Kohler ECV940 Service Manual

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Table of Contents

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ECV940 & ECV980

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 cations

Tools and Aids

Troubleshooting

Air Cleaner/Intake

Electronic Fuel Injection (EFI) System Electronic Throttle Body (ETB)

Electronic Fuel Injection (EFI) System

Governor System

112

Lubrication System

114

Electrical System

121

Starter System

125

Disassembly/Inspection and Service

151

Reassembly

62 690 05 Rev. H

KohlerEngines.com

Table of Contents

Troubleshooting

Summary of Contents for Kohler ECV940

Page 1 ECV940 & ECV980 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
PRO oil and PRO ﬁ lter. ® 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 05 Rev. H...
Page 4: Oil Recommendations
KOHLER PRO Extended Life Oil Filter. Alternative full-synthetic oil). Remove spark plug(s) and pour engine oils and oil ﬁ lters may be used with KOHLER about 1 oz. of engine oil into cylinder(s). Replace engines but require 100-Hour oil and 200-Hour oil ﬁ lter spark plug(s) and crank engine slowly to distribute change intervals for proper maintenance.
Page 5: Specifications
Speciﬁ cations Engine Dimensions - Flywheel Side 503.4 mm (19.82 in.) 484.6 mm (19.08 in.) Air Filter Element 267.4 mm (10.53 in.) 152.5 mm (6.00 in.) Removal 30.0 mm (1.18 in.) 17.3 mm (0.68 in.) 99.6 mm (3.92 in.) Cylinder #1 Shroud Cylinder #1 Shroud Spark Plug Lead Removal...
Page 6 Speciﬁ cations Engine Dimensions - PTO Side (Earlier Design) 428.1 mm (16.86 in.) 45° 55° 35° 2X Ø 35 mm (1.38 in.) 60 mm (2.36 in.) M8 X 1.25 mm Ø 254.0 mm (10.0 in.) Muﬄ er Gasket Exhaust Port #2 4 Studs M8 X 1.25-6H 25 mm (0.98 in.) Deep 7...
Page 7 Speciﬁ cations Engine Dimensions - PTO Side (Later Design) 2X Ø 35 mm (1.38 in.) 428.1 mm (16.86 in.) 45° 35° Muﬄ er Gasket 3/8-16 UNF-2B Inch 60 mm (2.36 in.) M8 X 1.25 mm Ø 254.0 mm (10.0 30 mm (1.18 in.) Exhaust Port #2 4 Studs in.)
Page 8 Speciﬁ cations Engine Dimensions - Starter Side 93.5 mm (3.68 in.) Engine Mounting 680.8 mm (26.80 in.) Oil Pressure Switch Exhaust Port #1 Surface 7/16-20 UNF-2B Inch 6.4 mm (0.25 in.) 80.2 mm (3.16 in.) 38.1 mm (1.50 in.) Ø 28.6 mm (1.13 in.) Square Keyway Deep 156.2 mm (6.15 in.)
Page 9 Speciﬁ cations Engine Dimensions - Opposite Starter Side 156.2 mm (6.15 in.) Lifting Point Cylinder #2 Shroud Access to Oil Cooler Cylinder #2 Shroud Removal Fuel Filter 70.5 mm (2.78 in.) Lifting Point Fits 6.4 mm (0.25 in.) Mounting Hole "A" Exhaust Port #2 Fuel Line Oil Drain Plug...
Page 10: Engine Identification Numbers
Kohler engine identiﬁ cation numbers (model, speciﬁ cation and serial) should be referenced for eﬃ cient repair, ordering correct parts, and engine replacement. Model ..... ECV940 EFI Command Engine...
Page 11 Speciﬁ cations TORQUE SPECIFICATIONS ECV940 ECV980 Connecting Rod Cap Fastener (torque in increments) 11.6 N·m (103 in. lb.) Crankcase Breather Cover Fastener 12.4 N·m (110 in. lb.) Oil Drain Plug 21.4 N·m (16 ft. lb.) Engine (Oil) Temperature Sensor (ETB) 7.3 N·m (65 in.
Page 12 Speciﬁ cations TORQUE SPECIFICATIONS ECV940 ECV980 Ignition Spark Plug 27 N·m (20 ft. lb.) Coil Fastener 10.2 N·m (90 in. lb.) Electronic Control Unit (ECU) to Bracket Screw 6.2 N·m (55 in. lb.) ECU to Isolation Mount Nut (ETB) 2 N·m (18 in. lb.) ECU Bracket to HDAC Screw (ETB) 7.9 N·m (70 in.
Page 13 Speciﬁ cations TORQUE SPECIFICATIONS ECV940 ECV980 Oil Pan Fastener 25.6 N·m (227 in. lb.) Engine (Oil) Temperature Sensor 13.6 N·m (120 in. lb.) Engine (Oil) Temperature Sensor Reducer Bushing 17.6 N·m (156 in. lb.) Engine (Oil) Temperature Sensor Nut 2.3 N·m (20 in. lb.)
Page 14: Clearance Specifications
Speciﬁ cations CLEARANCE SPECIFICATIONS ECV940 ECV980 Camshaft End Play 0.3/1.3 mm (0.011/0.051 in.) Running Clearance 0.025/0.063 mm (0.0010/0.0025 in.) Bore I.D. 20.000/20.025 mm (0.7874/0.7884 in.) Max. Wear Limit 20.038 mm (0.7889 in.) Bearing Surface O.D. 19.962/19.975 mm (0.7859/0.7864 in.) Max. Wear Limit 19.959 mm (0.7858 in.)
Page 15 Speciﬁ cations CLEARANCE SPECIFICATIONS ECV940 ECV980 Crankshaft (continued) Connecting Rod Journal O.D. - New 43.982/44.000 mm (1.731/1.732 in.) O.D. - Max. Wear Limit 43.97 mm (1.731 in.) Max. Taper 0.018 mm (0.0007 in.) Max. Out-of-Round 0.025 mm (0.0010 in.) Width 53.00/53.09 mm (2.0866/2.0901 in.)
Page 16 Speciﬁ cations CLEARANCE SPECIFICATIONS ECV940 ECV980 Piston, Piston Rings, and Piston Pin Piston-to-Piston Pin Running Clearance 0.006/0.018 mm (0.0002/0.0007 in.) Pin Bore I.D. 19.006/17.013 mm (0.7482/0.7485 in.) Max. Wear Limit 19.025 mm (0.7490 in.) Pin O.D. 18.995/19.000 mm (0.7478/0.7480 in.) Max.
Page 17: 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 18: 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 K-Line Adapter Jumper Lead Wiring Harness Kohler 25 176 23-S...
Page 19 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 20 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 21: 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 22 Troubleshooting Sludge is a natural by-product of combustion; a small Engine Loses Power accumulation is normal. Excessive sludge formation ● Dirty air cleaner element. could indicate over rich fuel settings, weak ignition, ● Engine overheated. overextended oil change interval or wrong weight or ●...
Page 23: 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. Never run engine indoors or in enclosed spaces. Keep hands, feet, hair, and clothing away from all Engine exhaust gases contain poisonous carbon moving parts to prevent injury.
Page 24: Compression Test
Diagnostic System (KDS) Gen 2 system tests as mentioned within this manual, are available to ® Kohler dealers only. Special tests are not activated within KDS tool for non Kohler dealer users. A compression test is best performed on a warm engine. Clean any dirt or debris away from base of spark plug before removing it.
Page 25 Troubleshooting Test Pressure Chart for Dual Gauge Tool Left Gauge Regulated Pressure Selection Right Gauge Reading in PSI 80 PSI Recommended for engines over 200 cc or those exhibiting high leakage at 35 PSI setting. 35 PSI Recommended for single cylinder 31.5 24.5 17.5...
Page 26: Air Cleaner/Intake
Air Cleaner/Intake AIR CLEANER BREATHER TUBE These systems are CARB/EPA certiﬁ ed and components Ensure both ends of breather tube are properly should not be altered or modiﬁ ed in any way. connected. AIR COOLING WARNING Hot Parts can cause severe burns. Do not touch engine while operating or just after stopping.
Page 27: Fuel Recommendations
● Engine operation is at a steady state (not starting, warming up, accelerating, etc.). FUEL LINE Low permeation fuel line must be installed on all Kohler During closed loop operation ECU has ability to readjust Co. engines to maintain EPA and CARB regulatory and learn adaptive controls, providing compensation compliance.
Page 28 A technician can started. Sensor must be properly connected at all times. access stored fault code using a blink code diagnosis If sensor becomes disconnected for any reason, engine ﬂ ashed out through MIL or use KOHLER Diagnostic will quit running. ®...
Page 29 EFI SYSTEM-ELECTRONIC THROTTLE BODY (ETB) Purpose of sensing air temperature is to help ECU A high-voltage, solid-state, battery ignition system is calculate air density. Higher air temperature less dense used with EFI system. ECU controls ignition output and air becomes. As air becomes less dense ECU knows timing through transistorized control of primary current that it needs to lessen fuel ﬂ...
Page 30: Important Notes
EFI SYSTEM-ELECTRONIC THROTTLE BODY (ETB) High pressure fuel line is an assembly of hoses, injector IMPORTANT NOTES! caps and a fuel connector to fuel pump module. High ● Cleanliness is essential and must be maintained at all pressure fuel line feeds fuel to top of injectors through times when servicing or working on EFI system.
Page 31: Electrical Components
EFI SYSTEM-ELECTRONIC THROTTLE BODY (ETB) ELECTRICAL COMPONENTS Grey Connector Side Electronic Control Unit (ECU) Pin # Description Pinout of ECU Not Used Black Connector Side Not Used Pin # Description Malfunction Indicator Light (MIL) Ground Ignition Coil #1 Ground Not Used Battery Ground Not Used Not Used...
Page 32 1. Turn key/ignition OFF. void if case is opened or tampered with in any way. 2. Install Green colored wire jumper from Kohler EFI All operating and control functions within ECU are service kit on to diagnostic port (or connect white preset.
Page 33 EFI SYSTEM-ELECTRONIC THROTTLE BODY (ETB) 62 690 05 Rev. H KohlerEngines.com...
Page 34 EFI SYSTEM-ELECTRONIC THROTTLE BODY (ETB) ETB EFI Wiring Harness 20 Amp Detail Stator Rectiﬁ er-Regulator Purple 30A Fuse Battery Black Red/Black Pink Fuel Pump Module Red/White White 8-Terminal Connector Red/Yellow Green/White Dark Blue Starter Motor Dark Green Oil Pressure Switch Yellow/Black 10A Fuse Grey Connector...
Page 35 EFI SYSTEM-ELECTRONIC THROTTLE BODY (ETB) 62 690 05 Rev. H KohlerEngines.com...
Page 36 If either of these two faults is present or a TPS fault is suspected, recommended diagnostic test is as follows: If KOHLER Diagnostic System (KDS) Gen 2 is available (see Tools and Aids) ®...
Page 37 EFI SYSTEM-ELECTRONIC THROTTLE BODY (ETB) throttle body assembly. If no results are found while 5. Unplug sensor from wire harness and check sensor performing this test, a small load or gentle back and forth resistance separately across pin. Resistance value motion can be applied to connectors or wires just outside should again be 1850-2450 Ω.
Page 38 Still, with a good understanding of system and sensor, it is possible to diagnose many Pin B sensor problems in ﬁ eld. Using KOHLER Diagnostic System (KDS) Gen 2, see Pin A ® Tools and Aids, connected to ECU is a useful technique for observing sensor performance.
Page 39 1. With sensor connected and using KOHLER ® Diagnostic System (KDS) Gen 2, see Tools and Aids, start engine to observe O2 sensor activity. Run engine at suﬃ...
Page 40 Perform repairs as necessary. Cold engine. Engine temperature Normal operation, or engine operated below 150°F (66°C) as displayed by in an excessively cold environment. KOHLER Diagnostic System (KDS) ® Gen 2, see Tools and Aids. Rich biased sensor failure. Replace sensor.
Page 41 10.5 N·m (93 in. lb.). An ECU Reset will need to be on one cylinder) or a change in injector noise or completed. vibration. 3. Using KOHLER Diagnostic System (KDS) Gen 2, ® see Tools and Aids, perform Adjust Injector Timing test or Injector #1 or #2 test as found in test section 62 690 05 Rev.
Page 42: Fuel Components
Using an ohmmeter set on Rx1 scale, check resistance high pressure fuel line. Insert pressure test jumper in circuits as follows: (from Kohler EFI Service Kit) between high pressure fuel line and FPM. 1. To check cylinder coil 1 (starter side), disconnect Black connector from ECU and test between Black 2.
Page 43: Troubleshooting
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 44 EFI SYSTEM-ELECTRONIC THROTTLE BODY (ETB) Troubleshooting Guide Condition Possible Cause Faulty spark plugs. Fuel pump not running. Fuel pressure low. Insuﬃ cient fuel delivery. Engine Starts Hard TPS set incorrect (ECU Reset). or Fails to Start Crankshaft position sensor loose or faulty. When Hot.
Page 45 EFI SYSTEM-ELECTRONIC THROTTLE BODY (ETB) 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. One second pause Code Fluid puncture injuries are highly toxic and hazardous.
Page 46 EFI SYSTEM-ELECTRONIC THROTTLE BODY (ETB) Fault Code Summary SAE J1939 Fault Codes Fault Code MIL Blinks Connection or Failure Description P2119 1/5/2/11 Throttle Actuator Stuck 5419 P2100 1/5/2/11 Throttle Actuator Control Motor Circuit Open (Low Current Fault) 5419 P0171 1/10/8/13 Maximum Adaptation Limit Exceeded 4237 P0172...
Page 47 EFI SYSTEM-ELECTRONIC THROTTLE BODY (ETB) MIL may not be provided with engine. If equipment manufacturer has not added a MIL to equipment, one can be added easily for quick diagnostics. Main engine to vehicle connection will have a tan wire which is ground for MIL. Either incandescent or LED type bulbs can be used for MIL as long as they do not draw more than 0.1 amps.
Page 48 EFI SYSTEM-ELECTRONIC THROTTLE BODY (ETB) Fault Code MIL Blinks Fault Code MIL Blinks Code P0112 10/10/6/9 Code P0117 10/10/6/14 Component: Intake Air Temperature (TMAP) Component: Engine Temperature Sensor Fault: Intake Air Temperature Sensor Circuit Fault: Engine Temperature Sensor Circuit Low Low Voltage Voltage Condition:...
Page 49 EFI SYSTEM-ELECTRONIC THROTTLE BODY (ETB) Fault Code MIL Blinks Fault Code MIL Blinks Code P0122 10/10/3/3 Code P0131 10/11/15/10 3056 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:...
Page 50 EFI SYSTEM-ELECTRONIC THROTTLE BODY (ETB) Fault Code MIL Blinks Fault Code MIL Blinks Code P0171 1/10/8/13 4237 Code P0172 1/10/8/13 4237 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...
Page 51 EFI SYSTEM-ELECTRONIC THROTTLE BODY (ETB) Fault Code MIL Blinks Fault Code MIL Blinks Code P0174 1/10/8/13 4237 Code P0202 10/2/8/11 Component: Fuel Injector Component: Fuel System Fault: Injector 2 Circuit Malfunction Fault: Lean fuel condition Condition: Injector damaged or faulty, shorted or Condition: Fuel inlet screen/ﬁ...
Page 52 EFI SYSTEM-ELECTRONIC THROTTLE BODY (ETB) Fault Code MIL Blinks Fault Code MIL Blinks Code P0230 10/5/4/3 1347 Code P0337 10/2/7/12 NOTE: If fault code P0337 is present and engine does Component: Fuel Pump not start/run, proceed to step 1 of Crankshaft Fault: Circuit Low Voltage or Open Position Sensor earlier in this section.
Page 53 EFI SYSTEM-ELECTRONIC THROTTLE BODY (ETB) Fault Code MIL Blinks Fault Code MIL Blinks Code P0351 10/4/15/4 1268 Code P0563 10/10/6/8 Component: Ignition Coil Component: System Voltage Fault: Cylinder 1 Ignition Coil Malfunction Fault: System Voltage High Condition: Broken/shorted wire in harness (may not Condition: Faulty voltage regulator or shorted be visible), shorted connection or faulty...
Page 54 EFI SYSTEM-ELECTRONIC THROTTLE BODY (ETB) EFI Diagnostic Flow Diagram START OF TEST PROCEED TO START OF TEST FOR RETEST KEY ON ETB AND FUEL PUMP CYCLE? REFER TO DIAGNOSTIC AID #1 MALFUNCTION INDICATOR SYSTEM POWER LIGHT ON? REFER TO ARE FAULT CODES FAULT (P) CODE SUMMARY PRESENT? CLEAR CODES...
Page 55 ● Plug wire supply to bulb will be part of vehicle wire ● Coil harness. Kohler key switch model will have MIL ● Coil circuit(s), pin circuits Grey 10 and Black 1. on engine with 12V supply to bulb. ● ECU grounds Conclusion ●...
Page 56 EFI SYSTEM-ELECTRONIC THROTTLE BODY (ETB) Diagnostic Aid #11 SPEED CONTROL-CAN Communications (engine speed does not change when requested) Condition ● Speed request from OEM CAN controller is not being received by engine. Consult OEM service information for OEM diagnostics. ● Bad connection in engine connectors (ETB/equipment connector).
Page 57: Efi System
FUEL LINE ratio is required and system operates in an open loop Low permeation fuel line must be installed on all Kohler mode. In open loop operation oxygen sensor output is Co. engines to maintain EPA and CARB regulatory used to ensure engine is running rich, and controlling compliance.
Page 58 EFI SYSTEM ECU compares input signals to programmed maps in Crankshaft Position Sensor Bracket its memory to determine appropriate fuel and spark requirements for immediate operating conditions. ECU then sends output signals to set injector duration and ignition timing. ECU continually performs a diagnostic check of itself, each of sensors, and system performance.
Page 59 EFI SYSTEM Earlier engines have a separate intake air temperature Fuel injectors mount into intake manifold, and high (IAT) sensor (located in throttle body) and a manifold pressure fuel line attaches to them at top end. absolute pressure (MAP) sensor. Later engines have Replaceable O-rings on both ends of injector prevent a combined temperature/manifold absolute pressure external fuel leakage and also insulate it from heat and...
Page 60 EFI SYSTEM When key switch is turned ON and all safety switch For starting and warm up, ECU will adjust fuel and requirements are met, ECU activates fuel pump module ignition timing, based upon ambient temperature, engine for about six seconds, which pressurizes system for temperature, and loads present.
Page 61 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 62 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 63 EFI SYSTEM 62 690 05 Rev. H KohlerEngines.com...
Page 64 EFI SYSTEM KohlerEngines.com 62 690 05 Rev. H...
Page 65 EFI SYSTEM 62 690 05 Rev. H KohlerEngines.com...
Page 66 EFI SYSTEM Contacting (Brush) Type TPS Crankshaft Position Sensor Resistance Table Throttle Between Resistance Continuity Position Terminal Value (Ω) Closed A & C 1400-1800 Full with A & C 3200-4100 Stop Pin Full without A & C 4600-5200 Stop Pin A &...
Page 67 EFI SYSTEM Contactless (Magnet) Type TPS Replace magnet assembly TPS is a sealed, non-serviceable assembly. If diagnosis indicates a bad sensor, complete replacement is necessary. Magnet that sensor detects is separate, and can be replaced or reused. If a blink code indicates a problem with TPS, it can be tested as follows: Diagnostics of sensor: ECU will still have electrical faults captured in fault codes: P0122 &...
Page 68 EFI SYSTEM Engine (Oil) Temperature Sensor Manifold Absolute Pressure Sensor (MAP) A sealed, non-serviceable assembly. A faulty sensor A sealed, non-serviceable assembly. A faulty sensor must be replaced. If a blink code indicates a problem must be replaced. If a blink code indicates a problem with temperature sensor, it can be tested as follows: with manifold absolute pressure sensor, it can be tested as follows:...
Page 69 EFI SYSTEM 6. Check circuits (input, ground), from main harness Cutaway Oxygen Sensor Components (02) connector to sensor plug for continuity, damage, etc. Connect one ohmmeter lead to Black pin 8 in main harness connector (as in step 4). Connect other lead to terminal #3 in sensor plug.
Page 70 EFI SYSTEM Visual Inspection NOTE: Do not cut into or pierce sensor or engine wiring to make this connection. Sensor Sensor Wire Detail produces a very small signal. Corrosion or damage to wiring could lead to an incorrect signal because of repairs or contamination to sensor.
Page 71 EFI SYSTEM 5. 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 72 EFI SYSTEM 1. With engine running at idle, listen for a buzzing or Fuel Injectors clicking sound. 2. Disconnect electrical connector from an injector and WARNING listen for a change in idle performance (only running Explosive Fuel can cause ﬁ res and severe on one cylinder) or a change in injector noise or burns.
Page 73 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 74 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 75 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 76 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 77 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 78 EFI SYSTEM Code 0032 Code 0108 NOTE: Codes 0031 and 0032 may have been Component: Manifold Absolute Pressure (MAP or mistakenly activated by turning key ON with TMAP) Sensor oxygen sensor disconnected. If either code Fault: MAP or TMAP Circuit High Voltage status is historic, that code may have set during assembly or a previous repair and may not be Condition:...
Page 79 EFI SYSTEM Code 0117 Code 0122 Component: Coolant/Oil Sensor Component: Throttle Position Sensor (TPS) Fault: Coolant/Oil Temperature Sensor Circuit Fault: TPS Circuit Low Voltage or Open Low Voltage Condition: Open connection, broken wire or faulty Condition: Shorted connection, faulty sensor or sensor.
Page 80 EFI SYSTEM Code 0131 Code 0171 Component: Oxygen Sensor Component: Fuel System Fault: O2S 1 Circuit Low Voltage Fault: Maximum adaptation limit exceeded Condition: Open connection, broken wire or faulty Condition: Fuel inlet screen/ﬁ lter plugged, low sensor. pressure at high pressure fuel line, TPS malfunction, shorted connection, faulty Conclusion: Oxygen Sensor Related sensor, low fuel or wrong fuel type.
Page 81 EFI SYSTEM Code 0172 Code 0174 Component: Fuel System Component: Fuel System Fault: Minimum adaptation limit exceeded Fault: Lean fuel condition Condition: Too high pressure at high pressure fuel Condition: Fuel inlet screen/ﬁ lter plugged, low line, TPS malfunction, shorted pressure at high pressure fuel line, TPS connection, faulty sensor or fuel pump malfunction, shorted connection or faulty...
Page 82 EFI SYSTEM Code 0202 Code 0336 Component: Fuel Injector Component: Crankshaft Position Sensor Fault: Injector 2 Circuit Malfunction Fault: Crankshaft Position Sensor Noisy Signal Condition: Injector damaged or faulty, shorted or Condition: Air gap incorrect, loose sensor, faulty/bad open connection. battery, shorted or faulty connection, faulty sensor or faulty sensor grounding.
Page 83 EFI SYSTEM Code 0351 Code 1693 Component: Ignition Coil Component: Tach Output (ECU) Fault: Cylinder 1 Ignition Coil Malfunction Fault: Tach Circuit Low Condition: Broken wire in harness (may not be Condition: Tachometer output circuit short to ground. visible), shorted connection or faulty Conclusion: Bad Tach Wire (grounded).
Page 84 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 85 ● Plug wire supply to bulb will be part of vehicle wire ● Coil harness. Kohler key switch model will have MIL ● Coil circuit(s), pin circuits Grey 10 and Black 1. on engine with 12V supply to bulb. ● ECU grounds ●...
Page 86: Governor System
Governor System GOVERNOR Some engines are equipped with an electronic governor or a mechanical governor. Other engines are equipped with an electronic throttle body (ETB) that uses a motor and controller to open throttle plate rather than a traditional mechanical governor or a separate governor control unit. ELECTRONIC GOVERNOR NOTE: Actual speeds depend on application.
Page 87 Governor System Proper link/spring assembly is critical. Insert spring Operation of Electronic Governor System hook tab of spring through DLA clevis hole until it exits 1. Key is turned ON, providing power to GCU (red lead opposite side, and tab of spring is allowed to snap into from engine harness to GCU harness).
Page 88 Governor System Electronic Governor System Designs Field Installed Updated Design As of this revision, there is an original design, a ﬁ eld installed updated design, and a new updated design. All designs function in same manner, and both updated designs have a non-serviceable electrical connection with a sealed (bonded) GCU module wiring harness assembly.
Page 89 Governor System New Updated Design New Sealed (Bonded) GCU Module New Updated Design Wiring Harness Assembly 4 Pin GCU to Main Speed Control Input Engine Harness New Updated Design features a sealed (bonded) GCU module wiring harness assembly that must NOT be separated.
Page 90 Governor System ORIGINAL DESIGN GCU/Harness Diagnostics and Troubleshooting NOTE: It is important to use proper sized probes to perform these tests. Probes that are incorrect size can damage connector or harness plug. Original design features a separate GCU and wiring harness that can be separated and tested for power and ground.
Page 91 Governor System ORIGINAL DESIGN Speed Control Input ORIGINAL DESIGN GCU Blink Code Tests Green LED Light Yellow LED Light Speed control issues can also be diagnosed utilizing on-board Blink Code diagnostic lights equipped in GCU. These GCUs store blink codes/trouble codes, that can be quickly diagnosed using blink code charts.
Page 92 Governor System ORIGINAL DESIGN GCU Blink Codes for Software Running Codes - Activated when engine is running. Response LED Diagnostics Failure Condition Possible Causes Response Time Yellow LED Green LED Running Normally None BLINKS BLINKS RPM Too High Mechanical bindage None BLINKS RPM Too Low...
Page 93 Governor System ORIGINAL DESIGN Troubleshooting Electronic Governor Failure Condition Possible Causes Equipment Observations Inspection/Testing Target/Selected Loss of GCU power When connection is lost, no DLA Test GCU power (red/B+) Speed not (B+ or Ground). movement will be seen. When wire for supply voltage and Maintained (Potentially connection is restored, GCU will...
Page 94 Governor System ORIGINAL DESIGN Electronic Governor Troubleshooting Flow Chart Turn oﬀ key switch. Do Not Touch Digital Linear Actuator (DLA) NOTE: DLA is not a solenoid. It is a precision electronic motor. Do not exert force to center clevis shaft! Visually inspect DLA and Linkage.
Page 95 Engine speed increases Operation Input Voltage: (if it was at low speed). 0-1 Volts at Idle/9+ Volts at High Speed. Kohler electronic governor system tests OK. Test Fail Pass control system of equipment. Refer to Equipment Manufacturer’s diagnostic procedures for control system.
Page 96 Governor System ORIGINAL DESIGN Electronic Governor Troubleshooting Flow Chart Continued Turn key switch to ON position. Test supply voltage to GCU using volt meter. Refer to page 90 (battery voltage +/- 1 volt) Note: Prevent Damage to Connector. Do Not Use Oversized Probe Tips. Proceed to DLA Circuit Test.
Page 97 Governor System FIELD INSTALLED UPDATED DESIGN GCU/Harness Diagnostics and Troubleshooting This updated design was ﬁ rst released as a ﬁ eld installed kit with a sealed GCU/wiring harness module assembly and separate red wire w/yellow tracer speed control input. Ground and Power Test NOTE: This updated design features a sealed GCU module wiring harness assembly that is serviced as an assembly and must NOT be separated.
Page 98 Governor System FIELD INSTALLED UPDATED DESIGN GCU Blink Speed control issues can also be diagnosed utilizing Code Tests on-board Blink Code diagnostic lights equipped in GCU. These GCUs store blink codes/trouble codes, that can be quickly diagnosed using blink code charts. Green LED Light Yellow LED Light FIELD INSTALLED UPDATED DESIGN GCU Blink Codes for Software Stored Codes - Activated when key...
Page 99 Governor System FIELD INSTALLED UPDATED DESIGN GCU Blink Codes for Software Running Codes - Activated when engine is running. Response LED Diagnostics Failure Condition Possible Causes Response Time Yellow LED Green LED Running Normally None BLINKS BLINKS RPM Too High Mechanical bindage None BLINKS...
Page 100 Governor System FIELD INSTALLED UPDATED DESIGN Troubleshooting Electronic Governor Failure Condition Possible Causes Equipment Observations Inspection/Testing Target/Selected Loss of GCU power When connection is lost, no DLA Test GCU power (red/B+) Speed not (B+ or Ground). movement will be seen. When wire for supply voltage and Maintained (Potentially...
Page 101 Governor System FIELD INSTALLED UPDATED DESIGN Electronic Governor Troubleshooting Flow Chart Turn oﬀ key switch. Do Not Touch Digital Linear Actuator (DLA) NOTE: DLA is not a solenoid. It is a precision electronic motor. Do not exert force to center clevis shaft! Visually inspect DLA and Linkage.
Page 102 Operation Input Voltage: Engine speed increases 0-1 Volts at Idle/9+ Volts at High Speed. (if it was at low speed). Kohler electronic governor system tests OK. Test Fail Pass control system of equipment. Refer to Equipment Manufacturer’s diagnostic procedures for control system.
Page 103 Governor System FIELD INSTALLED UPDATED DESIGN Electronic Governor Troubleshooting Flow Chart Continued Turn key switch to ON position. Test supply voltage to GCU using volt meter. Refer to page 97. (Battery voltage +/- 1 volt) DLA function can be tested and conﬁ rmed using a stepper motor controller tool. Refer to Tools and Aids. Testing instructions are included with tool.
Page 104 Governor System 6. With tool installed, start engine. Connect a jumper NEW UPDATED DESIGN GCU/Harness Diagnostics wire (technician supplied) to red w/yellow tracer and Troubleshooting bullet of tool. Connect other end of jumper wire to A new updated design has been released with a sealed battery 12 volt +.
Page 105 Governor System NEW UPDATED DESIGN GCU Blink Code Tests Speed control issues can also be diagnosed utilizing on-board Blink Code diagnostic lights equipped in GCU. These GCUs store blink codes/trouble codes, that can be quickly diagnosed using blink code charts. Green LED Light Yellow LED Light NEW UPDATED DESIGN GCU Blink Codes for Software Stored Codes - Activated when key is turned to ON...
Page 106 Governor System NEW UPDATED DESIGN GCU Blink Codes for Software Running Codes - Activated when engine is running. Response LED Diagnostics Failure Condition Possible Causes Response Time Yellow LED Green LED Running Normally None BLINKS BLINKS RPM Too High Mechanical bindage None BLINKS RPM Too Low...
Page 107 Governor System NEW INSTALLED UPDATED DESIGN Troubleshooting Electronic Governor Failure Condition Possible Causes Equipment Observations Inspection/Testing Target/Selected Loss of GCU power When connection is lost, no DLA Test GCU power (red/B+) Speed not (B+ or Ground). movement will be seen. When wire for supply voltage and Maintained (Potentially...
Page 108 Governor System NEW UPDATED DESIGN Electronic Governor Troubleshooting Flow Chart Turn oﬀ key switch. Do Not Touch Digital Linear Actuator (DLA) NOTE: DLA is not a solenoid. It is a precision electronic motor. Do not exert force to center clevis shaft! Visually inspect DLA and Linkage.
Page 109 Operation Input Voltage: Engine speed increases 0-1 Volts at Idle/9+ Volts at High Speed. (if it was at low speed). Kohler electronic governor system tests OK. Test Fail Pass control system of equipment. Refer to Equipment Manufacturer’s diagnostic procedures for control system.
Page 110 Governor System Basic Electrical Diagram of Electronic Governor System ECU Speed Output (speed signal) Power Speed Signal Green LED Light Device Yellow LED Light Ground DLA Driver Controls Application Supplied Speed Control Input Operation Input Voltage: 0-1 Volts at Idle/9+ Volts at High Speed KohlerEngines.com 62 690 05 Rev.
Page 111: Mechanical Governor
Governor System MECHANICAL 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. Governor gear/ﬂ yweight mechanism is mounted inside crankcase and is driven oﬀ gear on camshaft. Components Inside Engine Throttle Lever...
Page 112: 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 113 Lubrication System OIL COOLER (Engine Mounted) Testing NOTE: When oil cooler is remote mounted in application Compressed air, a pressure regulator, pressure gauge, and supplied by OEM, refer to your equipment and a continuity tester are required to test switch. manual for cleaning detail.
Page 114: Electrical System
Electrical System BATTERY CHARGING SYSTEM ● Disconnect rectiﬁ er-regulator plug (20/25 amp) or ring terminals (optional high output) and/or wiring harness plug before doing any electric welding on equipment CAUTION powered by engine. Also, disconnect all other Electrical Shock can cause injury. electrical accessories in common ground with engine.
Page 115 Electrical System 4. Perform these output tests for charging system using FUSES DVOM set to DC volts. This engine has 3 blade type automotive fuses. a. With engine oﬀ and key switch in OFF position, Replacement fuses must have same rating as blown measure voltage at battery.
Page 116 Electrical System 40/50 Amp High Output Regulated Charging System OEM Supplied B+ OEM Supplied Wiring Harness Battery Starter Ground Wiring with Charging Harness Fuse Flywheel Stator 4 Cooling Holes in Rectiﬁ er-Regulator Stator Wires Assembly Flywheel Stator Stator is mounted on crankcase behind ﬂ ywheel. Follow procedures in Disassembly/Inspection and Service and Reassembly if stator replacement is necessary.
Page 117 In separate wiring harness; tape, to ensure no accidental contact can be made. when OEM supplied, refer Kohler 60-amp Fuse NOTE: DVOM must be able to read to 0.05 ohms. to your equipment manual for fuse detail.
Page 118: Ignition System
Electrical System IGNITION SYSTEM Inspection Spark Plug Inspect each spark plug as it is removed from cylinder Spark Plug Component and Details head. Deposits on tip are an indication of general condition of piston rings, valves, and fuel mixture. Normal and fouled plugs are shown in following photos: Normal Plug taken from an engine operating under normal conditions will have light tan or gray colored deposits.
Page 119 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 120 Electrical System Condition Possible Cause Conclusion 1 cylinder is not ﬁ ring or 1 Wiring, Connections, or Using a DVOM, attach black (-) lead of meter to battery cylinder has good spark System Power ground, remove primary plug from coil, test voltage at and other cylinder has no or red wire with black tracer at coil primary connector with intermittent spark.
Page 121: 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 starter is engaged while ﬂ ywheel is rotating, starter pinion and ﬂ ywheel ring gear may clash and damage starter.
Page 122 Starter System SOLENOID SHIFT STARTERS Starter Disassembly When power is applied to starter electric solenoid moves NOTE: Do not reuse old retainer. drive pinion out onto drive shaft and into mesh with NOTE: Do not soak armature or use solvent when ﬂ...
Page 123 4 brushes and springs are serviced as a set. Use a new holes in metal clips must be up/out. Slide brush Kohler brush and spring kit if replacement is necessary. holder assembly down into place around 1. Perform steps 1-5 in Starter Disassembly.
Page 124 Starter System c. Install brush springs and snap on retainer caps. d. Hold starter assembly vertically on end housing, and carefully place tool (with extension) and assembled original brush holder assembly onto end of armature shaft. Slide brush holder assembly down into place around commutator, install positive (+) brush lead grommet in cutout of frame.
Page 125: 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 126 Block Cover and Disconnect Stator Wires 4. Remove oxygen sensor. NOTE: When high output charging system rectiﬁ er- regulator is supplied by Kohler, but installed by Remove Cylinder Shrouds and Blower Housing OEM in application, you must remove terminal block cover and disconnect stator wires before 1.
Page 127 Disassembly/Inspection and Service Remove Fuel Pump Module (FPM)/Fuel Pump Remove Oil Cooler (Engine Mounted) Assembly NOTE: When oil cooler is remote mounted in application and supplied by OEM, refer to your equipment WARNING manual for disassembly detail. Explosive Fuel can cause ﬁ res and severe NOTE: Earlier engines were built with spring clamps burns.
Page 128 Disassembly/Inspection and Service Flywheel/Backing Shroud/Intake and Throttle Body/Air Cleaner Assembly Components Special Washer Debris Screen Stiﬀ ener Flywheel Screw (Style A) (Style A) (Style A) Flywheel/Fan/Hex Backing Shroud/ Crankshaft Position Washer Stud Assembly Intake Manifold/ Sensor (Style A) Air Cleaner Rectiﬁ...
Page 129 1. Loosen screws securing screen and fan to ﬂ ywheel. Inspect ring gear for cracks or damage. Kohler does not 2. Hold screen and fan together. Carefully separate provide ring gear as a serviceable part. Replace ﬂ ywheel fan/screen assembly from face of ﬂ...
Page 130 Disassembly/Inspection and Service Remove Backing Shroud Assembly Remove Oil Filter Housing 1. Remove screws securing stator to backing shroud. Oil Filter Housing Components Keep leads in place and let stator lay on backing shroud. 2. Carefully slide lock tab on TMAP sensor outward. Press down on lock tab to release, then separate connectors.
Page 131 Disassembly/Inspection and Service Cylinder Head Components Style B Style A Gasket Valve Cylinder Head Pipe Plug Guide Plate Spacer Washer Spark Plug Valve Stem Seal Valve Spring Valve Spring Retainer Hydraulic Lifter Valve Spring Keeper Push Rod Rocker Arm Rocker Arm Pivots Valve Cover Seal Valve Cover Grommet (Plastic...
Page 132 Check base surface of hydraulic lifters for wear or Remove spark plug from each cylinder head. damage. If lifters need to be replaced, apply a liberal coating of Kohler lubricant to base of each new lifter Remove Valve Covers before it is installed.
Page 133: Exhaust Valve
Disassembly/Inspection and Service Disassemble Cylinder Heads NOTE: These engines use valve stem seals on intake and exhaust valves. Use a new seal whenever valves are removed, or if seal is deteriorated in any way. Never reuse an old seal. 1. Non-adjustable Valve Train Remove screws, rocker arm pivots, and rocker arms from cylinder head.
Page 134 Disassembly/Inspection and Service After cleaning, check ﬂ atness of cylinder head and Valve Seat Inserts corresponding top surface of crankcase using a Hardened steel alloy intake and exhaust valve seat surface plate or precision straight edge and feeler inserts are press ﬁ tted into cylinder head. Inserts are not replaceable but can be reconditioned if not too badly gauge.
Page 135 Disassembly/Inspection and Service Breather/Oil Pan Components Oil Pan Gerotor Gears Oil Pump O-Ring Oil Pump Housing Pickup Tube Inlet Seal Pickup Screen Drain Plug Crankshaft Thrust Bearing Oil Pan Gasket Breather Filter Breather Gasket (Flange PTO) Crankshaft Non- Breather Assembly Oil Seal Thrust Bearing Check Ball Kit...
Page 136 Disassembly/Inspection and Service Reassembly Remove Breather Assembly 1. Carefully remove harness clip from #1 valley baﬄ e Torque Sequence (if not already removed). 2. Remove fasteners securing breather assembly and gasket to crankcase. 3. Carefully break gasket seal and remove breather and ﬁ...
Page 137 Disassembly/Inspection and Service Crankcase Components Camshaft Locking Tab* Regulating Pin* Governor Gear* Lifter Feed Cross Shaft* Lifter Feed Cover Governor Yoke* Gasket Cover Connecting Rod Crankshaft Connecting Rod Piston Pin End Cap Piston Pin Retainer Piston Piston Ring Set Oil Seal *Mechanical Governor only.
Page 138 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 139 Disassembly/Inspection and Service 5. After installing new compression (top and middle) Remove Crankshaft rings on piston, make sure ring-to-groove side NOTE: If crankpin is reground, visually check to ensure clearance is 0.04/0.08 mm (0.0015/0.0031 in.). If that ﬁ llet blends smoothly with crankpin surface. side clearance is greater than speciﬁ...
Page 140 Remove shaft only if replacement is needed. 23°-33° Crosshatch Inspection NOTE: Kohler pistons are custom-machined to exacting Governor gear is located within crankcase. Inspect tolerances. When oversizing a cylinder, it should governor gear teeth. Replace gear if it is worn, chipped, be machined exactly 0.25 mm (0.010 in.) or 0.50...
Page 141 Disassembly/Inspection and Service While most commercially available cylinder hones can Measuring Piston-to-Bore Clearance be used with either portable drills or drill presses, use Piston Detail of a low speed drill press is preferred as it facilitates more accurate alignment of bore in relation to crankshaft crossbore.
Page 142 Disassembly/Inspection and Service Electronic Throttle Body (ETB) and Intake Remove Air Cleaner Assembly Components Remove ECU Air Cleaner Assembly 1. Remove nuts securing air cleaner assembly to electronic throttle body (ETB). Lower nuts also secure a clip and O2 sensor connector bracket. ECU Connector 2.
Page 143 Disassembly/Inspection and Service TMAP Screw TMAP High Pressure Fuel Injector Screw Line Assembly Electronic Throttle Vent Hose Fitting Body (ETB) Remove Fuel Injectors Breather Hose Clamp 1. Disconnect electrical connector. 2. Slide clamp and disconnect breather hose from ETB. 2. Remove screw for each injector and pull injector out 3.
Page 144 Disassembly/Inspection and Service 1. Remove screws securing fuel pump module to Remove Fuel Pump Module/Fuel Pump Assembly baﬄ e. 2. Using a side cutter or similar tool, cut Oetiker clamp WARNING to remove fuel line from fuel pump module inlet port. Explosive Fuel can cause ﬁ...
Page 145 Disassembly/Inspection and Service ORIGINAL DESIGN Electronic Governor Intake and Throttle Body Assembly Components Elbow Elbow O-ring Throttle Body Intake Manifold Fuel Rail Assembly Breather Hose Injector MAP Sensor Intake Air Air Cleaner Bracket Temperature Lifting Bracket Assembly Sensor Throttle Body Lever Linkage &...
Page 146 Disassembly/Inspection and Service FIELD INSTALLED UPDATED DESIGN Electronic Governor Intake and Throttle Body Assembly Components Elbow Elbow O-ring Throttle Body Intake Manifold Fuel Rail Assembly Breather Hose Injector TMAP Sensor Air Cleaner Bracket Throttle Body Lever Lifting Bracket Assembly Adapter Sealed (Bonded) GCU Module Linkage &...
Page 147 Disassembly/Inspection and Service Remove Sealed (Bonded) GCU Module Wiring Harness Assembly (FIELD INSTALLED UPDATED DESIGN Electronic Governor) 1. Remove screws securing sealed (bonded) GCU module wiring harness assembly to GCU bracket. 2. Disconnect DLA wire. 3. Cut nylon tie straps retaining GCU wiring harness to GCU wire tie-down bracket. 4.
Page 148 Disassembly/Inspection and Service Remove Throttle Body (NEW UPDATED DESIGN Electronic Governor) 1. Disconnect TPS wire. 2. Loosen 2 screws securing lifting bracket and air cleaner bracket to intake manifold. 3. Remove nuts securing elbow and throttle body. 4. Cut nylon tie strap retaining GCU wiring harness to GCU wire tie-down bracket. 5.
Page 149 Disassembly/Inspection and Service Mechanical Governor Intake and Throttle Body Assembly Components Elbow Elbow O-ring Throttle Body Intake Manifold Fuel Rail Assembly Breather Hose Injector MAP Sensor Intake Air Air Cleaner Bracket Speed Control Temperature Assembly Bracket Sensor Throttle Linkage Linkage Spring TMAP Sensor Remove Throttle Body (Mechanical Governor) 1.
Page 150 Disassembly/Inspection and Service Remove ECU Fuel Pump Module/Pump Assembly Components 1. Remove screws securing ECU to bracket. 2. Disconnect black and grey electrical connectors from ECU. 3. Reverse procedure to install. Torque screws to 6.2 N·m (55 in. lb.). Remove Fuel Injectors 1.
Page 151 Reassembly Crankcase Components Camshaft Locking Tab* Regulating Pin* Governor Gear* Lifter Feed Cross Shaft* Lifter Feed Cover Governor Yoke* Gasket Cover Connecting Rod Crankshaft Connecting Rod Piston Pin End Cap Piston Pin Retainer Piston Piston Ring Set Oil Seal * Mechanical Governor only. 62 690 05 Rev.
Page 152 Reassembly NOTE: Make sure engine is assembled using all Install Governor Shafts, Seal, and Governor Gear speciﬁ ed torque values, torque sequences, and (Mechanical Governor only) clearances. Failure to observe speciﬁ cations Governor Components and Details could cause severe engine wear or damage. Always use new gaskets.
Page 153 Reassembly Install Crankshaft Install Camshaft Apply a light coat of clean engine oil to inner surface of 1. Liberally apply camshaft lubricant to each cam lobe. ﬂ ywheel end oil seal and crankshaft bearing surface. Lubricate camshaft bearing surfaces of crankcase Carefully slide ﬂ...
Page 154 Reassembly Breather/Oil Pan Components Oil Pan Gerotor Gears Oil Pump O-Ring Oil Pump Housing Pickup Tube Inlet Seal Pickup Screen Drain Plug Crankshaft Thrust Bearing Oil Pan Gasket Breather Filter Breather Gasket (Flange PTO) Crankshaft Non- Breather Assembly Oil Seal Thrust Bearing Check Ball Kit (PTO)
Page 155 Reassembly PTO Oil Seal Install Oil Pan Assembly Details Torque Sequence 3.0 mm (0.118 in.) Oil Seal 1. Check to make sure there are no nicks or burrs in crankshaft seal bore of oil pan. 2. Apply a light coat of P80 Emulsion Lubricant (refer to Tools and Aids) to outside diameter of oil seal.
Page 156 Reassembly Cylinder Head Components Style B Style A Gasket Valve Cylinder Head Pipe Plug Guide Plate Spacer Washer Spark Plug Valve Stem Seal Valve Spring Valve Spring Retainer Hydraulic Lifter Valve Spring Keeper Push Rod Rocker Arm Rocker Arm Pivots Valve Cover Seal Valve Cover Grommet (Plastic...
Page 157 Reassembly Non-adjustable Valve Cover Seal Adjustable Valve Rocker Arm Screw Valve Train (Non- (Aluminum Valve Train (AVT) AVT) Cover) Roll Pin (Aluminum Valve Cover O-Ring (Aluminum Screw (Aluminum Valve Cover) (Aluminum) Valve Cover) Valve Cover) Install Hydraulic Lifters Install Cylinder Heads NOTE: Hydraulic lifters should always be installed in Torque Sequence same position as they were disassembled.
Page 158 Reassembly 3. Pre-Bled Lifters: Install Guide Plate, Pivot Studs, Push Rods and Rocker Arms a. Apply downward pressure to push rod side of rocker arm to compress lifter and bottom internal NOTE: Install push rod guide plate so ﬂ ange is down plunger.
Page 159 Reassembly Install Valve Covers Oil Cooler/Filter Components Plastic Valve Covers 1. Make sure sealing surfaces are clean and free of any nicks or burrs. 2. Install and properly seat seal onto each valve cover. 3. Install valve covers on same side as they were originally installed.
Page 160 Reassembly Backing Shroud/Intake Manifold/Throttle Body/Air Cleaner/Flywheel/Fan Assembly Components Special Washer Debris Screen Stiﬀ ener Flywheel Screw (Style A) (Style A) (Style A) Flywheel/Fan/Hex Backing Shroud/ Crankshaft Position Washer Stud Assembly Intake Manifold/ Sensor (Style A) Air Cleaner Rectiﬁ er-Regulator MAP or TMAP Stator Ground Lead Connector...
Page 161 Reassembly Install Intake Manifold/Throttle Body/Air Cleaner/ Install Oil Cooler (Engine Mounted) Backing Shroud Assembly NOTE: When oil cooler is remote mounted in application Intake Manifold Torque Sequence and supplied by OEM, refer to your equipment manual for reassembly detail. NOTE: Earlier engines were built with spring clamps securing oil cooler hoses.
Page 162 Reassembly Install Flywheel Install Crankshaft Position Sensor NOTE: Ensure all parts are clean, undamaged, and free CAUTION of debris; make sure electrical connectors have seal in place. Damaging Crankshaft and Flywheel can cause personal injury. NOTE: On engines with earlier design bracket, an air gap must be set when installing.
Page 163 Reassembly Install Cooling Fan and Debris Screen (Style A) CAUTION Failure to utilize or reassemble debris screen as designed could result in debris screen failure and serious personal injury. If cooling fan was removed from ﬂ ywheel perform step 1; if hex studs were removed from ﬂ...
Page 164 Reassembly External Engine Components Dipstick Oil Drain Plug Oil Fill Tube Valley Baﬄ e Spark Plug Lead Barrel Baﬄ e Starter Assembly Ignition Coil Fuel Pump Module Fuel Filter Fuel Pump Module Fuel Pump Baﬄ e High Pressure Fuel Electrical Connector Evap Line Oil Cooler Line Connector...
Page 165 Reassembly Install Valley and Cylinder Barrel Baﬄ es Install Electric Starter 1. Install #1 side valley baﬄ e and secure with screws. 1. Install electric starter motor using screws. If equipped, reinstall clip securing harness to baﬄ e. 2. Torque screws to 16 N·m (142 in. lb.). Install #2 side valley baﬄ...
Page 166 Reassembly Mechanical Governor Control Bracket Components Throttle Lever Control Bracket Throttle Linkage Linkage Spring Cross Shaft Governor Lever Governor Spring Idle Spring Install Governor Lever (Mechanical Governor Only) Install governor lever onto governor shaft and connect throttle linkage with black clip. Adjusting Mechanical Governor 1.
Page 167 Reassembly Install Muﬄ er Connect Spark Plug Leads Oxygen Sensor Wire Detail Connect leads to spark plugs. Prepare Engine for Operation NOTE: Any service to ECU, TPS/Electronic Throttle Body (ETB), or fuel pump module replacement should include ECU Reset. Refer to Electronic Fuel Injection (EFI) System Electronic Throttle Body (ETB) section.
Page 168 2. Adjust idle speed screw located on throttle body as NOTE: When high output charging system rectiﬁ er- necessary. Standard idle speed setting for EFI regulator is supplied by Kohler, but installed by engines is 1500 RPM, but certain applications might OEM in application, you must connect stator require a diﬀ...
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