here - Steam Vac Australia
Contents
1. fA Pe TU li ZN gt DS 59 4 Bes CALIFORNIA PROPOSITION 65 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 To ensure safe operation please read the following statements and understand their meaning Also refer to your equipment manufacturer s manual for other important safety information This manual contains safety precautions which are explained below Please read carefully A 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 A CAUTION Caution is used to indicate the presence of a hazard that will or can cause minor persona 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 prec2. dxo 01 mi 95 MODEL MB3006 PARTS LIST AII Configurations Item QTY Part Number Description Material 1 1 MB3006 0101 Impeller Case Gray 2 1 MB3006 0500 Drive Rotor Ductile Iron 1 MB3006 0600 Driven Rotor Ductile Iron 4 1 ZG 1102 50 Drive Helical Gear Alloy Steel 1 ZG 1101 50 Driven Helical Gear Alloy Steel 6 2 MB30101 Locking Assembly Z7B 36x72 Steel 7 2 MB30102 Ball Bearing 6306 Steel 8 2 MB30103 Roller Bearing NJ306E C3 Steel 9 4 ZG 1012 50 Ring Seal Stator Insert Gray Iron 10 4 ZG 1011A 50 Ring Seal Rotor Sleeve oteel 11 5 MB30104 O Ring 30x2 65 IDXCS Viton 12 12 ZG 1013 50 Piston Ring Alloy Iron 13 4 ZG 1106A 50 Oil Slinger Steel 14 1 G 50 SJT Lock Sleeve Assembly Steel 15 il ZG 50 SYP Oil Flinger Assembly Steel 16 2 G 0202 50 Gear Spacer Steel 17 8 ZG 1202 50 Bearing Shim 0 5 0 2mm Steel 17A 8 ZG 1202 50 Bearing Shim 0 1 0 05mm Steel 18 1 MB30105 Key C8x63 Steel 19 1 ZG 1021 50 Wear Ring Steel 20 1 MB30106 Lip Seal 45x65x7 Viton 21 4 MB30107 Plug M16x1 5 Steel 22 2 MB30108 Magnetic Plug M16x1 5 Steel 23 2 MB30109 Sight Glass M16x1 5 Steel 24 6 MB30111 Dowel Pin B8x28 Steel 25 2 ZG 1205A 50 Cover Gasket 26 1 ZG 1201 50 Cylinder Shim 0 1 Fish paper 2 2 ZG 0201A 50 Endplate Gray Iron 28 1 ZG 0311A 50 Gear Oil Cover Aluminium 29 1 ZG 0411A
3. ISSUED 10 10 REVISED 11 10 1P24 590 Ill 85612 Rotary Blower Service Manual Models MB3006 MB4007 Oil Capacities Model MB3006 MB4007 Drive end 157 ml 414 ml Vertical Gear end 260 ml 828 ml Recommended lubricant Use the recommended grade and viscosity of industrial type non detergent rust inhibiting anti foaming oil Reference Chart 1 below The correct oil depends on the range of ambient temperatures as well as the range of discharged temperatures Recommended Viscosity 20 266 18 239 Typical window of operation 190 162 129 PRESSURE DIFFERENTIAL PSI 100 DISCHARGE TEMPERATURE FAHRENHEIT 68 0 20 40 60 80 AMBIENT TEMPERATURE FAHRENHEIT Synthetic lubricants are highly recommended over mineral lubricants synthetics last up to 4 times longer and a single viscosity can cover a broader temperature range 100 COMPRESSION RATIO Regular Maintenance Schedule Period Work to be done 1 24 hours after 1st startup Check oil level frequently Check belt tension Record baseline data 100 200 hours after 1st startup Change lubricating oil Monthly Check oil level 1 500 2 000 hours Change oil mineral 6 000 8 000 hours Change oil synthetic The maintenance period can vary depending on the service and environmental conditions The oil should be changed at least once a year even
4. kack Moord INSTRUCTIONIMANUAL E CONTENTS 203 Pg 04 Pg 04 Pe A Pg 06 Pg 08 Machine overview amp Specs Boss 500 EFI Boss 590 EFI Boss 650 EFI Boss 600 EFI Hybrid Motor Service amp owner Information Service Intrums amp Requirements 25 Pg 36 Pg A4 Pg 45 Pg 46 Pg 48 Blower Service Manual Belt Tension amp Maintenance Pump Breakdowns Filter Maintenance Machine Maintenance Safety Instructions Warranty Information CONGRATULATIONS Thank you For Your Purchase Congratulations on purchasing your new SteamVac carpet cleaning machine and or equipment With proper maintenance your new equipment will provide many years of reliable trouble free operation Although the equipment may first look complex it is relatively simple to use and maintain This manual has been designed to familiarise you with your new SteamVac equipment and to provide you with service maintenance and operating advice that will assist you to achieve all the benefits of maximum operating performance It has also been prepared with the intention of acquainting users of SteamVac equipment with some of the design principals that have been adopted to ensure that by world standards SteamVac equipment is the most efficient and most reliable cleaning equipment on the market today Once again Congratulations on your purchase and good luck with your operations S
5. 16 1601 21 Brass plug GV Tappo Gt 1 17 1801 18 Manifold stud bolt Vite 8 60 8 18 1400 01 Washer Roseta8BS5 8 19 0603 06 Copper washer 3 8 Guarnizione rame G3 86 1 20 1601 17 Brass plug 6 8 1 j TappoG38 2 21 1503 28 Valveset Sedevalvola 6 22 1202 00 Valveplate JjPiattellovalvola 6 23 0900 30 Valve spring Molla valvola 6 24 0604 10 Valve cage Gabbiavalvola 6 25 1801 12 screw ViteMex16 120 26 0203 18 Bearingcover Coperchiocuscinetto 2 28 1500 03 Snapring Anelo225 1 29 0213 00 bearing Cuscinetto a aere 2 0006 05 Crankshat Albero eccentrico 1 0006 06 Crankshat Albero eccentrico 1 0006 08 Crankshat Albero eccentrico 1 0006 10 Crankshat Alberoeccentico 1 0006 11 Crankshaft Albero eccentrico 1 0006 12 Crankshaft Albero eccentrico 1 31 0206 04 Crankshaftkey Chiavetta 1 32 1600 12 Oil dip Tappolivelloolio 1 33 0001 10 Crankshaftseal Anelloradile 1 34 0302 11 Plunger nut Dado pistone 3 35 1400 06 Copperspacer Rosetta 9 2 13 5x05 3 36 1200 22 Plunger 18mm Pistone omg 3 38 0601 30 l O Ring 21 78x5 28 7 O Ring 1 78x5 28 3
6. 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 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 SERVICE and DEALER LOCATOR 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 AND CLASS 1 LSI ENGINES The U S Environmental Protection Agency EPA the California Air Resources Board CARB and Kohler Co are pleased to explain the 2011 and later Federal and Cali
7. Make sure when tensioning belts blower feet should be at equal distance from edge of frame Re Tension Belts with 5 10mm deflection Or to loosen the blower release the bolts anti clockwise and lever blower towards other side of machine this will slacken off the belts for easy replacement Make sure you re tighten lock nuts B after adjustment is complete to lock blower in place and also re tighten blower feet bolts A Pump Adjust mE DI To adjust the Pump you will need to release the four Pump feet nuts there are two on each side of the Pump Simply crack the seal on the bolt heads so that the pump can move freely Release the two lock nuts on the inside of the adjustment bolts un tighten roughly half way so that you can slide the Pump back and forth Use these adjusting bolts to tension the Pump belts or to release the Pump for belt replacement Tighten bolts clockwise to tension Pump belts Make sure when tensioning belts Pump feet should be at aa equal distance from edge of frame Re Tension Belts with 5 10mm deflection Or to loosen the Pump release the bolts anti clockwise and lever pump towards other side of machine this will slacken off the belts for easy replacement HYBRID SYSTEM BLOWER BELT TENSION AND REPLACEMENT INSTRUCTIONS The following instructions will help you to maintain D a good level of tension on your Blower Belts and if First step is to release the four blower feet nuts needed to
8. may be found on the certification label Emission Compliance Period EPA Catagory A 1000 hours CARB Extended 500 hours Refer to certification label for engine displacement Exhaust Emission Control System for models ECH630 WCH650 ECH680 ECH 730 ECH 740 ECH 749 is EM 02 ECM MPI for U S EPA California and Europe Specifications Model ECH630 ECH650 ECH680 ECH730 ECH740 ECH749 mm 80 83 Bore im 32 3 3 mm 69 69 Stroke in 2 72 2 72 cme 694 694 694 4 747 747 Displacement in 3 42 4 42 4 424 45 6 45 6 45 6 Gross Power kW 14 1 15 7 17 2 18 6 POI 21 6 3600 RPM HP 19 21 23 5 er 29 Net Power o 13 8 146 154 17 4 17 9 3600 RPM 18 6 19 6 20 7 23 3 24 0 N m 44 3 46 8 90 4 50 8 Peak Torque min ft Ib 31 6 32 7 34 5 37 4 37 5 Compression Ratio 8 8 1 9 11 Kg 46 Weight Ibs 102 L 1 9 1 9 Oil Capacity U S qt 2 2 Exhaust Emission Control System EM 02S ECM MPI for U S EPA California and Europe 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
9. 39 0009 13 Teflon ring antiestrusione 40 0003 20 Plungerrod Asta pistone 3 41 1502 04 Connectingrodpin Spinto 3 42 0100 08 rod Biella completa 3 43 1401 02 Spring washer 7 Rosettaelastica 26 6 44 1801 32 Connecting rod soten Vite M x30 6 45 0700 05 Sightglass 7 Spialivelloolio 634 1 46 0603 02 Gasket 7 Guamizione G3 8 1 48 0601 04 Ring 22 62x107 62 O Ring 22 62x107 62 1 SPARE PARTS LIST HAWK HD PUMPS SERIES LISTA RICAMBI Part available Particolare disponibile in kit only solo in kit ZZ Part available Particolare disponibile in kit also anche in kit SPARE PARTS KIT KIT RICAMBI Q ta Pomp Posizioni Item Part Number amp Description Codice e Descrizione a Q ty Pump 3 5 7 2600 44 2600 44 1 Plunger Seals 18 mm Guarnizioni pistone 218 2600 43 2600 43 Pacco completo Complete seal Packing 18 mm Guarnizioni pistone 218 34 36 37 38 2614 05 2614 05 3 39 Plunger 18 mm Pistone 018 2600 28 2600 28 Complete Valve Valvola completa 2608 26 2608 26 Plunger Seals Anelli tenuta olio Asta 2612 39 Testata completa 3100 20 3 Premontato biella asta HD HD8515RL HD1015RL HD1115RL HD1215RL HD1315RL HD1415RL sauas 2007 sdund JIW IW 9007 3495 IIN IN 98G9H 9 I9GGOH 9GG H IS90G0H I90S9H 90S9H 5967 OH I9GTOH 9G
10. Ether M TBE and unleaded gasoline blends up to a maximum of 15 MTBE by volume are approved as a fuel for Kohler engines Other gasoline ether blends are not approved Operating Instructions Also read the instructions of equipment this engine powers Check Oil Level see figures 1 2 and 3 The importance of checking and maintaining the proper oil level in the crankcase cannot be overemphasised Check oil BEFORE EACH USE as follows IN 7 Make sure the engine is stopped level and cool so the oil has had time to drain into the sump Clean the area around the dipstick D to keep dirt and debris out of the engine See figure 1 Remove the dipstick D wipe off oil Reinsert the dipstick D Push or screw on the dipstick in all the way Remove dipstick D again and check oil level Oil should be up to but not over F or Full mark B on dipstick See figure 2 If oil level is low add the correct type of oil up to the F or Full mark B on dipstick Remove the fill cap A or the dipstick C to fill the crankcase with new oil of a proper type Recheck oil level before adding more oil Always check the oil level with the dipstick before adding more See figures 2 amp 3 Reinstall the oil fill cap and dipstick securely NOTE To prevent extensive engine wear or damage always maintain proper oil level in crankcase Never operate engine with oil level below the L or Low mark C or over the F o
11. Never use unleaded petrol as a cleaning agent DO NOT place hands feet hair or clothing near rotating or moving parts Avoid any contact with moving parts Rotating machinery can cause Injury or fatality Never operate this unit without belt guards The high Speed moving parts such as belts and pulley s should be avoided while this unit is running Severe injury damage or fatality may result DO NOT service this unit while it is running The high speed mechanical parts as well as high temperature components may result in severe injury or severed limbs DO NOT cut or slice any of the vehicle fuel lines during fuel line installation This may result in fuel leaks and potentially dangerous conditions There is no fuel solenoid shut off on this unit Use only the provided abrasion resistant fuel hose for fuel lines When traversing the vehicle floor with fuel lines always use a bulkhead adapter This will prevent leakage and ensure that the hose is not punctured by vehicle vibration abrasion DO NOT operate the unit without the water supply attached and turned on The water pump and other vital components may be seriously damaged if this unit is permitted to operate dry without water DO NOT operate this unit without the filter installed in the waste tank Keep your vehicle work area clean Wands stair tools and other accessories must be securely fastened before driving the vehicle All high pressure hoses must be rated for 3
12. conform with applicable regulations for a period of three years Small off road engines and Class 1 LSI engines are warranted for three years in California EPA requires manufacturers to warrant engines for three 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 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 include the following if they were present in the engine purchased Oxygen sensor if equipped Intake manifold if equipped Exhaust manifold if equipped Catalytic muffler if equipped Thermal reactor muffler if equipped Fuel lines fuel line fittings and clamps if equipped Spark advance module if equipped Crankcas
13. 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 KOHLER ENGINES FOR SALES AND SERVICE INFORMATION IN U S AND CANADA CALL 1 800 544 2444 KohlerEngines com ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 2010 by Kohler Co All rights reserved FORM NO 24 590 16 Rev
14. flywheel is rotating the starter pinion and flywheel ring gear may crash resulting in damage to the starer 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 Centre to service assistance Stopping 1 Remove the load by disengaging all PTO driven attachments 2 Move the throttle to the slow or idle position turn key OFF to stop engine Battery A 12 volt battery is 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 Follow the battery manufacture s instructions Operating Angle of Operation This engine will operate continuously at angles up to 25 In all directions for one minute or less Oil levels must be at F or FULL mark on dipstick Refer to the operating instructions of the equipment this engine powers Due to 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 because engine damage could result from insufficient lubrication Cooling See figure 1 Hot Parts can cause severe burns Do not touch engine while operating or just aft
15. hoses and tools Drain waste tank O1 A 9 5 YEAR CONDITIONAL WARRANTY Steam Vac International Pty Ltd warrants the Sub Frame and Heat Exchanger against faulty workmanship or failure for a period of 5 years from date of purchase Any defect must be notified to the Company in writing immediately and the equipment must not be used until such defect is rectified The customer must wear all freight costs This warranty shall not apply where the equipment has been abused or damaged by misuse or negligent handling only structural or mechanical defaults Steam Vac International Pty Ltd warrants all items Supplied by it to be free from defects in material or workmanship In the event of a defect being disclosed in any item within 1 year of receipt by the customer the Company will if satisfied on it s examination that failure was due to defective material or workmanship repair or replace the defective item provided the purchaser gives the Company immediate written notice of such alleged defects All accessories furnished by Steam Vac International Pty Ltd but manufactured by others bears only that manufacturer s standard warranty All defective items shall become the property of the company when replaced by the company All freight costs must be worn by the customer Vacuum and Solution Hoses carry a 6 month warranty against faulty workmanship but kinks cuts or damage caused by over heating of the solution hose shall be worn by
16. humidity and altitude Kohler reserves the right to change product specifications designs and equipment without notice and without incurring obligation Based on preliminary information LIMITED 3 YEAR COMMAND ENGINE WARRANTY Kohler Co warrants to the original consumer that each new COMMAND engine sold by Kohler Co will be free from manufacturing defects in materials or workmanship in normal service for a period of three 3 years from date of purchase provided it is operated and maintained in accordance with Kohler Co s instructions and manuals 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 one 1 year from date of purchase except catalytic mufflers which are warranted for three 3 years 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
17. if the blower is not operated Oil Sight Glasses otop the rotary blower before checking the oil level Use the sight glasses to determine the oil level as instructed below Check oil level on both sides of each end as the rotary blower can be off level An oil level 1 4 below the center line is in DANGER of failure an oil level 1 8 below the centerline indicated the oil level is low Note Oil level should be between the center line and 1 8 above centre line if the oil level is more than above the centerline there is a risk of oil leakage LOW CENTER Oil level sight glass HIGH To check the lubricating oil level 1 Stop the rotary blower 2 Check the lubrication oil level at all oil level sight glasses To initially fill the lubricating oil 1 Stop the rotary blower and lock out the power source to prevent a restart 2 Unscrew the fill plug on top of the unit 3 Pour the indicated amount of oil into the port and look at the new oil level in the sight glasses 4 Fill with lubricating oil to the correct height Changing the oil Change the oil when the following situations occur e Change oil after approximately 150 hours of service e Change oil after approximately 1500 2500 service hours of mineral lubricants and approximately 6000 8000 service hours for synthetic lubricants e Change at least once annually SPARE PARTS AND AFTER SALES SERVICE SLL
18. 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 into contact with hot parts or sparks from ignition Do not start the engine near spilled fuel Never use gasoline as a cleaning agent General Fuel Recommendations Purchase gasoline in small quantities and store in clean approved containers Use a container with a capacity of two gallons or less with a pouring spout is recommended as It is easier to handle and helps eliminate spillage during refuelling To minimize gum deposits in fuel system do not use gasoline left over from previous seasons 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 a pump sticker octane rating of 87 R M 2 or higher In countries using the Research Octane Number RON it should be 90 octane minimum Leaded gasoline is not recommended and must not be used on EFI engines or on other models where exhaust emissions are regulated Gasoline Alcohol blends Gasohol up to 1076 ethyl alcohol 9076 unleaded gasoline by volume is approved as a fuel for Kohler engines Other gasoline alcohol blends including E20 and E85 are not to be used and not approved Any failure resulting from use of these fuels will not be warranted Gasoline Ether blends Methyl Tertiary butyl
19. most cases a MIL light may be added to an engine see Parts Ordering Troubleshooting If the MIL comes on or the engine becomes hard to start runs roughly or stalls at low idle speed initial checks should be made in the following areas e Check that the fuel tank is filled with clean fresh gasoline and shut off valve if so equipped is opened completely e Check that the fuel tank vent cap is not blocked and it Is operating properly non California models e Check that the air cleaner element and precleaner are clean and all components are properly secured Clean or replace as necessary e Check that the proper fuel filter is being used and it is clean and unobstructed Replace filter s only with genuine Kohler parts e Check that all connections to sensors ECU and fuel injectors are properly secured e Check that there is 12 volt battery being used and is fully charged e Check that fuses are not burnt out If so then replace If these checks do not correct the problem or the MIL remains on further diagnosis and servicing by an authorised Kohler Engine Centre is necessary Adjustment Throttle Body See figure 10 Low idle speed RPM is the only adjustment that can be made All other fuel calibrations are controlled by the ECU The standard low idle speed is 1500 RPM 75 RPM NOTE The actual low idle speed depends on the application refer to equipment manufacturer s recommendations When an EFI e
20. oil Seals 4 5 6 7 8 9 2608 13 Complete Manifold 10 11 12 13 2608 14 14 15 18 19 Complete Manifold 38 rs E ICH e ressssic Ee Ee e meson GSO SE oo e 78 C o ICH Lc C c RUCKMOUNT FILTER ENANCE In order to ensure your Truckmount operates efficiently you must clean your waste tank filters on a regular basis There are two filters in the waste tank 1 Main Catch Filter This is your main lint waste filter you should clean this out after every days use 2 Blower Filter This is your Blower filter it is very important to keep this filter clean as it protects your blower entry from potential blockage or damage If this filter is blocked or dirty you will notice a drop in vacuum recovery which will also put your engine under more load on start up and operation you should clean this out after every days use 3 Waste Pump Filter To remove the waste filter you need to take the waste pump out In order to do so you first need to unscrew the black fitting shown in diagram 3b then you will be able to pull the entire waste pump assembly out and remove the filter bag to clean as well as rinse your waste pump Simply pull these filters out and clean them under a tap after some use the filters will start to turn black if you want to restore them to their origi
21. port Outlet Pression D bit tours min Puissance HP Entr e Sortie Druck Leistung u p m Leistung HP Eingang Ausgang Pressione Portata giri min Potenza HP Aspirazione Mandata Dimensioni d ingombro Overall dimensions N 285 n 4Fori 6 Lubrificazione Olio 20 40W Lubrication SAE 20 40W Oil Capacit 0 4 Litri Capacity 0 4 Litri SPARE PARTS LIST HAWK HD PUMPS SERIES LISTA RICAMBI 4 Part Description Descrizione a nol lulois tem e5 i ad Li Number Q tyPump 1 0202 92 ae 1 2 2 0001 05 Plunger _______ radiale 3 3 0601 81 Ring 21 78 28 0 7 91 78 28 30_ 3 4 1201 41 Pressure ring 18mm 7 8 2 3 5 0002 51 U seal dia 18mm Anello tenuta U 018 6 0300 63 Intermed ring 18mm Diffusore Interm 018 3 U seal dia 18mm Anello tenuta U 018 8 1601 20 Brass plug 612 7 2 1 9 0603 07 Copper washer 1 2 Guarnizione rame Gt 2 1 10 1602 28 Manifold housing Testata 1 11 0601 55 Ring 91 78 15 54 7 O Ring 91 78 15 54 6 12 3604 73 Valve assembly 7 6 13 0601 22 Ring 22 62x18 77 0262 877 6 714 160147 Valve plug Tappo valvola 6 15 0603 08 Copper washer 1 4 7 Guarnizionerame 61 4 1
22. replace them Simply crack the seal on the nylock nuts so that the blow er can move freely when levered Next you will need to un tighten the hose clamp on the blower exhaust to allow for movement Release these two lock nuts back towards the blower so that the blower has room to travel when adjusting Use these adjusting bolts to tension the blower belts or to release the blower for belt replacement Refer to diagram below for adjustment Re Tension Belts with 5 10mm deflection BLOWER TENSION 1 Back nuts off to allow Blower room to move 2 Tighten nuts clockwise to tension blower belts Make sure when tensioning belts blower feet should be at equal distance from edge of frame BLOWER 3 Re tighten 1 nuts and lock back into place Pulley Generator ry To tension or release the generator the first step is to release the lock nuts A Release both nuts up on the thread to allow for travel room Next you need to use the Nylock nut B to tension the generator if you tighten the nylock nut B it will raise the generator giving you more tension on the belt if you un tighten the nylock nut it will drop the generator and loosen of the belt Once you have the desired position re tighten lock nuts A Re Tension Belts with 10mm deflection HAWK pumps HD series Caratteristiche Tecniche HAWK H D S E RI ES Technical Characteristics Pressure Volume RPM Required HP Inlet
23. the customer This warranty shall not apply to any hose end connections All freight costs must be worn by the customer CONDITIONS 1 No warranty on equipment or parts exposed to freezing temperatures due to improper enclosed protection or improper heating No warranty on neglect of oil in Motor No warranty on neglect of oil in Pump No warranty on neglect of oil in Blower No warranty on abuse or damages to the Heating Exchanger This warranty does not extend to any item which in the judgement of the company shall have been repaired altered abused neglected or used In any way so as to affect adversely it s stability or reliability 7 It is agreed that in the event of breach of any warranty liability of the seller shall be limited to repairing or replacing the non conforming goods 8 The foregoing warranty is in lieu of and excludes all other warranties and conditions expressed or implied whether under common law statute or otherwise and every form of liability for loss or damage direct or consequential or for any accident resulting from defective material faulty workmanship or otherwise is expressly excluded 9 Items excluded by the warranty shall be normal service items that will need to be replaced from time to time eg Belts Bearings Pump Seals etc
24. 000 PSI at 100 C Thermoplastic hoses do not meet these specifications and should not be used Severe burns and injury may result if the hoses do not meet these requirements Make certain that you receive complete training by the distributor from whom you purchased this unit This unit uses high pressure and temperature Improper or irresponsible use may result in serious injury Do not modify this unit in any manner Improper or irresponsible use may result in serious injury or fatality Never touch electrical wires or components while the engine is running They can be sources of electrical shock 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 the engine is turned off DO NOT touch the exhaust system while this unit is running Severe burns may result Before servicing this unit allow it to cool down This will prevent burns from occurring Water under high pressure at high temperature can cause burns severe personal injury or fatality Shut down machine allow to cool down and relieve system of all pressure before removing valves plugs fittings filters and bolts 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 unleaded petrol vapours are present When disconnecting the ba
25. 50 Drive Side Oil Cover Aluminium 30 N A N A N A N A al 24 MB30113 Stud Bolt M3x90 Steel 32 24 MB30114 Nut M8 Steel 9 24 MB30115 Washer 8 oteel 34 24 MB30116 Lock Washer 8 Alloy Steel 35 2 G 0202 50 Bearing Clamp Plate Steel 36 8 MB30112 socket Head Screw M6x12 Steel MODEL MB4007 PARTS LIST AII Configurations Item QTY Part Number Description Material 1 1 M4506 0101 Impeller Case Gray Iron 2 M4506 0500 Drive Rotor Ductile Iron 3 1 M4506 0600 Driven Rotor Ductile Iron 4 1 45 1102 Drive Helical Gear Alloy Steel e 1 M45 1101 Driven Helical Gear Alloy Steel 6 2 45101 Locking Assembly Z7B 55x100 Steel 7 2 MB45102 Angular Contact Ball Bearing 3309 Steel 8 2 MB45103 Roller Bearing NJ309E C3 Steel 9 4 M45 1012A Ring Seal Stator Insert Gray Iron 10 4 M45 1011B Ring Seal Rotor Sleeve Steel 11 5 MB45104 O Ring 45x2 65 IDXCS Viton 12 12 M45 1013 Piston Ring Alloy Iron 13 4 M45 1106B Oil Slinger oteel 14 M45 SJT Lock Sleeve Assembly Steel 15 2 M45 SYP Oil Flinger Assembly Steel 16 2 M45 0202 Gear Spacer Steel 1 3 M45 1202A Bearing Shim 0 5 0 2mm Steel 17A 8 M45 1202A Bearing Shim 0 1 0 05mm Steel 18 1 45105 Key C12x70 Steel 19 1 M45 1021B Wear Ring Steel 20 1 MB45106 Lip Seal 55 5 8 Viton 21 4 MB45107 Plug M20x1 5 Steel 22 2 MB45108 Plug Magnetic M20x1 5 Stee
26. Drain Engine Exhaust 05 BOSS 600 EFI HYBRID Temp Gauge Hour Meter zd Choke Vacuum Gauge Ignition Blower Lubrication Valve p a Solution Outlet a a Pressure Control Engine Oil Drain Engine Exhaust HYBRID SYSTEM SETUP DIRECTIONS Connect water to male Connect water to rear of heat exchanger coupler on portable Connect vac hose from portable dome to your cleaning tool Connect vac hose from booster port on portable to the blower port on the Hybrid Connect solution hose from this outlet and run to cleaning tool Connect solution hose from portable to the top of heat exchanger Connect power leads from portable to the power outlets on the rear of the Hybrid KOHLER Command PRO ECH630 ECH749 HORIZONTAL CRANKSHAFT LI p Dun Se SIT n SE 7 ES Lo 7 5 cC 0 POSE ECH d DD LD LD BP AS DI B a E N Ls
27. Install the fuse cover B See figure 11 Additional Electrical Information The yellow accessory wire on the original Kohler Engine Key switch can not draw more than 2 amps A relay may be used in order to use a higher drawing accessory Contact a Kohler Engines application specialist for further instructions A current draw of more than 2 amps will cause damage to the ECU Fuel Pump Module or other electrical system components and will void the warranty TROUBLESHOOTING When troubles occur be sure to check the simple causes which at first amy seem too obvious to be considered For example a startling 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 Centre do this work Possible Causes Problem No Fuel Improper Fuel Blocked Fuel Line System Low Battery Voltage Broken Fusible Link Dirty Fixed Guard Incorrect Oil Level Engine Overload Dirty Air Cleaner Faulty Spark Plug Will not Start Hard Starting Stop Suddenly Lacks Power Operates Erratically Knocks or Pings Skips or Misfires Backfires Overheats High Fuel Con sumption Storage see Figure 1 If the e
28. PECIFICATIONS BOSS 500 EFI Console 150LTR Waste Tank Length 860 mm 500mm Width 550mm 400mm Height 965mm 925mm Features e World wide patented design 25 HP EFI V Twin air cooled Kohler motor Hawk pump 1800 AMX working pressure Hot Vapour heat exchange system giving you 100 c in under 10 minutes 3 6 Roots Blower 15 HG CFM 300 150L Stainless steel waste tank with 240V pump Powder coated hammer tone finish steel frame Low oil and water shut off Can be pumped to vehicle fuel supply National dealer network for servicing FEWER PARTS THAN ANY COMPARABLE UNIT BOSS 590 EFI Console 860mm 550mm 965mm 150TR Wate Tank 500mm 400mm 925mm Length Width Height Features e World wide patented design 29 HP EFI V Twin air cooled Kohler motor Hawk pump 2800 PSI working pressure Hot Vapour heat exchange system giving you 100 c in under 10 minutes 3 6 Roots Blower 15 HG CFM 300 150 CTR waste tank with 240V waste pump Powder coated hammer tone finish steel frame Low oil and water shut off Can be pumped to vehicle fuel supply National dealer network for servicing FEWER PARTS THAN ANY COMPARABLE UNIT BOSS 600 HYBRID EFI SYSTEM Length 1140mm Width 550mm Hight 915mm Features e World wide patented design e 29 HP EFI Kohler motor e Hot Vapour heat exchange system giving you Truck Mount heat from your portable 100 C in under ten minutes e 3 6 Roots Blower giving you Truck m
29. and install it according to the directional arrows Failure to use the proper filter can result in engine damage and void the warranty Fuel Line These engines use low permeation related fuel lines certified to comply with California and U S EPA evaporative emission requirements Fuel lines that do not meet these requirements may not be used Order replacement hose through a Kohler Service Centre A high pressure fuel line runs between the high pressure pumps and the injectors The special fuel line capable of withstanding the high pressure of the EFI fuel system meets SAE R9 specifications If fuel line must be replaced See your Kohler Engine Service Centre Electronic Fuel Injection EFI System The EFI system is a complete electronically controlled fuel management system designed to deliver a precisely controlled fuel flow under all operating conditions The electronic control unit ECU the brain of the system automatically adjusts fuel delivery and ignition timing based upon load speed operating temperature and exhaust emission levels The low idle speed is the only manual adjustment possible The ECU continuously monitors operation of the EFI system If it detects a problem or fault within the system it will illuminate the Malfunction Indicator Light MIL if so equipped This is a signal that normal programmed operation has been affected and service by an authorised Kohler Engine service Centre is required In
30. autions could result in injury to yourself and others Explosive Fuel can cause fires and severe burns Do not fill the fuel tank while the engine is hot or running Explosive Fuel Gasoline is extremely flammable and its vapours 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 into contact with hot parts or sparks from ignition Do not start the engine near spilled fuel Never use gasoline as a cleaning agent Accidental Starts can cause severe injury or death Disconnect and ground spark plug lead s 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 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 WARNING Carbon Monoxide can cause severe nausea fainting or death Avoid inhaling exhaust fumes and
31. bearing housing 1 _ u Closed bearing housing 1 elo 27 0601 63 Rng 01786005 2 e B 28 0001 02 Crankshattseal gt ES Rollerbearng 2 B 0004 01 poubie ended sat 1 oooga 000408 7 0004 06 single endea srat 0004130 3 LLLLLISLLELLLELELLLEL 7004131 7 3 gt 7000450 Pe NN 7000457 7 l 3 00040 7 LLLILLLELLELLLLI 7000482 7 32 0206 00 Crankshatkey 1 1 00 NN PARTS LIST MT pumps 2008 series Part 030102 Sam TT 38 0009 04 3 739 1200 10 Plunger 20mm 3 1400 15 Copper spacer 3 741 0003 01 Plungerrod 3 42 0100 01 Connecting 3 1802 01 Connecting rod pin 3 44 1801 05 Connecting rod screw 6 _ 45 1500 01 6 46 1401 02 Spring washer 6 HC536RL 1801 12 A DU 778 TI DI DU Gera DAT in kit only Part available in kit also SPARE PARTS KIT Included Part Number amp Positions Description 2608 01 Plunger Seals 20mm 39 40 Plunger 20mm Complete Valve 2608 03 Plunger
32. e breather Air Injection System if equipped Air pump or pulse valve assembly if equipped Control distribution valve if equipped Distribution manifold if equipped Air hoses if equipped Vacuum lines if equipped 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 Ignition module s with high tension lead Gaseous fuel regulator if equipped Electronic control unit if equipped Carburetor or fuel injection system Fuel metering valve if equipped Air filter fuel filter and spark plugs only to first scheduled replacement point Evaporative System if equipped Canister if equipped Canister filter if equipped Vapor hose if equipped Orifice connector if equipped Fuel tank if equipped Fuel cap if equipped Primer bulb canister if equipped 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
33. e the fill cap A or use the dipstick fill tube D to fill the crankcase with new oil of the proper type to the F or FULL mark B on the dipstick Recheck oil level before adding more oil Refer to Check Oil Level See figures 2 and 3 10 Reinstall the oil fill cap and dipstick securely 11 Test run the engine to check for leaks Stop the engine allow a minute for the oil to drain down and recheck the level on the dipstick Verify the oil level is up to but not over the F or FULL mark B on the dipstick See figure 2 Service Oil Cooler If Equipped See figure 5 Some engines are equipped with an optional oil cooler Inspect and clean oil cooler every 100 hours of operation more frequently under severe conditions Oil cooler must be kept free of debris Service the oil cooler as follows 1 Remove the hardware B holding the oil cooler C to the blower housing D 2 Clean the inside of the cooler with a brush 3 Reinstall the oil cooler C to the blower housing D securing with the mounting hardware B Air Cleaner Service Heavy Duty Air Cleaner See figures 1 6 and Weekly and every 150 hours Check filter minder F if equipped perform inspection of the paper element B and inlet screen G area See figure 6 Annually or every 300 hours of operation more often under extremely dirty or dusty conditions replace the paper element and check the inner element Follow these steps Do not wash the
34. ed tools and equipment Kohler Service Centres have the facilities training and genuine Kohler replacement parts necessary to perform these services For the nearest sales and service location visit our Web Site at KohlerEngines com or in the U S and Canada call 1 800 544 2444 Parts Ordering The engine model specification and serial numbers are required when ordering replacement parts from your Kohler Service Centre These numbers are found on the identification plate which is affixed to the engine shrouding Including letter suffixes if there are any Refer to Engine Identification Numbers Always insist on genuine Kohler replacement parts as they adhere to strict standards for fit reliability and performance Visit KohlerEngines com or your Kohler service Centre Engine Identification ENGINE IDENTIFICATION NUMBERS See figure 1 Engine identification numbers will appear on the engine data tag M See figure 1 When ordering parts or in any communication concerning this engine always give the model name specification number and serial number including any letter suffixes Emission Compliance 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 which
35. ed with Oil Sentry M MAINTENANCE INSTRUCTIONS 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 authorised service centre A WARNING Accidental Starts can cause severe injury or death Disconnect and ground spark plug lead s before servicing 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 below They should also be included as part of any seasonal tune up FREQUENCY MAINTENANCE REQUIRED Daily or Before Starting Engine Check oil level Fill fule tank Check air intake and cooling areas clean as necessary Check air cleaner for dirty loose or damaged parts Ever 25 Hours Check or replace precleaner if equipped clean as 1 3 Every 100 Hours Change oil more frequently under sever conditions Replace element low profile air cleaner models Remove and clean shrouds and cooling areas Check oil cooler fins clean as necessary if equipped Weekly or every 150 Hours Check filter minder 4 Inspect air filter paper element and inlet sc
36. ed 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 web site 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
37. er stopping 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 To ensure proper cooling amke sure the fixed guard G oil cooler H some models and other external surfaces of the engine are kept clean at all times NOTE If debris builds up on the fixed guard G oil cooler H some models 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 Refer to Clean Air Intake Cooling Areas 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 no load for these engines is 4200 RPM Oil Sentry some engines are equipped with as optional Oil Sentry switch This switch is designed to prevent the engine from starting in a low oil or no oil condition The Oil sentry may not shut down a running engine before damage occurs In some applications this switch may activate a warning signal Read your equipment manuals for more information NOTE Make sure the oil level is checked BEFORE EACH USE and is maintained up to the F or FULL mark on the dipstick This includes engines equipp
38. fill the crankcase with new oil of the proper type to the F or FULL mark B on the dipstick Recheck oil level before adding more oil See figures 2 and 3 5 Reinstall the oil fill cap and dipstick securely Change Oil Filter See figures 1 2 3 4 and 5 Replace the oil filter at least every other oil change every 200 hours of operation Always use a genuine Kohler oil filter Replace the oil filter as follows 1 To keep dirt debris etc out of the engine clean the area around the dipstick D remove the dipstick See figure 1 2 Remove the oil drain plug on the starter side A or the drain plug oil filter side B Allow ample time for complete drainage See figure 4 3 Reinstall the drain plug A or B and torque to 13 6 N m 10 ft Ib See figure 4 4 To keep dirt debris etc out of the engine clean the area around the oil filter A remove the oil filter See figure 5 5 Wipe the surface where the oil filter mounts 6 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 centre 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 7 Apply a this film of clean oil to the rubber gasket on the new filter 8 Install the new oil filter to the filter adapter or oil cooler Refer to instructions on the oil filter for proper installation 9 Remov
39. fornia Emission Control Systems Warranty on your off road equipment engine Emissions means both exhaust and evaporative emissions For California small off road engines and Class 1 LSI Large Spark Ignited engines at or below 1 0 liter must be designed built and equipped to meet the state s stringent anti smog standards In other states 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 three 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 Small off road engines and Class 1 LSI engines are warranted for three years in California and other states If any emission related part on the engine is defective the part will be repair
40. l 23 2 MB45109 Sight Glass M20x1 5 Steel 24 6 MB45111 Dowel Pin B12x40 Steel 25 2 M45 1205A Cover Gasket 26 1 M45 0201A Cylinder Shim 0 1 Fish paper 2 2 M45 0201B Endplate Gray Iron 28 1 M45 0311A Gear Oil Cover Aluminium 29 1 45 0411 Drive Side Oil Cover Aluminium 30 1 45 1107 Oil Flinger Gear Side Steel 3l 24 MB45113 Stud Bolt M10x110 Steel 32 24 MB45114 Nut M10 Steel 39 24 MB45115 Washer 10 oteel 34 24 MB45116 Lock Washer 10 Alloy Steel 35 2 M45 0202 Bearing Clamp Plate Steel 36 3 MB45112 socket Head Screw M8x12 Steel MAINTENANCE SCHEDULE SHEET Rotary blower Serial Number Date Description of work Service hours Signature 500 590 amp 650 BLOWER amp PUMP BELT TENSION amp REPLACEMENT INSTRUCTIONS These instructions will help maintain a good level of tension on your Blower amp Pump belts or if needed to replace them First step is to release the four blower feet nuts there are two on each side of the blower Simply crack the seal on the nylock nuts so that the blower can move freely when levered Release the two lock nuts on the inside of the adjustment bolts un tighten roughly half way so that you can slide the blower back and forth Use these adjusting bolts to tension the blower belts or to release the blower for belt replacement Blower Adjust Tighten bolts clockwise to tension blower belts
41. lement G every 100 hours or annually Do not wash the air cleaner inner element or use compressed air this will damage the elements Replace dirty bent or damaged elements with new genuine Kohler elements as required Handle the new air cleaner elements carefully do not use if the sealing surfaces are bent or damaged Loosen the cover retaining knob A and remove cover B Remove and inspect the precleaner F wash or replace as necessary Clean area around the air cleaner element G to prevent dirt and debris from entering the engine Remove and inspect the air cleaner element G replace as necessary 6 Check the conditions of the rubber seal E on the air cleaner stud I Replace if the seal is worn damaged or questionable 7 Reinstall the components in reverse order of removal Clean Air Intake Cooling Areas oee figure 1 To ensure proper cooling make sure the fixed guard G 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 L Clean the cooling fins and external surfaces as necessary Reinstall the blower housing and other cooling shrouds NOTE Operating the engine with a blocked fixed guard dirty or plugged cooling fins and or cooling shrouds removed will cause engine damage to overheating Ignition EFI Engine
42. low all of the battery warnings and safety guidelines and procedures provided by the battery manufacturer and equioment manufacturer Jump starting Follow all safety guidelines and procedures provided by the battery manufacturer and or original equipment manufacturer OEM gt Failure to follow proper procedures may result in serious personal injury and or non warrantable damage to the engine s Electronic Fuel Injection EFI components Fuel System oee figure 1 A WARNING High Pressure Fluids can puncture skin and cause severe injury or death Do not work on fuel systems without proper training or safety equipment General The precision components inside the fuel pump module are not serviceable DO NOT attempt to open the fuel pump module Damage to the components will result and the warranty will be void Because the fuel pump module is not serviceable the engines are equipped with a special 10 micron EFI fuel filter J to prevent harmful contamination from entering the module If there are two filters in the system the one before the lift pump will be a standard 51 5 micron filter and the one after the lift pump will be the special 10 micron filter Be sure to use an approved 10 micron filter for replacement Service Periodically inspect the filter and replace every 200 operating hours or more frequently under extremely dusty or dirty conditions Use only a genuine Kohler filter Kohler Part No 25 050 42 5
43. ment with hydrostatic drive The shift lever must be in neutral to prevent resistance which could keep the engine from starting Starting 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 Engine exhaust gases contain poisonous carbon monoxide Carbon monoxide is odourless colourless and can cause death if inhaled Avoid inhaling exhaust fumes and never run the engine in a closed building or confined area 1 Place the throttle control midway between the SLOW and FAST positions 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 ata time If the engine does not start allow a 60 second cool down period between starting attempts Failure to follow these guidelines can damage the starter motor NOTE Upon start up a metallic ticking may occur This is caused by hydraulic lifter leakdown during storage The noise will normally cease in the first minute If the noise continues run the engine at mid throttle for 20 minutes If noise persists take the engine to your Kohler Engine Service Centre NOTE If the stater cranks the engine but does not start the engine the engine rotation must be allowed to come to a complete stop before attempting to restart the engine If the starter is engaged while the
44. nal white appearance you may soak them in bleach and they will return to a white condition MAINTENANCE SCHEDULE Pre Run Instructions Engine Service air cleaner elements Ensure you are connected to water supply Engine Check spark plugs for carbon deposits and Connect all vacuum and solution hoses before starting proper gap unit 200 Hours Let machine run between 1800 2000rpm to warm up for Fuel Pump Check hose connection 5 mins 500 Hours Engine oil and filter MUST be changed after first 50 hours Check and change belts if needed of operation Replace pump oll oet desired throttle speed and working pressure eg e Upholstery 150 200psi Check blower oil e Carpets at around 5OOpsi e ile and grout 500 1200psi e Concrete 1200 2500psi Daily Engine Check engine oil level Fill to proper level Vacuum Pump Spray WD 40 in lubrication cup at front of console for 5 seconds Water Pump Check oil level Fill to proper level solution Inlet Tube Strainer Check strainer for blockage remove any debris Waste Tank Filter in waste tank Clean filter inspect replace if damaged Vacuum Hoses Wash out with clean water Automatic Waste Pump Inspect and remove any debris or sediment Weekly Vacuum Pump Check oil level Fill to proper level Water Pump Inlet Filter Check for debris and clean Battery Check for proper fluid level Fill with distilled water only Engine Check belt tightness 100 Ho
45. ne is guided by our exclusive Performance Engineering Philosophy e operate on the leading edge of innovation e push the boundaries of cleaner more efficient engines e manufacture the highest performing most reliable engines on the market You can rest assured that your Kohler Engine will provide maximum power and reliability in all operating conditions Also Kohler engines are backed by a worldwide network of over 10 000 distributors and dealers For more information on Kohler Engines or to find a Kohler Service Centre visit KohlerEngines com To keep your engine in top operating conditions follow the maintenance procedures in this manual 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 oll Causes premature engine wear and failure Oil Type Use high quality detergent oil of API Ameriacn Petroleum Institute service class SJ or higher Select the viscosity based on the air temperature at the time of operation as shown in the Recommended Viscosity Grades table N Fuel Recommendations Explosive Fuel can cause fires and severe burns Do not fill the fuel tank while the engine is hot or running Gasoline is extremely flammable and its vapours can explode if ignited Store gasoline only in approved containers
46. never run the engine in a closed building or confined area Lethal Exhaust Gases Engine exhaust gases contain poisonous carbon monoxide Carbon monoxide is odourless colourless and can cause death if inhaled Avoid inhaling exhaust fumes and never run the engine in a closed building or confined area Rotating Parts can cause severe injury Stay away while engine is in operation 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 A WARNING High Pressure Fluids can puncture skin and cause severe injury or death Do not work on fuel systems without proper training or safety equipment High Pressure Fluid Puncture Fuel system is to be serviced only by properly trained personnel wearing protective safety equipment Fluid puncture injuries are highly toxic and hazardous If injury occurs seek immediate medical attention Electrical Shock can cause injury Do not touch wires while engine is running Electric Shock Never touch electrical wires or components while the engine is running They can be sources of electrical shock SYMBOLS ASSOCIATED WITH THIS PRODUCT A Alert LU Read Manual Co Start fap Slow On A d Fast Q Off FD Congratulations on your purchase of a Kohler Engine Every part every component every system on a Kohler engi
47. ngine is started cold the ECU will briefly set a higher 200 400 RPM low idle speed similar to a fast idle Do not attempt to preform any readjustment during this warm up period If adjustment is to be made the engine must be at operating temperature air cleaner in place and check engine light must be off no fault codes present 1 Start the engine and run at half throttle for 5 to 10 minutes to warm up 2 Place the throttle control into the idle or slow position 3 Turn the low idle speed adjusting screw A in or out and check RPM with a tachometer Fuse replacement See figure 11 and 12 This engine has three 3 blade type automotive fuses Replacement fuses must have the same rating as the blown fuse Use the fuse chart below to determine the correct fuse See figure 14 WIRE COLOUR FUSE RATING 2 Purple wires 30 amp Fuse 1 Red wire with Back stripe 10 amp Fuse 1 Rd Wire with White stripe 2 Red wires 10 amp Fuse Figure 14 Fuse Rating Chart To replace a fuse 1 Shut engine off and remove key 2 Locate the fuse holders A See figure 11 3 Remove the fuse cover B and pull out fuse see figure 11 4 Inspect the fuse for a solid fusible Link A or a broken fusible link B Replace the fuse if the fusible link is broken B If you are not sure if the fusible link is broken replace the fuse See figure 12 5 Insert the fuse into the fuse holder A until it is seated properly
48. ngine will be out of service for two months or more follow these storage procedures 1 Clean the exterior surfaces of the engine Avoid spraying water at the wiring harness or any of the electrical components 2 Change the oil and filter while the engine is still warm from operation Refer to change Oil and Filter 3 The fuel system must be completely emptied or the gasoline must be treated with a fuel stabilizer to prevent deterioration If you choose to use a fuel stabilizer follow the manufacturers recommendations and add the correct amount for the capacity of the fuel system 4 Fill the fuel tank with clean fresh gasoline Run the engine for 2 3 minutes to get stabilized fuel into the fuel system Close fuel shut off valve if equipped when unit is being stored or transported To empty the system run the engine until the tank and fuel system are empty 5 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 6 Disconnect the negative battery cable or use a Battery Minder trickle charger while the unit is in storage 7 Store the engine in a clean dry place Repairs Repair information is available in Kohler Engine service manuals which are available at KohlerEngines com or at Kohler Service Centres Major repairs generally require the services of a trained mechanic and the use of specialis
49. ount suction 15 HG CFM 300 e 12 KVA generator with key start work anywhere anytime Powder coated hammer tone finish steel frame 4 safety switch power outlets Low oil warning and water shut off Portable can be easily removed from Van trailer for the hard to access jobs Can be pumped to vehicle fuel supply e National dealer network for servicing BOSS 650 EFI Console 200LTR Wate Tank Length 1140mm 800mm Width 550mm 400mm Height 915mm 925mm Features e 0 100 c in less than 10 minutes e Full 5 year warranty on heat exchanger e 2 year warranty on Kohler Engine e 12 month warranty on all other parts e Engine 29 HP V Twin Kohler EFI air cooled e Pump Hawk 2600 PSI working pressure e Blower 4007 Roots Blower 15 HG CFM 450 e Hot Vapour heat exchange system giving you 100 c in under 10 minutes e 200LTR Stainless steel waste tank with 240V waste pump BOSS 500 amp 590 Temp Gauge Pressure Gauge Hour Meter Vacuum Gauge Throttle Control Ignition Engine Warning Low Oil Warning Blower Lubrication Pressure Control Valve Solution Outlet Engine Oil Drain i D Waste Pump Inventor Engine Exhaust pss oU kl Temp Gauge Hour Meter Vacuum Gauge Throttle Control Ignition Pressure Gauge A Waste Switch Engine Warning Pressure Control Low oil Warning Solution Outlet Blower Lubrication Valve Engine Oil
50. paper element and inner element or use compressed air this will damage the elements Replace dirty bent or damaged elements with new genuine Kohler elements as required Handle the new elements carefully do not use if the sealing surfaces are bent or damaged E Unhook the two retaining clips B on each end and remove the end caps from the air cleaner housing D See figures 1 and 6 Check and clean the inlet screen G using a brush See figure 6 Remove and inspect the air cleaner outer element Replace if it seems dirty or is at the annually or 300 hour interval See figure 6 Remove and inspect the air cleaner inner element C Replace if it appears dirty or is at the 600 hour interval See figure 6 Clean the area around the base of the inner element before removing it so dirt does not get into the engine See figure 6 Check all parts for wear cracks or damage and make Sure ejector area B is clean Replace any damaged components See figure 7 Install elements B and C and covers A and E in reverse order of removal See figure 6 Secure covers with clips B See figure 1 Low Profile Air Cleaner See figure 8 Every two months or every 25 hours of operation wash or replace the precleaner F Wash precleaner in warm water and detergent Rinse the precleaner thoroughly and squeeze out excess water do not wring Allow precleaner to air dry Replace the air cleaner e
51. r Full mark B on dipstick See figure 2 Check Cooling Areas see figure 1 To ensure proper cooling make sure the fixed guard oil cooler some models H and other external surfaces of the engine are kept clean at all times Check Air Cleaner See figure 1 This engine is equipped with heavy duty shown air cleaner flat style air cleaner or special air cleaner supplied by equipment manufacturer Check the air cleaner A daily or before starting the engine for a buildup of dirt and debris Keep the area in and around the air cleaner clean Also check for loose or damaged components Replace all worn or damaged air cleaner components NOTE Operating engine with loose or damaged air cleaner components could allow unfiltered air into engine causing premature wear and failure Pre Start Checklist 1 Check oil level if low add oil Do not overfill NOTE Engines are shipped without oil Do not start engine with low or no oil This will cause damage to the engine and will not be covered under warranty Check fuel level if low add fuel Do not overfill Check cooling areas air intake areas and external surfaces of engine make sure they are clean and unobstructed Check 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 equip
52. reen area 4 Every 200 Hours Replace fuel filter Change oil filter Clean set gap or replace spark plug and set gap Annually or Every 300 Hours Replace heavy duty air cleaner element and check inner element Annually or Every 500 Hours adi 1 Perform these maintenance procedures more frequently under extremely dusty dirty conditions 2 Have a Kholer Engine Service Dealer perform this service 3 Low profile air cleaner 4 Heavy duty air cleaner Oil Disposal Protect and respect the environment Dispose of oil at your local recycling centre or municipal collection centre in accordance with local ordinances Change Ou See figures 1 2 3 and 4 Change oil after every 100 hours of operation more frequently under sever conditions Refill with oil as specified in the Recommended Viscosity Grades table 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 oll 1 To keep dirt debris etc out of the engine clean the area around the dipstick D remove the dipstick see figure 1 2 Remove the oil drain plug on the starter side A or the drain plug oil filter side B Allow ample time for complete drainage See figure 4 3 Reinstall the drain plug A or B and torque to 13 6 N m 10 ft Ib See figure 4 4 Remove the fill cap A or use the dipstick fill tube D to
53. ri PARTS LIST MT pumps 2008 series Q ty _ sl x x Part 2 G G Q S Blo Sa I T Crankcase 1 jejejejejeje Jeje Jeje Crankcase 1 T jele jeje 2 0602 01 Plunger guide 3 3 0001 03 Plunger seal 3 4 0601 07 O Ring 1 78 31 47 3 5 0002 05 V seal dia20mm 6 6 1201 04 Pressure ring 20mm 3 8 0300 08 Intermed ring 20mm 3 HEOLIT Brass plug G3 8 1 jejejejeje 14999 J Brass plug G1 2 Jejejeje 10 0605 06 Copper washer 1 jejejejeje 14999 J Copper washer ej Jejejeje KRUS Manifold housing 1 e e elelo lejeje J Manifold housing WEISS ej jejejeje 12 0601 19 O Ring 2 62x17 13 6 13 3604 70 assembly 6 15 1601 30 Valveplug 6 16 1801 04 Manifold studbolt 8 EAE UE gt 8 8 8 8 8 8 16 16 8 8 16 1400 02 Washer 8 jej e e ele jejej 0603 06 Copperwasher 0 Tee i jeje ele Jeje 112 SOON Leit tele HMM WW ES pot TTT Pee el el se 44 e jeje sin po ot el oto 18 ES 21 CHE E NN Ex e SS 1801 19 Hexagonal screw e s 243 a Closed
54. s incorporate a computer controlled battery ignition system with individual coils Other than periodically checking replacing the spark plugs no maintenance timing or adjustments are necessary or possible with this system Spark Plug See figures 1 and 9 Every 200 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 12 123 02 5 RFI complient engines use a Champion XC12YC Kohler Part No 25 132 14 S spark plug A high performance spark plug Champion Platinum 3071 used on Pro series engines Kohler Part No 25 132 12 S is also available Equivalent alternative brand plugs can also be used 1 Before removing the spark plugs E clean the area round the base of the plug to keep dirt and debris out of the engine See figure 1 2 Remove the plugs E and check it s condition Replace the plugs if worn or reuse is questionable oee figure 1 NOTE Do not clean the spark plug using abrasive grit Some grit could remain in the spark plug and enter the engine causing extensive wear and damage 3 Check the gap D using a wire feeler gauge A Adjust the gap to 0 76 mm 0 030 in by carefully bending the ground electrode C See figure 9 4 Reinstall the spark plug E into the cylinder head Torque the spark plugs to 24 4 29 8 N m 18 22 ft Ib See figure 1 Battery Charging Fol
55. t hose as a water inlet hose Use only clean hoses for water inlet 2 Turn the water supply faucet on The water will fill the water box High Pressure Hoses Before starting the unit connect the pressure hose s to the outlet connection s at the front of the unit Connect the cleaning tool s to the pressure hose s DANGER ROTATING MACHINERY WATER UNDER PRESSURE A DANGER AT HIGH TEMPERATURE IMPROPER MODIFICATION OF EQUIPMENT CAN DO NOT MODIFY UNIT A CAUSE SEVERE WITHOUT WRITTEN gt PERSONAL INJURY OR PERMISSION FROM WATER UNDER HIGH PRESSURE AT HIGH SES EE TEMPERATURE CAUSE BURNS V SEVER PERSONAL INJURY OR COULD BE _ FATAL SHUT DOWN MACHINE ALLOW TO COOL DOWN AND RELIEVE SYSTEM OF ALL PRESSURE BEFORE REMOVING VALVES CAPS PLUGS FITTINGS FILTERS Gg BOLTS Vacuum Hose Connect the vacuum hose s to the vacuum inlet connection s at the front of the unit Connect the other end of the vacuum hose s to the cleaning tool s Shut Down amp Daily Maintenance Low Pressure 1 Allow the unit to run for two minutes with the vacuum hose disconnected to remove moisture Turn blower lube valve open for ten seconds This will prevent corrosion due to moisture 2 Set engine throttle at idle position and allow the water temperature to cool down to bleed off residual hot water left in the system Turn off ignition switch Disconnect all
56. ttery ALWAYS disconnect the negative terminal FIRST DO NOT smoke around the unit Unleaded petrol fumes may accumulate and be ignited The battery is also extremely flammable This will prevent possible explosions DO NOT damage the vehicle in any manner during installation When routing fuel lines DO NOT place the hose in any location where damage may occur to the hose or vehicle Avoid any contact with moving parts area of high temperature brake lines fuel lines muffler catalytic converter or sharp objects OPERATIONS Pre Run Inspection NOTE Operation of this unit is simple However only trained personnel should proceed Operate this unit and equipment only in a well ventilated area Exhaust fumes contain carbon monoxide which is an odourless and deadly poison that can cause severe injury or fatality DO NOT operate this unit where the exhaust may enter any building doorway window vent or opening of any type Check for Adequate Fuel Check the fuel tank to be certain there is adequate fuel to complete the job Remove Tools From Vehicle Remove any tools or hoses from the van which you will require Water Supply Connection NOTE Before connecting your water hose to the supply faucet flush out the faucet until the water is free of any debris Flush out any debris which may be in your water inlet hose 1 Connect the water supply hose to the water inlet quick connect NOTE Never use the waste pump outle
57. urs High Pressure Hoses Inspect for damage or impending damage Engine Change oll filter Battery Clean Battery terminal IMPORTANT SAFETY INFORMATION When using this machine basic precautions must always be followed including the following Read all instructions before using this machine Read the operators manual before installing or starting this unit Failure to adhere to instructions could result in severe personal injury or could be fatal Operate this unit and equipment only in a well ventilated area Exhaust fumes contain carbon monoxide which is an odourless and deadly poison that can cause severe injury or fatality DO NOT run this unit in an enclosed area DO NOT operate this unit where the exhaust may enter any building doorway window vent or opening of any type Unleaded petrol is extremely flammable and it s vapours can explode if ignited Store unleaded petrol only in approved containers in well ventilated unoccupied buildings away from sparks or flames Never carry any unleaded petrol or flammable material in the vehicle Fumes may accumulate inside the vehicle and ignite Causing an explosion DO NOT store any type of flammable material in the vehicle This unit must be operated with the vehicle or trailer doors open in order to ensure adequate engine ventilation DO NOT operate engine if unleaded petrol is spilled Avoid creating any ignition until the unleaded petrol has been cleaned up
58. yOH 90H AMVH 41 Caratteristiche Tecniche MT Serie 2008 Series Technical Characteristics Volume D bit Pressure Pression RPM Required HP Inlet port Outlet Weight Kg tours min Puissance HP Entr e Sortie Poids Kg u p m Leistung HP Eingang Ausgang Gewicht Kg Druck Pressione Leistung Portata 100 64 ne lee 100 7 giri min Potenza HP Aspirazione Mandata Peso Kg 2 HC456 HC4561 0 3000 5 1450 3 8 37 8 1725 1 1 1450 4 C172 G 3 8 1725 NNNM 1490 3 8 1725 G 3 8 1725 i 1450 61 2 G 3 8 1725 i i 1450 2 G 1 2 G 3 8 1725 1450 10 7 Eq G 3 8 1725 12 7 1450 11 0 1 2 3 8 1725 13 1 Dimensioni d ingombro Overall dimensions 5 2 HC456SI 0 HC506 HC506l 2 oO HCSOGSI 0 CA oO oO vi 7 2 d Y yi Yi CA oO HC556 HC5561 200 5000 CA oO oO oO CA gt co co oo o 4 co 4 gt 0 00 200 00 200 200 HC576l 200 200 12 12 E 19 0 16 18 21 0 I z C C G2 CA N CO CA oO oO N RX Deen ine A 229 99 H306 H406 HC456 HC506 HC536 HC556 HC586 HC456l HC456SI HC506l HC506SI HC556l HC576l Lubrificazione Olio SAE 20 40W Lubrication SAE 20 40W Oil Capacit 0 7 Litri Capacity 0 Lit
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