Kohler Courage SV470 User's Manual
Contents
1. or using dirty oil causes premature engine wear and failure Cil 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 Kohler 10W 30 F 20 0 C 30 do do L ii I L TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANG 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 NOTE Synthetic oils meeting the listed classifications may be used with oil changes performed at the recommended intervals However to allow piston rings to properly seat a new or rebuilt engine should be operated for at least 50 hours using standard petroleum based oil before switching to synthetic oil A logo or symbol on oil containers identifies the API service class and SAE viscosity grade See Figure 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 f2. 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 In other states 1997 and later model year engines are warranted for two years If 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 The engine owner is responsible for the performance of the required maintenance listed in the owner s manual Kohler recommends tha
3. FOR AFTERTREATMENT FAMILY TYPE APP DISPL CC MODEL NO 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 KohlerEngines com KOHLER CO KOHLER WISCONSIN USA Q6 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 EPA Category Category Category 250 Hours 500 Hours 1000 Hours CARB Moderate Intermediate Extended 125 Hours 250 Hours 500 Hours Refer to certification label for engine displacement Exhaust Emission Control System for models 5 470 5 620 is EM U S EPA and Europe PAIR for California Tier III Specifications Modelis e 5 470 SV480 5 530 SV540 BOG eene mm in 94 94 8 7 94 3 7 94 3 7 mm in 86 3 4 86 3 4 86 3 4 86 3 4 Displacement eu 597
4. exceed 1500 RPM 75 RPM 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 of the needle Set the adjusting needle midway between the rich and lean settings See Figure 15 Troubleshooting When troubles occur be sure to check the simple causes which at first may seem too obvious to be considered For example a starting problem could be caused by an empty fuel tank Some common causes of engine troubles are listed in the following table Adjust to Laan Midpoint Do not attempt to service or replace major engine components or any items that require special timing or adjustment procedures Have your Kohler Engine Service Dealer do this work Figure 15 Optimum Low Idle Fuel Setting Possible Cause No Improper Dirt In Dirty Incorrect Engine Dirty Air Faulty Problem Fuel Fuel FuelLine Grass Screen Oil Level Overloaded Cleaner Spark Plug Will Not Start Hard Starting Stops Suddenly Lacks Power Operates Erratically Knocks or Pings Skips Misfires Backfires Overheats High Fuel Consumption Storage If the engine will be out of service for two months or more use the following storage procedure To empty the system run the engine until the tank and system are empty 4 Due
5. 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 oil filter to the mounting pad Turn the oil filter until the rubber gasket contacts the pad then tighten the filter an additional 3 4 to 1 turn 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 Mipstick and push firmly into place Test run the engine to check for leaks Stop the engine allow a minute for the oil to drain down and recheck the level on the dipstick Add more oil as necessary so the oil level is up to but not over the mark on the dipstick NOTE To prevent extensive engine wear or damage always maintain the proper oil level in the crankcase Never operate the engine with the oil level below the L mark or over the F mark on the dipstick Service Precleaner and Air Cleaner Element This engine is equipped with a replaceable high density paper air cleaner element Some engines are also equipped with an oiled foam precleaner located in the outer air cleaner cover See Figure 9 Check the air cleaner daily or before starting the engine Check for a buildup of dirt and debris around the air cleaner system Keep this area clean Also check for loose or damaged components Rep
6. residential use by a retail consumer Commercial use means all other uses including use for commercial or rental purposes Once in commercial use the engine will thereafter be considered a commercial use engine for the purposes of this warranty 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 90 days from date of purchase This warranty does not apply to defects caused by casualty or unreasonable use including faulty repairs by others and failure to provide reasonable and necessary maintenance The following items are not covered by this warranty Engine accessories such as fuel tanks clutches transmissions power drive assemblies and batteries unless supplied or installed by Kohler Co These are subject to the warranties if any of their manufacturers 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 DURA
7. to the deep recess around the spark plug blow out the cavity with compressed air Remove the spark plug The spark plug is most accessible when the blower housing is removed for cleaning 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 Filter on page 9 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 Connect the plug lead 3 The fuel system must be completely emptied or the gasoline must be treated with a stabilizer to prevent deterioration If you choose to use a stabilizer follow the manufacturers recommendations and add the correct amount 5 Reinstall the blower housing if removed for the capacity of the fuel system Fill the fuel previously and torque the blower housing tank with clean fresh gasoline Run the engine for screws to 7 5 N m 65 in Ib 2 3 minutes to get stabilized fuel into the carburetor 6 Store the engine in a clean dry place 13 Parts Ordering The engine Model Specification and Serial Numbers are required when ordering replacement parts from your Kohler Engine Service Dealer These numbers are found on the identification plate which is affixed to the engine shrouding Include letter suffixes if there are any See Engine Identification Numbers on page 5 Always insist on genuine Kohler parts All g
8. working on the engine or equipment disable the engine as follows 1 Disconnect the spark plug lead s 2 Disconnect negative battery cable from battery Maintenance Schedule These required maintenance procedures should be performed at the frequency stated in the table They should also be included as part of any seasonal tune up 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 2 Months Service precleaner element if equipped or 25 Hours Service air cleaner element if not equipped with precleaner Replace air cleaner element if equipped with precleaner Change oil and filter refer to Viscosity Table Page 4 based on seasonal temperatures Remove blower housing and clean cooling areas Check that all fasteners are in place and components are properly secured Replace fuel filter Every 2 Years or Check spark plug condition and gap 200 Hours Have bendix starter drive serviced Every 200 Hours i e Have valve lash checked Adjusted Daily or Before Starting Engine Annually or Every 100 Hours Every 200 to 400 Hours Clean combustion chamber Every 500 Hours Replace spark plug Perform these maintenance procedures more frequently under extremely dusty dirty conditions Have a Kohler Engine Service Dealer perform this service Check Oil Level The importance of check
9. 36 4 597 36 4 597 36 4 597 36 4 Power at 3600 RPM kW HP 11 2 I5 s 11 9 16 12 75 75 Sca 13 4 18 Compression me Por E 8 5 1 ke 1b nnn 235 9 79 Lotes 32 8 79 995 9 79 Gon 35 8 79 Oil Capacity U S qt 1 5 1 6 2 2 1 5 L6 atte 1 5 1 6 e 1 5 1 6 Lubrication mmm mmm mere meer Full Pressure w Full Flow Filter Model iiis SV 600 ciens SVOLTO ie SV620 Bore iicet mm in 94 3 7 iic 94 3 7 scents 94 3 7 cem 94 3 7 Stroke eee mm in 86 3 4 86 3 4 86 3 4 86 3 4 Displacement cc eu 3n us 597 36 4 597 36 4 597 36 4 597 36 4 Power at 3600 RPM kW HP 14 2 19 14 9 20 157 219 16 4 22 Compression stes ood s tuos 8 51 kg Ib 95 8 9 95 8 79 5e cene 925 8 79 ets 35 8 79 Oil Capacity w filter L U S qt 1 5 126 iu 1 5 1 6 1 5 146 5e 1 5 1 6 Lubrication rmm mmm mmm m meon Full Pressure w Full Flow Filter Horsepower ratings exceed Society of Automotive Engineers Small Engine Test Co
10. Due to the deep recess around the spark plug blowing out the cavity with compressed air is usually the most effective method for cleaning The spark plug is most accessible when the blower housing is removed for cleaning 2 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 3 Check the gap using a wire feeler gauge Adjust the gap by carefully bending the ground electrode See Figure 12 Gap plugs to 0 76 mm 0 030 in 4 Reinstall the spark plug into the cylinder head Torque the spark plug to 24 30 N m 18 22 ft Ib 5 Reconnect the spark plug lead and reinstall the blower housing if removed previously Torque the blower housing screws to 7 5 65 in Ib Wire Gauge Spark Plug 0 76 mm 0 030 in Electrode Gap Figure 12 Servicing Spark Plug Battery Charging 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 disconnecting the negative ground cable make sure all switches are OFF I
11. Owner s MANUAL KOHLER COURAGE 5 470 620 VERTICAL CRANKSHAFT KOHLER ENGINES Safety Precautions To ensure safe operation 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 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 Your Safety These precautions should be followed at all times Failure to follow these precautions could result in injury to yourself and others WARNING Rotating Parts can cause severe injury WARNING WARNING 4 Saas Explosive Fuel can cause fires and Hot Parts can cause severe burns severe burns Do not touch engine while operating Do not fill the fuel tank while the engine is hot or running Explosive Fuel Gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only in approved containers in well ventilated unoccupied buildings away from
12. RE EACH USE and is maintained up to the mark on the dipstick This includes engines equipped with Oil Sentry Change and Filter Change the oil and oil filter annually or 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 and filter while the engine is still warm The oil will flow more freely and carry away more impurities Make sure the engine is level when filling checking or changing the oil Always use a genuine Kohler oil filter Use chart below to determine part number to order Cil Filter Part No Length 12050 01 S 2 1 2 52 050 02 5 3 3 8 Change the oil and oil filter as follows see Figure 8 1 To keep dirt grass clippings etc out of the engine clean the area around the oil fill cap dipstick before removing it 10 Figure 8 Drain Plug Cil Filter and Optional Cil Sentry Switch Remove the oil drain plug and oil fill cap dipstick Be sure to allow ample time for complete drainage Remove the old filter and wipe off the mounting pad Reinstall the drain plug Make sure it is tightened to 14 N m 125 in Ib torque Place the 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
13. TION 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 locate the nearest facility visit our website www kohlerengines com and click on DEALER LOCATOR to use the locator function consult your Yellow Pages or telephone 1 800 544 2444 ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 With the exception of countries governed by the European Union EU where a one 1 year warranty is required for commercial professional use 14 FEDERAL AND CALIFORNIA EMISSION CONTROL SYSTEMS LIMITED WARRANTY SMALL OFF ROAD ENGINES The U S Environmental Protection Agency EPA the California Air Resources Board CARB and Kohler Co are pleased to explain the Federal and California Emission Control Systems Warranty on your small off road equipment engine In California beginning in 2006 emissions means both exhaust and evaporative emissions For California engines produced in 2006 and later must be designed built and equipped to meet the state
14. arburetor 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 These 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 engine must be warm before doing steps 2 and 3 2 Low Idle Fuel Needle Setting Place 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 3 Low Idle Speed Setting Place the throttle control into the idle or slow position Set the low idle speed to 1500 RPM 75 RPM by turning the low idle speed adjusting screw in or out Check the speed using a tachometer NOTE The actual low idle speed depends on the application refer to equipment manufacturer s recommendations The recommended low idle speed for basic engines is 1500 RPM To ensure best results when setting the low idle fuel needle the low idle speed must not
15. buretors have a low idle speed adjustment screw and either a fixed or low idle fuel adjusting needle with a limiter cap Low Idle Speed Adjusting Screw Low Idle Fuel Adjusting Needle with Limiter Figure 14 Carburetor 12 The carburetor is designed to deliver the correct fuel to air mixture to the engine under all operating conditions The main fuel jet is calibrated at the factory and is not adjustable The low idle fuel adjusting needle is also set at the factory and normally does not need adjustment NOTE ensure correct engine operation at altitudes above 1525 meters 5000 ft it may be necessary to have an authorized Kohler dealer 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 it is operating properly e Ifthe fuel tank is equipped with a shut off valve make sure it is open e Ifthe 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 c
16. d to first scheduled replacement point Crankcase breather Evaporative System if equipped Air Injection System if equipped Canister if equipped Air pump or pulse valve assembly if equipped Canister filter if equipped Control distribution valve if equipped Vapor hose if equipped Distribution manifold if equipped Orifice connector if equipped Air hoses if equipped Fuel tank if equipped Vacuum lines if equipped Fuel cap if equipped Primer bulb canister if equipped LIMITATIONS This Emission Control Systems Warranty shall not cover any of the following a 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 c consequential damages such as loss of time inconvenience loss of use of the engine or equipment etc d diagnosis and inspection fees that do not result in eligible warranty service being performed and e 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 u
17. de J1940 Actual engine horsepower is lower and affected by but not limited to accessories air cleaner exhaust charging cooling fuel pump 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 Operating Instructions Also read the operating instructions of the equipment this engine powers Pre Start Checklist 3 A warm battery has much more starting Check oil level Add oil if low Do not overfill capacity than a cold battery Check fuel level Add fuel if low 4 Use fresh winter grade fuel NOTE Winter grade gasoline has higher volatility to improve Check cooling air intake areas and external starting Do not use gasoline left over from surfaces of engine Make sure they are clean and summer unobstructed Starting Check that the air cleaner components and all 1 a Fora Single Lever Throttle Choke Control shrouds equipment covers and guards are in Place the lever into fast choke on position place and securely fastened See Figure 5 Check that any clutches or transmissions are b For Separate Levers Place the throttle disengaged or placed in neutral This is especially control midway between the slow and important on equipment with hydrostatic drive fast positions Place the choke control into The shift lever must be exactly in neut
18. enuine Kohler parts meet strict standards for fit reliability and performance Model Designation Model 5 5305 for example S designates Courage engine V designates vertical crankshaft and 530 is the model designation A letter suffix designates a specific version as follows Suffix Designates 5 Electric Start COURAGE ENGINE LIMITED WARRANTY Kohler Co warrants to the original retail consumer that each new COURAGE engine sold by Kohler Co will be free from manufacturing defects in materials or workmanship in normal residential homeowner service for a period of two 2 years from date of purchase provided it is operated and maintained in accordance with Kohler 5 instructions and manuals If used commercially the COURAGE engine is covered by a 90 day limited warranty Major Repair Major repair information is available in Kohler Engine 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 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 The warranty period begins on the date of purchase by the original retail consumer or commercial end user Residential homeowner service means
19. f ON a spark will occur at the ground cable terminal which could cause an explosion if hydrogen gas or gasoline vapors are present 11 Fuel Filter Some engines are equipped with an in line fuel filter Periodically inspect the filter and replace when dirty Replacement is recommended annually or every 100 hours Use a genuine Kohler filter Fuel Line In compliance with CARB Tier Emission Regulations engines with a Family identification number beginning with 6 or greater see Figure 13 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 II SN 4 EMISSION REGS FOR SI SMALL OFF ROAD ENGINES S 6 KHXS XXXXGB FAMILY TYPE APP DISPL CC MODEL NO 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 N11236 Figure 13 Family Number Location Carburetor Troubleshooting and Adjustments NOTE Carburetor adjustments should be made only after the engine has warmed up These engines are equipped with a Walbro fixed main jet carburetor See Figure 14 Walbro car
20. he precleaner if so equipped service as required See Figure 9 2 Remove the air cleaner element with the integral rubber seal See Figure 10 Air Cleaner Element with Rubber Seal Figure 10 Removing Air Cleaner Element 3 Gently tap the pleated side of the paper element to dislodge dirt Do not wash the paper element or use pressurized air as this will damage the element Replace a dirty bent or damaged element with a genuine Kohler element Handle new elements carefully do not use if the rubber seal is damaged 4 Clean all air cleaner components of any accumulated dirt or foreign material Prevent any dirt from entering the throat of carburetor 5 Install the air cleaner element with the pleated side out and seat the rubber seal onto the edges of the air cleaner base See Figure 11 6 Reinstall the precleaner if so equipped into the upper section of the air cleaner cover Make sure the hole in precleaner is aligned with the upper mounting knob See Figure 9 7 Reinstall the air cleaner cover and secure with the two knobs See Figure 9 8 When element replacement is necessary order Kohler Part No 20 083 02 S Figure 11 Installing Air Cleaner Element 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 Annually or every 100 hours of operation more often under extremel
21. ing and maintaining the proper oil level in the crankcase cannot be overemphasized Check oil BEFORE EACH USE as follows 1 Make sure the engine is stopped level and is cool so the oil has had time to drain into the sump 2 To keep dirt grass clippings etc out of the engine clean the area around the oil fill cap dipstick before removing it Figure 6 Checking Oil Level 3 Pull and remove the oil fill cap Mipstick wipe oil off Reinsert the dipstick and push firmly into place See Figure 6 4 Remove the dipstick and check the oil level The oil level should be up to but not over the mark on the dipstick See Figure 7 Mark Operating Range Figure 7 Oil Level Dipstick 5 If the level is low add oil of the proper type up to the F mark on the dipstick Refer to Oil Type on page 4 Always check the level with the dipstick before adding more oil NOTE To prevent extensive engine wear or damage always maintain the proper oil level in the crankcase Never operate the engine with the oil level below the L mark or over the F mark on the dipstick Oil Sentry Some engines are equipped with an optional Oil Sentry oil pressure switch See Figure 8 If the oil pressure decreases below an acceptable level the Oil Sentry will either activate a warning signal or shut off the engine depending on the application NOTE Make sure the oil level is checked BEFO
22. lace all bent or damaged air cleaner components NOTE Operating the engine with loose or damaged air cleaner components could allow unfiltered air into the engine causing premature wear and failure Cover Air Cleaner Element Air Cleaner Cover Figure 9 Air Cleaner Assembly Details Service Precleaner If so equipped wash and reoil the precleaner every two months or every 25 hours of operation more often under extremely dusty or dirty conditions 1 Loosen the air cleaner cover knobs and remove the cover See Figure 9 2 Remove the precleaner 3 Wash the precleaner in warm water with detergent Rinse the precleaner thoroughly until all traces of detergent are eliminated Squeeze out excess water do not wring Allow the precleaner to air dry 4 Saturate the precleaner with new engine oil Squeeze out all excess oil 5 Reinstall the precleaner into the upper section of the air cleaner cover Make sure hole in precleaner is aligned with the upper mounting knob 6 Reinstall the air cleaner cover and secure with the two knobs 7 When precleaner replacement is necessary order genuine Kohler Part No 20 083 03 S Service Paper Element Check the paper element every two months or every 25 hours of operation more often under extremely dusty or dirty conditions Clean or replace the element as necessary Replace the air cleaner element annually or every 100 hours 1 Remove the air cleaner cover and t
23. lammable and its vapors can explode if ignited Store gasoline only in approved containers in well ventilated unoccupied buildings away from sparks or flames Do not fill the fuel tank while the engine is hot or running since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition Do not start the engine near spilled fuel Never use gasoline as a cleaning agent General Recommendations Purchase gasoline in small quantities and store in clean approved containers A container with a capacity of 2 gallons or less with a pouring spout is recommended Such a container is easier to handle and helps eliminate spillage during refueling Do not use gasoline left over from the previous season to minimize gum deposits in your fuel system and to ensure easy starting Do not add oil to the gasoline Do not overfill the fuel tank Leave room for the fuel to expand 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 heads may require more frequent service Gasoline Alcohol blends Gasohol up to 10 ethyl alcohol 90 unleaded gasoline by
24. le dependability you can count on Here are some reasons why Efficient twin cam overhead valve design with full pressure lubrication provides maximum power torque and reliability under all operating conditions Dependable maintenance free electronic ignition ensures fast easy starts time after time A reciprocating balance system ensures smooth running and low vibration Kohler engines are easy to service All routine service areas like the dipstick and oil fill air cleaner and carburetor are easily and quickly accessible Parts subject to the most wear and tear like the cylinder liner are made from precision formulated cast iron for longer life 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 amp Canada for Sales amp Service assistance Or visit www KohlerEngines com To keep your engine in top operating condition follow the maintenance procedures in this manual Blower Housing Oil Fill Dipstick Main Control Bracket Ss Oil Filter Air Cleaner Oil Drain Plug Blower Housing Carburetor Electric Starter Engine Identification Label Figure 1 Typical COURAGE Series Vertical Shaft 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
25. ne as follows 1 Disconnect the spark plug lead s 2 Disconnect negative battery cable from battery Safety Precautions Cont WARNING Carbon Monoxide can cause severe nausea fainting or death Avoid inhaling exhaust fumes and never run the engine in a closed building or confined area Lethal Exhaust Gases Engine exhaust gases contain poisonous carbon monoxide Carbon monoxide is odorless colorless and can cause death if inhaled Avoid inhaling exhaust fumes and never run the engine in a closed building or confined area 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 single cylinder air cooled engine Kohler designs long life strength and on the job durability into each engine making a Kohler engine dependab
26. orrected Do not jump start using another battery refer to Battery See your Kohler Engine Service Dealer for trouble analysis 4 For Operation after the engine starts a Fora Single Lever Throttle Choke Control Move the lever from the fast choke on position and set the desired engine operating speed between the slow and fast position b For Separate Levers Gradually move the choke control to the off position If the engine is warm the choke control can be returned to the off position as soon as the engine starts If the engine is cold it may be operated during the warm up period but it may be necessary to leave the choke partially on until the engine warms up Stopping 1 Remove the load by disengaging all PTO attachments 2 a For engines without a shutdown solenoid Move the throttle to the slow or low idle position Allow the engine to run at idle for 30 60 seconds then stop the engine b For engines equipped with a shutdown solenoid Position the throttle control 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 If the battery charge is not sufficient to crank the engine recharge the battery see page 11 Operating Angle of Operation This engine will operate continuously at angles up to 25 Check oil level to assure crankcase oil level is a
27. ral to the on position 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 closed building or confined area Cold Weather Starting Hints 1 Be sure to use the proper oil for the temperature expected See Figure 2 on page 4 Figure 5 Throttle Position for Starting Engine with 2 Declutch all possible external loads Single Lever Control 2 Make sure equipment is in neutral 3 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 a 60 second cool down period between starting attempts Failure to follow these guidelines can burn out the starter motor NOTE Ifthe 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 If the starter does not turn the engine over shut off starter immediately Do not make further attempts to start the engine until the condition is c
28. s in all other states These warranty periods will begin on the date the engine is purchased by the initial purchaser If any emission related part on the engine is defective the part will be replaced by Kohler Co at no cost to the owner Kohler Co is liable for damages to other engine components caused by the failure of a warranted part still under warranty Kohler Co shall remedy warranty defects at any authorized Kohler Co engine dealer or warranty station Warranty repair work done at an authorized dealer or warranty station shall be free of charge to the owner if such work determines that a warranted part is defective Continued on next page 15 Listed below are parts covered by 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 include the following if they were present in the engine purchased Oxygen sensor if equipped Ignition module s with high tension lead Intake manifold if equipped Gaseous fuel regulator if equipped Exhaust manifold if equipped Electronic control unit if equipped Catalytic muffler if equipped Carburetor or fuel injection system Thermal reactor muffler if equipped Fuel metering valve if equipped Fuel lines fuel line fittings and clamps if equipped Air filter fuel filter and spark plugs only Spark advance module if equippe
29. se and maintenance of the engine Kohler Co recommends that all receipts and records covering the performance of regular maintenance be retained in case questions arise If the engine is resold during the warranty period the maintenance records should be transferred to each subsequent owner Kohler Co reserves the right to deny warranty coverage if the engine has not been properly maintained however Kohler Co may not deny warranty repairs solely because of the lack of repair maintenance or failure to keep maintenance records 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 repairs and shall not reduce the warranty obligations of the engine manufacturer FORMNO 20 590 01 B ISSUED 11 04 REVISED 3 09 NGI N ES LITHO IN U S A INUS AND CANADA CALL 1 800 544 244 IN U S AND CANADA CALL 1 800 544 2444 1P20 590 01 ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 6 50531 66675 8 KohlerEngines com
30. 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 Stay away while engine is in operation Rotating Parts Keep hands feet hair and clothing away fromall moving parts to prevent injury Never operate the engine with covers shrouds or guards removed CAUTION L 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 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 defects or other reproductive harm WARNING a5 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 engi
31. t the mark on the dipstick 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 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 operate 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
32. t you retain all receipts covering maintenance on the engine But Kohler Co cannot deny warranty solely for the lack of receipts or for your failure to assure that all scheduled maintenance was performed Be aware however that Kohler Co may deny warranty coverage if the engine or a part has failed due to abuse neglect improper maintenance or unapproved modifications 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 regulations Kohler Co also warrants to the initial purchaser and each subsequent purchaser that the engine is free from defects in materials and workmanship which cause the engine to fail to conform with applicable regulations for a period of two years Engines produced in 2006 or later are warranted for two years in California For 1997 and later model years EPA requires manufacturers to warrant engines for two year
33. 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 engine Other gasoline ther 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 KOHLER IMPORTANT ENGINE INFORMATION THIS ENGINE MEETS U S EPA PH2 AND EC STAGE II SN 4 EMISSION REGS FOR SI SORE NOT FOR SALE IN CALIFORNIA UNLESS PREEMPT PER SEC 209 e 1 OF CAA FAMILY TYPE APP DISPL CC MODEL NO 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 KohlerEngines com KOHLER CO KOHLER WISCONSIN USA KOHLER IMPORTANT ENGINE INFORMATION THIS ENGINE MEETS U S EPAPH2 AND CA 2008 AND LATER EXH EMISSION REGS FOR SI SORE USING DELEGATED ASSEMBLY
34. y dusty dirty conditions remove the blower housing and any other cooling shrouds Clean the cooling fins and external surfaces as necessary Make sure the cooling shrouds are reinstalled Torque the blower housing screws to 7 5 N m 65 in Ib 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 CD 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 plug see your Kohler Engine Service Dealer for trouble analysis Check Spark Plug Every 2 years or 200 hours of operation remove the spark plug check condition and reset 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 RFI compliant engines use a Champion QC12YC Kohler Part No 20 132 02 5 spark plug A high performance spark plug Champion Platinum 3071 Kohler Part No 25 132 12 5 is also available Equivalent alternate brand plugs can also be used Spark plug replacement is recommended at 500 hours 1 Before removing the spark plug clean the area around the base of the plug to keep dirt and debris out of the engine
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