Kohler command pro CH940 Service Manual

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CH940-CH1000

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

Specifications

Tools and Aids

Troubleshooting

Air Cleaner/Intake

Fuel System

Governor System

Lubrication System

Electrical System

Starter System

Disassembly/Inspection and Service

Reassembly

62 690 01 Rev. J

KohlerEngines.com

Table of Contents

Summary of Contents for Kohler command pro CH940

Page 1 CH940-CH1000 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 Specifications Tools and Aids Troubleshooting Air Cleaner/Intake Fuel System...
Page 2: Safety Precautions
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: Maintenance Instructions
Have a Kohler authorized dealer perform this service. REPAIRS/SERVICE PARTS Kohler genuine service parts can be purchased from Kohler authorized dealers. To find a local Kohler authorized dealer visit KohlerEngines.com or call 1-800-544-2444 (U.S. and Canada). 62 690 01 Rev. J...
Page 4: Oil Recommendations
OIL RECOMMENDATIONS STORAGE If engine will be out of service for 2 months or more We recommend use of Kohler oils for best performance. follow procedure below. Other high-quality detergent oils (including synthetic) of API (American Petroleum Institute) service class SJ 1.
Page 5: Specifications
Specifications Engine Dimensions with Heavy-Duty Air Cleaner - Flywheel Side 135.0 mm (5.32 in.) 130.0 mm (5.12 in.) 484.3 mm (19.07 in.) Rain Cap Cover 365.5 mm (14.39 in.) Air Filter Cover Removal Removal Mechanical Fuel 74.0 mm (2.91 in.) Choke Control Throttle Control Pump...
Page 6 Specifications Engine Dimensions with Heavy-Duty Air Cleaner - PTO Side 427.8 mm (16.84 in.) 107.9 mm (4.25 in.) 35° 30° 60.0 mm (2.37 in.) Oil Level Dipstick 45° 340.8 mm (13.42 in.) Exhaust Port 177.8 mm (7.0 in.) Solenoid Shift Starter Mounting Hole "A"...
Page 7 Specifications Engine Dimensions with Heavy-Duty Air Cleaner - Starter Side 422.7 mm (16.64 in.) 4 X 47.3 mm (1.86 in.) PTO Mounting 105.3 mm (4.14 in.) Cylinder #1 Shroud Air Cleaner Clip Surface Exhaust Port #1 Removed Clearance 460.0 mm (18.11 9.5 mm (0.38 in.) 192.3 mm (7.57 in.) Muffler (Optional)
Page 8 Specifications Engine Dimensions with Heavy-Duty Air Cleaner - Opposite Starter Side 422.7 mm (16.64 in.) Cylinder #2 Shroud Lifting Point Cylinder #2 Shroud Access to Oil Cooler Removed Fuel Filter Mounting Hole "A" 16.0 mm (0.63 in.) 119.0 mm (4.69 in.) Oil Drain Plug Engine Mounting 135.0 mm (5.32 in.)
Page 9 Specifications Engine Dimensions - Mounting Surface View 8 X 10.3 mm (0.40 in.) 232.0 mm (9.13 in.) Mounting Hole "A" 239.5 mm (9.43 in.) Thru Mounting Holes PTO Mounting 106.0 mm (4.17 in.) 135.0 mm (5.32 in.) 119.0 mm (4.69 in.) Surface 16.0 mm (0.63 in.) 62 690 01 Rev.
Page 10 Specifications Engine Dimensions with Low-Profile Air Cleaner - Flywheel Side 106.0 mm (4.17 in.) 484.3 mm (19.07 in.) 364.5 mm (14.35 in.) 85.7 mm (3.38 in.) Lifting Point Lifting Point 14.7 mm (0.58 in.) 76.3 mm (3.00 in.) 10 X 12 mm 136.2 mm (5.36 in.) Spark Plug Lead (0.39 X 0.47 in.) Slot...
Page 11 Specifications Engine Dimensions with Low-Profile Air Cleaner - PTO Side Lifting Point 85.5 mm (3.37 in.) 427.8 mm (18.84 in.) 107.9 mm (4.25 in.) 10 X 12 mm Lifting Point (0.39 X 0.47 in.) Slot Oil Level Dipstick M8 X 1.25 mm Studs 45°...
Page 12 Specifications Engine Dimensions with Low-Profile Air Cleaner - Starter Side 45.0 mm (1.77 in.) 50.0 mm (1.97 in.) Cylinder #1 Shroud 570.8 mm (22.47 in.) Cylinder #1 Shroud Oil Filter Removal Removal 422.7 mm (16.64 in.) 181.9 mm (7.16 in.) Grass Screen Cylinder #1 Shroud 401.7 mm (15.82 in.)
Page 13 Specifications Engine Dimensions with Low-Profile Air Cleaner - Opposite Starter Side 63.0 mm (2.48 in.) 254.3 mm (10.01 in.) Air Cleaner 184.8 mm (7.28 in.) 26.7 mm (1.05 in.) Cover Removal 45.0 mm (1.77 in.) Access to Lifting Point Cylinder #2 Cylinder #2 Shroud Oil Cooler Shroud Removal...
Page 14: Engine Identification Numbers
Exceeding maximum angle of operation may cause engine damage from insufficient lubrication. Lubricate threads with engine oil prior to assembly. Any and all horsepower (hp) references by Kohler are Certified Power Ratings and per SAE J1940 & J1995 hp standards. Details on Certified Power Ratings can be found at KohlerEngines.com.
Page 15 Specifications TORQUE SPECIFICATIONS CH940 CH960 CH980 CH1000 Control Panel M6 screw 11.3 N·m (100 in. lb.) into new holes 7.7 N·m (69 in. lb.) into used holes M5 screws 6.5 N·m (58 in. lb.) into new holes 4.1 N·m (37 in. lb.) into used holes Crankcase Breather Cover Fastener 12.4 N·m (110 in.
Page 16: Clearance Specifications
Specifications TORQUE SPECIFICATIONS CH940 CH960 CH980 CH1000 Oil Filter Adapter/Housing Adapter/Housing Mounting Screw 23.7 N·m (210 in. lb.) Oil Filter Nipple 17.8 N·m (158 in. lb.) Oil Pickup Screen Mounting Screw 9.3 N·m (82 in. lb.) into new holes 7.7 N·m (68 in. lb.) into used holes Oil Pickup Tube Mounting Screw 11.3 N·m (100 in.
Page 17 Specifications CLEARANCE SPECIFICATIONS CH940 CH960 CH980 CH1000 Cam Lobe Profile (minimum dimension, measured from base circle to top of lobe) Exhaust 35 mm (1.3779 in.) Intake 34.1 mm 35 mm (1.3779 in.) (1.3425 in.) Connecting Rod Crankpin End I.D. @ 70°F 44.030/44.037 mm (1.7334/1.7337 in.) Max.
Page 18 Specifications CLEARANCE SPECIFICATIONS CH940 CH960 CH980 CH1000 Flywheel End Main Bearing Journal O.D. - New 44.978/45.00 mm (1.770/1.771 in.) O.D. - Max. Wear Limit 44.90 mm (1.767 in.) Max. Taper 0.022 mm (0.0009 in.) Max. Out-of-Round 0.025 mm (0.0010 in.) Cylinder Bore Cylinder Bore I.D.
Page 19 Specifications CLEARANCE SPECIFICATIONS CH940 CH960 CH980 CH1000 Piston, Piston Rings, and Piston Pin (continued) Piston Style B Piston-to-Piston Pin Running Clearance 0.006/0.017 mm (0.0002/0.0007 in.) Piston Pin Bore I.D. 20.006/20.012 mm (0.7876/0.7879 in.) Max. Wear Limit 20.025 mm (0.7884 in.) Piston Pin O.D.
Page 20: General Torque Values
Specifications 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 21: Tools And Aids
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 22 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 23 Tools and Aids FLYWHEEL HOLDING TOOL ROCKER ARM/CRANKSHAFT TOOL A flywheel holding tool can be made out of an old junk A spanner wrench to lift rocker arms or turn crankshaft flywheel ring gear and used in place of a strap wrench. may be made out of an old junk connecting rod.
Page 24: Troubleshooting Guide
Troubleshooting TROUBLESHOOTING GUIDE When troubles occur, be sure to check 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 general common causes of engine troubles are listed below and vary by engine specification. Use these to locate causing factors.
Page 25 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 26: Crankcase Vacuum Test
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 27: Compression Test
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 28: Air Cleaner/Intake
Air Cleaner/Intake AIR CLEANER NOTE: Operating engine with loose or damaged air cleaner components could cause premature These systems are CARB/EPA certified and components wear and failure. Replace all bent or damaged should not be altered or modified in any way. components.
Page 29: Fuel Pump
FUEL LINE Disassembly and Reassembly. Low permeation fuel line must be installed on carbureted 3. Reconnect fuel lines to inlet and outlet fittings and Kohler Co. engines to maintain EPA and CARB secure with clamps. regulatory compliance. FUEL SYSTEM TESTS When engine starts hard or turns over but will not start, fuel system might be causing problems.
Page 30 Fuel System CARBURETOR Gasoline is extremely flammable and its vapors can WARNING explode if ignited. Store gasoline only in approved Explosive Fuel can cause fires and severe containers, in well ventilated, unoccupied buildings, away burns. from sparks or flames. Spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition.
Page 31 Fuel System Engines in this series are equipped with a two-barrel, 4. Make sure air cleaner base and carburetor are side-draft carburetor with fixed main jets on a matching securely fastened to engine using gaskets in good intake manifold. Carburetor features a self-relieving condition.
Page 32 Fuel System Fuel Shut-off Solenoid Carburetor Adjustments Most carburetors are equipped with a fuel shut-off NOTE: Carburetor adjustments should be made only solenoid. Solenoid is attached to fuel bowl. Solenoid has after engine has warmed up. a spring-loaded pin that retracts when 12 volts is applied Carburetor is designed to deliver correct fuel-to-air to lead, allowing fuel flow to main jets.
Page 33 Fuel System NOTE: Engines will have fixed low idle or limiter caps 1. Perform removal procedures for appropriate air on idle fuel adjusting needles. Step 2 can only cleaner and carburetor outlined in Disassembly. be performed within limits allowed by cap. Do 2.
Page 34: High Altitude Operation
Install new cap. above 1219 meters (4000 ft.). To obtain high 18. Clean carburetor body, main jets, vent ports, seats, altitude kit information or to find a Kohler etc., using a good commercially available carburetor authorized dealer visit KohlerEngines.com or call solvent.
Page 35: Governor System
Governor System GOVERNOR Governed speed setting is determined by position of throttle control. It can be variable or constant, depending on engine application. Governor is designed to hold engine speed constant under changing load conditions. Most engines are equipped with a centrifugal flyweight mechanical governor.
Page 36: 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-efficiency gerotor oil pump maintains high oil flow and oil pressure, even at low speeds and high operating temperatures.
Page 37 Lubrication System OIL RECOMMENDATIONS OIL COOLER Refer to Maintenance. NOTE: Oil cooler is mounted under cylinder shroud. Removal of cylinder shroud is necessary to CHECK OIL LEVEL access oil cooler. NOTE: To prevent extensive engine wear or damage, 1. Clean fins with a brush or compressed air. never run engine with oil level below or above operating range indicator on dipstick.
Page 38: 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 carburetor. Do not touch wires while engine is running. Normal and fouled plugs are shown in following photos: Normal Spark Plug Component and Details...
Page 39 Electrical System Carbon Fouled ELECTRONIC IGNITION SYSTEMS Ignition System Components Soft, sooty, black deposits indicate incomplete combustion caused by a restricted air cleaner, over rich Kill Switch/ carburetion, weak ignition, or poor compression. Off Position of Air Gap Key Switch Overheated Flywheel Magnet...
Page 40 Electrical System A typical fixed ignition system consists of: ● 1 magnet assembly which is permanently affixed to flywheel. ● 2 electronic capacitive-discharge (CDI) or magnetic discharge (MDI) ignition modules which mount on engine crankcase. ● 1 kill switch (or key switch) which grounds modules to stop engine. ●...
Page 41 Electrical System Wire Diagram-15/20/25 Amp Regulated Battery Charging System with CDI/MDI, Five Pin Connector, Key Switch, and Fuse Green (Oil Sentry Blue Yellow ™ Pulse Signal) Violet White Black Key Switch To Battery To Accessory Ground To Rectifier-Regulator Oil Sentry Light To Magneto To Starter...
Page 42 Electrical System Digital Spark Advance Ignition (DSAI) System This system uses a digital microprocessor which is located in ignition modules. Ignition timing varies depending upon engine speed with this system. There are 2 inductive-style ignition modules that control ignition timing based on engine RPM.
Page 43 Electrical System Wire Diagram-15/20/25 Amp Regulated Battery Charging System with DSAI Ignition and Four Pin Connector (LP-NG Kohler Power Systems Application) Green Orange Violet White Black Connector Polarity Ribs Battery Battery Positive Battery Negative Starter Solenoid Stud External Starter Rectifier-Regulator...
Page 44 Electrical System Wire Diagram-15/20/25 Amp Regulated Battery Charging System with DSAI Ignition and Five Pin Connector (Gasoline/LP-NG Non-Kohler Power Systems Application) Blue Green Orange Violet White Black Connector Polarity Ribs Battery Battery Positive Battery Negative Starter Solenoid Stud Starter Solenoid Tang...
Page 45 Electrical System Electronic Ignition Systems Tests NOTE: Ignition tester must be used to test ignition on these engines. Use of any other tester can result in inaccurate findings. Battery on unit must be fully charged and properly connected before performing tests (a battery that is hooked up or charged backward will crank engine but it won’t have spark).
Page 46 Electrical System Check Ignition Modules and Connections (CDI/MDI only) 1. Remove blower housing from engine. Inspect kill wire for any damage, cuts, or shorts to engine or ignition module body. Check that connections are oriented properly on terminals of modules. 2.
Page 47: Battery Charging System
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 rectifier-regulator plug and/or wiring harness plug before doing any electric welding on equipment powered by engine.
Page 48 Electrical System 15/20/25 Amp Battery Charging Systems NOTE: Always zero ohmmeter on each scale before testing to ensure accurate readings. Voltage tests should be made with engine running at 3600 RPM with no load. Battery must be good and fully charged. When problems occur in keeping battery charged or battery charges at high rate, charging system or battery might be causing problems.
Page 49: Starter System
Starter System ELECTRIC STARTING MOTOR 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 sufficient 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 50 Starter System Solenoid Shift Starter Components 5. Remove commutator end plate assembly, containing brush holder, brushes, springs, and locking caps. Remove thrust washer from inside commutator end. 6. Remove frame from armature and drive end cap. 7. Remove drive lever pivot bushing and backing plate (if equipped) from end cap.
Page 51 4 brushes and springs are serviced as a set. Use a new holes in metal clips must be up/out. Slide brush Kohler brush and spring kit if replacement is necessary. holder assembly down into place around commutator, and install positive (+) brush lead 1.
Page 52 Starter System 12. Install thru bolts and brush holder mounting screws. Torque bolts to 5.6-9.0 N·m (49-79 in. lb.) and brush holder mounting screws to 2.5-3.3 N·m (22-29 in. lb.). 13. Hook plunger behind upper end of drive lever and install spring into solenoid. Insert mounting screws through holes in drive end cap.
Page 53: Disassembly/Inspection And Service
Disassembly/Inspection and Service WARNING Before working on engine or equipment, disable engine as Accidental Starts can cause severe injury or follows: 1) Disconnect spark plug lead(s). 2) Disconnect death. negative (–) battery cable from battery. Disconnect and ground spark plug lead(s) before servicing.
Page 54 Disassembly/Inspection and Service Clean all parts thoroughly as engine is disassembled. Removing Control Bracket, Governor Springs, and Only clean parts can be accurately inspected Lever and gauged for wear or damage. There are many 1. Unhook governed idle and governor springs from commercially available cleaners that will quickly remove controls on main bracket and governor lever.
Page 55 Disassembly/Inspection and Service 1. Remove screw securing oil filter housing and Remove Oil Cooler individual O-rings to adapter. Carefully separate NOTE: New clamps are recommended any time parts. disassembly is performed, or if clamps have Perform following only if oil filter housing assembly been loosened (expanded) several times.
Page 56 Disassembly/Inspection and Service Flywheel/Ignition Components Rectifier-Regulator Ignition Module Washer Flywheel Screw Special Washer Debris Screen Wire Harness Clamp (Style A) (Style A) (Style A) Stiffener Hex Stud Flywheel Magnet (Style A) Debris Screen Stator Backing Shroud Woodruff Key (Style B) Support Ring Spacer (Style B)
Page 57 Replace flywheel if it is cracked. Replace flywheel, crankshaft, and key if flywheel 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 flywheel if ring gear is damaged.
Page 58 Disassembly/Inspection and Service Cylinder Head Components Gasket Valve Cylinder Head Pipe Plug Spacer Washer Spark Plug Valve Stem Seal Valve Spring Hydraulic Lifter Valve Spring Retainer Push Rod Valve Spring Keeper Rocker Arm Rocker Arm Pivots Valve Cover Gasket Hydraulic Lifter Hydraulic Lifter Valve Cover Grommet...
Page 59 Check base surface of hydraulic lifters for wear or Remove spark plug from each cylinder head. damage. If lifters need to be replaced, apply a liberal coating of Kohler lubricant to base of each new lifter Remove Valve Covers and Fuel Pump before it is installed.
Page 60: Exhaust Valve
Disassembly/Inspection and Service Inspection and Service Valve Details EXHAUST VALVE INTAKE VALVE Dimension Intake Exhaust Seat Angle 89° 89° Seat Taper 30° 30° Guide Depth 8.5 mm (0.334 in.) 8.5 mm (0.334 in.) Guide I.D. 7.038/7.058 mm (0.2771/0.2779 in.) 7.038/7.058 mm (0.2771/0.2779 in.) Valve Head Diameter 38.625/38.685 mm (1.5206/1.5230 in.) 31.625/31.825 mm (1.2450/1.2549 in.)
Page 61 Disassembly/Inspection and Service Lapping Valves Valve Stem Seals Reground or new valves must be lapped in, to provide These engines use valve stem seals on intake and proper fit. Use a hand valve grinder with a suction cup exhaust valves. Always use new seals when valves for final lapping.
Page 62 Disassembly/Inspection and Service Reassembly Remove Breather Assembly Torque Sequence 1. Remove fasteners securing breather assembly, breather adapter (style based on spec), and gaskets to crankcase. 2. Carefully break gasket seals and remove all parts. Do not pry on sealing surfaces as it could cause damage resulting in leaks.
Page 63 Disassembly/Inspection and Service Crankcase Components Camshaft Locking Tab Regulating Pin Governor Gear Lifter Feed Cover Cross Shaft Lifter Feed Cover Governor Yoke Gasket Connecting Rod End Crankshaft Connecting Rod Piston Pin Piston Pin Retainer Piston (Style A) Piston Ring Set Oil Seal Crankshaft Thrust Crankshaft...
Page 64 Disassembly/Inspection and Service Scuffing and scoring of pistons and cylinder walls occurs Remove Camshaft when internal engine temperatures approach welding Remove camshaft and shim (if used). point of piston. Temperatures high enough to do this are created by friction, which is usually attributed to improper Inspection lubrication and/or overheating of engine.
Page 65 Disassembly/Inspection and Service Piston Style A Install New Piston Rings 1. Cylinder bore must be de-glazed before service ring Piston Ring Orientation sets are used. 2. If cylinder bore does not need re-boring and if old piston is within wear limits and free of score or scuff marks, old piston may be reused.
Page 66 Disassembly/Inspection and Service Inspect crankpin for score marks or metallic pickup. Remove Crankshaft Slight score marks can be cleaned with crocus cloth NOTE: If crankpin is reground, visually check to ensure soaked in oil. If wear limits, as stated in Clearance that fillet blends smoothly with crankpin surface.
Page 67 23°-33° Crosshatch use a press and support casting surface around bearing flange. Do not press against or support NOTE: Kohler pistons are custom-machined to exacting by gasket/outer perimeter surface. tolerances. When oversizing a cylinder, it should be machined exactly 0.25 mm (0.010 in.) or Crankcase 0.50 mm (0.020 in.) over new diameter.
Page 68 Disassembly/Inspection and Service Clean Cylinder Bore After Honing Proper cleaning of cylinder walls following boring and/ 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. Final cleaning operation should always be a thorough scrubbing with a brush and hot, soapy water.
Page 69 Reassembly Crankcase Components Camshaft Locking Tab Regulating Pin Governor Gear Lifter Feed Cover Cross Shaft Lifter Feed Cover Governor Yoke Gasket Connecting Rod End Crankshaft Connecting Rod Piston Pin Piston Pin Retainer Piston (Style A) Piston Ring Set Oil Seal Crankshaft Thrust Crankshaft Bearing...
Page 70 Reassembly NOTE: Make sure engine is assembled using all Install Governor Shafts, Seal, and Governor Gear specified torque values, torque sequences, and clearances. Failure to observe specifications Governor Components and Details could cause severe engine wear or damage. Always use new gaskets. Apply a small amount of oil to threads of critical fasteners before assembly, unless a sealant or Loctite ®...
Page 71 Reassembly Install Crankshaft Install Camshaft Carefully slide flywheel end of crankshaft through 1. Liberally apply camshaft lubricant to each cam lobe. bearing in crankcase. Lubricate camshaft bearing surfaces of crankcase and camshaft with engine oil. Install Connecting Rods with Pistons and Rings 2.
Page 72 Reassembly Breather/Closure Plate/Oil Reservoir Components Closure Plate Gerotor Gears Oil Pump O-ring Oil Pump Housing Relief Valve Baffle Pickup Tube Clamp Inlet Seal Pickup Screen Oil Reservoir Drain Plug Gasket Crankshaft Thrust Bearing Closure Plate Gasket Dipstick Dipstick Tube (Flange PTO) Breather Assembly Breather Gasket Filter...
Page 73 Reassembly Oil Seal 5. Orient flat of oil pump gear to match position of flat Details on camshaft. Then install closure plate to crankcase. Carefully seat camshaft and crankshaft into their mating bearings. Rotate crankshaft slightly to help oil pump and governor gears mesh. 6.
Page 74 Reassembly Breather Components Used on Serial No. 37070xxxxx and Below Used on Serial No. 37071xxxxx and Higher Breather Fastener Torque Sequence Filter must Not Extend Above Casting SECTION A-A Breather Hose Flange Nuts Breather Gasket Screw Baffle Filter Adapter Studs Install Breather Assembly 1.
Page 75 Reassembly Cylinder Head Components Gasket Valve Cylinder Head Pipe Plug Spacer Washer Spark Plug Valve Stem Seal Valve Spring Hydraulic Lifter Valve Spring Retainer Push Rod Valve Spring Keeper Rocker Arm Rocker Arm Pivots Valve Cover Gasket Hydraulic Lifter Hydraulic Lifter Valve Cover Grommet Style A (Ribbed)
Page 76 Reassembly Install Hydraulic Lifters Install Cylinder Heads Torque Sequence NOTE: Hydraulic lifters should always be installed in same position as they were disassembled. Exhaust lifters are located on output shaft side of engine while intake lifters are located on fan side of engine.
Page 77 Reassembly Install Push Rods and Rocker Arms Install Valve Covers NOTE: Push rods should always be installed in same 1. Make sure sealing surfaces are clean and free of position as before disassembly. any nicks or burrs. 1. Note mark or tag identifying push rod as either 2.
Page 78 Reassembly Oil Cooler/Filter Components Install Oil Filter Adapter 1. Make sure all sealing surfaces are clean and dowel pins are in place on crankcase adapter surface. Carefully install a new O-ring around each dowel pin. Then install new O-rings onto dowel pins of oil filter adapter.
Page 79 Reassembly Flywheel/Ignition Components Rectifier-Regulator Ignition Module Washer Flywheel Screw Special Washer Debris Screen Wire Harness Clamp (Style A) (Style A) (Style A) Stiffener Hex Stud Flywheel Magnet (Style A) Debris Screen Stator Backing Shroud Woodruff Key (Style B) Support Ring Spacer (Style B) (Style B)
Page 80 Reassembly 2. Install flywheel onto crankshaft, being careful not to Install Backing Shroud Assembly shift woodruff key. NOTE: New hose clamps are recommended for 3. Install screw and washer. reassembly, or if clamps have been loosened (expanded) several times to avoid leakage. 4.
Page 81 Reassembly Install Cooling Fan and Debris Screen (Style A) Install Metal Debris Screen (Style B) Spring Washer Details CAUTION Failure to utilize or reassemble debris screen as designed could result in debris screen failure and serious personal injury. 1. Position cooling fan onto flywheel aligning mounting locations.
Page 82 Reassembly External Engine Components Oil Filter Oil Filter Nipple Oil Filter Cup Valve Spring Cup Spring Valve Oil Filter Housing Valley Baffle Outer Cylinder Baffle Electric Starter Cylinder Shroud Blower Housing Fixed Guard Oil Sentry O-ring ™ Fitting Oil Filter Adapter Oil Cooler Hose Hose Clamp...
Page 83 Reassembly Install Outer Cylinder Baffles Install Valley Baffles 1. Install outer cylinder baffles. Make sure spark plug 1. Install valley baffles and secure with mounting lead is routed through corresponding opening in screws. Lower section should fit under outer baffle. each baffle.
Page 84 Reassembly Control Bracket Components Throttle Lever Throttle Linkage Governor Arm Governor Spring Governed Idle Spring Cross Shaft Governor Lever Choke Cable Clamp Control Pivot Pin Pal Nut Choke Linkage Choke Return Spring Choke Bracket Choke Lever Install Governor Lever Install governor lever onto governor shaft and connect throttle linkage with black clip. Do not tighten governor lever at this time.
Page 85 Reassembly 1. Connect choke linkage to appropriate hole in choke Install Control Bracket and Air Cleaner Assembly lever and secure with small clip. Torque Sequence 2. Connect throttle linkage to appropriate hole in throttle lever and secure with small clip. Adjusting Governor 3, 7 1, 5...
Page 86 Reassembly Install Control Panel (if equipped) Install Muffler Control Panel Component 1. Install new exhaust gaskets onto exhaust studs. 2. Install port liners (if equipped). Attach muffler and secure with nuts onto exhaust studs. Torque nuts to 24.4 N·m (216 in. lb.). 3.
Page 87 62 690 01 Rev. J KohlerEngines.com...

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