Kohler Command CV17 Manual de usuario

KohlerEngines.com24 690 07 Rev. B 1

CV17-CV25, CV620-CV730, CV740, CV750

Service Manual

2 Safety

3 Maintenance

5 Speciﬁcations

15 Tools and Aids

18 Troubleshooting

22 Air Cleaner/Intake

23 Fuel System

29 Governor System

30 Lubrication System

32 Electrical System

48 Starter System

57 Disassembly/Inspection and Service

72 Reassembly

IMPORTANT: Read all safety precautions and instructions carefully before operating equipment. Refer to operating

instruction of equipment that this engine powers.

Ensure engine is stopped and level before performing any maintenance or service.

SAFETY PRECAUTIONS

WARNING: A hazard that could result in death, serious injury, or substantial property damage.

CAUTION: A hazard that could result in minor personal injury or property damage.

NOTE: is used to notify people of important installation, operation, or maintenance information.

WARNING

Explosive Fuel can cause

ﬁres and severe burns.

Do not ﬁll fuel tank while

engine is hot or running.

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.

Spilled fuel could ignite if it comes

in contact with hot parts or sparks

from ignition. Never use gasoline

as a cleaning agent.

WARNING

Rotating Parts can cause

severe injury.

Stay away while engine is

in operation.

Keep hands, feet, hair, and

clothing away from all moving

parts to prevent injury. Never

operate engine with covers,

shrouds, or guards removed.

WARNING

Carbon Monoxide can

cause severe nausea,

fainting or death.

Avoid inhaling exhaust

fumes.

Engine exhaust gases contain

poisonous carbon monoxide.

Carbon monoxide is odorless,

colorless, and can cause death if

inhaled.

WARNING

Accidental Starts can

cause severe injury or

death.

Disconnect and ground

spark plug lead(s) before

servicing.

Before working on engine or

equipment, disable engine as

follows: 1) Disconnect spark plug

lead(s). 2) Disconnect negative (–)

battery cable from battery.

WARNING

Hot Parts can cause

severe burns.

Do not touch engine while

operating or just after

stopping.

Never operate engine with heat

shields or guards removed.

WARNING

Cleaning Solvents can

cause severe injury or

death.

Use only in well ventilated

areas away from ignition

sources.

Carburetor cleaners and solvents

are extremely ﬂammable. Follow

cleaner manufacturer’s warnings

and instructions on its proper and

safe use. Never use gasoline as a

cleaning agent.

CAUTION

Electrical Shock can

cause injury.

Do not touch wires while

engine is running.

CAUTION

Damaging Crankshaft

and Flywheel can cause

personal injury.

Using improper procedures can

lead to broken fragments. Broken

fragments could be thrown from

engine. Always observe and use

precautions and procedures when

installing ﬂywheel.

WARNING

Uncoiling Spring can

cause severe injury.

Wear safety goggles or

face protection when

servicing retractable

starter.

Retractable starters contain a

powerful, recoil spring that is

under tension. Always wear safety

goggles when servicing retractable

starters and carefully follow

instructions in Retractable Starter

for relieving spring tension.

Safety

2 24 690 07 Rev. BKohlerEngines.com

MAINTENANCE INSTRUCTIONS

WARNING

Before working on engine or equipment, disable engine as

follows: 1) Disconnect spark plug lead(s). 2) Disconnect

negative (–) battery cable from battery.

Accidental Starts can cause severe injury or

death.

Disconnect and ground spark plug lead(s)

before servicing.

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 dealer.

MAINTENANCE SCHEDULE

Weekly

●Check heavy-duty air cleaner element. Air Cleaner/Intake

Every 25 Hours or Annually¹

●Service/replace low-proﬁle precleaner. Air Cleaner/Intake

Every 100 Hours or Annually¹

●Replace low-proﬁle air cleaner element. Air Cleaner/Intake

●Change oil. Lubrication System

●Remove cooling shrouds and clean cooling areas. Air Cleaner/Intake

●Check oil cooler ﬁns, clean as necessary (if equipped). Lubrication System

Every 200 Hours

●Change oil ﬁlter. Lubrication System

●Replace fuel ﬁlter.

Every 250 Hours¹

●Replace heavy-duty air cleaner element and check inner element. Air Cleaner/Intake

Every 500 Hours¹

●Replace heavy-duty inner air cleaner element. Air Cleaner/Intake

●Replace spark plugs and set gap. Electrical System

Every 500 Hours2

●Have crankshaft spline lubricated.

1Perform these procedures more frequently under severe, dusty, dirty conditions.

2Have a Kohler authorized dealer perform this service.

REPAIRS/SERVICE PARTS

Kohler genuine service parts can be purchased from Kohler authorized dealers. To ﬁnd a local Kohler authorized

dealer visit KohlerEngines.com or call 1-800-544-2444 (U.S. and Canada).

Maintenance

324 690 07 Rev. B KohlerEngines.com

OIL RECOMMENDATIONS

We recommend use of Kohler oils for best performance.

Other high-quality detergent oils (including synthetic)

of API (American Petroleum Institute) service class SJ

or higher are acceptable. Select viscosity based on

air temperature at time of operation as shown in table

below.

FUEL RECOMMENDATIONS

WARNING

Explosive Fuel can cause ﬁres and severe

burns.

Do not ﬁll fuel tank while engine is hot or

running.

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. Spilled fuel could ignite

if it comes in contact with hot parts or sparks from

ignition. Never use gasoline as a cleaning agent.

NOTE: E15, E20 and E85 are NOT approved and

should NOT be used; effects of old, stale or

contaminated fuel are not warrantable.

Fuel must meet these requirements:

●Clean, fresh, unleaded gasoline.

●Octane rating of 87 (R+M)/2 or higher.

●Research Octane Number (RON) 90 octane minimum.

●Gasoline up to 10% ethyl alcohol, 90% unleaded is

acceptable.

●Methyl Tertiary Butyl Ether (MTBE) and unleaded

gasoline blend (max 15% MTBE by volume) are

approved.

●Do not add oil to gasoline.

●Do not overﬁll fuel tank.

●Do not use gasoline older than 30 days.

STORAGE

If engine will be out of service for 2 months or more

follow procedure below.

1. Add Kohler PRO Series fuel treatment or equivalent

to fuel tank. Run engine 2-3 minutes to get stabilized

fuel into fuel system (failures due to untreated fuel

are not warrantable).

2. Change oil while engine is still warm from operation.

Remove spark plug(s) and pour about 1 oz. of

engine oil into cylinder(s). Replace spark plug(s) and

crank engine slowly to distribute oil.

3. Disconnect negative (-) battery cable.

4. Store engine in a clean, dry place.

Maintenance

4 24 690 07 Rev. BKohlerEngines.com

Dimensions in millimeters.

Inch equivalents shown in [ ].

Engine Dimensions with Low-Proﬁle Air Cleaner

Speciﬁcations

524 690 07 Rev. B KohlerEngines.com

Dimensions in millimeters.

Inch equivalents shown in [ ].

Engine Dimensions with Commercial Mower Air Cleaner

Speciﬁcations

6 24 690 07 Rev. BKohlerEngines.com

Dimensions in millimeters.

Inch equivalents shown in [ ].

Engine Dimensions with Heavy-Duty Air Cleaner

93.30

[3.673]

EXHAUST

PORT #1

73.30

[2.886]

EXHAUST

PORT #2

OIL DRAIN PLUG

3/8 NPT (INCH)

40.80

[1.606]

ENGINE MOUNTING

SURFACE

14.20

[.559]

317.77

[12.511]

377.59

[14.866]

155.30

[6.114]

SPARK PLUG

424.75

[16.722]

89.94

[3.541]

134.97

[5.314]

15.76

[.621]

495.31

[19.501]

45.59

[1.795]

126.31

[4.973]

OIL FILL &

DIPSTICK

MOUNTING

HOLE “A”

15.75

[.620]

OIL FILTER

REMOVAL

301.77

[11.881] 130.03

[5.119]

AIR FILTER COVER

ASSEMBLY REMOVAL

SAFTY AIR FILTER

ELEMENT REMOVAL

PRIMARY AIR FILTER

ELEMENT REMOVAL

AIR FILTER RAIN

CAP REMOVAL

SPARK PLUG

FUEL

FILTER

275.56

[10.849]

15.80

[.622]

SPARK PLUG

417.59

[16.441]

529.91

[20.863]

CRANKSHAFT

89.41

[3.520]

241.66

[9.514]

77.68

[3.058]

334.19

[13.157]

50.00

[1.969]

EXHAUST

PORT #1

2X 89.41

[3.520]

2X 72.85

[2.868]

M8 X 1.25

4 STUDS

SOLENOID

SHIFT STARTER

MOUNTING HOLE “A”

4X Ø 9.20 [.362] THRU

Ø 254.00 [10.00] B.C.

104.02

[4.095]

50.00

[1.969]

EXHAUST

PORT #2

30˚

405.97

[15.983]

247.90

[9.760]

REGULATOR

RECTIFIER

135.30

[5.327]

SPARK

PLUG

52.76

[2.077]

OIL FILTER

14.44

[.569]

96.37

[3.794]

MOUNTING

HOLE “A”

26.41

[1.040]

405.97

[15.983]

OIL DRAIN PLUG

3/8 NPT (INCH)

85.50

[3.366]

KEYWAY

7/16-20 UNF 2B (INCH)

38.1 [1.500]

1/4 IN. SQ KEYWAY Ø 28.56

[1.125]

ENGINE MOUNTING

SURFACE

449.63

[17.702]

PULSE FUEL

PUMP

OIL COOLER

Speciﬁcations

724 690 07 Rev. B KohlerEngines.com

GENERAL SPECIFICATIONS3,6 CV17 CV18/CV20/

CV22/

CV620-CV640

CV22/CV23/

CV670-CV680 CV25/CV730/

CV740 CV750

Bore 73 mm

(2.87 in.)

77 mm

(3.03 in.)

80 mm

(3.15 in.)

83 mm (3.27 in.)

Stroke 67 mm (2.64 in.) 69 mm

(2.7 in.)

Displacement 561 cc

(34 cu. in.)

624 cc

(38 cu. in.)

674 cc

(41 cu. in.)

725 cc

(44 cu. in.)

747 cc

(46 cu. in.)

Oil Capacity (reﬁll) 1.6-1.8 L (1.7-1.9 U.S. qt.)

ENGINE IDENTIFICATION NUMBERS

Kohler engine identiﬁcation numbers (model, speciﬁcation and serial) should be referenced for efﬁcient repair,

ordering correct parts, and engine replacement.

Model. . . . . . . . . . . . . . . . . . . . . CV620

Command Engine

Vertical Shaft

Numerical Designation

Speciﬁcation . . . . . . . . . . . . . . . CV620-0001

Serial . . . . . . . . . . . . . . . . . . . . . 3923500328

Year Manufactured Code Factory Code

Code Year

39 2009

40 2010

41 2011

Maximum Angle of Operation (@ full oil level)425°

TORQUE SPECIFICATIONS3,5 CV17 CV18/CV20/

CV22/

CV620-CV640

CV22/CV23/

CV670-CV680 CV25/CV730/

CV740 CV750

Blower Housing and Sheet Metal

M5 Fasteners 6.2 N·m (55 in. lb.) into new holes

4.0 N·m (35 in. lb.) into used holes

M6 Fasteners 10.7 N·m (95 in. lb.) into new holes

7.3 N·m (65 in. lb.) into used holes

Carburetor and Intake Manifold

Intake Manifold Mounting Fastener (torque in

2 increments)

ﬁrst to 7.4 N·m (66 in. lb.)

ﬁnally to 9.9 N·m (88 in. lb.)

Carburetor Mounting Nut 6.2-7.3 N·m (55-65 in. lb.)

Connecting Rod

Cap Fastener (torque in increments)

8 mm straight shank

8 mm step-down

6 mm straight shank

22.7 N·m (200 in. lb.)

14.7 N·m (130 in. lb.)

11.3 N·m (100 in. lb.)

3 Values are in Metric units. Values in parentheses are English equivalents.

4Exceeding maximum angle of operation may cause engine damage from insufﬁcient lubrication.

5Lubricate threads with engine oil prior to assembly.

6Any and all horsepower (hp) references by Kohler are Certiﬁed Power Ratings and per SAE J1940 & J1995 hp

standards. Details on Certiﬁed Power Ratings can be found at KohlerEngines.com.

Speciﬁcations

8 24 690 07 Rev. BKohlerEngines.com

TORQUE SPECIFICATIONS3,5 CV17 CV18/CV20/

CV22/

CV620-CV640

CV22/CV23/

CV670-CV680 CV25/CV730/

CV740 CV750

Crankcase

Breather Cover Fastener 7.3 N·m (65 in. lb.)

Oil Drain Plug 13.6 N·m (10 ft. lb.)

Cylinder Head

Head Fastener

Hex Flange Nut (torque in 2 increments) ﬁrst to 16.9 N·m (150 in. lb.)

ﬁnally to 33.9 N·m (300 in. lb.)

Head Bolt (torque in 2 increments) ﬁrst to 22.6 N·m (200 in. lb.)

ﬁnally to 41.8 N·m (370 in. lb.)

Rocker Arm Screw 11.3 N·m (100 in. lb.)

Flywheel

Fan Fastener 9.9 N·m (88 in. lb.)

Flywheel Retaining Screw 66.4 N·m (49 ft. lb.)

Fuel Pump

Fastener 2.3 N·m (20 in. lb.)

Governor

Lever Nut 6.8 N·m (60 in. lb.)

Ignition

Spark Plug 27 N·m (20 ft. lb.)

Module Fastener 4.0-6.2 N·m (35-55 in. lb.)

Rectiﬁer-Regulator Fastener 1.4 N·m (12.6 in. lb.)

Mufﬂer

Retaining Nuts 24.4 N·m (216 in. lb.)

Oil Cooler

Adapter Nipple 27 N·m (20 ft. lb.)

Oil Sentry™

Pressure Switch 4.5 N·m (40 in. lb.)

Oil Pan

Fastener 24.4 N·m (216 in. lb.)

Solenoid (Starter)

Mounting Hardware

Nippondenso Starter

Delco-Remy Starter

6.0-9.0 N·m (53-79 in. lb.)

4.0-6.0 N·m (35-53 in. lb.)

Nut, Positive (+) Brush Lead

Nippondenso Starter

Delco-Remy Starter

8.0-12.0 N·m (71-106 in. lb.)

8.0-11.0 N·m (71-97 in. lb.)

Speed Control Bracket

Fastener 10.7 N·m (95 in. lb.) into new holes

7.3 N·m (65 in. lb.) into used holes

3 Values are in Metric units. Values in parentheses are English equivalents.

5Lubricate threads with engine oil prior to assembly.

Speciﬁcations

924 690 07 Rev. B KohlerEngines.com

TORQUE SPECIFICATIONS3,5 CV17 CV18/CV20/

CV22/

CV620-CV640

CV22/CV23/

CV670-CV680 CV25/CV730/

CV740 CV750

Starter Assembly

Thru Bolt

Inertia Drive

Nippondenso Solenoid Shift

Delco-Remy Solenoid Shift

4.5-5.7 N·m (40-50 in. lb.)

4.5-7.5 N·m (40-84 in. lb.)

5.6-9.0 N·m (49-79 in. lb.)

Mounting Screw 15.3 N·m (135 in. lb.)

Brush Holder Mounting Screw Delco-Remy 2.5-3.3 N·m (22-29 in. lb.)

Stator

Mounting Screw 6.2 N·m (55 in. lb.)

Valve Cover

Gasket Style Cover Fastener 3.4 N·m (30 in. lb.)

Black O-ring Style Cover

With shoulder screws

With ﬂange screws and spacers

5.6 N·m (50 in. lb.)

9.9 N·m (88 in. lb.)

Yellow or Brown O-ring Style Cover

With integral metal spacers 6.2 N·m (55 in. lb.)

CLEARANCE SPECIFICATIONS3CV17 CV18/CV20/

CV22/

CV620-CV640

CV22/CV23/

CV670-CV680 CV25/CV730/

CV740 CV750

Camshaft

End Play (with shim) 0.076/0.127 mm (0.0030/0.0050 in.)

Running Clearance 0.025/0.063 mm (0.0010/0.0025 in.)

Bore I.D.

New

Max. Wear Limit

20.000/20.025 mm (0.7874/0.7884 in.)

20.038 mm (0.7889 in.)

Bearing Surface O.D.

New

Max. Wear Limit

19.962/19.975 mm (0.7859/0.7864 in.)

19.959 mm (0.7858 in.)

Connecting Rod

Connecting Rod-to-Crankpin Running

Clearance

New

Max. Wear Limit

0.030/0.055 mm (0.0012/0.0022 in.)

0.070 mm (0.0028 in.)

Connecting Rod-to-Crankpin Side Clearance 0.26/0.63 mm (0.0102/0.0248 in.)

Connecting Rod-to-Piston Pin Running

Clearance

0.015/0.028 mm (0.0006/0.0011 in.)

Piston Pin End I.D.

New

Max. Wear Limit

17.015/17.023 mm (0.6699/0.6702 in.)

17.036 mm (0.6707 in.)

3 Values are in Metric units. Values in parentheses are English equivalents.

5Lubricate threads with engine oil prior to assembly.

Speciﬁcations

10 24 690 07 Rev. BKohlerEngines.com

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