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Table Of Contents - Kohler command pro ECH749 Service Manual

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Service manual (154 pages)

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Owner's manual (17 pages)

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Service manual (124 pages)

Table Of Contents

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Table of Contents

Safety Precautions2

Maintenance Instructions3

Maintenance Schedule3

Repairs/Service Parts3

Oil Recommendations4

Fuel Recommendations4

Specifications5

Engine Dimensions With Heavy-Duty Air Cleaner-Flywheel Side5

Engine Dimensions With Heavy-Duty Air Cleaner-Oil Filter Side6

Engine Dimensions With Heavy-Duty Air Cleaner-Pto Side7

Engine Dimensions With Heavy-Duty Air Cleaner-Starter Side8

Engine Dimensions With Low-Proﬁ Le Air Cleaner-Flywheel Side9

Engine Dimensions With Low-Proﬁ Le Air Cleaner-Oil Filter Side10

Engine Dimensions With Low-Proﬁ Le Air Cleaner-Pto Side11

Engine Dimensions With Low-Proﬁ Le Air Cleaner-Starter Side12

Engine Identification Numbers13

General Specifications13

Torque Specifications13

Clearance Specifications16

General Torque Values21

Metric Fastener Torque Recommendations For Standard Applications21

Separate Tool Supplies22

Flywheel Holding Tool24

Rocker Arm/Crankshaft Tool24

Troubleshooting Guide25

External Engine Inspection26

Cleaning Engine26

Crankcase Vacuum Test27

Compression Test28

Cylinder Leakdown Test28

Low-Profile Air Cleaner29

Heavy-Duty Air Cleaner29

Breather Tube29

Crankshaft Position Sensor Bracket31

Important Notes33

Electrical Components34

Electronic Control Unit (Ecu)34

Pinout Of Ecu34

Ecu Reset Procedure35

Tps Learn Procedure35

Wiring Harness36

Efi Wiring Diagram 6-Terminal Connector (Engines With Separate Map Sensor And Intake Air Temperature Sensor)36

Efi Wiring Diagram 5-Terminal Connector And Optional Key Switch (Engines With Separate Map Sensor And Intake Air Temperature Sensor)37

Efi Wiring Diagram 6-Terminal Connector (Engines With Separate Map Sensor)38

Efi Wiring Diagram 5-Terminal Connector And Optional Key Switch (Engines With Tmap Sensor)39

Crankshaft Position Sensor40

Throttle Position Sensor (Tps)40

Contacting (Brush) Type Tps Resistance Table40

Replace Magnet Assembly41

Contactless (Magnet) Type Tps41

Engine (Oil) Temperature Sensor42

Intake Air Temperature Sensor42

Manifold Absolute Pressure Sensor (Map)42

Temperature/Manifold Absolute Pressure (Tmap) Sensor42

Oxygen Sensor Components43

Cutaway Oxygen Sensor Components43

Sensor Signal Observation44

Removal Inspection44

Troublshooting-Oxygen Sensor45

Fuel Injectors46

Fuel Components47

Ignition Coil47

Fuel Pump Module (Fpm)47

High Pressure Fuel Line48

Purge Port And Vent Hose Assembly48

Throttle Body/Intake Manifold Assembly48

Function Test50

Example Of Diagnostic Display50

Diagnostic Fault Code Summary50

Diagnostic Code Summary51

Troubleshooting Flow Chart57

Efi Diagnostic Flow Diagram58

Bosch Efi System59

Initial Starting/Priming Procedure62

Speed Sensor Circuit63

Tps Initialization Procedure64

Cutaway Of Oxygen Sensor66

To Replace Oxygen Sensor67

Fuel Injector Details68

Injector Inspection Points69

Fuel Pressure Regulator Details70

Idle Speed Adjustment (Rpm)71

Idle Speed Screw Dampening Spring71

Initial Governor Adjustment71

"35 Pin" (MA 1.7) Metal-Cased ECU Systems74

"24 Pin" (MSE 1.0) Plastic-Cased ECU Systems76

"32 Pin" (MSE 1.1) Plastic-Cased ECU Systems78

Flow Chart Diagnostic Aids89

Bosch Efi Diagnostic Flow Diagram91

Lubrication System92

Lubrication Components92

Check Oil Level92

Change Oil And Filter93

Spark Plug Component And Details94

Electrical System94

Battery Size Recommendations95

Battery Maintenance95

Battery Charging System96

Fuse Replacement98

Starter System99

Solenoid Shift Starter Components100

Starter Disassembly100

Brushes And Springs Detail100

Armature Components And Details101

Brush Replacement101

Starter Reassembly101

Solenoid Tests102

Disassembly/Inspection And Service103

External Engine Components103

Disconnect Spark Plug Leads104

Drain Oil From Crankcase And Remove Oil Filter104

Remove Oil Cooler104

Remove Mufﬂer104

External Governor Control (Ech Efi)105

Remove External Governor Controls105

Remove Lift Fuel Pump And Fuel Pump Module106

Remove Fuel Pump Module (Ech Efi)107

Remove Electronic Control Unit (Ecu)107

Remove Electronic Control Unit Bracket And Electric Starter Motor107

Throttle Body Components107

Remove Debris Screen Guard108

Remove Debris Screen108

Remove Outer Bafﬂes And Blower Housing108

Remove Oil Sentry108

Remove Inner Bafﬂes And Breather Cover109

Intake Manifold Components (Ech Efi)109

Remove Crankshaft Position Sensor109

Remove Manifold Absolute Pressure (Map) Sensor Or Temperature/Manifold Absolute Pressure (Tmap) Sensor (Ech Efi)109

Cylinder Head Components110

Remove Valve Covers (Ech Efi)110

Remove Cylinder Heads And Hydraulic Lifters110

Disassemble Cylinder Heads111

Valve Details112

Valve Guides112

Valve Seat Inserts113

Lapping Valves113

Flywheel Components113

Remove Fan And Flywheel113

Remove Stator And Backing Plate (Ech Efi)114

Remove Closure Plate Assembly114

Governor Shaft Press Depth Details114

Oil Pump Assembly115

Crankcase Components116

Remove Camshaft116

Remove Governor Cross Shaft116

Governor Cross Shaft Oil Seal117

Remove Connecting Rods With Pistons And Rings117

Piston And Rings Components And Details117

Install New Piston Rings118

Piston Ring Orientation118

Connecting Rods119

Crankshaft Components And Details119

Crankcase Inspection And Service120

Honing Detail120

Clean Cylinder Bore After Honing120

Measuring Piston-To-Bore Clearance121

Piston Detail121

Install Flywheel End Oil Seal123

Oil Seal Detail123

Install Crankshaft123

Install Connecting Rods With Pistons And Rings123

Governor Gear Assembly124

Thrust Bearing, Washer And Shim124

Install Closure Plate Oil Seal124

Oil Seal Details124

Install Closure Plate Assembly125

Closure Plate Fastener Torque Sequence125

Install Stator And Backing Plate125

Install Flywheel126

Install Hydraulic Lifters127

Valve Stem Seals128

Assemble Cylinder Heads128

Install Cylinder Heads128

Install Push Rods And Rocker Arms128

Install Intake Manifold129

Install Fuel Injectors129

Install Oil Temperature Sensor (Ech Efi)131

Install Oil Sentry131

Install Blower Housing And Outer Bafﬂes132

Install Rectiﬁer-Regulator132

Install Metal Debris Screen132

Install Plastic Debris Screen133

Install Electric Starter Motor And Ecu Bracket (Ech Efi)133

Install Electronic Control Unit (Ecu)133

Install Lift Fuel Pump And Fuel Pump Module134

Install External Governor Control (Ech Efi)135

Install Throttle Control Panel137

Install Air Cleaner Assembly137

Setting Initial Governor Adjustment137

Install Mufﬂer137

Sensitivity Adjustment138

Testing Engine138

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