Kohler Command CV25S Manuals

Manuals and User Guides for Kohler Command CV25S. We have 1 Kohler Command CV25S manual available for free PDF download: Service Manual

Kohler Command CV25S Service Manual

Kohler Command CV25S Service Manual (218 pages)

VERTICAL CRANKSHAFT

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

Table of Contents

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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