EFI Table of Contents Section 1 – EFI Page No. Installation Instructions TT-5109 .................................................................................................................. 5 New Malfunction Indicator Light ................................................................................................................... 5 New Primary High-Flow Fuel Filter ..............................................................................................................
EFI Section 7 – COMMAND PRO 34, 36, 38 Introducing COMMAND PRO 34, 36, 38 ................................................................................................... 25 Section 8 – Miscellaneous Improved Breather Hoses ......................................................................................................................... 27 Low-Permeation Fuel Line, Bulk Roll ........................................................................................................
EFI Section 1 EFI Installation Instructions TT-5109 When repowering or installing a Basic EFI engine on new equipment, please use TT-5109. This installation guideline has been developed for both air and liquid-cooled EFI engines.
EFI Stainless Steel Ground Eyelets There have been reports of stainless steel eyelets found in both the 24 452 01-S and 24 755 134-S kit with recent date codes. The correct eyelets should be tin-plated copper and can be identified by scratching the surface with a file. The silvercolored tin plating can easily be scratched to reveal the copper material underneath. Also, the stainless eyelets will not accept solder.
EFI New Jump Start Hang Tag TT-5177 A new hang tag has been created to warn against the dangers of jump starting EFI engines. The hang tag is attached to the ECU and must be physically removed before installation. The technician should then pass the information on to the customer, or attach the tag to the equipment. LH775 Overheating - Walker There have been isolated reports of overheating caused by the fan not running, or running at a low speed.
EFI 8
EFI 9
EFI 10
Command Twin Section 2 Command Twin CH/CV750 Rough Running Issues SB-280/ TT-5176 A new air cleaner elbow has been developed for the CH/CV750 engines built before Serial No. 3618800001. This modification extends the bowl vent up into the elbow, improving performance on rough terrain, hills, and abrupt turns. The elbow kit part number is 24 054 19-S and must be used with the new gasket.
Command Twin Improved Breather Hoses Recent reports of cracked or deteriorating breather hoses on Command, Aegis, and Courage engines have prompted a material change. A previous material change in 2004 has been found to be inadequate in some applications for long term reliability. Cracking or Deterioration Cracks in Breather Hoses New hoses with improved ozone protection have been developed and carry new part numbers. They also have the part number printed in white for easy identification.
Command Twin • Easy service replacement • Mount and go with no air gap setting required • Improved engine cosmetics • No external control box Kohler will continue to offer the SAM Ignition Modules as replacement parts. Oil Coolers Replaced with High-Flow Fan During development of the Command 750, the design engineers developed a new, more effective, high-flow cooling fan.
Command Twin Connecting Rod Design Changes Three design changes have been made to the Command and Courage Twin connecting rods. 1. The small chamfer on the edge of the locking step was changed from 45° to 30°. The chamfer is small but extremely effective as the cap is easier to assemble and seat. The improved seating provides better torque retention on the bolts. 2. The dies for making the shank and cap were modified to mold in the chamfer around the crankshaft bore, eliminating a machining operation. 3.
Command Twin Kohler/Miller Dealer Match Program This program is designed to allow Kohler dealers to be matched with Miller dealers to provide our mutual end customers with a more seamless service experience. •Miller Electric supplied Kohler with a list of Miller dealers. •Kohler distributed sections of this list to the appropriate Central Distributor. •Kohler Central Distributors were able to match Kohler Dealers to 727 Miller dealers, and in some cases, signed the Miller dealer as a Kohler dealer.
Command Twin CV Oil Pan Gaskets When the CV25 was developed and tested, Kohler Engineering determined a gasket would be necessary to properly seal the block on the oil pan. Pan With Oil Transfer Groove (Use RTV) In August 2004, approximately 20 specs below 25 HP were given the oil pan gasket feature. This oil pan does not include the machined O-Ring groove in the oil transfer on the gasket surface, as used on the RTV-style pan.
Command Single Section 3 Command Single CV Air Cleaner Change Proper assembly of the air cleaner element to the base is necessary to ensure a complete seal. To help make sure the element is installed correctly, Kohler has modified the air cleaner base with higher profile tabs for ease of proper assembly. Old Style Fingers Part No. 12 094 07-S Starter Failures on Compressor Units We continue to receive numerous calls for starter failures on compressor applications.
Command Single 18
Aegis Section 4 Aegis Oil Dilution There have been some reports of fuel causing oil dilution on some applications of the LH640-775. This excess fuel in the oil is due to incomplete fuel vaporization caused by the relatively cool cylinder walls in the liquid-cooled engine family. Liquid fuel present on the cylinder walls can work past the rings to the oil sump. Applications with light loads may not work the engine hard enough to warm the engine sufficiently.
Aegis 20
Courage Single Section 5 Courage Single New Balance Weight System The Courage balance weight system has been modified to use a link in place of the guide shoe to keep the weight in-line with the piston travel. Starting with Serial No. 3618005223, the engine block has an additional mounting boss inside to accept a press fit pin for mounting the new link to the current balance weight. Part No. 20 755 04-S was developed to service the balance weights.
Courage Single Broken ACR Stops Kohler has experienced some ACR failures on Courage engines where the molded stop breaks off the cam gear allowing the flyweight to swing too far. A change has been implemented to improve the strength of this component. The new camshaft is Part No. 20 010 04-S. Broken Valve Keepers Broken ACR Stop Kohler testing has found that broken ACR stops on the cam gear may cause valve keeper breakage. For any reports of broken keepers, be sure to inspect for broken ACR stops.
Courage Twin Section 6 Courage Twin Improved Rocker Adjustment Kohler Engineering has redesigned the valve train to make tappet adjustment easier. The new system resembles the Courage single. A set screw is used to lock the adjustment made at the rocker arm pivot. The new system is expected to be in production the first quarter of 2007. New Muffler/Manifold Kit Improved Rocker Assembly A Courage Twin muffler/manifold kit is now available as Part No. 32 786 01-S in the Accessories Catalog.
Courage Twin Teardown and Reassembly CDs & DVDs Training CDs & DVDs are available to become familiar with this product as customers begin to bring units in for service. 32 802 01 32 802 02 Courage Twin CD-ROM ($4.95) Courage Twin DVD ($7.95) Teardown/Reassembly CD Courage PRO Twin Introducing the Courage PRO series of engines.
COMMAND PRO 34, 36, 38 Section 7 COMMAND PRO 34, 36, 38 Introducing Command Pro 34, 36, & 38 Available the first quarter of 2007 in both horizontal and vertical configurations, this engine has a 90 mm bore and 78.5 mm stroke for a total displacement of 999 cc.
COMMAND PRO 34, 36, 38 26
Miscellaneous Section 8 Miscellaneous Improved Breather Hoses Recent reports of cracked or deteriorating breather hoses on Command, Aegis, and Courage engines have prompted a material change. A previous material change in 2004 has been found to be inadequate in some applications for long term reliability. New hoses with improved ozone protection have been developed and carry new part numbers.
Miscellaneous Kohler PLUS Update We continue to receive numerous calls from dealers who either do not know how to log into the system, have forgotten their password, or do not realize that their warranty number has been changed. Here are some tips to help ease the login process: Kohler PLUS Login Screen First-time users 1. Enter your User Name: 11-digit Warranty ID Password: kohler (no caps) 2. If you are prompted to install the ActiveX plugin, click Install Components.
Relentless Power. Legendary Performance.
Miscellaneous 30
Warranty Section 9 Warranty New Warranty System for 2007 Kohler is pleased to announce a new fully functional warranty system, effective January 2007. The goal is to implement a warranty system that the service network will identify as a total package solution.
Warranty 32
Bulletins Section 10 Bulletins NO. Parts Bulletin 228 MODEL None DATE ISSUED DATE REVISED 11/05 2/01 Change in Kohler Special Tools Program In an effort to better serve our distribution network, Kohler Co., along with two outside suppliers will be the primary sources for most of the special tools offered for engine servicing. Here is the list of tools and their sources. Only those tools with Kohler Part Numbers will be available through Kohler Co.
Bulletins Description Source/Part No. Kohler 25 761 20-S Kohler 25 761 41-S Rect ifier -Regulat or Test er (for 120 volt cur r ent ) Rect ifier -Regulat or Test er (for 240 volt cur r ent ) U sed to test rectifier-regulators. Components of 25 761 20-S and 25 761 41-S CS -PRO Regulator Test Harness S pecial Regulator Test Harness with Diode Design Technology Inc. DTI-031 DTI-033 Spar k Advance Module Test er U sed to test the S AM (AS AM/DS AM) on engines with S MART-S PARK™.
Bulletins This Bulletin Has Been Added for Your Reference Only. It Contains No Revisions. NO. Parts Bulletin 233 MODEL CH/CV Twins with Smart Spark™ DATE ISSUED DATE REVISED 2/03 Digital Spark Advance Module (DSAM) and Flywheel Compatibility New “digital” spark advance modules (DSAMs) are now being used on CH/CV twin cylinder engines for enhanced ignition timing (see 2001-2002 update program booklet, page 12).
Bulletins NO. Parts Bulletin 244 MODEL CH18-26, CH730-745, CV17-26, CV730-745 DATE ISSUED DATE REVISED 6/06 Cylinder Head Service Kits for Command Twin Engines The following table is a handy reference for servicing Command twin cylinder heads. It includes the kit part numbers for all levels of service, from simply changing the head gasket to replacing a complete head assembly. 1. If the head is reusable, order only the gasket kit.
Bulletins NO. Service Bulletin 240 MODEL CH/CV18-26 CH/CV730-750 DATE ISSUED DATE REVISED 7/96 6/06 Damaged Main Bearings We occasionally receive reports of premature heavy wear and/or pitting of the main bearing surfaces in Command twin cylinder engines. Customer complaints or noted symptoms can include a “knocking” noise, oil leaking at the crankshaft seal, flywheel and/or grass screen wobbling or shifting, and charging system components shorted out.
Bulletins Clutch and Stator Test Procedures NOTE: To get the most accurate results, perform this test with clutch mounted and the belt attached to the clutch. Clutch Test (for a 2-wire clutch) Conclusion 1. Disconnect the clutch leads from the equipment 1. Resistance should be 1.5-4 Ohms*. wiring harness. Zero an ohmmeter on the Rx1 scale and test resistance across the clutch leads. 2. Connect the ohmmeter to one of the clutch leads and the clutch housing.
Bulletins NO. Service Bulletin 276 MODEL All Carbureted Models DATE ISSUED 12/04 DATE REVISED 8/06 Carburetor Replacement Policy A majority of the carburetors being replaced and returned under warranty are for problems related to fuel quality and contamination, not due to defects in materials or workmanship.
Bulletins Maintenance Schedule These required maintenance procedures should be performed at the frequency stated in the table. They should also be included as part of any seasonal tune-up. Frequency Daily Or Before Starting Engine 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 100 Hours • • • • Every 200 Hours • Change oil filter. • Check spark plug condition and gap.
Bulletins NO. Service Bulletin 279 MODEL All Command, Aegis, and Courage Engines DATE ISSUED DATE REVISED 8/06 6/94 Cracking/Deteriorating Molded Style Breather Hoses Dealers have reported recent incidents of cracked/deteriorating molded style breather hoses on Command, Aegis, and Courage engines.
Bulletins NO. Service Bulletin 280 MODEL CH/CV750 DATE ISSUED DATE REVISED 7/06 6/94 CH/CV750 Momentary Sputtering, Interrupted Operation on Varying Terrain We have investigated various reports of momentary engine sputtering, interrupted operation and low/loss of power on CH/CV750 engines. Generally this has occurred in mowing applications when traveling over hilly, rough terrain but has also exhibited itself to a lesser extent on relatively level ground when making hard, fast turns.
Service Program Test Section 11 Service Program Test Directions: This test contains 40 multiple choice questions. The questions all have at least four possible answers, letters a, b, c, and d. Select the ONE best answer and mark your answer sheet (on page 51), by placing a dark ‘‘X’’ over the letter that identifies your selection. Example: 25. The Kohler engine plant is located in: a. Chicago, IL. b. Kohler, WI. c. Phoenix, AZ. d. none of the above.
Service Program Test 1. The K-Series anti-dieseling solenoid 45 435 02-S has been discontinued at Kohler Co. but can be purchased at _____________ under part number 2-2026. a.) John Deere b.) Auto Zone c.) NAPA d.) some China copy retailer 2. Training CDs and DVDs for the Courage Twin are available as part number: a.) 12 802 01-S & 12 802 02-S b.) 20 802 01-S & 20 802 02-S c.) 24 802 01-S & 24 802 02-S d.) 32 802 01 & 32 802 02 3. The Courage Single camshaft was improved to avoid: a.
Service Program Test 7. Breather hoses on Command, Aegis, and Courage engines have undergone a material change for: a.) crush resistance b.) improved ozone protection c.) increased elasticity d.) water retention 8. A customer purchases a new unit with a Courage Twin and would like a grass screen guard. You should install part number: a.) 20 755 11-S b.) 20 755 14-S c.) 20 027 08-S d.) 32 027 08-S 9. The Courage Single has a new flywheel key and M12 bolt. The torque on this new bolt is: a.) 49 ft. lb. b.
Service Program Test 13. Starting October 2006, the metric exhaust studs have been replaced with 5/16”-18 bolts on ____________ engines. a.) all Command b.) all Courage c.) Command & Courage d.) Aegis 14. The Courage PRO Twin warranty covers: a.) two year consumer and one year commercial b.) two year consumer and commercial c.) three year consumer and two year commercial d.) three year consumer or commercial 15. A customer purchases a new unit with a Courage Single and would like a grass screen guard.
Service Program Test 19. Major features of the Command PRO 34, 36, 38 include: a.) top access oil filter with self-draining design b.) removable access covers in the blower housing c.) integrated oil cooler d.) all of the above 20. The valve train on the Courage Twin was redesigned: a.) to make tappet adjustment easier b.) to be more cost effective c.) for high RPM applications d.) to make it look more like an SBC 21. What can cause broken valve keepers in a Courage Single? a.) nothing b.
Service Program Test 25. Miller welder removal and reassembly procedures: a.) can be found on www.kohlerplus.com b.) require expensive tools c.) are for Miller welder dealers only d.) are much too difficult for a Kohler Expert Dealer 26. Oil dilution on the LH640-775 may be relieved by: a.) replacing the 175°F with the 190°F thermostat b.) replacing the #190 main jet with a #175 c.) replacing spark plug RC14YC with RC12YC d.) removing the cooling fan 27.
Service Program Test 31. What is the most common reason found for dealers to have difficulty using KohlerPLUS? a.) do not know how to log on b.) forgot password c.) didn’t realize their 11-digit Warranty ID had changed d.) all of the above 32. In the latest edition of the Accessories Catalog E-1953-J, what is the part number of the new Malfunction Indicator Light that is used on EFI applications? a.) 25 704 05-S b.) 25 352 21-S c.) 25 702 02-S d.) 25 352 19-S 33.
Service Program Test 37. The Command Twin pistons have been redesigned to reduce the risk of smoke during start-up. The pistons now have: a.) wider oil slots to return more oil back to the crankcase b.) narrower oil slots to reduce the amount of oil draining back to the rings c.) reed valves on each piston d.) an added oil return hole in the top of the piston 38. The Courage Single balance weight system has: a.) not changed b.) been removed c.) been modified with a link d.) rotating shafts 39.
Service Program Test Answer Sheet for the 2006-2007 Kohler Technicians Service Program Test Company Name Warranty I.D. No. Name of Individual Taking Test 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. a a a a a a a a a a a a a a a a a a a a b b b b b b b b b b b b b b b b b b b b c c c c c c c c c c c c c c c c c c c c d d d d d d d d d d e d d d d d d d d d d 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40.
Service Program Test 52
3U RXGO\ +RVWLQJ WKH 3URXGO\ +RVWLQJ WKH ((7 & $QQ XDO &RXQFLO 0HHWLQJ ((7& $QQ & $QQXDO &RXQFLO 0HHWLQJ ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044 LITHO IN U.S.A.