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CH940-CH1000

ervice Manual

KohlerEngines.com

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.

62 690 01 Rev. J

Safety

Maintenance

Specifications

Tools and Aids

Troubleshooting

Air Cleaner/Intake

Fuel System

Governor System

Lubrication System

Electrical System

Starter System

Disassembly/Inspection and Service

Reassembly

Содержание Command Pro CH1000

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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