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Kohler CV960 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 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[...]

  • 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 ¹V alues are in Metric units. V alues in parentheses are English equivalents. Lubricate threads with engine oil prior to assembly . *HQHUDO6SHFL¿FDWLRQVï 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 ................................................. ęȱȱŗŜǯşȱȉȱǻŗśŖȱ?[...]

  • Page 13

    1.9 Section 1 Safety and General Information 1 Ğȱȱȱȱǻȱȱ Ǽ 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 Ŷȱ ȱŗŗȱȱǻŖǯŚřřȱǯǼȱȱȱĴȱȱȱȱȱȱȱȱȱȱȱǯ 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¢ȱ ȱȱĞȱ¢ ǯ ȱ ȱȬŞŘŚŖś Ğȱȱ?[...]

  • Page 20

    2.2 Section 2 T ools & Aids T ools (Continued) Description Source/Part No. ¢ȱ ȱĞȱ   ȱȱȱȱ¢ȱĞǯ ȱŘśȱŝŜŗȱřŞȬ ȱ¢[...]

  • Page 21

    2.3 Section 2 T ools & Aids 2 Aids Description Source/Part No. Ğȱ ȱǻ ȱŜŗřǼ ȱŘśȱřśŝȱŗŚȬ ȱ ȱǻȦ ȱŜŜŗǼ ȱŘśȱřśŝȱŗŗȬ?[...]

  • Page 22

    2.4 Section 2 T ools & Aids Special T ools Y ou Can Make Flywheel Holding T ool  ȱĚ¢ȱȱȱȱȱȱȱȱȱȱ ȱĚ¢ȱȱȱȱȱȱȱŘȬŗǰȱ?[...]

  • Page 23

    3.1 3 Section 3 T roubleshooting T roubleshooting Guide When troubles occur , be sure to check the simple ȱǰȱȱęǰȱ¢ȱȱȱȱȱȱ considered. For example, a starting problem could be ȱ¢ȱȱ¢ȱ[...]

  • Page 24

    3.2 Section 3 T roubleshooting Engine Overheats ȱ ŗǯȱ ȱȦȱǰȱȱęǰȱȱȱ shrouds clogged. ȱ Řǯȱ ¡ȱȱǯ ȱ řǯȱ 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¢ȱǯ 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 ǰȱĴ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ǯȱȱ¢ ǰȱȱȱȱ 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¡¢ȱĚ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¢ȱȱȱȱǰȱȱ?[...]

  • 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 ¢ ǯȱȱȱśȬŗȱ?[...]

  • 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 ȱȱȱȱȱȱęȱȱǰȱ?[...]

  • Page 33

    5.5 Section 5 Fuel System and Governor 5 Fuel Shut-Off Solenoid High Altitude Operation ȱȱȱȱȱȱȱŗśŖŖȱȱ ǻśŖŖŖȱĞǯǼȱȱǰȱȱȱ¡ȱȱȱ?[...]

  • 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 ȱȱȱȱȱ¢ȱ Ğȱȱȱȱ[...]

  • Page 35

    5.7 Section 5 Fuel System and Governor 5 Governed Idle System  ȱ ȱȱȱ¢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. ȱ Ŝǯȱ 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 . DZȱ ȱ¢ȱȱȱȱȱ is not necessary unless the Fuel Solenoid Kit, or Fuel Bowl Kit (obtained separately), will also be installed. ȱȱ Řǯȱ ?[...]

  • Page 39

    5.1 1 Section 5 Fuel System and Governor 5 śǯȱ ȱȱȱȱǻǼȱȱȱ and spring from the carburetor . Discard the parts. DZȱ ȱȱȱȱȱ?[...]

  • Page 40

    5.12 Section 5 Fuel System and Governor Figure 5-26. Installing Float Assembly . ŗŚǯȱ ȱȱȱ¢ȱȱȱĚȱ¢ȱ 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 śǯȱ ȱȱȱ¡ȱǻ¢ȬǼȱȱȱȱ ȱȱĞȱȱȱȱȱȱ lever from the carburetor housing. S[...]

  • Page 42

    5.14 Section 5 Fuel System and Governor ȱŗŘǯȱ ȬȱǻȱȱȬȱǼ 13. Drain Screw 14. Bowl Screw (4) ȱŗśǯȱ ȱ ȱŗŜǯȱ ȱ  17. Float 18. Pin 19. Screw ȱŘŖǯȱ ȱ ȱŘŗǯȱ [...]

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

  • Page 47

    6.3 Section 6 Lubrication System 6 ȱ řǯȱ ȱȱȱȱȱȱȱ 21.4 N·m ǻŗśǯŝȱĞǯȱǯǼ . ȱ Śǯȱ ȱȱǰȱȱȱȱȱȱȱ ¢[...]

  • Page 48

    6.4 Section 6 Lubrication System Pressure Switch Service Oil Cooler ȱȱȱȱȱȱȱȱ ȱȱȱǯȱŘȱȱ¢ȱǰȱ [...]

  • Page 49

    6.5 Section 6 Lubrication System 6 Installation ȱȱ¢Ȝȱȱȱȱȱȱȱ ȱȱȱǯȱȱȱŜȬŗŘǯȱ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: • Spark Plugs ȱ Ȋȱ Ĵ¢ȱȱȱ¢ • Electric Starter ȱ Ȋȱ ?[...]

  • Page 52

    7.2 Section 7 Electrical System and Components DZ ȱ  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  ȱŗŘȬ ȱĴ¢ȱȱŚŖŖȱȱȱȱǻǼȱȱ generally recommended for starting in all conditions.  ȱȱ¢ȱĴ?[...]

  • Page 54

    7.4 Section 7 Electrical System and Components Molex Plug (Some Models) ȱȱȱěȱ¢ȱȱȱ¢ȱȱȱǯȱ ȱ¢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 ǯȱ ȱȱȱȱǰȱȱȱ¢ȱ ȱȱȱȱǯȱȱȱ¢ȱǰȱ wires, connections, safety interlocks, [...]

  • Page 57

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

  • Page 58

    7.8 Section 7 Electrical System and Components ȱ Řǯȱ ȱȱȱ ǰȱȱȱȱ ȱśśŖȬŜŖŖȱǰȱȱȱǻǼȱȱǯ ȱ řǯȱ 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¢ǯȱȱȱŝȬşȱȱŝȬŗřǯȱ DZȱ 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 ȱĚ¢ǯȱȱȱȱȱȱŞȱȬȱ ȃ?[...]

  • Page 64

    7.14 Section 7 Electrical System and Components śǯȱ ȱȱȱȱȱȱ ȱȦȱ ȱȱȱǯȱ ȱȱȱȱǯȱ 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Ĵ¢ȱȱȱȱĴ¢ȱȱȱȱȱȱ?[...]

  • Page 66

    7.16 Section 7 Electrical System and Components DC V oltmeter 5HFWL¿HU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'LI¿FXOWLHV Delco-Remy Starters Figure 7-21. Delco-Remy Starter . Starter Disassembly ȱ ŗǯȱ ȱȱ¡ȱȱȱȱȱ ȱ ǻ?[...]

  • Page 68

    7.18 Section 7 Electrical System and Components Figure 7-23. Solenoid Removed from Starter . Figure 7-24. Removing Plunger . ȱ Śǯȱ ȱȱ ȱȱǻǼȱǯȱȱȱ ŝȬŘśǯ Figure 7-25. Removing Thru Bolts. ȱ śǯȱ 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 ȱ Şǯȱ  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DZ ǯȱ 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ȱǻŚǼǯȱȱ ȱȱȱȱȱȱǰȱȱ?[...]

  • Page 72

    7.22 Section 7 Electrical System and Components řǯȱ ȱȱěȱȱǻǼȱ ȱȱȱ ȱȃěȄȱȱȱ ȱȱȱȦ  ǯȱ?[...]

  • Page 73

    7.23 Section 7 Electrical System and Components 7 Figure 7-43. Installing Thrust W asher . ȱ ŗŖǯȱ ȱ¢ȱȱ  ȱȱȦ ȱȱ ¢DZ ǯȱ ȱȱ?[...]

  • Page 74

    7.24 Section 7 Electrical System and Components Extension. ǯȱ ȱȱȱ¢ȱ¢ȱȱȱ end housing, and carefully place the tool ǻȱ¡Ǽȱȱȱȱ ?[...]

  • 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. ȱȱȱȱȱȱȱȱ¡Řȱǰȱȱ connect the two ohmmeter leads to the tw o large post ǯȱ ?[...]

  • 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DZȱŗǼȱȱȱȱȱ?[...]

  • Page 78

    8.2 Section 8 Disassembly Cylinder Shroud Shut Off Fuel Supply Drain Oil from Crankcase and Remove Oil Filter ȱ ŗǯȱ ȱȱȱęȱȱȱǯȱȱȱ ȱȱȱę ǯȱ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ǯ Figure 8-7. Removing Oil Fill T ube. Remove Electric Starter Motor 1. Disconnect the leads from the starter . ȱ Řǯȱ ȱȱ ȱ¡ȱĚ[...]

  • Page 80

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

  • Page 81

    8.5 Section 8 Disassembly 8 Figure 8-15. Removing Control Bracket. ȱ Ŝǯȱ ȱȱ¡ȱĚȱȱȱȱȱ ȱ ȱȱȱĞǯȱȱȱŞȬŗŜǯ 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¢ȱĝȱȱǯȱ?[...]

  • Page 83

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

  • Page 84

    8.8 Section 8 Disassembly Remove Grass Screen and Cooling Fan ȱ ŗǯȱ ȱȱǰȱĴȱ ǰȱȱ¡ȱ ȱȱȱȱǰȱěǰȱȱ ?[...]

  • Page 85

    8.9 Section 8 Disassembly 8 Wiring Harness Molded Clips 2. Remov e the mounting screws securing the ęȬȱȱȱȱȱ assembly . Note the location of the ground lead. ȱȱęȬ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¢ȱȱěǯȱȱȱŞȬřŞǯ 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 ȱŞȬŚŚǯ 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 ¢ȂȂ ȱȱȱşǯ Remove Camshaft ȱ ŗǯȱ ȱ[...]

  • Page 90

    8.14 Section 8 Disassembly 2. Carefully remov e the connecting rod and piston ¢ȱȱȱ¢ȱǯȱȱȱŞȬśŜǯ 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 ȱ ŗǯȱ ȱȱȱȱȱȱĞȱȱ chamber cover , and gaskets. Carefully separate ȱȱȱȱǯ[...]

  • 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 ŜŖȱȱȱǯȱ 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. ȱ řǯȱ ȬȬ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¢ȱ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¢ ȱęǰȱȱȱ 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. ȱ ŗǯȱ ȱȱȱǻĴȱǼDZȱȱȱ 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 ǻȱȱȱŗǰȱ?[...]

  • 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 ǰȱȱ ǰȱȱǯȱȱȱȱ ę[...]

  • Page 108

    10.2 Section 10 Reassembly ȱ Řǯȱ ¢ȱȱȱȱȱȱȱȱȱȱ ȱȱȱȱȱǯ ȱ řǯȱ 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ǰȱǰȱȦȱ?[...]

  • Page 110

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

  • Page 111

    10.5 Section 10 Reassembly 10 No. 1 Side No. 2 Side Install Connecting Rods with Pistons and Rings DZȱ ȱ¢ȱȱȱ ȱȱǯȱ ȱȱȱȱȱǰȱ?[...]

  • Page 112

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

  • Page 113

    10.7 Section 10 Reassembly 10 Oil Seal 3 mm (0.1 18 in.) ȱ śǯȱ ȱȱȱ¢ȱȱȱȱȱ ȱȱ¢ ǯ 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 ŗǯȱ ȱȱȱȱȱȱȱȱȱȱ ȱȱǰȱ¢ ǰȱȱȱȱ?[...]

  • Page 115

    10.9 Section 10 Reassembly 10 Crankcase Filter Breather Hose Flange Nuts (4) Gasket Check Crankshaft End play ȱ ŗǯȱ ȱȱȱȱǰȱȱȱȱȱȱ ȱȱȱĞȱȱ¢ȱ?[...]

  • Page 116

    10.10 Section 10 Reassembly 1 3 4 2 ȱ řǯȱ ȱȱȱ¡ȱĚȱǰȱȱȱ ȱȱȱȱȱȱŗŖȬřśȱȱ 5.7 N·m (51 in. lb.) ǯ Figure 10-35. Breather Assembly[...]

  • Page 117

    10.1 1 Section 10 Reassembly 10 DZȱ ¢ȱĞȱȱ ¢ȱȱ ȱȱȱȱȱȱȱ ¢ ǯȱ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 ȱ ŗǯȱ ȱȱȱȱȱȱȱȱȱȱ ȱȱȱ?[...]

  • Page 119

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

  • Page 120

    10.14 Section 10 Reassembly ȱ ȱDZ ȱ ȱ ǯȱ ȱȱȱȱȱȱȱȱ ȱ ȱǯ ȱ ȱ ǯȱ ¢ ¢ȱȱĞȱȱȱȱ?[...]

  • Page 121

    10.15 Section 10 Reassembly 10 Figure 10-53. Establishing the "0" Lash Point. Śǯȱ ȱȱȱȱĴȱȱȱȱǰȱ ȱȱǻǼȱȱȱȱ four (4) complete re[...]

  • Page 122

    10.16 Section 10 Reassembly Spring Install Spark Plugs ȱ ŗǯȱ ȱȱ ® ȱŗŖȱǻȱ Ǽȱ ȱǯ ȱ Řǯȱ ȱȱȱȱ 0.76 mm (0.030 in.) ǯ ȱ řǯȱ 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 ȱ ŗǯȱ 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 Řǯȱ ȱȱȱȱȱȱ¢ȱǯȱ ȱȱȱȱȱȱȱȱ ?[...]

  • Page 125

    10.19 Section 10 Reassembly 10 Figure 10-71. Installing Stator . śǯȱ ȱȱȱȱȱȱȱȱȱƸȱ 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 . DZȱ ȱȱȱĚ¢ȱ¢ȱȱȱ ¢ȱȱȱ¢ ¢ ǯȱȱĚ¢ȱȱ [...]

  • Page 127

    10.21 Section 10 Reassembly 10 śǯȱ ȱȱ 0.30 mm (0.012 in.) ȱĚȱȱȱ ȱȱȱȱȱȱǯȱ ȱȱŗŖȬŞŖǯȱȱȱȱ?[...]

  • Page 128

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

  • Page 129

    10.23 Section 10 Reassembly 10 ȱ řǯȱ ȱȱȱȱȱǯȱȱȱ ŗŖȬŞŞǯ Figure 10-88. Connecting Leads to Starting Motor . ,QVWDOO9 DOOH%DIÀHV ȱ ŗǯȱ ȱȱȱ ¢ȱĝ?[...]

  • Page 130

    10.24 Section 10 Reassembly 1, 5 4 3 2 Mounting Screws Install Control Bracket and Air Cleaner Assembly ȱ ŗǯȱ  ȱȱȱȱ¢ȱȱ ȱȱȱȱǰȱ?[...]

  • 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ĴȦȱȱȱȱ ?[...]

  • Page 132

    10.26 Section 10 Reassembly Oil Pan Adjusting Governor ȱ ŗǯȱ  ȱȱȱȱȱȱȱȱ ȱȱȱ¢ȱ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 ȱ Řǯȱ ȱȱȱȱȱȱȱȱ¢ ™ ǯ Install Blower Housing and Cylinder Shrouds ŗǯȱ [...]

  • Page 134

    10.28 Section 10 Reassembly Install Oil Filter and Add Oil to Crankcase ȱ ŗǯȱ ȱȱȱȱǯȱȱȱŗŖȬŗŖşǯȱ  ȱȱȱȱ ŘŗǯŚȱȉȱǻŗśǯŝȱĞǯȱǯǼ ǯ DZȱ [...]

  • 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[...]

  • Page 136

    10.30[...]

  • Page 137

    [...]

  • Page 138

    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[...]