Kohler CH270 User's Manual
Contents
1. 17 Clean Air Intake Cooling Areas 17 Carburetor Troubleshooting and Adjustments a 18 u tene aei ntc 18 Troubleshooting 19 ppp eee T X 19 amp e 19 Major Hep aif obe re puc ep ERE uenis 20 Parts Ordering 20 Specifications 20 Engine Warranty 21 Emission Control System Warranty 22 23 Safety Precautions To ensure safe operation please read the following statements and understand their meaning Also refer to your equipment owner s manual for other important safety information This manual contains safety precautions which are explained below Please read carefully WARNING Warning is used to indicate the presence of a hazard that can cause severe personal injury death or substantial property damage if the warning is ignored CAUTION Caution is used to indicate the presence of a hazard that will or can cause minor personal injury or property damage if the 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 followed2. 2 Safety Precautions 3 5 Symbols Associated with This Product 5 Control and Service Point Locations 6 Oil 7 as 7 Fuel Recommendations 7 General Fuel Recommendations xi EE a 7 Operating Instructions 8 Pre Start 8 Cold Weather Starting Hints 8 SANING ee e 8 MT kasus 9 Operating 10 Angle of Operation 10 10 Maintenance Instructions 11 Maintenance Schedule 11 Check Oil 11 Change Oil serres 12 Service Precleaner and Air Cleaner Element 13 Service Precleaner If Equipped 13 Service Paper Element 14 Ignition System 15 Check Spark Plug 15 Fuel Tank Filter 15 d 2 71 He 16 Muffler Screen
3. Maintenance Schedule These required maintenance procedures should be performed at the frequency stated in the table below They should also be included as part of any seasonal tune up Frequency Maintenance Required Check oil level Fill fuel tank Check air intake and cooling areas clean as necessary Daily or Before Starting Engine Check air cleaner and precleaner Check muffler screen if equipped clean as necessary Yearly or Every 50 Hours Clean or replace precleaner Change oil Clean cooling areas Clean muffler screen if equipped Clean set gap or replace spark plug and set gap Replace air cleaner element Replace fuel filter if equipped Check and adjust valve clearance when engine is cold Yearly or Every 200 Hours Service starter motor drive if so equipped Have combustion chamber decarbonized Perform these maintenance procedures more frequently under extremely dusty dirty conditions Have a Kohler Engine Service Center perform this service Yearly or Every 100 Hours Yearly or Every 200 Hours 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 f Oil Fill 2 Clean the area around and beneath the dipstick or O 2 Plug
4. the oil fill plug before removing it This will help keep dirt debris and other foreign matter out of Oil Drain Plug Oil Drain Plug the engine See Figure 16 NOTE The engine may be equipped with two dipsticks Figure 16 Location of Dipstick and Oil Fill Plug or an oil fill plug and a dipstick These can be placed in either hole See Figure 16 11 3 Checking oil level with a dipstick Unscrew and remove the dipstick wipe off oil Reinsert the dipstick into the oil fill tube and rest the dipstick on the oil fill neck Turn it counterclockwise until the oil fill cap drops down to the lowest point of the thread leads Do not thread the dipstick cap onto the tube See Figure 18 Checking oil level with an oil fill plug Unscrew and remove the oil fill plug The level should be up to but not over the point of overflowing the filler neck See Figure 19 4 Ifthe level is low add oil of the proper type Refer to Oil Type and to the correct level Always check the level before adding more oil See Figures 18 and 19 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 above the correct level Change Oil For a new engine change oil after the first 5 hours of operation Thereafter change oil after every 100 hours of operation For an overhauled engine use Kohler 10W 30 service class SJ or higher oil for the first 5 hours o
5. WISCONSIN 53044
6. OwNER s MANUAL KOHLER Command PRO HoRIZONTAL CRANKSHAFT CH270 CH395 CH440 KOHLER ENGINES 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 Efficient overhead valve design 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 and spark plugs are easily and quickly accessible Parts subject to the most wear and tear like the cylinder liner and camshaft are made from precision formulated cast iron 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 Or visit www KohlerEngines com To keep your engine in top operating condition follow the maintenance procedures in this manual California Proposition 65 Warning Engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Table of Contents Congratulations
7. against the thumb is greatest Reinstall the plug 1 Clean the exterior surfaces of the engine but do not connect the plug lead 2 Change the oil while the engine is still warm from 6 Store the engine in a clean dry place operation See Change Oil 3 The fuel system must be completely emptied Transport or the gasoline must be treated with a stabilizer to prevent deterioration If you choose to 1 Turn the fuel valve to the OFF position use a stabilizer follow the manufacturers recommendations and add the correct amount 2 Tighten the fuel cap for the capacity of the fuel system Fill the fuel tank with clean fresh gasoline Run the engine 3 Read and follow the transport guidelines for 2 8 minutes to get stabilized fuel into the provided by equipment manufacturer carburetor To empty the system run the engine until the tank and system are empty 4 Remove the spark plug Add one tablespoon of engine oil into the spark plug hole Install the plug but do not connect the plug lead Crank the engine two or three revolutions 19 Major Repair Major repair information is available in Kohler Engine Service Manuals This type of repair generally requires the services of a trained mechanic and the use of special tools and equipment Kohler Engine Service Centers have the facilities training and genuine Kohler replacement parts necessary to perform this Parts Ordering The engine model specification and serial numbers
8. are required when ordering replacement parts from your Kohler Engine Service Center These numbers are found on the identification plate which is affixed to the engine shrouding Include letter suffixes if there are any See Serial Data Label on Page 6 service Always insist on genuine Kohler parts All genuine Kohler parts meet strict standards for fit reliability and performance For the nearest sales and service location Visit our Web site www KohlerEngines com Call 1 800 544 2444 U S and Canada Look in your local telephone directory under Engines Gasoline Specifications CH440 70 78 89 2 8 8 1 8 5 54 58 69 2 1 2 3 2 7 Displacement 208 ni Hed p 12 7 16 9 24 7 5 2 TA 10 5 Gross Power 3600 RPM 7 9 5 14 4 4 6 4 8 9 Net Power 3600 RPM 6 8 5 11 9 Peak Torque RPM 12 3 9 1 2800 17 8 13 1 2600 2600 Compression Ratio 8 5 1 8 2 1 8 1 17 5 27 8 34 7 Weight Recoil Start 38 7 61 5 76 5 m 0 6 14 Cil Capacity 0 63 1 16 4 1 7 3 Fuel Tank Capacity 4 3 7 7 Exhaust Emission Control System EM for U S EPA and Europe Horsepower ratings exceed Society of Automotive Engineers Small Engine Test Code J1940 Actual engine horsepower is lower and affected by but not limited to accessories air cleaner exhaust charging coo
9. 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 Reinstall the precleaner over the paper element 5 Slide the precleaner and paper element onto the air cleaner base See Figure 22 Precleaner If Equipped La Paper Element Air Cleaner er Figure 23 Air Cleaner Cover Removal 13 6 Position the air cleaner cover For normal operation conditions see Figure 25 For cold weather operation conditions see Figure 26 NOTE Running the engine in the cold weather operation position in normal conditions can damage the engine Reinstall and secure the air cleaner cover Align the air cleaner cover latches with the tabs on the base Place the latches under the tabs and lift up on the bails See Figure 24 Service Paper Element Every 200 hours of operation more often under extremely dusty or dirty conditions replace the paper element 1 Remove the air cleaner cover Move the bails on the air cleaner cover down Remove the latches from under the tabs of the air cleaner base Lift and remove the air cleaner cover from the air cleaner base Separate the precleaner from the element and service as outlined above See Figures 22 and 23 Do not wash the paper element or use pressu
10. or equipment etc diagnosis and inspection fees that do not result in eligible warranty service being performed and 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 23 FORM NO 17 590 01 A ISSUED 10 08 NGI N ES REVISED 3 09 oM E mmm KohlerEngines com MDM 50531 87069 o ENGINE DIVISION KOHLER CO KOHLER
11. premature engine wear and failure Cil Type Use high quality detergent oil of API American Petroleum Institute service class SJ or higher Select the viscosity based on the air temperature at the time of operation as shown in the following table RECOMMENDED SAE VISCOSITY GRADES Kohler 10W 30 F 20 0 20 32 40 50 60 cd gt v 3 TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANGE Figure 3 Oil Viscosity Grades Table Refer to Maintenance Instructions for detailed oil check and oil change procedures Fuel Recommendations WARNING Explosive Fuel can cause fires and severe burns Do not fill the fuel tank while the engine is hot or running Gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only in approved containers in well ventilated unoccupied buildings away from sparks or flames Do not fill the fuel tank while the engine is hot or running since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition Do not start the engine near spilled fuel Neoer use gasoline as a cleaning agent General Recommendations Purchase gasoline in small quantities and store in clean approved containers A container with a capacity of 2 gallons or less with a pouring spout is recommended Such a container is easier to handle and helps eliminate spillage during refueling Do not use gasoline left over from the previou
12. 21 Dipstick Reinstallation Oil Sentry Some engines are equipped with an optional Oil Sentry oil level switch If the oil level drops below an acceptable level the Oil Sentry will either shut off the engine or activate a warning signal depending on the application NOTE Check the oil level BEFORE EACH USE and maintain to the correct level This includes engines equipped with Oil Sentry Service Precleaner and Air Cleaner Element These engines are equipped with a replaceable high density paper air cleaner element Some engines are also equipped with a preoiled foam precleaner which surrounds the paper element See Figure 22 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 Equipped Wash the precleaner every 50 hours of operation more often under extremely dusty or dirty conditions 1 Remove the air cleaner cover Move the bails on the air cleaner cover down Remove the latches from under the tabs of the air cleaner base Lift and remove the air cleaner cover from the air cleaner base See Figure 23 2 Remove the precleaner from the paper
13. ance or adjustments are necessary or possible with this system In the event starting problems should occur which are not corrected by replacing the spark plug see your Kohler Engine Service Center for trouble analysis Check Spark Plug Annually or every 100 hours of operation remove the spark plug check condition and reset the gap or replace with a new plug as necessary The original spark plug is a Champion RC12YC the Kohler equivalent is Kohler Part No 12 132 02 S or for RFI Kohler Part No 25 132 14 S Equivalent alternate brand plugs can also be used 1 Before removing the spark plug clean the area around the base of the plug to keep dirt and debris out of the engine 2 Remove the plug and check its condition Replace the plug if worn or reuse is questionable NOTE Do not clean the spark plug in a machine using abrasive grit Some grit could remain in the spark plug and enter the engine causing extensive wear and damage 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 27 4 Reinstall the spark plug into the cylinder head Torque the spark plug to 20 N m 14 ft Ib Fuel Tank Filter A serviceable fuel tank filter is located under the fuel tank cap in the filler neck WARNING Explosive Fuel can cause fires and severe burns Do not fill the fuel tank while the engine is hot or running Daily or as required
14. at all times Failure to follow these precautions could result in injury to yourself and others WARNING Explosive Fuel can cause fires and severe burns Do not fill the fuel tank while the engine is hot or running Explosive Fuel Gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only in approved containers in well ventilated unoccupied buildings away from sparks or flames Do not fill the fuel tank while the engine is hot or running since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition Do not start the engine near spilled fuel Never use gasoline as a cleaning agent Safety Precautions Continued WARNING A Carbon Monoxide can cause severe nausea fainting or death Avoid inhaling exhaust fumes and never run the engine in a closed building 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 ll Gi 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 Nev
15. cessary 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 Muffler Screen 17 Carburetor Troubleshooting and Adjustments NOTE Carburetor adjustments should be made only after the engine is at operating temperature The carburetor is designed to deliver the correct fuel to air mixture to the engine under all operating conditions The idle mixture is set at the factory and normally does not require adjustment If the engine is hard to start runs roughly or stalls at low idle speed it may be necessary to adjust or service the carburetor Engine must not exceed 3750 RPM if the high speed screw is adjusted See Figure 33 Troubleshooting If engine troubles are experienced that appear to be fuel system related check the following areas before adjusting the carburetor Make sure the fuel tank is filled with clean fresh gasoline Make sure the fuel tank cap vent is not blocked and that it is operating properly Make sure the fuel shut off valve is fully open e Make sure fuel shut off valve strainer and in line fuel filter if used are clean and unobstructed Clean or replace as necessary Make sure fuel is reaching the carburetor This includes checking the fuel lines and components for restrictions or problems Replace as necessary Mak
16. clean filter of any accumulation as follows 1 Remove the fuel tank cap and filter See Figure 28 2 Clean the filter with solvent replace if damaged 3 Wipe the filter and insert it 4 Tighten the tank cap securely 0 76 mm 0 030 in Gap Electrode Figure 27 Servicing Spark Plug Fuel Tank Cap Non Evap Shown CO Fuel Tank Filter gt Fuel S Filler Neck Figure 28 Fuel Tank Filter 15 Fuel Valve Engines are equipped with a fuel valve and integral screen filter located at the inlet of the carburetor It controls and filters fuel flow from the tank to the carburetor Every 100 hours of operation clean fuel valve cup of any accumulated debris If the screen becomes clogged or damaged replace it WARNING Explosive Fuel can cause fires and severe burns Do not fill the fuel tank while the engine is hot or running 1 Stop the engine 2 Remove the securing hardware and the carburetor cover panel See Figure 29 3 Turn the fuel valve lever to the OFF position 4 Remove the fuel valve cup See Figure 30 5 Clean the fuel valve cup with solvent and wipe it off 6 Check the O ring replace if damaged Check the screen for blockage or damage replace if necessary The new screen must be located on the pick up tube as shown in Figure 31 7 Place the O ring on the screen fo
17. e sure On Off switch is functioning properly Make sure the air cleaner element is clean and all air cleaner components are fastened securely If after checking the items listed above the engine is hard to start runs roughly or stalls at low idle speed it may be necessary to adjust or service the carburetor Figure 33 Speed Screw Troubleshooting When troubles occur be sure to check the simple causes which at first may seem too obvious to be considered For example a starting problem could be caused by an empty fuel tank Some common causes of engine troubles are listed in the table below Do not attempt to service or replace major engine components or any items that require special timing or adjustment procedures Have this work done by a Kohler Engine Service Center Possible Cause Problem Improper Dirt In Dirty Incorrect Dirty Air Faulty Fuel FuelLine Grass Screen Oil Level Overloaded Cleaner Spark Plug Will Not Start e e Hard Starting Stops Suddenly e Lacks Power Operates Erratically Knocks or Pings Skips or Misfires Backfires Overheats High Fuel Consumption Storage 5 Remove the spark plug Cover the spark plug If the engine will be out of service for two months or hole with your thumb and turn the engine over more use the following storage procedure until the piston is at the top of its stroke Pressure
18. er operate the engine with heat shields or guards removed Safety Precautions Continued WARNING WARNING CAUTION 7 Accidental Starts cause severe Rotating Parts can cause severe Electrical Shock can cause injury ewe Do not touch wires while engine is Disconnect and ground spark plug Stay away while engine is in running leads before servicing operation Electrical Shock Accidental Starts Rotating Parts Never touch electrical wires or Disabling engine Accidental starting Keep hands feet hair and clothing away components while the engine is running can cause severe injury or death Before from all moving parts to prevent injury They can be sources of electrical shock working on the engine or equipment Never operate the engine with covers disable the engine as follows 1 shrouds or guards removed Disconnect the spark plug lead s 2 Disconnect negative battery cable from battery Symbols Associated With This Product Stop Normal Operation Cold Weather Operation Ms 7 Muffler uel Tank Cap Shield Spark Plug Air Cleaner Fuel Tank Throttle Lever Lever On Off Switch Shut Off 44 7 If Equipped 4 he Starter J Handie Dipstick Retractable Oil Drain Starter PM Serial and Oil Drain Data Label Plug Figure 1 Control and Service Point Locations The Emis
19. esult of carburetor icing is rough running at idle or low speed as well as black smoke To reduce the likelihood of carburetor icing the air cleaner cover can be rotated to draw warmer air from the muffler side To set the air cleaner cover to cold weather operation see Figure 14 To set the air cleaner cover to normal operation see Figure 15 NOTE Running the engine in the cold weather operation position in normal conditions can damage the engine D Air Cleaner Cover Figure 14 Cold Weather Operation Position of Air Cleaner Cover Muffler 88988606800 LO 0800 M J Air Air Cleaner Intake Cover Figure 15 Normal Operation Position of Air Cleaner Cover 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 Engine Service Center WARNING Accidental Starts can cause severe injury or death Disconnect and ground spark plug leads before servicing 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
20. etween the SLOW and FAST positions See Figure 6 Place the choke control into the on position See Figure 7 For a Warm Engine normal operating temperatures Place the throttle control midway between the SLOW and FAST positions See Figure 6 A warm engine usually does not require the choke on FAST SLOW Throttle Q Control lt wa 5 v 9 A A NS TT Figure 6 Fast Position of Throttle Control Figure 7 On Position of Choke Lever NOTE The choke position for starting may vary depending upon temperature and other factors Once engine is running and warm turn choke to OFF position See Figure 10 3 Start the engine as follows For Retractable Start Engine Turn engine On Off switch to the ON See Figure 8 On Off Switch DX SS Figure 8 Engine Switch 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 see Figure 9 Starter Handle NOTE Extend the starting rope periodically and check its condition If the rope is frayed have it replaced immediately by yo
21. f 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 Theengine 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 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 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 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 de
22. f operation Change the oil after this initial run in period Refill with service class SJ or higher oil as specified in the Viscosity Grades table Figure 3 Change the oil while the engine is still warm The oil will flow freely and carry away more impurities Make sure the engine is level when filling checking or changing the oil Change the oil as follows 1 To keep dirt debris etc out of the engine clean the area around the oil fill plug dipstick before removing it 2 Remove the oil drain plug and the dipstick oil fill plug Allow ample time for complete drainage 3 Reinstall the drain plug and tighten to 17 6 N m 13 ft Ib 4 Fill the crankcase with new oil of the proper type up to the point of overflowing the filler neck Refer to Oil Type Always check the level before adding more oil 5 Reinstall the dipstick oil fill plug and tighten securely See Figure 21 NOTE Over tightening the dipstick will distort the gasket and may cause oil weeping Oil Fill Plug Oil Level Bottom Edge Z Engine Oil Low Oil a Level TY Upper auo Cil Level lu Oil Fill Plug V d Fill Neck Bottom Edge Cil Fill Hi Plug N Cil Drain oii Drain Plug Plug Figure 20 Location of Dipstick and Oil Drain Plug Dipstick Cil Fill Plug Dipstick Cil Fill Plug Gasket 29 distorted Incorrect 2 Gasket flat Correct Figure
23. fects in materials and workmanship which cause the engine to fail to conform with applicable regulations for a period of two years Engines produced in 2006 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 22 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 include the following if they were present in the engine purchased Oxygen sensor if equipped Intake manifold if equipped Exhaust manifold if equipped Catalytic muffler if equipped Thermal reactor muffler if equipped Spark advance module if equipped Air fi
24. ling fuel pump etc application engine speed and ambient operating conditions temperature humidity and altitude Kohler reserves the right to change product specifications designs and equipment without notice and without incurring obligation Based on preliminary information 20 LIMITED 3 YEAR CH270 CH395 CH440 COMMAND PRO ENGINE WARRANTY Kohler Co warrants to the original consumer that each new COMMAND engine sold by Kohler Co will be free from manufacturing defects in materials or workmanship in normal service for a period of three 3 years from date of purchase provided it is operated and maintained in accordance with Kohler Co 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 three 3 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 unles
25. llowed by the fuel valve cup Rotate the fuel valve cup until it is finger tight Turn with a wrench 1 2 to 3 4 full turn See Figure 31 8 Turn the fuel valve to the ON position and check for leaks If fuel valve cup leaks repeat step 6 and 7 9 Tighten the tank cap securely 10 Reinstall the carburetor cover panel securing with hardware removed in step 2 Figure 31 Pick up Tube and Screen Orientation Muffler Screen Engines are equipped with a muffler screen for operational and environmental safety Every 100 hours of operation remove and clean or replace the muffler screen following the instructions below WARNING Hot Parts can cause severe burns lh Gi Do not touch engine while operating just after stopping 1 Remove the securing hardware and the muffler screen See Figure 32 2 Clean the carbon deposits out of the screen using a wire brush 3 Check the muffler screen replace if damaged 4 Reinstall the muffler screen securing with the hardware previously removed Clean Air Intake Cooling Areas To ensure proper cooling make sure the grass screen cooling fins and other external surfaces of the engine are kept clean at all times 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 ne
26. lter fuel filter and spark plugs only to first scheduled replacement Crankcase breather Air injection system if equipped Air pump or pulse valve assembly if equipped Control distribution valve if equipped Distribution manifold if equipped Air hoses if equipped Vacuum lines if equipped LIMITATIONS Ignition module s with high tension lead Gaseous fuel regulator if equipped Electronic control unit if equipped Carburetor or fuel injection system if equipped Fuel lines fuel line fittings and clamps if equipped Fuel metering valve if equipped Evaporative system if equipped Canister if equipped Canister filter if equipped Vapor hose if equipped Orifice connector if equipped Fuel tank if equipped Fuel cap if equipped Primer bulb canister if equipped 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 replacement of parts and other services and adjustments necessary for required maintenance at and after the first scheduled replacement point consequential damages such as loss of time inconvenience loss of use of the engine
27. minute at angles up to 30 with 1 2 full fuel tank Check oil level to assure crankcase oil level is correct See Check Oil Level 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 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 See Clean Air Intake Cooling Areas WARNING ZM Do not touch engine while operating or Hot Parts can cause severe burns Just after stopping Engine components can get extremely hot from operation To prevent severe burns do not touch these areas while the engine is running or immediately after it is turned off Never operate the engine with heat shields or guards removed Engine Speed NOTE Do not tamper with the governor setting to increase the maximum engine speed Overspeed is hazardous and will void the engine warranty The maximum allowable high idle speed for these engines is 3750 RPM no load Carburetor Icing Carburetor icing can take place when certain combinations of temperature and humidity exist The r
28. ner 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 Carbon Monoxide can cause severe nausea fainting or death Avoid inhaling exhaust fumes and never run the engine in a closed building or confined area 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 Besure to use the proper oil for the temperature expected See Oil Recommendations 2 Declutch all possible external loads 3 Use fresh winter grade fuel NOTE Winter grade gasoline has higher volatility to improve starting Do not use gasoline left over from summer 4 Electric Start Models Be sure the battery is in good condition warm battery has much more starting capacity than a cold battery Starting 1 Turn the fuel shut off valve to the ON position See Figure 5 Fuel Shut Off Valve Figure 5 On Position of Fuel Shut Off Valve 2 For a Cold Engine Place the throttle control midway b
29. rized 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 When servicing the air cleaner check the air cleaner base Make sure it is secured and not bent or damaged Check the air cleaner cover housing for damage or improper fit Replace all bent or damaged air cleaner components Slide the precleaner and paper element onto the air cleaner base See Figure 22 Position the air cleaner cover For normal operation conditions see Figure 25 For cold weather operation conditions see Figure 26 NOTE Running the engine in cold weather operation position of the air cleaner cover in normal conditions can damage the engine Reinstall and secure the air cleaner cover Align the air cleaner cover latches with the tabs on the base Place the latches under the tabs and lift up on the bails See Figure 24 EE CREE CD C D Muffler e 8886860868090 TIN Air Air Cleaner Intake Cover Figure 25 Normal Operation Position of Air Cleaner Cover Air Cleaner Cover Figure 26 Cold Weather Operation Position of Air Cleaner Cover Ignition System This engine is equipped with a dependable electronic magneto ignition system Other than periodically checking replacing the spark plug no mainten
30. s season to minimize gum deposits in your fuel system and to ensure easy starting Do not add oil to the gasoline Do not overfill the fuel tank Leave room for the fuel to expand See Figure 4 Fuel Tank Filter Maximum Fuel Level Fuel Type For best results use only clean fresh unleaded gasoline with a pump sticker octane rating of 87 or higher In countries using the Research method it should be 90 octane minimum Unleaded gasoline is recommended as it leaves less combustion chamber deposits and reduces harmful exhaust emissions Leaded gasoline is not recommended 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 including E20 and E85 are not to be used and are not approved Any failures resulting from use of these fuels will not be warranted Gasoline Ether blends Methyl Tertiary Butyl Ether MTBE and unleaded gasoline blends up to a maximum of 1576 MTBE by volume are approved as a fuel for Kohler engine Other gasoline ether blends are not approved 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 clea
31. s supplied or installed by Kohler Co These are subject to the warranties if any of their manufacturers KOHLER CO AND OR THE SELLER 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 IMPLIED OR STATUTORY WARRANTIES INCLUDING WARRANTIES 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 on 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 To locate the nearest facility visit our website www KohlerEngines com or telephone 1 800 544 2444 consult your local telephone directory ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 21 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
32. sion 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 KOHLER IMPORTANT ENGINE INFORMATION THIS ENGINE MEETS U S EPA PH2 STE AND CA 2008 AND LATER EMISSION REGS FOR SI COD BUILD D 189 CC MPLIANCE PERIOD CARB ON Emission Compliance Period Hours REFER TO OWNER S MANUAL FOR HP RATING SAFETY MAINTENANCE AND ADJUSTMENTS 1 800 544 2444 kohlerengines com KOHLER CO KOHLER WISCONSIN USA CRAFTED IN CHINA Figure 2 Serial and Data Label Example EPA Category C Category B Category A 225 CC 125 hours 250 hours 500 hours gt 225 250 hours 500 hours 1000 hours 125 hours Intermediate 250 hours Extended 500 hours Refer to certification label for engine displacement Exhaust Emission Control System for models CH270 CH395 CH440 is EM for U S EPA and Europe Oil Recommendations Using the proper type and weight ot oil in the crankcase is extremely important So is checking oil daily and changing oil regularly Failure to use the correct oil or using dirty oil causes
33. to explain the Federal and California Emission Control Systems Warranty on your small off road equipment engine In California beginning in 2006 emissions means both exhaust and evaporative emissions For California engines produced in 2006 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 2006 or later are warranted for two years in California In other states 1997 and later model year engines are warranted for two years I
34. ur Kohler Engine Service Center 4 Gradually return the choke control to the OFF position after the engine starts and warms up See Figure 10 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 Stopping 1 If possible remove the load 2 Move the throttle control to the SLOW or LOW idle position Allow the engine to run at idle for 30 60 seconds See Figure 11 S lt se 4 vb Throttle Figure 11 Slow Position of Throttle Control 3 Turn key switch or on off switch to the OFF position Move throttle to the stop position if equipped See Figure 12 On Off Switch Figure 12 Engine Switch 4 Close the fuel shut off valve See Figure 13 Fuel Shut Off R ZL E U Figure 13 Off Position of Fuel Shut Off Valve Figure 10 Off Position of Choke Lever Operating Angle of Operation Continuous operation at angles up to 25 with 1 2 full fuel tank Before operation check oil level to assure crankcase oil level is correct See Check Oil Level Intermittent operation up to one
Download Pdf Manuals
Related Search