SERVICE MANUAL COMMAND CV11-16, CV460-465, CV490-495 VERTICAL CRANKSHAFT 1
Contents Section 1. Safety and General Information ............................................................................ Section 2. Special Tools .......................................................................................................... Section 3. Troubleshooting ..................................................................................................... Section 4. Air Cleaner and Air Intake System ........................................................................
CV11-16 Section 1 CV460-465, CV490-495 Safety and General Information Go Back 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.
Section 1 Safety and General Information WARNING WARNING WARNING Explosive Fuel can cause fires and severe burns. Carbon Monoxide can cause severe nausea, fainting or death. Explosive Gas can cause fires and severe acid burns. Stop engine before filling fuel tank. Do not operate engine in closed or confined area. Charge battery only in a well ventilated area. Keep sources of ignition away. Explosive Fuel! Gasoline is extremely flammable and its vapors can explode if ignited.
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. 1 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.
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.
Section 1 Safety and General Information Periodic Maintenance 1 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.
Section 1 Safety and General Information Air Filter and Cover CL Cylinder Oil Filter Carburetor Fuel Shut-off Solenoid 47 (1.85) Carburetor Fuel Inlet Engine Mounting Surface Oil Drain Plug 3/8 NPT Inch 17 (.67) 262 (10.31) CL Cylinder Oil Filter Side 24.0 (9.4) 25.4 (1.00) Valve Cover End 411 (16.18) Air Cleaner Cover Removal 6.34 Keyway Width (.250) 296 (11.65) 321 (12.64) CL Cylinder 137.5 (5.41) Exhaust Flange Mounting Surface Engine Mounting Surface 25.4 (1.00) Starter Motor 26.
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.
Section 1 Safety and General Information Balance Shaft End Play ...................................................................................................... 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.
Section 1 Safety and General Information Crankshaft End Play (free) ........................................................................................ 0.0575/0.4925 mm (0.0022/0.0193 in.) End Play (thrust bearing with shims) ...................................................... 0.050/0.530 mm (0.0020/0.0209 in.) 1 Crankshaft Bore in Crankcase I.D. New .................................................................................................. 44.965/44.990 mm (1.7702/1.7712 in.) Max.
Section 1 Safety and General Information Cylinder Head Cylinder Head Fastener Torque (torque in 2 increments) ......... 20, 40.7 N·m (15, 30 ft. lb.) Max. Out-of-Flatness ............................................................... 0.076 mm (0.003 in.) Rocker Pedestal Fastener Torque ........................................... 11.3 N·m (100 in. lb.) Electric Starter Starter Thru Bolt Torque UTE/Johnson Electric, Eaton (Inertia Drive) ...................... 4.5-5.7 N·m (40-50 in. lb.
Section 1 Safety and General Information Ignition (Cont'd) Spark Plug Torque ................................................................... 24.4-29.8 N·m (18-22 ft. lb.) 1 Ignition Module Air Gap ........................................................... 0.200/0.300 mm (0.0078/0.0118 in.) Ignition Module Fastener Torque ............................................. 6.2 N·m (55 in. lb.) Into new as-cast hole 4.0 N·m (35 in. lb.) Into used hole Muffler Muffler Retaining Nuts ..........................
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, CV16, CV490-495 ................................................ 0.22/0.48 mm (0.008/0.018 in.) Used Bore (max.) .............................................................. 0.76 mm (0.030 in.) Oil Control Ring End Gap CV11-14, CV460-465 .............................
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.) 1 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 I.D. New ................................................................................... 7.038/7.058 mm (0.2771/0.
Section 1 Safety and General Information General Torque Values Metric Fastener Torque Recommendations for Standard Applications Tightening Torque: N·m (in. lb.) + or - 10% Property Class Size M4 M5 M6 M8 4.8 5.8 8.8 10.9 12.9 Noncritical Fasteners Into Aluminum 1.2 (11) 2.5 (22) 4.3 (38) 10.5 (93) 1.7 (15) 3.2 (28) 5.7 (50) 13.6 (120) 2.9 (26) 5.8 (51) 9.9 (88) 24.4 (216) 4.1 (36) 8.1 (72) 14.0 (124) 33.9 (300) 5.0 (44) 9.7 (86) 16.5 (146) 40.7 (360) 2.0 (18) 4.0 (35) 6.8 (60) 17.
Section 2 CV11-16 Special Tools CV460-465, CV490-495 Go Back Section 2 Special Tools Kohler Special Service Tools Kohler Co. has made an agreement with the Service Tools Div. of SPX Corp. (a subsidiary of Owatonna Tool Corp.) to handle our special service tools. The intent of this program is to provide you with a single source for all Kohler special tools, and to make it easy and convenient to obtain those tools, at reasonable cost. Tool orders can be placed with SPX by any of three methods.
Section 2 Special Tools Diagnostic and Repair Tools The tools listed in the following table are used for specific diagnosis or repair procedures, as described. Order from SPX Corp. Description SPX Part No.
Section 2 Special Tools Special Tools You Can Make Flywheel Holding Tool Flywheel removal and reinstallation becomes a “snap” using a handy holding tool you can make out of a piece of an old “junk” flywheel ring gear as shown in Figure 2-1. Using an abrasive cut-off wheel, cut out a six tooth segment of the ring gear as shown. Grind off any burrs or sharp edges. The segment can be used in place of a strap wrench.
Section 2 Special Tools 2.
Section CV11-16 3 CV460-465, Troubleshooting CV490-495 Go Back Section 3 Troubleshooting Troubleshooting Guide When troubles occur, be sure to check the simple causes which, at first, may seem too obvious to be considered. For example, a starting problem could be caused by an empty fuel tank. Some common causes of engine troubles are listed below. Use these to locate the causing factors. Engine Cranks But Will Not Start 1. Empty fuel tank. 2. Fuel shut-off valve closed. 3.
Section 3 Troubleshooting Engine Loses Power 1. Low crankcase oil level. 2. High crankcase oil level. 3. Dirty air cleaner element. 4. Dirt or water in the fuel system. 5. Excessive engine load. 6. Engine overheated. 7. Faulty spark plug. 8. Low compression. 9. Exhaust restriction. Engine Uses Excessive Amount Of Oil 1. Incorrect oil viscosity/type. 2. Clogged or improperly-assembled breather. 3. Crankcase being overfilled. 4. Worn or broken piston rings. 5. Worn cylinder bore. 6.
Section 3 Troubleshooting 2. Start the engine and run at no-load, high idle speed (3200 to 3750 RPM). Basic Engine Tests Crankcase Vacuum Test A partial vacuum should be present in the crankcase when the engine is operating at normal temperatures. Pressure in the crankcase (normally caused by a clogged or improperly-assembled breather) can cause oil to be forced out at oil seals, gaskets, or other available spots. Crankcase vacuum is best measured with a water manometer or vacuum/pressure test gauge.
Section 3 Troubleshooting Compression Test These engines are equipped with an automatic compression release (ACR) mechanism. Because of the ACR mechanism, it is difficult to obtain an accurate compression reading. As an alternate, use the leakdown test described below. Cylinder Leakdown Test A cylinder leakdown test can be a valuable alternative to a compression test. By pressurizing the combustion chamber from an external air source you can determine if the valves or rings are leaking, and how badly.
CV11-16 Section 4 CV490-495 Air CleanerCV460-465, and Air Intake System Go Back Section 4 Air Cleaner and Air Intake System Air Cleaner Air Duct These engines are equipped with a replaceable, high density paper air cleaner element and most also have the optional oiled, foam precleaner which surrounds the paper element. Two basic types of air cleaners are used. The original configuration is shown in Figure 4-1 and the later configuration in Figure 4-2.
Section 4 Air Cleaner and Air Intake System On these, air is drawn in around the bottom of the cover, or from the blower housing, rather than from slots. The flat base allows debris to be brushed away before the paper element is removed. All types can use either the standard size element or a higher, extra capacity paper element. The original type uses a separate cover retaining knob which has to be turned completely off to remove the cover.
Section 4 Air Cleaner and Air Intake System NOTE: Damaged, worn, or loose air cleaner components can allow unfiltered air into the engine causing premature wear and failure. Tighten or replace all loose or damaged components. Disassembly The following procedure is for complete disassembly of all air cleaner components. 1. Loosen the air cleaner cover retaining knob and remove the air cleaner cover. 2. Remove the wing nut and air cleaner element. 3.
Section 4 Air Cleaner and Air Intake System 4.
CV11-16 Section 5 FuelCV460-465, System andCV490-495 Governor Go Back Section 5 Fuel System and Governor Gasoline fuel systems are covered in the first part of this section. LPG (liquefied propane gas) systems and the Kohler Emission Sentry™ LPG system are covered starting on page 5.11. The governor systems start on page 5.14. Unleaded gasoline is recommended, as it leaves less combustion chamber deposits.
Section 5 Fuel System and Governor Fuel System Troubleshooting Guide (Gasoline) 1. 2. 3. 4. Test Check for the following: a. Make sure the fuel tank contains clean, fresh, proper fuel. b. Make sure the vent in fuel cap is open. c. Make sure the fuel valve is open. Check for fuel in the combustion chamber. a. Disconnect and ground spark plug lead. b. Close the choke on the carburetor. c. Crank the engine several times. d. Remove the spark plug and check for fuel at the tip.
Section 5 Fuel System and Governor 3. Torque the hex. flange screws as follows: Repair Nylon-bodied fuel pumps are not serviceable and must be replaced when faulty. Replacement pumps are available in kits that include the pump and mounting gasket. Removal 1. Disconnect the fuel lines from the inlet and outlet fittings of the pump. Into new as-cast hole–9.0 N·m (80 in. lb.). Into used hole–4.2-5.1 N·m (37-45 in. lb.). 4. Connect the fuel lines to the inlet and outlet fittings. Carburetor (Gasoline) 2.
Section 5 Fuel System and Governor Troubleshooting - Gasoline Systems If engine troubles are experienced that appear to be fuel system related, check the following areas before adjusting or disassembling the carburetor. • Make sure the fuel tank is filled with clean, fresh gasoline. • Make sure the fuel tank cap vent is not blocked and that it is operating properly. • Make sure fuel is reaching the carburetor.
Section 5 Fuel System and Governor Adjustment NOTE: Carburetor adjustments should be made only after the engine has warmed up. The carburetor is designed to deliver the correct fuelto-air mixture to the engine under all operating conditions. The main fuel jet is calibrated at the factory and is not adjustable*. The idle fuel adjusting needle is also set at the factory and normally does not need adjustment. Now turn the adjusting needle in (clockwise).
Section 5 Fuel System and Governor Disassembly Throttle Lever and Shaft Dust Seal Throttle Plate Screw(s) Choke Lever and Shaft Choke Return Spring Throttle Plate Low Idle Speed Adjusting Screw and Spring Low Idle Fuel Adjusting Needle and Spring (may not be present or may have limiter cap on certified engines) Choke Plate Fuel Inlet Seat Float Fuel Inlet Needle Float Shaft Bowl Gasket Fuel Bowl Bowl Retaining Screw Gasket Fuel Shut-off Solenoid or Bowl Retaining Screw Figure 5-6.
Section 5 Fuel System and Governor Choke Plate Tool No. KO1018 Do Not Allow Tip to Strike Carburetor Body Pry Out Plug Pierce Plug with Tip Carburetor Body Welch Plug Figure 5-7. Removing Welch Plug. Main Fuel Jet Removal The main jet on Walbro carburetors is pressed into the side of the tower portion of the body. Removal is not recommended, unless a high-altitude kit is being installed, in which case the removal instructions will be included in the kit.
Section 5 Fuel System and Governor Cleaning Dust Cap Choke Lever Spring Brass Bushing Stop Pin Choke Valve Screws Figure 5-10. Cutaway View Showing Self-Relieving Choke Carburetor. Removing Old Parts 1. Remove the black dust cover. This cover snaps on and off. 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.
Section 5 Fuel System and Governor Repair Always use new gaskets when servicing or reinstalling carburetors. Repair kits are available which include new gaskets and other components. Always refer to the Parts Manual for the engine being serviced to ensure the correct repair kits are ordered. Reassembly Choke Shaft Installation (Non-Self-Relieving) 1. Install the choke return spring to the choke shaft. 2. Insert the choke shaft with return spring into the carburetor body. 3.
Section 5 Fuel System and Governor Welch Plug Installation–Walbro Carburetors Use Tool No. KO1017 and install new plugs as follows: 1. Position the carburetor body with the welch plug cavities to the top. 4. Insert the fuel inlet needle into the float. Lower the float/needle into the carburetor body. See Figure 5-14. Install the float shaft. 2. Place a new welch plug into the cavity with the raised surface up. Float 3. Use the end of the tool that is about the same size as the plug and flatten the plug.
Section 5 Fuel System and Governor If these check out, the solenoid should be removed for bench testing. Remember to shut off fuel supply and catch any fuel spilling from the carburetor as the solenoid is removed. Bench test the solenoid by grounding the solenoid case and applying 12 volt DC to the spade terminal. If the plunger does not retract in this test, the solenoid is faulty and must be replaced. Always use a new fuel bowl gasket whenever the solenoid is installed.
Section 5 Fuel System and Governor Troubleshooting - LPG Systems Adjust Carburetor If engine troubles are experienced that appear to be caused by the carburetor, check the following areas before adjusting the carburetor. • 1. With the engine stopped, reset the main fuel setting by closing the adjusting screw until it bottoms then turn it 2 1/4 to 2 1/2 turns open (see Figure 5-16).* Make sure the air cleaner element is clean and all air cleaner components are fastened securely.
Section 5 Fuel System and Governor Kohler Emission Sentry™ System Some Kohler Command engines are equipped with the Emission Sentry™ System. Emission Sentry™ is a feature which assures the operator that the exhaust emission levels of the engine are well within safe exposure limits. The system does not require any additional daily maintenance beyond the schedule normally specified for Command engines. Principle of Operation The Emission Sentry™ System can be broken down into two functions.
Section 5 Fuel System and Governor 2. The stepper motor, electronic control unit (ECU) and oxygen sensor can all be checked with the Kohler Emission Sentry™ Tester (Kohler Part No. 12 761 07-S). a. Separate the plug connector between the electronic control unit (ECU) and the stepper motor. Plug the separated connectors into the mating connectors on the Emission Sentry™ Tester. Connect the single black lead to battery negative or a good ground on the engine/unit.
Section 5 Fuel System and Governor When the engine is at rest, and the throttle is in the ‘‘fast’’ position, the tension of the governor spring holds the throttle plate open. When the engine is operating (the governor gear assembly is rotating), the force applied by the regulating pin against the cross shaft tends to close the throttle plate. The governor spring tension and the force applied by the regulating pin are in ‘‘equilibrium‘‘ during operation, holding the engine speed nearly constant. 1.
Section 5 Fuel System and Governor 1. Make sure the throttle cable is adjusted properly (see ‘‘Throttle Cable Adjustment"). 2. Start the engine and allow it to warm up. Place the throttle control lever into the ‘‘fast’’ or high idle position. 3. Align the hole in the throttle lever with the hole in the speed control bracket by inserting a pencil or 6.35 mm (1/4 in.) drill bit. See Figure 5-21. Cold Engine Warm Engine Figure 5-20. Typical Throttle/Choke Controls. 4.
Section 5 Fuel System and Governor Choke Adjustment This procedure must follow the "High Idle Speed Adjustment" just described. If not already completed, perform that operation first. 1. Turn the choke adjusting screw out (counterclockwise), until it no longer contacts the choke lever. Then turn it back in (clockwise), until it just makes contact. Governor Lever 2. While observing the choke link, move the throttle control lever to the low idle (slow) position, then back to full throttle (fast).
Section 5 Fuel System and Governor 2. Position the application throttle control in the full (fast) throttle position. Then move the throttle lever back 3/16" or 4.75 mm. Insert the cable boden wire into the throttle control lever on the control plate. 2. Position the choke cable under the cable clamp. 3. Position the throttle cable under the cable clamp. 4. Push on the choke cable, above the clamp on the engine control plate, until the choke lever stops. Then tighten the cable clamp screw. 4.
Section 5 Fuel System and Governor Starting an Engine Equipped with Separate Control Cables 1. Place the throttle control midway between the "slow" and "fast" positions. Place the choke control into the "on" position. 7. Turn the high idle stop screw inward (clockwise) until it stops against the throttle control lever. Then tighten the stop screw retaining nut. 8. Recheck high idle RPM to assure the required RPM has been obtained. 2. Start the engine. 3.
Section 5 Fuel System and Governor Governed Idle Adjusting Screw Figure 5-26. Location of Governed Idle Adjusting Screw. 5.
Section CV11-16 6 CV460-465, Lubrication CV490-495 System Go Back Section 6 Lubrication System Oil Recommendations Using the proper type and weight of oil in the crankcase is extremely important. So is checking oil daily and changing oil regularly. Failure to use the correct oil, or using dirty oil, causes premature engine wear and failure.
Section 6 Lubrication System Optional Oil Filter Drain Plug Oil Fill Cap/Dipstick Oil Filter Oil Fill Tube Oil Drain Plug (Carburetor Side) Figure 6-3. Checking Oil Level. Optional Oil Sentry™ Pressure Switch 4. Remove the dipstick and check the oil level. The oil level should be up to, but not over the ‘‘F’’ mark on the dipstick. See Figure 6-4. Oil Filter Oil Drain Plug Operating Range Optional Oil Sentry™ Pressure Switch Figure 6-4. Oil Level Dipstick. 5.
Section 6 Lubrication System 4. Reinstall the oil fill cap/dipstick and tighten securely. NOTE: To prevent extensive engine wear or damage, always maintain the proper oil level in the crankcase. Never operate the engine with the oil level below the ‘‘L’’ mark or over the ‘‘F’’ mark on the dipstick. Change Oil Filter Replace the oil filter every other oil change (every 200 hours of operation). Always use a genuine Kohler oil filter.
Section 6 Lubrication System Figure 6-9. Engine Mounted Oil Filter. Figure 6-7. Oil Pickup. Oil Sentry™ Oil Pressure Relief Valve Some engines are equipped with an optional Oil Sentry™ oil pressure monitor. If the oil pressure gets low, Oil Sentry™ will either shut off the engine or activate a warning signal, depending on the application. Operation The pressure switch is designed to break contact as the oil pressure increases and make contact as the oil pressure decreases.
Section 6 Lubrication System Installation The pressure switch is installed in the oil filter adapter, in one of the main oil galleries of the oil pan. See Figure 6-10. On engines not equipped with Oil Sentry™, the installation hole is sealed with a 1/8-27 N.P.T.F. pipe plug. Testing the Oil Sentry™ Switch The Oil Sentry™ pressure monitor is a normally-closed switch. It is calibrated to open (break contact) with increasing pressure and close (make contact) with decreasing pressure, within the range of 2.
Section 6 Lubrication System 6.
CV11-16 Section 7 CV460-465, CV490-495 Retractable Starter Go Back Section 7 Retractable Starter WARNING: 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 this section for relieving spring tension. Starter Housing Hex. Flange Screws Handle with Rope Retainer To Remove Starter 1. Remove the five hex.
Section 7 Retractable Starter Rope Replacement The rope can be replaced without complete starter disassembly. 1. Remove the starter from the engine blower housing. 9. Insert the new rope through the rope hole in starter pulley and rope guide bushing of housing. See Figure 7-4. Keep Pulley from Rotating 2. Pull the rope out approximately 12" and tie a temporary (slip) knot in it to keep it from retracting into the starter. See Figure 7-3.
Section 7 Retractable Starter Disassembly 4. Carefully note the positions of the pawls and pawl springs before removing them. CAUTION: Spring Under Tension! Do not remove the center screw from the starter until the spring tension is released. Removing the center screw before releasing spring tension, or improper starter disassembly, can cause the sudden and potentially dangerous release of the spring. Follow these instructions carefully to ensure personal safety and proper starter disassembly.
Section 7 Retractable Starter Inspection and Service 1. Carefully inspect the rope, pawls, housing, center screw, and other components for wear or damage. Pulley & Spring 2. Replace all worn or damaged components. Use only genuine Kohler replacement parts as specified in the Parts Manual. All components shown in Figure 7-1 are available as service parts. Do not use nonstandard parts. 3. Do not attempt to rewind a spring that has come out of the keeper. Order and install a new spring and keeper assembly. 4.
CV11-16 Section 8 CV460-465, CV490-495 Electrical System and Components Go Back Section 8 Electrical System and Components This section covers the operation, service, and repair of the electrical system and electrical system components. Major electrical systems and components covered in this section include the ignition system, battery, battery charging systems, and electric starters. WARNING: Electrical Shock Never touch electrical wires or components while the engine is running.
Section 8 Electrical System and Components 4. Reinstall the spark plug into the cylinder head. Torque the spark plug to 24.4-29.8 N·m (18-22 ft. lb.). Inspection Inspect the spark plug as soon as it is removed from the cylinder head. The deposits on the tip are an indication of the general condition of the piston rings, valves, and carburetor. Normal and fouled plugs are shown in the following photos. Chalky White Deposits: Chalky white-colored deposits indicate overheating.
Section 8 Electrical System and Components Electronic Magneto Ignition System, CV11-15, CV460-465, CV490-495 Engines Spark Plug Boot Spark Plug Terminal (C) Spark Plug Air Gap 0.2-0.3 mm (0.008-0.012 in.) Ignition Module Magnet Lamination (A) Kill Terminal (B) Flywheel Kill Switch or Off Position of Key Switch Figure 8-2. Electronic Magneto Ignition System, CV11-15, CV460-465, CV490-495 Engines. CV11-15, CV460-465, CV490-495 engines are equipped with a dependable electronic magneto ignition system.
Section 8 Electrical System and Components Magneto Ignition System Troubleshooting Guide The following guide will help locate and correct ignition system problems. Problem Engine Will Not Start Conclusion Test 1. Make sure the spark plug lead is connected to the spark plug. 2. Check the condition of spark plug. Make 2. If plug is in good condition, check/adjust sure gap is set correctly. See page 8.1. gap and reinstall. 3. a. Test for spark with ignition tester, Part 3.
Section 8 Electrical System and Components Electronic Ignition System with Spark Advance (Smart Spark™), CV16 Engines 12 Volt Battery Kill Switch or Off Position of Key Switch Spark Advance Module Spark Plug Air Gap (0.2/0.3 mm) 0.008/0.012 in. Ignition Module Magnet Flywheel Figure 8-5. Capacitive Discharge Ignition System with Spark Advance. The CV16 engines are equipped with an electronic capacitive discharge ignition system with electronic spark advance.
Section 8 Electrical System and Components Operation As the flywheel rotates, the magnet grouping passes the input coil (L1) of the ignition module, inducing energy in the coil. The resultant pulse is rectified by diode (D1) and charges capacitor (C1). Current from the same pulse also travels through the brown lead to the spark advance module (SAM), and enters the input of the conditioning circuit. The conditioning circuit shapes this pulse, putting it in a useable form for the other circuits.
Section 8 Electrical System and Components Troubleshooting CD Ignition Systems The CD ignition system is designed to be trouble-free for the life of the engine. Other than periodically checking/replacing the spark plug, no maintenance or timing adjustment is necessary or possible. Mechanical systems do occasionally fail or break down, however, so the following troubleshooting information is provided to help you get to the root of a reported problem.
Section 8 Electrical System and Components 4. Remove the blower housing from the engine. a. Trace the black ground lead from the SAM and check that the ground tab and terminal connections are all tight. Recheck voltage at engine connector. If voltage is still low, check battery, key switch, and wiring on unit. b. When you are certain there is proper voltage at the connector, retest for spark. If there is still no spark, proceed to step 5. 5. If you skipped step 4, remove the blower housing at this time.
Section 8 Electrical System and Components Battery Test 3 Amp Charging Stator Test the battery voltage by connecting DC voltmeter across the battery terminals - crank the engine. If the battery drops below 9 volts while cranking, the battery is discharged or faulty. Refer to Figure 8-8. Lighting Lead (Yellow) DC Voltmeter Lighting Stator Diode Charging Lead (Black) Battery Figure 8-9. 3 amp/70 Watt Stator. 1. Make sure the battery polarity is correct. A negative (-) ground system is used.
Section 8 Electrical System and Components Ground-To-Kill Lead (White) A Light R S (Blue) GND Ignition Module Diode B (Red) Spark Plug Key Switch (Black) Optional Fuse Flywheel Stator (Green) (Yellow) Optional Optional Oil SentryTM Ammeter Switch (Indicator Optional Light) Oil TM Sentry Switch 12 V. Battery (Shutdown) Optional 70 Watt Lighting Stator Optional Stator Brake Safety Switch Solenoid Starter Figure 8-10. CV11-15, CV460-465, CV490-495 3 amp Unregulated Battery Charging System.
Section 8 Electrical System and Components Troubleshooting Guide 3 amp Battery Charging System with 70 Watt Lighting Stator NOTE: Zero ohmmeters on each scale to ensure accurate readings. Voltage tests should be made with engine running at 3000 RPM - no load. Battery must be fully charged. Problem Test 1. With engine running at 3000 RPM, measure voltage across battery terminals using a DC voltmeter. 2. Disconnect the charging lead from battery.
Section 8 Electrical System and Components Troubleshooting Guide 3 amp/70 Watt Braking Stator NOTE: Zero ohmmeteres on each scale to ensure accurate readings. Voltage tests should be made with engine running at 3400 RPM - no load. Battery must be fully charged. Problem Test 1. With engine running at 3400 RPM, measure voltage across battery terminals using a DC voltmeter. 2. Disconnect the charging lead (black) from the wiring harness.
Section 8 Electrical System and Components Problem No Lights Or Battery Charging (Braking System Test) Test 1. Make sure lights are not burned out. 2. Disconnect the braking lead (green) from the wiring harness. With engine running at 3400 RPM, measure voltage from braking lead to ground using an AC voltmeter. 3. With the engine stopped, measure the resistance from braking lead to ground using an ohmmeter. Conclusion 1. Replace burned out lights. 2. If voltage is 35 volts or more, stator is OK.
Section 8 Electrical System and Components CV11-15, CV460-465, CV490-495 Electric Start Engines 15 amp Battery Charging System Ground-to-Kill Lead (White) (Violet) A R M S (Blue) GND B (Red) Rectifier Regulator AC B+ Key Switch Flywheel Stator AC Optional Fuse Auto Choke Diodes Optional Ammeter Optional Oil Optional Oil Sentry™ Switch Sentry™ (Indicator Switch _ (Shutdown) Light) Spark Plug Ignition Module Fuel Solenoid + Battery Solenoid Starter Figure 8-12.
Section 8 Electrical System and Components Rectifier-Regulator AC Leads AC AC B+ 15 Amp Stator Figure 8-14. 15 amp Stator and Rectifier-Regulator. DC Volt Meter Rectifier-Regulator AC 8 B+ AC Flywheel Stator (-) Battery Ammeter Figure 8-15. Proper Connection to Test 15 amp Charging System. 8.
Section 8 Electrical System and Components Troubleshooting Guide 15 amp Regulated Battery Charging System. NOTE: Zero ohmmeters on each scale to ensure accurate readings. Voltage tests should be made with engine running at 3600 RPM - no load. The battery must be fully charged. Problem Test 1. Trace B+ lead from rectifier-regulator to key switch, or other accessible connection. Disconnect it from switch or connection. Connect an ammeter from loose end of B+ lead to positive terminal of battery.
Section 8 Electrical System and Components Electric Starters Some engines in this series use inertia drive starting motors while others use solenoid shift type. The inertia drive types are covered first and the solenoid shift type is covered starting on page 8.23. NOTE: If the starter does not crank the engine, shut off the starter immediately. Do not make further attempts to start the engine until the condition is corrected. NOTE: Do not drop the starter or strike the starter frame.
Section 8 Electrical System and Components Operation - Inertia Drive Starters When power is applied to the starter, the armature rotates. As the armature rotates, the drive pinion moves out on the splined drive shaft and into mesh with the flywheel ring gear. When the pinion reaches the end of the drive shaft, it rotates the flywheel and “cranks” the engine. When the engine starts, the flywheel rotates faster than the starter armature and drive pinion.
Section 8 Electrical System and Components Style "B" Drive Service 1. The rubber dust cover has a molded lip on the inside that snaps into a groove in the dust cover spacer (see Figure 8-17). Turn the drive pinion clockwise until it reaches the fully extended position. While holding it in the extended position, grasp the tip of the dust cover with a pliers or vise grip and pull it free from the spacer. Dust Cover Spring Retainer Retaining Ring Anti-Drift Spring Figure 8-18.
Section 8 Electrical System and Components Retaining Ring Installation 1. Position the retaining ring in the groove in one of the inner halves. Assemble the other half over the top and slide on the outer collar. 2. Be certain the drive components are installed in correct sequence onto the armature shaft. 3. Slip the tool over the end of the armature shaft, so the retaining ring inside is resting on the end of the shaft. Hold the tool with one hand, exerting slight pressure toward the starter.
Section 8 Electrical System and Components NOTE: Use a brush holder tool to keep the brushes in the pockets. A brush holder tool can easily be made from thin sheet metal See Figure 8-22. Stud Terminal with Positive (+) Brushes Negative (-) Brush Self-Tapping Screw Brush Holder Starter Reassembly 1. Place the thrust washer (if so equipped) over the drive shaft of armature. 2. Insert the armature into the starter frame. Make sure the magnets are closer to the drive shaft end of armature.
Section 8 Electrical System and Components 6. Install the thru bolts and tighten securely. 7. Lubricate the drive shaft with Kohler bendix starter drive lubricant (Part No. 52 357 01-S). Install the drive components following the instructions for servicing the drive. Figure 8-24. Style "B" Commutator End Cap with Brushes. 110 Volt AC Starter Some engines, on floor care equipment, are equipped with 110 volt, UL approved starters. See Figure 8-25. These starters have no serviceable components.
Section 8 Electrical System and Components Solenoid Shift Electric Starters The following subsection covers the solenoid shift electric starters. Much of the information in the preceding subsection relates to these starters, therefore it is not repeated here. Refer to Figure 8-26 for disassembly and assembly procedure of the UTE solenoid shift starter. The Nippendenso solenoid shift starter is covered starting on page 8.24. The Delco solenoid shift starter starts on page 8.28.
Section 8 Electrical System and Components Operation (Solenoid Shift Starters) 3. Place lever in position on drive shaft. When power is applied to the starter the electric solenoid moves the drive pinion out onto the drive shaft and into mesh with the flywheel ring gear. When the pinion reaches the end of the drive shaft it rotates the flywheel and cranks the engine. 4.
Section 8 Electrical System and Components Nut Drive End Cap Frame Wire Drive Lever Front Stop Collar Dust Cover Retainer Rear Stop Collar Starter Assembly Brushes Brush Holder Brush Spring Solenoid Insulator Nut Drive Pinion Commutator End Cap Thru Bolt 8 Armature Figure 8-27. Nippendenso Solenoid Shift Starter. 9. When the stop collars are removed, the retainer can be removed from the armature shaft.
Section 8 Electrical System and Components Starter Reassembly 1. Install the drive pinion onto the armature shaft. 2. Slide the stop collar onto the armature shaft below the retaining ring groove. Make sure the recessed side of the stop collar is ‘‘up’’. 3. Position a new retainer in the groove of the armature shaft, and carefully tighten with a pliers to secure. NOTE: Always use a new retainer. Do not nick or damage armature shaft. 4.
Section 8 Electrical System and Components 8. Position the insulator over the brushes and springs. Hold it firmly in place so the springs do not come out. See Figure 8-31. Figure 8-33. Installing Frame with Brush Plate Assembly. Figure 8-31. Holding Insulator in Place. 11. Remove the tool and install the commutator end cap, aligning the cutout with the insulating grommet. See Figure 8-34. 9. Stand the armature/drive end cap assembly on end so the commutator end is ‘‘up’’.
Section 8 Electrical System and Components Starter Disassembly 1. Remove the hex. nut and disconnect the positive brush lead/bracket from the solenoid terminal. 2. Remove the three screws securing the solenoid to the starter. Remove the solenoid and plunger spring from the drive end cap. See Figures 8-38 and 8-39. Some solenoids are fastened with external Torx head screws. Figure 8-35. Installing Thru Bolts. 14. Connect the braided (brush) lead to lower main solenoid terminal and secure with the hex.
Section 8 Electrical System and Components 3. Lift and unhook the plunger assembly from the drive lever. Remove the gasket from the recess in the housing. See Figure 8-40. Figure 8-42. Removing Commutator End Plate Assembly. Figure 8-40. Removing Plunger. 6. Remove the frame from the armature and drive end cap. See Figure 8-43. 4. Remove the two thru (larger) bolts. See Figure 8-41. 8 Figure 8-43. Starter Frame Removed. Figure 8-41. Removing Thru Bolts. 7.
Section 8 Electrical System and Components 8. Take out the drive lever and pull the armature out from the drive end cap. See Figure 8-45. 9. Remove the thrust washer from the armature shaft. See Figure 8-45. Figure 8-47. Removing Retaining Ring. 12. Remove the drive pinion assembly from the armature. Figure 8-45. Armature and Lever Removed. 10. Push the stop collar down to expose the retaining ring. See Figure 8-46. Figure 8-46. Retaining Ring Detail. 11. Remove the retainer from the armature shaft.
Section 8 Electrical System and Components Screw Collar Ring Stop Plunger Spring Drive Lever Plate Plug Armature Solenoid Frame & Field Washer Brush Holder Nut Tube CE Frame ASM 8 Screw Bolt Figure 8-48. Delco-Remy Solenoid Shift Starter. Inspection Drive Pinion Check and inspect the following areas: a. The pinion teeth for abnormal wear or damage. Brushes and Springs Inspect both the springs and brushes for wear, fatigue, or damage. Measure the length of each brush.
Section 8 Electrical System and Components Armature 1. Clean and inspect the commutator (outer surface). The mica insulation of the commutator must be lower than the O.D surface (undercut) to ensure proper operation of the commutator. See Figure 8-50. Commutator O.D. Brush Replacement The brushes and springs are serviced as a set (4). Use Brush and Spring Kit, Kohler Part No. 25 221 01-S, if replacement is necessary. 1. Perform steps 1-5 in “Starter Disassembly.” 2.
Section 8 Electrical System and Components Starter Service Clean the drive lever and armature shaft. Apply Kohler electric starter drive lubricant, Part No. 52 357 02-S (Versilube G322L or Mobil Temp SHC 32), to the lever and shaft. Clean and check the other starter parts for wear or damage as required. Starter Reassembly 1. Apply new drive lubricant (Kohler Part No. 52 357 02-S) to the armature shaft splines. Install the drive pinion onto the armature shaft. 2.
Section 8 Electrical System and Components 7. Install the backup washer, followed by the rubber grommet, into the matching recess of the drive end cap. The molded recesses in the grommet should be “out”, matching and aligned with those in the end cap. See Figure 8-57. Figure 8-59. Installing Thrust Washer. 10. Starter reassembly when replacing the Brushes/ Brush Holder Assembly: Figure 8-57. Installing Backup Washer and Grommet. 8.
Section 8 Electrical System and Components Figure 8-61. Removing Retaining Caps. b. Position each of the brushes back in their slots so they are flush with the I.D. of the brush holder assembly. Insert Brush Installation Tool No. KO3226-1 (w/extension), or use the tube described above from a prior brush installation, through the brush holder assembly, so the holes in the metal mounting clips are “up/out.” c. Install the brush springs and snap on the four retainer caps. See Figure 8-62. Figure 8-63.
Section 8 Electrical System and Components Figure 8-65. Torquing Brush Holder Screws. Figure 8-67. Positive Brush Lead Connection. 13. Hook the plunger behind the upper end of the drive lever, and install the spring into the solenoid. Insert the three mounting screws through the holes in the drive end cap. Use these to hold the solenoid gasket in position, then mount the solenoid. Torque the screws to 4.0-6.0 N·m (35-53 in. lb.). See Figure 8-66. Completed Starter Photo Figure 8-68.
CV11-16 Section 9 CV460-465, CV490-495 Disassembly Go Back Section 9 Disassembly 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. The following sequence is suggested for complete engine disassembly. This procedure can be varied to accommodate options or special equipment.
Section 9 Disassembly Muffler Spark Plug Lead Hex. Flange Nuts Oil Filter Gasket Oil Drain Optional Oil Sentry™ Switch or Oil Filter Drain Plug Figure 9-1. Removing Spark Plug Lead, Oil Drains, Oil Filter, and Oil Sentry™ Switch (oil filter drain plug not on all models). Figure 9-3. Removing Muffler. Remove Retractable Starter 1. Remove the five hex. flange screws and retractable starter. See Figure 9-4. Remove Muffler 1. Remove the hex. flange nuts from exhaust studs and hex.
Section 9 Disassembly Breather Hose Hex. Flange Screws Hose Clamps Air Cleaner Base Electric Starter Valve Cover Stud Terminal Gasket Hex. Flange Nuts Figure 9-5. Removing Bendix Drive Starter. Figure 9-7. Removing Air Cleaner Base. Remove Air Cleaner Remove External Governor Components and Carburetor 1. Loosen the knob and remove the air cleaner cover. See Figure 9-6. 2. Remove the wing nut, air cleaner element, and precleaner (if so equipped). 3.
Section 9 Disassembly 3. Remove the two hex. flange screws and speed control bracket. See Figure 9-9. Choke Linkage Speed Control Bracket Choke Control Lever Mounting Screws Hex. Flange Nut Ground Lead (some models) Baffle Screw and Washer Figure 9-11. Removing Baffle Screw and Washer. Governor Lever Figure 9-9. Removing Speed Control Bracket. 4. Disconnect the choke linkage from the choke control lever of speed control bracket. 5. Loosen the hex.
Section 9 Disassembly Remove Rectifier-Regulator (If Required) Blower Housing 1. Remove the connector from the rectifier-regulator. See Figure 9-13. Mounting Screws 2. Remove the two screws securing the rectifierregulator and individual ground lead (if used). Hex. Flange Screws RectifierRegulator Cylinder Cylinder Baffle Baffle Mounting Screw Figure 9-15. Removing Blower Housing and Baffles. Ground Lead Connector Mounting Screws Figure 9-13. Removing Rectifier-Regulator (not on all models).
Section 9 Disassembly 3. Remove the hex. flange nut on stud securing the carburetor side baffle,* if not removed previously during carburetor removal. Remove the screws attaching the cylinder head baffle. See Figure 9-18. Hex. Flange Screws * If so equipped. Blower Housing Back Plate Figure 9-20. Removing Back Plate. Remove Ignition Module Cylinder Baffle (Carburetor Side) Cylinder Head Baffle Hex. Flange Nut or Screw Figure 9-18. Removing Blower Housing and Baffles. 4.
Section 9 Disassembly Rubber Grommet Fuel Line Hex. Flange Screw and Clip If the push rods will be reused, they should be marked with a piece of tape ("I" or "E" at the time of removal, so they are reinstalled in the same location. See Figures 9-24 and 9-25. Hex. Flange Screws Figure 9-22. Removing Fuel Line (not on all models). Remove Valve Cover and Cylinder Head 1. Remove the remaining hex. flange mounting screws and any loose spacers (stamped steel covers) from the valve cover.
Section 9 Disassembly Exhaust Side Rocker Shaft Rocker Arms Hex. Flange Screw Breather Reed Retainer and Breather Reed Valve Spring Cap Valve Keepers Rocker Arm Rocker Arm Spark Plug Pivot Ball Breather Reed Parts Guide Plate Non-Adjustable Figure 9-26. Removing Spark Plug, Breather, and Rocker Arms (Rocker Bridge Head). Rocker Arm 2. Remove the hex. flange screw, breather reed retainer, and breather reed. Rocker Arm Adj. Nut with Set Screw 3. Rocker Bridge Heads - Figure 9-26 a.
Section 9 Disassembly Plain Washer Hex. Flange Screw Drive Cup Figure 9-28. Removing Valves with Valve Spring Compressor. Figure 9-30. Removing Flywheel Retaining Screw and Drive Cup. (Recoil Start Models.) Strap Wrench Figure 9-29. Removing Valves. (Bridge Type Head.) Remove Drive Cup, Grass Screen, Flywheel and Fan NOTE: Always use a flywheel strap wrench or flywheel holding tool (see Section 2) to hold the flywheel when loosening or tightening the flywheel retaining screw.
Section 9 Disassembly 1. Check if the extra retaining clips are present. If so, cut the clips, so they can be removed and discard. Mark the tops of the knobs where they were located. Order 3 new clips, Part No. 24 018 03-S, for installation during reassembly. Hex. Flange Screws (4) Spacers (4) Fan Flywheel 2. Remove the screen by unsnapping it from the fan. See Figure 9-32. Unsnap Grass Screen from Fan Fan Figure 9-34. Removing Fan from Flywheel. Remove the Stator and Wiring Harness 1.
Section 9 Disassembly Hex. Flange Screws (12) Hex. Flange Screw Oil Pickup Screen Cover Oil Pan Figure 9-36. Removing Oil Pan. 3. Locate the splitting tabs on the oil pan and crankcase. Insert the drive end of a 3/8" breaker bar between the splitting tabs and rotate the handle to break the RTV seal between the crankcases and oil pan. See Figure 9-37. Oil Pickup Screen Figure 9-38. Removing Oil Pickup. 3. Identify the type of oil pressure relief valve used.
Section 9 Disassembly Hex. Flange Screws Oil Pump Cover O-Ring Oil Pump Rotors Figure 9-41. Later Style - Oil Pressure Relief Valve. NOTE: Later one-piece relief valves (Figure 9-41) are staked in place and do not require removal, unless replacement is necessary. 4. Remove the three hex. flange screws, oil pump cover, O-Ring, and oil pump rotors. See Figures 9-42 and 9-43. Figure 9-43. New Style - Removing Oil Pump Covers and Rotors. Hex.
Section 9 Disassembly Remove Balance Shaft 1. Remove the balance shaft from the crankcase. See Figure 9-45. On CV460-495 engines rotate the crankshaft clockwise so the timing marks are one to two teeth past being aligned. See Figure 9-46. This will permit the counterweights of the two shafts to clear. Connecting Rod Cap Hex. Flange Screws Balance Shaft Figure 9-47. 2. Carefully push the connecting rod and the piston away from the crankshaft and out of the cylinder bore.
Section 9 Disassembly Remove Piston Rings Plain Washer 1. Remove the top and center compression rings using a ring expander tool. See Figure 9-49. Hitch Pin Governor Cross Shaft Piston Ring Plain Washer Piston Ring Expander Figure 9-51. Removing Governor Cross Shaft. 2. Remove the cross shaft and plain washer from the crankcase. Figure 9-49. Removing Piston Rings. 2. Remove the oil control ring rails, then remove the spacer. 3. Remove the governor shaft oil seal from the crankcase. See Figure 9-52.
Section 9 Disassembly Regulating Pin Governor Gear Figure 9-53. Removing Governor Gear. 9 9.
Section 9 Disassembly 9.
CV11-16 Section 10 CV460-465, CV490-495 Inspection and Reconditioning Go Back Section 10 Inspection and Reconditioning This section covers the operation, inspection, and repair/reconditioning of major internal engine components. The following components are not covered in this section. They are covered in sections of their own: Air Cleaner, Section 4 Carburetor & External Governor, Section 5 Retractable Starter, Section 7 Ignition, Charging & Electric Starter, Section 8 Clean all parts thoroughly.
Section 10 Inspection and Reconditioning 4. The choke control setting is less critical with ACR. In the event of flooding, excess fuel is blown out the opened exhaust valve and does not hamper starting. 5. Engines with ACR start much faster in cold weather than engines without ACR. 6. Engines with ACR can be started with spark plugs that are worn or fouled. Engines without ACR probably could not be started with those same spark plugs. Camshaft Inspection and Service Inspect the gear teeth of the camshaft.
Section 10 Inspection and Reconditioning Self-Tapping Screw Flat Washer 12345678 12345678 12345678 12345678 Plug Crankshaft Figure 10-2. Removing Plug. Crankcase Inspection and Service Check all gasket surfaces to make sure they are free of gasket fragments. Gasket surfaces must also be free of deep scratches or nicks. Check the cylinder bore wall for scoring. In severe cases, unburned fuel can cause scuffing and scoring of the cylinder wall.
Section 10 Inspection and Reconditioning Use the following procedure to accurately measure the piston-to-bore clearance: 1. Use a micrometer and measure the diameter of the piston perpendicular to the piston pin, and up from the bottom of the piston skirt as indicated in Figure 10-4, based on the model involved. Measure 6 mm (0.24 in.) on CV11-14, CV460-465 Engines, 8.5 mm (0.33 in.) on CV15,16, CV490-495 Engines, Above the Bottom of Piston Skirt at Right Angles to Piston Pin. Figure 10-3.
Section 10 Inspection and Reconditioning Hard starting or loss of power, accompanied by high fuel consumption, may be symptoms of faulty valves. Although these symptoms could also be attributed to worn rings, remove and check the valves first. After removal, clean the valve heads, faces, and stems with a power wire brush. Then, carefully inspect each valve for defects such as warped head, excessive corrosion, burned face, or worn stem end. Replace valves found to be in bad condition.
Section 10 Inspection and Reconditioning Normal: Even after long hours of operation a valve can be reconditioned and reused if the face and margin are in good shape. If a valve is worn to where the margin is less than 1/32" do not reuse it. The valve shown was in operation for almost 1000 hours under controlled test conditions. Leakage: A poor grind on face or seat of valve will allow leakage resulting in a burned valve on one side only. Bad Condition: The valve depicted here should be replaced.
Section 10 Inspection and Reconditioning Excessive Combustion Temperatures: The white deposits seen here indicate very high combustion temperatures, usually due to a lean fuel mixture. Stem Corrosion: Moisture in fuel or from condensation are the most common causes of valve stem corrosion. Condensation occurs from improper preservation during storage and when engine is repeatedly stopped before it has a chance to reach normal operating temperatures. Replace corroded valves.
Section 10 Inspection and Reconditioning Valve Guides If a valve guide is worn beyond specifications, it will not guide the valve in a straight line. This may result in burnt valve faces or seats, loss of compression, and excessive oil consumption. To check valve guide-to-valve stem clearance, thoroughly clean the valve guide and, using a split-ball gauge, measure the inside diameter.
Section 10 Inspection and Reconditioning Ring failure is usually indicated by excessive oil consumption and blue exhaust smoke. When rings fail, oil is allowed to enter the combustion chamber where it is burned along with the fuel. High oil consumption can also occur when the piston ring end gap is incorrect, because the ring cannot properly conform to the cylinder wall. Oil control is also lost when ring gaps are not staggered during installation.
Section 10 Inspection and Reconditioning Some important points to remember when servicing piston rings: 1. If the cylinder bore does not need reboring and if the old piston is within wear limits and free of score or scuff marks, the old piston may be reused. 2. Remove old rings and clean up grooves. Never reuse old rings. 3. Before installing the rings on the piston, place each of the top two rings in its running area in the cylinder bore and check the end gap (see Figure 10-8). This gap should be 0.
Section 10 Inspection and Reconditioning 1. Oil Control Ring (Bottom Groove): Install the expander and then the rails. Make sure the ends of the expander are not overlapped. 2. Compression Ring (Center Groove): Install the center ring using a piston ring installation tool. Make sure the ‘‘pip’’ mark is up and the PINK dykem stripe (if present) is to the left of the end gap. 3. Compression Ring (Top Groove): Install the top ring using a piston ring installation tool.
Section 10 Inspection and Reconditioning Procedure to Install Governor Shaft: 1. Install new pin by pressing or lightly tapping into crankcase. It must be installed so that it protrudes 1.289 plus or minus .004 in. above the crankcase boss. See Figure 10-13. Stamped Steel Valve Cover If the engine has stamped steel valve cover, the sealing surface must be checked for flatness prior to reinstallation.
Section 11 CV11-16 CV460-465,Reassembly CV490-495 Go Back Section 11 Reassembly The following sequence is suggested for complete engine reassembly. This procedure assumes that all components are new or have been reconditioned, and all component subassembly work has been completed. This procedure may be varied to accommodate options or special equipment. NOTE: Make sure the engine is assembled using all specified torque values, tightening sequences, and clearances.
Section 11 Reassembly 3. Using the KO1030 oil seal installer, install a new governor cross shaft oil seal into the crankcase. See Figure 11-2. Crankshaft Cross Shaft Oil Seal Figure 11-4. Installing Crankshaft. Install Piston Rings Figure 11-2. Cross Shaft Oil Seal. 4. Install smaller plain washer to the cross shaft and insert the cross shaft (from inside) through the crankcase and oil seal. See Figure 11-3. 5. Install larger plain washer and hitch pin.
Section 11 Reassembly On CV460-495 models the offset of the connecting rod and cap must be oriented to the left, with the part number up. The arrow on the piston must point away from the part number. See Figure 11-6 and 11-7. Piston Ring Compressor Installed around Piston Figure 11-6. Connecting Rod Configuration to Piston with the Part Number "up". Figure 11-8. Installing Piston and Connecting Rod. Figure 11-7. Arrow on Piston. Install Piston and Connecting Rod 3.
Section 11 Reassembly 4. Lubricate the crankshaft journal and connecting rod bearing surfaces with engine oil. Install the rod cap to connecting rod. 5. Three different types of connecting rod bolts have been used in production and each has a different torque value. See Figures 11-10 and 11-11. The 8 mm straight shank style rod bolts must be torqued in increments to 22.7 N·m (200 in. lb.). The 8 mm step-down shank style rod bolts must be torqued in increments to 14.7 N·m (130 in. lb.).
Section 11 Reassembly Installing Camshaft 1. Lubricate the camshaft lobes and bearing surfaces with engine oil. 2. Align the timing marks on the camshaft gear and the smaller crankshaft gear. Lower the camshaft into the bearing surface in crankcase. Make sure the camshaft gear and smaller gear on crankshaft mesh and the timing marks are aligned. See Figure 11-13. 3. Using a flat feeler gauge, measure the camshaft end play between the shim* spacer and the end play checking tool.
Section 11 Reassembly 3. Push bracket down until it seats against top of relief valve body. Secure with hex. flange screw. See Figure 11-16. Hex. Flange Screw Oil Pressure Relief Bracket Relief Valve Body Figure 11-18. Inserting New Relief Valve into Bore of Closure Plate. Figure 11-16. Installing Oil Pressure Relief Valve Bracket. 3. Stake the casting boss with a center punch in 3 or 4 locations near the inner edge to lock the relief valve into place. See Figure 11-19. Do not use Loctite®.
Section 11 Reassembly Hex. Flange Screw Oil Pickup Screen Cover 3. Install the oil pan to the crankcase and install the twelve hex. flange screws. Tighten the screws hand tight. 4. Torque the fasteners, in the sequence shown in Figure 11-22 to 24.4 N·m (216 in. lb.). 12 Oil Pickup Screen 1 3 5 10 Figure 11-20. Installing Oil Pickup Components. 7 8 9 Install Oil Pan to Crankcase RTV silicone sealant is used as a gasket between the oil pan and crankcase. Refer to page 2.1 for the approved sealant.
Section 11 Reassembly Install Oil Pump 1. Lubricate the oil pump cavity and oil pump rotors with engine oil. Install the outer and inner oil pump rotors. See Figure 11-23. Outer Rotor Hex. Flange Screws Oil Pump Cover Inner Rotor Hex. Flange Screws Oil Pump Cover Outer Rotor Balance Shaft Inner Rotor Figure 11-24. Installing Oil Pump Cover. Torque the screws as follows: Into new as-cast hole–6.2 N·m (55 in. lb.). Into used hole–4.0 N·m (35 in. lb.). Figure 11-23. Installing Oil Pump Gears and O-Ring.
Section 11 Reassembly Install Fuel Line 1. Install the grommet to the carburetor side of fuel line. 2. Install the fuel line, clamp and hex. flange screw. Make sure the grommet is inserted in the notch in the crankcase. See Figure 11-27.* Oil Seal *Not on all models. Rubber Grommet KO1036 Handle and KO1027 Driver Fuel Line Figure 11-25. Installing Oil Seals. Install Stator and Wiring Harness 1. Push the stator leads through the hole to the outside of the crankcase. See Figure 11-26. Stator Hex.
Section 11 Reassembly 2. Reattach the fan to the flywheel, using the spacers and hex. flange screws, or shoulder screws. See Figure 11-28. Torque the hex. flange screws to 9.9 N·m (88 in. lb.). On electric start models, with the domed fan, proceed through step 4 before reattaching the fan. Hex. Flange Screw Washer Hex. Flange Screws (4) Spacers (4) Fan Fan Figure 11-30. Installing Flywheel Retaining Screw and Washer (Electric Start Models). Flywheel 4.
Section 11 Reassembly Figure 11-34. Push Rod Tool. Figure 11-32. Torquing Flywheel Fastener (Electric Start Models). NOTE: Another tool for bleeding may be made from an old tappet and ball bearing welded together. See Figure 11-35. 5. Install the grass screen onto the fan assembly (electric start models). See Figure 11-33. If the engine originally had extra retainers on three of the snap knobs, you were instructed to mark those knobs during the disassembly procedure. Install new retainers (Part No.
Section 11 Reassembly Reassemble Cylinder Head Refer to Figure 11-37 for cylinder head differences. Assemble the components accordingly, based on head configuration involved.
Section 11 Reassembly Rocker Bridge Hex. Cap Screws Heads with Separate Pivots/Rocker Arms– Figure 11-37 • Non-Adjustable Valve Lash Configuration a. Position the pivots in the sockets of the rocker arms. Insert the screws through the pivots, rocker arms, and guide plate (some models). Start the screws into the cylinder head and finger tighten only at this time. Exhaust Valve Rotator Intake Valve Stem Seal Intake Valve Spring Seat Figure 11-38. Installing Rocker Bridge and Valves.
Section 11 Reassembly b. Start the set screw into the nut, but only a few turns or it may hamper lash adjustment. Start the adjustment nut with the set screw on the end of each stud. b. Apply Loctite® No. 59241 thread sealant to the threads of two of the shorter (81 mm/3.1 in.) head bolts, and install them into location 3 and 4. See Figure 11-44. c. If the engine has a high temperature cutout switch, insert a long (90 mm/3.5 in.
Section 11 Reassembly Heads with Separate Pivots/Rocker Arms– Figure 11-37 • Non-Adjustable Valve Lash Configuration a. Seat the push rods into sockets under the end of the rocker arm and align the rocker arms over the valve stems. Hold the rocker arm in the position and torque the screws to 11.3 N·m (100 in. lb.). See Figure 11-45. Figure 11-46. Adjusting Valve Lash. d. Hold the adjustment nut from turning and tighten the set screw to lock it in position. Torque the set screw to 7.3 N·m (65 in. lb.).
Section 11 Reassembly Install Ignition Module 1. Rotate the flywheel so the magnet is away from the ignition module bosses. Install the ignition module to the bosses on crankcase, using the hex. flange screws. The directional arrow (on some modules) denoting proper flywheel rotation must be up. Move the module as far from the flywheel/magnet as possible. Tighten the hex. flange screws slightly. 2. Insert a 0.25 mm (0.010 in.) flat feeler gauge or shim stock between the magnet and ignition module.
Section 11 Reassembly Mounting Screws Gasket Intake Studs Heat Deflector Silver Screw for Ground Lead Figure 11-51. Installing Heat Deflector and Carburetor Side Baffle (not on all models). 4. Install the cylinder head baffle and secure with the two hex. flange screws. Later production models use one screw and one hex. flange nut. See Figure 11-52. Figure 11-53. Installing Blower Housing. Mounting Screws Cylinder Head Baffle Figure 11-54. Installing Blower Housing. Hex.
Section 11 Reassembly 2. Apply a 1/16" bead of RTV sealant to the cylinder head as shown in Figure 11-55. NOTE: To ensure proper adhesion of the sealant to both sealing surfaces, perform Step 3 immediately (5 minutes maximum) after application of RTV sealant. 4 2 1 5 3 Figure 11-57. Valve Cover Torque Sequence. Install Extended Oil Fill Tube 1. Make sure the two O-Rings on the oil fill tube and the O-Ring in the oil fill cap are in place. Figure 11-55. Valve Cover Sealant Pattern. 3.
Section 11 Reassembly Install Carburetor and External Governor Components Mounting Screws and Washers 1. Install the rubber fuel line and secure the rubber fuel line to the metal fuel line with a hose clamp. 2. Install the bushing and attach the throttle linkage to the carburetor throttle lever. See Figure 11-61. RectifierRegulator Bushing Throttle Linkage Connector Ground Lead Figure 11-59. Installing Rectifier-Regulator (not on all models). Install Fuel Pump (If So Equipped) 1.
Section 11 Reassembly 4. Attach the ground lead from carburetor fuel solenoid (if applicable) to the silver screw and lock washer on the cylinder baffle. See Figure 11-63. Carburetor Choke Lever Choke Linkage Choke Lever Silver Screw Speed Control Bracket Governor Lever Grounding Lock Washer Ground Lead Figure 11-63. Attaching the Ground Lead. 5. Install the governor lever onto the cross shaft, but DO NOT tighten at this time.
Section 11 Reassembly b. Grasp the cross shaft with a pliers and turn the shaft couterclockwise as far as it will go, then tighten the hex. nut securely. See Figure 11-66. 5. Be sure the rubber sleeve seal is installed on the air cleaner base stud. Install the air cleaner element and precleaner. Secure the element with the wing nut. See Figure 11-67. Governor Lever Air Duct Knob (Part of Cover) Air Cleaner Cover Governor Shaft Figure 11-66. Adjusting the Governor.
Section 11 Reassembly 6. Install the air cleaner cover and tighten the knob securely. See Figure 11-68. 2. Pull the starter handle out until the pawls engage in the drive cup. Hold the handle in this position and tighten the screws securely. See Figure 11-70. Knob Air Cleaner Cover Figure 11-68. Installing Air Cleaner Cover. Install Electric Starter Figure 11-70. Installing Retractable Starter. Electric Starter (Bendix Drive or Solenoid Shift) 1. Install the starter and secure with the two hex.
Section 11 Reassembly Hex. Flange Screws Muffler Muffler Bracket 5. Before starting the engine, turn the engine over slowly by hand. If it can be turned over completely and compression is noted, the engine can be test run. If, however, it cannot be turned over completely (locks up at some point), return the piston to TDC between the intake and exhaust strokes and wait ten minutes to allow the lifters time to bleed down, then check for compression again.
SERVICE MANUAL COMMAND CV11-16, CV460-465, CV490-495 VERTICAL CRANKSHAFT 1
FOR SALES AND SERVICE INFORMATION IN U.S. AND CANADA, CALL 1-800-544-2444 ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044 FORM NO.: TP-2339-D ISSUED: 3/89 REVISED: 7/02 MAILED: 8/02 LITHO IN U.S.A.
