Download
Share
Print this page
Kohler Command PRO ECV630 Service Manual
  1. Manuals
  2. Brands
  3. Kohler Manuals
  4. Crankshaft
  5. Command PRO ECV630
  6. Service manual

Kohler Command PRO ECV630 Service Manual

Vertical crankshaft
Hide thumbs Also See for Command PRO ECV630:

Advertisement

Quick Links

Download this manual See also: Service Manual, Owner's Manual
ECV630-ECV749, CV735, CV26, CV745
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
Specifications
15
Tools and Aids
18
Troubleshooting
22
Air Cleaner/Intake
23
Electronic Fuel Injection (EFI) System-ECV
48
Electronic Fuel Injection (EFI) System-Bosch
78
Lubrication System
80
Electrical System
85
Starter System
89
Disassembly/Inspection and Service
104
Reassembly
24 690 02 Rev. D
KohlerEngines.com
1

Advertisement

loading

Related Manuals for Kohler Command PRO ECV630

Summary of Contents for Kohler Command PRO ECV630

  • Page 1 ECV630-ECV749, CV735, CV26, CV745 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 Specifications Tools and Aids...
  • Page 2 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 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 find a local Kohler authorized dealer visit KohlerEngines.com or call 1-800-544-2444 (U.S. and Canada). 24 690 02 Rev. D...
  • Page 4 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

    Specifications Engine Dimensions with Heavy-Duty Air Cleaner Dimensions in millimeters. Inch equivalents shown in [ ]. 24 690 02 Rev. D KohlerEngines.com...
  • Page 6 Specifications Engine Dimensions with Low-Profile Air Cleaner 427.72 [16.839] Dimensions in millimeters. 302.03 60.00 [11.891] Inch equivalents shown in [ ]. [2.362] AIR CLEANER COVER REMOVAL 12.15 [.478] 17.01 16.31 [.670] [.642] SPARK SPARK PLUG PLUG FUEL FILTER 397.06 [15.632] 334.62 [13.174] 2X 89.41...
  • Page 7 Exceeding maximum angle of operation may cause engine damage from insufficient lubrication. Lubricate threads with engine oil prior to assembly. Any and all horsepower (hp) references by Kohler are Certified Power Ratings and per SAE J1940 & J1995 hp standards. Details on Certified Power Ratings can be found at KohlerEngines.com.
  • Page 8 Specifications TORQUE SPECIFICATIONS ECV630-ECV680 ECV730-ECV749 CV26 CV735 CV745 Oil Temperature Sensor 7.3 N·m (65 in. lb.) Oil Drain Plug 13.6 N·m (10 ft. lb.) Cylinder Head Hex Flange Nut (torque in 2 first to 16.9 N·m (150 in. lb.) increments) finally to 33.9 N·m (300 in.
  • Page 9 Specifications TORQUE SPECIFICATIONS ECV630-ECV680 ECV730-ECV749 CV26 CV735 CV745 Muffler Retaining Nut 27.8 N·m (246 in. lb.) 24.4 N·m (216 in. lb.) Oxygen Sensor 50.1 N·m (37 ft. lb.) Oil Cooler Oil Cooler/Adapter Nipple 28.5 N·m (21 ft. lb.) 27 N·m (20 ft. lb.) Fastener 2.8 N·m (25 in.
  • Page 10 Specifications TORQUE SPECIFICATIONS ECV630-ECV680 ECV730-ECV749 CV26 CV735 CV745 Valve Cover Valve Cover Fastener 6.2 N·m (55 in. lb.) Gasket Style Cover 3.4 N·m (30 in. lb.) Black O-Ring Style Cover w/Shoulder Screws 5.6 N·m (50 in. lb.) w/Flange Screws and 9.9 N·m (88 in.
  • Page 11 Specifications CLEARANCE ECV630-ECV680 ECV730-ECV749 CV26 CV735 CV745 SPECIFICATIONS Crankshaft End Play (free) 0.025/0.635 mm (0.001/0.025 in.) 0.070/0.590 mm (0.0028/0.0230 in.) Bore (in crankcase) 40.972/40.997 mm (1.6131/1.6141 in.) 40.965/41.003 mm (1.6128/1.6143 in.) Max. Wear Limit 41.011 mm (1.6146 in.) 41.016 mm (1.6148 in.) Bore (in oil pan) 40.974/41.000 mm (1.6131/1.6141 in.) 40.987/40.974 mm (1.6136/1.6131 in.)
  • Page 12 Specifications CLEARANCE ECV630-ECV680 ECV730-ECV749 CV26 CV735 CV745 SPECIFICATIONS Governor Governor Cross Shaft-to- 0.025/0.126 mm (0.0009/0.0049 in.) Crankcase Running Clearance 6 mm Shaft 0.013/0.075 mm (0.0005/0.0030 in.) 8 mm Shaft 0.025/0.126 mm (0.0009/0.0049 in.) Cross Shaft O.D. 7.949/8.000 mm (0.3129/0.3149 in.) Max.
  • Page 13 Specifications CLEARANCE ECV630-ECV680 ECV730-ECV749 CV26 CV735 CV745 SPECIFICATIONS Piston, Piston Rings, and Piston Pin (continued) Piston Thrust Face-to-Cylinder Bore Running Clearance 0.020/0.063 mm 0.0039/0.082 mm 0.001/0.045 mm (0.039/0.0018 in.) (0.0008/0.0024 in.) (0.0015/0.0032 in.) Valves and Valve Lifters Hydraulic Lifter to Crankcase 0.011/0.048 mm (0.0004/0.0019 in.) 0.0241/0.0501 mm (0.0009/0.0020 in.) Running Clearance...
  • Page 14 Specifications 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 15 Here is a list of tools and their source. SEPARATE TOOL SUPPLIERS Kohler Tools SE Tools Design Technology Inc. Contact your local Kohler source of 415 Howard St. 768 Burr Oak Drive supply. Lapeer, MI 48446 Westmont, IL 60559...
  • Page 16 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 Valve Guide Service Kit (Courage, Aegis, Command, OHC) SE Tools KLR-82415 For servicing worn valve guides.
  • Page 17 Tools and Aids FLYWHEEL HOLDING TOOL ROCKER ARM/CRANKSHAFT TOOL A flywheel holding tool can be made out of an old junk A spanner wrench to lift rocker arms or turn crankshaft flywheel ring gear and used in place of a strap wrench. may be made out of an old junk connecting rod.

  • Page 18: Troubleshooting

    Troubleshooting TROUBLESHOOTING GUIDE When troubles occur, be sure to check simple causes which, at first, may seem too obvious to be considered. For example, a starting problem could be caused by an empty fuel tank. Some general common causes of engine troubles are listed below and vary by engine specification. Use these to locate causing factors.
  • Page 19 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 20 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 21 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 22 Air Cleaner/Intake AIR CLEANER NOTE: Operating engine with loose or damaged air cleaner components could cause premature These systems are CARB/EPA certified and components wear and failure. Replace all bent or damaged should not be altered or modified in any way. components.
  • Page 23 FUEL LINE compensation for changes in overall engine condition Low permeation fuel line must be installed on all Kohler and operating environment, so it will be able to maintain Co. engines to maintain EPA and CARB regulatory ideal air/fuel ratio.
  • Page 24 EFI SYSTEM-ECV 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 flywheel.
  • Page 25 EFI SYSTEM-ECV Tip of sensor, protruding into exhaust gas, is hollow. EFI engines are equipped with either a 20 or 25 amp Outer portion of tip is surrounded by exhaust gas, with charging system to accommodate combined electrical inner portion exposed to ambient air. When oxygen demands of ignition system and specific application.
  • Page 26 EFI SYSTEM-ECV High pressure fuel line is serviced as a complete IMPORTANT NOTES! assembly to prevent tampering and safety hazards. ● Cleanliness is essential and must be maintained at all Components are not individually serviceable. times when servicing or working on EFI system. Dirt, Vent hose assembly is intended to vent fuel vapor out of even in small quantities, can cause significant fuel pump module and direct fuel vapor into throttle body.
  • Page 27 EFI SYSTEM-ECV ELECTRICAL COMPONENTS Grey Connector Electronic Control Unit (ECU) Pin # Description Pinout of ECU Not Used Black Connector Not Used Pin # Function Malfunction Indicator Light (MIL) Ground Ignition Coil #1 Ground Not Used Battery Ground Not Used Diagnostic Communication Line Not Used Speed Sensor input...
  • Page 28 This system will NOT reset when battery is disconnected! ECU Reset Procedure 1. Turn key 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).
  • Page 29 EFI SYSTEM-ECV 24 690 02 Rev. D KohlerEngines.com...
  • Page 30 EFI SYSTEM-ECV KohlerEngines.com 24 690 02 Rev. D...
  • Page 31 EFI SYSTEM-ECV Crankshaft Position Sensor b. Hold throttle closed and check resistance. It A sealed, non-serviceable assembly. If Fault Code should be 1400-1800 Ω. diagnosis indicates a problem within this area, test and 4. Leave leads connected to pin terminals as described correct as follows.
  • Page 32 EFI SYSTEM-ECV 6. Check circuits (input, ground), from wire harness Cutaway Oxygen Sensor Components (O connector to sensor plug for continuity, damage, etc. Connect one ohmmeter lead to Black pin 14 in wire harness connector (as in step 4). Connect other lead to terminal #1 in sensor plug.
  • Page 33 EFI SYSTEM-ECV Sensor Signal Observation NOTE: Do not cut into or pierce sensor or engine Removal Inspection wiring to make this connection. Sensor NOTE: Apply anti-seize compound only to threads. produces a very small signal. Corrosion or Anti-seize compound will affect sensor damage to wiring could lead to an incorrect performance if it gets into lower shield of signal because of repairs or contamination to...
  • Page 34 EFI SYSTEM-ECV Troublshooting-Oxygen Sensor (O Condition Possible Cause Conclusion Low voltage output. Shorted sensor or sensor circuit. Replace sensor or repair wiring. Shorted lead wire. Wiring shorted to ground. Contamination of air reference. Remove source of external contamination, protect air reference area.
  • Page 35 EFI SYSTEM-ECV 2. Disconnect electrical connector from an injector and Fuel Injectors listen for a change in idle performance (only running on one cylinder) or a change in injector noise or WARNING vibration. Explosive Fuel can cause fires and severe If an injector is not operating, it can indicate either a bad burns.
  • Page 36 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 37 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 fitting is specific to system and must be maintained. Visit KohlerEngines.com for recommended Kohler replacement parts.
  • Page 38 EFI SYSTEM-ECV Troubleshooting Guide Condition Possible Cause Faulty spark plugs. Fuel pump not running. Fuel pressure low. Insufficient 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 39 EFI SYSTEM-ECV 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 40 EFI SYSTEM-ECV 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 System Voltage Low 0563...
  • Page 41 EFI SYSTEM-ECV Code 0108 Code 0118 Component: Manifold Absolute Pressure Sensor Component: Coolant/Oil Sensor Fault: MAP Circuit High Voltage Fault: Coolant/Oil Temperature Sensor Circuit Condition: Intake manifold leak, shorted connection High Voltage or Open or faulty sensor. Condition: Shorted connection, faulty sensor, open Conclusion: MAP Sensor Related connection or broken wire.
  • Page 42 EFI SYSTEM-ECV Code 0123 Code 0171 Component: Throttle Position Sensor (TPS) Component: Fuel System Fault: TPS Circuit High Voltage Fault: Maximum adaptation limit exceeded Condition: Shorted connection or faulty sensor. Condition: Fuel inlet screen/filter plugged, low pressure at high pressure fuel line, TPS Conclusion: TPS Sensor Related malfunction, shorted connection, faulty ●...
  • Page 43 EFI SYSTEM-ECV 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/filter plugged, low line, TPS malfunction, shorted pressure at high pressure fuel line, TPS connection, faulty sensor or fuel pump malfunction, shorted connection or faulty module failure.
  • Page 44 EFI SYSTEM-ECV 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 45 Ignition System Related supply to bulb will be part of vehicle wire ● Incorrect spark plug(s) used. harness. Kohler key switch model will have MIL ● Poor connection to spark plug. on engine with 12V supply to bulb. Code 0352...
  • Page 46 EFI SYSTEM-ECV Diagnostic Aid #6 IGNITION SYSTEM (no spark) Condition ● Spark plug ● Plug wire ● Coil ● Coil circuit(s), pin circuits Grey 10 and Black 1. ● ECU grounds ● ECU ● Vehicle safety interlocks, ground signal on safety wire. Diagnostic Aid #7 FUEL SYSTEM ELECTRICAL (no fuel delivery) Condition...
  • Page 47 EFI SYSTEM-ECV 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 48 EFI SYSTEM-BOSCH Gasoline is extremely flammable and its vapors can WARNING explode if ignited. Store gasoline only in approved Explosive Fuel can cause fires and severe containers, in well ventilated, unoccupied buildings, away burns. from sparks or flames. Spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition.
  • Page 49 These adaptive values are maintained as FUEL LINE long as ECU is not reset. Low permeation fuel line must be installed on all Kohler Co. engines to maintain EPA and CARB regulatory During certain operating periods such as cold starts, compliance.
  • Page 50 EFI SYSTEM-BOSCH ECU requires a minimum of 7.0 volts to operate. Oxygen sensor functions like a small battery, generating Adaptive memory in ECU is operational whenever a voltage signal to ECU based upon difference in oxygen required voltage is present, however adapted values content between exhaust gas and ambient air.
  • Page 51 EFI SYSTEM-BOSCH A high-voltage, solid-state, battery ignition system is For starting and warm up, ECU will adjust fuel and used with EFI system. ECU controls ignition output and ignition timing, based upon ambient temperature, engine timing through transistorized control of primary current temperature, and loads present.
  • Page 52 EFI SYSTEM-BOSCH a. Turn key switch to ON/RUN position. Fuel pump 4. Disconnect main harness connector from ECU. will run for about three seconds and stop. Turn 5. Connect an ohmmeter between designated pin switch off and back on to restart fuel pump. terminals in plug: Repeat this procedure until fuel pump has cycled “24 Pin”...
  • Page 53 EFI SYSTEM-BOSCH Throttle Position Sensor (TPS) Throttle Between Resistance Continuity Position Terminals Value (Ω) Closed 2 & 3 800-1200 Closed 1 & 3 1800-3000 Full 2 & 3 1800-3000 Full 1 & 3 800-1200 1 & 2 1600-2500 If resistance values in steps 3, 4, and 5 are within specifications, go to step 6.
  • Page 54 EFI SYSTEM-BOSCH “24 Pin” (MSE 1.0) Plastic-Cased ECU: 7. Watch MIL. When light starts blinking rapidly, (5 Connect a jumper wire from TPS initialization pin blinks per second), move throttle lever to low idle #24 (violet wire) to battery voltage pin (red wire), speed position.
  • Page 55 EFI SYSTEM-BOSCH “32 Pin” (MSE 1.1) Plastic-Cased ECU: Pin c. Replace oxygen sensor (see next page). Run circuits #6 and #4. engine long enough to bring new sensor up to temperature and repeat output test from step 1. Cutaway of Oxygen Sensor Cycling voltage from 0.2 to 1.0 v should be indicated.
  • Page 56 EFI SYSTEM-BOSCH b. If continuity is indicated, go to step 6. 6. Attach ohmmeter leads to #30 and #87 terminals in relay. First, there should be no continuity. Using a 12 6. With key switch in ON/RUN position, using a high volt power supply, connect positive (+) lead to #85 impedance voltmeter, check voltage from wiring terminal and touch negative (-) lead to #86 terminal.
  • Page 57 EFI SYSTEM-BOSCH 1. With engine running at idle, feel for operational Injector Inspection Points vibration, indicating that they are opening and closing. 2. When temperatures prohibit touching, listen for a buzzing or clicking sound with a screwdriver or mechanic’s stethoscope. NOTE: Do not apply voltage to fuel injector(s).
  • Page 58 EFI SYSTEM-BOSCH 12. If either injector exhibits leakage of more than two to b. If reading(s) are still not within specified range, four drops per minute from tip, or shows any sign of test coils separately from main harness as leakage around outer shell, turn ignition switch off follows: and replace injector as follows.
  • Page 59 EFI SYSTEM-BOSCH b. If pressure is too low, install in-line ‘‘T’’ between 4. External Regulator- pump and regulator and retest pressure at that a. Remove screws securing mounting bracket to point. If it is too low there also, replace fuel pump. regulator housing.
  • Page 60 EFI SYSTEM-BOSCH 3. Place throttle control in IDLE/SLOW position and Initial Governor Adjustment check idle speed with a tachometer. Turn idle speed Initial governor adjustment is especially critical on screw in or out as required to obtain 1500 RPM, or EFI engines because of accuracy and sensitivity of idle speed specified by equipment manufacturer.
  • Page 61 EFI SYSTEM-BOSCH 4. Verify that governor has been set correctly. With linkage still retained in FULL THROTTLE position (Step 2), unsnap bushing clip, separate linkage from bushing, and remove bushing from lever. Follow Steps 3 and 4 in Checking Initial Adjustment. 5.
  • Page 62 EFI SYSTEM-BOSCH TROUBLESHOOTING Troubleshooting Guide Condition Possible Cause Faulty/malfunctioning ignition system. Dirty air filter. Insufficient fuel delivery. Improper governor adjustment. Low Power Plugged/restricted exhaust. One injector not working. Basic engine problem exists. TPS faulty or mounting exist.s Throttle plates in throttle body/intake manifold not fully opening to WOT stop (if so equipped). Electrical System NOTE: When performing voltage or continuity tests, avoid putting excessive pressure on or against connector pins.
  • Page 63 EFI SYSTEM-BOSCH “24 Pin” (MSE 1.0) Plastic-Cased ECU Systems Pin # Component Permanent Battery Voltage Switched Ignition Voltage Safety Switch Throttle Position Sensor (TPS) and Temperature Sensor Ground Not Used Oil Temperature Sensor Input Not Used Throttle Position Sensor (TPS) Input Speed Sensor Input Speed Sensor Ground Oxygen Sensor Input...
  • Page 64 EFI SYSTEM-BOSCH KohlerEngines.com 24 690 02 Rev. D...
  • Page 65 EFI SYSTEM-BOSCH “32 Pin” (MSE 1.1) Plastic-Cased ECU Systems Pin # Component Permanent Battery Voltage Switched Battery Voltage TPS Set; “Auto-Learn” Initialization Terminal Throttle Position Sensor (TPS) and Temperature Sensor Ground Not Used Oil Temperature Sensor Input Not Used Throttle Position Sensor (TPS) Input Speed Sensor Input (+) Speed Sensor Ground (-) Not Used...
  • Page 66 EFI SYSTEM-BOSCH KohlerEngines.com 24 690 02 Rev. D...
  • Page 67 EFI SYSTEM-BOSCH Fuel System Fault Codes ECU continuously monitors engine operation against preset performance limits. If operation is outside limits, WARNING: Fuel System Under Pressure! ECU activates MIL and stores a diagnostic code in its Fuel system operates under high pressure. System fault memory.
  • Page 68 EFI SYSTEM-BOSCH After problem has been corrected, fault codes may be cleared as follows. 1. Disconnect negative (-) battery cable from battery terminal, or remove main fuse for ECU for approximately 1 minute. 2. Reconnect cable and tighten securely, or reinstall main fuse. Start engine and allow it to run for several minutes. MIL should remain off if problem was corrected, and fault codes should not reappear (codes 31, 32, 33, and 34 may require 10-15 minutes of running to reappear).
  • Page 69 EFI SYSTEM-BOSCH "24 Pin" "32 Pin" OBD2 (MSE 1.0) (MSE 1.1) P-Code Blink Connection or Failure Plastic- Plastic- Applicable to: "32 Note Code Description Cased Cased Pin" (MSE 1.1) ECU/ ECU/ ECU/System Only System System Temperature Sensor Circuit: Open P0118 Circuit or Short to Battery Failure Completing Autolearn - TPS Offset below minimum allowable limit...
  • Page 70 EFI SYSTEM-BOSCH Code 21 Conclusion: TPS Sensor Related Component: Engine Speed Sensor ● Sensor connector or wiring. Fault: ECU receiving inconsistent tooth count ● Sensor output affected or disrupted by signals from speed sensor. dirt, grease, oil, wear, or breather tube position (must be to side opposite Condition: Possible misfire as ECU attempts to...
  • Page 71 EFI SYSTEM-BOSCH Code 32 Conclusion: Engine Speed Sensor Related Component: Oxygen Sensor ● Sensor connector or wiring. ● Sensor loose or air gap incorrect. Fault: No change in sensor output signal. Condition: Open loop operation only, may cause a drop in system performance and fuel Speed Sensor Wheel Related efficiency.
  • Page 72 EFI SYSTEM-BOSCH Code 33 Code 34 Component: Oxygen Sensor/Fuel System Component: Oxygen Sensor/Fuel System Components Fault: System too rich. Temporary fuel adaptation control is at upper limit. Fault: Long term fuel adaptation control is at upper or lower limit. Condition: Fuel Supply Related (nothing lean–only rich) Condition:...
  • Page 73 EFI SYSTEM-BOSCH Code 42 Code 51 "32 Pin" (MSE 1.1) Plastic-Cased ECU only. Component: Engine (Oil) Temperature Sensor Component: Injector #1 circuit open, shorted to ground, or shorted to battery. Fault: Not sending proper signal to ECU. Fault: Injector #1 is not functioning because Condition: Engine may be hard to start because circuit is open, shorted to ground, or...
  • Page 74 EFI SYSTEM-BOSCH Code 52 "32 Pin" (MSE 1.1) Plastic-Cased ECU only. Component: Injector #2 circuit open, shorted to ground, or shorted to battery. Code 56 "32 Pin" (MSE 1.1) Plastic-Cased ECU only. Fault: Injector #2 is not functioning because Component: Fuel pump relay circuit open, shorted to circuit is open, shorted to ground, or ground, or shorted to battery.
  • Page 75 EFI SYSTEM-BOSCH ● Ignition switch “32 Pin” (MSE 1.1) Plastic-Cased ECU: Pin circuit ● Permanent ECU power circuit problem “24 Pin” (MSE 1.0) Plastic-Cased ECU: Pin circuit 1. ● ECU “32 Pin” (MSE 1.1) Plastic-Cased ECU: Pin circuit 1. ● Switched ECU power circuit problem Diagnostic Aid #4 SPEED SENSOR (MIL does not turn “24 Pin”...
  • Page 76 EFI SYSTEM-BOSCH Diagnostic Aid #8 “FUEL SYSTEM-ELECTRICAL” (no fuel delivery) Possible causes: ● No fuel ● Air in fuel rail ● Fuel valve shut off ● Fuel filter/line plugged ● Injector circuit(s) “24 Pin” (MSE 1.0) Plastic-Cased ECU: Circuits 16, 17, 45, and 45A.
  • Page 77 EFI SYSTEM-BOSCH 24 690 02 Rev. D KohlerEngines.com...

  • Page 78: 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-efficiency gerotor oil pump maintains high oil flow and oil pressure, even at low speeds and high operating temperatures.
  • Page 79 Lubrication System 7. Reinstall oil fill cap/dipstick and tighten securely. Testing 8. Start engine; check for oil leaks. Stop engine; correct Compressed air, a pressure regulator, pressure gauge, leaks. Recheck oil level. and a continuity tester are required to test switch. 9.

  • Page 80: 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 carburetor. Do not touch wires while engine is running. Normal and fouled plugs are shown in following photos: Normal Spark Plug Component and Details...
  • Page 81 Electrical System Carbon Fouled BATTERY A 12-volt battery with 400 cold cranking amps (cca) is generally recommended for starting in all conditions. A smaller capacity battery is often sufficient if an application is started only in warmer temperatures. Refer to following table for minimum capacities based on anticipated ambient temperatures.
  • Page 82 Electrical System BATTERY CHARGING SYSTEM NOTE: Observe following guidelines to avoid damage to the electrical system and components: ● Make sure battery polarity is correct. A negative (-) ground system is used. ● Disconnect rectifier-regulator plug and/or wiring harness plug before doing any electric welding on equipment powered by engine.
  • Page 83 Electrical System Condition Conclusion 20/25 amp OK (green) light comes on and stays steady. Disconnect tester black lead attached to 1 AC terminal and reconnect it to other AC terminal. Repeat test. If OK (green) light comes on again, part is good and may be used.
  • Page 84 Electrical System 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 2 Purple Wires 30-amp Fuse 1 Red Wire w/ Black Stripe 10-amp Fuse 1 Red Wire w/ White Stripe 2 Red Wires...
  • Page 85 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 sufficient 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 86 Starter System SOLENOID SHIFT ELECTRIC STARTERS Starter Disassembly Solenoid Shift Starter Components NOTE: Do not reuse old retainer. NOTE: Do not soak armature or use solvent when cleaning. Wipe clean using a soft cloth, or use compressed air. 1. Remove nut and disconnect positive (+) brush lead/ bracket from solenoid terminal.
  • Page 87 4 brushes and springs are serviced as a set. Use a new end of commutator/armature. Mounting screw 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 88 Starter System b. Position brushes back in their slots so they are flush with I.D. of brush holder assembly. Insert brush installation tool (with extension), or use tube described above from a prior brush installation, through brush holder assembly, so holes in metal mounting clips are up/out. c.
  • Page 89 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 90 Disassembly/Inspection and Service Clean all parts thoroughly as engine is disassembled. Remove Top Mount Control Panel Only clean parts can be accurately inspected 1. Remove throttle control shaft nut on top of throttle and gauged for wear or damage. There are many shaft and remove throttle control lever and spring.
  • Page 91 Disassembly/Inspection and Service External Governor Control (ECV EFI) Speed Control Cable Clamp Throttle Actuator Bracket Screw Lever (bottom) Throttle Control Lever Spring Washer Flat Washer (top) Return Spring Remove External Governor Controls 1. Disconnect governor spring attached to governor lever. Note hole location for reassembly. 2.
  • Page 92 Disassembly/Inspection and Service WARNING Gasoline is extremely flammable and its vapors can explode if ignited. Store gasoline only in approved containers, in Explosive Fuel can cause fires and severe well ventilated, unoccupied buildings, away from sparks or burns. flames. Spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition.
  • Page 93 Disassembly/Inspection and Service 7. Remove screws securing fuel pump module baffle Remove Outer Baffles and Blower Housing which pump was mounted to. NOTE: Some engines may have 2 fuses mounted to a bracket above ECU, and a third in-line fuse by Remove Throttle Body rectifier-regulator.
  • Page 94 Disassembly/Inspection and Service Cylinder Head Components Valve Cover Valve Cover Gasket Hex Flange Screw Rocker Arm Piviot Rocker Arm Push Rod Hydraulic Lifter Valve Cap Valve Spring Valve Keeper Valve Spring Valve Seal Retainer Cylinder Head Cylinder Head Valve Dowel Pin Gasket Remove Manifold Absolute Pressure (MAP) Sensor Remove Valve Covers (ECV EFI)
  • Page 95 Inspection Check base surface of hydraulic lifters for wear or damage. If lifters need to be replaced, apply a liberal coating of Kohler lubricant (see Tools and Aids) to base of each new lifter before it is installed. Bleeding Lifters...
  • Page 96 Disassembly/Inspection and Service Inspection and Service Valve Details EXHAUST VALVE INTAKE VALVE EXHAUST INSERT INTAKE INSERT Dimension Intake Exhaust Seat Angle 89° 89° Insert O.D. 36.987/37.013 mm (1.4562/1.4572 in.) 32.987/33.013 mm (1.2987/1.2997 in.) Guide Depth 4 mm (0.1575 in.) 6.5 mm (0.2559 in.) Guide I.D.
  • Page 97 Disassembly/Inspection and Service Valve Guides Flywheel Components If a valve guide is worn beyond specifications, it will not guide valve in a straight line. This may result in burnt valve faces or seats, loss of compression, and excessive oil consumption. To check valve guide-to-valve stem clearance, thoroughly clean valve guide and, using a split-ball gauge, measure inside diameter of guide.
  • Page 98 Replace flywheel if it is cracked. Replace flywheel, crankshaft, and key if flywheel key is sheared or keyway is damaged. Inspect ring gear for cracks or damage. Kohler does not provide ring gear as a serviceable part. Replace flywheel if ring gear is damaged.
  • Page 99 Disassembly/Inspection and Service Oil Pump Assembly Crankcase Components Oil Pump Torque Sequence Oil pump is mounted inside oil pan. If service is required, continue with Disassembly, Inspection, and Reassembly. Disassembly 1. Remove screws. 2. Remove oil pump assembly from oil pan. 3.
  • Page 100 Disassembly/Inspection and Service 4. Remove piston pin from piston for inspection. Use a Remove Camshaft small screwdriver to pry pin retainer out of groove. Remove camshaft. Inspection Inspection and Service Piston and Rings Components and Details Check lobes of camshaft for wear or damage. See Specifications for minimum lift tolerances.
  • Page 101 Disassembly/Inspection and Service Ring failure is usually indicated by excessive oil To install new piston rings, proceed as follows: consumption and blue exhaust smoke. When rings fail, 1. Oil Control Ring (Bottom Groove): Install expander oil is allowed to enter combustion chamber where it is and then rails.
  • Page 102 Disassembly/Inspection and Service Inspect crankpin for score marks or metallic pickup. Remove Crankshaft Slight score marks can be cleaned with crocus cloth Carefully pull crankshaft from crankcase. soaked in oil. If wear limits, as stated in Specifications and Tolerances are exceeded, it will be necessary to Inspection and Service either replace crankshaft or regrind crankpin to 0.25 mm Crankshaft Components and Details...
  • Page 103 Measuring Piston-to-Bore Clearance Piston Detail 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 (Specifications).
  • Page 104 Reassembly NOTE: Make sure engine is assembled using all Crankcase Components specified torque values, tightening sequences, and clearances. Failure to observe specifications could cause severe engine wear or damage. Always use new gaskets. Apply a small amount of oil to threads of critical fasteners before assembly, unless a Sealant or Loctite ®...
  • Page 105 Reassembly 3. Install nylon washer onto governor cross shaft, then Install Connecting Rods with Pistons and Rings start push-on retaining ring. Hold cross shaft up in Piston Detail position, place a 0.50 mm (0.020 in.) feeler gauge on top of nylon washer, and push retaining ring down shaft to secure.
  • Page 106 Reassembly 6. Install screws securing oil pan to crankcase. Torque Install Oil Pan Assembly fasteners in sequence shown to 25.6 N·m (227 in. Oil Pan Sealant Pattern lb.). One mounting screw has a thread sealant patch. This screw is typically installed in number 10 hole shown.
  • Page 107 Reassembly NOTE: Before installing flywheel, make sure crankshaft Install Flywheel taper and flywheel hub are clean, dry, and completely free of any lubricants. Presence of lubricants can cause flywheel to be over CAUTION stressed and damaged when screw is torqued to Damaging Crankshaft and Flywheel Can specifications.
  • Page 108 Reassembly Cylinder Head Components Valve Cover Valve Cover Gasket Hex Flange Screw Rocker Arm Piviot Rocker Arm Push Rod Hydraulic Lifter Valve Cap Valve Spring Valve Keeper Valve Spring Valve Seal Retainer Cylinder Head Cylinder Head Valve Dowel Pin Gasket KohlerEngines.com 24 690 02 Rev.
  • Page 109 Reassembly Studs closest to lifters must have an exposed height of Valve Stem Seals 75 mm (2 15/16 in.). These engines use valve stem seals on intake valves Studs furthest from lifters must have an exposed height and on exhaust valves. Use a new seal whenever valve of 69 mm (2 3/4 in.).
  • Page 110 Reassembly 2. Torque screw to 7.3 N·m (65 in. lb.). Install Intake Manifold 3. Push electrical connector on MAP sensor making Torque Sequence sure a good connection is made. Install Crankshaft Position Sensor NOTE: Ensure all parts are clean, undamaged and free of debris and make sure electrical connectors have seal in place.
  • Page 111 Reassembly External Engine Components Debris Screen Guard Debris Screen Outer Baffle Rectifier-Regulator Oil Temperature Inner Baffle Oil Sentry™ Breather Cover Sensor Breather Cover Gasket 24 690 02 Rev. D KohlerEngines.com...
  • Page 112 Reassembly 2. Position outer baffles and secure using M6 screws Install Breather Cover and Inner Baffles Install M6 screws (20 mm long) into intake port side Torque Sequence of cylinder heads, including any lifting strap. Install M6 screws (16 mm long) into exhaust port side of cylinder head.
  • Page 113 Reassembly 6. Install a plain washers on each of screws. Apply Install Metal Debris Screen Loctite to screw threads. ® ® Spring Washer Details 7. Carefully remove studs and replace with screws. Torque screws to 9.9 N·m (88 in. lb.). Repeat procedure for other studs and screws.
  • Page 114 Reassembly ECU (ECV EFI) Install Electronic Control Unit (ECU) Electronic Control ECU Bracket Unit (ECU) Starter 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 115 Reassembly Gasoline is extremely flammable and its vapors can WARNING explode if ignited. Store gasoline only in approved Explosive Fuel can cause fires and severe containers, in well ventilated, unoccupied buildings, away burns. from sparks or flames. Spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition.
  • Page 116 Reassembly NOTE: Some applications may have two in-line fuel filters. In those applications, connect in-line 51-75 micron mesh fuel filter and hose to inlet barb of lift fuel pump and secure with a spring clamp. In-line 10 micron EFI paper fuel filter and hose must be connected to outlet barb of lift fuel pump and secured with a spring clamp.
  • Page 117 Reassembly 4. Attach governor spring to previously marked hole on Install Oil Cooler (if equipped) governor lever. 1. Secure adapter to oil pan with oil filter nipple. Torque oil filter nipple to 28.5 N·m (21 ft. lb.). Install Bottom Mount Control Panel (If Equipped) 2.
  • Page 118 Reassembly Sensitivity Adjustment Governor Lever Hole 1 Hole 2 Hole 3 Hole 4 Governor sensitivity is adjusted by repositioning governor spring in holes of governor lever. If speed surging occurs with a change in engine load, governor is set too sensitive. If a big drop in speed occurs when normal load is applied, governor should be set for greater sensitivity.
  • Page 119 24 690 02 Rev. D KohlerEngines.com...
  • Page 120 © 2011 by Kohler Co. All rights reserved. KohlerEngines.com 24 690 02 Rev. D...

This manual is also suitable for:

Command pro cv735Command pro ecv680Command pro ecv730Command pro ecv749Command pro cv26Command pro cv745