Kohler ECV680, ECV730, ECV630, ECV740, ECV650 Manual

5 (1)

SERVICE MANUAL

ECV630-ECV749

VERTICAL CRANKSHAFT

Contents

Section 1. Safety and General Information .............................................................................

Section 2. Tools & Aids.............................................................................................................

Section 3. Troubleshooting ......................................................................................................

Section 4. Air Cleaner and Air Intake System .........................................................................

Section 5. Electronic Fuel Injection (EFI) System ..................................................................

Section 6. Lubrication System .................................................................................................

Section 7. Electrical System and Components ......................................................................

Section 8. Disassembly.............................................................................................................

Section 9. Inspection and Reconditioning..............................................................................

Section 10. Reassembly............................................................................................................

1

2

3

4

5

6

7

8

9

10

Section 1

Safety and General Information

1

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 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.

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.

WARNING

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.

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 is running, or immediately after it is turned o . Never operate the engine with heat shields or guards removed.

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 is 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.

1.1

Section 1

Safety and General Information

WARNING

Carbon Monoxide can cause severe nausea, fainting or death.

Avoid inhaling exhaust 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

Explosive Fuel can cause fires and severe burns.

Fuel systems ALWAYS remains under HIGH PRESSURE.

Fuel Fire and Burns!

Wrap a shop towel completely around the fuel pump module connector. Press the release button(s) and slowly pull the connector away from the fuel pump module allowing the shop towel to absorb any residual fuel in the high pressure fuel line. Any spilled fuel must be completely wiped up immediately.

CAUTION

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.

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.

WARNING

High Pressure Fluids can puncture skin and cause severe injury or death.

Do not work on fuel system without proper training or safety equipment.

High Pressure Fluid Puncture!

Fuel system is to be serviced only by properly trained personnel wearing protective safety equipment. Fluid puncture injuries are highly toxic and hazardous. If an injury occurs, seek immediate medical attention.

Engine Identification Numbers

When ordering parts, or in any communication involving an engine, always give the Model,

Specification and Serial Numbers of the engine.

The engine identification numbers appear on a decal, or decals, a xed to the engine shrouding. See

Figure 1-1. An explanation of these numbers is shown in Figure 1-2.

Identification

Decal

Figure 1-1. Engine Identification Decal Location.

1.2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Section 1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Safety and General Information

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

A. Model No.

 

 

 

 

 

 

 

 

 

E C V 749

1

 

Electronic Fuel Injection (EFI)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Command Engine

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Vertical Crankshaft

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Numerical Designation

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

630

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

650

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

680

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

730

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

740

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

749

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

B. Spec. No.

ECV630-XXXX

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ECV650-XXXX

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ECV680-XXXX

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ECV730-XXXX

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ECV740-XXXX

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ECV749-XXXX

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

C. Serial No.

3905810334

 

 

 

 

 

 

 

 

 

 

 

Year Manufactured Code

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Factory Code

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Code

Year

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

392009

402010

412011

Figure 1-2. Explanation of Engine Identification Numbers.

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 SJ or higher. Select the viscosity based on the air temperature at the time of operation as shown in the following table.

NOTE: Using other than service class 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.

 

 

 

 

Kohler 10W-30

 

 

 

 

 

 

 

10W-30

 

 

 

 

 

 

 

 

SAE 30

 

 

5W-30

 

 

 

 

 

 

°F -20

0

20

32

40

50

60

80

100

°C -30

-20

-10

0

 

10

20

30

40

1.3

Section 1

Safety and General Information

A logo or symbol on oil containers identifies the API service class and SAE viscosity grade. See Figure 1-3.

Figure 1-3. Oil Container Logo.

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 is 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.

Refer to Section 6 - Lubrication System for detailed procedures on checking the oil, changing the oil and changing the oil filter.

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.

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. 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.

Periodic Maintenance Instructions

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.

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.

1.4

Section 1

Safety and General Information

Frequency

Maintenance Required

Refer to:

1

 

Check oil level.

Section 6

Daily or Before

Fill fuel tank.

Section 5

 

 

Starting Engine

Check air cleaner for dirty1, loose, or damaged parts.

Section 4

 

 

• Check air intake and cooling areas, clean as necessary.1

Section 4

 

Every 25 Hours

Clean or replace precleaner (if equipped) clean as necessary.1,3

Section 4

 

 

Replace element1 (low-profile air cleaner models).

Section 4

 

Every 100 Hours

• Remove and clean shrouds and cooling areas.1

Section 4

 

• Change oil. (More frequently under severe conditions).

Section 6

 

 

 

 

• Check oil cooler fins, clean as necessary (if equipped).

Section 6

 

 

 

 

 

 

Weekly or Every

Check filter minder.4

Section 4

 

150 Hours

Inspect air filter paper element and inlet screen area.4

Section 4

 

 

Replace fuel filter.1

Section 5

 

Every 200 Hours

Clean, set gap or replace spark plug, and set gap.

Section 7

 

 

Change oil filter.

Section 6

 

 

 

 

 

 

Every 300 Hours

Replace heavy-duty air cleaner element and check inner element.1

Section 4

 

Annually or

Have starter serviced.2

Section 7

 

Every 500 Hours

 

 

 

 

¹Perform these maintenance procedures more frequently under extremely dusty, dirty conditions. ²Have a Kohler Engine Service Dealer perform this service.

3Low-profile air cleaner.

4Heavy-duty air cleaner.

Storage

If the engine will be out of service for two months or more, use the following storage procedure:

1.Clean the exterior surfaces of the engine. On EFI engines, avoid spraying water at the wiring harness or any of the electrical components.

2.Change the oil and oil filter while the engine is still warm from operation. See Change Oil and Oil Filter in Section 6.

3.The fuel system must be completely emptied, or the gasoline must be treated with a stabilizer to prevent deterioration. If you choose to

use a stabilizer, follow the manufacturer’s recommendations, and add the correct amount for the capacity of the fuel system. Fill the fuel tank with clean, fresh gasoline.

Run the engine for 2 to 3 minutes to get stabilized fuel into the rest of the system. Close the fuel shut-o valve when the unit is being stored or transported.

To empty the system, run the engine until the tank and the system is empty.

4.Remove the spark plugs. Add one tablespoon of engine oil into each spark plug hole. Install plugs, but do not connect the plug leads. Crank the engine two or three revolutions.

5.Disconnect the negative (-) battery cable or use a battery minder trickle charger while the unit is in storage.

6.Store the engine in a clean, dry place.

1.5

Kohler ECV680, ECV730, ECV630, ECV740, ECV650 Manual

Section 1

Safety and General Information

Dimensions in millimeters.

Inch equivalents shown in [ ].

Figure 1-4. Typical Engine Dimensions - ECV749 with Heavy-Duty Air Cleaner.

1.6

 

 

 

 

 

 

 

 

 

 

Section 1

 

 

 

 

 

 

Safety and General Information

 

 

427.72

 

 

 

 

 

 

 

 

 

1

 

 

[16.839]

302.03

 

 

 

 

 

 

 

 

60.00

 

 

 

 

 

 

 

 

 

 

 

 

[11.891]

 

 

 

Dimensions in millimeters.

[2.362]

 

 

 

 

 

AIR CLEANER

 

 

 

 

 

 

Inch equivalents shown in [ ].

 

COVER REMOVAL

 

 

 

 

 

 

 

 

12.15

 

 

 

 

 

 

 

 

 

 

 

17.01

[.478]

 

 

 

16.31

 

 

 

 

 

 

 

[.670]

 

 

 

 

[.642]

 

 

 

 

 

 

 

SPARK

 

 

 

 

SPARK

 

 

 

 

 

 

 

PLUG

 

 

 

 

PLUG

 

 

 

 

 

 

 

FUEL

 

 

 

 

 

 

 

 

 

 

 

 

FILTER

 

 

 

 

 

 

 

 

 

 

 

 

397.06

 

 

 

 

 

 

 

 

 

 

 

 

[15.632]

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

334.62

 

 

 

 

 

 

 

 

 

 

 

 

[13.174]

2X 89.41

 

 

 

 

 

 

 

 

 

 

 

 

[3.520]

 

 

 

 

CRANKSHAFT

 

 

 

 

 

 

 

2X 72.85

77.90

 

 

 

 

 

 

 

 

 

 

[2.868]

[3.067]

 

 

 

45.57

 

 

 

 

M8 X 1.25

 

 

 

 

50.00

 

 

 

 

 

 

 

 

[1.969]

[1.794]

 

 

 

 

4 STUDS

 

 

 

 

EXHAUST

15.70

145.58

 

ENGINE

 

OIL FILL &

 

 

 

 

 

PORT #2

[.618]

[5.731]

 

 

DIPSTICK

30º

 

 

 

30º

 

 

OIL FILTER

 

MOUNTING

 

 

 

 

 

 

 

 

REMOVAL

 

 

 

 

 

 

 

 

 

 

 

 

 

HOLE “A”

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

50.00

 

 

 

 

 

 

 

 

 

FLYWHEEL

 

[1.969]

 

 

 

 

 

 

 

 

 

 

EXHAUST

 

 

 

 

 

 

 

 

 

SIDE

 

 

PORT #1

 

35º

35º

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

104.02

 

 

 

 

 

 

 

 

 

 

 

[4.095]

241.87

 

 

 

 

 

 

 

 

 

 

 

 

[9.523]

 

 

 

 

 

 

 

 

 

 

89.41

 

 

 

 

 

 

SOLENOID

 

 

 

 

[3.520]

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

OIL

SHIFT

 

45º

45º

 

 

 

 

 

 

 

 

STARTER

 

 

 

 

 

 

 

 

 

COOLER

 

 

 

 

 

 

 

 

 

 

 

REGULATOR

 

 

 

 

 

 

 

 

 

 

 

RECTIFIER

 

 

 

MOUNTING HOLE “A”

 

 

 

 

 

 

 

4X Ø 9.20 [.362] THRU

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Ø 254.00 [10.000] B.C.

ENGINE MOUNTING SURFACE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(PTO SIDE)

 

 

 

 

 

 

 

52.26

 

 

 

 

 

 

 

 

 

 

 

 

[2.057]

 

 

 

 

 

 

 

 

 

 

 

 

OIL FILTER

134.94

 

 

 

 

 

 

 

 

 

 

 

 

[5.312]

 

 

 

 

 

 

 

 

 

 

 

SPARK PLUG

 

 

 

 

 

 

 

 

 

 

26.41

13.95

ENGINE MOUNTING SURFACE

 

 

 

 

 

 

 

85.50

85.91

[1.040]

[.549]

 

 

 

 

 

 

 

MOUNTING

96.70

 

 

 

 

 

 

 

 

[3.366]

[3.382]

[3.807]

 

 

 

 

 

 

 

 

KEYWAY

OIL FILTER

HOLE “A”

 

 

 

 

 

 

 

 

 

1/4 IN. SQ.

 

OIL DRAIN PLUG

 

OIL FILL &

 

 

 

 

 

 

 

KEYWAY

28.56

3/8 NPT [INCH]

 

DIPSTICK

 

 

 

 

 

 

7/16-20 UNF 2B [INCH]

 

 

 

 

 

 

 

 

 

 

[1.125]

 

 

 

 

 

 

 

 

 

 

 

38.1 [1.500]

 

 

 

 

 

 

 

 

 

 

 

 

OIL FILTER

 

 

 

 

 

 

 

 

 

 

 

SIDE

 

 

 

 

 

 

 

 

 

154.94

 

 

 

 

 

367.37

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

[6.100]

 

 

 

 

 

[14.463]

 

 

 

 

 

 

SPARK

 

 

 

 

 

317.23

 

 

 

 

 

PLUG

 

 

 

 

 

[12.489]

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

72.69

92.94

 

 

 

 

 

 

 

 

 

 

[3.659]

 

 

 

 

 

 

 

 

 

 

[2.862]

EXHAUST

 

 

 

 

 

 

 

 

 

 

EXHAUST

 

 

 

 

 

 

 

 

 

 

PORT #2

PORT #1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

13.49

 

 

 

 

ENGINE

 

 

 

 

 

 

 

[.531]

MOUNTING

 

 

 

 

 

 

 

 

 

 

 

 

 

 

MOUNTING

 

 

 

 

 

 

 

 

HOLE “A”

40.41

STARTER

SURFACE

 

 

 

 

 

 

 

OIL DRAIN PLUG

 

 

 

 

 

 

 

 

SIDE

 

 

 

 

 

 

 

 

 

3/8 N.P.T [INCH]

[1.591]

 

 

 

Figure 1-5. Typical Engine Dimensions - ECV749 with Low-Profile Air Cleaner.

1.7

Section 1

Safety and General Information

General Specifications1

Power (@3600 RPM, exceeds Society of Automotive Engineers-Small Engine Test Code J1940.)

ECV630 ........................................................................................................................................

14.1 kW (19 HP)

ECV650 ........................................................................................................................................

15.7 kW (21 HP)

ECV680 ........................................................................................................................................

17.2 kW (23 HP)

ECV730 ........................................................................................................................................

18.6 kW (25 HP)

ECV740 ........................................................................................................................................

20.1 kW (27 HP)

ECV749 ........................................................................................................................................

21.6 kW (29 HP)

Bore

 

ECV630,ECV650,ECV680..........................................................................................................

80 mm (3.15 in.)

ECV730,ECV740,ECV749..........................................................................................................

83 mm (3.27 in.)

Stroke

 

ECV630,ECV650,ECV680,ECV730,ECV740,ECV749 ...........................................................

69 mm (2.72 in.)

Displacement

 

ECV630,ECV650,ECV680..........................................................................................................

694 cc (42.4 cu. in.)

ECV730,ECV740,ECV749..........................................................................................................

747 cc (45.6 cu. in.)

Compression Ratio

 

ECV630,ECV650,ECV680..........................................................................................................

8.8:1

ECV730,ECV740,ECV749..........................................................................................................

9.1:1

Weight................................................................................................................................................

46 kg (102 lb.)

Oil Capacity (w/filter) - approximate,

 

determined by oil filter and oil cooler used: ................................................................................

1.9 L (2 U.S. qt.)

Angle of Operation - Maximum (At Full Oil Level) All Directions...........................................

25°

Blower Housing Screws (into cored aluminum hole or weld nut)

 

 

M5 Fasteners Torque..................................................................................................

6.2

N·m (55 in. lb.) into new holes

 

4.0

N·m (35 in. lb.) into used holes

M6 Fasteners Torque..................................................................................................

10.7 N·m (95 in. lb.) into new holes

 

7.3

N·m (65 in. lb.) into used holes

Blower Housing Screws (into extruded hole in sheet metal)

 

 

M5 Fasteners Torque..................................................................................................

2.8

N·m (25 in. lb.) into new holes

 

2.3

N·m (20 in. lb.) into used holes

M6 Fasteners Torque..................................................................................................

2.8

N·m (25 in. lb.) into new holes

 

2.3

N·m (20 in. lb.) into used holes

Blower Housing Screws

 

 

Rectifier-Regulator Fastener Torque........................................................................

1.4

N·m (12.6 in. lb.)

Camshaft

 

 

End Play (With Shim) ................................................................................................

0.051/0.381 mm (0.002/0.015 in.)

1Values 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

 

 

 

 

Running Clearance

0.025/0.105 mm (0.001/0.004 in.)

 

1

Bore I.D.

 

 

 

 

 

 

 

New.......................................................................................................................

20.000/20.025 mm (0.7874/0.7884 in.)

Max. Wear Limit..................................................................................................

20.038 mm (0.7889 in.)

Camshaft Bearing Surface O.D.

 

 

 

New.......................................................................................................................

19.920/19.975 mm (0.7843/0.7864 in.)

Max. Wear Limit..................................................................................................

19.914 mm (0.7840 in.)

Connecting Rod

 

 

 

Cap Fastener Torque (torque in increments) .........................................................

11.6 N·m (103 in. lb.)

Connecting Rod-to-Crankpin Running Clearance @ 21°C (70°F)

 

 

 

New.......................................................................................................................

0.043/0.073 mm (0.0017/0.0029 in.)

Max. Wear Limit..................................................................................................

0.088 mm (0.0035 in.)

Connecting Rod-to-Crankpin Side Clearance........................................................

0.26/0.63 mm (0.0102/0.0248 in.)

Connecting Rod-to-Piston Pin Running Clearance @ 21°C (70°F) ......................

0.015/0.028 mm (0.0006/0.0011 in.)

Connecting Rod Piston Pin End I.D. @ 21°C (70°F)

 

 

 

New.......................................................................................................................

17.015/17.023 mm (0.6699/0.6702 in.)

Max. Wear Limit..................................................................................................

17.036 mm (0.6707 in.)

Crankcase

 

 

 

Governor Cross Shaft Bore I.D.

 

 

 

New.......................................................................................................................

8.025/8.075 mm (0.3159/0.3179 in.)

Max. Wear Limit..................................................................................................

8.088 mm (0.3184 in.)

Breather Cover Fastener Torque ..............................................................................

11.3 N·m (100 in. lb.) into new holes

 

7.3 N·m (65 in. lb.) into used holes

Oil Temperature Sensor Torque ...............................................................................

7.3 N·m (65 in. lb.)

Oil Drain Plug Torque ..............................................................................................

13.6 N·m (10 ft. lb.)

Oil Pan

 

 

 

Oil Pan Fastener Torque............................................................................................

25.6 N·m (227 in. lb.)

Crankshaft

 

 

 

End Play (Free) ...........................................................................................................

0.025/0.635 mm (0.001/0.025 in.)

Crankshaft Bore (In Crankcase)

 

 

 

New.......................................................................................................................

40.972/40.997 mm (1.6131/1.6141 in.)

Max. Wear Limit..................................................................................................

41.011 mm (1.6146 in.)

Crankshaft to Sleeve Bearing (Oil Pan)

 

 

 

Running Clearance - New .................................................................................

0.03/0.12 mm (0.001/0.005 in.)

Crankshaft Bore (Oil Pan) - New .............................................................................

40.974/41.000 mm (1.6131/1.6141 in.)

Crankshaft Bore (Oil Pan)-to-Crankshaft

 

 

 

Running Clearance - New .................................................................................

0.039/0.087 mm (0.0015/0.0034 in.)

1.9

Section 1

Safety and General Information

Crankshaft - Flywheel End Main Bearing Journal

 

O.D. - New ...........................................................................................................

40.913/40.935 mm (1.6107/1.6116 in.)

O.D. - Max. Wear Limit ......................................................................................

40.843 mm (1.608 in.)

Max. Taper Limit.................................................................................................

0.022 mm (0.0009 in.)

Max. Out-of-Round Limit..................................................................................

0.025 mm (0.0010 in.)

Crankshaft - Oil Pan End Main Bearing Journal

 

O.D. - New ...........................................................................................................

40.913/40.935 mm (1.6107/1.6116 in.)

O.D. - Max. Wear Limit ......................................................................................

40.843 mm (1.608 in.)

Max. Taper ...........................................................................................................

0.022 mm (0.0009 in.)

Max. Out-of-Round ............................................................................................

0.025 mm (0.0010 in.)

Crankshaft - Connecting Rod Journal

 

O.D. - New ...........................................................................................................

35.950/35.973 mm (1.4153/1.4163 in.)

O.D. - Max. Wear Limit ......................................................................................

35.941 mm (1.4150 in.)

Max. Taper Limit.................................................................................................

0.018 mm (0.0007 in.)

Max. Out-of-Round Limit..................................................................................

0.025 mm (0.0010 in.)

Crankshaft T.I.R.

 

PTO End, Crank in Engine ................................................................................

0.279 mm (0.0110 in.)

Entire Crank, in V-Blocks...................................................................................

0.10 mm (0.0039 in.)

Cylinder Bore

 

Cylinder Bore I.D.

 

New - ECV630,ECV650,ECV680.......................................................................

80.000/80.025 mm (3.1496/3.1506 in.)

New - ECV730,ECV740,ECV749.......................................................................

83.006/83.031 mm (3.2680/3.2689 in.)

Max. Wear Limit - ECV630,ECV650,ECV680..................................................

80.075 mm (3.1526 in.)

Max. Wear Limit - ECV730,ECV740,ECV749..................................................

83.081 mm (3.2709 in.)

Max. Out-of-Round ............................................................................................

0.120 mm (0.0047 in.)

Max. Taper ...........................................................................................................

0.05 mm (0.0020 in.)

Cylinder Head

 

Cylinder Head Fastener Torque

 

Hex Flange Nut - Torque in Two Stages..........................................................

first to 16.9 N·m (150 in. lb.)

 

finally to 33.9 N·m (300 in. lb.)

Head Bolt - Torque in Two Stages ....................................................................

first to 22.6 N·m (200 in. lb.)

 

finally to 41.8 N·m (370 in. lb.)

Cylinder Head Max. Out-of-Flatness......................................................................

0.076 mm (0.003 in.)

Rocker Arm Screw Torque........................................................................................

11.9 N·m (105 in. lb.)

Fan/Flywheel

 

Fan Fastener Torque...................................................................................................

9.9 N·m (88 in. lb.)

Flywheel Retaining Screw Torque...........................................................................

71.6 N·m (52.8 ft. lb.)

Fuel Pump

 

Fuel Pump Module Ba e Fastener Torque............................................................

11.9 N·m (105 in. lb.)

Fuel Pump Module Fastener Torque.......................................................................

9.2 N·m (81 in. lb.)

Pulse Pump Bracket Fastener Torque .....................................................................

2.1 N·m (25 in. lb.)

Pulse Pump Fastener to Bracket Torque.................................................................

7.3 N·m (68 in. lb.) into new holes

 

6.2 N·m (55 in. lb.) into used holes

1.10

 

Section 1

 

 

Safety and General Information

 

Governor

 

 

 

 

1

Governor Cross Shaft-to-Crankcase Running Clearance ....................................

0.025/0.126 mm (0.0009/0.0049 in.)

 

Governor Cross Shaft O.D.

 

 

New.......................................................................................................................

7.949/8.000 mm (0.3129/0.3149 in.)

 

Max. Wear Limit..................................................................................................

7.936 mm (0.3124 in.)

 

Governor Gear Shaft-to-Governor

 

 

Gear Running Clearance....................................................................................

0.090/0.160 mm (0.0035/0.0063 in.)

 

Governor Gear Shaft O.D.

 

 

New.......................................................................................................................

5.990/6.000 mm (0.2358/0.2362 in.)

 

Max. Wear Limit..................................................................................................

5.977 mm (0.2353 in.)

 

Governor Lever Nut Torque.....................................................................................

7.1 N·m (63 in. lb.)

 

Ignition

 

 

Spark Plug Type (Champion® or Equivalent) ........................................................

RC12YC, XC12YC, or Platinum 3071

 

Spark Plug Gap...........................................................................................................

0.76 mm (0.030 in.)

 

Spark Plug Torque......................................................................................................

24.4-29.8 N·m (18-22 ft. lb.)

 

Ignition Coil Fastener Torque...................................................................................

10.2 N·m (90 in. lb.)

 

Crankshaft Position Sensor Screw Torque..............................................................

6.2 N·m (55 in. lb.)

 

Crankshaft Position Sensor Bracket Screw Torque ...............................................

7.3 N·m (65 in. lb.)

 

Crankshaft Position Sensor Air Gap........................................................................

0.2-0.7 mm (0.008-0.027 in.)

 

Electronic Control Unit Screw Torque ....................................................................

6.2 N·m (55 in. lb.)

 

Intake Manifold

 

 

Intake Manifold Mounting Fastener Torque

 

 

Torque in Two Stages .........................................................................................

first to 7.8 N·m (69 in. lb.)

 

 

finally to 10.5 N·m (93 in. lb.)

 

Fuel Injector Cap Fastener Torque...........................................................................

7.3 N·m (65 in. lb.)

 

Manifold Absolute Pressure (MAP) Sensor Fastener Torque..............................

7.3 N·m (65 in. lb.)

 

Bracket for Heavy-Duty Air Cleaner to Intake Manifold.....................................

9.9 N·m (88 in. lb.)

 

Air Cleaner to Throttle Body Fastener Nut Torque...............................................

8.2 N·m (73 in. lb.)

 

Muffler

 

 

Mu er Retaining Nuts Torque................................................................................

27.8 N·m (246 in. lb.)

 

Oxygen Sensor Torque ..............................................................................................

50.1 N·m (37 ft. lb.)

 

Oil Filter

 

 

Oil Filter Torque .........................................................................................................

refer to filter for instructions

 

1.11

Section 1

Safety and General Information

Oil Cooler

 

Oil Cooler/Adapter Nipple Torque .........................................................................

28.5 N·m (21 ft. lb.)

Oil Cooler Fastener Torque

 

Top Fastener.........................................................................................................

2.8 N·m (25 in. lb.)

Bottom Fastener...................................................................................................

2.3 N·m (20 in. lb.)

Piston, Piston Rings, and Piston Pin

 

Piston-to-Piston Pin Running Clearance ................................................................

0.006/0.017 mm (0.0002/0.0007 in.)

Piston Pin Bore I.D.

 

New.......................................................................................................................

17.006/17.012 mm (0.6695/0.6698 in.)

Max. Wear Limit..................................................................................................

17.025 mm (0.6703 in.)

Piston Pin O.D.

 

New.......................................................................................................................

16.995/17.000 mm (0.6691/0.6693 in.)

Max. Wear Limit..................................................................................................

16.994 mm (0.6691 in.)

Top Compression Ring-to-Groove Side Clearance ...............................................

0.050/0.095 mm (0.0019/0.0037 in.)

Middle Compression Ring-to-Groove Side Clearance .........................................

0.030/0.075 mm (0.0012/0.0030 in.)

Oil Control Ring-to-Groove Side Clearance...........................................................

0.010/0.011 mm (0.0004/0.0043 in.)

Top and Middle Compression Ring End Gap

 

New Bore .............................................................................................................

0.025/0.56 mm (0.010/0.022 in.)

Used Bore (Max.) - ECV630,ECV650,ECV680.................................................

0.080 mm (0.0315 in.)

Used Bore (Max.) - ECV730,ECV740,ECV749.................................................

0.094 mm (0.0370 in.)

Piston Thrust Face O.D.²

 

ECV630,ECV650,ECV680...................................................................................

79.962/79.980 mm (3.1481/3.1488 in.)

ECV730,ECV740,ECV749...................................................................................

82.949/82.967 mm (3.2657/3.2664 in.)

Max. Wear Limit - ECV630,ECV650,ECV680..................................................

79.831 mm (3.1430 in.)

Max. Wear Limit - ECV730,ECV740,ECV749..................................................

82.818 mm (3.2606 in.)

Piston Thrust Face-to-Cylinder Bore² Running Clearance

 

New - ECV630,ECV650,ECV680.......................................................................

0.020/0.063 mm (0.0008/0.0024 in.)

New - ECV730,ECV740,ECV749.......................................................................

0.0039/0.082 mm (0.0015/0.0032 in.)

Speed Control Bracket (Assembled to Cylinder Heads)

 

Fastener Torque ..........................................................................................................

10.7 N·m (95 in. lb.) into new holes

 

7.3 N·m (65 in. lb.) into used holes

Speed Control Bracket (Assembled to Blower Housing)

 

Fastener Torque ..........................................................................................................

2.8 N·m (25 in. lb.) into new holes

 

2.3 N·m (20 in. lb.) into used holes

Starter Assembly

 

Thru Bolt Torque ........................................................................................................

5.6-9.0 N·m (49-79 in. lb.)

Mounting Screw Torque (All)...................................................................................

16.0 N·m (142 in. lb.)

Brush Holder Mounting Screw Torque...................................................................

2.5-3.3 N·m (22-29 in. lb.)

²Measure 6 mm (0.236 in.) above the bottom of the piston skirt at right angles to the piston pin.

1.12

 

Section 1

 

 

Safety and General Information

 

 

 

 

 

Solenoid (Starter)

 

 

 

 

 

1

Mounting Hardware Torque

4.0-6.0 N·m (35-53 in. lb.)

 

Nut, Positive (+) Brush Lead Torque

8.0-11.0 N·m (71-97 in. lb.)

 

 

Stator

 

 

 

Mounting Screw Torque............................................................................................

6.2 N·m (55 in. lb.) into new holes

 

 

4.0 N·m (35 in. lb.) into used holes

 

Valve Cover

 

 

 

Valve Cover Fastener Torque....................................................................................

6.2 N·m (55 in. lb.)

 

Valves and Valve Lifters

 

 

 

Hydraulic Valve Lifter to Crankcase Running Clearance ....................................

0.011/0.048 mm (0.0004/0.0019 in.)

 

Intake Valve Stem-to-Valve Guide Running Clearance ........................................

0.040/0.078 mm (0.0016/0.0031 in.)

 

Exhaust Valve Stem-to-Valve Guide Running Clearance.....................................

0.052/0.090 mm (0.0020/0.0035 in.)

 

Intake Valve Guide I.D.

 

 

 

New.......................................................................................................................

7.040/7.060 mm (0.2772/0.2780 in.)

 

Max. Wear Limit..................................................................................................

7.134 mm (0.2809 in.)

 

Exhaust Valve Guide I.D.

 

 

 

New.......................................................................................................................

7.040/7.060 mm (0.2772/0.2780 in.)

 

Max. Wear Limit..................................................................................................

7.159 mm (0.2819 in.)

 

Valve Guide Reamer Size

 

 

 

Standard ...............................................................................................................

7.050 mm (0.2776 in.)

 

0.25 mm O.S. ........................................................................................................

7.300 mm (0.2874 in.)

 

Intake Valve Minimum Lift ......................................................................................

8.07 mm (0.3177 in.)

 

Exhaust Valve Minimum Lift...................................................................................

8.07 mm (0.3177 in.)

 

Nominal Valve Seat Angle ........................................................................................

45°

 

 

1.13

Section 1

Safety and General Information

General Torque Values

Metric Fastener Torque Recommendations for Standard Applications

Tightening Torque: N·m (in. lb.) + or - 10%

 

 

 

 

 

Property Class

 

 

 

 

Noncritical

 

 

 

 

 

 

 

 

 

 

 

Fasteners

 

 

 

 

 

 

 

 

 

 

 

Into Aluminum

Size

 

 

 

 

 

 

 

 

 

 

 

 

M4

1.2

(11)

1.7

(15)

2.9

(26)

4.1

(36)

5.0

(44)

2.0

(18)

M5

2.5

(22)

3.2

(28)

5.8

(51)

8.1

(72)

9.7

(86)

4.0

(35)

M6

4.3

(38)

5.7

(50)

9.9

(88)

14.0

(124)

16.5

(146)

6.8

(60)

M8

10.5

(93)

13.6

(120)

24.4

(216)

33.9

(300)

40.7

(360)

17.0

(150)

Tightening Torque: N·m (ft. lb.) + or - 10%

 

 

 

Property Class

 

 

 

 

Noncritical

 

 

 

 

 

 

 

 

 

Fasteners

 

 

 

 

 

 

 

 

 

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)

1.14

Section 1

Safety and General Information

English Fastener Torque Recommendations for Standard Applications

1

Tightening Torque: N·m (in. lb.) + or - 20%

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Bolts, Screws, Nuts and Fasteners

 

 

 

 

 

 

 

 

 

 

 

 

Grade 2 or 5

Assembled Into Cast Iron or Steel

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Fasteners Into

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Aluminum

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Grade 2

 

Grade 5

Grade 8

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Size

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

8-32

2.3

(20)

2.8 (25)

 

---------

 

 

 

 

 

2.3 (20)

 

 

10-24

3.6

(32)

4.5 (40)

 

---------

 

 

 

 

 

3.6 (32)

 

 

10-32

3.6

(32)

4.5 (40)

 

---------

 

 

 

 

 

---------

 

 

1/4-20

7.9

(70)

13.0 (115)

 

18.7 (165)

 

7.9 (70)

 

 

1/4-28

9.6

(85)

15.8 (140)

 

22.6 (200)

 

---------

 

 

5/16-18

17.0

(150)

28.3 (250)

 

39.6 (350)

 

17.0 (150)

 

 

5/16-24

18.7

(165)

30.5 (270)

 

---------

 

 

 

 

 

---------

 

 

3/8-16

29.4

(260)

 

---------

 

 

 

 

---------

 

 

---------

 

 

3/8-24

33.9

(300)

 

---------

 

 

 

 

---------

 

 

---------

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Tightening Torque: N·m (ft. lb.) + or - 20%

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Size

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5/16-24

---------

 

----------

 

40.7

(30)

---------

 

 

3/8-16

---------

 

47.5 (35)

 

67.8

(50)

---------

 

 

3/8-24

---------

 

54.2 (40)

 

81.4

(60)

---------

 

 

7/16-14

47.5

(35)

74.6

(55)

 

108.5

(80)

---------

 

 

7/16-20

61.0

(45)

101.7

(75)

 

142.4

(105)

---------

 

 

1/2-13

67.8

(50)

108.5

(80)

 

155.9

(115)

---------

 

 

1/2-20

94.9

(70)

142.4

(105)

 

223.7

(165)

---------

 

 

9/16-12

101.7

(75)

169.5

(125)

 

237.3

(175)

---------

 

 

9/16-18

135.6

(100)

223.7

(165)

 

311.9

(230)

---------

 

 

5/8-11

149.2

(110)

244.1

(180)

 

352.6

(260)

---------

 

 

5/8-18

189.8

(140)

311.9

(230)

 

447.5

(330)

---------

 

 

3/4-10

199.3

(150)

332.2

(245)

 

474.6

(350)

---------

 

 

3/4-16

271.2

(200)

440.7

(325)

 

637.3

(470)

---------

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Torque

 

 

 

 

 

 

 

 

 

 

 

 

 

Conversions

 

 

 

 

 

 

 

 

 

 

 

 

 

N·m = in. lb. x 0.113

 

 

 

 

 

 

 

 

 

 

 

 

 

N·m = ft. lb. x 1.356

 

 

 

 

 

 

 

 

 

 

 

 

 

in. lb. = N·m x 8.85

 

 

 

 

 

 

 

 

 

 

 

 

 

ft. lb. = N·m x 0.737

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1.15

Section 1

Safety and General Information

1.16

Section 2

Tools & Aids

Section 2

 

Tools & Aids

2

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

Contact your source of supply.

SE Tools

Design Technology Inc.

415 Howard St.

768 Burr Oak Drive

Lapeer, MI 48446

Westmont, IL 60559

Phone 810-664-2981

Phone 630-920-1300

Toll Free 800-664-2981

Fax 630-920-0011

Fax 810-664-8181

 

Tools

 

Description

Source/Part No.

Camshaft Endplay Plate

SE Tools KLR-82405

For checking camshaft endplay.

 

Camshaft Seal Protector (Aegis)

SE Tools KLR-82417

To protect seal during camshaft installation.

 

Cylinder Leakdown Tester

Kohler 25 761 05-S

For checking combustion retention and if cylinder, piston, rings, or valves are worn.

 

Electronic Fuel Injection (EFI) Diagnostic Software

Kohler 25 761 23-S

Use with Laptop or Desktop PC.

 

EFI Service Kit

Kohler 24 761 01-S

For troubleshooting and setting up an EFI engine.

 

Individual Components Available

Design Technology Inc.

Fuel Pressure Tester

DTI-019

Noid Light

DTI-021

90° Adapter

DTI-023

In-line "T" Fitting

DTI-035

Code Plug, Red Wire

DTI-027

Code Plug, Blue Wire

DTI-029

Shrader Valve Adapter Hose

DTI-037

Flywheel Holding Tool (CS Series)

SE Tools KLR-82407

Flywheel Puller

SE Tools KLR-82408

To remove flywheel from engine.

 

Flywheel Strap Wrench

SE Tools KLR-82409

To hold flywheel during removal.

 

2.1

Section 2

Tools & Aids

Tools (Continued)

 

Description

Source/Part No.

Hydraulic Valve Lifter Tool

Kohler 25 761 38-S

To remove and install hydraulic lifters.

 

Ignition System Tester

Kohler 25 455 01-S

For testing output on all systems, including CD.

 

O set Wrench (K & M Series)

Kohler 52 455 04-S

To remove and reinstall cylinder barrel retaining nuts.

 

Oil Pressure Test Kit

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-S

Used to test rectifier-regulators.

 

Individual Components Available

Design Technology Inc.

CS-PRO Regulator Test Harness

DTI-031

Special Regulator Test Harness with Diode

DTI-033

Spark Advance Module (SAM) Tester

Kohler 25 761 40-S

To test the SAM (ASAM and DSAM) on engines with SMART-SPARK™.

 

 

 

Starter Servicing Kit (All Starters)

SE Tools KLR-82411

To remove and reinstall drive retaining rings and brushes.

 

Individual Component Available

SE Tools KLR-82416

Starter Brush Holding Tool (Solenoid Shift)

 

 

 

Tachometer (Digital Inductive)

Design Technology Inc.

For checking operating speed (RPM) of an engine.

DTI-110

Vacuum/Pressure Tester

Kohler 25 761 22-S

Alternative to a water manometer.

 

2.2

 

Section 2

 

 

Tools & Aids

 

 

 

 

 

 

 

 

 

 

 

Aids

 

 

 

 

Description

Source/Part No.

 

 

Camshaft Lubricant (Valspar ZZ613)

Kohler 25 357 14-S

 

 

Dielectric Grease (GE/Novaguard G661)

Kohler 25 357 11-S

 

 

2

 

 

Dielectric Grease (Fel-Pro)

Lubri-Sel

 

 

Electric Starter Drive Lubricant (Inertia Drive)

Kohler 52 357 01-S

 

 

Electric Starter Drive Lubricant (Solenoid Shift)

Kohler 52 357 02-S

 

 

RTV 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

 

 

 

 

characteristics.

 

 

 

 

Loctite® 5910®

 

 

 

 

Loctite® Ultra Black 598™

 

 

 

 

Loctite® Ultra Blue 587™

 

 

 

 

Loctite® Ultra Copper 5920™

 

 

 

 

Spline Drive Lubricant

Kohler 25 357 12-S

 

 

 

 

 

 

 

2.3

Section 2

Tools & Aids

Special Tools You Can Make

Flywheel Holding Tool

A flywheel holding tool can be made out of an old flywheel ring gear as shown in Figure 2-1, and used in place of a strap wrench.

1.Using an abrasive cut-o wheel, cut out a six tooth segment of the ring gear as shown.

2.Grind o any burrs or sharp edges.

3.Invert the segment and place it between the ignition bosses on the crankcase so that the tool bosses will lock the tool and flywheel in position for loosening, tightening or removing with a puller.

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 a used connecting rod from a 10 HP or larger engine. Remove and discard the rod cap.

2.Remove the studs of a Posi-Lock rod or grind o the aligning steps of a Command rod, so the joint surface is flat.

3.Find a 1 in. long capscrew with the correct thread size to match the threads in the connecting rod.

4.Use a flat washer with the correct I.D. to slip on the capscrew and approximately 1 in. O.D.

(Kohler Part No. 12 468 05-S). Assemble the capscrew and washer to the joint surface of the rod, as shown in Figure 2-2.

Figure 2-2. Rocker Arm/Crankshaft Tool.

2.4

Section 3

Troubleshooting

Section 3

Troubleshooting

3

Troubleshooting Guide

3.

Clogged fuel line or fuel filter.

When troubles occur, be sure to check the simple

4.

Loose or faulty wires or connections.

causes which, at first, may seem too obvious to be

5.

Faulty spark plugs.

considered. For example, a starting problem could be

6.

Low compression.

caused by an empty fuel tank.

7.

Weak spark.

 

 

8.

Fuel pump malfunction causing lack of fuel.

Some general common causes of engine troubles are

9.

Engine overheated - cooling/air circulation

listed below. Use these to locate the causing factors.

 

restricted.

Refer to the specific section(s) within this service

10.

Quality of fuel.

manual for more detailed information.

11.

Flywheel key sheared.

 

 

12.

Intake system leak.

Engine Cranks But Will Not Start

13.

Faulty or improperly adjusted throttle controls.

1.

Empty fuel tank.

Engine Will Not Crank

2.

Fuel shut-o valve closed.

3.

Poor fuel, dirt or water in the fuel system.

1.

PTO drive is engaged.

4.

Clogged fuel line.

2.

Battery is discharged.

5.

Spark plug lead(s) disconnected.

3.

Safety interlock switch is engaged.

6.

Key switch or kill switch in OFF position.

4.

Loose or faulty wires or connections.

7.

Faulty spark plugs.

5.

Faulty key switch or ignition switch.

8.

Faulty ignition coil(s).

6.

Faulty electric starter or solenoid.

9.

Battery connected backwards.

7.

Seized internal engine components.

10. Safety interlock system engaged.

8.

Blown fuse.

11. Vacuum fuel pump malfunction, or oil in vacuum

9.

Insu cient voltage to electronic control unit.

 

hose.

10.

Faulty electronic control unit.

12. Vacuum hose to fuel pump leaking or cracked.

Engine Runs But Misses

13.

Blown fuse.

14. Faulty electronic control unit.

1.

Dirt or water in the fuel system.

15.

Insu cient voltage to electronic control unit.

2.

Spark plug lead disconnected.

 

 

3.

Poor quality of fuel.

Engine Starts But Does Not Keep Running

4.

Faulty spark plug(s).

1.

Restricted fuel tank cap vent.

5.

Loose wires or connections.

2.

Poor fuel, dirt or water in the fuel system.

6.

Engine overheated.

3.

Loose wires or connections.

7.

Faulty ignition coil or coils.

4.

Faulty cylinder head gasket.

8.

Incorrect crankshaft position sensor air gap.

5.

Intake system leak.

9.

Insu cient voltage to electronic control unit.

6.

Faulty ignition coil or coils.

Engine Will Not Idle

7.

Faulty or improperly adjusted throttle controls.

8.

Vacuum fuel pump malfunction, or oil in vacuum

1.

Dirt or water in the fuel system.

 

hose.

2.

Stale fuel or dirty fuel injectors.

9.

Vacuum hose to fuel pump leaking or cracked.

3.

Faulty spark plugs.

10.

Blown fuse.

4.

Fuel supply inadequate.

11.

Insu cient voltage to electronic control unit.

5.

Low compression.

 

 

6.

Restricted fuel tank cap vent.

Engine Starts Hard

7.

Engine overheated - cooling system/air

1.

PTO drive is engaged.

 

circulation problem.

2.

Dirt or water in the fuel system.

 

 

3.1

Section 3

Troubleshooting

Engine Overheats

1.Air intake/grass screen, cooling fins, oil cooler or cooling shrouds clogged.

2.Excessive engine load.

3.Low crankcase oil level.

4.High crankcase oil level.

5.Lean air-fuel mixture.

Engine Knocks

1.Excessive engine load.

2.Low crankcase oil level.

3.Old or improper fuel.

4.Internal wear or damage.

5.Hydraulic lifter malfunction.

6.Quality of fuel.

7.Incorrect grade of oil.

Engine Loses Power

1.Low crankcase oil level.

2.High crankcase oil level.

3.Dirty air cleaner element.

4.Dirt or water in the fuel system.

5.Excessive engine load.

6.Engine overheated.

7.Faulty spark plugs.

8.Low compression.

9.Exhaust restriction.

10.Low battery.

11.Incorrect governor setting.

Engine Uses Excessive Amount of Oil

1.Incorrect oil viscosity/type.

2.Clogged or improperly assembled breather.

3.Breather reed broken.

4.Worn or broken piston rings.

5.Worn cylinder bore.

6.Worn valve stems/valve guides.

7.Crankcase overfilled.

8.Blown head gasket/overheated.

Oil Leaks from Oil Seals, Gaskets

1.Crankcase breather is clogged or inoperative.

2.Breather reed broken.

3.Loose or improperly torqued fasteners.

4.Piston blowby, or leaky valves.

5.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 oil level. Note if the oil level is within the operating range on the dipstick, or if it is low or overfilled.

• Check 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 weak ignition, overextended oil change intervals or wrong weight or type of oil was used, to name a few.

NOTE: It is 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.

3.2

Section 3

Troubleshooting

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 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.

To test the crankcase vacuum with the manometer:

1.Insert the stopper/hose into the oil fill hole. Leave the other tube of manometer open to atmosphere. Make sure the shut-o clamp is closed.

2.Start the engine and run at no-load high speed (3200-3750 RPM).

4.Close the shut-o clamp before stopping the engine.

To test the crankcase vacuum with the Vacuum/ Pressure Gauge Kit:

1.

Remove the dipstick or oil fill plug/cap.

 

2.

Install the adapter into the oil fill/dipstick tube

 

3

 

opening.

 

 

 

3.Push the barbed fitting on the gauge solidly into the hole in the adapter.

4.Start the engine and bring it up to operating speed (3200-3600 RPM).

5.Check the reading on the gauge. If the reading is to the left of “0” on the gauge, vacuum or negative pressure is indicated. If the reading is to the right of “0” on the gauge, positive pressure is present.

3.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 below.

Crankcase vacuum should be 4-10 (inches of water). If the reading is below specification, or if pressure is present, check the following table for possible causes and remedies.

No Crankcase Vacuum/Pressure in Crankcase

 

Possible Cause

 

Solution

 

 

 

 

1.

Crankcase breather clogged or inoperative.

1.

Disassemble breather, clean parts thoroughly,

 

 

 

reassemble, and recheck pressure.

2.

Seals and/or gaskets leaking. Loose or

2.

Replace all worn or damaged seals and gaskets.

 

improperly torqued fasteners.

 

Make sure all fasteners are tightened securely.

 

 

 

Use appropriate torque values and sequences

 

 

 

when necessary.

3.

Piston blowby or leaky valves (confirm by

3.

Recondition piston, rings, cylinder bore, valves,

 

inspecting components).

 

and valve guides.

4.

Restricted exhaust.

4.

Repair/replace restricted mu er/exhaust

 

 

 

system.

3.3

Section 3

Troubleshooting

Compression Test

A compression test can be performed using a compression tester. Follow the manufacturers instructions for performing the 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 the engine for 3-5 minutes to warm it up.

2.Remove the spark plug(s) and the air filter from engine.

3.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 in. breaker bar into the hole/slot of the holding tool, so it is perpendicular to both the holding tool and crankshaft PTO.

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 o 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) direction 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 throttle body, exhaust outlet, and crankcase breather.

8.Check the test results against the following table:

Leakdown Test Results

Air escaping from crankcase breather .......................................................

Rings or cylinder worn.

Air escaping from exhaust system .............................................................

Defective exhaust valve/improper seating.

Air escaping from throttle body..................................................................

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...........................................................

Rings and/or cylinder have considerable

 

wear. Engine should be reconditioned

 

or replaced.

3.4

Section 4

Air Cleaner and Air Intake System

Section 4

Air Cleaner and Air Intake System

This engine is equipped with a heavy-duty air cleaner, low-profile air cleaner, or special air cleaner supplied by

 

the equipment manufacturer.

4

 

Heavy-Duty Air Cleaner

General

These engines use a heavy-duty style air cleaner shown in Figure 4-1, consisting of a cylindrical housing mounted to a bracket, on the throttle body/intake manifold. 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.

Service

Weekly and every 150 hours: Check filter minder (if equipped), perform inspection of the paper element and inlet screen area.

Yearly or every 300 hours of operation (more often under extremely dusty or dirty conditions), replace the paper element and check the inner element.

Follow these steps.

1.Unhook the two retaining clips on each end and remove the end caps from the air cleaner housing. See Figure 4-1.

Retaining

Clips

Filter

Minder

Figure 4-1. Heavy-Duty Air Cleaner.

2.Check and clean the inlet screen. Pull the paper element out of the housing on the opposite side. See Figures 4-2 and 4-3.

Paper Element

Inner Element

Figure 4-2. Removing Elements.

Inlet Screen

Figure 4-3. Accessing Inlet Screen.

4.1

Section 4

Air Cleaner and Air Intake System

3.After the paper element is removed, check the condition of the inner element. It should be replaced whenever it appears dirty, typically every other time the main element is replaced or every 600 hours. Clean the area around the base of the inner element before removing it, so dirt does not get into the engine.

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 carefully;

do not use if the sealing surfaces are bent or damaged.

5.Check all parts for wear, cracks, or damage, and make sure ejector area is clean. See Figure 4-4. Replace any damaged components.

Ejector

Area

Figure 4-4. Ejector Area.

6.Install the new inner element, followed by the paper element. Slide each fully into place in the air cleaner housing.

7.Reinstall the end caps and secure with the retaining clips. See Figure 4-1.

Removal

1.Remove the three hex flange nuts securing the assembly to the throttle body. See Figure 4-5.

Hex Flange

Nuts

Figure 4-5. Air Cleaner Hex Flange Nuts.

2.Remove two hex flange screws securing the air cleaner assembly to air cleaner bracket.

3.Lift the entire air cleaner assembly o the engine. Disassemble or service as required.

4.Reinstall the components in reverse order of removal.

5.Reset the governor (see Section 5).

Low-Profile Air Cleaner (Optional)

General

An optional air cleaner is the low-profile air cleaner with an oiled-foam precleaner which surrounds a paper element.

The low-profile air cleaner is shown in Figure 4-6.

Figure 4-6. Low-Profile Air Cleaner.

4.2

Loading...
+ 122 hidden pages