooler
The importance of checking and maintaining the proper
oil level in the crankcase cannot be overemphasized.
Check oil BEFORE EACH USE as follows:
1. Make sure the engine is stopped, level, and is
cool so the oil has had time to drain into the sump.
2. To keep dirt, debris, etc., out of the engine, clean
the area around the dipstick before removing it.
3. Remove the dipstick; wipe oil off. Reinsert the
dipstick into the tube and press all the way down.
Change Oil
Change oil after every 100 hours of operation (more
frequently under severe conditions). Refill with service
class SG, SH, SJ or higher oil as specified in the
“Viscosity Grades” table (Figure 3) on page 5.
Change the oil while the engine is still warm. The oil
will flow more freely and carry away more impurities.
Make sure the engine is level when filling, checking,
and changing the oil.
Change the oil as follows (see Figures 8 and 9):
4. Remove the dipstick and check the oil level.
1. To keep dirt, debris, etc., out of the engine, clean
the area around the oil fill cap/dipstick before
removing it.
The oil level should be up to, but not over, the “ F
mark on the dipstick. See Figure 7.
2. Remove one of the oil drain plugs, oil fill cap, and
dipstick. Be sure to allow ample time for complete
drainage.
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3. Reinstall the drain plug. Make sure it is tightened
to 13.6 N-m (10 ft. lb.) torque.
“F” Mark
Operating
Range
4. Fill the crankcase, with new oil of the proper type,
to the “F’ mark on the dipstick. Refer to “Oil Type”
on page 5. Always check the level with the dipstick
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before adding more oil.
5. Reinstall the oil fill cap and tighten securely.
Reinstall dipstick.
Figure 7. Oil Level Dipstick,
NOTE: To prevent extensive engine wear or
damage, always maintain the proper oil
level in the crankcase. Never operate the
engine with the oil level below the “L”
mark or over the “F’ mark on the dipstick.
5. If the level is low, add oil of the proper type, up to
the “ F mark on the dipstick. (Refer to “Oil Type”
on page 5.) Always check the level with the
dipstick before adding more oil.
NOTE: To prevent extensive engine wear or
damage, always maintain the proper oil
level in the crankcase. Never operate the
engine with the oil level below the “L”
mark or over the “F’ mark on the dipstick.
Oil SentryTM
Some engines are equipped with an optional Oil
SentryTMoil pressure switch. If the oil pressure
decreases below an acceptable level, the Oil SentryTM
will either shut off the engine or activate a warning
signal, depending on the application.
NOTE: Make sure the oil level is checked BEFORE
EACH US€ and is maintained up to the “ F
mark on the dipstick. This includes engines
equipped with Oil SentryTM.
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oil Cooler
‘Oil Drain Plug
Figure 8. Oil Drain Plugs, Oil Filter, and Oil Cooler
(CH25 shown),
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Service Oil Cooler
Some engines are equipped with an oil cooler. One
style of oil cooler mounts on the engine crankcase and
has the oil filter on it (See Figure 8). The other style of
oil cooler is mounted on the blower housing (See
Figure 9), separate from the oil filter.
Inspect and clean the oil cooler every 100 hours of
operation (more frequently under severe conditions).
Oil cooler must be kept free of debris.
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Oil Drain’ Plug
oil cooler
Figure 9. Oil Drain Plugs, Oil Filter, and Oil Cooler
(CH26 shown),
Change Oil Filter
Replace the oil filter at least every other oil change
(every 200 hours of operation).Always use a
genuine Kohler oil filter, Part No. 12 050 OI-S.
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To service the crankcase mounted oil cooler clean off
the outside fins with a brush or with compressed air.
To service the blower housing mounted oil cooler,
clean the outside of fins with a brush. Remove the two
screws holding the cooler unit to the blower housing.
Tilt the cooler downward as shown in Figure 10. Clean
the inside of cooler with a brush as shown in Figure 10
or with compressed air. After cleaning, reinstall oil
cooler to blower housing with two mounting screws.
Replace the oil filter as follows:
1. Drain the oil from the engine crankcase.
2. Allow the oil filter to drain.
3. Before removing the oil filter, clean the area
around the oil filter to keep dirt and debris out of
the engine. Remove the old filter. Wipe off the
surface where the oil filter mounts.
4. Place a new replacement filter in a shallow pan
with the open end up. Pour new oil, of the proper
type, in through the threaded center hole. Stop
pouring when the oil reaches the bottom of the
threads. Allow a minute or two for the oil to be
absorbed by the filter material.
5. Put a drop of oil on your fingertip and wipe it on
the rubber gasket.
Figure 10,
Service Precleaner and Air Cleaner Element
This engine is equipped with a replaceable, high
density paper air cleaner element. Most engines are
also equipped with an oiled, foam precleaner which
surrounds the paper element. See Figure 11.
6. Install the replacement oil filter to the filter adapter or
oil cooler. Turn the oil filter clockwise until the rubber
gasket contacts the filter adapter or oil cooler, then
tighten the filter an additional 2/3 to 1 turn.
7. Reinstall the drain plug. Make sure it is tightened
to 13.6 N-m (10 ft, lb.) torque.
8 . Fill the crankcase with new oil of the proper type
to the “ F mark on the dipstick.
9. Start the engine and check for oil leaks. Correct
any leaks before placing the engine into service.
Check oil level to be sure it is up to but not over
the “ F mark.
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Figure 11. Air Cleaner System Components,
Check the air cleaner daily or before starting the
engine. Check for a buildup of dirt and debris around
the air cleaner system. Keep this area clean. Also
check for loose or damaged components. Replace all
bent or damaged air cleaner components.
4. Do not wash the paper element or use
pressurized air, as this will damage the element.
Replace a dirty, bent, or damaged element with a
genuine Kohler element. Handle new elements
carefully; do not use if the sealing surfaces are
bent or damaged.
NOTE: Operating the engine with loose or damaged
air cleaner components could allow unfiltered
air into the engine causing premature wear
and failure.
5. When servicing the air cleaner, check the air
cleaner base. Make sure it is secured and not
bent or damaged. Also, check the element cover
for damage or improper fit. Replace all damaged
air cleaner components.
Service Precleaner
If so equipped, wash and reoil the precleaner every 25
hours of operation (more often under extremely dusty
or dirty conditions).
NOTE: If any loose dirt or debris fell on the air
cleaner base when the element was
removed, carefully remove it and wipe
the base clean. Be careful that none of it
drops into the intake throat. Check the
condition of the rubber seal on the air
cleaner stud. If the condition is
questionable in any way, replace it with
the new seal packaged with the
replacement element.
1. Loosen the cover retaining knob and remove the
cover.
2. Remove the precleaner from the paper element.
3. Wash the precleaner in warm water with
detergent. Rinse the precleaner thoroughly until all
traces of detergent are eliminated. Squeeze out
excess water (do not wring). Allow the precleaner
to air dry.
6. Reinstall the paper element, precleaner, element
cover, element cover nut, and air cleaner cover.
Secure cover with the cover retaining knob.
4. Saturate the precleaner with new engine oil.
Squeeze out all excess oil.
7. When element replacement is necessary, order
genuine Kohler parts.
5. Reinstall the precleaner over the paper element.
47 083 0 3 4
24 083 0 3 4
6. Reinstall the air cleaner cover. Secure cover with
the cover retaining knob.
Heavy-Duty Air Cleaner
7. When precleaner replacement is necessary, order
genuine Kohler parts.
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24 083 0 2 4 61 mm deep x 173 mm O.D,
24 083 0 5 4 71 mm deep x 173 mm O.D,
Service Paper Element
Every 100 hours of operation (more often under
extremely dusty or dirty conditions) replace the paper
element.
1. Loosen the cover retaining knob and remove the
cover.
2. Remove the element cover nut, element cover,
and paper element with precleaner.
3. Remove the precleaner (if so equipped) from the
paper element. Service the precleaner as
described above.
65 mm deep x 178 mm O.D,
74 mm deep x 178 mm O.D,
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To Service
Every 250 hours of operation (more often under
extremely dusty or dirty conditions), replace the paper
element and check inner element. Follow these steps.
1. Unhook the two retaining clips and remove the
end cap from the air cleaner housing.
2. Pull the air cleaner element out of the housing.
See Figure 12.
Clean Air Intake/CoolingAreas
To ensure proper cooling, make sure the grass screen,
cooling fins, and other external surfaces of the engine
are kept clean at all times.
Every 100 hours of operation (more often under
extremely dusty, dirty conditions), remove the blower
housing* and other cooling shrouds. Clean the cooling
fins and external surfaces as necessay. Make sure the
cooling shrouds are reinstalled.
NOTE: Operating the engine with a blocked grass
screen, dirty or plugged cooling fins, and/or
cooling shrouds removed, will cause engine
damage due to overheating.
Figure 12. Removing Elements,
3. After the main element is removed, check the
condition of the inner element. It should be
replaced whenever it appears dirty, typically every
other time the main element is replaced. Clean the
area around the base of the inner element before
removing it, so dirt does not get into the engine.
4. Do not was the paper element and inner element
or use pressurized air, this will damaged the
elements. Replace dirty, bent or damaged
elements with new genuine Kohler elements as
required. Handle new elements carefully; do not
use if the sealing surfaces are bent or damaged.
5. Check all parts for wear, cracks, or damage.
Replace any damaged components.
6. Install the new inner element, Kohler Part No.
25 083 04-S followed by the outer element, Kohler
Part No. 25 083 01-S. Slide each fully into place in
the air cleaner housing.
7. Reinstall the end cap so the dust ejector valve is
down and secure with the two retaining clips. See
Figure 13.
*Cleanout kits 25 755 20-S (black) or 25 755 21-S
(gold) allow inspection and cleanout of the cooling
fins, without removing the blower housing.
Ignition System
-
Carbureted Engines Use an electronic Capacitive
Discharge (CD) ignition system. Other than periodically
checkingheplacingthe spark plugs, no maintenance,
timing, or adjustments are necessary or possible with
this system.
-
EFI Engines Incorporate a computer-controlled
battery ignition system with individual coils. Other than
periodically checkingheplacingthe spark plugs, no
maintenance, timing, or adjustments are necessary or
possible with this system.
Check Spark Plugs
Every 200 hours of operation, remove the spark plugs,
check condition, and reset the gap or replace with new
plugs as necessay. The standard spark plug is a
[email protected] (Kohler Part No. 12 132 02-S). A
high-performance spark plug, [email protected]
Gold 2071 (used on Pro Series engines, Kohler Part
No. 12 132 06-S) is also available. Equivalent alternate
brand plugs can also be used.
1. Before removing the spark plug, clean the area
around the base of the plug to keep dirt and debris
out of the engine.
2. Remove the plug and check its condition.
Replace the plug if worn or reuse is questionable.
Dust
Ejector
Valve
'igure 13, Heavy-Duty Air CleanerAssembly.
12
NOTE: Do not clean the spark plug in a machine
using abrasive grit. Some grit could
remain in the spark plug and enter the
engine causing extensive wear and
damage.
3. Check the gap using a wire feeler gauge. Adjust
the gap to 0,76 mm (0.030 in,) by carefully
bending the ground electrode. See Figure 14.
Fuel Filter
Carbureted Engines: Some engines are equipped
with an in-line fuel filter. Periodically inspect the filter
and replace when dirty. Always use genuine Kohler
parts.
EFI Engines: A special, high volume, high pressure
filter with greater filtration capabilities and internal
surface area is used. See Figure 15.
#
Gro;:
Electrode -
0.76mm
(0,030 in,) Gap
Fuel Filter
I
7gure 14, Servicing Spark Plug,
4. Reinstall the spark plug into the cylinder head.
Torque the spark plug to 24.4-29J N-m
(18-22 ft. lb,).
Battery Charging
WARNING: Explosive Gas!
Batteries produce explosive hydrogen gas while being
charged. To prevent a fire or explosion, charge
batteries only in well ventilated areas. Keep sparks,
open flames, and other sources of ignition a way from
the battery at all times. Keep batteries out of the reach
of children. Remove all jewelry when servicing
batteries.
Before disconnecting the 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 gasoline vapors are
present.
NOTE: Do not apply 12 volt DC to kill terminal of
ignition module.
Fuel System
a
WARNING: Fuel System Under Pressure!
The EFI fuel system operates under high pressure,
and the fuel filter and fuel line used must be approved
system components only Use of substitute parts can
result in system failure, gasoline leakage and possible
explosion.
Figure 15. EFI Fuel Filter and Line,
Replacement is recommended every 1500 hours, or
more frequently under extremely dusty or dirty
conditions. When replacement is necessary, always
use genuine Kohler parts.
Fuel Line
EFI Engines: A special fuel line, capable of
withstanding the high pressure of the EFI fuel system,
is used (must meet SAE R9 specifications). See Figure
15. If fuel line must be replaced, see your Kohler
Engine Service Dealer.
Carburetor Troubleshooting and
Adjustments
NOTE: Carburetor adjustments should be made only
after the engine has warmed up.
The carburetor is designed to deliver the correct
fuel-to-air mixture to the engine under all operating
conditions. To comply with current emission
regulations, the fuel mixture settings are made at the
factory and cannot be adjusted.
NOTE: To ensure correct engine operating at
altitudes above 1525 meters (SOOOft.), it may
be necessary to have an authorized Kohler
dealer install a special high-altitude jet kit in
the carburetor. If a high-altitude kit has been
installed, the engine must be reconverted to
the original jet size, before it is operated at
lower altitudes, or overheating and engine
damage can result.
13
2. L o w ldle Speed Setting: Place the throttle control
into the “idle”or “slow”position. Set the low idle
speed to 7200 RPM” (+ 75 RPM) by turning the
low idle speed adjusting screw in or out. Check
the speed using a tachometer.
*NOTE: The actual low idle speed depends on the
application - refer to equipment
manufacturers recommendations. The
standard low idle speed is 1200 RPM.
3. If proper operation is not restored after adjusting
the low idle speed, carburetor servicing by an
authorized Kohler Engine Service Dealer may be
required.
Troubleshooting
Electronic Fuel Injection (EFI) System
If engine troubles are experienced that appear to be
fuel system related, check the following areas before
adjusting the carburetor.
The EFI system is a complete, electronically-controlled
fuel management system, designed to deliver a
precisely controlled fuel flow under all operating
conditions. The electronic control unit (ECU), the
“brain” of the system, automatically adjusts fuel
delivery and ignition timing based upon load, speed,
operating temperature, and exhaust emission levels.
The low idle speed is the only manual adjustment
possible.
Make sure the fuel tank is filled with clean, fresh
gasoline.
Make sure the fuel tank cap vent is not blocked
and that it is operating properly.
If the fuel tank is equipped with a shut-off valve,
make sure it is open.
If the engine is equipped with an in-line fuel filter,
make sure it is clean and unobstructed. Replace
the filter if necessary.
Make sure fuel is reaching the carburetor. This
includes checking the fuel lines and fuel pump for
restrictions or faulty components, replace as
necessary.
Make sure the air cleaner element is clean and all
air cleaner element components are fastened
securely.
If, after checking the items listed above, the engine is
hard to start, runs roughly, or stalls at low idle speed, it
may be necessary to adjust or service the carburetor.
Adjust Carburetor
There are no accessible mixture adjustment screws on
the carburetor. The only setting which can be changed
is the low idle speed.
1. Start the engine and run at half throttle for 5 to 10
minutes to warm up. The engine must be warm
before making final settings (steps 2 and 3).
14
The ECU continuously monitors operation of the EFI
system. If it detects a problem or fault within the
system, it will illuminate the malfunction indicator light
(MIL), which is mounted in view of the operator. This is
a signal that normal, programmed operation has been
affected, and service by an authorized Kohler Engine
Dealer is required.
NOTE: The EFI system requires a rather complex
wiring harness to carry the electrical signals
between the sensors and the ECU. Do not
spray water at the wiring harness or any of the
electrical components, especially the ECU, as
it could cause malfunction, damage, or failure.
Troubleshooting
If the MIL comes on, or the engine becomes hard to
start, runs roughly, or stalls at low idle speed, initial
checks should be made in the following areas:
Make sure the fuel tank is filled with clean, fresh
gasoline, and shut-off valve (if so equipped) is
opened completely.
Make sure fuel tank vent cap is not blocked and it
is operating properly.
Make sure the air cleaner element and precleaner
are clean and all components are properly
secured. Clean or replace as necessary.
Make sure the proper fuel filter is being used, and
it is clean and unobstructed. Replace filter only
with genuine Kohler parts.
If adjustment is to be made, the engine must be at
operating temperature, air cleaner in place, and check
engine light must be off (no fault codes present).
Make sure all connections to sensors, ECU, and
fuel injectors are properly secured.
1. Start the engine and run at half throttle for 5 to 10
minutes to warm up.
Make sure a good 12 volt battery is being used and
is fully charged.
2. Place the throttle control into the “id1e”or “slow”
position.
If these checks do not correct the problem, or the MIL
remains on, further diagnosis and servicing by an
authorized Kohler Engine Dealer is necessary.
3. Turn the low idle speed adjusting screw in or out
and check RPM with a tachometer. See Figure 17.
Adjustment - EFI Throttle Body
Adiustina Screw
Low Idle Speed (RPM) is the only adjustment that can
be made. All other fuel calibrations are permanently
preset and controlled by the ECU. The standard low idle
speed is 1500 RPM” (k 75 RPM).
*NOTE: The actual low idle speed depends on the
application -- refer to equipment
manufacturer’s recommendations.
When an EFI engine is started cold, the ECU will be
using internal programming for cold running, and the
idle speed may vary from the manual setting. Do not
attempt to perform any readjustment during this “warmup” period.
I
Figure 17, EFI Throttle Body Manifold.
Troubleshooting
When troubles occur, be sure to check the simple causes which, at first, may seem too obvious to be considered.
For example, a starting problem could be caused by an empty fuel tank. Some common causes of engine troubles
are listed in the following table.
Do not attempt to service or replace major engine components, or any items that require special timing or
adjustment procedures. Have your Kohler Engine Service Dealer do this work.
Possible Cause No Improper
Dirt In
Dirty
Incorrect
Problem
Fuel
Fuel Fuel Line/System Grass Screen Oil Level
Will Not Start
Hard Starting
Stops Suddenly
Lacks Power
Operates Erratically
Knocks or Pings
Skips or Misfires
Backfires
Overheats
High Fuel Consumption
Engine
Overloaded
Dirty Air
Cleaner
Faulty
Spark Plug
15
Storage
Parts Ordering
If the engine will be out of service for two months or
more, use the following storage procedure:
1. Clean the exterior surfaces of the engine. On EFI
engines, avoid spraying water at the wiring
harness or any of the electrical components.
The engine Specification, Model, and Serial Numbers
are required when ordering replacement parts from
your Kohler Engine Service Dealer. These numbers are
found on the identification plate which is affixed to the
engine shrouding. Include letter suffixes if there are
any. See “Engine Identification Numbers” on page 6.
2. Change the oil and filter while the engine is still
warm from operation. See “Change Oil and Oil
Filter” on page 9.
Always insist on genuine Kohler parts. All genuine
Kohler parts meet strict standards for fit, reliability, and
performance.
3. The fuel system must be completely emptied, or
the gasoline must be treated with a stabilizer to
prevent deterioration. If you choose to use a
stabilizer, follow the manufacturers
recommendations, and add the correct amount for
the capacity of the fuel system. Fill the fuel tank
with clean, fresh gasoline. Run the engine for 2-3
minutes to get stabilized fuel into the rest of the
system. Close fuel shut-off valve when unit is
being stored or transported.
To empty the system, run the engine until the tank
and system are empty.
Major Repair
Major repair information is available in Kohler Engine
Service Manuals. However, major repair generally
requires the attention of a trained mechanic and the
use of special tools and equipment. Your Kohler
Engine Service Dealer has the facilities, training, and
genuine Kohler replacement parts necessary to
perform this service. For Sales & Service assistance
call 1-800-544-2444 (U.S. & Canada) or contact your
Kohler Engine Dealer or Service Distributor, they’re in
the Yellow Pages under Engines-Gasoline.
4. Remove the spark plugs. Add one tablespoon of
engine oil into each spark plug hole. Install the
plugs, but do not connect the plug leads. Crank
the engine two or three revolutions.
5. Store the engine in a clean, dry place.
Specifications
Model: .........................................................................
Bore: ...................................... rnrn (in.) ......................
Stroke: ....................................
rnrn (in.) ......................
Displacement:........................ cm3 (in3)......................
Power (Q3600 RPM): .......... kW (HP) ......................
CH18,20,22 ...........................................
77 (3.03)#...............................................
67 (2.64) ................................................
624 (38.1)#.............................................
13.4 (18*)/14.9 (20*)/16.4 (22*) ............
Max. Torque ( Q RPM): ......... N.rn (ft. Ib.) ......................
41 (30) Q2500 ........................................
44 (32) Q2500 ........................................
45 (33) Q2500 ........................................
Compression Ratio: ....................................................
Weight: .................................... kg (Ib.) ......................
Oil Capacity (w/filter): ........ L (U.S. qt.) ......................
. .
Lubrication: ..........................................
8.51 ......................................................
41 (90) ...................................................
2 (2.1) ....................................................
CH25,26,730,740
83 (3.27)
67 (2.64)
725 (44.0)
18.4 (25*)/19.4 (26)
18.6 (25*)/20.1 (27)
54 (39.5) Q2200
56.4 (41.6) Q2200
52 (38) Q2800
54 (40) Q2800
9.O:l
43 (94)
2 (2.1)
Full Pressure w/full Flow Filter
Exhaust Emission Control System for models CH18,20,22,23,25,730,740 is EM.
Exhaust Emission Control System for model CH26 is EM, 02S, ECM, MFI.
*Horsepower ratings are established in accordance with Society of Automotive Engineers - Small Engine Test Code 4 1 995
GROSS. Kohler Co. reserves the right to change product specifications, design, and standard equipment without notice and
without incurring obligation.
#CH22or CH23 engines with Spec. Numbers of 765xx have bore size of 80 rnrn (3.15 in.) and displacement of 674 cm3
(41.1 in3).
16
LIMITED 2 YEAR COMMAND ENGINE WARRANTY
We warrant to the original consumer that each new COMMAND engine sold by us will be free from manufacturing defects in materials or
workmanship in normal service for a period of two (2) years from date of purchase, provided it is operated and maintained in accordance with
Kohler Co.’s instructions and manuals.
Our obligation under this warranty is expressly limited, at our option, to the replacement or repair at Kohler Co., Kohler, Wisconsin 53044, or
at a service facility designated by us of such parts as inspection shall disclose to have been defective.
EXCLUSIONS:
Mufflers on engines used commercially (non-residential) are warranted for one (1) year from date of purchase, except catalytic mufflers,
which are warranted for two (2) years.
This warranty does not apply to defects caused by casualty or unreasonable use, including faulty repairs by others and failure to provide
reasonable and necessay maintenance.
The following items are not covered by this warranty:
Engine accessories such as fuel tanks, clutches, transmissions, power-drive assemblies, and batteries, unless supplied or installed by Kohler
Co. These are subject to the warranties, if any, of their manufacturers.
WE SHALL NOT BE LIABLE FOR SPECIAL, INDIRECT, INCIDENTAL, OR CONSEQUENTIAL DAMAGES OF ANY KIND, including but not
limited to labor costs or transportation charges in connection with the repair or replacement of defective parts.
ANY IMPLIED OR STATUARY WARRANTIES, INCLUDING WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE, ARE EXPRESSLY LIMITED TO THE DURATION OF THIS WRITEN WARRANTY. We make no other express warranty, nor is
any one authorized to make any in our behalf.
Some states do not allow limitations on how long an implied warranty lasts, or the exclusion or limitation of incidental or consequential
damages, so the above limitation or exclusion may not apply to you.
This warranty gives you specific legal rights, and you may also have other rights which v a y from state to state.
TO OBTAIN WARRANTY SERVICE:
Purchaser must bring the engine to an authorized Kohler service facility. For the facility nearest you, consult your Yellow Pages or write
Kohler Co., Attn: Engine Warranty Service Dept., Kohler, Wisconsin, 53044.
ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 530
FEDERAL AND CALIFORNIA EMISSION CONTROL SYSTEMS
LIMITED WARRANTY
SMALL OFF-ROAD ENGINES
The U.S. Environmental Protection Agency (EPA), the California Air Resources Board (CARB), and Kohler Co. are pleased to explain the Federal
and California Emission Control Systems Warranty on your small off-road equipment engine. For California, engines produced in 1995
and later must be designed, built and equipped to meet the state’s stringent anti-smog standards. In other states, 1997 and later model year
engines must be designed, built and equipped, to meet the US. EPA regulations for small non-road engines. The engine must be free from
defects in materials and workmanship which cause it to fail to conform with US. EPA standards for the first two years of engine use from the date
of sale to the ultimate purchaser. Kohler Co. must warrant the emission control system on the engine for the period of time listed above, provided
there has been no abuse, neglect or improper maintenance.
The emission control system may include parts such as the catburetor or fuel injection system, the ignition system, and catalytic converter.
Also included are the hoses, belts and connectors and other emission related assemblies.
Where a warrantable condition exists, Kohler Co. will repair the engine at no cost, including diagnosis (if the diagnostic work is performed at an
authorized dealer), parts and labor.
MANUFACTURERS WARRANTY COVERAGE
Engines produced in 1995 or later are warranted for two years in California. In other states, 1997 and later model year engines are warranted for
two years. If any emission related part on the engine is defective, the part will be repaired or replaced by Kohler Co. free of charge.
0WNER’S WARRANTY RESPONSIBILITIES
(a) The engine owner is responsible for the performance of the required maintenance listed in the owner’s manual. Kohler Co. recommends
that you retain all receipts covering maintenance on the engine, but Kohler Co. cannot deny warranty solely for the lack of receipts or for
your failure to assure that all scheduled maintenance was performed.
(b)
Be aware, however, that Kohler Co. may deny warranty coverage if the engine or a part has failed due to abuse, neglect, improper
maintenance or unapproved modifications.
Continued on next page.
17
(c)
For warranty repairs, the engine must be presented to a Kohler Co. setvice center as soon as a problem exists. Call 1-800-544-2444 or
access our website at: www.kohlerengines.com, for the names of the nearest setvice centers. The warranty repairs should be completed
in a reasonable amount of time, not to exceed 30 days.
If you have any questions regarding warranty rights and responsibilities, you should contact Kohler Co. at 1-920-457-4441 and ask for an Engine
Service representative.
COVERAGE
Kohler Co. warrants to the ultimate purchaser and each subsequent purchaser that the engine will be designed, built and equipped, at the time
of sale, to meet all applicable regulations. Kohler Co. also warrants to the initial purchaser and each subsequent purchaser, that the engine is
free from defects in materials and workmanship which cause the engine to fail to conform with applicable regulations for a period of two years.
Engines produced in 1995 or later are warranted for two years in California. For 1997 and later model years, EPA requires manufacturers to
warrant engines for two years in all other states. These warranty periods will begin on the date the engine is purchased by the initial purchaser. If
any emission related part on the engine is defective, the part will be replaced by Kohler Co. at no cost to the owner. Kohler Co. is liable for
damages to other engine components caused by the failure of a warranted part still under warranty.
Kohler Co. shall remedy warranty defects at any authorized Kohler Co. engine dealer or warranty station. Warranty repair work done at an
authorized dealer or warranty station shall be free of charge to the owner if such work determines that a warranted part is defective.
Listed below are the parts covered by the Federal and California Emission Control Systems Warranty. Some parts listed below may require
scheduled maintenance and are warranted up to the first scheduled replacement point for that part. The warranted parts are:
Catburetor assembly
Throttle body (EFI Systems)
Catalytic muffler (if equipped)
Fuel metering valve (if equipped)
Crankcase breather
Fuel pressure regulator (EFI Systems)
Ignition module(s) with high tension lead
Spark advance module (if equipped)
Oxygen, speed, throttle position, and temperature sensors (if equipped)
Electronic control unit (if equipped)
Fuel injectors (EFI Systems)
Air filter, fuel filter, and spark plugs (only to first scheduled replacement point)
LIMITATIONS
This Emission Control Systems Warranty shall not cover any of the following:
(a)
repair or replacement required because of misuse or neglect, improper maintenance, repairs improperly performed or replacements not
conforming to Kohler Co. specifications that adversely affect performance and/or durability and alterations or modifications not
recommended or approved in writing by Kohler Co.,
(b)
replacement of parts and other services and adjustments necessay for required maintenance at and after the first scheduled replacement
point,
(c)
consequential damages such as loss of time, inconvenience, loss of use of the engine or equipment, etc.,
(d)
diagnosis and inspection fees that do not result in eligible warranty setvice being performed, and
(e)
any add-on or modified part, or malfunction of authorized parts due to the use of add-on or modified parts.
MAINTENANCE AND REPAIR REQUIREMENTS
The owner is responsible for the proper use and maintenance of the engine. Kohler Co. recommends that all receipts and records coveting the
performance of regular maintenance be retained in case questions arise. If the engine is resold during the warranty period, the maintenance
records should be transferred to each subsequent owner. Kohler Co. reserves the right to deny warranty coverage if the engine has not been
properly maintained; however, Kohler Co. may not deny warranty repairs solely because of the lack of repair maintenance or failure to keep
maintenance records.
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 service center. Any replacement part or service that
is equivalent in performance and durability may be used in non-warranty maintenance or repairs, and shall not reduce the warranty obligations of the
engine manufacturer.
18
FOR SALES AND SERVICE INFORMATION
IN US . AND CANADA, CALL
1-800-544-2444
I FORM NO.:
I ISSUED:
60-
110 RUN'"
ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044
TP-2474-H
12/94
12/01
REVISED:
MAILED:
LITHO IN U.S.A.
I
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