Kohler COMMAND 20=25HP User Manual

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Page 1

WNER

MANUAL

COMMAND

HOREONUL

Gas Fueled

20=25

CRANKSHAFT

Dual-Fueled

(LP

Gas - Gasoline)

RUN'"

Page 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 or substantial property damage if the warning is ignored.

CAUTION

Caution is used to indicate the presence of a hazard that 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.

WARNING

can

will

cause

can

severe

cause

personal injury, death,

minor

personal injury or

WARNING

Accidental Starts can cause severe injury or death.

Disconnect and leads before servicing.

Accidental Starts!

Disa6fing engine. Acciden fa/

sfading can cause severe injuu/r or deafh.

or equipment, disable the engine as

follows: lead(s). battery cable from battery.

Before disconnecting the negative ground cable, make sure all switches are

the ground cable terminal which could cause an explosion if hydrogen gas or LP/gasoline fuel vapors are present.

Before working on the engine

OFF:

ground

Disconnect the spark plug Disconnect negative

ON,

a spark will occur at

spark

plug

(-)

Rotating Parts can cause severe injury.

Stay away operation.

Rotating 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.

running.

while

CAUTION

not

touch

engine is

wires

while

engine

Hot Parts can cause severe burns.

not

touch

engine

while

operating

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

off.

turned with heat shields or guards removed.

Proposition

Engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

Never operate the engine

California

Warning

Electrical Shock!

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

Page 3

Safefy Precautions (Conf.)

WARNING

Explosive Fuel can cause fires and severe burns.

Stop engine before filling fuel tank.

Explosive Fuel!

LPG

is extremely flammable and is heavier than air and tends to settle in low areas where a spark or flame could ignite the gas. Do not start or operate this engine in a poorly ventilated area where leaking gas could accumulate and endanger the safety of persons in the area.

To insure personal safety, installation and repair of LPG fuel supply systems must be performed only by qualified LPG system technicians. Improperly installed and maintained LPG equipment could cause fuel supply system or other components to malfunction, causing gas leaks.

Observe federal, state and local laws governing LPG fuel, storage, and systems.

Continued in next column

GasoEne

and its vapors can explode if ignited.

Store gasoline only in approved containers, in well ventilated, unoccupied buildings, a way 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. start the engine near spilled fuel. Never use gasoline as a cleaning agent.

Carbon Monoxide can cause severe nausea, fainting or death.

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.

is extremely flammable

WARNING

not operate engine in closed or

not

WARNING

Explosive Gas can cause fires and severe acid burns.

Charge battey only in a well ventilated area. Keep sources of ianition awav.

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

OFF:

ON,

switches are occur at the ground cable terminal which could cause an explosion if hydrogen gas or LP/gasoline fuel vapors are present.

a spark will

Congratulations

strength and on-the-job durability into each engine count on. Here are some reasons why:

Efficient overhead valve design and full pressure 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.

and carburetor) are easily and quickly accessible.

Parts subject to the most wear and tear (like the cylinder liner* and camshaft) are made from precision formulated

cast iron. Because the cylinder liner* can be rebored, these engines can last even longer. *CH25 engines have POWER-BORETM Cylinders. These cylinders are plated with nickel-silicon to give increased

power, virtually permanent cylinder life, superior oil control, and reduced exhaust emissions. These cylinders cannot be rebored.

Every Kohler engine is backed by a worldwide network of over

just

phone call away. Call

To keep your engine in top operating condition, follow the maintenance procedures in this manual.

-You

have

selected

1-800-544-2444

a fine four-cycle, twin cylinder, air-cooled engine. Kohler designs long life

...

making a Kohler engine dependable

All

routine service areas (like the dipstick and oil fill, air cleaner, spark plugs,

(US.

10,000

Canada) for Sales & Service assistance.

distributors and dealers. Service support is

...

dependability you can

Page 4

:igure

Air Cleaner

Dipstick

tric

Typical Command Horizontal Shaft LP Gas Fueled Engine,

Oil

Recommendations

Using the proper type and weight of oil in the crankcase is extremely important. changing oil regularly. Using oil that is incorrect or dirty can cause premature engine wear and failure.

Synthetic oil

engines because there is less oxidation or thickening, and deposit accumulation on intake valves is substantially reduced. Conventional petroleum-based oil may be used, but valve service will be required every

500

hours to remove the accumulated deposits. Dual-fueled engines can use conventional oil without requiring speciaVadditional valve service.

Oil

Type

Use high quality, oil of

Institute) service class SG, SH,

the viscosity based on the air temperature at the time of operation as shown in the following table.

ECOM

is recommended for use in LPG-fueled

M EN DED

is checking oil daily and

API (American Petroleum

or higher.

SA E VISCOSITY

GRADES

Select

NOTE: Using other than service class SG,

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

Figure 3. Oil Container Logo,

Refer to “Maintenance Instructions” beginning on

page

for detailed oil check, oil change, and oil

filter change procedures,

OW30

SH, SJ

I I

-50

ncko

TEMPERATURE RANGE EXPECTED BEFORE NEXT

Use of synthetic oil is recommended.

Figure

-10

Viscosity Grades Table,

-io

0 10

OIL

CHANGE

100

Page 5

LPG Engines

LPG Fuel Recommendations

Liquefied Petroleum Gas (LPG) from an appropriate LP fuel tank (supplied separately) is required to operate this engine.

General Recommendations

Purchase gasoline in small quantities and store in clean, approved containers. of 2 gallons or less with a pouring spout is recommended. Such a container is easier to handle and helps eliminate spillage during refueling.

container with a capacity

WARNING: Pressurized LPG!

Fuel tanks are filled under pressure and should be handled with care. To prevent tank damage which could endanger the safety of the operator or persons in the area, do not drop or drag tanks on any surface. Use a hand truck when moving, or tilt the tank on its footring in a position slightly off vertical and roll it.

Avoid personal contact with LPG fuel to prevent

frostbite. See a physician if frostbite occurs.

WARNING: Explosive Fuel!

LPG is extremely flammable, is heavier than air and tends to settle in low areas where a spark or flame could ignite the gas. in a poorly ventilated area where leaking gas could accumulate and endanger the safety of persons in the area.

LPG fuel consists primarily of propane, although the fuel supplier may sometimes mix other gases with propane.

Fuel tanks must be filled only by persons qualified in the handling of LPG. Tanks are filled by weight and should not be overfilled (never to more than capacity). An air space must be present in the tank to allow fuel to expand.

not start or operate this engine

percent of total

Do not use gasoline left over from 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, gasoline with a pump sticker octane rating of higher. In countries using the Research method, it should be

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 heads may require more frequent se nice.

Gasoline/Alcohol blends

Gasohol (up to gasoline by volume) is approved as a fuel for Kohler engines. Other gasoline/alcohol blends are not approved.

octane minimum.

10%

ethyl alcohol,

90%

unleaded

Tanks must be removed from equipment before filling.

Dual-Fuel Engines

Dual-fuel engines are designed to operate on either LPG or gasoline. For LPG operation, the above information and warnings apply. For gasoline operation,

the following information and warnings apply.

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, a way from sparks or flames. while the engine is hot or running, since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition. spilled fuel. Never use gasoline as a cleaning agent.

not fill the fuel tank

not start the engine near

Gasoline/Ether blends

Methyl Tertiary Butyl Ether (MTBE) and unleaded gasoline blends (up to a maximum of

volume) are approved as a fuel for Kohler engines.

Other gasoline/ether blends are not approved.

15%

MTBE by

Model Designation

Model CH20S for example: C designates Command engine, designates horsepower. specific version as follows:

Suffix Designates

designates horizontal crankshaft, and 20

S Electric Start

letter suffix designates a

Page 6

Engine Identification Numbers

When ordering parts, or in any communication

involving an engine, always give the

Specification, and Serial Numbers

The engine identification numbers appear on a decal affixed to the engine shrouding. Include letter suffixes,

if there are any. Record your engine identification numbers on the

identification label below (Figure

Model,

of the engine.

for future reference.

Operating Instructions

Also read the operating instructions of the equipment this engine powers.

Pre-Start Checklist

Check oil level. Add oil if low. Do not overfill. Check fuel gauge on LPG tank. Tanks should be

filled to a specific weight. To insure safety and proper fuel system operation, tanks must not be overfilled.

IMPORTANT ENGINE INFORMATION THIS ENGINE MEETS U.S. EPA PHASE 1 ANC CALIFORNIA 2006 AND LATER EMISSION CONTROL REGULATIONS FOR SI SORE*

FAMILY

DISPL, (CC)

MODEL NO,

SPEC. NO,

SERIAL

EMISSION COMPLIANCE PERIOD:

E PA: CARB: THIS ENGINE

ON:

REFER TO OWNER'S MANUAL FOR SAFETY, MAINTENANCE SPECS AND ADJUSTMENTS.

FOR SALES/SERVICE IN USKANADA, CALL:

NO.

CERTIFIED TO OPERATE

1-800-544-2444

www.

kohlerengines.com

KOHLEREIFil@BIQS

KOHLER CO. KOHLER, WISCONSIN USA

*Small Off-Road Engines

7gure

Engine ldentifica tion Label,

The Emission Compliance Period referred to on the

Emission Control or Air Index label indicates the

number of operating hours for which the engine has been shown to meet CARB emission requirements. The following table provides the Engine Compliance

Period (in hours) associated with the category descriptor found on the certification label.

Check fuel lines, regulator, and other system components for leaks. Do not start engine until leaks are eliminated.

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. This is especially important on equipment with hydrostatic drive. The shift lever must be exactly in neutral to prevent resistance which could keep the engine from starting.

WARNING: Lethal Exhaust Gases!

Although carbon monoxide than gasoline, some carbon monoxide is produced. Avoid inhaling exhaust gases, especially over prolonged periods engine to run unattended.

LPG

burns more efficiently and emits less

time.

not allow

CARB

Exhaust Emission Control System for models CH20 LP, CH25 LP, and CH25 Dual Fuel (open loop),

is EM. Exhaust Emission Control System for model CH25 Dual Fuel (closed loop) is EM, 02S, ECM.

Moderate Intermediate 125 hours 250 hours

Extended

500

hours

Cold Weather Starting Hints

Be sure to use the proper oil for the temperature expected. See Figure 2 on page

2. Disengage all possible external loads.

Be sure the battery is in good condition. A warm battery has much more starting capacity than a cold battery.

Page 7

Starting

Place the throttle control

the

idle

position. Place

the choke control into the “on”position. See

Figure

On dual-fueled engines, place the three-

position fuel control switch in the

gasoline

and place the throttle control between half and full throttle (engine gasoline for

Figure Choke Controls,

Optional Engine Mounted Throttle and

Slowly turn the fuel valve on the LPG (propane)

must

be started and run on

minute to heat up oxygen sensor).

tank to full open position. For “gasoline only” operation on dual-fuel units, leave valve closed.

Start the engine by activating the key switch.

Release the switch as soon as the engine starts. Return choke to

“off”

position after engine starts. On a cold engine, it may be necessary to leave choke partially on until engine begins to warm up. Dual-fuel engines must be allowed to warm up on gasoline for at least

minute. To switch to LPG operation, move the three-position switch to the LPG position.

position

If the starter does not turn the engine over, shut off starter immediately.

not make further attempts to

start the engine until the condition is corrected. Do not jump start using another battery (refer to “Battery” on page 8). See your Kohler Engine Service Dealer for trouble analysis.

NOTE: Upon start-up, a metallic ticking may occur.

This is caused by hydraulic lifter leakdown during storage. Run the engine for

minutes. The noise will normally cease in the first minute. If noise continues, run the engine at mid-throttle for

minutes.

noise persists, take the engine to your local Kohler Service outlet.

Stopping

LPG-Only Engines

Turn fuel valve on LPG tank to full closed position and allow the engine to continue running until it

runs out of fuel. Turn ignition switch to

“off”

position.

Dual-Fuel Engines

Dual-fuel engines may be stopped any of three

ways:

When operating on LPG, one method is the same as described above for LPG-only engines.

LPG operation can also be stopped by moving the three-position fuel control switch to the “off”position and letting the engine run out of fuel. Turn

off

ignition switch. If engine will not be restarted for some time, also close fuel valve at LPG tank.

NOTE: Do not crank the engine continuously for

more than engine does not start, allow a

seconds at a time. If the

second cool down period between starting attempts. Failure to follow these guidelines can burn out the starter motor.

NOTE: If the engine develops sufficient speed to

disengage the starter but does not keep running (a false start), engine rotation must be allowed to come to a complete stop before attempting to restart the engine.

the starter is engaged while the flywheel is rotating, the starter pinion and flywheel ring gear may clash, resulting in damage to the starter.

To stop the engine from gasoline operation, it should be running between half and full throttle. Move the three-position fuel control switch and/or the ignition switch to the

“off”

position.

emergency,

In an

stop

or turn the ignition switch

move the throttle control to

off.

NOTE: Backfiring may occur when using the

emergency stop method!

Page 8

Battery

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

Angle

This engine will operate continuously at angles up to

25".

the

Operation

Check oil level to assure crankcase oil level is at

"F'

mark on the dipstick.

Cooling

NOTE: If debris builds up on the flywheel screen or

other cooling areas, stop the engine immediately and clean. Operating the engine with blocked or dirty air intake and cooling areas can cause extensive damage due to overheating.

WARNING: Hot Parts!

Engine components can get extremely hot from operation. areas while the engine is running, or immediately after it is turned off. Never operate the engine with heat shields or guards removed.

prevent severe burns, do not touch these

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:

not operate this engine continuously at angles exceeding damage could result from insufficient

lubrication.

25"

in any direction. Engine

Engine Speed

NOTE:

not tamper with the governor setting to increase the maximum engine speed. Overspeed is hazardous and will void the engine warranty. The maximum allowable high speed for these engines is load.

3750

RPM, no

Maintenance Instructions

Maintenance, repai5 or replacement the customers expense, may be performed by any* non-road engine repair establishment or individual,

Warranty repairs must be performed by an authorized Kohler service outlet,

*For safety and health reasons, many states require special licensing or certification for servicing LPG fuel

systems. Check local and state regulations before choosing a repair establishment to perform fuel system repairs.

Disabhg engine. Accidenta/startng can cause severe injuv

equipment, disable the engine as follows:

(-)

WARNING: Accidental Starts!

battery cable from battery

the emission control devices and systems, which are being done at

death

Disconnect the spark plug lead@).

Before working on the engine or

Disconnect negative

(-)

negative

Before disconnecting the negative

ground cable terminal which could cause an explosion if hydrogen gas or LP/gasoline fuel vapors are present.

(-)

ground cable, make sure all switches are off. If on, a spark will occur at the

Page 9

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.

Frequency

Daily or Before

Starting Engine

Every 25 Hours

Every

Everv200 Hours

Every

Every 500 Hours

Every 1500 Hours

‘Perform these maintenance procedures more frequently under extremely dusty, dirty conditions. 2Have a Kohler Engine Service Dealer perform this service. 3Must be performed by an Authorized Kohler Engine Dealer or qualified L P personnel

100

Hours

Annually or

300

Hours

Annually or

Maintenance Required

Check fuel gauge on propane Check oil level.

Check air cleaner for dirty’, loose, or damaged parts. Check air intake and cooling areas, clean as necessary’.

Service precleaner element’. Replace air cleaner element’.

Change Oil. Remove cooling shrouds and clean cooling areas’.

Check oil cooler fins, clean as necessary (if equipped). Check spark plug condition and gap.

Change oil filter.

Replace spark plugs. Check all lines (high pressure/vacuum) including fittings for leaks.

Have electric starter serviced2. Have lock-off/filter serviced3. Have combustion deposits removed if using non-synthetic oil (not on dual-fuel engines). Drain regulator of accumumulated fuel deposits (Nikki regulators only).

Have regulator disassembled, cleaned, and reset3.

(LPG)

tank. Fill gasoline tank (dual-fuel units only).

on&

Check Oil Level

The importance of checking and maintaining the proper oil level in the crankcase cannot be overemphasized. Check oil follows:

Make sure the engine is stopped, level, and is

cool

the oil has had time to drain into the sump.

To keep dirt, debris, etc., out of the engine, clean the area around the dipstick before removing it.

Remove the dipstick; wipe oil off. Reinsert the

dipstick into the tube and press all the way down.

Remove the dipstick and check the oil level.

The oil level should be up to, but not over, the

mark on the dipstick. See Figure

BEFORE EACH USE

“F

“F”

Mark

Operating

Figure

Oil Level Dipstick,

If the level is low, add oil of the proper type, up to

the

“F

mark on the dipstick. (Refer to “Oil Type”

4.)

on page dipstick before adding more oil.

NOTE: To prevent extensive engine wear or

Always check the level with the

damage, always maintain the proper oil

level in the crankcase. Never operate the

engine with the oil level below the

mark or over the

“F’

mark

“L”

the dipstick.

Page 10

Oil SentryTM

Some engines are equipped with an optional Oil Sentry’” oil pressure switch. decreases below an acceptable level, the Oil Sentry’” will either shut

off

the engine or activate a warning

signal, depending on the application.

the oil pressure

NOTE: Make sure the oil level is checked

EACH USE

and is maintained up to the

BEFORE

“F

mark on the dipstick. This includes engines

equipped with Oil Sentry’”.

Change Oil and Oil Filter

Change Oil

Change oil after every with service class SG, in the “Viscosity Grades” table (Figure

Change the oil while the engine is still warm. The oil will flow more freely and carry away more impurities.

Make sure the engine is level when filling, checking,

and changing the oil. Change the oil as follows (see Figure

To keep dirt, debris, etc., out of the engine, clean the area around the oil fill cap/dipstick before removing it.

Remove one of the oil drain plugs, oil fill cap, and dipstick. Be sure to allow ample time for complete drainage.

700

SH,

hours

of operation. Refill

or higher oil as specified

on page

7):

Engine Oil Drain Plug’

Figure

Change Oil Filter

Replace the oil filter

(every

genuine Kohler oil filter,

Oil Drain Plug and Oil Filter.

at least every other oil change

200

hours of operation).

Part

No.

Always

050

use

OI-S.

Replace the oil filter as follows:

Drain the oil from the engine crankcase by removing one of the drain plugs and allowing ample time for complete drainage.

Before removing the oil filter, clean the area around the oil filter to keep dirt and debris out of the engine. Remove the old filter. Wipe off the surface where the oil filter mounts.

Reinstall the drain plug. Make sure it is tightened to

73.6

N.m

(70

ft.

lb.)

torque.

Fill the crankcase, with new oil of the proper type, to the

“F’

mark on the dipstick. Refer to “Oil Type”

on page

Always check the level with the dipstick

before adding more oil.

Reinstall the oil fill cap and tighten securely.

Reinstall dipstick.

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 mark or over the

“F’

mark on the dipstick.

“L”

Place a new replacement filter in a shallow pan with the open end up. Pour new oil of the proper type in through the threaded center hole. Stop pouring when the oil reaches the bottom of the threads. Allow a minute or two for the oil to be absorbed by the filter material.

Put a drop of oil on your fingertip and wipe it on the rubber gasket.

Install the new oil filter onto the filter adapter. Turn the oil filter clockwise until the rubber gasket contacts the mounting surface, then tighten the filter an additional

Reinstall the drain plug. Make sure to

73.6

N.m

Fill the crankcase with new oil of the proper type

“F

to the

mark on the dipstick.

(70

ft.

2/3

lb.)

to 7 turn.

torque.

is tightened

Page 11

Test run the engine to check for leaks. Stop the

engine, allow a minute for the oil to drain down, and recheck the level on the dipstick. Add more oil as necessary

the

"F"

the oil level is up to but not over

mark on the dipstick.

Service Precleaner and Air Cleaner Element

This engine is equipped with a replaceable, high density paper air cleaner element. Most engines are also equipped with an oiled, foam precleaner which surrounds the paper element. See Figures

Air Cleaner Cover

Air Cleaner Cover Knob

and

Loosen the cover retaining knob and remove the cover.

Remove the precleaner from the paper element.

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.

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

Reinstall the precleaner over the paper element.

Reinstall the air cleaner cover. Secure cover with

the cover retaining knob.

When precleaner replacement is necessary order genuine Kohler parts.

CH20-22

24083024 I 24083054

CH25

Figure

Check the air cleaner

engine.

the air cleaner system. Keep this area clean. Also check for loose or damaged components. Replace all bent or damaged air cleaner components.

NOTE: Operating the engine with loose or damaged

Service Precleaner

hours

or dirty conditions).

Air Cleaner Housing Components,

Air Cleaner System Components.

daily or before starting the

Check for a buildup of dirt and debris around

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

equipped, wash and reoil the precleaner every

of operation (more often under extremely dusty

Service Paper Element

Every

700

hours

extremely dusty or dirty conditions) replace the paper element.

Loosen the cover retaining knob and remove the

air cleaner cover.

Remove the element cover nut, element cover,

and paper elemenVprecleaner.

Remove the precleaner (if

paper element and service as instructed above.

not wash the paper element or

pressurized air,

Replace a dirty, bent, or damaged element with a

genuine Kohler element. Handle new elements carefully; do not use if the sealing surfaces are bent or damaged.

When servicing the air cleaner, check the air

cleaner base. Make sure it is secured and not bent or damaged. Also, check the element cover for damage or improper fit. Replace all damaged air cleaner components.

NOTE: Before air cleaner reassembly make sure

Reinstall the paper element, precleaner, element

cover, element cover nut, and air cleaner cover. Secure cover with cover retainina knob.

of operation (more often under

equipped) from the

use

as this will damage the element.

rubber seal is in position around stud. Inspect, making sure it is not damaged and seals with the element cover.

Page 12

When element replacement is necessary order genuine Kohler parts.

CH20-22

47083034

CH25

2408303-S

I I

Clean Air Intake/Cooling Areas

To ensure proper cooling, make sure the flywheel screen, cooling fins, and other external surfaces of the engine are kept clean

Every

700

hours of operation (more often under

extremely dusty, dirty conditions), remove the blower

housing and other cooling shrouds. Clean the cooling fins and external surfaces as necessary. Make sure the cooling shrouds are reinstalled.

NOTE: Operating the engine with a blocked flywheel

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

at all times.

Check the gap using a wire feeler gauge. Adjust the gap to bending the ground electrode. See Figure 10.

4. Reinstall the spark plug into the cylinder head. Torque the spark plug to

(78-22

ft.

0.76

lb,).

(0,030

24.4-29J

in,) by carefully

N-m

Ignition System

This engine is equipped with an electronic CD ignition system. Other than periodically checking/replacing the spark plugs, no maintenance, timing, or adjustments are necessary or possible with this system.

In the event starting problems should occur which are not corrected by replacing the spark plugs, see your Kohler Engine Service Dealer for trouble analysis.

Check Spark Plugs

Every

700

hours of operation, remove the spark plugs,

check condition, and reset the gap or replace with new plugs as necessary.

replace the spark plugs. Replacement spark plugs are Kohler Part No. 12 132 02-S (Champion@ type RCl2YC). Equivalent alternate brand plugs can also

be used.

1. Before removing the spark plug, clean the area around the base of the plug to keep dirt and debris out of the engine.

2. Remove the plug and check its condition. Replace the plug if worn or reuse is questionable.

NOTE: Do not clean the spark plugs in a

could remain in the spark plug and enter the engine causing extensive wear and damage.

Every

300

hours or annually

machine using abrasive grit. Some grit

-/“IW

Ground Electrode

Ygure

70,

Servicing Spark Plug,

Battery Charging

WARNING: Explosive Gas!

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

Before disconnecting the negative make sure all switches are occur at the ground cable terminal which could cause an explosion if hydrogen gas or LP/gasoline fuel vapors are present.

Charging of battery should be performed as outlined by the original equipment manufacturer (OEM) in their operator’s manual.

prevent a fire or explosion, charge

(-)

OFF:

ON,

0.76

(0,030

ground cable,

in,) Gap

a spark will

Page 13

Fuel Filter

The filter of the LP fuel system is an integral part within

All

the lock-off/filter assembly.

lock-off/filter is to be performed by an authorized Kohler

Engine Service Dealer or qualified LP personnel only. Servicing of filter is recommended every gasoline system (dual-fuel only) has an in-line fuel filter.

Periodically inspect the filter and replace when dirty. Use a genuine Kohler filter, Part No.

service relating to the

500

hours. The

050

02-S.

Carburetor Troubleshooting and Adjustments

In compliance with government emission standards, the carburetor and the regulator are calibrated and preset to deliver the correct fuel-to-air mixture to the engine under all operating conditions and cannot be adjusted, except for low idle speed. Carburetor servicing is to be performed by an authorized Kohler

Engine Service Dealer only. See Figure

11.

Regulator

In compliance with government emission standards, the regulator is preset at the factory to provide the proper supply of fuel. No adjustment or resetting of regulator is to be made. regulator must be performed by an authorized Kohler

Engine Service Dealer or qualified LP personnel only. Over time, fuel deposits can accumulate inside the

regulator. Draining of these deposits is recommended (Nikki regulators only) every annually, whichever comes first.

Nikki Regulators Every

500

hours/annually drain regulator:

Turn fuel supply valve off, run engine out of fuel, and turn off ignition switch.

Disconnect and ground the spark plug leads.

Remove the regulator and drain any accumulated deposits.

See Figure

12.

All

service relating to the

500

operating hours, or

1/8"

pipe plug from the bottom of

7gure

11,

Vacuum Line

7gure

13.

Schematic Showing Components of LP System,

Fuel Delivery Line

Dry Gas Regulator

Propane Supply Tan

id Withdrawal)

(Liqui

7gure

Vaporizer

Regulatbr Drain Plug

12.

Nikki Regulator Drain Plug,

High Pressure

Lock-OfVFiIter

(12

VoltDC)

Page 14

Reinstall plug using Teflon@ pipe sealant (not Teflon@ tape) on threads and tighten securely. If required, a replacement plug is available as Kohler Part

No.

X-75-23-S.

Troubleshooting - Fuel Related

If engine problems are experienced that appear to be fuel system related, check the following areas before seeking service assistance.

All Regulators

Every

Complete cleaning (disassembling, servicing, and

resetting)

recommended. As all adjustments and settings must be reset using specific test equipment, this must be performed by an

Dealer or qualified

1500

Hours:

regulator at

1500

hour intervals is

authorized Kohler Engine Service

personnel only.

Lock-Off/Filter Assembly

This opens, closes, and filters the liquid fuel flow from the supply tank before reaching the vaporizer. Servicing, if required, is to be performed by an authorized Kohler Engine Service Dealer or qualified

LP personnel only. See Figure

13.

Vaporizer

The vaporizer changes the Liquified Petroleum (LP) from the supply tank to a gaseoushapor state. Other than keeping the body clean, no maintenance, adjustment, or servicing is required. See Figure

13.

Leakage ChecWTesting

Every

500

hours or annually.

fully opened, engine not running, turn key switch Check all LPG system connections and lines for leaks

using soapy water. Any leakage must be corrected

before

an authorized Kohler Engine Service Dealer or qualified LP personnel only.

restarting engine. Have service performed by

With LPG tank valve

“on.”

Make sure the LPG tank is properly filled (never to

more than space must be present in the tank to allow fuel to expand.

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

Check for loose, kinked, or cracked vacuum lines causing regulator not to open.

Check to make sure the fuel valve on LPG tank is fully open.

Check gauge on LPG tank to make sure pressure

is sufficient to open the regulator.

For problems with the gasoline system (dual-fuel), check that there is adequate fresh fuel in the tank, the fuel valve at the tank (if the fuel tank cap is properly vented, the lines are

not kinked or blocked, and that the in-line filter is

not dirty or restricted.

If after checking the items listed above, the engine is hard to start, runs roughly, or stalls at low idle speed, qualified fuel system servicing may be necessary. Contact your nearest authorized Kohler Engine Service Dealer for further assistance.

percent of total capacity). An air

equipped) is open,

Troubleshoofing

When troubles occur, be sure to check the simple causes which at first may seem too obvious to be considered.

For example, a starting problem could be caused by an empty fuel tank. Some common causes of engine troubles

are listed in the following table. Do not attempt to service or replace major engine components, or any items that require special timing or

adjustment procedures. Have your Kohler Engine Service Dealer do this work.

Dirt Dirty/

In Restricted Dirty Incorrect Dirty Faulty Dirty/Possible Cause Problem Fuel

Will Not Start

Hard Starting . . . . . . . . . .

Stops Suddenly . . . . . . .

Lacks Power . . . . . . . . .

Operates Erratically . . . . . . . .

Knocks or Pings . . . . . .

Skips or Misfires . . . . . . .

Backfires . . . . .

Overheats . . . . . . .

High Fuel Consumption . .

Improper Fuel

Fuel Line Fuel Filter Screen

. . . . . . . . .

Lock-off Flywheel

Oil Engine

Level Overloaded Cleaner Plug Regulator

Air Spark

Restricted

Page 15

Storage

When the engine is not in use, use the following storage procedure. Federal, state, or local laws governing LPG fuel tank storage may also apply. Follow the applicable storage laws.

Clean the exterior surfaces of the engine.

2. Change the oil and filter while the engine is still warm from operation. See "Change Oil and Oil

Filter" on page

10.

Store the engine in a clean, dry place. Store the fuel tank in a designated safe LPG storage area at all times when not in use.

Parts Ordering

The engine Specification, Model, and Serial Numbers are required when ordering replacement parts from your Kohler Engine Service Dealer. These numbers are found on the identification plate which is affixed to the engine shrouding. Include letter suffixes if there are any. See "Engine Identification Numbers" on page 6.

3. Turn valve on LPG tank off and run engine until the fuel system is empty. Turn ignition key switch off. Separate LPG tank from the unit and store separately in an area designated for safe LPG tank storage. On dual-fuel units, the gasoline 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 manufacturer's 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. Close fuel shut-off valve when unit is being stored or transported.

4. Remove the spark plugs. Add one tablespoon of engine oil into each spark plug hole. Install the plugs, but do not connect the plug leads. Crank the engine two or three revolutions.

Specifications

Model:

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

Bore:

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

Stroke:

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

Displacement: Power (03600

Max.

Torque

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

RPM):

(QRPM):

Compression Ratio: Weight:

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

Oil Capacity (w/filter):

Lubrication:

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

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

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

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

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

cm3

N.m

(U.S.

mm mm

(HP)

(ft. Ib.)

kg (Ib.)

(in.)

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

(in.)

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

(in.3)

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

qt.)

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

Always

insist on genuine Kohler

parts.

All genuine Kohler parts meet strict standards for fit, reliability, and performance.

Major Repair

Major repair information is available in Kohler Engine Service Manuals. However, major repair generally requires the attention of a trained mechanic and the use of special tools and equipment. Your Kohler Engine Service Dealer has the facilities, training, and genuine Kohler replacement parts necessary to perform this service. For Sales 1-800-544-2444 Kohler Engine Dealer or Service Distributor, they're in the Yellow Pages under Engines-Gasoline.

CH20-22

67 (2.64)

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

(3.03)

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

624 (38.1)

14.9 (20*)

8.5:l

41 2

(2.1)

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

(32) Q2500

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

(90)

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

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

Full Pressure w/full Flow Filter

Service assistance call

(U.S.

Canada) or contact your

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

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

CH25 83 (3.27) 67 (2.64) 725 (44.0)

18.4 (25*) 54 (39.5) Q2400

9.O:l 43 (94)

(2.1)

Exhaust Emission Control System Exhaust Emission Control System

for

models CH20

for

model

LP,

CH25

CH25 Dual Fuel (closed loop) is

*Horsepower ratings are established in accordance with Society

GROSS. Kohler Co. reserves the right without incurring obligation. use

LPG as fuel.

horsepower reduction

change product specifications, design, and standard equipment without notice and

approximately 10 percent may

LP,

and CH25 Dual

Automotive Engineers - Small Engine

Fuel

EM, 02S,

(open

loop) is

ECM.

expected with the operation and

EM.

Test

Code

J1995

Page 16

LIMITED 2 YEAR COMMAND ENGINE WARRANTY

We warrant workmanship in normal service for a period of with Kohler Co.’s instructions and manuals.

Our obligation under this warranty is expressly limited, at our option, to the replacement or repair at Kohler Co., Kohler, Wisconsin 53044, or at a service facility designated by us of such parts as inspection shall disclose to have been defective.

EXCLUSIONS: Mufflers on engines used commercially (non-residential) are warranted for one (1) year from date of purchase, except catalytic mufflers, which are warranted for two

This warranty does not apply to defects caused by casualty or unreasonable use, including faulty repairs by others and failure to provide reasonable and necessary maintenance.

The following items are not covered by this warranty: Engine accessories such as fuel tanks, clutches, transmissions, power-drive assemblies, and batteries, unless supplied or installed by

Kohler Co. These are subject to the warranties, if any, of their manufacturers. WE SHALL NOT BE LIABLE FOR SPECIAL, INDIRECT, INCIDENTAL, OR CONSEQUENTIAL DAMAGES OF ANY KIND, including but

not limited to labor costs or transportation charges in connection with the repair or replacement of defective parts. ANY IMPLIED OR STATUARY WARRANTIES, INCLUDING WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR

PURPOSE, ARE EXPRESSLY LIMITED TO THE DURATION OF THIS WRITTEN WARRANTY. We make no other express warranty, nor is any one authorized to make any in our behalf.

the original consumer that each new Command engine sold by us will be free from manufacturing defects in materials or

(2)

years.

two

(2)

years from date of purchase, provided it is operated and maintained in accordance

Some states do not allow limitations on how long an implied warranty lasts, or the exclusion or limitation of incidental or consequential damages,

This warranty gives you specific legal rights, and you may also have other rights which vay from state to state. TO OBTAIN WARRANTY SERVICE:

Purchaser must bring the engine to an authorized Kohler service facility. For the facility nearest you, consult your Yellow Pages or write Kohler Co., Attn: Engine Warranty Service Dept., Kohler, Wisconsin, 53044.

so the above limitation or exclusion may not apply to you.

ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044

KOHLER CO,

FEDERAL AND CALIFORNIA EMISSION CONTROL SYSTEMS

LIMITED WARRANTY

SMALL OFF-ROAD ENGINES

The US. Environmental Protection Agency (EPA), the California Air Resources Board (CARB), and Kohler Co. are pleased to explain the Federal and California Emission Control Systems Warranty on your small off-road equipment engine. For California, engines produced in 1995 and later must be designed, built and equipped to meet the state’s stringent anti-smog standards. In other states, 1997 and later model year engines must be designed, built and equipped, to meet the US. EPA regulations for small non-road engines. The engine must be free from defects in materials and workmanship which cause it to fail to conform with US. EPA standards for the first engine use from the date of sale to the ultimate purchaser. Kohler Co. must warrant the emission control system on the engine for the period of time listed above, provided there has been no abuse, neglect or improper maintenance.

The emission control system may include parts such as the carburetor or fuel injection system, the ignition system, and catalytic converter. Also included are the hoses, belts and connectors and other emission related assemblies.

Where a warrantable condition exists, Kohler Co. will repair the engine at no cost, including diagnosis (if the diagnostic work is performed at an authorized dealer), parts and labor.

two

years of

MANUFACTURER’S WARRANTY COVERAGE

Engines produced in 1995 or later are warranted for warranted for charge.

OWNER’S WARRANTY RESPONSIBILITIES

(a)

(b)

two

years. If any emission related part on the engine is defective, the part will be repaired or replaced by Kohler

The engine owner is responsible for the performance of the required maintenance listed in the owner’s manual. Kohler Co. recommends that you retain all receipts covering maintenance on the engine, But Kohler Co. cannot deny warranty solely for the lack of receipts or for your failure to assure that all scheduled maintenance was performed.

Be aware, however, that Kohler Co. may deny warranty coverage if the engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.

two

years in California. In other states, 1997 and later model year engines are

Continued on next page.

Co.

free of

Page 17

For warranty repairs, the engine must be presented to a Kohler Co. service center as soon as a problem exists. Call 1-800-544-2444

(c)

or access our website at www.kohlerengines.com, for the names of the nearest setvice centers. The warranty repairs should be completed in a reasonable amount of time, not to exceed

If you have any questions regarding warranty rights and responsibilities, you should contact Kohler Co. at 1-920-457-4441 and ask for an Engine Service representative.

COVERAGE

Kohler Co. warrants to the ultimate purchaser and each subsequent purchaser that the engine will be designed, built and equipped, at the time of sale, to meet all applicable regulations. Kohler Co. also warrants to the initial purchaser and each subsequent purchaser, that the engine is free from defects in materials and workmanship which cause the engine to fail to conform with applicable regulations for a period of two years.

Engines produced in 1995 or later are warranted for two years in California. For 1997 and later model years, EPA requires manufacturers to warrant engines for two years in all other states. These warranty periods will begin on the date the engine is purchased by the initial

purchaser. If any emission related part on the engine is defective, the part will be replaced by Kohler Co. at no cost to the owner. Kohler

Co. is liable for damages to other engine components caused by the failure of a warranted part still under warranty.

Kohler Co. shall remedy warranty defects at any authorized Kohler Co. engine dealer or warranty station. Warranty repair work done at an authorized dealer or warranty station shall be free of charge to the owner if such work determines that a warranted part is defective.

Listed below are the parts covered by the Federal and California Emission Control Systems Warranty. Some parts listed below may require scheduled maintenance and are warranted up to the first scheduled replacement point for that part. The warranted parts are:

days.

Oxygen sensor (if equipped)

Intake manifold (if equipped) Exhaust manifold (if equipped) Catalytic muffler (if equipped) Fuel metering valve (if equipped) Spark advance module (if equipped) Crankcase breather

LIMITATIONS

This Emission Control Systems Warranty shall not cover any of the following:

repair or replacement required because of misuse or neglect, improper maintenance, repairs improperly performed or replacements

(a)

not conforming to Kohler Co. specifications that adversely affect performance and/or durability and alterations or modifications not

recommended or approved in writing by Kohler Co., replacement of parts and other services and adjustments necessary for required maintenance at and after the first scheduled

(b)

replacement point,

loss

consequential damages such as

(c)

diagnosis and inspection fees that do not result in eligible warranty service being performed, and

(d)

any add-on or modified part, or malfunction of authorized parts due to the use of add-on or modified parts.

(e)

MAINTENANCE AND REPAIR REQUIREMENTS

The owner is responsible for the proper use and maintenance of the engine. Kohler Co. recommends that all receipts and records covering the performance of regular maintenance be retained in case questions arise. If the engine is resold during the warranty period, the

maintenance records should be transferred to each subsequent owner. Kohler Co. reserves the right to deny warranty coverage if the engine has not been properly maintained; however, Kohler Co. may not deny warranty repairs solely because of the lack of repair

maintenance or failure to keep maintenance records.

of time, inconvenience, loss of use of the engine or equipment, etc.,

Ignition module(s) with high tension lead Gaseous fuel regulator (if equipped) Electronic control unit (if equipped) Carburetor or fuel injection system Fuel lines (if equipped) Air filter, fuel filter, and spark plugs (only to first scheduled replacement point)

Normal maintenance, replacement or repair of emission control devices and systems may be performed by any repair establishment or

individual; however, equivalent in performance and durability may be used in non-warranty maintenance or repairs, and shall not reduce the warranty obligations of the engine manufacturer.

warranty repairs must be performed by a Kohler authorized service center.

Any replacement part or service that

Page 18

Page 19

Page 20

60-

110

RUN'"

FOR

SALES AND SERVICE INFORMATION

US.

AND CANADA, CALL

1-800-544-2444

FORM

ISSUED:

NO.:

TP-2483-C 10/96

ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN

53044

LITHO IN

U.S.A.