Kohler COMMAND CH22 Manuals

Manuals and User Guides for Kohler COMMAND CH22. We have 4 Kohler COMMAND CH22 manuals available for free PDF download: Service Manual

Kohler COMMAND CH22 Service Manual

Kohler COMMAND CH22 Service Manual (93 pages)

Brand: Kohler | Category: Engine | Size: 4 MB

Table of Contents

Contents
1
Safety Precautions
2
Maintenance Instructions
3
Maintenance Schedule
3
Repairs/Service Parts
3
Weekly
3
Maintenance
4
Oil Recommendations
4
Fuel Recommendations
4
Storage
4
Engine Dimensions with Low-Profile Air Cleaner
5
Specifications
5
Engine Dimensions with Heavy-Duty Air Cleaner
6
Engine Identification Numbers
7
General Specifications
7
Torque Specifications
7
Blower Housing and Sheet Metal
7
Connecting Rod
8
Crankcase
8
Cylinder Head
8
Clearance Specifications
9
General Torque Values
14
English Fastener Torque Recommendations for Standard Applications
14
Metric Fastener Torque Recommendations for Standard Applications
14
Separate Tool Suppliers
15
Tools
15
Flywheel Holding Tool
17
Rocker Arm/Crankshaft Tool
17
Troubleshooting Guide
18
Engine Cranks but will Not Start
18
Engine Starts but Does Not Keep Running
18
Engine Starts Hard
18
External Engine Inspection
19
Cleaning Engine
19
Engine Loses Power
19
Engine Uses Excessive Amount of Oil
19
Crankcase Vacuum Test
20
To Test Crankcase Vacuum with Manometer
20
To Test Crankcase Vacuum with Vacuum/Pressure Gauge
20
Compression Test
21
Cylinder Leakdown Test
21
Air Cleaner
22
Low-Profile Air Cleaner Components
22
Low-Profile
22
Heavy-Duty
22
Breather Tube
22
Air Cooling
22
Performance
23
Fuel Pump Replacement
23
Fuel System Tests
23
Carburetors
24
Keihin Two-Barrel Carburetor Components
24
Keihin One-Barrel Carburetor Components
25
Troubleshooting Checklist
25
Troubleshooting-Carburetor Related Causes
26
Fuel Shut-Off Solenoid
26
Carburetor Circuits
27
Carburetor Adjustments
27
Float
27
Slow and MID-Range
27
Carburetor Servicing
28
High Altitude Operation
28
Governor Components
29
Governor Adjustments
29
Initial Adjustment Procedure
29
Governor System
29
Electronic Governor
30
Digital Linear Actuator (DLA)
30
GCU Safety Features
30
Linkage
30
Lubrication Components
31
Blower Housing Mounted Oil Cooler
31
Crankcase Mounted Oil Cooler
31
Check Oil Level
31
Lubrication System
31
Oil Sentry
32
Installation
32
Spark Plugs
33
Spark Plug Component and Details
33
Worn
33
Wet Fouled
33
Electrical System
33
Electronic Ignition Systems
34
Carbon Fouled
34
Overheated
34
Ignition System Components
34
Wiring Diagram
35
Fixed Ignition System
36
Smart-Spark
38
Advance Ignition System
38
Digital Spark Advance Ignition (DSAI) System
40
Electronic Ignition Systems Tests
41
Test Ignition Systems
41
Test for Spark
42
Test Timing Advance
42
Test Ignition Modules and Connections (DSAI Only)
42
Ignition Module Resistance Table
43
Test SAM
44
Test ASAM and DSAM
44
To Test ASAM Only Using 25 761 21-S Tester
45
To Test DSAM and ASAM Using 25 761 40-S Tester
45
Battery Charging System
45
15/20/25 Amp Regulated Charging System
46
To Test 4/15 Amp Rectifier-Regulators
46
To Test 20/25 Amp Rectifier-Regulators
46
15/20/25 Amp Battery Charging Systems
47
3 Amp/70 Watt Lighting Stator
48
Troubleshooting-Starting Difficulties
49
Inertia Drive Electric Starters
50
Inertia Drive Starter Components
50
Starter Drive Service
50
Retaining Ring Installation
51
Starter Disassembly
51
Brush Replacement
51
Commutator Service
51
Solenoid Shift Electric Starters
52
Nippondenso Starters
52
Solenoid Shift Starter Components
52
Delco-Remy Starters
52
Drive Pinion
53
Brushes and Springs
53
Armature
53
Shift Fork
53
Starter Reassembly
54
Solenoid Tests
55
To Test Solenoid Pull-In Coil/Plunger
55
To Test Solenoid Hold-In Coil
55
Retractable Starters
56
Retractable Starter Components
56
Remove Starter
56
Rope Replacement
56
Pawls (Dogs) Replacement
57
Install Starter
57
Clutch
58
Wet Disc Type Clutch
58
Wet Disc Type Clutch Components
58
Clutch Adjustment Components
59
Disassembly/Inspection and Service
60
External Engine Components
60
Disconnect Spark Plug Leads
61
Drain Oil from Crankcase and Remove Oil Filter
61
Remove Muffler
61
Remove Air Cleaner Assembly
61
Remove Throttle and Choke Controls
62
Control Bracket Components
62
Remove External Governor Controls
62
Remove Carburetor
62
Remove Inner Baffles and Breather Cover
63
Cylinder Head Components
63
Remove Intake Manifold
63
Remove Valve Covers
63
Disassemble Cylinder Heads
64
Valve Details
64
Exhaust Valve
64
Valve Guides
65
Valve Seat Inserts
65
Lapping Valves
65
Hydraulic Lifters Inspection
65
Flywheel/Ignition Components
66
Remove Ignition Modules
66
Remove Debris Screen and Fan
66
Remove Flywheel
66
Remove Stator and Backing Plates
67
Crankcase Components
67
Remove Closure Plate Assembly
67
Governor Gear Assembly
68
Governor Shaft Component and Details
68
Oil Pump Assembly (Style A)
68
Oil Pump Assembly (Style B)
69
Remove Camshaft
69
Remove Connecting Rods with Pistons and Rings
70
Piston and Rings
70
Piston and Rings Components and Details
70
Install New Piston Rings
71
Piston Ring Orientation
71
Connecting Rods
72
Remove Crankshaft
72
Crankshaft Components and Details
72
Remove Governor Cross Shaft
72
Governor Cross Shaft Oil Seal
73
Cross Shaft Oil Seal Details
73
Honing
73
Remove Flywheel End Oil Seal
73
Measuring Piston-To-Bore Clearance
74
Piston Detail
74
Install Flywheel End Oil Seal
75
Install Governor Cross Shaft
76
Install Crankshaft
76
Install Connecting Rods with Pistons and Rings
76
Piston and Connecting Rod Details
76
Determining Camshaft End Play
77
Oil Pump Assembly
77
Thrust Bearing, Washer and Shim
77
Thrust Bearing, Washer, and Shim Sequence
77
Install Closure Plate Oil Seal
78
Install Closure Plate Assembly
78
Sealant Pattern and Torque Sequence
78
Install Stator and Backing Plates
79
Install Flywheel
79
Install Flywheel Fan
79
Install Plastic Debris Screen
80
Install Supports for Metal Debris Screen
80
Install Hydraulic Lifters
80
Valve Stem Seals
80
Assemble Cylinder Heads
81
Install Cylinder Heads
81
Cylinder Head Torque Sequence
81
Install Push Rods and Rocker Arms
81
Install Spark Plugs
82
Install Ignition Modules
82
Install Intake Manifold
82
Install Breather Cover and Inner Baffles
84
Breather Cover Torque Sequence
84
Install Blower Housing and Outer Baffles
84
Reconnect Rectifier-Regulator
84
Install Fuel Pump
85
Install Carburetor
85
Install External Governor Controls
85
Install Throttle & Choke Controls
85
Governor Lever Hole Position (6 MM)
86
6 MM Governor Lever and Hole Position/Rpm Chart
86
Governor Lever Hole Position (8 MM)
86
8 MM Governor Lever and Hole Position/Rpm Chart for CH20-CH740 Engines
87
8 MM Governor Lever and Hole Position/Rpm Chart for CH750 Engines
87
Install Control Panel
87
Install Valve Covers
87
Install Air Cleaner Assembly
88
Install Muffler
88
Install Oil Cooler
88
Install Oil Filter and Fill Crankcase with Oil
88

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