OWNER'S MANUAL COMMAND 18-26 HP HORIZONTAL CRANKSHAFT 1 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. 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 warning 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. WARNING 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, away 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. Rotating Parts! Keep hands, feet, hair, and clothing away from all moving parts to prevent injury. Never operate the engine with covers, shrouds, or guards removed. CAUTION Hot Parts can cause severe burns. Do not touch engine while operating or just after stopping. 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 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. 2 WARNING Engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Safety Precautions (Cont.) WARNING WARNING WARNING Accidental Starts can cause severe injury or death. Carbon Monoxide can cause severe nausea, fainting or death. Explosive Gas can cause fires and severe acid burns. Disconnect and ground spark plug leads before servicing. Do not operate engine in closed or confined area. Charge battery only in a well ventilated area. Keep sources of ignition away. Accidental Starts! Disabling engine. Accidental starting can cause severe injury 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. 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. 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. 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. *CH25/26 engines have POWER-BORE™ Cylinders. 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. 3 Air Cleaner Dipstick Oil Fill Fuel Pump Oil Filter Oil Cooler Electric Starter Rectifier-Regulator Side Oil Drain Plugs Figure 1. Typical Command Horizontal Shaft Engine (CH18-25). Throttle Body Intake Manifold Ignition Coil Fuel Injectors Ignition Coil Oil Filter Oil Cooler Rectifier-Regulator Figure 2. CH26 Command Horizontal Shaft Engine. 4 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 SG, SH, SJ or higher. Select the viscosity based on the air temperature at the time of operation as shown in the following table. 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, away 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 Recommendations 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. ** * *Use of synthetic oil having 5W-20 or 5W-30 rating is acceptable, up to 40°F. **Synthetic oils will provide better starting in extreme cold (below -10°F). Figure 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 use gasoline left over from the previous season, to minimize gum deposits in fuel system and to insure easy starting. 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 engines. 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. 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. Refer to “Maintenance Instructions” beginning on page 8 for detailed oil check, oil change, and oil filter change procedures. 5 Engine Identification Numbers When ordering parts, or in any communication involving an engine, always give the Model, Specification, and Serial Numbers of the engine. The engine identification numbers appear on a decal (or decals) 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. 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. • Check fuel level. Add fuel if low. • Check cooling air intake areas and external surfaces of engine. Make sure they are clean and unobstructed. MODEL NO. SPEC. NO. DISPL (CC) SERIAL NO. • Check that the air cleaner components and all shrouds, equipment covers, and guards are in place and securely fastened. REFER TO OWNER'S MANUAL FOR SAFETY, MAINTENANCE SPECS AND ADJUSTMENTS. FOR SALES AND SERVICE IN US/CANADA CALL: 1-800-544-2444 • 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. KOHLER CO. KOHLER, WI USA IMPORTANT ENGINE INFORMATION THIS ENGINE MEETS U.S. EPA PHASE 1 AND 1995-1999 CALIFORNIA EMISSION CONTROL REGULATIONS FOR SORE* FAMILY MODEL NO. SPEC. NO. DISPL (CC) SERIAL NO. REFER TO OWNER'S MANUAL FOR SAFETY, MAINTENANCE SPECS AND ADJUSTMENTS. FOR SALES AND SERVICE IN US/CANADA CALL: 1-800-544-2444 KOHLER CO. KOHLER, WI USA If your engine has this identification label, it is certified to meet EPA/CARB standards. *Small Off-Road Engines Figure 5. Engine Identification Labels. 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. Cold Weather Starting Hints 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. Set speed control at part throttle position. 4. Be sure the battery is in good condition. A warm battery has much more starting capacity than a cold battery. 5. Use fresh winter grade fuel. NOTE: Winter grade gasoline has a higher volatility to improve starting. Do not use gasoline left over from summer. Starting CH18-26 Engines: 1. Place the throttle control midway between the ‘‘slow’’ and ‘‘fast’’ positions. Place the choke control (CH18-25 engines only) into the ‘‘on’’ position. See Figure 6. 6 4. For a Warm Engine – Return choke to “off” position as soon as engine starts. Stopping Choke Control Throttle Control Figure 6. Optional Engine Mounted Throttle and Choke Controls (CH18-25). 2. Start the engine by activating the key switch. Release the switch as soon as the engine starts. NOTE: 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. Upon start up, a metallic ticking may occur. This is caused by the 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. If the engine develops sufficient speed to disengage the starter but does not keep running (a false start), the engine rotation must be allowed to come to a complete stop before atttempting 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. CH18-25 Engines Only: 3. For a Cold Engine – Gradually return the choke control to the “off” position after the engine starts and warms up. 1. Remove the load by disengaging all PTO driven attachments. 2. For CH18-25 Engines Without A 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 CH18-25 Engines Equipped With A Shutdown Solenoid: Position the throttle control somewhere between half and full throttle; then stop the engine. For CH26 Engines: 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 12). 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. 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. 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. 7 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. 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. Maintenance Instructions Maintenance, repair, 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. WARNING: Accidental Starts! Disabling engine. Accidental starting can cause severe injury 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. 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 25 Hours Every 100 Hours Maintenance Required • • • • Fill fuel tank. Check oil level. Check air cleaner for dirty1, loose, or damaged parts. Check air intake and cooling areas, clean as necessary1. • • • • • Service precleaner element1. Replace air cleaner element1. Change oil. (More frequently under severe conditions.) Remove cooling shrouds and clean cooling areas1,3. Check oil cooler fins, clean as necessary (if equipped). Every 200 Hours • Check spark plug condition and gap. • Change oil filter. Annually or Every 500 Hours • Have bendix starter drive serviced2. • Have solenoid shift starter disassembled and cleaned2. Every 1500 Hours • Replace fuel filter1 (CH26 engines). 1 Perform these maintenance procedures more frequently under extremely dusty, dirty conditions. Have a Kohler Engine Service Dealer perform this service. 3 Cleanout Kits 25 755 20 (black) or 25 755 21 (gold) allow cooling areas to be cleaned without removing shrouds. 2 Check Oil Level 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. 8 3. Remove the dipstick; wipe oil off. Reinsert the dipstick into the tube and press all the way down. 4. Remove the dipstick and check the oil level. 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. “F” Mark Operating Range Figure 7. Oil Level 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. 3. Reinstall the drain plug. Make sure it is tightened to 13.6 N·m (10 ft. lb.) torque. 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 before adding more oil. 5. Reinstall the oil fill cap and tighten securely. Reinstall 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. Oil Sentry™ Some engines are equipped with an optional Oil Sentry™ oil pressure switch monitor. If the oil pressure decreases below an acceptable level, the Oil Sentry™ 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 USE and is maintained up to the “F” mark on the dipstick. This includes engines equipped with Oil Sentry™. Oil Filter Oil Cooler Oil Drain Plug Figure 8. Oil Drain Plugs, Oil Filter, and Oil Cooler (CH25 shown). Change Oil and Filter, Service Oil Cooler 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 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): 1. To keep dirt, debris, etc., out of the engine, clean the area around the oil fill cap/dipstick before removing it. Oil Filter Oil Drain Plug Oil Cooler Figure 9. Oil Drain Plugs, Oil Filter, and Oil Cooler (CH26 shown). 9 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 01. Service Precleaner and Air Cleaner Element This engine is equipped with a replaceable, high density paper air cleaner element. Some engines are also equipped with an oiled, foam precleaner which surrounds the paper element. See Figure 10. Replace the oil filter as follows: 1. Drain the oil from the engine crankcase. Air Cleaner Cover Cover Knob 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. Element Cover Nut Element Cover Element Precleaner Figure 10. 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. 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 1/2 turn. NOTE: Operating the engine with loose or damaged air cleaner components could allow unfiltered air into the engine causing premature wear and failure. 7. Reinstall the drain plug. Make sure it is tightened to 13.6 N·m (10 ft. lb.) torque. Service Precleaner If so equipped, wash and reoil the precleaner every 25 hours of operation (more often under extremely dusty or dirty conditions). 8. Fill the crankcase with new oil of the proper type to the “F” mark on the dipstick. Add 0.24 L (1/2 pint) of oil for the filter capacity. 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. Service Oil Cooler Some engines are equipped with an oil cooler. Inspect and clean the oil cooler every 100 hours of operation (more frequently under severe conditions). Oil cooler must be kept free of debris. To service the oil cooler, clean off the outside fins with a brush or with compressed air. 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. 4. Saturate the precleaner with new engine oil. Squeeze out all excess oil. 5. Reinstall the precleaner over the paper element. 6. Reinstall the air cleaner cover. Secure cover with the cover retaining knob. 10 7. When precleaner replacement is necessary, order genuine Kohler parts. 24 083 02 61 mm deep x 173 mm O.D. Clean Air Intake/Cooling Areas To ensure proper cooling, make sure the grass screen, cooling fins, and other external surfaces of the engine are kept clean at all times. 24 083 05 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. 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. 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. 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. 6. Reinstall the paper element, precleaner, element cover, element cover nut, and air cleaner cover. Secure cover with the cover retaining knob. 7. When element replacement is necessary, order genuine Kohler parts. 47 083 03 65 mm deep x 178 mm O.D. 24 083 03 74 mm deep x 178 mm O.D. 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 necessary. 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. *Cleanout kits 25 755 20 (black) or 25 755 21 (gold) allow inspection and cleanout of the cooling fins. Ignition System CH18-25 Engines - Use an electronic Capacitive Discharge (CD) ignition system. Other than periodically checking/replacing the spark plugs, no maintenance, timing, or adjustments are necessary or possible with this system. CH26 Engines - Incorporate a computer controlled and monitored ignition system with individual coils. Other than periodically checking/replacing the 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 necessary. The standard spark plug is a Champion® RC12YC (Kohler Part No. 12 132 02). A high-performance spark plug, Champion® Premium Gold 2071 (used on Pro Series engines, Kohler Part No. 12 132 06) 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. 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. 11 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 11. Wire Gauge Spark Plug Fuel System WARNING: Fuel System Under Pressure! The CH26 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. Fuel Filter CH18-25 Engines: Some engines are equipped with an in-line fuel filter. Periodically inspect the filter and replace when dirty. Always use genuine Kohler parts. CH26 Engines: A special, high volume, high pressure filter with greater filtration capabilities and internal surface area is used. See Figure 12. Ground Electrode 0.76 mm (0.030 in.) Gap Fuel Filter Figure 11. Servicing Spark Plug. 4. Reinstall the spark plug into the cylinder head. Torque the spark plug to 24.4/29.8 N·m (18/22 ft. lb.). Fuel Line Battery Charging Figure 12. CH26 Fuel Filter and Line. 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 away from the battery at all times. Keep batteries out of the reach of children. Remove all jewelry when servicing batteries. Replacement is recommended every 1500 hours, or more frequently under extremely dusty or dirty conditions. When replacement is necessary, always use genuine Kohler parts. 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. 12 Fuel Line CH26 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 12. If fuel line must be replaced, see your Kohler Engine Service Dealer. CH18-25 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. The high idle is set at the factory and cannot be adjusted. The low idle fuel adjusting needle is also set at the factory and normally does not need adjustment. If the engine is hard to start, runs roughly, or stalls at low idle speed, it may be necessary to adjust or service the carburetor. • 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 NOTE: Certified engines may have a fixed idle or limiter cap on the idle fuel adjusting needle. Do not attempt steps 1 and 2 below. Proceed directly to step 3. Step 4 can only be performed within the limits allowed by the cap. 1. With the engine stopped, turn the low idle fuel adjusting needle in (clockwise) until it bottoms lightly. NOTE: Low Idle Speed Adj. Screw Low Idle Fuel Adj. Needle & Spring Fixed Main Jet (under optional solenoid) Figure 13. Carburetor (CH18-25). Troubleshooting If engine troubles are experienced that appear to be fuel system related, check the following areas before adjusting the carburetor. • 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. The tip of the low idle fuel adjusting needle is tapered to critical dimensions. Damage to the needle and the seat in carburetor body will result if the needle is forced. 2. Preliminary Low Idle Fuel Needle Setting: Turn the adjusting needle out (counterclockwise) from lightly bottomed position 1-5/8 turns. 3. 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 4 and 5). 4. Low Idle Fuel Needle Setting: Place the throttle into the “idle” or “slow” position. Turn the low idle fuel adjusting needle in (slowly) from the preliminary setting until engine speed decreases and then back out approximately 3/4 to 1 turn to obtain the best low-speed performance. 5. Low Idle Speed Setting: Place the throttle control into the “idle” or “slow” position. Set the low idle speed to 1200 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 manufacturer’s recommendations. The recommended low idle speed for basic engines is 1200 RPM. To ensure best results when setting the low idle fuel needle, the low idle speed must not exceed 1200 RPM (± 75 RPM). 13 CH26 Electronic Fuel Injection (EFI) System Adjustment – EFI Throttle Body 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. 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* (+ 75 RPM). 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. 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. *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 briefly set a higher (200-400 RPM) low idle speed, similar to a fast idle. Do not attempt to perform any readjustment during this ‘‘warm-up’’ period. 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). 1. Start the engine and run at half throttle for 5 to 10 minutes to warm up. 2. Place the throttle control into the ‘‘idle’’ or ‘‘slow’’ position. 3. Turn the low idle speed adjusting screw in or out and check RPM with a tachometer. See Figure 14. • Make sure fuel tank vent cap is not blocked and it is operating properly. Low Idle Speed Adjusting Screw • Make sure the air cleaner element and precleaner are clean and all components are properly secured. Clean or replace as necessary. Throttle Body Intake Manifold • Make sure the proper fuel filter is being used, and it is clean and unobstructed. Replace filter only with genuine Kohler parts. Fuel Rail • Make sure all connections to sensors, ECU, and fuel injectors are properly secured. • Make sure a good 12 volt battery is being used and is fully charged. 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. 14 Figure 14. 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 • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Storage Parts Ordering If the engine will be out of service for two months or more, use the following storage procedure: 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. 1. Clean the exterior surfaces of the engine. 2. Change the oil and filter while the engine is still warm from operation. See “Change Oil and Oil Filter” on page 9. 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 carburetor. 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. 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. Always insist on genuine Kohler parts. All genuine Kohler parts meet strict standards for fit, reliability, and performance. 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. Model Designation Model CH20S for example: C designates Command engine, H designates horizontal crankshaft, and 20 designates horsepower. A letter suffix designates a specific version as follows: Suffix Designates S Electric Start GS Generator Application/Electric Start ST Electric Start/Retractable Start QS Quiet Model/Electric Start EP Electric Plant CS Clutch Model/Electric Start 15 Specifications Model: ................................................ CH18 .................. CH20 .................. CH22 ................. CH25/CH26 Bore: ............................... in. (mm) ... 3.03 (77) ............. 3.03 (77) ............ 3.03 (77)# ................... 3.27 (83)/3.27 (83) Stroke: ............................ in. (mm) ... 2.64 (67) ............. 2.64 (67) ............ 2.64 (67) ............ 2.64 (67)/2.64 (67) Displacement: ................ in3 (cm3) ... 38.1 (624) ........... 38.1 (624) .......... 38.1 (624)# ............... 44.0 (725)/44.0 (725) Power (@3600 RPM): ..... HP (kW) ... 18* (13.4) ........... 20* (14.9) ........... 22* (16.4) ........... 25* (18.4)/26 (19.4 ) Max. Torque: ........... (ft. lbs. @ RPM) ... 30 (41) @2500 ..... 32 (44) @2500 .... 33 (45) @2500 .... 39.5 (54) @2400/41.6 (56.4) @2200 Compression Ratio: ......................... 8.5:1 .................... 8.5:1 ................... 8.5:1 ................... 9.0:1/9.0:1 Weight: ............................. lbs. (kg) ... 90 (41) ................ 90 (41) ................ 90 (41) ............... 94 (43)/94 (43) Oil Capacity (w/filter): .. U.S. qt. (L) ... 2.1 (2) ................. 2.1 (2) ................. 2.1 (2) ................ 2.1 (2)/2.1 (2) Lubrication: ................................................ Full Pressure w/full Flow Filter *Horsepower ratings are established in accordance with Society of Automotive Engineers – Small Engine Test Code – J1349 GROSS. Kohler Co. reserves the right to change product specifications, design, and standard equipment without notice and without incurring obligation. # CH22 engines with Spec. Numbers of 765xx have bore size of 3.15 in. (80 mm) and displacement of 41.1 in3 (674 cm3). 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: This warranty does not apply to defects caused by casualty or unreasonable use, including faulty repairs by others and failure to provide reasonable and necessary 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 WRITTEN 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 vary 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 53044 16 KOHLER CO. FEDERAL AND CALIFORNIA EMISSION CONTROL SYSTEMS LIMITED WARRANTY UTILITY AND LAWN AND GARDEN 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 utility/lawn/garden equipment engine (herein 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, new 1997 and later model year engines must be designed, built and equipped, at the time of sale, to meet the U.S. 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 U.S. 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 carburetor 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. MANUFACTURER’S 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. OWNER’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. (c) For warranty repairs, the engine must be presented to a Kohler Co. service center as soon as a problem exists. Call 1-800-544-2444 for the names of the nearest service 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. Engine Service at 1-920-457-4441. 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: • • • • • • Carburetor 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) Continued on next page. 17 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 necessary 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 service 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 covering 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 19 FOR SALES AND SERVICE INFORMATION IN U.S. AND CANADA, CALL 1-800-544-2444 ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044 FORM NO.: TP-2474-E ISSUED: 12/94 REVISED: 5/99 MAILED: LITHO IN U.S.A.