Kohler CV960 User Manual

COMMAND PRO

CV940-CV1000

VERTICAL CRANKSHAFT

OWNER'S MANUAL

Safety Precautions

To ensure 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 caution is ignored.

NOTE

Note is used to notify people of installation, operation, or maintenance information that is important but not hazard-related.

For Y our Safety!

These precautions should be followed at all times. Failure to follow these precautions could result in injury to yourself and others.

WARNING

Explosive Fuel can cause fires and severe burns.

Do not fill the fuel tank while the engine is hot or running.

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

Rotating Parts can cause severe injury.

Stay away while engine is in operation.

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.

CAUTION

Electrical Shock can cause injury .

Do not touch wires while engine is running.

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. T o 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.

California

Proposition 65 Warning

Engine exhaust from this product contains chemicals known to the State of California to cause cancer , birth defects, or other reproductive harm.

Electrical Shock!

Never touch electrical wires or components while the engine is running. They can be sources of electrical shock.

Safety Precautions (Cont.)

WARNING

Accidental Starts can cause severe injury or death.

Disconnect and ground spark plug lead before servicing.

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.

WARNING WARNING

Carbon Monoxide can cause severe nausea, fainting or death.

Avoid inhaling exhaust fumes, and never run the engine in a closed building or confined area.

Lethal Exhaust Gases!

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

Explosive Gas can cause fires and severe acid burns.

Charge battery only in a well ventilated area. Keep sources of ignition away.

Explosive Gas!

Batteries produce explosive hydrogen gas while being charged. T o pr event 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.

Congratulations – You have selected a fine four-cycle, twin cylinder , air-cooled engine. Kohler designs long life strength and on-the-job durability into each engine…making a Kohler engine dependable…dependability you can count on. Here are some reasons why:

• Efficient overhead valve design and full pressure lubrication provide maximum power, torque, and reliability under all operating conditions.

• Dependable, maintenance free electronic ignition ensures fast, easy starts time after time.

• Kohler engines are easy to service. All routine service areas (like the oil filter, dipstick, oil fill, air cleaner, spark plug, and carburetor) are easily and quickly accessible.

• Parts subject to the most wear and tear (like the cylinder liner and camshaft) are made from precision formulated cast iron.

• Every Kohler engine is backed by a worldwide network of over 10,000 distributors and dealers. Service support is just a phone call away. Call 1-800-544-2444 (U.S. & Canada) for Sales & Service assistance.

To keep your engine in top operating condition, follow the maintenance procedures in this manual.

Oil Fill/Dipstick

Oil Filter

Carburetor

Air Cleaner

Cylinder Shrouds

Blower Housing

Electric Starter

Oil Drain Plug

Optional Muffler

Figure 1. Typical Command PRO Vertical Shaft Engine.

Oil Recommendations

Using the proper type, weight, and a consistent brand 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.

Oil Type

Use high quality detergent oil of API (American Petroleum Institute) service class SJ or higher. Select

the viscosity based on the air temperature at the time of operation as shown in the following table.

RECOMMENDED SAE VISCOSITY GRADES

10W-30

5W-20, 5W-30

Spark Plug

NOTE: Synthetic oils meeting the listed

classifications may be used with oil changes performed at the recommended intervals. However to allow piston rings to properly seat, a new or rebuilt engine should be operated for at least 50 hours using standard petroleum based oil before switching to synthetic oil.

A logo or symbol on oil containers identifies the API service class and SAE viscosity grade. See Figure 3.

Kohler 10W-30

°F -20 0 20 32 40 60 80 100

°C -30 -20 -10 0 10 20 30 40

TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANGE

* Use of synthetic oil having 5W-20 or 5W-30 rating is acceptable,

up to 4°C (40°F)

** Synthetic oils will provide better starting in extreme cold below

23°C (-10°F)

Figure 2. Viscosity Grades Table.

NOTE: Using other than service class SJ or higher oil

or extending oil change intervals longer than recommended can cause engine damage.

Figure 3. Oil Container Logo.

Refer to Maintenance Instructions beginning on page 8 for detailed oil check, oil change, and oil filter change procedures.

Fuel Recommendations

WARNING: Explosive Fuel!

General Recommendations

Purchase gasoline in small quantities that can be used within 30 days and store only in clean, approved containers. Do not use gasoline left over from the previous season unless treated with a fuel stabilizer (see Storage), to minimize gum deposits and ensure easy starting. Do not use gasoline containing Methanol, or add oil to the gasoline.

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

Fuel Type

For best results use only clean, fresh, 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 and reduces harmful exhaust emissions. Leaded gasoline is not recommended and must not be used in any models where exhaust emissions are regulated.

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 including E20 and E85 are not to be used and not approved. Any failures resulting from use of these fuels will not be warranted.

Gasoline/Ether blends

Methyl T ertiary Butyl Ether (MTBE) and unleaded gasoline blends (up to a maximum of 15% MTBE by volume) are approved as a fuel for Kohler engines. Other gasoline/ether blends are not approved.

Engine Identification Numbers

When ordering parts, or in any communication involving an engine, always give the Model, Specification, and Serial Numbers of the engine.

The engine identification numbers appear on a decal affixed to the engine shrouding. Include letter suffixes, if there are any.

Record your engine identification numbers on the identification label below (Figure 4) for future reference.

IMPORTANT ENGINE INFORMATION THIS ENGINE MEETS EMISSION REGS FOR U.S. EPA PH 2 SMALL OFF–ROAD ENGINES AND CA 2006 AND LA TER LSI ENGINES

FAMIL Y

DISPL. (CC) MODEL NO. SPEC. NO. SERIAL NO. BUILD DATE OEM PROD. NO.

EMISSION COMPLIANCE PERIOD: EPA: CERTIFIED ON: REFER TO OWNER'S MANUAL FOR HP RA TING, SAFETY, MAINTENANCE AND ADJUSTMENTS

IMPORTANT ENGINE INFORMATION THIS ENGINE MEETS EMISSION REGS FOR U.S. EPA 2006 AND LATER AND EC ST AGE II (SN:4) SI SMALL OFF–ROAD ENGINES AND CA 2006 AND LA TER LSI ENGINES

FAMILY TYPE APP DISPL. (CC) MODEL NO. SPEC. NO. SERIAL NO. BUILD DATE OEM PROD. NO.

EMISSION COMPLIANCE PERIOD: EPA: CERTIFIED ON: REFER TO OWNER'S MANUAL FOR HP RA TING, SAFETY, MAINTENANCE AND ADJUSTMENTS

1-800-544-2444 www.kohlerengines.com

KOHLER CO. KOHLER, WISCONSIN USA

1-800-544-2444 KohlerEngines.com

KOHLER CO. KOHLER, WISCONSIN USA

Figure 4. Engine Identification Label.

The Emission Compliance Period referred to on the Emission Control or Air Index label indicates the number of operating hours for which the engine has been shown to meet Federal and CARB emission requirements. The following table provides the Engine Compliance Period (in hours) associated with the category descriptor found on the certification label.

Emission Compliance Period (Hours):

EP A

Category A 1000 hours

Refer to certification label for engine displacement.

Exhaust Emission Control System for models CV940CV1000 is EM.

Model Designation

Model CV980 for example: C designates Command engine, V designates vertical crankshaft, and 980 indicates the numerical model designation. A letter suffix designates a specific version as follows:

Suffix Designates

S Electric Start

Operating Instructions

Also read the operating instructions of the equipment this engine powers.

Pre-Start Checklist

• Check oil level. Add oil if low. Do not ov erfill.

• Check fuel level. Add fuel if low.

• Check cooling air intake areas and external surfaces of engine. Make sure they are clean and unobstructed.

• Check that the air cleaner components and all shrouds, equipment covers, and guards are in place and securely fastened.

• Check that any clutches or transmissions are disengaged or placed in neutral. This is especially important on equipment with hydrostatic drive. The shift lever must be exactly in neutral to prevent resistance which could keep the engine from starting.

Throttle and Choke Control Linkage Setup

The throttle and choke levers on these engines allow remote mounted control operation from either side. The linkage for the throttle and choke is connected in one of the two available hole locations; A or B in the control levers. Hole location A in each lever is used for

Outer Pull actuation. Hole Location B used for Inner Pull actuation. Most engines will have the control

linkage connected in Location A, the primary location. If the application requires opposite side control direction or function, unhook the link(s) from the small clip and reconnect in the other hole location. See Figures 5 and 6.

(B)

Linkages Connected Here

Figure 6. Throttle and Choke Control Linkage in "Inner Pull" Configuration.

WARNING: Lethal Exhaust Gases!

Cold Weather Starting Hints

1. Be sure to use the proper oil for the temperature expected. See Figure 2 on page 4.

2. Disengage all possible external loads.

3. Be sure the battery is in good condition. A warm battery has much more starting capacity than a cold battery.

(A)

Linkages Connected Here

Figure 5. Throttle and Choke Control Linkage in "Outer Pull" Configuration.

(A)

4. Use fresh winter grade fuel. NOTE: Winter grade gasoline has higher volatility to improve starting. Do not use gasoline left over from summer.

Starting

1. Place the throttle control midway between the slow and fast positions. Place the choke control into the on position. See Figures 7 and 8.

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