Kohler COMMAND20=25HP User's Manual

Kohler COMMAND20=25HP User's Manual
0WNER's MANUAL
COMMAND 20=25HP
HOREONUL
CRANKSHAFT
LP Gas Fueled or Dual-Fueled (LP Gas - Gasoline)
--
RUN'"
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.
a
a
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
I
II
a WARNING
Accidental Starts can cause severe
injury or death.
Rotating Parts can cause severe
injury.
Disconnect and ground spark plug
leads before servicing.
Stay away while engine is in
operation.
Accidental Starts!
Disa6fing engine. Accidenfa/
sfading can cause severe injuu/r or
deafh. 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.
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 LP/gasoline fuel vapors are
present.
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.
a CAUTION
I
a WARNING
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
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
II
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.)
I
a WARNING
Explosive Fuel can cause fires and
severe burns.
Stop engine before filling fuel tank.
Explosive Fuel!
LPG is extremely flammable and is
heavier than air and tends to settle in
low areas where a spark or flame
could ignite the gas. Do not start or
operate this engine in a poorly
ventilated area where leaking gas
could accumulate and endanger the
safety of persons in the area.
To insure personal safety, installation
and repair of LPG fuel supply
systems must be performed only by
qualified LPG system technicians.
Improperly installed and maintained
LPG equipment could cause fuel
supply system or other components
to malfunction, causing gas leaks.
Observe federal, state and local laws
governing LPG fuel, storage, and
systems.
- Continued in next column -
I
GasoEne 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.
I
a WARNING
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.
WARNING
7
1
Explosive Gas can cause fires and
severe acid burns.
Charge battey only in a well
ventilated area. Keep sources of
ianition awav.
I
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 LP/gasoline fuel
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 and oil fill, air cleaner, spark plugs,
and carburetor) 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 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(US. & Canada) for Sales & Service assistance.
To keep your engine in top operating condition, follow the maintenance procedures in this manual.
3
Dipstick
,
Air Cleaner
!tric
/si
:igure I , Typical Command Horizontal Shaft LP Gas Fueled Engine,
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. Using oil that is incorrect or dirty
can cause premature engine wear and failure.
Synthetic oil is recommended for use in LPG-fueled
engines because there is less oxidation or thickening,
and deposit accumulation on intake valves is
substantially reduced. Conventional petroleum-based oil
may be used, but valve service will be required every
500 hours to remove the accumulated deposits.
Dual-fueled engines can use conventional oil without
requiring speciaVadditional valve service.
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
A logo or symbol on oil containers identifies the API
service class and SAE viscosity grade. See Figure 3.
1OW30
Oil Type
Use high quality, 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.
I
R E C O M M E N D E D S A E V I S C O S I T Y GRADES
I
OF -50
J
ncko
,
I
1
0
20
-10
-io
d2
0
I
4b
10
$0
Refer to “Maintenance Instructions” beginning on
page 8 for detailed oil check, oil change, and oil
filter change procedures,
1
80
60
100
30
40
TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANGE
I Use of synthetic oil is recommended.
Figure 2, Viscosity Grades Table,
4
W
Figure 3. Oil Container Logo,
I
LPG Engines
LPG Fuel Recommendations
Liquefied Petroleum Gas (LPG) from an appropriate LP
fuel tank (supplied separately) is required to operate
this engine.
a
WARNING: Pressurized LPG!
Fuel tanks are filled under pressure and should be
handled with care. To prevent tank damage which could
endanger the safety of the operator or persons in the
area, do not drop or drag tanks on any surface. Use a
hand truck when moving, or tilt the tank on its footring in
a position slightly off vertical and roll it.
Avoid personal contact with LPG fuel to prevent
frostbite. See a physician if frostbite occurs.
a
WARNING: Explosive Fuel!
LPG is extremely flammable, is heavier than air and
tends to settle in low areas where a spark or flame
could ignite the gas. Do not start or operate this engine
in a poorly ventilated area where leaking gas could
accumulate and endanger the safety of persons in the
area.
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.
Do not use gasoline left over from previous season,
to minimize gum deposits in your 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.
LPG fuel consists primarily of propane, although the fuel
supplier may sometimes mix other gases with propane.
Unleaded gasoline is recommended as it leaves less
combustion chamber deposits. Leaded gasoline may be
used in areas where unleaded is not available and
exhaust emissions are not regulated. Be aware
however, that the cylinder heads may require more
frequent se nice.
Fuel tanks must be filled only by persons qualified in the
handling of LPG. Tanks are filled by weight and should
not be overfilled (never to more than 80 percent of total
capacity). An air space must be present in the tank to
allow fuel to expand.
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.
Tanks must be removed from equipment before filling.
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.
Dual-Fuel Engines
Dual-fuel engines are designed to operate on either
LPG or gasoline. For LPG operation, the above
information and warnings apply. For gasoline operation,
the following information and warnings apply.
Fuel Recommendations
a
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.
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
S
Designates
Electric Start
5
Engine Identification Numbers
Operating Instructions
When ordering parts, or in any communication
involving an engine, always give the Model,
Specification, and Serial Numbers of the engine.
Also read the operating instructions of the equipment
this engine powers.
Pre-Start Checklist
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 4) for future reference.
IMPORTANT
- ENGINE INFORMATION
THIS ENGINE MEETS U.S. EPA PHASE 1 ANC
CALIFORNIA 2006 AND LATER EMISSION
CONTROL REGULATIONS FOR SI SORE*
FAMILY
DISPL, (CC)
MODEL NO,
SPEC. NO,
SERIAL NO.
FOR SALES/SERVICE IN USKANADA, CALL:
1-800-544-2444
www. kohlerengines.com
[email protected]
KOHLER CO. KOHLER, WISCONSIN USA
*Small Off-Road Engines
7gure 4, 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 CARB emission requirements.
The following table provides the Engine Compliance
Period (in hours) associated with the category
descriptor found on the certification label.
Moderate
125 hours
Check fuel gauge on LPG tank. Tanks should be
filled to a specific weight. To insure safety and
proper fuel system operation, tanks must not be
overfilled.
Check fuel lines, regulator, and other system
components for leaks. Do not start engine until
leaks are eliminated.
Check cooling air intake areas and external
surfaces of engine. Make sure they are clean and
unobstructed.
EMISSION COMPLIANCE PERIOD:
EPA:
CARB:
THIS ENGINE IS CERTIFIED TO OPERATE
ON:
REFER TO OWNER'S MANUAL FOR SAFETY,
MAINTENANCE SPECS AND ADJUSTMENTS.
CARB
Check oil level. Add oil if low. Do not overfill.
Intermediate Extended
250 hours
500 hours
Check that the air cleaner components and all
shrouds, equipment covers, and guards are in
place and securely fastened.
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.
a
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.
Although LPG burns more efficiently and emits less
carbon monoxide than gasoline, some carbon
monoxide is produced. Avoid inhaling exhaust gases,
especially over prolonged periods of time. Do not allow
engine to run unattended.
Cold Weather Starting Hints
1. Be sure to use the proper oil for the temperature
expected. See Figure 2 on page 4.
2. Disengage all possible external loads.
Exhaust Emission Control System for models
CH20 LP, CH25 LP, and CH25 Dual Fuel (open loop),
is EM. Exhaust Emission Control System for model
CH25 Dual Fuel (closed loop) is EM, 02S, ECM.
6
3. Be sure the battery is in good condition. A warm
battery has much more starting capacity than a
cold battery.
Starting
1. Place the throttle control in the idle position. Place
the choke control into the “on”position. See
Figure 5. On dual-fueled engines, place the threeposition fuel control switch in the gasoline position
and place the throttle control between half and full
throttle (engine must be started and run on
gasoline for 1 minute to heat up oxygen sensor).
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
page 8). See your Kohler Engine Service Dealer for
trouble analysis.
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-throttlefor 20 minutes. If noise persists,
take the engine to your local Kohler Service
outlet.
Stopping
Figure 5. Optional Engine Mounted Throttle and
Choke Controls,
2. Slowly turn the fuel valve on the LPG (propane)
tank to full open position. For “gasoline only”
operation on dual-fuel units, leave valve closed.
3. Start the engine by activating the key switch.
Release the switch as soon as the engine starts.
Return choke to “off” position after engine starts.
On a cold engine, it may be necessary to leave
choke partially on until engine begins to warm up.
Dual-fuel engines must be allowed to warm up on
gasoline for at least 1 minute. To switch to LPG
operation, move the three-position switch to the
LPG position.
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 the starter motor.
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.
LPG-Only Engines
1. Turn fuel valve on LPG tank to full closed position
and allow the engine to continue running until it
runs out of fuel. Turn ignition switch to “off”
position.
Dual-Fuel Engines
1. Dual-fuel engines may be stopped any of three
ways:
When operating on LPG, one method is the
same as described above for LPG-only
engines.
LPG operation can also be stopped by
moving the three-positionfuel control switch
to the “off”position and letting the engine
run out of fuel. Turn off ignition switch. If
engine will not be restarted for some time,
also close fuel valve at LPG tank.
To stop the engine from gasoline operation, it
should be running between half and full
throttle. Move the three-position fuel control
switch and/or the ignition switch to the “off”
position.
In an emergency, move the throttle control to
stop or turn the ignition switch off.
NOTE: Backfiring may occur when using the
emergency stop method!
7
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 flywheel screen or
other cooling 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.
a
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
speed for these engines is 3750 RPM, no
load.
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,
*For safety and health reasons, many states require special licensing or certification for servicing LPG fuel
systems. Check local and state regulations before choosing a repair establishment to perform fuel system repairs.
a
WARNING: Accidental Starts!
Disabhg engine. Accidenta/startng can cause severe injuv or death Before working on the engine or
equipment, disable the engine as follows: 1) Disconnect the spark plug [email protected]).2) Disconnect negative (-)negative
(-)battery cable from battery
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 LP/gasoline fuel vapors are present.
8
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.
I
Frequency
Daily or Before
Starting Engine
Every 25 Hours
I
Maintenance Required
Check fuel gauge on propane (LPG) tank. Fill gasoline tank (dual-fuel units only).
Check oil level.
Check air cleaner for dirty’, loose, or damaged parts.
Check air intake and cooling areas, clean as necessary’.
Every 100 Hours
Service precleaner element’.
Replace air cleaner element’.
Change Oil.
Remove cooling shrouds and clean cooling areas’.
Check oil cooler fins, clean as necessary (if equipped).
Check spark plug condition and gap.
Everv200 Hours
Change oil filter.
Annually or
Every 300 Hours
Replace spark plugs.
Annually or
Every 500 Hours
Check all lines (high pressure/vacuum) including fittings for leaks.
Have electric starter serviced2.
Have lock-off/filter serviced3.
Have combustion deposits removed if using non-synthetic oil (not on dual-fuel engines).
Drain regulator of accumumulated fuel deposits (Nikki regulators only).
Every 1500 Hours
Have regulator disassembled, cleaned, and reset3.
‘Perform these maintenance procedures more frequently under extremely dusty, dirty conditions.
2Havea Kohler Engine Service Dealer perform this service.
3Mustbe performed by an Authorized Kohler Engine Dealer or qualified LP personnel on&
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:
I
Operating
“F” Mark
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.
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 6.
I
Figure 6. 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 4.) 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.
9
Oil SentryTM
Some engines are equipped with an optional Oil
Sentry’” oil pressure switch. 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’”.
Change Oil and Oil Filter
Change Oil
Change oil after every 700 hours of operation. Refill
with service class SG, SH, SJ or higher oil as specified
in the “Viscosity Grades” table (Figure 2) on page 4.
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 Figure 7):
1. To keep dirt, debris, etc., out of the engine, clean
the area around the oil fill cap/dipstick before
removing it.
2. Remove one of the oil drain plugs, oil fill cap, and
dipstick. Be sure to allow ample time for complete
drainage.
3. Reinstall the drain plug. Make sure it is tightened
to 73.6 N.m (70 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 4. 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.
Engine Oil Drain Plug’
Figure 7. Oil Drain Plug and Oil Filter.
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.
Replace the oil filter as follows:
1. Drain the oil from the engine crankcase by
removing one of the drain plugs and allowing
ample time for complete drainage.
2. 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.
3. 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.
4. Put a drop of oil on your fingertip and wipe it on
the rubber gasket.
5. Install the new oil filter onto the filter adapter. Turn
the oil filter clockwise until the rubber gasket
contacts the mounting surface, then tighten the
filter an additional 2/3 to 7 turn.
6. Reinstall the drain plug. Make sure it is tightened
to 73.6 N.m (70 ft. lb.) torque.
7. Fill the crankcase with new oil of the proper type
to the “ F mark on the dipstick.
10
8. Test run the engine to check for leaks. Stop the
engine, allow a minute for the oil to drain down,
and recheck the level on the dipstick. Add more oil
as necessary so the oil level is up to but not over
the "F" mark on the dipstick.
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 Figures 8 and 9.
I Air Cleaner Cover
Air Cleaner Cover Knob I
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.
7. When precleaner replacement is necessary order
genuine Kohler parts.
I
I
Figure 8- Air Cleaner Housing Components,
CH20-22
24083024
I
I
CH25
24083054
I
I
Service Paper Element
Every 700 hours of operation (more often under
extremely dusty or dirty conditions) replace the paper
element.
1. Loosen the cover retaining knob and remove the
air cleaner cover.
2. Remove the element cover nut, element cover,
and paper elemenVprecleaner.
3. Remove the precleaner (if so equipped) from the
paper element and service as instructed above.
Figure 9. 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.
NOTE: Operating the engine with loose or damaged
air cleaner components could allow unfiltered
air into the engine causing premature wear
and failure.
Service Precleaner
If so equipped, wash and reoil the precleaner every 25
hours of operation (more often under extremely dusty
or dirty conditions).
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: Before air cleaner reassembly make sure
rubber seal is in position around stud.
Inspect, making sure it is not damaged
and seals with the element cover.
6. Reinstall the paper element, precleaner, element
cover, element cover nut, and air cleaner cover.
Secure cover with cover retainina knob.
7. When element replacement is necessary order
genuine Kohler parts.
I
I
CH20-22
47083034
I
I
CH25
2408303-S
I
I
Clean Air Intake/Cooling Areas
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 10.
4. Reinstall the spark plug into the cylinder head.
Torque the spark plug to 24.4-29J N-m
(78-22 ft. lb,).
To ensure proper cooling, make sure the flywheel
screen, cooling fins, and other external surfaces of the
engine are kept clean at all times.
Every 700 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 flywheel
screen, dirty or plugged cooling fins, and/or
cooling shrouds removed, will cause engine
damage due to overheating.
I
-/“IW
Ignition System
This engine is equipped with an electronic CD ignition
system. Other than periodically checking/replacing the
spark plugs, no maintenance, timing, or adjustments
are necessary or possible with this system.
In the event starting problems should occur which are
not corrected by replacing the spark plugs, see your
Kohler Engine Service Dealer for trouble analysis.
Check Spark Plugs
Every 700 hours of operation, remove the spark plugs,
check condition, and reset the gap or replace with new
plugs as necessary. Every 300 hours or annually
replace the spark plugs. Replacement spark plugs are
Kohler Part No. 12 132 02-S ([email protected]
RCl2YC). 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 plugs in a
machine using abrasive grit. Some grit
could remain in the spark plug and enter
the engine causing extensive wear and
damage.
12
Ground
Electrode
0.76 mm
(0,030 in,) Gap
Ygure 70, Servicing Spark Plug,
Battery Charging
a
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 LP/gasoline fuel
vapors are present.
Charging of battery should be performed as outlined by
the original equipment manufacturer (OEM) in their
operator’s manual.
Fuel Filter
The filter of the LP fuel system is an integral part within
the lock-off/filter assembly. All service relating to the
lock-off/filter is to be performed by an authorized Kohler
Engine Service Dealer or qualified LP personnel only.
Servicing of filter is recommended every 500 hours. The
gasoline system (dual-fuel only) has an in-line fuel filter.
Periodically inspect the filter and replace when dirty. Use
a genuine Kohler filter, Part No. 24 050 02-S.
Carburetor Troubleshooting and
Adjustments
In compliance with government emission standards,
the carburetor and the regulator are calibrated and
preset to deliver the correct fuel-to-air mixture to the
engine under all operating conditions and cannot be
adjusted, except for low idle speed. Carburetor
servicing is to be performed by an authorized Kohler
Engine Service Dealer only. See Figure 11.
LPG Regulator
In compliance with government emission standards,
the regulator is preset at the factory to provide the
proper supply of fuel. No adjustment or resetting of
regulator is to be made. All service relating to the
regulator must be performed by an authorized Kohler
Engine Service Dealer or qualified LP personnel only.
Over time, fuel deposits can accumulate inside the
regulator. Draining of these deposits is recommended
(Nikki regulators only) every 500 operating hours, or
annually, whichever comes first.
Nikki Regulators
Every 500 hours/annually drain regulator:
1. Turn fuel supply valve off, run engine out of fuel,
and turn off ignition switch.
2. Disconnect and ground the spark plug leads.
3. Remove the 1/8" pipe plug from the bottom of
regulator and drain any accumulated deposits.
See Figure 12.
Regulatbr Drain Plug
7gure 11,
7gure 12. Nikki Regulator Drain Plug,
Fuel Delivery Line
High Pressure
Lock-OfVFiIter
(12 VoltDC)
1
I I
Vaporizer
Vacuum Line
Dry Gas Regulator
Propane Supply Tan
(Liquiid Withdrawal)
7gure 13. Schematic Showing Components of LP System,
13
-
4. Reinstall plug using [email protected] sealant (not
[email protected]) on threads and tighten securely. If
required, a replacement plug is available as
Kohler Part No. X-75-23-S.
Troubleshooting Fuel Related
If engine problems are experienced that appear to be
fuel system related, check the following areas before
seeking service assistance.
All Regulators
Every 1500 Hours:
Complete cleaning (disassembling, servicing, and
resetting) of regulator at 1500 hour intervals is
recommended. As all adjustments and settings must
be reset using specific test equipment, this must be
performed by an authorized Kohler Engine Service
Dealer or qualified LP personnel only.
Make sure the LPG tank is properly filled (never to
more than 80 percent of total capacity). An air
space must be present in the tank to allow fuel to
expand.
Make sure the air cleaner element is clean and all
air cleaner components are fastened securely.
Check for loose, kinked, or cracked vacuum lines
causing regulator not to open.
Lock-Off/Filter Assembly
This opens, closes, and filters the liquid fuel flow from
the supply tank before reaching the vaporizer.
Servicing, if required, is to be performed by an
authorized Kohler Engine Service Dealer or qualified
LP personnel only. See Figure 13.
Check to make sure the fuel valve on LPG tank is
fully open.
Check gauge on LPG tank to make sure pressure
is sufficient to open the regulator.
Vaporizer
For problems with the gasoline system (dual-fuel),
check that there is adequate fresh fuel in the tank,
the fuel valve at the tank (if so equipped) is open,
the fuel tank cap is properly vented, the lines are
not kinked or blocked, and that the in-line filter is
not dirty or restricted.
The vaporizer changes the Liquified Petroleum (LP)
from the supply tank to a gaseoushapor state. Other
than keeping the body clean, no maintenance,
adjustment, or servicing is required. See Figure 13.
Leakage ChecWTesting
Every 500 hours or annually. With LPG tank valve
fully opened, engine not running, turn key switch “on.”
Check all LPG system connections and lines for leaks
using soapy water. Any leakage must be corrected
before restarting engine. Have service performed by
an authorized Kohler Engine Service Dealer or
qualified LP personnel only.
If after checking the items listed above, the engine is
hard to start, runs roughly, or stalls at low idle speed,
qualified fuel system servicing may be necessary.
Contact your nearest authorized Kohler Engine Service
Dealer for further assistance.
Troubleshoofing
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.
Cause
Problem
No
Fuel
Will Not Start
Hard Starting
..
Stops Suddenly
Lacks Power
Operates Erratically
Knocks or Pings
Skips or Misfires
Backfires
Overheats
High Fuel Consumption
14
Improper
Fuel
.
.
..
.
.
Dirt
In
Fuel
Line
..
..
.
..
.
Dirty/
Restricted
Lock-off
Fuel Filter
..
..
..
..
.
Dirty
Flywheel
Screen
..
..
..
.
.
Incorrect
Oil
Level
..
..
.
Dirty
Engine
Air
Overloaded Cleaner
..
..
..
.
..
..
.
..
..
Faulty Dirty/Possible
Spark Restricted
Plug
Regulator
..
.
..
..
.
..
..
..
..
.
Storage
When the engine is not in use, use the following
storage procedure. Federal, state, or local laws
governing LPG fuel tank storage may also apply.
Follow the applicable storage laws.
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 10.
3. Turn valve on LPG tank off and run engine until
the fuel system is empty. Turn ignition key switch
off. Separate LPG tank from the unit and store
separately in an area designated for safe LPG
tank storage. On dual-fuel units, the gasoline 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 manufacturer's
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.
5. Store the engine in a clean, dry place. Store the
fuel tank in a designated safe LPG storage area at
all times when not in use.
Parts Ordering
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.
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.
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.
Specifications
Model: .................................................................................................
Bore: ...................................................
mm (in.) .................................
Stroke: .................................................
mm (in.) .................................
Displacement:.................................... cm3 (in.3).................................
Power (03600 RPM): ....................... kW (HP) .................................
Max. Torque (QRPM): ................... N.m (ft. Ib.) .................................
Compression Ratio: ............................................................................
Weight: .................................................
kg (Ib.) .................................
Oil Capacity (w/filter): ..................... L (U.S. qt.) .................................
Lubrication: .........................................................................................
CH20-22 ..........................................
77 (3.03) ..........................................
67 (2.64) ..........................................
624 (38.1) ........................................
14.9 (20*).........................................
44 (32) Q2500 ................................
8.5:l .................................................
41 (90) .............................................
2 (2.1) ..............................................
+ Full Pressure w/full Flow Filter
CH25
83 (3.27)
67 (2.64)
725 (44.0)
18.4 (25*)
54 (39.5) Q2400
9.O:l
43 (94)
2 (2.1)
+
Exhaust Emission Control System for models CH20 LP, CH25 LP, and CH25 Dual Fuel (open loop) is EM.
Exhaust Emission Control System for model CH25 Dual Fuel (closed loop) is EM, 02S, ECM.
*Horsepower ratings are established in accordance with Society of Automotive Engineers - Small Engine Test Code - J1995
GROSS. Kohler Co. reserves the right to change product specifications, design, and standard equipment without notice and
without incurring obligation. A horsepower reduction of approximately 10 percent may be expected with the operation and
use of LPG as fuel.
15
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 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 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 53044
KOHLER CO,
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 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)
16
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.
(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
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:
Oxygen sensor (if equipped)
Intake manifold (if equipped)
Exhaust manifold (if equipped)
Catalytic muffler (if equipped)
Fuel metering valve (if equipped)
Spark advance module (if equipped)
Crankcase breather
Ignition module(s) with high tension lead
Gaseous fuel regulator (if equipped)
Electronic control unit (if equipped)
Carburetor or fuel injection system
Fuel lines (if equipped)
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 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.
17
FOR SALES AND SERVICE INFORMATION
IN U S . AND CANADA, CALL
1-800-544-2444
I FORM NO.:
ISSUED:
60-
TP-2483-C
10/96
110 RUN'"
ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044
LITHO IN U.S.A.
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