Model SP2000 - Carlton Professional Tree Equipment · The Carlton Model SP2000 is a profitable...

Model SP2000

Machine Serial # ____________ Engine Model & Spec # ____________ Engine Serial # ____________ Purchase Date ____________ Dealer ____________

Carlton J.P. Carlton Company Div. D.A.F. Inc. 121 John Dodd Road Spartanburg S.C. 29303 Ph. (864) 578-9335 Fax (864) 578-0210 www.stumpcutters.com

DIESEL ENGINE EXHAUST WARNING

CALIFORNIA

Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproduction harm.

SP2000 SAFETY ALERT

STUMP GRINDER LIMITED WARRANTY

J.P. Carlton Co. Inc., hereafter referred to as the “Manufacturer”, warrants each new Carlton Grinder to be free of defects in workmanship and material for a period of one year. This warranty takes effect upon delivery to the original retail purchaser. The manufacturer at its option will replace or repair at a point designated by the manufacturer, any parts which appear to have been defective in material or workmanship. The manufacturer is not responsible for consequential damages. This warranty will not apply if the grinder is not operated in a manner recommended by the manufacturer. The following examples would void warranty: 1. The grinder has been abused. 2. The machine is involved in or damaged by an accident. 3. Repairs or attempted repairs were made without prior written authorization. 4. Including but not limited to repairs made due to normal wear. The owner is responsible for all regular maintenance as explained in the operators’ manual. Neglect in regular maintenance or failure to replace normal wear items such as teeth, pockets, lubrication oils, filters, belts, bearings, etc. may void warranty. This warranty is expressly in lieu of any other warranties, expressed or implied, including any implied warranty or merchantability of fitness for a particular purpose and of any non-contractual liabilities including product liabilities based upon negligence or strict liability. J.P. Carlton Co. Inc. will not be liable for consequential damages resulting from breach of warranty. IT IS NECESSARY TO RETURN THE WARRANTY VALIDATION FORM AND NOTIFY J. P. CARLTON CO. INC. IN WRITING WITHIN TEN (10) DAYS FROM DELIVERY DATE TO VALIDATE THIS WARRANTY. NOTE: This warranty applies only to new and unused equipment or parts thereof manufactured by J.P. Carlton Co. Inc. ANY MACHINES USED FOR LEASE OR RENTAL - WARRANTY IS LIMITED TO 90 DAYS FROM FIRST DAY OF INITIAL SERVICE. NOTICE: All power units and associated components are NOT warranted by J.P. Carlton Co. Inc. or their dealers. It is the customers’ responsibility to return machine to the local engine distributor. INFORMATION PHONE NUMBERS TO FIND YOUR LOCAL ENGINE & PARTS SERVICE CENTERS: Honda ............................................ 1-770-497-6400 (GA-Eastern Time Zone) Kohler Engines.............................. 1-800-544-2444 (Toll Free) Briggs & Stratton Engines ........... 1-800-233-3723 (Toll Free) Lombardini ................................... 1-770-623-3554 (GA-Eastern Time Zone) Deutz Engines................................ 1-800-241-9886 (Toll Free) John Deere Engines ...................... 1-800-533-6446 (Toll Free) Caterpillar ..................................... 1-877-636-7658 (Toll Free) Kubota ........................................... 1-847-955-2500 (IL-Central Time Zone) Kawasaki Engines......................... 1-616-949-6500 (MI-Eastern Time Zone) Wisconsin Engines ........................ 1-800-932-2858 (Toll Free) Onan Engine ................................. 1-800-888-6626 (Toll Free) In order to process any warranty claims. It is the owners’ responsibility to report claims promptly to us or the authorized dealer from whom the equipment was purchased. It is necessary to include the following information on any and all request for warranty: 1. Dealer from whom purchased 5. Engine make and serial number 2. Date of delivery 6. Length of time in use 3. Serial number of unit 7. Date of failure 4. Model number of unit 8. Nature of failure

STUMP GRINDER LIMITED WARRANTY

EXPLANATION OF LIMITED WARRANTY

The manufacturer will not reimburse the customer or dealer labor cost incurred for installing “bolt-on” or “slip-on” items, such as pumps and motors, bearings, belts, pulleys, etc. The manufacturer will provide replacement parts at no cost to the customer for defective parts during the warranty period. Defective parts must be returned to J.P. Carlton Company. It will be the customers’ responsibility to install the replacement parts unless arrangements are made with the selling dealer. The manufacturer will not reimburse travel cost to servicing dealer. It is the customers’ responsibility to deliver machine to dealers’ facility, unless other arrangements have been agreed to between the selling dealer and the customer. The manufacturer may elect, at its discretion, to reimburse reasonable labor cost to customer or dealer for major defect repairs. Prior approval must be obtained from J.P. Carlton Company Inc.

IMPORTANT NOTICE

1. AIR FILTER MAINTENANCE IS CRITICAL ON STUMP GRINDING MACHINES.

DIRT INGESTION WILL NOT BE WARRANTED BY THE ENGINE MANUFACTURER OR J.P. CARLTON

COMPANY.

2. OIL AND OIL FILTER MAINTENANCE AND STAYING WITHIN THE LIMITS OF THE ANGLE OF OPERATION IS ALSO CRITICAL ON STUMP GRINDING MACHINES.

STARVING THE ENGINE FOR OIL WILL NOT BE WARRANTED BY THE ENGINE MANUFACTURER OR J.P. CARLTON COMPANY.

Warranty Validation Form Congratulations on your purchase of a Carlton Stump Grinder. This product has been designed and manufactured to provide years of profitable service while minimizing maintenance and downtime. Please take the time now to complete this warranty validation form. This information is necessary for Carlton to instate your warranty. Return Form To: J.P. Carlton Company, Div. D.A.F. Inc. 121 John Dodd Road

Spartanburg, SC 29303 Phone: 1-864-578-9335

Purchaser Information: Company Name:_______________________ Street Address:_____________________________ City:_________________________ State:__________ Zip Code:__________________________ Telephone:_______________________Contact:________________________________________ Machine Information: Model Number :_______________________ Engine Model :________________________ Serial Number :________________________ Serial Number :________________________ Dealer Information: Dealer Name:____________________ Street Address:___________________________ City: _______________________ State:__________ Zip Code:____________________ Contact Name: ____________________ 1. ______ Customer has been instructed on operation and safety aspects of operating the equipment. 2. ______ Customer has been advised not to reach into cutter wheel area. 3. ______ Customer has been advised to stop machine and remove key before performing any type of

maintenance. 4. ______ Customer has been warned not to operate the machine without the cutter wheel guard in place. 5. ______ Customer has been furnished with all parts and operators manuals. 6. ______ Customer has been instructed on equipment maintenance schedules and procedures. 7. ______ Customer has been advise that the engine or power unit that is used on this machine is warranted

by the engine manufacturer and NOT J.P. Carlton Company. All engine warranty issues should be addressed to the local engine dealer.

8. ______ Customer understands the importance of air and oil filter maintenance, and the importance of staying within the angle of operation of the engine. If either of these is not adhered to, the engine warranty is VOID.

9. ______ Customer understands to keep locking collars tight and purge bearings with grease. 10. ______ All operation and warning decals are properly displayed on equipment. 11. ______ Customer understands it is his responsibility to train all operators on operator safety. I have inspected this equipment and find it in good working condition. To the best of my knowledge, the customer and his personnel are aware of the above procedures. Date: _______________ Signed: ____________________________________ Dealer Representative The equipment has been thoroughly checked by the above named dealer representative, and I am satisfied with his instructions. Date: ________________ Signed: ___________________________________ Purchaser

SP2000 TABLE OF CONTENTS INTRODUCTION FOREWORD 1 GENERAL INFORMATION 2 MACHINE FEATURES 3 MACHINE SPECIFICATIONS 4 OPERATION SAFETY PRECAUTIONS 5 DAILY CHECKLIST 8 MACHINE CONTROLS 11 TRANSPORTING 14 MACHINE OPERATION 15 MAINTENANCE MACHINE MAINTENANCE 19 LUBRICATION CHART 22 TROUBLESHOOTING GUIDE 23 SERVICING CUTTER WHEEL 24 WIRING DIAGRAM 29 PARTS FRAME ASSEMBLY 30 AXLE ASSEMBLY 32 ENGINE ASSEMBLY 34 BELT ASSEMBLY 36 CUTTER WHEEL ASSEMBLY 38 CHIP GUARD ASSEMBLY 40 BACK KOHLER ENGINE MANUAL TRANSMISSION PARTS LIST HYDROSTAT PARTS LIST

SP2000 FOREWORD

1

Congratulations on your purchase of a new Carlton® Professional Stump Grinder! Carlton Stump Grinders have a reputation for superior performance and reliability. A machine is not profitable if it's broken-down and we do our absolute best to help you avoid costly downtime. Each and every machine has been over designed and overbuilt to ensure years and years of trouble-free operation. In this, we take pride.

The Carlton Model SP2000 is designed and intended for use in unique situations where size and maneuverability are foremost. As a result, the Model SP2000 has it's own unique operational requirements.

Read this manual carefully and TAKE RESPONSIBILITY for thoroughly familiarizing yourself with the controls and the concepts behind the operation of this machine before attempting to operate it. Slowly experiment with the controls and gradually work yourself up to the full capabilities of this machine. The Carlton Model SP2000 is a profitable professional stump grinder. Read this manual. Use proper safety precautions. Follow the instructions provided and use common sense and your "OX" will perform like its namesake. If getting more work done in a day, with less trouble, is your idea of good business, then you'll love your new Carlton Stump Grinder!

We welcome your suggestions on how we might better build our machines. We solicit any and all questions concerning the safe operation or proper servicing of your new stump grinder.

Please feel free to write to us with any comments. We'll enjoy hearing from you!

SP2000 GENERAL INFORMATION

2

The J. P. Carlton Company constantly strives to create the best equipment available in the stump cutting industry. Therefore, the material in this manual is correct at the time of publication. Carlton reserves the right to make improvements, modifications and even discontinue features, as we deem necessary to meet our goal. Carlton also reserves the right to discontinue models without any prior notification or obligation. Inspect your new Carlton Stump Grinder as soon as you receive it. Any damages incurred during shipment are not warranted and therefore not covered repairs. You should have the truck driver verify or acknowledge any damages caused during shipment. If not, contact the truck lines as soon as possible with your complaint. Any reference made to right, left, front or rear in relationship to the stump cutter is illustrated in the following picture. Please refer to these any time you call your dealer or J. P. Carlton Company for parts or assistance.

Left Right

Front Rear Front

SP2000 MACHINE FEATURES

3

• Gas Power • Heavy construction • Tapered roller bearings on

cutter wheel. • 3/4” thick Blanchard

ground cutter wheel • Freewheeling capability • Low maintenance, multiple

drive belt • 16 carbide tipped cutter

teeth

• 34 1/2” width to clear fence gates

• Safety tie down loops • Epoxy primer • DuPont Imron® protective

finish • Premium tires • Heavy duty rubber

and metal chip guards

• Self propelled • Easy engine belt

adjustment • Heavy duty electric

industrial clutch • High capacity air filtration

system • Key start • High capacity battery • Marine battery box • Fuel Filter

We Pride Ourselves in the strength and quality of each and every machine

SP2000 MACHINE SPECIFICATIONS

4

Engine ............................................................Kohler® 27 HP Weight............................................................695 lbs. Length ............................................................80” Height.............................................................54” Width..............................................................34 1/2” Cutting Depth Below Ground................................................24” Cutting Height Above Ground................................................27” Number of Teeth on Cutter Wheel .............................................16 Cutter Wheel Diameter w/Teeth...........................................19” Cutter Wheel Thickness.................................3/4” Blanchard Ground Engine Engagement .......................................Electric Clutch Drive Belt.......................................................A100 (2) Cutter Wheel Shaft.........................................1 7/16” Cutter Head Bearings.....................................1 7/16” Tapered Roller Fuel Tank Capacity ........................................5 Gallons

SP2000 SAFETY PRECAUTIONS

5

Before operating the stump cutter, read this manual, the engine manual, and all the safety decals on the machine. Know all parts of the machine and their functions, especially the shut down procedures in case of emergency. No inexperienced person may operate machine. Inexperience may cause injury. SAFETY FIRST ALWAYS! This is the Safety-Alert Symbol. This symbol is placed on the machine and in the manual to alert the operator to the potential for bodily injury or death. The operator should pay close attention to the instructions whenever they see this symbol. The Safety-Alert Symbol will be accompanied by one of the following words:

DANGER, WARNING, or CAUTION • A DANGER symbol means that if the instructions are not followed the possibility of

serious personal injury or death is probable. • A WARNING symbol means that if the instructions are not followed there is a

possibility of serious personal injury or death. • A CAUTION symbol means there is an unsafe condition or practice that may cause

personal injury or property damage. PERSONAL PROTECTION:

Wear face shield and hearing protection Do not wear loose-fitting

clothing Tie back long hair Do not wear jewelry Keep clear of cutter wheel Keep away from moving parts Only operate in a well ventilated

area because of carbon monoxide

P/N 0700008 P/N 0700010 P/N 0700027


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Be Safe and Practice Safe Operation using the following guidelines.

• Any individual operating this machine must first read and understand this manual, the engine manual, all component manuals, and all safety decals on machine.

• DO NOT permit children to operate machinery or to play near machinery during operation.

• Always wear face shield and hearing protection during operation. Loud noise and flying debris may cause severe injury.

• Keep hands, feet, legs, clothing, hair and all other body parts away from cutter wheel and other moving machine parts to eliminate the possibility of injury.

• Shut down machine completely and remove key before removing debris from work area (i.e. clearing rocks, wood chips, etc.).

• DO NOT modify or change any part without written approval from J. P. Carlton Company.

• Do not ride, sit, stand, lay or climb anywhere on this machine during operation, while running, or during transport.

• Do not move, position, or transport this machine while cutter wheel is engaged.

• DO NOT operate any machinery while under the influence of alcohol or drugs (prescription, over the counter, or otherwise).

• Do not refill fuel tank while engine is hot, running, or indoors. Danger of fire or explosion exists.

• Fuel and its vapors are highly flammable and explosive. Handle with care. Only use approved (red) fuel containers for storage.

• Do not store fuel containers near any open flames, sparks or other sources of ignition.

• Do not store equipment with fuel in the tank.

• Battery fumes are explosive. Recharge battery in an open area away from fire, sparks, or other sources of ignition.

• Battery acid can cause severe burns. Keep away from eyes, skin, and clothing.

• Always remove battery before welding on equipment.

• Never check for hydraulic leaks using hand or finger, use cardboard or wood. Keep away from pressurized leaks. Pressurized fluid can penetrate the skin and cause injury or even death. Seek immediate medical attention if penetration occurs. Always wear eye protection.


7

• DO NOT OPERATE THE ENGINE AT AN ANGLE

GREATER THAN 25° OR SEVERE ENGINE DAMAGE WILL OCCUR. PROPER ENGINE OIL LEVEL MUST BE MAINTAINED TO ACHIEVE MAXIMUM ANGLE OF OPERATION OF 25°. (See Engine Owner’s Manual for proper oil level.)

• Never allow spectators to stand and watch machine in operation

without proper hearing and eye protection and standing at a safe distance. Loud noise and flying debris may cause severe injury.

• Do not operate around water, gas, power or phone lines. Check with property owner or call utilities if not sure.

• Avoid fences and clear away other objects (i.e. sticks, stones, metal, etc.).

• Be aware of the possibility of foreign objects imbedded in or buried around the stump. Do not cut crosswise of roots above ground to prevent roots being thrown.

• If unusual vibration occurs, stop engine immediately and correct problem before continuing operation.

• Keep all guards in place and properly secured during operation. • Keep all safety devices working properly and all other machine

parts in good working condition. • Never leave the controls unattended while in operation. Be sure

machine is not capable of operation when left unattended. • Stop engine and remove key when repairing or adjusting machine

or drive belts. • Keep engine in good condition service as instructed in engine

manual. • Do not touch engine while running or hot (serious burns may

result). • Allow all machine parts to cool sufficiently before servicing or

making adjustments. Hot machine parts can cause severe burns. • Do not run the machine without a complete number of teeth in the

cutter wheel tightened to the correct torque. • Do not place machine in free wheel without first placing tongue

stake in the ground. • Park machine on level surfaces only. Lower cutter head to the

ground and use wheel chocks to prevent unattended movement. • Do not operate stump cutter in dark, dim lit, or concealed areas. • Keep machine clean and clear of debris to eliminate fire hazard.

It is especially important to clean any oil or fuel spills to prevent the danger of fire.

• Keep cutter wheel skirt guards in good condition to help control chips during grinding.

• Keep safety and instructional decals clean and replace any that are damaged, difficult to read, or missing. Decals may be purchased from J. P. Carlton or an authorized dealer.


8

SP2000 DAILY CHECKLIST

9

• Check engine oil at dipstick (see picture). Take oil

reading with engine sitting level. Add recommended oil type as required (see engine owners’ manual).

• Check fuel filter for debris or water. • Replenish fuel tank with fresh fuel.

Gasoline and its vapors are highly flammable and explosive. HANDLE WITH CARE. Use only in well ventilated areas.

• Check condition and tightness of drive belts. (See

Maintenance section)

Allow all machine parts to cool sufficiently before servicing or making adjustments.

• Check for any loose, broken, or missing cutter teeth

or pockets. (See Servicing Cutter Wheel section)

Do not run machine without a complete set of 16 teeth in the cutter wheel tightened to the correct torque.

SP2000 DAILY CHECKLIST

10

• Inspect bolts, wiring harnesses, and equipment for

tightness and wear. Replace if necessary. • Check air filters and pre-cleaners. Inspect dry air

cleaners. Do not blow out or tap on ground. REPLACE WITH MANUFACTURER RECOMMENDED AIR FILTER ONLY. Dirty air filters can lead to dirt ingestion in the engine. This is the most common cause of engine failure and is not warrantable. (Reference engine manual)

• Check condition of tires. Check for cuts, worn

treads, bulges, or damaged rims. • Inflate to proper pressure. • Make sure tire tread is in direction shown in picture

otherwise may dig into and tear up ground while traveling to work area.

Tire can explode if:

• Tire pressure exceeds recommended limit.

• Wheel has cuts, bubbles, or damaged rims.

• Wheel assembly is heated or welded. Heat increases tire pressure.

SP2000 MACHINE CONTROLS

11

ENGINE CONTROLS – Refer to the engine manufacturers owners’ manual for controls,

operation, and service information.

The SP2000 is equipped with a Kohler engine. The controls are on the machine handle as shown below. Read the engine manual for all other information. DO NOT OPERATE THE ENGINE AT AN ANGLE GREATER THAN 25° OR SEVERE ENGINE DAMAGE WILL OCCUR. PROPER ENGINE OIL LEVEL MUST BE MAINTAINED TO ACHIEVE MAXIMUM ANGLE OF OPERATION OF 25°. (See Engine Owner’s Manual for proper oil level.) MACHINE CONTROLS Figure 1 illustrates: A. Cutter Wheel Engagement Switch – This switch

starts the cutter wheel when the engine is running. To start cutter wheel push switch forward to the engage position, you may find a need to push switch back and forth from engage to disengage until wheel starts and continues running. To disengage push switch backward to disengage position.

B. Engine Ignition Switch - This switch has three

positions: Off, Run & Start. Turn to right to start.

Remove key when working on machine, clearing stump area, or leaving machine unattended.

C. Engine Choke Control – Pull out to choke

engine. Cold engine requires momentary choke to start.

D. Engine Throttle Control – Pull out to increase

engine speed. Twist clockwise to lock. Always turn counterclockwise to release throttle before pushing throttle handle down.

Figure 1

A B DC


12

Figure 2 illustrates: A. Safety Shut Off System – The safety shut off

bar must be held down for engine to start. This bar must continue to be held down for the machine to operate. Releasing this bar will automatically shut off the machine.

Never disengage, bind, or impair the safety shut off handle in any way.

Figure 3 illustrates: A. Parking brake Engagement Lever – Shown in

the locked position. Push forward to release parking brake to move the machine. The parking brake will not allow the machine to move forward or reverse.

The machine will pivot while the parking brake is engaged.

B. Transmission Control Lever - Push forward to

propel machine forward. Pull rearward to propel machine in reverse. The further the lever is pushed the faster the machine will travel.

Figure 4 illustrates: A. Transmission Bypass Valve – Pull out knob for

normal operation. In this position, the Transmission Control Lever will propel the machine. Push knob in for freewheeling of transmission. Use this position for manually pushing or towing the machine at slow speeds. Always use caution when pulling down hill not to be overrun by equipment.

Do not run engine with the Transmission Bypass Valve in the in position.

Figure 2

Figure 3

Figure 4

A

A

B

A


13

Figure 5 illustrates: A. Height Adjustment Plate – There are six

different locations in the plate to allow the operator to adjust the height of the handlebar for ease of operation while grinding the stump.

B. Height Adjustment Handle – Use this handle to

change the height of the handlebar (see Figure 6) for ease of operation during grinding stump. The handlebar can be positioned from very low (see Figure 7) to very high (see Figure 8).

Figure 7 Figure 8

Figure 5

Figure 6

A B

SP2000 TRANSPORTING

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DO NOT TOW! THE MODEL SP2000 IS DESIGNED TO TRANSPORT TO THE JOB SITE ON A TRAILER. Transport machine in a suitable vehicle designed for a load equal to the dimensions and weight of the SP2000. A low trailer is recommended due to its decreased height. • Check trailer for security and make sure chains are

properly installed. • Check tires for correct inflation pressure. • Know and follow all laws and procedures for towing

that are applicable to the state you are currently in. • Start and stop gradually. The model SP2000 can be loaded into a pickup truck, but increased safety precautions against tipping are necessary. • Loading ramps must be sturdy and attached to

the transport vehicle before attempting to load or unload the machine.

• Do not transport the SP2000 while the engine is running.

• Equipment must be secured to the trailer. Use tie

downs attached to the support plates and cable holders on the machine and attached to the trailer.

SP2000 MACHINE OPERATION

15

BEFORE STARTING, ANY INDIVIDUAL OPERATING THIS MACHINE MUST READ AND UNDERSTAND THIS MANUAL, THE ENGINE MANUAL, AND ALL SAFETY INFORMATION IN MANUALS OR ON MACHINE. DO NOT OPERATE THE ENGINE AT AN ANGLE GREATER THAN 25° OR SEVERE ENGINE DAMAGE WILL OCCUR. PROPER ENGINE OIL LEVEL MUST BE MAINTAINED TO ACHIEVE MAXIMUM ANGLE OF OPERATION OF 25°. (See Engine Owner’s Manual for proper oil level.)

• Check all fluids first. • Inspect all connections, teeth, tires, etc. (see Daily Checklist). • Start engine at idle speed and allow sufficient time for the engine to warm up before

proceeding. Place throttle control at “slow “ position (push in). Engage the choke for cold weather operation (pull out). The safety shut off bar must be held down for engine to

start. You must continue to hold down the bar for the machine to operate. Releasing this bar will automatically shut off the machine.

Make sure Cutter Wheel Engagement Switch is in the off (disengage) position.

Start engine using ignition switch. For a cold engine – gradually return the choke control to

the “off” position after the engine starts and warms up.

• Always stand behind the control handle; never leave this position while cutter wheel is running. Use extra caution because this is the discharge area. Keep chip guards in good condition and secured in position.

• Never leave controls unattended while in operation. Remove key and make sure machine is not capable of operation when left unattended.

• Position machine in front of stump with cutter wheel a slight distance away (see Figure 2).

The SP2000 is self-propelled to allow the operator to position the machine in the proper position without too much effort. Figure 3 shows forward position and Figure 4 shows reverse position.

Figure 2 Figure 3 Figure 4

Ignition Choke Throttle


16

• Always wear eye and ear protection and sturdy footwear. • Do not operate around water, gas, power, or phone lines. Check

with property owner or call utilities if not sure. • Avoid fences and clear away other objects (i.e. sticks, stones, metal,

etc.). • Never allow spectators to stand and watch machine in operation

without proper hearing and eye protection and standing at a safe distance.

• Stop engine and remove key when repairing or adjusting machine or drive belts. Keep engine in good condition.

• Allow all machine parts to cool sufficiently before servicing or making adjustments. Hot machine parts can cause severe burns.

• Do not touch engine while running or hot (serious burns may result). • Never refill gas tank while engine is hot, running, or indoors.

Danger of fire or explosion exists. • Apply brake. Figure 5 shows

the brake in the on (stop) position and Figure 6 shows the brake in the off (move) position.

• The machine will pivot while the brake is engaged. Do not depend

on the brake to hold the machine stationary. The brake will stop forward and reverse motion but will still allow the machine to pivot right and left to grind stump.

• Raise engine speed to half throttle. • Engage cutter wheel with the engagement switch. To start cutter wheel push switch forward

to the engage position, you may find a need to push switch back and forth from engage to disengage until wheel starts and continues running. To disengage push switch backward to disengage position

• If engine cuts off when starting cutter wheel, increase RPM after starting engine before restarting cutter wheel.

• Keep hands, feet, legs, clothing, hair and all other body parts away from cutter wheel and other moving machine parts to eliminate the possibility of injury.

Figure 6Figure 5


17

• Keep all guards in place and properly secured during operation. • Do not run the machine without a complete number of teeth in the

cutter wheel tightened to the correct torque. • When cutting the stump, pivot machine right to left to cut across the width of the stump.

Gradually work down to the desired depth continuing to go across the stump as you go deeper (see Figures 8 thru 10).

• Unlock the brake, move the machine forward slightly, reset

the brake, and resume cutting the stump. • Continue in this manner until the stump has been removed

(see Figure 11). • Reduce the engine to idle. Disengage the cutter wheel.

Allow cutter wheel to come to a complete stop. • Propel the machine in reverse, shut the engine down, and

remove key before inspecting the work area (see Figure 12). Allow the cutter wheel to come to a complete stop before inspecting the work area.

• Shut down machine completely and remove key before removing debris from work area (i.e. clearing rocks, wood chips, etc.).

• If necessary to clear work area before finishing grinding stump, reduce the engine to idle.

Disengage the cutter wheel. Allow cutter wheel to come to a complete stop. Propel the machine in reverse and SHUT MACHINE DOWN COMPLETELY and REMOVE KEY.

Figure 8 Figure 9 Figure 10


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For optimal performance, the stump should be cut with the portion of the cutterwheel shown. NEVER UNDERCUT THE STUMP. Undercutting the stump can cause severe kickback, vibration and component damage. NEVER CUT THE STUMP FROM THE TOP. The cutterwheel will throw debris up and toward the operator, instead of down and under the machine.

SP2000 MACHINE MAINTENANCE

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• Check engine oil at dipstick DAILY (see Figure 1). • Take oil reading with engine sitting level. • Add recommended oil type and change oil and filter as

required. (See engine owners’ manual). • Grease cutter wheel bearings DAILY (see figure 2). • Wipe grease fittings clean before attaching grease gun! • These bearings should be purged using grease DAILY.

Purge until new grease comes out. Clean machine to remove all excess grease after purging.

• Use Texaco Starplex® II grease. • Check cutter wheel, teeth, and pockets for wear. If any

repair is needed, see “Servicing Cutter wheel” section for further instruction.

• Make sure all teeth and pockets are tightened properly. • Tighten pocket bolts to 150 foot/pounds. • There are two belts used on the cutter wheel pulley and

electric clutch pulley and a third belt used on the idler pulley, the pump drive pulley, and the motor drive pulley (see Figure 4).

• New belts will stretch and become loose as machine runs. Check belt tension often when belts are new.

Figure 1

Figure 2

Figure 3

Figure 4


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• Check cutter wheel belts for proper tension by removing

cover. First, disconnect the electric clutch as shown in Figure 5.

• Then, remove bolts on belt guard cover as shown in Figure 6

and remove cover. • To adjust belt tension, loosen the four bolts on engine plate.

Figure 7 shows two of the four bolts, the other two are on the other side of the engine.

• Then adjust engine slide plate tightening or loosening bolt to

get the correct belt tension as shown in Figure 8. Make only slight adjustments at a time and recheck tension; repeat as necessary until tension is correct.

• Proper tension of cutter wheel belts is 5/32” deflection at center span between pulleys with 10 pounds of pressure applied. Too much tension results in excessive wear and stress on flywheel shaft bearings.

Belts tend to “seat-in” during the first few hours of operation. Carlton recommends adjustment of belt tension after the first two hours of operation. Replace belts when worn or when repeated adjustments are necessary. Belts should never get so loose that all of the adjustment capability is used. Always use Carlton recommended belts. They are available through your dealer or from the factory.

Figure 5

Figure 6

Figure 7

Figure 8


21

• Check level of hydraulic fluid and replenish as necessary on

the Hydrostatic drive (see Figure 9). • Make sure not to fill above the fill line (very low on

container). • Recommended to use AW32 hydraulic fluid. • Adjust reverse speed to keep

machine from running over the operator using the speed control adjustment on the left side of the machine (see Figure 10). Turn bolt to come out, thus reducing the travel of the speed control lever, to reduce speed and turn bolt to go in to increase speed.

• Transmission features an oil bath lubrication

with fill and drain plugs (see Figure 11). • Drain oil and replace with 24 ounces of new

90-weight oil. Never fill more than 3/4 full; operating at high temperature will cause oil to expand and spill over if gearbox is full.

• Access fill plug from top of machine through opening next to hydraulic fluid tank (see Figure 9).

• Recommended to change every 500 hours of operation.

• Brake (see Figure 12) will

require periodic maintenance and adjustment to assure safe operation of equipment. Call 1-800-558-5402 to find your local Tecumseh repair center.

Figure 10 Adjustment Bolt

Speed Control Lever

Location

Drain Plug

Brake

Fill Plug

Figure 9

Figure 12

Figure 11

SP2000 LUBRICATION CHART

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• The model SP2000, as well as all of our machines, is built to be rugged performers. Your new machine is sturdy and our design goals are simplicity and reliability.

• A regularly scheduled maintenance program will pay big dividends in machine life, performance and avoided damage.

• Make sure to wipe all grease fittings clean before attaching grease hose. Failure to do

this forces dirt into the surfaces and shortens life. • Always use Texaco® Starplex® II grease. Grease frame handle, both sides, every 15 - 20 hours of operation. Grease the cutter wheel bearings daily. These bearings should be purged using grease DAILY. Purge until new grease comes out. Machine should be cleaned to remove excess grease after purging.

SP2000 TROUBLE SHOOTING GUIDE

23

COMPLAINT CAUSE CORRECTION

Engine will not start (see Engine Manufacturer Manual for further information).

• Loose ground wire. • Loose hot wire. • Dead battery.

• Clean and tighten. • Clean and tighten. • Recharge or replace.

Belt Squeal. • Belts tension too loose. • Belts out of line.

• Tighten belts (see Maintenance Section).

• Align Pulleys. Belt jumping off. • Engaging or disengaging

belt at high engine RPM. • Belts too loose.

• Only engage or disengage belts at medium engine speeds.

• Tighten belts (see Maintenance Section).

Cutter wheel vibration. • Tooth missing. • Pocket out of balance. • Improper tooth

arrangement.

• Replace missing teeth. • Always replace pockets in

pairs across from each other. • Install correctly (see

Servicing Cutter Wheel diagram for arrangement of teeth).

Cutter wheel throwing teeth. • Bad pocket. • Dirt in pocket • Worn cutter wheel • Teeth set too far out of

pocket. • Cutter wheel bolts not

properly tightened.

• Replace pocket and teeth. • Clean pocket and replace

missing teeth. • Replace cutter wheel • Use gauge to set teeth

correctly. • Torque bolts to 150 ft/lbs

Cutter wheel breaking teeth. • Teeth set too far out of pocket.

• Debris in cutting path.

• Use gauge to set teeth correctly.

• Inspect area and remove rocks and foreign material.

Cutter wheel stops turning. • Belt not engaged. • Engine belt broke. • Sheared key in shaft. • Broke cutter wheel shaft. • Broke clutch.

• Adjust yoke assembly. • Replace belt. • Replace key. • Replace shaft. • Replace clutch.

Roar in machine when cutter wheel is engaged.

• Belt guards rubbing on cutter wheel shaft.

• Cutter wheel bearings going bad.

• Re-position guards off of shafts.

• Replace bearings.

Bearing will not take grease. • Grease fitting clogged. • Replace fitting.

SP2000 SERVICING CUTTER WHEEL

24

• Do not run the machine without a

complete number of teeth in the cutter wheel tightened to the correct torque.

There are sixteen (16) teeth to a complete set on the model SP2000. Two (2) straights, seven (7) left 45’s and seven (7) right 45’s. A locking pin is provided to hold cutter wheel in position during tooth removal and re-installation. Shown in the stored location. Insert locking pin through hole on cutter wheel guard. Locking pin will only lock on outer teeth. NEVER PLACE HAND ON CUTTER WHEEL TO HOLD IN PLACE WHILE CHANGING TEETH. BE SURE TO REMOVE PIN BEFORE OPERATING. A Tooth Setting Gauge (P/N 0450111) is provided with each machine for proper tooth installation. Line all teeth up with the inside edge of the groove in the gauge. Set ALL teeth to this edge. See Cutter Wheel Assembly for breakdown.


25

TOOTH ARRANGEMENT • Inspect pockets, teeth and bolts for damage

and replace as required. • When replacing pockets, always replace

new pockets across from each other in order to prevent vibration.

• Replacement teeth must be carbide tipped and of like design as provided with the machine.

• Use anti-seize on threads to prevent bolts from “freezing up” in cutter wheel.

• When replacing complete set of teeth, be sure to duplicate original factory tooth arrangement.

• Torque bolts to 150 ft/lbs.

• Straight teeth are mounted in TWO

OPPOSING OUTSIDE POCKETS (Positions 1 & 5). A straight tooth must have a 45° tooth accompanying it in the same pocket set (Position 1). The opposite pocket set should have this same combination of straight and 45° teeth, except with positions reversed (Position 5). Mounting these teeth opposite each other on the cutting wheel cancels damaging vibration and provides a smooth cut.

• Two 45° teeth of the same direction (Right in one and Left in one) are in pocket positions 3 & 7.

• All other pockets have a right and left 45° tooth as shown in position 2.


26

OPTIONAL: Sandvik® Dura Disk II Cutter Wheel • If the machine is supplied with the

optional Dura Disk II cutter wheel, there are thirty (30) teeth to a complete set. There are ten (10) Short Plow Bolt Bits (Carlton part #0450131) and twenty (20) Plow Bolt Bits (Carlton part #0450130).

• DO NOT OPERATE A MACHINE WITHOUT A COMPLETE NUMBER OF TEETH IN THE CUTTER WHEEL PROPERLY INSTALLED. EXCESSIVE MACHINE VIBRATION WILL OCCUR CAUSING PREMATURE BEARING FAILURE AND EQUIPMENT DAMAGE.

• A locking pin is provided to hold cutter

wheel in position during tooth removal and re-installation.

• The locking pin will only lock on an outside 20° tooth. Line the tooth up with the locking pin slot and insert the pin to lock position. The pin will need to be removed and reinserted as wheel is rotated to change remaining teeth. NEVER PLACE YOUR HAND ON THE CUTTER WHEEL TO HOLD IT IN PLACE WHILE CHANGING TEETH.

• BE SURE TO REMOVE THE PIN BEFORE OPERATING THE STUMP CUTTER.

• The teeth do not require a setting gauge.

The only requirement is to be installed in the proper direction and tightened to the proper torque as discussed in the next section.

• When replacing a cutter wheel tooth, replace the tooth and nut as a set and use anti-seize on the threads.


27

OPTIONAL: Sandvik® Dura Disk II Cutter Wheel TOOTH ARRANGEMENT • Inspect pockets, teeth and bolts for damage and

replace as required. • When replacing a cutter wheel tooth, replace

the tooth and nut as a set and use anti-seize on the threads.

• When replacing teeth and pockets, also replace the teeth and pockets across from each other diagonally in order to maintain wheel balance and prevent vibration.

• All teeth and pockets are of a specific design and must be replaced with original manufacturer’s replacement parts. Replacement teeth must be carbide tipped.

• When replacing complete set of teeth, be sure to duplicate original factory tooth arrangement. SEE DIAGRAM BELOW.

• The seating surfaces of the tooth and pocket are formed, but make sure the tooth is inserted with the carbide facing the direction of rotation.

• The pictured view is the engraved side of the wheel. The wheel is engraved with outside pocket numbers, outside pocket angle/direction (20 R or 20 L), and wheel rotation. (The engraved side of wheel is marked left side of wheel; this is for manufacturing purposes only. It does not refer to the left side of the machine as described in the General Information section.)

• Outside pocket teeth are Short Plow Bolt Bits. These pockets are angled and welded in place. You can switch teeth from one outside pocket to a pocket that is the opposite direction to prolong tooth life, such as switching a tooth from a 20 R with a tooth from a 20 L pocket. The cutting edge is the corner and this will turn the opposite corner out for use.

• These teeth are tightened with Stover Lock Nuts. Torque on Stover locking nuts is not to exceed 270 ft. lbs.

• All teeth on cutter wheel sides are Plow Bolt Bits. When changing these teeth you must remove both teeth in the same pocket, one on each side of the wheel. When the nuts are torqued, the pocket is jammed and the teeth can only be removed this way.

• These teeth are also tightened with Stover Lock Nuts. Torque on Stover locking nuts is not to exceed 270 ft/lbs.

• The pocket will receive wear when cutting and can be switched from one side of the cutter wheel to the other to prolong life. Remember the teeth must be replaced in the original position on each side of the wheel.

It may be necessary to use a 1 1/4” hole saw to remove debris around nut to make tooth removal easier.


28

TOOTH SHARPENING

Begin by removing the exposed area of the steel shank shown above with a standard

grinding stone to provide relief for the cut. After the shank has been ground, use a silicon carbide green stone to dress the carbide.

• Cut the shank with a standard grinding stone and cut the carbide with a

silicone carbide green stone or diamond rock.

EYE PROTECTION ALONG WITH A FRESH AIR RESPIRATOR MUST BE WORN WHILE GRINDING CARBIDE.

SP2000 WIRING DIAGRAM

29

SP2000 FRAME ASSEMBLY

30

ITEM NO PART NO DESCRIPTION QTY 1 SP2500-10 Handle Assembly 1 2 900105 Safety Shut-Off Bar 1 3 0150303A 5/16” Flat Washer 4 4 0150207A 5/16” Hex Nut 2 5 0150116A 5/16”-18 x 2 HH Bolt 2 6 0150302 1/4" Flat Washer 4 7 1/4"-20 Hex Nut 1 8 SP25001502 Control Panel Cover 1 9 0150102A 1/4"-20 x 3/4" HH Bolt 6 10 1/4"-20 Extruded U-Nut 6 11 1”-8 Nylon Lock Nut 2 12 1”-8 x 5 1/2" HHCS 2 13 0150104 3/8”-16 x 2 1/2 HHCS 1 14 0150119B 3/8”-16 Hex Nut 1 15 0150600 Grease Fitting 2 16 SP2500121-2 Safety Switch Linkage 1 17 Cotter Pin – 3/64” 2 18 SP2500146 Safety Switch Spring 1 19 1/4" Flat Washer (1” OD) 1 20 SP2500145 Safety Switch Engager 1 21 0350011E Kill Switch 1 22 0200299 Throttle Cable 1 23 0200300 Choke Cable 1 24 0200102L Ignition Switch 1 25 0200102AC Wiring Harness 1 26 0350011F Cutter Wheel Engagement Switch 1 27 Cutter Wheel Engagement Wire 1 28 0150627 3/4" Spring Latch 1 29 0250197A 1 3/8” Diameter By-Pass Knob 1 30 SP2500108 By-Pass Linkage 1 31 0250127B Transmission By-Pass Linkage Spring 1 32 6-32 X 1 1/2" HHCS 2 33 6-32 Lock Nut 2

SP2000 FRAME ASSEMBLY

31

SP2000 AXLE ASSEMBLY

32

ITEM NO PART NO DESCRIPTION QTY 1 0250197 Transmission – SP2000 1 2 0250198 Transmission Pump – SP2000 1 3 0250199 Gasket #01 1 4 0400234 Tire Assembly – SP2000 2 5 0550102 Lug Nut – 1/2"-20 8 6 Lock Ring – SHR-98-PA 2 7 SP25001231 Wheel Hub – BS – SP2000 1 8 SP25001221 Wheel Hub – DS – SP2000 1 9 5/16”-18 Set Screw 6 10 1/2"-20 x 1 1/2” HH Bolt 8 11 3/8”-16 x 1 1/2" U-Clamp 2 12 Rectangle Washer 2 13 3/8”-16 Hex Flange Nut 4 14 SP2500231 Pump Drive Pulley 1 15 #3 Woodruff Key (1/8” x 1/2") 1 16 0150403 1/4" Fender Washer 1 17 0150402 1/4" Lock Washer 1 18 0150102 1/4"-20 x 1” Hex Cap Screw 1 19 0150303 3/8” Flat Washer 4 20 0150404 3/8” Lock Washer 8 21 3/8”-16 x 1 1/4" HH Bolt 3 22 SP2500116 Fwd/Rev Engager 1 23 0150119B 3/8”-16 Hex Nut 1 24 3/8”-16 x 3” HH Bolt 4 25 0200304 Drive Handle – SP2000 1 26 1/4"-20 x 3 HH Bolt 3 27 0150302 1/4" Flat Washer 9 28 0150218 1/4"-20 Lock Nut 3 29 0200301 Drive Cable – SP2000 1 30 0200302 Drive Cable Ball Joint – SP2000 1 31 0150510 Brake Handle (Lever Assembly w/Kit 900) 1 32 5/16”-20 x 2 HH Bolt 2 33 0150303A 5/16” Flat Washer 6 34 5/16”-20 Lock Nut 2 35 0150510A Brake Cable- 40” OAL - 900H 1 36 5/16”-28 Lock Nut 1 37 10-32 Lock Nut 1 38 Transmission Plate 1 0200300 Choke Cable 1

SP2000 AXLE ASSEMBLY

33

Parts # 14, 16, 17, & 18 also shown on Belt Assembly.

SP2000 ENGINE ASSEMBLY

34

ITEM NO PART NO DESCRIPTION QTY 1 0200102AB Kohler Command PRO® 27 1 2 SP2500119 Motor Plate – Blanchard Ground 1 3 3/8”-16 x 2” Carriage Bolt 2 4 0150104 3/8”-16 x 2 1/2” Carriage Bolt 2 5 0150303 3/8” Washer 5 6 0150119B 3/8”-16 Hex Nut 5 7 SP2500115 Motor/Belt Adjustment Plate 1 8 0150119A 3/8”-16 x 3” HH Bolt 1 9 0150404 3/8” Lock Washer 1 10 - 3/8” Square x 3 3/4" Key 1 11 SP2500232 Motor Drive Pulley 1 12 0250165 Clutch - Electric 1 13 0150307 3/4" Flat Washer 1 14 5/8” Lock Washer 1 15 5/8”-18 x 2 HH Bolt 1 16 SP2500151 Gas Tank 1 17 0150117 3/8”-16 x 1 Carriage Bolt 3 18 0200006 Gas Cap 1

SP2000 ENGINE ASSEMBLY

35

Parts # 11 through 15 also shown on Belt Assembly

SP2000 BELT ASSEMBLY

36

ITEM NO PART NO DESCRIPTION QTY 1 SP2500254 Belt Guard Back 1 2 SP2500257 Belt Guard Cover 1 3 0150119 3/8”-16 x 3/4" Carriage Bolt 6 4 0150303 3/8” Flat Washer 6 5 0150404 3/8” Lock Washer 11 6 0150119B 3/8”-16 Hex Nut 6 7 SP2500231 Pump Drive Pulley 1 8 0150403 1/4" Fender Washer 1 9 0150402 1/4" Lock Washer 1 10 0150102 1/4"-20 x 1” HH Bolt 1 11 0250201 Idler Pulley 1 12 0150304 1/2" Flat Washer 1 13 0150406 1/2" Lock Washer 1 14 0150205 1/2"-13 Hex Nut 1 15 SP2500229 Idler Bushing 1 16 1/2"-13 x 1 3/4 Carriage Bolt 1 17 SP2500232 Motor Drive Pulley 1 18 0250165 Clutch 1 19 0150307 3/4" Flat Washer 1 20 5/8” Lock Washer 1 21 5/8”-18 x 2 HH Bolt 1 22 0400231 A45 Belt 1 23 0400100 A100 Belt 2 24 0250101A 2B58 SDS Pulley – Cutter Wheel 1 25 0150118 3/8”-16 x 1" HH Bolt 5 26 3/8” Zinc Washer 5

SP2000 BELT ASSEMBLY

37

Parts # 7 thru 10 also shown on Axle Assembly Parts # 17 thru 21 also shown on Engine Assembly Part # 24 also shown on Cutter Wheel Assembly

SP2000 CUTTER WHEEL ASSEMBLY

38

ITEM NO PART NO DESCRIPTION QTY 1 0150106B 1/2"-13 X 1 1/2" HH Bolt 1 2 2300197 Shaft Washer – 1 7/16" 1 3 0500112 Bearing – 1 7/16" – Link Belt 2 4 0150106F 1/2"-13 x 2 1/4" HCS 4 5 1/2" Hardened Flat Washer 8 6 0150206 1/2"-13 Lock Nut 4 7 0250120 Bushing – 25 JS,CW - SK 1 7/16” 1 8 SP2500186 Cutter Wheel – SP2000 1 9 SP2500184 Cutter Wheel Shaft – 1 7/16” 1 10 A160T012A Key – 3/8” Square x 2” 1 11 - Key – 3/8” Square x 1 1/4” 1 12 2300188 Cutter Wheel Hub – SK600A 1 13 0250101A Sheave SP2000 2B5.8 1 14 0250127N Bushing 1 7/16” SP2000 CW Pulley 1 15 0450106 Round Pocket – C/S 8 16 0450107 Round Pocket - THD 8 17 0450101 Tooth - Straight 2 18 0450102 Tooth – Right 45 Degree 7 19 0450103 Tooth – Left 45 Degree 7 20 0450109 Tooth Bolt - 5/8”-18 x 2 1/8” 16 21 0150605 Hitch Pin – 3/4 – 6 1/4 1 OPTIONAL: 0450131 JP Sandvik Short P/B Tooth 10 0450130 JP Sandvik Plow Bolt Tooth 20 0450132 JP Sandvik Plow Bolt Holder 20 0450125 Sandvik Stover Jam Nut 30

SP2000 CUTTER WHEEL ASSEMBLY

39

Part #13 is also shown on Belt Assembly.

SP2000 CHIP GUARD ASSEMBLY

40

ITEM NO PART NO DESCRIPTION QTY 1 SP2500118 Rear Chip Guard Bracket 1 2 SP2500211 Chip Guard Bracket – 9 1/4" 1 3 SP2500212 Chip Guard Bracket – 13” 1 4 SP2500213 Chip Guard Bracket – 21 1/2" 1 5 SP2500214 Chip Guard Bracket – 10 1/8” 1 6 SP2500215 Chip Guard Bracket – 10 3/4" 1 7 SP2500216 Chip Guard Bracket – 15 1/4" 1 8 SP2500217 Chip Guard Skirt - Rear 1 9 SP2500218 Chip Guard Skirt - Left 1 10 SP2500219 Chip Guard Skirt - Right 1 11 0150119 3/8”-16 x 3/4" Carriage Bolt 20 12 0150303 3/8” Flat Washer 20 13 0150207 3/8”-16 Lock Nut 20

STUMP CUTTERS

MODEL TYPE ENGINE HP FUEL CUTTING

DEPTH CUTTINGHEIGHT

CUT SWING

NO. TEETH

WHEELDIA.

WHEEL THICKNESS

TONGUE EXTENSION

WEIGHT(lbs.)

900H Walk- Behind Honda 13 Gas 9" 21" N/A 12 12.25" .5" N/A 220

SP2000 Walk- Behind Kohler 27 Gas 24" 27" N/A 16 19" .5" N/A 695

Self- Propelled Kohler 27 Gas 13" 34" 40" arc 20 21" 1" 30" 1,550

Self- Propelled

Briggs- Vanguard 35 Gas 13" 34" 40" arc 20 21" 1" 30" 1,650 SP4012

Self- Propelled Lombardini 28.7 Diesel 13" 34" 40" arc 20 21" 1" 30" 1,650

SP7015 Self- Propelled Deutz Turbo 60 Diesel 15" 43" 70" arc 32 26.5" 1" N/A 3,500

SP7015TRX Track- Mounted Deutz Turbo 60 Diesel 15" 43" 70" arc 32 26.5" 1" N/A 4,300

SP8018 TRX Track- Mounted Deutz Turbo 78 Diesel 18" 43" 80" arc 32 26.5" 1" N/A 5,420

HURRICANE RS

Track- Mounted

John Deere Turbo 140 Diesel 25" 53" 360° 48 31" 1.5" N/A 8,500

Track- Mounted


Track- Mounted


HURRICANE TRX

Track- Mounted


3500D Tow- Behind Deutz Turbo 60 Diesel 15" 40" 80" arc 32 26.5" 1" 48" 2,900

7500 Tow- Behind Deutz Turbo 78 Diesel 24" 46" 92" arc 48 31" 1.5" 60" 4,400

Call and ask about Carlton’s line of Chippers or visit our website: www.stumpcutters.com CARLTON—QUALITY PRODUCTS AND EXCEPTIONAL SERVICE

Carlton Owner’s Manual SP2000 Revised: 10/2008

COMMAND SERIESCH18-26, CH730-745

OWNER'S MANUAL

HORIZONTAL CRANKSHAFT

2

Explosive Fuel can cause fires andsevere burns.

Stop engine before filling fuel tank.

WARNING

Explosive Fuel!Gasoline is extremely flammableand its vapors can explode ifignited. Store gasoline only inapproved containers, in wellventilated, unoccupied buildings,away from sparks or flames. Do notfill the fuel tank while the engine ishot or running, since spilled fuelcould ignite if it comes in contactwith hot parts or sparks fromignition. Do not start the engine nearspilled fuel. Never use gasoline as acleaning agent.

Rotating Parts can cause severeinjury.

Stay away while engine is inoperation.

WARNING

Rotating Parts!Keep hands, feet, hair, and clothingaway from all moving parts toprevent injury. Never operate theengine with covers, shrouds, orguards removed.

Hot Parts can cause severe burns.

Do not touch engine while operatingor just after stopping.

WARNING

Hot Parts!Engine components can getextremely hot from operation. Toprevent severe burns, do not touchthese areas while the engine isrunning, or immediately after it isturned off. Never operate the enginewith heat shields or guardsremoved.

Electrical Shock can cause injury.

Do not touch wires while engine isrunning.

CAUTION

Electrical Shock!Never touch electrical wires orcomponents while the engine isrunning. They can be sources ofelectrical shock.

CaliforniaProposition 65 Warning

Engine exhaust from this productcontains chemicals known to theState of California to causecancer, birth defects, or otherreproductive harm.

Safety Precautions

To ensure safe operations please read the following statements and understand their meaning. Alsorefer to your equipment owner's manual for other important safety information. This manual containssafety precautions which are explained below. Please read carefully.

WARNINGWarning 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.

CAUTIONCaution is used to indicate the presence of a hazard that will or can cause minor personal injury orproperty damage if the caution is ignored.

NOTENote is used to notify people of installation, operation, or maintenance information that is importantbut not hazard-related.

For Your Safety!These precautions should be followed at all times. Failure to follow these precautions could resultin injury to yourself and others.

3

Safety Precautions (Cont.)

Accidental Starts can cause severeinjury or death.

Disconnect and ground spark plugleads before servicing.

WARNING

Carbon Monoxide can causesevere nausea, fainting or death.

Do not operate engine in closed orconfined area.

WARNING WARNING

Explosive Gas can cause fires andsevere acid burns.Charge battery only in a wellventilated area. Keep sources ofignition away.

Accidental Starts!Disabling engine. Accidentalstarting can cause severe injuryor death. Before working on theengine or equipment, disable theengine as follows: 1) Disconnect thespark plug lead(s). 2) Disconnectnegative (-) battery cable frombattery.

Explosive Gas!Batteries produce explosivehydrogen gas while being charged.To prevent a fire or explosion,charge batteries only in wellventilated areas. Keep sparks, openflames, and other sources ofignition away from the battery at alltimes. Keep batteries out of thereach of children. Remove alljewelry when servicing batteries.

Before disconnecting the negative(-) ground cable, make sure allswitches are OFF. If ON, a sparkwill occur at the ground cableterminal which could cause anexplosion if hydrogen gas orgasoline vapors are present.

Congratulations � You have selected a fine four-cycle, twin cylinder, air-cooled engine. Kohler designs long lifestrength and on-the-job durability into each engine...making a Kohler engine dependable...dependability you cancount on. Here are some reasons why:

� Efficient overhead valve design and full pressure lubrication provide maximum power, torque, and reliabilityunder all operating conditions.

� Dependable, maintenance-free electronic ignition ensures fast, easy starts time after time.

� Kohler engines are easy to service. All routine service areas like the dipstick, oil fill, air cleaner, and sparkplugs are easily and quickly accessible.

� Parts subject to the most wear and tear (like the cylinder liner* and camshaft) are made from precisionformulated cast iron. Because the cylinder liner* can be rebored, these engines can last even longer.

*Some CH25/26 engines have POWER-BORE� Cylinders. These cylinders are plated with nickel-silicon to give increased power, virtually permanent cylinder life, superior oil control, and reduced exhaust emissions. These cylinders cannot be rebored.

� Every Kohler engine is backed by a worldwide network of over 10,000 distributors and dealers. Servicesupport is just a phone call away. Call 1-800-544-2444 (U.S. & Canada) for Sales & Service assistance.

To keep your engine in top operating condition, follow the maintenance procedures in this manual.

Lethal Exhaust Gases!Engine exhaust gases containpoisonous carbon monoxide.Carbon monoxide is odorless,colorless, and can cause death ifinhaled. Avoid inhaling exhaustfumes, and never run the engine ina closed building or confined area.

4

Figure 1. Typical Command Horizontal Shaft Carbureted Engine.

Figure 2. Typical Command Horizontal Shaft EFI Engine.

Air CleanerOil Fill

Rectifier-Regulator

Throttle Body Intake Manifold

Ignition Coil

Fuel Injectors

Ignition Coil

Oil Filter

Oil Cooler

Oil Filter

Rectifier-Regulator

FuelPump

ElectricStarter

Oil Cooler

Dipstick

Side Oil Drain Plugs

5

Refer to �Maintenance Instructions� beginning onpage 8 for detailed oil check, oil change, and oilfilter change procedures.

Fuel RecommendationsWARNING: Explosive Fuel!

Gasoline is extremely flammable and its vapors canexplode if ignited. Store gasoline only in approvedcontainers, in well ventilated, unoccupied buildings,away from sparks or flames. Do not fill the fuel tankwhile the engine is hot or running, since spilled fuelcould ignite if it comes in contact with hot parts orsparks from ignition. Do not start the engine nearspilled fuel. Never use gasoline as a cleaning agent.

General RecommendationsPurchase gasoline in small quantities and store inclean, approved containers. A container with a capacityof 2 gallons or less with a pouring spout isrecommended. Such a container is easier to handleand helps eliminate spillage during refueling.

Do not use gasoline left over from the previous season,to minimize gum deposits in fuel system and to ensureeasy starting.

Do not add oil to the gasoline.

Do not overfill the fuel tank. Leave room for the fuel toexpand.

Fuel TypeFor best results use only clean, fresh, unleadedgasoline with a pump sticker octane rating of 87 orhigher. In countries using the Research method, itshould be 90 octane minimum.

Unleaded gasoline is recommended as it leaves lesscombustion chamber deposits and reduces harmfulexhaust emissions. Leaded gasoline is notrecommended and must not be used on EFI engines,or on other models where exhaust emissions areregulated.

Gasoline/Alcohol blendsGasohol (up to 10% ethyl alcohol, 90% unleadedgasoline by volume) is approved as a fuel for Kohlerengines. Other gasoline/alcohol blends are notapproved.

Gasoline/Ether blendsMethyl Tertiary Butyl Ether (MTBE) and unleadedgasoline blends (up to a maximum of 15% MTBE byvolume) are approved as a fuel for Kohler engines.Other gasoline/ether blends are not approved.

Oil RecommendationsUsing the proper type and weight of oil in thecrankcase is extremely important. So is checking oildaily and changing oil regularly. Failure to use thecorrect oil, or using dirty oil, causes premature enginewear and failure.

Oil TypeUse high quality detergent oil of API (AmericanPetroleum Institute) service class SG, SH, SJ orhigher. Select the viscosity based on the airtemperature at the time of operation as shown in thefollowing table.

Figure 3. Viscosity Grades Table.

NOTE: Using other than service class SG, SH, SJ orhigher oil or extending oil change intervalslonger than recommended can cause enginedamage.

NOTE: Synthetic oils meeting the listed classificationsmay be used with oil changes performed at therecommended intervals. However to allowpiston rings to properly seat, a new or rebuiltengine should be operated for at least 50 hoursusing standard petroleum based oil beforeswitching to synthetic oil.

A logo or symbol on oil containers identifies the APIservice class and SAE viscosity grade. See Figure 4.

Figure 4. 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).

***

6

Engine Identification NumbersWhen ordering parts, or in any communication involvingan engine, always give the Model, Specification, andSerial Numbers of the engine.

The engine identification numbers appear on a decalaffixed to the engine shrouding. Include letter suffixes,if there are any.

Record your engine identification numbers on theidentification label below (Figure 5) for future reference.

Model DesignationModel CH20S for example: C designates Commandengine, H designates horizontal crankshaft, and 20designates horsepower. Some model numbers(CH730) use a numerical designation rather thanhorsepower. A letter suffix designates a specific versionas follows:Suffix Designates

S Electric StartST Electric Start/Retractable StartQS Quiet Model/Electric StartEP Electric PlantCS Clutch Model/Electric Start

Operating InstructionsAlso read the operating instructions of the equipmentthis engine powers.

Pre-Start Checklist� Check oil level. Add oil if low. Do not overfill.

� Check fuel level. Add fuel if low.

� Check cooling air intake areas and externalsurfaces of engine. Make sure they are clean andunobstructed.

� Check that the air cleaner components and allshrouds, equipment covers, and guards are inplace and securely fastened.

� Check that any clutches or transmissions aredisengaged or placed in neutral. This is especiallyimportant on equipment with hydrostatic drive. Theshift lever must be exactly in neutral to preventresistance which could keep the engine from starting.

WARNING: Lethal Exhaust Gases!Engine exhaust gases contain poisonous carbonmonoxide. Carbon monoxide is odorless, colorless,and can cause death if inhaled. Avoid inhaling exhaustfumes, and never run the engine in a closed building orconfined area.

Cold Weather Starting Hints1. Be sure to use the proper oil for the temperature

expected. See Figure 3 on page 5.

2. Disengage all possible external loads.

3. Be sure the battery is in good condition. A warmbattery has much more starting capacity than acold battery.

4. Use fresh winter grade fuel. NOTE: Winter gradegasoline has higher volatility to improve starting.Do not use gasoline left over from summer.

Figure 5. Engine Identification Label.

The Emission Compliance Period referred to on theEmission Control or Air Index label indicates thenumber of operating hours for which the engine hasbeen shown to meet Federal and CARB emissionrequirements. The following table provides the EngineCompliance Period (in hours) associated with thecategory descriptor found on the certification label.

Emission Compliance Period (Hours)

EPA

CARB

Category C250 hours

Moderate125 hours

Category B500 hours

Category A1000 hours

Intermediate250 hours

Extended500 hours

Refer to certification label for engine displacement.

Exhaust Emission Control System for modelsCH18,20,22,23,25,730,740 is EM. Exhaust EmissionControl System for models CH26 and CH745 are EM,O2S, ECM, MFI.

IMPORTANT ENGINE INFORMATIONTHIS ENGINE MEETS U.S. EPA AND CA 2005 ANDLATER AND EC STAGE II (SN:4) EMISSION REGSFOR SI SMALL OFF�ROAD ENGINES

KOHLER CO. KOHLER, WISCONSIN USA

EMISSION COMPLIANCE PERIOD:EPA: CARB:CERTIFIED ON:REFER TO OWNER'S MANUAL FOR HP RATING,SAFETY, MAINTENANCE AND ADJUSTMENTS

FAMILYTYPE APPDISPL. (CC)MODEL NO.SPEC. NO.SERIAL NO.BUILD DATEOEM PROD. NO.

1-800-544-2444 www.kohlerengines.com

N11236

7

flywheel is rotating, the starter pinion andflywheel ring gear may clash resulting indamage to the starter.

If the starter does not turn the engine over, shut offstarter immediately. Do not make further attemptsto start the engine until the condition is corrected.Do not jump start using another battery (refer to�Battery� on this page). See your Kohler EngineService Dealer for service assistance.

Carbureted Engines Only:3. For a Cold Engine � Gradually return the choke

control to the �off� position after the engine startsand warms up.

The engine/equipment may be operated duringthe warm-up period, but it may be necessary toleave the choke partially on until the enginewarms up.

4. For a Warm Engine � Return choke to �off�position as soon as engine starts.

Stopping1. Remove the load by disengaging all PTO driven

attachments.

2. For Carbureted Engines Without A ShutdownSolenoid: Move the throttle to the �slow� or�low� idle position. Allow the engine to run at idlefor 30-60 seconds; then stop the engine.

For Carbureted Engines Equipped With AShutdown Solenoid: Position the throttle controlsomewhere between half and full throttle; thenstop the engine.

For EFI Engines: Move the throttle to the "slow"or "idle" position; turn key ��off�� to stop engine.

BatteryA 12 volt battery is normally used. Refer to theoperating instructions of the equipment this enginepowers for specific battery requirements.

If the battery charge is not sufficient to crank theengine, recharge the battery (see page 13).

Operating

Angle of OperationThis engine will operate continuously at angles up to25°. Check oil level to assure crankcase oil level is atthe �F� mark on the dipstick.

Figure 6. Optional Engine Mounted Throttle andChoke Controls (CH18-25,CH730,740).

2. Start the engine by activating the key switch.Release the switch as soon as the engine starts.

EFI Engines Only � Initial Starting or After Runningout of Fuel (Dry System)a. Turn the key switch to the �on� position for one

minute. Allow the fuel pump to cycle and primethe system. Turn the key switch �off�.

b. Turn the key switch to the �start� position,crank and start engine.

c. If the engine fails to start, repeat steps �a� and�b�. If the engine does not start after two primingintervals, contact your Kohler Engine ServiceDealer for further assistance.

NOTE: Do not crank the engine continuously formore than 10 seconds at a time. If theengine does not start, allow a 60 secondcool down period between startingattempts. Failure to follow theseguidelines can burn out, or permanentlydamage, the starter motor.

NOTE: Upon start-up, a metallic ticking mayoccur. This is caused by hydraulic lifterleakdown during storage. Run the enginefor 5 minutes. The noise will normallycease in the first minute. If noisecontinues, run the engine at mid-throttlefor 20 minutes. If noise persists, take theengine to your local authorized KohlerEngine Service Dealer.

NOTE: If the engine develops sufficient speed todisengage the starter but does not keeprunning (a false start), engine rotationmust be allowed to come to a completestop before attempting to restart theengine. If the starter is engaged while the

Starting1. Place the throttle control midway between the

��slow�� and ��fast�� positions. Place the chokecontrol (non-EFI engines only) into the ��on��position. See Figure 6.

8

Refer to the operating instructions of the equipment thisengine powers. Because of equipment design orapplication, there may be more stringent restrictionsregarding the angle of operation.

NOTE: Do not operate this engine continuously atangles exceeding 25° in any direction. Enginedamage could result from insufficientlubrication.

CoolingNOTE: If debris builds up on the grass screen or other

cooling air intake areas, stop the engineimmediately and clean. Operating the enginewith blocked or dirty air intake and coolingareas can cause extensive damage due tooverheating.

WARNING: Hot Parts!Engine components can get extremely hot fromoperation. To prevent severe burns, do not touch theseareas while the engine is running, or immediately after itis turned off. Never operate the engine with heat shieldsor guards removed.

Engine SpeedNOTE: Do not tamper with the governor setting to

increase the maximum engine speed.Overspeed is hazardous and will void theengine warranty. The maximum allowable highidle speed for these engines is 3750 RPM, noload.

� Replace fuel filter1 (EFI engines).

Daily or BeforeStarting Engine

Maintenance RequiredFrequency� Fill fuel tank.� Check oil level.� Check air cleaner for dirty1, loose, or damaged parts.� Check air intake and cooling areas, clean as necessary1.� Service precleaner element1.Every 25 Hours� Replace air cleaner element1.� Change oil. (More frequently under severe conditions.)� Remove cooling shrouds and clean cooling areas1,3.� Check oil cooler fins, clean as necessary (if equipped).� Check spark plug condition and gap.� Change oil filter.� Replace fuel filter (carbureted engines).

Annually orEvery 500 Hours

� Have bendix starter drive serviced2.� Have solenoid shift starter disassembled and cleaned2.

Every 100 Hours

Every 200 Hours

Every 1500 Hours

Maintenance InstructionsMaintenance, repair, or replacement of the emission control devices and systems, which are being doneat the customers expense, may be performed by any non-road engine repair establishment or individual.Warranty repairs must be performed by an authorized Kohler service outlet.

WARNING: Accidental Starts!Disabling engine. Accidental starting can cause severe injury or death. Before working on the engine orequipment, disable the engine as follows: 1) Disconnect the spark plug lead(s). 2) Disconnect negative (-) batterycable from battery.

Maintenance ScheduleThese required maintenance procedures should be performed at the frequency stated in the table. They shouldalso be included as part of any seasonal tune-up.

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 performthis service.

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

� Have crankshaft spline lubricated2.Every 500 Hours

Every 250 Hours � Replace heavy-duty air cleaner element and check inner element1.

9

Change Oil and Filter, Service Oil Cooler

Change OilChange oil after every 100 hours of operation (morefrequently under severe conditions). Refill with serviceclass SG, SH, SJ or higher oil as specified in the��Viscosity Grades�� table (Figure 3) on page 5.

Change the oil while the engine is still warm. The oil willflow more freely and carry away more impurities. Makesure the engine is level when filling, checking, andchanging the oil.

Change the oil as follows (see Figures 8 and 9):

1. To keep dirt, debris, etc., out of the engine, cleanthe area around the oil fill cap/dipstick beforeremoving it.

2. Remove one of the oil drain plugs, oil fill cap, anddipstick. Be sure to allow ample time for completedrainage.

3. Reinstall the drain plug. Make sure it is tightenedto 13.6 N·m (10 ft. lb.) torque.

4. Fill the crankcase, with new oil of the proper type,to the �F� mark on the dipstick. Refer to �Oil Type�on page 5. Always check the level with the dipstickbefore adding more oil.

5. Reinstall the oil fill cap and tighten securely.Reinstall dipstick.

NOTE: To prevent extensive engine wear ordamage, always maintain the proper oillevel in the crankcase. Never operate theengine with the oil level below the �L� markor over the �F� mark on the dipstick.

Figure 8. Oil Drain Plugs, Oil Filter, and Oil Cooler(CH25 shown).

Oil Filter

Oil Cooler Oil Drain Plug

Check Oil LevelThe importance of checking and maintaining the properoil level in the crankcase cannot be overemphasized.Check oil BEFORE EACH USE as follows:

1. Make sure the engine is stopped, level, and is coolso the oil has had time to drain into the sump.

2. To keep dirt, debris, etc., out of the engine, cleanthe area around the dipstick before removing it.

3. Remove the dipstick; wipe oil off. Reinsert thedipstick into the tube and press all the way down.

4. Remove the dipstick and check the oil level.

The oil level should be up to, but not over, the �F�mark on the dipstick. See Figure 7.

�F� Mark

OperatingRange

Figure 7. Oil Level Dipstick.

5. If the level is low, add oil of the proper type, up tothe �F� mark on the dipstick. (Refer to �Oil Type� onpage 5.) Always check the level with the dipstickbefore adding more oil.

NOTE: To prevent extensive engine wear ordamage, always maintain the proper oillevel in the crankcase. Never operate theengine with the oil level below the �L�mark or over the �F� mark on the dipstick.

Oil Sentry�Some engines are equipped with an optional OilSentry� oil pressure switch. If the oil pressuredecreases below an acceptable level, the Oil Sentry�will either shut off the engine or activate a warningsignal, depending on the application.

NOTE: Make sure the oil level is checked BEFOREEACH USE and is maintained up to the �F�mark on the dipstick. This includes enginesequipped with Oil Sentry�.

10

Service Oil CoolerSome engines are equipped with an oil cooler. Onestyle of oil cooler mounts on the engine crankcase andhas the oil filter on it (See Figure 8). The other style ofoil cooler is mounted on the blower housing (SeeFigure 9), separate from the oil filter.

Inspect and clean the oil cooler every 100 hours ofoperation (more frequently under severe conditions).Oil cooler must be kept free of debris.

To service the crankcase mounted oil cooler clean offthe outside fins with a brush or with compressed air.

To service the blower housing mounted oil cooler,clean the outside of fins with a brush. Remove the twoscrews holding the cooler unit to the blower housing.Tilt the cooler downward as shown in Figure 10. Cleanthe inside of cooler with a brush as shown in Figure 10or with compressed air. After cleaning, reinstall oilcooler to blower housing with two mounting screws.

Figure 10.

Service Precleaner and Air Cleaner ElementThis engine is equipped with a replaceable, highdensity paper air cleaner element. Most engines arealso equipped with an oiled, foam precleaner whichsurrounds the paper element. See Figure 11.

Precleaner

Element Cover

Element

Air CleanerCover

Cover Knob

ElementCover Nut

Figure 11. Air Cleaner System Components.

Figure 9. Oil Drain Plugs, Oil Filter, and Oil Cooler(CH26 shown).

Change Oil FilterReplace the oil filter at least every other oil change(every 200 hours of operation). Always use a genuineKohler oil filter, Part No. 12 050 01-S.

Replace the oil filter as follows:

1. Drain the oil from the engine crankcase.

2. Allow the oil filter to drain.

3. Before removing the oil filter, clean the areaaround the oil filter to keep dirt and debris out ofthe engine. Remove the old filter. Wipe off thesurface where the oil filter mounts.

4. Place a new replacement filter in a shallow panwith the open end up. Pour new oil, of the propertype, in through the threaded center hole. Stoppouring when the oil reaches the bottom of thethreads. Allow a minute or two for the oil to beabsorbed by the filter material.

5. Apply a thin film of clean oil to the rubber gasketon the new filter.

6. Install the replacement oil filter to the filter adapter oroil cooler. Turn the oil filter clockwise until the rubbergasket contacts the filter adapter or oil cooler, thentighten the filter an additional 2/3 to 1 turn.

7. Reinstall the drain plug. Make sure it is tightenedto 13.6 N·m (10 ft. lb.) torque.

8. Fill the crankcase with new oil of the proper typeto the �F� mark on the dipstick.

9. Start the engine and check for oil leaks. Correctany leaks before placing the engine into service.Check oil level to be sure it is up to but not overthe �F� mark.

Oil Filter

Oil Drain Plug Oil Cooler

11

4. Do not wash the paper element or usepressurized air, as this will damage the element.Replace a dirty, bent, or damaged element with agenuine Kohler element. Handle new elementscarefully; do not use if the sealing surfaces arebent or damaged.

5. When servicing the air cleaner, check the aircleaner base. Make sure it is secured and notbent or damaged. Also, check the element coverfor damage or improper fit. Replace all damagedair cleaner components.

NOTE: If any loose dirt or debris fell on the aircleaner base when the element wasremoved, carefully remove it and wipethe base clean. Be careful that none of itdrops into the intake throat. Check thecondition of the rubber seal on the aircleaner stud. If the condition isquestionable in any way, replace it withthe new seal packaged with thereplacement element.

6. Reinstall the paper element, precleaner, elementcover, element cover nut, and air cleaner cover.Secure cover with the cover retaining knob.

7. When element replacement is necessary, ordergenuine Kohler parts.

Check the air cleaner daily or before starting theengine. Check for a buildup of dirt and debris aroundthe air cleaner system. Keep this area clean. Alsocheck for loose or damaged components. Replace allbent or damaged air cleaner components.

NOTE: Operating the engine with loose or damagedair cleaner components could allow unfilteredair into the engine causing premature wearand failure.

Service PrecleanerIf so equipped, wash and reoil the precleaner every 25hours of operation (more often under extremely dustyor dirty conditions).

1. Loosen the cover retaining knob and remove thecover.

2. Remove the precleaner from the paper element.

3. Wash the precleaner in warm water withdetergent. Rinse the precleaner thoroughly until alltraces of detergent are eliminated. Squeeze outexcess water (do not wring). Allow the precleanerto air dry.

4. Saturate the precleaner with new engine oil.Squeeze out all excess oil.

5. Reinstall the precleaner over the paper element.

6. Reinstall the air cleaner cover. Secure cover withthe cover retaining knob.

7. When precleaner replacement is necessary, ordergenuine Kohler parts.

Heavy-Duty Air Cleaner

To ServiceEvery 250 hours of operation (more often underextremely dusty or dirty conditions), replace the paperelement and check inner element. Follow these steps.

1. Unhook the two retaining clips and remove the endcap from the air cleaner housing.

2. Pull the air cleaner element out of the housing. SeeFigure 12.

Service Paper ElementEvery 100 hours of operation (more often underextremely dusty or dirty conditions) replace the paperelement.

1. Loosen the cover retaining knob and remove thecover.

2. Remove the element cover nut, element cover,and paper element with precleaner.

3. Remove the precleaner (if so equipped) from thepaper element. Service the precleaner asdescribed above.

S-2038042S-5038042

.D.O).ni18.6(mm371xhgih).ni04.2(mm16


S-3038074S-3038042



12

Clean Air Intake/Cooling AreasTo ensure proper cooling, make sure the grass screen,cooling fins, and other external surfaces of the engineare kept clean at all times.

Every 100 hours of operation (more often underextremely dusty, dirty conditions), remove the blowerhousing* and other cooling shrouds. Clean the coolingfins and external surfaces as necessary. Make sure thecooling shrouds are reinstalled.

NOTE: Operating the engine with a blocked grassscreen, dirty or plugged cooling fins, and/orcooling shrouds removed, will cause enginedamage due to overheating.

*Cleanout kits 25 755 20-S (black) or 25 755 21-S (gold) allow inspection and cleanout of the cooling fins, without removing the blower housing.

Ignition System

Carbureted Engines - Use an electronic CapacitiveDischarge (CD) ignition system. Other than periodicallychecking/replacing the spark plugs, no maintenance,timing, or adjustments are necessary or possible withthis system.

EFI Engines - Incorporate a computer-controlledbattery ignition system with individual coils. Other thanperiodically checking/replacing the spark plugs, nomaintenance, timing, or adjustments are necessary orpossible with this system.

Check Spark PlugsEvery 200 hours of operation, remove the spark plugs,check condition, and reset the gap or replace with newplugs as necessary. The standard spark plug is aChampion® RC12YC (Kohler Part No. 12 132 02-S). Ahigh-performance spark plug, Champion® Platinum 3071(used on Pro Series engines, Kohler Part No.25 132 12-S) is also available. Equivalent alternatebrand plugs can also be used.

1. Before removing the spark plug, clean the areaaround the base of the plug to keep dirt and debrisout of the engine.

2. Remove the plug and check its condition.Replace the plug if worn or reuse is questionable.

NOTE: Do not clean the spark plug in a machineusing abrasive grit. Some grit couldremain in the spark plug and enter theengine causing extensive wear anddamage.

Figure 12. Removing Elements.

3. After the main element is removed, check thecondition of the inner element. It should bereplaced whenever it appears dirty, typically everyother time the main element is replaced. Clean thearea around the base of the inner element beforeremoving it, so dirt does not get into the engine.

4. Do not wash the paper element and inner elementor use pressurized air, this will damage theelements. Replace dirty, bent or damagedelements with new genuine Kohler elements asrequired. Handle new elements carefully; do notuse if the sealing surfaces are bent or damaged.

5. Check all parts for wear, cracks, or damage.Replace any damaged components.

6. Install the new inner element, Kohler Part No.25 083 04-S followed by the outer element, KohlerPart No. 25 083 01-S. Slide each fully into place inthe air cleaner housing.

7. Reinstall the end cap so the dust ejector valve isdown and secure with the two retaining clips. SeeFigure 13.

Figure 13. Heavy-Duty Air Cleaner Assembly.

MainElement

InnerElement

DustEjectorValve

13

Fuel FilterCarbureted Engines: Most engines are equipped withan in-line fuel filter. Periodically inspect the filter andreplace with a genuine Kohler filter every 200 operatinghours.

EFI Engines: A special, high volume, high pressurefilter with greater filtration capabilities and internalsurface area is used. See Figure 15.

Figure 14. Servicing Spark Plug.

4. Reinstall the spark plug into the cylinder head.Torque the spark plug to 24.4-29.8 N·m(18-22 ft. lb.).

Battery Charging

WARNING: Explosive Gas!Batteries produce explosive hydrogen gas while beingcharged. To prevent a fire or explosion, chargebatteries only in well ventilated areas. Keep sparks,open flames, and other sources of ignition away fromthe battery at all times. Keep batteries out of the reachof children. Remove all jewelry when servicingbatteries.

Before disconnecting the negative (-) ground cable,make sure all switches are OFF. If ON, a spark willoccur at the ground cable terminal which could causean explosion if hydrogen gas or gasoline vapors arepresent.

NOTE: Do not apply 12 volt DC to kill terminal ofignition module.

Fuel System

WARNING: Fuel System Under Pressure!The EFI fuel system operates under high pressure,and the fuel filter and fuel line used must be approvedsystem components only. Use of substitute parts canresult in system failure, gasoline leakage and possibleexplosion.

Wire Gauge

GroundElectrode

Spark Plug

0.76 mm(0.030 in.) Gap

3. Check the gap using a wire feeler gauge. Adjustthe gap to 0.76 mm (0.030 in.) by carefullybending the ground electrode. See Figure 14.

Figure 15. EFI Fuel Filter and Line.

Replacement is recommended every 1500 hours, ormore frequently under extremely dusty or dirtyconditions. When replacement is necessary, alwaysuse genuine Kohler parts.

Fuel LineEFI Engines: A special fuel line, capable ofwithstanding the high pressure of the EFI fuel system,is used (must meet SAE R9 specifications). See Figure15. If fuel line must be replaced, see your KohlerEngine Service Dealer.

Carburetor Troubleshooting andAdjustmentsNOTE: Carburetor adjustments should be made only

after the engine has warmed up.

The carburetor is designed to deliver the correctfuel-to-air mixture to the engine under all operatingconditions. To comply with current emissionregulations, the fuel mixture settings are made at thefactory and cannot be adjusted.

NOTE: To ensure correct engine operation at altitudesabove 1525 meters (5000 ft.), it may benecessary to have an authorized Kohler dealerinstall a special high-altitude jet kit in thecarburetor. If a high-altitude kit has beeninstalled, the engine must be reconverted tothe original jet size, before it is operated atlower altitudes, or overheating and enginedamage can result.

Fuel Filter

Fuel Line

14

Figure 16. Carburetor (CH18-25,CH730,740).

TroubleshootingIf engine troubles are experienced that appear to befuel system related, check the following areas beforeadjusting the carburetor.

� Make sure the fuel tank is filled with clean, freshgasoline.

� Make sure the fuel tank cap vent is not blockedand that it is operating properly.

� If the fuel tank is equipped with a shut-off valve,make sure it is open.

� If the engine is equipped with an in-line fuel filter,make sure it is clean and unobstructed. Replacethe filter if necessary.

� Make sure fuel is reaching the carburetor. Thisincludes checking the fuel lines and fuel pump forrestrictions or faulty components, replace asnecessary.

� Make sure the air cleaner element is clean and allair cleaner element components are fastenedsecurely.

If, after checking the items listed above, the engine ishard to start, runs roughly, or stalls at low idle speed, itmay be necessary to adjust or service the carburetor.

Adjust CarburetorThere are no accessible mixture adjustment screws onthe carburetor. The only setting which can be changedis the low idle speed.

1. Start the engine and run at half throttle for 5 to 10minutes to warm up. The engine must be warmbefore making final settings (steps 2 and 3).

2. Low Idle Speed Setting: Place the throttlecontrol into the �idle� or �slow� position. Set thelow idle speed to 1200 RPM* (± 75 RPM) byturning the low idle speed adjusting screw in orout. Check the speed using a tachometer.

*NOTE: The actual low idle speed depends on theapplication � refer to equipmentmanufacturers recommendations. Thestandard low idle speed is 1200 RPM.

3. If proper operation is not restored after adjustingthe low idle speed, carburetor servicing by anauthorized Kohler Engine Service Dealer may berequired.

Electronic Fuel Injection (EFI) SystemThe EFI system is a complete, electronically-controlledfuel management system, designed to deliver aprecisely controlled fuel flow under all operatingconditions. The electronic control unit (ECU), the��brain�� of the system, automatically adjusts fueldelivery and ignition timing based upon load, speed,operating temperature, and exhaust emission levels.The low idle speed is the only manual adjustmentpossible.

The ECU continuously monitors operation of the EFIsystem. If it detects a problem or fault within thesystem, it will illuminate the malfunction indicator light(MIL), which is mounted in view of the operator. This isa signal that normal, programmed operation has beenaffected, and service by an authorized Kohler EngineDealer is required.

NOTE: The EFI system requires a rather complexwiring harness to carry the electrical signalsbetween the sensors and the ECU. Do notspray water at the wiring harness or any of theelectrical components, especially the ECU, asit could cause malfunction, damage, or failure.

TroubleshootingIf the MIL comes on, or the engine becomes hard tostart, runs roughly, or stalls at low idle speed, initialchecks should be made in the following areas:

� Make sure the fuel tank is filled with clean, freshgasoline, and shut-off valve (if so equipped) isopened completely.

� Make sure fuel tank vent cap is not blocked and itis operating properly.

� Make sure the air cleaner element and precleanerare clean and all components are properlysecured. Clean or replace as necessary.

Low IdleSpeed Adj.Screw

Low IdleFuel Adj.Needle &Spring

Fixed Main Jet(under optionalsolenoid)

15

TroubleshootingWhen troubles occur, be sure to check the simple causes which, at first, may seem too obvious to be considered.For example, a starting problem could be caused by an empty fuel tank. Some common causes of engine troublesare listed in the following table.

Do not attempt to service or replace major engine components, or any items that require special timing oradjustment procedures. Have your Kohler Engine Service Dealer do this work.

� Make sure the proper fuel filter is being used, and itis clean and unobstructed. Replace filter only withgenuine Kohler parts.

� Make sure all connections to sensors, ECU, andfuel injectors are properly secured.

� Make sure a good 12 volt battery is being used andis fully charged.

If these checks do not correct the problem, or the MILremains on, further diagnosis and servicing by anauthorized Kohler Engine Dealer is necessary.

Adjustment � EFI Throttle Body

Low Idle Speed (RPM) is the only adjustment that canbe made. All other fuel calibrations are permanentlypreset and controlled by the ECU. The standard low idlespeed is 1500 RPM* (+ 75 RPM).

*NOTE: The actual low idle speed depends on theapplication -- refer to equipmentmanufacturer's recommendations.

When an EFI engine is started cold, the ECU will beusing internal programming for cold running, and theidle speed may vary from the manual setting. Do notattempt to perform any readjustment during this ��warm-up�� period.

Low Idle SpeedAdjusting Screw

Fuel Rail

Throttle BodyIntake Manifold

Will Not Start � � � � � � �Hard Starting � � � � � �

Possible Cause No Improper Dirt In Dirty Incorrect Engine Dirty Air FaultyProblem Fuel Fuel Fuel Line/System Grass Screen Oil Level Overloaded Cleaner Spark Plug

Stops Suddenly � � � � � �Lacks Power � � � � � � �Operates Erratically � � � � � �Knocks or Pings � � � �Skips or Misfires � � � � �Backfires � � � �Overheats � � � � �High Fuel Consumption � � �

Figure 17. EFI Throttle Body Manifold.

If adjustment is to be made, the engine must be atoperating temperature, air cleaner in place, and checkengine light must be off (no fault codes present).

1. Start the engine and run at half throttle for 5 to 10minutes to warm up.

2. Place the throttle control into the ��idle�� or ��slow��position.

3. Turn the low idle speed adjusting screw in or outand check RPM with a tachometer. See Figure 17.

16

StorageIf the engine will be out of service for two months ormore, use the following storage procedure:

1. Clean the exterior surfaces of the engine. On EFIengines, avoid spraying water at the wiringharness or any of the electrical components.

2. Change the oil and filter while the engine is stillwarm from operation. See �Change Oil and OilFilter� on page 9.

3. The fuel system must be completely emptied, orthe gasoline must be treated with a stabilizer toprevent deterioration. If you choose to use astabilizer, follow the manufacturersrecommendations, and add the correct amount forthe capacity of the fuel system. Fill the fuel tankwith clean, fresh gasoline. Run the engine for 2-3minutes to get stabilized fuel into the rest of thesystem. Close fuel shut-off valve when unit isbeing stored or transported.

To empty the system, run the engine until the tankand system are empty.

4. Remove the spark plugs. Add one tablespoon ofengine oil into each spark plug hole. Install theplugs, but do not connect the plug leads. Crankthe engine two or three revolutions.

5. On units with EFI engines, disconnect the negative(-) battery cable or use a "battery minder" tricklecharger while the unit is in storage.

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

Parts OrderingThe engine Specification, Model, and Serial Numbersare required when ordering replacement parts fromyour Kohler Engine Service Dealer. These numbers arefound on the identification plate which is affixed to theengine shrouding. Include letter suffixes if there areany. See �Engine Identification Numbers� on page 6.

Always insist on genuine Kohler parts. All genuineKohler parts meet strict standards for fit, reliability, andperformance.

Major RepairMajor repair information is available in Kohler EngineService Manuals. However, major repair generallyrequires the attention of a trained mechanic and theuse of special tools and equipment. Your KohlerEngine Service Dealer has the facilities, training, andgenuine Kohler replacement parts necessary to performthis service. For Sales & Service assistance call1-800-544-2444 (U.S. & Canada) or contact yourKohler Engine Dealer or Service Distributor, they're inthe Yellow Pages under Engines-Gasoline.

SpecificationsModel: ....................................................................... CH18,20,22 .......................................... CH25,26,730,740,745Bore: ..................................... mm (in.) ..................... 77 (3.03)# .............................................. 83 (3.27)Stroke: ................................... mm (in.) ..................... 67 (2.64) ............................................... 67 (2.64)Displacement: ....................... cm3 (in3) ..................... 624 (38.1)# ............................................ 725 (44.0)Power (@3600 RPM): ........... kW (HP) ..................... 13.4 (18*)/14.9 (20*)/16.4 (22*) ........... 18.4 (25*)/19.4 (26*)

18.6 (25*)/20.1 (27*)/20.9(28*)Max. Peak Torque (@ RPM): N·m (ft. lb.) ..................... 43.7 (32.2) @2200 ................................ 54 (39.5) @2200

44.3 (32.7) @2400 ................................ 54.2 (40.0) @280050.6 (37.3) @2400 ................................ 53.7 (39.6) @2600

58.6 (43.2) @240057.9 (42.7) @2600

Compression Ratio: ................................................. 8.5:1 ..................................................... 9.0:1Weight: .................................... kg (lb.) ..................... 41 (90) .................................................. 43 (94)Lubrication: ........................................ Full Pressure w/full Flow FilterOil Capacity (w/filter) - approximate,determined by oil filter and oil cooler used: 1.6-1.8 L (1.7-1.9 U.S. qt.)

Exhaust Emission Control System for models CH18,20,22,23,25,730,740 is EM.Exhaust Emission Control System for models CH26 and CH745 are EM, O2S, ECM, MFI.

*Horsepower ratings exceed Society of Automotive Engineers Small Engine Test Code J1940. Actual engine horsepower islower and affected by, but not limited to, accessories (air cleaner, exhaust, charging, cooling, fuel pump, etc.), application,engine speed and ambient operating conditions (temperature, humidity, and altitude). Kohler reserves the right to changeproduct specifications, designs and equipment without notice and without incurring obligation.

#CH22 or CH23 engines with Spec. Numbers of 765xx have bore size of 80 mm (3.15 in.) and displacement of 674 cm3

(41.1 in3).

17

KOHLER CO.FEDERAL AND CALIFORNIA EMISSION CONTROL SYSTEMS

LIMITED WARRANTYSMALL OFF-ROAD ENGINES

The U.S. Environmental Protection Agency (EPA), the California Air Resources Board (CARB), and Kohler Co. are pleased to explain the Federaland California Emission Control Systems Warranty on your small off-road equipment engine. For California, engines produced in 1995and later must be designed, built and equipped to meet the state�s stringent anti-smog standards. In other states, 1997 and later model yearengines must be designed, built and equipped, to meet the U.S. EPA regulations for small non-road engines. The engine must be free fromdefects 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 dateof sale to the ultimate purchaser. Kohler Co. must warrant the emission control system on the engine for the period of time listed above, providedthere 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 anauthorized dealer), parts and labor.

MANUFACTURER�S WARRANTY COVERAGEEngines produced in 1995 or later are warranted for two years in California. In other states, 1997 and later model year engines are warranted fortwo years. If any emission related part on the engine is defective, the part will be repaired or replaced by Kohler Co. free of charge.

OWNER�S WARRANTY RESPONSIBILITIES(a) The engine owner is responsible for the performance of the required maintenance listed in the owner�s manual. Kohler 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 foryour failure to assure that all scheduled maintenance was performed.

(b) Be aware, however, that Kohler Co. may deny warranty coverage if the engine or a part has failed due to abuse, neglect, impropermaintenance or unapproved modifications.

Continued on next page.

LIMITED 2 YEAR COMMAND ENGINE WARRANTYKohler Co. warrants to the original consumer that each new COMMAND engine sold by Kohler Co. will be free from manufacturingdefects in materials or workmanship in normal service for a period of two (2) years from date of purchase, provided it is operated andmaintained in accordance with Kohler Co.�s instructions and manuals.

Our obligation under this warranty is expressly limited, at our option, to the replacement or repair at Kohler Co., Kohler, Wisconsin53044, 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 one (1) year from date of purchase, except catalyticmufflers, which are warranted for two (2) years.

This warranty does not apply to defects caused by casualty or unreasonable use, including faulty repairs by others and failure toprovide reasonable and necessary maintenance.

The following items are not covered by this warranty:

Engine accessories such as fuel tanks, clutches, transmissions, power-drive assemblies, and batteries, unless supplied or installed byKohler 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 OFANY KIND, including but not limited to labor costs or transportation charges in connection with the repair or replacement of defectiveparts.

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 oneauthorized 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 consequentialdamages, so the above limitation or exclusion may not apply to you.

This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

TO OBTAIN WARRANTY SERVICE:Purchaser must bring the engine to an authorized Kohler service facility. To locate the nearest facility, visit our website,www.kohlerengines.com, and click on SALES AND SERVICES to use the locator function, consult your Yellow Pages or telephone1-800-544-2444.

ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044

18

(c) 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 oraccess our website at: www.kohlerengines.com, for the names of the nearest service centers. The warranty repairs should be completedin 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 EngineService representative.

COVERAGEKohler Co. warrants to the ultimate purchaser and each subsequent purchaser that the engine will be designed, built and equipped, at the timeof sale, to meet all applicable regulations. Kohler Co. also warrants to the initial purchaser and each subsequent purchaser, that the engine isfree 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 1995 or later are warranted for two years in California. For 1997 and later model years, EPA requires manufacturers towarrant engines for two years in all other states. These warranty periods will begin on the date the engine is purchased by the initial purchaser. Ifany 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 fordamages 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 anauthorized 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 requirescheduled maintenance and are warranted up to the first scheduled replacement point for that part. The warranted parts are:

� Carburetor assembly � Ignition module(s) with high tension lead� Throttle body (EFI Systems) � Spark advance module (if equipped)� Catalytic muffler (if equipped) � Oxygen, speed, throttle position, and temperature sensors (if equipped)� Fuel metering valve (if equipped) � Electronic control unit (if equipped)� Crankcase breather � Fuel injectors (EFI Systems)� Fuel pressure regulator (EFI Systems) � Air filter, fuel filter, and spark plugs (only to first scheduled replacement point)

LIMITATIONSThis Emission Control Systems Warranty shall not cover any of the following:

(a) repair or replacement required because of misuse or neglect, improper maintenance, repairs improperly performed or replacements notconforming to Kohler Co. specifications that adversely affect performance and/or durability and alterations or modifications notrecommended or approved in writing by Kohler Co.,

(b) replacement of parts and other services and adjustments necessary for required maintenance at and after the first scheduled replacementpoint,

(c) consequential damages such as loss of time, inconvenience, loss of use of the engine or equipment, etc.,

(d) diagnosis and inspection fees that do not result in eligible warranty service being performed, and

(e) any add-on or modified part, or malfunction of authorized parts due to the use of add-on or modified parts.

MAINTENANCE AND REPAIR REQUIREMENTSThe owner is responsible for the proper use and maintenance of the engine. Kohler Co. recommends that all receipts and records covering theperformance of regular maintenance be retained in case questions arise. If the engine is resold during the warranty period, the maintenancerecords should be transferred to each subsequent owner. Kohler Co. reserves the right to deny warranty coverage if the engine has not beenproperly maintained; however, Kohler Co. may not deny warranty repairs solely because of the lack of repair maintenance or failure to keepmaintenance records.

Normal maintenance, replacement or repair of emission control devices and systems may be performed by any repair establishment orindividual; however, warranty repairs must be performed by a Kohler authorized service center. Any replacement part or service thatis equivalent in performance and durability may be used in non-warranty maintenance or repairs, and shall not reduce the warranty obligations of theengine manufacturer.

ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044

FOR SALES AND SERVICE INFORMATIONIN U.S. AND CANADA, CALL 1-800-544-2444

LITHO IN U.S.A.

FORM NO.: 24 590 01ISSUED: 11/04REVISED: 1/05MAILED:

M-6 HYDROSTATIC TRANSMISSION MODEL NO. 00600-024

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