Kohler Command Pro CV960 Service Manual
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Kohler Command Pro CV960 Service Manual

Kohler vertical crankshaft service manual
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S
M
ERVICE
ANUAL
COMMAND PRO
CV940-CV1000
V
C
ERTICAL
RANKSHAFT

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Summary of Contents for Kohler Command Pro CV960

  • Page 1 ERVICE ANUAL COMMAND PRO CV940-CV1000 ERTICAL RANKSHAFT...

  • Page 3: Table Of 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

    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. Please read carefully. WARNING Warning is used to indicate the presence of a hazard that can cause severe personal injury, death, or substantial property damage if the warning is ignored.
  • Page 6 Section 1 Safety and General Information WARNING severe burns. engine is hot or running. Explosive Fuel! its vapors can explode if ignited. Store gasoline only in approved containers, in well ventilated, unoccupied engine is hot or running, since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition.

  • Page 7: Version Code

    When ordering parts, or in any communication involving an engine, always give the Model, Figure 1-1. An explanation of these numbers is shown in Figure 1-2. A. Model No. Command Engine Vertical Crankshaft Numerical Designation B. Spec. No. C. Serial No. Year Manufactured Code Code Year...

  • Page 8: Fuel Recommendations

    Gasoline/Alcohol blends Gasohol (up to 10% ethyl alcohol, 90% unleaded gasoline by volume) is approved as a fuel for Kohler engines. Other gasoline/alcohol blends including E20 and E85 are not to be used and not approved. Any failures resulting from use of these fuels will not be warranted.
  • Page 9 Every 600 Hours • Replace spark plugs. ¹Perform these maintenance procedures more frequently under extremely dusty, dirty conditions. Have a Kohler Engine Service Dealer perform this service. Storage use the following storage procedure. 1. Clean the exterior surfaces of the engine. Avoid spraying water at the wiring harness or any of the electrical components.
  • Page 10 Section 1 Safety and General Information 484.33 [19.068] 135.00 365.50 90.22 [5.315] [3.552] [14.390] 577.09 [22.720] [.23] 325.30 [12.807] 89.80 62.70 [3.536] [2.468] (Optional Guard) 427.80 [16.843] 124.10 [4.886] 50.00 [2.362] 275.08 84.20 [10.829] [3.315] 115.12 [4.532] 89.80 [(3.536)] (89.80) [(3.536)] Figure 1-4.
  • Page 11 Power (@3600 RPM, exceeds Society of Automotive Engineers-Small Engine Test Code J1940.) CV940... 25.3 kW (34 HP) CV960... 26.9 kW (36 HP) CV980... 28.3 kW (38 HP) CV1000... 29.8 kW (40 HP) Bore ... 90 mm (3.54 in.) Stroke ... 78.5 mm (3.09 in.) Displacement ...
  • Page 12 Section 1 Safety and General Information Carburetor, Intake Manifold, and Air Cleaner Torque Using Sequence in Two Stages ... Carburetor/Air Cleaner Mounting Nut Torque... 7.9 N·m (70 in. lb.) Control Bracket Connecting Rod Cap Fastener Torque (torque in increments)... 11.3 N·m (100 in. lb.) New...
  • Page 13 Running Clearance - New ... 0.040/0.167 mm (0.0015/0.0065 in.) 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.) Closure Plate End Main Bearing Journal O.D.
  • Page 14 Section 1 Safety and General Information Grass Screen Hex Stud Torque ... 9.9 N·m (88 in. lb.) Mounting Screw Torque... 9.9 N·m (88 in. lb.) Governor Governor Cross Shaft O.D. New... 7.963/8.000 mm (0.3135/.3149 in.) Max. Wear Limit... 7.936 mm (0.3124 in.) New...
  • Page 15 Top Compression Ring-to-Groove Side Clearance ... 0.04/0.08 mm (0.0015/0.0031 in.) Middle Compression Ring-to-Groove Side Clearance ... 0.04/0.08 mm (0.0015/0.0031 in.) Oil Control Ring-to-Groove Side Clearance... 0.03/0.19 mm (0.0011/0.0074 in.) Top and Center Compression Ring End Gap New Bore ... 0.30/0.55 mm (0.011/0.021 in.) Used Bore (Max.)...
  • Page 16 Section 1 Safety and General Information Valve Guide Reamer Size Standard ... 7.048 mm (0.2775 in.) 0.25 mm O.S..7.298 mm (0.2873 in.) Nominal Valve Face Angle ... 45° General Torque Values Metric Fastener Torque Recommendations for Standard Applications Tightening Torque: N·m (in.

  • Page 17: Torque Conversions

    English Fastener Torque Recommendations for Standard Applications Tightening Torque: N·m (in. lb.) + or - 20% Bolts, Screws, Nuts and Fasteners Assembled Into Cast Iron or Steel Grade 2 Size 8-32 2.3 (20) 10-24 3.6 (32) 10-32 3.6 (32) 1/4-20 7.9 (70) 1/4-28 9.6 (85)
  • Page 18 1...

  • Page 19: Section 2. Tools & Aids

    Section 2 Tools & Aids Section 2 Tools & Aids Separate Tool Suppliers: Tools Description Source/Part No.
  • Page 20 Starter Brush Holding Tool (Solenoid Shift) Tachometer (Digital Inductive) For checking operating speed (RPM) of an engine. Vacuum/Pressure Tester Alternative to a water manometer. Source/Part No. SE Tools KLR-82411 SE Tools KLR-82416 Design Technology Inc. DTI-110 Kohler 25 761 22-S...
  • Page 21 Aids Description ® ® ® ® ® Section 2 Tools & Aids Source/Part No.
  • Page 22 Section 2 Tools & Aids Special Tools You Can Make Flywheel Holding Tool Figure 2-1. Flywheel Holding Tool. Rocker Arm/Crankshaft Tool Figure 2-2. Rocker Arm/Crankshaft Tool.

  • Page 23: Section 3. Troubleshooting

    Troubleshooting Guide When troubles occur, be sure to check the simple considered. For example, a starting problem could be Engine Cranks But Will Not Start hose. Engine Starts But Does Not Keep Running 4. Loose wires or connections that short the kill hose.

  • Page 24: Cleaning The Engine

    Section 3 Troubleshooting Engine Overheats shrouds clogged. Engine Knocks 4. Internal wear or damage. Engine Loses Power 8. Low compression. 9. Exhaust restriction. Engine Uses Excessive Amount of Oil breather. 3. Worn or broken piston rings. Oil Leaks from Oil Seals, Gaskets breather.
  • Page 25 the engine is reassembled and placed into operation. Basic Engine Tests Crankcase Vacuum Test crankcase when the engine is operating. Pressure 2. Start the engine and run at no-load high speed tube. 10.2 cm (4 in.) No Crankcase Vacuum/Pressure in Crankcase Possible Cause Restricted exhaust.
  • Page 26 Section 3 Troubleshooting Compression Test the test. Compression should be at least 160 psi and Cylinder Leakdown Test adapter hose, and a holding tool. Leakdown Test Instructions engine. the compression stroke. Hold the engine in this position while testing. The holding tool supplied is perpendicular to both the holding tool and 4.

  • Page 27: Section 4 Air Cleaner And Air Intake System

    Air Cleaner and Air Intake System Air Cleaners General These engines utilize a Heavy-Duty style air cleaner as shown in Figure 4-1, consisting of a cylindrical manifold. The air cleaner housing contains a paper element and inner element, designed for longer in any way.

  • Page 28: Section 4 Air Cleaner And Air Intake System

    Air Cleaner and Air Intake System 4. Do not wash the paper element and inner element or use compressed air, this will damage elements with new genuine Kohler elements as required. Handle the new elements carefully; damaged. that ejector area is clean. See Figure 4-4. Replace any damaged components.

  • Page 29: Section 5 Fuel System And Governor

    Leaded gasoline is not recommended. Gasoline/Alcohol blends Gasohol (up to 10% ethyl alcohol, 90% unleaded gasoline by volume) is approved as a fuel for Kohler failures resulting from use of these fuels will not be warranted. Gasoline/Ether blends volume) are approved as a fuel for Kohler engines.
  • Page 30 Section 5 Fuel System and Governor Fuel System Tests When the engine starts hard, or turns over but will not start, it is possible that the problem is in the fuel system. Troubleshooting – Fuel System Related Causes Test 1. Check the following: a.

  • Page 31: Fuel Pump - Replacement

    Fuel Pump General These engines use either a pulse style fuel pump, or optional remote-mounted electric fuel pump of pulse style pumps is created by the oscillation of positive and negative pressures within the crankcase. through the rubber hose connected between the pump and crankcase.
  • Page 32 Section 5 Fuel System and Governor Troubleshooting Checklist When the engine starts hard, runs roughly or stalls at low idle speed, check the following areas before adjusting or disassembling the carburetor. gasoline. • Make sure the fuel tank cap vent is not blocked and that it is operating properly.

  • Page 33: Carburetor Details

    High Altitude Operation over-rich. This can cause conditions such as black, power, poor fuel economy, and poor or slow governor response. high altitude jet kits are available. The kits include new main jets, slow jets (where applicable), necessary correct kit number. Fuel Shut-off Solenoid Figure 5-4.

  • Page 34: Carburetor Adjustments

    Section 5 Fuel System and Governor Carburetor Adjustments Adjustment The carburetor is designed to deliver the correct fuel-to-air mixture to the engine under all operating conditions. The main fuel jet is calibrated at the factory and is not adjustable*. The idle fuel adjusting needle is also set at the factory and normally does not need adjustment.
  • Page 35 Governed Idle System desired idle speed regardless of ambient conditions (temperature, parasitic load, etc.) that may change. governor lever and the governed idle adjuster on the main bracket establishes the governed idle speed. See Governor Spring Governed Idle Spring Figure 5-7. Governor Springs Installed. Governed Idle Speed Adjustment 1.
  • Page 36 Section 5 Fuel System and Governor Move and Hold Lever in "Full Throttle" Position High Speed (RPM) Adjustment Screw Figure 5-11. Setting High Speed RPM (Air Cleaner Removed for Clarity). Carburetor Servicing The following section covers the disassembly, various servicing procedures and reassembly of the carburetor.
  • Page 37 Float Figure 5-14. Float and Inlet Needle Details. seat and carburetor body. Install the new pivot Retaining Screw Pivot Figure 5-15. Installing Float Assembly. hangs vertically and rests lightly against the fuel inlet needle. The inlet needle should be fully seated but the center pin of the needle (on retainer clip end) should not be depressed.
  • Page 38 Section 5 Fuel System and Governor Fuel Bowl Bowl Drain Screw Figure 5-18. Fuel Bowl Removed From Carburetor. is not necessary unless the Fuel Solenoid Kit, or Fuel Bowl Kit (obtained separately), will also be installed. Discard all the old parts. The seat for the inlet needle is not serviceable, and should not be removed.
  • Page 39 and spring from the carburetor. Discard the parts. appropriate cleaning and installation of the parts in the overhaul kit. Further disassembly is not necessary. The idle fuel adjustment screws with limiter, and carburetor body, are non-serviceable items and should not be removed. The however it should not be removed unless a Choke Repair Kit will be installed.
  • Page 40 Section 5 Fuel System and Governor Retaining Screw Pivot Figure 5-26. Installing Float Assembly. hangs vertically and rests lightly against the fuel inlet needle. The inlet needle should be fully seated but the center pin of the needle (on retainer clip end) should not be depressed. Check the fuel inlet needle without depressing the center pin.
  • Page 41 lever from the carburetor housing. Save the bushing to use as a driver for installing the new bushing. Discard the old lever. required. 7. Insert the new bushing through the new choke lever from the outside, and start the bushing in the protruding boss on the carburetor housing is between the two stops formed in the choke lever.
  • Page 42 Section 5 Fuel System and Governor Figure 5-34. Installing Choke Plate. 1. Carburetor Body Subassembly 3. Idle Speed Spring 4. Screw 7. Slow Jet - RH Side 8. Slow Jet - LH Side 10. Fuel Bowl Figure 5-35. Keihin BK Two-Barrel Carburetor - Exploded View. 5.14 the parts.
  • Page 43 Governor General The governor is designed to hold the engine speed constant under changing load conditions. Most mechanism of the mechanical governor is mounted • Centrifugal force acting on the rotating governor outward as speed increases. Governor spring tension moves them inward as speed decreases. Linkage Governor Lever...
  • Page 44 Section 5 Fuel System and Governor 3. Stop when the desired RPM speed is obtained. Hold Lever in "Full Throttle" Position High Speed (RPM) Adjustment Screw Figure 5-37. Adjusting High Speed RPM (Air Cleaner Removed for Clarity). 5.16...

  • Page 45: Oil Recommendations

    R E C O M M E N D E D S A E V I S C O S I T Y G R A D E S 10W-30 5W-20, 5W-30 Kohler 10W-30 °F -20 °C -30 TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANGE Use of synthetic oil having 5W-20 or 5W-30 rating is acceptable, up to 4°C (40°F)

  • Page 46: Changing Oil And Oil Filter

    Section 6 Lubrication System Checking Oil Level The importance of checking and maintaining the proper oil level in the crankcase cannot be overemphasized. Check oil BEFORE EACH USE as so the oil has had time to drain into the sump. the tube.
  • Page 47 securely. Figure 6-6. Reinstalling Oil Fill Cap/Dipstick. Changing Oil Filter seasonally (150 hours) every 300 hours Oil Filter Housing Figure 6-7. Engine Mounted Oil Filter. 21.4 N·m Figure 6-8. Optional Remote Mounted Oil Filter. crankcase. is recommended. Oil Filter additional 3/4-1 turn. 8.
  • Page 48 Section 6 Lubrication System Service Oil Cooler Oil Cooler Figure 6-9. Oil Cooler. Inspect and clean the oil cooler every 150 hours of operation of debris. Figure 6-10. Cleaning Top of Oil Cooler. Oil Cooler Figure 6-11. Cleaning Underside of Oil Cooler. Oil Sentry™...
  • Page 49 Installation 1/8-27 N.P.T.F. pipe plug. Testing 0 psi ® ® should indicate continuity (switch closed). the pressure increases through the range of 7-11 psi the tester should indicate a change to no continuity (switch open) remain open as the pressure is increased to 90 psi maximum.

  • Page 51: Section 7 Electrical System And Components

    Electrical System and Components This section covers the operation, service, and repair of the electrical system components. Systems and components covered in this section are: • Spark Plugs • Electric Starter Spark Plugs condition. The engine is equipped with the following spark plugs: Type: used.
  • Page 52 Section 7 Electrical System and Components normal conditions will have light tan or gray colored deposits. If the center electrode is not worn, a plug reused. compression. Worn: gap. Replace a worn spark plug immediately. worn piston rings or valve guides. Overheated: temperatures.
  • Page 53 Battery General generally recommended for starting in all conditions. application is started only in warmer temperatures. actual cold cranking requirement depends on engine size, application, and starting temperatures. The cranking requirements increase as temperatures operating instructions of the equipment this engine Battery Size Recommendations Temperature Battery Required...
  • Page 54 Section 7 Electrical System and Components Electronic Ignition Systems engine speed. which is located in the ignition modules. The ignition timing varies depending upon the engine speed with this system. Molex Plug (Some Models) Figure 7-3. Electronic CD Fixed Ignition Timing System. Operation of CD Ignition Systems Fixed Timing System components:...
  • Page 55 Kill Switch or ‘‘Off’’ Position of Key Switch Figure 7-4. Capacitive Discharge Fixed Timing Ignition System. dead center. Figure 7-5. Capacitive Discharge (CD) Ignition Module Schematic. Troubleshooting CD Ignition Systems information is provided to help you get to the root of CAUTION: High-Energy Electric Spark! wires are connected, including the spark plug leads.
  • Page 56 Section 7 Electrical System and Components wires, connections, safety interlocks, etc. associated with the ignition or electrical isolated until all testing is completed. a good ground, not to the spark plug. Molex Plug (Some Models) Figure 7-6. Digital Spark Advance Ignition (DSAI) System. Operation of DSAI Ignition Systems DSAI Ignition System Explanation consists of the following components:...
  • Page 57 Troubleshooting DSAI Ignition Systems wires are connected, including the spark plug leads. sure the ignition switch is in the RUN position. Test Procedure for DSAI Ignition Systems The following procedures are provided for engines. They will allow you to isolate and pinpoint Special Tools Required: •...
  • Page 58 Section 7 Electrical System and Components engine runs poorly, or existing plug condition spark plugs gapped at 0.76 mm (0.030 in.), Test 3. Check for Timing Advance with a marking pen, chalk, or narrow tape. See that had good spark. Flywheel Screen Mark Figure 7-7.

  • Page 59: Battery Charging System

    Battery Charging System General Most engines are equipped with a 15, 20, or 25 amp avoid damage to the electrical system and components: common ground with the engine. shorting while the engine is running. This could damage the stator. Electrical System and Components Section 7...
  • Page 60 Section 7 Electrical System and Components 15/20/25 Amp Regulated Charging System Figure 7-11. Wiring Diagram - 15/20/25 Amp Regulated Battery Charging System with CD Ignition and Four Pin Connector. 7.10...
  • Page 61 Section 7 Electrical System and Components Figure 7-12. Wiring Diagram - 15/20/25 Amp Regulated Battery Charging System with DSAI Ignition and Four Pin Connector. 7.11...
  • Page 62 Section 7 Electrical System and Components Figure 7-13. Wiring Diagram - 15/20/25 Amp Regulated Battery Charging System with DSAI Ignition and Five Pin Connector. 7.12...
  • Page 63 Stator replacement is necessary. remove the two mounting screws, then disconnect the plug and ground lead. note of the terminal positions and install the plug correctly. Regulator Connector Plug To Test – removed from the engine for clarity. Repeat times to determine the condition of the part. tested and the squared single end of the tandem Electrical System and Components Figure 7-15.
  • Page 64 Section 7 Electrical System and Components does not represent the condition of the part. Figure 7-17. Powered Tester. one of the four lights will illuminate indicating of the part. Figure 7-18. Pressing Test Button. 7.14 as a result of an inadequate ground lead connection.
  • Page 65 Troubleshooting Guide 15/20/25 Amp Battery Charging Systems NOTE: Problem an ammeter from loose end of B+ end of B+ lead to negative terminal voltmeter. ammeter. No Charge to Battery voltmeter. resistance across stator leads using an ohmmeter. the resistance from each stator lead to ground using an ohmmeter.
  • Page 66 Section 7 Electrical System and Components DC Voltmeter Figure 7-20. Connections for Testing Charging System. Electric Starting Motors typically used. Starting Motor Precautions starter motor. gear may clash, resulting in damage to the starter. condition is corrected. 7.16 Ammeter Battery Operation –...
  • Page 67 Problem Possible Fault Battery Starter Wiring Does Not Energize Starter Switch or Solenoid Battery Brushes Starter Energizes but Turns Slowly Transmission Engine Delco-Remy Starters Figure 7-21. Delco-Remy Starter. Starter Disassembly Electrical System and Components Correction insulation. cranks normally, replace the faulty components. Remove and perform individual solenoid test procedure.
  • Page 68 Section 7 Electrical System and Components Figure 7-23. Solenoid Removed from Starter. Figure 7-24. Removing Plunger. Figure 7-25. Removing Thru Bolts. and locking caps. Remove the thrust washer from 7.18 Figure 7-26. Removing Commutator End Plate Assembly. Figure 7-27. Starter Frame Removed. Figure 7-28.
  • Page 69 Figure 7-29. Armature and Lever Removed. Figure 7-30. Retaining Ring Detail. Electrical System and Components Save the stop collar. Figure 7-31. Removing Retaining Ring. armature. Do not soak the armature or use solvent cloth, or use compressed air. Drive End Cap Collar Retaining Ring Stop...
  • Page 70 Section 7 Electrical System and Components Inspection Drive Pinion damage. mechanism for nicks, or irregularities which could cause seal damage. housing and rotating the pinion. The pinion should rotate in one direction only. Brushes and Springs 7.6 mm (0.300 in.) Wear Limit Length 7.6 mm (0.300 in.) Figure 7-33.

  • Page 71: Brush Replacement

    Brush Replacement necessary. Figure 7-36. Removing Brush Holder. Figure 7-37. Service Brush Kit. armature, drive lever, and frame are installed, if Electrical System and Components Starter Service wear or damage as required. Starter Reassembly Install the stop collar down onto the armature pliers to compress it in the groove.
  • Page 72 Section 7 Electrical System and Components Figure 7-39. Installing Thrust Washer. drive end cap, and install the armature with the drive pinion. captured washer and the rear of the pinion. at the same time seat the drive lever into the housing.
  • Page 73 Thrust Washer Figure 7-43. Installing Thrust Washer. end housing, and carefully position the down into place around the commutator, and future servicing. Figure 7-44. Installing Brush Holder Assembly with Supplied Tube. Electrical System and Components Figure 7-45. Removing Retaining Clips. Figure 7-46.
  • Page 74 Section 7 Electrical System and Components Extension. end housing, and carefully place the tool lead grommet in the cutout of the frame. See Figure 7-47. Installing Brush Holder Assembly using Tool with Extension. the corresponding slot in the grommet of the holder mounting screws to 2.5-3.3 N·m Figure 7-48.

  • Page 75: Solenoid Test Procedure

    Solenoid Test Procedure Solenoid Shift Style Starters terminal. Remove the mounting hardware and separate the solenoid from the starter for testing. Test 1. Solenoid Pull-In Coil/Plunger Actuation Test. on the solenoid. Momentarily* connect the other lead Repeat the test several times. If the solenoid fails to connected to the solenoid for any time over what is necessary for performing each of the individual tests.
  • Page 76 Section 7 Electrical System and Components Test 4. Solenoid Hold-In Coil/Contact Continuity Test. connect the two ohmmeter leads to the two large post indicate continuity, if no continuity is indicated the 7.26 VOM Meter Leads Plunger Pushed "In" 12 volt Test Leads Figure 7-54.

  • Page 77: Section 8 Disassembly

    WARNING: Accidental Starts! Disabling engine. Accidental starting can cause severe injury or death. Before working on the engine or equipment, Clean all parts thoroughly as the engine is disassembled. Only clean parts can be accurately inspected and gauged for wear or damage. There are many commercially available cleaners that will quickly remove grease, oil and grime from engine parts.

  • Page 78: Shut Off Fuel Supply

    Section 8 Disassembly Shut Off Fuel Supply Drain Oil from Crankcase and Remove Oil Filter Figure 8-2. Removing Oil Filter. 2. Remove the dipstick and one of the oil drain plugs. Figure 8-3. Removing Dipstick from Tube. Drain Plug (Starter Side Shown) Figure 8-4.

  • Page 79: Remove Air Cleaner Assembly

    3. Remove the lower mounting screw and pull the Oil Fill Tube Lower Mounting Screw Location Figure 8-7. Removing Oil Fill Tube. Remove Electric Starter Motor 1. Disconnect the leads from the starter. Mounting Screws Figure 8-8. Removing Electric Starter. Remove Air Cleaner Assembly 1.
  • Page 80 Section 8 Disassembly Remove Fuel Pump WARNING: Explosive Fuel! running, since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition. Do not start the engine near spilled fuel. Never use gasoline as a cleaning agent.

  • Page 81: Remove Carburetor

    Control Bracket Figure 8-15. Removing Control Bracket. Figure 8-16. Removing Governor Lever. Remove Carburetor WARNING: Explosive Fuel! running, since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition. Do not start the engine near spilled fuel. Never use gasoline as a cleaning agent.
  • Page 82 Section 8 Disassembly 2. Remove the four screws securing each of the Mounting Screw Locations intake manifold to the cylinder heads. Cut any wire ties securing wiring. 4. Remove the intake manifold and gaskets. See Mounting Locations Figure 8-21. Removing Intake Manifold. Remove Oil Cooler 1.

  • Page 83: Remove Ignition Modules

    Oil Filter Housing Figure 8-24. Removing Oil Filter Housing. assembly requires individual servicing. Figure 8-25. Removing Nipple. Housing Spring Figure 8-26. Disassembled Cup and Spring. c. Remove the rubber valve and spring from the Mounting Screw Rubber Valve Figure 8-27. Rubber Valve and Spring Removed from Cup.

  • Page 84: Remove Flywheel

    Section 8 Disassembly Remove Grass Screen and Cooling Fan Figure 8-29. Removing Grass Screen Fasteners. Screws (3) Figure 8-30. Removing Cooling Fan and Hex Studs. Remove Flywheel screw. Do not use any type of bar or cracked or damaged. Fasteners Figure 8-31.

  • Page 85: Remove Spark Plugs

    2. Remove the mounting screws securing the assembly. Note the location of the ground lead. it may remain mounted to the backing shroud 3. Remove the two screws securing the stator to the crankcase and carefully separate the stator wires Mounting Screws Figure 8-34.

  • Page 86: Remove Valve Covers

    Section 8 Disassembly Remove Valve Covers 1. Remove the screw and grommet securing each valve cover. 2. Remove the valve cover and gasket from each cylinder head. Note the locations of individual Figure 8-38. Removing Valve Covers. Remove Cylinder Heads and Hydraulic Lifters rocker arm adjusting nuts.
  • Page 87 Figure 8-42. Removing Hydraulic Lifters. Figure 8-43. Match Numbers on Cylinder Barrel and Heads. Disassemble Cylinder Heads 1. Remove the two adjusters, rocker arm pivots, and rocker arms from the cylinder head. Remove the pivot studs and guide plate as required. See Figure 8-44.
  • Page 88 Section 8 Disassembly Valve Stem Seals Figure 8-47. Valve Stem Seals. 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.

  • Page 89: Oil Pump Assembly

    Figure 8-52. Removing Oil Pan. Oil Pump Assembly The oil pump is mounted to the inside of the oil pan. If service is required, refer to the service procedures Remove Camshaft Figure 8-53. Removing Camshaft. Remove Connecting Rods with Pistons and Rings closest connecting rod end cap.

  • Page 90: Remove Crankshaft

    Section 8 Disassembly 2. Carefully remove the connecting rod and piston Figure 8-56. Removing Piston/Connecting Rod Assemblies. 3. Repeat the above procedures for the other connecting rod and piston assembly. Remove Crankshaft used. Figure 8-57. Removing Crankshaft. Removal of Governor Gear Assembly molded tabs in the gear.
  • Page 91 Remove Lifter Feed Chamber Cover and Gaskets chamber cover, and gaskets. Carefully separate Screws Cover Gasket Figure 8-60. Removing Lifter Feed Chamber Cover Components. Remove Flywheel and PTO End Oil Seals 1. Remove the oil seals from the crankcase and oil Figure 8-61.
  • Page 92 8...

  • Page 93: Section 9 Inspection And Reconditioning

    Inspection and Reconditioning This section covers the operation, inspection, and repair/reconditioning of major internal engine components. The following components are not covered in this section. They are covered in sections of their own: Air Cleaner, Section 4 Carburetor & External Governor, Section 5 Ignition, Charging &...
  • Page 94 Section 9 Inspection and Reconditioning NOTE: If the crankpin is reground, visually check to the crankpin surface. See Figure 9-1. High Point from Fillet Intersections The Fillet Must Blend Smoothly with the Bearing ° Journal Surface Minimum This Fillet Area Must Be Completely Smooth Figure 9-1.
  • Page 95 accomplished at a drill speed of about 250 RPM and hone, proceed as follows: so the stones are in contact with the cylinder recommended. 2. With the lower edge of each stone positioned even with the lowest edge of the bore, start drill and honing process.

  • Page 96: Cylinder Head And Valves

    Section 9 Inspection and Reconditioning 2. Use an inside micrometer, telescoping gauge, or bore gauge and measure the cylinder bore. Take the measurement approximately 63.5 mm (2.5 in.) below the top of the bore and perpendicular to the piston pin. the bore diameter and the piston diameter (step 2 minus step 1).
  • Page 97 EXHAUST VALVE Dimension Seat Angle Seat Taper 30° Guide Depth Guide I.D. Valve Face Angle 45° Valve Margin (Min.) 1.0 mm (0.0393 in.) Valve Stem Diameter Figure 9-6. Valve Details. fuel consumption may be symptoms of faulty valves. removal, clean the valve heads, faces, and stems with a power wire brush.
  • Page 98 Section 9 Inspection and Reconditioning Normal: can be reconditioned and reused if the face and margin are in good shape. If a valve is worn to where the margin is less than 1/32" do not reuse it. The valve shown was in operation for almost 1000 hours under controlled test conditions.
  • Page 99 Excessive Combustion Temperatures: The white deposits seen here indicate very high combustion temperatures, usually due to a lean fuel mixture. Gum: Gum deposits usually result from using stale gasoline. Gum is a prevalent cause of valve sticking. The cure is to ream the valve guides and clean or replace the valves, depending on their condition.

  • Page 100: Pistons And Rings

    Section 9 Inspection and Reconditioning Valve Guides not guide the 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 the valve guide and, using a split- ball gauge, measure the inside diameter of the guide.
  • Page 101 Ring failure is usually indicated by excessive oil consumption and blue exhaust smoke. When rings fail, oil is allowed to enter the combustion chamber consumption can also occur when the piston ring end gap is incorrect because the ring cannot properly conform to the cylinder wall under this condition.
  • Page 102 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 103: Hydraulic Lifters

    Piston Ring End Gap Mark Piston Oil Control Ring (Three-piece) Expander Figure 9-12. Piston Ring Installation. expander and then the rails. Make sure the ends of the expander are not overlapped. 2. Middle Compression Ring (Center Groove): Install the center ring using a piston ring mark is up or the dykem stripe (if contained) is to 3.

  • Page 104: Oil Pan Assembly

    Section 9 Inspection and Reconditioning Oil Pan Assembly Inspection Inspect the oil seal in the oil pan and remove it if it is worn or damaged. Refer to ‘‘Install Oil Pan Oil Seal’’ in Section 10 for new oil seal installation. Inspect the main bearing surface for wear or damage pan assembly if required.
  • Page 105 4. Install the O-Ring in the groove of the oil pump housing. Use a small quantity of grease to hold it in place. See Figure 9-16. O-Ring Figure 9-16. O-Ring Installed in Oil Pump Housing. 5. Lightly lubricate the I.D. of the inlet seal with oil and carefully insert the end of the pickup through the seal, into the oil pump housing.
  • Page 106 9...

  • Page 107: Section 10 Reassembly

    General NOTE: Make sure the engine is assembled using ® Typical Reassembly Sequence Section 10 Reassembly Install Flywheel End Oil Seal Figure 10-1. Seal Bore of Crankcase. ™ 10.1...
  • Page 108 Section 10 Reassembly Figure 10-2. Installing Oil Seal. Figure 10-3. Installed Flywheel Side Oil Seal. Install Lifter Feed Chamber Gaskets and Cover 6.2 N·m (55 in. lb.) (35 in. lb.) 10.2 Lifter Feed Chamber Figure 10-4. Lifter Feed Chamber Assembly Details.
  • Page 109 Main Notch Bearing Figure 10-6. Installed Main Bearing. Install Governor Shafts, Seal, and Governor Gear Figure 10-7. Installing Governor Cross Shaft Seal. Seal depth 1.5 - 2.0 mm (0.059 - 0.078 in) Crankcase Surface Oil Seal Figure 10-8. Governor Shaft Seal Depth. Governor Gear Shaft Figure 10-9.

  • Page 110: Install Crankshaft

    Section 10 Reassembly (20 in. lb.) Figure 10-12. Installed Governor Shaft Yoke. Governor Gear Figure 10-13. Regulating Pin Details. 10.4 ® 2.2 N·m Figure 10-14. Installing Governor Gear Assembly. Position Figure 10-15. Installed Locking Tab Washer. Install Crankshaft Second Regulating First Regulating Figure 10-16.

  • Page 111: Install Connecting Rods With Pistons And Rings

    Install Connecting Rods with Pistons and Rings Do not No. 1 Side Figure 10-17. Proper Piston and Connecting Rod Orientation. Figure 10-18. “Fly” Mark on Piston. Figure 10-19. Installing Piston Assembly Using Ring Compressor Tool. No. 2 Side Section 10 Reassembly 11.3 N·m (100 in.

  • Page 112: Install Camshaft

    Section 10 Reassembly Figure 10-20. Torquing Connecting Rod End Cap Screws. Install Camshaft 25 357 14-S Lubricant Applied Figure 10-21. Camshaft Lubricant Applied to Cam Lobes. 10.6 Timing Marks Figure 10-22. Aligning Crankshaft and Camshaft Timing Marks. Determining Camshaft End Play (0.011/0.051 in.) Feeler Gauge...
  • Page 113 Install Oil Pan Seal and Main Bearing Main Bearing Main Notch Bearing Figure 10-24. Installed Main Bearing In Oil Pan. Oil Seal Oil Seal Figure 10-25. Installed Oil Seal in Oil Pan. 3 mm (0.118 in.) Seal Figure 10-26. Oil Seal Depth in Oil Pan. Oil Pump Assembly Section 10 Reassembly...
  • Page 114 Section 10 Reassembly Install Oil Pan Assembly O-Ring Figure 10-27. O-Ring Installed. Figure 10-28. Locking Tab Washer Details. 10.8 Figure 10-29. Installing Oil Pan. 24.4 N·m (216 in. lb) Figure 10-30. Torquing Oil Pan Fasteners. Figure 10-31. Oil Pan Fastener Torque Sequence.

  • Page 115: Check Crankshaft End Play

    Check Crankshaft End play Figure 10-32. Checking Crankshaft End play. Figure 10-34. Breather Assembly Details. Install Breather Do not Figure 10-33. Breather Chamber and Gasket. Breather Hose Flange Nuts (4) Gasket Adapter Gasket Filter Studs (4) Crankcase Section 10 Reassembly 10.9...
  • Page 116 Section 10 Reassembly 5.7 N·m (51 in. lb.) Figure 10-35. Breather Assembly Fastener Torque Sequence. Install Hydraulic Lifters pressure two or three times Figure 10-36. Push Rod Tool. 10.10 Figure 10-37. Tappet and Ball Bearing Welded Together. Figure 10-38. Applying Camshaft Lubricant to Bottom of Lifters.

  • Page 117: Valve Stem Seals

    Figure 10-39. Installing Hydraulic Lifters. Figure 10-40. Match Numbers on Cylinder Barrel and Head. Valve Stem Seals Figure 10-41. Valve Stem Seals. Assemble Cylinder Heads Match Numbers Guide Plate Pivot Studs Figure 10-42. Valve Components. Section 10 Reassembly Valve Stem Seals Valve Spring Retainer...

  • Page 118: Install Cylinder Heads

    Section 10 Reassembly Figure 10-43. Installing Valves with Valve Spring Compressor. Install Cylinder Heads Figure 10-44. Installing New Head Gaskets. lower two locations (1 and 3) closest (location 5) 10.12 Washers Figure 10-45. Washers and Spacer Locations on Cylinder Head Screws. 22.6 N·m (200 in.

  • Page 119: Adjust Valve Clearance

    29.3 N·m (260 in. lb.) Figure 10-48. Installing Pipe Plug in Cylinder Heads. Install Guide Plate, Pivot Studs, Push Rods and Rocker Arms (110 in. lb.). down No. 1 side No. 2 side Push Rods Figure 10-49. Installing Guide Plate, Pivot Studs and Push Rods.
  • Page 120 Section 10 Reassembly in this position for Step 4. 0.127 mm (0.005 in.) (65 in. lb.). 0.101/0.152 mm (0.004/0.006 in.) Push Down to "Bottom" Lifter Plunger and Hold Adjust Feeler Gauge Figure 10-52. Adjusting Valve Clearance. 10.14 clearance is 0.25 mm (0.010 in.) Hold Check Assembly Important:...

  • Page 121: Install Valve Covers

    Turn Adjuster Rotate Push Rod and Feel for Drag Figure 10-53. Establishing the "0" Lash Point. complete revolutions clockwise nut (1/6 turn), or a total of 4-1/6 turns Turn 4-1/6 Revolutions From "0" Lash Figure 10-54. Setting Valve Lash (Non-Bled Lifters). 7.3 N·m (65 in.
  • Page 122 Section 10 Reassembly Install Spark Plugs ® 0.76 mm (0.030 in.) Figure 10-57. Installing Spark Plugs. Install Oil Filter Housing Assembly Spring Valve Oil Filter Housing Figure 10-58. Oil Filter Housing Components. 10.16 24.4-29.8 N·m Figure 10-59. Installing Valve and Spring to Cup. Spring Figure 10-60.

  • Page 123: Install Intake Manifold

    Figure 10-62. Installing Nipple into Cup and Oil Filter Housing. Figure 10-63. Torquing Nipple into Housing. Installation O-Rings Around Dowel Pins Figure 10-64. O-Rings Installed on Crankcase for Oil Filter Housing. Nipple Cup (with Spring and (216 in. lb.) Valve) Mounting Screw Housing...
  • Page 124 Section 10 Reassembly 16.9 N·m (150 in. lb.) 22.6 N·m (200 in. lb.) Figure 10-67. Installing Intake Manifold. Cylinder 1 Figure 10-68. Intake Manifold Torque Sequence. Install Backing Shroud Assembly 10.18 Figure 10-69. Lower Oil Cooler Hose Details. 10.7 N·m (99 in. lb.) (65 in.

  • Page 125: Install Flywheel

    Mounting Screws Figure 10-71. Installing Stator. Lead Figure 10-72. B+ Charging Lead Details. Molded Clips Figure 10-73. Installing Wiring Harness. Tabs 2.0 N·m (18 in lb.) Install Flywheel WARNING: Damaging Crankshaft and Flywheel Can Cause Personal Injury! Figure 10-75. Clean and Dry Taper of Crankshaft. Section 10 Reassembly Ground...

  • Page 126: Install Ignition Modules

    Section 10 Reassembly Figure 10-76. Clean and Dry Flywheel Hub. Figure 10-77. Installed Flywheel Key. 10.20 Figure 10-78. Installing and Torquing Flywheel Fastener. Install Ignition Modules Clip Kill Lead Figure 10-79. Ignition Module Mounting Details.
  • Page 127 0.30 mm (0.012 in.) Feeler Gauge Figure 10-80. Setting Ignition Module Air Gap. 6.2 N·m (55 in. lb.) 4.0 N·m (35 in. lb.) 0.280/0.330 mm (0.011/0.013 in.) Molded Clip Figure 10-81. Lead Routing Details. 4.0 N·m (35 in. lb.) 2.0 N·m (17.7 in. lb.) 10.7 N·m (95 in.

  • Page 128: Install Electric Starter

    Section 10 Reassembly Install Oil Cooler Hoses Figure 10-84. Connecting Oil Cooler Hoses. Mounting Screws Figure 10-85. Installing Oil Cooler. Install Cooling Fan and Grass Screen CAUTION: ® 9.9 N·m (88 in. lb.) 10.22 9.9 N·m (88 in. lb.) ® Figure 10-86.

  • Page 129: Install Carburetor

    Figure 10-88. Connecting Leads to Starting Motor. lb.) 7.3 N·m (65 in. lb.) (35 in. lb.) Valley Mounting Screw Install Carburetor WARNING: Explosive Fuel! Gasket (Tab "Up") Carburetor Choke Linkage Figure 10-90. Installing Carburetor onto Manifold. Install Governor Lever 10.7 N·m (95 in. 3.9 N·m Figure 10-91.
  • Page 130 Section 10 Reassembly Install Control Bracket and Air Cleaner Assembly Control Bracket Figure 10-92. Installing Control Bracket. 7.9 N·m (70 in. lb.) in 9.9 N·m (88 in. lb.) Breather Hose Port Ground Lead Location Figure 10-93. Installing Air Cleaner. 10.24 Mounting Locations Figure 10-94.
  • Page 131 Push-on Nut Choke Linkage Figure 10-96. Installing Choke Link and Push-On Nut. Install Throttle and Choke Linkages On Control Levers: Outer Pull Inner Pull Choke Control Clamp Location Links Connected Here Figure 10-97. Throttle/Choke Linkage Details for "Outer Pull" Actuation. Figure 10-98.
  • Page 132 Section 10 Reassembly Adjusting Governor Brushed/ Knurled Area Figure 10-100. Brushed/Knurled Area. toward 7.3 N·m (65 in. lb.) Move and Hold Towards Carburetor Lift/Rotate Clockwise Figure 10-101. Adjusting Governor. 10.26 Governor Lever Figure 10-102. Governor Springs Installed. Governor Spring/RPM Chart Governor Idle Spring (Color) Clear...
  • Page 133 Install Blower Housing and Cylinder Shrouds (35 in. lb.) 9.9 N·m (88 in. lb.) Lift Bracket Figure 10-105. Oil Fill Tube and and Lift Bracket. 4.0 N·m (35 in. lb.) 2.0 N·m (17.7 in. lb.) Figure 10-106. Installing Blower Housing. 4.0 N·m (35 in.
  • Page 134 Section 10 Reassembly Install Oil Filter and Add Oil to Crankcase Drain Plug (Starter Side Shown) Figure 10-109. Reinstall Oil Drain Plugs. Figure 10-110. Installing and Tightening Oil Filter. 10.28 Figure 10-111. Reinstall the Dipstick in Tube. Connect Spark Plug Leads Figure 10-112.
  • Page 135 Section 10 Reassembly Testing the Engine 10.29...
  • Page 136 10...
  • Page 138 FOR SALES AND SERVICE INFORMATION IN U.S. AND CANADA, CALL 1-800-544-2444 KohlerEngines.com ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044 FORM NO.: TP-2581 ISSUED: 1/09 REVISED: LITHO IN U.S.A.

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