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  9. Kohler Command 6 HP User manual

Kohler Command 6 HP User manual

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1
COMMAND 6 HP
HORIZONTAL CRANKSHAFT
OWNER'S MANUAL
2
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 ha ard 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 ha ard 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 ha ard-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.
Engine exhaust from this product
contains chemicals known to the
State of California to cause cancer
birth defects or other reproductive
harm.
California
Proposition 65 Warning
Explosive Fuel can cause fires and
severe burns.
Stop engine before filling fuel tank.
WARNING
Explosive Fuel!
Gasoline is extremely flammable
and its vapors can explode if
ignited. Store gasoline only in
approved containers in well
ventilated unoccupied buildings
away from sparks or flames. Do not
fill the fuel tank while the engine is
hot or running since spilled fuel
could ignite if it comes in contact
with hot parts or sparks from
ignition. Do not start the engine near
spilled fuel. Never use gasoline as a
cleaning agent.
Rotating Parts can cause severe
injury.
Stay away while engine is in
operation.
WARNING
Rotatin 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.
Hot Parts can cause severe burns.
Do not touch engine while operating
or just after stopping.
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.
Electrical Shock can cause injury.
Do not touch wires while engine is
running.
CAUTION
Electrical Shock!
Never touch electrical wires or
components while the engine is
running. They can be sources of
electrical shock.
3
Safety Precautions (Cont.)
Accidental Starts can cause severe
injury or death.
Disconnect and ground spark plug
lead before servicing.
WARNING
arbon Monoxide can cause
severe nausea, fainting or death.
Do not operate engine in closed or
confined area.
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.
WARNING
Explosive Gas can cause fires and
severe acid burns.
Charge battery only in a well
ventilated area. Keep sources of
ignition away.
Accidental Starts!
Disabling engine. Accidental
starting can cause severe injury
or death. Before working on the
engine or equipment disable the
engine as follows: 1) Disconnect the
spark plug lead(s). 2) Disconnect
negative (-) battery cable from
battery.
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.
Con ratulations  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 and splash 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 oil fill/check plug, air cleaner, spark
plug, and carburetor) are easily and quickly accessible.
 Parts subject to the most wear and tear (like the cylinder liner, crankshaft, 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. & Canada) for Sales & Service assistance.
To keep your engine in top operating condition, follow the maintenance procedures in this manual.
4
Fi ure 1. Location of Controls and Service Points on C6.
Oil Recommendations
Using the proper type and weight of oil in the crankcase
is extremely important. So is checking oil daily and
changing oil regularly. Failure to use the correct oil, or
using dirty oil, causes premature engine wear and
failure.
Oil Type
Use high quality detergent oil of API (American
Petroleum Institute) service class SG, SH, SJ or
hi her. Select the viscosity based on the air
temperature at the time of operation as shown in the
following table.
NOTE: Using other than service class SG, SH, SJ or
higher oil or extending oil change intervals
longer than recommended can cause engine
damage.
A logo or symbol on oil containers identifies the API
service class and SAE viscosity grade. See Figure 3.
3 U.S. Quart Capacity
Fuel Tank
Start-Stop
Switch (Optional)
Oil SentryTM Li ht
Fuel Shut-Off Valve
Control Panel
Coolin Air Intake
Retractable Starter
Housin
Retractable Starter Handle Oil Drain & Oil Fill/Check
Plu on Opposite Side
Oil Drain Plu
Air Cleaner Cover
Carburetor
Choke Lever
Valve Cover
Spark Plu
Coolin Air Outlet
Exhaust Pipe Muffler Shield Fuel Tank Cap
Throttle Lever
Air Cleaner Retainin Knob
*Use of synthetic oil having 5W-20 or 5W-30 rating is
acceptable, up to 40°F.
**Synthetic oils will provide better starting in extreme
cold (below -10°F).
Fi ure 2. Viscosity Grades Table.
** *Fi ure 3. Oil Container Lo o.
Refer to Maintenance Instructions be innin on
pa e 8 for detailed oil check, oil chan e, and oil
filter chan e procedures.
5
Engine Identification umbers
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 below (Figure 4) for future reference.
Fuel Recommendations
WARNING: Explosive Fuel!
Gasoline is extremely flammable and its vapors can
explode if ignited. Store gasoline only in approved
containers in well ventilated unoccupied buildings
away from sparks or flames. Do not fill the fuel tank
while the engine is hot or running since spilled fuel
could ignite if it comes in contact with hot parts or
sparks from ignition. Do not start the engine near spilled
fuel. Never use gasoline as a cleaning agent.
General Recommendations
Purchase gasoline in small quantities and store in
clean, approved containers. A container with a capacity
of 2 gallons or less with a pouring spout is
recommended. Such a container is easier to handle
and helps eliminate spillage during refueling.
Do not use gasoline left over from the previous season,
to minimi e 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.
Fi ure 4. En ine 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 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)
*Small Off-Road En ines
IMPORTANT ENGINE INFORMATION
THIS ENGINE MEETS U.S. EPA PHASE 1 AND
CALIFORNIA 2006 AND LATER EMISSION
CONTROL REGULATIONS FOR SI SORE*
FAMILY
DISPL. (CC)
MODEL NO.
SPEC. NO.
SERIAL NO.
EMISSION COMPLIANCE PERIOD:
EPA: CARB:
KOHLER CO. KOHLER, WISCONSIN USA
THIS ENGINE IS CERTIFIED TO OPERATE
ON:
REFER TO OWNER'S MANUAL FOR SAFETY,
MAINTENANCE SPECS AND AD USTMENTS.
FOR SALES/SERVICE IN US/CANADA, CALL:
1-800-544-2444
www.kohlerengines.com
CARB Moderate
125 hours
Intermediate
250 hours
Extended
500 hours
Refer to certification label for engine displacement.
Exhaust Emission Control System for model CH6 is EM.
6
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.
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.
2. Declutch all possible external loads.
3. A warm battery has much more starting capacity
than a cold battery.
4. Use fresh winter grade fuel. NOTE: Winter grade
gasoline has higher volatility to improve starting.
Do not use gasoline left over from summer.
Fi ure 6. Location of Choke Lever.
Starting
1. Open fuel shut-off valve.
2. For a Cold En ine  Place the throttle control
midway between the slow and fast
positions. See Figure 5. Place the choke control
into the on position. See Figure 6.
For a Warm En ine (normal operatin
temperatures)  Place the throttle/choke control
midway between the slow and fast
positions. Place the choke control in the on
position. See Figure 6.
3. Place start-stop switch in the start position if so
equipped. See Figure 5.
4. Start the engine as follows:
For Retractable Start En ine  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.
WARNING: Accidental Starts!
Before extending and checking retractable starter rope
remove the spark plug lead to prevent the engine from
starting accidentally. Ground the lead to prevent sparks
that could cause fires. Make sure the equipment is in
neutral.
Fi ure 5. Control Panel.
Choke Lever
Choke On
Choke Off
7
For an Electric Start En ine  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 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.
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").
See your Kohler Engine Service Dealer for trouble
analysis.
3. For a Cold En ine  Gradually return the choke
control to the off position after the engine starts
and warms up.
The engine/equipment may be operated during
the warm up period, but it may be necessary to
leave the choke partially on until the engine warms
up.
4. For a Warm En ine  Return choke to "off"
position as soon as engine starts.
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.
3. Move the throttle control to the stop position. Or
if equipped with optional startstop switch, move
the switch into the stop position.
4. Close fuel shut-off valve.
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 11).
Operating
An le of Operation
This engine will operate continuously at angles up
to 20°. Check oil level to assure crankcase oil is up to
the point of overflowing the filler neck. See Figure 8.
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 20° in any direction. Engine
damage could result from insufficient
lubrication.
Coolin
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 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.
En ine Speed
NOTE: Do not tamper with the governor setting to
increase the maximum engine speed.
Overspeed is ha ardous and will void the
engine warranty.
8
Maintenance Instructions
Maintenance, repair, or replacement of the emission control devices and systems, which are bein done at
the customers expense, may be performed by any non-road en ine repair establishment or individual.
Warranty repairs must be performed by an authorized Kohler service outlet.
WARNING: Accidental Starts!
Disabling engine. Accidental starting can cause severe injury or death. Before working on the engine or
equipment disable the engine as follows: 1) Disconnect the spark plug lead(s). 2) Disconnect negative (-) battery
cable from battery.
Maintenance Schedule
These required maintenance procedures should be performed at the frequency stated in the table. They should
also be included as part of any seasonal tune-up.
¹Perform these maintenance procedures more frequently under extremely dusty dirty conditions.
²Have 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 overemphasi ed.
Check oil BEFORE EACH USE as follows:
1. Make sure the engine is stopped, level, and is
cool so the oil has had time to drain into the sump.
2. To keep dirt, debris, etc., out of the engine, clean
the area around the oil fill/check plug before
removing it.
3. Unthread and remove the oil fill/check plug.
4. The level should be up to but not over, the point of
overflowing the filler neck.
Fi ure 7. Location of Oil Drain and Check Plu s.
NOTE: Just because you can see oil in the crankcase
doesn't mean the level is in the safe range.
Bring the level up to the point of overflowing
the filler neck.
 Service precleaner element¹.
Daily or Before
Startin En ine
Maintenance RequiredFrequency
 Fill fuel tank.
 Check oil level.
 Check air cleaner for dirty¹, loose, or damaged parts.
 Check air intake and cooling areas, clean as necessary¹.
Every 25 Hours
 Replace air cleaner element¹.
 Change oil¹.
 Remove cooling shrouds and clean cooling areas¹.
 Check spark plug condition and gap.
Every 100 Hours
Every 200 Hours
 Have bendix starter drive serviced2.
 Have valve to rocker arm clearance checked².
 Have Oil Sentry float switch checked2.
Annually or
Every 500 Hours
Filler
Neck
Oil Drain
Plu
Oil Fill/Check Plu
9
Change the oil as follows (see Figures 7 and 8):
1. To keep dirt, debris, etc., out of the engine, clean
the area around the oil fill cap/dipstick before
removing it.
2. Remove the oil drain plug and oil fill/check plug.
Be sure to allow ample time for complete drainage.
3. Reinstall the drain plug. Make sure it is tightened to
17.6 N·m (13 ft. lb.) torque.
4. Fill the crankcase, with new oil, of the proper type,
up to the point of overflowing the filler neck. Refer
to Oil Type on page 4. Always check the level
before adding more oil.
5. Reinstall the oil fill/check 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 point of
overflowing the filler neck.
Service Precleaner and ir Cleaner Element
This engine is equipped with a replaceable, high density
paper air cleaner element. All engines are also
equipped with an oiled, foam precleaner which covers
the paper element. See Figure 9.
Check the air cleaner daily or before startin the
en ine. 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 air cleaner 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. Squee e out excess
water (do not wring). Allow the precleaner to air dry.
Fi ure 8. Cutaway Showin Proper Oil Level.
5. If the level is low, add oil of the proper type, up to
the point of overflowing the filler neck. (Refer to
Oil Type on page 4.) Always check the level
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 point of
overflowing the filler neck.
Oil Sentry
Some engines are equipped with an optional Oil
Sentry oil level switch. If the oil level 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 point
of overflowing the filler neck. This includes
engines equipped with Oil Sentry.
Change Oil
For a new en ine, change oil after the first 20 hours
of operation. Thereafter, change oil after every 100
hours of operation.
For an overhauled en ine, use 10W-30 service class
SG, SH, SJ or higher oil for the first 5 hours of
operation. Change the oil after this initial run-in period.
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 freely and carry away more impurities. Make
sure the engine is level when filling, checking, or
changing the oil.
Filler Neck
Brin Level Up
To Point Of
Overflow
10
4. Saturate the precleaner with new engine oil.
Squee e out all excess oil.
5. Reinstall the precleaner over the paper element.
6. Reinstall air cleaner cover.
7. Tighten the air cleaner cover retaining knob.
Service Paper Element
Every 100 hours of operation (more often under
extremely dusty or dirty conditions), replace the paper
element.
1. Loosen air cleaner cover retaining knob and
remove the cover.
2. Remove the precleaner from the paper element.
3. Remove the wing nut, washer, and element cover
with grommet. Remove paper element.
4. Replace a dirty, bent, or damaged element with a
genuine Kohler element. Do not wash the paper
element or use pressurized air, as this will
damage the 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 air cleaner
element cover for damage or improper fit. Replace
all bent or damaged air cleaner components.
6. Install new or serviced paper element and
components as follows:
a. Position paper element on base.
b. Slide element cover with grommet then
washer onto stud, secure with wing nut.
c. Reinstall the precleaner over the paper
element.
d. If the air cleaner cover ring separated from
the element cover, reinstall it.
e. Reinstall air cleaner cover and secure with
the retaining knob.
Fi ure 9. Air Cleaner Elements.
Air Cleaner
Base
Precleaner
Paper
Element
Element
Cover
Air Cleaner
Cover Rin
Grommet
Washer
Win Nut
Air Cleaner
Cover
Cover
Retainin Knob