Kohler CV1000 manual

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Table of contents for the manual

  • Page 1

    S ER VICE M ANUAL V ERTICAL C RANKSHAFT COMMAND PRO CV940-CV1000[...]

  • Page 2

    [...]

  • Page 3

    Contents Section 1. Safety and General Information ............................................................................. Section 2. T ools & Aids ........................................................................................................ ..... Section 3. T roubleshooting .....................................................[...]

  • Page 4

    [...]

  • 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[...]

  • Page 6

    1.2 Section 1 Safety and General Information ¡ȱȱȱȱęȱȱ severe burns. ȱȱęȱȱȱȱȱȱ engine is hot or running. W ARNING Explosive Fuel! ȱȱ¡[...]

  • 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[...]

  • 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[...]

  • Page 9

    1.5 Section 1 Safety and General Information 1 ÂđPerform 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[...]

  • 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[...]

  • Page 11

    1.7 Section 1 Safety and General Information 1 ÂđV alues are in Metric units. V alues in parentheses are English equivalents. Lubricate threads with engine oil prior to assembly . *HQHUDO6SHFLÂŋFDWLRQVÃŊ P ower (@3600 RPM, exceeds Society of Automotive Engineers-Small Engine T est Code J1940.) CV940...............................................[...]

  • Page 12

    1.8 Section 1 Safety and General Information Carburetor , Intake Manifold, and Air Cleaner ȱȱȱȱ  T orque Using Sequence in T wo Stages ................................................. Ä™î‚›î‚œî‚Čąî‚î‚˜ČąÅ—ÅœĮŊÅŸČąî€Č‰î‚–ČąĮŧÅ—Å›Å–Čą?[...]

  • Page 13

    1.9 Section 1 Safety and General Information 1 ĞȱȱȱȱĮŧȱȱ Įž Running Clearance - New ...................................................................... 0.040/0.167 mm (0.0015/0.0065 in.) Flywheel End Main Bearing Journal O.D. - New ...............[...]

  • 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 ?[...]

  • Page 15

    1.1 1 Section 1 Safety and General Information 1 ÅķČą î€î‚Žî‚Šî‚œî‚žî‚›î‚ŽČąÅ—Å—Čąî‚–î‚–ČąĮŧŖĮŊÅšÅ™Å™Čąî‚’î‚—ĮŊĮžČąî‚Šî‚‹î‚˜î‚Ÿî‚ŽČąî‚î‚‘î‚ŽČąî‚‹î‚˜ÄīȱȱȱȱȱȱȱȱȱȱȱĮŊ T op Compression Ring-to-Groove Side [...]

  • 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.[...]

  • 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[...]

  • Page 18

    1.14[...]

  • Page 19

    2.1 Section 2 T ools & Aids 2 Section 2 T ools & Aids T ools Description Source/Part No. ĞȱÂĒȱ ȱȱĞȱÂĒ ĮŊ ȱ î‚˜î‚˜î‚•î‚œČąî€î€Žî€”ČŽÅžÅ˜ÅšÅ–Å› Ğȱȱ?[...]

  • Page 20

    2.2 Section 2 T ools & Aids T ools (Continued) Description Source/Part No. ÂĒȱ ȱĞȱ   ȱȱȱȱÂĒȱĞĮŊ î€î‚˜î‚‘î‚•î‚Žî‚›ČąÅ˜Å›ČąÅÅœÅ—ČąÅ™ÅžČŽî€• ȱÂĒ[...]

  • Page 21

    2.3 Section 2 T ools & Aids 2 Aids Description Source/Part No. Ğȱ ČąĮŧ î‚Šî‚•î‚œî‚™î‚Šî‚›Čąî€œî€œÅœÅ—Å™Įž î€î‚˜î‚‘î‚•î‚Žî‚›ČąÅ˜Å›ČąÅ™Å›ÅČąÅ—ÅšČŽî€• ȱ ČąĮŧČĶ î‚Šî‚î‚žî‚Šî‚›î‚Čąî€‰ÅœÅœÅ—Įž î€î‚˜î‚‘î‚•î‚Žî‚›ČąÅ˜Å›ČąÅ™Å›ÅČąÅ—Å—ČŽ?[...]

  • Page 22

    2.4 Section 2 T ools & Aids Special T ools Y ou Can Make Flywheel Holding T ool  ȱĚÂĒȱȱȱȱȱȱȱȱȱȱ ȱĚÂĒî‚ î‚‘î‚Žî‚Žî‚•Čąî‚›î‚’î‚—î‚Čąî‚î‚Žî‚Šî‚›Čąî‚Šî‚œČąî‚œî‚‘î‚˜î‚ î‚—Čąî‚’î‚—Čąî€ˆî‚’î‚î‚žî‚›î‚ŽČąÅ˜ČŽÅ—Į°Čąî‚Š?[...]

  • Page 23

    3.1 3 Section 3 T roubleshooting T roubleshooting Guide When troubles occur , be sure to check the simple ȱĮ°Čąî‚Šî‚ČąÄ™î‚›î‚œî‚Į°Čąî‚–î‚ŠÂĒȱȱȱȱȱȱ considered. For example, a starting problem could be ȱÂĒȱȱÂĒȱ[...]

  • Page 24

    3.2 Section 3 T roubleshooting Engine Overheats Čą ŗĮŊČą ȱČĶȱĮ°Čąî‚Œî‚˜î‚˜î‚•î‚’î‚—î‚ČąÄ™î‚—î‚œĮ°Čąî‚˜î‚›Čąî‚Œî‚˜î‚˜î‚•î‚’ȹ shrouds clogged. Čą ŘĮŊČą ¡ȱȱĮŊ Čą řĮŊČą ȱȱȱ?[...]

  • Page 25

    3.3 Section 3 T roubleshooting 3 ȱȱȱȱȱȱȱȱȱȱ the engine is reassembled and placed into operation. ȱȱȱȱȱȱ[...]

  • Page 26

    3.4 Section 3 T roubleshooting Leakdown T est Results ȱȱȱȱ ....................................................... ȱȱÂĒȱĮŊ ȱȱȱ¡?[...]

  • 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 Į°Čąî‚ŠÄīȱȱȱȱȱȱ man[...]

  • 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 ȱĮŊȱȱÂĒ Į°Čąî‚‹î‚Žî‚—î‚Čąî‚˜î‚›Čąî‚î‚Šî‚–î‚Šî‚î‚Žî‚Čą elements with new genuine Kohler elements as required[...]

  • 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! ȱȱ¡ÂĒȱĚȱȱȱȱȱ?[...]

  • 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.  ȱęȱȱȱȱȱÂĒȱȱȱȱĮ°Čąî‚™î‚Žî‚›î‚î‚˜î‚›î‚–Čą?[...]

  • 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 ÂĒ ĮŊČąî€•î‚Žî‚ŽČąî€ˆî‚’î‚î‚žî‚›î‚Žî‚œČąÅ›ČŽÅ—Čą?[...]

  • 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 . Čą Ȋȱ ȱȱȱȱȱȱęȱȱĮ°Čąî‚?[...]

  • Page 33

    5.5 Section 5 Fuel System and Governor 5 Fuel Shut-Off Solenoid High Altitude Operation î€™î‚‘î‚Žî‚—Čąî‚˜î‚™î‚Žî‚›î‚Šî‚î‚’î‚—î‚Čąî‚î‚‘î‚ŽČąî‚Žî‚—î‚î‚’î‚—î‚ŽČąî‚Šî‚Čąî‚Šî‚•î‚î‚’î‚î‚žî‚î‚Žî‚œČąî‚˜î‚ČąÅ—Å›Å–Å–Čąî‚–Čą ĮŧÅ›Å–Å–Å–ČąÄžĮŊĮžČąî‚Šî‚—î‚Čąî‚Šî‚‹î‚˜î‚Ÿî‚ŽĮ°Čąî‚î‚‘î‚ŽČąî‚î‚žî‚Žî‚•Čąî‚–î‚’ÂĄî‚î‚žî‚›î‚ŽČąî‚î‚Žî‚—î‚î‚œČąî‚î‚˜Čąî‚?[...]

  • 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 ĮąČą ȱȱȱȱȱÂĒČą Ğȱȱȱȱ[...]

  • Page 35

    5.7 Section 5 Fuel System and Governor 5 Governed Idle System  ȱ ȱȱȱÂĒȱȱȱȱȱȱ desired idle speed regardless of ambient conditions (temperature, parasitic load, etc.) that may change. ȱȱ?[...]

  • 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[...]

  • Page 37

    5.9 Section 5 Fuel System and Governor 5 Figure 5-14. Float and Inlet Needle Details. Čą ŜĮŊČą ȱȱĚȱȱȱȱȱȱȱ seat and carburetor body . Install the new pivot ȱȱȱĚȱ[...]

  • Page 38

    5.10 Section 5 Fuel System and Governor Figure 5-18. Fuel Bowl Removed From Carburetor . ĮąČą ȱÂĒȱȱȱȱȱ is not necessary unless the Fuel Solenoid Kit, or Fuel Bowl Kit (obtained separately), will also be installed. ȹȹ ŘĮŊČą ?[...]

  • Page 39

    5.1 1 Section 5 Fuel System and Governor 5 śĮŊČą ȱȱȱȱĮŧĮžČąî‚Šî‚î‚“î‚žî‚œî‚î‚–î‚Žî‚—î‚Čąî‚œî‚Œî‚›î‚Žî‚ Čą and spring from the carburetor . Discard the parts. ĮąČą ȱȱȱȱȱ?[...]

  • Page 40

    5.12 Section 5 Fuel System and Governor Figure 5-26. Installing Float Assembly . ŗŚĮŊČą ȱȱȱÂĒȱȱȱĚȱÂĒČą hangs vertically and rests lightly against the fuel inlet needle. The inlet needle should be fully seated but the center pin of the [...]

  • Page 41

    5.13 Section 5 Fuel System and Governor 5 śĮŊČą ȱȱȱ¡ȱĮŧÂĒȮĮžČąî‚Šî‚—î‚Čąî‚›î‚Žî‚–î‚˜î‚Ÿî‚ŽČąî‚î‚‘î‚ŽČą ȱȱĞȱȱȱȱȱȱ lever from the carburetor housing. S[...]

  • Page 42

    5.14 Section 5 Fuel System and Governor ČąÅ—Å˜ĮŊČą ȮȱĮŧȱȱȮȱĮž 13. Drain Screw 14. Bowl Screw (4) ČąÅ—Å›ĮŊČą ȱ ČąÅ—ÅœĮŊČą ȱ  17. Float 18. Pin 19. Screw ČąÅ˜Å–ĮŊČą ȱ ČąÅ˜Å—ĮŊČą [...]

  • 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 ȱȱȱȱȱȱ[...]

  • 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).[...]

  • 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[...]

  • 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 Įą Čą ŗĮŊČą ȱȱȱȱȱ[...]

  • Page 47

    6.3 Section 6 Lubrication System 6 Čą řĮŊČą ȱȱȱȱȱȱȱ 21.4 N·m ĮŧŗśĮŊÅČąÄžĮŊȱĮŊĮž . Čą ŚĮŊČą ȱȱĮ°Čąî‚ î‚’î‚î‚‘Čąî‚—î‚Žî‚ Čąî‚˜î‚’î‚•Čąî‚˜î‚Čąî‚î‚‘î‚ŽČąî‚™î‚›î‚˜î‚™î‚Žî‚›Čą ÂĒ[...]

  • Page 48

    6.4 Section 6 Lubrication System Pressure Switch Service Oil Cooler ȱȱȱȱȱȱȱȱ ȱȱȱĮŊČąÅ˜Čąî‚œî‚’î‚î‚ŽČąî‚ŒÂĒȱĮ°Čą [...]

  • Page 49

    6.5 Section 6 Lubrication System 6 Installation ȱȱÂĒȜȱȱȱȱȱȱȱ ȱȱȱĮŊČąî€•î‚Žî‚ŽČąî€ˆî‚’î‚î‚žî‚›î‚ŽČąÅœČŽÅ—Å˜ĮŊȱȱȱȱ [...]

  • Page 50

    6.6[...]

  • 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: â€Ē Spark Plugs Čą Ȋȱ ÄīÂĒȱȱȱÂĒ â€Ē Electric Starter Čą Ȋȱ ?[...]

  • Page 52

    7.2 Section 7 Electrical System and Components Įą Čą  ȱȱȱȱȱȱȱȱ normal conditions will have light tan or gray colored deposits. If the center electrode is not worn, a plug ȱȱ?[...]

  • Page 53

    7.3 Section 7 Electrical System and Components 7 DC V oltmeter Battery Battery General  ČąÅ—Å˜ČŽî‚Ÿ ȱÄīÂĒČąî‚ î‚’î‚î‚‘ČąÅšÅ–Å–Čąî‚Œî‚˜î‚•î‚Čąî‚Œî‚›î‚Šî‚—î‚”î‚’î‚—î‚Čąî‚Šî‚–î‚™î‚œČąĮŧĮžČąî‚’î‚œČą generally recommended for starting in all conditions.  ȱȱÂĒȱÄī?[...]

  • Page 54

    7.4 Section 7 Electrical System and Components Molex Plug (Some Models) ȱȱȱěȱÂĒȱȱȱÂĒȱȱȱĮŊČą ȱÂĒȱȱȱȱ?[...]

  • 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[...]

  • Page 56

    7.6 Section 7 Electrical System and Components ĮŊČą ȱȱȱȱĮ°Čąî‚î‚‘î‚ŽČąî‚Žî‚•î‚Žî‚Œî‚î‚›î‚’î‚Œî‚Šî‚•Čąî‚œÂĒȱ ȱȱȱȱĮŊȱȱȱÂĒȱĮ°Čą wires, connections, safety interlocks, [...]

  • Page 57

    7.7 Section 7 Electrical System and Components 7 T roubleshooting DSAI Ignition Systems ȱȱȱÂĒȱȱȱȱȱȱ ȱȱȱȱȱȱĮŊȱȱ?[...]

  • Page 58

    7.8 Section 7 Electrical System and Components Čą ŘĮŊČą ȱȱȱ Į°Čąî‚Žî‚œî‚î‚Šî‚‹î‚•î‚’î‚œî‚‘î‚’î‚—î‚Čąî‚ŠČąî‚–î‚’î‚—î‚’î‚–î‚žî‚–Čą î‚˜î‚ČąÅ›Å›Å–ČŽÅœÅ–Å–Čąî€”î€’î€Į°Čąî‚Šî‚—î‚Čąî‚˜î‚‹î‚œî‚Žî‚›î‚Ÿî‚ŽČąî‚î‚Žî‚œî‚î‚Žî‚›ĮŧĮžČąî‚î‚˜î‚›Čąî‚œî‚™î‚Šî‚›î‚”ĮŊ Čą řĮŊČą ȱ?[...]

  • 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 ȱȱÂĒĮŊČąî€•î‚Žî‚ŽČąî€ˆî‚’î‚î‚žî‚›î‚Žî‚œČąÅČŽÅŸČąî‚î‚‘î‚›î‚˜î‚žî‚î‚‘ČąÅČŽÅ—Å™ĮŊČą ĮąČą ȱȱ?[...]

  • 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 .[...]

  • 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 .[...]

  • 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 .[...]

  • Page 63

    7.13 Section 7 Electrical System and Components 7 Stator ȱȱȱȱȱȱȱȱ ȱĚÂĒĮŊČąî€ˆî‚˜î‚•î‚•î‚˜î‚ Čąî‚î‚‘î‚ŽČąî‚™î‚›î‚˜î‚Œî‚Žî‚î‚žî‚›î‚Žî‚œČąî‚’î‚—Čąî€•î‚Žî‚Œî‚î‚’î‚˜î‚—ČąÅžČąČŽČą ȃ?[...]

  • Page 64

    7.14 Section 7 Electrical System and Components śĮŊČą ȱȱȱȱȱȱ ȱČĶȱ ȱȱȱĮŊȱ ȱȱȱȱĮŊČą ȱȁȁ?[...]

  • Page 65

    7.15 Section 7 Electrical System and Components 7 T roubleshooting Guide 15/20/25 Amp Battery Charging Systems ȱȱȱȱȱȱÄīÂĒȱȱȱȱÄīÂĒȱȱȱȱȱȱ?[...]

  • Page 66

    7.16 Section 7 Electrical System and Components DC V oltmeter 5HFWLÂŋHU5HJXODWRU Flywheel Stator Ammeter Battery (-) (+) Figure 7-20. Connections for T esting Charging System. Electric Starting Motors ȱȱȱȱĞȱȱȱ?[...]

  • Page 67

    7.17 Section 7 Electrical System and Components 7 T orx Head Screws 7 URXEOHVKRRWLQJ*XLGH±6WDUWLQJ'LIÂŋFXOWLHV Delco-Remy Starters Figure 7-21. Delco-Remy Starter . Starter Disassembly Čą ŗĮŊČą ȱȱ¡ȱȱȱȱȱ ȱ Įŧ?[...]

  • Page 68

    7.18 Section 7 Electrical System and Components Figure 7-23. Solenoid Removed from Starter . Figure 7-24. Removing Plunger . Čą ŚĮŊČą ȱȱ ȱȱĮŧĮžČąî‚‹î‚˜î‚•î‚î‚œĮŊȱȱȱ ÅČŽÅ˜Å›ĮŊ Figure 7-25. Removing Thru Bolts. Čą śĮŊČą ȱ?[...]

  • 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 Čą ŞĮŊČą  ȱȱȱȱ ȱȱȱ[...]

  • 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 ȱȱȱȱȱĮą ĮŊČą ȱȱȱȱȱ?[...]

  • Page 71

    7.21 Section 7 Electrical System and Components 7 Brush Replacement ȱȱȱȱȱȱȱȱȱĮŧŚĮžĮŊȱȱ ȱȱȱȱȱȱĮ°Čąî‚’î‚Čąî‚›î‚Žî‚™î‚•î‚Šî‚Œî‚Žî‚–?[...]

  • Page 72

    7.22 Section 7 Electrical System and Components řĮŊČą ȱȱěȱȱĮŧĮžČąî‚  ȱȱȱ ȱȃěȄȱȱȱ ȱȱȱČĶ  ĮŊȱ?[...]

  • Page 73

    7.23 Section 7 Electrical System and Components 7 Figure 7-43. Installing Thrust W asher . Čą ŗŖĮŊČą ȱÂĒȱȱ  ȱȱČĶ ȱȱ ÂĒĮą ĮŊČą ȱȱ?[...]

  • Page 74

    7.24 Section 7 Electrical System and Components Extension. ĮŊČą ȱȱȱÂĒȱÂĒȱȱȱ end housing, and carefully place the tool Įŧȱ¡ĮžČąî‚Šî‚—î‚Čąî‚Šî‚œî‚œî‚Žî‚–î‚‹î‚•î‚Žî‚Čąî‚˜î‚›î‚’î‚î‚’î‚—î‚Šî‚•Čą ?[...]

  • 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 ȱȱȱȱȱȱȱ ȱȱ?[...]

  • Page 76

    7.26 Section 7 Electrical System and Components T est 4. Solenoid Hold-In Coil/Contact Continuity T est. î€—î‚œî‚ŽČąî‚Šî‚—Čąî‚˜î‚‘î‚–î‚–î‚Žî‚î‚Žî‚›Čąî‚œî‚Žî‚Čąî‚î‚˜Čąî‚î‚‘î‚ŽČąî‚Šî‚žî‚î‚’î‚‹î‚•î‚ŽČąî‚˜î‚›Čąî€”ÂĄÅ˜î€Čąî‚œî‚Œî‚Šî‚•î‚ŽĮ°Čąî‚Šî‚—î‚Čą connect the two ohmmeter leads to the tw o large post ĮŊȱ ?[...]

  • 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, ȱȱȱȱĮąČąÅ—ĮžČąî€†î‚’î‚œî‚Œî‚˜î‚—î‚—î‚Žî‚Œî‚Čąî‚î‚‘î‚ŽČąî‚œî‚™î‚Šî‚›î‚”Čąî‚™î‚•î‚žî‚Čąî‚•î‚Žî‚Š?[...]

  • Page 78

    8.2 Section 8 Disassembly Cylinder Shroud Shut Off Fuel Supply Drain Oil from Crankcase and Remove Oil Filter Čą ŗĮŊČą ȱȱȱęȱȱȱĮŊȱȱȱ ȱȱȱę ĮŊȱȱ[...]

  • Page 79

    8.3 Section 8 Disassembly 8 3. Remov e the lower mounting screw and pull the ȱęȱȱȱȱȱĮŊ Figure 8-7. Removing Oil Fill T ube. Remove Electric Starter Motor 1. Disconnect the leads from the starter . Čą ŘĮŊČą ȱȱ ȱ¡ȱĚ[...]

  • Page 80

    8.4 Section 8 Disassembly Remove Fuel Pump W ARNING: Explosive Fuel! ȱȱ¡ÂĒȱĚȱȱȱȱȱ¡ȱ ȱĮŊȱȱȱÂĒȱȱ [...]

  • Page 81

    8.5 Section 8 Disassembly 8 Figure 8-15. Removing Control Bracket. Čą ŜĮŊČą ȱȱ¡ȱĚȱȱȱȱȱ ȱ ȱȱȱĞĮŊČąî€•î‚Žî‚ŽČąî€ˆî‚’î‚î‚žî‚›î‚ŽČąÅžČŽÅ—ÅœĮŊ Figure 8-16. Removing Governor[...]

  • 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. )LJXUH5HPRYLQJ9 DOOH%DIÀHV 2. Remov e the four screws securing each of the ȱÂĒȱĝȱȱĮŊȱ?[...]

  • Page 83

    8.7 Section 8 Disassembly 8 Figure 8-24. Removing Oil Filter Housing.  ȱȱȱÂĒȱȱȱȱęȱȱ assembly requires individual servicing. Čą ĮŊČą ȱȱȱȱȱ[...]

  • Page 84

    8.8 Section 8 Disassembly Remove Grass Screen and Cooling Fan Čą ŗĮŊČą ȱȱĮ°Čąî‚ŠÄīȱ Į°Čąî‚Šî‚—î‚Čąî‚‘î‚ŽÂĄČą ȱȱȱȱĮ°Čąî‚œî‚î‚’ěĮ°Čąî‚Šî‚—î‚Čą ?[...]

  • Page 85

    8.9 Section 8 Disassembly 8 Wiring Harness Molded Clips 2. Remov e the mounting screws securing the ęȮȱȱȱȱȱ assembly . Note the location of the ground lead. ȱȱęȮȱȱ[...]

  • 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  ȱȱȱÂĒȱȱěĮŊČąî€•î‚Žî‚ŽČąî€ˆî‚’î‚î‚žî‚›î‚ŽČąÅžČŽÅ™ÅžĮŊ Figu[...]

  • 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 î€ˆî‚’î‚î‚žî‚›î‚ŽČąÅžČŽÅšÅšĮŊ Figure 8-44. Removi[...]

  • 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[...]

  • 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 ȱȁȁȱȱ ÂĒȂȂ Čąî‚’î‚—Čąî€•î‚Žî‚Œî‚î‚’î‚˜î‚—ČąÅŸĮŊ Remove Camshaft Čą ŗĮŊČą ȱ[...]

  • Page 90

    8.14 Section 8 Disassembly 2. Carefully remov e the connecting rod and piston ÂĒȱȱȱÂĒȱĮŊČąî€•î‚Žî‚ŽČąî€ˆî‚’î‚î‚žî‚›î‚ŽČąÅžČŽÅ›ÅœĮŊ Figure 8-56. Removing Piston/Connecting Rod Assemblies. 3. Repeat the abov e procedures for the other connecting rod and piston assembly . [...]

  • Page 91

    8.15 Section 8 Disassembly 8 Remove Lifter Feed Chamber Cover and Gaskets Čą ŗĮŊČą ȱȱȱȱȱȱĞȱȱ chamber cover , and gaskets. Carefully separate ȱȱȱȱĮŊ[...]

  • Page 92

    8.16[...]

  • Page 93

    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 &[...]

  • 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 ȱȱȱęȱȱ?[...]

  • 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 ÅœÅ–Čąî‚œî‚î‚›î‚˜î‚”î‚Žî‚œČąî‚™î‚Žî‚›Čąî‚–î‚’î‚—î‚žî‚î‚ŽĮŊČą Ğȱȱȱȱȱ[...]

  • 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. Čą řĮŊČą ȮȮȱȱ?[...]

  • 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. ȱȱȱȱȱȱȱÂĒȱȱ fuel consumption may be symptoms of faulty v alves. ?[...]

  • Page 98

    Section 9 Inspection and Reconditioning 9.6 Normal: ȱȱĞȱȱȱȱȱȱ 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 [...]

  • 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[...]

  • Page 100

    Section 9 Inspection and Reconditioning 9.8 V alve Seat Cutter Pilot V alve Guides ȱȱ ȱȱȱȱÂĒ ȱęĮ°Čąî‚’î‚Čąî‚ î‚’î‚•î‚•Čą not guide the v alve in a straight line. This may result in burnt v alve faces or seats, loss of compression, an[...]

  • 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 ȱȱȱȱ[...]

  • 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[...]

  • Page 103

    Section 9 Inspection and Reconditioning 9 9.1 1 Figure 9-12. Piston Ring Installation. Čą ŗĮŊČą ȱȱȱĮŧÄīȱĮžĮąČąî€‹î‚—î‚œî‚î‚Šî‚•î‚•Čąî‚î‚‘î‚ŽČą expander and then the rails. Make sure the ends of the expander are not overlapped. 2. Middle Compression Ring (Center Groov e):[...]

  • 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 Įŧî‚›î‚Žî‚î‚Žî‚›Čąî‚î‚˜Čąî€•î‚Žî‚Œî‚î‚’î‚˜î‚—ČąÅ—Į°Čą?[...]

  • 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[...]

  • Page 106

    9.14[...]

  • Page 107

    10.1 10 Section 10 Reassembly General NOTE: Make sure the engine is assembled using ȱęȱȱ Į°Čąî‚î‚’î‚î‚‘î‚î‚Žî‚—î‚’î‚—î‚Čą Į°Čąî‚Šî‚—î‚Čąî‚Œî‚•î‚Žî‚Šî‚›î‚Šî‚—î‚Œî‚Žî‚œĮŊȱȱȱȱ ę[...]

  • Page 108

    10.2 Section 10 Reassembly Čą ŘĮŊČą ÂĒȱȱȱȱȱȱȱȱȱȱ ȱȱȱȱȱĮŊ Čą řĮŊČą ȱȱȱȱȱ?[...]

  • 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 ȱȱȱĞĮ°Čąî‚œî‚Žî‚Šî‚•Į°Čąî‚Šî‚—ČĶȱ?[...]

  • Page 110

    10.4 Section 10 Reassembly ŚĮŊČą ÄīȱȱȱÂĒ ȱȱȱȱĞȱȱȱ ȱȱȱȃȄȱȱĮŊȱȱȱ ȱȱĮŊȱȱ[...]

  • Page 111

    10.5 Section 10 Reassembly 10 No. 1 Side No. 2 Side Install Connecting Rods with Pistons and Rings ĮąČą ȱÂĒȱȱȱ ȱȱĮŊČą ȱȱȱȱȱĮ°Čąî‚Œî‚˜î‚—î‚—?[...]

  • Page 112

    10.6 Section 10 Reassembly Figure 10-20. T orquing Connecting Rod End Cap Screws. Čą ŜĮŊČą ȱȱȱȱȱȱȱ ȱȱȱȱÂĒ ĮŊ Install Camshaft Čą ŗĮŊČą ?[...]

  • Page 113

    10.7 Section 10 Reassembly 10 Oil Seal 3 mm (0.1 18 in.) Čą śĮŊČą ȱȱȱÂĒȱȱȱȱȱ ȱȱÂĒ ĮŊ Install Oil Pan Seal and Main Bearing Main Bearing ȱȱȱȱȱ?[...]

  • 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 ŗĮŊČą ȱȱȱȱȱȱȱȱȱȱ ȱȱĮ°Čąî‚î‚›ÂĒ Į°Čąî‚Šî‚—î‚Čąî‚î‚›î‚Žî‚ŽČąî‚˜î‚Čąî‚Š?[...]

  • Page 115

    10.9 Section 10 Reassembly 10 Crankcase Filter Breather Hose Flange Nuts (4) Gasket Check Crankshaft End play Čą ŗĮŊČą ȱȱȱȱĮ°Čąî‚Šî‚—î‚Čąî‚žî‚œî‚ŽČąî‚ŠČąî‚î‚’î‚Šî‚•Čąî‚’î‚—î‚î‚’î‚Œî‚Šî‚î‚˜î‚›Čą ȱȱȱĞȱȱÂĒČą?[...]

  • Page 116

    10.10 Section 10 Reassembly 1 3 4 2 Čą řĮŊČą ȱȱȱ¡ȱĚȱĮ°Čąî‚Šî‚—î‚Čąî‚î‚˜î‚›î‚šî‚žî‚ŽČą î‚žî‚œî‚’î‚—î‚Čąî‚î‚‘î‚ŽČąî‚œî‚Žî‚šî‚žî‚Žî‚—î‚Œî‚ŽČąî‚œî‚‘î‚˜î‚ î‚—Čąî‚’î‚—Čąî€ˆî‚’î‚î‚žî‚›î‚ŽČąÅ—Å–ČŽÅ™Å›Čąî‚î‚˜Čą 5.7 N·m (51 in. lb.) ĮŊ Figure 10-35. Breather Assembly[...]

  • Page 117

    10.1 1 Section 10 Reassembly 10 ĮąČą ÂĒȱĞȱȱ ÂĒȱȱ ȱȱȱȱȱȱȱ ÂĒ ĮŊȱȱ¡ȱĞ?[...]

  • 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 Čą ŗĮŊČą ȱȱȱȱȱȱȱȱȱȱ ȱȱȱ?[...]

  • Page 119

    10.13 Section 10 Reassembly 10 Čą ŜĮŊČą ȱȱȱȱȱȱȱȱȱȱ ÂĒȱȱȱȱȱÂĒ ĮŊȱȱȱȱ ȱȱÂĒ?[...]

  • Page 120

    10.14 Section 10 Reassembly Čą ȱĮą Čą Čą ĮŊČą ȱȱȱȱȱȱȱȱ Čą ȱĮŊ Čą Čą ĮŊČą ÂĒ ÂĒȱȱĞȱȱȱȱ?[...]

  • Page 121

    10.15 Section 10 Reassembly 10 Figure 10-53. Establishing the "0" Lash Point. ŚĮŊČą ȱȱȱȱÄīȱȱȱȱĮ°Čą ȱȱĮŧĮžČąî‚î‚‘î‚ŽČąî‚Šî‚î‚“î‚žî‚œî‚î‚Žî‚›Čąî‚—î‚žî‚Čą four (4) complete re[...]

  • Page 122

    10.16 Section 10 Reassembly Spring Install Spark Plugs Čą ŗĮŊČą ȱȱ ÂŪ Čąî€šî€…Å—Å–î€›î€…ČąĮŧȱ ĮžČą ȱĮŊ Čą ŘĮŊČą ȱȱȱȱ 0.76 mm (0.030 in.) ĮŊ Čą řĮŊČą ȱȱ[...]

  • 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 Čą ŗĮŊČą ȱȱȱȱȱȱȱȱȱ ȱ?[...]

  • Page 124

    10.18 Section 10 Reassembly 1 2 Cylinder 1 Cylinder 2 3 4 ŘĮŊČą ȱȱȱȱȱȱÂĒȱĮŊČą ȱȱȱȱȱȱȱȱ ?[...]

  • Page 125

    10.19 Section 10 Reassembly 10 Figure 10-71. Installing Stator . śĮŊČą ȱȱȱȱȱȱȱȱȱÆļČą ȱȱȱȱȱȱȱȱȱ ȱ[...]

  • Page 126

    10.20 Section 10 Reassembly Figure 10-76. Clean and Dry Flywheel Hub. Figure 10-77. Installed Flywheel Key . ĮąČą ȱȱȱĚÂĒȱÂĒȱȱȱ ÂĒȱȱȱÂĒ ÂĒ ĮŊȱȱĚÂĒȱȱ [...]

  • Page 127

    10.21 Section 10 Reassembly 10 śĮŊČą ȱȱ 0.30 mm (0.012 in.) ȱĚȱȱȱ ȱȱȱȱȱȱĮŊČą î€•î‚Žî‚ŽČąî€ˆî‚’î‚î‚žî‚›î‚ŽČąÅ—Å–ČŽÅžÅ–ĮŊȱȱȱȱ?[...]

  • Page 128

    10.22 Section 10 Reassembly Install Oil Cooler ŗĮŊČą ȱȱȱȱȱȱ ȱȱȱ ęȱȱȱȱȱ ĮŊȱȱȱȱ [...]

  • Page 129

    10.23 Section 10 Reassembly 10 Čą řĮŊČą ȱȱȱȱȱĮŊȱȱȱ Å—Å–ČŽÅžÅžĮŊ Figure 10-88. Connecting Leads to Starting Motor . ,QVWDOO9 DOOH%DIÀHV Čą ŗĮŊČą ȱȱȱ ÂĒȱĝ?[...]

  • Page 130

    10.24 Section 10 Reassembly 1, 5 4 3 2 Mounting Screws Install Control Bracket and Air Cleaner Assembly Čą ŗĮŊČą  ȱȱȱȱÂĒȱȱ ȱȱȱȱĮ°Čąî‚Šî‚•î‚’?[...]

  • 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 ȱȱȱÄīČĶȱȱȱȱ ?[...]

  • Page 132

    10.26 Section 10 Reassembly Oil Pan Adjusting Governor Čą ŗĮŊČą  ȱȱȱȱȱȱȱȱ ȱȱȱÂĒȱȱȱȱȱȱ [...]

  • Page 133

    10.27 Section 10 Reassembly 10 Oil Fill T ube Lift Bracket Lower Mounting Screw Cylinder Shrouds Mounting Screws Čą ŘĮŊČą ȱȱȱȱȱȱȱȱÂĒ â„Ē ĮŊ Install Blower Housing and Cylinder Shrouds ŗĮŊČą [...]

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    10.28 Section 10 Reassembly Install Oil Filter and Add Oil to Crankcase Čą ŗĮŊČą ȱȱȱȱĮŊČąî€•î‚Žî‚ŽČąî€ˆî‚’î‚î‚žî‚›î‚ŽČąÅ—Å–ČŽÅ—Å–ÅŸĮŊČą  ȱȱȱȱ ŘŗĮŊÅšČąî€Č‰î‚–ČąĮŧŗśĮŊÅČąÄžĮŊȱĮŊĮž ĮŊ ĮąČą [...]

  • Page 135

    10.29 Section 10 Reassembly 10 T esting the Engine ȱȱȱȱȱȱȱȱȱȱ ȱȱȱȱȱȱȱȱȱȱ[...]

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    10.30[...]

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    [...]

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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[...]