Kohler Command PRO CH682 Service Manual Download Page 42

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Disassembly/Inspection and Service

KohlerEngines.com

24 690 34 Rev. D

External Engine Components

Intake Manifold

Gasket

Carburetor Gasket

Carburetor

Air Cleaner Gasket

Outer Baf

Breather Tube

Oil Sentry

™

Breather Cover

Breather Gasket

Inner Baf

Breather Reed

WARNING

Before working on engine or equipment, disable engine as

follows: 1) Disconnect spark plug lead(s). 2) Disconnect

negative (–) battery cable from battery.

Accidental Starts can cause severe injury or

death.
Disconnect and ground spark plug lead(s)

before servicing.

Summary of Contents for Command PRO CH682

Page 1: ...cation System 31 Electrical System 38 Starter System 42 Disassembly Inspection and Service 56 Reassembly IMPORTANT Read all safety precautions and instructions carefully before operating equipment Ref...

Page 2: ...contain poisonous carbon monoxide Carbon monoxide is odorless colorless and can cause death if inhaled WARNING Accidental Starts can cause severe injury or death Disconnect and ground spark plug lead...

Page 3: ...nually Change oil Lubrication System Remove cooling shrouds and clean cooling areas Air Cleaner Intake Check oil cooler fins clean as necessary if equipped Lubrication System Every 200 Hours Change oi...

Page 4: ...proved and should NOT be used effects of old stale or contaminated fuel are not warrantable Fuel must meet these requirements Clean fresh unleaded gasoline Octane rating of 87 R M 2 or higher Research...

Page 5: ...T 2 67 50 2 657 MUFFLERMOUNTING BOSSES OILFILL OILDIPSTICK 113 08 4 452 95 50 3 760 36 50 1 437 622 41 24 504 5 8 18UNF2B INCH 38 10 1 500 155 58 6 125 152 08 5 987 OILFILTER 5 50 217 PILOT FUELPUMP 1...

Page 6: ...in lb into new holes 4 0 N m 35 in lb into used holes M6 Fasteners 10 7 N m 95 in lb into new holes 7 3 N m 65 in lb into used holes Carburetor Intake Manifold and Air Cleaner Intake Manifold Mounting...

Page 7: ...eel Fan Fastener 9 9 N m 88 in lb Flywheel Retaining Screw 66 4 N m 49 ft lb Fuel Pump Pulse Fastener 2 3 N m 20 in lb Governor Lever Nut 6 8 N m 60 in lb Ignition Spark Plug 27 N m 20 ft lb Module Fa...

Page 8: ...d Play 0 076 0 127 mm 0 0030 0 0050 in Running Clearance 0 025 0 063 mm 0 0010 0 0025 in Bore I D New Max Wear Limit 20 000 20 025 mm 0 7874 0 7884 in 20 038 mm 0 7889 in Bearing Surface O D New Max W...

Page 9: ...6116 in 40 84 mm 1 608 in 0 022 mm 0 0009 in 0 025 mm 0 0010 in Closure Plate End Main Bearing Journal O D New O D Max Wear Limit Max Taper Max Out of Round 40 913 40 935 mm 1 6107 1 6116 in 40 84 mm...

Page 10: ...sion Ring to Groove Side Clearance 0 030 0 070 mm 0 001 0 0026 in Middle Compression Ring to Groove Side Clearance 00 030 0 070 mm 0 001 0 0026 in Oil Control Ring to Groove Side Clearance 0 060 0 190...

Page 11: ...lve Guide Running Clearance 0 050 0 088 mm 0 0020 0 0035 in Intake Valve Guide I D New Max Wear Limit 7 038 7 058 mm 0 2771 0 2779 in 7 134 mm 0 2809 in Exhaust Valve Guide I D New Max Wear Limit 7 03...

Page 12: ...English Fastener Torque Recommendations for Standard Applications Bolts Screws Nuts and Fasteners Assembled Into Cast Iron or Steel Grade 2 or 5 Fasteners Into Aluminum Size Grade 2 Grade 5 Grade 8 Ti...

Page 13: ...logy Inc DTI 731 03 Dealer Tool Kit Domestic Complete kit of Kohler required tools Components of 25 761 39 S Ignition System Tester Cylinder Leakdown Tester Oil Pressure Test Kit Rectifier Regulator T...

Page 14: ...d brushes Individual component available Starter Brush Holding Tool Solenoid Shift SE Tools KLR 82411 SE Tools KLR 82416 Triad OHC Timing Tool Set For holding cam gears and crankshaft in timed positio...

Page 15: ...ing gear teeth Bosses will lock tool and flywheel in position for loosening tightening or removing with a puller A spanner wrench to lift rocker arms or turn crankshaft may be made out of an old junk...

Page 16: ...e to check simple causes which at first may seem too obvious to be considered For example a starting problem could be caused by an empty fuel tank Some general common causes of engine troubles are lis...

Page 17: ...indications of improper fit and seal Check air cleaner element Look for holes tears cracked or damaged sealing surfaces or other damage that could allow unfiltered air into engine A dirty or clogged e...

Page 18: ...s closed 2 Start engine and run no load high speed 3 Open clamp and note water level in tube Level in engine side should be a minimum of 10 2 cm 4 in above level in open side If level in engine side i...

Page 19: ...t Install a 3 8 in breaker bar into hole slot of holding tool so it is perpendicular to both holding tool and crankshaft PTO If flywheel end is more accessible use a breaker bar and socket on flywheel...

Page 20: ...Ensure both ends of breather tube are properly connected AIR COOLING WARNING Hot Parts can cause severe burns Do not touch engine while operating or just after stopping Never operate engine with heat...

Page 21: ...nnected to fitting on crankcase 4 Attach new fuel pump using screws Torque screws to 2 3 N m 20 in lb 5 Reconnect fuel lines to inlet and outlet fittings and secure with clamps Mechanical Pump Mechani...

Page 22: ...gine is hot or running Walbro Two Barrel Carburetor Components A B C D E F G H I J K L M N O P Q R S T U V W X A Carburetor Body Subassembly B Vacuum Hose C Float Valve Inlet Needle D Float E Bowl Gas...

Page 23: ...uns rough or stalls at idle speed Low idle speed improperly adjusted Adjust low idle speed tab Engine runs rich indicated by black sooty exhaust smoke misfiring loss of speed and power governor huntin...

Page 24: ...in through fixed and metered idle progression holes As throttle plate opens further vacuum signal becomes great enough so main circuit begins to work Main high speed At high speeds loads engine operat...

Page 25: ...pen end wrench and carefully remove nozzle tubes from bowl Note and mark jets by location for proper reassembly Main jets and main nozzles may be size side specific Main jets are pressed into bottom o...

Page 26: ...held in between body mounting legs insert new pivot pin through float hinge and into opposite hole 20 Invert carburetor body as shown and measure dimension between top of float and top of gasket floa...

Page 27: ...tion tension of governor spring holds throttle plate open When engine is operating governor gear assembly is rotating Force applied by regulating pin against cross shaft tends to close throttle plate...

Page 28: ...rnor lever If speed surging occurs with a change in engine load governor is set too sensitive If a big drop in speed occurs when normal load is applied governor should be set for greater sensitivity a...

Page 29: ...L AND FILTER Change oil while engine is warm 1 Clean area around oil fill cap dipstick drain plug oil drain valve a Remove drain plug and oil fill cap dipstick Allow oil to drain completely or b Open...

Page 30: ...ivalent to threads of switch 2 Install switch into tapped hole in breather cover 3 Torque switch to 4 5 N m 40 in lb Testing Compressed air a pressure regulator pressure gauge and a continuity tester...

Page 31: ...e feeler gauge Adjust gap to 0 76 mm 0 03 in 2 Install plug into cylinder head 3 Torque plug to 27 N m 20 ft lb Inspection Inspect each spark plug as it is removed from cylinder head Deposits on tip a...

Page 32: ...C 200 cca minimum 0 F to 32 F 18 C to 0 C 250 cca minimum 5 F to 0 F 21 C to 18 C 300 cca minimum 10 F 23 C or below 400 cca minimum If battery charge is insufficient to turn over engine recharge batt...

Page 33: ...KohlerEngines com Electrical System W C H D B I A AD E G F F A K B L J N M P O R Q S T U V R W R X Y Z V AA AB AC AF AI AJ AL AE AK AH AG R T V V AM AN AO AH Wiring Diagram 15 20 25 Amp Regulated Batt...

Page 34: ...Starter AJ Ground AK Key Switch Ground AL Rectifier AM Blue Red AN Battery Positive AO Battery Negative Electronic Ignition Systems Tests NOTE Ignition tester must be used to test ignition on these e...

Page 35: ...wing guidelines to avoid damage to electrical system and components Make sure battery polarity is correct A negative ground system is used Disconnect rectifier regulator plug and or wiring harness plu...

Page 36: ...g tester into proper AC outlet power for tester being used Turn on power switch POWER light should be illuminated and 1 of 4 status lights may be on as well This does not represent condition of part 6...

Page 37: ...regulator steps 2 and 3 2 Remove connector from rectifier regulator With engine running at 3600 RPM measure AC voltage across stator leads using an AC voltmeter Condition Conclusion Voltage is 28 volt...

Page 38: ...ssible Cause Conclusion Starter does not energize Battery Check specific gravity of battery If low recharge or replace battery as necessary Wiring Clean corroded connections and tighten loose connecti...

Page 39: ...and plunger spring from drive end cap If solenoid was mounted with external Torx head screws plunger is part of solenoid unhook plunger pin from drive lever Remove gasket from recess in housing 4 Remo...

Page 40: ...ines Install drive pinion onto armature shaft 2 Install and assemble stop collar retainer assembly a Install stop collar down onto armature shaft with counter bore recess up b Install a new retainer i...

Page 41: ...to solenoid for any time over what is necessary for performing each of individual tests Internal damage to solenoid may occur Disconnect all leads from solenoid including positive brush lead attached...

Page 42: ...sket D Carburetor E Air Cleaner Gasket F Outer Baffle G Breather Tube H Oil Sentry I Breather Cover J Breather Gasket K Inner Baffle L Breather Reed WARNING Before working on engine or equipment disab...

Page 43: ...ged for wear or damage There are many commercially available cleaners that will quickly remove grease oil and grime from engine parts When such a cleaner is used follow manufacturer s instructions and...

Page 44: ...screw and washer securing rectifier regulator ground lead or grounding strap 8 Remove remaining screws and detach blower housing 9 Disconnect plug from key switch in blower housing if engine is equipp...

Page 45: ...s NOTE Cylinder heads are retained using either screws or nuts and washers on studs Do not interchange or mix components as cylinder heads may have different machining unique to each fastening method...

Page 46: ...alve stem seals intake valve only 4 Repeat above procedure for other cylinder head Do not interchange parts from one cylinder head to other Inspection and Service Valve Details EXHAUST VALVE INTAKE VA...

Page 47: ...ms are worn beyond limits install new valves Valve Seat Inserts Hardened steel alloy intake and exhaust valve seat inserts are press fitted into cylinder head Inserts are not replaceable but can be re...

Page 48: ...ng backing plates and stator wire bracket if equipped Remove backing plates and stator wire bracket 2 Remove screws and stator Remove Ignition Modules 1 Disconnect lead from each ignition module 2 Rot...

Page 49: ...er O ring Style B X Oil Pump Assembly Style B Y Oil Pick Up Tube Style B Remove Closure Plate Assembly 1 Remove screws securing closure plate to crankcase 2 Locate splitting tabs cast into perimeter o...

Page 50: ...aft Oil Pump Assembly Style A Oil Pump Style A Torque Sequence 1 2 Oil pump is mounted inside closure plate If service is required refer to Disassembly Inspection and Reassembly Disassembly 1 Remove s...

Page 51: ...t into corresponding recess in closure plate Apply consistent downward pressure to oil pump cover compressing oil pressure relief spring and start screws Secure oil pump by torquing screws in no speci...

Page 52: ...re severe than detonation damage Preignition is caused by a hot spot in combustion chamber from sources such as glowing carbon deposits blocked cooling fins an improperly seated valve or wrong spark p...

Page 53: ...r crankcase Do not replace bearings unless they show signs of damage or are out of running clearance specifications If crankshaft turns easily and noiselessly and there is no evidence of scoring groov...

Page 54: ...tches or nicks Inspect main bearing if equipped for wear or damage Replace crankcase using a miniblock or short block as required Check cylinder bore wall for scoring In severe cases unburned fuel can...

Page 55: ...taper and size Use an inside micrometer telescoping gauge or bore gauge to take measurements These measurements should be taken at 3 locations in cylinder at top middle and bottom There are 2 measure...

Page 56: ...small amount of oil to threads of critical fasteners before assembly unless a sealant or Loctite is specified or preapplied Make sure all traces of any cleaner are removed before engine is assembled...

Page 57: ...Lubricate cylinder bore piston and piston rings with engine oil Compress rings of piston 1 using a piston ring compressor 3 Lubricate crankshaft journals and connecting rod bearing surfaces with engi...

Page 58: ...RTV sealant and secure it with only 2 or 3 fasteners at this time Use a dial indicator to check crankshaft end play End play should be 0 070 1 190 mm 0 0028 0 0468 in Shim spacers are available in 3 c...

Page 59: ...eaned and prepared Install a new O ring in closure plate 2 Check to make sure there are no nicks or burrs on sealing surfaces of closure plate or crankcase 3 Apply a 1 5 mm 1 16 in bead of sealant to...

Page 60: ...all screw and washer 4 Use a flywheel strap wrench or holding tool to hold flywheel Torque screw securing flywheel to crankshaft to 66 4 N m 49 ft lb Install Flywheel Fan NOTE Position ears located at...

Page 61: ...ttom surface of each lifter Lubricate hydraulic lifters and lifter bores in crankcase with engine oil 3 Note mark or tag identifying hydraulic lifters as either intake or exhaust and cylinder 1 or cyl...

Page 62: ...est to lifters must have an exposed height of 75 mm 2 15 16 in Studs furthest from lifters must have an exposed height of 69 mm 2 3 4 in c Remove nuts and repeat procedure as required 4 Install cylind...

Page 63: ...crews to 4 0 6 2 N m 35 55 in lb 7 Repeat steps 4 through 6 for other ignition module 8 Rotate flywheel back and forth checking for clearance between magnet and ignition modules Make sure magnet does...

Page 64: ...Air Cleaner Gasket F Outer Baffle G Breather Tube H Oil Sentry I Breather Cover J Breather Gasket K Inner Baffle L Breather Reed M Filter N Electric Starter O Lifting Bracket P Fixed Guard Q Blower Ho...

Page 65: ...s are routed out through proper offsets or notches so they will not be pinched between blower housing and baffles 4 If rectifier regulator was not removed attach ground wire or metal grounding bracket...

Page 66: ...and are open 2 Apply Loctite 242 to shorter inner set of threads of any removed studs 3 Assemble carburetor gasket and carburetor to intake manifold and start any removed studs Use two flange nuts lo...

Page 67: ...o breather cover Torque to 4 5 N m 40 in lb 2 Connect wire lead green to Oil Sentry terminal Install Control Panel if equipped 1 Install panel to blower housing 2 Connect throttle control cable or sha...

Page 68: ...and torqued to specifications to prevent oil leakage 1 Install oil drain plug s Torque plug s to 13 6 N m 10 ft lb If oil drain valve is used make sure valve body is closed and cap is on 2 Place new f...

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