Kohler Command PRO EFI Series Manuals

Manuals and User Guides for Kohler Command PRO EFI Series. We have 1 Kohler Command PRO EFI Series manual available for free PDF download: Service Manual

Kohler Command PRO EFI Series Service Manual (129 pages)

Brand: Kohler | Category: Engine | Size: 11 MB

Contents
1
Safety Precautions
2
Maintenance Instructions
3
Maintenance Schedule
3
Repairs/Service Parts
3
Maintenance
4
Oil Recommendations
4
Fuel Recommendations
4
Storage
4
Engine Dimensions - Flywheel Side
5
Specifications
5
Specifications
6
Engine Dimensions - PTO Side (Earlier Design)
6
Engine Dimensions - PTO Side (Later Design)
7
Engine Dimensions - Starter Side
8
Engine Dimensions - Opposite Starter Side
9
Engine Identification Numbers
10
General Specifications
10
Torque Specifications
10
Blower Housing and Sheet Metal
10
Clearance Specifications
13
General Torque Values
16
Tools and Aids
17
Separate Tool Suppliers
17
Aids
19
Flywheel Holding Tool
19
Rocker Arm/Crankshaft Tool
19
Troubleshooting Guide
20
Engine Cranks but will Not Start
20
Engine Starts but Does Not Keep Running
20
Engine Starts Hard
20
External Engine Inspection
21
Cleaning Engine
21
Engine Loses Power
21
Engine Uses Excessive Amount of Oil
21
Crankcase Vacuum Test
22
To Test Crankcase Vacuum with Manometer
22
Compression Test
23
Cylinder Leakdown Test
23
Air Cleaner
24
Breather Tube
24
Air Cooling
24
Air Cleaner/Intake
24
Efi System
25
Fuel Line
25
Fuel Recommendations
25
Operation
25
Crankshaft Position Sensor Bracket
26
Important Notes
28
Electrical Components
29
Electronic Control Unit (ECU)
29
Pinout of ECU
29
ECU Reset Procedure
30
TPS Learn Procedure
30
EFI Wiring Diagram & Terminal Connection
31
Crankshaft Position Sensor
34
Contacting (Brush) Type TPS
34
Resistance Table
34
Throttle Position Sensor (TPS)
34
Contactless (Magnet) Type TPS
35
Replace Magnet Assembly
35
If a Computer with Diagnostic Software Is Available
35
If Only a Volt Meter Is Available
35
Engine (Oil) Temperature Sensor
36
Intake Air Temperature Sensor
36
Manifold Absolute Pressure Sensor (MAP)
36
Temperature/Manifold Absolute Pressure (TMAP) Sensor
36
Oxygen Sensor (O2)
37
Cutaway Oxygen Sensor Components (02)
37
Visual Inspection
38
Sensor Wire Detail
38
Sensor Signal Observation
38
Engine Harness O2 Sensor Connector Plug Detail
38
Removal Inspection
39
Troubleshooting-Oxygen (O2) Sensor
39
Fuel Injectors
40
Details
40
Fuel Components
41
Ignition Coil
41
Fuel Pump Module (FPM)
41
High Pressure Fuel Line
42
Purge Port and Vent Hose Assembly
42
Throttle Body/Intake Manifold Assembly
42
Function Test
44
Fault Codes
44
Example of Diagnostic Display
44
Diagnostic Fault Code Summary
44
Diagnostic Code Summary
45
Code 0031
45
Code 0032
46
Code 0107
46
Code 0108
46
Code 0112
46
Code 0117
47
Code 0118
47
Code 0122
47
Code 0123
47
Code 0131
48
Code 0132
48
Code 0171
48
Code 0172
49
Code 0174
49
Code 0201
49
Code 0202
50
Code 0230
50
Code 0232
50
Code 0336
50
Code 0351
51
Code 0352
51
Code 1693
51
Code 1694
51
EFI Diagnostic Flow Diagram
52
Start of Test
52
Flow Chart Diagnostic Aids
53
Diagnostic Aid #2 FAULT CODES
53
Diagnostic Aid #4 CRANKSHAFT POSITION SENSOR
53
Diagnostic Aid #5 FUEL PUMP
53
Electronic Governor
54
Electronic Governor System Designs
54
Electronic Governor System
54
Throttle Linkage
54
Operation of Electronic Governor System
55
ORIGINAL DESIGN Gcu/Harness Diagnostics and Troubleshooting
58
Test 1 Probe Location (Original Design)
58
ORIGINAL DESIGN Speed Control Input
59
ORIGINAL DESIGN GCU Blink Code Tests
59
ORIGINAL DESIGN Electronic Governor Troubleshooting Flow Chart
62
Field Installed Updated Design
65
FIELD INSTALLED UPDATED DESIGN GCU Blink Code Tests
66
FIELD INSTALLED UPDATED DESIGN Troubleshooting Electronic Governor
68
Basic Electrical Diagram of Electronic Governor System
71
NEW UPDATED DESIGN Gcu/Harness Diagnostics and Troubleshooting
72
NEW UPDATED DESIGN GCU Power Test/Probe Location
72
New Updated Design Speed Control Input
72
NEW UPDATED DESIGN GCU Blink Code Tests
73
NEW INSTALLED UPDATED DESIGN Troubleshooting Electronic Governor
75
NEW UPDATED DESIGN Electronic Governor Troubleshooting Flow Chart
76
Mechanical Governor
79
Governor Adjustments
79
Initial Adjustment Procedure
79
Check Oil Level
80
Change Oil and Filter
80
Change Oil While Engine Is Warm
80
Lubrication System
80
Oil Cooler
81
Oil Sentry
81
Battery Charging System
82
20/25 Amp Regulated Charging System
82
Battery Size Recommendations
82
Battery Maintenance
82
Electrical System
82
Fuses
83
Fuse Replacement
83
To Test Charging System
83
Spark Plug
84
Spark Plug Component and Details
84
Service
84
Wet Fouled
84
Ignition System
84
Carbon Fouled
85
Overheated
85
Test for Spark
86
Troubleshooting-Starting Dificulties
87
Starter System
87
Solenoid Shift Starters
88
Solenoid Shift Starter Components
88
Starter Disassembly
88
Drive Pinion
88
Armature
89
Brush Replacement
89
Starter Reassembly
89
Solenoid Tests
90
To Test Solenoid Pull-In Coil/Plunger
90
To Test Solenoid Hold-In Coil
90
External Engine Components
91
Disassembly/Inspection and Service
91
Disconnect Spark Plug Leads
92
Drain Oil from Crankcase and Remove Oil Filter
92
Remove Muffler
92
Remove Cylinder Shrouds and Blower Housing
92
Remove #2 Barrel and Valley Baffles
93
Flywheel/Backing Shroud/Intake and Throttle Body
93
Air Cleaner Assembly Components
93
Remove Crankshaft Position Sensor
94
Remove Debris Screen (Style A)
94
Remove Debris Screen (Style B)
94
Remove Flywheel/Fan/Hex Stud Assembly
94
Remove Oil Filter Housing
95
Oil Filter Housing Components
95
Cylinder Head Components
96
Remove Spark Plugs
97
Remove Valve Covers
97
Remove Cylinder Heads and Hydraulic Lifters
97
Disassemble Cylinder Heads
97
Valve Details
98
Exhaust Valve
98
Breather/Oil Pan Components
99
Lapping Valves
99
Valve Stem Seals
99
Remove Breather Assembly
100
Remove Oil Pan Assembly
100
Oil Pump Assembly
100
Torque Sequence
100
Crankcase Components
101
Remove Camshaft
102
Remove Connecting Rods with Pistons and Rings
102
Piston and Rings
102
Piston and Rings Components and Details
102
Install New Piston Rings
103
Piston Ring Orientation
103
Crankshaft Components and Details
103
Remove Crankshaft
103
Clearance Specifications-Connecting Rod Journal
104
Remove Governor Gear Assembly
104
Honing
104
Remove Governor Yoke, Cross Shaft, and Seal
104
Measuring Piston-To-Bore Clearance Piston Detail
105
Clean Cylinder Bore after Honing
105
Remove Throttle Body
106
Remove GCU
106
Electronic Governor Intake and Throttle Body Assembly Components
107
Remove Sealed (Bonded) GCU Module Wiring Harness Assembly
108
Remove Throttle Body (NEW UPDATED DESIGN Electronic Governor)
109
Remove New Sealed (Bonded) GCU Module Wiring Harness Assembly
109
Mechanical Governor Intake and Throttle Body Assembly Components
110
Remove Throttle Body (Mechanical Governor)
110
Remove ECU
111
Remove Fuel Injectors
111
Fuel Pump Module/Pump Assembly Components
111
Remove Fuel Pump Module/Fuel Pump Assembly
111
Install Flywheel End Oil Seal
113
Install Lifter Feed Chamber Gasket and Cover
113
Install Governor Shafts, Seal, and Governor Gear
113
Governor Components and Details
113
Install Crankshaft
114
Install Connecting Rods with Pistons and Rings
114
Install Camshaft
114
Determining Camshaft End Play
114
Install Oil Pan Seal and Crankshaft Bearing (PTO)
115
Install Oil Pan Assembly
116
PTO Oil Seal
116
Install Check Ball Kit
116
Check Crankshaft End Play
116
Install Hydraulic Lifters
118
Assemble Cylinder Heads
118
Install Cylinder Heads
118
Install Guide Plate, Pivot Studs, Push Rods and Rocker Arms
119
Adjust Valve Clearance (AVT Only)
119
Install Valve Covers
119
Install Spark Plugs
119
Oil Cooler/Filter Components
120
Install Oil Filter Housing Assembly
120
Intake Manifold Torque Sequence
122
Install Breather Hose
122
Install Flywheel
122
Install Fan (Style B)
122
Install Crankshaft Position Sensor
123
Install Metal Debris Screen (Style B)
123
Spring Washer Details
123
Install Cooling Fan and Debris Screen (Style A)
123
Install Valley and Cylinder Barrel Baffles
125
Torque Oil Cooler Screws
125
Install Fuel Pump Module/Fuel Pump Assembly
125
Install Electric Starter
125
Mechanical Governor Control Bracket Components
126
Install Governor Lever (Mechanical Governor Only)
126
Install Oil Sentry
126
Oxygen Sensor Wire Detail
126
Install Oil Filter and Add Oil to Crankcase
127
Testing Engine
127
Connect Spark Plug Leads
127
Prepare Engine for Operation
127

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Kohler Command PRO EFI Series Service Manual (129 pages)

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