Kohler Command Pro CH1000 Service Manual Download Page 41

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Electrical System

62 690 01 Rev. J

KohlerEngines.com

F B G

Blue

Red

Green (Oil Sentry

™

Pulse Signal)

Yellow

Violet

White

Black

Key Switch

To Battery

To Accessory

Ground

To Rectifier-Regulator

To Magneto

To Starter

Oil Sentry

™

Light

(Optional)

Oil Sentry

™

Carburetor Mounting

Stud

Ground

Spark Plug(s)

Flywheel Stator

Assembly

Ignition Module(s)

Rectifier-Regulator

Connector

Battery

Battery Negative

Battery Positive

Starter

Fuse

Starter Solenoid Stud

Carburetor

Starter Solenoid Tang

Ignition Module

Mounting Screw

Solenoid Lead

Connector (5-Circuit)

Connector (1-Circuit)

White

(AC Charging Leads)

Wire Diagram-15/20/25 Amp Regulated Battery Charging System with CDI/MDI, Five Pin Connector, Key

Switch, and Fuse

Not valid with indicator light or no pressure switch.

Summary of Contents for Command Pro CH1000

Page 1: ...ipment that this engine powers Ensure engine is stopped and level before performing any maintenance or service 62 690 01 Rev J 1 2 Safety 3 Maintenance 5 Specifications 21 Tools and Aids 24 Troublesho...

Page 2: ...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...

Page 3: ...n System Every 150 Hours Replace low profile air cleaner element Air Cleaner Intake Remove cooling shrouds and clean cooling areas Air Cleaner Intake Every 150 Hours Check heavy duty air cleaner eleme...

Page 4: ...ning 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 Oc...

Page 5: ...0 mm 2 91 in F Choke Control G Throttle Control H Mechanical Fuel Pump I 698 6 mm 27 50 in J 5 4 mm 0 21 in Spark Plug Lead K Supply Fuel Filter L Engine Mounting Surface M 8 X 10 3 mm 0 40 in Thru Mo...

Page 6: ...40 8 mm 13 42 in I Solenoid Shift Starter J Mounting Hole A K Rotation Direction L 177 8 mm 7 0 in Optional Pilot M M8 X 1 25 mm 6H in 25 mm 0 98 in Deep on a 254 mm 10 0 in B C N 4 X 7 16 14 UNC 2B i...

Page 7: ...7 in F Muffler Optional G 460 0 mm 18 11 in H 9 5 mm 0 38 in SQ Keyway I 36 5 mm 1 44 in J 155 6 mm 6 13 in K 5 8 18 UNF 2B in 38 1 mm 1 5 in Deep L 113 2 mm 4 46 in M Engine Mounting Surface N Oil Dr...

Page 8: ...int C Cylinder 2 Shroud D Access to Oil Cooler E Fuel Filter F Mounting Hole A G 16 0 mm 0 63 in H 119 0 mm 4 69 in I 135 0 mm 5 32 in J 239 5 mm 9 43 in K Oil Drain Plug 1 2 NPT Inch L Engine Mountin...

Page 9: ...ngine Dimensions Mounting Surface View A 232 0 mm 9 13 in B 8 X 10 3 mm 0 40 in Thru Mounting Holes C Mounting Hole A D 239 5 mm 9 43 in E 106 0 mm 4 17 in F PTO Mounting Surface G 135 0 mm 5 32 in H...

Page 10: ...L M A 484 3 mm 19 07 in B 364 5 mm 14 35 in C 106 0 mm 4 17 in Lifting Point D 85 7 mm 3 38 in E 76 3 mm 3 00 in F Lifting Point 10 X 12 mm 0 39 X 0 47 in Slot G 136 2 mm 5 36 in H 14 7 mm 0 58 in Spa...

Page 11: ...ing Point L 340 8 mm 13 42 in M 181 9 mm 7 16 in Starter Stud N Mounting Hole A O 68 6 mm 2 70 in Starter Stud P 106 0 mm 4 17 in Q 177 8 mm 7 01 in Pilot R M8 X 1 25 mm 6H in 25 mm 0 98 in Deep on a...

Page 12: ...in Starter Stud F Grass Screen G 422 7 mm 16 64 in Cylinder 1 Shroud Removal H 401 7 mm 15 82 in I Mounting Hole A J 58 8 mm 2 31 in Spark Plug K 91 5 mm 3 6 in L 239 5 mm 9 43 in M Oil Drain Plug 1 2...

Page 13: ...26 7 mm 1 05 in E Lifting Point F 45 0 mm 1 77 in Cylinder 2 Shroud Removal G Cylinder 2 Shroud H Access to Oil Cooler I Mounting Hole A J 81 8 mm 3 22 in Spark Plug K 91 5 mm 3 60 in L 422 7 mm 16 64...

Page 14: ...increments first to 16 9 N m 150 in lb finally to 22 6 N m 200 in lb Carburetor Air Cleaner Mounting Nut 11 3 N m 100 in lb Carburetor Fuel Bowl Screw 2 5 N m 22 in lb 0 3 N m 3 in lb Air Cleaner Moun...

Page 15: ...m 180 in lb Mounting Screw Button Head Cap Screw 9 9 N m 88 in lb Front Drive Shaft Screw into flywheel 24 4 N m 216 in lb Fan Flywheel Fan Fastener Screw Truss Head 10 4 N m 92 in lb Fan Fastener Sc...

Page 16: ...35 53 in lb Nut Positive Brush Lead 8 0 11 0 N m 71 97 in lb Starter Assembly Thru Bolt 5 6 9 0 N m 49 79 in lb Mounting Screw 16 0 N m 142 in lb Brush Holder Mounting Screw 2 5 3 3 N m 22 29 in lb St...

Page 17: ...ring 0 30 1 50 mm 0 011 0 059 in 0 20 0 94 mm 0 008 0 037 in Crankshaft Bore in crankcase New Without Main Bearing With Main Bearing Installed Max Wear Limit 50 00 50 025 mm 1 9685 1 969 in 45 040 45...

Page 18: ...MDI Ignition Module 0 28 0 33 mm 0 011 0 013 in Crankshaft Bearing flywheel PTO New installed Max Wear Limit 45 040 45 145 mm 1 773 1 777 in 45 158 mm Piston Piston Rings and Piston Pin Piston Style...

Page 19: ...Max Wear Limit 0 900 1 179 mm 0 0354 0 0464 in 1 432 mm 0 0564 in Piston Thrust Face O D 7 New Bore Used Bore max 89 972 mm 3 5422 in 89 827 mm 3 5365 in Piston Thrust Face to Cylinder Bore7 Running C...

Page 20: ...English Fastener Torque Recommendations for Standard Applications Bolts Screws Nuts and Fasteners Assembled Into Cast Iron or Steel Grade 2 or 5 Fasteners Into Aluminum Size Grade 2 Grade 5 Grade 8 Ti...

Page 21: ...leakdown test on XT 6 engines Kohler 25 761 05 S Design Technology Inc DTI 731 03 Dealer Tool Kit Domestic Complete kit of Kohler required tools Components of 25 761 39 S Ignition System Tester Cylind...

Page 22: ...available Starter Brush Holding Tool Solenoid Shift SE Tools KLR 82411 SE Tools KLR 82416 Triad OHC Timing Tool Set For holding cam gears and crankshaft in timed position while installing timing belt...

Page 23: ...ing gear teeth Bosses will lock tool and flywheel in position for loosening tightening or removing with a puller A spanner wrench to lift rocker arms or turn crankshaft may be made out of an old junk...

Page 24: ...e to check simple causes which at first may seem too obvious to be considered For example a starting problem could be caused by an empty fuel tank Some general common causes of engine troubles are lis...

Page 25: ...indications of improper fit and seal Check air cleaner element Look for holes tears cracked or damaged sealing surfaces or other damage that could allow unfiltered air into engine A dirty or clogged e...

Page 26: ...s closed 2 Start engine and run no load high speed 3 Open clamp and note water level in tube Level in engine side should be a minimum of 10 2 cm 4 in above level in open side If level in engine side i...

Page 27: ...t Install a 3 8 in breaker bar into hole slot of holding tool so it is perpendicular to both holding tool and crankshaft PTO If flywheel end is more accessible use a breaker bar and socket on flywheel...

Page 28: ...with knobs Heavy Duty 1 Unhook retaining clips and remove end cap s 2 Check and clean inlet screen if equipped 3 Pull air cleaner element out of housing and replace Check condition of inner element re...

Page 29: ...replacing valve cover Refer to Disassembly and Reassembly 3 Reconnect fuel lines to inlet and outlet fittings and secure with clamps FUEL SYSTEM TESTS When engine starts hard or turns over but will n...

Page 30: ...ain Nozzle Left Side X Main Jet Right Side Y Main Jet Left Side Z Choke Dust Cap AA Choke Shaft AB Spring AC Bushing AD Choke Lever AE Choke Plate AF Choke Plate Screw D E F G H I C B Z J N P O M S T...

Page 31: ...l mixture is improperly adjusted Adjust low idle fuel needle some models Float level is set too high Adjust float according to Float Replacement Procedure Dirt under fuel inlet needle Remove needle cl...

Page 32: ...l becomes great enough so main circuit begins to work Main high speed At high speeds loads engine operates on main circuit As a metered amount of air is drawn through 4 air jets fuel is drawn through...

Page 33: ...or easy out and remove original choke shaft bushing with old choke lever from carburetor housing Save bushing to use as a driver for installing new bushing Discard old lever 11 Clean I D of both choke...

Page 34: ...21 Install large flat retaining washer and secure with mounting screw attaching ground lead if originally secured by screw 22 Install new idle speed RPM adjustment screw and spring onto carburetor Th...

Page 35: ...and force applied by regulating pin will again offset each other to hold a steady engine speed Governor Adjustments NOTE Do not tamper with governor setting Overspeed is hazardous and could cause per...

Page 36: ...ency gerotor oil pump maintains high oil flow and oil pressure even at low speeds and high operating temperatures A pressure relief valve limits maximum pressure of system Closure plate must be remove...

Page 37: ...remain open as pressure is increased to 90 psi maximum 3 Gradually decrease pressure through range of 7 11 psi Tester should indicate a change to continuity switch closed down to 0 psi 4 Replace swit...

Page 38: ...e feeler gauge Adjust gap to 0 76 mm 0 03 in 2 Install plug into cylinder head 3 Torque plug to 27 N m 20 ft lb Inspection Inspect each spark plug as it is removed from cylinder head Deposits on tip a...

Page 39: ...ssary to prolong battery life Battery Test To test battery follow manufacturer s instructions ELECTRONIC IGNITION SYSTEMS Ignition System Components A Kill Switch Off Position of Key Switch B Air Gap...

Page 40: ...L Oil Sentry M Spark Plug s N Flywheel Stator Assembly O Ignition Module s P Carburetor Q Intake Manifold Screw R Starter Solenoid Stud S Ground T Rectifier Regulator Connector U Starter Solenoid Tang...

Page 41: ...Sentry Q Carburetor Mounting Stud R Ground S Spark Plug s T Flywheel Stator Assembly U Ignition Module s V Rectifier Regulator W Rectifier Regulator Connector X Battery Y Battery Negative Z Battery Po...

Page 42: ...E Connector 5 Circuit AF Connector 1 Circuit AG Solenoid Lead AH White AC Charging Leads AI Spark Plug Lead Digital Spark Advance Ignition DSAI System This system uses a digital microprocessor which i...

Page 43: ...Violet E White F Black G Connector H Polarity Ribs I Battery J Battery Positive K Battery Negative L Starter Solenoid Stud M External Starter Solenoid Wire N Starter O Rectifier Regulator Connector P...

Page 44: ...Green D Orange E Violet F White G Black H Connector I Polarity Ribs J Battery K Battery Positive L Battery Negative M Starter Solenoid Stud N Starter Solenoid Tang O Starter P Oil Sentry Q Rectifier R...

Page 45: ...isolated until all testing is completed Identify white kill lead of engine wiring harness connector Establish a connection to a known good ground location Engine should kill completely If not or only...

Page 46: ...male with aerosol electrical contact cleaner to remove any old dielectric compound dark residue dirt or contamination Disconnect spark plug leads from spark plugs 3 Using a multi meter check that a pr...

Page 47: ...AC terminal and reconnect it to other AC terminal Repeat test If OK green light comes on again part is good and may be used Part is good and may be used NOTE A flashing LOW light can also occur as a r...

Page 48: ...4 3 With engine stopped measure resistance across stator leads using an ohmmeter Condition Conclusion Resistance is 0 1 0 2 ohms Stator is OK Resistance is 0 ohms Stator is shorted replace Resistance...

Page 49: ...gine starts and start switch is released starter solenoid is deactivated drive lever moves back and drive pinion moves out of mesh with ring gear into retracted position Troubleshooting Starting Diffi...

Page 50: ...om armature 13 Clean parts as required Inspection Drive Pinion Check and inspect following areas Pinion teeth for abnormal wear or damage Surface between pinion and clutch mechanism for nicks or irreg...

Page 51: ...out c Install brush springs and snap on retainer caps d Hold starter assembly vertically on end housing and carefully place tool with extension and assembled original brush holder assembly onto end of...

Page 52: ...0 6 0 N m 35 53 in lb 14 Connect positive brush lead bracket to solenoid and secure with nut Torque nut to 8 11 N m 71 97 in lb Do not overtighten Solenoid Tests NOTE DO NOT leave 12 volt test leads...

Page 53: ...spark plug lead s before servicing External Engine Components T I H J K M L K I H N R Q U O O P S T U Q X V W V V G F E D C B A A S T T U Q L H H I A Oil Filter B Oil Filter Nipple C Oil Filter Cup D...

Page 54: ...aner as an assembly from engine Removing Control Bracket Governor Springs and Lever 1 Unhook governed idle and governor springs from controls on main bracket and governor lever Note color location and...

Page 55: ...Adapter NOTE Further disassembly of oil filter housing assembly is not required unless being serviced individually Follow substeps a b and c 1 Remove screw securing oil filter housing and individual O...

Page 56: ...C D S P E L Q R B F A Rectifier Regulator B Ignition Module C Washer D Flywheel Screw E Special Washer Style A F Wire Harness Clamp G Debris Screen Style A H Fan Style A I Stiffener Style A J Hex Stud...

Page 57: ...e cracked or damaged 1 Use a flywheel strap wrench or holding tool to hold flywheel and loosen screw securing flywheel to crankshaft 2 Remove screw and washer 3 Use a puller to remove flywheel from cr...

Page 58: ...I K M N O P Q R J A Gasket B Valve C Cylinder Head D Pipe Plug E Spacer F Washer G Spark Plug H Valve Stem Seal I Valve Spring J Hydraulic Lifter K Valve Spring Retainer L Push Rod M Valve Spring Kee...

Page 59: ...lic lifter tool Do not use a magnet to remove lifters Mark lifters by location as either intake or exhaust and cylinder 1 or 2 Hydraulic lifters should always be reinstalled in same position Inspectio...

Page 60: ...30 C Guide Depth 8 5 mm 0 334 in 8 5 mm 0 334 in D Guide I D 7 038 7 058 mm 0 2771 0 2779 in 7 038 7 058 mm 0 2771 0 2779 in E Valve Head Diameter 38 625 38 685 mm 1 5206 1 5230 in 31 625 31 825 mm 1...

Page 61: ...l to prevent rusting Valve Stem Seals These engines use valve stem seals on intake and exhaust valves Always use new seals when valves are removed from cylinder head Seals should also be replaced if d...

Page 62: ...vicing possible If a problem with relief valve is encountered oil pump should be replaced Inspection Inspect oil pump housing gerotor gears and closure plate recess for nicks burrs wear or any visible...

Page 63: ...C Regulating Pin D Governor Gear E Cross Shaft F Lifter Feed Cover Gasket G Lifter Feed Cover H Governor Yoke I Crankshaft J Connecting Rod End Cap K Connecting Rod L Piston Pin M Piston Pin Retainer...

Page 64: ...riginal piston and connecting rod can be reused after new rings are installed original pin can also be reused but new piston pin retainers are required Piston pin is included as part of piston assembl...

Page 65: ...d gap Top compression ring end gap clearance is 0 125 0 304 mm 0 0049 0 0120 in for a new bore or 0 515 mm 0 0203 in for a used bore Middle compression ring end cap is 0 900 1 179 mm 0 0354 0 0464 in...

Page 66: ...s removed from shaft these tabs are destroyed and gear must be replaced Therefore remove gear only if absolutely necessary If governor cross shaft yoke or gear condition does not require removal gover...

Page 67: ...oversize piston and ring assemblies Initially resize using a boring bar then use following procedures for honing cylinder Honing Detail A 23 33 Crosshatch A NOTE Kohler pistons are custom machined to...

Page 68: ...engine oil to prevent rusting Measuring Piston to Bore Clearance Piston Detail Piston Details A A Style A Style B A 11 mm 0 4331 in NOTE Do not use a feeler gauge to measure piston to bore clearance...

Page 69: ...king Tab C Regulating Pin D Governor Gear E Cross Shaft F Lifter Feed Cover Gasket G Lifter Feed Cover H Governor Yoke I Crankshaft J Connecting Rod End Cap K Connecting Rod L Piston Pin M Piston Pin...

Page 70: ...install a new bearing using an arbor press and driver 1 Make sure crankcase bore for bearing is clean dry and free of nicks or burrs 2 Press flywheel side main bearing in place with notch oriented in...

Page 71: ...peat this procedure for other connecting rod and piston assembly Install Camshaft 1 Liberally apply camshaft lubricant to each cam lobe Lubricate camshaft bearing surfaces of crankcase and camshaft wi...

Page 72: ...or Gears C Oil Pump O ring D Oil Pump Housing E Relief Valve Baffle F Pickup Tube G Clamp H Inlet Seal I Pickup Screen J Oil Reservoir K Drain Plug L Gasket M Crankshaft Thrust Bearing Flange PTO N Cl...

Page 73: ...rankcase Carefully seat camshaft and crankshaft into their mating bearings Rotate crankshaft slightly to help oil pump and governor gears mesh 6 Install screws securing closure plate to crankcase Torq...

Page 74: ...filter does not extend above top surface and all parts are properly aligned 3 Install M5 nuts onto studs then torque using sequence shown to 12 4 N m 110 in lb 4 Lightly oil lower end of breather hose...

Page 75: ...Q R J A Gasket B Valve C Cylinder Head D Pipe Plug E Spacer F Washer G Spark Plug H Valve Stem Seal I Valve Spring J Hydraulic Lifter K Valve Spring Retainer L Push Rod M Valve Spring Keeper N Rocker...

Page 76: ...e Cylinder Heads Prior to installation lubricate all components with engine oil paying particular attention to lip of valve stem seal valve stems and valve guides Install in order listed below using a...

Page 77: ...From PTO end rotate crankshaft 270 3 4 turn counterclockwise and align crankshaft keyway with cylinder 2 This now puts cylinder 2 at TDC on compression stroke 7 Repeat steps 1 5 for remaining cylinder...

Page 78: ...tion Torque screws in 2 stages using sequence shown first to 16 9 N m 150 in lb finally to 22 6 N m 200 in lb 3 Install carburetor mounting studs into intake manifold if previously removed Use nuts lo...

Page 79: ...Q R B F A Rectifier Regulator B Ignition Module C Washer D Flywheel Screw E Special Washer Style A F Wire Harness Clamp G Debris Screen Style A H Fan Style A I Stiffener Style A J Hex Stud K Flywheel...

Page 80: ...all woodruff key into crankshaft keyway Make sure key is properly seated and parallel with shaft taper 2 Install flywheel onto crankshaft being careful not to shift woodruff key 3 Install screw and wa...

Page 81: ...utton head cap screws to 9 9 N m 88 in lb Install Metal Debris Screen Style B Spring Washer Details A A Spring Washer A B C D E A Metal Debris Screen B Fan C Flywheel D Spacer E Hex Bolt 1 Verify loca...

Page 82: ...lter Nipple C Oil Filter Cup D Valve Spring E Cup Spring F Valve G Oil Filter Housing H Valley Baffle I Outer Cylinder Baffle J Electric Starter K Cylinder Shroud L Blower Housing M Fixed Guard N Oil...

Page 83: ...d fit under outer baffle Torque M6 screws going into cylinder head to 10 7 N m 95 in lb for new holes or 7 3 N m 65 in lb for used holes Start upper M6 screws only if main control bracket rear support...

Page 84: ...o not tighten governor lever at this time Control Bracket Components G E F A I H N M O C D B K L J D A I B F E G A Throttle Lever B Throttle Linkage C Nut D Governor Arm E Governor Spring F Governed I...

Page 85: ...clip 2 Connect throttle linkage to appropriate hole in throttle lever and secure with small clip Adjusting Governor 1 Position governor lever so clamping area is inboard but completely on knurled are...

Page 86: ...new oil until oil reaches bottom of threads Allow 2 minutes for oil to be absorbed by filter material 3 Apply a thin film of clean oil to rubber gasket on new filter 4 Refer to instructions on oil fi...

Page 87: ...87 62 690 01 Rev J KohlerEngines com...

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