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Command CV17
Kohler Command CV17 User Manual
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9.17
Section 9
Disassembly
9
3.
Repeat the above procedure for the other
connecting rod and piston assembly
.
Remove Crankshaf
t
1.
Carefully pull the crankshaft from the crankcase.
See Figure 9-62.
Figure 9-62. Removing Crankshaft.
Figure 9-63. Removing Oil Seal.
Remove Flywheel End Oil Seal
1.
Remove the oil seal from the crankcase. See
Figure 9-63.
172
174
Table of Contents
Table of Contents
2
Safety Precautions
3
Section 1. Safety and General Information
3
Engine Identification Decal Location
5
Engine Identification Numbers
5
Oil Recommendations
6
Fuel Recommendations
6
Oil Type
6
General Recommendations
6
Periodic Maintenance Instructions
7
Storage
7
Dimensions in Millimeters
8
Typical Engine Dimensions CV Series with Standard Flat Air Cleaner
8
General Torque Values
18
Metric Fastener Torque Recommendations for Standard Applications
18
English Fastener Torque Recommendations for Standard Applications
19
Section 2. Tools & Aids
20
Rocker Arm/Crankshaft Tool
23
Special Tools You Can Make
23
Flywheel Holding Tool
23
Engine Cranks but will Not Start
24
Engine Starts but Does Not Keep Running
24
Engine Starts Hard
24
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
Paper Element Service
30
Precleaner on Standard Air Cleaner
30
Precleaner on Commercial Mower Type Air Cleaner
30
Air Cleaner System Components - Standard
31
Air Cleaner System Components - Commercial Mower Type
31
Air Cleaner Components
32
Disassembly/Reassembly - Standard Type
32
Disassembly/Reassembly - Commercial Mower Type
32
Base Plate Removal on Standard Type
32
Removing Elements
33
Heavy-Duty Air Cleaner
33
To Service
33
Air Intake/Cooling System
34
Cleanout Kit Installed on Blower Housing
34
Fuel System Components
35
Fuel Type
35
Gasoline/Alcohol Blends
35
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
B-4. Speed Sensor Connector
73
Throttle Position Sensor (TPS)
73
TPS Location
74
B-7. Service Connector Plug, Plastic Cased ECU Harness
75
TPS Initialization Procedure
75
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
Internal Fuel Pressure Regulators
86
External Regulators and Base/Holders
87
Fuel Pressure Regulator Details
87
Internal (In-Tank) Regulator
87
Internal (In-Tank) Regulator and Base/Holder
87
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
Upper Throttle Body/Intake Manifold Details
89
Checking the Initial Adjustment
90
Idle Speed Screw Details
90
Initial Governor Adjustment
90
Throttle Details
90
Adjusting Governor Shaft
91
Checking ‘‘Split’’ of Clamp
91
Inserting Feeler Gauge
91
Throttle Link in Center of Hole
91
Engine Stalls or Idles Roughly (Cold or Warm)
92
Engine Starts Hard or Fails to Start When Cold
92
Engine Starts Hard or Fails to Start When Hot
92
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
4
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Kohler Command CV17 Specifications
General
Brand
Kohler
Model
Command CV17
Category
Engine
Language
English
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