Kohler Command Pro CV940 Manual de usuario

CV940-CV1000

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 02 Rev. D 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

38 Starter System

42 Disassembly/Inspection and Service

56 Reassembly

Safety

2 62 690 02 Rev. DKohlerEngines.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

362 690 02 Rev. D 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

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 ﬁnd a local Kohler authorized

dealer visit KohlerEngines.com or call 1-800-544-2444 (U.S. and Canada).

Maintenance

462 690 02 Rev. DKohlerEngines.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

562 690 02 Rev. D KohlerEngines.com

Dimensions in millimeters.

Inch equivalents shown in [ ].

(Optional Guard)

Engine Dimensions

Speciﬁcations

662 690 02 Rev. DKohlerEngines.com

TORQUE SPECIFICATIONS3,5 CV940 CV960 CV980 CV1000

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.)

Air Cleaner Mounting Screw (into intake manifold) 9.9 N·m (88 in. lb.)

Fuel Bowl Screw 2.5 ± 0.3 N·m (22 ± 2.3 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.)

Crankcase

Breather Cover Fastener 5.7 N·m (51 in. lb.)

Oil Drain Plug 21.4 N·m (16 ft. lb.)

Dipstick Tube Screw 4.0 N·m (35 in. lb.)

GENERAL SPECIFICATIONS3,6 CV940 CV960 CV980 CV1000

Bore 90 mm (3.54 in.)

Stroke 78.5 mm (3.1 in.)

Displacement 999 cc (61 cu. in.)

Oil Capacity (reﬁll) 2.9 L (3.1 U.S. qt.)

Maximum Angle of Operation (@ full oil level)425°

Model. . . . . . . . . . . . . . . . . . . . . CV940

Command Engine

Vertical Shaft

Numerical Designation

Speciﬁcation . . . . . . . . . . . . . . . CV940-0001

Serial . . . . . . . . . . . . . . . . . . . . . 3923500328

Year Manufactured Code Factory Code

Code Year

39 2009

40 2010

41 2011

ENGINE IDENTIFICATION NUMBERS

Kohler engine identiﬁcation numbers (model, speciﬁcation and serial) should be referenced for efﬁcient repair,

ordering correct parts, and engine replacement.

3 Values are in Metric units. Values in parentheses are English equivalents.

4Exceeding maximum angle of operation may cause engine damage from insufﬁcient lubrication.

5Lubricate threads with engine oil prior to assembly.

6Any 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.

Speciﬁcations

762 690 02 Rev. D KohlerEngines.com

TORQUE SPECIFICATIONS3,5 CV940 CV960 CV980 CV1000

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 Stud (AVT) 11.3 N·m (100 in. lb.)

Setscrew, AVT pivot locking 7.3 N·m (65 in. lb.)

Debris Screen

Hex Stud 9.9 N·m (88 in. lb.)

Mounting Screw 9.9 N·m (88 in. lb.)

Flywheel

Fan Fastener 9.9 N·m (88 in. lb.)

Retaining Screw 67.8 N·m (50 ft. lb.)

Fuel Pump

Screw 8.0-12.1 N·m (71-107 in. lb.) into new holes

6.0-9.0 N·m (53-80 in. lb.) into used holes

Governor

Lever Nut 7.3 N·m (65 in. lb.)

Yoke Mounting Screw 2.2 N·m (20 in. lb.)

Ignition

Spark Plug 27 N·m (20 ft. lb.)

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

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.)

Screw, intermittent bracket (into weld nut) 13.5 N·m (120 in. lb.)

Oil Cooler

Mounting Screw 2.2 N·m (20 in. lb.)

Oil Filter Adapter/Housing

Mounting Screw 24.4 N·m (216 in. lb.)

Oil Filter Nipple 18 N·m (159 in. lb.)

Oil Pan

Fastener 27 N·m (238 in. lb.)

Oil Pickup Tube

Mounting Screw 10.7 N·m (95 in. lb.) into a new hole

7.3 N·m(65 in. lb.) into a used hole

3 Values are in Metric units. Values in parentheses are English equivalents.

5Lubricate threads with engine oil prior to assembly.

Speciﬁcations

862 690 02 Rev. DKohlerEngines.com

TORQUE SPECIFICATIONS3,5 CV940 CV960 CV980 CV1000

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 SentryTM

Pressure Switch 10.1 N·m (90 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

Fastener 13.6 N·m (120 in. lb.)

CLEARANCE SPECIFICATIONS3CV940 CV960 CV980 CV1000

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.

5Lubricate threads with engine oil prior to assembly.

Speciﬁcations

962 690 02 Rev. D KohlerEngines.com

CLEARANCE SPECIFICATIONS3CV940 CV960 CV980 CV1000

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

19.015/19.023 mm (0.7486/0.7489 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.)

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 (crankcase) Running Clearance

New 0.040/0.167 mm (0.0015/0.0065 in.)

Bore (in oil pan)

New, Without Bearing 50.025/50.00 mm (1.9694/1.9685 in.)

Crankshaft to Sleeve Bearing (in oil pan) Running Clearance

New 0.040/0.167 mm (0.0015/0.0065 in.)

Oil Pan 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.)

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.)

Crankshaft Bearing (ﬂywheel/PTO)

New (installed)

Max. Wear Limit

45.040/45.145 mm (1.773.1.777 in.)

45.158 mm

3 Values are in Metric units. Values in parentheses are English equivalents.

Speciﬁcations

10 62 690 02 Rev. DKohlerEngines.com

CLEARANCE SPECIFICATIONS3CV940 CV960 CV980 CV1000

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.)

Cylinder Head

Max. Out-of-Flatness 0.076 mm (0.003 in.)

Governor

Governor Cross Shaft-to-Crankcase Running Clearance 0.025/0.087 mm (0.0009/0.0034 in.)

Cross Shaft O.D.

New

Max. Wear Limit

7.963/8.000 mm (0.3135/.3149 in.)

7.936 mm (0.3124 in.)

Governor Gear Shaft-to-Governor Gear Running Clearance 0.070/0.160 mm (0.0027/0.0063 in.)

Gear Shaft O.D.

New

Max. Wear Limit

5.990/6.000 mm (0.2358/0.2362 in.)

5.977 mm (0.2353 in.)

Ignition

Spark Plug Gap 0.76 mm (0.030 in.)

Module Air Gap 0.28/0.33 mm (0.011/0.013 in.)

Piston, Piston Rings, and Piston Pin

Piston-to-Piston Pin Running Clearance 0.006/0.018 mm (0.0002/0.0007 in.)

Pin Bore I.D.

New

Max. Wear Limit

19.006/17.013 mm (0.7482/0.7485 in.)

19.025 mm (0.7490 in.)

Pin O.D.

New

Max. Wear Limit

18.995/19.000 mm (0.7478/0.7480 in.)

18.994 mm (0.7478 in.)

Top Compression Ring-to-Groove Side Clearance 0.04/0.08 mm (0.0015/0.0031 in.)

Middle Compression Ring-to-Groove Side Clearance 0.04/0.08 mm (0.0015/0.0031 in.)

Oil Control Ring-to-Groove Side Clearance 0.03/0.19 mm (0.0011/0.0074 in.)

Top and Center Compression Ring End Gap

New Bore

Used Bore (max.)

0.30/0.55 mm (0.011/0.021 in.)

0.94 mm (0.037 in.)

Thrust Face O.D.7

New

Max. Wear Limit

89.953/89.967 mm (3.5414/3.5420 in.)

89.925 mm (3.540 in.)

Piston Thrust Face-to-Cylinder Bore7Running Clearance

New 0.033/0.071 mm (0.0013/0.0028 in.)

3 Values are in Metric units. Values in parentheses are English equivalents.

7Measure 11 mm (0.433 in.) above bottom of piston skirt at right angles to piston pin.

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