Kohler Courage Model Xt 7 4 8hp Engine Shop Manual

SERVICE MANUAL COURAGE XT-6, XT-7 VERTICAL CRANKSHAFT

Contents Section 1. Safety and General Information .............................................................................

Section 2. Tools and Aids .........................................................................................................

Section 3. Troubleshooting ......................................................................................................

Section 4. Air Cleaner and Air Intake System .........................................................................

Section 5. Fuel System and Governor.....................................................................................

Section 6. Lubrication System .................................................................................................

Section 7. Electrical System and Components ......................................................................

Section 8. Disassembly.............................................................................................................

Section 9. Inspection and Reconditioning ..............................................................................

Section 10. Reassembly............................................................................................................

1 2 3 4 5 6 7 8 9 10

Section 1 Safety and General Information

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Section 1 Safety and General Information 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.

WARNING Warning is used to indicate the presence of a hazard that can cause severe personal injury, death, or substantial property damage if the warning is ignored.

CAUTION Caution is used to indicate the presence of a hazard that will or can cause minor personal injury or property damage if the caution is ignored.

NOTE Note is used to notify people of installation, operation, or maintenance information that is important but not hazard-related.

For Your Safety!

These precautions should be followed at all times. Failure to follow these precautions could result in injury to yourself and others.

WARNING

WARNING

Accidental Starts can cause severe injury or death.

Rotating Parts can cause severe injury.

Disconnect and ground spark plug leads before servicing.

Stay away while engine is in operation.

Accidental Starts!

Disabling engine. Accidental starting can cause severe injury or death. Before working on the engine or equipment, disable the engine by disconnecting the spark plug lead.

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.

WARNING

Hot Parts can cause severe burns.

Do not touch engine while operating ȱ ȱ Ğ ȱ ǯ

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 Ğ ȱ ȱ ȱ ȱ ěǯȱ ȱ ȱ the engine with heat shields or guards removed.

1.1

Section 1 Safety and General Information

WARNING

WARNING

([SORVLYH )XHO FDQ FDXVH ¿UHV DQG severe burns.

Carbon Monoxide can cause severe nausea, fainting or death.

ȱ ȱę ȱ ȱ ȱ ȱ ȱ ȱ engine is hot or running.

Avoid inhaling exhaust fumes, and never run the engine in a closed ȱ ȱ ę ȱ ǯ

Explosive Fuel! ȱ ȱ ¡ ¢ȱĚ ȱ ȱ its vapors can explode if ignited. Store gasoline only in approved containers, in well ventilated, unoccupied ǰȱ ¢ȱ ȱ ȱ ȱĚ ǯȱ ȱ ȱę ȱ ȱ ȱ ȱ ȱ ȱ 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.

WARNING

Cleaning Solvents can cause severe injury or death.

Use only in well ventilated areas away from ignition sources.

Flammable Solvents!

Carburetor cleaners and solvents are ¡ ¢ȱĚ ǯȱ ȱ ǰȱ Ě ǰȱ ȱ ȱ ȱ ȱ ȱ away from the area. Follow the cleaner manufacturer’s warnings and instructions on its proper and safe use.

Never use gasoline as a cleaning agent.

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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 ȱ ȱ ȱ ȱ ȱ ȱ ę ȱ area.

CAUTION

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.

Section 1 Safety and General Information (QJLQH ,GHQWL¿FDWLRQ 1XPEHUV When ordering parts, or in any communication involving an engine, always give the Model, ę ǰȱ ȱ ȱ of the engine.

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ȱ ę ȱ ȱ ȱ ȱ ȱ ȱ Ĝ¡ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱŗȬŗǯȱ ȱ ¡ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱŗȬŘǯ

,GHQWL¿FDWLRQ /DEHO )LJXUH ,GHQWL¿FDWLRQ /DEHO

A. Model No.

XT 7

Courage Vertical Shaft Engine Numerical Designation

B. Spec. No. Engine Model Model XT-6 XT-7

C. Serial No.

XT173-0001 )LUVW VSHFL¿FDWLRQ written in this model series

3723500328

Year Manufactured Code Code Year 37 2007 38 2008

Factory Code

)LJXUH ([SODQDWLRQ RI ,GHQWL¿FDWLRQ 1XPEHUV

1.3

Section 1 Safety and General Information Oil Recommendations

Fuel Recommendations

Using the proper type and weight of oil in the engine is extremely important, as is daily checking of oil level Š—Â?ČąÂŒÂ‘ÂŠÂ—Â?’—Â?ČąÂ˜Â’Â•ČąÂ›ÂŽÂ?ž•Š›•¢ǯȹ Š’•ž›ŽȹÂ?Â˜ČąÂžÂœÂŽČąÂ?Â‘ÂŽČąÂŒÂ˜Â›Â›ÂŽÂŒÂ?Čą oil, or using dirty oil, will cause premature engine wear and failure.

Oil Type Use high quality detergent oil of ȹǝ Â–ÂŽÂ›Â’ÂŒÂŠÂ—Čą ÂŽÂ?Â›Â˜Â•ÂŽÂžÂ–Čą —œÂ?Â’Â?žÂ?ÂŽÇźČąÂœÂŽÂ›Â&#x;Â’ÂŒÂŽČąÂŒÂ•ÂŠÂœÂœČą ČąÂ˜Â›ČąÂ‘Â’Â?‘Ž›. Select the viscosity based on the air temperature at the time ˜Â?ČąÂ˜Â™ÂŽÂ›ÂŠÂ?Â’Â˜Â—ČąÂŠÂœČąÂœÂ‘Â˜Â Â—ČąÂ’Â—Čą Â’Â?ž›Žȹŗȏřǯ RECOMMENDED SAE VISCOSITY GRADES 10W-30, SAE 30 10W-30 °F -20 °C -30

0 -20

20 -10

32 0

40

60 10

80 20

30

100 40

TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANGE

Figure 1-3. Viscosity Grades Table.

NOTE:

Using other than service class SJ or higher oil or extending oil change intervals longer than recommended can cause engine damage.

ČąÂ•Â˜Â?Â˜ČąÂ˜Â›ČąÂœÂ˘Â–Â‹Â˜Â•ČąÂ˜Â—ČąÂ˜Â’Â•ČąÂŒÂ˜Â—Â?ÂŠÂ’Â—ÂŽÂ›ÂœČąÂ’Â?Ž—Â?Â’Ä™ÂŽÂœČąÂ?‘Žȹ Čą œŽ›Â&#x;Â’ÂŒÂŽČąÂŒÂ•ÂŠÂœÂœČąÂŠÂ—Â?Čą ČąÂ&#x;’œŒ˜œ’Â?¢ȹÂ?›ŠÂ?ÂŽÇŻČą ÂŽÂŽČą Â’Â?ž›ŽȹŗȏŚǯȹ

10W-30

SJ

API

RVIC E

SE

Figure 1-4. Oil Container Logo.

Refer to Section 6, Lubrication System, for detailed oil check and oil change procedures.

1.4

WARNING: Explosive Fuel! ÂŠÂœÂ˜Â•Â’Â—ÂŽČąÂ’ÂœČąÂŽÂĄÂ?›Ž–Ž•¢ȹ̊––Š‹•ŽȹŠ—Â?ȹ’Â?ÂœČąÂ&#x;ÂŠÂ™Â˜Â›ÂœČąÂŒÂŠÂ—ČąÂŽÂĄÂ™Â•Â˜Â?ÂŽČą if ignited. Store gasoline only in approved containers, in well ventilated, unoccupied buildings, away from sparks or ÄšÂŠÂ–ÂŽÂœÇŻČą Â˜ČąÂ—Â˜Â?ȹꕕȹÂ?‘ŽȹÂ?žŽ•ȹÂ?Š—”ȹ ‘’•ŽȹÂ?‘ŽȹŽ—Â?Â’Â—ÂŽČąÂ’ÂœČąÂ‘Â˜Â?ČąÂ˜Â›Čą 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 ŒŠ™ŠŒ’Â?Â˘ČąÂ˜Â?ČąĹ˜ČąÂ?ÂŠÂ•Â•Â˜Â—ÂœČąÂ˜Â›ČąÂ•ÂŽÂœÂœČąÂ Â’Â?Â‘ČąÂŠČąÂ™Â˜ÂžÂ›Â’Â—Â?ČąÂœÂ™Â˜ÂžÂ?ČąÂ’ÂœČą recommended. Such a container is easier to handle and helps eliminate spillage during refueling.

To ensure easy starting and minimize gum deposits in Â?‘ŽȹÂ?ÂžÂŽÂ•ČąÂœÂ˘ÂœÂ?Ž–ǰȹÂ?Â˜ČąÂ—Â˜Â?ČąÂžÂœÂŽČąÂ?ÂŠÂœÂ˜Â•Â’Â—ÂŽČąÂ•ÂŽÄžČąÂ˜Â&#x;Ž›ȹÂ?Â›Â˜Â–ČąÂ?‘Žȹ previous season. Do not add oil to the gasoline. Do not ˜Â&#x;Ž›ę••ȹÂ?‘ŽȹÂ?žŽ•ȹÂ?Š—”Dzȹ•ŽŠÂ&#x;ÂŽČąÂ›Â˜Â˜Â–ČąÂ?Â˜Â›ČąÂŽÂĄÂ™ÂŠÂ—ÂœÂ’Â˜Â—ÇŻ Fuel Type Â˜Â›ČąÂ‹ÂŽÂœÂ?ČąÂ›ÂŽÂœÂžÂ•Â?ÂœÇ°ČąÂžÂœÂŽČąÂ˜Â—Â•Â˘ČąÂŒÂ•ÂŽÂŠÂ—Ç°ČąÂ?Â›ÂŽÂœÂ‘Ç°ČąÂžÂ—Â•ÂŽÂŠÂ?ÂŽÂ?Čą gasoline with a pump sticker octane rating of 86 or ‘’Â?‘Ž›ǯȹ Â—ČąÂŒÂ˜ÂžÂ—Â?Â›Â’ÂŽÂœČąÂžÂœÂ’Â—Â?ČąÂ?Â‘ÂŽČąÂ›ÂŽÂœÂŽÂŠÂ›ÂŒÂ‘ČąÂ–ÂŽÂ?‘˜Â?ǰȹ’Â?Čą should be 90 octane minimum.

Unleaded gasoline is recommended, as it leaves less combustion chamber deposits. Leaded gasoline may be used in areas where unleaded is not available and exhaust emissions are not regulated. Be aware however, using unleaded gasoline will require more frequent cylinder head servicing.

Gasoline/Alcohol Blends ÂŠÂœÂ˜Â‘Â˜Â•ČąÇťÂžÂ™ČąÂ?Â˜ČąĹ—Ĺ–Ć–ČąÂŽÂ?Â‘Â˘Â•ČąÂŠÂ•ÂŒÂ˜Â‘Â˜Â•Ç°ČąĹ&#x;ŖƖȹž—•ŽŠÂ?ÂŽÂ?Čą gasoline by volume) is approved as a fuel for Kohler Ž—Â?Â’Â—ÂŽÂœÇŻČą Â?‘Ž›ȹÂ?ÂŠÂœÂ˜Â•Â’Â—ÂŽČŚÂŠÂ•ÂŒÂ˜Â‘Â˜Â•ČąÂ‹Â•ÂŽÂ—Â?ÂœČąÂ’Â—ÂŒÂ•ÂžÂ?’—Â?Čą Ĺ˜Ĺ–Čą and E85 are not to be used and are not approved. Any failures resulting from use of these fuels will not be warranted.

Gasoline/Ether Blends Methyl Tertiary Butyl Ether (MTBE) and unleaded Â?ÂŠÂœÂ˜Â•Â’Â—ÂŽČąÂ‹Â•ÂŽÂ—Â?ÂœČąÇťÂžÂ™ČąÂ?Â˜ČąÂ–ÂŠÂĄÂ’Â–ÂžÂ–ČąÂ˜Â?ȹŗśƖȹ ȹ‹¢ȹ volume) are approved as a fuel for Kohler engines.

Other gasoline/ether blends are not approved.

Section 1 Safety and General Information Periodic Maintenance WARNING: Accidental Starts!

Disabling engine. Accidental starting can cause severe injury or death. Before working on the engine or equipment, disable the engine by disconnecting the spark plug lead.

Maintenance Schedule These required maintenance procedures should be performed at the frequency stated in the table. They should also be included as part of any seasonal tune-up.

Frequency ÂŠÂ’Â•Â˘ČąÂ˜Â›Čą ÂŽÂ?Â˜Â›ÂŽČą Â?Š›Â?’—Â?Čą —Â?’—Ž Yearly or Every 25 Hours Yearly or Every 50 Hours ÂŽÂŠÂ›Â•Â˘ČąÂ˜Â›Čą Â&#x;ÂŽÂ›Â˘ČąĹ—Ĺ–Ĺ–ČąÂ‘Â˜ÂžÂ›Âœ

Maintenance Required ’••ȹÂ?žŽ•ȹÂ?Š—”ǯ Check oil level. Â‘ÂŽÂŒÂ”ČąÂŠÂ’Â›ČąÂ’Â—Â?Š”ŽȹŠ—Â?ČąÂŒÂ˜Â˜Â•Â’Â—Â?ČąÂŠÂ›ÂŽÂŠÂœÇ˛ČąÂŒÂ•ÂŽÂŠÂ—ČąÂŠÂœČąÂ—ÂŽÂŒÂŽÂœÂœÂŠÂ›Â˘ÇŻĹľ Ž›Â&#x;Â’ÂŒÂŽČąÂ˜Â›ČąÂ›ÂŽÂ™Â•ÂŠÂŒÂŽČąÂ™Â›ÂŽÂŒÂ•ÂŽÂŠÂ—ÂŽÂ›ČąÂŽÂ•ÂŽÂ–ÂŽÂ—Â?ȹǝ’Â?ȹŽšž’™™ŽÂ?ǟǯž Â‘ÂŽÂŒÂ”ČąÂŠÂ’Â›ČąÂŒÂ•ÂŽÂŠÂ—ÂŽÂ›ČąÂŽÂ•ÂŽÂ–ÂŽÂ—Â?ČąÂ?Â˜Â›ČąÂ?’›Â?Â˘Ç°ČąÂ•Â˜Â˜ÂœÂŽČąÂ˜Â›ČąÂ?Š–ŠÂ?ÂŽÂ?ȹ™Š›Â?ÂœÇŻĹľ ÂŽÂ™Â•ÂŠÂŒÂŽČąÂ?žŽ•ȹę•Â?Ž›ǰȹ’Â?ȹŽšž’™™ŽÂ?ÇŻ Change oil.

Replace spark plug and set gap. ÂŽÂ™Â•ÂŠÂŒÂŽČąÂŠÂ’Â›ČąÂŒÂ•ÂŽÂŠÂ—ÂŽÂ›ČąÂŽÂ•ÂŽÂ–ÂŽÂ—Â?ÇŻĹľ

šPerform these maintenance procedures more frequently under extremely dusty, dirty conditions.

Storage Â?ČąÂ?‘ŽȹŽ—Â?Â’Â—ÂŽČąÂ Â’Â•Â•ČąÂ‹ÂŽČąÂ˜ÂžÂ?ČąÂ˜Â?ČąÂœÂŽÂ›Â&#x;Â’ÂŒÂŽČąÂ?Â˜Â›ČąÂ?Â Â˜ČąÂ–Â˜Â—Â?Â‘ÂœČąÂ˜Â›Čą more, use the following storage procedure:

ȹ Śǯȹ Remove the spark plug. Add one tablespoon of engine oil into the spark plug hole. Reinstall the plug, but do not connect the plug lead. Crank the engine two or three revolutions.

Čą Ĺ—ÇŻČą •ŽŠ—ȹÂ?‘ŽȹŽ¥Â?ÂŽÂ›Â’Â˜Â›ČąÂœÂžÂ›Â?ÂŠÂŒÂŽÂœČąÂ˜Â?ČąÂ?‘ŽȹŽ—Â?’—Žǯ Čą Ĺ˜ÇŻČą ‘Š—Â?ÂŽČąÂ?Â‘ÂŽČąÂ˜Â’Â•ČąÂ Â‘Â’Â•ÂŽČąÂ?‘ŽȹŽ—Â?Â’Â—ÂŽČąÂ’ÂœČąÂœÂ?’••ȹ Š›–ȹ Â?Â›Â˜Â–ČąÂ˜Â™ÂŽÂ›ÂŠÂ?Â’Â˜Â—ÇŻČą Â˜Â›ČąÂ?ž›Â?‘Ž›ȹ’—Â?˜›–ŠÂ?Â’Â˜Â—Ç°ČąÂœÂŽÂŽČą Section 6, Lubrication System. Čą řǯȹ ‘ŽȹŽ—Â?Â’Â—ÂŽČąÂ–ÂžÂœÂ?ȹ‹Žȹ›ž—ȹž—Â?’•ȹÂ?‘ŽȹÂ?žŽ•ȹÂ?ÂŠÂ—Â”ČąÂ’ÂœČą completely emptied, or the gasoline must be treated with a stabilizer to prevent deterioration. Â?ČąÂ˘Â˜ÂžČąÂŒÂ‘Â˜Â˜ÂœÂŽČąÂ?Â˜ČąÂžÂœÂŽČąÂŠČąÂœÂ?Š‹’•’£Ž›ǰȹÂ?Â˜Â•Â•Â˜Â ČąÂ?‘Žȹ –Š—žÂ?ŠŒÂ?ÂžÂ›ÂŽÂ›Č‡ÂœČąÂ›ÂŽÂŒÂ˜Â–Â–ÂŽÂ—Â?ŠÂ?Â’Â˜Â—ÂœÇŻČą ’••ȹÂ?‘ŽȹÂ?žŽ•ȹ tank with clean, fresh gasoline, and run the Ž—Â?’—ŽȹÂ?Â˜Â›ČąĹ˜ČŹĹ™ČąÂ–Â’Â—ÂžÂ?ÂŽÂœČąÂ?Â˜ČąÂ?ÂŽÂ?ČąÂœÂ?Š‹’•’£ŽÂ?ČąÂ?žŽ•ȹ’—Â?Â˜Čą the carburetor.

5. Remove the spark plug. Cover the spark plug hole with your thumb and turn the engine over until the piston is at the top of its stroke (pressure against the thumb is greatest). Reinstall the spark plug, but do not connect the plug lead.

6. Store the engine in a clean, dry place. Never store the machine or fuel container where there is an Â˜Â™ÂŽÂ—ČąÄšÂŠÂ–ÂŽÇ°ČąÂœÂ™ÂŠÂ›Â”Ç°ČąÂ˜Â›ČąÂ™Â’Â•Â˜Â?ȹ•’Â?‘Â?ČąÂœÂžÂŒÂ‘ČąÂŠÂœČąÂ˜Â—ČąÂŠČą water heater or on other appliances.

1.5

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