Cub Cadet 522 WE Owner's Manual

10Command Series

ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044 LITHO IN U.S.A.

11AegisSealed Relay KitNew ThermostatInstallation InstructionsTT-5232Sealed Relay Kit 66 755 19-SThis kit replaces an unsealed relay with a sealed rel

AegisCub Cadet Harness Protection and Vapor Lock&XE&DGHWKDVGHYHORSHG6HUYLFH.LWWRUHGXFHWKHFKDQFHRIZLUHKDUQHVVGDPDJHDQ

13Courage SeriesSection 3 - Courage SeriesMachined CamCourage TwinAssembled Camshaft The new automotive style, “assembled camshaft” consists of a mach

14Courage SeriesEmissions StatementWe are updating the Owner’s Manual regarding emissions compliance. We are adding a statement that will recommend th

15Courage SeriesNew Cam DesignThe new design cam reduces the number of parts in the engine as the gear, lobe, and shaft will be assembled as one part.

16Courage SeriesLess reciprocating mass means less force to balance within the system. That means lower bearing loads and longer engine life. To accom

17Courage SeriesCrankshaft Detail“2” Indicates New Balance System“3” IndicatesCARB Tier IIIDecal ReminderWhen placing the decal for the short EORFNP

18Courage SeriesCourage XTXT Fuel Tank DebrisWe have found some evidence of debris showing up in the IXHOWDQNVRQWKH;7HQJLQH$WKRURXJKLQYHVWL

19Kohler DieselSection 4 - Kohler DieselModel Number ReviewThe chart below is included to help you become familiar with and more easily identify the d

2Table of ContentsCommand SeriesGeneral 6$(2LO$ERYHÛ)Û& ...

20Kohler Diesel15LD 400/KD400Hydraulic Lifter Rocker Arm Torque Procedure7KHUHKDYHEHHQUHSRUWVLQWKH¿HOGRIVRPHFRQIXVLRQRQthe hydraulic lifter

21Kohler Diesel15LD 315-440/KD315-440Injection Pump Check Valve:HKDYHKDGVRPHUHSRUWVIURPWKH¿HOGRISUREOHPVZLWKthese engines not shutting down

22Kohler DieselAll Liquid-Cooled Series)XHO)LOWHU+HDG0RGL¿FDWLRQBeginning at engine Serial Number 5002295WKHIXHO¿OWHUKHDGRQWKHDERYHPHQWLR

23Kohler DieselLDW 702-1404/KDW702-1404)XHO/LIW3XPS&DPVKDIW/REH0RGL¿FDWLRQStarting with the following engine serial numbers:  /':.

24Kohler DieselOil Pan RemovalPlease note that when removing the oil pan on these engines, care must be taken not to pull the lateral oil seals, locat

25Kohler DieselControl Panel Indicator Lights7KHFRQWUROSDQHORQWKH/':.':VHULHVRIHQJLQHVKDVDVHOIFRQWDLQHGHQJLQHVDIHW\shutdown

26Kohler DieselKey/Key Switch ChangeStarting at engine Serial Number 5252706, the engine key/key switch has been changed to a new style that incorpora

27New ProductSection 5 - New ProductKohler Introduces New Command Pro Horizontal Engine LineKohler Engines is pleased to introduce a new line of produ

28New Product:DUP:HDWKHUYV$QWL,FLQJ&RQ¿JXUDWLRQ+HDY\'XW\$LU¿OWHUA heavy duty patented air cleaner is standard. It has an indexable c

29New ProductOther FeaturesAlong with all of the other standard features, the Command Pro includes electronic ignition, Oil SentryTMORZRLOSURWHFWLR

3Command SeriesLDW 702-1404/KDW702-1404 (cont.) Control Panel Indicator Lights...

30New ProductKohler Enters Consumer Horizontal MarketThe leader in commercial engine products is now manufacturing a line of horizontal consumer engin

31New ProductWater Trap CarburetorThe water trap carburetor controls the moisture that can sometimes create a problem for getting these engines starte

32New ProductNew Commercial EFIIntroducing the all new self-contained EFI system from Kohler Engines. This “Closed Loop” “Sequential Fuel Injection” s

33New ProductCourage XT-6September 2007 marked a great milestone for Kohler (QJLQHVZLWKWKHODXQFKRIRXU¿UVWHYHUHQJLQHIRUWKHconsumer walk behi

34New Product

35MiscellaneousSection 6 - MiscellaneousReplace Mating GearsIt is recommended in situations where a broken crankshaft gear is replaced as a repair tha

36Miscellaneous1800 3600140808 320 640100 4,000 8,000200 8,000 16,000500 20,000 40,0002,000 80,000 160,0003,000 120,000 240,000Makes You Think...This

37MiscellaneousWho Left the Oil Lights On7KH2LO3UHVVXUH6ZLWFK3DUW1R6ZDV¿UVWintroduced into production in January of 2008. We hav

38MiscellaneousBearing FailuresBearing failures can be easy to identify but extremely GLI¿FXOWWRWURXEOHVKRRW2QHFDXVHRIORZHUEHDULQJIDLOXUHcan

39MiscellaneousAnti-Icing ComponentsFor applications that are used in warm as well as cold weather environments, we have some kits available to keep y

4Command SeriesTechnician’s Service TestGasoline ...

40MiscellaneousReplacement Engine ReminderThis is a reminder when replacing an engine you must check to see if the original engine is emission complia

41MiscellaneousStep 1 Step 1Step 2 Step 2Step 2 Step 2Step 4 Step 4Step 4 Step 4Step 5 Step 5Step 6 Step 6(list none if corrective actions were not ne

42MiscellaneousPage 1Solenoid Shift Starting Circuit Test ProcedureREV. 07/23/2008Before Starting:Battery voltage should be tested and must be at 12.4

43MiscellaneousPage 1Inertia Drive Starting Circuit Test ProcedureREV. 07/21/2008Before Starting:Battery voltage should be tested and must be at 12.4

44MiscellaneousKohler PLUS NewsCarburetor Repair Kits in Kohler PLUSKohler PLUS has been improved to list the individual carburetor repair kits at the

45MiscellaneousDescriptions Now SearchableSearchable Literature Descriptions Some recent changes to Kohler PLUS formatting include the ability to now

46MiscellaneousOther Enhancements Now AvailableRPM Idle and High Speed Settings -ORFDWHGLQWKHVSHFL¿FDWLRQKHDGHUFast Moving Parts - found immedia

47MiscellaneousFactory Schools 2008-2009Expanding the limits of power.

48MiscellaneousTelephone No.( ) - Business Telephone Number ( )Expert DealerSpecialized Dealer&HUWL¿HG7HFKQLFLDQA

49Warranty NewsSection 7 - Warranty NewsWarranty System NOW AVAILABLEThe Kohler Engine Division is pleased to announce the start of a new era. Our new

5Command SeriesSection 1 - Command SeriesGeneralSAE-30 Oil Above 50°F (10°C)It has been standard practice and was recommendedforever to use 10W-30 oil

50Warranty NewsAfter entering the system you will see the Warranty Home Page.Trusted Site DirectionIf you encounter a problem while entering a warrant

51Warranty NewsEnter Warranty as a Trusted SiteSecurity Settings5. Type the warranty site web address and press theType the warranty site web address

52Warranty NewsHelpful System Tips• To use the system, all users must obtain a User Account to gain access. Contact your local CD or call the User Acc

53Warranty NewsEWR Review (Engine Warranty Return),I\RXKDYHHYHUGHDOWZLWKDGLI¿FXOWZDUUDQW\VLWXDWLRQ\RXmay occasionally have asked yourself

54Warranty NewsEWR When?EWR is issued after a Dealer or Kohler Representative have examined engine or component and:• are unable to determine the root

55Bulletins, Etc.Section 8 - Bulletins, Etc.Beginning this year, we will include every Bulletin, Technical Flash, and TechTip released throughout the

56Bulletins, Etc.251Walker CH26 7/07DATE REVISEDDATE ISSUEDMODELNO.PartsBulletinNew EFI Long Block for Walker CH26A new CH26 EFI long block, pa

57Bulletins, Etc.253Some CH/CV/SV Twins and Singles10/08Correct Fuel Filter Selectionȱȱȱȱȱȱȱ¢ȱȱȱ

58Bulletins, Etc.254SV470-SV62010/08Short Blocks for Courage Single Cylinder EnginesFor model year 2009, the Courage single-cylinder engines will inco

59Bulletins, Etc.Figure 1. Example of Cracked Flywheel Ring Gear. 3/08SV470-SV620SV710-SV840Loose/Cracked Flywheel Ring Gearsȱȱ¢ȱ

6Command SeriesDSAI Wiring Harness UpgradeTo combat occasional voltage spikes, we have upgradedthe wiring harness for both the vertical and horizontal

60Bulletins, Etc.ServiceManagerInitial HereSalesManagerPartsManagerChiefMechanicMechanicNo. 1MechanicNo. 2MechanicNo. 3MechanicNo. 4ReturnThis ToRouti

61Bulletins, Etc.6/94CH/CV940-980Flywheel and Mounting Stud Replacementȱȱęȱǰȱȱȱ¢ȱȱȱȱ¢ȱȦşŚŖȬşŞŖȱ

62Bulletins, Etc.26. Remove the screws, reinforcing washers, grass ǰȱȱěǯȱȱȱŚǯFigure 4. Removing Grass Screen Fasteners.7. 

63Bulletins, Etc.3Figure 9. Clean and Dry Crankshaft Taper.Figure 8. Clean and Dry Flywheel Hub.2. ȱȱĚ¢ȱȱȱĞǰȱȱ

64Bulletins, Etc.4Figure 13. Lead Routing Details.14. ȱȱȱȱȱȱĚ¢ǰȱȱȱȱǯȱ¢ȱȱȱ

65Bulletins, Etc.CH/CV7302891/08DATE REVISEDDATE ISSUEDMODELNO.ServiceBulletin WARNING: Accidental Starts!Disabling engine. Accidental starting can ca

66Bulletins, Etc.2Figure 6. Correct Offset Key Orientation.Figure 5. Correct Offset Key Installation.Figure 4. Offset Key.Offset KeyCrankshaftFlywheel

67Bulletins, Etc.6/94Various2905/08DATE REVISEDDATE ISSUEDMODELNO.ServiceBulletinOil Pressure Switch 25 099 27-Sȱęȱȱȱȱ

68Bulletins, Etc.10/08CH740 and CV7402919/08DATE REVISEDDATE ISSUEDMODELNO.ServiceBulletinDSAI Interface Wire Harnesses with Diodesȱęȱ

69Bulletins, Etc.1ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044Ground Relocation on Dixon ZTR MowersFigure 1. Original Layout (Kodiak 908 Show

7Command SeriesIncorrect Solenoid Jet (24 757 22-S)7KHVROHQRLGNLW3DUW1R6KDVEHHQLGHQWL¿HGas having been built with the No. 120 jet

70Bulletins, Etc.1Litho In U.S.A. 12/07 ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044Engines Stalling With Fuel in Tankȱȱęȱ

71Bulletins, Etc.1Litho In U.S.A. 03/08 ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044KEK-032008 WARNING: Accidental Starts!Disabling engine. A

72Bulletins, Etc.1Litho In U.S.A. 05/08 ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044ARIENS-052008 WARNING: Accidental Starts!Disabling engine

73Bulletins, Etc.Te chTipLitho In U.S.A. 9/08 ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044Electronic GovernorOverview, Diagnosing, and Troub

74Bulletins, Etc.2Figure 3. Governor Control Unit Locations.Governor Control UnitGovernor Control UnitActuatorClevis ShaftRubber BootFigure 5. Explode

75Bulletins, Etc.3Harness/GCU Trouble Shooting and Diagnostic Procedures1. ȱȱ¢ȱȱȱěȱǯ2. Remove the GCU and unplug the wiring h

76Bulletins, Etc.4OHMs TestsRemove the GCU and unplug the wiring harness. See Figure 6 and 7.The following two tests are for measuring the resistance

77Bulletins, Etc.5Figure 16. GCU Blink Code Chart with the engine Running.Governor Control Unit (24 584 59-S) Blink Codes for Software Version: KGETO3

78Bulletins, Etc.6Kohler Electronic Governor Troubleshooting ChartTurn off key switchDo Not Touch the Digital Linear Actuator (DLA) NOTE: The DLA is n

79Bulletins, Etc.7Test 1: Identify the following wire ends in the plug. Using a digital multi-meter set to the lowest scale (0-200 ohms) place the pro

8Command SeriesOil Pump Gear Interference (24 393 51-S)When the CH/CV750 and LH755/775 were developed in2005, the stroke of the crankshaft was increas

80Bulletins, Etc.8B+10812131412671B1A2A2BApplication Supplied Speed Control InputFigure 17. Basic Electrical Diagram of System. Operation Input Voltag

81Bulletins, Etc.Te chTipLitho In U.S.A. 2/08 Rev. 9/08 ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044Electronic GovernorOverview, Diagnosing

82Bulletins, Etc.2Figure 3. Governor Control Unit Locations.Governor Control UnitGovernor Control UnitActuatorClevis ShaftRubber BootFigure 5. Explode

83Bulletins, Etc.3Harness/GCU Trouble Shooting and Diagnostic Procedures1. ȱȱ¢ȱȱȱěȱǯ2. Remove the GCU and unplug the wiring h

84Bulletins, Etc.4OHMsTestsRemove the GCU and unplug the wiring harness. See Figure 6 and 7.The following two tests are for measuring the resistance o

85Bulletins, Etc.5Kohler Engines - GCU (24 584 40-S or 24 584 56-S) Blink CodesLED DiagnosticsFailure Condition Possible Causes Response Response Time

86Bulletins, Etc.6Kohler Electronic Governor Troubleshooting ChartTurn off key switchDo Not Touch the Digital Linear Actuator (DLA) NOTE: The DLA is n

87Bulletins, Etc.7Test 1: Identify the following wire ends in the plug. Using a digital multi-meter set to the lowest scale (0-200 ohms) place the pro

88Bulletins, Etc.8B+10812131412671B1A2A2BApplication Supplied Speed Control InputFigure 17. Basic Electrical Diagram of System. Operation Input Voltag

89Bulletins, Etc.Litho In U.S.A. 7/07 ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044Kohler Engines Truck-Mounted Applications Grounding Instru

9Command SeriesOld vs. New PumpEFINew EFI Fuel Pumps (24 393 52-S)Starting in March 2008, all EFI engines have been built withfuel pumps from a new su

90Bulletins, Etc.

91Technician’s Service TestSection 9Technician’s Service TestThis section contains two tests. The Gasoline test is 40 multiple-choice questions; the D

92Technician’s Service TestGasoline Test Questions1. When should an EWR be started?a. When the Dealer is too busy to process a warranty claim.b. When

93Technician’s Service Test11. What is covered in the Electronic Governor TechTips?a. Blink code informationb. Mechanical checksc. Troubleshooting pro

94Technician’s Service Test 7KH¿UVWVWHSLQDQ\VWDUWHUWHVWLQJSURFHGXUHLVWRFKHFNEDWWHU\YROWDJH:KDWLVWKHYROWDJHRIDIXOO\FKDUJHGED

95Technician’s Service Test :KDWIXHO¿OWHUSDUWQXPEHUQXPEHUVFDQEHXVHGRQHQJLQHVZLWKIXHOSXPSV"a. 25 050 22-S and 25 050 21-Sb. 25

96Technician’s Service TestDiesel Test Questions  7KHQHZVW\OHNH\IRUWKH/':DQGRU.':VHULHVHQJLQHVNH\VZLWFKLVFXWRQKRZPDQ\

97Technician’s Service Test*DVROLQH7HVW$QVZHU6KHHW1. a b c d2. a b c d3. a b c d4. a b c d5. a b c d'LHVHO7HVW$QVZHU6KHHW1. a b c d2. a b c

98Technician’s Service Test