Kohler Command PRO CH940 Manual de usuario

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. J 1

2 Safety

3 Maintenance

5Specications

21 Tools and Aids

24 Troubleshooting

28 Air Cleaner/Intake

29 Fuel System

35 Governor System

36 Lubrication System

38 Electrical System

49 Starter System

53 Disassembly/Inspection and Service

69 Reassembly

Safety

262 690 01 Rev. JKohlerEngines.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

362 690 01 Rev. J 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 lter minder. Air Cleaner/Intake

Every 25 Hours or Annually¹

● Service/replace low-prole precleaner. Air Cleaner/Intake

Every 100 Hours or Annually¹

● Change oil. Oil lter is recommended. Lubrication System

Every 150 Hours¹

● Replace low-prole air cleaner element. Air Cleaner/Intake

● Remove cooling shrouds and clean cooling areas. Air Cleaner/Intake

Every 150 Hours

● Check heavy-duty air cleaner element. Air Cleaner/Intake

● Replace fuel lter.

● Check oil cooler ns, clean as necessary. Lubrication System

Every 200 Hours

● Change oil lter. Lubrication System

Every 300 Hours

● Replace heavy-duty air cleaner element. Air Cleaner/Intake

Every 500 Hours or Annually¹

● Replace spark plugs and set gap. Electrical System

Every 500 Hours²

● Have crankshaft splines lubricated.

Every 600 Hours

● Replace heavy-duty inner air cleaner element. Air Cleaner/Intake

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

2Have 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

462 690 01 Rev. JKohlerEngines.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.

°F -20 020324060

50 80 100

°C -30 -20 -10 0 10 20 30 40

10W-30

5W-30

SAE 30

20W-50

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

562 690 01 Rev. J KohlerEngines.com

Engine Dimensions with Heavy-Duty Air Cleaner - Flywheel Side

A484.3 mm (19.07 in.) B

135.0 mm (5.32 in.)

Rain Cap Cover

Removal

C365.5 mm (14.39 in.) D

130.0 mm (5.12 in.)

Air Filter Cover

Removal

E74.0 mm (2.91 in.) FChoke Control GThrottle Control HMechanical Fuel

Pump

I698.6 mm

(27.50 in.) J5.4 mm (0.21 in.)

Spark Plug Lead KSupply Fuel Filter LEngine Mounting

Surface

8 X 10.3 mm

(0.40 in.)

Thru Mounting Holes

NCenter Line Engine O232.0 mm (9.13 in.) P106.0 mm (4.17 in.)

QMounting Hole "A" R136.2 mm (5.36 in.) S14.7 mm (0.58 in.)

Spark Plug Lead T

328.3 mm

(12.93 in.)

Air Filter Element

Removal

UOil Fill

Specications

662 690 01 Rev. JKohlerEngines.com

Engine Dimensions with Heavy-Duty Air Cleaner - PTO Side

A427.8 mm (16.84 in.) B107.9 mm (4.25 in.) C35° D30°

EOil Level Dipstick F45° G60.0 mm (2.37 in.)

Exhaust Port H340.8 mm (13.42 in.)

ISolenoid Shift Starter JMounting Hole "A" KRotation Direction L177.8 mm (7.0 in.)

Optional Pilot

M8 X 1.25 mm-6H in.

25 mm (0.98 in.)

Deep on a Ø 254 mm

(10.0 in.) B.C.

4 X 7/16-14 UNC-2B in.

21 mm (0.83 in.) Deep

on a Ø 142.9 mm

(5.63 in.) B.C.

4 X 3/8-16 UNC-2B in.

17 mm (0.67 in.) Deep

on a Ø 196.9 mm

(7.750 in.) B.C.

P2 X 35.0 mm (1.38 in.)

Gasket

Q4 X M8 X 1.25 mm

Studs

Specications

762 690 01 Rev. J KohlerEngines.com

Engine Dimensions with Heavy-Duty Air Cleaner - Starter Side

422.7 mm (16.64 in.)

Cylinder #1 Shroud

Removed

4 X 47.3 mm (1.86 in.)

Air Cleaner Clip

Clearance

CPTO Mounting

Surface D105.3 mm (4.14 in.)

Exhaust Port #1

E192.3 mm (7.57 in.) FMufer (Optional) G460.0 mm (18.11

in.) H9.5 mm (0.38 in.)

SQ. Keyway

I36.5 mm (1.44 in.) J155.6 mm (6.13 in.) K5/8-18 UNF-2B in.

38.1 mm (1.5 in.) Deep L113.2 mm (4.46 in.)

MEngine Mounting

Surface NOil Drain Plug

1/2 NPT Inch O435.0 mm (17.13 in.) P401.8 mm (15.82 in.)

Q135.0 mm (5.3 in.) R119.0 mm (4.69 in.) S16.0 mm (0.63 in.) TGrass Screen

UMounting Hole "A" V570.8 mm (22.47 in.) W50.0 mm (1.97 in.)

Oil Filter Removal XCylinder #1 Shroud

Specications

862 690 01 Rev. JKohlerEngines.com

Engine Dimensions with Heavy-Duty Air Cleaner - Opposite Starter Side

422.7 mm (16.64 in.)

Cylinder #2 Shroud

Removed

BLifting Point CCylinder #2 Shroud DAccess to Oil Cooler

EFuel Filter FMounting Hole "A" G16.0 mm (0.63 in.) H119.0 mm (4.69 in.)

I135.0 mm (5.32 in.) J239.5 mm (9.43 in.) KOil Drain Plug

1/2 NPT Inch LEngine Mounting

Surface

M4 X 4.0 mm (0.16 in.)

Pilot Height NPTO Mounting

Surface OPilot Surface POil Pressure Switch

Q82.3 mm (3.24 in.)

Exhaust Port #2

Specications

962 690 01 Rev. J KohlerEngines.com

Engine Dimensions - Mounting Surface View

A232.0 mm (9.13 in.) B8 X 10.3 mm (0.40 in.)

Thru Mounting Holes CMounting Hole "A" D239.5 mm (9.43 in.)

E106.0 mm (4.17 in.) FPTO Mounting

Surface G135.0 mm (5.32 in.) H119.0 mm (4.69 in.)

I16.0 mm (0.63 in.)

Specications

10 62 690 01 Rev. JKohlerEngines.com

Engine Dimensions with Low-Prole Air Cleaner - Flywheel Side

A484.3 mm (19.07 in.) B364.5 mm (14.35 in.) C106.0 mm (4.17 in.)

Lifting Point D85.7 mm (3.38 in.)

E76.3 mm (3.00 in.) F

Lifting Point

10 X 12 mm

(0.39 X 0.47 in.) Slot

G136.2 mm (5.36 in.) H14.7 mm (0.58 in.)

Spark Plug Lead

IMounting Hole "A" JEngine Mounting

Surface K575.1 mm (22.64 in.)

Lifting Point L5.4 mm (0.21 in.)

Spark Plug Lead

MOil Fill

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