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Table Of Contents - Kohler Command CV17 Service Manual

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Service manual (92 pages)

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Owner's manual (20 pages)

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Service manual (88 pages)

Table Of Contents

Table of Contents

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Table of Contents

Table Of Contents2

Safety Precautions3

Section 1. Safety And General Information3

Engine Identification Numbers5

Engine Identification Decal Location5

Oil Recommendations6

Fuel Recommendations6

General Recommendations6

Periodic Maintenance Instructions7

Dimensions In Millimeters8

Typical Engine Dimensions Cv Series With Standard Flat Air Cleaner8

General Torque Values18

Metric Fastener Torque Recommendations For Standard Applications18

English Fastener Torque Recommendations For Standard Applications19

Section 2. Tools & Aids20

Special Tools You Can Make23

Flywheel Holding Tool23

Rocker Arm/Crankshaft Tool23

Engine Cranks But Will Not Start24

Engine Starts But Does Not Keep Running24

Engine Starts Hard24

Section 3. Troubleshooting24

Engine Will Not Idle25

Engine Overheats25

Engine Knocks25

Engine Loses Power25

Cleaning The Engine26

Basic Engine Tests26

Crankcase Vacuum Test26

To Test The Crankcase Vacuum With The Manometer26

No Crankcase Vacuum/Pressure In Crankcase27

Compression Test27

Cylinder Leakdown Test27

Leakdown Test Instructions27

Leakdown Test Results28

Standard Air Cleaner29

Commercial Mower Air Cleaner29

Section 4. Air Cleaner And Air Intake System29

Paper Element Service30

Precleaner On Standard Air Cleaner30

Precleaner On Commercial Mower Type Air Cleaner30

Air Cleaner System Components - Standard31

Air Cleaner System Components - Commercial Mower Type31

Air Cleaner Components32

Disassembly/Reassembly - Standard Type32

Disassembly/Reassembly - Commercial Mower Type32

Base Plate Removal On Standard Type32

Heavy-Duty Air Cleaner33

Removing Elements33

Air Intake/Cooling System34

Cleanout Kit Installed On Blower Housing34

Fuel System Components35

Gasoline/Alcohol Blends35

Section 5. Fuel System And Governor35

"Family" Number Location36

Troubleshooting – Fuel System Related Causes37

Fuel System Tests37

Replacing The Fuel Pump38

Troubleshooting – Carburetor Related Causes41

Troubleshooting Checklist41

High Altitude Operation42

Fuel Shut-Off Solenoid42

Carburetor Adjustments (Cv17-740)42

Fuel Shut-Off Solenoid Location42

Models With Governed Idle System43

Carburetor Adjustments43

Governed Idle Spring Location44

Carburetor Servicing (Cv17-740)44

Proper Float Level44

Holding Throttle Lever Against Idle Stop Screw (One-Barrel Carburetor)44

Typical Carburetor - Exploded View46

Carburetor Repair Kit47

Reassembly Procedure47

Float Replacement47

Removing Float And Inlet Needle47

Installing Float Assembly48

Installing Fuel Bowl48

Checking Float Height48

Fuel Bowl Removed From Carburetor48

Main Jet And Slow Jet Removed49

Installing Main Nozzle And Main Jet49

Installing Slow Jet50

Installing Plug Into Slow Jet Tube50

Float And Inlet Needle50

Installing Fuel Bowl O-Rings51

Accelerator Pump Rebuild51

Installing Idle Fuel Adjusting Screw And Spring51

Installing Idle Speed Adjusting Screw And Spring51

Accelerator Pump Cover And Diaphragm Removed52

Removing Retaining Ring52

Check Valve And Retaining Ring Installed52

Diaphragm Installed52

Installing Accelerator Pump Housing Screws And Hose53

Assembling Choke Lever53

Choke Details53

Keihin Bk Two-Barrel Carburetor (Cv750)54

Float Circuit54

Slow & Mid-Range Circuit54

Main (High-Speed) Circuit54

Carburetor Adjustment55

Low Idle Speed (Rpm) Adjustment55

Low Idle Fuel Adjustment55

Carburetor Servicing56

Optimum Low Idle Fuel Settings56

Holding Throttle Lever Against Idle Stop Screw (Two-Barrel Carburetor)56

Float And Inlet Needle Details57

Main Jets And Nozzles Removed59

Slow Jets And O-Ring Detail59

Removing Screw And Washer59

Keihin Bk Two-Barrel Carburetor - Exploded View63

Initial Adjustment64

Governor Controls And Linkage64

Sensitivity Adjustment65

Left Side Pull65

Governor Control Connections65

Choke Lever Detail66

Commercial Mower Governor Arrangement66

Governor Used With Commercial Mower Air Cleaner (Cv17-745)66

Governor/Controls Assembly (Cv750)67

Electronic Fuel Injection (Efi) Fuel System68

Initial Starting/Priming Procedure69

Efi Fuel System Components70

Gasoline/Ether Blends70

Electrical Components71

Electronic Control Unit (Ecu)71

Important Service Notes71

Engine Speed Sensor72

Throttle Position Sensor (Tps)73

B-4. Speed Sensor Connector73

Tps Initialization Procedure75

B-7. Service Connector Plug, Plastic Cased Ecu Harness75

Engine (Oil) Temperature Sensor76

Oxygen Sensor77

Cutaway Of Oxygen Sensor77

Electrical Relay79

To Replace Oxygen Sensor79

Efi Fuel System80

Relay Connector80

Relay Terminal Details80

Fuel Injectors80

Style 2 Fuel Injector81

Fuel Injector Details81

Checking Injectors82

Volt Noid Light82

Injector Inspection Points83

Ignition System84

Ignition Coil84

Wiring Harness85

Battery Charging System85

Fuel Components85

Fuel Pressure Regulator86

External Fuel Pressure Regulators86

Internal Fuel Pressure Regulators86

Internal (In-Tank) Regulator87

Fuel Pressure Regulator Details87

External Regulators And Base/Holders87

Internal (In-Tank) Regulator And Base/Holder87

Throttle Body/Intake Manifold88

In-Line Fuel Filter88

High Pressure Fuel Line88

Throttle Body/Intake Manifold Assembly89

Idle Speed Adjustment (Rpm)89

Upper Throttle Body/Intake Manifold Details89

Initial Governor Adjustment90

Checking The Initial Adjustment90

Idle Speed Screw Details90

Throttle Details90

Inserting Feeler Gauge91

Throttle Link In Center Of Hole91

Checking ''Split'' of Clamp91

Adjusting Governor Shaft91

Troubleshooting Guide92

Engine Starts Hard Or Fails To Start When Cold92

Engine Starts Hard Or Fails To Start When Hot92

Engine Stalls Or Idles Roughly (Cold Or Warm)92

Electrical System93

"24 Pin" (MSE 1.0) Plastic-Cased ECU Systems93

"32 Pin" (MSE 1.1) Plastic-Cased ECU Systems96

Example Of Diagnostic Display98

Diagnostic Code Summary98

Troubleshooting Flow Chart105

Bosch Efi Diagnostic Flow Diagram106

Flow Chart Diagnostic Aids107

Oil Container Logo109

Section 6. Lubrication System109

Checking Oil Level110

Changing Oil And Oil Filter110

Oil Fill Cap/Dipstick110

Oil Level Marks On Dipstick110

Changing Oil Filter111

Service Oil Cooler111

Crankcase Mounted Oil Cooler111

Blower Housing Mounted Oil Cooler111

Oil Sentry Location112

Testing The Switch112

Retractable Starter – Exploded View113

Removing Starter Handle113

To Install Starter113

Section 7. Retractable Starter113

Pawls (Dogs) Replacement114

Installing Rope114

Center Screw, Washer And Pawl Retainer115

Brake Spring And Washer, Pawls, And Pawl Springs115

Removing Pulley From Housing115

Position Of Spring And Keeper In Pulley115

Installing Pulley And Spring Into Housing116

Installing Pawls And Pawl Springs116

Servicing Spark Plug117

Section 8. Electrical System And Components117

Carbon Fouled118

Battery Size Recommendations119

Battery Test119

Battery Maintenance119

Electronic Cd Ignition Systems120

Operation Of Cd Ignition Systems120

Capacitive Discharge (Fixed Timing) Ignition System121

Capacitive Discharge Ignition Module Schematic121

Capacitive Discharge With Electronic Spark Advance122

Capacitive Discharge Ignition System With Spark Advance122

Block Diagram - Spark Advance Module122

Test Procedure For Standard (Fixed Timing) Cd Ignition System123

Troubleshooting Cd Ignition Systems123

Check For Timing Advance125

Test The Ignition Modules And Connections125

Ignition Module Resistance Table126

Test The Sam126

To Test – Using 25 761 21-S Tester127

Asam (Only) Test Procedure127

To Test – Using 25 761 40-S Tester129

Dsam/Asam Test Procedure129

Connected Tester Leads129

Select Test Number130

"Pass" Indicator130

15/20/25 Amp Regulated Charging System131

15 Amp Stator And Rectifier-Regulator132

20 Amp Stator And Rectifier-Regulator132

3 Amp Unregulated Charging System133

25 Amp Stator And Rectifier-Regulators133

Rectifier-Regulator134

15 Amp Rectifier-Regulators134

Section 9. Disassembly134

20/25 Amp Rectifier-Regulators135

Connections For Testing Charging System137

15/20/25 Amp Battery Charging Systems138

3 Amp Battery Charging System With 70 Watt Lighting Stator139

Electric Starting Motors140

Starting Motor Precautions140

Inertia Drive Electric Starters140

Starter Removal And Installation140

Operation - Inertia Drive Starters141

Starter Drive Service141

Style ''A'' Drive Service141

Style ''B'' Drive Service142

Drive Components, ''Bonded'' Inertia Drive Starter142

Holding Tool And Turning Center142

Retaining Ring Installation143

Starter Disassembly143

Style ''A'' End Cap Brush Replacement143

Style ''B'' End Cap Brush Replacement144

Commutator Service144

Starter Reassembly144

For Style ''B'' Commutator End Caps144

Solenoid Shift Electric Starters145

Operation – Solenoid Shift Starter145

Nippondenso Solenoid Shift Starter145

Delco-Remy Starters146

Completed Delco-Remy Starter146

Starter Service146

Removing Solenoid Screws147

Solenoid Removed From Starter147

Removing Plunger147

Removing Thru Bolts148

Removing Commutator End Plate Assembly148

Starter Frame Removed148

Armature And Lever Removed148

Retaining Ring Detail149

Delco-Remy Starter149

Drive Pinion150

Brushes And Springs150

Checking Brushes150

Checking Armature150

Brush Replacement151

Removing Brush Holder151

Service Brush Kit151

Installing Stop Collar And Retainer151

Installing Thrust Washer152

Installing Armature And Pivot Lever152

Installing Backup Washer And Grommet152

Installing Frame And Drain Tube152

Removing Retaining Clips153

Installing Brush Holder Assembly With Supplied Tube153

Brush Installation Tool With Extension153

Installing Brush Holder Assembly Using Tool With Extension154

Torquing Brush Holder Screws154

Torquing Thru Bolts154

Positive (+) Brush Lead Connection154

Solenoid Test Procedure155

Solenoid Shift Style Starters155

Testing Pull-In Coil/Plunger Actuation155

Testing Pull-In Coil/Solenoid Contact Continuity155

Solenoid Hold-In Coil/Contact Continuity Test156

Testing Hold-In Coil/Solenoid Contact Continuity156

Typical Disassembly Sequence157

Disconnect Spark Plug Leads157

Shut Off Fuel Supply157

Remove Oil Cooler158

Remove Muffler158

Remove Air Cleaner Assembly158

Removing Oil Fill Cap/Dipstick158

Removing Standard Element And Precleaner159

Removing Standard Air Cleaner Base159

Removing Commercial Mower Element And Precleaner159

Disconnect Breather Hose From Base159

Heavy Duty Air Cleaner160

Remove Control Panel160

Removing Breather Hose, Hex Nuts And Adapter Elbow160

Removing Upper Mounting Screws160

Remove Fuel Pump161

Remove Throttle Controls161

Removing Throttle Control Bracket161

Removing Control Panel161

Remove Carburetor162

Remove External Governor Controls162

Removing Control Bracket162

Removing Governor Lever162

Remove Electric Starter Motor163

Removing Carburetor And Linkage163

Removing Carburetor Mounting Nuts163

Removing Carburetor163

Remove Outer Baffles And Blower Housing164

Disconnecting Plug From Rectifier- Regulator164

Note Location Of Short Screws164

Removing Outer Baffles164

Remove Oil Sentry165

Removing Flywheel Screen165

Remove Inner Baffles And Breather Cover165

Rectifier-Regulator Ground Strap165

Remove Valve Covers166

Remove Ignition Modules166

Break Breather Cover Seal166

Removing Valve Cover166

Remove Intake Manifold167

Remove Spark Plugs167

Position Of Ignition Modules167

Removing Intake Manifold167

Remove Cylinder Heads And Hydraulic Lifters168

Disassemble Cylinder Heads168

Removing Cylinder Head168

Removing Hydraulic Lifters168

Remove Grass Screen And Fan169

Removing Rocker Arm169

Valve Components169

Intake Valve Seal Location169

Remove Flywheel170

Remove Stator And Backing Plates170

Removing Plastic Grass Screen170

Removing Fan170

Remove Oil Pan Assembly171

Oil Pump Assembly171

Remove Camshaft171

Remove Governor Cross Shaft171

Remove Connecting Rods With Pistons And Rings172

Removing Governor Cross Shaft Hitch Pin172

Removing Governor Cross Shaft Retainer (8 Mm Shaft Design)172

Removing Connecting Rod End Cap172

Remove Crankshaft173

Remove Flywheel End Oil Seal173

Automatic Compression Release (Acr)174

Section 10. Inspection And Reconditioning174

Procedure To Install New Plug175

Crankpin Fillets175

Removing Crankpin Plug175

Cylinder Bore Crosshatch After Honing176

Clean Cylinder Bore After Honing177

Cylinder Head And Valves177

Measuring Piston Diameter177

Checking Cylinder Head Flatness178

Valve Details178

Valve Guides181

Valve Seat Inserts181

Pistons And Rings181

Intake Valve Stem Seal181

Common Types Of Piston Damage182

Stuck, Broken Rings182

Abrasive Scratched Rings182

Overheated Or Deteriorated Oil182

Install New Piston Rings183

Measuring Piston Ring End Gap183

Installing Piston Rings183

Measuring Piston Ring Side Clearance183

Connecting Rods184

Hydraulic Lifters184

Oil Pan Assembly184

"Bleeding" the Lifters184

Removing Governor Gear185

Removing Oil Pump185

Governor Shaft Press Depth185

Section 11. Reassembly185

Oil Pump, Oil Pickup, And Relief Valve (Original Style)186

Oil Pump, Plastic Oil Pickup, And One-Piece Relief Valve (Later Style)186

Oil Pressure Relief Valve Piston And Spring186

Oil Pump Torque Sequence186

Crankcase Breather System187

Governor Cross Shaft Oil Seal187

Crankcase With Breather Reed187

Installing Cross Shaft Oil Seal187

Typical Reassembly Sequence188

Install Flywheel End Oil Seal188

Seal Bore Of Crankcase188

Install Governor Cross Shaft189

Installing Oil Seal In Crankcase189

Installing Governor Cross Shaft Hitch Pin (6 Mm Shaft)189

Installing 8 Mm Governor Cross Shaft189

Install Crankshaft190

Install Connecting Rods With Pistons And Rings190

Proper Piston Connecting Rod Orientation190

Installing Piston Assembly Using Ring Compressor Tool190

Install Camshaft191

Connecting Rod Bolts191

Torquing Connecting Rod End Cap191

Apply Camshaft Lubricant To Cam Lobes191

Determining Camshaft End Play192

Governor Gear Assembly192

Install Oil Seal In Oil Pan192

Checking Camshaft End Play192

Install Oil Pan Assembly193

Install Stator And Backing Plates193

Oil Pan Sealant Pattern Cv17-23193

Torquing Oil Pan Fasteners193

Install Flywheel194

Torquing Stator Screws194

Route Stator Leads In Groove194

Carefully Align Keyway To Key194

Install Fan And Grass Screen195

Install Supports For The Metal Grass Screen195

Installing Fan195

Installing Plastic Grass Screen195

Install Hydraulic Lifters196

Installing Supports For Metal Grass Screen196

Applying Camshaft Lubricant To Bottom Of Lifters196

Torquing Supports For Metal Screen196

Valve Stem Seals197

Assemble Cylinder Heads197

Match Numbers On Cylinder Barrel And Head197

Install Cylinder Heads198

Installing Valves With Valve Spring Compressor198

Torquing Cylinder Head Fasteners198

Cylinder Head Fastener Torque Sequence198

Install Push Rods And Rocker Arms199

Installing New Mounting Studs To Specified Height199

Torquing The Cylinder Head Mounting Nuts (Stud Design)199

Install Push Rods In Their Original Position199

Install Ignition Modules200

Torquing Rocker Arm Screws200

Installing Spark Plugs200

Install Intake Manifold201

Setting Ignition Module Air Gap201

Installing Intake Manifold Gaskets201

Intake Manifold Torque Sequence201

Install Breather Cover And Inner Baffles202

Sealant Applied To Terminals202

Breather Cover And Gasket202

Connect Leads On Smart-Spark Ignition Modules202

Installing Screws (Locations 3 And 4)203

Installing Inner Baffles203

Finger Tighten Two Remaining Cover Screws203

Wires On Oil Filter Side Of Engine203

Installing Blower Housing204

Tightening Outer Baffle Front Screws204

Tightening Short Screws For Outer Baffles204

Breather Cover Fastener Torque Sequence204

Install Oil Sentry205

Install Control Panel205

Reconnect Rectifier-Regulator205

Smart-Spark Module205

Install Valve Covers206

Install Carburetor206

Valve Cover Fastener Torque Sequence206

Installing Carburetor, Throttle Linkage, And Governor Lever207

Installing Two-Barrel Carburetor207

Install Governor Lever To Shaft207

Installing External Governor Controls207

Choke Linkage Details208

Throttle Linkage Details208

Installing Lower Support Control Bracket208

Installing Control Panel208

Install Throttle And Choke Controls209

Connecting Governor Spring To Governor Lever209

Standard Control Bracket209

6 Mm Governor Lever And Hole Position/Rpm Chart210

Throttle/Choke Control Bracket Detail210

8 Mm Governor Lever And Hole Position/Rpm Chart211

Cv18 Engines211

Cv20-740 Engines With 0.0299 + 0.003 In. Thick Throttle Limiter211

Cv17, Cv20-740 Engines Without Throttle Limiter211

Install Electric Starter Motor212

Installing Starter And Lift Bracket212

Installing Dipstick Tube212

Install Fuel Pump213

Install Air Cleaner Assembly213

Install Pulse Line213

Standard Air Cleaners213

Heavy Duty Air Cleaners214

Breather Hose And Separator Details214

Torquing Base And Spitback Cup Mounting Nuts214

Torquing Hex Nuts214

Install Muffler215

Install Oil Cooler215

Install Oil Filter And Fill Crankcase With Oil215

Installing And Tightening Oil Filter215

Connect Spark Plug Leads216

Prepare The Engine For Operation216

Testing The Engine216

Install Oil Drain Plug(S)216

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Table of Contents

Troubleshooting