Kohler CV960 Bedienungsanleitung

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Zur Seite of

Richtige Gebrauchsanleitung

Die Vorschriften verpflichten den Verkäufer zur Übertragung der Gebrauchsanleitung Kohler CV960 an den Erwerber, zusammen mit der Ware. Eine fehlende Anleitung oder falsche Informationen, die dem Verbraucher übertragen werden, bilden eine Grundlage für eine Reklamation aufgrund Unstimmigkeit des Geräts mit dem Vertrag. Rechtsmäßig lässt man das Anfügen einer Gebrauchsanleitung in anderer Form als Papierform zu, was letztens sehr oft genutzt wird, indem man eine grafische oder elektronische Anleitung von Kohler CV960, sowie Anleitungsvideos für Nutzer beifügt. Die Bedingung ist, dass ihre Form leserlich und verständlich ist.

Was ist eine Gebrauchsanleitung?

Das Wort kommt vom lateinischen „instructio”, d.h. ordnen. Demnach kann man in der Anleitung Kohler CV960 die Beschreibung der Etappen der Vorgehensweisen finden. Das Ziel der Anleitung ist die Belehrung, Vereinfachung des Starts, der Nutzung des Geräts oder auch der Ausführung bestimmter Tätigkeiten. Die Anleitung ist eine Sammlung von Informationen über ein Gegenstand/eine Dienstleistung, ein Hinweis.

Leider widmen nicht viele Nutzer ihre Zeit der Gebrauchsanleitung Kohler CV960. Eine gute Gebrauchsanleitung erlaubt nicht nur eine Reihe zusätzlicher Funktionen des gekauften Geräts kennenzulernen, sondern hilft dabei viele Fehler zu vermeiden.

Was sollte also eine ideale Gebrauchsanleitung beinhalten?

Die Gebrauchsanleitung Kohler CV960 sollte vor allem folgendes enthalten:
- Informationen über technische Daten des Geräts Kohler CV960
- Den Namen des Produzenten und das Produktionsjahr des Geräts Kohler CV960
- Grundsätze der Bedienung, Regulierung und Wartung des Geräts Kohler CV960
- Sicherheitszeichen und Zertifikate, die die Übereinstimmung mit entsprechenden Normen bestätigen

Warum lesen wir keine Gebrauchsanleitungen?

Der Grund dafür ist die fehlende Zeit und die Sicherheit, was die bestimmten Funktionen der gekauften Geräte angeht. Leider ist das Anschließen und Starten von Kohler CV960 zu wenig. Eine Anleitung beinhaltet eine Reihe von Hinweisen bezüglich bestimmter Funktionen, Sicherheitsgrundsätze, Wartungsarten (sogar das, welche Mittel man benutzen sollte), eventueller Fehler von Kohler CV960 und Lösungsarten für Probleme, die während der Nutzung auftreten könnten. Immerhin kann man in der Gebrauchsanleitung die Kontaktnummer zum Service Kohler finden, wenn die vorgeschlagenen Lösungen nicht wirksam sind. Aktuell erfreuen sich Anleitungen in Form von interessanten Animationen oder Videoanleitungen an Popularität, die den Nutzer besser ansprechen als eine Broschüre. Diese Art von Anleitung gibt garantiert, dass der Nutzer sich das ganze Video anschaut, ohne die spezifizierten und komplizierten technischen Beschreibungen von Kohler CV960 zu überspringen, wie es bei der Papierform passiert.

Warum sollte man Gebrauchsanleitungen lesen?

In der Gebrauchsanleitung finden wir vor allem die Antwort über den Bau sowie die Möglichkeiten des Geräts Kohler CV960, über die Nutzung bestimmter Accessoires und eine Reihe von Informationen, die erlauben, jegliche Funktionen und Bequemlichkeiten zu nutzen.

Nach dem gelungenen Kauf des Geräts, sollte man einige Zeit für das Kennenlernen jedes Teils der Anleitung von Kohler CV960 widmen. Aktuell sind sie genau vorbereitet oder übersetzt, damit sie nicht nur verständlich für die Nutzer sind, aber auch ihre grundliegende Hilfs-Informations-Funktion erfüllen.

Inhaltsverzeichnis der Gebrauchsanleitungen

  • Seite 1

    S ER VICE M ANUAL V ERTICAL C RANKSHAFT COMMAND PRO CV940-CV1000[...]

  • Seite 2

    [...]

  • Seite 3

    Contents Section 1. Safety and General Information ............................................................................. Section 2. T ools & Aids ........................................................................................................ ..... Section 3. T roubleshooting .....................................................[...]

  • Seite 4

    [...]

  • Seite 5

    1.1 1 Rotating Parts! Keep hands, feet, hair , and clothing away from all moving parts to pr event injury . Never operate the engine with covers, shrouds, or guards r emoved. Section 1 Safety and General Information Safety Precautions T o ensure safe operation please read the following statements and understand their meaning. Also refer to your equ[...]

  • Seite 6

    1.2 Section 1 Safety and General Information ¡ȱȱȱȱęȱȱ severe burns. ȱȱęȱȱȱȱȱȱ engine is hot or running. W ARNING Explosive Fuel! ȱȱ¡[...]

  • Seite 7

    1.3 Section 1 Safety and General Information 1 A. Model No. C V 980 S B. Spec. No. Command Engine V ersion Code S = Electric Start C. Serial No. Y ear Manufactured Code Code Y ear 37 2007 38 2008 39 2009 CV940-0001 CV960-0001 CV980- 0001 CV1000-0001 Complete Spec Number (Incorporating Model No. with V ariation No. of Basic Spec.) Factory Code 37058[...]

  • Seite 8

    1.4 Section 1 Safety and General Information SAE 10W30 A P I S E R V I C E S J 5W-20, 5W -30 RECOMMENDED SAE VISCOSITY GRADES 10W-30 Kohler 10W-30 °F -20 0 20 32 40 60 80 100 °C -30 -20 -10 0 10 20 30 40 TEMPERA TURE RANGE EXPECTED BEFORE NEXT OIL CHANGE Use of s ynthetic oil having 5W-20 or 5W-30 rating is acceptable, up to 4°C (40°F) * Synthe[...]

  • Seite 9

    1.5 Section 1 Safety and General Information 1 ¹Perform these maintenance procedur es more frequently under extr emely dusty, dirty conditions. 2 Have a Kohler Engine Service Dealer perform this service. Periodic Maintenance Instructions W ARNING: Accidental Starts! Disabling engine. Accidental starting can cause severe injury or death. Before wor[...]

  • Seite 10

    1.6 Section 1 Safety and General Information Dimensions in millimeters. Inch equivalents shown in [ ]. 41 1.64 [16.206] 14.7 [.58] 130.00 [5.1 18] 152.36 [5.999] 232.22 [9.143] 344.54 [13.565] 89.80 [3.536] 62.70 [2.468] 325.30 [12.807] 577.09 [22.720] 5.9 [.23] 135.00 [5.315] 484.33 [19.068] 365.50 [14.390] 90.22 [3.552] 30.00 [1.181] 45.00 [1.772[...]

  • Seite 11

    1.7 Section 1 Safety and General Information 1 ¹V alues are in Metric units. V alues in parentheses are English equivalents. Lubricate threads with engine oil prior to assembly . *HQHUDO6SHFL¿FDWLRQVï P ower (@3600 RPM, exceeds Society of Automotive Engineers-Small Engine T est Code J1940.) CV940...............................................[...]

  • Seite 12

    1.8 Section 1 Safety and General Information Carburetor , Intake Manifold, and Air Cleaner ȱȱȱȱ  T orque Using Sequence in T wo Stages ................................................. ęȱȱŗŜǯşȱȉȱǻŗśŖȱ?[...]

  • Seite 13

    1.9 Section 1 Safety and General Information 1 Ğȱȱȱȱǻȱȱ Ǽ Running Clearance - New ...................................................................... 0.040/0.167 mm (0.0015/0.0065 in.) Flywheel End Main Bearing Journal O.D. - New ...............[...]

  • Seite 14

    1.10 Section 1 Safety and General Information Grass Screen Hex Stud T orque ............................................................................................ 9.9 N·m (88 in. lb.) Mounting Screw T orque ................................................................................. 9.9 N·m (88 in. lb.) Governor ?[...]

  • Seite 15

    1.1 1 Section 1 Safety and General Information 1 Ŷȱ ȱŗŗȱȱǻŖǯŚřřȱǯǼȱȱȱĴȱȱȱȱȱȱȱȱȱȱȱǯ T op Compression Ring-to-Groove Side [...]

  • Seite 16

    1.12 Section 1 Safety and General Information Tightening T orque: 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.[...]

  • Seite 17

    1.13 Section 1 Safety and General Information 1 English Fastener T orque Recommendations for Standard Applications Grade 2 or 5 Fasteners Into Aluminum 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) 1[...]

  • Seite 18

    1.14[...]

  • Seite 19

    2.1 Section 2 T ools & Aids 2 Section 2 T ools & Aids T ools Description Source/Part No. Ğȱ¢ȱ ȱȱĞȱ¢ ǯ ȱ ȱȬŞŘŚŖś Ğȱȱ?[...]

  • Seite 20

    2.2 Section 2 T ools & Aids T ools (Continued) Description Source/Part No. ¢ȱ ȱĞȱ   ȱȱȱȱ¢ȱĞǯ ȱŘśȱŝŜŗȱřŞȬ ȱ¢[...]

  • Seite 21

    2.3 Section 2 T ools & Aids 2 Aids Description Source/Part No. Ğȱ ȱǻ ȱŜŗřǼ ȱŘśȱřśŝȱŗŚȬ ȱ ȱǻȦ ȱŜŜŗǼ ȱŘśȱřśŝȱŗŗȬ?[...]

  • Seite 22

    2.4 Section 2 T ools & Aids Special T ools Y ou Can Make Flywheel Holding T ool  ȱĚ¢ȱȱȱȱȱȱȱȱȱȱ ȱĚ¢ȱȱȱȱȱȱȱŘȬŗǰȱ?[...]

  • Seite 23

    3.1 3 Section 3 T roubleshooting T roubleshooting Guide When troubles occur , be sure to check the simple ȱǰȱȱęǰȱ¢ȱȱȱȱȱȱ considered. For example, a starting problem could be ȱ¢ȱȱ¢ȱ[...]

  • Seite 24

    3.2 Section 3 T roubleshooting Engine Overheats ȱ ŗǯȱ ȱȦȱǰȱȱęǰȱȱȱ shrouds clogged. ȱ Řǯȱ ¡ȱȱǯ ȱ řǯȱ ȱȱȱ?[...]

  • Seite 25

    3.3 Section 3 T roubleshooting 3 ȱȱȱȱȱȱȱȱȱȱ the engine is reassembled and placed into operation. ȱȱȱȱȱȱ[...]

  • Seite 26

    3.4 Section 3 T roubleshooting Leakdown T est Results ȱȱȱȱ ....................................................... ȱȱ¢ȱǯ ȱȱȱ¡?[...]

  • Seite 27

    4.1 4 Section 4 Air Cleaner and Air Intake System Paper Element Inner Element Inlet Screen Air Cleaners General These engines utilize a Heavy-Duty style air cleaner as shown in Figure 4-1, consisting of a cylindrical ǰȱĴȱȱȱȱȱȱ man[...]

  • Seite 28

    4.2 Section 4 Air Cleaner and Air Intake System Ejector Area Cylinder Shroud 4. Do not w ash the paper element and inner element or use compressed air , this will damage ȱǯȱȱ¢ ǰȱȱȱȱ elements with new genuine Kohler elements as required[...]

  • Seite 29

    5.1 5 Section 5 Fuel System and Governor Description This section covers the carbureted fuel system used on these engines. The governor system is cov ered at the end of this section. W ARNING: Explosive Fuel! ȱȱ¡¢ȱĚȱȱȱȱȱ?[...]

  • Seite 30

    5.2 Section 5 Fuel System and Governor Fuel System T ests When the engine starts hard, or turns over but will not start, it is possible that the problem is in the fuel system.  ȱęȱȱȱȱȱ¢ȱȱȱȱǰȱȱ?[...]

  • Seite 31

    5.3 Section 5 Fuel System and Governor 5 Self-Relieving Choke Fuel Shut-Off Solenoid Bowl Drain Screw Slow Jets Bowl V ent Low Idle Fuel Adjustments (With Limiters) Fuel Pump General These engines use either a pulse style fuel pump, or optional remote-mounted electric fuel pump ¢ ǯȱȱȱśȬŗȱ?[...]

  • Seite 32

    5.4 Section 5 Fuel System and Governor T roubleshooting Checklist When the engine starts hard, runs roughly or stalls at low idle speed, check the following areas before adjusting or disassembling the carburetor . ȱ Ȋȱ ȱȱȱȱȱȱęȱȱǰȱ?[...]

  • Seite 33

    5.5 Section 5 Fuel System and Governor 5 Fuel Shut-Off Solenoid High Altitude Operation ȱȱȱȱȱȱȱŗśŖŖȱȱ ǻśŖŖŖȱĞǯǼȱȱǰȱȱȱ¡ȱȱȱ?[...]

  • Seite 34

    5.6 Section 5 Fuel System and Governor Lean Rich Adjust to Midpoint Lean Rich Adjust to Midpoint Left Side Right Side Carburetor Adjustments Adjustment DZȱ ȱȱȱȱȱ¢ȱ Ğȱȱȱȱ[...]

  • Seite 35

    5.7 Section 5 Fuel System and Governor 5 Governed Idle System  ȱ ȱȱȱ¢ȱȱȱȱȱȱ desired idle speed regardless of ambient conditions (temperature, parasitic load, etc.) that may change. ȱȱ?[...]

  • Seite 36

    5.8 Section 5 Fuel System and Governor Figure 5-1 1. Setting High Speed RPM (Air Cleaner Removed for Clarity). Carburetor Servicing The following section covers the disassembly , v arious servicing procedures and reassembly of the carburetor . For each procedure carefully inspect all components and replace those that are worn or damaged. The follow[...]

  • Seite 37

    5.9 Section 5 Fuel System and Governor 5 Figure 5-14. Float and Inlet Needle Details. ȱ Ŝǯȱ ȱȱĚȱȱȱȱȱȱȱ seat and carburetor body . Install the new pivot ȱȱȱĚȱ[...]

  • Seite 38

    5.10 Section 5 Fuel System and Governor Figure 5-18. Fuel Bowl Removed From Carburetor . DZȱ ȱ¢ȱȱȱȱȱ is not necessary unless the Fuel Solenoid Kit, or Fuel Bowl Kit (obtained separately), will also be installed. ȱȱ Řǯȱ ?[...]

  • Seite 39

    5.1 1 Section 5 Fuel System and Governor 5 śǯȱ ȱȱȱȱǻǼȱȱȱ and spring from the carburetor . Discard the parts. DZȱ ȱȱȱȱȱ?[...]

  • Seite 40

    5.12 Section 5 Fuel System and Governor Figure 5-26. Installing Float Assembly . ŗŚǯȱ ȱȱȱ¢ȱȱȱĚȱ¢ȱ hangs vertically and rests lightly against the fuel inlet needle. The inlet needle should be fully seated but the center pin of the [...]

  • Seite 41

    5.13 Section 5 Fuel System and Governor 5 śǯȱ ȱȱȱ¡ȱǻ¢ȬǼȱȱȱȱ ȱȱĞȱȱȱȱȱȱ lever from the carburetor housing. S[...]

  • Seite 42

    5.14 Section 5 Fuel System and Governor ȱŗŘǯȱ ȬȱǻȱȱȬȱǼ 13. Drain Screw 14. Bowl Screw (4) ȱŗśǯȱ ȱ ȱŗŜǯȱ ȱ  17. Float 18. Pin 19. Screw ȱŘŖǯȱ ȱ ȱŘŗǯȱ [...]

  • Seite 43

    5.15 Section 5 Fuel System and Governor 5 Governor Lever Governor Cross Shaft Governed Idle Spring Linkage Governor Spring Governor General The governor is designed to hold the engine speed constant under changing load conditions. Most ȱȱȱȱȱȱ[...]

  • Seite 44

    5.16 Section 5 Fuel System and Governor Hold Lever in "Full Throttle" Position High Speed (RPM) Adjustment Screw 3. Stop when the desired RPM speed is obtained. Figure 5-37. Adjusting High Speed RPM (Air Cleaner Removed for Clarity).[...]

  • Seite 45

    6.1 6 Section 6 Lubrication System SAE 10W30 A P I S E R V I C E S J 5W-20, 5W -30 RECOMMENDED SAE VISCOSITY GRADES 10W-30 Kohler 10W-30 °F -20 0 20 32 40 60 80 100 °C -30 -20 -10 0 10 20 30 40 TEMPERA TURE RANGE EXPECTED BEFORE NEXT OIL CHANGE Use of s ynthetic oil having 5W-20 or 5W-30 rating is acceptable, up to 4°C (40°F) * Synthetic oils w[...]

  • Seite 46

    6.2 Section 6 Lubrication System Oil Drain Plug Drain Plug Operating Range Checking Oil Level The importance of checking and maintaining the proper oil level in the crankcase cannot be overemphasized. Check oil BEFORE EA CH USE as DZ ȱ ŗǯȱ ȱȱȱȱȱ[...]

  • Seite 47

    6.3 Section 6 Lubrication System 6 ȱ řǯȱ ȱȱȱȱȱȱȱ 21.4 N·m ǻŗśǯŝȱĞǯȱǯǼ . ȱ Śǯȱ ȱȱǰȱȱȱȱȱȱȱ ¢[...]

  • Seite 48

    6.4 Section 6 Lubrication System Pressure Switch Service Oil Cooler ȱȱȱȱȱȱȱȱ ȱȱȱǯȱŘȱȱ¢ȱǰȱ [...]

  • Seite 49

    6.5 Section 6 Lubrication System 6 Installation ȱȱ¢Ȝȱȱȱȱȱȱȱ ȱȱȱǯȱȱȱŜȬŗŘǯȱȱȱȱ [...]

  • Seite 50

    6.6[...]

  • Seite 51

    7.1 7 Section 7 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 ȱ Ȋȱ Ĵ¢ȱȱȱ¢ • Electric Starter ȱ Ȋȱ ?[...]

  • Seite 52

    7.2 Section 7 Electrical System and Components DZ ȱ  ȱȱȱȱȱȱȱȱ normal conditions will have light tan or gray colored deposits. If the center electrode is not worn, a plug ȱȱ?[...]

  • Seite 53

    7.3 Section 7 Electrical System and Components 7 DC V oltmeter Battery Battery General  ȱŗŘȬ ȱĴ¢ȱȱŚŖŖȱȱȱȱǻǼȱȱ generally recommended for starting in all conditions.  ȱȱ¢ȱĴ?[...]

  • Seite 54

    7.4 Section 7 Electrical System and Components Molex Plug (Some Models) ȱȱȱěȱ¢ȱȱȱ¢ȱȱȱǯȱ ȱ¢ȱȱȱȱ?[...]

  • Seite 55

    7.5 Section 7 Electrical System and Components 7 Kill Switch or ‘ ‘Off ’ ’ Position of Key Switch Ignition Modules Spark Plug Magnet Flywheel (0.28/0.33 mm) 0.01 1/0.013 in. Air Gap L1 D1 C1 T1 P S Spark Plug L2 SCS Figure 7-5. Capacitive Discharge (CD) Ignition Module Schematic. Figure 7-4. Capacitive Discharge Fixed Timing Ignition System[...]

  • Seite 56

    7.6 Section 7 Electrical System and Components ǯȱ ȱȱȱȱǰȱȱȱ¢ȱ ȱȱȱȱǯȱȱȱ¢ȱǰȱ wires, connections, safety interlocks, [...]

  • Seite 57

    7.7 Section 7 Electrical System and Components 7 T roubleshooting DSAI Ignition Systems ȱȱȱ¢ȱȱȱȱȱȱ ȱȱȱȱȱȱǯȱȱ?[...]

  • Seite 58

    7.8 Section 7 Electrical System and Components ȱ Řǯȱ ȱȱȱ ǰȱȱȱȱ ȱśśŖȬŜŖŖȱǰȱȱȱǻǼȱȱǯ ȱ řǯȱ ȱ?[...]

  • Seite 59

    7.9 Section 7 Electrical System and Components 7 Battery Charging System General Most engines are equipped with a 15, 20, or 25 amp ȱȱ¢ǯȱȱȱŝȬşȱȱŝȬŗřǯȱ DZȱ ȱȱ?[...]

  • Seite 60

    7.10 Section 7 Electrical System and Components 15/20/25 Amp Regulated Charging System Figure 7-1 1. Wiring Diagram - 15/20/25 Amp Regulated Battery Charging System with CD Ignition and Four Pin Connector .[...]

  • Seite 61

    7.1 1 Section 7 Electrical System and Components 7 Figure 7-12. Wiring Diagram - 15/20/25 Amp Regulated Battery Charging System with DSAI Ignition and Four Pin Connector .[...]

  • Seite 62

    7.12 Section 7 Electrical System and Components Figure 7-13. Wiring Diagram - 15/20/25 Amp Regulated Battery Charging System with DSAI Ignition and Five Pin Connector .[...]

  • Seite 63

    7.13 Section 7 Electrical System and Components 7 Stator ȱȱȱȱȱȱȱȱ ȱĚ¢ǯȱȱȱȱȱȱŞȱȬȱ ȃ?[...]

  • Seite 64

    7.14 Section 7 Electrical System and Components śǯȱ ȱȱȱȱȱȱ ȱȦȱ ȱȱȱǯȱ ȱȱȱȱǯȱ ȱȁȁ?[...]

  • Seite 65

    7.15 Section 7 Electrical System and Components 7 T roubleshooting Guide 15/20/25 Amp Battery Charging Systems ȱȱȱȱȱȱĴ¢ȱȱȱȱĴ¢ȱȱȱȱȱȱ?[...]

  • Seite 66

    7.16 Section 7 Electrical System and Components DC V oltmeter 5HFWL¿HU5HJXODWRU Flywheel Stator Ammeter Battery (-) (+) Figure 7-20. Connections for T esting Charging System. Electric Starting Motors ȱȱȱȱĞȱȱȱ?[...]

  • Seite 67

    7.17 Section 7 Electrical System and Components 7 T orx Head Screws 7 URXEOHVKRRWLQJ*XLGH±6WDUWLQJ'LI¿FXOWLHV Delco-Remy Starters Figure 7-21. Delco-Remy Starter . Starter Disassembly ȱ ŗǯȱ ȱȱ¡ȱȱȱȱȱ ȱ ǻ?[...]

  • Seite 68

    7.18 Section 7 Electrical System and Components Figure 7-23. Solenoid Removed from Starter . Figure 7-24. Removing Plunger . ȱ Śǯȱ ȱȱ ȱȱǻǼȱǯȱȱȱ ŝȬŘśǯ Figure 7-25. Removing Thru Bolts. ȱ śǯȱ ȱ?[...]

  • Seite 69

    7.19 Section 7 Electrical System and Components 7 Drive End Cap Screw Plunger Spring Lever Plate Plug Solenoid Frame & Field Brush Holder Nut Commutator End Plate Screw Bolt Collar Retaining Ring Stop Drive Armature W asher T ube ȱ Şǯȱ  ȱȱȱȱ ȱȱȱ[...]

  • Seite 70

    7.20 Section 7 Electrical System and Components Wear Limit Length 7.6 mm (0.300 in.) Mica Insulation Commutator O.D. Inspection Drive Pinion ȱȱȱȱȱDZ ǯȱ ȱȱȱȱȱ?[...]

  • Seite 71

    7.21 Section 7 Electrical System and Components 7 Brush Replacement ȱȱȱȱȱȱȱȱȱǻŚǼǯȱȱ ȱȱȱȱȱȱǰȱȱ?[...]

  • Seite 72

    7.22 Section 7 Electrical System and Components řǯȱ ȱȱěȱȱǻǼȱ ȱȱȱ ȱȃěȄȱȱȱ ȱȱȱȦ  ǯȱ?[...]

  • Seite 73

    7.23 Section 7 Electrical System and Components 7 Figure 7-43. Installing Thrust W asher . ȱ ŗŖǯȱ ȱ¢ȱȱ  ȱȱȦ ȱȱ ¢DZ ǯȱ ȱȱ?[...]

  • Seite 74

    7.24 Section 7 Electrical System and Components Extension. ǯȱ ȱȱȱ¢ȱ¢ȱȱȱ end housing, and carefully place the tool ǻȱ¡Ǽȱȱȱȱ ?[...]

  • Seite 75

    7.25 Section 7 Electrical System and Components 7 VOM Leads 12 volt T est Leads Momentary Connection Only Solenoid T est Procedure Solenoid Shift Style Starters ȱȱȱȱȱȱȱ ȱȱ?[...]

  • Seite 76

    7.26 Section 7 Electrical System and Components T est 4. Solenoid Hold-In Coil/Contact Continuity T est. ȱȱȱȱȱȱȱȱ¡Řȱǰȱȱ connect the two ohmmeter leads to the tw o large post ǯȱ ?[...]

  • Seite 77

    8.1 8 Section 8 Disassembly W ARNING: Accidental Starts! Disabling engine. Accidental starting can cause severe injury or death. Before working on the engine or equipment, ȱȱȱȱDZȱŗǼȱȱȱȱȱ?[...]

  • Seite 78

    8.2 Section 8 Disassembly Cylinder Shroud Shut Off Fuel Supply Drain Oil from Crankcase and Remove Oil Filter ȱ ŗǯȱ ȱȱȱęȱȱȱǯȱȱȱ ȱȱȱę ǯȱȱ[...]

  • Seite 79

    8.3 Section 8 Disassembly 8 3. Remov e the lower mounting screw and pull the ȱęȱȱȱȱȱǯ Figure 8-7. Removing Oil Fill T ube. Remove Electric Starter Motor 1. Disconnect the leads from the starter . ȱ Řǯȱ ȱȱ ȱ¡ȱĚ[...]

  • Seite 80

    8.4 Section 8 Disassembly Remove Fuel Pump W ARNING: Explosive Fuel! ȱȱ¡¢ȱĚȱȱȱȱȱ¡ȱ ȱǯȱȱȱ¢ȱȱ [...]

  • Seite 81

    8.5 Section 8 Disassembly 8 Figure 8-15. Removing Control Bracket. ȱ Ŝǯȱ ȱȱ¡ȱĚȱȱȱȱȱ ȱ ȱȱȱĞǯȱȱȱŞȬŗŜǯ Figure 8-16. Removing Governor[...]

  • Seite 82

    8.6 Section 8 Disassembly NOTE: New clamps are recommended any time disassembly is performed, or if clamps have been loosened (expanded) sev eral times. )LJXUH5HPRYLQJ9 DOOH%DIÀHV 2. Remov e the four screws securing each of the ȱ¢ȱĝȱȱǯȱ?[...]

  • Seite 83

    8.7 Section 8 Disassembly 8 Figure 8-24. Removing Oil Filter Housing.  ȱȱȱ¢ȱȱȱȱęȱȱ assembly requires individual servicing. ȱ ǯȱ ȱȱȱȱȱ[...]

  • Seite 84

    8.8 Section 8 Disassembly Remove Grass Screen and Cooling Fan ȱ ŗǯȱ ȱȱǰȱĴȱ ǰȱȱ¡ȱ ȱȱȱȱǰȱěǰȱȱ ?[...]

  • Seite 85

    8.9 Section 8 Disassembly 8 Wiring Harness Molded Clips 2. Remov e the mounting screws securing the ęȬȱȱȱȱȱ assembly . Note the location of the ground lead. ȱȱęȬȱȱ[...]

  • Seite 86

    8.10 Section 8 Disassembly Remove V alve Covers 1. Remov e the screw and grommet securing each v alve cover . 2. Remov e the valve cov er and gasket from each cylinder head. Note the locations of individual  ȱȱȱ¢ȱȱěǯȱȱȱŞȬřŞǯ Figu[...]

  • Seite 87

    8.1 1 Section 8 Disassembly 8 Figure 8-42. Removing Hydraulic Lifters. Figure 8-43. Match Numbers on Cylinder Barrel and Heads. Disassemble Cylinder Heads 1. Remov e the two adjusters, rocker arm pivots, and rocker arms from the cylinder head. Remove the pivot studs and guide plate as required. See ȱŞȬŚŚǯ Figure 8-44. Removi[...]

  • Seite 88

    8.12 Section 8 Disassembly Figure 8-47. V alve Stem Seals. NOTE: These engines use v alve stem seals on the intake and exhaust v alves. Use a new seal whenever v alves are remov ed, or if the seal is deteriorated in any w ay . Never reuse an old seal. 4. Repeat the abov e procedure for the other cylinder head. Do not interchange parts from one cyli[...]

  • Seite 89

    8.13 Section 8 Disassembly 8 Figure 8-52. Removing Oil Pan. Oil Pump Assembly The oil pump is mounted to the inside of the oil pan. If service is required, refer to the service procedures ȱȁȁȱȱ ¢ȂȂ ȱȱȱşǯ Remove Camshaft ȱ ŗǯȱ ȱ[...]

  • Seite 90

    8.14 Section 8 Disassembly 2. Carefully remov e the connecting rod and piston ¢ȱȱȱ¢ȱǯȱȱȱŞȬśŜǯ Figure 8-56. Removing Piston/Connecting Rod Assemblies. 3. Repeat the abov e procedures for the other connecting rod and piston assembly . [...]

  • Seite 91

    8.15 Section 8 Disassembly 8 Remove Lifter Feed Chamber Cover and Gaskets ȱ ŗǯȱ ȱȱȱȱȱȱĞȱȱ chamber cover , and gaskets. Carefully separate ȱȱȱȱǯ[...]

  • Seite 92

    8.16[...]

  • Seite 93

    9 9.1 Section 9 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 cov ered in sections of their own: Air Cleaner , Section 4 Carburetor & External Gov ernor , Section 5 Ignition, Charging &[...]

  • Seite 94

    Section 9 Inspection and Reconditioning 9.2 45 ° High Point from Fillet Intersections This Fillet Area Must Be Completely Smooth Minimum The Fillet Must Blend Smoothly with the Bearing Journal Surface NOTE: If the crankpin is reground, visually check to ȱȱȱęȱȱ?[...]

  • Seite 95

    Section 9 Inspection and Reconditioning 9 9.3 1 1 mm (0.433 in.) Measure 1 1 mm above the Bottom of Piston Skirt at Right Angles to Piston Pin accomplished at a drill speed of about 250 RPM and ŜŖȱȱȱǯȱ Ğȱȱȱȱȱ[...]

  • Seite 96

    Section 9 Inspection and Reconditioning 9.4 Feeler Gauge 2. Use an inside micrometer , telescoping gauge, or bore gauge and measure the cylinder bore. T ake the measurement approximately 63.5 mm (2.5 in.) below the top of the bore and perpendicular to the piston pin. ȱ řǯȱ ȬȬȱȱ?[...]

  • Seite 97

    Section 9 Inspection and Reconditioning 9 9.5 EXHAUST V AL VE INT AKE V AL VE A B C D D F E G H F E G H INT EXH Figure 9-6. V alve Details. ȱȱȱȱȱȱȱ¢ȱȱ fuel consumption may be symptoms of faulty v alves. ?[...]

  • Seite 98

    Section 9 Inspection and Reconditioning 9.6 Normal: ȱȱĞȱȱȱȱȱȱ ȱ can be reconditioned and reused if the face and margin are in good shape. If a v alve is worn to where the margin is less than 1/32" do not reuse it. The v alve shown w as [...]

  • Seite 99

    Section 9 Inspection and Reconditioning 9 9.7 Excessive Combustion T emperatures: The white deposits seen here indicate very high combustion temperatures, usually due to a lean fuel mixture. Gum: Gum deposits usually result from using stale gasoline. Gum is a prev alent cause of valve sticking. The cure is to ream the v alve guides and clean or rep[...]

  • Seite 100

    Section 9 Inspection and Reconditioning 9.8 V alve Seat Cutter Pilot V alve Guides ȱȱ ȱȱȱȱ¢ ȱęǰȱȱȱ not guide the v alve in a straight line. This may result in burnt v alve faces or seats, loss of compression, an[...]

  • Seite 101

    Section 9 Inspection and Reconditioning 9 9.9 Overheated or Deteriorated Oil Scored Piston and Rings Abrasive Scratched Rings Stuck, Broken Rings Ring failure is usually indicated by excessive oil consumption and blue exhaust smoke. When rings fail, oil is allowed to enter the combustion chamber ȱȱȱȱ[...]

  • Seite 102

    Section 9 Inspection and Reconditioning 9.10 Replacement pistons are av ailable 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 av ailable separately for STD, 0.25 mm (0.010 in.), and 0.50 mm (0.020 in.) oversize pist[...]

  • Seite 103

    Section 9 Inspection and Reconditioning 9 9.1 1 Figure 9-12. Piston Ring Installation. ȱ ŗǯȱ ȱȱȱǻĴȱǼDZȱȱȱ expander and then the rails. Make sure the ends of the expander are not overlapped. 2. Middle Compression Ring (Center Groov e):[...]

  • Seite 104

    Section 9 Inspection and Reconditioning 9.12 Oil Pan Assembly Inspection Inspect the oil seal in the oil pan and remove it if it is worn or damaged. Refer to ‘‘Install Oil P an Oil Seal’’ in Section 10 for new oil seal installation. Inspect the main bearing surface for wear or damage ǻȱȱȱŗǰȱ?[...]

  • Seite 105

    Section 9 Inspection and Reconditioning 9 9.13 O-Ring 3 2 1 4 4. Install the O-Ring in the groove of the oil pump housing. Use a small quantity of grease to hold it in place. See Figure 9-16. Figure 9-16. O-Ring Installed in Oil Pump Housing. 5. Lightly lubricate the I.D. of the inlet seal with oil and carefully insert the end of the pickup through[...]

  • Seite 106

    9.14[...]

  • Seite 107

    10.1 10 Section 10 Reassembly General NOTE: Make sure the engine is assembled using ȱęȱȱ ǰȱȱ ǰȱȱǯȱȱȱȱ ę[...]

  • Seite 108

    10.2 Section 10 Reassembly ȱ Řǯȱ ¢ȱȱȱȱȱȱȱȱȱȱ ȱȱȱȱȱǯ ȱ řǯȱ ȱȱȱȱȱ?[...]

  • Seite 109

    10.3 Section 10 Reassembly 10 Oil Seal Seal depth 1.5 - 2.0 mm (0.059 - 0.078 in) Crankcase Surface 12.66 mm (0.498 in.) Crankcase Surface Governor Gear Shaft Figure 10-6. Installed Main Bearing. Install Governor Shafts, Seal, and Governor Gear ȱȱȱĞǰȱǰȱȦȱ?[...]

  • Seite 110

    10.4 Section 10 Reassembly Śǯȱ Ĵȱȱȱ¢ ȱȱȱȱĞȱȱȱ ȱȱȱȃȄȱȱǯȱȱȱ ȱȱǯȱȱ[...]

  • Seite 111

    10.5 Section 10 Reassembly 10 No. 1 Side No. 2 Side Install Connecting Rods with Pistons and Rings DZȱ ȱ¢ȱȱȱ ȱȱǯȱ ȱȱȱȱȱǰȱ?[...]

  • Seite 112

    10.6 Section 10 Reassembly Figure 10-20. T orquing Connecting Rod End Cap Screws. ȱ Ŝǯȱ ȱȱȱȱȱȱȱ ȱȱȱȱ¢ ǯ Install Camshaft ȱ ŗǯȱ ?[...]

  • Seite 113

    10.7 Section 10 Reassembly 10 Oil Seal 3 mm (0.1 18 in.) ȱ śǯȱ ȱȱȱ¢ȱȱȱȱȱ ȱȱ¢ ǯ Install Oil Pan Seal and Main Bearing Main Bearing ȱȱȱȱȱ?[...]

  • Seite 114

    10.8 Section 10 Reassembly O-Ring 10 8 1 14 3 5 12 7 9 11 6 4 2 13 Install Oil Pan Assembly ŗǯȱ ȱȱȱȱȱȱȱȱȱȱ ȱȱǰȱ¢ ǰȱȱȱȱ?[...]

  • Seite 115

    10.9 Section 10 Reassembly 10 Crankcase Filter Breather Hose Flange Nuts (4) Gasket Check Crankshaft End play ȱ ŗǯȱ ȱȱȱȱǰȱȱȱȱȱȱ ȱȱȱĞȱȱ¢ȱ?[...]

  • Seite 116

    10.10 Section 10 Reassembly 1 3 4 2 ȱ řǯȱ ȱȱȱ¡ȱĚȱǰȱȱȱ ȱȱȱȱȱȱŗŖȬřśȱȱ 5.7 N·m (51 in. lb.) ǯ Figure 10-35. Breather Assembly[...]

  • Seite 117

    10.1 1 Section 10 Reassembly 10 DZȱ ¢ȱĞȱȱ ¢ȱȱ ȱȱȱȱȱȱȱ ¢ ǯȱȱ¡ȱĞ?[...]

  • Seite 118

    10.12 Section 10 Reassembly Spacer W ashers 2 2 4 5 5 4 1 3 3 1 No. 1 No. 2 Figure 10-43. Installing V alves with V alve Spring Compressor . Install Cylinder Heads ȱ ŗǯȱ ȱȱȱȱȱȱȱȱȱȱ ȱȱȱ?[...]

  • Seite 119

    10.13 Section 10 Reassembly 10 ȱ Ŝǯȱ ȱȱȱȱȱȱȱȱȱȱ ¢ȱȱȱȱȱ¢ ǯȱȱȱȱ ȱȱ¢?[...]

  • Seite 120

    10.14 Section 10 Reassembly ȱ ȱDZ ȱ ȱ ǯȱ ȱȱȱȱȱȱȱȱ ȱ ȱǯ ȱ ȱ ǯȱ ¢ ¢ȱȱĞȱȱȱȱ?[...]

  • Seite 121

    10.15 Section 10 Reassembly 10 Figure 10-53. Establishing the "0" Lash Point. Śǯȱ ȱȱȱȱĴȱȱȱȱǰȱ ȱȱǻǼȱȱȱȱ four (4) complete re[...]

  • Seite 122

    10.16 Section 10 Reassembly Spring Install Spark Plugs ȱ ŗǯȱ ȱȱ ® ȱŗŖȱǻȱ Ǽȱ ȱǯ ȱ Řǯȱ ȱȱȱȱ 0.76 mm (0.030 in.) ǯ ȱ řǯȱ ȱȱ[...]

  • Seite 123

    10.17 Section 10 Reassembly 10 O-Rings Around Dowel Pins Figure 10-62. Installing Nipple into Cup and Oil Filter Housing. Figure 10-63. T orquing Nipple into Housing. Installation ȱ ŗǯȱ ȱȱȱȱȱȱȱȱȱ ȱ?[...]

  • Seite 124

    10.18 Section 10 Reassembly 1 2 Cylinder 1 Cylinder 2 3 4 Řǯȱ ȱȱȱȱȱȱ¢ȱǯȱ ȱȱȱȱȱȱȱȱ ?[...]

  • Seite 125

    10.19 Section 10 Reassembly 10 Figure 10-71. Installing Stator . śǯȱ ȱȱȱȱȱȱȱȱȱƸȱ ȱȱȱȱȱȱȱȱȱ ȱ[...]

  • Seite 126

    10.20 Section 10 Reassembly Figure 10-76. Clean and Dry Flywheel Hub. Figure 10-77. Installed Flywheel Key . DZȱ ȱȱȱĚ¢ȱ¢ȱȱȱ ¢ȱȱȱ¢ ¢ ǯȱȱĚ¢ȱȱ [...]

  • Seite 127

    10.21 Section 10 Reassembly 10 śǯȱ ȱȱ 0.30 mm (0.012 in.) ȱĚȱȱȱ ȱȱȱȱȱȱǯȱ ȱȱŗŖȬŞŖǯȱȱȱȱ?[...]

  • Seite 128

    10.22 Section 10 Reassembly Install Oil Cooler ŗǯȱ ȱȱȱȱȱȱ ȱȱȱ ęȱȱȱȱȱ ǯȱȱȱȱ [...]

  • Seite 129

    10.23 Section 10 Reassembly 10 ȱ řǯȱ ȱȱȱȱȱǯȱȱȱ ŗŖȬŞŞǯ Figure 10-88. Connecting Leads to Starting Motor . ,QVWDOO9 DOOH%DIÀHV ȱ ŗǯȱ ȱȱȱ ¢ȱĝ?[...]

  • Seite 130

    10.24 Section 10 Reassembly 1, 5 4 3 2 Mounting Screws Install Control Bracket and Air Cleaner Assembly ȱ ŗǯȱ  ȱȱȱȱ¢ȱȱ ȱȱȱȱǰȱ?[...]

  • Seite 131

    10.25 Section 10 Reassembly 10 Fuel Pump Outlet Hose Pulse Hose Inlet Hose Figure 10-96. Installing Choke Link and Push-On Nut. Install Throttle and Choke Linkages ȱȱȱĴȦȱȱȱȱ ?[...]

  • Seite 132

    10.26 Section 10 Reassembly Oil Pan Adjusting Governor ȱ ŗǯȱ  ȱȱȱȱȱȱȱȱ ȱȱȱ¢ȱȱȱȱȱȱ [...]

  • Seite 133

    10.27 Section 10 Reassembly 10 Oil Fill T ube Lift Bracket Lower Mounting Screw Cylinder Shrouds Mounting Screws ȱ Řǯȱ ȱȱȱȱȱȱȱȱ¢ ™ ǯ Install Blower Housing and Cylinder Shrouds ŗǯȱ [...]

  • Seite 134

    10.28 Section 10 Reassembly Install Oil Filter and Add Oil to Crankcase ȱ ŗǯȱ ȱȱȱȱǯȱȱȱŗŖȬŗŖşǯȱ  ȱȱȱȱ ŘŗǯŚȱȉȱǻŗśǯŝȱĞǯȱǯǼ ǯ DZȱ [...]

  • Seite 135

    10.29 Section 10 Reassembly 10 T esting the Engine ȱȱȱȱȱȱȱȱȱȱ ȱȱȱȱȱȱȱȱȱȱ[...]

  • Seite 136

    10.30[...]

  • Seite 137

    [...]

  • Seite 138

    LITHO IN U.S.A. FORM NO.: TP-2581 ISSUED: 1/09 REVISED: ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044 FOR SALES AND SER VICE INFORMA TION IN U.S. AND CANADA, CALL 1-800-544-2444 KohlerEngines.com[...]