Kohler COMMAND CH18 Service Manual Download Page 19 | Manualshive

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2.1

Section 2

Tools & Aids

2

Section 2

Tools & Aids

Certain quality tools are designed to help you perform specific disassembly, repair, and reassembly procedures.
By using tools designed for the job, you can properly service engines easier, faster, and safer! In addition, you’ll
increase your service capabilities and customer satisfaction by decreasing engine downtime.

Here is the list of tools and their source.

Separate Tool Suppliers:

Kohler Tools
Contact your source
of supply.

SE Tools
415 Howard St.
Lapeer, MI 48446
Phone 810-664-2981
Toll Free 800-664-2981
Fax 810-664-8181

Design Technology Inc.
768 Burr Oak Drive
Westmont, IL 60559
Phone 630-920-1300

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Summary of Contents for COMMAND CH18

Page 1: ...SERVICE MANUAL HORIZONTAL CRANKSHAFT COMMAND CH18 750...

Page 2: ...on 5 Fuel System and Governor Section 5A LPG Fuel Systems Section 5B Electronic Fuel Injection EFI Fuel System Section 6 Lubrication System Section 7 Retractable Starter Section 8 Electrical System an...

Page 3: ...s should be followed at all times Failure to follow these precautions could result in injury to yourself and others Rotating Parts can cause severe injury Stay away while engine is in operation WARNIN...

Page 4: ...ther sources of ignition away from the battery at all times Keep batteries out of the reach of children Remove all jewelry when servicing batteries Before disconnecting the negative ground cable make...

Page 5: ...ariation of Basic Engine B Spec No 62500 Command Engine Horizontal Crankshaft Horsepower 17 17 HP 18 18 HP 20 20 HP 22 22 HP 23 23 HP 25 25 HP 26 26 HP Numerical Designation 730 740 745 750 or Engine...

Page 6: ...oline Do not overfill the fuel tank Leave room for the fuel to expand Fuel Type For best results use only clean fresh unleaded gasoline with a pump sticker octane rating of 87 or higher In countries u...

Page 7: ...e tablespoon of engine oil into each spark plug hole Install the spark plugs but do not connect the plug leads Crank the engine two or three revolutions 5 On equipment with an EFI engine disconnect th...

Page 8: ...1 6 Section 1 Safety and General Information Figure 1 4 Typical Engine Dimensions CH Series with Standard Flat Air Cleaner Dimensions in millimeters Inch equivalents shown in...

Page 9: ...1 7 Section 1 Safety and General Information 1 Figure 1 5 Typical Engine Dimensions CH EFI Series with Heavy Duty Air Cleaner Dimensions in millimeters Inch equivalents shown in...

Page 10: ...00 RPM 57 3 N m 42 3 ft lb CH745 2600 RPM 57 9 N m 42 7 ft lb CH750 2400 RPM 64 4 N m 47 5 ft lb Bore CH18 CH20 CH22 624 cc 77 mm 3 03 in CH22 23 674 cc 80 mm 3 15 in CH25 CH26 CH730 750 83 mm 3 27 in...

Page 11: ...anifold Intake Manifold Mounting Fastener Torque Torque in Two Stages first to 7 4 N m 66 in lb finally to 9 9 N m 88 in lb Carburetor Mounting Screw Torque M6 6 2 7 3 N m 55 65 in lb Adapter for Heav...

Page 12: ...003 mm 1 6128 1 6143 in Max Wear Limit 41 016 mm 1 6148 in Crankshaft to Sleeve Bearing Crankcase Running Clearance New 0 03 0 09 mm 0 0012 0 0035 in Crankshaft Bore In Closure Plate New 40 987 40 974...

Page 13: ...to 16 9 N m 150 in lb finally to 33 9 N m 300 in lb Head Bolt Torque in Two Stages first to 22 6 N m 200 in lb finally to 41 8 N m 370 in lb Max Out of Flatness 0 076 mm 0 003 in Rocker Arm Screw Tor...

Page 14: ...rance 0 006 0 017 mm 0 0002 0 0007 in Piston Pin Bore I D New 17 006 17 012 mm 0 6695 0 6698 in Max Wear Limit 17 025 mm 0 6703 in Piston Pin O D New 16 995 17 000 mm 0 6691 0 6693 in Max Wear Limit 1...

Page 15: ...831 mm 3 1430 in Max Wear Limit CH25 CH26 CH730 750 82 841 mm 3 2614 in Piston Thrust Face to Cylinder Bore Running Clearance New CH18 CH20 CH22 624 cc 0 014 0 057 mm 0 0005 0 0022 in New CH22 23 674...

Page 16: ...0241 0 0501 mm 0 0009 0 0020 in Intake Valve Stem to Valve Guide Running Clearance 0 038 0 076 mm 0 0015 0 0030 in Exhaust Valve Stem to Valve Guide Running Clearance 0 050 0 088 mm 0 0020 0 0035 in I...

Page 17: ...124 16 5 146 6 8 60 M8 10 5 93 13 6 120 24 4 216 33 9 300 40 7 360 17 0 150 Tightening Torque N m ft lb or 10 Property Class Noncritical Fasteners Into Aluminum M10 21 7 16 27 1 20 47 5 35 66 4 49 81...

Page 18: ...7 8 50 3 8 24 54 2 40 81 4 60 7 16 14 47 5 35 74 6 55 108 5 80 7 16 20 61 0 45 101 7 75 142 4 105 1 2 13 67 8 50 108 5 80 155 9 115 1 2 20 94 9 70 142 4 105 223 7 165 9 16 12 101 7 75 169 5 125 237 3...

Page 19: ...n E t f a h s m a C y a l p d n e t f a h s m a c g n i k c e h c r o F 5 0 4 2 8 R L K s l o o T E S r e t s e T n w o d k a e L r e d n i l y C n r o w e r a s e v l a v r o s g n i r n o t s i p r...

Page 20: ...o n h c e T n g i s e D 1 3 0 I T D 3 3 0 I T D r e t s e T M A S e l u d o M e c n a v d A k r a p S K R A P S T R A M S h t i w s e n i g n e n o M A S D d n a M A S A M A S e h t t s e t o T S 0 4...

Page 21: ...e l E t f i h S d i o n e l o S S 2 0 7 5 3 2 5 r e l h o K t n a l a e S e n o c i l i S V T R e t i t c o L r e s n e p s i d l o s o r e a z o 4 n i y d o B y v a e H 0 0 9 5 e s u r o f d e v o r...

Page 22: ...ng or removing with a puller Figure 2 1 Flywheel Holding Tool Rocker Arm Crankshaft Tool A spanner wrench to lift the rocker arms or turn the crankshaft may be made out of an old junk connecting rod 1...

Page 23: ...choke or throttle controls 4 Loose wires or connections that short the kill terminal of ignition module to ground 5 Faulty cylinder head gasket 6 Faulty carburetor 7 Vacuum fuel pump malfunction or oi...

Page 24: ...Worn valve stems valve guides 7 Crankcase overfilled 8 Blown head gasket overheated Oil Leaks from Oil Seals Gaskets 1 Crankcase breather is clogged or inoperative 2 Breather reed broken 3 Loose or im...

Page 25: ...at oil seals gaskets or other available spots Crankcase vacuum is best measured with either a water manometer or a vacuum gauge see Section 2 Complete instructions are provided in the kits To test th...

Page 26: ...ket on the flywheel nut screw to hold it in position An assistant may be needed to hold the breaker bar during testing If the engine is mounted in a piece of equipment it may be possible to hold it by...

Page 27: ...ping from carburetor Defective intake valve improper seating Gauge reading in low green zone Piston rings and cylinder in good condition Gauge reading in moderate yellow zone Engine is still usable bu...

Page 28: ...the air cleaner daily or before starting the engine Check for and correct any buildup of dirt and debris along with loose or damaged components NOTE Operating the engine with loose or damaged air cle...

Page 29: ...rd Type Every 100 hours of operation more often under extremely dusty or dirty conditions replace the paper element Follow these steps 1 Unhook the latches or loosen the retaining knob and remove the...

Page 30: ...cleaner element cover and wing nut 7 Reinstall the air cleaner cover and secure with the latches or the retaining knob NOTE Make sure the correct depth air cleaner element and rubber seal are used for...

Page 31: ...res 4 9 and 4 10 Remove the bracket 3 Pinch the sealing collar on the breather hose and push it down through the hole in the air cleaner base Carefully feed the upper section of the breather tube down...

Page 32: ...4 12 Removal 1 Remove the upper valve cover screws on each side securing the main bracket and loosen the hose clamp on the adapter inlet or remove the adapter mounting screws 2 Lift the entire air cl...

Page 33: ...onditions remove the blower housing and other cooling shrouds Clean the cooling fins and external surfaces as necessary Make sure the cooling shrouds are reinstalled Figure 4 15 Cleanout Kit Installed...

Page 34: ...r and fuel lines by the fuel pump On engines not equipped with a fuel pump the fuel tank outlet is located above the carburetor inlet allowing gravity to feed fuel to the carburetor Fuel then enters t...

Page 35: ...cation number beginning with 6 or greater See Figure 5 1 must use Low Permeation SAE 30 R7 rated fuel line certified to meet CARB requirements Standard fuel line may not be used Order replacement hose...

Page 36: ...chamber If there is no fuel at the tip of the spark plug check for fuel flow from the fuel tank Test 3 3 Check for fuel flow from the tank to the fuel pump a Remove the fuel line from the inlet fittin...

Page 37: ...ure at 0 3 psi and a fuel lift of 18 in from carburetor inlet A 1 3 L hr 0 34 gal hr fuel rate must be maintained at 5 Hz Fuel Pump Replacement Replacing the Pulse Fuel Pump Replacement pumps are avai...

Page 38: ...lls at idle speed 2 Engine runs rich indicated by black sooty exhaust smoke misfiring loss of speed and power governor hunting or excessive throttle opening 2a Clogged air cleaner Clean or replace b C...

Page 39: ...a new main jet slow jet where applicable necessary gaskets and O Rings Refer to the parts manual for the correct kit number Fuel Shut off Solenoid Most carburetors are equipped with a fuel shut off so...

Page 40: ...on Refer to the equipment manufacturer s recommendations The low idle speed for basic engines is 1200 RPM To ensure best results when setting the low idle fuel needle the low idle speed should be 1200...

Page 41: ...ne to return to the governed idle speed Check it with a tachometer against the equipment manufacturers recommended idle speed Governed Idle Speed RPM is typically 300 RPM approximate higher than the l...

Page 42: ...the off idle vent ports and bowl vent thoroughly use a good carburetor solvent like Gumout Blow clean compressed air through the idle adjusting needle hole Be careful to use a suitable shop rag to pre...

Page 43: ...or Make sure jet is fully seated 3 Install the low idle adjusting needle and spring 4 Assemble the upper body onto the lower carburetor body using the four screws Torque the screws to 1 7 N m 15 in lb...

Page 44: ...mount of air is drawn through the slow air bleed jets fuel is drawn through the two main jets and further metered through the slow jets Air and fuel are mixed in the body of the slow jet and exit to t...

Page 45: ...m is supplied on some engines The purpose of this system is to maintain a desired idle speed regardless of ambient conditions temperature parasitic load etc that may change Engines with this feature c...

Page 46: ...16 1 Make any necessary speed or control adjustments following the appropriate instructions covered in this section 2 Move the throttle control to the idle position Hold the governor lever away from t...

Page 47: ...ve the float pin screw and lift out the old float pin and inlet needle See Figure 5 17 Discard all of the parts The seat for the inlet needle is not serviceable and should not be removed Figure 5 19 I...

Page 48: ...the jets by location for proper reassembly The main jets may be size side specific After the main jets are removed the main nozzles can be removed out through the bottom of the main towers Note the o...

Page 49: ...main jets Make sure the nozzles are completely bottomed Carefully install the main jets into the towers of the carburetor body on the appropriate side as identified when removal was performed See Figu...

Page 50: ...justment NOTE The inlet needle center pin is spring loaded Make sure the float rests against the fuel inlet needle without depressing the center pin 15 The correct float height setting is 17 mm 0 669...

Page 51: ...the self relieving choke mechanism thoroughly 3 Remove and discard the plastic cap from the end of the choke lever shaft assembly 4 Note the position of the spring legs and the choke plate for correct...

Page 52: ...n tighten the screws securely Do not overtighten See Figure 5 37 9 Install the new return spring onto the new choke shaft so the upper leg of the spring is between the two formed stops on the end of t...

Page 53: ...6 Retaining Washer 7 Slow Jet RH Side 8 Slow Jet LH Side 9 O Ring Slow Jet 2 10 Fuel Bowl 11 O Ring Fuel Bowl Upper 12 O Ring Fuel Bowl Lower 13 Drain Screw 14 Bowl Screw 4 15 Fuel Solenoid 16 Sealing...

Page 54: ...ng governor gear assembly causes the flyweights to move outward as speed increases Governor spring tension moves them inward as speed decreases When load is applied and the engine speed and governor g...

Page 55: ...vity See Figure 5 40 and adjust as follows 1 To increase the sensitivity move the spring closer to the governor cross shaft 2 To decrease the sensitivity move the spring away from the governor cross s...

Page 56: ...er or a single pole single throw SPST switch Potentiometer Specifications 1860 low speed endpoint variable speed endpoint 3600 high speed endpoint Wiper Voltage 0 1 1 9 9 16 Engine Speed RPM 1860 low...

Page 57: ...upplied key switch in the start or run position 3 Test the potentiometer wiper output voltage if equipped 4 Test the SPST switch if equipped 5 Check the wire harness and connections Engine does not ru...

Page 58: ...nd special equipment Many states require special licensing or certification for LPG repair shops and or technicians Check state and local regulations before attempting any adjustment service or repair...

Page 59: ...pening electrically preventing fuel flow to vaporizer 3 Fuel filter located inside lock off dirty or blocked 4 Insufficient vacuum signal regulator not opening a Vacuum line between carburetor and reg...

Page 60: ...Check lines connections and system components for leaks with soapy water Fix any leaks immediately 2 Incorrectly set regulator or leakage from valves in regulator Readjust service or replace regulator...

Page 61: ...en or alter the mounted position of the clamping brackets and or stop collar on the throttle shaft Each is preset in correlation to a specific position of the throttle plate shaft or acts as a stop No...

Page 62: ...ving the three screws See Figure 5A 3 Carefully remove the cover and gasket Discard the gasket 4 The main jet is fixed and nonadjustable but may be accessed for cleaning by removing the rear plug and...

Page 63: ...sition of each before proceeding Follow the complete instructions listed after step 7 then continue with steps 6 and 7 6 Manually move the governor lever toward the carburetor as far as it will go 7 C...

Page 64: ...without binding or restriction Throttle Linkage Clamp Bracket Position Carburetor must be assembled to engine with linkage attached to set this position 1 The throttle linkage clamp bracket should be...

Page 65: ...he carburetor and new air cleaner base gasket 4 Reconnect the throttle and choke linkages and the fuel and vacuum lines 5 Reinstall the air cleaner base and breather tube Secure base with two mounting...

Page 66: ...e and flow of fuel within the LP system It is comprised of both a primary and secondary chamber which are dependent upon one another Two different styles of regulators are used based upon the system i...

Page 67: ...ting adjustment is made with a tamper resistant screw 17 which regulates the whisker wire system not shown opening up the secondary orifice slightly but only when the vacuum diaphragm is drawn down Ve...

Page 68: ...e between the secondary valve 11 and the valve seat 12 While the engine is operating and fuel is being drawn from the secondary chamber the secondary diaphragm 14 is raised by atmospheric pressure sim...

Page 69: ...any accumulated deposits See Figure 5A 23 4 Reinstall plug using pipe sealant with Teflon Loctite 592 or equivalent on threads and tighten securely If required a replacement plug is available as Kohle...

Page 70: ...en Sensor 5B 11 5B 13 Electrical Relay 5B 13 5B 14 Fuel Injectors 5B 14 5B 17 Ignition System 5B 17 5B 18 Spark Plugs 5B 18 Wiring Harness 5B 18 5B 19 Battery Charging System 5B 19 Fuel Components Fue...

Page 71: ...e fuel pump will run for about three seconds and stop Turn the switch off and back on to restart the fuel pump Repeat this procedure until the fuel pump has cycled five times then start the engine 3 T...

Page 72: ...controlled injection of the fuel occurs each crankshaft revolution or twice for each 4 stroke cycle One half the total amount of fuel needed for one firing of a cylinder is injected during each injec...

Page 73: ...nstallation Avoid direct water or spray contact with system components Do not disconnect or reconnect the wiring harness connector to the control unit or any individual components with the ignition on...

Page 74: ...de in its fault memory and goes into a default operating mode Depending on the significance or severity of the fault normal operation may continue or limp home operation slowed speed richer running ma...

Page 75: ...or problems 3 Make sure the engine has resistor type spark plugs 4 Disconnect main harness connector from ECU 5 Connect an ohmmeter between the designated pin terminals in the plug 35 Pin MA 1 7 Metal...

Page 76: ...Counting the number of turns back out the idle speed adjusting screw counterclockwise until the throttle plates can be closed completely 2 Disconnect the main harness connector from the ECU but leave...

Page 77: ...etc 3 Start the engine and allow it to warm up for 5 10 minutes so oil temperature is above 55 C 130 F 4 Move the throttle control to the idle position and allow engine to stabilize for a minimum of...

Page 78: ...nctionally within specifications Important 2 Remove disconnect ALL external loads from the engine belts pumps electric PTO clutch alternator rectifier regulator etc 3 Locate the service connector plug...

Page 79: ...ng harness 6 Run the engine at full throttle above 3000 RPM to warm up the engine and initiate O2 sensor function in closed loop operation 7 Watch the MIL When the light starts blinking rapidly 5 blin...

Page 80: ...pin terminals 5 Unplug the sensor connector and check sensor resistance separately Resistance value should again be 2375 2625 a If the resistance is out of specifications replace the temperature sens...

Page 81: ...ouch the black lead at various points backtracking from the engine ground back toward the sensor watching for a voltage change at each location If the correct voltage reading reappears at some point c...

Page 82: ...compound sparingly to threads of new oxygen sensor if none already exists DO NOT get any on the tip as it will contaminate the sensor Install sensor and torque to 50 60 N m 37 44 ft lb 4 Reconnect the...

Page 83: ...be present a No voltage present indicates a problem in the wiring or at the connector b If voltage is present the wiring to the connector is good Turn ignition switch off and proceed to test 5 to tes...

Page 84: ...d closed once for each crankshaft revolution however only one half the total amount of fuel needed for one firing is injected during each opening The amount of fuel injected is controlled by the ECU a...

Page 85: ...or and injector terminals are making a good connection If the resistance is not correct replace the injector following steps 1 8 and 13 16 below b If no flashing occurs reattach connectors to both inj...

Page 86: ...ors the high fuel pressure and the detergent additives in the gasoline Symptoms that could be caused by dirty clogged injectors include rough idle hesitation stumble during acceleration or triggering...

Page 87: ...5B 31 32 Pin MSE 1 1 Plastic Cased ECU Locate pins 30 and 31 in the 32 pin connector See page 5B 32 2 Disconnect connector from relay and locate terminal 87 in connector 3 Using an ohmmeter set on th...

Page 88: ...nk style pumps will have a pre filter attached to the inlet In line pump systems may also have a filter ahead of the pump on the pick up low pressure side The final filter is covered separately on pag...

Page 89: ...off and connect an ohmmeter between the terminals on the pump to check for continuity a If there was no continuity between the pump terminals replace the fuel pump b If the voltage was below 7 test th...

Page 90: ...holder Internal In Tank Regulator Remove the three screws securing the retaining ring and regulator in the base holder assembly Grasp and pull the regulator out of the base holder See Figure 5B 31 Ou...

Page 91: ...l cleaning or replacement Fuel Line Figure 5B 32 In Line Fuel Filter Service Fuel filter replacement is recommended every 1500 hours of operation or more frequently under extremely dusty or dirty cond...

Page 92: ...he end of the idle speed screw of some EFI engines to help stabilize no load operating speeds See Figure 5B 36 Figure 5B 35 Upper Intake Manifold General The EFI engines have no carburetor so the thro...

Page 93: ...039 0 117 in of the spring extending beyond the end of the idle speed screw 2 Secure spring onto the screw with a small amount of Permabond LM 737 or equivalent Loctite adhesive Do not get any adhesi...

Page 94: ...ready installed position the governor lever on the cross shaft but leave the clamping screw loose Feeler Gauge Figure 5B 40 Throttle Link in Center of Hole Figure 5B 41 Checking Split of Clamp 2 Follo...

Page 95: ...not running 2 Faulty spark plugs 3 Old stale fuel 4 Incorrect fuel pressure 5 Speed sensor loose or faulty 6 TPS offset incorrect initialization 7 TPS faulty 8 Engine temperature sensor faulty 9 Fault...

Page 96: ...sed in system operation Cleaning the connectors and grounds will solve problems in many cases In an emergency situation simply disconnecting and reconnecting the connectors may clean up the contacts e...

Page 97: ...Sensor Not Used Oil Temperature Sensor Not Used ECU Permanent Battery Voltage ECU Switched Battery Voltage Engine Ground Ignition Coil 2 Vehicle Ground Engine Speed Sensor Not Used Not Used Not Used...

Page 98: ......

Page 99: ......

Page 100: ...Temperature Sensor Input Not Used Throttle Position Sensor TPS Input Speed Sensor Input Speed Sensor Ground Oxygen Sensor Input Not Used Oxygen Sensor Ground if needed Diagnostic Line Throttle Positio...

Page 101: ...ature Sensor Input Not Used Throttle Position Sensor TPS Input Speed Sensor Input Speed Sensor Ground Not Used Not Used Not Used Injector 1 Output Injector 2 Output Not Used Diagnostic Line Throttle P...

Page 102: ......

Page 103: ...l line connections are good 6 Test fuel pump and relay operation as described earlier under Fuel Pump Service Fault Codes The ECU continuously monitors engine operation against preset performance limi...

Page 104: ...the chart is a list of the individual codes with an explanation of what triggers them what symptoms might be expected and the probable causes Diagnostic Code Summary Example of Diagnostic Display Lon...

Page 105: ...A N Y 1 5 0 6 2 1 P t i u c r i C n e p O 1 r o t c e j n I A N A N Y 1 5 1 6 2 0 P d n u o r G o t t i u c r i C t r o h S 1 r o t c e j n I A N A N Y 1 5 2 6 2 0 P y r e t t a B o t t i u c r i C t...

Page 106: ...r not properly grounded c Poor or improper grounds in system battery ECU oxygen sensor shielding fuel pump ignition output d Pin circuits 9 and or 10 routed near noisy electrical signals coils spark p...

Page 107: ...n MSE 1 0 Plastic Cased ECU Pin s 9 and or 10 for 32 Pin MSE 1 1 Plastic Cased ECU 4 ECU Harness Related a ECU to harness connection problem Code 31 Source Fuel Mixture or Oxygen Sensor Explanation Sy...

Page 108: ...nectors Pin 10 for 35 Pin MA 1 7 Metal Cased ECU Pin 11 for 24 Pin MSE 1 0 Plastic Cased ECU Pin 20 for 32 Pin MSE 1 1 Plastic Cased ECU 3 TPS Sensor Related a Throttle plate position incorrectly set...

Page 109: ...ged b TPS signal input circuit damaged 2 TPS Sensor Related a Throttle plate position incorrect during Initialization procedure b TPS problem or malfunction 3 Engine Wiring Harness Related a Differenc...

Page 110: ...anation Injector 2 is not functioning because the circuit is open shorted to ground or shorted to battery Expected Engine Response Engine will run very poorly with only one cylinder functioning Possib...

Page 111: ...a Fuel pump open or shorted internally 3 Engine Wiring Harness Related a Fuel pump fuse F1 open b Broken or shorted wire in harness ECU pin 28 to fuel pump relay pin 86 Ignition switch to fuel pump re...

Page 112: ...5B 43 Section 5B EFI Fuel System 5B Figure 5B 44 Operate for an appropriate period of time based upon original fault codes...

Page 113: ...ased ECU only 10 Code 44 TPS Auto Learn Initialization Function Above Max Limit 32 Pin MSE 1 1 Plastic Cased ECU only 11 Code 51 Injector 1 32 Pin MSE 1 1 Plastic Cased ECU only 12 Code 52 Injector 2...

Page 114: ...1 0 Plastic Cased ECU Circuits 18 85 30 and 87 32 Pin MSE 1 1 Plastic Cased ECU Circuits 28 85 30 and 87 3 Relay 4 ECU grounds 5 ECU Diagnostic Aid 7 IGNITION SYSTEM no spark Possible causes 1 Spark p...

Page 115: ...SH SJ or higher Select the viscosity based on the air temperature at the time of operation as shown in the following table NOTE Using other than service class SG SH SJ or higher oil or extending oil...

Page 116: ...de of the crankcase one is adjacent to and below the oil filter the other is below the starter See Figure 6 4 Figure 6 4 Location of Oil Drains Checking Oil Level The importance of checking and mainta...

Page 117: ...until the rubber gasket contacts the adapter then tighten the filter an additional 3 4 1 turn 8 Remove the oil fill cap and fill the engine with the proper oil to the F mark on the dipstick Always ch...

Page 118: ...designed to break contact as the oil pressure increases above 3 5 psi and make contact as the oil pressure decreases below 3 5 psi On stationary or unattended applications pumps generators etc the pre...

Page 119: ...ntinuity tester across the blade terminal and the metal case of the switch With 0 psi pressure applied to the switch the tester should indicate continuity switch closed 2 Gradually increase the pressu...

Page 120: ...g leaving the five hex flange screws slightly loose 2 Pull the starter handle out until the pawls engage in the drive cup Hold the handle in this position and tighten the screws securely Rope Replacem...

Page 121: ...de the starter handle Untie the single knot and remove the rope retainer and handle 4 Hold the pulley firmly and untie the slipknot Allow the pulley to rotate slowly as the spring tension is released...

Page 122: ...sitions of the pawls and pawl springs before removing them Remove the pawls and pawl springs from the starter pulley Figure 7 5 Brake Spring and Washer Pawls and Pawl Springs 5 Rotate the pulley clock...

Page 123: ...l a new spring and keeper assembly 4 Clean all old grease and dirt from the starter components Generously lubricate the spring and center shaft with any commercially available bearing grease Reassembl...

Page 124: ...lean dry and free of grease and oil 6 Apply a small amount of Loctite No 271 to the threads of the center screw Install the center screw with the washer and retainer to the center shaft Torque the scr...

Page 125: ...Spark Plug Service Every 200 hours of operation remove each spark plug Check its condition and either reset the gap or replace with a new plug as necessary To service the plugs perform the following...

Page 126: ...stion chamber is usually caused by a restricted air cleaner a breather problem worn piston rings or valve guides Carbon Fouled Soft sooty black deposits indicate incomplete combustion caused by a rest...

Page 127: ...rting temperatures The cranking requirements increase as temperatures decrease and battery capacity shrinks Refer also to the operating instructions of the equipment being this engine powers for speci...

Page 128: ...em For Customer Connected Tractor Applications Operation of CD Ignition Systems A Capacitive Discharge with Fixed Timing This system Figure 8 3 consists of the following components A magnet assembly w...

Page 129: ...module which mounts to the engine shrouding Figure 8 7 A 12 volt battery which supplies current to the spark advance module A kill switch or key switch which grounds the spark advance module to stop...

Page 130: ...e Figure 8 7 The timing of the spark is controlled by the location of the flywheel magnet group as referenced to the engine top dead center and the delay created by the spark advance module Power Sour...

Page 131: ...Always provide a path for the spark to discharge to ground Reported ignition problems are most often due to poor connections Before beginning the test procedure check all external wiring Be certain a...

Page 132: ...he problem is gone the electrical system on the unit is suspect Check the key switch wires connections safety interlocks etc b If the problem persists the condition is associated with the ignition or...

Page 133: ...Replace them with part number M 561025 S Look in the mounting hole with a flashlight and use a small round wire brush to remove any loose rust from the laminations inside the mounting hole 4 Refer to...

Page 134: ...to 4 0 N m 35 in lb On a twin cylinder engine repeat these 6 steps to set the opposite side ignition module 6 Reattach the lead wires to the ignition module s noting if resistance is felt indicating...

Page 135: ...eal the base of the ignition module connections with GE Novaguard G661 see Section 2 Fel Pro Lubri Sel dielectric compound The beads should overlap between the two connections to form a solid bridge o...

Page 136: ...the module mounted or loose The figures show the part removed from the engine for clarity See Figure 8 14 2 Check the SAM part number stamped on the side of the housing Verify that you have an analog...

Page 137: ...2 3 4 3 Depress the tester button repeatedly until the correct test number appears on the display After a few seconds the test number will flash three times and the test will begin A reverse numerica...

Page 138: ...n for a full test cycle F or P appears and then display shuts off while monitoring the voltage reading on the voltmeter If the voltage drops below 7 5 at any time during the cycle the 9 volt tester ba...

Page 139: ...gines utilize a 3 amp unregulated system with optional 70 watt lighting circuit Refer to Figure 8 22 NOTE Observe the following guidelines to avoid damage to the electrical system and components Make...

Page 140: ...trical System and Components Figure 8 18 Wiring Diagram 15 20 25 Amp Regulated Battery Charging System with SMART SPARK Figure 8 19 15 Amp Stator and Rectifier Regulator Figure 8 20 20 Amp Stator and...

Page 141: ...V Battery Solenoid Starter Lights Yellow Black 3 Amp 70 Watt Flywheel Stator Ignition Modules Spark Plug Red Blue R A S B GND Light Optional Fuse Optional Ammeter Spark Plug 1st Style 2nd Style 25 Amp...

Page 142: ...regulator being tested 2 Connect the tester red lead to the B terminal of the rectifier regulator and the two black tester leads to the two AC terminals See Figure 8 25 Figure 8 25 Ground Strap or lea...

Page 143: ...entarily one of the four lights will illuminate indicating the condition of the part 20 25 Amp Rectifier Regulators 1 Connect the single lead adapter in between the B center terminal of rectifier regu...

Page 144: ...not location specific 4 Connect the remaining black lead from tester to one of the black AC outside leads from rectifier regulator See Figure 8 31 Figure 8 31 5 Plug the tester into the proper AC out...

Page 145: ...n until a click is heard and then release See Figure 8 27 Momentarily either the HIGH LOW or SHORT light will flash a If the HIGH light flashes on off the part is good and may be used b If any other l...

Page 146: ...robably faulty and should be replaced Test stator further using an ohmmeter Test 3 No Charge to Battery 3a With engine stopped measure the resistance across stator leads using an ohmmeter 3a If resist...

Page 147: ...nnect the lighting lead from the wiring harness With engine running at 3000 RPM measure voltage from lighting lead to ground using an AC voltmeter 3 With engine stopped measure the resistance of stato...

Page 148: ...ace the faulty components Solenoid Shift Starters Perform individual solenoid test procedure See pages 8 39 and 8 40 1 Check the specific gravity of battery If low recharge or replace battery as neces...

Page 149: ...drive components Style A Drive Service 1 Remove the starter from the engine and remove the dust cover 2 Hold the drive pinion in a vice with soft jaws when removing or installing the stop nut The arm...

Page 150: ...etaining Ring Anti Drift Spring Drive Pinion Drive Nut Collar Dust Cover Spacer Spring Retainer Figure 8 35 Drive Components Bonded Inertia Drive Starter 2 Disassemble the snap ring removal tool see S...

Page 151: ...cate the small raised line on the edge of the drive end cap On starters with Style A commutator end caps it will be aligned with a premarked line on the starter frame The frame is not premarked on sta...

Page 152: ...p 1 2 1 1 3 4 2 1 2 2 Insert the armature into the starter frame Make sure the magnets are closer to the drive shaft end of armature The magnets will hold the armature inside the frame 3 Install the d...

Page 153: ...rter is covered first and the Delco Remy starter servicing follows Operation Solenoid Shift Starter When power is applied to the starter the electric solenoid moves the drive pinion out onto the drive...

Page 154: ...n the post 4 The replacement brushes have a solid portion on them which should be crimped on the post 5 Solder the crimped portion to the post 6 Replace the brush holder in the frame and place the bru...

Page 155: ...mounted with external Torx head screws the plunger is part of the solenoid unhook the plunger pin from the drive lever Remove the gasket from the recess in the housing See Figures 8 46 and 8 47 NOTE T...

Page 156: ...Plate Assembly 6 Remove the frame from the armature and drive end cap See Figure 8 50 Figure 8 52 Armature and Lever Removed 10 Push the stop collar down to expose the retaining ring See Figure 8 53 F...

Page 157: ...ature or use solvent when cleaning Wipe clean using a soft cloth or use compressed air Figure 8 53 Retaining Ring Detail 11 Remove the retainer from the armature shaft Save the stop collar NOTE Do not...

Page 158: ...pinion teeth for abnormal wear or damage b The surface between the pinion and the clutch mechanism for nicks or irregularities which could cause seal damage c Check the drive clutch by holding the cl...

Page 159: ...armature shaft Apply Kohler electric starter drive lubricant see Section 2 Versilube G322L or Mobil Temp SHC 32 to the lever and shaft Clean and check the other starter parts for wear or damage as re...

Page 160: ...the machined surface of the housing which receives the backup washer See Figure 8 63 Figure 8 63 Installing Armature and Pivot Lever Figure 8 64 Installing Backup Washer and Grommet 8 Install the fra...

Page 161: ...h the I D of the brush holder assembly Insert the Brush Installation Tool with extension or use the tube described above from a prior brush installation through the brush holder assembly so the holes...

Page 162: ...ing screws to 2 5 3 3 N m 22 29 in lb See Figures 8 71 and 8 72 Figure 8 71 Torquing Thru Bolts Figure 8 72 Torquing Brush Holder Screws 13 Hook the plunger behind the upper end of the drive lever and...

Page 163: ...st terminal See Figure 8 74 When the connection is made the solenoid should energize audible click and the plunger retract Repeat the test several times If the solenoid fails to activate it should be...

Page 164: ...to the audible or Rx2K scale and connect the two ohmmeter leads to the two large post terminals Perform the preceding test 3 and check for continuity See Figure 8 77 The meter should indicate continu...

Page 165: ...nufacturer s instructions and safety precautions carefully Make sure all traces of the cleaner are removed before the engine is reassembled and placed into operation Even small amounts of these cleane...

Page 166: ...3 Removing Oil Fill Cap from Cover Figure 9 6 Removing Oil Filter Adapter Nipple Figure 9 4 Removing Oil Drain Plug 2 Allow ample time for the oil to drain from the crankcase and oil filter Figure 9...

Page 167: ...ssembly Standard Air Cleaner 1 Unhook the latches or loosen the knob and remove the cover Refer to Section 4 2 Remove the wing nut from the element cover 3 Remove the element cover the air cleaner ele...

Page 168: ...pped Do not lose any of the hardware See Figure 9 13 Mounting Nuts Breather Hose Figure 9 13 Air Cleaner Bracket Mounting Screws Two Barrel Model Pictured 4 Remove the heavy duty air cleaner as an ass...

Page 169: ...cket or to the blower housing See Figure 9 18 The fuel pump body may be metal or plastic Figure 9 18 Removing Screws Holding Fuel Pump Metal Bodied Pump Shown 4 Note or mark the orientation of the fue...

Page 170: ...ng Choke Linkage from Actuator Lever Figure 9 21 Removing Control Bracket Figure 9 20 Mechanical Fuel Pump Remove Control Panel If So Equipped 1 Disconnect the Oil Sentry Indicator Light wires 2 Disco...

Page 171: ...line as a cleaning agent 1 Disconnect the fuel shut off solenoid lead and ground lead if equipped See Figure 9 26 Figure 9 28 Removing Carburetor Assembly with Governor Lever Attached 4 Remove the car...

Page 172: ...two hex flange screws See Figure 9 30 5 If necessary the carburetor throttle linkage and governor lever can be separated Reattach the bushings to the linkage following separation to avoid losing them...

Page 173: ...ure 9 35 6 On engines equipped with a metal grass screen remove the screen before removing the blower housing See Figure 9 36 Plastic grass screens can be removed after the blower housing is removed F...

Page 174: ...t could cause damage resulting in leaks Most engines use a formed gasket rather than RTV sealant Figure 9 38 Removing Blower Housing Remove Inner Baffles and Breather Cover The inner valley baffles ar...

Page 175: ...atest design uses a brown O Ring and the bolt holes spacers are molded in place 1 Remove the four hex flange screws securing each valve cover Note the position of any attached brackets or lifting stra...

Page 176: ...g the intake manifold to the cylinder heads Note which screws hold the wiring clamps 2 Remove the intake manifold and the intake manifold gaskets aluminum intake manifolds or O Rings plastic intake ma...

Page 177: ...hex flange screws or hex flange nuts and washers on studs Do not interchange or mix components as the cylinder heads may have different machining unique to each fastening method 1 Remove the four hex...

Page 178: ...ydraulic lifters should always be reinstalled in the same position See Figures 9 53 and 9 54 NOTE The exhaust lifters are located on the output shaft side of the engine while the intake lifters are lo...

Page 179: ...ves mark position Valve stem seals intake valve only Valve Retainer Spring Keepers Cap Valve Seal Figure 9 59 Intake Valve Seal Location NOTE These engines use valve stem seals on the intake valves Us...

Page 180: ...wheel to become cracked or damaged Figure 9 62 Removing Flywheel Fastener Using Strap Wrench 2 Remove the hex flange screw and washer 3 Use a puller to remove the flywheel from the crankshaft See Figu...

Page 181: ...ee Figure 9 65 Note the routing of the stator lead in the channel Figure 9 65 Removing Stator Remove Closure Plate Assembly 1 Remove the ten hex flange screws securing the closure plate to the crankca...

Page 182: ...end cap Remove the end cap See Figure 9 70 Figure 9 71 Mark End Cap with Cylinder Number Before Removal NOTE The cylinders are numbered on the crankcase Use the numbers to mark each end cap connecting...

Page 183: ...haft from the crankcase See Figure 9 73 Note thrust washers and shims if used Figure 9 75 Removing Governor Cross Shaft Retainer 8 mm Shaft Design 2 Pull the cross shaft with small washer out through...

Page 184: ...asurement Guide TP 2159 B and Engine Inspection Data Record TP 2435 are also available use these to record inspection results Automatic Compression Release ACR Some engines are equipped with the optio...

Page 185: ...with a flat washer into the drilled hole The flat washer must be large enough to seat against the shoulder of the plug bore See Figure 10 2 3 Tighten the self tapping screw until it draws the plug out...

Page 186: ...a drill speed of about 250 RPM and 60 strokes per minute After installing coarse stones in hone proceed as follows 1 Lower hone into bore and after centering adjust so the stones are in contact with t...

Page 187: ...ter and the piston diameter step 2 minus step 1 Flywheel Inspection Inspect the flywheel for cracks and the flywheel keyway for damage Replace the flywheel if it is cracked Replace the flywheel the cr...

Page 188: ...2987 1 2997 in 6 5 mm 0 2559 in 7 038 7 058 mm 0 2771 0 2779 in 29 37 29 63 mm 1 1563 1 1665 in 45 1 5 mm 0 0591 in 6 970 6 988 mm 0 2744 0 2751 in Figure 10 6 Valve Details Hard starting or loss of p...

Page 189: ...1000 hours under controlled test conditions Bad Condition The valve depicted here should be replaced Note the warped head margin damaged and too narrow These conditions could be attributed to excessi...

Page 190: ...on their condition Stem Corrosion Moisture in fuel or from condensation are the most common causes of valve stem corrosion Condensation occurs from improper preservation during storage and when engin...

Page 191: ...an 89 cutter as specified for the valve seat angle in Figure 10 6 Cutting the proper 45 valve face angle as specified in Figure 10 6 and the proper valve seat angle 44 5 half of the full 89 angle will...

Page 192: ...ive material such as carbon dirt or pieces of hard metal Detonation damage occurs when a portion of the fuel charge ignites spontaneously from heat and pressure shortly after ignition This creates two...

Page 193: ...4 Before installing the new rings on the piston place the top two rings each in turn in its running area in the cylinder bore and check the end gap See Figure 10 9 Compare the ring gap to the specific...

Page 194: ...e base surface of the hydraulic lifters for wear or damage If the lifters need to be replaced apply a liberal coating of Kohler lubricant see Section 2 to the base of each new lifter before it is inst...

Page 195: ...pump body 5 If the relief valve is like that shown in Figure 10 15 drive out the pin to remove the oil pressure relief valve piston and spring Refer to the following inspection and reassembly procedur...

Page 196: ...ssure relief valve piston It should be free of nicks or burrs Check the spring for wear or distortion The free length of the spring should be approximately 47 4 mm 1 8 in Replace the spring if it is d...

Page 197: ...asurement Guide TP 2159 B and Engine Inspection Data Record TP 2435 are also available use these to record inspection results Automatic Compression Release ACR Some engines are equipped with the optio...

Page 198: ...seal is damaged and or leaks replace it using the following procedure Remove the oil seal from the crankcase and replace it with a new one Install the new seal to the depth shown in Figure 10 18 using...

Page 199: ...ions or special equipment Detailed procedures follow 1 Install flywheel end oil seal 2 Install governor cross shaft 3 Install crankshaft 4 Install connecting rods with pistons and rings 5 Install cams...

Page 200: ...nylon washer onto the governor cross shaft then start the push on retaining ring Hold the cross shaft up in position place a 0 50 mm 0 020 in feeler gauge on top of the nylon washer and push the reta...

Page 201: ...kcase Make sure to install the piston connecting rod and end cap into its appropriate cylinder bore as previously marked at disassembly Do not mix the end caps and connecting rods NOTE Proper orientat...

Page 202: ...timing marks aligned See Figure 11 13 Figure 11 11 Torquing Connecting Rod End Cap 6 Repeat the above procedure for the other connecting rod and piston assembly Install Camshaft 1 Liberally apply cam...

Page 203: ...in 5 Reinstall the end play checking tool and recheck the end play Oil Pump Assembly The oil pump is mounted inside the closure plate If service was required and the oil pump was removed refer to the...

Page 204: ...onto the thrust washer Install the closure plate onto the crankcase without applying RTV sealant and secure it with only two or three of the fasteners at this time Use a dial indicator to check the c...

Page 205: ...nt to the stator mounting holes 2 Position the stator aligning the mounting holes so that the leads are at the bottom towards the crankcase 3 Install and torque the two hex flange screws to 6 2 N m 55...

Page 206: ...e the crankshaft taper and the flywheel hub are clean dry and completely free of any lubricants The presence of lubricants can cause the flywheel to be over stressed and damaged when the hex flange sc...

Page 207: ...flywheel onto the crankshaft being careful not to shift the woodruff key See Figure 11 28 3 Install the hex flange screw and washer 4 Use a flywheel strap wrench or holding tool to hold the flywheel T...

Page 208: ...n bleed down procedures 2 Apply camshaft lubricant see Section 2 to the bottom surface of each lifter See Figure 11 34 Lubricate the hydraulic lifters and the lifter bores in the crankcase with engine...

Page 209: ...ke sure there are no nicks or burrs on the sealing surfaces of the cylinder head or the crankcase Figure 11 37 Intake Valve Seal Location Valve Stem Seals These engines use valve stem seals on the int...

Page 210: ...ightening motion without interruption until the proper height is obtained Otherwise the frictional heat from the engaging threads may cause the locking compound to set up prematurely The studs closest...

Page 211: ...ion 2 to lift the rocker arms and position the push rods underneath See Figure 11 47 NOTE Push rods should always be installed in the same position as before disassembly 1 Note the mark or tag identif...

Page 212: ...ith SMART SPARK both modules are installed the same way with the two tabs out See Figure 11 55 On engines are not equipped with SMART SPARK the modules are installed with the spark plug lead wire from...

Page 213: ...equence shown in Figure 11 51 1 2 3 4 Sealant Figure 11 51 Intake Manifold Torque Sequence Figure 11 52 Sealant Applied to Terminals NOTE If the wires were disconnected from the ignition modules on en...

Page 214: ...ll as follows 1 Be sure the sealing surfaces of the crankcase and breather cover are clean of old gasket material or RTV sealant Do not scrape the surfaces as this could result in leakage 2 Check to m...

Page 215: ...hten screws until all items are installed to allow shifting for hole alignment 1 Connect the plug to the key switch in the blower housing if so equipped 2 Slide the blower housing into position over t...

Page 216: ...ole See Figure 11 66 3 Position the outer baffles and loosely start the mounting screws The two M6 screws go into the back of the cylinders The short M5 screws go into the lower holes closest to the b...

Page 217: ...tifier regulator in the blower housing if removed previously then connect the rectifier regulator ground lead with the washer and silver screw through the eyelet as shown in Figure 11 69 If a groundin...

Page 218: ...Torque the two hex flange screws to 15 3 N m 135 in lb Figure 11 73 Installing Electric Starter Motor Cylinder Baffle Mounting Location Blower Housing Mounting Location Figure 11 71 Grounding Bracket...

Page 219: ...e new pump is consistent with the removed pump Internal damage may occur if installed incorrectly 2 Install the fuel pump using the two hex flange screws Torque the screws to 2 3 N m 20 in lb 3 On mod...

Page 220: ...and carburetor to the intake manifold and start any removed studs Use two hex nuts locked flange to flange and tighten each of the studs until bottomed tight See Figure 11 78 Figure 11 76 Installing...

Page 221: ...kage to the carburetor and choke actuator lever See Figure 11 83 Figure 11 83 Connecting Choke Linkage 2 Mount the main control bracket and air cleaner support bracket if used to the cylinder heads us...

Page 222: ...overnor lever See Figures 11 85 and 11 86 and the appropriate chart 6 mm Governor Lever and Hole Position RPM Chart 3801 4000 3601 3800 3451 3600 3301 3450 3101 3300 2951 3100 2800 2950 3750 3150 High...

Page 223: ...rd Parent Material 3888 3780 3672 3564 3456 3348 3240 3132 3024 3600 3500 3400 3300 3200 3100 3000 2900 2800 Orange Black Red Green Red Green Blue Clear 3 3 3 2 2 1 1 1 8 mm Governor Lever and Hole Po...

Page 224: ...ol Panel If So Equipped 1 Install the panel to the blower housing 2 Connect the throttle control cable or shaft 3 Connect the choke control cable to the control bracket 4 Connect the Oil Sentry indica...

Page 225: ...For covers requiring RTV sealant apply a 1 5 mm 1 16 in bead to the sealing surface of both cylinder heads install a new valve cover gasket on each then apply a second bead of sealant on the top surf...

Page 226: ...reful not to drop screws into the carburetor If a rear air cleaner bracket is used install the two M5 screws through the rear of the base Torque the three M6 screws to 6 2 7 3 N m 55 65 in lb and the...

Page 227: ...e air cleaner hose to elbow or adapter on carburetor and secure with a clamp Install and tighten hood onto the air cleaner inlet See Figure 11 98 Figure 11 98 Assembled Heavy Duty Air Cleaner Two Barr...

Page 228: ...ting Oil Cooler Blower Housing Mounted Cooler Install Oil Filter and Fill Crankcase with Oil 1 Prefill a new oil filter following the instructions in Section 6 2 Apply a thin film of clean engine oil...

Page 229: ...the correct amount weight and type of oil Refer to oil recommendations and procedures in the Safety and General Information and Lubrication System sections 4 Adjust the carburetor idle fuel needle or...

Page 230: ...view of clutch Figure 12 1 Wet Type Clutch Exploded View Nameplate Gasket Shifting Lever Seal Shaft Yoke Clutch Housing Key Yoke Roll Pin Ball Bearing Power Shaft Adjusting Ring Driven Member Clutch A...

Page 231: ...l clutch assembly off 6 To replace clutch simply turn adjusting collar off and remove plate Reverse procedure for reassembly Adjust and lubricate following previous instructions Adjustment Slight read...

Page 232: ...LITHO IN U S A FORMNO TP 2428 C ISSUED 4 92 REVISED 3 06 ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 FOR SALESAND SERVICE INFORMATION IN U S AND CANADA CALL 1 800 544 2444...

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