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McL-20C Parts Manual.pmd

1. 2400222 MAIN DRIVE FASTENERS 2050132 SHIFT LEVER KIT NOT SHOWN 092109 E BORASSY013 McL 20 CLEVIS PIN AND CLIP PIN 091709 E BORASSY007 McL 20C PARTNO DESCRIPTION 2050028 HYDRAULIC TANK U000860 SCREW HC 500 13 X 1 75 U210100 WASHER LOCK 500 U000400 SCREW 375 16 X 750 U210060 WASHER LOCK 375 2050068 HYDRAULIC TANK CAP HD00092 PRESSURE GAUGE 2050170 CONTROL VALVE DOES NOTINCLUDE PISTOL GRIP U000140 SCREW HC 250 20 X 2 50 U210020 WASHER LOCK 250 700100 PISTOL GRIP COMPLETE 2050145 HYDRAULIC PUMP 2050165 HYDRAULIC CYLINDER 2400127 HYDRAULIC MANIFOLD T402159 TEE 1 2MP 1 2MP 1 2FP T000320 VALVE CHECK T405062 PLUG 1 2 T404030 UNION 12MP T700080 FILTERASSEMBLY 2400371 SOLENOID CONTROL VALVE 091709 E BORASSY007 McL 20C 7 5 5 gt 2 O LL MANIFOLD RETURN FILTER ADJUSTABLE CHECK VALVE BORASSY012 092109 E Hydraulic Hoses amp McL 20 Fittings PART DESCRIPTION TH00053 HOSE ASSEMBLY TANK PUMP TH00054 HOSE ASSEMBLY PUMP VALVE TH00059 HOSE ASSEMBLY VALVE GAUGE TH00055 HOSE ASSEMBLY VALVE MANIFOLD TH00052 HOSE ASSEMBLY MANIFOLD CYLINDER BASE TH00051 HOSE ASSEMBLY MANIFOLD CYLINDER ROD TH00057 HOSE ASSEMBLY VALVE ADJ CHECK VALVE TH00058 HOSE ASSEMBLY ADJ CHECK VALVE SOLENOID TH00050 HOSE ASSEMBLY SOLENOID CLUTCH T400070 UNION
2. ee 64 65 Repair HONS erahnen 68 75 Warranty Return Goods POC ys lie 76 77 1990 by McLaughlin Manufacturing Company reprinted 2000 Revision Date 011810 All rights reserved No part of this manual may be reproduced in any form or by any means without prior permission of McLaughlin Manufacturing Company ECS amp MAINTENANGE 20 SPECIFICATIONS MCL 20B EARTH BORING MACHINE Tunnel Diameter Free Bore Cased Bore Planetary Final Drive Hex Size Dimensions Carriage and Pusher Centerline Height Width Height Weight Master Track Length Weight Extension Track Length Weight Performance Power Unit Advance Thrust 3 000 PSI 207 BAR Drive Chuck Speed 3600 engine RPM 3rd Gear 2nd Gear 1st Gear Reverse Drive Chuck Torque 2600 engine RPM 3rd Gear 2nd Gear 1st Gear Reverse ENGLISH 3 12 4 20 2 1 4 120 330 120 310 16 S A E 42 000 100 RPM 53 RPM 32 RPM 26 RPM 1008 ft Ibs 1872 ft Ibs 3132 ft Ibs 3780 ft Ibs METRIC 7 6 cm 30 5 cm 10 2 cm 50 8 cm 5 7 36 2 cm 73 6 cm 127 584 kg 305 140 kg 305 140 kg 12kW S A E 19 000 kg 100 RPM 53 RPM 32 RPM 26 RPM 1366 NM 2538 NM 4247 NM 5125 NM REPAIR AND MAINTENANCE GENERAL Carriage Tightness of Nuts and Bolts Check bolts that mount chuck to th
3. Level Dipstick For engines with a thread on style dipstick Reinsert the dipstick into the tube and rest the oil Ifthe level is low add oil of the proper type up to the F mark the dipstick Refer Oil fill cap on the tube Do not thread the cap onto the tube Figure 6 page 4 Always check the level with the dipstick i before adding more oil NOTE Topreventextensive engine wear or damage always maintain the proper oil levelinthe crankcase Never operate the engine with the oil level below the L mark or over the mark the dipstick Press On Thread On Figure 6 Dipstick Styles 8 Oil Sentry Some engines are equipped with an optional Oil Sentry oil pressure switch If the oil pressure decreases below an acceptable level the Oil Sentry will either shut off the engine or activate a warning signal depending on the application NOTE Make sure the oil level is checked BEFORE EACH USE and is maintained up to the F mark on the dipstick This includes engines equipped with Oil Sentry Change Oil and Oil Filter Change Oil Change oil after every 100 hours of operation Refill with service class SG SH SJ or higher oil as specified in the Viscosity Grades table Figure 2 on page 4 Change the oil while the engine is still warm The oil will flow more freely and carry away more impurities Make sure the engine is level when f
4. 5 Emission Compliance Period Hours 250 Hours 500 Hours 1000 Hours 125 Hours 250 Hours 1500 Hours Refer to certification label for engine displacement Exhaust Emission Control System for models CH11 12 5 13 14 15 16 5 EM 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 level Add fuel if low Check cooling air intake areas and external surfaces of engine Make sure they are clean and unobstructed Check that the air cleaner componenis 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 A WARNING Lethal Exhaust Gases Engine exhaust gases contain poisonous carbon monoxide Carbon monoxide is odorless colorless and can cause death if inhaled Avoid inhaling exhaust fumes and never run the engine in a closed building or confined area Cold Weather Starting Hints Be sure to use the proper oil for the temperature expected See Figure 2 on page 4 Declutch all possible external loads A warm battery has much more starting capacity than cold battery Use fresh winter grade fuel NOTE Wi
5. 1 P300004 BRG TAPERED CUP 1 P300005 BRG TAPERED CONE 1 P300006 BRG TAPERED CUP 1 P300007 BRG TAPERED CONE 1 P301005 HOUSING 1 P300009 WASHER THRUST 1 P300010 RETAINING RING EXT P300030 PIPE PLUG STD NPTF P301007 STUD 1 P301006 PIPE PLUG MAGN NPTF 1 P301003 SEAL BOOT 1 P300012 GEAR INTERNAL 1 P300014 CARRIER P300015 WASHER THRUST TANGED 6 P300016 BRG NEEDLE P300017 THRUST P300018 SHAFT PLANET 3 P300019 GEAR CLUSTER 3 P301004 PIN ROLL 1 P300021 GEAR RING P300022 O RING 1 P300023 COVER INPUT 1 P300024 GEAR SUN 1 P300025 SPACER INPUT 1 P300026 WASHER THRUST P300027 WASHER THRUST P300028 BOLT HEX UNC P300029 BOLT SHOULDER 1 P300030 PIPE PLUG STD NPTF 4 P300032 SCREW DRIVE 2 9 6 9 3 3 2 2 8 4 NOT SHOWN 121609 E BORASSY015 1 Drain oil from unit and discard 2 Pressure test unit at 8 PSI for 10 minutes Seal and O ring check 3 Mark housing from bolt head down O D of cover across ring gear to hub O D This is necessary especially if rebuilding on machine 4 Remove four 4 shoulder bolts and eight 8 grade bolts from cover items 12 amp 13 5 Remove cover item 6 6 Remove thrust washer item 10 and thrust washer item 11 7 Remove input sun gear item 8 8 Remove O ring between cover and ring gear 9 Remove ring gear item 4 10 Remove carrier sub assembly item 3A 11 Remove item 11 between ring ge
6. COMPONENTS AND REPAIR MANUAL MODEL McL 20C EARTH BORING MACHINE PART NO 2050000 Repair Manual Part No Machine Serial E250115 Purchased amp Serviced Thru Purchased Date TABLE OF CONTENTS SPECS ee 2 3 Filters amp Fill POINTS cases 4 5 Carriage Assembly 6 7 Dog aan 8 9 Trace 2 1 1 18 10 11 Casing uuu reed 12 13 Wiring 14 15 Power Train Assembly 16 17 Hyaraulic Pump nee 18 19 Transmission ea ee 20 21 Replacement Disc Seal amp Bearing Kia rnrn 22 23 Maintenance Record 24 25 Engine Service Mainlenanee un 26 41 Torque AIR DAR 42 52 Maintenance bie ce __ _____ aasawa aga saa 53 Transmission POP 54 55 Hydra li Parts u uuu ee ee 56 57 Hydraulic Hoses amp Filtings seen 58 59 Hydra lic ee ee ee 60 61 Control Valve 62 63 Hydraulle Pump Seal
7. 8MP 12MJ T401670 ELBOW 90 12MB 12MJ LONG T401300 ELBOW 90 10MB 8MJ T402150 TEE 8FJ 8MJ 8MJ T401320 ELBOW 90 12MB 8MJ T400700 REDUCER 8FJ 4MJ T400160 UNION 10MB 8MJ T400140 UNION 8MB 8MJ T401140 ELBOW 90 8MP 8MJ 2050109 HTDRAULIC FITTING ASSY T402156 TEE 8MP 8FP 8FP T404030 UNION 12MP 8MP T405060 PLUG T400800 UNION 12MP 12MP T400550 UNION 6MB 4MJ T400028 UNION 6MP 6MJ w 6 SAE O RING T400010 UNION 2MP 4MJ T400020 UNION 4MP 4MJ T401015 ELBOW 45 4FP 4MP 092109 E BORASSY012 Hydraulic Cylinder McL 20C 092109 E BORASSY010 McL 20C PART NO DESCRIPTION 2050165 HYDRAULIC CYLINDER 2000010 CYLINDER INCLUDES 2000010 1 O RING 2000010 2 BACK UP 2000010 3 WIPER 2000010 4 U CUP LOADED 2000010 5 O RING 2000010 6 U CLIP T840080 CLEVIS PIN G820050 CLIP PIN 2050065 RETAINING RING HEAD CAP T810040 RODASSEMBLY Q QO N PERCYLINDER 092109 E BORASSY010 092109 E BORASSY011 Control Valve Nssembly ITEM QTY PART DESCRIPTION 1 1 2050067 RELIEF VALVE CARTRIDGE 2 1 2050175 VALVE HANDLE BORASSY011 raulic Pump Seal Kit McL 20 092309 BORASSY014 Hydraulic Pump Seal Kit NOT SHOWN 092309 E PART 2050146 2050146 7 2050146 8 2050146 9 2050146 10 2050146 12 2050146 13 2050146 17 2050146 40 2000227 DESCRIPTION SEAL KIT WEAR PLATE O RING SHAFT SEAL WASHER BACKUP GASKET SEAL W
8. Insert the master link pin in the chain 15 Replace the coupling guard 16 Connect the battery HYDRAULIC CLUTCH REPLACEMENT DISASSEMBLY Step 1 Transmission Coupling Removal 1 Follow the TRANSMISSION COUPLING REPLACEMENT Disassembly instructions Step 2 Clutch Removal 2 Once the transmission coupling has been removed further breakdown of the power train can be done 3 Remove the six 6 bolts that hold the transmis sion in place Remove transmission 4 Remove bell housing inspection plate 5 Disconnect the hydraulic hose at the clutch Use a male cap to block the hose NOT SUFFI CIENTLY BLOCKING THE HOSE COULD RESULT IN A LOSS OF HYDRAULIC FLUID 6 Remove the bell housing 3 7 Remove the clutch by pulling it straight out of the drive shell 4 IF TOTALLY REPLACING THE CLUTCH REFER TO NO 33 5 6 Step 3 Clutch Disassembly Refer to the following steps for clutch disassembly Steps 8 10 Disk Kit Replacement Steps 8 13 Seal Kit Replacement Steps 8 15 Bearing Kit Replacement 8 Remove and discard the snap ring holding the disks together NOTE THE DISKS ARE UNDER PRESSURE THE DISKS MUST BE COM PRESSED BEFORE THE SNAP RING CAN BE REMOVED EYE PROTECTION MUST BE WORN FOR SAFETY 9 Once the snap ring is off remove the front plate Remove and discard the following six 6 belleville springs five 5 seperator disks and six 6 friction disks DO NOT DISCARD THE FRONT PLATE OR
9. Shut Off Throttle Lever Retractable Starter 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 3 Figure 3 Oil Container Logo Refer to Maintenance Instructions beginning on page 8 for detailed oil check oil change and oil filter change procedures Fuel Recommendations WARNING Explosive Fuel Gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only in approved containers in well ventilated unoccupied buildings away from sparks or flames Do not fill the fuel tank while the engine is hot or running since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition Do not start the engine near spilled fuel Never use gasoline as a cleaning agent General Recommendations Purchase gasoline in small quantities and store in clean approved containers A container with a capacity of 2 gallons or less with a pouring spout is recommended Such a container is easier to handle and helps eliminate spillage during refueling Do not use gasoline left over from the previous season to minimize gum deposits in your f
10. install a special high altitude jet kit in the carburetor If a high altitude kit has been installed the engine must be reconverted to the original jet size before it is operated at lower altitudes or overheating and engine damage can result Troubleshooting If engine troubles are experienced that appear to be fuel system related check the following areas before adjusting 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 itis operating properly If the fuel tank is equipped with a shut off valve make sure it is open if the engine is equipped with an in line fuel filter make sure it is clean and unobstructed Replace the filter if necessary Make sure fuel is reaching the carburetor This includes checking the fuel lines and fuel pump for restrictions or faulty components replace as necessary Make sure the air cleaner element is clean and all air cleaner components are fastened securely If after checking the items listed above the engine is hard to start runs roughly or stalls at low idle speed it may be necessary to adjust or service the carburetor Carburetor Adjustment NOTE Certified engines may have a fixed idle or limiter cap on the idle fuel adjusting needle Step 2 can only be performed within the limits allowed by the cap 1 Start the engine and run at half throttle for 5 to 10 minutes to warm up The engi
11. the California Air Resources Board CARB and Kohler Co are pleased to explain ihe Federal and California Emission Control Systems Warranty on your small off road equipment engine In California beginning in 2006 emissions means both exhaust and evaporative emissions For California engines produced in 2006 and later must be designed 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 U S 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 U S EPA standards for the first two years of 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 MANUFACTURER S WARRANTY COVERAGE Engines produced in 2006 or later are warranted for two years in California I
12. manual supplied for gasoline or diesel grade recommendations Auger Couplings Clean and coat with light oil after every use Cutting Heads Examine all teeth and replace as necesary before use Check all conical bits on rock heads for rotary freedom Check condition and freedom of wing cutters Auger Examine use for fractures and reweld as necessary NOTE USE ONLY GENUINE McLAUGHLIN REPLACEMENT PARTS WARNING IN ws weight can cause serious injury Place mahine on solid surface to prevent rollover or falling WARNING Do not modify this machine Use only authorized McLaughlin repair parts Failure to comply can result in serious injury Service this equipment according to maintenance instructions in this manual LTERS AND FILL POINTS McL 206 1 Engine Oil Fill change oil after every 25 hours of use Use SAE 30 when the temperature is over 32 F Use SAE 5W20 or SAE 5W30 when the temperature is below 32 F 2 Dip Stick Check daily with engine warm Fill as needed to the full mark on the dip stick 3 Fuel Level Fill as needed with branded grades of gasoline 4 Hydraulic Oil Fill Fill as needed with cylinders retracted with 300SSU oil Change oil after first 1 000 hours of use then annually Recommended Hydraulic oils Mobile Fluid 350 or 423 Shell Telus 29 Sunoco Sunvis 831 WR 5 Hydraulic Oil Filter Replace with every oil change and every 350 hours or three months Replacement numbe
13. replacement parts necessary to perform this service For the nearest Sales amp Service location visit our website www kohlerengines com call 1 800 544 2444 U S amp Canada look in the yellow pages under Engines Gasoline Specifications CH12 5 CH13 CH14 CH15 CH16 mm in 87 3 43 87 3 43 87 3 43 87 3 43 90 3 55 90 3 55 Stroke 67 2 64 67 2 64 67 2 64 67 2 64 67 2 64 67 2 64 Displacement cm in 398 24 3 398 24 3 398 24 3 398 24 3 426 26 0 426 26 0 Power 03600 RPM KW HP 8 2 117 9 33 12 5 9 75 137 10 50 147 11 2 15 11 9 16 Max Peak Torque ft 19 7 2400 20 5 2500 21 1 2200 21 3 02500 24 8 2400 25 3 92400 Compression Ratio 8 5 12 85 8 5 1 8 5 1 Weight 40 88 3 40 88 3 40 88 3 40 88 3 40 88 3 40 88 3 Oil Capacity w filter L U S 1 9 2 1 9 2 1 9 2 1 9 2 1 9 2 nenn H Full Pressure w full Flow Filter Exhaust Emission Control System for CH11 12 5 13 14 15 16 is EM Horsepower ratings exceed Society of Automotive Engineers Small Engine Test Code J1940 Actual engine horsepower is lower and affected by but not limited to accessories air cleaner exhaust charging cooling fuel pu
14. this point the carrier sub assembly is complete HUB SPINDLE SUB ASSEMBLY NOTE Make sure the cup sits square with the counterbore before pressing 1 Set hub 1G on work surface wide end up Using a bearing cup pressing tool press bearing cup 1E into the counterbore in the wide end of hub 1G Oil the bearing cup NOTE Make sure the cup sits square with the counterbore before pressing 2 Using a bearing cup pressing tool press bearing cup 1C into the counterbore in the small end of hub 1G Oil the bearing cup 3 Place bearing cone 1D into the small end of hub 1G Oil the bearing cone 4 Using a seal pressing tool press seal 1B closed side facing up into the small end of hub 1G Oil the seal 2 5 Press studs 1N into the holes in flange of hub 1G 3 Reinstall seal boot 1Q onto the hub 1G Ref drawing pg 56 Replace seal if damaged or missing 4 6 Apply a light coat of Never Seize to pipe plug 1P and install it into the bottom wide end of spindle 1A 7 Place spindle 1A on table wide end down Slowly lower hub 1G small end down onto spindle 1A watching seal 1B to make sure it stays in place 8 Using a bearing cone pressing tool press bearing cone 1F onto spindle 1A in hub 1G Oil the bearing cone 9 Place spacer 1H over the end of spindle 1A CAUTION Beware of sharp edges in the counterbore when you install O ring 7 10 Place ret
15. 3 g Plate Assembly McL 20 lt PART NO DESCRIPTION 2020020 DOG PIN U600040 SPRING COMP 105 X 1 06 X 4 25 2020010 DOG PLATE HOUSING U020060 SCREW SQ 500 13 X 2 00 U210100 WASHER LOCK 500 U100120 NUT HEX 500 13 2020050 LINKAGE ARM U000815 SCREW HC 500 13 X 1 00 2020040 LINKAGE SHIFTER T500020 FITTING GREASE 125 STRAIGHT U000815 SCREW HC 500 13 X 1 00 U120100 NUT LOCK 500 13 2020060 TOP COVER PLATE U000960 SCREW HC 500 13 X 4 00 U210100 WASHER LOCK 500 2020070 OPERATOR LEVER U000400 SCREW HC 375 16 X 750 U100060 NUT HEX 375 16 U410055 KEY STR 250 X 250 X 1 00 Q 2 2 1 2 2 2 2 2 1 1 2 2 1 4 4 1 1 1 1 082609 BORASSY003 McL 20 BORASSY004 082809 E gt r 0 0 lt O ck Assembly McL 20 082809 E PART 2040000 U000860 U100120 U210100 2040060 U000860 U100120 U210100 DESCRIPTION TRACK SCREW HC 500 13 X 1 75 NUT HEX 500 13 WASHER LOCK 500 THRUST PLATE SCREW 500 13 X 1 75 NUT HEX 500 13 WASHER LOCK 500 BORASSY004 Casing Pusher Spoil McL 20C jector Assembly 091509 E BORASSY005 Casing Pusher Spoil jector Assembly ITEM PART DESCRIPTION 1 2050041 CASING PUSHERASSEMBLY U001355 SCREW HC 750 10 X 1 25 U210160 WASHER LOCK 750 U320015 PIN COTTER 125 X 1 00 U020120 SCREW SQ 750 10 X 2 00 2050101 PADDLE ASSEMBLY COMPLETE A200440 2 25 HEX
16. ASHER PLUG SEAL KIT LOADED SEALS SEALS SQUARE CUT RING STATIC SEAL LOAD SEAL SPACER BORASSY014 Cold weater effects the operation and performance of the boring machine Cold hydraulic fluid causes sluggish machine performance and can contribute to the premature failure of some machine components Before starting to bore the machine and hydraulic fluid must be at operating temperature i e the machine must be warmed up before boring Warm up Procedure Start the machine and let it run at idle for 1 2 minutes Slowly increase the engine to about 1 2 to 3 4 full throttle Allow the engine to run at this higher speed for 4 5 minutes Extend and retract the thrust cylinders to warm up the hydraulic fluid Occasionally running the machine over relief will help to reduce the warm up time Only after the machine is warmed up should you begin to bore Hydraulic Clutch Operation SLUGGISH OR DELAYED APPLY TIME FOR THE CLUTCH CAN CAUSE PREMATURE FAILURE The apply time for the clutch the time it takes to build full pressure is critical to the operation of the machine Normal clutch apply time is less than 2 seconds If the apply time is greater than 2 seconds wait until oil temperature increases before boring Cycle the clutch during warm up waiting 10 seconds between engagements WHEN APPLYING THE CLUTCH DURING THE WARM UP PERIOD THE TRANSMISSION MUST BE IN NEUTRAL Do not cycle the clutch during warm up
17. CHUCKASSEMBLY U000860 SCREW HC 500 13 X 1 750 U210100 WASHER LOCK 500 U001510 SCREW HC 750 10 X 4 50 U120040 NUT NY 750 10 R800545 CHUCK EXTENSION 2 250 TO 2 250 2050051 SADDLE ASSEMBLY U020120 SCREW SQ 750 10 X 2 00 Optional Equipment Available upon request 7 1 A200040 ADAPTER KIT 4 A200060 ADAPTER KIT 6 A200080 ADAPTER KIT 8 A200100 ADAPTER KIT 10 A200120 ADAPTER KIT 12 A200140 ADAPTER KIT 14 A200160 ADAPTER KIT 16 A200180 ADAPTER KIT 18 A20004P ADAPTER KIT 4 PVC A20006P ADAPTER KIT 6 A20008F ADAPTER KIT 8 A20010P ADAPTER KIT 10 A20012P ADAPTER KIT 12 2090110 SPACER 4 ADAPTER 2090120 SPACER 6 ADAPTER 2090130 SPACER 8 ADAPTER 2090140 SPACER 10 ADAPTER 2090150 SPACER 12 ADAPTER 2090160 SPACER 14 ADAPTER 2013045 SHOE 16 ADAPTER SHOE 18 ADAPTER 2050149 REPLACEMENT DOOR KIT 2013070 DOOR WELDMENT 2013080 HINGE ROD U320015 COTTER PIN 125 X 1 00 2050160 SEAL SHIELD NOT SHOWN 091509 E BORASSY005 McL 20 05 HOLA II NOTI3A 9 MOTISA 101 d IAS LS 3 N HILIMSAFN BORASSY016 011910 E ing Diagram PART DESCRIPTION X000020 STOP
18. G RING 2050091 15 INLET PORT CAP OQ Q N NOT SHOWN Clutch Pressure 100 psi CLUTCH HYD KITS Use 0 300 psi gauge 3 1 2050093 KIT INCLUDES 6LUGDISCS 5 SPACER PLATES 6 BELLEVILLE SPRINGS 1 CIRCULAR 2050147 FRONT PLATE 2050094 KIT INCLUDES 1 SMALL O RING 1 LARGE O RING 2050095 KIT INCLUDES 1 SMALL BEARING 1 LARGE BEARING 1 SNAP RING NOTE INSTALL BELLEVILLE SPRINGS 1 0 1 0 AND O D TO O D NOTE FOR SERIAL NO 20062993536 AND HIGHER CONSULT MANUFACTURER FOR DISK SEAL AND BEARING KIT ASSEMBLES ON EARLIER MODELS 092109 E BORASSY009 NTENANGE RECORD McL 206 SERVICE PERFORMED PAGE LEFT BLANK LOwNER s MANUAL KOHLER COMMAND 1 16 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 A 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 A CAUTION Caution is used to indicate the presence of a hazard that will 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 iniormation that is im
19. LUGS TO JUST BELOW THE CYLINDER AND PISTON FACES 17 Press a new sealed bearing into cylinder by pressing on the outer race of the bearing 18 Press a new sealed bearing onto the pressure plate by pressing on the inner race of the bearing 19 a light oil to all o ring surfaces and grooves before assembling the clutch Install o rings into the proper o ring grooves 20 Align the anti rotation pin in the piston with the blind hole in the cylinder Carefully press the piston onto the cylinder As the piston o ring begins to slide onto the cylinder it may be necessary to guide the o ring into the o ring groove 21 Assemble the pressure plate and bearing assembly into the cylinder and piston assembly by 19 pressing on the pressure plate 22 Assemble the hub into the cylinder assembly by supporting hub on the splined end Place the 20 cylinder assembly on the hub and press the bearing onto the hub NOTE PRESS ON THE INNER RACE OF THE BEARING As the bearing is being pressed onto the hub it is necessary to align the internal spine of the pressure plate with the external spline of the hub 23 Install the retaining ring EYE PROTECTION MUST BE WORN FOR SAFETY 24 Seat the bearing against the retaining ring by supporting pressure plate and pressing on the hub 25 The reassembly order of the disk kit is as follows 1st friction disk 2nd belleville spring O D facing pressure plate 3rd sp
20. NG 2050156 TRANSMISSION SPACERS 121609 E BORASSY006 Hyt raulic Pump Coupling 091509 E Hydraulic Pump Coupling Assembly 091509 E PART NO P400000 P400002 P400001 U410015 U410055 DESCRIPTION COUPLING HALF COUPLING INSERT COUPLING HALF 625 BORE KEY STR 125 X 125 X 625 KEY STR 250 X 250 X 1 00 McL 20C BORASSY006 McL 20C O O 0 gt 0 0 lt BORASSY008 092109 E Transmission Coupling Assembly 1 2 3 ITEM QTY 1 1 1 1 1 092109 E PART T260008 T260006 U410060 T260007 U410140 DESCRIPTION DELRIN CHAIN COUPLING 1 00 BORE KEY STR 250 X 250 X 1 25 COUPLING 1 375 BORE KEY STR 375 X 375 X 2 00 McL 20C BORASSY008 placement Disc Kit McL 20 Assembly 2 875 CLUTCH AXIAL LENGTH 1 8 27 INLET PORT 1 672214 1 4 77222 222 092109 BORASSY009 olacement Disc Kit McL 20C Assembly QTY PART DESCRIPTION 1 2050091 CLUTCH HYD 1 2050091 1 HUB 1 2050091 2 CYLINDERASSEMBLY 1 2050091 3 PISTONASSEMBLY 5 2050091 4 SEPARATOR DISC 6 1 1 6 1 1 1 1 1 1 1 2050091 5 DISC ASSEMBLY 2050091 6 BACK PLATE 2050091 7 PRESSURE PLATE 2050091 8 BELLEVILLE SPRING 2050091 9 HUB BEARING 2050091 10 THRUST BEARING 2050091 11 O RING 2050091 12 O RING 2050091 13 RETAINING RING 2050091 14 RETAININ
21. OF BUYER SET FORTH HEREINARE EXCLUSIVE AND ARE IN LIEU OF ALL OTHER REM EDIES THE LIABILITY OF MANUFACTURER WHETHER IN CONTRACT TORT UNDER ANY WAR RANTY OR OTHERWISE SHALL NOT EXTEND RANTY RETURN GOODS POLICY BEYOND ITS OBLIGATION TO REPAIR OR REPLACE AT ITS OPTION ANY PRODUCT OR PART FOUND BY MANUFACTURER TO BE DEFECTIVE IN MATE RIAL OR WORKMANSHIP MANUFACTURER SHALL NOT BE LIABLE FOR COST OF INSTALLATION AND OR REMOVAL OR BE RESPONSIBLE FOR DIRECT INDIRECT SPECIAL OR CONSEQUENTIAL DAM AGES OF ANY NATURE FOR SERVICE OR ASSISTANCE SEE THE AUTHO RIZED McLAUGHLIN DEALER IN YOUR AREA GENERAL RETURNS FOR MERCHANDISE 1 All material returned to McLaughlin Mfg Company must have a return authorization number This number can be obtained by calling the dealer from whom the material was originally purchased 2 All returned material must be shipped PREPAID 3 Material without a material authorization number or returned collect will be refused at our dock 4 All material ordered incorrectly or new material re turned for no valid reason will be subject to a 20 re stocking charge 5 In the case of warranty claims a letter explaining the problem or requesting repair must accompany the ma terial 6 On warranty consideration all material shipped by McLaughlin will be invoiced until the defective material is returned for inspection After inspection credit will be issued for all parts deemed defective 7 All re
22. PRESSURE PLATE 10 Clean the front plate and pressure plate if necessary MAKE SURE THAT BOTH PLATES ARE COMPLETELY DRY BEFORE REASSEM BLING 11 Support cylinder assembly on bearing side and push down on hub Remove and discard snap ring EYE PROTECTION MUST BE WORN FOR SAFETY 12 Support clutch on pressure plate Push down on hub to remove from cylinder assembly 13 Use low air pressure to separate cylinder assembly from piston assembly and pressure plate Remove and discard o rings At this point inspect 8 bearings for wear If bearings are acceptable refer to step 23 14 Remove the two 2 bearing removal plugs in 12 cylinder face Use two 2 1 4 diameter rods to tap bearing out of cylinder counterbore NOTE DO NOT STRIKE THE COUNTERBORE WITH THE RODS 13 15 Remove the two 2 bearing removal plugs in piston face Use two 2 1 4 diameter rods to tap bearing out of piston counterbore NOTE DO 14 NOT STRIKE THE COUNTERBORE WITH THE RODS ASSEMBLY Step 4 Clutch Assembly Refer to the following steps for clutch assembly Steps 25 27 Disk Kit Assembly Steps 19 28 Seal Kit Assembly Steps 16 28 Bearing Kit Assembly 16 Install bearing removal plugs in the cylinder and piston face Apply a light coat of Locktite remov able thread locker 242 or equivalent to the inner and outer races of the bearings NOTE APPLY A FEW DROPS OF REMOVABLE THREAD SEAL ANT TO THE PLUGS TIGHTEN P
23. SWITCH X400040 BATTERY X300140 CABLE BATTERY neg X300150 CABLE BATTERY pos 700100 PISTOL GRIP COMPLETE X000090 KEY SWITCH X000013 STOP SWITCH BUTTON NOT SHOWN 011910 E BORASSY016 er Train Assembly McL 20 121609 BORASSY006 er Train Assembly McL 20 PART DESCRIPTION P300000 0100190 625 11 0210140 WASHER LOCK 625 P330000 INPUT SHAFT 0000820 SCREW 500 13 X 56 0210100 WASHER LOCK 500 U410092 KEY STR 313 X 313 X 56 W200160 O RING 4 0 X 4 18 X 103 T260008 COUPLING ELEMENT DELRIN CHAIN 2050120 TRANSMISSION OUTPUT SHAFT U000760 SCREW HC 438 14 X 1 25 U210080 WASHER LOCK 438 U410061 KEY STR 250 X 250 X 56 2050155 TRANSMISSION MODEL 14 U000760 SCREW HC 438 14 X 1 25 U210080 WASHER LOCK 438 U000840 SCREW HC 500 13 X 1 50 U210100 WASHER LOCK 500 2050113 TRANS BELL HOUSING SPACER U010080 SCREW HSH 375 16 X 1 00 2050112 BELL HOUSING U000760 SCREW HC 438 14 X 1 25 U210080 WASHER LOCK 438 2050091 CLUTCH HYD 2050099 INSPECTION COVER 2050092 DRIVE CAP P240001 CLUTCH SPACER 2099001 CLUTCH ADAPTER SHAFT 2060000 ENGINE KOHLER 15HP P400003 STUB SHAFT P400000 COUPLING HALF 1 X 1 4 KEY U010080 SCREW HSH 375 16 X 1 000 U210060 WASHER LOCK 375 U410060 KEY STR 250 X 250 1 25 1 9 9 1 2 2 1 1 1 1 4 4 4 1 2 2 2 2 1 4 1 4 4 1 1 1 1 1 1 1 1 4 4 1 2050114 SNAP RI
24. acer plate This order is repeated until all disks springs and spacer plates are in place Belleville Springs must be installed to I D for proper clutch operation 26 Install front plate and reinsert snap ring EYE PROTECTION MUST BE WORN FOR SAFETY NOTE DISKS MUST BE COMPRESSED IN ORDER TO HAVE ACCESS TO THE SNAP RING GROOVE 27 Rotate disks by hand to insure proper seating 25 The disks should be evenly spaced 28 Rotate the hub in the cylinder to insure that the bearings are free ASSEMBLY Step 5 Installing the hydraulic clutch fitting These instructions are for use only if the fitting is being changed or replaced 29 Remove the hydraulic clutch fitting from the old clutch 30 Clean off any remaining sealant into the clutch and tighten 31 Apply a drop of removable thread sealant to the pipe thread of the fitting NOTE THE FITTING MUST BE CLEAN AND DRY BEFORE ANY SEALANT CAN BE APPLIED 32 Install the fitting with the sealant into the clutch and tighten Step 6 Installing the clutch 33 Line up the clutch disks with the slots in the drive shell The disks must be aligned one at a time EXTRA CARE MUST BE TAKEN WHEN INSTALLING THE 32 CLUTCH INTO THE DRIVE SHELL ANY SUDDEN MOVEMENT SIDE TO SIDE OR UP AND DOWN CAN CAUSE THE TEETH OF THE DISKS TO BREAK OFF DO NOT FORCE THE DISKS INTO THE DRIVE SHELL 34 34 Once all four 4 disks are fully in the drive shell slide th
25. acturers of component parts which may extend to Buyer Claims or defects in material and workmanship shall be made in writing to Manufacturer within ten days of dis covery of defect Manufacturer may either send a ser vice representative or have the product returned to its factory at Buyer s expense for inspection Upon notifi cation of defect Manufacturer will issue a return good authorization number to Buyer The return goods au thorization number must accompany the product re turned If judged by the Manufacturer to be defective in material or workmanship the product will be replaced or repaired at the option of Manufacturer free from all charges except authorized transportation Buyer shall be responsible for all maintenance services consisting of lubrication and cleaning of equipment replacing ex pendable parts making minor adjustments and perform ing operating checks all in accordance with procedures outlined in Manufacturer s maintenance literature THE FOREGOING WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES AND NO REPRESENTA TIONS GUARANTEES OR WARRANTIES EXPRESS OF IMPLIED INCLUDING BUT NOT LIMITED TO A WARRANTY OF MERCHANTABILITY OR FITNESS FOR APARTICULAR PURPOSE ARE MADE BY THE MANUFACTURER IN CONNECTION WITH THE MANUFACTURE OR SALE OF ITS PRODUCTS NO EMPLOYEE DISTRIBUTOR OR REPRESENTATIVE IS AUTHORIZED TO CHANGE THIS WARRANTY INANY WAY OR GRANT ANY OTHER WARRANTY ON BE HALF OF MANUFACTURER THE REMEDIES
26. aining ring 11 over spindle 8 11 Check endplay 9 12 Apply a light coat of Never Seize to pipe plug 1 and install it into the side of hub 1G 10 13 At this point the hub spindle sub assembly is complete 12 MAIN ASSEMBLY 1 Lower internal gear 2 small end down into hub 1G 2 Grease and place thrust washer 11 into internal gear 2 and around spindle 1A CAUTION Beware of sharp edges in the counterbore when you install O ring 3 Grease and place O ring 5 into the counterbore of hub 1G NOTE O ring can be stretched to fit counterbore if it is too small or squeezed together bit by bit if it is too large to make O ring fit exactly 4 Set carrier sub assembly 3 on table large gear ends facing up Line up the punch marks on the gear teeth to the 12 o clock position See Diagram 1 5 Place ring gear 4 onto carrier sub assembly 3 to keep the punch marks in position 6 Holding onto ring gear lower carrier sub assembly 3 into hub 1G 7 Now lift ring gear 4 off of hub 16 and line up the bolt holes in hub and ring gear then replace ring gear into hub 8 Place thrust spacer 9 down into middle of carrier 3 9 Place input gear 8 larger splined end down on top of thrust spacer 9 in the middle of carrier 3 10 Place thrust washer 10 down around input gear 8 CAUTION Beware of sharp edges in the counterbore when yo
27. anet shaft tap planet shaft out of carrier housing ROUE HUB ASSEMBLY McL 206 CARRIER SUB ASSEMBLY 1 Grease the inside of small end of one cluster gear 3F and line the inside of small end of cluster gear 3F with 16 needle rollers 3C 2 Place spacer 3D on top of needle rollers 3C inside cluster gear 3F 3 Grease the inside of large end of cluster gear 3F and line the inside of large end of cluster gear with 16 needle rollers 3C 4 Stand carrier housing 3A on its side Starting from the roll pin holed side of carrier insert a planet shaft 3E roll pin hole last into one of the planet shaft holes in carrier housing 3A 5 Grease and place one tanged thrust washer 3B onto the end of planet shaft 3E inserting tang of the thrust washer into the slot in the side of the carrier housing 6 Following the thrust washer oil assembled cluster gear 3F and place it onto planet shaft 3E 7 Following the planet gear grease and place one more thrust washer 3B onto planet shaft 3E inserting tang of the thrust washer into the slot in the side of carrier housing Now insert planet shaft 3E into the opposite planet shaft hole in carrier housing 3A 8 Using an alignment punch align the roll pin holes in carrier housing 3A and planet shaft 3E and hammer roll pin 3G into the aligned holes 9 Repeat steps 1 to 8 to assemble and install the two remaining cluster gears 10 At
28. ar and hub counter bore 12 Remove thrust washer item 11 between carrier housing and internal gear 13 Remove internal gear item 2 14 Remove retaining gear item 1T from hub spindle sub assembly and throw away This re quires retaining ring pliers NOTE Do not reuse retaining ring It might require that the bearing be tapped down to remove the interference of press fit 15 Remove bearing spacer thrust washer item 1H 16 Place hub spindle under a press and push spindle out of hub NOTE Both bearing cones are press fit 17 When spindle comes out of hub the seal item 1B and bearing cone item 1D will be attached A bearing puller must be used to remove cone Do not reuse bearing cone or seal at this area 18 Remove bearing cone from hub item 1F 19 Remove seal boot item 1Q 20 Place hub on table using a grade 5 bolt ground to a flat side tap one cup out Turn hub over and tap other cup out Upon repair install new cups and cones seal retaining ring for hub spindle sub assembly and new O rings NOTE Take care to time carrier sub assembly per building procedures If carrier is mistimed gear teeth will fail in a short amount of operating hours Failure mode will be same as torque overload which is bi directional bending fatigue in the cluster gears If disassembling the carrier sub assembly simply tape the roll pins into the planet shaft roll pins will self contain in the pl
29. ce or replace major engine components or any items that require special timing or adjustment procedures Have your Kohler Engine Service Dealer do this work Possible Cause Improper Dirt In Dirty Incorrect Engine Dirty Air Faulty Problem Fuel Fuel Fuel Line SystemGrass Screen Oil Level Overloaded Cleaner Spark Plug Will Not Start Starting Stops Suddenly Lacks Power Erratically Knocks or Pings Skips or Misfires Backfires Overheats High Fuel Consumption Storage If the engine will be out of service for two months more use the following storage procedure To empty the system run the engine until the fuel tank and system are empty 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 1 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 9 Remove the spark piug Cover the spark plug hole with your thumb and turn the engine over until the The fuel system must be completely emptied or piston is at the top of its stroke Pressure against the gasoline must be treated with a stabilizer to prevent deterioration If you choose to use stabilizer follow the manufacturers recommendations and add the correct am
30. dirty air intake and cooling areas can cause extensive damage due to overheating A WARNING Hot Parts Engine components can get extremely hot from operation To prevent severe burns do not touch these areas while the engine is running or immediately after it is turned off Never the engine with heat shields or guards removed Engine Speed NOTE Do not tamper with the governor setting to increase the maximum engine speed Overspeed is hazardous and will void the engine warranty Maintenance Instructions Maintenance repair or replacement of the emission control devices and systems which are being done at 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 A WARNING Accidental Starts Disabling engine Accidental starting can cause severe injury or death Before working on the engine or equip ment disable the engine as follows 1 Disconnect the spark plug lead s 2 Disconnect negative battery cable from battery Maintenance Schedule These required maintenance procedures should be performed at the frequency stated in the table They should also be included as part of any seasonal tune up Maintenance Required Fill fuel tank Check oil level Check air cleaner for dirty loose or damaged parts Check air intake and cooling areas clean as necessary Every 25 Hours Se
31. e bell housing into its pilot on the engine and tighten bolts 35 35 Connect the hydraulic hose to the clutch 36 Replace the bell housing inspection plate 38 37 Slide transmission input shaft into clutch Replace and tighten six 6 bolts for the transmission Step 7 Reinstalling the transmission coupling 38 Follow the Transmission Coupling Replacement Assembly instructions Step 8 Machine Test Before Starting Engine 39 Check movement of transmission lever and engagement of all transmission gears Step 9 Machine Test 40 Start Engine 41 Check movement of transmission lever and engagement of all transmission gears 42 Check clutch pressure with 0 300 psi gauge Pressure setting 95 psi 43 Check control valve pressure setting with 0 5000 psi gauge Pressure setting 3000 psi McLAUGHLIN LIMITED WARRANTY The Manufacturer warrants its products to be free from defects in material and workmanship for a period of twelve months from the date of shipment from the fac tory The Manufacturer shall not be responsible for any damage resulting to or caused by its products by rea son of installation improper storage unauthorized ser vice alteration of the products neglect or abuse or use of the product in a manner inconsistent with its de sign This warranty does not extend to any component parts not manufactured by Manufacturer however Manufacturer s warranty herein shall not limit any war ranties made by manuf
32. e drive shaft flange of the machine initially then check each week when in continuous use Each bolts should have lock washer Tighten as needed Check all hydraulic fittings initially then check each week when continuous use Tighten as needed taking not to twist hoses from original positions Check bolts 4 on cam rollers inititally then once each month when in continuous use Tighten as needed Check and torque all bolts in engine mounts transmission plan etary flexible coupling and pump mount every 50 hours See parts and service manual for proper bolt torque specifi cations Carriage Miscellaneous Once a month inspect the hitch pins also called auger pins R clips R pins that hold the clevis pins in place Replace if worn or damaged Also check clevis pins that hold machine down in place ifworn or damaged After each boring operation is completed clean the carriage to remove dirt and mud Use water if available Always clean the unit before storage Track General Maintenance Check the rolling surfaces of the track for dirt or contamina tion Clean as required Tighten push plate bolts periodi cally Always inspect bolts before boring begins Inspect the track for fractures and reweld as necessary Engine General Maintenance Review the engine manual supplied before starting and operating the engine Follow manufacturer s recommenda tions for operation and manintenance to mainta
33. ecessary to leave the choke partially on until the engine warms up For a Warm Engine Return choke to off position as soon as engine starts Stopping 1 Remove the load by disengaging all PTO attachments 2a For engines without a shutdown solenoid Move the throttle to the slow low idle position Allow the engine to run at idle for 30 60 seconds then stop the engine b Forengines equipped witha shutdown solenoid Position the throtile control somewhere between half and full throttle then stop the engine Battery A 12 volt battery is normally used Refer to the operating instructions of the equipment this engine powers for specific battery requirements the battery charge is not sufficient to crank the engine recharge the battery see page 12 Operating Angle of Operation This engine will operate continuously at angles up to 25 Check oil level to assure crankcase oil level is at the mark Refer to the operating instructions of the equipment this engine powers Because of equipment design or application there may be more stringent restrictions regarding the angle of operation NOTE Do not operate this engine continuously at angles exceeding 25 in any direction Engine damage could result from insufficient lubrication Cooling NOTE If debris builds up on the grass screen or other cooling air intake areas stop the engine immediately and clean Operating the engine with blocked or
34. equipped Gaseous fuel regulator if equipped Exhaust manifold if equipped Electronic control unit it equipped Catalytic muffler if equipped Carburetor or fuel injection system Fuel metering valve if equipped Fuel lines fuel line fittings and clamps if equipped Spark advance module if equipped Air filter fuel filter and spark plugs only Crankease breather to first scheduled replacement point LIMITATIONS This Emission Control Systems Warranty shail not cover any of the following repair or replacement required because of misuse or neglect improper maintenance repairs improperly performed or replacements 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 replacement point consequential damages such as loss of time inconvenience loss of use of the engine or equipment etc diagnosis and inspection fees that do not result in eligible warranty service being performed and any add on or modified part or malfunction of authorized parts due to the use of add on or modified parts MAINTENANCE AND REPAIR REQUIREMENTS The owner is responsible for the proper use and maintenance of the engine Kohler Co recommends that all receipts and rec
35. er components NOTE Operating the engine with loose or damaged air cleaner components could allow unfiltered air into the engine causing premature wear and failure Service Precleaner Wash and reoil every 25 hours of operation more often under extremely dusty or dirty conditions 1 Loosen the air cleaner cover knob and remove the cover 10 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 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 and tighten the knob securely When precleaner replacement is necessary order Part No 52 083 01 S Service Paper Element Every 100 hours of operation more often under _ extremely dusty or dirty conditions replace the paper element Loosen the air cleaner cover knob and remove the cover Remove the wing nut and then remove the air cleaner element with precleaner Remove the precleaner from the element and service as necessary Do 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 sea
36. extremely hot from operation To prevent severe burns do not touch these areas while 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 defects or other reproductive harm A WARNING Accidental Starts can cause severe injury or death Disconnect and ground spark plug lead before servicing Accidental Starts Disabling engine Accidental starting can cause severe injury or death Before working on the engine or equipment disable the engine as follows 1 Disconnect the spark plug 5 2 Disconnect negative battery cable from battery Safety Precautions Cont WARNING Carbon Monoxide can cause severe nausea fainting or death Avoid inhaling xhaust 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 A WARNING 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 c
37. harged 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 ail 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 single 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 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 All routine service areas like the dipstick and oil fill oil filter air cleaner spark plug 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 Every Kohler engine is backed by a worldwide network of over 10 000 distributo
38. he identification label Figure 4 for future reference Engines without fuel tank KOHLER MPORTANT ENGINE INF THIS ENGINE MEETS U S EPA AND 2005 AND LATER AND STAGE II SN 4 EMISSION REGS FOR SI SMALL OFF ROAD ENGINES FAMILY TYPE APP DISPL MODEL SPEC NO SERIAL NO BUILD DATE 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 112 Engines with fuel tank supplied KOHLER IMPORTANT ENGINE INFORMATION THIS ENGINE MEETS U S EPA 2005 CA2006 EXH EVPAND EC STAGEII SN 4 EMISSION REGS FOR SISMALL OFF ROAD ENGINES FAMILY TYPE APP DISPL CC MODEL NO SPEC NO SERIAL NO BUILD DATE OEM PROD NO EMISSION COMPLIANCE PERIOD EPA CARB CERTIFIED ON REFER OWNER S MANUAL FOR HP RATING SAFETY MAINTENANCE AND ADJUSTMENTS 1 800 544 2444 www kohlerengines com KOHLER CO KOHLER WISCONSIN USA N1236 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 onthe certification label
39. illing checking or changing the oil Change the oil as follows see Figure 8 1 To keep dirt grass clippings etc out of the engine clean the area around the oil fill cap disptick before removing it Remove the oil drain plug and oil fill cap dipstick Be sure to allow ample time for complete drainage Reinstall the drain plug Make sure it is tightened to 13 6 N m 10 ft Ib torque Fill the crankcase with new oil of the proper type to the mark on the dipstick Refer to Oil Type on page 4 Always check the level with the dipstick before adding more oil Reinstall the oil fill cap or plug and tighten securely NOTE prevent extensive engine wear damage always maintain the proper oil level the crankcase Never operate the engine with the oil level below the L mark or over the F mark on the dipstick Oil Filter Figure 8 Oil Filter and Optional Oil Sentry Switch Change Oil Filter Replace the oil filter at least every other oil change every 200 hours of operation Always use a genuine Kohler oil filter Use chart below to determine part number to order _ Oil Filter Part No 52 050 02 S 3 3 8 Replace the oil filter as follows 1 Drain the oil from the engine crankcase 2 Allow the oil filter to drain Before r moving the oil filter clean the area around the oil filter to keep dirt and debris out of the engine Remove the old filter Wipe
40. in your engine warranty Check fluid levels as follows Engine Check oil level daily fill with seasonal grade oil as recommended in manufacturers manual provided Change oil per engine manufacturers recommendation Transmission Fill to check point with EP 90 gear oil change after first 50 hours of use then every 1000 hours or annually Final Drive Fill to check point with EP 90 gear oil change after first 50 hours of use then every 1000 hours or annually Hydraulic Reservoir Fill with cylinders retracted with 300SSU oil change oil after first 1000 hours of use then annually Recommended Hydraulic Oils Mobile Fluid 350 or 423 Shell Tellus 29 Sunoco Sunvis 831 WR Hydraulic Filter Replace with every oil change and every 750 hours or three months PAIR INSTRUCTIONS 206 WARNING Moving parts Keep all guards in place Shut down engine before service or maintenance Being caught in machinery may cause serious injury WARNING High pressure Leaking hydraulic fluid under pressure can penetrate and cause serious injury Check for leaks with card board Relieve pressure before working on any system Dog Plate Oil all members including dogs initially and then weekly when in continuous use light machine oil or spray lubricant is recommended It is also recommended that the dog plate be disas sembled and cleaned periodically especially after use in sticky clay conditions or sand Fuel Refer to engine
41. ling 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 Reinstall all components as described above When air cleaner element replacement is necessary order No 47 083 01 5 Clean Air Intake Cooling Areas 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 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 Ignition System This engine is equipped with a dependable electronic magneto ignition system Other than periodically checking replacing the spark plug 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 fortrouble analysis Check Spark Plug Every 200 hours of operation remove the spark plug check its condition and re
42. lling WARNING Do not modify this machine Use only authorized McLaughlin repair parts Failure to comply can result in serious injury Service this equipment according with maintenance instructions in this manual REASSEMBLY 8 Slide coupling half onto the pump shaft until it is the way to the back 9 Replace and tighten the set screw 10 Slide the other coupling half onto engine shaft but do not tighten 11 Replace rubber insert 12 Replace pump and tighten two 2 bolts and lockwashers 13 Slide other coupling half into rubber insert and tighten set screw Note gap 14 Replace pump guard 13 TRANSMISSION COUPLING REPLACEMENT DISASSEMBLY 1 Disconnect the battery 2 Remove the coupling guard 3 Drive out the master link pin in the chain 4 Remove the chain IF ONLY REPLACING THE CHAIN REFER TO NO 13 5 Loosen the set screws in the sprocket hubs Removal of the screw is not necessary 6 Remove the nine 9 nuts that bolt the planetary to the front plate 7 Slide the planetary forward until coupling half clears 8 Remove the coupling halves REASSEMBLY 9 Slide the coupling halves onto the shafts Make sure the sprocket is flush with the end of the shaft 10 Slide the planetary backward into its pilot 11 Tighten the nine 9 nuts that bolt the planetary to the front plate 12 Tighten the set screws in the sprocket hubs 13 Replace the chain 14
43. mp etc application engine speed and ambient operating conditions temperature humidity and altitude Kohler reserves the right to change product specifications designs and equipment without notice and without incurring obligation CH16 engine is equipped with SMART SPARK computerized ignition system LIMITED 2 YEAR ENGINE WARRANTY Kohler Co warrants to the original consumer that each new COMMAND engine sold by Kohler Co will be free from manufacturing defects in materials or workmanship in normal service for a period of two 2 years from date of purchase provided it is operated and maintained in accordance 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 2 years 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 unle
44. n other states 1997 and later model year engines are warranted for two years H any emission related part on the engine is defective the part will be repaired or replaced by Kohler Co free of charge OWNER S WARRANTY RESPONSIBILITIES a 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 schedufed maintenance was performed 5 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 Continued on next page 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 or access our web site at www kohlerengines com for the names of the nearest service centers The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days 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 reg
45. ne must be warm before doing steps 2 and 3 Low Idle Fuel Needle Setting Place the throttle into the idle or slow position Turn the low idle fuel adjusting needle out counterclockwise from the preliminary setting until engine speed decreases rich Note the position of the needle Now turn the adjusting needle in clockwise The engine speed may increase then it will decrease as the needle is turned in lean Note the position 3 Low Idle Speed Setting Place the throttle control into the idle or slow position Set the low idle speed to 1200 RPM 75 RPM by turning of the needle the low idle speed adjusting screw in or out Check the speed using a tachometer Set the adjusting needle midway between the rich and lean settings See Figure 14 NOTE The actual low idle speed depends on the application refer to equipment Lean manufacturer s recommendations The Adjustto Midpoint i Figure 14 Optimum Low Idle Fuel Setting recommended low idle speed for basic engines is 1200 RPM To ensure best results when setting the low idle fuel needle the low idle speed must not exceed 1200 RPM 75 RPN Troubleshooting When troubles occur be sure to check the simple causes which at first may seem to 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 servi
46. necting the negative ground cable make sure all switches are If ON a spark will occur at the ground cable terminal which could cause an explosion if hydrogen gas or gasoline vapors are present 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 Emission Regulations these engines with a Family identification number beginning with 6 or greater see Figure 12 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 KOHLER IMPORTANT ENGINE INFORMATION THIS ENGINE MEETS U S EPAAND CA 2005 AND LATER AND EC STAGE 1 SN 4 EMISSION REGS FOR SI SMALL OFF ROAD ENGINES FAMILY XS XXXXGC TYPE APP DISPL CC MODEL NO SPEC NO SERIAL BUILD DATE OEM PROD EMISSION COMPLIANCE PERIOD EPA CARB CERTIFIED ON REFERTO OWNER S MANUAL FOR HP RATING SAFETY MAINTENANCE AND ADJUSTMENTS 1 800 544 2444 www kohlerengines com KOHLER CO KOHLER WISCONSIN USA 11236 Figure 12 Family Number Location Reduction Gear Units On engines equipped with a reduction gear unit remove the oil plug on lower part of cover every 50 hours of operation to check oil level With the engine le
47. nter grade gasoline has higher volatility to improve starting Do not use gasoline left over from summer Starting 1 For a Cold Engine Place the throttle control midway between the slow and fast positions Place the choke control into the on position For a Warm Engine normal operating temperatures Place the throttle choke control midway between the slow and fast positions Place the choke into the on position See Figure 5 Figure 5 Throttle and Choke Positions for Starting Engine 2 Start the engine as follows For a Retractable Start Engine SLOWLY pull the starter handle until just past compression STOP Return starter handle pull firmly with a smooth steady motion to start Pull the handle straight out to avoid excessive rope wear from the starter rope guide Extend the starting rope periodically and check its condition if the rope is frayed have it replaced immediately by your Kohler Engine Service Dealer A WARNING Accidental Starts Before extending and checking the retractable starter rope remove the spark plug lead to prevent the engine from starting accidentally Make sure the equipment is in neutral For Electric Start Engine Activate the starter switch Release the switch as soon as the engine starts NOTE Do not crank the engine continuously for more than 10 seconds at a time If the engine does not start allow 60 second cool down period between starting attempts Failu
48. off the surface where the oil filter mounts 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 Apply a thin film of clean oil to the rubber gasket on the new filter Install the replacement filter to the filter adapter Turn the oil filter clockwise until the rubber gasket coniacts the filter adapter then tighten the filter an additional 3 4 to 1 turn Reinstall the drain plug Fill the crankcase with new oil of the proper type to the mark on the dipstick 9 Start the engine and check for oil leaks Correct any leaks before placing the engine into service Check oil level to be sure it is up to but not over the F mark 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 precleaner which surrounds the paper element See Figures 9 and 10 Air Cleaner Cover Element Figure 10 Air Elements Check the air cleaner daily or before starting the engine Check for a buildup dirt and debris around the air cleaner system Keep this area clean Also check for loose or damaged components Replace all bent or damaged air clean
49. ords covering the performance of regular maintenance be retained in case questions arise If the ngine 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 Normal maintenance replacement or repair of emission control devices and systems may be performed by any repair establishment or individual however warranty repairs must be performed by a Kohler authorized service center Any replacement part or service that is equivalent in performance and durability may be used in non warranty maintenance or sepairs and shall not reduce the warranty obligations of the engine manufacturer KOHLER Se ENGINES KohlerEngines com 50531 41986 U S AND CANADA CALL 1 800 544 2444 FOR SALES AND SERVICE INFORMATION HNW ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 5 5 TORQUE HUB 05090909 OOOO amp D PNA 2271 1177 VAG 217 lt 17 VIEW OF SHOULDER BOLTS 4 PLACES BORASSY015 TORQUE HUB McL 20 QTY PART DESCRIPTION 1 P301002 SPINDLE 1 P300003 SEAL
50. ount 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 ihumb is greatest Reinstall the plug but do not connect the plug lead Store the engine in a clean dry place Parts Ordering Model Designation The engine Model Specification and Serial Numbers Model CH15ST for example C designates Command are required when ordering replacement parts from your engine H designates horizontal crankshaft and 15 Kohler Engine Service Dealer These numbers are found designates horsepower letter suffix designates a on the identification plate which is affixed to the engine specific version as follows shrouding Include letter suffixes if there are any See Engine Identification Numbers on page 5 Suffix Designates s Electric Start Always insist on genuine Kohler parts genuine T Retractable Start Kohler parts meet strict standards for fit reliability and 5 Electric Retractable Start performance GT Generator Application Retractable Start GS Generator Application Electric Start Major Repair PT Pump Retractable Start Major repair information is available in Kohler Engine RT Gear Reduction Retractable Start Service Manuals This type of repair generally requires the services of a trained mechanic and the use of special tools and equipment Kohler Engine Service Dealers have the facilities training and genuine Kohler
51. portant 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 Explosive Fuel can cause fires and 3 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 approved containers in well ventilated unoccupied buildings away from sparks or flames Do not fill the fuel tank while the engine is hot or running since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition Do not start the engine near spilled fuel Never use gasoline as a cleaning agent Rotating Parts c se severe injury 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 A 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 WARNING Hot Parts can cause severe burns Do not touch engine while operating just after stopping Hot Parts Engine components can get
52. pressure of 5 PSI for 2 3 minutes 20 21 At this point the main assembly is complete RECORD McL 206 SERVICE PERFORMED Transmission Parts McL 20 7 VU 092109 BORASSY013 Transmission Parts McL 20C lt PART DESCRIPTION 2400186 SHIFT COVER CAP 2400187 SHIFT COVER 2400188 SCREW HHCS 312 18 X 875 2400189 LOCKWASHER 312 EXT TOOTHED 2400190 INTERLOCK PLATE 2400191 COUNTERSHAFT 2400192 THRUST WASHER 2400193 COUNTERSHAFT BEARING 2400194 COUNTERSHAFT SPACER 2400195 COUNTERSHAFT CLUSTER GEAR 2400196 MAINSHAFT 2400197 LOCKPLATE U000400 SCREW HCS 375 16 X 750 2400199 SHIFT RAIL 2400200 SHIFT FORK 2400201 DETENT BALL 2400202 DETENT SPRING 2400203 REVERSE IDLER SHAFT 2400204 REVERSE IDLER GEAR 2400205 BEARING 2400206 BEARING CASE SNAPRING 2400207 BEARING SPACER 2400208 MAINSHAFT RETAINER 2400209 MAINSHAFT OILSEAL 2400210 2nd amp 3rd SLIDING GEAR 2400211 151 amp REVERSE SLIDING GEAR AS REQ D 2400212 BEARING SHAFT SNAPRING 087 AS REQ D 2400213 BEARING SHAFT SNAPRING 090 AS REQ D 2400214 BEARING SHAFT SNAPRING 093 AS REQ D 2400215 BEARING SHAFT SNAPRING 097 1 2400216 BEARING SLINGER 1 2050136 CASE 14 2400218 MAIN DRIVE ROLLER 1 2050137 MAIN DRIVE GEAR 1 2400220 MAIN DRIVE OILSEAL 1 4 1 1 1 6 6 1 1 4 2 1 1 1 1 5 2 2 2 2 1 1 2 2 1 1 1 1 1 2400221 MAIN DRIVE
53. r 921 999 T700090 McL 6 Transmission Oil Fill Fill to check point with EP 90 gear oil Change after first 50 hours of use then every 1 000 hours or annually 7 Planetary Oil Fill Fill to check point with EP 90 gear oil Change after first 50 hours of use then every 1 000 hours or annually McL 20 BORASSY002 2 7 X 47 17 8 TAS VON OST DEN r 0 0 lt Carriage Assembly lt 082009 2011115 0130020 400040 2050115 0000400 0210060 0000810 0210100 2099006 2011144 0000020 2011140 0000440 0100060 0210060 2099035 0340045 2099034 0340045 W000075 2099017 8030689 0000040 U200020 U230040 U120100 DESCRIPTION BATTERY HOLD DOWN NUT WING 312 18 BATTERY SP 35 COUPLING GUARD SCREW 375 16 X 750 WASHER LOCK 375 SCREW 500 13 X 750 WASHER LOCK 500 CARRIAGE WELDMENT PUMP GUARD SCREW HC 250 20 X 500 HYD PUMP MOUNT BRACKET SCREW 375 16 X 1 25 NUT HEX 375 16 WASHER LOCK 375 PIN CLEVIS 745 X 4 9375 PIN R CLIP PIN L 500 X 4 5 PIN R CLIP 2 1 2 CAM ROLLER W 1 DIA STUD HOLD DOWN WELDMENT BOX PLASTIC for SAFETY MANUAL SCREW HC 250 20 X 75 WASHER FLAT 250 WASHER RUBBER 250 NUT LOCK 250 20 BORASSY002 y Plate Assembly McL 20C BORASSY00
54. re to follow these guidelines can burn out starter motor lt U L UUUUUUUUUULUUILLLLILUDGI E Upon start up a metallic ticking may occur This is caused by hydraulic lifter leakdown during storage Run the engine for 5 minutes The noise will normally cease in the first minute noise continues run the engine at mid throttle for 20 minutes If noise persists take the engine to your local Kohler Service outlet lf 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 If the starter is engaged while the flywheel is rotating the starter pinion and flywheel ring gear may clash resulting in damage to the starter lf the starter does not turn the engine over shut off starter immediately Do not make further attempts to start the engine until the condition is corrected Do not jump start using another battery refer to Battery See your Kohler Engine Service Dealer for trouble analysis For Cold Engine Gradually return the choke control to the off position after the engine starts and warms ups The engine equipment may be operated during the warm up period but it may be n
55. rs and dealers Service support is just a phone call away Call 1 800 544 2444 U S amp Canada for Sales amp Service assistance To keep your engine in top operating condition follow the maintenance procedures in this manual Oil Fill Dipstick Muffler Electric Starter Oil Drain Plug Oil Drain Plug Oil Filter Oil Drain Plug Figure 1 Typical Command Horizontal Shatt Engine 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 RECOMMENDED SAE VISCOSITY GRADES 10W 30 Kohler 10W 30 32 40 50 8 g 20 30 n TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANGE 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 Optional Air Cleaner Fuel Tank Fuel
56. rvice precleaner element Every 50 Hours Check gear reduction unit air cleaner element Every 100 Hours Change oil Remove cooling shrouds and clean cooling areas Change oil filter Every 200 Hours Check spark plug condition and gap Replace fuel filter Annually or Have bendix starter drive serviced Every 500 Hours Have solenoid shift starter disassembled and cleaned 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 Daily or Before Starting Engine Check Oil Level 4 Remove the dipstick and check the oil level The importance of checking and maintaining the proper oillevelin the crankcase cannot be overemphasized The oil level should be up to but not over the F Check oil BEFORE EACH USE as follows mark on the dipstick See Figure 7 1 Make sure the engine is stopped level and is cool so the oil has had time to drain into the sump To keep dirt grass clippings etc out of the F Mark engine clean the area around the oil fill cap d dipstick before removing it Operating Range Remove oil fill cap dipstick wipe oil off 55 For engines with press on style dipstick Reinsert the dipstick into the tube and press onto the tube See Figure 6 9 Figure 7
57. set the gap or replace with a new plug as necessary The standard spark plug is a Champion RC12YC Kohler Part No 12 132 02 5 high performance spark plug Champion Platinum 3071 used on Pro Series engines Kohler Part No 25 132 12 5 also available 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 Remove the plug and check its condition Replace the plug if worn or reuse is questionable NOTE Do not clean the spark plug in a machine using abrasive grit Some grit could remain in the spark plug and enter the engine causing extensive wear and damage Check the gap using a wire feeler gauge Adjust the gap by carefully bending the ground electrode See Figure 11 Gap CH11 15 plugs to 1 02 mm 0 040 in Gap CH16 plugs to 0 76 mm 0 030 in Wire Gauge Ground Electrode Figure 11 Servicing Spark Plug 4 Reinstall the spark plug into the cylinder head Torque the spark plug to 38 0 43 4 N m 28 32 ft Ib Battery Charging A WARNING 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 discon
58. ss supplied or installed by Kohler Co These are subject to the warranties if any of their manufacturers KOHLER CO AND OR THE SELLER 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 IMPLIED OR STATUTORY WARRANTIES INCLUDING WARRANTIES 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 on our behalf Some states do not allow limitations on how long an implied warranty lasts or the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state TO OBTAIN WARRANTY SERVICE Purchaser must bring the engine to an authorized Kohler service facility To the nearest facility visit our website www kohler ngines com and click on SALES AND SERVICES 10 the locator function consult your Yellow Pages or telephone 1 800 544 2444 ENGINE DIVISION WISCONSIN 53044 KOHLER FEDERAL AND CALIFORNIA EMISSION CONTROL SYSTEMS LIMITED WARRANTY SMALL OFF ROAD ENGINES The U S Environmental Protection Agency EPA
59. turn authorized numbers expire 30 days after issue After this time warranty claims and material re turns are void and merchandise must be paid in full 8 McLaughlin must be notified and authorize all war ranty work performed by your service personnel This authorization must be obtained PRIOR to any work be ing performed for proper warranty consideration Credit will not be issued for unauthorized service work per formed
60. u install O ring 11 Place cover 6 on work surface interior side up Grease and place O ring 5 into the counterbore around rim of cover 6 NOTE O rings may be stretched to fit counterbore If an O ring has been stretched too much simply squeeze the O ring together bit by bit as you place it around the counterbore It be made to fit exactly 12 Grease and place thrust washer 11 around edge of raised circular center of cover 6 11 12 13 Lower cover 6 interior side down onto ring gear 4 aligning the bolt holes in cover and ring gear See you assembly print for pipe plug timing 14 Place shoulder bolts 13 into their holes in cover 6 and tighten by hand 15 Place bolts 12 into their holes in cover 6 and tighten 16 Apply 23 27 ft Ibs of torque to each shoulder bolt 13 17 Apply 23 27 ft Ibs of torque to each bolt 12 18 Apply light coat of Never Seize to pipe plug 20 and install it into the pipe plug hole in cover 6 13 14 15 16 18 19 Roll test the unit in both clockwise and counterclockwise directions the same number of turns in each direction as the ratio of the unit This number is the same as the last two digits in the model number found on the ID tag of the unit For example if the model number of this unit is S1B1003369 then roll the unit 69 times in each direction 19 20 Lead test the unit at a
61. uel 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 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 including E20 and E85 are not to be used and not approved Any failures resulting from use of these fuels will not be warranted 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 eiher 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 t
62. ulations 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 2006 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 K hler at no cost to the owner Kohler Co is liable for damages to other engine components caused by failure 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 to the extent they were present in the engine purchased Oxygen sensor if equipped Ignition module s with high tension lead Intake ma ifold if
63. vel the oil level of the unit should be up to the bottom of the oit plug hole To add oil remove the vented plug at the top of the unit Use AGMA No 7 EP oil in the reduction gear unit Following are a few products that meet this spec Mobilgear 634 Pennzoil Super Maxol S Pennzoil Maxol EP Gear Oil Pennzoil Super Maxol EP Gear Oil Pennzoil Super Pennztac EP Gear Oil Carburetor Troubleshooting Adjustments NOTE Carburetor adjustments should be made only after the engine has warmed up These engines are equipped with one of two basic types of fixed jet carburetors Walbro or Nikki The carburetor is designed to deliver the correct fuel io air mixture to the engine under all operating conditions On both types of carburetors the fixed main jet is calibrated at the factory and is not adjustable On Walbro carburetors the low idle fuel adjusting needle is set at the factory and normally does not need adjustment Certified engines may have a fixed idle or limiter cap on the idle fuel adjusting needle The idle fuel can only be adjusted within the limits allowed by the cap Nikki carburetors have a sealed idle fuel adjusting needle which is not adjustable Walbro Low Idie Speed Adj Low Idle Fuel Adj Needie Low Idle Speed Adj Figure 13 Carburetors 12 NOTE To ensure correct engine operation at altitudes above 1525 meters 5000 ft it may be necessary to have an authorized Kohler dealer
64. while coupled to loaded augers Boring with an extended clutch apply time will cause premature failure of the clutch Hydraulic Fluid Use the alternate hydraulic fluid for the following To reduce warm up time before boring When consistently boring in cold weather Standard hydraulic fluid Iso grade 46 with anti wear additives 76 Unax AW 46 or equivalent Alternate hydraulic fluid Iso grade 32 Wide Temperature Range oil with anti wear additives 76 Unax AW WR 32 or equivalent Consult McLaughlin Mfg Co for more information PAIR INSTRUCTIONS 206 WARNING Moving parts Keep all guards in place Shut down engine before service or maintenance Being caught in machinery may cause serious injury WARNING High pressure Leaking hydraulic fluid under pressure can penetrate and cause serious injury Check for leaks with cardboard Relieve pressure before working on any system HYDRAULIC PUMP COUPLING REPLACEMENT DISASSEMBLY 1 Remove the pump guard 2 Remove the tow 2 bolts and lockwashers that attach the pump to the pump mount 3 Slide the pump and coupling half out of the pump mount 4 Remove old rubber insert IF ONLY REPLACING THE INSERT REFER TO 11 5 Loosen the screw in the coupling half 6 Slide coupling off shaft 7 Use same method for other coupling half WARNING Crushing weight can cause serious injury Place machine on solid surface to prevent rollover or fa

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