SERVICE BULLETIN ATTN: PARTS AND SERVICE MANAGER. Mandatory Rework: Installation of an In Line Fuse.

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SERVICE BULLETIN ATTN: PARTS AND SERVICE MANAGER DATE: April 21, 2014 NUMBER: 14-04 SUBJECT: Kohler DSAI Ignition Module UNITS AFFECTED: SITUATION: SOLUTION: Lazer & Pioneer Models: Kohler-Powered

1 SERVICE BULLETIN ATTN: PARTS AND SERVICE MANAGER DATE: April 21, 2014 NUMBER: SUBJECT: Kohler DSAI Ignition Module UNITS AFFECTED: SITUATION: SOLUTION: Lazer & Pioneer Models: Kohler-Powered Units designated as 27KC or 740KC Serial Range: 790, ,999,999 Navigator Models: NV27KC & NV740KC Serial Range: 933, ,654,022 Note: Attached is a detailed Model & Serial list of units affected. We have received reports that the Kohler DSAI (Digital Spark Advanced Ignition) ignition module could overheat and potentially cause a fire. Mandatory Rework: Installation of an In Line Fuse. PARTS NEEDED: Fuse Kit: A letter (copy enclosed) will be sent to all registered owners to notify them of this program. If you have sold a unit which may not be registered, you should contact the owner concerning this program. Also, all unsold inventory must be reworked prior to delivery. Once the inventory is reworked, it can be sold. Note: The affected units were built from During the 2013 build, Kohler changed from the DSAI to the MDI system with the last DSAI Kohler engine serial number 43151xxxxx. WARRANTY: There will be a quick file claim available for all units, utilizing this service bulletin number for the failure code (14-04), which pays a labor allowance of.5 hrs. The standard $45 pick-up and delivery reimbursement will apply for personal use/residential owners. EXMARK MFG. CO., INC. Lenny Mangnall Technical Service Manager ROUTING REQUEST Please initial and properly route Service Manager Mechanics Parts Manager Salesperson Warranty Administrator Exmark Mfg. Co., Inc. Beatrice, NE /

2 SERVICE BULLETIN ATTN: PARTS AND SERVICE MANAGER DATE: April 21, 2014 NUMBER: SUBJECT: Kohler DSAI Ignition Module Model and Serial Range List Model Number Serial Number Range Description LZA27KC through Exmark Lazer Z Advantage Series LZAS27KC through Exmark Lazer Z Advantage Series LZAS27KC524CA through Exmark Lazer Z Advantage Series LZAS27KC through Exmark Lazer Z Advantage Series LZAS27KC604CA through Exmark Lazer Z Advantage Series LZE27KC through Exmark Lazer Z E-Series LZE740KC through Exmark Lazer Z E-Series LZE740KC604L through Exmark Lazer Z E-Series LZS27KC through Exmark Lazer Z S-Series LZS27KC through Exmark Lazer Z S-Series LZS27KC604CA through Exmark Lazer Z S-Series LZS27KC604SS through Exmark Lazer Z S-Series LZS740KC through Exmark Lazer Z S-Series LZS740KC through Exmark Lazer Z S-Series LZS740KC604CA through Exmark Lazer Z S-Series LZX27KC through Exmark Lazer Z X-Series LZX27KC526CA through Exmark Lazer Z X-Series LZX27KC through Exmark Lazer Z X-Series LZX27KC606CA through Exmark Lazer Z X-Series LZX740KC through Exmark Lazer Z X-Series LZX740KC through Exmark Lazer Z X-Series LZX740KC606CA through Exmark Lazer Z X-Series LZZ27KC through Exmark Lazer Z LZZ27KC526CA through Exmark Lazer Z LZZ27KC through Exmark Lazer Z LZZ27KC606CA through Exmark Lazer Z NV27KC through Exmark Navigator NV740KC through Exmark Navigator PNS740KC through Exmark Pioneer S-Series PNS740KC604SS through Exmark Pioneer S-Series Exmark Mfg. Co., Inc. Beatrice, NE /

P/N 126-3837 In Line Fuse Kit P/N 130-8475 Lazer Z, Pioneer & Navigator Series Installation Instructions Note: Affected units built from 2009-2013.

3 P/N In Line Fuse Kit P/N Lazer Z, Pioneer & Navigator Series Installation Instructions Note: Affected units built from During the 2013 build, Kohler changed from the DSAI to the MDI system with the last DSAI Kohler engine serial number of 43151xxxxx. Kohler engine serial explanation: o 2 nd digit indicates year of production o 3 rd, 4 th, & 5 th digits indicate Julian date Loose Parts WARNING This product contains a chemical or known to the State of California to cause birth defects, or reproductive Use the chart below to verify that all parts have been shipped. Description Qty. Part # In-line fuse holder Fuse-Blade, 5 AMP Cable tie CAUTION If the machine has been running, the muffler and exhaust system will be very hot and can cause serious burns if you touch them. Allow the machine to cool completely before performing this procedure. Check the Engine Serial Number Check the engine serial number to verify the unit is part of the rework and equipped with the Kohler DSAI system. If the engine has been converted to the MDI system, do not perform the rework. Figure 1 Page 1 of 4

P/N 126-3837 In Line Fuse Kit P/N 130-8475 Lazer Z, Pioneer & Navigator Series Installation Instructions Installing the Fuse 1.

Disengage the PTO, move the motion control levers to the neutral locked position, and set the parking brake. 3.

Remove the negative battery cable. NOTE: For Navigator units, access to the chassis harness is achieved by removing the battery.

4 P/N In Line Fuse Kit P/N Lazer Z, Pioneer & Navigator Series Installation Instructions Installing the Fuse 1. Drive the machine to a level surface. 2. Disengage the PTO, move the motion control levers to the neutral locked position, and set the parking brake. 3. Stop the engine, remove the key, and wait for all moving parts to stop before leaving the operating position. Figure 2 4. Remove the negative battery cable. NOTE: For Navigator units, access to the chassis harness is achieved by removing the battery. Reinstall the battery once complete. 5. Locate the chassis harness to engine harness plug and disconnect the plug. Figure 2 6. Cut the wire tie around the wiring harness. Figure 3 Figure 3 7. Using a pair of scissors, make a cut in the black heat shrink about 4 inches from the plug. Figure 4 Figure 4 Page 2 of 4

P/N 126-3837 In Line Fuse Kit P/N 130-8475 Lazer Z, Pioneer & Navigator Series

Peel the heat shrink toward the engine to expose the wires. Figure 5 9.

Cut the red wire about 3 inches from the plug. Figure 5 10.

5 P/N In Line Fuse Kit P/N Lazer Z, Pioneer & Navigator Series Installation Instructions 8. Peel the heat shrink toward the engine to expose the wires. Figure 5 9. Identify the red wire that is connected along with the purple wire. Cut the red wire about 3 inches from the plug. Figure Strip each cut end in preparation to connect to the fuse holder connectors. Figure Connect the fuse holder. Crimp both connectors. Figure 7 Figure 5 Figure 6 Figure 7 Page 3 of 4

P/N 126-3837 In Line Fuse Kit P/N 130-8475 Lazer Z, Pioneer & Navigator Series Installation Instructions 12. Fold back the heat shrink. Figure 8 13.

Reconnect the battery negative ground to the battery. 16.

6 P/N In Line Fuse Kit P/N Lazer Z, Pioneer & Navigator Series Installation Instructions 12. Fold back the heat shrink. Figure Using the cable ties, anchor the fuse holder and the end of the shrink wrap. Figure Reconnect the engine harness plug to the chassis harness plug. 15. Reconnect the battery negative ground to the battery. 16. Using a black or silver permanent marker, mark the model/serial number tag with RF to indicate that the rework has been completed. Figure Test run the unit to verify power is getting to the DSAI modules. 18. File a warranty claim per instructions noted in Service Bulletin Figure 9 Page 4 of 4

SAFETY RECALL Kohler Engines in Exmark Mowers

possible to have them replace the identified

Stop using the identified Exmark products

7 SAFETY RECALL Kohler Engines in Exmark Mowers The Kohler engine electrical system can fail and may cause a fire hazard. Contact your Authorized Exmark Dealer as soon as possible to have them replace the identified electrical components. Stop using the identified Exmark products immediately. Additional Information Call: Exmark Manufacturing Co., Inc. Beatrice, NE 68310

8 POST UNTIL (6 months from recall) The following models and serial number ranges are equipped with the identified Kohler engine models CH740 and CV740. Recalled Products Model Number Serial Number Range Description LZA27KC through Exmark Lazer Z Advantage Series LZAS27KC through Exmark Lazer Z Advantage Series LZAS27KC524CA through Exmark Lazer Z Advantage Series LZAS27KC through Exmark Lazer Z Advantage Series LZAS27KC604CA through Exmark Lazer Z Advantage Series LZE27KC through Exmark Lazer Z E-Series LZE740KC through Exmark Lazer Z E-Series LZE740KC604L through Exmark Lazer Z E-Series LZS27KC through Exmark Lazer Z S-Series LZS27KC through Exmark Lazer Z S-Series LZS27KC604CA through Exmark Lazer Z S-Series LZS27KC604SS through Exmark Lazer Z S-Series LZS740KC through Exmark Lazer Z S-Series LZS740KC through Exmark Lazer Z S-Series LZS740KC604CA through Exmark Lazer Z S-Series LZX27KC through Exmark Lazer Z X-Series LZX27KC526CA through Exmark Lazer Z X-Series LZX27KC through Exmark Lazer Z X-Series LZX27KC606CA through Exmark Lazer Z X-Series LZX740KC through Exmark Lazer Z X-Series LZX740KC through Exmark Lazer Z X-Series LZX740KC606CA through Exmark Lazer Z X-Series LZZ27KC through Exmark Lazer Z LZZ27KC526CA through Exmark Lazer Z LZZ27KC through Exmark Lazer Z LZZ27KC606CA through Exmark Lazer Z NV27KC through Exmark Navigator NV740KC through Exmark Navigator PNS740KC through Exmark Pioneer S-Series PNS740KC604SS through Exmark Pioneer S-Series POST UNTIL (6 months from recall)

(WD) Dodge Durango (WK) Jeep Grand Cherokee

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