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Owner's Manual for KOHLER models including: KS530, KS595, KS530 5400 Series Engine, KS530, 5400 Series Engine, Engine
Engine Manuals | Kohler Engines
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DocumentDocumentEN ESS KS530-KS595 FRC Owner's Manual IMPORTANT: Read all safety precautions and instructions carefully before operating equipment. Refer to operating instruction of equipment that this engine powers. Ensure engine is stopped and level before performing any maintenance or service. Warranty coverage as outlined in warranty card and on KohlerEngines.com. Please review carefully as it provides your specific rights and obligations. To maintain compliance with applicable emission regulations, exhaust system backpressure may not exceed limits which can be found on KohlerEngines.com. Search by Model No., then select Specs tab. Kohler Engines has published CO2 values on KohlerEngines.com website. Record engine information to reference when ordering parts or obtaining warranty coverage. Engine Model Specification Serial Number Purchase Date 22 590 05 Rev. A KohlerEngines.com Safety Precautions WARNING: A hazard that could result in death, serious injury, or substantial property damage. CAUTION: A hazard that could result in minor personal injury or property damage. NOTE: is used to notify people of important installation, operation, or maintenance information. WARNING Explosive Fuel can cause fires and severe burns. Do not fill fuel tank while engine is hot or running. 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. Spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition. Never use gasoline as a cleaning agent. WARNING Carbon Monoxide can cause severe nausea, fainting or death. Avoid inhaling exhaust fumes. Never run engine indoors or in enclosed spaces. Engine exhaust gases contain poisonous carbon monoxide. Carbon monoxide is odorless, colorless, and can cause death if inhaled. WARNING Accidental Starts can cause severe injury or death. Disconnect and ground spark plug lead(s) before servicing. Before working on engine or equipment, disable engine as follows: 1) Disconnect spark plug lead(s). 2) Disconnect negative () battery cable from battery. WARNING Rotating Parts can cause severe injury. Stay away while engine is in operation. Keep hands, feet, hair, and clothing away from all moving parts to prevent injury. Never operate engine with covers, shrouds, or guards removed. CAUTION Electrical Shock can cause injury. Do not touch wires while engine is running. WARNING Hot Parts can cause severe burns. Do not touch engine while operating or just after stopping. Never operate engine with heat shields or guards removed. WARNING: This product can expose you to chemicals including carbon monoxide and benzene, which are known to the State of California to cause cancer and birth defects or other reproductive harm. For more information go to www.P65Warnings.ca.gov. 2 KohlerEngines.com 22 590 05 Rev. A EN K A B J I H C H I G D E F J J L M N L M N G PO Q PO A Oil Fill/Dipstick B Fuel Filter C Oil SentryTM D E Main Control Bracket F Oil Drain Plug G Standard Air Cleaner Cover H I Lock Symbol J Cover Knob K Fixed Guard L M Paper Element N Debris Screen O Air Cleaner Adapter P Q PRO Air Cleaner Cover Visit KohlerEngines.com for service parts information and purchasing options. Oil Filter Unlock Symbol Precleaner Retainer Pre-Start Checklist 1. Check oil level. Add oil if low. Do not overfill. 2. Check fuel level. Add fuel if low. Check fuel system components and lines for leaks. 3. Check and clean cooling areas, air intake areas and external surfaces of engine (particularly after storage). 4. Check that air cleaner components and all shrouds, equipment covers, and guards are in place and securely fastened. 5. Check spark arrestor (if equipped). 22 590 05 Rev. A KohlerEngines.com 3 Starting WARNING Carbon Monoxide can cause severe nausea, fainting or death. Avoid inhaling exhaust fumes. Never run engine indoors or in enclosed spaces. Engine exhaust gases contain poisonous carbon monoxide. Carbon monoxide is odorless, colorless, and can cause death if inhaled. Cold Weather Starting Hints 1. Use proper oil for temperature expected. 2. Disengage all possible external loads. 3. Use fresh winter grade fuel. Winter grade fuel is formulated to improve starting. 4. Make sure battery has a full charge. Stopping 1. If possible, remove load by disengaging all PTO driven attachments. 2. Position throttle control between half and full throttle; stop engine. WARNING Rotating Parts can cause severe injury. Stay away while engine is in operation. Keep hands, feet, hair, and clothing away from all moving parts to prevent injury. Never operate engine with covers, shrouds, or guards removed. Standard Choke System Above 32°F (0°C) Refer to operating instructions of equipment this engine powers for specific starting instructions. 32°F (0°C) and Below 1. Refer to operating instructions of equipment this engine powers for specific starting instructions. 2. Refer to Cold Weather Starting Hints within this manual. Smart-ChokeTM Above 32°F (0°C) 1. This feature will automatically adjust engine choke on start up with throttle in any position. 2. If engine does not start on first attempt, wait 3-5 seconds and try again (if no start after third attempt wait 1 minute). 3. If engine does not consistently start by fifth attempt, consult Kohler authorized dealer for assistance. 32°F (0°C) and Below 1. This feature will automatically adjust engine choke on start up with throttle in any position (winter blend fuel is recommended). 2. If engine does not start on first attempt, wait 5-10 seconds and try again (if no start after third attempt wait 1 minute). 3. If engine does not consistently start by fifth attempt, consult Kohler authorized dealer for assistance. Angle of Operation Refer to operating instructions of equipment this engine powers. Do not operate this engine exceeding maximum angle of operation; see specification table. Engine damage could result from insufficient lubrication. Engine Speed NOTE: Do not tamper with governor setting to increase maximum engine speed. Overspeed is hazardous and will void warranty. High Altitude Operation If this engine is operated at an altitude of 4000 ft. (1219 meters) or above, a high altitude carburetor kit is required. To obtain high altitude carburetor kit information or to find a Kohler authorized dealer, visit KohlerEngines.com or call 1-800-544-2444 (U.S. and Canada). This engine should be operated in its original configuration below 4000 ft. (1219 meters). Operating this engine with the wrong engine configuration at a given altitude may increase its emissions, decrease fuel efficiency and performance, and result in damage to the engine. 4 KohlerEngines.com 22 590 05 Rev. A Maintenance Instructions EN WARNING Accidental Starts can cause severe injury or death. Disconnect and ground spark plug lead(s) before servicing. Before working on engine or equipment, disable engine as follows: 1) Disconnect spark plug lead(s). 2) Disconnect negative () battery cable from battery. 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 dealer found at KohlerEngines.com or 1-800-544-2444 (U.S. and Canada). Maintenance Schedule Every 25 Hours or Annually¹ (whichever comes first) Service/replace precleaner (if equipped). Replace air cleaner element (if not equipped with precleaner). Every 100 Hours or Annually¹ (whichever comes first) Replace air cleaner element (if equipped with precleaner). Change oil and filter. Remove cooling shrouds and clean cooling areas. Every 100 Hours Replace fuel filter. Check that all fasteners are in place and components are properly secured. Every 200 Hours² Have valve lash checked/adjusted. Every 300 Hours3 Change oil and filter (KOHLER PRO 10W-50 oil and KOHLER PRO filter only). Every 500 Hours Replace spark plug and set gap. ¹ Perform these procedures more frequently under severe, dusty, dirty conditions. ² Have a Kohler authorized dealer perform this service. 3 Option only if using KOHLER® PRO oil and PRO filter. Oil Recommendations AOlill-siseathseonidKeaOl HoLil EfoRr®KPORHOLE1R0Wen-5g0inSeysn. tIht eistic specifically formulated to extend the oil and oil filter change interval to 300 Hours when paired with a KOHLER PRO Extended Life Oil Filter. 300-Hour oil and oil filter change intervals are exclusive to and only authorized on KOHLER engines that utilize both the KOHLER PRO 10W-50 Synthetic Oil and KOHLER PRO Extended Life Oil Filter. Alternative engine oils and oil filters may be used with KOHLER engines but require 100-Hour oil and oil filter change intervals for proper maintenance. Oil must be API (American Petroleum Institute) service class SJ or higher. Select viscosity based on air temperature at time of operation as shown below. KOHLER PRO 10W-50 10W-30 5W-30 SAE 30 °F -20 0 20 32 40 50 60 80 100 °C -30 -20 -10 0 10 20 30 40 22 590 05 Rev. A KohlerEngines.com 5 Check Oil Level NOTE: To prevent extensive engine wear or damage, never run engine with oil level below or above operating range indicator on dipstick. Ensure engine is cool and level. Clean oil fill/ dipstick areas of any debris. 1. Remove dipstick; wipe oil off. 2. Reinsert dipstick into tube; press completely down. 3. Remove dipstick; check oil level. Level should be at top of indicator on dipstick. 4. If oil is low on indicator, add oil up to top of indicator mark. 5. Reinstall and secure dipstick. Change Oil and Filter Change oil while engine is warm. 1. Clean area around oil fill cap/dipstick. Remove drain plug and oil fill cap/dipstick. Allow oil to drain completely. 2. Clean area around oil filter. Place a container under filter to catch any oil and remove filter. Wipe off mounting surface. Reinstall drain plug. Torque to 125 in. lb. (14 N·m). 3. Place new filter in shallow pan with open end up. Fill with new oil until oil reaches bottom of threads. Allow 2 minutes for oil to be absorbed by filter material. 4. Apply a thin film of clean oil to rubber gasket on new filter. 5. Refer to instructions on oil filter for proper installation. 6. Fill crankcase with new oil. Level should be at top of indicator on dipstick. 7. Reinstall oil fill cap/dipstick and tighten securely. 8. Start engine; check for oil leaks. Stop engine; correct leaks. Recheck oil level. 9. Dispose of used oil and filter in accordance with local ordinances. Fuel Recommendations WARNING Explosive Fuel can cause fires and severe burns. Do not fill fuel tank while engine is hot or running. 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. Spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition. Never use gasoline as a cleaning agent. NOTE: E15, E20 and E85 are NOT approved and should NOT be used; effects of old, stale or contaminated fuel are not warrantable. Fuel must meet these requirements: Clean, fresh, unleaded gasoline. Octane rating of 87 (R+M)/2 or higher. Research Octane Number (RON) 90 octane minimum. Gasoline up to 10% ethyl alcohol, 90% unleaded is acceptable. Methyl Tertiary Butyl Ether (MTBE) and unleaded gasoline blend (max 15% MTBE by volume) are approved. Do not add oil to gasoline. Do not overfill fuel tank. Do not use gasoline older than 30 days. Fuel Line Low permeation fuel line must be installed on carbureted Kohler Co. engines to maintain EPA and CARB regulatory compliance. Oil SentryTM (if equipped) This switch is designed to prevent engine from starting in a low oil or no oil condition. Oil SbeefnotrreyTMdammaaygneoot cschuurtsd.oInwnsoamreunanpipnlgiceantigoinnse this switch may activate a warning signal. Read your equipment manuals for more information. 6 KohlerEngines.com 22 590 05 Rev. A Spark Plugs CAUTION Electrical Shock can cause injury. Do not touch wires while engine is running. Clean out spark plug recess. Remove plug and replace. 1. Check gap using wire feeler gauge. Adjust gap, see specification table for adjustment. 2. Install plug into cylinder head. 3. Torque plug to 20 ft. lb. (27 N·m). Air Cleaner NOTE: Operating engine with loose or damaged air cleaner components could cause premature wear and failure. Replace all bent or damaged components. NOTE: Paper element cannot be blown out with compressed air. Turn knobs toward unlock symbol and remove air cleaner cover. Precleaner (if equipped): 1. Remove precleaner from paper element. 2. Replace or wash precleaner in warm water with detergent. Rinse and allow to air dry. 3. Lightly oil precleaner with new engine oil; squeeze out excess oil. 4. Reinstall precleaner over paper element. Paper Element: 1. Remove element from air cleaner adapter; service precleaner. Discard element. 2. Install precleaner over new paper element and install on air cleaner adapter. Secure element behind retainer in housing. Position air cleaner cover on housing and line up knobs with unlock symbol. Turn knobs toward lock symbol to secure. Breather Tube EN Ensure both ends of breather tube are properly connected. Air Cooling WARNING Hot Parts can cause severe burns. Do not touch engine while operating or just after stopping. Never operate engine with heat shields or guards removed. Proper cooling is essential. To prevent over heating, clean screens, cooling fins, and other external surfaces of engine. Avoid spraying water at wiring harness or any electrical components. See Maintenance Schedule. Repairs/Service Parts We recommend that you use a Kohler authorized dealer for all maintenance, service, and replacement parts for engine. To find a Kohler authorized dealer visit KohlerEngines.com or call 1-800-544-2444 (U.S. and Canada). Storage If engine will be out of service for 2 months or more follow procedure below. 1. Add KOHLER PRO Series fuel treatment or equivalent to fuel tank. Run engine 2-3 minutes to get stabilized fuel into fuel system (failures due to untreated fuel are not warrantable). 2. Change oil while engine is still warm from operation (NOT required if using KOHLER PRO 10W-50 full-synthetic oil). Remove spark plug(s) and pour about 1 oz. of engine oil into cylinder(s). Replace spark plug(s) and crank engine slowly to distribute oil. 3. Disconnect negative (-) battery cable. 4. Store engine in a clean, dry place. 22 590 05 Rev. A KohlerEngines.com 7 Troubleshooting Do 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 authorized dealer. Problem Will Not Start Possible Cause Dirt In Dirty No Improper Fuel Debris Incorrect Engine Dirty Air Fuel Fuel Line Screen Oil Level Overloaded Cleaner Faulty Spark Plug Hard Starting Stops Suddenly Lacks Power Operates Erratically Knocks or Pings Skips or Misfires Backfires Overheats High Fuel Consumption Engine Specifications Model Bore Stroke Displacement Oil Capacity (Refill) Spark Plug Gap Maximum Angle of Operation (@ full oil level)* KS530 KS540 KS590 3.7 in. 3.1 in. 33.0 cu. in. 1.5 U.S. qt. 0.030 in. (94 mm) (78 mm) (541 cc) 1.4 L (0.76 mm) 25° KS595 *Exceeding maximum angle of operation may cause engine damage from insufficient lubrication. Additional specification information can be found in service manual at KohlerEngines.com. Any and all horsepower (hp) references by Kohler are Certified Power Ratings and per SAE J1940 & J1995 hp standards. Details on Certified Power Ratings can be found at KohlerEngines.com. Emission Control System Exhaust Emission Control System for models KS530-KS595 is EM for U.S. EPA, California, and Europe. NOTE: Tampering with the engine and its emission control system voids the EPA Certificate of Conformity, ARB Executive Order, and EU type-approval. 8 KohlerEngines.com 22 590 05 Rev. A