Kohler Command PRO CV732 Manual de usuario

CV682, CV732, CV742, CV752

Service Manual

2 Safety

3 Maintenance

5Specications

13 Tools and Aids

16 Troubleshooting

20 Air Cleaner/Intake

21 Fuel System

27 Governor System

28 Lubrication System

30 Electrical System

37 Starter System

41 Disassembly/Inspection and Service

54 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 37 Rev. B KohlerEngines.com

Safety

224 690 37 Rev. BKohlerEngines.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

res and severe burns.

Do not ll fuel tank while

engine is hot or running.

Gasoline is extremely ammable

and its vapors can explode if

ignited. Store gasoline only in

approved containers, in well

ventilated, unoccupied buildings,

away from sparks or ames.

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 ammable. 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 ywheel.

CAUTION

Failure to utilize or

reassemble debris

screen as designed could

result in debris screen

failure and serious

personal injury.

Maintenance

324 690 37 Rev. B 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 ns, clean as necessary (if equipped). Lubrication System

Every 200 Hours

● Change oil lter. Lubrication System

● Replace fuel lter.

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.

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

2 Have a Kohler authorized dealer perform this service.

REPAIRS/SERVICE PARTS

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

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

Maintenance

424 690 37 Rev. BKohlerEngines.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 res and severe

burns.

Do not ll fuel tank while engine is hot or

running.

Gasoline is extremely ammable and its vapors can

explode if ignited. Store gasoline only in approved

containers, in well ventilated, unoccupied buildings,

away from sparks or ames. 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 overll 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.

Specications

524 690 37 Rev. B KohlerEngines.com

413.28

[16.271]

296.44

[11.691]

272.44

[10.726]

93.05

[3.664]

VALVE COVER

135.00

[5.315]

AIR FILTER

RAIN CAP

REMOVAL

22.77

[0.896]

SPARK PLUG BOOT 253.35

[9.974]

SPARK PLUG

REMOVAL

52.02

[2.048]

SPARK PLUG

BOOT

REMOVAL

OIL FILL &

DIPSTICK TUBE

253.35

[9.974]

SPARK PLUG

REMOVAL

VALVE COVER

353.69

[13.925]

PRIMARY AIR FILTER ELEMENT REMOVAL

241.37

[9.503]

SAFETY AIR FILTER

ELEMENT REMOVAL

130.00

[5.118]

AIR FILTER COVER

ASSEMBLY REMOVAL

246.12

[9.690]

SPARK PLUG

BOOT

REMOVAL

72.81

[2.867]

SPARK PLUG REMOVAL

MOUNTING

HOLE“A”

LENGINE

72.81

[2.867]

SPARK PLUG REMOVAL

FUEL

FILTER

LCRANKSHAFT

27.53

[1.084]

SPARK PLUG BOOT

52.02

[2.048]

SPARK PLUG BOOT REMOVAL

145.19

[5.716]

45.19

[1.779]

15.70

[0.618]

OIL FILTER REMOVAL

246.12

[9.690]

SPARK PLUG

BOOT

REMOVAL

20°

FLYWHEEL SIDE

345.34

[13.596]

505.67

[19.908]

PULSE FUEL PUMP

316.44

[12.458]

154.85

[6.096]

ENGINE MOUNTING SURFACE

OIL COOLER

REGULATOR

RECTIFIER

OIL DRAIN PLUG

3/8 NPT [INCH]

OIL FILTER SIDE

MOUNTING HOLE “A”

LSPARK PLUG

134.04 [5.277]

109.59

[4.314]

28.56

[1.125]

25.80

[1.016]

97.20

[3.827]

KE YWAY

7/16-20 UNF 2B [INCH]

1/4 IN. SQ KEYWAY

38.1 [1.500]

80.26

[3.160]

OIL FILTER

51.25

[2.018]

OIL FILTER

12.99

[0.511]

MOUNTING HOLE “A”

ENGINE MOUNTING SURFACE

(PTO END)

2X 242.29

[9.539]

2X 104.03

[4.096]

2X 89.80

[3.536]

30°

SOLENOID SHIFT STARTER

50.00

[1.969]

EXHAUST

PORT #1

MOUNTING

HOLES

4X Ø 9.20 [0.362] THRU

Ø 254.00 [10.00] B.C.

50.00

[1.969]

EXHAUST PORT #2

MOUNTING HOLES

2X 89.80

[3.536]

2X 77.53

[3.052]

2X 72.84

[2.868]

M8 X 1.25

4 STUDS

334.67

[13.176]

367.34

[14.462]

316.96

[12.479]

40.80

[1.606]

OIL DRAIN PLUG

3/8 NPT [INCH]

12.99

[0.511] ENGINE MOUNTING SURFACE

LSPARK PLUG

72.04

[2.836]

EXHAUST

PORT #2

154.04 [6.065]

92.04

[3.624]

EXHAUST

PORT #1

STARTER SIDE

Engine Dimensions

Dimensions in millimeters.

Inch equivalents shown in [ ].

Specications

624 690 37 Rev. BKohlerEngines.com

ENGINE IDENTIFICATION NUMBERS

Kohler engine identication numbers (model, specication and serial) should be referenced for efcient repair,

ordering correct parts, and engine replacement.

Model .....................CV682

Command Engine

Vertical Shaft

Numerical Designation

Specication ...............CV682-0001

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

Year Manufactured Code Factory Code

Code Year

43 2013

44 2014

45 2015

GENERAL SPECIFICATIONS3,6 CV682 CV732 CV742 CV752

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 (rell) 1.6-1.8 L (1.7-1.9 U.S. qt.)

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

TORQUE SPECIFICATIONS3,5 CV682 CV732 CV742 CV752

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 to Head Mounting Fastener (torque in 2

increments)

rst to 7.4 N·m (66 in. lb.)

nally to 9.9 N·m (88 in. lb.)

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

nally to 8.2 N·m (73 in. lb.)

Support Bracket to Intake Manifold Fastener 9.9 N·m (88 in. lb.)

Support Bracket to Air Cleaner Housing Fastener 7.9 N·m (70 in. lb.)

Evap Connector Fitting to Air Cleaner Housing HI-LO

Fastener (if equipped) 2.1 N·m (19 in. lb.)

Connecting Rod

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

Crankcase

Breather Cover Fastener 7.3 N·m (65 in. lb.)

Oil Drain Plug 13.6 N·m (10 ft. lb.)

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

4 Exceeding maximum angle of operation may cause engine damage from insufcient lubrication.

5 Lubricate threads with engine oil prior to assembly.

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

standards. Details on Certied Power Ratings can be found at KohlerEngines.com.

Specications

724 690 37 Rev. B KohlerEngines.com

TORQUE SPECIFICATIONS3,5 CV682 CV732 CV742 CV752

Cylinder Head

Fastener (torque in 2 increments)

Nut rst to 16.9 N·m (150 in. lb.)

nally to 35.5 N·m (315 in. lb.)

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

nally 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.)

Rectier-Regulator Fastener 1.4 N·m (12.6 in. lb.)

Mufer

Retaining Nut 24.4 N·m (216 in. lb.)

Oil Cooler

Adapter Nipple 27 N·m (20 ft. lb.)

Oil Pan

Fastener 24.4 N·m (216 in. lb.)

Oil Pump

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

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

Hi-Lo Screw into Blower Housing 2.2 N·m (19 in. lb.)

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.)

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

5 Lubricate threads with engine oil prior to assembly.

Specications

824 690 37 Rev. BKohlerEngines.com

TORQUE SPECIFICATIONS3,5 CV682 CV732 CV742 CV752

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 SPECIFICATIONS3CV682 CV732 CV742 CV752

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.)

Crankshaft

End Play (free) 0.070/0.590 mm (0.0028/0.0230 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 oil pan)

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

Crankshaft Bore (in oil pan)-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.)

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

5 Lubricate threads with engine oil prior to assembly.

Specications

924 690 37 Rev. B KohlerEngines.com

CLEARANCE SPECIFICATIONS3CV682 CV732 CV742 CV752

Crankshaft (continued)

Oil Pan 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.)

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.)

Governor

Governor Cross Shaft-to-Crankcase

Running Clearance 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.)

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

Specications

10 24 690 37 Rev. BKohlerEngines.com

CLEARANCE SPECIFICATIONS3CV682 CV732 CV742 CV752

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 0.030/0.070 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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