Kohler COMMAND CH18 Manual de usuario

SERVICE MANUAL

HORIZONTAL CRANKSHAFT

COMMAND CH18-750

Contents

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

Section 2. Special Tools ..........................................................................................................

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

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

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

Section 5A. LPG Fuel Systems ...............................................................................................

Section 5B. Electronic Fuel Injection (EFI) Fuel System ......................................................

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...........................................................................................................

Section 12. Clutch ....................................................................................................................

1.1

Section 1

Safety and General Information

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 can cause severe

injury.

Stay away while engine is in

operation.

WARNING

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 can cause severe burns.

Do not touch engine while operating

or just after stopping.

WARNING

HotParts!

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 can cause severe

injury or death.

Disconnect and ground spark plug

leads before servicing.

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.

1.2

Section 1

Safety and General Information

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

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

Explosive Gas can cause fires and

severe acid burns.

Charge battery only in a well

ventilated area. Keep sources of

ignition away.

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.

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.

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.

Explosive Fuel can cause fires and

severe burns.

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.

Cleaning Solvents can cause severe

injury or death.

Use only in well ventilated areas

away from ignition sources.

WARNING

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.

Electrical Shock!

Never touch electrical wires or

components while the engine is running.

They can be sources of electrical shock.

Do not fill the fuel tank while the

engine is hot or running.

1.3

Section 1

Safety and General Information

A. Model No.

Version Code

S = Electric Start

C H 18 S

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 there are 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

Figure 1-2.

Figure 1-1. Engine Identification Decal Location.

Variation of

Basic Engine

B. Spec. No. 62500

Command Engine

Horizontal Crankshaft

Horsepower

17 = 17 HP

18 = 18 HP

20 = 20 HP

22 = 22 HP

23 = 23 HP

25 = 25 HP

26 = 26 HP

Numerical Designation

730

740

745

750

Engine Model Code

Code Model

62 CH18

64 CH20

66 CH22 (624 cc)

68 CH25

76 CH22/23 (674 cc)

78 CH26

CH730-0001

CH740-0001

CH745-0001

CH750-0001

CompleteSpecNumber

(IncorporatingModelNo.

withVariationNo. of

Basic Spec.)

Figure 1-2. Explanation of Engine Identification Numbers.

C. Serial No.

Year Manufactured Code

Code Year

21 1991

22 1992

23 1993

24 1994

25 1995

26 1996

27 1997

28 1998

29 1999

Factory Code

3305810334

Code Year

30 2000

31 2001

32 2002

33 2003

34 2004

35 2005

36 2006

37 2007

Identification Decal

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.

Refer to Section 6 - “Lubrication System” for detailed

procedures on checking the oil, changing the oil and

changing the oil filter.

Fuel Recommendations

WARNING: Explosive Fuel!

Gasoline is extremely flammable and its vapors can explode if

ignited. Before servicing the fuel system, make sure there are no

sparks, open flames or other sources of ignition nearby as these

can ignite gasoline vapors. Disconnect and ground the spark plug

leads to prevent the possibility of sparks from the ignition system.

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.

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 and reduces harmful

exhaust emissions. Leaded gasoline is not recommended

and must not be used on EFI engines, or on other models

where exhaust emissions are regulated.

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 a maximum of 15% MTBE by

volume) are approved as a fuel for Kohler engines. Other

gasoline/ether blends are not approved.

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.

Figure 1-3. Oil Container Logo.

*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 Instructions

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.

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.

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. On

Electronic Fuel Injected (EFI) engines, avoid

spraying water at the wiring harness or any of

the electrical components.

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 manufacturer’s

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 to 3 minutes to get stabilized fuel

into the rest of the system. Close the fuel shut-off

valve when the unit is being stored or

transported.

To empty the system, run the engine until the

tank and the system are empty.

4. Remove the spark plugs and add one tablespoon

of engine oil into each spark plug hole. Install the

spark plugs, but do not connect the plug leads.

Crank the engine two or three revolutions.

5. On equipment with an EFI engine, disconnect the

battery or use a battery minder to keep the

battery charged during storage.

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

• Replace fuel filter1(EFI engines). Section 5B

Daily or Before

Starting Engine

Maintenance RequiredFrequency

• Fill fuel tank Section 5

• Check oil level. Section 6

• Check air cleaner for dirty1, loose, or damaged parts. Section 4

• Check air intake and cooling areas, clean as necessary1. Section 4

• Service precleaner element1. Section 4

Every 25 Hours

• Replace air cleaner element1. Section 4

• Change oil. (More frequently under severe conditions.) Section 6

• Remove cooling shrouds and clean cooling areas1,3. Section 4

• Check oil cooler fins, clean as necessary (if equipped). Section 6

• Check spark plug condition and gap. Section 8

• Change oil filter. Section 6

• Change fuel filter (carbureted engines). Section 5

Annually or

Every 500 Hours • Have bendix starter drive serviced2. Section 8

• Have solenoid shift starter disassembled and cleaned2. Section 8

Every 100 Hours

Every 200 Hours

Every 1500 Hours

• Have crankshaft splines lubricated2. Section 2

Every 500 Hours

Every 250 Hours • Replace heavy-duty air cleaner element and check inner element1. Section 4

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

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

³Cleanout Kits 25 755 20-S (black) or 25 755 21-S (gold) allow cooling areas to be cleaned without removing shrouds.

Refer to:

1.6

Section 1

Safety and General Information

Figure 1-4. Typical Engine Dimensions CH Series with Standard Flat Air Cleaner.

Dimensions in millimeters.

Inch equivalents shown in [ ].

1.7

Section 1

Safety and General Information

Figure 1-5. Typical Engine Dimensions CH EFI Series with Heavy-Duty Air Cleaner.

Dimensions in millimeters.

Inch equivalents shown in [ ].

1.8

Section 1

Safety and General Information

General Specifications¹

Power (@ 3600 RPM, exceeds Society of Automotive Engineers-Small Engine Test Code J1940.)

CH18 ........................................................................................................................................ 13.4 kW (18 HP)

CH20 ........................................................................................................................................ 14.9 kW (20 HP)

CH22 ........................................................................................................................................ 16.4 kW (22 HP)

CH23 ........................................................................................................................................ 17.2 kW (23 HP)

CH25, CH730 .......................................................................................................................... 18.6 kW (25 HP)

CH26 ........................................................................................................................................ 19.4 kW (26 HP)

CH740 ...................................................................................................................................... 20.1 kW (27 HP)

CH745 ...................................................................................................................................... 20.9 kW (28 HP)

CH750 ...................................................................................................................................... 22.3 kW (30 HP)

Peak Torque

CH18 @ 2200 RPM ................................................................................................................. 43.6 N·m (32.2 ft. lb.)

CH20 @ 2400 RPM ................................................................................................................. 44.3 N·m (32.7 ft. lb.)

CH22 @ 2400 RPM ................................................................................................................. 49.1 N·m (36.2 ft. lb.)

CH23 @ 2400 RPM ................................................................................................................. 54.1 N·m (37.9 ft. lb.)

CH25 @ 2200 RPM ................................................................................................................. 54.0 N·m (39.5 ft. lb.)

CH730 @ 2400 RPM ............................................................................................................... 55.4 N·m (40.9 ft. lb.)

CH26 @ 2800 RPM ................................................................................................................. 54.2 N·m (40.0 ft. lb.)

CH740 @ 2400 RPM ............................................................................................................... 57.3 N·m (42.3 ft. lb.)

CH745 @ 2600 RPM ............................................................................................................... 57.9 N·m (42.7 ft. lb.)

CH750 @ 2400 RPM ............................................................................................................... 64.4 N·m (47.5 ft. lb.)

Bore

CH18, CH20, CH22 (624 cc) .................................................................................................. 77 mm (3.03 in.)

CH22/23 (674 cc) .................................................................................................................... 80 mm (3.15 in.)

CH25, CH26, CH730-750 ....................................................................................................... 83 mm (3.27 in.)

Stroke

CH18-745 ................................................................................................................................ 67 mm (2.64 in.)

CH750 ...................................................................................................................................... 69 mm (2.7 in.)

Displacement

CH18, CH20, CH22 (624 cc) .................................................................................................. 624 cc (38 cu. in.)

CH22/23 (674 cc) .................................................................................................................... 674 cc (41 cu. in.)

CH25, CH26, CH730-745 ....................................................................................................... 725 cc (44 cu. in.)

CH750 ...................................................................................................................................... 755 cc (46 cu. in.)

Compression Ratio

CH18, CH20, CH22/23 ........................................................................................................... 8.5:1

CH25, CH26, CH730-745 ....................................................................................................... 9.0:1

CH750 ...................................................................................................................................... 9.4:1

Dry Weight

CH18, CH20, CH22/23 ........................................................................................................... 41 kg (90 lb.)

CH25, CH26, CH730-745 ....................................................................................................... 43 kg (94 lb.)

CH750 ...................................................................................................................................... 48 kg (105 lb.)

Oil Capacity (w/filter) - approximate,

determined by oil filter and oil cooler used ............................................................................. 1.6-1.8 L (1.7-1.9 U.S. qt.)

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

prior to assembly.

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