Kohler Command CV22 Manuals

Manuals and User Guides for Kohler Command CV22. We have 6 Kohler Command CV22 manuals available for free PDF download: Service Manual, Owner's Manual

Kohler Command CV22 Service Manual (218 pages)

VERTICAL CRANKSHAFT

Brand: Kohler | Category: Engine | Size: 7.83 MB

Table of Contents
2
Safety Precautions
3
Section 1. Safety and General Information
3
Section 3. Troubleshooting
24
- Engine will Not Idle
  25
- Engine Overheats
  25
- Engine Knocks
  25
- Engine Loses Power
  25
- Cleaning the Engine
  26
- Basic Engine Tests
  26
- Crankcase Vacuum Test
  26
- To Test the Crankcase Vacuum with the Manometer
  26
- Leakdown Test Instructions
  27
- Compression Test
  27
- Cylinder Leakdown Test
  27
- No Crankcase Vacuum/Pressure in Crankcase
  27
- Leakdown Test Results
  28
- Standard Air Cleaner
  29
- Commercial Mower Air Cleaner
  29
Section 4. Air Cleaner and Air Intake System
29
Section 5. Fuel System and Governor
35
- Fuel Filter
  36
- Fuel Line
  36
- “Family” Number Location
  36
- Fuel System Tests
  37
- Troubleshooting – Fuel System Related Causes
  37
- Carburetor
  38
- Fuel Pump
  38
- Performance
  38
- Replacing the Fuel Pump
  38
- Slow Circuit
  39
- Main Circuit
  40
- Troubleshooting Checklist
  41
- Troubleshooting – Carburetor Related Causes
  41
- Carburetor Adjustments (CV17-740)
  42
- Fuel Shut-Off Solenoid
  42
- Fuel Shut-Off Solenoid Location
  42
- High Altitude Operation
  42
- Carburetor Adjustments
  43
- Models with Governed Idle System
  43
- Carburetor Servicing (CV17-740)
  44
- Governed Idle Spring Location
  44
- Holding Throttle Lever against Idle Stop Screw (One-Barrel Carburetor)
  44
- Proper Float Level
  44
- Typical Carburetor - Exploded View
  46
- Carburetor Repair Kit
  47
- Float Replacement
  47
- Reassembly Procedure
  47
- Removing Float and Inlet Needle
  47
- Checking Float Height
  48
- Fuel Bowl Removed from Carburetor
  48
- Installing Float Assembly
  48
- Installing Fuel Bowl
  48
- Installing Main Nozzle and Main Jet
  49
- Main Jet and Slow Jet Removed
  49
- Float and Inlet Needle
  50
- Installing Plug into Slow Jet Tube
  50
- Installing Slow Jet
  50
- Accelerator Pump Rebuild
  51
- Installing Fuel Bowl O-Rings
  51
- Installing Idle Fuel Adjusting Screw and Spring
  51
- Installing Idle Speed Adjusting Screw and Spring
  51
- Accelerator Pump Cover and Diaphragm Removed
  52
- Check Valve and Retaining Ring Installed
  52
- Diaphragm Installed
  52
- Removing Retaining Ring
  52
- Assembling Choke Lever
  53
- Choke Details
  53
- Choke Repair
  53
- Installing Accelerator Pump Housing Screws and Hose
  53
- Float Circuit
  54
- Keihin BK Two-Barrel Carburetor (CV750)
  54
- Main (High-Speed) Circuit
  54
- Slow & MID-Range Circuit
  54
- Carburetor Adjustment
  55
- Low Idle Fuel Adjustment
  55
- Low Idle Speed (RPM) Adjustment
  55
- Carburetor Servicing
  56
- Holding Throttle Lever against Idle Stop Screw (Two-Barrel Carburetor)
  56
- Optimum Low Idle Fuel Settings
  56
- Float and Inlet Needle Details
  57
- Main Jets and Nozzles Removed
  59
- Removing Screw and Washer
  59
- Slow Jets and O-Ring Detail
  59
- Keihin BK Two-Barrel Carburetor - Exploded View
  63
- Governor
  64
- Governor Controls and Linkage
  64
- Initial Adjustment
  64
- Governor Control Connections
  65
- Left Side Pull
  65
- Sensitivity Adjustment
  65
- Choke Lever Detail
  66
- Commercial Mower Governor Arrangement
  66
- Governor Used with Commercial Mower Air Cleaner (CV17-745)
  66
- Governor/Controls Assembly (CV750)
  67
- Electronic Fuel Injection (EFI) Fuel System
  68
- Description
  69
- Fuel Recommendations
  69
- Initial Starting/Priming Procedure
  69
- EFI Fuel System Components
  70
- Gasoline/Ether Blends
  70
- Operation
  70
- Electrical Components
  71
- Electronic Control Unit (ECU)
  71
- Important Service Notes
  71
- Engine Speed Sensor
  72
- Engine (Oil) Temperature Sensor
  76
- Cutaway of Oxygen Sensor
  77
- Oxygen Sensor
  77
- Electrical Relay
  79
  - To Replace Oxygen Sensor
    79
  - EFI Fuel System
    80
- Fuel Injectors
  80
  - Relay Connector
    80
  - Relay Terminal Details
    80
  - Fuel Injector Details
    81
  - Style 2 Fuel Injector
    81
  - Checking Injectors
    82
  - Volt Noid Light
    82
  - Injector Inspection Points
    83
  - Ignition Coil
    84
- Ignition System
  84
- Battery Charging System
  85
- Fuel Components
  85
- Fuel Pump
  85
- Spark Plugs
  85
- Wiring Harness
  85
- External Fuel Pressure Regulators
  86
- Fuel Pressure Regulator
  86
- Fuel Rail
  88
  - High Pressure Fuel Line
    88
  - In-Line Fuel Filter
    88
  - Throttle Body/Intake Manifold
    88
- Idle Speed Adjustment (RPM)
  89
- Throttle Body/Intake Manifold Assembly
  89
- Initial Governor Adjustment
  90
- Troubleshooting Guide
  92
- Electrical System
  93
  - “24 Pin” (MSE 1.0) Plastic-Cased ECU Systems
    93
  - “32 Pin” (MSE 1.1) Plastic-Cased ECU Systems
    96
- Fault Codes
  97
- Fuel System
  97
  - Diagnostic Code Summary
    98
  - Example of Diagnostic Display
    98
- Troubleshooting Flow Chart
  105
- Bosch EFI Diagnostic Flow Diagram
  106
- Flow Chart Diagnostic Aids
  107
Oil Container Logo
109
Section 6. Lubrication System
109
- Oil Level Marks on Dipstick
  110
- Checking Oil Level
  110
- Oil Fill Cap/Dipstick
  110
- Changing Oil and Oil Filter
  110
- Changing Oil Filter
  111
- Service Oil Cooler
  111
- Crankcase Mounted Oil Cooler
  111
- Blower Housing Mounted Oil Cooler
  111
- Oil Sentry
  112
- Oil Sentry Location
  112
- Testing the Switch
  112
- Retractable Starter – Exploded View
  113
- Removing Starter Handle
  113
- To Install Starter
  113
Section 7. Retractable Starter
113
- Installing Rope
  114
- Pawls (Dogs) Replacement
  114
- Position of Spring and Keeper in Pulley
  115
- Center Screw, Washer and Pawl Retainer
  115
- Brake Spring and Washer, Pawls, and Pawl Springs
  115
- Removing Pulley from Housing
  115
- Installing Pulley and Spring into Housing
  116
- Installing Pawls and Pawl Springs
  116
- Servicing Spark Plug
  117
Section 8. Electrical System and Components
117
- Normal
  118
- Carbon Fouled
  118
- Wet Fouled
  118
- Overheated
  118
- Battery Test
  119
- Battery Maintenance
  119
- Battery Size Recommendations
  119
- Battery
  119
- Operation of CD Ignition Systems
  120
- Electronic CD Ignition Systems
  120
- Capacitive Discharge (Fixed Timing) Ignition System
  121
- Capacitive Discharge Ignition Module Schematic
  121
- Capacitive Discharge with Electronic Spark Advance
  122
- Capacitive Discharge Ignition System with Spark Advance
  122
- Block Diagram - Spark Advance Module
  122
- Troubleshooting CD Ignition Systems
  123
- Test Procedure for Standard (Fixed Timing) CD Ignition System
  123
- Check for Timing Advance
  125
- Test the Ignition Modules and Connections
  125
- Ignition Module Resistance Table
  126
- Test the SAM
  126
- To Test – Using 25 761 21-S Tester
  127
- ASAM (Only) Test Procedure
  127
- Connected Tester Leads
  129
- To Test – Using 25 761 40-S Tester
  129
- DSAM/ASAM Test Procedure
  129
- Select Test Number
  130
- “Pass” Indicator
  130
- 15/20/25 Amp Regulated Charging System
  131
- 15 Amp Stator and Rectifier-Regulator
  132
- 20 Amp Stator and Rectifier-Regulator
  132
- 3 Amp Unregulated Charging System
  133
- 25 Amp Stator and Rectifier-Regulators
  133
- Stator
  134
- Rectifier-Regulator
  134
- 15 Amp Rectifier-Regulators
  134
Section 9. Disassembly
134
- 20/25 Amp Rectifier-Regulators
  135
- Connections for Testing Charging System
  137
- 15/20/25 Amp Battery Charging Systems
  138
- 3 Amp Battery Charging System with 70 Watt Lighting Stator
  139
- Electric Starting Motors
  140
- Starting Motor Precautions
  140
- Inertia Drive Electric Starters
  140
- Starter Removal and Installation
  140
- Operation - Inertia Drive Starters
  141
- Starter Drive Service
  141
- Style ‘‘A’’ Drive Service
  141
- Style ‘‘B’’ Drive Service
  142
- Drive Components, ‘‘Bonded’’ Inertia Drive Starter
  142
- Holding Tool and Turning Center
  142
- Retaining Ring Installation
  143
- Starter Disassembly
  143
- Style ‘‘A’’ End Cap Brush Replacement
  143
- Starter Reassembly
  144
- For Style ‘‘B’’ Commutator End Caps
  144
- Commutator Service
  144
- Style ‘‘B’’ End Cap Brush Replacement
  144
- Solenoid Shift Electric Starters
  145
- Operation – Solenoid Shift Starter
  145
- Nippondenso Solenoid Shift Starter
  145
- Delco-Remy Starters
  146
- Completed Delco-Remy Starter
  146
- Starter Service
  146
- Removing Solenoid Screws
  147
- Solenoid Removed from Starter
  147
- Removing Plunger
  147
- Removing Thru Bolts
  148
- Removing Commutator End Plate Assembly
  148
- Starter Frame Removed
  148
- Armature and Lever Removed
  148
- Retaining Ring Detail
  149
- Delco-Remy Starter
  149
- Checking Armature
  150
- Brushes and Springs
  150
- Checking Brushes
  150
- Drive Pinion
  150
- Brush Replacement
  151
- Removing Brush Holder
  151
- Service Brush Kit
  151
- Installing Stop Collar and Retainer
  151
- Installing Thrust Washer
  152
- Installing Armature and Pivot Lever
  152
- Installing Backup Washer and Grommet
  152
- Installing Frame and Drain Tube
  152
- Removing Retaining Clips
  153
- Installing Brush Holder Assembly with Supplied Tube
  153
- Brush Installation Tool with Extension
  153
- Positive (+) Brush Lead Connection
  154
- Installing Brush Holder Assembly Using Tool with Extension
  154
- Torquing Thru Bolts
  154
- Torquing Brush Holder Screws
  154
- Solenoid Test Procedure
  155
- Solenoid Shift Style Starters
  155
- Testing Pull-In Coil/Plunger Actuation
  155
- Testing Pull-In Coil/Solenoid Contact Continuity
  155
- Solenoid Hold-In Coil/Contact Continuity Test
  156
- Testing Hold-In Coil/Solenoid Contact Continuity
  156
- Disassembly
  157
- Typical Disassembly Sequence
  157
- Disconnect Spark Plug Leads
  157
- Shut off Fuel Supply
  157
- Removing Oil Fill Cap/Dipstick
  158
- Remove Air Cleaner Assembly
  158
- Remove Muffler
  158
- Remove Oil Cooler
  158
- Removing Standard Element and Precleaner
  159
- Removing Standard Air Cleaner Base
  159
- Removing Commercial Mower Element and Precleaner
  159
- Disconnect Breather Hose from Base
  159
- Heavy Duty Air Cleaner
  160
- Remove Control Panel
  160
- Removing Breather Hose, Hex Nuts and Adapter Elbow
  160
- Removing Upper Mounting Screws
  160
- Remove Fuel Pump
  161
- Remove Throttle Controls
  161
- Removing Throttle Control Bracket
  161
- Removing Control Panel
  161
- Removing Governor Lever
  162
- Remove External Governor Controls
  162
- Removing Control Bracket
  162
- Remove Carburetor
  162
- Remove Electric Starter Motor
  163
- Removing Carburetor and Linkage
  163
- Removing Carburetor Mounting Nuts
  163
- Removing Carburetor
  163
- Remove Outer Baffles and Blower Housing
  164
- Disconnecting Plug from Rectifier- Regulator
  164
- Note Location of Short Screws
  164
- Removing Outer Baffles
  164
- Remove Oil Sentry
  165
- Removing Flywheel Screen
  165
- Remove Inner Baffles and Breather Cover
  165
- Rectifier-Regulator Ground Strap
  165
- Removing Valve Cover
  166
- Break Breather Cover Seal
  166
- Remove Ignition Modules
  166
- Remove Valve Covers
  166
- Remove Intake Manifold
  167
- Remove Spark Plugs
  167
- Position of Ignition Modules
  167
- Removing Intake Manifold
  167
- Remove Cylinder Heads and Hydraulic Lifters
  168
- Disassemble Cylinder Heads
  168
- Removing Cylinder Head
  168
- Removing Hydraulic Lifters
  168
- Remove Grass Screen and Fan
  169
- Removing Rocker Arm
  169
- Valve Components
  169
- Intake Valve Seal Location
  169
- Removing Fan
  170
- Removing Plastic Grass Screen
  170
- Remove Stator and Backing Plates
  170
- Remove Flywheel
  170
- Remove Oil Pan Assembly
  171
- Oil Pump Assembly
  171
- Remove Camshaft
  171
- Remove Governor Cross Shaft
  171
- Remove Connecting Rods with Pistons and Rings
  172
- Removing Governor Cross Shaft Hitch Pin
  172
- Removing Connecting Rod End Cap
  172
- Removing Governor Cross Shaft Retainer (8 MM Shaft Design)
  172
- Remove Crankshaft
  173
- Remove Flywheel End Oil Seal
  173
- Automatic Compression Release (ACR)
  174
- Camshaft
  174
- Crankshaft
  174
Section 10. Inspection and Reconditioning
174
- Removing Crankpin Plug
  175
- Procedure to Install New Plug
  175
- Crankpin Fillets
  175
- Crankcase
  176
- Cylinder Bore Crosshatch after Honing
  176
- Clean Cylinder Bore after Honing
  177
- Flywheel
  177
- Cylinder Head and Valves
  177
- Measuring Piston Diameter
  177
- Checking Cylinder Head Flatness
  178
- Valve Details
  178
- Valve Guides
  181
- Valve Seat Inserts
  181
- Pistons and Rings
  181
- Intake Valve Stem Seal
  181
- Abrasive Scratched Rings
  182
- Overheated or Deteriorated Oil
  182
- Stuck, Broken Rings
  182
- Common Types of Piston Damage
  182
- Install New Piston Rings
  183
- Measuring Piston Ring Side Clearance
  183
- Measuring Piston Ring End Gap
  183
- Installing Piston Rings
  183
- Hydraulic Lifters
  184
- Oil Pan Assembly
  184
- “Bleeding” the Lifters
  184
- Connecting Rods
  184
- Removing Governor Gear
  185
- Removing Oil Pump
  185
- Governor Shaft Press Depth
  185
Section 11. Reassembly
185
- Oil Pump Torque Sequence
  186
- Oil Pressure Relief Valve Piston and Spring
  186
- Oil Pump, Plastic Oil Pickup, and One-Piece Relief Valve (Later Style)
  186
- Oil Pump, Oil Pickup, and Relief Valve (Original Style)
  186
- Governor Cross Shaft Oil Seal
  187
- Crankcase with Breather Reed
  187
- Installing Cross Shaft Oil Seal
  187
- Crankcase Breather System
  187
- Reassembly
  188
- Typical Reassembly Sequence
  188
- Install Flywheel End Oil Seal
  188
- Seal Bore of Crankcase
  188
- Install Governor Cross Shaft
  189
- Installing Oil Seal in Crankcase
  189
- Installing Governor Cross Shaft Hitch Pin (6 MM Shaft)
  189
- Installing 8 MM Governor Cross Shaft
  189
- Proper Piston Connecting Rod Orientation
  190
- Installing Piston Assembly Using Ring Compressor Tool
  190
- Install Connecting Rods with Pistons and Rings
  190
- Install Crankshaft
  190
- Apply Camshaft Lubricant to Cam Lobes
  191
- Install Camshaft
  191
- Connecting Rod Bolts
  191
- Torquing Connecting Rod End Cap
  191
- Determining Camshaft End Play
  192
- Governor Gear Assembly
  192
- Install Oil Seal in Oil Pan
  192
- Checking Camshaft End Play
  192
- Install Oil Pan Assembly
  193
- Install Stator and Backing Plates
  193
- Oil Pan Sealant Pattern CV17-23
  193
- Torquing Oil Pan Fasteners
  193
- Route Stator Leads in Groove
  194
- Carefully Align Keyway to Key
  194
- Torquing Stator Screws
  194
- Install Flywheel
  194
- Installing Plastic Grass Screen
  195
- Install Supports for the Metal Grass Screen
  195
- Installing Fan
  195
- Install Fan and Grass Screen
  195
- Install Hydraulic Lifters
  196
- Installing Supports for Metal Grass Screen
  196
- Applying Camshaft Lubricant to Bottom of Lifters
  196
- Torquing Supports for Metal Screen
  196
- Valve Stem Seals
  197
- Assemble Cylinder Heads
  197
- Match Numbers on Cylinder Barrel and Head
  197
- Install Cylinder Heads
  198
- Installing Valves with Valve Spring Compressor
  198
- Torquing Cylinder Head Fasteners
  198
- Cylinder Head Fastener Torque Sequence
  198
- Install Push Rods in Their Original Position
  199
- Install Push Rods and Rocker Arms
  199
- Torquing the Cylinder Head Mounting Nuts (Stud Design)
  199
- Installing New Mounting Studs to Specified Height
  199
- Install Ignition Modules
  200
- Installing Spark Plugs
  200
- Torquing Rocker Arm Screws
  200
- Install Intake Manifold
  201
- Setting Ignition Module Air Gap
  201
- Installing Intake Manifold Gaskets
  201
- Intake Manifold Torque Sequence
  201
- Install Breather Cover and Inner Baffles
  202
- Sealant Applied to Terminals
  202
- Breather Cover and Gasket
  202
- Connect Leads on SMART-SPARK Ignition Modules
  202
- Finger Tighten Two Remaining Cover Screws
  203
- Wires on Oil Filter Side of Engine
  203
- Installing Inner Baffles
  203
- Installing Screws (Locations 3 and 4)
  203
- Breather Cover Fastener Torque Sequence
  204
- Installing Blower Housing
  204
- Tightening Short Screws for Outer Baffles
  204
- Tightening Outer Baffle Front Screws
  204
- Install Oil Sentry
  205
- Install Control Panel
  205
- Reconnect Rectifier-Regulator
  205
- SMART-SPARK Module
  205
- Install Valve Covers
  206
- Install Carburetor
  206
- Valve Cover Fastener Torque Sequence
  206
- Installing Carburetor, Throttle Linkage, and Governor Lever
  207
- Installing Two-Barrel Carburetor
  207
- Install Governor Lever to Shaft
  207
- Installing External Governor Controls
  207
- Installing Control Panel
  208
- Choke Linkage Details
  208
- Installing Lower Support Control Bracket
  208
- Throttle Linkage Details
  208
- Install Throttle and Choke Controls
  209
- Connecting Governor Spring to Governor Lever
  209
- Standard Control Bracket
  209
- 6 MM Governor Lever and Hole Position/Rpm Chart
  210
- Throttle/Choke Control Bracket Detail
  210
- 8 MM Governor Lever and Hole Position/Rpm Chart
  211
- CV18 Engines
  211
- CV20-740 Engines with 0.0299 + 0.003 In. Thick Throttle Limiter
  211
- CV17, CV20-740 Engines Without Throttle Limiter
  211
- Install Electric Starter Motor
  212
- Installing Starter and Lift Bracket
  212
- Installing Dipstick Tube
  212
- Standard Air Cleaners
  213
- Install Air Cleaner Assembly
  213
- Install Pulse Line
  213
- Install Fuel Pump
  213
- Heavy Duty Air Cleaners
  214
- Breather Hose and Separator Details
  214
- Torquing Base and Spitback Cup Mounting Nuts
  214
- Torquing Hex Nuts
  214
- Install Muffler
  215
- Install Oil Cooler
  215
- Install Oil Filter and Fill Crankcase with Oil
  215
- Installing and Tightening Oil Filter
  215
- Connect Spark Plug Leads
  216
- Prepare the Engine for Operation
  216
- Testing the Engine
  216
- Install Oil Drain Plug(S)
  216

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Safety Precautions
2
California Proposition 65 Warning
2
Oil Recommendations
5
Fuel Recommendations
5
Engine Identification Numbers
6
Model Designation
6
Pre-Start Checklist
6
Operating Instructions
6
Cold Weather Starting Hints
7
Maintenance Instructions
8
Maintenance Schedule
8
Check Oil Level
9
Service Precleaner and Air Cleaner Element
11
Heavy-Duty Air Cleaner
13
Clean Air Intake/Cooling Areas
13
Ignition System
13
Check Spark Plugs
14
Battery Charging
14
Fuel System
14
Troubleshooting
15
Carburetor Troubleshooting and Adjustments
15
Parts Ordering
19
Major Repair
19
Specifications
20

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