Kohler CV11-16 Manual de usuario

COMMAND SERVICE MANUAL

VERTICAL CRANKSHAFT

CV11-16,

CV460-465,

CV490-495

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. Inspection and Reconditioning ...........................................................................

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

1.1

Section 1

Safety and General Information

Section 1

Safety and General Information

CV11-16

CV460-465, CV490-495

Safety Precautions

To insure safe operations please read the following statements and understand their meaning.Also

refer to your equipment manufacturer'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.

Rotating Parts can cause severe

injury.

Stay away while engine is in

operation.

WARNING

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.

Hot Parts can cause severe burns.

Do not touch engine while operating

or just after stopping.

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.

Accidental Starts can cause

severe injury or death.

Disconnect and ground spark plug

leads before servicing.

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.

1.2

Section 1

Safety and General Information

Carbon Monoxide can cause

severe nausea, fainting or death.

Do not operate engine in closed or

confined area.

WARNING

Electrical Shock can cause injury.

Do not touch wires while engine is

running.

CAUTION

Uncoiling Spring can cause severe

injury.

Wear safety goggles or face

protection when servicing retractable

starter.

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.

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 "Retractable Starter"

Section 7 for relieving spring

tension.

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.

Electrical Shock!

Never touch electrical wires or

components while the engine is

running. They can be sources of

electrical shock.

Explosive Fuel can cause fires and

severe burns.

Stop engine before filling fuel tank.

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.

Cleaning Solvents can cause

severe injury or death.

Use only in well ventilated areas

away from ignition sources.

WARNING

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.

WARNING

Explosive Gas can cause fires and

severe acid burns.

Charge battery only in a well

ventilated area. Keep sources of

ignition away.

1.3

Section 1

Safety and General Information

A. Model No.

Command Engine

Vertical Crankshaft

Displacement (cc)

460 = 460 cc

490 = 490 cc

Version Code

S = Electric Start

T = Retractable Start

ST = Electric/Retractable Start

Variation of

Basic Engine

B. Spec. No.

Engine Model Code

Code Model

11 CV11

12 CV12.5

22 CV13

14 CV14

41 CV15

43 CV16

265 CV460-465

275 CV490-495

C. Serial No.

Year Manufactured Code

Code Model

21 1991

22 1992

23 1993

24 1994

25 1995

26 1996

27 1997

28 1998

29 1999

30 2000

31 2001

32 2002

Factory Code

2105810334

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 a on decal

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

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

Figure 1-2.

Figure 1-2. Explanation of Engine Identification Numbers.

C V 12.5 ST

1203

Figure 1-1. Engine Identification Decal Location.

or Horsepower

11 = 11 HP

12.5 = 12.5 HP

13 = 13 HP

14 = 14 HP

15 = 15 HP

16 = 16 HP

Identification Decal

MODEL NO.

SPEC. NO.

SERIAL NO.

REFER TO OWNER'S MANUAL FOR

SAFETY, MAINTENANCE SPECS

AND ADJUSTMENTS. FOR SALES

AND SERVICE IN US/CANADA

CALL: 1-800-544-2444.

www.kohlerengines.com

KOHLER CO. KOHLER, WI USA

CV12.5ST

1203

2105810334

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. Synthetic oil is recommended for

use in LPG-fueled engines because there is less

oxidation or thickening, and deposit accumulation on

intake valves is substantially reduced.

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.

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 the API

service class and SAE viscosity grade. See Figure 1-3.

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 1-3. Oil Container Logo.

Refer to Section 6 - “Lubrication System” for detailed

oil check, oil change, and oil filter change procedures.

*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).

** *

1.5

Section 1

Safety and General Information

Periodic Maintenance

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.

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 and oil filter while the engine is still

warm from operation. See “Change Oil and Oil

Filter” in Section 6.

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 thumb is greatest.) Reinstall the plug, but

do not connect the plug lead.

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

Frequency Maintenance Required Refer to:

• Fill fuel tank.

• Check oil level.

• Check air cleaner for dirty1, loose, or damaged parts.

• Check air intake and cooling areas, clean as necessary1.

Daily or Before

Starting Engine

Section 5

Section 6

Section 4

• Service precleaner element1.

Every 25 Hours Section 4

• Replace air cleaner element1.

• Change oil1.

• Remove cooling shrouds and clean cooling areas1.

Every

100 Hours Section 4

Section 6

Section 4

• Change oil filter1.

• Check spark plug condition and gap.

Every

200 Hours Section 6

Section 8

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

2Have a Kohler Engine Service Dealer perform this service. Not necessary on Delco Starters.

Annually or

Every

500 Hours

• Have bendix starter drive serviced2.

• Have solenoid shift starter disassembled and cleaned2.Section 8

Section 8

1.6

Section 1

Safety and General Information

Figure 1-4. Typical Engine Dimensions.

Air Filter

and Cover

Cylinder

Carburetor

Fuel Shut-off

Solenoid Carburetor

Fuel Inlet

Oil Drain Plug

3/8 NPT Inch

Oil Filter Side

(.67)

Engine Mounting

Surface

Oil Filter

Cylinder

262

(10.31)

(1.85)

24.0

(9.4)

Valve Cover End 25.4

(1.00)

6.34

(.250)Keyway Width

220.2

(8.67)

45° 45°

60.0

(2.36)

4.0

(.16)

40°

M8x1.25

2 Studs

Exhaust Flange

Mounting Surface

Engine Mounting Surface

35° 35°

Rotation

254

(10.0)

Cylinder

4xM8x1.25

296

(11.65)

321

(12.64)

Cylinder

137.5

(5.41)

411

(16.18)

Air Cleaner

Cover Removal

62.5

(2.46)

(.74)

Exhaust Flange

Mounting Surface

25.4

(1.00)

6.34

(.250)Keyway Width

Starter Side

Starter Motor

Engine Mounting

Surface

26.5

(1.04) Throttle Cable

207

(80.16)

176.6

(6.95)

Oil Level

Dipstick & Fill

328*

(12.91)

463*

(18.23)

108

(4.25)

135.0

(5.31)

Flywheel End

372

(14.66)

204

(8.04)

124

(4.88)

Dimensions in () are inch equivalents.

*CV11-16 10 mm shorter

Cylinder

1.7

Section 1

Safety and General Information

General Specifications¹

Power (@ 3600 RPM, corrected to SAE J1995)

CV11 ...............................................................................8.2 kW (11 HP)

CV12.5 ............................................................................9.33 kW (12.5 HP)

CV13...............................................................................9.75 kW (13 HP)

CV14...............................................................................10.5 kW (14 HP)

CV15...............................................................................11.19 kW (15 HP)

CV16...............................................................................11.9 kW (16 HP)

CV460-465......................................................................11.9 kW (16 HP)-13.0 kW (16.5 HP)

CV490-495......................................................................12.7 kW (17 HP)-13.4 kW (18 HP)

Max Torque (@ RPM indicated)

CV11 ................................................................................ 27.4 N·m (20.2 ft. lb.) @ 2000

CV12.5 ............................................................................. 27.8 N·m (20.5 ft. lb.) @ 2500

CV13................................................................................ 27.8 N·m (20.5 ft. lb.) @ 2500

CV14................................................................................ 28.9 N·m (21.3 ft. lb.) @ 2500

CV15................................................................................ 33.2 N·m (24.5 ft. lb.) @ 2400

CV16................................................................................ 35.3 N·m (26.0 ft. lb.) @ 2400

CV460-465....................................................................... 36.3 N·m (26.8 ft. lb.) @ 2400

CV490-495....................................................................... 37.8 N·m (27.9 ft. lb.)-38.1 N·m (28.1 ft. lb.) @ 2400

Bore

CV11-14, CV460-465 ........................................................ 87 mm (3.43 in.)

CV15, CV16, CV490-495 .................................................. 90 mm (3.60 in.)

Stroke

CV11-16 ..........................................................................67 mm (2.64 in.)

CV460-465, CV490-495 ..................................................77 mm (3.03 in.)

Displacement

CV11-14 ............................................................................ 398 cc (24.3 cu. in.3)

CV15, CV16 ...................................................................... 426 cc (26.0 cu. in.3)

CV460-465........................................................................ 460 cc (27.9 cu. in.3)

CV490-495........................................................................ 490 cc (29.9 cu. in.3)

Compression Ratio .................................................................. 8.5:1

Weight (approx.)

CV11-16 ............................................................................ 39.54 kg (87 lb.)

CV460-465, CV490-495 .................................................... 41.9 kg (90 lb.)

Oil Capacity (approx.).............................................................. 1.9 L (2.0 U.S. qt.)

Air Cleaner

Base Nut Torque...................................................................... 9.9 N·m (88 in. lb.)

Wing Nut Torque...................................................................... 1.5 N·m (12 in. lb.)

Angle of Operation - Maximum (at full oil level)

Intermittent -All Directions....................................................... 35°

Continuous -All Directions....................................................... 20°

1Values are in Metric units. Values in parentheses are English equivalents. Lubricate threads with engine oil prior to

assembly.

1.8

Section 1

Safety and General Information

Balance Shaft

EndPlay ...................................................................................................... 0.0575/0.3625 mm (0.0027/0.0137 in.)

Running Clearance ...................................................................................... 0.0250/0.1520 mm (0.0009/0.0059 in.)

Bore I.D.

New....................................................................................................... 20.000/20.025 mm (0.7874/0.7884 in.)

Max. Wear Limit .................................................................................... 20.038 mm (0.7889 in.)

Balance Shaft Bearing Surface O.D.

New....................................................................................................... 19.962/19.975 mm (0.7859/0.7864 in.)

Max. Wear Limit .................................................................................... 19.959 mm (0.7858 in.)

Camshaft

End Play (free)............................................................................................. 0.088/0.393 mm (0.003/0.015 in.)

End Play (with shims) .................................................................................. 0.076/0.127 mm (0.003/0.005 in.)

Running Clearance ...................................................................................... 0.025/0.105 mm (0.0010/0.0041 in.)

Bore I.D.

New....................................................................................................... 20.000/20.025 mm (0.7874/0.7884 in.)

Max. Wear Limit .................................................................................... 20.038 mm (0.7889 in.)

Camshaft Bearing Surface O.D.

New...................................................................................................... 19.962/19.975 mm (0.7859/0.7864 in.)

Max. Wear Limit ................................................................................... 19.959 mm (0.7858 in.)

Carburetor

Preliminary Low Idle Fuel Needle Setting ................................................... 1 Turn

Fuel Bowl Retaining Screw Torque ............................................................. 5.1-6.2 N·m (45-55 in. lb.)

Connecting Rod

Cap Fastener Torque (torque in increments)

6 mm straight shank bolt ....................................................................... 11.3 N·m (100 in. lb.)

8 mm step-down bolt............................................................................. 14.7 N·m (130 in. lb.)

8 mm straight shank bolt ....................................................................... 22.7 N·m (200 in. lb.)

Connecting Rod-to-Crankpin Running Clearance at 21°C (70°F)

New....................................................................................................... 0.030/0.055 mm (0.0012/0.0022 in.)

Max. Wear Limit .................................................................................... 0.07 mm (0.0025 in.)

Connecting Rod-to-Crankpin Side Clearance .............................................. 0.18/0.41 mm (0.007/0.016 in.)

Connecting Rod-to-Piston Pin Running Clearance at 21°C (70°F) .............. 0.015/0.028 mm (0.0006/0.0011 in.)

Piston Pin End I.D.

New...................................................................................................... 19.015/19.023 mm (0.7486/0.7489 in.)

Max. Wear Limit ................................................................................... 19.036 mm (0.7495 in.)

Crankcase

Governor Cross Shaft Bore I.D.

New...................................................................................................... 6.025/6.050 mm (0.2372/0.2382 in.)

Max. Wear Limit................................................................................... 6.063 mm (0.2387 in.)

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