Kohler PCH680 Generator Set

Tools: nail

1. Move governor lever toward throttle body as far as it will go (wide-open throttle) and hold in position.
2. Insert a nail into hole on cross shaft and rotate shaft counterclockwise as far as it will turn.
3. Torque nut to 7.1 N·m (63 in. lb.).

1. Turn idle screw clockwise one full turn prior to key/ignition ON after ECU Reset.
2. Start engine, run at low idle until engine is warm.
3. Idle speed must be above 1500 RPM. If below, turn idle screw up to 1700 RPM; shut down engine and perform ECU Reset again.
4. Adjust idle speed down to 1500 RPM. Allow engine to dwell at 1500 RPM for about 3 seconds.
5. Adjust idle speed to final specified speed setting.
6. Turn key/ignition OFF and count to 10 seconds. Learn procedure is complete.

Tools: compression tester

1. Perform on a warm engine. Clean dirt away from base of spark plug(s).
2. Be sure battery is fully charged, unplug ECU, and throttle is wide open during test.
3. Compression should be at least 160 psi and should not vary more than 15% between cylinders.

⚠ Carbon Monoxide can cause severe nausea, fainting or death. Only operate in well ventilated areas.

Tools: manometer, rubber stopper, pinch clamp, tapered adapters

1. Insert rubber stopper into oil fill hole. Be sure pinch clamp is installed on hose and use tapered adapters to connect hose between stopper and one manometer tube. Leave other tube open to atmosphere.
2. Start engine and run no-load high speed.
3. Open clamp and note water level in tube.
4. Level in engine side should be a minimum of 10.2 cm (4 in.) above level in open side.
5. Close pinch clamp before stopping engine.

Tools: Dual Gauge Cylinder Leakdown Tester, 12 mm x 14 mm adapter if required

1. Run engine until oil temperature reaches and maintains 150°F (66°C) or more for a minimum of 5 minutes.
2. Remove spark plug(s) and air filter.
3. Rotate crankshaft until piston is at top dead center (TDC) of compression stroke. Hold engine in this position.
4. Connect an air source (at least 100 PSI) to tool.
5. Turn regulator knob clockwise. Confirm both gauges read approximately same air pressure from 0 to 80 PSI. Release pressure before proceeding.
6. Install adapter hose into spark plug hole.
7. Turn regulator knob clockwise until left gauge reads 20 PSI.
8. Slowly turn regulator knob clockwise until left hand gauge maintains selected test pressure (80 PSI recommended for engines over 200 cc).
9. Compare right gauge reading to Test Pressure Chart to identify percentage of leakage.

Tools: Kohler EFI service kit Red wire jumper

1. Turn key/ignition OFF.
2. Install Red wire jumper from Kohler EFI service kit onto service port (connect white wire to black wire in 4 way diagnostic port).
3. Turn key/ignition ON, then OFF and count 10 seconds.
4. Turn key/ignition ON, then OFF and count to 10 seconds a second time.
5. Remove Red wire jumper.
6. Turn key/ignition ON, then OFF and count to 10 seconds a third time. ECU is reset.

⚠ High Pressure Fluids can puncture skin and cause severe injury or death. Do not work on fuel system without proper training or safety equipment.

1. Remove manifold mounting bolts and separate throttle body/manifold from engine leaving TPS, high pressure fuel line, injectors and fuel line connections intact. Discard old gaskets.
2. Position manifold assembly over container to capture fuel and turn key switch ON to activate/energize lock-off valve and pressurize system. Do not turn switch to START position.
3. If either injector exhibits leakage of more than two to four drops per minute from tip, or shows any sign of leakage around outer shell, turn ignition switch OFF and replace injector.

1. Clean area around oil fill cap/dipstick and drain plug.
2. Remove drain plug and oil fill cap/dipstick. Allow oil to drain completely.
3. Remove oil filter. Wipe mounting surface. Reinstall drain plug; torque to 13.6 N·m (10 ft. lb.).
4. Prefill new filter with oil; allow 2 minutes.
5. Apply thin film of clean oil to rubber gasket.
6. Install new filter per instructions.
7. Fill crankcase with new oil. Level at top of indicator.
8. Start engine; check for leaks. Stop engine; correct leaks. Recheck oil level.

1. Remove dipstick; wipe oil off.
2. Reinsert dipstick into tube; press completely down.
3. Remove dipstick; check oil level. Level should be at top of indicator.
4. If low, add oil up to top of indicator mark.
5. Reinstall and secure dipstick.

1. Remove inlet fitting w/O-ring, button filter and gasket.
2. Discard filter, gasket, and O-ring.
3. Position new gasket into regulator, install button filter (large end in).
4. Install new O-ring on inlet fitting.
5. Reinstall inlet fitting and torque to 20 N·m (177 in. lb.).

1. Change oil while engine is warm (not required if using KOHLER PRO 10W-50 full-synthetic oil).
2. Remove spark plug(s); pour about 1 oz. of engine oil into cylinder(s).
3. Replace spark plug(s); crank engine slowly to distribute oil.
4. Disconnect negative (-) battery cable.
5. Separate propane tank from unit; store separately in designated safe area.
6. Store engine in a clean, dry place.

1. Disconnect plug from lock-off. Remove nut and lock-off. Remove lock-off valve body and plunger. Discard all parts.
2. Install plunger, then lock-off valve body. Torque body to 20 N·m (177 in. lb.).
3. Install lock-off assembly and nut. Torque nut to 6.5 N·m (57 in. lb.).
4. Reconnect plug to lock-off.