Kohler Command PRO CV682 Service Manual Download Page 5

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Specifications

24 690 37 Rev. B

KohlerEngines.com

413.28

[16.271]

296.44

[11.691]

272.44

[10.726]

93.05

[3.664]

VALVE COVER

135.00
[5.315]

AIR FILTER

RAIN CAP
REMOVAL

22.77

[0.896]

SPARK PLUG BOOT

253.35
[9.974]

SPARK PLUG

REMOVAL

52.02

[2.048]

SPARK PLUG

BOOT

REMOVAL

OIL FILL &

DIPSTICK TUBE

253.35
[9.974]

SPARK PLUG

REMOVAL

VALVE COVER

353.69

[13.925]

PRIMARY AIR FILTER ELEMENT REMOVAL

241.37
[9.503]

SAFETY AIR FILTER

ELEMENT REMOVAL

130.00
[5.118]

AIR FILTER COVER

ASSEMBLY REMOVAL

246.12
[9.690]

SPARK PLUG

BOOT

REMOVAL

72.81

[2.867]

SPARK PLUG REMOVAL

MOUNTING
HOLE “A”

ENGINE

72.81

[2.867]

SPARK PLUG REMOVAL

FUEL

FILTER

CRANKSHAFT

27.53

[1.084]

SPARK PLUG BOOT

52.02

[2.048]

SPARK PLUG BOOT REMOVAL

145.19
[5.716]

45.19

[1.779]

15.70

[0.618]

OIL FILTER REMOVAL

246.12
[9.690]

SPARK PLUG

BOOT

REMOVAL

20°

FLYWHEEL SIDE

345.34

[13.596]

505.67

[19.908]

PULSE FUEL PUMP

316.44

[12.458]

154.85
[6.096]

ENGINE MOUNTING SURFACE

OIL COOLER

REGULATOR
RECTIFIER

OIL DRAIN PLUG

3/8 NPT [INCH]

OIL FILTER SIDE

MOUNTING HOLE “A”

SPARK PLUG

134.04 [5.277]

109.59
[4.314]

28.56

[1.125]

25.80

[1.016]

97.20

[3.827]

KEYWAY

7/16-20 UNF 2B [INCH]

1/4 IN. SQ KEYWAY

38.1 [1.500]

80.26

[3.160]

OIL FILTER

51.25

[2.018]

OIL FILTER

12.99

[0.511]

MOUNTING HOLE “A”

ENGINE MOUNTING SURFACE

(PTO END)

2X 242.29

[9.539]

2X 104.03

[4.096]

2X 89.80

[3.536]

30°

SOLENOID SHIFT STARTER

50.00

[1.969]

EXHAUST

PORT #1

MOUNTING

HOLES

4X Ø 9.20 [0.362] THRU

Ø 254.00 [10.00] B.C.

50.00

[1.969]

EXHAUST PORT #2
MOUNTING HOLES

2X 89.80

[3.536]

2X 77.53

[3.052]

2X 72.84

[2.868]

M8 X 1.25

4 STUDS

334.67

[13.176]

367.34

[14.462]

316.96

[12.479]

40.80

[1.606]

OIL DRAIN PLUG

3/8 NPT [INCH]

12.99

[0.511]

ENGINE MOUNTING SURFACE

SPARK PLUG

72.04

[2.836]

EXHAUST

PORT #2

154.04 [6.065]

92.04

[3.624]

EXHAUST

PORT #1

STARTER SIDE

Engine Dimensions

Dimensions in millimeters.

Inch equivalents shown in [ ].

Summary of Contents for Command PRO CV682

Page 1: ...cation System 30 Electrical System 37 Starter System 41 Disassembly Inspection and Service 54 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: ...WHEEL SIDE 345 34 13 596 505 67 19 908 PULSE FUEL PUMP 316 44 12 458 154 85 6 096 ENGINE MOUNTING SURFACE OIL COOLER REGULATOR RECTIFIER OIL DRAIN PLUG 3 8 NPT INCH OIL FILTER SIDE MOUNTING HOLE A C L...

Page 6: ...7 3 N m 65 in lb into used holes Carburetor Intake Manifold and Air Cleaner Intake Manifold to Head Mounting Fastener torque in 2 increments first to 7 4 N m 66 in lb finally to 9 9 N m 88 in lb Air...

Page 7: ...tener 4 0 6 2 N m 35 55 in lb Rectifier Regulator Fastener 1 4 N m 12 6 in lb Muffler Retaining Nut 24 4 N m 216 in lb Oil Cooler Adapter Nipple 27 N m 20 ft lb Oil Pan Fastener 24 4 N m 216 in lb Oil...

Page 8: ...Rod to Piston Pin Running Clearance 0 015 0 028 mm 0 0006 0 0011 in Piston Pin End I D New Max Wear Limit 17 015 17 023 mm 0 6699 0 6702 in 17 036 mm 0 6707 in Crankcase Governor Cross Shaft Bore I D...

Page 9: ...e I D New 80 000 80 025 mm 3 1496 3 1506 in 82 988 83 013 mm 3 2672 3 2682 in Max Wear Limit 80 065 mm 3 1522 in 83 051 mm 3 2697 in Max Out of Round 0 12 mm 0 0047 in Max Taper 0 05 mm 0 0020 in Cyli...

Page 10: ...Top Compression Ring End Gap New Bore 0 100 0 279 mm 0 0039 0 0110 in 0 189 0 277 mm 0 0074 0 0109 in Used Bore Max 0 490 mm 0 0192 in 0 531 mm 0 0209 in Middle Compression Ring End Gap New Bore 1 40...

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: ...leakdown test on XT 6 engines Kohler 25 761 05 S Design Technology Inc DTI 731 03 Dealer Tool Kit Domestic Complete kit of Kohler required tools Components of 25 761 39 S Ignition System Tester Cylind...

Page 14: ...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 position while installing timing belt...

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 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 listed below and va...

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: ...oth 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 shields...

Page 21: ...and pulse fittings on fuel pump 2 Remove screws and take off pump 3 Connect pulse line to new fuel pump and make sure opposite end is properly connected to fitting on crankcase 4 Attach new fuel pump...

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: ...ough or stalls at idle speed Low idle speed improperly adjusted Adjust idle speed governed idle tab Engine runs rich indicated by black sooty exhaust smoke misfiring loss of speed and power governor h...

Page 24: ...hrough 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 operates o...

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: ...overnor spring tension and force applied by regulating pin balance each other during operation to maintain engine speed When load is applied and engine speed and governor gear speed decreases governor...

Page 28: ...ighten securely CHANGE OIL 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 dr...

Page 29: ...d metal case of switch With 0 psi pressure applied to switch tester should indicate continuity switch closed 2 Gradually increase pressure to switch As pressure increases through range of 2 5 psi test...

Page 30: ...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 31: ...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 32: ...2 24 690 37 Rev B KohlerEngines com 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 33: ...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 34: ...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 35: ...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 36: ...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 37: ...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 38: ...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 39: ...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 40: ...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 41: ...Screen R Support Ring S Spacer T Fan Clean all parts thoroughly as engine is disassembled Only clean parts can be accurately inspected and gauged for wear or damage There are many commercially availab...

Page 42: ...Remove screws mounting oil cooler to blower housing Remove cooler lines and filter adapter as an assembly Remove Muffler Remove exhaust system and attaching hardware from engine On engines equipped w...

Page 43: ...ed screw used for rectifier regulator ground strap or lead Oil separator can remain on blower housing but remove from valve cover Remove blower housing 7 Remove cooling fan Remove Oil Sentry 1 Disconn...

Page 44: ...washers securing each cylinder head Unless screws are damaged or questionable they can be reused Discard nuts and washers once removed do not reuse Studs if present should only be removed if damaged...

Page 45: ...r cylinder head Do not interchange parts from 1 cylinder head to other Inspection and Service Valve Details EXHAUST VALVE INTAKE VALVE EXHAUST INSERT INTAKE INSERT C D D A B A B A H F E G F E G H Dime...

Page 46: ...teel alloy intake and exhaust valve seat inserts are press fitted into cylinder head Inserts are not replaceable but can be reconditioned if not too badly pitted or distorted If cracked or badly warpe...

Page 47: ...om crankshaft Do not strike crankshaft or flywheel as these parts could become cracked or damaged Striking puller or crankshaft can cause crank gear to move affecting crankshaft endplay 1 Use a flywhe...

Page 48: ...ect governor gear teeth Replace gear if it is worn chipped or if any teeth are missing Inspect governor weights They should move freely in governor gear Disassembly NOTE Governor gear is held onto sha...

Page 49: ...center shaft into corresponding recess in oil pan Apply consistent downward pressure to oil pump cover compressing oil pressure relief spring and start screws Secure oil pump by torquing screws in no...

Page 50: ...pressures on a specific area of piston Detonation generally occurs from using low octane fuels Preignition or ignition of fuel charge before timed spark can cause damage similar to detonation Preignit...

Page 51: ...to left of end gap Connecting Rods Offset stepped cap connecting rods are used in all these engines Inspection and Service Check bearing area big end for excessive wear score marks running and side c...

Page 52: ...kshaft is ground provides easy access for removing any grinding deposits collected in oil passages Use following procedure to remove and replace plug Procedure to Remove Crankshaft Plug 1 Drill a 3 16...

Page 53: ...e measurements These measurements should be taken at 3 locations in cylinder at top middle and bottom There are 2 measurements that should be taken perpendicular to each other at all 3 locations Clean...

Page 54: ...re oil seal is installed straight and true in bore and tool bottoms against crankcase Install Governor Cross Shaft 1 Lubricate governor cross shaft bearing surfaces in crankcase with engine oil 2 Slid...

Page 55: ...d Connecting Rod Details B A A Cylinder 1 B Cylinder 2 NOTE Cylinders are numbered on crankcase Make sure to install piston connecting rod and end cap into its appropriate cylinder bore as previously...

Page 56: ...gear meshes 5 Install screws securing oil pan to crankcase Torque fasteners to 24 4 N m 216 in lb following sequence On some engines one mounting screw is plated Plated screw is typically installed i...

Page 57: ...ke sure flywheel key is installed properly in keyway Flywheel can become cracked or damaged if key is not properly installed 1 Install woodruff key into keyway of crankshaft Make sure key is properly...

Page 58: ...being replaced Do not intermix components NOTE Match numbers embossed on cylinder heads and crankcase Heads Secured With Screws 1 Check to make sure there are no nicks or burrs on sealing surfaces of...

Page 59: ...nder On cylinder 1 single kill tab should be towards you On cylinder 2 single kill tab should be away from you in MDI modules are installed with flat side out towards you 3 Install each ignition modul...

Page 60: ...r D Rectifier Regulator E Outer Baffle F Electric Starter G Inner Baffle H Air Cleaner I Air Cleaner Gasket J Support Bracket K Fuel Pump L Oil Cooler M O ring N Nipple O Oil Filter P Plastic Debris S...

Page 61: ...sure any leads are routed out through proper offsets or notches so they will not be pinched between blower housing and baffles 4 Tighten all shrouding fasteners Torque blower housing screws to 6 2 N...

Page 62: ...ator ground lead with washer and green screw through eyelet If a grounding bracket is used secure with mounting screw and washer against outer side of rectifier regulator 2 Install B terminal lead int...

Page 63: ...ause fires and severe burns Do not fill fuel tank while engine is hot or running Gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only in approved containers in wel...

Page 64: ...e Position RPM Chart Note that hole positions are counted from pivot point of governor lever Governor Lever Hole Position B A F E D C A Governor Lever B Governed Idle Hole C Hole 1 D Hole 2 E Hole 3 F...

Page 65: ...nto mounting studs Secure with hex flange nuts Torque nuts in 2 stages first to 7 3 N m 65 in lb then finally to 8 2 N m 73 in lb using sequence shown 4 Install 2 screws securing support bracket to ai...

Page 66: ...ting Engine It is recommended that engine be operated on a test stand or bench prior to installation in piece of equipment 1 Set engine up on a test stand Install an oil pressure gauge Start engine an...

Page 67: ...67 24 690 37 Rev B KohlerEngines com...

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Kohler Command PRO CV682, Service Manual

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