Kohler Command PRO CV26 Service Manual Download Page 75

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EFI SYSTEM-BOSCH

24 690 02 Rev. H

KohlerEngines.com

Flow Chart Diagnostic Aids

Diagnostic Aid #1 "system power"

(MIL does not

illuminate when key is turned ON)
NOTE: MIL in Metal-Cased ECU systems is an LED.

MIL in Plastic-Cased ECU systems must be a

1/4 watt incandescent lamp.

Possible causes:

●

Battery

●

Main system fuse

●

MIL light bulb burned out

●

MIL electrical circuit problem

“24 Pin” (MSE 1.0) Plastic-Cased ECU:

Pin circuits

19 and 84.

“32 Pin” (MSE 1.1) Plastic-Cased ECU:

Pin circuits

29 and 84.

●

Ignition switch

●

Permanent ECU power circuit problem

“24 Pin” (MSE 1.0) Plastic-Cased ECU:

Pin circuit 1.

“32 Pin” (MSE 1.1) Plastic-Cased ECU:

Pin circuit 1.

●

Switched ECU power circuit problem

“24 Pin” (MSE 1.0) Plastic-Cased ECU:

Pin circuit 2.

“32 Pin” (MSE 1.1) Plastic-Cased ECU:

Pin circuit 2.

●

ECU grounds

●

ECU

Diagnostic Aid #2 “FAULT CODES”

(Refer to detailed

fault code listing before

ow chart and servicing

information for respective components)

●

Code 21-Engine Speed Synchronization

●

Code 22-Throttle Position Sensor (TPS)

●

Code 23-Engine Control Unit (ECU)

●

Code 31-Oxygen Sensor

●

Code 32-Oxygen Sensor

●

Code 33-Fuel System (temporary adaptation factor)

●

Code 34-Fuel System (permanent adaptation factor)

●

Code 42-Engine (Oil) Temperature Sensor

●

Code 43-TPS “Auto-Learn” Initialization Function

(Below Min. Limit),

"32 Pin" (MSE 1.1) Plastic-Cased

ECU only

●

Code 44-TPS “Auto-Learn” Initialization Function

(Above Max. Limit),

"32 Pin" (MSE 1.1) Plastic-

Cased ECU only

●

Code 51-Injector 1,

"32 Pin" (MSE 1.1) Plastic-

Cased ECU only

●

Code 52-Injector 2,

"32 Pin" (MSE 1.1) Plastic-

Cased ECU only

●

Code 55-MIL Light,

"32 Pin" (MSE 1.1) Plastic-

Cased ECU only

●

Code 56-Pump Relay,

"32 Pin" (MSE 1.1) Plastic-

Cased ECU only

●

Code 61-End of Fault/Blink Code Transmission.

Diagnostic Aid #3 RUN/ON

(MIL remains “on” while

engine is running)*
Possible causes:

●

Fault codes which turn on MIL when engine is running.

●

Code 21-Engine Speed Synchronization

●

Code 22-Throttle Position Sensor (TPS)

●

Code 23-Engine Control Unit (ECU)

●

Code 31-Oxygen Sensor (shorted)

●

Code 34-Fuel System (permanent adaptation at limit)

●

Code 42-Engine (Oil) Temperature Sensor

●

Code 43-TPS “Auto-Learn” Initialization Function

(Below Min. Limit),

"32 Pin" (MSE 1.1) Plastic-Cased

ECU only

●

Code 44-TPS “Auto-Learn” Initialization

●

Function (Above Max. Limit)

"32 Pin" (MSE 1.1)

Plastic-Cased ECU only

●

Code 51-Injector 1,

"32 Pin" (MSE 1.1) Plastic-

Cased ECU only

●

Code 52-Injector 2,

"32 Pin" (MSE 1.1) Plastic-

Cased ECU only

●

Code 55-MIL Light,

"32 Pin" (MSE 1.1) Plastic-

Cased ECU only

●

Code 56-Pump Relay,

"32 Pin" (MSE 1.1) Plastic-

Cased ECU only

●

MIL circuit grounded between light and ECU.

“35 Pin” (MA 1.7) Metal-Cased ECU:

Pin circuit 31.

“24 Pin” (MSE 1.0) Plastic-Cased ECU:

Pin circuit

19.

“32 Pin” (MSE 1.1) Plastic-Cased ECU:

Pin circuit

29.

●

ECU

Diagnostic Aid #4 SPEED SENSOR

(MIL does not turn

off during cranking). Indicates ECU is not receiving a

signal from speed sensor.
Possible causes:

●

Speed sensor

●

Speed sensor circuit problem

“24 Pin” (MSE 1.0) Plastic-Cased ECU:

Pin circuits

9 and 10.

“32 Pin” (MSE 1.1) Plastic-Cased ECU:

Pin circuits

9 and 10.

●

Speed sensor/toothed wheel air gap

●

Toothed wheel

●

Flywheel key sheared

●

ECU

Diagnostic Aid #5 FUEL PUMP

(fuel pump not turning

on)
Possible causes:

●

Fuel pump fuse

●

Fuel pump circuit problem

“24 Pin” (MSE 1.0) Plastic-Cased ECU:

Circuits 30,

87, and relay.

“32 Pin” (MSE 1.1) Plastic-Cased ECU:

Circuits 30,

87, and relay.

●

Fuel pump

Summary of Contents for Command PRO CV26

Page 1: ...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 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 ...

Page 2: ...quipment disable engine as follows 1 Disconnect spark plug lead s 2 Disconnect negative battery cable from battery WARNING Hot Parts can cause severe burns Do not touch engine while operating or just after stopping Never operate engine with heat shields or guards removed WARNING Cleaning Solvents can cause severe injury or death Use only in well ventilated areas away from ignition sources Carburet...

Page 3: ...aner element Air Cleaner Intake Remove and clean shrouds and cooling areas Air Cleaner Intake Check oil cooler fins clean as necessary if equipped Lubrication System Every 150 Hours Check heavy duty filter minder Air Cleaner Intake Inspect heavy duty air filter paper element and inlet screen area Air Cleaner Intake Every 200 Hours Replace unique Electronic Fuel Injection EFI fuel filter Every 200 ...

Page 4: ...pproved and should NOT be used effects of old stale or contaminated fuel are not warrantable Fuel must meet these requirements Clean fresh unleaded gasoline Octane rating of 87 R M 2 or higher Research Octane Number RON 90 octane minimum Gasoline up to 10 ethyl alcohol 90 unleaded is acceptable Methyl Tertiary Butyl Ether MTBE and unleaded gasoline blend max 15 MTBE by volume are approved Do not a...

Page 5: ...Specifications 5 24 690 02 Rev H KohlerEngines com Engine Dimensions with Heavy Duty Air Cleaner Dimensions in millimeters Inch equivalents shown in ...

Page 6: ...Specifications 6 24 690 02 Rev H KohlerEngines com Engine Dimensions with Low Profile Air Cleaner Dimensions in millimeters Inch equivalents shown in ...

Page 7: ...holes 2 8 N m 25 in lb into new holes 2 3 N m 20 in lb into used holes 2 8 N m 25 in lb into new holes 2 3 N m 20 in lb into used holes 6 2 N m 55 in lb into new holes 4 0 N m 35 in lb into used holes 10 7 N m 95 in lb into new holes 7 3 N m 65 in lb into used holes Connecting Rod Cap Fastener torque in increments 8 mm straight shank 8 mm step down 6 mm straight shank 11 6 N m 103 in lb 22 7 N m 2...

Page 8: ...m 81 in lb Pulse Pump Bracket Fastener 2 1 N m 25 in lb Pulse Pump Fastener to Bracket 7 3 N m 68 in lb into new holes 6 2 N m 55 in lb into used holes Governor Electronic Governor Control Unit GCU to GCU Bracket 2 1 N m 19 in lb Digital Linear Actuator DLA Bracket to GCU Bracket 10 2 N m 90 in lb DLA to DLA Bracket Screw 3 2 N m 28 in lb Governor Mechanical Lever Nut 7 1 N m 63 in lb 6 8 N m 60 i...

Page 9: ... in lb into new holes 7 3 N m 65 in lb into used holes Fastener Assembled to Blower Housing 2 8 N m 25 in lb into new holes 2 3 N m 20 in lb into used holes Fastener Torque 10 7 N m 95 in lb into new holes 7 3 N m 65 in lb into used holes Starter Assembly Thru Bolt Nippondenso Solenoid Shift Delco Remy Solenoid Shift 5 6 9 0 N m 49 79 in lb 4 5 7 5 N m 40 84 in lb 5 6 9 0 N m 49 79 in lb Mounting ...

Page 10: ...025 mm 0 7874 0 7884 in 20 038 mm 0 7889 in Bearing Surface O D New Max Wear Limit 19 920 19 975 mm 0 7843 0 7864 in 19 914 mm 0 7840 in 19 962 19 975 mm 0 7859 0 7864 in 19 959 mm 0 7858 in Connecting Rod Connecting Rod to Crankpin Running Clearance 21 C 70 F New Max Wear Limit 0 043 0 073 mm 0 0017 0 0029 in 0 088 mm 0 0035 in 0 030 0 055 mm 0 0012 0 0022 in 0 070 mm 0 0028 in Connecting Rod to ...

Page 11: ... 0 025 mm 0 0010 in Oil Pan End Main Bearing Journal O D New O D Max Wear Limit Max Taper Max Out of Round 40 913 40 935 mm 1 6107 1 6116 in 40 843 mm 1 608 in 0 022 mm 0 0009 in 0 025 mm 0 0010 in 40 913 40 935 mm 1 6107 1 6116 in 40 84 mm 1 608 in 0 022 mm 0 0009 in 0 025 mm 0 0010 in Connecting Rod Journal O D New O D Max Wear Limit Max Taper Limit Max Out of Round Limit 35 950 35 973 mm 1 4153...

Page 12: ...e I D New Max Wear Limit 17 006 17 012 mm 0 6695 0 6698 in 17 025 mm 0 6703 in 17 006 17 012 mm 0 6695 0 6698 in 17 025 mm 0 6703 in Pin O D New Max Wear Limit 16 995 17 000 mm 0 6691 0 6693 in 16 994 mm 0 6691 in 16 995 17 000 mm 0 6691 0 6693 in 16 994 mm 0 6691 in Top Compression Ring to Groove Side Clearance 0 050 0 095 mm 0 0019 0 0037 in 0 025 0 048 mm 0 0010 0 0019 in Middle Compression Rin...

Page 13: ...0020 0 0035 in 0 050 0 088 mm 0 0020 0 0035 in Intake Valve Guide I D New Max Wear Limit 7 040 7 060 mm 0 2772 0 2780 in 7 134 mm 0 2809 in 7 038 7 058 mm 0 2771 0 2779 in 7 134 mm 0 2809 in Exhaust Valve Guide I D New Max Wear Limit 7 040 7 060 mm 0 2772 0 2780 in 7 159 mm 0 2819 in 7 038 7 058 mm 0 2771 0 2779 in 7 159 mm 0 2819 in Valve Guide Reamer Size Standard 0 25 mm O S 7 050 mm 0 2776 in ...

Page 14: ... 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 2 3 20 10 24 3 6 32 4 5 40 3 6 32 10 32 3 6 32 4 5 40 1 4 20 7 9 70 13 0 115 18 7 165 7 9 70 1 4 28 9 6 85 15 8 140 22 6 200 5 16 18 17 0 150 28 3 250 ...

Page 15: ...3 Dealer Tool Kit Domestic Complete kit of Kohler required tools Components of 25 761 39 S Ignition System Tester Cylinder Leakdown Tester Oil Pressure Test Kit Rectifier Regulator Tester 120 V AC 60Hz Kohler 25 761 39 S Kohler 25 455 01 S Kohler 25 761 05 S Kohler 25 761 06 S Kohler 25 761 20 S Dealer Tool Kit International Complete kit of Kohler required tools Components of 25 761 42 S Ignition ...

Page 16: ...ent available Starter Brush Holding Tool Solenoid Shift SE Tools KLR 82411 SE Tools KLR 82416 Triad OHC Timing Tool Set For holding cam gears and crankshaft in timed position while installing timing belt Kohler 28 761 01 S Valve Guide Reamer K and M Series For properly sizing valve guides after installation Design Technology Inc DTI K828 Valve Guide Reamer O S Command Series For reaming worn valve...

Page 17: ...ring gear teeth Bosses will lock tool and flywheel in position for loosening tightening or removing with a puller A spanner wrench to lift rocker arms or turn crankshaft may be made out of an old junk connecting rod 1 Find a used connecting rod from a 10 HP or larger engine Remove and discard rod cap 2 Remove studs of a Posi Lock rod or grind off aligning steps of a Command rod so joint surface is...

Page 18: ...re 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 Engine Will Not Crank Battery is discharged Faulty electric starter or solenoid Faulty key switch or ignition switch Int...

Page 19: ... indications of improper fit and seal Check air cleaner element Look for holes tears cracked or damaged sealing surfaces or other damage that could allow unfiltered air into engine A dirty or clogged element could indicate insufficient or improper maintenance Check carburetor throat for dirt Dirt in throat is further indication that air cleaner was not functioning properly Check if oil level is wi...

Page 20: ...is closed 2 Start engine and run no load high speed 3 Open clamp and note water level in tube Level in engine side should be a minimum of 10 2 cm 4 in above level in open side If level in engine side is less than specified low no vacuum or level in engine side is lower than level in open side pressure check for conditions in table below 4 Close pinch clamp before stopping engine To test crankcase ...

Page 21: ...ft Install a 3 8 in breaker bar into hole slot of holding tool so it is perpendicular to both holding tool and crankshaft PTO If flywheel end is more accessible use a breaker bar and socket on flywheel nut screw to hold it in position An assistant may be needed to hold breaker bar during testing If engine is mounted in a piece of equipment it may be possible to hold it by clamping or wedging a dri...

Page 22: ...t 1 Clean area around element Remove wing nut element cover and paper element with precleaner 2 Separate precleaner from element service precleaner and replace paper element 3 Check condition of rubber seal and replace if necessary 4 Install new paper element on base install precleaner over paper element reinstall element cover and secure with wing nut Reinstall air cleaner cover and secure with k...

Page 23: ... to over 12 milliseconds depending on fuel requirements Controlled injection of fuel occurs every other crankshaft revolution or once for each 4 stroke cycle When intake valve opens air fuel mixture is drawn into combustion chamber compressed ignited and burned ECU controls amount of fuel being injected and ignition timing by monitoring primary sensor signals for engine temperature speed RPM and t...

Page 24: ...ed indicating that wiring of that particular circuit is OK Crankshaft position sensor is essential to engine operation constantly monitoring rotation and speed RPM of crankshaft There are 23 consecutive teeth cast into flywheel One tooth is missing and is used to reference crankshaft position for ECU Inductive crankshaft position sensor is mounted 0 20 0 70 mm 0 008 0 027 in from flywheel During r...

Page 25: ...m is used with EFI system ECU controls ignition output and timing through transistorized control of primary current delivered to coils Based on input from crankshaft position sensor ECU determines correct firing point for speed at which engine is running At proper instant it interrupts flow of primary current in coil causing electromagnetic flux field to collapse Flux collapse induces an instantan...

Page 26: ...rt lower than normal but gradually increase to established setting as operation continues Do not attempt to circumvent this warm up period or readjust idle speed during this time Engine must be completely warmed up in closed loop operating mode for accurate idle adjustment IMPORTANT NOTES Cleanliness is essential and must be maintained at all times when servicing or working on EFI system Dirt even...

Page 27: ...il Sensors 11 Manifold Absolute Pressure MAP sensor input 12 Throttle Position Sensor TPS input 13 Speed Sensor Ground 14 Oil Temperature Sensor input 15 Ignition Switch Switched 12V 16 Power for TPS and MAP Sensors 5V 17 Oxygen Sensor O2 input 18 Battery Power Permanent 12V Grey Connector Pin Description 1 Not Used 2 Not Used 3 Malfunction Indicator Light MIL Ground 4 Not Used 5 Not Used 6 GCU Ta...

Page 28: ...ear all trouble codes all closed loop learned offsets all max values and all timers besides permanent hour meter This system will NOT reset when battery is disconnected 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 4 T...

Page 29: ...il Pressure Switch V MIL Optional W 10A Fuse X Black Connector Y Grey Connector Z Fuel Injector 1 AA Fuel Injector 2 AB Ignition Coil 1 AC Ignition Coil 2 AD Crankshaft Position Sensor AE Oxygen Sensor AF Throttle Position Sensor AG Manifold Absolute Pressure Sensor AH Oil Temperature Sensor AI Intake Air Temperature Sensor AJ Diagnostic Connector AK Grey Blue AL Electronic Governor only C J G B F...

Page 30: ...een G Dark Blue H Purple I Pink J Tan K White L Grey M Black N Stator O Rectifi er Regulator P 30A Fuse Q Battery R Fuel Pump S 5 Terminal Connector T Starter Motor U Oil Pressure Switch V MIL Optional W 10A Fuse X Black Connector Y Grey Connector Z Fuel Injector 1 AA Fuel Injector 2 AB Ignition Coil 1 AC Ignition Coil 2 AD Crankshaft Position Sensor AE Oxygen Sensor AF Throttle Position Sensor AG...

Page 31: ...ack negative ohmmeter lead to Black pin 10 terminal to test b Hold throttle closed and check resistance It should be 1400 1800 Ω 4 Leave leads connected to pin terminals as described in step 3 Rotate throttle shaft slowly to full throttle position Monitor dial during rotation for indication of any momentary short or open circuits Note resistance at full throttle position It should be 4600 5200 Ω w...

Page 32: ...tion Shield B Planar Element and Heater C Lower Insulator D Stainless Steel Housing E Upper Insulator F Terminal Connection to Element G High Temp Water Seal Temperature must be controlled very accurately and gas constituents measured to a high degree of accuracy for absolute sensor measurements This requires laboratory equipment to determine a good or bad sensor in field Furthermore as with most ...

Page 33: ...ade if problem is with engine or sensor 3 Check engine harness for battery voltage on heater circuit Removal Inspection NOTE Apply anti seize compound only to threads Anti seize compound will affect sensor performance if it gets into lower shield of sensor 1 If sensor has heavy deposits on lower shield engine oil or fuel may be source 2 If heavy carbon deposits are observed incorrect engine fuel c...

Page 34: ...gine oil consumption causing exhaust contamination or other exhaust side contamination Correct engine condition Heater circuit open shorted or out of specification Repair short in harness wires replace sensor Manifold Absolute Pressure Sensor MAP A sealed non serviceable assembly A faulty sensor must be replaced If a blink code indicates a problem with manifold absolute pressure sensor it can be t...

Page 35: ...t Crank engine and check for flashing of test light Turn key OFF for at least 10 seconds between tests to allow ECU to go to sleep and reawake Repeat test at other connector a If flashing occurs use an ohmmeter Rx1 scale and check resistance of each injector across two terminals Proper resistance is 11 13 Ω If injector resistance is correct check whether connector and injector terminals are making...

Page 36: ... disconnect Grey connector from ECU and test between Grey pins 10 and 17 Wiring and coil primary circuits are OK if readings are 0 5 0 8 2 If reading s are not within specified range check and clean connections and retest 3 If reading s are still not within specified range test coils separately from main harness as follows a Remove screw retaining coil to housing and disconnect primary leads conne...

Page 37: ...Vent Hose Assembly No specific servicing is required for vent hose assembly or purge port unless operating conditions indicate replacement is required All components are serviced individually Abrasion sleeves on hoses should be reused or replaced when servicing vent hoses Please note vent hose routing and replicate after service or component replacement to prevent pinching or abrasion of vent hose...

Page 38: ...ty engine temperature sensor Faulty injectors Engine Misses Hesitates or Stalls Under Load Fuel injector s fuel filter fuel line or fuel pick up dirty restricted Dirty air cleaner Insufficient fuel pressure or fuel delivery Vacuum intake air leak Improper governor setting adjustment or operation TPS faulty mounting problem or TPS Initialization Procedure incorrect Bad coil s spark plug s or wires ...

Page 39: ...roken 6 Test fuel pump module operation as described earlier under Fuel Pump Fault Codes Example of Diagnostic Display One second pause One second pause One second pause One second pause Three second pause 0 0 7 6 1 1 End Code 61 Fault Code 0107 Diagnostic Fault Code Summary Fault Code Connection or Failure Description 0031 Oxygen Sensor Heater Circuit High Voltage 0032 Oxygen Sensor Heater Circui...

Page 40: ...wing ECU Reset and TPS Learn Procedures Diagnostic Fault Code Summary lists fault codes and what they correspond to Diagnostic Code Summary is a list of individual codes with an explanation of what triggers them what symptoms might be expected and probable causes A MIL may not be provided with engine If equipment manufacturer has not added a MIL to equipment one can be added easily for quick diagn...

Page 41: ...ant Oil Temperature Sensor Circuit Low Voltage Condition Shorted connection faulty sensor or shorted wire Conclusion Temperature Sensor Related Sensor wiring or connection Engine Wiring Harness Related Pin circuits Black 10 and Black 14 maybe damaged or routed near noisy signal coils stator etc ECU to harness connection problem Code 0118 Component Coolant Oil Sensor Fault Coolant Oil Temperature S...

Page 42: ...ltage Condition Shorted connection or faulty sensor Conclusion Oxygen Sensor Related Sensor connector or wiring problem Sensor contaminated or damaged Poor ground path Pin circuit wiring or connectors ECU Black pin 10 or Black pin 17 Engine Wiring Harness Related Difference in voltage between sensed voltage and actual sensor voltage Short in wire harness Code 0171 Component Fuel System Fault Maxim...

Page 43: ...rings valves Fuel in crankcase oil Fuel pump module is over filled Lift pump diaphragm is ruptured Code 0174 Component Fuel System Fault Lean fuel condition Condition Fuel inlet screen filter plugged low pressure at high pressure fuel line TPS malfunction shorted connection or faulty sensor Conclusion TPS Learn Incorrect Lean condition check oxygen sensor signal with VOA and see Oxygen Sensor Engi...

Page 44: ... Position Sensor Noisy Signal Condition Air gap incorrect loose sensor faulty bad battery shorted or faulty connection faulty sensor or faulty sensor grounding Conclusion Crankshaft Position Sensor Related Sensor connector or wiring Sensor loose or air gap incorrect Crankshaft Position Sensor Wheel Related Damaged teeth Gap section not registering Engine Wiring Harness Related Pin circuit wiring o...

Page 45: ...ltage regulator or shorted connection Conclusion Faulty Rectifier Regulator Bad Stator Bad Battery Code 1693 Component Tach Output ECU Fault Tach Circuit Low Condition Tachometer output circuit short to ground Conclusion Bad Tach Wire grounded GCU circuit short to ground Code 1694 Component Tach Output ECU Fault Tach Circuit High Condition Tachometer output circuit short to battery Conclusion ECU ...

Page 46: ...it problem pin circuits Black 9 and Grey 17 Fuel pump module 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 No fuel Air in high pressure fuel line Fuel valve shut OFF Fuel filter line...

Page 47: ...IC FAULT CODE SUMMARY CLEAR CODES NO REFER TO DIAGNOSTIC AID 3 RUN ON OPERATE AT VARIOUS SPEED LOAD CONDITIONS ARE FAULT CODES PRESENT NO END OF TEST REFER TO DIAGNOSTIC AID 4 CRANKSHAFT POSITION SENSOR REFER TO DIAGNOSTIC AID 5 FUEL PUMP REFER TO DIAGNOSTIC AID 6 IGNITION SYSTEM REFER TO DIAGNOSTIC AID 7 FUEL SYSTEM ELECTRICAL REFER TO DIAGNOSTIC AID 8 FUEL SYSTEM REFER TO DIAGNOSTIC AID 9 BASIC ...

Page 48: ...act with hot parts or sparks from ignition Never use gasoline as a cleaning agent Explosive Fuel can cause fires and severe burns Do not fill fuel tank while engine is hot or running Bosch EFI System A A O A N M L K J I H E F D C B I A Fuel Pressure Regulator B Valley Baffle C Air Deflector D Fuel Rail E Intake Manifold Kit F Throttle Position Sensor G Module H Fuel Injector I ECU J Speed Pick up ...

Page 49: ... of unused oxygen in exhaust indicating whether fuel mixture being delivered is rich or lean Based upon this feedback ECU further adjusts fuel input to re establish ideal air fuel ratio This operating mode is referred to as closed loop operation EFI system operates closed loop when all three of following conditions are met Oil temperature is greater than 35 C 95 F Oxygen sensor has warmed sufficie...

Page 50: ...delivery maps ECU then knows how much fuel is required for starting at that temperature Oxygen sensor functions like a small battery generating a voltage signal to ECU based upon difference in oxygen content between exhaust gas and ambient air Tip of sensor protruding into exhaust gas is hollow Outer portion of tip is surrounded by exhaust gas with inner portion exposed to ambient air When oxygen ...

Page 51: ...sensor fuel rail air baffle idle speed screw and air cleaner assembly Idle speed is only adjustment that may be performed on EFI system Standard idle speed setting for EFI engines is 1500 RPM but certain applications might require a different setting Check equipment manufacturer s recommendation For starting and warm up ECU will adjust fuel and ignition timing based upon ambient temperature engine...

Page 52: ... is encountered and you determine ECU to be faulty contact your source of supply Do not replace ECU without factory authorization Relationship between ECU and throttle position sensor TPS is very critical to proper system operation If TPS or ECU is changed or mounting position of TPS is altered applicable TPS Initialization Procedure must be performed to restore synchronization Engine speed sensor...

Page 53: ...Yes Yes Yes If resistance values in steps 3 4 and 5 are within specifications go to step 6 If resistance values are not within specifications or a momentary short or open circuit was detected during rotation step 4 TPS needs to be replaced go to step 7 6 Check TPS circuits input ground between TPS plug and main harness connector for continuity damage etc See chart on pages 63 and 65 24 Pin MSE 1 0...

Page 54: ...ry 2 seconds 5 Remove jumper wire or plug from service connector plug in wiring harness 6 Run engine at full throttle above 3000 RPM to warm up engine and initiate O2 sensor function in closed loop operation 7 Watch MIL When light starts blinking rapidly 5 blinks per second move throttle lever to low idle speed position Check and adjust idle speed to 1500 RPM using a tachometer Lamp should continu...

Page 55: ...om 0 2 to 1 0 v should be indicated 2 Move black voltmeter lead to engine ground location and repeat output test Same voltage 0 2 v 1 0 v should be indicated a If same voltage reading exists go on to Step 3 b If voltage output is no longer correct a bad ground path exists between sensor and engine ground Touch black lead at various points backtracking from engine ground back toward sensor watching...

Page 56: ...hould indicate continuity ground circuit is completed for 1 to 3 seconds Turn key switch back off a Clean connection and check wiring if circuit was not completed 3 Set meter for DC voltage Touch red tester lead to 30 terminal in relay connector A reading of 12 volts should be indicated at all times 4 Connect red lead of meter to 85 terminal in relay connector Turn key switch to ON position Batter...

Page 57: ...n MSE 1 1 Plastic Cased ECU Check resistance between relay terminal 87 and pin 14 in main connector Then check resistance between relay terminal 87 and pin 15 Resistance should be 4 15 Ω for each circuit Check all electrical connections connectors and wiring harness leads if resistance is incorrect Injector leakage is very unlikely but in those rare instances it can be internal past tip of valve n...

Page 58: ... reading of 1 8 4 0 Ω in each test indicates that wiring and coil primary circuits are OK a If reading s are not within specified range check and clean connections and retest b If reading s are still not within specified range test coils separately from main harness as follows 1 Disconnect red and black primary leads from coil terminals 2 Connect an ohmmeter set on Rx1 scale to primary terminals P...

Page 59: ...gulator out of housing b Remove snap ring and remove regulator from base holder Internal In Tank Regulator Remove screws securing retaining ring and 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 A new replacement regulator will have new O Rings already installed Lubricate O Rings external regulator...

Page 60: ...e 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 Checking Initial Adjustment 1 Unsnap plastic linkage bushing attaching throttle linkage to governor lever Unhook damper spring from lever separate linkage from bushing and remove bushing from lever Mark hole position and unhook gove...

Page 61: ... fuel Incorrect fuel pressure Speed sensor loose or faulty TPS offset incorrect initialization Engine temperature sensor faulty Engine temp sensor faulty Faulty coils Low system voltage Faulty injectors Engine starts hard or fails to start when hot Faulty spark plugs Fuel pump not running Fuel pressure low Insufficient fuel delivery TPS offset incorrect Initialization Speed sensor loose or faulty ...

Page 62: ...starting A fully charged 12 volt battery with a minimum of 350 cold cranking amps is important in maintaining steady and reliable system operation Battery condition and state of charge should always be checked first when troubleshooting an operational problem Keep in mind that EFI related problems are more often caused by wiring harness or connections than by EFI components Even small amounts of c...

Page 63: ...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 Not Used Oxygen Sensor Ground if needed Diagnostic Line Throttle Position Supply Voltage Battery Ground Injector 1 Output Injector 2 Output Main Relay Output Malfunction Indicator Light MIL Not Used T...

Page 64: ...EFI SYSTEM BOSCH 64 24 690 02 Rev H KohlerEngines com ...

Page 65: ...tialization 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 Not Used Not Used Injector 1 Output Injector 2 Output Not Used Diagnostic Line Throttle Position Sensor Supply Voltage Battery Ground Oxygen Sensor Input Battery Ground Secondary Not Used No...

Page 66: ...EFI SYSTEM BOSCH 66 24 690 02 Rev H KohlerEngines com ...

Page 67: ... as described earlier under Fuel Pump Fault Codes ECU continuously monitors engine operation against preset performance limits If operation is outside limits ECU activates MIL and stores a diagnostic code in its fault memory If component or system returns to proper function ECU will eventually self clear fault code and turn off MIL If MIL stays illuminated it warns customer that dealer service is ...

Page 68: ...of what triggers them what symptoms might be expected and probable causes Blink Code OBD2 P Code Applicable to 32 Pin MSE 1 1 ECU System Only Connection or Failure Description 24 Pin MSE 1 0 Plastic Cased ECU System 32 Pin MSE 1 1 Plastic Cased ECU System Note No RPM Signal Y Y 21 P0335 Loss of Synchronization Y Y 22 P0120 TPS Signal Implausible N N 2 22 P0122 TPS Open or Short Circuit to Ground Y...

Page 69: ... N A Y 52 P0265 Injector 2 Short Circuit to Battery N A Y 55 P1651 Diagnostic Lamp Open Circuit N A Y 55 P1652 Diagnostic Lamp Short Circuit to Ground N A Y 55 P1653 Diagnostic Lamp Short Circuit to Battery N A Y 56 P1231 Pump Relay Open Circuit N A Y 56 P1232 Pump Relay Short Circuit to Ground N A Y 56 P1233 Pump Relay Short Circuit to Battery N A Y 61 End of Code Transmission Y Y 6 System too Le...

Page 70: ...sensor too high too low inconsistent Condition A limp home operating mode occurs with an overall decrease in operating performance and efficiency Fuel delivery is based upon oxygen sensor and five mapped values only Rich running black smoke will occur until closed loop operation is initiated A stumble or misfire on hard acceleration and or erratic operation may be exhibited Conclusion TPS Sensor R...

Page 71: ... lean popping or misfiring fuel mixture is suspect probably incorrect TPS initialization or low fuel pressure TPS Initialization Incorrect Lean condition check oxygen sensor signal with VOA and see Oxygen Sensor section Engine Wiring Harness Related Pin circuit wiring or connectors Pin 11 for 24 Pin MSE 1 0 Plastic Cased ECU Pin 20 for 32 Pin MSE 1 1 Plastic Cased ECU Low Fuel Pressure Oxygen Sens...

Page 72: ...l in crankcase oil Blocked or restricted fuel return circuit to tank ECU Harness Related ECU to harness connection problem Code 34 Component Oxygen Sensor Fuel System Components Fault Long term fuel adaptation control is at upper or lower limit Condition System operates closed loop No appreciable performance loss as long as temporary adaptation can provide sufficient compensation Conclusion Oxygen...

Page 73: ...S rotated on throttle shaft assembly beyond allowable range TPS bad Engine Wiring Harness Related Broken or shorted wire in harness ECU pin 18 to TPS pin 1 ECU pin 4 to TPS pin 2 ECU pin 8 to TPS pin 3 Throttle Body Related Throttle shaft inside TPS worn broken or damaged Throttle plate loose or misaligned Throttle plate bent or damaged allowing extra airflow past or restricting movement ECU Relat...

Page 74: ...d MIL element opened or element shorted to ground Lamp missing Engine Wiring Harness Related Broken or shorted wire in harness ECU pin 29 to lamp open or shorted Vehicle Wiring Harness Related Broken or shorted wire in harness Power lead to MIL open or shorted ECU Related Circuit controlling lamp damaged Code 56 32 Pin MSE 1 1 Plastic Cased ECU only Component Fuel pump relay circuit open shorted t...

Page 75: ... Light 32 Pin MSE 1 1 Plastic Cased ECU only Code 56 Pump Relay 32 Pin MSE 1 1 Plastic Cased ECU only Code 61 End of Fault Blink Code Transmission Diagnostic Aid 3 RUN ON MIL remains on while engine is running Possible causes Fault codes which turn on MIL when engine is running Code 21 Engine Speed Synchronization Code 22 Throttle Position Sensor TPS Code 23 Engine Control Unit ECU Code 31 Oxygen ...

Page 76: ...1 65 66 relay and relay circuit 30 ECU grounds ECU Diagnostic Aid 8 FUEL SYSTEM ELECTRICAL no fuel delivery Possible causes No fuel Air in fuel rail Fuel valve shut off Fuel filter line plugged Injector circuit s 24 Pin MSE 1 0 Plastic Cased ECU Circuits 16 17 45 and 45A 32 Pin MSE 1 1 Plastic Cased ECU Circuits 14 15 and 45 Injector ECU grounds ECU Diagnostic Aid 9 FUEL SYSTEM fuel pressure Possi...

Page 77: ...77 EFI SYSTEM BOSCH 24 690 02 Rev H KohlerEngines com ...

Page 78: ...near Actuator DLA Energizing bi directional digital linear actuator coils in proper sequence causes threaded shaft to move out of or back into rotor in precise linear increments When power is removed actuator shaft remains in position DLA must initialize fully extend to move throttle plate to closed position and partially open for starting Correct adjustment of DLA is critical to achieve full rang...

Page 79: ...stall as follows 1 Disconnect linkage and remove DLA from bracket 2 Remove clevis shaft completely out of DLA 3 Reinstall rubber boot onto DLA if required 4 Place clevis shaft into actuator Rotate clevis shaft clockwise 3 full turns applying slight pressure until you feel clevis shaft keyway make contact with key in actuator When clevis shaft is installed properly flat of clevis will be aligned wi...

Page 80: ...onnection or input is most likely at fault Test 1 Probe Location A A Probe Locations for OHMs Test 1 Test 1 Identify probe locations in connector Using a digital multi meter set to lowest scale 0 200 ohms place probes onto harness making sure of a good connection Resistance should be between 47 7 and 58 3 ohms If test 1 checks OK locate wire ends in connector and check using test 2 Test 2 Probe Lo...

Page 81: ...Failure Condition Possible Causes Response Response Time LED Diagnostics Yellow LED Green LED Speed Error BLINKS ON Watchdog Interrupt RFI interference Ground to kill close throttle plate BLINKS BLINKS Overtemp Software bug Lightning Overspeed Over 4500 RPM for 0 5 seconds sustained External noise on ECU input Ground to kill close throttle plate 1 second delay ON ON Frozen throttle plate DLA failu...

Page 82: ...Faulty ECU Faulty ECU wiring ON ON Missing Pulse RPM Too Low Faulty ECU Faulty ECU wiring OFF ON Sleep Mode Power at GCU with no ECU pulses left in run mode System shutdown 30 minutes OFF OFF Watchdog Interrupt RFI interference Ground to kill close throttle plate N A BLINKS OFF Overtemp Software bug Lightning Overspeed Over 4500 RPM for 1 second sustained External noise on ECU input 1 second delay...

Page 83: ...ch Flat surface clevis should be in alignment with DLA mounting holes 7 Firmly push DLA to bottom 8 Connect clip 9 Connect wire Confirm that 1 Clevis shaft and boot in place 2 Clip attached 3 DLA wire attached Fail if Pass if Fail Pass Clevis shaft and boot are out of DLA Test control system of equipment Refer to Equipment Manufacturer s diagnostic procedures for control system Go to 12 Volt Power...

Page 84: ...peed increases if it was at low speed Engine speed does not change Kohler electronic governor system tests OK Test control system of equipment Refer to Equipment Manufacturer s diagnostic procedures for control system 12 Volt Power Test Fail Pass Operation Input Voltage 0 1 Volts at Idle 9 Volts at High Speed GCU Circuit Test Remove GCU and unplug wiring harness See illustration on page 78 Inspect...

Page 85: ...t connection or input is most likely at fault Test 2 Identify wire ends in connector Using a digital multi meter set to lowest scale 0 200 ohms place probes onto harness making sure of a good connection Resistance should be between 47 7 and 58 3 ohms Refer to page 80 Proceed to DLA Circuit Test Turn key switch to ON position Test supply voltage to GCU using volt meter Refer to page 80 battery volt...

Page 86: ...Clean oil fill dipstick areas of any debris 1 Remove dipstick wipe oil off 2 Reinsert dipstick into tube rest cap on tube do not thread cap onto tube 3 Remove dipstick check oil level Level should be at top of indicator on dipstick 4 If oil is low on indicator add oil up to top of indicator mark 5 Reinstall and secure dipstick CHANGE OIL AND FILTER Change oil while engine is warm 1 Clean area arou...

Page 87: ...pressure gauge and a continuity tester are required to test switch ECV Models Normally Closed Switch 1 Connect continuity tester across blade terminal and metal case of switch With 0 psi pressure applied to switch tester should indicate continuity switch closed 2 Gradually increase pressure to switch As pressure increases through range of 2 0 5 0 psi tester should indicate a change to no continuit...

Page 88: ...re feeler gauge Adjust gap to 0 76 mm 0 03 in 2 Install plug into cylinder head 3 Torque plug to 27 N m 20 ft lb Inspection Inspect each spark plug as it is removed from cylinder head Deposits on tip are an indication of general condition of piston rings valves and carburetor Normal and fouled plugs are shown in following photos Normal Plug taken from an engine operating under normal conditions wi...

Page 89: ...ufficient if an application is started only in warmer temperatures Refer to following table for minimum capacities based on anticipated ambient temperatures Actual cold cranking requirement depends on engine size application and starting temperatures Cranking requirements increase as temperatures decrease and battery capacity shrinks Refer to equipment s operating instructions for specific battery...

Page 90: ...ator take note of terminal markings and install plug s accordingly NOTE Disconnect all electrical connections attached to rectifier regulator Testing may be performed with rectifier regulator mounted or loose Repeat applicable test procedure 2 or 3 times to determine condition of part Rectifier regulator is mounted on blower housing To replace disconnect plug s remove mounting screws and ground wi...

Page 91: ...ttery terminals on battery to reduce voltage Observe ammeter Condition Conclusion Charge rate increases when load is applied Charging system is OK and battery was fully charged Charge rate does not increase when load is applied Test stator and rectifier regulator steps 2 and 3 2 Remove connector from rectifier regulator With engine running at 3600 RPM measure AC voltage across stator leads using a...

Page 92: ...0 amp Fuse 1 Red Wire w Black Stripe 1 Red Wire w White Stripe 10 amp Fuse 2 Red Wires 10 amp Fuse Fuse Replacement 1 Shut engine off and remove key 2 Locate fuse holders 3 Remove fuse cover and pull out fuse 4 Inspect fuse for a solid fusible link or a broken fusible link Replace fuse if fusible link is broken If you are not sure if fusible link is broken replace fuse 5 Insert fuse into fuse hold...

Page 93: ...ossible Cause Conclusion Starter does not energize Battery Check specific gravity of battery If low recharge or replace battery as necessary Wiring Clean corroded connections and tighten loose connections Replace wires in poor condition and with frayed or broken insulation Starter Switch or Solenoid By pass switch or solenoid with a jumper wire If starter cranks normally replace faulty components ...

Page 94: ...inal 2 Remove screws securing solenoid to starter 3 Remove retaining ring from armature shaft using either a retaining ring pliers or snap ring removal tool as described in Steps 4 and 5 Do not reuse old retainer 4 Remove thru larger bolts 5 Remove commutator end plate assembly containing brush holder brushes springs and locking caps Remove thrust washer from inside commutator end 6 Remove frame f...

Page 95: ...ure shaft splines Install drive pinion onto armature shaft 2 Install and assemble stop collar retainer assembly a Install stop collar down onto armature shaft with counter bore recess up b Install a new retainer in larger rear groove of armature shaft Squeeze with a pliers to compress it in groove c Slide stop collar up and lock it into place so recess surrounds retainer in groove If necessary rot...

Page 96: ... to solenoid for any time over what is necessary for performing each of individual tests Internal damage to solenoid may occur Disconnect all leads from solenoid including positive brush lead attached to lower stud terminal Remove mounting hardware and separate solenoid from starter for testing To test solenoid pull in coil plunger Actuation 1 Use a 12 volt power supply and 2 test leads 2 Connect ...

Page 97: ...Components S R L M N O D F C A B E Q H I J J G K P A Heavy Duty Air Cleaner B Low Profile Air Cleaner Cover C Paper Element D Low Profile Air Cleaner Base E Oil Filter F Oil Cooler G O ring H Oil Fill Dipstick I Oil Fill Tube J Oil Drain Plug K GCU Wire Harness Connector L DLA M Linkage Spring N DLA Bracket O GCU Bracket P GCU Module Q Top Mount Control Panel R Spark Plug Lead S Low Profile Air Cl...

Page 98: ...e GCU bracket NOTE If not replacing GCU or DLA remove GCU bracket with GCU and DLA attached 1 Remove screws securing GCU to GCU bracket 2 Pull GCU away from bracket and remove connector from GCU Route connector back through bracket 3 Disconnect link clip from outboard end of DLA remove spring and linkage 4 Remove connector from DLA 5 Remove screws securing DLA to bracket 6 Remove screws attaching ...

Page 99: ... Nut I Return Spring Remove External Governor Controls Mechanical Governor 1 Disconnect governor spring attached to governor lever Note hole location for reassembly 2 Disconnect throttle linkage spring Remove throttle linkage bushing and throttle linkage from governor lever 3 Loosen nut and remove governor lever from cross shaft Disassembly Inspection and Service 99 24 690 02 Rev H KohlerEngines c...

Page 100: ... Remove Lift Fuel Pump 1 Disconnect inlet and outlet fuel lines at lift pump 2 Disconnect pulse vacuum hose at lift fuel pump from crankcase 3 Remove screws securing lift fuel pump to bracket Pulse Style Pumps CV 1 Disconnect fuel line at in line fuel filter on tank to pulse pump line 2 Disconnect pulse vacuum line from crankcase 3 Remove screws securing fuel pump to bracket on blower housing 4 No...

Page 101: ... 2 Disconnect breather tube from throttle body 3 Disconnect throttle position sensor connector 4 Disconnect vent hose from throttle body 5 If equipped remove screws securing heavy duty air cleaner bracket take off bracket and slide throttle body off intake manifold Starter and ECU Components ECV EFI B A C A Electronic Control Unit ECU B ECU Bracket C Starter Remove ECU ECV EFI 1 Remove screws secu...

Page 102: ...ssembly pulling assembly out and away from valve cover Remove Debris Screen Guard Remove screws and spacers securing debris screen guard and remove debris screen guard Remove Debris Screen NOTE Fan will be loose but cannot be removed until after blower housing is removed 1 Remove socket head cap screws securing metal screen and remove screen 2 Remove spacers paying attention to curvature of spring...

Page 103: ...temperature sensor is damaged or malfunctioning disassembly from breather cover is unnecessary 1 Disconnect lead from oil temperature sensor 2 Remove oil temperature sensor from breather cover 3 Remove breather hose from breather cover Remove Inner Baffles and Breather Cover NOTE Removing oil temperature sensor is not required to remove breather cover or inner baffles 1 Remove screws securing inne...

Page 104: ...f intake manifold for each injector 3 When removed pull metal retaining clip connecting fuel injector to fuel injector cap There may be some fuel left in line Any spilled fuel must be cleaned up immediately Remove Intake Manifold 1 Remove screw securing a ring terminal which is part of wiring harness 2 Remove screws securing intake manifold to cylinder heads Note which screws hold wiring clamp 3 U...

Page 105: ...ead Discard screws or nuts and washers once removed Do not reuse Studs if present should only be removed if damaged or if cylinder reconditioning is necessary Once removed they must be replaced 2 Mark location of push rods as either intake or exhaust and cylinder 1 or 2 Push rods should always be reinstalled in same positions 3 Carefully remove push rods cylinder heads and head gaskets 4 Remove li...

Page 106: ...nkcase using a surface plate or piece of glass and feeler gauge as shown Maximum allowable out of flatness is 0 076 mm 0 003 in Carefully inspect valve mechanism parts Inspect valve springs and related hardware for excessive wear or distortion Check valves and valve seat area or inserts for evidence of deep pitting cracks or distortion Check clearance of valve stems in guides See valve details and...

Page 107: ...e made with an 89 cutter as specified for valve seat angle Cutting proper 45 valve face angle as specified and proper valve seat angle 44 5 half of full 89 angle will achieve desired 0 5 1 0 full cut interference angle where maximum pressure occurs on outside diameters of valve face and seat Lapping Valves Reground or new valves must be lapped in to provide proper fit Use a hand valve grinder with...

Page 108: ...damage Kohler does not provide ring gear as a serviceable part Replace flywheel if ring gear is damaged Remove Stator and Backing Plate 1 Remove screws securing backing plate Remove backing plate 2 Remove screws and stator Note position routing of stator lead Crankcase Components C D E A B F G H I J K L M N O P Q X R S T V U W A Oil Pan Seal B Oil Pan Style A C Gerotor Gears Style A D Oil Pump Ass...

Page 109: ...ove locking tab thrust washer located under governor gear assembly 3 Carefully inspect governor gear shaft and replace it only if it is damaged After removing damaged shaft press or lightly tap replacement shaft into oil pan to depth shown Reassembly 1 Install locking tab thrust washer on governor gear shaft with tab down 2 Position regulating pin within governor gear flyweight assembly and slide ...

Page 110: ...quence to 7 9 N m 70 in lb 5 After torquing rotate gear and check for freedom of movement Make sure there is no binding If binding occurs loosen screws reposition pump retorque screws and recheck movement Remove Camshaft Remove camshaft Inspection and Service Check lobes of camshaft for wear or damage See Specifications for minimum lift tolerances Measurement must be performed while valve train is...

Page 111: ... charge before timed spark can cause damage similar to detonation Preignition damage is often more severe than detonation damage Preignition is caused by a hot spot in combustion chamber from sources such as glowing carbon deposits blocked cooling fins an improperly seated valve or wrong spark plug s Replacement pistons are available in STD bore size and in 0 25 mm 0 010 in and 0 50 mm 0 020 in ov...

Page 112: ...re marks or metallic pickup Slight score marks can be cleaned with crocus cloth soaked in oil If wear limits as stated in Specifications and Tolerances are exceeded it will be necessary to either replace crankshaft or regrind crankpin to 0 25 mm 0 010 in undersize If reground a 0 25 mm 0 010 in undersize connecting rod big end must then be used to achieve proper running clearance Measure crankpin ...

Page 113: ... done correctly Crosshatch should intersect at approximately 23 33 off horizontal Too flat an angle could cause rings to skip and wear excessively and too steep an angle will result in high oil consumption 4 After resizing check bore for roundness taper and size Use an inside micrometer telescoping gauge or bore gauge to take measurements These measurements should be taken at 3 locations in cylind...

Page 114: ...al contact cleaner Install Flywheel End Oil Seal Oil Seal Detail B A A 4 5 mm 177 in B Oil Seal 1 Make sure that seal bore of crankcase is clean and free of any nicks or burrs 2 Apply a light coat of engine oil to outside diameter of oil seal 3 Drive oil seal into crankcase using a seal driver Make sure oil seal is installed straight and true in bore to depth shown Install Crankshaft 1 Lubricate c...

Page 115: ...th engine oil 2 Slide small lower washer onto governor cross shaft and install cross shaft from inside of crankcase 3 Install nylon washer onto governor cross shaft then start push on retaining ring Hold cross shaft up in position place a 0 50 mm 0 020 in feeler gauge on top of nylon washer and push retaining ring down shaft to secure Remove feeler gauge which will have established proper end play...

Page 116: ...pply a 1 5 mm 1 16 in bead of sealant to sealing surface of oil pan Verify O ring is present 4 Make sure end of governor cross shaft is lying against bottom of cylinder 1 inside crankcase 5 Install oil pan to crankcase Carefully seat camshaft and crankshaft into their mating bearings Rotate crankshaft slightly to help engage oil pump and governor gear meshes 6 Install screws securing oil pan to cr...

Page 117: ...screws to 9 9 N m 88 in lb Install Hydraulic Lifters NOTE Hydraulic lifters should always be installed in same position as before disassembly Exhaust lifters are located on output shaft oil pan side of engine while intake lifters are located on fan side of engine Cylinder numbers are embossed on top of crankcase and each cylinder head 1 See Servicing Hydraulic Lifters in Disassembly Inspection and...

Page 118: ...Spark Plug Valve Stem Seals These engines use valve stem seals on intake valves and on exhaust valves Use a new seal whenever valve is removed or if seal is deteriorated or damaged in any way Never reuse an old seal Assemble Cylinder Heads Prior to installation lubricate all components with engine oil paying particular attention to lip of valve stem seal valve stems and valve guides Install follow...

Page 119: ...ke sure head is flat on gasket and dowel pins 6 Lightly lubricate exposed upper threads of studs with engine oil Install a flat washer and nut onto each of mounting studs Torque nuts in 2 stages first to 16 9 N m 150 in lb then finally to 33 9 N m 300 in lb following sequence Heads secured with screws 2 Install a new cylinder head gasket part number facing up 3 Install cylinder head and start scre...

Page 120: ... clip snaps into place 4 Press fuel injector into bore in intake manifold and rotate to original position 5 Install fuel injector cap screw into intake manifold and torque to 7 3 N m 65 in lb 6 Push electrical connector on fuel injector making sure a good connection is made 7 Repeat steps 1 through 6 for other fuel injector Install Manifold Absolute Pressure MAP Sensor ECV EFI NOTE Ensure all part...

Page 121: ...a new O ring in groove of each cover 4 Position covers on cylinder heads Locate cover with oil separator hole on cylinder 1 Install screws in each cover and finger tighten 5 Torque valve cover fasteners to Torque Model Gasket RTV 3 4 N m 30 in lb CV Black O ring w shoulder screws w screws and spacers 5 6 N m 50 in lb 9 9 N m 88 in lb CV Yellow or Brown O ring w integral spacers 6 2 N m 55 in lb CV...

Page 122: ...gines com External Engine Components A B C J F G H I E D A Debris Screen Guard B Debris Screen C Outer Baffle D Rectifier Regulator E Inner Baffle F Oil Sentry G Oil Temperature Sensor H Breather Cover I Breather Cover Gasket J Oil Separator ...

Page 123: ...s and secure using M6 screws Install M6 screws 20 mm long into intake port side of cylinder heads including any lifting strap Install M6 screws 16 mm long into exhaust port side of cylinder head Install short M5 screws 10 mm long in upper mounting holes of outer baffles into backing plate Be sure any leads are routed out through proper offsets or notches so they will not be pinched between blower ...

Page 124: ...n on fan and secure with four 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 Insert rubber grommet into valve cover Push oil separator into rubber grommet in valve cover 2 Secure oil separator to blower housing placing spacer and oil separator bracket against blower housing and securing with strap and screws To...

Page 125: ...hrottle body throttle position sensor intake air temperature sensor throttle linkage spring and bushing as an assembly 3 Install air cleaner bracket models with heavy duty air cleaner only to throttle body with screws Torque screws to 9 9 N m 88 in lb 4 Connect breather separator hose to top of throttle body using a pliers to compress spring clip Route hose through housing by pressing hose into cu...

Page 126: ...ontact with hot parts or sparks from ignition Never use gasoline as a cleaning agent Explosive Fuel can cause fires and severe burns Do not fill fuel tank while engine is hot or running Fuel Pump ECV EFI Install Lift Fuel Pump and Fuel Pump Module I A B H F J C E G D A Pulse Pump B Inlet Hose C Outlet to Fuel Pump Module D Pulse Hose E Electrical Connector F Fuel Pump Module G Fuel Pump Module Baf...

Page 127: ...g clamp 4 Install fuel pump module baffle to crankcase using screws Torque screws to 11 9 N m 105 in lb 5 Push high pressure fuel line connector onto fuel pump module fitting 6 If Oetiker clamp was cut to remove inlet fuel line slide a new Oetiker clamp onto fuel line and connect fuel line Only use an Oetiker clamp pliers to crimp Oetiker clamps Oetiker clamp crimp must point up away from top of f...

Page 128: ...or lever Install Bottom Mount Control Panel if equipped NOTE To identify various parts and assembly of throttle control panel refer to External Governor Control Components 1 Install bottom control panel and air cleaner support bracket if used to cylinder heads using screws Torque screws to 10 7 N m 95 in lb into new holes or 7 3 N m 65 in lb into used holes 2 Connect governor spring from throttle ...

Page 129: ...leaner B Low Profile Air Cleaner Cover C Paper Element D Low Profile Air Cleaner Base E Oil Filter F Oil Cooler G O ring H Oil Fill Dipstick I Oil Fill Tube J Oil Drain Plug K GCU Wire Harness Connector L DLA M Linkage Spring N DLA Bracket O GCU Bracket P GCU Module Q Top Mount Control Panel R Spark Plug Lead S Low Profile Air Cleaner ...

Page 130: ...DLA clevis shaft to move 8 Hand tighten DLA bracket Ensure DLA bracket side is flush with edge of GCU bracket Torque to 10 2 N m 90 in lb 9 Push electrical connector onto DLA Setting Initial Governor Adjustment Mechanical Governor Only ECV EFI 1 Move governor lever toward throttle body as far as it will go wide open throttle and hold in position 2 Insert a nail into hole on cross shaft and rotate ...

Page 131: ...en normal load is applied governor should be set for greater sensitivity Adjust as follows 1 To increase sensitivity move spring closer to governor lever pivot point 2 To decrease sensitivity move spring away from governor lever pivot point Testing Engine It is recommended engine be operated on a stand or bench prior to installation in piece of equipment 1 Start engine inspect for leaks and check ...

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Kohler Command PRO CV26, Service Manual

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