SERVICE MANUAL COMMAND CV11-16, CV460-465, CV490-495 VERTICAL CRANKSHAFT 1 Contents 1 Section 1. Safety and General Information ............................................................................ 2 Section 2. Special Tools .......................................................................................................... 3 Section 3. Troubleshooting ..................................................................................................... 4 Section 4. Air Cleaner and Air Intake System ........................................................................ 5 Section 5. Fuel System and Governor .................................................................................... 6 Section 6. Lubrication System ................................................................................................ 7 Section 7. Retractable Starter ................................................................................................. 8 Section 8. Electrical System and Components ..................................................................... 9 Section 9. Disassembly ........................................................................................................... 10 Section 10. Inspection and Reconditioning ........................................................................... 11 Section 11. Reassembly........................................................................................................... SectionCV11-16 1 Safety andCV460-465, General Information CV490-495 1 Section 1 Safety and General Information 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. WARNING WARNING WARNING Accidental Starts can cause Rotating Parts can cause severe Hot Parts can cause severe burns. severe injury or death. injury. Do not touch engine while operating Disconnect and ground spark plug Stay away while engine is in or just after stopping. leads before servicing. operation. Accidental Starts! Rotating Parts! Hot Parts! Disabling engine. Accidental Keep hands, feet, hair, and Engine components can get starting can cause severe injury clothing away from all moving extremely hot from operation. To or death. Before working on the parts to prevent injury. Never prevent severe burns, do not engine or equipment, disable the operate the engine with covers, touch these areas while the engine as follows: 1) Disconnect the shrouds, or guards removed. engine is running—or immediately spark plug lead(s). 2) Disconnect after it is turned off. Never operate negative (-) battery cable from the engine with heat shields or battery. guards removed. 1.1 Section 1 Safety and General Information WARNING WARNING WARNING Explosive Fuel can cause fires and Carbon Monoxide can cause Explosive Gas can cause fires and severe burns. severe nausea, fainting or death. severe acid burns. Charge battery only in a well Stop engine before filling fuel tank. Do not operate engine in closed or ventilated area. Keep sources of confined area. ignition away. Explosive Fuel! Lethal Exhaust Gases! Explosive Gas! Gasoline is extremely flammable Engine exhaust gases contain Batteries produce explosive and its vapors can explode if poisonous carbon monoxide. hydrogen gas while being ignited. Store gasoline only in Carbon monoxide is odorless, charged. To prevent a fire or approved containers, in well colorless, and can cause death if explosion, charge batteries only in ventilated, unoccupied buildings, inhaled. Avoid inhaling exhaust well ventilated areas. Keep away from sparks or flames. Do not fumes, and never run the engine sparks, open flames, and other fill the fuel tank while the engine is in a closed building or confined sources of ignition away from the hot or running, since spilled fuel area. battery at all times. Keep batteries could ignite if it comes in contact out of the reach of children. with hot parts or sparks from Remove all jewelry when servicing ignition. Do not start the engine WARNING batteries. near spilled fuel. Never use gasoline as a cleaning agent. Before disconnecting the negative (-) ground cable, make sure all switches are OFF. If ON, a spark WARNING Uncoiling Spring can cause severe will occur at the ground cable injury. terminal which could cause an Wear safety goggles or face explosion if hydrogen gas or protection when servicing retractable gasoline vapors are present. starter. Cleaning Solvents can cause Spring Under Tension! CAUTION severe injury or death. Retractable starters contain a powerful, recoil spring that is under Use only in well ventilated areas away from ignition sources. tension. Always wear safety goggles when servicing retractable starters and carefully follow Flammable Solvents! Electrical Shock can cause injury. Carburetor cleaners and solvents instructions in "Retractable Starter" Section 7 for relieving spring are extremely flammable. Keep Do not touch wires while engine is sparks, flames, and other sources tension. running. of ignition away from the area. Follow the cleaner manufacturer’s warnings and instructions on its Electrical Shock! proper and safe use. Never use Never touch electrical wires or gasoline as a cleaning agent. components while the engine is running. They can be sources of electrical shock. 1.2 Section 1 Safety and General Information Engine Identification Numbers When ordering parts, or in any communication involving an engine, always give the Model, 1 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. Identification Decal Figure 1-1. Engine Identification Decal Location. A. Model No. C V 12.5 ST Command Engine Version Code Vertical Crankshaft S = Electric Start T = Retractable Start Displacement (cc) or Horsepower ST = Electric/Retractable Start 460 = 460 cc 11 = 11 HP 490 = 490 cc 12.5 = 12.5 HP 13 = 13 HP 14 = 14 HP 15 = 15 HP 16 = 16 HP B. Spec. No. 1203 A Engine Model Code Variation of MODEL NO.CV12.5ST SPEC. NO. 1203 B Code Model Basic Engine SERIAL NO.2105810334 11 CV11 C 12 CV12.5 REFER TO OWNER'S MANUAL FOR 22 CV13 SAFETY, MAINTENANCE SPECS AND ADJUSTMENTS. FOR SALES 14 CV14 AND SERVICE IN US/CANADA 41 CV15 CALL: 1-800-544-2444. 43 CV16 www.kohlerengines.com 265 CV460-465 275 CV490-495 C. Serial No. 2105810334 KOHLER CO. KOHLER, WI USA Year Manufactured Code Factory 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 Figure 1-2. Explanation of Engine Identification Numbers. 1.3 Section 1 Safety and General Information Oil Recommendations Fuel Recommendations Using the proper type and weight of oil in the crankcase is extremely important, as is checking oil WARNING: Explosive Fuel! daily, and changing oil regularly. Failure to use the Gasoline is extremely flammable and its vapors can correct oil, or using dirty oil, causes premature engine explode if ignited. Store gasoline only in approved wear and failure. Synthetic oil is recommended for containers, in well ventilated, unoccupied buildings, use in LPG-fueled engines because there is less away from sparks or flames. Do not fill the fuel tank oxidation or thickening, and deposit accumulation on while the engine is hot or running, since spilled fuel intake valves is substantially reduced. could ignite if it comes in contact with hot parts or sparks from ignition. Do not start the engine near Oil Type spilled fuel. Never use gasoline as a cleaning agent. Use high-quality detergent oil of API (American Petroleum Institute) service class SG, SH, SJ or General Recommendations higher. Select the viscosity based on the air Purchase gasoline in small quantities and store in temperature at the time of operation as shown below. 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. *Use of synthetic oil having 5W-20 or 5W-30 rating is Do not overfill the fuel tank. Leave room for the fuel to acceptable, up to 4°C (40°F). expand. **Synthetic oils will provide better starting in extreme cold below -23°C (-10°F). Fuel Type For best results, use only clean, fresh, unleaded NOTE: Using other than service class SG, SH, SJ or gasoline with a pump sticker octane rating of 87 or higher oil, or extending oil change intervals higher. In countries using the Research method, it longer than recommended, can cause engine should be 90 octane minimum. damage. Unleaded