Kohler CV1000- User Manual

Kohler CV1000

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Table of Contents:

  • Page 3 – Contents
  • Page 5 – Safety Precautions; Accidental Starts can cause; WARNING; Rotating Parts can cause severe; WARNING; Hot Parts can cause severe burns.; WARNING
  • Page 6 – ¡™•˜œ’ŸŽȱžŽ•ȱŒŠ—ȱŒŠžœŽȱꛎœȱŠ—ȱ; Cleaning Solvents can cause severe; Carbon Monoxide can cause severe; Lethal Exhaust Gases!; Electrical Shock can cause injury.; CAUTION; ¡™•˜œ’ŸŽȱ ŠœȱŒŠ—ȱŒŠžœŽȱꛎœȱŠ—ȱ
  • Page 7 – Command Engine; Version Code; Year; Factory Code; Numerical Designation
  • Page 8 – R E C O M M E N D E D S A E V I S C O S I T Y G R A D E S; Oil Recommendations; Oil Type; NOTE: Using other than service class SJ or higher oil; Fuel Recommendations; General Recommendations
  • Page 11 – *HQHUDO6SHFL¿FDWLRQVï; M6 Screw Torque; Camshaft; ˜›Žȱǯǯ
  • Page 12 – Connecting Rod-to-Crankpin Running Clearance
  • Page 13 – ›Š—”œ‘ŠĞȱ˜ȱ•ŽŽŸŽȱŽŠ›’—ȱǻ—ȱ’•ȱŠ—Ǽ; Flywheel End Main Bearing Journal; ¢•’—Ž›ȱ˜›Žȱǯǯ; Cylinder Head; Cylinder Head Fastener Torque
  • Page 15 – ŶȱŽŠœž›Žȱŗŗȱ––ȱǻŖǯŚřřȱ’—ǯǼȱŠ‹˜ŸŽȱ‘Žȱ‹˜Ĵ˜–ȱ˜ȱ‘Žȱ™’œ˜—ȱœ”’›ȱŠȱ›’‘ȱŠ—•Žœȱ˜ȱ‘Žȱ™’œ˜—ȱ™’—ǯ; Starter Assembly; Brush Holder Mounting Screw Torque; Stator; —Š”ŽȱŠ•ŸŽȱ ž’Žȱǯǯ
  • Page 16 – Valve Guide Reamer Size
  • Page 17 – Grade 2; Torque
  • Page 19 – Section 2; Tools; Description
  • Page 20 – To remove and reinstall drive retaining rings and brushes.; Vacuum/Pressure Tester; Alternative to a water manometer.
  • Page 21 – Aids
  • Page 22 – Special Tools You Can Make; Flywheel Holding Tool
  • Page 23 – Troubleshooting Guide; Loose wires or connections that short the kill
  • Page 24 – External Engine Inspection
  • Page 25 – Basic Engine Tests; Crankcase Vacuum Test; Start the engine and run at no-load high speed; No Crankcase Vacuum/Pressure in Crankcase; Possible Cause
  • Page 26 – Leakdown Test Results; wear present. Customer should start; Compression Test
  • Page 27 – Paper Element; Air Cleaners; General; Heavy-Duty Style Air Cleaner; Service; ȱ ŗǯȱȱ —‘˜˜”ȱ‘Žȱ ˜ȱ›ŽŠ’—’—ȱŒ•’™œȱ˜—ȱŽŠŒ‘ȱŽ—ȱ
  • Page 28 – Do not wash the paper element and inner; ȱ śǯȱ ‘ŽŒ”ȱŠ••ȱ™Š›œȱ˜›ȱ ŽŠ›ǰȱŒ›ŠŒ”œǰȱ˜›ȱŠ–ŠŽǰȱŠ—ȱ; Air Cleaner Components; NOTE: Damaged, worn or loose air cleaner; Air Intake/Cooling System
  • Page 29 – Fuel Tank and Valve
  • Page 30 – Fuel System Tests; Troubleshooting – Fuel System Related Causes; Test; no fuel at the tip of the spark plug,
  • Page 31 – Fuel Pump; Disconnect the fuel lines from the inlet, outlet; Reconnect the fuel lines to the inlet and outlet; ęĴ’—œȱŠ—ȱœŽŒž›Žȱ ’‘ȱ‘ŽȱŒ•Š–™œǯ; Carburetor
  • Page 32 – Troubleshooting Checklist; Troubleshooting – Carburetor Related Causes; Condition
  • Page 33 – High Altitude Operation; ȱ ŗǯȱ ‘žȱ˜ěȱžŽ•ȱŠ—ȱ›Ž–˜ŸŽȱ‘Žȱœ˜•Ž—˜’ȱ›˜–ȱ‘Žȱ; Carburetor Details
  • Page 34 – Carburetor Adjustments; ˜ ȱ•Žȱ™ŽŽȱǻǼȱŽĴ’—DZȱ•ŠŒŽȱ‘Žȱ‘›˜Ĵ•Žȱ; a. Turn one of the low idle fuel adjusting
  • Page 35 – Governed Idle System; Make sure the governed idle spring is in the outer
  • Page 36 – Carburetor Servicing; ȱ Ȋȱ —œ™ŽŒȱ‘ŽȱĚ˜Šȱ˜›ȱŒ›ŠŒ”œǰȱ‘˜•ŽœǰȱŠ—ȱ–’œœ’—ȱ; Float Replacement; Perform the removal procedures for the; Fuel Bowl
  • Page 37 – Install the carburetor and reassemble the engine; Float
  • Page 39 – and spring from the carburetor. Discard the parts.
  • Page 40 – Choke Repair; Remove the carburetor from the engine. Discard
  • Page 41 – śǯȱ œŽȱŠȱœŒ›Ž ȱŽ¡›ŠŒ˜›ȱǻŽŠœ¢Ȭ˜žǼȱŠ—ȱ›Ž–˜ŸŽȱ‘Žȱ; Stops
  • Page 43 – Linkage; Governor; regulating pin to move outward.; Adjustments; Insert a long thin rod or tool into the hole on the
  • Page 44 – Stop when the desired RPM speed is obtained.
  • Page 45 – SAE; PI; DZȱ œ’—ȱ˜‘Ž›ȱ‘Š—ȱœŽ›Ÿ’ŒŽȱŒ•Šœœȱǰȱ˜›ȱ‘’‘Ž›ȱ
  • Page 46 – Checking Oil Level; so the oil has had time to drain into the sump.; Changing Oil and Oil Filter; Changing Oil
  • Page 47 – Changing Oil Filter; Start the engine and check for oil leaks. Correct; Oil Filter
  • Page 49 – Installation
  • Page 51 – Spark Plugs; Spark Plug Service
  • Page 53 – Battery; Temperature
  • Page 54 – Fixed Timing System; ȱ Ȋȱ ȱ–Š—ŽȱŠœœŽ–‹•¢ȱ ‘’Œ‘ȱ’œȱ™Ž›–Š—Ž—•¢ȱŠĜ¡Žȱ
  • Page 55 – DZȱ ‘Žȱȱ’—’’˜—ȱœ¢œŽ–œȱŠ›ŽȱœŽ—œ’’ŸŽȱ˜ȱ
  • Page 56 – Operation of DSAI Ignition Systems; DSAI Ignition System Explanation; spark advance module to stop the engine.; Operation
  • Page 57 – Troubleshooting DSAI Ignition Systems; Special Tools Required:; Hand Tachometer; SHFL¿FDWLRQV5HTXLUHG; c. Identify the white kill lead of the engine wiring; Test 2. Test for Spark
  • Page 58 – If the line on the screen moved away from; Test 4. Test the Ignition Modules and Connections
  • Page 59 – Battery Charging System; $PS6WDWRUDQG5HFWL¿HU5HJXODWRU
  • Page 63 – To Test –; $PS5HFWL¿HU5HJXODWRUV
  • Page 65 – NOTE: • Š¢œȱ£Ž›˜ȱ˜‘––ŽŽ›ȱ˜—ȱŽŠŒ‘ȱœŒŠ•Žȱ‹Ž˜›ŽȱŽœ’—ȱto ensure accurate readings. Voltage tests should; Problem; If voltage is less than ŘŞȱŸ˜•œ, stator is
  • Page 66 – HFWL¿HU5HJXODWRU; Electric Starting Motors; DZȱ ˜ȱ—˜ȱŒ›Š—”ȱ‘ŽȱŽ—’—ŽȱŒ˜—’—ž˜žœ•¢ȱ˜›ȱ
  • Page 69 – Save the stop collar.
  • Page 70 – Inspection
  • Page 71 – Brush Replacement; Install the stop collar down onto the armature
  • Page 72 – Thrust Washer
  • Page 75 – VOM Leads; Solenoid Test Procedure; Solenoid Shift Style Starters
  • Page 76 – 2 volt Test Leads
  • Page 77 – Typical Disassembly Sequence; Remove connecting rods with pistons and rings.; Disconnect Spark Plug Leads; Disconnect the leads from the spark plugs. See
  • Page 78 – Cylinder Shroud; Shut Off Fuel Supply; ȱ ŗǯȱ •ŽŠ—ȱ‘Žȱ˜’•ȱę•Ž›ȱŠ—ȱ‘˜žœ’—ȱŠ›ŽŠǯȱŽ–˜ŸŽȱŠ—ȱ
  • Page 79 – Remove the lower mounting screw and pull the; Remove Electric Starter Motor; Disconnect the leads from the starter.; Remove Air Cleaner Assembly; Disconnect the breather hose from the air cleaner,; Oil Fill Tube
  • Page 80 – Remove Fuel Pump; Pulse Style Fuel Pump; ȱ Řǯȱ ’œŒ˜——ŽŒȱ‘Žȱ‘›˜Ĵ•Žȱ•’—”ŠŽȱŠ—ȱŠ–™Ž—’—ȱ; Pal Nut
  • Page 81 – Remove Carburetor; Switch Location in Oil
  • Page 82 – Remove Oil Cooler; Remove the two oil cooler mounting screws. Do; Remove Oil Filter Housing
  • Page 83 – ȱ Šǯȱ Ž–˜ŸŽȱ‘Žȱ—’™™•Žȱ›˜–ȱ‘ŽȱŒž™ȱŠ—ȱ˜’•ȱę•Ž›ȱ; Remove Ignition Modules; ȱ ŗǯȱ ˜ŠŽȱ‘ŽȱĚ¢ ‘ŽŽ•ȱœ˜ȱ‘Žȱ–Š—Žȱ’œȱŠ Š¢ȱ›˜–ȱ; Kill Lead
  • Page 84 – Fan
  • Page 85 – Remove the mounting screws securing the; Remove Backing Shroud Assembly; Remove the four screws securing the backing; Remove Spark Plugs; Remove the spark plug from each cylinder head.; Plug
  • Page 86 – Remove Valve Covers; ȱ ŗǯȱ ˜˜œŽ—ȱ‘Žȱ’——Ž›ȱœŽȱœŒ›Ž œȱŠ—ȱ‹ŠŒ”ȱ˜ěȱ‘Žȱ; Pipe Plug
  • Page 87 – Disassemble Cylinder Heads; Œ˜–™›Žœœ˜›ǯȱŽŽȱ’ž›ŽȱŞȬŚśǯ
  • Page 88 – Remove Breather Assembly; ȱ ŗǯȱ Ž–˜ŸŽȱ‘Žȱ˜ž›ȱ‘Ž¡ȱĚŠ—ŽȱœŒ›Ž œȱœŽŒž›’—ȱȱ‘Žȱ; Remove Oil Pan Assembly; ȱ ŗǯȱ Ž–˜ŸŽȱ‘Žȱ˜ž›ŽŽ—ȱ‘Ž¡ǯȱĚŠ—ŽȱœŒ›Ž œȱœŽŒž›’—ȱ; Valve Stem Seals
  • Page 89 – Oil Pump Assembly; ȱ ŗǯȱ Ž–˜ŸŽȱ‘ŽȱŒŠ–œ‘ŠĞȱŠ—ȱœ‘’–ȱǻ’ȱžœŽǼǯȱŽŽȱ
  • Page 90 – ŠœœŽ–‹•¢ȱ›˜–ȱ‘ŽȱŒ¢•’—Ž›ȱ‹˜›ŽǯȱŽŽȱ’ž›ŽȱŞȬśŜǯ; Remove Crankshaft; ŗǯȱ Š›Žž••¢ȱ™ž••ȱ‘ŽȱŒ›Š—”œ‘ŠĞȱ›˜–ȱ‘ŽȱŒ›Š—”ŒŠœŽǯȱ; Removal of Governor Gear Assembly; ȱ řǯȱ —œ™ŽŒȱ‘Žȱ˜ŸŽ›—˜›ȱŽŠ›ȱœ‘ŠĞȱ˜›ȱ ŽŠ›ȱ˜›ȱ; Governor Gear
  • Page 91 – ȱ ŗǯȱ Ž–˜ŸŽȱ‘Žȱ‘›ŽŽȱœŒ›Ž œȱœŽŒž›’—ȱ‘Žȱ•’ĞŽ›ȱŽŽȱ; Remove Flywheel and PTO End Oil Seals; Remove the oil seals from the crankcase and oil; Removal of Main Bearings; DZȱ •¢ ‘ŽŽ•ȱŠ—ȱȱœ’Žȱ–Š’—ȱ‹ŽŠ›’—œȱȱ; Cover
  • Page 93 – Crankshaft; Inspection and Service
  • Page 94 – Crankcase
  • Page 95 – ȱ ŗǯȱ ˜ Ž›ȱ‘˜—Žȱ’—˜ȱ‹˜›ŽȱŠ—ȱŠĞŽ›ȱŒŽ—Ž›’—ǰȱŠ“žœȱ; Clean Cylinder Bore After Honing; NOTE: Do not use a feeler gauge to measure piston-
  • Page 96 – Feeler Gauge; ȱ řǯȱ ’œ˜—Ȭ˜Ȭ‹˜›ŽȱŒ•ŽŠ›Š—ŒŽȱ’œȱ‘Žȱ’쎛Ž—ŒŽȱ‹Ž ŽŽ—ȱ; Flywheel; Cylinder Head and Valves
  • Page 97 – EXHAUST VALVE; Dimension; Seat Angle
  • Page 100 – Pistons and Rings
  • Page 101 – Overheated or Deteriorated Oil
  • Page 102 – Never reuse old rings.; ȱ śǯȱ ĞŽ›ȱ’—œŠ••’—ȱ‘Žȱ—Ž ȱŒ˜–™›Žœœ’˜—ȱǻ˜™ȱŠ—ȱ; Install New Piston Rings
  • Page 103 – ȱ ŗǯȱ ’•ȱ˜—›˜•ȱ’—ȱǻ˜Ĵ˜–ȱ ›˜˜ŸŽǼDZȱ—œŠ••ȱ‘Žȱ; Connecting Rods; old push rod and chuck it in a drill press.; Governor Gear Assembly; DZȱ ‘Žȱ˜ŸŽ›—˜›ȱŽŠ›ȱ’œȱ‘Ž•ȱ˜—˜ȱ‘Žȱœ‘ŠĞȱ‹¢ȱ
  • Page 104 – ȱ ŗǯȱ Ž–˜ŸŽȱ‘Žȱ‘›ŽŽȱ‘Ž¡ȱĚŠ—ŽȱœŒ›Ž œȱœŽŒž›’—ȱ
  • Page 105 – ȱ Şǯȱ —œŠ••ȱŠ—ȱ˜›šžŽȱ‘Žȱ™’Œ”ž™ȱ–˜ž—’—ȱœŒ›Ž ȱ˜ȱ; Pickup
  • Page 107 – Reassembly; NOTE: Make sure the engine is assembled using; Typical Reassembly Sequence; œ ’Œ‘ȱǻ’ȱŽšž’™™ŽǼǯ; Install Flywheel End Oil Seal; ȱ ŗǯȱ Š”Žȱœž›Žȱ‘Šȱ‘ŽȱœŽŠ•ȱ‹˜›Žȱ˜ȱ‘ŽȱŒ›Š—”ŒŠœŽȱ’œȱ
  • Page 108 – Install Flywheel End Main Bearing
  • Page 109 – Oil Seal; ȱ ŗǯȱ ’‘•¢ȱ•ž‹›’ŒŠŽȱ‘Žȱ•’™ȱŠ—ȱ˜žœ’Žȱ’Š–ŽŽ›ȱ˜ȱ; Seal
  • Page 110 – Install Crankshaft; ȱ ŗǯȱ Š›Žž••¢ȱœ•’Žȱ‘ŽȱĚ¢ ‘ŽŽ•ȱŽ—ȱ˜ȱ‘ŽȱŒ›Š—”œ‘ŠĞȱ
  • Page 112 – Black:ȱ ŖǯşşŜşśȦŗǯŖřśŖśȱ––ȱǻŖǯŖřşŘśȦŖǯŖŚŖŝśȱ’—ǯǼ
  • Page 113 – Install Oil Pan Seal and Main Bearing; Main Bearing; Notch
  • Page 114 – Install Oil Pan Assembly
  • Page 115 – Check Crankshaft End play; ȱ ŗǯȱ Žȱ‘ŽȱŽ—’—ŽȱŠœȱœ‘˜ —ǰȱŠ—ȱžœŽȱŠȱ’Š•ȱ’—’ŒŠ˜›ȱ; Install Breather; ȱ ŗǯȱ Š”Žȱœž›Žȱ‘ŽȱœŽŠ•’—ȱœž›ŠŒŽœȱ˜ȱ‘ŽȱŒ›Š—”ŒŠœŽȱ
  • Page 116 – Install Hydraulic Lifters
  • Page 117 – DZȱ ¢›Šž•’Œȱ•’ĞŽ›œȱœ‘˜ž•ȱŠ• Š¢œȱ‹Žȱ
  • Page 118 – Install Cylinder Heads
  • Page 119 – Adjust Valve Clearance; Rocker Arms
  • Page 120 – ȱ˜—Ȭ•Žȱ’ĞŽ›œǰȱ‘Ž—ȱ¢•’—Ž›ȱŽŠœȱŠ—ȱ’ĞŽ›œȱ
  • Page 121 – Check Assembly; Install Valve Covers; Turn Adjuster
  • Page 122 – Install Spark Plugs; ǻŗŞȬŘŘȱĞǯȱ•‹ǯǼǯȱŽŽȱ’ž›ŽȱŗŖȬśŝǯ; Install Oil Filter Housing Assembly
  • Page 123 – ȱ ŗǯȱ Š”Žȱœž›ŽȱŠ••ȱœŽŠ•’—ȱœž›ŠŒŽœȱŠ›ŽȱŒ•ŽŠ—ȱŠ—ȱŠ••ȱ; Install Intake Manifold; ȱ ŗǯȱ —œŠ••ȱ—Ž ȱ’—Š”Žȱ–Š—’˜•ȱŠœ”Žœȱœ˜ȱ‘Žȱ; Notches
  • Page 124 – Install Backing Shroud Assembly
  • Page 125 – śǯȱ ‘ŽŒ”ȱ‘ŽȱŽ›–’—Š•ȱ˜—ȱ‘ŽȱŽ—ȱ˜ȱ‘ŽȱžœŽȱƸȱ; Install Flywheel; DZȱ Ž˜›Žȱ’—œŠ••’—ȱ‘ŽȱĚ¢ ‘ŽŽ•ȱ–Š”Žȱœž›Žȱ; Tabs
  • Page 126 – Install Ignition Modules; Clip
  • Page 128 – Hoses
  • Page 129 – Install Carburetor
  • Page 131 – Install Throttle and Choke Linkages; Control Cable Clamp Locations
  • Page 132 – Governor Spring/RPM Chart; Pressure Switch
  • Page 133 – Cylinder Shrouds
  • Page 135 – Testing the Engine; ȱ ŗǯȱ Žȱ‘ŽȱŽ—’—Žȱž™ȱ˜—ȱŠȱŽœȱœŠ—ǯȱ—œŠ••ȱŠ—ȱ˜’•ȱ
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CV940-CV1000

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Summary

Page 3 - Contents

Contents Section 1. Safety and General Information ............................................................................. Section 2. Tools & Aids ............................................................................................................. Section 3. Troubleshooting .........

Page 5 - Safety Precautions; Accidental Starts can cause; WARNING; Rotating Parts can cause severe; WARNING; Hot Parts can cause severe burns.; WARNING

1.1 1 Rotating Parts! Keep hands, feet, hair, and clothing away from all moving parts to prevent injury. Never operate the engine with covers, shrouds, or guards removed. Section 1 Safety and General Information Safety Precautions To ensure safe operation please read the following statements and und...

Page 6 - ¡™•˜œ’ŸŽȱžŽ•ȱŒŠ—ȱŒŠžœŽȱꛎœȱŠ—ȱ; Cleaning Solvents can cause severe; Carbon Monoxide can cause severe; Lethal Exhaust Gases!; Electrical Shock can cause injury.; CAUTION; ¡™•˜œ’ŸŽȱ ŠœȱŒŠ—ȱŒŠžœŽȱꛎœȱŠ—ȱ

1.2 Section 1Safety and General Information ¡™•˜œ’ŸŽȱžŽ•ȱŒŠ—ȱŒŠžœŽȱꛎœȱŠ—ȱ severe burns. ˜ȱ—˜ȱꕕȱ‘ŽȱžŽ•ȱŠ—”ȱ ‘’•Žȱ‘Žȱengine is hot or running. WARNING Explosive Fuel! Šœ˜•’—Žȱ’œȱŽ¡›Ž–Ž•¢ȱ̊––Š‹•ŽȱŠ—ȱits vapors can explode if ignited. Store gasoline only in approved containers, in well vent...

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