Command PRO Series XT Series New Product

Command PRO Series
Command PRO Twin
Long Block Assemblies .......................................................................................................................................5
New Lifter Bleeding Procedures .........................................................................................................................6
Loss of Exhaust Valve Keepers/Increased Rocker Torque .................................................................................6
Two-Barrel Carburetor Update ............................................................................................................................7
New CV Service and Production Oil Pan ............................................................................................................7
Old Spark Advance Module Availability and Use ................................................................................................8
Welder Removal and Replacement Procedures .................................................................................................8
Correct Dipstick and Checking Procedure ..........................................................................................................9
Excessive Oil in CV940-1000 Breather Hose or Oil Leak from Housing ..........................................................10
CV940-1000 Secondary Air Injection Hose Heat Failure .................................................................................. 11
CV Oil Pan Check Ball and Spring Installation ................................................................................................. 11
CV940-1000 Adjustable Valve Train Discontinued............................................................................................ 11
Electronic Fuel Injection (EFI)
Fuel Pump Module Vapor Lock .........................................................................................................................12
Diagnostic Extension Lead ...............................................................................................................................12
Fuel in Vent Line ...............................................................................................................................................13
Kohler EFI Diagnostic Software 2.11.0007 Upgrade ........................................................................................13
ECV940-980 E-Gov Erratic Speed with PTO Engaged ....................................................................................14
Repower Opportunities .....................................................................................................................................14
10-Micron Fuel Filter Options............................................................................................................................15
Command PRO Single
CH270-440 Expanded Gear Reduction Offerings ............................................................................................15
XT Series
XT Series
White Specks in Carburetor ..............................................................................................................................17
New Product
KOHLER 7000 Series .......................................................................................................................................19
KOHLER Confidant ...........................................................................................................................................20
KOHLER 2000 Series .......................................................................................................................................21
Miscellaneous
New 2-Wire Walbro Fuel Solenoids ..................................................................................................................23
Spark Plugs (Champion) XC vs. RC vs. P ........................................................................................................23
New 83 mm Piston Specifications.....................................................................................................................24
Oil Filter Supplied with All Short Blocks, Long Blocks, and Miniblocks .............................................................24
Kohler Engine Model Changes ................................................................................................................... 25-28
New Kohler 20W-50 Oil.....................................................................................................................................28
MDI Ignition Module (Conversion from DSAI) ...................................................................................................29
25 403 21-S Rectifier-Regulator........................................................................................................................29
Kohler PLUS Explorer 10/Windows 8 Information ...................................................................................... 30-33
2014 Factory School Brochure .........................................................................................................................34
3
Command PRO Series
Command PRO Twin
Long Block Assemblies .......................................................................................................................................5
New Lifter Bleeding Procedures .........................................................................................................................6
Loss of Exhaust Valve Keepers/Increased Rocker Torque .................................................................................6
Two-Barrel Carburetor Update ............................................................................................................................7
New CV Service and Production Oil Pan ............................................................................................................7
Old Spark Advance Module Availability and Use ................................................................................................8
Welder Removal and Replacement Procedures .................................................................................................8
Correct Dipstick and Checking Procedure ..........................................................................................................9
Excessive Oil in CV940-1000 Breather Hose or Oil Leak from Housing ..........................................................10
CV940-1000 Secondary Air Injection Hose Heat Failure .................................................................................. 11
CV Oil Pan Check Ball and Spring Installation ................................................................................................. 11
CV940-1000 Adjustable Valve Train Discontinued............................................................................................ 11
Electronic Fuel Injection (EFI)
Fuel Pump Module Vapor Lock .........................................................................................................................12
Diagnostic Extension Lead ...............................................................................................................................12
Fuel in Vent Line ...............................................................................................................................................13
Kohler EFI Diagnostic Software 2.11.0007 Upgrade ........................................................................................13
ECV940-980 E-Gov Erratic Speed with PTO Engaged ....................................................................................14
Repower Opportunities .....................................................................................................................................14
10-Micron Fuel Filter Options............................................................................................................................15
Command PRO Single
CH270-440 Expanded Gear Reduction Offerings ............................................................................................15
XT Series
XT Series
White Specks in Carburetor ..............................................................................................................................17
New Product
KOHLER 7000 Series .......................................................................................................................................19
KOHLER Confidant ...........................................................................................................................................20
KOHLER 2000 Series .......................................................................................................................................21
Miscellaneous
New 2-Wire Walbro Fuel Solenoids ..................................................................................................................23
Spark Plugs (Champion) XC vs. RC vs. P ........................................................................................................23
New 83 mm Piston Specifications.....................................................................................................................24
Oil Filter Supplied with All Short Blocks, Long Blocks, and Miniblocks .............................................................24
Kohler Engine Model Changes ................................................................................................................... 25-28
New Kohler 20W-50 Oil.....................................................................................................................................28
MDI Ignition Module (Conversion from DSAI) ...................................................................................................29
25 403 21-S Rectifier-Regulator........................................................................................................................29
Kohler PLUS Explorer 10/Windows 8 Information ...................................................................................... 30-33
2014 Factory School Brochure .........................................................................................................................34
3
Bulletins, Etc.
Introduction...............................................................................................................................................................
35
Technical Flash
Belt Driven Application PTO Bearing Failures ..................................................................................................36
Installation Instructions
25 790 15 Hydraulic Lifter
Kit...........................................................................................................................37
25 790 16 Retractable Starter Kit.....................................................................................................................38
Technician's Service Test
Technician's Service Test ............................................................................................................................ 3941
4
Command PRO Twin
Long Block Assemblies
The practice of rebuilding engines is almost a lost art. Much of this is due to labor costs of the rebuild vs. the short
block replacement. If the engine in question has extended hours you may also be looking at worn valve guides and
possible replacement of the heads.
Kohler has released several new Command Long Block assemblies for both the EFI and 999 Series engines. All long
blocks are fully assembled complete up to the valve covers with all the internal components. The following table lists
the available long blocks by part number, the short block it was built from, engine model and basic features.
Command PRO Long Block Selection Chart
Engine Model Long Block Part No. From Short Block Part No.
Features
ECH730-749
24 523 02
24 522 480
Crank - 1.125" X 4.00"
Closure Plate - 66 009 08-S
ECH730-749
24 523 03
24 522 497
Crank - 1 7/16" X 4.46"
Closure Plate - 66 009 08-S
ECH730-749
24 523 04
24 522 462
Crank- 1"-14 Threaded
Closure Plate - 24 009 98-S
ECV650-680
24 523 05
24 522 477
ECV730-749
24 523 06
24 522 489
ECV730-749
24 523 07
24 522 464
CH960-1000
62 523 04
62 522 01
Crank - 1 7/16" X 4.45"
Closure Plate - 62 009 12-S
CV940
62 523 03
62 522 07
Crank- 1 7/16" X 3.81"
Oil Pan - 62 199 06-S
CV960-1000
62 523 02
62 522 05
Crank- 1 7/16" X 3.81"
Oil Pan - 62 199 06-S
ECV940/980
62 523 01
62 522 12
Crank - 1.125" X 4.29"
Oil Pan - 62 199 30-S
These assemblies provide a significant cost savings
option over a compete engine and may avoid the
discarding of good EFI components.
All long blocks are listed by engine spec on Kohler
PLUS and come with a one (1) year limited warranty.
Crank- 1" X 3.41"
Oil Pan - 24 199 30-S
Crank- 1.125" X 3.16"
Oil Pan - 24 199 30-S
Crank - 1.125" X 4.30"
Oil Pan - 24 199 30-S
5
Command PRO Series
New Lifter Bleeding Procedures
Bleeding lifters during engine assembly has always been the
rule. Breaking this rule can lead to the possibility of bent push
rods and broken rockers. This happens when the fully extended
lifter causes the valve to open too far and contacts the piston or
compresses the valve spring until it is solid.
Proper bleeding ensures the lifter can reach its fully collapsed
position, then refill with pressurized oil to maintain the correct zero
valve lash under all running conditions.
The latest lifters found in Command engines has a smooth center
section on the body, as opposed to the previous ribbed style. This
new lifter has a slight change to the internal valving that allows it
to stay pumped up where the previous lifter bled out. The internal
piston inside the lifter body is cross drilled to reprime the reservoir
as it is compressed.
With this change in lifters comes a change in the bleed down
procedure as found in the Service Manual.
Service Manual Instructions:
1. Lay a rag or shop towel on table of drill press. Place an 8 mm
(5/16 in.) socket on towel with well end up, then place open
end of lifter on socket. Ensure socket does not contact lifter
ball surface.
2. Place some material, such as wood, plastic, or aluminum on
top of lifter to protect lifter finish.
3. Lower drill press chuck until it contacts material on lifter.
Slowly pump lifter 2 or 3 times to force oil out of feed hole in
side of lifter.
Loss of Exhaust Valve Keepers/Increased Rocker Torque
In recent years Kohler Service has noticed an elevated number of
exhaust valve failures on CH/CV620-750 engines where the keeper
comes apart causing the valve to enter the combustion chamber
with the piston at SOC.
Investigation revealed the rocker arm pivot mounting screw had lost
clamping force due to thermal cycling and allowed the rocker arm
to rotate. The rocker arm no longer compressed the top of the valve
but now made contact with the valve spring cap causing the keeper
to release.
Performance Engineering has increased the rocker arm screw
torque from 100 in. lbs. to 165 in. lbs. (18.6 N•m) on current
production engines from serial number 4321 OXXXXX and later.
Please refer to Service Bulletin 318 for more information.
Excessive heat will add to the probability of this failure to occur.
Make sure the cooling fins and fan screen are not blocked. This
failure will not be covered under warranty if there are obvious
indications of excessive heat.
6
Previous Lifter
Style "A"
Current Lifter
Style "B"
Cross Drilled
Command PRO Series
Two-Barrel Carburetor Update
Last year Kohler introduced the new Walbro LTB two-barrel carburetor for the CH-Twins using the Heavy Duty Air
Cleaner (HDAC) system. Reducing emissions was the biggest goal during development as each cylinder can be
tuned individually. Performance also improved using larger venturies for power and the accelerator pump for load
pick-up performance.
This year the line has expanded with CV-Twin engine also using the HDAC
system. The model number has been changed to identify this new series of
engines using the two-barrel carburetors.
Models Now Include:
CH682 (694cc)
CH732 (747cc)
CH742 (747cc)
CH752 (747cc)
CV682
CV732
CV742
CV752
(694cc)
(747cc)
(747cc)
(747cc)
Today's fuels have been extremely hard on carburetors making service
parts an important area of the carburetor design. Most of the fuel damage
can be found in the float bowl area where the fuel, and in many cases
ethanol, is allowed to sit and form deposits. Kohler now offers several
levels of repair as needed to keep engines running smooth including a
complete bowl kit.
Kits Available:
Fuel Shut-Down Solenoid
Choke Repair
• Accelerator Pump
Standard Overhaul Kit = Gaskets + Screws +Ace. Pump + Float + Needle
Complete Overhaul Kit= Standard Overhaul Kit+ Bowl Kit (No Jets)
High Altitude Kit for 6000-8000 Ft. (1800-2400 m)
As with any kit, it is important to follow all instructions. You may find that the "Left" and "Right" side jetting is not the
same and each side needs to be labeled during disassembly.
New CV Service and Production Oil Pan
All CV620-750 oil pans have been updated, designed, and machined to
use a gasket and eliminate the use of shims on the crankshaft and
camshaft. When replacing the oil pan you must discard any shims on
the crankshaft and camshaft. Also, you must use the gasket, even if the
old oil pan was sealed with RTV. If the shims are reused or RTV is used
for the gasket, the engine will not turn and the oil pan will likely crack.
Check the dowel on the oil filter side of the pan. If it has the split dowel
style, replace it with the included closed seam style found in the kit.
The service kit includes:
Oil Pan Assembly
Oil Pan Gasket
Closed Seam Dowel Pin
Installation Instructions 24 790 17
7
Command PRO Series
Old Spark Advance Module Availability and Use
Analog Spark Advance Modules (ASAM): 24 584 09-S and 24 584 10-S
were used on earlier CH/CV 23 and 25 hp engines before the DSAM,
DSAI and now MDI systems. The Analog and later Digital systems are
not interchangeable.
24 584 09-S
24 584 10-S
Inventory of the 24 584 10-S module has been exhausted, and is no
longer available from Kohler. The 24 584 09-S module is still available.
Functionally the 24 584 09-S and 24 584 10-S are identical as they use
the same timing curve. Their only difference is the 24 584 09-S contains
“Bullet” style connectors and the 24 584 10-S contains “Spade” style
connectors on the red (power) lead and the white (kill) lead, where they
connect to the main engine harness.
The 24 584 10-S modules have been superseded to the 24 584 09-S;
by adding two (2) 1/4” insulated male “Spade” terminals Part No.
15 452 01-S to the kit.
Welder Removal and Replacement Procedures
In 2007 Kohler Engines and Miller Electric/Hobart had worked together to create a complete set of instructions to
remove and replace the Kohler Command engine from the Miller welder. Many dealers have found these instructions,
complete with color pictures, helpful when repairs are necessary.
To date, three engine R&R procedures are now available on-line for separating the engine from Miller and Hobart
branded products (welders/generators/compressors).
These cover R&R on:
1.) Miller/Hobart Welders with Rear Mounted Engines
2.) Miller/Hobart Welders with Front Mounted Engines
3.) Miller “Air-Pak” Units (Welder/Generator/Compressor)
The detailed step-by-step procedures with pictures are
located on the www.kohlerplus.com website, under
“Service Literature” in the “Associated Documents”
section. These should be followed whenever separation of
the engine from the unit is required to avoid unnecessary
labor and product disassembly.
8
Command PRO Series
Correct Dipstick and Checking Procedure
Last year Kohler introduced a special dipstick with a black cap to replace the yellow cap standard version for certain
CV940-1000 applications. This has created some confusion as to when the black cap stick should be used and what
is the proper procedure to check the oil level?
1.) The engine oil level must always be checked with the engine in a level position. Some applications have the
engine mounted at a slight angle of approximately 3° with the dipstick side up. This can result in an incorrect or low oil
level being indicated. In most cases the result is an overfilled crankcase.
2.) When checking oil level the dipstick must be resting on top of the dipstick tube. Do Not Thread it in. The same
Instructions are contained in the Owner's Manual, and also imprinted on the blade of the dipstick.
The dipstick 62 038 05-S with the yellow screw-on cap has been in use on all the CV PRO 999 series engines as the
standard dipstick.
The 62 038 08-S dipstick with the black screw-on cap was introduced last year as an available "Service Replacement"
for use on specific applications; when operation on uneven terrain or angled engine mounting resulted in some oil
smoking. The new dipstick effectively lowers the crankcase oil level slightly to minimize oil entry into the breather
system. Markings on this dipstick were approximately -x in. lower than on the standard yellow cap dipstick.
Kohler for the 2013 Model year (S/N 43000xxxxx and higher), has made an internal design change to the breather
system within the crankcase on all Command PRO (999) CV/CH models to prevent this from occurring. These
engines will all utilize the standard yellow cap 62 038 05-S dipstick unless specified otherwise.
9
Command
PRO Series
Excessive Oil in CV940-1000 Breather Hose or Oil Leak from
Housing
Oil in Breather Hose
When the oil filter is removed from the filter housing of this engine, a
plastic cup will rise to open a port allowing oil to drain back into the
sump. With the recently revised breather system of this engine, some oil
will also drain into the oil separator cavity. Testing has shown this does
not cause smoking at start up.
With the current breather system, if the oil filter housing drain port does
not seal, pressurized oil can enter and overwhelm the oil separator,
causing pressurized oil to exit the breather hose. With the previous
breather system, a loss of oil pressure could occur.
Reassembly is critical. To date, there have only been three reported
cases of this occurring with the current/revised breather system. Two
have been repaired in the field without replacing components. It is
believed the plastic cup was misaligned with the housing and preventing
the port from properly sealing.
Oil Leak from Housing
It is also important to note the difference between housings. Part number
62 081 10-S will be drilled for a pulse pump fitting (see illustration).
There have been isolated reports of this housing installed on incorrect
applications, resulting in zero crankcase vacuum/pressure and oil
leakage from the open port. Part number 62 081 39-S is not machined
on the casting boss.
10
Command PRO Series
CV940-1000 Secondary Air Injection Hose Heat Failure
During the second half of the 2012 season heat deteriorated failure of
secondary air injection (SAl) hoses was reported from the field. This
deterioration generally occurred between 200-300 hours. For unknown
reasons, deterioration with replacement hoses was less commonly
reported. The replacement hose is part number 25 326 14-S.
Investigation revealed the failures occur due to excess radiant heat on
applications not using a Kohler muffler. The current plan is to develop a
higher temperature hose for these applications. The scheduled date for
introduction of this hose has not been announced at this time.
During the interim, for repeat failures contact your source of supply.
CV Oil Pan Check Ball and Spring Installation
t
+
0.625 in.
A check ball and spring is installed in the oil feed passage of the oil
pans for all CV940-1000 series engines. This prevents oil drain-back
from the filter and lubrication circuit when the engine is shut off.
If for any reason these parts have been removed, the following
illustration shows the correct assembly orientation. The spring retainer
is the last part installed and should be 0.625 in. (16.2 mm) below the
machined surface of the oil pan. The ball, spring, and retainer are
available as kit 62 194 01-S.
The Service Manual will be updated with this information at the next
revision.
CV940-1000 Adjustable Valve Train Discontinued
In May 2013 the adjustable valve train was removed from CV engines. Previous engines used the adjustment to
compensate for lifters that took too long to prime with cold oil.
Recent changes to the hydraulic lifters have shown great improvement in priming time to keep the lifters quiet.
Thorough testing with 20W-50 oil and the new lifters has proven that there is no longer a need for rocker arm
adjustment on these engines.
The adjustable rocker cylinder heads are machined different and use different rockers and pivots than the nonadjustable type. Service replacement cylinder heads have been superseded to the non-adjustable type. The kit is
complete with a valve train and new lifters.
11
Command PRO Series
Electronic Fuel Injection (EFI)
Fuel Pump Module Vapor Lock
The Commercial EFI system uses two fuel pumps to operate the
system. The first pump is identical to the carbureted systems as it pulls
fuel to the Fuel Pump Module (FPM) mounted to the side of the engine
block. The FPM then creates high pressure to operate the system.
Vapor lock is a condition that typically happens on the low pressure side
before the FPM.
Vapor lock in the fuel pump module had been reported on some
applications. This condition occurred after a hot restart mostly in high
ambient temperatures during periods of heavy load/use.
When the temperature in the fuel pump rises, the fuel can begin to boil.
As the vapors from the boiling fuel rush out of the vent line, the rollover
protection ball can be forced up to stop the venting process. Adding
to this problem, the vent line is connected to the throttle body and will
create vacuum when the engine starts. At this point the vapor pressure
begins to rise until it is greater than the entering fuel pressure and new
fuel stops flowing into the pump.
Eventually the FPM will run out of fuel and the engine will stop. After it
cools the vapor pressure drops and the ball will fall back into place. The
engine will operate as normal.
To test the FPM, install your pressure gauge and run the engine to
duplicate the problem. You will see the pressure drop and the engine
stall, but you will still have power to the FPM. At that time remove the
vent line from the FPM and insert a paper clip or wire into the nipple. By
unseating the ball, you will hear the release of pressure from the tank.
To address this problem Performance Engineering designed a deeper
pocket where the check ball sits preventing it from being forced into
the vent tube. The ball now sits in a cup, rather than a flat surface,
where the rushing vapors cannot get under to push the ball up and
block the venting process. The new part number 25 393 14-S was
added to Service Parts and production in May of 2013 and supersedes
all previous FPM part numbers. Fuel filter 24 050 13-S (10 micron) is
included with the FPM kit.
Diagnostic Extension Lead
To aid connection to the diagnostic plug on the Command EFI engines, an extension harness (202 mm/7.95 in.) has
been developed. The extension simply plugs into the diagnostic connector to make life a little easier to reach the
connector in the future. You will see the extension harness on some production units this upcoming year and the
same extension will be listed in the Service Accessories Catalog using the 25 176 17-S part number.
12
Command PRO Series
Fuel in Vent Line
The Commercial EFI Fuel Pump Module (FPM) utilizes a vent line to
keep a consistent atmospheric pressure inside the module. The vent
line runs from the module to the throttle body and has a "r fitting for an
optional vent to the OEM fuel tank.
Concerns of raw fuel found in this line leads to the assumption that
the FPM must be over fueling from a bad needle or seat. Although it
is possible, it is typically followed by an extremely rich or no running
condition.
If you suspect this condition you must check for excessive amounts
of fuel in the FPM vent line. Checking at just the 'T' fitting, OEM
connection, or plastic cap connection is not sufficient. There is likely
a small amount of fuel that gets trapped at this location as a result of
normal venting of the module and fuel condensation.
Test Procedure:
Remove the vent hose from the fuel pump module. If this line is full
of fuel you will need to determine if the gas is coming from the FPM
or the OEM fuel tank. With the vent line disconnected, attach a new
line to the FPM and run it to a catch can. Run the engine and observe
if there is gas coming out of the test line connected to the fuel pump
module. If so, replace the fuel pump module. If gas is coming out of the
disconnected vent line, there is a problem with the venting of the OEM
fuel tank. Repair as necessary.
Kohler EFI Diagnostic Software 2.11.0007 Upgrade
The launch of the ECV940, ECV980, and PCV/PCH Propane EFI
engines are well underway and the needed upgrade for the diagnostic
software has also been completed. This upgrade allows the system to
function with these new models as well as all older models previously
produced.
The free upgrade is available for any version 2.11 Kohler Diagnostic
Software user by simply going to:
http://kohler.diagsys.com
From the downloads section of the site, you can simply click on the
update listed and select "Kohler Diagnostic System Version 2.11.0007
Update". Please remember that you must be running version 2.11 for
this free update to load.
Please Note: If you are running an older version of the software (2.09
or older), you must first upgrade to version 2.11 prior to downloading
the free update.
13
Command PRO Series
ECV940-980 E-Gov Erratic Speed with PTO Engaged
There have been reports of erratic engine speed where the rpm drops
to low idle (approx. 1500 rpm).
Investigation has found excess strain on the GCU harness resulting in
damage to the GCU harness connector. This has caused intermittent
electrical connections and/or loss of electrical connections to the GCU.
Proper repair includes replacement of the GCU harness. Proper
harness routing is critical to remove excess strain from the GCU
harness connector. Once the harness is replaced and reinstalled,
relieve strain from the GCU harness connector and secure the harness
relative to the J-clamp with 2 wire clamps/zip ties 25 454 03-S as
illustrated.
This change has already occurred for production engines.
Repower Opportunities
Repowering carburetor to EFI has been made easier than ever with the
Commercial EFI engines.
Kohler has released an EFI Repower spec for the Exmark Lazer Z and
the Toro Z-Master ZTR's, produced between 1998 and 2011 to replace
the horizontal shaft carbureted Kohler Command Engine.
Engine spec, ECH749-3007, includes a wiring harness adapter (24
176 225-S) and installation instructions (24 790 18) for trouble free
installation. In addition, TT-5238 is also included which will assist with
the installation of the EFI engine in any application.
Kohler also has an assortment vertical and horizontal shaft engine
specs available as a Basic offering. The ECV680-3001 features a 1 X
3.16 in. crankshaft with the heavy-duty air cleaner assembly where the
ECV749-3001 is a larger displacement offer featuring a 1.125 X 4 in.
crankshaft as well as the heavy-duty air cleaner assembly.
Not only does Kohler offer Gasoline EFI repowers, there is also a
PCH740-3002 Propane EFI. The spec features closed loop EFI, a
heavy-duty air cleaner assembly and a 1.125 X 3.996 in. crankshaft.
Throttle and key switch controls will need to be application supplied.
The Commercial EFI engines use a standard wiring harness connection
that can be adapted to almost any of the previous carbureted harness
connectors. See Parts Bulletin 258 to find the correct adapter for each
carbureted engine spec.
More information can be obtained by contacting your Kohler Source of
Supply.
14
Command PRO Series
10-Micron Fuel Filter Options
The importance of using a 10-micron fuel filter on any Kohler EFI
product cannot be overstated. Using a filter with a larger micron rating
will allow larger particles to either plug the filter in the fuel pump module,
damage the fuel pump, or plug up and destroy the fuel injectors.
There are 3 options when installing or replacing a fuel filter on an EFI
engine. Each filter has a recommended service replacement limit.
25 050 42-S
24 050 13-S
25 050 42-S
200 Hours
24 050 13-S
600 Hours
24 050 03-S
1500 Hours
Must Use Support Brackets
Command PRO Single
CH270–440 Expanded Gear Reduction Offerings
Last year Kohler introduced some gear reduction options for the
CH270-395 engines. This year the offerings have expanded to include
the CH440.
CH270 6:1
The 6:1 gearbox is separate from the engine crankcase and has its own
oil level. Use proper engine oil for temperature expected.
CH270-440 2:1 with Wet Clutch
The 2:1 gearbox is separate from the engine crankcase and has its own
dipstick and oil level. Use 20W-40 or 20W-50 oil. The engagement and
disengagement speed of the clutch is 1800 +/- 200 rpm.
CH395-440 6:1
The 6:1 gearbox is part of the crankcase and is lubricated with engine
oil. Use proper engine oil for the temperature expected.
24 050 03-S
15
Command PRO Series
16
White Specks in Carburetor
During the 4th quarter of 2012. Kohler Service noticed a trend of calls
reporting "white specks" in the carburetor. The bulk of these calls were
from Kohler dealers in Texas. Arizona. and California. Return of affected
carburetors and fuel tanks revealed the deposits to be nylon.
These deposits are generally found to restrict and/or plug the pilot and
main jets; and appear as illustrated.
To date we have not documented the fault reoccurring after carburetor
replacement. Testing suggests that once the nylon leaches from the
fuel tank in a sufficient volume to affect carburetor operation, continued
leaching resulting in carburetor faults does not occur.
Nylon has been used in XT fuel tanks since their introduction and
typically will not leach into the fuel system unless an excess amount of
alcohol is present, such as mistakenly using E85. The specific reason
for the issue to occur has not been positively identified.
Prior to this fault occurring. a new non-nylon material was being
developed for fuel tanks. We are aiming for this material to be used in
model year 2014.
Carburetor coverage will be provided for units that exhibit this specific
condition. The effects of stale and/or contaminated fuel are not
warrantable defects and will be handled as outlined by SB-276.
17
XT Series
18
KOHLER® 7000 SeriesTM
Kohler Performance Engineering has been busy this year working on product improvements to the consumer twin
engine.
Introducing the 7000 Series. replacing Courage Twin
cylinder engines with a variety of performance
upgrades.
New Models Include:
KT715
KT725
KT730
20 hp
22 hp
23 hp
KT735
KT740
KT745
{2dBa) Quieter than Courage Twin
• More Efficient Blower Using a Scroll Design
Higher Power Density
• Cooler Operation
• More Efficient Air Induction
Stronger
• 28% Higher Density Head Gasket
• 30% Greater Flow Oil Pump
• 8x Stronger Oil Pan
• 30% Increased Bearing Area
• Nitrite-Coated Exhaust Valves
Easier To Maintain
·One Sided Oil and Fuel Inspection
• Ergonomic Dipstick Handle
• Top Access and No Tools Required Air
Cleaner Inspection and Replacement
Improved Angle of Operation
• External Breather System
• Up to 25° Continuous Angle of Operation
·Up to 30° Intermittent Angle of Operation
Standard or PRO Performance Filtration Option
24 hp
25 hp
26 hp
19
New Product
KOHLER® Confidant™
This engine has been endurance tested to meet the rugged
standards of the commercial market. Adding to our
commercial product offering, the KOHLER Confidant engine
is designed and tested to meet the rugged demands of
the landscape professional or large property owner with a
passion for lawn care.
New Models Include:
ZT710
ZT720
19 hp
21 hp
ZT730
ZT740
23 hp
25 hp
Commercial Durability (1000 hrs Test)
• 30% Greater Flow Oil pump
• 8x Stronger Oil Pan
• 30% Increased Bearing Area
• Nitrite-Coated Exhaust Valves
• Steel Fire Ring Head Gasket
• Stronger Crankcase
• Increased Cooling Fin Area to the
Cylinders and Heads
(3dBa) Quieter than Courage Twin
•More Efficient Blower with Scroll Design
·Composite Cam Gear (Std)
Increased Power Density
·Cooler Operation
·More Efficient Air Induction
Heavy-Duty Cyclonic Air Filter (Optional)
Walk Behind Wide Area Mower Spec (Optional)
Recoil Starter w/ACR Optional (Lower hp)
20
7000 Series
Confidant
New Product
2000 SeriesTM
The RH265 is the latest entry into the horizontal slant cylinder market.
The compact size and light weight design makes it one of the smallest
engines available at 6.5 hp.
Standard features include:
• Overhead Valve Design
• Quiet Muffler
• Dual Oil Drains
• Ergonomic Starting Handle
• Splash Lubrication
• Accu-Fill™ on Large Fuel Tank
• Single Lever Control
Model
RH265
Gross Power @ 3600 rpm Max. hp (kW)
6.5 (4.9)
Net Power @ 3600 rpm
5.5 (4.1)
Displacement
Max. hp (kW)
cu in (cc)
12.1 (196)
Bore
in (mm)
2.7 (68)
Stroke
in (mm)
2.1 (54)
Net Peake Torque @ rpm
ft lb (Nm)
Compression Ratio
8.5 (11.5)@ 2800
8.5:1
Dry Weight
lb (kg)
28.8 (3.6
Oil Capacity
U.S. qt (L)
0.63 (0.6)
Fuel Capacity
U.S. qt (L)
3.8 (3.6)
Lubrication
Splash
Dimensions L x W x H
in (mm)
12.2 x12.9 X 12.8 (310 X 329 X 325)
Crankshaft Height
in (mm)
4.17 (106.0)
21
New Product
22
New 2-Wire Walbro Fuel Solenoids
New 2-wire fuel solenoids are now being used in production on
single cylinder Courage and Command Series engines with Walbro
carburetors. Previous Walbro carburetors used a 1-wire fuel solenoid
25 757 25-S or 12 757 33-S with a molded-in wire lead. The new
2-wire solenoid offers a higher level of thermal protection and
durability. It is easily identified being slightly larger in diameter, and
has a detachable "plug-in" 2-wire connector assembly.
Kohler will be servicing with the 2-wire Fuel Solenoid Kit 20 757 01-S
exclusively, upon inventory depletion of the 1-wire solenoid kits. The
2-wire connector harness 20 518 04-S is included with the solenoid
kit, and all applicable Walbro replacement carburetors now supplied
from Service.
Production of Courage Twin cylinder engines since 2010 involved
use of carburetors from both Keihin and Walbro on a specific spec.
The Walbro supplied carburetors will now contain a similar 2-wire
solenoid. Some of the Keihin carburetors are now being discontinued
and will be serviced with a Walbro carburetor, containing the 2-wire
fuel solenoid. The replacement carburetor offers the same features
as above, and will include the 2-wire plug-in connector assembly
32 518 01-S which is longer in length, to allow hook up to the existing
engine wire harness.
The original 1-wire Walbro Fuel Solenoid Kit 32 757 01-S will be
serviced with a new 2-wire Fuel Solenoid Kit 32 757 12-S, upon
depletion of single wire stock.
The fuel solenoid kit and other individual repair kits for the existing
Keihin carburetors will continue to be offered.
Spark Plugs (Champion) "XC vs. RC vs. P"
In the last couple of years, there has been an increase in use of spark plugs
that wear the "XC" designation (as printed on the spark plug) vs. the typical
"RC" spark plug. The main reason for the "XC" designation is to allow the
OEM application to meet R.F.I. (radio frequency interference) compliance as
mandated in certain countries. To avoid logistic issues, many OEM's build one
unit to service all areas where they intend to sell.
The "RC" labeled plug is the standard resistor spark plug and the "XC" is a
"resistor/inductor" featured spark plug. When the engine is equipped with the
XC spark plugs, many times the engine is equipped with a special ignition
coil featuring a shielded high tension wire (RFI/EMC). When the OEM
requests an R.F.I. engine, this alone does not guarantee that the application
will be compliant. The engine mounted in the unit is tested at an approved
independent laboratory as a complete unit. There are other spark plug features
found on some of our engine specs, such as "Platinum" spark plugs for
extended life.
The purpose of this topic is to simply inform you of the different types of plugs
and the reasons there are different plugs being used. Kohler suggests that
when servicing these units in the field, replacing the spark plugs with the same
features as the ones removed to ensure that the whole application stays in
compliance as built. By adhering to this recommendation, you will avoid the
potential for running issues and/or liabilities.
23
Miscellaneous
New 83 mm Piston Specifications
Last year we introduced the new piston design for the 83 mm bore engines and how it improved emissions. Now
that we have engines in the field running on these pistons, it is time to release the new specifications as they are
significantly different from the previous design. This new piston has narrower rings and ring grooves with a modified
piston skirt.
The second ring on the new pistons functions more as a controlling ring or scraper ring than a compression ring. As a
result a much larger gap is used. Please note the difference between the two styles and listed specifications. Piston
style A is the previous piston design and style B is the new design.
Style “A”
Specification Differences
Top Ring-to-Groove Side Clearance
Middle Ring-to Groove Side Clearance
Oil Control Ring-to Groove Side Clearance
Top Ring End Gap
New Bore
Used Bore (Max.)
Center Ring End Gap
New Bore
Used Bore (Max.)
Thrust Face O.D.
New
Max. Wear Limit
Piston Thrust Face-to-Cylinder Bore Clearance
New
Style “B”
Style “A”
Style “B”
0.025/0.048 mm
(0.0010/0.0019 in.)
0.030/0.070 mm
(0.001/0.0026 in.)
0.015/0.037 mm
(0.006/0.015 in.)
0.030/0.070 mm
(0.001/0.0026 in.)
0.026/0.176 mm
(0.0010/0.0070 in.)
0.060/0.190 mm
(0.0022/0.0073 in.)
0.250/0.560 mm
(0.0100/0.0224 in.)
0.94 mm
(0.037 in.)
0.189/0.277 mm
(0.0074/0.0109 in.)
0.531 mm
(0.0209 in.)
0.250/0.560 mm
(0.0100/0.0224 in.)
0.94 mm
(0.037 in.)
1.519/1.797 mm
(0.0598/0.0708 in.)
2.051 mm
(0.0808 in.)
82.947 mm
(3.2656 in.)
82.802 mm
(3.2599 in.)
82.978 mm
(3.2668 in.)
82.833 mm
(3.2611 in.)
0.06/0.100 mm
(0.0023/0.0039 in.)
0.019/0.062 mm
(0.0007/0.0024 in.)
Oil Filter Supplied with All Short Blocks, Long Blocks, and Miniblocks
Effective with Serial Number 43021xxxxx (January 21, 2013), a 12 050 01-S Oil Filter has been included with all
Command, Courage, and Aegis engine Short Blocks, Long Blocks, and Miniblocks.
When servicing is performed using any of these assemblies, please keep in mind it is no longer necessary or
appropriate to order or charge for an oil filter as a separate item. The cost of the filter is included in the assembly.
Kohler warranty has already provided a 10 month grace period to use existing and field inventory which formerly did
not contain a filter, and in most cases, has allowed the filters when claimed separately.
All warranty claims submitted using these sub-assemblies will also require the Serial Number of the new block
assembly being used, or the claim will be returned for this information before processing. The filter will be removed
from any claims listing the filter separately based on the implementation date.
24
Miscellaneous
Kohler Engine Model Changes
SAE J1940
Improved engine design and manufacturing technologies over the past decade have reduced variations in the power
output of small engines. This has prompted the SAE to update its standardized rating procedure. The new standard
requires all engines produced from October 1, 2013 must be within 95% of the declared rated power and torque as
opposed to the old standard of 85%. SAE has also stated that the engine manufacturer must disclose the rpm for
rating and gross vs. net.
Phase 3/Tier 3 Emission Regulations
As emission regulations continue to tighten, Kohler has implemented two-barrel carburetors on some models to
improve engine performance and emission ratings with the ability to tune each cylinder on the larger horsepower twin
cylinder engines. Models using the heavy-duty air cleaners have been converted to the new carburetors. To easily
identify these engines, the model numbers were changed on the third digit to signify the two-barrel design.
Effective October 2013 Kohler Engines made changes to some of the engine models, ratings, and displacements.
Past Models
Model Year 2014
Commercial
Model Number
J1940 Hp
Displacement
(cc)
Model Number
J1940 Hp
Displacement
(cc)
ECV630
19
694
ECV630
19
694
ECV650
21
694
ECV650
21
694
ECV680
23
694
ECV680
ECV730
25
747
ECV730
23
747
ECV740
27
747
ECV740
25
747
ECV749
29
747
ECV749
26.5
747
ECV940
34
999
ECV940
33
999
ECV980
38
999
ECV980
35.5
999
Discontinued
Gross Rated @ 3600 rpm
Model Number
J1940 Hp
Displacement
(cc)
CV620
18
624
CV640
21
624
CV680
23
674
CV730
25
725
CV740
27
725
CV750
30
747
CV940
34
999
CV960
36
999
CV980
38
999
CV1000
40
999
CV980
35
999
CV1000
37
999
Gross Rated @ 3600 rpm
25
Miscellaneous
Model Number
J1940 Hp
Model Number
J1940 Hp
Displacement
(cc)
Displacement
(cc)
ECH630
19
694
21
694
ECH630
19
694
ECH650
ECH650
21
694
ECH680
ECH680
23
694
ECH730
23
747
ECH730
25
747
ECH740
25
747
ECH740
27
747
ECH749
26.5
747
ECH749
29
747
Discontinued
Gross Rated @ 3600 rpm
Model Number
J1940 Hp
Displacement
(cc)
CH620
19
674
CH640
20.5
674
CH680
22.5
674
CH682
22.5
694
CH730
23.5
725
CH732
23.5
747
CH740
25
725
CH742
25
747
CH750
27
747
CH752
27
747
CH940
32.5
999
Model Number
J1940 Hp
Displacement
(cc)
CH620
18
624
CH640
22
624
CH680
23
674
CH730
25
725
CH740
27
725
CH750
30
747
CH940
34
999
CH960
CH960
36
999
CH980
35
999
CH980
38
999
CH1000
37
999
CH1000
40
999
Model Number
J1940 Hp
Displacement
(cc)
LH640
24
624
LH690
26
674
LH755
28
747
LH775
31
747
Discontinued
Gross Rated @ 3600 rpm
26
Miscellaneous
Small Horizontal
Model Number
J1940 Hp
Displacement
(cc)
Model Number
J1940 Hp
Displacement
(cc)
RH265
6.5
196
RH265
6.5
196
SH265
6.5
196
SH265
6.5
196
CH260
6
208
CH260
6
208
CH270
7
208
CH270
7
208
CH395
9.5
277
CH395
9.5
277
CH440
14
429
CH440
14
429
Gross Rated @ 4000 rpm
Consumer Walk
Model Number
J1940 Tq
Displacement
(cc)
Model Number
J1940 Tq
Displacement
(cc)
XT650
6.5
149
XT650
6.5
149
XT675
6.75
149
XT675
6.75
149
XT775
7.75
149
XT800
8
173
XT800
Discontinued
Gross Rated @ 2800 rpm
Consumer Twin
Model Number
J1940 Hp
Model Number
J1940 Hp
Displacement
(cc)
Displacement
(cc)
KT715
20
725
SV710/810
20
725
KT725
22
725
SV715
22
725
KT730
23
725
SV720/820
23
725
KT735
24
725
SV725
24
725
KT740
25
725
SV730/830
25
725
KT745
26
747
SV735
26
725
Discontinued
27
SV740/840
27
725
Gross Rated @ 3600 rpm
27
Miscellaneous
Consumer Single
Model Number
J1940 Hp
Displacement
(cc)
Model Number
J1940 Hp
Displacement
(cc)
SV470
15
597
SV471
19
597
SV480
16
597
Discontinued
21
SV530
17
597
SV530
17
597
SV540
18
597
SV541
18
597
SV590
19
597
SV591
19
597
SV600
20
597
SV601
20
597
SV610
21
597
Discontinued
21
SV620
22
597
Discontinued
22
Gross Rated @ 3600 rpm
New Commercial Twin (Confidant)
Model Number
J1940 Hp
Displacement
(cc)
ZT710
19
725
ZT720
21
725
ZT730
23
725
ZT740
25
725
Gross Rated @ 3600 rpm
New Kohler 20W-50 Oil
Kohler is introducing 20W-50 oil as the recommended
lubricant for Command PRO® CH/CV940-1000 series
engines in operating temperatures above freezing. It is well
suited for any commercial applications operating in warm
temperatures. Kohler 20W-50 is a premium oil formulated
to meet the stringent lubrication requirements of hard
working commercial engines and meets or exceeds the
requirements of API Service rating SN, SM, SL and SJ.
It features a unique blend of high viscosity index mineral
oils combined with a carefully selected additive package
to provide maximum protection against wear, corrosion,
oxidative thickening, acid formation, and deposits. This
higher viscosity oil provides improved wear protection at
elevated operating temperatures and features low volatility
to help reduce oil consumption. Kohler 20W-50 oil will be
available in November 2013.
Kohler 20W-50 Part Numbers
25 357 42-S case (12 x 1 quarts)
25 357 41-S quart
28
Miscellaneous
MDI Ignition Module (Conversion from DSAI)
The Kohler 12 volt Digital Spark Advanced Ignition (DSAI) has been
discontinued for all Courage and Command Twins (not CV/CH940-1000)
and replaced with Magneto Digital Ignition (MDI). All new engine specs that
were originally equipped with the DSAI system have been upgraded to the
new MDI ignition.
The MDI ignition system offers the same ignition timing advance features
as its predecessor, however it does not require a 12 volt power source to
function. Some of the key features of the MDI system:
Eliminates dependence on 12 volt battery power
Eliminates concern with high voltage transients input to the module
MDI module uses a capacitor discharge ignition (CDI) design
Ignition power and performance same as fixed timing CDI
Shielded-RFI
Standard
The DSAI system will be phased out of service after inventory has been depleted. At that time an MDI kit will be used
to supersede as the replacement part.
If the engine Spec. No. is not found, please use Parts Bulletin 259 which lists a comprehensive chart of engine models
and their respective MDI conversion kit part numbers. The kits will feature two new MDI ignition modules, as well as
all of the required components to convert the engine to an MDI system. Service installation sheet 25 790 12 is also
included with every kit providing step by step instructions to perform the conversion.
25 403 21-S Rectifier-Regulator
25 Amp- Full Wave with Over-voltage Protection
Kohler Service has seen an increase in warranty claims pertaining to the 25 403 21-S rectifier-regulator. Customers
report that the charging system does not function and the battery goes dead. The majority of the regulators returned
are tested and found to function properly. The over-voltage protection feature is designed to "trip-our if a voltage spike
is sensed and no charge will occur. To reset the system the circuit must be opened by removing the negative battery
cable or by temporarily unplugging the regulator when the engine is off or by simply removing the charging circuit
battery fuse (Green 30 amp). By opening up the circuit, the protection device will automatically reset.
Due to this increased activity, we are again making you aware of the over-voltage protection built into the 25 403 21-S
as well as instruct you to be diligent when inspecting the units for a no-charge condition. The repair could be as simple
as a loss of the regulator ground or a loose mounting screw. Resetting the regulator is the first step when diagnosing
an over -voltage protected charging system.
The "tripping" event can be caused by a number of conditions. If the system receives a spike during operation or if
there is a momentary break in any of the connections anywhere on the unit, a spike can occur when the connection is
reestablished. As mentioned before, many of the reported situations have been found to have poor regulator grounds
or poor connections. Kohler is issuing field kit 24 518 12-S to help address the poor/loose grounds at the regulator
mounting screws. The kit includes the regulator grounding wire, two split washers, and a thread forming screw.
Instructions and a Service Bulletin are being issued for the repair kit.
Poor connections on the positive (B+) circuit could also affect the
regulator. Inspection of the positive (B+) circuit is equally important
including (but not limited to) the fuse, the fuse holder as well as
regulator connections and again the battery connections. It is highly
recommended that a visual and mechanical check of the connections be
performed. Remove the fuse and inspect for poor crimp/loose fit. There
have been reported cases where the fuse holder terminals are not
mating with the fuse spade firmly and allowing for a loose fit. Check by
inspecting each fuse terminal individually by simply inserting only half of
the fuse in the holder for each side. This will allow the tech to inspect for
adequate interference fit between the holder and the fuse blade.
29
Miscellaneous
Kohler PLUS Explorer 10/Windows 8 Information
Love it or hate it, Explorer 10 and Windows 8 is out there and many people have had a difficult time adapting to the
change.
Windows 8 can launch Internet Explorer 10 (IE10) from two different locations.
Tile View- Launching IE10 from the Tile View will only allow limited function or "Kiosk Mode." Kohler PLUS needs the
full function of IE10 to operate and will not open.
IE10 Tile
Kiosk Mode
..._...
.
11itt
Desktop Tile
Desktop View
Desktop View- Launching IE10 from the Desktop View allows full function and capable of running Kohler PLUS. You
must first select the Desktop Tile to open the Desktop View. This is when things begin to look familiar again.
Desktop IE10
Standard Mode
30
Miscellaneous
Once IE10 is launched, your favorite home page will be displayed. Example: Yahoo.com
Look for the command tool bar. If the bar is not visible, simply push the "Ait" button to make it appear.
.,
I .,..---._
., u- -
Command
ToolBar
'
-
·-. - ·...................
. .
o..-
:.
0. .. . ....
J......... .
-_
. . . ....
.--·-
j ...
it.>-<
...
.........
. ...
.......,
....................
o... f-
......_
-
.
.
......,
--- --
... ..1/ _,..._I
Remember, the old rules still apply so you still need to make sure Kohler PLUS is a trusted site and ActiveX Controls
are installed. Additionally, in Explorer 10 you must turn on the IE Compatibility View.
Please review these step-by-step instructions:
Make sure that Kohler PLUS is a trusted site
From the tool bar click on tools and then Internet Options- if you do not have a tool bar, click on the Alt button next to
the space bar and the tool bar will open.
_..
.._ ..._
ltuillllll-
.... ,_,....
ll'll----"'-·l ll
v .rN.....i!IW - - . ...
1..'-..-.,t.w., ·_-. ..--
.. .,. .........
-
...._._.'lrlhi-: N
-1
.,_,...,
•I.N9wl_ ............. ......._
o
!'=---- ..
•n!.wtrc-br;lbw)
1M!
Make sure to use https:
when adding a site
31
Miscellaneous
To turn on IE Compatibility View
1. Open Internet Explorer.
2. Click the Tools button, and then click Compatibility View.
If Internet Explorer recognizes a webpage that is not compatible, you will see the Compatibility View button on the
Address bar. To turn Compatibility View on or off, click the Compatiblity View button.
P • C: G
"*·-
"'-""19
n tnw.....I
Toaclcmg
Ell v-"-
ill!rc!III'Ctlolrl-
lil!""""i
f"1> COI"L'>>": I
litcepoon ....
ift-
•II- oto'-m
mp
-
A IIIIIIIIlil11l SUiftl S«!Hf'l
c vc v..w..... "'
Subu:ntt. to 1tv1o loeclf..,ddecowry
Wincllcowlllp4oe•
11.211 1...,
'5.....:11!10 -h
ActiveX Installation Error
Your ActiveX Microsoft Internet Explorer controls are not enabled.
1) Click the Tools menu located in the top menu bar of Microsoft Internet Explorer.
2) From the drop down menu, click Internet Options....
row G Od N ew s
.... ,
Manage Add'«tt...
'S'pncl-....
W•fldot.rfs e
32
Miscellaneous
3) Click the Security tab in the Internet Options
dialog box.
,@rEJ
lnLNne1 Optioni
4) Click the Custom Level... button.
IP'Itemet
Tl'it lUllcer&wII 'Wtb liet ,au
'
l1i1t"C
1 o:lewd!f %CII'Iet
CuJtaC.U
• To lho JOimgs. L...• ToU efle r ddt Ddtull.cvol
5) Locate the "ActiveX controls and plug-ins"
group within the list and enable each of the
control functions.
·,
?I]
Secudty Settings
ettings:
Check that the following control functions are
depending on your system setup):
Automatic prompting for Active controls
Binary and script behaviors
Download signed ActiveX controls
Initialize and script ActiveX controls not
marked as safe
Run ActiveX controls and plug-ins
Script ActiveX controls marked safe for
scripting
6) Click OK to close the Security Settings.
Automatic prompting For ActiveX controls
Q Disable
@ Enable
Binary and script behaviors
Administrator approved
Disable
Enable
Download signed ActiveX controls
Disable
Enable
Prompt
Download unsigned ActiveX controls
00
00 /"'\ ,..,
._,_
V,
I
7) Click OK to close the Internet Options dialog
box.
Reset custom settings
B.eset to:
._I M_e_d_ui m
-'v--"1 I
R set
to lookup parts and manuals.
OK
II
Cancel
33
Miscellaneous
2014 Factory Schools
Levell
The Level I course is designed to provide students with a working knowledge of Kohler four-cycle engines and engine
systems. It is assumed the students will have a basic understanding of small gasoline engines upon enrolling in the
class. Contact your distributor for more information.
Information covered will include:
• Kohler PLUS
• Troubleshooting
• Use of Measuring Instruments
• Failure Analysis
• Ignition/Electrical Theory
• Fuel Systems
• Warranty Information
• Engine Tear Down/Reassembly
2014 Levell School Dates and Locations
February 18-21
El Reno, OK
Medart Inc.
Olive Branch, MS
Medart Inc.
March 11-13
Jacksonville, FL
Gardner, FL
March 11-14
Franklin, MA
Gardner-Connell
September 9-12
Franklin, MA
Gardner-Connell
September 15-19
Ashland, VA
Chesapeake Eng. Dist.
March 4-7
October 6-10
Ashland, VA
St. Louis, MO
November 4-7
Chesapeake Eng. Dist.
Medart Inc.
Chesapeake Eng. Dist.
November 10-14
Ashland, VA
November 11-14
Kansas City, MO
Medart Inc.
November 18-21
Memphis, TN
Medart Inc.
December 8-12
Ashland, VA
December 9-13
Salem, OR
Chesapeake Eng. Dist.
Original Eq.
Level II
The LevellI course is designed for students who have completed a Levell course at Kohler, at a
Central Distributor, or have passed the Kohler Expert Dealer test. The class size is smaller to allow for more one-onone instruction and hands-on activities. Download your application form at:
www.kohlerengines.com/dealers/kohlerFactorySchool.htm
Information covered will include:
• Electrical Systems - Ignition, Starting,
• Engine Tear Down/Reassembly
• Hands-On Diagnosis and
Charging
• Fuel Systems- EFI, Gasoline, Gaseous
Troubleshooting in a Variety of Areas
• Advanced Failure Analysis
2014 Level II Factory Schools
(Kohler Location Only) March
3-7, 2014
August 4-8, 2014
December 8-12, 2014
Classes are filled on a first-come, first-served basis. Submit your registration soon!
KOHLER.Engines
34
Below is a list of all service and parts-related documents released or revised in late 2012 through
mid-2013. For printing purposes, we have included a specific few in this section. The most up-todate service and parts-related information can always be found at: www.kohlerplus.com.
Parts Bulletins
PB-258 Command Wiring Harness Adapters (EFI)
PB-259 DSAI/MDI Ignition
Service Bulletins
SB-317 Oil Consumption
SB-318 Rocker Arm Pivot Screw Torque Change
SB-319 Grounding of Rectifier-Regulators
SB-320 Poor Running Due to Improper Ground Connection
Technical Flash
Belt Driven Application PTO Bearing Failures
Installation Instructions
25 790 15 Hydraulic Lifter Kit
25 790 16 Retractable Starter Kit
35
Bulletins, Etc.
KOHLER
ENGINES
CMT Belt Driven Applications-32013
Belt Driven Application PTO Bearing Failures
There have been several reports of Command Twin main bearing failures on applications using belt drives, where
the pulley centers are several feet apart. Many of the failures have also been seen in colder climates where belt
shrink may also be a factor.
The initial report of several of these failures was the rotating of the PTO sleeve bearing in the closure plate, leading
to the blockage of the oil supply to the crankshaft PTO bearing. Based on the analysis of returned engines and the
subsequent testing of new engines under various conditions, it has been determined that these failures are due to
excessive belt loading. It has further been shown that the bearing rotation is a result of the excessive bearing load
and failure; not the cause.
Kohler Engines requests that OEMs implement initial belt adjustment practices and operators manual warnings
that address the potential for excessive bearing side load.
Kohler Engines recommends:
1. Pulley Selection and Tension Design (one or more of the following):
a. The addition of an intermediate pulley positioned close to the engine, to allow the engine to run shorter
belts (shorter center line span distance).
b. The implementation of a spring loaded belt tension system.
c. The engine pulley be mounted as close to the closure plate as possible, to decrease the effective load on the
engine bearings. Kohler recommends within 4" from mounting feet, using a minimum 4" diameter drive
pulley. A larger pulley (5" or 6" drive pulley) may be necessary for engines that are 27 hp or greater.
2. Belt Tension
a. If belt tension is measured statically, tension per strand should not exceed 125 lbs using parent material
bearing (aluminum) closure plate configurations, or 250 lbs with sleeve bearing configurations.
b. Drive belts be re-tensioned seasonally, and after the first 24 hours of use (checked cold). The belts are
typically comprised of materials that will shrink/expand due to thermal contraction/expansion leading to
either belt slip or bearing overload during seasonal temperature changes.
3/13
© 2013 by Kohler Co. All rights reserved.
ENGINE DIVISION, KOHLER CO , KOHLER, WISCONSIN 53044
36
Bulletins, Etc.
25 790 15
KOHLER.
Engines
Installation Instructions
Hydraulic Lifter Kit
This kit provides a hydraulic lifter and camshaft lubricant.
1st
£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.
This Kit Contains Qty.
1
1
1
Description
Lifter, Hydraulic
Lubricant, Camshaft
Installation Instruction
To InstallNOTE: These instructions cover bleeding of the hydraulic
lifter only. Refer to the service manual for
Disassembly and Reassembly procedures.
NOTE: Bleed the hydraulic lifter of internal oil so the
plunger in the lifter can be depressed by hand.
Plunger
Figure 1. Hydraulic Lifter Details.
4. Follow service manual procedures and reassemble
engine.
NOTE: To prevent a possible bent push rod or broken rocker
arm, it is important to bleed any excess oil out of
lifters before they are installed.
1. Lay a rag or shop towel on table of drill press. Place an
8 mm (5/16 in.) socket on towel with well end up, then
place open end of lifter on socket. Ensure socket does not
contact lifter ball surface.
2. Place some material, such as wood, plastic or aluminum,
on top of lifter to protect lifter finish.
3. Lower drill press d1uck until it contacts material on
lifter. Slowly pump lifter 2 or 3 times to force oil out of
feed hole in side of lifter.
6/13 Rev.-c 2013 by Kohler Co. All rights reserved.
ENGINE DIVISION, KOHLER CO., KOHLER. WISCONSIN 53044
37
Bulletins, Etc.
25 790 16
KOHLER.
Engines
Installation Instructions
Retractable Starter Kit
This kit provides a replacement retractable starter. When securing this new starter to the blower housing, it is very important to
engage the pawls in the drive cup bef ore tightening the screws securely.
'1
'X:
.... WARNING
Accidental Starts can cause severe injury or
death.
Disconnect and grotmd 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.
This Kit ContainsQty.
1
1
Description
Starter Assembly, Retractable
Installation Instruction
To lnstall1. Remove the screws securing the starter to the blower
housing. Save the screws and discard the starter.
2. Install the new starter onto the blower housing leaving
the mounting screws slightly loose.
3. Pull the starter handle out until tl1e pawls engage in the
drive cup. Hold the handle in tllis position and tighten
the screws securely. See Figure 1.
8/13 Rev.--
© 2013 by Kohler Co. All rights reserved.
Figure 1. Engage Pawls in Drive Cup, Tighten Screws.
ENGINE DIVISION,KOHLER CO , KOHLER,WISCONSIN 53044
38
Service Update testing is being administered online. If you do not attend the Service Update in person, you are
required to take this test.
Your Central Distributor will provide you with the Access ID and Password. The test can be found online at:
http://www.kohlerengines.com/dealers/certification.htm.
The following pages contain the questions that will be included in the online tests. We will continue with separate
testing for gasoline and diesel. You will only need to take the test(s) that apply to your current technician/dealer status.
Test Questions
1. Loss of torque on the Command Twin
rocker arm pivot mounting screw has
caused valve train failures. What is the new
torque value?
a.
b.
c.
d.
12.4 N•m
100 in. lbs.
165 in. lbs.
318 in. lbs.
2. Secondary Air Injection hose failures on
CV940-1000 are due to extreme heat. What
is the proper repair?
a. Replace with hose part number 25 326 14-S.
b. Replace with brass fitting from Kohler Plumbing
part number C396-454.
c. Replace with hose part number 25 326 14-S
and reflective heat tape.
d. Order and install Long Block 62 523 03.
3. An EFI diagnostic extension lead is now
available making it easier to reach the
plug on some applications. Length of this
harness is about:
a.
b.
c.
d.
8 inches.
20 inches.
1 meter.
6 feet.
4. What is not considered an EFIrepower
opportunity?
a.
b.
c.
d.
ECH749-3007 Toro/Exmark
MCH?49-3003 Golf Cart
ECV680-3001
PCH740-3002
5. To open Kohler PLUS in Windows 8 you
must first launch Internet Explorer 10 from:
a.
b.
c.
d.
the tile view.
the compatibility view.
the desk top view.
the Active X view.
6. An oil filter will now be included with all
. Do not add the oil filter to a
warranty claim for this type of repair.
a.
b.
c.
d.
Short Blocks
Long Blocks
Miniblocks
All of the above.
7. What is the difference between the
24 584 09-S and 24 584 10-S Modules?
a. One has more advance for lower compression
engines.
b. One is ASAM and the other is DSAM.
c. One is for single cylinder engines and the other
is for twins.
d. One has "Bullet" connectors and the other has
"Spade" connectors.
8. Failure to bleed a lifter during engine
assembly can lead to:
a.
b.
c.
d.
aeration of the oil in the crankcase.
ticking lifters when the engine is warmed up.
worn camshaft lobes.
bent push rods and broken rockers.
9. CV940-1000 oil filter housing reassembly
is critical on current build engines. If the
plastic cup is misaligned the drain port
may not seal properly. What symptoms
may result?
a. An oil leak from the base of the oil filter will
occur.
b. Only a loss of system pressure can occur.
c. The engine will run out of fuel because the
pulse pump hose will fill with oil.
d. Pressurized oil can exit the breather hose.
39
Technician’s Service Test
10. The EFI Fuel Pump Module has been
modified to reduce the chance of vapor
lock. What was changed?
a. Fuel system pressure has been raised to 42 psi.
b. A deeper pocket was designed for the check ball
and vent system.
c. The vent line has been moved from the throttle
body to the intake manifold.
d. New pumps will be wrapped with silver reflective
tape.
11. Kohler Service received calls on “white
specks” in the float bowls of XT Series
carburetors. After replacing the carburetor
the problem does not reoccur. Where did
the “Specks” come from?
a.
b.
c.
d.
Aluminum corrosion from ethanol.
Fuel deposits.
Tree sap.
Nylon leached from the fuel tank.
12. Many engines have changed the Champion
spark plug from the RC to XC designation.
Why?
a.
b.
c.
d.
XC spark plugs are more cost effective.
The XC spark plugs run hotter than RC.
The XC spark plugs run cooler than RC.
To meet RFI compliance.
13. The 25 403 21-S Rectifier-Regulator has a
built-in breaker for overvoltage protection.
What is not a method used to reset the
25 403 21-S Rectifier-Regulator?
a.
b.
c.
d.
Engine “Off,” remove the negative battery cable.
Engine “Off,” unplug the Rectifier-Regulator.
Engine “Off,” jump the B+ to ground.
Engine “Off,” remove the green 30 amp battery
fuse.
14. What engine model is offered with a 6:1
gear reduction that is separate from the
crankcase and has its own oil level?
a.
b.
c.
d.
SH265
CH270
CH395
CH440
15. Kohler has released two-barrel carburetors
for both CH and CV Twin engines using
HDAC. What parts are included in the
Standard Overhaul Kit?
a.
b.
c.
d.
Gaskets + Screws + Float + Needle
Gaskets + Screws + Bowl Kit (No Jets)
Gaskets + Screws + Bowl Kit + Jets
Gaskets + Screws + Acc. Pump + Float +
Needle
16. Last year Kohler introduced a special black
cap dipstick for CV PRO 999 Series engines.
When should this cap not be used?
a. When uneven terrain causes the engine to
smoke from the exhaust.
b. When the engine is mounted at an angle causing
exhaust smoke.
c. When the engine serial number is 43000xxxxx
and higher.
d. Both a. and b.
17. EFI Diagnostic Software version 2.11.0007
will work with:
a.
b.
c.
d.
ECH/ECV630-749.
ECV940, 980 and PCH/PCV Propane EFI.
all previous Bosch systems.
All the above.
18. Solenoids on Walbro carburetors are
changing from 1 wire to 2 wire. What engine
model is not changing?
a.
b.
c.
d.
Command Twin
Command Single
Courage Twin
Courage Single
19. A new piston design was released last year
for twins with 83 mm bores. Many of the
ring and piston dimensions have changed.
Aside from the piston skirt, what is the most
significant change?
a.
b.
c.
d.
The increased compression ratio.
There is a larger gap on the second ring.
The lighter weight reduces vibration.
The rings are pinned to keep them from
rotating.
20. The Long Block has become available for
selected engine models and situations
where a short block and heads were
previously needed. What engine model
listed does not currently have a long block
available?
a.
b.
c.
d.
CH960-1000
ECV650-680
ECV940-980
CV730-749
40
Technician’s Service Test
21. The CV940-1000 has a check ball and spring in
the oil pan. Assembly instructions are found in
the Update article. What is the purpose of this
assembly?
a. It regulates oil to 40 psi system pressure.
b. This prevents oil drain-back from the filter and
lubrication circuit after shut-down.
c. This prevents the oil light from turning “On” due to
a false alarm.
d. Both a. and c.
22. If raw fuel (liquid) is found in the fuel pump
module vent line:
a. the needle and seat must be defective and the
FPM must be replaced.
b. the cap must be removed from the vent line and
discarded.
c. it may be the result of normal venting of the
module or fuel condensation.
d. use compressed air to dry the line completely
before reassembly.
23. The Confidant™ has been developed for
commercial durability. What is not a feature of
this engine?
a. Steel fire ring head gaskets.
b. Increased cooling fin area to the cylinders and
heads.
c. Closed loop EFI fuel system.
d. Optional recoil starter with ACR
.
24. Kohler has developed and introduced a new oil
for the CH/CV940-1000 engines to be used above
freezing. What is the weight of this oil?
a.
b.
c.
d.
SAE30
10W-30
20W-50
15W-40
25. MDI ignition systems are replacing DSAI
systems. What feature is not found on the MDI
system?
a. No air gap to measure between the flywheel
magnet and ignition module.
b. Eliminates dependence on 12 volt battery power.
c. Eliminates concern with high voltage transients
input to the module.
d. MDI module uses a capacitor discharge ignition
(CDI) design.
26. When installing a recoil starter, why do you pull
the rope before tightening the mounting screws?
a.
b.
c.
d.
This will center the starter to the cup on the flywheel.
You are checking to see if the rope is too long.
To make sure the handle is secure to the rope.
To make sure the engine spins in the proper direction.
27. What feature of the latest hydraulic lifter
has prompted the change to the up side
down bleeding procedure?
a.
b.
c.
d.
Inverted valving
Solid push rod cup
Torsion wound spring
Cross drilled internal piston
28. CV940-1000 adjustable rocker cylinder
heads are machined different than
nonadjustable and use:
a.
b.
c.
d.
different rockers and pivots.
new roller rocker arms.
a solid lifter and 7/16” pushrods.
hydraulic roller lifters.
29. The importance of using a 10 micron
filter on an EFI engine cannot be
overstated. What is the proper filter to be
used on an EFI engine?
a.
b.
c.
d.
25 050 42-S
24 050 13-S
24 050 03-S
All the above.
30. The 7000 Series has been developed to
replace the Courage Twin engine line.
What is not a feature of this engine?
a.
b.
c.
d.
2dBa quieter than Courage Twin
1.7 liter fuel tank
30% greater flow oil pump
One sided oil and fuel inspection
41
Technician’s Service Test
42
Command PRO Series
Old Spark Advance Module Availability and Use
Analog Spark Advance Modules (ASAM): 24 584 09-S and 24 584 10-S
were used on earlier CH/CV 23 and 25 hp engines before the DSAM,
DSAI and now MDI systems. The Analog and later Digital systems are
not interchangeable.
24 584 09-S
24 584 10-S
Inventory of the 24 584 10-S module has been exhausted, and is no
longer available from Kohler. The 24 584 09-S module is still available.
Functionally the 24 584 09-S and 24 584 10-S are identical as they use
the same timing curve. Their only difference is the 24 584 09-S contains
“Bullet” style connectors and the 24 584 10-S contains “Spade” style
connectors on the red (power) lead and the white (kill) lead, where they
connect to the main engine harness.
The 24 584 10-S modules have been superseded to the 24 584 09-S;
by adding two (2) 1/4” insulated male “Spade” terminals Part No.
15 452 01-S to the kit.
Welder Removal and Replacement Procedures
In 2007 Kohler Engines and Miller Electric/Hobart had worked together to create a complete set of instructions to
remove and replace the Kohler Command engine from the Miller welder. Many dealers have found these instructions,
complete with color pictures, helpful when repairs are necessary.
To date, three engine R&R procedures are now available on-line for separating the engine from Miller and Hobart
branded products (welders/generators/compressors).
These cover R&R on:
1.) Miller/Hobart Welders with Rear Mounted Engines
2.) Miller/Hobart Welders with Front Mounted Engines
3.) Miller “Air-Pak” Units (Welder/Generator/Compressor)
The detailed step-by-step procedures with pictures are
located on the www.kohlerplus.com website, under
“Service Literature” in the “Associated Documents”
section. These should be followed whenever separation of
the engine from the unit is required to avoid unnecessary
labor and product disassembly.
8
Command PRO Series
10-Micron Fuel Filter Options
The importance of using a 10-micron fuel filter on any Kohler EFI
product cannot be overstated. Using a filter with a larger micron rating
will allow larger particles to either plug the filter in the fuel pump module,
damage the fuel pump, or plug up and destroy the fuel injectors.
There are 3 options when installing or replacing a fuel filter on an EFI
engine. Each filter has a recommended service replacement limit.
25 050 42-S
24 050 13-S
25 050 42-S
200 Hours
24 050 13-S
600 Hours
24 050 03-S
1500 Hours
Must Use Support Brackets
Command PRO Single
CH270–440 Expanded Gear Reduction Offerings
Last year Kohler introduced some gear reduction options for the
CH270-395 engines. This year the offerings have expanded to include
the CH440.
CH270 6:1
The 6:1 gearbox is separate from the engine crankcase and has its own
oil level. Use proper engine oil for temperature expected.
CH270-440 2:1 with Wet Clutch
The 2:1 gearbox is separate from the engine crankcase and has its own
dipstick and oil level. Use 20W-40 or 20W-50 oil. The engagement and
disengagement speed of the clutch is 1800 +/- 200 rpm.
CH395-440 6:1
The 6:1 gearbox is part of the crankcase and is lubricated with engine
oil. Use proper engine oil for the temperature expected.
24 050 03-S
15
Command PRO Series
16
XT Series
18
New Product
22
Miscellaneous
New 83 mm Piston Specifications
Last year we introduced the new piston design for the 83 mm bore engines and how it improved emissions. Now
that we have engines in the field running on these pistons, it is time to release the new specifications as they are
significantly different from the previous design. This new piston has narrower rings and ring grooves with a modified
piston skirt.
The second ring on the new pistons functions more as a controlling ring or scraper ring than a compression ring. As a
result a much larger gap is us ed. Please note the difference between the two styles and listed specifications. Piston
style A is the previous piston d esign and style B is the new design.
,.-,
Style "A"
·:
•
-
.
Style "B"
-....
-·- wl '
Specification Differences
Top Ring-to-Groove Side Clearance
Middle Ring-to Groove Side Clearance
Oil Control Ring-to Groove Side Clearance
Top Ring End Gap
New Bore
Used Bore (Max.)
Center Ring End Gap
New Bore
Used Bore (Max.)
Thrust Face 0.0.
New
Max. Wear Limit
Piston Thrust Face-to-Cylinder Bore Clearance
New
Style "A"
Style "B"
0.025/0.048 mm
(0.0010/0.0019 in.)
0.030/0.070 mm
(0.00110.0026 in.)
0.015/0.037 mm
(0.006/0.015 in.)
0.030/0.070 mm
(0.00110.0026 in.)
0.026/0.176 mm
(0.0010/0.0070 in.)
0.060/0.190 mm
(0.0022/0.0073 in.)
0.250/0.560 mm
(0.0100/0.0224 in.)
0.94 mm
(0.037 in.)
0.189/0.277 mm
(0.0074/0.0109 in.)
0.531 mm
(0.0209 in.)
0.250/0.560 mm
(0.0100/0.0224 in.)
0.94 mm
(0.037 in.)
1.519/1.797 mm
(0.0598/0.0708 in.)
2.051 mm
(0.0808 in.)
82.947 mm
(3.2656 in.)
82.802 mm
(3.2599 in.)
82.978 mm
(3.2668 in.)
82.833 mm
(3.2611 in.)
0.06/0.100 mm
(0.0023/0.0039 in.)
0.019/0.062 mm
(0.0007/0.0024 in.)
Oil Filter Supplied with All Short Blocks, Long Blocks, and Miniblocks
Effective with Serial Number 43021xxxxx (January 21, 2013), a 12 050 01-S Oil Filter has been included with all
Command, Courage, and Aegis engine Short Blocks, Long Blocks, and Miniblocks.
When servicing is performed using any of these assemblies, please keep in mind it is no longer necessary or
appropriate to order or charge for an oil filter as a separate item. The cost of the filter is included in the assembly.
Kohler warranty has already provided a 10 month grace period to use existing and field inventory which formerly did
not contain a filter, and in most cases, has allowed the filters when claimed separately.
All warranty claims submitted using these sub-assemblies will also require the Serial Number of the new block
assembly being used, or the claim will be returned for this information before processing. The filter will be removed
from any claims listing the filter separately based on the implementation date.
24
Miscellaneous
Kohler Engine Model Changes
SAE J1940
Improved engine design and manufacturing technologies over the past decade have reduced variations in the power
output of small engines. This has prompted the SAE to update its standardized rating procedure. The new standard
requires all engines produced from October 1, 2013 must be within 95% of the declared rated power and torque as
opposed to the old standard of 85%. SAE has also stated that the engine manufacturer must disclose the rpm for
rating and gross vs. net.
Phase 3/Tier 3 Emission Regulations
As emission regulations continue to tighten, Kohler has implemented two-barrel carburetors on some models to
improve engine performance and emission ratings with the ability to tune each cylinder on the larger horsepower twin
cylinder engines. Models using the heavy-duty air cleaners have been converted to the new carburetors. To easily
identify these engines, the model numbers were changed on the third digit to signify the two-barrel design.
Effective October 2013 Kohler Engines made changes to some of the engine models, ratings, and displacements.
Past Models
Model Year 2014
Commercial
Model Number
J1940 Hp
Displacement
(cc)
Model Number
J1940 Hp
Displacement
(cc)
ECV630
19
694
ECV630
19
694
ECV650
21
694
ECV650
21
694
ECV680
23
694
ECV680
ECV730
25
747
ECV730
23
747
ECV740
27
747
ECV740
25
747
ECV749
29
747
ECV749
26.5
747
ECV940
34
999
ECV940
33
999
ECV980
38
999
ECV980
35.5
999
Discontinued
Gross Rated @ 3600 rpm
Model Number
J1940 Hp
Displacement
(cc)
CV620
18
624
CV640
21
624
CV680
23
674
CV730
25
725
CV740
27
725
CV750
30
747
CV940
34
999
CV960
36
999
CV980
38
999
CV1000
40
999
CV980
35
999
CV1000
37
999
Gross Rated @ 3600 rpm
25
Miscellaneous
Model Number
J1940 Hp
Model Number
J1940 Hp
Displacement
(cc)
Displacement
(cc)
ECH630
19
694
21
694
ECH630
19
694
ECH650
ECH650
21
694
ECH680
ECH680
23
694
ECH730
23
747
ECH730
25
747
ECH740
25
747
ECH740
27
747
ECH749
26.5
747
ECH749
29
747
Discontinued
Gross Rated @ 3600 rpm
Model Number
J1940 Hp
Displacement
(cc)
CH620
19
674
CH640
20.5
674
CH680
22.5
674
CH682
22.5
694
CH730
23.5
725
CH732
23.5
747
CH740
25
725
CH742
25
747
CH750
27
747
CH752
27
747
CH940
32.5
999
Model Number
J1940 Hp
Displacement
(cc)
CH620
18
624
CH640
22
624
CH680
23
674
CH730
25
725
CH740
27
725
CH750
30
747
CH940
34
999
CH960
CH960
36
999
CH980
35
999
CH980
38
999
CH1000
37
999
CH1000
40
999
Model Number
J1940 Hp
Displacement
(cc)
LH640
24
624
LH690
26
674
LH755
28
747
LH775
31
747
Discontinued
Gross Rated @ 3600 rpm
26
Miscellaneous
Small Horizontal
Model Number
J1940 Hp
Displacement
(cc)
Model Number
J1940 Hp
Displacement
(cc)
RH265
6.5
196
RH265
6.5
196
SH265
6.5
196
SH265
6.5
196
CH260
6
208
CH260
6
208
CH270
7
208
CH270
7
208
CH395
9.5
277
CH395
9.5
277
CH440
14
429
CH440
14
429
Gross Rated @ 4000 rpm
Consumer Walk
Model Number
J1940 Tq
Displacement
(cc)
Model Number
J1940 Tq
Displacement
(cc)
XT650
6.5
149
XT650
6.5
149
XT675
6.75
149
XT675
6.75
149
XT775
7.75
149
XT800
8
173
XT800
Discontinued
Gross Rated @ 2800 rpm
Consumer Twin
Model Number
J1940 Hp
Model Number
J1940 Hp
Displacement
(cc)
Displacement
(cc)
KT715
20
725
SV710/810
20
725
KT725
22
725
SV715
22
725
KT730
23
725
SV720/820
23
725
KT735
24
725
SV725
24
725
KT740
25
725
SV730/830
25
725
KT745
26
747
SV735
26
725
Discontinued
27
SV740/840
27
725
Gross Rated @ 3600 rpm
27
Technician’s Service Test
10. The EFI Fuel Pump Module has been
modified to reduce the chance of vapor
lock. What was changed?
a. Fuel system pressure has been raised to 42 psi.
b. A deeper pocket was designed for the check ball
and vent system.
c. The vent line has been moved from the throttle
body to the intake manifold.
d. New pumps will be wrapped with silver reflective
tape.
11. Kohler Service received calls on “white
specks” in the float bowls of XT Series
carburetors. After replacing the carburetor
the problem does not reoccur. Where did
the “Specks” come from?
a.
b.
c.
d.
Aluminum corrosion from ethanol.
Fuel deposits.
Tree sap.
Nylon leached from the fuel tank.
12. Many engines have changed the Champion
spark plug from the RC to XC designation.
Why?
a.
b.
c.
d.
XC spark plugs are more cost effective.
The XC spark plugs run hotter than RC.
The XC spark plugs run cooler than RC.
To meet RFI compliance.
13. The 25 403 21-S Rectifier-Regulator has a
built-in breaker for overvoltage protection.
What is not a method used to reset the
25 403 21-S Rectifier-Regulator?
a.
b.
c.
d.
Engine “Off,” remove the negative battery cable.
Engine “Off,” unplug the Rectifier-Regulator.
Engine “Off,” jump the B+ to ground.
Engine “Off,” remove the green 30 amp battery
fuse.
14. What engine model is offered with a 6:1
gear reduction that is separate from the
crankcase and has its own oil level?
a.
b.
c.
d.
SH265
CH270
CH395
CH440
15. Kohler has released two-barrel carburetors
for both CH and CV Twin engines using
HDAC. What parts are included in the
Standard Overhaul Kit?
a.
b.
c.
d.
Gaskets + Screws + Float + Needle
Gaskets + Screws + Bowl Kit (No Jets)
Gaskets + Screws + Bowl Kit + Jets
Gaskets + Screws + Acc. Pump + Float +
Needle
16. Last year Kohler introduced a special black
cap dipstick for CV PRO 999 Series engines.
When should this cap not be used?
a. When uneven terrain causes the engine to
smoke from the exhaust.
b. When the engine is mounted at an angle causing
exhaust smoke.
c. When the engine serial number is 43000xxxxx
and higher.
d. Both a. and b.
17. EFI Diagnostic Software version 2.11.0007
will work with:
a.
b.
c.
d.
ECH/ECV630-749.
ECV940, 980 and PCH/PCV Propane EFI.
all previous Bosch systems.
All the above.
18. Solenoids on Walbro carburetors are
changing from 1 wire to 2 wire. What engine
model is not changing?
a.
b.
c.
d.
Command Twin
Command Single
Courage Twin
Courage Single
19. A new piston design was released last year
for twins with 83 mm bores. Many of the
ring and piston dimensions have changed.
Aside from the piston skirt, what is the most
significant change?
a.
b.
c.
d.
The increased compression ratio.
There is a larger gap on the second ring.
The lighter weight reduces vibration.
The rings are pinned to keep them from
rotating.
20. The Long Block has become available for
selected engine models and situations
where a short block and heads were
previously needed. What engine model
listed does not currently have a long block
available?
a.
b.
c.
d.
CH960-1000
ECV650-680
ECV940-980
CV730-749
40
Technician’s Service Test
21. The CV940-1000 has a check ball and spring in
the oil pan. Assembly instructions are found in
the Update article. What is the purpose of this
assembly?
a. It regulates oil to 40 psi system pressure.
b. This prevents oil drain-back from the filter and
lubrication circuit after shut-down.
c. This prevents the oil light from turning “On” due to
a false alarm.
d. Both a. and c.
22. If raw fuel (liquid) is found in the fuel pump
module vent line:
a. the needle and seat must be defective and the
FPM must be replaced.
b. the cap must be removed from the vent line and
discarded.
c. it may be the result of normal venting of the
module or fuel condensation.
d. use compressed air to dry the line completely
before reassembly.
23. The Confidant™ has been developed for
commercial durability. What is not a feature of
this engine?
a. Steel fire ring head gaskets.
b. Increased cooling fin area to the cylinders and
heads.
c. Closed loop EFI fuel system.
d. Optional recoil starter with ACR
.
24. Kohler has developed and introduced a new oil
for the CH/CV940-1000 engines to be used above
freezing. What is the weight of this oil?
a.
b.
c.
d.
SAE30
10W-30
20W-50
15W-40
25. MDI ignition systems are replacing DSAI
systems. What feature is not found on the MDI
system?
a. No air gap to measure between the flywheel
magnet and ignition module.
b. Eliminates dependence on 12 volt battery power.
c. Eliminates concern with high voltage transients
input to the module.
d. MDI module uses a capacitor discharge ignition
(CDI) design.
26. When installing a recoil starter, why do you pull
the rope before tightening the mounting screws?
a.
b.
c.
d.
This will center the starter to the cup on the flywheel.
You are checking to see if the rope is too long.
To make sure the handle is secure to the rope.
To make sure the engine spins in the proper direction.
27. What feature of the latest hydraulic lifter
has prompted the change to the up side
down bleeding procedure?
a.
b.
c.
d.
Inverted valving
Solid push rod cup
Torsion wound spring
Cross drilled internal piston
28. CV940-1000 adjustable rocker cylinder
heads are machined different than
nonadjustable and use:
a.
b.
c.
d.
different rockers and pivots.
new roller rocker arms.
a solid lifter and 7/16” pushrods.
hydraulic roller lifters.
29. The importance of using a 10 micron
filter on an EFI engine cannot be
overstated. What is the proper filter to be
used on an EFI engine?
a.
b.
c.
d.
25 050 42-S
24 050 13-S
24 050 03-S
All the above.
30. The 7000 Series has been developed to
replace the Courage Twin engine line.
What is not a feature of this engine?
a.
b.
c.
d.
2dBa quieter than Courage Twin
1.7 liter fuel tank
30% greater flow oil pump
One sided oil and fuel inspection
41
Technician’s Service Test
42