"service manual"
Contents
1. 6 0 9 0 N m 53 79 in Ib Fan Flywheel Fan Fastener 9 9 N m 88 Ib Flywheel Retaining Screw Torque 66 4 N m 49 ft Ib Fuel Pump Fuel Pump Fastener Torque 9 0 N m 80 in Into new as cast hole 4 2 5 1 N m 37 45 in Into used hole Fuel Pump Pad Cover Fastener Torque 10 7 N m 95 in Into new as cast hole 7 3 65 in lb Into used hole Governor Governor Cross Shaft to Crankcase Running Clearance 0 025 0 075 mm 0 0010 0 0030 in Governor Cross Shaft O D eee RAS 5 975 6 000 mm 0 2352 0 2362 in Wear 5 962 0 2347 Governor Gear Shaft to Governor Gear Running Clearance 0 050 0 160 mm 0 0019 0 0063 Governor Gear Shaft O D NOW neti aaa a rit faint 5 990 6 000 mm 0 2358 0 2362 in Wear 5 977 0 2353 Ignition Spark Plug Type Champion or RC12YC Standard or Premium Gold 2071 Pro Series Spark Plug Gap CV11 15 CV460 465 490 495 1 02 mm 0 040 in CV11 214s LP CV 0 0 76 mm 0 030 in 1 10 Ignition Cont d Spark PlUg Torque sii2. 15 837 16 127 mm 0 63 0 64 in Max Wear Limit 16 13 0 640 Rocker Shaft O D NCW cas te Sits hee as 15 90 15 85 mm 0 63 in Wear Limit 15 727 mm 0 619 in Non Adjustable Valve Lash Configuration Rocker Arm Screw 2 11 3 N m 100 in Ib Adjustable Valve Lash Configuration Rocker Arm Pivot Stud Torque 11 3 N m 100 in Ib Adjustment Set Screw Torque 7 3 N m 65 in Ib Section 1 Safety and General Information Valves and Valve Lifters Hydraulic Valve Lifter to Crankcase Running Clearance 0 0124 0 0501 mm 0 0005 0 0020 in Intake Valve Stem to Valve Guide Running Clearance 0 038 0 076 mm 0 0015 0 0030 in Exhaust Valve Stem to Valve Guide Running Clearance 0 050 0 088 mm 0 0020 0 0035 in Intake Valve Guide 7 038 7 058 mm 0 2771 0 2779 in Max Wear Limit EEA AONGEA 7 134 mm 0 2809 in Exhaust Valve Guide a ritual 7 038 7 058 mm 0 2771 0 2779 in Max Wear 7 159 mm 0 2819 in Valve Guide Reamer Size tte ed Aiea 7 048 mm 0 2775 in O25 MM OSS E eee 7 298 mm 0 2873
3. 44022 111 Section 1 Safety and General Information 24 4 29 8 N m 18 22 ft Ib 0 200 0 300 mm 0 0078 0 0118 6 2 N m 55 in Into new as cast hole 4 0 35 in Into used hole 24 4 N m 216 in Ib 10 4 12 7 N m 90 110 in Ib 7 3 9 0 65 80 in 24 4 N m 216 in Ib 6 8 N m 60 in Ib 6 2 N m 55 Ib Into new as cast hole 4 0 35 in Into used hole 0 006 0 017 mm 0 0002 0 0007 in 19 006 19 012 mm 0 7483 0 7485 in 19 025 mm 0 7490 in 18 995 19 000 mm 0 7478 0 7480 in 18 994 mm 0 74779 in 0 034 0 100 mm 0 0013 0 0039 in 0 060 0 105 mm 0 0023 0 0041 in 0 040 0 080 mm 0 0016 0 0032 in 0 040 0 085 mm 0 0015 0 0033 in 0 036 0 186 mm 0 001 4 0 0073 0 036 0 186 mm 0 001 4 0 0073 in 0 250 0 500 mm 0 010 0 020 in 0 28 0 51 mm 0 011 0 020 in 0 79 mm 0 031 in Section 1 Safety and General Information Piston Piston Rings and Piston Pin Cont d Center Compression Ring End Gap New Bore CV11 14 CV460 465 0 250 0 510 mm 0 0010 0 020 in CV15 16 490 495 0 22 0 48 mm 0 008 0 018 in Used Bore 0 76 mm 0 030 in Oil Control Ring End Gap CV11 14 CV460 465 0 250 1 020 mm 0 010 0 040 in CV15 16 4
4. 5 31 108 4 25 228 12 91 463 18 23 Flywheel End M8x1 25 2 Studs Exhaust Flange Mounting Surface Figure 1 4 Typical Engine Dimensions 1 6 CV11 16 10 mm shorter Dimensions in are inch equivalents General Specifications Power 3600 RPM corrected to SAE J1995 CMAN in a es GVI 11 14 CV460 465 CV15 CV16 CV490 495 Stroke Displacement ONV11 14 indie adie 460 465 0 22 2000 2 490 495 eee Compression Ratio Weight CVIT G i 460 465 CV490 495 Oil Capacity Air Cleaner Base Nut Wing Nut Angle of Operation Maximum at full oil level Intermittent All Directions Continuous All Directions Values are in Metric units Values in parentheses are English equivalents Lubricate threads with engine oil prior to assembly 398 426 460 AAN A 490 cc Safety and
5. NOTE Using other than service class SG SH SJ or higher oil or extending oil change intervals longer than recommended can cause engine damage A logo or symbol on oil containers identifies the service class and SAE viscosity grade See Figure 1 3 Figure 1 3 Oil Container Logo Refer to Section 6 Lubrication System for detailed oil check oil change and oil filter change procedures 1 4 Fuel Recommendations A 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
6. 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 1 2 amp WARNING Carbon Monoxide can cause severe nausea fainting or death Do not operate engine in closed or confined area 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 closed building or confined area WARNING Uncoiling Spring can cause severe injury Wear safety goggles or face protection when servicing retractable starter 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 can cause fires and severe acid burns Charge battery only in a well ventilated area Keep sources of ignition away 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 chil
7. 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 Periodic Maintenance WARNING Accidental Starts Section 1 Safety and General Information 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 Fill fuel tank Daily or Before Check oil level Section 5 Section 6 Starting Engine Check air cleaner for d
8. 0 0010 0 30 mm 0 012 in 0 10 mm 0 0039 in 87 000 87 025 3 4252 3 4262 90 000 90 025 3 5433 3 5443 87 063 3 4277 Pc acta 90 063 mm 3 5458 in otto 0 12 mm 0 0047 in 0 05 mm 0 0020 in 1 9 Section 1 Safety and General Information Cylinder Head Cylinder Head Fastener Torque torque in 2 increments 20 40 7 N m 15 30 ft Ib 0 076 mm 0 003 Rocker Pedestal Fastener Torque 11 3 N m 100 in Ib Electric Starter Starter Thru Bolt Torque UTE Johnson Electric Eaton Inertia 4 5 5 7 N m 40 50 in Ib Nippendenso Solenoid Shift 4 5 7 5 40 84 in Ib Delco Remy Solenoid Shift 5 6 9 0 N m 49 79 in Ib Starter Mounting Screw Torque All 15 3 N m 135 in Ib Solenoid Mounting Hardware Nut Screw Torque Nippendenso Starter 6 0 9 0 N m 53 79 Ib Delco Remy 4 0 6 0 N m 35 53 Ib Brush Holder Mounting Screw Torque Delco Remy 2 5 3 3 22 29 in lb Nut Positive Brush Lead Torque Nippendenso Starter 8 0 12 0 N m 71 106 in Ib Delco Remy Starter
9. 0 7858 1 Camshaft ee elon tae 0 088 0 393 mm 0 003 0 015 in End Play with ShitmS 0 076 0 127 mm 0 003 0 005 in Running Clearance 2 2 neal eee a eee eal 0 025 0 105 mm 0 0010 0 0041 in Bore I D 20 000 20 025 mm 0 7874 0 7884 Max Wear CIT 20 038 0 7889 Camshaft Bearing Surface NOW tained ye 19 962 19 975 mm 0 7859 0 7864 in Wear 19 959 mm 0 7858 Carburetor Preliminary Low Idle Fuel Needle Setting 1 Turn Fuel Bowl Retaining Screw Torque 5 1 6 2 N m 45 55 in Ib Connecting Rod Cap Fastener Torque torque in increments 6 mm straight shank 11 3 N m 100 in Ib BS MmMistep dOwn 14 7 N m 130 in 8 mm straight Shank 22 7 N m 200 in Ib Connecting Rod to Crankpin Running Clearance at 21 C 70 F INOW AA A 0 030 0 055 0 0012 0 0022 Wear CiM 0 07 0 0025 Connecting Rod to Crankpin Side Clearance 0 18 0 41 mm 0 0
10. 07 0 016 in Connecting Rod to Piston Pin Running Clearance at 21 C 70 0 015 0 028 mm 0 0006 0 0011 in Piston Pin End I D 19 015 19 023 0 7486 0 7489 in E 19 036 0 7495 Governor Cross Shaft Bore I D 6 025 6 050 mm 0 2372 0 2382 6 063 mm 0 2387 1 8 Crankshaft End Play obi act anata End Play thrust bearing with shims Crankshaft Bore Crankcase I D P Crankshaft Bore Pan Running Clearance Acetate Seats Flywheel End Main Bearing Journal Max Wear Max Out Of ROUNC Oil Pan End Main Bearing Journal O D Max Wear Out Of ROUNC Connecting Rod Journal Dee NOW O D Max Wear Cranksh
11. 90 495 0 250 0 760 mm 0 0098 0 0299 Piston Thrust Face O D See Figure 10 4 New CV11 14 CV460 465 86 941 86 959 mm 3 4229 3 4236 in CV15 CV16 CV490 495 89 951 89 969 mm 3 541 3 3 5420 Max Wear Limit CV11 14 460 465 0 000 1 86 814 mm 3 4179 CV15 CV16 490 495 89 824 mm 3 5363 in Piston Thrust Face See Figure 10 4 to Cylinder Bore Running Clearance New CV11 14 460 465 2 0 00400 00 0 041 0 044 mm 0 0016 0 0017 in CV15 16 490 495 0 031 0 043 mm 0 0012 0 0016 Retractable Starter Center Screw 7 4 8 5 N m 65 75 in Ib Stator Stator Mounting Screw 6 2 N m 55 in Ib Throttle Choke Controls Governor Control Lever Fastener Torque 9 9 N m 88 in Ib Speed Control Bracket Assembly Fastener Torque 10 7 N m 95 in Into new as cast hole 7 3 65 in Into used hole Valve Cover Rocker Arms Valve Cover Fastener Torque 10 7 N m 95 Into new as cast hole 7 3 65 in Into used hole Rocker Arm I D
12. General Information 8 2 kW 11 9 33 kW 12 5 HP 9 75 kW 13 HP 10 5 kW 14 HP 11 19 kW 15 HP 11 9 kW 16 HP 11 9 kW 16 HP 13 0 kW 16 5 HP 12 7 kW 17 HP 13 4 kW 18 HP 27 4 N m 20 2 ft Ib 2000 27 8 N m 20 5 ft lb 2500 27 8 N m 20 5 ft Ib 2500 28 9 N m 21 3 ft Ib 2500 33 2 N m 24 5 ft Ib 2400 35 3 N m 26 0 ft Ib 2400 36 3 26 8 ft b 240 37 8 N m 27 9 ft Ib EEEE 87 mm 3 43 in E 90 mm 3 60 in 67 mm 2 64 in 77 mm 3 03 in 24 3 cu i 26 0 cu i 27 9 cu i 29 9 cu i 5 5 5 a 5 Dried ou 39 54 kg 87 Ib nee coe 41 9 kg 90 Ib Nee aa ee key 1 9L 2 0 U S qt 9 9 N m 88 in Ib 1 5 12 in Ib Section 1 1 7 Section 1 Safety and General Information Balance Shaft ENG alate vedi ii Bite a ee rh bea fn 0 0575 0 3625 mm 0 0027 0 0137 Running 0 0250 0 1520 mm 0 0009 0 0059 Bore I D Racer ener rete 20 000 20 025 mm 0 7874 0 7884 in Max 20 038 0 7889 1 Balance Shaft Bearing Surface O D AE 19 962 19 975 mm 0 7859 0 7864 in Max Wear Simoes 19 959
13. SERVICE IN US CANADA CV15 CALL 1 800 544 2444 MODEL NO CV12 5ST CV16 www kohlerengines com CV460 465 CV490 495 KOHLER ies 2105810334 KOHLER CO KOHLER WI USA Serial No Year Manufactured Code _ Factory Code Model 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 Figure 1 2 Explanation of Engine Identification Numbers 1 3 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 RECOMMEHDED SAE VISCOSITY GRADES hoa NG Soar 4 1 a 1 A Use of synthetic oil having 5W 20 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
14. SERVICE MANUAL COMMAND CV11 16 CV460 465 CV490 495 VERTICAL CRANKSHAFT KOHLER emmes HBOrnr we Fear CV11 16 Go Back CV460 465 CV490 495 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 A 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 A 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 or just after stopping leads before servicing Stay away while engine is in operation Accidental St
15. aft T I R PTO End Crank in Engine Entire Crank in V BIOCKS Cylinder Bore Cylinder Bore I D New 11 14 460 465 222222 CV15 16 490 495 Wear Limit 11 14 460 465 CV15 CV16 CV490 495 Section 1 Safety and General Information 0 0575 0 4925 mm 0 0022 0 0193 0 050 0 530 mm 0 0020 0 0209 in 44 965 44 990 1 7702 1 7712 in 44 9758 45 0012 1 7707 1 7717 0 0300 0 0770 0 0011 0 0030 41 965 42 003 1 6521 1 6536 41 9760 42 0141 1 6526 1 6541 0 0300 0 0880 0 0011 0 0034 44 913 44 935 mm 1 7682 1 7691 res 44 84 mm 1 765 in 0 022 0 0009 0 025 0 0010 41 915 41 935 mm 1 6502 1 6510 in 41 86 1 648 0 020 mm 0 0008 in 0 025 0 0010 38 958 30 970 1 5338 1 5343 38 94 1 5328 0 012 0 0005 0 025 mm
16. arts Disabling engine Accidental starting can cause severe injury or death Before working on the parts to prevent injury Never engine or equipment disable the operate the engine with covers engine as follows 1 Disconnect the shrouds or guards removed Rotating Parts Keep hands feet hair and clothing away from all moving 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 spark plug lead s 2 Disconnect negative battery cable from battery after it is turned off Never operate the engine with heat shields or guards removed 1 1 Section 1 Safety and General Information WARNING Explosive Fuel can cause fires and severe burns Stop engine before filling fuel tank 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 A WARNING Cleaning Solvents can cause severe injury or death Use only in well ventilated areas away from ignition sources Flammable Solvents Carburetor cleaners and solvents
17. dren 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 k 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 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 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 CV 12 5 ST Command Engine Version Code Vertical Crankshaft S Electric Start T Retractable Start 21 i or ST Electric Retractable Start 490 490 12 5 12 5 HP 13 13 HP 14 14HP 15 15 HP 16 16 HP Spec 1203 Engine Model Code Variation of 1 Basic Engine 5 1203 SERIAL NO 2105810334 CV12 5 REFER TO OWNER S MANUAL FOR CV13 SAFETY MAINTENANCE SPECS AND ADJUSTMENTS FOR SALES CV14 AND
18. in Ignition Module Air Ignition Module Fastener Torque Muffler Muffler Retaining 6 Oil Filter Oil Pan Oil Filt6r ieee eae eit cele Oil Filter Drain Plug 1 8 NPT Torque Oil Pan Fastener Torque Oil Sentry Pressure Switch Torque Oil Pump Cover Fastener Torque Piston Piston Rings and Piston Pin Piston to Piston Pin Selective fit Piston Pin Bore I D Top Compression Ring to Groove Side Clearance 11 14 460 465 CV15 CV16 CV490 495 Middle Compression Ring to Groove Side Clearance 11 14 CV460 465 CV15 16 490 495 Oil Control Ring to Groove Side Clearance 11 14 460 465 CV15 CV16 CV490 495 Top Compression Ring End Gap New Bore CV11 14 CV460 465 CV15 CV16 490 495 Used Bore
19. in Intake Valve Minimum 8 96 mm 0 353 in Exhaust Valve Minimum 9 14 mm 0 360 in Nominal Valve Seat 45
20. irty loose or damaged parts Section 4 e Check air intake and cooling areas clean as necessary Section 4 Every 25 Hours Service precleaner element j 1 Every e Replace air cleaner element 100 Hours Change oil Section 4 Section 6 e Remove cooling shrouds and clean cooling areas Section 4 Every Change oil filter Section 6 200 Hours e Check spark plug condition and gap Section 8 Annually or Have bendix starter drive serviced Section 8 Every Have solenoid shift starter disassembled and cleaned Section 8 500 Hours Perform these maintenance procedures more frequently under extremely dusty dirty conditions Have a Kohler Engine Service Dealer perform this service Not necessary on Delco Starters 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 em
21. pty the system run the engine until the tank and system are empty 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 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 Store the engine clean dry place 1 5 Section 1 Safety and General Information Air Filter and Cover Y Cylinder Carburetor Fuel Shut off lenoi Solenoid Carburetor Fuel Inlet Oil Drain Plug 3 8 NPT Inch Oil Filter Side L 296 11 65 dA R 321 Cylinder 2 12 64 ies 137 5 7 ks 170 5 41 1 a 1 H Engine Mounting gt i Surface Starter Motor 0 25 4 00 oan Starter Side 4xM8x1 25 254 10 0 Cylinder Rotation Engine Mounting Surface Oil Filter _Engine Mounting Surface 67 411 16 18 Air Cleaner Cover Removal Exhaust Flange Mounting Surface 19 74 Keyway Width 372 14 66 25 4 Valve Cover End 1 1 00 6 34 Keyway Width 250 Throttle Cable Pee 176 6 1 1 Cylinder Oil Level 135 0 Dipstick amp Fill
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