Kohler Command PRO CH18 User manual

0 WNER 's MANUAL
COMMAND S€R/€S
CHW.24 CH730=740
HOREONUL
CRANKSHAFT
60-
RUN'"

Safety Precautions
To insure safe operations please read the following statements and understandtheir meaning.
Also refer to your equipmentowner's manualfor other importantsafety information.This manual
contains safety precautionswhich are explainedbelow. Please readcarefully.
a WARNING
Warning is usedto indicatethe presenceof a hazard that can cause severe personalinjury, death,
or substantialpropertydamage if the warning is ignored.
a CAUTION
Caution is usedto indicatethe presenceof a hazard that will or can cause minor personalinjuryor
property damage if the caution is ignored.
NOTE
Note is usedto notifypeopleof installation,operation, or maintenanceinformationthat is important
but not hazard-related.
For YourSafety!
Theseprecautionsshouldbe followedat all times. Failure to follow theseprecautionscould result
in injury to yourself and others.
I a WARNING
Explosive Fuel can cause fires and
severe burns.
Stop engine before filling fuel tank.
Explosive Fuel!
Gasolineis extremely flammable
and its vaporscan explodeif
ignited. Storegasoline only in
approvedcontainers,in well
ventilated,unoccupiedbuildings,
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
withhotparts or sparks from
ignition.Do not start the engine near
spilled fuel. Never use gasolineas a
cleaningagent.
a WARNING
Rotating Parts can cause severe
injury.
Stay away while engine is in
operation.
RotatingParts!
Keephands, feet,hair,andclothing
away from all movingparts to
prevent injuty Never operatethe
engine withcovers, shrouds,or
guards removed.
a CAUTION
Yll 1
ElectricalShock can cause injury.
Do not touch wires while engine is
running.
I a WARNING
I Hot Parts can cause severe burns.
Do not touch engine while operating
or just after stopping.
Hot Parts!
Engine components can get
extremelyhot from operation. To
prevent severeburns, do not touch
theseareas while the engine is
running,or immediatelyafter it is
turned off. Never operate the engine
withheat shieldsor guards
removed.
California
Proposition
65 Warning
Engine exhaustfrom this product
containschemicalsknown to the
Stateof Californiato cause
cancer,birthdefects,or other
reproductiveharm.
ElectricalShock!
Never touch electrical wiresor
components while the engineis
running. Theycan be sources of
electricalshock.
2

Safefy Precautions (Conf.)
WARNING
Accidental Starts can cause severe
injury or death.
Disconnect and ground spark plug
leads before sewicing.
Accidental Starts!
Disabingengine. Accidents/
staringcan cause severe injuv
or death.
Before workingon the
engine or equipment,disablethe
engineas follows:
1) Disconnectthe
sparkplug lead(s).
2) Disconnect
negative
(-) batterycable from
battery.
a WARNING
CarbonMonoxide can cause
severe nausea, fainting or death.
Do not operate engine in closed or
confined area.
\. -6
I Explosive Gas can cause fires and
severe acid burns.
Charge battey only in a well
ventilated area. Keep
sources of
ianition awav.
Lethal Exhaust Gases!
Engine exhaustgases contain
poisonous carbon monoxide.
Carbonmonoxide is odorless,
colorless,and can causedeath if
inhaled.Avoid inhaling exhaust
Explosive Gas!
Batteriesproduce explosive
hydrogen gas whilebeing charged.
Toprevent a fire or explosion,
chargebatteries only in well
ventilatedareas. Keep sparks, open
fumes,andnever run-the enginein
a closedbuilding or confinedarea. flames, and other sources of ignitionaway from thebattery atall
times. Keepbatteriesout of the
reach of children.Remove all
jewelry whenservicingbatteries.
'
Beforedisconnectingthe negative
(-) groundcable,make sure all
switches are
OFF: If ON, a spark
will occurat thegroundcable
terminalwhichcould cause an
explosionif hydrogen gas or
gasoline vaporsarepresent.
Congratulations -You have selected a fine four-cycle,twin cylinder,air-cooledengine. Kohler designs long life
strengthand on-the-jobdurability into each engine
... makinga Kohler engine dependable ... dependabilityyou can
count on. Hereare some reasons why:
Efficientoverheadvalve design and full pressure lubrication provide maximum power,torque, and reliability
under all operatingconditions.
Dependable, maintenance-freeelectronic ignitionensures fast, easy starts time after time.
Kohler engines are easy to service. All routine service areas like the dipstick, oil fill, air cleaner, and spark
plugs are easily and quickly accessible.
Partssubject to the most wear and tear (likethe cylinder liner* and camshaft)are made from precision
formulated cast iron. Becausethe cylinder liner* can be rebored,these engines can last even longer.
*Some CH25/26 engines have POWER-BORETMCylinders.These cylindersare platedwith nickel-siliconto
give increasedpower,virtually permanent cylinder life, superior oil control, and reducedexhaust emissions.
These cylinderscannot be rebored.
Every Kohlerengine is backed by a worldwide networkof over 10,000distributorsand dealers. Service
support isjust a phonecall away. Call 1-800-544-2444
(U.S. & Canada)for Sales & Serviceassistance.
To keepyour engine in top operatingcondition,follow the maintenanceproceduresin this manual.
3

Dipstick
\
Air Cleaner
OilFill,
' Side Oil Drain Plugs /
:igure I, TypicalCommandHorizontalShaft Engine (CH18-25,CH730,740),
Oil
anifold
Coil
lnjecta
' 1 Rectifier-Regulafor
Figure 2. CH26 CommandHorizontal Shaft Engine,
4

Oil Recommendations
Usingthe propertype and weight of oil inthe
crankcase is extremely important.
So is checkingoil
dailyand changingoil regularly.Failureto usethe
correctoil, or usingdirty oil, causes prematureengine
wear and failure.
Oil Type
Use highquality detergentoil of API (American
Petroleum Institute)service class
SC; SH, SJ or
higher.
Selectthe viscosity basedon the air
temperatureat the time of operationas shown in the
followingtable.
RECOMMENDED SAE VISCOSITY GRADES
v
*Use of syntheticoil having 5W-20 or 5W-30 rating is
**Syntheticoils will providebetter startingin extreme
rigure 3. ViscosityGrades Table.
acceptable,upto 40°F.
cold (below
-1 0°F).
NOTE: Usingother than service class SG,
SH, SJ or
higheroil or extendingoil change intervals
longerthan recommendedcan cause engine
damage.
Alogo or symbolon oilcontainersidentifiestheAPI
service classand SAEviscositygrade. See Figure
4.
Figure 4. Oil ContainerLogo,
Refer to “MaintenanceInstructions”beginning on
page
8 for detailed oil check, oil change,and oil
filter change procedures,
Fuel Recommendations
Gasolineis extremely flammableand its vaporscan
explodeif ignited. Storegasoline only in approved
containers,in well ventilated,unoccupiedbuildings,
away from sparks or flames.
Do not fill the fuel tank
while the engineis hot or running,sincespilled fuel
could ignite if it comes in contact withhot parts or
sparks from ignition.
Do not start the engine near
spilled fuel. Never use gasolineas a cleaning agent.
WARNING: ExplosiveFuel!
General Recornmendations
Purchasegasoline in small quantitiesand store in
clean,approvedcontainers.Acontainer with acapacity
of
2 gallonsor less with a pouringspout is
recommended.Such a containeris easier to handle
and helpseliminatespillageduring refueling.
Do not use gasoline left over from the previousseason,
to minimizegum depositsin fuel system andto insure
easy starting.
Do not add oilto the gasoline.
Do not overfillthe fuel tank. Leave roomfor the fuel to
expand.
Fuel Type
For best resultsuse only clean, fresh, unleaded
gasoline with a pump sticker octane rating of 87 or
higher. Incountriesusingthe Research method, it
shouldbe
90 octane minimum.
Unleadedgasoline is recommendedas it leaves less
combustionchamber depositsand reducesharmful
exhaust emissions. Leadedgasoline is not
recommendedand
must not be usedon CH26
engine,or on other modelswhere exhaust emissions
are regulated.
Gasoline/Alcoholblends
Gasohol (upto 10% ethylalcohol, 90% unleaded
gasoline byvolume) is approvedas a fuel for Kohler
engines. Other gasoline/alcohol blendsare not
approved.
Gasoline/Etherblends
MethylTertiaryButyl Ether (MTBE) and unleaded
gasoline blends(upto a maximumof
15% MTBEby
volume)are approvedas a fuel for Kohlerengines.
Other gasoline/ether blendsare notapproved.
5

Engine Identification Numbers
When ordering parts, or in any communication
involvingan engine, always give the
Model,
Specification,and Serial Numbers
of the engine.
CategoryC
I EPA I 250 hours
The engine identificationnumbersappear on a decal
affixedto the engine shrouding. Include letter suffixes,
if there are any.
CategoryB CategoryA
500 hours 1000 hours
Recordyour engine identification numbers on the
identificationlabel below (Figure
5) for future reference.
Moderate
125 hours
-- IMPORTANT ENGINE INFORMATION
THIS ENGINE MEETS U.S. EPA 2004 AND
Intermediate Extended
250 hours
500 hours
CALIFORNIA 2006 AND LATER EMISSION
CONTROL REGULATIONSFOR SI SORE*
FAMILY
DISPL, (CC)
MODEL NO,
SPEC. NO,
eN11236
SERIALNO,
EMISSION COMPLIANCE PERIOD:
EPA: CARB:
THIS ENGINE IS CERTIFIEDTO OPERATE
ON:
REFER TO OWNER'S MANUAL FOR SAFETY,
MAINTENANCE SPECS AND ADJUSTMENTS.
FOR SALES/SERVICE IN US/CANADA, CALL:
www. kohlerengines.com
1-800-544-2444
u
KOHLER CO. KOHLER, WISCONSIN USA
*Small Off-RoadEngines
7gure
5. Engine ldentification Label,
The EmissionCompliance Period referredto on the
EmissionControl or Air Indexlabel indicatesthe
numberof operating hoursfor which the engine has
been shown to meet Federaland CARB emission
requirements. The followingtable providesthe Engine
Compliance Period(in hours) associatedwith the
category descriptorfound on the certification label.
Emission CompliancePeriod (Hours)
I I
Refer to certification labelfor engine displacement.
Exhaust EmissionControl System for models
CHI8,20,22,23,25,730,740 is EM. Exhaust Emission
Control System for modelCH26 is EM, 02S, ECM, MFI.
Model Designation
ModelCH20S for example:C designatesCommand
engine, H designateshorizontalcrankshaft,and 20
designateshorsepower. Some model numbers
(CH730) use the approximate displacementratherthan
horsepower.A letter suffix designatesa specific version
as follows:
Suffix Designates
S Electric Start
ST Electric StarVRetractableStart
QS Quiet ModeVElectricStart
EP Electric Plant
cs Clutch ModeVElectricStart
Operating Instructions
Also read the operating instructionsof the equipment
this enginepowers.
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
surfacesof engine. Make sure they are clean and
unobstructed.
Check that the air cleaner components and all
shrouds, equipmentcovers, and guards are in
place and securelyfastened.
Checkthat any clutchesor transmissions are
disengaged or placedin neutral.This isespecially
importanton equipment with hydrostaticdrive.The
shift lever must beexactly in neutralto prevent
resistancewhich could keepthe engine from starting.
a WARNING: Lethal Exhaust Gases!
Engineexhaustgases containpoisonous carbon
monoxide. Carbonmonoxideis odorless,colorless,
and can cause deathif inhaled.Avoid inhalingexhaust
fumes,and never run the engine in a closedbuildingor
confinedarea.
Cold WeatherStarting Hints
1. Be sure to usethe proper oil for the temperature
expected. See Figure3 on page
5.
2. Disengageall possibleexternal loads.
3. Be sure the battery is in good condition.Awarm
battery has much more startingcapacity than a
cold battery.
4. Use fresh winter grade fuel. NOTE:Winter grade
gasoline has highervolatility to improvestarting.
Do not use gasoline left over from summer.
6

Starting
1. Place the throttle control midway betweenthe
“slow” and “fast” positions. Place the choke
control (non-EFIenginesonly) intothe
“on”
position. See Figure6.
Figure 6, Optional Engine Mounted Throttleand
Choke Controls(CH18-25,CH730,740),
2. Startthe engine byactivatingthe key switch.
Releasethe switch as soon as the engine starts.
NOTE:
NOTE:
NOTE:
Do not crank the engine continuouslyfor
morethan
10 secondsat a time. If the
enginedoes not start, allow a
60 second
cool down period betweenstarting
attempts. Failureto follow these
guidelinescan burn out, or permanently
damage, the starter motor.
Upon start-up,a metallic ticking may
occur.This iscaused by hydraulic lifter
leakdownduring storage. Runthe engine
for
5 minutes. The noisewill normally
cease in the first minute.
If noise
continues, run the engineat mid-throttle
for
20 minutes. If noise persists, take the
engineto your local authorized Kohler
Engine Service Dealer.
If the engine developssufficientspeed to
disengagethe starter but does not keep
running (afalse start),engine rotation
must be allowedto come to a complete
stop before attemptingto restart the
engine.
If the starter is engagedwhile the
flywheel is rotating, the starter pinionand
flywheel ring gear mayclash resulting in
damage to the starter.
If the starter does not turn the engineover, shut
off starter immediately. Do not make further
attemptsto start the engine untilthe condition is
corrected. Do notjump start usinganother battery
(refer to “Battery” on this page). Seeyour Kohler
Engine Service Dealer for service assistance.
CarburetedEngines Only:
3.
4.
For a ColdEngine -Gradually returnthe choke
controlto the
“off” position after the engine starts
and warms up.
The engine/equipment may be operatedduring
the warm-up period, but it may be necessaryto
leavethe choke partiallyon untilthe engine
warms up.
For a WarmEngine - Returnchoke to “off”
position as soon as engine starts.
Stopping
1. Removethe load by disengagingall PTO driven
attachments.
2. For CarburetedEngines WithoutA Shutdown
Solenoid:
Movethe throttle to the “slow” or
“low”idle position.Allow the engine to run at idle
for 30-60 seconds; then stop the engine.
For CarburetedEnginesEquipped WithA
ShutdownSolenoid:
Positionthe throttle control
somewhere between half and full throttle; then
stop the engine.
For EFl Engines: Movethe throttleto the “slow”
or “idle”position;turn key
“off” to stop engine.
Battery
A 12 volt battery is normallyused. Refer to the
operating instructionsof the equipmentthis engine
powersfor specific battery requirements.
If the battery charge is not sufficient to crank the
engine, rechargethe battery (see page 13).
Operating
Angle of Operation
This enginewill operatecontinuouslyat angles upto
25”. Check oil levelto assure crankcase oil level is at
the
“F’ mark on the dipstick.
Refer to the operating instructionsof the equipment
this engine powers. Becauseof equipment design or
application,there may be more stringent restrictions
regardingthe angle of operation.
NOTE: Do not operatethis engine continuouslyat
angles exceeding
25” in any direction. Engine
damage could result from insufficient
lubrication.
7

Cooling Engine Speed
NOTE: If debris builds up on the grass screen or
other coolingair intakeareas, stop the engine
immediatelyandclean. Operatingthe engine
with blockedor dirty air intakeand cooling
areas can cause extensive damagedue to
overheating. load.
NOTE: Do nottamperwith the governorsettingto
increasethe maximumengine speed.
Overspeedis hazardousand will void the
enginewarranty.The maximumallowable high
idle speed for these engines is
3750 RPM, no
a WARNING: Hot Parts!
Engine components can get extremelyhot from
operation. To prevent severeburns, do not touch these
areas while the engine is running,or immediately after
it is turned off. Never operatethe engine withheat
shieldsor guards removed.
Frequency
Daily or Before
StartingEngine
Maintenance Instructions
Maintenance,repai5 or replacementof the emission controldevicesand systems, whichare being done at
the customersexpense,may be performed by any non-road enginerepair establishmentor individual,
Warrantyrepairsmust be performed by an authorized Kohler service outlet,
a WARNING: AccidentalStarts!
DisabHng engine.Accidenta/staHingcan cause severe injuryor death. Before workingon the engine or
equipment,disablethe engineas follows: I) Disconnectthesparkplug lead@).2)Disconnectnegative (-) battery
cable from battery.
Maintenance Required
Fillfuel tank.
Check oil level.
Check air cleanerfor dirty’, loose,or damaged parts.
Check air intakeand coolingareas, clean as necessary’.
Maintenance Schedule
These requiredmaintenanceproceduresshould be performedat the frequency stated in the table. They should
also be includedas partof any seasonaltune-up.
Every25Hours
Every
700 Hours
Hours
Every250 Hours
Service precleanerelement’.
Replaceair cleaner element’.
Changeoil. (Morefrequently undersevere conditions.)
Removecoolingshrouds and clean coolingareas’,3.
Check oil cooler fins, clean as necessary (if equipped).
Check spark plugconditionand gap.
Changeoil filter.
Replaceheavy-dutyair cleaner element and check inner element’.
Every 500 Hours
Every
7500 Hours
Annually or
Havebendix starter drive serviced2.
Every 500 Hours
Havesolenoid shift starter disassembled and cleaned2.
Have crankshaft spline lubricated2.
Replacefuel filter’ (EFI engines).
8

Check Oil Level
The importanceof checking and maintainingthe proper
oil level in the crankcase cannot be overemphasized.
Check oil
BEFORE EACH USE as follows:
1. Make sure the engine is stopped, level, and is
cool
so the oil has had time to drain into the sump.
2. To keep dirt, debris, etc., out of the engine,clean
the area around the dipstick before removing it.
3. Removethe dipstick; wipe oil off. Reinsertthe
dipstick intothe tube and press all the way down.
4. Removethe dipstick and check the oil level.
The oil levelshould be up to, but not over, the
“F
mark on the dipstick. See Figure 7.
I
I
Operating
Range
“F” Mark
Figure
7. Oil Level Dipstick,
5. If the level is low, add oil of the propertype, upto
the
“F mark on the dipstick. (Refer to “Oil Type”
on page
5.) Always checkthe levelwith the
dipstick before adding more oil.
NOTE: To preventextensiveenginewear or
damage, always maintainthe proper oil
level in the crankcase. Never operatethe
enginewith the oil level belowthe
“L”
mark or over the “F’ mark on the dipstick.
Oil SentryTM
Some engines are equippedwith an optional Oil
SentryTMoil pressureswitch. If the oil pressure
decreases below an acceptable level,the Oil SentryTM
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
US€ and is maintainedupto the “F
mark on the dipstick. This includesengines
equippedwith Oil SentryTM.
Change Oil and Filter, Service Oil Cooler
Change Oil
Change oil after every 100 hours of operation (more
frequently under severeconditions). Refillwith service
class SG,
SH, SJ or higher oil as specified inthe
“Viscosity Grades”table (Figure
3) on page 5.
Changethe oil while the engine is still warm. The oil
will flow more freely and carry away more impurities.
Make sure the engine is levelwhen filling, checking,
and changing the oil.
Changethe oil as follows (see Figures
8 and 9):
1. To keep dirt, debris, etc., out of the engine, clean
the area aroundthe oil fill cap/dipstickbefore
removing it.
2. Remove one of the oil drain plugs, oil fill cap, and
dipstick. Be sure to allow ample time for complete
drainage.
3. Reinstallthe drain plug. Makesure it is tightened
to
13.6 N-m (10 ft. lb.) torque.
4. Fillthe crankcase,with new oil of the propertype,
to the
“F’ mark on the dipstick. Refer to “Oil Type”
on page
5. Always checkthe levelwith the dipstick
before adding more oil.
5. Reinstallthe oil fill cap and tighten securely.
Reinstall dipstick.
NOTE: To preventextensiveenginewear or
damage, always maintainthe proper oil
level in the crankcase. Never operatethe
enginewith the oil level belowthe
“L”
mark or over the “F’ mark on the dipstick.
oil Cooler
‘ Oil Drain Plug
I
Figure 8. Oil Drain Plugs, Oil Filter,and Oil Cooler
(CH25 shown),
9

Oil Drain’ Plug oil cooler
I
I
Service Oil Cooler
Someengines are equippedwith an oil cooler. One
style of oil cooler mounts on the engine crankcase and
hasthe oil filter on it (See Figure
8). The other style of
oil cooler is mounted on the blower housing (See
Figure
9), separate from the oil filter.
Inspectand clean the oil cooler
every 100 hours of
operation
(morefrequently under severe conditions).
Oil cooler must be keptfree of debris.
To servicethe crankcase mounted oil cooler clean
off
the outside fins with a brush or with compressed air.
Figure 9. Oil Drain Plugs, Oil Filter, and Oil Cooler
(CH26 shown),
Change Oil Filter
Replacethe oil filter at least every other oil change
(every200 hours of operation).
Always use a
genuineKohler oil filter,Part No. 12 050 OI-S.
Replacethe oil filter as follows:
1. Drainthe oil from the engine crankcase.
2. Allow the oil filter to drain.
3. Before removingthe 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 replacementfilter in a shallow pan
with the open end up. Pour new oil, of the proper
type, inthrough the threadedcenter hole. Stop
pouringwhen the oil reachesthe bottomof the
threads.Allow a minute or two for the oil to be
absorbed by the filter material.
5. Put a drop of oil on your fingertip and wipe it on
the rubber gasket.
6. Installthe replacementoilfilter to the filter adapter or
oil cooler.Turnthe oil filter clockwise untilthe rubber
gasket contactsthefilter adapter or oilcooler,then
tighten the filter an additional
2/3 to 1 turn.
7. Reinstallthe drain plug. Make sure it is tightened
to
13.6 N-m (10 ft, lb.) torque.
8. Fillthe crankcasewith new oil of the propertype
to the
“F mark on the dipstick.
9. Start the engine and check for oil leaks. Correct
any leaks before placingthe engine into service.
Check oil level to be sure it is up to but not over
the
“F mark.
To servicethe blower housing mountedoil cooler,
clean the outside of fins with a brush. Removethe two
screws holdingthe cooler unit to the blower housing.
Tilt the cooler downward as shown in Figure
10. Clean
the insideof cooler with a brush as shown in Figure
10
or with compressedair.After cleaning, reinstall oil
cooler to blower housingwith two mountingscrews.
Figure 10,
Service Precleaner and Air Cleaner Element
This engine is equippedwith a replaceable,high
density paper air cleaner element. Most engines are
also equippedwith an oiled, foam precleanerwhich
surrounds the paper element.See Figure
11.
Figure 11. Air CleanerSystem Components,
10