Kohler CH15, CH13, CH11 User Manual

COMMAND CH11-16

HORIZONTAL CRANKSHAFT

SERVICE MANUAL

Section 1. Safety and General Information ............................................................................

Section 2. T ools & Aids ............................................................................................................

Section 3. Troubleshooting .....................................................................................................

Section 4. Air Cleaner and Air Intake System ........................................................................

Section 5. Fuel System and Governor....................................................................................

Section 6. Lubrication System ................................................................................................

Section 7. Retractable Starter .................................................................................................

Section 8. Electrical System and Components .....................................................................

Section 9. Disassembly ...........................................................................................................

Section 10. Inspection and Reconditioning ...........................................................................

Section 11. Reassembly...........................................................................................................

Section 1

Safety and General Information

Section 1

Safety and General Information

Safety Precautions

To ensure safe operation please read the following statements and understand their meaning. Also refer to your equipment manufacturer'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 Y our Safety!

These precautions should be followed at all times. Failure to follow these precautions could result in injury to yourself and others.

WARNING

Accidental Starts can cause severe injury or death.

Disconnect and ground spark plug lead before servicing.

Accidental St arts!

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.

Rotating Parts can cause severe injury.

Stay away while engine is in operation.

Rotating Part s!

Keep hands, feet, hair, and clothing away from all moving parts to prevent injury. Never operate the engine with covers, shrouds, or guards removed.

WARNING

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. Never operate the engine with heat shields or guards removed.

1.1

Section 1 Safety and General Information

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.

WARNING

WARNING 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.

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

Uncoiling Spring can cause severe injury.

Wear safety goggles or face protection when servicing retractable starter.

Explosive Gas can cause fires and severe acid burns.

Charge battery only in a well ventilated area. Keep sources of ignition away.

Explosive Gas!

Batteries produce explosive hydrogen gas while being charged. To prevent a fire or explosion, charge batteries only in well ventilated areas. Keep sparks, open flames, and other sources of ignition away from the battery at all times. Keep batteries out of the reach of children. Remove all jewelry when servicing batteries.

Before disconnecting the negative (-) ground cable, make sure all switches are OFF. If ON, a spark will occur at the ground cable terminal which could cause an explosion if hydrogen gas or gasoline vapors are present.

Cleaning Solvents can cause severe injury or death.

Use only in well ventilated areas away from ignition sources.

Flammable Solvents!

Carburetor cleaners and solvents are extremely flammable. Keep sparks, flames, and other sources of ignition away from the area. Follow the cleaner manufacturer’s warnings and instructions on its proper and safe use. Never use gasoline as a cleaning agent.

Spring Under T ension!

Retractable starters contain a powerful, recoil spring that is under tension. Always wear safety goggles when servicing retractable starters and carefully follow instructions in the Retractable Starter Section 7 for relieving spring tension.

CAUTION

Electrical Shock can cause injury.

Do not touch wires while engine is running.

Electrical Shock!

Never touch electrical wires or components while the engine is running. They can be sources of electrical shock.

1.2

Engine Identification Numbers

When ordering parts, or in any communication involving an engine, always give the Model, Specification, and Serial Numbers, including letter suffixes if any.

The engine identification numbers appear on a decal, or decals, affixed to the engine shrouding. See Figure 1-1. An explanation of these numbers is shown in Figure 1-2.

Section 1

Safety and General Information

Identification Decal

Figure 1-1. Engine Identification Decal Location.

A. Model No.

Command Engine

Horizontal Crankshaft

Horsepower

11 = 11 HP

12.5 = 12.5 HP 13 = 13 HP 14 = 14 HP 15 = 15 HP 16 = 16 HP

B. Spec. No.

Engine Model Code Code Model

16 CH11 19 CH12.5 22 CH13 18 CH14 44 CH15 45 CH16

C. Serial No.

Year Manufactured Code Code Year

20 1990 21 1991 22 1992 23 1993 24 1994 25 1995 26 1996 27 1997 28 1998

C H 12.5 ST

1903

2005810334

Code Year

29 1999 30 2000 31 2001 32 2002 33 2003 34 2004 35 2005 36 2006 37 2007

Version Code

S = Electric Start T = Retractable S t art ST = Electric/Retractable S tart GT = Generator Application/Retractable Start GS = Generator Application/Electric Start PT = Pump/Retractable S t art RT = Gear Reduction/Retractable Start

Variation of Basic Engine

Factory Code

MODEL NO. SPEC. NO. SERIAL NO.

REFER TO OWNER'S MANUAL FOR SAFETY, MAINTENANCE SPECS

AND ADJUSTMENTS. FOR SALES AND SERVICE IN US/CANADA CALL: 1-800-544-2444.

www.kohlerengines.com

KOHLER CO. KOHLER, WI USA

CH12.5ST

1903

2005810334

A B

Figure 1-2. Explanation of Engine Identification Numbers.

1.3

Section 1 Safety and General Information

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 higher. Select the viscosity based on the air

temperature at the time of operation as shown in the following table.

*Use of synthetic oil having 5W-20 or 5W-30 rating is

acceptable, up to 4°C (40°F).

**Synthetic oils will provide better starting in

extreme cold below 23°C (-10°F).

NOTE: Using other than service class SG, SH, SJ, or

higher oil or extending oil change intervals longer than recommended can cause engine damage.

Fuel Recommendations

WARNING: Explosive Fuel!

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 spilling during refueling.

Do not use gasoline left over from the previous 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.

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.

NOTE: Synthetic oils meeting the listed

classifications may be used with oil changes performed at the recommended intervals. However to allow piston rings to properly seat, a new or rebuilt engine should be operated for at least 50 hours using standard petroleum based oil before switching to synthetic oil.

A logo or symbol on oil containers identifies the API service class and SAE viscosity grade. See Figure 1-3.

Figure 1-3. Oil Container Logo.

Refer to Section 6 Lubrication System for detailed oil check, oil change, and oil filter procedures.

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 maximum of 15% MTBE by volume) are approved as a fuel for Kohler engines. Other gasoline/ether blends are not approved.

1.4

Periodic Maintenance

Section 1

Safety and General Information

WARNING: Accident al St arts!

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

The following required maintenance procedures should be performed at the frequency stated in the table and should also be included as part of any seasonal tune-up.

Frequency

• Fill fuel tank.

Daily or Before

Starting Engine

Every 25 Hours

Every 50 Hours

Every

100 Hours

Every

200 Hours

Annually or Every

500 Hours

Perform these maintenance procedures more frequently under extremely dusty, dirty conditions.

Only required for Denso starters. Not necessary on Delco starters. Have a Kohler Engine Service Dealer perform this service.

• Check oil level.

• Check air cleaner for dirty1, loose, or damaged parts.

• Check air intake and cooling areas, clean as necessary1.

• Service precleaner element1.

• Check oil level in gear reduction unit.

• Replace air cleaner element1.

• Change oil1.

• Remove cooling shrouds and clean cooling areas1.

• Change oil filter.

• Check spark plug condition and gap.

• Replace fuel filter.

• Have bendix starter drive serviced2.

• Have solenoid shift starter disassembled and cleaned2.

Maintenance Required

Refer to:

Section 5 Section 6 Section 4 Section 4

Section 4

Section 6

Section 4 Section 6 Section 4

Section 6 Section 8 Section 5

Section 8 Section 8

Storage

If the engine will be out of service for two months or more, use the following storage procedure:

1. Clean the exterior surfaces of the engine.

2. Change the oil and oil filter while the engine is still warm from operation. See Change Oil and Oil Filter in Section 6.

3. The fuel system must be completely emptied, or the gasoline must be treated with a stabilizer to prevent deterioration. If you choose to use a stabilizer, follow the manufacturers recommendations, and add the correct amount for the capacity of the fuel system. Fill the fuel tank with clean, fresh gasoline. Run the engine for 2-3 minutes to get stabilized fuel into the 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.

5. Remove the spark plug. Cover the spark plug hole with your thumb, and turn the engine over until the piston is at the top of its stroke. (Pressure against thumb is greatest.) Reinstall the plug, but do not connect the plug lead.

6. Store the engine in a clean, dry place.

1.5

Section 1 Safety and General Information

Dimensions in millimeters. Inch equivalents shown in ( ).

Figure 1-4. T ypical Engine Dimensions.

1.6

Section 1

Safety and General Information

General Specifications

Power (@ 3600 RPM, exceeds SAE J1940 HP standards)

CH11 .......................................................................................................... 8.20 kW (11 HP)

CH12.5 ....................................................................................................... 9.33 kW (12.5 HP)

CH13 .......................................................................................................... 9.75 kW (13 HP)

CH14 .......................................................................................................... 10.50 kW (14 HP)

CH15 .......................................................................................................... 11.20 kW (15 HP)

CH16 .......................................................................................................... 11.90 kW (16 HP)

Peak Torque (@ RPM indicated)

CH11 (@ 2400 RPM) ................................................................................. 26.7 N·m (19.7 ft. lb)

CH12.5 (@ 2500 RPM) .............................................................................. 27.8 N·m (20.5 ft. lb)

CH13 (@ 2400 RPM) ................................................................................. 28.8 N·m (21.2 ft. lb)

CH14 (@ 2500 RPM) ................................................................................. 27.8 N·m (21.3 ft. lb)

CH15 (@ 2400 RPM) ................................................................................. 34.3 N·m (25.3 ft. lb)

CH16 (@ 2400 RPM) ................................................................................. 33.9 N·m (25.0 ft. lb)

Bore

CH11, CH12.5, CH13, CH14 .................................................................... 87 mm (3.43 in.)

CH15, CH16 .............................................................................................. 90 mm (3.54 in.)

Stroke ................................................................................................................ 67 mm (2.64 in.)

Displacement

CH11, CH12.5, CH13, CH14 .................................................................... 398 cc (24.3 cu. in.³)

CH15, CH16 .............................................................................................. 426 cc (26.0 cu. in.³)

Compression Ratio ......................................................................................... 8.5:1

Weight .............................................................................................................. 40 kg (88.3 lb.)

Max. Oil Capacity (w/filter) .......................................................................... 1.9 L (2.0 qt.)

Lubrication ...................................................................................................... full pressure w/full flow filter

Air Cleaner

Base Nut Torque .............................................................................................. 9.9 N·m (88 in. lb.)

Angle of Operation - Maximum (at full oil level)

Intermittent - All Directions ......................................................................... 35°

Continuous - All Directions .......................................................................... 25°

Balance Shaft

End Play (Free) ................................................................................................ 0.0575/0.3625 mm (0.0023/0.0137 in.)

Running Clearance ......................................................................................... 0.025/0.1520 mm (0.0009/0.0059 in.)

Bore I.D.

New ........................................................................................................... 20.000/20.025 mm (0.7874/0.7884 in.)

Max. Wear Limit ...................................................................................... 20.038 mm (0.7889 in.)

Balance Shaft Bearing Surface O.D.

New ........................................................................................................... 19.962/19.975 mm (0.7859/0.7864 in.)

Max. Wear Limit ...................................................................................... 19.959 mm (0.7858 in.)

Values are in Metric units. Values in parentheses are English equivalents. Lubricate threads with engine oil prior to assembly.

1.7

Section 1 Safety and General Information

Camshaft

End Play (Free) ................................................................................................ 0.0875/0.3925 mm (0.0034/0.0154 in.)

End Play (with Shims) ................................................................................... 0.0762/0.1270 mm (0.0030/0.0050 in.)

Running Clearance ......................................................................................... 0.025/0.1050 mm (0.00098/0.0041 in.)

Bore I.D.

New ........................................................................................................... 20.000/20.025 mm (0.7874/0.7884 in.)

Max. Wear Limit ...................................................................................... 20.038 mm (0.7889 in.)

Camshaft Bearing Surface O.D.

New ........................................................................................................... 19.962/19.975 mm (0.7859/0.7864 in.)

Max. Wear Limit ...................................................................................... 19.959 mm (0.7858 in.)

Carburetor

Fuel Bowl Nut Torque .................................................................................... 5.1-6.2 N·m (45-55 in. lb.)

Charging

Stator Mounting Screw Torque .................................................................... 6.2 N·m (55 in. lb.)

Closure Plate

Oil Filter Tightening....................................................................................... 3/4-1 turn after gasket contacts.

Oil Filter Adapter Fastener Torque .............................................................. 11.3 N·m (100 in. lb.)

Oil Filter Drain Plug (1/8" NPT) Torque....................................................... 7.3-9.0 N·m (65-80 in. lb.)

Closure Plate Fastener Torque ...................................................................... 24.4 N·m (216 in. lb.)

Oil Sentry Pressure Switch Torque .............................................................. 6.8 N·m (60 in. lb.)

Oil Pump Cover Fastener Torque² ............................................................... 4.0,6.2 N·m (35,55 in. lb.)

Connecting Rod

Cap Fastener Torque

6 mm straight shank bolt....................................................................... 11.3 N·m (100 in. lb.)

8 mm straight shank bolt....................................................................... 22.6 N·m (200 in. lb.)

8 mm step-down type bolt .................................................................... 14.7 N·m (130 in. lb.)

Connecting Rod-to-Crankpin Running Clearance at 21°C (70°F)

New ........................................................................................................... 0.030/0.055 mm (0.0012/0.0022 in.)

Max. Wear Limit ...................................................................................... 0.07 mm (0.0025 in.)

Connecting Rod-to-Crankpin Side Clearance ............................................ 0.18/0.41 mm (0.007/0.016 in.)

Connecting Rod-to-Piston Pin Running Clearance 21°C (70°F) ............... 0.015/0.028 mm (0.0006/0.0011 in.)

Piston Pin End I.D.

New ........................................................................................................... 19.015/19.023 mm (0.7486/0.7489 in.)

Max. Wear Limit ...................................................................................... 19.036 mm (0.7495 in.)

Crankcase

Governor Cross Shaft Bore I.D.

New ........................................................................................................... 6.025/6.050 mm (0.2372/0.2382 in.)

Max. Wear Limit ...................................................................................... 6.063 mm (0.2387 in.)

For self-tapping (thread-forming) fasteners, the higher torque value is for installation into a new cored (non-threaded) hole.

The lower torque value is for installation into a used or threaded hole.

1.8

Section 1

Safety and General Information

Crankshaft

End Play (Free) ................................................................................................ 0.0575/0.4925 mm (0.0022/0.0193 in.)

End Play (Thrust Bearing with Shims) ....................................................... 0.0500/0.5300 mm (0.0019/0.0208 in.)

Crankshaft Bearing I.D. (In Crankcase)

Sleeve Bearing (Installed) - New ........................................................... 44.965/45.003 mm (1.7703/1.7718 in.)

Sleeve Bearing - Max. Wear Limit ......................................................... 45.016 mm (1.7723 in.)

Parent Material (No Sleeve Bearing) - New ........................................ 44.965/44.990 mm (1.7703/1.7713 in.)

Parent Material (No Sleeve Bearing) - Max. Wear Limit ................... 45.003 mm (1.7718 in.)

Crankshaft to Bearing Running Clearance - New

Sleeve Bearing .......................................................................................... 0.030/0.090 mm (0.0011/0.0035 in.)

Parent Material (No Sleeve Bearing) .................................................... 0.030/0.077 mm (0.0011/0.0030 in.)

Crankshaft Bearing I.D. (In Closure Plate)

Sleeve Bearing (Installed) - New ........................................................... 41.960/42.035 mm (1.6519/1.6549 in.)

Sleeve Bearing - Max. Wear Limit ......................................................... 42.048 mm (1.6554 in.)

Parent Material (No Sleeve Bearing) - New ........................................ 41.965/42.003 mm (1.6521/1.6536 in.)

Parent Material (No Sleeve Bearing) - Max. Wear Limit ................... 42.015 mm (1.6541 in.)

Crankshaft Bore (In Closure Plate) to Crankshaft Running Clearance - New

Sleeve Bearing .......................................................................................... 0.025/0.1200 mm (0.00098/0.00472 in.)

Parent Material (No Sleeve Bearing) .................................................... 0.030/0.0880 mm (0.0011/0.0034 in.)

Flywheel End Main Bearing Journal

O.D. - New ................................................................................................ 44.913/44.935 mm (1.7682/1.7691 in.)

O.D. - Max. Wear Limit ........................................................................... 44.84 mm (1.765 in.)

Max. Taper ................................................................................................ 0.022 mm (0.0009 in.)

Max. Out-of-Round ................................................................................. 0.025 mm (0.0010 in.)

Closure Plate End Main Bearing Journal

O.D. - New ................................................................................................ 41.915/41.935 mm (1.6502/1.6510 in.)

O.D. - Max. Wear Limit ........................................................................... 41.86 mm (1.648 in.)

Max. Taper ................................................................................................ 0.020 mm (0.0008 in.)

Max. Out-of-Round ................................................................................. 0.025 mm (0.0010 in.)

Connecting Rod Journal

O.D. - New ................................................................................................ 38.958/38.970 mm (1.5338/1.5343 in.)

O.D. - Max. Wear Limit ........................................................................... 38.94 mm (1.5328 in.)

Max. Taper ................................................................................................ 0.012 mm (0.0005 in.)

Max. Out-of-Round ................................................................................. 0.025 mm (0.0010 in.)

Crankshaft T.I.R.

PTO End, Crank in Engine ...................................................................... 0.304 mm (0.012 in.)

Entire Crank, in V-Blocks ....................................................................... 0.10 mm (0.0039 in.)

Cylinder Bore

Cylinder Bore I.D.

New

CH11-14 .................................................................................................. 87.000/87.025 mm (3.4252/3.4262 in.)

CH15, CH16 ............................................................................................ 90.000/90.025 mm (3.5433/3.5442 in.)

Max. Wear Limit

CH11-14 .................................................................................................. 87.063 mm (3.4277 in.)

CH15, CH16 ............................................................................................ 90.063 mm (3.5457 in.)

1.9

Section 1 Safety and General Information

Cylinder Bore I.D. cont'd.

Max. Out-of-Round

CH11-14 .................................................................................................. 0.12 mm (0.0047 in.)

CH15, CH16 ............................................................................................ 0.12 mm (0.0047 in.)

Max. Taper

CH11-14 .................................................................................................. 0.05 mm (0.0020 in.)

CH15, CH16 ............................................................................................ 0.05 mm (0.0020 in.)

Cylinder Head

Cylinder Head Fastener Torque (torque in 2 increments) ........................ 24,48.9 N·m (18,36 ft. lb.)

Max. Out-of-Flatness ...................................................................................... 0.076 mm (0.003 in.)

Rocker Pedestal Fastener Torque ................................................................. 9.9 N·m (88 in. lb.)

Electric Starter

Thru Bolt Torque

UTE/Johnson Electric, Eaton (Inertia Drive) ..................................... 4.5-5.7 N·m (40-50 in. lb.)

Nippondenso (Solenoid Shift) ............................................................ 4.5-7.5 N·m (40-84 in. lb.)

Delco-Remy (Solenoid Shift) ............................................................... 5.6-9.0 N·m (49-79 in. lb)

Drive Pinion Fastener Torque (some Inertia Drive Starters) .................... 15.3 N·m (135 in. lb.)

Brush Holder Mounting Screw Torque

Delco-Remy Starter ............................................................................. 2.5-3.3 N·m (22-29 in. lb.)

Solenoid (Starter)

Mounting Hardware Torque

Nippondenso Starter .......................................................................... 6.0-9.0 N·m (53-79 in. lb.)

Delco-Remy Starter ............................................................................. 4.0-6.0 N·m (35-53 in. lb.)

Nut, Positive (+) Brush Lead Torque

Nippondenso Starter .......................................................................... 8.0-12.0 N·m (71-106 in. lb)

Delco-Remy Starter ............................................................................. 6.0-9.0 N·m (53-79 in. lb.)

Fan/Flywheel

Fan Fastener Torque ....................................................................................... 9.9 N·m (88 in. lb.)

Flywheel Retaining Screw Torque ............................................................... 66.4 N·m (49 ft. lb.)

Fuel Pump

Fuel Pump/Cover Fastener Screw Torque .................................................. 9.0 N·m (80 in. lb.) into new holes

4.2-5.1 N·m (37-45 in. lb.) into used holes

Fuel Tank

Fuel Tank Fastener Torque ............................................................................. 7.3 N·m (65 in. lb.)

Governor

Governor Cross Shaft to Crankcase Running Clearance

Governor Cross Shaft O.D.

Governor Gear Shaft-to-Governor Gear Running Clearance

Governor Gear Shaft O.D.

1.10

...........................................................................................................

New Max. Wear Limit

...........................................................................................................

New Max. Wear Limit

......................................................................................

.........................

.................

0.025/0.075 mm (0.0010/0.0030 in.)

5.975/6.000 mm (0.2352/0.2362 in.)

5.962 mm (0.2347 in.)

0.015/0.140 mm (0.0006/0.0055 in.)

5.990/6.000 mm (0.2358/0.2362 in.)

5.977 mm (0.2353 in.)

Safety and General Information

Ignition

Spark Plug Type (Champion® or equivalent) ............................................. RC12YC or Platinum 3071

Section 1

Spark Plug Gap

CH11-15 .................................................................................................... 1.02 mm (0.040 in.)

CH16 .......................................................................................................... 0.76 mm (0.030 in.)

Spark Plug Torque .......................................................................................... 38.0-43.4 N·m (28-32 ft. lb.)

Ignition Module Air Gap ............................................................................... 0.203/0.305 mm (0.008/0.012 in.)

Ignition Module Fastener Torque ................................................................. 4.0 N·m (35 in. lb.) into new holes

6.2 N·m (55 in. lb.) into used holes

Muffler

Muffler Retaining Nuts .................................................................................. 24.4 N·m (216 in. lb.)

Piston, Piston Rings, and Piston Pin

Piston-to-Piston Pin (selective fit) ............................................................... 0.006/0.017 mm (0.0002/0.0007 in.)

Piston Pin Bore I.D.

New ........................................................................................................... 19.006/19.012 mm (0.7483/0.7485 in.)

Max. Wear Limit ...................................................................................... 19.025 mm (0.7490 in.)

Piston Pin O.D.

New ........................................................................................................... 18.995/19.000 mm (0.7478/0.7480 in.)

Max. Wear Limit ...................................................................................... 18.994 mm (0.74779 in.)

Top Compression Ring-to-Groove Side Clearance

CH11-14 .................................................................................................... 0.040/0.105 mm (0.0016/0.0041 in.)

CH15, CH16 .............................................................................................. 0.060/0.105 mm (0.0023/0.0041 in.)

Middle Compression Ring-to-Groove Side Clearance

CH11-14 .................................................................................................... 0.040/0.072 mm (0.0016/0.0028 in.)

CH15, CH16 .............................................................................................. 0.040/0.085 mm (0.0015/0.0002 in.)

Oil Control Ring-to-Groove Side Clearance

CH11-14 .................................................................................................... 0.551/0.675 mm (0.0217/0.0266 in.)

CH15, CH16 .............................................................................................. 0.176/0.026 (0.0069/0.0010 in.)

Top and Center Compression Ring End Gap

New Bore

CH11-14 ................................................................................................ 0.3/0.5 mm (0.012/0.020 in.)

CH15, CH16 .......................................................................................... 0.27/0.51 mm (0.010/0.020 in.)

Used Bore (Max.) ...................................................................................... 0.77 mm (0.030 in.)

Piston Thrust Face O.D.

New

CH11-14

CH15, CH164......................................................................................... 89.951/89.969 mm (3.5413/3.5420 in.)

Max. Wear Limit

CH11-14 ................................................................................................ 86.814 mm (3.4179 in.)

CH15, CH16 .......................................................................................... 89.824 mm (3.5363 in.)

Measure 6 mm (0.236 in.) above the bottom of the piston skirt at right angles to the piston pin.

Measure 8 mm (0.314 in.) above the bottom of the piston skirt at right angles to the piston pin.

............................................................................................... 86.941/86.959 mm (3.4229/3.4236 in.)

1.11

Section 1 Safety and General Information

Piston Thrust Face-to-Cylinder Bore Running Clearance - New

CH11-14 .................................................................................................... 0.041/0.044 mm (0.0016/0.0017 in.)

CH15, CH16 .............................................................................................. 0.031/0.043 mm (0.0012/0.0016 in.)

Retractable Starter

Center Screw Torque ...................................................................................... 7.4-8.5 N·m (65-75 in. lb.)

Throttle/Choke Controls

Governor Control Lever Fastener Torque .................................................. 9.9 N·m (88 in. lb.)

Speed Control Bracket Assembly Fastener Torque² .................................. 7.3-10.7 N·m (65-95 in. lb.)

Valve Cover/Rocker Arms

Valve Cover Fastener Torque² ...................................................................... 7.3-10.7 N·m (65-95 in. lb.)

Rocker Arm I.D.

New ........................................................................................................... 15.837/16.127 mm (0.63/0.64 in.)

Max. Wear Limit ...................................................................................... 16.13 mm (0.640 in.)

Rocker Shaft O.D.

New ........................................................................................................... 15.90/15.85 mm (0.63 in.)

Max. Wear Limit ...................................................................................... 15.727 mm (0.619 in.)

Valves and Valve Lifters

Hydraulic Valve Lifter to Crankcase Running Clearance ........................ 0.0124/0.0501 mm (0.0005/0.0020 in.)

Intake Valve Stem-to-Valve Guide Running Clearance ........................... 0.038/0.076 mm (0.0015/0.0030 in.)

Exhaust Valve Stem-to-Valve Guide Running Clearance ........................ 0.050/0.088 mm (0.0020/0.0035 in.)

Intake Valve Guide I.D.

New ........................................................................................................... 7.038/7.058 mm (0.2771/0.2779 in.)

Max. Wear Limit ...................................................................................... 7.134 mm (0.2809 in.)

Exhaust Valve Guide I.D.

New ........................................................................................................... 7.038/7.058 mm (0.2771/0.2779 in.)

Max. Wear Limit ...................................................................................... 7.159 mm (0.2819 in.)

Valve Guide Reamer Size

STD ............................................................................................................. 7.048 mm (0.2775 in.)

0.25 mm O.S. ............................................................................................. 7.298 mm (0.2873 in.)

Intake Valve Minimum Lift ........................................................................... 8.96 mm (0.353 in.)

Exhaust Valve Minimum Lift ....................................................................... 9.14 mm (0.360 in.)

Nominal Valve Seat Angle ............................................................................ 45°

For self-tapping (thread-forming) fasteners, the higher torque value is for installation into a new cored (non-threaded) hole.

The lower torque value is for installation into a used or threaded hole.

1.12

General Torque Values

Section 1

Safety and General Information

Metric Fastener T orque Recommendations for St andard Applications

Tightening Torque: N·m (in. lb.) + or - 10%

Property Class

Noncritical

4.8

Size M4 1.2 (11) 1.7 (15) 2.9 (26) 4.1 (36) 5.0 (44) 2.0 (18) M5 2.5 (22) 3.2 (28) 5.8 (51) 8.1 (72) 9.7 (86) 4.0 (35) M6 4.3 (38) 5.7 (50) 9.9 (88) 14.0 (124) 16.5 (146) 6.8 (60) M8 10.5 (93) 13.6 (120) 24.4 (216) 33.9 (300) 40.7 (360) 17.0 (150)

5.8 8.8 10.9 12.9

Fasteners

Into Aluminum

Tightening Torque: N·m (ft. lb.) + or - 10%

Property Class

4.8

M10 21.7 (16) 27.1 (20) 47.5 (35) 66.4 (49) 81.4 (60) 33.9 (25) M12 36.6 (27) 47.5 (35) 82.7 (61) 116.6 (86) 139.7 (103) 61.0 (45) M14 58.3 (43) 76.4 (55) 131.5 (97) 184.4 (136) 219.7 (162) 94.9 (70)

5.8 8.8 10.9 12.9

Oil Drain Plugs Tightening Torque: N·m (English Equiv.)

Size 1/8" NPT 1/4" 3/8" 1/2" 3/4" X-708-1

Into Cast Iron

–

17.0 (150 in. lb.)

20.3 (180 in. lb.)

27.1 (20 ft. lb.)

33.9 (25 ft. lb.)

27.1/33.9 (20/25 ft. lb.)

Into Aluminum

4.5 (40 in. lb.)

11.3 (100 in. lb.)

13.6 (120 in. lb.)

17.6 (13 ft. lb.)

21.7 (16 ft. lb.)

27.1/33.9 (20/25 ft. lb.)

Conversions

N·m = in. lb. x 0.113 N·m = ft. lb. x 1.356 in. lb. = N·m x 8.85 ft. lb. = N·m x 0.737

Noncritical

Fasteners

Into Aluminum

Torque

1.13

Section 2

Tools & Aids

Section 2

Tools & Aids

Certain quality tools are designed to help you perform specific disassembly, repair, and reassembly procedures. By using tools designed for the job, you can properly service engines easier, faster, and safer! In addition, you’ll increase your service capabilities and customer satisfaction by decreasing engine downtime.

Here is the list of tools and their source.

Separate Tool Suppliers:

Kohler Tools Contact your source of supply.

SE Tools 415 Howard St. Lapeer, MI 48446 Phone 810-664-2981 Toll Free 800-664-2981 Fax 810-664-8181

Design Technology Inc. 768 Burr Oak Drive Westmont, IL 60559 Phone 630-920-1300

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Section 2 Tools & Aids

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Section 2

Tools & Aids

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2.3

Section 2 Tools & Aids

Special Tools You Can Make

Flywheel Holding Tool

A flywheel holding tool can be made out of an old junk flywheel ring gear as shown in Figure 2-1, and used in place of a strap wrench.

1. Using an abrasive cut-off wheel, cut out a six tooth segment of the ring gear as shown.

2. Grind off any burrs or sharp edges.

3. Invert the segment and place it between the ignition bosses on the crankcase so that the tool teeth engage the flywheel ring gear teeth. The bosses will lock the tool and flywheel in position for loosening, tightening or removing with a puller.

2. Remove the studs of a Posi-Lock rod or grind off the aligning steps of a Command rod, so the joint surface is flat.

3. Find a 1 in. long capscrew with the correct thread size to match the threads in the connecting rod.

4. Use a flat washer with the correct I.D. to slip on the capscrew and approximately 1” O.D. (Kohler Part No. 12 468 05-S). Assemble the capscrew and washer to the joint surface of the rod, as shown in Figure 2-2.

Figure 2-1. Flywheel Holding Tool.

Rocker Arm/Crankshaft Tool

A spanner wrench to lift the rocker arms or turn the crankshaft may be made out of an old junk connecting rod.

1. Find a used connecting rod from a 10 HP or larger engine. Remove and discard the rod cap.

Figure 2-2. Rocker Arm/Crankshaf t T ool.

2.4

Section 3

Troubleshooting

Section 3

Troubleshooting

Troubleshooting Guide

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 trouble are listed below. Use these to locate the causing factors.

Engine Cranks But Will Not Start

1. Empty fuel tank.

2. Fuel shut-off valve closed.

3. Dirt or water in the fuel system.

4. Clogged fuel line.

5. Spark plug lead disconnected.

6. Key switch or kill switch in off position.

7. Faulty spark plug.

8. Faulty ignition module.

9. Choke not closing.

10. Faulty oil sending unit.

Engine Start s But Does Not Keep Running

1. Restricted fuel tank vent.

2. Dirt or water in the fuel system.

3. Faulty choke or throttle controls/cable.

4. Loose wires or connections that short the kill terminal of ignition module to ground.

5. Faulty cylinder head gasket.

6. Faulty fuel pump.

7. Faulty carburetor.

8. Faulty fuel pump.

Engines Start s Hard

1. Hydrostatic transmission not in neutral/PTO drive is engaged.

2. Dirt or water in the fuel system.

3. Clogged fuel line.

4. Loose or faulty wires or connections.

5. Faulty choke or throttle controls/cables.

6. Faulty spark plug.

7. Low compression.

8. Faulty Automatic Compression Release (ACR) mechanism.

Engine Will Not Crank

1. Hydrostatic transmission not in neutral/PTO drive is engaged.

2. Battery is discharged.

3. Safety interlock switch is engaged.

4. Loose or faulty wires or connections.

5. Faulty key switch or ignition switch.

6. Faulty electric starter/starter solenoid.

7. Retractable starter not engaging in drive cup.

8. Seized internal engine components.

Engine Runs But Misses

1. Dirt or water in the fuel system.

2. Spark plug lead disconnected.

3. Loose wires or connections that intermittently short the kill terminal of ignition module to ground.

4. Engine overheated.

5. Faulty ignition module.

Engine Will Not Idle

1. Restricted fuel tank cap vent.

2. Dirt or water in the fuel system.

3. Faulty spark plug.

4. Idle fuel adjusting needle improperly set.

5. Idle speed adjusting screw improperly set.

6. Low compression.

7. Stale fuel and/or gum in carburetor.

Engine Overheats

1. Air intake or grass screen, cooling fins, or cooling shrouds clogged.

2. Excessive engine load.

3. Low crankcase oil level.

4. High crankcase oil level.

5. Faulty carburetor.

6. Lean fuel condition.

7. Restricted exhaust.

3.1

Section 3 Troubleshooting

Engine Knocks

1. Excessive engine load.

2. Low crankcase oil level.

3. Old or improper fuel.

4. Internal wear or damage.

Engine Loses Power

1. Low crankcase oil level.

2. High crankcase oil level.

3. Dirty air cleaner element.

4. Dirt or water in the fuel system.

5. Excessive engine load.

6. Engine overheated.

7. Faulty spark plug.

8. Low compression.

9. Exhaust restriction.

Engine Uses Excessive Amount Of Oil

1. Incorrect oil viscosity/type.

2. Crankcase overfilled.

3. Clogged or improperly assembled breather.

4. Worn or broken piston rings.

5. Worn cylinder bore.

6. Worn valve stems or valve guides.

External Engine Inspection

Before cleaning or disassembling the engine, make a thorough inspection of its external appearance and condition. This inspection can give clues to what might be found inside the engine (and the cause) when it is disassembled.

• Check for buildup of dirt and debris on the crankcase, cooling fins, grass screen and other external surfaces. Dirt or debris on these areas are causes of overheating.

• Check for obvious fuel and oil leaks, and damaged components. Excessive oil leakage can indicate a clogged or improperly assembled breather, worn or damaged seals and gaskets, or loose or improperly torqued fasteners.

• Check the air cleaner cover and base for damage or indications of improper fit and seal.

• Check the air cleaner element. Look for holes, tears, cracked or damaged sealing surfaces, or other damage that could allow unfiltered air into the engine. Also note if the element is dirty or clogged. These could indicate that the engine has been underserviced.

• Check the carburetor throat for dirt. Dirt in the throat is further indication that the air cleaner is not functioning properly.

• Check that the oil level is within the operating range on the dipstick, or if it is low or overfilled.

• Check the condition of the oil. Drain the oil into a container - the oil should flow freely. Check for metal chips and other foreign particles.

Sludge is a natural by-product of combustion; a small accumulation is normal. Excessive sludge formation could indicate the oil has not been changed at the recommended intervals, the incorrect type or weight of oil was used, overrich carburetion, and weak ignition, to name a few.

Cleaning the Engine

After inspecting the external condition of the engine, clean the engine thoroughly before disassembling it. Also clean individual components as the engine is disassembled. Only clean parts can be accurately inspected and gauged for wear or damage. There are many commercially available cleaners that will quickly remove grease, oil, and grime from engine parts. When such a cleaner is used, follow the

manufacturer’s instructions and safety precautions carefully.

Make sure all traces of the cleaner are removed before the engine is reassembled and placed into operation. Even small amounts of these cleaners can quickly break down the lubricating properties of engine oil.

3.2

Section 3

Troubleshooting

Basic Engine Tests

Crankcase Vacuum Test

A partial vacuum should be present in the crankcase when the engine is operating at normal temperatures. Pressure in the crankcase (normally caused by a clogged or improperly-assembled breather) can cause oil to be forced out at oil seals, gaskets, or other available spots.

Crankcase vacuum is best measured with a water manometer or vacuum/pressure test gauge. See Section 2. Complete instructions are provided with the testers.

Test the crankcase vacuum with the manometer as follows:

1. Insert the rubber stopper into the oil fill hole. Be sure the pinch clamp is installed on the hose and use the tapered adapters to connect the hose between the stopper and one of the manometer tubes. Leave the other tube open to the atmosphere. Check that the water level in the manometer is at the "0" line. Make sure the pinch clamp is closed.

2. Start the engine and run at no-load, high idle speed (3200 to 3750 RPM).

3. Open the clamp and note the water level in the tube.

The level in the engine side should be a minimum of 10.2 cm (4 in.) above the level in the open side.

If the level in the engine side is the same as the open side (no vacuum), or the level in the engine side is lower than the level in the open side (pressure), check for the conditions in the table below.

4. Close the shut-off clamp before stopping the engine.

To perform the test with the vacuum/pressure gauge, insert the stopper as in step 1. Insert the barbed gauge fitting into the hole in the stopper. Be sure the gauge needle is at "0". Run the engine, as in step 2, and observe the gauge reading. Needle movement to the left of "0" is a vacuum, and movement to the right indicates a pressure.

Incorrect Vacuum in Crankcase

Possible Cause

1. Crankcase breather clogged or inoperative.

2. Seals and/or gaskets leaking. Loose or improperly torqued fasteners.

3. Piston blowby or leaky valves. Confirm with cylinder leakdown test.

4. Restricted exhaust.

Solution

1. Disassemble breather, clean parts thoroughly, reassemble, and recheck pressure.

2. Replace all worn or damaged seals and gaskets. Make sure all fasteners are tightened securely. Use appropriate torque values and sequences when necessary.

3. Recondition piston, rings, cylinder bore, valves, and valve guides.

4. Repair/replace restricted muffler/exhaust system.

3.3

Section 3 Troubleshooting

Compression T est

These engines are equipped with an automatic compression release (ACR) mechanism. Because of the ACR mechanism, it is difficult to obtain an accurate compression reading. As an alternate, use the leakdown test described below.

Cylinder Leakdown T est

A cylinder leakdown test can be a valuable alternative to a compression test. By pressurizing the combustion chamber from an external air source you can determine if the valves or rings are leaking, and how badly.

The tester is a relatively simple, inexpensive leakdown tester for small engines. The tester includes a quick disconnect for attaching the adapter hose and a holding tool.

Leakdown T est Instructions

1. Run engine for 3-5 minutes to warm it up.

2. Remove spark plug and air filter from engine.

3. Rotate crankshaft until piston is at top dead center of compression stroke. You will need to hold the engine in this position while testing. The holding tool supplied with the tester can be used if the PTO end of the crankshaft is accessible. Slide the holding tool onto the crankshaft. See TT-364-A. Install a 3/8" breaker bar into the

square hole of the holding tool, so it is perpendicular to both the holding tool and crankshaft PTO.

If the flywheel end is more accessible, you can use a breaker bar and socket on the flywheel nut/ screw to hold it in position. You may need an assistant to hold the breaker bar during testing. If the engine is mounted in a piece of equipment, you may be able to hold it by clamping or wedging a driven component. Just be certain that the engine cannot rotate off of TDC in either direction.

4. Install the adapter into the spark plug hole, but do not attach it to the tester at this time.

5. Connect an adequate air source of at least 50 psi to the tester.

6. Turn the regulator knob in the increase (clockwise) direction until the gauge needle is in the yellow “set” area at the low end of the scale.

7. Connect tester quick-disconnect to the adapter hose while firmly holding the engine at TDC. Note the gauge reading and listen for escaping air at the carburetor intake, exhaust outlet, and crankcase breather.

8. Check your test results against the table below:

Leakdown Test Results

Air escaping from crankcase breather .............................................. Defective rings or worn cylinder walls.

Air escaping from exhaust system ..................................................... Defective exhaust valve.

Air escaping from carburetor .............................................................. Defective intake valve.

Gauge reading in “low” (green) zone................................................ Piston rings and cylinder in good condition.

Gauge reading in “moderate” (yellow) zone.................................... Engine is still usable, but there is some wear

present. Customer should start planning for overhaul or replacement.

Gauge reading in “high” (red) zone .................................................. Rings and/or cylinder have considerable wear.

Engine should be reconditioned or replaced.

3.4

Air Intake and Air Cleaner System

Section 4

Air Cleaner and Air Intake System

Section 4

Air Cleaner

General

These engines are equipped with a replaceable, highdensity paper air cleaner element. Most are also equipped with an oiled-foam precleaner which surrounds the paper element. See Figures 4-1 and 4-2.

Air Cleaner Cover Knob

Air Cleaner Cover

Figure 4-1. Air Cleaner Housing Components.

Air Cleaner Base

Element Cover Wing Nut

Service

Check the air cleaner daily or before starting the engine. Check for and correct any buildup of dirt and

debris, along with loose or damaged components.

NOTE: Operating the engine with loose or damaged

air cleaner components could allow unfiltered air into the engine, causing premature wear and failure.

Precleaner Service

If so equipped, wash and reoil the precleaner every 25 hours of operation (more often under extremely dusty

or dirty conditions).

To service the precleaner, perform the following steps:

1. Loosen the cover retaining knob and remove the cover.

2. Remove the foam precleaner from the paper air cleaner 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.

Paper Element

Foam Precleaner

Figure 4-2. Air Cleaner Element s.

Element Cover

4. Saturate the precleaner with new engine oil. Squeeze out all excess oil.

5. Reinstall the precleaner over the paper air cleaner element.

6. Reinstall the air cleaner cover. Secure the cover

with the retaining knob.

4.1

Section 4 Air Cleaner and Air Intake System

Paper Element Service

Every 100 hours of operation (more often under extremely dusty or dirty conditions), replace the paper element. Follow these steps:

1. Loosen the cover retaining knob and remove the cover.

2. Remove the wing nut, element cover, and air cleaner element.

3. Remove the precleaner (if so equipped) from the paper element. Service the precleaner as described in “Precleaner Service”.

4. 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.

5. Check the rubber sleeve seal for any damage or deterioration. Replace as necessary. A new seal comes packed with each replacement element.

2. Remove the wing nut, element cover, and air cleaner element.

3. If so equipped, remove the precleaner from the paper element.

4. Disconnect the breather hose from the valve cover.

5. Remove the air cleaner base mounting nuts, air cleaner base, and gasket.

6. If necessary, remove the self-tapping screws and elbow from air cleaner base.

Reassembly

The following procedure is for complete assembly of all air cleaner components.

1. Install the elbow and self-tapping screws to air cleaner base.

2. Install the gasket, air cleaner base, and base mounting nuts. Torque the nuts to 9.9 N·m (88 in. lb.).

6. Reinstall the paper element, precleaner, element cover, and wing nut.

7. Reinstall the air cleaner cover and secure with the two latches or the retaining knob.

Inspect Air Cleaner Components

Whenever the air cleaner cover is removed, or the paper element or precleaner are serviced, check the following areas/components:

Air Cleaner Base - Make sure the base is secured and not cracked or damaged. Since the air cleaner base and carburetor are secured to the intake port with common hardware, it is extremely important that the nuts securing these components are tight at all times.

Breather Tube - Make sure the breather tube is installed to both the air cleaner base and valve cover.

Disassembly

The following procedure is for complete disassembly of all air cleaner components.

1. Loosen the air cleaner cover retaining knob and remove the air cleaner cover.

3. Connect the breather hose to the valve cover (and air cleaner base). Secure with hose clamps.

4. If so equipped, install the precleaner (washed and oiled) over the paper element.

5. Install the air cleaner element, element cover, and wing nut.

6. Install the air cleaner cover and air cleaner cover retaining knob. Tighten the knob securely.

Air Intake/Cooling System

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 or dirty conditions), remove the blower housing and other cooling shrouds. Clean the cooling fins and external surfaces as necessary. Make sure the cooling shrouds are reinstalled.

NOTE: Operating the engine with a blocked grass

screen, dirty or plugged cooling fins, and/or cooling shrouds removed, will cause engine damage due to overheating.

4.2

Fuel System and Governor

Section 5

Fuel System and Governor

Section 5

Description

WARNING: Explosive Fuel!

Fuel System Components

The typical fuel system and related components include the following:

• Fuel Tank • Fuel Lines

• In-Line Fuel Filter • Fuel Pump

• Carburetor

Operation

The fuel from the tank is moved through the in-line filter and fuel lines by the fuel pump. On engines not equipped with a fuel pump, the fuel tank outlet is located above the carburetor inlet; gravity moves the fuel.

Fuel then enters the carburetor float bowl and is moved into the carburetor body. There, the fuel is mixed with air. This fuel-air mixture is then burned in the engine combustion chamber.

Fuel Filter

Most engines are equipped with an in-line fuel filter. Periodically inspect the filter and replace with a genuine Kohler filter every 200 operating hours.

Fuel Line

In compliance with CARB Tier III Emission Regulations, these engines with a Family identification number beginning with 6 or greater (see Figure 5-1), must use Low Permeation SAE 30 R7 rated fuel line; certified to meet CARB requirements. Standard fuel line may not be used. Order replacement hose by part number through a Kohler Engine Service Dealer.

IMPORTANT ENGINE INFORMATION THIS ENGINE MEETS U.S. EPA AND CA 2005 AND LATER AND EC ST AGE II (SN:4) EMISSION REGS FOR SI SMALL OFF–ROAD ENGINES

FAMILY 6 KHXS.XXXX PH TYPE APP

DISPL. (CC) MODEL NO. SPEC. NO. SERIAL NO. BUILD DA TE OEM PROD. NO.

EMISSION COMPLIANCE PERIOD: EPA: CARB: CERTIFIED ON: REFER TO OWNER'S MANUAL FOR HP RATING, SAFETY , MAINTENANCE AND ADJUSTMENTS

1-800-544-2444 www.kohlerengines.com

KOHLER CO. KOHLER, WISCONSIN USA

N11236

Figure 5-1. "Family" Number Location.

5.1

Section 5 Fuel System and Governor

Fuel System T ests

When the engine starts hard, or turns over but will not start, it is possible that the problem is in the fuel system. To find out if the fuel system is causing the problem, perform the following tests.

Troubleshooting - Fuel System Related Causes

T e st Conclusion

1. Check for the following: a. Make sure the fuel tank contains clean, fresh,

proper fuel. b. Make sure the vent in fuel tank cap is open. c. Make sure the fuel valve is open.

2. Check for fuel in the combustion chamber. a. Disconnect and ground spark plug lead. b. Close the choke on the carburetor. c. Crank the engine several times. d. Remove the spark plug and check for fuel at

the tip.

3. Check for fuel flow from the tank to the fuel pump. a. Remove the fuel line from the inlet fitting of

fuel pump.

b. Hold the line below the bottom of the tank.

Open the shut-off valve (if so equipped) and observe flow.

4. Check the operation of fuel pump. a. Remove the fuel line from the inlet fitting of

carburetor.

b. Crank the engine several times and observe

flow.

Fuel Pump

2. If there is fuel at the tip of the spark plug, fuel is

reaching the combustion chamber.

If there is no fuel at the tip of the spark plug, check for fuel flow from the fuel tank. (Test 3)

3. If fuel does flow from the line, check for faulty

fuel pump. (Test 4)

If fuel does not flow from the line, check for clogged fuel tank vent, fuel pick-up screen, in-line filter, shut-off valve, and fuel lines.

4. If fuel does flow from the line, check for faulty

carburetor. (Refer to the “Carburetor” portions of this section.)

If fuel does not flow from the line, check for clogged fuel line. If the fuel line is unobstructed, the fuel pump is faulty and must be replaced.

Outlet Check Valve

Camshaft

General

Most engines are equipped with an optional mechanically operated fuel pump. On applications using a gravity feed fuel system, the fuel pump mounting pad is covered with a metal plate.

The fuel pump body is constructed of nylon. The nylon body insulates the fuel from the engine crankcase. This prevents the fuel from vaporizing inside the pump.

Operation

The mechanical pump is operated by a lever which rides on the engine camshaft. The lever transmits a pumping action to the diaphragm inside the pump body. On the downward stroke of the diaphragm, fuel is drawn in through the inlet check valve. On the upward stroke of the diaphragm, fuel is forced out through the outlet check valve. See Figure 5-2.

5.2

Diaphragm

Figure 5-2. Cutaway - Typical Fuel Pump.

Inlet Check Valve

Fuel Pump Lever

Replacing the Fuel Pump

Nonmetallic fuel pumps are not serviceable and must be replaced when faulty. Replacement pumps are available in kits that include the pump, fittings, and mounting gasket.

1. Disconnect the fuel lines from the inlet and outlet fittings.

2. Remove the hex flange screws, fuel pump, and gasket.

3. If necessary, remove the fittings from the pump body.

Section 5

Fuel System and Governor

Figure 5-3.

4. Install Fittings

Threaded Fittings

a. Apply a small amount of Permatex® Aviation

Perm-a-Gasket (or equivalent) gasolineresistant thread sealant to the threads of fittings. Turn the fittings into the pump 5 full turns; continue turning the fittings in the same direction until the desired position is reached.

Lock-in Fittings

The inlet and outlet hose fittings must be installed into the fuel pump prior to mounting. The pump housing incorporates a special locking feature to retain the fittings. The release tabs must be depressed when the fittings are installed or removed, to avoid damage to the fitting ORings and a potential fuel leak. Do not attempt to install or force the fittings into place without first depressing the tabs. There is a snap ring included with the new fuel pump kit that will serve as a tool for this purpose.

a. Note the direction arrows molded into the

pump housing and position the snap ring so the ends depress the two square release tabs at the inlet end. See Figure 5-3.

b. Lubricate the O-Ring on each fitting with oil.

c. Insert the 90° fitting until the toothed flange is

just outside of the pump body. Rotate the fitting to the desired orientation and then apply pressure to seat/snap it into the housing. The flange face will be flush with the end of the housing.

d. Transfer the snap ring to the opposite end and

repeat the sequence to install the straight fitting. Remove the snap ring.

5. Clean off any remaining gasket material from the fuel pump mounting surface. Refer to the pump installation instructions to determine if the extra spacer and gasket are required to mount the new pump. Install new gasket, fuel pump, and hex flange screws.

NOTE: Make sure the fuel pump lever is

positioned to the RIGHT of the camshaft (when looking at fuel pump mounting pad). Damage to the fuel pump, and subsequent severe engine damage could result if the lever is positioned to the left of the camshaft.

Torque the hex flange screws as follows:

Into new holes–9.0 N·m (80 in. lb.).

Into used holes–4.2-5.1 N·m (37-45 in. lb.).

6. Connect the fuel lines to the inlet and outlet fittings.

5.3

Section 5 Fuel System and Governor

Carburetors

These engines, based upon when produced, are equipped with either an adjustable main jet carburetor, or an emission compliant fixed jet carburetor manufactured be Walbro or Nikki. See Figure 5-4.

Walbro carburetors have a low idle speed screw and a low idle fuel adjusting needle. Nikki carburetors only have a low idle speed screw. Certified carburetors will have fixed idle fuel or a limiter cap on the idle fuel adjusting needle.

Walbro

Low Idle Speed Adjustment Screw

Low Idle Fuel Adjustment Needle

Nikki

Low Idle Speed Adjustment Screw

Troubleshooting

If engine troubles are experienced that appear to be fuel system related, check the following areas before adjusting or disassembling 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 fuel is reaching the carburetor. This includes checking the fuel shut-off valve, fuel tank filter screen, in-line fuel filter, fuel lines, and fuel pump for restrictions or faulty components as necessary.

• Make sure the air cleaner base and carburetor is securely fastened to the engine using gaskets in good condition.

• Make sure the air cleaner element is clean and all air cleaner components are fastened securely.

• Make sure the ignition system, governor system, exhaust system, and throttle and choke controls are operating properly.

If the engine is still hard-to-start, runs roughly, or stalls at low idle speed, it may be necessary to adjust or service the carburetor.

Figure 5-4. Carburetor Adjustment.

WARNING: Explosive Fuel!

5.4

Conditi on Possible Cause/Probable Remedy

1. Engine starts hard, or runs roughly or stalls at idle speed.

Section 5

Fuel System and Governor

1. Low idle fuel mixture or speed are improperly adjusted. Adjust the low idle speed screw, then adjust the low idle fuel needle (adjustable carburetors), or clean the carburetor as required (fixed jet carburetors).

2. Engine runs rich (indicated by black, sooty exhaust smoke, misfiring, loss of speed and power, governor hunting, or excessive throttle opening).

3. Engine runs lean

(indicated by misfiring, loss of speed and power, governor hunting, or excessive throttle opening).

2a. Choke partially closed during operation. Check the choke lever/linkage/self-

relieving mechanism to ensure choke is operating properly.

b. Low idle fuel mixture is incorrect. Adjust low idle speed screw, then adjust

low idle fuel needle (adjustable carburetors), or clean the carburetor passages as required (fixed jet carburetors).

c. Float level is set too high. With fuel bowl removed and carburetor inverted,

the exposed surface of float must be parallel with the bowl gasket surface of the carburetor body.

d. Dirt under the fuel inlet needle. Remove needle; clean needle and seat and

blow with compressed air.

e. Air filter dirty or restricted.

f. Bowl vent or air bleeds plugged. Remove fuel bowl, low idle fuel adjusting

needle, (not on all models), and welch plugs. Clean vent, ports, passages and air bleeds. Blow out all passages with clean, compressed air.

g. Leaky, cracked, or damaged float. Submerge float to check for leaks.

3a. Low idle fuel mixture incorrect. Adjust the low idle speed screw, then adjust

low idle fuel needle (adjustable carburetors), or clean the carburetor passages as required (fixed jet carburetors).

b. Float level is set too low. With fuel bowl removed and carburetor inverted,

the exposed surface of float must be parallel with the bowl gasket surface of the carburetor body.

4. Fuel leaks from carburetor.

c. Idle holes plugged; dirt in fuel delivery channels. Remove fuel bowl, low idle

fuel adjusting needle (not on all models) and welch plugs. Clean main fuel jet and all passages; blow out cleaned compressed air.

4a. Float level set too high. See Remedy 2c.

b. Dirt under fuel inlet needle. See Remedy 2d.

c. Bowl vent plugged. Remove fuel bowl and clean bowl vent. Blow out with

compressed air.

d. Float is cracked or damaged. Replace float.

e. Bowl gasket damaged. Replace gasket.

f. Bowl screw or shut-off solenoid loose or gasket damaged. Tighten/torque

screw to specifications.

5.5

+ 86 hidden pages

Kohler CH15, CH13, CH11 User Manual

Contents

Section 1

Section 2

Section 3

Section 4

Section 5