Table Of Contents - Kohler command CH18 Service Manual

Table of Contents

Contents1
Safety Precautions2
Maintenance Instructions3
Maintenance Schedule3
Repairs/Service Parts3
Weekly3
Maintenance4
Oil Recommendations4
Fuel Recommendations4
Storage4
Engine Dimensions With Low-Profile Air Cleaner5
Specifications5
Engine Dimensions With Heavy-Duty Air Cleaner6
Engine Identification Numbers7
General Specifications7
Torque Specifications7
Blower Housing And Sheet Metal7
Connecting Rod8
Crankcase8
Cylinder Head8
Clearance Specifications9
General Torque Values14
English Fastener Torque Recommendations For Standard Applications14
Metric Fastener Torque Recommendations For Standard Applications14
Separate Tool Suppliers15
Tools15
Flywheel Holding Tool17
Rocker Arm/Crankshaft Tool17
Troubleshooting Guide18
Engine Cranks But Will Not Start18
Engine Starts But Does Not Keep Running18
Engine Starts Hard18
External Engine Inspection19
Cleaning Engine19
Engine Loses Power19
Engine Uses Excessive Amount Of Oil19
Crankcase Vacuum Test20
To Test Crankcase Vacuum With Manometer20
To Test Crankcase Vacuum With Vacuum/Pressure Gauge20
Compression Test21
Cylinder Leakdown Test21
Air Cleaner22
Low-Profile Air Cleaner Components22
Low-Profile22
Heavy-Duty22
Breather Tube22
Air Cooling22
Performance23
Fuel Pump Replacement23
Fuel System Tests23
Carburetors24
Keihin Two-Barrel Carburetor Components24
Keihin One-Barrel Carburetor Components25
Troubleshooting Checklist25
Troubleshooting-Carburetor Related Causes26
Fuel Shut-Off Solenoid26
Carburetor Circuits27
Carburetor Adjustments27
Float27
Slow And Mid-Range27
Carburetor Servicing28
High Altitude Operation28
Governor Components29
Governor Adjustments29
Initial Adjustment Procedure29
Governor System29
Electronic Governor30
Digital Linear Actuator (Dla)30
Gcu Safety Features30
Linkage30
Lubrication Components31
Blower Housing Mounted Oil Cooler31
Crankcase Mounted Oil Cooler31
Check Oil Level31
Lubrication System31
Oil Sentry32
Installation32
Spark Plugs33
Spark Plug Component And Details33
Worn33
Wet Fouled33
Electrical System33
Electronic Ignition Systems34
Carbon Fouled34
Overheated34
Ignition System Components34
Wiring Diagram35
Fixed Ignition System36
Smart-Spark38
Advance Ignition System38
Digital Spark Advance Ignition (Dsai) System40
Electronic Ignition Systems Tests41
Test Ignition Systems41
Test For Spark42
Test Timing Advance42
Test Ignition Modules And Connections (Dsai Only)42
Ignition Module Resistance Table43
Test Sam44
Test Asam And Dsam44
To Test Asam Only Using 25 761 21-S Tester45
To Test Dsam And Asam Using 25 761 40-S Tester45
Battery Charging System45
15/20/25 Amp Regulated Charging System46
To Test 4/15 Amp Rectifier-Regulators46
To Test 20/25 Amp Rectifier-Regulators46
15/20/25 Amp Battery Charging Systems47
3 Amp/70 Watt Lighting Stator48
Troubleshooting-Starting Difficulties49
Inertia Drive Electric Starters50
Inertia Drive Starter Components50
Starter Drive Service50
Retaining Ring Installation51
Starter Disassembly51
Brush Replacement51
Commutator Service51
Solenoid Shift Electric Starters52
Nippondenso Starters52
Solenoid Shift Starter Components52
Delco-Remy Starters52
Drive Pinion53
Brushes And Springs53
Armature53
Shift Fork53
Starter Reassembly54
Solenoid Tests55
To Test Solenoid Pull-In Coil/Plunger55
To Test Solenoid Hold-In Coil55
Retractable Starters56
Retractable Starter Components56
Remove Starter56
Rope Replacement56
Pawls (Dogs) Replacement57
Install Starter57
Clutch58
Wet Disc Type Clutch58
Wet Disc Type Clutch Components58
Clutch Adjustment Components59
Disassembly/Inspection And Service60
External Engine Components60
Disconnect Spark Plug Leads61
Drain Oil From Crankcase And Remove Oil Filter61
Remove Muffler61
Remove Air Cleaner Assembly61
Remove Throttle And Choke Controls62
Control Bracket Components62
Remove External Governor Controls62
Remove Carburetor62
Remove Inner Baffles And Breather Cover63
Cylinder Head Components63
Remove Intake Manifold63
Remove Valve Covers63
Disassemble Cylinder Heads64
Valve Details64
Exhaust Valve64
Valve Guides65
Valve Seat Inserts65
Lapping Valves65
Hydraulic Lifters Inspection65
Flywheel/Ignition Components66
Remove Ignition Modules66
Remove Debris Screen And Fan66
Remove Flywheel66
Remove Stator And Backing Plates67
Crankcase Components67
Remove Closure Plate Assembly67
Governor Gear Assembly68
Governor Shaft Component And Details68
Oil Pump Assembly (Style A)68
Oil Pump Assembly (Style B)69
Remove Camshaft69
Remove Connecting Rods With Pistons And Rings70
Piston And Rings70
Piston And Rings Components And Details70
Install New Piston Rings71
Piston Ring Orientation71
Connecting Rods72
Remove Crankshaft72
Crankshaft Components And Details72
Remove Governor Cross Shaft72
Governor Cross Shaft Oil Seal73
Cross Shaft Oil Seal Details73
Honing73
Remove Flywheel End Oil Seal73
Measuring Piston-To-Bore Clearance74
Piston Detail74
Install Flywheel End Oil Seal75
Install Governor Cross Shaft76
Install Crankshaft76
Install Connecting Rods With Pistons And Rings76
Piston And Connecting Rod Details76
Determining Camshaft End Play77
Oil Pump Assembly77
Thrust Bearing, Washer And Shim77
Thrust Bearing, Washer, And Shim Sequence77
Install Closure Plate Oil Seal78
Install Closure Plate Assembly78
Sealant Pattern And Torque Sequence78
Install Stator And Backing Plates79
Install Flywheel79
Install Flywheel Fan79
Install Plastic Debris Screen80
Install Supports For Metal Debris Screen80
Install Hydraulic Lifters80
Valve Stem Seals80
Assemble Cylinder Heads81
Install Cylinder Heads81
Cylinder Head Torque Sequence81
Install Push Rods And Rocker Arms81
Install Spark Plugs82
Install Ignition Modules82
Install Intake Manifold82
Install Breather Cover And Inner Baffles84
Breather Cover Torque Sequence84
Install Blower Housing And Outer Baffles84
Reconnect Rectifier-Regulator84
Install Fuel Pump85
Install Carburetor85
Install External Governor Controls85
Install Throttle & Choke Controls85
Governor Lever Hole Position (6 Mm)86
6 Mm Governor Lever And Hole Position/Rpm Chart86
Governor Lever Hole Position (8 Mm)86
8 Mm Governor Lever And Hole Position/Rpm Chart For Ch20-Ch740 Engines87
8 Mm Governor Lever And Hole Position/Rpm Chart For Ch750 Engines87
Install Control Panel87
Install Valve Covers87
Install Air Cleaner Assembly88
Install Muffler88
Install Oil Cooler88
Install Oil Filter And Fill Crankcase With Oil88