Kohler Command Pro CH940-CH1000 Engine Service Repair Manual

CH940-CH1000 Service 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. C 1 2 Safety 3 Maintenance 5 Speciﬁcations 13 Tools and Aids 16 Troubleshooting 20 Air Cleaner/Intake 21 Fuel System 27 Governor System 28 Lubrication System 30 Electrical System 45 Disassembly/Inspection and Service 59 Reassembly

Safety 2 62 690 01 Rev. C KohlerEngines.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 3 62 690 01 Rev. C 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 filter minder. Air Cleaner/Intake Every 25 Hours or Annually¹ ● Service/replace low-profile precleaner. Air Cleaner/Intake Every 150 Hours¹ ● Replace low-profile air cleaner element. Air Cleaner/Intake ● Change oil. Oil filter is recommended. Lubrication System ● Remove cooling shrouds and clean cooling areas. Air Cleaner/Intake Every 150 Hours ● Check heavy-duty air cleaner element. Air Cleaner/Intake ● Replace fuel filter. ● Check oil cooler fins, clean as necessary. Lubrication System Every 300 Hours ● Change oil filter. Lubrication System ● Replace heavy-duty air cleaner element. Air Cleaner/Intake Every 500 Hours² ● Have crankshaft splines lubricated. Every 600 Hours ● Replace heavy-duty inner air cleaner element. Air Cleaner/Intake ● Replace spark plugs and set gap. Electrical System 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 find a local Kohler authorized dealer visit KohlerEngines.com or call 1-800-544-2444 (U.S. and Canada).

Maintenance 4 62 690 01 Rev. C KohlerEngines.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 5 62 690 01 Rev. C KohlerEngines.com Dimensions in millimeters. Inch equivalents shown in [ ]. Engine Dimensions with Heavy-Duty Air Cleaner

Speciﬁcations 6 62 690 01 Rev. C KohlerEngines.com Dimensions in millimeters. Inch equivalents shown in [ ]. Engine Dimensions with Low-Proﬁle Air Cleaner

Specifications 7 62 690 01 Rev. C KohlerEngines.com ENGINE IDENTIFICATION NUMBERS Kohler engine identification numbers (model, specification and serial) should be referenced for efficient repair, ordering correct parts, and engine replacement. GENERAL SPECIFICATIONS 3,6 CH940 CH960 CH980 CH1000 Bore 90 mm (3.54 in.) Stroke 78.5 mm (3.1 in.) Displacement 999 cc (61 cu. in.) Oil Capacity (refill) 2.7 L (2.9 U.S. qt.) Maximum Angle of Operation (@ full oil level) 4 25° TORQUE SPECIFICATIONS 3,5 CH940 CH960 CH980 CH1000 Blower Housing and Sheet Metal M6 Screw New, Untapped Hole (casting) Used, Tapped Hole (casting) New, Extruded Hole (sheet metal) Used, Extruded Hole (sheet metal) Mounting Clip (valley baffle) 10.7 N·m (95 in. lb.) 7.3 N·m (65 in. lb.) 4.0 N·m (35 in. lb.) 2.0 N·m (18 in. lb.) 2.5 N·m (22 in. lb.) Carburetor, Intake Manifold, and Air Cleaner Intake Manifold Mounting Fastener (torque in 2 increments) first to 16.9 N·m (150 in. lb.) finally to 22.6 N·m (200 in. lb.) Carburetor/Air Cleaner Mounting Nut 7.9 N·m (70 in. lb.) Carburetor Fuel Bowl Screw 2.5 N·m (22 in. lb.) ± 0.3 N·m (3 in. lb.) Air Cleaner Mounting Screw (into intake manifold) 9.9 N·m (88 in. lb.) Closure Plate Closure Plate Fastener 24.4 N·m (216 in. lb.) Connecting Rod Cap Fastener (torque in increments) 11.3 N·m (100 in. lb.) Control Bracket Mounting Screw (into intake manifold from air cleaner) 9.9 N·m (88 in. lb.) 3 Values are in Metric units. Values in parentheses are English equivalents. 4 Exceeding maximum angle of operation may cause engine damage from insufficient lubrication. 5 Lubricate threads with engine oil prior to assembly. 6 Any 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. Model . . . . . . . . . . . . . . . . . . . . . CH940 Command Engine Horizontal Shaft Numerical Designation Specification . . . . . . . . . . . . . . . CH940-0001 Serial . . . . . . . . . . . . . . . . . . . . . 3923500328 Year Manufactured Code Factory Code Code Year 39 2009 40 2010 41 2011

Specifications 8 62 690 01 Rev. C KohlerEngines.com TORQUE SPECIFICATIONS 3,5 CH940 CH960 CH980 CH1000 Control Panel M6 screw 10.7 N·m (95 in. lb.) into new holes 7.3 N·m (65 in. lb.) into used holes M5 screws 6.2 N·m (55 in. lb.) into new holes 4.0 N·m (35 in. lb.) into used holes Crankcase Breather Cover Fastener 5.7 N·m (51 in. lb.) Oil Drain Plug 21.4 N·m (16 ft. lb.) Cylinder Head Cylinder Head Fastener (torque in 2 increments) Head Bolt first to 22.6 N·m (200 in. lb.) finally to 45.2 N·m (400 in. lb.) Pipe Plug (3/4 in.) 28.25 N·m (250 in. lb.) Rocker Arm Screw 14.6 N·m (130 in. lb.) Debris Screen Hex Stud 9.9 N·m (88 in. lb.) Mounting 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 9.9 N·m (88 in. lb.) Flywheel Retaining Screw 67.8 N·m (50 ft . lb.) Governor Governor Lever Nut 7.3 N·m (65 in. lb.) Governor Yoke Mounting Screw 2.2 N·m (20 in. lb.) Ignition Spark Plug 27 N·m (20 ft. lb.) Ignition Module Fastener 6.2 N·m (55 in. lb.) into new holes 4.0 N·m (35 in. lb.) into used holes Rectifier-Regulator Fastener 2.0 N·m (18 in. lb.) Lifter Feed Chamber Cover/Baffle Screw 6.2 N·m (55 in. lb.) into new holes 4.0 N·m (35 in. lb.) into used holes Muffler Retaining Nut 24.4 N·m (216 in. lb.) M6 Screw 9.9 N·m (88 in. lb.) M8 Screw 24.4 N·m (216 in. lb.) Oil Cooler Mounting Screws 2.2 N·m (20 in. lb.) Oil Filter Adapter/Housing Adapter/Housing Mounting Screw 24.4 N·m (216 in. lb.) Oil Filter Nipple 18.0 N·m (159 in. lb.) 3 Values are in Metric units. Values in parentheses are English equivalents. 5 Lubricate threads with engine oil prior to assembly.

Speciﬁcations 9 62 690 01 Rev. C KohlerEngines.com TORQUE SPECIFICATIONS 3,5 CH940 CH960 CH980 CH1000 Oil Pickup Screen Mounting Screw 10.7 N·m (95 in. lb.) into new holes 7.3 N·m (65 in. lb.) into used holes Oil Pickup Tube Mounting Screw 10.7 N·m (95 in. lb.) into new holes 7.3 N·m (65 in. lb.) into used holes Oil Pump Mounting Screw 10.7 N·m (95 in. lb.) into new holes 6.7 N·m (60 in. lb.) into used holes Oil Sentry TM Pressure Switch 10.1 N·m (90 in. lb.) Reservoir (oil) Mounting Screw 24.4 N·m (216 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.) 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.) Throttle/Choke Control Bracket Fastener 9.9 N·m (88 in. lb.) Valve Cover Valve Cover Fastener 13.6 N·m (120 in. lb.) CLEARANCE SPECIFICATIONS 3 CH940 CH960 CH980 CH1000 Camshaft End Play 0.3/1.3 mm (0.011/0.051 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.) Cam Lobe Proﬁle (minimum dimension, measured from base circle to top of lobe) Exhaust 35 mm (1.3779 in.) Intake 34.1 mm (1.3425 in.) 35 mm (1.3779 in.) 3 Values are in Metric units. Values in parentheses are English equivalents. 5 Lubricate threads with engine oil prior to assembly.

Speciﬁcations 10 62 690 01 Rev. C KohlerEngines.com CLEARANCE SPECIFICATIONS 3 CH940 CH960 CH980 CH1000 Connecting Rod Crankpin End I.D. @ 70°F New Max. Wear Limit 44.030/44.037 mm (1.7334/1.7337 in.) 0.070 mm (0.0028 in.) 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 0.30/0.59 mm (0.0118/0.0232 in.) Connecting Rod-to-Piston Pin Running Clearance 0.015/0.028 mm (0.0006/0.0011 in.) Piston Pin End I.D. @ 70°F New Max. Wear Limit 19.023/19.015 mm (0.7489/0.7486 in.) 19.036 mm (0.7494 in.) Crankcase Governor Cross Shaft Bore I.D. New Max. Wear Limit 8.025/8.050 mm (0.3159/0.3169 in.) 8.088 mm (0.3184 in.) Crankshaft End Play (free) 0.30/1.50 mm (0.011/0.059 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.) 45.040/45.145 mm (1.7732/1.7773 in.) 45.158 mm (1.7778 in.) Crankshaft to Sleeve Bearing (in crankcase) Running Clearance New 0.040/0.167 mm (0.0015/0.0065 in.) Crankshaft Bore (in closure plate) New, Without Bearing 50.025/50.00 mm (1.9694/1.9685 in.) Crankshaft to Sleeve Bearing (in closure plate) Running Clearance New 0.040/0.167 mm (0.0015/0.0065 in.) Closure Plate End Main Bearing Journal O.D. - New O.D. - Max. Wear Limit Max. Taper Max. Out-of-Round 44.978/45.00 mm (1.770/1.771 in.) 44.90 mm (1.767 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 Width 43.982/44.000 mm (1.731/1.732 in.) 43.97 mm (1.731 in.) 0.018 mm (0.0007 in.) 0.025 mm (0.0010 in.) 53.00/53.09 mm (2.0866/2.0901 in.) Crankshaft 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.) Flywheel End Main Bearing Journal O.D. - New O.D. - Max. Wear Limit Max. Taper Max. Out-of-Round 44.978/45.00 mm (1.770/1.771 in.) 44.90 mm (1.767 in.) 0.022 mm (0.0009 in.) 0.025 mm (0.0010 in.) Cylinder Bore Cylinder Bore I.D. New Max. Wear Limit Max. Taper Max. Out-of-Round 90.000/90.025 mm (3.543/3.544 in.) 90.075 mm (3.546 in.) 0.013 mm (0.00051 in.) 0.013 mm (0.00051 in.) 3 Values are in Metric units. Values in parentheses are English equivalents.

Kohler Command Pro CH940-CH1000 Engine Service Repair Manual

You're Reading a Preview

Recently Viewed