Kohler Command PRO CH742 Manual de usuario

CH682, CH732, CH742, CH752

Service Manual

2 Safety

3 Maintenance

5 Speciﬁcations

13 Tools and Aids

16 Troubleshooting

20 Air Cleaner/Intake

21 Fuel System

27 Governor System

29 Lubrication System

31 Electrical System

38 Starter System

42 Disassembly/Inspection and Service

56 Reassembly

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

instruction of equipment that this engine powers.

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

124 690 34 Rev. D KohlerEngines.com

Safety

2 24 690 34 Rev. DKohlerEngines.com

SAFETY PRECAUTIONS

WARNING: A hazard that could result in death, serious injury, or substantial property damage.

CAUTION: A hazard that could result in minor personal injury or property damage.

NOTE: is used to notify people of important installation, operation, or maintenance information.

WARNING

Explosive Fuel can cause

ﬁres and severe burns.

Do not ﬁll fuel tank while

engine is hot or running.

Gasoline is extremely ﬂammable

and its vapors can explode if

ignited. Store gasoline only in

approved containers, in well

ventilated, unoccupied buildings,

away from sparks or ﬂames.

Spilled fuel could ignite if it comes

in contact with hot parts or sparks

from ignition. Never use gasoline

as a cleaning agent.

WARNING

Rotating Parts can cause

severe injury.

Stay away while engine

is in operation.

Keep hands, feet, hair, and

clothing away from all moving

parts to prevent injury. Never

operate engine with covers,

shrouds, or guards removed.

WARNING

Carbon Monoxide can

cause severe nausea,

fainting or death.

Avoid inhaling exhaust

fumes.

Engine exhaust gases contain

poisonous carbon monoxide.

Carbon monoxide is odorless,

colorless, and can cause death if

inhaled.

WARNING

Accidental Starts can

cause severe injury or

death.

Disconnect and ground

spark plug lead(s) before

servicing.

Before working on engine or

equipment, disable engine as

follows: 1) Disconnect spark plug

lead(s). 2) Disconnect negative (–)

battery cable from battery.

WARNING

Hot Parts can cause

severe burns.

Do not touch engine

while operating or just

after stopping.

Never operate engine with heat

shields or guards removed.

WARNING

Cleaning Solvents can

cause severe injury or

death.

Use only in well

ventilated areas away

from ignition sources.

Carburetor cleaners and solvents

are extremely ﬂammable. Follow

cleaner manufacturer’s warnings

and instructions on its proper and

safe use. Never use gasoline as a

cleaning agent.

CAUTION

Electrical Shock can

cause injury.

Do not touch wires while

engine is running.

CAUTION

Damaging Crankshaft

and Flywheel can cause

personal injury.

Using improper procedures can

lead to broken fragments. Broken

fragments could be thrown from

engine. Always observe and use

precautions and procedures when

installing ﬂywheel.

CAUTION

Failure to utilize or

reassemble debris

screen as designed could

result in debris screen

failure and serious

personal injury.

Maintenance

324 690 34 Rev. D KohlerEngines.com

MAINTENANCE INSTRUCTIONS

WARNING

Before working on engine or equipment, disable engine as

follows: 1) Disconnect spark plug lead(s). 2) Disconnect

negative (–) battery cable from battery.

Accidental Starts can cause severe injury or

death.

Disconnect and ground spark plug lead(s)

before servicing.

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 dealer.

MAINTENANCE SCHEDULE

Weekly

●Check air cleaner element. Air Cleaner/Intake

Every 100 Hours or Annually¹

●Change oil. Lubrication System

●Remove cooling shrouds and clean cooling areas. Air Cleaner/Intake

●Check oil cooler ﬁns, clean as necessary (if equipped). Lubrication System

Every 200 Hours

●Change oil ﬁlter. Lubrication System

●Replace fuel ﬁlter.

Every 250 Hours¹

●Replace air cleaner element and check inner element. Air Cleaner/Intake

Every 500 Hours¹

●Replace air cleaner inner element. Air Cleaner/Intake

●Replace spark plugs and set gap. Electrical System

Every 500 Hours2

●Have crankshaft spline lubricated.

1Perform these procedures more frequently under severe, dusty, dirty conditions.

2Have a Kohler authorized dealer perform this service.

REPAIRS/SERVICE PARTS

Kohler genuine service parts can be purchased from Kohler authorized dealers. To ﬁnd a local Kohler authorized

dealer visit KohlerEngines.com or call 1-800-544-2444 (U.S. and Canada).

Maintenance

4 24 690 34 Rev. DKohlerEngines.com

OIL RECOMMENDATIONS

We recommend use of Kohler oils for best performance.

Other high-quality detergent oils (including synthetic)

of API (American Petroleum Institute) service class SJ

or higher are acceptable. Select viscosity based on

air temperature at time of operation as shown in table

below.

FUEL RECOMMENDATIONS

WARNING

Explosive Fuel can cause ﬁres and severe

burns.

Do not ﬁll fuel tank while engine is hot or

running.

Gasoline is extremely ﬂammable and its vapors can

explode if ignited. Store gasoline only in approved

containers, in well ventilated, unoccupied buildings,

away from sparks or ﬂames. Spilled fuel could ignite

if it comes in contact with hot parts or sparks from

ignition. Never use gasoline as a cleaning agent.

NOTE: E15, E20 and E85 are NOT approved and

should NOT be used; effects of old, stale or

contaminated fuel are not warrantable.

Fuel must meet these requirements:

●Clean, fresh, unleaded gasoline.

●Octane rating of 87 (R+M)/2 or higher.

●Research Octane Number (RON) 90 octane minimum.

●Gasoline up to 10% ethyl alcohol, 90% unleaded is

acceptable.

●Methyl Tertiary Butyl Ether (MTBE) and unleaded

gasoline blend (max 15% MTBE by volume) are

approved.

●Do not add oil to gasoline.

●Do not overﬁll fuel tank.

●Do not use gasoline older than 30 days.

STORAGE

If engine will be out of service for 2 months or more

follow procedure below.

1. Add Kohler PRO Series fuel treatment or equivalent

to fuel tank. Run engine 2-3 minutes to get stabilized

fuel into fuel system (failures due to untreated fuel

are not warrantable).

2. Change oil while engine is still warm from operation.

Remove spark plug(s) and pour about 1 oz. of

engine oil into cylinder(s). Replace spark plug(s) and

crank engine slowly to distribute oil.

3. Disconnect negative (-) battery cable.

4. Store engine in a clean, dry place.

Speciﬁcations

524 690 34 Rev. D KohlerEngines.com

319.12

[12.564]

SPARK PLUG

REMOVAL

311.90

[12.280]

SPARK PLUG

BOOT REMOVAL

526.84 [20.742]

PRIMARYAIR FILTER

ELEMENT REMOVAL

414.52 [16.320]

SAFETYAIR FILTER

ELEMENT REMOVAL

VALVE

COVER

298.74

[11.761]

272.52

[10.729]

450.90

[17.752]

135.00

[5.315]

AIR FILTER

RAIN CAP

REMOVAL

92.98

[3.661]

FUEL PUMP

15.70 [.618]

OIL FILTER

REMOVAL

312.01 [12.284]

SPARK PLUG

BOOT REMOVAL

319.23 [12.568]

SPARK PLUG

REMOVAL 14.52 [.572]

SPARK PLUG

BOOT REMOVAL

10.09 [.397]

SPARK PLUG

BOOT

FUEL FILTER

FUEL PUMP

35.31 [1.390]

SPARK PLUG

REMOVAL

142.89

[5.626]

92.10

[3.626]

20°

MOUNTING

HOLE "A"

130.00 [5.118]

AIR FILTER

COVER

ASSEMBLY

REMOVAL

72.81 [2.867]

SPARK PLUG REMOVAL

52.02 [2.048]

SPARK PLUG BOOT REMOVAL

22.77 [.897]

SPARK PLUG BOOT

184.20

[7.252]

FLYWHEEL SIDE

CRANKSHAFT

20°

ENGINE MOUNTING SURFACE

4X Ø 10.3

MOUNTING HOLES (THRU)

ENGINE

SPARK

PLUG

370.68 [14.594]

42.25

[1.663]

115.88 [4.562]

30.00 [1.181]

32.00 [1.260]

EXHAUST PORT #2

67.50 [2.657]

MUFFLER MOUNTING

BOSSES OIL FILL

OIL DIPSTICK

113.08 [4.452]

95.50 [3.760]

Ø 36.50 [1.437]

622.41

[24.504]

5/8-18 UNF 2B [INCH]

38.10 [1.500]

155.58

[6.125]

152.08 [5.987]

OIL FILTER

5.50 [.217]

PILOT

FUEL PUMP

100.00

[3.937]

89.00

[3.504]

51.00

[2.008]

52.75

[2.077]

OIL FILTER

12.28

[.483]

REGULATOR

RECTIFIER

ENGINE MOUNTING SURFACE

OIL DRAIN PLUG

3/8 NPT [INCH]

OIL FILTER SIDE

MOUNTING

HOLE "A"

(C-2,2)

334.78

[13.180]

75.35

[2.966]

122.10

[4.807]

65.00 [2.559]

MUFFLER

MOUNTING

M8 X 1.25

4 STUDS

50.00 [1.969]

EXHAUST

PORT #1

MOUNTING

HOLES

SOLENOID

SHIFT

STARTER

PILOT Ø 177.80 [7.000]

OPTIONAL PILOT Ø 146.050 [5.750] ENGINE MOUNTING

SURFACE

7/16-14 UNC 2B [INCH]

21.0 [.827] Ø 196.85 [7.750] B.C.

283.58

[11.164]

MUFFLER

MOUNTING

308.17

[12.133]

50.00 [1.969]

EXHAUST

PORT #2

MOUNTING

HOLES

30°

OIL FILL LOCATION

LIFT STRAP

MOUNTING

HOLE "A"

PTO SIDE

3/8-16 UNC 2B [INCH]

21.0 [.827] Ø 165.1 [5.000] B.C.

7/16-14 UNC 2B [INCH]

21.0 [.827] Ø 196.85 [7.750] B.C.

OPTIONAL BOLT PATTERN

5/16-24 UNC 2B [INCH]

17.0 [.669] Ø 127.0 [5.000] B.C.

30°

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/1706+0)

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Engine Dimensions

Dimensions in millimeters.

Inch equivalents shown in [ ].

Speciﬁcations

6 24 690 34 Rev. DKohlerEngines.com

ENGINE IDENTIFICATION NUMBERS

Kohler engine identiﬁcation numbers (model, speciﬁcation and serial) should be referenced for efﬁcient repair,

ordering correct parts, and engine replacement.

Model. . . . . . . . . . . . . . . . . . . . . CH682

Command Engine

Horizontal Shaft

Numerical Designation

Speciﬁcation . . . . . . . . . . . . . . . CH682-0001

Serial . . . . . . . . . . . . . . . . . . . . . 4323500328

Year Manufactured Code Factory Code

Code Year

43 2013

44 2014

45 2015

GENERAL SPECIFICATIONS3,6 CH682 CH732 CH742 CH752

Bore 80 mm

(3.15 in.)

83 mm (3.27 in.)

Stroke 69 mm (2.72 in.)

Displacement 694 cc

(42.4 cu. in.)

747 cc (45.6 cu. in.)

Oil Capacity (reﬁll) 1.6-1.8 L (1.7-1.9 U.S. qt.)

Maximum Angle of Operation (@ full oil level)425°

TORQUE SPECIFICATIONS3,5 CH682 CH732 CH742 CH752

Blower Housing and Sheet Metal

M5 Fasteners 6.2 N·m (55 in. lb.) into new holes

4.0 N·m (35 in. lb.) into used holes

M6 Fasteners 10.7 N·m (95 in. lb.) into new holes

7.3 N·m (65 in. lb.) into used holes

Carburetor, Intake Manifold, and Air Cleaner

Intake Manifold Mounting Fastener (torque in 2

increments)

ﬁrst to 7.4 N·m (66 in. lb.)

ﬁnally to 9.9 N·m (88 in. lb.)

Adapter (for Heavy-Duty Air Cleaner) Mounting

Fastener 9.9 N·m (88 in. lb.)

Air Cleaner Nut (torque in 2 increments) ﬁrst to 7.3 N·m (65 in. lb.)

ﬁnally to 8.2 N·m (73 in. lb.)

Closure Plate

Fastener 24.4 N·m (216 in. lb.)

Connecting Rod

Cap Fastener (torque in increments) 13.6 N·m (120 in. lb.)

3 Values are in Metric units. Values in parentheses are English equivalents.

4Exceeding maximum angle of operation may cause engine damage from insufﬁcient lubrication.

5Lubricate threads with engine oil prior to assembly.

6Any and all horsepower (hp) references by Kohler are Certiﬁed Power Ratings and per SAE J1940 & J1995 hp

standards. Details on Certiﬁed Power Ratings can be found at KohlerEngines.com.

Speciﬁcations

724 690 34 Rev. D KohlerEngines.com

TORQUE SPECIFICATIONS3,5 CH682 CH732 CH742 CH752

Crankcase

Breather Cover Fastener 11.3 N·m (100 in. lb.) into new holes

7.3 N·m (65 in. lb.) into used holes

Oil Drain Plug 13.6 N·m (10 ft. lb.)

Cylinder Head

Fastener (torque in 2 increments)

Nut ﬁrst to 16.9 N·m (150 in. lb.)

ﬁnally to 35.5 N·m (315 in. lb.)

Bolt (torque in 2 increments) ﬁrst to 22.6 N·m (200 in. lb.)

ﬁnally to 41.8 N·m (370 in. lb.)

Rocker Arm Screw 18.1 N·m (160 in. lb.)

Flywheel

Fan Fastener 9.9 N·m (88 in. lb.)

Flywheel Retaining Screw 66.4 N·m (49 ft. lb.)

Fuel Pump-Pulse

Fastener 2.3 N·m (20 in. lb.)

Governor

Lever Nut 6.8 N·m (60 in. lb.)

Ignition

Spark Plug 27 N·m (20 ft. lb.)

Module Fastener 4.0-6.2 N·m (35-55 in. lb.)

Rectiﬁer-Regulator Fastener 1.4 N·m (12.6 in. lb.)

Mufﬂer

Retaining Nut 24.4 N·m (216 in. lb.)

Oil Cooler

Adapter Nipple 27 N·m (20 ft. lb.)

Oil Pump

Oil Pump Style A

Screw (torque in 2 increments) 10.7 N·m (95 in. lb.) into new hole

6.7 N·m (60 in. lb.) into used holes

Oil Pump Style B

Screw (no torque sequence) 9.0 N·m (80 in. lb.)

3 Values are in Metric units. Values in parentheses are English equivalents.

5Lubricate threads with engine oil prior to assembly.

Speciﬁcations

8 24 690 34 Rev. DKohlerEngines.com

TORQUE SPECIFICATIONS3,5 CH682 CH732 CH742 CH752

Oil Sentry™

Pressure Switch 4.5 N·m (40 in. lb.)

Solenoid (Starter)

Mounting Hardware 4.0-6.0 N·m (35-53 in. lb.)

Nut, Positive (+) Brush Lead 8.0-11.0 N·m (71-97 in. lb.)

Speed Control Bracket

Fastener 10.7 N·m (95 in. lb.) into new holes

7.3 N·m (65 in. lb.) into used holes

Starter Assembly

Thru Bolt 5.6-9.0 N·m (49-79 in. lb.)

Mounting Screw 15.3 N·m (135 in. lb.)

Brush Holder Mounting Screw 2.5-3.3 N·m (22-29 in. lb.)

Stator

Mounting Screw 6.2 N·m (55 in. lb.)

Valve Cover

Yellow O-Ring Style Cover Fastener

w/Integral Metal Spacers 6.2 N·m (55 in. lb.)

CLEARANCE SPECIFICATIONS3CH682 CH732 CH742 CH752

Camshaft

End Play 0.076/0.127 mm (0.0030/0.0050 in.)

Running Clearance 0.025/0.063 mm (0.0010/0.0025 in.)

Bore I.D.

New

Max. Wear Limit

20.000/20.025 mm (0.7874/0.7884 in.)

20.038 mm (0.7889 in.)

Bearing Surface O.D.

New

Max. Wear Limit

19.962/19.975 mm (0.7859/0.7864 in.)

19.959 mm (0.7858 in.)

Connecting Rod

Connecting Rod-to-Crankpin Running Clearance

New

Max. Wear Limit

0.030/0.055 mm (0.0012/0.0022 in.)

0.070 mm (0.0028 in.)

Connecting Rod-to-Crankpin Side Clearance 0.26/0.63 mm (0.0102/0.0248 in.)

Connecting Rod-to-Piston Pin Running Clearance 0.015/0.028 mm (0.0006/0.0011 in.)

Piston Pin End I.D.

New

Max. Wear Limit

17.015/17.023 mm (0.6699/0.6702 in.)

17.036 mm (0.6707 in.)

Crankcase

Governor Cross Shaft Bore I.D.

New

Max. Wear Limit

8.025/8.075 mm (0.3159/0.3179 in.)

8.088 mm (0.3184 in.)

3 Values are in Metric units. Values in parentheses are English equivalents.

5Lubricate threads with engine oil prior to assembly.

Speciﬁcations

924 690 34 Rev. D KohlerEngines.com

CLEARANCE SPECIFICATIONS3CH682 CH732 CH742 CH752

Crankshaft

End Play (free) 0.070/0.590 mm (0.0028/0.0230 in.)

End Play (w/thrust bearing components) 0.070/1.190 mm (0.0028/0.0468 in.)

Bore (in crankcase)

New

Max. Wear Limit

40.965/41.003 mm (1.6128/1.6143 in.)

41.016 mm (1.6148 in.)

Crankshaft to Sleeve Bearing (crankcase)

Running Clearance-New 0.03/0.09 mm (0.0012/0.0035 in.)

Bore (in closure plate)

New 40.987/40.974 mm (1.6136/1.6131 in.)

Crankshaft Bore (in closure plate)-to-Crankshaft

Running Clearance-New 0.039/0.074 mm (0.0015/0.0029 in.)

Flywheel End Main Bearing Journal

O.D. - New

O.D. - Max. Wear Limit

Max. Taper

Max. Out-of-Round

40.913/40.935 mm (1.6107/1.6116 in.)

40.84 mm (1.608 in.)

0.022 mm (0.0009 in.)

0.025 mm (0.0010 in.)

Closure Plate End Main Bearing Journal

O.D. - New

O.D. - Max. Wear Limit

Max. Taper

Max. Out-of-Round

40.913/40.935 mm (1.6107/1.6116 in.)

40.84 mm (1.608 in.)

0.022 mm (0.0009 in.)

0.025 mm (0.0010 in.)

Crankshaft (continued)

Connecting Rod Journal

O.D. - New

O.D. - Max. Wear Limit

Max. Taper

Max. Out-of-Round

35.955/35.973 mm (1.4156/1.4163 in.)

35.94 mm (1.415 in.)

0.018 mm (0.0007 in.)

0.025 mm (0.0010 in.)

T.I.R.

PTO End, Crank in Engine

Entire Crank, in V-Blocks

0.279 mm (0.0110 in.)

0.10 mm (0.0039 in.)

Cylinder Bore

Bore I.D.

New 80.000/

80.025 mm

(3.1496/

3.1506 in.)

82.988/83.013 mm

(3.2672/3.2682 in.)

Max. Wear Limit 80.065 mm

(3.1522 in.)

83.051 mm

(3.2697 in.)

Max. Out-of-Round 0.12 mm (0.0047 in.)

Max. Taper 0.05 mm (0.0020 in.)

Cylinder Head

Max. Out-of-Flatness 0.076 mm

(0.003 in.)

0.1 mm (0.004 in.)

3 Values are in Metric units. Values in parentheses are English equivalents.

Speciﬁcations

10 24 690 34 Rev. DKohlerEngines.com

CLEARANCE SPECIFICATIONS3CH682 CH732 CH742 CH752

Governor

Governor Cross Shaft-to-Crankcase

Running Clearancet 0.025/0.126 mm (0.0009/0.0049 in.)

Cross Shaft O.D.

New

Max. Wear Limit

7.949/8.000 mm (0.3129/0.3149 in.)

7.936 mm (0.3124 in.)

Governor Gear Shaft-to-Governor Gear

Running Clearance

0.015/0.140 mm (0.0006/0.0055 in.)

Gear Shaft O.D.

New

Max. Wear Limit

5.990/6.000 mm (0.2358/0.2362 in.)

5.977 mm (0.2353 in.)

Ignition

Spark Plug Gap 0.76 mm (0.030 in.)

Module Air Gap 0.203/0.305 mm (0.008/0.012 in.)

Piston, Piston Rings, and Piston Pin

Piston-to-Piston Pin Running Clearance 0.006/0.017 mm (0.0002/0.0007 in.)

Pin Bore I.D.

New

Max. Wear Limit

17.006/17.012 mm (0.6695/0.6698 in.)

17.025 mm (0.6703 in.)

Pin O.D.

New

Max. Wear Limit

16.995/17.000 mm (0.6691/0.6693 in.)

16.994 mm (0.6691 in.)

Top Compression Ring-to-Groove Side Clearance 0.030/0.070 mm (0.001/0.0026 in.)

Middle Compression Ring-to-Groove Side Clearance 00.030/0.070 mm (0.001/0.0026 in.)

Oil Control Ring-to-Groove Side Clearance 0.060/0.190 mm (0.0022/0.0073 in.)

Top Compression Ring End Gap

New Bore 0.100/

0.279 mm

(0.0039/

0.0110 in.)

0.189/0.277 mm

(0.0074/0.0109 in.)

Used Bore (Max) 0.490 mm

(0.0192 in.)

0.531 mm (0.0209 in.)

Middle Compression Ring End Gap

New Bore 1.400/

1.679 mm

(0.0551/

0.0661 in.)

1.519/1.797 mm

(0.0598/0.0708 in.)

Used Bore (Max) 1.941 mm

(0.0764 in.)

2.051 mm (0.0808 in.)

Thrust Face O.D.

New 79.966 mm

(3.1483 in.)8

82.978 mm (3.2668 in.)7

Max. Wear Limit 79.821 mm

(3.1426 in.)8

82.833 mm (3.2611 in.)7

Piston Thrust Face-to-Cylinder Bore Running

Clearance

New

0.025/

0.068 mm

(0.0010/

0.0027 in.)8

0.019/0.062 mm (0.0007/0.0024 in.)7

3 Values are in Metric units. Values in parentheses are English equivalents.

7 Measure 6 mm (0.2362 in.) above bottom of piston skirt at right angles to piston pin.

8 Measure 13 mm (0.5118 in.) above bottom of piston skirt at right angles to piston pin.

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