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A good user manual
The rules should oblige the seller to give the purchaser an operating instrucion of Kohler Command Pro CV960, along with an item. The lack of an instruction or false information given to customer shall constitute grounds to apply for a complaint because of nonconformity of goods with the contract. In accordance with the law, a customer can receive an instruction in non-paper form; lately graphic and electronic forms of the manuals, as well as instructional videos have been majorly used. A necessary precondition for this is the unmistakable, legible character of an instruction.
What is an instruction?
The term originates from the Latin word „instructio”, which means organizing. Therefore, in an instruction of Kohler Command Pro CV960 one could find a process description. An instruction's purpose is to teach, to ease the start-up and an item's use or performance of certain activities. An instruction is a compilation of information about an item/a service, it is a clue.
Unfortunately, only a few customers devote their time to read an instruction of Kohler Command Pro CV960. A good user manual introduces us to a number of additional functionalities of the purchased item, and also helps us to avoid the formation of most of the defects.
What should a perfect user manual contain?
First and foremost, an user manual of Kohler Command Pro CV960 should contain:
- informations concerning technical data of Kohler Command Pro CV960
- name of the manufacturer and a year of construction of the Kohler Command Pro CV960 item
- rules of operation, control and maintenance of the Kohler Command Pro CV960 item
- safety signs and mark certificates which confirm compatibility with appropriate standards
Why don't we read the manuals?
Usually it results from the lack of time and certainty about functionalities of purchased items. Unfortunately, networking and start-up of Kohler Command Pro CV960 alone are not enough. An instruction contains a number of clues concerning respective functionalities, safety rules, maintenance methods (what means should be used), eventual defects of Kohler Command Pro CV960, and methods of problem resolution. Eventually, when one still can't find the answer to his problems, he will be directed to the Kohler service. Lately animated manuals and instructional videos are quite popular among customers. These kinds of user manuals are effective; they assure that a customer will familiarize himself with the whole material, and won't skip complicated, technical information of Kohler Command Pro CV960.
Why one should read the manuals?
It is mostly in the manuals where we will find the details concerning construction and possibility of the Kohler Command Pro CV960 item, and its use of respective accessory, as well as information concerning all the functions and facilities.
After a successful purchase of an item one should find a moment and get to know with every part of an instruction. Currently the manuals are carefully prearranged and translated, so they could be fully understood by its users. The manuals will serve as an informational aid.
Table of contents for the manual
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Page 1
S ER VICE M ANUAL V ERTICAL C RANKSHAFT COMMAND PRO CV940-CV1000[...]
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Page 2
[...]
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Page 3
Contents Section 1. Safety and General Information ............................................................................. Section 2. T ools & Aids ........................................................................................................ ..... Section 3. T roubleshooting .....................................................[...]
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Page 4
[...]
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Page 5
1.1 1 Rotating Parts! Keep hands, feet, hair , and clothing away from all moving parts to pr event injury . Never operate the engine with covers, shrouds, or guards r emoved. Section 1 Safety and General Information Safety Precautions T o ensure safe operation please read the following statements and understand their meaning. Also refer to your equ[...]
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Page 6
1.2 Section 1 Safety and General Information ¡ȱȱȱȱęȱȱ severe burns. ȱȱęȱȱȱȱȱȱ engine is hot or running. W ARNING Explosive Fuel! ȱȱ¡[...]
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Page 7
1.3 Section 1 Safety and General Information 1 A. Model No. C V 980 S B. Spec. No. Command Engine V ersion Code S = Electric Start C. Serial No. Y ear Manufactured Code Code Y ear 37 2007 38 2008 39 2009 CV940-0001 CV960-0001 CV980- 0001 CV1000-0001 Complete Spec Number (Incorporating Model No. with V ariation No. of Basic Spec.) Factory Code 37058[...]
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Page 8
1.4 Section 1 Safety and General Information SAE 10W30 A P I S E R V I C E S J 5W-20, 5W -30 RECOMMENDED SAE VISCOSITY GRADES 10W-30 Kohler 10W-30 °F -20 0 20 32 40 60 80 100 °C -30 -20 -10 0 10 20 30 40 TEMPERA TURE RANGE EXPECTED BEFORE NEXT OIL CHANGE Use of s ynthetic oil having 5W-20 or 5W-30 rating is acceptable, up to 4°C (40°F) * Synthe[...]
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Page 9
1.5 Section 1 Safety and General Information 1 ¹Perform these maintenance procedur es more frequently under extr emely dusty, dirty conditions. 2 Have a Kohler Engine Service Dealer perform this service. Periodic Maintenance Instructions W ARNING: Accidental Starts! Disabling engine. Accidental starting can cause severe injury or death. Before wor[...]
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Page 10
1.6 Section 1 Safety and General Information Dimensions in millimeters. Inch equivalents shown in [ ]. 41 1.64 [16.206] 14.7 [.58] 130.00 [5.1 18] 152.36 [5.999] 232.22 [9.143] 344.54 [13.565] 89.80 [3.536] 62.70 [2.468] 325.30 [12.807] 577.09 [22.720] 5.9 [.23] 135.00 [5.315] 484.33 [19.068] 365.50 [14.390] 90.22 [3.552] 30.00 [1.181] 45.00 [1.772[...]
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Page 11
1.7 Section 1 Safety and General Information 1 ¹V alues are in Metric units. V alues in parentheses are English equivalents. Lubricate threads with engine oil prior to assembly . *HQHUDO6SHFL¿FDWLRQVï P ower (@3600 RPM, exceeds Society of Automotive Engineers-Small Engine T est Code J1940.) CV940...............................................[...]
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Page 12
1.8 Section 1 Safety and General Information Carburetor , Intake Manifold, and Air Cleaner ȱȱȱȱ T orque Using Sequence in T wo Stages ................................................. ęȱȱŗŜǯşȱȉȱǻŗśŖȱ?[...]
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Page 13
1.9 Section 1 Safety and General Information 1 Ğȱȱȱȱǻȱȱ Ǽ Running Clearance - New ...................................................................... 0.040/0.167 mm (0.0015/0.0065 in.) Flywheel End Main Bearing Journal O.D. - New ...............[...]
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Page 14
1.10 Section 1 Safety and General Information Grass Screen Hex Stud T orque ............................................................................................ 9.9 N·m (88 in. lb.) Mounting Screw T orque ................................................................................. 9.9 N·m (88 in. lb.) Governor ?[...]
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Page 15
1.1 1 Section 1 Safety and General Information 1 Ŷȱ ȱŗŗȱȱǻŖǯŚřřȱǯǼȱȱȱĴȱȱȱȱȱȱȱȱȱȱȱǯ T op Compression Ring-to-Groove Side [...]
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Page 16
1.12 Section 1 Safety and General Information Tightening T orque: N·m (in. lb.) + or - 10% Property Class Noncritical Fasteners Into Aluminum Size M4 1.2 (11) 1.7 (15) 2.9 (26) 4.1 (36) 5.0 (44) 2.0 (18) M5 2.5 (22) 3.2 (28) 5.8 (51) 8.1 (72) 9.7 (86) 4.0 (35) M6 4.3 (38) 5.7 (50) 9.9 (88) 14.0 (124) 16.5 (146) 6.8 (60) M8 10.5 (93) 13.6 (120) 24.[...]
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Page 17
1.13 Section 1 Safety and General Information 1 English Fastener T orque Recommendations for Standard Applications Grade 2 or 5 Fasteners Into Aluminum Size 8-32 2.3 (20) 2.8 (25) --------- 2.3 (20) 10-24 3.6 (32) 4.5 (40) --------- 3.6 (32) 10-32 3.6 (32) 4.5 (40) --------- --------- 1/4-20 7.9 (70) 13.0 (115) 18.7 (165) 7.9 (70) 1/4-28 9.6 (85) 1[...]
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Page 18
1.14[...]
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Page 19
2.1 Section 2 T ools & Aids 2 Section 2 T ools & Aids T ools Description Source/Part No. Ğȱ¢ȱ ȱȱĞȱ¢ ǯ ȱ ȱȬŞŘŚŖś Ğȱȱ?[...]
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Page 20
2.2 Section 2 T ools & Aids T ools (Continued) Description Source/Part No. ¢ȱ ȱĞȱ ȱȱȱȱ¢ȱĞǯ ȱŘśȱŝŜŗȱřŞȬ ȱ¢[...]
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Page 21
2.3 Section 2 T ools & Aids 2 Aids Description Source/Part No. Ğȱ ȱǻ ȱŜŗřǼ ȱŘśȱřśŝȱŗŚȬ ȱ ȱǻȦ ȱŜŜŗǼ ȱŘśȱřśŝȱŗŗȬ?[...]
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Page 22
2.4 Section 2 T ools & Aids Special T ools Y ou Can Make Flywheel Holding T ool ȱĚ¢ȱȱȱȱȱȱȱȱȱȱ ȱĚ¢ȱȱȱȱȱȱȱŘȬŗǰȱ?[...]
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Page 23
3.1 3 Section 3 T roubleshooting T roubleshooting Guide When troubles occur , be sure to check the simple ȱǰȱȱęǰȱ¢ȱȱȱȱȱȱ considered. For example, a starting problem could be ȱ¢ȱȱ¢ȱ[...]
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Page 24
3.2 Section 3 T roubleshooting Engine Overheats ȱ ŗǯȱ ȱȦȱǰȱȱęǰȱȱȱ shrouds clogged. ȱ Řǯȱ ¡ȱȱǯ ȱ řǯȱ ȱȱȱ?[...]
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Page 25
3.3 Section 3 T roubleshooting 3 ȱȱȱȱȱȱȱȱȱȱ the engine is reassembled and placed into operation. ȱȱȱȱȱȱ[...]
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Page 26
3.4 Section 3 T roubleshooting Leakdown T est Results ȱȱȱȱ ....................................................... ȱȱ¢ȱǯ ȱȱȱ¡?[...]
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Page 27
4.1 4 Section 4 Air Cleaner and Air Intake System Paper Element Inner Element Inlet Screen Air Cleaners General These engines utilize a Heavy-Duty style air cleaner as shown in Figure 4-1, consisting of a cylindrical ǰȱĴȱȱȱȱȱȱ man[...]
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Page 28
4.2 Section 4 Air Cleaner and Air Intake System Ejector Area Cylinder Shroud 4. Do not w ash the paper element and inner element or use compressed air , this will damage ȱǯȱȱ¢ ǰȱȱȱȱ elements with new genuine Kohler elements as required[...]
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Page 29
5.1 5 Section 5 Fuel System and Governor Description This section covers the carbureted fuel system used on these engines. The governor system is cov ered at the end of this section. W ARNING: Explosive Fuel! ȱȱ¡¢ȱĚȱȱȱȱȱ?[...]
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Page 30
5.2 Section 5 Fuel System and Governor Fuel System T ests When the engine starts hard, or turns over but will not start, it is possible that the problem is in the fuel system. ȱęȱȱȱȱȱ¢ȱȱȱȱǰȱȱ?[...]
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Page 31
5.3 Section 5 Fuel System and Governor 5 Self-Relieving Choke Fuel Shut-Off Solenoid Bowl Drain Screw Slow Jets Bowl V ent Low Idle Fuel Adjustments (With Limiters) Fuel Pump General These engines use either a pulse style fuel pump, or optional remote-mounted electric fuel pump ¢ ǯȱȱȱśȬŗȱ?[...]
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Page 32
5.4 Section 5 Fuel System and Governor T roubleshooting Checklist When the engine starts hard, runs roughly or stalls at low idle speed, check the following areas before adjusting or disassembling the carburetor . ȱ Ȋȱ ȱȱȱȱȱȱęȱȱǰȱ?[...]
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Page 33
5.5 Section 5 Fuel System and Governor 5 Fuel Shut-Off Solenoid High Altitude Operation ȱȱȱȱȱȱȱŗśŖŖȱȱ ǻśŖŖŖȱĞǯǼȱȱǰȱȱȱ¡ȱȱȱ?[...]
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Page 34
5.6 Section 5 Fuel System and Governor Lean Rich Adjust to Midpoint Lean Rich Adjust to Midpoint Left Side Right Side Carburetor Adjustments Adjustment DZȱ ȱȱȱȱȱ¢ȱ Ğȱȱȱȱ[...]
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Page 35
5.7 Section 5 Fuel System and Governor 5 Governed Idle System ȱ ȱȱȱ¢ȱȱȱȱȱȱ desired idle speed regardless of ambient conditions (temperature, parasitic load, etc.) that may change. ȱȱ?[...]
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Page 36
5.8 Section 5 Fuel System and Governor Figure 5-1 1. Setting High Speed RPM (Air Cleaner Removed for Clarity). Carburetor Servicing The following section covers the disassembly , v arious servicing procedures and reassembly of the carburetor . For each procedure carefully inspect all components and replace those that are worn or damaged. The follow[...]
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Page 37
5.9 Section 5 Fuel System and Governor 5 Figure 5-14. Float and Inlet Needle Details. ȱ Ŝǯȱ ȱȱĚȱȱȱȱȱȱȱ seat and carburetor body . Install the new pivot ȱȱȱĚȱ[...]
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Page 38
5.10 Section 5 Fuel System and Governor Figure 5-18. Fuel Bowl Removed From Carburetor . DZȱ ȱ¢ȱȱȱȱȱ is not necessary unless the Fuel Solenoid Kit, or Fuel Bowl Kit (obtained separately), will also be installed. ȱȱ Řǯȱ ?[...]
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Page 39
5.1 1 Section 5 Fuel System and Governor 5 śǯȱ ȱȱȱȱǻǼȱȱȱ and spring from the carburetor . Discard the parts. DZȱ ȱȱȱȱȱ?[...]
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Page 40
5.12 Section 5 Fuel System and Governor Figure 5-26. Installing Float Assembly . ŗŚǯȱ ȱȱȱ¢ȱȱȱĚȱ¢ȱ hangs vertically and rests lightly against the fuel inlet needle. The inlet needle should be fully seated but the center pin of the [...]
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Page 41
5.13 Section 5 Fuel System and Governor 5 śǯȱ ȱȱȱ¡ȱǻ¢ȬǼȱȱȱȱ ȱȱĞȱȱȱȱȱȱ lever from the carburetor housing. S[...]
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Page 42
5.14 Section 5 Fuel System and Governor ȱŗŘǯȱ ȬȱǻȱȱȬȱǼ 13. Drain Screw 14. Bowl Screw (4) ȱŗśǯȱ ȱ ȱŗŜǯȱ ȱ 17. Float 18. Pin 19. Screw ȱŘŖǯȱ ȱ ȱŘŗǯȱ [...]
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Page 43
5.15 Section 5 Fuel System and Governor 5 Governor Lever Governor Cross Shaft Governed Idle Spring Linkage Governor Spring Governor General The governor is designed to hold the engine speed constant under changing load conditions. Most ȱȱȱȱȱȱ[...]
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Page 44
5.16 Section 5 Fuel System and Governor Hold Lever in "Full Throttle" Position High Speed (RPM) Adjustment Screw 3. Stop when the desired RPM speed is obtained. Figure 5-37. Adjusting High Speed RPM (Air Cleaner Removed for Clarity).[...]
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Page 45
6.1 6 Section 6 Lubrication System SAE 10W30 A P I S E R V I C E S J 5W-20, 5W -30 RECOMMENDED SAE VISCOSITY GRADES 10W-30 Kohler 10W-30 °F -20 0 20 32 40 60 80 100 °C -30 -20 -10 0 10 20 30 40 TEMPERA TURE RANGE EXPECTED BEFORE NEXT OIL CHANGE Use of s ynthetic oil having 5W-20 or 5W-30 rating is acceptable, up to 4°C (40°F) * Synthetic oils w[...]
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Page 46
6.2 Section 6 Lubrication System Oil Drain Plug Drain Plug Operating Range Checking Oil Level The importance of checking and maintaining the proper oil level in the crankcase cannot be overemphasized. Check oil BEFORE EA CH USE as DZ ȱ ŗǯȱ ȱȱȱȱȱ[...]
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Page 47
6.3 Section 6 Lubrication System 6 ȱ řǯȱ ȱȱȱȱȱȱȱ 21.4 N·m ǻŗśǯŝȱĞǯȱǯǼ . ȱ Śǯȱ ȱȱǰȱȱȱȱȱȱȱ ¢[...]
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Page 48
6.4 Section 6 Lubrication System Pressure Switch Service Oil Cooler ȱȱȱȱȱȱȱȱ ȱȱȱǯȱŘȱȱ¢ȱǰȱ [...]
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Page 49
6.5 Section 6 Lubrication System 6 Installation ȱȱ¢Ȝȱȱȱȱȱȱȱ ȱȱȱǯȱȱȱŜȬŗŘǯȱȱȱȱ [...]
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Page 50
6.6[...]
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Page 51
7.1 7 Section 7 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 ȱ Ȋȱ Ĵ¢ȱȱȱ¢ • Electric Starter ȱ Ȋȱ ?[...]
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Page 52
7.2 Section 7 Electrical System and Components DZ ȱ ȱȱȱȱȱȱȱȱ normal conditions will have light tan or gray colored deposits. If the center electrode is not worn, a plug ȱȱ?[...]
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Page 53
7.3 Section 7 Electrical System and Components 7 DC V oltmeter Battery Battery General ȱŗŘȬ ȱĴ¢ȱȱŚŖŖȱȱȱȱǻǼȱȱ generally recommended for starting in all conditions. ȱȱ¢ȱĴ?[...]
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Page 54
7.4 Section 7 Electrical System and Components Molex Plug (Some Models) ȱȱȱěȱ¢ȱȱȱ¢ȱȱȱǯȱ ȱ¢ȱȱȱȱ?[...]
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Page 55
7.5 Section 7 Electrical System and Components 7 Kill Switch or ‘ ‘Off ’ ’ Position of Key Switch Ignition Modules Spark Plug Magnet Flywheel (0.28/0.33 mm) 0.01 1/0.013 in. Air Gap L1 D1 C1 T1 P S Spark Plug L2 SCS Figure 7-5. Capacitive Discharge (CD) Ignition Module Schematic. Figure 7-4. Capacitive Discharge Fixed Timing Ignition System[...]
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Page 56
7.6 Section 7 Electrical System and Components ǯȱ ȱȱȱȱǰȱȱȱ¢ȱ ȱȱȱȱǯȱȱȱ¢ȱǰȱ wires, connections, safety interlocks, [...]
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Page 57
7.7 Section 7 Electrical System and Components 7 T roubleshooting DSAI Ignition Systems ȱȱȱ¢ȱȱȱȱȱȱ ȱȱȱȱȱȱǯȱȱ?[...]
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Page 58
7.8 Section 7 Electrical System and Components ȱ Řǯȱ ȱȱȱ ǰȱȱȱȱ ȱśśŖȬŜŖŖȱǰȱȱȱǻǼȱȱǯ ȱ řǯȱ ȱ?[...]
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Page 59
7.9 Section 7 Electrical System and Components 7 Battery Charging System General Most engines are equipped with a 15, 20, or 25 amp ȱȱ¢ǯȱȱȱŝȬşȱȱŝȬŗřǯȱ DZȱ ȱȱ?[...]
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Page 60
7.10 Section 7 Electrical System and Components 15/20/25 Amp Regulated Charging System Figure 7-1 1. Wiring Diagram - 15/20/25 Amp Regulated Battery Charging System with CD Ignition and Four Pin Connector .[...]
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Page 61
7.1 1 Section 7 Electrical System and Components 7 Figure 7-12. Wiring Diagram - 15/20/25 Amp Regulated Battery Charging System with DSAI Ignition and Four Pin Connector .[...]
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Page 62
7.12 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 .[...]
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Page 63
7.13 Section 7 Electrical System and Components 7 Stator ȱȱȱȱȱȱȱȱ ȱĚ¢ǯȱȱȱȱȱȱŞȱȬȱ ȃ?[...]
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Page 64
7.14 Section 7 Electrical System and Components śǯȱ ȱȱȱȱȱȱ ȱȦȱ ȱȱȱǯȱ ȱȱȱȱǯȱ ȱȁȁ?[...]
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Page 65
7.15 Section 7 Electrical System and Components 7 T roubleshooting Guide 15/20/25 Amp Battery Charging Systems ȱȱȱȱȱȱĴ¢ȱȱȱȱĴ¢ȱȱȱȱȱȱ?[...]
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Page 66
7.16 Section 7 Electrical System and Components DC V oltmeter 5HFWL¿HU5HJXODWRU Flywheel Stator Ammeter Battery (-) (+) Figure 7-20. Connections for T esting Charging System. Electric Starting Motors ȱȱȱȱĞȱȱȱ?[...]
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Page 67
7.17 Section 7 Electrical System and Components 7 T orx Head Screws 7 URXEOHVKRRWLQJ*XLGH±6WDUWLQJ'LI¿FXOWLHV Delco-Remy Starters Figure 7-21. Delco-Remy Starter . Starter Disassembly ȱ ŗǯȱ ȱȱ¡ȱȱȱȱȱ ȱ ǻ?[...]
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Page 68
7.18 Section 7 Electrical System and Components Figure 7-23. Solenoid Removed from Starter . Figure 7-24. Removing Plunger . ȱ Śǯȱ ȱȱ ȱȱǻǼȱǯȱȱȱ ŝȬŘśǯ Figure 7-25. Removing Thru Bolts. ȱ śǯȱ ȱ?[...]
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Page 69
7.19 Section 7 Electrical System and Components 7 Drive End Cap Screw Plunger Spring Lever Plate Plug Solenoid Frame & Field Brush Holder Nut Commutator End Plate Screw Bolt Collar Retaining Ring Stop Drive Armature W asher T ube ȱ Şǯȱ ȱȱȱȱ ȱȱȱ[...]
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Page 70
7.20 Section 7 Electrical System and Components Wear Limit Length 7.6 mm (0.300 in.) Mica Insulation Commutator O.D. Inspection Drive Pinion ȱȱȱȱȱDZ ǯȱ ȱȱȱȱȱ?[...]
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Page 71
7.21 Section 7 Electrical System and Components 7 Brush Replacement ȱȱȱȱȱȱȱȱȱǻŚǼǯȱȱ ȱȱȱȱȱȱǰȱȱ?[...]
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Page 72
7.22 Section 7 Electrical System and Components řǯȱ ȱȱěȱȱǻǼȱ ȱȱȱ ȱȃěȄȱȱȱ ȱȱȱȦ ǯȱ?[...]
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Page 73
7.23 Section 7 Electrical System and Components 7 Figure 7-43. Installing Thrust W asher . ȱ ŗŖǯȱ ȱ¢ȱȱ ȱȱȦ ȱȱ ¢DZ ǯȱ ȱȱ?[...]
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Page 74
7.24 Section 7 Electrical System and Components Extension. ǯȱ ȱȱȱ¢ȱ¢ȱȱȱ end housing, and carefully place the tool ǻȱ¡Ǽȱȱȱȱ ?[...]
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Page 75
7.25 Section 7 Electrical System and Components 7 VOM Leads 12 volt T est Leads Momentary Connection Only Solenoid T est Procedure Solenoid Shift Style Starters ȱȱȱȱȱȱȱ ȱȱ?[...]
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Page 76
7.26 Section 7 Electrical System and Components T est 4. Solenoid Hold-In Coil/Contact Continuity T est. ȱȱȱȱȱȱȱȱ¡Řȱǰȱȱ connect the two ohmmeter leads to the tw o large post ǯȱ ?[...]
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Page 77
8.1 8 Section 8 Disassembly W ARNING: Accidental Starts! Disabling engine. Accidental starting can cause severe injury or death. Before working on the engine or equipment, ȱȱȱȱDZȱŗǼȱȱȱȱȱ?[...]
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Page 78
8.2 Section 8 Disassembly Cylinder Shroud Shut Off Fuel Supply Drain Oil from Crankcase and Remove Oil Filter ȱ ŗǯȱ ȱȱȱęȱȱȱǯȱȱȱ ȱȱȱę ǯȱȱ[...]
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Page 79
8.3 Section 8 Disassembly 8 3. Remov e the lower mounting screw and pull the ȱęȱȱȱȱȱǯ Figure 8-7. Removing Oil Fill T ube. Remove Electric Starter Motor 1. Disconnect the leads from the starter . ȱ Řǯȱ ȱȱ ȱ¡ȱĚ[...]
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Page 80
8.4 Section 8 Disassembly Remove Fuel Pump W ARNING: Explosive Fuel! ȱȱ¡¢ȱĚȱȱȱȱȱ¡ȱ ȱǯȱȱȱ¢ȱȱ [...]
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Page 81
8.5 Section 8 Disassembly 8 Figure 8-15. Removing Control Bracket. ȱ Ŝǯȱ ȱȱ¡ȱĚȱȱȱȱȱ ȱ ȱȱȱĞǯȱȱȱŞȬŗŜǯ Figure 8-16. Removing Governor[...]
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Page 82
8.6 Section 8 Disassembly NOTE: New clamps are recommended any time disassembly is performed, or if clamps have been loosened (expanded) sev eral times. )LJXUH5HPRYLQJ9 DOOH%DIÀHV 2. Remov e the four screws securing each of the ȱ¢ȱĝȱȱǯȱ?[...]
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Page 83
8.7 Section 8 Disassembly 8 Figure 8-24. Removing Oil Filter Housing. ȱȱȱ¢ȱȱȱȱęȱȱ assembly requires individual servicing. ȱ ǯȱ ȱȱȱȱȱ[...]
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Page 84
8.8 Section 8 Disassembly Remove Grass Screen and Cooling Fan ȱ ŗǯȱ ȱȱǰȱĴȱ ǰȱȱ¡ȱ ȱȱȱȱǰȱěǰȱȱ ?[...]
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Page 85
8.9 Section 8 Disassembly 8 Wiring Harness Molded Clips 2. Remov e the mounting screws securing the ęȬȱȱȱȱȱ assembly . Note the location of the ground lead. ȱȱęȬȱȱ[...]
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Page 86
8.10 Section 8 Disassembly Remove V alve Covers 1. Remov e the screw and grommet securing each v alve cover . 2. Remov e the valve cov er and gasket from each cylinder head. Note the locations of individual ȱȱȱ¢ȱȱěǯȱȱȱŞȬřŞǯ Figu[...]
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Page 87
8.1 1 Section 8 Disassembly 8 Figure 8-42. Removing Hydraulic Lifters. Figure 8-43. Match Numbers on Cylinder Barrel and Heads. Disassemble Cylinder Heads 1. Remov e the two adjusters, rocker arm pivots, and rocker arms from the cylinder head. Remove the pivot studs and guide plate as required. See ȱŞȬŚŚǯ Figure 8-44. Removi[...]
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Page 88
8.12 Section 8 Disassembly Figure 8-47. V alve Stem Seals. NOTE: These engines use v alve stem seals on the intake and exhaust v alves. Use a new seal whenever v alves are remov ed, or if the seal is deteriorated in any w ay . Never reuse an old seal. 4. Repeat the abov e procedure for the other cylinder head. Do not interchange parts from one cyli[...]
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Page 89
8.13 Section 8 Disassembly 8 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 ȱȁȁȱȱ ¢ȂȂ ȱȱȱşǯ Remove Camshaft ȱ ŗǯȱ ȱ[...]
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Page 90
8.14 Section 8 Disassembly 2. Carefully remov e the connecting rod and piston ¢ȱȱȱ¢ȱǯȱȱȱŞȬśŜǯ Figure 8-56. Removing Piston/Connecting Rod Assemblies. 3. Repeat the abov e procedures for the other connecting rod and piston assembly . [...]
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Page 91
8.15 Section 8 Disassembly 8 Remove Lifter Feed Chamber Cover and Gaskets ȱ ŗǯȱ ȱȱȱȱȱȱĞȱȱ chamber cover , and gaskets. Carefully separate ȱȱȱȱǯ[...]
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8.16[...]
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9 9.1 Section 9 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 cov ered in sections of their own: Air Cleaner , Section 4 Carburetor & External Gov ernor , Section 5 Ignition, Charging &[...]
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Page 94
Section 9 Inspection and Reconditioning 9.2 45 ° High Point from Fillet Intersections This Fillet Area Must Be Completely Smooth Minimum The Fillet Must Blend Smoothly with the Bearing Journal Surface NOTE: If the crankpin is reground, visually check to ȱȱȱęȱȱ?[...]
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Page 95
Section 9 Inspection and Reconditioning 9 9.3 1 1 mm (0.433 in.) Measure 1 1 mm above the Bottom of Piston Skirt at Right Angles to Piston Pin accomplished at a drill speed of about 250 RPM and ŜŖȱȱȱǯȱ Ğȱȱȱȱȱ[...]
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Page 96
Section 9 Inspection and Reconditioning 9.4 Feeler Gauge 2. Use an inside micrometer , telescoping gauge, or bore gauge and measure the cylinder bore. T ake the measurement approximately 63.5 mm (2.5 in.) below the top of the bore and perpendicular to the piston pin. ȱ řǯȱ ȬȬȱȱ?[...]
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Page 97
Section 9 Inspection and Reconditioning 9 9.5 EXHAUST V AL VE INT AKE V AL VE A B C D D F E G H F E G H INT EXH Figure 9-6. V alve Details. ȱȱȱȱȱȱȱ¢ȱȱ fuel consumption may be symptoms of faulty v alves. ?[...]
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Page 98
Section 9 Inspection and Reconditioning 9.6 Normal: ȱȱĞȱȱȱȱȱȱ ȱ can be reconditioned and reused if the face and margin are in good shape. If a v alve is worn to where the margin is less than 1/32" do not reuse it. The v alve shown w as [...]
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Page 99
Section 9 Inspection and Reconditioning 9 9.7 Excessive Combustion T emperatures: 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 prev alent cause of valve sticking. The cure is to ream the v alve guides and clean or rep[...]
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Page 100
Section 9 Inspection and Reconditioning 9.8 V alve Seat Cutter Pilot V alve Guides ȱȱ ȱȱȱȱ¢ ȱęǰȱȱȱ not guide the v alve in a straight line. This may result in burnt v alve faces or seats, loss of compression, an[...]
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Page 101
Section 9 Inspection and Reconditioning 9 9.9 Overheated or Deteriorated Oil Scored Piston and Rings Abrasive Scratched Rings Stuck, Broken Rings Ring failure is usually indicated by excessive oil consumption and blue exhaust smoke. When rings fail, oil is allowed to enter the combustion chamber ȱȱȱȱ[...]
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Page 102
Section 9 Inspection and Reconditioning 9.10 Replacement pistons are av ailable 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 av ailable separately for STD, 0.25 mm (0.010 in.), and 0.50 mm (0.020 in.) oversize pist[...]
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Page 103
Section 9 Inspection and Reconditioning 9 9.1 1 Figure 9-12. Piston Ring Installation. ȱ ŗǯȱ ȱȱȱǻĴȱǼDZȱȱȱ expander and then the rails. Make sure the ends of the expander are not overlapped. 2. Middle Compression Ring (Center Groov e):[...]
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Page 104
Section 9 Inspection and Reconditioning 9.12 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 P an Oil Seal’’ in Section 10 for new oil seal installation. Inspect the main bearing surface for wear or damage ǻȱȱȱŗǰȱ?[...]
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Page 105
Section 9 Inspection and Reconditioning 9 9.13 O-Ring 3 2 1 4 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. 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[...]
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9.14[...]
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Page 107
10.1 10 Section 10 Reassembly General NOTE: Make sure the engine is assembled using ȱęȱȱ ǰȱȱ ǰȱȱǯȱȱȱȱ ę[...]
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Page 108
10.2 Section 10 Reassembly ȱ Řǯȱ ¢ȱȱȱȱȱȱȱȱȱȱ ȱȱȱȱȱǯ ȱ řǯȱ ȱȱȱȱȱ?[...]
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Page 109
10.3 Section 10 Reassembly 10 Oil Seal Seal depth 1.5 - 2.0 mm (0.059 - 0.078 in) Crankcase Surface 12.66 mm (0.498 in.) Crankcase Surface Governor Gear Shaft Figure 10-6. Installed Main Bearing. Install Governor Shafts, Seal, and Governor Gear ȱȱȱĞǰȱǰȱȦȱ?[...]
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Page 110
10.4 Section 10 Reassembly Śǯȱ Ĵȱȱȱ¢ ȱȱȱȱĞȱȱȱ ȱȱȱȃȄȱȱǯȱȱȱ ȱȱǯȱȱ[...]
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Page 111
10.5 Section 10 Reassembly 10 No. 1 Side No. 2 Side Install Connecting Rods with Pistons and Rings DZȱ ȱ¢ȱȱȱ ȱȱǯȱ ȱȱȱȱȱǰȱ?[...]
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Page 112
10.6 Section 10 Reassembly Figure 10-20. T orquing Connecting Rod End Cap Screws. ȱ Ŝǯȱ ȱȱȱȱȱȱȱ ȱȱȱȱ¢ ǯ Install Camshaft ȱ ŗǯȱ ?[...]
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Page 113
10.7 Section 10 Reassembly 10 Oil Seal 3 mm (0.1 18 in.) ȱ śǯȱ ȱȱȱ¢ȱȱȱȱȱ ȱȱ¢ ǯ Install Oil Pan Seal and Main Bearing Main Bearing ȱȱȱȱȱ?[...]
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Page 114
10.8 Section 10 Reassembly O-Ring 10 8 1 14 3 5 12 7 9 11 6 4 2 13 Install Oil Pan Assembly ŗǯȱ ȱȱȱȱȱȱȱȱȱȱ ȱȱǰȱ¢ ǰȱȱȱȱ?[...]
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Page 115
10.9 Section 10 Reassembly 10 Crankcase Filter Breather Hose Flange Nuts (4) Gasket Check Crankshaft End play ȱ ŗǯȱ ȱȱȱȱǰȱȱȱȱȱȱ ȱȱȱĞȱȱ¢ȱ?[...]
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Page 116
10.10 Section 10 Reassembly 1 3 4 2 ȱ řǯȱ ȱȱȱ¡ȱĚȱǰȱȱȱ ȱȱȱȱȱȱŗŖȬřśȱȱ 5.7 N·m (51 in. lb.) ǯ Figure 10-35. Breather Assembly[...]
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Page 117
10.1 1 Section 10 Reassembly 10 DZȱ ¢ȱĞȱȱ ¢ȱȱ ȱȱȱȱȱȱȱ ¢ ǯȱȱ¡ȱĞ?[...]
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Page 118
10.12 Section 10 Reassembly Spacer W ashers 2 2 4 5 5 4 1 3 3 1 No. 1 No. 2 Figure 10-43. Installing V alves with V alve Spring Compressor . Install Cylinder Heads ȱ ŗǯȱ ȱȱȱȱȱȱȱȱȱȱ ȱȱȱ?[...]
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Page 119
10.13 Section 10 Reassembly 10 ȱ Ŝǯȱ ȱȱȱȱȱȱȱȱȱȱ ¢ȱȱȱȱȱ¢ ǯȱȱȱȱ ȱȱ¢?[...]
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Page 120
10.14 Section 10 Reassembly ȱ ȱDZ ȱ ȱ ǯȱ ȱȱȱȱȱȱȱȱ ȱ ȱǯ ȱ ȱ ǯȱ ¢ ¢ȱȱĞȱȱȱȱ?[...]
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Page 121
10.15 Section 10 Reassembly 10 Figure 10-53. Establishing the "0" Lash Point. Śǯȱ ȱȱȱȱĴȱȱȱȱǰȱ ȱȱǻǼȱȱȱȱ four (4) complete re[...]
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Page 122
10.16 Section 10 Reassembly Spring Install Spark Plugs ȱ ŗǯȱ ȱȱ ® ȱŗŖȱǻȱ Ǽȱ ȱǯ ȱ Řǯȱ ȱȱȱȱ 0.76 mm (0.030 in.) ǯ ȱ řǯȱ ȱȱ[...]
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Page 123
10.17 Section 10 Reassembly 10 O-Rings Around Dowel Pins Figure 10-62. Installing Nipple into Cup and Oil Filter Housing. Figure 10-63. T orquing Nipple into Housing. Installation ȱ ŗǯȱ ȱȱȱȱȱȱȱȱȱ ȱ?[...]
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Page 124
10.18 Section 10 Reassembly 1 2 Cylinder 1 Cylinder 2 3 4 Řǯȱ ȱȱȱȱȱȱ¢ȱǯȱ ȱȱȱȱȱȱȱȱ ?[...]
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Page 125
10.19 Section 10 Reassembly 10 Figure 10-71. Installing Stator . śǯȱ ȱȱȱȱȱȱȱȱȱƸȱ ȱȱȱȱȱȱȱȱȱ ȱ[...]
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Page 126
10.20 Section 10 Reassembly Figure 10-76. Clean and Dry Flywheel Hub. Figure 10-77. Installed Flywheel Key . DZȱ ȱȱȱĚ¢ȱ¢ȱȱȱ ¢ȱȱȱ¢ ¢ ǯȱȱĚ¢ȱȱ [...]
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Page 127
10.21 Section 10 Reassembly 10 śǯȱ ȱȱ 0.30 mm (0.012 in.) ȱĚȱȱȱ ȱȱȱȱȱȱǯȱ ȱȱŗŖȬŞŖǯȱȱȱȱ?[...]
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Page 128
10.22 Section 10 Reassembly Install Oil Cooler ŗǯȱ ȱȱȱȱȱȱ ȱȱȱ ęȱȱȱȱȱ ǯȱȱȱȱ [...]
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Page 129
10.23 Section 10 Reassembly 10 ȱ řǯȱ ȱȱȱȱȱǯȱȱȱ ŗŖȬŞŞǯ Figure 10-88. Connecting Leads to Starting Motor . ,QVWDOO9 DOOH%DIÀHV ȱ ŗǯȱ ȱȱȱ ¢ȱĝ?[...]
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Page 130
10.24 Section 10 Reassembly 1, 5 4 3 2 Mounting Screws Install Control Bracket and Air Cleaner Assembly ȱ ŗǯȱ ȱȱȱȱ¢ȱȱ ȱȱȱȱǰȱ?[...]
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Page 131
10.25 Section 10 Reassembly 10 Fuel Pump Outlet Hose Pulse Hose Inlet Hose Figure 10-96. Installing Choke Link and Push-On Nut. Install Throttle and Choke Linkages ȱȱȱĴȦȱȱȱȱ ?[...]
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Page 132
10.26 Section 10 Reassembly Oil Pan Adjusting Governor ȱ ŗǯȱ ȱȱȱȱȱȱȱȱ ȱȱȱ¢ȱȱȱȱȱȱ [...]
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Page 133
10.27 Section 10 Reassembly 10 Oil Fill T ube Lift Bracket Lower Mounting Screw Cylinder Shrouds Mounting Screws ȱ Řǯȱ ȱȱȱȱȱȱȱȱ¢ ™ ǯ Install Blower Housing and Cylinder Shrouds ŗǯȱ [...]
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Page 134
10.28 Section 10 Reassembly Install Oil Filter and Add Oil to Crankcase ȱ ŗǯȱ ȱȱȱȱǯȱȱȱŗŖȬŗŖşǯȱ ȱȱȱȱ ŘŗǯŚȱȉȱǻŗśǯŝȱĞǯȱǯǼ ǯ DZȱ [...]
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Page 135
10.29 Section 10 Reassembly 10 T esting the Engine ȱȱȱȱȱȱȱȱȱȱ ȱȱȱȱȱȱȱȱȱȱ[...]
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10.30[...]
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LITHO IN U.S.A. FORM NO.: TP-2581 ISSUED: 1/09 REVISED: ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044 FOR SALES AND SER VICE INFORMA TION IN U.S. AND CANADA, CALL 1-800-544-2444 KohlerEngines.com[...]