Manual - Northern Tool + Equipment
Contents
1. lt MANUAL COMMAND 11 16 HP HORIZONTAL CRANKSHAFT KOHLER BORN TO 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 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 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 WARNING amp WARNING WARNING Explosive Fuel can cause fires and Rotating Parts can cause severe Hot Parts can cause severe burns severe burns injury Do not touch engine while operating Stop engine before filling fuel tank Stay away while engine is in or just after stopping operation Explosive Fuel Rotating Parts Hot Parts Gasoline is extremely flammable Keep hands feet hair and clothing Engine components get and i2. adjust or service the carburetor Carburetor Adjustment Figure 13 Optimum Low Idle Fuel Setting NOTE Certified engines may have a fixed idle or limiter cap on the idle fuel adjusting needle 3 Low Idle Speed Setting Place the throttle control Step 2 can only be performed within the limits into the idle or slow position Set the low idle allowed by the cap speed to 1200 RPM 75 RPM by turning the low idle speed adjusting screw or out Check 1 Start the engine and run at half throttle for 5 to 10 the speed using a tachometer minutes to warm up The engine must be warm before doing steps 2 and 3 NOTE The actual low idle speed depends on the application refer to equipment 2 Low Idle Fuel Needle Setting Place the throttle manufacturer s recommendations The into the idle or slow position recommended low idle speed for basic engines is 1200 RPM To ensure best Turn the low idle fuel adjusting needle out results when setting the low idle fuel counterclockwise from the preliminary setting needle the low idle speed must not until engine speed decreases rich Note the exceed 1200 RPM 75 RPM position of the needle Now turn the adjusting needle in clockwise The engine speed may increase then it will decrease as the needle is turned in lean Note the position of the needle Troubleshooting When troubles occur be sure to check the simple causes which at first may seem t
3. drainage Reinstall the drain plug Make sure it is tightened to 13 6 N m 10 ft Ib torque 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 Reinstall the oil fill cap or plug and tighten securely 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 Filter Figure 8 Oil Filter and Optional Oil Sentry Switch Change Oil Filter Replace the oil filter at least every other oil change every 200 hours of operation Always use genuine Kohler oil filter Part No 52 050 02 S Replace the oil filter as follows 1 Drain the oil from the engine crankcase 2 Allow the oil filter to drain 3 Before removing the oil filter clean the area around the oil filter to keep dirt and debris out of the engine Remove the old filter Wipe off the surface where the oil filter mounts 4 Place a new replacement filter in a shallow pan with the open end up Pour new oil of the proper type in through the threaded center hole Stop pouring when the oil reaches the bottom of the threads Allow a minute or two for the oil to be absorbed by the filter material 5 Puta drop of oil on your fingertip and wipe it on the rubber gasket
4. from summer Starting 1 Figure 5 Throttle and Choke Positions for Starting For a Cold Engine Place the throttle control midway between the slow and fast positions Place the choke control into the on position For a Warm Engine normal operating temperatures Place the throttle choke control midway between the slow and fast positions Place the choke into the on position See Figure 5 AS SY a a Oe Engine 2 Start the engine as follows For a Retractable Start Engine SLOWLY pull the starter handle until just past compression STOP Return starter handle pull firmly with a smooth steady motion to start Pull the handle straight out to avoid excessive rope wear from the starter rope guide Extend the starting rope periodically and check its condition If the rope is frayed have it replaced immediately by your Kohler Engine Service Dealer A WARNING Accidental Starts Before extending and checking the retractable starter rope remove the spark plug lead to prevent the engine from starting accidentally Make sure the equipment is in neutral For Electric Start Engine Activate the starter switch Release the switch as soon as the engine starts NOTE Do not crank the engine continuously for more than 10 seconds at a time If the engine does not start allow a 60 second cool down period between starting attempts Failure to fol
5. intervals longer than recommended can cause engine damage 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 the 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 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 head will require more frequent service 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 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 Engine Identification Numbe
6. 2 Disconnect negative battery cable from battery Safety Precautions Cont 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 Explosive Gas can cause fires and severe acid burns Charge battery only in a well ventilated area Keep sources of ignition away 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 single 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 e Efficient ove
7. 200 Hours Check spark plug condition and Annually or e Have bendix starter drive serviced Every 500 Hours e Have solenoid shift starter disassembled and cleaned Daily or Before Starting Engine Perform these maintenance procedures more frequently under extremely dusty dirty conditions Have a Kohler Engine Service Dealer perform this service 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 grass clippings etc out of the engine clean the area around the oil fill cap dipstick before removing it Press On Thread On 3 Remove the oil fill cap dipstick wipe oil off Figure 6 Dipstick Styles For engines with a press on style dipstick Reinsert the dipstick into the tube and press onto the tube See Figure 6 For engines with a thread on style dipstick Reinsert the dipstick into the tube and rest the oil fill cap on the tube Do not thread the cap onto the tube See Figure 6 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 F Mark Operating Range 0006 A Figure 7 Oil Level Dipstick 5 Ifthe level is low add oil of the proper type
8. 250 Hours 500 Hours Refer to certification label for engine displacement Exhaust Emission Control System for models CH11 12 5 13 14 15 16 is EM 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 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 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 2 on page 4 Declutch all possible external loads A warm battery has much more starting capacity than a cold battery Use fresh winter grade fuel NOTE Winter grade gasoline has higher volatility to improve starting Do not use gasoline left over
9. 6 Install the replacement oil filter to the filter adapter Turn the oil filter clockwise until the rubber gasket contacts the filter adapter then tighten the filter an additional 2 3 to 1 turn 7 Reinstall the drain plug 8 Fill the crankcase with new oil of the proper type to the F mark on the dipstick 9 Start the engine and check for oil leaks Correct any leaks before placing the engine into service Check oil level to be sure it is up to but not over the F mark 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 9 and 10 10 Air Cleaner Cover Element Cover Foam Precloan Figure 10 Air Cleaner Elements 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 Wash and reoil the precleaner every 25 hours of operation more often under extremely dusty or dirty conditions 1 Loosen the air cleaner cover knob and remove the cover 2 Remove th
10. 88 3 40 88 3 40 88 3 40 88 3 40 88 3 Capacity w filter L U S pt 1 9 4 1 9 4 1 9 4 1 9 4 1 9 4 1 9 4 Full Pressure w full Flow Filter Exhaust Emission Control System for CH11 12 5 13 14 15 16 is EM 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 CH16 engine is equipped with Smart Spark computerized ignition system 14 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 wh
11. e 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 pa
12. e 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 3 Check the gap using a wire feeler gauge Adjust the gap by carefully bending the ground electrode See Figure 11 Gap CH11 15 plugs to 1 02 mm 0 040 in Gap CH16 plugs to 0 76 mm 0 030 in Wire Gauge Spark Plug Electrode Figure 11 Servicing Spark Plug 4 Reinstall the spark plug into the cylinder head Torque the spark plug to 38 0 43 4 N m 28 32 ft Ib 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 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 Fuel Filter Some engines are equipped with an in line fuel filter Periodically inspect the filter and replace when dirty Use a genuine Kohler filter Reduction Gear Unit
13. e 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 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 and tighten the knob securely 7 When precleaner replacement is necessary order Part No 52 083 01 S Service Paper Element Every 100 hours of operation more often under extremely dusty or dirty conditions replace the paper element 1 Loosen the air cleaner cover knob and remove the cover Remove the wing nut and then remove the air cleaner element with precleaner Remove the precleaner from the element and service as necessary 2 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 3 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 4 Reinstall all components as described above 5 When air cleaner element replacement is necessary order Part No 47 083 01 S Clean Ai
14. ffix designates a with your thumb and turn the engine over until the specific version as follows piston is at the top of its stroke Pressure against thumb is greatest Reinstall the plug but do not Suffix Designates connect the plug lead Electric Start Retractable Start 6 Store the engine in a clean dry place ST Electric Retractable Start GT Generator Application Retractable Start GS Generator Application Electric Start PT Pump Retractable Start RT Gear Reduction Retractable Start Specifications CHT 12 5 14 CH15 CH16 a mm in 87 3 43 87 3 43 87 3 43 87 3 43 90 3 55 90 3 55 Stroke mm in 67 2 64 67 2 64 67 2 64 67 2 64 67 2 64 67 2 64 in 398 24 3 398 24 3 398 24 3 398 24 3 426 26 0 426 26 0 Power 3600 kW 8 2 11 9 33 12 59 975 V3 cadet 10 50 147 11 2 15 11 9 16 Torque ft Ib 20 2 2000 20 5 92500 20 5 2500 21 3 2500 24 5 2400 25 2400 Compression Ratio ea EEEE aripa 8 5 1 8 5 1 Weight kg Ib 40 88 3 40
15. h 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 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 A 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 Maintenance Required Fill fuel tank Check oil level Check air cleaner for dirty loose or damaged parts Check air intake and cooling areas clean as necessary Every 25 Hours Service precleaner element Every 50 Hours e Check gear reduction unit Replace air cleaner element Every 100 Hours Change oil Remove cooling shrouds and clean cooling areas e Change oil filter Every
16. ich 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 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 C
17. 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 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 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 15 c For warranty repairs the engine must be presented to Kohler Co service center as soon as a problem exists Call 1 800 544 2444 or access our web site at www kohlerengines com 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 at 1 920 457 4441 and ask for an Engine Service representativ
18. low these guidelines can burn out the starter motor NOTE Upon start up a metallic ticking may occur This is caused by hydraulic lifter leakdown during storage Run the engine for 5 minutes The noise will normally cease in the first minute If noise continues run the engine at mid throttle for 20 minutes If noise persists take the engine to your local Kohler Service outlet 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 lf 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 See your Kohler Engine Service Dealer for trouble analysis For a Cold Engine Gradually return the choke control to the off position after the engine starts and warms ups 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 For a Warm Engine Return choke to off position as soon as engine starts Stopping 1 2a Remove the load by disengaging all PTO a
19. nsible 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 FOR SALES AND SERVICE INFORMATION IN U S AND CANADA CALL 1 800 544 2444 KOHLER 21161195 ISSUED 12 94 BORN TO RUN REVISED 12 01 MAILED ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 LITHO IN U S A
20. o Attn Engine Warranty Service Dept Kohler Wisconsin 53044 ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 KOHLER 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 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 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
21. o 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 Figure 3 Oil Container Logo RECOMMENDED SAE VISCOSITY GRADES Refer to Maintenance Instructions beginning on page 8 for detailed oil check oil change and oil filter change procedures Kohler Command ooo ee ooo Fuel Recommendations 80 10 F 20 0 20 32 40 60 9 20 20 10 gt 10 20 30 40 A WARNING Explosive Fuel TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANGE Gasoline is extremely flammable and its vapors can Use of synthetic oil having 5W 20 or 5W 30 rating is explode if ignited Store gasoline only in approved acceptable up to 40 F containers in well ventilated unoccupied buildings Synthetic oils will provide better starting in extreme away from sparks or flames Do not fill the fuel tank cold below 10 F 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 Figure 2 Viscosity Grades Table NOTE Using other than service class SG SH SJ or higher oil or extending oil change
22. o 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 Engine Dirty Air Faulty Problem Fuel Fuel Fuel Line Grass Screen Oil Level Overloaded Cleaner Spark Plug Will Not Start e Hard Starting 8 Stops Suddenly Lacks Power Operates Erratically Knocks or Pings Skips or Misfires e Backfires Overheats High Fuel Consumption 13 Storage If the engine will be out of service for two months or more use the following storage procedure Parts Ordering The engine Model Specification and Serial Numbers are required when ordering replacement parts from your Kohler Engine Service Dealer These numbers are 1 Clean the exterior surfaces of the engine found on the identification plate which is affixed to the engine shrouding Include letter suffixes if there are 2 Change the oil and filter while the engine is still any See Engine Identification Numbers on page 5 warm from operation See Change Oil and Oil Filter on page 9 Always insist on gen
23. peed Adj Screw Figure 12 Carburetors NOTE To ensure correct engine operation at altitudes above 1525 meters 5000 ft it may be necessary to have an authorized Kohler dealer install a special high altitude jet kit in the carburetor If a high altitude kit has been installed the engine must be reconverted to the original jet size before it is operated at lower altitudes or overheating and engine damage can result Troubleshooting If engine troubles are experienced that appear to be fuel system related check the following areas before adjusting the carburetor e Make sure the fuel tank is filled with clean fresh gasoline e Make sure the fuel tank cap vent is not blocked and that it is operating properly e lf the fuel tank is equipped with a shut off valve make sure it is open e If the engine is equipped with an in line fuel filter make sure it is clean and unobstructed Replace the filter if necessary e Make sure fuel is reaching the carburetor This Set the adjusting needle midway between the rich includes checking the fuel lines and fuel pump for and lean settings See Figure 13 restrictions or faulty components replace as L necessary Adjust to e Midpoint e Make sure the air cleaner element is clean and all air cleaner components fastened securely lf 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
24. r 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 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 Ignition System This engine is equipped with a dependable electronic magneto ignition system Other than periodically checking replacing the spark plug 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 Plug Every 200 hours of operation remove the spark plug check its condition and reset the gap or replace with a new plug as necessary The standard spark plug is a Champion RC12YC Kohler Part No 12 132 02 S A high performance spark plug Champion Premium Gold 2071 used on Pro Series engines Kohler Part No 12 132 06 S is also available Equivalent alternate brand plugs can also be used 1 Before removing the spark plug clean the area around the base of th
25. rhead 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 oil filter air cleaner spark plug 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 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 amp Canada for Sales amp Service assistance To keep your engine in top operating condition follow the maintenance procedures in this manual Oil Fill Dipstick Muffler Air Cleaner Fuel Tank Choke Lever a ub Fuel Electric Starter Oil Sentry Ne Oil Drain Plug Optional Ni Shut Off Oil Drain Plug Oil Filter Oil Drain Plug Throttle Lever Retractable Starter Figure 1 Typical Command Horizontal Shaft Engine Oil Recommendations A logo or symbol on oil containers identifies the API Using the proper type and weight of oil in the service class and SAE viscosity grade See Figure 3 crankcase is extremely important S
26. rs 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 affixed to the engine shrouding Include letter suffixes if there are any Record your engine identification numbers on the identification label Figure 4 for future reference IMPORTANT ENGINE INFORMATION THIS ENGINE MEETS U S EPA 2004 AND CALIFORNIA 2006 AND LATER EMISSION CONTROL REGULATIONS FOR SI SORE FAMILY DISPL CC MODEL NO SPEC NO SERIAL NO OG N11236 EMISSION COMPLIANCE PERIOD EPA CARB THIS ENGINE IS CERTIFIED TO OPERATE ON REFER TO OWNER S MANUAL FOR SAFETY MAINTENANCE SPECS AND ADJUSTMENTS FOR SALES SERVICE IN US CANADA CALL 1 800 544 2444 www kohlerengines com KOHLER iniclinas KOHLER CO KOHLER WISCONSIN USA Small Off Road Engines Figure 4 Engine Identification Label The Emission Compliance Period referred to on the Emission Control or Air Index label indicates the number of operating hours for which the engine has been shown to meet Federal and CARB emission requirements The following table provides the Engine Compliance Period in hours associated with the category descriptor found on the certification label Emission Compliance Period Hours EPA Category Category Category 250 Hours 500 Hours 1000 Hours CARB Moderate Intermediate Extended 125 Hours
27. rt The warranted parts are Oxygen sensor if equipped Ignition module s with high tension lead e Intake manifold if equipped Gaseous fuel regulator if equipped e Exhaust manifold if equipped e Electronic control unit if equipped e Catalytic muffler if equipped e Carburetor or fuel injection system e Fuel metering valve if equipped Fuel lines if equipped e Spark advance module if equipped Air filter fuel filter and spark plugs only Crankcase breather 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 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 respo
28. s On engines equipped with a reduction gear unit remove the oil plug on lower part of cover every 50 hours of operation to check oil level With the engine level the oil level of the unit should be up to the bottom of the oil plug hole To add oil remove the vented plug at the top of the unit Use AGMA No 7 EP oil in the reduction gear unit Following are a few products that meet this spec Mobilgear 634 Pennzoil Super Maxol S Pennzoil Maxol EP Gear Oil Pennzoil Super Maxol EP Gear Oil Pennzoil Super Pennztac EP Gear Oil Carburetor Troubleshooting and Adjustments NOTE Carburetor adjustments should be made only after the engine has warmed up These engines are equipped with one of two basic types of fixed jet carburetors Walbro or Nikki The carburetor is designed to deliver the correct fuel to air mixture to the engine under all operating conditions On both types of carburetors the fixed main jet is calibrated at the factory and is not adjustable On Walbro carburetors the low idle fuel adjusting needle is set at the factory and normally does not need adjustment Certified engines may have a fixed idle or limiter cap on the idle fuel adjusting needle The idle 12 fuel can only be adjusted within the limits allowed by the cap Nikki carburetors have a sealed idle fuel adjusting needle which is not adjustable Walbro Low Idle Speed Adj Low Idle SS Fuel Adj Needle Low Idle S
29. ts vapors can explode if away from all moving parts to extremely hot from operation To ignited Store gasoline only in prevent injury Never operate the prevent severe burns do not touch approved containers in well engine with covers shrouds or these areas while the engine is ventilated unoccupied buildings guards removed running or immediately after it is away from sparks or flames Do not turned off Never operate the engine 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 with heat shields or guards CAUTION California Proposition 65 Warning Engine exhaust from this product Electrical Shock can cause injury Do not touch wires while engine is running contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Electrical Shock Never touch electrical wires or components while the engine is running They can be sources of electrical shock amp WARNING Accidental Starts can cause severe injury or death Disconnect and ground spark plug lead before servicing 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
30. ttachments For 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 b Forengines equipped witha shutdown solenoid Position the throttle control somewhere between half and full throttle then stop the engine Battery A 12 volt battery is normally used Refer to the operating instructions of the equipment this engine powers for specific battery requirements lf 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 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 WARNING Hot Parts Engine components can get extremely hot from operation To prevent severe burns do not touc
31. uine Kohler parts All genuine Kohler parts meet strict standards for fit reliability and 3 The fuel system must be completely emptied or performance the gasoline must be treated with a stabilizer to prevent deterioration If you choose to use a Major Repair stabilizer follow the manufacturers Major repair information is available in Kohler Engine recommendations and add the correct amount for Service Manuals However major repair generally the capacity of the fuel system Fill the fuel tank requires the attention of a trained mechanic and the with clean fresh gasoline Run the engine for 2 3 use of special tools and equipment Your Kohler minutes to get stabilized fuel into the carburetor Engine Service Dealer has the facilities training and genuine Kohler replacement parts necessary to To empty the system run the engine until the fuel perform this service For Sales amp Service assistance tank and system are empty call 1 800 544 2444 U S amp Canada or contact your Kohler Engine Dealer or Service Distributor they re in 4 Remove the spark plug Add one tablespoon of the Yellow Pages under Engines Gasoline engine oil into the spark plug hole Install the plug but do not connect the plug lead Crank the engine Model Designation two or three revolutions Model CH15ST for example C designates Command engine H designates horizontal crankshaft and 15 9 Remove the spark plug Cover the spark plug hole designates horsepower A letter su
32. 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 Oil Sentry 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 100 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 or changing the oil Change the oil as follows see Figure 8 1 To keep dirt grass clippings etc out of the engine clean the area around the oil fill cap disptick before removing it Remove the oil drain plug and oil fill cap dipstick Be sure to allow ample time for complete
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