KOHLER COMMand PRO Model CV980 28HP Engine Full Service & Repair Manual

SERVICE MANUAL HORIZONTAL CRANKSHAFT COMMAND CH18-745 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 www.mymowerparts.com

1.1 1 Section 1 Safety and General Information CH18-745 Safety Precautions To ensure safe operation please read the following statements and understand their meaning. Also refer to your equipment manufacturer's manual for other important safety information. This manual contains safety precautions which are explained below. Please read carefully. WARNING Warning is used to indicate the presence of a hazard that can cause severe personal injury, death, or substantial property damage if the warning is ignored. CAUTION Caution is used to indicate the presence of a hazard that will or can cause minor personal injury or property damage if the caution is ignored. NOTE Note is used to notify people of installation, operation, or maintenance information that is important but not hazard-related. For Your Safety! These precautions should be followed at all times. Failure to follow these precautions could result in injury to yourself and others. Rotating Parts can cause severe injury. Stay away while engine is in operation. WARNING Rotating Parts! Keep hands, feet, hair, and clothing away from all moving parts to prevent injury. Never operate the engine with covers, shrouds, or guards removed. Hot Parts can cause severe burns. Do not touch engine while operating or just after stopping. WARNING Hot Parts! Engine components can get extremely hot from operation. To prevent severe burns, do not touch these areas while the engine is running - or immediately after it is turned off. Never operate the engine with heat shields or guards removed. Accidental Starts can cause severe injury or death. Disconnect and ground spark plug leads before servicing. WARNING Accidental Starts! Disabling engine. Accidental starting can cause severe injury or death. Before working on the engine or equipment, disable the engine as follows: 1) Disconnect the spark plug lead(s). 2) Disconnect negative (-) battery cable from battery. Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 www.mymowerparts.com

1.2 Section 1 Safety and General Information Carbon Monoxide can cause severe nausea, fainting or death. Do not operate engine in closed or confined area. WARNING WARNING Electrical Shock can cause injury. Do not touch wires while engine is running. CAUTION Uncoiling Spring can cause severe injury. Wear safety goggles or face protection when servicing retractable starter. WARNING Explosive Gas can cause fires and severe acid burns. Charge battery only in a well ventilated area. Keep sources of ignition away. Lethal Exhaust Gases! Engine exhaust gases contain poisonous carbon monoxide. Carbon monoxide is odorless, colorless, and can cause death if inhaled. Avoid inhaling exhaust fumes, and never run the engine in a closed building or confined area. Spring Under Tension! Retractable starters contain a powerful, recoil spring that is under tension. Always wear safety goggles when servicing retractable starters and carefully follow instructions in the "Retractable Starter" Section 7 for relieving spring tension. Explosive Gas! Batteries produce explosive hydrogen gas while being charged. To prevent a fire or explosion, charge batteries only in well ventilated areas. Keep sparks, open flames, and other sources of ignition away from the battery at all times. Keep batteries out of the reach of children. Remove all jewelry when servicing batteries. Before disconnecting the negative (-) ground cable, make sure all switches are OFF. If ON, a spark will occur at the ground cable terminal which could cause an explosion if hydrogen gas or gasoline vapors are present. Electrical Shock! Never touch electrical wires or components while the engine is running. They can be sources of electrical shock. Explosive Fuel can cause fires and severe burns. Stop engine before filling fuel tank. WARNING Explosive Fuel! 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. Do not fill the fuel tank while the engine is hot or running, since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition. Do not start the engine near spilled fuel. Never use gasoline as a cleaning agent. Cleaning Solvents can cause severe injury or death. Use only in well ventilated areas away from ignition sources. WARNING Flammable Solvents! Carburetor cleaners and solvents are extremely flammable. Keep sparks, flames, and other sources of ignition away from the area. Follow the cleaner manufacturer’s warnings and instructions on its proper and safe use. Never use gasoline as a cleaning agent. Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 www.mymowerparts.com

1.3 Section 1 Safety and General Information 1 A. Model No. Version Code S = Electric Start C H 18 S Engine Identification Numbers When ordering parts, or in any communication involving an engine, always give the Model, Specification and Serial Numbers, including letter suffixes if there are any. The engine identification numbers appear on a decal, or decals, affixed to the engine shrouding. See Figure 1-1. An explanation of these numbers is shown in Figure 1-2. Figure 1-1. Engine Identification Decal Location. Variation of Basic Engine B. Spec. No. 62500 Command Engine Horizontal Crankshaft Horsepower 17 = 17 HP 18 = 18 HP 20 = 20 HP 22 = 22 HP 23 = 23 HP 25 = 25 HP 26 = 26 HP Numerical Designation 730 740 745 or Engine Model Code Code Model 62 CH18 64 CH20 66 CH22 (624 cc) 68 CH25 76 CH22/23 (674 cc) 78 CH26 CH730-0001 CH740-0001 CH745-0001 Complete Spec Number (Incorporating Model No. with Variation No. of Basic Spec.) or Figure 1-2. Explanation of Engine Identification Numbers. C. Serial No. Year Manufactured Code Code Y ear 21 1991 22 1992 23 1993 24 1994 25 1995 26 1996 27 1997 28 1998 29 1999 Factory Code 3305810334 Code Y ear 30 2000 31 2001 32 2002 33 2003 34 2004 35 2005 Identification Decal Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 www.mymowerparts.com

1.4 Section 1 Safety and General Information Oil Recommendations Using the proper type and weight of oil in the crankcase is extremely important. So is checking oil daily and changing oil regularly. Failure to use the correct oil, or using dirty oil, causes premature engine wear and failure. Oil Type Use high-quality detergent oil of API (American Petroleum Institute) Service Class SG, SH, SJ or higher. Select the viscosity based on the air temperature at the time of operation as shown in the following table. Fuel Recommendations WARNING: Explosive Fuel! Gasoline is extremely flammable and its vapors can explode if ignited. Before servicing the fuel system, make sure there are no sparks, open flames or other sources of ignition nearby as these can ignite gasoline vapors. Disconnect and ground the spark plug leads to prevent the possibility of sparks from the ignition system. General Recommendations Purchase gasoline in small quantities and store in clean, approved containers. A container with a capacity of 2 gallons or less with a pouring spout is recommended. Such a container is easier to handle and helps eliminate spillage during refueling. Do not use gasoline left over from the previous season, to minimize gum deposits in your fuel system and to ensure easy starting. Do not add oil to the gasoline. Do not overfill the fuel tank. Leave room for the fuel to expand. Fuel Type For best results, use only clean, fresh, unleaded gasoline with a pump sticker octane rating of 87 or higher. In countries using the Research method, it should be 90 octane minimum. Unleaded gasoline is recommended as it leaves less combustion chamber deposits and reduces harmful exhaust emissions. Leaded gasoline is not recommended and must not be used on EFI engines, or on other models where exhaust emissions are regulated. Gasoline/Alcohol blends Gasohol (up to 10% ethyl alcohol, 90% unleaded gasoline by volume) is approved as a fuel for Kohler engines. Other gasoline/alcohol blends are not approved. Gasoline/Ether blends Methyl Tertiary Butyl Ether (MTBE) and unleaded gasoline blends (up to a maximum of 15% MTBE by volume) are approved as a fuel for Kohler engines. Other gasoline/ether blends are not approved. NOTE: Using other than service class SG, SH, SJ or higher oil or extending oil change intervals longer than recommended can cause engine damage. NOTE: Synthetic oils meeting the listed classifications may be used with oil changes performed at the recommended intervals. However, to allow piston rings to properly seat, a new or rebuilt engine should be operated for at least 50 hours using standard petroleum based oil before switching to synthetic oil. A logo or symbol on oil containers identifies the API service class and SAE viscosity grade. See Figure 1-3. Figure 1-3. Oil Container Logo. Refer to Section 6 - “Lubrication System” for detailed procedures on checking the oil, changing the oil and changing the oil filter. * *Use of synthetic oil having 5W-20 or 5W-30 rating is acceptable, up to 40°F. **Synthetic oils will provide better starting in extreme cold (below -10°F). ** Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 www.mymowerparts.com

1.5 Section 1 Safety and General Information 1 Periodic Maintenance Instructions WARNING: Accidental Starts! Disabling engine. Accidental starting can cause severe injury or death. Before working on the engine or equipment, disable the engine as follows: 1) Disconnect the spark plug lead(s). 2) Disconnect negative (-) battery cable from battery. Maintenance Schedule These required maintenance procedures should be performed at the frequency stated in the table. They should also be included as part of any seasonal tune-up. 1 Perform these maintenance procedures more frequently under extremely dusty, dirty conditions. 2 Have a Kohler Engine Service Dealer perform this service. 3 Cleanout Kits 25 755 20-S (black) or 25 755 21-S (gold) allow cooling areas to be cleaned without removing shrouds. Storage If the engine will be out of service for two months or more, use the following storage procedure. 1. Clean the exterior surfaces of the engine. On Electronic Fuel Injected (EFI) engines, avoid spraying water at the wiring harness or any of the electrical components. 2. Change the oil and oil filter while the engine is still warm from operation. See “Change Oil and Oil Filter” in Section 6. 3. The fuel system must be completely emptied, or the gasoline must be treated with a stabilizer to prevent deterioration. If you choose to use a stabilizer, follow the manufacturer’s recommendations, and add the correct amount for the capacity of the fuel system. Fill the fuel tank with clean, fresh gasoline. Run the engine for 2 to 3 minutes to get stabilized fuel into the rest of the system. Close the fuel shut-off valve when the unit is being stored or transported. To empty the system, run the engine until the tank and the system are empty. 4. Remove the spark plugs and add one tablespoon of engine oil into each spark plug hole. Install the spark plugs, but do not connect the plug leads. Crank the engine two or three revolutions. 5. On equipment with an EFI engine, disconnect the battery or use a battery minder to keep the battery charged during storage. 6. Store the engine in a clean, dry place. • Replace fuel filter 1 (EFI engines). Section 5B Daily or Before Starting Engine Maintenance Required Refer to: Frequency • Fill fuel tank. Section 5 • Check oil level. Section 6 • Check air cleaner for dirty 1 , loose, or damaged parts. Section 4 • Check air intake and cooling areas, clean as necessary 1 . Section 4 • Service precleaner element 1 . Section 4 Every 25 Hours • Replace air cleaner element 1 . Section 4 • Change oil. (More frequently under severe conditions.) Section 6 • Remove cooling shrouds and clean cooling areas 1,3 . Section 4 • Check oil cooler fins, clean as necessary (if equipped). Section 6 • Check spark plug condition and gap. Section 8 • Change oil filter. Section 6 Annually or Every 500 Hours • Have bendix starter drive serviced 2 . Section 8 • Have solenoid shift starter disassembled and cleaned 2 . Section 8 Every 100 Hours Every 200 Hours Every 1500 Hours • Have crankshaft spline lubricated 2 . Section 2 Every 500 Hours Every 250 Hours • Replace heavy-duty air cleaner element and check inner element 1 . Section 4 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 www.mymowerparts.com

1.6 Section 1 Safety and General Information Figure 1-4. Typical Engine Dimensions CH Series with Standard Flat Air Cleaner. Dimensions in millimeters. Inch equivalents shown in (). Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 www.mymowerparts.com

1.7 Section 1 Safety and General Information 1 Figure 1-5. Typical Engine Dimensions CH EFI Series with Heavy-Duty Air Cleaner. Dimensions in millimeters. Inch equivalents shown in (). Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 www.mymowerparts.com

1.8 Section 1 Safety and General Information General Specifications¹ Power (@ 3600 RPM, corrected to SAE J1995) CH18 ............................................................................................................................ 13.4 kW (18 HP) CH20 ............................................................................................................................ 14.9 kW (20 HP) CH22/23 ....................................................................................................................... 16.4 kW (22 HP) CH25, CH730 ............................................................................................................... 18.4 kW (25 HP) CH26 ............................................................................................................................ 19.4 kW (26 HP) CH740 .......................................................................................................................... 20.1 kW (27 HP) CH745 .......................................................................................................................... 20.9 kW (28 HP) Peak Torque CH18 - @ 2200 RPM ................................................................................................... 44.4 N·m (32.8 ft. lb.) CH20 - @ 2600 RPM ................................................................................................... 44.2 N·m (32.6 ft. lb.) CH22/23 - @ 2200 RPM .............................................................................................. 51.7 N·m (38.2 ft. lb.) CH25, CH730 - @ 2800 RPM ...................................................................................... 54.1 N·m (39.9 ft. lb.) CH26 - @ 2800 RPM ................................................................................................... 54.2 N·m (40.0 ft. lb.) CH740 - @ 3000 RPM ................................................................................................. 57.9 N·m (42.7 ft. lb.) CH745 - @ 2200 RPM ................................................................................................. 60.7 N·m (44.8 ft. lb.) Bore CH18, CH20, CH22 (624 cc) ........................................................................................ 77 mm (3.03 in.) CH22/23 (674 cc) ......................................................................................................... 80 mm (3.15 in.) CH25, CH26, CH730-745 ............................................................................................. 83 mm (3.27 in.) Stroke ................................................................................................................................. 67 mm (2.64 in.) Displacement CH18, CH20, CH22 (624 cc) ........................................................................................ 624 cc (38 cu. in.) CH22/23 (674 cc) ......................................................................................................... 674 cc (41 cu. in.) CH25, CH26, CH730-745 ............................................................................................. 725 cc (44 cu. in.) Compression Ratio CH18, CH20, CH22/23 ................................................................................................. 8.5:1 CH25, CH26, CH730-745 ............................................................................................. 9.0:1 Dry Weight CH18, CH20, CH22/23 ................................................................................................. 41 kg (90 lb.) CH25, CH26, CH730-745 ............................................................................................. 43 kg (94 lb.) Oil Capacity (with filter) CH18, CH20, CH22/23, CH25, CH26, CH730-745 ...................................................... 1.9 L (2.0 U.S. qt.) Angle of Operation - Maximum (At Full Oil Level) All Directions ......................................... 25° Blower Housing and Sheet Metal M5 Fasteners Torque .......................................................................................................... 4.0 N·m (35 in. lb.) M6 Fasteners Torque .......................................................................................................... 6.8 N·m (60 in. lb.) Rectifier-Regulator Fastener Torque ................................................................................... 4.0 N·m (35 in. lb.) ¹Values are in Metric units. Values in parentheses are English equivalents. Lubricate threads with engine oil prior to assembly. Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 www.mymowerparts.com

1.9 Section 1 Safety and General Information 1 Camshaft End Play (With Shim) .................................................................................. 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 ....................................................................................................... 20.000/20.025 mm (0.7874/0.7884 in.) Max. Wear Limit .................................................................................... 20.038 mm (0.7889 in.) Camshaft Bearing Surface O.D. New ....................................................................................................... 19.962/19.975 mm (0.7859/0.7864 in.) Max. Wear Limit .................................................................................... 19.959 mm (0.7858 in.) Carburetor and Intake Manifold Intake Manifold Mounting Fastener Torque Torque in Two Stages ............................................................................ initially to 7.4 N·m (66 in. lb.) finally to 9.9 N·m (88 in. lb.) Carburetor Mounting Screw Torque M6 ....................................................... 6.2-7.3 N·m (55-65 in. lb.) Adapter (for Heavy Duty Air Cleaner) Mounting Fastener Torque ................ 7.3 N·m (65 in. lb.) Connecting Rod Cap Fastener Torque (torque in increments) 8 mm straight shank .............................................................................. 22.7 N·m (200 in. lb.) 8 mm step-down ................................................................................... 14.7 N·m (130 in. lb.) 6 mm straight shank .............................................................................. 11.3 N·m (100 in. lb.) Connecting Rod-to-Crankpin Running Clearance New ....................................................................................................... 0.030/0.055 mm (0.0012/0.0022 in.) Max. Wear Limit .................................................................................... 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 ....................................................................................................... 17.015/17.023 mm (0.6699/0.6702 in.) Max. Wear Limit .................................................................................... 17.036 mm (0.6707 in.) Crankcase Governor Cross Shaft Bore I.D. 6 mm Shaft New ................................................................................................... 6.025/6.050 mm (0.2372/0.2382 in.) Max. Wear Limit ................................................................................. 6.063 mm (0.2387 in.) 8 mm Shaft New ................................................................................................... 8.025/8.075 mm (0.3159/0.3179 in.) Max. Wear Limit ................................................................................. 8.088 mm (0.3184 in.) Breather Cover Fastener Torque ................................................................. 7.3 N·m (65 in. lb.) Oil Drain Plug Torque ................................................................................... 13.6 N·m (10 ft. lb.) Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 www.mymowerparts.com

KOHLER COMMand PRO Model CV980 28HP Engine Full Service & Repair Manual

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