Kohler Comand Pro CH1000 Service Manual

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ERVICE

ANUAL

CH940-CH1000

ORIZONTAL

RANKSHAFT

Table of Contents

Troubleshooting

Summary of Contents for Kohler Comand Pro CH1000

Page 1 ERVICE ANUAL CH940-CH1000 ORIZONTAL RANKSHAFT...
Page 3: Table Of Contents
Contents Section 1. Safety and General Information ................Section 2. Tools & 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.
Page 5: Section 1. Safety And General Information
Section 1 Safety and General Information 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.
Page 6 Section 1 Safety and General Information WARNING WARNING WARNING Explosive Gas can cause ﬁ res and Explosive Fuel can cause ﬁ res and Carbon Monoxide can cause severe severe acid burns. severe burns. nausea, fainting or death. Charge batt ery only in a well Do not ﬁ...
Page 7 Section 1 Safety and General Information Engine Identiﬁ cation Numbers When ordering parts, or in any communication involving an engine, always give the Model, Speciﬁ cation, and Serial Numbers, including lett er suﬃ xes if there are any. The engine identiﬁ cation numbers appear on a decal, or decals, aﬃ...
Page 8 Gasohol (up to 10% ethyl alcohol, 90% unleaded However, to allow piston rings to properly gasoline by volume) is approved as a fuel for Kohler seat, a new or rebuilt engine should be engines. Other gasoline/alcohol blends including E20 operated for at least 50 hours using standard and E85 are not to be used and not approved.
Page 9 1) Disconnect the spark plug lead(s). 2) Disconnect negative (-) batt ery cable from batt ery. Maintenance Schedule Normal maintenance, replacement or repair of emission control devices and systems may be performed by any repair establishment or individual; however, warranty repairs must be performed by a Kohler authorized service center. Frequency...
Page 10 Section 1 Safety and General Information Dimensions in millimeters. Inch equivalents shown in [ ]. Figure 1-4. Typical CH PRO Series Engine Dimensions with Heavy-Duty Air Cleaner.
Page 11 Section 1 Safety and General Information Dimensions in millimeters. Inch equivalents shown in [ ]. LIFTING POINT 10.00 12.00 [0.394] [0.472] 364.51 106.00 85.64 [14.351] [4.173] 76.25 63.00 [3.372] AIR CLEANER [3.002] [2.480] COVER REMOVAL FILL 575.09 [22.641] 600.09 [23.625] ENGINE 41.4 MOUNTING...
Page 12 Section 1 Safety and General Information General Speciﬁ cations¹ Power (@ 3600 RPM, exceeds Society of Automotive Engineers-Small Engine Test Code J1940.) CH940 ......................25.4 kW (34 HP) CH960 ......................26.9 kW (36 HP) CH980 ......................28.3 kW (38 HP) CH1000 ......................
Page 13 Section 1 Safety and General Information Cam Lobe Proﬁ le (Minimum Dimension, Measured From Base Circle To Top Of Lobe) Exhaust CH940,CH960,CH980,CH1000 ............35 mm (1.3779 in.) Intake CH940 ....................34.1 mm (1.3425 in.) CH960,CH980,CH1000 ..............35 mm (1.3779 in.) Carburetor, Intake Manifold, and Air Cleaner Intake Manifold Mounting Fastener Torque Torque (Using Sequence) in Two Stages ..........
Page 14 Section 1 Safety and General Information Crankshaft Bore (In Crankcase) New, Without Main Bearing ..............50.00/50.025 mm (1.9685/1.969 in.) With Main Bearing Installed ..............45.040/45.145 mm (1.7732/1.7773 in.) Max. Wear Limit ..................45.158 mm (1.7778 in.) Crankshaft to Sleeve Bearing (In Crankcase) Running Clearance - New ..............
Page 15 Section 1 Safety and General Information Fan/Flywheel Fan Fastener Torque..................9.9 N·m (88 in. lb.) Flywheel Retaining Screw Torque ..............67.8 N·m (50 ft . lb.) Grass Screen Hex Stud Torque ..................... 9.9 N·m (88 in. lb.) Mounting Screw Torque ................. 9.9 N·m (88 in. lb.) Front Drive Shaft Screw Torque (Into Flywheel) ........
Page 16 Section 1 Safety and General Information Piston, Piston Rings, and Piston Pin Piston-to-Piston Pin Running Clearance ............. 0.006/0.018 mm (0.0002/0.0007 in.) Piston Pin Bore I.D. New ......................19.006/17.013 mm (0.7482/0.7485 in.) Max. Wear Limit ..................19.025 mm (0.7490 in.) Piston Pin O.D. New ......................
Page 17 Section 1 Safety and General Information Valves and Valve Lifters Hydraulic Valve Lift er to Crankcase Running Clearance ......0.012/0.050 mm (0.0004/0.0019 in.) Intake Valve Stem-to-Valve Guide Running Clearance ......0.038/0.076 mm (0.0015/0.0030 in.) Exhaust Valve Stem-to-Valve Guide Running Clearance ......0.050/0.088 mm (0.0020/0.0035 in.) Intake Valve Guide I.D.
Page 18 Section 1 Safety and General Information English Fastener Torque Recommendations for Standard Applications Tightening Torque: N·m (in. lb.) + or - 20% Bolts, Screws, Nuts and Fasteners Grade 2 or 5 Assembled Into Cast Iron or Steel Fasteners Into Aluminum Grade 2 Grade 5 Grade 8...
Page 19: Section 2. Tools & Aids
Fax 810-664-8181 Tools Description Source/Part No. Balance Gear Timing Tool (K & M Series) Kohler 25 455 06-S To hold balance gears in timed position when assembling engine. (Formerly Y-357) Camshaft Endplay Plate SE Tools KLR-82405 For checking camshaft endplay.
Page 20 Flywheel Strap Wrench SE Tools KLR-82409 To hold ﬂ ywheel during removal. Hydraulic Valve Lift er Tool Kohler 25 761 38-S To remove and install hydraulic lift ers. Ignition System Tester For testing output on all systems, except CD. Kohler 25 455 01-S For testing output on capacitive discharge (CD) ignition system.
Page 21 Section 2 Tools & Aids Aids Description Source/Part No. Camshaft Lubricant (Valspar ZZ613) Kohler 25 357 14-S Dielectric Grease (GE/Novaguard G661) Kohler 25 357 11-S Dielectric Grease (Loctite ® 51360 Electric Starter Drive Lubricant (Inertia Drive) Kohler 52 357 01-S...
Page 22 1 in. O.D. tooth segment of the ring gear as shown. (Kohler Part No. 12 468 05-S). Assemble the capscrew and washer to the joint surface of the 2. Grind oﬀ any burrs or sharp edges.
Page 23: Section 3. Troubleshooting
Section 3 Troubleshooting Section 3 Troubleshooting 11. Quality of fuel. Troubleshooting Guide 12. Flywheel key sheared. When troubles occur, be sure to check the simple 13. Intake system leak. causes which, at ﬁ rst, may seem too obvious to be considered.
Page 24 Section 3 Troubleshooting • Check for obvious fuel and oil leaks, and Engine Knocks 1. Excessive engine load. damaged components. Excessive oil leakage 2. Low crankcase oil level. can indicate a clogged or improperly-assembled 3. Old or improper fuel. breather, worn/damaged seals and gaskets, or 4.
Page 25 Section 3 Troubleshooting 4. Close the shut-oﬀ clamp before stopping the Basic Engine Tests engine. Crankcase Vacuum Test To test the crankcase vacuum with the Vacuum/ A partial vacuum should be present in the Pressure Gauge Kit (see Section 2): crankcase when the engine is operating.
Page 26 Section 3 Troubleshooting Compression Test If the ﬂ ywheel end is more accessible, use a A compression test is best performed on a warm breaker bar and socket on the ﬂ ywheel nut/screw engine. Clean any dirt or debris away from the base to hold it in position.
Page 27: Section 4. Air Cleaner And Air Intake System
Section 4 Air Cleaner and Air Intake System Section 4 Air Cleaner and Air Intake System Air Cleaners 2. Check and clean the screen area on the inlet side. Pull the air cleaner paper element out of the These engines use a heavy-duty style air cleaner or a housing on opposite side.
Page 28 Air Cleaner the elements. Replace dirty, bent, or damaged Cover elements with new genuine Kohler elements as required. Handle the new elements carefully; do not use if the sealing surfaces are bent or damaged.
Page 29 Replace a dirty, bent, or damaged element with Clean the cooling ﬁ ns and external surfaces as a genuine Kohler element. Handle new elements necessary. Make sure all shrouds are reinstalled. carefully; do not use if the sealing surfaces are bent or damaged.
Page 30 Section 4 Air Cleaner and Air Intake System...
Page 31: Section 5. Fuel System And Governor
• Fuel Pump Gasoline/Alcohol blends • Carburetor Gasohol (up to 10% ethyl alcohol, 90% unleaded gasoline by volume) is approved as a fuel for Kohler Operation engines. Other gasoline/alcohol blends including E20 The fuel from the tank is moved through the in-line and E85 are not to be used and not approved.
Page 32 To ﬁ nd out if the fuel system is causing the not meet these requirements may not be used. Order problem, perform the following tests. replacement hose through a Kohler Service Center. Troubleshooting – Fuel System Related Causes Test Conclusion 1.
Page 33 Section 5 Fuel System and Governor Low Idle Fuel Self-Relieving Adjustments Choke (With Limiters) Slow Jets Bowl Vent Fuel Shut-Off Solenoid Figure 5-3. Keihin Two-Barrel Carburetor. Figure 5-2. Optional Electric Fuel Pump. Troubleshooting Checklist Fuel Pump - Replacement When the engine starts hard, runs roughly, or stalls at low idle speed, check the following areas before Replacing the Mechanical Fuel Pump adjusting or disassembling the carburetor.
Page 34 To obtain high altitude kit information or locate a Solenoid dealer near you, call 1-800-544-2444 to ﬁ nd the names of the nearest Kohler Co. Service Centers or, access our web site at: www.kohlerengines.com and click on the Service & Dealer Locator located in the upper right hand corner.
Page 35 Section 5 Fuel System and Governor Below is a simple test, made with the engine oﬀ , that Slow & Mid-Range Circuit: can determine if the solenoid is functioning properly: At low speeds the engine operates only on the slow circuit.
Page 36 Section 5 Fuel System and Governor Low Idle Speed (RPM) Adjustment a. Turn one of the low idle fuel adjusting 1. Low Idle Speed (RPM) Sett ing: Place the thrott le needles out (counterclockwise) from the control in the idle or slow position. Set the low preliminary sett ing until the engine speed idle speed approximately 300 RPM* less than decreases (rich).
Page 37 Section 5 Fuel System and Governor Governor Governor Spring Spring Governed Idle Governed Idle Spring Spring Figure 5-7. Governor Springs Installed. Figure 5-9. Throttle Lever in Idle Position. Hold/Pull Governor Hold/Pull Governor Lever Back Lever Back Governed Idle Speed Governed Idle Speed Adjustment Screw Adjustment Screw Governor Spring Must...
Page 38 Section 5 Fuel System and Governor Carburetor Servicing The following section covers the disassembly, Fuel Bowl various servicing procedures, and reassembly of the carburetor. For each procedure carefully inspect all components and replace those that are worn or damaged. The following should also be noted as service is performed.
Page 39 Section 5 Fuel System and Governor Clip Inlet Needle Float Figure 5-14. Float and Inlet Needle Details. Figure 5-16. Checking Float Height. 6. Install the ﬂ oat and inlet needle down into the NOTE: Be sure to measure from the casting surface, seat and carburetor body.
Page 40 Section 5 Fuel System and Governor Disassembly/Overhaul 3. Use an appropriate size ﬂ at screwdriver, and 1. Clean the exterior surfaces of dirt or foreign carefully remove the two main jets from the material before disassembling the carburetor. carburetor. Note and mark the jets by location for Remove the four mounting screws and separate proper installation.
Page 41 Section 5 Fuel System and Governor Slow (Idle Fuel) Jets Nozzle End with Two Shoulders O-ring O-ring (Out/Down) Main Jets Figure 5-22. Slow Jets and O-ring Detail. Figure 5-23. Installing Main Nozzles and Main Jets. 5. Remove the idle speed (RPM) adjustment screw 9.
Page 42 Section 5 Fuel System and Governor 12. Att ach the inlet needle to the plastic tang of 15. The correct ﬂ oat height sett ing is 17 mm the ﬂ oat with the wire clip. The formed 90° lip (0.669 in.) ± 1.5 mm (0.059 in.), measured from should point up, with the needle valve hanging the ﬂ...
Page 43 Section 5 Fuel System and Governor 3. Remove and discard the plastic cap from the end 8. Turn the old bushing upside down and use it of the choke lever/shaft assembly. as a driver to carefully press or tap the new bushing into the carburetor body until it bott oms.
Page 44 Section 5 Fuel System and Governor Figure 5-33. Installing Choke Assembly Components. ® 11. Place a drop of Loctite 222MS™ on the threads of each new screw. Position and install the new choke plate to the ﬂ at side of the choke shaft .
Page 45 Section 5 Fuel System and Governor 1. Carburetor Body 11. O-ring (Fuel Bowl - Upper) 22. Main Nozzle - Right Side Subassembly 12. O-ring (Fuel Bowl - Lower) 23. Main Nozzle - Left Side 2. Idle Speed Screw 13. Drain Screw 24.
Page 46 Section 5 Fuel System and Governor • One end of the cross shaft protrudes through the Initial Adjustment Procedure crankcase. The rotating action of the cross shaft is Make this adjustment whenever the governor arm is transmitt ed to the thrott le lever of the carburetor loosened or removed from the cross shaft .
Page 47: Section 6. Lubrication System
, camshaft , and connecting rod bearing 5W-20, 5W-30 surfaces. In addition to lubricating the bearing surfaces, the lubrication system supplies oil to the Kohler 10W-30 hydraulic valve lift ers. °F -20 °C -30 A high-eﬃ ciency gerotor pump is located in the TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANGE closure plate.
Page 48 Section 6 Lubrication System The top portion of the symbol shows service class such as API SERVICE CLASS SJ. The symbol may show additional categories such as SH, SG/CC, or CD. The center portion shows the viscosity grade such as SAE 10W-30. If the bott om portion shows Energy Conserving, it means that oil is intended to improve fuel economy in passenger car engines.
Page 49: Lubrication System
(every 300 hours of operation). Always use a genuine Kohler oil ﬁ lter. The oil ﬁ lter 4. Reinstall the drain plug and torque to 21.4 N·m on most engines is located on top of the crankcase (16 ft .
Page 50 Section 6 Lubrication System 7. Fill the crankcase with new oil of the proper type to the F mark on the dipstick. 8. Start the engine and check for oil leaks. Correct any leaks before placing the engine into service. Check oil level to be sure it is up to but not over the F mark.
Page 51 Section 6 Lubrication System 3. Torque the switch to 10.1 N·m (90 in. lb.). Testing Compressed air, a pressure regulator, pressure gauge, and a continuity tester are required to test the switch. 1. Connect the continuity tester across the blade terminal and the metal case of the switch.
Page 52 Section 6 Lubrication System...
Page 53: Section 7. Electrical System And Components
The engine is equipped with the following spark plugs: Type: The standard spark plug is a Champion ® XC10YC (Kohler Part No. 62 132 04-S). Ground 0.76 mm Equivalent alternate brand plugs can also be Electrode (0.030 in.) Gap used.
Page 54 Section 7 Electrical System and Components Normal: A plug taken from an engine operating under Wet Fouled: A wet plug is caused by excess fuel or normal conditions will have light tan or gray colored oil in the combustion chamber. Excess fuel could deposits.
Page 55 Section 7 Electrical System and Components Battery 2. Keep the cables, terminals, and external surfaces of the batt ery clean. A build-up of corrosive acid or grime on the external surfaces can cause the General batt ery to self-discharge. Self-discharge occurs A 12-volt batt ery with 400 cold cranking amps (cca) is rapidly when moisture is present.
Page 56 Section 7 Electrical System and Components Electronic Ignition Systems There are two diﬀ erent types of ignition systems used on these engines. All systems use an ignition module which energizes the spark plug. The diﬀ erence in the system is in the way the ignition timing is triggered. The Fixed Ignition System utilizes a Capacitive Discharge (CD) coil (See Figure 7-3).
Page 57 Section 7 Electrical System and Components Ignition Kill Switch or Off Position of Modules Key Switch Spark Plug Magnet (0.28/0.33 mm) 0.011/0.013 in. Air Gap Flywheel Figure 7-4. Capacitive Discharge Fixed Timing Ignition System. The timing of the spark is controlled by the location of the ﬂ ywheel magnet group as referenced to engine top dead center.
Page 58 RPM. A typical DSAI application (Figure 7-6) 2. Test for spark on both cylinders with Kohler consists of the following components: ignition tester (see Section 2). Disconnect one spark plug lead and connect it to the post •...
Page 59 • Hand Tachometer The DSAI ignition system is designed to be trouble • Ignition Tester* (Kohler Part No. 25 455 01-S) free for the life of the engine. Other than periodically • Automotive Timing Light checking/replacing the spark plugs, no maintenance, •...
Page 60 Connect the spark plug lead to 3. Run the engine at idle and use the timing light post terminal of spark tester (Kohler Part No. beam to locate the line on the screen. Draw a line 25 455 01-S), and att ach tester clip to a good on the blower housing next to the line on the engine ground.
Page 61 Section 7 Electrical System and Components 3. Using a multi-meter, check that a proper ground is established between the ground (black) lead of the DSAI module (closest to spark plug lead), and a known good ground location on the engine. 4.
Page 62 Section 7 Electrical System and Components 15/20/25 Amp Regulated Charging System Figure 7-9. 25 Amp Stator and 20/25 Amp Rectiﬁ er- Figure 7-10. 15 Amp Stator and Rectiﬁ er-Regulator. Regulator. NOTE: 20 amp charging systems use a 15 amp stator with a 25 amp rectiﬁ er-regulator. Figure 7-11.
Page 63 Section 7 Electrical System and Components Figure 7-12. Wire Diagram-15/20/25 Amp Regulated Battery Charging System with Fixed Timing, Five Pin Connector, Key Switch, and Fuse. 7.11...
Page 64 Section 7 Electrical System and Components Figure 7-13. Wire Diagram-15/20/25 Amp Regulated Battery Charging System with DSAI Ignition, Five Pin Connector and Key Switch. 7.12...
Page 65 Section 7 Electrical System and Components Figure 7-14. Wire Diagram-15/20/25 Amp Regulated Battery Charging System with DSAI Ignition and Four Pin Connector (LP-NG Kohler Power Systems Application). 7.13...
Page 66 Section 7 Electrical System and Components Figure 7-15. 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). 7.14...
Page 67 Section 7 Electrical System and Components Stator The stator is mounted on the crankcase behind the ﬂ ywheel. Follow the procedures in Section 9 - Disassembly and Section 11 - Reassembly if stator replacement is necessary. Rectiﬁ er-Regulator The rectiﬁ er-regulator is mounted on the backing shroud assembly.
Page 68 Section 7 Electrical System and Components 5. Plug the tester into the proper AC outlet/power *NOTE: A ﬂ ashing LOW light can also occur as for tester being used. Turn on the power switch. a result of an inadequate ground lead The POWER light should be illuminated and one connection.
Page 69: Troubleshooting Guide
Section 7 Electrical System and Components Troubleshooting Guide 15/20/25 Amp Battery Charging Systems When problems occur in keeping the batt ery charged or the batt ery charges at too high a rate, the problem can usually be found somewhere in the charging system or with the batt ery. NOTE: Always zero ohmmeter on each scale before testing to ensure accurate readings.
Page 70 Section 7 Electrical System and Components Rectiﬁ er-Regulator DC Voltmeter Flywheel Stator Ammeter Battery Figure 7-22. Connections for Testing Charging System. Electric Starting Motors Starter Removal and Installation Refer to the Disassembly and Reassembly Sections for The engines in this series use solenoid shift starters. A starter removal and installation procedures.
Page 71 Section 7 Electrical System and Components Troubleshooting Guide – Starting Difﬁ culties Problem Possible Fault Correction 1. Check the speciﬁ c gravity of the batt ery. If low, recharge or replace Battery batt ery as necessary. 1. Clean corroded connections and tighten loose connections. Starter Wiring 2.
Page 72 Section 7 Electrical System and Components Figure 7-28. Removing Commutator End Plate Figure 7-25. Solenoid Removed from Starter. Assembly. 6. Remove the frame from the armature and drive end cap. See Figure 7-29. Figure 7-26. Removing Plunger. 4. Remove the two thru (larger) bolts. See Figure 7-27.
Page 73 Section 7 Electrical System and Components 8. Take out the drive lever and pull the armature out of the drive end cap. See Figure 7-31. 9. Remove the thrust washer from the armature shaft . See Figure 7-31. Figure 7-33. Removing Retaining Ring. 12.
Page 74 Section 7 Electrical System and Components Inspection Commutator O.D. Drive Pinion Check and inspect the following areas: a. The pinion teeth for abnormal wear or damage. b. The surface between the pinion and the clutch mechanism for nicks, or irregularities which could cause seal damage.
Page 75 Starter Service The brushes and springs are serviced as a set (4). Use Clean the drive lever and armature shaft . Apply a new Kohler Brush and Spring Kit, if replacement is Kohler electric starter drive lubricant (see Section 2) necessary.
Page 76 Section 7 Electrical System and Components 3. Install the oﬀ set thrust (stop) washer so the 7. Install the backup washer, followed by the rubber smaller oﬀ set of the washer faces the retainer/ grommet, into the matching recess of the drive collar.
Page 77 Section 7 Electrical System and Components 9. Install the ﬂ at thrust washer onto the commutator end of the armature shaft . See Figure 7-45. Thrust Washer Figure 7-47. Removing Retaining Clips. b. Position each of the brushes back in their Figure 7-45.
Page 78 Section 7 Electrical System and Components d. Hold the starter assembly vertically on the end housing, and carefully place the tool (with extension) and assembled original brush holder assembly onto the end of the armature shaft . Slide the brush holder assembly down into place around the commutator, install the positive (+) brush lead grommet in the cutout of the frame.
Page 79 Section 7 Electrical System and Components Solenoid Test Procedure 12 volt Test Leads Momentary Solenoid Shift Style Starters Connection Only Disconnect all leads from the solenoid including the positive brush lead att ached to the lower stud VOM Leads terminal. Remove the mounting hardware and separate the solenoid from the starter for testing.
Page 80 Section 7 Electrical System and Components Test 4. Solenoid Hold-In Coil/Contact Continuity Test. Use an ohmmeter set to the audible or Rx2K scale, and connect the two ohmmeter leads to the two large post terminals. Perform the preceding test (3) and check for continuity.
Page 81: Section 8. Disassembly
Section 8 Disassembly Section 8 Disassembly WARNING: Accidental Starts! Disabling engine. Accidental starting can cause severe injury or death. Before working on the engine or equipment, disable the engine as follows: 1) Disconnect the spark plug lead(s). 2) Disconnect negative (-) batt ery cable from batt ery. 20.
Page 82 Section 8 Disassembly Shut Off Fuel Supply 3. Allow ample time for the oil to drain from the crankcase. Drain Oil from Crankcase and Remove Oil Remove Mufﬂ er Filter 1. Remove the exhaust system and att aching 1. Clean the oil ﬁ lter and housing area. Remove and hardware from the engine.
Page 83 Section 8 Disassembly Mounting Screws Mounting Screws Figure 8-7. Removing Electric Starter. Figure 8-9. Mounting Screws. 4. Remove the air cleaner as an assembly from the Remove Air Cleaner Assembly engine. See Figure 8-10. 1. Disconnect the breather hose from the air cleaner, and the formed vent hose from the vent port on the carburetor.
Page 84 Section 8 Disassembly 3. Carefully pry oﬀ the pal nut, remove the two washers (note assembly order), and disconnect the choke linkage from the pivot lever. Do not lose any parts. Secure remaining pivot parts with tape to avoid losing them. Always use a new pal nut during reassembly.
Page 85 Section 8 Disassembly 5. The carburetor and linkages can be separated as necessary. Remove Oil Sentry™ (If Equipped) 1. Disconnect the lead from the Oil Sentry™ switch. 2. Remove the Oil Sentry™ switch from the closure Mounting plate. See Figure 8-15. Screws Figure 8-17.
Page 86 Section 8 Disassembly Remove Oil Cooler 1. Remove the two oil cooler mounting screws. Do not lose any washers (if used). See Figure 8-19. Housing Housing Mounting Mounting Screw Screw Figure 8-21. Removing Oil Filter Housing From Adapter. Perform the following only if the oil ﬁ lter housing assembly requires individual servicing.
Page 87 Section 8 Disassembly Ignition Modules Valve Spring Figure 8-24. Rubber Valve and Spring Removed from Cup. Figure 8-26. Removing Ignition Modules. 2. Remove the screw securing the oil ﬁ lter adapter Remove Grass Screen and Cooling Fan and individual O-rings to the crankcase, then 1.
Page 88 Section 8 Disassembly Mounting Mounting Screws Screws Figure 8-31. Removing Flywheel with a Puller. Figure 8-29. Removing Fan. 4. Remove the woodruﬀ key from the crankshaft . Remove Flywheel 1. Use a ﬂ ywheel strap wrench or holding tool (see Remove Stator, Rectiﬁ...
Page 89 Section 8 Disassembly Remove Spark Plugs 1. Remove the spark plug from each cylinder head. Molded Clips Mounting Screws Figure 8-33. Removing Stator. 4. Unhook the wiring harness from the molded Figure 8-36. Removing Spark Plugs. clips if it is being serviced separately. See Figure 8-34.
Page 90 Section 8 Disassembly Electric Fuel Pump 1. Removal will be determined based on mounted location and application. Disconnect the lead connections, fuel line connections, and mounting hardware as required. Properly contain any remaining fuel. Valve Covers 1. Remove the screw and grommet securing each Spacer valve cover.
Page 91 Section 8 Disassembly Figure 8-45. Removing Valves with Valve Spring Figure 8-42. Removing Hydraulic Lifters. Compressor. 3. Once the valve spring is compressed, remove the following items. See Figures 8-46 and 8-47. Match • Valve spring keepers Numbers • Valve spring retainers •...
Page 92 Section 8 Disassembly NOTE: These engines use valve stem seals on the intake and exhaust valves. Use a new seal whenever valves are removed, or if the seal is deteriorated in any way. Never reuse an old seal. 4. Repeat the above procedure for the other cylinder head.
Page 93 Section 8 Disassembly 2. Locate the two protruding tabs on the closure plate. Carefully tap to break the gasket seal. Do not pry on the sealing surfaces as this could cause leaks. Separate the closure plate from the crankcase. See Figure 8-53 and 8-54. Remove the old gasket.
Page 94 Section 8 Disassembly Figure 8-57. Remove Connecting Rod Caps. Figure 8-59. Removing Crankshaft. Removal of Governor Gear Assembly NOTE: The cylinders are numbered on the crankcase. Use the numbers to mark each end cap, The governor gear is held onto the shaft by small connecting rod and piston for reassembly.
Page 95 Section 8 Disassembly Remove Governor Yoke, Cross Shaft, and Seal 1. Remove the two mounting screws securing the yoke to the governor cross shaft . See Figure 8-61. Figure 8-63. Removing Oil Seals. Removal of Main Bearings NOTE: Flywheel and PTO side main bearings should only be removed if replacement Figure 8-61.
Page 96 Section 8 Disassembly 8.16...
Page 97: Section 9. Inspection And Reconditioning
Section 9 Inspection and Reconditioning Section 9 Inspection and Reconditioning This section covers the operation, inspection, and Camshaft repair/reconditioning of major internal engine components. The following components are not Inspection and Service covered in this section. They are covered in sections of Check the lobes of the camshaft for wear or damage.
Page 98 . the crankpin surface. See Figure 9-1. Procedure to Install New Plug: 1. Use a single cylinder camshaft pin, Kohler Part High Point from No. 47 380 09-S as a driver and tap the plug into...
Page 99 Use a strong detergent that is capable of breaking down the machining oil while maintaining NOTE: Kohler pistons are custom-machined to a good level of suds. If the suds break down during cleaning, discard the dirty water and start again exacting tolerances.
Page 100 ﬂ ywheel key is sheared or the keyway is damaged. Inspect the ring gear for cracks or damage. Kohler does not provide the ring gear as a serviceable part. Replace the ﬂ ywheel if the ring gear is damaged.
Page 101 Section 9 Inspection and Reconditioning INTAKE VALVE EXHAUST VALVE Dimension Intake Exhaust 89° Seat Angle 89° 30° Seat Taper 30° 8.5 mm (0.334 in.) Guide Depth 8.5 mm (0.334 in.) 7.038/7.058 mm (0.2771/0.2779 in.) Guide I.D. 7.038/7.058 mm (0.2771/0.2779 in.) 38.625/38.685 mm (1.5206/1.5230 in.) Valve Head Diameter 31.625/31.825 mm (1.2450/1.2549 in.)
Page 102 Section 9 Inspection and Reconditioning Normal: Even aft er long hours of operation a valve Leakage: A poor grind on face or seat of valve will can be reconditioned and reused if the face and allow leakage resulting in a burned valve on one side margin are in good shape.
Page 103 Section 9 Inspection and Reconditioning Excessive Combustion Temperatures: The white Stem Corrosion: Moisture in fuel or from deposits seen here indicate very high combustion condensation are the most common causes of valve temperatures, usually due to a lean fuel mixture. stem corrosion.
Page 104 Section 9 Inspection and Reconditioning Valve Guides If a valve guide is worn beyond speciﬁ cations, it will not guide the valve in a straight line. This may result in burnt valve faces or seats, loss of compression, and excessive oil consumption. Valve Seat Cutter To check valve guide-to-valve stem clearance, thoroughly clean the valve guide and, using a...
Page 105 Section 9 Inspection and Reconditioning Ring failure is usually indicated by excessive oil Detonation damage occurs when a portion of the fuel consumption and blue exhaust smoke. When rings charge ignites spontaneously from heat and pressure fail, oil is allowed to enter the combustion chamber shortly aft er ignition.
Page 106 Section 9 Inspection and Reconditioning Replacement pistons are available in STD bore size, and in 0.25 mm (0.010 in.), and 0.50 mm (0.020 in.) oversize. Replacement pistons include new piston ring sets and new piston pins. Replacement ring sets are also available separately for STD, 0.25 mm (0.010 in.), and 0.50 mm (0.020 in.) oversize pistons.
Page 107 Check the base surface of the hydraulic lift ers for wear or damage. If the lift ers need to be replaced, apply a liberal coating of Kohler lubricant (see Section 2) to Piston the base of each new lift er before it is installed.
Page 108 Section 9 Inspection and Reconditioning Closure Plate Assembly Inspection Inspect the oil pump housing, gerotor gears, and closure plate recess for nicks, burrs, wear, or any Inspection visible damage. Inspect the inlet seal for the pickup Inspect the oil seal in the closure plate and remove it if tube in the housing.
Page 109 Section 9 Inspection and Reconditioning 4. Install the O-ring in the groove of the oil pump b. Install fastener into location No. 2 and fully housing. Use a small quantity of grease to hold it torque to the recommended value. in place.
Page 110 Section 9 Inspection and Reconditioning 9.14...
Page 111: Section 10. Reassembly
Section 10 Reassembly Section 10 Reassembly General 16. Install push rods and rocker arms. 17. Install valve covers. NOTE: Make sure the engine is assembled using 18. Install spark plugs. all speciﬁ ed torque values, tightening 19. Install oil ﬁ lter adapter. sequences, and clearances.
Page 112 Section 10 Reassembly 2. Apply a light coat of clean engine oil to the Mounting outside diameter of the oil seal. Screws Bafﬂ e (Used on Some 3. Install the oil seal into the crankcase using a seal Models Only) driver.
Page 113 Section 10 Reassembly 2. If the governor gear shaft was removed, press or lightly tap the replacement shaft into the closure Notch plate to depth shown in Figure 10-10. Main Bearing Governor Gear Shaft Figure 10-6. Installed Main Bearing. Install Governor Shafts, Seal, and Governor Gear Figure 10-9.
Page 114 Section 10 Reassembly 4. Att ach the governor yoke to the cross shaft so the curved section is up as marked. Secure with the two screws. If a thread locking compound is ® not preapplied, apply a small amount of Loctite 266™...
Page 115 Section 10 Reassembly Install Connecting Rods with Pistons and Rings NOTE: The cylinders are numbered on the crankcase. Make sure to install the piston, connecting rod and end cap into the appropriate cylinder bore as previously marked at disassembly. Do not mix the end caps and connecting rods.
Page 116 Section 10 Reassembly 6. Repeat this procedure for the other connecting 2. Position the camshaft end play checking tool over rod and piston assembly. the camshaft . Use a feeler gauge to check the end play between the camshaft and end play checking tool.
Page 117 Section 10 Reassembly Notch Main Bearing 3.0 mm (0.118 in.) Oil Seal Figure 10-26. Oil Seal Depth in Closure Plate. Figure 10-24. Installed Main Bearing In Closure Plate. 4. Apply a light coat of clean engine oil to the inner surface of the main bearing.
Page 118 Section 10 Reassembly 4. Ensure the end of the tabbed washer on the governor gear is positioned outward in the 6 o’clock position inside the crankcase. See Figure 10-28. Figure 10-30. Torquing Closure Plate Screws. Figure 10-28. Tabbed Washer Details. 5.
Page 119 Section 10 Reassembly Mounting Screw Figure 10-33. Torquing Pickup Mounting Screw. Figure 10-35. Torquing Oil Reservoir Fasteners. Install Oil Reservoir 1. Use two bolts with the heads removed, or a similar item as temporary alignment pins and install into the two center holes on the ends as shown in Figure 10-34.
Page 120 Section 10 Reassembly Install Breather Assembly 3. Install the M5 hex ﬂ ange nuts onto the studs, then torque using the sequence shown in Figure 10-40 1. Make sure the sealing surfaces of the crankcase to 5.7 N·m (51 in. lb.). and breather cover are clean and free of any nicks or burrs.
Page 121 Section 10 Reassembly Install Hydraulic Lifters 1. See Servicing Hydraulic Lift ers in Section 9 for lift er preparation (bleed down) procedures. Match Numbers 2. Apply camshaft lubricant (see Section 2) to the bott om surface of each lift er. See Figure 10-41. Lubricate the hydraulic lift ers and the lift er bores in the crankcase with engine oil.
Page 122 Section 10 Reassembly Assemble Cylinder Heads Prior to installation, lubricate all components with engine oil, paying particular att ention to the lip of the valve stem seal, valve stems, and valve guides. Install the following items in the order listed below using a valve spring compressor.
Page 123 Section 10 Reassembly Install Push Rods and Rocker Arms NOTE: Push rods should always be installed in the same position as before disassembly. 1. Note the mark or tag identifying the push rod as either intake or exhaust and cylinder 1 or 2. Dip the ends of the push rods in engine oil and install, making sure that each push rod ball seats in its hydraulic lift er socket.
Page 124 Section 10 Reassembly 4. Torque the hex ﬂ ange screws to 14.6 N·m Install Valve Covers (130 in. lb.). See Figure 10-54. 1. Make sure the sealing surfaces are clean and free of any nicks or burrs. 2. Install and properly seat the seal onto each of the valve covers.
Page 125 Section 10 Reassembly 3. Install new plugs and torque to 24.4-29.8 N·m (18-22 ft . lb.). See Figure 10-58. Mounting Screw Oil Filter Adapter Figure 10-60. Torquing Oil Filter Adapter. Install Intake Manifold Figure 10-58. Installing Spark Plugs. 1. Install new intake manifold gaskets so the notched section is inward and points toward the Install Oil Filter Adapter ﬂ...
Page 126 Section 10 Reassembly 2. Mount the intake manifold to the cylinder heads. Make sure the gaskets remain in the proper position. Torque the four screws in two stages, ﬁ rst to 16.9 N·m (150 in. lb.), ﬁ nally to 22.6 N·m (200 in.
Page 127 Section 10 Reassembly 4. Install the nipple in housing and torque to 2. Install the oil ﬁ lter housing assembly to the 18.0 N·m (159 in. lb.). See Figures 10-67 and adapter and secure with the M8 hex head screw. 10-68.
Page 128 Section 10 Reassembly 2. Install the backing shroud assembly and secure 5. Check the terminal on the end of the B+ charging to the crankcase with the four M6 screws. Torque lead to be sure the locking tang is angled upward. the screws to 10.7 N·m (95 in.
Page 129 Section 10 Reassembly Ground Lead Rectiﬁ er- Regulator Connector Plug Figure 10-76. Installing Rectiﬁ er-Regulator and Figure 10-78. Clean and Dry Flywheel Hub. Ground Lead. NOTE: Make sure the ﬂ ywheel key is installed properly in the keyway. The ﬂ ywheel can Install Flywheel become cracked or damaged if the key is not properly installed.
Page 130 Section 10 Reassembly 4. Use a ﬂ ywheel strap wrench or holding tool 5. Insert a 0.30 mm (0.012 in.) ﬂ at feeler gauge to hold the ﬂ ywheel. Torque the hex ﬂ ange between the magnet and the ignition module. See screw securing the ﬂ...
Page 131 Section 10 Reassembly Install Outer Cylinder Bafﬂ es 1. Install the outer cylinder baﬄ es. Make sure the spark plug lead is routed through the corresponding opening in each baﬄ e. Start each of the screws. Torque the M6 shoulder screws going through the backing shroud assembly Hoses into the extruded holes in the baﬄ...
Page 132 Section 10 Reassembly Install Cooling Fan and Grass Screen Mounting Screws CAUTION: Failure to utilize or reassemble the grass screen as designed could result in grass screen failure and serious personal injury. 1. Position the cooling fan onto the ﬂ ywheel aligning the mounting locations.
Page 133 Section 10 Reassembly Gasket (Tab Up) Carburetor Carburetor Valley Bafﬂ e Throttle Throttle Linkage Linkage Choke Choke Linkage Linkage Figure 10-90. Installing Valley Bafﬂ es. Figure 10-92. Installing Carburetor with Linkages. 4. Connect the fuel line to the carburetor inlet and Install Carburetor secure with a clamp.
Page 134 Section 10 Reassembly Install Control Bracket and Air Cleaner 4. Slide the air cleaner assembly onto the four carburetor mounting studs. Align the two Assembly forward mounting holes in the base with the 1. Position the control bracket assembly onto mounting holes/bosses of the intake manifold the two intake manifold bosses.
Page 135 Section 10 Reassembly 2. Connect the thrott le linkage to the appropriate hole in the thrott le lever and secure with the small clip. 11, 5 Choke Control Throttle Control Clamp Location Clamp Locations Figure 10-98. Torque Sequence for Air Cleaner Mounting Nuts.
Page 136 Section 10 Reassembly 2. Move the governor lever toward the carburetor as Governor Spring/RPM Chart far as it will go (wide-open thrott le) and hold in position. See Figure 10-102. CH940-CH1000 Governor Idle Spring High Speed (RPM) 3. Insert a long thin rod or tool into the hole on the (Color) cross shaft and rotate the shaft clockwise (viewed Clear...
Page 137 Section 10 Reassembly Mounting Locations Cylinder Shrouds Figure 10-106. Oil Sentry Pressure Switch Figure 10-108. Installing Cylinder Shrouds. Location. Install Control Panel (If Equipped) 2. Connect the green wire lead to the Oil Sentry™ 1. Install the control panel to the main control terminal.
Page 138 Section 10 Reassembly Install Mufﬂ er 3. Apply a thin ﬁ lm of clean engine oil to the rubber gasket on the oil ﬁ lter and thread the ﬁ lter onto 1. Install new exhaust gaskets onto the exhaust the adapter nipple. See Figure 10-112. studs.
Page 139 Section 10 Reassembly Figure 10-114. Connect Spark Plug Leads. Prepare the Engine for Operation The engine is now completely reassembled. Before starting or operating the engine, be sure to do the following. 1. Make sure all hardware is tightened securely. 2.
Page 140 Section 10 Reassembly 10.30...
Page 142 FORM NO.: 62 690 01 Rev. A ISSUED: 9/10 REVISED: 3/11 FOR SALES AND SERVICE INFORMATION IN U.S. AND CANADA, CALL 1-800-544-2444 KohlerEngines.com ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044 © 2011 by Kohler Co. All rights reserved.

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