Kohler CH-11-16 Manual de usuario

SERVICE MANUAL

HORIZONTAL CRANKSHAFT

COMMAND CH11-16

Contents

Section 1. Safety and General Information ............................................................................

Section 2. Tools & Aids ............................................................................................................

Section 3. Troubleshooting .....................................................................................................

Section 4. Air Cleaner and Air Intake System ........................................................................

Section 5. Fuel System and Governor....................................................................................

Section 6. Lubrication System ................................................................................................

Section 7. Retractable Starter .................................................................................................

Section 8. Electrical System and Components .....................................................................

Section 9. Disassembly ...........................................................................................................

Section 10. Inspection and Reconditioning ...........................................................................

Section 11. Reassembly...........................................................................................................

1.1

Section 1

Safety and General Information

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 ignored.

CAUTION

Caution is used to indicate the presence of a hazard that will or can cause minor personal injury or

property damage if the caution is ignored.

NOTE

Note is used to notify people of installation, operation, or maintenance information that is important

but not hazard-related.

For Your Safety!

These precautions should be followed at all times. Failure to follow these precautions could result in injury to

yourself and others.

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.

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.

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 (-)

battery cable from battery.

Accidental Starts can cause severe

injury or death.

Disconnect and ground spark plug

lead before servicing.

WARNING

Rotating Parts can cause severe

injury.

Stay away while engine is in

operation.

WARNING

Hot Parts can cause severe burns.

Do not touch engine while operating

or just after stopping.

WARNING

Section 1

Safety and General Information

1.2

Section 1

Safety and General Information

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.

ExplosiveGas!

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.

Spring Under Tension!

Retractable starters contain a powerful,

recoil spring that is under tension.

Always wear safety goggles when

servicing retractable starters and

carefully follow instructions in the

Retractable Starter Section 7 for relieving

spring tension.

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.

Flammable Solvents!

Carburetor cleaners and solvents are

extremely flammable. Keep sparks,

flames, and other sources of ignition

away from the area. Follow the cleaner

manufacturer’s warnings and

instructions on its proper and safe use.

Never use gasoline as a cleaning agent.

Explosive Fuel can cause fires and

severe burns.

Do not fill the fuel tank while the

engine is hot or running.

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.

WARNING WARNING

Explosive Gas can cause fires and

severe acid burns.

Charge battery only in a well

ventilated area. Keep sources of

ignition away.

Cleaning Solvents can cause severe

injury or death.

Use only in well ventilated areas

away from ignition sources.

WARNING

Electrical Shock can cause injury.

Do not touch wires while engine is

running.

CAUTION

Uncoiling Spring can cause severe

injury.

Wear safety goggles or face

protection when servicing

retractable starter.

WARNING

Electrical Shock!

Never touch electrical wires or

components while the engine is

running. They can be sources of

electrical shock.

1.3

Section 1

Safety and General Information

Engine Identification Numbers

When ordering parts, or in any communication

involving an engine, always give the Model,

Specification, and Serial Numbers, including letter

suffixes if any.

The engine identification numbers appear on a decal,

or decals, affixed to the engine shrouding. See Figure

1-1. An explanation of these numbers is shown in

Figure1-2.

Figure 1-2. Explanation of Engine Identification Numbers.

Figure 1-1. Engine Identification Decal Location.

B. Spec. No.

Engine Model Code

Code Model

16 CH11

19 CH12.5

22 CH13

18 CH14

44 CH15

45 CH16

Variation of

Basic Engine

1903

A. Model No.

Command Engine

Horizontal Crankshaft

Horsepower

11 = 11 HP

12.5 = 12.5 HP

13 = 13 HP

14 = 14 HP

15 = 15 HP

16 = 16 HP

Version Code

S = Electric Start

T = Retractable Start

ST = Electric/Retractable Start

GT = GeneratorApplication/Retractable Start

GS = GeneratorApplication/Electric Start

PT = Pump/Retractable Start

RT = Gear Reduction/Retractable Start

C H 12.5 ST

Factory Code

C. Serial No.

Year Manufactured Code

Code Year

20 1990

21 1991

22 1992

23 1993

24 1994

25 1995

26 1996

27 1997

28 1998

2005810334

MODEL NO.

SPEC. NO.

SERIAL NO.

REFER TO OWNER'S MANUAL FOR

SAFETY, MAINTENANCE SPECS

AND ADJUSTMENTS. FOR SALES

AND SERVICE IN US/CANADA

CALL: 1-800-544-2444.

www.kohlerengines.com

KOHLER CO. KOHLER, WI USA

CH12.5ST

1903

2005810334

Identification

Decal

Code Year

29 1999

30 2000

31 2001

32 2002

33 2003

34 2004

35 2005

36 2006

37 2007

1.4

Section 1

Safety and General Information

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.

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 1-3.

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 spilling 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.

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 are not

approved.

Gasoline/Ether blends

Methyl Tertiary Butyl Ether (MTBE) and unleaded

gasoline blends (up to maximum of 15% MTBE by

volume) are approved as a fuel for Kohler engines.

Other gasoline/ether blends are not approved.

Figure 1-3. Oil Container Logo.

Refer to Section 6 Lubrication System for detailed oil

check, oil change, and oil filter procedures.

*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).

** *

1.5

Section 1

Safety and General Information

Periodic Maintenance

1Perform these maintenance procedures more frequently under extremely dusty, dirty conditions.

2Only required for Denso starters. Not necessary on Delco starters. Have a Kohler Engine Service Dealer perform this service.

Storage

If the engine will be out of service for two months or

more, use the following storage procedure:

1. Clean the exterior surfaces of the engine.

2. Change the oil and oil filter while the engine is

still warm from operation. See Change Oil and

Oil Filter in Section 6.

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

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.

To empty the system, run the engine until the

tank and system are empty.

4. 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.

5. Remove the spark plug. Cover the spark plug

hole with your thumb, and turn the engine over

until the piston is at the top of its stroke.

(Pressure against thumb is greatest.) Reinstall

the plug, but do not connect the plug lead.

6. Store the engine in a clean, dry place.

Maintenance Schedule

The following required maintenance procedures should be performed at the frequency stated in the table and

should also be included as part of any seasonal tune-up.

WARNING: 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 (-) battery cable from battery.

Frequency Maintenance Required Refer to:

• Fill fuel tank.

• Check oil level.

• Check air cleaner for dirty1, loose, or damaged parts.

• Check air intake and cooling areas, clean as necessary1.

Daily or Before

Starting Engine

Section 5

Section 6

Section 4

• Service precleaner element1.

Every 25 Hours Section 4

• Replace air cleaner element1.

• Change oil1.

• Remove cooling shrouds and clean cooling areas1.

Every

100 Hours

Section 4

Section 6

Section 4

• Change oil filter.

• Check spark plug condition and gap.

• Replace fuel filter.

Every

200 Hours

Section 6

Section 8

Section 5

Annually or Every

500 Hours • Have bendix starter drive serviced2.

• Have solenoid shift starter disassembled and cleaned2.

Section 8

Every 50 Hours • Check oil level in gear reduction unit. Section 6

1.6

Section 1

Safety and General Information

Figure 1-4. Typical Engine Dimensions.

Dimensionsinmillimeters.

Inch equivalents shown in ( ).

1.7

Section 1

Safety and General Information

General Specifications1

Power (@ 3600 RPM, exceeds SAE J1940 HP standards)

CH11 .......................................................................................................... 8.20 kW (11 HP)

CH12.5 ....................................................................................................... 9.33 kW (12.5 HP)

CH13 .......................................................................................................... 9.75 kW (13 HP)

CH14 .......................................................................................................... 10.50 kW (14 HP)

CH15 .......................................................................................................... 11.20 kW (15 HP)

CH16 .......................................................................................................... 11.90 kW (16 HP)

Peak Torque (@ RPM indicated)

CH11 (@ 2400 RPM) ................................................................................. 26.7 N·m (19.7 ft. lb)

CH12.5 (@ 2500 RPM) .............................................................................. 27.8 N·m (20.5 ft. lb)

CH13 (@ 2400 RPM) ................................................................................. 28.8 N·m (21.2 ft. lb)

CH14 (@ 2500 RPM) ................................................................................. 27.8 N·m (21.3 ft. lb)

CH15 (@ 2400 RPM) ................................................................................. 34.3 N·m (25.3 ft. lb)

CH16 (@ 2400 RPM) ................................................................................. 33.9 N·m (25.0 ft. lb)

Bore

CH11, CH12.5, CH13, CH14 .................................................................... 87 mm (3.43 in.)

CH15, CH16 .............................................................................................. 90 mm (3.54 in.)

Stroke ................................................................................................................ 67 mm (2.64 in.)

Displacement

CH11, CH12.5, CH13, CH14 .................................................................... 398 cc (24.3 cu. in.³)

CH15, CH16 .............................................................................................. 426 cc (26.0 cu. in.³)

Compression Ratio ......................................................................................... 8.5:1

Weight .............................................................................................................. 40 kg (88.3 lb.)

Max. Oil Capacity (w/filter) .......................................................................... 1.9 L (2.0 qt.)

Lubrication ...................................................................................................... full pressure w/full flow filter

Air Cleaner

Base Nut Torque .............................................................................................. 9.9 N·m (88 in. lb.)

Angle of Operation - Maximum (at full oil level)

Intermittent - All Directions ......................................................................... 35°

Continuous - All Directions .......................................................................... 25°

Balance Shaft

End Play (Free) ................................................................................................ 0.0575/0.3625 mm (0.0023/0.0137 in.)

Running Clearance ......................................................................................... 0.025/0.1520 mm (0.0009/0.0059 in.)

Bore I.D.

New ........................................................................................................... 20.000/20.025 mm (0.7874/0.7884 in.)

Max. Wear Limit ...................................................................................... 20.038 mm (0.7889 in.)

Balance Shaft Bearing Surface O.D.

New ........................................................................................................... 19.962/19.975 mm (0.7859/0.7864 in.)

Max. Wear Limit ...................................................................................... 19.959 mm (0.7858 in.)

1Values are in Metric units. Values in parentheses are English equivalents. Lubricate threads with engine oil prior to

assembly.

1.8

Section 1

Safety and General Information

Camshaft

End Play (Free) ................................................................................................ 0.0875/0.3925 mm (0.0034/0.0154 in.)

End Play (with Shims) ................................................................................... 0.0762/0.1270 mm (0.0030/0.0050 in.)

Running Clearance ......................................................................................... 0.025/0.1050 mm (0.00098/0.0041 in.)

Bore I.D.

New ........................................................................................................... 20.000/20.025 mm (0.7874/0.7884 in.)

Max. Wear Limit ...................................................................................... 20.038 mm (0.7889 in.)

Camshaft Bearing Surface O.D.

New ........................................................................................................... 19.962/19.975 mm (0.7859/0.7864 in.)

Max. Wear Limit ...................................................................................... 19.959 mm (0.7858 in.)

Carburetor

Fuel Bowl Nut Torque .................................................................................... 5.1-6.2 N·m (45-55 in. lb.)

Charging

Stator Mounting Screw Torque .................................................................... 6.2 N·m (55 in. lb.)

Closure Plate

Oil Filter Tightening ....................................................................................... 3/4-1 turn after gasket contacts.

Oil Filter Adapter Fastener Torque .............................................................. 11.3 N·m (100 in. lb.)

Oil Filter Drain Plug (1/8" NPT) Torque ....................................................... 7.3-9.0 N·m (65-80 in. lb.)

Closure Plate Fastener Torque ...................................................................... 24.4 N·m (216 in. lb.)

Oil Sentry Pressure Switch Torque .............................................................. 6.8 N·m (60 in. lb.)

Oil Pump Cover Fastener Torque² ............................................................... 4.0,6.2 N·m (35,55 in. lb.)

Connecting Rod

Cap Fastener Torque

6 mm straight shank bolt....................................................................... 11.3 N·m (100 in. lb.)

8 mm straight shank bolt....................................................................... 22.6 N·m (200 in. lb.)

8 mm step-down type bolt .................................................................... 14.7 N·m (130 in. lb.)

Connecting Rod-to-Crankpin Running Clearance at 21°C (70°F)

New ........................................................................................................... 0.030/0.055 mm (0.0012/0.0022 in.)

Max. Wear Limit ...................................................................................... 0.07 mm (0.0025 in.)

Connecting Rod-to-Crankpin Side Clearance ............................................ 0.18/0.41 mm (0.007/0.016 in.)

Connecting Rod-to-Piston Pin Running Clearance 21°C (70°F) ............... 0.015/0.028 mm (0.0006/0.0011 in.)

Piston Pin End I.D.

New ........................................................................................................... 19.015/19.023 mm (0.7486/0.7489 in.)

Max. Wear Limit ...................................................................................... 19.036 mm (0.7495 in.)

Crankcase

Governor Cross Shaft Bore I.D.

New ........................................................................................................... 6.025/6.050 mm (0.2372/0.2382 in.)

Max. Wear Limit ...................................................................................... 6.063 mm (0.2387 in.)

2For self-tapping (thread-forming) fasteners, the higher torque value is for installation into a new cored (non-threaded) hole.

The lower torque value is for installation into a used or threaded hole.

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