Page 2 - Table of Contents; Command Series
2 Table of Contents Command Series General 6$(2LO$ERYHÛ)Û& .............................................................................................................................5 Command Twin '6$,&RQYHUVLRQ.LW5HPLQGHU ......................................................................
Page 3 - New Product; Parts Bulletins
3 Command Series LDW 702-1404/KDW702-1404 (cont.) Control Panel Indicator Lights.............................................................................................................................25 Key/Key Switch Change .........................................................................
Page 4 - Technician’s Service Test
4 Command Series Technician’s Service Test Gasoline ............................................................................................................................................................. 92-95Diesel..................................................................................
Page 5 - Section 1 - Command Series; General; DSSOLFDWLRQV7HVWLQJKDVUHFHQWO\VKRZQEHQH¿WVVXFKDV; Approved Warm Weather Oil; Command Twin; DSAI Conversion Kit Reminder; The two systems are not; No Conversion - Order by
5 Command Series Section 1 - Command Series General SAE-30 Oil Above 50°F (10°C) It has been standard practice and was recommendedforever to use 10W-30 oil in all Command hydraulic lifter DSSOLFDWLRQV7HVWLQJKDVUHFHQWO\VKRZQEHQH¿WVVXFKDV improved emissions and reduced oil consumption whenSAE-30 oil i...
Page 7 - KHVROHQRLGNLW3DUW1R6KDVEHHQLGHQWL¿HG; Oil Pan Gasket and Shim; KRZHYHULWLVDOVRUHTXLUHGWKDWFUDQNVKDIWVKLP6
7 Command Series Incorrect Solenoid Jet (24 757 22-S) 7KHVROHQRLGNLW3DUW1R6KDVEHHQLGHQWL¿HG as having been built with the No. 120 jet instead of a SOXJ:KHQXVLQJWKLVNLWLWXVXDOO\UHTXLUHVWKDWWKHSOXJ be removed, and the jet from the original solenoid betransferred to the new solenoid. (QJLQHVWKDWXVHWKLV...
Page 8 - PRGL¿HGWRPDNHURRPIRUWKHODUJHUFUDQNVKDIW; Interference; reported due to excessive combustion pressure. To reduce; Timing Change
8 Command Series Oil Pump Gear Interference (24 393 51-S) When the CH/CV750 and LH755/775 were developed in2005, the stroke of the crankshaft was increased as wellas the size of the counter weight. The oil pump was also PRGL¿HGWRPDNHURRPIRUWKHODUJHUFUDQNVKDIW The old style pump is 3 mm taller than t...
Page 9 - EFI; SXPSLVPRUHUREXVWLQERWKDLUDQGOLTXLGFRROHGHQJLQHV; Command Single; XQLWVWKDWZHUHLGHQWL¿HGDUH; to February 6; Correct
9 Command Series Old vs. New Pump EFI New EFI Fuel Pumps (24 393 52-S) Starting in March 2008, all EFI engines have been built withfuel pumps from a new supplier. Testing has proven the new SXPSLVPRUHUREXVWLQERWKDLUDQGOLTXLGFRROHGHQJLQHV The new pump is similar in size and design and willinterchange...
Page 11 - Section 2 - Aegis Series; Oil Dilution Solution; Aegis engines is a; all weather connector that seals the terminals from moisture
11 Aegis Sealed Relay Kit New Thermostat Installation Instructions TT-5232 Sealed Relay Kit 66 755 19-S This kit replaces an unsealed relay with a sealed relay on Kohler EFI engines. WARNING: Accidental Starts! Disabling engine. Accidental starting can cause severe injury or death. Before working on...
Page 13 - Section 3 - Courage Series; Courage Twin; KHQHZVWUDLJKWFXWWRRWKGHVLJQZLOOQRWUHWUR¿WLQWRROGHU; ¿HOGDOO&RXUDJHHQJLQHVDUHQRZEXLOWZLWKVWHHOULQJJHDUV
13 Courage Series Section 3 - Courage Series Machined Cam Courage Twin Assembled Camshaft The new automotive style, “assembled camshaft” consists of a machined metal shaft, powdered metal lobes, and a nylon gear. This design is not new technology, and is used by some of the most successful and well ...
Page 14 - FUDQNFDVHIRUFUDFNVRUDQ\RWKHUVLJQL¿FDQWGDPDJH,IQRQH; Blue Loctite; Courage Single; Crankcase Sealed With Loctite
14 Courage Series Emissions Statement We are updating the Owner’s Manual regarding emissions compliance. We are adding a statement that will recommend the combustion chamber be cleaned between 200 and 400 hours to retain emission compliance status. This is recommended but not required and will be le...
Page 15 - RIWKHZHLJKWDVVHPEO\WKDWFDXVHGPLQRUIUHWWLQJRQWKHMRLQW
15 Courage Series New Cam Design The new design cam reduces the number of parts in the engine as the gear, lobe, and shaft will be assembled as one part. The assembled cam will provide quality control and consistency in production on the Courage engine equal to the Command Series engines. The design...
Page 16 - Courage Series; UHGXFHPDVV$GYDQWDJHVLQFOXGH; Old Style; The connecting rod went through some; Connecting Rod Detail
16 Courage Series Less reciprocating mass means less force to balance within the system. That means lower bearing loads and longer engine life. To accomplish this, the piston was completely redesigned to UHGXFHPDVV$GYDQWDJHVLQFOXGH Wider skirt for better heat transfer from the crown 3LQKHLJKWLVUDLVH...
Page 17 - next; to the; EHORZRUUHIHUWR3DUWV%XOOHWLQIRUIXUWKHULQIRUPDWLRQ
17 Courage Series Crankshaft Detail “2” Indicates New Balance System “3” Indicates CARB Tier III Decal Reminder When placing the decal for the short EORFNPDNHVXUHLWLVDI¿[HG next to the original engine decal, not over it . The original engine information will be required when servicing any external c...
Page 18 - Courage XT; WDQNRXWOHWDQGEORFNHGRUUHVWULFWHGIXHOÀRZ6\PSWRPV
18 Courage Series Courage XT XT Fuel Tank Debris We have found some evidence of debris showing up in the IXHOWDQNVRQWKH;7HQJLQH$WKRURXJKLQYHVWLJDWLRQRIWKHFDXVHKDVUHVXOWHGLQWKHVH¿QGLQJV $VDFRQVHTXHQFHRIWKHYHQGRU¶VSURFHVVRI³YLEUDWLRQZHOGLQJ´¿QHKDLUOLNH¿EHUVRUÀDVKLQJKDYHEHHQIRXQG inside the tank. This ...
Page 19 - Kohler Diesel; Section 4 - Kohler Diesel; Model Number Review; do not; Explanation of Diesel Engine Model Numbers; Kohler Diesel Service and Support; On May
19 Kohler Diesel Section 4 - Kohler Diesel Model Number Review The chart below is included to help you become familiar with and more easily identify the diesel product line. It also shows the difference between a Lombardini Diesel model number and a Kohler Diesel model number. You may want to make a...
Page 20 - KHUHKDYHEHHQUHSRUWVLQWKH¿HOGRIVRPHFRQIXVLRQRQ; Rocker Arm Spacer Installed; All Air-Cooled Series; .RKOHU'LHVHOUHFRPPHQGVDQLQOLQH¿OWHUEHLQVWDOOHG; QSD Fuel Line Routing
20 Kohler Diesel 15LD 400/KD400 Hydraulic Lifter Rocker Arm Torque Procedure 7KHUHKDYHEHHQUHSRUWVLQWKH¿HOGRIVRPHFRQIXVLRQRQ the hydraulic lifter rocker arm torque procedure on these engines. The engine uses hydraulic lifters so no valve settings are required. To properly install the rocker arms on t...
Page 21 - Fuel Supply Line
21 Kohler Diesel 15LD 315-440/KD315-440 Injection Pump Check Valve :HKDYHKDGVRPHUHSRUWVIURPWKH¿HOGRISUREOHPVZLWK these engines not shutting down properly. If checks of the fuel shut-off valve (if supplied) are found to be OK, then the injection pump check valve should be checked. The check valve may...
Page 22 - All Liquid-Cooled Series; Beginning at engine; New Style Fuel Filter Head; Starting at engine; Comparison of Head Bolts; Part Number
22 Kohler Diesel All Liquid-Cooled Series )XHO)LOWHU+HDG0RGL¿FDWLRQ Beginning at engine Serial Number 5002295 WKHIXHO¿OWHU KHDGRQWKHDERYHPHQWLRQHGHQJLQHVKDVEHHQPRGL¿HG 7KHQHZ¿OWHUKHDGGHVLJQSURYLGHVEHWWHUSUHVVXUH regulation and reduces fuel lift pump fatigue, resulting in better startability and resp...
Page 23 - Starting with the following engine serial numbers:; no start; condition is discovered, use the starter to; New Style
23 Kohler Diesel LDW 702-1404/KDW702-1404 )XHO/LIW3XPS&DPVKDIW/REH0RGL¿FDWLRQ Starting with the following engine serial numbers: /':.': /':.': /':.': 7KHIXHOOLIWSXPSFDPVKDIWOREHKDVEHHQPRGL¿HGWR improve fuel lift pump drive rod and camshaft lobe wear, while also allowing easier parts replacement....
Page 24 - :KHQUHPRYLQJWKHRLOSDQEHVXUHWRXVHDSXWW\NQLIH; Front Lateral; Removed
24 Kohler Diesel Oil Pan Removal Please note that when removing the oil pan on these engines, care must be taken not to pull the lateral oil seals, located between the crankcase, front, and rear bearing support, out of their seat. The factory uses a silicone gasket material to seal the oil pan to th...
Page 25 - shutdown system as well as several warning indicators.; Control Panel Detail
25 Kohler Diesel Control Panel Indicator Lights 7KHFRQWUROSDQHORQWKH/':.':VHULHVRIHQJLQHVKDVDVHOIFRQWDLQHGHQJLQHVDIHW\ shutdown system as well as several warning indicators. The engine will shut down for the following reasons: Low Oil PressureHigh Coolant TemperatureLow Alternator OutputAuxiliary Sh...
Page 26 - Old Style Key/Key Switch
26 Kohler Diesel Key/Key Switch Change Starting at engine Serial Number 5252706 , the engine key/key switch has been changed to a new style that incorporates a sliding cover. This prevents debris from contaminating the key switch body when the key is removed. The key switch body also has leak holes ...
Page 27 - Section 5 - New Product; Gracious Living
27 New Product Section 5 - New Product Kohler Introduces New Command Pro Horizontal Engine Line Kohler Engines is pleased to introduce a new line of product that exceeds the current offering of any other manufacturer in the industry. With a 6 to 14 HP range and standard features that meet or exceed ...
Page 28 - ZDUPDLUIURPWKHPXIÀHUDQGKHDWWKHFDUEXUHWRUDLURQ; Dual Ball Bearings
28 New Product :DUP:HDWKHUYV$QWL,FLQJ&RQ¿JXUDWLRQ +HDY\'XW\$LU¿OWHU A heavy duty patented air cleaner is standard. It has an indexable cover that allows it to be rotated to capture ZDUPDLUIURPWKHPXIÀHUDQGKHDWWKHFDUEXUHWRUDLURQ applications that operate in both warm and cold weather conditions. D...
Page 29 - for commercial users.
29 New Product Other Features Along with all of the other standard features, the Command Pro includes electronic ignition, Oil Sentry TM ORZRLOSURWHFWLRQGXDORLO¿OODQGGUDLQORFDWLRQVKHOLFDOFXWJHDUVDQGD\HDUZDUUDQW\ for commercial users. Helical Cut Gears Dual Oil Fill Oil Sentry TM Protection
Page 30 - Kohler Enters Consumer Horizontal Market
30 New Product Kohler Enters Consumer Horizontal Market The leader in commercial engine products is now manufacturing a line of horizontal consumer engines that has some of the same features as it commercial line. The Slant cylinder overhead valve design engine line has a cast iron liner, dual ball ...
Page 32 - New Commercial EFI; Currently designed for Command Twins in both horizontal; Consumer EFI with Heavy-Duty
32 New Product New Commercial EFI Introducing the all new self-contained EFI system from Kohler Engines. This “Closed Loop” “Sequential Fuel Injection” system has all the advantages of the current system and more. The self contained system means that all the previously added components are now mount...
Page 33 - (QJLQHVZLWKWKHODXQFKRIRXU¿UVWHYHUHQJLQHIRUWKH; Technology
33 New Product Courage XT-6 September 2007 marked a great milestone for Kohler (QJLQHVZLWKWKHODXQFKRIRXU¿UVWHYHUHQJLQHIRUWKH consumer walk behind mower market. Although the market has been slow, there are strong indications that sales will grow dramatically in this market as well as in the pressure ...
Page 35 - Miscellaneous; Section 6 - Miscellaneous; Replace Mating Gears; $OWKRXJKWKHIXHOSXPS¿OWHUGRHVDEHWWHUMRERIUHPRYLQJ; Bearing Concern; LQFRUUHFWO\7KH6KDVDQRLOKROHWKDWLVÛ; 0° is Correct
35 Miscellaneous Section 6 - Miscellaneous Replace Mating Gears It is recommended in situations where a broken crankshaft gear is replaced as a repair that the camshaft should also be replaced. The mating gear will develop a wear pattern, and failure to change it may cause a repeat failure. This sug...
Page 36 - twice; Miles Traveled vs. RPM; DSSOLFDWLRQWKHRLO¿OOWXEHDQGGLSVWLFNFRQ¿JXUDWLRQZHUH; OEM Parts; Hours
36 Miscellaneous 1800 3600 1 40 80 8 320 640 100 4,000 8,000 200 8,000 16,000 500 20,000 40,000 2,000 80,000 160,000 3,000 120,000 240,000 Makes You Think... This information came from a service bulletin written by an OEM in the mid ‘70’s. Although there are many factors that play into the life expe...
Page 38 - Bearing failures can be easy to identify but extremely
38 Miscellaneous Bearing Failures Bearing failures can be easy to identify but extremely GLI¿FXOWWRWURXEOHVKRRW2QHFDXVHRIORZHUEHDULQJIDLOXUH can be the result of electrolysis. No, it does not involve hair removal. It is stray voltage attempting to seek an area to ground itself. In this case that are...
Page 39 - ANTI-ICING COMPONENTS
39 Miscellaneous Anti-Icing Components For applications that are used in warm as well as cold weather environments, we have some kits available to keep your engine compliant with CARB and EPA regulations while operating in cold weather. Because of the closed breather system required by these regulat...
Page 40 - On engines that are not emissions compliant, a suitable; Emissions Compliant; Letter Regarding Compliancy
40 Miscellaneous Replacement Engine Reminder This is a reminder when replacing an engine you must check to see if the original engine is emission compliant. When re-powering a piece if equipment, it is required by U.S. law that a compliant engine be used if the original engine was EPA or CARB compli...
Page 41 - Kohler Starting Circuit Test Procedure; Troubleshooting Electric Starters; Service
41 Miscellaneous Step 1 Step 1 Step 2 Step 2 Step 2 Step 2 Step 4 Step 4 Step 4 Step 4 Step 5 Step 5 Step 6 Step 6 (list none if corrective actions were not needed) Kohler Starting Circuit Test Procedure Ambient Air Temperature: Operating Hours: Use attached sheet(s) for test procedures and insert r...
Page 42 - Solenoid Shift Starting Circuit Test Procedure; Starter Testing Procedures
42 Miscellaneous Page 1 Solenoid Shift Starting Circuit Test Procedure REV. 07 /23/2008 Before Starting: Ba ttery voltage shou ld be tested a n d m ust be a t 12.4 V DC or higher . Do not proce e d if batte ry voltage is les s than 12.4 VDC as battery should be charged. Test meter lea ds befo re u s...
Page 43 - Inertia Drive Starting Circuit Test Procedure
43 Miscellaneous Page 1 Inertia Drive Starting Circuit Test Procedure REV. 07 /21/2008 Before Starting: Ba ttery voltage shou ld be tested a n d m ust be a t 12.4 V DC or higher . Do not proce e d if batte ry voltage is les s than 12.4 VDC as battery should be charged. Test meter lea ds befo re u s ...
Page 44 - Kohler PLUS News; Search by the XX 853 XX-S part number and bring up
44 Miscellaneous Kohler PLUS News Carburetor Repair Kits in Kohler PLUS Kohler PLUS has been improved to list the individual carburetor repair kits at the part level of the service carburetor. You can: 1. Search by the XX 853 XX-S part number and bring up the search part information record to see th...
Page 45 - E\GHVFULSWLRQLQVWHDGRIMXVWWKHGRFXPHQWSDUWQXPEHU; “Go”; or hit the; “Enter”
45 Miscellaneous Descriptions Now Searchable Searchable Literature Descriptions Some recent changes to Kohler PLUS formatting include the ability to now search for a document E\GHVFULSWLRQLQVWHDGRIMXVWWKHGRFXPHQWSDUWQXPEHU :KHQVHDUFKLQJIRUDGRFXPHQWMXVWW\SHDQXPEHUNH\ZRUGRUSKUDVHLQWRWKHVHDUFKER[IRU th...
Page 46 - ORFDWHGLQWKHVSHFL¿FDWLRQKHDGHU
46 Miscellaneous Other Enhancements Now Available RPM Idle and High Speed Settings - ORFDWHGLQWKHVSHFL¿FDWLRQKHDGHU Fast Moving Parts - found immediately below the engine group listings. Click Here to View Image News Flash on Kohler PLUS We are now posting all new released literature into one locati...
Page 47 - Factory Schools; Expanding the limits of power.
47 Miscellaneous Factory Schools 2008-2009 Expanding the limits of power.
Page 49 - Warranty News; Section 7 - Warranty News; Warranty System NOW AVAILABLE; Login Screen
49 Warranty News Section 7 - Warranty News Warranty System NOW AVAILABLE The Kohler Engine Division is pleased to announce the start of a new era. Our new Web-Based Warranty Processing System is now available. This Web-Based Warranty System will provide users the capability to submit their own warra...
Page 50 - FODLPDOZD\VFKHFNWKDW\RXUFRPSXWHULGHQWL¿HVWKH
50 Warranty News After entering the system you will see the Warranty Home Page. Trusted Site Direction If you encounter a problem while entering a warranty FODLPDOZD\VFKHFNWKDW\RXUFRPSXWHULGHQWL¿HVWKH Warranty System as a “Trusted Site.” Use the following step-by-step instructions to verify and chan...
Page 51 - HTXLUHVHUYHUYHUL¿FDWLRQ; FRQ¿UP\RXUFKRLFHWKHQFOLFN
51 Warranty News Enter Warranty as a Trusted Site Security Settings 5. Type the warranty site web address and press the Type the warranty site web address and press the Add button. 6. If the check box by If the check box by 5HTXLUHVHUYHUYHUL¿FDWLRQ (https:) for all sites in this zone is selected, re...
Page 53 - LQWKH¿HOG7KHSURFHVVIRUZDUUDQW\DSSURYDOIRUHQJLQHV
53 Warranty News EWR Review (Engine Warranty Return) ,I\RXKDYHHYHUGHDOWZLWKDGLI¿FXOWZDUUDQW\VLWXDWLRQ\RX may occasionally have asked yourself how you resolve the problem and who you should go to for help. The following steps outline the procedure required to speed up the painful process. The EWR (En...
Page 54 - (QJLQH6SHFL¿FDWLRQ; EWR Caution; without prior authorization
54 Warranty News EWR When? EWR is issued after a Dealer or Kohler Representative have examined engine or component and: • are unable to determine the root cause of failure in relationship to defects in workmanship or material. WKHFXVWRPHUGLVSXWHVWKH¿QGLQJVRI'HDOHUDQG.RKOHU 5HSUHVHQWDWLYHDQGUHTXHVW...
Page 56 - Walker CH26; Parts; New EFI Long Block for Walker CH26; ȱȱȱȱȱęȱȬȱȱȱȱȱȱȱǯȱ; Flywheel Side
56 Bulletins, Etc. 251 Walker CH26 7/07 DATE REVISED DATE ISSUED MODEL NO. Parts Bulletin New EFI Long Block for Walker CH26 A new CH26 EFI long block, part number 24 523 01, is now available for servicing Walker CH26 model engines. This long block consists of an assembled crankcase/closure plate (i...
Page 57 - Twins and Singles; Correct Fuel Filter Selection; Fuel Line Installation
57 Bulletins, Etc. 253 Some CH/CV/SV Twins and Singles 10/08 Correct Fuel Filter Selection ȱȱȱȱȱȱȱ¢ȱȱȱȱȱȱęȱȱ ȱȱȦȦȱ ȱȱǯȱȱȱęȱ ȱȱȱȱǯȱ ȱȱȱęȱȱȱǯȱ...
Page 58 - Short Blocks for Courage Single Cylinder Engines; Engine Model; ÀRZ
58 Bulletins, Etc. 254 SV470-SV620 10/08 Short Blocks for Courage Single Cylinder Engines For model year 2009, the Courage single-cylinder engines will incorporate a new balance system ȱȱȱ£ǯȱȱȱȱĴǰȱȱȱȱȱȱȱȱȱ ȱȱ ȱ...
Page 59 - Figure 1. Example of Cracked Flywheel Ring Gear.; Loose/Cracked Flywheel Ring Gears; Crack
59 Bulletins, Etc. Figure 1. Example of Cracked Flywheel Ring Gear. 3/08 SV470-SV620SV710-SV840 Loose/Cracked Flywheel Ring Gears ȱȱ¢ȱȱȱ ȱȱȱȱȱȱĚ¢ ȱbeginning in 2006. Due to isolated cases of failure, we have made a change from powdered m...
Page 60 - &UDQNFDVH2LO2YHU¿OO5HYLVHG; Checking Oil Level
60 Bulletins, Etc. ServiceManager Initial Here SalesManager PartsManager ChiefMechanic MechanicNo. 1 MechanicNo. 2 MechanicNo. 3 MechanicNo. 4 ReturnThis To Routing SV710-SV840 &UDQNFDVH2LO2YHU¿OO5HYLVHG ȱȱȱȱȱĴȱȱȱȱ ȱǯȱȱ¢ȱȱȱ...
Page 61 - Flywheel and Mounting Stud Replacement; Disassembly Procedures; NOTE: ȱȱȱ¢ǰȱȱȱȱȱ
61 Bulletins, Etc. 6/94 CH/CV940-980 Flywheel and Mounting Stud Replacement ȱȱęȱǰȱȱȱ¢ȱȱȱȱ¢ȱȦşŚŖȬşŞŖȱȱȱǯȱȱȱĚ¢ ȱȱȱȱȱȱȱȱȱȱǯȱ ȱȱȱȱȱǯȱ...
Page 65 - Flywheel Timing Change
65 Bulletins, Etc. CH/CV730 289 1/08 DATE REVISED DATE ISSUED MODEL NO. Service Bulletin WARNING: Accidental Starts! Disabling engine. Accidental starting can cause severe injury or death. Before working on the engine or equipment, ȱȱȱȱ DZȱŗǼȱȱȱȱȱǻǼǯȱ...
Page 67 - Various; Suspect
67 Bulletins, Etc. 6/94 Various 290 5/08 DATE REVISED DATE ISSUED MODEL NO. Service Bulletin Oil Pressure Switch 25 099 27-S ȱęȱȱȱȱȱȱȱȱȱ ȱȱȱȱ ȱȱǯȱȱȱȱȱȱȱȱȱŗŖȬŖŝȱȱŗŗȬŖŝǯ ȱ...
Page 68 - DSAI Interface Wire Harnesses with Diodes; ȱ ȱȱȱ¢ȱȱȱSerial Number 3823303501 and belowǯ
68 Bulletins, Etc. 10/08 CH740 and CV740 291 9/08 DATE REVISED DATE ISSUED MODEL NO. Service Bulletin DSAI Interface Wire Harnesses with Diodes ȱęȱȱȱȱȱȱȱȱȱȱȱǯȱȱȱȱȱȱȱǰȱȱȱ...
Page 69 - Ground Relocation on Dixon ZTR Mowers
69 Bulletins, Etc. 1 ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044 Ground Relocation on Dixon ZTR Mowers Figure 1. Original Layout (Kodiak 908 Shown). 3. Remove the silver-plated closure plate screw (Kohler Part No. 24 086 17-S) from the RH corner (No. 4)ǯȱȱȱȱȱǻȬǼ...
Page 70 - Engines Stalling With Fuel in Tank
70 Bulletins, Etc. 1 Litho In U.S.A. 12/07 ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044 Engines Stalling With Fuel in Tank ȱȱęȱǰȱȱȱȬ¢ȱȱ¢ȱȱȦȱȱȱ ȱȱȱȱŗȦŘȱȱȱȱȱȱȱ ȱȱȱȱ...
Page 71 - Fuel Tank Outlet Flash Removal; XT-7 Fuel Tank Outlet Flash Removal
71 Bulletins, Etc. 1 Litho In U.S.A. 03/08 ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044 KEK-032008 WARNING: Accidental Starts! Disabling engine. Accidental starting can cause severe injury or death. Before working on the engine or equipment, disable the ȱȱ DZȱŗǼȱȱȱ...
Page 72 - Courage XT-7 Flywheel Brake Ignition Grounding Issue
72 Bulletins, Etc. 1 Litho In U.S.A. 05/08 ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044 ARIENS-052008 WARNING: Accidental Starts! Disabling engine. Accidental starting can cause severe injury or death. Before working on the engine or equipment, disable the engine as follows: Disconnect the s...
Page 73 - TechTip; Electronic Governor; Overview, Diagnosing, and Troubleshooting
73 Bulletins, Etc. TechTip Litho In U.S.A. 9/08 ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044 Electronic Governor Overview, Diagnosing, and Troubleshooting (Units with Governor Control Unit 24 584 59-S) There have been some reports regarding the function, adjustment, and troubleshooting of th...
Page 74 - Mechanical Checks
74 Bulletins, Etc. 2 Figure 3. Governor Control Unit Locations. Governor Control Unit Governor Control Unit Actuator Clevis Shaft Rubber Boot Figure 5. Exploded View of Clevis Shaft. Keyway Keys Clevis Mounting Holes Mechanical Checks The DLA must be in the fully retracted position during ¢ǯȱ...
Page 75 - Ground and Power Tests
75 Bulletins, Etc. 3 Harness/GCU Trouble Shooting and Diagnostic Procedures 1. ȱȱ¢ȱȱȱěȱǯ 2. Remove the GCU and unplug the wiring harness. See Figures 6 and 7. Figure 7. GCU, Wiring Harness, and Connector. Governor Control Unit (GCU) Connector Figure 6. GCU Location Removal an...
Page 77 - Running Codes - Activated when the engine is running.
77 Bulletins, Etc. 5 Figure 16. GCU Blink Code Chart with the engine Running. Governor Control Unit (24 584 59-S) Blink Codes for Software Version: KGETO301 Stored Codes - Activated when the key is turned to the "on" position. LED Diagnostics Failure Condition Possible Causes Response Respon...
Page 84 - OHMsTests; Blink Code Tests for the GCU
84 Bulletins, Etc. 4 OHMsTests Remove the GCU and unplug the wiring harness. See Figure 6 and 7. The following two tests are for measuring the resistance of the DLA circuit that send a signal to the GCU. If either test fails the DLA is no good and should be replaced. If both test are good the DLA is...
Page 89 - SAE Cable Size; Gauge
89 Bulletins, Etc. Litho In U.S.A. 7/07 ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044 Kohler Engines Truck-Mounted Applications Grounding Instructions There have been some reports regarding poor cranking performance on Kohler Engine-powered truck-mounted air compressors. ȱȱ...
Page 91 - Section 9; Gasoline; LGHQWL¿HV\RXUVHOHFWLRQ; Do not mark more than one answer for any one
91 Technician’s Service Test Section 9 Technician’s Service Test This section contains two tests. The Gasoline test is 40 multiple-choice questions; the Diesel test is 10 multiple-choice questions. All questions have at least four possible answers, letters a, b, c, and d. Select the ONE best answer ...
Page 92 - Gasoline Test Questions
92 Technician’s Service Test Gasoline Test Questions 1. When should an EWR be started? a. When the Dealer is too busy to process a warranty claim.b. When the Representative feels the necessity to do a goodwill claim on behalf of his/her customer. c. When a Dealer or Representative cannot assess the ...
Page 96 - Diesel Test Questions
96 Technician’s Service Test Diesel Test Questions 7KHQHZVW\OHNH\IRUWKH/':DQGRU.':VHULHVHQJLQHVNH\VZLWFKLVFXWRQKRZPDQ\VLGHV" a. Oneb. Two c. None d. Three ,IUHSODFLQJWKHROGVW\OHFRRODQWWHPSHUDWXUHVZLWFKDQGWKHUPLVWRUVZLWFKHVZLWKWKHQHZVW\OHVLQJOHVZLWFK ZKDWLVWKHSDUWQXPEHURIWKHSLJWDLOZLULQJDGDSWRU\R...
Page 97 - $QVZHU6KHHWIRUWKH.RKOHU7HFKQLFLDQ¶V6HUYLFH3URJUDP7HVW; Name
97 Technician’s Service Test *DVROLQH7HVW$QVZHU6KHHW 1. a b c d 2. a b c d 3. a b c d 4. a b c d 5. a b c d 'LHVHO7HVW$QVZHU6KHHW 1. a b c d 2. a b c d 3. a b c d 4. a b c d 5. a b c d 6. a b c d 7. a b c d 8. a b c d 9. a b c d 10. a b c d 11. a b c d 12. a b c d 13. a b c d 14. a b c d 15. a b c d...