Kohler TH650, TH575, TH520 User Manual

OWNER'S MANUAL

KOHLER TRIAD OHC

TH520-TH650 HORIZONTAL CRANKSHAFT

Safety Precautions

To ensure safe operations please read the following statements and understand their meaning. Also refer to your equipment owner's manual for other important safety information. This manual contains safety precautions which are explained below. Please read carefully.

WARNING

Warning is used to indicate the presence of a hazard that can cause severe personal 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

Explosive Fuel can cause fires and severe burns.

Stop engine before filling fuel tank.

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

Rotating Parts can cause severe injury.

Stay away while engine is in 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.

CAUTION

Electrical Shock can cause injury.

Do not touch wires while engine is running.

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.

California

Proposition 65 Warning

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

Electrical Shock!

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

Safety Precautions (Cont.)

WARNING

Accidental Starts can cause severe injury or death.

Disconnect and ground spark plug leads 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 .

WARNING WARNING

Carbon Monoxide can cause severe nausea, fainting or death.

Do not operate engine in closed 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.

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.

Congratulations – You have selected a fine four-cycle, twin cylinder, air-cooled engine. Kohler designs long life strength and on-the-job durability into each engine...making a Kohler engine dependable...dependability you can count on. Here are some reasons why:

• Efficient overhead cam and valve design, and pressure lubrication provide maximum power , torque, and reliability under all operating conditions. The overhead cam design also provides extremely quiet operation.

• Dependable, maintenance free electronic ignition ensures fast, easy starts time after time.

• Kohler engines are easy to service. All routine service areas (like the dip stick and oil fill, air cleaner, spark plugs, 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.

• Every Kohler engine is backed by a worldwide network of over 10,000 distributors and dealers. Service support is just a phone call away . Call 1-800-544-2444 (U.S. & Canada) for Sales & Service assist ance.

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

Air Cleaner Cover

Blower Housing

Dipstick

Cooling Shrouds

Oil Fill

Grass Screen

Figure 1. T ypical Triad OHC Engine.

Electric Starter

Oil Drain Plug

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 T ype

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.

Oil Filter

Oil Drain Plug

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 cont ainers identifies the API service class and SAE viscosity grade. See Figure 3.

*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).

Figure 2. Viscosity Grades Table.

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

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

Figure 3. Oil Container Logo.

Refer to “Maintenance Instructions” beginning on page 7 for detailed oil check, oil change, and oil filter change procedures.

Fuel Recommendations

WARNING: Explosive Fuel!

General Recommendations

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

Do not use gasoline left over from the previous season, to minimize gum deposits in 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 T ype

For best results use only clean, fresh, unleaded gasoline with a pump sticker octane rating of 87 or higher. In countries using the Research method, it should be 90 octane minimum.

Unleaded gasoline is recommended as it leaves less combustion chamber deposits and reduces harmful exhaust emissions. Leaded gasoline is not recommended and must not be used in OHC engines.

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.

IMPORTANT ENGINE INFORMATION THIS ENGINE MEETS U.S. EPA 2005 AND CALIFORNIA 2006 EMISSION REGS FOR SI SMALL OFF-ROAD ENGINES

FAMILY DISPL. (CC) MODEL NO. SPEC. NO.

N11236

SERIAL NO. OEM PROD. NO.

EMISSION COMPLIANCE PERIOD: EPA: CARB: THIS ENGINE IS CERTIFIED TO OPERATE ON: REFER TO OWNER'S MANUAL FOR SAFETY, MAINTENANCE SPECS AND ADJUSTMENTS. FOR SALES/SERVICE IN US/CANADA, CALL:

1-800-544-2444

www.kohlerengines.com

KOHLER CO. KOHLER, WISCONSIN USA

Figure 4. Engine Identification Label.

The Emission Compliance Period referred to on the Emission Control or Air Index label indicates the number of operating hours for which the engine has been shown to meet Federal and CARB emission requirements. The following table provides the Engine Compliance Period (in hours) associated with the category descriptor found on the certification label.

Emission Compliance Period (Hours)

Gasoline/Ether blends

Methyl Tertiary Butyl Ether (MTBE) and unleaded gasoline blends (up to a maximum of 15% MTBE by volume) are approved as a fuel for Kohler engines. Other gasoline/ether blends are not approved.

Engine Identification Numbers

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

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

Record your engine identification numbers on the identification label (Figure 4) for future reference.

EP A

CARB

Category C 250 Hours Moderate 125 Hours

Category B 500 Hours Intermediate 250 Hours

Category A 1000 Hours Extended 500 Hours

Refer to certification label for engine displacement. Exhaust Emission Control System for models TH520,

TH575, TH650 is EM.

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