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CV682, CV732, CV742, CV752
S

ervice Manual

Safety

Maintenance

Specifications

Tools and Aids

Troubleshooting

Air Cleaner/Intake

Fuel System

Governor System

Lubrication System

Electrical System

Starter System

Disassembly/Inspection and Service

Reassembly

IMPORTANT: Read all safety precautions and instructions carefully before operating equipment. Refer to operating

instruction of equipment that this engine powers.

Ensure engine is stopped and level before performing any maintenance or service.

24 690 37 Rev. B

KohlerEngines.com

Содержание Command PRO CV682

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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