Kohler Command PRO ECV630 Service Manual
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Kohler Command PRO ECV630 Service Manual

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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
Specifi cations
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
Governor System
86
Lubrication System
88
Electrical System
93
Starter System
97
Disassembly/Inspection and Service
114
Reassembly
24 690 02 Rev. H
KohlerEngines.com
1

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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 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

    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 fi nd a local Kohler authorized dealer visit KohlerEngines.com or call 1-800-544-2444 (U.S. and Canada). 24 690 02 Rev. H...

  • Page 4: Oil Recommendations

    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

    Specifi cations Engine Dimensions with Heavy-Duty Air Cleaner Dimensions in millimeters. Inch equivalents shown in [ ]. 24 690 02 Rev. H KohlerEngines.com...
  • Page 6 Specifi cations Engine Dimensions with Low-Profi le Air Cleaner Dimensions in millimeters. Inch equivalents shown in [ ]. KohlerEngines.com 24 690 02 Rev. H...

  • Page 7: Engine Identification Numbers

    Lubricate threads with engine oil prior to assembly. Any and all horsepower (hp) references by Kohler are Certifi ed Power Ratings and per SAE J1940 & J1995 hp standards. Details on Certifi ed Power Ratings can be found at KohlerEngines.com.
  • Page 8 Specifi cations TORQUE SPECIFICATIONS ECV630-ECV680 ECV730-ECV749 CV26 CV735 CV745 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 7.3 N·m (65 in. lb.) Oil Drain Plug 13.6 N·m (10 ft.
  • Page 9 Specifi cations TORQUE SPECIFICATIONS ECV630-ECV680 ECV730-ECV749 CV26 CV735 CV745 Intake Manifold Mounting Fastener (torque in 2 fi rst to 7.8 N·m (69 in. lb.) fi rst to 7.4 N·m (66 in. lb.) increments) fi nally to 10.5 N·m (93 in. lb.) fi...

  • Page 10: Clearance Specifications

    Specifi cations 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 Specifi cations 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 Specifi cations 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 Specifi cations CLEARANCE ECV630-ECV680 ECV730-ECV749 CV26 CV735 CV745 SPECIFICATIONS 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 Intake Valve Stem-to-Valve 0.040/0.078 mm (0.0016/0.0031 in.) 0.038/0.076 mm (0.0015/0.0030 in.) Guide Running Clearance Exhaust Valve Stem-to-Valve 0.052/0.090 mm (0.0020/0.0035 in.) 0.050/0.088 mm (0.0020/0.0035 in.)

  • Page 14: 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 15: Tools And Aids

    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 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 18: 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 engine troubles are listed below and vary by engine specifi cation. 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: 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. Engine exhaust gases contain poisonous carbon Keep hands, feet, hair, and clothing away from all monoxide.

  • Page 21: Compression Test

    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/Intake AIR CLEANER NOTE: Operating engine with loose or damaged air cleaner components could cause premature These systems are CARB/EPA certifi ed and components wear and failure. Replace all bent or damaged should not be altered or modifi ed in any way. components.

  • Page 23: Fuel Recommendations

    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 fl...
  • 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 specifi...

  • Page 26: Important Notes

    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 signifi...

  • Page 27: Electrical Components

    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 GCU Tach Output (Electronic Governor) Speed Sensor input...
  • Page 28 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 29 EFI SYSTEM-ECV 24 690 02 Rev. H KohlerEngines.com...
  • Page 30 EFI SYSTEM-ECV KohlerEngines.com 24 690 02 Rev. H...
  • 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 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-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 vibration. WARNING Explosive Fuel can cause fi res and severe If an injector is not operating, it can indicate either a bad burns.

  • Page 36: Fuel Components

    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: 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 38 EFI SYSTEM-ECV 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 39 EFI SYSTEM-ECV 4. Make sure battery is supplying proper voltage. Function Test 5. Check that fuses are good, and that no electrical or fuel line connections are damaged WARNING or broken. High Pressure Fluids can puncture skin and cause severe injury or death. 6.
  • Page 40 EFI SYSTEM-ECV Fault Code Connection or Failure Description 0352 Cylinder 2 Ignition Coil Malfunction 0562 System Voltage Low 0563 System Voltage High 1693 Tach Output (ECU) Low 1694 Tach Output (ECU) High End of Code Transmission ECU continuously monitors engine operation against Diagnostic Code Summary preset performance limits.
  • 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 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-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/fi lter 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/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 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 ● Poor connection to spark plug. NOTE: MIL is installed by vehicle OEM. Twelve volt supply to bulb will be part of vehicle wire Code 0562 harness. Kohler key switch model will have MIL Component: System Voltage on engine with 12V supply to bulb. Fault:...
  • Page 46 EFI SYSTEM-ECV Diagnostic Aid #3 RUN/ON Diagnostic Aid #8 FUEL SYSTEM (MIL remains ON while engine is running)* (fuel pressure) Condition Low Fuel Pressure-Condition NOTE: Either incandescent or LED type bulbs can be ● Low fuel used for MIL as long as they do not draw more ●...
  • 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 fl ammable and its vapors can WARNING explode if ignited. Store gasoline only in approved Explosive Fuel can cause fi res and severe containers, in well ventilated, unoccupied buildings, away burns. from sparks or fl ames. 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 specifi...
  • 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 6. Check temperature sensor circuits (input, ground) 2. Move black voltmeter lead to engine ground location from main harness connector to corresponding and repeat output test. Same voltage (0.2 v-1.0 v) terminal in sensor plug for continuity, damage, etc. should be indicated.
  • Page 56 EFI SYSTEM-BOSCH 6. With key switch in ON/RUN position, using a high 6. Attach ohmmeter leads to #30 and #87 terminals in impedance voltmeter, check voltage from wiring relay. First, there should be no continuity. Using a 12 harness oxygen sensor connector to engine ground volt power supply, connect positive (+) lead to #85 location.
  • 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 specifi ed 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 specifi...

  • Page 61: Troubleshooting

    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 fi lter. Insuffi cient fuel delivery. Improper governor adjustment. Low Power Plugged/restricted exhaust. One injector not working. Basic engine problem exists. TPS faulty or mounting exist. 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. H...
  • 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. H...
  • 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 OBD2 "24 Pin" "32 Pin" P-Code Applicable (MSE 1.0) (MSE 1.1) Blink Connection or Failure to: "32 Pin" (MSE Plastic- Plastic- Note Code Description 1.1) ECU/System Cased ECU/ Cased ECU/ Only System System Temperature Sensor Circuit: Open P0118 Circuit or Short to Battery Failure Completing Autolearn - TPS Offset below minimum allowable...
  • 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 misfi...
  • 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 effi...
  • 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. Code 56 "32 Pin" (MSE 1.1) Plastic-Cased ECU only. Component: Injector #2 circuit open, shorted to Component: Fuel pump relay circuit open, shorted to ground, or shorted to battery. ground, or shorted to battery.
  • Page 75 EFI SYSTEM-BOSCH Flow Chart Diagnostic Aids Diagnostic Aid #3 RUN/ON (MIL remains “on” while Diagnostic Aid #1 "system power" (MIL does not engine is running)* illuminate when key is turned ON) Possible causes: NOTE: MIL in Metal-Cased ECU systems is an LED. ●...
  • Page 76 EFI SYSTEM-BOSCH Diagnostic Aid #6 “RELAY” (relay not operating) Possible causes: ● Safety switches/circuit(s) problem “24 Pin” (MSE 1.0) Plastic-Cased ECU: Circuit 3. “32 Pin” (MSE 1.1) Plastic-Cased ECU: Circuit 25. ● Relay circuit(s) problem “24 Pin” (MSE 1.0) Plastic-Cased ECU: Circuits 18, 85, 30, and 87.
  • Page 77 EFI SYSTEM-BOSCH 24 690 02 Rev. H KohlerEngines.com...

  • Page 78: Governor System

    Governor System GOVERNOR Some engines are equipped with an electronic governor. ELECTRONIC GOVERNOR (ECV EFI) Components Governor Control Digital Linear DLA Throttle Plate Wiring Harness Unit (GCU) Actuator (DLA) Mounting Screws Throttle Body Throttle Body Lever Connector Linkage Spring Assembly Adapter Plastic Linkage Throttle Linkage...
  • Page 79 Governor System 4. Place clevis shaft into actuator. Rotate clevis shaft Linkage clockwise 3 full turns, applying slight pressure, until NOTE: Throttle linkage spring must be in place and you feel clevis shaft keyway make contact with key installed correctly to ensure proper throttle in actuator.
  • Page 80 Governor System Test 2 Probe Location Test 2 Probe Location Probe Locations for OHMs Test 2. Probe Location for Voltage Test 2. Test 2: Identify probe locations in connector. Using a Test 2: Identify probe location in connector. Using a digital multi-meter set to lowest scale (0-200 ohms), 12 volt meter test for voltage.
  • Page 81 Governor System 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 GCU Blink Codes for Software Stored Codes - Activated when key is turned to ON position.
  • Page 82 Governor System 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 Mechanical bindage None...
  • Page 83 Governor System 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. See illustrations on page 78. Confi...
  • Page 84 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 85 Governor System Electronic Governor Troubleshooting Flow Chart Continued Turn key switch to ON position. Test supply voltage to GCU using volt meter. Refer to page 80 (battery voltage +/- 1 volt) Note: Prevent Damage to Connector. Do Not Use Oversized Probe Tips. Proceed to DLA Circuit Test.

  • Page 86: 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 87 Lubrication System 7. Reinstall oil fi ll 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 88: 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 89 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 suffi cient if an application is started only in warmer temperatures. Refer to following table for minimum capacities based on anticipated ambient temperatures.

  • Page 90: Battery Charging System

    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 rectifi er-regulator plug and/or wiring harness plug before doing any electric welding on equipment powered by engine.
  • Page 91 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 92 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 93: 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 engine develops suffi cient 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 94 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 95 Mounting screw 4 brushes and springs are serviced as a set. Use a new Kohler brush and spring kit if replacement is necessary. holes in metal clips must be up/out. Slide brush holder assembly down into place around 1.
  • Page 96 Starter System b. Position brushes back in their slots so they are fl ush 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 97: 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 98 Disassembly/Inspection and Service Clean all parts thoroughly as engine is disassembled. Remove Air Cleaner Assembly Only clean parts can be accurately inspected Heavy-Duty Air Cleaner and gauged for wear or damage. There are many 1. Remove nuts securing air cleaner to mounting studs. commercially available cleaners that will quickly remove grease, oil, and grime from engine parts.
  • Page 99 Disassembly/Inspection and Service External Governor Control (ECV EFI) Speed Control Throttle Actuator Cable Clamp Screw Bracket Lever (bottom) Throttle Control Spring Washer Flat Washer Lever (top) Return Spring Remove External Governor Controls (Mechanical Governor) 1. Disconnect governor spring attached to governor lever. Note hole location for reassembly. 2.
  • Page 100 Disassembly/Inspection and Service WARNING Gasoline is extremely fl ammable and its vapors can explode if ignited. Store gasoline only in approved Explosive Fuel can cause fi res and severe containers, in well ventilated, unoccupied buildings, away burns. from sparks or fl ames. Spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition.
  • Page 101 Disassembly/Inspection and Service 6. Using a side cutter or similar tool, cut Oetiker clamp Starter and ECU Components (ECV EFI) to remove inlet fuel line. A new Oetiker clamp will need to be used for reassembly. 7. Remove screws securing fuel pump module baffl e which pump was mounted to.
  • Page 102 Disassembly/Inspection and Service External Engine Components Debris Screen Guard Debris Screen Outer Baffl e Rectifi er-Regulator Oil Temperature Inner Baffl e Oil Sentry™ Breather Cover Sensor Breather Cover Oil Separator Gasket Remove Oil Separator and Hardware Remove Debris Screen Remove screws securing oil separator assembly, pulling NOTE: Fan will be loose, but cannot be removed until assembly out and away from valve cover.
  • Page 103 Disassembly/Inspection and Service 3. If there is a plastic debris screen attached to fan, Intake Manifold Components (ECV EFI) remove screws securing debris screen. Removing screen will expose screws fastening fan to fl ywheel. Remove Outer Baffl es and Blower Housing NOTE: Some engines may have 2 fuses mounted to a bracket above ECU, and a third in-line fuse by rectifi...
  • Page 104 Disassembly/Inspection and Service Remove Fuel Injectors Remove Intake Manifold 1. Disconnect electrical connector. 1. Remove screw securing a ring terminal which is part of wiring harness. 2. Remove screw and pull injector out of intake manifold for each injector. 2. Remove screws securing intake manifold to cylinder heads.
  • Page 105 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 106: Exhaust Valve

    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 107 Disassembly/Inspection and Service Valve Guides Flywheel Components If a valve guide is worn beyond specifi cations, 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 108 fl ywheel, crankshaft, and key if fl ywheel 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 fl ywheel if ring gear is damaged.
  • Page 109 Disassembly/Inspection and Service 2. Remove locking tab thrust washer located under Outer Gerotor Gear Oil Pump Cover governor gear assembly. (Style B) O-ring (Style B) 3. Carefully inspect governor gear shaft and replace it Spring (Style B) Ball (Style B) only if it is damaged.
  • Page 110 Disassembly/Inspection and Service 4. After torquing, rotate gear and check for freedom of Governor Cross Shaft Oil Seal (Mechanical movement. Make sure there is no binding. If binding Governor) occurs, loosen screws, reposition pump, retorque Cross Shaft Oil Seal Details screws and recheck movement.
  • Page 111 Disassembly/Inspection and Service Inspection When cylinder temperatures get too high, lacquer and varnish collect on pistons causing rings to stick, which Piston and Rings Components and Details results in rapid wear. A worn ring usually takes on a shiny or bright appearance. Scratches on rings and pistons are caused by abrasive material such as carbon, dirt, or pieces of hard metal.
  • Page 112 Disassembly/Inspection and Service 3. Top Compression Ring (Top Groove): Install top ring NOTE: If crankpin is reground, visually check to ensure using a piston ring expender. Make sure fi llet blends smoothly with crankpin surface. identifi cation mark is up or dye colored stripe (if Inspect gear teeth of crankshaft.
  • Page 113 Piston Detail 23°-33° Crosshatch 6 mm (0.2362 in.) NOTE: Kohler pistons are custom-machined to exacting tolerances. When oversizing a cylinder, it should NOTE: Do not use a feeler gauge to measure piston-to- be machined exactly 0.25 mm (0.010 in.) or 0.50 bore clearance –...
  • Page 114 Reassembly Crankcase Components Outer Gerotor Gear Oil Pump Cover (Style B) O-ring (Style B) Spring (Style B) Ball (Style B) Oil Screen (Style B) Oil Pan (Style B) *Mechanical Governor only. NOTE: Make sure engine is assembled using all specifi ed torque values, tightening sequences, and clearances.
  • Page 115 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 116 Reassembly 6. Install screws securing oil pan to crankcase. Torque Install Oil Pan Assembly fasteners in sequence shown to 25.6 N·m Oil Pan Sealant Pattern (227 in. lb.). One mounting screw has a thread sealant patch. This screw is typically installed in number 10 hole shown.
  • Page 117 Reassembly NOTE: Before installing fl ywheel, make sure crankshaft Install Flywheel taper and fl ywheel hub are clean, dry, and completely free of any lubricants. Presence of lubricants can cause fl ywheel to be over CAUTION stressed and damaged when screw is torqued to Damaging Crankshaft and Flywheel Can specifi...
  • Page 118 Reassembly Cylinder Head Components Valve Cover Valve Cover Gasket Hex Flange Screw Rocker Arm Pivot 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 Spark Plug Valve Stem Seals Assemble Cylinder Heads...
  • Page 119 Reassembly Heads secured with screws: Install Cylinder Heads 2. Install a new cylinder head gasket (part number Torque Sequence facing up). 3. Install cylinder head and start screws. 4. Torque screws in 2 stages; fi rst to 22.6 N·m (200 in. lb.), then fi nally to 41.8 N·m (370 in. lb.), following sequence.
  • Page 120 Reassembly 2. Install ground terminal to crankcase post with a Intake Manifold Components (ECV EFI) silver screw. Torque to 4.0 N·m (35 in. lb.) into used holes or 6.2 N·m (55 in. lb.) in new holes. 3. Install wire harness clip to other crankcase post. Torque to 4.0 N·m (35 in.
  • Page 121 Reassembly Install Valve Covers Torque Sequence 1. Make sure sealing surfaces are clean. 2. Make sure there are no nicks or burrs on sealing surfaces. 3. Install a new O-ring in groove of each cover. 4. Position covers on cylinder heads. Locate cover with oil separator hole on cylinder 1.
  • Page 122 Reassembly External Engine Components Debris Screen Guard Debris Screen Outer Baffl e Rectifi er-Regulator Oil Temperature Inner Baffl e Oil Sentry™ Breather Cover Sensor Breather Cover Oil Separator Gasket KohlerEngines.com 24 690 02 Rev. H...
  • Page 123 Reassembly 2. Position outer baffl es and secure using M6 screws Install Breather Cover and Inner Baffl es 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 124 Reassembly Install Metal Debris Screen Install Plastic Debris Screen Place plastic debris screen on fan and secure with four Spring Washer Details screws. Torque screws to 4.0 N·m (35 in. lb.). Install Oil Separator and Hardware 1. Ensure rubber oil separator grommet is in good condition.
  • Page 125 Reassembly Throttle Body Components (ECV EFI) Install Throttle Body (ECV EFI) NOTE: For engines with electronic governor, do not install screws to air cleaner bracket. NOTE: Ensure all parts are clean, undamaged and free of debris and make sure electrical connector has seal in place.
  • Page 126 Reassembly Gasoline is extremely fl ammable and its vapors can WARNING explode if ignited. Store gasoline only in approved Explosive Fuel can cause fi res and severe containers, in well ventilated, unoccupied buildings, away burns. from sparks or fl ames. Spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition.
  • Page 127 Reassembly NOTE: Some applications may have two in-line fuel 3. Connect in-line 10 micron EFI fuel fi lter and hose to fi lters. In those applications, connect in-line inlet barb of lift fuel pump and secure with spring 51-75 micron mesh fuel fi lter and hose to inlet clamp.
  • Page 128 Reassembly Control Panel Components (Mechanical Governor) Install Throttle Control Panel Assemble Top Mount Control Panel 1. Install lower support control bracket with throttle control shaft. 2. Install top mount control panel over throttle control shaft. Secure control panel to blower housing with screws.
  • Page 129 Reassembly External Engine Components Heavy-Duty Low-Profi le Air Low-Profi le Air Paper Element Air Cleaner Cleaner Cover Cleaner Base Oil Filter Oil Cooler O-ring Oil Fill/Dipstick GCU Wire Oil Fill Tube Oil Drain Plug Harness Connector Linkage & Spring DLA Bracket GCU Bracket GCU Module Top Mount...
  • Page 130 Reassembly 6. Secure DLA to DLA bracket. Torque to 3.2 N·m Install Air Cleaner Assembly (28 in. lb.). NOTE: For engines with an electronic governor, only 7. Move throttle to wide open throttle and adjust DLA install 1 screw to air cleaner bracket on starter bracket up to where linkage is tight, but not forcing side.
  • Page 131 Reassembly Connect Spark Plug Leads Testing Engine Connect leads to spark plugs. It is recommended engine be operated on a stand or bench prior to installation in piece of equipment. Prepare Engine for Operation (ECV EFI) 1. Start engine, inspect for leaks and check to make NOTE: If ECU, throttle body, TPS or fuel pump module certain that oil pressure (20 psi or more) is present.
  • Page 132 © 2014 by Kohler Co. All rights reserved. KohlerEngines.com 24 690 02 Rev. H...

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