Kohler Courage SH265 User's Manual
Contents
1. Intake manifold if equipped Fuel lines fuel line fittings and clamps if equipped Fuel metering valve if equipped Exhaust manifold if equipped Air injection system if equipped Catalytic muffler if equipped Air pump or pulse valve assembly if equipped Control distribution valve if equipped Distribution manifold if equipped Air hoses if equipped Vacuum lines if equipped Thermal reactor muffler if equipped Spark advance module if equipped Air filter fuel filter and spark plugs only to first scheduled replacement point Evaporative system if equipped Crankcase breather Ignition module s with high tension lead Gaseous fuel regulator if equipped Electronic control unit if equipped Carburetor or fuel injection system if equipped Canister if equipped Canister filter if equipped Vapor hose if equipped Orifice connector if equipped Fuel tank if equipped Fuel cap if equipped Primer bulb canister if equipped LIMITATIONS This Emission Control System Warranty shall not cover any of the following a Repair or replacement required because of misuse or neglect improper maintenance improper repairs 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 b Replacement of parts and other services and adjustments necessary for required ma2. 11 09 ENGINES FOR SALES AND SERVICE INFORMATION 1P18 590 02 U S AND CANADA CALL 1 800 544 2444 KohlerEngines com 6 50531 9288 1 ENGINE DIVISION KOHLER KOHLER WISCONSIN 53044
3. Cooling Areas To ensure proper cooling make sure the recoil starter screen cooling fins and other external surfaces of the engine are kept clean at all times NOTE Operating the engine with a blocked screen dirty or plugged cooling fins and or cooling shrouds removed will cause engine damage due to over heating Check Air Cleaner See Figure 1 This engine is equipped with either a replaceable high density paper air cleaner element In addition an optional foam precleaner may also be included Check the air cleaner A for a buildup of dirt and debris daily or before starting the engine Keep the area in and around the air cleaner clean Also check for loose or damaged components Replace all worn 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 Pre Start Checklist 1 Check oil level if low add oil Do not overfill Refer to Check Oil Level NOTE Engines are shipped without oil Do not start engine with low or no oil This will cause damage to the engine and will not be covered under warranty Check fuel level if low add fuel Do not overfill Check cooling areas air intake areas and external surfaces of engine Make sure they are clean and unobstructed 4 Check that the air cleaner components and all shrouds equipment covers and guards are in place and securel
4. Kohler Engine Service Center These numbers are found on the identification plate which is affixed to the engine shrouding Include letter suffixes if there are any Refer to Engine Identification Numbers Always insist on genuine Kohler replacement parts as they adhere to strict standards for fit reliability and performance Visit KohlerEngines com or your Kohler Engine Service Center Engine Identification Numbers See Figures 1 and 22 Engine identification numbers will appear on one of several variations of labels affixed to the engine Figure 22 See Figure 1 for Engine Identification Label location H When ordering parts or in any communication concerning this engine always give the model name specification number and serial number including any letter suffixes Record all engine ID numbers for future reference Serial Number and Spec Number See Figures 21 and 22 The spec number A and serial number is etched into the engine block directly below the fuel tank When ordering parts or in any communication always provide model specification number A and serial number B Record these numbers for future reference See Figure 21 Additional engine identification numbers can be found on the engine ID labels See Figure 22 Emission Compliance See Figure 22 The Emission Compliance Period referred to on the Emission Control or Air Index label indicates the number of operating hours for
5. air cleaner element Change oil after first 5 hours then yearly or 100 hours Clean cooling areas Clean spark arrestor if equipped Clean or replace spark plug and set gap Clean fuel valve cup Replace fuel filter if equipped Check and adjust valve clearance when engine is cold Service starter motor drive if equipped Have combustion chamber decarbonized Every 200 Hours or as Necessary Replace fuel line 1 Perform these maintenance procedures more frequently under extremely dusty dirty conditions 2 These procedures should be performed by a Kohler Engine Service Center Daily or Before Starting Engine Yearly or Every 100 Hours Oil Disposal Protect and respect the environment Dispose of oil at your local recycling center or municipal collection location in accordance with local ordinances Change Oil See Figures 1 2 3 and 4 For a new engine change oil after the first 5 hours of operation Thereafter change oil after every 100 hours of operation For an overhauled engine use Kohler 10W 30 service class 5 or higher oil for the first 5 hours of operation Change the oil after this initial run in period Refill with service class 5 or higher oil as specified in Oil Type Change the oil while the engine is still warm The oil will flow freely and carry away more impurities Make sure the engine is level when filling checking or changing th
6. cap in the filler neck A WARNING Explosive Fuel can cause fires and severe burns Do not fill the fuel tank while the engine is hot or running Daily or as required clean screen of any accumulation as follows 1 Remove fuel tank cap A and screen 2 Clean the screen B with solvent Replace if damaged 3 Wipe the screen and insert it into the filler neck C 4 Tighten the tank A securely Fuel Valve See Figure Engines are equipped with a fuel valve and integral screen filter located at the inlet of the carburetor It controls and filters fuel flow from the tank to the carburetor Every 100 hours of operation clean fuel valve cup of any accumulated debris If the screen becomes clogged or damaged replace it A WARNING Explosive Fuel can cause fires and severe burns Do not fill the fuel tank while the engine is hot or running Stop the engine Turn the fuel valve lever A to the OFF position Remove the fuel valve cup C Clean the fuel valve cup C with solvent and wipe it off Check the O ring B Replace if damaged gi Place the O ring B on the fuel valve cup C Rotate the fuel valve cup until it is finger tight Turn with a wrench 1 2 to 3 4 full turn 7 Turn the fuel valve A to the ON position and check for leaks If fuel valve cup leaks repeat steps 5 and 6 8 Tighten the tank cap securely Spark Arrestor Se
7. gasoline by volume is approved as a fuel for Kohler engines Other gasoline alcohol blends including E20 and E85 should not be used 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 ether blends are not approved Fuel Line These engines use Low Permeation SAE 30 R7 rated fuel lines certified to meet emission requirements Standard fuel lines may not be used Order replacement hose through a Kohler Service Center Operating Instructions Also read the operating instructions of equipment this engine powers Check Oil Level See Figures 1 2 3 and 4 The importance of checking 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 cool so the oil has had time to drain into the sump 2 Clean the area around and beneath the dipstick or the oil fill plug F before removing it This will help keep dirt debris and other foreign matter out of the engine See Figure 1 NOTE The engine may be equipped with two dipsticks or an oil fill plug and a dipstick These can be placed in either hole 3 Checking oil level with a dipstick A Unscrew and remove the dipstick wipe off oil Reinsert the dipstick into th
8. or every 100 hours of operation remove the spark plug check its condition and reset the gap or replace with a new plug as necessary The original spark plug is a Champion RC12YC the Kohler equivalent is Kohler Part No 12 132 02 S or for RFI Kohler Part No 25 132 14 5 Equivalent alternate brand plugs can also be used 1 Before removing the spark plug D clean the area around the base of the plug to keep dirt and debris out of the engine See Figure 1 2 Remove the plug D and check its condition Replace the plug if worn or if reuse is questionable See Figure 16 3 Check the gap B using a feeler gauge A See Figure 16 NOTE 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 4 Adjust the gap by carefully bending ground electrode C Gap spark plug to 0 76 mm 0 030 in See Figure 16 5 Reinstall the spark plug into the cylinder head Torque the plug to 20 N m 14 ft Ib Fuel Filter If Equipped WARNING Explosive Fuel can cause fires and severe burns Do not fill the fuel tank while the engine is hot or running 12 Replace with a Kohler fuel filter yearly or every 50 hours of operation Removing the air filter cover will allow easy access to the fuel filter for servicing Fuel Tank Screen See Figure A serviceable fuel tank screen is located under the fuel tank
9. 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 Below 225 cc 125 hours Refer to certification label for engine displacement Exhaust Emission Control System for model SH265 is EM for U S EPA and Europe Engine Specifications 58 mm 2711 54 mm 2 1 in Displacement 196 cc 12 cu in Gross Power 3600 RPM 4 9 kW 6 5 HP Net Power 3600 RPM 4 1 kW 5 5 HP Net Peak Torque 2800 RPM 11 5 N m 8 5 ft lb Compression Ratio 8 5 1 Weight Recoil Start 16 kg 35 3 lb Oil Capacity 601 63 qt Fuel Capacity 3 6L 3 8 qt Exhaust Emission Control EM for U S EPA and System Europe Kohler Co reserves the right to change product specifications designs and equipment without notice and without incurring obligation Horsepower ratings exceed Society of Automotive Engineers Small Engine Test Code J1940 Actual engine horsepower 15 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 15 ENGINE LIMITED WARRANTY Kohler Co warrants to the original retail consumer that each new COURAGE engi
10. Intake Cooling Areas To ensure proper cooling make sure the recoil starter screen cooling fins and other external surfaces of the engine are kept clean at all times Before each season of operation clean the cooling fins and external surfaces as necessary Reinstall the blower housing and other cooling shrouds Engine Speed engine must be reconverted to the original jet size before it 15 operated at lower altitudes or NOTE Do not tamper with the governor setting overheating and engine damage may resulf to increase the maximum engine speed Overspeed is hazardous and will void the If engine troubles appear to be fuel system related engine warranty The maximum allowable check the following areas before seeking service from high idle speed for these engines is 3850 a Kohler Engine Service Center o load e Ensure the fuel tank is filled with clean fresh asoline Carburetor 5 The carburetor is designed to deliver the correct fuel to air mixture to the engine under all operating conditions It has been calibrated at the factory and is not adjustable e Ensure the air cleaner and precleaner are clean and securely fastened Ensure that the fuel tank cap vent is not blocked and that itis operating properly Ensure the in line fuel filter if equipped is clean NOTE ensure correct engine operation at and unobstructed Replace if necessary AO 5 If after checking these items the engine is still har
11. KOHLER COURAGE SH265 HORIZONTAL CRANKSHAFT OWNER S MANUAL HORIZONTALE KURBELWELLE BETRIEBSANLEITUNG MANUALE DEL PROPRIETARIO ALBERO MOTORE ORIZZONTALE RBOL DE CIGUE AL HORIZONTAL MANUAL DEL OPERADOR VILEBREQUIN HORIZONTAL MANUEL DE L UTILISATEUR KOHLER ENGINES T Q e 28 18 as y 2 4 2 m GA II O 11236 Read Manual Safety Precautions To ensure safe operation please read the following statements and understand their meaning Also refer to your equipment manufacturer s manual for other important safety information This manual contains safety precautions which are explained below Please read carefully WARNING Warning is used to indicate the presence of a hazard that can cause severe personal injury death or substantial property damage if the warning is igno
12. RRANTY 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 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 Eng
13. STOP position if equipped See Figure 13 4 Close the fuel shut off valve A See Figure 14 Operating Angle of Operation Continuous operation at angles up to 25 with 1 2 full fuel tank Before operation check oil level to ensure crankcase oil level is correct Refer to Check Oil Level Intermittent operation up to one minute at angles up to 30 with 1 2 full fuel tank Check oil level to ensure crankcase oil level is correct Refer to Check Oil Level 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 because engine damage could result from insufficient lubrication Cooling WARNING Hot Parts can cause severe burns Do not touch engine while operating or just after stopping Engine components can get extremely hot from operation 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 NOTE If debris builds up on the recoil starter screen or other cooling areas stop the engine immediately and clean Operating the engine with blocked or dirty air intake and cooling areas can cause extensive damage due to overheating Refer to Clean Air
14. al Operating Temperatures Place the throttle control A midway between the SLOW and FAST positions A warm engine usually does not require the choke on See Figure 7 NOTE The choke position for starting may vary depending upon temperature and other factors Once engine is running and warm turn choke to OFF position A See Figure 9 3 Start the engine as follows For Retractable Start Engine Turn engine On Off switch A to the ON position See Figure 10 SLOWLY pull the starter handle A until just past compression STOP Return starter handle and pull firmly with a smooth steady motion to start Pull the handle straight out to avoid excessive rope wear from the starter rope guide See Figure 11 NOTE Extend the starting periodically and check its condition If the rope is frayed have it replaced immediately by your Kohler Engine Service Center 4 Gradually return choke control to the OFF position A after the engine starts and warms up See Figure 9 The engine equipment 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 See Figures 12 13 and 1 If possible remove the load 2 Move the throttle control to the SLOW LOW idle position Allow the engine to run at idle for 30 60 seconds See Figure 12 3 Turn On Off switch or key switch A to the OFF position Move throttle to the
15. ating conditions The idle mixture is set at the factory and normally does not require adjustment If the engine is hard to start runs roughly or stalls at low idle speed it may be necessary to adjust or service the carburetor Engine must not exceed 3850 100 RPM if the high speed screw A is adjusted If engine troubles are experienced that appear to be fuel system related check the following areas before adjusting the carburetor Make sure fuel tank is filled with clean fresh gasoline Make sure that the fuel tank cap vent is not blocked and that it is operating properly Make sure the fuel shut off valve is fully open Make sure fuel shut off valve strainer and in line fuel filter if used are clean and unobstructed Clean or replace as necessary Make sure fuel is reaching the carburetor This includes checking the fuel lines and components for restrictions or problems Replace as necessary Make sure On Off switch is functioning properly 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 13 Troubleshooting When problems occur first check for simple reasons for a problem for example an empty fuel tank or the fuel shut off valve is turned off Additional troubl
16. d to start runs roughly stalls at low idle speed it Service Center install a high altitude jet kit may be necessary to have the carburetor serviced by a If a high altitude kit has been installed the Kohler Engine Service Center Maintenance Instructions Maintenance repair or replacement of the emission control devices and systems which are being done at the customer s expense may be performed by any non road engine repair establishment or individual Warranty repairs must be performed by a Kohler Engine Service Center WARNING Accidental Starts can cause severe injury or death Disconnect and ground spark plug lead s before servicing Disabling engine Accidental starting can cause severe injury or death Before working on the engine or equipment disable the engine as follows 1 Disconnect the spark plug lead s 2 Disconnect negative battery cable from battery Maintenance Schedule These required maintenance procedures should be performed at the frequency stated in the table below They should also be included as part of any seasonal tune up Frequency Maintenance Required Check oil level Fill fuel tank Check air intake and cooling areas clean as necessary Check fuel screen Check air cleaner element and precleaner if equipped Check spark arrestor if equipped clean as necessary Yearly or Every 50 Hours Clean or replace precleaner if equipped Replace
17. e Figure Engines are equipped with a spark arrestor for operational and environmental safety Every 100 hours of operation remove and clean or replace the spark arrestor following the instructions below WARNING Hot Parts can cause severe burns Do not touch engine while operating or just after stopping 1 Remove the securing hardware and the spark arrestor A 2 Clean the carbon deposits out of the screen using a wire brush 3 Check the spark arrestor A Replace if damaged 4 Reinstall the spark arrestor A securing with the hardware B previously removed Clean Air Intake Cooling Areas To ensure proper cooling make sure the recoil starter screen cooling fins and other external surfaces of the engine are kept clean at all times Check daily 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 Carburetor Troubleshooting and Adjustments See Figure NOTE Carburetor adjustments should be made only after the engine is at operating temperature The carburetor is designed to deliver the correct fuel to air mixture to the engine under all oper
18. e leading edge of innovation push the boundaries of cleaner more efficient engines To manufacture the highest performing most reliable engines on the market You can rest assured that your Kohler Engine will provide maximum power and reliability in all operating conditions Also Kohler engines are backed by a worldwide network of over 10 000 distributors and dealers For more information on Kohler Engines or to find a Kohler Service Center visit KohlerEngines com To keep your engine in top operating condition follow the maintenance procedures in this manual Oil Recommendations Using the proper type and weight of oil in the engine is extremely important as is daily checking of oil level and changing oil regularly Failure to use the correct oil or using dirty oil will cause premature engine wear and failure Oil Type Use high quality oil that ranks at or above the American Petroleum Institute s API 5 service class Select the oil s viscosity based on air temperature at the time of operation as shown in the viscosity grades table Recommended SAE Viscosity Grades Kohler 10W 30 Use service class 5 rated oil or higher Do not extend the oil change intervals longer than recommended as this can cause engine damage and may void the warranty An API symbol on the oil container identifies the service class and SAE viscosity grade Fuel Recommendations Explosive Fuel can cau
19. e oil Change the oil as follows 1 To keep dirt debris etc out of the engine clean the area around the dipstick oil fill plug before removing it See Figure 1 2 Remove the oil plug E and the dipstick oil fill plug Allow ample time for complete drainage See Figure 1 3 Reinstall the drain plug E and tighten to 17 6 Nm 13 ft 1b See Figure 1 4 Fill the crankcase with new oil of the proper type up to the point of overflowing the filler neck Refer to Oil Type Always check the level before adding more oil 5 Reinstall the dipstick oil fill plug A and gasket B and tighten securely See Figures 2 and 3 NOTE Over tightening the dipstick oil fill plug A will distort the gasket C and may cause oil weeping See Figure 4 Oil Sentry Some engines are equipped with an optional Oil Sentry switch This switch is designed to prevent the engine from being started in a low oil or no oil condition The Oil Sentry may not shut down a running engine before damage occurs In some applications this switch may activate a warning signal NOTE Check the oil level BEFORE EACH USE and maintain to the correct level This includes engines equipped with Oil Sentry Service Precleaner and Air Cleaner Element See Figure 15 These engines are equipped with a replaceable high density paper air cleaner element F Some engines are also equipped with a pre oiled foam preclean
20. e oil fill tube and rest the dipstick on the oil fill neck B Turn it counterclockwise until the oil fill cap drops down to the lowest point of the thread leads Do not thread the dipstick cap onto the tube See Figure 2 Checking oil level with an oil fill plug Unscrew and remove the oil fill plug A The level should be up to but not over the point of overflowing the filler neck B See Figure 3 4 If the level is low add oil of the proper type and to the correct level Refer to Oil Type Always check the level before adding more oil 5 Reinstall the dipstick oil fill plug A and gasket B and tighten securely See Figure 4 NOTE Over tightening the dipstick oil fill plug A will distort the gasket C and may cause oil weeping See Figure 4 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 above the correct level Add Fuel See Figures 1 and 5 WARNING Explosive Fuel can cause fires and severe burns Do not fill the fuel tank while the engine is hot or ruming 1 Make sure the engine is OFF level and is cool 2 Clean the area around fuel cap See Figure 1 3 Remove the fuel cap Fill to the base of the filler neck A Do not overfill the fuel tank B Leave room for the fuel to expand See Figure 5 4 Reinstall the fuel and tighten securely See Figure 1 Check
21. er D which surrounds the paper element 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 Replace 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 Service Precleaner If Equipped See Figure 15 Wash or replace the precleaner every 50 hours of operation more often under extremely dusty or dirty conditions 1 Remove the top wing nut A and air cleaner cover B 2 Remove the wing nut C some models and special washer E 3 Remove the precleaner D from the paper element 4 Wash the precleaner D 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 Do not oil precleaner 5 Reinstall the precleaner D over the paper element 6 Slide the precleaner D and paper element F onto the air cleaner stud G Secure with special washer E and wing nut C some models 7 Reinstall the air cleaner cover and secure with wing nut A Service Air Cleaner Element See Figure 15 Yearly or 100 hours which ever comes first of operation more often under extremely dusty or d
22. eshooting tips can be found in the troubleshooting table NOTE not attempt to service or replace major engine components or any items that require special timing or adjustment procedures This work should be performed by a Kohler Engine Service Center Possible Cause Problem Fuel Improper Dirt In Dirty Incorrect Dirty Air Fuel Line Debris Oil Overloaded Cleaner Closed Screen Level will Not Start will Not Start Start Hard Starting Stops Suddenly Operates Erratically Knocks or Pings Skips or Misfires Backfires Overheats High Fuel Consumption Storage 6 Remove the spark plug D Cover the spark plug See Figures 1 and 6 hole with your thumb and turn the engine over If the engine will be out of service for two months or until the piston is at the top of its stroke pressure more follow these storage procedures against the thumb is greatest Reinstall the spark plug but do not connect the spark plug lead See 1 Clean the exterior surfaces of the engine Figure 1 2 Change the oil while the engine is still warm from operation Refer to Change Oil 7 Store the engine on a level surface in a clean dry place Never store the unit where there is an open 3 The engine must be run until the fuel tank is flame spark or pilot light such as on a water completely emptied or the gasoline must be heater or other appliances treated with a stabilizer
23. ies 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 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 locate the nearest facility visit our Web site www KohlerEngines com consult your local telephone directory or telephone 1 800 544 2444 ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 1 With the exception of countries governed by the European Union EU where a one 1 year warranty is required for commercial professional use KOHLER CO FEDERAL AND CALIFORNIA EMISSION CONTROL SYSTEMS LIMITED WA
24. ines 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 Continued on the next page 16 OWNER S WARRANTY RESPONSIBILITIES a The engine owner is responsible for the performance of the required maintenance listed in the owner s manual Kohler Co recommends that you retain all receipts covering maintenance on the engine but Kohler Co cannot deny warranty solely for the lack of receipts or for your failure to assure that all scheduled maintenance was performed Be aware however that Kohler Co may deny warranty coverage if the engine or a part has failed due to abuse neglect improper maintenance or unapproved modifications 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 desig
25. intenance 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 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 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 17 FORM NO 18 590 02 ISSUED
26. irty conditions replace the paper element 1 Remove the top wing nut A and air cleaner cover B Remove the wing nut C some models and special washer E 2 Separate the precleaner D from the element and service as outlined in Service Precleaner NOTE Do not wash the paper element or use pressurized air as this will damage the element Replace a dirty bent or damaged element with a genuine Kohler element Handle new elements carefully do not use if the sealing surfaces are bent or damaged 3 When servicing the air cleaner check the air cleaner base H Make sure it is secured and not bent or damaged Check the air cleaner cover housing B for damage or improper fit Replace all bent or damaged air cleaner components 11 4 Slide the precleaner D and paper element F onto the air cleaner stud G Secure with special washer E and wing nut C some models 5 Reinstall the air cleaner cover and secure with wing nut A Ignition This engine is equipped with a dependable maintenance free ignition system Other than periodically checking replacing the spark plug no adjustments are necessary or possible with this system In the event starting problems should occur that are not corrected by replacing the spark plug see your Kohler Engine Service Center NOTE Some engines may be equipped with components that comply with REI regulations Spark Plug See Figures 1 and Yearly
27. ne 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 instructions and manuals If used commercially the COURAGE engine is covered by a 90 limited warranty The warranty period begins on the date of purchase by the original retail consumer or commercial end user Residential homeowner 5 service means 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 batter
28. ned 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 years in all other states These warranty periods will begin on the date the engine is purchased by the initial purchaser If any emission related part on the engine is defective the part will be replaced by Kohler Co at no cost to the owner Kohler Co is liable for damages to other engine components caused by the failure of a warranted part still under warranty Kohler Co shall remedy warranty defects at any authorized Kohler Co engine dealer or warranty station Warranty repair work done at an authorized dealer or warranty station shall be free of charge to the owner if such work determines that a warranted part is defective Listed below are the parts covered by the Federal and California Emission Control Systems Warranty Some parts listed below may require scheduled maintenance and are warranted up to the first scheduled replacement point for that part The warranted parts include the following if they were present in the engine purchased Oxygen sensor if equipped
29. red 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 WARNING Carbon Monoxide can cause severe others WARNING I Y Explosive Fuel can cause fires Y and severe burns Do not fill the fuel tank while the engine is hot or ruming Explosive Fuel Gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only in approved containers in well ventilated unoccupied buildings away from sparks or flames Do not fill the fuel tank while the engine is hot or running since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition Do not start the engine near spilled fuel Never use gasoline as a cleaning agent WARNING Accidental Starts can cause severe injury or death Disconnect and ground spark plug lead s 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 lead s 2 Disconnect negative batter
30. se fires and severe burns Do not fill the fuel tank while the engine is hot or ruming 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 Fuel Recommendations See Figure 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 To minimize gum deposits in your fuel system and to ensure easy starting do not use gasoline left over from the previous season Do not add oil to the gasoline Do not overfill the fuel tank C Leave room for the fuel to expand Fuel Type For best results use only clean fresh unleaded gasoline with an octane rating of 87 or higher In countries using the Research method it should be 90 octane minimum Unleaded gasoline is recommended as it leaves less combustion chamber deposits and reduces harmful exhaust emissions Leaded gasoline is not recommended Gasoline Alcohol Blends Gasohol to 10 ethyl alcohol 90 unleaded
31. to prevent deterioration If a stabilizer is used follow the manufacturer s Transport instructions Fill the tank with fresh gasoline 1 Turn the fuel valve to the OFF position and run the engine for 2 3 minutes to ensure 2 Tighten the fuel cap stabilized fuel has entered the carburetor Read and follow the transport guidelines To empty the system run the engine until the provided by equipment manufacturer tank and system are empty 4 Before transporting the engine ensure the fuel valve A is in the OFF position to prevent fuel spillage See Figure 6 5 Remove the spark plug D Add one tablespoon of engine oil into the spark plug hole Reinstall the plug but do not connect the plug lead Turn the crank to rotate the engine two to three revolutions See Figure 1 14 Repairs Repair information is available in Kohler Engine service manuals which are available at KohlerEngines com or at Kohler Engine Service Centers Major repairs generally require the services of a trained mechanic and the use of specialized tools and equipment Kohler Engine Service Centers have the facilities training and genuine Kohler replacement parts necessary to perform these services For the nearest sales and service location visit our Web site at KohlerEngines com or in the U S and Canada call 1 800 544 2444 Parts Ordering The engine model specification and serial numbers are required when ordering replacement parts from your
32. y cable from battery WARNING 246 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 Hot Parts can cause severe burns Do not touch engine while operating or just after stopping nausea fainting or death Avoid inhaling exhaust fumes and never run the engine in a closed building or confined area Lethal Exhaust Gases Engine exhaust gases contain poisonous carbon monoxide Carbon monoxide is odorless colorless and can cause death if inhaled Avoid inhaling exhaust fumes and never run the engine in a closed building or confined area WARNING Rotating Parts can cause severe injury Stay away while engine is in Operation Rotating Parts Keep hands feet hair and clothing away from all moving parts to prevent injury Never operate the engine with covers shrouds or guards removed CAUTION Electrical Shock can cause injury Do not touch wires while engine is ruming Electrical Shock Never touch electrical wires or components while the engine is running They can be sources of electrical shock Congratulations on your purchase of a Kohler Engine Every part every component every system on a Kohler engine is guided by our exclusive Performance Engineering philosophy operate on th
33. y fastened 5 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 that could keep the engine from starting Cold Weather Starting Hints 1 sure to use the proper oil for the temperature expected Refer to Oil Recommendations 2 Declutch all possible external loads 3 Use fresh winter grade fuel NOTE Winter grade gasoline has higher volatility to improve starting Do not use gasoline left over from summer 4 Electric Start Models Be sure the battery is in good condition A warm battery has much more starting capacity than a cold battery Starting See Figures 6 8 9 10 and 11 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 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 1 Turn the fuel shut off valve A to the ON position See Figure 6 2 Cold Engine Place the throttle control midway between the SLOW and FAST positions See Figure 7 Place the choke control A into the ON position See Figure 8 For a Warm Engine Norm
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