Kohler COMMAND CH22S Manuals

Manuals and User Guides for Kohler COMMAND CH22S. We have 2 Kohler COMMAND CH22S manuals available for free PDF download: Service Manual

Kohler COMMAND CH22S Service Manual (218 pages)

HORIZONTAL CRANKSHAFT

Brand: Kohler | Category: Engine | Size: 6.25 MB

Accidental Starts
2
Safety Precautions
2
Rotating Parts
2
Safety and General Information
2
Section 1 Safety and General Information
3
Engine Identification Decal Location
4
Engine Identification Numbers
4
Fuel Recommendations
5
General Recommendations
5
Oil Recommendations
5
Oil Type
5
Maintenance Schedule
6
Periodic Maintenance Instructions
6
Storage
6
Inch Equivalents Shown in ()
7
Typical Engine Dimensions CH Series with Standard Flat Air Cleaner
7
Typical Engine Dimensions CH EFI Series with Heavy-Duty Air Cleaner
8
General Specifications
9
Tightening Torque: N·M (In. Lb.) + or
15
Metric Fastener Torque Recommendations for Standard Applications
15
General Torque Values
15
English Fastener Torque Recommendations for Standard Applications
16
Special Tools
18
Cylinder Leakdown Tester
19
Flywheel Holding Tool
19
Rocker Arm/Crankshaft Tool
19
Section 2 Special Tools
19
Tool Catalog and Price List
19
Spline Drive Lubricant
20
Camshaft Break-In Lubricant
20
RTV Silicone Sealant
20
Dielectric Grease
20
Engine Cranks but will Not Start
22
Engine Starts but Does Not Keep Running
22
Engine Starts Hard
22
Troubleshooting
22
Grade
23
Engine will Not Idle
23
Engine Loses Power
23
Engine Overheats
23
Engine Knocks
23
Basic Engine Tests
24
Cleaning the Engine
24
Crankcase Vacuum Test
24
To Test the Crankcase Vacuum with the Vacuum
24
Compression Test
25
Cylinder Leakdown Test
25
Leakdown Test Instructions
25
Section 3 Troubleshooting
25
No Crankcase Vacuum/Pressure in Crankcase
25
Leakdown Test Results
26
Air Cleaner and Air Intake System
28
Air Cleaners
28
Removing Latch Style Cover
28
Standard Air Cleaner
28
Removing Rubber Seal from Bracket
29
Section 4 Air Cleaner and Air Intake System
29
Paper Element Service (Standard Type)
29
Removing Element Cover Wing Nut
29
Air Cleaner Components
29
Exploded View of Standard Air Intake System Components
30
Bracket Retaining Screw
31
Breather Tube
31
Heavy-Duty Air Cleaner
31
Rear Mounting Screws
31
Removing Elements
32
Adapters for Heavy-Duty Air Cleaners
33
Air Intake/Cooling System
33
Fuel System and Governor
34
Fuel System Components
34
Fuel Type
34
Gasoline/Alcohol Blends
34
Troubleshooting – Fuel System Related Causes
35
Section 5 Fuel System and Governor
35
Gasoline/Ether Blends
35
Fuel Filter
35
Fuel System Tests
35
Fuel Pump
36
Fuel Pump - Replacement
36
Replacing the Mechanical Pump
36
Replacing the Pulse Fuel Pump
36
Carburetor
37
Troubleshooting - Carburetor Related Causes
37
Troubleshooting Checklist
38
Fuel Shut-Off Solenoid
38
High Altitude Operation
38
Carburetor Adjustments
39
Float
39
“Certified” Compliance Carburetor
39
Carburetor Detail
40
Carburetor Float Adjustment
40
Inspection/Repair
41
Accelerator Pump Version Only
42
Carburetor – Exploded View
42
Governor
43
Governor Linkage
43
Governor Sensitivity Adjustments
44
Initial Adjustment
44
Procedure – Carburetor Equipped Engines
44
Sensitivity Adjustment
44
Left Side Pull
45
Electronic Governor
45
Electronic Governor Assembly
45
Digital Linear Actuator (DLA)
45
GCU Safety Features
46
Linkage
46
Potentiometer Specifications
46
SPST Switch Specifications
46
LPG Fuel System Components
48
LPG Fuel Systems
48
Irregular or Inconsistent Idle
49
Hard Starting, Runs Roughly, or Stalls at Idle Speed
49
Engine Runs Lean
50
Engine Stalls During Operation
50
Low Power
50
LPG Carburetor Adjustments
50
Idle Speed Adjustment
51
Impco Carburetor
51
LPG Carburetor - Cleaning
51
LPG Fuel System Component Service
51
LPG Carburetor - Inspection
52
Nikki Carburetor
52
A-8. Backing off Idle Speed Screw
53
Closing Throttle Plate
53
Idle Speed Clamp Bracket Position
53
LPG Carburetor - Reassembly
53
Adjusting/Setting Stop Colla
54
Full Throttle Position
54
High Speed/Stop Collar Position
54
Electric Lock-Off/Filter Assembly - Filter Service
55
Electric Lock-Off/Filter Assembly - Functional Test
55
Impco (Beam) Regulator
56
LPG Regulator
56
Vaporizer Assembly
56
Nikki Regulator Primary Chamber
58
Nikki Regulator Secondary Chamber
58
Primary Chamber
58
Secondary Chamber
58
Regulator Service
59
Preventative Maintenance
59
Regulator Drain Plug (some Models)
59
Impco (Beam) Regulator Service
59
Table of Contents
60
Electronic Fuel Injection (EFI) Fuel System
60
Initial Starting/Priming Procedure
61
Test Valve in Fuel Rail
61
Description

61
- Fuel Recommendations
  61
- EFI Fuel System Components
  62
- Operation
  62
Electrical Components

63
- Electronic Control Unit (ECU)
  63
- Important Service Notes
  63
- Service
  64
- Engine Speed Sensor
  64
  - Speed Sensor Connector
    65
  - Throttle Position Sensor (TPS)
    66
  - Throttle Position Sensor Details
    66
  - TPS Location
    66
  - TPS Initialization Procedure
    67
- Engine (Oil) Temperature Sensor
  69
- Oxygen Sensor
  70
- Cutaway of Oxygen Sensor
  70
- Electrical Relay
  72
- To Replace Oxygen Sensor
  72
- Fuel Injectors
  73
  - Relay Connector
    73
  - Style 1 Fuel Injector
    73
  - Style 2 Fuel Injector
    73
  - Fuel Injector Details
    74
  - Checking Injectors
    74
  - Volt Test Light
    75
  - Injector Inspection Points
    75
- Ignition System
  76
  - Ignition Coil
    76
  - Grade
    76
  - Spark Plugs
    77
- Wiring Harness
  77
Fuel Components

78
Troubleshooting

85
- Troubleshooting Guide
  85
- Electrical System
  86
- Fault Codes
  92
- Fuel System
  92
  - Example of Diagnostic Display
    93
  - Diagnostic Code Summary
    93
  - Engine Wiring Harness Related
    95
  - Throttle Body Related
    95
  - Ecu/Harness Related
    95
  - Ignition System Related
    95
  - Systems Related
    98
- Troubleshooting Flow Chart
  100
- Diagnostic Flow Diagram
  101
- Flow Chart Diagnostic Aids
  102
  - Lubrication System
    105
  - Oil Container Logo
    105
  - Recommended SAE Viscosity Grades
    105
  - Checking Oil Level
    106
  - Changing Oil and Oil Filter
    106
  - Location of Oil Fill Cap and Dipstick
    106
  - Oil Drain Plug Starter Side
    106
  - Section 6 Lubrication System
    106
  - Changing Oil Filter
    107
  - Removing Oil Fill Cap
    107
  - Oil Drain Plug and Oil Filter
    107
  - Service Oil Cooler
    108
  - Oil Sentry
    108
  - Oil Coolers
    108
  - Location of Oil Sentry Switch
    108
  - To Install the Switch
    109
  - Retractable Starter
    111
  - To Remove Starter
    111
  - To Install Starter
    111
  - Rope Replacement
    111
  - Removing Starter Handle
    112
  - Installing Rope
    112
  - Pawls (Dogs) Replacement
    112
  - Section 7 Retractable Starter
    112
  - Center Screw, Washer and Pawl Retainer
    113
  - Removing Pulley from Housing
    113
  - Position of Spring and Keeper in Pulley
    114
  - Installing Pulley and Spring into Housing
    114
  - Installing Pawls and Pawl Springs
    114
  - Electrical System and Components
    117
  - Servicing Spark Plug
    117
  - Section 8 Electrical System and Components
    118
  - Battery
    119
  - Battery Size Recommendations
    119
  - Battery Test
    119
  - Battery Maintenance
    119
  - Electronic CD Ignition Systems
    120
  - Operation of CD Ignition Systems
    120
  - Capacitive Discharge (Fixed Timing) Ignition System
    121
  - Capacitive Discharge Ignition Module Schematic
    121
  - Capacitive Discharge Ignition System with Spark Advance
    122
  - Block Diagram - Spark Advance Module
    122
  - Test Procedure for Standard (Fixed Timing) CD Ignition System
    123
  - Troubleshooting CD Ignition Systems
    123
  - Special Tools Required
    124
  - Specifications Required
    124
  - Test for Spark
    124
  - Section 2 Special Tools
    124
  - Check for Timing Advance
    125
  - Test the Ignition Modules and Connections
    125
  - Ignition Module Resistance Table
    126
  - Test the SAM
    126
  - 15/20/25 Amp Regulated Charging System
    130
  - Wiring Diagram - 15/20/25 Amp Regulated Battery Charging System
    130
  - 15 Amp Stator and Rectifier-Regulator
    130
  - 20 Amp Stator and Rectifier-Regulator
    130
  - 3 Amp Unregulated Charging System
    131
  - Amp Stator and Rectifier-Regulators
    131
  - 3 Amp/70 Watt Stator
    132
  - Rectifier-Regulator
    132
  - 15 Amp Rectifier-Regulators
    132
  - 20/25 Amp Rectifier-Regulators
    133
  - 25 Amp Rectifier-Regulators (Original Style)
    134
  - 4 Amp Unregulated Rectifiers
    134
  - Connections for Testing Charging System
    135
  - Troubleshooting Guide
    136
  - 15/20/25 Amp Battery Charging Systems
    136
  - 3 Amp Battery Charging System with 70 Watt Lighting Stator
    137
  - Electric Starting Motors
    138
  - Starting Motor Precautions
    138
  - Starter Removal and Installation
    138
  - Inertia Drive Electric Starters
    138
  - Operation - Inertia Drive Starters
    139
  - Starter Drive Service
    139
  - Style ‘‘A’’ Drive Service
    139
  - Inertia Drive Electric Starter
    139
  - Style ‘‘B’’ Drive Service
    140
  - Retaining Ring Installation
    141
  - Style ‘‘A’’ End Cap Brush Replacement
    141
  - Starter Disassembly
    141
  - Style ‘‘B’’ End Cap Brush Replacement
    142
  - Commutator Service
    142
  - Starter Reassembly
    142
  - Starter Assembly Match Marks
    142
  - Solenoid Shift Electric Starters
    143
  - Operation – Solenoid Shift Starter
    143
  - Nippondenso Solenoid Shift Starter
    143
  - Starter Service
    144
  - Brush Replacement
    144
  - Removing Solenoid Screws
    145
  - Solenoid Removed from Starter
    145
  - Removing Plunger
    145
  - Removing Thru Bolts
    146
  - Removing Commutator End Plate Assembly
    146
  - Armature and Lever Removed
    146
  - Starter Frame Removed
    146
  - Retaining Ring Detail
    147
  - Removing Retaining Ring
    147
  - Delco-Remy Starter
    147
  - Drive Pinion
    148
  - Brushes and Springs
    148
  - Commutator Mica Inspection
    148
  - Checking Armature
    148
  - Removing Brush Holder
    149
  - Service Brush Kit
    149
  - Installing Stop Collar and Retainer
    149
  - Installing Thrust Washer
    150
  - Installing Armature and Pivot Lever
    150
  - Installing Frame and Drain Tube
    150
  - Removing Retaining Clips
    151
  - Brush Installation Tool with Extension
    151
  - Installing Brush Holder Assembly with Supplied Tube
    151
  - Torquing Brush Holder Screws
    152
  - Torquing Thru Bolts
    152
  - Positive (+) Brush Lead Connection
    152
  - Disassembly
    153
  - Typical Disassembly Sequence
    153
  - Disconnect Spark Plug Leads
    153
  - Shut off Fuel Supply
    153
  - Removing Dipstick from Tube
    154
  - Removing Oil Fill Cap from Cover
    154
  - Removing Oil Drain Plug
    154
  - Removing Oil Filter Adapter Nipple
    154
  - Section 9 Disassembly
    154
  - Remove Muffler
    155
  - Remove Air Cleaner Assembly
    155
  - Removing Oil Cooler
    155
  - Removing Air Cleaner Base Retainer
    155
  - Remove Fuel Pump
    156
  - Removing Tube from Breather Cover
    156
  - Pulse Style Pumps
    156
  - Disconnecting Pulse Line from Valve Cover (Early Models)
    156
  - Mechanical Fuel Pump
    157
  - Removing Screws Holding Fuel Pump
    157
  - Remove Fuel Pump and Lines
    157
  - Removing Control Bracket
    157
  - Remove Carburetor
    158
  - Remove External Governor Controls
    158
  - Rear Air Cleaner Bracket
    158
  - Disconnecting Spring from Bracket
    158
  - Remove Electric Starter Motor
    159
  - Remove Outer Baffles and Blower Housing
    159
  - Remove Oil Sentry
    159
  - Disconnecting Plug from Rectifier-Regulator
    159
  - Remove B+ Lead from Terminal Plug
    160
  - Note Location of Two Short Screws
    160
  - Removing Outer Baffles
    160
  - Removing the Spark Advance Module
    160
  - Removing Metal Grass Screen
    161
  - Removing Blower Housing
    161
  - Remove Inner Baffles and Breather Cover
    161
  - Removing Inner Baffles
    161
  - Breaking Breather Cover Seal
    162
  - Remove Valve Covers
    162
  - Removing Breather Cover
    162
  - Removing Breather Filter
    162
  - Remove Ignition Modules
    163
  - Removing Intake Manifold
    163
  - Bolt Wiring Harness Detail
    163
  - Remove Intake Manifold
    163
  - Remove Spark Plugs
    164
  - Remove Cylinder Heads and Hydraulic Lifters
    164
  - Removing Cylinder Head Fasteners
    164
  - Hex. Flange Screw
    164
  - Removing Cylinder Head Assembly
    165
  - Removing Hydraulic Lifter
    165
  - Mark Position of Hydraulic Lifters
    165
  - Match Marks on Cylinder Barrel and Heads
    165
  - Disassemble Cylinder Heads
    166
  - Removing Rocker Arms
    166
  - Intake Valve Seal Location
    166
  - Remove Grass Screen and Fan
    166
  - Removing Plastic Type Grass Screen
    167
  - Removing Fan
    167
  - Remove Flywheel
    167
  - Remove Stator and Backing Plates
    167
  - Flywheel Strap Wrench
    167
  - Remove Closure Plate Assembly
    168
  - Governor Gear Assembly
    168
  - Oil Pump Assembly
    168
  - Breaking Seal on Top Splitting Tab
    168
  - Remove Camshaft
    169
  - Remove Connecting Rods with Pistons and Rings
    169
  - Removing Piston/Connecting Rod Assemblies
    169
  - Removing Connecting Rod Bolts
    169
  - Remove Crankshaft
    170
  - Remove Governor Cross Shaft
    170
  - Remove Flywheel End Oil Seal
    170
  - Removing Oil Seal
    170
  - Inspection and Reconditioning
    171
  - Automatic Compression Release (ACR)
    171
  - Camshaft
    171
  - Crankshaft
    171
  - Procedure to Remove Crankshaft Plug
    172
  - Procedure to Install New Plug
    172
  - Crankpin Fillets
    172
  - Removing Crankpin Plug
    172
  - Section 10 Inspection and Reconditioning
    172
  - Honing
    173
  - Cylinder Bore Crosshatch after Honing
    173
  - Clean Cylinder Bore after Honing
    173
  - Flywheel
    174
  - Cylinder Head and Valves
    174
  - Checking Cylinder Head Flatness
    174
  - Measuring Piston Diameter
    174
  - Valve Details
    175
  - Normal
    176
  - Leakage
    176
  - Bad Condition
    176
  - Coking
    176
  - Excessive Combustion Temperatures
    177
  - Stem Corrosion
    177
  - Gum
    177
  - Overheating
    177
  - Valve Guides
    178
  - Lapping Valves
    178
  - Valve Seat Inserts
    178
  - Pistons and Rings
    178
  - Common Types of Piston Damage
    179
  - Stuck, Broken Rings
    179
  - Abrasive Scratched Rings
    179
  - Overheated or Deteriorated Oil
    179
  - Install New Piston Rings
    180
  - Measuring Piston Ring End Gap
    180
  - Installing Piston Rings
    180
  - Hydraulic Lifters
    181
  - “Bleeding” the Lifters
    181
  - Closure Plate Assembly
    181
  - Connecting Rods
    181
  - Removing Governor Gear
    182
  - Governor Shaft Press Depth
    182
  - Oil Pump, Oil Pickup, and Relief Valve
    182
  - Governor Cross Shaft Oil Seal
    183
  - Installing Cross Shaft Oil Seal
    183
  - Reassembly
    185
  - Typical Reassembly Sequence
    185
  - Seal Bore of Crankcase
    185
  - Install Flywheel End Oil Seal
    185
  - Install Governor Cross Shaft
    186
  - Install Crankshaft
    186
  - Installing 8 MM Governor Cross Shaft
    186
  - Setting Governor Cross Shaft End Play
    186
  - Section 11 Reassembly
    186
  - Install Connecting Rods with Pistons and Rings
    187
  - Installing Crankshaft
    187
  - Installing Piston Assembly Using Ring Compressor Tool
    187
  - Piston, Connecting Rod and End Cap Detail
    187
  - Connecting Rod Bolts
    188
  - Torquing Connecting Rod End Cap
    188
  - Determining Camshaft End Play
    188
  - Apply Camshaft Lubricant to Cam Lobes
    188
  - Thrust Bearing, Washer and Shim
    189
  - Checking Camshaft End Play
    189
  - Install Closure Plate Oil Seal
    190
  - Install Closure Plate Assembly
    190
  - Crankshaft End Play Shims
    190
  - Closure Plate Sealant Pattern
    191
  - Torquing Closure Plate Fasteners
    191
  - Install Stator and Backing Plates
    191
  - Install Flywheel
    192
  - Torquing Stator Screws
    192
  - Route Stator Leads in Groove
    192
  - Clean and Dry Taper of Crankshaft
    192
  - Install Flywheel Fan
    193
  - Install Plastic Grass Screen
    193
  - Installing Fan on Flywheel
    193
  - Installing Plastic Grass Screen
    193
  - Install Supports for the Metal Grass Screen
    194
  - Install Hydraulic Lifters
    194
  - Installing Supports for Metal Grass Screen
    194
  - Valve Stem Seals
    195
  - Assemble Cylinder Heads
    195
  - Install Cylinder Heads
    195
  - Valve Components
    195
  - Torquing Cylinder Head Fasteners
    196
  - Cylinder Head Fastener Torque Sequence
    196
  - Install Push Rods and Rocker Arms
    197
  - Torquing Rocker Arm Screws
    197
  - Install Push Rods in Their Original Position
    197
  - Installing Ignition Module
    198
  - Install Spark Plugs
    198
  - Install Ignition Modules
    198
  - Setting Ignition Module Air Gap
    199
  - Sealant Applied to Terminals
    199
  - Install Intake Manifold
    199
  - Routing of Wiring Harness
    199
  - Install Breather Cover and Inner Baffles
    200
  - Installing New Breather Filter
    200
  - Installing Breather Reed Assembly
    200
  - Install Blower Housing and Outer Baffles
    201
  - Installing Blower Housing
    201
  - Installing Inner Baffles
    201
  - Routing Wiring Harness and Leads
    201
  - Ground Lead Details
    202
  - Tighten Baffle Mounting Screws
    202
  - Installing Metal Type Grass Screen
    202
  - Reconnect Rectifier-Regulator
    203
  - Installing B+ Lead into Plug
    203
  - Connecting Ground Lead
    203
  - Grounding Bracket and Attached Connector
    203
  - Install Fuel Pump
    204
  - Install Electric Starter Motor
    204
  - Reinstalling SAM Module
    204
  - Installing Electric Starter Motor
    204
  - Install Carburetor
    205
  - Install External Governor Controls
    205
  - Installing Carburetor Assembly
    205
  - Metal-Cased Pulse Fuel Pump
    205
  - Adjusting Governor Lever
    206
  - Holding and Tightening Governor Arm
    206
  - Install Throttle & Choke Controls
    206
  - Connecting Choke Linkage
    206
  - 6 MM Governor Lever and Hole Position/Rpm Chart
    207
  - 8 MM Governor Lever and Hole Position/Rpm Charts
    208
  - CH18 Engines
    208
  - CH20-740 Engines
    208
  - CH26,CH745 EFI Engines
    208
  - Throttle/Choke Control Bracket Detail
    209
  - Install Oil Sentry
    209
  - Install Control Panel
    209
  - Install Valve Covers
    210
  - Valve Cover Fastener Torque Sequence
    210
  - Install Air Cleaner Assembly
    210
  - Tightening Valve Cover Screws
    210
  - Connecting Fuel Inlet Line
    211
  - Pulling Breather Hose through Base
    211
  - Torquing Base Screws
    211
  - Tightening Rear Base/Bracket Screws
    211
  - Install Oil Cooler
    212
  - Install Oil Filter and Fill Crankcase with Oil
    212
  - Installing New Oil Filter
    212
  - Hand Tightening Oil Filter
    212
  - Prepare the Engine for Operation
    213
  - Testing the Engine
    213
  - Connect Spark Plug Leads
    213
  - Reinstall the Dipstick in Tube
    213
  - Clutch
    215
  - Wet Type Clutch - Exploded View
    215
  - Adjusting Clutch
    216
  - Section 12 Clutch
    216

Kohler COMMAND CH22S Service Manual (218 pages)

HORIZONTAL CRANKSHAFT

Brand: Kohler | Category: Engine | Size: 5.93 MB

Section 1 Safety and General Information
3
Special Tools
18
Section 2 Special Tools
19
Section 3 Troubleshooting
23
Section 4 Air Cleaner and Air Intake System
29
Section 5 Fuel System and Governor
35
Table of Contents
60
Description

61
- Initial Starting/Priming Procedure
  61
- Fuel Recommendations
  61
- EFI Fuel System Components
  62
- Operation
  62
- Important Service Notes
  63
Electrical Components

63
- Electronic Control Unit (ECU)
  63
- Engine Speed Sensor
  64
- Engine (Oil) Temperature Sensor
  69
- Oxygen Sensor
  70
- Electrical Relay
  72
- Fuel Injectors
  73
- Ignition System
  76
- Spark Plug
  77
- Wiring Harness
  77
- Battery Charging System
  78
Fuel Components

78
- Fuel Pump
  78
- Fuel Pressure Regulator
  79
- Fuel Filter
  81
- Fuel Rail
  81
- Fuel Line
  81
- Throttle Body/Intake Manifold Assembly
  82
- Idle Speed Adjustment (RPM)
  82
- Initial Governor Adjustment
  83
Troubleshooting

85
- Troubleshooting Guide
  85
- Electrical System
  86
- Fuel System
  93
- Fault Codes
  93
- Troubleshooting Flow Chart
  101
- Flow Chart Diagnostic Aids
  103
  - Section 6 Lubrication System
    107
  - Section 7 Retractable Starter
    113
  - Section 8 Electrical System and Components
    119
  - Section 9 Disassembly
    155
  - Section 10 Inspection and Reconditioning
    173
  - Section 11 Reassembly
    187

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Kohler COMMAND CH22S Manuals

Kohler COMMAND CH22S Service Manual (218 pages)

Table of Contents

Description

Electrical Components

Fuel Components

Troubleshooting

Kohler COMMAND CH22S Service Manual (218 pages)

Table of Contents

Description

Electrical Components

Fuel Components

Troubleshooting

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