Kohler CV11 User's Manual

Kohler CV11 User's Manual
OWNER'S MANUAL
COMMAND SERIES
CV11, CV12.5, CV13, CV14, CV15, CV16,
CV460, CV490
VERTICAL CRANKSHAFT
1
Safety Precautions
To insure 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
Explosive Fuel can cause fires and
severe burns.
Rotating Parts can cause severe
injury.
Stop engine before filling fuel tank.
Stay away while engine is in
operation.
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.
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.
CAUTION
Hot Parts can cause severe burns.
Do not touch engine while operating
or just after stopping.
Hot Parts!
Engine components can get
extremely hot from operation. To
prevent severe burns, do not touch
these areas while the engine is
running, or immediately after it is
turned off. Never operate the engine
with heat shields or guards
removed.
California
Proposition 65 Warning
Electrical Shock can cause injury.
Do not touch wires while engine is
running.
Electrical Shock!
Never touch electrical wires or
components while the engine is
running. They can be sources of
electrical shock.
2
WARNING
Engine exhaust from this product
contains chemicals known to the
State of California to cause cancer,
birth defects, or other reproductive
harm.
Safety Precautions (Cont.)
WARNING
WARNING
WARNING
Accidental Starts can cause severe
injury or death.
Carbon Monoxide can cause
severe nausea, fainting or death.
Explosive Gas can cause fires and
severe acid burns.
Disconnect and ground spark plug
lead before servicing.
Do not operate engine in closed or
confined area.
Charge battery only in a well
ventilated area. Keep sources of
ignition away.
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.
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.
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, single 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 dipstick and 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. Because the cylinder liner can be rebored, these engines can last even longer.
• 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.
To keep your engine in top operating condition, follow the maintenance procedures in this manual.
3
Air Cleaner
Engine
Identification Plate
Retractable Starter
Oil Fill/Dipstick
Blower Housing
Muffler
Oil Filter
Carburetor
Oil Drain Plug
Optional
Oil Filter
Drain Plug
Cooling Shrouds
Optional Oil Sentry Switch
Or Oil Filter Drain Plug
Electric Starter
Cover Or
Optional Fuel Pump
Oil Drain Plug
Figure 1. Typical Command Vertical 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. Failure to use the
correct oil, or using dirty oil, causes premature engine
wear and failure.
A logo or symbol on oil containers identifies the API
service class and SAE viscosity grade. See Figure 3.
Oil Type
Use high quality detergent oil of API (American
Petroleum Institute) service class SG, SH, SJ or
higher. Select the viscosity based on the air
temperature at the time of operation as shown in the
following table.
Figure 3. Oil Container Logo.
**
*
Refer to “Maintenance Instructions” beginning on
page 8 for detailed oil check, oil change, and oil
filter change procedures.
Fuel Recommendations
*Use of synthetic oil having 5W-20 or 5W-30 rating is
acceptable, up to 40°F.
**Synthetic oils will provide better starting in extreme
cold (below -10°F).
Figure 2. Viscosity Grades Table.
NOTE: Using other than service class SG, SH, SJ or
higher oil or extending oil change intervals
longer than recommended can cause engine
damage.
4
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 and store in
clean, approved containers. A container with a capacity
of 2 gallons or less with a pouring spout is
recommended. Such a container is easier to handle
and helps eliminate spillage during refueling.
Do not use gasoline left over from the previous season,
to minimize gum deposits in your fuel system and to
insure easy starting.
Do not 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. Leaded gasoline may
be used in areas where unleaded is not available and
exhaust emissions are not regulated. Be aware
however, that the cylinder heads may require more
frequent service.
Record your engine identification numbers on the
identification label below (Figure 4) for future
reference.
IMPORTANT ENGINE INFORMATION
THIS ENGINE MEETS U.S. EPA 2004 AND
CALIFORNIA 2006 AND LATER EMISSION
CONTROL REGULATIONS FOR SI SORE*
FAMILY
DISPL. (CC)
MODEL NO.
SPEC. NO.
SERIAL NO.
N11236
EMISSION COMPLIANCE PERIOD:
EPA:
CARB:
THIS ENGINE IS CERTIFIED TO OPERATE
ON:
REFER TO OWNER'S MANUAL FOR SAFETY,
MAINTENANCE SPECS AND ADJUSTMENTS.
FOR SALES/SERVICE IN US/CANADA, CALL:
1-800-544-2444
www.kohlerengines.com
KOHLER CO. KOHLER, WISCONSIN USA
*Small Off-Road Engines
Figure 4. Engine Identification Label.
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 are not
approved.
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 and CARB emission
requirements. The following table provides the Engine
Compliance Period (in hours) associated with the
category descriptor found on the certification label.
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 engine.
Other gasoline/ether blends are not approved.
Emission Compliance Period (Hours)
Category C Category B
EPA
250 Hours 500 Hours
Moderate
Intermediate
CARB
125 Hours 250 Hours
Engine Identification Numbers
When ordering parts, or in any communication
involving an engine, always give the Model,
Specification, and Serial Numbers of the engine.
Category A
1000 Hours
Extended
500 Hours
Refer to certification label for engine displacement.
Exhaust Emission Control System for models
CV11,12.5,13,14,15,16,CV460,CV490 is EM.
The engine identification numbers appear on a decal
affixed to the engine shrouding. Include letter suffixes,
if there are any.
5
Specifications
Model: ............................................ CV11/CV12.5 ..................... CV13/CV14 ....................... CV15/CV16** .................. CV460/CV490
Bore: ............................. mm (in.) .. 87 (3.43)/87 (3.43) ............ 87 (3.43)/87 (3.43) ............ 90 (3.55)/90 (3.55) ......... 87 (3.43)/90 (3.55)
Stroke: ........................... mm (in.) .. 67 (2.64)/67 (2.64) ............ 67 (2.64)/67 (2.64) ............ 67 (2.64)/67 (2.64) ......... 77 (3.03)/77 (3.03)
Displacement: ............... cm3 (in3) .. 398 (24.3)/398 (24.3) ........ 398 (24.3)/398 (24.3) ........ 426 (26.0)/426 (26.0) ..... 458 (28.0)/490 (29.9)
Power (@3600 RPM): . kW (HP) .. 8.2 (11*)/9.33 (12.5*) ......... 9.75 (13*)/10.50 (14*) ........ 11.2 (15*)/11.9 (16*) ....... 11.9 (16*)/12.7 (17*)
Max. Torque (@ RPM): ...... ft. lb. .. 20.2 @2000/20.5 @2500 .. 20.5 @2500/21.3 @2500 .. 24.5 @2400/25 @2400 .. 26.8 @2400/27.7 @2400
Compression Ratio: ....................... 8.5:1/8.5:1 ......................... 8.5:1/8.5:1 ......................... 8.5:1/8.5:1 ...................... 8.5:1/8.5:1
Weight: ............................ kg (lb.) .. 39.5 (87.0)/39.5 (87.0) ...... 39.5 (87.0)/39.5 (87.0) ...... 39.5 (87.0)/39.5 (87.0) ... 41 (90)/41 (90)
Oil Capacity
(w/filter): .................... L (U.S. pt.) .. 1.9 (4)/1.9 (4) ..................... 1.9 (4)/1.9 (4) ..................... 1.9 (4)/1.9 (4) .................. 1.9 (4)/1.9 (4)
Lubrication: ....................................
Full Pressure w/full Flow Filter
Exhaust Emission Control System for CV11,12.5,13,14,15,16,CV460,CV490 is EM.
*Horsepower ratings are established in accordance with Society of Automotive Engineers – Small Engine Test Code – J1995 GROSS. Kohler
Co. reserves the right to change product specifications, design, and standard equipment without notice and without incurring obligation.
**CV16 engine is equipped with Smart SparkTM computerized ignition system.
Operating Instructions
Also read the operating instructions of the equipment
this engine powers.
Pre-Start Checklist
4. Use fresh winter grade fuel. NOTE: Winter grade
gasoline has higher volatility to improve starting.
Do not use gasoline left over from summer.
• Check oil level. Add oil if low. Do not overfill.
Starting
• Check fuel level. Add fuel if low.
• Check cooling air intake areas and external
surfaces of engine. Make sure they are clean and
unobstructed.
1. For a Cold Engine or a Warm Engine – Place
the throttle/choke control into the “fast/choke on”
position. This will also place the choke into the
“on” position. See Figure 5.
• 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.
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. Declutch all possible external loads.
3. A warm battery has much more starting capacity
than a cold battery.
6
Figure 5. Throttle Position for Starting Engine.
2. Start the engine as follows:
For a Retractable Start Engine – SLOWLY pull
the starter handle until just past compression –
STOP! Return starter handle, pull firmly with a
smooth, steady motion to start. Pull the handle
straight out to avoid excessive rope wear from the
starter rope guide.
Extend the starting rope periodically and check its
condition. If the rope is frayed, have it replaced
immediately by your Kohler Engine Service
Dealer.
WARNING: Accidental Starts!
Before extending and checking retractable starter rope,
remove the spark plug lead to prevent the engine from
starting accidentally. Make sure the equipment is in
neutral.
For an Electric Start Engine – Activate the
starter switch. Release the switch as soon as the
engine starts.
NOTE: Do not crank the engine continuously for
more than 10 seconds at a time. If the
engine does not start, allow a 60 second
cool down period between starting
attempts. Failure to follow these
guidelines can burn out the starter motor.
NOTE: Upon start-up, a metallic ticking may
occur. This is caused by hydraulic lifter
leakdown during storage. Run the engine
for 5 minutes. The noise will normally
cease in the first minute. If noise
continues, run the engine at mid-throttle
for 20 minutes. If noise persists, take the
engine to your local Kohler Service outlet.
NOTE: If the engine develops sufficient speed to
disengage the starter but does not keep
running (a false start), engine rotation
must be allowed to come to a complete
stop before attempting to restart the
engine. If the starter is engaged while the
flywheel is rotating, the starter pinion and
flywheel ring gear may clash, resulting in
damage to the starter.
If the starter does not turn the engine over, shut
off starter immediately. Do not make further
attempts to start the engine until the condition is
corrected. Do not jump start using another battery
(refer to “Battery”). See your Kohler Engine
Service Dealer for trouble analysis.
3. For Operation – After the engine starts, move the
throttle/choke control from the “fast/choke on”
position and set the desired engine operating
speed (between the “slow” and “fast” position).
The engine/equipment may be operated during
the warm-up period, but it may be necessary to
leave the choke partially on until the engine warms
up.
Stopping
1. Remove the load by disengaging all PTO
attachments.
2a. For engines without a shutdown solenoid:
Move the throttle to the ‘‘slow‘‘ or ‘‘low’’ idle
position. Allow the engine to run at idle for 30-60
seconds; then stop the engine.
b. For engines equipped with a shutdown
solenoid: Position the throttle control somewhere
between half and full throttle; then stop the engine.
Battery
A 12 volt battery is normally used. Refer to the
operating instructions of the equipment this engine
powers for specific battery requirements.
If the battery charge is not sufficient to crank the
engine, recharge the battery (see page 12).
Operating
Angle of Operation
This engine will operate continuously at angles up
to 25°. Check oil level to assure crankcase oil level is
at the “F” mark on the dipstick.
Refer to the operating instructions of the equipment
this engine powers. Because of equipment design or
application, there may be more stringent restrictions
regarding the angle of operation.
NOTE: Do not operate this engine continuously at
angles exceeding 25° in any direction. Engine
damage could result from insufficient
lubrication.
Cooling
NOTE: If debris builds up on the grass screen or
other cooling air intake areas, stop the engine
immediately and clean. Operating the engine
with blocked or dirty air intake and cooling
areas can cause extensive damage due to
overheating.
WARNING: Hot Parts!
Engine components can get extremely hot from
operation. To prevent severe burns, do not touch these
areas while the engine is running–or immediately after
it is turned off. Never operate the engine with heat
shields or guards removed.
Engine Speed
NOTE: Do not tamper with the governor setting to
increase the maximum engine speed.
Overspeed is hazardous and will void the
engine warranty.
7
Maintenance Instructions
Maintenance, repair, or replacement of the emission control devices and systems, which are being done at
the customers expense, may be performed by any non-road engine repair establishment or individual.
Warranty repairs must be performed by an authorized Kohler service outlet.
WARNING: 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.
Maintenance Schedule
These required maintenance procedures should be performed at the frequency stated in the table. They should
also be included as part of any seasonal tune-up.
Frequency
Daily or Before
Starting Engine
Every 25 Hours
Every 100 Hours
Every 200 Hours
Maintenance Required
•
•
•
•
•
•
Fill fuel tank.
Check oil level.
Check air cleaner for dirty¹, loose, or damaged parts.
Check air intake and cooling areas, clean as necessary¹.
Service precleaner element¹ (if equipped).
Service air cleaner element¹ (if not equipped with precleaner).
•
•
•
•
•
Replace air cleaner element¹ (if equipped with precleaner).
Change oil.
Remove cooling shrouds and clean cooling areas¹.
Check spark plug condition and gap.
Change oil filter.
Annually or
Every 500 Hours
• Have bendix starter drive serviced².
• Have solenoid shift starter disassembled and cleaned2.
¹Perform these maintenance procedures more frequently under extremely dusty, dirty conditions.
²Have a Kohler Engine Service Dealer perform this service.
Check Oil Level
The importance of checking and maintaining the proper
oil level in the crankcase cannot be overemphasized.
Check oil BEFORE EACH USE as follows:
Oil Fill Cap/Dipstick
1. Make sure the engine is stopped, level, and is
cool so the oil has had time to drain into the sump.
2. To keep dirt, grass clippings, etc., out of the
engine, clean the area around the oil fill cap/
dipstick before removing it.
3. Unthread and remove the oil fill cap/dipstick; wipe
oil off. Reinsert the dipstick into the tube and rest
the oil fill cap on the tube. Do not thread the cap
onto the tube. See Figure 6.
Oil Fill Tube
Figure 6. Checking Oil Level.
4. Remove the dipstick and check the oil level.
The oil level should be up to, but not over, the “F”
mark on the dipstick. See Figure 7.
8
Change the oil as follows (see Figure 8):
“F” Mark
Operating
Range
1. To keep dirt, grass clippings, etc., out of the
engine, clean the area around the oil fill cap/
dipstick before removing it.
2. Remove the oil drain plug and oil fill cap/dipstick.
Be sure to allow ample time for complete
drainage.
3. Reinstall the drain plug. Make sure it is tightened
to 13.6 N·m (10 ft. lb.) torque.
Figure 7. Oil Level Dipstick.
5. If the level is low, add oil of the proper type, up to
the “F” mark on the dipstick. (Refer to “Oil Type”
on page 4.) Always check the level with the
dipstick before adding more oil.
NOTE: To prevent extensive engine wear or
damage, always maintain the proper oil
level in the crankcase. Never operate the
engine with the oil level below the “L”
mark or over the “F” mark on the dipstick.
Oil Sentry™
4. Fill the crankcase, with new oil of the proper type,
to the “F” mark on the dipstick. Refer to “Oil Type”
on page 4. Always check the level with the dipstick
before adding more oil.
5. Reinstall the oil fill cap or plug and tighten
securely.
NOTE: To prevent extensive engine wear or
damage, always maintain the proper oil
level in the crankcase. Never operate the
engine with the oil level below the “L”
mark or over the “F” mark on the dipstick.
Some engines are equipped with an optional Oil
Sentry™ oil pressure switch. If the oil pressure
decreases below an acceptable level, the Oil Sentry™
will either shut off the engine or activate a warning
signal, depending on the application.
Optional Oil
Filter Drain Plug
Oil Filter
NOTE: Make sure the oil level is checked BEFORE
EACH USE and is maintained up to the “F”
mark on the dipstick. This includes engines
equipped with Oil Sentry™.
Change Oil and Oil Filter
Oil Drain Plug
(Carb. Side)
Optional Oil Sentry™ Switch
Change Oil
Change oil after every 100 hours of operation. Refill
with service class SG, SH, SJ or higher oil as specified
in the “Viscosity Grades” table (Figure 2) on page 4.
Change the oil while the engine is still warm. The oil
will flow more freely and carry away more impurities.
Make sure the engine is level when filling, checking, or
changing the oil.
Oil Drain Plug
(Starter Side)
Figure 8. Oil Drain Plugs, Oil Filter, Oil Filter Drain
Plug, and Optional Oil Sentry™ Switch.
9
Change Oil Filter
Replace the oil filter at least every other oil change
(every 200 hours of operation). Always use a
genuine Kohler oil filter, Part No. 52 050 02-S.
Air Cleaner
Cover
w/Knob
Replace the oil filter as follows:
Foam
Precleaner
1. Drain the oil from the engine crankcase.
2. Remove the oil filter drain plug located at the base
of the oil filter adapter (if so equipped). Allow the
oil filter to drain.
3. Remove the old filter and wipe off the filter
adapter. Reinstall the oil filter drain plug (if so
equipped).
4. Place a new replacement filter in a shallow pan
with the open end up. Pour new oil of the proper
type, in through the threaded center hole. Stop
pouring when the oil reaches the bottom of the
threads. Allow a minute or two for the oil to be
absorbed by the filter material.
Wing Nut with
Locking Material
Air Cleaner
Element
Seal
5. Put a drop of oil on your fingertip and wipe it on
the rubber gasket.
Screw (2)
Stud
6. Install the replacement oil filter to the filter adapter.
Turn the oil filter clockwise until the rubber gasket
contacts the filter adapter, then tighten the filter an
additional 2/3 to 1 turn.
Gasket
7. Fill the crankcase with new oil of the proper type,
to the “F” mark on the dipstick.
8. Test run the engine to check for leaks. Stop the
engine, allow a minute for the oil to drain down,
and recheck the level on the dipstick. Add more
oil, as necessary, so the oil level is up to but not
over the "F" mark on the dipstick.
Service Precleaner and Air Cleaner Element
This engine is equipped with a replaceable, high
density paper air cleaner element. Most engines are
also equipped with an oiled, foam precleaner which
surrounds the paper element. See Figure 9.
Check the air cleaner daily or before starting the
engine. Check for a buildup of dirt and debris around
the air cleaner system. Keep this area clean. Also
check for loose or damaged components. Replace all
bent or damaged air cleaner components.
NOTE: Operating the engine with loose or damaged
air cleaner components could allow unfiltered
air into the engine causing premature wear
and failure.
10
Air Cleaner Base
Figure 9. Air Cleaner Assembly – Exploded View.
Service Precleaner
Wash and reoil the precleaner every 25 hours of
operation, if equipped, (more often under extremely
dusty or dirty conditions).
1. Loosen the air cleaner cover knob and remove the
cover.
2. Remove the precleaner from the paper element.
3. Wash the precleaner in warm water with
detergent. Rinse the precleaner thoroughly until all
traces of detergent are eliminated. Squeeze out
excess water (do not wring). Allow the precleaner
to air dry.
4. Saturate the precleaner with new engine oil.
Squeeze out all excess oil.
5. Reinstall the precleaner over the paper element.
6. Reinstall the air cleaner cover and tighten the
knob securely.
7. When replacement is necessary order genuine
Kohler parts.
Standard
U.L. Approved
Extra Capacity
CV11-CV16
12 083 08-S
12 083 08-S
12 083 12-S
CV460, CV490
12 083 12-S
Service Paper Element
Every 100 hours of operation replace the paper
element, if equipped with a precleaner. Check every 25
hours of operation if not equipped with a precleaner.
(More often under extremely dusty or dirty conditions.)
1. Loosen the air cleaner cover knob and remove the
cover. Remove the wing nut and remove the air
cleaner element with precleaner (if so equipped).
Remove the precleaner from the element and
service as necessary.
2. Do not wash the paper element or use
pressurized air, as this will damage the element.
Replace a dirty, bent, or damaged element with a
genuine Kohler element. Handle new elements
carefully; do not use if the sealing surfaces are
bent or damaged.
3. When servicing the air cleaner, check the air
cleaner base. Make sure it is secured and not
damaged. Also, check the air cleaner cover for
damage or improper fit. Replace all damaged air
cleaner components.
4. If any loose dirt or debris fell on the air cleaner
base when the element was removed, carefully
remove it and wipe the base clean. Be careful that
none of it drops into the intake throat. Check the
condition of the rubber seal on the air cleaner
stud. If condition is questionable in any way,
replace it with the new seal packaged with the
replacement element.
5. Install the precleaner over the element. Install the
element with precleaner on the base and secure it
with the wing nut. Reinstall the cover and tighten
the knob securely.
6. When replacement is necessary order genuine
Kohler parts.
Clean Air Intake/Cooling Areas
To ensure proper cooling, make sure the grass screen,
cooling fins, and other external surfaces of the engine
are kept clean at all times.
Every 100 hours of operation (more often under
extremely dusty, dirty conditions), remove the blower
housing and other cooling shrouds. Clean the cooling
fins and external surfaces as necessary. Make sure the
cooling shrouds are reinstalled.
NOTE: Operating the engine with a blocked grass
screen, dirty or plugged cooling fins, and/or
cooling shrouds removed, will cause engine
damage due to overheating.
Ignition System
This engine is equipped with a dependable electronic
magneto ignition system. Other than periodically
checking/replacing the spark plug, no maintenance,
timing, or adjustments are necessary or possible with
this system.
In the event starting problems should occur which are
not corrected by replacing the spark plug, see your
Kohler Engine Service Dealer for trouble analysis.
Check Spark Plug
Every 200 hours of operation, remove the spark plug,
check condition, and reset the gap or replace with a
new plug as necessary. The standard spark plug is a
Champion® RC12YC (Kohler Part No. 12 132 02-S). A
high-performance spark plug, Champion® Premium
Gold 2071 (used on Pro Series engines, Kohler Part
No. 12 132 06-S) is also available. Equivalent alternate
brand plugs can also be used.
1. Before removing the spark plug, clean the area
around the base of the plug to keep dirt and debris
out of the engine.
2. Remove the plug and check its condition.
Replace the plug if worn or reuse is questionable.
NOTE: Do not clean the spark plug in a machine
using abrasive grit. Some grit could
remain in the spark plug and enter the
engine causing extensive wear and
damage.
CV11-CV16
CV460, CV490
Standard
12 083 05-S (71 mm)
U.L. Approved 12 083 09-S (71 mm)
Extra Capacity 12 083 10-S (84 mm) 12 083 10-S
11
3. Check the gap using a wire feeler gauge. Adjust
the gap by carefully bending the ground electrode.
See Figure 10. Gap CV11-15, CV460, and CV490
plugs to 1.0 mm (0.040 in.). Gap CV16 plugs to
0.76 mm (0.030 in.).
4. Reinstall the spark plug into the cylinder head.
Torque the spark plug to 38.0-43.4 N·m
(28-32 ft. lb.).
Walbro carburetors have a low idle speed screw and a
low idle fuel adjusting needle. Nikki carburetors only
have a low idle speed screw. Certified carburetors will
have fixed idle fuel or a limiter cap on the idle fuel
adjusting needle.
Walbro
Low Idle
Speed Adj.
Screw
Wire Gauge
Low Idle
Fuel Adj.
Needle
Spark Plug
Nikki
Low Idle
Speed Adj.
Screw
Ground
Electrode
Gap
Figure 10. Servicing Spark Plug.
Battery Charging
WARNING: 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.
Figure 11. Carburetor.
The carburetor is designed to deliver the correct
fuel-to-air mixture to the engine under all operating
conditions. The main fuel jet is calibrated at the factory
and is not adjustable. The low idle fuel adjusting needle
is also set at the factory and normally does not need
adjustment.
NOTE: To ensure correct engine operation at
altitudes above 1525 meters (5000 ft.), it may
be necessary to have an authorized Kohler
dealer install a special high-altitude jet kit in
the carburetor. If a high-altitude kit has been
installed, the engine must be reconverted to
the original jet size, before it is operated at
lower altitudes, or overheating and engine
damage can result.
Fuel Filter
Some engines are equipped with an in-line fuel filter.
Periodically inspect the filter and replace when dirty.
Use a genuine Kohler filter.
Carburetor Troubleshooting and
Adjustments
NOTE: Carburetor adjustments should be made
only after the engine has warmed up.
These engines are equipped with one of two basic
types of fixed main jet carburetors – Walbro or Nikki.
See Figure 11.
12
Troubleshooting
If engine troubles are experienced that appear to be
fuel system related, check the following areas before
adjusting the carburetor.
• Make sure the fuel tank is filled with clean, fresh
gasoline.
• Make sure the fuel tank cap vent is not blocked
and that it is operating properly.
Set the adjusting needle midway between the rich
and lean settings. See Figure 12.
• If the fuel tank is equipped with a shut-off valve,
make sure it is open.
• If the engine is equipped with an in-line fuel filter,
make sure it is clean and unobstructed. Replace
the filter if necessary.
Adjust to
Midpoint
• Make sure fuel is reaching the carburetor. This
includes checking the fuel lines and fuel pump for
restrictions or faulty components, replace as
necessary.
Rich
• Make sure the air cleaner element is clean and all
air cleaner element components are fastened
securely.
If, after checking the items listed above, the engine is
hard to start, runs roughly, or stalls at low idle speed, it
may be necessary to adjust or service the carburetor.
Figure 12. Optimum Low Idle Fuel Setting.
3. Low Idle Speed Setting: Place the throttle control
into the “idle” or “slow” position. Set the low idle
speed to 1200 RPM* (± 75 RPM) by turning the
low idle speed adjusting screw in or out. Check
the speed using a tachometer.
Carburetor Adjustment
*NOTE: The actual low idle speed depends on the
application – refer to equipment
manufacturer’s recommendations. The
recommended low idle speed for basic
engines is 1200 RPM. To ensure best
results when setting the low idle fuel
needle, the low idle speed must not
exceed 1200 RPM (± 75 RPM).
NOTE: Certified engines may have a fixed idle or
limiter cap on the idle fuel adjusting needle.
Step 2 can only be performed within the limits
allowed by the cap.
1. Start the engine and run at half throttle for 5 to 10
minutes to warm up. The engine must be warm
before doing steps 2 and 3.
Troubleshooting
2. Low Idle Fuel Needle Setting-Walbro
Carburetor: Place the throttle into the “idle” or
“slow” position.
When troubles occur, be sure to check the simple
causes which, at first, may seem too obvious to be
considered. For example, a starting problem could be
caused by an empty fuel tank. Some common causes
of engine troubles are listed in the following table.
Turn the low idle fuel adjusting needle out
(counterclockwise) from the preliminary setting
until engine speed decreases (rich). Note the
position of the needle.
Now turn the adjusting needle in (clockwise). The
engine speed may increase, then it will decrease
as the needle is turned in (lean). Note the position
of the needle.
Possible Cause No
Problem
Fuel
Will Not Start
•
Hard Starting
•
Stops Suddenly •
Lacks Power
Operates Erratically
Knocks or Pings
Skips or Misfires
Backfires
Overheats
High Fuel Consumption
Improper
Fuel
•
•
•
•
•
•
Do not attempt to service or replace major engine
components, or any items that require special timing or
adjustment procedures. Have your Kohler Engine
Service Dealer do this work.
Dirt In
Dirty
Fuel Line Grass Screen
•
•
•
•
•
•
•
•
Lean
•
•
•
•
•
•
Incorrect
Oil Level
Engine
Overloaded
Dirty Air
Cleaner
Faulty
Spark Plug
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
13
Storage
Parts Ordering
If the engine will be out of service for two months or
more, use the following storage procedure:
The engine Model, Specification, and Serial Numbers
are required when ordering replacement parts from
your Kohler Engine Service Dealer. These numbers are
found on the identification plate which is affixed to the
engine shrouding. Include letter suffixes if there are
any. See “Engine Identification Numbers” on page 5.
1. Clean the exterior surfaces of the engine.
2. Change the oil and filter while the engine is still
warm from operation. See “Change Oil and Oil
Filter” on page 9.
3. The fuel system must be completely emptied, or
the gasoline must be treated with a stabilizer to
prevent deterioration. If you choose to use a
stabilizer, follow the manufacturers
recommendations, and add the correct amount for
the capacity of the fuel system. Fill the fuel tank
with clean, fresh gasoline. Run the engine for 2-3
minutes to get stabilized fuel into the carburetor.
To empty the system, run the engine until the tank
and system are empty.
4. Remove the spark plug. Add one tablespoon of
engine oil into the spark plug hole. Install the plug,
but do not connect the plug lead. Crank the engine
two or three revolutions.
5. Remove the spark plug. Cover the spark plug hole
with your thumb, and turn the engine over until the
piston is at the top of its stroke. (Pressure against
the thumb is greatest.) Reinstall the plug, but do
not connect the plug lead.
6. Store the engine in a clean, dry place.
14
Always insist on genuine Kohler parts. All genuine
Kohler parts meet strict standards for fit, reliability, and
performance.
Major Repair
Major repair information is available in Kohler Engine
Service Manuals. However, major repair generally
requires the attention of a trained mechanic and the
use of special tools and equipment. Your Kohler
Engine Service Dealer has the facilities, training, and
genuine Kohler replacement parts necessary to
perform this service. For Sales & Service assistance
call 1-800-544-2444 (U.S. & Canada) or contact your
Kohler Engine Dealer or Service Distributor, they're in
the Yellow Pages under Engines-Gasoline.
Model Designation
Model CV15ST for example: C designates Command
engine, V designates vertical crankshaft, and 15
designates horsepower. Some model numbers
(CV460, CV490) use the approximate displacement
rather than horsepower. A letter suffix designates a
specific version as follows:
Suffix
S
T
ST
Designates
Electric Start
Retractable Start
Electric/Retractable Start
LIMITED 2 YEAR COMMAND ENGINE WARRANTY
We warrant to the original consumer that each new COMMAND engine sold by us will be free from manufacturing defects in materials or
workmanship in normal service for a period of two (2) years from date of purchase, provided it is operated and maintained in accordance
with Kohler Co.’s instructions and manuals.
Our obligation under this warranty is expressly limited, at our option, to the replacement or repair at Kohler Co., Kohler, Wisconsin 53044,
or at a service facility designated by us of such parts as inspection shall disclose to have been defective.
EXCLUSIONS:
Mufflers on engines used commercially (non-residential) are warranted for one (1) year from date of purchase, except catalytic mufflers,
which are warranted for two (2) years.
This warranty does not apply to defects caused by casualty or unreasonable use, including faulty repairs by others and failure to provide
reasonable and necessary maintenance.
The following items are not covered by this warranty:
Engine accessories such as fuel tanks, clutches, transmissions, power-drive assemblies, and batteries, unless supplied or installed by
Kohler Co. These are subject to the warranties, if any, of their manufacturers.
WE SHALL NOT BE LIABLE FOR SPECIAL, INDIRECT, INCIDENTAL, OR CONSEQUENTIAL DAMAGES OF ANY KIND, including but
not limited to labor costs or transportation charges in connection with the repair or replacement of defective parts.
ANY IMPLIED OR STATUARY WARRANTIES, INCLUDING WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE, ARE EXPRESSLY LIMITED TO THE DURATION OF THIS WRITTEN WARRANTY. We make no other express warranty, nor
is any one authorized to make any in our behalf.
Some states do not allow limitations on how long an implied warranty lasts, or the exclusion or limitation of incidental or consequential
damages, so the above limitation or exclusion may not apply to you.
This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
TO OBTAIN WARRANTY SERVICE:
Purchaser must bring the engine to an authorized Kohler service facility. For the facility nearest you, consult your Yellow Pages or write
Kohler Co., Attn: Engine Warranty Service Dept., Kohler, Wisconsin, 53044.
ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044
KOHLER CO.
FEDERAL AND CALIFORNIA EMISSION CONTROL SYSTEMS
LIMITED WARRANTY
SMALL OFF-ROAD ENGINES
The U.S. Environmental Protection Agency (EPA), the California Air Resources Board (CARB), and Kohler Co. are pleased to explain the
Federal and California Emission Control Systems Warranty on your small off-road equipment engine. For California, engines produced in
1995 and later must be designed, built and equipped to meet the state’s stringent anti-smog standards. In other states, 1997 and later
model year engines must be designed, built and equipped, to meet the U.S. EPA regulations for small non-road engines. The engine must
be free from defects in materials and workmanship which cause it to fail to conform with U.S. EPA standards for the first two years of engine
use from the date of sale to the ultimate purchaser. Kohler Co. must warrant the emission control system on the engine for the period of
time listed above, provided there has been no abuse, neglect or improper maintenance.
The emission control system may include parts such as the carburetor or fuel injection system, the ignition system, and catalytic converter.
Also included are the hoses, belts and connectors and other emission related assemblies.
Where a warrantable condition exists, Kohler Co. will repair the engine at no cost, including diagnosis (if the diagnostic work is performed at
an authorized dealer), parts and labor.
MANUFACTURER’S WARRANTY COVERAGE
Engines produced in 1995 or later are warranted for two years in California. In other states, 1997 and later model year engines are
warranted for two years. If any emission related part on the engine is defective, the part will be repaired or replaced by Kohler Co. free of
charge.
OWNER’S WARRANTY RESPONSIBILITIES
(a) The engine owner is responsible for the performance of the required maintenance listed in the owner’s manual. Kohler Co.
recommends that you retain all receipts covering maintenance on the engine, But Kohler Co. cannot deny warranty solely for the lack
of receipts or for your failure to assure that all scheduled maintenance was performed.
(b)
Be aware, however, that Kohler Co. may deny warranty coverage if the engine or a part has failed due to abuse, neglect, improper
maintenance or unapproved modifications.
Continued on next page.
15
(c)
For warranty repairs, the engine must be presented to a Kohler Co. service center as soon as a problem exists.
Call 1-800-544-2444 or access our web site at: www.kohlerengines.com, for the names of the nearest service centers. The warranty
repairs should be completed in a reasonable amount of time, not to exceed 30 days.
If you have any questions regarding warranty rights and responsibilities, you should contact Kohler Co. at 1-920-457-4441 and ask for an
Engine Service representative.
COVERAGE
Kohler Co. warrants to the ultimate purchaser and each subsequent purchaser that the engine will be designed, built and equipped, at the
time of sale, to meet all applicable regulations. Kohler Co. also warrants to the initial purchaser and each subsequent purchaser, that the
engine is free from defects in materials and workmanship which cause the engine to fail to conform with applicable regulations for a period
of two years.
Engines produced in 1995 or later are warranted for two years in California. For 1997 and later model years, EPA requires manufacturers to
warrant engines for two years in all other states. These warranty periods will begin on the date the engine is purchased by the initial
purchaser. If any emission related part on the engine is defective, the part will be replaced by Kohler Co. at no cost to the owner. Kohler
Co. is liable for damages to other engine components caused by the failure of a warranted part still under warranty.
Kohler Co. shall remedy warranty defects at any authorized Kohler Co. engine dealer or warranty station. Warranty repair work done at an
authorized dealer or warranty station shall be free of charge to the owner if such work determines that a warranted part is defective.
Listed below are the parts covered by the Federal and California Emission Control Systems Warranty. Some parts listed below may require
scheduled maintenance and are warranted up to the first scheduled replacement point for that part. The warranted parts are:
•
•
•
•
•
•
•
•
•
•
•
•
•
Oxygen sensor (if equipped)
Intake manifold (if equipped)
Exhaust manifold (if equipped)
Catalytic muffler (if equipped)
Fuel metering valve (if equipped)
Spark advance module (if equipped)
Crankcase breather
Ignition module(s) with high tension lead
Gaseous fuel regulator (if equipped)
Electronic control unit (if equipped)
Carburetor or fuel injection system
Fuel lines (if equipped)
Air filter, fuel filter, and spark plugs (only
to first scheduled replacement point)
LIMITATIONS
This Emission Control Systems Warranty shall not cover any of the following:
(a)
repair or replacement required because of misuse or neglect, improper maintenance, repairs improperly performed or replacements
not conforming to Kohler Co. specifications that adversely affect performance and/or durability and alterations or modifications not
recommended or approved in writing by Kohler Co.,
(b)
replacement of parts and other services and adjustments necessary for required maintenance at and after the first scheduled
replacement point,
(c)
consequential damages such as loss of time, inconvenience, loss of use of the engine or equipment, etc.,
(d)
diagnosis and inspection fees that do not result in eligible warranty service being performed, and
(e)
any add-on or modified part, or malfunction of authorized parts due to the use of add-on or modified parts.
MAINTENANCE AND REPAIR REQUIREMENTS
The owner is responsible for the proper use and maintenance of the engine. Kohler Co. recommends that all receipts and records covering
the performance of regular maintenance be retained in case questions arise. If the engine is resold during the warranty period, the
maintenance records should be transferred to each subsequent owner. Kohler Co. reserves the right to deny warranty coverage if the
engine has not been properly maintained; however, Kohler Co. may not deny warranty repairs solely because of the lack of repair
maintenance or failure to keep maintenance records.
Normal maintenance, replacement or repair of emission control devices and systems may be performed by any repair establishment or
individual; however, warranty repairs must be performed by a Kohler authorized service center. Any replacement part or service that is
equivalent in performance and durability may be used in non-warranty maintenance or repairs, and shall not reduce the warranty obligations
of the engine manufacturer.
FOR SALES AND SERVICE INFORMATION
IN U.S. AND CANADA, CALL
1-800-544-2444
ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044
FORM NO.: TP-2472-I
ISSUED:
12/94
REVISED: 12/01
MAILED:
LITHO IN U.S.A.
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