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Kohler Command PRO ECH630 Service Manual
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Kohler Command PRO ECH630 Service Manual

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Download this manual See also: Service Manual, Owner's Manual
ECH630-ECH749, CH735, CH26, CH745
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-ECH
48
Electronic Fuel Injection (EFI) System-Bosch
81
Lubrication System
83
Electrical System
88
Starter System
92
Disassembly/Inspection and Service
107
Reassembly
24 690 01 Rev. D
KohlerEngines.com
1

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Summary of Contents for Kohler Command PRO ECH630

  • Page 1 ECH630-ECH749, CH735, CH26, CH745 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 01 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. 424.29 135.00 Inch equivalents shown in [ ]. 130.00 (16.704) 304.72 (5.315) (5.118) (11.997) 277.30 Air Filter Rain 88.20 Air Filter Cover (10.917) Cap Removal (3.473) Assembly Removal 230.20 (9.063) Safety Air Filter Element Removal 342.52...
  • Page 6 Specifications Engine Dimensions with Low-Profile Air Cleaner Dimensions in millimeters. 426.44 (16.789) Inch equivalents shown in [ ]. 302.63 (11.915) 60.00 12.15 17.07 (2.362) (0.478) (0.672) AIR CLEANER SPARK PLUG COVER REMOVAL 17.53 (0.690) SPARK PLUG 32.00 (1.260) 50.00 (1.969) EXHAUST PORT #2 SPARK PLUG 12.00 (0.472)
  • 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 ECH630-ECH680 ECH730-ECH749 CH26 CH735 CH745 Crankcase Breather Cover Fastener 11.3 N·m (100 in. lb.) into new holes 7.3 N·m (65 in. lb.) 7.3 N·m (65 in. lb.) into used holes Oil Temperature Sensor (into breather 7.3 N·m (65 in. lb.) cover) Oil Sentry (into breather cover)
  • Page 9 Specifications TORQUE SPECIFICATIONS ECH630-ECH680 ECH730-ECH749 CH26 CH735 CH745 Intake Manifold Fastener (torque in 2 increments) first to 7.8 N·m (69 in. lb.) first to 7.4 N·m (66 in. lb.) finally to 10.5 N·m (93 in. lb.) finally to 9.9 N·m (88 in. lb.) Manifold Absolute Pressure (MAP) 7.3 N·m (65 in.
  • Page 10 Specifications TORQUE SPECIFICATIONS ECH630-ECH680 ECH730-ECH749 CH26 CH735 CH745 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 Spacers 9.9 N·m (88 in. lb.) Yellow or Brown O-Ring Style Cover w/Integral Metal Spacers 6.2 N·m (55 in.
  • Page 11 Specifications CLEARANCE ECH630-ECH680 ECH730-ECH749 CH26 CH735 CH745 SPECIFICATIONS Crankshaft End Play (free) 0.070/0.590 mm (0.0028/0.0230 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 closure plate) 40.974/41.000 mm (1.6131/1.6141 in.) 40.987/40.974 mm (1.6136/1.6131 in.)
  • Page 12 Specifications CLEARANCE ECH630-ECH680 ECH730-ECH749 CH26 CH735 CH745 SPECIFICATIONS Governor Governor Cross Shaft -to- Crankcase Running Clearance 0.025/0.126 mm (0.0009/0.0049 in.) 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 ECH630-ECH680 ECH730-ECH749 CH26 CH735 CH745 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 This system requires a minimum Low permeation fuel line must be installed on all Kohler engine oil temperature greater than 80°C (176°F) to Co. engines to maintain EPA and CARB regulatory properly adapt.
  • Page 24 EFI SYSTEM-ECH 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-ECH 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-ECH 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, even in small quantities, can cause significant problems.
  • Page 27 EFI SYSTEM-ECH 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-ECH 24 690 01 Rev. D KohlerEngines.com...
  • Page 30 EFI SYSTEM-ECH KohlerEngines.com 24 690 01 Rev. D...
  • Page 31 EFI SYSTEM-ECH b. Hold throttle closed and check resistance. It Electrical System should be 1400-1800 Ω. Crankshaft Position Sensor Electrical System 4. Leave leads connected to pin terminals as described A sealed, non-serviceable assembly. If Fault Code in step 3. Rotate throttle shaft slowly to full throttle diagnosis indicates a problem within this area, test and position.
  • Page 32 EFI SYSTEM-ECH 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-ECH Sensor Signal Observation Removal Inspection NOTE: Do not cut into or pierce sensor or engine NOTE: Apply anti-seize compound only to threads. wiring to make this connection. Sensor Anti-seize compound will affect sensor produces a very small signal. Corrosion or performance if it gets into lower shield of damage to wiring could lead to an incorrect sensor.
  • Page 34 EFI SYSTEM-ECH 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-ECH 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-ECH 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-ECH 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-ECH 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-ECH Code 0108 Code 0118 Component: Manifold Absolute Pressure Sensor Component: Coolant/Oil Sensor Fault: MAP Circuit High Voltage Fault: Coolant/Oil Temperature Sensor Circuit High Voltage or Open Condition: Intake manifold leak, shorted connection or faulty sensor. Condition: Shorted connection, faulty sensor, open connection or broken wire.
  • Page 42 EFI SYSTEM-ECH 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-ECH 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-ECH 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-ECH 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-ECH 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 80°C (176°F) to properly adapt. These adaptive values are maintained as Low permeation fuel line must be installed on all Kohler long as ECU is not reset. Co. engines to maintain EPA and CARB regulatory compliance.
  • Page 50 EFI SYSTEM-BOSCH ECU requires a minimum of 7.0 volts to operate. Tip of sensor, protruding into exhaust gas, is hollow. Adaptive memory in ECU is operational whenever Outer portion of tip is surrounded by exhaust gas, with required voltage is present, however adapted values inner portion exposed to 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 2. For plastic-cased ECU’s below 24 584 28-S, system 3. Make sure engine has resistor type spark plugs. can be primed by manually cycling fuel pump. 4. Disconnect main harness connector from ECU. a. Turn key switch to “ON/RUN” position. Fuel pump 5.
  • 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 7. Locate service connector plug in wiring harness. 6. Run engine at full throttle (above 3000 RPM), to warm up engine and initiate O sensor function in “35 Pin” (MA 1.7) Metal-Cased ECU: Connect a “closed-loop” operation. jumper wire from TPS initialization pin #8 (gray wire) to ground pin (black wire), or use jumper 7.
  • Page 55 EFI SYSTEM-BOSCH 5. Unplug sensor connector and check sensor b. If voltage is not in specified range, reconnect resistance separately. Resistance value should oxygen sensor lead. With lead connected, probe again be 2375-2625 Ω. or connect sensor connection with red VOA meter lead.
  • Page 56 EFI SYSTEM-BOSCH 5. With oxygen sensor disconnected and engine not a. Clean connection and check wiring if circuit was running, disconnect main harness connector from not completed. ECU and set meter to Rx1 scale. Check circuit 3. Set meter for DC voltage. Touch red tester lead to continuity as follows.
  • Page 57 EFI SYSTEM-BOSCH 2. Make sure all safety switch requirements are met. Fuel Injector Details Crank engine and check for flashing of test light. Repeat test at other connector. a. If flashing occurs, use an ohmmeter (Rx1 scale) and check resistance of each injector across two terminals.
  • Page 58 EFI SYSTEM-BOSCH 16. Reverse appropriate procedures to install new Injector Inspection Points injector(s) and reassemble engine. Use new O-Rings any time an injector is removed (new replacement injectors include new O-Rings). Lubricate O-Rings lightly with oil. Torque fuel rail and blower housing mounting screws to 3.9 N·m (35 in.
  • Page 59 EFI SYSTEM-BOSCH 3. Disconnect secondary lead from spark plug. a. If there was no continuity between pump Connect an ohmmeter set on Rx10K scale terminals, replace fuel pump. between spark plug boot terminal and red b. If voltage was below 7, test wiring harness and primary terminal.
  • Page 60 EFI SYSTEM-BOSCH Internal (In-Tank) Regulator- Idle Speed Screw Dampening Spring Remove screws securing retaining ring and Idle Speed Screw Details regulator in base/holder assembly. Grasp and pull regulator out of base/holder. 5. Always use new O-Rings and hose clamps when installing a regulator.
  • Page 61 EFI SYSTEM-BOSCH If governor/throttle components are all intact, but you think there may be a problem with adjustment, follow Procedure A to check setting. If governor lever was loosened or removed, go immediately to Procedure B to perform initial adjustment. A.
  • Page 62 EFI SYSTEM-BOSCH Faulty spark plugs. Fuel pump not running. Fuel pressure low. Insufficient fuel delivery. Engine starts hard or fails to start TPS offset incorrect (Initialization). when hot Speed sensor loose or faulty. TPS faulty. Engine temperature sensor faulty. Faulty injectors. Faulty spark plugs.
  • Page 63 EFI SYSTEM-BOSCH “35 Pin” (MA 1.7) Metal-Cased ECU Systems Pin # Component Ignition Coil #1 Not used Engine Speed Sensor ECU Production Test Terminal Not Used Not Used Not Used TPS Initialization Terminal Engine Ground O2 Sensor Not Used Throttle Position Sensor Not Used Oil Temperature Sensor Not Used...
  • Page 64 EFI SYSTEM-BOSCH KohlerEngines.com 24 690 01 Rev. D...
  • Page 65 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 66 EFI SYSTEM-BOSCH KohlerEngines.com 24 690 01 Rev. D...
  • Page 67 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 68 EFI SYSTEM-BOSCH KohlerEngines.com 24 690 01 Rev. D...
  • Page 69 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 70 EFI SYSTEM-BOSCH Example of Diagnostic Display 1. Diagnostic display initiated through ignition key sequencing. Long Pause Short Pauses Code 32 Long Pause Code 61 Long Pause Light remains on at end of transmission After the problem has been corrected, fault codes may be cleared as follows. 1.
  • Page 71 EFI SYSTEM-BOSCH "32 Pin" OBD2 "35 Pin" "24 Pin" (MSE P-Code Ap- (MA 1.7) (MSE 1.0) Blink 1.1) plicable to: Connection or Failure Description Metal- Plastic- Note Code Plastic- "32 Pin" (MSE Cased Cased Cased 1.1) ECU/Sys- ECU/ ECU/Sys- ECU/ tem Only System System...
  • Page 72 EFI SYSTEM-BOSCH "32 Pin" OBD2 "35 Pin" "24 Pin" (MSE P-Code Ap- (MA 1.7) (MSE 1.0) Blink 1.1) plicable to: Connection or Failure Description Metal- Plastic- Code Plastic- Note "32 Pin" (MSE Cased Cased Cased 1.1) ECU/Sys- ECU/ ECU/Sys- ECU/ tem Only System System...
  • Page 73 EFI SYSTEM-BOSCH Code 22 Code 23 Component: Throttle Position Sensor (TPS) Component: ECU Fault: Unrecognizable signal is being sent from Fault: ECU is unable to recognize or process sensor (too high, too low, inconsistent). signals from its memory. Condition: A “limp-home” operating mode occurs, Condition: Engine will not run.
  • Page 74 EFI SYSTEM-BOSCH Code 31 Code 32 Component: Fuel Mixture or Oxygen Sensor Component: Oxygen Sensor Fault: System too lean. Oxygen sensor not Fault: No change in sensor output signal. sending expected voltage to ECU. Condition: Open loop operation only, may cause Condition: System operates under “open loop”...
  • Page 75 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 76 EFI SYSTEM-BOSCH Code 42 Code 43 and 44 "32 Pin" (MSE 1.1) Plastic-Cased ECU only. Component: Engine (Oil) Temperature Sensor Component: TPS “Auto-Learn” initialization function Fault: Not sending proper signal to ECU. failed, throttle angle out of learning range. Condition: Engine may be hard to start because Fault: While performing tTPS “Auto-Learn”...
  • Page 77 EFI SYSTEM-BOSCH Code 51 "32 Pin" (MSE 1.1) Plastic-Cased ECU only. Code52 "32 Pin" (MSE 1.1) Plastic-Cased ECU only. Component: Injector #1 circuit open, shorted to Component: Injector #2 circuit open, shorted to ground, or shorted to battery. ground, or shorted to battery. Fault: Injector #1 is not functioning because Fault:...
  • Page 78 EFI SYSTEM-BOSCH Code 56 "32 Pin" (MSE 1.1) Plastic-Cased ECU only. “32 Pin” (MSE 1.1) Plastic-Cased ECU: Pin circuits 29 and 84. Component: Fuel pump relay circuit open, shorted to ground, or shorted to battery. ● Ignition switch Fault: Fuel pump, ignition coils, and fuel ●...
  • Page 79 EFI SYSTEM-BOSCH ● Code 51-Injector 1, "32 Pin" (MSE 1.1) Plastic- “32 Pin” (MSE 1.1) Plastic-Cased ECU: Circuits Cased ECU only. 28,85, 30, and 87. ● Code 52-Injector 2, "32 Pin" (MSE 1.1) Plastic- ● Relay Cased ECU only. ● ECU grounds ●...
  • Page 80 EFI SYSTEM-BOSCH KohlerEngines.com 24 690 01 Rev. D...

  • Page 81: 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 82 Lubrication System CHANGE OIL AND FILTER Installation Change oil while engine is warm. 1. Apply pipe sealant with Teflon (Loctite 592™ ® ® ® 1. Clean area around oil fill cap/dipstick and drain plug. Thread Sealant or equivalent) to threads of switch. Remove drain plug and oil fill cap/dipstick.

  • Page 83: 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 84 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 85 Electrical System BATTERY CHARGING SYSTEM NOTE: Observe following guidelines to avoid damage to electrical system and components: ● Make sure battery polarity is correct. A negative (-) ground system is used. ● Disconnect rectifier-regulator plug and/or wiring harness plug before doing any electric welding on equipment powered by engine.
  • Page 86 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 87 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 88 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 89 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 90 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 91 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 92 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 93 Disassembly/Inspection and Service Clean all parts thoroughly as engine is disassembled. Remove Throttle Control Panel Only clean parts can be accurately inspected 1. Disconnect throttle control cable. and gauged for wear or damage. There are many commercially available cleaners that will quickly remove 2.
  • Page 94 Disassembly/Inspection and Service External Governor Control (ECH 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 attaching governor lever to throttle actuator lever. 2.
  • Page 95 Disassembly/Inspection and Service WARNING Gasoline is extremely flammable and its vapors can explode if ignited. Store gasoline only in approved Explosive Fuel can cause fires and severe containers, in well ventilated, unoccupied buildings, burns. away from sparks or flames. Spilled fuel could ignite if it comes in contact with hot parts or sparks from Do not fill fuel tank while engine is hot or ignition.
  • Page 96 Disassembly/Inspection and Service 5. Press release button(s) and slowly pull connector 1. Remove socket head cap screws securing metal away from fuel pump module, allowing shop towel to grass screen and remove screen. absorb any residual fuel in high pressure fuel line. 2.
  • Page 97 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 Valve Covers (ECH EFI) Remove Manifold Absolute Pressure (MAP) Sensor...
  • Page 98 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 To prevent a possible bent push rod or broken rocker arm, it is important to bleed any excess oil out of lifters before they are installed.
  • Page 99 Disassembly/Inspection and Service Inspection and Service Valve Details 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.) 4 mm (0.1575 in.) Guide I.D. 7.038/7.058 mm (0.2771/0.2779 in.) 7.038/7.058 mm (0.2771/0.2779 in.) Valve Head Diameter 33.37/33.63 mm (1.3138/1.3240 in.)
  • Page 100 Disassembly/Inspection and Service If guides are within limits but valve stems are worn beyond limits, install new valves. Valve Seat Inserts Hardened steel alloy intake and exhaust valve seat inserts are press fitted into cylinder head. Inserts are not replaceable but can be reconditioned if not too badly pitted or distorted. If cracked or badly warped, cylinder head should be replaced.
  • Page 101 They should move freely in governor gear. or keyway is damaged. Disassembly Inspect ring gear for cracks or damage. Kohler does not NOTE: Governor gear is held onto shaft by small provide ring gear as a serviceable part. Replace flywheel molded tabs in gear.
  • Page 102 Disassembly/Inspection and Service Reassembly 1. Install oil pickup to oil pump body. Lubricate O-ring with oil and make sure it remains in groove as pickup is being installed. 2. Install rotor. 3. Install oil pump body to closure plate and secure with screws. Torque screws as follows: a.
  • Page 103 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 Check lobes of camshaft for wear or damage. See Piston and Rings Components and Details Specifications for minimum lift tolerances.
  • Page 104 Disassembly/Inspection and Service Ring failure is usually indicated by excessive oil Install New Piston Rings consumption and blue exhaust smoke. When rings fail, NOTE: Rings must be installed correctly. Ring oil is allowed to enter combustion chamber where it is installation instructions are usually included with burned along with fuel.
  • Page 105 Use these following procedures to remove and replace 23°-33° Crosshatch plug. NOTE: Kohler pistons are custom-machined to exacting Procedure to Remove Crankshaft Plug: tolerances. When oversizing a cylinder, it should 1. Drill a 3/16 in. hole through plug in crankshaft.
  • Page 106 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 107 Reassembly Crankcase Components Closure Plate Seal Closure Plate Gerotor Gears Oil Pump Assembly Governor Shaft Governor Washer Governor Gear Governor Cup Camshaft Connecting Rod Crankshaft Piston Piston Pin Retainer Governor Cross Piston Pin Crankcase Clip Shaft Piston Rings NOTE: Make sure engine is assembled using all specified torque values, tightening sequences and clearances. Failure to observe specifications could cause severe engine wear or damage.
  • Page 108 Reassembly NOTE: Proper orientation of piston/connecting rod Install Flywheel End Oil Seal assemblies inside engine is extremely important. Oil Seal Detail Improper orientation can cause extensive wear or damage. Be certain pistons and connecting rods are assembled exactly as shown. NOTE: Align chamfer of connecting rod with chamfer of its mating end cap.
  • Page 109 Reassembly Clearance Specifications-Crankshaft End Play Shims Governor Gear Assembly Green 0.8366-0.9127 mm Governor gear assembly is located inside closure plate. (0.8750 mm/0.034 in. Nominal) If service was required, and governor was removed, Yellow 1.0652-1.1414 mm refer to assembly procedures under Governor Gear (1.1033 mm/0.043 in.
  • Page 110 Reassembly Closure Plate Fastener Torque Sequence Install Closure Plate Assembly RTV Must Be All Around O-ring Groove. RTV sealant is used as a gasket between closure plate and crankcase. Refer to Tools and Aids for a listing of approved sealants. Always use fresh sealant. Using Install Stator and Backing Plate outdated sealant can result in leakage.
  • Page 111 Reassembly NOTE: Make sure flywheel key is installed properly in Install Flywheel keyway. Flywheel can become cracked or damaged if key is not properly installed. CAUTION 1. Install woodruff key into keyway of crankshaft. Make sure key is properly seated and parallel with shaft Damaging Crankshaft and Flywheel Can taper.
  • Page 112 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 Assemble Cylinder Heads Valve Stem Seals Prior to installation, lubricate all components with engine...
  • Page 113 Reassembly • Intake and exhaust valves. 6. Lightly lubricate exposed (upper) threads of studs • Valve spring retainers. with engine oil. Install a flat washer and hex nut onto • Valve springs. each mounting stud. Torque hex nuts in 2 stages; •...
  • Page 114 Reassembly Install Intake Manifold Install Crankshaft Position Sensor NOTE: Ensure all parts are clean, undamaged and free Torque Sequence of debris and make sure electrical connectors have seal in place. 1. Install crankshaft position sensor and bracket assembly to crankcase posts. 2.
  • Page 115 Reassembly External Engine Components Debris Screen Blower Housing Outer Baffle Breather Cover Oil Temperature Oil Sentry™ Inner Baffle Sensor 24 690 01 Rev. D KohlerEngines.com...
  • Page 116 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 2 M6 screws (16 mm long) into exhaust port side of cylinder head.
  • Page 117 Reassembly 7. Carefully remove 2 studs and replace with 2 screws. Install Metal Debris Screen Torque screws to 9.9 N·m (88 in. lb.). Repeat Spring Washer Details procedure for other 2 studs and screws. Install Plastic Debris Screen Place plastic grass screen on fan and secure with hex screws.
  • Page 118 Reassembly NOTE: Ensure all parts are clean, undamaged and free of debris and make sure electrical connector has seal in place. 1. Install a new throttle body O-ring prior to installation. Make sure all holes align and are open. 2. Install throttle body, throttle position sensor, intake air temperature sensor, throttle linkage, spring and bushing, as an assembly.
  • Page 119 Reassembly NOTE: Some applications may have 2 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 120 Reassembly 1. Secure throttle control panel to crankcase with 1. Prefill a new oil filter following instructions. thread forming screws. 2. Place new filter in shallow pan with open end up. Fill 2. Attach governor spring to previously marked hole on with new oil until oil reaches bottom of threads.
  • Page 121 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 122 Reassembly KohlerEngines.com 24 690 01 Rev. D...
  • Page 123 Reassembly 24 690 01 Rev. D KohlerEngines.com...
  • Page 124 © 2011 by Kohler Co. All rights reserved. KohlerEngines.com 24 690 01 Rev. D...

This manual is also suitable for:

Command pro ech680Command pro ech730Command pro ch735Command pro ch745Command pro ch26Command pro ech749