Kohler CH6 Generator Set

⚠ Carburetor adjustments only after engine has warmed up

Tools: Tachometer

1. With engine stopped, turn low idle fuel needle in until it bottoms lightly (also main fuel needle on adjustable type).
2. Preliminary settings: idle fuel 1-1/4 turns open; main fuel 1-1/8 turns open (adjustable type only).
3. Start engine, run at half throttle 5-10 minutes to warm up.
4. Main fuel setting (adjustable type only): turn main fuel needle clockwise until speed decreases, then back out about 1/4 turn.
5. Low idle speed: set to 1200 (+/- 75) RPM; must not exceed 1500 RPM.
6. Low idle fuel: set needle midway between rich and lean.
7. On constant speed applications turn low idle fuel needle out 1-1/4 turns and leave.

⚠ Carburetor adjustments should be made only after engine has warmed up.

Tools: Tachometer, screwdriver

1. With engine stopped, turn low idle fuel adjusting needle in until it bottoms lightly.
2. Turn needle counterclockwise 1-1/4 turns open for idle fuel; main fuel (if adjustable) 1-1/8 turns open.
3. Start engine and run at half throttle for 5-10 minutes to warm up.
4. Main Fuel Needle Setting: Place throttle in fast position. Slowly turn main fuel needle clockwise until engine speed decreases, then back out about 1/4 turn.
5. Low Idle Speed Setting: Place throttle in idle position. Check RPM with tachometer. Adjust low idle speed screw to 1200 +/- 75 RPM. Do not exceed 1500 RPM.
6. Low Idle Fuel Setting: Move throttle to idle. Turn low idle fuel needle out until engine speed decreases (rich), note position, then turn in until speed increases then decreases (lean). Set needle mid
7. Recheck low idle speed with tachometer and reset as needed.

Tools: Pliers, wrench

1. Loosen governor lever hex nut.
2. Pull and hold governor lever away from carburetor so throttle plate is wide open.
3. Grasp governor cross shaft with pliers and turn counterclockwise as far as it will go.
4. Tighten hex nut securely.

⚠ Do not tamper with governor setting; overspeed is hazardous

Tools: Tachometer

1. Start engine and allow to warm up; place throttle control in fast/high idle position.
2. Check engine speed with a tachometer.
3. To increase: turn high idle speed adjusting screw out (counterclockwise) while moving throttle lever toward carburetor.
4. To decrease: turn high idle speed adjusting screw in (clockwise) until desired speed is attained.

⚠ Do not tamper with governor setting; overspeed is hazardous

Tools: Pliers

1. Loosen the governor lever hex nut.
2. Pull and hold governor lever away from carburetor so throttle plate is wide open.
3. Grasp governor cross shaft with pliers and turn counterclockwise as far as it will go.
4. Tighten the hex nut securely.

⚠ Make sure engine cannot rotate off top dead center in either direction

Tools: Kohler Cylinder Leakdown Tester Part No. 47 800 02, Breaker bar, Holding tool

1. Run engine 3-5 minutes to warm up.
2. Remove spark plug and air filter.
3. Rotate crankshaft until piston is at top dead center of compression stroke; hold in position.
4. Install adapter into spark plug hole but do not attach to tester.
5. Connect air source to tester; turn regulator clockwise until gauge needle is in yellow set area.
6. Connect tester quick-disconnect to adapter; note gauge reading and listen for escaping air.
7. Compare results with leakdown test results table.

⚠ Batteries contain sulfuric acid. Avoid contact with skin, eyes, clothing.

⚠ Batteries produce explosive hydrogen gas while charging. Charge only in well-ventilated areas.

Tools: D.C. voltmeter, baking soda solution

1. Regularly check level of electrolyte. Add distilled water as necessary.
2. Keep cables, terminals, and external surfaces clean. Wash with baking soda and water solution. Rinse thoroughly.
3. Test battery voltage by connecting D.C. voltmeter across terminals. Crank engine. If below 9 volts while cranking, battery is discharged or faulty.

⚠ Never operate with oil level below L mark or over F mark

1. Remove oil drain plug and oil fill cap/dipstick or oil fill/check plug; allow complete drainage.
2. Reinstall drain plug; tighten to 17.6 N·m (13 ft. lb.).
3. Fill crankcase with new oil to F mark on dipstick or to point of overflowing filler neck.
4. Reinstall oil fill cap/dipstick and tighten securely.

⚠ Do not connect spark plug lead

1. Change oil while engine is still warm.
2. Empty fuel system completely or treat gasoline with stabilizer; run engine 2-3 minutes.
3. Remove spark plug, add one tablespoon engine oil into plug hole, reinstall plug without connecting lead, crank two or three revolutions.
4. Remove spark plug, rotate crankshaft until piston is at top of stroke, reinstall plug without connecting lead.
5. Clean exterior surfaces of engine.
6. Store engine in a clean, dry place.

⚠ Install switch by hand as long as it is loose enough

Tools: 9/16 in. open end wrench

1. Drain oil from crankcase.
2. Apply Loctite No. 592 Teflon sealant to entire thread area of switch.
3. Apply thick film of clean SAE 30 oil to float and switch body.
4. Insert switch with flat surface vertical (N.C./N.O. marking left) and turn 1/4 turn until flat surface horizontal.
5. Turn switch clockwise in 1/2 turn increments with smooth continuous action.
6. Turn switch about 5 to 6 full turns; tighten with 9/16 in. open end wrench with N.C. markings at top.

⚠ Do not pause rotation with N.C./N.O. markings in position that causes float to strike oil pan

Tools: 9/16 in. open end wrench

1. Rest engine on level surface; remove oil drain plug and drain oil.
2. Disconnect float switch leads.
3. Using 9/16 in. open end wrench, turn switch counterclockwise 1/4 turn to loosen; stop when flat surface is horizontal.
4. Turn switch counterclockwise in 1/2 turn increments with smooth continuous action.
5. Remove switch by hand as soon as it is loose enough.

⚠ Do not wash paper element or use pressurized air

1. Remove air cleaner cover.
2. Remove precleaner from element retainer.
3. Loosen four slot head screws in element retainer; unhook retainer from bottom tabs; remove retainer and paper element.
4. Replace dirty, bent or damaged element with genuine Kohler element.
5. Reinstall paper element with pleats parallel to cylinder; hook retainer on tabs.
6. Tighten four screws evenly so screws are snug.
7. Reinstall precleaner and cover.