Kohler CH960, CH1000, CH940, CH980 User Manual

4 (1)

OWNER'S MANUAL

COMMAND PRO

CH940-CH1000

HORIZONTAL CRANKSHAFT

1

Safety Precautions

To ensure safe operations please read the following statements and understand their meaning. Also refer to your equipment owner's manual for other important safety information. This manual contains safety precautions which are explained below. Please read carefully.

WARNING

Warning is used to indicate the presence of a hazard that can cause severe personal injury,death, or substantial property damage if the warning is ignored.

CAUTION

Caution is used to indicate the presence of a hazard that will or can cause minor personal injury or property damage if the caution is ignored.

NOTE

Note is used to notify people of installation, operation, or maintenance information that is important but not hazard-related.

For Your Safety!

These precautions should be followed at all times. Failure to follow these precautions could result in injury to yourself and others.

WARNING

WARNING

WARNING

Explosive Fuel can cause fires and

Rotating Parts can cause severe

Hot Parts can cause severe burns.

severe burns.

injury.

Do not touch engine while operating

 

 

Do not fill the fuel tank while the

Stay away while engine is in

or just after stopping.

engine is hot or running.

operation.

 

Explosive Fuel!

Rotating Parts!

Hot Parts!

Gasoline is extremely flammable and its

Keep hands, feet, hair, and clothing away

Engine components can get extremely hot

vapors can explode if ignited. Store

from all moving parts to prevent injury.

from operation. To prevent severe burns,

gasoline only in approved containers, in

Never operate the engine with covers,

do not touch these areas while the engine

well ventilated, unoccupied buildings,

shrouds, or guards removed.

is running, or immediately after it is

away from sparks or flames. Do not fill

 

 

turned off. Never operate the engine with

the fuel tank while the engine is hot or

 

 

heat shields or guards removed.

running, since spilled fuel could ignite if

 

 

 

CAUTION

 

 

it comes in contact with hot parts or

 

 

sparks from ignition. Do not start the

 

 

 

 

 

 

 

 

California

engine near spilled fuel. Never use

 

 

gasoline as a cleaning agent.

 

 

Proposition 65 Warning

 

 

 

Engine exhaust from this product

 

Electrical Shock can cause injury.

 

 

 

contains chemicals known to the State

 

Do not touch wires while engine is

 

of California to cause cancer, birth

 

 

defects, or other reproductive harm.

 

running.

 

 

 

 

 

 

 

 

 

 

 

 

 

Electrical Shock!

 

 

Never touch electrical wires or

 

 

components while the engine is running.

 

 

They can be sources of electrical shock.

 

2

WARNING

Accidental Starts can cause severe injury or death.

Disconnect and ground spark plug lead before servicing.

Accidental Starts!

Disabling engine. Accidental starting can cause severe injury or death.

Before working on the engine or equipment, disable the engine as follows:

1)Disconnect the spark plug lead(s).

2)Disconnect negative (-) battery cable from battery.

Safety Precautions (Cont.)

WARNING

Carbon Monoxide can cause severe nausea, fainting or death.

Avoid inhaling exhaust fumes, and never run the engine in a closed building or confined area.

Lethal Exhaust Gases!

Engine exhaust gases contain poisonous carbon monoxide. Carbon monoxide is odorless, colorless, and can cause death if inhaled. Avoid inhaling exhaust fumes, and never run the engine in a closed building or confined area.

WARNING

Explosive Gas can cause fires and severe acid burns.

Charge battery only in a well ventilated area. Keep sources of ignition away.

Explosive Gas!

Batteries produce explosive hydrogen gas while being charged. To prevent a fire or explosion, charge batteries only in well ventilated areas. Keep sparks, open flames, and other sources of ignition away from the battery at all times. Keep batteries out of the reach of children. Remove all jewelry when servicing batteries.

Before disconnecting the negative (-) ground cable, make sure all switches are OFF. If ON, a spark will occur at the ground cable terminal which could cause an explosion if hydrogen gas or gasoline vapors are present.

Congratulations – You have selected a fine four-cycle, twin cylinder, air-cooled engine. Kohler designs long life strength and on-the-job durability into each engine…making a Kohler engine dependable…dependability you can count on. Here are some reasons why:

Efficient overhead valve design and full pressure lubrication provide maximum power, torque, and reliability under all operating conditions.

Dependable, maintenance free electronic ignition ensures fast, easy starts time after time.

Kohler engines are easy to service. All routine service areas (like the oil filter, dipstick, oil fill, air cleaner, spark plug, and carburetor) are easily and quickly accessible.

Parts subject to the most wear and tear (like the cylinder liner and camshaft) are made from precision formulated cast iron.

Every Kohler engine is backed by a worldwide network of over 10,000 distributors and dealers. Service support is just a phone call away. Call 1-800-544-2444 (U.S. & Canada) for Sales & Service assistance. Or visit www.KohlerEngines.com.

To keep your engine in top operating condition, follow the maintenance procedures in this manual.

3

Kohler CH960, CH1000, CH940, CH980 User Manual

Air

Lifting Point

 

 

Cleaner

 

 

 

 

 

 

Oil Filter

 

Fuel

Throttle

Choke

 

Carburetor

Pump

Control

Control

Lever

Lever

 

 

 

Oil Fill

Lifting

 

 

Strap

Spark

Dipstick

 

Plug

 

 

Cylinder

Electric

 

Starter

Oil

Shrouds

 

Drain

 

 

Plugs

Blower

 

 

Housing

Screen

 

 

 

 

 

Figure 1. Typical Command PRO Horizontal Shaft Engine.

 

Oil Recommendations

Using the proper type and weight of oil in the crankcase is extremely important. So is checking oil daily and changing oil regularly. It is also recommended that a consistent brand of oil be used. Failure to use the correct oil, or using dirty oil, causes premature engine wear and failure.

Oil Type

Use high quality detergent oil of API (American Petroleum Institute) service class SJ or higher. Select the viscosity based on the air temperature at the time of operation as shown in the following table.

RECOMMENDED SAE VISCOSITY GRADES

 

**

 

 

*

 

10W-30

 

 

 

5W-20, 5W-30

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Kohler 10W-30

 

 

°F

-20

0

20

32

40

 

60

80

100

°C -30

-20

-10

0

 

10

20

30

40

TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANGE

* Use of synthetic oil having 5W-20 or 5W-30 rating is acceptable, up to 4°C (40°F)

**Synthetic oils will provide better starting in extreme cold below 23°C (-10°F)

Figure 2. Viscosity Grades Table.

NOTE: Synthetic oils meeting the listed classifications may be used with oil changes performed at the recommended intervals. However to allow piston rings to properly seat, a new or rebuilt engine should be operated for at least 50 hours using standard petroleum based oil before switching to synthetic oil.

A logo or symbol on oil containers identifies the API service class and SAE viscosity grade. See Figure 3.

 

 

 

RV

 

 

 

 

 

 

E

I

 

 

 

 

 

S

 

C

 

 

P

I

 

E

 

 

 

 

 

 

 

S

A

 

 

SAE

 

 

 

 

 

J

 

 

 

10W-30

 

 

 

 

 

 

Figure 3. Oil Container Logo.

Refer to Maintenance Instructions beginning on page 8 for detailed oil check, oil change, and oil filter change procedures.

NOTE: Using other than service class SJ or higher oil or extending oil change intervals longer than recommended can cause engine damage.

4

Fuel Recommendations

WARNING: Explosive Fuel!

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. Do not fill the fuel tank while the engine is hot or running, since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition. Do not start the engine near spilled fuel. Never use gasoline as a cleaning agent.

General Recommendations

Purchase gasoline in small quantities that can be used within 30 days and store only in clean, approved containers. Do not use gasoline left over from the

previous season unless treated with a fuel stabilizer (refer to Storage), to minimize gum deposits and

ensure easy starting. Do not use gasoline containing Methanol, or add oil to the gasoline.

Do not overfill the fuel tank. Leave room for the fuel to expand.

Fuel Type

For best results use only clean, fresh, unleaded gasoline with a pump sticker octane rating of 87 or higher. In countries using the Research method, it should be 90 octane minimum.

Unleaded gasoline is recommended as it leaves less combustion chamber deposits and reduces harmful exhaust emissions. Leaded gasoline is not recommended and must not be used in any models where exhaust emissions are regulated.

Gasoline/Alcohol blends

Gasohol (up to 10% ethyl alcohol, 90% unleaded gasoline by volume) is approved as a fuel for Kohler engines. Other gasoline/alcohol blends including E20 and E85 are not to be used and not approved. Any failures resulting from use of these fuels will not be warranted.

Gasoline/Ether blends

Methyl Tertiary Butyl Ether (MTBE) and unleaded gasoline blends (up to a maximum of 15% MTBE by volume) are approved as a fuel for Kohler engines. Other gasoline/ether blends are not approved.

Engine Identification Numbers

When ordering parts, or in any communication involving an engine, always give the Model, Specification, and Serial Numbers of the engine.

The engine identification numbers appear on a decal affixed to the engine shrouding. Include letter suffixes, if there are any.

Record your engine identification numbers on the identification label below (Figure 4) for future reference.

IMPORTANT ENGINE INFORMATION

THIS ENGINE MEETS EMISSION REGS FOR U.S. EPA PH 2 SMALL OFF–ROAD ENGINES AND CA 2006 AND LATER LSI ENGINES

FAMILY

DISPL. (CC)

MODEL NO.

SPEC. NO.

SERIAL NO.

BUILD DATE OEM PROD. NO.

EMISSION COMPLIANCE PERIOD: EPA:

CERTIFIED ON:

REFER TO OWNER'S MANUAL FOR HP RATING, SAFETY, MAINTENANCE AND ADJUSTMENTS

1-800-544-2444 www.kohlerengines.com KOHLER CO. KOHLER, WISCONSIN USA

IMPORTANT ENGINE INFORMATION

THIS ENGINE MEETS EMISSION REGS FOR U.S. EPA 2006AND LATER AND EC STAGE II (SN:4) SI SMALL OFF–ROAD ENGINES AND CA 2006 AND LATER LSI ENGINES

FAMILY

TYPE APP

DISPL. (CC)

MODEL NO.

SPEC. NO.

SERIAL NO.

BUILD DATE OEM PROD. NO.

EMISSION COMPLIANCE PERIOD: EPA:

CERTIFIED ON:

REFER TO OWNER'S MANUAL FOR HP RATING, SAFETY, MAINTENANCE AND ADJUSTMENTS

1-800-544-2444 KohlerEngines.com

KOHLER CO. KOHLER, WISCONSIN USA

Figure 4. Engine Identification Label.

The Emission Compliance Period referred to on the Emission Control or Air Index label indicates the number of operating hours for which the engine has been shown to meet Federal emission requirements. The following table provides the Engine Compliance Period (in hours) associated with the category descriptor found on the certification label.

Emission Compliance Period (Hours)

EPA

Category A

1000 hours

 

Refer to certification label for engine displacement.

Exhaust Emission Control System for models CH940CH1000 is EM.

Model Designation

Model CH980 for example: C designates Command engine, H designates horizontal crankshaft, and 980 indicates the numerical model designation. A letter suffix designates a specific version as follows:

Suffix Designates

S Electric Start

5

Operating Instructions

Also read the operating instructions of the equipment this engine powers.

Pre-Start Checklist

Check oil level. Add oil if low. Do not overfill.

Check fuel level. Add fuel if low.

Check cooling air intake areas and external surfaces of engine. Make sure they are clean and unobstructed.

Check that the air cleaner components and all shrouds, equipment covers, and guards are in place and securely fastened.

Check that any clutches or transmissions are disengaged or placed in neutral. This is especially important on equipment with hydrostatic drive. The shift lever must be exactly in neutral to prevent resistance which could keep the engine from starting.

Throttle and Choke Control Linkage Setup

The throttle and choke levers on these engines allow remote mounted control operation from either side. The linkage for the throttle and choke is connected in one of the two available hole locations; A or B in the control levers. Hole location A in each lever is used for Outer Pull actuation. Hole Location B used for Inner Pull actuation. Most engines will have the control linkage connected in Location A, the primary location. If the application requires opposite side control direction or function, unhook the link(s) from the small clip and reconnect in the other hole location. See Figures 5 and 6.

(A)

(A)

Linkages

Connected Here

Figure 5. Throttle and Choke Control Linkage in Outer Pull Configuration.

(B)

(B)

Linkages

Connected Here

Figure 6. Throttle and Choke Control Linkage in Inner Pull Configuration.

WARNING: Lethal Exhaust Gases!

Engine exhaust gases contain poisonous carbon monoxide. Carbon monoxide is odorless, colorless, and can cause death if inhaled. Avoid inhaling exhaust fumes, and never run the engine in a closed building or confined area.

Cold Weather Starting Hints

1.Be sure to use the proper oil for the temperature expected. See Figure 2 on page 4.

2.Disengage all possible external loads.

3.Be sure the battery is in good condition. A warm battery has much more starting capacity than a cold battery.

4.Use fresh winter grade fuel. NOTE: Winter grade gasoline has higher volatility to improve starting. Do not use gasoline left over from summer.

Starting

1.Place the throttle control midway between the SLOW and FAST positions. Place the choke control into the ON position. See Figures 7 and 8.

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