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Table Of Contents - Kohler Command PRO EFI Series Service Manual

Table Of Contents

Table of Contents

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Table of Contents

Safety Precautions2

Maintenance Instructions3

Maintenance Schedule3

Repairs/Service Parts3

Oil Recommendations4

Fuel Recommendations4

Engine Dimensions - Flywheel Side5

Specifications5

Engine Dimensions - Pto Side (Earlier Design)6

Engine Dimensions - Pto Side (Later Design)7

Engine Dimensions - Starter Side8

Engine Dimensions - Opposite Starter Side9

Engine Identification Numbers10

General Specifications10

Torque Specifications10

Blower Housing And Sheet Metal10

Clearance Specifications13

General Torque Values16

Tools And Aids17

Separate Tool Suppliers17

Flywheel Holding Tool19

Rocker Arm/Crankshaft Tool19

Troubleshooting Guide20

Engine Cranks But Will Not Start20

Engine Starts But Does Not Keep Running20

Engine Starts Hard20

External Engine Inspection21

Cleaning Engine21

Engine Loses Power21

Engine Uses Excessive Amount Of Oil21

Crankcase Vacuum Test22

To Test Crankcase Vacuum With Manometer22

Compression Test23

Cylinder Leakdown Test23

Breather Tube24

Air Cleaner/Intake24

Crankshaft Position Sensor Bracket26

Important Notes28

Electrical Components29

Electronic Control Unit (Ecu)29

Pinout Of Ecu29

Ecu Reset Procedure30

Tps Learn Procedure30

Efi Wiring Diagram & Terminal Connection31

Crankshaft Position Sensor34

Contacting (Brush) Type Tps34

Resistance Table34

Throttle Position Sensor (Tps)34

Contactless (Magnet) Type Tps35

Replace Magnet Assembly35

If A Computer With Diagnostic Software Is Available35

If Only A Volt Meter Is Available35

Engine (Oil) Temperature Sensor36

Intake Air Temperature Sensor36

Manifold Absolute Pressure Sensor (Map)36

Temperature/Manifold Absolute Pressure (Tmap) Sensor36

Oxygen Sensor (O2)37

Cutaway Oxygen Sensor Components (02)37

Visual Inspection38

Sensor Wire Detail38

Sensor Signal Observation38

Engine Harness O2 Sensor Connector Plug Detail38

Removal Inspection39

Troubleshooting-Oxygen (O2) Sensor39

Fuel Injectors40

Fuel Components41

Ignition Coil41

Fuel Pump Module (Fpm)41

High Pressure Fuel Line42

Purge Port And Vent Hose Assembly42

Throttle Body/Intake Manifold Assembly42

Function Test44

Example Of Diagnostic Display44

Diagnostic Fault Code Summary44

Diagnostic Code Summary45

Efi Diagnostic Flow Diagram52

Start Of Test52

Flow Chart Diagnostic Aids53

Diagnostic Aid #2 Fault Codes53

Diagnostic Aid #4 Crankshaft Position Sensor53

Diagnostic Aid #5 Fuel Pump53

Electronic Governor54

Electronic Governor System Designs54

Electronic Governor System54

Throttle Linkage54

Operation Of Electronic Governor System55

Original Design Gcu/Harness Diagnostics And Troubleshooting58

Test 1 Probe Location (Original Design)58

Original Design Speed Control Input59

Original Design Gcu Blink Code Tests59

Original Design Electronic Governor Troubleshooting Flow Chart62

Field Installed Updated Design65

Field Installed Updated Design Gcu Blink Code Tests66

Field Installed Updated Design Troubleshooting Electronic Governor68

Basic Electrical Diagram Of Electronic Governor System71

New Updated Design Gcu/Harness Diagnostics And Troubleshooting72

New Updated Design Gcu Power Test/Probe Location72

New Updated Design Speed Control Input72

New Updated Design Gcu Blink Code Tests73

New Installed Updated Design Troubleshooting Electronic Governor75

New Updated Design Electronic Governor Troubleshooting Flow Chart76

Mechanical Governor79

Governor Adjustments79

Initial Adjustment Procedure79

Check Oil Level80

Change Oil And Filter80

Change Oil While Engine Is Warm80

Lubrication System80

Battery Charging System82

20/25 Amp Regulated Charging System82

Battery Size Recommendations82

Battery Maintenance82

Electrical System82

Fuse Replacement83

To Test Charging System83

Spark Plug Component And Details84

Ignition System84

Carbon Fouled85

Test For Spark86

Troubleshooting-Starting Dificulties87

Starter System87

Solenoid Shift Starters88

Solenoid Shift Starter Components88

Starter Disassembly88

Brush Replacement89

Starter Reassembly89

Solenoid Tests90

To Test Solenoid Pull-In Coil/Plunger90

To Test Solenoid Hold-In Coil90

External Engine Components91

Disassembly/Inspection And Service91

Disconnect Spark Plug Leads92

Drain Oil From Crankcase And Remove Oil Filter92

Remove Muffler92

Remove Cylinder Shrouds And Blower Housing92

Remove #2 Barrel And Valley Baffles93

Flywheel/Backing Shroud/Intake And Throttle Body93

Air Cleaner Assembly Components93

Remove Crankshaft Position Sensor94

Remove Debris Screen (Style A)94

Remove Debris Screen (Style B)94

Remove Flywheel/Fan/Hex Stud Assembly94

Remove Oil Filter Housing95

Oil Filter Housing Components95

Cylinder Head Components96

Remove Spark Plugs97

Remove Valve Covers97

Remove Cylinder Heads And Hydraulic Lifters97

Disassemble Cylinder Heads97

Valve Details98

Exhaust Valve98

Breather/Oil Pan Components99

Lapping Valves99

Valve Stem Seals99

Remove Breather Assembly100

Remove Oil Pan Assembly100

Oil Pump Assembly100

Torque Sequence100

Crankcase Components101

Remove Camshaft102

Remove Connecting Rods With Pistons And Rings102

Piston And Rings102

Piston And Rings Components And Details102

Install New Piston Rings103

Piston Ring Orientation103

Crankshaft Components And Details103

Remove Crankshaft103

Clearance Specifications-Connecting Rod Journal104

Remove Governor Gear Assembly104

Remove Governor Yoke, Cross Shaft, And Seal104

Measuring Piston-To-Bore Clearance Piston Detail105

Clean Cylinder Bore After Honing105

Remove Throttle Body106

Electronic Governor Intake And Throttle Body Assembly Components107

Remove Sealed (Bonded) Gcu Module Wiring Harness Assembly108

Remove Throttle Body (New Updated Design Electronic Governor)109

Remove New Sealed (Bonded) Gcu Module Wiring Harness Assembly109

Mechanical Governor Intake And Throttle Body Assembly Components110

Remove Throttle Body (Mechanical Governor)110

Remove Fuel Injectors111

Fuel Pump Module/Pump Assembly Components111

Remove Fuel Pump Module/Fuel Pump Assembly111

Install Flywheel End Oil Seal113

Install Lifter Feed Chamber Gasket And Cover113

Install Governor Shafts, Seal, And Governor Gear113

Governor Components And Details113

Install Crankshaft114

Install Connecting Rods With Pistons And Rings114

Install Camshaft114

Determining Camshaft End Play114

Install Oil Pan Seal And Crankshaft Bearing (Pto)115

Install Oil Pan Assembly116

Pto Oil Seal116

Install Check Ball Kit116

Check Crankshaft End Play116

Install Hydraulic Lifters118

Assemble Cylinder Heads118

Install Cylinder Heads118

Install Guide Plate, Pivot Studs, Push Rods And Rocker Arms119

Adjust Valve Clearance (Avt Only)119

Install Valve Covers119

Install Spark Plugs119

Oil Cooler/Filter Components120

Install Oil Filter Housing Assembly120

Intake Manifold Torque Sequence122

Install Breather Hose122

Install Flywheel122

Install Fan (Style B)122

Install Crankshaft Position Sensor123

Install Metal Debris Screen (Style B)123

Spring Washer Details123

Install Cooling Fan And Debris Screen (Style A)123

Install Valley And Cylinder Barrel Baffles125

Torque Oil Cooler Screws125

Install Fuel Pump Module/Fuel Pump Assembly125

Install Electric Starter125

Mechanical Governor Control Bracket Components126

Install Governor Lever (Mechanical Governor Only)126

Install Oil Sentry126

Oxygen Sensor Wire Detail126

Install Oil Filter And Add Oil To Crankcase127

Testing Engine127

Connect Spark Plug Leads127

Prepare Engine For Operation127

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Troubleshooting

This manual is also suitable for:

Command pro efi ecv940 Command pro efi ecv980