Kohler CV22S Service Manual

8/10/2019 Kohler CV22S Service Manual

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Contents

Section 1. Safety and General Information ............................................................................

Section 2. Tools & Aids ..........................................................................................................

Section 3. Troubleshooting .....................................................................................................

Section 4. Air Cleaner and Air Intake System ........................................................................

Section 5. Fuel System and Governor ....................................................................................

Section 5B. Electronic Fuel Injection (EFI) Fuel System ......................................................

Section 6. Lubrication System ................................................................................................

Section 7. Retractable Starter .................................................................................................

Section 8. Electrical System and Components .....................................................................

Section 9. Disassembly ...........................................................................................................

Section 10. Inspection and Reconditioning ...........................................................................

Section 11. Reassembly ...........................................................................................................

2

1

4

5

3

5B

8

9

10

11

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7


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2.2

Section 2Tools & Aids

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noitpir cseD .oNtr aP /ecr uoS

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2.3

Section 2Tools & Aids

2

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/,#/&0$%&!$/1/%2 !#$$78&'9:';57, -.##01"12&3*456

/,#/&0$%&!$/1/%2 !5&?.*3@, *3-.A& B9C

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!"#$%&'()/3%&2&/!!4$%&!$/15 !EIA4-8A5F3*5-, -.2H01"21&3*456

!"#1#/4/"6$%1%47893EAEJ5C K L&3)F3()A8*5)5&3'M5/FAN85ON;'3PHHQ1

L3)9&5I83;5&(('3&' R83E)A*3)54E)'4J9) R)EF'*'3)+STEF'E)A)3&*A5 R83)' B.3UAV5N*FW

3EAEJ5C K

L)JAE)A&3EJ'&'4J:FA*'3)E)3 B&5I838F3UU5J3&3&'H#Q1&5HHQ1L)5+ *&-(%(/8- $,1=+9&$(, (. $&1 +Q&+%,*0 *==+*%*,9+ *,69(,6$&$(," T-$1 $,1=+9&$(, 9*, 8$K+ 90/+1 &( )-*&3$8-& :+ .(/,6 $,1$6+ &-+ +,8$,+ D*,6 &-+ 9*/1+E)-+, $& $1 6$1*11+3:0+6"

^ [-+9> .(% :/$06/= (. 6$%& *,6 6+:%$1 (, &-+9%*,>9*1+P 9((0$,8 .$,1P 8%*11 19%++,P *,6 (&-+%+Q&+%,*0 1/%.*9+1" #$%& (% 6+:%$1 (, &-+1+ *%+*1 *%9*/1+1 (. -$8-+% (=+%*&$,8 &+3=+%*&/%+1 *,6(K+%-+*&$,8"

^ [-+9> .(% (:K$(/1 ./+0 *,6 ($0 0+*>1P *,6

6*3*8+6 9(3=(,+,&1" MQ9+11$K+ ($0 0+*>*8+ 9*,$,6$9*&+ * 90(88+6 (% $3=%(=+%02N*11+3:0+6 :%+*&-+%P )(%,76*3*8+6 1+*01 *,6 8*1>+&1P (%0((1+ (% $3=%(=+%02N&(%@/+6 .*1&+,+%1"

^ [-+9> &-+ *$% 90+*,+% 9(K+% *,6 :*1+ .(% 6*3*8+(% $,6$9*&$(,1 (. $3=%(=+% .$& *,6 1+*0"

^ [-+9> &-+ *$% 90+*,+% +0+3+,&" H((> .(% -(0+1P&+*%1P 9%*9>+6 (% 6*3*8+6 1+*0$,8 1/%.*9+1P (%(&-+% 6*3*8+ &-*& 9(/06 *00() /,.$0&+%+6 *$% $,&(&-+ +,8$,+" O01( ,(&+ $. &-+ +0+3+,& $1 6$%&2 (%90(88+6" T-+1+ 9(/06 $,6$9*&+ &-*& &-+ +,8$,+ -*1

:++, /,6+% 1+%K$9+6"

^ [-+9> &-+ 9*%:/%+&(% &-%(*& .(% 6$%&" #$%& $, &-+&-%(*& $1 ./%&-+% $,6$9*&$(, &-*& &-+ *$% 90+*,+% $,(& ./,9&$(,$,8 =%(=+%02"

^ [-+9> &-+ ($0 0+K+0" _(&+ $. &-+ ($0 0+K+0 $1 )$&-$,&-+ (=+%*&$,8 %*,8+ (, &-+ 6$=1&$9>P (% $. $& $1 0()(% (K+%.$00+6"


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3.3

Section 3Troubleshooting

3

! "#$%& (#$ %)*+,(,)* )- (#$ ),./ 012,* (#$ ),. ,*() 2%)*(2,*$1 3 (#$ ),. 4#)5.+ -.)6 -1$$.7/ "#$%& -)18$(2. %#,94 2*+ )(#$1 -)1$,:* 921(,%.$4/

;.5+:$ ,4 2 *2(512.


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3.4


Possible Cause Solution

!" #$%&%%'()*' ),'&-.',/ 0*'&1 2&,-% -.3,345.*6/,'&%%'()*'/ &17 ,'0.'08 2,'%%4,'"

9" :'2*&0' &** ;3,1 3, 7&(&5'7 %'&*% &17 5&%8'-%"


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3

!"# %&'()"*+ ,#-. '#(*/'(&% 0#%(12%# 3333333333333333333333333333333333333333333333333333334"*+& -# '56"*7%# 8!"# %&'()"*+ ,#-. %92(:&1 &5&1%. 333333333333333333333333333333333333333333333333333333333333;%,%'1"(:+% #%(7"*+ "* ?6-8@ A+#%%*B C-*% 33333333333333333333333333333333333333333333333333333333D"&1-* #"*+&>(:+% #%(7"*+ "* ?.-7%#(1%@ A5%66-8B C-*%33333333333333333333333333333333333333333333E*+"*% "& &1"66 :&(

8%(# )#%&%*13 G:&1-.%# &2-:67 &1(#1)6(**"*+ ,-# -


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3.6



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4.1

Section 4Air Cleaner and Air Intake System

4


Air Cleaners

General!"#$# #&'($ )*# #+,(--#. /(0" ) *#-1)2#)31#4 "('"5.#&$(06 -)-#* )(* 21#)* #1#7#&08 9:$0 )*# )1$:#+,(--#. /(0" )& :(1#.5;:)7 -*#21#)* /"(2"$,**:,&.$ 0"# -)-#* #1#7#&08

!"*## .(;;#*#&0 06-#$ )*# ,$#.8 !"# (',*#$ ?5N :* ?5? )&.-#*;:*7 0"# ;:11:/(&' $0#-$I

@8 O::$#& 0"# 2:B#* *#0)(&(&' E&:3 :* ,&"::E 0"#1)02"#$ )&. *#7:B# 0"# 2:B#*8

A8 P#7:B# 0"# ;:)7 -*#21#)* ;*:7 0"# -)-#* )(*21#)* #1#7#&08

N8 Q)$" 0"# -*#21#)* (& /)*7 /)0#* /(0".#0#*'#&08 P(&$# 0"# -*#21#)* 0":*:,'"16 ,&0(1)11 0*)2#$ :; .#0#*'#&0 )*# #1(7(&)0#.8 R+,##S# :,0#L2#$$ /)0#* K.: &:0 /*(&'M8 T11:/ 0"# -*#21#)*0: )(* .*68

?8 R)0,*)0# 0"# -*#21#)* /(0" / #&'( :(18R+,##S# :,0 )11 #L2#$$ :(18

U8 P#(&$0)11 0"# -*#21#)* :B#* 0"# -)-#* )(* 21#)*#1#7#&08

V8 P#(&$0)11 0"# )(* 21#)* 2:B#*8 R#2,*# 0"# 2:B#*/(0" 0"# 0/: 1)02"#$ :* 0"# *#0)(&(&' E&:38

Figure 4-2. Commercial Mower Air Cleaner.


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4.2


Figure 4-4. Precleaner on Commercial Mower TypeAir Cleaner.

Figure 4-3. Precleaner on Standard Air Cleaner.

Paper Element Service (Standard and CommercialMower Types)!"#$% !"" $%&'( '( ')#$*+,'- ./'$# '(+#- 0-1#$#2+$#/#3% 104+% '$ 1,$+% 5'-1,+,'-467 $#)3*5# +8# )*)#$#3#/#-+9 :## ;,? '$ =>@7 *-1 ('33'A +8#4# 4+#)4B

C9 D-8''E +8# 3*+58#4 '$ 3''4#- +8# 5'"#$ $#+*,-,-?@7 A)/)6#01 5-&$ -& ,--.# )*& +,#)$#&+-/2-$#$(. +)$ ),,-5 9$4*,(# )*& *$(- ("#

#$6*$# +)9.*$6 2/)(9 5#)& )$0 4)*,9?*6"(#$ -& ,)+# ),, ,--.# -& 0)/)6#0+-/2-$#$(.;

Figure 4-7. Base Plate Removal on Standard Type.

Disassembly/Reassembly - Standard TypeB4 ("# :).# 2,)(# -$ ("# .()$0)&0 (+ ?@@18@ ")9 &79A;

G; D#/-%# ("# :).# )$0 6).3#(; T)1,,< 4##0 ("# :)("#& "-.# ("&-96" ("# :).#;

I; D#%#&.# 2&-+#09 (- )..#/:,# +-/2-$#$(.;?-&M9# ("# (5- "#L 4,)$6# $9(. (- 89:1;9< =>+

?@@18@ ")9 &79A )$0 ("# (5- ,-5#& 8I /-9$(*$6.+. E5"# )22,*+):,#J (- B9C =>+ ?


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4.5


4

Heavy-Duty Air Cleaner

General!"# "#%&'()*+' %,- ./#%0#- .102,2+2 13 % .'/,0)-,.%/"1*2,045 +'6,.%//' 71*0+#) +1 % 8-%.9#+5 %0).100#.+#) :,+" % 31-7#) -*88#- "12# +1 %0 %)%6+#- 10+"# .%-8*-#+1- 1- +"-1++/# 81)';,0+%9# 7%0,31/) ?*0,+2@A !"# %,- ./#%0#- "1*2,04 .10+%,02 % 6%6#-#/#7#0+ %0) ,00#- #/#7#0+5 )#2,40#) 31- /104#-2#-&,.# ,0+#-&%/2A !"# 2'2+#7 ,2 BCDE;=FC .#-+,3,#)%0) +"# .17610#0+2 2"1*/) 01+ 8# %/+#-#) 1- 71),3,#),0 %0' :%'A

Figure 4-9. Heavy-Duty Air Cleaner.

To Service=-' !"# %&'() 13 16#-%+,10 ,4*-# L(WA

Inner ElementElement


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7.1

Section 7Retractable Starter

7


WARNING: Spring Under Tension!!"#$%%'(" *#%$#"$* &+,#%-, % .+/"$01(2 $"&+-( *.$-,3 #4%# -* 1,5"$ #",*-+,6 7(/%8* /"%$ *%0"#8 3+33("* /4", *"$9-&-,3 $"#*#%$#"$* %,5 &%$"01((8 0+((+/ -,*#$1-+,* -, #4-* *"-+, 0+$ $"(-"9-,3 *.$-,3 #",*-+,6

Handle withRope Retainer

Drive Cup

Starter Housing

Rope

Pawl Springs

Pawls

Pawl Retainer

Plain Washer

Center Screw

Brake Spring

Brake Washer

Pulley

Spring andKeeper

HexFlangeScrews

Figure 7-1. Retractable Starter Exploded View.

To Remove Starter !" #$%&'$ )*$ +,'$ *$- +./01$ 234$52 2$364,01 )*$

2)/4)$4 )& )*$ 7.&5$4 *&62,01"

8" #$%&'$ )*$ 2)/4)$4"

To Install Starter !" 902)/.. )*$ 4$)4/3)/7.$ 2)/4)$4 &0)& )*$ 7.&5$4

*&62,01 .$/',01 )*$ +,'$ *$- +./01$ 234$522.,1*).: .&&2$"

Figure 7-2. Removing Starter Handle.

;" #$%&'$ )*$ 4&


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7.2


!" #$% ' ($)*+% ,)-. $) -)% %)/ -0 .1% )%2 3-4%"

5" 6-.'.% .1% 47++%8 9-7).%39+-9,2$(% :21%);$%2%/ 03-< 4'2+ ($/% -0 47++%8= 7).$+ .1% (43$)*$( .$*1. :'443->$


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7.4


Figure 7-8. Installing Pulley and Spring intoHousing.

!" #$%&'(( &*+ ,'-( %,./$0% '$1 ,'-(% /$&2 &*+%&'.&+. ,3((+4" 5++ 6/03.+ 789"

Pulley & Spring

Housing

Pawl

Pawl Spring

!" :2 $2& '&&+;,& &2 .+-/$1 ' %,./$0 &*'& *'% ++,+." ?.1+. '$1 /$%&'(( ' $+- %,./$0'$1 >++,+. '%%+;@(4"

A" B(+'$ '(( 2(1 0.+'%+ '$1 1/.& =.2; &*+ %&'.&+.

++,+. '%%+;@(4 /$&2&*+ ,3((+4 H-/&* %,./$0 &2-'.1 ,3((+4I" 5++6/03.+ 787"

J" #$%&'(( &*+ ,3((+4 '%%+;@(4 /$&2 &*+ %&'.&+.*23%/$0" 5++ 6/03.+ 78K" F'>+ %3.+ &*+ ,3((+4 /%=3((4 %+'&+1 '0'/$%& &*+ %&'.&+. *23%/$0" :2 $2&

-/$1 &*+ ,3((+4 '$1 .+


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9.1

Section 9Disassembly

9


WARNING: Accidental Starts!!"#$%&"'( *'("'*+ ,--".*'/$& #/$0/"'( -$' -$1#* #*2*0*"'3104 50 .*$/6+ !"#$%" '$%()*+ $* ,-" "*+)*" $%"./)01"*,2 3)4567" ,-" "*+)*" 54 #$77$'48 9: ;)4


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9.2


Figure 9-2. Removing Oil Fill Cap/Dipstick.

!" #$%&'$ )*$ %&+,)-,. /01$2 3,4 4$)30* )*$ &-56-55 )+7$" 8$$ 9-.+1$ :;!"

+-??$42-)* 3 ?&1) 5-,$1@ 1$%&'$ -) ,&2"

Remove Air Cleaner Assembly

Standard Air Cleaner E" F,*&&K )*$ 53)0*$/ 5&03)$4 &, $-)*$1 /-4$ &6 )*$

3-1 05$3,$1 0&'$1@ &1 5&&/$, )*$ 0&'$1;1$)3-,-,.K,&7@ 3,4 1$%&'$ )*$ 0&'$1" 8$$ 9-.+1$ :;G"

Figure 9-3. Removing Oil Fill Tube Bracket.

Figure 9-4. Removing Oil Filter.

J" N55&2 3%?5$ )-%$ 6&1 )*$ &-5 )& 413-, 61&% )*$013,K03/$ 3,4 &-5 6-5)$1"

Figure 9-5. Removing Standard Air Cleaner Cover.

J" #$%&'$ )*$ 2-,. ,+) 61&% )*$ $5$%$,) 0&'$1"


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9.3


9

Figure 9-8. Removing Commercial Mower Elementand Precleaner.

Figure 9-6. Removing Standard Element andPrecleaner.

!" #$%&'$ )*$ $+$%$,) -&'$./ $+$%$,) 0,12.$-+$0,$." 3$$ 4567.$ 89:"

Figure 9-7. Removing Standard Air Cleaner Base.

;" #$%&'$ )*$ )+0,6$ ,7)? ?$-7.5,6 )*$?25)@0-A -72/ @0>>+$ &. @.0-A$)/ 0,1 05. -+$0,$. @0?$" 3$$ 4567.$ 89B" C


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9.4


Figure 9-11. Air Cleaner Bracket/Valve Cover Mounting Screws (Two-Barrel Model Pictured).

Heavy Duty Air Cleaner !" #$%&'(()&* *,) -.)/*,). ,'%) 0.'1 *,) 0$**$(2 $(

/3/4*). '. )5-'6" 7)1'8) *,) ,)9 05/(2) (:*%%)&:.$(2 *,) /3/4*). /(3 /(; /**/&,)3 &5$4% *' *,)1':(*$(2 %*:3%" ?!@"

Figure 9-13. Removing Heavy Duty Air Cleaner Assembly (Two-Barrel Model Pictured).

Remove Control Panel (If So Equipped)!" #$%&'(()&* *,) A$5


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9.5


9

Figure 9-14. Removing Throttle Control Bracket.

Figure 9-15. Removing Control Panel.

Remove Fuel Pump

WARNING: Explosive Fuel!!"#$%&'( *"+ ,( -.(#('/ &' /0( 1".,2.(/$. "'3 42(% #+#/(*5!"#$%&'( (6/.(*(%+ 4%"**",%( "'3 &/# 7"-$.# 1"' (6-%$3(&4 &8'&/(35 9((- #-".:#; $-(' 4%"*(# "'3 $/0(. #$2.1(# $4 &8'&/&$' " %&1)C%-1'9 *,) 2/'C)1 ,'.%$(> 0(3 1)9'8) *,) -.)/6.96 0(3 /$()% 0% 0( 0%%)92/E" .1) ?4!F"

Remove Throttle Controls!" B)9'8) *,) -'.1 ,)D -/0(>) %&1)C% %)&.1$(> *,)

*,1'**/) &'(*1'/ 210&;)* 0(3 /'C)1 0$1 &/)0()1 210&;)* 7%'9) 9'3)/%:G *' *,) &E/$(3)1 ,)03%" .1)% ?4!H 0(3 ?4!?"

Fuel Pump

Outlet Hose(To Carburetor)

Inlet Hose

PulseHose

Mounting Screws

Figure 9-16. Disconnecting Pulse Line fromCrankcase.

PulseHose


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9.6


Figure 9-18. Removing Control Bracket.

Figure 9-19. Removing Control Bracket and Air Cleaner Bracket (Some Models).

!" #$%&'(()&* *,) %-.$(/ 0.'1 *,) /'2).('. 3)2).4('*) ,'3) 3'&5*$'(% 0'. .)5%%)1637"

8" 9)1'2) *,) &,':) 3$(:5/) 0.'1 *,) &,':)5&*;5*'. 3)2). 5(< &5.6;.)*'."

Remove External Governor Controls=" >''%)( *,) ,)? 035(/) (;* 5(< .)1'2) *,)

/'2).('. 3)2). 0.'1 *,) &.'%% %,50*" @)) A$/;.)BC!D" >)52) *,) 3)2). 5**5&,)< *' *,) *,.'**3)3$(:5/)"

Figure 9-20. Removing Governor Lever.

Remove Carburetor

WARNING: Explosive Fuel!!"#$%&'( *"+ ,( -.(#('/ &' /0( 1".,2.(/$. "'3 42(% #+#/(*5!"#$%&'( (6/.(*(%+ 4%"**",%(7 "'3 &/# 8"-$.# 1"' (6-%$3(&4 &9'&/(35 :((- #-".;# "'3 $/0(. #$2.1(# $4 &9'&/&$' "


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9.7


9

!" #$%&'$ )*$ +,-./-$)&-0 )*-&))1$ 1234,5$ ,365&'$-3&- 1$'$- ,7 ,3 ,77$%.18"

Figure 9-22. Removing Carburetor and Linkage(Two-Barrel Model Pictured).

Figure 9-23. Removing Carburetor Mounting Nuts(Commercial Mower Base Shown).

9" :; 3$+$77,-80 )*$ +,-./-$)&-0 )*-&))1$ 1234,5$ ,365&'$-3&- 1$'$- +,3 .$ 7$" ?27+&33$+) )*$ 1$,67 ;-&% )*$ 7),-)$-"

@" #$%&'$ )*$ )=& *$A ;1,35$ 7+-$=7" B$$ C25/-$DE@9"

Figure 9-25. Removing Electric Starter Motor.

!" #$%&'$ )*$ 7),-)$- ,77$%.18 ,36 12;) .-,+4$)"B&%$ 23$-)2, 6-2'$ 7),-)$-7 /7$ , 7$


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9.8


Figure 9-29. Removing Outer Baffles.

!" #$ &'( $)*+'(() ,-.((/ 01(.)23, &'( 4)0+(.'05,6/78 .(901( &'( $2,&(/(., 2/: ,-.((/" #$ 6&+2, 2 9(&2) ,-.((/ +6&' )0/7 40)&,8 2),0 .(901(&'( .(926/6/7 )00,( '2.:+2.( 2/: -00)6/7 $2/";(( ?@"

Figure 9-27. Loosening Spark Advance Module(Applicable Models).

Figure 9-28. Note Location of Short Screws.

A" B(901( &'( 05&(. 42$$)(," ;(( C="

ShortScrew

Figure 9-26. Disconnecting Plug from Rectifier-Regulator.

C" D'( .(-&6$6(.>.(75)2&0. :0(, /0& '21( &0 4(:(&2-'(: $.09 &'( 4)0+(. '05,6/7" #$ &'( (/76/(6, (E5633(: +6&' ;FGBD>;HGBI

J 8 .(901( &'(

905/&6/7 ,-.(+, $.09 &'( ,32.K 2:12/-( 90:5)(L;GFM" ;(( CN" D'( 90:5)( +6)) '2/7)00,( 2, 32.& 0$ &'( +6.6/7 '2./(,,"

?" B(901( &'( &'.(( L(2-' ,6:(M '(O $)2/7( ,-.(+,,(-5.6/7 &'( 05&(. 42$$)(," P0&( &'( )0-2&60/ 0$2/* )6$&6/7 ,&.23 2/: &'( 30,6&60/ 0$ &'( &+0 ,'0.&,-.(+, L0/( (2-' ,6:( 0/ 40&&09M $0. .(2,,(94)*";(( CQ"

Remove Outer Baffles and Blower Housing

R" S6,-0//(-& &'( +6.( )(2:, $.09 &'( ,&2.& ,+6&-'0/ &'( 4)0+(. '05,6/7 L6$ ,0 (E5633(:M"S6,-0//(-& &'( 3)57 $.09 &'( .(-&6$6(.>.(75)2&0."T,( &'( &63 0$ &'( :63,&6-K 0. 2 ,696)2. ,92)) $)2&&00) &0 4(/: &'( )0-K6/7 &2/78 &'(/ .(901( &'( UV&(.96/2) $.09 &'( -(/&(. 30,6&60/ 6/ &'( 3)57" ;((CW" D'6, +6)) 2))0+ &'( 4)0+(. '05,6/7 &0

4( .(901(: +6&'05& :6,&5.46/7 &'( +6.6/7'2./(,,"


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9.9


9

Figure 9-30. Removing Flywheel Screen.

!" #$%&'$ )*$ +$%,-.-./ *$0 12,./$ 34+$53 3$46+-./)*$ 72&5$+ *&63-./" 8&)$ )*$ &.$ 3-2'$+ 92,)$:34+$5 63$: 1&+ )*$ +$4)-1-$+;+$/62,)&+ /+&6.:3)+,9 &+ 2$,:" #$%&'$ )*$ 72&5$+ *&63-./" ;?@ ,.: >;?A"

Figure 9-32. Removing Blower Housing.

Figure 9-31. Rectifier-Regulator Ground Strap.

Ground Strap

Silver Screw

Figure 9-34. Removing Inner Baffles.

?" #$%&'$ )*$ )5& +$%,-.-./ *$0 12,./$ 34+$531+&% )*$ 7+$,)*$+ 4&'$+"

B" C+D 6.:$+ )*$ 9+&)+6:-./ $:/$ &1 )*$ 7+$,)*$+4&'$+ 5-)* , 34+$5:+-'$+ )& 7+$,E )*$ #FG &+/,3E$) 3$,2" ;?H" I& .&) 9+D &. )*$3$,2-./ 36+1,4$3 ,3 -) 4&62: 4,63$ :,%,/$+$362)-./ -. 2$,E3" J&3) $./-.$3 63$ , 1&+%$:/,3E$) +,)*$+ )*,. #FG 3$,2,.)"

Remove Oil Sentry@" I-34&..$4) )*$ 2$,: 1+&% )*$ K-2


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9.10


Figure 9-37. Removing Valve Cover.

Remove Ignition Modules!" #$%&'(()&* *,) -)./0%1 23'4 ).&, $5($*$'( 4'/6-)"

7)) 8$563) 9:;'*.*) *,) 2-?@,))- %' *,) 4.5()* $% .@.? 23'4*,) 4'/6-)%" 7)) 8$563) 9:;9"

SMART-SPARK Module Leads

Fixed TimingIgnition ModuleKill Lead

Figure 9-36. Removing Breather Cover Gasket.

Remove Valve CoversA,3)) B.-B) &'B)3 /)%$5(% ,.B) C))( 6%)/" A,) ).3-$)%**?D) 6%)/ . 5.%E)* .(/ >AF %).-.(* C)*@))( *,) &'B)3.(/ %).-$(5 %632.&) '2 *,) &?-$(/)3 ,)./" A,) %)&'(/*?D) ,./ . C-.&E G:>$(5 $(%*.--)/ $( . 53''B) '( *,)6(/)3%$/) '2 *,) &'B)3 .(/ 4.? ,.B) 4)*.- %D.&)3% $(*,) C'-* ,'-)%" A,) -.*)%* /)%$5( 6%)% . ?)--'@ '3 C3'@( G:>$(5H .(/ *,) C'-* ,'-) %D.&)3% .3) 4'-/)/$( D-.&)"

!" >)4'B) *,) 2'63 ,)I 2-.(5) %&3)@% %)&63$(5 ).&,B.-B) &'B)3" J'*) B.-B) &'B)3 /$22)3)(&)% 2'3D3'D)3 -'&.*$'( $( 3).%%)4C-?"

=" A,) G:>$(5 *?D) &'B)3% %,'6-/ -$2* '22 @$*,'6*D3?$(5" K2 -''%) %D.&)3% .3) D3)%)(*H %.B) *,)4"L$*, *,) 5.%E)* *?D)H C3).E *,) %).- C? &.3)26--?D3?$(5 6(/)3 *,) )/5)% '2 *,) &'B)3"

Figure 9-35. Break Breather Cover Seal.

M" >)4'B) *,) C3).*,)3 &'B)3 .(/ 5.%E)* 0$2 6%)/1"7)) 8$563) 9:;N"


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9.11


9

Figure 9-39. Position of Ignition Modules.

!" #$%&'$ )*$ %&+,)-,. /01$2/ 3,4 -.,-)-&,%&4+5$/" 6&)$ )*$ 7&/-)-&, &8 )*$ -.,-)-&,%&4+5$/"

Remove Intake Manifold9" #$%&'$ )*$ 8&+1 *$: 853,.$ /01$2/ /$0+1-,. )*$

-,)3;$ %3,-8&54 )& )*$ 0


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9.12


Figure 9-43. Removing Cylinder Head.

!" #$%&'$ )*$ +,-)$./ -.&% )*$ +,-)$. 0&.$/" 1/$ 2*34.25+,6 +,-)$. )&&+" 7& 8&) 5/$ 2 %298$) )&.$%&'$ +,-)$./" :2.; )*$ +,-)$./ 03 +&62),&8< 2/$,)*$. ,8)2;$ &. $=*25/)< 284 63+,84$. > &. ?"@34.25+,6 +,-)$./ /*&5+4 2+A23/ 0$ .$,8/)2++$4 ,8)*$ /2%$ B&/,),&8" C$$ D,95.$ EF!!"

Figure 9-44. Removing Hydraulic Lifters.

Disassemble Cylinder Heads>" #$%&'$ )*$ )A& *$= -+289$ /6.$A/< .&6;$. 2.%

B,'&)/ 284 .&6;$. 2.%/ -.&% )*$ 63+,84$. *$24"C$$ D,95.$ EF!G"

Hydraulic Lifter Tool

Remove Cylinder Heads and HydraulicLiftersHIJKL M3+,84$. *$24/ 2.$ .$)2,8$4 5/,89 $,)*$. *$=

-+289$ /6.$A/ &. *$= -+289$ 85)/ 284 A2/*$./&8 /)54/" 7& 8&) ,8)$.6*289$ &. %,=6&%B&8$8)/< 2/ )*$ 63+,84$. *$24/ %23 *2'$4,--$.$8) %26*,8,89< 58,N5$ )& $26* -2/)$8,89%$)*&4"

>" #$%&'$ )*$ -&5. *$= -+289$ /6.$A/ &. *$= 85)/284 A2/*$./ /$65.,89 $26* 63+,84$. *$24" C$$D,95.$ EF!?" 7,/62.4 )*$ /6.$A/ &. 85)/ 284A2/*$./ &86$ .$%&'$4" 7& 8&) .$5/$" C)54/ O,-B.$/$8)P /*&5+4 &8+3 0$ .$%&'$4 ,- 42%29$4 &. ,-63+,84$. .$6&84,),&8,89 ,/ 8$6$//2.3" I86$.$%&'$4< )*$3 %5/) 0$ .$B+26$4"

?" :2.; )*$ +&62),&8 &- )*$ B5/* .&4/ 2/ $,)*$.,8)2;$ &. $=*25/) 284 63+,84$. > &. ?" Q5/* .&4//*&5+4 2+A23/ 0$ .$,8/)2++$4 ,8 )*$ /2%$B&/,),&8/"

Figure 9-42. Removing Cylinder Head Fasteners.

R" M2.$-5++3 .$%&'$ )*$ B5/* .&4/< 63+,84$. *$24//0 23./;1*.,) $/58-.:"

Figure 9-52. Removing Flywheel with a Puller.

J" #$%&'$ )*$ 4&&539,, ;$:"

Remove Stator and Backing PlatesK" #$%&'$ )*$ ,&93 123$41 1$293>/0 )*$ I.2;>/0

8-.)$1 ./5 1).)&3 4>3$ I3.2;$) L>, 1& $M9>88$5N"093$ ?@A6" #$%&'$ )*$ I.2;>/0 8-.)$1 ./51).)&3 4>3$ I3.2;$)"

Figure 9-49. Removing Plastic Grass Screen.

!" #$%&'$ )*$ ,&93 *$+ ,-./0$ 123$41 &3 *$+ 1)951./5 4.1*$31" #$%&'$ )*$ 8-.1)>2 ,./ ,3&% )*$,-:4*$$-" 093$ ?@AO"

Figure 9-50. Removing Fan.

Remove FlywheelK" 71$ . ,-:4*$$- 1)3.8 43$/2* &3 *&-5>/0 )&&- L1$$

&/ !N )& *&-5 )*$ ,-:4*$$- ./5 -&&1$/ )*$ *$+,-./0$ 123$4 1$293>/0 )*$ ,-:4*$$- )& )*$23./;1*.,)" 093$ ?@AK"

BCDEF G-4.:1 91$ . ,-:4*$$- 1)3.8 43$/2* &3*&-5>/0 )&&- )& *&-5 )*$ ,-:4*$$- 4*$/-&&1$/>/0 &3 )>0*)$/>/0 )*$ ,-:4*$$-

123$4"!" $"%

91$ ./: ):8$ &, I.3 &34$50$ )& *&-5 )*$ ,-:4*$$-" 71$ &, 192*)&&-1 2&9-5 2.91$ )*$ ,-:4*$$- )& I$2&%$23.2;$5 &3 5.%.0$5"


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9.15


9Figure 9-54. Removing Stator.

Remove Oil Pan Assembly!" #$%&'$ )*$ )$+ *$, -./+0$ 123$41 1$2536+0 )*$ &6.

7/+ )& )*$ 23/+82/1$" 9$$ :6053$ ;J H3$/8$3

H/3 H$)4$$+ )*$ 17.6))6+0 )/H /+? )*$ 23/+82/1$/+? )53+ 6) )& H3$/8 )*$ #KL 1$/." 9$$ :6053$;


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9.16


Figure 9-60. Removing Connecting Rod End Cap.

!"#$% &' ) *)+,-. +/012 /3 4+232.5 )5 562 5-4 -'2/562+ *78/.02+ ,-+29 :32 ) +/012 +2);2+5--8 5- +2;-


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9.17


9

!" #$%$&' ')$ &*+,$ %-+.$/0-$ 1+- ')$ +')$-.+22$.'324 -+/ &2/ %35'+2 &55$6*78"

Remove Crankshaft9" :&-$10778 %077 ')$ .-&2;5)&1' 1-+6 ')$ .-&2;.&5$"

?@A"

Figure 9-62. Removing Crankshaft.

Figure 9-63. Removing Oil Seal.

Remove Flywheel End Oil Seal9" #$6+,$ ')$ +37 5$&7 1-+6 ')$ .-&2;.&5$" ?@!"


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9.18



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10.2

Section 10Inspection and Reconditioning

!"# %&''#%()'* +&, -&.+'/0 %/' 1# *+&.', &'# 2)3#.',#+4 5"#' *+)',)'* ("# %+/'62"/7(8 *+)',)'* 2(&'#,#9&2)(2 %/' *#( %/.*"( )' ("# &)0 9/22/*#28 :")%"%&.0, %/.2# 2#;#+# #'*)'# ,/ (& 9+#;#'(0#/6/*#4

O'29#%( ("# %+/'62"/7( 1#/+)'* 2.+7/%#2 7&+ 2%&+)'*8*+&&;)'*8 #(%4 N#/2.+# ("# +.'')'* %0#/+/'%# 1#(:##'("# %+/'62"/7( -&.+'/02 /', ("#)+ +#29#%();# 1#/+)'*

1&+#24 ?2# /' )'2),#


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10.3


10

!" #$%&' )$*& +*,$ -$'& .*/ .0,&' 1&*,&'+*23 ./456,6$ ,)., ,)& 6,$*&6 .'& +* 1$*,.1, %+,) ,)& 178+*/&'%.88" 96& $0 . 1$::&'1+.8 15,,+*2;1$$8+*2 .2&*, +6'&1$::&*/&/"

.*/ /$%*%)+8& '&6+A+*2 ,$ >'&?&*, ,)& 0$':.,+$* $0 15,,+*2'+/2&6" B)&1C ,)& 6+A& 0'&D5&*,87"

EFGHI J$)8&' >+6,$*6 .'& 156,$:;:.1)+*&/ ,$&K.1,+*2 ,$8&'.*1&6" =)&* $?&'6+A+*2 .178+*/&'3 +, 6)$58/ -& :.1)+*&/ &K.1,87!"#$ && '!"!(! )*"+ $' !"$! && '!"!#! )*"+$?&' ,)& *&% /+.:&,&' LM&1,+$* !N" G)&1$''&6>$*/+*2 $?&'6+A& J$)8&' '&>8.1&:&*,>+6,$* %+88 ,)&* 0+, 1$''&1,87"

O" =)&* ,)& -$'& +6 %+,)+*!"!,- && '!"!!#$ )*"+ $0,)& /&6+'&/ 6+A&3 '&:$?& ,)& 1$.'6& 6,$*&6 .*/'&>8.1& ,)&: %+,) -5'*+6)+*2 6,$*&6" B$*,+*5&%+,) ,)& -5'*+6)+*2 6,$*&6 5*,+8 ,)& -$'& +6%+,)+*!"!(. && '!"!!!$ )*"+ $0 ,)& /&6+'&/ 6+A&.*/ ,)&* 56& 0+*+6) 6,$*&6 L'$K+:.,&87 .*/ %&.' &K1&66+?&873 .*/,$$ 6,&&> .* .*28& %+88 '&658, +* )+2) $+81$*65:>,+$*" M&& T+25'& !P;O"

Crankcase

Inspection and ServiceB)&1C .88 2.6C&, 65'0.1&6 ,$ :.C& 65'& ,)&7 .'& 0'&& $02.6C&, 0'.2:&*,6" U.6C&, 65'0.1&6 :56, .86$ -& 0'&& $0/&&> 61'.,1)&6 $' *+1C6"

B)&1C ,)& 178+*/&' -$'& 0$' 61$'+*2" V* 6&?&'& 1.6&635*-5'*&/ 05&8 1.* 1.56& 61500+*2 .*/ 61$'+*2 $0 ,)&178+*/&' %.88" V, %.6)&6 ,)& *&1&66.'7 85-'+1.,+*2 $+86$00 ,)& >+6,$* .*/ 178+*/&' %.88" R6 '.% 05&8 6&&>6/$%* ,)& 178+*/&' %.883 ,)& >+6,$* '+*26 :.C& :&,.8,$ :&,.8 1$*,.1, %+,) ,)& %.88" M1$'+*2 $0 ,)& 178+*/&'%.88 1.* .86$ -& 1.56&/ -7 8$1.8+A&/ )$, 6>$,6'&658,+*2 0'$: -8$1C&/ 1$$8+*2 0+*6 $' 0'$:+*./&D5.,& $' 1$*,.:+*.,&/ 85-'+1.,+$*"

V0 ,)& 178+*/&' -$'& +6 -./87 61$'&/3 &K1&66+?&87 %$'*3

,.>&'&/3 $' $5,;$0;'$5*/3 '&6+A+*2 +6 *&1&66.'7" 96& .*+*6+/& :+1'$:&,&' ,$ /&,&':+*& ,)& .:$5*, $0 %&.'L'&0&' ,$ WM>&1+0+1.,+$*63 G$8&'.*1&63 .*/ M>&1+.8G$'D5& X.85&6Y +* M&1,+$* !N3 ,)&* 6&8&1, ,)& *&.'&6,65+,.-8& $?&'6+A& $0 &+,)&'!"#$ && '!"!(! )*"+ $'!"$! && '!"!#! )*"+ " Z&6+A+*2 ,$ $*& $0 ,)&6& $?&'6+A&6%+88 .88$% 56.2& $0 ,)& .?.+8.-8& $?&'6+A& >+6,$* .*/'+*2 .66&:-8+&6" T+'6,3 '&6+A& 56+*2 . -$'+*2 -.'3 ,)&*56& ,)& 0$88$%+*2 >'$1&/5'&6 0$' )$*+*2 ,)& 178+*/&'"

EFGHI M$:& BX&1+.83 >.,&*,&/ *+1C&8;6+8+1$*&>8.,+*2 >'$1&66 0$' +*1'&.6&/ >$%&'3 65>&'+$'

$+8 1$*,'$83 '&/51&/ &K).56, &:+66+$*3 .*/?+',5.887 >&':.*&*, 178+*/&' 8+0&" \F=HZ;]FZH^ 178+*/&'6 1.**$, -& '&6+A&/ $' )$*&/.6 /&61'+-&/ +* ,)& 0$88$%+*2 >'$1&/5'&" V0 .>8.,&/ 178+*/&' -$'& +6 /.:.2&/ $' $5, $06>&1+0+1.,+$*3 56& . *&% :+*+-8$1C $' 6)$', -8$1C ,$ '&>.+' ,)& &*2+*&" 96& ,)& 0$88$%+*2>'$1&/5'&6 0$' 1'.*C1.6&6 %+,) . 1.6, +'$*68&&?&"

Honing=)+8& :$6, 1$::&'1+.887 .?.+8.-8& 178+*/&' )$*&6 1.* -& 56&/ %+,) &+,)&' >$',.-8& /'+886 $' /'+88 >'&66&63 ,)&56& $0 . 8$% 6>&&/ /'+88 >'&66 +6 >'&0&''&/ .6 +,0.1+8+,.,&6 :$'& .115'.,& .8+2*:&*, $0 ,)& -$'& +*'&8.,+$* ,$ ,)& 1'.*C6).0, 1'$66-$'&" _$*+*2 +6 -&6,.11$:>8+6)&/ ., . /'+88 6>&&/ $0 .-$5, #$! /01 .*/,! 2345672 >&' :+*5,&" R0,&' +*6,.88+*2 1$.'6& 6,$*&6 +*)$*&3 >'$1&&/ .6 0$88$%6I

Figure 10-3. Cylinder Bore Crosshatch After Honing.


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10.4


Figure 10-4. Measuring Piston Diameter.

!" #$% '( )($)*% +),-.+%/%-0 /%1%$,.2)(3 3'43%0 .- 5.-% 3'43% '(* +%'$4-% /6% ,71)(*%- 5.-%" 8'9%/6% +%'$4-%+%(/ '22-.:)+'/%17 !"#$ &&'(#$ )*#+ 5%1.; /6% /.2 .< /6% 5.-% '(*2%-2%(*),41'- /. /6% 2)$/.( 2)("

=" >)$/.(?/.?5.-% ,1%'-'(,% )$ /6% *)


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10.5


10

Figure 10-5. Checking Cylinder Head Flatness.

!"#$%&''( *+,-$./ /0$ 1"'1$ 2$.0"+*,2 -"#/,3 4+,-$.//0$ 1"'1$ ,-#*+5, "+6 #$'"/$6 0"#67"#$ %8# $9.$,,*1$7$"# 8# 6*,/8#/*8+3 !0$.: /0$ 1"'1$, "+6 1"'1$ ,$"/"#$" 8# *+,$#/, %8# $1*6$+.$ 8% 6$$- -*//*+5; .#".:,; 8#6*,/8#/*8+3 !0$.: .'$"#"+.$ 8% /0$ 1"'1$ ,/$2, *+ /0$

5&*6$,3 ?@A %8# 1"'1$ 6$/"*', "+6,-$.*%*."/*8+,3

Figure 10-6. Valve Details.

B"#6 ,/"#/*+5; 8# '8,, 8% -87$# "..82-"+*$6 C( 0*50%&$' .8+,&2-/*8+ 2"( C$ ,(2-/82, 8% %"&'/( 1"'1$,3D'/08&50 /0$,$ ,(2-/82, .8&'6 "',8 C$ "//#*C&/$6 /878#+ #*+5,; #$281$ "+6 .0$.: /0$ 1"'1$, %*#,/3 D%/$##$281"'; .'$"+ /0$ 1"'1$ 0$"6,; %".$,; "+6 ,/$2, 7*/0 "

-87$# 7*#$ C#&,03 E0$+; ."#$%&''( *+,-$./ $".0 1"'1$%8# 6$%$./, ,&.0 ", 7"#-$6 0$"6; $9.$,,*1$ .8##8,*8+;8# 78#+ ,/$2 $+63 F$-'".$ 1"'1$, %8&+6 /8 C$ *+ C"6.8+6*/*8+3 D +8#2"' 1"'1$ "+6 1"'1$, *+ C"6 .8+6*/*8+"#$ ,087+ *+ /0$ "..82-"+(*+5 *''&,/#"/*8+,3

EXHAUSTVALVE

E

G

F

H

D

D

C

A

B A

B A F E

G

H

INTAKE VALVE

EXHAUSTINSERT

INTAKEINSERT

ABCDEFGH


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10.6


!"#$%&' "#$% &'($) *+%, -+.)/ +' +0$)&(1+% & #&*#$2&% 3$ )$2+%41(1+%$4 &%4 )$./$4 1' (-$ '&2$ &%45&),1% &)$ 1% ,++4 /-&0$6 7' & #&*#$ 1/ 8+)% (+ 8-$)$(-$ 5&),1% 1/ *$// (-&% 9:;-$ #&*#$

/-+8% 8&/ 1% +0$)&(1+% '+) &*5+/( 9??? -+.)/ .%4$)2+%()+**$4 ($/( 2+%41(1+%/6

(%) +",)-.-",' >-$ #&*#$ 4$012($4 -$)$ /-+.*4 3$)$0*&2$46 @+($ (-$ 8&)0$4 -$&4A 5&),1% 4&5&,$4 &%4(++ %&))+86 >-$/$ 2+%41(1+%/ 2+.*4 3$ &(()13.($4 (+$B2$//1#$ -+.)/ +) & 2+531%&(1+% +' 0++) +0$)&(1%,2+%41(1+%/6

/0%1%20'C 0++) ,)1%4 +% '&2$ +) /$&( +' #&*#$ 81**&**+8 *$&D&,$ )$/.*(1%, 1% & 3.)%$4 #&*#$ +% +%$ /14$+%*E6

+"1-,2' F+D1%, 1/ %+)5&* +% 1%(&D$ #&*#$/ &%4 1/ %+(-&)5'.*6 7' (-$ /$&( 1/ ,++4G (-$ #&*#$ 2+.*4 3$ )$./$4&'($) 2*$&%1%,6


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10.7


10

!"#$%%&'$ )*+,-%.&*/ 0$+1$23.-2$%4 "#$ %#&'$($)*+&'+ +$$, #$-$ &,(&./'$ 0$-1 #&2# .*345+'&*,'$3)$-/'5-$+6 5+5/771 (5$ '* / 7$/, 85$7 3&9'5-$:

5-+4 ;53 ($)*+&'+ 5+5/771 -$+57' 8-*3 5+&,2 +'/7$2/+*7&,$: ;53 &+ / )-$0/7$,' ./5+$ *8 0/70$ +'&.


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10.8


Valve Guides!" $ %$&%' ()*+' *, -./0 1'2.0+ ,3'4*"*4$5*.0,6 *5 -*&&0.5 ()*+' 57' %$&%' *0 $ ,5/$*(75 &*0'8 97*, :$2 /',)&5*0 1)/05 %$&%' "$4', ./ ,'$5,6 &.,, ." 4.:3/',,*.06 $0+';4',,*%' .*& 4.0,):35*.08

9. 47'4< %$&%' ()*+'=5.=%$&%' ,5': 4&'$/$04'657./.)(7&2 4&'$0 57' %$&%' ()*+' $0+6 ),*0( $ ,3&*5= 1$&& ($)('6 :'$,)/' 57' *0,*+' +*$:'5'/ ." 57' ()*+'897'06 ),*0( $0 .)5,*+' :*4/.:'5'/6 :'$,)/' 57'+*$:'5'/ ." 57' %$&%' ,5': $5 ,'%'/$& 3.*05, .0 57',5': -7'/' *5 :.%', *0 57' %$&%' ()*+'8 >,' 57'&$/(',5 ,5': +*$:'5'/ 5. 4$&4)&$5' 57' 4&'$/$04' 12,)15/$45*0( 57' ,5': +*$:'5'/ "/.: 57' ()*+'+*$:'5'/8 !" 57' *05$


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10.9


10

!"#$ &'"()*+ ", ),)'((- "#."/'0+. 1- +2/+,,"3+ 4"(/4#,)560"4# '#. 1()+ +27'),0 ,548+9 :7+# *"#$,&'"(; 4"( ", '((4


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10.10


Figure 10-10. Measuring Piston Ring SideClearance.

Install New Piston Rings!" $%&'()) %*+ ,$&'"% -$%.&/ ,-"0**1 (& 2"))"+&3

45!63 7$%.& 89&' :* $%&'())*1 0"--*0');< 7$%.$%&'())('$"% $%&'-90'$"%& (-* 9&9()); $%0)91*1+$'= %*+ -$%. &*'&< >"))"+ $%&'-90'$"%&0(-*29));< ?&* ( ,$&'"% -$%. *@,(%1*- '"$%&'()) -$%.&< A** >$.9-* BCDBB< E%&'()) '=*

:"''"8 F"$) 0"%'-")G -$%. 2$-&' (%1 '=* '",0"8,-*&&$"% -$%. )(&'< 7*2*- '" >$.9-* BCDBH+"/ 7+') *+, 1"3 .15% #-2% +'2%.1+"# +" ')% /2**9% 1# ')% $+&5-$ +# 6%+"/+"#'1,,%3:

H: !"#'1,, ')% 2*'*2:

I: !"#'1,, ')% *+, $-.$ 6*38 '* ')% *+, $1" 1"3#%&-2% 7+') ')% '7* )%= 4,1"/% #&2%7#:


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10.14


!" #$%&' %)'*+,-./ ')%0%& %1& .&0' 0-2 31&34 $)'$'&&2)5 )$ 5)6&5&-%" 704& 8+'& %1&'& ,8 -)

9,-2,-." :$ 9,-2,-. )33+'8/ ;))8&- %1& 83'&


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Kohler CV22S Service Manual

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Transcript of Kohler CV22S Service Manual