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Kohler command pro PCH740 Service Manual
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Kohler command pro PCH740 Service Manual

Propane electronic fuel injection (efi)
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Download this manual See also: Owner's Manual
PCH680, PCH740
Propane Electronic Fuel Injection (EFI)
Service Manual
IMPORTANT:
Read all safety precautions and instructions carefully before operating equipment. Refer to operating
instruction of equipment that this engine powers.
Ensure engine is stopped and level before performing any maintenance or service.
2
Safety
3
Maintenance
5
Specifi cations
14
Tools and Aids
17
Troubleshooting
21
Air Cleaner/Intake
22
Propane Electronic Fuel Injection (EFI) System
47
Lubrication System
49
Electrical System
54
Starter System
58
Disassembly/Inspection and Service
74
Reassembly
24 690 32 Rev. A
KohlerEngines.com
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Summary of Contents for Kohler command pro PCH740

  • Page 1 PCH680, PCH740 Propane Electronic Fuel Injection (EFI) Service Manual IMPORTANT: Read all safety precautions and instructions carefully before operating equipment. Refer to operating instruction of equipment that this engine powers. Ensure engine is stopped and level before performing any maintenance or service. Safety Maintenance Specifi...
  • Page 2 Safety SAFETY PRECAUTIONS WARNING: A hazard that could result in death, serious injury, or substantial property damage. CAUTION: A hazard that could result in minor personal injury or property damage. NOTE: is used to notify people of important installation, operation, or maintenance information. CAUTION WARNING WARNING...
  • Page 3 Must be performed by a Kohler authorized dealer or qualifi ed propane personnel only. REPAIRS/SERVICE PARTS Kohler genuine service parts can be purchased from Kohler authorized dealers. To fi nd a local Kohler authorized dealer visit KohlerEngines.com or call 1-800-544-2444 (U.S. and Canada).
  • Page 4 Maintenance OIL RECOMMENDATIONS STORAGE Synthetic oil is recommended for use in propane fueled If engine will be out of service for 2 months or more engines. Non-synthetic oil must be low ash* rated oil. follow procedure below. Oils (including synthetic) must meet API (American 1.
  • Page 5 Specifi cations Engine Dimensions with Heavy-Duty Air Cleaner Dimensions in millimeters. 344.13 [13.548] Inch equivalents shown in [ ]. PRIMARY AIR FILTER ELEMENT REMOVAL 231.81 [9.126] SAFETY AIR FILTER ELEMENT REMOVAL 138.19 132.54 [5.440] 94.01 [5.218] AIR FILTER COVER [3.701] AIR FILTER COVER ASSEMBLY REMOVAL 413.75...
  • Page 6 Specifi cations Engine Dimensions with Low-Profi le Air Cleaner Dimensions in millimeters. 413.75 Inch equivalents shown in [ ]. [16.289] 299.14 [11.777] 72.41 VALVE COVER [2.851] 59.90 [2.358] SPARK PLUG AIR CLEANER 353.02 REMOVAL COVER REMOVAL [13.898] VALVE COVER 115.90 AIR CLEANER COVER [4.563] 70.21...
  • Page 7 Lubricate threads with engine oil prior to assembly. Any and all horsepower (hp) references by Kohler are Certifi ed Power Ratings and per SAE J1940 & J1995 hp standards. Details on Certifi ed Power Ratings can be found at KohlerEngines.com.
  • Page 8 Specifi cations TORQUE SPECIFICATIONS PCH680, PCH740 Crankcase Breather Cover Fastener 11.3 N·m (100 in. lb.) into new holes 7.3 N·m (65 in. lb.) into used holes Oil Temperature Sensor (into breather cover) 7.3 N·m (65 in. lb.) Oil Drain Plug 13.6 N·m (10 ft.
  • Page 9 Specifi cations TORQUE SPECIFICATIONS PCH680, PCH740 Oil Cooler Oil Cooler/Adapter Nipple 28.5 N·m (21 ft . lb.) Fastener Into Blower Housing 2.8 N·m (25 in. lb.) Between Oil Cooler Hoses 2.3 N·m (20 in. lb.) Speed Control Bracket Fastener assembled to cylinder heads 10.7 N·m (95 in.
  • Page 10 Specifi cations CLEARANCE PCH680, PCH740 SPECIFICATIONS Connecting Rod Connecting Rod-to-Crankpin Running Clearance @ 21°C (70°F) 0.043/0.073 mm (0.0017/0.0029 in.) Max. Wear Limit 0.088 mm (0.0035 in.) Connecting Rod-to-Crankpin Side Clearance 0.26/0.63 mm (0.0102/0.0248 in.) Connecting Rod-to-Piston Pin Running Clearance @ 21°C 0.015/0.028 mm (0.0006/0.0011 in.) (70°F) Piston Pin End I.D.
  • Page 11 Specifi cations CLEARANCE PCH680, PCH740 SPECIFICATIONS Cylinder Bore Bore I.D. 83.006/83.031 mm (3.2680/3.2689 in.) O.D. - Max. Wear Limit 83.081 mm (3.2709 in.) Max. Out-of-Round Limit 0.120 mm (0.0047 in.) Max. Taper 0.05 mm (0.0020 in.) Cylinder Head Max. Out-of-Flatness 0.01 mm (0.004 in.) Governor Governor Cross Shaft -to-...
  • Page 12 Specifi cations CLEARANCE PCH680, PCH740 SPECIFICATIONS Piston, Piston Rings, and Piston Pin (continued) Thrust Face O.D. 82.978 mm (3.2668 in.) Max. Wear Limit 82.833 mm (3.2611 in.) Piston Thrust Face-to Cylinder Bore Running Clearance 0.019/0.062 mm (0.0007/0.0024 in.) Valves and Valve Lifters Hydraulic Lifter to Crankcase 0.011/0.048 mm (0.0004/0.0019 in.) Running Clearance...
  • Page 13 Specifi cations GENERAL TORQUE VALUES English Fastener Torque Recommendations for Standard Applications Bolts, Screws, Nuts and Fasteners Assembled Into Cast Iron or Steel Grade 2 or 5 Fasteners Into Aluminum Size Grade 2 Grade 5 Grade 8 Tightening Torque: N·m (in. lb.) ± 20% 8-32 2.3 (20) 2.8 (25)
  • Page 14 Here is a list of tools and their source. SEPARATE TOOL SUPPLIERS Kohler Tools SE Tools Design Technology Inc. Contact your local Kohler source of 415 Howard St. 768 Burr Oak Drive supply. Lapeer, MI 48446 Westmont, IL 60559...
  • Page 15 For reaming worn valve guides to accept replacement oversize valves. Can be used in low-speed drill press or with handle below for hand reaming. Reamer Handle Design Technology Inc. For hand reaming using Kohler 25 455 12-S reamer. DTI-K830 AIDS Description Source/Part No.
  • Page 16 Tools and Aids FLYWHEEL HOLDING TOOL ROCKER ARM/CRANKSHAFT TOOL A fl ywheel holding tool can be made out of an old junk A spanner wrench to lift rocker arms or turn crankshaft fl ywheel ring gear and used in place of a strap wrench. may be made out of an old junk connecting rod.

  • Page 17: Troubleshooting

    Troubleshooting TROUBLESHOOTING GUIDE When troubles occur, be sure to check simple causes which, at fi rst, may seem too obvious to be considered. For example, a starting problem could be caused by an empty fuel tank. Some general common causes of engine troubles are listed below and vary by engine specifi cation. Use these to locate causing factors.
  • Page 18 Troubleshooting EXTERNAL ENGINE INSPECTION Engine Loses Power NOTE: It is good practice to drain oil at a location away ● Dirty air cleaner element. from workbench. Be sure to allow ample time for ● Engine overheated. complete drainage. ● Excessive engine load. ●...
  • Page 19 Troubleshooting CRANKCASE VACUUM TEST WARNING WARNING Carbon Monoxide can cause severe nausea, Rotating Parts can cause severe injury. fainting or death. Stay away while engine is in operation. Avoid inhaling exhaust fumes. Engine exhaust gases contain poisonous carbon Keep hands, feet, hair, and clothing away from all monoxide.
  • Page 20 Troubleshooting COMPRESSION TEST For Command Twins: A compression test is best performed on a warm engine. Clean any dirt or debris away from base of spark plug(s) before removing them. Be sure choke is off, and throttle is wide open during test. Compression should be at least 160 psi and should not vary more than 15% between cylinders.
  • Page 21 Air Cleaner/Intake AIR CLEANER Low-Profi le These systems are CARB/EPA certifi ed and components Loosen knob and remove air cleaner cover. should not be altered or modifi ed in any way. Precleaner Low-Profi le Air Cleaner Components 1. Remove precleaner from paper element. 2.
  • Page 22 High pressure fuel line meeting a minimum of SAE mode. In open loop operation oxygen sensor output is R7 standard must be installed on Kohler Co. engines used to ensure engine is running rich, and controlling equipped with propane EFI system (from vaporizer/ adjustments are based on primary sensor signals and regulator to injectors).
  • Page 23 Propane EFI System ECU compares input signals to programmed maps in Crankshaft position sensor is essential to engine its memory to determine appropriate fuel and spark operation; constantly monitoring rotation and speed requirements for immediate operating conditions. ECU (RPM) of crankshaft. There are 23 consecutive teeth then sends output signals to set injector duration and cast into fl...
  • Page 24 Propane EFI System Oxygen sensor functions like a small battery, generating it interrupts fl ow of primary current in coil, causing a voltage signal to ECU based upon difference in oxygen electromagnetic fl ux fi eld to collapse. Flux collapse content between exhaust gas and ambient air.
  • Page 25 Propane EFI System IMPORTANT NOTES! ● Do not disconnect or reconnect ECU wiring harness connector or any individual components with ignition ● Cleanliness is essential and must be maintained at all on. This can send a damaging voltage spike through times when servicing or working on EFI system.
  • Page 26 Propane EFI System ELECTRICAL COMPONENTS Grey Connector Electronic Control Unit (ECU) Pin # Description Pinout of ECU Not Used Black Connector Not Used Pin # Function Malfunction Indicator Light (MIL) Ground Ignition Coil #1 Ground Not Used Battery Ground Not Used Diagnostic Communication Line Not Used Speed Sensor input...
  • Page 27 ECU Reset Procedure 1. Turn key/ignition OFF. 2. Install Red wire jumper from Kohler EFI service kit on to service port (connect white wire to black wire in 4 way diagnostic port). 3. Turn key/ignition ON, then OFF and count 10 seconds.
  • Page 28 Propane EFI System KohlerEngines.com 24 690 32 Rev. A...
  • Page 29 Propane EFI System 24 690 32 Rev. A KohlerEngines.com...
  • Page 30 Propane EFI System Crankshaft Position Sensor b. Hold throttle closed and check resistance. It A sealed, non-serviceable assembly. If Fault Code should be 1400-1800 Ω. diagnosis indicates a problem within this area, test and 4. Leave leads connected to pin terminals as described correct as follows.
  • Page 31 Propane EFI System 6. Check circuits (input, ground), from wire harness Cutaway Oxygen Sensor Components (O connector to sensor plug for continuity, damage, etc. Connect one ohmmeter lead to Black pin 14 in wire harness connector (as in step 4). Connect other lead to terminal #1 in sensor plug.
  • Page 32 Propane EFI System Sensor Signal Observation Removal Inspection NOTE: Do not cut into or pierce sensor or engine NOTE: Apply anti-seize compound only to threads. wiring to make this connection. Sensor Anti-seize compound will affect sensor produces a very small signal. Corrosion or performance if it gets into lower shield of damage to wiring could lead to an incorrect sensor.
  • Page 33 Propane EFI System Troublshooting-Oxygen Sensor (O Condition Possible Cause Conclusion Low voltage output. Shorted sensor or sensor circuit. Replace sensor or repair wiring. Shorted lead wire. Wiring shorted to ground. Contamination of air reference. Remove source of external contamination, protect air reference area.
  • Page 34 Propane EFI System If an injector is not operating, it can indicate either a bad Fuel Injectors injector, or a wiring/electrical connection problem. Check as follows: WARNING 1. Disconnect electrical connector from both injectors. High Pressure Fluids can puncture skin and Plug a 12 volt noid light into one connector.
  • Page 35 fi tting and remove quick connect fi tting to allow fuel to escape from line. Insert pressure test jumper (from Kohler EFI Service Kit) between high pressure fuel line and fuel lock-off. 24 690 32 Rev. A...
  • Page 36 Please note routing and replicate after service or component replacement to prevent pinching or abrasion of line. Only Kohler replacement parts can be used because vacuum line is specifi c to system and must be maintained. Visit KohlerEngines.com for recommended Kohler replacement parts.
  • Page 37 Propane EFI System TROUBLESHOOTING Troubleshooting Guide Condition Possible Cause Lock-off not functioning. Faulty spark plugs. Incorrect fuel. Incorrect fuel pressure. Crankshaft position sensor loose or faulty. TPS set incorrect (ECU Reset and TPS Learn). Engine Starts Hard or Fails to Start TPS faulty.
  • Page 38 Propane EFI System Troubleshooting Guide Condition Possible Cause Faulty/malfunctioning ignition system. Dirty air fi lter. Insuffi cient fuel delivery or pressure. Improper governor adjustment. Low Power Plugged/restricted exhaust. One injector not working. Basic engine problem exists. TPS faulty or mounting exists. Throttle plate in throttle body not fully opening to WOT stop (if equipped).
  • Page 39 Propane EFI System 0174 Lean Fuel Condition at High Load (Open Loop) or Insuffi cient Fuel Supply. 0201 Injector 1 Circuit Malfunction 0202 Injector 2 Circuit Malfunction 0230 Fuel Lock-off Circuit Low Voltage or Open 0232 Fuel Lock-off Circuit High Voltage 0336 Crankshaft Position Sensor Noisy Signal 0337...
  • Page 40 Propane EFI System Code 0107 Code 0113 Component: Manifold Absolute Pressure Sensor Component: Intake Air Temperature Sensor Fault: MAP Circuit Low Voltage or Open Fault: Intake Air Temperature Sensor Circuit High Voltage or Open Condition: Intake manifold leak, open connection or faulty sensor.
  • Page 41 Propane EFI System Code 0122 Code 0131 Component: Throttle Position Sensor (TPS) Component: Oxygen Sensor Fault: TPS Circuit Low Voltage or Open Fault: O2S 1 Circuit Low Voltage Condition: Open connection, broken wire or faulty Condition: Open connection, broken wire or faulty sensor.
  • Page 42 Propane EFI System Code 0171 Code 0172 Component: Fuel System Component: Fuel System Fault: Maximum adaptation limit exceeded Fault: Minimum adaptation limit exceeded Condition: Fuel fi lters plugged, low pressure at Condition: Too high pressure at high pressure fuel high pressure fuel line, TPS malfunction, line, TPS malfunction, shorted shorted connection, faulty sensor, low connection, faulty sensor or regulator...
  • Page 43 Propane EFI System Code 0174 Code 0202 Component: Fuel System Component: Fuel Injector Fault: Lean fuel condition Fault: Injector 2 Circuit Malfunction Condition: Fuel fi lters plugged, low pressure at high Condition: Injector damaged or faulty, shorted or pressure fuel line, TPS malfunction, open connection.
  • Page 44 Propane EFI System Code 0336 Code 0351 Component: Crankshaft Position Sensor Component: Ignition Coil Fault: Crankshaft Position Sensor Noisy Signal Fault: Cylinder 1 Ignition Coil Malfunction Condition: Air gap incorrect, loose sensor, faulty/bad Condition: Broken wire in harness (may not be battery, shorted or faulty connection, visible), shorted connection or faulty faulty sensor or faulty sensor grounding.
  • Page 45 NOTE: MIL is installed by vehicle OEM. Twelve volt (no fuel delivery) supply to bulb will be part of vehicle wire Condition harness. Kohler key switch model will have MIL ● No fuel on engine with 12V supply to bulb. ● Air in high pressure fuel line Conclusion ●...
  • Page 46 Propane EFI System EFI Diagnostic Flow Diagram START OF TEST PROCEED TO START OF TEST FOR RETEST KEY ON MALFUNCTION REFER TO DIAGNOSTIC AID #1 INDICATOR LIGHT SYSTEM POWER REFER TO ARE FAULT CODES DIAGNOSTIC FAULT CODE SUMMARY PRESENT? CLEAR CODES REFER TO DIAGNOSTIC AID #3 DOES ENGINE START? MIL GOES OFF?

  • Page 47: Lubrication System

    Lubrication System This engine uses a full pressure lubrication system which delivers oil under pressure to crankshaft, camshaft, connecting rod bearing surfaces, and hydraulic valve lifters. A high-effi ciency gerotor oil pump maintains high oil fl ow and oil pressure, even at low speeds and high operating temperatures.
  • Page 48 Lubrication System CHANGE OIL AND FILTER OIL SENTRY (if equipped) ™ Change oil while engine is warm. This switch is designed to prevent engine from starting in a low oil or no oil condition. Oil Sentry may not shut 1. Clean area around oil fi ll cap/dipstick and drain plug. ™...

  • Page 49: Electrical System

    Electrical System SPARK PLUGS Inspection Inspect each spark plug as it is removed from cylinder CAUTION head. Deposits on tip are an indication of general Electrical Shock can cause injury. condition of piston rings, valves, and fuel system. Do not touch wires while engine is running. Normal and fouled plugs are shown in following photos: Normal Spark Plug Component and Details...
  • Page 50 Electrical System Carbon Fouled BATTERY A 12-volt battery with 400 cold cranking amps (cca) is generally recommended for starting in all conditions. A smaller capacity battery is often suffi cient if an application is started only in warmer temperatures. Refer to following table for minimum capacities based on anticipated ambient temperatures.
  • Page 51 Electrical System BATTERY CHARGING SYSTEM NOTE: Observe following guidelines to avoid damage to electrical system and components: ● Make sure battery polarity is correct. A negative (-) ground system is used. ● Disconnect rectifi er-regulator plug and/or wiring harness plug before doing any electric welding on equipment powered by engine.
  • Page 52 Electrical System Condition Conclusion 20/25 amp OK (green) light comes on and stays steady. Disconnect tester black lead attached to 1 AC terminal and reconnect it to other AC terminal. Repeat test. If OK (green) light comes on again, part is good and may be used.
  • Page 53 Electrical System FUSES This engine has 3 blade type automotive fuses. Replacement fuses must have same rating as blown fuse. Use fuse chart below to determine correct fuse. Wire Color Fuse Rating 2 Purple Wires 30-amp Fuse 1 Red Wire w/Black Stripe 10-amp Fuse 1 Red Wire w/White Stripe 2 Red Wires...

  • Page 54: Starter System

    Starter System NOTE: Do not crank engine continuously for more than 10 seconds. Allow a 60 second cool down period between starting attempts. Failure to follow these guidelines can burn out starter motor. NOTE: If engine develops suffi cient speed to disengage starter but does not keep running (a false start), engine rotation must be allowed to come to a complete stop before attempting to restart engine.
  • Page 55 Starter System SOLENOID SHIFT ELECTRIC STARTERS Starter Disassembly Solenoid Shift Starter Components NOTE: Do not reuse old retainer. NOTE: Do not soak armature or use solvent when cleaning. Wipe clean using a soft cloth, or use compressed air. 1. Remove nut and disconnect positive (+) brush lead/ bracket from solenoid terminal.
  • Page 56 Mounting screw 4 brushes and springs are serviced as a set. Use a new Kohler brush and spring kit if replacement is necessary. holes in metal clips must be up/out. Slide brush holder assembly down into place around 1.
  • Page 57 Starter System b. Position brushes back in their slots so they are fl ush with I.D. of brush holder assembly. Insert brush installation tool (with extension), or use tube described above from a prior brush installation, through brush holder assembly, so holes in metal mounting clips are up/out. c.
  • Page 58 Disassembly/Inspection and Service WARNING Before working on engine or equipment, disable engine as follows: 1) Disconnect spark plug lead(s). 2) Disconnect negative (–) battery cable from battery. Accidental Starts can cause severe injury or death. Before disconnecting negative (–) ground cable, make sure all switches are OFF.
  • Page 59 Disassembly/Inspection and Service Clean all parts thoroughly as engine is disassembled. Remove Oil Cooler Only clean parts can be accurately inspected 1. Use an 8 mm Allen wrench to remove oil fi lter and gauged for wear or damage. There are many threaded nipple.
  • Page 60 Disassembly/Inspection and Service External Governor Controls Speed Control Throttle Actuator Cable Clamp Screw Bracket Lever (bottom) Throttle Control Lever Spring Washer Flat Washer (top) Return Spring Vaporizer/Regulator/Lock-Off Assembly Propane is extremely fl ammable and is heavier than air and WARNING tends to settle in low areas where a spark or fl...
  • Page 61 Disassembly/Inspection and Service Remove Vaporizer/Regulator/Lock-Off Vacuum Line Vaporizer/Regulator Inlet Fitting Lock-Off Assembly Outlet Fitting Oetiker Clamp Propane Fuel Filter Bracket 1. Disconnect electrical plug from lock-off. 2. Disconnect vacuum line from front of vaporizer/ Remove Electronic Control Unit (ECU) regulator. 3.
  • Page 62 Disassembly/Inspection and Service Remove Guard and Debris Screen Remove Crankshaft Position Sensor NOTE: Fan will be loose, but cannot be removed until 1. Remove screws securing crankshaft position sensor after blower housing is removed. bracket. 1. Remove screws securing guard to blower housing 2.
  • Page 63 Disassembly/Inspection and Service Cylinder Head Components Style B Style A Valve Cover Valve Cover O-ring Hex Flange Screw Rocker Arm Pivot Rocker Arm Push Rod Hydraulic Lifter Valve Cap Valve Spring Valve Keeper Valve Spring Valve Seal Retainer Cylinder Head Spark Plug Cylinder Head Valve...
  • Page 64 If lifters need to be replaced, apply a liberal 1. Remove screws, rocker arm pivots and rocker arms coating of Kohler lubricant (see Tools and Aids) to base from cylinder head. of each new lifter before it is installed.
  • Page 65 Disassembly/Inspection and Service Inspection and Service Valve Details EXHAUST VALVE INTAKE VALVE EXHAUST INSERT INTAKE INSERT Dimension Intake Exhaust Seat Angle 89° 89° Insert O.D. 36.987/37.013 mm (1.4562/1.4572 in.) 32.987/33.013 mm (1.2987/1.2997 in.) Guide Depth 4 mm (0.1575 in.) 6.5 mm (0.2559 in.) Guide I.D.
  • Page 66 Disassembly/Inspection and Service Valve Guides If a valve guide is worn beyond specifi cations, it will not guide valve in a straight line. This may result in burnt valve faces or seats, loss of compression, and excessive oil consumption. To check valve guide-to-valve stem clearance, thoroughly clean valve guide and, using a split-ball gauge, measure inside diameter of guide.
  • Page 67 fl ywheel, crankshaft, and key if fl ywheel key is sheared or keyway is damaged. Inspect ring gear for cracks or damage. Kohler does not provide ring gear as a serviceable part. Replace fl ywheel if ring gear is damaged.
  • Page 68 Disassembly/Inspection and Service Oil Pump Assembly Oil pump is mounted inside closure plate. If service is required, refer to Disassembly, Inspection, and Reassembly. Disassembly 1. Remove screws. 2. Lift oil pump assembly from closure plate. Remove outer gerotor gear from closure plate. 3.
  • Page 69 Disassembly/Inspection and Service Piston Pin Retainer Piston Pin Piston Rings Crankcase Clip Governor Cross Shaft 1. Remove screws securing closest connecting rod end Remove Camshaft cap. Remove end cap. Remove camshaft. 2. Carefully remove connecting rod and piston Inspection and Service assembly from cylinder bore.
  • Page 70 Disassembly/Inspection and Service varnish collect on pistons causing rings to stick, which Install New Piston Rings results in rapid wear. A worn ring usually takes on a Piston Ring Orientation shiny or bright appearance. Scratches on rings and pistons are caused by abrasive material such as carbon, dirt, or pieces of hard metal.
  • Page 71 Disassembly/Inspection and Service NOTE: If crankpin is reground, visually check to ensure Connecting Rods fi llet blends smoothly with crankpin surface. Offset, stepped-cap connecting rods are used in all NOTE: To prevent repeat failures, camshaft and these engines. crankshaft should always be replaced as a set. Inspection and Service Inspect gear teeth of crankshaft.
  • Page 72 (refer to Specifi cations), then select nearest suitable oversize NOTE: Kohler pistons are custom-machined to exacting of either 0.25 mm (0.010 in.) or 0.50 mm (0.020 in.). tolerances. When oversizing a cylinder, it should Resizing to one of these oversizes will allow usage of be machined exactly 0.25 mm (0.010 in.) or 0.50...
  • Page 73 Disassembly/Inspection and Service Clean Cylinder Bore After Honing Measuring Piston-to-Bore Clearance Proper cleaning of cylinder walls following boring and/ Piston Detail or honing is very critical to a successful overhaul. Machining grit left in cylinder bore can destroy an engine in less than 1 hour of operation after a rebuild.
  • Page 74 Reassembly Crankcase Components Closure Plate Seal Closure Plate Oil Pickup Tube Oil Pump Assembly Oil Pump Cover Ball Spring Outer Gerotor Gear O-ring Governor Shaft Governor Washer Governor Gear Governor Cup Camshaft Crankshaft Connecting Rod Piston Piston Pin Retainer Piston Pin Piston Rings Crankcase Clip...
  • Page 75 Reassembly NOTE: Proper orientation of piston/connecting rod Install Flywheel End Oil Seal assemblies inside engine is extremely important. Oil Seal Detail Improper orientation can cause extensive wear or damage. Be certain pistons and connecting rods are assembled exactly as shown. NOTE: Align chamfer of connecting rod with chamfer of its mating end cap.
  • Page 76 Reassembly 1. Be sure sealing surfaces have been cleaned and Oil Pump Assembly prepared. Oil pump is mounted inside closure plate. If service was 2. Check to make sure there are no nicks or burrs on required, and oil pump was removed, refer to assembly sealing surfaces of closure plate or crankcase.
  • Page 77 Reassembly Flywheel Components Flywheel Fan Flywheel Stator Backing Plate NOTE: Before installing fl ywheel, make sure crankshaft Install Fan taper and fl ywheel hub are clean, dry, and NOTE: Position locating tabs on back of fan into locating completely free of any lubricants. Presence of holes of fl...
  • Page 78 Reassembly Cylinder Head Components Valve Cover Valve Cover O-ring Hex Flange Screw Rocker Arm Pivot Rocker Arm Push Rod Hydraulic Lifter Valve Cap Valve Spring Valve Keeper Valve Spring Valve Seal Retainer Cylinder Head Spark Plug Cylinder Head Valve Gasket Dowel Pin 2.
  • Page 79 Reassembly Studs closest to lifters must have an exposed height of Valve Stem Seals 75 mm (2 15/16 in.). These engines use valve stem seals on intake valves Studs furthest from lifters must have an exposed height and on exhaust valves. Use a new seal whenever valve of 69 mm (2 3/4 in.).
  • Page 80 Reassembly External Engine Components Heavy-Duty Air Low-Profi le Air Oil Filter Nipple Cleaner Cleaner Air Temperature Throttle Body Oil Cooler Oil Cooler O-Ring Sensor Assembly Oil Temperature Barrel Baffl e Valley Baffl e Oil Sentry Sensor ™ Breather Cover Dipstick Tube Dipstick Breather Cover Gasket...
  • Page 81 Reassembly Install Intake Manifold Install Manifold Absolute Pressure (MAP) Sensor NOTE: Ensure all parts are clean, undamaged and free Torque Sequence of debris and make sure electrical connector has seal in place. 1. Lightly oil MAP sensor O-ring and push MAP sensor into bore in intake manifold.
  • Page 82 Reassembly Install Breather Cover and Inner Baffl es Install Blower Housing, Outer Baffl es, and Debris Screen Torque Sequence NOTE: Do not completely tighten screws until all items are installed to allow shifting for hole alignment. 1&5 1. Connect plug to key switch in blower housing (if equipped).
  • Page 83 Reassembly Install Throttle Body Install Electric Starter Motor and ECU Bracket NOTE: Ensure all parts are clean, undamaged and free 1. Install electric starter motor using screws. Position of debris and make sure electrical connector has ECU bracket. seal in place. 2.
  • Page 84 Reassembly Install Vaporizer/Regulator/Lock-Off Propane is extremely fl ammable and is heavier than air and WARNING tends to settle in low areas where a spark or fl ame could ignite gas. Do not start or operate this engine in a poorly ventilated area where leaking gas could accumulate and endanger safety of persons in area.
  • Page 85 Reassembly Install External Governor Controls Speed Control Throttle Actuator Cable Clamp Screw Bracket Lever (bottom) Throttle Control Lever Spring Washer Flat Washer (top) Return Spring 1. Install governor lever onto governor cross shaft. 2. Make sure throttle linkage, linkage spring, black linkage bushing are connected to governor lever and to throttle lever on throttle body.
  • Page 86 Reassembly Install Air Cleaner Assembly Install Oil Cooler Refer to Air Cleaner/Intake for air cleaner reassembly 1. Secure adapter to closure plate with oil fi lter nipple. procedure. Torque oil fi lter nipple to 28.5 N·m (21 ft. lb.). Heavy-Duty Air Cleaner 2.
  • Page 87 Reassembly Prepare Engine for Operation Testing Engine NOTE: If ECU or TPS/throttle body were replaced, an It is recommended engine be operated on a stand or ECU Reset and TPS Learn is required. Refer to bench prior to installation in piece of equipment. ECU Reset and TPS Learn procedures in Fuel 1.
  • Page 88 1P24 690 32 © 2015 by Kohler Co. All rights reserved. 85612 30912 KohlerEngines.com 24 690 32 Rev. A...

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