Troy-Bilt 17AF2ACP766 Zero Turn Mower Owner Manual

Troy-Bilt 17AF2ACP766 Zero Turn Mower Owner Manual
OWNER'S MANUAL
COURAGE™ SERIES
SV710-740
VERTICAL CRANKSHAFT
Safety Precautions
To ensure safe operation please read the following statements and understand their meaning. Also refer to
your equipment owner's manual for other important safety information. This manual contains safety
precautions which are explained below. Please read carefully.
WARNING
Warning is used to indicate the presence of a hazard that can cause severe personal injury, death, or
substantial property damage if the warning is ignored.
CAUTION
Caution is used to indicate the presence of a hazard that will or can cause minor personal injury or
property damage if the caution is ignored.
NOTE
Note is used to notify people of installation, operation, or maintenance information that is important
but not hazard-related.
For Your Safety!
These precautions should be followed at all times. Failure to follow these precautions could result in injury to
yourself and others.
WARNING
WARNING
Explosive Fuel can cause fires and
severe burns.
Rotating Parts can cause severe
injury.
Do not fill the fuel tank while the
engine is hot or running.
Stay away while engine is in
operation.
Explosive Fuel!
Gasoline is extremely flammable and its
vapors can explode if ignited. Store
gasoline only in approved containers, in
well ventilated, unoccupied buildings,
away from sparks or flames. Do not fill
the fuel tank while the engine is hot or
running, since spilled fuel could ignite if
it comes in contact with hot parts or
sparks from ignition. Do not start the
engine near spilled fuel. Never use
gasoline as a cleaning agent.
Rotating Parts!
Keep hands, feet, hair, and clothing away
from all moving parts to prevent injury.
Never operate the engine with covers,
shrouds, or guards removed.
Hot Parts can cause severe burns.
Do not touch engine while operating
or just after stopping.
Hot Parts!
Engine components can get extremely hot
from operation. To prevent severe burns,
do not touch these areas while the engine
is running, or immediately after it is
turned off. Never operate the engine with
heat shields or guards removed.
CAUTION
California
Proposition 65 Warning
Electrical Shock can cause injury.
Do not touch wires while engine is
running.
Electrical Shock!
Never touch electrical wires or
components while the engine is running.
They can be sources of electrical shock.
2
WARNING
Engine exhaust from this product
contains chemicals known to the State
of California to cause cancer, birth
defects, or other reproductive harm.
Safety Precautions (Cont.)
WARNING
Accidental Starts can cause severe
injury or death.
Disconnect and ground spark plug
leads before servicing.
Accidental Starts!
Disabling engine. Accidental starting
can cause severe injury or death.
Before working on the engine or
equipment, disable the engine as follows:
1) Disconnect the spark plug lead(s). 2)
Disconnect negative (-) battery cable from
battery.
WARNING
Carbon Monoxide can cause severe
nausea, fainting or death.
Avoid inhaling exhaust fumes, and
never run the engine in a closed
building or confined area.
Lethal Exhaust Gases!
Engine exhaust gases contain poisonous
carbon monoxide. Carbon monoxide is
odorless, colorless, and can cause death if
inhaled. Avoid inhaling exhaust fumes,
and never run the engine in a closed
building or confined area.
WARNING
Explosive Gas can cause fires and
severe acid burns.
Charge battery only in a well
ventilated area. Keep sources of
ignition away.
Explosive Gas!
Batteries produce explosive hydrogen gas
while being charged. To prevent a fire or
explosion, charge batteries only in well
ventilated areas. Keep sparks, open
flames, and other sources of ignition
away from the battery at all times. Keep
batteries out of the reach of children.
Remove all jewelry when servicing
batteries.
Before disconnecting the negative
(-) ground cable, make sure all switches
are OFF. If ON, a spark will occur at the
ground cable terminal which could cause
an explosion if hydrogen gas or gasoline
vapors are present.
Congratulations – You have selected a fine four-cycle, twin cylinder, air-cooled engine. Kohler designs long life
strength and on-the-job durability into each engine...making a Kohler engine dependable...dependability you
can count on. Here are some reasons why:
• Efficient overhead valve design, and pressure lubrication provide maximum power, torque, and
reliability under all operating conditions.
• Dependable, maintenance-free electronic ignition ensures fast, easy starts time after time.
• Kohler engines are easy to service. All routine service areas (like the dipstick and oil fill, air cleaner, spark
plugs, and carburetor) are easily and quickly accessible.
• Parts subject to the most wear and tear (like the cylinder liner and camshaft) are made from precision
formulated cast iron.
• Every Kohler engine is backed by a worldwide network of over 10,000 distributors and dealers. Service
support is just a phone call away. Call 1-800-544-2444 (U.S. & Canada) for Sales & Service assistance.
To keep your engine in top operating condition, follow the maintenance procedures in this manual.
3
Oil Fill/
Dipstick
Air Cleaner
Access Door
Air Cleaner Access
Door Handle
Rectifier-Regulator
Electric
Starter
Spark Plug
Fuel Pump
Oil Filter
Identification Plate
Figure 1. Typical Courage™ Series Vertical Shaft Engine.
Oil Recommendations
Using the proper type and weight of oil in the
crankcase is extremely important. So is checking oil
daily and changing oil regularly. Failure to use the
correct oil, or using dirty oil, causes premature engine
wear and failure.
Oil Type
Use high quality detergent oil of API (American
Petroleum Institute) service class SG, SH, SJ or higher.
Select the viscosity based on the air temperature at the
time of operation as shown in the following table.
**
A logo or symbol on oil containers identifies the API
service class and SAE viscosity grade. See Figure 3.
*
*Use of synthetic oil having 5W-20 or 5W-30 rating is acceptable,
up to 4°C (40°F).
**Synthetic oils will provide better starting in extreme cold below
23°C (-10°F).
Figure 2. Viscosity Grades Table.
NOTE: Using other than service class SG, SH, SJ or
higher oil or extending oil change intervals
longer than recommended can cause engine
damage.
4
NOTE: Synthetic oils meeting the listed classifications
may be used with oil changes performed at
the recommended intervals. However to allow
piston rings to properly seat, a new or rebuilt
engine should be operated for at least 50 hours
using standard petroleum based oil before
switching to synthetic oil.
Figure 3. Oil Container Logo.
Refer to “Maintenance Instructions” beginning on
page 7 for detailed oil check, oil change, and oil filter
change procedures.
Fuel Recommendations
WARNING: Explosive Fuel!
Gasoline is extremely flammable and its vapors can explode if
ignited. Store gasoline only in approved containers, in well
ventilated, unoccupied buildings, away from sparks or flames.
Do not fill the fuel tank while the engine is hot or running,
since spilled fuel could ignite if it comes in contact with hot parts
or sparks from ignition. Do not start the engine near spilled fuel.
Never use gasoline as a cleaning agent.
General Recommendations
Purchase gasoline in small quantities and store in
clean, approved containers. A container with a
capacity of 2 gallons or less with a pouring spout is
recommended. Such a container is easier to handle and
helps eliminate spillage during refueling.
Record your engine identification numbers on the
identification label (Figure 4) for future reference.
IMPORTANT ENGINE INFORMATION
THIS ENGINE MEETS U.S. EPA AND CA 2005 AND
LATER AND EC STAGE II (SN:4) EMISSION REGS
FOR SI SMALL OFF–ROAD ENGINES
FAMILY
TYPE APP
DISPL. (CC)
MODEL NO.
SPEC. NO.
SERIAL NO.
BUILD DATE
OEM PROD. NO.
EMISSION COMPLIANCE PERIOD:
EPA:
CARB:
CERTIFIED ON:
REFER TO OWNER'S MANUAL FOR HP RATING,
SAFETY, MAINTENANCE AND ADJUSTMENTS
1-800-544-2444 www.kohlerengines.com
Do not use gasoline left over from the previous season,
to minimize gum deposits in your fuel system and to
ensure easy starting.
Do not add oil to the gasoline.
Do not overfill the fuel tank. Leave room for the fuel to
expand.
Fuel Type
For best results use only clean, fresh, unleaded gasoline
with the pump sticker octane rating of 87 or higher. In
countries using the Research method, it should be 90
octane minimum.
Unleaded gasoline is recommended as it leaves less
combustion chamber deposits and reduces harmful
exhaust emissions. Leaded gasoline is not
recommended.
Gasoline/Alcohol blends
Gasohol (up to 10% ethyl alcohol, 90% unleaded
gasoline by volume) is approved as a fuel for Kohler
engines. Other gasoline/alcohol blends are not
approved.
Gasoline/Ether blends
Methyl Tertiary Butyl Ether (MTBE) and unleaded
gasoline blends (up to a maximum of 15% MTBE by
volume) are approved as a fuel for Kohler engine.
Other gasoline/ether blends are not approved.
Engine Identification Numbers
When ordering parts, or in any communication
involving an engine, always give the Model,
Specification, and Serial Numbers of the engine.
N11236
KOHLER CO. KOHLER, WISCONSIN USA
Figure 4. Engine Identification Label.
The Emission Compliance Period referred to on the
Emission Control or Air Index label indicates the
number of operating hours for which the engine has
been shown to meet Federal and CARB emission
requirements. The following table provides the Engine
Compliance Period (in hours) associated with the
category descriptor found on the certification label.
Emission Compliance Period (Hours)
EPA
Category C
250 hours
Category B
500 hours
CARB
Moderate
125 hours
Intermediate Extended
500 hours
250 hours
Category A
1000 hours
Refer to certification label for engine displacement.
Exhaust Emission Control System for models
SV710-740 is EM.
Model Designation
Model SV730 for example: S designates Courage engine,
V designates vertical crankshaft, and 730 indicates the
numerical model designation. A letter suffix designates
a specific version as follows:
Suffix Designates
S
Electric Start
The engine identification numbers appear on a decal
(or decals) affixed to the engine shrouding. Include
letter suffixes, if there are any.
5
Operating Instructions
Also read the operating instructions of the equipment this
engine powers.
Pre-Start Checklist
• Check oil level. Add oil if low. Do not overfill.
• Check fuel level. Add fuel if low.
• Check cooling air intake areas and external
surfaces of engine. Make sure they are clean and
unobstructed.
• Check that the air cleaner components and all
shrouds, equipment covers, and guards are in
place and securely fastened.
• Check that any clutches or transmissions are
disengaged or placed in neutral. This is especially
important on equipment with hydrostatic drive.
The shift lever must be exactly in neutral to
prevent resistance which could keep the engine
from starting.
WARNING: Lethal Exhaust Gases!
Engine exhaust gases contain poisonous carbon monoxide.
Carbon monoxide is odorless, colorless, and can cause death if
inhaled. Avoid inhaling exhaust fumes, and never run the
engine in a closed building or confined area.
NOTE: If the engine develops sufficient speed to
disengage the starter but does not keep
running (a false start), engine rotation must
be allowed to come to a complete stop before
attempting to restart the engine.
If the starter is engaged while the flywheel is rotating,
the starter pinion and flywheel ring gear may clash,
resulting in damage to the starter.
If the starter does not turn the engine over, shut off
starter immediately. Do not make further attempts to
start the engine until the condition is corrected. Do not
jump start using another battery (refer to “Battery”).
See your Kohler Engine Service Dealer for service
assistance.
3. For a Cold Engine – Gradually return the choke
control to the “off” position after the engine
starts and warms up.
The engine/equipment may be operated during
the warm-up period, but it may be necessary to
leave the choke partially on until the engine
warms up.
4. For a Warm Engine – Return choke to “off”
position as soon as engine starts.
Stopping
Cold Weather Starting Hints
1. Be sure to use the proper oil for the temperature
expected. See Figure 2 on page 4.
2. Declutch all possible external loads.
3. Be sure the battery is in good condition. A warm
battery has much more starting capacity than a
cold battery.
4. Use fresh winter grade fuel. NOTE: Winter grade
gasoline has higher volatility to improve
starting. Do not use gasoline left over from
summer.
Starting
1. Place the throttle control midway between the
“slow” and “fast” positions. Place the choke
control into the “on” position.
2. Start the engine by activating the key switch.
Release the switch as soon as the engine starts.
NOTE: Do not crank the engine continuously for
more than 10 seconds at a time. If the engine
does not start, allow a 60 second cool down
period between starting attempts. Failure to
follow these guidelines can burn out the
starter motor.
6
1. Remove the load by disengaging all PTO driven
attachments.
2. For Engines without a Shutdown Solenoid:
Move the throttle to the ‘‘slow’’ or ‘‘low’’ idle
position. Allow the engine to run at idle for 30-60
seconds; then stop the engine.
For Engines Equipped with a Shutdown
Solenoid: Position the throttle control between
half and full throttle; then stop the engine.
Battery
A 12 volt battery is normally used. Refer to the
operating instructions of the equipment this engine
powers for specific battery requirements.
If the battery charge is not sufficient to crank the
engine, recharge the battery.
Operating
Angle of Operation
This engine will operate continuously at angles up to
25°. Check oil level to assure crankcase oil level is at
the “FULL” or “F” mark on the dipstick.
Refer to the operating instructions of the equipment
this engine powers. Because of equipment design or
application, there may be more stringent restrictions
regarding the angle of operation.
NOTE: Do not operate this engine continuously at
angles exceeding 25° in any direction. Engine
damage could result from insufficient
lubrication.
Cooling
NOTE: If debris builds up on the grass screen or other
cooling areas, stop the engine immediately
and clean. Operating the engine with blocked
or dirty air intake and cooling areas can cause
extensive damage due to overheating. See
Clean Air Intake/Cooling Area.
WARNING: Hot Parts!
Engine components can get extremely hot from operation. To
prevent severe burns, do not touch these areas while the engine
is running, or immediately after it is turned off. Never operate
the engine with heat shields or guards removed.
Engine Speed
NOTE: Do not tamper with the governor setting to
increase the maximum engine speed.
Overspeed is hazardous and will void the
engine warranty. The maximum allowable
high idle speed for these engines is 3750 RPM,
no load.
Maintenance Instructions
Maintenance, repair, or replacement of the emission control devices and systems, which are being done at the
customers expense, may be performed by any non-road engine repair establishment or individual. Warranty
repairs must be performed by an authorized Kohler service outlet.
WARNING: Accidental Starts!
Disabling engine. Accidental starting can cause severe injury or death. Before working on the engine or
equipment, disable the engine as follows: 1) Disconnect the spark plug lead(s). 2) Disconnect negative (-) battery
cable from battery.
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
Every 25 Hours
•
•
•
•
•
Every 50 Hours
• Check air cleaner element, clean or replace as necessary¹.
Annually or
Every 100 Hours
•
•
•
•
•
•
Daily Or Before
Starting Engine
Every 300 Hours
Every 500 Hours
1
2
Maintenance Required
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.
Replace air cleaner element and precleaner¹.
Change oil and oil filter (more frequently under severe conditions).
Remove cooling shrouds and clean cooling areas¹.
Check oil cooler fins, clean as necessary (if equipped).
Replace fuel filter.
Check spark plug condition and gap.
• Have valve lash checked/adjusted2.
• Have bendix starter drive serviced2.
• Have solenoid shift starter disassembled and cleaned2.
Perform these maintenance procedures more frequently under extremely dusty, dirty conditions.
Have a Kohler Engine Service Dealer perform these services.
Check Oil Level
The importance of checking and maintaining the
proper oil level in the crankcase cannot be
overemphasized. Check oil BEFORE EACH USE as
follows:
1. Make sure the engine is stopped, level, and is cool
so the oil has had time to drain into the sump.
2. To keep dirt, debris, etc., out of the engine, clean
the area around the dipstick before removing it.
7
3. Unscrew and remove the dipstick; wipe oil off.
Reinsert the dipstick into the tube and rest the
cap on the tube. Do not screw the cap onto the
tube. See Figure 5.
Oil Sentry™
Some engines are equipped with an optional Oil
Sentry™ oil pressure switch. If the oil pressure drops
below an acceptable level, the Oil Sentry™ will either
shut off the engine or activate a warning signal,
depending on the application.
NOTE: Make sure the oil level is checked BEFORE
EACH USE and is maintained up to the
“FULL” or “F” mark on the dipstick. This
includes engines equipped with Oil Sentry™.
Change Oil and Filter, Service Oil Cooler
Figure 5. Checking Oil Level.
4. Pull the dipstick out and check the oil level. The
oil level should be up to, but not over, the “FULL”
or “F” mark on the dipstick. See Figure 6.
Change Oil and Oil Filter
Change the oil and oil filter annually or every 100
hours of operation (more frequently under severe
conditions). Refill with service class SG, SH, SJ, or
higher oil as specified in the ‘‘Viscosity Grades’’ table
(Figure 2) on page 4. Always use a genuine Kohler oil
filter. Use chart below to determine part number to
order.
Oil Filter Part No.
Length
12 050 01-S
2-1/2"
52 050 02-S
3-3/8"
Change the oil while the engine is still warm. The oil
will flow more freely and carry away more
impurities. Make sure the engine is level when filling,
checking, or changing the oil.
Starter
Figure 6. Oil Level Dipstick (Typical).
5. If the level is low, add oil of the proper type, up to
the “FULL” or “F” mark on the dipstick. (Refer to
“Oil Type” on page 4.) Always check the level
with the dipstick before adding more oil.
Oil Drain Plug
Figure 7. Oil Drain Plug.
NOTE: To prevent extensive engine wear or damage,
always maintain the proper oil level in the
crankcase. Never operate the engine with the
oil level below the “ADD” or “L” mark or
above the “FULL” or “F” mark on the
dipstick.
4. Remove dipstick and check oil level. The level
should be between the “Full or F” and “Add or L”
marks. If low, add oil of the proper type up to the
full mark. Reinstall oil fill cap/dipstick and screw
tight.
Oil Filter
Figure 8. Oil Filter Location.
8
Change the oil and oil filter as follows.
1. The drain plug is located on the starter side of the
oil pan. See Figure 7. Clean the area around the oil
drain plug and the oil fill cap/dipstick.
2. Remove the drain plug and the oil fill cap/
dipstick.
Mounting
Screws
3. Allow the oil to drain and then reinstall the drain
plug. Tighten 13.6 N·m (10 ft. lb.).
4. Remove the old filter and wipe off the filter
adapter with a clean cloth.
5. Place a new replacement filter in a shallow pan
with the open end up. Pour new oil, of the proper
type, in through the threaded center hole. Stop
pouring when the oil reaches the bottom of the
threads. Allow a minute or two for the oil to be
absorbed by the filter material.
6. Apply a thin film of clean oil to the rubber gasket
on the new oil filter.
Figure 9. Cleaning Outside of Oil Cooler.
To service the oil cooler, clean the outside of fins with
a soft brush. See Figure 9. Remove the mounting
screws holding the cooler unit to the blower housing.
Tilt the cooler outward as shown in Figure 10. Clean
the inside of the cooler with a brush or with
compressed air. After cleaning, reinstall the oil cooler
to the blower housing with the mounting screws.
7. Install the new oil filter to the filter adapter. Hand
tighten the filter clockwise until the rubber
gasket contacts the adapter, then tighten the filter
an additional 3/4-1 turn.
8. Fill the engine with the proper oil to the “FULL”
or “F” mark on the dipstick. Always check the oil
level with the dipstick before adding more oil.
9. Reinstall the oil fill cap/dipstick and tighten
securely.
Figure 10. Cleaning Inside of Oil Cooler.
10. Start the engine and check for oil leaks. Recheck
oil level before placing the engine into service.
Stop the engine, correct any leaks, and allow a
minute for the oil to drain down, then recheck the
level on the dipstick.
NOTE: To prevent extensive engine wear or damage,
always maintain the proper oil level in the
crankcase. Never operate the engine with the
oil level below the “ADD” or “L” mark or
above the “FULL” or “F” mark on the
dipstick.
Service Oil Cooler
Some engines are equipped with an optional oil cooler.
Inspect and clean the oil cooler annually or every 100
hours of operation (more frequently under severe
conditions). Oil cooler must be kept free of debris.
Service Precleaner and Air Cleaner
Element
These engines are equipped with a replaceable, high
density paper air cleaner element. Some engines are
also equipped with an oiled, foam precleaner which
surrounds the paper element. See Figure 11. Two
different capacity air cleaner systems are available.
Check the air cleaner daily or before starting the
engine. Check for a buildup of dirt and debris around
the air cleaner system. Keep this area clean. Also check
for loose or damaged components. Replace all bent or
damaged air cleaner components.
NOTE: Operating the engine with loose or damaged
air cleaner components could allow unfiltered
air into the engine causing premature wear
and failure.
9
6. Close and latch the door.
Precleaner (Some Models)
7. When precleaner replacement is necessary order
genuine Kohler Parts.
Door
32 083 05-S Precleaner
37 mm (1.45 in.) high
32 083 08-S Precleaner
71 mm (2.79 in.) high
Latch
Air Cleaner Element
Figure 11. Air Cleaner System.
Service Paper Element
Check the paper element every 50 hours of operation,
(more often under extremely dusty or dirty
conditions). Clean or replace the element as necessary.
Replace the air cleaner element annually, or every 100
hours.
1. Open the door on the blower housing to access
the air cleaner element. See Figure 11.
Unhooked
Latch
2. Unhook the latch and remove the air cleaner
element and precleaner (if equipped). See Figure
12.
3. Remove the precleaner (if so equipped) from the
paper element. Service the precleaner as
described in “Precleaner Service”.
Figure 12. Unhooking Latch.
Service Precleaner
If so equipped, wash and reoil the precleaner every 25
hours of operation (more often under extremely dusty
or dirty conditions). Replace the precleaner annually
or every 100 hours.
1. Open the door on the blower housing to access
the air cleaner element and precleaner. See Figure
11.
2. Unhook the latch and remove the precleaner from
the air cleaner element, or remove as an assembly
for servicing. Make sure the base and the sealing
area is clean before reassembly is performed. See
Figure 12.
3. Wash the precleaner in warm water with
detergent. Rinse the precleaner thoroughly until
all traces of detergent are eliminated. Squeeze out
excess water (do not wring). Allow the precleaner
to air dry.
4. Saturate the precleaner with new engine oil.
Squeeze out all excess oil.
5. Reinstall the precleaner over the paper element
and secure with the latch.
10
4. Gently tap the paper element to dislodge dirt. Do
not wash the paper element or use pressurized
air, as this will damage the element. Replace a
dirty, bent, or damaged element with a genuine
Kohler part. Handle the new element carefully; do
not use if the sealing surfaces are bent or
damaged.
32 083 03-S Element
44 mm (1.73 in.) high
32 083 06-S Element
78 mm (3.07 in.) high
5. Clean the air cleaner base as required and check
condition.
6. Reinstall the precleaner (if equipped) over the
paper air cleaner element and install on the base.
Secure with the latch.
7. Close and latch the door.
Clean Air Intake/Cooling Areas
To ensure proper cooling, make sure the grass screen,
cooling fins, and other external surfaces of the engine
are kept clean at all times.
Every 100 hours of operation (more often under
extremely dusty, dirty conditions), remove the blower
housing and other cooling shrouds. Clean the cooling
fins and external surfaces as necessary. Make sure the
cooling shrouds are reinstalled.
NOTE: Operating the engine with a blocked grass
screen, dirty or plugged cooling fins, and/or
cooling shrouds removed, will cause engine
damage due to overheating.
Ignition System
These engines use an electronic Capacitive Discharge
(CD) ignition system. Other than periodically
checking/replacing the spark plugs, no maintenance,
timing, or adjustments are necessary or possible with
this system.
Check Spark Plugs
Every 100 hours of operation, remove the spark plugs,
check condition, and reset the gap or replace with new
plugs as necessary. The standard spark plug is a
Champion® RC12YC (Kohler Part No. 12 132 02-S). RFI
complaint engines use a Champion® XC12YC (Kohler
Part No. 25 132 14-S) spark plug. A high-performance
spark plug, Champion® Platinum 3071 (Kohler Part
No. 25 132 12-S) is also available. Equivalent alternate
brand plugs can also be used.
1. Before removing the spark plug, clean the area
around the base of the plug to keep dirt and
debris out of the engine.
2. Remove the plug and check its condition. Replace
the plug if worn or reuse is questionable.
Battery Charging
WARNING: Explosive Gas!
Batteries produce explosive hydrogen gas while being charged.
To prevent a fire or explosion, charge batteries only in well
ventilated areas. Keep sparks, open flames, and other sources of
ignition away from the battery at all times. Keep batteries out of
the reach of children. Remove all jewelry when servicing
batteries.
Before disconnecting the negative (-) ground cable, make sure
all switches are OFF. If ON, a spark will occur at the ground
cable terminal which could cause an explosion if hydrogen gas
or gasoline vapors are present.
Fuel System
Fuel Filter
Some engines are equipped with an in-line fuel filter.
Periodically inspect the filter and replace with a
genuine Kohler filter every 100 operating hours.
Fuel Line
In compliance with CARB Tier III Emission
Regulations, these engines use Low Permeation SAE
30 R7 rated fuel line; certified to meet CARB
requirements. Standard fuel line may not be used.
Order replacement hose by part number through a
Kohler Engine Service Dealer.
NOTE: Do not clean the spark plug in a machine
using abrasive grit. Some grit could remain
in the spark plug and enter the engine
causing extensive wear and damage.
3. Check the gap using a wire feeler gauge. Adjust
the gap to 0.76 mm (0.030 in.) by carefully
bending the ground electrode. See Figure 13.
4. Reinstall the spark plug into the cylinder head.
Torque the spark plug to 24.4-29.8 N·m
(18-22 ft. lb.).
Wire Gauge
Figure 14. Low Permeation Fuel Line.
Spark Plug
Ground
Electrode
0.76 mm
(0.030 in.) Gap
Figure 13. Servicing Spark Plug.
11
Carburetor Troubleshooting and
Adjustments
In compliance with government emission standards,
the carburetor is calibrated to deliver the correct fuelto-air mixture to the engine under all operating
conditions. The high speed mixture is set at the
factory and cannot be adjusted. The low idle fuel
adjustment screw (if equipped) is also set at the
factory and normally does not require adjustment. See
Figure 15.
Low Idle
Mixture Screw
Idle Speed
(RPM)
Adjustment
Screw
• Make sure fuel is reaching the carburetor. This
includes checking the fuel lines and fuel pump for
restrictions or faulty components, replace as
necessary.
• Make sure the air cleaner element is clean and all
air cleaner element components are fastened
securely.
If, after checking the items listed above, the engine is
hard to start, runs roughly, or stalls at low idle speed,
it may be necessary to adjust or service the
carburetor.
Adjust Carburetor
NOTE: Some engines may have a fixed (capped) idle
fuel adjusting screw or limiter cap. On these
engines, do not attempt steps 1 and 2 below.
Proceed directly to Step 3. On limiter
equipped models, adjustment can only be
performed within the limits allowed by the
cap.
Fuel Solenoid
Figure 15. Carburetor.
Low Idle Mixture Screw
1. Idle Fuel Adjustment: with the engine stopped,
turn the low idle fuel adjusting screw in
(clockwise) until it bottoms lightly. See Figures 15
and 16.
NOTE: The tip of the low idle fuel adjusting screw is
tapered to critical dimensions. Damage to the
needle tip and the seat in carburetor body
will result if the needle is forced.
Idle Speed (RPM)
Adjustment Screw
Element
Figure 16. Carburetor Adjustment Access Locations
(Latch Removed For Clarity).
Troubleshooting
If engine troubles are experienced that appear to be
fuel system related, check the following areas before
adjusting the carburetor.
• Make sure the fuel tank is filled with clean, fresh
gasoline.
• Make sure the fuel tank cap vent is not blocked
and that it is operating properly.
• If the fuel tank is equipped with a shut-off valve,
make sure it is open.
• If the engine is equipped with an in-line fuel filter,
make sure it is clean and unobstructed. Replace
the filter if necessary.
12
2. Preliminary Settings: Turn the adjusting screw
out (counterclockwise) from lightly bottomed
2-1/4 turns.
3. Start the engine and run at half throttle for 5 to 10
minutes to warm up. The engine must be warm
before making final settings (steps 4, 5, and 6).
4. Low Idle Speed (RPM) Setting: Place the throttle
control into the “idle” or “slow” position. Set the
low idle speed to 1200 RPM* (± 75 RPM) by
turning the low idle speed adjusting screw in or
out. Check the speed using a tachometer.
*NOTE: The actual low idle speed depends on the
application – refer to equipment
manufacturer’s recommendations. The
recommended low idle speed for basic
engines is 1200 RPM. To ensure best results
when setting the low idle fuel needle, the low
idle speed must not exceed 1200 RPM
(± 75 RPM).
5. If proper operation is not restored after adjusting,
carburetor servicing by an authorized Kohler
Engine Service Dealer may be required.
Troubleshooting
When troubles occur, be sure to check the simple causes which, at first, may seem too obvious to be considered.
For example, a starting problem could be caused by an empty fuel tank. Some common causes of engine troubles
are listed in the following table.
Do not attempt to service or replace major engine components, or any items that require special timing or
adjustment procedures. Have your Kohler Engine Service Dealer do this work.
Possible Cause No
Problem
Fuel
Will Not Start
•
Hard Starting
Stops Suddenly •
Lacks Power
Operates Erratically
Knocks or Pings
Skips or Misfires
Backfires
Overheats
High Fuel Consumption
Improper
Fuel
•
•
•
•
•
•
•
•
Dirt In
Dirty
Fuel Line Grass Screen
/System
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Incorrect
Oil Level
Engine
Overloaded
Dirty Air
Cleaner
Faulty
Spark Plug
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Storage
Parts Ordering
If the engine will be out of service for two months or
more, use the following storage procedure:
The engine Specification, Model, and Serial Numbers
are required when ordering replacement parts from
your Kohler Engine Service Dealer. These numbers are
found on the identification plate which is affixed to the
engine shrouding. Include letter suffixes if there are
any. See “Engine Identification Numbers” on page 5.
1. Clean the exterior surfaces of the engine.
2. Change the oil and filter while the engine is still
warm from operation. See “Change Oil and Oil
Filter” on page 8.
3. The fuel system must be completely emptied, or
the gasoline must be treated with a stabilizer to
prevent deterioration. If you choose to use a
stabilizer, follow the manufacturer’s
recommendations, and add the correct amount
for the capacity of the fuel system. Fill the fuel
tank with clean, fresh gasoline. Run the engine for
2-3 minutes to get stabilized fuel into the
carburetor. Close fuel shut off valve when unit is
being stored or transported.
To empty the system, run the engine until the
tank and system are empty.
Always insist on genuine Kohler parts. All genuine Kohler
parts meet strict standards for fit, reliability, and
performance.
Major Repair
Major repair information is available in Kohler Engine
Service Manuals. However, major repair generally
requires the attention of a trained mechanic and the
use of special tools and equipment. Your Kohler Engine
Service Dealer has the facilities, training, and genuine
Kohler replacement parts necessary to perform this
service. For Sales & Service assistance call
1-800-544-2444 (U.S. & Canada) or contact your Kohler
Engine Dealer or Service Distributor, they’re in the
Yellow Pages under Engines-Gasoline.
4. Remove the spark plugs. Add one tablespoon of
engine oil into each spark plug hole. Install plugs,
but do not connect the plug leads. Crank the
engine two or three revolutions.
5. Store the engine in a clean, dry place.
13
Specifications
Model: ................................................................................. SV710 ............................... SV715 ......................... SV720
Bore: ............................................... mm (in.) .................... 83 (3.27) ........................... 83 (3.27) ..................... 83 (3.27)
Stroke: ............................................ mm (in.) .................... 67 (2.64) ........................... 67 (2.64) ..................... 67 (2.64)
Displacement: .............................. cm3 (in3) .................... 725 (44.2) ......................... 725 (44.2) ................... 725 (44.2)
Power (@ 3600 RPM): ................... kW (HP) .................... 14.9 (20*) .......................... 16.4 (22*) .................... 17.2 (23*)
Max. Torque#: ............ N·m (ft. lb.) @ RPM .................... 54.2 (40.0) @ 2000 ............ 60.9 (44.9) @ 2000 ...... 60.9 (44.9) @ 2000
Compression Ratio: ......................................................... 9.0:1 .................................. 9.0:1 ............................ 9.0:1
Weight: .............................................. kg (lb.) .................... 41.2 (91) ........................... 41.2 (91) ..................... 41.2 (91)
Oil Capacity (w/filter) - approximate,
determined by oil filter and if oil cooler equipped:
1.6-1.8 L (1.7-1.9 U.S. qt.)
Lubrication:
Combination Pressure/Splash Lube w/full Flow Filter
Model: ................................................................................. SV730 ............................... SV735 ......................... SV740
Bore: ............................................... mm (in.) .................... 83 (3.27) ........................... 83 (3.27) ..................... 83 (3.27)
Stroke: ............................................ mm (in.) .................... 67 (2.64) ........................... 67 (2.64) ..................... 67 (2.64)
Displacement: .............................. cm3 (in3) .................... 725 (44.2) ......................... 725 (44.2) ................... 725 (44.2)
Power (@ 3600 RPM): ................... kW (HP) .................... 18.6 (25*) .......................... 19.3 (26*) .................... 20.1(27*)
Max. Torque#: ............ N·m (ft. lb.) @ RPM .................... 63.2 (46.6) @ 2000 ............ 61.2 (45.2) @ 2400 ...... 61.2 (45.2) @ 2400
Compression Ratio: ......................................................... 9.0:1 .................................. 9.0:1 ............................ 9.0:1
Weight: .............................................. kg (lb.) .................... 41.2 (91) ........................... 41.2 (91) ..................... 41.2 (91)
Oil Capacity (w/filter) - approximate,
determined by oil filter and if oil cooler equipped:
1.6-1.8 L (1.7-1.9 U.S. qt.)
Lubrication:
Combination Pressure/Splash Lube w/full Flow Filter
Exhaust Emission Control System for models SV710-740 is EM.
#Preliminary Figures
*Horsepower ratings exceed Society of Automotive Engineers Small Engine Test Code J1940. Actual engine
horsepower is lower and affected by, but not limited to, accessories (air cleaner, exhaust, charging, cooling, fuel
pump, etc.), application, engine speed and ambient operating conditions (temperature, humidity, and altitude).
Kohler reserves the right to change product specifications, design, and standard equipment without notice and
without incurring obligation.
COURAGETM ENGINE LIMITED WARRANTY
Kohler Co. warrants to the original retail consumer that each new COURAGE™ engine sold by Kohler Co. will be free from
manufacturing defects in materials or workmanship in normal residential homeowner service for a period of two (2) years from date of
purchase, provided it is operated and maintained in accordance with Kohler Co.’s instructions and manuals. If used commercially the
COURAGE™ engine is covered by a 90 day limited warranty.
The warranty period begins on the date of purchase by the original retail consumer or commercial end user. “Residential homeowner
service” means residential use by a retail consumer. “Commercial use” means all other uses, including use for commercial, or rental
purposes. Once in commercial use, the engine will thereafter be considered a commercial use engine for the purposes of this
warranty.
Our obligation under this warranty is expressly limited, at our option, to the replacement or repair at Kohler Co., Kohler, Wisconsin
53044, or at a service facility designated by us of such parts as inspection shall disclose to have been defective.
EXCLUSIONS:
Mufflers on engines used commercially (non-residential) are warranted for 90 days from date of purchase.
This warranty does not apply to defects caused by casualty or unreasonable use, including faulty repairs by others and failure to
provide reasonable and necessary maintenance.
The following items are not covered by this warranty:
Engine accessories such as fuel tanks, clutches, transmissions, power-drive assemblies, and batteries, unless supplied or installed by
Kohler Co. These are subject to the warranties, if any, of their manufacturers.
KOHLER CO. AND/OR THE SELLER SHALL NOT BE LIABLE FOR SPECIAL, INDIRECT, INCIDENTAL, OR CONSEQUENTIAL
DAMAGES OF ANY KIND, including but not limited to labor costs or transportation charges in connection with the repair or
replacement of defective parts.
Continued on next page.
14
IMPLIED OR STATUTORY WARRANTIES, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE, ARE EXPRESSLY LIMITED TO THE DURATION OF THIS WRITTEN WARRANTY. We make no other
express warranty, nor is any one authorized to make any on our behalf.
Some states do not allow limitations on how long an implied warranty lasts, or the exclusion or limitation of incidental or
consequential damages, so the above limitation or exclusion may not apply to you.
This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
TO OBTAIN WARRANTY SERVICE:
Purchaser must bring the engine to an authorized Kohler service facility. To locate the nearest facility, visit our website,
www.kohlerengines.com, and click on SALES AND SERVICES to use the locator function, consult your Yellow Pages or telephone
1-800-544-2444.
ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044
KOHLER CO.
FEDERAL AND CALIFORNIA EMISSION CONTROL SYSTEMS
LIMITED WARRANTY
SMALL OFF-ROAD ENGINES
The U.S. Environmental Protection Agency (EPA), the California Air Resources Board (CARB), and Kohler Co. are pleased to explain the
Federal and California Emission Control Systems Warranty on your small off-road equipment engine. For California, engines
produced in 1995 and later must be designed, built and equipped to meet the state’s stringent anti-smog standards. In other states, 1997 and
later model year engines must be designed, built and equipped, to meet the U.S. EPA regulations for small non-road engines. The engine
must be free from defects in materials and workmanship which cause it to fail to conform with U.S. EPA standards for the first two years of
engine use from the date of sale to the ultimate purchaser. Kohler Co. must warrant the emission control system on the engine for the period
of time listed above, provided there has been no abuse, neglect or improper maintenance.
The emission control system may include parts such as the carburetor or fuel injection system, the ignition system, and catalytic converter.
Also included are the hoses, belts and connectors and other emission related assemblies.
Where a warrantable condition exists, Kohler Co. will repair the engine at no cost, including diagnosis (if the diagnostic work is performed at
an authorized dealer), parts and labor.
MANUFACTURER’S WARRANTY COVERAGE
Engines produced in 1995 or later are warranted for two years in California. In other states, 1997 and later model year engines are warranted for
two years. If any emission related part on the engine is defective, the part will be repaired or replaced by Kohler Co. free of charge.
OWNER’S WARRANTY RESPONSIBILITIES
(a) The engine owner is responsible for the performance of the required maintenance listed in the owner’s manual. Kohler Co. recommends
that you retain all receipts covering maintenance on the engine, but Kohler Co. cannot deny warranty solely for the lack of receipts or
for your failure to assure that all scheduled maintenance was performed.
(b)
Be aware, however, that Kohler Co. may deny warranty coverage if the engine or a part has failed due to abuse, neglect, improper
maintenance or unapproved modifications.
(c)
For warranty repairs, the engine must be presented to a Kohler Co. service center as soon as a problem exists. Call 1-800-544-2444 or
access our website at: www.kohlerengines.com, for the names of the nearest service centers. The warranty repairs should be
completed in a reasonable amount of time, not to exceed 30 days.
If you have any questions regarding warranty rights and responsibilities, you should contact Kohler Co. at 1-920-457-4441 and ask for an
Engine Service representative.
COVERAGE
Kohler Co. warrants to the ultimate purchaser and each subsequent purchaser that the engine will be designed, built and equipped, at the time
of sale, to meet all applicable regulations. Kohler Co. also warrants to the initial purchaser and each subsequent purchaser, that the engine is
free from defects in materials and workmanship which cause the engine to fail to conform with applicable regulations for a period of two
years.
Engines produced in 1995 or later are warranted for two years in California. For 1997 and later model years, EPA requires manufacturers to
warrant engines for two years in all other states. These warranty periods will begin on the date the engine is purchased by the initial purchaser.
If any emission related part on the engine is defective, the part will be replaced by Kohler Co. at no cost to the owner. Kohler Co. is liable for
damages to other engine components caused by the failure of a warranted part still under warranty.
Kohler Co. shall remedy warranty defects at any authorized Kohler Co. engine dealer or warranty station. Warranty repair work done at an
authorized dealer or warranty station shall be free of charge to the owner if such work determines that a warranted part is defective.
Continued on next page.
15
Listed below are the parts covered by the Federal and California Emission Control Systems Warranty. Some parts listed below may require
scheduled maintenance and are warranted up to the first scheduled replacement point for that part. The warranted parts are:
•
•
•
•
•
•
Oxygen sensor (if equipped)
Intake manifold (if equipped)
Exhaust manifold (if equipped)
Catalytic muffler (if equipped)
Fuel metering valve (if equipped)
Spark advance module (if equipped)
•
•
•
•
•
•
Ignition module(s) with high tension lead
Gaseous fuel regulator (if equipped)
Electronic control unit (if equipped)
Carburetor or fuel injection system
Fuel lines (if equipped)
Air filter, fuel filter, and spark plugs (only to first scheduled replacement point)
LIMITATIONS
This Emission Control Systems Warranty shall not cover any of the following:
(a)
repair or replacement required because of misuse or neglect, improper maintenance, repairs improperly performed or replacements
not conforming to Kohler Co. specifications that adversely affect performance and/or durability and alterations or modifications not
recommended or approved in writing by Kohler Co.,
(b)
replacement of parts and other services and adjustments necessary for required maintenance at and after the first scheduled replacement
point,
(c)
consequential damages such as loss of time, inconvenience, loss of use of the engine or equipment, etc.,
(d)
diagnosis and inspection fees that do not result in eligible warranty service being performed, and
(e)
any add-on or modified part, or malfunction of authorized parts due to the use of add-on or modified parts.
MAINTENANCE AND REPAIR REQUIREMENTS
The owner is responsible for the proper use and maintenance of the engine. Kohler Co. recommends that all receipts and records covering
the performance of regular maintenance be retained in case questions arise. If the engine is resold during the warranty period, the
maintenance records should be transferred to each subsequent owner. Kohler Co. reserves the right to deny warranty coverage if the
engine has not been properly maintained; however, Kohler Co. may not deny warranty repairs solely because of the lack of repair
maintenance or failure to keep maintenance records.
Normal maintenance, replacement or repair of emission control devices and systems may be performed by any repair establishment or
individual; however, warranty repairs must be performed by a Kohler authorized service center. Any replacement part or service that
is equivalent in performance and durability may be used in non-warranty maintenance or repairs, and shall not reduce the warranty obligations of the
engine manufacturer.
FORM NO.: 32 590 01-A
ISSUED:
9/05
REVISED:
10/05
LITHO IN U.S.A.
FOR SALES AND SERVICE INFORMATION
IN U.S. AND CANADA, CALL 1-800-544-2444
ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044
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