CH940-CH1000 Service Manual 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.
Safety SAFETY PRECAUTIONS WARNING: A hazard that could result in death, serious injury, or substantial property damage. CAUTION: A hazard that could result in minor personal injury or property damage. NOTE: is used to notify people of important installation, operation, or maintenance information. WARNING Explosive Fuel can cause 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.
Maintenance MAINTENANCE INSTRUCTIONS WARNING Accidental Starts can cause severe injury or death. Disconnect and ground spark plug lead(s) before servicing. Before working on engine or equipment, disable engine as follows: 1) Disconnect spark plug lead(s). 2) Disconnect negative (–) battery cable from battery.
Maintenance OIL RECOMMENDATIONS We recommend use of Kohler oils for best performance. Other high-quality detergent oils (including synthetic) of API (American Petroleum Institute) service class SJ or higher are acceptable. Select viscosity based on air temperature at time of operation as shown in table below. STORAGE If engine will be out of service for 2 months or more follow procedure below. 1. Add Kohler PRO Series fuel treatment or equivalent to fuel tank.
Specifications Engine Dimensions with Heavy-Duty Air Cleaner Dimensions in millimeters. Inch equivalents shown in [ ]. 62 690 01 Rev. C KohlerEngines.
Specifications Engine Dimensions with Low-Profile Air Cleaner Dimensions in millimeters. Inch equivalents shown in [ ]. 6 KohlerEngines.com 62 690 01 Rev.
Specifications ENGINE IDENTIFICATION NUMBERS Kohler engine identification numbers (model, specification and serial) should be referenced for efficient repair, ordering correct parts, and engine replacement. Model . . . . . . . . . . . . . . . . . . . . . CH940 Command Engine Horizontal Shaft Numerical Designation Specification . . . . . . . . . . . . . . . CH940-0001 Serial . . . . . . . . . . . . . . . . . . . . .
Specifications TORQUE SPECIFICATIONS3,5 CH940 Control Panel M6 screw CH960 CH980 10.7 N·m (95 in. lb.) into new holes 7.3 N·m (65 in. lb.) into used holes 6.2 N·m (55 in. lb.) into new holes 4.0 N·m (35 in. lb.) into used holes M5 screws Crankcase Breather Cover Fastener Oil Drain Plug 5.7 N·m (51 in. lb.) 21.4 N·m (16 ft. lb.) Cylinder Head Cylinder Head Fastener (torque in 2 increments) Head Bolt first to 22.6 N·m (200 in. lb.) finally to 45.2 N·m (400 in. lb.) 28.25 N·m (250 in. lb.) 14.
Specifications TORQUE SPECIFICATIONS3,5 CH940 Oil Pickup Screen Mounting Screw CH960 CH980 10.7 N·m (95 in. lb.) into new holes 7.3 N·m (65 in. lb.) into used holes Oil Pickup Tube Mounting Screw 10.7 N·m (95 in. lb.) into new holes 7.3 N·m (65 in. lb.) into used holes Oil Pump Mounting Screw 10.7 N·m (95 in. lb.) into new holes 6.7 N·m (60 in. lb.) into used holes Oil SentryTM Pressure Switch 10.1 N·m (90 in. lb.) Reservoir (oil) Mounting Screw 24.4 N·m (216 in. lb.
Specifications CLEARANCE SPECIFICATIONS3 CH940 Connecting Rod Crankpin End I.D. @ 70°F New Max. Wear Limit Connecting Rod-to-Crankpin Running Clearance New Max. Wear Limit Connecting Rod-to-Crankpin Side Clearance Connecting Rod-to-Piston Pin Running Clearance Piston Pin End I.D. @ 70°F New Max. Wear Limit Crankcase Governor Cross Shaft Bore I.D. New Max. Wear Limit Crankshaft End Play (free) Crankshaft Bore (in crankcase) New, Without Main Bearing With Main Bearing Installed Max.
Specifications CLEARANCE SPECIFICATIONS3 Cylinder Head Max. Out-of-Flatness Governor Governor Cross Shaft-to-Crankcase Running Clearance Governor Cross Shaft O.D. New Max. Wear Limit Governor Gear Shaft-to-Governor Gear Running Clearance Governor Gear Shaft O.D. New Max. Wear Limit Ignition Spark Plug Gap Ignition Module Air Gap Crankshaft Bearing (flywheel/PTO) New (installed) Max. Wear Limit Piston, Piston Rings, and Piston Pin Piston-to-Piston Pin Running Clearance Piston Pin Bore I.D. New Max.
Specifications GENERAL TORQUE VALUES 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 Tightening Torque: N·m (in. lb.) ± 20% 8-32 2.3 (20) 10-24 3.6 (32) 10-32 3.6 (32) 1/4-20 7.9 (70) 1/4-28 9.6 (85) 5/16-18 17.0 (150) 5/16-24 18.7 (165) 3/8-16 29.4 (260) 3/8-24 33.9 (300) Grade 5 Grade 8 2.8 (25) 4.5 (40) 4.5 (40) 13.0 (115) 15.8 (140) 28.3 (250) 30.
Tools and Aids Certain quality tools are designed to help you perform specific disassembly, repair, and reassembly procedures. By using these tools, 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 a list of tools and their source. SEPARATE TOOL SUPPLIERS Kohler Tools Contact your local Kohler source of supply. SE Tools 415 Howard St.
Tools and Aids TOOLS Description Hydraulic Valve Lifter Tool For removing and installing hydraulic lifters. Ignition System Tester For testing output on all systems, including CD. Inductive Tachometer (Digital) For checking operating speed (RPM) of an engine. Offset Wrench (K and M Series) For removing and reinstalling cylinder barrel retaining nuts. Oil Pressure Test Kit For testing/verifying oil pressure on pressure lubricated engines.
Tools and Aids FLYWHEEL HOLDING TOOL ROCKER ARM/CRANKSHAFT TOOL A flywheel holding tool can be made out of an old junk flywheel ring gear and used in place of a strap wrench. 1. Using an abrasive cut-off wheel, cut out a six tooth segment of ring gear as shown. 2. Grind off any burrs or sharp edges. 3. Invert segment and place it between ignition bosses on crankcase so tool teeth engage flywheel ring gear teeth.
Troubleshooting TROUBLESHOOTING GUIDE When troubles occur, be sure 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 listed below and vary by engine specification. Use these to locate causing factors. Engine Cranks But Will Not Start ● Battery connected backwards. ● Blown fuse. ● Carburetor solenoid malfunction. ● Choke not closing.
Troubleshooting Engine Loses Power ● Dirty air cleaner element. ● Engine overheated. ● Excessive engine load. ● Restricted exhaust. ● Faulty spark plug(s). ● High crankcase oil level. ● Incorrect governor setting. ● Low battery. ● Low compression. ● Low crankcase oil level. ● Quality of fuel (dirt, water, stale, mixture). Engine Uses Excessive Amount of Oil ● Loose or improperly torqued fasteners. ● Blown head gasket/overheated. ● Breather reed broken. ● Clogged, broken, or inoperative crankcase breather.
Troubleshooting CRANKCASE VACUUM TEST WARNING WARNING Carbon Monoxide can cause severe nausea, fainting or death. Avoid inhaling exhaust fumes. Engine exhaust gases contain poisonous carbon monoxide. Carbon monoxide is odorless, colorless, and can cause death if inhaled. Rotating Parts can cause severe injury. Stay away while engine is in operation. Keep hands, feet, hair, and clothing away from all moving parts to prevent injury. Never operate engine with covers, shrouds, or guards removed.
Troubleshooting COMPRESSION TEST For Command Twins: A compression test is best performed on a warm engine. Clean any dirt or debris away from base of spark plug(s) before removing them. Be sure choke is off, and throttle is wide open during test. Compression should be at least 160 psi and should not vary more than 15% between cylinders. All other models: These engines are equipped with an automatic compression release (ACR) mechanism.
Air Cleaner/Intake AIR CLEANER These systems are CARB/EPA certified and components should not be altered or modified in any way.
Fuel System Typical carbureted fuel system and related components include: ● Fuel tank and valve. ● Fuel lines. ● In-line fuel filter. ● Fuel pump. ● Carburetor. Fuel from tank is moved through in-line filter and fuel lines by fuel pump. Fuel then enters carburetor float bowl and is drawn into carburetor body and mixed with air. This fuel-air mixture is then burned in engine combustion chamber. FUEL RECOMMENDATIONS Refer to Maintenance.
Fuel System CARBURETOR Gasoline is extremely flammable and its vapors can explode if ignited. Store gasoline only in approved containers, in well ventilated, unoccupied buildings, away from sparks or flames. Spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition. Never use gasoline as a cleaning agent. WARNING Explosive Fuel can cause fires and severe burns. Do not fill fuel tank while engine is hot or running.
Fuel System Engines in this series are equipped with a two-barrel, side-draft carburetor with fixed main jets on a matching intake manifold. Carburetor features a self-relieving choke, serviceable slow jets, main jets, bowl drain and a fuel shutdown solenoid. Troubleshooting Checklist When engine starts hard, runs rough, or stalls at low idle speed, check these areas before adjusting or disassembling carburetor. 1. Make sure fuel tank is filled with clean, fresh gasoline. 2.
Fuel System Fuel Shut-off Solenoid Most carburetors are equipped with a fuel shut-off solenoid. Solenoid is attached to fuel bowl. Solenoid has a spring-loaded pin that retracts when 12 volts is applied to lead, allowing fuel flow to main jets. When current is removed pin extends blocking fuel flow. Below is a simple test, performed with engine off, that can determine if solenoid is functioning properly: 1. Shut off fuel and remove solenoid from carburetor.
Fuel System NOTE: Engines will have fixed low idle or limiter caps on idle fuel adjusting needles. Step 2 can only be performed within limits allowed by cap. Do not attempt to remove limiter caps. 1. Place throttle control into idle or slow position. Adjust low idle speed to 1200 RPM. Follow Low Idle Speed (RPM) Adjustment. 2. Low idle fuel needle(s) setting: place throttle into idle or slow position. a.
Fuel System 13. Turn old bushing upside down and use it as a driver to carefully press or tap new bushing into carburetor body until it bottoms. Check that choke lever pivots freely without restriction or binding. 14. Install new return spring onto new choke shaft, so outboard leg of spring is behind formed stop on end of choke shaft. Make sure it stays in this location during following step. 15. Slide choke shaft and spring into carburetor.
Governor System GOVERNOR Governed speed setting is determined by position of throttle control. It can be variable or constant, depending on engine application. Governor is designed to hold engine speed constant under changing load conditions. Most engines are equipped with a centrifugal flyweight mechanical governor. Governor gear/flyweight mechanism of mechanical governor is mounted inside crankcase and is driven off gear on camshaft.
Lubrication System This engine uses a full pressure lubrication system which delivers oil under pressure to crankshaft, camshaft, connecting rod bearing surfaces, and hydraulic valve lifters. A high-efficiency gerotor oil pump maintains high oil flow and oil pressure, even at low speeds and high operating temperatures. A pressure relief valve limits maximum pressure of system. Closure plate must be removed to service oil pickup, pressure relief valve, and oil pump.
Lubrication System OIL COOLER NOTE: Oil cooler is mounted under cylinder shroud. Removal of cylinder shroud is necessary to access oil cooler. 1. Clean fins with a brush or compressed air. 2. Remove screws securing oil cooler and tilt to clean back side. 3. Reinstall oil cooler and torque to 2.2 N·m (20 in. lb.). OIL SENTRY™ (if equipped) This switch is designed to prevent engine from starting in a low oil or no oil condition. Oil Sentry™ may not shut down a running engine before damage occurs.
Electrical System SPARK PLUGS CAUTION Electrical Shock can cause injury. Do not touch wires while engine is running. Spark Plug Component and Details Inspection Inspect each spark plug as it is removed from cylinder head. Deposits on tip are an indication of general condition of piston rings, valves, and carburetor. Normal and fouled plugs are shown in following photos: Normal A B Plug taken from an engine operating under normal conditions will have light tan or gray colored deposits.
Electrical System ELECTRONIC IGNITION SYSTEMS Ignition System Components Carbon Fouled F A E B Soft, sooty, black deposits indicate incomplete combustion caused by a restricted air cleaner, over rich carburetion, weak ignition, or poor compression. Overheated C A C E Chalky, white deposits indicate very high combustion temperatures. This condition is usually accompanied by excessive gap erosion.
Electrical System Fixed Ignition System This system uses a capacitive discharge (CD) coil. Ignition timing and spark remains constant regardless of engine speed. Timing of spark is controlled by location of flywheel magnet group as referenced to engine TDC. A typical fixed ignition system consists of: ● 1 magnet assembly which is permanently affixed to flywheel. ● 2 electronic capacitive-discharge ignition modules which mount on engine crankcase.
Electrical System Wire Diagram-15/20/25 Amp Regulated Battery Charging System with Fixed Timing, Five Pin Connector, Key Switch, and Fuse H I J N O P K M B G AI AG AH X G C B A F B D D L S B Q Z R B AD Y R AF A T F AB B G D U V AC C AJ AJ S AE F AA W E 8 A Blue B Red C Green (Oil Sentry™ Pulse Signal)8 D Yellow E Violet F White G Black H Key Switch I To Battery J To Accessory K Ground L To Rectifier-Regulator M To Magneto N To Starter
Electrical System Digital Spark Advance Ignition (DSAI) System This system uses a digital microprocessor which is located in ignition modules. Ignition timing varies depending upon engine speed with this system. There are 2 inductive-style ignition modules that control ignition timing based on engine RPM. A typical DSAI application consists of: ● 1 magnet assembly, which is permanently affixed to flywheel. ● 2 inductive, 12-volt ignition modules, which mount on engine crankcase.
Electrical System Wire Diagram-15/20/25 Amp Regulated Battery Charging System with DSAI Ignition and Four Pin Connector (LP-NG Kohler Power Systems Application) H G A C AB E Z AE S Q J A R K T P I AA Z T O D C L F T AD U S M AD V N X W Y B AC Red B Green C Orange D E White I Battery F Black J Battery Positive G Connector H Polarity Ribs K Battery Negative L Starter Solenoid Stud M External Starter Solenoid Wire N Starter O Rectifier-Regulator Connector P Rec
Electrical System Wire Diagram-15/20/25 Amp Regulated Battery Charging System with DSAI Ignition and Five Pin Connector (Gasoline/LP-NG Non-Kohler Power Systems Application) H I B D AF X AE A S K W B T L F V Q J U X T R M G E Y Z S N T B Y AA AC AB O AD C P Blue B Red C Green D E Violet I Polarity Ribs F White J Battery G Black H Connector K Battery Positive L Battery Negative M Starter Solenoid Stud N Starter Solenoid Tang O Starter P Oil Sentry™
Electrical System Electronic Ignition Systems Tests Special Tools Required: NOTE: Ignition tester must be used to test ignition on these engines. Use of any other tester can result in inaccurate findings. Battery on unit must be fully charged and properly connected before performing tests (a battery that is hooked up or charged backward will crank engine but it won’t have spark). Be certain drive is in neutral and all external loads are disconnected. ● Hand tachometer. ● Ignition tester.
Electrical System Test Timing Advance (DSAI only) 1. Make a line near edge of flywheel screen with a marking pen, chalk, or narrow tape. 2. Connect an automotive timing light to cylinder that had good spark. 3. Run engine at idle and use timing light beam to locate line on screen. Draw a line on blower housing next to line on screen. Accelerate to full throttle and watch for movement of line on screen relative to line on blower housing. If both cylinders had good spark, repeat test on other cylinder.
Electrical System BATTERY CHARGING SYSTEM NOTE: Observe following 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 plug before doing any electric welding on equipment powered by engine. Disconnect all other electrical accessories in common ground with engine. ● Prevent stator (AC) leads from touching or shorting while engine is running.
Electrical System 15/20/25 Amp Battery Charging Systems NOTE: Always zero ohmmeter on each scale before testing to ensure accurate readings. Voltage tests should be made with engine running at 3600 RPM with no load. Battery must be good and fully charged. When problems occur in keeping battery charged or battery charges at high rate, charging system or battery might be causing problems. To test charging system for no charge to battery: 1. Insert an ammeter in B+ lead from rectifier-regulator.
Electrical System ELECTRIC STARTING MOTOR NOTE: Do not crank engine continuously for more than 10 seconds. Allow a 60 second cool down period between starting attempts. Failure to follow these guidelines can burn out starter motor. NOTE: If engine develops sufficient speed to disengage starter but does not keep running (a false start), engine rotation must be allowed to come to a complete stop before attempting to restart engine.
Electrical System Solenoid Shift Starter Components I H J G K F L E M D N C O Inspection Drive Pinion Check and inspect following areas: ● Pinion teeth for abnormal wear or damage. ● Surface between pinion and clutch mechanism for nicks or irregularities which could cause seal damage. ● Check drive clutch by holding clutch housing and rotating pinion. Pinion should rotate in only 1 direction. Brushes and Springs Detail P Q B R S A 5.
Electrical System C 3. D E 4. C Insulation Check D Armature Coil E Continuity Check 1. Clean and inspect commutator (outer surface). Mica insulation must be lower than commutator bars (undercut) to ensure proper operation of commutator. 2. Use an ohmmeter set to Rx1 scale. Touch probes between 2 different segments of commutator, and check for continuity. Test all segments. Continuity must exist between all or armature is bad. 3.
Electrical System 12. Install thru bolts and brush holder mounting screws. Torque bolts to 5.6-9.0 N·m (49-79 in. lb.) and brush holder mounting screws to 2.5-3.3 N·m (22-29 in. lb.). 13. Hook plunger behind upper end of drive lever and install spring into solenoid. Insert mounting screws through holes in drive end cap. Use these to hold solenoid gasket in position, then mount solenoid. Torque screws to 4.0-6.0 N·m (35-53 in. lb.). 14. Connect positive (+) brush lead/bracket to solenoid and secure with nut.
Disassembly/Inspection and Service WARNING Accidental Starts can cause severe injury or death. Disconnect and ground spark plug lead(s) before servicing. Before working on engine or equipment, disable engine as follows: 1) Disconnect spark plug lead(s). 2) Disconnect negative (–) battery cable from battery.
Disassembly/Inspection and Service 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 available cleaners that will quickly remove grease, oil and grime from engine parts. When such a cleaner is used, follow manufacturer’s instructions and safety precautions carefully. Make sure all traces of cleaner are removed before engine is reassembled and placed into operation.
Disassembly/Inspection and Service Remove Oil Cooler NOTE: New clamps are recommended any time disassembly is performed, or if clamps have been loosened (expanded) several times. 1. Remove oil cooler mounting screws. Do not lose any washers (if used). 2. Loosen clamps and disconnect hoses from oil cooler. Remove Oil Filter Housing and Oil Filter Adapter NOTE: Further disassembly of oil filter housing assembly is not required unless being serviced individually. Follow substeps a, b, and c. 1.
Disassembly/Inspection and Service Remove Flywheel NOTE: Always use a flywheel strap wrench or holding tool to hold flywheel when loosening or tightening flywheel screw. Do not use any type of bar or wedge to hold flywheel. Use of such tools could cause flywheel to become cracked or damaged. NOTE: Always use a flywheel puller to remove flywheel from crankshaft. Do not strike crankshaft or flywheel, as these parts could become cracked or damaged. 1.
Disassembly/Inspection and Service Cylinder Head Components A R Q P M I K O L D N J H E F G C B A Gasket B Valve C Cylinder Head D Pipe Plug E Spacer F Washer G Spark Plug H Valve Stem Seal I Valve Spring J Hydraulic Lifter K Valve Spring Retainer L Push Rod M Valve Spring Keeper N Rocker Arm O Rocker Arm Pivots P Valve Cover Gasket Q Valve Cover R Grommet Remove Valve Covers and Fuel Pump WARNING Explosive Fuel can cause fires and severe burns.
Disassembly/Inspection and Service 3. Mark position of push rods as either intake or exhaust and cylinder 1 or 2. Push rods should always be reinstalled in same positions. 4. Carefully remove push rods, cylinder head and head gasket. 5. Repeat procedure for other cylinder head. 6. Remove lifters from lifter bores. Use a hydraulic lifter tool. Do not use a magnet to remove lifters. Mark lifters by location, as either intake or exhaust and cylinder 1 or 2.
Disassembly/Inspection and Service After cleaning, check flatness of cylinder head and corresponding top surface of crankcase using a surface plate or piece of glass and feeler gauge. Maximum allowable out of flatness is 0.076 mm (0.003 in.). Carefully inspect valve mechanism parts. Inspect valve springs and related hardware for excessive wear or distortion. Check valves and valve seat area or inserts for evidence of deep pitting, cracks, or distortion. Check clearance of valve stems in guides.
Disassembly/Inspection and Service Breather/Closure Plate/Oil Reservoir Components O T P Q R S E D C A B U M H N G F I H K L J V K A Closure Plate B Gerotor Gears C Oil Pump O-Ring D Oil Pump Housing E Relief Valve Baffle F Pickup Tube G Clamp H Inlet Seal I Pickup Screen J Oil Reservoir K Drain Plug L Gasket M Crankshaft Bearing (PTO) N Closure Plate Gasket O Dipstick P Dipstick Tube Q Breather Assembly R Breather Gasket S Filter T Breather Hose U Lifti
Disassembly/Inspection and Service Remove Closure Plate Assembly 1. Remove screws securing closure plate to crankcase. 2. Locate protruding tabs on closure plate. Carefully tap to break gasket seal. Do not pry on sealing surfaces as this could cause leaks. Separate closure plate from crankcase. Remove old gasket. Inspection Inspect oil seal in closure plate and remove it if worn or damaged. Inspect crankshaft bearing surface for wear or damage. Replace bearing or closure plate assembly if required.
Disassembly/Inspection and Service Crankcase Components Q P H B C D C O E F G A L M N K I J A Camshaft B Locking Tab C Regulating Pin D Governor Gear E Cross Shaft F Lifter Feed Cover Gasket G Lifter Feed Cover H Governor Yoke I Crankshaft J Connecting Rod End Cap K Connecting Rod L Piston Pin M Piston Pin Retainer N Piston O Piston Ring Set P Oil Seal Q Crankshaft Bearing (Flywheel) Remove Camshaft Remove camshaft and shim (if used).
Disassembly/Inspection and Service Piston and Rings Inspection Piston and Rings Components and Details A B C D E F G I H A Piston Ring B End Gap C Identification Mark D Piston E Top Compression Ring F Center Compression Ring G Rails H Expander I Oil Control Ring (3 Piece) Scuffing and scoring of pistons and cylinder walls occurs when internal engine temperatures approach welding point of piston.
Disassembly/Inspection and Service 3. Top compression ring (top groove): Install top ring using a piston ring expander. Make sure identification mark is up or colored dye stripe (if contained), is to left of end gap. Remove Crankshaft NOTE: If crankpin is reground, visually check to ensure that fillet blends smoothly with crankpin surface. Carefully pull crankshaft from crankcase. Note thrust washers and shims if used.
Disassembly/Inspection and Service Remove Governor Yoke, Cross Shaft, and Seal 1. Remove mounting screws securing yoke to governor cross shaft. 2. Pull governor cross shaft out of crankcase and remove seal. Honing Detail A Remove Lifter Feed Chamber Cover and Gaskets Remove screws securing lifter feed chamber baffle (some models only), cover, and gaskets. Carefully separate parts from crankcase. Remove Flywheel and PTO End Oil Seals Remove oil seals from crankcase and closure plate using a seal puller.
Disassembly/Inspection and Service Clean Cylinder Bore After Honing Proper cleaning of cylinder walls following boring and/ or honing is very critical to a successful overhaul. Machining grit left in cylinder bore can destroy an engine in less than 1 hour of operation after a rebuild. Final cleaning operation should always be a thorough scrubbing with a brush and hot, soapy water. Use a strong detergent that is capable of breaking down machining oil while maintaining a good level of suds.
Reassembly Crankcase Components Q P H B C D C O E F G A L Camshaft N K I A M J B Locking Tab C Regulating Pin D Governor Gear G Lifter Feed Cover H Governor Yoke E Cross Shaft F Lifter Feed Cover Gasket I Crankshaft J Connecting Rod End Cap K Connecting Rod L Piston Pin M Piston Pin Retainer N Piston O Piston Ring Set P Oil Seal Q Crankshaft Bearing (Flywheel) NOTE: Make sure engine is assembled using all specified torque values, torque sequences, and clearan
Reassembly Install Governor Shafts, Seal, and Governor Gear Governor Components and Details B Install Crankshaft Carefully slide flywheel end of crankshaft through bearing in crankcase. Install Connecting Rods with Pistons and Rings Piston Details C A C F D E A A Crankcase Surface B Seal Depth 1.5-2.0 mm (0.059-0.078 in.) C Oil Seal D 12.66 mm (0.498 in.) E Crankcase Surface F Governor Gear Shaft If governor shafts, seal, and/or governor gear were removed, reassemble as follows. 1.
Reassembly Breather/Closure Plate/Oil Reservoir Components O T P Q R S E D C A B U M H N G F I H K L J V K A Closure Plate B Gerotor Gears C Oil Pump O-Ring D Oil Pump Housing E Relief Valve Baffle F Pickup Tube G Clamp H Inlet Seal I Pickup Screen J Oil Reservoir K Drain Plug L Gasket M Crankshaft Bearing (PTO) N Closure Plate Gasket O Dipstick P Dipstick Tube Q Breather Assembly R Breather Gasket S Filter T Breather Hose U Lifting Strap V Oil Seal I
Reassembly Several color coded shims are available: White: 0.69215/0.73025 mm (0.02725/0.02875 in.) Blue: 0.74295/0.78105 mm (0.02925/0.03075 in.) Red: 0.79375/0.83185 mm (0.03125/0.03275 in.) Yellow: 0.84455/0.88265 mm (0.03325/0.03475 in.) Install Closure Plate Assembly Torque Sequence 1 3 14 Gray: 0.94615/0.98425 mm (0.03725/0.03875 in.) Black: 0.99695/1.03505 mm (0.03925/0.04075 in.) 4. Reinstall end play checking tool and recheck end play.
Reassembly 1. Use bolts with heads removed, or a similar item as temporary alignment pins and install into 2 center holes on ends. 2. Install a new oil reservoir gasket onto bottom of crankcase using alignment pins. Notched side of gasket must be towards flywheel. 3. Install oil reservoir onto crankcase and temporary alignment pins. Flywheel side is indicated on cover. Install and finger tighten screws. Remove alignment pins and install remaining screws. Torque screws in sequence shown to 24.4 N·m (216 in.
Reassembly Cylinder Head Components A R Q P M I K O L D N J H E F G C B A Gasket B Valve C Cylinder Head D Pipe Plug E Spacer F Washer G Spark Plug H Valve Stem Seal I Valve Spring J Hydraulic Lifter K Valve Spring Retainer L Push Rod M Valve Spring Keeper N Rocker Arm O Rocker Arm Pivots P Valve Cover Gasket Q Valve Cover R Grommet Install Hydraulic Lifters NOTE: Hydraulic lifters should always be installed in same position as they were disassembled.
Reassembly Install Cylinder Heads Torque Sequence 2 2 5 4 1 3 1 5 4 3 1 2 NOTE: Match numbers embossed on cylinder heads and crankcase. 1. Check to make sure there are no nicks or burrs on sealing surfaces of cylinder head or crankcase. 2. Check dowel pins are in place in 2 lower locations, and install a new cylinder head gasket, (printed side up). 3. Install cylinder head. Make sure head is flat on gasket and dowel pins. Install a flat washer on screws in locations 1 and 3.
Reassembly Oil Cooler/Filter Components Install Intake Manifold Torque Sequence K J A M 3 4 N B 1 2 C M D E L F K G I J I H A Oil Filter B Oil Filter Nipple C Cup D Valve Spring E Cup Spring F Oil Filter Valve G Oil Filter Housing H Pin I O-ring J Hose Clamp K Fitting L Adapter M Hose N Oil Cooler Install Oil Filter Adapter 1. Make sure all sealing surfaces are clean and dowel pins are in place on crankcase adapter surface.
Reassembly Flywheel/Ignition Components O B A F C N M D L K J E I H G A Rectifier-Regulator B Ignition Module C Washer D Flywheel Screw E Special Washer F Wire Harness Clamp G Debris Screen H Fan I Stiffener J Hex Stud K Flywheel L Magnet M Stator N Backing Shroud O Woodruff Key Install Backing Shroud Assembly NOTE: New hose clamps are recommended for reassembly, or if clamps have been loosened (expanded) several times to avoid leakage. 1.
Reassembly Install Flywheel Install Cooling Fan and Debris Screen CAUTION CAUTION Damaging Crankshaft and Flywheel Can cause personal injury. Using improper procedures can lead to broken fragments. Broken fragments could be thrown from engine. Always observe and use precautions and procedures when installing flywheel. NOTE: Before installing flywheel make sure crankshaft taper and flywheel hub are clean, dry, and completely free of any lubricants.
Reassembly External Engine Components T Q U A B C S T D E F R Q U V W G O O P V X H V I N J H K I M L K A Oil Filter B Oil Filter Nipple C Oil Filter Cup D Valve Spring E Cup Spring F Valve G Oil Filter Housing H Valley Baffle I Outer Cylinder Baffle J Electric Starter K Cylinder Shroud L Blower Housing M Fixed Guard N Oil Sentry™ O O-ring P Pin Q Fitting R Oil Filter Adapter S Oil Cooler T Hose U Hose Clamp V Gasket W Carburetor X Intake Man
Reassembly Install Oil Cooler 1. Connect hoses between oil filter adapter and oil cooler. Secure with new clamps. 2. Align oil cooler with bosses in backing shroud assembly. Secure screws and washers to 2.2 N·m (20 in. lb.). Install Carburetor WARNING Explosive Fuel can cause fires and severe burns. Do not fill fuel tank while engine is hot or running. Install Electric Starter 1. Install electric starter motor using screws. 2. Torque screws to 15.3 N·m (135 in. lb.). 3. Connect leads to solenoid.
Reassembly Install Governor Lever Install governor lever onto governor shaft and connect throttle linkage with black clip. Do not tighten governor lever at this time. Install Control Bracket and Air Cleaner Assembly Torque Sequence 3, 7 1, 5 2, 6 4, 8 NOTE: Low-profile air cleaner is installed similarly to Heavy-duty air cleaner. 1. Position control bracket assembly onto 2 intake manifold bosses.
Reassembly Install Oil Sentry™ (if equipped) 1. Apply pipe sealant with Teflon® (Loctite® PST® 592™ Thread Sealant or equivalent) to Oil Sentry™ threads switch and install it into 1/8 in. port in closure plate. Torque switch to 10.1 N·m (90 in. lb.). 2. Connect green wire lead to Oil Sentry™ terminal. Install Blower Housing and Cylinder Shrouds 1. Align and install blower housing. 2. Secure blower housing with screws. Torque screws to 4.0 N·m (35 in. lb.) into new holes, or 2.0 N·m (18 in. lb.
62 690 01 Rev. C KohlerEngines.
KohlerEngines.com 62 690 01 Rev.
62 690 01 Rev. C KohlerEngines.
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