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Kohler Command PRO ECV630, Service Manual

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Kohler Command PRO ECV630 Service Manual Download Page 82

7.8

Section 7
Electrical System and Components

Figure 7-8. Completed Delco-Remy Starter.

Screw

Plunger 

Spring

Lever
Plate

Collar

Ring
Stop

Drive

Armature 

Plug

Solenoid 

Frame & Field 

Brush Holder

Washer

Tube

Nut

CE Frame 

Screw

Bolt

Figure 7-9. Delco-Remy Starter.

Troubleshooting Guide - Starting Diffi culties

Solenoid Shift Electric Starters

Operation – Solenoid Shift Starter

When power is applied to the starter the electric 
solenoid moves the drive pinion out onto the drive 
sha

ft

  and into mesh with the 

fl

 ywheel ring gear. When 

the pinion reaches the end of the drive sha

ft

  it rotates 

the 

fl

 ywheel and cranks the engine.

When the engine starts and the start switch is released 
the starter solenoid is deactivated, the drive lever 
moves back, and the drive pinion moves out of mesh 
with the ring gear into the retracted position.

Problem

Possible Fault

Correction

Starter Does Not 

Energize

Battery

  1.  Check the speci

fi

 c gravity of ba

tt

 ery. If low, recharge or replace 

ba

tt

 ery as necessary.

Wiring

  1.  Clean corroded connections and tighten loose connections.
  2.  Replace wires in poor condition and with frayed or broken 

insulation.

Starter Switch or 

Solenoid

  1.  By-pass the switch or solenoid with a jumper wire. If starter 

cranks normally, replace the faulty components. 

Solenoid Shi

ft

  

Starters:

 Perform individual solenoid test procedure. See pages 

7.16 and 7.17.

Starter Energizes 

But Turns Slowly

Battery

  1.  Check the speci

fi

 c gravity of ba

tt

 ery. If low, recharge or replace 

ba

tt

 ery as necessary.

Brushes

  1.  Check for excessively dirty or worn brushes and commutator. 

Clean using a coarse cloth (not emery cloth).

  2.  Replace brushes if excessively or unevenly worn.

Transmission or 

Engine

  1.  Make sure the clutch or transmission is disengaged or placed 

in neutral. This is especially important on equipment with 
hydrostatic drive. The transmission must be exactly in neutral to 
prevent resistance which could keep the engine from starting.

  2.  Check for seized engine components such as the bearings, 

connecting rod, and piston.

Summary of Contents for Command PRO ECV630

Page 1: ...SERVICE MANUAL ECV630 ECV749 VERTICAL CRANKSHAFT ...

Page 2: ......

Page 3: ...Troubleshooting Section 4 Air Cleaner and Air Intake System Section 5 Electronic Fuel Injection EFI System Section 6 Lubrication System Section 7 Electrical System and Components Section 8 Disassembly Section 9 Inspection and Reconditioning Section 10 Reassembly 2 1 4 5 3 9 10 6 7 8 ...

Page 4: ......

Page 5: ...starting can cause severe injury or death Before working on the engine or equipment disable the engine as follows 1 Disconnect the spark plug lead s 2 Disconnect negative battery cable from battery WARNING Rotating Parts can cause severe injury Stay away while engine is in operation Rotating Parts Keep hands feet hair and clothing away from all moving parts to prevent injury Never operate the engi...

Page 6: ...urces of electrical shock WARNING Cleaning Solvents can cause severe injury or death Use only in well ventilated areas away from ignition sources Flammable Solvents Carburetor cleaners and solvents are extremely flammable Keep sparks flames and other sources of ignition away from the area Follow the cleaner manufacturer s warnings and instructions on its proper and safe use Never use gasoline as a...

Page 7: ...r using dirty oil causes premature engine wear and failure Oil Type Use high quality detergent oil of API American Petroleum Institute Service Class SJ or higher Select the viscosity based on the air temperature at the time of operation as shown in the following table NOTE Using other than service class SJ or higher oil or extending oil change intervals longer than recommended can cause engine dam...

Page 8: ...ot be used on EFI engines or on other models where exhaust emissions are regulated Gasoline Alcohol Blends Gasohol up to 10 ethyl alcohol 90 unleaded gasoline by volume is approved as a fuel for Kohler engines Other gasoline alcohol blends including E20 and E85 are not to be used and not approved Any failures resulting from use of these fuels will not be warranted Gasoline Ether Blends Methyl Tert...

Page 9: ...et screen area 4 Section 4 Every 25 Hours Clean or replace precleaner if equipped clean as necessary 1 3 Section 4 Storage If the engine will be out of service for two months or more use the following storage procedure 1 Clean the exterior surfaces of the engine On EFI engines avoid spraying water at the wiring harness or any of the electrical components 2 Change the oil and oil filter while the e...

Page 10: ...1 6 Section 1 Safety and General Information Dimensions in millimeters Inch equivalents shown in Figure 1 4 Typical Engine Dimensions ECV749 with Heavy Duty Air Cleaner ...

Page 11: ... 25 4 STUDS 30º 334 62 13 174 2X 89 41 3 520 ENGINE MOUNTING SURFACE PTO SIDE OIL FILTER SIDE STARTER SIDE 2X 72 85 2 868 77 90 3 067 30º 45º 45º 104 02 4 095 241 87 9 523 89 41 3 520 MOUNTING HOLE A 50 00 1 969 EXHAUST PORT 2 35º 35º ENGINE MOUNTING SURFACE 154 94 6 100 SPARK PLUG 92 94 3 659 EXHAUST PORT 1 72 69 2 862 EXHAUST PORT 2 1 4 IN SQ KEYWAY 85 50 3 366 KEYWAY 85 91 3 382 OIL FILTER OIL ...

Page 12: ...termined by oil filter and oil cooler used 1 9 L 2 U S qt Angle of Operation Maximum At Full Oil Level All Directions 25 Blower Housing Screws into cored aluminum hole or weld nut M5 Fasteners Torque 6 2 N m 55 in lb into new holes 4 0 N m 35 in lb into used holes M6 Fasteners Torque 10 7 N m 95 in lb into new holes 7 3 N m 65 in lb into used holes Blower Housing Screws into extruded hole in sheet...

Page 13: ...g Rod Piston Pin End I D 21 C 70 F New 17 015 17 023 mm 0 6699 0 6702 in Max Wear Limit 17 036 mm 0 6707 in Crankcase Governor Cross Shaft Bore I D New 8 025 8 075 mm 0 3159 0 3179 in Max Wear Limit 8 088 mm 0 3184 in Breather Cover Fastener Torque 11 3 N m 100 in lb into new holes 7 3 N m 65 in lb into used holes Oil Temperature Sensor Torque 7 3 N m 65 in lb Oil Drain Plug Torque 13 6 N m 10 ft ...

Page 14: ...CV650 ECV680 80 000 80 025 mm 3 1496 3 1506 in New ECV730 ECV740 ECV749 83 006 83 031 mm 3 2680 3 2689 in Max Wear Limit ECV630 ECV650 ECV680 80 075 mm 3 1526 in Max Wear Limit ECV730 ECV740 ECV749 83 081 mm 3 2709 in Max Out of Round 0 120 mm 0 0047 in Max Taper 0 05 mm 0 0020 in Cylinder Head Cylinder Head Fastener Torque Hex Flange Nut Torque in Two Stages first to 16 9 N m 150 in lb finally to...

Page 15: ... Coil Fastener Torque 10 2 N m 90 in lb Crankshaft Position Sensor Screw Torque 6 2 N m 55 in lb Crankshaft Position Sensor Bracket Screw Torque 7 3 N m 65 in lb Crankshaft Position Sensor Air Gap 0 2 0 7 mm 0 008 0 027 in Electronic Control Unit Screw Torque 6 2 N m 55 in lb Intake Manifold Intake Manifold Mounting Fastener Torque Torque in Two Stages first to 7 8 N m 69 in lb finally to 10 5 N m...

Page 16: ...ECV650 ECV680 0 080 mm 0 0315 in Used Bore Max ECV730 ECV740 ECV749 0 094 mm 0 0370 in Piston Thrust Face O D ECV630 ECV650 ECV680 79 962 79 980 mm 3 1481 3 1488 in ECV730 ECV740 ECV749 82 949 82 967 mm 3 2657 3 2664 in Max Wear Limit ECV630 ECV650 ECV680 79 831 mm 3 1430 in Max Wear Limit ECV730 ECV740 ECV749 82 818 mm 3 2606 in Piston Thrust Face to Cylinder Bore Running Clearance New ECV630 ECV...

Page 17: ...earance 0 011 0 048 mm 0 0004 0 0019 in Intake Valve Stem to Valve Guide Running Clearance 0 040 0 078 mm 0 0016 0 0031 in Exhaust Valve Stem to Valve Guide Running Clearance 0 052 0 090 mm 0 0020 0 0035 in Intake Valve Guide I D New 7 040 7 060 mm 0 2772 0 2780 in Max Wear Limit 7 134 mm 0 2809 in Exhaust Valve Guide I D New 7 040 7 060 mm 0 2772 0 2780 in Max Wear Limit 7 159 mm 0 2819 in Valve ...

Page 18: ...8 M5 2 5 22 3 2 28 5 8 51 8 1 72 9 7 86 4 0 35 M6 4 3 38 5 7 50 9 9 88 14 0 124 16 5 146 6 8 60 M8 10 5 93 13 6 120 24 4 216 33 9 300 40 7 360 17 0 150 Tightening Torque N m ft lb or 10 Property Class Noncritical Fasteners Into Aluminum M10 21 7 16 27 1 20 47 5 35 66 4 49 81 4 60 33 9 25 M12 36 6 27 47 5 35 82 7 61 116 6 86 139 7 103 61 0 45 M14 58 3 43 76 4 55 131 5 97 184 4 136 219 7 162 94 9 70...

Page 19: ... 67 8 50 3 8 24 54 2 40 81 4 60 7 16 14 47 5 35 74 6 55 108 5 80 7 16 20 61 0 45 101 7 75 142 4 105 1 2 13 67 8 50 108 5 80 155 9 115 1 2 20 94 9 70 142 4 105 223 7 165 9 16 12 101 7 75 169 5 125 237 3 175 9 16 18 135 6 100 223 7 165 311 9 230 5 8 11 149 2 110 244 1 180 352 6 260 5 8 18 189 8 140 311 9 230 447 5 330 3 4 10 199 3 150 332 2 245 474 6 350 3 4 16 271 2 200 440 7 325 637 3 470 Tighteni...

Page 20: ...1 16 Section 1 Safety and General Information ...

Page 21: ...gn Technology Inc DTI 019 DTI 021 DTI 023 DTI 035 DTI 027 DTI 029 DTI 037 Flywheel Holding Tool CS Series SE Tools KLR 82407 Flywheel Puller To remove flywheel from engine SE Tools KLR 82408 Flywheel Strap Wrench To hold flywheel during removal SE Tools KLR 82409 Section 2 Tools Aids Certain quality tools are designed to help you perform specific disassembly repair and reassembly procedures By usi...

Page 22: ...sed to test rectifier regulators Kohler 25 761 20 S Kohler 25 761 41 S Individual Components Available CS PRO Regulator Test Harness Special Regulator Test Harness with Diode Design Technology Inc DTI 031 DTI 033 Spark Advance Module SAM Tester To test the SAM ASAM and DSAM on engines with SMART SPARK Kohler 25 761 40 S Starter Servicing Kit All Starters To remove and reinstall drive retaining rin...

Page 23: ... 52 357 01 S Electric Starter Drive Lubricant Solenoid Shift Kohler 52 357 02 S RTV Silicone Sealant Loctite 5900 Heavy Body in 4 oz aerosol dispenser Only oxime based oil resistant RTV sealants such as those listed are approved for use Loctite Nos 5900 or 5910 are recommended for best sealing characteristics Loctite 5910 Loctite Ultra Black 598 Loctite Ultra Blue 587 Loctite Ultra Copper 5920 Koh...

Page 24: ...er Figure 2 1 Flywheel Holding Tool Rocker Arm Crankshaft Tool A spanner wrench to lift the rocker arms or turn the 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 the rod cap 2 Remove the studs of a Posi Lock rod or grind off the aligning steps of a Command rod so the joint surface is flat 3 Find a 1 in long cap...

Page 25: ...mp malfunction or oil in vacuum hose 9 Vacuum hose to fuel pump leaking or cracked 10 Blown fuse 11 Insufficient voltage to electronic control unit Engine Starts Hard 1 PTO drive is engaged 2 Dirt or water in the fuel system 3 Clogged fuel line or fuel filter 4 Loose or faulty wires or connections 5 Faulty spark plugs 6 Low compression 7 Weak spark 8 Fuel pump malfunction causing lack of fuel 9 Engi...

Page 26: ...ous fuel and oil leaks and damaged components Excessive oil leakage can indicate a clogged or improperly assembled breather worn damaged seals and gaskets or loose or improperly torqued fasteners Check the air cleaner cover and base for damage or indications of improper fit and seal Check the air cleaner element Look for holes tears cracked or damaged sealing surfaces or other damage that could al...

Page 27: ...he engine To test the crankcase vacuum with the Vacuum Pressure Gauge Kit 1 Remove the dipstick or oil fill plug cap 2 Install the adapter into the oil fill dipstick tube opening 3 Push the barbed fitting on the gauge solidly into the hole in the adapter 4 Start the engine and bring it up to operating speed 3200 3600 RPM 5 Check the reading on the gauge If the reading is to the left of 0 on the ga...

Page 28: ...et on the flywheel nut screw to hold it in position An assistant may be needed to hold the breaker bar during testing If the engine is mounted in a piece of equipment it may be possible to hold it by clamping or wedging a driven component Just be certain that the engine cannot rotate off of TDC in either direction 4 Install the adapter into the spark plug hole but do not attach it to the tester at ...

Page 29: ...igure 4 1 Heavy Duty Air Cleaner 2 Check and clean the inlet screen Pull the paper element out of the housing on the opposite side See Figures 4 2 and 4 3 Figure 4 2 Removing Elements Figure 4 3 Accessing Inlet Screen This engine is equipped with a heavy duty air cleaner low profile air cleaner or special air cleaner supplied by the equipment manufacturer Service Weekly and every 150 hours Check f...

Page 30: ...d make sure ejector area is clean See Figure 4 4 Replace any damaged components Figure 4 4 Ejector Area 6 Install the new inner element followed by the paper element Slide each fully into place in the air cleaner housing 7 Reinstall the end caps and secure with the retaining clips See Figure 4 1 Removal 1 Remove the three hex flange nuts securing the assembly to the throttle body See Figure 4 5 Fi...

Page 31: ...ure Precleaner Service If so equipped wash and reoil the precleaner every 25 hours of operation more often under extremely dusty or dirty conditions To service the precleaner see Figures 4 7 4 8 and 4 9 and perform the following steps Figure 4 9 Base Plate Removal on Low Profile Air Cleaner 1 Loosen the cover retaining knob and remove the cover 2 Remove the foam precleaner from the paper air clean...

Page 32: ...htly to the throttle body and not cracked or damaged NOTE Damaged worn or loose air cleaner components can allow unfiltered air into the engine causing premature wear and failure Tighten or replace all loose or damaged components Disassembly Reassembly Low Profile If the base plate on the low profile air cleaner has to be removed proceed as follows 1 Remove the air cleaner components from the base...

Page 33: ...es 5 8 5 10 Engine Oil Temperature Sensor 5 10 5 11 Intake Air Temperature Sensor 5 11 Oxygen Sensor 5 12 5 14 Manifold Absolute Pressure MAP Sensor 5 15 Fuel Injectors 5 15 5 18 Ignition System 5 18 5 19 Spark Plugs 5 19 Battery Charging System 5 19 Fuel Components Fuel Pump 5 19 5 21 Fuel Filter 5 21 High Pressure Fuel Line 5 21 5 22 Purge Port and Vent Hose Assembly 5 22 Throttle Body Intake Ma...

Page 34: ...Fuel Line The EFI fuel system remains under high pressure even when the engine is stopped Before attempting to service any part of the fuel system the pressure must be relieved by following Fuel Pump Module Fuel Connector Removal instructions below Fuel Pump Module Fuel Connector Removal Wrap a shop towel completely around the fuel pump module connector Press the release button s and slowly pull t...

Page 35: ...amount of unused oxygen in the exhaust indicating whether the fuel mixture being delivered is rich or lean Based upon this feedback the ECU further adjusts fuel input to re establish the ideal air fuel ratio This operating mode is referred to as closed loop operation The EFI system operates closed loop when all three of the following conditions are met a The oil temperature is greater than 60 C 14...

Page 36: ...4500 is exceeded the ECU suppresses the injection signals cutting off the fuel flow This process repeats itself in rapid succession limiting operation to the preset maximum Service Never attempt to disassemble the ECU It is sealed to prevent damage to internal components Warranty is void if the case is opened or tampered with in any way All operating and control functions within the ECU are preset ...

Page 37: ...n of voltage sensitive components such as the ECU fuel pump ignition coils and injectors will be intermittent or disrupted causing erratic operation or hard 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 ope...

Page 38: ... Ignition Coil 1 Ground 2 Battery Ground 3 Diagnostic Communication Line 4 Speed Sensor input 5 Fuel Injector Output 1 Ground 6 Fuel Injector Output 2 Ground 7 Oxygen Sensor Heater 8 Intake Air Temperature IAT sensor input 9 Fuel Pump Ground 10 Ground for IAT TPS MAP O2 and Oil Sensors 11 Manifold Absolute Pressure MAP sensor input 12 Throttle Position Sensor TPS input 13 Speed Sensor Ground 14 Oi...

Page 39: ...MIL 1 9 10 18 1 9 10 18 RED WHITE WHITE BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK BLACK RED WHITE RED BLACK GREY GREY PURPLE PURPLE PURPLE PURPLE TAN TAN DARK BLUE DARK BLUE DARK BLUE DARK BLUE DARK GREEN DARK GREEN DARK GREEN DARK GREEN YELLOW PINK LIGHT GREEN RED BLACK RED BLACK RED BLACK RED BLACK RED BLACK RED BLACK 3 1 2 6 4 5 Stator Rectifier Regulator Starter Motor RED RED 10A F...

Page 40: ...p of the sensor It must be 0 20 0 70 mm 0 008 0 027 in 2 Inspect the wiring and connections for damage or problems 3 Make sure the engine has resistor type spark plugs 4 Disconnect the Black connector from the ECU 5 Connect an ohmmeter between the 4 and 13 pin terminals A resistance value of 325 395 at room temperature 20 C 68 F should be obtained If resistance is correct check the mounting air ga...

Page 41: ...re integrating the new sensor to the ECU Throttle Position Between Terminal Resistance Value Ω Continuity Closed A C 1400 1800 Yes Full with Stop Pin A C 3200 4100 Yes Full without Stop Pin A C 4600 5200 Yes Any A B 3000 7000 Yes Figure 5 5 TPS Location Service The TPS is a sealed non serviceable assembly If diagnosis indicates a bad sensor complete replacement is necessary If a blink code indicat...

Page 42: ...erform ECU Reset again 4 Adjust idle speed down to 1500 RPM Allow engine to dwell at 1500 RPM for about 3 seconds 5 After this adjust the idle speed to the final specified speed setting 6 Turn the key OFF and count to 10 seconds Learn is complete and the engine is ready for operation Engine Oil Temperature Sensor Figure 5 7 Engine Oil Temperature Sensor General The engine oil temperature sensor Fi...

Page 43: ... 3900 5 Unplug the sensor from the wire harness and check the sensor resistance separately across the two pins Resistance value should again be 3100 3900 a If the resistance is out of specifications replace the temperature sensor b If it is within specifications proceed to Step 6 6 Check the circuits input ground from the main harness connector to the sensor plug for continuity damage etc Connect ...

Page 44: ...Element and Heater 3 Lower Insulator 4 Stainless Steel Housing 5 Upper Insulator 6 Terminal Connection to Element 7 High Temp Water Seal Pin B Pin A Oxygen Sensor Service The temperature must be controlled very accurately and gas constituents measured to a high degree of accuracy for absolute sensor measurements Since this requires laboratory equipment it is not possible to distinguish a marginall...

Page 45: ...f this cycling is not observed a determination must be made If the problem is with the engine or the sensor 3 Check engine harness for battery voltage on the heater circuit NOTE Using the diagnostic software the wiring and ECU integrity can be checked by grounding the signal wire the output of the sensor read on the software should be around 4 mv Removal Inspection 1 If the sensor has heavy deposi...

Page 46: ... high quality fuel Engine problem misfire Correct cause of misfire Excessive rich air fuel ratio Correct air fuel ratio Wiring shorted to voltage Repair wiring Open circuit no activity from sensor Broken element Replace sensor Sensor dropped Hard blow to engine or exhaust system Defective sensor Thermal shock Slow time response Open heater circuit Replace sensor Improper handling Carbon deposits I...

Page 47: ...a series of calibrated openings which directs the fuel into the manifold in a cone shaped spray pattern Figure 5 11 Manifold Absolute Pressure Sensor and Connector General The manifold absolute pressure MAP sensor provides immediate manifold pressure information to the ECU The MAP measures the difference in pressure between the outside atmosphere and the vacuum level inside the intake manifold and ...

Page 48: ... noid light part of EFI Service Kit see Section 2 into one connector 8 2 The injectors have sequential fueling that open and close once every other crankshaft revolution The amount of fuel injected is controlled by the ECU and determined by the length of time the valve needle is held open also referred to as the injection duration or pulse width The time the injector is open milliseconds may vary ...

Page 49: ...gaskets 18 Position the manifold assembly over an appropriate container to capture fuel and turn the key switch ON to activate the fuel pump and pressurize the system Do not turn switch to START position 19 If either injector exhibits leakage of more than two to four drops per minute from the tip or shows any sign of leakage around the outer shell turn the ignition switch OFF and replace the injec...

Page 50: ... if clogging has been a problem Ignition System Figure 5 16 Ignition Coil General A high voltage solid state battery ignition system is used with the EFI system The ECU controls the ignition output and timing through transistorized control of the primary current delivered to the coils Based on input from the crankshaft position sensor the ECU determines the correct firing point for the speed at wh...

Page 51: ... Connect an ohmmeter set on the Rx10K scale between the spark plug boot terminal and the B primary terminal Secondary resistance should be 6400 7800 4 If the secondary resistance is not within the specified range the coil is faulty and needs to be replaced NOTE If the ignition coil s are disabled and an ignition fault is registered the system will automatically disable the corresponding fuel injec...

Page 52: ...ump may be conducted 1 Relieve fuel pressure at the fuel pump module following the instructions on page 5 2 The fuel pump module may need to be loosened or pulled away from the engine Disconnect the fuel coupler from the fuel pump module and insert the pressure test jumper from Kohler EFI Service Kit between the high pressure fuel line and the fuel pump module 2 Connect the black hose of Pressure ...

Page 53: ...en the pump terminals replace the fuel pump b If the voltage was below 7 test the wiring harness 7 If voltage at the plug was good and there was continuity across the pump terminals reconnect the plug to the pump making sure you have a good connection Turn on the key switch and listen for the pump to activate a If the pump starts repeat steps 2 and 3 to verify correct pressure b If the pump still ...

Page 54: ...high pressure fuel line is mounted to the intake manifold No specific servicing is required unless operating conditions indicate that it needs replacement It can be detached by removing the two mounting screws wire ties and the injector retaining clips Thoroughly clean the area around all joints and relieve any pressure before starting any disassembly by following the instruction on page 5 2 Purge...

Page 55: ...acturer See Figure 5 23 4 If the idle speed is adjusted up over 1800 RPM you must first decrease idle RPM to 1500 RPM and then up to final idle speed setting for the TPS to be properly learned by the ECU 5 The idle speed adjustment can affect the high idle speed setting Move the throttle control to the full throttle position and check the high idle speed Adjust as necessary to 3750 RPM or the speed...

Page 56: ... the governor arm has not twisted up or down after the nut has been tightened Figure 5 27 Checking Split of Clamp 2 Follow the instructions in Step 2 of Checking the Initial Adjustment then reattach the throttle linkage to the governor lever with the bushing clip It is not necessary to reattach the damper or governor springs at this time Figure 5 28 Adjusting Governor Shaft 4 Verify that the gover...

Page 57: ...emperature sensor 6 Faulty injectors Engine misses hesitates or stalls under load 1 Fuel injector s fuel filter fuel line or fuel pick up dirty restricted 2 Dirty air cleaner 3 Insufficient fuel pressure or fuel delivery 4 Vacuum intake air leak 5 Improper governor setting adjustment or operation 6 TPS faulty mounting problem or TPS Learn Procedure incorrect 7 Bad coil s spark plug s or wires Low Po...

Page 58: ...ing and dealer service is required Upon receipt the dealer technician can access the fault code s to help determine what portion of the system is malfunctioning The 4 digit fault codes available are listed on page 5 28 The codes are accessed through the key switch and displayed as blinks or flashes of the MIL Access the codes as follows 1 Check that the battery voltage is above 11 volts 2 Start wi...

Page 59: ...dded easily for quick diagnostics The main engine to vehicle connection will have a tan wire which is the ground for the MIL Either incandescent or LED type bulbs can be used for the MIL as long as they do not draw more than 0 1 amps The bulb needs to be rated at 1 4 Watts or less or needs to have a total resistance of 140 Ω or more LEDs typically draw less than 0 03 amps Attach 12 volts to the po...

Page 60: ...age or Open 0122 Throttle Position Sensor Circuit Low Voltage or Open 0123 Throttle Position Sensor Circuit High Voltage 0131 Oxygen Sensor 1 Circuit Low Voltage or Open 0132 Oxygen Sensor 1 Circuit High Voltage 0171 Maximum Adaptation Limit Exceeded 0172 Minimum Adaptation Limit Exceeded 0174 Lean Fuel Condition at High Load Open Loop 0201 Injector 1 Circuit Malfunction 0202 Injector 2 Circuit Ma...

Page 61: ...ness and connectors loose damaged or corroded c Pin circuit wiring or connectors at Black 10 11 and 16 3 Bad TPS Learn Code 0108 Component Manifold Absolute Pressure Sensor Fault MAP Circuit High Voltage Condition Intake manifold leak shorted connection or faulty sensor Possible Causes 1 MAP Sensor Related a Sensor malfunction b Vacuum leaks from loose manifold or sensor 2 Wire Harness Related a P...

Page 62: ...orted wire in harness 1 ECU Black pin 10 to TPS pin 1 2 ECU Black pin 12 to TPS pin 3 3 ECU Black pin 16 to TPS pin 2 3 Throttle Body Related a Throttle shaft inside TPS worn broken or damaged b Throttle plate loose or misaligned c Throttle plate bent or damaged allowing extra airflow past or restricting movement 4 ECU Related a Circuit providing voltage or ground to TPS damaged b TPS signal input...

Page 63: ...voltage between sensed voltage and actual sensor voltage b Problem in wiring harness c ECU to harness connection problem 4 Systems Related a Ignition spark plug plug wire ignition coil b Fuel fuel type quality injector fuel pressure too low fuel pump module or lift pump c Combustion air air cleaner dirty restricted intake leak throttle bores d Base engine problem rings valves e Exhaust system leak...

Page 64: ...or Related a Injector coil shorted or opened 2 Engine Wiring Harness Related a Broken or shorted wire in harness ECU pin Black 5 b Wiring from Ignition 3 ECU Related a Circuit controlling injector 1 damaged Code 0202 Component Fuel Injector Fault Injector 2 Circuit Malfunction Condition Injector damaged or faulty shorted or open connection Possible Causes 1 Injector Related a Injector coil shorted...

Page 65: ...in circuit wiring or connectors ECU pin Black 4 or Black 13 b ECU to harness connection problem 4 If code is stored in fault history and starts normally Clear code no other service required Code 0351 Component Ignition Coil Fault Cylinder 1 Ignition Coil Malfunction Condition Broken wire in harness may not be visible shorted connection or faulty sensor Possible Causes 1 Engine Wiring Harness Relat...

Page 66: ...ry Code 61 Fault End of Code Transmission Troubleshooting Flow Chart The following flow chart provides an alternative method of troubleshooting the EFI system The chart will enable you to review the entire system in about 10 15 minutes Using the chart the accompanying diagnostic aids listed after the chart and any signaled fault codes you should be able to quickly locate any problems within the sy...

Page 67: ...IAGNOSTIC AID 2 FAULT CODES 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 ...

Page 68: ...daptation limit exceeded Code 0172 Minimum adaptation limit exceeded Code 0174 Lean fuel condition at high load or open loop Code 0201 Injector 1 Circuit Malfunction Code 0202 Injector 2 Circuit Malfunction Code 0230 Fuel Pump Module Circuit Low Voltage or Open Code 0232 Fuel Pump Module Circuit High Voltage Code 0336 Crankshaft Position Sensor Noisy Signal Code 0337 Crankshaft Position Sensor No ...

Page 69: ...s 8 ECU 9 Lift pump not working Diagnostic Aid 8 FUEL SYSTEM fuel pressure Possible causes for low fuel system pressure 1 Low fuel 2 Fuel filter plugged 3 Fuel supply line plugged 4 Lift fuel pump insufficient fuel supply 5 Fuel pump lift or module internally plugged Possible causes for high fuel system pressure 1 Pressure regulator not functioning properly inside fuel pump module Diagnostic Aid 9 B...

Page 70: ...5 38 Section 5 EFI Fuel System ...

Page 71: ... SJ or higher Select the viscosity based on the air temperature at the time of operation as shown in the following table Figure 6 2 Oil Container Logo The top position of the symbol shows service class such as API SERVICE CLASS SJ The symbol may show additional categories such as SH SG CC or CD The center portion shows the viscosity grade such as SAE 10W 30 If the bottom portion shows Energy Conse...

Page 72: ...re 6 3 5 If the level is low add oil of the proper type Refer to Oil Recommendations on page 6 1 and to the correct level Always check the level before adding more oil NOTE To prevent extensive engine wear or damage always maintain the oil level within the Operating Range 6 Reinstall the oil fill cap dipstick and tighten on oil fill tube Oil Disposal Protect and respect the environment Dispose of ...

Page 73: ...ace a new replacement filter in a shallow pan with the open end up Pour new oil of the proper type in through the threaded center hole Stop pouring when the oil reaches the bottom of the threads Allow a minute or two for the oil to be absorbed by the filter material 5 Apply a thin film of clean oil to the rubber gasket on the new filter 6 Install the new oil filter to the filter adapter or oil coo...

Page 74: ...lead to switch terminal Testing the Switch Compressed air a pressure regulator pressure gauge and a continuity tester are required to test the switch Normally Closed Switch 1 Connect the continuity tester across the blade terminal and the metal case of the switch With 0 psi pressure applied to the switch the tester should indicate continuity switch closed 2 Gradually increase the pressure to the s...

Page 75: ...ration Check their condition and either reset the gap or replace with new plugs as necessary To service the plugs perform the following steps 1 Before removing a spark plug clean the area around the base of the plug to keep dirt and debris out of the engine 2 Remove the plug and check its condition See Inspection following this procedure Replace the plug if necessary NOTE Do not clean spark plugs ...

Page 76: ...e will be rounded and the gap will be greater than the specified gap Replace a worn spark plug immediately Wet Fouled A wet plug is caused by excess fuel or oil in the combustion chamber Excess fuel could be caused by a restricted air cleaner or rich air fuel ratio Oil in the combustion chamber is usually caused by a restricted air cleaner a breather problem or worn piston rings cylinder walls or ...

Page 77: ...re disconnecting the negative ground cable make sure all switches are OFF If ON a spark will occur at the ground cable terminal which could cause an explosion if hydrogen gas or gasoline vapors are present 1 Regularly check the level of electrolyte Add distilled water as necessary to maintain the recommended level NOTE Do not overfill the battery Poor performance or early failure due to loss of el...

Page 78: ...any electric welding on the equipment powered by the engine Also disconnect all other electrical accessories in common ground with the engine Prevent the stator AC leads from touching or shorting while the engine is running This could damage the stator Stator The stator is mounted on the crankcase behind the flywheel Follow the procedures in Section 8 Disassembly and Section 10 Reassembly if stato...

Page 79: ...egulator mounted or loose The figures show the part removed from the engine for clarity Repeat the applicable test procedure two or three times to determine the condition of the part 1 Connect the tester ground lead with spring clamp to the body of the rectifier regulator 2 Connect the red lead from the tester to the middle terminal labeled B 3 Connect the two black leads from the tester to both o...

Page 80: ...n alternative connect a jumper lead from rectifier regulator housing to the battery ground and retest charging voltage If charge voltage measures 13 7 14 7 volts the charging system is functioning If resistance is greater than 1 ohm or charge voltage is less than 13 7 then re establish ground between the ground strap and mounting screw If voltage is less than 13 8 or charge rate does not increase ...

Page 81: ...t start allow a 60 second cool down period between starting attempts Failure to follow these guidelines can burn out the starter motor NOTE If the starter cranks the engine but does not start the engine the engine rotation must be allowed to come to a complete stop before attempting to restart the engine again If the starter is engaged while the flywheel is rotating the starter pinion and flywheel...

Page 82: ...ck the specific gravity of battery If low recharge or replace battery as necessary Wiring 1 Clean corroded connections and tighten loose connections 2 Replace wires in poor condition and with frayed or broken insulation Starter Switch or Solenoid 1 By pass the switch or solenoid with a jumper wire If starter cranks normally replace the faulty components Solenoid Shift Starters Perform individual s...

Page 83: ... starter solenoid on pages 7 16 and 7 17 Torx Head Screws Figure 7 11 Solenoid Removed from Starter 3 Remove the two thru larger bolts See Figure 7 12 Figure 7 12 Removing Thru Bolts 4 Remove the commutator end plate assembly containing the brush holder brushes springs and locking caps Remove the thrust washer from inside the commutator end See Figure 7 13 Figure 7 13 Removing Commutator End Plate...

Page 84: ...e the rubber grommet and backing plate from the end cap See Figure 7 15 Figure 7 15 Rubber Grommet and Bushing Plate 7 Take out the drive lever and pull the armature out of the drive end cap See Figure 7 16 8 Remove the thrust washer from the armature shaft See Figure 7 16 Figure 7 18 Removing Retaining Ring 11 Remove the drive pinion assembly from the armature 12 Clean the parts as required NOTE ...

Page 85: ...hes Armature 1 Clean and inspect the commutator outer surface The mica insulation must be lower than the commutator bars undercut to ensure proper operation of the commutator See Figure 7 20 Figure 7 20 Commutator Mica Inspection 2 Use an ohmmeter set to the Rx1 scale Touch the probes between two different segments of the commutator and check for continuity See Figure 7 21 Test all the segments Con...

Page 86: ... assembly See Figure 7 24 a Install the stop collar down onto the armature shaft with the counter bore recess up b Install a new retainer in the larger rear groove of the armature shaft Squeeze with a pliers to compress it in the groove c Slide the stop collar up and lock it into place so the recess surrounds the retainer in the groove If necessary rotate the pinion outward on the armature splines...

Page 87: ...backup washer See Figure 7 26 Figure 7 26 Installing Armature and Pivot Lever Figure 7 27 Installing Backing Plate and Grommet 8 Install the frame with the small notch forward onto the armature and drive end cap Align the notch with the corresponding section in the rubber grommet Install the drain tube in the rear cutout if it was removed previously See Figure 7 28 7 Install the backing plate foll...

Page 88: ...D of the brush holder assembly Insert the Brush Installation Tool with extension or use the tube described above from a prior brush installation through the brush holder assembly so the holes in the metal mounting clips are up out c Install the brush springs and snap on the four retainer caps See Figure 7 32 Figure 7 30 Installing Brush Holder Assembly with Supplied Tube Starter reassembly when no...

Page 89: ...nting screws to 2 5 3 3 N m 22 29 in lb See Figures 7 34 and 7 35 Figure 7 35 Torquing Brush Holder Screws 13 Hook the plunger behind the upper end of the drive lever and install the spring into the solenoid Insert the three mounting screws through the holes in the drive end cap Use these to hold the solenoid gasket in position then mount the solenoid Torque the screws to 4 0 6 0 N m 35 53 in lb 1...

Page 90: ...herwise occur Figure 7 37 Testing Pull In Coil Plunger Actuation Test 2 Solenoid Pull In Coil Contact Continuity Use an ohmmeter set to the audible or Rx2K scale and connect the two ohmmeter leads to the two large post terminals Perform the preceding test 1 and check for continuity See Figure 7 38 The ohmmeter should indicate continuity if no continuity is indicated the solenoid should be replaced...

Page 91: ...eter leads to the two large post terminals Perform the preceding test 3 and check for continuity See Figure 7 40 The meter should indicate continuity if no continuity is indicated the solenoid should be replaced Repeat test several times to confirm condition Figure 7 40 Testing Hold In Coil Solenoid Contact Continuity Plunger Pushed In VOM Meter Leads 12 volt Test Leads ...

Page 92: ...7 18 Section 7 Electrical System and Components ...

Page 93: ...ried to accommodate options or special equipment 1 Disconnect spark plug leads 2 Shut off fuel supply 3 Drain oil from crankcase and remove oil filter 4 Remove oil cooler 5 Remove muffler 6 Remove air cleaner assembly 7 Remove throttle control panel 8 Remove external governor controls 9 Remove lift fuel pump and fuel pump module 10 Remove throttle body 11 Remove electronic control unit 12 Remove elec...

Page 94: ...tem and attaching hardware from the engine On engines equipped with a port liner remove it now Remove Air Cleaner Assembly Heavy Duty Air Cleaner 1 Remove the hex flange nuts securing the air cleaner to the mounting studs See Figure 8 5 Figure 8 3 Removing Oil Fill Tube Bracket Figure 8 4 Removing Oil Filter 2 Allow ample time for the oil to drain from the crankcase and oil filter 3 Remove the mou...

Page 95: ...igure 8 8 Remove Top Mount Control Panel 1 Remove the throttle control shaft nut on top of the throttle shaft and remove the throttle control lever and spring See Figure 8 9 2 Remove the two screws fastening the control panel and remove the panel from the blower housing See Figure 8 9 3 Remove the lower throttle control bracket from the cylinder head Hex Flange Nuts Lower Bracket Screws Figure 8 9...

Page 96: ...utlet to Fuel to Fuel Pump Pump Module Module Inlet Hose Inlet Hose Pulse Pulse Pump Pump WARNING Explosive Fuel can cause fires and severe burns Do not fill the fuel tank while the engine is hot or running Explosive Fuel Gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only in approved containers in well ventilated unoccupied buildings away from sparks or flame...

Page 97: ...orb any residual fuel in the high pressure fuel line Any spilled fuel must be completely wiped up immediately See Figure 8 15 NOTE Figure 8 15 depicts removing the connector without a shop towel wrapped around it for instructional purposes only Release Buttons Figure 8 17 Disconnect Intake Air Temperature Sensor 2 Disconnect the breather tube See Figure 8 18 Vent Fitting Slide Locking Tab 6 Using ...

Page 98: ...ose from beneath the throttle body See Figure 8 20 Figure 8 20 Disconnect the Vent Hose Figure 8 22 Remove ECU Screws 2 Disconnect the Black and Grey electrical connectors from the ECU See Figure 8 23 Figure 8 18 Disconnect Breather Tube 3 Disconnect the throttle position sensor connector See Figure 8 19 Figure 8 21 Remove Air Cleaner Bracket Screws Remove the Electronic Control Unit ECU 1 Remove ...

Page 99: ...re 8 25 Figure 8 25 Remove Oil Separator Assembly Remove Grass Screen 1 Remove the four socket head cap screws securing the metal grass screen and remove the screen See Figure 8 26 Figure 8 26 Remove Grass Screen 2 Remove the four spacers paying attention to the curvature of the spring washers between the spacers and the fan NOTE The fan will be loose but cannot be removed until after the blower h...

Page 100: ... engines may have two fuses mounted to a bracket above the ECU and a third in line fuse near the rectifier regulator 4 Remove the three each side hex flange screws securing the outer baffles Note the location of any lifting strap and the position of the two short screws one each side on bottom for reassembly See Figure 8 30 The coil and any hoses may remain attached to the baffle after being unplugged...

Page 101: ...er 1 Remove the four hex flange screws securing the inner baffles to the crankcase 2 Remove the inner valley baffles See Figure 8 33 Figure 8 34 Remove the Oil Temperature Sensor 4 Remove the two remaining hex flange screws from the breather cover See Figure 8 35 Figure 8 33 Removing Inner Baffles 3 Disconnect and remove the oil temperature sensor See Figure 8 34 NOTE This is optional Removing the oil...

Page 102: ...breather cover with a screwdriver to break the gasket seal See Figure 8 35 Do not pry on the sealing surfaces as it could cause damage resulting in leaks 6 Remove the breather cover and gasket See Figure 8 36 Figure 8 36 Removing Breather Cover Gasket Remove Valve Covers 1 Remove the four hex flange screws securing each valve cover Note valve cover differences for proper location in reassembly Ensu...

Page 103: ...ve MAP Screw Remove Fuel Injectors 1 Disconnect the electrical connector See Figure 8 42 Figure 8 42 Remove Connector 2 Remove the hex flange screw and pull the injector out of the intake manifold for each injector See Figure 8 43 2 Detach the connector 3 Remove the hex flange screw and pull the MAP sensor out of the intake manifold See Figure 8 41 Figure 8 44 Remove Retaining Clip Remove Intake M...

Page 104: ...ing Intake Manifold 5 Leave the wiring harness attached to the manifold Remove Spark Plugs 1 Remove the spark plug from each cylinder head See Figure 8 49 Figure 8 49 Removing Spark Plugs Remove Cylinder Heads and Hydraulic Lifters NOTE Cylinder heads are retained using either hex flange screws or hex flange nuts and washers on studs Do not interchange or mix components 1 Remove the four hex flang...

Page 105: ...Use a hydraulic lifter tool Do not use a magnet to remove lifters Mark the lifters by location as either intake or exhaust and cylinder 1 or 2 Hydraulic lifters should always be reinstalled in the same position See Figure 8 52 and 8 53 Hydraulic Lifter Tool Figure 8 52 Removing Hydraulic Lifters Figure 8 54 Removing Rocker Arm 2 Compress the valve springs using a valve spring compressor See Figure...

Page 106: ...hen loosening or tightening the flywheel screw Do not use any type of bar or wedge to hold the flywheel Use of such tools could cause the flywheel to become cracked or damaged Figure 8 55 Removing Valves with Valve Spring Compressor 3 Once the valve spring is compressed remove the valve spring keepers then remove the following items See Figures 8 56 and 8 57 Valve spring retainers Valve springs Va...

Page 107: ...asteners 2 Locate the splitting tab cast into the perimeter of the oil pan Insert the drive end of a 1 2 in breaker bar between the splitting tab and the crankcase and turn it to loosen seal See Figure 8 62 Do not pry on the sealing surfaces as this can cause leaks Tap with a rubber mallet to finish removing the oil pan Remove the oil seal and replace at reassembly Governor Gear Assembly The gover...

Page 108: ... and piston for reassembly Do not mix end caps and connecting rods Figure 8 65 Removing Governor Cross Shaft Remove Connecting Rods with Pistons and Rings 1 Remove the two hex flange screws securing the closest connecting rod end cap Remove the end cap See Figure 8 66 Remove Camshaft 1 Remove the camshaft and shim if used See Figure 8 63 Figure 8 63 Removing Camshaft Remove Governor Cross Shaft 1 ...

Page 109: ...on pin from piston for inspection Use a small screwdriver to pry the pin retainer out of the groove See Figure 8 68 Figure 8 68 Remove Piston Pin Remove Crankshaft 1 Carefully pull the crankshaft from the crankcase See Figure 8 69 Figure 8 69 Removing Crankshaft Remove Flywheel End Oil Seal 1 Remove the oil seal from the crankcase See Figure 8 70 Figure 8 70 Removing Oil Seal ...

Page 110: ...8 18 Section 8 Disassembly ...

Page 111: ...ations The measurement must be performed while the valve train is still assembled Inspect the cam gear for badly worn chipped or missing teeth Replacement of the camshaft will be necessary if any of these conditions exist Crankshaft Inspection and Service Inspect the gear teeth of the crankshaft If the teeth are badly worn chipped or some are missing replacement of the crankshaft will be necessary...

Page 112: ...ll presses the use of a low speed drill press is preferred as it facilitates more accurate alignment of the bore in relation to the crankshaft crossbore Honing is best accomplished at a drill speed of about 250 RPM and 60 strokes per minute After installing coarse stones in hone proceed as follows 1 Lower hone into bore and after centering adjust so that the stones are in contact with the cylinder...

Page 113: ...measurements should be taken perpendicular to each other at each of the three locations Clean Cylinder Bore After Honing Proper cleaning of the cylinder walls following boring and or honing is very critical to a successful overhaul Machining grit left in the cylinder bore can destroy an engine in less than one hour of operation after a rebuild NOTE Kohler pistons are custom machined to exacting to...

Page 114: ...a serviceable part Replace the flywheel if the ring gear is damaged Cylinder Head and Valves Inspection and Service After cleaning check the flatness of the cylinder head and the corresponding top surface of the crankcase using a surface plate or piece of glass and feeler gauge as shown in Figure 9 5 The maximum allowable out of flatness is 0 076 mm 0 003 in EXHAUST VALVE E G F H D D C A B A B A F...

Page 115: ...illustrations Normal Even after long hours of operation a valve can be reconditioned and reused if the face and margin are in good shape If a valve is worn to where the margin is less than 1 32 in do not reuse it The valve shown was in operation for almost 1000 hours under controlled test conditions Bad Condition The valve depicted here should be replaced Note the warped head margin damaged and to...

Page 116: ...on their condition Stem Corrosion Moisture in fuel or from condensation are the most common causes of valve stem corrosion Condensation occurs from improper preservation during storage and when engine is repeatedly stopped before it has a chance to reach normal operating temperatures Replace corroded valves Overheating An exhaust valve subject to overheating will have a dark discoloration in the a...

Page 117: ...s specified for the valve seat angle in Figure 9 6 Cutting the proper 45 valve face angle as specified in Figure 9 6 and the proper valve seat angle 44 5 half of the full 89 angle will achieve the desired 0 5 1 0 full cut interference angle where the maximum pressure occurs on the outside diameters of the valve face and seat Figure 9 7 Typical Valve Seat Cutter Lapping Valves Reground or new valve...

Page 118: ...ive material such as carbon dirt or pieces of hard metal Detonation damage occurs when a portion of the fuel charge ignites spontaneously from heat and pressure shortly after ignition This creates two flame fronts which meet and explode to create extreme hammering pressures on a specific area of the piston Detonation generally occurs from using low octane fuels Preignition or ignition of the fuel ...

Page 119: ...ling pistons Never use old rings Some important points to remember when servicing piston rings 1 The cylinder bore must be deglazed before service ring sets are used 2 If the cylinder bore does not need reboring and if the old piston is within wear limits and free of score or scuff marks the old piston may be reused 3 Remove the old rings and clean up the grooves Never reuse old rings 4 Before inst...

Page 120: ...the base surface of the hydraulic lifters for wear or damage If the lifters need to be replaced apply a liberal coating of Kohler lubricant see Section 2 to the base of each new lifter before it is installed Bleeding the Lifters To prevent a possible bent push rod or broken rocker arm it is important to bleed any excess oil out of the lifters before they are installed 1 Cut a 50 75 mm 2 3 in piece...

Page 121: ... pan NOTE The governor gear is held onto the shaft by small molded tabs in the gear When the gear is removed from the shaft these tabs are destroyed and the gear must be replaced Therefore remove the gear only if absolutely necessary 1 Remove the regulating pin and governor gear assembly See Figure 9 13 Figure 9 14 Governor Shaft Press Depth Figure 9 15 Removing Oil Pump 3 Remove the oil pump roto...

Page 122: ... the amount of oil in the head area and still maintain the necessary vacuum in the crankcase Oil Pump Torque Sequence Figure 9 17 Crankcase with Breather Reed A spring steel reed and stop is mounted on each bank of the crankcase between the lifter bores See Figure 9 17 When the pistons move downward air is pushed past the reeds into the cylinder head cavities On the 2 cylinder the upper end of the...

Page 123: ... Governor Cross Shaft Oil Seal If the governor cross shaft seal is damaged and or leaks replace it using the following procedure Remove the oil seal from the crankcase and replace it with a new one Install the new seal to the depth shown in Figure 9 19 using a seal installer 2 0 mm 0 0787 in Governor Cross Shaft Seal ...

Page 124: ...9 14 Section 9 Inspection and Reconditioning ...

Page 125: ...Install connecting rods with pistons and rings 4 Install governor cross shaft 5 Install camshaft 6 Install oil pan assembly 7 Install stator and backing plate 8 Install flywheel and fan 9 Install cylinder heads and hydraulic lifters 10 Install push rods and rocker arms 11 Install spark plugs 12 Install intake manifold 13 Install fuel injectors 14 Install manifold absolute pressure sensor 15 Instal...

Page 126: ...nnecting rods are assembled exactly as shown in Figure 10 4 Figure 10 5 Installing Piston Assembly Using Ring Compressor Tool 4 Install the inner rod cap to the connecting rod using the two hex flange screws Torque in increments to 11 6 N m 103 in lb Illustrated instructions are provided in the service rod package See Figure 10 6 Figure 10 4 Proper Piston Connecting Rod Orientation 1 Stagger the p...

Page 127: ...the nylon washer and push the retaining ring down the shaft to secure Remove the feeler gauge which will have established the proper end play See Figures 10 7 and 10 8 Figure 10 8 Setting Governor Cross Shaft End Play Install Camshaft 1 Liberally apply camshaft lubricant see Section 2 to each of the cam lobes Lubricate the camshaft bearing surfaces of the crankcase and camshaft with engine oil See...

Page 128: ...10 11 and 10 12 Figure 10 12 Oil Seal Depth in Oil Pan Install Oil Pan Assembly Most engines use an oil pan gasket Optionally RTV sealant is used as a gasket between the oil pan and the crankcase When assembling the oil pan only use a gasket if a gasket was removed Likewise if RTV was used only replace with RTV Do Not use both Refer to Section 2 for a listing of approved sealants Always use fresh ...

Page 129: ...alent to the number 10 oil pan screw as required See Figure 10 15 Figure 10 15 Torquing Oil Pan Fasteners Install Stator and Backing Plate 1 Apply pipe sealant with Teflon Loctite 592 PST Thread Sealant or equivalent to the stator mounting holes 2 Position the stator aligning the mounting holes so that the leads are at the bottom towards the crankcase 3 Install and torque the two hex flange screws...

Page 130: ...er and flywheel hub are clean dry and completely free of any lubricants The presence of lubricants can cause the flywheel to be over stressed and damaged when the hex flange screw is torqued to specifications See Figures 10 19 and 10 20 Figure 10 19 Clean and Dry Taper of Crankshaft Figure 10 17 Route Stator Leads in Groove Figure 10 20 Clean and Dry Flywheel Hub 1 Install the woodruff key into the...

Page 131: ...on the back of the fan into the locating holes of the flywheel See Figure 10 23 2 Torque the screws to 9 9 N m 88 in lb Figure 10 23 Installing Fan Install Cylinder Heads and Hydraulic Lifters 1 See Servicing Hydraulic Lifters in Section 9 for lifter preparation bleed down procedures 2 Apply camshaft lubricant see Section 2 to the bottom surface of each lifter See Figure 10 24 Lubricate the hydrau...

Page 132: ...e is removed or if the seal is deteriorated or damaged in any way Never reuse an old seal See Figure 10 28 Figure 10 28 Valve Seal Location Assemble Cylinder Heads Prior to installation lubricate all components with engine oil paying particular attention to the lip of the valve stem seal valve stems and valve guides Install the following items in the order listed below using a valve spring compres...

Page 133: ...til the specified height from the crankcase surface is achieved See Figure 10 31 When threading in the studs use a steady tightening motion without interruption until the proper height is obtained Otherwise the frictional heat from the engaging threads may cause the locking compound to set up prematurely Figure 10 31 Installing New Mounting Studs to Specified Height The studs closest to the lifter...

Page 134: ...o 22 6 N m 200 in lb then finally to 41 8 N m 370 in lb following the sequence in Figure 10 34 1 2 Figure 10 35 Install Push Rods in Their Original Position 2 Apply grease to the contact surfaces of the rocker arms and rocker arm pivots Install the rocker arms and rocker arm pivots on one cylinder head and start the two hex flange screws 3 Torque the hex flange screws to 11 9 N m 105 in lb See Fig...

Page 135: ... operation Install Spark Plugs 1 Use new Champion or equivalent spark plugs 2 Set the gap at 0 76 mm 0 030 in Figure 10 36 Torquing Rocker Arm Screws 4 Use a spanner wrench or rocker arm lifting tool see Section 2 to lift the rocker arms and position the push rods underneath See Figure 10 37 Figure 10 38 Installing Spark Plugs Install Intake Manifold 1 Install the intake manifold and new gaskets w...

Page 136: ...lip and snap clip together Figure 10 44 Install Fuel Injector Retaining Clip 3 Press the fuel injector into the fuel injector cap until the retaining clip snaps into place 4 Press the fuel injector into the bore in the intake manifold and rotate to original position Figure 10 43 Install Wire Harness Clip Install Fuel Injectors NOTE Ensure all parts are clean undamaged and free of debris and make s...

Page 137: ...parts are clean undamaged and free of debris and make sure the electrical connectors have the seal in place 1 Install the crankshaft position sensor and bracket assembly to the crankcase posts 2 Snug the hex flange screws and check the air gap of the sensor with a feeler gauge It must be 0 20 0 70 mm 0 008 0 027 in 3 Torque the bracket screws to the crankcase to 4 0 N m 35 in lb into used holes or...

Page 138: ...ure there are no nicks or burrs on the sealing surfaces 3 Position the breather gasket and cover on the crankcase Install the first two hex flange screws in locations 3 and 4 shown in Figure 10 50 Finger tighten at this time Figure 10 50 Installing Screws Locations 3 and 4 4 Install the inner baffles using the remaining two hex flange screws see Figures 10 51 and 10 52 and finger tighten Do not torq...

Page 139: ...Sentry 2 Connect the wire lead green to the Oil Sentry terminal Install Blower Housing and Outer Baffles NOTE Do not completely tighten screws until all items are installed to allow shifting for hole alignment 1 Slide the blower housing into position over the front edge of the inner baffles See Figure 10 55 Start a few of the screws to hold it in place Figure 10 55 Installing Blower Housing 2 Positi...

Page 140: ...reather Cover Fastener Torque Sequence Install Reconnect Rectifier Regulator 1 Install the rectifier regulator in the blower housing if removed previously then secure grounding bracket against the outer side of the rectifier regulator with a silver screw See Figure 10 59 Figure 10 59 Rectifier Regulator Ground Details 2 Torque the two black rectifier regulator hex flange screws to 1 4 N m 12 6 in ...

Page 141: ...screws Apply Loctite 242 to the hex cap screw threads 7 Carefully remove two of the studs and replace with two of the hex cap screws Torque the screws to 9 9 N m 88 in lb See Figure 10 63 Repeat the procedure for the other two studs and hex cap screws Figure 10 62 Spacer Shoulder Resting on Spring Washer Figure 10 61 Spring Washer with Concave Side Down 4 Install a spacer on each stud with the ste...

Page 142: ... holes See Figure 10 69 2 Connect the Black and Grey electrical connectors The connectors and ECU are keyed in such a way so they cannot be installed incorrectly Figure 10 66 Install Oil Separator Install Electric Starter Motor and ECU Bracket 1 Install the electric starter motor using the two hex flange screws Position the ECU bracket as shown See Figure 10 67 Figure 10 65 Torque Plastic Grass Sc...

Page 143: ... 71 Install Air Cleaner Bracket 4 Connect the breather separator hose to the top of the throttle body using a pliers to compress the spring clip Route the hose through the housing by pressing the hose into the cutout of the blower housing Position abrasion sleeve as shown See Figure 10 72 5 Push the electrical connector onto the intake air temperature sensor making sure a good connection is made b...

Page 144: ...the two hex flange screws Torque the M6 screws to 7 3 N m 68 in lb in new holes or 6 2 N m 55 in lb in used holes See Figure 10 75 Figure 10 75 Reinstalled Lift Fuel Pump 3 Connect the in line 10 micron EFI fuel filter and hose to the inlet barb of the lift fuel pump and secure with the spring clamp NOTE Some applications may have two in line fuel filters In those applications connect the in line ...

Page 145: ...Push the connector onto the terminal until a click is heard then push in the grey locking tab to lock the connector See Figure 10 77 NOTE The fuel pump module pins should be coated with a thin layer of electrical grease to prevent fretting and corrosion and may be reapplied if the fuel pump module is being reused Figure 10 77 Connecting Fuel Pump Module Connector 8 Install the fuel pump module to ...

Page 146: ...vernor Lever Install Bottom Mount Control Panel If So Equipped 1 Install the bottom control panel and the air cleaner support bracket if used to the cylinder heads using the four hex flange screws Torque the screws to 10 7 N m 95 in lb into new holes or 7 3 N m 65 in lb into used holes See Figure 10 84 Figure 10 84 Bottom Mount Control Panel 2 Connect the governor spring from the throttle control ...

Page 147: ...Low Profile Air Cleaner 1 Verify O ring is present around the machined O D of the throttle body and place air cleaner base onto throttle body studs Secure the air cleaner base using three hex flange nuts Attach the air cleaner base bracket to the cylinder heads with four hex flange screws behind any control panel or bracket Attach the air cleaner base to the lower bracket with the two M5 screws th...

Page 148: ...lb 2 Verify all fuel and vent hoses are routed properly and not pinched Install the two hex flange screws to secure the oil cooler to the blower housing Torque the top screw to 2 8 N m 25 in lb and the lower screw to 2 3 N m 20 in lb See Figure 10 91 Figure 10 89 Low Profile Air Cleaner and Bracket 2 Install the air cleaner components as described in Section 4 Setting Initial Governor Adjustment 1...

Page 149: ...ons Figure 10 93 Install Oil Drain Plug s NOTE Make sure that both oil drain plugs are installed and torqued to the above specifications to prevent oil leakage Figure 10 94 Connect Spark Plug Leads Prepare the Engine for Operation The engine is now completely reassembled Before starting or operating the engine be sure to do the following 1 Make sure all hardware is tightened securely 2 Make sure t...

Page 150: ...ove the spring away from the governor lever pivot point Testing the Engine It is recommended that the engine be operated on a test stand or bench prior to installation in the piece of equipment 1 Set the engine up on a test stand Start engine inspect for leaks and check to make certain that oil pressure 20 psi or more is present Run the engine at idle for 2 3 minutes then 5 6 minutes more between ...

Page 151: ......

Page 152: ...90 02 Rev C ISSUED 5 10 REVISED 11 10 FOR SALES AND SERVICE INFORMATION IN U S AND CANADA CALL 1 800 544 2444 KohlerEngines com ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 2010 by Kohler Co All rights reserved ...

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