Kohler Command CV18 Service Manual Download Page 1

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24 690 07 Rev. H

KohlerEngines.com

CV17-CV25, CV620-CV730, CV740, CV750
S

ervice Manual

Safety

Maintenance

Specifications

Tools and Aids

Troubleshooting

Air Cleaner/Intake

Fuel System

Governor System

Lubrication System

Electrical System

Starter System

Disassembly/Inspection and Service

Reassembly

IMPORTANT: Read all safety precautions and instructions carefully before operating equipment. Refer to operating

instruction of equipment that this engine powers.

Ensure engine is stopped and level before performing any maintenance or service.

Summary of Contents for Command CV18

Page 1: ...24 Fuel System 30 Governor System 31 Lubrication System 33 Electrical System 49 Starter System 58 Disassembly Inspection and Service 75 Reassembly IMPORTANT Read all safety precautions and instructions carefully before operating equipment Refer to operating instruction of equipment that this engine powers Ensure engine is stopped and level before performing any maintenance or service ...

Page 2: ...ury or death Disconnect and ground spark plug lead s before servicing Before working on engine or equipment disable engine as follows 1 Disconnect spark plug lead s 2 Disconnect negative battery cable from battery WARNING Hot Parts can cause severe burns Do not touch engine while operating or just after stopping Never operate engine with heat shields or guards removed WARNING Cleaning Solvents can...

Page 3: ...lement Air Cleaner Intake Change oil Lubrication System Remove cooling shrouds and clean cooling areas Air Cleaner Intake Check oil cooler fins clean as necessary if equipped Lubrication System Every 200 Hours Change oil filter Lubrication System Replace fuel filter Every 250 Hours Replace heavy duty air cleaner element and check inner element Air Cleaner Intake Every 500 Hours Replace heavy duty ...

Page 4: ...ale or contaminated fuel are not warrantable Fuel must meet these requirements Clean fresh unleaded gasoline Octane rating of 87 R M 2 or higher Research Octane Number RON 90 octane minimum Gasoline up to 10 ethyl alcohol 90 unleaded is acceptable Methyl Tertiary Butyl Ether MTBE and unleaded gasoline blend max 15 MTBE by volume are approved Do not add oil to gasoline Do not overfill fuel tank Do ...

Page 5: ...Dimensions in millimeters Inch equivalents shown in Engine Dimensions with Low Profile Air Cleaner Specifications 5 24 690 07 Rev H KohlerEngines com ...

Page 6: ...Dimensions in millimeters Inch equivalents shown in Engine Dimensions with Commercial Mower Air Cleaner Specifications 6 24 690 07 Rev H KohlerEngines com ...

Page 7: ...L AIR FILTER RAIN CAP REMOVAL SPARK PLUG FUEL FILTER 275 56 10 849 15 80 622 SPARK PLUG 417 59 16 441 529 91 20 863 CRANKSHAFT 89 41 3 520 241 66 9 514 77 68 3 058 334 19 13 157 50 00 1 969 EXHAUST PORT 1 2X 89 41 3 520 2X 72 85 2 868 M8 X 1 25 4 STUDS SOLENOID SHIFT STARTER MOUNTING HOLE A 4X Ø 9 20 362 THRU Ø 254 00 10 00 B C 104 02 4 095 50 00 1 969 EXHAUST PORT 2 30 30 405 97 15 983 247 90 9 7...

Page 8: ...50 Blower Housing and Sheet Metal M5 Fasteners 6 2 N m 55 in lb into new holes 4 0 N m 35 in lb into used holes M6 Fasteners 10 7 N m 95 in lb into new holes 7 3 N m 65 in lb into used holes Carburetor and Intake Manifold Intake Manifold Mounting Fastener torque in 2 increments first to 7 4 N m 66 in lb finally to 9 9 N m 88 in lb Carburetor Mounting Nut 6 2 7 3 N m 55 65 in lb Connecting Rod Cap ...

Page 9: ...Ignition Spark Plug 27 N m 20 ft lb Module Fastener 4 0 6 2 N m 35 55 in lb Rectifier Regulator Fastener 1 4 N m 12 6 in lb Muffler Retaining Nuts 24 4 N m 216 in lb Oil Cooler Adapter Nipple 27 N m 20 ft lb Oil Sentry Pressure Switch 4 5 N m 40 in lb Oil Pan Fastener 24 4 N m 216 in lb Solenoid Starter Mounting Hardware Nippondenso Starter Delco Remy Starter 6 0 9 0 N m 53 79 in lb 4 0 6 0 N m 35...

Page 10: ...2 CV620 CV621 CV640 CV641 CV22 CV23 CV620 CV640 CV670 CV680 CV25 CV730 CV740 CV750 Camshaft End Play with shim 0 076 0 127 mm 0 0030 0 0050 in Running Clearance 0 025 0 063 mm 0 0010 0 0025 in Bore I D New Max Wear Limit 20 000 20 025 mm 0 7874 0 7884 in 20 038 mm 0 7889 in Bearing Surface O D New Max Wear Limit 19 962 19 975 mm 0 7859 0 7864 in 19 959 mm 0 7858 in Connecting Rod Connecting Rod to...

Page 11: ...in 40 84 mm 1 608 in 0 022 mm 0 0009 in 0 025 mm 0 0010 in Oil Pan End Main Bearing Journal O D New O D Max Wear Limit Max Taper Max Out of Round 40 913 40 935 mm 1 6107 1 6116 in 40 84 mm 1 608 in 0 022 mm 0 0009 in 0 025 mm 0 0010 in Connecting Rod Journal O D New O D Max Wear Limit Max Taper Max Out of Round 35 955 35 973 mm 1 4156 1 4163 in 35 94 mm 1 415 in 0 018 mm 0 0007 in 0 025 mm 0 0010 ...

Page 12: ... Rings and Piston Pin Piston Style A Piston to Piston Pin Running Clearance 0 006 0 017 mm 0 0002 0 0007 in Pin Bore I D New Max Wear Limit 17 006 17 012 mm 0 6695 0 6698 in 17 025 mm 0 6703 in Pin O D New Max Wear Limit 16 995 17 000 mm 0 6691 0 6693 in 16 994 mm 0 6691 in Top Compression Ring to Groove Side Clearance 0 040 0 085 mm 0 0016 0 0033 in 0 040 0 080 mm 0 0016 0 0031 in 0 030 0 076 mm ...

Page 13: ...t 72 839 mm 2 8677 in 76 816 mm 3 0242 in 79 816 mm 3 1423 in 82 822 mm 3 2606 in Piston Thrust Face to Cylinder Bore8 Running Clearance New 0 022 0 065 mm 0 0009 0 0026 in 0 039 0 082 mm 0 0015 0 0032 in Piston Style B Piston to Piston Pin Running Clearance 0 006 0 017 mm 0 0002 0 0007 in Pin Bore I D New Max Wear Limit 17 006 17 012 mm 0 6695 0 6698 in 17 025 mm 0 6703 in Pin O D New Max Wear Li...

Page 14: ... Valve Lifters Hydraulic Valve Lifter to Crankcase Running Clearance 0 0241 0 0501 mm 0 0009 0 0020 in Intake Valve Stem to Valve Guide Running Clearance 0 038 0 076 mm 0 0015 0 0030 in Exhaust Valve Stem to Valve Guide Running Clearance 0 050 0 088 mm 0 0020 0 0035 in Intake Valve Guide I D New Max Wear Limit 7 038 7 058 mm 0 2771 0 2779 in 7 134 mm 0 2809 in Exhaust Valve Guide I D New Max Wear ...

Page 15: ...d Applications Bolts Screws Nuts and Fasteners Assembled Into Cast Iron or Steel Grade 2 or 5 Fasteners Into Aluminum Size Grade 2 Grade 5 Grade 8 Tightening Torque N m in lb 20 8 32 2 3 20 2 8 25 2 3 20 10 24 3 6 32 4 5 40 3 6 32 10 32 3 6 32 4 5 40 1 4 20 7 9 70 13 0 115 18 7 165 7 9 70 1 4 28 9 6 85 15 8 140 22 6 200 5 16 18 17 0 150 28 3 250 39 6 350 17 0 150 5 16 24 18 7 165 30 5 270 3 8 16 2...

Page 16: ... leakdown test on XT 6 engines Kohler 25 761 05 S Design Technology Inc DTI 731 03 Dealer Tool Kit Domestic Complete kit of Kohler required tools Components of 25 761 39 S Ignition System Tester Cylinder Leakdown Tester Oil Pressure Test Kit Rectifier Regulator Tester 120 V AC 60Hz Kohler 25 761 39 S Kohler 25 455 01 S Kohler 25 761 05 S Kohler 25 761 06 S Kohler 25 761 20 S Dealer Tool Kit Intern...

Page 17: ...t available Starter Brush Holding Tool Solenoid Shift SE Tools KLR 82411 SE Tools KLR 82416 Triad OHC Timing Tool Set For holding cam gears and crankshaft in timed position while installing timing belt Kohler 28 761 01 S Valve Guide Reamer K and M Series For properly sizing valve guides after installation Design Technology Inc DTI K828 Valve Guide Reamer O S Command Series For reaming worn valve g...

Page 18: ...ring gear teeth Bosses will lock tool and flywheel in position for loosening tightening or removing with a puller A spanner wrench to lift rocker arms or turn crankshaft may be made out of an old junk connecting rod 1 Find a used connecting rod from a 10 HP or larger engine Remove and discard rod cap 2 Remove studs of a Posi Lock rod or grind off aligning steps of a Command rod so joint surface is...

Page 19: ...re to check simple causes which at first may seem too obvious to be considered For example a starting problem could be caused by an empty fuel tank Some general common causes of engine troubles are listed below and vary by engine specification Use these to locate causing factors Engine Will Not Crank Battery is discharged Faulty electric starter or solenoid Faulty key switch or ignition switch Int...

Page 20: ... indications of improper fit and seal Check air cleaner element Look for holes tears cracked or damaged sealing surfaces or other damage that could allow unfiltered air into engine A dirty or clogged element could indicate insufficient or improper maintenance Check carburetor throat for dirt Dirt in throat is further indication that air cleaner was not functioning properly Check if oil level is wi...

Page 21: ...is closed 2 Start engine and run no load high speed 3 Open clamp and note water level in tube Level in engine side should be a minimum of 10 2 cm 4 in above level in open side If level in engine side is less than specified low no vacuum or level in engine side is lower than level in open side pressure check for conditions in table below 4 Close pinch clamp before stopping engine To test crankcase ...

Page 22: ...ft Install a 3 8 in breaker bar into hole slot of holding tool so it is perpendicular to both holding tool and crankshaft PTO If flywheel end is more accessible use a breaker bar and socket on flywheel nut screw to hold it in position An assistant may be needed to hold breaker bar during testing If engine is mounted in a piece of equipment it may be possible to hold it by clamping or wedging a dri...

Page 23: ... precleaner over paper element Paper Element 1 Clean area around element Remove wing nut element cover and paper element with precleaner 2 Separate precleaner from element service precleaner and replace paper element 3 Check condition of rubber seal and replace if necessary 4 Install new paper element on base install precleaner over paper element reinstall element cover and secure with wing nut Re...

Page 24: ...ne from inlet fitting of fuel pump b Hold line below bottom of tank Open shut off valve if equipped and observe flow Performance Minimum fuel delivery rate must be 7 5 L hr 2 gal hr with a pressure at 0 3 psi and a fuel lift of 24 in A 1 3 L hr 0 34 gal hr fuel rate must be maintained at 5 Hz Fuel Pump Replacement NOTE Make sure orientation of new pump is consistent with removed pump Internal dama...

Page 25: ... running Keihin Two Barrel Carburetor Components D E F G H I C B Z J N P O M S T Q R U K L V X W Y A AF AE AA AB AC AD A Carburetor Body Subassembly B Idle Speed Screw C Idle Speed Spring D Screw E Ground Lead F Retaining Washer G Slow Jet Right Side H Slow Jet Left Side I O ring Slow Jet J Fuel Bowl K O ring Fuel Bowl Upper L O ring Fuel Bowl Lower M Drain Screw N Bowl Screw O Fuel Solenoid P Sea...

Page 26: ...ature a self relieving choke CV750 engines in this series are equipped with a Keihin two barrel side draft design with fixed main jets A self relieving choke similar to that used on single venturi carburetors is also contained in design Troubleshooting Checklist When engine starts hard runs roughly or stalls at low idle speed check following areas before adjusting or disassembling carburetor 1 Mak...

Page 27: ...mpressed air Fuel leaks from carburetor Float stuck Separate fuel bowl from carburetor body Free if stuck or replace float Dirt under fuel inlet needle Remove needle clean needle and seat and blow with compressed air Bowl vents plugged Blow out with compressed air Carburetor bowl gasket leaks Replace gasket Fuel Shut Off Solenoid Most carburetors are equipped with a fuel shut off solenoid Solenoid...

Page 28: ...eed depends on application Refer to equipment manufacturer s recommendations Low idle speed for basic engines is 1200 RPM Place throttle control into idle or slow position Turn low idle speed adjusting screw in or out to obtain allow idle speed of 1200 RPM 75 RPM Governed Idle Speed Adjustment If equipped 1 Hold governor lever away from carburetor so throttle lever is against idle speed RPM adjust...

Page 29: ...ing bowl drain screw 3 Remove float pin some carburetors may have a screw which requires removal and inlet needle Seat for inlet needle is not serviceable and should not be removed 4 Clean carburetor bowl and inlet seat areas as required 5 Carefully remove main jets from carburetor For two barrel carburetors note and mark jets by location for proper reassembly Main jets may be size side specific A...

Page 30: ...rnor spring tension and force applied by regulating pin will again offset each other to hold a steady engine speed Governor Adjustments NOTE Do not tamper with governor setting Overspeed is hazardous and could cause personal injury Initial Adjustment Procedure Make this adjustment whenever governor arm is loosened or removed from cross shaft Adjust as follows 1 Make sure throttle linkage is connec...

Page 31: ... in I D hose to direct oil into appropriate container twist valve drain body counterclockwise and pull Remove dipstick Allow oil to drain completely 2 Clean area around oil filter Place a container under filter to catch any oil and remove filter Wipe off mounting surface a Reinstall drain plug Torque to 13 6 N m 10 ft lb or b Close oil drain valve body remove hose if used and replace cap 3 Place n...

Page 32: ...itch 1 Connect continuity tester across blade terminal and metal case of switch With 0 psi pressure applied to switch tester should indicate continuity switch closed 2 Gradually increase pressure to switch As pressure increases through range of 3 5 psi tester should indicate a change to no continuity switch open Switch should remain open as pressure is increased to 90 psi maximum 3 Gradually decre...

Page 33: ...re feeler gauge Adjust gap to 0 76 mm 0 03 in 2 Install plug into cylinder head 3 Torque plug to 27 N m 20 ft lb Inspection Inspect each spark plug as it is removed from cylinder head Deposits on tip are an indication of general condition of piston rings valves and carburetor Normal and fouled plugs are shown in following photos Normal Plug taken from an engine operating under normal conditions wi...

Page 34: ...0 C 200 cca minimum 0 F to 32 F 18 C to 0 C 250 cca minimum 5 F to 0 F 21 C to 18 C 300 cca minimum 10 F 23 C or below 400 cca minimum If battery charge is insufficient to turn over engine recharge battery Battery Maintenance Regular maintenance is necessary to prolong battery life Battery Test To test battery follow manufacturer s instructions ELECTRONIC IGNITION SYSTEMS Ignition System Component...

Page 35: ...nes com Electrical System Wiring Diagram 15 20 25 Amp Regulated Battery Charging System with Fixed Timing E K B W F C H V D B I F T V N A AD G L M P R Q S T U V V R AM R AN A J O V X AF AH AI AJ AL AK AO R AA AB Y T Z AC AG AE V AH ...

Page 36: ... spark plugs A Spark Plug s B Oil Pressure Switch C Oil SentryTM Green D White Kill E Flywheel Stator Assembly F Ignition Module G Non Smart SparkTM Ignition H Rectifier Regulator Connector I Rectifier Regulator J Oil SentryTM Kill Green K Violet B L Solenoid Shift Starter Assembly M Starter Solenoid Tang N Starter Solenoid Stud O Fuse P Blue Q Alternate Ignition Kill R White S Accessory Terminal ...

Page 37: ...cal System Wiring Diagram 15 20 25 Amp Regulated Battery Charging System with Smart SparkTM F B A AA W H Z N I F X K C D Q P E C G M A O R S K T L K J J W W U T T V AB AC Y AP AS AR AQ AN AO AT AT AH W W AM AK AE AF AG AH AI AJ D E AD AL W K W T ...

Page 38: ...l Pressure Switch B Oil Sentry Green C Spark Plug s D Kill E Trigger F Ignition Module G Flywheel Stator Assembly H 22 25 HP Smart Spark Ignition I Module Speed Advance 22 25 HP J Brown K Yellow L Yellow on Analog SAMs Pink on Digital SAMs M Rectifier Regulator Connector N Rectifier Regulator O Oil Sentry Kill Green P Solenoid Shift Starter Assembly Q Violet B R Alternate Ignition Kill S Accessory...

Page 39: ...C B E D L U E F D G G K I M H I M J P O Q R R V W U D F T Y E Z X F X Z E AD AC AE AF AA AB AG AH AI AJ AM AL AN AK AQ AO AP AE AR F Z E F AT AN AS AU AV N S A F J H Wiring Diagram 15 20 25 Amp Regulated Battery Charging System with DSAI Ignition and Key Switch ...

Page 40: ...SentryTM Pulse Signal Lead C Black Ground Intake Manifold Mounting Screw D Black E White F Red G Spark Plug s H Black Ground I Red B J White DSAI Kill K Module Screw L Flywheel Stator Assembly M DSAI Module N White AC Charging Leads O Rectifier Regulator Connector P Rectifier Regulator Q Violet B Lead R Starter Assembly S Oil SentryTM Pulse Signal T Alternate Ignition Pulse Signal U Fuse V Starter...

Page 41: ...Systems NOTE If engine starts or runs during testing you may need to ground kill lead to shut it down Because you have interrupted kill circuit it may not stop using switch Isolate and verify trouble is within engine 1 Locate connectors where wiring harnesses from engine and equipment are joined Separate connectors and remove white kill lead from engine connector Rejoin connectors and position or ...

Page 42: ... 2 Connect an automotive timing light to cylinder that had good spark 3 Run engine at idle and use timing light beam to locate line on screen Draw a line on blower housing next to line on screen Accelerate to full throttle and watch for movement of line on screen relative to line on blower housing If both cylinders had good spark repeat test on other cylinder Condition Possible Cause Conclusion Li...

Page 43: ...o 1175 ohms 119 to 136 ohms 5600 to 9000 ohms 24 584 36 S 2 1 16 in H 590 to 616 ohms 183 to 208 ohms 8000 to 40 000 ohms Ignition Module Resistance Table 5 Check and or adjust ignition module air gap s An air gap of 0 28 0 33 mm 0 011 0 013 in must be maintained under all three legs of ignition module s Checking adjusting should be performed with parts at room temperature Condition Possible Cause...

Page 44: ...according to style with tester 25 761 21 S tests ASAM style modules only or tester 25 761 40 S tests both ASAM and DSAM style modules Use test instructions following or those provided with tester If SAM tests bad replace it 3 Reattach SAM leads verifying a snug fit at ignition module terminals If any connections do not feel snug disconnect lead lightly pinch female terminal with a pliers and reche...

Page 45: ...If it is an ASAM 24 584 09 or 24 584 10 separate short yellow and brown leads from long ones Each set will be tested separately Connect tester to SAM as follows Yellow tester lead to long yellow module lead Brown tester lead to long brown module lead Red tester lead to red module lead Black tester lead to black or green module lead Remaining tester leads pink and brown with black band are not used...

Page 46: ...ST button until a click is heard and then release Momentarily 1 of 4 status lights will illuminate indicating condition of part To test 20 25 amp rectifier regulators 1 20 amp Connect single lead adapter in between B center terminal of rectifier regulator being tested and squared single end of tandem adapter lead 25 amp Connect squared single end of tandem lead adapter to B center red lead of rect...

Page 47: ... regulator steps 2 and 3 2 Remove connector from rectifier regulator With engine running at 3600 RPM measure AC voltage across stator leads using an AC voltmeter Condition Conclusion Voltage is 28 volts or more Stator is OK Rectifier regulator is faulty replace Voltage is less than 28 volts Stator is faulty replace Test stator further using an ohmmeter steps 3 and 4 3 With engine stopped measure r...

Page 48: ...should be measured about midscale on Rx1 range Condition Conclusion Resistance is low in both directions Diode is shorted Replace diode Resistance is high in both directions Diode or stator winding is open Continue testing 4 Cut sleeving on charging lead to expose diode connections Measure resistance from stator side of diode to ground using an ohmmeter Condition Conclusion Resistance is approxima...

Page 49: ...ies Condition Possible Cause Conclusion Starter does not energize Battery Check specific gravity of battery If low recharge or replace battery as necessary Wiring Clean corroded connections and tighten loose connections Replace wires in poor condition and with frayed or broken insulation Starter Switch or Solenoid By pass switch or solenoid with a jumper wire If starter cranks normally replace fau...

Page 50: ...ve lubricant to splines Use of other lubricants may cause drive pinion to stick or bind 6 Apply a small amount of Loctite 271 to stop nut threads 7 Install drive pinion dust cover spacer anti drift spring stop gear spacer and stop nut Torque stop nut to 17 0 19 2 N m 150 170 in lb Reinstall dust cover Style B 1 Rubber dust cover has a molded lip on inside that snaps into a groove in dust cover spa...

Page 51: ...elf tapping screws negative brushes and plastic brush holder 3 Remove nut and fiber washer from stud terminal Remove stud terminal with positive brushes and plastic insulating bushing from end cap 4 Install insulating bushing on stud terminal of new positive brushes Install stud terminal into commutator end cap Secure stud with fiber washer and screw 5 Install brush holder new negative brushes and...

Page 52: ...eld in place by being snapped over a retainer Retainer is held in place by a groove in armature shaft To remove stop collar two pieces must be pried off retainer 9 When stop collars are removed retainer can be removed from armature shaft Do not reuse retainer Brush Replacement Brushes in starter are part of starter frame Brush kit contains four replacement brushes and springs If replacement is nec...

Page 53: ...s for wear fatigue or damage Measure length of each brush Minimum length for each brush is 7 6 mm 0 300 in Replace brushes if they are worn undersize or condition is questionable Armature Components and Details A B A Commutator O D B Mica Insulation D E C C Insulation Check D Armature Coil E Continuity Check 1 Clean and inspect commutator outer surface Mica insulation must be lower than commutator...

Page 54: ...bly when replacing brushes brush holder assembly a Hold starter assembly vertically on end housing and carefully position assembled brush holder assembly with supplied protective tube against end of commutator armature Mounting screw holes in metal clips must be up out Slide brush holder assembly down into place around commutator and install positive brush lead grommet in cutout of frame Protectiv...

Page 55: ... 1 Use an ohmmeter set to audible or Rx2K scale and connect 2 ohmmeter leads to 2 large post terminals 2 Perform solenoid pull in coil plunger actuation test and check for continuity Ohmmeter should indicate continuity Repeat test several times To test solenoid hold in coil Function 1 Connect a 12 volt test lead to flat spade S start terminal on solenoid and other lead to body or mounting surface ...

Page 56: ...g into starter 3 Pull knot end out of handle untie knot and slide handle off 4 Hold pulley firmly and untie slipknot Allow pulley to rotate slowly as spring tension is released 5 When all spring tension on starter pulley is released remove rope from pulley 6 Tie a double left hand knot in one end of new rope 7 Rotate pulley counterclockwise when viewed from pawl side of pulley until spring is tigh...

Page 57: ...se to new brake washer and spring install them in center pocket 6 Install pawl springs and pawls into pawl slots of pulley All parts must be dry 7 Position drive plate over pawls with actuating ears down and inside of pawls 8 Apply a small amount of Loctite 271 to threads of center screw Install center screw with washer Torque screw to 7 4 8 5 N m 65 75 in lb 9 Remove clamp and pull starter rope o...

Page 58: ...severe injury or death Disconnect and ground spark plug lead s before servicing External Engine Components A Guard B Blower Housing C Fuel Filter D Rectifier Regulator E Outer Baffle F Electric Starter G Inner Baffle H Fuel Pump I Hose J Oil Cooler K O ring L Nipple M Oil Filter A B I G L H G E E J K M F D C Disassembly Inspection and Service 58 24 690 07 Rev H KohlerEngines com ...

Page 59: ...Remove element cover element and precleaner 4 Remove nuts securing spitback cup baffle or bracket and air cleaner base Additional lower screws must be removed if engine contains a lower air cleaner support bracket 5 Disconnect breather tube from nipple on underside or hose from base as equipped 6 Remove base and gasket while carefully pulling rubber breather tube through base Heavy Duty Air Cleane...

Page 60: ... linkage and governor lever as an assembly 4 Remove carburetor gasket 5 If necessary carburetor throttle linkage and governor lever can be separated Reattach bushings to linkage following separation to avoid losing them Remove Electric Starter Motor 1 Disconnect leads from starter 2 Remove screws 3 Remove starter assembly and lift bracket Some inertia drive starters use a separate starter cover an...

Page 61: ...g edge of breather cover with a screwdriver to break RTV or gasket seal Do not pry on sealing surfaces as it could cause damage resulting in leaks Most engines use a formed gasket rather than RTV sealant 5 Remove breather cover and gasket if used Crankcase Breather System Breather system is designed to control amount of oil in head area and still maintain necessary vacuum in crankcase A spring ste...

Page 62: ...d Unless screws are damaged or questionable they can be reused Discard nuts and washers once removed do not reuse Studs if present should only be removed if damaged or if cylinder reconditioning is necessary Once removed they must be replaced 2 Mark location of push rods as either intake or exhaust and cylinder 1 or 2 Push rods should always be reinstalled in same positions 3 Carefully remove push...

Page 63: ...058 mm 0 2771 0 2779 in 7 038 7 058 mm 0 2771 0 2779 in E Valve Head Diameter 33 37 33 63 mm 1 3138 1 3240 in 29 37 29 63 mm 1 1563 1 1665 in F Valve Face Angle 45 45 G Valve Margin Min 1 5 mm 0 0591 in 1 5 mm 0 0591 in H Valve Stem Diameter 6 982 7 000 mm 0 2749 0 2756 in 6 970 6 988 mm 0 2744 0 2751 in After cleaning check flatness of cylinder head and corresponding top surface of crankcase usin...

Page 64: ...n bad condition Valve Guides If a valve guide is worn beyond specifications it will not guide valve in a straight line This may result in burnt valve faces or seats loss of compression and excessive oil consumption To check valve guide to valve stem clearance thoroughly clean valve guide and using a split ball gauge measure inside diameter of guide Then using an outside micrometer measure diameter...

Page 65: ...ng flywheel screw Do not use any type of bar or wedge to hold flywheel Use of such tools could cause flywheel to become cracked or damaged NOTE Always use a flywheel puller to remove flywheel from crankshaft Do not strike crankshaft or flywheel as these parts could become cracked or damaged Striking puller or crankshaft can cause crank gear to move affecting crankshaft endplay 1 Use a flywheel str...

Page 66: ...asher L Oil Screen Style A M Gerotor Gear Style A N Oil Pick Up Tube Style A O Oil Pump Assembly Style A P Piston Pin Q Piston Style A R Piston Ring Set S Piston Ring Retainer T Connecting Rod End Cap U Connecting Rod V Crankshaft W Camshaft X Piston Style B Y Oil Pan Style A Z Oil Pan Style B AA Oil Pump Assembly Style B AB Outer Gerotor Gear Style B AC Oil Pump Cover O ring Style B AD Spring Sty...

Page 67: ...y procedures Inspection Inspect governor gear teeth Replace gear if it is worn chipped or if any teeth are missing Inspect governor weights They should move freely in governor gear Disassembly NOTE Governor gear is held onto shaft by small molded tabs in gear When gear is removed from shaft these tabs are destroyed and gear must be replaced Therefore remove gear only if absolutely necessary Govern...

Page 68: ... Valve J Torque Sequence Style A Oil Pump Assembly Style A Oil pump is mounted inside oil pan If service is required continue with Disassembly Inspection and Reassembly Disassembly 1 Remove screws 2 Remove oil pump assembly from oil pan 3 Remove oil pump rotor If a plastic pickup is used unhook locking clip and carefully pull it free from oil pump housing 4 If relief valve is like that shown drive...

Page 69: ...r torquing rotate gear and check for freedom of movement Make sure there is no binding If binding occurs loosen screws reposition pump retorque screws and recheck movement Remove Camshaft Remove camshaft and shim if used Inspection and Service NOTE To prevent repeat failures camshaft and crankshaft should always be replaced as a set Check lobes of camshaft for wear or damage See Specifications for...

Page 70: ...etal Detonation damage occurs when a portion of fuel charge ignites spontaneously from heat and pressure shortly after ignition This creates 2 flame fronts which meet and explode to create extreme hammering pressures on a specific area of piston Detonation generally occurs from using low octane fuels Preignition or ignition of fuel charge before timed spark can cause damage similar to detonation P...

Page 71: ...ve side clearance and is 0 030 0 070 mm 0 0010 0 0026 in and middle compression ring to groove side clearance 0 030 0 070 mm 0 0010 0 0026 in If side clearance is greater than specified a new piston must be used Install New Piston Rings Piston Ring Orientation 10 10 F A B C D E A Top Oil Ring Rail Gap B Bottom Oil Ring Rail Gap C Intermediate Ring Gap D Oil Ring Expander Gap E Top Ring Gap F FLY S...

Page 72: ...ters to get running clearances Check results against tolerances in Specifications If running clearances are within specification and there is no evidence of scoring grooving etc no further reconditioning is necessary If bearing surfaces are worn or damaged crankcase and or oil pan will need to be replaced Inspect crankshaft keyways If worn or chipped replacement of crankshaft will be necessary Ins...

Page 73: ...be machined exactly 0 25 mm 0 010 in or 0 50 mm 0 020 in over new diameter refer to Specifications A corresponding oversize Kohler replacement piston will then fit correctly While most commercially available cylinder hones can be used with either portable drills or drill presses use of a low speed drill press is preferred as it facilitates more accurate alignment of bore in relation to crankshaft ...

Page 74: ... CV641 6 mm 0 2362 in CV22 CV23 CV670 CV680 6 mm 0 2362 in 13 mm 0 5118 in CV620 674cc CV640 674cc 13 mm 0 5118 in CV25 CV730 CV740 CV750 6 mm 0 2362 in 6 mm 0 2362 in NOTE Do not use a feeler gauge to measure piston to bore clearance it will yield inaccurate measurements Always use a micrometer Before installing piston into cylinder bore it is necessary clearance be accurately checked This step i...

Page 75: ...Tab Thrust Washer L Oil Screen Style A M Gerotor Gear Style A N Oil Pick Up Tube Style A O Oil Pump Assembly Style A P Piston Pin Q Piston Style A R Piston Ring Set S Piston Ring Retainer T Connecting Rod End Cap U Connecting Rod V Crankshaft W Camshaft X Piston Style B Y Oil Pan Style A Z Oil Pan Style B AA Oil Pump Assembly Style B AB Outer Gerotor Gear Style B AC Oil Pump Cover O ring Style B A...

Page 76: ...s before assembly unless a sealant or Loctite is specified or preapplied Make sure all traces of any cleaner are removed before engine is assembled and placed into operation Even small amounts of these cleaners can quickly break down lubricating properties of engine oil Check oil pan crankcase cylinder heads and valve covers to be certain that all old sealing material has been removed Use gasket r...

Page 77: ...1 Install shim removed during disassembly onto camshaft 2 Position camshaft end play checking tool on camshaft 3 Apply pressure on camshaft end play checking tool pushing camshaft toward crankshaft Use a feeler gauge to measure camshaft end play between shim spacer and checking tool Camshaft end play should be 0 076 0 127 mm 0 003 0 005 in 4 If camshaft end play is not within specified range remov...

Page 78: ...case 3 Apply a 1 5 mm 1 16 in bead of sealant to sealing surface of oil pan on CV17 23 engines CV25 750 engines use a new gasket Before installing gasket check dowel pin on oil filter side of crankcase If a split style dowel pin is contained replace it with a closed seam style pin provided with new gasket 4 Make sure end of governor cross shaft is lying against bottom of cylinder 1 inside crankcas...

Page 79: ...lean dry and completely free of any lubricants Presence of lubricants can cause flywheel to be over stressed and damaged when screw is torqued to specifications NOTE Make sure flywheel key is installed properly in keyway Flywheel can become cracked or damaged if key is not properly installed 1 Install woodruff key into keyway of crankshaft Make sure key is properly seated and parallel with shaft t...

Page 80: ...s are located on output shaft oil pan side of engine while intake lifters are located on fan side of engine Cylinder numbers are embossed on top of crankcase and each cylinder head 1 Refer to Disassembly Inspection and Service for hydraulic bleeding lifter procedures 2 Apply camshaft lubricant to bottom surface of each lifter Lubricate hydraulic lifters and lifter bores in crankcase with engine oi...

Page 81: ...t is obtained Otherwise frictional heat from engaging threads may cause locking compound to set up prematurely Studs closest to lifters must have an exposed height of 75 mm 2 15 16 in Studs furthest from lifters must have an exposed height of 68 mm 2 3 4 in c Remove nuts and repeat procedure as required 4 Check that dowel pins are in place and install a new cylinder head gasket printing up 5 Insta...

Page 82: ...uard G661 or equivalent dielectric compound Beads should overlap between terminals to form a solid bridge of compound Do not put any compound inside terminals 24 584 15 S ignition modules have a separator barrier between terminals On these modules seal base of terminals but it is not necessary to have overlapping beads of sealant between connections 1 Install intake manifold and new gaskets or O r...

Page 83: ... new hole or to 7 3 N m 65 in lb in a used hole 5 If engine had a plastic debris screen that overlaps blower housing reinstall it now Torque mounting screws to 4 0 N m 36 in lb For a metal screen apply Loctite 242 to screw threads and torque screws to 9 9 N m 88 in lb 6 Torque four breather cover screws to 7 3 N m 65 in lb in sequence shown Install Oil Sentry if equipped 1 Apply pipe sealant with ...

Page 84: ...e covers install a new O ring in groove of each cover Do not use gaskets or RTV sealant 4 Position covers on cylinder heads Locate cover with oil separator hole on cylinder 1 If loose spacers were used insert a spacer in each screw hole Install screws in each cover and finger tighten 5 Torque valve cover fasteners to proper specification using sequence shown unless screws also attach heavy duty ai...

Page 85: ...t to 6 8 N m 60 in lb 5 Reconnect lead wire to fuel shut off solenoid if equipped 6 Install lower support control bracket if equipped with a control panel 7 Secure control panel to blower housing with screws if not equipped with heavy duty air cleaner 8 Assemble throttle control shaft to control bracket 9 Assemble choke control to control bracket 10 Connect Oil Sentry Indicator light wires Attach ...

Page 86: ...rple Blue Orange Black 4 4 3 4 3 2 2 1 1 Orange Green Blue Orange Green Blue Purple Blue Green 4 4 4 3 3 3 2 2 1 CV20 740 Engines with 0 0299 0 003 in Thick 22 GA Throttle Limiter Intended Maximum RPM Standard Throttle Control Engine Mounted Throttle Control Pivot Shaft High Idle WOT Spring Color Hole No Spring Color Hole No 3888 3780 3672 3564 3456 3348 3240 3132 3024 3600 3500 3400 3300 3200 310...

Page 87: ...r if installed incorrectly 1 Install fuel pump and lines as an assembly Connect pulse line to crankcase vacuum fitting 2 Install fuel pump using screws Torque screws to 2 3 N m 20 in lb 3 Connect fuel lines Install Air Cleaner Assembly Low Profile and Commercial Mower Air Cleaners 1 Connect breather hose and attach breather separator to valve cover Position hose in cutout of blower housing later m...

Page 88: ... gasket on oil filter 4 Refer to instructions on oil filter for proper installation 5 Fill crankcase with new oil Level should be at top of indicator on dipstick 6 Reinstall oil fill cap dipstick and tighten securely Connect Spark Plug Leads Connect leads to spark plugs Prepare Engine for Operation Engine is now completely reassembled Before starting or operating engine be sure to do following 1 M...

Page 89: ...89 24 690 07 Rev H KohlerEngines com ...

Page 90: ...90 24 690 07 Rev H KohlerEngines com ...

Page 91: ...91 24 690 07 Rev H KohlerEngines com ...

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Kohler Command CV18, Service Manual

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Summary of Contents for Command CV18

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