Kohler CS10 Manual de usuario

SERVICE MANUAL

COMMAND PRO CS SERIES 4-12 HP

HORIZONTAL CRANKSHAFT

Contents

Section 1. Safety and General Information ............................................................................

Section 2. Special Tools...........................................................................................................

Section 3. Troubleshooting .....................................................................................................

Section 4.Air Cleaner and Air Intake System .........................................................................

Section 5. Fuel System and Governor ....................................................................................

Section 6. Lubrication System ................................................................................................

Section 7. Retractable Starter..................................................................................................

Section 8. Electrical System and Components......................................................................

Section 9. Disassembly............................................................................................................

Section 10. Internal Components............................................................................................

Section 11. Reassembly...........................................................................................................

1.1

Section 1

Safety and General Information

Section 1

Safety and General Information

CS4-12

For Your Safety!

These precautions should be followed at all times. Failure to follow these precautions could result

in injury to yourself and others.

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 warning is ignored.

NOTE

Note is used to notify people of installation, operation, or maintenance information that is

important but not hazard-related.

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.

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.

Rotating Parts can cause severe

injury.

Stay away while engine is in

operation.

WARNING

Hot Parts can cause severe burns.

Do not touch engine while operating

or just after stopping.

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.

Accidental Starts can cause severe

injury or death.

Disconnect and ground spark plug

lead before servicing.

WARNING

1.2

Section 1

Safety and General Information

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.

Flammable Solvents!

Carburetor cleaners and solvents

are extremely flammable. Keep

sparks, flames, and other sources

of ignition away from the area.

Follow the cleaner manufacturer’s

warnings and instructions on its

proper and safe use. Never use

gasoline as a cleaning agent.

Spring Under Tension!

Retractable starters contain a

powerful, recoil spring that is under

tension. Always wear safety

goggles when servicing retractable

starters and carefully follow

instructions in the "Retractable

Starter" Section 7 for relieving

spring tension.

Electrical Shock!

Never touch electrical wires or

components while the engine is

running. They can be sources of

electrical shock.

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.

Cleaning Solvents can cause

severe injury or death.

Use only in well ventilated areas

away from ignition sources.

WARNING

Explosive Gas can cause fires and

severe acid burns.

Charge battery only in a well

ventilated area. Keep sources of

ignition away.

Carbon Monoxide can cause

severe nausea, fainting or death.

Do not operate engine in closed or

confined area.

WARNING

Uncoiling Spring can cause severe

injury.

Wear safety goggles or face

protection when servicing retractable

starter.

WARNING

Electrical Shock can cause injury.

Do not touch wires while engine is

running.

CAUTION

WARNING

Explosive Fuel can cause fires and

severe burns.

Stop engine before filling fuel tank.

1.3

Section 1

Safety and General Information

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

(or decals) affixed to the engine shrouding. See Figure

1-1.An explanation of these numbers is shown in

Figure 1-2.

Model Designation

Model CS6ST for example: C designates Command

engine, S designates slanted cylinder configuration,

and 6 designates horsepower. Asuffix letter

designates a specific version as follows: Figure 1-1. Engine Identification Decal Location.

Identification Decal

A. Model No.

Command Engine

Slanted Cylinder

Horsepower

4 = 4 HP

6 = 6 HP

8.5 = 8.5 HP

10 = 10 HP

12 = 12 HP

Suffix Designates

T Retractable Start

S Electric Start

G Tapered Crankshaft

P Threaded Crankshaft

R Gear Reduction (2:1 or 6:1)

Figure 1-2. Explanation of Engine Identification Numbers.

#NOTE: CS8.5 engines have been produced in two different specification series, 92xxxx and 95xxxx. The design

features of 92xxxx spec. no. engines are identical to CS10 and CS12 engines, and share the same

service procedures. The 95xxxx spec. no. engines incorporate certain design differences from the

92xxxx spec. no. series. All service and repair information unique to the 95xxxx spec. no. series will be

listed and covered separately.

C S 6 ST

Variation of

Basic Engine

B. Spec. No.

Engine Model Code

Code Model

90 CS4

91 CS6

92 CS8.5#300 cc

93 CS10

94 CS12

95 CS8.5#250 cc

911509

C. Serial No.

Year Manufactured Code

Code Year

28 1998

29 1999

30 2000

Factory Code

28 23701265

IMPORTANT ENGINE INFORMATION

THIS ENGINE MEETS U.S. EPA

PHASE 1 AND 2000-2001

CALIFORNIA EMISSION CONTROL

REGULATIONS FOR SORE*

FAMILY

MODEL NO. CS6ST

SPEC. NO. 911509

DISPL (CC)

SERIAL NO. 2823701265

REFER TO OWNER'S MANUAL FOR

SAFETY, MAINTENANCE SPECS,

AND ADJUSTMENTS. FOR SALES

AND SERVICE IN US/CANADA CALL:

1-800-544-2444

KOHLER CO. KOHLER, WI USA

(Ref.***-*******)

*Small Off-Road Engines.

1.4

Section 1

Safety and General Information

Oil Recommendations

Using the proper type and weight of oil in the

crankcase is extremely important, as is checking oil

daily and changing oil regularly. 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 SG, SH, SJ or

higher. Select the viscosity based on the air

temperature at the time of operation as shown below.

Figure1-3. 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.

Alogo or symbol on oil containers identifies theAPI

service class and SAE viscosity grade. See Figure

1-4.

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 and store in

clean, approved containers.Acontainer 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 head will require more

frequent service.

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.

Gasoline/Ether blends

Methyl Tertiary Butyl Ether (MTBE) and unleaded

gasoline blends (up to maximum of 15% MTBE by

volume) are approved as a fuel for Kohler engines.

Other gasoline/ether blends are not approved.

Figure 1-4. Oil Container Logo.

Refer to Section 6-‘‘Lubrication System’’ for detailed oil

check and oil change procedures.

1.5

Section 1

Safety and General Information

Maintenance Instructions

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.

Daily or Before

Starting Engine

Maintenance RequiredFrequency • Fill fuel tank.

• Check oil level.

• Check air cleaner for dirty, loose, or damaged parts.1

• Check air intake and cooling areas, clean as necessary.1

Refer to:

Section 5

Section 6

Section 4

• Service precleaner element. Replace if necessary.1

Every 25 Hours Section 4

• Change oil.

• Replace air cleaner element.1

• Remove cooling shrouds and clean cooling areas.1

• Check all fittings and fasteners.

• Clean fuel shut-off valve filter. Replace if necessary.

• Check muffler screen/spark arrestor. Clean/replace if necessary.

• Check spark plug condition and gap. Replace if necessary.

Every 100 Hours

• Check and adjust valve clearance when engine is cold.2

• Check and adjust idle speed.2

• Service starter motor drive, if so equipped.2

• Have combustion chamber decarbonized.2

Annually or

Every 300 Hours

Section 6

Section 4

Section 1

Section 5

Section 8

Section 11

Section 5

Section 7

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

²Have a Kohler Engine Service Dealer perform this service.

Storage

If the engine will be out of service for two months or

more, use the following storage procedure:

1. Clean the exterior surfaces of the engine.

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

operation. See ‘‘Change Oil’’on page 6.2.

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 and then turn it up

against compression (when highest pull force or

cranking force is required).

5. Store the engine in a clean, dry place.

• Service solid foam element. Replace if necessary.1Section 4Every 50 Hours

1.6

Section 1

Safety and General Information

Figure 1-5. Typical Engine Dimensions CS4 and CS6.

Dimensions in millimeters.

Inch equivalents shown in ( ).

373.00

(14.685)

66.00

(2.598) 162.00

(6.378)

5/16-24 [qty. 5]

14 mm (.551) deep

106.00

(4.173)

30.00

(1.181)

347.00

(13.661)

321.50 (Straight PTO)

(12.657)

143.00

(5.630)

100.00

(3.937) 162.00

(6.378)

Spark Plug

Oil Fill

Oil Drain

Plug

Mounting Face

5.00

(.197)

44.50

(1.752)

80.00

(3.150)

37.00

(1.457)

384.25

(15.128)

145.25

(5.719) 380.03

(14.962)

9.0 (.354) dia. [qty. 2]

9.0x14.0 (.354x.551) slot

[qty.2]

1.7

Section 1

Safety and General Information

Figure 1-6. Typical Engine Dimensions CS8.5 (spec. 92xxxx), CS10, and CS12.

Dimensions in millimeters.

Inch equivalents shown in ( ).

454.00

(17.874)

445.85

(17.553)

156.68

(6.168) 45°

45°

30° 30°

423.50

(16.673)

70.00

(2.756)

165.10 (6.500)

dia.

146.08

(5.751) dia.

103.00

(4.055)

195.50

(7.697)

90.50

(3.563)

110.00

(4.331) dia.

127.00

(5.000) dia.

133.50

(5.256)

452.90

(17.831)

417.50 (Straight PTO)

(16.437)

187.50

(7.382)

118.34

(4.659) 205.00

(8.071)

99.00

(3.898)

Spark Plug

Oil Fill

Oil Drain Plug

Mounting Face

16.00

(.630)

37.00

(1.457)

62.00

(2.441) 102.00

(4.016)

65.00

(2.559)

152.00

(5.984) 298.00

(11.732)

5/16-24 [qty. 4]

18 mm (.709) deep

3/8-16 [qty. 4]

18 mm (.709) deep

5/16-24 [qty. 2] 18 mm

(.709) deep

11.00 (.433) dia. [qty. 2]

11.00x27 (.433x1.063) slot

[qty. 2]

1.8

Section 1

Safety and General Information

Figure 1-7. Typical Engine Dimensions CS8.5 (spec. 95xxxx).

431.00

(16.968)

156.00

(6.142)

428.00

(16.850)

410.00

(16.142)

133.50

(5.256)

90.50

(3.563) 103.00

(4.055)

195.50

(7.697)

424.00

(16.693)

70.00

(2.756)

165.1 (6.50)

110 (4.33)

5/16-24 18 mm (.709) deep [qty. 2]

5/16-24 18 mm (.709) deep [qty. 4]

3/8-16 18 mm (.709) deep

[qty. 4]

146.08 (5.78)

380.00

(14.961)

183.00

(7.205)94.5

(3.720)

16.00 (.630)

57.50 (2.264) 96.00

(3.780)

59.00 (2.323)

11.00x27.00

(.433x1.063)

slotted hole

[qty. 2]

11 (.433) hole [qty. 2]

37.00 (1.457)

Dimensions in millimeters.

Inch equivalents shown in ( ).

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