KOHLER KS530 5400 Series Engine Owner’s Manual

KOHLER KS530 5400 Series Engine

IMPORTANT:

Read all safety precautions and instructions carefully before operating equipment. Refer to the operating instructions of the equipment that this engine powers. Ensure engine is stopped and level before performing any maintenance or service. Warranty coverage as outlined in the warranty card and on KohlerEngines.com. Please review carefully as it provides your specifi c rights and obligations. To maintain compliance with applicable emission regulations, exhaust system backpressure may not exceed limits which can be found on KohlerEngines.com. Search by Model No., then select the Specs tab. Kohler Engines has published CO2 values on the KohlerEngines.com website.

Record engine information to reference when ordering parts or obtaining warranty coverage.

• Engine Model Specification
• Serial Number
• Purchase Date

Safety Precautions

• WARNING: A hazard that could result in death, serious injury, or substantial property damage.
• CAUTION: A hazard that could result in minor personal injury or property damage.
• NOTE: is used to notify people of important installation, operation, or maintenance information.

WARNING

• Explosive Fuel can cause fires and severe burns. Do not fill fuel tank while the engine is hot or running. Gasoline is extremely
  flammable and its vapors can explode if ignited. Store gasoline only in approved containers, in well-ventilated, unoccupied buildings, away from sparks or fl ames. Spilled fuel could ignite if it comes in contact with hot parts or sparks from the ignition. Never use gasoline as a cleaning agent.

• Rotating Parts can cause severe injury. Stay away while the engine is in operation. Keep hands, feet, hair,and clothing away from all moving parts to prevent injury. Never operate the engine with covers, shrouds, or guards removed.

• Carbon Monoxide can cause severe nausea, fainting or death. Avoid inhaling exhaust fumes. Never run engine indoors or in enclosed spaces. Engine exhaust gases contain poisonous carbon monoxide. Carbon monoxide is odorless, and colorless, and can cause death if inhaled.

CAUTION
Electrical Shock can cause injury. Do not touch wires while the engine is running.

• Accidental Starts can cause severe injury or death. Disconnect and ground spark plug lead(s) before servicing. Before working on engine or equipment, disable engine as follows: 1) Disconnect spark plug lead(s). 2) Disconnect negative (–) battery cable from battery.
• Hot Parts can cause severe burns. Do not touch engine while operating or just after stopping. Never operate engine with heat shields or guards removed.

WARNING: This product can expose you to chemicals including carbon monoxide and benzene, which are known to the State of California to cause cancer and birth defects or other reproductive harm. For more information go to www.P65Warnings.ca.gov.

Visit KohlerEngines.com for service parts information and purchasing options.

Pre-Start Checklist

1. Check oil level. Add oil if low. Do not overfi ll.
2. Check fuel level. Add fuel if low. Check fuel system components and lines for leaks.
3. Check and clean cooling areas, air intake areas and external surfaces of engine (particularly after storage).
4. Check that air cleaner components and all shrouds, equipment covers, and guards are in place and securely fastened.
5. Check spark arrestor (if equipped).

Starting

WARNING
Carbon Monoxide can cause severe nausea, fainting or death. Avoid inhaling exhaust fumes. Never run engine indoors or in enclosed spaces. Engine exhaust gases contain poisonous carbon monoxide. Carbon monoxide is odorless, colorless, and can cause death if inhaled.

WARNING
Rotating Parts can cause severe injury. Stay away while engine is in operation. Keep hands, feet, hair, and clothing away from all moving parts to prevent injury. Never operate engine with covers, shrouds, or guards removed.

Standard Choke System

• Above 32°F (0°C) Refer to operating instructions of equipment this engine powers for specifi c starting instructions.
• 32°F (0°C) and Below
  1. Refer to operating instructions of equipment this engine powers for specifi c starting instructions.
  2. Refer to Cold Weather Starting Hints within this manual.

Smart-ChokeTM

• Above 32°F (0°C)

1. This feature will automatically adjust engine choke on start up with throttle in any position.
2. If engine does not start on fi rst attempt, wait
3. 5 seconds and try again (if no start after third attempt wait 1 minute).
4. If engine does not consistently start by fi fth attempt, consult Kohler authorized dealer for assistance.

• 32°F (0°C) and Below

1. This feature will automatically adjust engine choke on start up with throttle in any position (winter blend fuel is recommended).
2. If the engine does not start on fi rst attempt, wait 5- 10 seconds and try again (if no start after third attempt wait 1 minute).
3. If the engine does not consistently start by fi fth attempt, consult Kohler authorized dealer for assistance.

Cold Weather Starting Hints

1. Use proper oil for the temperature expected.
2. Disengage all possible external loads.
3. Use fresh winter-grade fuel. Winter-grade fuel is formulated to improve starting.
4. Make sure the battery has a full charge.

Stopping

1. If possible, remove load by disengaging all PTO driven attachments.
2. Position throttle control between half and full throttle; stop engine.

Angle of Operation
Refer to the operating instructions of the equipment this engine powers. Do not operate this engine exceeding maximum angle of operation; see specifi cation table. Engine damage could result from insuffi cient lubrication.

Engine Speed

NOTE: Do not tamper with the governor set to increase maximum engine speed. Overspeed is hazardous and will void the warranty.

High Altitude Operation
If this engine is operated at an altitude of 4000 ft. (1219 meters) or above, a high-altitude carburetor kit is required. To obtain high altitude carburetor kit information or to fi nd a Kohler authorized dealer, visit KohlerEngines.com or call 1-800-544-2444 (U.S. and Canada). This engine should be operated in its original confi guration below 4000 ft. (1219 meters).Operating this engine with the wrong engine confi guration at a given altitude may increase its emissions, decrease fuel effi ciency and performance, and result in damage to the engine.

Maintenance Instructions

WARNING

• Accidental Starts can cause severe injury or death. Disconnect and ground spark plug lead(s) before servicing.Before working on engine or equipment, disable engine as follows: 1) Disconnect spark plug lead(s). 2) Disconnect negative (–) battery cable from battery. Normal maintenance, replacement or repair of emission control devices and systems may be performed by any repair establishment or individual; however, warranty repairs must be performed by a Kohler authorized dealer found at KohlerEngines.com or 1-800-544-2444 (U.S. and Canada).

Maintenance Schedule

Every 25 Hours or Annually¹ (whichever comes first)
● Service/replace precleaner (if equipped).

● Replace air cleaner element (if not equipped with precleaner).

Every 100 Hours or Annually¹ (whichever comes first)
● Replace air cleaner element (if equipped with precleaner).

● Change oil and filter.

● Remove cooling shrouds and clean cooling areas.

Every 100 Hours
● Replace fuel filter.

● Check that all fasteners are in place and components are properly secured.

Every 200 Hours²
● Have valve lash checked/adjusted.
Every 300 Hours3
● Change oil and filter (KOHLER PRO 10W-50 oil and KOHLER PRO filter only).
Every 500 Hours
● Replace spark plug and set gap.
¹ Perform these procedures more frequently under severe, dusty, dirty conditions. ² Have a Kohler authorized dealer perform this service.

3 Option only if using KOHLER PRO oil and PRO filter.

®

Oil Recommendations

All-season KOHLER® PRO 10W-50 Synthetic Oil is the ideal oil for KOHLER engines. It is specifi cally formulated to extend the oil and oil fi lter change interval to 300 Hours when paired with a KOHLER PRO Extended Life Oil Filter. 300-Hour oil and oil filter change intervals are exclusive to and only authorized on KOHLER engines that utilize both the KOHLER PRO 10W-50 Synthetic Oil and KOHLER PRO Extended Life Oil Filter. Alternative engine oils and oil fi lters may be used with KOHLER engines but require 100-Hour oil and oil fi lter change intervals for proper maintenance. Oil must be API (American Petroleum Institute) service class SJ or higher. Select viscosity based on air temperature at time of operation as shown below.

Check Oil Level

NOTE: To prevent extensive engine wear or damage, never run engine with oil level below or above operating range indicator on dipstick. Ensure engine is cool and level. Clean oil fi ll/dipstick areas of any debris.

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

Change Oil and Filter

Change oil while engine is warm.

1. Clean area around oil fi ll cap/dipstick. Remove drain plug and oil fi ll cap/dipstick. Allow oil to drain completely.
2. Clean area around oil fi lter. Place a container under fi lter to catch any oil and remove fi lter. Wipe off mounting surface. Reinstall drain plug. Torque to 125 in. lb. (14 N·m).
3. Place new fi lter in a shallow pan with open end up. Fill with new oil until oil reaches the bottom of threads. Allow 2 minutes for oil to be absorbed by fi lter material.
4. Apply a thin fi lm of clean oil to the rubber gasket on new filter.
5.  Refer to instructions on oil fi lter for proper installation.
6. Fill the crankcase with new oil. The level should be at top of the indicator on the dipstick. Reinstall oil fi ll cap/dipstick and tighten securely.
7. Start the engine; check for oil leaks. Stop the engine; correct leaks. Recheck oil level.
8. Dispose of used oil and fi lter in accordance with local ordinances.

Oil Sentry™ (if equipped)
This switch is designed to prevent the engine from starting in a low-oil or no-oil condition. Oil Sentry™ may not shut down a running engine before damage occurs. In some applications, this switch may activate a warning signal. Read your equipment manuals for more information.

Fuel Recommendations

WARNING
Explosive Fuel can cause fi res and severe burns. Do not fi ll fuel tank while engine is hot or running. Gasoline is extremely fl ammable and its vapors can explode if ignited. Store gasoline only in approved containers, in well- ventilated, unoccupied buildings, away from sparks or fl ames. Spilled fuel could ignite if it comes in contact with hot parts or sparks from the ignition. Never use gasoline as a cleaning agent.

NOTE: E15, E20 and E85 are NOT approved and should NOT be used; eff ects of old, stale or contaminated fuel are not warrantable. Fuel must meet these requirements:

• Clean, fresh, unleaded gasoline.
• Octane rating of 87 (R+M)/2 or higher.
• Research Octane Number (RON) 90 octane minimum.
• Gasoline up to 10% ethyl alcohol, 90% unleaded is acceptable.
• Methyl Tertiary Butyl Ether (MTBE) and unleaded gasoline blend (max 15% MTBE by volume) are approved.
• Do not add oil to gasoline.
• Do not overfi ll fuel tank.
• Do not use gasoline older than 30 days.

Fuel Line
Low permeation fuel line must be installed on carbureted Kohler Co. engines to maintain EPA and CARB regulatory compliance.

Spark Plugs

CAUTION
Electrical Shock can cause injury. Do not touch wires while engine is running. Clean out spark plug recess. Remove plug and replace.

1. Check gap using wire feeler gauge. Adjust gap, see specifi cation table for adjustment.
2. Install plug into cylinder head.
3. Torque plug to 20 ft. lb. (27 N·m).

Air Cleaner

NOTE: Operating engine with loose or damaged air cleaner components could cause premature wear and failure. Replace all bent or damaged components.
NOTE: Paper element cannot be blown out with compressed air. Turn knobs toward unlock symbol and remove air cleaner cover.

Precleaner (if equipped):

1. Remove precleaner from paper element.
2. Replace or wash precleaner in warm water with detergent. Rinse and allow to air dry.
3. Lightly oil precleaner with new engine oil; squeeze out excess oil.
4. Reinstall precleaner over paper element. Paper Element:
5. Remove element from air cleaner adapter; service precleaner. Discard element.
6. Install precleaner over new paper element and install on air cleaner adapter. Secure element behind retainer in housing. Position air cleaner cover on housing and line up knobs with unlock symbol. Turn knobs toward lock symbol to secure.

Breather Tube

• Ensure both ends of the breather tube are properly connected.

Air Cooling

WARNING

Hot Parts can cause severe burns. Do not touch engine while operating or just after stopping. Never operate engine with heat shields or guards removed. Proper cooling is essential. To prevent overheating, clean screens, cooling fi ns, and other external surfaces of engine. Avoid spraying water at wiring harness or any electrical components. See Maintenance Schedule.

Repairs/Service Parts
We recommend that you use a Kohler authorized dealer for all maintenance, service, and replacement parts for engine. To find a Kohler-authorized dealer visit KohlerEngines.com or call 1-800-544-2444 (U.S. and Canada).

Storage
If the engine will be out of service for 2 months or more follow the procedure below.

1. Add KOHLER PRO Series fuel treatment or equivalent to fuel tank. Run engine 2-3 minutes to get stabilized fuel into fuel system (failures due to untreated fuel are not warrantable).
2. Change oil while the engine is still warm from operation (NOT required if using KOHLER PRO 10W-50 full-synthetic oil). Remove spark plug(s) and pour about 1 oz. of engine oil into the cylinder(s). Replace the spark plug(s) and crank the engine slowly to distribute oil.
3. Disconnect the negative (-) battery cable.
4. Store the engine in a clean, dry place.

Troubleshooting

Do not attempt to service or replace major engine components, or any items that require special timing or adjustment procedures. This work should be performed by a Kohler-authorized dealer.

Engine Specifications

Model

|

Bore

|

Stroke

|

Displacement

|

Oil Capacity (Refill)

|

Spark Plug Gap

| Maximum Angle of Operation

**(@ full oil level)***

KS530|

3.7 in. (94 mm)

|

3.1 in. (78 mm)

|

33.0 cu. in. (541 cc)

|

1.5 U.S. qt.

1.4 L

|

0.030 in. (0.76 mm)

|

25°

KS540
KS590
KS595

• Exceeding the maximum angle of operation may cause engine damage from insufficient lubrication. Additional specifi cation information can be found in the service manual at KohlerEngines.com.Any and all horsepower (hp) references by Kohler are Certifi ed Power Ratings and  per SAE J1940 & J1995 hp standards. Details on Certifi ed Power Ratings can be found at KohlerEngines.com.

Emission Control System

The exhaust Emission Control System for models KS530-KS595 is EM for U.S. EPA, California, and Europe.

NOTE: Tampering with the engine and its emission control system voids the EPA Certificate of Conformity, ARB Executive Order, and EU type-approval.

References

• Engines | KOHLER Power
• P65Warnings.ca.gov

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