Kohler Command Pro CS 6HP Engine Service Repair Manual

SERVICE MANUAL COMMAND PRO CS SERIES 4-12 HP HORIZONTAL CRANKSHAFT

Contents Section 1. Safety and General Information ............................................................................

Section 2. Special Tools ...........................................................................................................

Section 3. Troubleshooting .....................................................................................................

Section 4. Air Cleaner and Air Intake System .........................................................................

Section 5. Fuel System and Governor ....................................................................................

Section 6. Lubrication System ................................................................................................

Section 7. Retractable Starter ..................................................................................................

Section 8. Electrical System and Components ......................................................................

Section 9. Disassembly ............................................................................................................

Section 10. Internal Components ............................................................................................

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

1 2 3 4 5 6 7 8 9 10 11

Section 1 Safety and General Information CS4-12

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 owner's manual for other important safety information. This manual contains safety precautions which are explained below. Please read carefully.

WARNING Warning is used to indicate the presence of a hazard that can cause severe personal injury, death, or substantial property damage if the warning is ignored.

CAUTION Caution is used to indicate the presence of a hazard that will or can cause minor personal injury or property damage if the warning 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

Accidental Starts can cause severe injury or death.

Rotating Parts can cause severe injury.

Disconnect and ground spark plug lead before servicing.

Stay away while engine is in operation.

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.

Rotating Parts!

Keep hands, feet, hair, and clothing away from all moving parts to prevent injury. Never operate the engine with covers, shrouds, or guards removed.

WARNING

Hot Parts can cause severe burns.

Do not touch engine while operating or just after stopping.

Hot Parts!

Engine components can get extremely hot from operation. To prevent severe burns, do not touch these areas while the engine is running—or immediately after it is turned off. Never operate the engine with heat shields or guards removed.

1.1

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. 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.

WARNING

Lethal Exhaust Gases!

Engine exhaust gases contain poisonous carbon monoxide.

Carbon monoxide is odorless, colorless, and can cause death if inhaled. Avoid inhaling exhaust fumes, and never run the engine in a closed building or confined area.

WARNING

Uncoiling Spring can cause severe injury.

Wear safety goggles or face protection when servicing retractable starter.

Cleaning Solvents can cause severe injury or death.

Use only in well ventilated areas away from ignition sources.

Flammable Solvents!

Carburetor cleaners and solvents are extremely flammable. Keep sparks, flames, and other sources of ignition away from the area.

Follow the cleaner manufacturer’s warnings and instructions on its proper and safe use. Never use gasoline as a cleaning agent.

1.2

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 the "Retractable Starter" Section 7 for relieving spring tension.

Explosive Gas! Batteries produce explosive hydrogen gas while being charged.

To prevent a fire or explosion, charge batteries only in well ventilated areas. Keep sparks, open flames, and other sources of ignition away from the battery at all times. Keep batteries out of the reach of children. Remove all jewelry when servicing batteries.

Before disconnecting the negative () ground cable, make sure all switches are OFF. If ON, a spark will occur at the ground cable terminal which could cause an explosion if hydrogen gas or gasoline vapors are present.

CAUTION

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.

1

The engine identification numbers appear on a decal (or decals) affixed to the engine shrouding. See Figure 1-1. An explanation of these numbers is shown in Figure 1-2.

Model Designation Model CS6ST for example: C designates Command engine, S designates slanted cylinder configuration, and 6 designates horsepower. A suffix letter designates a specific version as follows:

A. Model No.

C S 6 ST

Command Engine Slanted Cylinder Horsepower 4 = 4 HP 6 = 6 HP 8.5 = 8.5 HP 10 = 10 HP 12 = 12 HP

B. Spec. No. Engine Model Code Code Model 90 CS4 91 CS6 92 CS8.5# 300 cc 93 CS10 94 CS12 95 CS8.5# 250 cc

C. Serial No. Year Manufactured Code Code Year 28 1998 29 1999 30 2000

Identification Decal Figure 1-1. Engine Identification Decal Location.

Suffix T S G P R

Designates Retractable Start Electric Start Tapered Crankshaft Threaded Crankshaft Gear Reduction (2:1 or 6:1)

911509 Variation of Basic Engine

28 23701265 Factory Code

IMPORTANT ENGINE INFORMATION THIS ENGINE MEETS U.S. EPA PHASE 1 AND 2000-2001 CALIFORNIA EMISSION CONTROL REGULATIONS FOR SORE*

FAMILY MODEL NO. SPEC. NO. DISPL (CC) SERIAL NO.

A CS6ST 911509

B

2823701265

C

REFER TO OWNER'S MANUAL FOR SAFETY, MAINTENANCE SPECS, AND ADJUSTMENTS. FOR SALES AND SERVICE IN US/CANADA CALL: 1-800-544-2444

KOHLER CO. KOHLER, WI USA

(Ref.***-*******) *Small Off-Road Engines.

Figure 1-2. Explanation of Engine Identification Numbers. #

NOTE: CS8.5 engines have been produced in two different specification series, 92xxxx and 95xxxx. The design features of 92xxxx spec. no. engines are identical to CS10 and CS12 engines, and share the same service procedures. The 95xxxx spec. no. engines incorporate certain design differences from the 92xxxx spec. no. series. All service and repair information unique to the 95xxxx spec. no. series will be listed and covered separately.

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.

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.

Fuel Recommendations WARNING: Explosive Fuel!

Gasoline is extremely flammable and its vapors can explode if ignited. Store gasoline only in approved containers, in well ventilated, unoccupied buildings, away from sparks or flames. Do not fill the fuel tank while the engine is hot or running, since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition. Do not start the engine near spilled fuel. Never use gasoline as a cleaning agent.

General Recommendations Purchase gasoline in small quantities and store in clean, approved containers. 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.

Figure1-3. Viscosity Grades Table.

Do not add oil to the gasoline.

NOTE: Using other than service class SG, SH, SJ or higher oil or extending oil change intervals longer than recommended can cause engine damage.

Do not overfill the fuel tank. Leave room for the fuel to expand.

A logo or symbol on oil containers identifies the API service class and SAE viscosity grade. See Figure 1-4.

Fuel Type For best results, use only clean, fresh, unleaded gasoline with a pump sticker octane rating of 87 or higher. In countries using the Research method, it should be 90 octane minimum.

Unleaded gasoline is recommended, as it leaves less combustion chamber deposits. Leaded gasoline may be used in areas where unleaded is not available and exhaust emissions are not regulated. Be aware however, that the cylinder head will require more frequent service.

Figure 1-4. Oil Container Logo.

Refer to Section 6-‘‘Lubrication System’’ for detailed oil check and oil change procedures.

1.4

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.

Section 1 Safety and General Information Maintenance Instructions

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.

Frequency

Maintenance Required

Refer to:

Daily or Before Starting Engine

• • • •

Fill fuel tank.

Check oil level.

Check air cleaner for dirty, loose, or damaged parts.1 Check air intake and cooling areas, clean as necessary.1

Section 5 Section 6 Section 4 Section 4

Every 25 Hours

•

Service precleaner element. Replace if necessary.1

Section 4

Every 50 Hours

Every 100 Hours

Annually or Every 300 Hours

• • • • • • • • • • • •

1

Service solid foam element. Replace if necessary.

Change oil.

Replace air cleaner element.1 Remove cooling shrouds and clean cooling areas.1 Check all fittings and fasteners.

Clean fuel shut-off valve filter. Replace if necessary.

Check muffler screen/spark arrestor. Clean/replace if necessary.

Check spark plug condition and gap. Replace if necessary.

2

Check and adjust valve clearance when engine is cold.

Check and adjust idle speed.2 Service starter motor drive, if so equipped.2 Have combustion chamber decarbonized.2

Section 4 Section 6 Section 4 Section 4 Section 1 Section 5 Section 8 Section 11 Section 5 Section 7

¹Perform these maintenance procedures more frequently under extremely dusty, dirty conditions. ²Have a Kohler Engine Service Dealer perform this service.

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 while the engine is still warm from operation. See ‘‘Change Oil’’ on page 6.2.

3. The fuel system must be completely emptied, or the gasoline must be treated with a stabilizer to prevent deterioration. If you choose to use a stabilizer, follow the manufacturers recommendations, and add the correct amount for the capacity of the fuel system. Fill the fuel tank with clean, fresh gasoline. Run the engine for 2-3 minutes to get stabilized fuel into the carburetor.

To empty the system, run the engine until the tank and system are empty.

4. Remove the spark plug. Add one tablespoon of engine oil into the spark plug hole. Install the plug, but do not connect the plug lead. Crank the engine two or three revolutions and then turn it up against compression (when highest pull force or cranking force is required).

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

1.5

Thank you very much for your reading. Please Click Here Then Get More Information.

NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.

Section 1 Safety and General Information

347.00 (13.661) 30.00 (1.181)

373.00 (14.685)

106.00 (4.173) 5/16-24 [qty. 5] 14 mm (.551) deep

66.00 (2.598) 162.00 (6.378)

384.25 (15.128)

321.50 (Straight PTO) (12.657)

143.00 (5.630) 100.00 (3.937)

162.00 (6.378)

145.25 (5.719)

Spark Plug

380.03 (14.962)

Oil Fill Oil Drain Plug Mounting Face

5.00 (.197)

9.0 (.354) dia. [qty. 2]

9.0x14.0 (.354x.551) slot [qty.2]

37.00 (1.457)

44.50 (1.752) 80.00 (3.150)

Figure 1-5. Typical Engine Dimensions CS4 and CS6.

1.6

Dimensions in millimeters.

Inch equivalents shown in ( ).

Section 1 Safety and General Information 454.00 (17.874) 445.85 (17.553)

1

156.68 (6.168) 45° 30°

45° 30°

423.50 (16.673)

452.90 (17.831)

70.00 (2.756)

133.50 (5.256)

127.00 (5.000) dia.

165.10 (6.500) dia.

5/16-24 [qty. 4] 18 mm (.709) deep

5/16-24 [qty. 2] 18 mm (.709) deep 146.08 (5.751) dia.

3/8-16 [qty. 4] 18 mm (.709) deep 110.00 (4.331) dia.

90.50 (3.563) 417.50 (Straight PTO) (16.437) 187.50 (7.382) 118.34 205.00 (4.659) (8.071) 99.00 (3.898)

195.50 (7.697)

103.00 (4.055)

152.00 (5.984)

298.00 (11.732)

Spark Plug

Oil Fill

Oil Drain Plug Mounting Face 11.00 (.433) dia. [qty. 2]

16.00 (.630)

11.00x27 (.433x1.063) slot [qty. 2] 65.00 (2.559)

37.00 (1.457) 62.00 (2.441)

102.00 (4.016)

Dimensions in millimeters.

Inch equivalents shown in ( ).

Figure 1-6. Typical Engine Dimensions CS8.5 (spec. 92xxxx), CS10, and CS12.

1.7

Section 1 Safety and General Information 431.00 (16.968) 156.00 (6.142)

165.1 (6.50)

110 (4.33)

424.00 (16.693) 410.00 (16.142) 428.00 (16.850) 133.50 (5.256)

146.08 (5.78)

90.50 (3.563) 3/8-16 18 mm (.709) deep [qty. 4]

103.00 (4.055)

195.50 (7.697)

70.00 (2.756)

5/16-24 18 mm (.709) deep [qty. 2] 5/16-24 18 mm (.709) deep [qty. 4]

380.00 (14.961) 183.00 (7.205) 94.5 (3.720)

11.00x27.00 (.433x1.063) slotted hole [qty. 2] 16.00 (.630) 37.00 (1.457) 57.50 (2.264)

CL

11 (.433) hole [qty. 2] 59.00 (2.323)

96.00 (3.780)

Figure 1-7. Typical Engine Dimensions CS8.5 (spec. 95xxxx).

1.8

Dimensions in millimeters.

Inch equivalents shown in ( ).