U.S. General 91824 User manual

STOCK# 91824
OPERATOR’S MANUAL
!
WARNING
To reduce the risk of injury, the user
must read and understand the
Operator’s Manual before using this
product.
30 GALLON
AIR COMPRESSOR
REV0905
12.75 HP KOHLER
GAS ENGINE
MODEL: US1230G
Warranty Statement
LIMITED
WARRANTY
Harbor Freight Tools Co. makes every effort to assure that its products meet high
quality and durability standards, and warrants to the original purchaser that this
product is free from defects in materials and workmanship for a period of two years
from date of purchase.
(90 days if used by a professional contractor or if used as rental equipment).
This warranty does not apply to damage due directly or indirectly to misuse, abuse,
negligence or accidents; repairs or alterations outside our facilities; or lack of
maintenance. We shall in no event be liable for death, injuries to persons or
property, or for incidental, contingent, special or consequential damages arising
from the use of our product.
Some states do not allow the exclusion or limitation of incidental or consequential
damages, so the above limitation of exclusion may not apply to you. To take
advantage of this warranty, the product or part must be returned to us with
transportation charges prepaid. Proof of purchase date and an explanation of the
complaint must accompany the merchandise. If our inspection verifies the defect,
we will either repair or replace the product at our election or we may elect to refund
the purchase price if we cannot readily and quickly provide you with a replacement.
We will return the repaired products at our expense, but if we determine there is no
defect, or that the defect resulted from causes not within the scope of our warranty,
then you must bear the cost of returning the product. This warranty gives you
specific legal rights and you may also have other rights which vary from state to
state.
3491 Mission Oaks Blvd. PO Box 6009 Camarillo, CA 93011 [phone]

Parts List US1230G
September 2005
Pump
B6000
Engine
ECS12ST
Safety Valve (200 psi)
SV25200
Beltguard
BG31184R
Pressure Gauge
GA300
Tank
TK30GB
Drive Pulley S2AK74H
Belt(2) BA69
Idle Control IC34
Beltguard Fastener 5001369
Unloader/Pilot Valve
Tank Drain
U109
Ball Valve
BV75
FIB02DC16
Discharge Tube
DT027
Filter Assem.
FS002
2Page 1
Safety Instructions
This manual contains information that is
very important to know and understand.
This information is provided for SAFETY
and to PREVENT EQUIPMENT PROB-
LEMS. To help recognize this informa-
tion, observe the following symbols.
Safety Signal Words
Danger indicates
an imminently haz-
ardous situation which, if not avoided,
WILL result in death or serious injury.
Warning indicates
a potentially haz-
ardous situation which, if not avoided,
COULD result in death or serious injury.
Caution indicates a
potentially haz-
ardous situation which, if not avoided,
MAY result in minor or moderate injury.
Notice indicates
important informa-
tion, that if not followed, may cause dam-
age to equipment.
!
NOTICE
!
CAUTION
!
WARNING
!
DANGER
Since the air compressor and other com-
ponents (pump, spray guns, filters, lubri-
cators, hoses, etc.) used make up a high
pressure pumping system, the following
safety precautions must be observed at
all times:
1. Read all manuals includ-
ed with this product care-
fully. Be thoroughly famil-
iar with the controls and
the proper use of the
equipment.
2. Follow all local safety codes as well
as the United States Occupational
Safety and Health Act (OSHA)
3. Only persons well acquainted with
these rules of safe operation should
be allowed to use the compressor.
4. Keep visitors away and NEVER allow
children in the work area.
5. Wear safety glasses and
use hearing protection
when operating the pump
or unit.
6. Do not stand on or use the pump or
unit as a handhold.
7. Before each use, inspect compressed
air system, fuel system and electrical
components for signs of damage,
deterioration, weakness or leakage.
Repair or replace defective items
before using.
8. Check all fasteners at frequent inter-
vals for proper tightness.
9. Do not wear loose clothing or jewelry
that will get caught in the moving
parts of the unit.
Before Using the Air Compressor
MANUAL
Never operate
compressor without
a beltguard. Com-
pressors can start automatical-
ly without warning. Personal
injury or property damage
could occurfrom contact with
moving parts.
!
WARNING
Compressor parts
may be hot even if
the unit is stopped.
!
CAUTION
Page 1

10. Keep fingers away from a running
compressor; fast moving and hot
parts will cause injury and/or burns.
11. If the equipment should start to
vibrate abnormally, STOP the
engine/motor and check immediately
for the cause. Vibration is generally a
warning of trouble.
!
WARNING
NEVER refuel a run-
ning or hot engine.
Explosive fuel can cause fires and
severe burns. Avoid overfilling fuel
tank.
12. Check fuel level before starting the
engine. Do not fill the gas tank
indoors. Wipe off any spilled gas
before starting the engine.
!
DANGER
Gasoline vapor is highly flamma-
ble. Refill outdoors or only in well
ventilated areas. Do not store,
spill or use gasoline near an open
flame or heat devices such as a
stove, furnace, or water heater,
which utilize a pilot light, or any
device that can create a spark. If
gasoline is accidentally spilled,
move unit away from the spill area
and avoid creating any source of
ignition until gasoline vapors have
dissipated.
!
WARNING
Motors, electrical equip-
ment and controls can
cause electrical arcs that will
ignite a flammable gas or vapor.
Never operate or repair in or near
a flammable gas or vapor. Never
store flammable liquids or gases
in the vicinity of the compressor.
!
WARNING
Carbon monoxide can
cause severe nausea,
fainting or death. Do
not operate unit
inside a closed building or a poor-
ly ventilated area.
13. To reduce fire hazard, keep
engine/motor exterior free of oil, sol-
vent, or excessive grease.
!
WARNING
Never remove or attempt to adjust
safety valve. Keep safety valve
free from paint and other accumu-
lations.
14. Do not tamper with governor setting
on engine. Overspeeding the unit
severely shortens engine life and may
also be very hazardous.
!
DANGER
Never attempt to repair
or modify tank!
Welding, drilling or any
other modifications will weaken the
tank resulting in damage from rup-
ture or explosion. Always replace
worn or damaged tanks.
15. Tanks rust from moisture build-up,
which weakens the tank. Make sure to
drain tank daily and inspect periodical-
ly for unsafe conditions such as rust
formation and corrosion.
Safety Instructions (continued)
Page 2
1. Crankcase 6061100
2. Cylinder 6030000
3. Head 6061401
4. Crankshaft 6061200
5. Crankcase Bottom 6061301
6. Crankcase Bottom Gasket 6050101
7. Valve Plate 6040051
8. Conrod Bearing (2 per Rod) 9013014
9. Connecting Rod 6011101
10. Conrod Nut 9128234
11. HP Piston 6021100
12. LP Piston 6022100
13. HP Wrist Pin 6021200
14. LP Wrist Pin 6022200
15. Circlip 9140060
16. HP Ring 9020011
17. HP Ring 9020041
18. HP Ring 9020073
19. LP Ring 9020016
20. LP Ring 9020046
21. LP Ring 9020076
22. Aftercooler 5070100
23. Bearing Housing (NDS) 5061690
24. Bearing Housing (DS) 6061590
25. Intercooler 5262010
26. Flywheel 5000100
27. Main Bearing 9170020
28. Main Bearing 9170090
29. Oil Sight Glass 9022003
30. Oil Fill Plug 9024006
31. Oil Seal 9163030
32. Flywheel Bolt 9110024
33 Flywheel Washer 9004009
34. Aftercooler Safety Valve Sv25225
35. Intercooler Safety Valve 9049064
36. Head Bolt 9101754
37. Cooler Bolt 9101254
38. Cylinder Bolt 9101324
39. Crankcase Btm. Bolt 9114262
40. Head Gasket 6050400
41. Cylinder Gasket 6050300
42. Aftercooler Gasket 5070200
43. Intercooler Gasket 5050600
44. Bearing Housing Gasket DS 6050500
45. Bearing Housing Gasket NDS 5050500
46. Frame Gasket 6050200
47. Oil Drain Tube 9053201
Gasket Kit 6050057
Filter Assembly FS002
Filter Element FE001
Page 11

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Page 10
B6000 16. Fast moving air will stir up dust and
debris which may be harmful.
Release air slowly when draining
moisture or depressurizing the com-
pressor system.
17. STOP the engine whenever leaving the
work area, before cleaning, making
repairs or inspections. When cleaning,
!
DANGER
This Compressor/pump is not equipped and should not be used “as is” to supply
breathing quality air. For any application of air for human consumption, the air
compressor/pump will need to be fitted with suitable in-line safety and alarm equip-
ment. This additional equipment is necessary to properly filter and purify the air to
meet minimal specifications for Grade D breathing as described in Compressed Gas
Association Commodity Specification G 7.1 - 1966, OSHA 29 CFR 1910. 134, and/or
Canadian Standards Associations (CSA).
DISCLAIMER OF WARRANTIES
In the event the compressor is used for the purpose of breathing air application and
proper in-line safety and alarm equipment is not simultaneously used, existing
warranties shall be voided, and The Manufacturer disclaims any liability whatsoever
for any loss, personal injury or damage.
!
WARNING
Do not spray flamma-
ble materials in vicini-
ty of open flame or
near ignition sources including the
compressor unit.
repairing or inspecting, make certain all
moving parts have stopped. Disconnect
the spark plug wire and keep the wire
away from the plug to prevent acciden-
tal starting.
18. Allow engine to cool before storing.
Spraying Precautions
19. Do not smoke when spraying paint,
insecticides, or other flammable sub-
stances.
20. Use a face mask/respirator when
spraying and spray in a well ventilat-
ed area to prevent health and fire
hazards.
21. Do not direct paint or other sprayed
material at the compressor. Locate
compressor as far away from the
spraying area as possible to mini-
mize overspray accumulation on the
compressor.
22. When spraying or cleaning with sol-
vents or toxic chemicals, follow the
instructions provided by the chemi-
cal manufacturer.
Breathable Air Warning
Page 3

ASME Safety Valve
A safety valve that automatically releases
the air if the air receiver (tank) pressure
exceeds the preset maximum.
PSI (Pounds per Square Inch)
Measurement of the pressure exerted by
the force of the air. The actual psi output
is measured by a pressure gauge on the
compressor.
ACFM (Actual Cubic Feet per Minute)
Sometimes called CFM (Cubic Feet per
Minute). Measurement of air volume
delivered by the compressor at a given
pressure..
Air Delivery
A combination of psi and SCFM. The air
delivery required by a tool is stated as
(number) SCFM at (Number) psi. The
combination of these figures determines
what size compressor is needed.
!
WARNING
Glossary of Terms
Regulator (Not Included)
A control that adjusts the line pressure to
the proper amount needed to operate
spray guns and air tools.
Tank Pressure Gauge
Indicates tank pressure in psi.
Unpacking and Checking Contents
1. Remove the air compressor from the
carton.
2. Place the compressor on a secure,
stationary work surface and look it
over carefully.
Do not operate unit if damaged
during shipping, handling or use.
Damage may result in bursting
and cause injury or property damage.
!
WARNING
To reduce the risk of injury, if any
parts are missing, do not attempt to
assemble the air compressor until
the missing parts are obtained and
installed correctly.
!
WARNING
For your own safety, never operate
unit until all assembly steps are
complete and until you have read
and understood the entire operator’s
manual.
Page 4
Troubleshooting
TROUBLE REMEDYPROBABLE CAUSE
Overheating 1. Relocate the compressor
to an area where an ample
supply of cool, clean, dry
and well-circulated air is
available
2. Clean the cooling surfaces
of pump and engine.
3. Check air requirements of
tools
1. Poor ventilation
2. Dirty cooling surfaces
3. Compressor undersized for
application
1. Increase idle, refer to
engine manual for details
2. Check for proper oil level
3. Replace
1. Low engine idle
2. Improper lubrication
3. Defective pilot/unloader valve
Unit stalls
Excessive noise 1. Loose pulleys are a com-
mon cause of “knocking”.
Tighten appropriate bolts
2. Check for proper oil level
3. Replace
4. Remove piston assembly
and replace necessary
parts
5. Replace bearings and oil
6. Check for proper belt
tension
1. Loose drive pulley or flywheel
2. Lack of oil in crankcase
3. Worn connecting rod
4. Worn wrist pin bushing
5. Worn bearings
6. Loose belts
Oil in the discharge
air
1. Change oil. Check oil
recommendations on page
7 of this manual
2. See above section
3. Clean or replace air filter
4. Replace
1. Wrong type or inferior grade
of oil
2. Overheating
3. Restricted intake air
4. Worn piston rings
Page 9

Getting to Know Your Air Compressor
Belt Guard
Pilot/Unloader Vave
Air Filter
Safety Valve
Air Storage Tank
Tank Drain
Ball Valve
Oil Sight Glass
1. Belt Guard. The belt guard encloses the
pulleys and drive belt. It protects the
user from moving parts and directs
cooling air to the compressor pump.
2. Air Filter. The air filter keeps dirt and
debris from entering the compressor
pump and reduces compressor noise.
3. Oil Sight Glass. The oil sight glass
shows proper level and cleanliness of
the oil. Oil level should show ½ full
4. Tank Drain Valve. The tank drain valve
allows moisture to be removed from the
tank.
5. Pilot/Unloader Valve. The pilot/unloader
valve controls the engine rpm. When
loaded, the engine will run at maximum
operating speed and air will enter the
tank. When compressor reaches maximum
pressure, the engine will slow to an idle
and air will vent to atmosphere.
6. ASME Safety Valve. This valve auto-
matically releases air if the tank pressure
exceeds the preset maximum.
7. Ball Valve. The ball valve allows unregulated
outlet air with pressure up to 175 psi.
8. Air Storage Tank. The tank stores air for
later use.
9. Regulator and Gauge (Not Included).
Outlet air can be regulated by adjusting
the regulator knob. Clockwise will raise
outlet pressure and counterclockwise will
lower outlet pressure. Outlet pressure will
be displayed on gauge.
10. Tank Pressure Gauge. The tank pressure
gauge will display air pressure in tank.
Page 5
Troubleshooting
!
WARNING
For your own safety do not try and
run the air compressor while troubleshooting.
TROUBLE REMEDYPROBABLE CAUSE
Low discharge pres-
sure
1. Listen for escaping air.
Ally soap solution to all
fittings and connections.
Bubbles will appear at
points of leakage. Tighten
or replace leaking fittings
or connections
2. Remove head and inspect
for valve breakage, weak
valves, scored valve plate,
etc. Replace defective
parts and reassemble
1. Air leaks
2. Leaking valves
!
CAUTION
Be sure that the old head
gasket is replaced with a
new one each time the
head is removed
3. Clean or replace air filter
element.
4. Replace and gaskets
proven faulty on inspection
5. Loosen engine mounting
bolts and move engine in
a direction away from the
compressor, being sure
that the engine pulley is
perfectly aligned with the
flywheel. Tighten engine
mounting bolts. Proper
belt tension should not
allow more than about ½
travel with less that 5
pounds of force
3. Restricted air intake
4. Blown gaskets
5. Slipping belts
Page 8

Operating Your Compressor
!
CAUTION
All lubricated compressor pumps dis-
charge some condensed water and oil
with the compressed air. Install appropri-
ate water/oil removal equipment and con-
trols as necessary for the intended appli-
cation.
NOTICE
Before starting the compressor,
thoroughly read all component
instruction manuals, especially the
engine manual.
NOTICE
Failure to install appropriate
water/oil removal equipment may
result in damage to machinery or
workpiece.
NOTICE
Do not attach air tools to open
end of the hose until start-up is
completed and unit checks OK.
To ensure proper operation, unit
must be on a level surface.
Moisture in compressed air will form into
droplets as it comes from an air compres-
sor pump. When humidity is high or when
a compressor is in continuous use for an
extended period of time, this moisture will
collect in the tank. When using a paint
spray gun, this water will be carried from
the tank through the hose, and out of the
gun as droplets mixed with the spray
material.
Moisture in Compressed Air
IMPORTANT: This condensation will cause
water spots in a paint job, especially when
spraying other than water based paints.
A filter in the air line, located as near to the
gun as possible will eliminate most of this
moisture..
Start-Up
3. Connect the negative (-) battery cable
to a mounting bolt or an acceptable
engine ground connection.
4. Connect the positive (+) battery cable
to the positive (+) battery terminal.
5. Connect the negative (-) battery cable
to the negative (-) battery terminal.
IMPORTANT: Number 2 wire or larger
is recommended.
1. Locate the starter solenoid terminal.
This is the top post farthest from the
block with the small red wire..
2. Connect the positive (+) battery cable
to the starter solenoid terminal.
Battery Connection
!
CAUTION
Make sure to follow instructions
carefully to avoid a short and poss-
ible damage to the starter solenoid
and/or battery. Always connect the
positive (+) battery cable to the
starter solenoid before connecting
the negative (-) battery cable.
1. Turn the gas lever to the “On” position.
Turn the choke lever to the left.
Turn key to the “On” position, then to
the “Start” position or pull start grip to
start the engine. Once the engine is
running, turn the choke lever to the
original “right hand” position.
See Engine Manual for More Detailed Instructions
Page 6
2. This compressor is equipped with an auto-
matic start- relief valve. This valve allows
the unit to run (unloaded) for a few
seconds before air pressure starts to build
in the tank.
3. When maximum tank pressure is reached,
the compressor automatically unloads,
slowing the engine to idle. The engine
remains at idle until tank pressure falls
to a preset level. The engine will then
accelerate and air will once again build
pressure in the tank.
4. To turn off compressor, turn key to the
“Off” position.
Note: Turn Gas Off when not in use.
Remember to drain moisture from tank
daily.
Operating Your Compressor (continued)
Adjusting A Regulator
(Regulator must be purchased Separately)
1. To adjust the regulator, pull out on the
regulator knob. Turn regulator knob
clockwise to raise outlet pressure and
turn regulator knob counterclockwise to
decrease outlet air pressure.
2. Once desired outlet pressure is obtained,
push regulator knob in to lock setting.
Maintenance
!
WARNING
Disconnect spark plug and drain
air system completely of all air
pressure prior to performing
maintenance on compressor..
NOTICE
Consult engine manual for scheduled
maintenance instructions.
DAILY
1. Check oil level at sight glass. Check
engine oil level.
2. Drain moisture from tank.
3. Visually check for loose parts or
excessive noise or vibration.
WEEKLY
1. Inspect air filter. Replace if necessary.
2. Check safety valve by pulling ring and
releasing. Valve should seal once
released.
3. Clean excessive dirt/dust from unit..
MONTHLY
Check belt tension and alignment.
3 Months
Change Oil. A compressor grade non-
detergent oil should be used.
Most automotive detergent oils cause excess
carbon build-up and should not be used.
Cold climates (Below 30°F) use 20WT
Moderate Climates (30°F-90°F) use 30WT
Hot Climates (Above 90°F) use 40WT
Page 7

Table of Contents
Section Page
Safety Instructions 1
Safety Signal Words
Before Using the Air
Compressor
Spraying Precautions
Breathable Air Warning
Glossary of Terms 4
Unpacking and Checking
Content 4
Getting to Know Your Air
Compressor 5
Operating Your Air Compressor 6
Moisture in Compressed Air
Lubricaton
Start-up
To Start Gasoline Engine
Section Page
Maintenance 7
Maintenance Schedule
Adjusting the Regulator
Filter Removal, Inspection, and
Replacement
Drive Belt
Troubleshooting 8-9
Replacement Parts 10-12
Notes 13
1
1
3
3
6
7
6
6
7
7
7
7
Warranty Statement 14
Notes

4
2
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3
9
5
6
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1
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18
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15
14
13
11
12
10
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32
31
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29
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26
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37
36
B6000
40
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45
44
46
38
39
47

1. Crankcase 6061100
2. Cylinder 6030000
3. Head 6061401
4. Crankshaft 6061200
5. Crankcase Bottom 6061301
6. Crankcase Bottom Gasket 6050101
7. Valve Plate 6040051
8. Conrod Bearing (2 per Rod) 9013014
9. Connecting Rod 6011101
10. Conrod Nut 9128234
11. HP Piston 6021100
12. LP Piston 6022100
13. HP Wrist Pin 6021200
14. LP Wrist Pin 6022200
15. Circlip 9140060
16. HP Ring 9020011
17. HP Ring 9020041
18. HP Ring 9020073
19. LP Ring 9020016
20. LP Ring 9020046
21. LP Ring 9020076
22. Aftercooler 5070100
23. Bearing Housing (NDS) 5061690
24. Bearing Housing (DS) 6061590
25. Intercooler 5262010
26. Flywheel 5000100
27. Main Bearing 9170020
28. Main Bearing 9170090
29. Oil Sight Glass 9022003
30. Oil Fill Plug 9024006
31. Oil Seal 9163030
32. Flywheel Bolt 9110024
33 Flywheel Washer 9004009
34. Aftercooler Safety Valve SV25225
35. Intercooler Safety Valve 9049064
36. Head Bolt 9101754
37. Cooler Bolt 9101254
38. Cylinder Bolt 9101324
39. Crankcase Btm. Bolt 9114262
40. Head Gasket 6050400
41. Cylinder Gasket 6050300
42. Aftercooler Gasket 5070200
43. Intercooler Gasket 5050600
44. Bearing Housing Gasket DS 6050500
45. Bearing Housing Gasket NDS 5050500
46. Frame Gasket 6050200
47. Oil Drain Tube 9053201
Gasket Kit 6050057
Filter Assembly 6281007 or FS002
Filter Element 7081106 or FE001
B6000

COMMAND PRO CS SERIES 4-12 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 hazard that can cause severe personal in ury,
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 in ury
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.
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- ob 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 sub ect 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 ust 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 CS En ines.
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.
Fuel Tank Cap
Air Cleaner
Air Cleaner
Cover Retainin
Knob Fuel Tank
Choke Lever
Fuel
Shut-Off
Retractable Starter Throttle Lever
Oil Sentry
Li ht
On/Off Switch
(some models)
Muffler Shield
Muffler
Spark Plu
Carburetor
Oil Drain
Valve Cover
Oil Fill/
Check Plu
Synthetic oils should not be used.
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 and oil 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
(or decals) 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 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.
If your engine has this identification label, it is
certified to meet EPA/CARB standards.
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 Federal and CARB emission
requirements. The following table provides the Engine
Complicance Period (in hours) associated with the
category descriptor found on the certification label.
Emission Compliance Period (Hours)
EPA
CARB
Category C
250 Hours
Moderate
125 Hours
Category B
500 Hours
Intermediate
250 Hours
Category A
1000 Hours
Extended
500 Hours
Refer to certification label for engine displacement.
Exhaust Emission Control System for models CS4-12
is EM.

6
Operating Instructions
Also read the operating instructions of the equipment this engine powers.
Pre-Start Checklist
NOTE: This engine has been shipped without engine
oil. Fill with oil, otherwise it will not start.
 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. Set speed control at part throttle position.
4. A warm battery has much more starting capacity
than a cold battery.
5. Use fresh winter grade fuel. NOTE: Winter grade
gasoline has a higher volatility to improve starting.
Do not use gasoline left over from summer.
Starting
1. Turn fuel shut-off valve to on position. See
Figure 6.
Fi ure 5. Control Panel.
Fi ure 6. On Position of 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.
For a Warm En ine (normal operatin
temperatures)  Place the throttle control midway
between the slow and fast positions. The
choke is not required to start a warm engine.
3. Start the engine as follows:
For Retractable Start En ine  Turn engine
On/Off switch to on (see Figure 7) and SLOWLY
pull the starter handle until ust 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.
Fi ure 7. Retractable Start En ine On/Off Switch.
Extend the starting rope periodically and check its
condition. If the rope is frayed, have it replaced
immediately by your Kohler Engine Service Dealer.
Throttle
Control
Choke
Control

7
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.
For an Electric Start En ine  Activate the
starter switch. Release the switch as soon as the
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 slow position.
Turn key switch or on/off switch to off 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 12).
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 overfilling the filler neck.
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 hazardous and will void the
engine warranty.
Fi ure 8. Electric Start En ine Starter Switch.
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), the engine rotation
must be allowed to come to a complete
stop before attempting to restart the
engine. If the start 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
ump start using another battery (refer to "Battery").
See your Kohler Engine Service Dealer for trouble
analysis.
4. 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.
Off
On
Start

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.
Daily or Before
Startin En ine
Maintenance RequiredFrequency
 Fill fuel tank.
 Check oil level.
 Check air cleaner for dirty, loose, or damaged parts.1
 Check air intake and cooling areas, clean as necessary.1
 Check fuel hose for cracks or damage. Replace if necessary.
 Check exhaust system for leakage. Retighten or replace gasket if necessary.2
 Check choke operation.
 Check retractable starter operation.
 Service precleaner element. Replace if necessary.1
Every 25 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.
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.
¹Perform these maintenance procedures more frequently under extremely dusty dirty conditions.
²Have a Kohler Engine Service Dealer perform this service.
 Change oil.
 Replace air cleaner element.1
 Remove cooling shrouds and clean cooling areas.1
 Check all fittings and fasteners.
 Clean fuel valve shut-off filter. Replace if necessary.
 Check muffler screen/spark arrestor. Clean/replace if necessary.
 Check spark plug condition, ad ust gap, and clean. Replace if necessary.
Every 100 Hours
 Check and ad ust valve clearance when engine is cold.2
 Check and ad ust idle speed.
 Service starter motor drive, if so equipped.2
 Check cooling fan for damage.
 Have combustion chamber decarbonized.2
Annually or
Every 300 Hours
Fi ure 9. Location of Oil Drain and Check Plu s.
Oil Fill/
Check Plu Oil Drain Plu

9
NOTE: If the engine stalls or does not start, turn the
engine switch to on position and then pull
the recoil starter or attempt to start engine. If
the oil warning light flickers for a few seconds,
the engine oil is insufficient. Add oil and
restart.
NOTE: Make sure the oil level is checked BEFORE
EACH USE and is maintained up to the point
of overflowing the filler neck.
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  weight
service class SG, SH, SJ or higher oil for the first 20
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.
Change the oil as follows (see Figure 9):
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.
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.
Fi ure 10. 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
Engines are equipped with an Oil Sentry oil monitor.
When the oil level falls below the safe level, the engine
stops automatically. Unless you refill with oil, the
engine will not start again. See Figure 11.
Fi ure 11.
Filler Neck
Brin Level Up To
Point of Overflow
(Cutaway Showin
Proper Oil Level)

10
Reduction Systems
2:1 Reduction Systems
All 2:1 reduction systems are lubricated by the
crankcase oil of the engine through special openings in
the closure plate. No special maintenance or service is
necessary. Check and maintain the oil level as outlined
on pages 8 and 9.
6:1 Reduction Systems
CS4 and CS6: Use an internal pinion and ring gear
system, independent of, and separated from the main
crankcase lubrication. See Figure 12. Use the same
weight oil in the reduction system that is being used in
the crankcase. Reduction System Capacity = .15
liters (5.07 fl. oz.). Change the reduction system oil
every 300 hours as follows:
1. Drain old oil out through the oil level/drain plug, tip
engine as required.
2. Engine must be level. Fill with new oil through the
oil fill plug hole on top until the oil level is up to the
bottom of the oil level/drain plug hole. Reinstall
both plugs securely.
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. Remove the outer cover of the air cleaner
assembly and access the element.
2. Remove the precleaner from the paper element.
3. Wash the precleaner in warm water with
detergent. Rinse the precleaner thoroughly until all
traces of detergent are eliminated. Squeeze out
excess water (do not wring). Allow the precleaner
to air dry.
4. Saturate the precleaner with new engine oil and
squeeze out all excess oil.
5. Reinstall the precleaner over the paper element.
6. Reinstall and secure the air cleaner cover.
Service Paper Element
Every 100 hours of operation (more often under
extremely dusty or dirty conditions), replace the paper
element.
1. Remove the outer cover of the air cleaner
assembly and access the element/precleaner
assembly. Remove the wing nut securing the
element assembly, or pull the complete assembly
out of the cover/housing (some Heavy Duty Air
Cleaners). Separate the precleaner from the
element and service as outlined above.
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. Check the air cleaner cover/
housing for damage or improper fit. Replace all
bent or damaged air cleaner components.
On Standard Air Cleaner Systems:
Before air cleaner is reassembled make sure
rubber seal is in position around stud. Inspect seal
and replace if its condition is questionable in any
way.
Fi ure 12. CS4 and CS6 6:1 Reduction System.
CS8.5, CS10, and CS12: Use a gear reduction system
which is lubricated by the crankcase oil of the engine
through holes in the closure plate. No special
maintenance or service is necessary.
Service Precleaner and Air 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 13 on page 11.
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.
Oil Fill Plu
Oil Level/Drain Plu