Kohler Comand Series - User Manual

Need help?

Do you have a question about the Kohler Comand Series and is the answer not in the manual?

Summary

Safety Precautions

Hazard Definitions (Warning, Caution, Note)

Defines hazard levels (Warning, Caution) and informational notes.

Fire, Burn, and Mechanical Hazards

Hazards related to fuel, hot parts, and moving engine parts.

Electrical Shock and Proposition 65 Warnings

Warnings about electrical shock and California Proposition 65.

Safety Precautions (Cont.)

Accidental Start and Exhaust Gas Hazards

Hazards from unintended engine starts and carbon monoxide.

Battery Charging and Gas Explosions

Warnings about explosive gas from batteries and ignition sources.

Oil Recommendations

Selecting the Right Oil Type and Viscosity

Specifies recommended oil type, service class, and viscosity grades.

Fuel Recommendations

Safe Gasoline Handling and Storage

Reinforces warning about gasoline flammability and ignition hazards.

General Recommendations

Approved Fuel Types and Blends

Specifies approved gasoline types, octane, and approved blends.

Identifying Your Engine

Explains the importance and location of model, specification, and serial numbers.

Operating Instructions

Pre-Start Engine Checks

Key checks before starting the engine, including oil, fuel, and cleaning.

Cold Weather Starting Tips

Tips for starting the engine in cold temperatures.

Engine Starting Procedures

Step-by-step instructions for starting the engine, including electric start.

Operating Instructions (Cont.)

Engine Operation, Angle, Cooling, and Stopping

How to operate, angle limitations, cooling, and stopping procedures.

Operational Safety Warnings

Warnings about accidental starts, hot parts, and engine speed.

Maintenance Instructions

Safety and Maintenance Schedule Overview

Safety warning about accidental starts and the overall maintenance schedule.

Checking Engine Oil Level Procedure

Step-by-step guide for checking the engine oil level.

Maintenance Instructions (Cont.)

Oil Level Dipstick and Sentry System Explained

Guide to the dipstick and description of the optional Oil Sentry system.

Changing Engine Oil and Oil Filter

Instructions for changing the engine oil and oil filter.

Maintenance Instructions (Cont.)

Oil Filter and Air Cleaner Element Maintenance

Procedures for replacing the oil filter and servicing the air cleaner.

Precleaner Service Procedure

Detailed steps for washing and re-oiling the precleaner element.

Maintenance Instructions (Cont.)

Air Cleaner Element and Cooling System Cleaning

Replacing paper element and cleaning cooling areas.

Ignition System and Spark Plug Service

Overview of ignition system and procedure for spark plug service.

Maintenance Instructions (Cont.)

Spark Plug Servicing and Battery Charging Safety

Steps for spark plug service and safety during battery charging.

Fuel Filter Replacement and Carburetor Troubleshooting

Instructions for fuel filter replacement and carburetor troubleshooting.

Maintenance Instructions (Cont.)

Carburetor Adjustment and Idle Speed Setting

Detailed steps for adjusting carburetor settings and idle speed.

Troubleshooting Common Engine Problems

Guide for diagnosing and resolving common engine problems.

Engine Storage and Service Information

Long-Term Engine Storage Procedure

Step-by-step procedure for storing the engine for extended periods.

Parts Ordering and Major Repair Services

Details on ordering parts and where to find major repair information.

Understanding Engine Model Designations

Explanation of how to interpret engine model numbers and suffixes.

Warranty Information

2-Year Command Engine Warranty Details

Details the terms and conditions of the 2-year engine warranty.

Warranty Exclusions and Owner Responsibilities

Lists warranty exclusions and outlines owner's duties for maintaining coverage.

Emission Control Systems Warranty

Emission Control Warranty Coverage Period

Details the duration of emission control system warranty coverage.

Emission Control Systems Warranty (Cont.)

Emission Warranty Coverage and Limitations

Details warranty coverage, limitations, and exclusions.

Maintenance for Warranty Compliance

Specifies owner's responsibility for maintenance and record keeping.

This document is an owner's manual for the Kohler Command Series vertical crankshaft engines, specifically models CV11, CV12.5, CV13, CV14, CV15, CV16, CV460, and CV490. It provides essential information for safe operation, maintenance, and troubleshooting of these air-cooled, four-cycle, single-cylinder engines.

Function Description

The Kohler Command Series engines are designed to provide reliable power for various small off-road equipment applications. They are characterized by their overhead valve (OHV) design and full pressure lubrication system, which contribute to maximum power, torque, and reliability under diverse operating conditions. The engines feature a maintenance-free electronic ignition system for fast and easy starts. Components like the cylinder liner and camshaft are made from precision-formulated cast iron, allowing for reboring and extended engine life.

Important Technical Specifications

The manual details specifications for various models:

Bore: 87 mm (3.43 in.) for CV11-CV14, 90 mm (3.55 in.) for CV15/CV16, and 87 mm (3.43 in.) for CV460, 90 mm (3.55 in.) for CV490.
Stroke: 67 mm (2.64 in.) for CV11-CV16, and 77 mm (3.03 in.) for CV460/CV490.
Displacement: 398 cm³ (24.3 in³) for CV11-CV14, 426 cm³ (26.0 in³) for CV15/CV16, and 458 cm³ (28.0 in³) for CV460, 490 cm³ (29.9 in³) for CV490.
Power (@3600 RPM): Ranges from 8.2 kW (11 HP) for CV11 to 12.7 kW (17 HP) for CV490. Horsepower ratings are established according to SAE J1995 GROSS.
Max. Torque (@RPM): Ranges from 20.2 ft. lb. @2000 for CV11 to 27.7 ft. lb. @2400 for CV490.
Compression Ratio: 8.5:1 for all listed models.
Weight: Approximately 39.5 kg (87.0 lb.) for CV11-CV16, and 41 kg (90 lb.) for CV460/CV490.
Oil Capacity (w/filter): 1.9 L (4 U.S. pt.) for all models.
Lubrication: Full Pressure with full Flow Filter.
Exhaust Emission Control System: EM for all listed models.
Ignition System: Electronic magneto ignition system. CV16 models are equipped with Smart Spark™ computerized ignition.
Spark Plug Gap: 1.0 mm (0.040 in.) for CV11-CV15, CV460, CV490; 0.76 mm (0.030 in.) for CV16.
Low Idle Speed: 1200 RPM (± 75 RPM) recommended for basic engines.
Angle of Operation: Continuous operation up to 25° in any direction.

Usage Features

The manual emphasizes several usage features:

Fuel Recommendations: Use clean, fresh, unleaded gasoline with an octane rating of 87 or higher (90 octane minimum by Research method). Gasohol (up to 10% ethyl alcohol) and MTBE blends (up to 15% MTBE) are approved. Do not use gasoline left over from previous seasons, overfill the tank, or add oil to gasoline.
Oil Recommendations: Use high-quality detergent oil of API service class SG, SH, SJ, or higher. Viscosity should be selected based on ambient air temperature (e.g., SAE 10W-30 for most conditions, synthetic 5W-20 or 5W-30 for cold temperatures).
Starting Procedure: For both cold and warm engines, place the throttle/choke control to "fast/choke on." For retractable start engines, pull the handle slowly past compression, then firmly and steadily. For electric start engines, activate the starter switch.
Stopping Procedure: Disengage all PTO attachments. For engines without a shutdown solenoid, move the throttle to "slow" or "low" idle for 30-60 seconds, then stop. For engines with a shutdown solenoid, position the throttle between half and full throttle, then stop.
Angle of Operation: The engine can operate continuously at angles up to 25°. Operating beyond this angle can cause insufficient lubrication and engine damage.
Engine Speed: Do not tamper with the governor setting to increase maximum engine speed, as overspeeding is hazardous and voids the warranty.
Carburetor Adjustment: Carburetor adjustments, particularly for low idle fuel and speed, should only be performed after the engine has warmed up. Certified engines may have fixed idle or limiter caps. Special high-altitude jet kits may be required for operation above 1525 meters (5000 ft.).
Cold Weather Starting Hints: Use proper oil viscosity, declutch external loads, and ensure a warm battery. Use fresh winter-grade fuel for better volatility.

Maintenance Features

The manual outlines a comprehensive maintenance schedule to ensure optimal engine performance and longevity:

Daily or Before Starting: Fill fuel tank, check oil level, inspect air cleaner for dirt/damage, and clean air intake/cooling areas.
Every 25 Hours: Service precleaner element (if equipped).
Every 100 Hours: Service air cleaner element (if not equipped with precleaner), replace air cleaner element (if equipped with precleaner), change oil, and remove cooling shrouds to clean cooling areas.
Every 200 Hours: Check spark plug condition and gap, and change oil filter.
Annually or Every 500 Hours: Have bendix starter drive serviced and solenoid shift starter disassembled and cleaned (these services require a Kohler Engine Service Dealer).
Oil Check and Change: Check oil level daily using the dipstick, ensuring it's at the "F" mark. Change oil every 100 hours while the engine is warm to facilitate drainage of impurities. Always use genuine Kohler oil filters (Part No. 52 050 02-S) and replace them every other oil change (every 200 hours).
Air Cleaner Service: The engine uses a high-density paper air cleaner element, often with an oiled foam precleaner. Check daily for dirt/debris. Wash and reoil the precleaner every 25 hours. Do not wash the paper element; replace it every 100 hours (or 25 hours if no precleaner).
Clean Air Intake/Cooling Areas: Keep grass screen, cooling fins, and external surfaces clean. Remove blower housing and shrouds every 100 hours to clean cooling fins.
Spark Plug Service: Check spark plug every 200 hours. Clean the area around the plug before removal. Replace if worn or questionable. Do not clean with abrasive grit. Standard plug is Champion® RC12YC (Kohler Part No. 12 132 02-S).
Fuel Filter: Periodically inspect and replace in-line fuel filters if equipped.
Storage: For storage exceeding two months, clean the engine, change oil and filter, empty the fuel system or treat with a stabilizer, add a tablespoon of engine oil into the spark plug hole, and store in a clean, dry place.

The manual also includes safety precautions, a troubleshooting guide for common engine issues, and information on Kohler's limited 2-year warranty for Federal and California emission control systems. It stresses the importance of using genuine Kohler parts and seeking service from authorized Kohler Engine Service Dealers for major repairs.