Kohler Command Pro CV980 Bedienungsanleitung

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Inhaltsverzeichnis

Seite 1 - COMMAND PRO

SERVICE MANUALVERTICAL CRANKSHAFTCOMMAND PRO CV940-CV1000

Seite 2

1.6Section 1Safety and General InformationDimensions in millimeters. Inch equivalents shown in [ ].411.64[16.206]14.7[.58]130.00[5.118]152.36[5.999]23

Seite 3 - Contents

Section 9Inspection and Reconditioning9.8Valve Seat Cutter PilotValve Guidesȱȱȱȱȱȱ¢ȱęǰȱȱȱnot guide the valve

Seite 4

Section 9Inspection and Reconditioning99.9Overheated or Deteriorated OilScored Piston and RingsAbrasive Scratched RingsStuck, Broken RingsRing failure

Seite 5

Section 9Inspection and Reconditioning9.10Replacement pistons are available in STD bore size, and in 0.25 mm (0.010 in.), and 0.50 mm (0.020 in.) over

Seite 6

Section 9Inspection and Reconditioning99.11Figure 9-12. Piston Ring Installation.ȱ ŗǯȱ ȱȱȱǻĴȱǼDZȱȱȱexpander and then

Seite 7

Section 9Inspection and Reconditioning9.12Oil Pan AssemblyInspectionInspect the oil seal in the oil pan and remove it if it is worn or damaged. Refer

Seite 8

Section 9Inspection and Reconditioning99.13O-Ring32144. Install the O-Ring in the groove of the oil pump housing. Use a small quantity of grease to ho

Seite 10 - Section 1

10.110Section 10ReassemblyGeneralNOTE: Make sure the engine is assembled usingȱęȱȱǰȱȱǰȱȱǯȱ

Seite 11

10.2Section 10Reassemblyȱ Řǯȱ ¢ȱȱȱȱȱȱȱȱȱȱȱȱȱȱȱǯȱ řǯȱ ȱȱȱȱȱȱ

Seite 12

10.3Section 10Reassembly10Oil SealSeal depth1.5 - 2.0 mm (0.059 - 0.078 in)CrankcaseSurface12.66 mm(0.498 in.)Crankcase SurfaceGovernorGear ShaftFigu

Seite 13

1.7Section 1Safety and General Information1¹Values are in Metric units. Values in parentheses are English equivalents. Lubricate threads with engine o

Seite 14

10.4Section 10ReassemblyŚǯȱ Ĵȱȱȱ¢ȱȱȱȱĞȱȱȱȱȱȱȃȄȱȱǯȱȱȱȱȱǯȱȱȱ

Seite 15

10.5Section 10Reassembly10No. 1 SideNo. 2 SideInstall Connecting Rods with Pistons and RingsDZȱ ȱ¢ȱȱȱȱȱǯȱȱ

Seite 16

10.6Section 10ReassemblyFigure 10-20. Torquing Connecting Rod End Cap Screws.ȱ Ŝǯȱ ȱȱȱȱȱȱȱȱȱȱȱ

Seite 17

10.7Section 10Reassembly10OilSeal3 mm (0.118 in.)ȱ śǯȱ ȱȱȱ¢ȱȱȱȱȱȱȱ¢ǯInstall Oil Pan Seal and Main Bea

Seite 18

10.8Section 10ReassemblyO-Ring1081143512791164213Install Oil Pan Assemblyŗǯȱ ȱȱȱȱȱȱȱȱȱȱȱȱǰȱ

Seite 19 - Section 2

10.9Section 10Reassembly10CrankcaseFilterBreather HoseFlange Nuts (4)GasketCheck Crankshaft End playȱ ŗǯȱ ȱȱȱȱǰȱȱȱȱȱ

Seite 20

10.10Section 10Reassembly1342ȱ řǯȱ ȱȱȱ¡ȱĚȱǰȱȱȱȱȱȱȱȱȱŗŖȬřśȱȱ5.7 N·m (51 in. lb.)ǯFigu

Seite 21

10.11Section 10Reassembly10DZȱ ¢ȱĞȱȱ¢ȱȱȱȱȱȱȱȱȱ¢ǯȱȱ¡ȱĞȱȱ

Seite 22

10.12Section 10ReassemblySpacerWashers2245541331No. 1 No. 2Figure 10-43. Installing Valves with Valve Spring Compressor.Install Cylinder He

Seite 23 - Troubleshooting

10.13Section 10Reassembly10ȱ Ŝǯȱ ȱȱȱȱȱȱȱȱȱȱ¢ȱȱȱȱȱ¢ǯȱȱȱȱȱȱ¢ȱ

Seite 24

1.8Section 1Safety and General InformationCarburetor, Intake Manifold, and Air CleanerȱȱȱȱTorque Using Sequence in

Seite 25

10.14Section 10ReassemblyȱȱDZȱ ȱ ǯȱ ȱȱȱȱȱȱȱȱȱ ȱǯȱ ȱ ǯȱ ¢¢ȱȱĞȱȱȱȱȱǛ

Seite 26

10.15Section 10Reassembly10Figure 10-53. Establishing the "0" Lash Point.Śǯȱ ȱȱȱȱĴȱȱȱȱǰȱȱȱǻ

Seite 27 - Section 4

10.16Section 10ReassemblySpringInstall Spark Plugsȱ ŗǯȱ ȱȱ®ȱŗŖȱǻȱǼȱȱǯȱ Řǯȱ ȱȱȱȱ0.76 mm (0.030 in.)ǯ

Seite 28

10.17Section 10Reassembly10O-Rings AroundDowel PinsFigure 10-62. Installing Nipple into Cup and Oil Filter Housing.Figure 10-63. Torquing Nipple into

Seite 29 - Fuel System and Governor

10.18Section 10Reassembly12Cylinder 1Cylinder 234Řǯȱ ȱȱȱȱȱȱ¢ȱǯȱȱȱȱȱȱȱȱȱ

Seite 30 - Test Conclusion

10.19Section 10Reassembly10Figure 10-71. Installing Stator.śǯȱ ȱȱȱȱȱȱȱȱȱƸȱȱȱȱȱȱȱȱ

Seite 31

10.20Section 10ReassemblyFigure 10-76. Clean and Dry Flywheel Hub.Figure 10-77. Installed Flywheel Key.DZȱ ȱȱȱĚ¢ȱ¢ȱȱȱ

Seite 32

10.21Section 10Reassembly10śǯȱ ȱȱ0.30 mm (0.012 in.)ȱĚȱȱȱȱȱȱȱȱȱǯȱȱȱŗŖȬŞŖǯȱȱ

Seite 33

10.22Section 10ReassemblyInstall Oil Coolerŗǯȱ ȱȱȱȱȱȱȱȱȱęȱȱȱȱȱǯȱȱȱȱ

Seite 34

10.23Section 10Reassembly10ȱ řǯȱ ȱȱȱȱȱǯȱȱȱŗŖȬŞŞǯFigure 10-88. Connecting Leads to Starting Motor.,QVWDOO9DOOH\%

Seite 35

1.9Section 1Safety and General Information1ĞȱȱȱȱǻȱȱǼRunning Clearance - New ...

Seite 36

10.24Section 10Reassembly1, 5432MountingScrewsInstall Control Bracket and Air Cleaner Assemblyȱ ŗǯȱ ȱȱȱȱ¢ȱȱȱ

Seite 37 - Disassembly/Overhaul

10.25Section 10Reassembly10Fuel PumpOutlet HosePulseHoseInletHoseFigure 10-96. Installing Choke Link and Push-On Nut.Install Throttle and Choke Linkag

Seite 38

10.26Section 10ReassemblyOil PanAdjusting Governorȱ ŗǯȱ ȱȱȱȱȱȱȱȱȱȱȱ¢ȱȱȱȱ

Seite 39

10.27Section 10Reassembly10Oil FillTubeLiftBracketLowerMountingScrewCylinder ShroudsMountingScrewsȱ Řǯȱ ȱȱȱȱȱȱȱȱ¢™

Seite 40

10.28Section 10ReassemblyInstall Oil Filter and Add Oil to Crankcaseȱ ŗǯȱ ȱȱȱȱǯȱȱȱŗŖȬŗŖşǯȱȱȱȱȱŘŗǯŚȱȉ

Seite 41

10.29Section 10Reassembly10Testing the Engineȱȱȱȱȱȱȱȱȱȱȱȱȱȱȱȱȱȱȱ

Seite 44

LITHO IN U.S.A.FORM NO.: TP-2581ISSUED: 1/09REVISED: ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044FOR SALES AND SERVICE INFORMATION IN U.S. AN

Seite 45 - Lubrication System

1.10Section 1Safety and General InformationGrass Screen Hex Stud Torque ...

Seite 46 - Range

1.11Section 1Safety and General Information1ŶȱȱŗŗȱȱǻŖǯŚřřȱǯǼȱȱȱĴȱȱȱȱȱȱȱȱȱȱȱǯTop Comp

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1.12Section 1Safety and General InformationTightening Torque: N·m (in. lb.) + or - 10%Property ClassNoncriticalFastenersInto AluminumSizeM4 1.2 (11) 1

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1.13Section 1Safety and General Information1English Fastener Torque Recommendations for Standard ApplicationsGrade 2 or 5Fasteners IntoAluminumSize8-3

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2.1Section 2Tools & Aids2Section 2Tools & AidsToolsDescription Source/Part No.Ğȱ¢ȱȱȱĞȱ¢ǯȱȱȬŞ

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2.2Section 2Tools & AidsTools (Continued)Description Source/Part No.¢ȱȱĞȱȱȱȱȱ¢ȱĞǯȱŘśȱŝŜŗ

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2.3Section 2Tools & Aids2AidsDescription Source/Part No.ĞȱȱǻȱŜŗřǼ ȱŘśȱřśŝȱŗŚȬȱȱǻȦȱŜŜŗǼ

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2.4Section 2Tools & AidsSpecial Tools You Can MakeFlywheel Holding ToolȱĚ¢ȱȱȱȱȱȱȱȱȱȱȱĚ¢ȱȱȱȱ

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3.13Section 3TroubleshootingTroubleshooting GuideWhen troubles occur, be sure to check the simple ȱǰȱȱęǰȱ¢ȱȱȱȱȱȱco

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3.2Section 3TroubleshootingEngine Overheatsȱ ŗǯȱ ȱȦȱǰȱȱęǰȱȱȱshrouds clogged.ȱ Řǯȱ ¡ȱȱǯȱ řǯȱ 

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3.3Section 3Troubleshooting3ȱȱȱȱȱȱȱȱȱȱthe engine is reassembled and placed into operation. ȱȱ

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3.4Section 3TroubleshootingLeakdown Test Resultsȱȱȱȱ ...ȱȱ

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4.14Section 4Air Cleaner and Air Intake SystemPaper ElementInnerElementInlet ScreenAir CleanersGeneralThese engines utilize a Heavy-Duty style air cle

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4.2Section 4Air Cleaner and Air Intake SystemEjectorAreaCylinderShroud4. Do not wash the paper element and inner element or use compressed air, this w

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5.15Section 5Fuel System and GovernorDescriptionThis section covers the carbureted fuel system used on these engines. The governor system is covered a

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ContentsSection 1. Safety and General Information...Section 2. Tools & A

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5.2Section 5Fuel System and GovernorFuel System TestsWhen the engine starts hard, or turns over but will not start, it is possible that the problem is

Seite 64 - $PS5HFWL¿HU5HJXODWRUV

5.3Section 5Fuel System and Governor5Self-RelievingChokeFuel Shut-OffSolenoidBowl Drain ScrewSlow JetsBowl VentLow Idle Fuel Adjustments(With Limiters

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5.4Section 5Fuel System and GovernorTroubleshooting ChecklistWhen the engine starts hard, runs roughly or stalls at low idle speed, check the followin

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5.5Section 5Fuel System and Governor5Fuel Shut-OffSolenoidHigh Altitude OperationȱȱȱȱȱȱȱŗśŖŖȱȱǻśŖŖŖȱĞǯǼȱȱǰ

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5.6Section 5Fuel System and GovernorLeanRichAdjust to MidpointLeanRichAdjust to MidpointLeft SideRight SideCarburetor AdjustmentsAdjustmentDZȱ 

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5.7Section 5Fuel System and Governor5Governed Idle Systemȱȱȱȱ¢ȱȱȱȱȱȱdesired idle speed regardless of ambient

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5.8Section 5Fuel System and GovernorFigure 5-11. Setting High Speed RPM (Air Cleaner Removed for Clarity).Carburetor ServicingThe following section co

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5.9Section 5Fuel System and Governor5Figure 5-14. Float and Inlet Needle Details. ȱ Ŝǯȱ ȱȱĚȱȱȱȱȱȱȱseat and carbu

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5.10Section 5Fuel System and GovernorFigure 5-18. Fuel Bowl Removed From Carburetor.DZȱ ȱ¢ȱȱȱȱȱis not necessary unles

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5.11Section 5Fuel System and Governor5śǯȱ ȱȱȱȱǻǼȱȱȱand spring from the carburetor. Discard the parts.DZȱ ȱ

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5.12Section 5Fuel System and GovernorFigure 5-26. Installing Float Assembly.ŗŚǯȱ ȱȱȱ¢ȱȱȱĚȱ¢ȱhangs vertically and re

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5.13Section 5Fuel System and Governor5śǯȱ ȱȱȱ¡ȱǻ¢ȬǼȱȱȱȱȱȱĞȱȱȱȱȱȱlever from th

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5.14Section 5Fuel System and GovernorȱŗŘǯȱ ȬȱǻȱȱȬȱǼ 13. Drain Screw 14. Bowl Screw (4)ȱŗśǯȱ ȱȱŗŜǯȱ ȱ 17. Fl

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5.15Section 5Fuel System and Governor5GovernorLeverGovernorCross ShaftGovernedIdle SpringLinkageGovernorSpringGovernorGeneralThe governor is designed

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5.16Section 5Fuel System and GovernorHold Lever in"Full Throttle"PositionHigh Speed (RPM)Adjustment Screw3. Stop when the desired RPM speed

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6.16Section 6Lubrication SystemSAE10W30APISERVICESJ5W-20, 5W-30RECOMMENDED SAE VISCOSITY GRADES10W-30Kohler 10W-30°F-200203240 6080100°C-30 -20-10 010

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6.2Section 6Lubrication SystemOil Drain PlugDrain PlugOperating RangeChecking Oil LevelThe importance of checking and maintaining the proper oil lev

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6.3Section 6Lubrication System6ȱ řǯȱ ȱȱȱȱȱȱȱ21.4 N·m ǻŗśǯŝȱĞǯȱǯǼ.ȱ Śǯȱ ȱȱǰȱȱȱȱȱȱ

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6.4Section 6Lubrication SystemPressureSwitchService Oil CoolerȱȱȱȱȱȱȱȱȱȱȱǯȱŘȱȱ¢ȱ

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6.5Section 6Lubrication System6Installationȱȱ¢ȜȱȱȱȱȱȱȱȱȱȱǯȱȱȱŜȬŗŘǯȱȱȱȱ

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1.11Rotating Parts!Keep hands, feet, hair, and clothing away from all moving parts to prevent injury. Never operate the engine with covers, shrouds, o

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7.17Section 7Electrical System and ComponentsThis section covers the operation, service, and repair of the electrical system components. Systems and c

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7.2Section 7Electrical System and ComponentsDZȱȱȱȱȱȱȱȱȱnormal conditions will have light tan or gray colored

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7.3Section 7Electrical System and Components7DC VoltmeterBatteryBatteryGeneralȱŗŘȬȱĴ¢ȱȱŚŖŖȱȱȱȱǻǼȱȱgenerally recommen

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7.4Section 7Electrical System and ComponentsMolex Plug(Some Models)ȱȱȱěȱ¢ȱȱȱ¢ȱȱȱǯȱȱ¢ȱ

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7.5Section 7Electrical System and Components7Kill Switch or ‘‘Off’’ Position of Key SwitchIgnitionModulesSpark PlugMagnetFlywheel(0.28/0.33 mm)0.011/0

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7.6Section 7Electrical System and Componentsǯȱ ȱȱȱȱǰȱȱȱ¢ȱȱȱȱȱǯȱȱȱ¢ȱǰȱwires, con

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7.7Section 7Electrical System and Components7Troubleshooting DSAI Ignition Systemsȱȱȱ¢ȱȱȱȱȱȱȱȱȱ

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7.8Section 7Electrical System and Componentsȱ Řǯȱ ȱȱȱǰȱȱȱȱȱśśŖȬŜŖŖȱǰȱȱȱǻǼȱȱǯȱ řǯȱ

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7.9Section 7Electrical System and Components7Battery Charging SystemGeneralMost engines are equipped with a 15, 20, or 25 ampȱȱ¢

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1.2Section 1Safety and General Information¡ȱȱȱȱęȱȱsevere burns.ȱȱęȱȱȱȱȱȱengine is hot or running.W

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7.10Section 7Electrical System and Components15/20/25 Amp Regulated Charging SystemFigure 7-11. Wiring Diagram - 15/20/25 Amp Regulated Battery Chargi

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7.11Section 7Electrical System and Components7Figure 7-12. Wiring Diagram - 15/20/25 Amp Regulated Battery Charging System with DSAI Ignition and Four

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7.12Section 7Electrical System and ComponentsFigure 7-13. Wiring Diagram - 15/20/25 Amp Regulated Battery Charging System with DSAI Ignition and Five

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7.13Section 7Electrical System and Components7StatorȱȱȱȱȱȱȱȱȱĚ¢ǯȱȱȱȱȱȱŞȱȬȱȃ

Seite 100 - Inspection and Reconditioning

7.14Section 7Electrical System and Componentsśǯȱ ȱȱȱȱȱȱȱȦȱȱȱȱǯȱȱȱȱȱǯȱȱ

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7.15Section 7Electrical System and Components7Troubleshooting Guide15/20/25 Amp Battery Charging SystemsȱȱȱȱȱȱĴ¢ȱ

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7.16Section 7Electrical System and ComponentsDC Voltmeter5HFWL¿HU5HJXODWRUFlywheelStatorAmmeterBattery(-)(+)Figure 7-20. Connections for Testing Char

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7.17Section 7Electrical System and Components7Torx Head Screws7URXEOHVKRRWLQJ*XLGH±6WDUWLQJ'LI¿FXOWLHVDelco-Remy StartersFigure 7-21. Delco-R

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7.18Section 7Electrical System and ComponentsFigure 7-23. Solenoid Removed from Starter. Figure 7-24. Removing Plunger.ȱ Śǯȱ ȱȱȱȱǻ

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7.19Section 7Electrical System and Components7DriveEnd CapScrewPlungerSpringLeverPlatePlugSolenoidFrame & FieldBrush HolderNutCommutatorEnd PlateS

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1.3Section 1Safety and General Information1A. Model No.C V 980 SB. Spec. No.Command EngineVersion CodeS = Electric StartC. Serial No.Year Manufactured

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7.20Section 7Electrical System and ComponentsWear Limit Length7.6 mm (0.300 in.)Mica InsulationCommutator O.D.InspectionDrive Pinionȱȱȱ

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7.21Section 7Electrical System and Components7Brush ReplacementȱȱȱȱȱȱȱȱȱǻŚǼǯȱȱȱȱȱȱȱȱ

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7.22Section 7Electrical System and Componentsřǯȱ ȱȱěȱȱǻǼȱȱȱȱȱȃěȄȱȱȱȱȱȱȦ

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7.23Section 7Electrical System and Components7Figure 7-43. Installing Thrust Washer.ȱŗŖǯȱ ȱ¢ȱȱȱȱȦȱȱ

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7.24Section 7Electrical System and ComponentsExtension.ǯȱ ȱȱȱ¢ȱ¢ȱȱȱend housing, and carefully place the tool ǻ

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7.25Section 7Electrical System and Components7VOM Leads12 volt Test LeadsMomentaryConnection OnlySolenoid Test ProcedureSolenoid Shift Style Starters

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7.26Section 7Electrical System and ComponentsTest 4. Solenoid Hold-In Coil/Contact Continuity Test.ȱȱȱȱȱȱȱȱ¡Řȱǰȱ

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8.18Section 8DisassemblyWARNING: Accidental Starts!Disabling engine. Accidental starting can cause severe injury or death. Before working on the engin

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8.2Section 8DisassemblyCylinder ShroudShut Off Fuel SupplyDrain Oil from Crankcase and Remove Oil Filterȱ ŗǯȱ ȱȱȱęȱȱȱǯȱ

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8.3Section 8Disassembly83. Remove the lower mounting screw and pull the ȱęȱȱȱȱȱǯFigure 8-7. Removing Oil Fill Tube.Remove El

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1.4Section 1Safety and General InformationSAE10W30APISERVICESJ5W-20, 5W-30RECOMMENDED SAE VISCOSITY GRADES10W-30Kohler 10W-30°F-200203240 6080100°C-30

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8.4Section 8DisassemblyRemove Fuel PumpWARNING: Explosive Fuel!ȱȱ¡¢ȱĚȱȱȱȱȱ¡ȱȱǯȱȱȱ

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8.5Section 8Disassembly8Figure 8-15. Removing Control Bracket.ȱ Ŝǯȱ ȱȱ¡ȱĚȱȱȱȱȱȱȱȱȱĞǯȱȱ

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8.6Section 8DisassemblyNOTE: New clamps are recommended any time disassembly is performed, or if clamps have been loosened (expanded) several times.)L

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8.7Section 8Disassembly8Figure 8-24. Removing Oil Filter Housing.ȱȱȱ¢ȱȱȱȱęȱȱassembly requires individual serv

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8.8Section 8DisassemblyRemove Grass Screen and Cooling Fanȱ ŗǯȱ ȱȱǰȱĴȱǰȱȱ¡ȱȱȱȱȱǰȱě

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8.9Section 8Disassembly8Wiring HarnessMoldedClips2. Remove the mounting screws securing the ęȬȱȱȱȱȱassembly. Note th

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8.10Section 8DisassemblyRemove Valve Covers1. Remove the screw and grommet securing each valve cover. 2. Remove the valve cover and gasket from each c

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8.11Section 8Disassembly8Figure 8-42. Removing Hydraulic Lifters. Figure 8-43. Match Numbers on Cylinder Barrel and Heads.Disassemble Cylinder Heads1.

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8.12Section 8DisassemblyFigure 8-47. Valve Stem Seals.NOTE: These engines use valve stem seals on the intake and exhaust valves. Use a new seal whenev

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8.13Section 8Disassembly8Figure 8-52. Removing Oil Pan.Oil Pump AssemblyThe oil pump is mounted to the inside of the oil pan. If service is required,

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1.5Section 1Safety and General Information1¹Perform these maintenance procedures more frequently under extremely dusty, dirty conditions.2Have a Kohle

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8.14Section 8Disassembly2. Carefully remove the connecting rod and piston ¢ȱȱȱ¢ȱǯȱȱȱŞȬśŜǯFigure 8-56. Removing Pisto

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8.15Section 8Disassembly8Remove Lifter Feed Chamber Cover and Gasketsȱ ŗǯȱ ȱȱȱȱȱȱĞȱȱchamber cover, and gaskets.

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99.1Section 9Inspection and ReconditioningThis section covers the operation, inspection, and repair/reconditioning of major internal engine components

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Section 9Inspection and Reconditioning9.245°High Point from Fillet IntersectionsThis Fillet AreaMust Be Completely SmoothMinimumThe Fillet Must Blend

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Section 9Inspection and Reconditioning99.311 mm (0.433 in.)Measure 11 mm above the Bottom of Piston Skirt at Right Angles to Piston Pinaccomplished at

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Section 9Inspection and Reconditioning9.4Feeler Gauge2. Use an inside micrometer, telescoping gauge, or bore gauge and measure the cylinder bore. Take

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Section 9Inspection and Reconditioning99.5EXHAUST VALVEINTAKE VALVEABCDDFEGHFEGHINTEXHFigure 9-6. Valve Details.ȱȱȱȱȱȱ

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Section 9Inspection and Reconditioning9.6Normal:ȱȱĞȱȱȱȱȱȱȱcan be reconditioned and reused if the face and margin are

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Section 9Inspection and Reconditioning99.7Excessive Combustion Temperatures: The white deposits seen here indicate very high combustion temperatures,

Verwandte Modelle: Command Pro CV1000

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