Kohler SV810 User's Manual
Contents
1. Every 200 Hours Every 500 Hours 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 2 follows 1 Make sure the engine is stopped level and is cool so the oil has had time to drain into the sump Clean the area around and the underside of the oil fill cap dipstick before removing it This will help keep dirt debris and other foreign matter out of the engine 3 Remove the oil fill cap dipstick wipe oil off For engines with a press on style dipstick Reinsert the dipstick into the tube and press all the way down See Figure 5 For engines with a thread on style dipstick Reinsert the dipstick into the oil fill tube and thread the dipstick in completely See Figures 5 and 6 Press On Incorrect Figure 6 Thread on Oil Fill Cap Dipstick 4 Remove the oil fill cap dipstick and check oil level The oil level needs to be within the operating range See Figure 7 If low add oil of the proper type up to the full mark If oil is above the F or FULL mark drain oil to reach proper level Reinstall the oil fill cap 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 above the F or FULL mark or below the L or LOW mark on the dipstick LE x q XKX Yee eee LNN 4 2 Operating2. x6 X QL ae x Q X LI x G a Figure 7 Oil Level Marks on Dipstick Typical 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 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 Oil Filter Figure 9 Oil Filter Location Change the oil and oil filter as follows 1 The drain plug is located on the starter side of the oil pan See Figure 8 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 3
3. Allow the oil to drain and then reinstall the drain plug Tighten 13 6 N m 10 ft Ib 4 Remove the old filter and wipe off the filter adapter with a clean cloth 5 Place anew 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 7 Install the new oil filter to the filter adapter Hand tighten the filter 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 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 above the F or FULL mark or below the L or LOW mark on the dipstick Service Precleaner and Air Cleaner Element These engines are equipped with a re
4. 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 Courage spark plug is a Champion RC12YC Kohler Part No 12 132 02 5 RFI compliant engines use a Champion XC12YC Kohler Part No 25 132 14 5 spark plug A high performance spark plug Champion Platinum 3071 Kohler Part No 25 132 12 S is standard on Courage PRO models Equivalent alternate brand plugs can also be u
5. 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 step 4 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 Models with Governed Idle System An optional governed idle control system is supplied on some engines The purpose of this system is to maintain a desired idle speed regardless of ambient conditions temperature parasitic load etc that may change Engines with this feature contain a small secondary spring connected between the governor lever and the lower adjustment tab of the main bracket See Figure 18 The system requires an additional procedure for setting the idle speed If speed adjustments are required proceed as follows i Governed 2 Idle spride 1 Make any necessary speed or control a
6. if equipped Crankcase 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 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 This Emission Control Systems Warranty shall not cover any of the following 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 replacement of parts and other services and adjustments necessary for required maintenance at and after the first scheduled replacement point consequential damages such as loss of time inconvenience loss of use of the engine or equipment etc diagnosis and inspection fees that do not result in eligible warranty service being performed and any add on or modified part or malfunction of authorized parts due to the use of add on or modified parts MAINTE
7. MAINTENANCE AND ADJUSTMENTS 1 800 544 2444 KohlerEngines com KOHLER CO KOHLER WISCONSIN USA OG N11236 OG N11236 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 Category B Category A 250 hours 500 hours 1000 hours Intermediate Extended 250 hours 500 hours Refer to certification label for engine displacement CARB Moderate 125 hours Exhaust Emission Control System for models SV710 SV840 is EM for U S EPA and Europe PAIR for California Tier II 5 Operating Instructions Also read the operating instructions of the equipment this engine powers Pre Start Checklist e Check oil level Add oil if low Do not overfill e Check fuel level Add fuel if low e Check cooling air intake areas and external surfaces of engine Make sure they are clean and unobstructed e Check that the air cleaner components and all shrouds equipment covers and guards are in place and securely fastened e Check that any clutches or transmissions are disengaged or placed in neutral This is especially important on equipment with hydrosta
8. 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 The engine identification numbers appear on a decal or decals affixed to the engine shrouding Include letter suffixes if there are any Record your engine identification numbers on the identification label Figure 4 for future reference KOHLER IMPORTANT ENGINE INFORMATION THIS ENGINE MEETS U S EPA PH2 AND EC STAGE II SN 4 EMISSION REGS FOR SI SORE NOT FOR SALE IN CALIFORNIA UNLESS PREEMPT PER SEC 209 e 1 OF CAA 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 KohlerEngines com KOHLER CO KOHLER WISCONSIN USA KOHLER IMPORTANT ENGINE INFORMATION THIS ENGINE MEETS U S EPA PH2 AND CA 2008 AND LATER EXH EMISSION REGS FOR SI SORE USING DELEGATED ASSEMBLY FOR AFTERTREATMENT 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
9. PERTE A E E ET SI N O une Ree CID er NP AI EEE NER eee tian Rance 41 2 91 Oil Capacity w filter approximate determined by oil filter used 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 SV810 SV840 is EM for U S EPA and Europe PAIR for California Tier III 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 16 COURAGE PRO SV810 840 ENGINE LIMITED WARRANTY Kohler Co warrants to the original retail consumer that each new COURAGE PRO 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 PRO engine is covered by a one 1
10. Plug o O Will Not Start e a o Hard Starting Stops Suddenly o e Lacks Power e o e Operates Erratically gt Knocks or Pings Skips or Misfires Backfires e Overheats High Fuel Consumption e Storage 2 Change the oil and filter while the engine is still If the engine will be out of service for two months or warm from operation See Change Oil and Oil more use the following storage procedure Filter on page 8 1 Clean the exterior surfaces of the engine 13 3 The fuel system must be completely emptied Always insist on genuine Kohler parts All genuine Kohler or the gasoline must be treated with a stabilizer parts meet strict standards for fit reliability and to prevent deterioration If you choose to performance use a stabilizer follow the manufacturer s recommendations and add the correct amount for Major Repair the capacity of the fuel system Fill the fuel tank Major repair information is available in Kohler Engine with clean fresh gasoline Run the engine for 2 3 Service Manuals This type of repair generally requires minutes to get stabilized fuel into the carburetor the services of a trained mechanic and the use of Close fuel shut off valve when unit is being stored special tools and equipment Kohler Engine Service or transported Dealers have the facilities training and genuine Kohler replacement parts necessary to
11. 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 Maintenance Instructions A 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 s 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 3675 RPM no load 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 e
12. NANCE 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 19 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 FORM NO 32 590 01 B ISSUED 9 05 REVISED 6 09 LITHO IN U S A 08 6 WMT 50531 5136 6
13. OWNER S MANUAL KOHLER COURAGE sv710 740 KOHLER COURAGE PRO sv810 840 VERTICAL CRANKSHAFT KOHLER ENGINES 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 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 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 A WARNING 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 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
14. 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 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 e Ignition module s with high tension lead e Intake manifold if equipped e Gaseous fuel regulator if equipped quipp 8 quipp e Exhaust manifold if equipped e Electronic control unit if equipped quipp quipp Catalytic muffler if equipped Carburetor or fuel injection system Thermal reactor muffler if equipped Fuel metering valve if equipped quipp 8 quipp Continued on next page 18 Fuel lines fuel line fittings and clamps if equipped Spark advance module
15. 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 2006 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
16. djustments following the appropriate instructions covered in this section 2 Move the throttle control to the idle position Hold the governor lever away from the carburetor or hold the throttle lever so it is tight against the idle speed adjusting screw to negate the governor activation See Figure 19 Check the speed with a tachometer and adjust it to 1500 RPM 3 Release the governor lever and allow the engine to return to the governed idle speed Check it with a tachometer against the equipment manufacturers recommended idle speed Governed Idle Speed i Hold RPM is typically 300 RPM approximate Throttle higher than the low idle speed If adjustment is Lever necessary bend the adjusting tab on the speed Against control assembly to set See Figure 18 Screw Figure 19 Holding Throttle Lever Against Idle Stop Screw 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 Improper Dirt In Dirty Incorrect Engine Dirty Air Faulty Problem Fuel Fuel Fuel Line Grass ScreenOil Level Overloaded Cleaner Spark
17. ement 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 use the locator function consult your Yellow Pages or telephone 1 800 544 2444 ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 17 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 In California beginning in 2006 emissions means both exhaust and evaporative emissions For California engines produced in 2006 and later must be designed built and equipped to meet the state s string
18. ent 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 2006 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
19. ervice facility To locate the nearest facility visit our website www kohlerengines com and use the locator function consult your Yellow Pages or telephone 1 800 544 2444 ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 With the exception of countries governed by the European Union EU where a one 1 year warranty is required for commercial professional use p 8 y p y q p 15 Courage PRO SV810 840 Specifications IN Co 5 paneer FEUER ERBE rer ER BEE eevee E SAd I eee er SV820 Dolores DIT IN een A L oar tre cece etea nee ee sucnueatte AEE 8312 27 SO ee DAON Clare OPERIERT OL ZA Vene RUE E A 67 2 64 PS PACS MISTI une EM IN innen TD E E A INREE MEN IRRE T 725 44 2 Power 3600 RPM uses KA CELE sraige TER 0 Ve E 17 2 123 omipiression ee een ee ee ee 9 1 MOT PING nase Felsen BR Pre SE 41 2 91 Oil Capacity w filter approximate determined by oil filter used 1 6 1 8 L 1 7 1 9 U S qt Lubrication Combination Pressure Splash Lube w full Flow Filter MIO een ON KERN ONE RER ON RENNEN REITER NER SV 840 POE a SEIEN ER SEIE EES TI I ee CEA IA ENTA EEEE A ASA 83 3 27 POC res MN IN A OF EA PEE ETC EN E A TN 67 2 64 Displacement nd EM IN een TLD C 802 E E E 725 44 2 Power 3600 RPM men KE Venen SE Ver ne 20 1 27 Compression Kalio ee ee E
20. flers 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 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 s
21. 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 A WARNING t los 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 CAUTION k 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 A WARNING 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 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 amp 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 e
22. n fresh gasoline e Make sure the fuel tank cap vent is not blocked and that it is operating properly e Ifthe fuel tank is equipped with a shut off valve make sure it is open e Ifthe engine is equipped with an in line fuel filter make sure it is clean and unobstructed Replace the filter if necessary e Make sure fuel is reaching the carburetor This includes checking the fuel lines and fuel pump for restrictions or faulty components replace as necessary e Make sure the air cleaner element is clean and all air cleaner element components are fastened securely 12 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 1 Idle Fuel Adjustment with the engine stopped turn the low idle fuel adjusting screw in clockwise until it bottoms lightly See Figures 16 and 17 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 2 Preliminary Settings Turn the adjusting screw out counterclockwise
23. ngine or equipment disable the engine as follows 1 Disconnect the spark plug lead s 2 Disconnect negative battery cable from battery Safety Precautions Cont 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 amp 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 durabilit
24. o 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 14 COURAGE SV710 740 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 Muf
25. o 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 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
26. perform this service To empty the system run the engine until the tank and system are empty For the nearest Sales amp Service location 4 Remove the spark plugs Add one tablespoon of UN Wen a engine oil into each spark plug hole Install plugs call 1 800 544 2444 U S amp Canada but do not connect the plug leads Crank the e look in the yellow pages under Engines Gasoline engine two or three revolutions Model Designation Model SV730 for example S designates Courage engine V designates vertical crankshaft and 730 5 Store the engine in a clean dry place Parts Ordering indicates the numerical model designation A letter The engine Specification Model and Serial Numbers suffix designates a specific version as follows are required when ordering replacement parts from your Kohler Engine Service Dealer These numbers are Suffix Designates found on the identification plate which is affixed to the S Electric Start engine shrouding Include letter suffixes if there are any See Engine Identification Numbers on page 5 Courage SV710 740 Specifications MMO a E E IN seen DV AO E SV720 DOTO ee A DANA IM Jiresisisreruces BI 6 2277 aiai 00 1 00 207 Se SEHR SIENE 8312 27 DIOR er DI ers TA PA ee OF LOT isenta n 67 2 64 Displacement nennen Ei IN os cctroscoanoceteceanes 725 44 2 rsescccsssecssreeeseeeees 725 44 2 eccscecsssseesenees 725 44 2 Power 3600 RP Ds KN HIP seners ER SVD a ssactegstedeyitonstae
27. placeable high density paper air cleaner element Some engines are also equipped with an oiled foam precleaner which surrounds the paper element See Figures 10 and 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 Precleaner Some Models 4 Element _x Figure 12 Unhooking Latch Courage Figure 13 Unhooking Latch Courage PRO 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 Figures 10 and 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 Figures 12 and 13 3 Wash the precleaner in warm water with detergent Rinse the precleaner thoroughly until all traces of detergent are eliminated Squeeze out excess
28. r and replace with a genuine Kohler filter every 100 operating hours Fuel Line In compliance with CARB Tier HI 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 Figure 15 Low Permeation Fuel Line Carburetor Troubleshooting and Adjustments In compliance with government emission standards the carburetor is calibrated to deliver the correct fuel to 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 16 Engines in this series depending on the model and application may also be equipped with a Governed Idle System If the engine is equipped with a Governed Idle System refer to Models with Governed Idle System when performing any carburetor adjustment as an additional step to the listed procedure s is required 11 Adjustment 4 Screw peed R J u st j nen x Figure 17 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 e Make sure the fuel tank is filled with clea
29. re Oil Type Use high quality detergent oil of API American Petroleum Institute service class SG 5H SJ or higher Select the viscosity based on the air temperature at the time of operation as shown in the following table RECOMMENDED SAE VISCOSITY GRADES Kohler 10W 30 TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANGE 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 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 A logo or symbol on oil containers identifies the API service class and SAE viscosity grade See Figure 3 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 A WARNING Explosive Fuel Gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only in approved containers in well ventilated unocc
30. sed 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 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 14 4 Reinstall the spark plug into the cylinder head Torque the spark plug to 24 4 29 8 N m 18 22 ft Ib Wire Gauge Spark Plug 0 76 mm 0 030 in Gap Figure 14 Servicing Spark Plug Electrode Battery Charging A 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 filte
31. stablishment or individual Warranty repairs must be performed by an authorized Kohler service outlet A 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 Maintenance Required Fill fuel tank Daily Or Before Check oil level Starting Engine Check air cleaner for dirty loose or damaged parts Check air intake and cooling areas clean as necessary Every 25 Hours e Service precleaner element Every 50 Hours e Check air cleaner element clean or replace as necessary Replace air cleaner element and precleaner Change oil and oil filter more frequently under severe conditions Annually or Every 100 Hours Replace fuel filter Check spark plug condition and gap e Have valve lash checked adjusted e Have bendix starter drive serviced e Have solenoid shift starter disassembled and cleaned Perform these maintenance procedures more frequently under extremely dusty dirty conditions Have a Kohler Engine Service Dealer perform these services e Remove cooling shrouds and clean cooling areas
32. tic drive The shift lever must be exactly in neutral to prevent resistance which could keep the engine from starting A 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 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 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 t
33. upied 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 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 including E20 and E85 are not to be used and not approved Any failures resulting from use of these fuels will not be warranted Gasoline Ether blends
34. 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 6 Close and latch the door 7 When precleaner replacement is necessary order genuine Kohler Parts 32 083 05 S Precleaner 37 mm 1 45 in high 32 083 08 S Precleaner PRO 71 mm 2 79 in high 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 Figures 9 and 10 2 Unhook the latch and remove the air cleaner element and precleaner if equipped See Figure 12 and 13 3 Remove the precleaner if so equipped from the paper element Service the precleaner as described in Precleaner Service 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 PRO 78 mm 3 07 in high 5 Clean the air cleaner base as required and check condition 6
35. y TOA een 17 2 23 Compression vcs LO een Oe AA OHREN een 9 1 YNO E anera SA ee A acatsyaeeestasededersetegs Al ee 41 2 91 Oil Capacity w filter approximate determined by oil filter used 1 6 1 8 L 1 7 1 9 U S qt Lubrication Combination Pressure Splash Lube w full Flow Filter DO E V72 OV eisen ONT OO casera SV740 DOTE ene eer ren ee PMA IN ee e SA 007 078 ae ar A EE NSA P B3 3 27 DIOR een DIN ee OF DB OF 0er 67 2 64 Displacement nenn CH IN Yo 725 44 2 rssccccsssecssrsesseeees 725 44 2 eccscecssrseesrrees 725 44 2 Power 3600 RPM EW HE Joseren 17 IP 21186 20 Jesns I O een 20 1 27 Compression RAlO ee Dee a EE 9 1 WVO E ae calles eee re BN PAO esse PUP ON re 41 2 91 Oil Capacity w filter approximate determined by oil filter used 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 SV740 is EM for U S EPA and Europe PAIR for California Tier III Horsepower ratings exceed Society of Automotive Engineers Small Engine Test Code J1940 Actual engine horsepower is lower and affected by but not limited t
36. y into each engine making a Kohler engine dependable dependability you can count on Here are some reasons why e 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 amp Canada for Sales amp Service assistance Or visit www KohlerEngines com To keep your engine in top operating condition follow the maintenance procedures in this manual Courage Air Cleaner Access Door Handle Courage PRO Raised Air Cleaner Dipstick Access Door Electric Starter Spark Plug Figure 1 Typical Courage and Courage PRO Series Vertical Shaft Engines 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 failu
37. year 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 one 1 year 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 replac
Download Pdf Manuals
Related Search