Kohler Command Pro CV940

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KohlerEngines.com 62 690 02 Rev. D72 KohlerEngines.com 62 690 02 Rev. D72

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Contents1
Safety Precautions2
Maintenance Instructions3
Maintenance Schedule3
Weekly3
Every 25 Hours or Annually3
Maintenance4
Oil Recommendations4
Fuel Recommendations4
Storage4
Engine Dimensions5
Specifications6
Engine Identification Numbers6
General Specifications6
Torque Specifications6
Clearance Specifications8
General Torque Values12
Tools and Aids13
Separate Tool Suppliers13
Flywheel Holding Tool15
Rocker Arm/Crankshaft Tool15
Engine Cranks but will Not Start16
Engine Starts but Does Not Keep Running16
Engine Starts Hard16
Troubleshooting Guide16
External Engine Inspection17
Cleaning Engine17
Engine Loses Power17
Engine Uses Excessive Amount of Oil17
Crankcase Vacuum Test18
To Test Crankcase Vacuum with Manometer18
To Test Crankcase Vacuum with Vacuum/Pressure Gauge18
Compression Test19
Cylinder Leakdown Test19
Air Cleaner20
Air Cleaner Components20
Breather Tube20
Air Cooling20
Fuel Pump21
Fuel Line21
Fuel Pump Replacement21
Fuel System Tests21
Carburetor22
Two-Barrel Carburetor Components22
Troubleshooting Checklist23
Troubleshooting-Carburetor Related Causes23
Fuel Shut-Off Solenoid24
Carburetor Adjustments24
Carburetor Circuits24
Slow and MID-Range24
Carburetor Servicing25
Float Replacement/Overhaul/Choke Repair25
High Altitude Operation26
Governor Components27
Governor Adjustments27
Governor System27
Lubrication System28
Lubrication Components28
Check Oil Level28
Change Oil and Filter28
Oil Cooler29
Oil Sentry29
Electrical System30
Spark Plugs30
Spark Plug Component and Details30
Wet Fouled30
Electronic Ignition Systems31
Carbon Fouled31
Overheated31
Battery31
Fixed Ignition System32
Wire Diagram32
Digital Spark Advance Ignition (DSAI) System33
Electronic Ignition Systems Tests34
Test Ignition Systems34
Test for Spark35
Test Timing Advance (DSAI Only)35
Test Ignition Modules and Connections (DSAI Only)35
Battery Charging System36
15/20/25 Amp Regulated Charging System36
To Test 20/25 Amp Rectifier-Regulators36
To Test 15 Amp Rectifier-Regulators36
15/20/25 Amp Battery Charging Systems37
To Test Charging System for no Charge to Battery37
Starter System38
Troubleshooting-Starting Difficulties38
Solenoid Shift Starters39
Solenoid Shift Starter Components39
Starter Disassembly39
Drive Pinion39
Armature40
Brush Replacement40
Starter Reassembly40
Solenoid Tests41
To Test Solenoid Pull-In Coil/Plunger41
To Test Solenoid Hold-In Coil41
Disassembly/Inspection and Service42
External Engine Components42
Disconnect Spark Plug Leads43
Drain Oil from Crankcase and Remove Oil Filter43
Remove Cylinder Shrouds and Blower Housing43
Remove Electric Starter Motor43
Remove Carburetor44
Remove Oil Cooler44
Remove Oil Filter Housing44
Remove Baffles and Intake Manifold44
Flywheel/Ignition Components45
Remove Ignition Modules45
Remove Debris Screen and Cooling Fan45
Remove Flywheel45
Cylinder Head Components46
Remove Valve Covers46
Remove Cylinder Heads and Hydraulic Lifters46
Bleeding Lifters46
Disassemble Cylinder Heads47
Valve Details47
Exhaust Valve47
Valve Guides48
Valve Seat Inserts48
Lapping Valves48
Valve Stem Seals48
Breather/Oil Pan Components49
Remove Breather Assembly49
Remove Oil Pan Assembly49
Oil Pump Assembly50
Remove Camshaft51
Remove Connecting Rods with Pistons and Rings51
Connecting Rods51
Piston and Rings52
Piston and Rings Components and Details52
Install New Piston Rings52
Remove Crankshaft53
Crankshaft Components and Details53
Clearance Specifications-Connecting Rod Journal53
Remove Crankshaft Plug53
Remove Governor Gear Assembly54
Remove Governor Yoke, Cross Shaft, and Seal54
Remove Lifter Feed Chamber Cover and Gaskets54
Remove Flywheel and PTO End Oil Seals54
Clean Cylinder Bore after Honing55
Measuring Piston-To-Bore Clearance55
Crankcase Components56
Install Flywheel End Oil Seal56
Install Lifter Feed Chamber Gaskets and Cover56
Install Crankshaft Bearing56
Install Governor Shafts, Seal, and Governor Gear57
Install Crankshaft57
Install Connecting Rods with Pistons and Rings57
Governor Components and Details57
Install Camshaft58
Determining Camshaft End Play58
Install Oil Pan Seal and Crankshaft Bearing (PTO)59
Install Oil Pan Assembly59
Check Crankshaft End Play59
Install Breather60
Install Hydraulic Lifters60
Assemble Cylinder Heads61
Install Cylinder Heads61
Adjust Valve Clearance61
Check Assembly62
Oil Cooler/Filter Components62
Install Spark Plugs62
Install Valve Covers62
Install Oil Filter Housing Assembly63
Install Backing Shroud Assembly64
Install Stator, Wiring Harness, and Rectifier-Regulator64
Install Ignition Modules64
Install Flywheel64
Install Cooling Fan and Debris Screen66
Install Electric Starter66
Install Valley Baffles66
Control Bracket Components66
Install Carburetor67
Install Governor Lever67
Install Control Bracket and Air Cleaner Assembly67
Install Throttle and Choke Linkages67
Governor Spring/Rpm Chart68
Install Oil Sentry68
Install Blower Housing and Cylinder Shrouds68
Install Muffler68

Kohler Command Pro CV940 - Page 72

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