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1. 58 18 58 19 Datery C hargine oye 5B 19 Fuel Components P T 5B 19 5B 20 Puel Pressure Kep 5B 20 5B 22 T 5 22 TET ME IL 2822 PHS 5 22 5 23 Throttle body Intake T 5B 23 466 20 ME 5B 23 5B 24 miat Ere AS NT cm 5 24 5 26 Troubleshooting i Exe lo err Mirren Teer Teer Terre Trent eer er tren o mT er eT rn rT 5B 26 T TIT 5B 27 5B 33 T 5B 34 CS areas EE 5B 34 5B 43 EIOW 5 43 5 44 Flow 5B 45 5B 46 Fe VC BOO Refer to Section 2 58 1 Section 5B EFI Fuel System Description A WARNING Explosive Fuel can cause fires and severe burns Fuel system ALWAYS remains under HIGH PRESSURE
2. 35 Pin ECU ALL Weather Connector 8i Ignition Ignition Coil 1 IL a2 811 wr PS Red Red Cylinder 1 Terminal Terminal Cylinder 2 Relay Spark Plug Spark Plug Black Terminal shielded Wire Diog Lasp um AMNES aS ci a es et Me ae ee MEE _______ PP ___ 8g 2 18 Note GD ___ nile 3 Z 5 TPS Initialization 08 8 5 8 s F211 B 2 2 1 ge fU D LJ See Ground EB Note A POSITION T Injector 1 Injector 2 Diagnostic Connector MOTOR SENSOR SENSR Inductive pick up 321 321 Loabde sensor i See Ground ee Groun E Note Note F Grounding Notes Injector Ignition Output Driver Attach to chassis as close to ECU as possible Battery Attach to engine block near starter E Shield Attach to engine block near Coll 2 Wire from shield to ground Location to be as short as possible The Lambda the engine via the exhaust sustem If a slip joint exhaust system is used ding strap Fon the engine to the Muffler near the La ibda sensor iS required Fuel Pump Attach to chassis See Ground 30 87A Normal 1 2 4 5 6 7 8 9 9
3. nennen nnn nn nnne rn nr 12 C Defective Service Parts Installed oe 12 D Defective Service Parts Installed During Engine Warranty Period 12 E Warranty Options and Accessories 12 Tha Options Factory NsSialled UU c m 12 2 Accessories Field Installed ENTE 12 Section 5 Warranty Exclusion Non Reimburseable _______ __ __ 13 Section 6 Claims Procedure A Responsibility for Submitting Proper and Completed Warranty Claim 13 E Waranty Re 13 Sure IEEE ____ _ __ 13 15 Section 7 Reimbursement Procedures ME eaters sce T Te 15 B Reimbursement Calculation Details a Cun d oii 15 16 Ts USA NE Tec MIO mo 9 dE 15 16 A OS NEIN 16 2 ___ biu UE pe 16 A Inter
4. 80 000 80 025 mm 3 1496 3 1506 in 25 26 735 730 740 745 750 82 988 83 013 mm 3 2672 3 2682 in Max Wear Limit CH18 CH620 CH20 CH640 CH22 624 77 063 mm 3 0340 in Max Wear Limit CH22 CH670 CH23 CH680 674 80 065 mm 3 1522 in Max Wear Limit CH25 CH26 CH735 CH730 CH740 CH745 CH750 83 051 mm 3 2697 in COU FO OUNCE 0 12 mm 0 0047 in A ro Mio pect set 0 05 mm 0 0020 in Cylinder Head Cylinder Head Fastener Torque Hex Flange Nut Torque in Two first to 16 9 N m 150 in Ib finally to 33 9 N m 300 in Ib Head Bolt imn TWO CS first to 22 6 N m 200 in Ib finally to 41 8 N m 370 in Ib Max LOB OS occiduo dia itu a Er EEA a 0 076 mm 0 003 in Rocker T 11 3 N m 100 in Ib Fan Flywheel Lon leausmmaesaetesate 9 9 N m 88 in Ib Flywheel Retaining Screw 66 4 N m 49 ft Ib Governor Governor Cross Shaft to Crankcase Running Clearance EL E RR MD PEN 0 013 0 075 mm 0 0005 0 0030 in B qnt
5. Mo 6 025 6 050 mm 0 2372 0 2382 in Max Wear Croit RI 6 063 mm 0 2387 in 8 mm Shaft ho 8 025 8 075 mm 0 3159 0 3179 in IIS hoc atieessg ecto car unas tasa gt 8 088 mm 0 3184 in breater Cover P aS dtu URL headers 7 3 N m 65 in Ib ODD t de sameeren ret 13 6 N m 10 ft Ib Closure Plate Closure Plate Fastener FOEQUIO Losses beiden et hated donis adus 24 4 N m 216 in Ib Crankshaft uc dui MT 0 070 0 590 mm 0 0028 0 0230 in End Play With Thrust Bearing 0 070 0 270 mm 0 0028 0 0100 in Except CH25 Engines Below Serial No 2403500008 0 050 0 750 mm 0 0020 0 0295 in Crankshaft Bore In Crankcase Mo 40 965 41 003 mm 1 6128 1 6143 in Max Wear CIT rH 41 016 mm 1 6148 in Crankshaft to Sleeve Bearing Crankcase Ronne NOW 0 03 0 09 mm 0 0012 0 0035 in Crankshaft Bore In Closure Plate NeW iccsssesaccssaccscncvesecdesatuasdevasiecatsesncansnteeanios 40 987 40 974 mm 1 6136 1 6131 in Crankshaft Bore In Closure Plate to Crankshaft
6. J TP 2466 A Distribution White Attach to Warranty Claim 9 94 Rev 4 97 Canary File Copy 29 KOHLER Carburetor Replacement Evaluation Form ENGI NI ES Attach to Warranty Claim Dealer Inspector Inspection Date Model Serial Spec Warranty Claim Carburetor No EWR Purpose Please read the Symptoms Observed below and complete only the section that applies to the carburetor failure This form must be filled out each time a warranty claim is submitted for a replacement carburetor Any claims submitted without this form attached will be returned Symptoms Observed 1 Cranks But Does Not Start Black Exhaust Smoke rich condition Check carburetor solenoid operation Check choke setting Check fuel supply Check air filter Check accelerator pump for leakage clamp hose to test Dies After Starting L Check for carburetor needle and seat leakage C Check fuel quality Check HDAC hose position L H side Check fuel supply to carburetor Check fuel tank venting Flooding Carburetor Check carburetor solenoid operation C Check fuel quality Check carburetor needle and seat for leakage Idles Rough Misfires _ Check fuel pump pressure 1 5 to 2 0 psi C Check fuel quality Check for intake leaks After Bang on Shutdown Check for dirt debris in carburetor jets Ensure engine is shutdown according to proper pr
7. Eee tT 82 841 mm 3 2614 in Piston Thrust Face to Cylinder Bore Running Clearance New CELTS C TEIG20 CHG40 C E122 624 0 014 0 057 mm 0 0005 0 0022 in CHO C H23 C H680 67 0 021 0 062 mm 0 0008 0 0024 in Ole C 0 001 0 045 mm 0 039 0 0018 in Speed Control Bracket PAS Be 1 10 7 N m 95 in into new holes 7 3 N m 65 in Ib into used holes Starter Assembly Thru Bolt Torque UTE Johnson Electric Eaton Inertia 4 5 5 7 N m 40 50 in Ib Nippondenso Solenoid 4 5 7 5 N m 40 84 in Ib IOI OD 5 6 9 0 N m 49 79 in Screw Torque emer nmr re Tere tren Terr Tart DS 15 3 N m 135 in Ib Brush Holder Mounting Screw Torque Delco Keny ic IM 2 5 3 3 22 29 in Ib Solenoid Starter Mounting Hardware Torque INTP PONG SENSO Sarte 6 0 9 0 N m 53 79 in E o nese a screens econ nes 4 0 6 0 N m 35 53 in Ib Nut Positive Brush Lead Torque INTO SO at tong 8 0 12 0 N m 71 106 in Ib doli iu rci emt Tc T 8 0 11 0 N m 71 97 in Ib Stator
8. Style B Style C Measure just below oil ring groove and at right angle to Measure 1 2 inch above the bottom of the skirt and at right Measure 6 mm 0 24 in piston pin angle to piston pin above the bottom of piston skirt at right angles to piston pin CYLINDER 1 CYLINDER 2 CYLINDER 1 CYLINDER 2 Scored LJ Scratched LJ LJ Worn O Not Damaged O L Cracked L Others Broken 0 LJ Ring Grooves Worn 0 L CYLINDER 1 CYLINDER 2 Galled L L Piston Diameter Discolored LJ CYLINDER BORE CYLINDER 1 CYLINDER 2 Bore Scored O L Worn LJ Not Damaged LJ Others MAXIMUM WEAR SPEC CYLINDER 2 MAX OUT OF oun p Top Center o Bottom Max Taper 31 KOHLER 2110195 ISSUED 1 79 BORN TO RUN REVISED 2 02 MAILED ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 LITHO IN U S A
9. Engine Short Block Transmission Authorized Signature Req d Authorized By Division Firm Name ESA 1571 REV 10 98 Box 1 Check box for type of claim and manufacturer Box 2 Enter Warranty Code Number Box 3 Enter engine owner s name address and have owner sign Box 4 Enter name of repairing dealer check box for type of dealer have technician sign Enter dates as requested Box 5 For regular Engine Warranty Claim fill in completely giving all information requested A Parts new defective in stock Enter parts in engine transmission model number section and leave the remaining sections blank Short block or miniblock new defective in stock Enter parts in engine transmission model number section List the defective assembly part number in the type or spec number section List the serial number in the code or serial number section Leave the remaining sections blank C Parts short block or miniblock found defective within 90 days after installation Enter parts engine model number Example Parts M8 in engine transmission model number section For a miniblock or short block list the part number in the type or spec number section List the serial number of the defective short block or miniblock in the code or serial number section and complete the remaining sections NOTE Boxes 1 2 4 8 and 16 are required for defective service parts In addition
10. Measure just below oil ring groove and at right angle to piston pin Measure 1 2 inch above the bottom of the skirt and at right Measure 6 mm 0 24 in angle to piston pin above the bottom of piston skirt at right angles to piston pin PANEER SERA CYLINDER1 CYLINDER 2 Scored E E Scratched LJ LJ Worn Not Damaged Cracked LJ Others Broken Ring Grooves Worn 0 CYLINDER 1 CYLINDER 2 Galled Piston Diameter Discolored LJ LJ CYLINDER BORE CYLINDER 1 CYLINDER 2 Bore Scored LJ LI Worn LJ 0 Not Damaged Others MAXIMUM WEAR SPEC MAX OUT OF x Y X XY ROUND Top EM Center Bottom scm 3 19 Section 9 Flat Rate Schedules Command Pro CS Series Flat Rate Schedule Major Repairs Engine R amp R Engine R amp R From Generator Set Major Overhaul Includes Valve Service Minor Overhaul Excludes Valve Service Connecting Rod Piston and or Rings Crankshaft Crankshaft 4 Main Bearing R R Crankshaft PTO Seal Crankshaft Flywheel Seal Crankshaft amp Connecting Rod Balance Shaft R Camshaft amp Valves Lifters Valve R amp R No Grinding Valve Tappet Adjustment Valve Grinding Valve Spring Replacement Valve Cover Gasket and or Breather Camshaft R amp R Rocker Arm Ignition Module R amp R Flywheel R amp R Charging Regulator Test Replace 0 5
11. Major Repairs 4051 Stator Test amp Replace Includes Flywheel R R Starter Retractable R Replace Rope amp Spring Starting Motor Bendix Type R amp Starter Drive R amp R Starter Solenoid R amp R Carburetor amp Air Intake Carburetor R amp R Carburetor Rebuild Includes R amp R Carburetor Adjust Air Cleaner Damage in Shipment Fuel Tank R amp R Intake Manifold Miscellaneous Repairs Cylinder Head and or Gasket Replace each Shrouds only R amp R Oil Pan Closure Plate and or Gasket Replace Muffler Replace Governor Adjustment Governor R amp R Crankshaft Grinding ENTER NET COST Crankcase Boring ENTER NET COST Governor Seal Replacement Oil Sentry Module Oil Sentry Float Gear Reduction R amp R 20 Courage XT Series Courage Single amp Maximum Time Hr Command Single Flat Rate Schedule CH11 16 Job No Description XT 6 XT 7 SV470 620 CH5 6 CV11 495 Major Repairs Engine R amp R Generator Set R amp R Motor Home Engine R amp R From Generator Set Short Block Replacement Major Overhaul Includes Valve Service Minor Overhaul Excludes Valve Service Connecting Rod Piston and or Rings Crankshaft Crankshaft 4 Main Bearing R R Crankshaft PTO Seal Crankshaft Flywheel Seal Crankshaft amp Connecting Rod Balance Shaft Weights R amp Camshaft amp Valves L
12. ences 6 2 N m 55 in Ib Measure 6 mm 0 236 in above the bottom of the piston skirt at right angles to the piston pin Section 1 Safety and General Information Valve Cover Valve Cover Fastener Torque Or C renee ee ee ere ere 3 4 N m 30 in Ib Black O Ring Style Cover SCLC WS eaea noei enini 5 6 N m 50 in wW Flange Screws Spacers 9 9 N m 88 in Ib Yellow or Brown O Ring Style Cover w Integral Metal Spacers 6 2 N m 55 in Ib Valves and Valve Lifters Hydraulic Valve Lifter to Crankcase Running Clearance 0 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 Intake Valve Guide I D lU 7 038 7 058 mm 0 2771 0 2779 in DIRE VDO CUTIE 7 134 mm 0 2809 in Exhaust Valve Guide I D o 7 038 7 058 mm 0 2771 0 2779 in Mae Vear CUNE 7 159 mm 0 2819 in Valve Guide Reamer Size Po du MEER T E 7 048 mm 0 2775 in OZ a io 7 298 mm 0 2873 in I
13. I 6 im Light remains on at end of transmission Figure 5B 43 After the problem has been corrected the fault codes may be cleared as follows 1 Disconnect the negative battery cable from battery terminal or remove the main fuse for the ECU for approximately 1 minute 2 Reconnect the cable and tighten securely or reinstall the main fuse Start the engine and allow it to run for several minutes The MIL should remain off if the problem was corrected and the fault codes should not reappear codes 31 32 33 and 34 may require 10 15 minutes of running to reappear The following chart lists the fault codes what they correspond to and what the visual indications will be Following 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 OBD2 35 Pin 24 Pin 32 Pin P Code Ap MA 1 7 MSE 1 0 plicable to Connection or Failure Description Metal Plastic 32 Pin MSE Cased Cased 1 1 ECU Sys ECU ECU Sys tem Only System tem o oo qwmw rj __ RC RR cont on next page 58 35 Section 5B EFI Fuel System OBD2 35 Pin 24 Pin 32 Pin P Code Ap MA 1 7 MSE 1 0 plicable to Connection or Failure Description Metal Plastic EIS 32 Pin MSE Cased Cased Cacad 1 1 ECU Sys ECU ECU Sys ECU tem Onl
14. OHC Triad 7 Close the on off valve of the manometer before stopping the engine Vibration Testing Vibration testing also requires sophisticated equipment Vibration however may be a more subjective matter than an objective one Operate the equipment Do you find the vibration unpleasant distracting or dangerous The level at which vibration becomes a problem will vary from operator to operator but you can make a fair estimate of the vibration levels simply by operating the equipment yourself What we have done in this section is to give you a general idea of the minimum testing necessary to ensure that your equipment and our engine are a good match Is That All There Is The engine performance check outlined in this guide is quite simple and for most applications it should give you an adequate basis for selecting the right engine for installing it properly and for testing the application At Kohler we are constantly testing our engines to improve their suitability for your needs Our testing facility for instance has rooms in which temperatures may be maintained at any desired level We test engines over a wide range from extremely hot to very cold Highly sensitive monitoring devices provide accurate readings of the various temperatures in critical engine areas We can load engines or engine powered equipment to any degree needed for accurate testing Our quiet room enables us to measure sound le
15. lt A X Magnetic Flux Lines All compounds are made up of atoms and electrons Each of the electrons is spinning on an individual axis just as the earth rotates on its axis Normally these axes are pointed in a helter skelter pattern However if we take an artificial magnetic substance and place it within a magnetic field the axes align themselves and the individual fields combine to form a strong magnetic field around the substance This phenomenon is known as magnetic induction In a substance which is not very dense such as iron the axes will return to the helter skelter pattern and the induced magnetism will be quickly lost once the magnetic field is removed In very demse substances the axes will remain in alignment and the induced magnetism will be retained indefinitely even when the magnetic field is removed Such substances are referred to as permanent magnets Electron V T Magnetic Flux Lines De Magnetized Substance Magnetized Substance Magnetized De Magnetized Substance How does all of this magnetic theory relate to the magneto ignition system In the magneto system we have one or more permanent magnets mounted to the inside rim of the flywheel We have a laminated iron core mounted to the bearing plate within the magnetic field of the permanent magnets Iron has low magnetic reluctance so when
16. uonjubj YMS SUUM 390g 1 5 1467 eyowey Aur vu Aus jquiessy saun unis prousjos wARUES 0 403 9 B uopiub piousjos usus cun S 19485 4 1 pns piousjos 5 MONA 4 i hueneg j 4 4 12129 IE 660 Sz H 660 SZ LO 991 Bp 10 2euuo um M Miossacoy V Koneg 8 eyuM oJ punog aM sai enn IM Figure 8 23 Wiring Diagram 15 20 25 Amp Regulated Battery Charging System with Fixed Timing 8 19 Section 8 Electrical System and Components 9 191 01 saun 3145 uee15 HIM Oe Eno 1986 Co piousjos NIMS 841n 89Jd tO
17. 0 060 0 202 mm 0 0024 0 0080 in CH22 CH670 C EI2SIC H690 CC Ea 0 046 0 196 mm 0 0018 0 0077 in CH25 CH26 CH733 CH730 C H740 0 026 0 176 mm 0 0010 0 0070 in Section 1 Safety and General Information Piston Piston Rings and Piston Pin cont Top and Center Compression Ring End Gap New Bore CH18 CH620 CH20 CH640 CH22 624 5 0 25 0 45 mm 0 0098 0 0177 in CH22 CH670 CH23 CH680 674 CO 0 18 0 46 mm 0 0071 0 0181 in CEPS CEPS CHAU 0 25 0 56 mm 0 0100 0 0224 in Used Bore Max E20 CCET640 C E122 624 0 77 mm 0 030 in H680 4078 08 0 80 mm 0 0315 in 25 126 735 730 17 4 0 94 mm 0 037 in Piston Thrust Face O D New CH18 CH620 CH20 CH640 CH22 624 GO 76 967 76 985 mm 3 0302 3 0309 in G74 CC ter Ip 79 963 79 979 mm 3 1481 3 1488 in 82 986 mm 3 2671 in Max Wear Limit CH18 CH620 CH20 CH640 CH22 624 0 ree error ere rere 76 840 mm 3 0252 in 07E CC 79 831 mm 3 1430 in CEDSCHZS
18. Figure 11 27 Clean and Dry Flywheel Hub Figure 11 25 Installing Backing Plates and Stator Wire Bracket Section 11 Reassembly Install Flywheel Fan 1 Install the fan onto the flywheel using the four hex flange screws NOTE Position the ears located at rear perimeter of the fan in the recesses of the flywheel See Figure 11 30 Figure 11 28 Carefully Align Keyway to Key NOTE Make sure the flywheel key is installed properly in the keyway The flywheel can become cracked or damaged if the key is not properly installed 1 Install the woodruft key into the keyway of the crankshaft Make sure that the key is properly Figure 11 30 Installing Fan on Flywheel seated and parallel with the shaft taper 2 Torque the screws to 9 9 N m 88 in Ib 2 Install the flywheel onto the crankshaft being careful not to shift the woodruff key See Figure Install Plastic Grass Screen 11 28 1 Ifthe engine has a plastic grass screen snap the screen onto the fan See Figure 11 31 Due to the possibility of damaging the posts during removal install the retainers on different posts from which 3 Install the hex flange screw and washer 4 Use flywheel strap wrench or holding tool to they were removed Start the retainers by hand hold the flywheel Torque the hex flange screw then push them down with a 13 mm 1 2 socket securing the flywheel to the crankshaft to until they lock If the engine has a metal screen
19. Reverse the leads and measure resistance again In one direction the resistance should be infinity ohms open circuit With the leads reversed some resistance should be measured about midscale on 1 range 4 Cut the sleeving on the charging lead to expose the diode connections 4 if resistance is 0 7 1 3 ohms stator winding is OK If resistance is 0 ohms stator winding is shorted Replace stator Measure the resistance from the stator side of diode to ground using an ohmmeter If resistance is infinity ohms stator winding or lead is open Replace stator 1 Make sure lights are not burned out 1 Replace burned out lights 2 Disconnect the lighting lead from the 2 If voltage is 15 volts or more stator is OK wiring harness Check for loose connections or shorts in wiring harness With engine running at 3000 RPM If voltage is less than 15 volts test stator NO measure voltage from lighting lead to ground using an ohmmeter Test 3 LIGHTS using an AC voltmeter 3 If resistance is approx 0 4 ohms stator is OK 3 With engine stopped measure the resistance of stator from lighting lead to ground using an ohmmeter If resistance is 0 ohms stator is shorted Heplace stator If resistance is infinity ohms stator or lighting lead is open Replace stator 29 Electric Start Engines 15 Amp Regulated Battery Charging Sy
20. SWYS uo pnis Bojeuy uo piouejJos 192835 1 my IH 7 E i aum 08461 i i gt i i m 3 1H p i 4 HUM pay 1 _ eds yews FE n dH 52 zz plousios t 1 que I A t 4 1 JOT _ Maneg pjojiueyw i j e nisod 3 4 1010 3 x1eds ojeubew W 660 SZ 5 o 10 991 10j2euuo2 8 31 MOJA SUM aM ms peu enig 1467 eyoueu Aur oued 1095 YONG Figure 8 24 Wiring Diagram 15 20 25 Amp Regulated Battery Charging System with Smart Spark 8 20 Section 8 Electrical System and Components Figure 8 25 Wiring Diagram 15 20 25 Amp Regulated Battery Charging System with DSAI Ignition and Key Switch 8 21 Section 8 Electrical System and Components 3 Amp Unregulated Charging System Ground To Kill Lead White Ignition Modules Spark Spark 1 Plug Plug v Black Key Switch Optional 1 i 3 Amp 70 Watt Fuse UN Flywheel Optional Yellow ywheel Stator Oil Sentry Op
21. mE Hg Y H irm VM If ay Hil T Uo Alc AA d T oM Overheated Deteriorated Oil Scored Piston and Rings Figure 10 8 Common Types of Piston Damage 10 9 Section 10 Inspection and Reconditioning Replacement pistons are available in STD bore size and in 0 25 mm 0 010 in and 0 50 mm 0 020 in oversize Replacement pistons include new piston ring sets and new piston pins Replacement ring sets are also available separately for STD 0 25 mm 0 010 in and 0 50 mm 0 020 in oversize pistons Always use new piston rings when installing pistons Never use old rings Some important points to remember when servicing piston rings 1 The cylinder bore must be deglazed before service ring sets are used 2 If the cylinder bore does not need reboring and if the old piston is within wear limits and free of score or scuff marks the old piston may be reused 3 Remove the old rings and clean up the grooves Never reuse old rings 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 specifications listed in Section 1 Figure 10 9 Measuring Piston Ring End Gap 5 After installing the new compression top and middle rings on the piston check the piston to ring side clearance Compare the
22. C Near NEW d 0 039 0 074 mm 0 0015 0 0029 in Flywheel Main Bearing Journal QURE 40 913 40 935 mm 1 6107 1 6116 in OD Max T aliii m TM 40 84 mm 1 608 in M 0 022 mm 0 0009 in CTO ls OU ING seisena ba iniu d co dd d 0 025 mm 0 0010 in Closure Plate End Main Bearing Journal OARRA 40 913 40 935 mm 1 6107 1 6116 in UD IMA Wear LIOI oec 40 84 mm 1 608 in Bs loli E 0 022 mm 0 0009 in Max 0 025 mm 0 0010 in Connecting Rod Journal TN 35 955 35 973 mm 1 4156 1 4163 in VV a bii 35 94 mm 1 415 in 0 018 mm 0 0007 in Max Outo 0 025 mm 0 0010 in Section 1 Safety and General Information Crankshaft cont Crankshaft T I R PIO ERG EDS 0 279 mm 0 0110 in Entire Crank gm gt OC cia cere ceca 0 10 mm 0 0039 in Cylinder Bore Cylinder Bore LD New CEI20 C 624 77 000 77 025 mm 3 0315 3 0325 in CH22 C H670 CH23 CH680 674 OC
23. fo gt MALFUNCTION Talo 1 a de E Sle cm i 35 d i 18 E 52 T T Y 5 a a 20 01 2 1 az gt a 5 z T E d 6 10A a Motor Throttle INJECTOR 1 INJECTOR 2 Temperature Position Sensor Sensor 2 1 12 a E GROUNDING NOTES A Battery B Lambda Sensor C Fuel Pump D Shield 21 122 SEE Attached to engine block near starter GROUNDING The sensor return is via the engine muffler NOTE B If a slip joint is used a grounding strap is required If a 2 leaded sensor is used pin 4 or pin 21 can be used for the is the return Attached to the chassis Attached to the engine block close to the coils CONNECTOR DIAGNOSTIC SEE GROUND NOTE C 50 D D 87 RELAY MAIN POWER co 11 12 SWITCH IGNITION BATTERY GROUND I SEE GROUNDING NOTE A A d BATTERY GENERAL SYSTEM INSTALLATION NOTES The ignition switch must maintain a constant voltage to circuits 84 85 and J1 2 as the key is swept from the start to the run position to prevent ECU reset during starting The voltage on circuits 84 85 J1 2 and J1 1 must remain within 0 2 V of each other regardless of system current draw to prevent differences between actuator voltages circuits 65 66 45 and 87 and system voltage J1 1 If the ignition switch controls a powered circuit i e lights horn it is
24. 0 025 0 126 mm 0 0009 0 0049 in Governor Cross Shaft O D 6 mm Shaft iU 5 975 6 012 mm 0 2352 0 2367 in Max Wear E E ai 5 962 mm 0 2347 in 8 mm Shaft IN c 7 949 8 000 mm 0 3129 0 3149 in Usuardo E 7 936 mm 0 3124 in Governor Gear Shaft to Governor Gear Running Clearance 0 015 0 140 mm 0 0006 0 0055 in Governor Gear Shaft O D hU AIE EE EEEE 5 990 6 000 mm 0 2358 0 2362 in E Suidae E E T T 5 977 mm 0 2353 in COV TTO NA eine 6 8 60 in Ib Section 1 Safety and General Information Type Champion or Equivalent eet RC12YC 12 or Platinum 3071 UU Gio Mem ects cas coe 0 76 mm 0 030 in Pue 24 4 29 8 N m 18 22 ft Ib Module Air 0 28 0 33 mm 0 011 0 013 in Modile Fastener 4 0 6 2 N m 35 55 in Ib Speed Sensor Zur Gap EET gelidus tuse HUS aptus dire 1 50 0 25 mm 0 059 0 010 in Muffler etate NOt esc se neci oa
25. Analysis Guidebook Failure Analysis Introduction It couldn t have run low on oil just changed it three weeks ago How could it get dirt in it blow out the air cleaner every time use it Everyone involved in the service of small engines has heard similar statements at one time or another It s human nature to blame problems on the machine or on someone else Therefore it is important for every small engine serviceman to develop the ability to accurately diagnose the cause of an engine failure If an incorrect analysis is made the repair may not remedy the original cause and a repeat failure may occur Figure 1 Figure 1 shows two sets of parts from the same engine The original piston failed from excessive clearance and slapping The mechanic didn t measure the bore for wear and rebuilt the engine with standard parts The bore wear was still present so the new piston began slapping and broke up nearly identical to the original Some failures are the result of manufacturing defects but it is a very small percentage compared to those which result from normal wear or customer neglect You must be able to distinguish the difference to know if a failure qualifies for warranty consideration If the failure was due to neglect you should provide an accurate explanation so the customer refrains from making the same error again The following information is provided to help you develop your e
26. Ee LOU Carburetor Subassembly Idle Speed Screw Idle Speed Spring Screw Ground Lead Retaining Washer Slow Jet RH Side Slow Jet LH Side O Ring Slow Jet 2 Fuel Bowl O Ring Fuel Bowl Upper O Ring Fuel Bowl Lower Drain Screw Bowl Screw 4 Fuel Solenoid Sealing Washer Float Pin Screw Float Clip Float Valve Inlet Needle Main Nozzle Right Side Main Nozzle Left Side Main Jet Right Side Main Jet Left Side Choke Dust Cap Choke Shaft opring Bushing Choke Lever Choke Plate Choke Plate Screw 2 Governor General The governor is designed to hold the engine speed constant under changing load conditions Most engines are equipped with a centrifugal flyweight mechanical governor Some engines utilize an optional electronic governor which is shown and covered on page 5 23 5 24 The governor gear flyweight mechanism of the mechanical governor is mounted inside the crankcase and is driven off the gear on the camshaft This governor design works as follows e Centrifugal force acting on the rotating governor gear assembly causes the flyweights to move outward as speed increases Governor spring tension moves them inward as speed decreases Governor Spring Governor Throttle Linkage Figure 5 38 Governor Linkage e As the flyweights move outward they cause the regulating pin to move outward
27. Every 500 hours of operation or annually whichever occurs first clean and lubricate the splines on the starter drive shaft If the drive pinion is worn or has chipped or broken teeth it must be replaced See Figure 8 38 It is not necessary to completely disassemble the starter to service the 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 armature will rotate with the nut until the drive pinion stops against internal spacers NOTE Do not overtighten the vise as this can distort the drive pinion 3 Remove the stop nut stop gear spacer anti drift spring dust cover spacer and drive pinion 4 Clean the splines on drive shaft thoroughly with solvent Dry the splines thoroughly 5 Apply a small amount of Kohler electric starter drive lubricant see Section 2 to the splines The use of other lubricants may cause the drive pinion to stick or bind 6 Apply a small amount of Loctite No 271 to the stop nut threads Style A Style B Figure 8 38 Inertia Drive Electric Starter 8 30 Section 8 Electrical System and Components Style B Drive Service 1 The rubber dust cover has a molded lip on the inside that snaps into a groove in the dust cover spacer see Figure 8 39 Turn the drive pinion clockwise until it reaches the fully extended
28. e The regulating pin contacts the tab on the cross shaft causing the shaft to rotate e One end of the cross shaft protrudes through the crankcase The rotating action of the cross shaft is transmitted to the throttle lever of the carburetor through the external throttle linkage See Figure 5 38 e When the engine is at rest and the throttle is in the fast position the tension of the governor spring holds the throttle plate open When the engine is operating the governor gear assembly is rotating The force applied by the regulating pin against the cross shaft tends to close the throttle plate The governor spring tension and the force applied by the regulating pin balance each other during operation to maintain engine speed Section 5 Fuel System and Governor e When load is applied and the engine speed and governor gear speed decreases the governor spring tension moves the governor arm to open the throttle plate wider This allows more fuel into the engine increasing the engine speed As the speed reaches the governed setting the governor spring tension and the force applied by the regulating pin will again offset each other to hold a steady engine speed Adjustments NOTE Do not tamper with the governor setting Overspeed is hazardous and could cause personal injury General The governed speed setting is determined by the position of the throttle control It can be variable or constant depending on the
29. 7 Air cleaner base Tight LlLoose LlScrew s missing L Distorted Cracked L Breather hose detached J Other damage Crankcase Oil 1 Amount on dipstick 1 Overfilled Full LJAbove add LlBelow add reading 2 Condition of oil L New Used Dirty L Black Thick Sticky Burnt smelling L Fuel diluted 3 Quantity of oil Amount drained 1 Amount req d Observations 0 Metal chips present 0 Sludge present LJ Non factory oil filter TP 2435 Continued on page 2 17 Preliminary Examination continued Cooling System 1 Flywheel Screen 2 Cooling fins 0 Clean Plugged Partially blocked 96 0 Clean Plugged 1 Partially blocked 96 3 Engine exterior 0 Clean O Dirty Oily L Evidence of prior disassembly or repair Visible oil leaks where Carburetor and Fuel Supply 1 Condition of carburetor 2 Settings Okay Broken L Loose L Shafts worn Dirt in throat L Main fuel adj L Idle fuel adj 3 Condition of fuel 0 Clean 0 Fresh 0 Stale 1 Contaminated water debris etc Governor 1 Components 2 Function Ll Intact L Missing L Modified 0 Operative L Inoperative 1 Modified L Misadjusted Dirt Ingestion 1 Is there evidence of possible dirty entry via LJ Air cleaner 0 Carburetor 0 Breather 1 Gasket Seal 1 Oil fill opening Other Spark Plug Spark Plug Cylinder 1 Cylinder 2 Combustion Deposits Cylin
30. 77 mm 3 03 in EIAS C E4090 C 80 mm 3 15 in CH25 26 735 730 740 745 emer ene 83 mm 3 27 in Stroke i 5 heise cea sab 67 mm 2 64 in Sub ____ _____ _____ 69 mm 2 7 in Displacement C22 624 cet nea 624 38 in CH23 CH680 074 CC pni end E a 674 cc 41 cu in CH25 26 735 730 740 745 725 cc 44 in ep 755 cc 46 cu in Compression Ratio CHIS CH20 CEDO CTI640 CED2 CTIO70 natat eat 8 5 1 CH eV UNG ay R Tee 9 0 1 A m AA A A 9 4 1 Dry Weight C 9 41 kg 90 Ib i rare aust 43 kg 94 Ib A uU C TE 48 kg 105 Ib Oil Capacity w filter approximate determined by oil MICE and oil cooler Sedan f
31. Figure 9 13 Air Cleaner Bracket Mounting Screws Two Barrel Model Pictured 4 Remove the heavy duty air cleaner as an assembly from the engine See Figure 9 14 Figure 9 14 Removing Heavy Duty Air Cleaner Assembly Two Barrel Model Pictured Remove Fuel Pump A WARNING Explosive Fuel 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 Do not fill the fuel tank while the engine 18 hot or running since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition Do not start the engine near spilled fuel Never use gasoline as a cleaning agent Pulse Style Pumps 1 Disconnect the fuel lines at the carburetor and at the in line fuel filter See Figure 9 15 Section 9 Disassembly 3 Remove the two hex flange screws securing the fuel pump to the bracket or to the blower housing See Figure 9 18 The fuel pump body may be metal or plastic Figure 9 15 Disconnecting Fuel Inlet Line at Carburetor Figure 9 18 Removing Screws Holding Fuel Pump Metal Bodied Pump Shown 4 Note or mark the orientation of the fuel pump then remove the fuel pump with lines attached as shown in Figure 9 19 Figure 9 16 Disconnecting Pulse Line from Crankcase Figure 9 19 Remove Fuel Pump and Lines Mechanical Fuel Pump The mechanical style fuel pump
32. Indicator The tester is powered by 9 volt battery Most SAMs are designed to operate down to a minimum of 7 25 volts If the tester battery drops below that level incorrect test readings will result The tester battery should be checked periodically by connecting a DC voltmeter between the red and ereen lead wires with the tester connected to a SAM Press and hold the test button for a full test cycle 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 battery must be replaced Use an extended life alkaline battery To replace the battery remove the outer set of screws on the faceplate and carefully lift the panel from the body Unplug the connector and pull battery with mounting tape off the back of the tester Attach the connector to the new battery and mount the battery to the case with double backed tape Reinstall the faceplate and secure with the four screws Section 8 Electrical System and Components C DSAI Ignition System Operation A digital spark advance ignition system DSAI is The system provides more consistent energy to the used on some models The DSAI ignition system is an spark plugs at all engine speeds by using the 12 volt advanced 12 volt version of the fixed timing ignition battery as its source of power Engine speed and top system used on other models Two inductive
33. the oil to drain down then recheck the level on the dipstick 6 3 Section 6 Lubrication System Service Oil Cooler Some engines are equipped with an oil cooler One style of oil cooler mounts on the engine crankcase and has the oil filter on it The other style of oil cooler is mounted on the blower housing separate from the oil filter See Figure 6 7 Crankcase Mounted Oil Cooler Figure 6 7 Oil Coolers Inspect and clean the oil cooler every 100 hours of operation more frequently under severe conditions In order to be effective the oil cooler must be kept free of debris To service the crankcase mounted oil cooler clean off the outside fins with a brush or with compressed air To service the blower housing mounted oil cooler clean the outside of fins with a brush Remove the two screws holding the cooler unit to the blower housing Tilt the cooler downward Clean the inside of the cooler with a brush or with compressed air After cleaning reinstall the oil cooler to the blower housing with the two mounting screws 6 4 Oil Sentry General Some engines are equipped with an optional Oil Sentry switch This switch is designed to prevent the engine from starting in a low oil or no oil condition The Oil Sentry may not shut down a running engine before damage occurs In some applications this switch may activate a warning signal Read your equipment manuals for more information The pressure swi
34. 15 Figure 56 Figure 56 There are many different failure modes on connecting rods but some of them are more common or prevalent than others A few years ago a task force at Kohler Co analyzed more than 400 connecting rod failures When they compiled their data nearly 75 of the failures they had looked at were similar to the rod in this photo so this could be considered a typical connecting rod failure The connecting rod had seized onto the crankshaft melting and searing the aluminum on the bearing surface in the process The exterior surfaces are dark with burned oil deposits around the journal area Often the burned oil deposits will extend part way up the beam and down onto the dipper if it s a splash lube rod The rod may be fractured possibly a single break or several pieces Sometimes on twin cylinder engines the engine keeps on running on the opposite cylinder after one rod has failed and the broken rod gets smashed into many tiny fragments Those are probably the most difficult to analyze because the pieces are so small it s difficult to find and identify any good failure indicators Figure 57 Figure 57 All of these rods failed by seizing onto the crankpin While there are many similarities if you look closely there are also some subtle differences 16 To correctly analyze rod failures you will need to identify both The similarities will usually help you determine a general failure ca
35. KOHLER ENGINES Technicians Certification Test Study Guide SERVICE MANUAL KOHLER COMMAND 18 26 CH620 CH750 HoRizoNTAL CRANKSHAFT S dt j Em 4 EL LM KOHLER ENGINES Contents Section 1 Safety and General Information Section 2 Tools amp 45 cccccccecececececececececscenenencncaceceeeeeenensneacaceaeeeaenensneneeeeseeseenensneneasensasesaenss Section 3 Troubleshooting ccceeeeeeeesecenneecensecensecenseeceseecaneecaseeoasesoansesoassseensecensenensesones Section 4 Air Cleaner and Air Intake System Section 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 and Components Section 9 Disassembly 11 llle ieeeliiecliieeeiee nna n unen hash aa saa a a ausa n suas assa cra Section 10 Inspection and Reconditioning Sechon TT RGIS EMDI ee Section 12 Clutch c ccccecececcceccncncececececscscenencnencececeaeeeneceneneaseneaeeeaseenensesecsenaeeuneneneneneaeeaeesseeneas Section 1 Safety and General Information Safety Precautions To ensure safe operation please read the following statements and understand their meaning Also refer to your
36. Relay Contacts 30 87 pose Losed Not Used See Ground Note B Optional Rel ngs y General System Installation Notes The ignition switch must maintain constant voltage to circuits 17 31A and 41A as the key is swept fron run to start or siart to run positions to prevent an ECU reset during starting The voltage on circuits 16 17 and 43 must remain within 40 2 volts of each other regardless of system current draw to prevent differences between actuator voltage circuits 40 44 and 45 and system sensed voltage circuit 17 If the ignition switch controls a powered circuit Cie Lights horn it is recommended that relay be used to control the powered circuit as shown Each application wire harness conf iguration should be checked that the fuel pump fuse F2 fails open when the fuel pump is in a stalled or Locked condition A resistive spark plug with either a resistive spark plug wire on resistive spark plug boot must be used to prevent electrical system noise The safety switches are to be wired in series with the power relay It is recommended that the ECU be mounted vertically with the wire bundle down or horizontally with the ALL Weather connector down It is recommended that the ECU housing be grounded to the chassis The ECU should not be mounted to the engine nor should it be powerwashed When not in operation the battery must maintain minimum system voltage of 7 volts with a current dr
37. See chart on pages 5B 28 5 31 or 5B 32 35 Pin MA 1 7 Metal Cased ECU Check between the 14 and 27 pin terminals Section 5B EFI Fuel System 24 Pin MSE 1 0 Plastic Cased ECU Check The tip of the sensor protruding into the exhaust between the 6 and 4 pin terminals gas is hollow see cutaway Figure 5B 12 The outer portion of the tip is surrounded by the exhaust gas 32 Pin MSE 1 1 Plastic Cased ECU Check with the inner portion exposed to the ambient air between the 6 and 4 pin terminals When the oxygen concentration on one side of the tip is different than that of the other side a voltage signal 5 Unplug the sensor connector and check sensor typically cycling between 0 2 and 1 0 volt is generated resistance separately Resistance value should between the electrodes and sent to the ECU The again 2375 2625 voltage signal tells the ECU if the engine is straying from the ideal 14 7 1 fuel mixture and the ECU then a If the resistance is out of specifications adjusts the injector pulse accordingly replace the temperature sensor b If itis within specifications proceed to Step 6 6 Check the temperature sensor circuits input ground from the main harness connector to the corresponding terminal in the sensor plug for continuity damage etc CNW SAX 35 Pin MA 1 7 Metal Cased ECU Pin circuits 14 and 27 1 Connection Cable 5 Contact Element 2 Disc Spring 6 S
38. Three valve cover designs have been used The earliest type used a gasket and sealant between the cover and sealing surface of the cylinder head The second type had a black O Ring installed in a groove on the underside of the cover and may have metal spacers in the bolt holes The newest design uses a yellow or brown O Ring with bolt hole spacers molded in place The tightening torque differs between gasket and O Ring style covers Kits are available for converting to the latest O Ring type covers Differences are pointed out in the following installation steps NOTE Do not scrape old sealant if used off the sealing surface of the cylinder head as this could cause damage and result in leaks The use of gasket remover solvent paint remover is recommended 1 If using the gasket or sealant type cover prepare the sealing surfaces of the cylinder head and cover as directed in Service Bulletin 252 Refer to Section 2 for approved sealants Always use fresh sealant using outdated sealant could result in leakage With O Ring type covers make sure the sealing surfaces are clean 2 Make sure there are no nicks or burrs on the sealing surfaces 3 For covers requiring RTV sealant apply 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 surface of the gaskets For O Ring type covers install new O Ring i
39. Winding Electronically Gate SCR Variable Resistor Capacitor No Regulation Battery Voltage Less Than Breakdown Voltage of Zener Diode When the battery comes up to charge and the battery voltage exceeds the breakdown voltage of the zener diode current will flow through the variable resistor to the gate or control element of the SCR When the gate voltage exceeds the ground side voltage the SCR switches electronically to complete the regulating circuit and current flows into the regulator windings of the stator The regulator windings are wound in the opposite direction of the AC windings so when current flows through the regulator windings the magnetic field established around the regulator windings will counteract the field of the AC windings to control the AC output and thus control the charge to the battery 24 Switches Electronically Magnetic Field Passes Current Switches SCR Regulation Battery Voltage Exceeds Breakdown Voltage Of Zener Diode In the 15 amp system rectification and regulation is performed by the same circuit The outer circuit in our schematic consists of the alternator stator the battery and CR5 which is a programmable unijunction transistor PUT The PUT functions as both a diode and an SCR In its function as a diode it provides our 1 2 wave rectification In its function as an SCR it controls the flow of current in our charging circuit The
40. b Install fastener into location No 2 and fully torque to the recommended value c Torque fastener in location No 1 to the recommended value Figure 10 16 Oil Pump Oil Pickup and One Piece Relief Valve Later Style Inspection Inspect the oil pump housing gear and rotors for nicks burrs wear or any visible damage If any parts are worn or damaged replace the oil pump Inspect the oil pressure 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 distorted or worn see Figure 10 17 First Time Installation 10 7 N m 95 in Ib All Reinstallations 6 7 60 in Ib 5 After torquing rotate the gear and check for freedom of movement Make sure there is no binding If binding occurs loosen the screws reposition the pump retorque the hex flange screws and recheck the movement Piston Spring Roll Pin Figure 10 17 Oil Pressure Relief Valve Piston and Spring Reassembly 1 Install the pressure relief valve piston and spring 2 Install the oil pickup to the oil pump body Lubricate the O Ring with oil and make sure it remains in the groove as the pickup is being installed 10 13 Section 10 Inspection and Reconditioning Governor Cross Shaft Oil Seal If the governor cross shaft seal is damaged and or leaks
41. engine to check and adjust the float 1 Remove the air cleaner and breather hose Refer to Section 9 Disassembly 2 Disconnect the fuel line from the carburetor See Figure 5 8 3 Clean dirt and debris from exterior of carburetor 4 Remove the four screws holding the two carburetor halves together Carefully lift the upper body off the carburetor body and disconnect choke linkage 5 7 Section 5 Fuel System and Governor Figure 5 8 Carburetor Detail 5 Hold the carburetor upper body so that the float assembly hangs vertically and rests lightly against the fuel inlet needle The fuel inlet needle should be fully seated but the needle tip should not be depressed See Figure 5 9 NOTE The fuel inlet needle tip is spring loaded Make sure the float assembly rests against the fuel inlet needle without depressing the tip 6 The correct float height adjustment is 22 mm 0 86 in measured from the float bottom to the air horn casting Adjust the float height by carefully bending the tab NOTE Be sure to measure from the casting surface not the rubber gasket surface 7 If proper float height adjustment cannot be achieved check to see if the fuel inlet needle is dirty obstructed or worn Remove the brass screw and float assembly to remove the fuel inlet needle 5 8 Figure 5 9 Carburetor Float Adjustment 8 10 Once the proper float height is obtained carefully lower the carbur
42. labor costs or transportation charges in connection with the replacement or repair of defective parts ANY IMPLIED OR STATUTORY WARRANTIES INCLUDING WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY LIMITED TO THE DURATION OF THIS WRITTEN WARRANTY We make no other express warranty nor is anyone authorized to make any in our behalf Some states do not allow limitations on how long an implied warranty lasts or the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state TO OBTAIN WARRANTY SERVICE Purchaser must bring the service parts to an authorized Kohler service facility For the facility nearest you consult your Yellow Pages under Engines Gasoline or phone 1 800 544 2444 ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 One year limited warranty for long blocks KOHLER FEDERAL AND CALIFORNIA EMISSION CONTROL SYSTEMS LIMITED WARRANTY SMALL OFF ROAD ENGINES The U S Environmental Protection Agency EPA the California Air Resources Board CARB and Kohler Co are pleased to explain the Federal and California Emission Control Systems Warranty on your small off road equipment engine In California beginning in 2006 emissions means both exhaust and evaporative emissions For California engines produced i
43. or set to application specifications Check the speed using a tachometer NOTE The actual low idle speed RPM depends on the application Refer to the equipment manufacturer s recommendations The low idle speed for basic engines is 1200 RPM LPG Fuel System Component Service LPG Carburetor Cleaning The carburetor may be cleaned if necessary Removal from the engine and limited disassembly will aid in cleaning NOTE Impco Carburetor Do not loosen 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 None of these attached components including the throttle plate or shaft requires disassembly or removal for any carburetor servicing All the components on the throttle shaft should be left intact If the settings of any one of these is inadvertently loosened or altered each must be checked reset or performance and operation will be affected Refer to the procedure included in the reassembly installation sequence to check or reset 5A 4 Impco Carburetor 1 Turn off fuel supply at tank 2 Remove the air cleaner breather hose fuel line vacuum hose choke and throttle linkages Remove the mounting hardware carburetor and gaskets from the engine Discard the gaskets 3 The carburetor venturi may be removed for inspection and appropriate cleaning a Remove the four
44. 1 See Servicing Hydraulic Lifters in Section 10 for lifter preparation bleed down procedures Figure 11 35 Installing Hydraulic Lifters 2 Apply camshatt 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 oil 11 10 Figure 11 36 Match Numbers on Cylinder Barrel and Head Figure 11 37 Intake Valve Seal Location Valve Stem Seals These engines use valve stem seals on the intake valves and occasionally on the exhaust valves Always use a new seal whenever the valve is removed or if the seal is deteriorated or damaged in any way Never reuse an old seal Figure 11 37 Assemble Cylinder Heads Prior to installation lubricate all components with engine oil paying particular attention to the lip of the valve stem seal valve stems and valve guides Install the following items in the order listed below using a valve spring compressor See Figures 11 38 and 11 39 Intake and exhaust valves Valve spring caps Valve springs Valve spring retainers Valve spring keepers Section 11 Reassembly Figure 11 39 Installing Valves with Valve Spring Compressor Install Cylinder Heads NOTE Cylinder heads must be attached with the original type of mounting hardware using either hex flange screws or mounting n studs with nuts and washers The heads are machined differently for studs than for screws 50 the
45. 1 11 16 in H Test Use Digital Ohmmeter 945 to 1175 ohms 149 to 166 ohms 3750 to 7000 ohms 24 584 15 S or 24 584 36 S 2 1 16 in H 24 584 15 S 2 1 16 in H 890 to 1175 ohms 119 to 136 ohms 8000 to 40 000 ohms 5600 to 9000 ohms 5 Check and or adjust the ignition module air gap s An air gap of 0 28 0 33 mm 0 011 0 013 in must be maintained under all three legs of the ignition module s Checking adjusting should be performed with the parts at room temperature a If the module was not loosened or replaced check that the specified air gap is present under all three legs If the gap is correct reinstall the second mounting screw removed earlier and recheck gap after tightening b If the gap is incorrect or the module was loosened or replaced adjust the gap as follows 1 Turn the flywheel magnet away from the module position 2 Attach the module to the mounting legs pull it away from the flywheel and snug the screws to hold it temporarily 3 Rotate the flywheel so the magnet is centered under the module 4 Position a 0 30 mm 0 012 in feeler gauge between the magnet and all three legs of the module The ignition module air gap is critical to proper system performance Do not attempt to set it with a business card or folded microfiche card use the feeler gauge specified 5 Loosen the mounting screws allow the magnet to pull the module down agains
46. 2 Check condition of spark plugs Make If plugs are in good condition check adjust Sure gaps are set to 025 gaps and reinstall 3 Check ignition module using ignition If visible and audible sparks ARE system tester produced the ignition module is OK If visible and audible sparks ARE NOT produced a Remove the high tension leads from the engine spark plugs and connect them to the test plugs a Make sure engine ignition switch and or keyswitch are in the run position NOTE To maintain engine speeds normally normally obtained during cranking do not remove the engine spark plugs b Check wires and terminals of ignition module and other components for accidental grounding and or damaged insulation b Make sure the engine ignition switch kill switch and or keyswtich are in the run position ENGINE c Crank the engine and observe the test c If wires and terminals are OK the ignition WILL plugs Visible and audible sparks should be module is probably faulty and should NOT be produced replaced Test module further using an ohmmeter Test 4 START NOTE Use a low voltage ohmmeter when ohmmeter is required Always zero ohmmeter on each scale before testing to ensure accurate readings If resistance is low or 0 ohms module primary is shorted Replace module If resistance is high or infinity ohms module primary 15 open Ch
47. 28 575 mm diameter or greater Section 2 Properly Connecting the Engine to the Load Universal Joints are required in some arrangements when the engine is not in line with the driven unit Follow the drive manufacturer s recommendations regarding installation and maintenance Engine Driven Unit Figure 2 6 Universal Joints 10 Three Bearing Housing When this type of housing is used make certain the mounting faces on both the housing and the engine are perfectly true and square and that the bearing is in perfect alignment with engine bearings Use dial indicators to determine alignment and prevent shaft bending problems Mounting Face Mounting Face Figure 2 7 Three Main Bearings some applications like generators hydraulic pumps and others require a separate bearing housing be used to connect the load to the engine Gear Reducer Where engine and driven speeds vary greatly or to permit the engine and equipment to operate at a preferred RPM a gear reducer may be specified Follow manufacturer s recommendations for installation and maintenance Properly Installing the Engine In most applications the provision of adequate power is only part of the solution It is careful attention to the particular features of each application that will lead to reliability good engine performance long engine life and customer satisfaction The installation requirements addressed in this section
48. 30 Ass MOUNT ING ako D SURFACE EN 22 E MOUNTING HOLE A 275 TANN n was di tl T M 3 8 16 UNC 2B INCH 17 90 0 669 DEEP 301 95 142 88 15 6251 B C 11 888 NI r AKO ia 7 16 14 UNC 28 INCH 21 00 0 827 1 DEEP X 5 196 85 7 750 B C PILOT 177 80 7 000 Figure 1 4 Typical Engine Dimensions CH Series with Standard Flat Air Cleaner 1 6 Section 1 Safety and General Information Dimensions in millimeters Inch equivalents shown in 441 45 17 380 312 81 12 318 3 00 118 SPARK PLUG 01 FI Cr L ALTERNATE OIL FILL LOCATION FUEL RAIL INLET IGNITION COIL IGNITION COIL 4 87 184 SPARK PLUG e CRANKSHAFT 4 j 7 ho y A e aL P j j ine 0007 PRS ral gt Hes PST Wi PS S77 gt STARTER 15 70 142 04 62 16 618 5 592 3 628 ENGINE OIL FILTER REMOVAL 184 15 MOUNTING HOLES FLYWHEEL SIDE Figure 1 5 Typical Engine Dimensions CH EFI Series with Heavy Duty Air Cleaner 1 7 Section 1 Safety and General Information General Specifications Power 3600 RPM exceeds Society of Automotive Engineers Small Engine Test Code J1940 CALS sa ost teed E E
49. After starting engine speed increases to over 700 RPM and centrifugal force overcomes the force of the flyweight spring The flyweight moves outward pulling the arm of the control pin so it pivots into the run position The control pin no longer has any effect on the exhaust valve and the engine operates at full power When the engine is stopped the spring returns the flyweight lever and control pin assembly to the compression release position ready for the next start Camshaft Inspection and Service Check the lobes of the camshaft for wear or damage See Section 1 for minimum lift specifications Inspect the cam gear for badly worn chipped or missing teeth Replacement of the camshaft will be necessary if any of these conditions exist Crankshaft Inspection and Service Inspect the gear teeth of the crankshaft If the teeth are badly worn chipped or some are missing replacement of the crankshaft will be necessary 10 1 Section 10 Inspection and Reconditioning Inspect the crankshaft bearing surfaces for scoring erooving etc Some engines have bearing inserts in the crankshaft bore of the closure plate and or crankcase Do not replace bearings unless they show signs of damage or are out of running clearance specifications If the crankshaft turns easily and noiselessly and there is no evidence of scoring erooving etc on the races or bearing surfaces the bearings can be reused Inspect the crankshaft k
50. As the speed reaches the governed setting the governor spring tension and the force applied by the regulating pin will again be in equilibrium This maintains engine speed at a relatively constant level Governed speed may be at a fixed point as on constant speed applications or variable as determined by a throttle control lever Understanding how the governor functions should help in connecting controls to the control plate and to properly adjust the governed speeds Other types of governors are available including Electronic Governing Contact your Kohler Engine representative for information on using or converting to this type of system Refer to TP 2445 A for connecting and adjusting Throttle and Choke Controls on various Kohler Engine Models 20 Engine Speed Settings The high and low idle speed settings on all Kohler engines are set in our engine test cell after assembly Unless otherwise specified by an OEM customer standard Kohler RPM specifications are followed usually 1200 RPM idle 3750 RPM max These settings are made on a new cold engine that is run for less than eight minutes with no load Engine break in and warm up can be expected to alter the initial factory settings usually resulting in a speed increase Installation on a piece of equipment is also likely to affect the settings with the applied load usually resulting in a speed decrease Speed readings after installation break in etc can be expected t
51. Do not disconnect or reconnect the wiring harness connector to the control unit or any individual components with the ignition on This can send a damaging voltage spike through the ECU e Do not allow the battery cables to touch opposing terminals When connecting battery cables attach the positive cable to positive battery terminal first followed by negative cable to negative battery terminal e Never start the engine when the cables are loose or poorly connected to the battery terminals 58 4 e Never disconnect battery while engine is running e Never use a quick battery charger to start the engine e Do not charge battery with key switch on e Always disconnect negative battery cable lead before charging battery and also unplug harness from ECU before performing any welding on equipment Electrical Components Electronic Control Unit ECU Boscy T MEY BAD E Figure 5B 1 35 Pin 1 7 Metal Cased ECU Figure 5B 2 24 Pin MSE 1 0 Plastic Cased ECU Section 5B EFI Fuel System The ECU continually performs a diagnostic check of itself each of the sensors and the system performance If a fault is detected the ECU turns on the Malfunction Indicator Light MIL on the equipment control panel stores the fault code in its fault memory and goes into a default operating mode Depending on the significance or severity of the fault normal operati
52. Engine R amp R from Generator Set Short Block Replacement Miniblock Replacement Major Overhaul Includes Valve Service Minor Overhaul Excludes Valve Service Bare Block Connecting Rod Piston and or Rings Crankshaft Crankshaft amp Main Bearing R amp R Crankshaft PTO Seal Crankshaft Flywheel Seal Crankshaft amp Connecting Rod Balance Gears R amp R Camshaft amp Valves Valve R amp R No Grinding Each Cylinder Valve Tappet Adjustment Valve Grinding Each Cylinder Valve Guide Replacement Valve Spring Replacement Valve Cover Gasket and or Breather Camshaft R 8 R Ignition Ignition Timing Points and or Condenser Replace amp Adjust Shipping Damaged Spark Plug Replace amp Adjust Spark Plug Wire Replace Battery Ignition Spark Plug Wire Replace Magneto Ignition Ignition Coil Replace Magneto Coil Test amp Replace Includes Flywheel R amp R Flywheel R amp R Charging Regulator Test amp Replace Stator Test amp Replace Includes Flywheel R R Starter Retractable amp Replace Rope amp Spring Starting Motor Bendix Type R amp R Starter Rebuild Includes R amp R Starter Drive R amp Starter Solenoid R amp R Carburetor amp Air Intake Carburetor R amp R Carburetor Rebuild Includes R amp R Carburetor Adjust Air Cleaner Damage in Shipment Fuel Tank R amp R Fuel Pump R amp R M
53. Engine representative for specifics on the use of these fuels To plan for a permanent installation such as a home standby generator using utility supplied gaseous fuel refer to the supply requirements in Section 5 Technical Guidelines Engine Controls Whenever convenient consider using engine mounted throttle and choke controls Automatic chokes solenoid operated chokes and idle solenoids are available on some engine models With constant speed applications the throttle linkage allows the engine to come up to full RPM almost immediately after start up When remote controls are needed single or dual cable throttle choke control systems are offered For specific details on actual hook up of the controls and adjustments procedures refer to TP 2445 A Governor Operation Kohler engines are equipped with a centrifugal mechanical governor to hold speed constant under changing load conditions The governor mechanism is mounted inside the crankcase and is driven off the crankshaft or camshaft Refer to Figure 3 13 for typical components as described in the following explanation Section 3 Properly Installing the Engine Throttle Linkage Governor Arm Carburetor Throttle Lever Flyweights Governor Gear Assembly Governor Spring High Speed Stop AL Throttle Control Figure 3 13 Typical Governor Components Centrifugal force acting on the rotating governor gear assembly causes the flyweights to move outward as
54. Figure 8 36 3 Plug the tester into the proper AC outlet power Figure 8 35 for tester being used Turn on the power switch The POWER light should be illuminated and 5 Plug the tester into the proper AC outlet power one of the four status lights may be on as well for tester being used Turn on the power switch See Figure 8 30 This does not represent the The POWER light should be illuminated and condition of the part one of the four status lights may be on as well See Figure 8 30 This does not represent the condition of the part 8 25 Section 8 Electrical System and Components 4 Press the TEST button until a click is heard and then release See Figure 8 31 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 light is displayed the rectifier is faulty and should not be used NOTE A flashing LOW light can also occur as a result of an inadequate ground lead connection Make certain connection location is clean and clamp is secure Rectifier Regulator Flywheel Stator Ammeter Figure 8 37 Connections for Testing Charging System 8 26 Section 8 Electrical System and Components Troubleshooting Guide 15 20 25 Amp Battery Charging Systems When problems occur in keeping the battery charged or the battery charges at too high a rate the problem can usually be found somewhere in
55. If aslip joint is used a grounding strap is required Attached to chassis Attached to engine block close to the coil Terminal ered 65 Terninal Black Cylinder 2 AN Spark Plug 22 lt 1 16 45 875 104 Injector 1 Injector 2 LII 87g Fuel Pump See Grounding Note C Ignition Switch 1 Battery 20A Gnd See Grounding Battery Note A Saftey Switch Tan Kill Lead Option No Gnd General System Installation Notes 1 The ignition switch must maintain a constant voltage to circuits 84 85 and Ji 2 as the key is swept from run position to prevent an ECU reset during starting 2 The voltage on circuits 84 85 1 and 1 1 must remain 0 2 volts of each other regardless of system current draw to prevent differences between actuator voltages circuits 65 66 45 and 87 and system voltage 1 If the ignition switch controls o powered circuit lights horn it is recommended that a relay be used to control the power 3 To prevent signal errors load circuits horn lights shall not be powered from the EFI engine or wire chassis harness 4 A resistive spark plug with either a resistive spark plug wire or boot must used to prevent electrical system noise 5 It is recommend that the ECU housing be mounted vertically with the wire bundle down or horizontally with the weother pok connector down 6
56. It is recommended that the ECU not be mounted to the engine but be attached it an isolator plate or or bracket that con keep the vibrations within the ECU specs 7 When not in operation the battery must maintain a minimum system voltage of 7 volts with a current draw of 2mA to maintain the adaptive memory 8 During start the battery must maintain 7 volts minimum for the ECU operations during crank 9 Unless otherwise specified All wires are 18AWG 102 Inductive pickup wires 9 and 10 are to be a twisted pair with 1 twist per inch 1D Diagnosis lamp is to be o 12V 1 4A incandescent lamp 12 Normal Operational Voltage is 16Vdc 9Vdc With a cold cranking voltage of 7Volts 13 TPS connection shown is for counter clockwise rotation of the TPS Clockwise rotaion requires switching wires to TPS pins 1 amp 2 Section 5B EFI Fuel System 24 Pin MSE 1 0 Plastic Cased ECU Systems Pin Function Permanent Battery Voltage Switched Ignition Voltage Safety Switch Throttle Position Sensor TPS and Temperature Sensor Ground Not Used Oil 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 Position Supply Voltage Battery Ground Injector 1 Output Injector 2 Output Main Relay Output Malfunction Indicator Light MIL Not Used Tach Output if needed Not Used Ignition Coil
57. Km a pr Eu ee T 3 Reconnect the hose to the adapter and tighten the clamp or install a new adapter gasket if the adapter was separated from the carburetor and torque the mounting fasteners to 7 3 N m Figure 4 13 Removing Elements 65 in Ib 3 After the element is removed check the condition NOTE Adapter configurations MET of the inner element It should be replaced depending on engine and application whenever it appears dirty typically every other involved Two adapters are shown in time the main element is replaced Clean the area Figure 4 14 around the base of the inner element before removing it so dirt does not get into the engine 4 5 Section 4 Air Cleaner and Air Intake System Figure 4 14 Adapters for Heavy Duty Air Cleaners Air Intake Cooling System To ensure proper cooling make sure the grass screen cooling fan fins and external surfaces of the engine are kept clean at all times Every 100 hours of operation more often under extremely dusty or dirty conditions remove the blower housing and other cooling shrouds Clean the cooling fins and external surfaces as necessary Make sure the cooling shrouds are reinstalled 4 6 Cleanout kits Kohler Part No 25 755 20 S black or 25 755 21 S gold are recommended to aid inspection and cleanout of the cooling fins See Figure 4 15 NOTE Operating the engine with a blocked grass screen dirty or plugg
58. See Figure 5 18 5 14 Figure 5 18 Installing Float Assembly 7 Hold the carburetor body so the float assembly hangs vertically and rests lightly against the fuel inlet needle The inlet needle should be fully seated but the center pin of the needle on retainer clip end should not be depressed Check the float height adjustment NOTE The inlet needle center pin is spring loaded Make sure the float rests against the fuel inlet needle without depressing the center pin The correct float height setting is 17 mm 0 669 in 1 5 mm 0 059 in measured from the float bottom to the body of the carburetor See Figure 5 19 Replace the float if the height is different than the specified setting DO NOT attempt to adjust by bending float tab Figure 5 19 Checking Float Height NOTE Be sure to measure from the casting surface not the rubber gasket if still attached Section 5 Fuel System and Governor 9 When the proper float height is obtained NOTE Further disassembly of the fuel bowl is not carefully reinstall the fuel bowl using new necessary unless the Fuel Solenoid Kit or O Rings onto the carburetor Secure with the four Fuel Bowl Kit obtained separately will also original screws Torque the screws to 2 5 0 3 be installed 23 2 6 in Ib See Figure 5 20 2 Remove the float pin screw and lift out the old float pin and inlet needle See Figure 5 22 Discard all the old parts Th
59. The two M6 screws go into the back of the cylinders The short M5 screws into the lower holes closest to the blower housing The short screw on the oil filter side is also used to mount the wire harness clip Be sure any wire harnesses or leads are routed out through the proper offsets or notches so they will not be pinched between the blower housing and baffles See Figure 11 63 Figure 11 63 Routing Wiring Harness and Leads 4 If the rectifier regulator was not removed attach the ground wire or metal grounding bracket for the rectifier regulator using the silver colored screw and washer to the lower blower housing hole See Figure 11 64 Figure 11 64 Ground Lead Details 5 Tighten all of the shrouding fasteners Torque the blower housing screws to 6 2 N m 55 in Ib in a new hole or to 4 0 N m 35 in Ib in a used hole Torque the shorter M5 side baffle screws to 4 0 N m 35 in Ib See Figure 11 65 Torque the upper M5 side baffle screws into cylinder head to 6 2 N m 55 in Ib in a new hole to 4 0 Ne m 35 in Ib in a used hole Torque the two rear M6 baffle mounting screws to 10 7 N m 95 in Ib in a new hole or to 7 3 65 in Ib in a used hole See Figure 11 66 11 18 Section 11 Reassembly 7 Torque the four breather cover screws to 7 3 N m 65 in Ib in the sequence shown in Figure 11 68 Figure 11 65 Tighten Short Screws to Torque Specified Figure 11 68 B
60. This gives the engine a good lugging characteristic The torque curve is modified by modifying valve timing in the initial development of the engine EFFECTS OF OPERATING CONDITIONS Fouroperating conditions have an effect on useable engine horsepower and must be considered when rating an engine 1 Duty Cycle 2 Altitude 3 Temperature 4 Connecting to the load These conditions are not unusual they are normal and apply to all makes and models of engines Each condition has an industry accepted factor which must be allowed for when calculating the available horsepower of an engine Refer to page 12 for an example of how to calculate useable engine horsepower 1 Duty Cycle Engines are rated at maximum allowable RPM and wide open throttle WOT meaning that 8 HP engine will deliver 8 HP underlaboratory conditions If that same engine were continuously operated in an application at that power its life could be shortened To offset excessive application demands and there by increase engine performance and engine life it is recommended that the following duty cycle factors be included in determining useable horsepower For Constant Duty at constant speed and load an 80 factor should be used W For Intermittent Duty with 50 percent or less duty cycle an 85 factor should be used 2 Effects of Altitude Engines are rated using barometric pressure at sea level With an increase in altitud
61. ar U Remove Ground ME Electrode 9 Plug Alligator Clip 025 Spring Clip Gap 1 2 I D Fuel Line 1 1 4 Long Ignition System Tester Twin Cylinder Engines 20 Testing Module Secondary Twin Cylinder Engines CHARGING SYSTEMS The engines which use battery ignition usually have electric start also Depending upon the application there may be accessories or lights running off the battery as well With all the demands put on the battery provision must be made for recharging or the energy available would soon be depleted There are currently several different flywheel alternator systems used on Kohler engines for battery recharging The following information will help you to identify the various systems The 15 amp system which is the most common incorporates a flywheel with six ceramic magnets cemented to the inside rim an aiternator stator ring and a rectifier regulator which may be externally mounted long fins 3 terminals in offset configuration or 15 Amp Charging System Externally Mounted Rectifier Regulator may mount directly into the blower housing 2 short fins 3 terminals in line Blower Housing Mounted 15 Amp Rectifier Regulator For those O E M accounts that needed more than 15 amp charging we offered a 30 amp system This system had a flywheel with a magnet ring assembly pressed in an alternator stator with two separate sets of windings
62. are to draw attention to the particular considerations necessary in all applications Engine Location Engine location is the key to proper installation and it must be considered in relationship to e Unrestricted Cooling Air Flow in and out e Secure Mounting Provision Availability of Combustion Air Easy Serviceability Good Exit of Exhaust Gases e Maintenance of Electrical System e Access to Fuel Supply Access to Throttle and Choke Each item is important to successful application of an engine and should be considered when designing the equipment and locating the engine Cooling Air One of the most important factors effecting engine performance and engine life is cooling air Air cooled engines depend on a constant flow of cooling air to remove the heat generated during combustion Approximately 70 of the heat value of fuel consumed by an engine will be rejected to the cooling air and to the exhaust Without an adequate flow of clean unheated air into the engine it will overheat To emphasize the importance of this a CH14 engine will consume about 1 U S gallon 3 785 liters of gasoline an hour at 3200 RPM which can be seen in the fuel consumption curve on page 4 The heat value of one gallon of gasoline is about 120 500 BTU s Of this about 3096 is rejected to the cooling air another 40 is rejected along with the exhaust gases and to radiation which leaves only about 30 of the input available for usef
63. both of which were due to manufacturing defects since corrected by the vendor 13 Theory of Operation The basic magneto ignition system has been around for many years and for good reason it s difficult to improve on its simplicity and durability However in developing an ignition system for the new Magnum engines it was decided there were two major areas where improvement could be accomplished the output at low RPM s for better starting characteristics Eliminate the need for maintenance The new system has achieved both of those goals We have already discussed the theory of a magneto ignition system The new Magnum system utilizes that same basic theory with a few start of the art refinements Typical Magneto Cycle The Magnum module includes a three leg laminated iron core and a coil with primary and secondary windings However this is where the similarity to past systems ends The new module also includes a small triggering coil and some solid state circuitry Kill Terminal Laminations 5 Position of Triggering Coil Coil Assembly Magnum Solid State Ignition Module 14 The flywheel magnet rotating past the laminated core causes magnetic flux to flow through the left and center legs of the core This induces an electromotive force in the primary and secondary windings The EMF in the primary causes a transistor to switch on which completes a circui
64. box 17 must be signed by a Central Distributor representative for non expert dealers or a certified Expert Dealer for short block miniblock or engine replacement Box 6 Record hours used Box 7 Enter name of original seller of equipment Box 8 Check box describing parts disposition Box 9 Enter part number of defective part 14 The part number should normally not an assembly part number The actual part number of the component within an assembly that failed should be shown For example a wrist pin retainer failure caused extensive damage to the cylinder bore requiring a miniblock assembly The Kohler Engine Failure code in this case would be the part number of the retainer 235811 You would not enter the miniblock assembly number in this case The only time an assembly number should be entered is when no parts breakdown is given for the failed assembly Example a magnet came loose on a flywheel There is no service part number for the flywheel magnet therefore the part number for the flywheel would be listed Box 10 Enter failure suffix from listing on claim also shown below Box 11 Conditions Found Describe in detail the failure If more space is required attach a note Probable Cause of Failure List in detail the most probable cause Box 12 Enter the job numbers of work performed as stated in the Flat Rate Schedule and indicate time spent in repairing the engine When it becomes necessary
65. carburetor removed from the engine for clarity 5A 6 Idle Speed Clamp Bracket Position 1 Counting the number of turns back the idle speed adjustment screw off counterclockwise so only 1 to 1 1 2 of the threads are visible See Figure 5A 8 Idle Speed Clamp Bracket Mounting Screw Figure 5A 8 Backing Off Idle Speed Screw 2 Loosen the clamp bracket mounting screw and pivot the throttle shaft to fully close the throttle plate See Figure 5A 9 Figure 5A 9 Closing Throttle Plate 3 Hold the throttle plate closed and rotate the clamp bracket until the end of the screw contacts the stop Insert a 0 025 mm 0 001 in feeler gauge between the carburetor housing and the side of the clamp bracket to set the endplay then tighten the mounting screw securely See Figure 5A 10 Section LPG Fuel Systems 3 Insert a 0 025 mm 0 001 in feeler gauge between the side of the stop collar and the carburetor housing then check or set the position of the stop collar The head of the mounting screw must be in contact with the carburetor boss from the back hose fitting side preventing any further rotation over center Set or adjust the stop collar as required See Figure 5A 12 Figure 5A 10 Tightening Idle Speed Clamp Mounting Screw High Speed Stop Collar 4 Reset the idle speed adjustment screw back to the original position High Speed Stop Collar Position 1 Make sure the idle speed clamp
66. combustion engine For example the gas turbine type of engine such as used in jet aircraft is one form of internal combustion engine This text will con centrate on the reciprocating or piston type internal combustion engine HISTORICAL HIGHLIGHTS To get a good over all understanding of any subject it helps to have some knowledge of its history and development Briefly here are some of the high lights of internal combustion engine history In 1824 Carnot a Frenchman described a theoreti cal heat engine process This was an ideal process and is still recognized as the aim in the development of any engine However it is interesting to note that to this date engineers have been unable to develop the maximum conversion of heat energy into work as was described in Carnot s theory In 1838 Barnett an Englishman described a two stroke cycle engine His description also was theore tical and many difficulties were encountered at tempting to develop a working model During the Civil War period Beau de Rechas a Frenchman set forth the principles of the four stroke cycle However it was not until 1873 that a German by the name of Otto built the first success ful four stroke cycle engine The gasoline engine to this day is often called an Otto cycle engine In 1892 another German Rudolph Diesel proposed an engine in which the air and fuel mixture would be ignited by the heat developed during rapid compressio
67. from the top of the carburetor then carefully pull lift out the two slow jets The slow jets may be sized side specific mark or tag for proper reassembly Note the small O Ring on the bottom of each jet See Figures 5 24 and 5 25 Save parts for cleaning and reuse unless a Jet Kit is also being installed Clean the slow jets using compressed air Do not use wire or carburetor cleaner Clean the carburetor body main jets vent ports seats etc using a good commercially available carburetor solvent Keep away from plastic or rubber parts if non compatible Use clean dry compressed air to blow out the internal channels and ports Do not use metal tools or wire to clean orifices and jets Inspect and thoroughly check the carburetor for cracks wear or damage Inspect the fuel inlet seat for wear or damage Check the spring loaded choke plate to make sure it moves freely on the shaft Clean the carburetor fuel bowl as required Install the two main nozzles into the towers of the carburetor body The end of the main nozzles with the two raised shoulders should be out down adjacent to the 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 Figure 5 26 Nozzle End with Two Shoulders Out Down Main Jets Figure 5 26 Installing Main Nozzles and Main Jets Figure 5 25
68. injection duration or pulse width It may vary in length from 1 5 8 milliseconds depending on the speed and load requirements of the engine Section 5B EFI Fuel System Service Injector problems typically fall into three general categories electrical dirty clogged or leakage An electrical problem usually causes one or both of the injectors to stop functioning Several methods may be used to check if the injectors are operating 1 With the engine running at idle feel for operational vibration indicating that they are opening and closing 2 When temperatures prohibit touching listen for a buzzing or clicking sound with a screwdriver or mechanic s stethoscope see Figure 5B 19 Figure 5B 19 Checking Injectors 3 Disconnect the electrical connector from an injector and listen for a change in idle performance only running on one cylinder or a change in injector noise or vibration If an injector is not operating it can indicate either a bad injector or a wiring electrical connection problem Check as follows NOTE Do not apply voltage to the fuel injector s Excessive voltage will burn out the injector s Do not ground the injector s with the ignition on Injector s will open turn on if relay is energized 1 Disconnect the electrical connector from both injectors Plug the 12 volt Noid Light part of EFI Service Kit see Section 2 in one connector 58 15 Section 5B EFI Fuel System Fig
69. larger engine Remove and discard the rod cap 2 4 Section 3 Troubleshooting Troubleshooting Guide When troubles occur be sure to check the 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 Use these to locate the causing factors Refer to the specific section s within this service manual for more detailed information Engine Cranks But Will Not Start 1 Empty fuel tank Fuel shut off valve closed Poor fuel dirt or water in the fuel system Clogged fuel line Spark plug lead s disconnected Key switch or kill switch in off position Faulty spark plugs Faulty ignition module s Carburetor solenoid malfunction Diode in wiring harness failed in open circuit mode Vacuum fuel pump malfunction or oil in vacuum hose 13 Vacuum hose to fuel pump leaking cracked 14 Battery connected backwards 15 Safety interlock system engaged rm DO US SELON ae Sl m N Engine Starts But Does Not Keep Running 1 Restricted fuel tank cap vent 2 Poor fuel dirt or water in the fuel system 3 Faulty or misadjusted choke or throttle controls 4 Loose wires or connections that short the kill terminal of ignition module to ground Faulty cylinder head gasket Faulty carburetor 7 Vacuum fuel pump malfunction or oil in vacuum hose 8 Leaking cracked
70. position While holding it in the extended position grasp the tip of the dust cover with a pliers or vise grip and pull it free from the spacer Dust Cover gt Pm Figure 8 40 Assembling Inner Half of Tool Around e Retaining Armature Shaft and Retaining Ring Spring Retainer Ring 5 Thread the center screw into the removal tool Anti Drift until you feel resistance Use a wrench 1 1 8 or Spring adjustable to hold the base of the removal tool Use another wrench socket 1 2 or 13 mm to turn the center screw clockwise see Figure 8 41 The resistance against the center screw will tell Dust Cover Spacer 3 Drive the groove in the armature shaft Pinion p you when the retaining ring has popped out of Drive Collar Figure 8 39 Drive Components Bonded Inertia Drive Starter 2 Disassemble the snap ring removal tool see Section 2 3 Again referring to Figure 8 39 grasp the spring retainer and push it toward the starter Figure 8 41 Holding Tool and Turning Center compressing the anti drift spring and exposing Screw Clockwise to Remove Retaining Ring the retaining ring 6 Remove the drive components from the armature 4 Holding the spring retainer in the retracted shaft paying attention to the sequence If the position assemble the inner halves of the removal splines are dirty clean them with solvent tool around the armatu
71. procedures under Governor Gear Assembly in Section 10 Oil Pump Assembly The oil pump is mounted to the inside of the closure plate If service is required refer to the service procedures under Oil Pump Assembly in Section 10 Figure 9 66 Removing the Ten Closure Plate Fasteners 9 17 Section 9 Disassembly Remove Camshaft 1 Remove the camshaft and shim See Figure 9 69 Figure 9 71 Mark End Cap with Cylinder Number Before Removal Figure 9 69 Removing Camshaft Note Shim NOTE The cylinders are numbered on the crankcase Use the numbers to mark each Remove Connecting Rods with Pistons end cap connecting rod and piston for and Rings reassembly Do not mix end caps and 1 Remove the two hex flange screws securing the connecting rods closest connecting rod end cap Remove the end cap See Figure 9 70 Figure 9 72 Removing Piston Connecting Rod Assemblies CONNEC NNG Bol 2 Carefully remove the connecting rod and piston NOTE If a carbon ridge is present at the top of assembly from the cylinder bore See Figure 9 72 either cylinder bore use a ridge reamer tool to remove the ridge before attempting to remove the piston 3 Repeat the above procedures for the other connecting rod and piston assembly 9 18 Section 9 Disassembly Remove Crankshaft 1 Carefully pull the crankshaft from the crankcase See Figure 9 73 Note thrust washer
72. replace the affected module b Ifany of the tests are bad determine cause and fix as required then retest 8 17 Section 8 Electrical System and Components Battery Charging System General Most engines are equipped with a 15 or 20 amp regulated charging system Some have a 25 amp regulated charging system See Figures 8 23 8 24 and 8 25 for the 15 20 25 amp charging system diagrams Some engines utilize a amp unregulated system with optional 70 watt lighting circuit Refer to Figure 8 26 NOTE Observe the following guidelines to avoid damage to the electrical system and components Make sure the battery polarity is correct A negative ground system is used e Disconnect the rectifier regulator plug and or the wiring harness plug before doing any electric welding on the equipment powered by the engine Also disconnect all other electrical accessories in common ground with the engine e Prevent the stator AC leads from touching or shorting while the engine is running This could damage the stator 15 20 25 Amp Regulated Charging System Figure 8 20 15 Amp Stator and Rectifier Regulator Figure 8 21 20 Amp Stator and Rectifier Regulator 1st Style 25 Amp Stator 2nd Style Figure 8 22 25 Amp Stator and Rectifier Regulators 8 18 Section 8 Electrical System and Components e Bnid eds l Aiquassy 0 20365 4 lh
73. same position as before disassembly 1 Note the mark or tag identifying the push rod as either intake or exhaust and cylinder 1 or 2 Dip the ends of the push rods in engine oil and install making sure that each push rod ball seats in its hydraulic lifter socket See Figure 11 45 Figure 11 45 Install Push Rods in Their Original Position 2 Apply grease to the contact surfaces of the rocker arms and rocker arm pivots Install the rocker arms and rocker arm pivots on one cylinder head and start the two hex flange screws See Figure 11 46 m M S 4 Figure 11 46 Torquing Rocker Arm Screws 3 Torque the hex flange screws to 11 3 N m 100 in Ib Repeat for the other rocker arm 4 Use wrench or rocker arm lifting tool see Section 2 to lift the rocker arms and position the push rods underneath See Figure 11 47 11 13 Section 11 Reassembly 5 Repeat the above steps for the remaining cylinder Do not interchange parts from the cylinder heads Install Ignition Modules 1 Rotate the flywheel to position the magnet away from the ignition module bosses Figure 11 47 Using Spanner Wrench to Lift Rocker Arm Over Push Rod 6 Rotate the crankshaft to check for free operation of the valve train Check the clearance between the valve spring coils at full lift Minimum allowable clearance is 0 25 mm 0 010 11 Check Assembly Important Rotate the crankshaft a minimum
74. severe acid burns Charge battery only in a well ventilated area Keep sources of ignition away Explosive Gas Batteries produce explosive hydrogen gas while being charged To prevent a fire or explosion charge batteries only in well ventilated areas Keep sparks open flames and other 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 sure all switches are OFF If ON a spark will occur at the ground cable terminal which could cause an explosion if hydrogen gas or gasoline vapors are present A WARNING 5 Rotating Parts can cause severe injury Stay away while engine is in operation Rotating Parts Keep hands feet hair and clothing away from all moving parts to prevent injury Never operate the engine with covers shrouds or guards removed A WARNING Hot Parts can cause severe burns Do not touch engine while operating or just after stopping Hot Parts Engine components can get extremely hot from operation To prevent severe burns do not touch these areas while the engine 15 running or immediately after it is turned off Never operate the engine with heat shields or guards removed A WARNING Carbon Monoxide can cause severe nausea fainting or death Do not operate engine in closed or confined area Lethal Exhaust Ga
75. speed increases As the flyweights move outward they force the regulating pin of the gear assembly to move outward The regulating pin contacts the tab on the cross shaft causing the shaft to rotate with changing speed One end of the cross shaft protrudes through the side of the crankcase and has a lever or arm attached to the protruding end A linkage connects one end of the governor arm to the throttle lever in the carburetor so the rotational movement of the governor shaft moves the throttle plate in the carburetor toward the closed position The governor spring is hooked between the opposite end of the governor arm and the throttle control lever When the engine is at rest and the throttle control is in the fast position the tension of the governor spring holds the throttle valve open When the engine is started and comes up to speed governor gear assembly is rotating the force applied by the regulating pin against the cross shaft tends to close the throttle valve The governor spring tension and the force applied by the regulating pin are in equilibrium holding the engine speed constant 19 Section 3 Properly Installing the Engine When a load is applied and the engine speed and governor speed decreases the governor spring tension moves the governor arm to open the throttle plate wider This admits more fuel and restores engine speed This action takes place very rapidly so a reduction in speed is hardly noticed
76. 0 Plastic Cased ECU Circuits 22 23 65 66 30 and relay 32 Pin MSE 1 1 Plastic Cased ECU Circuits 30 31 65 66 relay and relay circuit 30 5 ECU grounds 6 ECU Diagnostic Aid 8 FUEL SYSTEM ELECTRICAL no fuel delivery Possible causes 1 No fuel Air in fuel rail Fuel valve shut off Fuel filter line plugged Injector circuit s 35 Pin MA 1 7 Metal Cased ECU Circuits 35 35A 45 and 45A 24 Pin MSE 1 0 Plastic Cased ECU Circuits 16 17 45 and 45A 32 Pin MSE 1 1 Plastic Cased ECU Circuits Ohi DD qud 14 15 and 45 6 Injector 7 ECU grounds o ECU Diagnostic Aid 9 FUEL SYSTEM fuel pressure Possible causes for low fuel system pressure 1 Low fuel 2 Fuel filter plugged 3 Fuel supply line plugged 4 Pressure regulator 5 Fuel pump Possible causes for high fuel system pressure 1 Pressure regulator 2 Fuel return line plugged or restricted Diagnostic Aid 10 BASIC ENGINE cranks but will not run Possible causes 1 Refer to basic engine troubleshooting charts within service manual sections 3 5 and 8 Section 6 Lubrication System General This engine uses a full pressure lubrication system This system delivers oil under pressure to the crankshaft camshaft and connecting rod bearing surfaces In addition to lubricating the bearing surfaces the lubrication system supplies oil to the hydraulic valve lifters A high efficiency ger
77. 12 1 Section 12 Clutch Service 2 After adjustment is made engage clutch and On this type an oil splash type lubrication system is check to make sure rollers go over center to lock used The proper oil level must be maintained to the unit in engaged position and prevent provide efficient lubrication The oil should be releasing under load If trouble persists after changed after each 100 hours of operation When readjustment clutch reconditioning is indicated refilling use 0 47 L 1 pt of motor oil of proper viscosity See chart below Reconditioning Drain the oil remove the nameplate and use the SAE Viscosity following procedure Above 10 C 50 F SAE 30 1 Remove capscrews 2 from clutch yoke and 17 8 C 0 to 10 C 50 SAE 20 remove spacers Below 17 8 C SAE 10 2 Remove cross shaft Adjustment Slight readjustment may be needed after a few hours on a new clutch to accommodate normal run in wear Firm pressure should be required to engage clutch 40 45 pounds pull at lever handle Readjust if clutch slips and overheats or if clutch handle jumps out after 5 engagement Use the following procedure 3 Remove housing bolts 4 and slide housing off 4 Loosen bolts securing clutch assembly to crankshaft then remove locking screw Pull clutch assembly off 6 replace clutch simply turn adjusting collar off 1 Release clutch and remove nameplate Using a and remove plate larg
78. 12 in and tie a temporary slip knot in it to keep it from retracting into the starter See Figure 7 2 Hex Starter Housing Flange Screws Handle with Rope Retainer Pulley Springs 5 Brake Washer C PANIS Brake Spring Plain Washer Center Screw Figure 7 1 Retractable Starter Exploded View Retainer Drive Cup 7 1 Section 7 Retractable Starter Slipknot Rope Retainer Figure 7 2 Removing Starter Handle 3 Remove the rope retainer from inside 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 5 When all spring tension on the starter pulley is released remove the rope from the pulley 6 Tiea single knot in one end of the new 7 Rotate the pulley counterclockwise when viewed from pawl side of pulley until the spring is tight approximately 6 full turns of pulley 8 Rotate the pulley clockwise until the rope hole in the pulley is aligned with the rope guide bushing of the starter housing NOTE Do not allow the pulley spring to unwind Enlist the aid of a helper if necessary or use a C clamp to hold the pulley in position 9 Insert the new rope through the rope hole in the starter pulley and the rope guide bushing of the housing See Figure 7 3 7 2 p D Ro pe Guide Bush
79. 12 volts between the terminals If the terminals are connected electric current will flow through the circuit By hooking our ignition coil into the circuit we can use current from the battery to energize the primary windings in our coil Electron Theory mmm Value Electron Flow Cell Plates Difference In Electrical Potential Produced In Simple Battery The coil used for battery ignition is very similar in construction and function to the magneto coil already discussed The major difference is that the secondary windings are located between the primary windings and the core Also the battery coil has laminations outside the primary windings This provides maximum concentration of the magnetic fields to achieve optimum coil output IMPORTANT It should be pointed out here that although the battery ignition coil for single cylinder Kohler engines looks like a standard automotive coil the number of windings and internal components often vary Use of an automotive coil on a Kohler engine will often result in poor or erratic ignition High Tension Terminal Primary Terminals Cap Lamination Secondary Winding Primary Winding Case Construction Details Typical Ignition Coil The battery ignition coils for twin cylinder Kohler engines are very similar to the single cylinder coil with one exception In the single cylinder coil one end of the secondary windings is connected to the high tension lead
80. 3 and 4 2 Disconnect the charging lead from battery 2 If voltage is 28 volts or more stator winding is OK With engine running at 3000 RPM measure voltage from charging lead to ground using a If voltage is less than 28 volts test stator using DC voltmeter an ohmmeter Tests 3 and 4 3 With charging lead disconnected from battery 3 If resistance is low in both directions the diode and engine stopped measure resistance from is shorted Replace the diode charging lead to ground using an ohmmeter Note reading If resistance is high in both directions the diode or stator winding is open Use Test 4 Reverse the leads and measure resistance again In one direction the resistance should be infinity ohms open circuit With the leads reversed some resistance should be measured about midscale on Rx1 range 4 Cutthe sleeving on the charging lead to exposd 4 Ifresistance is approximately 1 07 ohms the diode connections stator winding is OK Measure the resistance from the stator side of If resistance is 0 ohms stator winding is shorted diode to ground using an ohmmeter Replace stator If resistance is infinity ohms stator winding or lead is open Replace stator 1 Make sure lights are not burned out 1 Replace burned out lights 2 Disconnect the lighting lead from the wiring 2 If voltage is 15 volts or more stator 15 OK Check harness for loose connections or shorts in wiring harness With en
81. 4 N m 66 in finally to 9 9 N m 88 in Ib Carburetor Screw TOFOHO 6 2 7 3 N m 55 65 in Ib Adapter for Heavy Duty Air Cleaner Mounting Fastener Torque 7 3 N m 65 in Ib Connecting Rod Cap Fastener Torque torque in increments DE cesses ene ue te esrb lacinia iM Doo bn dU 22 7 200 in Ib RET m E E E 14 7 N m 130 in Ib bo leche eel es DE SBODIS oca edicit ue HM Ur etme ere 11 3 N m 100 in Ib Connecting Rod to Crankpin Running Clearance Dno PH 0 030 0 055 mm 0 0012 0 0022 in hup iM Eier OE 0 070 mm 0 0028 in Connecting Rod to Crankpin Side Lai eio ire 0 26 0 63 mm 0 0102 0 0248 in Connecting Rod to Piston Pin Running Clearance sss 0 015 0 028 mm 0 0006 0 0011 in Piston Pin End I D hino m m 17 015 17 023 mm 0 6699 0 6702 in IE eee ace mue A estis stus Ia EEUU A E E E A 17 036 mm 0 6707 in Values are in Metric units Values in parentheses are English equivalents Lubricate threads with engine oil prior to assembly 1 9 Section 1 Safety and General Information Crankcase Governor Cross Shaft Bore I D 6 mm Shaft eee
82. 4b Measure resistance of stator windings across the following leads using an ohmmeter Refer to Figure 2 View If resistance is within ranges stated stator is O K Resistance If resistance is low or 0 ohms Lead Specification stator is shorted and should be replaced Yellow 1 Yellow 2 2 5 3 5 ohms If resistance is infinity ohms Yellow 1 Black 1 2 1 8 ohms stator windings or lead is open Yellow 2 Black 1 2 1 8 ohms Stator should be replaced If continuity is present across leads stator core stator windings are shorted to core Stator should be replaced Also check for continuity across each lead and and the laminated stator core 27 Electric Start Engines 1 25 Amp Or 3 Amp Unregulated Battery Charging System Optional 70 Watt Lighting Optional Ground To Kill Lead White Diode Ignition Module f Flywheel Keyswitch Stator Optional 70 Watt Optional Lighting Stator Fuse 1 774 Optional felon Oil Sentry Optional Switch diel oe Indicator Light Optional Oil Sentry o uL L t3 Shutdown 2 Solenoid 12 Battery enel Starter a Wiring Diagram Electric Start Engines 1 25 Amp or 3 Amp Unregulated Battery Charging System 70 Watt Lighting Lighting Stator 6 Poles Lighting Stator 6 Poles 1 25 Amp Charging Stator 2 Poles Lighting Lead Yellow 3 Am
83. 5 Connect an ohmmeter Rx1 scale between the prevent external fuel leakage and also insulate it 85 and 86 terminals in the relay There should from heat and vibration A special clip connects each be continuity See Figure 5B 15 injector to the fuel rail retaining it in place 58 14 When the key switch is on and the relay is closed the fuel rail is pressurized and voltage is present at the injector At the proper instant the ECU completes the ground circuit energizing the injector The valve needle in the injector is opened electromagnetically and the pressure in the fuel rail forces fuel down through the inside The director plate at the tip of the injector see inset contains a series of calibrated openings which directs the fuel into the manifold in a cone shaped spray pattern 5 Kg n DE a y aimee ia p 9 Multi Orifice Director Plate with Calibrated Opening 5 Armature 6 Valve body 7 Valve needle 1 Filter strainer in fuel supply 2 Electrical connection 3 Solenoid winding 4 Valve housing Figure 5B 18 Fuel Injector Details The injector is opened and 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 and determined by the length of time the valve needle is held open also referred to as the
84. 746 Kilowatt hour 1 Horsepower 746 Watts 0 748 Kilowatt 1 Kilowatt 1 34 Horsepower 1 Kilowatt 1000 Watts Engine HP Developed Approximate Gasoline Fuel 12 HP hours per U S gallon Liquid Propane LPG 10 HP hours per U S gallon Power Calculations Some common applications Use the following formulas below to calculate rough requirements for some typical engine applications Contact the equipment manufacturers for specific details PUMP Water GPM x Total Dynamic Head in feet HP 3960 x Efficiency 50 factor if unknown HP GPM x Pressure psi 1714 x Efficiency 50 factor if unknown PUMP Trash HP GPM x Head x Specific Gravity 8960 x Efficiency 40 factor if unknown HP GPM x Pressure psi x Specific Gravity 1714 x Efficiency 40 factor if unknown PUMP Hydraulic x Pressure psi 1714 x Efficiency 80 factor if unknown FLOW RATE at Pump RPM x Pump Displ Cu in Rev Flow GPM 2 GPM Gallons Per Minute 24 Constants Used In Connection With Pumping Liquids acre foot 325 900 U S gallons atmosphere 34 feet head of water cubic foot 7 48 U S gallons cubic foot per second cubic foot of water foot head of water foot head of water inch of mercury inch of mercury U S gallon of water U S gallon pound per square inch pound per square inch 448 8 gallons per minute 62 4 pounds 0 4335 pounds per sq in 0 89 inches of
85. 8 6 This system uses an analog ASAM or a digital DSAM spark advance module that triggers the ignition modules and spark The ignition timing varies depending upon the engine speed with this system The Digital Spark Advance Ignition DSAI System Figure 8 17 This system uses a digital microprocessor which is located in the ignition modules The ignition timing varies depending upon the engine speed with this system A Capacitive Discharge with Fixed Timing This system Figure 8 3 consists of the following components Amagnet assembly which is permanently affixed to the flywheel e Two electronic capacitive discharge ignition modules which mount on the engine crankcase Figure 8 4 e switch or key switch which grounds the modules to stop the engine Two spark plugs Ignition Starter and a Module Carburetor Pressure Advance Input Solenoid Module Input i Optional Oil Pressure EN B and ji Carburetor Spark Plugs Ignition Modules Safety Input Rectifier Regulator Figure 8 3 Electronic CD Ignition System For Customer Connected Tractor Applications 8 4 Kill Switch Off Position of Key Switch r BS i 0 28 0 33 mm Section 8 Electrical System and Components Ignition Modules _ Spark Plug Figure 8 4 Capacitive Discharge Fixed Timing Ignition System The timing of the spark is controlled by the location of the flywheel magnet group a
86. CH750 engines use a Keihin BK two barrel carburetor on a matching intake manifold This carburetor with related servicing and adjustments is covered beginning on page 5 11 Troubleshooting Carburetor Related Causes Possible Cause Probable Remedy 1 Engine starts hard runs roughly 1 or stalls 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 3 Engine runs lean indicated by misfiring loss of speed and power governor hunting or excessive throttle opening 4 Fuel leaks from carburetor Aa b e d 5 4 Low idle fuel mixture some models speed improperly adjusted Adjust the low idle speed tab then adjust the low idle fuel needle Clogged air cleaner Clean or replace Choke partially closed during operation Check the choke lever linkage to ensure choke is operating properly Low idle fuel mixture is improperly adjusted Adjust low idle fuel needle some models Float level is set too high Separate carburetor air horn from carburetor body adjust float to specification Dirt under the fuel inlet needle Remove needle clean needle and seat and blow with compressed air Bowl vent or air bleeds plugged Remove low idle fuel adjusting needle Clean vent ports and air bleeds Blow out all passages with compressed air Leaky cracked or damaged float Submerge floa
87. Clean the areas around the choke shaft and the selt relieving choke mechanism thoroughly Remove and discard the plastic cap from the end of the choke lever shaft assembly Note the position of the spring legs and the choke plate for correct reassembly later See Figure 5 32 Remove the two screws attaching the choke plate to the choke shaft Pull the shaft out of the carburetor body and discard the removed parts Figure 5 32 Choke Details 5 18 Usea screw extractor easy out and remove the original choke shaft bushing with the old choke lever from the carburetor housing Save the bushing to use as a driver for installing the new bushing Discard the old lever Clean the I D of both choke shaft bores as required Insert the new bushing through the new choke lever from the outside and start the bushing in the outer shaft bore Position the choke lever so the protruding boss on the carburetor housing is between the two stops formed in the choke lever See Figure 5 33 Figure 5 33 Assembling Choke Lever 8 Turn the old bushing upside down and use it as a driver to carefully press or tap the new bushing into the carburetor body until it bottoms Check that the choke lever pivots freely without restriction or binding See Figure 5 34 Figure 5 34 Installing Bushing 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
88. Credit List price of replacement engine or parts Freight emergency stock code 4 or 5 only Posted Full Shop Labor Rate U S dollars Miscellaneous Costs Diagnostic Incidentals Kohler parts only C Freight Cost U S A amp Canada FOB and Truck Freight costs for warranty work will be reimbursed where a short block miniblock or service engine is required Submit a warranty claim form and a copy of the freight bill No transportation costs for individual parts will be reimbursed unless required by individual USA State regulations When shipped by a distributor and a freight bill is not available list in box 13 the FOB charges you received from your distributor and have the Central Distributor representative initial the charge Section 8 Engine Inspection Data Record A Engine Inspection Data Record Instructions Engine Inspection Data Record TP 2435 must be completed for the following situations policy adjustments disputed warranty or when a short block miniblock or engine is required Section 1 of the Engine Inspection Data Record should be filled in immediately when you receive an engine that has had a major failure within the warranty period If possible review it while the customer is still present as you will probably need their input to answer some of the questions Section 1 should be completed and for your distributor representative when they arrive to make their analysis Section 2
89. Do not interchange parts from one cylinder head to the other Remove Grass Screen and Fan 1 Small metal retainers are typically attached on three of the seven mounting posts for positive retention of the plastic grass screen Use a hook end tool next to the post and pull outward to separate each of the small metal retainers Then unsnap the fan from the remaining mounting posts See Figure 9 60 Figure 9 57 Removing Valves with Valve Spring Compressor Keepers Retainer Figure 9 58 Valve Train Components 9 15 Section 9 Disassembly Figure 9 60 Removing Plastic Type Grass Screen 2 Remove the four hex flange screws and fan See Figure 9 61 Figure 9 61 Removing Fan Remove Flywheel 1 Use a flywheel strap wrench or holding tool see Section 2 to hold the flywheel and loosen the hex flange screw securing the flywheel to the crankshaft See Figure 9 62 NOTE Always use a flywheel strap wrench or holding tool to hold the flywheel when loosening or tightening the flywheel screw Do not use any type of bar or wedge to hold the flywheel Use of such tools could cause the flywheel to become cracked or damaged 9 16 il 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 Figure 9 63 NOTE Always use a flywheel puller to remove the flywheel from the cranksha
90. Engine Speed Sensor Explanation tooth signal from speed sensor MIL light will not go out when cranking Expected Engine Response None engine will not start or run as ECU is unable to estimate speed Possible Causes 1 Engine Speed Sensor Related a Sensor connector or wiring b Sensor loose or air gap incorrect 2 Speed Sensor Wheel Related a Damaged teeth b Gap section not registering 3 Engine Wiring Harness Related a Pin circuit wiring or connectors Pin s 3 and or 21 for 35 Pin MA 1 7 Metal Cased ECU Pin s 9 and or 10 for 24 Pin 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 Section 5B EFI Fuel System Code 31 Source Fuel Mixture or Oxygen Sensor Explanation System too lean Oxygen sensor not sending expected voltage to ECU Expected Engine Response System operates under open loop control only Until fault is detected and registered by ECU engine will run rich if oxygen sensor is shorted to ground or lean if it is shorted to battery voltage After fault is detected performance can vary depending on cause If performance is pretty good the problem is probably with the oxygen sensor wiring or connectors If the engine is still running rich laboring short on power or lean popping or misfiring the fuel mixtureis suspect probably incorrect TPS initialization
91. Engine accessories such as fuel tanks clutches transmissions power drive assemblies and batteries unless supplied or installed by Kohler Co These are subject to the warranties if any of their manufacturers KOHLER CO AND OR THE SELLER SHALL NOT BE LIABLE FOR SPECIAL INDIRECT INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY KIND including but not limited to labor costs or transportation charges in connection with the repair or replacement of defective parts IMPLIED OR STATUTORY WARRANTIES INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY LIMITED TO THE DURATION OF THIS WRITTEN WARRANTY We make no other express warranty nor is any one authorized to make any on our behalf Some states do not allow limitations on how long an implied warranty lasts or the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state TO OBTAIN WARRANTY SERVICE Purchaser must bring the engine to an authorized Kohler service facility To locate the nearest facility visit our website www kohlerengines com and click on SALES AND SERVICE to use the locator function consult your Yellow Pages or telephone 1 800 544 2444 ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 KOHLER COURAGE SV470 610 SV710 740 ENGINE LIMITED WARRANTY Kohler Co
92. Expert Dealer f Specialized Dealer l Other Current Dealer Warranty Code 3 Company C LLC C Corporation Partnership Sole Proprietor Other Is your source of supply changing Yes BUSINESS ADDRESS Country United States Address Ei otate Aipf Postal Code Phone F ax Business EMail Year Established Website Address 0 Loo Type af Internet Connection Internet High Speed Dial Up Please sign me up to receive notification of new or Updated service information bulletins alerts new application Information and product specials by email Kohler will nat sell ar distribute contact information under any circumstances A Service Information Record must be on file at Kohler Failure to supply or provide a correct Fed 1 0 or Social Co before a service account will be authorized to do Security number will result in a 2096 net withholding warranty repairs payable to the IRS Important Section 6109 of the IRS Code requires The Service Information Record is an electronic form that recipients of payments to give their identifying number to is available in our electronic parts lookup system Kohler payers PLUS You must login to Kohler PLUS with your user name and password to see the SIR form B Warranty Repair Authorization Only registered Kohler Service Accounts are authorized to perform Kohler engine warranty repairs A Service Information Record form must
93. Newton meter N m Pound force foot Ibf ft x 1 356 Newton meter N m Volume Capacity Cubic inch in x 16 387 Milliliter mL Cubic centimeter cm Fluid ounce fl oz x 29 574 Milliliter mL Cubic centimeter cm Pint pt x 0 473 Liter L Quart qt x 0 946 Liter L Gallon gal x 3 785 Liter L Cubic foot ft x 0 0283 Cubic meter Cubic foot ft x 28 317 Liter L Volume Flow Cubic foot minute ft min x 28 317 Liter minute L min Cubic foot minute ft min x 0 0283 Cubic meter minute m min Miscellaneous Diameter of Circle Circumference x 0 31831 Circumference of Circle Diameter x 3 1416 27 FOR SALES AND SERVICE INFORMATION IN U S AND CANADA CALL 1 800 544 2444 www kohlerengines com KOHLER FORM NO TP 2132 D engines MAILED ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 LITHO IN U S A KOHLER HgINS ENGINE ELECTRICAL SYSTEMS IGNITION THEORY AND FUNCTION Power in an internal combustion engine 15 developed by the expanding gases which result from the burning of an air fuel mixture in the combustion chamber With a quality of fuel that meets the engine requirements the proper air fuel mixture and correct timing of the spark to ignite the mixture that burning process should occur evenly and steadily to give normal continuous power or combustion It is the function of an engine ignition system to deliver enough voltage to
94. Other gasoline alcohol blends including E20 and E85 are not to be used and not approved Any failures resulting from use of these fuels will not be warranted Gasoline Ether blends Methyl Tertiary Butyl Ether MTBE and unleaded gasoline blends up to a maximum of 1576 MTBE by volume are approved as a fuel for Kohler engines Other gasoline ether blends are not approved Section 1 Safety and General Information Periodic Maintenance Instructions WARNING Accidental Starts Disabling engine Accidental starting can cause severe injury or death Before working on the engine or equipment disable the engine as follows 1 Disconnect the spark plug lead s 2 Disconnect negative battery cable from battery Maintenance Schedule Normal maintenance replacement or repair of emission control devices and systems may be performed by any repair establishment or individual however warranty repairs must be performed by a Kohler authorized service center Fill fuel tank Section 5 Daily or Before Check oil level Section 6 Starting Engine Check air cleaner for dirty loose or damaged parts Section 4 Check air intake and cooling areas clean as necessary Section 4 Replace air cleaner element Section 4 Change oil More frequently under severe conditions Section 6 Remove cooling shrouds and clean cooling areas Section 4 Check oil cooler fins clean as necessary if equipped Section 6 Every 100 Hours Check spark plu
95. Prefill a new oil filter following the instructions in Section 6 2 Apply a thin film of clean engine oil to the rubber gasket on the oil filter and thread the filter onto the adapter nipple See Figure 11 101 Figure 11 101 Installing New Oil Filter 3 Install the new oil filter to the filter adapter or oil cooler Refer to instructions on the oil filter for proper installation 11 30 Figure 11 102 Install Oil Filter 4 Install the oil drain plugs See Figure 11 103 Torque the plugs to 13 6 N m 10 ft Ib NOTE Make sure that both oil drain plugs are installed and torqued to the above specifications to prevent oil leakage Figure 11 103 Reinstall and Torque Both Oil Drain Plugs 5 Add oil to bring the level up to F mark and reinstall the dipstick See Figure 11 104 Section 11 Reassembly Prepare the Engine for Operation The engine is now completely reassembled Before starting or operating the engine be sure to do the following 1 Make sure all hardware is tightened securely 2 Make sure the oil drain plugs oil sentry pressure switch and a new oil filter are installed 3 Fill the crankcase with the correct amount weight and type of oil Refer to oil recommendations and procedures in the Safety and General Information and Lubrication Figure 11 104 Reinstall the Dipstick in Tube System sections 6 Make sure the O Ring is in place then reinstall the 4 Adjust t
96. Replacement Valve Cover Gasket and or Breather Camshaft R amp R Camshaft PTO Seal Timing Belt R amp R Rocker Arm Ignition Ignition Module R amp R Includes Both Modules Flywheel R amp R Charging Regulator Test amp Replace Stator Test amp Replace Includes Flywheel R amp R Starter Retractable R R Replace Rope amp Spring Starting Motor Bendix R amp R Starter Bendix Rebuild Includes R amp R Starter Drive R amp R Starter Solenoid R amp R Carburetor amp Air Intake Carburetor R amp R Carburetor Rebuild Includes R amp R Carburetor Adjust Air Cleaner Damage in Shipment Fuel Tank R amp R Fuel Pump R amp R Miscellaneous Repairs Shrouds only R amp R Oil Pan Closure Plate and or Gasket Replace Muffler Replace Governor Adjustment Governor R amp R Oil Pump R amp R Crankshaft Grinding ENTER NET COST Crankcase Boring ENTER NET COST Governor Seal Replacement ACrankcase cannot be rebored Magnum Flat Rate Schedule e Major Repairs Engine R amp R Generator Set R amp R Motor Home Engine R amp R From Generator Set Short Block Replacement Miniblock Replacement Major Overhaul Includes Valve Service Minor Overhaul Excludes Valve Service Connecting Rod Piston and or Rings Crankshaft Crankshaft amp Main Bearing R R Crankshaft PTO Seal Crankshaft Flywheel
97. Research rating method it should be 90 octane minimum Unleaded is recommended since it leaves less com bustion chamber deposits Regular grade leaded gasoline may also be used however be aware that the combustion chamber and cylinder head will require more frequent service When gasoline is stored for any extended period of time certain portions of it tend to oxidize and thereby form a heavy gummy substance This gum can plug up the tiny holes in carburetors and thereby cause unsatisfactory engine performance The best way to avoid this condition is to avoid lengthy storage of the gasoline Alcohol on the other hand is a single chemical compound with a single boiling and ignition point for a given pressure When alcohol is used as a fuel it has a tendency to burn too rapidly and uncon trollably Gaseous fuels Engines can be made to run on gaseous fuels such as propane butane natural or manufactured gas The energy potential of these fuels is as follows Propane Butane 2600 3000 BTU cu ft Natural Gas 1000 BTU cu ft Manufactured Gas 400 600 BTU cu ft Natural gas being roughly 1 3 the BTU value of propane must be supplied in three times the volume required for propane for a given engine power output Manufactured gas is always quite low on BTU value and is sometimes modified en riched with natural gas It is important to know which gas is to be used when furnishing carbure tion equipme
98. Rotate the crankshaft until the piston of cylinder being tested is at top dead center of the compression stroke Hold the engine in this position while testing The holding tool supplied with the tester can be used if the PTO end of the crankshaft is accessible Lock the holding tool onto the crankshaft Install a 3 8 breaker bar into the hole slot of the holding tool so it is perpendicular to both the holding tool and crankshaft PTO 3 4 1 Disassemble breather clean parts thoroughly check sealing surfaces for flatness reassemble and recheck pressure Replace all worn or damaged seals and gaskets Make sure all fasteners are tightened securely Use appropriate torque values and sequences when necessary Recondition piston rings cylinder bore valves and valve guides Repair replace restricted muffler exhaust system If the flywheel end is more accessible use a breaker bar and socket 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 clamping or wedging a driven component Just be certain that the engine cannot rotate off of TDC in either direction 4 Install the adapter into the spark plug hole but do not attach it to the tester at this time 5 Connect an air source of at least 50 psi to the tester 6 Turn the regulator knob in the increase clockwise di
99. Secondary Valve Seat 17 Vacuum Lock Off 13 Secondary Chamber Diaphragm 14 Secondary Diaphragm 18 Idle Adjust Screw 15 Secondary Diaphragm Spring 19 Balance Spring Figure 5A 22 Secondary Chamber 5A 11 Section LPG Fuel Systems Preventative Maintenance The regulator is preset at the factory and generally requires no further adjustment No periodic service is required Over time depending on fuel quality operating environment and system performance fuel deposits can accumulate inside the regulator Those regulators containing a drain plug Nikki should be drained every 500 hours to remove any accumulated deposits See Figure 5A 23 Regulator Drain Plug Figure 5A 23 Regulator Drain Plug Some Models 1 Turn supply valve off run engine out of fuel and turn off ignition switch 2 Disconnect and ground the spark plug leads 3 Remove the 1 8 pipe plug from bottom of regulator and drain 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 Kohler Part No X 75 23 S 5A 12 Regulator Service Every 1500 hours it is recommended that disassembly cleaning and resetting of the regulator be performed using the regulator rebuilding kit available Specific instructions are included in the rebuilding kit Perform the regulator service following the i
100. Slow Jets and O Ring Detail 9 Make sure the O Ring near the bottom of each slow jet is new or in good condition Align and insert the two slow jets into the top of carburetor See Figure 5 25 5 Remove the idle speed RPM adjustment screw and spring from the carburetor Discard the parts NOTE The carburetor is now disassembled for 10 appropriate cleaning and installation of the parts in the overhaul Kit Further disassembly is not necessary The throttle shaft assembly fuel inlet seat idle fuel adjustment screws 11 with limiter and carburetor body are non serviceable items and should not be removed The choke shaft assembly is serviceable however it should not be removed unless a Choke Repair Kit will be installed Install the large flat retaining washer and secure with the mounting screw attaching the ground lead if originally secured by the screw Install the new idle speed RPM adjustment screw and spring onto the carburetor Thread in until 3 or 4 threads are exposed as an initial adjustment See Figure 5 27 5 16 Figure 5 27 Installing Idle Speed Adjusting Screw and Spring 12 Attach the inlet needle to the plastic tang of the float with the wire clip The formed 90 lip should point up with the needle valve hanging down See Figure 5 28 Figure 5 28 Float and Inlet Needle Details 13 Install the float and inlet needle down into the seat and carburetor body Install the new pivot pin throug
101. The Command OHC Triad and Kohler Aegis twins and the Courage Series and CV CH16 single cylinder engines are equipped with capacitive discharge CD ignition systems The solid state system used on the other Command engines is the inductive type On inductive types timing is controlled by the module position so the firing point remains constant See Figure 3 7 The capacitive discharge systems can have either fixed or variable ignition timing depending on engine model and customer requirements See Figure 3 8 15 Section 3 Properly Installing the Engine Ignition Module Kill Switch or Off Position of Keyswitch Ignition Module Figure 3 7 Fixed Timing Type Electronic Ignition System Schematic Operation The CD ignition system functions much the same as the inductive systems with one exception In an inductive system the voltage generated is fed directly from primary to secondary to the spark plug The voltage cannot be held or stored and the spark timing doesn t vary In a CD system the primary voltage is used to charge a capacitor where it is stored until it receives a Signal to release the charge to the secondary and the spark plug Although not done the charge could theoretically be held up to a full revolution The spark timing can also be varied through control of Eyelet Terminal for Ignition 9 Key Switch or Starter Post Diodes Ignition Module Red B and Carburetor Solenoid Input Oil Pressur
102. The most common problems related to valves are burning sticking and valve erosion To help distinguish good from bad we have included some examples of both Figure 24 Figure 24 This intake valve was removed from an engine in good operating condition Notice the bright uniform sealing ring around the face The coke deposits on the underside of the head and upper stem are normal for an engine with some running time on it Figure 25 Figure 25 This engine was also in satisfactory running condition However you will notice that the coking is significantly worse Possible contributing factors are prolonged periods of idling continuous duty at light load lugging the engine during operation running with a restricted air cleaner or valve stem and guide wear The deposits are not yet interfering with normal operation but they could if allowed to accumulate much more Figure 26 Figure 26 This is an exhaust valve from an engine in good operating condition Again note a good sealing ring on the face Relatively light brownish deposits indicate good operating conditions An engine running under proper conditions will usually have light brown brown or gray deposits Figure 27 Figure 27 The white deposits seen here indicate very high combustion temperatures usually due to a lean fuel mixture The engine had only run for a short time so the faces have not yet started to burn but y
103. a lean starting condition If required testing of the fuel pump and relay may be conducted 58 19 Section 5B EFI Fuel System 1 Connect the black hose of Pressure Tester part of EFI Service Kit see Section 2 to the test valve in the fuel rail Route the clear hose into a portable gasoline container or the equipment fuel tank 2 Turn on the key switch to activate the pump and check the system pressure on the gauge If system pressure of 39 psi 3 is observed the relay fuel pump and regulator are working properly Turn the key switch off and depress the valve button on the tester to relieve the system pressure a Ifthe pressure is too high and the regulator is outside the tank just down line from the pump check that the return line from the regulator to the tank is not kinked or blocked If the return line is good replace the regulator see Regulator Service on page 5B 21 b If the pressure is too low install in line between the pump and regulator and retest the pressure at that point If it is too low there also replace the fuel pump 3 If the pump did not activate step 2 disconnect the plug from the fuel pump Connect a DC voltmeter across the terminals in the plug turn on the key switch and observe if a minimum of 7 volts is present If voltage is between 7 and 14 turn key switch off and connect an ohmmeter between the terminals on the pump to check for continuity a If there was no c
104. acceptable limits Expected Engine Response MIL illuminated Engine will continue to run but not properly Upon restart TPS Auto Learn function will run again unless voltage to ECU disconnected to clear memory Possible Causes 1 TPS Related a TPS rotated on throttle shaft assembly beyond allowable range b TPS bad 2 Engine Wiring Harness Related a Broken or shorted wire in harness ECU pin 18 to TPS pin 1 ECU pin 4 to TPS pin 2 ECU pin 8 to TPS pin 3 3 Throttle Body Related a Throttle shaft inside TPS worn broken or damaged b Throttle plate loose or misaligned c Throttle plate bent or damaged allowing extra airflow past or restricting movement 4 ECU Related a Circuit providing voltage or ground to TPS damaged b TPS signal input circuit damaged 58 41 Section 5B EFI Fuel System 5 Oxygen Sensor Harness Related a Oxygen sensor bad b Wiring problem to oxygen sensor c Muffler leak causing O sensor to falsely indicate a lean condition d Bad ground between ECU and engine Code 51 32 Pin MSE 1 1 Plastic Cased ECU only Source Injector 1 circuit open shorted to ground or shorted to battery Explanation Injector 1 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 Possible Causes 1 Injector Related a Injector coil shorted or o
105. allowed is for each cylinder ECU Engine Control Unit TPS Throttle Position Sensor Additional 0 5 for 2nd cylinder Plated cylinders cannot be rebored Additional 0 5 for EFI engines TCH CV750 is 1 0 hr 22 Command Twin amp Command PRO Twin Maximum Time Hr Flat Rate Schedule CH18 23 CV17 23 CH CV730 740 CH CV25 26 Description CH CV750 CH CV745 940 980 CV940 980 Miscellaneous Repairs Cylinder Head and or Gasket Replace each Shrouds only R amp R Oil Pan Closure Plate and or Gasket Replace Muffler Replace Governor Adjustment Governor R amp R Oil Pump R amp R Crankshaft Grinding ENTER NET COST Crankcase Boring ENTER NET COST Governor Seal Replacement Oil Sentry Oil Temp Oxygen Sensor Adjust Belt Tension Flywheel Cover Breather Cover R amp R Lifter Feed Chamber Cover 4 R Oil Cooler R amp R Oil Filter Housing R amp R Oil Filter Adapter R amp R Backing Plate Shroud Assembly Valley Baffle R amp R Control Bracket R amp R Oil Reservoir Gasket R amp R O l Time allowed is each cylinder ECU Engine Control Unit TPS Throttle Position Sensor Additional 0 5 for 2nd cylinder Plated cylinders cannot be rebored Additional 0 5 for EFI engines Courage Twin Courage PRO Twin Maximum Time Hr amp Aegis Flat Rate Sched
106. and not approved Any failures resulting from use of these fuels will not be warranted 5 1 Section 5 Fuel System and Governor Gasoline Ether blends Methyl Tertiary Butyl Ether MTBE and unleaded gasoline blends up to a maximum of 15 by volume are approved as a fuel for Kohler engines Other gasoline ether blends are not approved Fuel Filter Most engines are equipped with an in line fuel filter Periodically inspect the filter and replace with a genuine Kohler filter every 200 operating hours Fuel Line These engines use low permeation rated fuel lines certified to comply with California and U S EPA evaporative emission requirements Fuel lines that do not meet these requirements may not be used Order replacement hose through a Kohler Service Center Fuel System Tests When the engine starts hard or turns over but will not start it is possible that the problem is in the fuel system To find out if the fuel system is causing the problem perform the following tests Troubleshooting Fuel System Related Causes Test Conclusion 1 Check the following Make sure the fuel tank contains clean fresh proper fuel Make sure the vent in fuel tank is open Make sure the fuel valve is open Make sure vacuum and fuel lines to fuel pump are secured and in good condition Check for fuel in the combustion chamber If there is fuel at the tip of the spark plug fuel is a Disconnect and ground spark plug leads r
107. and the other end is connected to the primary windings at the negative terminal In the twin cylinder coils both ends of the secondary are connected to a high tension lead and there is no link between primary and secondary The secondary functions as an independent loop circuit to fire both spark plugs simultaneously Battery Ignition Coils The condensers used for battery ignition systems have the same function as those used with the magneto system However the capacitance will normally be higher because of higher primary voltage Kohler battery ignition condensers can be distinguished by their pigtail lead wire as opposed to the end terminal found on the magneto condensers The lead wire must always be attached to the negative terminal of the coil Candaan IGNITION TIMING Exact timing of the ignition spark is essential to efficient operation of an engine The spark must occur at exactly the right moment in respect to the position of the piston in the cylinder When the spark plug ignites the fuel charge in the combustion chamber the flame pattern moves outward from the spark plug electrode into the combustion chamber A constant amount of time is always needed for complete combustion and during this interval of time the pressures of the burning gases start low build up to a maximum value at about midpoint in the burning process and then taper off again TERMINAL NUTI CIMENT INSULATOR NATOR uu LELEC
108. are clean and dry as well as making sure there is no warpage It is also good practice to check the recommended replacement data when it comes to the retaining fasteners 24 Figure 90 Figure 90 Here is a close up of the piston and wrist pin area Notice the blackened and burnt deposits in the wrist pin area as well as the rest of the piston skirt This can be caused by multiple factors Some which would be poor oil quality infrequent oil changes and or overheating ao N SS NY e WW Figure 91 Figure 91 This is a typical starter motor winding burned up due to overheating Again your job as a technician is to determine what can cause this to occur Was it due to overcranking and not allowing it to cool down Was it do to parasitic loads Improper voltage etc Figure 92 Figure 92 On the crankshafts look for signs of dirt wear lack of lubrication and or side loading Note condition of all bearing surfaces In this case notice the PTO bearing shows signs of severe scoring This could indicate a lubrication or excessive side load problem It could also be caused by a faulty electric clutch Figure 93 25 You Call the Failure The following four 4 pictures are parts that have failed Take a look at the pictures and try to decide what could have caused each failure Figure 96 Figure 94 Figure 97 Figure 95 26 D Summary Failure analysis is an imp
109. are good Replace rectifier regulator if lamp indication is the same in both directions 3 Charging system output less 20 amps Faulty regulator winding on stator replace stator Charge rate is 4 amps or less Stator is good Replace rectifier regulator Charging system continues to charge at high rate Regulator winding shorted replace stator 35 36 D C AMPS OUTPUT 15 AMP ALTERNATOR MAXIMUM OUTPUT D C AMPS OUTPUT 25 AMP ALTERNATOR MAXIMUM OUTPUT eee eee m tet ty 0 ELI ELI E IEEE Ree nine eS EBEN 37 38 D C AMPS OUTPUT 30 AMP ALTERNATOR MAXIMUM OUTPUT ENGINE DIVISION KOHLER KOHLER WISCONSIN 53044 LITHO IN U S A WARRANTY POLICY AND PROCEDURE ENGINES Contents Section 1 Introduction The Warranty Decision mU ot 3 Pre Sale Disclosure Requirement ER t t gt 3 Warranty Responsibility Begins Before Delivery ior aerae etapa rea io 3 Section 2 Limited Warranty Statements A Kohler Aegis Warranty _ __ _ __ _ __ _____ 4 B Courage SV470 610 SV710 740 Warranty 4
110. 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 Section 3 Troubleshooting To test the crankcase vacuum with the manometer i Insert the stopper hose into the oil fill hole Leave the other tube of manometer open to atmosphere Make sure the shut off clamp is closed Start the engine and run at no load high speed 3200 to 3750 RPM Open the clamp and note the water level in the tube The level in the engine side should be a minimum of 10 2 cm 4 in above the level in the open side If the level in the engine side is less than specified low no vacuum or the level in the engine side is lower than the level in the open side pressure check for the conditions in the table on page 3 4 Close the shut off clamp before stopping the engine To test the crankcase vacuum with the Vacuum Pressure Gauge Kit see Section 2 1 2 Remove the dipstick or oil fill plug cap Install the adapter into the oil fill dipstick tube opening upside down over the end of a small diameter dipstick tube or directly into engine a tube is not used Push the barbed fitting on the gauge solidly in the hole in the adapter Start the engine and bring it up to operating speed 3200 3600 RPM if to Check the reading on the gauge If the reading is to the
111. at to move out of or back into the rotor in precise linear varying loads It consists of a governor control unit increments When power is removed the actuator digital linear actuator and linkage shaft remains in position The DLA must initialize fully extend to move the throttle plate to the closed position and partially open for starting Correct adjustment of the DLA is critical to achieve the full range of throttle plate movement See Adjustment Procedure Governor Control Unit GCU senses engine speed by pulse voltage inputs from the ignition modules The GCU regulates the engine speed by variable input voltage from a customer supplied potentiometer or a single pole single throw SPST switch Potentiometer Specifications Wiper Voltage Engine Speed RPM low speed endpoint Figure 5 41 Electronic Governor Assembly variable speed endpoint 1 Digital Linear Actuator 2 Throttle Linkage 3 Linkage Spring SPST Switch Specifications 4 Choke Linkage 5 Throttle Lever Adapter Switch Position Engine Speed RPM Open low speed endpoint Closed high speed endpoint NOTE The actual speeds depend on the application Refer to the equipment manufacturer s recommendations GCU Safety Features In the event of an engine overspeed condition the GCU will shut down the engine by grounding the ignition modules The GCU will shut down the engine by grounding the ignition when power to the GCU i
112. been contamination between the piston and cylinder wall causing excessive wear The erosion at the very top edge of the piston is also due to the wear As the rings wear oil consumption increases resulting in more combustion deposits and a carbon ridge forms at the top of the cylinder 11 In the area near the exhaust valve the carbon becomes very hard and abrasive from the exhaust temperatures When the piston repeatedly hits those hard deposits the material is gradually eaten away The newer Mahle pistons used in most Kohler engines today have the top land machined to a smaller diameter to allow more clearance and help prevent this type of damage Figure 39 Figure 39 Damage from contamination entering an engine can occur over an extended period of time with very slight leakage or it can be quite rapid if a significant amount of dirt is entering This damage occurred in just 15 hours of running from ingesting about 1 4 teaspoon of dust per hour If a customer punctured their air cleaner element by using compressed air or assembled the air cleaner incorrectly that the element was not sealing then ran the engine for a week or two before discovering the error the engine could already be worn beyond acceptable limits Figure 40 Figure 40 If the engine is running hot blocked screen or fins and ingesting dirt at the same time the wear will occur even more rapidly This Command engine was completely worn
113. both carburetors function similarly Low power each is unique and should not be interchanged 1 Air cleaner or exhaust system dirty restricted 2 Low fuel 3 Rich gas condition flooding through regulator a Dirty restricted valves in regulator b Damaged primary diaphragm in regulator 4 No fuel a Electric lock off not opening filter blocked or restriction within fuel line b Leaking loose or cracked vacuum line from carburetor to regulator Load Block Assembly c Leaking or loose intake system components d Regulator primary valve not opening e Secondary or vacuum lock off diaphragm Idle Speed within regulator leaking Adjusting Screw f Low pressure rubber hose kinked g Frozen regulator 5 Improper ignition timing 6 Loose incorrect throttle lever clamp bracket positioning 7 Loose or incorrectly positioned high speed Rear Plug throttle plate stop with Sealing Washer Afer Engine runs lean 1 Electrical problem causing intermittent lock off operation or lock off is faulty 2 Filter in lock off dirty or restricted 3 Restriction in fuel system 4 Idle holes plugged dirt in fuel delivery channels 5 Carburetor fuel circuit restriction di 6 Loose leaking fuel enrichment hose Impco Plastic Bushing Adjusting Screw carburetor system Figure 3 Nikki Carburetor High fuel consumption Impco carburetors also incorporate the use of an 1 Fuelleak Check lines
114. brush assemblies Do not lose the springs 8 42 Section 8 Electrical System and Components Figure 8 74 Installing Brush Holder Assembly Figure 8 76 Torquing Brush Holder Screws using Tool with Extension 13 Hook the plunger behind the upper end of 11 Install the end cap onto the armature and frame the drive lever and install the spring into the aligning the thin raised rib in the end cap with solenoid Insert the three mounting screws the corresponding slot in the grommet of the through the holes in the drive end cap Use these positive brush lead to hold the solenoid gasket in position then mount the solenoid Torque the screws to 12 Install the two thru bolts and the two brush 4 0 6 0 N m 35 53 in Ib holder mounting screws Torque the thru bolts to 5 6 9 0 N m 49 79 in Ib Torque the brush 14 Connect the positive brush lead bracket holder mounting screws to 2 5 3 3 N m 22 29 in to the solenoid and secure with the hex nut Ib See Figures 8 75 and 8 76 Torque the nut to 8 11 N m 71 97 in Ib Do not overtighten See Figure 8 77 Figure 8 75 Torquing Thru Bolts Figure 8 77 Positive Brush Lead Connection 8 43 Section 8 Electrical System and Components Solenoid Test Procedure Solenoid Shift Style Starters Disconnect all leads from the solenoid including the positive brush lead attached to the lower stud terminal Remove the mounting hardware and separate the solenoid from
115. coil as follows A Connect small red tester lead to positive terminal or primary lead wire of coil B Connect small black tester lead to negative terminal or coil ground wire C Connect large red tester lead to spark plug lead terminal D If testing coil with components mounted on engine place a piece of cardboard between the points E For twin cylinder coils connect a jumper lead between the negative terminal and the second spark plug lead terminal 2 Make sure current control knob is turned to the extreme left 3 Turn selector switch to position No 1 Coil Power Test 4 Slowly turn current control knob clockwise and watch the current value on Scale No 1 5 If a steady spark is observed at the spark gap with a current value of 1 5 or less the coil is good NOTE Coil 277375 used on K482 K532 and K582 engines has relatively high resistance Coil power test should be made on tester which uses 115 volts power source Merc O tronic Testers Model 98 9800 with 7 1 2 volt battery power source often give erroneous results 6 If spark is faint intermittent or current value exceeds 1 5 coil should be replaced 7 Return current control knob to extreme left and turn selector knob to OFF NOTE Magneto coils must be mounted on stator laminations for Coil Power Test and Surface Insulation Test Coil Power Test 1 Surface Insulation Test 1 Leave coil connected as for Coil P
116. connection so replacement is necessary each time Oetiker Clamp Pliers part of EFI Service Kit see Section 2 is used to crimp the replacement clamps A CAUTION Fuel lines between the fuel pump and fuel rail must be made from SAE 30 R9 fuel line Standard fuel line SAE 30 R7 may only be used between the fuel tank and pump 5 16 ID and for the return line from the pressure regulator to the tank 1 4 ID All high pressure fuel line connections must be secured with Oetiker Clamps Kohler Part No 24 237 05 S installed crimped with the corresponding pliers Throttle Body Intake Manifold Assembly Idle Speed Adjusting Screw Comer Figure 5B 35 Upper Intake Manifold General The EFI engines have no carburetor so the throttle function regulate incoming combustion airflow is incorporated in the intake manifold assembly The manifold consists of a one piece aluminum casting which also provides mounting for the fuel injectors throttle position sensor fuel rail air baffle idle speed screw and air cleaner assembly Service The throttle body intake manifold is serviced as an assembly with the throttle shaft throttle plates and idle speed adjusting screw installed The throttle shaft rotates on needle bearings non serviceable capped with rubber seals to prevent air leaks Idle Speed Adjustment RPM General The idle speed is the only adjustment that may be performed on the EFI system The stan
117. current to prevent arcing as the contacts are separating Dielectric To Primary To Ground Typical Condenser The capacity of the condenser to absorb and store electrons capacitance must be matched to the output of the coil A condenser with too much capacitance will cause a weaker spark while one with insufficient capacitance will obviously not prevent the arc Metal transfer on the breaker points wil be an indicator of incorrect capacitance The problems which can result from incorrect capacitance make it very important that you always use the condenser which is specified for any given engine Build Up on Ve Contact Build Up on Stationary Contact Could Indicate Excess Capacitance Could Indicate Insufficient Capacitance Effect of Condenser Condition On Breaker Points The last remaining component in our ignition system is the spark plug Without it the rest of our ignition system would be useless A typical spark plug consists of a metal shell a ceramic insulator a center electrode connected to the end terminal and a side electrode connected to the shell The electrodes are separated by an air gap of 025 Producing an electric arc across the air gap is the end purpose of the entire ignition system Ground Electrode Terminal Center Electrode Typical Spark Plug The center electrode through the end terminal is connected to the secondary windings in the coil by a high te
118. disassembled or repaired previously D Cooling System Figure 12 Figure 12 5 the grass screen plugged or restricted possibly contributing to overheating Figure 13 Figure 13 What about the cooling fins The engine needs adequate air flow across the cooling fins to dissipate heat E Carburetor and Intake Figure 14 Figure 14 Carefully examine the carburetor and the intake manifold Is anything broken or loose Is there dirt or debris in the manifold intake area Are the mounting gaskets in the right location and are they the right ones F Governor Components Figure 15 Figure 15 Check the external governor components and linkages Are any of the pieces bent broken or missing Have any non factory modifications been made Figure 16 Figure 16 Operate the throttle control and check whether the mechanism can move freely through its normal range Check the initial governor adjustment setting Also note the position of the governor spring Has it been moved G Final Check Finally in addition to the air cleaner system which has already been checked look for any other possible point s where dirt or contamination may have entered the engine The conditions found during your preliminary examination should be noted for future reference The Engine Inspection Data Record TP 2435 is available from Kohler Co to record your findings see sample at back of book If a majo
119. down Very little vacuum is needed to start this vacuum diaphragm travel 0 2 in Mercury to start and 0 5 in Mercury for full travel The instant the engine stops rotating loss of vacuum in section D releases diaphragm 10 causing bumper K to push against secondary lever 16 overcoming action of whisker wire and ensuring 100 lock off This patented Beam design will lock off primary pressures up to five times in excess of normal and permits starting without priming or choking 5A 10 Sor nm T E Se NNNNY CON NA 2 Ns P N PEZ i 1 8 27 NPT Plug Primary Diaphragm Assembly Primary Spring Expansion Plug Secondary Diaphragm Spring Primary Lever Assembly Fillister Head Screw Primary Pivot Pin Torx Head Screw Vac Lock Diaphragm Assembly Vac Lock Spring Figure 5A 20 Sd WW B A 4 y VS _ _ um d p NO N So RL 4 NS ens E E 15 18 22 D 43 12 2 2777777 SE d yf 927 Secondary Diaphragm Pan Head Screw Secondary Lever Spring Secondary Pivot Pin Secondary Lever Assembly Adjustment Screw Pan Head Screw Expansion Plug Diaphragm Gasket Split Lock Washer Section 5A LPG Fuel Systems Nikki Regulato
120. due to incorrect TPS initialization Shut off the engine perform TPS initialization and then repeat the test If TPS initialization cannot be achieved perform step c c Replace the oxygen sensor page 5B 13 Run the engine long enough to bring the new sensor up to temperature and repeat the output test from step 1 The cycling voltage from 0 2 to 1 0 volt should be indicated 2 Move the black voltmeter lead to the engine ground location and repeat the output test The same voltage 0 2 v 1 0 v should be indicated a If the same voltage reading exists go on to otep 3 b If the voltage output is no longer correct a bad ground path exists between the sensor and the engine ground Touch the black lead at various points backtracking from the engine ground back toward the sensor watching for a 58 12 voltage reading reappears at some point check for a problem rust corrosion loose joint or connection between that point and the previous checkpoint For example if the reading is too low at points on the crankcase but correct voltage is indicated when the black lead is touched to the skin of the muffler the flange joints at the exhaust ports become suspect With sensor still hot minimum of 400 C 752 F switch meter to the Rx1K or Rx2K scale and check the resistance between the sensor lead and sensor case It should be less than 2 0 KQ a If the resistance is less than 2 0 KQ go to Step 4 b If the resis
121. each new COURAGE PRO engine sold by Kohler Co will be free from manufacturing defects in materials or workmanship in normal residential homeowner service for a period of two 2 years from date of purchase provided it is operated and maintained in accordance with Kohler 5 instructions and manuals If used commercially the COURAGE PRO engine is covered by one 1 year limited warranty The warranty period begins on the date of purchase by the original retail consumer or commercial end user Residential homeowner service means residential use by a retail consumer Commercial use means all other uses including use for commercial or rental purposes Once in commercial use the engine will thereafter be considered a commercial use engine for the purposes of this warranty Our obligation under this warranty is expressly limited at our option to the replacement or repair at Kohler Co Kohler Wisconsin 53044 or at a service facility designated by us of such parts as inspection shall disclose to have been defective EXCLUSIONS Mufflers on engines used commercially non residential are warranted for 90 days from date of purchase This warranty does not apply to defects caused by casualty or unreasonable use including faulty repairs by others and failure to provide reasonable and necessary maintenance The following items are not covered by this warranty Engine accessories such as fuel tanks clutches transmissions powe
122. engine while operating or just after stopping Hot Parts Engine components can get extremely hot from operation To prevent severe burns do not touch these areas while the engine is running or immediately after it is turned off Never operate the engine with heat shields or guards removed 1 1 Section 1 Safety and General Information WARNING Explosive Fuel can cause fires and severe burns Do not fill the fuel tank while the engine is hot or running Explosive Fuel 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 Do not fill the fuel tank while the engine 18 hot or running since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition Do not start the engine near spilled fuel Never use gasoline as a cleaning agent WARNING Cleaning Solvents can cause severe injury or death Use only in well ventilated areas away from ignition sources Flammable Solvents Carburetor cleaners and solvents are extremely flammable Keep sparks flames and other sources of ignition away from the area Follow the cleaner manufacturer s warnings and instructions on its proper and safe use Never use gasoline as a cleaning agent 1 2 WARNING Carbon Monoxide can cause severe nausea fainting or death Avoid inhaling exhau
123. for each cylinder ECU Engine Control Unit TPS Throttle Position Sensor Additional 0 5 for 2nd cylinder Plated cylinders cannot be rebored Additional 0 5 for EFI engines 24 Courage Twin Courage PRO Twin amp Aegis Flat Rate Schedule Courage Courage Twin PRO Twin Miscellaneous Repairs Cylinder Head and or Gasket Replace each Shrouds only R amp R Oil Pan Closure Plate and or Gasket Replace Muffler Replace Governor Adjustment Governor R amp R Oil Pump R amp R Crankshaft Grinding ENTER NET COST Crankcase Boring ENTER NET COST Governor Seal Replacement Oil Sentry Oil Temp Oxygen Sensor Adjust Belt Tension Flywheel Cover Breather Cover R amp R Time allowed is for each cylinder ECU Engine Control Unit TPS Throttle Position Sensor Additional 0 5 for 2nd cylinder Plated cylinders cannot be rebored Additional 0 5 for engines 25 OHC Flat Rate Schedule TH16 Major Repairs Engine R amp R Short Block Replacement Miniblock Crankcase Major Overhaul Includes Valve Service Minor Overhaul Excludes Valve Service Connecting Rod Piston and or Rings Crankshaft Crankshaft amp Main Bearing R amp R Crankshaft PTO Seal Crankshaft Flywheel Seal Crankshaft amp Connecting Rod Camshaft amp Valves Valve R amp R No Grinding Valve Tappet Adjustment Valve Grinding Valve Spring
124. fuel and spark position sensor TPS is very critical to proper system requirements for the immediate operating conditions operation If the TPS or ECU is changed or the The ECU then sends output signals to set the injector mounting position of the TPS is altered the applicable duration and ignition timing TPS Initialization Procedure see pages 5B 8 or 5B 9 must be performed to restore the synchronization 58 5 Section 5B EFI Fuel System Engine Speed Sensor Figure 58 4 Engine Speed Sensor General The engine speed sensor is essential to engine operation constantly monitoring the rotational speed RPM of the crankshaft A ferromagnetic 60 tooth ring gear with two consecutive teeth missing is mounted on the flywheel The inductive speed sensor is mounted 1 5 0 25 mm 0 059 0 010 in away from the ring gear During rotation an AC voltage pulse is created within the sensor for each passing tooth The ECU calculates engine speed from the time interval between the consecutive pulses The two tooth gap creates an interrupted input signal corresponding to specific crankshaft position 84 BTDC for cylinder 1 This signal serves as a reference for the control of ignition timing by the ECU Synchronization of the inductive speed pickup and crankshaft position takes place during the first two revolutions each time the engine is started The sensor must be properly connected at all times If the sensor becomes d
125. gg s Crankcase breather is clogged or inoperative Breather reed broken Loose or improperly torqued fasteners Piston blowby or leaky valves Restricted exhaust External Engine Inspection Before cleaning or disassembling the engine make a thorough inspection of its external appearance and condition This inspection can give clues to what might be found inside the engine and the cause when it is disassembled Check for buildup of dirt and debris on the crankcase cooling fins grass screen and other external surfaces Dirt or debris on these areas are causes of higher operating temperatures and overheating Check for obvious fuel and oil leaks and damaged components Excessive oil leakage can indicate a clogged or improperly assembled breather worn damaged seals and gaskets or loose or improperly torqued fasteners Check the air cleaner cover and base for damage or indications of improper fit and seal Check the air cleaner element Look for holes tears cracked or damaged sealing surfaces or other damage that could allow unfiltered air into the engine Also note if the element is dirty or clogged These could indicate that the engine has been under serviced Check the carburetor throat for dirt Dirt in the throat is further indication that the air cleaner is not functioning properly Check the oil level Note if the oil level is within the operating range on the dipstick or if it is low or overfilled e Ch
126. grounded Poor or improper grounds in system battery ECU oxygen sensor shielding fuel pump ignition output Pin circuits 9 and or 10 routed near noisy electrical signals coils spark plug lead plug connector 3 Engine Wiring Harness Related 32 Pin MSE 1 1 Plastic Cased ECU a b 58 38 Pin circuits 9 and or 10 wiring connectors Shielding for pin circuits 9 and or 10 damaged or not properly grounded Poor or improper grounds in system battery ECU oxygen sensor shielding fuel pump ignition output Pin circuits 9 and or 10 routed near noisy electrical signals coils spark plug lead plug connector 4 ECU Harness Related a ECU to harness connection problem 5 Ignition System Related a Non resistor spark plug s used Code 22 Source Throttle Position Sensor TPS Explanation Unrecognizable signal is being sent from sensor too high too low inconsistent Expected Engine Response limp home operating mode occurs with an overall decrease in operating performance and efficiency Fuel delivery is based upon the oxygen sensor and five mapped values only Rich running black smoke will occur until closed loop operation is initiated A stumble or misfire on hard acceleration and or erratic operation may be exhibited Possible Causes 1 TPS Sensor Related a b C Sensor connector or wiring Sensor output affected or disrupted by dirt gre
127. idle port passages At low idle when the vacuum signal is weak the air fuel mixture is controlled by the setting of the idle fuel adjusting screws This mixture is then mixed with the main body of air and delivered to the engine As the throttle plate opening increases greater amounts of air fuel mixture are drawn in through the fixed and metered idle progression holes As the throttle plate opens further the vacuum signal becomes great enough so the main circuit begins to work Section 5 Fuel System and Governor Main High Speed Circuit At high speeds loads the engine operates on the main circuit As a metered amount of air is drawn through the four air jets fuel is drawn through the main jets The air and fuel are mixed in the main nozzles and then enter the main body of airflow where further mixing of the fuel and air occurs This mixture is then delivered to the combustion chamber The carburetor has a fixed main circuit no adjustment is possible Carburetor Adjustments Adjustment NOTE Carburetor adjustments should be made only after the engine has warmed up The carburetor is designed to deliver the correct fuel to air mixture to the engine under all operating conditions The main fuel jet is calibrated at the factory and is not adjustable The idle fuel adjusting needle is also set at the factory and normally does not need adjustment Depending on model and application engines may also be equipped with a Gov
128. is part of the valve cover assembly See Figure 9 20 1 Disconnect the fuel lines at the pump outlet and 22 at the in line fuel filter Figure 9 17 Disconnecting Pulse Line from Valve Cover Early Models 2 The fuel pump will be removed with the valve cover Refer to the valve cover removal 2 Disconnect the pulse vacuum line from the procedure crankcase or from the valve cover on earlier models See Figures 9 16 and 9 17 9 5 Section 9 Disassembly Figure 9 20 Mechanical Fuel Pump Figure 9 22 Rear Air Cleaner Bracket Some Models Remove Control Panel If So Equipped 1 Disconnect the Oil Sentry Indicator Light 2 Mark the spring hole locations and disconnect wires the spring from the governor lever See Figure 9 23 2 Disconnect the choke control cable from the control bracket 3 Disconnect the throttle control cable or shaft 4 Remove the panel from the blower housing Remove Throttle amp Choke Controls 1 Remove the four hex flange screws securing the control bracket and rear air cleaner bracket some models to the cylinder heads See Figures 9 21 and 9 22 E lt V Figure 9 23 Disconnecting Spring from Bracket 3 Remove the choke linkage from the choke actuator lever and carburetor See Figure 9 24 Actuator Lever 9 6 Section 9 Disassembly Remove External Governor Controls 2 One Barrel Carburetor Models Only Remove 1 Lo
129. longer being circulated to the bearing surface The high friction temperatures generated during seizure cause the oil to burn around the journal area and down to the break line A definite color variation will be obvious at the break line 17 Figure 63 Figure 63 The break surface of a fatigue break will be smoother than a tensile break Often the fatigue process leaves semi circular markings called beach marks on the break surface The center of the markings is the point at which the break originated Here the dipper was bumped or damaged from the side Figure 64 Figure 64 Examination of this break surface confirms that it is a fatigue break and also reveals the cause of the break a casting defect Figure 65 18 Figure 65 The second area of examination is the bearing surface of the rod The bearing surface will often be smeared but it can still reveal clues about the conditions at the time of failure These two rod caps are a good example Notice the difference in color The cap on the right has streaks of burned oil blended with the smeared aluminum indicating that there was some oil present but not enough for adequate lubrication It s from an engine that was run low on oil The cap on the left has only the bright smeared aluminum no traces of oil It was from an engine started without oil Figure 66 Figure 66 What led up to this failure If you guessed it was another engine star
130. made of 1 Install anew carburetor gasket Make sure all n metal or plastic See Figure 11 75 If a holes align and are open new fuel pump is being installed make sure the orientation of the new pump 2 Install the carburetor throttle linkage and is consistent with the removed pump governor lever as an assembly See Figure 11 Internal damage may occur if installed 76 If a plastic intake manifold is used and the incorrectly carburetor is equipped with a fuel solenoid attach the ground lead to the carburetor 2 Install the fuel pump using the two hex flange mounting screw See Figure 11 77 screws Torque the screws to 2 3 20 in Ib 11 21 Section 11 Reassembly Figure 11 77 Ground Lead on Carburetor Mounting Screw One Barrel Carburetor 3 Torque the two carburetor mounting screws to 6 2 7 3 N m 55 65 in 1 Two Barrel Carburetor Models 1 Use anew carburetor gasket Make sure all holes align and are open 2 Apply Loctite 242 to the shorter inner set of threads of any removed studs 3 Assemble carburetor gasket 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 11 22 A B w Figure 11 78 Installing Studs and Carburetor Two Barrel Carburetor 4 Connect the ground lead and fuel solenoid lead as equipped See Figure 11 79 Figure 11 79
131. many other features to fit the job Example 2 As another example let s figure a constant duty fan application The fan manufacturer s specs call for an 8 HP load demand at 3600 RPM This unit will be operated at an altitude of 3000 feet above sea level and the maximum operating temperature of 115 F Drive will be V belt The factors will be 1 Duty Constant speed and load 80 available 2 Altitude 3 5 loss for every 1000 feet above 10 5 loss 89 5 available Section 1 Selecting the Right Engine 3 Temperature 1 loss for every 10 F above 77 4 96 available 4 Transmission V belt at midpoint range 97 available The calculation for this application is as follows 8 HP Estimated Load __8_ _ 80x89 5x 96x 97 _ 6667 required A good choice for this second example would be a Kohler Command CH13 for a little extra reserve power Example 3 What about a lower speed application that calls for a load of 8 HP at 2800 RPM The duty cycle Will be intermittent 8596 temperature below 77 F no factor the altitude about 500 feet above sea level 3 5 per 1000 feet divided by 2 1 75 loss or 98 25 factor and the load will be belt driven 9796 factor off a horizontal shaft Using these factors let s calculate what the actual power requirement will be using the HP formula 8 HP Estimated Load _ 8 85x1x 9825x 97 840 988 HP actual Checking the power curves we find that a CH11 w
132. mercury 1 133 feet head of water 0 4912 pounds per sq in 8 34 pounds at 60 F 231 cubic inches 2 31 feet head of water 2 03 inches of mercury Imperial gallon 1 2 U S gallons Welder HP amps x volts 746 x Efficiency 70 factor if unknown Generators Kilowatts x 1 34 Efficiency 70 factor if unknown NOTE 2 per kW required at 70 efficiency Compressor air piston type e Allow 0 25 brake HP for each cubic foot of free air drawing against a working pressure of 75 to 100 psi BHP 0 25 x cubic foot minute e When compressor and engine are direct connected and operated at same speed the cubic inch displacement of compressor multiplied by 1 3 will give the displacement of the engine required Belt Drives The following is provided as a guide to selecting the best belt cross section and pulleys to use after the basic belt drive configurations has been determined Contact belt manufacturers for assistance in finalizing the drive and selecting the best belt construction to use for your particular application Factors such as shock loading alignment heat dirt engagement and disengagement must be considered To use the chart the speed of the faster shaft and peak design horsepower must be known If the intersecting points for your application fall above and or to the left of the cross sectional line the section letter indicated should provide good service life If however it falls
133. not a digital SAM DSAM Part No 24 584 18 and higher Follow sub step a for testing an ASAM with this tester Digital SAM DSAM modules require Tester 25 761 40 5 for proper testing a Depress the tester button and hold it down After approximately four seconds a numerical sequence should be displayed beginning with 1 or 2 and continuing to 8 or 9 followed by a letter P pass or F fail See Figures 8 11 and 8 12 DO NOT release the tester button until the test cycle completes and the display goes off If you get a sign instead of the numerical sequence and or an F at the end of the cycle the SAM is probably bad Recheck all of the connections check the condition of the tester battery and repeat the test If you get the sign and or F again in the retest replace that SAM IMPORTANT Allow 15 20 seconds for the tester to clear and reset itself between tests or if test is interrupted before completion of test cycle Otherwise a false reading may be displayed in the form of a or a faint 8 3 Disconnect the yellow and brown tester leads from the long module leads Connect the brown tester lead to the short brown module lead Connect the yellow tester lead to the short yellow or pink module lead See Figure 8 13 Leave the red and green leads connected Repeat step 2 Figure 8 13 Ihe tester is powered by a 9 volt battery Most SAMs are designed to operate down to a minimum of 7 2
134. of the starter in reverse order from disassembly 9 When the stop collars are removed the retainer 8 can be removed from the armature shaft Do not Delco Remy Starters reuse the retainer Brush Replacement The brushes in the starter are part of the starter frame Brush kit Kohler Part No 52 221 01 S contains four replacement brushes and springs If replacement is necessary all four brushes should be replaced 1 Remove the brushes from the brush holder and remove the brush holder from the frame 2 Cut the brush lead wire at the edge of the post with a pair of nippers 3 File off any burrs on the post Figure 8 48 Completed Delco Remy Starter 4 The replacement brushes have a solid portion on Starter Disassembly Oe 1 Remove the hex nut and disconnect the positive brush lead ket f the solenoid terminal 5 Solder the crimped portion to the post 2 Remove the three screws securing the solenoid to 6 Replace the brush holder in the frame and place the starter See Figure 8 49 the brushes in the brush holder Reinstall the springs 8 35 Section 8 Electrical System and Components Phillips Head Screws Figure 8 49 Removing Solenoid Screws 3 If the solenoid was mounted with Phillips head screws separate the solenoid and plunger spring from the drive end cap If the solenoid was mounted with external Torx head screws the plunger is part of the so
135. of two revolutions to check longblock assembly and overall proper operation Install Spark Plugs 1 Use new Champion or equivalent spark plugs 2 Setthe gap at 0 76 mm 0 030 in Install new plugs and torque to 24 4 29 8 18 22 ft Ib See Figure 11 48 Figure 11 48 Installing Spark Plugs 11 14 Figure 11 49 Installing Ignition Module 2 Onengines equipped with 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 module always away from the cylinder On 1 cylinder the single kill tab should be towards you See Figure 11 54 On 2 cylinder the single kill tab should be away from you in Install each ignition module to the crankcase bosses with the two screws hex flange or allen head based on model Slide the modules up as far away from the flywheel as possible and snug the screws to hold them in that position Rotate the flywheel to position the magnet directly under one ignition module Insert a 0 30 mm 0 012 in flat feeler gauge between the magnet and the ignition module See Figure 11 50 Loosen the screws enough to allow the magnet to pull the module down against the feeler gauge Figure 11 50 Setting Ignition Module Air Gap 6 i Torque the screws to 4 0 6 2 35 55 in Ib Repeat step
136. on the stud terminal of the new positive brushes Install the stud terminal into the commutator end cap Secure the stud with the fiber washer and hex flange screw Install the brush holder new negative brushes and self tapping screws Install the brush springs and brushes into the pockets in brush holder Make sure the chamfered sides of the brushes are away from the brush springs Section 8 Electrical System and Components NOTE Use a brush holder tool to keep the brushes 2 Insert the armature into the starter frame Make in the pockets A brush holder tool can easily sure the magnets are closer to the drive shaft end be made from thin sheet metal See Figure of armature The magnets will hold the armature 8 44 inside the frame Self Tapping Brush Springs 3 Install the drive end cap over the drive shaft Screw Brush Make sure the match marks on the end cap and Holder starter frame are aligned See Figure 8 45 Negative Negative Brush Stud Terminal with Positive Brushes Screw Figure 8 43 Style A Commutator End Cap with Brushes Brush Holder Tool Installed Figure 8 45 Starter Assembly Match Marks For Style Commutator End Caps 4 Install the brush holder tool to keep the brushes in the pockets of the commutator end cap 5 Align the match marks on the commutator end cap and the starter frame Hold the drive end and the commutator end caps firmly to the st
137. or No 23 drill and carefully clean resize the hole to restore proper operation Blow out the hole with air and lightly lubricate with oil on reassembly Carburetor Keihin BK Two Barrel Carburetor CH750 The carburetor used on CH750 engines is a Keihin two barrel side draft design with fixed main jets See Figure 5 11 A self relieving choke similar to that used on single venturi carburetors is also contained in the design The circuits within the carburetor function as described following Float Circuit The fuel level in the bowl is maintained by the float and fuel inlet needle The buoyant force of the float stops fuel flow when the engine is at rest When fuel is being consumed the float will drop and fuel pressure will push the inlet needle away from the seat allowing more fuel to enter the bowl When demand ceases the buoyant force of the float will again overcome the fuel pressure rising to the predetermined setting and stop the flow Slow amp Mid Range Circuit At low speeds the engine operates only on the slow circuit As a metered amount 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 the transfer port From the transfer port the air fuel mixture is delivered to the idle progression chamber From the idle progression chamber the air fuel mixture is metered through the
138. or low fuel pressure Possible Causes 1 TPS Initialization Incorrect a Lean condition check oxygen sensor signal with VOA and see Oxygen Sensor section 2 Engine Wiring Harness Related a Pin circuit wiring or connectors 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 Low Fuel Pressure 4 Oxygen Sensor Related a Sensor connector or wiring problem b Exhaust leak c Poor ground path to engine sensor is case grounded 5 Poor system ground from ECU to engine causing rich running while indicating lean 58 39 Section 5B EFI Fuel System Code 32 Source Oxygen Sensor Explanation change in the sensor output signal Expected Engine Response Open loop operation only may cause a drop in system performance and fuel efficiency Possible Causes 1 Engine Wiring Harness Related a Pin circuit wiring or connectors 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 2 Oxygen Sensor Related a Sensor connector or wiring problem b Sensor contaminated or damaged c Sensor below the minimum operating temperature 375 C 709 F d Poor ground path from sensor to engine sensor grounds through shell see Oxygen Sensor section Code 33 Source Oxygen Sensor Fuel System Exp
139. performed by the flywheel Flywheels ordinarily are designed somewhat on the light side to reduce engine weight and also depend on the equipment being driven by the engine for part of the flywheel action Even at best there is always some slowing down of the engine between power strokes This slowing down and subsequent speeding up during the power stroke is termed cyclic irregularity This becomes an important consideration on those applications where the functions of couplings drive pulleys or clutches is effected Such components must be adequate to take this speed variation ENGINE VIBRATION amp BALANCE In a single cylinder engine the reciprocating action of the piston and connecting rod causes a shaking action which must be controlled as much as possi ble by balancing By adding acounter weight on the crankshft opposite the crank throw the reciproca ting unbalance can be counteracted If a 100 counteraction is provided in the direction of the unbalance force then the counterweight sets up an equal unbalance in a plane perpendicular to the axis of the cylinder Kohler single cylinder engines are dynamically balanced The balance of multi cylinder engines is more complex but the same basic principles apply COOLING Cooling of valves is a critical part of engine perfor mance The intake valve ordinarily does not achieve excessively high temperatures It is cooled by the incoming air and fuel mixture The exhaust
140. position has already been checked or properly set Figure 5A 12 Adjusting Setting Stop Collar 2 Rotate and hold the throttle shaft so the throttle plate is fully open perfectly vertical See Figure 5A 11 4 Tighten the screw securely NOTE After the idle speed clamp bracket and the high speed stop collar positions have been set check that the throttle shaft pivots freely 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 positioned as shown in Figure 5A 13 on the idle speed clamp bracket side of the throttle shaft High Speed Stop Collar Figure 5A 11 Full Throttle Position Throttle Linkage Clamp Bracket Figure 5A 13 Throttle Linkage Clamp Bracket Position 5A 7 Section LPG Fuel Systems 2s Figu Manually move the governor lever with the throttle linkage connected toward the carburetor as far as it will go Hold it in this position Looking down the throat of the carburetor check that the throttle plate is in the full throttle position and that the head of the high speed collar stop screw 15 in contact with the carburetor boss If not loosen the carburetor mounting screws and reposition the carburetor slightly Torque the carburetor mounting screws to 9 9 N m 88 in Ib NOTE If additional adjustment is required loosen t
141. recheck the high speed no load RPM setting Observe the overall performance TPS Initialization Procedure For 32 Pin MSE 1 1 Plastic Cased ECU Only Auto Learn Initialization 1 Check that the basic engine all sensors fuel fuel pressure and battery are good and functionally within specifications Important 2 Remove disconnect ALL external loads from the engine belts pumps electric PTO clutch Bae PD e alternator rectifier regulator etc 3 Locate the service connector plug in the wiring harness To initiate the TPS auto learn function connect a jumper wire from the TPS initialization pin 24 violet wire to the battery voltage pin red wire or use the jumper plug with the blue jumper wire If using the PC based diagnostic tool and software see Section 2 go to Special Tests and follow the prompts to complete 8 Hold throttle against idle speed stop screw turn the ignition switch to on position do not start engine and observe the Malfunction Indicator Light MIL a The light should blink on off quickly for approximately 3 seconds and then go off and stay off indicating the initialization procedure has been successful 4 Start the engine and immediately observe the Malfunction Indicator Light MIL The light should start blinking 4 consecutive times every 2 seconds 58 9 Section 5B EFI Fuel System Remove the jumper wire or plug from the service conn
142. recommended that a relay be used to control the power To prevent signal errors load circuits i e horn lights shall not be powered from engine or chassis wire harness resistive spark plug with either a resistive spark plug wire or boot must be used to prevent electrical system noise It is recommended that the ECU housing is mounted with the wire harness down to facilitate proper drainage away from the electrical connector When not in operation the battery must maintain a minimum system voltage of 7V with a current draw of 2 mA to maintain the adaptive memory During starting the system voltage must be 7V minimum for the ECU operation during cranking Unless otherwise specified all wires are 18AWG Speed sensor wires pins 9 and 10 are to be a twisted pair with 1 twist inch minimum Malfunction indicator lamp MIL can be a 12V 0 25A incandescent lamp Optionally a 20 mA LED can be used This requires a resistor of approximately 600 ohms wired in parallel Normal operating voltage is to 16V dc 9Vdc with a cold cranking voltage of 7V The throttle position sensor TPS connection shown is for CCW rotation of the TPS from idle to wide open throttle as viewed from the throttle shaft side of the TPS CW rotation requires switching the wires to TPS pins 1 and 3 Section 5B EFI Fuel System Fuel System A WARNING Fuel System Under Pressure The fuel system operates under high pressure System pressure must be relie
143. service e Can the oil be checked filled and drained easily Are carburetor and governor adjustments accessible e the air and oil filter elements be changed without difficulty e Can the spark plug s be changed easily e Is the cooling air intake screen easily accessible for cleaning e Can the starter be serviced or replaced without removing the engine If you follow this checklist your equipment will be easy to service and your customer will benefit from less downtime and lower labor charges Oil Level Dipstick Air Cleaner Cover Carburetor under cover Governor Oil Fill Cap on either side 2 Valve Cover 2 Exhaust Port opark Plug 22 Side Oil Filter Rectifier Regulator Oil Drain starter side Oil Drain oil filter side etarting Motor and Solenoid Spark Plug 1 Side 1 Valve Cover Coolant Bottle Radiator Radiator Drain Plug eos Ordo qe Exhaust System The exhaust system must channel hot exhaust gases out of and away from the engine The exhaust must be directed away from the source of cooling air where it cannot be recirculated and add to the temperature of incoming air The pipes and muffler must be located where they will not restrict airflow Back Pressure The exhaust system produces an ever present resistance to the flow of exhaust gases called back pressure If this pressure exceeds 40 inches less for CS engines of water as read ona water manometer a si
144. show up in testing or in the field By preventing problems at the design stage you save time money future service problems and frustration Design Check Points Keep cooling air to the fan no greater than 20 F 11 C above ambient temperature and no more than 130 F 54 C Make sure all service points are easily accessible The muffler used should not create more back pressure than the maximum amounts shown in the table on page 22 Keep fuel lines as straight as possible with no kinks or loops Whenever possible avoid parasitic loads Prepare Account Information Records forms for review by Kohler Co Air cleaner systems are governed by EPA regulation non standard air cleaners are not recommended If a non standard system is used including any changes or modifications to a Kohler supplied system laboratory confirmation of EPA compliance will be required 23 Section 5 Technical Guidelines Technical Guidelines This section contains some additional information which may be useful in calculating engine requirements for some specific applications and or for basic engine educational purposes Horsepower Definition One horsepower is the timed rate of force required to lift weight of 33 000 pounds one vertical foot in one minute The formula is 1 HP 33 000 ft Ib per minute or 550 ft Ib per second Power Conversion Table 1 Horsepower hour 2544 BTU 1 Horsepower hour 0
145. some time and you re liable to find indications that dust or dirt has bypassed the system as you continue your analysis 476 6 Bee 5 K VN y LE v K 44 9 Figure 4 Figure 4 Carefully remove the precleaner Check it for tears or deterioration Does it look like it s been serviced regularly at the recommended 25 hour interval Figure 5 Figure 5 Remove the element cover if separate otherwise remove the whole element If there was no rubber sleeve on the outer portion of the stud you should find one on the inner portion Check its condition and look for an imprint or mark on the underside of the element cover to indicate that it was making contact and sealing Figure 6 Figure 6 Is the air cleaner element dirty plugged or damaged Is it a genuine factory part Figure 7 Figure 7 Take a close look element sealing surfaces Are there any dirt tracks across the sealing surface indicating leakage Have the reinforcing wires punctured the rubber seal If so it indicates that the cover was overtightened Protruding wires could allow leakage This air cleaner element is obviously damaged Note the crushed wire mesh This is an example of an element that can not properly seal out dirt and debris The lesson here is to check the sealing area of the paper element and the wire mesh for signs of damage due to over tightening dam
146. style dead center location reference information ignition modules control the ignition timing based on is provided by the flywheel magnet group as it engine RPM A typical DSAI application Figure 8 17 passes the ignition module System triggering and consists of the following components engine timing is performed by a digitally controlled microprocessor This digital control provides e Amagnet assembly which is permanently affixed repeatable and consistent engine cylinder spark to the flywheel timing Each DSAI module performs its function independently for each engine cylinder e Two inductive 12 volt ignition modules which mount on the engine crankcase Figure 8 17 e A 12 volt battery which supplies current to the ignition modules e switch or key switch which grounds the spark advance module to stop the engine e Two spark plugs Key Switch or Off Position of Key Switch on 12 Volt Battery Spark an Plug Ignition keg Paes Modules Figure 8 17 Digital Spark Advance Ignition DSAI System 8 15 Section 8 Electrical System and Components Troubleshooting DSAI Ignition Systems The DSAI ignition system is designed to be trouble free for the life of the engine Other than periodically checking replacing the spark plugs no maintenance timing or module adjustments are necessary or possible Mechanical systems do occasionally fail or break down however
147. the charging system or with the battery NOTE Always zero ohmmeter on each scale before testing to ensure accurate readings Voltage tests should be made with the engine running at 3600 RPM no load The battery must be good and fully charged 1 If voltage is 13 8 14 7 and charge rate increases when load is applied the charging system is OK and battery was fully charged Trace B lead from rectifier regulator to key switch or other accessible connection Disconnect it from switch or connection Connect an ammeter from loose end of B lead to positive terminal of battery Connect DC voltmeter from loose end of B lead to negative terminal of battery With engine running at 3600 RPM read voltage on voltmeter If voltage is less than 13 8 or charge rate does not increase when load is applied test stator Tests 2 and 3 If voltage is 13 8 volts or more place a minimum load of 5 amps on battery to reduce voltage Observe ammeter NOTE Turn on lights if 60 watts or more Or place a 2 5 ohm 100 watt resistor across battery terminals No Charge Remove connector from rectifier regulator If voltage is 28 volts or more stator is OK to Battery With engine running at 3600 RPM measure Rectifier regulator is faulty Replace the AC voltage across stator leads using an AC rectifier regulator voltmeter If voltage is less than 28 volts stator is probabl faulty and should be replaced Test stator f
148. the choke shaft See Figure 5 35 NOTE Make sure it stays in this location during the following step Figure 5 35 Choke Shaft and Spring Details 10 11 Slide the choke shaft and spring into the carburetor Pivot preload the shaft and set the inner leg of the spring against the formed stop within the choke lever as originally assembled See Figure 5 32 The opposing leg of the spring must still be between the formed stops of the choke shaft Place a drop of Loctite on the threads of each new screw Position and install the new choke plate to the flat side of the choke shaft Start the two screws Close the choke and check the plate alignment within the carburetor throat then tighten the screws securely Do not overtighten See Figure 5 36 Section 5 Fuel System and Governor Figure 5 36 Installing Choke Plate 12 Check for proper operation and free movement of the parts Install the new cap Always use new gaskets when servicing or reinstalling carburetors Repair kits are available which include new gaskets and other components Service repair kits available for Keihin BK two barrel carburetors and affiliated components are Carburetor Overhaul Kit Float Kit Fuel Solenoid Kit Choke Repair Kit Bowl Kit High Altitude Kit 1219 2434 m 4 000 8 000 ft 5 19 Section 5 Fuel System and Governor Figure 5 37 Keihin BK Two Barrel Carburetor Exploded View 5 20
149. the permanent magnet rotates past the iron core the flux lines will travel through the core and the core will temporarily take on magnetic properties The Magneto Cycle Around the iron core we have an ignition coil which contains two sets of windings commonly referred to as primary and secondary wrapped in a circular pattern within the ignition coil These windings are made of copper which is a good conductor of electrical current Whenever magnetic lines of force cut across a conductor an electromotive force EMF is induced within the conductor Primary Winding Secondary Winding Laminated Iron Core Typical High Tension Coil If the conductor is part of a completed or closed circuit this EMF will cause current to flow When the breaker points are closed the primary windings are part of a completed circuit and current will flow in those windings Condenser Breaker Permanent Magnets Typical Flywheel Magneto Ignition System Now another form of inductance called self inductance is utilized to intensify the electrical energy in the primary Whenever current flows in a conductor a magnetic field is created around the conductor If the conductor is wound in a coil the field created around each loop links magnetically with adjacent loops whenever the current changes in value An abrupt halt in the flow of current will cause the field from each winding to collapse across the adja
150. the stones are in contact with the cylinder wall Use of a commercial cutting cooling agent is recommended 2 With the lower edge of each stone positioned even with the lowest edge of the bore start drill and honing process Move the hone up and down while resizing to prevent the formation of cutting ridges Check the size frequently Section 10 Inspection and Reconditioning NOTE Kohler pistons are custom machined to exacting tolerances When oversizing a cylinder it should be machined exactly 0 25 mm 0 010 in or 0 50 mm 0 020 in over the new diameter Section 1 The corresponding oversize Kohler replacement piston will then fit correctly 3 When the bore is within 0 064 mm 0 0025 in of the desired size remove the coarse stones and replace them with burnishing stones Continue with the burnishing stones until the bore is within 0 013 mm 0 0005 in of the desired size and then use finish stones 220 280 grit and polish the bore to its final size A crosshatch should be observed if honing is done correctly The crosshatch should intersect at approximately 23 33 off the horizontal Too flat an angle could cause the rings to skip and wear excessively and too steep an angle will result in high oil consumption See Figure 10 3 N T X uo E Figure 10 3 Cylinder Bore Crosshatch after Honing 4 After resizing check the bore for roundness taper and size Use an inside micrometer
151. vacuum hose to fuel pump 9 Intake system leak o o SMART SPARK malfunction applicable models 10 Diode in wiring harness failed in open circuit mode Engine Starts Hard 1 11 12 13 c Mesue AS PTO drive is engaged Dirt or water in the fuel system Clogged fuel line Loose or faulty wires or connections Faulty or misadjusted choke or throttle controls Faulty spark plugs Low compression Weak spark Fuel pump malfunction causing lack of fuel Engine overheated cooling air circulation restricted Quality of fuel Flywheel key sheared Intake system leak Engine Will Not Crank 1 Se Ste T9 PTO drive is engaged Battery is discharged Safety interlock switch is engaged Loose or faulty wires or connections Faulty key switch or ignition switch Faulty electric starter or solenoid Seized internal engine components Engine Runs But Misses 1 qe en Dirt or water in the fuel system Spark plug lead disconnected Poor quality of fuel Faulty spark plug s Loose wires or connections that intermittently eround the ignition kill circuit Engine overheated Faulty ignition module or incorrect air gap Carburetor adjusted incorrectly SMART SPARK malfunction applicable models 3 1 Section 3 Troubleshooting Engine Will Not Idle 1 ph Ole S DUI Dirt or water in the fuel system Stale fuel and or gum in carbure
152. valve receives the full blast of the exhaust gases Ordinarily at wide open throttle it will be red hot You can see it through the exhaust port To withstand such temperatures the valve head must be of stainless steel or it will corrode very rapidly For extreme conditions the face of the valve must also be coated with Stellite to provide suffi cient hardness and corrosion resistance Valve rota tors aid in providing good valvelife under heavyload conditions The exhaust valve transfers its heat through the stem and into the guide which in turn conducts it to theoutside of the cylinder block Some valve heat is also transferred through the seating face to the valve seat insert and from there to the surrounding portion of the block Providing adequate cooling air or cooling water depending on the type of engine to that portion of a cylinder block is of prime importance The cylinder head contains most of the combustion chamber and becomes hot during the power stroke It must be cooled so that the head itself retains its physical strength and shape and to prevent the hot spots from developing in the combustion chamber caus ing pre ignition The piston is cooled to some extent by oil splashing against the underside of it The piston rings transmit heat from the piston to the cylinder walls The heat picked up by the cylinder walls plus that resulting from direct ex posure to the combustion flame must be disposed of by air for
153. venturi retaining screw Torque the screw to 4 0 N m 36 in Ib 3 Install anew adapter gasket and mount the air cleaner adapter onto the carburetor with the four screws Torque the screws to 4 0 N m 36 in Ib 4 Install anew carburetor gasket onto the intake manifold adapter followed by the carburetor Install and finger tighten the mounting fasteners 5 Connect the Z end of the throttle linkage and the dampening spring to the throttle clamp bracket on the throttle shaft Attach the opposite end of linkage and spring to the governor lever NOTE The clamp brackets and stop collar mounted on the throttle shaft should still be in their original positions See Figure 5A 2 and not require any readjustment resetting Continue with steps 6 and 7 If the mounted position of any one of these was affected or changed it will be necessary to check and reset the position 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 Check that the throttle plate is now fully open or reposition the carburetor slightly on the mounting screws so it is fully open Torque the mounting screws to 9 9 N m 88 in Ib Instructions for Checking Positioning the Clamp Brackets Mounted on the Throttle Shaft Use only if the position or mounting of the clamp bracket s has been disturbed Figures show the
154. 1 1 Plastic Cased ECU only Diagnostic Aid 2 FAULT CODES Refer to detailed Code 55 MIL Light 32 Pin MSE 1 1 fault code listing before flow chart and servicing Plastic Cased ECU only information for the respective components l Code 56 Pump Relay 32 Pin MSE 1 1 Plastic Cased ECU only 1 Code 21 Engine Speed Synchronization 2 MIL circuit grounded between light and ECU 2 Code 22 Throttle Position Sensor TPS 35 Pin MA 1 7 Metal Cased ECU Pin circuit 3 Code 23 Engine Control Unit ECU 31 4 Code 31 Oxygen Sensor 24 Pin MSE 1 0 Plastic Cased ECU Pin 5 Code 32 Oxygen Sensor circuit 19 6 Code 33 Fuel System temporary adaptation 32 Pin MSE 1 1 Plastic Cased ECU Pin factor circuit 29 7 Code 34 Fuel System permanent adaptation 3 ECU factor 8 Code 42 Engine Oil Temperature Sensor NOTE MIL in Metal Cased ECU systems is an LED 9 Code 43 TPS Auto Learn Initialization The MIL in Plastic Cased ECU systems must Function Below Min Limit 32 Pin MSE 1 1 be a 1 4 watt incandescent lamp Plastic Cased ECU only 10 Code 44 TPS Auto Learn Initialization Function Above Max Limit 32 Pin MSE 1 1 Plastic Cased ECU only 5B 45 Section 5B EFI Fuel System Diagnostic Aid 4 SPEED SENSOR MIL does not turn off during cranking Indicates the ECU is not receiving a signal from the speed sensor Possible causes 1 Speed sensor
155. 1 Output Ignition Coil 2 Output TPS Initialization Terminal o0O 00 goo 00 0c Oo 000000000 58 31 Section 5B EFI Fuel System 32 Pin MSE 1 1 Plastic Cased ECU Systems Pin Function Permanent Battery Voltage Switched Battery Voltage TPS Set Auto Learn Initialization Terminal Throttle Position Sensor TPS and Temperature Sensor Ground Not Used Oil Temperature 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 Position Sensor Supply Voltage Battery Ground Oxygen Sensor Input Battery Ground Secondary Not Used Not Used Not Used Safety Switch Input Not Used Not Used Main Relay Output Malfunction Indicator Light MIL Ignition Coil 1 Output Ignition Coil 2 Output Not Used 58 32 N a 0000000000 00000000 0 SEE GENERAL NOTE 9 SAFETY SWITCH J1 25 N O GROUND J1 10 J1 9 SENSOR ENCINE SPEED 5 21 PD bia Pe Rea MX uc mv Cylinder 1 y 8 Grove 5 Qo m 7 J e MEN wie cing Nowe A Al Si gt CIA 5 5 Sj 4 opp S9 712 123 24 Hs 2l us 10 26 1 12 A AMA ACA 12 0 128 dis clu e A S cA Alo
156. 10 13 2 Remove the oil pump assembly from the closure plate 3 Remove the oil pump rotor 4 Remove the oil pickup by unhooking the locking clip and pulling it free from the oil pump body 5 Ifthe 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 procedures If the relief valve is a one piece style staked to the oil pump housing See Figure 10 16 removal should not be attempted nor is internal servicing possible If a problem with the relief valve is encountered the oil pump should be replaced Figure 10 13 Removing Governor Gear 2 Remove the locking tab thrust washer located under the governor gear assembly 3 Carefully inspect the governor gear shaft and replace it only if it is damaged After removing the damaged shaft press or lightly tap the replacement shaft into the closure plate to the depth shown in Figure 10 14 pear Shaft 34 0 mm 1 3386 in 33 5 mm 1 3189 in Figure 10 15 Oil Pump Oil Pickup and Relief Valve Original Style Figure 10 14 Governor Shaft Press Depth 10 12 Section 10 Inspection and Reconditioning 3 Install the rotor 4 Install the oil pump body to the closure plate and secure with the two hex flange screws Torque the hex flange screws as follows a Install fastener into location No 1 and lightly tighten to position pump
157. 2 Speed sensor circuit problem 35 Pin MA 1 7 Metal Cased ECU Pin circuits 3 and 21 24 Pin MSE 1 0 Plastic Cased ECU Pin circuits 9 and 10 32 Pin MSE 1 1 Plastic Cased ECU Pin circuits 9 and 10 3 Speed sensor toothed wheel air gap 4 Toothed wheel 5 Flywheel key sheared 6 ECU Diagnostic Aid 5 FUEL PUMP fuel pump not turning on Possible causes 1 Fuel pump fuse 2 Fuel pump circuit problem 35 Pin MA 1 7 Metal Cased ECU Circuits 43 44 and relay 24 Pin MSE 1 0 Plastic Cased ECU Circuits 30 87 and relay 32 Pin MSE 1 1 Plastic Cased ECU Circuits 30 87 and relay 3 Fuel pump Diagnostic Aid 6 RELAY relay not operating Possible causes 1 Safety switches circuit s problem 35 Pin MA 1 7 Metal Cased ECU Circuits 41 and 41A 24 Pin MSE 1 0 Plastic Cased ECU Circuit 3 32 Pin MSE 1 1 Plastic Cased ECU Circuit 25 2 Relay circuit s problem 35 Pin MA 1 7 Metal Cased ECU Circuits 28 41 and 24 Pin MSE 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 B ECU 5B 46 Diagnostic Aid 7 IGNITION SYSTEM no spark Possible causes 1 Spark plug 2 Plug wire 3 Coil 4 Coil circuit s 35 Pin MA 1 7 Metal Cased ECU Circuits 1 19 40 40A 43 and relay 24 Pin MSE 1
158. 4 Partition Baffle Prevents Recirculation Mounting When mounting an engine into an application consideration must also be given to torque reaction belt or chain side load pull end loading thrust vehicle movement rough terrain and engine vibration forces Vibration frequency increases as engine speed increases This depends on the natural frequency of the system engine and unit Types of Mounting Systems Solid or Flexible with the choice usually based upon the relationship required between engine and machine 1 Solid Mounting is effective simple and inexpensive It might contribute to operator discomfort and to possible failure of mounting points due to higher vibration levels 2 Flexible Mounting or isolator mounts enables the supporting structure to be isolated from engine vibration Although more expensive it is effective and contributes to operator comfort Be aware of clearance problems caused by the mounts and the movement or bounce of the engine 0 Emm d _____ L oa Large Opening Allows Easy Outlet of Heated Air S Figure 3 5 Typical Flexible or Isolator Mounting 13 Section 3 Properly Installing the Engine Resonance At certain engine speeds a condition of secondary vibration or resonance may occur in machines It is caused when the vibration frequencies of the engine and the natural frequencies of the equipment c
159. 5 to pin 86 is open or shorted during engine operation Note after key off then key on code 56 would be set also 4 ECU Related a Circuit controlling injector 2 damaged b Circuit controlling fuel pump relay damaged Code 55 32 Pin MSE 1 1 Plastic Cased ECU only Source MIL Diagnostic lamp circuit open shorted to ground or shorted to battery Explanation MIL is not functioning because the circuit is open shorted to ground or shorted to battery Expected Engine Response Engine will run normally if no other errors are present Possible Causes 1 MIL diagnostic lamp Related a MIL element opened or element shorted to ground b Lamp missing 2 Engine Wiring Harness Related a Broken or shorted wire in harness ECU pin 29 to lamp open or shorted 3 Vehicle Wiring Harness Related a Broken or shorted wire in harness Power lead to MIL open or shorted 4 ECU Related a Circuit controlling lamp damaged Section 5B EFI Fuel System Code 56 32 Pin MSE 1 1 Plastic Troubleshooting Flow Chart Cased ECU only The following flow chart on page 5B 44 provides Source Fuel pump relay circuit open shorted an alternative method of troubleshooting the EFI to ground or shorted to battery system The chart will enable you to review the entire Explanation Fuel pump ignition coils and fuel system in about 10 15 minutes Using the chart the injectors will not function because the accompanying diagnost
160. 5 volts If the tester battery drops below that level incorrect test readings will result The tester battery should be checked periodically by connecting a DC voltmeter between the red and green lead wires with the tester connected to a SAM Press and hold the test button 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 battery must be replaced Use an extended life alkaline battery To replace the battery remove the outer set of screws on the faceplate and carefully lift the panel from the body Unplug the connector and pull battery with mounting tape off the back of the tester Attach the connector to the new battery and mount the battery to the case with double backed tape Reinstall the faceplate and secure with the four screws To Test Using 25 761 40 S Tester DSAM ASAM Test Procedure NOTE The SAM must be at room temperature when tested Disconnect all of the SAM leads isolating it from the main wiring harness and the ignition module s Testing may be performed with the module mounted or loose The figures show the part removed from the engine for clarity See Figure 8 14 Section 8 Electrical System and Components ASAM Module Test Connections DSAM Module Test Connections Figure 8 14 Connected Tester Leads The test procedure for twin cylinder S
161. 8 in or about 9 32 in 7 14 mm To check tension place a straight edge across the span and push the belt down midway between the pulleys and measure the deflection Adjust tension as needed 26 Battery Supplemental Information Battery capacity or output shrinks as the temperature decreases as shown in the chart below At about 80 F a fully charged battery in good condition should be at 100 capacity At 20 F 6 7 C the capacity shrinks to about 30 Unfortunately the cranking requirements steadily increase as temperatures decrease Make sure the cold cranking amperage cca rating of the battery used is at least 250 cca for single cylinder engines or 400 cca for twins at O F 17 8 C c c LL 0 o 10 20 30 40 50 60 70 80 90 100 Percentage of Capacity Battery Capacity Temperature Chart Section 5 Technical Guidelines Gaseous Fuel Installation Supplemental Information Gaseous fuels have less heat energy than gasoline To utilize supply from a local utility it is important to confirm that the supply will be adequate to meet the demand of the engine Consult the gas utility company for a home fuel demand analysis prior to installation A larger gas meter and or separate supply line may be required Fuel supplied to the engine must meet the specifications below for expected performance and durability Failure to do so may result in hard starting low power and or r
162. 9 4 260 33 9 300 Tightening Torque N m ft Ib or 20 40 7 30 47 5 35 67 8 50 54 2 40 81 4 60 47 5 35 74 6 55 108 5 80 61 0 45 101 7 75 142 4 105 67 8 50 108 5 80 155 9 115 94 9 70 101 7 75 135 6 100 149 2 110 189 8 140 199 3 150 271 2 200 142 4 105 169 5 125 223 7 165 244 1 180 311 9 230 332 2 245 440 7 325 Torque Conversions N m in Ib x 0 113 ft Ib x 1 356 in Ib N m x 8 85 ft Ib x 0 737 223 7 165 237 3 175 311 9 230 352 6 260 447 5 330 474 6 350 637 3 470 Section 2 Tools amp 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 SE Tools Design Technology Inc Contact your source 415 Howard St 768 Burr Oak Drive of supply Lapeer MI 48446 Westmont IL 60559 Phone 810 664 2981 Phone 630 920 1300 Toll Free 800 664 2981 Fax 810 664 8181 Tools Balance Gear Timing Tool amp M Series Kohler 25 455 06 5 To hold balance gears in timed position when assembling engine Formerly Y 357 Camshaft Endplay Plate For checki
163. A WARNING Explosive Fuel 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 Do not fill the fuel tank while the engine 18 hot or running since spilled fuel could ignite if it comes contact with hot parts or sparks from ignition Do not start the engine near spilled fuel Never use gasoline as a cleaning agent The EFI fuel system remains under high pressure even when the engine 18 stopped Before attempting to service any part of the fuel system the pressure must be relieved Pressure Tester part of EFI Service Kit see Section 2 has an integral relief valve Connect the black tester hose to the test valve in the fuel rail Route the clear hose into a portable gasoline container Depress the button on the tester relief valve Initial Starting Priming Procedure Important The EFI fuel system must be purged of air primed prior to the initial start up and or any time the system has been disassembled or the fuel tank run dry 1 Locate the electronic control unit ECU for the EFI system Check the part number on the end If the Part No is 24 584 28 or higher the ECU has a built in priming feature a Turn the key switch to the on run position You will hear the fuel pump cycle on and off When the fuel pump stops cycling approximately one minute the system is primed start the engin
164. AMs will vary slightly depending on whether the module is analog ASAM or digital DSAM 1 Check the SAM part number stamped on the end of the housing a If itis an ASAM 24 584 09 or 24 584 10 separate the short yellow and brown leads from the long ones Each set will be tested separately Connect the tester to the SAM as follows Yellow tester lead to long yellow module lead Brown tester lead to long brown module lead Red tester lead to the red module lead Black tester lead to the black or green module lead The remaining tester leads pink and brown with black band are not used for testing ASAMS b Ifitis a DSAM all except 24 584 09 or 24 584 10 connect the tester as follows Yellow tester lead to the long yellow module lead Brown tester lead to the long brown module lead Red tester lead to the red module lead Black tester lead to the green or black module ground lead with the eyelet terminal Pink tester lead to the short yellow or pink module lead 8 13 Section 8 Electrical System and Components e Brown tester lead with black band or terminal to the short brown module lead NOTE Some modules contain two black ground leads with one containing a white stripe Do not connect to the black white lead with the bullet connector or a Fail test result will occur regardless of actual condition Caution Do not allow alligator clip leads to touch e
165. Assembly so they are flush with the LD of the brush holder assembly Insert the Brush Installation a Hold the starter assembly vertically on the Tool with extension or use the tube described end housing and carefully position the above from a prior brush installation through assembled brush holder assembly with the the brush holder assembly so the holes in the supplied protective tube against the end of metal mounting clips are up out the commutator armature The mounting screw holes in the metal clips must be up c Install the brush springs and snap on the four out Slide the brush holder assembly down retainer caps See Figure 8 73 into place around the commutator and install the positive brush lead grommet in the cutout of the frame See Figure 8 71 The protective tube may be saved and used for future servicing Figure 8 73 Brush Installation Tool with Extension d Hold the starter assembly vertically on the end housing and carefully place the tool Figure 8 71 Installing Brush Holder Assembly with with extension and assembled original brush Supplied Tube holder assembly onto the end of the armature shaft Slide the brush holder assembly down Starter reassembly when not replacing the Brushes into place around the commutator install the Brush Holder Assembly positive brush lead grommet in the cutout of the frame See Figure 8 74 a Carefully unhook the retaining caps from over each of the
166. C Posted Full Shop Labor Rate U S dollars Miscellaneous Costs e e Miscellaneous Cost Cylinder honing and crankshaft grinding f K Series and Magnum engines use net price g Profit on parts for K Series and Magnum engines 10 2 U S A amp CANADA EXPERT All Standard Warranty Repairs Total Credit List price of replacement engine or parts Freight Posted Full Shop Labor Rate U S dollars Miscellaneous Costs Diagnostic Incidentals Kohler parts only 3 INTERNATIONAL NON EXPERT Standard Warranty Repair Parts and Labor no engines Total Credit Net price of replacement part Parts Profit b c d Posted Full Shop Labor Rate U S dollars Miscellaneous Costs e Handling Allowance b Short Blocks or Miniblocks 10 c Parts Profit for Authorized Service Outlet 20 d Parts Profit for Specialized Service Outlet 10 e Miscellaneous Cost Cylinder honing and crankshaft grinding Standard Warranty Repair Engine and Labor Total Credit List price of replacement Command Courage Aegis series engine less 10 f Parts Profit g Posted Full Shop Labor Rate U S dollars Miscellaneous Costs e Handling Allowance e Miscellaneous Cost Cylinder honing and crankshaft grinding f K Series and Magnum engines use net price g Profit on parts for K Series and Magnum engines 10 4 INTERNATIONAL EXPERT All Standard Warranty Repair Total
167. C Courage PRO SV810 840 Warranty iunio orans it esa oranes auc esau buen lassen on saepe D Us 5 D COMMAND PRO Command Magnum OHC Warranty Statement 9 E _ ____________ ______ __ __ ___ _ _ _ _ 6 CL ICS een 6 G Kohler Co Federal and California Emission Control Systems Warranty Statement 7 8 Section 3 Warranty Procedures A Service Intormatomn Record 9 Warranty Repair Authorization m 10 Manufacturing Defects ecu m 10 D Major Warranty Repair m 10 E Carburetor Warranty Replacement 10 F Retaining FAC Ae AS IEEE EE m 10 10 11 Disputed Questionable Unusual Warranty or Policy Adjustments 11 I Engines Manufactured Over 3 Years 11 12 Section 4 Warranty Service Parts arcane tenet A 12 B Defective Service Parts New Inventory
168. CU connector and test for continuity between the component connector terminals and the corresponding terminals in the ECU connector using an ohmmeter Little or no resistance should be measured indicating that the wiring of that particular circuit is OK An illustrated listing of numerical terminal locations for each style of ECU connector is provided on pages 5B 28 5B 31 or 5B 32 58 28 for 35 Pin MA 1 7 Metal Cased ECU 5B 31 for 24 Pin MSE 1 0 Plastic Cased ECU 5B 32 for 32 Pin MSE 1 1 Plastic Cased ECU NOTE When performing voltage or continuity tests avoid putting excessive pressure on or against the connector pins Flat pin probes are recommended for testing to avoid spreading or bending the terminals 58 27 Section 5B EFI Fuel System 35 Pin MA 1 7 Metal Cased ECU Systems Pug Component Ignition Coil 1 Not used Engine Speed Sensor ECU Production Test Terminal Not Used Not Used Not Used TPS Initialization Terminal Engine Ground O Sensor Not Used Throttle Position 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 Throttle Position Sensor Not Used Throttle Position Sensor Oil Temperature Sensor Power Relay Not Used Not Used Malfunction Indicator Light Not Used Vehicle Ground Not Used Fuel Injectors CON BD OF WN FR 58 28
169. Connecting Ground Lead Two Barrel Carburetor Install External Governor Controls 1 Install the governor lever onto the governor cross shaft See Figure 11 80 Section 11 Reassembly 2 Make sure the throttle linkage is connected to the governor lever and the throttle lever on the carburetor 3 Move the governor lever toward the carburetor as far as it will go wide open throttle and hold in position See Figure 11 81 Figure 11 83 Connecting Choke Linkage 2 Mount the main control bracket and air cleaner support bracket if used to the cylinder heads using the four hex flange screws Torque the screws to 10 7 N m 95 in Ib into new holes or 7 3 65 in Ib into used holes See Figure 11 84 227 Figure 11 81 Adjusting Governor Lever 4 Insert a nail into the hole on the cross shaft and rotate the shaft counterclockwise as far as it will turn then torque the hex nut to 6 8 N m 60 in Ib See Figure 11 82 7 PF 4 5 wd Figure 11 82 Holding and Tightening Governor Arm 5 Reconnect the lead wire to the fuel shut off solenoid if so equipped Install Throttle amp Choke Controls 1 Connect the choke linkage to the carburetor and choke actuator lever See Figure 11 83 Figure 11 84 Torquing Main Control Bracket 11 23 Section 11 Reassembly 3 Connect the governor spring from the main control bracket to the app
170. E 13 4 kW 18 HP Plo _ 14 9 20 I CH A 16 4 kW 22 HP arbe Wr X X 17 2 kW 23 HP Giu RES MT 18 6 kW 25 HP amp T 19 4 kW 26 HP OTTO E faves 20 1 kW 27 HP CEE 20 9 kW 28 HD CIT O T 22 3 kW 30 HD Peak Torque CRU LE 43 6 N m 32 2 ft Ib CEREO 44 3 N m 32 7 ft Ib CEZ O CO AOR N T 49 1 N m 36 2 ft Ib ACO OOF Cr 54 1 N m 37 9 ft Ib Baa E 54 0 N m 39 5 ft Ib S 55 4 N m 40 9 ft Ib 0 2300RPM T 54 2 N m 40 0 ft Ib Sar EN OG P 57 3 N m 42 3 ft Ib Berc er ZO du ERN c MM 57 9 N m 42 7 ft Ib Giu INA Re Wi E EEE E A E E EE EEE EE E EE 64 4 N m 47 5 ft Ib Bore EIU
171. F CLAIM CHECK ONLY ONE 0 Warranty Repair New Defective Service Parts Policy Adjustment J Questionable Disputed PHONE HH JI 1191554 WARRANTY CODE NO 4 WARRANTY PERFORMED CCD 050 ODEALER Firm Name Address Repair Date Customer Signature E Engine Transmission Short Block Mode No Equipment Manufacturer Type of Equipment Engine Received 3 PARTS HAVE BEEN L Retumed to Factory Retumed to Central Retained amp Tagged OEFECTIVE PART NUMBER 10 0 CI Mounted Detached 5 Shipping Damage SG Scored Galled SS Stuck Seized ST Stripped Unknown Other VC Valve Clearance WN Worn WP Warped AW Assembled Wrong BC Broken Cracked BL Blown BT Bent Twisted CD Porous Casting Deficiency CL Came Loose Off CP Corroded Pitted EF Electric Failure FM Foreign Material IF Improper Flt LK Leaked MI Missing ML Magnet Loose NS Not Seating NY Noisy OA Out of Adjustment Part Made Machined Incorrectly 1 Condition Found Probable Cause of Failure Word Defective Not Sufficient 12 Job Number Work Performed Necessary to Remove amp Replace R amp R Engine from Equipment then Show R amp R Separately BE Miscellaneous Freight Postage Allowance Attach Freight Bill E Labor J MINS TENTHS Repair 1 er Description
172. Kohler Engine representative for a review of the observed temperatures FEG 550 288 500 260 500 260 470 243 325 163 275 135 130 54 95 35 175 79 125 52 A Spark plug B Head bolt C Oil sump D Air into cooling fan E Air into carburetor inlet After the temperatures have become stabilized and are recorded stop the engine Let the machine sit for 10 to 15 minutes and then try to start it again This will give you an indication whether your application is susceptible to vapor lock Starting Tests Cold Starting A Kohler engine in good condition with no parasitic load should start well at 20 F 6 6 C Parasitic load refers to any load that is not disconnected during starting such as a hydraulic pump or hydrostatic transmission To test for cold starting ability in your application the following test equipment must be prepared A 12 volt battery with a minimum current rating of 250 cold cranking amps cca for single cylinder models or 400 cca for twins Voltmeter connected between the positive terminal on the starter and the engine block Ammeter connected to measure the current in the positive cable between the battery and starter capable of measuring up to 300 amps Tachometer capable of reading RPM in the 100 to 500 range Thermometer or thermocouple to measure ambient temperature 21 Section 4 Testing the Inst
173. L GO OFF Yes KEY OFF AND KEY ON LISTEN FOR FUEL PUMP REFER TO DIAGNOSTIC AID 4 SPEED SENSOR DOES FUEL PUMP CYCLE ON THEN OFF AFTER 1 2 SECONDS LOCATE ELECTRICAL RELAY WHILE HOLDING RELAY KEY OFF AND KEY ON DOES RELAY CYCLE ON THEN OFF AFTER 1 2 SECONDS Proceed to Start of Test for retest Yes Yes REFER TO DIAGNOSITC AID 5 FUEL PUMP REFER TO DIAGNOSTIC AID 6 RELAY WHILE CRANKING CHECK IGNITION SYSTEM REFER TO DIAGNOSTIC AID 7 IGNITION SYSTEM Yes WHILE CHECKING CHECK INJECTOR FUEL DELIVERY WET SPARK PLUG Yes INSTALL IN LINE PRESSURE GAUGE AND KEY ON FUEL PRESSURE IN SPECIFICATION REFER TO DIAGNOSTIC AID 8 FUEL SYSTEM ELECTRICAL REFER DIAGNOSTIC AID 9 FUEL SYSTEM REFER TO DIAGNOSTIC AID 10 Yes BASE ENGINE Operate for an appropriate period of time based upon original fault codes Figure 5B 44 58 44 Section 5B EFI Fuel System Flow Chart Diagnostic Aids 11 Code 51 Injector 1 32 Pin MSE 1 1 Plastic Diagnostic Aid 1 SYSTEM POWER MIL does not Cased ECU only illuminate when key is turned on 12 Code 52 Injector 2 32 Pin MSE 1 1 Plastic Cased ECU only Possible causes 13 Code 55 MIL Light 32 Pin MSE 1 1 Plastic 1 Battery Cased ECU only 2 Main system fuse 14 Code 56 Pump Relay 32 Pin MSE 1 1 Plastic 3 MIL light bulb burned out Cased ECU on
174. ON Electrical Shock can cause injury Do not touch wires while engine is running Electrical Shock Never touch electrical wires or components while the engine is running They can be sources of electrical shock Engine Identification Numbers When ordering parts or in any communication involving an engine always give the Model Specification and Serial Numbers including letter suffixes if there are any The engine identification numbers appear on a decal or decals affixed to the engine shrouding See Figure 1 1 An explanation of these numbers is shown in Figure 1 2 A Model No Command Engine T Horizontal Crankshaft Horsepower 17 17 HP 18 18 20 20 22 22 23 23 25 25 26 26 Spec Variation of Engine Model Code Basic Engine Model CH18 CH20 CH22 624 cc CH25 CH22 23 674 cc CH26 Serial No 3305810334 Year Manufactured Code Year Year 1991 2000 1992 2001 1993 2002 1994 2003 1995 2004 1996 2005 1997 2006 1998 2007 1999 2008 Section 1 Safety and General Information S Electric Start Numerical Designation 730 740 745 750 CH620 0001 CH640 0001 CH670 0001 CH680 0001 CH730 0001 CH735 0001 CH740 0001 CH745 0001 CH750 0001 Complete Spec Number Incorporating Model No with Variation No of Basic Spec Factory Code Code 39 40 Figure 1 2 Explanation of Engine Identification Numbers 1 3
175. OR STATUTORY WARRANTIES INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY LIMITED TO THE DURATION OF THIS WRITTEN WARRANTY We make no other express warranty nor is anyone authorized to make any on our behalf Some states do not allow limitations on how long an implied warranty lasts or the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state TO OBTAIN WARRANTY SERVICE Purchaser must bring the engine to an authorized Kohler service facility To locate the nearest facility visit our website www kohlerengines com and click on SALES AND SERVICE to use the locator function consult your Yellow Pages or telephone 1 800 544 2444 ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 5 K Series Warranty Statement Limited 1 Year Engine Warranty We warrant to the original consumer that each new engine sold by us will be free from manufacturing defects in materials or workmanship in normal service for a period of one 1 year from date of purchase provided it is operated and maintained in accordance with Kohler Co s instructions and manuals Our obligation under this warranty is expressly limited at our option to the replacement or repair at Kohler Co Kohler Wisconsin 53044 or at a service facility designated b
176. OTE If the engine develops sufficient speed to This subsection covers the operation troubleshooting disengage the starter but does not keep and repair of the inertia drive permanent magnet running a false start the engine rotation electric starters must be allowed to come to a complete stop before attempting to restart the engine If the starter is engaged while the flywheel is rotating the starter pinion and flywheel ring gear may clash resulting in damage to the starter Troubleshooting Guide Starting Difficulties Battery 1 Check the specific gravity of battery If low recharge or replace battery as necessary Starter 1 Clean corroded connections and tighten loose connections Does Not 2 Replace wires in poor condition and with frayed or broken Energize insulation Starter Switch 1 By pass the switch or solenoid with a jumper wire If starter or Solenoid cranks normally replace the faulty components Solenoid Shift Starters Perform individual solenoid test procedure See pages 8 44 and 8 45 Batt 1 Check the specific gravity of battery If low recharge or replace d battery as necessary 1 Check for excessively dirty or worn brushes and commutator Starter Clean using a coarse cloth not emery cloth Energizes 2 Replace brushes if excessively or unevenly worn but Turns Slowly 1 Make sure the clutch or transmission is disengaged or placed in neutral This is especially important on equipment with Transmission
177. Seal Crankshaft amp Connecting Rod Balance Gears R Camshaft amp Valves Valve R amp R No Grinding Each Cylinder Valve Tappet Adjustment Valve Grinding Each Cylinder Valve Guide Replacement Valve Spring Replacement Valve Cover Gasket and or Breather Camshaft R amp R Ignition Ignition Module R amp R Flywheel R amp R Charging Regulator Test amp Replace Stator Test amp Replace Includes Flywheel R amp R Starter Retractable R R Replace Rope amp Spring Starting Motor Bendix Type R amp R Starter Bendix Rebuild Includes R R Starter Drive R amp R Starter Solenoid R R Carburetor amp Air Intake Carburetor R amp R Carburetor Rebuild Includes R amp R Carburetor Adjust Air Cleaner Damage in Shipment Fuel Tank R amp R Fuel Pump R amp RH Fuel Pump Rebuild Includes R amp R Miscellaneous Repairs Cylinder Head and or Gasket Replace each Cylinder Head Retorque Shrouds only R amp R Oil Pan and or Gasket Replace Muffler Replace Governor Adjustment Governor R amp R Oil Pump R amp R Crankshaft Grinding ENTER NET COST Crankcase Boring ENTER NET COST 2 K Series Flat Rate Schedule K91 K161 K181 K241 K301 K321 K341 imd Job Description Std Sid Std 0 Std Major Repairs Engine R amp R Generator Set R amp R Motor Home
178. Section 1 Safety and General Information Oil Recommendations Using the proper type and weight of oil in the crankcase is extremely important So is checking oil daily and changing oil regularly Failure to use the correct oil or using dirty oil causes premature engine wear and failure Oil Type Use high quality detergent oil of API American Petroleum Institute Service Class SG SH SJ or higher Select the viscosity based on the air temperature at the time of operation as shown in the following table RECOMMENDED SAE VISCOSITY GRADES 10W 30 C m 20 TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANGE Use of synthetic oil having 5W 20 or 5W 30 rating 15 acceptable up to 4 C 40 F Synthetic oils will provide better starting in extreme cold below 23 C 10 F NOTE Using other than service class SG SH SJ or higher oil or extending oil change intervals longer than recommended can cause engine damage NOTE Synthetic oils meeting the listed classifications may be used with oil changes performed at the recommended intervals However to allow piston rings to properly seat a new or rebuilt engine should be operated for at least 50 hours using standard petroleum based oil before switching to synthetic oil A logo or symbol on oil containers identifies the API service class and SAE viscosity grade See Figure 1 3 SA Figure 1 3 Oil Container Logo 1 4 Refer to Section 6 Lubrication Sy
179. Shut off engine 7 Locate the service connector plug in the wiring harness 35 Pin MA 1 7 Metal Cased ECU Connect a jumper wire from the TPS initialization pin 8 gray wire to the ground pin black wire or use the jumper plug with the red jumper wire See Figure 5B 8 Section 5B EFI Fuel System 24 Pin MSE 1 0 Plastic Cased ECU Connect b If light stays on or blinking ceases a jumper wire from the TPS initialization pin 24 prematurely the procedure was unsuccessful violet wire to the battery voltage pin red wire and must be repeated Possible causes for or use the jumper plug with the blue jumper unsuccessful learning may be 1 Movement wire See Figure 5B 9 occurred in either the TPS or throttle shaft during procedure 2 Crankshaft movement rotation was detected by the speed sensor during procedure 3 Throttle plate position was out of learnable range recheck the 1500 RPM idle speed adjustment or 4 Problem with ECU or TPS 9 When the initialization procedure has been successfully completed turn off the key switch remove the jumper wire or connector and remove the rubber band from the throttle lever 10 Disconnect negative battery cable temporarily 5B to clear all learned adjustments Figure 5B 8 Service Connector Plug Metal Cased 11 Reconnect the battery cable and all external ECU Harness loads Readjust the idle speed to the equipment manufacturer s specified setting and
180. Spring A small dampening spring Kohler Part No 24 089 42 S is attached to the end of the idle speed screw of some EFI engines to help stabilize no load operating speeds See Figure 58 36 58 23 Section 5B EFI Fuel System 1 3 mm 0 039 0 117 in Exposed Length Off End Of Adjustment Screw Dampening Spring Some Models Idle Speed Screw Figure 5B 36 Idle Speed Screw Details The idle speed adjustment procedure remains the same for engines with or without a dampening spring Typically no periodic servicing is necessary in this area If however removal replacement of the dampening spring is required reinstall it as follows 1 Thread the spring onto the end of idle screw leaving 1 3 mm 0 039 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 adhesive on free coils of spring 3 Start the engine and recheck the idle speed settings after sufficient warm up Readjust as required Initial Governor Adjustment The initial governor adjustment is especially critical on EFI engines because of the accuracy and sensitivity of the electronic control system Incorrect adjustment can result in overspeed loss of power lack of response or inadequate load compensation If you encounter any of these symptoms and suspect them to be related to the governor setting the followi
181. Switch Shutdown Optional Ground To Kill Lead White iode Red Ignition Module Keyswitch 2 Stator e et anf Rectifier e Regulator Optional Ammeter gt He Optional I Oil Sentry Switch 1 Solenoid Starter Indicator Light 12 V Battery Wiring Diagram Electric Start Engines 25 Amp Regulated Battery Charging System Stator 25 Amp Stator And Rectifier Regulator 32 Troubleshooting Guide 25 Amp Battery Charging System NOTE Zero ohmmeters and voltmeters on each scale to ensure accurate readings Voltage tests should be made with engine running at 3600 RPM no load Battery must be fully charged 1 Insert an ammeter in B lead from 1 If charge rate increases when load is rectifier regulator With engine running at applied the charging system is OK and 3600 RPM and B lead connected measure battery was fully charged the voltage from B at terminal on rectifier regulator to ground using a DC voitmeter If charge rate does not increase when load is applied test stator and rectifier regulator tests 2 and 3 if voltage is 13 8 volts or more place a minimum load of 5 Amps on battery to reduce voltage Observe ammeter NOTE Turn on lights if 60 watts or more Or place a 2 5 ohm 100 watt resistor across battery terminals Remove connector from rectifier regulator With en
182. Switch Key Start 30 Amp Stator and Rectifier Regulator 34 12 Volt Battery Breaker Points Full Wave Rectifier Troubleshooting Guide 30 Amp Regulated Battery Charging System Output tests should be made with engine running at 3600 RPM no load Battery must be fully charged ___ Test Conclusion ______ Remove 4 input leads from rectifier regulator Set ohmmeter 1 scale and zero scale 1 Connect ohmmeter across red leads and check resistance 1b Connect ohmmeter across black leads and check resistance Measure the resistance from each stator lead to ground NO Replace stator if specified values are not CHARGE found TO Connect leads of flashlight type continuity BATTERY tester from BAT NEG to one AC terminal then reverse leads Repeat procedure on the other AC terminal Remove red lead from REG terminal other leads connected to appropriate terminals If unit does not have ammeter connect ammeter between REG terminal and battery Start engine and operate at full speed Remove two red leads from rectifier BATTERY regulator connect these two leads ONTINUOUSLY together Start engine and operate at full CHARGES AT speed HIGH RATE Resistance should be 2 0 ohms Resistance should be 0 1 ohms Resistance should be infinity ohms no continuity 2 Lamp off in one direction on when leads are reversed Diodes in regulator
183. TROO E T zx a 13 Kw Igniting The Fuel In Combustion Chamber It is desirable that the highest combustion pressures are reached when the piston is still near the top of the power stroke Therefore the combustion process must actually be started before TDC in order to most effectively use the peak force of the combustion pressures If we waited until TDC before starting the combustion process the piston would be well on its way downward in the power stroke and the full force of combustion would be exerted too late to realize greatest power On most Kohler engines best overall performance is obtained if the spark occurs about 20 of crankshaft rotation BTDC Y MIXTURE Que A IGNES The Power Stroke The basic timing of the spark in relation to engine position is established through proper positioning of the ignition cam in respect to degrees of crankshaft rotation However it is possible to alter the timing within certain limits by altering the point at which the breaker points open The breaker point assembly is designed with one stationary contact and one movable contact which is part of an adjustable plate By shifting this plate the instant of point opening is changed in respect to movement of the ignition cam thus causing the spark to occur earlier or later in the engine cycle depending on which way the plate is shifted Opening the
184. The guides are not removable but can be reamed 0 25 mm 0 010 in oversize Valves with 0 25 mm oversize stems must then be used If the guides are within limits but the valve stems are worn beyond limits install new valves Valve Seat Inserts Hardened steel alloy intake and exhaust valve seat inserts are press fitted into the cylinder head The inserts are not replaceable but can be reconditioned if not too badly pitted or distorted If cracked or badly warped the cylinder head should be replaced Recondition the valve seat inserts following the instructions provided with the valve seat cutter being used typical cutter is shown in Figure 10 7 The final cut should be made with 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 achieve the desired 0 5 1 0 full cut interference angle where the maximum pressure occurs on the outside diameters of the valve face and seat 10 8 Valve Seat Cutter Figure 10 7 Typical Valve Seat Cutter Lapping Valves Reground or new valves must be lapped in to provide proper fit Use a hand valve grinder with a suction cup for final lapping Lightly coat the valve face with a fine grade of grinding compound then rotate the valve on its seat with the grinder Continue grinding until a smooth surface is obtained on the seat an
185. Using light pressure rotate the governor shaft counterclockwise as far as it will turn then torque the hex nut on the clamping screw to 6 8 N m 60 in Ib See Figure 5B 42 Make sure that the governor arm has not twisted up or down after the nut has been tightened Figure 5B 42 Adjusting Governor Shaft 58 25 Section 5B EFI Fuel System 4 Verify that the governor has been set correctly With the linkage still retained in the Full Throttle position Step 2 unsnap the bushing clip separate the linkage from the bushing and remove the bushing from the lever Follow Steps 4 in Checking the Initial Adjustment 5 Reconnect the dampening spring into its governor lever hole from the bottom Reinstall the bushing and reattach the throttle linkage See Figure 5B 37 Reattach the governor spring in the marked hole 6 Start the engine and allow it to fully warm up and establish closed loop operation approximately 5 10 min Check the speed settings and adjust as necessary first the low idle speed and then the high speed setting Troubleshooting General When troubleshooting a problem on an engine with EFI basic engine operating problems must be eliminated first before faulting the EFI system components What appears to be an EFI problem could be something as simple as a fuel tank with debris in the bottom or a plugged vent Be sure the engine is in good mechanical operating condition and all oth
186. ach other 2 Recheck the SAM part number noting the last two digits Refer to the table below or on the tester faceplate to determine the test number to be used SAM A 27 Ds 24 584 30 24 55133 54 584 32 Part No 24 28409 24 58431 24 584 34 SAM Part No 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 numerical sequence will be displayed starting with a 6 and progressing down to 1 followed by a P pass or fail indicating the condition of the part See Figures 8 15 and 8 16 If testing an ASAM return to step 1 and move the yellow and brown tester leads to the short set of module leads then repeat the test 24 584 18 24 584 38 44 dd 4 If you get a sign instead of the numerical sequence and or an F at the end of the test cycle recheck all of the connections check the condition of the tester battery and repeat the test If you get the or F sign again in the retest replace the SAM IMPORTANT Allow 15 20 seconds for the tester to clear and reset itself between tests or if the test is interrupted before completion of the test cycle Otherwise a false reading may be displayed in the form of a or a faint 8 8 14 PRESS UNTIL CORRE TEST LI T5 Figure 8 16 Pass
187. acing the spark plugs no maintenance or timing adjustments are necessary or possible Mechanical systems do occasionally fail or break down however so the following troubleshooting information is provided to help you get to the root of a reported problem CAUTION High Energy Electric Spark The CD ignition systems produce a high energy electric spark but the spark must be discharged or damage to the system can result Do not crank or run an engine with a spark plug lead disconnected 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 all ignition related wires are connected including the spark plug leads Be certain all terminal connections fit snugly Make sure the ignition switch is in the run position 8 8 NOTE The CD ignition systems are sensitive to excessive load on the kill lead If a customer complains of hard starting low power or misfire under load it may be due to excessive draw on the kill circuit Perform the appropriate test procedure Test Procedure for SMART SPARK Ignition Systems The following procedures are provided for troubleshooting ignition problems on SMART SPARK equipped engines They will allow you to isolate and pinpoint the failed component s Special Tools Required Hand Tachometer e Tester see Section 2 e Automotive timing l
188. acteristics Loctite 5910 Loctite Ultra Black 598 Loctite Ultra Blue 587 Loctite Ultra Copper Spline Drive Lubricant Kohler 25 357 12 5 2 3 Section 2 Tools amp Aids Special Tools You Can Make 2 Remove the studs of a Posi Lock rod or grind off the aligning steps of a Command rod so the joint Flywheel Holding Tool surface is flat A flywheel holding tool can be made out of an old junk flywheel ring gear as shown in Figure 2 1 and 3 Find a 1 in long capscrew with the correct used in place of a strap wrench thread size to match the threads in the connecting rod 1 Using an abrasive cut off wheel cut out a six tooth segment of the ring gear as shown 4 Use a flat washer with the correct I D to slip on the capscrew and approximately 1 O D Kohler 2 Grind off any burrs or sharp edges Part No 12 468 05 S Assemble the capscrew and washer to the joint surface of the rod as 3 Invert the segment and place it between the shown in Figure 2 2 ignition bosses on the crankcase so that the tool teeth engage the flywheel ring gear teeth The bosses will lock the tool and flywheel in position for loosening tightening or removing with a puller Figure 2 2 Rocker Arm Crankshaft Tool 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 Find used connecting rod from a 10 HP or
189. acts 5 Read resistance across contacts 6 Resistance should be 2 ohms or less 7 If resistance is above 2 ohms clean contacts with electrical contact cleaner and or stiff paper business card Recheck resistance 8 If resistance cannot be brought below 2 ohms replace points Breaker Point Resistance Test Ohmmeter Test MAGNUM SOLID STATE IGNITION SYSTEM The new Magnum engines feature an entirely new solid state inductive magneto ignition system AI engines both electric and recoil start will utilize the same system Solid State Ignition Test The ignition modules for the M8 and M10 M16 are identical except for the larger lamination radius on the 10 16 HP module Magnum Solid State Ignition Module Single Cylinder Engines The twin cylinder module uses the same basic circuitry but has more windings to produce the energy necessary to fire two cylinders Magnum Solid State Ignition Module Twin Cylinder Engines The performance of the new solid state ignition system has exceeded even Kohler s strict specifications The system was tested in the laboratory for high temperature performance and endurance sait spray and high humidity and vibration resistance There were no failures in more than 17 000 hours of endurance testing To test the system under field conditions 50 Magnum engines were put into service at an amusement park The engines accumulated over 200 000 hours with only two failures
190. ad to the B terminal of the rectifier regulator and the two black tester leads to the two AC terminals See Figure 8 29 Section 8 Electrical System and Components Figure 8 29 3 Plug the tester into the proper AC outlet power for tester being used Turn on the power switch See Figure 8 30 The POWER light should be illuminated and one of the four status lights may be on as well This does not represent the condition of the part Figure 8 30 4 Press the TEST button until a click is heard and then release See Figure 8 31 Momentarily one of the four lights will illuminate indicating the condition of the part 8 23 Section 8 Electrical System and Components 3 Connect the red lead and one of the black leads to the pair of terminals on the open end of the n tandem adapter lead connections are not location a specific 4 Connect the remaining black lead from the tester RE SU e to one of the outer AC terminals on the rectifier 78 regulator See Figure 8 33 Figure 8 31 a Ifthe OK green light comes on and stays steady the part is good and may be used b If any other light is displayed the rectifier regulator is faulty and should not be used NOTE A flashing LOW light can also occur Figure 8 33 as a result of an inadequate ground lead connection Make certain connection location 5 Plug the tester into the proper AC outlet powe
191. age or abuse Figure 8 Figure 8 Check the element with a light for punctures in the paper filtering material If you cannot see any light at the base of the creases the filter should be replaced Figure 9 Figure 9 Check the inner portion of the air cleaner base plate and the carburetor throat for signs of dust or dirt If any traces are found recheck all of the air cleaner components to determine the source of dirt entry Perhaps the breather hose was pulled loose from the base plate allowing dirty entry through the hole B Oil Figure 10 Figure 10 Pull the dipstick and check the oil Look at the level of oil but also note the color and consistency of the oil Is it fresh clean oil that was added after a failure Or perhaps it s so thick and dirty it won t drip off the stick because it hasn t been changed in 150 or 200 hours When you drain the oil measure the amount that you drain out and examine it closely Notice again the color and consistency Does it have an abnormal smell Do you see any metal chips or wear particles Do you notice any sludge If the engine has an oil filter notice whether is a genuine factory part External Surfaces Figure 11 Figure 11 Check the overall condition of the exterior Is the outside relatively clean or is there an accumulation of oil dirt chaff etc Are there any visible oil leaks Also check for any indication that the engine may have been
192. agnet assembly which is permanently affixed to the flywheel Two electronic capacitive discharge ignition modules which mount on the engine crankcase Figure 8 6 A spark advance 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 the engine Two spark plugs Key Switch or Off Position of Key Switch White Spark Plug NS 0 28 0 33 mm 0 011 0 013 in Air Gap Section 8 Electrical System and Components Green Spark Advance Module il Spark Plug P MN 4 U j Module Flywheel Magnet Figure 8 6 Capacitive Discharge Ignition System with Spark Advance 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 Input Coil V 7 2V From Brown Conditioning Delay Circuit Circuit Circuit To Comparator Generator Semi Conductor Switch Figure 8 7 Block Diagram Spark Advance Module Operation The ignition module for this system operates in the same fashion as the fixed timing module except the trigger circuit for the semiconductor L2 Figure 8 5 is replaced by the spark advance module Figure 8 7 8 7 Section 8 Electrical System and Components The pulse generated by the in
193. air cleaner mounting bracket with the valve cover mounting holes and start the screws Install Muffler On two barrel carburetor models start the two 1 Install the port liners if equipped Install the mounting screws into the top of intake manifold muffler and attaching hardware to the muffler See Figure 11 97 bracket Torque screws to 9 9 N m 88 in Ib 2 Install the hex flange nuts to the exhaust studs Torque hex flange nuts to 24 4 N m 216 in Ib Install Oil Cooler 1 Reinstall the oil cooler on the engine if equipped Install a new gasket between the cooler and the closure plate Torque nipple adapter to 27 N m 20 ft Ib See Figures 11 99 and 11 100 1 a2 j i 4 F i A Figure 11 97 Mounted Air Cleaner Bracket Two Barrel Carburetor 3 Check alignment of bracket and torque the valve cover screws as prescribed in Install Valve Covers Torque the upper mounting screws into the manifold two barrel models only to 9 9 N m 88 in Ib 4 Connect the air cleaner hose to elbow or adapter on carburetor and secure with a clamp Install and Figure 11 99 Torquing Oil Filter Nipple Crankcase tighten hood onto the air cleaner inlet See Figure Mounted Cooler 11 98 11 29 Section 11 Reassembly ee re Mounting Locations d Figure 11 100 Mounting Oil Cooler Blower Housing Mounted Cooler Install Oil Filter and Fill Crankcase with Oil 1
194. ake Precise Measurements Figure 101 Rolled Material Caused by what 28 KOHLER 216195 Engine Inspection Data Record To facilitate accurate evaluation enter as much information as possible mark location of break or crack on drawing provide as many dimensions as possible record conditions found with check mark X whenever possible SECTION 1 OWNER AND EQUIPMENT INFORMATION Owner s Name Street Address City State Zip Code Phone No Type of Equipment Manufacturer of Equipment Previous Repairs Warranty Claim No YES NO USAGE MAINTENANCE INFORMATION Oil type Z Hours since last oil change Gaw iowao C How often is the oil level checked Must oil be added between changes Everytime 1 Never Other Ll Yes LI 1 How much Was an oil additive used How often is the air cleaner checked LI Yes LI No What brand Precleaner Element Was it ever replaced or cleaned How recently Precleaner Element lYes No Precleaner_ Element 1 Were any adjustments made to the carburetor or governor By whom Yes No If yes specify Customer Dealer PRELIMINARY EXAMINATION Air Cleaner Assembly Type LI Dry 1 L Remote LI Oil Bath LI Tri Phase 1 Wing Nut Wing nut seal Factory Original Non standard replacement Intact LI Separated LI Missing 2 Outer Cover 1 Good condition 1 Center hole oblong Other damage s
195. al The electrical relay is used to supply power to the injectors coils and fuel pump When the key switch is turned on and all safety switch requirements met the relay provides 12 volts to the fuel pump circuit injectors and ignition coils The fuel pump circuit is continuously grounded so the pump is immediately activated and pressurizes the system Activation of the ignition coils and injectors is controlled by the ECU which grounds their respective circuits at the proper times Service A malfunctioning relay can result in starting or operating difficulties The relay and related wiring can be tested as follows 1 Disconnect the relay connector plug from the relay Connect black lead of VOA meter to a chassis ground location Connect red lead to the 86 terminal in relay connector see Figure 5B 14 Set meter to test resistance Rx1 Turn ignition switch from off to on Meter should indicate continuity ground circuit is completed for 1 to 3 seconds Turn key switch back off 58 13 Section 5B EFI Fuel System Terminal 85 Terminal 87 6 Attach ohmmeter leads to the 30 and 87 Ignition Switch E T Feed To Ignition terminals in relay Initially there should be no Voltage n Coils Fuel continuity Using a 12 volt power supply connect Injectors and the positive lead to the 85 terminal and Fuel Pump touch the negative lead to the 86 terminal 1 When 12 volts is applied the rela
196. al tests must be performed The side not being tested must have the spark plug lead connected or grounded Do not crank the engine or perform tests with one spark plug lead disconnected and not grounded or permanent system damage may occur 2 Crank the engine over establishing a minimum of 550 600 RPM and observe tester s for spark 3 Repeat the spark test on the opposite cylinder if cylinders are being tested individually a Ifboth cylinders have good spark but the engine runs poorly or existing plug condition or appearance is questionable install new spark plugs gapped at 0 76 mm 0 030 in and retest engine performance If problem persists go to Test 3 b If one cylinder had good spark but the other cylinder had no spark or intermittent spark go to Test 4 c If there was spark on both cylinders but power is suspect go to Test 3 Test 3 Check for Timing Advance 1 Makea line near the edge of the flywheel screen with a marking pen chalk or narrow tape See Figure 8 18 2 Connect an automotive timing light to cylinder that had good spark Figure 8 18 Mark for Timing Advance 3 Run the engine at idle and use the timing light beam to locate the line on the screen Draw a line on the blower housing next to the line on the screen Accelerate to full throttle and watch for movement of the line on the screen relative to the line on the blower housing If both cylinders had good spark repeat the test
197. ale 0 Contaminated water debris etc Governor 1 Components 2 Function LJ Intact 0 Missing 0 Modified L Bent Broken 0 Operative C Inoperative 0 Modified 0 Misadjusted Dirt Ingestion 1 Is there evidence of possible dirty entry LJAir cleaner 0 Carburetor 0 Breather 1 Gasket Seal Ll Oil fill opening Ll Other Spark Plug le SECTION 2 EVALUATION PERFORMED BY Evaluator Date Company Name Type of Acct 1 Central Distributor 1 Service Distributor L Service Dealer Address TEAR DOWN ANALYSIS Giewm o Oo CLEARANCE COLD CYLINDER 2 PISTON RINGS CYLINDER 2 Intake in Production Rings HD LI Exhaust in Service Rings a LJ CONNECTING ROD CYLINDER 2 Rings Free Grooves O Discolored LI Rings Stuck in Grooves __ Broken Bearing Scored E LJ in in Cap Screws Loose 1D o a in Dipper Bent LB o n Dipper Broken LJ Rod Seized to Crankpin D o 0 Note For Crankshaft Pistons amp Cylinder Bore Measurements Rod OK Not Damaged D See Page 3 2 Continued on 3 30 Tear Down Analysis continued CRANKSHAFT ROD JOURNAL CYLINDER 1 CYLINDER 1 Others Maximum Wear Spec CYLINDER 2 MAX OUT OF ER Left Middle Right LLL PISTON Select the following piston type and measure diameter using appropriate method Style
198. allation Ideally the test should be performed in a special cold room where low temperatures can be developed and controlled by refrigeration Since cold room testing is an elaborate and expensive procedure you may not be able to run such tests Instead you can leave the machine for 12 hours at the lowest temperature at which you expect it to be used then test it for starting using the test equipment noted on 21 The spark plug leads should be disconnected and grounded while observing starter voltage current and engine RPM The starter should be engaged and readings taken of voltage RPM and current ignore the initial surge Note the ambient temperature Using the line showing the temperature closest to your observed ambient temperature compare your test readings with the minimums and maximums noted Consult your Kohler Engine representative for a review of the reading observed Ambient Minimum Typical Temp Voltage Current 8 5 250 0 18 C 20 F 6 C 50 F 10 C 70 F 21 C 150 Amp 120 Amp 80 Amp 60 Amp If voltage is below the minimum there are several possible causes 1 Battery is discharged or is too small insufficient Capacity 2 Cables are too long or too small Poor connections at starter battery amp switch or in ground circuit 4 Inadequate ground circuit between terminal on battery and engine block 5 Too much parasitic load If the RPM is b
199. ance across stator leads using an ohmmeter 3b With engine stopped measure the resistance from each stator lead to ground using an ohmmeter 1 With engine running at 3600 RPM measure voltage from B lead to ground using a DC BATTERY voltmeter CONTINUOUSLY CHARGES AT HIGH RATE 1 If charge rate increases when load is applied the charging system is OK and battery was fully charged If charge rate does not increase when load is applied test stator and rectifier regulator tests 2 and 3 If voltage is 28 volts or more stator is OK Rectifier regulator is faulty Replace the rectifier regulator If voltage is less than 28 volts stator is probably faulty and shouid be replaced Test stator further using an ohmmeter test 3 3a If resistance is 0 1 0 2 ohms the stator is OK If resistance is infinity ohms stator is open Replace stator 3b If resistance is infinity ohms no continuity the stator is OK not shorted to ground If resistance or continuity is measured the stator leads are shorted to ground Replace stator 1 If voltage is 14 7 volts or less the charging system is OK The battery is unable to hold charge Service battery or replace as necessary If voltage is more than 14 7 volts the rectifier regulator is faulty Replace rectifier regulator 31 Electric Start Engine 25 Amp Regulated Battery Charging System Optional Oil Sentry
200. and other components for accidental grounding and or damaged insulation If wires and terminals are OK the ignition module is probably faulty and should be replaced Test module further using an ohmmeter Test 4 NOTE Use a low voltage ohmmeter when ohmmeter is required Always zero ohmmeter on each scale before testing to ensure accurate readings 4a Measure the primary resistance of module using an ohmmeter NOTE Connect negative lead of ohmmeter to kill terminal B Primary Primary Leads Terminals Resistance A B 1 0 1 3 ohms 4b Measure the secondary resistance of module using an ohmmeter Secondary Secondary Leads Terminals Resistance A C 7 900 10 850 ohms If resistance is 0 ohms module primary is shorted Replace module If resistance is infinity ohms module primary is open Check keyswitch wiring for shorts or connections which could apply 12V to kill terminal B Correct those conditions then replace module If resistance is within range module primary is OK Test secondary Test 4b If resistance is within range module secondary is OK If resistance is low or 0 ohms module secondary is shorted Replace module If resistance is high or infinity ohms module secondary is open Replace module Ignition System Tester A simple tester can be made to determine if the ignition module is functioning properly 1 2 Obtain a new RJ 8 or RCJ 8 spark plug Remove the ground electro
201. and proper engine use special additives are unnecessary FUELS Gasoline Petroleum is a mixture ofa large number of different hydrocarbons materials composed of hydrogen and carbon These two elements may be combined in a wide variety of ways with each combination being quite stable and having its own Ee eer 30 60 80 100 TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANGE individual boiling point and ignition point This charactertistic varies quite widely depending on how the gasoline was refined The characteristic ofa varying boiling and ignition point is the principle reason for gasoline being a superior engine fucl The basic chemistry of gasoline allows it to burn ina controlled sequence according to the temperature and pressure required for the various hydrocarbon materials Octane is one of the hydrocarbon compounds in gasoline It has superior anti knock characteristics and at one time was considered the ideal or nearly perfect engine fuel It was therefore used as a basis for comparing the anti knock performance of var ious gasolines The octane rating bas developed from this concept Two different octane ratings are in current usage the pump sticker rating and the research rating method which is primarily used in Canada and is always a higher rating For best results use only clean fresh regular grade unleaded gasoline with a pump sticker octane rating of 87 or higher in the U S A In countries using the
202. aner and housed under a flat outer cover This is typically referred to as the standard air cleaner assembly See Figures 4 1 and 4 4 Some engines utilize a heavy duty style air cleaner as shown in Figure 4 12 Figure 4 1 Standard Air Cleaner Standard Air Cleaner Service Check 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 cleaner components could allow unfiltered air into the engine causing premature wear and failure Air Cleaner Element Precleaner _ gt Figure 4 3 Removing Knob Style Cover Precleaner Service If so equipped wash and reoil the precleaner every 25 hours of operation more often under extremely dusty or dirty conditions To service the precleaner perform the following steps 1 Unhook the latches or loosen the retaining knob and remove the cover 2 Remove the foam precleaner from the paper air cleaner element 4 1 Section 4 Air Cleaner and Air Intake System 3 Wash the precleaner in warm water with detergent Rinse the precleaner thoroughly until all traces of detergent are eliminated Squeeze out excess water do not wring Allow the precleaner to air dry 4 Saturate the precleaner with new engine oil Squeeze out all excess oil 5 Reinstall the precleaner over the paper air cleaner element 6 Reinstall th
203. arburetor Configuration Spring Color Color Spring Color 0 DD e 1 5 Standard Parent Material NH CH26 CH745 EFI Engines CH750 Engines Intended Highidie SpringColor HoleNo Spring Color Hole No Standard Parent Material NN WW W Section 11 Reassembly Description Bracket speed control Clamp cable some applications Kill Switch some applications Lever choke top position Lever throttle control middle Linkage choke control Lever throttle actuator bottom Screw M5x0 8x20 Washer wave Washer flat 3 Spring choke return Nut M5x0 8 lock c6 90 09 Figure 11 87 Throttle Choke Control Bracket Detail Install Oil Sentry If So Equipped 1 Apply pipe sealant with Teflon Loctite No 59241 or equivalent to the threads of the Oil Sentry switch and install it into the breather cover See Figure 11 88 Torque to 4 5 N m 40 in Ib 2 Connect the wire lead green to the Oil Sentry terminal Install Control 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 indicator light wires 11 26 Figure 11 88 Installing Oil Sentry Switch Install Valve Covers
204. arefully do not use if the sealing surfaces are bent or damaged 5 Check all parts for wear cracks or damage Replace any damaged components 6 Install the new inner element followed by the outer element Slide each fully into place in the air cleaner housing Figure 4 12 Heavy Duty Air Cleaner 7 Reinstall the end cap so the dust ejector valve is down and secure with the two retaining clips See Figure 4 12 To Service Every 250 hours of operation more often under extremely dusty or dirty conditions replace the paper element and check the inner element Follow these steps 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 1 Unhook the two retaining clips and remove the end cap from the air cleaner housing 2 Pull the air cleaner element out of the housing 2 Lift the entire air cleaner assembly off the engine See Figure 4 13 Disassemble or service as required Installation Inner 1 Install the main mounting bracket with the center Element gt section up and the cutout around the carburetor Element aligning the mounting holes with the four upper valve cover holes 2 Install and torque the four valve cover mounting screws to specified torque value di mms at am cam ee as E ai ras c
205. arger engines When using a chain and sprocket type of drive the tension on the chain is of importance because there may be a whipping action due to the engine speed variation from one cycle to the next cyclic irregularity This may be injurious to both engine and equipment V belts with their ability to stretch act somewhat as a shock absorber and are much easier on the engines Sometimes customers require a clutch between the engine and their equipment which is frequently purchased separately from clutch manufacturers There may also be the requirement for a reduction in rotating speed for which gear reductions are available In working with a gear reduction it should always be kept in mind that engine torque is multiplied by the same ratio as the speed is reduced With a chain and sprocket type drive on a gear reduction firmness of engine mounting becomes essential If the chain is directed out to the side of the engine the torque tends to twist the engine and may show up as loosened mounting cap screws or loose screws between the engine block and base Combination clutch and reduction units can also be applied to engines These applications should always be discussed with the engine manufacturer There are normal losses of engine power to the equipment depending upon the method of connect ing the engine to the load Refer to the chart as a guide for efficiency values for common transmis sion equipment Transmi
206. arranty coverage for a situation you feel is not covered by the standard policy contact the Central Distributor for a Policy Adjustment Authorization The Central Distributor must fill out and sign the Policy Adjustment Explanation Form TP 2466 A shown on page 29 and attach it to the Warranty Claim Kohler Co will advise you regarding its decision If the repair in question is determined to be covered by warranty payment will be made If the customer has already paid for the repair issue reimbursement for all charges paid relating to the Kohler engine warranty If for some reason the request for warranty consideration is denied or a partial allowance is offered you will be advised of our findings along with the reasons for our decision Engines Manufactured Over Years Ago A verification of the date of purchase Example Bill of Sale Receipt or Invoice must accompany the Warranty Claim for all engines that are 3 or more years old The chart on the next page will aid in determining the year of manufacture 11 Serial Number Significance Year of Manufacture identified by 1 ALetter 2 First Two Digits If Seven Digit Number 172452 9276430 L First Two Digits If Eight or Ten Digit Number 10026692 Remaining digits are a factory code 1501897591 36 2006 3 2007 38 2008 Section 4 Warranty Service Parts A Policy Service parts short blocks miniblocks and accessory kits a
207. art terminal on the solenoid and the other lead to the body or mounting surface of the solenoid Then manually push the plunger In and check if the Hold In coil holds the plunger retracted See Figure 8 80 Do not allow the test leads to remain connected to the solenoid for a prolonged period of time If the plunger fails to stay retracted the solenoid should be replaced Manually Push Plunger In 12 volt Test Leads Connect Only Long Enough to Test Figure 8 80 Testing Hold In Coil Function Test Test 4 Solenoid Hold In Coil Contact Continuity Test Use an ohmmeter set 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 81 The meter should indicate continuity if no continuity is indicated the solenoid should be replaced Repeat test several times to confirm condition Section 8 Electrical System and Components Plunger Pushed In 12 volt Test Leads Figure 8 81 Testing Hold In Coil Solenoid Contact Continuity 8 45 Section 8 Electrical System and Components 8 46 Section 9 Disassembly A WARNING Accidental Starts Disabling engine Accidental starting can cause severe injury or death Before working on the engine or equipment disable the engine as follows 1 Disconnect the spark plug lead s 2 Disconnect negative battery cable from battery Genera
208. arter Sheet Metal Brush lt frame Remove the brush holder tool Holder Tool For Style Commutator End Caps Figure 8 44 Brush Holder Tool Style 4 Ifthe brush assembly is not being replaced Cap position the brushes in their pockets in the carrier Move them to the retracted position and Style B End Cap Brush Replacement install carton staples to retain them See Figure Starters with Style B end caps have the brushes 8 46 in a plastic carrier housing separate from the end cap Replacement brushes come preassembled in the 5 Align the terminal stud block with the notch carrier housing retained with two carton staples in the starter frame and slide the brush carrier assembly into the frame The commutator will Commutator Service push the carton staples out as the brush assembly Clean the commutator with a coarse lint free cloth Do is installed Position the end cap over the brush not use emery cloth assembly so the holes for the thru bolts are aligned with those in the brush carrier If the commutator is badly worn or grooved turn it down on a lathe or replace the armature Starter Reassembly 1 Place the thrust washer if so equipped over the drive shaft of the armature 8 33 Section 8 Electrical System and Components Figure 8 46 Style Commutator End Cap with Brushes 6 Install the thru bolts and tighten securely 7 Lubricate the drive shaft with Kohler bendix star
209. ase oil wear or breather tube position must be to side opposite the TPS Sensor loose on throttle body manifold 2 Throttle Body Related a Throttle shaft or bearings worn damaged 3 Engine Wiring Harness Related 35 Pin MA 1 7 Metal Cased ECU a b Pin circuits 12 25 and or 27 damaged wiring or connectors Pin circuits 12 25 and or 27 routed near noisy electrical signal coils alternator Intermittent 5 volt source from ECU pin circuit 25 3 Engine Wiring Harness Related 24 Pin MSE 1 0 Plastic Cased ECU a b Pin circuits 4 8 and or 14 damaged wiring connectors Pin circuits 4 8 and or 14 routed near noisy electrical signal coils alternator Intermittent 5 volt source from ECU pin circuit 14 3 Engine Wiring Harness Related 32 Pin MSE 1 1 Plastic Cased ECU a Pin circuits 4 8 and or 18 damaged wiring connectors b Pin circuits 4 8 and or 18 routed near noisy electrical signal coils alternator c Intermittent 5 volt source from ECU pin circuit 18 4 ECU Harness Related a ECU to harness connection problem Code 23 Source ECU Explanation is unable to recognize or process signals from its memory Expected Engine Response Engine will not run Possible Causes 1 ECU internal memory problem a Diagnosable only through the elimination of all other system component faults Code 24 Will not blink out Source
210. ata to select an engine However there are other factors to be considered Engines are rated at maximum allowable RPM which is 3600 RPM on all Command engines except the CH6 which is rated at 4000 RPM and wide open throttle WOT Continuous operation under such conditions could adversely affect the engine life This and other operating conditions to consider are as follows NOTE Thefollowing are the normal industry accepted operational factors which apply to all makes of engines Operational Factors Duty Cycle If the engines is to be operated at constant speed and load such as to power a generator or pump use an 80 power factor For intermittent duty applications with 5096 or less duty use an 85 factor Tractors and tillers are intermittent duty applications Altitude Effect Air needed for combustion becomes less dense as altitude increases This results in a proportionate decrease in engine horsepower For every 1000 foot 305 m increase above sea level calculate a 3 596 decrease in available horsepower At altitudes higher than 5000 ft 1524 m for all models except CS engines which is 6000 ft 1829 m above sea level special main fuel jets are required for some carburetors Refer to the chart on page 6 Section 1 Selecting the Right Engine 100 96 5 93 0 89 5 86 0 82 5 79 0 75 5 72 0 Sea Level Chart Altitude Effect on HP 1000 2000 3000 4000 Temperature Effect 1 decrea
211. ate the connectors and remove the white kill lead from the engine connector Rejoin the connectors and position or insulate the kill lead terminal so it cannot touch ground 8 16 Try to start the engine to verify whether the reported problem is still present NOTE If the engine starts or runs during any of the testing you may need to ground the kill lead to shut it down Because you have interrupted the kill circuit it may not stop using the switch a If the problem goes away the electrical system on the equipment is suspect Check the key switch wires connections safety interlocks etc b If the problem persists the condition is associated with the ignition or electrical system of the engine Leave the kill lead isolated until all testing is completed c Identify the white kill lead of the engine wiring harness connector Establish a connection to a known good ground location The engine should kill completely If not or only one cylinder is affected go to Test 4 but also check the white kill lead connection for the affected DSAI module Test 2 Test for Spark 1 With the engine stopped disconnect one spark plug lead Connect the spark plug lead to post terminal of spark tester Kohler Part No 25 455 01 5 and attach tester clip to a good engine ground NOTE Iftwo testers are available testing can be performed simultaneously for both cylinders However if only one tester is available two individu
212. ation In a liquid withdrawal system the Liquefied Petroleum Gas LPG is released from the bottom of the supply tank under high pressure Upon opening the shut off valve on the tank liquid fuel travels out through the high pressure line to the electric lock off filter assembly The lock off opens internally when the key switch is turned on permitting filtered fuel to flow to the vaporizer The vaporizer is mounted in the flow of the discharged cooling air It absorbs heat from the cooling air and transfers it to the fuel changing the liquefied petroleum to a vapor or gaseous state while partially stepping down the fuel pressure The gas vapor flows under this decreased pressure to the regulator where it is further reduced to a usable regulated pressure The regulator activated by intake manifold vacuum controls fuel flow to the carburetor In the venturi of the carburetor the fuel vapor is mixed with incoming air from the air cleaner in the correct ratio for efficient combustion Troubleshooting Checklist If the engine starts hard runs roughly or stalls check the following areas e Make sure the LPG fuel tank is filled and shut off valve is fully opened e Make sure fuel is reaching the carburetor e Make sure the air cleaner element and precleaner are clean and all components are fastened securely e Make sure the ignition governor exhaust throttle and choke control systems are all operating properly e Che
213. ator A new replacement regulator will have new O Rings already installed Lubricate the O Rings external regulator with light grease or oil 6 a Install the new regulator by carefully pushing and rotating it slightly into the base or housing b External Regulators with Square Base Housing Only Install a new O Ring between the regulator and the mounting bracket Set the mounting bracket into position c Secure the regulator in base with the original retaining ring or screws Be careful not to dent or damage the body of the regulator as operating performance can be affected 7 Reassemble any parts removed in step 3 58 21 Section 5B EFI Fuel System 8 Reconnect the negative battery cable 9 Recheck regulated system pressure at fuel rail test valve Fuel Filter EFI engines use a high volume high pressure 10 15 micron in line fuel filter 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 conditions Use only the specified filter and install it according to the directional arrows Do not use a substitute filter as operating performance and safety can be affected Relieve system pressure through the safety valve in the fuel rail before servicing Fuel Rail Fuel Rail 4 3 Locking Clip Fuel Injector Figure 5B 33 Manifold Assembly 58 22 General The fuel rail
214. aw of 20mA to maintain adaptive memory During stort the battery must maintain 7 volts minimum system voltage for ECU operation during crank Unless otherwise specified ALL wires are 18 Connector Ji PIN FUNCTION D Battery Supply Permanent 2 Switched Ignition 3 Saftey Switch 4 TPS amp Temp Ground 5 Not Used 6 Motor Temp Input 7 Spare A D Input 8 TPS input 9 VR Input 10 VR Input lt gt 1D Lambda Input 12 Lambda Ground i need 13 K Line 14 TPS Supply Voltage 15 Battery Ground 162 Injector 1 Output 17 Injector 2 Output 18 Pump Relay Output 19 Diag Lamp Output 20 Tach Output ep Spare output 22 Igni output 23 Igne output 24 EDL TPS set Battery Gnd See Grounding Note Jl Bi T L V J1 9 agen XX See General Note 10 TPS Intlatization J1 24 J1 11 gt 2 Sensor Speed Sensor Inductive Pick up See Grounding Note B C J1 1e5 1 GROUNDING NOTES Note Item A Battery B Lambda Sensor Fuel Pump o Shield A PD Spork Plug VA Cylinder 1 9 9 Lamp J1 8 hl Q 12 Volt Line 1 13 J1 6 L Sensor Temp Blue Motor Sensor Position Throttle Connector nostic Instruction Attached to engine block near starter The sensor grounds to the engine via the muffler If two leaded sensor is used pin 12 is lambda ground
215. ay also have other rights which vary from state to state TO OBTAIN WARRANTY SERVICE Purchaser must bring the engine to an authorized Kohler service facility For the facility nearest you consult your Yellow Pages under Engines Gasoline or phone 1 800 544 2444 ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 Service Parts Warranty Limited 90 Day Service Parts Warranty We warrant to the original consumer that each new service part sold by us will be free from manufacturing defects in materials or workmanship in normal service for a period of 90 days from date of purchase provided it is installed properly and the engine maintained in accordance with Kohler Co s instructions and manuals Our obligation under this warranty is expressly limited at our option to the replacement or repair at Kohler Co Kohler Wisconsin 53044 or at a service facility designated by us of such part or parts as inspection shall disclose to have been defective EXCLUSIONS This warranty does not apply to defects caused by casualty or unreasonable use including faulty repairs by others and failure to provide reasonable and necessary maintenance The following items are not covered by this warranty Engine accessories unless supplied or installed by Kohler Co These are subject to the warranties if any of their manufacturers WE SHALL NOT BE LIABLE FOR SPECIAL INDIRECT INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY KIND including but not limited to
216. back in to its original setting c Reconnect connector plugs start engine and retest system operation 58 8 7 Remove the two mounting screws from the TPS Save the screws for reuse Remove and discard the faulty TPS Install the replacement TPS and secure with the original mounting screws a Reconnect both connector plugs b Perform the appropriate TPS Initialization Procedure integrating the new sensor to the ECU TPS Initialization Procedure For 35 Pin MA 1 7 Metal Cased ECU and 24 Pin MSE 1 0 Plastic Cased ECU only 1 Check that the basic engine all sensors fuel fuel pressure and battery are good and functionally within specifications Important 2 Remove disconnect ALL external loads from engine belts pumps electric PTO clutch alternator rectifier regulator etc 3 Start the engine and allow it to warm up for 5 10 minutes so oil temperature is above 55 C 130 Move the throttle control to the idle position and allow engine to stabilize for a minimum of one minute 5 Install a heavy rubber band around the throttle lever and the manifold boss to firmly hold the throttle against the idle stop On some EFI engines there is a dampening spring on the end of the idle speed screw The dampening spring if used should be fully compressed and the tab on the throttle lever in direct contact with the speed screw Adjust the idle speed to 1500 RPM using a tachometer 6
217. baffle or blower housing See Figure 9 33 The 3 Remove the starter assembly and any spacers if module willing hang loose as part of the wiring used harness 9 8 Section 9 Disassembly Figure 9 35 Removing Outer Baffles 5 Remove the outer baffles on both sides See Figure 9 35 6 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 Figure 9 33 Removing the Spark Advance Module Applicable Models 4 Remove the three each side hex flange screws securing the outer baffles Note the location of any lifting strap and position of the two short screws one each side on bottom for reassembly See Figure 9 34 Figure 9 36 Removing Metal Grass Screen 7 Remove the lower blower housing screw and washer securing the rectifier regulator ground lead or grounding strap 8 Two Barrel Carburetor Models Only Remove the two screws securing the debris shield to the blower housing The wiring harness is attached to the underside of shield See Figure 9 37 Figure 9 34 Note Location of Two Short Screws 9 9 Section 9 Disassembly Debris Shield Mounting Screws 4 i E 4 i TE Y PF 4 M 73 21 cual _ z Figure 9 37 Debris Shield Details Two Barrel Figure 9 39 Removing Fasteners Holdi
218. be completed and on file at Kohler Co before a service account will be authorized to do warranty repairs These forms are to be submitted through your Central Distributor To change your Retail Labor Rate or Warranty Discount information have your Central Distributor complete a new Service Information Record and submit the updated information to Kohler Co Change to the Retail Labor Rate or Warranty Discount must be received at Kohler Co Kohler Wisconsin 30 days prior to the effective date of change The information on the Service Information Record will be used by Kohler Co for warranty processing and update mailings If any of the information changes Company name address ownership key personnel etc be certain to notify your Central Distributor so they can update their records They will submit the updated data to Kohler Co C Manufacturing Defects Covered The warranty applies to repair and replacement of defective parts caused by faulty material and or workmanship in manufacture It does not apply to defects caused by negligence in servicing or operating an engine The following conditions cannot be considered under warranty Normal wear e Routine tune up or adjustment Damage due to improper handling or accident Damage due to operating at speeds or load conditions contrary to published specifications Damage due to improper or insufficient lubrication Damage from overheating due to clog
219. be expressed V V V Total or Displ Clear V V Clearance Clearance The amount of power an engine develops is directly related to the degree of compression achieved in the cylinder The efficiency with which the fuel is burned is also higher with a high degree of com pression This is the reason for the trend in auto motive engines toward higher compression ratios Progress toward higher compression ratios is lim ited by the burning characteristics of the fuel In overhead valve engines where the valves are nor mally over the engine there are no limitations in design for achieving a high compression ratio because it is easy to design such an engine with a small clearance volume With L head engines it is not easy to keep the clearance volume small and therefore compression ratios are limited in the range of 6 to 6 5 The engine components that hold the compression and power stroke pressures in the cylinder are the valves and seats the cylinder head gasket and the piston rings To get proper power from a given engine and to get proper starting characteristics there can be no leakage through any of these parts In Diesel engines the pressures in the cylinder during compression and combustion range from 700 to 1200 psi as compared with to 500 psi in gasoline engines Compression ratios in Diesel engines range from 15 1 to 20 1 as compared with 5 5 1 to 10 5 1 for gasoline engines As air is compres
220. below and or to the right of the line go to the next letter Cross Section Use the chart below to make the initial selection of the best belt cross section final selection will depend on pulleys used and drive geometry n m Ka o S LL Gan 14 Section 5 Technical Guidelines Pulley Selection Using larger pulleys allows reducing belt tension and bearing loading resulting in increased bearing belt and pulley life When idler pulleys are used for tensioning and take up they should be spring loaded to provide nearly constant tension When an idler is used for clutching it should be located close to the drive pulley Idler pulleys should be located on the belt slack side or belt strand going away from the drive pulley The belt manufacturer should be contacted for specifics regarding pulleys Generally the outer diameter of pulleys used with A type belts should be no less than 3 5 in 90 mm while the pulley O D minimum 15 4 in 101 6 mm with B style belts There are exceptions to these recommendations which should be reviewed with belt manufacturers The average O D of drive pulleys used on Kohler engines is 4 in 101 6 mm Belt Speed Is calculated as the circumference of a pulley times its revolutions per minute For a 6 in diameter 0 5 ft the circumference is figured as 3 1416 x 5 1 57 If the belt speed in this example is 500 RPM multiply 500 x 1 57 which equals 785 feet pe
221. belts with smaller cross section which improves efficiencies Check the belt supplier s specifications for help in designing the V belt drive Generally A type belts and pulleys with outer diameters of at least 3 6 in 90 mm or B type pulleys with outer diameters of 4 8 in 120 mm are used on Kohler engine applications See belt selection data in Section 5 Technical Guidelines Inside location preferred Figure 2 1 Pulley Drive System V belts must be kept perfectly aligned between the engine and load Belt tension should be set to the belt supplier s specifications which in general is about 1 64 in 0 396 mm deflection per inch at midpoint in the span Misalignment contributes to shaft stress and premature wear on belts Refer to V belt Drive data in section 5 for tension formula To avoid stressing the crankshaft and bearings keep the pulley from extending beyond the end of the shaft See Figure 2 2 Do Not Extend Pulley Beyond End of Shaft Crankshaft Figure 2 2 Pulley Location on Shaft When a pulley is installed on a front PTO extension make sure the pulley does not restrict cooling air entering the air intake or grass screen Keep it away from the screen but not too far where it would place stress on the crankshaft and front bearing A minimum clearance of 2 in 50 8 mm is needed for a 4 in 101 6 mm diameter pulley Engine application testing is required if this clearance is not available or i
222. ble Starter 4 Place the brake washer in the recess in starter 7 Tension the spring and install the rope and pulley over the center shaft handle as instructed in steps 6 through 12 under Rope Replacement on page 7 2 5 Lubricate the brake spring sparingly with erease Place the spring on the plain washer 8 Install the starter to the engine blower housing Make sure the threads in the center shaft remain as instructed in To Install Starter on page 7 1 clean dry and free of grease and oil 6 Apply asmall 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 screw to 7 4 8 5 N m 65 75 in Ib 7 5 Section 7 Retractable Starter 7 6 Section 8 Electrical System and Components This section covers the operation service and repair of the electrical system components Systems and components covered in this section are Spark Plugs Battery and Charging System Electronic Ignition Systems CD and DSAI Electric Starter Spark Plugs Engine misfire or starting problems are often caused by a spark plug that has improper gap or is in poor condition The engine is equipped with the following spark plugs Type The standard spark plug is a Champion RC12YC Kohler Part No 12 132 02 5 RFI compliant engines use a Champion XC12YC Kohler 25 132 14 5 spark plug A high performance spark plug Champion Pla
223. ced through cooling fins around the cylinder of an air cooled engine or by a water jacket on the water cooled engines If the cylinder is inadequately cooled the oil tem perature tends to run high and will break down in thering section causing ring sticking and excessive carbon and varnish buildup Providing a blower for cooling air requirements of an engine whether it be air cooled or radiator cooled ordinarily takes from 596 to 1096 of the available engine power LUBRICATION A very thin film of oil is adequate to lubricate cylinder walls The rings are designed to scrape excess oil from the walls and prevent passage of excessive amounts to the combustion chamber Gasoline and Diesel engines are lubricated to some extent on the upper portion of the cylinder by the fuel itself When operating on gaseous fuels such as propane and natural gas some engines run so dry that a top oiler must be added for providing suffi cient lubrication for the upper end of the piston travel The connecting rod bearings are critical parts of the engine High and varying pressures and high rotat ing speeds make the lubrication job at this point important In splash lubricted engines the oil must find its way into the bearing surface through drilled holes or grooves after being picked up as droplets during the rotation of the crank and connecting rod The simplicity of a splash lubrication system is desir able on smaller engines in order to ke
224. cent windings inducing an EMF which creates another surge of current that is many times greater than the original current induced by the magneto Increasing Current O Decreasing Current Self Inductance In order to create the high voltage necessary to jump the spark gap still another form of inductance is utilized If we place a second set of windings in close proximity to the primary windings the self induced magnetic field surrounding the primary also cuts the secondary windings and an EMF is built up in those windings through mutual inductance In a typical ignition coil there may be as many as 100 secondary windings for each primary winding If we allow the current in the primary windings to reach a maximum value and then break the circuit the self induced field around each winding will collapse and cut all of the corresponding secondary windings Since there are 100 times as many windings in the secondary the voltage imposed in the secondary can be up to 100 times greater than the voltage in the primary For example if the voltage in the primary reaches 200 volts the voltage in the secondary could go as high as 20 000 volts Secondary Coil Windings Primary Coil Mutual Inductance Current in the primary windings will reach its maximum value at the instant that the magnetic flux changes direction within the stator core This is the point at which ignition should take place so we get optimum output f
225. ck compression If engine continues to start hard run roughly or stall after these checks have been made use the following troubleshooting guide Engine cranks but will not start 1 LPG fuel tank closed low or empty 2 Lock off not opening electrically preventing fuel flow to vaporizer 3 Fuel filter located inside lock off dirty or blocked 2 4 Insufficient vacuum signal regulator not opening a Vacuum line between carburetor and regulator cracked leaking kinked or pinched b Carburetor loose c Intake manifold loose or leaking d Excessive internal engine wear 5 Faulty regulator a Primary valve not opening b Diaphragm spring adjustment incorrect c Idle adjustment screw incorrectly set d Vent s blocked restricted 6 Restricted blocked fuel line Blocked carburetor fuel circuit 8 Loose leaking fuel enrichment hose Impco carburetor system pa Hard starting runs roughly or stalls at idle speed 1 LPG fuel tank low 2 Vacuum line between carburetor and regulator pinched cracked or leaking 3 Carburetor idle speed set too low should be at least 1200 RPM 4 Carburetor idle circuit restricted 5 Dirty restricted air cleaner 6 Dirty restricted lock off filter 7 Frozen malfunctioning regulator Check adjust primary pressure 8 Excessive external load on engine 9 Excessive internal wear 10 Loose leaking fuel enrichment hose Impco carburetor system Irregular or in
226. clearance to specifications listed in Section 1 If the side clearance is greater than specified a new piston must be used Refer to Figure 10 10 10 10 Figure 10 10 Measuring Piston Ring Side Clearance Install New Piston Rings To install new piston rings proceed as follows NOTE Rings must be installed correctly Ring installation instructions are usually included with new ring sets Follow instructions carefully Use a piston ring expander to install rings see Figure 10 11 Install the bottom oil control ring first and the top compression ring last Refer to Figure 10 12 Piston Ring 7 LES 1 en gt k pt Piston E Expander Figure 10 11 Installing Piston Rings Piston Ring End ia Identification Mark Top Compression Center Compression Ring a Expander Oil Control Ring Three piece Figure 10 12 Piston Ring Installation 1 Oil Control Ring Bottom Groove Install the expander and then the rails Make sure the ends of expander are not overlapped 2 Middle Compression Ring Center Groove Install the center ring using a piston ring installation tool Make sure the identification mark is up or the dykem stripe if contained is to the left of the end gap 3 Top Compression Ring Top Groove Install the top ring using a piston ring expender Make sure the identification mark is up or the dykem s
227. connections and system external Load Block assembly which controls the components for leaks with soapy water Fix any final fuel flow to the carburetor for all throttle leaks immediately positions except idle See Figure 5A 2 Calibrated and 2 Incorrectly set regulator or leakage from valves flow matched to the carburetor it functions similarly in regulator Readjust service or replace to preset fuel mixture settings in other carburetors regulator as required The load block assembly is not available separately 3 Dirty air cleaner or precleaner nor is any internal servicing permitted or possible If a 4 Choke plate in carburetor not opening problem is encountered and determined to be caused completely by the load block the carburetor should be replaced 5A 3 Section 5A LPG Fuel Systems High Altitude Operation The standard carburetor calibrations will provide proper operation up to altitudes of 1500 m 5000 ft No internal changes are necessary or available for either carburetor NOTE Carburetor adjustments should be made only after the engine has warmed up Idle Speed Adjustment 1 Start the engine and run at half throttle for 5 to 10 minutes Check that the throttle and choke Nikki carburetor plates can open fully 2 Place the throttle control into the idle or slow position Turn the low idle speed adjusting screw See Figure 5A 2 or 5A 3 in or out to obtain a low idle speed of 1200 RPM 75 RPM
228. consistent idle 1 Improper operation adjustment of regulator idle adjustment screw throttle opening and or engine governor 2 Secondary valve in regulator not closing Readjust idle screw couterclockwise so valve can close fully against seat 3 Loose leaking vacuum line 4 Loose carburetor mounting and or line connections 5 Damaged diaphragm s within regulator 6 Debris in regulator Flush debris from drain plug or remove regulator from system disassemble body and remove debris 7 Dirt or debris in carburetor Remove carburetor disassemble and clean service as required If venturi Impco carburetor removal is performed mark its orientation to the carburetor body for proper reinstallation 8 Loose leaking fuel enrichment hose Impco carburetor system Section LPG Fuel Systems Engine stalls during operation LPG Carburetor Adjustments 1 No fuel 2 Faulty lock off or blocked filter General 3 Improper governor setting The LPG carburetor and regulator are designed to 4 Damaged diaphragms within regulator deliver the correct fuel to air mixture to the engine 5 Vacuum line leaking loose or pinched under all operating conditions The high and low idle 6 Restricted fuel line fuel mixture settings are preset at the factory and 7 Loose leaking fuel enrichment hose Impco cannot be adjusted These engines are equipped with carburetor system an Impco or Nikki carburetor See Figure 5A 2 and 5A 3 Although
229. ctions covering the theory of operation and general service information for each style of regulator Detailed service repair instructions are included in the rebuild kit for each regulator 5A 9 Section 5A LPG Fuel Systems Impco Beam Regulator See Figure 5A 20 LPG vapor enters at point A then passes into primary area B at point 28 where pressure is reduced from up to 250 psi at the tank to 4 5 psi in area B Fuel pressure against diaphragm 2 overcomes spring 3 and as movement increases spring 5 will close lever 6 The primary diaphragm breather not shown in drawing is vented to secondary chamber so that rupture of this diaphragm would direct fuel into the carburetor Fuel now moves through passage E past secondary valve 25 into secondary area C As negative pressure vacuum is created at the carburetor venturi and is transmitted through the dry gas hose to chamber C secondary diaphragm 12 is drawn down and contacts the secondary lever 16 Fuel will flow in proportion to air velocity through the carburetor venturi ensuring an ideal mixture at all engine speeds Whenever the engine is operating the vacuum diaphragm 10 is down against the floor H and the spring 11 is compressed The idle and starting 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
230. d earlier 2 Remove the hex flange screws securing the bracket and base See Figures 4 9 and 4 10 Remove the bracket Figure 4 10 Rear Mounting Screws Used with 3 Pinch the sealing collar on the breather hose and Plastic Intake Manifold push it down through the hole in the air cleaner base Carefully feed the upper section of the breather tube down through the base See Figure 4 11 4 Remove the base and gasket 5 Reverse the procedure to reinstall new or serviced components Torque screws to 9 9 N m 88 in Ib Heavy Duty Air Cleaner General The heavy duty air cleaner consists of a cylindrical housing typically mounted to a bracket off the upper valve cover screws and connected with a formed rubber hose to an adapter on the carburetor or throttle body intake manifold EFI units The air cleaner housing contains a paper element and inner element designed for longer service intervals The system is CARB EPA certified and the components should not be altered or modified in any way Figure 4 11 Breather Tube Air Cleaner Components Whenever the air cleaner cover is removed or the paper element or precleaner are serviced check the following 4 4 Section 4 Air Cleaner and Air Intake System 4 Do not wash the paper element and inner element or use compressed air this will damage the elements Replace dirty bent or damaged elements with new genuine Kohler elements as required Handle the new elements c
231. d more than 20 in 50 8 cm above the fuel inlet the pressure could exceed the pressure of the float valve causing the carburetor to overflow Install a fuel flow regulator to prevent this See Figure 3 11 Gravity Feed Limits 3 in 76 2 mm Minimum 20 in 50 8 mm Maximum Remote Tank Carburetor Fuel Inlet Fuel Shutdown Solenoid Figure 3 11 Gravity Feed System With Remote Tank 18 Fuel Lift System If the engine is equipped with a mechanical fuel pump the tank can be located below the carburetor but not more than 3 ft 91 44 cm below the fuel pump An electric fuel pump is available to provide maximum suction up to 10 ft 3 048 m Refer to the Kohler Engine Accessories Catalog If a vacuum pulse pump is used the maximum lift is 18 in 45 7 cm Operation of vacuum pulse pumps is affected by altitude diminished performance will be experienced at higher elevations Fuel Pump Inlet Remote Tank With Mechanical Pump Figure 3 12 Fuel Lift Limits with a Mechanical Fuel Pump Fuel Lines Keep fuel lines as short as possible maximum 10 ft 3 048 m avoid kinks and loops in the lines Route fuel lines along the bottom of the engine compartment away from all high temperature components The fuel lines must be a minimum of 1 4 in 6 35 mm inside diameter and be of high quality material meeting SAE specifications for fuel lines An in line fuel filter is recommended especially in extremely dusty a
232. d on the valve face Thoroughly clean the cylinder head in soap and hot water to remove all traces of grinding compound After drying the cylinder head apply a light coating of SAE 10 oil to prevent rusting Intake Valve Stem Seal These engines use valve stem seals on the intake valves Always use a new seal when the valves are removed from the cylinder head The seals should also be replaced if deteriorated or damaged in any way Never reuse an old seal Pistons and Rings Inspection Scuffing and scoring of pistons and cylinder walls occurs when internal engine temperatures approach the welding point of the piston Temperatures high enough to do this are created by friction which is usually attributed to improper lubrication and or overheating of the engine Normally very little wear takes place in the piston boss piston pin area If the original piston and connecting rod can be reused after new rings are installed the original pin can also be reused but new piston pin retainers are required The piston pin is included as part of the piston assembly if the pin boss in the piston or the pin are worn or damaged a new piston assembly is required Section 10 Inspection and Reconditioning Ring failure is usually indicated by excessive oil Detonation damage occurs when a portion of the fuel consumption and blue exhaust smoke When rings charge ignites spontaneously from heat and pressure fail oil is allowed to enter the combust
233. d to Kohler Co Engine Warranty Kohler WI 53044 for payment 2 f the customer is willing to wait for a warranty decision prior to having the services performed complete a Warranty Claim and an Engine Inspection Data Record Have your Central Distributor representative review the failed parts Warranty Claim and Engine Inspection Data Record If the claim is approved have the representative note authorization for the repair perform the repair and send the completed Warranty Claim and Engine Inspection Data Record to Kohler Co Engine Warranty Kohler WI 53044 for payment 3 If the customer insists on a decision by Kohler Co complete an Engine Inspection Data Record and a Warranty Claim Check the DISPUTED WARRANTY box at the top of the claim Contact the Kohler Service Department for an EWR Number This number should be placed on the outside of the return carton Send the completed Warranty Claim Engine Inspection Data Record and the relevant engine parts freight prepaid to Kohler Co Engine Warranty Disputed Claim Bldg 604 Kohler WI 53044 NOTE If you are located outside the continental U S send only the completed Warranty Claim and Engine Inspection Data Record to Kohler Co Engine Warranty Kohler WI 53044 If the failed parts are needed to make the warranty decision Kohler Co will contact you with specific instruction concerning the return of the failed parts 4 f a customer insists on w
234. dard idle speed setting for EFI engines is 1500 RPM but certain applications might require a different setting Check the equipment manufacturer s recommendation Section 5B EFI Fuel System For starting and warm up the ECU will adjust the fuel and ignition timing based upon ambient temperature engine temperature and loads present In cold conditions the idle speed will probably be higher than normal for a few moments Under other conditions the idle speed may actually start lower than normal but gradually increase to the established setting as operation continues Do not attempt to circumvent this warm up period or readjust the idle speed during this time The engine must be completely warmed up for accurate idle speed adjustment Adjustment Procedure 1 Make sure there are no fault codes present in the ECU memory 2 Start the engine and allow it to fully warm up and establish closed looped operation approximately 5 10 min 3 Place the throttle control in the idle slow position and check the idle speed with a tachometer Turn the idle speed screw in or out as required to obtain 1500 RPM or the idle speed specified by the equipment manufacturer 4 Thelow idle speed adjustment can affect the high speed setting Move the throttle control to the full throttle position and check the high speed Adjust as necessary to 3750 RPM no load or the speed specified by the equipment manufacturer Idle Speed Screw Dampening
235. de from the test plug This gives spark gap of 13 This large gap simulates the spark required under actual engine conditions Make a lead assembly using a large spring clip an alligator clip and 18 gauge wire as shown Cut off a 1 1 4 length of 1 2 D fuel line and slide it onto the threads of the test plug It will help to shade the firing tip to make the spark more visible 1 2 D Fuel Line Ignition System Tester 1 1 4 Long 18 GA Clip Ignition System Tester Single Cylinder Engines Remove Ground Electrode 008 012 Ignition Module Magnet Kill Switch or Off Position Flywheel Of Keyswitch High Tension High Tension Testing Module Secondary Single Cylinder Engines Troubleshooting Twin Cylinder The Magnum twin cylinder ignition system consists of the following components A magnet assembly which is PERMANENTLY affixed to the flywheel Coil e An electronic magneto ignition module which is Laminations A Assembly mounted to the 1 side cylinder barrel kill switch or Keyswitch which stops the engine by grounding the ignition module Solid State Ignition System Twin Cylinder Engines 18 Troubleshooting Guide Twin Cylinder The following guide will help locate and correct ignition system related starting problems PROBLEM TEST CONCLUSION 1 Make sure spark plug leads are connected to spark plugs
236. der 1 Cylinder 2 Make o BD o Number _____________ _ ___ __ SECTION 2 EVALUATION PERFORMED BY Evaluator Date Company Name Address City VALVES Stuck Face Burned Bent Guide Worn Not Damaged CLEARANCE COLD Intake Exhaust CONNECTING ROD Discolored Broken Bearing Scored Cap Screws Loose Dipper Bent Dipper Broken Rod Seized to Crankpin Rod OK Not Damaged Type of Acct 1 Central Distributor Ll Expert Dealer 1 Service Dealer TEAR DOWN ANALYSIS CYLINDER 1 CYLINDER 2 Exhaust CYLINDER 1 CYLINDER 2 PISTON RINGS CYLINDER 1 CYLINDER 2 in Service Rings __ tu CYLINDER 1 CYLINDER 2 Rings Free in Grooves L8 0 Rings Stuck in Grooves _ __ __ E __ in E i in in __ o BD a e 0 Note For Crankshaft Pistons amp Cylinder Bore Measurements 2 Continued on page 3 18 Tear Down Analysis continued CRANKSHAFT ROD JOURNAL CYLINDER 2 Unmeasureable LJ Not Damaged LJ Others Maximum Wear Spec CYLINDER 2 MAX OUT OF ROUND Left ___ _ _____ Middle Right PISTON Select the following piston type and measure diameter using appropriate method Style e B Style C SOS C OGO
237. draw the spring retainer up around the retaining ring Stop turning when resistance increases Disassemble and remove tool Reinstall the dust cover Starter Disassembly 1 8 32 Remove the drive components following the instructions for servicing the drive Locate the small raised line on the edge of the drive end cap On starters with Style commutator end caps it will be aligned with a premarked line on the starter frame The frame is not premarked on starters with Style B end caps Place a piece of masking tape on the frame and mark a line on the tape in line with the raised line on the end cap See Figure 8 45 Remove the thru bolts Remove the commutator end cap with brushes and brush springs Style Style B end caps remove as a separate piece with the brushes and carrier remaining in the frame Remove the drive end cap Remove the armature and thrust washer if so equipped from inside the starter frame Remove the brush carrier assembly from the frame Style B starters Style A End Cap Brush Replacement 1 Remove the brush springs from the pockets in the brush holder See Figure 8 43 Remove the self tapping screws negative brushes and plastic brush holder Remove the hex flange nut and fiber washer from the stud terminal Remove the stud terminal with the positive brushes and plastic insulating bushing from the end cap Install the insulating bushing
238. drive lubricant see Section 2 Position the fork end into the space between the captured washer and the rear of the pinion 6 Slide the armature into the drive end cap and at the same time seat the drive lever into the housing NOTE Correctly installed the center pivot section of the drive lever will be flush or below the machined surface of the housing which receives the backup washer See Figure 8 67 Figure 8 67 Installing Armature and Pivot Lever Section 8 Electrical System and Components Install the backup washer followed by the rubber erommet into the matching recess of the drive end cap The molded recesses in the grommet should be out matching and aligned with those in the end cap See Figure 8 68 Figure 8 68 Installing Backup Washer and Grommet 8 Install the frame with the small notch forward onto the armature and drive end cap Align the notch with the corresponding section in the rubber grommet Install the drain tube in the rear cutout if it was removed previously See Figure 8 69 Figure 8 69 Installing Frame and Drain Tube 9 Install the flat thrust washer onto the commutator end of the armature shaft See Figure 8 70 8 41 Section 8 Electrical System and Components Figure 8 70 Installing Thrust Washer Figure 8 72 Removing Retaining Clips 10 Starter reassembly when replacing the Brushes b Position each of the brushes back in their slots Brush Holder
239. e 2 For plastic cased ECU s below 24 584 28 5 the system can be primed by manually cycling the fuel pump 58 2 a Turn the key switch to the on run position The 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 The system can also be primed similar to relieving pressure a Connect the pressure gauge as described above for relieving fuel pressure Depress and hold the release button and crank the engine until the air is purged and fuel is visible in the discharge tube If fuel is not visible after 10 seconds stop cranking and allow the starter to cool for 60 seconds Priming Without a Test Valve in Fuel Rail 1 Crank the engine in 10 15 second intervals allowing a 60 second cool down period between cranking intervals until the engine starts NOTE The number of cranking intervals necessary will depend on the individual system design and or where the system has been disassembled Fuel Recommendations General Recommendations Purchase gasoline in small quantities and store in clean approved containers An approved container with a capacity of 2 gallons or less with a pouring spout is recommended Such a container is easier to handle and helps prevent spillage during refueling e Do not use gasoline left over from the previous season to minimize gum depo
240. e Safety Input V 88 7 PIENE ET a U Violet Be white Flywheel Stator Rectifier Regulator the release signal to the capacitor On some models a microprocessor 15 used to automatically adjust the spark timing to the speed of the engine to provide the best possible combination of power and fuel efficiency Do not connect 12 volts directly to the ignition modules as this could burn the modules out Excessive load on the ground kill circuit some types of safety switches semiconductor circuits etc can affect the performance of CD ignition systems Contact your Kohler Engine representative to discuss Carburetor Solenoid Oil Pressure 4 EB Ignition Modules pa Spark Plugs For Customer Connected Tractor Applications Figure 3 8 Electronic CD Ignition System Schematic 16 Solenoid Bendix Starter Oil Sentry Kill Accessories Key switch Indicator Fuel Shut off Solenoid Optional Oil Sentry Shutdown Switch Figure 3 9 15 amp Stator and Rectifier Regulator Section 3 Properly Installing the Engine Solenoid Shift Starter ga Optional Ammeter Ground to Kill White Rectifier Regulator Flywheel Stator Safety Advisory Kohler Co offers low oil and high temperature switches which can be used to shut the engine down or trigger a warning signal Do not use the shutdown feature on mobile applications use a light or audible warning in
241. e such as going up a mountain there is a decrease in barometric pressure and a proportionate decrease in engine horsepower Horsepower decreases 3 5 for each 1000 feet above sea level This reduction must be taken into account if the engine is to be used at higher elevations 3 Effects of Temperature Engines are rated at 60 F Increased temperatures to the carburetor will cause a predictable loss of power m Horsepower decreases 1 for every 10 above 60 Allow for higher carburetor inlet temperatures than 60 F due to operating conditions 4 Transmission Efficiencies Types of Drives Power is taken from engines either by means of coupling directly to the crank shaft or by means of belt and pulley or chain and sprocket types of drive If the equipment is direct coupled the type of coupling and the alignment between the engine shaft and equipment shaft is important If it is direct coupled with a solid coup ling alignment must be kept within a few thou sandths ofan inch Ifa flexible type coupling is used some additional misalignment can be allowed but if the misalignment is excessive and the coupling flexes to a considerable degree it is possible to lose much engine power right in the coupling When using V belt drives it is important that the size of the drive pulley and belt be suitable for the amount of power being transmitted Many times it is necessary to use several V belts on the l
242. e Figure 11 2 Section 11 Reassembly Figure 11 2 Installing Oil Seal Figure 11 4 Installing Governor Cross Shaft Hitch Pin 6 mm Shaft Install Governor Cross Shaft 1 Lubricate the governor cross shaft bearing surfaces in the crankcase with engine oil 2 Slide the small lower washer onto the governor cross shaft and install the cross shaft from the inside of the crankcase 3 6mm Governor Shaft Install the plain washer and then insert the hitch pin into the smaller lower hole of the governor cross shaft See Figures 11 3 and 11 4 8 mm Governor Shaft Install the 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 retaining ring down the shaft to secure Remove the feeler gauge which will have established the proper end play See Figures 11 5 and 11 6 Figure 11 6 Setting Governor Cross Shaft End Play 8 mm Shaft Install Crankshaft 1 Carefully slide the flywheel end of the crankshaft through the main bearing in the crankcase See Figure 11 7 Figure 11 3 Installing 6 mm Governor Cross Shaft Section 11 Reassembly 2 Lubricate the cylinder bore piston and piston rings with engine oil Compress the rings of the 1 piston using a piston ring compressor 3 Lubricate the crankshaft journals and connecting rod bearing surfaces with engine oil 4 Ma
243. e actual engine and shipping costs this documentation can either be attached to the online warranty form or faxed to Kohler at 920 459 1743 Warranty claims authorized by Expert Dealers must be submitted online with a copy of the claim going to the appropriate Central Distributor representative Note An engine or short block replacement may be done in advance of the needed preapproval as long as the customer is aware that they may be responsible for the repair cost depending on the findings by Central Distributor or factory representative E Carburetor Warranty Replacement Warranty claims for carburetor replacements must include the use of the Carburetor Replacement Evaluation Form TP 2570 shown on page 30 This form must be filled out each time a warranty claim is submitted for a replacement carburetor Hard copies of this form can be made and submitted along with the paper claims or an electronic version of the form can be completed online and submitted as an attachment with the online warranty claim form Any claims submitted without this form attached will be returned F Retaining Failed Parts claim number is imprinted on each Warranty Claim Report Tag all parts replaced under a particular warranty claim with the corresponding claim number and keep those parts until you have received your warranty reimbursement Kohler Co may request return of some parts for study but if specific instructions are not given prior to receipt
244. e air cleaner The wire does not compress under the clamps preventing a good seal and allowing unfiltered air to enter at the joints E Major Components The cylinder crankcase crankshaft connecting rod and piston assembly are usually considered to be the major components of an engine They are the parts that confine the energy of combustion and transmit the power of that energy to the piece of equipment to perform work Because of the tremendous forces and stresses they must withstand they are the components with the most critical running tolerances They are also the components most subject to failure Figure 36 Figure 36 Be careful when disassembling the major components so you do not disturb or destroy any critical evidence Leave the parts in their original state as much as possible until the failure analysis procedure has been completed Do not clean anything unless it is necessary to make an accurate inspection IV Analyzing the Failure A Pistons and Rings Figure 37 Figure 37 Problems relating to the piston and rings will usually fall into one of two categories excessive wear or piston seizure Figure 38 Figure 38 Excessive wear can often be detected visually even before any measurements are taken From normal operation the wear pattern on the thrust face of a piston will cover about 20 40 of the face If it cover 50 or more with visible vertical scratches you know there has
245. e air cleaner cover Secure the cover with the two latches or the retaining knob Element Cover Wing Nut Precleaner Figure 4 7 Removing Rubber Seal from Bracket Paper Element Service Standard 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 cover AUR MEN i NF 2 Remove the wing nut element cover and paper element with precleaner if so equipped et E 5 5 m ne E E wm er cl Mir ee 4 a ip n d 3 Remove the precleaner if so equipped from the paper element Service the precleaner as described in Precleaner Service Figure 4 5 Removing Element Cover Wing Nut 4 Do not wash the paper element or use pressurized air as this will damage the element Replace a dirty bent or damaged element with a genuine Kohler element Handle new elements carefully do not use if the sealing surfaces are bent or damaged 4 2 Section 4 Air Cleaner and Air Intake System 5 Check the seal for any damage or deterioration 7 Reinstall the air cleaner cover and secure with the Replace as necessary See Figure 4 7 latches or the retaining knob 6 Reinstall the seal paper element precleaner NOTE Make sure the correct depth air cleaner element cover and wing nut element and rubber seal are used f
246. e black remove them both and discard 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 Refer to the chart on page 8 10 to identify which ignition module s you have If they are the smaller style check the vendor part number on the face All modules with vendor part numbers MA 2 MA 2A or MA 2B Kohler Part No 24 584 03 should be replaced with 24 584 11 or 24 584 15 S For small modules with vendor numbers MA 2C or MA 2D Kohler Part No 24 584 11 or the larger style modules 24 584 15 5 and 24 584 36 5 use a digital ohmmeter to check the resistance values and compare them to the table following When testing resistance to the laminations touch the probe to the laminations inside the screw hole as some laminations have a rust preventative coating on the surface which could alter the resistance reading a If all of the resistance values are within the ranges specified in the table go to step 5 b If any of the resistance values are not within the ranges specified in the table that module is faulty and must be replaced NOTE The resistance values apply only to modules that have been on a running engine New service modules may have higher resistance until they have been run Ignition Module Resistance Table 24 584 03 or 24 584 11 1 11 46 in H 24 584 03 24 584 11
247. e clearance was too tight causing the stress and failure of the connecting rod Notice that the rod bolt is sheared Figure 86 Figure 86 This connecting rod shows multiple breaks The break in the middle of the beam was a secondary break in other words it occurred after the rod seized to the crankshaft The bearing surface indicates that the initial seizure was from insufficient lubrication Figure 87 Figure 87 Sometimes you may only have a small amount of evidence to look at to make a determination as to what happened This lower rod cap shows some peening and shifting This could have been caused by a loose rod bolt Again you have to look for other signs and or ask questions of the owner and or of the engine itself In this case the unit had plenty of lubrication The failure occurred shortly after an overhaul by a service technician who forgot to torque the rod bolt to proper specifications 23 Figure 88 Figure 88 This is head assembly from a Command Engine Notice the heavy carbon deposit on the face of the head and valves The combustion deposits appear to be wet or shiny This is an indication that excessive oil was entering the combustion chamber Figure 89 Figure 89 This is a close up of a Command head gasket Notice the RTV sealant around the return passages Someone wanted to get a positive seal between the head and block and applied RTV This is not necessary if the surface areas
248. e connections for poor contact moisture or corrosion If no continuity was found in the first test also check for a poor broken ground path back through the exhaust system engine and mounting sensor is grounded through its shell b If continuity is indicated go to step 6 With the key switch in the on run position using a high impedance voltmeter check the voltage from the wiring harness oxygen sensor connector to the engine ground location Look for a steady voltage from 350 550 mv 0 35 0 55 v a If voltage reading is not as specified move the black voltmeter lead to the negative post of the battery to be certain of a good ground If the voltage is still not correct the ECU is probably bad b If voltage readings are correct clear the fault codes and run the engine to check if any fault codes reappear To Replace Oxygen Sensor 1 Disconnect the oxygen sensor connector from wiring harness Loosen and remove the oxygen sensor from the exhaust manifold muffler assembly Apply anti seize 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 Ib Reconnect the lead to wiring harness connector Make sure it can not contact hot surfaces moving parts etc Test run the engine Section 5B EFI Fuel System Electrical Relay Figure 5B 13 Electrical Relay Gener
249. e equipment owner s manual should emphasize this OEM Sizing Where the spline drive is the primary means of power transmission sizing of the drive system should be restricted as follows 9 Tooth Max 15 HP Engine Output 11 Tooth Max 20 HP Engine Output 13 Tooth Max 35 HP Engine Output In engine families where the model range crosses these limits it is advisable to select the larger sized drive system Flexible Couplings are preferred for most direct coupled applications because they tolerate some minor axial and angular misalignment Even with flexible couplings however it is important to maintain the best possible alignment to reduce the load on the coupling and or to avoid strain on the crankshafts and bearings Axial Misalignment Angular Misalignment Correct Alignment Figure 2 5 Flexible Coupling Belt Loading via Crankshaft There are many components to be considered in a belt drive system In order to perform a thorough analysis full documentation should be provided to Kohler Co Application Engineering Department The following guidelines should be observed A Where the centerline of the main drive pulley is more than 2 5 in 65 mm from the cylinder block a belt load review is required by Kohler Co B Where an electric clutch is used to drive a commercial mower deck a PTO bearing insert is required C Commercial Mowers utilizing engines of 18 HP amp over should use crankshafts of 1 125 in
250. e following procedure to accurately measure the piston to bore clearance 1 Use a micrometer and measure the diameter of the piston 6 mm 0 24 in above the bottom of the piston skirt and perpendicular to the piston pin See Figure 10 4 6 mm 0 24 in Measure 6 mm above the Bottom of Piston Skirt at Right Angles to Piston Pin Figure 10 4 Measuring Piston Diameter 2 Use an inside micrometer telescoping gauge or bore gauge and measure the cylinder bore Take the measurement approximately 63 5 mm 2 5 in below the top of the bore and perpendicular to the piston pin 10 4 3 Piston to bore clearance is the difference between the bore diameter 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 crankshaft and the key if flywheel key is sheared or the keyway is damaged Inspect the ring gear for cracks or damage Kohler does not provide the ring gear as a serviceable part Replace the flywheel if the ring gear is damaged Cylinder Head and Valves Inspection and Service After cleaning check the flatness of the cylinder head and the corresponding top surface of the crankcase using a surface plate or piece of glass and feeler gauge as shown in Figure 10 5 The maximum allowable out of flatness is 0 076 mm 0 003 in Figure 10 5 Checking Cylind
251. e good sudsing action This way you can be certain that the machining oil is broken down to allow complete removal of the grit particles from the pores of the iron 13 Figure 48 Figure 48 On single cylinder block also be certain to clean and flush out the oil drain hole which goes from the valve chamber into the cylinder Figure 49 Figure 49 Piston seizure is also visually obvious but it can be a little more difficult to analyze There are a number of possible causes but the appearance doesn t vary much from one to another Possible causes include overheating from insufficient cooling air lack of lubrication insufficient running clearance oil additives and contamination or foreign material in the engine This is one instance where your preliminary examination may be very helpful Did you find dirty thick oxidized oil in the engine Was the cooling system restricted You may also find other indicators on other portions of the seized piston 14 Figure 50 Figure 50 The scoring on a seized piston is sometimes just on the primary thrust face Look at the opposite thrust face and the sides for other possible indicators Figure 51 Figure 51 This piston shows evidence of overheating Notice the dark brown deposits as well as the blackened area near the wrist pin This is severely overheated oil starting to bake Your next challenge would be to see what is causing this condition Figu
252. e is induced in the primary windings of the module When the primary voltage is precisely at its peak the module induces a high voltage in its secondary windings This high voltage creates a spark at the tip of the spark plug igniting the fuel air mixture in the combustion chamber The timing of the spark is automatically controlled by the module Therefore no ignition timing adjustments are necessary or possible with this system 3 COMBUSTION Contrary to most opinions combustion is not an explosion or a simultaneous burning of all parts of the fuel and air mixture Desired engine combustion is a progressive burn ing of the fuel and air mixture The flame starts at thespark plug and travels in all directions from that point It can beinfluenced by extreme turbulence of the fuel and air mixture Researchers have actually photographed this flame front at various stages as it proceeds across the combustion chamber As the flame travels heat is generated and gaseous products of combustion are released A rapid build up of pressure results This pressure is also built up on the forward side of the flame in the fuel and air mixture which the flame has not yet reached The pressure and temperature of this forward part of the mixture may reach the point where it is ignited by itself similar to Diesel ignition A very rapid buildup of temperature and pressure is produced and combustion becomes uncontrolled Ignition of the charge i
253. e of the cylinder head The second type had a black O Ring installed in a groove on the underside of the cover and may have metal spacers in the bolt holes The latest 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 n brackets or lifting straps Figure 9 42 Removing Breather Cover 2 Remove the valve covers valve cover gaskets or O Rings and any brackets or lifting straps Note 6 Remove the breather filter from chamber See which side of the engine has the oil fill and or fuel Figure 9 45 pump valve cover See Figure 9 45 Figure 9 43 Removing Breather Filter Figure 9 45 Removing Valve Covers 9 11 Section 9 Disassembly Remove Ignition Modules 3 Leave the wiring harness attached to the 1 Disconnect the lead s from each ignition manifold module See Figure 9 46 Modules for non SMART SPARK ignition systems have only Aluminum kill lead Intake Manifold Figure 9 46 Disconnecting Leads from Ignition Modules 2 Rotate the flywheel so the magnet is away from the modules 3 Remove the mounting screws and ignition modules Note the position of ignition modules Two Barrel 2 Intake Manifold Figure 9 47 Position of SMART SPARK Ignition Module Figure 9 48 Removing Intake Manifold Remove Intake Manifold 1 Remove the four hex flange screws secur
254. e screwdriver turn adjusting ring clockwise one notch at a time until firm pressure is required to engage clutch See Figure 12 2 Adjusting ring is spring loaded and does not have to be loosened before adjustment is made Do not attempt to pry or force spring lock away from the ring Reverse procedure for reassembly Adjust and lubricate following previous instructions Spring Lock Figure 12 2 Adjusting Clutch 12 2 ENIGSINES LITHO IN U S A FOR SALES AND SERVICE INFORMATION IN U S AND CANADA CALL 1 800 544 2444 1P24 690 06 ENGINE DIVISION KOHLER KOHLER WISCONSIN 53044 6 50531 99104 1 KohlerEngines com ENGINE OPERATION OF PRINCIPLES N 5871 14 T 8400 3600 3800 4000 i pu NE m co CN am SAYLAW NOLMAN S LLVMOTIIM fRevoLuriows P 2 2 as TP 2209 ENERGY SOURCES Our living standards have improved in direct pro portion to our ability to harness various forms of energy to do our work for us Our first accomplishment was to domesticate and train animals to carry materials and eventually to pull simple machines Later we learned to put flowing water to work for us by means of water wheels Today a portion of the electricity we use in homes and factories is developed from turbin
255. e seat for the inlet needle is not serviceable and should not be removed Figure 5 20 Installing Fuel Bowl 10 Install the carburetor and the heavy duty air cleaner as outlined in Section 11 Reassembly Disassembly Overhaul 1 Clean the exterior surfaces of dirt or foreign material before disassembling the carburetor Remove the four mounting screws and separate the fuel bowl from the carburetor Transfer any remaining fuel into an approved container Remove and discard the old O Rings Fuel can also be drained prior to bowl removal by loosening removal of the bowl drain screw See Figure 5 21 Figure 5 22 Removing Float and Inlet Needle 3 Usean appropriate size flat screwdriver and carefully remove the two main jets from the carburetor Note and mark 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 orientation direction of the nozzles The end with the two raised shoulders should be out down adjacent to the main jets Save the parts for cleaning and Fuel Bowl reuse 5ee Figure 5 23 Bowl Drain Screw Figure 5 21 Fuel Bowl Removed From Carburetor tr Nozzles Main Jets te Figure 5 23 Main Jets and Nozzles Removed 5 15 Section 5 Fuel System and Governor 4 Remove the screw securing the flat washer and eround lead if equipped
256. e testing you may need to ground the kill lead to shut it down Because you have interrupted the kill circuit it may not stop using the switch Test 2 Test for spark 1 With the engine stopped disconnect one spark plug lead Connect the spark plug lead to post terminal of spark tester see Section 2 and attach tester clip to a good engine ground NOTE Iftwo testers are available testing can be performed simultaneously for both cylinders However if only one tester is available two individual tests must be performed The side not being tested must have the spark plug lead connected or grounded Do not crank the engine or perform tests with one spark plug lead disconnected and not grounded or permanent system damage may occur 2 Crank the engine over establishing a minimum of 550 600 RPM and observe tester s for spark 3 Onatwin cylinder engine repeat the spark test on the opposite cylinder if cylinders are being tested individually a If both cylinders have good spark but the engine runs poorly install new spark plugs gapped at 0 76 mm 0 030 in and retest engine performance If problem persists go to Test 3 b If one cylinder had good spark but the other cylinder had no spark or intermittent spark go to Test 3 c If there was no spark or intermittent spark on both cylinders go to Test 4 Section 8 Electrical System and Components Test 3 Check for timing advance Figure 8 8 1 Ma
257. e the governor on a Diesel engine varies the length of time that fuel is sprayed into the cylinder VALVE TIMING amp LIFT Referring again to the four basic strokes in a four stroke cycle engine the opening of the intake valve must begin before the start of the intake stroke During the first part of the valve opening movement is small in comparison with crank angle travel In order to have the valve open a suitable amount by the time the piston starts drawing air in the cylinder the start of the opening of the intake valve must begin before the piston reaches top dead center Then it must open as fast as mechanically possible and far enough to provide the minimum resistance to flow of air through the valve port IC af 4 922770 gt 10b Mille 50 cerner r eXHaust QDEMIO 30 sokor ce EXMAUST COSIIO after top come When the piston approaches bottom dead center air is being drawn in atarapid rate Because the air has inertia the intake valve may be kept open somewhat beyond bottom dead center so the mo mentum of the air into the intake system will tend to pack more air into the cylinder The ideal place to close the intake valve would be at the point where air movement through the intake valve starts to reverse itself In most high speed engines in use today this point will range from 35 to 65 of cran
258. eable assembly If diagnosis indicates a bad sensor complete replacement is necessary If a blink code indicates a problem with the TPS it can be tested as follows 1 Counting the number of turns back out the idle 1 Throttle Valve Shaft speed adjusting screw counterclockwise until 2 Resistor Track the throttle plates can be closed completely 3 Wiper Arm w Wiper 4 Electrical Connection 2 Disconnect the main harness connector from the ECU but leave the TPS mounted to the throttle Figure 5B 6 Throttle Position Sensor Details body manifold General 3 Connect the ohmmeter leads as follows The throttle position sensor 5 is used to indicate See chart on pages 5B 28 5B 31 or 5B 32 throttle plate angle to the ECU Since the throttle by way of the governor reacts to engine load the angle 55 Pin MA 1 7 Metal Cased ECU Red of the throttle plate is directly proportional to the load positive ohmmeter lead to 12 pin terminal on the engine and Black negative ohmmeter lead to 27 pin terminal 24 Pin MSE 1 0 Plastic Cased ECU Red positive ohmmeter lead to 8 pin terminal and Black negative ohmmeter lead to 4 pin terminal 32 Pin MSE 1 1 Plastic Cased ECU Red positive ohmmeter lead to 8 pin terminal and Black negative ohmmeter lead to 4 pin Mounted Throttle terminal Position Sensor Hold the throttle closed and check the resistance It should be 800 1200 Q Figu
259. eaching the combustion chamber b Close the choke on the carburetor c Crank the engine several times If there is no fuel at the tip of the spark plug d Remove the spark plug and check for fuel at check for fuel flow from the fuel tank Test 3 the tip Check for fuel flow from the tank to the fuel If fuel does flow from the line check for faulty pump fuel pump Test 4 a Remove the fuel line from the inlet fitting of fuel pump If fuel does not flow from the line check the b Hold the line below the bottom of the tank fuel tank vent fuel pickup screen in line filter Open the shut off valve if so equipped and shut off valve and fuel line Correct any observed observe flow problem and reconnect the line Check the operation of fuel pump If fuel does flow from the line check for faulty a Remove the fuel line from the inlet fitting of carburetor Refer to the Carburetor portions of carburetor this section b Crank the engine several times and observe flow If fuel does not flow from the line check for a clogged fuel line If the fuel line is unobstructed check for overfilled crankcase and or oil in pulse line If none of the checks reveal the cause of the problem replace the pump 5 2 Fuel Pump General These engines are equipped with either a pulse or mechanical fuel pump See Figures 5 1 and 5 2 The pumping action is created by either the oscillation of positive and negative pressures within the cran
260. eads Full wave Rectifier Figure 2 1 25 Amp Rectifier 26 Troubleshooting Guide 1 25 Amp Unregulated Battery Charging System With Magneto NOTE Always zero meters on each scale before testing to ensure accurate readings 1 Check for and correct poor or corroded connections and broken wires 2 Check condition of battery Make sure it If battery is in poor condition recharge or will accept and hold a charge replace battery If battery is in good condition check for Voltage Test 3 If D C Voltage is low or if no voltage is present check for faulty rectifier or stator Test 4 3 Disconnect B lead from battery With engine running at 3200 RPM measure _ D C voltage from B to ground D C Voltage Lead Specification B GND 12 6 20 4 volts 4a Disconnect stator leads plug from rectifier With engine running at 3200 If A C voltage is within ranges stated and D C voltage measured in test 3 was low or BATTERY RPM measure A C voltage of stator 0 volts NOT across the following leads rectifier is faulty and should be replaced Refer to Figure 2 View If A C voltage is low or 0 volts CHARGING A C Voltage stator is probably faulty Test stator further Lead Specification using an ohmmeter 5 4b Yellow 1 Yellow 2 13 9 23 0 volts Yellow 1 Black 7 3 11 6 volts Yellow 2 Black 7 3 11 6 volts
261. earance Figure 71 Figure 71 If there is a heavy concentration of dirt or the particles are large and abrasive honing grit you may see a dirt trail around the center of the bearing surface The dirt entering through the oil hole gets pounded into the surface of the aluminum leaving a trail around the bearing in line with the hole 19 Figure 72 Figure 72 This connecting rod came from the engine mentioned earlier Figure 47 where the block was not cleaned properly after honing Again note the worn bearing surface with the abrasive trail in line with the oil hole Figure 73 Figure 73 This rod came from another engine that was not cleaned properly prior to rebuilding After only 6 hours of running the crankpin was worn 008 in undersize The rod had started pounding because of the excessive running clearance causing the aluminum to begin smearing The customer became alarmed when the engine started knocking and losing speed Within one more hour of running a total seizure would have occurred 20 Figure 74 Figure 74 The mating surfaces of the connecting rod are the third area that should be inspected The machining marks that you see here are normal They are made by the saw blade when the rod is out Figure 75 Figure 75 Here you cannot see any of the saw blade markings Instead the mating surface has a hammered or peened appearance The rod bolts were not tightened p
262. eck keyswitch wiring for shorts or connections which could apply 12V to kill terminal B Correct those conditions then replace module 4a Measure the primary resistance of module using an ohmmeter NOTE Connect negative lead of ohmmeter to kill terminal B Primary Primary Leads Terminals Resistance A B 1 0 1 5 ohms If resistance is within range module primary is OK Test secondary Test 4b If resistance is within range module secondary is OK 4b Measure the secondary resistance of module using an ohmmeter If resistance is low or 0 ohms module secondary is shorted Replace module Secondary Secondary Leads Terminals Resistance C D 22 000 42 000 ohms If resistance is high or infinity ohms module secondary is open Replace module 19 Ignition System Tester A simple tester can be constructed to determine if the ignition module is functioning properly 3 Obtain another large spring clip 4 Attach the spring clip to the new spark plug connect the alligator clip from the single cylinder tester to the terminal end of the spring 1 Use the same tester that was made for testing clip single cylinder modules 5 Install another 1 1 4 length of 1 2 I D fuel line 2 Obtain another new RJ 8 or RCJ 8 spark plug on the threads of the new plug set gap at 025 Spring Clip 18 GA Wire Plug 2 ASE SP
263. eck the condition of the oil Drain the oil into a container the oil should flow freely Check for metal chips and other foreign particles Sludge is a natural by product of combustion a small accumulation is normal Excessive sludge formation could indicate overrich carburetion weak ignition overextended oil change interval or wrong weight or type of oil was used to name a few NOTE Itis good practice to drain oil at a location away from the workbench Be sure to allow ample time for complete drainage Cleaning the Engine After inspecting the external condition of the engine clean the engine thoroughly before disassembling it Also clean individual components as the 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 the manufacturer 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 cleaners can quickly break down the lubricating properties of engine oil Basic Engine Tests Crankcase Vacuum Test A partial vacuum should be present in the crankcase when the engine is operating Pressure in the crankcase normally caused by a clogged or improperly assembled breather can cause oil to be forced out
264. ector plug in wiring harness Run the engine at full throttle above 3000 RPM to warm up the engine and initiate O sensor function in closed loop operation Watch the MIL When the light starts blinking rapidly 5 blinks per second move the throttle lever to the low idle speed position Check and adjust the idle speed to 1500 RPM using a tachometer The lamp should continue to blink rapidly for another 30 seconds before switching to a slow blink When the MIL blinks slowly do not do anything but wait until the MIL shuts off This indicates that this procedure has been completed successfully Shut off the engine If the learn procedure was successfully completed the external loads removed disconnected in Step 2 may be reconnected If the procedure was unsuccessful see Steps a and b following a If during this procedure the MIL goes back into blinking 4 consecutive blinks every 2 seconds the engine and O sensor have cooled down and out of closed loop operation prohibiting the learning from occurring Repeat Steps 6 9 b If during the procedure with the engine running the MIL stays on continuously for more than 15 seconds turn off the ignition Then initiate the fault code sequence by doing three consecutive key on key off cycles leaving the key in the last sequence each key on key off sequence must be less than 2 5 seconds long The fault detected
265. ed a ECU to harness connection problem Code 34 Source Oxygen Sensor Fuel System Components Explanation Long term fuel adaptation control is at the upper or lower limit Expected Engine Response System operates closed loop appreciable performance loss as long as the temporary adaptation can provide sufficient compensation Possible Causes 1 Sensor Related Sensor connector or wiring problem Sensor contaminated or damaged Exhaust leak Poor ground path Pin circuit wiring or connectors 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 op 2 TPS Sensor Related a Throttle plate position incorrect during Initialization procedure b TPS problem or malfunction 3 Engine Wiring Harness Related a Difference in voltage between sensed voltage pin circuit 17 for metal cased ECU pin circuit 2 for plastic cased ECU and actual injector voltage circuit 45 45A b Problem in wiring harness c ECU to harness connection problem 4 Systems Related a Ignition spark plug plug wire ignition coil b Fuel fuel type quality injector fuel pressure fuel pump c Combustion air air cleaner dirty restricted intake leak throttle bores d Base engine problem rings valves e Exhaust system leak muffler flange oxygen sensor mounting boss etc f Fuelin the crankcase oi
266. ed blow compressed air through it to determine if it is blocked or restricted Figure 5A 15 Figure 5A 16 Electric Lock Off Filter Assembly Filter Service The filter inside the lock off assembly should be replaced every 500 hours of operation or if it becomes blocked or restricted Cleaning of the filter element is not recommended Order a replacement filter element by the appropriate Kohler part number Section LPG Fuel Systems Vaporizer Assembly The outer surface of the vaporizer should be kept free of dirt and debris accumulation which will cause a loss of vaporization efficiency Visual inspection and necessary cleaning should be performed on a regular basis more frequently under dusty or dirty conditions The vaporizer should be disassembled cleaned and serviced using a rebuild kit every 1500 hours or if a problem is encountered Figure 5A 17 LPG Regulator The regulator controls both the pressure 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 involved The Impco Beam regulator is shown in Figure 5A 18 and the Nikki regulator is shown in Figure 5A 19 Although the basic design and operating principles are similar due to system differences the regulators should not be interchanged Figure 5A 19 Nikki Regulator Following are separate se
267. ed cooling fins and or cooling shrouds removed will cause engine damage due to overheating Figure 4 15 Cleanout Kit Installed on Blower Housing Section 5 Fuel System and Governor Description The Command horizontal twins use three different types of fuel systems carbureted electronic fuel injection EFI or gaseous Gaseous fuel systems can be either liquefied petroleum gas LPG or LP or natural gas NG Some dual fuel engines have a combination system which allows the operator to select either gasoline or LP This section covers the standard carbureted fuel systems The gaseous systems are covered in subsection 5A and the EFI systems are covered in subsection 5B The governor systems used are covered at the end of this section A WARNING Explosive Fuel 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 Do not fill the fuel tank while the engine 18 hot or running since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition Do not start the engine near spilled fuel Never use gasoline as a cleaning agent Fuel System Components The typical carbureted fuel system and related components include the following Fuel Tank Fuel Lines In line Fuel Filter Fuel Pump Carburetor Operation The fuel from the tank is moved through the in line filt
268. educed engine life Fuel energy content can vary by geographic region Production of full rated power requires 1000 BT U cu ft for natural gas and 2500 BTU cu ft for propane The engine is designed to operate between 5 15 water column inches fuel pressure measured at the secondary fuel regulator with engine under full load and can demand up to 200 cu ft hr of fuel flow Verify that the fuel line diameter is properly sized based upon the distance from the gas meter Gas Pipe Length from Meter 25 50 Minimum Gas Pipe I D in 3 4 1 100 150 200 11 4 11 4 Metric Conversion Factors Units of Measure Force Pound force Ibf x 4 448 Newton N Length Inches x 25 4 Millimeter mm Mass Pound Ib x 453 592 Grams g Ounce 28 350 Grams g Oil Consumption Pound hour Ib h x 453 592 Grams hour g h Fluid ounce hour fl oz h x 29 574 Milliliter nour mL h Power Output Horsepower HP x 0 746 Kilowatt KW Pressure amp Stress Inch of Water in H O x 0 249 Kilopascal kPa Inch of Mercury x 3 377 kilopascal kPa Pound force square inch Ibf in psi x 6 895 Kilopascal kPa Pound force square inch Ibf in psi x 0 0069 Megapascal Mpa Specific Fuel amp Oil Consumption Pound Horsepower hour x 608 277 Gram Kilowatt hour g KW h Temperature Degree Fahrenheit 5 x F 32 Deg Celsius C 9 Torque Pound force inch x 0 113
269. elow the minimums and battery voltage is OK possible causes are 1 Too much parasitic load 2 Defective starter Note that when RPM is below minimum the current is likely above maximum amperage which will quickly lead to starter failure due to overheating 22 Exhaust System Tests If the muffler is not supplied by Kohler EPA requires that the OEM certify that back pressure does not exceed 40 water at 3600 RPM at wide open throttle WOT 1 Weld the pipe coupling 1 8 NPTF to the exhaust pipe as shown in the inset of Figure 4 1 Figure 4 1 Measuring Exhaust Back Pressure 2 Drill a 1 4 diameter hole through the exhaust pipe wall in the center of the coupling 3 Attach the copper tube assembly SPX Part No KO1011C to the coupling Position the loop away from the exhaust system or in the cooling air stream if possible See Figure 4 1 4 Connect gauge SPX Part 223 or manometer SPX Part No KO1005 to the copper tube Part available from SPX Corp OTC Call 1 800 533 0492 5 Move the on off valve to the off position if using manometer Start the engine and bring it to operating speed 3200 3600 RPM Apply load until wide open throttle WOT is reached 6 Open the on off valve manometer only and measure the back pressure Check your reading against the table below Enaine Seri Max Allowable Exhaust Back Pressure at WOT 40 H O 45 H O
270. ely emptied or the gasoline must be treated with a stabilizer 5 On equipment with an EFI engine disconnect to prevent deterioration If you choose to the battery or use a battery minder to keep the use a Stabilizer follow the manufacturer s battery charged during storage recommendations and add the correct amount for the capacity of the fuel system 6 Store the engine in a clean dry place 1 5 Section 1 Safety and General Information Dimensions in millimeters Inch equivalents shown in 14 77 14 77 582 582 ALTERNATE OIL 60 00 AIR CLEANER FILL LOCATION 2 362 COVER REMOVAL 470 86 18 538 FUEL FILTER SOLENOID SHIFT STARTER 15 70 42 04 92 10 4X g10 30 1 4061 rei MOUNTING HOLES LIFTING STRAP OIL FILTER ENGINE MI REMOVAL 184 15 E MOUNTING 7 250 HOLE a 6 SPARK ADVANCE 468 28 MODULE STANDARD 18 436 ON SOME MODELS 20 28 HP 456 58 17 876 113 20 18 HP 4 457 20 28 HP CAL 101 50 FUEL PUMP 3 9961 18 HP 8 525 S0 KEYWAT 20 28 6 350 250 SQ KEYWAY 18 HP 2X OIL DRAIN PLUG m 3 8 N P T INCH sin MOUNTING HOLE A 3 504 287 09 11 303 5 6 18 UNF 2B 38 10 11 500 DEEP 20 28 OIL COOLER S 7 18 20 UNF 2B 4 00 JS Pat 38 10 1 500 DEEP 557 100 00 x Pf d AS S 3 504
271. ely worn tapered or out of round resizing is necessary Use an inside micrometer to determine the amount of wear refer to the Specifications Tolerances and Special Torque Values in Section 1 then select the nearest suitable oversize of either 0 25 mm 0 010 in or 0 50 mm 0 020 in Resizing to one of these oversizes will allow usage of the available oversize piston and ring assemblies First resize using a boring bar then use the following procedures for honing the cylinder NOTE Some CH25 26 engines feature POWER BORE cylinders a special patented nickel silicone plating process for increased power superior oil control reduced exhaust emission and virtually permanent cylinder life POWER BORE cylinders cannot be resized or honed as described in the following procedure If a plated cylinder bore is damaged or out of specification use a new miniblock or short block to repair the engine Use the following procedure for crankcases with a cast iron sleeve Honing While most commercially available cylinder hones can be used with either portable drills or drill presses the use of a low speed drill press is preferred as it facilitates more accurate alignment of the bore in relation to the crankshaft crossbore Honing is best accomplished at 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
272. em and then release See Figure 8 31 Momentarily lead adapter to the B center red lead of one of the four lights will relight indicating the rectifier regulator being tested See Figure 8 34 partial condition of the part a Ifthe OK green light comes on disconnect the tester black lead attached to the AC lead reconnect it to the opposite side AC lead and repeat the test If the OK light green again comes on the part is good and may be used b If any other light is displayed in either of the tests the rectifier regulator is faulty and should not be used NOTE A flashing LOW light can also occur as a result of an inadequate ground lead connection Make certain connection location is clean and clamp is secure Figure 8 34 4 Amp Unregulated Rectifiers 1 Connect the tester ground lead with spring clamp to the body of rectifier being tested 2 Connect the ground lead of tester with spring clamp to the housing of rectifier regulator 3 Connect the red lead and one of the black leads from the tester to the pair of terminals on opposite end of adapter lead connections are not location specific 2 Connect the red tester lead to the B center terminal of the rectifier and the two black tester leads to the two AC outside terminals See Figure 8 36 4 Connect the remaining black lead from tester to one of the black AC outside leads from rectifier regulator See Figure 8 33
273. embly R amp R Command Twin amp Command PRO Twin Maximum Time Hr Flat Rate Schedule CH18 23 CV17 23 CH CV730 740 CH CV25 26 Description CH CV750 CH CV745 CH940 980 CV940 980 Major Repairs Engine R amp R Engine R amp R From Generator Set Welder Short Block Replacement Miniblock Major Overhaul Includes Valve Service Minor Overhaul Excludes Valve Service Connecting Rod Piston and or Rings Crankshaft Crankshaft 4 Main Bearing R R Crankshaft PTO Seal Crankshaft Flywheel Seal Crankshaft amp Connecting Rod Camshaft amp Valves Lifters Valve R amp R No Grinding Valve Adjustment Valve Grinding Valve Spring Replacement Valve Cover Gasket and or Breather Camshaft R amp R Camshaft PTO Seal Rocker Arm Ignition Ignition Module R amp R Includes Both Modules Flywheel R amp R Spark Advance Module ECU TPS Speed Sensor Charging Regulator Test amp Replace Stator Test amp Replace Includes Flywheel R amp R Wiring Harness R 4 R Starter Retractable amp R Replace Rope amp Spring Starting Motor Bendix Type R amp R Starter Bendix Rebuild Includes R amp Starter Drive R amp R Starter Solenoid R amp Fuel System amp Air Intake Carburetor R amp R Carburetor Rebuild Includes R amp R Carburetor Adjust Air Cleaner Damage in Shipment Fuel Pump R R Intake Manifold Injectors Fuel Rail Time
274. engine application Initial Adjustment NOTE EFI engines require a special initial adjustment procedure which is covered in subsection 5B Refer to Initial Governor Adjustment in that section for setting the governor on EFl equipped engines Procedure Carburetor Equipped Engines Make this adjustment whenever the governor arm is loosened or removed from the cross shaft See Figure 5 38 and adjust as follows 1 Make sure the throttle linkage is connected to the governor arm and the throttle lever on the carburetor 2 Loosen the hex nut holding the governor lever to the cross shaft 3 Move the governor lever toward the carburetor as far as it will move wide open throttle and hold in this position 4 Insert a nail into the hole on the cross shaft and rotate the shaft counterclockwise as far as it will turn then tighten hex nut securely 5 21 Section 5 Fuel System and Governor Sensitivity Adjustment Governor sensitivity is adjusted by repositioning the governor spring in the holes of the governor lever If speed surging occurs with a change in engine load the governor is set too sensitive If a big drop in speed occurs when normal load is applied the governor should be set for greater sensitivity See Figure 5 39 and adjust as follows 1 To increase the sensitivity move the spring closer to the governor cross shaft 2 decrease the sensitivity move the spring away from the governor cross
275. ensor Wire Harness Assembly amp Affiliated Wiring Malfunction Indicator Light MIL Operation The EFI system is designed to provide peak engine performance with optimum fuel efficiency and lowest possible emissions The ignition and injection functions are electronically controlled monitored and continually corrected during operation to maintain the theoretical ideal or stoichiometric air fuel ratio of 14 7 1 The central component of the system is the Motronic Engine Control Unit ECU which manages system operation determining the best combination of fuel mixture and ignition timing for the current operating conditions An electric fuel pump is used to move fuel from the tank through the fuel line and in line fuel filter A Section 5B EFI Fuel System fuel pressure regulator maintains a system operating pressure of 39 psi and returns any excess fuel to the tank At the engine fuel is fed through the fuel rail and into the injectors which inject it into the intake ports The ECU controls the amount of fuel by varying the length of time that the injectors are on This can range from 1 5 8 0 milliseconds depending on fuel requirements The 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 injection When the intake valve opens the fuel air mixture is drawn into the combustion c
276. ensor Housing 94 Pin MSE 1 0 Plastic Cased ECU Pin 3 Ceramic Support Tube 7 Active Ceramic Sensor circuits 6 and 4 4 Protective Sleeve 8 Protective Tube 32 Pin MSE 1 1 Plastic Cased ECU Pin Figure 5B 12 Cutaway of Oxygen Sensor circuits 6 and 4 The oxygen sensor can function only after being heated by exhaust temperatures to a minimum of 375 C 709 F A cold oxygen sensor will require approximately 1 2 minutes at moderate engine load to warm sufficiently to generate a voltage signal Proper grounding is also critical The oxygen sensor grounds through the metal shell so a good solid unbroken ground path back through the exhaust system components engine and wiring harness is required Any disruption or break in the ground circuit can affect the output signal and trigger misleading fault codes Keep that in mind when doing any troubleshooting associated with the oxygen sensor The oxygen sensor can also be contaminated by leaded fuel certain RTV and or other silicone compounds carburetor cleaners etc Use only those products indicated as O Sensor Safe Oxygen Sensor Figure 5B 11 Oxygen Sensor Service Like the other sensors already discussed the oxygen sensor is a non serviceable component Complete replacement is required if it is faulty The sensor and wiring harness can be checked as follows General The oxygen sensor functions like a small battery generating a voltage sig
277. ent is necessary bend the adjusting tab material before disassembling the carburetor on the speed control assembly to set See Figure Remove the four mounting screws and carefully 5 13 separate the fuel bowl from the carburetor Do not damage the inner or bowl O Ring Transfer any remaining fuel into an approved container P Save all parts Fuel can also be drained prior to bowl removal loosening removal of the bowl drain screw See Figure 5 15 _ Hold Throttle Against Bowl Drain Screw Figure 5 15 Fuel Bowl Removed From Carburetor Figure 5 14 Holding Throttle Lever Against Idle Stop Screw Two Barrel Carburetor 5 13 Section 5 Fuel System and Governor 3 Remove the float pin screw and lift out the old float pin and inlet needle See Figure 5 16 Discard all of the parts The seat for the inlet needle is not serviceable and should not be removed Figure 5 16 Removing Float and Inlet Needle 4 Clean the carburetor bowl and inlet seat areas as required before installing the new parts 5 Attach the inlet needle to the plastic tang of the float with the wire clip The formed 90 lip should point up with the needle valve hanging down See Figure 5 17 Figure 5 17 Float and Inlet Needle Details 6 Install the float and inlet needle down into the seat and carburetor body Install the new pivot pin through the float hinge and secure with the new retaining screw
278. ep costs to a minimum On larger engines a gear type oil pump is used to force oil through the drilled passages to various spots in the cylinder block where bearings includ ing the connecting rod bearing are present An oil transfer sleeve is provided between the cylinder block and the crankshaft in order to get oil into the shaft From there it goes through drilled passages to the crank pin journals where they feed the connect ing rod bearings Pressure lubrication to the con necting rod bearings is advantageous in providing a more positive supply and definite oil circulation through the bearings A certain amount of cooling of the bearings is accomplished with the oil The lubrication of sleeve type main bearings is provided by oil pumps and drilled passages the same as for the rod bearings An anti friction bearing needs very little lubrication In fact it is undesirable to allow excessive amounts of oil to pass through the bearings Camshafts timing gears governor magneto and oil pump drive gears are very lightly loaded and receive adequate lubrication just from oil thrown off from other parts in their vicinity The camshaft bushings on larger engines receive pressure lubri cation but it is not at all critical Lubrication around the flyweights of a governor must be moder ate and excessive amounts of oil will adversely affect the action of the flyweights Reduction gears are highly stressed and must be lubricated very ca
279. equipment manufacturer s manual for other important safety information This manual contains safety precautions which are explained below Please read carefully WARNING Warning is used to indicate the presence of a hazard that can cause severe personal injury death or substantial property damage if the warning is ignored CAUTION Caution is used to indicate the presence of a hazard that will or can cause minor personal injury or property damage if the caution is ignored NOTE Note is used to notify people of installation operation or maintenance information that is important but not hazard related For Your Safety These precautions should be followed at all times Failure to follow these precautions could result in injury to yourself and others Accidental Starts can cause severe injury or death Disconnect and ground spark plug leads before servicing Accidental Starts Disabling engine Accidental starting can cause severe injury or death Before working on the engine or equipment disable the engine as follows 1 Disconnect the spark plug lead s 2 Disconnect negative battery cable from battery Rotating Parts can cause severe injury Stay away while engine is in operation Rotating Parts Keep hands feet hair and clothing away from all moving parts to prevent injury Never operate the engine with covers shrouds or guards removed Hot Parts can cause severe burns Do not touch
280. er Head Flatness Carefully inspect the valve mechanism parts Inspect the valve springs and related hardware for excessive wear or distortion Check the valves and valve seat area or inserts for evidence of deep pitting cracks or distortion Check clearance of the valve stems in the euides See Figure 10 6 for valve details and specifications EXHAUST VALVE E F E G Seat Angle Guide Depth 4 mm 0 1575 in Valve Face Angle 45 Valve Margin Min 1 5 mm 0 0591 in A B C D E F G H Figure 10 6 Valve Details Hard starting or loss of power accompanied by high fuel consumption may be symptoms of faulty valves Although these symptoms could also be attributed to worn rings remove and check the valves first After removal clean the valve heads faces and stems with a power wire brush Section 10 Inspection and Reconditioning INTAKE VALVE EXHAUST INSERT INTAKE INSERT Insert O D 36 987 37 013 mm 1 4562 1 4572 in 32 987 33 013 mm 1 2987 1 2997 in 6 5 mm 0 2559 in Guide I D 7 038 7 058 mm 0 2771 0 2779 in 7 038 7 058 mm 0 2771 0 2779 in Valve Head Diameter 33 37 33 63 mm 1 3138 1 3240 in 29 37 29 63 mm 1 1563 1 1665 in 45 1 5 mm 0 0591 in Valve Stem Diameter 6 982 7 000 mm 0 2749 0 2756 in 6 970 6 988 mm 0 2744 0 2751 in Then carefully inspect each valve for defects such as a warped head excessive corrosion or a worn stem end Replace valves fou
281. er 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 the carburetor float bowl and is drawn into the carburetor body There the fuel is mixed with air This fuel air mixture is then burned in the engine combustion chamber Fuel Recommendations General Recommendations Purchase gasoline in small quantities and store in clean approved containers A container with a capacity of 2 gallons or less with a pouring spout is recommended Such a container is easier to handle and helps eliminate spillage during refueling e Do not use gasoline left over from the previous season to minimize gum deposits in your fuel system and to ensure easy starting e Do not add oil to the gasoline 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 R M 2 or higher In countries using the Research Octane Number RON it should be 90 octane minimum Leaded gasoline is not recommended and must not be used on EFI engines or on other models where exhaust emissions are regulated Gasoline Alcohol blends Gasohol up to 10 ethyl alcohol 90 unleaded gasoline by volume is approved as a fuel for Kohler engines Other gasoline alcohol blends including E20 and E85 are not to be used
282. er rope Refer to Rope Replacement steps 2 through 5 on pages 7 1 and 7 2 2 Remove the center screw washer and pawl retainer See Figure 7 4 3 Remove the brake spring and the brake washer See Figure 7 5 4 Carefully note the positions of the pawls and pawl springs before removing them Remove the pawls and pawl springs from the starter pulley enter Screw d Washers Ww 08 7 n gt oe 7 gt 9 NI LAS Ws Sa Figure 7 4 Center Screw Washer and Pawl Retainer Section 7 Retractable Starter Figure 7 5 Brake Spring and Washer Pawls and Pawl Springs 5 Rotate the pulley clockwise 2 full turns This will ensure the spring is disengaged from the starter housing 6 Hold the pulley in the starter housing Invert the pulley housing so the pulley is away from your face and away from others in the area 7 Rotate the pulley slightly from side to side and carefully separate the pulley from the housing See Figure 7 6 If the pulley and the housing do not separate easily the spring could be engaged in the starter housing or there is still tension on the spring Return the pulley to the housing and repeat step 5 before separating the pulley and housing Figure 7 6 Removing Pulley from Housing 7 3 Section 7 Retractable Starter 8 Note the position of the spring and keeper assembly in the pulley See Figure 7 7 Remove the sp
283. er systems are functional before attempting to troubleshoot the EFI system Troubleshooting Guide Engine starts hard or fails to start when cold 1 Fuel pump not running Faulty spark plugs Old stale fuel Incorrect fuel pressure Speed sensor loose or faulty TPS offset incorrect initialization TPS faulty Engine temperature sensor faulty Faulty coils Low system voltage Faulty injectors oe A E i c 58 26 Engine starts hard or fails to start when hot 1 E DS oe gt Faulty spark plugs Fuel pump not running Fuel pressure low Insufficient fuel delivery TPS offset incorrect Initialization Speed sensor loose or faulty TPS faulty Engine temperature sensor faulty Faulty injectors Engine stalls or idles roughly cold or warm 1 Qs un T9 Faulty spark plugs Insufficient fuel delivery TPS offset incorrect TPS faulty Faulty engine temperature sensor Faulty injectors Engine misses hesitates or stalls under load 1 DUE gt Fuel injector s fuel filter fuel line or fuel pick up dirty restricted Dirty air cleaner Insufficient fuel pressure or fuel delivery Vacuum intake air leak Improper governor setting adjustment or operation Speed sensor malfunction TPS faulty mounting problem or TPS Initialization Procedure incorrect 8 Bad coil s spark plug s or wires Low Power 1 Faulty malfunctioning ignition system oe Ss Dirt
284. eratures As temperatures decrease cranking requirements increase but battery cranking capacity shrinks Refer to the Battery Capacity Temperature Chart on page 26 to see the effects of declining temperatures on a battery Section 3 Properly Installing the Engine Battery Cables Use 4 or 6 gauge wire from the battery positive terminal to the starter switch or starter solenoid and from the negative terminal to ground Make certain that the remainder of the circuit from the negative terminal to the engine block is electrically equivalent Ideally the negative ground cable will be connected directly from battery negative to the engine block Refer to chart below for SAE size and length recommendations Always use the shortest length of wire possible SAE Cable Size Max Length 60 0 in 152 4 cm 86 0 in 218 4 cm 144 0 in 365 7 cm Parasitic Starting Loads This refers to any load that is not disconnected from an engine while it is being started Normally a Kohler engine in good winterized condition with fully charged battery will start at temperatures down to minus 20 F 29 C without any parasitic load Parasitic loads such as hydraulic pumps and hydrostatic drives can prevent starting at lower temperatures Starters can overheat and be destroyed trying to crank cold equipment with excessive parasitic loads A parasitic load disconnect should be considered during the design of the application Ignition Systems
285. ernal circuitry as well as the wiring harness none suppresses the injection signals cutting off the fuel of the ECU s are interchangeable Certain individual flow This process repeats itself in rapid succession service troubleshooting procedures also apply where limiting operation to the preset maximum applicable they are covered individually as 35 Pin MA 1 7 Metal Cased ECU 24 Pin MSE 1 0 Service Plastic Cased ECU or 32 Pin MSE 1 1 Plastic Never attempt to disassemble the ECU It is sealed to Cased ECU prevent damage to internal components Warranty is void if the case is opened or tampered with in any General way The ECU is the brain or central processing computer of the entire EFI fuel ignition management system All operating and control functions within the ECU During operation sensors continuously gather data are preset No internal servicing or readjustment may which is relayed through the wiring harness to input be performed lfa problem is encountered and you circuits within the ECU Signals to the ECU include determine the ECU to be faulty contact your source ignition on off crankshaft position and speed of supply Do not replace the ECU without factory RPM throttle position oil temperature exhaust authorization oxygen levels and battery voltage The ECU compares the input signals to the programmed maps in its The relationship between the ECU and the throttle memory to determine the appropriate
286. erned Idle System If equipped with a Governed Idle System refer to Models with Governed Idle System when performing any carburetor adjustment as an additional step to the listed adjustment procedure s is required NOTE Engines operating at altitudes above approximately 1219 m 4000 ft may require a special high altitude main jet Refer to High Altitude Operation If however the engine is hard starting or does not operate properly it may be necessary to adjust or service the carburetor 5 11 Section 5 Fuel System and Governor Low Idle Fuel Adjustments Low Idle Speed RPM Adjustment Screw Fuel Solenoid Figure 5 11 Keihin Two Barrel Carburetor Carburetor Adjustment Low Idle Speed RPM Adjustment 1 Low Idle Speed RPM Setting Place the throttle control into the idle or slow position Set the low idle speed to 1200 RPM 75 RPM turning the low idle speed adjusting screw in or out Check the speed using a tachometer NOTE The actual low idle speed depends the application 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 RPM 75 RPM Low Idle Fuel Adjustment NOTE Engines will have fixed low idle or limiter caps on the two idle fuel adjusting needles Step 3 can only be performed within the limit
287. ernment emission standards the carburetor is calibrated to deliver the correct air to fuel mixture to the engine under all operating conditions The high speed mixture is preset and cannot be adjusted Pre compliance carburetors contain a low idle fuel adjusting needle on certified compliance carburetors both the low and high speed mixture circuits are pre established and cannot be adjusted The low idle speed RPM is the only adjustment available See Figures 5 4 and 5 5 Depending on model and application engines may also be equipped with a Governed Idle System If equipped with a Governed Idle System refer to Models with Governed Idle System when performing any carburetor adjustment as an additional step to the listed adjustment procedure s is required Low Idle Speed Adjustment Fe Jj P 1 E i Y Low Idle Fuel Adjusting Needle b Figure 5 4 Pre Compliance Carburetor with Low Idle Adjustment 5 6 l Fuel Shut Off Solenoid Main Jet Location Figure 5 5 Certified Compliance Carburetor NOTE Carburetor adjustments should be made only after the engine has warmed up Adjusting Low Idle Speed and Fuel Some Models To adjust the carburetor idle speed see Figure 5 4 and follow these steps 1 With the engine stopped turn the low idle fuel adjusting needle in clockwise until it bottoms lightly NOTE The tip of the
288. es and generators an application of that age old water wheel principle Next came the use of the so called fossil fuels coal and oil Converting the latent energy of coal and oil into useful mechanical work is accomplished ina variety of ways as discussed below The sun is the original source of energy in fossil fuels Coal and oil come from former living or ganisms and without the sun and its energy that life would not have been possible The sun is still pouring down a tremendous amount of energy but only a very Small fraction of it is being put to work Scientists are finding more ways of economically harnessing the energy from the sun but much still remains to be done Of all the sources of energy indicated above we obtain by far the greatest amount of work from coal and oil The process of releasing energy from coal has reached its highest development in coal power ed steam generating plants for providing electricity Steam engines operated from coal fired boilers have also been used in providing useful work However they have many limitations and their use is decreas ing The reciprocating steam engine and steam turbines are classed as heat engines of the external combustion type In other words combustion of the fuel and release of the heat energy is accomplished at some external point of the engine In contrast to this the release of energy from oil has reached a high state of development in the internal
289. es up these ports are closed and the charge is compressed The fuel and air mixture is ignited when the piston is near the top dead center and the rapid burning and expansion of the gases forces the piston downward again Part way down in its travel other ports are opened allowing the burned gases to exhaust and clean the cylinder in preparation for the next incoming charge Two cycle operation is used today in both gasoline and Diesel engines Intake Stroke At the beginning of this stroke the piston is at the position closest to the cylinder head thereby filling the cylinder space and reducing the open volume of the cylinder and combustion cham ber toa minimum As the piston moves toward the crankshaft and with the intake valve open air is drawn into the cylinder Power Stroke As the fuel burns in the cylinder heat is released causing a rapid pressure buildup as the gases expand This pressure causes the piston to move downward and through the mechanism of the connecting rod and crankshaft delivers useful energy to the rotating crankshaft Compression Stroke With air in the cylinder and the piston at the point closest to the crankshaft the intake valve closes As the piston travels toward the top of the cylinder the air in the cylinder is com pressed In the gasoline engine the fuel is already mixed with the air as it is drawn into the cylinder In the Diesel engine fuel is injected into the cylinder to
290. et Address Type Equipment Manufacturer of Equipment Date Purchased Date Failed Hours Used Times Used Previous Repairs Warranty Claim No L YES NO USAGE MAINTENANCE INFORMATION Oil type 10W 30 5W 20 Hours since last oil change L ______________ 10W 40 5W 30 How often is the oil level checked Must oil be added between changes Ll Every time L Never 1 Other Yes LI No How much Was an oil additive used How often is the air cleaner checked Yes No What brand _____________ Element Was it ever replaced or cleaned How recently Precleaner LI Yes Element LJ Yes No ___________ Element Were any adjustments made to the carburetor governor By whom Yes Ifyes specify Customer L Dealer PRELIMINARY EXAMINATION Air Cleaner Assembly Type LI Dry Precleaner Remote Bath Tri Phase 1 Wing Nut Wing nut seal Factory Original Non standard replacement LJ Intact 1 Separated 0 Missing 2 Outer Cover 1 Good condition 1 Center hole oblong Ll Other damage specify 3 Precleaner 0 Clean 0 Dirty 1 Plugged lOiled Dry Torn L Other damage 4 Inner Cover 0 Retaining seal nut in place Center hole oblong L Distorted Ll Other damage 5 Element Clean Dusty LJDiry Plugged Missing Dry L Non factory replacement L Other damage 6 Element seals 0 Pliable Harda Sealing Leaking L Other damage
291. etor air horn assembly onto the carburetor body connecting the choke linkage Install the four screws Torque the screws to 1 7 15 in Ib See Figure 5 8 Connect the fuel line Install the breather hose and air cleaner assembly following the steps in Section 11 Reassembly Disassembly Disassemble the carburetor using the following steps See Figure 5 10 Remove the air cleaner breather hose and carburetor Refer to Section 9 Disassembly Remove the four screws and carefully separate the air horn assembly from the carburetor body Loosen the screw securing the float assembly to the air horn and remove the float float shaft and fuel inlet needle Remove the slow jet from the carburetor body NOTE The main jet is a fixed jet and can be removed if required Fixed jets for high altitude are available Remove the black cap on the end of the choke shaft only if it is necessary to inspect and clean the shaft spring Remove the low idle speed adjusting screw and spring from the carburetor body Section 5 Fuel System and Governor 7 In order to clean the off idle vent ports and Reassembly bowl vent thoroughly use a good carburetor Reassemble the carburetor using the following steps solvent like Gumout Blow clean compressed See Figure 5 10 air through the idle adjusting needle hole Be careful to use a suitable shop rag to prevent 1 Assemble the fuel inlet needle to the float tab deb
292. ey switch in both the START and RUN positions A minimum of 7 25 volts must be present a If correct voltage is not measured connect black voltmeter lead directly to the negative post of the battery and test voltage again in both key positions If correct voltage is now indicated check the ground circuit connections If the ground screw bolt or any other fasteners in the ground circuit are black oxide coated replace them with zinc plated silver colored fasteners b If correct voltage is still not indicated check the harness connector terminal for a good connection and crimp to the lead Then trace the power source circuit back through the harness key switch etc looking for any poor connections or faulty circuits 2 Disconnect all of the SAM leads isolating it from the engine Test the SAM according to style with tester 25 761 21 5 tests ASAM style modules only or tester 25 761 40 S tests both ASAM and DSAM style modules Use the test instructions following or those provided with the tester 3 Reattach the SAM leads veritying a snug fit at the ignition module terminals If any connections do not feel snug disconnect the lead lightly pinch the female terminal with a pliers and recheck the fit 4 Sealthe 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 sol
293. eyways If they are worn or chipped replacement of the crankshaft will be necessary Inspect the crankpin for score marks or metallic pickup Slight score marks can be cleaned with crocus cloth soaked in oil If the wear limits as stated in Specifications and Tolerances are exceeded it will be necessary to either replace the crankshaft or regrind the crankpin to 0 25 mm 0 010 in undersize If reground a 0 25 mm 0 010 in undersize connecting rod big end must then be used to achieve proper running clearance Measure the crankpin for size taper and out of round NOTE Ifthe crankpin is reground visually check to ensure that the fillet blends smoothly with the crankpin surface See Figure 10 1 High Point from Fillet Intersections The Fillet Must Blend Smoothly with the Bearing 45 Journal Surface Minimum This Fillet Area Must Be Completely Smooth Figure 10 1 Crankpin Fillets The connecting rod journal can be ground one size under When grinding a crankshaft grinding stone deposits can get caught in the oil passages which could cause severe engine damage Removing the crankpin plug when the crankshaft is ground provides easy access for removing any grinding deposits that may collect in the oil passages Use the following procedure to remove and replace the plug 10 2 Procedure to Remove Crankshaft Plug 1 Drill a 3 16 hole through the plug in the crankshaft 2 Thread a 3 4 or 1 long self
294. f the pulley diameter is exceeded Pulley too Close to Air Intake Restricts Air Intake Figure 2 3 Front PTO Pulley Section 2 Properly Connecting the Engine to the Load Top View ES VENICE e UN EE mL UmEEL Bird Keep Belt amp Pulleys Aligned to Avoid Stress P Figure 2 4 Keep Pulleys and Belts Aligned Direct Coupled Drives In some applications the engine will be direct coupled to the load This type is 100 efficient however the engine and driven equipment must be rigidly mounted to maintain proper and accurate alignment Spline Drives We offer a variety of crankshafts with a female spline insert and an adapter plate for hydraulic pump mounting Because of the extremely high torque pulses generated by a 1 or 2 cylinder 4 cycle engine it is not possible to size spline drives on the same basis as other power sources e g electric motors High torque pulses generate extreme face pressures which will result in fretting damage if not continuously lubricated For this reason we recommend the following practices be adopted to ensure proper service life and customer satisfaction OEM Initial Assembly Lubricate the entire spline assembly with GN Assembly paste Dow Corning or equivalent Kohler Part No 25 357 12 5 OEM Installation Install the engine in such a manner to permit relubrication of the spline every 500 hours sooner under dusty conditions Th
295. fastening method cannot be altered unless the heads are being replaced Do not intermix the components 1 Check to make sure there are no nicks or burrs on the sealing surfaces of the cylinder head or the crankcase 11 11 Section 11 Reassembly Heads secured with hex flange screws 2 Install a new cylinder head gasket with printing up Figure 11 42 Cylinder Head Fastener Torque Sequence Heads secured with mounting studs nuts and washers NOTE Watch 1 If all of the studs were left intact go to Step 6 If cylinder heads and crankcase See Figure any studs were disturbed or removed install new 11 36 studs as described in Step 3 Do not use reinstall any loosened or removed studs 3 Install the cylinder head and start the four new hex flange screws 2 Install new mounting stud s into the crankcase NOTE When installing cylinder heads new hex a Thread and lock two of the mounting nuts flange screws should always be used together on the smaller diameter threads 4 Torque the hex flange screws in two stages first b Thread the opposite end of the stud with the to 22 6 N m 200 in Ib finally to 41 8 N m preapplied locking compound into the 370 in Ib following the sequence in Figure crankcase until the specified height from the 11 42 crankcase surface is achieved See Figure 11 43 When threading in the studs use a steady tightening motion without inte
296. fe cycle Notice the elongation of the hole where the bolt comes through You can also notice where the bolt wore a groove into the rod cap 21 Figure 80 Figure 80 This is shot of the you saw in Figure 79 Again notice the way the bolt is elongated and how there is no sign of heat or burned oil Figure 81 Figure 81 This connecting rod broke in the beam but has no other visible damage and did not seize When we look at the break surface there is no sign of fatigue or a casting defect just a tensile break of a good casting This failure was caused by engine overspeed C Combination Failures Many failures involve more than one engine component When two or more parts have failed or been damaged during failure analysis can be more difficult In those situations look at each individual component to see if it actually failed and why or if it just received secondary damage Then look at the parts collectively If more than one part failed try to develop a logical sequence Weigh all of the evidence before making a decision 22 Figure 82 Figure 82 Our first example includes a broken connecting rod and a broken governor gear The rod bearing surface looks like it ran without oil Notice however that the dipper is broken and not discolored The dipper broke first and caused the rod to seize But the real culprit here is the governor gear One of the roll pins backed out and the flywei
297. ft Do not strike the crankshaft or flywheel as these parts could become cracked or damaged Striking the puller or crankshaft can cause the crank gear to move affecting the crankshaft end play Figure 9 63 Removing Flywheel with a Puller 4 Remove the woodruff key from the crankshaft Remove Stator and Backing Plates 1 Remove the four hex flange screws securing the backing plates and stator wire bracket if equipped See Figure 9 64 Remove the backing plates and stator wire bracket Section 9 Disassembly 2 Locate the three splitting tabs that are cast into the perimeter of the closure plate Insert the drive end of a 1 2 breaker bar between the top splitting tab and the crankcase Hold the handle horizontal and pull toward you to break the RTV seal If necessary pry at the bottom tabs also See Figures 9 67 and 9 68 Do not pry on the sealing surfaces as this could cause leaks Carefully pull closure plate from crankcase Figure 9 64 Removing Backing Plates and Stator Wire Bracket 2 Remove the two hex head screws and stator See Figure 9 65 Note the routing of the stator lead in the channel Remove Closure Plate Assembly 1 Remove the ten hex flange screws securing the closure plate to the crankcase See Figure 9 66 Figure 9 68 Breaking Seal on Top Splitting Tab Governor Gear Assembly The governor gear assembly is located inside the closure plate If service is required refer to the service
298. full wave rectifier By using four diodes and arranging them to form an electrical bridge both positive and negative alternations can be rectified into a relatively smooth unidirectional flow of DC Alternator Stator Primary Winding Full Wave Bridge Rectifier Once converted from AC to DC the current can used for battery charging The 1 25 and 3 amp systems have such low charge rates that the current goes directly to the battery after rectification With the 15 25 and 30 amp systems however a regulating circuit must be used in conjunction with the rectifier as these 3 systems have enough charging capacity to boil the electrolyte in the battery if the charging rate is not controlled It was stated earlier that the 30 amp system has two sets of windings on the alternator stator One set of windings heavy wire with black insulation is where our AC current is generated The other set finer wire with red insulation is the regulator winding 23 30 Amp Charging System The regulator winding is connected to a regulator circuit in the rectifier regulator module which includes a zener diode a silicon controlled rectifier SCR a variable resistor and a capacitor When the battery is low and in need of charging the regulating circuit does not function and the battery is charged at full capacity by the alternator During this time the zener diode blocks any current flow into the regulator circuit Regulator
299. g condition and gap Section 8 Every 200 Hours Change oil filter Section 6 Change fuel filter NU engines Section 5 Every 500 Hours e Have solenoid shift starter and cleaned Section 8 these maintenance procedures more frequently under extremely dusty dirty conditions Only requried for Denso starters Not necessary on Delco starters Have a Kohler Engine Service Dealer perform this service 3Cleanout Kits 25 755 20 5 black or 25 755 21 5 gold allow cooling areas to be cleaned without removing shrouds Storage Fill the fuel tank with clean fresh gasoline Run If the engine will be out of service for two months or the engine for 2 to 3 minutes to get stabilized more use the following storage procedure fuel into the rest of the system Close the fuel shut off valve when the unit is being stored or 1 Clean the exterior surfaces of the engine On transported Electronic Fuel Injected EFI engines avoid spraying water at wiring harness any of the To empty the system run the engine until the electrical components tank and the system are empty 2 Change the oil and oil filter while the engine is 4 Remove the spark plugs and add one tablespoon still warm from operation See Change Oil and of engine oil into each spark plug hole Install the Oil Filter in Section 6 spark plugs but do not connect the plug leads Crank the engine two or three revolutions 3 The fuel system must be complet
300. g low emissions All Command OHC Triad Kohler Aegis and Courage engines have been certified to meet applicable U S and California Emission Control Regulations for SORE Small Off Road Engines or Class 1 LSI Large Spark Ignited regulations as applicable Our goal is also to reduce operational noise and provide the end user a low maintenance product Our wide range of quality built engines from 4 to 29 horsepower provide you a choice of power that best fits your application and performance requirements And when you put one of our engines in your equipment the Kohler name and reputation for quality go along with it Naturally we want to make sure our engine and your equipment form a combination that will be a credit to both of us That is why we have produced this Engine Application Guide gives you an organized coordinated approach to selecting and installing a Kohler Engine in your specific application In following the procedures explained here you can be sure that you are considering most of the practical aspects of engine application We ve divided the guide into five sections Selecting Vas IP FIM RETE section 1 e Properly Connecting the Engine to the Load section 2 SOS TI NE ENGINE ERE Ten omms section 3 lesing ine INSANAUON TETTE Section 4 Tecnica Guidelines ersi Section 5 This guide is meant to be an easy to use tool something you ll turn to when your new ideas are ready
301. gap advances the timing and closing the gap retards the timing Point Gap Stationary Contact Point Breaker Arm Contact Point Terminal Breaker Rod Breaker Arm Spring amp Lead Typical Ignition Breaker Points The initial timing setting is made by adjusting the breaker point gap to 020 as checked with a feeler gauge Assuming that all other conditions are right this setting should allow you to get the engine Started Movable Contact Gap Stationary Contact Breaker Point Gap The final timing adjustment is best performed with the use of an automotive timing light while the engine is operating All Kohler engines are equipped with a timing sight hole and timing marks on the flywheel Connect the timing light per the manufacturer s instr ctions Start the engine running and shine the timing light into the sight hole On magneto ignition engines the sight hole will be in the bearing plate on the side opposite the carburetor Setting Timing Magneto Ignition Engines On battery ignition engines it will be in the blower housing on the carburetor side Setting Timing Battery Ignition Engines Adjust the breaker points as necessary to bring the spark mark S into the center of the sight hole For twin cylinder engines refer to the appropriate service manual for sight hole location and timing procedure IGNITION COMPONENT TESTING Troubleshooting an ignition problem can be an exasperating
302. ged air intake and cooling fins Damage caused by improperly serviced inadequate air cleaner Damage due to improper storage D Major Warranty Repair Repairs that require a new short block miniblock or engine must be approved by a Central Distributor representative for non expert dealers or a certified Expert Dealer and require that section one of the Engine Inspection Data Record be completed before such approval is requested or granted see Section 8 Anew short block or engine can only be used for a warranty repair if the engine has clearly failed due to an identifiable defect in materials or workmanship In addition the engine must either be damaged beyond repair or the cost of the repair must have been 10 calculated to exceed 90 of the cost of the short block or engine to be used If an engine or short block is desired for reasons not explained above this approval must be provided by a certified Central Distributor representative Regardless of the circumstances the failed engine or block must be retained or returned to the authorizing party If the replacement guidelines explained above have been met and or appropriate approval has been received promptly repair the engine and submit a properly filled in Warranty Claim Report see Section 6 to Kohler Co within 30 days after making the repair Warranty claims for engines and short blocks must be accompanied by a copy of the original invoice to verify th
303. ght separated from the gear breaking the gear in the process The flyweight dropped into the oil pan and knocked the dipper off the rod If we had looked at only the rod bearing we may have concluded that the engine was run without oil and we would have been dead wrong Study all of the evidence and be certain that your decision incorporates everything you see Figure 83 Figure 83 A high percentage of small engine failures result from customer neglect Here you can see the dirty air cleaner considerable wear on the piston rings and traces of dirty burned oil on the connecting rod There is a color change line on the dipper but it was only about 3 8 inch from the tip so the oil level was well below the low mark on the dipstick at the time of failure Figure 84 Figure 84 This rod shows signs of aluminum transfer with burned oil deposits The rod seized from inadequate lubrication As it locked up on the crankshaft the turning force of the flywheel and crankshaft caused the connecting rod to snap in the beam and tried to pull the rod apart at the fastener joint The aluminum thread transferred to the rod bolt is a secondary occurrence and not a loose rod bolt Figure 85 Figure 85 This rod broke toward the bottom Notice the slight smear of aluminum and blackened oil The piston shows signs of overheating This could have been caused by an improper honing oversize procedure where the piston to bor
304. gine running at 3000 RPM measure If voltage is less than 15 volts test stator using No voltage from lighting lead to ground using an an ohmmeter Test 3 Lights AC voltmeter With engine stopped measure the resistance 3 If resistance is approximately 0 4 ohms of stator from lighting lead to ground using an stator is OK ohmmeter If resistance is 0 ohms stator is shorted Replace stator If resistance is infinity ohms stator or lighting lead is open Replace stator 8 28 Section 8 Electrical System and Components Electric Starting Motors NOTE If the starter does not crank the engine shut Some engines in this series use inertia drive starting off the starter immediately Do not make motors while most use solenoid shift starters The further attempts to start the engine until the inertia drive types are covered first and the solenoid condition is corrected shift types following NOTE Do not drop the starter or strike the starter Starting Motor Precautions frame Doing so can damage the starter NOTE Do not crank the engine continuously for more than 10 seconds at a time If the engine does not start allow a 60 second cool down period between starting attempts Failure to follow these guidelines can burn out the starter motor Starter Removal and Installation Refer to the Disassembly and Reassembly Sections for starter removal and installation procedures Inertia Drive Electric Starters N
305. gine running at 3600 RPM If voltage is 28 volts or more stator is OK Rectifier regulator is faulty Replace NO measure AC voltage across stator leads the rectifier regulator CHARGE using an AC voltmeter TO If voltage is less 28 volts stator is BATTERY probably faulty and should be repiaced Test stator further using an ohmmeter test 3 3a If resistance is 0 064 0 096 ohms the stator is OK 3a With engine stopped measure the resistance across stator leads using an ohmmeter If resistance is infinity ohms stator is open Replace stator If resistance is infinity ohms no continuity the stator is OK not shorted to ground With engine stopped measure the resistance from each stator lead to ground using an ohmmeter If resistance or continuity is measured the stator leads are shorted to ground Replace stator 1 With engine running at 3600 RPM 1 If voltage is 14 7 volts or less the measure voltage from B lead to ground charging system is OK The battery is BATTERY using a DC voltmeter unable to hold charge Service battery or CONTINUOUSLY replace as necessary CHARGES AT HIGH RATE if voltage is more than 14 7 volts the rectifier regulator is faulty Replace rectifier regulator 33 Electric Start 30 Amp Regulated Battery Charging System Starter Flywheel Alternator d Lights Va 99
306. gnificant loss of power will result EPA regulations require Kohler approval of all non factory exhaust systems Excessive back pressure can be caused by using an unapproved muffler exhaust piping too small in diameter too long or with too many bends Refer to the Kohler Engine Accessories Catalog for approved exhaust system components including all types of mufflers fittings guards shields and spark arrestor equipment Spark Arrestor Check local state or federal laws to determine if a spark arrestor is required particularly if the equipment is to be operated on state or federal lands Heavy Mufflers Adequate testing of heavy mufflers should be done to make sure they are properly braced and supported to withstand engine and or load vibrations Electric Start Systems Electric start engines have a 12 volt starting circuit and a battery charging system Regulated charging circuits with 15 20 and 25 amp capacity are available CS Pro engines have 7 10 and 18 amp systems In addition unregulated charging circuits are available with lower battery charging amperage and separate AC output for lighting or accessories Battery Requirements A 12 volt battery with a minimum current rating of 250 cold cranking amps cca should be sufficient for cranking most single cylinder engine models 400 cca is generally recommended for twin cylinder models The actual cca requirement depends on engine size application and starting temp
307. h Ignition Breaker Points Condenser Ground Primary Low Voltage and Secondary High Voitage Circuits The battery that is commonly used is a lead acid storage battery so named because lead is used to make the cell plates and sulfuric acid is used as the electrolyte It should be a 12 volt battery with a rating of 32 amp hour or higher A typical 12 volt battery has a hard rubber or plastic case with six individual compartments or cells Each cell contains a specific number of sets of negative and positive plates The plates are all made of lead but the positive plates have a coating of lead oxide while the negative plates have a porous or spongy surface Cell Connector Cell Vent Cover Plug Terminal Hard Rubber Case Sediment Chamber Construction Details Typical Battery When the battery is charged with electrolyte chemical reaction takes place between the lead plates and the electrolyte The chemical reaction results in a migration of electrons from one set of plates to the other Since electrons have a negative charge one set of plates takes on a negative charge and the other set takes on a positive charge All plates of like charge are interconnected and connected to their respective terminals of the battery so the cumulative totals of the charges are present at the terminals If the battery is fully charged there is a difference in electrical potential of about
308. h include new gaskets and other components These kits are described on the next page 5 9 Section 5 Fuel System and Governor Carburetor Upper Body Choke Self relieving Choke Body Gasket Formed Rubber Slow Speed Jet Inlet Needle Valve Clip Float Pin Float Assembly Kit Carburetor Lower Body Throttle Main Jet Idle Fuel Adjusting Needle some models Solenoid Seat Fuel Shut off Solenoid Kit Idle Speed Adjusting Screw Jet Accelerator Pump Carburetor only Accelerator Pump Cover Diaphragm Diaphragm Spring O Ring Rubber Boot Bushing Return Spring oO ae ae Des See Note on Page A 1 do 16 9 a9 Accelerator Pump Version Only Figure 5 10 CH18 740 Carburetor Exploded View Components such as the throttle and choke shaft assemblies throttle plate choke plate low idle fuel needle and others are available separately Always refer to the Parts Manual for the engine being serviced to ensure the correct repair kits and replacement parts are ordered Service repair kits available for the carburetor and affiliated components are Carburetor Repair Kit Float Kit High Altitude Kit 1219 2434 m 4 000 8 000 ft Solenoid Assembly Kit Accelerator Pump Seal and Bushing Kit Accelerator Pump Diaphragm Kit Choke Repair Kit 5 10 NOTE If accelerator pump rod movement is restricted or corrosion exists in the pump rod housing hole use a 0 153 in 3 9 mm
309. h the float hinge and secure with the new retaining screw See Figure 5 29 Section 5 Fuel System and Governor Figure 5 29 Installing Float Assembly 14 Hold the carburetor body so the float assembly hangs vertically and rests lightly against the fuel inlet needle The inlet needle should be fully seated but the center pin of the needle on retainer clip end should not be depressed Check the float height adjustment NOTE The inlet needle center pin is spring loaded 15 Make sure the float rests against the fuel inlet needle without depressing the center pin The correct float height setting is 17 mm 0 669 in 1 5 mm 0 059 in measured from the float bottom to the body of the carburetor See Figure 5 30 Replace the float if the height is different than the specified setting Do not attempt to adjust by bending float tab Figure 5 30 Checking Float Height NOTE Be sure to measure from the casting surface not the rubber gasket if still attached 5 17 Section 5 Fuel System and Governor 16 When the proper float height is obtained carefully reinstall the fuel bowl using new O Rings onto the carburetor Secure with the four original screws Torque the screws to 2 5 0 3 N m 23 2 6 in Ib See Figure 5 31 Figure 5 31 Installing Fuel Bowl Choke Repair Is Remove the carburetor from the engine Discard the old mounting gaskets for the air cleaner and carburetor
310. hamber ignited and burned The ECU controls the amount of fuel injected and the ignition timing by monitoring the primary sensor signals for engine temperature speed RPM and throttle position load These primary signals are compared to preprogrammed maps in the ECU computer chip and the ECU adjusts the fuel delivery to match the mapped values An oxygen sensor provides continual feedback to the ECU based upon the amount of unused oxygen in the exhaust indicating whether the fuel mixture being delivered is rich or lean Based upon this feedback the ECU further adjusts fuel input to reestablish the ideal air fuel ratio This operating mode is referred to as closed loop operation The EFI system operates closed loop when all three of the following conditions are met a The oil temperature is greater than 35 C 95 F b The oxygen sensor has warmed sufficiently to provide a signal minimum 375 C 709 c Engine operation is at a steady state not starting warming up accelerating etc During closed loop operation the ECU has the ability to readjust temporary and learned adaptive controls providing compensation for changes in overall engine condition and operating environment so it will be able to maintain the ideal air fuel ratio of 14 7 1 The system requires a minimum engine oil temperature greater than 55 C 130 F to properly adapt These adaptive values are maintained as long as the ECU is powered
311. he carburetor idle fuel needle or idle oil fill cap on the valve cover See Figure 11 105 speed adjusting screw as necessary Refer to Section 5 the Fuel System and Governor Testing the Engine It is recommended that the engine be operated on a test stand or bench prior to installation in the piece of equipment 1 Set the engine up on a test stand Install an oil pressure gauge Start the engine and check to be certain that oil pressure 20 psi or more is present Run the engine at idle for 2 3 minutes then 5 6 minutes more between idle and midrange Adjust the carburetor mixture settings as necessary as available Figure 11 105 Reinstalling Oil Fill Cap Some Models 2 Adjust the idle speed screw and high speed stop as necessary Make sure the maximum engine speed does not exceed 3750 RPM no load Connect Spark Plug Leads 1 Connect the leads to the spark plugs See Figure 11 106 Figure 11 106 Connect Spark Plug Leads 11 31 Section 11 Reassembly 11 32 Section 12 Clutch Clutch General Some engines are equipped with a wet disc type clutch See Figure 12 1 for exploded view of clutch Nameplate Shifting Lever Pin Oil Seal Ball Bearing Snap Ring Pressure Plate Retaining Rings Pilot Bearin Release Sleeve Clutch Assembly Assembly lt Bearing Release Adjusting 8 B Assembly Lock Figure 12 1 Wet Type Clutch Exploded View
312. he injectors 9 Disconnect the throttle linkage and damper spring from the throttle lever Disconnect the TPS lead from the harness 10 Remove the manifold mounting bolts and separate the throttle body manifold from the engine leaving the TPS fuel rail air baffle injectors and line connections intact Discard the old gaskets 11 Position the manifold assembly over an appropriate container and turn the key switch on to activate the fuel pump and pressurize the system Do not turn switch to start position 12 If either injector exhibits leakage of more than two to four drops per minute from the tip or shows any sign of leakage around the outer shell turn the ignition switch off and replace injector as follows 13 Depressurize the fuel system following the procedure in the fuel warning on page 58 2 Remove the two fuel rail mounting screws 14 Clean any dirt accumulation from the sealing mounting area of the faulty injector s and disconnect the electrical connector s 15 Pull the retaining clip off the top of the injector s and remove from manifold 16 Reverse the appropriate procedures to install the new injector s and reassemble the engine Use new O Rings any time an injector is removed new replacement injectors include new O Rings Lubricate O Rings lightly with oil Torque the fuel rail and blower housing mounting screws to 3 9 35 in Ib and the intake manifold and air cleaner mo
313. he person authorizing and date must be on the warranty claim B Warranty Claim Report Forms Three different Warranty Claim Report Forms are accepted by Kohler Co the OPEESA Outdoor Power Equipment and Engine Service Association the OPEI Outdoor Power Equipment Institute and Electronic The electronic Warranty Claim is available in Kohler PLUS You must login to Kohler PLUS with your user name and password to see the electronic Warranty Claim The OPEESA Warranty Claim Form is illustrated and instructions for completing it are given Please follow the instructions when making out the report Do not combine claims for more than one repair on a single form each claim must be filed separately Claims must be received at Kohler Co within 30 days after warranty repairs are made Send the white copy of the paper claim directly to Kohler Co Engine Warranty Kohler WI 53044 except in cases where Central Distributor approval for non expert dealers or certified Expert Dealer approval is required See Section A C Warranty Claim Instructions The Outdoor Power Equipment and Engine Service Association in conjunction with the manufacturers who use it have developed the following warranty claim form Follow these instructions when filling out a paper claim 13 WARRANTY CLAIM FOR 0 Generac PS 0 Kohler 2 Tecumseh 0 US Motor Power COMMERCIAL USER YES O NO PLEASE TYPE OR PRINT CLEARLY TYPE O
314. he throttle linkage clamp bracket mounting screw set the throttle shaft to the full throttle position against the head of the stop screw and retighten the clamp mounting screw securely See Figure 5A 14 re 5A 14 Tightening Throttle Linkage Clamp Bracket Nikki Carburetor 1 5 8 Reinstall the rear plug with a new sealing washer Tighten the plug securely Reinstall fuel transfer chamber cover with a new gasket Secure with the three screws Install new carburetor mounting gasket on manifold studs followed by the carburetor and new air cleaner base gasket Reconnect the throttle and choke linkages and the fuel and vacuum lines Reinstall the air cleaner base and breather tube Secure base with two mounting nuts Torque nuts to 9 9 88 in Ib Install the rest of the air cleaner system 6 Check to be sure all system connections are tight 7 Reset idle RPM and recheck high idle governed speed after starting and allowing sufficient warm up time Electric Lock Off Filter Assembly Functional Test The electric lock off can be easily tested to verify that it is functional Remove it from the system for testing Using a 12 volt power supply or battery connect one wire lead to the positive lead of power supply and touch remaining wire lead to negative lead of power supply When connection is made an audible click should be heard indicating the opening of the lock off While energiz
315. hen remove the base and Remove Muffler gasket while carefully pulling the rubber 1 Remove the exhaust system and attaching breather tube through the base See Figure 9 10 hardware from the engine On engines equipped with a port liner remove it now Remove Air Cleaner Assembly 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 element with precleaner and the stud seal y k 3 Figure 9 10 Removing Breather Tube from Base 9 3 Section 9 Disassembly Figure 9 11 Removing Tube from Breather Cover 6 Remove the rubber breather tube from the breather cover See Figure 9 11 Heavy Duty Air Cleaner 1 Disconnect the breather hose from the fitting in adapter or elbow 2 Remove the two screws one barrel carburetor models or the four hex flange nuts two barrel carburetor models securing the adapter or elbow See Figure 9 12 Breather l Nuts Figure 9 12 Breather Hose Mounting Nuts and Adapter Elbow Two Barrel Model Pictured 3 Remove the screws securing the main support bracket for air cleaner to the valve covers On two barrel carburetor models remove the two mounting screws into the top of intake manifold Unhook the choke return spring if equipped Do not lose any of the hardware See Figure 9 13 9 4 Mounting Screws
316. hydrostatic drive The transmission must be exactly in neutral to or prevent resistance which could keep the engine from starting Engine 2 Check for seized engine components such as the bearings connecting rod and piston 8 29 Section 8 Electrical System and Components Operation Inertia Drive Starters 7 Install the drive pinion dust cover spacer When power is applied to the starter the armature anti drift spring stop gear spacer and stop nut rotates As the armature rotates the drive pinion Torque the stop nut to 17 0 19 2 N m moves out on the splined drive shaft and into mesh 150 170 in Ib Reinstall the dust cover with the flywheel ring gear When the pinion reaches the end of the drive shaft it rotates the flywheel and Style A Style cranks the engine Dust Cover _ oust Cover i Retaining Ring __ 2 When the engine starts the flywheel rotates faster than the starter armature and drive pinion This amp Stop Nut Spring Retainer 3 moves the drive pinion out of mesh with the ring Stop Gear Spacer Anti Drift Spring B gear and into the retracted position When power is i Anti Drift Sprin removed from the starter the armature stops rotating 3 ae and the drive pinion is held in the retracted position Dust Cover PUSI Tover Spacer e by the anti drift spring Spacer Drive Pinion i Drive Pinion Starter Drive Service Drive Nut Collar
317. ic Spark The CD ignition systems produce a high energy electric spark but the spark must be discharged or damage to the system can result Do not crank or run an engine with a spark plug lead disconnected 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 all ignition related wires are connected including the spark plug leads Be certain all terminal connections fit snugly Make sure the ignition switch is in the run position NOTE The CD ignition systems are sensitive to excessive load on the kill lead If a customer complains of hard starting low power or misfire under load it may be due to excessive draw on the kill circuit Perform the appropriate test procedure 8 5 Section 8 Electrical System and Components Test Procedure for Standard Fixed Timing CD Ignition System Isolate and verify the trouble is within the engine ignition system L Locate the plug connectors where the wiring harnesses from the engine and equipment are joined Separate the connectors and remove the white kill lead from the engine connector Rejoin the connectors and position or insulate the kill lead terminal so it cannot touch ground Try to start the engine to verify whether the reported problem is still present a Ifthe problem is gone the electrical system on the unit is suspec
318. ic aids listed after the chart fuel pump relay circuit is either open and any signaled fault codes you should be able to shorted to ground or may be on quickly locate any problems within the system continuously if shorted to battery Expected Engine Response Engine will not run or fuel pump will continue to run when switch is off Possible Causes 1 Fuel Pump Relay Related a Bad fuel pump relay Primary side open or shorted 2 Fuel Pump Related 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 relay pin 85 4 ECU Related a Circuit controlling fuel pump relay damaged Code 61 Source Explanation Denotes the end of fault codes If signaled first no other fault codes are present 58 43 Section 5B EFI Fuel System Bosch Diagnostic Flow Diagram Proceed to Start of Test for retest KEY ON MALFUNCTION INDICATOR LIGHTS ON No REFER TO DIAGNOSTIC AID 1 FAULT CODES ARE FAULT CODES PRESENT REFER TO DIAGNOSTIC AID 2 FAULT CODES CLEAR CODES DOES ENGINE START Yes No REFER TO DIAGNOSTIC AID 3 RUN ON Yes gt OPERATE AT VARIOUS SPEED LOAD CONDITIONS ARE FAULT REFER TO DIAGNOSTIC AID 2 CODES PRESENT FAULT CODES END T TEST CRANK ENGINE DOES MI
319. ick it onto the thrust bearing Wipe some grease on the face of the original shim spacer and stick it onto the thrust washer Install the closure plate onto the crankcase without applying sealant and secure it with only two three of the fasteners at this time Use a dial indicator to check the crankshaft end play End play should be 0 05 0 50 mm 0 0020 0 0197 in except for CH25 engines below Serial No 2403500008 end play should be 0 050 0 75 mm 0 0020 0 0295 in Shim spacers are available in the three color coded thicknesses listed below if adjustment is needed Crankshaft End Play Shims GREEN 0 8366 0 9127 mm 0 8750 mm 0 034 in Nominal YELLOW 1 0652 1 1414 mm 1 1033 mm 0 043 in Nominal RED 1 2938 1 3700 mm 1 3319 mm 0 052 in Nominal Remove the closure plate If end play requires adjustment remove the original spacer and install the appropriate size shim spacer in its place Then follow the procedure under Install Closure Plate Assembly JJ Install Closure Plate Oil Seal 1 Check to make sure that there are no nicks or burrs in the crankshaft bore of the closure plate 2 Applya light coat of engine oil to the outside diameter of the oil seal 3 Drive the oil seal into the closure plate using a seal driver Make sure the oil seal is installed straight and true in the bore to the depth shown in Figure 11 18 Seal Figure 11 18 Oil Seal Depth in Closure Plate Install Clos
320. ictis o quA UU dtr 1 6 1 8 L 1 7 1 9 U S qt Values are in Metric units Values in parentheses are English equivalents Lubricate threads with engine oil prior to assembly 1 8 Section 1 Safety and General Information General Specifications cont Angle of Operation Maximum At Full Oil Level All Directions 257 Blower Housing and Sheet Metal lef Se rei ee renee o o 6 2 N m 55 in Ib into new holes 4 0 N m 35 in Ib into used holes Mo Fasteners NOT aa a 10 7 N m 95 in Ib into new holes 7 3 N m 65 in Ib into used holes ROC GT CoA Fastener TOPOHE 1 4 12 6 in Ib Camshaft Ead Play NE TT T ES 0 076 0 127 mm 0 0030 0 0050 in Running Ui RERUM 0 025 0 063 mm 0 0010 0 0025 in Bore I D lc 20 000 20 025 mm 0 7874 0 7884 in Maxe Wear LUIE C 20 038 mm 0 7889 in Camshaft Bearing Surface O D INV E E A E E E 19 962 19 975 mm 0 7859 0 7864 in Max Wear iai REEL E 19 959 mm 0 7858 in Carburetor and Intake Manifold Intake Manifold Mounting Fastener Torque S TWO OE E A first to 7
321. id bridge of compound Do not put any compound inside the connectors t The 24 584 15 5 ignition modules have a separator barrier between the terminals On these modules seal the base of the terminal if any portion of it is exposed but it is not necessary to have overlapping beads of sealant between the connections 5 Test for spark Test 2 to be sure the system is working before you reinstall the blower housing If there is still a spark problem on one side replace that ignition module and recheck spark 8 11 Section 8 Electrical System and Components To Test Using 25 761 21 S Tester ASAM only Test Procedure NOTE The SAM must be at room temperature when tested Disconnect all of the SAM leads isolating it from the main wiring harness and the ignition module s Testing may be performed with the module mounted or loose The figures show the part removed from the engine for clarity Figure 8 10 1 Connect the tester to the SAM as follows Attach A The yellow tester lead to the long yellow module lead B The brown tester lead to the long brown module lead C The red tester lead to the red module lead D The green tester lead to the green module lead Caution Do not allow the alligator clip leads to touch each other Figure 8 11 8 12 Figure 8 12 2 Check the SAM part number stamped on the side of the housing Verity that you have an analog SAM ASAM Part No 24 584 10 or lower
322. idle fuel adjusting needle is tapered to critical dimensions Damage to the needle and the seat in the carburetor body will result if the needle is forced 2 Now turn the adjusting needle out counterclockwise 1 1 2 turns 3 Start the engine and run at half throttle for 5 to 10 minutes to warm up The engine must be warm before making final settings Check that the throttle and choke plates can fully open NOTE The carburetor has a self relieving choke Choke plate and shaft assembly is spring loaded Check to make sure plate moves freely and is not binding and affecting idle fuel delivery 4 Place the throttle control into the idle or slow position Turn the low idle speed adjusting screw in or out to obtain a low idle speed of 1200 RPM 75 RPM Check the speed using a tachometer NOTE The actual low idle speed depends on the application 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 RPM 75 RPM 5 Turn the low idle fuel adjusting needle in slowly until engine speed decreases and then back out approximately 3 4 turn to obtain the best low speed performance 6 Recheck the idle speed using a tachometer and readjust the speed as necessary Models with Governed Idle System An optional governed idle control system is supplied on some engines The purp
323. ifters Valve R amp R No Grinding Valve Adjustment Valve Grinding Valve Spring Replacement Valve Cover Gasket and or Breather Camshaft R R Camshaft PTO Seal Rocker Arm Ignition Ignition Module R 4 R Flywheel R amp R Spark Advance Module Charging Regulator Test amp Replace Stator Test amp Replace Includes Flywheel R Starter Retractable R Replace Rope amp Spring Starting Motor Bendix Type R amp R Starter Bendix Rebuild Includes R amp R Starter Drive R amp Starter Solenoid R amp R Recoil Cup R amp R Fuel System amp Air Intake Carburetor Solenoid Includes Test Carburetor R amp R Carburetor Rebuild Includes R amp R Carburetor Adjust Air Cleaner Damage in Shipment Fuel Tank R amp R Fuel Pump R R Primer Assembly R amp R Miscellaneous Repairs Cylinder Head and or Gasket Blower Housing Shrouds only R amp R Oil Pan Closure Plate and or Gasket Replace Muffler Replace Governor Adjustment Governor R amp Oil Pump R amp R Crankshaft Grinding ENTER NET COST Crankcase Boring ENTER NET COST Governor Seal Replacement Oil Sentry Oil Temp Oxygen Sensor Cam Followers Includes Valve Adjustment Control Bracket R amp R Control Linkage Dipstick amp Tube Fuel Line and or Filter Cooling Fan Flywheel Breather Assembly Repair Breather Hose R amp R Flywheel Brake Ass
324. ight Multi meter digital Specifications Required e Spark plug gap 0 76 mm 0 030 in e Ignition module air gap 0 28 0 33 mm 0 011 0 013 in 0 30 mm 0 012 in nominal NOTE Ignition tester see Section 2 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 making any of these tests a battery that is hooked up or charged backward will crank the engine but it won t have spark Be sure drive is in neutral and all external loads are disconnected drive is in neutral and all external loads are disconnected Test 1 Isolate and verify the trouble is within the engine ignition system 1 Locate the plug connectors where the wiring harnesses from the engine and equipment are joined Separate the connectors and remove the white kill lead from the engine connector Rejoin the connectors and position or insulate the kill lead terminal so it cannot touch ground Try to start the engine to verify whether the reported problem is still present a Ifthe 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 electrical system of the engine Leave the kill lead isolated until all testing is completed NOTE If the engine starts or runs during any of th
325. ight shank bolts are used torque in increments to 11 3 N m 100 in Ib Illustrated instructions are provided in the service rod package See Figures 11 10 and 11 11 NOTE Align the chamfer of the connecting rod with the chamfer of its mating end cap When installed the flat faces of the connecting rods should face each other The faces with the raised rib should be Cylinder 1 Figure 11 8 Piston Connecting Rod and End Cap toward the outside Detail Section 11 Reassembly Torque these to 22 7 N m 200 in Ib 8 mm Straight Shank Torque these to 14 7 N m 130 in Ib 8 mm Step Down Torque these to 11 3 N m 100 in Figure 11 12 Apply Camshaft Lubricant to Cam 6 mm Straight Shank Lobes 2 Position the timing mark of the crankshaft gear at the 12 o clock position 3 Turn the governor cross shaft clockwise until the lower end of the shaft contacts the cylinder Make sure the cross shaft remains in this position while installing the camshaft See Figure 11 13 Figure 11 10 Connecting Rod Bolts 4 Slide the camshaft into the bearing surface of the crankcase positioning the timing mark of the camshaft gear at the 6 o clock position Make sure that the camshaft gear and crankshaft gear mesh with both timing marks aligned See Figure 11 13 Figure 11 11 Torquing Connecting Rod End Cap 6 Repeat the above procedure for the other Cross Shaft connecting rod and p
326. ing Figure 7 3 Installing Rope 10 11 12 Tie a slipknot approximately 12 in from the free end of rope Hold the pulley firmly and allow it to rotate slowly until the slipknot reaches the guide bushing of the housing Slip the handle and rope retainer onto the rope Tie a single knot at the end of the rope Install the rope retainer into the starter handle Untie the slipknot and pull on the handle until the rope is fully extended Slowly retract the rope into the starter When the spring is properly tensioned the rope will retract fully and the handle will stop against the starter housing Pawls Dogs Replacement To replace the pawls follow disassembly steps 1 4 and reassembly steps 3 8 on the following pages A repair kit is available which includes the following components ay Pawl Retainer Center Screw Pawl Dog Spring Brake Spring Starter Pawl Dog Brake Washer Washer Disassembly A WARNING Spring Under Tension Do not remove the center screw from the starter until the spring tension is released Removing the center screw before releasing spring tension or improper starter disassembly can cause the sudden and potentially dangerous release of the spring Follow these instructions carefully to ensure personal safety and proper starter disassembly Make sure adequate face protection is worn by all persons in the area 1 Release the spring tension and remove the handle and the start
327. ing System With Magneto The 1 25 amp alternator system is designed to charge a 12 volt lead acid storage battery witha minimum rating of 32 amp hr while reducing battery maintenance to a minimum It is for applications that have the electric starter as the only battery load This system consists of three major components a group of two die cast magnets which are affixed to the inner rim of the flywheel the magneto coil alternator stator mounted on the engine crankcase and a full wave rectifier unit APPLICATION Key Switch Off i Start b if 2 4 Fuse D C Ammeter res gt Solenoid LJ LJ LJ 12V Battery Min Rating 32 amp hr CAUTION Break before make type switch is required 12V applied to kill switch could burn out coil Refer to the following 1 25 Amp System Service Guide when servicing the system CAUTION 1 Make sure battery polarity is correct Negative ground systems are used 2 Prevent stator leads AC from touching or shorting Touching or shorted leads could permanently damage the stator 3 Disconnect leads at rectifier before electric welding is done on equipment in common ground with the engine ENGINE Rectifier Magneto Coil Spark Piug MEN Condenser Starter Breaker Points PU tp Switch Wiring Diagram 1 25 Amp Unregulated Battery Charging System With Magneto Yellow 1 Stator L
328. ing plates 23 Remove closure plate assembly 24 Remove camshaft 25 Remove connecting rods with pistons and rings 26 Remove crankshaft 27 Remove governor cross shaft 28 Remove flywheel end oil seal Disconnect Spark Plug Leads 1 Disconnect the leads from the spark plugs See Figure 9 1 NOTE Pull on boot only to prevent damage to spark plug lead Figure 9 1 Disconnect Both Spark Plug Leads Shut Off Fuel Supply Drain Oil from Crankcase and Remove Oil Filter 1 Remove the oil fill cap dipstick and one of the oil drain plugs 9 1 Section 9 Disassembly 3 Remove and discard the oil filter See Figure 9 5 Figure 9 4 Removing Oil Drain Plug Figure 9 6 Removing Oil Filter Adapter Nipple 2 Allow ample time for the oil to drain from the crankcase and oil filter 9 2 Section 9 Disassembly 4 Remove the hex flange screws securing the bracket and base See Figure 9 8 Two additional rear screws must be removed if the engine contains a rear air cleaner support bracket See Figure 9 9 Figure 9 7 Removing Oil Cooler 4 An oil cooler is standard equipment on some models and an option on others It may be a cast aluminum housing part of the oil filter adapter or attached to the blower housing separated from the oil filter adapter If so equipped remove the adapter and the cooler See Figures 9 6 and Figure 9 9 Rear Air Cleaner Bracket Screws 9 7 5 Remove the bracket t
329. ing 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 manifolds See Figure 9 48 9 12 Figure 9 49 Bolt Wiring Harness Detail Remove Spark Plugs 1 Remove the spark plug from each cylinder head Figure 9 50 Removing Spark Plugs Remove Cylinder Heads and Hydraulic Lifters NOTE Cylinder heads are retained using either 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 flange screws or hex nuts and washers securing each cylinder head See Figure 9 51 Discard the screws or nuts and washers once removed Do not reuse Studs if present should only be removed if damaged or if cylinder reconditioning is necessary Once removed they must be replaced Section 9 Disassembly Hex Flange Screw Hex Flange Nut and Washer Figure 9 51 Removing Cylinder Head Fasteners 2 Mark the position of the push rods as either intake or exhaust and cylinder 1 or 2 Push rods should always be reinstalled in the same positions 3 Carefully remove the push rods cylinder heads and head gaskets See Figure 9 52 9 13 Section 9 Disassembly Stud and Hex Flange Nut Style Mounting Figure 9 52 Removing C
330. inner portion of the circuit controls the fiow of current to the gate of the PUT Again we have a zener diode which functions as a voltage sensing device The zener diode is connected to the cathode of transistor Q1 The anode is connected across the battery through resistors R1 and R2 so it will receive a voltage proportional to the battery voltage The transistor continuously monitors or compares the voltages at its anode and cathode When the battery voltage drops below the desired regulation voltage the reference voltage reaching the cathode from the zener diode will exceed the voltage at the anode and current will flow from the anode through the gate terminal to the gate of the PUT The PUT switches electronically to complete the charging circuit and charge the battery When the battery comes up to full charge and the anode voltage exceeds the cathode voltage at transistor Q1 current to the gate of the PUT will be cut off and the PUT will block the flow of current in the charging circuit Regulator Rectifier Circuit Schematic now we hope you have gained a basic understanding of the functional theory of the ignition and charging systems If you have it should help you when troubleshooting and diagnosing problems in these areas To further assist you the following pages contain wiring diagrams and troubleshooting charts for the various charging systems 25 1 25 Amp Unregulated Battery Charg
331. ion chamber shortly after ignition This creates two flame fronts where it is burned along with the fuel High oil which meet and explode to create extreme hammering consumption can also occur when the piston ring end pressures on a specific area of the piston Detonation gap is incorrect because the ring cannot properly generally occurs from using low octane fuels conform to the cylinder wall under this condition Oil control is also lost when ring gaps are not staggered Preignition or ignition of the fuel charge before the during installation timed spark can cause damage similar to detonation Preignition damage is often more severe than When cylinder temperatures get too high lacquer and detonation damage Preignition is caused by a hot varnish collect pistons causing rings to stick which spot in the combustion chamber from sources such as results in rapid wear A worn ring usually takes on a glowing carbon deposits blocked cooling fins an shiny or bright appearance improperly seated valve or wrong spark plug s Scratches on rings and pistons are caused by abrasive See Figure 10 8 for some common types of piston and material such as carbon dirt or pieces of hard metal ring damage nal wi N qu n ou i AMET m t i i 1 AN i Wi if HG T IE Lm IL d N
332. ipes walls partitions etc in the path of air exiting the engine If contemplating using an oil cooler in the cooling air intake stream contact your Kohler Engine representative Enclosures If the engine must be located in a building or enclosure make certain that adequate air intake and air outlet openings are provided If necessary other means such as ducts or ventilating fans will have to be used to provide adequate cooling airflow Enclosure Causes Recirculation AES ES o EN ENS Pu No Outlet Figure 3 3 Recirculated Air Adds to Heat 12 Be sure room temperature remains cool enough so that the inlet air to the engine fan is always below 130 F 54 4 C Ducting in small enclosures the opening for inlet air must be at least 1 1 2 times larger than the blower housing inlet and the opening for outlet air must be at least 2 times larger than the size of the blower housing outlet The size of those openings must be increased to compensate for loss of air volume when louvers or gratings are used When an application requires the engine be enclosed or be mounted inside of equipment it is advisable to install a partition separating the inlet and exhaust air vents as shown in Figure 3 4 Enclosure Section 3 Properly Installing the Engine Easy In Easy Out Partition p Battle ESE Figure 3
333. is a formed tube assembly that feeds fuel to the top of the injectors The tops of the injectors fit into formed cups in the fuel rail When the rail is fastened to the manifold the injectors are locked into place A small retaining clip provides a secondary lock Incorporated into the fuel rail is a pressure relief test valve for testing operating pressure or relieving fuel system pressure for servicing The fuel supply line is attached to the barbed end of the fuel rail with an Oetiker hose clamp Service The fuel rail is mounted to the throttle body intake manifold It can be detached by removing the two mounting screws and the injector retaining clips Thoroughly clean the area around all joints prior to any disassembly No specific servicing is required unless operating conditions indicate that it needs internal cleaning or replacement Fuel Line Figure 5B 34 High Pressure Fuel Line General Special low permeation high pressure fuel line with an SAE30 R9 rating is required for safe and reliable operation due to the higher operating pressure of the EFI system If hose replacement is necessary order Fuel Line Service Kit Part No 25 111 37 S containing 60 of high pressure hose and 10 Oetiker clamps or use only the type specified Special Oetiker clamps Kohler Part No 24 237 05 S are used on all fuel line connections to prevent tampering and safety hazards with the high fuel pressure The old clamp must be cut to open a
334. iscellaneous Repairs Cylinder Head and or Gasket Replace each Cylinder Head Retorque Shrouds only R amp R Oil Pan and or Gasket Replace Muffler Replacement Governor Adjustment Governor Replacement Oil Pump Replacement Crankshaft Grinding ENTER NET COST Crankcase Boring ENTER NET COST K141 K161 K181 only 28 KOHLER Policy Adjustment Explanation Form NGI NI ES Attach to Warranty Claim Name Please Print ___________________________________ Inspection Date Central Distributor 1 Phone Claim No Purpose The Engine Service Department is responsible for providing an explanation for each warranty claim processed This form will fulfill the requirement for a uniform letter of explanation It is to be completed and attached to any warranty claim that is classified a policy adjustment or to be used with any claim that requires further explanation Failure to attach this form on all Policy Adjustment Claims will result in the warranty claim being returned to the Central Distributor which will delay processing Please Check One C Known defect that failed outside the standard warranty period C Non warranty situation irate customer Benefit of doubt Written Explanation Required Signature o e uu _ 0 DERCEI
335. isconnected for any reason the engine will quit running Service The engine speed sensor is a sealed non serviceable assembly If Fault Code diagnosis indicates a problem within this area check and test as follows 1 Check the mounting and air gap of sensor It must be 1 5 mm 0 25 mm 0 059 0 010 in 2 Inspect the wiring and connections for damage or problems 3 Make sure the engine has resistor type spark plugs 4 Disconnect main harness connector from ECU 58 6 5 Connect an ohmmeter between the designated pin terminals in the plug 35 Pin MA 1 7 Metal Cased ECU 3 and 21 pin terminals 24 Pin MSE 1 0 Plastic Cased ECU 9 and 10 pin terminals 32 Pin MSE 1 1 Plastic Cased ECU 9 and 10 pin terminals See pages 5B 28 5B 33 according to ECU style A resistance value of 750 1000 at room temperature 20 C 68 F should be obtained If resistance is correct check the mounting air gap toothed ring gear damage runout etc and flywheel key 6 Disconnect the speed sensor connector from wiring harness It is the connector with one heavy black lead see Figure 5B 5 Viewing the connector as shown dual aligning rails on top test the resistance between the terminals indicated A reading of 750 1000 should again be obtained Dual Aligning Rails Corresponds 2 21 Metal Cased ECU or 9 Plastic Casec ECU In Main 10 Plastic Cased Co
336. iston assembly Install Camshaft 1 Liberally apply camshaft lubricant see Section 2 to each of the cam lobes Lubricate the camshaft bearing surfaces of the crankcase and the Figure 11 13 Aligning Crankshaft and Camshaft camshaft with engine oil See Figure 11 12 Timing Marks Camshaft End Play Install the shim removed during disassembly onto the camshaft 2 Position the camshaft end play checking tool on the camshaft See Figure 11 14 Figure 11 14 Checking Camshaft End Play 3 Apply pressure on the camshaft end play checking tool pushing camshaft toward crankshaft Use a feeler gauge to measure the camshaft end play between the shim spacer and the checking tool Camshaft end play should be 0 076 0 127 mm 0 003 0 005 in 4 Ifthe camshaft end play is not within the specified range remove the checking tool and replace the shim as necessary 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 Green 0 89535 0 99345 mm 0 03525 0 03675 in Gray 0 94615 0 98425 mm 0 03725 0 03875 in Black 0 99695 1 03505 mm 0 03925 0 04075 in 5 a Play Figure 11 15 Change Shim to Obtain Correct End Section 11 Reassembly 5 Reinstall the end play checking tool and recheck the end play Oil Pump Assembl
337. it 66 4 N m 49 ft Ib See Figure 11 29 will be installed later Figure 11 29 Installing and Torquing Flywheel Figure 11 31 Installing Plastic Grass Screen Fastener Section 11 Reassembly Install Supports for the Metal Grass Screen 1 Ifa metal grass screen is used with threaded individual supports install a spacer washer on the external threads Apply blue Loctite No 242 removable onto the threads Install the four supports as shown in Figure 11 32 Figure 11 34 Applying Camshaft Lubricant to Bottom of Lifters 3 Note the mark or tag identifying the hydraulic lifters as either intake or exhaust and cylinder 1 or cylinder 2 Install the hydraulic lifters into their appropriate location in the crankcase Do not use a magnet Figure 11 35 Figure 11 32 Installing Supports for Metal Grass Screen NOTE Hydraulic lifters should always be installed in the same position as before 2 Tighten the supports with a torque wrench to disassembly The exhaust lifters are 9 9 N m 88 in Ib See Figure 11 33 The grass located on the output shaft side of screen will be installed to the supports after the the engine while the intake lifters are blower housing is in place located on the fan side of the engine The cylinder numbers are embossed on the top of the crankcase and each cylinder head See Figure 11 36 Figure 11 33 Torquing Supports for Metal Screen Some Models Install Hydraulic Lifters
338. k travel beyond bottom dead center Intake valve closing therefore is always after bot tom dead center and is specified in those terms Both valves are closed during the compression stroke and the early part of the power stroke During the power stroke some of the energy from the expanding gases is sacrificed to make sure that the exhaust gases are completely cleared from the cylinder in preparation for the next intake stroke It is common practice to open the exhaust valve before bottom center for intake valve opening Cams are designed to provide 1 a clearance of a few thousandths of an inch during a part of the cycle when the valves must be closed 2 a ramp for engaging the valve and starting its lift 3 a portion to accelerate the valve to maximum opening velocity 4 a section to decelerate it to a stop at the cam nose and 5 the other half of the cam lobe which closes the valve again through the same sequence but in reverse The intake manifold valve ports and throat area of the combustion chamber must be of such size and shape that air may flow through with minimum restriction Accumulations of carbon or lead de posits in any of these area will immediately decrease the maximum power FLYWHEEL An engine produces its power during the power stroke only Therefore there must be sufficient momentum built into the engine to carry it through the other three strokes without injurious loss of speed This function is
339. kcase through a hose or by direct lever pump actuation off rocker arm movement The pumping action causes the diaphragm on the inside of the pump to pull fuel in on its downward stroke and to push it into the carburetor on its upward stroke Internal check valves prevent fuel from going backward through the pump Outlet Line to Carburetor Pulse Fuel Pump Inlet Line Figure 5 1 Pulse Style Fuel Pump Performance Minimum fuel delivery rate must be 7 5 L hr 2 gal hr with a pressure 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 available through your source of supply To replace the pulse pump follow these steps 1 Disconnect the fuel lines from the inlet and outlet fittings 2 Remove the hex flange screws securing the fuel pump 3 Remove the pulse line that connects the pump to the crankcase or valve cover Section 5 Fuel System and Governor NOTE On most models the pulse line is connected to a fitting on the crankcase while on early models it is connected to the valve cover 4 Install the new fuel pump using the hex flange screws Torque the hex flange screws to 2 3 N m 20 in Ib NOTE Make sure the orientation of the new pump is consistent with the removed pump Internal damage may occur if installed incorrectly 5 Connect
340. ke a line near the edge of the flywheel screen with a marking pen or narrow tape Connect an automotive timing light to cylinder that had good spark Figure 8 9 3 Run the engine at idle and use the timing light beam to locate the line on the screen Draw a line on the blower housing adjacent to the line on the screen Accelerate to full throttle and watch for movement of the line on the screen relative to the line on the blower housing If both cylinders had good spark repeat the test on the other cylinder a Ifthe line on the screen moved away from the line on the blower housing during acceleration the SAM is working properly If it didn t move away go to Test 5 8 9 Section 8 Electrical System and Components b If you were able to check timing on both cylinders the lines you made on the blower housing should be 90 apart If they re not go to Test 4 Test 4 Test the ignition modules and connections 1 8 10 Remove the blower housing from the engine Inspect the wiring for any damage cuts bad crimps loose terminals or broken wires Disconnect the leads from the ignition module s and clean all of the terminals male and female with aerosol electrical contact cleaner to remove any old dielectric compound dark residue dirt or contamination Disconnect the spark plug leads from the spark plugs Remove one of the mounting screws from each of the ignition modules If the mounting screws ar
341. ke sure the Fly stamping on piston is facing towards the flywheel side of the engine Use a hammer with a rubber grip and gently tap the piston into the cylinder as shown in Figure 11 9 Be careful that the oil ring rails do not spring free between the bottom of the ring compressor and top of the cylinder Figure 11 7 Installing Crankshaft Install Connecting Rods with Pistons and Rings NOTE The cylinders are numbered on the crankcase 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 orientation of the piston connecting rod assemblies inside the engine is extremely important Improper orientation can cause extensive wear or damage Be certain the pistons and connecting rods are assembled Figure 11 9 Installing Piston Assembly Using Ring exactly as shown in Figure 11 8 Compressor Tool 1 Stagger the piston rings in the grooves until the 5 Install the inner rod cap to the connecting rod end gaps are 120 apart The oil ring rails should using the two hex flange screws Three different also be staggered types of connecting rod bolts have been used and each has a different torque value If 8 mm straight shank type bolts are used torque in increments to 22 7 200 in Ib If 8 mm step down bolts are used torque in increments to 14 7 130 in Ib If 6 mm stra
342. ken dipper caused the failure If the color had been the same on both sides of the break it would have indicated that the dipper broke after the seizure and the cause of failure would have to be found elsewhere The last rod from an engine that was started with no oil The bearing surface is smeared and the rod is darkened from the heat of the seizure but there are no burned oil deposits because there was no oil present Figure 59 Figure 59 If the dipper is broken look closely at the break surface Is it a tensile break or a fatigue break Figure 60 Figure 60 A tensile break results from a single sharp blow that breaks off the dipper The dipper will have a nick or scrape where it was hit and the break surface will be quite rough because the metal has been torn apart You might also notice a feather pattern which can indicate the direction of the breaking force Figure 61 Figure 61 A fatigue break usually results from damage done prior to or during assembly If the rod is dropped on the dipper or the dipper is bumped against the workbench a small stress crack can be created in the aluminum The forces of operation along with repeated heating and cooling will cause increased metal fatigue around the crack The crack will spread until the dipper finally separates and drops into the oil pan Figure 62 Figure 62 After the dipper drops off the rod will seize because the oil is no
343. l Altitude Blocked or restricted fuel return circuit to tank Code 42 Source Engine Oil Temperature Sensor Explanation Not sending proper signal to ECU Expected Engine Response Engine may be hard to start because ECU can t determine correct fuel mixture Possible Causes 1 Temperature Sensor Related a Sensor wiring or connection 2 Engine Wiring Harness Related 35 Pin MA 1 7 Metal Cased ECU a Pin circuits 14 and or 27A damaged wires connectors or routed near noisy signal coils alternator etc b ECU to harness connection problem 2 Engine Wiring Harness Related 24 Pin MSE 1 0 Plastic Cased ECU a Pin circuits 4 6 and or 4A damaged wires connectors or routed near noisy signal coils alternator etc b ECU to harness connection problem Section 5B EFI Fuel System 2 Engine Wiring Harness Related 32 Pin MSE 1 1 Plastic Cased ECU a circuits 4 6 and or 4A damaged wires connectors or routed near noisy signal coils alternator etc b ECU to harness connection problem 3 System Related a Engine is operating above the 176 C 350 F temperature sensor limit Code 43 and 44 32 Pin MSE 1 1 Plastic Cased ECU only Source TPS Auto Learn initialization function failed throttle angle out of learning range Explanation While performing the TPS Auto Learn function the measured throttle angle was not within
344. l Clean all parts thoroughly as the 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 the manufacturer 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 cleaners can quickly break down the lubricating properties of engine oil Typical Disassembly Sequence The following sequence is suggested for complete engine disassembly The sequence can be varied to accommodate options or special equipment Disconnect spark plug leads Shut off fuel supply Drain oil from crankcase and remove oil filter Remove muffler Remove air cleaner assembly Remove fuel pump Remove control panel if so equipped Remove throttle and choke controls 9 Remove external governor controls 10 Remove carburetor 11 Remove Oil Sentry if so equipped 12 Remove electric starter motor 13 Remove outer baffles and blower housing 14 Remove inner baffles and breather cover 15 Remove valve covers 16 Remove ignition modules 17 Remove intake manifold 18 Remove spark plugs 19 Remove cylinder heads and hydraulic lifters 20 Remove grass screen and fan 21 Remove flywheel 22 Remove stator and back
345. l Regulator Test Harness with Diode D T1 033 Spark Advance Module SAM Tester To test the SAM ASAM and DSAM on engines with SMART SPARK Starter Brush Holding Tool Solenoid Shift SE Tools KLR 82416 To hold brushes during servicing Starter Retaining Ring Tool Inertia Drive To remove and reinstall drive retaining rings excluding FASCO starters Starter Servicing Kit Starters To remove and reinstall drive retaining rings and brushes SE Tools KLR 82411 Individual Component Available Starter Brush Holding Tool Solenoid Shift Tachometer Digital Inductive Design Technology Inc For checking operating speed RPM of an engine D IT 110 Vacuum Pressure Tester Kohler 25 761 22 5 Alternative to a water manometer SE Tools KLR 82413 For sizing valve guides after installation Valve Guide Service Kit Courage Aegis Command OHC SE Tools KLR 82415 For servicing worn value guides SE Tools KLR 82416 2 2 Section 2 Tools amp Aids Biss Dielectric Grease GE Novaguard G661 Kohler 25 357 11 S Electric Starter Drive Lubricant Inertia Drive Kohler 52 357 01 S Electric Starter Drive Lubricant Solenoid Shift Kohler 52 357 02 S Silicone Sealant Kohler 25 597 07 S Loctite 5900 Heavy Body in 4 oz aerosol dispenser Only oxime based oil resistant RTV sealants such as those listed are approved for use Loctite Nos 5900 or 5910 are recommended for best sealing char
346. l or end of condenser lead 6 Make sure terminal attaching screw is turned 3 Connect small black tester lead to condenser all the way in so normal tension is applied to case or mounting bracket contacts 4 If condenser is mounted to engine condenser 7 Make sure contacts are closed and observe lead must be disconnected pointer on scale No 2 5 Turn selector switch to No 5 Leakage and 8 Pointer should be within OK block at left of Short scale 6 Depress red button on front of tester and hold 9 If resistance is above OK block clean points for at least 15 seconds with electrical contact cleaner and or stiff paper business card Repeat resistance test 7 Meter pointer should move to the right initially but return to the narrow black bar at left end of 10 If resistance cannot be brought within OK scale 5 Any readings to the right of black bar block replace points indicate condenser is defective Breaker Point Resistance Test Condenser Test Breaker Point Resistance Ohmmeter Test NOTE Ohmmeter used for this test must be capable of reading resistance values of 1 ohms 1 Set ohmmeter to most sensitive scale 2 Clip ohmmeter leads together and set meter 12 3 Clip one ohmmeter lead to moveable contact side of points clip other lead to stationary contact side 4 Make sure terminal attaching screw is turned all the way in so normal tension is applied to cont
347. lanation System too rich Temporary fuel adaptation control is at the upper limit Expected Engine Response Erratic performance Will run rich smoke Possible Causes 1 Fuel Supply Related nothing lean only rich a Restricted return line causing excessive fuel pressure b Fuelinlet screen plugged in tank fuel pump only c Incorrect fuel pressure at fuel rail 2 Oxygen Sensor Related Sensor connector or wiring problem Sensor contaminated or damaged Exhaust leak Poor ground path Pin circuit wiring or connectors Pin 10 for 35 Pin MA 1 7 Metal Cased ECU Pin 11 for 24 Pin MSE 1 0 Plastic Cased ECU Dus qe 58 40 Pin 20 for 32 Pin MSE 1 1 Plastic Cased ECU 3 TPS Sensor Related a Throttle plate position incorrectly set or registered during Initialization b TPS problem or malfunction 4 Engine Wiring Harness Related a Difference in voltage between sensed voltage pin circuit 17 for metal cased ECU pin circuit 2 for plastic cased ECU and actual injector voltage circuit 45 45A 5 Systems Related a Ignition spark plug plug wire ignition coil b Fuel fuel type quality injector fuel pump fuel pressure c Combustion air air cleaner dirty restricted intake leak throttle bores Base engine problem rings valves Exhaust system leak Fuel in the crankcase oil Blocked or restricted fuel return circuit to tank moo 6 ECU Harness Relat
348. le Install Electric Starter Motor 1 Install the starter motor using the two hex flange screws See Figure 11 73 Some inertia drive starters have a pinion cover and spacers on the starter bolts 2 Torque the two hex flange screws to 15 3 N m 135 in Ib Figure 11 73 Installing Electric Starter Motor Section 11 Reassembly 3 On models with a solenoid shift starter connect the leads to the solenoid See Figure 11 74 Figure 11 74 Connecting Leads to Starting Motor NOTE If the engine uses a side mount muffler on the starter side be sure to tie the wires close to the starter to avoid contact with hot exhaust gt 2 parts Install Fuel Pump Plastic Cased Pulse Fuel Pump Figure 11 75 Reinstalled Fuel Pump A WARNING Explosive Fuel Gasoline may be present in the carburetor and fuel system Gasoline is extremely flammable and its vapors can explode Install Carburetor if ignited Keep sparks and other sources of ignition awa i the i WARNING Explosive Fuel Gasoline may be present in the carburetor and fuel system 1 Install the pulse style fuel pump and lines as an Gasoline is extremely flammable and its vapors can explode assembly Connect the pulse line to the crankcase if ignited Keep sparks and other sources of ignition away vacuum fitting or the valve cover whichever from the engine source is used One Barrel Carburetor Models NOTE Pulse style fuel pumps may be
349. le gasoline Gum is a prevalent cause of valve sticking The cure is to ream the valve guides and clean or replace the valves depending on their condition Overheating An exhaust valve subject to overheating will have a dark discoloration in the area above the valve guide Worn guides and faulty valve springs may cause this condition Also check for clogged air intake and blocked fins when this condition is noted 10 7 Section 10 Inspection and Reconditioning Valve Guides If a valve guide is worn beyond specifications it will not guide the valve in a straight line This may result in burnt valve faces or seats loss of compression and excessive oil consumption To check valve guide to valve stem clearance thoroughly clean the valve guide and using a split ball gauge measure the inside diameter of the guide Then using an outside micrometer measure the diameter of the valve stem at several points on the stem where it moves in the valve guide Use the largest stem diameter to calculate the clearance by subtracting the stem diameter from the guide diameter If the intake clearance exceeds 0 038 0 076 mm 0 0015 0 0030 in or the exhaust clearance exceeds 0 050 0 088 mm 0 0020 0 0035 in determine whether the valve stem or guide is responsible for the excessive clearance The maximum I D wear on the intake valve guide is 7 134 mm 0 2809 in while 7 159 mm 0 2819 in is the maximum allowed on the exhaust guide
350. le the stop collar retainer assembly a Install the stop collar down onto the armature shaft with the counter bore recess up b Install a new retainer in the larger rear groove of the armature shaft Squeeze with a pliers to compress it in the groove c Slide the stop collar up and lock it into place so the recess surrounds the retainer in the groove If necessary rotate the pinion outward on the armature splines against the retainer to help seat the collar around the retainer Figure 8 63 Removing Brush Holder 3 Clean the component parts as required 4 The new brushes and springs come preassembled in a brush holder with a protective sleeve that will also serve as an installation tool See Figure 8 64 Figure 8 65 Installing Stop Collar and Retainer NOTE Always use a new retainer Do not reuse old retainers which have been removed 3 Install the offset thrust stop washer so the Figure 8 64 Service Brush Kit smaller offset of the washer faces the retainer collar See Figure 8 66 5 Perform Steps 10 13 in the Starter Reassembly sequence Installation must be done after the armature drive lever and frame are installed if the starter has been disassembled 8 40 Figure 8 66 Installing Thrust Washer 4 Apply asmall amount of oil to the bearing in the drive end cap and install the armature with the drive pinion 5 Lubricate the fork end and center pivot of the drive lever with
351. left of 0 on the gauge vacuum or negative pressure is indicated If the reading is the right of 0 on the gauge positive pressure present Crankcase vacuum should be 4 10 inches of to 15 water If the reading is below specification or if pressure is present check the following table for possible causes and remedies 3 3 Section 3 Troubleshooting No Crankcase Vacuum Pressure in Crankcase 1 Crankcase breather clogged or inoperative Seals and or gaskets leaking Loose or improperly torqued fasteners Piston blowby or leaky valves confirm by inspecting components Restricted exhaust Compression Test Some of these engines are equipped with an automatic compression release ACR mechanism Because of the ACR mechanism it is difficult to obtain an accurate compression reading As an alternative perform a cylinder leakdown test Cylinder Leakdown Test A cylinder leakdown test can be a valuable alternative to a compression test By pressurizing the combustion chamber from an external air source you can determine if the valves or rings are leaking and how badly Cylinder Leakdown Tester see Section 2 is a relatively simple inexpensive leakdown tester for small engines The tester includes a quick disconnect for attaching the adapter hose and a holding tool Leakdown Test Instructions 1 Run engine for 3 5 minutes to warm it up 2 Remove spark plug s and air filter from engine 3
352. lenoid unhook the plunger pin from the drive lever Remove the gasket from the recess in the housing See Figures 8 50 and 8 51 NOTE Test procedure for checking starter solenoid on pages 8 44 and 8 45 Figure 8 51 Removing Plunger 4 Remove the two thru larger bolts See Figure 8 52 8 36 Section 8 Electrical System and Components 7 Remove the drive lever pivot bushing and backing plate from the end cap See Figure 8 55 Figure 8 52 Removing Thru Bolts 5 Remove the commutator end plate assembly Figure 8 55 containing the brush holder brushes springs and locking caps Remove the thrust washer from 8 Take out the drive lever and pull the armature inside the commutator end See Figure 8 53 out of the drive end cap See Figure 8 56 9 Remove the thrust washer from the armature shaft See Figure 8 56 Figure 8 53 Removing Commutator End Plate Assembly 6 Remove the frame from the armature and drive end cap See Figure 8 54 Figure 8 56 Armature and Lever Removed Figure 8 54 Starter Frame Removed 8 37 Section 8 Electrical System and Components 10 Push the stop collar down to expose the retaining ring See Figure 8 57 Figure 8 57 Retaining Ring Detail 11 Remove the retainer from the armature shaft Save the stop collar NOTE Do not reuse the old retainer Armature Washer Figure 8 58 Removing Retaining Ring 12 Remove the drive pinion assembl
353. ly 4 MIL electrical circuit problem 15 Code 61 End of Fault Blink Code Transmission 35 Pin MA 1 7 Metal Cased ECU Pin circuits 31 and 31A Diagnostic Aid 3 RUN ON MIL remains on 24 Pin MSE 1 0 Plastic Cased ECU Pin while engine is running circuits 19 and 84 32 Pin MSE 1 1 Plastic Cased ECU Pin Possible causes circuits 29 and 84 1 Fault codes which turn on MIL when engine is 5 Ignition switch running 6 Permanent ECU power circuit problem a Code 21 Engine Speed Synchronization 35 Pin MA 1 7 Metal Cased ECU Pin circuit b Code 22 Throttle Position Sensor 5 16 c 23 Engine Control Unit ECU 24 Pin MSE 1 0 Plastic Cased ECU Pin d Code 31 Oxygen Sensor shorted circuit 1 e Code 34 Fuel System permanent adaptation 32 Pin MSE 1 1 Plastic Cased ECU Pin at limit circuit 1 f Code 42 Engine Oil Temperature Sensor 7 Switched ECU power circuit problem g Code 43 TPS Auto Learn Initialization 35 Pin MA 1 7 Metal Cased ECU Pin circuit Function Below Min Limit 32 Pin MSE 1 1 Plastic Cased ECU only 24 Pin MSE 1 0 Plastic Cased ECU Pin h Code 44 TPS Auto Learn Initialization circuit 2 Function Above Max Limit 32 Pin 32 Pin MSE 1 1 Plastic Cased ECU Pin MSE 1 1 Plastic Cased ECU only circuit 2 i Code 51 Injector 1 32 Pin MSE 1 1 8 ECU grounds Plastic Cased ECU only 9 ECU j Code 52 Injector 2 32 Pin MSE
354. ly produced by Kohler Co are rated under SAE test code J1940 Tests are based on sea level operation barometric pressure of 29 92 inches of mercury or 760 mm The J1940 test establishes a correlation temperature of 77 F 25 C The Horsepower Torque power curves shown and in our sales literature are Gross Horsepower generated under laboratory conditions When engines are shipped with the required air cleaner and approved emission compliant exhaust systems they will generate Net Horsepower this will be approximately 15 below the gross curve Available Horsepower calculations should be based on pec c a net output figure Operating at temperatures or elevations different from the test standards will change the horsepower output This will be figured in later along with other factors which influence engine horsepower The performance of an engine under test lab conditions is plotted on power data curves such as those shown in Figure 1 1 for the Kohler 11 13 and 15 HP Command engines Power curves are available for all Kohler engines In some publications only the torque curves are shown as in the sample in Figure 1 2 Torque is a turning or twisting motion that produces rotation or torsion perpendicular to the drive shaft An accurate comparison of Torque Output at the desired running speed is particularly critical when replacing older non emission compliant L head REVOLUTIONS PER MIN 1 34 engines with newer OHV e
355. maintenance listed in the owner s manual Kohler Co recommends that you retain all receipts covering maintenance on the engine But Kohler Co cannot deny warranty solely for the lack of receipts or for your failure to assure that all scheduled maintenance was performed b Be aware however that Kohler Co may deny warranty coverage if the engine or a part has failed due to abuse neglect improper maintenance or unapproved modifications c For warranty repairs the engine must be presented to a Kohler Co service center as soon as a problem exists Call 1 800 544 2444 or access our web site at www kohlerengines com for the names of the nearest service centers The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days If you have any questions regarding warranty rights and responsibilities you should contact Kohler Co at 1 920 457 4441 and ask for an Engine Service representative COVERAGE Kohler Co warrants to the ultimate purchaser and each subsequent purchaser that the engine will be designed built and equipped at the time of sale to meet all applicable regulations Kohler Co also warrants to the initial purchaser and each subsequent purchaser that the engine is free from defects in materials and workmanship which cause the engine to fail to conform with applicable regulations for a period of two years Engines produced in 2006 or later are warranted for two years in California For 1997 and late
356. must be corrected before the auto learn function can be re initiated The PC based diagnostic tool and software may be used to read out the fault code and assist with the troubleshooting and repair 58 10 Engine Oil Temperature Sensor Figure 5B 10 Engine Oil Temperature Sensor General The engine oil temperature sensor Figure 5B 10 is used by the system to help determine fuel requirements for starting a cold engine needs more fuel than one at or near operating temperature Mounted in the oil filter adapter housing it has a temperature sensitive resistor that extends into the oil flow The resistance changes with oil temperature altering the voltage sent to the ECU Using a table stored in its memory the ECU correlates the voltage drop to a specific temperature Using the fuel delivery maps the ECU then knows how much fuel is required for starting at that temperature Service The temperature sensor is a sealed non serviceable assembly A faulty sensor must be replaced If a blink code indicates a problem with the temperature sensor it can be tested as follows 1 Remove the oil temperature sensor from the adapter housing and cap or block the adapter hole 2 Wipe sensor clean and allow it to reach room temperature 20 C 68 F 3 Unplug the main harness connector from the ECU 4 With the sensor connected check the oil temperature sensor circuit resistance The value should be 2375 2625
357. n The development of engines in the 19th century was influenced by the need for pumping water from coal mines The use of coal was accelerating and it became necessary to go deeper into the ground for more coal rendering hand powered pumps imprac tical as the volume and lift of water to be handled increased The first engines developed for the mine applications were huge machines of small power output For a comprehensive historical outline of the history of engine power ask your Kohler Distributor for a copy of Introduction to Engine Power 2196 Three functions involving air fuel mixture necessary for internal combustion engines to operate 1 Compression 2 Ignition and 3 Combustion and they are engineered to perform those functions either through two stroke cycle or four stroke cycle designs Astroke is defined as movement of the piston from one end of its travel to the other It may be either toward the crankshaft or away from it TWO STROKE CYCLE FOUR STROKE CYCLE In the two stroke cycle engine or two cycle engine In the four stroke cycle engine or four cycle one as shortened in every day usage one operating operating cycle is completed for every four strokes of cycle is completed for every two strokes of the piston the piston or two revolutions of the crankshaft or one revolution of the crankshaft Air is usually introduced through holes or ports in the cylinder wall As the piston mov
358. n 2006 and later must be designed built and equipped to meet the state s stringent anti smog standards In other states 1997 and later model year engines must be designed built and equipped to meet the U S EPA regulations for small non road engines The engine must be free from defects in materials and workmanship which cause it to fail to conform with U S EPA standards for the first two years of engine use from the date of sale to the ultimate purchaser Kohler Co must warrant the emission control system on the engine for the period of time listed above provided there has been no abuse neglect or improper maintenance The emission control system may include parts such as the carburetor or fuel injection system the ignition system and catalytic converter Also included are the hoses belts and connectors and other emission related assemblies Where a warrantable condition exists Kohler Co will repair the engine at no cost including diagnosis if the diagnostic work is performed at an authorized dealer parts and labor MANUFACTURER S WARRANTY COVERAGE Engines produced in 2006 or later are warranted for two years in California In other states 1997 and later model year engines are warranted for two years If any emission related part on the engine is defective the part will be repaired or replaced by Kohler Co free of charge OWNER S WARRANTY RESPONSIBILITIES a The engine owner is responsible for the performance of the required
359. n front of the flame front is known as auto ignition or detonation Another form of uncontrolled combustion is caused by some spot in the cylinder remaining hot enough after the exhaust stroke to ignite the incoming mixture before the normal spark ignition This causes an abnormal buildup of pressure rough sounding operation and loss of power It is known as pre ignition All such forms of uncontrolled combustion result in excessive pressures on rings pistons cylinder heads and bearings and loss of power output Extended operation under such conditions will lead to mechanical failure of some part of the engine The air and fuel mixture in a gasoline engine must be within certain limits in order to ignite and burn The extreme limits of the ratio of air to fuel weights are approximately 7 1 for a rich mixture and 20 1 for a lean mixture For most engines this mixture usually falls in the range from 10 5 1 to 14 1 with maximum power usually obtained around 13 1 air fueled ratio In a Diesel engine combustion starts shortly after the beginning of fuel injection The fuel is sprayed into the combustion chamber at a carefully cali brated rate The amount of power the engine will develop is determined by the length of time the fuel is injected The pumps are so constructed that this time is varied according to the setting of the governor In comparison the governor on a gasoline engine varies the position ofthe carburetor throttle whil
360. n the groove of the covers Do not use gaskets or RTV sealant 4 Locate the cover with the oil fill neck on the same side as removed and install the lifting strap in the original position With O Ring type covers position the cover on the cylinder head If loose spacers were used insert a spacer in each of the screw holes On both types install the four hex flange screws in each cover and finger tighten 5 Torque the valve cover fasteners to the proper specification using the sequence shown in Figure 11 89 Section 11 Reassembly Gasket RTV style cover 3 4 N m 30 in Ib Black O Ring style cover with shoulder screws 5 6 N m 50 in Ib with screws and spacers 9 9 N m 88 in Ib Yellow or Brown O Ring style cover with integral spacers 6 2 55 in Ib Figure 11 89 Valve Cover Fastener Torque Sequence NOTE Fastener 2 may secure fuel pump bracket on earlier models Figure 11 90 Tightening Valve Cover Screws Install Air Cleaner Assembly Refer to Section 4 for air cleaner reassembly procedure Standard Air Cleaner 1 Attach the rubber breather hose to the breather cover Connect the fuel inlet line to the carburetor and secure with a clamp See Figure 11 91 11 27 Section 11 Reassembly 3 Secure the air cleaner base and bracket using the hex flange screws Position the bracket with the hole toward the breather hose Be careful not to drop scre
361. n two different segments of the commutator and check for continuity See Figure 8 62 Test all the segments Continuity must exist between all or the armature is bad Insulation Figure 8 62 Checking Armature 3 Check for continuity between the armature coil segments and the commutator segments See Figure 8 62 There should be no continuity If continuity exists between any two the armature is bad 4 Check the armature windings insulation for shorting Shift Fork Check that the shift fork is complete and the pivot and contact areas are not excessively worn cracked or broken 8 39 Section 8 Electrical System and Components Brush Replacement Starter Service The brushes and springs are serviced as a set 4 Use Clean the drive lever and armature shaft Apply Brush and Spring Kit Kohler Part No 25 221 01 S if Kohler electric starter drive lubricant see Section 2 replacement is necessary Versilube G322L or Mobil Temp SHC 32 to the lever and shaft Clean and check the other starter parts for 1 Perform steps 1 5 in Starter Disassembly wear or damage as required 2 Remove the two screws securing the brush Starter Reassembly holder assembly to the end cap plate Note the orientation for reassembly later See Figure 8 63 Discard the old brush holder assembly 1 Apply drive lubricant see Section 2 to the armature shaft splines Install the drive pinion onto the armature shaft 2 Install and assemb
362. nal to the ECU based upon the difference in oxygen content between the exhaust gas and the ambient air NOTE All tests should be conducted with a good quality high impedance digital VOA meter for accurate results 58 11 Section 5B EFI Fuel System 1 Oxygen sensor must be hot minimum of 400 C voltage change at each location If the correct 725 F Run engine for about 5 minutes With the engine running disconnect the oxygen sensor lead from the wiring harness Set VOA meter for DC volts and connect the red lead to the disconnected sensor lead and the black lead to the sensor shell Check for a voltage reading between 0 2 v 1 0 v a If voltage is in the specified range go to Step 2 b If the voltage is not in the specified range reconnect the oxygen sensor lead With the lead connected probe or connect the sensor connection with the red VOA meter lead Attach the black VOA meter lead to a known good ground location Start and run the engine at 3 4 throttle and note the voltage output The reading should cycle between 0 2 v 1 0 v which indicates the oxygen sensor is functioning normally and also the fuel delivery controlled by the ECU is within prescribed parameters If the voltage readings show a steady decline bump the governor lever to make the engine accelerate very quickly and check the reading again If voltage momentarily increases and then again declines without cycling engine may be running lean
363. national OCT ___ _ _ 16 C Freight Cost U S A amp Canada FOB and Truck eret ritate epa 16 Section 8 Engine Inspection Data Record Engine Inspection Data Record Ins IPUCHOTIS 16 B Engine inspeccion Data pis ee e ____ gt 17 19 Section 9 Flat Rate Schedules A Command Pro CS Series Flat Rate Schedule ccccccsseeeeeeeecececseeseeeeeeeeecaueeseeeeeeseaeaesseeeeeesessaasacseeeeeeessaaaaseeees 20 B Courage XT Series Courage Single and Command Single Flat Rate 21 C Command Twin and Command PRO Twin Flat Rate Schedule 22 23 D Courage Twin Courage PRO Twin and Aegis Flat Rate Schedule 24 25 TTE rp mE 26 menuitem 27 G K Series Flat Rate ____ _______ sue 28 Policy Adjustment tenance 29 Carburetor Replacement Evaluation 30 2 A The Warranty Decision Warranty decisions must be based on careful examination of the facts and circumstances sur
364. nd choke controls are operating properly If the engine is hard starting runs roughly or stalls at low idle speed it may be necessary to adjust or service the carburetor High Altitude Operation Operating the engine with the wrong engine configuration at a given altitude may increase its emissions and decrease fuel efficiency and performance To ensure correct engine operation at altitudes above 1219 meters 4000 ft it may be necessary to have an authorized Kohler dealer install a special high altitude jet kit in the carburetor If a high altitude kit has been installed the engine must be reconverted to the original jet size before it is operated at lower altitudes or overheating and engine damage can result To obtain high altitude kit information or locate a dealer near you call 1 800 544 2444 to find the names of the nearest Kohler Co Service Centers or access our web site at www kohlerengines com and click on the Service amp Dealer Locator located in the upper right hand corner The service center will need your engine specification number which is found on your Engine ID Label Section 5 Fuel System and Governor Fuel Shut off Solenoid Most carburetors are equipped with a fuel shut off solenoid The solenoid is attached in place of the fixed main jet screw on the flywheel side of the carburetor See Figure 5 3 The solenoid has a spring loaded pin that retracts when 12 volts is applied to the lead allowing f
365. nd dirty applications Avoid Vapor Lock Vapor lock is simply boiling fuel As fuel gets hot it forms a vapor in the fuel lines causing the engine to stall Restarting is impossible until the fuel in the line cools to liquid state again Route fuel lines away from areas of extreme heat and keep temperatures in the engine compartment from becoming too hot Fuel Recommendations Gasoline For best results use only clean fresh unleaded gasoline with a pump sticker octane rating of 87 or higher In countries using the Research method it should be 90 octane minimum Unleaded gasoline is recommended as it leaves less combustion chamber deposits Leaded gasoline may be used in areas where unleaded is not available and exhaust emissions are not regulated Be aware however that the cylinder head will require more frequent service due to extra deposits from leaded fuel Gasoline Alcohol blends Gasohol up to 10 ethyl alcohol 90 unleaded gasoline by volume is approved as a fuel for Kohler engines Other concentrations are not approved Gasoline Ether blends Methyl Tertiary Butyl Ether MTBE and unleaded gasoline blends up to a maximum of 15 MTBE by volume are approved as a fuel for Kohler Engines Other concentrations are not approved All Kohler engines meet applicable Emission Control Regulations Alternate Fuels Liquefied Petroleum Gas LPG and Natural Gas may be used on some Kohler engines Contact your Kohler
366. nd to be in bad condition A normal valve and valves in bad condition are shown in the accompanying illustrations 10 5 Section 10 Inspection and Reconditioning Normal Even after long hours of operation a valve Leakage A poor grind on face or seat of valve will can be reconditioned and reused if the face and allow leakage resulting in a burned valve on one side margin are in good shape If a valve is worn to where only the margin is less than 1 32 do not reuse it The valve shown was in operation for almost 1000 hours under controlled test conditions Bad Condition The valve depicted here should be Coking Coking is normal on intake valves and is not replaced Note the warped head margin damaged harmful If the seat is good the valve could be reused and too narrow These conditions could be attributed after cleaning to excessive hours or a combination of poor operating conditions 10 6 Excessive Combustion Temperatures The white deposits seen here indicate very high combustion temperatures usually due to a lean fuel mixture Section 10 Inspection and Reconditioning 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 engine is repeatedly stopped before it has a chance to reach normal operating temperatures Replace corroded valves Gum Gum deposits usually result from using sta
367. ng Baffle Carburetor Model Shown and Breather Cover 9 Remove the remaining hex flange screws and 2 Remove both inner baffles See Figure 9 40 detach the blower housing See Figure 9 38 10 Disconnect the plug from the key switch in the blower housing if engine is so equipped 3 Remove the two remaining screws holding the breather cover to the crankcase See Figure 9 40 Figure 9 38 Removing Blower Housing 4 Pry under the protruding edge of the breather Inner Baffles and Breather Cover cover with a screwdriver to break the RTV or The inner valley baffles are attached at one corner gasket seal See Figure 9 41 Do not pry on the using the same fasteners as the breather cover See sealing surfaces ds it could QUE damage Figure 9 39 resulting in leaks Most engines use a formed gasket rather than RTV sealant 1 Remove the two hex flange screws securing the inner baftles 9 10 Section 9 Disassembly 7 Remove the hex flange screw breather reed retainer and breather reed See Figure 9 44 d j gt _ 1 r 5 E 5 4 x 4 et k E i 1 gt E 4 P a Figure 9 41 Breaking Breather Cover Seal 5 Remove the breather cover and gasket if used See Figure 9 42 Remove Valve Covers Three valve cover designs have been used The earliest type used a gasket and sealant between the cover and sealing surfac
368. ng camshaft endplay Cylinder Leakdown Tester For checking combustion retention and if cylinder piston rings or valves are worn Electronic Fuel Injection EFI Diagnostic Software Kohler 25 761 23 5 Use with Laptop or Desktop PC EFI Service Kit For troubleshooting and setting up an EFI engine Kohler 24 761 01 5 Individual Components Available Design Technology Inc Pressure Tester DTI 019 Noid Light D T1 021 90 Adapter D T1 023 Oetiker Clamp Pliers DTI 025 Code Plug Red Wire DTI 027 Code Plug Blue Wire DTI 029 Flywheel Holding Tool CS Series SE Tools KLR 82407 ee SE Tools KLR 82408 To remove flywheel from engine 2 1 Section 2 Tools amp Aids Tools cont Flywheel Strap Wrench To hold flywheel during removal Hydraulic Valve Lifter Tool To remove and install hydraulic lifters Ignition System Tester For testing output on all systems except CD Kohler 25 455 01 S For testing output on capacitive discharge CD ignition system Kohler 24 455 02 S Offset Wrench K amp M Series To remove and reinstall cylinder barrel retaining nuts a shige dic Kohler 25 761 06 S To test and verify oil pressure Rectifier Regulator Tester 120 volt current Kohler 25 761 20 S Rectifier Regulator Tester 240 volt current Kohler 25 761 41 5 Used to test rectifier regulators Individual Components Available Design Technology Inc CS PRO Regulator Test Harness D IT 031 Specia
369. ng should be used to check and or adjust the governor and throttle linkage 58 24 If the governor throttle components are all intact but you think there may be a problem with the adjustment follow Procedure A to check the setting If the governor lever was loosened or removed go immediately to Procedure B to perform the initial adjustment A Checking the Initial Adjustment 1 Unsnap the plastic linkage bushing attaching the throttle linkage to the governor lever See Figure 5B 37 Unhook the damper spring from the lever separate the linkage from the bushing and remove the bushing from the lever Mark the hole position and unhook the governor spring from the governor lever NV TA Lie 5 ity Q Throttle a LI U 1 Linkage UL vs REST f A nhe as m Figure 5B 37 Throttle Linkage Governor Lever Connection 2 Check if the engine has a high speed throttle stop screw installed in the manifold casting boss See Figure 5B 38 High Speed Throttle Stop Screw Figure 5B 38 Throttle Details Figure 58 39 Inserting Feeler Gauge Engines Without Stop Screw engines without a stop screw pivot the throttle shaft and plate assembly into the Full Throttle position Insert a 1 52 mm 0 060 in feeler gauge between the rear tang of the throttle shaft plate and the underside of the manifold boss Use a locking pliers needle nose works best to temporaril
370. ng standard petroleum based oil before switching to synthetic oil A logo or symbol on oil containers identifies the API service class and SAE viscosity grade See Figure 6 1 A Figure 6 1 Oil Container Logo The top position of the symbol shows service class such as API SERVICE CLASS SJ The symbol may show additional categories such as SH SG CC or CD The center portion shows the viscosity grade such as SAE 10W 30 If the bottom portion shows Energy Conserving it means that oil is intended to improve fuel economy in passenger car engines 6 1 Section 6 Lubrication System Checking Oil Level The importance of checking and maintaining the proper oil level in the crankcase cannot be overemphasized Check oil BEFORE EACH USE as follows 1 Make sure the engine is stopped level and is cool so the oil has had time to drain into the sump 2 Clean the area around the dipstick before removing it This will help to keep dirt grass clippings etc out of the engine 3 Remove the dipstick wipe oil off Reinsert the dipstick into the tube until fully seated See Figure 6 2 Oil Fill Cap Valve _ Cover Location Figure 6 2 Location of Oil Fill Cap and Dipstick 4 Remove dipstick and check oil level The level should be between the F and L marks If low add oil of the proper type up to the mark Reinstall oil fill cap and dipstick Operating Range Figure 6 3 Oil Level Marks on Dips
371. ngines While both may 1800 2000 2200 2400 2800 2800 3000 3200 3400 3800 generate 25 HP at 3600 RPM the 1000 cc L head engine will produce significantly more Torque at 2400 RPM than a 750 cc OHV engine AL UN uit iL RENE aes ME UB ww KILOWATTS REVOLUT IONS PER MIN F aa wii rand posed GALLONS PER LITERS PER HR P 8 FUEL CONSUMPTION Figure 1 1 Power Curve Example Command 11 13 and 15 HP Section 1 Selecting the Right Engine 7 u E I 2800 1800 2200 2600 3000 3400 Revolutions Per Minute Figure 1 2 Torque Curve Example If you want to figure the brake horsepower of an engine when only the torque curve is given multiply the torque foot pounds by the time element which is the RPM Revolutions Per Minute and divide this by the constant 5252 The formula is expressed below Torque x RPM 5252 E Using the formula and the torque curve of the engine shown in Figure 1 2 we would arrive at the following horsepower rating 34 ft Ib torque x 3600 RPM 23 3 HP 5252 constant It would be great if we could just use the power curve d
372. nnector ECU In Main Connector Test Terminals Figure 5B 5 Speed Sensor Connector 7 a Ifthe resistance is incorrect remove the screw securing the sensor to the mounting bracket and replace the sensor b If the resistance in step 5 was incorrect but the resistance of the sensor alone was correct test the main harness circuits between the sensor connector terminals and the corresponding pin terminals in the main connector Correct any observed problem reconnect the sensor and perform step 5 again Section 5B EFI Fuel System Throttle Position Sensor TPS Mounted on the throttle body intake manifold and operated directly off the end of the throttle shaft the TPS works as a potentiometer varying the voltage signal to the ECU in direct correlation to the angle of the throttle plate This signal along with the other sensor signals is processed by the ECU and compared to the internal preprogrammed maps to determine the required fuel and ignition settings for the amount of load The correct position of the TPS is established and set at the factory Do not loosen the TPS or alter the mounting position unless absolutely required by fault code diagnosis or throttle shaft service If the TPS is loosened or repositioned the appropriate TPS Initialization Procedure pages 5B 8 5B 10 must be performed to reestablish the baseline relationship between the ECU and the TPS Service The TPS is a sealed non servic
373. nsion lead wire If the EMF generated in the secondary has sufficient strength current will flow through the high tension lead through the center electrode and bridge the air gap to make a completed circuit to ground Condenser Breaker Points Permanent Magnets Typical Flywheel Magneto Ignition System Several different magneto systems have been used on Kohler engines over the years but the principles of operation we have discussed will apply to all of them The flywheel magneto system used in current production is one of the simplest designs ever developed It does however offer one distinct advantage over most other magneto systems in general use The breaker points and condenser are mounted on the outside of the engine so timing adjustments and minor tune ups can be performed without removing the flywheel BATTERY IGNITION At one time all Kohler engines had magneto ignition More recently however the battery ignition system has had more widespread use especially on engines of ten or more horsepower The battery ignition system functions much the same as the magneto system except that the primary current is drawn from a storage battery Because of the comparatively high level of current available from a good storage battery this system will normally provide a stronger spark than the typical magneto system s Primary Circuit Secondary Circuit High Tension Lead Ignition Switc
374. nstructions provided As all adjustments and settings must be reset using specific test equipment this must be performed by qualified LP personnel only Impco Beam Regulator Service Kohler repair kit 24 757 40 5 should be used to service the regulator every 1500 hours or whenever cleaning and servicing is required Nikki Regulator Service Kohler repair kit 24 757 39 5 should be used every 1500 hours Section 5B Electronic Fuel Injection Fuel System Contents Page s Description 215 5B 2 1 EFI Fuel System Components OS eNO _6_____ i NEM CD Electrical Components onines ECU 5B 4 5B 5 SC SOM 5B 6 Throttle Position Sensor TPS and Initialization Procedures 5B 7 5B 10 Tenpera ire tr 5B 10 5B 11 Br Iun dor qo NET cct 5B 11 5B 13 ci T 58 13 58 14 TS COT 5B 14 5B 17 yy a assoc T R 5B 17 5B 18 io M E 5B 18 m T
375. nt for a specific job The low value gases require regulators lines etc which will supply many times the volume of propane gas for a given power output required One big advantage of gaseous fuels is their freedom from tetraethyl lead Deposits in the combustion chamber are kept to a minimum Diese fuel The Diesel fuel is simply specified as grade 1 and 2 Grade 71 is generally a lighter weight or lower viscosity Cetane rating is the quality of Diesel fuel and compares with octane rating in gasoline The mini mum cetane rating is usually considered 45 In low temperatures it is quite common for Diesel fuels to become jelly like The point at which they cease being a liquid is known as the pour point This fuel quality should be watched carefully in tempera tures of 20 F or lower RATING ENGINES All small engine manufacturers use the Society of Automotive Engineers SAE test code J607 to rate their engines The test code establishes m 29 92 inches 760 mm of Mercury as standard barometric pressure sea level and m 60 15 6 as standard temperature at which engines are rated It is general practice to rate engines at the maximum amount of power Maximum Brake Horsepower B H P they pro duce under those laboratory conditions Unfortunately engines do not usually operate under those same test conditions Actual horsepower kilo watt output is affected by temperature and baro metric pressu
376. ntake Valve Minimum Lifi 8 07 mm 0 3177 in Exhaust Valve Minimum 8 07 mm 0 3177 in Nonunal Valve peal 45 Section 1 Safety and General Information General Torque Values Metric Fastener Torque Recommendations for Standard Applications Tightening Torque N m in Ib 10 Property Class Noncritical Fasteners Into Aluminum Size M4 44 2 0 86 4 0 35 3 38 16 5 146 6 8 60 M8 10 5 93 40 7 360 17 0 150 11 5 0 18 9 7 12 M5 2 5 22 43 Tightening Torque N m ft Ib or 10 Property Class Noncritical Into Aluminum M10 21 7 16 27 1 20 47 5 35 66 4 49 81 4 60 33 9 25 M12 36 6 27 47 5 35 82 7 61 116 6 86 139 7 103 61 0 45 M14 58 3 43 76 4 55 131 5 97 184 4 136 219 7 162 94 9 70 Section 1 Safety and General Information English Fastener Torque Recommendations for Standard Applications Tightening Torque N m in Ib or 20 Bolts Screws Nuts and Fasteners Assembled Into Cast Iron or Steel Grade 2 or 5 Fasteners Into Aluminum 269 2 3 20 2 8 05 2 3 20 3 6 32 4 5 40 3 6 32 4 5 40 7 9 70 13 0 115 18 7 165 9 6 85 15 8 140 22 6 200 17 0 150 28 3 250 39 6 350 18 7 165 30 5 270 2
377. nts have proven that the minimal investment involved in preparing an engine prior to delivery eliminates unnecessary service calls and results in improved over all profit Before turning an engine over review the Owner s Manual with the customer stress the importance of good maintenance and explain the warranty Section 2 Limited Warranty Statements KOHLER Aegis Warranty Statement Limited 3 Year Kohler Aegis Engine Warranty Kohler Co warrants to the original retail consumer that each new KOHLER AEGIS engine sold by Kohler Co will be free from manufacturing defects in materials or workmanship in normal residential service for a period of three 3 years from date of purchase provided it is operated and maintained in accordance with Kohler Co s instructions and manuals Our obligation under this warranty is expressly limited at our option to the replacement or repair at Kohler Co Kohler Wisconsin 53044 or at a service facility designated by us of such parts as inspection shall disclose to have been defective EXCLUSIONS Mufflers on engines used commercially non residential are warranted for one 1 year from date of purchase except catalytic mufflers which are warranted for two 2 years This warranty does not apply to defects caused by casualty or unreasonable use including faulty repairs by others and failure to provide reasonable and necessary maintenance The following items are not covered by this warranty
378. o deviate from the factory settings by 150 RPM at high idle and 200 RPM low idle optional governed idle devices can reduce idle fluctuations on some models Itis recommended that the OEM run a sufficient number of test units to verify that the factory specifications result in the desired speed in the final product configuration Contact your Kohler Engine representative if further information is required Testing the Installation Engine application testing can range from simple field checks to complex setups requiring expensive and sophisticated monitoring devices In general the types of testing you do will depend upon your equipment Heat Tests There is at least one test that is critical The Heat Test It is most important that you gather temperature test data at several key areas Heat tests are done by installing thermocouples at the following points a Spark plug temperatures are checked by a special thermocouple installed under the spark plug b Oil sump temperatures are checked with a thermocouple that fits on the oil dipstick about 1 2 in 12 7 mm below the tip c Air temperature into the cooling fan is checked by fastening a thermocouple to the blower housing with the junction in the incoming air stream checks The junction or welded thermocouple tip should be 1 4 to 1 2 in 6 35 to 12 7 mm from the grass screen It is best to check at three or four locations around the inlet and average the temperat
379. o the use of add on or modified parts MAINTENANCE AND REPAIR REQUIREMENTS The owner is responsible for the proper use and maintenance of the engine Kohler Co recommends that all receipts and records covering the performance of regular maintenance be retained in case questions arise If the engine is resold during the warranty period the maintenance records should be transferred to each subsequent owner Kohler Co reserves the right to deny warranty coverage if the engine has not been properly maintained however Kohler Co may not deny warranty repairs solely because of the lack of repair maintenance or failure to keep maintenance records Normal maintenance replacement or repair of emission control devices and systems may be performed by any repair establishment or individual however warranty repairs must be performed by a Kohler authorized service center Any replacement part or service that is equivalent in performance and durability may be used in non warranty maintenance or repairs and shall not reduce the warranty obligations of the engine manufacturer Section 3 Warranty Procedures A Service Information Record SIR KOHLER ENGINES momason necon SIF Form will be assigned Central Distributor REASON FOR SUBMITTAL SIR Change Re sign C Mew t Termination Effective Date Change Type Address Labor Rate Ownership Other COMPANY t Authorized Dealer l
380. obvious material defect replace the bearing plate and submit a warranty claim for the repair D Defective Service Parts Installed During Engine Warranty Period Warranty coverage for components installed during an engine warranty period shall consist of the duration of the engine warranty coverage or 90 days whichever is greater provided the warranty installation is performed by an authorized Kohler service outlet E Warranty Options and Accessories 1 Options Factory Installed All factory installed options are warranted against defects in workmanship or material for the normal engine warranty period 2 Accessories Field Installed All field installed accessories are warranted against defects in material and workmanship for the duration of the engine warranty or 90 days whichever is greater provided the installation was performed by an authorized Kohler service outlet Except consumable items such as mufflers and maintenance items Section 5 Warranty Exclusion A Non Reimburseable Items 1 Repairs required to correct failures caused by neglect normal wear improper lubrication or abuse Kohler Co warranty covers defective workmanship and materials only 2 Parts and labor supplied by the user or any unauthorized repair facility 3 Normal maintenance adjustments or consumable items such as fuel spark plugs filters lubricating oil and hoses 4 Parts and accessories no
381. ocedure Check carburetor O Rings Verify fuel shut off solenoid is operational Verify fuel shut off solenoid is operational Check for accelerator pump leakage Hunts Surges Other describe Check fuel quality Check governor and speed settings Check for linkage interferences Cause of Failure Reason Replaced Check for dirt debris in carburetor lean condition Check accelerator pump diaphragm Check fuel pump delivery pressure 1 5 to 2 0 psi Poor Load Pickup Check fuel quality Check governor and speed settings Check for defective accelerator pump Check for parasitic loads If needle seat is leaking the recommended cleaning method is to use a cotton swab and mild abrasive to clean the seat Rinse the abrasive out of the seat with a suitable cleaner and blow dry with compressed air Poor fuel quality dirt debris water etc or the lack of maintenance is not covered by warranty Issues which are caused by dirt are not covered by warranty NOTE Removal of anti tamper caps will void warranty Kohler recommends the use of fuel stabilizers if engines are to be stored for over 30 days TP 2570 Issued 9 05 Rev 1 06 30 31 KOHLER ENGINES FOR SALES AND SERVICE INFORMATION IN U S AND CANADA CALL 1 800 544 2444 T T MENS KohlerEngines com ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 KOHLER inclines Failure
382. ocedures follow Install flywheel end oil seal Install governor cross shaft Install crankshaft Install connecting rods with pistons and rings Install camshaft Install closure plate assembly Install stator and backing plates Install flywheel 9 Install fan and grass screen 10 Install hydraulic lifters 11 Install cylinder heads 12 Install push rods and rocker arms 13 Install ignition modules per pu ee 14 15 16 17 18 19 20 21 22 20 24 25 26 zs 28 Install intake manifold Install breather cover and inner baffles Install blower housing and outer baftles Install electric starter motor Install fuel pump Install carburetor Install external governor controls Install throttle and choke controls Install Oil Sentry Install control panel if so equipped Install valve covers Install air cleaner assembly see Section 4 Install muffler Install oil filter and fill crankcase with oil Connect spark plug leads Install Flywheel End Oil Seal Make sure that seal bore of the crankcase is clean and free of any nicks or burrs See Figure 11 1 Figure 11 1 Seal Bore of Crankcase 2 3 Apply a light coat of clean engine oil to the outside diameter of the oil seal Drive the oil seal into the crankcase using a seal driver Make sure the oil seal is installed straight and true in the bore and that the tool bottoms against the crankcase Se
383. of your reimbursement check the failed parts may be discarded NOTE Do not return failed parts unless you have received instructions and an Engine Warranty Return EWR Number from the Kohler G Return of Failed Parts When Kohler Co does request the return of failed parts formal instructions plus a label with an EWR Number will be issued to the service account involved This label must be used to return the part or parts requested The instructions will include directions for the return shipment NOTE Do not return failed parts unless you have received instructions and an EWR Number from the Kohler Co Keep a record of the EWR Number for future reference H Disputed Questionable Unusual Warranty or Policy Adjustments In the event a customer requests or insists on a warranty repair that in your opinion is not covered by the Kohler Limited Engine Warranty offer the customer one of the following options 1 Repair the engine and charge the customer with the understanding that you will issue reimbursement if the claim is approved Complete a Warranty Claim see Section 6 and an Engine Inspection Data Record TP 2435 and have the damaged parts reviewed by your Central Distributor representative If the claim is approved have the Central Distributor representative note authorization for the repair reimburse the customer for the charges and send the completed Warranty Claim and Engine Inspection Data Recor
384. oil 1 Repeat the test between terminal 87 and pin 31 for coil 2 A reading of 1 8 4 0 Q in each test indicates that the wiring and coil primary circuits are OK If reading s are not within specified range check and clean connections and retest b If reading s still not within the specified range test the coils separately from main harness as follows 1 Disconnect the red and black primary leads from the coil terminals 2 Connect an ohmmeter set on the Rx1 scale to the primary terminals Primary resistance should be 1 8 2 5 58 18 3 Disconnect the secondary lead from the spark plug Connect an ohmmeter set on the Rx10K scale between the spark plug boot terminal and the red primary terminal Secondary resistance should be 13 000 17 500 4 If the secondary resistance is not within the specified range unscrew the spark plug lead nut from the coil secondary tower and remove the plug lead Repeat step b 3 testing from the secondary tower terminal to the red primary terminal If resistance is now correct the coil is good but the spark plug lead is faulty replace the lead If step b 2 resistance was incorrect and or the secondary resistance is still incorrect the coil is faulty and needs to be replaced Spark Plugs EFI engines are equipped with Champion RC12YC Kohler Part No 12 132 02 S resistor style spark plugs Equivalent alternate brand plugs can also be used but must be a resi
385. oincide with each other and form a severe vibration If not corrected resonance can cause fatigue failure of the engine mounts panel connectors etc This condition should be corrected through speed alteration if possible isolating the points of the resonant vibration or the use of isolator mounts Combustion Air Air Intake The air intake system air cleaner is one of the most important aspects of engine installation since it has a direct effect on engine power output fuel consumption exhaust emission and engine life Dirt induced through improperly installed poorly serviced or inadequate air cleaner elements wear out more engines than does long hours of operation Controlling the combustion air through shielding or ducting is desirable Contact your Kohler Engine representative regarding air cleaners remote pick up or heavy duty air cleaner availability and use The various types are shown and listed in the Kohler Engine Accessories Catalog Liquid Cooled Engines Only LH version shown Figure 3 6 Some Service Points on Typical Engine 14 Service Access If the location of the engine makes servicing difficult the required services may be neglected or may not be performed at all resulting in early failure of the engine When planning the installation promote good service by providing easy access to all service and maintenance points Checklist Here is a checklist to follow to make sure the engine is easy to
386. on may continue or limp home operation slowed speed richer running may be initiated A technician can access the stored fault code using a blink code diagnosis flashed out through the MIL An optional computer software diagnostic program is also available see Section 2 Figure 5B 3 32 Pin MSE 1 1 Plastic Cased The ECU requires a minimum of 7 0 volts to operate ECU The adaptive memory in the ECU is operational the moment the battery cables are connected however Three different styles of ECU s have been utilized the adapted values are lost if the battery becomes 5B in EFI production The first style 1S easily identified disconnected for any reason The ECU will relearn by its metal case with large 35 pin connector block the adapted values if the engine is operated for 10 15 and also as MA 1 7 See Figure 5B 1 The second minutes at varying speeds and loads after the oil and third styles have plastic cases but are smaller temperature exceeds 55 C 130 F in overall size These have either a 24 pin or 32 pin connector block and identified as MSE 1 0 or MSE To prevent engine over speed and possible failure a 1 1 respectively See Figures 5B 2 and 5B 3 Basic rev limiting feature is programmed into the ECU If function and operating control remains the same the maximum RPM limit 4125 RPM on MA 1 7 4500 between the three however due to differences in the RPM on MSE 1 0 amp MSE 1 1 is exceeded the ECU int
387. on the other cylinder See Figure 8 19 Figure 8 19 Check for Timing Advance Section 8 Electrical System and Components a Iftheline on the screen moved away from the line on the blower housing during acceleration the DSAI ignition module for the cylinder being tested is working properly If it didn t move away go to Test 4 b Ifyou were able to check timing on both cylinders the lines you made on the blower housing should be 90 apart If not go to Test 4 Test 4 Test the Ignition Modules and Connections 1 Remove the blower housing from the engine Inspect the wiring for any damage cuts bad crimps loose terminals or broken wires Check that connections are oriented properly on terminals of modules 2 Disconnect the leads from the ignition module s and clean all of the terminals male and female with aerosol electrical contact cleaner to remove any old dielectric compound dark residue dirt or contamination Disconnect the spark plug leads from the spark plugs 3 Using a multi meter check that a proper ground is established between the ground black lead of the DSAI module closest to spark plug lead and a known good ground location on the engine 4 Turn the key switch to the ON position and check for 12 volts at the center power red lead terminal of the DSAI module Use the same ground location for the multi meter as in Step 3 If all tests are OK and module has no spark or fails to advance
388. onnections 2 Two Barrel Manifold Carburetor Models Route the wiring harness through the mounting clip on the underside of debris shield if separated earlier Carefully position the debris shield to the rear as far as possible See Figure 11 53 Figure 11 53 Routing of Wiring Harness Two Barrel Models 11 15 Section 11 Reassembly 3 Connect the kill lead to the tab terminal on 3 Install the breather reed and breather reed standard ignition modules See Figure 11 54 retainer onto the crankcase and secure with the hex flange screw Hold the assembly in line when tightening Torque the screw to 3 9 N m 35 in Ib See Figure 11 56 Figure 11 54 Connecting Kill Leads on Standard Ignition Modules Figure 11 56 Installing Breather Reed Assembly 4 Insert the breather filter into position in the crankcase Make sure no filter strands are on the sealing surface See Figure 11 57 5 Install the new breather gasket Figure 11 55 Connect Leads on SMART SPARK Ignition Modules Install Breather Cover and Inner Baffles sealant was used on early models between the breather cover and the crankcase A gasket with imprinted sealant beads is now used and recommended Install as follows Figure 11 57 Installing New Breather Filter 1 sure the sealing surfaces of the crankcase and 6 Carefully position the breather cover on the breather cover are clean of old gasket material or crankcase Ins
389. ontinuity between the pump terminals replace the fuel pump b If the voltage was below 7 test the wiring harness and relay as covered in the Electrical Relay section 4 If voltage at the plug was good and there was continuity across the pump terminals reconnect the plug to the pump making sure you have a good connection Turn on the key switch and listen for the pump to activate a If the pump starts repeat steps 1 and 2 to verify correct pressure b If the pump still does not operate replace it 58 20 Fuel Pressure Regulator Figure 5B 27 External Fuel Pressure Regulators with Base Figure 5B 28 Internal Fuel Pressure Regulator General The fuel pressure regulator assembly maintains the required operating system pressure of 39 psi 3 A rubber fiber diaphragm see Figure 5B 29 divides the regulator into two separate sections the fuel chamber and the pressure regulating chamber The pressure regulating spring presses against the valve holder part of the diaphragm pressing the valve against the valve seat The combination of atmospheric pressure and regulating spring tension equals the desired operating pressure Any time the fuel pressure against the bottom of the diaphragm exceeds the desired top pressure the valve opens relieving the excess pressure returning the excess fuel back to the tank Pressure Regulating Pressure Regulating Chamber Diaphragm 824 ee Ke 9 C
390. or the engine spec involved Some engines use a deeper or extra capacity air cleaner and a longer rubber seal Cover Knob Cover Knob Air Cleaner Gasket Cover N Air Cleaner Latch Cover Spring Lever Latch Nut Latch Lever u p Pin 2 Element Air Cleaner X Element Air Cleaner Bracket Air Cleaner Base Gasket Intake 7 Carburetor ____ Manifold Gasket s O O Ring intake Manifold AE 5 Scien O Ring 20 Intake Manifold Manifold Figure 4 8 Exploded View of Standard Air Intake System Components 4 3 Section 4 Air Cleaner and Air Intake System Air Cleaner Element Cover and Seal Make sure element cover is not bent or damaged Make sure the wing nut and seal are in place to ensure the element is sealed against leakage Air Cleaner Base Make sure the base is secured tightly to the carburetor and not cracked or damaged Breather Tube Make sure the tube is attached to both the air cleaner base and the breather cover NOTE Damaged worn or loose air cleaner components can allow unfiltered air into the engine causing premature wear and failure Tighten or replace all loose or damaged components Rear Mounting Complete Disassembly and Reassembly Screws Standard Type If the base plate on the standard type has to be removed proceed as follows 1 Remove air cleaner components as describe
391. ortant part of the small engine repair business Some failures can be interesting and challenging Others can be quite puzzling almost exasperating But if you follow the steps outlined in this booklet you ll be more successful in reaching a logical correct decision and completing the proper repair Figure 99 e Carefully disassemble the engine and examine all of the components Even though some parts weren t involved in the actual failure they may still provide some indicators to assist you in reaching a correct decision If you are fortunate the location of the failure is or will be obvious Figure 98 Weigh all of the evidence against your experience Make a thorough preliminary examination to help as a professional small engine repairman Your determine the conditions under which the engine final decision should incorporate all of the evidence was operated and pick up any external signs of and provide a logical sensible explanation for the factors that may have contributed to the failure In failure which occurred Running an engine out of some cases there will be very obvious indicators gas doesn t cause a connecting rod failure but but not always This engine ran for over two hours running it out of oil probably will no load with no oil in the crankcase but there are no external indicators of that 2 Once you have made assumption back up your decision with facts and measurements Figure 102 T
392. ose 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 contain a small secondary spring connected between the governor lever and the lower adjustment tab of the main bracket See Figure 5 6 The system requires an additional procedure for setting the idle speed If speed adjustments are required proceed as follows 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 the carburetor or hold the throttle lever so it is tight against the idle speed adjusting screw to negate the governor activation See Figure 5 7 Check the speed with a tachometer and adjust it to 1500 RPM 3 Release the governor lever and allow the engine 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 low idle speed If adjustment is necessary bend the adjusting tab on the speed control assembly to set See Figure 5 6 Section 5 Fuel System and Governor a gt F Hold Throttle Lev r Against Figure 5 7 Holding Throttle Lever Against Idle Stop Screw One Barrel Carburetor Servicing Float It is not necessary to remove the carburetor from the
393. osen the hex flange nut and remove the the two carburetor mounting screws See Figure governor lever from the cross shaft See Figure 9 27 9 25 Leave lever attached to the throttle linkage and lay assembly on the top of the crankcase Two Barrel Carburetor Models Only If required use two hex flange nuts locked together and remove the two carburetor mounting studs on the starter side of the intake manifold and one of the studs on the oil filter side Pivot the carburetor to clear the breather cover fitting and pressure switch if equipped Remove the carburetor throttle linkage choke linkage and the governor lever as an assembly E Figure 9 25 Removing Governor Lever Remove Carburetor A WARNING Explosive Fuel 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 Do not fill the fuel tank while the engine 18 hot or running US 4 i gt P a i Li p s ET h KE since spilled fuel could ignite if it comes in contact with hot Figure 9 27 Removing Carburetor Mounting parts or sparks from ignition Do not start the engine near Screws spilled fuel Never use gasoline as a cleaning agent rn 3 Remove the carburetor throttle linkage and 1 Disconnect the fuel shut off solenoid lead and governor lever as an assembly See Figu
394. otor pump is located in the closure plate The oil pump maintains high oil flow and oil pressure even at low speeds and high operating temperatures A pressure relief valve limits the maximum pressure of the system Service The closure plate must be removed to service the oil pickup the pressure relief valve and the oil pump Refer to the appropriate procedures in Sections 9 and 10 Oil Recommendations Using the proper type and weight of oil in the crankcase is extremely important so is checking oil daily and changing the oil and filter regularly Use high quality detergent oil of API American Petroleum Institute service class SG SH SJ or higher Select the viscosity based on the air temperature at the time of operation as shown in the following table RECOMMENDED SAE VISCOSITY GRADES 10W 30 E 10W ry TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANGE Use of synthetic oil having 5W 20 or 5W 30 rating is acceptable up to 4 C 40 F Synthetic oils will provide better starting in extreme cold below 23 C 10 F NOTE Using other than service class SG SH SJ or higher oil or extending oil change intervals longer than recommended can cause engine damage NOTE Synthetic oils meeting the listed classifications may be used with oil changes performed at the recommended intervals However to allow piston rings to properly seat anew or rebuilt engine should be operated for at least 50 hours usi
395. otos 8 1 Section 8 Electrical System and Components Normal A plug taken from an engine operating under normal conditions will have light tan or gray colored deposits If the center electrode is not worn a plug in this condition could be set to the proper gap and reused Carbon Fouled Soft sooty black deposits indicate incomplete combustion caused by a restricted air cleaner over rich carburetion weak ignition or poor compression Worn On a worn plug the center electrode will be rounded and the gap will be greater than the specified gap Replace a worn spark plug immediately 8 2 Wet Fouled A wet plug is caused by excess fuel or oil in the combustion chamber Excess fuel could be caused by a restricted air cleaner a carburetor problem or operating the engine with too much choke Oil in the combustion chamber is usually caused by a restricted air cleaner a breather problem worn piston rings or valve guides Overheated Chalky white deposits indicate very high combustion temperatures This condition is usually accompanied by excessive gap erosion Lean carburetor settings an intake air leak or incorrect spark timing are normal causes for high combustion temperatures Section 8 Electrical System and Components Battery 2 Keep the cables terminals and external surfaces of the battery clean A build up of corrosive acid General or grime on the external surfaces can cause the A 12 volt ba
396. ou will note that the sealing ring has already started to deteriorate Figure 28 Figure 28 Continued operation with high combustion temperatures will result in more severe burning and deterioration of the valve face Figure 29 Figure 29 Valve burning will also occur if there are conditions present which prevent the valve from closing or sealing properly Here we see deposit accumulation around the entire circumference of the face This would normally indicate that the valve was not closing completely Perhaps the tappet clearance was incorrectly set or combustion deposits may have flaked loose in the head and lodged between the valve and seat Because the valve is not sealing it will start to burn with continued operation Figure 30 Figure 30 When the exhaust valve is burned or not sealing the fuel burn is no longer contained within the combustion chamber Each time the engine fires a burst of flame passes the valve As the face continues to burn and deteriorate the combustion leakage begins to act like a torch The valve material on the underside of the head and neck begins to burn away a condition referred to as valve erosion Figure 31 Figure 31 If the initial valve burning was due to extreme combustion temperatures lean mixture etc the blistered white deposits may also show up in the area of erosion Figure 32 Figure 32 Another fairly common valve related problem is val
397. ould do the job It produces 19 25 foot pounds of torque at 2800 RPM Using the torque to horsepower formula this indicates 10 26 HP is available 19 25 x 2800 53900 5252 10 26 Section 2 Properly Connecting the Engine to the Load Properly Connecting the Engine to the Load This section contains some recommendations and precautions relating to connecting the engine to the load The more common methods are V belt chain drive direct coupled and universal joint The crankshafts on Kohler engines rotate counterclockwise when viewed from the rear or PTO side of the engine side opposite cooling air intake Crankshaft End Thrust Note If anything is fitted to the engine that imposes an end load on the crankshaft such as an automotive type clutch make sure that the maximum allowable values for the crankshaft load are not exceeded Check with the manufacturer for details of the operating end thrust of their equipment Important Note Engines with ball bearings can absorb hammering forces imposed by drives in line with the crankshaft better than engines with sleeve type bearings or with machined bearing surfaces Contact your Kohler Engine representative if considering using engines in applications requiring tight interference fit drives V belt Drives Using larger pulleys can ease belt load on crankshaft and bearings Larger pulleys require less belt tension to transmit the same horsepower They also permit the use of
398. out after just 125 hours of operation The oil ring rails are so badly worn that the expander was rubbing the cylinder walls 12 Figure 41 Figure 41 On the other hand heavy ring wear with little or no bore wear indicates that high operating temperatures were present but little or no dirt Figure 42 Figure 42 If a customer ignores the first signs of wear oil consumption and blue exhaust smoke and continues to run the engine the wear will progress to the point that the piston begins to slap because of the excessive running clearance The piston slap puts increased stress on the piston skirts and they can begin to crack Figure 43 Figure 43 With continued operation the cracks will progress across the thrust face and or up toward the oil ring groove Figure 44 Figure 44 In some cases just the lower portion of the skirt will break off Figure 45 Figure 45 In other cases the whole piston will break up The customer will not be able to ignore it any longer Figure 46 Figure 46 A customer that doesn t maintain a twin cylinder engine ends up with double trouble Figure 47 Figure 47 This engine ran for only 6 hours following a rebuild The piston ring end gaps go as high as 042 in and the crankpin was 007 in undersize Always scrub the cylinder with hot water detergent and a brush after it has been bored or honed Use sufficient detergent to provid
399. overcome the tension of the secondary in the primary chamber drops below 29 kPa 4 psi the diaphragm spring 15 and the secondary diaphragm diaphragm spring 5 tension will be greater than the cannot open the valve Under those conditions the fuel pressure causing the primary diaphragm 4 to be idle adjusting screw 18 and balance spring 19 are pushed down This causes the contact button 6 to used to apply just enough pressure on the diaphragm push the primary lever 7 down in turn opening the 14 to maintain sufficient fuel flow for idle operation primary valve 1 and admitting more fuel In this manner the pressure within the primary chamber is The vacuum lock off mechanism is located in the maintained at a relatively constant 29 kPa 4 psi secondary chamber When the engine is running manifold vacuum above the diaphragm 17 draws it up so the secondary valve can function normally When the engine is stopped manifold vacuum is terminated and the diaphragm relaxes and pushes down on the secondary valve lever preventing any fuel flow or leakage through the regulator From Primary To Intake Manifold To Secondary Chamber 1 Primary Valve 6 Contact Button 2 Primary Valve Seat 7 Primary Valve Lever 3 Primary Chamber 8 Primary Lever Spring 4 Primary Diaphragm 9 Primary Pressure 5 Primary Diaphragm Spring Adjustment Figure 5A 21 Primary Chamber 11 Secondary Valve 16 Secondary Valve Lever 12
400. ower Test but disconnect large red lead from spark plug lead 2 Plug insulation test probe into jack on front of tester 3 Turn current control knob to HI or until meter reaches full scale 4 Move test probe quickly over insulated surfaces of coil and spark plug lead s IMPORTANT Do not hold probe at one point too long Complete test as quickly as possible 5 Return current control knob to extreme left and selector knob to OFF NOTE A faint spark occurring around the coil during probing is a corona spark and does not indicate a defective coil strong spark at any point indicates a leak and coil or lead should be replaced 11 IV Breaker Point Contact Resistance Test NOTE Breaker point resistance can be tested with either of the large commercial testers or with an ohmmeter capable of reading fractions of a ohm Procedures for both types of testers are provided 1 Turn selector switch to No 2 Distributor Resistance 2 Clip small red and black tester leads together 3 Turn meter adjustment knob for scale No 2 e until meter pointer lines up with set position Surface Insulation Test on left end of scale No 2 lll Condenser Leakage amp Short Test 4 Unclip tester leads 1 Plug tester into 115 V wall outlet 5 Clip one tester lead to stationary contact side of points clip other lead to moveable contact 2 Connect small red tester lead to condenser side termina
401. p Charging Stator 4 Poles Charging Lead Black 1 25 Amp or 3 Amp 70 Watt Lighting Stator 28 Troubleshooting Guide 1 25 Amp Or 3 Amp Unregulated Charging System Optional 70 Watt Lighting NOTE Zero ohmmeters and voltmeters on each scale to ensure accurate readings Voltage test should be made with engine running at 3000 RPM no load Battery must be fully charged 1 With engine running at 3000 RPM 1 If voltage is more than 12 5 volts measure voltage across battery terminals charging system is OK using a DC voltmeter If voltage is 12 5 volts or less the stator or diode are probably faulty Test the stator and diode Test 2 3 and 4 2 Disconnect the charging lead from battery 2 a 1 25 amp voltage is 11 5 volts or more stator winding is OK With engine running at 3000 RPM measure voltage from charging lead to ground using a DC voltmeter b amp If voltage is 28 volts or more stator winding is OK If voltage is less than specified test stator using an ohmmeter Tests 3 and 4 3 If resistance is low in both directions the diode is shorted Replace the diode 3 With charging lead disconnected from battery and engine stopped measure resistance from charging lead to ground using an ohmmeter Note reading NO CHARGE TO BATTERY If resistance is high in both directions the diode or stator winding is open Use Test 4
402. peat failures Section 1 Introduction If there is a question whether the repair is covered by the Kohler Limited Engine Warranty contact your Kohler Distributor to assist you in the analysis and warranty decision If after reviewing the matter with the Kohler Distributor representative a warranty decision still cannot be made have the representative follow the chain of command until a decision is reached Remember always keep the customer advised as to what is being done and why This will show the customer full consideration is being extended and will demonstrate our mutual concern B Pre Sale Disclosure Requirement One of the provisions of the Magnusson Moss Consumer Products Warranties Law is that a retail seller of consumer products must make the text of the warranty available for review by the prospective buyer prior to sale To help you comply with this law the warranty statements for each model series are printed at the back of the owner s manual for that series All of the warranty statements are included in Section 2 of this booklet C Warranty Responsibility Begins Before Delivery Each Kohler Service Account is responsible for preventing new engines and parts from deteriorating in storage and also for preparing new engines for delivery Failure to adequately protect and store engines and parts will result in unnecessary expense to the dealer and will inconvenience and annoy customers Successful service accou
403. pecify 3 Precleaner LI Clean 0 Dirty 0 Plugged L lOiled Torm L Other damage 4 Inner Cover Retaining seal nut in place 1 Center hole oblong Distorted 1 Other damage 5 Element Clean Dusty LJ Dirty LJ Plugged LJ Missing Dry 0 Non factory replacement Other damage 6 Element seals 0 Pliable _ Sealing Leaking Other damage 7 Air cleaner base LI Tight L Loose LJ Screw s missing Distorted Cracked LI Breather hose detached Other damage Crankcase Oil 1 Amount on dipstick 1 Overfilled Full LlAbove add _ add reading 2 Condition of oil LJ New 0 Used 0 Dirty LJ Black 0 Thick Sticky LJ Burnt smelling 0 Fuel diluted 3 Quantity of oil 1 Amount req d Observations Metal chips present Sludge present 1 Non factory oil filter TP 2435 Continued on page 2 29 Preliminary Examination Cont Cooling System 1 Flywheel Screen 2 Cooling fins 0 Clean 0 Plugged 0 Partially blocked ____________ 0 Clean 0 Plugged 1 Partially blocked 96 3 Engine exterior 0 Clean Ol Dirty LJOily L Evidence of prior disassembly or repair Visible oil leaks where Carburetor and Fuel Supply 1 Condition of carburetor 2 Settings 1 Okay Broken L Loose Ll Shafts worn L Dirt in throat 0 Main fuel ____________ idle fuel adj 3 Condition of fuel LJ Clean 0 Fresh 0 St
404. pened 2 Engine Wiring Harness Related a Broken or shorted wire in harness ECU pin 14 to injector pin 2 ECU pin 28 to fuel pump relay pin 86 Note after key off then key on code 56 would be set also Fuel pump relay pin 87 to injector pin 1 b Open main fuse F1 3 Fuel Pump Relay Related a Bad fuel pump relay Primary side functional but pin 30 to pin 87 remains open Primary side pin 85 to pin 86 is either open or shorted during engine operation Note after key off then key on code 56 would be set also 4 ECU Related a Circuit controlling injector 1 damaged b Circuit controlling fuel pump relay damaged Code 52 32 Pin MSE 1 1 Plastic Cased ECU only Source Injector 2 circuit open shorted to ground or shorted to battery Explanation 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 58 42 Possible Causes 1 Injector Related a Injector coil shorted or opened 2 Engine Wiring Harness Related a Broken or shorted wire in harness ECU pin 15 to injector pin 2 ECU pin 28 to fuel pump relay pin 86 Note after key off then key on code 56 would be set also Fuel pump relay pin 87 to injector pin 1 b Opened main fuse F1 3 Fuel Pump Relay Related a Bad fuel pump relay Primary side functional but pin 30 to pin 87 remains open Primary side pin 8
405. put coil of the ignition module L1 Figure 8 5 is fed to the input of the conditioning circuit The conditioning circuit shapes this pulse putting it in a useable form for the additional circuits This pulse starts the charge pump which charges a capacitor in a linear fashion that can be directly related to the engine speed At the same time the pulse resets the delay circuit for length of the pulse width The comparator is off during this period and no output is generated As soon as the original pulse drops back to zero the capacitor in the delay circuit begins to charge When the charge on the delay capacitor exceeds the charge on the charge pump capacitor the comparator changes state activating the pulse generator This pulse turns ON the CD ignition module semiconductor Energy is then transferred to the secondary of the output transformer T1 Figure 8 5 The high voltage pulse generated here is delivered to the spark plug causing arcing of the spark gap and igniting the fuel air mixture in the combustion chamber As the trigger pulse is generated all associated circuits are reset their capacitors discharged The longer it takes the delay circuit to surpass the charge pump capacitor voltage the later the trigger pulse will occur retarding the timing accordingly Troubleshooting CD Ignition Systems The CD ignition systems are designed to be trouble free for the life of the engine Other than periodically checking repl
406. quipped Fuel lines fuel line fittings and clamps if equipped e Spark advance module if equipped to first scheduled replacement point Crankcase breather Evaporative System if equipped Air Injection System if equipped Canister if equipped Air pump or pulse valve assembly if equipped Canister filter if equipped Control distribution valve if equipped Vapor hose if equipped Distribution manifold if equipped Orifice connector if equipped Air hoses if equipped Fuel tank if equipped Vacuum lines if equipped Fuel cap if equipped Primer bulb canister if equipped LIMITATIONS This Emission Control Systems Warranty shall not cover any of the following a repair or replacement required because of misuse or neglect improper maintenance repairs improperly performed or replacements not conforming to Kohler Co specifications that adversely affect performance and or durability and alterations or modifications not recommended or approved in writing by Kohler Co b replacement of parts and other services and adjustments necessary for required maintenance at and after the first scheduled replacement point c consequential damages such as loss of time inconvenience loss of use of the engine or equipment etc d diagnosis and inspection fees that do not result in eligible warranty service being performed and e add on or modified part or malfunction of authorized parts due t
407. r is clean and clamp is secure for tester being used Turn on the power switch The POWER light should be illuminated and Pi Amp Rectifier Regulators one of the four status lights may be on as well Connect the single lead adapter in between the See Figure 8 30 This does not represent the B center terminal of rectifier regulator being condition of the part tested and the squared single end of the tandem adapter lead See Figure 8 32 6 Press the TEST button until a click is heard and then release See Figure 8 31 Momentarily one of the four lights will illuminate indicating the partial condition of the part Ifthe OK green light comes on disconnect the tester black lead attached to one AC terminal and reconnect it to the other AC terminal Repeat the test If the OK green light comes on again the part is good and may be used b If any other light is displayed in either of the tests the rectifier regulator is faulty and should not be used Figure 8 32 NOTE A flashing LOW light can also occur as a result of an inadequate ground lead 2 Connect the tester ground lead with spring connection Make certain the connection clamp to the body of the rectifier regulator location is clean and the clamp is secure 8 24 Section 8 Electrical System and Components 25 Amp Rectifier Regulators Original Style 6 Press the TEST button until a click is heard 1 Connect the squared single end of the tand
408. r Primary Chamber Nikki Regulator Secondary Chamber See Figure 5A 21 See Figure 5A 22 The primary chamber reduces the high pressure fuel The secondary chamber further reduces the fuel flow from the tank and vaporizer down to pressure from the 29 kPa 4 psi of the primary approximately 4 psi Fuel flowing from the vaporizer chamber to near 0 kPa 0 psi pressure to prevent enters the inlet of the regulator under approximately excessive fuel flow to the carburetor Fuel enters the 76 kPa 11 psi of pressure There it is delivered to the secondary chamber 13 through the clearance primary chamber 3 through the clearance between between the secondary valve 11 and the valve seat the primary valve 1 and valve seat 2 As fuel 12 While the engine is operating and fuel is being continues to flow and the primary chamber drawn from the secondary chamber the secondary approaches 29 kPa 4 psi the primary diaphragm 4 diaphragm 14 is raised by atmospheric pressure overcomes the tension of the diaphragm spring 5 As simultaneously lifting the secondary valve lever 16 the diaphragm 4 and contact button 6 move up the opening the secondary valve 11 allowing fuel to primary lever spring 8 pushes the primary lever 7 flow When the engine is running at idle there may up in turn closing the primary valve 1 and stopping not be enough vacuum created in the carburetor the flow of fuel As fuel is consumed and the pressure venturi to
409. r and Backing Plates n 1 Apply pipe sealant with Teflon Loctite No 59241 or equivalent 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 Figure 11 20 Using Spanner Wrench to Turn 6 2 N m 55 in Ib See Figure 11 23 Crankshaft Section 11 Reassembly Install Flywheel WARNING Damaging Crankshaft and Flywheel Can Cause Personal Injury Using improper procedures to install the flywheel can crack or damage the crankshaft and or flywheel This not only causes extensive engine damage but can also cause personal injury since broken fragments could be thrown from the engine Always observe and use the following precautions and procedures when installing the flywheel NOTE Before installing the flywheel make sure 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 screw is torqued to specifications Figure 11 23 Torquing Stator Screws 4 Route the stator leads in the crankcase channel then install the backing plates and the stator wire bracket if used Secure using the four hex flange screws See Figures 11 24 and 11 25 Torque the screws to 7 3 N m 65 in Ib Figure 11 24 Route Stator Leads in Groove
410. r are removed before the engine is reassembled and placed into operation Even small amounts of these cleaners can quickly break down the lubricating properties of engine oil Use an aerosol gasket remover paint stripper or lacquer thinner to remove any old sealant Apply the solvent allow time for it to work and then brush the surface with a brass wire brush After the old sealant is removed clean the surface with isopropyl alcohol lacquer thinner or aerosol electrical contact cleaner Do not scrape the surfaces as any scratches nicks or burrs can result in leaks See Service Bulletin 252 for further information Refer to A Guide to Engine Rebuilding TP 2150 A for additional information Measurement Guide 2159 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 optional Automatic Compression Release ACR mechanism The ACR lowers compression at cranking speeds to make starting easier Operation The ACR mechanism consists of a flyweight spring and pivoting control pin assembly attached to the gear on the camshatt At cranking speeds 700 RPM or lower the control pin protrudes above the exhaust cam lobe This pushes the exhaust valve off its seat during the first part of the compression stroke The reduced compression results in an effective compression ratio of about 2 1 during cranking
411. r cute E 24 4 N m 216 in Ib Oil Filter COL ESO a refer to oil filter for instructions Oil Cooler GOOG FC a pier Nipple PM rt 27 N m 20 ft Ib Piston Piston Rings and Piston Pin Piston to Piston Pin Running Clearance eee 0 006 0 017 mm 0 0002 0 0007 in Piston Pin Bore I D M 17 006 17 012 mm 0 6695 0 6698 in Mae WC ATE TREE mM 17 025 mm 0 6703 in Piston Pin O D n 16 995 17 000 mm 0 6691 0 6693 in Mar VAC ae Eier EU 16 994 mm 0 6691 in Top Compression Ring to Groove Side Clearance CEHISCIHO20 D20 C T6430 C H22 024 4 35 0 040 0 080 mm 0 0016 0 0031 in CHSC HOSO O74 CO EaR 0 030 0 076 mm 0 0012 0 0030 in CIDSCHDSCEUSS 0 025 0 048 mm 0 0010 0 0019 in Middle Compression Ring to Groove Side Clearance CHIS CHO20 CEI2UKCEIG40 CH22 624 0 040 0 080 mm 0 0016 0 0031 in Ble Cn quivis er 0 030 0 076 mm 0 0012 0 0030 in 4 0 015 0 037 mm 0 0006 0 0015 in Oil Control Ring to Groove Side Clearance C H22 2 CE
412. r drive assemblies and batteries unless supplied or installed by Kohler Co These are subject to the warranties if any of their manufacturers KOHLER CO AND OR THE SELLER SHALL NOT BE LIABLE FOR SPECIAL INDIRECT INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY KIND including but not limited to labor costs or transportation charges in connection with the repair or replacement of defective parts IMPLIED OR STATUTORY WARRANTIES INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY LIMITED TO THE DURATION OF THIS WRITTEN WARRANTY We make no other express warranty nor is any one authorized to make any on our behalf Some states do not allow limitations on how long an implied warranty lasts or the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state TO OBTAIN WARRANTY SERVICE Purchaser must bring the engine to an authorized Kohler service facility To locate the nearest facility visit our website www kohlerengines com and click on SALES AND SERVICES to use the locator function consult your Yellow Pages or telephone 1 800 544 2444 ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 COMMAND PRO Command Magnum OHC Warranty Statement Limited 2 Year COMMAND PRO Command Magnum OHC Engine Warranty Kohler Co warrants to the o
413. r failure has occurred this form should be filled out before your distributor representative arrives to make the warranty analysis inspection Ill Disassembly You are now ready to proceed with the disassembly and failure analysis inspection procedures During disassembly there are again specific areas that should have investigative attention A Peripheral Parts Figure 17 Figure 17 After the shrouds have been removed check the cooling fins and cylinder block surfaces that were not visible earlier Note any additional findings on the Engine Inspection Data Record Figure 18 Figure 18 After removing the carburetor check the throat of the intake manifold or intake port for traces of dust dirt or other contamination B Cylinder Head Figure 19 After removal of the spark plug s and cylinder head s check the combustion deposits as they are often a good indicator of operating conditions This head has heavy black oil or gummy looking deposits indicating that the engine was burning oil usually from internal wear This particular engine had so much oil entering the combustion chamber that it was starting to flush out the combustion deposits And the head hadn t been cleaned for so long that the deposits completely cover the tip of the spark plug Figure 20 Figure 20 Here is another head with similar oily glossy looking deposits A build up of crankcase pressure breather plugged or inoperati
414. r minute 1241 2 A A 1 2 3 15 20 Design Horsepower 4 5 6 7 8910 30 40 50 25 Section 5 Technical Guidelines Belt Length Belt length is usually determined by placement of driven load Belt length is considered as the distance between the center of the drive driver and driven pulleys One formula for calculating length is as follows BL 1 57 D d TCD x 2 In this Belt Length D Diameter of Driver Pulley d Diameter of Driven Pulley TCD 7 Tentative Center Distance 1 57 Constant As an example if the diameter of the Driver pulley is 6 in the driven pulley is 4 in and the centers are 18 in apart this would calculate as follows BL 1 57 6 4 18 x 2 BL 1 57 x 10 36 BL 15 7 36 51 7 Belt Tension Tension is usually not critical however too much or too little tension could shorten belt and bearing life New belts usually stretch somewhat during initial run in and may slip Check tension of a new belt after the initial operation Correct tension is the lowest tension at which the belt will not slip under highest load condition Generally the belt should deflect about 1 64 in 0 396 mm for each inch of span length The formula for determining deflections is Deflection 0 016 inch x Length of Span center to center For example if the length of a span is 18 inches Deflection 0 016 x 18 0 28
415. r model years EPA requires manufacturers to warrant engines for two years in all other states These warranty periods will begin on the date the engine is purchased by the initial purchaser If any emission related part on the engine is defective the part will be replaced by Kohler Co at no cost to the owner Kohler Co is liable for damages to other engine components caused by the failure of a warranted part still under warranty Kohler Co shall remedy warranty defects at any authorized Kohler Co engine dealer or warranty station Warranty repair work done at an authorized dealer or warranty station shall be free of charge to the owner if such work determines that a warranted part is defective Continued on next page Listed below the parts covered by the Federal and California Emission Control Systems Warranty Some parts listed below may require scheduled maintenance and are warranted up to the first scheduled replacement point for that part The warranted parts include the following if they were present in the engine purchased Ignition module s with high tension lead Gaseous fuel regulator if equipped Electronic control unit if equipped Carburetor or fuel injection system Fuel metering valve if equipped Air filter fuel filter and spark plugs only Oxygen sensor if equipped Intake manifold if equipped Exhaust manifold if equipped Catalytic muffler if equipped Thermal reactor muffler if e
416. ransmissions power drive assemblies and batteries unless supplied or installed by Kohler Co These are subject to the warranties if any of their manufacturers KOHLER CO AND OR THE SELLER SHALL NOT BE LIABLE FOR SPECIAL INDIRECT INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY KIND including but not limited to labor costs or transportation charges in connection with the repair or replacement of defective parts IMPLIED OR STATUTORY WARRANTIES INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY LIMITED TO THE DURATION OF THIS WRITTEN WARRANTY We make no other express warranty nor is any one authorized to make any on our behalf Some states do not allow limitations on how long an implied warranty lasts or the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state TO OBTAIN WARRANTY SERVICE Purchaser must bring the engine to an authorized Kohler service facility To locate the nearest facility visit our website www kohlerengines com and click on SALES AND SERVICES to use the locator function consult your Yellow Pages or telephone 1 800 544 2444 ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 KOHLER COURAGE SV810 840 ENGINE LIMITED WARRANTY Kohler Co warrants to the original retail consumer that
417. re elevation above sea level The performance of an engine under those labora tory conditions is generally plotted on a Brake Horsepower or Power Data Curve Pes aa oe a es Hb Ge 6 T T 1 g ee ee O E _ __ _ __ _______ Dr E ul im CIS NNUS re Rue VERSER eee 5 j Land R HORSEPOWER to Four operating conditions have an effect on useable engine horsepower and must be considered when selecting an engine 1 Duty Cycle 2 Altitude 3 Temperature 4 How the engine will be connected to the load These conditions are not unusual they are normal and apply to all makes and models of engines Each condition has an industry accepted factor which must be allowed for when calculating the available horsepower of an engine Engine Torque amp Torque Curves The shape of the torque curve isimportant on many applications It is desirable to have a torque curve which is fairly flat or gently drooping toward the low end of the speed range At the high end of the speed range it should be approximately 10 lower than medium range in order to provide an increase in torque as the engine is pulled down in speed on heavy load
418. re 52 Figure 52 This engine had high combustion temperatures and restricted cooling resulting in very black scorched deposits Figure 53 Figure 53 Severe oxidation or use of an oil additive can cause a complete breakdown of the oil The deposits will appear to be a cross between axle grease and tar Figure 54 Figure 54 If the piston has signs of overheating and or oxidized oil look at the governor gear and breather filter for further confirmation The governor gear takes on a dark orange or rust color when exposed to overheated oil The breather filter will also be discolored with burned oil deposits In severe cases it may be so brittle that it crumbles Figure 55 Figure 55 Seizures due to insufficient running clearance will usually result in scoring without any other signs The scoring may show up on both thrust faces heavier on the primary face toward the valves B Connecting Rods Connecting rod failures will provide some of the greatest challenges to your failure analysis expertise Sometimes the indicators will be pretty clear However in other cases they may be difficult to spot or there may be two or three indicators that seem to contradict each other The rod may be broken in such small pieces that it s difficult to find any failure indicators Your preliminary examination of the engine may provide some valuable assistance where the rod failure indicators are elusive or unclear
419. re 5B 7 TPS Location 58 7 Section 5B EFI Fuel System 4 Leave the leads connected to the pin terminals as described in step 3 Rotate the throttle shaft slowly counterclockwise to the full throttle position Monitor the dial during rotation for indication of any momentary short or open circuits Note the resistance at the full throttle position It should be 1800 3000 5 Disconnect the main wiring harness connector from the TPS leaving the TPS assembled to the manifold Refer to the chart below and perform the resistance checks indicated between the terminals in the TPS switch with the throttle in the positions specified Throttle Between Resistance Closed 800 1200 Closed 1800 3000 Full 1800 3000 Full 800 1200 Any 1600 2500 If the resistance values in steps 3 4 and 5 are within specifications go to step 6 If the resistance values are not within specifications or momentary short or open circuit was detected during rotation step 4 the TPS needs to be replaced go to step 7 6 Check the TPS circuits input ground between the TPS plug and the main harness connector for continuity damage etc See chart on pages 5B 28 5B 31 or 5B 32 35 Pin MA 1 7 Metal Cased ECU Pin Circuits 12 and 27 24 Pin MSE 1 0 Plastic Cased ECU Pin Circuits 8 and 4 32 Pin MSE 1 1 Plastic Cased ECU Pin Circuits 8 and 4 a Repair or replace as required b Turn the idle speed screw
420. re 9 28 ground lead if equipped See Figure 9 26 Ground Lead Figure 9 28 Removing Carburetor Assembly with Governor Lever Attached Model Pictured 4 Remove the carburetor gasket 9 7 Section 9 Disassembly 5 If necessary the carburetor throttle linkage and Remove Outer Baffles and Blower governor lever can be separated Reattach the Housing bushings to the linkage following separation to 1 Disconnect the plug from the rectifier regulator avoid losing them on the blower housing See Figure 9 31 Remove Oil Sentry If So Equipped 1 Disconnect the lead from the Oil Sentry switch 2 Remove the Oil Sentry switch from the breather cover See Figure 9 29 Figure 9 31 Disconnecting Plug from Rectifier Regulator 2 Usethe tip of the dipstick or a similar small flat tool to bend the locking tang then remove the center lead from the terminal plug as shown in Figure 9 32 This will allow the blower housing to Breather Cover be removed without disturbing the wiring harness Remove Electric Starter Motor 1 Disconnect the leads from the starter 2 Remove the two hex flange screws See Figure 9 30 Figure 9 32 Remove B Lead from Terminal Plug 3 The rectifier regulator does not have to be detached from the blower housing If the engine is equipped with SMART SPARK the SAM Figure 9 30 Removing Electric Starter Motor module should be removed from the cylinder
421. re shaft with the retaining ring in the inner groove see Figure 8 40 Slide 7 The splines should have a light film of lubricant the collar over the inner halves to hold them in Relubricate as necessary with Kohler bendix position starter lubricant see Section 2 Reinstall or replace the drive components assembling them in the reverse order they were removed 8 31 Section 8 Electrical System and Components Retaining Ring Installation Position the retaining ring in the groove in of the inner halves Assemble the other half over the top and slide on the outer collar Be certain the drive components are installed in correct sequence onto the armature shaft Slip the tool over the end of the armature shaft so the retaining ring inside is resting on the end of the shaft Hold the tool with one hand exerting slight pressure toward the starter Tap the top of the tool with a hammer until you feel the retaining ring snap into the groove Disassemble and remove the tool Squeeze the retaining ring with a pliers to compress it into the groove Assemble the inner halves with the larger cavity around the spring retainer See Figure 8 42 Slide the collar over them and thread the center screw in until resistance is felt Figure 8 42 Assembling Larger Inner Half Around Spring Retainer 6 7 Hold the base of the tool with a 1 1 8 wrench and turn the center screw clockwise with a 1 2 or 13 mm wrench to
422. re warranted against manufacturing defects in workmanship and material for a period of 90 days from date of purchase by the original user B Defective Service Parts New Inventory When a part from new service part inventory is found to be defective in material or workmanship file a Warranty Claim as described in Section 6 Short blocks miniblocks and engines must have Central Distributor approval for non expert dealers or certified Expert Dealer approval with signatures Transportation costs for parts replacement will not be reimbursed Unless required by individual state C Defective Service Parts Installed If a new service part was installed by an authorized Kohler service outlet and failed within 90 days after installation submit a Warranty Claim for parts and labor as described in Section 6 For service parts installed by persons other than authorized Kohler service outlets and failed within 90 days from date of purchase submit a Warranty Claim and proof of purchase for the defective part only no labor as described in Section 6 Short blocks miniblocks and engines must have Central Distributor approval for non expert dealers or certified Expert Dealer approval with signatures 12 If the defective new parts are components of an assembly repair the assembly by replacing the defective parts whenever this is economically feasible For example if the bearing plate on a short block assembly is cracked due to
423. reather Cover Fastener Torque Sequence Reconnect Rectifier Regulator 1 Install the rectifier 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 grounding bracket is used secure with the lower mounting screw and washer against the outer side of the rectifier regulator See Figure 11 71 Figure 11 66 Tighten Baffle Mounting Screws 6 If an overlapping style flywheel screen is used attach it to the supports or flywheel For a metal flywheel screen apply Loctite No 242 to the screw threads M6 and torque to 9 9 N m 88 in Ib Torque the plastic screen mounting screws to 2 2 N m 20 in Ib Figure 11 69 Connecting Ground Lead 2 Install the terminal lead into the center position of the rectifier regulator plug and connect the plug to the rectifier regulator See Figures 11 70 and 11 71 N Figure 11 67 Installing Metal Type Grass Screen 11 19 Section 11 Reassembly E Grounding 3 2 Bracket Figure 11 71 Grounding Bracket and Attached Connector SMART SPARK Module 1 On engines with SMART SPARK reinstall the SAM module to the blower housing or cylinder baffle Do not overtighten the retaining screws See Figure 11 72 11 20 uff Blower Housing Mounting Location Figure 11 72 Reinstalling SAM Modu
424. rection until the gauge needle is in the yellow set area at the low end of the scale 7 Connect the tester quick disconnect to the adapter hose while firmly holding the engine at TDC Note the gauge reading and listen for escaping air at the carburetor intake exhaust outlet and crankcase breather 8 Check your test results against the following table Section 3 Troubleshooting Leakdown Test Results Air escaping from crankcase Defective rings or worn cylinder Air escaping from exhaust system Defective exhaust valve improper seating Alr escapine irom OU CLOW 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 but there is some wear present Customer should start planning for overhaul or replacement Gauge reading in high red zone x bu UR eA Rings and or cylinder have considerable wear Engine should be reconditioned or replaced 3 5 Section 3 Troubleshooting 3 6 Section 4 Air Cleaner and Air Intake System Air Cleaners General Most engines are equipped with a replaceable high density paper air cleaner element surrounded by an oiled foam precle
425. refully OIL RECOMMENDATIONS The importance of checking changing and using the proper crankcase oil cannot be overemphasized Failure to use the correct oil can affect engine life and reliability Use high quality detergent oil of API American Petroleum Institute service class SF Viscosity should be based on the air temperature at the time of operation as shown below 10W 30 10W 40 a 5W 20 5W 30 F 20 0 20 32 40 po C 30 20 10 0 10 20 30 40 Straight 30 weight oil is preferred If multi viscosity is used be aware of the resulting increase in oil consumption and combustion deposits when used in temperatures above 32 F 0 Using other than service class SF oil or extending oil change intervals longer than recommended could cause engine damage which is not covered by the engine warranty A logo or symbol on oil containers identifies the API service class and SAE viscosity grade The top portion of the symbol shows the service class which may be SF SF CC CD or others The center portion shows the viscosity grade such as SAE 30 in the example If the bottom portion shows Energy Conserving it means the oil is intended to improve fuel economy in passenger car engines There are a number of special additives on the market Although some of these materials have merit for certain conditions on some engines we believe that with adequate maintenance
426. 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 a seal installer Governor Cross Shaft Seal 10 14 Section 11 Reassembly General NOTE Make sure the engine is assembled using all specified torque values tightening sequences and clearances Failure to observe specifications could cause severe engine wear or damage Always use new gaskets Apply a small amount of oil to the 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 the engine is assembled and placed into operation Even small amounts of these cleaners can quickly break down the lubricating properties of engine oil Check the closure plate crankcase cylinder heads and valve covers to be certain that all old sealing material has been removed Use gasket remover lacquer thinner or paint remover to remove any remaining traces Clean the surfaces with isopropyl alcohol acetone lacquer thinner or electrical contact cleaner Typical Reassembly Sequence The following sequence is suggested for complete engine reassembly This procedure assumes that all components are new or have been reconditioned and all component subassembly work has been completed The sequence may vary to accommodate options or special equipment Detailed pr
427. riginal consumer that each new COMMAND PRO Command Magnum OHC engine sold by Kohler Co will be free from manufacturing defects in materials or workmanship in normal service for a period of two 2 years from date of purchase provided it is operated and maintained in accordance with Kohler Co s instructions and manuals Our obligation under this warranty is expressly limited at our option to the replacement or repair at Kohler Co Kohler Wisconsin 53044 or at a service facility designated by us of such parts as inspection shall disclose to have been defective EXCLUSIONS Mufflers on engines used commercially non residential are warranted for one 1 year from date of purchase except catalytic mufflers which are warranted for two 2 years This warranty does not apply to defects caused by casualty or unreasonable use including faulty repairs by others and failure to provide reasonable and necessary maintenance The following items are not covered by this warranty Engine accessories such as fuel tanks clutches transmissions power drive assemblies and batteries unless supplied or installed by Kohler Co These are subject to the warranties if any of their manufacturers KOHLER CO AND OR THE SELLER SHALL NOT BE LIABLE FOR SPECIAL INDIRECT INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY KIND including but not limited to labor costs or transportation charges in connection with the repair or replacement of defective parts IMPLIED
428. ring and keeper assembly from the pulley as a package A WARNING Spring Under Tension Do not remove the spring from the keeper Severe personal injury could result from the sudden uncoiling the spring Rope Hole Figure 7 7 Position of Spring and Keeper in Pulley Inspection and Service 1 Carefully inspect the rope pawls housing center screw and other components for wear or damage 2 Replace all worn or damaged components Use only genuine Kohler replacement parts as specified in the Parts Manual All components shown in Figure 7 1 are available as service parts Do not use nonstandard parts 3 Do not attempt to rewind a spring that has come out of the keeper Order and install 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 7 4 Reassembly Make sure the spring is well lubricated with grease Place the spring and keeper assembly inside the pulley with spring towards pulley See Figure 7 7 Install the pulley assembly into the starter housing See Figure 7 8 Make sure the pulley is fully seated against the starter housing Do not wind the pulley and recoil spring at this time Housing Figure 7 8 Installing Pulley and Spring into Housing 3 Install the pawl springs and pawls into the starter pulley See Figure 7 9 Section 7 Retracta
429. ring harness leads if resistance is incorrect Injector leakage is very unlikely but in those rare instances it can be internal past the tip of the valve needle or external weeping around the injector body See Figure 5B 21 The loss of system pressure from the leakage can cause hot restart problems and longer cranking times To check for leakage it will be necessary to remove the blower housing which may involve removing the engine from the unit Check For Leaks Figure 5B 21 Injector Inspection Points 1 Engine must be cool Depressurize fuel system through test valve in fuel rail 2 Disconnect spark plug leads from spark plugs 3 Remove the air cleaner outer cover inner wing nut element cover and air cleaner element precleaner Service air cleaner components as required 4 Remove the two screws securing the air cleaner base to throttle body manifold Remove the air cleaner base to permit access to the injectors Check condition of air cleaner base gasket replace if necessary 5 Remove the flywheel screen if it overlaps the blower housing 6 If the engine has a radiator type oil cooler mounted to the blower housing remove the two oil cooler mounting screws 7 Remove the blower housing mounting screws Note the location of the plated silver screw attaching the rectifier regulator ground lead Remove the blower housing 8 Thoroughly clean the area around and including the throttle body manifold and t
430. ris from hitting someone Install the float float shaft and inlet needle to the air horn Tighten the screw Check float height 8 Remove the preformed rubber gasket only if it using the procedure found previously in the is to be replaced If it is removed for any reason Adjustments subsection replace it 2 Install the slow jet with the stepped end toward Inspection Repair the bottom of the carburetor Make sure jet is Carefully inspect all components and replace those fully seated that are worn or damaged 3 Install the low idle adjusting needle and spring Inspect the carburetor body for cracks holes and other wear or damage 4 Assemble the upper body onto the lower 5 carburetor body using the four screws Torque Inspect the float for cracks holes and missing the screws to 1 7 15 in Ib or damaged float tabs Check the float hinge and shaft for wear or damage 5 Install the carburetor on the engine following the procedures in Section 11 Reassembly e Inspect the fuel inlet needle and seat for wear or damage e Inspect the tip of the low idle fuel adjusting needle for wear or grooves e The choke plate is spring loaded Check to make sure it moves freely on the shaft NOTE The choke and throttle plate assemblies are staked and matched to the shafts at the factory They are not serviceable items Always use new gaskets when servicing or reinstalling carburetors Repair kits are available whic
431. rom our ignition system and the hottest possible spark N The Magneto Cycle This is accomplished through the mechanism of the breaker points The points are part of our primary circuit As long as the contacts are closed current will flow in the primary circuit At the instant that current reaches the desired maximum value the ignition lobe on the camshaft will push against the breaker rod to open the contacts Current in the primary will stop the self induced magnetic field around the primary windings will collapse and the high voltage generated in the secondary windings will fire across the gap on the spark plug Point Gap Stationary Contact Adjusting Screw Point Breaker Rod Breaker Arm Contact Point Terminal Breaker Arm Spring amp Lead Typical Ignition Breaker Points The collapse of the magnetic field around the primary windings not only generates high voltage in the secondary it also causes an increased EMF in the primary This increased EMF wili have a tendency to arc across the breaker contacts and burn the contact surfaces To prevent that problem a condenser is mounted in the primary circuit somewhere between the coil and the points The condenser contains two foil strips separated by a dielectric insulator One foil strip is connected to the condenser terminal or lead wire and the other strip is connected to the case of the condenser The strip connected to the hot side absorbs just enough
432. roperly and the peening results from the two sections of the rod pounding together as the bolts backed out Figure 76 Figure 76 Here is another example of undertightening In this case the bolts were just loose enough for the rod sections to work against each other but not loose enough for them to hammer The result is a dull gray finish on the mating surface known as fretting If magnified this fretting would look like the peening you saw in the last slide This condition will not be seen on Posi Lock rods Figure 78 Figure 78 This rod cap shows signs of scoring and aluminum smearing If you look closely it has a double layer of aluminum on the right hand side This engine was started with no oil it seized and was freed up It was restarted and shortly after it seized again because the aluminum transfer from the first seizure left insufficient running clearance The lesson here is make sure there is oil in the engine before starting Figure 77 Figure 77 This piece has just a small peened area near the outer edge of the mating surface The looseness here resulted from the high temperatures generated by the seizure The bolts had been tightened properly and only began to yield when the rod started to seize This type of peening is secondary The cause of the failure was insufficient lubrication Figure 79 Figure 79 This is a shot of a rod bolt that was loose This came early within its li
433. ropriate hole in the governor lever as indicated in the following charts Note that hole positions are counted from the pivot point of the governor lever See Figures 11 85 and 11 86 and the appropriate chart CN aa fiw amp 3 Colored End Only ET Colored Completely Figure 11 86 Governor Spring 1 0 Color Markings Figure 11 85 Connecting Spring to Governor Lever 6 mm Governor Lever and Hole Position RPM Chart Gov Lever Governor Spring High Idle RPM Hole No Color Code 3801 4000 3601380 aA Governor 345 360 3 Clear Leve Governed Idle Hole 3301 3450 2 ear 310133 Pope 35 310 Purple 28002000 2 Pupe 3750 3 Clear 5 Regulation others 10 11 24 Section 11 Reassembly 8 mm Governor Lever and Hole Position RPM Charts CH18 Engines 4 3 Governor Lever 2 1 2 Intended Non Accelerator Accelerator Governor Shaft irae WOT RPM Pump Carburetor Pump Carburetor Configuration Spring Color Hole Spring Color No Standard Parent Material amp WB WW W CH20 740 Engines Intended Non Accelerator Accelerator Governor Shaft WoT RPM Pump Sar oie Wo Pump C
434. rounding the warranty request The warranty covers defects in material or workmanship so you must try to decide if the failure resulted from a manufacturing defect and is eligible for warranty consideration If you feel that a decision will be difficult or the customer is disputing your decision complete an Engine Inspection Data Record TP 2435 as shown on pages 17 19 and follow a systematic analysis procedure 1 Complete the Owner s Information portion of the Engine Inspection Data Record when the customer brings the unit in for consideration 2 Inspect the unit as delivered and complete the Air Filter Assembly Crankcase Oil Engine Cooling System and Governor sections of the Engine Inspection Data Record NOTE Experience has shown that the information gained from these sections frequently will lead to the cause of the failure and will determine what corrective action must be performed to prevent repeat failures 3 Carefully disassemble the engine and check components for any unusual markings or wear patterns 4 Take the necessary measurements and enter them in the proper sections in the Engine Inspection Data Record Compare the measurements against published specifications in Kohler service literature to identify parts that may require rework or replacement If your analysis points to a deficiency in engine care or maintenance recommend to your customer the preventive measures that must be performed to prevent re
435. rque the switch to 4 5 40 in Ib 3 Gradually decrease the pressure through the range of 3 0 5 0 psi The tester should indicate a Testing change to continuity switch closed down to Compressed air a pressure regulator pressure gauge 0 psi and a continuity tester are required to test the switch 4 Replace the switch if it does not operate as 1 Connect the continuity tester across the blade specified terminal and the metal case of the switch With 0 psi pressure applied to the switch the tester should indicate continuity switch closed 6 5 Section 6 Lubrication System 6 6 Section 7 Retractable Starter WARNING Spring Under Tension Retractable starters contain a powerful recoil spring that is under tension Always wear safety goggles when servicing retractable starters and carefully follow instructions this section for relieving spring tension To Remove Starter 1 Remove the five hex flange screws securing the starter to the blower housing 2 Remove the starter To Install Starter 1 Install the retractable starter onto the blower housing 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 Replacement The rope can be replaced without complete starter disassembly 1 Remove the starter from the blower housing 2 Pull the rope out approximately
436. rruption 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 to the lifters must have an exposed height of 75 mm 2 15 16 in The studs furthest from the lifters must have an exposed height of 69 mm 2 3 4 in c Remove the nuts and repeat the procedure as required Figure 11 41 Torquing Cylinder Head Fasteners 11 12 Figure 11 43 Installing New Mounting Studs to Specified Height 3 Check that the dowel pins are in place and install a new cylinder head gasket printing up 4 Install the cylinder head Match the numbers on the cylinder heads and the crankcase See Figure 11 36 Make sure the head is flat on the gasket and dowel pins 5 Lightly lubricate the exposed upper threads of the studs with engine oil Install a flat washer and hex nut onto each of the mounting studs Torque the hex nuts in two stages first to 16 9 N m 150 in Ib finally to 33 9 N m 300 in Ib following the sequence in Figure 11 42 Mounting Nuts Stud Design Install Push Rods and Rocker Arms Early models used hollow push rods with special rocker arms They are not interchangeable with the later current style solid push rods and associated rocker arms Do not mix these A replacement kit is available with solid components Section 11 Reassembly NOTE Push rods should always be installed in the
437. s the ECU activates the MIL and stores a diagnostic code in its fault memory If the component or system returns to proper function the ECU will eventually self clear the fault code and turn off the MIL If the MIL stays illuminated it warns the customer that dealer service is required Upon receipt the dealer technician can access the fault code s to help determine what portion of the system is malfunctioning The 2 digit blink codes available based upon the style of ECU are listed on pages 5B 35 Db 97 The codes are accessed through the key switch and displayed as blinks or flashes of the MIL Access the codes as follows 1 Start with the key switch off 2 Turn the key switch on off on off on leaving it on in the third sequence The time between sequences must be less than 2 5 seconds 3 Any stored fault codes will then be displayed as a series of MIL blinks from 2 to 6 representing the first digit followed by a pause and another series of blinks from 1 to 6 for the second digit see Figure 58 43 a It s a good idea to write down the codes as they appear as they may not be in numerical sequence b Code 61 will always be the last code displayed indicating the end of code transmission If code 61 appears immediately no other fault codes are present Section 5B EFI Fuel System Example of Diagnostic Display 1 Diagnostic display initiated through ignition key sequencing 2 7 Short Pauses wm k
438. s 4 through 6 for the other ignition module Rotate the flywheel back and forth checking for clearance between the magnet and ignition modules Make sure the magnet does not strike the modules Check the gap with a feeler gauge and readjust if necessary Final air gap 0 280 0 330 mm 0 011 0 013 in Install Intake Manifold ih Install the intake manifold and new gaskets or O Rings plastic manifold with wiring harness attached to the cylinder heads Slide any wiring harness clips onto the appropriate bolts before installing Make sure the gaskets are in the proper orientation Torque the four screws in two stages first to 7 4 N m 66 in Ib then to 9 9 88 in Ib using the sequence shown in Figure 11 51 Figure 11 51 Intake Manifold Torque Sequence Section 11 Reassembly Figure 11 52 Sealant Applied to Terminals NOTE If the wires were disconnected from the ignition modules on engines with SMART SPARK reattach the leads and seal the base of the terminal connectors with GE Novaguard G661 see Section 2 or Fel Pro Lubri Sel dielectric compound The beads should overlap between the terminals to form a solid bridge of compound See Figure 11 52 Do not put any compound inside the terminals The 24 584 15 5 ignition modules have a separator barrier between the terminals On these modules seal the base of the terminals but it is not necessary to have overlapping beads of sealant between the c
439. s allowed by the cap Do not attempt to remove the limiter caps 1 Start the engine and run at half throttle for 5 to 10 minutes to warm up The engine must be warm before doing steps 2 3 and 4 2 Place the throttle control into the idle or slow position Adjust the low idle speed to 1200 RPM Follow the Adjusting the Low Idle Speed RPM procedure 3 Low Idle Fuel Needle s Setting Place the throttle into the idle or slow position 9 12 a Turn one of the low idle fuel adjusting needles out counterclockwise from the preliminarysetting until the engine speed decreases rich Note the position of the needle Now turn the adjusting needle in clockwise The engine speed may increase then it will decrease as the needle is turned in lean Note the position of the needle Set the adjusting needle midway between the rich and lean settings See Figure 5 12 b Repeat the procedure on the other low idle adjustment needle 4 Recheck adjust the Low Idle Speed RPM to the specified setting Lean Lean Adjust to Right Side Adjust to Midpoint Left Side Figure 5 12 Optimum Low Idle Fuel Settings Models with Governed Idle System An optional governed idle control system 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 Engine
440. s 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 a through the inside of the crankcase See Figure Figure 9 73 Removing Crankshaft 9 76 Remove Governor Cross Shaft 1 Remove the hitch pin and plain washer or the retainer and nylon washer from the governor cross shaft See Figures 9 74 and 9 75 Figure 9 76 Pulling Governor Cross Shaft Remove Flywheel End Oil Seal IS 1 Remove oil seal from crankcase See Figure 9 77 er I Figure 9 74 Removing Governor Cross Shaft Hitch Pin 6 mm Shaft Design Figure 9 77 Removing Oil Seal 9 19 Section 9 Disassembly 9 20 Section 10 Inspection and Reconditioning This section covers the operation inspection and repair reconditioning of major internal engine components The following components are not covered in this section They are covered in sections of their own Air Cleaner Section 4 Carburetor amp External Governor Section 5 Ignition Charging amp Electric Starter Section 8 Clean all parts thoroughly 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 the manufacturer s instructions and safety precautions carefully Make sure all traces of the cleane
441. s lost Linkage The throttle linkage spring will fully open the throttle plate if the linkage becomes detached from the DLA This will create an overspeed condition causing the engine to shut down The DLA shaft will have to be manually screwed back into the body and then retracted before reassembling the linkage Governor Control Unit Figure 5 42 Governor Control Unit Locations 5 23 Section 5 Fuel System and Governor Adjustment Procedure The DLA must be in the fully retracted position during assembly The full range of throttle plate movement will not be achieved if the DLA is partially extended when assembled Loosen the two DLA mounting plate screws located on the top of the actuator plate With the throttle linkage centered in the U Clip or secured with a retaining clip at the end of the DLA shaft slide the DLA bracket assembly back until the throttle plate is fully open Torque the mounting plate screws to 2 5 22 in Ib Troubleshooting Procedure Engine does not run at the expected speed Engine starts but will not continue to run 1 Check to see that the throttle linkage and DLA 1 Check the linkage connection between the DLA have full range of motion having no mechanical and throttle plate interference 2 Verify the DLA initializes when power is 2 Test the potentiometer wiper voltage if supplied key switch in the start or run position equipped 3 Test the potentiometer wiper output voltage if 3 Tes
442. s of electro magnetic induction refer to Engine Ignition Sys tems TP 2210 Interruption of the primary current by means of breaker points on both battery and magneto systems causes a rapid change in the coil and thereby produces the high voltage necessary at the spark plug This voltage may run as high as 20 000 volts with approximately 7 000 being re quired for initial starting HiGH TENSION LEAO CIRCUIT SECONDARY CIRCUIT SPARK PLUG IGNITION Sk ee CONDENSER BB t 5 aes zE PRIMARY a t SECONDARY CCNNECT ION j sartery IGRIT LOK rts POINTS Pd V Nie 4 iN GROUND X I PRIMARY LOW VOLTAGE AND SECONDARY HIGH VOLTAGE CIRCUITS Timing of the spark is essential to obtain maximum power from the engine The point at which the spark should occur will vary with the speed and the design of the engine Under running conditions the spark should occur before the piston reaches top dead center so that the burning of the fuel has started before the piston begins its downward stroke Maximum pressure is necessary to get the maximum work from the rapidly expanding gases ELECTRONIC IGNITION Most newer engines are equipped with the elec tronic solid state type of ignition system In this system as the flywheel rotates and the magnet assembly moves past the ignition module a low voltag
443. s referenced to engine top dead center Spark Plug i Figure 8 5 Capacitive Discharge Ignition Module Schematic Operation As the flywheel rotates the magnet erouping passes the input coil L1 The corresponding magnetic field induces energy into the input coil L1 The resultant pulse is rectified by D1 and charges capacitor As the magnet assembly completes its pass it activates the triggering device L2 which causes the semiconductor switch SCS to turn on With the device switch ON the charging capacitor C1 is directly connected across the primary P of the output transformer T1 As the capacitor discharges the current initiates a fast rising flux field in the transformer core A high voltage pulse is generated from this action into the secondary winding of the transformer This pulse is delivered to the spark plug gap Ionization of the gap occurs resulting in an arc at the plug electrodes This spark ignites the fuel air mixture in the combustion chamber Troubleshooting CD Ignition Systems The CD ignition systems are designed to be trouble free for the life of the engine Other than periodically checking replacing the spark plugs no maintenance or timing adjustments are necessary or possible Mechanical systems do occasionally fail or break down however so the following troubleshooting information is provided to help you get to the root of a reported problem CAUTION High Energy Electr
444. s with this feature contain a small secondary spring connected between the governor lever and the lower adjustment tab of the main bracket See Figure 5 13 The system requires an additional procedure for setting the idle speed If speed adjustments are required proceed as follows 1 Make any necessary speed or control adjustments following the appropriate instructions covered in this section Section 5 Fuel System and Governor 2 Move the throttle control to the idle position Carburetor Servicing Hold the governor lever away from the carburetor or hold the throttle lever so it is tight Float Replacement against the idle speed adjusting screw to negate If symptoms described in the carburetor the governor activation See Figure 5 14 Check troubleshooting guide indicate float level problems the speed with a tachometer and adjust it to 1500 remove the carburetor from the engine to check and RPM or replace the float Use a float kit to replace the float pin float valve clip and screw 3 Release the governor lever and allow the engine to return to the governed idle speed Check 1 Perform the removal procedures for the Heavy it with a tachometer against the equipment Duty Air Cleaner and Carburetor outlined in manufacturers recommended idle speed Section 9 Disassembly Governed Idle Speed RPM is typically 300 RPM approximate higher than the low idle speed If 2 Clean the exterior surfaces of dirt or foreign adjustm
445. screws securing the air cleaner adapter and gasket to the carburetor See Figure 5A 4 Figure 5A 4 b Important Mark a small line on the outer edge of the venturi for proper orientation and reinstallation later c Loosen the venturi retaining screw on the side of the carburetor body and lift out the venturi See Figure 5A 5 Figure 5A 5 Inspect the overall condition of the fuel enrichment hose attached to the carburetor It must be free of cracks deterioration and damage Disconnect the fuel enrichment hose from the carburetor fittings to clean or check condition as required See Figure 5A 6 Replace with a new Kohler high pressure hose LP rated if the condition is questionable in any way Secure new hose using new clamps Figure 5A 6 5 Clean all parts as required use a good carburetor cleaner following the manufacturer s instructions Blow clean compressed air through all the passages Do not poke or probe into the load block assembly as damage can be done resulting in serious operational problems See Figure 5A 7 Figure 5A 7 Section 5A LPG Fuel Systems Nikki Carburetor 1 Turn off fuel supply at tank 2 Remove the air cleaner breather hose fuel line vacuum hose choke and throttle linkages Remove the nuts carburetor and gaskets from the engine Discard the gaskets Remove the fuel transfer chamber cover by removing the three screws See Figure 5A 3 Carefully remove
446. se in HP every 10 over 77 F 25 C Transmission Efficiencies The fourth factor to consider is how the engine will be connected to the load Other than using direct couplings such as a mower blade attached directly to the crankshaft of an engine there are normal losses of power Not all of the power is transmitted by other drives There are six basic drive systems which are listed as follows 1 Direct Shaft 2 Belt amp Pulley 3 Chain amp Sprocket 4 Friction Drive 5 Gear Drives 6 Electric Clutch which apply instant load 3 5 Drop for every 1000 above sea level Engines operating at altitudes 5000 ft 1524 m all models except CS engines which is 6000 ft 1829 m and higher may need a special high altitude main fuel jet in carburetor 8 5000 6000 7000 8000 Refer to the chart below for efficiency values for some common transmission methods Transmission Efficiencies Chart Efficiency Typical 96 Gear Reductions Contact Manufacturer 50 80 some important points regarding drives are described in Section 2 of this guide Matching the Engine to the Load The engine selected must be sized for the worst possible operating conditions An undersize engine no matter how carefully it is installed and operated is likely to cause problems Keep in mind the four factors described earlier when calculating usable horsepower The load requirement may be available from the drive equipmen
447. sed in the Diesel engine cylinder its temperature increases and as this occurs very rapidly there is insufficient time for the heat to escape to the surrounding cylinder walls With the high compression ratio and rapid compression of the air temperatures are reached which ignite the Diesel fuel when it is injected into the cylinder This is known as compression ignition and is the char acteristic operating principle of Diesel engines 2 IGNITION In gasoline engines the fuel and air mixture is ignited by means of an electric spark Tbe spark bridges or jumps the gap from one spark plug electrode to the other in the combustion chamber The electricity for that spark must be of sufficiently high voltage in order to jump the gap and ignite the fuel but is of relatively small current flow CONDENSER BREAKER PERMANENT MAGNETS FLYWHEEL TYPICAL FLYWHEEL MAGNETO IGNITION SYSTEM The high voltage is produced in a coil The coil has two windings Current is flowed at low voltage through the primary winding of the coil which is relatively heavy wire and few turns The charge of current in this winding causes a high voltage low amperage current in the secondary winding This is true of both magneto and battery ignition systems The current for the primary winding of a battery ignition system comes from the battery In a magneto system this primary current is gen erated within the coil through the proces
448. ses Engine exhaust gases contain poisonous carbon monoxide Carbon monoxide is odorless colorless and can cause death if inhaled Avoid inhaling exhaust fumes and never run the engine in a closed building or confined area Electrical Shock can cause injury Do not touch wires while engine is running Electrical Shock Never touch electrical wires or components while the engine is running They can be sources of electrical shock Section 1 Selecting the Right Engine Selecting the Right Engine When you start designing the new piece of power equipment you probably have some notion of what size engine will be needed Keep in mind however that there is more to consider in the selection process than just picking an engine based on power curves The engine selected must be capable of meeting the demands of the equipment under all of the conditions in which the equipment will have to operate The engine must be a good match to ensure success of the design and user satisfaction FT 4 8 Before the right engine can be selected it is essential to Know what the load or power requirement of the driven equipment is and what the operating requirements are These are covered in detail later NEWTON METERS TORQUE LBS Why Not Just Select From Power Curves All manufacturers of air cooled engines in the United States use the Society of Automotive Engineers SAE test codes to rate their engines Engines current
449. shaft Governor Lever Figure 5 39 Governor Sensitivity Adjustments Left Side Pull High Speed RPM Adjustment Refer to Figure 5 40 1 With the engine running move the throttle control to fast Use a tachometer to check the RPM speed 2 Loosen the lock nut on high speed adjusting screw Turn the screw outward to decrease or inward to increase the RPM speed Check RPM with a tachometer 3 When the desired RPM speed is obtained retighten the lock nut NOTE When the throttle and choke control cables are routed side by side especially under a single clamp there must be a small gap between the cables to prevent internal binding After the high speed setting has been completed check that there is a gap of at least 0 5 mm 0 020 in between the control cables Throttle Control Lever 2 Choke Control Lever 1 Choke Control Cable Kill Switch Throttle Control Cable Kill Switch Adjusting Screw Dual Control High Speed Lever Stop Screw Do Not Remove High Speed Adjusting Screw Figure 5 40 Governor Control Connections 5 22 Choke Linkage Z Bend Throttle Control Cable 0O DN High Speed Control Lever Right Side Pull Section 5 Fuel System and Governor Electronic Governor Digital Linear Actuator DLA Energizing the bi directional digital linear actuator General coils in the proper sequence causes the threaded shaft The electronic governor regulates engine speed
450. should be completed at the time the distributor representative makes their review and analysis and in the following situations 16 1 If the Service Distributor or Expert classified outlet representative cannot make a final decision due to inconclusive evidence or information Assistance from the Central Distributor or factory will be required 2 If the engine is on a piece of commercial equipment more than six months old and or the engine has more than 500 hours of running 3 If the engine has not yet reached the above criteria less than six months old less than 500 hours you need only complete that portion of Section 2 which pertains to the actual failure For example if the connecting rod has seized to the crankshaft you would only fill out the Connecting Rod Crankshaft Rod Journal and Evaluation Performed By segments of Section 2 However if you notice anything else that could have been a contributing factor such as burned oil deposits on the piston indicating possible overheating and or oil breakdown that should also be noted B Engine Inspection Data Record KOHLERENGINES _____ Engine Inspection Data Record To facilitate accurate evaluation enter as much information as possible mark location of break or crack on drawing provide as many dimensions as possible record conditions found with check mark X whenever possible SECTION 1 OWNER AND EQUIPMENT INFORMATION Owner s Name Stre
451. sits in your fuel system and to ensure easy starting e Do not add oil to the gasoline e 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 R M 2 or higher In countries using the Research Octane Number RON it should be 90 octane minimum Leaded gasoline is not recommended and must not be used on EFI engines or on other models where exhaust emissions are regulated Gasoline Alcohol blends Gasohol up to 10 ethyl alcohol 90 unleaded gasoline by volume is approved as a fuel for Kohler engines Other gasoline alcohol blends including E20 and E85 are not to be used and not approved Any failures resulting from use of these fuels will not be warranted Gasoline Ether blends Methyl Tertiary Butyl Ether MTBE and unleaded gasoline blends up to a maximum of 15 MTBE by volume are approved as a fuel for Kohler engines Other gasoline ether blends are not approved Fuel System Components General The Electronic Fuel Injection EFI system is a complete engine fuel and ignition management design The system includes the following principal components e Fuel Pump Fuel Filter Fuel Rail Fuel Line s Fuel Pressure Regulator Fuel Injectors Throttle Body Intake Manifold Engine Control Unit ECU Ignition Coils Engine Oil Temperature Sensor Throttle Position Sensor TPS Speed Sensor Oxygen S
452. so the following troubleshooting information is provided to help you get to the root of a problem Reported ignition problems are most often due to poor connections Before beginning the test procedure check all external wiring Be certain all ignition related wires are connected including the spark plug leads Be certain all terminal connections fit snugly Make sure the ignition switch is in the RUN position Test Procedure for DSAI Ignition Systems The following procedures are provided for troubleshooting ignition problems on DSAI equipped engines They will allow you to isolate and pinpoint the failed component s Special Tools Required Hand Tachometer e Ignition Tester Kohler Part No 25 455 01 S e Automotive Timing Light e Multi meter Digital Specifications Required e Spark plug gap 0 76 mm 0 030 in NOTE Ignition tester Kohler Part No 25 455 01 5 must be used to test ignition on these engines Use of any other tester can result in inaccurate findings The battery on the unit must be fully charged and properly connected before making any of these tests a battery that is hooked up or charged backward will crank the engine but it won t have spark Be certain the drive is in neutral and all external loads are disconnected Test 1 Isolate and Verify the Trouble is Within the Engine Ignition System 1 Locate the connectors where the wiring harnesses from the engine and equipment are joined Separ
453. solenoid and disassembled cleaned and relubricated Apply starter remove the solenoid from the starter assembly lubricant see Section 2 to the lever and shaft Failure to do so could result in an accumulation of dirt or 3 Remove the two thru bolts debris that might prevent the engine from starting and could cause damage to the starter or the flywheel 4 Remove the commutator end cap Service may be necessary more frequently under dusty or dirty conditions 5 Remove the insulator and the brush springs from the brush spring holder Starter Reassembly 1 Insert the rear stop collar on the armature shaft 6 Remove the armature from the frame 2 Place the retainer in the groove on the armature 7 Remove the drive lever and the armature from shaft the drive end cap NOTE Always use a new retainer Tighten the NOTE When removing the lever and the retainer in the groove to secure armature be careful not to lose the thrust washer 3 Fit the front stop collar over the shaft and bring the front and the rear stop collars together over 8 The stop collar consists of two similar pieces the retainer Using two pairs of pliers apply even held in place by being snapped over a retainer force to the two collars until they snap over the The retainer is held in place by a groove in the retainer and nest into one another armature shaft To remove the stop collar the two pieces must be pried off the retainer 4 Reassemble the remaining components
454. ssion Equipment Typical Efficiency Direct Coupled 100 V Belts 96 98 Roller Chain 95 97 Spur Gears 96 Gear Reducers Consult Manufacturer Refer to page 12 for an example of how to calculate useable engine horsepower 12 Example of Calculations CALCULATING USEABLE HP Application Fan 1 Duty Cycle use 80 factor constant Load 8 HP e 3600 RPM 3 5 Loss Manufacturer s specs 2 Altitude 4000 ft X E 14 loss or 86 available Duty Cycle Constant Altitude to 4000 ft 3 Temperature 100 60 X EN 4 loss or 96 available 10 Temperature Max 100 F Power Transmission 4 Power Transmission V belt 97 efficient V belts The engine HP actually required for this application can now be determined from the following formula Engine Hp Unknown X Cycle X effect X effect X Transmission Required to or 80 86 96 97 drive fan 8 HP Minimum Required to Drive Fan _ 12 4 HP Duty Alt Temp Trans Engine Cycle X Effect X Effect X Effic Actually 80 86 96 Og KOHLER ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 ENGINE APPLICATION GUIDE SEEK the innovation THE POWER KOHLER Sd Introduction At Kohler we are proud of the fact that we make fine four cycle air and liquid cooled engines We strive to keep ahead of changing requirements and offer the latest state of the art engines which were developed to meet stringent regulations mandatin
455. st fumes and never run the engine in a closed building or confined area Lethal Exhaust Gases Engine exhaust gases contain poisonous carbon monoxide Carbon monoxide is odorless colorless and can cause death if inhaled Avoid inhaling exhaust fumes and never run the engine in a closed building or confined area WARNING Uncoiling Spring can cause severe injury Wear safety goggles or face protection when servicing retractable starter Spring Under Tension Retractable starters contain a powerful recoil spring that is under tension Always wear safety goggles when servicing retractable starters and carefully follow instructions in the Retractable Starter Section 7 for relieving spring tension WARNING Explosive Gas can cause fires and severe acid burns Charge battery only in a well ventilated area Keep sources of ignition away Explosive Gas Batteries produce explosive hydrogen gas while being charged To prevent a fire or explosion charge batteries only in well ventilated areas Keep sparks open flames and other 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 sure all switches are OFF If ON a spark will occur at the ground cable terminal which could cause an explosion if hydrogen gas or gasoline vapors are present CAUTI
456. stead See Figure 3 9 Fuel Systems In Line Fuel Filter Fuel Line Fuel Tank Equipment or Remote Mounted ug Fuel Pickup Tube with Screen amp n Vented Fuel gt Fuel Line Figure 3 10 Components of a Typical Fuel System 17 Section 3 Properly Installing the Engine The fuel consumption curves published in sales brochures for each engine can be used to determine fuel storage requirements if other than an engine mounted fuel tank is to be used The brochure also specifies whether the engine is equipped with a fuel pump Components of a typical fuel system with fuel pump and remote tank are shown in Figure 3 10 A gallon of gasoline U S standard weighs about 6 1 pounds and produces about 120 500 of heat NOTE A fuel shut off valve is recommended on all systems to stop fuel flow during periods of non use or when transporting or servicing the equipment A fuel filter should also be installed ahead of the fuel pump on fuel lift systems or ahead of the carburetor on gravity feed systems Contact your Kohler Engine representative for fuel filter micron rating requirements Gravity Feed System This system is generally used on engines without fuel pumps The bottom of the fuel tank should be at least 3 in 76 2 mm above the fuel inlet on the carburetor to ensure sufficient pressure to open the inlet valve on the carburetor NOTE If the tank is locate
457. stem _ Ground To Kill Lead White Optional Diode Violet Ignition Module JE Flywheel Keyswitch _ C Stator Optional 4 Fuse Rectifier Regulator il Sentry m Optional Switch Optional Oil Sentry Indicator Light Switch Shutdown x E Solenoid Starter 12 V Battery Blue 1 7 i I J B Wiring Diagram Electric Start Engines 15 Amp Regulated Battery Charging System AC Leads gt 15 Amp Stator And Rectifier Regulator 30 Troubleshooting Guide 15 Amp Battery Charging System NOTE Zero ohmmeters and voltmeters on each scale to ensure accurate readings Voltage tests should be made with engine running at 3600 RPM no load Battery must be fully charged 1 Insert an ammeter in B lead from rectifier regulator With engine running at 3600 RPM and B lead connected measure the voitage from B at terminal on rectifier regulator to ground using DC voltmeter If voltage is 13 8 volts or more place a minimum load of 5 Amps on battery to reduce voltage Observe ammeter NOTE Turn on lights if 60 watts or more Or place a 2 5 ohm 100 watt resistor across battery terminals 2 Remove connector from rectifier regulator With engine running at 3600 RPM measure NO AC voltage across stator leads using an AC CHARGE voltmeter TO BATTERY 3a With engine stopped measure the resist
458. stem for detailed procedures on checking the oil changing the oil and changing the oil filter Fuel Recommendations A WARNING Explosive Fuel Gasoline is extremely flammable and its vapors can explode if ignited Before servicing the fuel system make sure there are no sparks open flames or other sources of ignition nearby as these can ignite gasoline vapors Disconnect and ground the spark plug leads to prevent the possibility of sparks from the ignition system General Recommendations Purchase gasoline in small quantities and store in clean approved containers A container with a capacity of 2 gallons or less with a pouring spout is recommended Such a container is easier to handle and helps eliminate spillage during refueling Do not use gasoline left over from the previous season to minimize gum deposits in your fuel system and to ensure easy starting Do not add oil to the gasoline 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 R M 2 or higher In countries using the Research Octane Number RON it should be 90 octane minimum Leaded gasoline is not recommended and must not be used on EFI engines or on other models where exhaust emissions are regulated Gasoline Alcohol blends Gasohol up to 10 ethyl alcohol 90 unleaded gasoline by volume is approved as a fuel for Kohler engines
459. stor style plug or permanent damage to the ECU will occur in addition to affecting operation Proper spark plug gap is 0 76 mm 0 030 in Wiring Harness The wiring harness used in the EFI system connects the electrical components providing current and ground paths for the system to operate All input and output signaling occurs through a special all weather connector that attaches and locks to the ECU see Figures 5B 23 58 24 and 5B 25 Figure 58 23 35 Pin MA 1 7 Metal Cased ECU Connector and O Ring Figure 58 24 24 Pin MSE 1 0 Plastic Cased ECU Connector Figure 5B 25 32 Pin MSE 1 1 Plastic Cased ECU Connector The condition of the wiring connectors and terminal connections is essential to system function and performance Corrosion moisture and poor connections are more likely the cause of operating problems and system errors than an actual component Refer to the Troubleshooting Electrical section for additional information Battery Charging System EFI engines are equipped with either a 15 or 25 amp charging system to accommodate the combined electrical demands of the ignition system and the specific application Charging system troubleshooting information is provided in Section 8 Section 5B EFI Fuel System Fuel Components Fuel Pump External Internal Figure 5B 26 Fuel Pump Styles General An electric fuel pump is used to transfer fuel in the EFI sys
460. t Check the key switch wires connections safety interlocks etc b If the problem persists the condition is associated with the ignition or electrical system of the engine Leave the kill lead isolated until all testing is completed NOTE If the engine starts or runs during any of 2 8 6 the testing you may need to ground the kill lead to shut it down Because you have interrupted the kill circuit it may not stop using the switch Test for spark on both cylinders with Kohler ignition tester see Section 2 Disconnect one spark plug lead and connect it to the post terminal of the tester Connect the clip to a good eround not to the spark plug Crank the engine and observe the tester spark gap Repeat the procedure on the other cylinder Remember to reconnect the first spark plug lead a If one side is not firing check all wiring connections and terminations on that side If wiring is okay replace ignition module and retest for spark b Ifthe tester shows spark but the engine misses or won t run on that cylinder try a new spark plug c If neither side is firing recheck position of ignition switch and check for shorted kill lead B Capacitive Discharge with Electronic Spark Advance SMART SPARK SMART SPARK equipped engines utilize an electronic capacitive discharge ignition system with electronic spark advance A typical application Figure 8 6 consists of the following components A m
461. t ie Valve Seat TIT LSE SIA 212 Fuel Chamber Inlet Port Return Port to tank to fuel rail Figure 5B 29 Fuel Pressure Regulator Details Service Depending on the application the regulator may be located in the fuel tank along with the fuel pump or outside the tank just down line from the pump The regulator is a sealed non serviceable assembly If it is faulty it must be separated from the base holder assembly and replaced as follows 1 Shut engine off make sure engine is cool and disconnect the negative battery cable 2 Depressurize fuel system through test valve in fuel rail see fuel warning on page 58 2 3 Access the regulator assembly as required and clean any dirt or foreign material away from the area 4 External Regulator Based upon the style of regulator used see Figure 58 30 a Remove the two screws securing the mounting bracket to the regulator housing Remove the O Ring and pull the regulator out of the housing b Remove the snap ring and remove regulator from base 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 Section 5B EFI Fuel System Figure 5B 30 External Regulators and Base Holders Figure 5B 31 Internal Regulator and Base Holder 5 Always use new O Rings and hose clamps when installing a regul
462. t installed or supplied by Kohler Co 5 Rental of another engine or other related equipment while engine repairs are in progress 6 Telephone facsimile and or other related communications expenses 7 Replacement and accessory parts not supplied by Kohler Co and damages resulting from their installation 8 Loss of revenue resulting from the failure 9 Loss or damage to personal property 10 Transportation charges accrued during transportation of failed unit or equipment Expert classifications are exempt Section 6 Claims Procedure NOTE Warranty Claims received without required information WILL BE RETURNED A Responsibility for Submitting Proper and Completed Warranty Claim Forms Warranty repairs and completion of properly filled out warranty claim forms are the responsibility of the authorized service outlet It is the responsibility of the service outlet to review each claim for thoroughness authenticity and accuracy of information Warranty claims will not be considered complete unless all the information requested on the claim form is filled in Incomplete or inaccurate claims will be returned to the service outlet Claim forms received more than 30 days after warranty repairs are completed will not be accepted Complete engines short blocks and miniblocks must have Central Distributor approval for non expert dealers or certified Expert Dealer approval with signatures When authorized the signature of t
463. t manufacturer if the engine is to power such equipment If it s a new application be cautious when using a trial and error method of load determination If you need help contact your Kohler Engine representative They have forms and the experience to assist you in selecting the right engine How to Calculate Usable Horsepower Example 1 As an example of how to calculate the actual horsepower requirements let s say you have designed a unique new tiller and estimate the load requirement to be 4 HP at 3600 RPM Don t forget however to apply the four industry accepted factors described earlier which are 1 Duty This will be an intermittent duty application 85 available 2 Altitude Maximum to be 2000 feet above sea level Factor 3 5 for every 1000 feet above 2 000 x 3 5 7 decrease or 93 available 3 Temperature Maximum ambient should not exceed 95 F On engines rated under J1940 test code figure 1 decrease for every 10 F over 77 F 25 C In this case 2 factor 98 available 4 Transmission This application will use chain drive which is listed at 95 97 in the chart Using the lowest 95 available Applying these factors the actual horsepower requirement is arrived at using the following formula 4 HP Estimated Load _ 4 85 x 93 x 98 95 736 5 435 actual HP Required A good match for this particular application would be the Kohler Command CH6 It would have reserve power and
464. t the SPST switch if equipped equipped 4 Test the SPST switch if equipped 5 Check the wire harness and connections 5 24 Section 5A LPG Fuel Systems A WARNING Explosive Fuel LPG 15 extremely flammable is heavier than air and tends to settle in low areas where a spark or flame could ignite the gas Do not start or operate this engine in a poorly ventilated area where leaking gas could accumulate and endanger the safety of persons in the area require special licensing or certification for LPG repair shops and or technicians Check state and local regulations before attempting any adjustment service or repair of the LPG system or components Faulty repairs by unqualified or underqualified personnel can have very serious ramifications The information in this segment is for the exclusive use of qualified LPG service providers Proper service and repair of LPG fuel systems requires qualified technicians and special equipment Many states 5A LPG Fuel System Components The typical liquid withdrawal LPG fuel system consists of the following components LPG Fuel Tank Liquid Withdrawal Electric Lock Off Filter Assembly Vaporizer LPG Regulator Combination Primary Secondary Vacuum Lock Off LPG Carburetor High Pressure Fuel Line s Vacuum Line Fuel Line Vaporizer p Vacuum Line Lock Off Filter Assembly LPG Regulator Figure 5A 1 Section 5A LPG Fuel Systems Oper
465. t the feeler gauge and retighten the mounting screws 6 Rotate the flywheel to remove the feeler gauge position the magnet back under the module and recheck that the specified gap minimum of 0 28 mm 0 011 in exists under each leg of the module When you are certain the gap is correct torque the module mounting screws to 4 0 N m 35 in Ib 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 a snug fit between the male and female terminals If any connections do not feel snug disconnect the lead lightly pinch the female terminal with a pliers and recheck the fit 7 When the integrity of all connections has been verified repeat the spark test Test 2 a Ifastrong steady spark is now present both sides on a twin your problem should be corrected Go to step 4 of Test 5 b If there is still a spark problem perform all of Test 5 Test 5 Test the SAM 1 Trace the red power source lead from the SAM to the harness connection Separate the connector and connect the red lead of a DC voltmeter to the harness terminal Trace the ground lead from the SAM black on singles green on twins to the grounding screw Connect the black voltmeter lead to the eyelet terminal of the ground lead or the ground screw bolt Section 8 Electrical System and Components Check the voltage with the k
466. t to ground and current flows in the primary windings Direction of Magnetic Flux Current Flowing In Primary The triggering coil within the module is positioned so that it will begin to generate an EMF at the same instant that the magnetic flux reverses direction in the laminations The EMF from the triggering coil causes the transistor in the primary circuit to switch off instantaneously and the collapsing field of the primary induces the high EMF in the secondary which bridges the spark gap and provides ignition Direction of Magnetic Flux Collapse Of Primary Spark From Secondary The Magnum module is positioned outside the flywheel The additional radius in combination with a 1 to 46 primary secondary ratio provides high output at low RPM s The spark energy at cranking speed surpasses previous Kohler magneto systems as well as competitive systems both past and present Primary Secondary increased Radius Increased Radius And Turns Ratio For Increased Output And Performance Troubleshooting Single Cylinder The Magnum single cylinder ignition system consists of the following components magnet assembly which is PERMANENTLY affixed to the flywheel A solid state ignition module which is mounted to the engine bearing plate kill switch or keyswitch which stops the engine by grounding the ignition module Diode 012 016 Igni
467. t to check for leaks Low idle fuel mixture is improperly adjusted Adjust low idle fuel needle some models Float level is set too low Separate carburetor air horn from carburetor body adjust float specification Idle holes plugged dirt in fuel delivery channels Remove low idle fuel adjusting needle Clean main fuel jet and all passages blow out with compressed air Float level set too high See Remedy 2d Dirt under fuel inlet needle See Remedy 2e Bowl vents plugged Blow out with compressed air Carburetor bowl gasket leaks Replace gasket Troubleshooting Checklist When the engine starts hard runs roughly or stalls at low idle speed check the following areas before adjusting or disassembling the carburetor e Make sure the fuel tank is filled with clean fresh gasoline e Make sure the fuel tank cap vent is not blocked and that it is operating properly e Make sure fuel is reaching the carburetor This includes checking the fuel shut off valve fuel tank filter screen in line fuel filter fuel lines and fuel pump for restrictions or faulty components as necessary e Make sure the air cleaner base and carburetor are securely fastened to the engine using gaskets in good condition e Make sure the air cleaner element including precleaner if equipped is clean and all air cleaner components are fastened securely e Make sure the ignition system governor system exhaust system and throttle a
468. tall first two hex flange screws sealant Do not scrape the surfaces as this at positions shown in Figure 11 58 and finger could result in leakage tighten at this time 2 Check to make sure there are no nicks or burrs on sealing surfaces 11 16 Section 11 Reassembly Install Blower Housing and Outer Baffles NOTE Do not completely tighten 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 the front edge of the inner baffles See Figure 11 61 Start a few of the screws to hold it in place On two barrel carburetor models lift the debris shield up above the mounting surface as the blower housing is installed Make sure Figure 11 58 Installing Screws Locations 3 and the ground lead fuel solenoid lead and oil 4 pressure switch leads are accessible and in proper position See Figures 11 61 and 11 62 7 Install the inner baffles using the two remaining hex flange screws see Figures 11 59 and 11 60 and finger tighten Do not torque the screws at this time they will be tightened after the blower housing and outer baffles are installed Figure 11 62 Routing Wiring Harness and Leads Two Barrel Models Figure 11 60 Finger Tighten Two Remaining Cover Screws 11 17 Section 11 Reassembly 3 Position the outer baffles and loosely start the mounting screws
469. tance is greater than 2 0 KQ the oxygen sensor is bad replace it Allow the sensor to cool less than 60 C 140 F and retest the resistance with the meter set on the Rx1M scale With sensor cool the resistance should be greater than 1 0 MQ a If the resistance is greater than 1 0 MQ go to Step 5 b If the resistance is less than 1 0 MQ the sensor is bad replace it With the oxygen sensor disconnected and engine not running disconnect the main harness connector from the ECU and set the meter to the Rx1 scale Check the circuit continuity as follows 35 Pin MA 1 7 Metal Cased ECU Check for continuity from pin 9 of the ECU connector see page 5B 28 to the shell of the oxygen sensor and from pin 10 to the sensor connector terminal of the main harness Both tests should indicate continuity 24 Pin MSE 1 0 Plastic Cased ECU Check for continuity from pin 15 of the ECU connector see page 5B 31 to the shell of the oxygen sensor and from pin 11 to the sensor connector terminal of the main harness Both tests should indicate continuity 32 Pin MSE 1 1 Plastic Cased ECU Check for continuity from pin 19 of the ECU connector see page 5B 32 to the shell of the oxygen sensor and from pin 20 to the sensor terminal of the main harness Both tests should indicate continuity a If there is no continuity displayed in either of the tests check the harness circuit for breaks or damage and th
470. tapping screw 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 of the crankshaft Procedure to Install New Plug 1 Usea single cylinder camshaft pin Kohler Part No 47 380 09 5 as a driver and tap the plug into the plug bore until it seats at the bottom of the bore Make sure the plug is tapped in evenly to prevent leakage Self Tapping Screw Flat Washer Crankshaft Figure 10 2 Removing Crankpin Plug Crankcase Inspection and Service Check all gasket surfaces to make sure they are free of gasket fragments Gasket surfaces must also be free of deep scratches or nicks Inspect the main bearing if so equipped for wear or damage refer to Section 1 Specifications Tolerances and Special Torque Values Replace the crankcase using a miniblock or short block as required Check the cylinder bore wall for scoring In severe cases unburned fuel can cause scuffing and scoring of the cylinder wall It washes the necessary lubricating oils off the piston and cylinder wall As raw fuel seeps down the cylinder wall the piston rings make metal to metal contact with the wall Scoring of the cylinder wall can also be caused by localized hot spots resulting from blocked cooling fins or from inadequate or contaminated lubrication If the cylinder bore is badly scored excessiv
471. task especially if you try to use hit and miss or component replacement techniques commercial ignition component tester is a must in the modern day small engine shop to avoid wasting mechanics time and customers money The two common brand names for small engine ignition component testers are Merc O Tronic and Graham Lee Both of these manufacturers make large multi scale table top models and also less expensive more portable models If one of the large models is within your means it will do an excellent job of testing nearly every phase of component operation However the small less expensive models are more than adequate to determine if a component is good or bad Ignition Component Testers 10 There many different tests which can made on ignition components but there are four basic tests which can normally help you determine if your ignition components are good or bad Since these four tests can all be performed with one of the less expensive commercial testers or a good quality ohmmeter we will concentrate our efforts on them The four tests are l Coil Power Test ll Surface insulation Test Ill Condenser Leakage and Short Test IV Breaker Point Contact Resistance The tester we will use is the Merc O Tronic model 98 If you have a different make or model follow manufacturer s instructions for performing the same four tests l Coil Power Test 1 Connect the tester to the
472. tch is 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 pressure switch can be used to ground the ignition module to stop the engine On vehicular applications lawn tractors mowers etc the pressure switch can only be used to activate a low oil warning light or signal NOTE Make sure the oil level is checked before each use and is maintained up to the F mark on the dipstick This includes engines equipped with Oil Sentry Installation The Oil Sentry pressure switch is installed in the breather cover See Figure 6 8 Oil Sentry Switch s Breather Cover rd 4 Figure 6 8 Location of Oil Sentry Switch or pipe plug On engines not equipped with Oil Sentry the installation hole is sealed with a 1 8 27 N P T F pipe plug Section 6 Lubrication System To install the switch follow these steps 2 Gradually increase the pressure to the switch As 1 Apply pipe sealant with Teflon Loctite No the pressure increases through the range of 59241 or equivalent to the threads of the switch 3 0 5 0 psi the tester should indicate a change to no continuity switch open The switch should 2 Install the switch into the tapped hole in the remain open as the pressure is increased to 90 psi breather cover See Figure 6 8 maximum 3 To
473. ted without oil you re right Figure 67 Figure 67 Here you see shiny smeared aluminum in the center of the bearing surface and no discoloration on the outer surfaces The failure was due to insufficient running clearance between the rod and crankshaft The rod had been overtightened and the bearing area collapsed squeezing out the film of lubricating oil The engine had oil in it which cooled the outer surfaces but it couldn t reach the center of the bearing surface Figure 68 Figure 68 The aluminum in a forged connecting rod appears brighter than a die cast rod This is a forged rod that failed from running without oil The smeared aluminum 15 very bright with no burned oil deposits Because a forging is stronger than a die casting you may also notice some unusual twisting or distortion Figure 69 Figure 69 If a connecting rod has not seized the bearing surface can also be a wear indicator The final finishing operation on a connecting rod leaves a textured but highly polished surface finish If there is dirt in an engine it combines with the oil and works like a buffing compound on the bearing surface The highest loading occurs at the top and bottom of the stroke so the top and bottom of the journal will show wear first Figure 70 Figure 70 This rod is from an engine that ran for 15 hours with dirt in the crankcase The original surface finish has been worn off leaving a dull satin app
474. tegory lack of oil manufacturing defect etc The differences will help you distinguish one from another and often provide clues to the circumstances or conditions that caused that particular failure Where then should we look to determine the cause of failure Actually there are four areas that should be scrutinized before a decision is made Figure 58 Figure 58 The first area to examine is the journal area and the dipper if it has one Did the rod seize causing the aluminum on the bearing surface to smear and transfer Is the outside of the journal area discolored darkened Are there burned oil deposits present Do the burned oil deposits extend down onto the dipper What is the condition of the dipper intact broken nicked or scraped discolored The first rod on the left is very similar to Figure 56 It seized on the crank and it has burned oil deposits on the outside of the journal A seizure results when there is inadequate lubrication between the crankshaft and the rod The burned oil deposits indicate there was some oil present but it wasn t providing adequate lubrication The engine was probably run low on oil The second rod had some running time but it never had failure or problem It is included in the photograph to help you distinguish color variations The third rod has a broken dipper The lighter color of the broken segment indicates that the break occurred before the rod seized In fact the bro
475. telescoping gauge or bore gauge to take measurements The measurements should be taken at three locations in the cylinder at the top middle and bottom Two measurements should be taken perpendicular to each other at each of the three locations Clean Cylinder Bore After Honing Proper cleaning of the cylinder walls following boring and or honing is very critical to a successful overhaul Machining grit left in the cylinder bore can destroy an engine in less than one hour of operation after a rebuild 10 3 Section 10 Inspection and Reconditioning The 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 the machining oil while maintaining a good level of suds If the suds break down during cleaning discard the dirty water and start again with more hot water and detergent Following the scrubbing rinse the cylinder with very hot clear water dry it completely and apply a light coating of engine oil to prevent rusting Measuring Piston to Bore Clearance Before installing the piston into the cylinder bore it is necessary that the clearance be accurately checked This step is often overlooked and if the clearances are not within specifications engine failure will usually result NOTE Do not use a feeler gauge to measure piston to bore clearance it will yield inaccurate measurements Always use a micrometer Use th
476. tem Depending on the application the pump may be inside the fuel tank or in the fuel line near the tank The pumps are rated for a minimum output of 25 liters per hour at 39 psi The pumps have an internal 60 micron filter In addition the in tank 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 page 5B 22 When the key switch is turned on and all safety switch requirements are met the ECU through the relay activates the fuel pump which pressurizes the system for start up If the key switch is not promptly turned to the start position the engine fails to start or the engine is stopped with the key switch on as in the case of an accident the ECU switches off the pump preventing the continued delivery of fuel In this situation the MIL will go on but it will go back off after 4 cranking revolutions if system function is OK Once the engine is running the fuel pump remains on Service The fuel pumps are non serviceable and must be replaced if determined to be faulty If a fuel delivery problem is suspected make certain the pump is being activated through the relay all electrical connections are properly secured the fuses are good and a minimum of 7 0 volts is being supplied If during cranking voltage drops below 7 0 volts a reduction of fuel pressure may occur resulting in
477. ter drive lubricant see Section 2 Install the drive components following the instructions for servicing the starter drive Starter Assembly Armature Figure 8 47 Nippondenso Solenoid Shift Starter 8 34 Solenoid Shift Electric Starters The following subsection covers the solenoid shift electric starters Much of the information in the proceeding subsection relates to this type starter also so it is not repeated here A Nippondenso or Delco Remy solenoid shift starter may be used The Nippondenso starter 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 shaft and into mesh with the flywheel ring gear When the pinion reaches the end of the drive shaft it rotates the flywheel and cranks the engine When the engine starts and the start switch is released the starter solenoid is deactivated the drive lever moves back and the drive pinion moves out of mesh with the ring gear into the retracted position Front Stop Collar gt __ Retainer Rear Stop Collar Insulator Commutator Thru Bolt Section 8 Electrical System and Components Starter Disassembly Starter Service 1 Disconnect the lead wire from the solenoid Every 500 hours of operation or annually whichever comes first solenoid shift starters must be 2 Remove the hex nuts securing the
478. the cover and gasket Discard the gasket The main jet is fixed and nonadjustable but may be accessed for cleaning by removing the rear plug and sealing washer Discard the washer In order to clean the off idle transfer passages and carburetor thoroughly use a good carburetor cleaner and follow the manufacturer s instructions Blow clean compressed air through the passages and make sure all are open before reassembling Do not use wire or metal objects to clean passages or carburetor body LPG Carburetor Inspection 1 Inspect the carburetor body and removable venturi Impco carburetor for cracks holes and other wear or damage Check the choke shaft Nikki carburetor only and the throttle shaft for wear and free movement NOTE Do not attempt to disassemble or remove either shaft from the carburetor body including the mounted clamp brackets on Impco style carburetors The screws attaching the choke and throttle plate to their respective shafts are staked or bonded to prevent loosening The plate s and shaft s are not available separately If detrimental wear or damage is found in any of the parts the carburetor should be replaced 5A 5 Section 5A LPG Fuel Systems LPG Carburetor Reassembly Impco Carburetor 1 Slide the venturi into the carburetor body aligning the position mark made prior to removal Correctly installed the discharge holes should not be visible from the top 2 Secure with the
479. the lifter Slowly pump the plunger two or three times to force the oil out of the feed hole in the side of the lifter Closure Plate Assembly Inspection Inspect the oil seal in the closure plate and remove it if it is worn or damaged Refer to Install Closure Plate Oil Seal in Section 11 for new oil seal installation Inspect the main bearing surface for wear or damage refer to Section 1 Specifications Tolerances and Special Torque Values Replace the closure plate assembly if required Governor Gear Assembly Inspection Inspect the governor gear teeth Replace the gear if it is worn chipped or if any teeth are missing Inspect the governor weights They should move freely in the governor gear 10 11 Section 10 Inspection and Reconditioning Disassembly Reassembly The governor gear must be replaced once it is 1 Install the locking tab thrust washer on the removed from the closure plate governor gear shaft with the tab down NOTE The governor gear is held onto the shaft by 2 Position the regulating pin within the governor small molded tabs in the gear When the gear gear flyweight assembly and slide both onto the is removed from the shaft these tabs are governor shaft destroyed and the gear must be replaced Therefore remove the gear only if absolutely Oil Pump Assembly necessary Disassembly 1 Remove the regulating pin and governor gear 1 Remove the two hex flange screws assembly See Figure
480. the pulse line to the pulse fitting 6 Connect the fuel lines to the inlet and outlet fittings Replacing the Mechanical Pump The mechanical pump is an integral part of the valve cover assembly and not serviced separately See Figure 5 2 1 Disconnect the fuel lines from the inlet and outlet fittings 2 Follow the procedure for replacing the valve cover Sections 9 and 11 3 Reconnect the fuel lines to the inlet and outlet fittings Outlet Line to Carburetor Mechanical Fuel Pump Inlet Line Figure 5 2 Mechanical Fuel Pump 5 3 Section 5 Fuel System and Governor Carburetor General Engines in this series are equipped with Keihin fixed main jet carburetors CH18 740 engines use a one barrel carburetor Most applications use a fuel shut off solenoid installed in place of the fuel bowl retaining screw and also contain an accelerator pump All carburetors feature a self relieving choke like or similar to the one shown in the exploded view A WARNING Explosive Fuel 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 Do not fill the fuel tank while the engine 18 hot or running since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition Do not start the engine near spilled fuel Never use gasoline as a cleaning agent on page 5 10
481. the spark plug at precisely the right instant within each engine cycle to ignite a compressed fuel air mixture in the combustion chamber and to repeat the process thousands of times every minute the engine is in operation That function may sound quite impressive just by itself However if we analyze exactly what is being done by the ignition system its function becomes awesome indeed A typical single cylinder engine with a spark gap of 025 requires from 5000 to 20 000 volts to bridge the spark gap In a magneto system that amount of voltage must be generated entirely within the system from a source that is capable of producing only about 200 volts And if the engine is running at 3600 RPM that 5000 20 000 voits must be generated and delivered to the spark plug 30 times each second So you see the job being done by the ignition system is no small task The next time someone complains that he needs to replace an ignition coil after only 500 hours of running remind him that the coil has already produced as many as 50 million ignition sparks during its life Due to their light weight and simplicity of operation magneto ignitions are used on most small gasoline engines Battery ignition systems require in addition to the battery a means to recharge it such as a generator or an alternator and are generally used on engines of 10 or more horsepower Whether the ignition system is magneto or battery the purpose is the same
482. the starter for testing Test 1 Solenoid Pull In Coil Plunger Actuation Test Use a 12 volt power supply and two test leads Connect one lead to the flat spade S start terminal on the solenoid Momentarily connect the other lead to the lower large post terminal See Figure 8 78 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 replaced NOTE DO NOT leave the 12 volt test leads connected to the solenoid for any time over what is necessary for performing each of the individual tests Internal damage to the solenoid may otherwise occur 12 volt Test Leads Momentary Connection Only Figure 8 78 Testing Pull In Coil Plunger Actuation Test 2 Solenoid Pull In Coil Contact Continuity Test Use an ohmmeter set to the audible or Rx2K scale and connect the two ohmmeter leads to the two large post terminals Perform the preceding test 1 and check for continuity See Figure 8 79 The ohmmeter should indicate continuity if no continuity is indicated the solenoid should be replaced Repeat test several times to confirm condition 8 44 12 volt Test Leads Momentary Connection Only VOM Leads E l Figure 8 79 Testing Pull In Coil Solenoid Contact Continuity Test 3 Solenoid Hold In Coil Function Test Connect one 12 volt test lead to the flat spade S st
483. tick NOTE To prevent extensive engine wear or damage always maintain the proper oil level in the crankcase Never operate the engine with the oil level below the L mark or above the F mark on the dipstick Changing Oil and Oil Filter Changing Oil Change the oil after every 100 hours of operation more frequently under severe conditions Refill with service class SG SH SJ or higher oil as specified in the Viscosity Grades table on page 6 1 Change the oil while the engine is still warm The oil will flow more freely and carry away more impurities Make sure the engine is level when filling or checking oil Change the oil as follows 1 Clean the areas around one of the oil drain plugs oil fill cap and dipstick 2 Remove one of the oil drain plugs A drain plug is located on either side 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 6 2 3 Allow all the oil to drain and then reinstall the drain plug Torque to 13 6 N m 10 ft Ib 4 Remove the oil fill cap and fill the engine with the proper oil to the F mark on the dipstick Always check the oil level with the dipstick before adding more oil Figure 6 5 Removing Oil Fill Cap 5 Reinstall the oil fill cap Changing Oil Filter Replace the oil filter at least every other oil change every 200 hours of operation Always use a gen
484. tinum 3071 used on Pro Series engines Kohler Part No 25 132 12 5 is also available Equivalent alternate brand plugs can also be used Gap 0 76 mm 0 030 in Thread Size 14 mm Reach 19 1 mm 3 4 in Hex Size 15 9 mm 5 8 in 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 steps 1 Before removing each spark plug clean the area around the base of the plug to keep dirt and debris out of the engine 2 Remove the plug and check its condition See Inspection following this procedure Replace the plug if necessary NOTE Do not clean spark plug in a machine using abrasive grit Some grit could remain in the spark plug and enter the engine causing extensive wear and damage 3 Check the gap using a wire feeler gauge Adjust the gap to 0 76 mm 0 030 in by carefully bending the ground electrode See Figure 8 1 Wire Gauge Spark Plug Ground Electrode 0 76 mm 0 030 in Gap Figure 8 1 Servicing Spark Plug 4 Reinstall the spark plug into the cylinder head and torque to 24 4 29 8 N m 18 22 ft Ib Inspection Inspect each spark plug as it is removed from the cylinder head The deposits on the tip are an indication of the general condition of the piston rings valves and carburetor Normal and fouled plugs are shown in the following ph
485. tion Module High Tension Kill Switch Lead C or Keyswitch Kill Terminal B Laminations A c C ia Coil Assembly a Solid State Ignition System Single Cylinder Engines 15 Troubleshooting Guide Single Cylinder The following guide will help locate and correct ignition problems CONCLUSION _ ENGINE WILL NOT START 16 1 Make sure spark plug lead is connected to spark plug 2 Check condition of spark plug Make sure gap is set to 025 3 Check ignition module using test plug refer to Ignition System Tester a Remove the high tension lead from the engine spark plug and connect it to the test plug NOTE To maintain engine speeds normally obtained during cranking do not remove the engine spark plug b Connect the large spring clip around the hex portion of the test plug Connect the alligator clip to a good ground on the engine c Make sure the engine throttle control kill switch and or keyswitch are in the run position d Crank the engine and observe the test plug A visible and audible spark should be produced If plug is in good condition check adjust gap and reinstall If a visible and audible spark IS produced the ignition module is OK If a visible and audible spark IS NOT produced a Make sure engine throttle control kill switch and or keyswitch are in the run position b Check wires and terminals of ignition module
486. tional i Switch Ammeter X Indicator Light Optional Oil Sentry Switch Shutdown 12 V Battery Lighting Lead Yellow Diode Charging Lead Black Figure 8 27 3 Amp 70 Watt Stator Stator The stator is mounted on the crankcase behind the flywheel Follow the procedures in Section 9 Disassembly and Section 11 Reassembly if stator replacement is necessary Rectifier Regulator The rectifier regulator is mounted on the blower housing See Figure 8 28 To replace it disconnect the plug s remove the two mounting screws and ground wire or metal grounding strap 8 22 NOTE When installing the rectifier regulator take note of the terminal markings and install the plug s accordingly Rectifier Regulator round Strap or lead Figure 8 28 Rectifier Regulator Testing of the rectifier regulator may be performed as follows using the appropriate Rectifier Regulator Tester see Section 2 To Test NOTE Disconnect all electrical connections attached to the rectifier regulator Testing may be performed with the rectifier regulator mounted or loose The figures show the part removed from the engine for clarity Repeat the applicable test procedure two or three times to determine the condition of the part 15 Amp Rectifier Regulators 1 Connect the tester ground lead with spring clamp to the body of the rectifier regulator being tested Connect the tester red le
487. tly Scored Galled Stuck Seized Stripped Trucking Damage Unknown Other Valve Clearance Weak Weld Worn Warped Others Shipping Damage Section 7 Reimbursement Procedures A Policy Kohler Co will reimburse only registered service outlets for warranty services performed provided a completed warranty claim is submitted and approved Method of reimbursement is by direct check within the United States or Canada International service outlets will be reimbursed through their local Central Distributor B Reimbursement Calculation Details Warranty reimbursement 15 calculated by using the following formulas for each worldwide service outlet classification 1 U S A amp CANADA NON EXPERT Standard Warranty Repair Parts and Labor no engines Total Credit Net price of replacement part Parts Profit a b c d Posted Full Shop Labor Rate U S dollars Miscellaneous Costs e Freight short blocks amp miniblocks only see section a Parts Profit may vary depending on individual state regulation b Short Blocks or Miniblocks 10 c Parts Profit for Authorized Service Outlet 20 d Parts Profit for Specialized Service Outlet 10 e Miscellaneous Cost Cylinder honing and crankshaft grinding 15 Standard Warranty Repair Engine and Labor Total Credit List price of replacement Command Courage Aegis series engine less 10 f Parts Profit g Freight see section
488. to remove an engine to make the repair enter job number 4000 for removing and reinstalling R amp R as a separate item Check against the flat rate maximums The flat rate times have been established using facilities and equipment that all Service Accounts should have available your repair time exceeds the flat rate and additional labor allowance is requested please send a note of explanation so consideration can be given Important Using the incorrect Flat Rate Schedule could result in incorrect payment and or delay in the processing of your claim Box 13 Fill in freight allowance details if applicable Box 14 Enter labor time in hours and decimal fractions Example 1 5 Box 15 Leave blank factory use only Box 16 List part numbers and description of each part replaced Box 17 Must be filled in and signed by a Central Distributor representative for non expert dealers or a certified Expert Dealer when any short block miniblock or engine is replaced An Engine Inspection Data Record TP 2435 should be completed and submitted with the Warranty Claim Failure Type Suffix Leaked Missing Assembled Wrong Broken Cracked Blown Bent Twisted Porous Casting Deficiency Not Seating Noisy Came Loose Off Corroded Pitted Dented Electric Failure Foreign Material Improper Fit Paint Peeling Magnets Loose Out of Adjustment Out of Balance Packing Material Defective Part Made Machined Incorrec
489. to go onto the drawing board We hope it makes your job easier and will help you build the best possible product for your customers Feel free to call your Kohler Engine representative if you have any questions not answered in this book or wish to discuss any of the suggestions offered within the book Safety Note When planning an installation keep safety in mind Refer to the Safety Precautions on page 3 for some important reminders A WARNING Explosive Fuel can cause fires and severe burns Stop engine before filling fuel tank Explosive Fuel 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 Do not fill the fuel tank while the engine 15 hot or running since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition Do not start the engine near Spilled fuel Never use gasoline as a cleaning agent A WARNING Accidental Starts can cause severe Injury or death Disconnect and ground spark plug lead before servicing Accidental Starts Disabling engine Accidental starting can cause severe injury or death Before working on the engine or equipment disable the engine as follows 1 Disconnect the spark plug lead s 2 Disconnect negative battery cable from battery Read Before Proceeding A WARNING Explosive Gas can cause fires and
490. to produce a properly timed surge of high voltage electrical energy which flows across the spark plug gap to create the spark which will ignite the fuel mixture Now that we have gained some appreciation for the job performed by an ignition system let s look at some of the theories and functions behind the systems MAGNETO IGNITION A magneto can be thought of as a type of generator which converts mechanical energy to electrical energy through the process known as electromagnetic induction In order to understand magnetic induction we need to have a basic understanding of magnets and magnetism There are two classifications of magnets natural and artificial The magnets used in ignition systems are artificial magnets which means their magnetic properties have been electrically induced or created The space surrounding a magnet is permeated by magnetic lines of force called flux which are concentrated at two points the north and south poles in theory the flux lines are directed away at the north pole and re enter at the south pole These flux lines form definite patterns which vary in density according to the strength of the particular magnet The region surrounding a magnet at which its magnetic influence is effective is referred to as its magnetic field N E I M N MA a 7 an X f t 1 e T
491. to prolong battery life A WARNING Explosive Gas Batteries produce explosive hydrogen gas while being charged To prevent a fire or explosion charge batteries only in well ventilated areas Keep 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 sure all switches are OFF If ON a spark will occur at the ground cable terminal which could cause an explosion if hydrogen gas or gasoline vapors are present Figure 8 2 Battery Voltage Test 1 Regularly check the level of electrolyte Add distilled water as necessary to maintain the recommended level NOTE Do not overfill the battery Poor performance or early failure due to loss of electrolyte will result 8 3 Section 8 Electrical System and Components Electronic Ignition Systems There are three different types of ignition systems used on these engines All systems use an ignition module which energizes the spark plug The difference in the system is in the way the ignition timing is triggered The Fixed Ignition System utilizes a Capacitive Discharge CD coil Figure 8 3 This is a basic ignition system that uses a fixed ignition module where the ignition timing and spark remains constant regardless of the engine speed The Electronic Spark Advance Smart Spark System utilizes a Capacitive Discharge CD coil Figure
492. tor Faulty spark plugs Fuel supply inadequate Idle speed adjusting screw improperly set Idle fuel adjusting needle improperly set some models Low compression Restricted fuel tank cap vent Engine overheated cooling system air circulation problem Engine Overheats 1 Air intake grass screen cooling fins or cooling shrouds clogged Excessive engine load Low crankcase oil level High crankcase oil level Faulty carburetor Lean fuel mixture SMART SPARK malfunction applicable models Engine Knocks 1 UO ie Se I Excessive engine load Low crankcase oil level Old or improper fuel Internal wear or damage Hydraulic lifter malfunction Quality of fuel Incorrect grade of oil Engine Loses Power 1 po euo iT qvo 3 2 Low crankcase oil level High crankcase oil level Dirty air cleaner element Dirt or water in the fuel system Excessive engine load Engine overheated Faulty spark plugs Low compression Exhaust restriction SMART SPARK malfunction applicable models Low battery Incorrect governor setting Engine Uses Excessive Amount of Oil 1 eb UM Or qe 09 Incorrect oil viscosity type Clogged or improperly assembled breather Breather reed broken Worn or broken piston rings Worn cylinder bore Worn valve stems valve guides Crankcase overfilled Blown head gasket overheated Oil Leaks from Oil Seals Gaskets
493. tripe if contained to the left of the end gap Connecting Rods Offset stepped cap connecting rods are used in all these engines Inspection and Service Check the bearing area big end for excessive wear score marks running and side clearances refer to Section 1 Specifications Tolerances and Special Torque Values Replace the rod and cap if scored or excessively worn Section 10 Inspection and Reconditioning Service replacement connecting rods are available in STD crankpin size and 0 25 mm 0 010 in undersize The 0 25 mm 0 010 in undersized rod can be identified by the drilled hole located in the lower end of the rod shank Always refer to the appropriate parts information to ensure that correct replacements are used Hydraulic Lifters Inspection Check the 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 installed Bleeding the Lifters To prevent a possible bent push rod or broken rocker arm it is important to bleed any excess oil out of the lifters before they are installed 1 Cuta 50 75 mm 2 3 in piece from the end of an old push rod and chuck it in a drill press 2 Lay arag or shop towel on the table of the drill press and place the lifter open end up on the towel 3 Lower the chucked push rod until it contacts the plunger in
494. ttery with 400 cold cranking amps is battery to self discharge Self discharge occurs generally recommended for starting in all conditions rapidly when moisture is present A smaller capacity battery is often sufficient if an application is started only in warmer temperatures 3 Wash the cables terminals and external surfaces Refer to the following table for minimum capacities with a mild baking soda and water solution cca based on anticipated ambient temperatures Rinse thoroughly with clear water The actual cold cranking requirement depends on engine size application and starting temperatures NOTE Do not allow the baking soda solution The cranking requirements increase as temperatures to enter the cells as this will destroy the decrease and battery capacity shrinks Refer also to electrolyte the operating instructions of the equipment being this engine powers for specific battery requirements Battery Test To test the battery you will need a DC voltmeter Battery Size Recommendations Perform the following steps See Figure 8 2 1 Connect the voltmeter across the battery Above 32 F 050 0 F to 32 F 18 C to 0 C 2 Crank the engine If the battery drops below 9 volts while cranking the battery is too small 5 to 0 21 C to 18 C discharged or faulty If the battery charge is insufficient to turn over the engine recharge the battery DC Voltmeter Battery Maintenance Regular maintenance is necessary
495. uel flow through the main jet When current is removed the pin extends blocking the main fuel jet and preventing fuel from entering the carburetor One Barrel Carburetor j az y e 2 NF 4 t Fuel Shut off Solenoid Two Barrel Carburetor Fuel Shut off Solenoid gt Figure 5 3 Fuel Shut off Solenoid Below is a simple test made with the engine off that can determine if the solenoid is functioning properly 1 Shut off fuel and remove the solenoid from the carburetor When the solenoid is loosened and removed gas will leak out of the carburetor Have a container ready to catch the fuel 2 Wipe the tip of the solenoid with a shop towel or blow it off with compressed air to remove any remaining fuel Take the solenoid to a location with good ventilation and no fuel vapors present You will also need a 12 volt power source that can be switched on and off 5 5 Section 5 Fuel System and Governor 3 sure the power source is switched off Connect the positive power source lead to the red lead of the solenoid Connect the negative power source lead to the solenoid bracket 4 Turn the power source on and observe the pin in the center of the solenoid The pin should retract with the power on and return to its original position with the power off Test several times to verify operation Carburetor Adjustments CH18 740 General In compliance with gov
496. ug Each coil fires every revolution but every other spark is wasted Service Except for removing the spark plug lead by unscrewing it from the secondary tower see Figure 5B 22 no coil servicing is possible If a coil is determined to be faulty replacement is necessary An ohmmeter may be used to test the wiring and coil windings Figure 5B 22 Ignition Coil NOTE Do not ground the coils with the ignition on as they may overheat or spark Testing 1 Disconnect the main harness connector from ECU 58 17 Section 5B EFI Fuel System 35 Pin MA 1 7 Metal Cased ECU Locate pins 1 and 19 in the 35 pin connector See page 5B 28 24 Pin MSE 1 0 Plastic Cased ECU Locate pins 22 and 23 in the 24 pin connector See page 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 the Rx1 scale check the resistance in circuits as follows 35 Pin MA 1 7 Metal Cased ECU Check between terminal 87 and pin 1 for coil 1 Repeat the test between terminal 87 and pin 19 for coil 2 24 Pin MSE 1 0 Plastic Cased ECU Check between terminal 87 and pin 22 for coil 1 Repeat the test between terminal 87 and pin 23 for coil 2 32 Pin MSE 1 1 Plastic Cased ECU Check between terminal 87 and pin 30 for c
497. uine Kohler oil filter Change the filter as follows See Figure 6 6 Cil Filter 1 Oil Cooler Oil Drain Plug Figure 6 6 Oil Drain Plug and Oil Filter Engine With Oil Cooler 10 Section 6 Lubrication System Clean the areas around the drain plug oil filter oil fill cap and dipstick Remove one of the oil drain plugs A drain plug is located on either side of the crankcase one is adjacent to and below the oil filter the other is below the starter Allow all oil to drain and then reinstall the drain plug Torque to 13 6 N m 10 ft Ib Remove the old filter and wipe off the filter adapter with a clean cloth Place a new replacement filter in a shallow pan with the open end up Pour new oil of the proper type in through the threaded center hole Stop pouring when the oil reaches the bottom of the threads Allow a minute or two for the oil to be absorbed by the filter material Apply a thin film of clean oil to the rubber gasket 6 on the new filter Install the new oil filter to the filter adapter or oil cooler Refer to instructions on the oil filter for proper installation Remove the oil fill cap and fill the engine with the proper oil to the F mark on the dipstick Always check the oil level with the dipstick before adding more oil Reinstall the oil fill cap and dipstick Start the engine and check for oil leaks Stop the engine correct any leaks and allow a minute for
498. ul work The 70 rejected represents 84 350 per hour Section 3 Properly Installing the Engine 30 Rejectedto Cooling Air Outlet 40 Rejected to Exhaust amp Radiation 30 Available for Useful Work Heat Distribution Chart It is equally important that there be an easy unrestricted exit of the heated air away from the engine Always remember easy access of engine cooling air In and Out This is critical Cutaway to Show Fins Figure 3 1 Cooling Air Circulation Inlet Air Temperature The temperature of the air into the flywheel must be approximately the same as the ambient air temperature Installing the engine near such equipment as hydraulic coolers compressors or heaters may cause the inlet air temperature to exceed the ambient air temperature See Figure 3 2 11 Section 3 Properly Installing the Engine e Under no conditions should the inlet air temperature into the flywheel be more than 20 F 6 6 C above the ambient air temperature Heat Exchange From Other Equipment Adds to Ambient Air in too Hot gt Maximum Average Temperature cannot exceed Located too Close to Engine Figure 3 2 Avoid Heat Source near Engine Recirculation of Air Heated air exiting from the engine can be deflected by some obstruction back into the flow of the cooling air thereby raising its temperature to unacceptable levels Be sure there are no p
499. ule Courage Courage Twin PRO Twin Major Repairs Engine R amp R Engine R amp R From Generator Set Welder Short Block Replacement Miniblock Major Overhaul Includes Valve Service Minor Overhaul Excludes Valve Service Connecting Rod Piston and or Rings Crankshaft Crankshaft amp Main Bearing R R Crankshaft PTO Seal Crankshaft Flywheel Seal Crankshaft amp Connecting Rod Camshaft amp Valves Lifters Valve R amp R No Grinding Valve Adjustment Valve Grinding Valve Spring Replacement Valve Cover Gasket and or Breather Camshaft R amp R Camshaft PTO Seal Rocker Arm Ignition Ignition Module R amp R Includes Both Modules Flywheel R amp R Spark Advance Module ECU TPS opeed Sensor Charging Regulator Test amp Replace Stator Test amp Replace Includes Flywheel R R Wiring Harness R amp R Cooling System Coolant R amp R Includes Coolant Temp Switch Radiator R amp R Thermostat R amp R Water Pump Pump Drive Belt Starter Retractable R R Replace Rope amp Spring Starting Motor Bendix Type R amp R Starter Bendix Rebuild Includes R amp R Starter Drive R amp R Starter Solenoid R amp Fuel System amp Air Intake Carburetor R amp Carburetor Rebuild Includes R 4 R Carburetor Adjust Air Cleaner Damage in Shipment Fuel Pump R amp R Intake Manifold Injectors Fuel Rail Time allowed is
500. unting screws to 9 9 N m 88 in Ib Injector problems due to dirt or clogging are generally unlikely due to the design of the injectors 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 of fault codes related to fuel delivery Injector clogging is usually caused by a buildup of deposits on the director plate restricting the flow of fuel resulting in a poor spray pattern Some contributing factors Section 5B EFI Fuel System to injector clogging include higher than normal operating temperatures short operating intervals and dirty incorrect or poor quality fuel Cleaning of clogged injectors is not recommended they should replaced Additives and higher grades of fuel can be used as a preventative measure if clogging has been a problem Ignition System General A high voltage solid state battery ignition system is used with the EFI system The ECU controls the ignition output and timing through transistorized control of the primary current delivered to the coils Based on input from the speed sensor the ECU determines the correct firing point for the speed at which the engine is running At the proper instant it releases the flow of primary current to the coil The primary current induces high voltage in the coil secondary which is then delivered to the spark pl
501. up by the battery 58 3 Section 5B EFI Fuel System During certain operating periods such as cold starts warm up acceleration etc an air fuel ratio richer than 14 7 1 is required and the system operates in an open loop mode In open loop operation the monitoring of exhaust gases output is not used and the controlling adjustments are based on the primary sensor signals and programmed maps only The system operates open loop whenever the three conditions for closed loop operation above are not being met Important Service Notes e Cleanliness is essential and must be maintained at all times when servicing or working on the EFI system Dirt even in small quantities can cause significant problems e Clean any joint or fitting with parts cleaning solvent before opening to prevent dirt from entering the system e Always depressurize the fuel system through the test valve in fuel rail before disconnecting or servicing any fuel system components See fuel warning on page 5 2 e Never attempt to service any fuel system component while engine is running or ignition switch is on Do not use compressed air if the system is open Cover any parts removed and wrap any open joints with plastic if they will remain open for any length of time New parts should be removed from their protective packaging just prior to installation Avoid direct water or spray contact with system components
502. ure 5B 20 Volt Noid Light 2 Make sure all safety switch requirements are met Crank the engine and check for flashing of noid light Repeat test at other connector a 58 16 If flashing occurs use ohmmeter Rx1 scale and check the resistance of each injector across the two terminals Proper resistance is 12 20 If injector resistance is correct check whether the connector 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 If no flashing occurs reattach connectors to both injectors Disconnect the main harness connector from the ECU and the connector from the relay Set the ohmmeter to the Rx1 scale and check the injector circuit resistance as follows 35 Pin MA 1 7 Metal Cased ECU Check the resistance between the relay terminal 87 and pin 35 in main connector Resistance should be 4 15 24 Pin MSE 1 0 Plastic Cased ECU Check the resistance between relay terminal 87 and pin 16 in main connector Then check resistance between relay terminal 87 and pin 17 Resistance should be 4 15 for each circuit 32 Pin MSE 1 1 Plastic Cased ECU Check the resistance between relay terminal 87 and pin 14 in the main connector Then check the resistance between relay terminal 87 and pin 15 Resistance should be 4 15 Q for each circuit Check all electrical connections connectors and wi
503. ure Plate Assembly RTV sealant is used as a gasket between the closure plate and the crankcase Refer to Section 2 for a listing of approved sealants Always use fresh sealant Using outdated sealant can result in leakage 1 Besure the sealing surfaces have been cleaned and prepared as described at the beginning of Section 10 or in Service Bulletin 252 2 Check to make sure that there are no nicks or burrs on the sealing surfaces of the closure plate or crankcase Section 11 Reassembly 3 Apply 1 5 mm 1 16 in bead of sealant to the 6 Install the ten hex flange screws securing the sealing surface of the closure plate See Figure closure plate to the crankcase Torque fasteners 11 19 for sealant pattern in the sequence shown in Figure 11 21 to 24 4 N m 216 in Ib On some engines one of the ten mounting screws is plated The plated screw is typically installed in the 6 hole shown in Figure 11 21 Figure 11 21 Closure Plate Fastener Torque Sequence Figure 11 19 Closure Plate Sealant Pattern 4 Make sure the end of the governor cross shaft is lying against the bottom of cylinder 1 inside the crankcase See Figure 11 13 5 Install the closure plate to the crankcase Carefully seat the camshaft and the crankshaft into their mating bearings Rotate the crankshaft slightly to help engage the oil pump and governor gear meshes See Figure 11 20 Figure 11 22 Torquing Closure Plate Fasteners Install Stato
504. ures 3 6 9 and 12 o clock positions d Airtemperature into the carburetor inlet is checked by clamping the thermocouple wire under the air cleaner element with the junction in the air stream above the choke plate Set engine at rated no load speed Attach a tachometer to monitor engine speed Ideally your engine installation should be tested in a controlled environment kept at 110 F 43 370 Variable speed applications should be loaded so that the engine is tested with wide open throttle WOT The engine must be loaded until the speed does not increase when the governor lever is pushed Constant speed applications should be loaded so that the engine is tested WOT atthe specified governed constant speed These can be simulated or can be done under actual working conditions The machine must be run under these conditions until temperatures have stabilized and are no longer increasing This usually takes about 1 hour of steady operation The temperatures reached must not exceed those listed in the following table in the 110 F 43 370 ambient test environment Section 4 Testing the Installation sometimes it is impossible to test the equipment in the 110 F 43 3 C environment so a second set of engine temperature values are listed for a 75 24 C environment Note that the permitted guidelines are reduced since the engine will operate at lower temperatures when tested at a lower ambient temperature Consult your
505. urther using an ohmmeter Test 3 With engine stopped measure the resistance Tf resistance is 0 064 0 2 ohms the stator is OK across stator leads using an ohmmeter If the resistance is infinity ohms stator is open Replace stator With the engine stopped measure the Ifthe resistance is infinity ohms no continuity resistance from each stator lead to ground the stator is OK not shorted to ground using an ohmmeter If resistance or continuity is measured the stator leads are shorted to ground Replace stator Perform same test as step 1 above Ifthe voltage is 14 7 volts or less the charging system is OK The battery is unable to hold a charge Service battery or replace as necessary Battery Continuously Charges at If voltage is more than 14 7 volts the rectifier High Rate regulator is faulty Replace rectifier regulator 8 27 Section 8 Electrical System and Components Troubleshooting Guide 3 Amp Battery Charging System with 70 Watt Lighting Stator NOTE Zero ohmmeters on each scale to ensure accurate readings Voltage tests should be made with engine running at 3000 RPM no load Battery must be good and fully charged 1 With engine running at 3000 RPM measure 1 If voltage is more than 12 5 volts charging voltage across battery terminals using a DC system is OK voltmeter If voltage is 12 5 volts or less the stator or diode are probably faulty Test the stator and diode Tests 2
506. ut with TPLAUS set to 50 C System too Lean used to be O Sensor Short to Ground P0131 System too Rich used to be Sensor Control at Lower Limit P0019 Obtainable only with ECU 24 584 28 5 or later Will not blink out ve pe SY uo 58 37 Section 5B EFI Fuel System Code 21 Source Engine Speed Sensor Explanation ECU receiving inconsistent tooth count signals from speed sensor Expected Engine Response Possible misfire as ECU attempts to resynchronize during which time fuel and spark calculations are not made Possible Causes 1 Engine Speed Sensor Related a b Sensor connector or wiring Sensor loose or incorrect air gap Flywheel key sheared 2 Speed Sensor Ring Gear Related a Damaged teeth b Varying gap gear loose out of alignment 3 Engine Wiring Harness Related 35 Pin MA 1 7 Metal Cased ECU a b Pin circuits 3 and or 21 wiring or connectors Shielding for pin circuits 3 and or 21 damaged or not properly grounded Poor or improper grounds in system battery ECU oxygen sensor shielding fuel pump ignition output Pin circuits 3 and or 21 routed near noisy electrical signals coils spark plug lead plug connector 3 Engine Wiring Harness Related 24 Pin MSE 1 0 Plastic Cased ECU a b Pin circuits 9 and or 10 wiring or connectors Shielding for pin circuits 9 and or 10 damaged or not properly
507. ve forcing oil past the rings could cause this also Figure 21 Figure 21 Soft black sooty deposits result from incomplete combustion They could be due to overrich carburetor settings a blocked air filter or retarded timing Figure 22 Figure 22 Hard crusty mottled white deposits result from high combustion chamber temperatures They could be from lean carburetion an intake air leak over advanced timing or poor quality gasoline Deposits of this type will often be accompanied by a blown head gasket The high temperatures and pressures that cause the white deposits also cause the head to distort and push the hot exhaust gases past the gasket If the engine is operated with the blown gasket the escaping hot gases can act like a torch and burn a slot through the gasket and sometimes even through the head Oil Sump Figure 23 Check the bottom of the oil sump A layer of sludge in the bottom of the engine indicates that contamination was entering the engine the oil was not being changed at the recommended interval or incorrect oil was used D Valves The valves can be very good indicators of various operating conditions They should be closely examined as part of your failure analysis procedure The symptoms associated with valve problems include the following hard starting high fuel consumption poor compression and loss of power or the engine will pop and stall after a period of running
508. ve sticking It is usually caused by an accumulation of burned oil deposits on the valve stem and in the guide The customer will usually complain that the engine runs anywhere from 15 to 90 minutes then loses power or pops out the exhaust and stalls It normally will not restart until the engine cools for 10 15 minutes and a metallic snap is heard 10 The burned oil deposits normally responsible for valve sticking are due to elevated temperatures in the valve guide area The problem will usually show up during hot weather especially on an engine that doesn t get adequate maintenance Figure 33 Figure 33 If a stem shows signs of abrasive material or scoring check the carburetor inlet and air cleaner base for signs of dirt bypassing the air filter or precleaner Figure 34 Figure 34 If your preliminary examination of the engine indicated the possibility of dust or dirt entry check the stem of the intake valve s for further confirmation The valve stems should appear shiny like the one on the left If contamination has been entering through the air intake the stems will have dull wear patterns where they travel in the guides Figure 35 Figure 35 In this example the dirt entry was due to a leaking remote air filtration system Again notice the buffed appearance of the valve stem Also notice the air cleaner hose which was used Wire reinforced hose should never be used with a remot
509. ved through the test valve in the fuel rail prior to servicing or removing any fuel system components Do not smoke or work near heaters or other fire hazards Have a fire extinguisher handy and work only in a well ventilated area The function of the fuel system is to provide sufficient delivery of fuel at the system operating pressure of 39 psi 3 If an engine starts hard or turns over but will not start it may indicate a problem with the EFI fuel system A quick test will verify if the system is operating 1 Disconnect and ground the spark plug leads 2 Complete all safety interlock requirements and crank the engine for approximately 3 seconds 3 Remove the spark plugs and check for fuel at the tips a If there is fuel at the tips of the spark plugs the fuel pump and injectors are operating b If there is no fuel at the tips of the spark plugs check the following 1 Make sure the fuel tank contains clean fresh proper fuel 2 Make sure that vent in fuel tank is open 3 Make sure fuel tank valve if so equipped is fully opened 4 Make sure battery is supplying proper voltage 5 Check that the fuses are good and that all electrical and fuel line connections are good 6 Testfuel pump and relay operation as described earlier under Fuel Pump Service 58 34 Fault Codes The ECU continuously monitors engine operation against preset performance limits If the operation is outside the limit
510. vels without the interference of ambient noise We have accelerometers to measure engine vibration equipment to measure fuel consumption equipment to test mechanisms and equipment to do other tests that enable us to manufacture the best possible engines for our customers If you have problems in your testing program let your Kohler Engine representative know about them At Kohler we re as interested as you are in seeing that our engines are properly matched to your equipment Special Considerations Angle of Operation must be a consideration though each engine has its own limitations in each direction As a rule of thumb a 25 limit in any direction should be followed Section 4 Testing the Installation Application Review It is a link in the chain toward complete satisfaction Match the engine to the job so the engine can do the job it was designed to do Account Information Record Prepare a Kohler Co Account Information Record AIR form for review by our engineers This is especially important where unusual power drives are used For instance a very small pulley located far from the engine would be an unusual power drive Avoid adding special mounting brackets or attachments to the engine as they could introduce high stress points which might lead to subsequent bracket or fastener failure By carefully considering all of these points when you design your equipment you can avoid many troublesome areas that may
511. ward the end of the compression stroke In both gasoline and Diesel engines just before it reaches top dead center or the point where it is farthest from the crankshaft the charge is ignited Exhaust Stroke At the end of the power stroke the exhaust valve opens and as the piston moves upward itforces the exhaust out of the cylinder The exhaust valve closes at the end of this stroke and the engine is ready to repeat the cycle 1 ENGINE COMPRESSION Displacement of an engine is indicated in cubic inches and is a measure of the size or potential power of that engine By definition it is the volume which the piston displaces In other words the displacement of a single cylinder engine can be calculated as follows Piston area multiplied by the length of stroke or ae X Cylinder bore X Stroke For a multi cylinder engine simply multiply this quantity by the number of cylinders in the engine b GASOLINE ENGINE Compression ratio is another engine measure ment In every engine there is a small volume of air around the heads of the valves and in the contours ofthe combustion chamber even when the piston is at top dead center This is called the clearance volume This volume plus the piston displacement is the total volume Compression Ratio C R is defined as the Total Volume divided by the Clear ance Volume or Displacement plus Clearance Vol ume divided by Clearance Volume As a formula it may
512. warrants to the original retail consumer that each new COURAGE engine sold by Kohler Co will be free from manufacturing defects in materials or workmanship in normal residential homeowner service for a period of two 2 years from date of purchase provided it is operated and maintained in accordance with Kohler Co s instructions and manuals If used commercially the COURAGE engine is covered by 90 day limited warranty The warranty period begins on the date of purchase by the original retail consumer or commercial end user Residential homeowner service means residential use by a retail consumer Commercial use means all other uses including use for commercial or rental purposes Once in commercial use the engine will thereafter be considered a commercial use engine for the purposes of this warranty Our obligation under this warranty is expressly limited at our option to the replacement or repair at Kohler Co Kohler Wisconsin 53044 or at a service facility designated by us of such parts as inspection shall disclose to have been defective EXCLUSIONS Mufflers on engines used commercially non residential are warranted for 90 days from date of purchase This warranty does not apply to defects caused by casualty or unreasonable use including faulty repairs by others and failure to provide reasonable and necessary maintenance The following items are not covered by this warranty Engine accessories such as fuel tanks clutches t
513. wheel are mounted with like poles together When the south poles align with a stator post magnetic flux will travel through the stator in one direction The flux lines cut the windings and the induced current will flow one direction As the flywheel rotates the north poles will align over the post the flux will reverse direction and the induced current will also reverse direction As long as the flywheel continues rotating the current will continue reversing thus the term alternating current or AC Flywheel Permanent Primary Stator Windings Stator Operation The current required for battery charging or ignition is direct current DC so the AC from the stator windings must be changed to DC before it can be used for battery charging This is done by using solid state electronic devices called diodes A diode when placed in an electrical circuit will allow current to pass in one direction but not the other If we place a single positive diode in an AC circuit the diode will allow current to flow only on the positive alternation and would block the return or negative alternation This would be called a half wave rectifier since only 1 2 of the current produced would be available as interrupted or pulsating DC The 15 amp 25 amp 1 25 amp and 3 amp systems all use half wave rectification Battery Half Wave Rectification The 30 amp system and the 1 25 amp system use a
514. wound in opposite directions on the same posts and a plate style regulator 30 Amp Charging System 21 The 30 amp system is being phased out in favor of anew 25 amp system The 25 amp system uses the same flywheel as a 15 amp system The stator and rectifier regulator are slightly different dimensionally but will interchange with their 15 amp counterparts 25 Amp Stator The 1 25 amp stator with magneto was used on K181ST engines installed on Troy Bilt tillers during 1984 and 1985 It used an externally mounted recitifer Ignition Magneto 1 25 Amp Unregulated Charging System For those applications which need minimal battery Charging capacity electric start only no accessories we now offer the 1 25 and 3 amp systems with optional 70 watt AC output for lighting or accessories By using different configurations of the same basic stator we get four possible combinations The flywheel used is similar to the 15 amp flywheel but it has one less magnet 22 1 25 Amp Stator Diode Repair Kit 51 755 01 1 25 Amp Unregulated Charging System iode Repair Kit _ C4 Vee n4 wil Pg 3 Amp Unregulated Charging System 70 Watt Lighting Stator Charging System Theory And Function The charging systems all function according to the same theory to provide the initial aiternating current The stators all have a core with 2 or more posts wound with copper windings The permanent magnets in the fly
515. ws 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 and the two rear M5 mounting screws when applicable to 4 0 N m 35 in Ib See Figures 11 94 and 11 95 Figure 11 91 Connecting Fuel Inlet Line 2 Position a new gasket and the air cleaner base while carefully pulling the loose end of the rubber breather hose through the base until properly seated collars sealed against each side of base See Figure 11 92 Figure 11 92 Pulling Breather Hose through Base NOTE Route the fuel line in the contour as shown in Figure 11 93 to avoid restriction Figure 11 95 Tightening Rear Base Bracket Screws Some Models 4 Install the breather hose in the hole in the bracket 5 Install the air cleaner components as described in Section 4 Heavy Duty Air Cleaner 1 Connect the breather hose to breather cover and fitting on adapter elbow Route the fuel line adjacent to fuel solenoid and secure to the carburetor inlet with a clamp See Figure 11 96 4 4 i j E j s M al BE a P 18 dO Figure 11 93 Fuel Inlet Line Detail 11 28 Section 11 Reassembly Carburetor Fuel Line Figure 11 96 Breather Hose and Fuel Line Details Figure 11 98 Assembled Heavy Duty Air Cleaner Two Barrel Carburetor 2 Align the
516. xpertise in analyzing engine failures Il Preliminary Examination Any time an engine comes into your shop for service you should begin by making an external examination External conditions are often directly related to internal problems Even if the engine is only in for routine maintenance or service you may find indications that the customer is not providing adequate care for the engine and should be advised to change maintenance practices If the engine has already failed the condition of the exterior may provide valuable insight for assistance in analyzing an internal failure Check the following areas as part of your external examination A Air Filtration Figure 2 Figure 2 Make a thorough examination of the air cleaner Remove the outer air cleaner cover and check it for damage or signs of impact Figure 3 Figure 3 Most engines also have an inner cover on the air cleaner element which provides backup protection in case the outer cover gets bumped or works loose The inner cover may be a separate piece of stamped sheet metal or it may be part of the element Three types of retainers are used on the element cover a short rubber sleeve a lock nut or a wing nut Check that the correct retainer s is are there and tight Remove the retainer s and look at the stud holes s in the element cover If the stud holes s is are wallowed out it s an indication that the air cleaner components were loose at
517. y The oil pump is mounted inside the closure plate If service was required and the oil pump was removed refer to the assembly procedures under Oil Pump Assembly in Section 10 Governor Gear Assembly The governor gear assembly is located inside the closure plate If service was required and the governor was removed refer to the assembly procedures under Governor Gear Assembly in Section 10 Thrust Bearing Washer and Shim Some specifications use a needle type thrust bearing thrust washer and shim spacer to control the end play of the crankshaft See Figure 11 16 If these items are noted during disassembly make sure they are reinstalled in the sequence shown in Figure 11 17 A different procedure will have to be followed to check and adjust crankshaft end play on these models gt li Figure 11 16 Thrust Bearing Washer and Shim Used on Some Models Section 11 Reassembly Thrust Shim Thrust Washer Needle Thrust Bearing Bearing Race ae Closure N Z lt gt Plate SW 0 Figure 11 17 Correct Sequence of Thrust Bearing Washer and Shim in Closure Plate The race for the thrust bearing presses loosely into the closure plate If it is not already installed push it into the crankshaft bore inside the closure plate Pack the thrust bearing with heavy grease and stick the bearing into the race Wipe some grease on the face of the thrust washer and st
518. y System tem System py py _ py NEN umm EARMEN e Lv _ NO oO 2 33 3 4 NO Temperature Sensor Circuit Shorted P0118 Temperature Sensor Circuit Open Circuit or Short to Battery Failure Completing Autolearn TPS Offset below minimum allowable limit Failure Completing Autolearn TPS N A offset above maximum allowable limit JI Co N 4 JI D D oO C2 NO NO NO 1 51 52 58 36 Section 5B EFI Fuel System 32 Pin OBD2 35 Pin 24 Pin P Code Ap MA 1 7 MSE 1 0 plicable to Connection or Failure Description Metal Plastic Bao 32 Pin MSE Cased Cased Cased 1 1 ECU Sys ECU ECU tem Only System EM P0264 Injector 2 Short Circuit to Ground EM P0265 Injector 2 Short Circuit to Batt EM P1651 Diagnostic Lamp Open Circu E Lamp Short Circuit to a we y _ e Note 1 Idle Switch not used Diagnostic of TPS Signal Implausible is disabled in code Sensor Short to Battery diagnostic detection is disabled with SAS fuel cutoff calibrated out Air Temperature Sensor not used Temperature Sensor Signal Implausible diagnostic detection is calibrated o
519. y air filter Insufficient fuel delivery Improper governor adjustment Plugged restricted exhaust One injector not working Basic engine problem exists TPS faulty or mounting exists Throttle plates in throttle body intake manifold not fully opening to WOT stop if so equipped Electrical System The EFI system is a 12 VDC negative ground system designed to operate down to a minimum of 7 0 volts If system voltage drops below this level the operation of voltage sensitive components such as the ECU fuel pump and injectors will be intermittent or disrupted causing erratic operation or hard starting A fully charged 12 volt battery with a minimum of 350 cold cranking amps is important in maintaining steady and reliable system operation Battery condition and state of charge should always be checked first when troubleshooting an operational problem Keep in mind that EFI related problems are more often caused by the wiring harness or connections than by the EFI components Even small amounts of corrosion or oxidation on the terminals can interfere with the milliamp currents used 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 enough to restore operation at least temporarily Section 5B EFI Fuel System If a fault code indicates a problem with an electrical component disconnect the E
520. y clamp the parts in this position See Figure 58 39 Feeler Gauge Section 5B EFI Fuel System B Setting the Initial Adjustment 1 Check the split where the clamping screw goes through the governor lever See Figure 5B 41 There should be a gap of at least 1 32 If the tips are touching and there is no gap present the lever should be replaced If not already installed position the governor lever on the cross shaft but leave the clamping screw loose b On engines with a stop screw pivot the throttle shaft and plate into the Full Throttle position so the tang of the throttle shaft plate is against the end of the high speed stop screw See Figure 5B 38 Temporarily clamp in this position Rotate the governor lever and shaft counterclockwise until it stops Use only enough pressure to hold it in that position Check how the end of the throttle linkage aligns with the bushing hole in the governor lever See Figure 5B 40 It should fall in the center of the hole If it doesn t perform the adjustment procedure as follows igure 5B 40 Throttle Link in Center of Hole Figure 5B 41 Checking Split of Clamp Follow the instructions in Step 2 of Checking the Initial Adjustment then reattach the throttle linkage to the governor lever with the bushing clip It is not necessary to reattach the damper or governor springs at this time Insert a nail into the hole in the top of the cross shaft
521. y from the armature 13 Clean the parts as required NOTE Do not soak the armature or use solvent when cleaning Wipe clean using a soft cloth use compressed air Plunger Spring Lever Plate Plug Solenoid Frame amp Field Brush Holder Nut CE Frame Screw Bolt Figure 8 59 Delco Remy Starter 8 38 Inspection Drive Pinion Check and inspect the following areas a The 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 clutch housing and rotating the pinion The pinion should rotate in one direction only Brushes and Springs Inspect both the springs and brushes for wear fatigue or damage Measure the length of each brush The minimum length for each brush is 7 6 mm 0 300 in See Figure 8 60 Replace the brushes if they are worn undersize or their condition is questionable Wear limit length 7 6 mm 0 300 in Figure 8 60 Checking Brushes Armature 1 Clean and inspect the commutator outer surface The mica insulation must be lower than the commutator bars undercut to ensure proper operation of the commutator See Figure 8 61 Section 8 Electrical System and Components Commutator O D Mica Insulation Figure 8 61 Commutator Mica Inspection 2 Use an ohmmeter set to the Rx1 scale Touch the probes betwee
522. y should Terminal 86 activate and continuity should exist circuit Terminal 8874 ECU made between the 30 and 87 terminals Repeat Not used E Controlled the test several times If at any time the relay fails Ground to activate the circuit replace the relay Terminal 30 Fuel Injectors Permanent Battery Voltage Figure 5B 14 Relay Connector a Clean the connection and check wiring if circuit was not completed 3 Set meter for DC voltage Touch red tester lead to the 30 terminal in relay connector A reading of 12 volts should be indicated at all times 4 Connect red lead of meter to the 85 terminal in relay connector Turn key switch to the on position Battery voltage should be present a No voltage present indicates a problem in the Figure 5B 16 Style 1 Fuel Injector 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 test the relay Terminal 86 Terminal 87 Feed ECU Controlled to Ignition Coils Ground Fuel Injectors and Fuel Pump Terminal Terminal 85 Ignition 487A a Switch Voltage Not Used Figure 5B 17 Style 2 Fuel Injector Terminal 30 Permanent General Battery Voltage fuel injectors mount into the intake manifold Figure 5B 15 Relay Terminal Details and the fuel rail attaches to them at the top end Replaceable O Rings on both ends of the injector
523. y us of such part or parts as inspection shall disclose to have been defective EXCLUSIONS Mufflers on engines used commercially non residential are warranted for one 1 year from date of purchase except catalytic mufflers which are warranted for two 2 years This warranty does not apply to defects caused by casualty or unreasonable use including faulty repairs by others and failure to provide reasonable and necessary maintenance The following items are not covered by this warranty Engine accessories such as fuel tanks clutches transmissions power drive assemblies and batteries unless supplied or installed by Kohler Co These are subject to the warranties if any of their manufacturers WE SHALL NOT BE LIABLE FOR SPECIAL INDIRECT INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY KIND including but not limited to labor costs or transportation charges in connection with the replacement or repair of defective parts ANY IMPLIED OR STATUTORY WARRANTIES INCLUDING WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY LIMITED TO THE DURATION OF THIS WRITTEN WARRANTY We make no other express warranty nor is anyone authorized to make any in our behalf Some states do not allow limitations on how long an implied warranty lasts or the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you This warranty gives you specific legal rights and you m
524. ylinder Head Assembly 4 Remove the lifters from the lifter bores Use a Hydraulic Lifter Tool Do not use a magnet to remove lifters Mark the lifters by location as either intake or exhaust and cylinder 1 or 2 Hydraulic 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 located on the fan side of the engine The cylinder head number is embossed on the outside of each cylinder head See Figure 9 55 9 14 Figure 9 55 Match Marks on Cylinder Barrel and Heads Section 9 Disassembly Disassemble Cylinder Heads 3 Once the valve spring is compressed remove the 1 Remove the two hex flange screws rocker arm following items See Figures 9 58 and 9 59 pivots and rocker arms from the cylinder head See Figure 9 56 Valve spring keepers Valve spring retainers Valve springs Valve spring caps Intake and exhaust valves mark position Valve stem seals intake valve only _ Valve Seal Figure 9 56 Removing Rocker Arms 2 Compress the valve springs using a valve spring compressor See Figure 9 57 Figure 9 59 Intake Valve Seal Location NOTE These engines use valve stem seals on the intake valves Use a new seal whenever valve is removed or if the seal is deteriorated in any way Never reuse an old seal 4 Repeat the above procedure for the other cylinder head

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