Kohler Command PRO CV940 Service Manual

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Page 1 CV940-CV1000 Service Manual 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. Safety Maintenance Speciﬁ cations Tools and Aids Troubleshooting Air Cleaner/Intake...
Page 2 Safety 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. CAUTION WARNING WARNING...
Page 3 Have a Kohler authorized dealer perform this service. REPAIRS/SERVICE PARTS Kohler genuine service parts can be purchased from Kohler authorized dealers. To ﬁ nd a local Kohler authorized dealer visit KohlerEngines.com or call 1-800-544-2444 (U.S. and Canada). 62 690 02 Rev. D...
Page 4 OIL RECOMMENDATIONS STORAGE If engine will be out of service for 2 months or more We recommend use of Kohler oils for best performance. follow procedure below. Other high-quality detergent oils (including synthetic) of API (American Petroleum Institute) service class SJ 1.
Page 5 Speciﬁ cations Engine Dimensions Dimensions in millimeters. Inch equivalents shown in [ ]. (Optional Guard) KohlerEngines.com 62 690 02 Rev. D...
Page 6 Lubricate threads with engine oil prior to assembly. Any and all horsepower (hp) references by Kohler are Certiﬁ ed Power Ratings and per SAE J1940 & J1995 hp standards. Details on Certiﬁ ed Power Ratings can be found at KohlerEngines.com.
Page 7 Speciﬁ cations TORQUE SPECIFICATIONS CV940 CV960 CV980 CV1000 Cylinder Head Fastener (torque in 2 increments) Head Bolt ﬁ rst to 22.6 N·m (200 in. lb.) ﬁ nally 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.
Page 8 Speciﬁ cations TORQUE SPECIFICATIONS 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 Sentry Pressure Switch 10.1 N·m (90 in. lb.) Solenoid (starter) Mounting Hardware 4.0-6.0 N·m (35-53 in.
Page 9 Speciﬁ cations CLEARANCE SPECIFICATIONS CV940 CV960 CV980 CV1000 Connecting Rod Crankpin End I.D. @ 70°F 44.030/44.037 mm (1.7334/1.7337 in.) Max. Wear Limit 0.070 mm (0.0028 in.) Connecting Rod-to-Crankpin Running Clearance 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 0.30/0.59 mm (0.0118/0.0232 in.) Connecting Rod-to-Piston Pin Running Clearance...
Page 10 Speciﬁ cations CLEARANCE SPECIFICATIONS CV940 CV960 CV980 CV1000 Cylinder Bore I.D. 90.000/90.025 mm (3.543/3.544 in.) Max. Wear Limit 90.075 mm (3.546 in.) Max. Taper 0.013 mm (0.00051 in.) Max. Out-of-Round 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.)
Page 11 Speciﬁ cations CLEARANCE SPECIFICATIONS CV940 CV960 CV980 CV1000 Valves and Valve Lifters Hydraulic Valve Lifter to Crankcase Running Clearance 0.012/0.050 mm (0.0004/0.0019 in.) Intake Valve Stem-to-Valve Guide Running Clearance 0.038/0.076 mm (0.0015/0.0030 in.) Exhaust Valve Stem-to-Valve Guide Running Clearance 0.050/0.088 mm (0.0020/0.0035 in.) Intake Valve Guide I.D.
Page 12 Speciﬁ cations GENERAL TORQUE VALUES 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 Tightening Torque: N·m (in. lb.) ± 20% 8-32 2.3 (20) 2.8 (25)
Page 13 Here is a list of tools and their source. SEPARATE TOOL SUPPLIERS Kohler Tools SE Tools Design Technology Inc. Contact your local Kohler source of 415 Howard St. 768 Burr Oak Drive supply. Lapeer, MI 48446 Westmont, IL 60559...
Page 14 For reaming worn valve guides to accept replacement oversize valves. Can be used in low-speed drill press or with handle below for hand reaming. Design Technology Inc. Reamer Handle For hand reaming using Kohler 25 455 12-S reamer. DTI-K830 SE Tools KLR-82415 Valve Guide Service Kit (Courage, Aegis, Command, OHC) For servicing worn valve guides.
Page 15 Tools and Aids FLYWHEEL HOLDING TOOL ROCKER ARM/CRANKSHAFT TOOL A ﬂ ywheel holding tool can be made out of an old junk A spanner wrench to lift rocker arms or turn crankshaft ﬂ ywheel ring gear and used in place of a strap wrench. may be made out of an old junk connecting rod.
Page 16: Troubleshooting
Troubleshooting TROUBLESHOOTING GUIDE When troubles occur, be sure to check simple causes which, at ﬁ rst, 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 listed below and vary by engine speciﬁ cation. Use these to locate causing factors.
Page 17 Troubleshooting EXTERNAL ENGINE INSPECTION Engine Loses Power NOTE: It is good practice to drain oil at a location away ● Dirty air cleaner element. from workbench. Be sure to allow ample time for ● Engine overheated. complete drainage. ● Excessive engine load. ●...
Page 18 Troubleshooting CRANKCASE VACUUM TEST WARNING WARNING Carbon Monoxide can cause severe nausea, Rotating Parts can cause severe injury. fainting or death. Stay away while engine is in operation. Avoid inhaling exhaust fumes. Engine exhaust gases contain poisonous carbon Keep hands, feet, hair, and clothing away from all monoxide.
Page 19 Troubleshooting COMPRESSION TEST For Command Twins: A compression test is best performed on a warm engine. Clean any dirt or debris away from base of spark plug(s) before removing them. Be sure choke is off, and throttle is wide open during test. Compression should be at least 160 psi and should not vary more than 15% between cylinders.
Page 20: Air Cleaner/Intake
Air Cleaner/Intake 1. Unhook retaining clips and remove end cap(s). AIR CLEANER These systems are CARB/EPA certiﬁ ed and components 2. Check and clean inlet screen (if equipped). should not be altered or modiﬁ ed in any way. 3. Pull air cleaner element out of housing and replace. Check condition of inner element;...
Page 21: Fuel System
To replace pulse pump follow these steps. Note Low permeation fuel line must be installed on carbureted orientation of pump before removing. Kohler Co. engines to maintain EPA and CARB 1. Disconnect fuel lines from inlet, outlet, and pulse regulatory compliance.
Page 22 Fuel System CARBURETOR Gasoline is extremely ﬂ ammable and its vapors can WARNING explode if ignited. Store gasoline only in approved Explosive Fuel can cause ﬁ res and severe containers, in well ventilated, unoccupied buildings, away burns. from sparks or ﬂ ames. Spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition.
Page 23 Fuel System Engines in this series are equipped with a two-barrel, 3. Make sure fuel is reaching carburetor. This includes side-draft carburetor with ﬁ xed main jets on a matching checking fuel shut-off valve, fuel tank ﬁ lter screen, intake manifold. Carburetor features a self-relieving in-line fuel ﬁ...
Page 24 Fuel System Fuel Shut-off Solenoid Carburetor Adjustments Most carburetors are equipped with a fuel shut-off NOTE: Carburetor adjustments should be made only solenoid. Solenoid is attached to fuel bowl. Solenoid has after engine has warmed up. a spring-loaded pin that retracts when 12 volts is applied Carburetor is designed to deliver correct fuel-to-air to lead, allowing fuel ﬂ...
Page 25 Fuel System NOTE: Engines will have ﬁ xed low idle or limiter caps 1. Perform removal procedures for appropriate air on idle fuel adjusting needles. Step 2 can only cleaner and carburetor outlined in Disassembly. be performed within limits allowed by cap. Do 2.
Page 26 Install new cap. above 1219 meters (4000 ft.). To obtain high 18. Clean carburetor body, main jets, vent ports, seats, altitude kit information or to ﬁ nd a Kohler etc., using a good commercially available carburetor authorized dealer visit KohlerEngines.com or call solvent.
Page 27: Governor System
Governor System GOVERNOR Governed speed setting is determined by position of throttle control. It can be variable or constant, depending on engine application. Governor is designed to hold engine speed constant under changing load conditions. Most engines are equipped with a centrifugal ﬂ...
Page 28: Lubrication System
Lubrication System This engine uses a full pressure lubrication system which delivers oil under pressure to crankshaft, camshaft, connecting rod bearing surfaces, and hydraulic valve lifters. A high-efﬁ ciency gerotor oil pump maintains high oil ﬂ ow and oil pressure, even at low speeds and high operating temperatures.
Page 29 Lubrication System OIL COOLER Installation NOTE: Oil cooler is mounted under cylinder shroud. 1. Apply pipe sealant with Teﬂ on (Loctite 592™ ® ® ® Removal of cylinder shroud is necessary to Thread Sealant or equivalent) to threads of switch. access oil cooler.
Page 30: Electrical System
Electrical System SPARK PLUGS Inspection Inspect each spark plug as it is removed from cylinder CAUTION head. Deposits on tip are an indication of general Electrical Shock can cause injury. condition of piston rings, valves, and carburetor. Do not touch wires while engine is running. Normal and fouled plugs are shown in following photos: Normal Spark Plug Component and Details...
Page 31 Electrical System Carbon Fouled ELECTRONIC IGNITION SYSTEMS Ignition System Components Soft, sooty, black deposits indicate incomplete combustion caused by a restricted air cleaner, over rich Kill Switch/ carburetion, weak ignition, or poor compression. Off Position of Air Gap Key Switch Overheated Flywheel Magnet...
Page 32 Electrical System Fixed Ignition System This system uses a capacitive discharge (CD) coil. Ignition timing and spark remains constant regardless of engine speed. Timing of spark is controlled by location of ﬂ ywheel magnet group as referenced to engine TDC. A typical ﬁ xed ignition system consists of: ●...
Page 33 Electrical System Digital Spark Advance Ignition (DSAI) System This system uses a digital microprocessor which is located in ignition modules. Ignition timing varies depending upon engine speed with this system. There are 2 inductive-style ignition modules that control ignition timing based on engine RPM.
Page 34 Electrical System Electronic Ignition Systems Tests Special Tools Required: NOTE: Ignition tester must be used to test ignition on these engines. Use of any other tester can result in inaccurate ﬁ ndings. Battery on unit must be fully charged and properly connected before performing tests (a battery that is hooked up or charged backward will crank engine but it won’t have spark).
Page 35 Electrical System Test for Spark NOTE: If 2 testers are available, testing can be performed simultaneously for both cylinders. However, if only 1 tester is available, 2 individual tests must be performed. Side not being tested must have spark plug lead connected or grounded.
Page 36 Electrical System BATTERY CHARGING SYSTEM NOTE: Observe following guidelines to avoid damage to electrical system and components: ● Make sure battery polarity is correct. A negative (-) ground system is used. ● Disconnect rectiﬁ er-regulator plug and/or wiring harness plug before doing any electric welding on equipment powered by engine.
Page 37 Electrical System 15/20/25 Amp Battery Charging Systems NOTE: Always zero ohmmeter on each scale before testing to ensure accurate readings. Voltage tests should be made with engine running at 3600 RPM with no load. Battery must be good and fully charged. When problems occur in keeping battery charged or battery charges at high rate, charging system or battery might be causing problems.
Page 38: Starter System
Starter System NOTE: Do not crank engine continuously for more than 10 seconds. Allow a 60 second cool down period between starting attempts. Failure to follow these guidelines can burn out starter motor. NOTE: If starter is engaged while ﬂ ywheel is rotating, starter pinion and ﬂ ywheel ring gear may clash and damage starter.
Page 39 Starter System SOLENOID SHIFT STARTERS Starter Disassembly When power is applied to starter electric solenoid moves NOTE: Do not reuse old retainer. drive pinion out onto drive shaft and into mesh with NOTE: Do not soak armature or use solvent when ﬂ...
Page 40 4 brushes and springs are serviced as a set. Use a new holes in metal clips must be up/out. Slide brush Kohler brush and spring kit if replacement is necessary. holder assembly down into place around 1. Perform steps 1-5 in Starter Disassembly.
Page 41 Starter System 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 armature shaft. Slide brush holder assembly down into place around commutator, install positive (+) brush lead grommet in cutout of frame.
Page 42 Disassembly/Inspection and Service WARNING Before working on engine or equipment, disable engine as Accidental Starts can cause severe injury or follows: 1) Disconnect spark plug lead(s). 2) Disconnect death. negative (–) battery cable from battery. Disconnect and ground spark plug lead(s) before servicing.
Page 43 Disassembly/Inspection and Service Clean all parts thoroughly as engine is disassembled. Remove Fuel Pump Only clean parts can be accurately inspected and gauged for wear or damage. There are many WARNING commercially available cleaners that will quickly remove grease, oil and grime from engine parts. When such a Explosive Fuel can cause ﬁ...
Page 44 Disassembly/Inspection and Service Remove Carburetor Remove Oil Cooler NOTE: New clamps are recommended any time WARNING disassembly is performed, or if clamps have been loosened (expanded) several times. Explosive Fuel can cause ﬁ res and severe burns. 1. Remove oil cooler mounting screws. Do not lose any washers (if used).
Page 45 ﬂ ywheel, crankshaft, and key if ﬂ ywheel key is sheared or keyway is damaged. Inspect ring gear for cracks or damage. Kohler does not provide ring gear as a serviceable part. Replace ﬂ ywheel if ring gear is damaged.
Page 46 If lifters need to be replaced, apply a liberal NOTE: Exhaust lifters are located on output shaft side coating of Kohler lubricant to base of each new lifter of engine while intake lifters are located on fan before it is installed.
Page 47 Disassembly/Inspection and Service Disassemble Cylinder Heads NOTE: These engines use valve stem seals on intake and exhaust valves. Use a new seal whenever valves are removed, or if seal is deteriorated in any way. Never reuse an old seal. 1. Remove adjusters, rocker arm pivots, and rocker arms from cylinder head. Remove pivot studs and guide plate as required.
Page 48 Disassembly/Inspection and Service After cleaning, check ﬂ atness of cylinder head and Valve Seat Inserts corresponding top surface of crankcase using a surface Hardened steel alloy intake and exhaust valve seat plate or piece of glass and feeler gauge. Maximum inserts are press ﬁ...
Page 49 Disassembly/Inspection and Service Breather/Oil Pan Components Oil Pan Gerotor Gears Oil Pump O-Ring Oil Pump Housing Relief Valve Bafﬂ e Pickup Tube Inlet Seal Pickup Screen Crankshaft Bearing Drain Plug Oil Pan Gasket Dipstick (PTO) Dipstick Tube Breather Assembly Breather Gasket Filter Breather Hose Oil Seal...
Page 50 Disassembly/Inspection and Service 1. Make sure recess in oil pan for oil pump gerotor Oil Pump Assembly gears is clean. Disassembly 2. Lubricate oil pump gerotor gears with grease 1. Remove screws securing oil pump housing including (Lubriplate ® 100 or equivalent), and install into relief valve bafﬂ...
Page 51 Disassembly/Inspection and Service Crankcase Components Remove Camshaft Remove camshaft and shim (if used). Inspection Check lobes of camshaft for wear or damage. Inspect cam gear for badly worn, chipped, or missing teeth. Replacement of camshaft will be necessary if any of these conditions exist.
Page 52 Disassembly/Inspection and Service When cylinder temperatures get too high, lacquer and Piston and Rings varnish collect on pistons causing rings to stick, which Inspection results in rapid wear. A worn ring usually takes on a shiny or bright appearance. Piston and Rings Components and Details Scratches on rings and pistons are caused by abrasive material such as carbon, dirt, or pieces of hard metal.
Page 53 Disassembly/Inspection and Service 2. Middle compression ring (center groove): Install Inspect crankshaft bearing surfaces for scoring, center ring using a piston ring installation tool. Make grooving, etc. Replaceable bearings are used in sure identiﬁ cation mark is up or colored dye stripe (if crankshaft bore of oil pan and/or crankcase.
Page 54 23°-33° Crosshatch 2. Pull governor cross shaft out of crankcase and remove seal. NOTE: Kohler pistons are custom-machined to exacting tolerances. When oversizing a cylinder, it should Remove Lifter Feed Chamber Cover and Gaskets be machined exactly 0.25 mm (0.010 in.) or Remove screws securing lifter feed chamber cover and 0.50 mm (0.020 in.) over new diameter.
Page 55 Disassembly/Inspection and Service 4. After resizing, check bore for roundness, taper, and size. Use an inside micrometer, telescoping gauge, or bore gauge to take measurements. These measurements should be taken at 3 locations in cylinder – at top, middle, and bottom. There are 2 measurements that should be taken (perpendicular to each other) at all 3 locations.
Page 56 Reassembly NOTE: Make sure engine is assembled using all Crankcase Components speciﬁ ed torque values, torque sequences, and clearances. Failure to observe speciﬁ cations could cause severe engine wear or damage. Always use new gaskets. Apply a small amount of oil to threads of critical fasteners before assembly, unless a sealant or Loctite ®...
Page 57 Reassembly Install Governor Shafts, Seal, and Governor Gear Install Crankshaft Carefully slide ﬂ ywheel end of crankshaft through Governor Components and Details bearing in crankcase. Install Connecting Rods with Pistons and Rings Piston Details Side 1 Side 2 Top of Piston NOTE: Cylinders are numbered on crankcase.
Page 58 Reassembly Breather/Oil Pan Components Breather Fastener Torque Sequence Oil Pan Gerotor Gears Oil Pump O-Ring Oil Pump Housing Relief Valve Bafﬂ e Pickup Tube Inlet Seal Pickup Screen Crankshaft Bearing Drain Plug Oil Pan Gasket Dipstick (PTO) Dipstick Tube Breather Assembly Breather Gasket Filter Breather Hose...
Page 59 Reassembly Several color coded shims are available: Install Oil Pan Assembly White: 0.69215/0.73025 mm (0.02725/0.02875 in.) Torque Sequence Blue: 0.74295/0.78105 mm (0.02925/0.03075 in.) Red: 0.79375/0.83185 mm (0.03125/0.03275 in.) Yellow: 0.84455/0.88265 mm (0.03325/0.03475 in.) Green: 0.89535/0.99345 mm (0.03525/0.03675 in.) Gray: 0.94615/0.98425 mm (0.03725/0.03875 in.) Black: 0.99695/1.03505 mm (0.03925/0.04075 in.) 4.
Page 60 Reassembly Cylinder Head Components Gasket Valve Cylinder Head Pipe Plug Guide Plate Spacer Washer Spark Plug Valve Stem Seal Valve Spring Valve Spring Retainer Hydraulic Lifter Valve Spring Keeper Push Rod Rocker Arm Rocker Arm Pivots Rocker Stud Valve Cover Seal Valve Cover Grommet Install Breather...
Page 61 Reassembly Valve Stem Seals Install Guide Plate, Pivot Studs, Push Rods and Rocker Arms These engines use valve stem seals on intake and exhaust valves. Always use new seals whenever valves NOTE: Install push rod guide plate so ﬂ ange is down are removed from cylinder head.
Page 62 Reassembly c. Hold adjuster nut in this position and tighten Oil Cooler/Filter Components locking setscrew. Torque setscrew to 7.3 N·m (65 in. lb.). d. Repeat procedure for other valve on this side. 4. Viewed from PTO end, rotate crankshaft 270° (3/4 turn) counterclockwise and align crankshaft keyway with cylinder 2, which now puts that cylinder at TDC on compression stroke.
Page 63 Reassembly Install Oil Filter Housing Assembly Flywheel/Ignition Components Reassemble oil ﬁ lter housing if disassembled previously. Reassembly 1. Install small spring onto rubber valve, and insert small end through corresponding hole in cup until properly seated. 2. Install larger spring into ﬁ lter housing. 3.
Page 64 Reassembly NOTE: Before installing ﬂ ywheel make sure crankshaft Install Backing Shroud Assembly taper and ﬂ ywheel hub are clean, dry, and NOTE: New hose clamps are recommended for completely free of any lubricants. Presence of reassembly, or if clamps have been loosened lubricants can cause ﬂ...
Page 65 Reassembly External Engine Components Oil Filter Oil Filter Nipple Oil Filter Cup Valve Spring Cup Spring Valve Oil Filter Housing Valley Bafﬂ e Outer Cylinder Bafﬂ e Electric Starter Cylinder Shroud Blower Housing Fixed Guard Oil Sentry O-Ring ™ Fitting Oil Cooler Hose Hose Clamp...
Page 66 Reassembly 2. Align oil cooler with bosses in backing shroud 3. Install stiffener followed by metal debris screen onto assembly. Secure screws and washers to 2.2 N·m studs. Secure with special washers and mounting (20 in. lb.). screws using Loctite ®...
Page 67 Reassembly Install Carburetor Install Throttle and Choke Linkages Cable Control Details WARNING Explosive Fuel can cause ﬁ res and severe burns. Do not ﬁ ll fuel tank while engine is hot or running. Gasoline is extremely ﬂ ammable and its vapors can explode if ignited.
Page 68 Reassembly Governor Spring/RPM Chart Install Oil Filter and Add Oil to Crankcase NOTE: Make sure both oil drain plugs are installed and CV940-CV1000 torqued to 21.4 N·m (16 ft. lb.). to prevent oil leakage. Governor Idle Spring (Color) High Speed (RPM) 1.
Page 69 62 690 02 Rev. D KohlerEngines.com...
Page 70 KohlerEngines.com 62 690 02 Rev. D...
Page 71 62 690 02 Rev. D KohlerEngines.com...

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Command pro cv960 Command pro cv980 Command pro cv1000

Kohler Command PRO CV940 Service Manual

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Summary of Contents for Kohler Command PRO CV940

Page 16: Troubleshooting

Page 20: Air Cleaner/Intake

Page 21: Fuel System

Page 27: Governor System

Page 28: Lubrication System

Page 30: Electrical System

Page 38: Starter System

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