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Kohler Command Pro EFI ECH940 Service Manual

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ECH940 & ECH980
Service Manual
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.
2
Safety
3
Maintenance
5
Specifi cations
21
Tools and Aids
24
Troubleshooting
28
Air Cleaner/Intake
29
Electronic Fuel Injection (EFI) System
53
Governor System
55
Lubrication System
57
Electrical System
63
Starter System
65
Disassembly/Inspection and Service
82
Reassembly
62 690 13 Rev. A
KohlerEngines.com
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Summary of Contents for Kohler Command Pro EFI ECH940

  • Page 1 ECH940 & ECH980 Service Manual 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. Safety Maintenance Specifi...

  • Page 2: Safety Precautions

    Safety SAFETY PRECAUTIONS WARNING: A hazard that could result in death, serious injury, or substantial property damage. CAUTION: A hazard that could result in minor personal injury or property damage. NOTE: is used to notify people of important installation, operation, or maintenance information. CAUTION WARNING WARNING...

  • Page 3: Maintenance Instructions

    Perform these procedures more frequently under severe, dusty, dirty conditions. REPAIRS/SERVICE PARTS Kohler genuine service parts can be purchased from Kohler authorized dealers. To fi nd a local Kohler authorized dealer visit KohlerEngines.com or call 1-800-544-2444 (U.S. and Canada). 62 690 13 Rev. A...

  • Page 4: Oil Recommendations

    OIL RECOMMENDATIONS STORAGE If engine will be out of service for 2 months or more We recommend use of Kohler oils for best performance. follow procedure below. Other high-quality detergent oils (including synthetic) of API (American Petroleum Institute) service class SJ 1.

  • Page 5: Specifications

    Specifi cations Engine Dimensions with Heavy-Duty Air Cleaner - Flywheel Side 328.69 mm (12.94 135.0 mm (5.32 in.) in.) 483.0 mm (19.02 in.) Rain Cap Cover 365.5 mm (14.39 in.) Primary Air Filter Removal Element Removal 235.39 mm (9.27 in.) 105.99 mm (4.17 in.) 136.17 mm (5.36 in.) 74.03 mm (2.92 in.)
  • Page 6 Specifi cations Engine Dimensions with Heavy-Duty Air Cleaner - PTO Side 85.47 mm (3.37 in.) 428.2 mm (16.86 in.) 107.9 mm (4.25 in.) Lifting Point Lifting Point M8 X 1.25 mm 45° 35° 30° 4 Studs 60.0 mm (2.36 in.) 2 X Ø...
  • Page 7 Specifi cations Engine Dimensions with Heavy-Duty Air Cleaner - Starter Side 4 X 47.3 mm (1.86 in.) 58.4 mm (2.30 in.) 50.0 mm (1.97 in.) 105.4 mm (4.15 in.) Air Cleaner Clip Center Line Spark Oil Filter Removal Exhaust Port #1 Clearance Plug 5/8-18 UNF-2B in.
  • Page 8 Specifi cations Engine Dimensions with Heavy-Duty Air Cleaner - Opposite Starter Side 81.8 mm (3.22 in.) 45.6 mm (1.80 in.) 84.0 mm (3.31 in.) 184.9 mm (7.28 in.) Center Line Spark Cylinder #2 Shroud Oil Filter Plug Removal Access to Oil Drain Plug Cylinder #2 Shroud Mounting Hole "A"...
  • Page 9 Specifi cations Engine Dimensions with Low-Profi le Air Cleaner - Flywheel Side 106.0 mm (4.17 in.) 483.0 mm (19.02 in.) 370.9 mm (14.60 in.) Lifting Point Lifting Point 68.6 mm (2.70 in.) 79.5 mm (3.13 in.) 136.2 mm (5.36 in.) Spark Plug Boot Oil Fill Removal...
  • Page 10 Specifi cations Engine Dimensions with Low-Profi le Air Cleaner - PTO Side 85.5 mm (3.37 in.) 428.2 mm (16.86 in.) 107.9 mm (4.25 in.) Lifting Point Lifting Point M8 X 1.25 mm 4 Oil Level Dipstick 45° 35° Studs 60.0 mm (2.37 in.) K 2 X Ø...
  • Page 11 Specifi cations Engine Dimensions with Low-Profi le Air Cleaner - Starter Side 45.0 mm (1.77 in.) 50.0 mm (1.97 in.) 130.4 mm (5.13 in.) Cylinder #1 Shroud Cylinder #1 Shroud Oil Filter Removal Removal 181.9 mm (7.16 in.) 562.7 mm (22.16 in.) Grass Screen 435.13 mm (17.13 in.) Starter Stud...
  • Page 12 Specifi cations Engine Dimensions with Low-Profi le Air Cleaner - Opposite Starter Side 81.8 mm (3.22 in.) 84.0 mm (3.31 in.) 184.9 mm (7.28 in.) 130.4 mm (5.13 in.) Center Line Spark Oil Filter Plug 45.6 mm (1.80 in.) Access to Integrated Cylinder #2 Shroud Cylinder #2 Shroud Mounting Hole "A"...

  • Page 13: Engine Identification Numbers

    Values are in Metric units. Values in parentheses are English equivalents. Any and all horsepower (hp) references by Kohler are Certifi ed Power Ratings and per SAE J1940 & J1995 hp standards. Details on Certifi ed Power Ratings can be found at KohlerEngines.com.
  • Page 14 Specifi cations TORQUE SEQUENCES ECH940 ECH980 (Refer to Torque Specifi cations for torque values). Cylinder Head Bolt Fasteners Intake Manifold Mounting Fasteners Closure Plate Fasteners Oil Reservoir Fasteners KohlerEngines.com 62 690 13 Rev. A...
  • Page 15 Specifi cations TORQUE SPECIFICATIONS ECH940 ECH980 Backing Shroud (torque sequence on page 13) Backing Shroud to Crankcase 10.7 N·m (95 in. lb.) into new holes 7.3 N·m (65 in. lb.) into used holes Blower Housing and Sheet Metal M6 Screw New, Untapped Hole (casting) 10.7 N·m (95 in.
  • Page 16 Specifi cations TORQUE SPECIFICATIONS ECH940 ECH980 Fuse Holder Bracket Fuse Holder Bracket to Cylinder Head Fastener 10.7 N·m (95 in. lb.) into new holes 7.3 N·m (65 in. lb.) into used holes Governor Governor Lever Nut 7.1 N·m (63 in. lb.) Governor Yoke Mounting Screw 2.2 N·m (20 in.

  • Page 17: Clearance Specifications

    Specifi cations TORQUE SPECIFICATIONS ECH940 ECH980 Oil Pump Mounting Screw 9.9 N·m (88 in. lb.) Reservoir (oil) (torque sequence on page 14) Mounting Screw 25.6 N·m (227 in. lb.) Starter Assembly Mounting Screw 16.0 N·m (142 in. lb.) Stator Mounting Screw 9.3 N·m (82 in.
  • Page 18 Specifi cations CLEARANCE SPECIFICATIONS ECH940 ECH980 Crankshaft End Play (free) Non-Thrust Bearing 0.20/0.94 mm (0.008/0.037 in.) Crankshaft Bore (in crankcase) New, Without Main Bearing 50.00/50.025 mm (1.9685/1.969 in.) With Main Bearing Installed 45.040/45.145 mm (1.7732/1.7773 in.) Max. Wear Limit 45.158 mm (1.7778 in.) Crankshaft to Sleeve Bearing (in crankcase) Running Clearance 0.040/0.167 mm (0.0015/0.0065 in.) Crankshaft Bore (in closure plate)
  • Page 19 Specifi cations CLEARANCE SPECIFICATIONS ECH940 ECH980 Ignition Spark Plug Gap 0.76 mm (0.030 in.) Crankshaft Bearing (fl ywheel/PTO) New (installed) 45.040/45.145 mm (1.773/1.777 in.) Max. Wear Limit 45.158 mm Piston, Piston Rings, and Piston Pin Piston-to-Piston Pin Running Clearance 0.006/0.017 mm (0.0002/0.0007 in.) Piston Pin Bore I.D.

  • Page 20: General Torque Values

    Specifi cations GENERAL TORQUE VALUES English Fastener Torque Recommendations for Standard 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)

  • Page 21: Tools And Aids

    Shrader Valve Adapter Hose DTI-037 Wire Probe Set (2 pieces regular wire with clip; 1 piece fused wire) DTI-031 Hose Removal Tool, Dual Size/End (also sold as individual Kohler tool) DTI-033 Flywheel Puller SE Tools KLR-82408 For properly removing fl ywheel from engine.
  • Page 22 For reaming worn valve guides to accept replacement oversize valves. Can be used in low-speed drill press or with handle below for hand reaming. Reamer Handle Design Technology Inc. For hand reaming using Kohler 25 455 12-S reamer. DTI-K830 AIDS Description Source/Part No.
  • Page 23 Tools and Aids FLYWHEEL HOLDING TOOL ROCKER ARM/CRANKSHAFT TOOL A fl ywheel holding tool can be made out of an old junk A spanner wrench to lift rocker arms or turn crankshaft fl ywheel ring gear and used in place of a strap wrench. may be made out of an old junk connecting rod.

  • Page 24: Troubleshooting Guide

    Troubleshooting TROUBLESHOOTING GUIDE When troubles occur, be sure to check simple causes which, at fi rst, 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 EFI engine troubles are listed below and vary by engine specifi cation. Use these to locate causing factors.
  • Page 25 Troubleshooting EXTERNAL ENGINE INSPECTION Engine Loses Power NOTE: It is good practice to drain oil at a location away ● Dirty air cleaner element. from workbench. Be sure to allow ample time for ● Engine overheated. complete drainage. ● Excessive engine load. ●...

  • Page 26: Crankcase Vacuum Test

    Troubleshooting CRANKCASE VACUUM TEST WARNING WARNING Carbon Monoxide can cause severe nausea, Rotating Parts can cause severe injury. fainting or death. Stay away while engine is in operation. Avoid inhaling exhaust fumes. Engine exhaust gases contain poisonous carbon Keep hands, feet, hair, and clothing away from all monoxide.

  • Page 27: Compression Test

    Troubleshooting COMPRESSION TEST For Command Twins: A compression test is best performed on a warm engine. Clean any dirt or debris away from base of spark plug(s) before removing them. Be sure choke is off , and throttle is wide open during test. Compression should be at least 160 psi and should not vary more than 15% between cylinders.

  • Page 28: Air Cleaner/Intake

    Air Cleaner/Intake AIR CLEANER NOTE: Operating engine with loose or damaged air cleaner components could cause premature These systems are CARB/EPA certifi ed and components wear and failure. Replace all bent or damaged should not be altered or modifi ed in any way. components.

  • Page 29: Efi System

    FUEL LINE oil temperature greater than 60-70°C (140-158°F) to properly adapt. These adaptive values are maintained as Low permeation fuel line must be installed on all Kohler long as ECU is not reset. Co. engines to maintain EPA and CARB regulatory compliance.
  • Page 30 EFI SYSTEM ECU compares input signals to programmed maps in Crankshaft position sensor is essential to engine its memory to determine appropriate fuel and spark operation; constantly monitoring rotation and speed requirements for immediate operating conditions. ECU (RPM) of crankshaft. There are 23 consecutive teeth then sends output signals to set injector duration and cast into fl...
  • Page 31 EFI SYSTEM Manifold Absolute Pressure check provides immediate A high-voltage, solid-state, battery ignition system is manifold pressure information to ECU. TMAP sensor used with EFI system. ECU controls ignition output and measures diff erence in pressure between outside timing through transistorized control of primary current atmosphere and vacuum level inside intake manifold delivered to coils.

  • Page 32: Important Notes

    This can send a damaging voltage spike through is 1500 RPM, but certain applications might require ECU. a diff erent setting. Check Kohler Plus and equipment ● Do not allow battery cables to touch opposing manufacturer’s recommended settings. terminals. When connecting battery cables attach positive (+) cable to positive (+) battery terminal fi...

  • Page 33: Electrical Components

    EFI SYSTEM ELECTRICAL COMPONENTS Grey Connector Side Electronic Control Unit (ECU) Pin # Description Pinout of ECU Not Used Black Connector Side Not Used Pin # Function Malfunction Indicator Light (MIL) Ground Ignition Coil #1 Ground Not Used Battery Ground Not Used Diagnostic Communication Line GCU Tach Output (Electronic Governor)
  • Page 34 ECU Reset Procedure 1. Turn key/ignition OFF. 2. Install Red wire jumper from Kohler EFI service kit on to service port (connect white wire to black wire in 4 way diagnostic port). 3. Turn key/ignition ON, then OFF and count 10 seconds.
  • Page 35 EFI SYSTEM 62 690 13 Rev. A KohlerEngines.com...
  • Page 36 EFI SYSTEM If one of these values is outside of specifi ed range Crankshaft Position Sensor and output transitions in a smooth manner, reset A sealed, non-serviceable assembly. If Fault Code ECU and run test again. Since there is no longer any diagnosis indicates a problem within this area, test and wear elements inside sensor, most likely faults will correct as follows.
  • Page 37 EFI SYSTEM 4. With throttle blade in full open position (WOT), press a. If resistance is out of specifi cations, check local magnet assembly fully on to throttle shaft. Full temperature. Sensor resistance will go down as insertion can be checked by measuring height from temperature is higher.
  • Page 38 EFI SYSTEM Visual Inspection Oxygen Sensor (O 1. Look for a damaged or disconnected sensor-to- Components engine harness connection. 2. Look for damage to sensor lead wire or associated engine wiring due to cutting, chaffi ng or melting on a hot surface.
  • Page 39 EFI SYSTEM 6. A special "dry to touch" anti-seize compound is applied to all new oxygen sensors at factory. If recommended mounting thread sizes are used, this material provides excellent anti-seize capabilities and no additional anti-seize is needed. If sensor is removed from engine and reinstalled, anti-seize compound should be reapplied. Use an oxygen sensor safe type anti-seize compound.
  • Page 40 EFI SYSTEM If an injector is not operating, it can indicate either a bad Fuel Injectors injector, or a wiring/electrical connection problem. Check as follows: WARNING 1. Disconnect electrical connector from both injectors. Explosive Fuel can cause fi res and severe Plug a 12 volt noid light into one connector.

  • Page 41: Fuel Components

    NOTE: If ignition coil(s) are disabled and an ignition pump module and insert pressure test jumper (from fault is registered, system will automatically Kohler EFI Service Kit) between high pressure fuel disable corresponding fuel injector drive line and fuel pump module.
  • Page 42 Please note vent hose routing and replicate after service or component replacement to prevent pinching or abrasion of vent hoses. Only Kohler replacement parts can be used because fi tting is specifi c to system and must be maintained. Visit KohlerEngines.com for recommended Kohler replacement parts.
  • Page 43 EFI SYSTEM Troubleshooting Guide Condition Possible Cause Faulty spark plugs. Fuel pump not running. Fuel pressure low. Insuffi cient fuel delivery. Engine Starts Hard or Fails to Start TPS set incorrect (ECU Reset and TPS Initialization). When Hot. Crankshaft position sensor loose or faulty. TPS faulty.
  • Page 44 EFI SYSTEM Function Test Fault Codes Example of Diagnostic Display WARNING High Pressure Fluids can puncture skin and cause severe injury or death. One second pause Do not work on fuel system without proper Fault training or safety equipment. Code One second pause Fluid puncture injuries are highly toxic and hazardous.
  • Page 45 EFI SYSTEM Fault Code Connection or Failure Description 0230 Fuel Pump Module Circuit Low Voltage or Open 0232 Fuel Pump Module Circuit High Voltage 0336 Crankshaft Position Sensor Noisy Signal 0337 Crankshaft Position Sensor No Signal 0351 Cylinder 1 Ignition Coil Malfunction 0352 Cylinder 2 Ignition Coil Malfunction 0562...
  • Page 46 EFI SYSTEM Code 0107 Code 0113 Component: Manifold Absolute Pressure (TMAP) Component: Intake Air Temperature (TMAP) Fault: TMAP Circuit Low Voltage or Open Fault: Intake Air Temperature Sensor Circuit High Voltage or Open Condition: Intake manifold leak, open connection or faulty sensor.
  • Page 47 EFI SYSTEM Code 0122 Code 0131 Component: Throttle Position Sensor (TPS) Component: Oxygen Sensor Fault: TPS Circuit Low Voltage or Open Fault: O2S 1 Circuit Low Voltage Condition: Open connection, broken wire or faulty Condition: Open connection, broken wire or faulty sensor.
  • Page 48 EFI SYSTEM Code 0171 Code 0172 Component: Fuel System Component: Fuel System Fault: Maximum adaptation limit exceeded Fault: Minimum adaptation limit exceeded Condition: Fuel inlet screen/fi lter plugged, low Condition: Too high pressure at high pressure fuel pressure at high pressure fuel line, TPS line, TPS malfunction, shorted malfunction, shorted connection, faulty connection, faulty sensor or fuel pump...
  • Page 49 EFI SYSTEM Code 0174 Code 0202 Component: Fuel System Component: Fuel Injector Fault: Lean fuel condition Fault: Injector 2 Circuit Malfunction Condition: Fuel inlet screen/fi lter plugged, low Condition: Injector damaged or faulty, shorted or pressure at high pressure fuel line, TPS open connection.
  • Page 50 EFI SYSTEM Code 0336 Code 0352 Component: Crankshaft Position Sensor Component: Ignition Coil Fault: Crankshaft Position Sensor Noisy Signal Fault: Cylinder 2 Ignition Coil Malfunction Condition: Loose sensor, faulty/bad battery, shorted Condition: Broken wire in harness (may not be or faulty connection, faulty sensor or visible), shorted connection or faulty faulty sensor grounding.
  • Page 51 ● Spark plug supply to bulb will be part of vehicle wire ● Plug wire harness. Kohler key switch model will have MIL ● Coil on engine with 12V supply to bulb. ● Coil circuit(s), pin circuits Grey 10 and Black 1.
  • Page 52 EFI SYSTEM EFI Diagnostic Flow Diagram START OF TEST PROCEED TO START OF TEST FOR RETEST KEY ON MALFUNCTION REFER TO DIAGNOSTIC AID #1 INDICATOR LIGHT SYSTEM POWER REFER TO ARE FAULT CODES DIAGNOSTIC FAULT CODE SUMMARY PRESENT? CLEAR CODES REFER TO DIAGNOSTIC AID #3 DOES ENGINE START? MIL GOES OFF?

  • Page 53: Governor System

    Governor System GOVERNOR Governed speed setting is determined by position of throttle control. It can be variable or constant, depending on engine application. Governor is designed to hold engine speed constant under changing load conditions. Most engines are equipped with a centrifugal fl...
  • Page 54 Governor System This governor design works as follows: Governor Adjustments ● Centrifugal force acting on rotating governor gear NOTE: Do not tamper with governor setting. Overspeed assembly causes fl yweights to move outward as is hazardous and could cause personal injury. speed increases.

  • Page 55: Lubrication System

    Lubrication System This engine uses a full pressure lubrication system which delivers oil under pressure to crankshaft, camshaft, connecting rod bearing surfaces, and hydraulic valve lifters. A high-effi ciency gerotor oil pump maintains high oil fl ow and oil pressure, even at low speeds and high operating temperatures.

  • Page 56: Oil Cooler

    Lubrication System CHANGE OIL AND FILTER Installation Change oil while engine is warm. 1. Apply pipe sealant with Tefl on (Loctite 592™ ® ® ® 1. Clean area around oil fi ll cap/dipstick and drain plug. Thread Sealant or equivalent) to threads of switch. Remove drain plug and oil fi...

  • Page 57: Electrical System

    Electrical System SPARK PLUGS Inspection Inspect each spark plug as it is removed from cylinder CAUTION head. Deposits on tip are an indication of general Electrical Shock can cause injury. condition of piston rings, valves, and throttle body. Do not touch wires while engine is running. Normal and fouled plugs are shown in following photos: Normal Spark Plug Component and Details...
  • Page 58 Electrical System Carbon Fouled Battery Maintenance Regular maintenance is necessary to prolong battery life. Battery Test To test battery, follow manufacturer's instructions. FUSES This engine has 3 blade type automotive fuses. Replacement fuses must have same rating as blown fuse. Use fuse chart below to determine correct fuse. Wire Color Fuse Rating Soft, sooty, black deposits indicate incomplete...
  • Page 59 Isolate and verify trouble is within engine. 1. If Kohler diagnostic software is available, review "Safety System Active" status in Data Display screen. If yes is displayed, equipment safety circuit is active (seat switch/PTO switch/Safety interlocks, etc.). This must be corrected prior to continuing testing.
  • Page 60 Electrical System Wire Diagram-8-pin Connector and Key Switch Auxiliary Harness Switch Power To Starter ECU Power 12V Constant Accessories Ground to Kill Key Switch Ground Yellow Starter 15 Amp Fuse Green White 8-Pin Connector 5-Pin Connector Red with White Stripe Blue 25 Amp Fuse KohlerEngines.com...

  • Page 61: Battery Charging System

    Electrical System BATTERY CHARGING SYSTEM NOTE: Observe following guidelines to avoid damage to electrical system and components: ● Make sure battery polarity is correct. A negative (–) ground system is used. ● Disconnect rectifi er-regulator plug and/or wiring harness plug before doing any electric welding on equipment powered by engine.
  • Page 62 Electrical System 20/25 Amp Battery Charging Systems NOTE: Always zero ohmmeter on each scale before testing to ensure accurate readings. Voltage tests should be made with engine running at 3600 RPM with no load. Battery must be good and fully charged. When problems occur in keeping battery charged or battery charges at high rate, charging system or battery might be causing problems.

  • Page 63: Starter System

    Starter System NOTE: Do not crank engine continuously for more than 10 seconds. Allow a 60 second cool-down period between starting attempts. Failure to follow these guidelines can burn out starter motor. NOTE: If engine develops suffi cient speed to disengage starter but does not keep running (a false start), engine rotation must be allowed to come to a complete stop before attempting to restart engine.
  • Page 64 Starter System Solenoid Tests NOTE: Please perform following testing as near to conditions during failure. Before Starting ● Disable ignition system: with key off , unplug EFI Electronic Control Unit (ECU) or remove both 10 amp (red) engine mounted fuses. ●...

  • Page 65: Disassembly/Inspection And Service

    Disassembly/Inspection and Service WARNING Before working on engine or equipment, disable engine as Accidental Starts can cause severe injury or follows: 1) Disconnect spark plug lead(s). 2) Disconnect death. negative (–) battery cable from battery. Disconnect and ground spark plug lead(s) before servicing.
  • Page 66 Disassembly/Inspection and Service Clean all parts thoroughly as engine is disassembled. Remove Control Panel (if equipped) Only clean parts can be accurately inspected NOTE: Unless control panel is damaged or and gauged for wear or damage. There are many malfunctioning, disassembly from engine is commercially available cleaners that will quickly remove unnecessary.
  • Page 67 Disassembly/Inspection and Service Remove #1 Valley Baffl e Disconnect Fuel Lines from Fuel Pump Module (FPM) and Fuel Pump Dipstick Tube Mounting WARNING Explosive Fuel can cause fi res and severe burns. Do not fi ll fuel tank while engine is hot or running.
  • Page 68 Disassembly/Inspection and Service Intake Manifold Components Crankshaft Position Intake Manifold Intake Manifold Fuel Rail Sensor Gasket TPS Sensor Throttle Body Fuel Injector Metal Retaining Clip TMAP Sensor Remove Temperature/Manifold Absolute Pressure (TMAP) Sensor NOTE: Unless TMAP sensor is damaged or malfunctioning, disassembly from intake manifold is unnecessary. 1.
  • Page 69 Disassembly/Inspection and Service Remove Intake Manifold/Injectors/Fuel Rail/FPM Screw Straight Fitting Assembly Pipe Plug Barbed Fitting 1. Carefully remove clip from #2 barrel baffl e. O-Ring Dowel 2. Remove screws securing intake manifold to cylinder NOTE: Further disassembly of oil fi lter housing heads.
  • Page 70 Disassembly/Inspection and Service Remove Debris Screen and Fan Option #2 Remove Flywheel Flywheel, Backing Shroud, and Baffl e Components Debris Screen NOTE: Use this disassembly sequence if fan and debris screen are not being repaired/replaced individually. NOTE: Inspect fan/screen assembly for cracks, nicks, or damage of any kind.
  • Page 71 fl ywheel and crankshaft if keyway is damaged. Replace fl ywheel key if sheared or damaged. Inspect ring gear for cracks or damage. Kohler does not provide ring gear as a serviceable part. Replace fl ywheel if ring gear is damaged.
  • Page 72 Disassembly/Inspection and Service Cylinder Head Components Style B Style A Gasket Valve Cylinder Head Spark Plug Valve Stem Seal Valve Spring Pipe Plug Hydraulic Lifter Valve Spring Valve Spring Keeper Push Rod Rocker Arm Rocker Arm Pivots Rocker Arm Screw Valve Cover Gasket Valve Cover Hydraulic Lifter...
  • Page 73 Inspection Check base surface of hydraulic lifters for wear or damage. If lifters need to be replaced, apply a liberal coating of Kohler lubricant to base of each new lifter before it is installed. Bleeding Lifters To prevent a possible bent push rod or broken rocker arm, it is important to bleed any excess oil out of lifters before they are installed.

  • Page 74: Exhaust Valve

    Disassembly/Inspection and Service Inspection and Service Valve Details EXHAUST VALVE INTAKE VALVE Dimension Intake Exhaust Seat Angle 89° 89° Seat Taper 30° 30° Guide Depth 8.5 mm (0.334 in.) 8.5 mm (0.334 in.) Guide I.D. 7.038/7.058 mm (0.2771/0.2779 in.) 7.038/7.058 mm (0.2771/0.2779 in.) Valve Head Diameter 38.625/38.685 mm (1.5206/1.5230 in.) 31.625/31.825 mm (1.2450/1.2549 in.)
  • Page 75 Disassembly/Inspection and Service Recondition valve seat inserts following instructions provided with valve seat cutter being used. Final cut should be made with an 89° cutter as specifi ed for valve seat angle. Cutting proper 45° valve face angle as specifi ed, and proper valve seat angle (44.5°, half of full 89°...
  • Page 76 Disassembly/Inspection and Service Reassembly Remove Breather Assembly Torque Sequence 1. Remove fasteners securing breather assembly and gasket to crankcase. 2. Carefully break gasket seal and remove all parts. Do not pry on sealing surfaces as it could cause damage resulting in leaks. Note assembly and orientation of parts.
  • Page 77 Disassembly/Inspection and Service Oil Seal Install Closure Plate Crankshaft Bearing (PTO) and Details Oil Seal If bearing was removed in servicing, install a new bearing using an arbor press and driver. 1. Make sure closure plate bore for bearing is clean, dry and free of nicks or burrs.
  • Page 78 Disassembly/Inspection and Service Scuffi ng and scoring of pistons and cylinder walls occurs Remove Camshaft when internal engine temperatures approach welding Remove camshaft and shim (if used). point of piston. Temperatures high enough to do this are created by friction, which is usually attributed to improper Inspection lubrication and/or overheating of engine.
  • Page 79 Disassembly/Inspection and Service 4. Before installing new rings on piston, place top 2 Remove Crankshaft rings, each in turn, in its running area in cylinder NOTE: If crankpin is reground, visually check to ensure bore and check end gap. Top compression ring end gap clearance is 0.125/0.304 mm (0.0049/0.0120 that fi...
  • Page 80 Disassembly/Inspection and Service Inspect crankshaft keyways. If they are worn or chipped, Remove Governor Yoke, Cross Shaft, and Seal replacement of crankshaft will be necessary. 1. Remove mounting screws securing yoke to governor Inspect crankpin for score marks or metallic pickup. cross shaft.
  • Page 81 Measuring Piston-to-Bore Clearance Piston Detail Piston Details 23°-33° Crosshatch NOTE: Kohler pistons are custom-machined to exacting tolerances. When oversizing a cylinder, it should be machined exactly 0.25 mm (0.010 in.) or 0.50 mm (0.020 in.) over new diameter. Corresponding oversize Kohler replacement piston will then fi...
  • Page 82 Reassembly Crankcase Components Camshaft Locking Tab Regulating Pin Governor Gear Lifter Feed Cover Governor Gear Shaft Lifter Feed Cover Governor Yoke Gasket Connecting Rod End Crankshaft Connecting Rod Piston Pin Piston Pin Retainer Piston Piston Ring Set Oil Seal Crankshaft Non-Thrust Bearing KohlerEngines.com 62 690 13 Rev.
  • Page 83 Reassembly NOTE: Make sure engine is assembled using all Install Governor Shafts, Seal, and Governor Gear specifi ed torque values, torque sequences, and clearances. Failure to observe specifi cations Governor Components and Details could cause severe engine wear or damage. Always use new gaskets.
  • Page 84 Reassembly Install Crankshaft Install Camshaft Carefully slide fl ywheel end of crankshaft through 1. Liberally apply camshaft lubricant (see Tools and bearing in crankcase. Aids) to each cam lobe. Lubricate camshaft bearing surfaces of crankcase and camshaft with engine oil. Install Connecting Rods with Pistons and Rings 2.
  • Page 85 Reassembly Breather/Closure Plate/Oil Reservoir Components Closure Plate Gerotor Gears Oil Pump O-ring Oil Pump Housing Pickup Tube Clamp Inlet Seal Pickup Screen Oil Reservoir Drain Plug Gasket Closure Plate Gasket Crankshaft Non-Thrust Bearing Dipstick Dipstick Tube Breather Assembly (PTO) Breather Gasket Filter Breather Hose Lifting Strap...
  • Page 86 Reassembly Oil Pump Assembly Install Oil Reservoir Oil pump is mounted inside closure plate. If service Torque Sequence was required and oil pump was removed, refer to Disassembly/Inspection and Service procedure. Install Closure Plate Assembly Torque Sequence 1. Use bolts with heads removed, or a similar item as temporary alignment pins and install into 2 center holes on ends.
  • Page 87 Reassembly Breather Components Breather Fastener Torque Sequence Breather Chamber Breather Hose Screws Breather Cover Gasket Filter Install Breather Assembly 1. Make sure sealing surfaces of crankcase and breather cover are clean and free of any nicks or burrs. Do not scrape surfaces, as this could result in leakage.
  • Page 88 Reassembly Cylinder Head Components Style B Style A Gasket Valve Cylinder Head Spark Plug Valve Stem Seal Valve Spring Pipe Plug Hydraulic Lifter Valve Spring Valve Spring Keeper Push Rod Rocker Arm Rocker Arm Pivots Rocker Arm Screw Valve Cover Gasket Valve Cover Hydraulic Lifter Hydraulic Lifter...
  • Page 89 Reassembly Install Hydraulic Lifters Install Cylinder Heads NOTE: Hydraulic lifters should always be installed in Torque Sequence same position as they were disassembled. Exhaust lifters are located on output shaft side of engine while intake lifters are located on fan side of engine.
  • Page 90 Reassembly Install Push Rods and Rocker Arms Install Valve Covers NOTE: Push rods should always be installed in same 1. Make sure sealing surfaces are clean and free of position as before disassembly. any nicks or burrs. 1. Note mark or tag identifying push rod as either 2.
  • Page 91 Reassembly Oil Filter Components Install Oil Filter Housing Assembly Reassemble oil fi lter housing if disassembled previously. Reassembly 1. Install small spring onto rubber valve, and insert small end through corresponding hole in cup until properly seated. 2. Install larger spring into fi lter housing. 3.
  • Page 92 Reassembly Flywheel, Backing Shroud, and Baffl e Components Install Backing Shroud Backing Shroud Wiring Harness NOTE: New hose clamps are recommended for reassembly, or if clamps have been loosened (expanded) several times to avoid leakage. 1. To aid assembly, and if it was removed, install lower oil cooler hose onto oil fi...
  • Page 93 Reassembly Install Stator Install Rectifi er-Regulator Stator Stator Leads Tie Strap Molded Clips Ground Lead Ground Lead Screw 1. Apply pipe sealant with Tefl on (Loctite 592™ ® ® ® Screw Rectifi er-Regulator Thread Sealant or equivalent) to stator mounting 1.
  • Page 94 Reassembly 3. Install screw and washer. Spring Washer Details 4. Use a fl ywheel strap wrench or holding tool to hold fl ywheel. Torque screw to 69.8 N·m (51 ft. lb.). 5. If equipped, install front drive shaft. Secure with screws and torque to 24.4 N·m (216 in.
  • Page 95 Reassembly 6. Install a plain washers on each of screws. Apply NOTE: Use this reassembly sequence if fan and debris Loctite to screw threads. ® ® screen were kept as a complete assembly and 7. Carefully remove studs and replace with screws. not replaced individually.
  • Page 96 Reassembly Intake Manifold Components Crankshaft Position Intake Manifold Intake Manifold Fuel Rail Sensor Gasket TPS Sensor Throttle Body Fuel Injector Metal Retaining Clip TMAP Sensor Gasket Notch Install Intake Manifold Install Fuel Injectors NOTE: Ensure all parts are clean, undamaged and free Torque Sequence of debris and make sure electrical connectors have seal in place.
  • Page 97 Reassembly 1. Install screws to secure FPM baffl e to crankcase. Install Fuel Pump Module (FPM) Torque screws to 11.3 N·m (100 in. lb.). 2. If removed, push high pressure fuel line connector WARNING onto FPM fi tting. Explosive Fuel can cause fi res and severe 3.
  • Page 98 Reassembly External Engine Components Fixed Guard Blower Housing Cylinder Shroud Electric Starter Electronic Control Vibration Stud Dipstick Valley Baffl e Unit (ECU) Isolator Heavy-Duty Air Low-Profi le Air Control Bracket Drain Plug Cleaner Cleaner Control Panel (if Oil Cooler Inlet Fuel Line Outlet Fuel Line equipped) Oil Filter...
  • Page 99 Reassembly Install Governor Lever Install #2 Valley Baffl e Install cylinder #2 valley baffl e with two screws and Install governor lever onto governor shaft and connect torque screws to 2.5 N·m (22 in. lb.) into new holes, or throttle linkage with black linkage bushing and 2.0 N·m (18 in.
  • Page 100 Reassembly Control Bracket Components Throttle Linkage and Control Bracket Throttle Body Cross Shaft Linkage Spring Governor Arm Governor Spring Governed Idle Spring Install Control Bracket and Air Cleaner Assembly NOTE: Low-profi le air cleaner is installed in similar manner to heavy-duty air cleaner. NOTE: ECU pins should be coated with a thin layer of electrical grease to prevent fretting and corrosion and may need to be reapplied if ECU is being reused.
  • Page 101 Reassembly Install and Adjust Governor Lever Install Oil Sentry (if equipped) ™ Details 1. Apply pipe sealant with Tefl on (Loctite 592™ ® ® ® Thread Sealant or equivalent) to Oil Sentry threads ™ switch and install it into 1/8 in. port in closure plate. Torque switch to 10.7 N·m (95 in.
  • Page 102 Reassembly Control Panel Components Oil Pressure Control Panel MIL Indicator Light Indicator Light Indicator Positive Washer Key Switch 5-Pin Connector (Red Mark) Terminal Ground Terminal Yellow Wire Tan Wire Green Wire Install Control Panel (if equipped) 1. If key switch was removed, install in control panel aligning slot in key switch housing with tab on control panel. Secure key switch with washer and nut on outside of control panel.
  • Page 103 Reassembly Install Oil Filter and Add Oil to Crankcase Testing Engine and Setting Speed NOTE: Make sure both oil drain plugs are installed and torqued to 21.4 N·m (16 ft. lb.) to prevent oil leakage. 1. Install oil drain plugs. Torque plugs to 21.4 N·m (16 ft.
  • Page 104 1P62 690 13 85612 49779 © 2017 by Kohler Co. All rights reserved. KohlerEngines.com 62 690 13 Rev. A...

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