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PCV680, PCV740 Service Manual

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1. Dimensions in millimeters 41298 116259 29638 H i m mee ma Inch equivalents shown in 5315 96 02 26948 5 18 AIR FILTER RAIN CAP Be 110 609 Fer REMOVAL COVERASSEMBLY p f REMOVAL S 00 HM 0 d o a i 712088 d SPARK PLUG REMOVAL i a i 2 36 2 061 12065 SPARK PLUG SPARK PUG BOOT REMOVAL BOOT REMOVAL 2 22 4 0499 1080 SPARK PLUG BOOT SPARK PLUG 4956 MEy ma 7 L w MPO assy 334 4 9688 ps 113 164 assy Men SPARK SPK 72844030 9426 eun DUM TO 2 868 0 118 7 span SPARK ENGINE BOOT REMOVAL Bm pwe PC REMOVAL Removal POT REMOVAL 41798 16456 i uec 35 0135 SAFETY AIR FILTER 35 0 135 HEMENT REMOVAL 53030 20 878 PRIMARY AR FITER ELEMENT REMOVAL lt y BB sto 11788 822 OILALLADIPSTICK MOUNTING HOLE ENGINE 15 70 137 09 FLYWHEEL SIDE 0318 15397 OL FILTER REMOVAL 152 99 2 16023 1 969 EXHAUST PORT 2 15 4839 MOUNTING 1 905 HOLE D 15225 242 22 15994 19 536 MOUNTING Tm HOLE C
2. Code 0122 Code 0131 Component Throttle Position Sensor TPS Component Oxygen Sensor Fault TPS Circuit Low Voltage or Open Fault O2S 1 Circuit Low Voltage Condition Open connection broken wire or faulty Condition Open connection broken wire or faulty sensor sensor Conclusion TPS Related Conclusion Oxygen Sensor Related e TPS bad or worn internally e Sensor connector or wiring problem e Sensor contaminated corroded or Engine Wiring Harness Related damaged e Broken or shorted wire in harness e Poor ground path ECU Black pin 10 to TPS pin 1 e Pin circuit wiring or connectors ECU Black pin 12 to TPS pin 3 ECU Black pin 10 or 17 ECU Black pin 16 to TPS pin 2 TPS Learn Procedure Incorrect Throttle Body Related e Lean condition check oxygen sensor e Throttle shaft inside TPS worn broken signal with VOA and see Oxygen or damaged Sensor section e Throttle plate loose or misaligned e Throttle plate bent or damaged Engine wiring harness related such as a allowing extra airflow past or restricting cut wire broken or pinched movement Code 0132 ECU Related C tTO S e Circuit providing voltage or ground to SAPOREM SOURCE ensor TPS damaged Fault O2S 1 Circuit High Voltage e TPS signal input circuit damaged Condition Shorted connection or faulty sensor Conclusion Oxygen Sensor Related Code 0123 e Sensor connector or wiring problem Componen
3. Soft sooty black deposits indicate incomplete combustion caused by a restricted air cleaner over rich Temperature Battery Required settings weak ignition or poor compression Above 32 F 0 C 200 cca minimum Qyerheated 0 F to 32 F 18 C to0 C 250 cca minimum 5 F to O F 21 C to 18 C 300 cca minimum 10 F 23 C or below 400 cca minimum If battery charge is insufficient to turn over engine recharge battery Battery Maintenance Regular maintenance is necessary to prolong battery life Chalky white deposits indicate very high combustion Battery Test temperatures This condition is usually accompanied To test battery follow manufacturer s instructions by excessive gap erosion Lean settings an intake air leak or incorrect spark timing are normal causes for high combustion temperatures 24 690 31 Rev B KohlerEngines com 49 Electrical System BATTERY CHARGING SYSTEM NOTE Observe following guidelines to avoid damage to electrical system and components e Make sure battery polarity is correct A negative ground system is used e Disconnect rectifier regulator plug and or wiring harness plug before doing any electric welding on equipment powered by engine Also disconnect all other electrical accessories in common ground with engine e Prevent stator AC leads from touching or shorting while engine is running This could damage stator These
4. v 01 0 O O O O O O OJO 8I i VA bit es 006000008 UN D 4 a jleuondo yoyMs Avy 103128uu0 euruue G we1Berg BuuM 143 24 690 31 Rev B KohlerEngines com co N Crankshaft Position Sensor A sealed non serviceable assembly If Fault Code diagnosis indicates a problem within this area test and correct as follows 1 Check mounting and air gap of sensor It must be 0 20 0 70 mm 0 008 0 027 in 2 Inspect wiring and connections for damage or problems 3 Make sure engine has resistor type spark plugs Disconnect Black connector from ECU 5 Connect an ohmmeter between 4 and 13 pin terminals A resistance value of 325 395 Q at room temperature 20 C 68 F should be obtained If resistance is correct check mounting air gap flywheel teeth damage run out etc and flywheel key 6 Disconnect crankshaft position sensor connector from wiring harness Test resistance between terminals A reading of 325 395 Q should again be obtained a If resistance is incorrect remove screws securing sensor to mounting bracket and replace sensor b If resistance in step 5 was incorrect but resistance of sensor alone was correct test wire harness circuits between sensor connector terminals and corresponding pin terminals 4 and 13 in main connector Correct any observed problem reconnect sensor and perform step 5 again
5. Governor gear assembly is located inside oil pan If service is required continue with Inspection Disassembly and Reassembly Inspection Inspect governor gear teeth Replace gear if it is worn chipped or if any teeth are missing Inspect governor weights They should move freely in governor gear Disassembly NOTE Governor gear is held onto shaft by small molded tabs in gear When gear is removed from shaft these tabs are destroyed and gear must be replaced Therefore remove gear only if absolutely necessary Governor gear must be replaced once it is removed from oil pan 1 Remove regulating pin and governor gear assembly 2 Remove 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 both onto governor shaft 24 690 31 Rev B Oil Pump Assembly Disassembly Inspection and Service Crankcase Components Oil Pump Torque Sequence Oil pump is mounted inside oil pan If service is required continue with Disassembly Inspection and Reassembly Disassembly 1 Remove screws 2 Remove oil pump assembly from oil pan 3 Remove oil pump
6. e Inspect lock off assembly for damage leakage Fuel System e Have combustion deposits removed if using non synthetic oil Every 600 Hours or Annually e Replace heavy duty air cleaner inner element Air Cleaner Intake Every 1500 Hours e Have vaporizer regulator tested Fuel System Perform these procedures more frequently under severe dusty dirty conditions Must be performed by a Kohler authorized dealer or qualified propane personnel only REPAIRS SERVICE PARTS Kohler genuine service parts can be purchased from Kohler authorized dealers To find a local Kohler authorized dealer visit KohlerEngines com or call 1 800 544 2444 U S and Canada 24 690 31 Rev B KohlerEngines com 3 Maintenance OIL RECOMMENDATIONS Synthetic oil is recommended for use in propane fueled engines Non synthetic oil must be low ash rated oil Oils including synthetic must meet API American Petroleum Institute service class SG SH SJ or SL Select viscosity based on air temperature at time of operation as shown in table below Low ash is defined as less than 1 sulfated ash F 20 0 20 32 40 50 60 80 100 ec 30 20 10 0 10 20 30 40 FUEL RECOMMENDATIONS A WARNING Explosive Fuel can cause fires and severe 2 burns 4 If a gaseous odor is detected ventilate area and contact an authorized service technician Propane
7. 14096 SOLENOID oe SHIFT STARTER Baa ue 4X 08 647 54 0340 0297 THRU A m 15878 7 0254 00 0 3 10000 B C lt eee 20 MOUNTING 24785 13 536 KOLE 19 758 452015 45 0 35 ENGINE MOUNTING SURFACE PTO END OIL COOLER REGULATOR RECTIFIER 44532 17 532 REGULATOR ASSEMBLY AS iar G23 seg 1372 sU 36738 PUG 10540 1999 114 464 ENGINE MOUNTING SURFACE 11055 10465 972 8630 3 827 T398 24 895 0 10 0 980 0 0039 9 2856 0 01 1 125 0005 OIL FILTER SIDE 38 1 0 00 381 i Th6 E a 7 6200NF28IN 4080 i ENGINE MOUNTING 1 606 SURFACE OLDRANPUG 3 BNPT INCH Lt STARTER SIDE 24 690 31 Rev B KohlerEngines com Specifications ENGINE IDENTIFICATION NUMBERS Kohler engine identification numbers model specification and serial should be referenced for efficient repair ordering correct parts and engine replacement Vertical Shaft Numerical Designation Specification DOM is oes sr ord hoe eh k Year Manufactured Code Code Year 43 2013 44 2014 45 2015 Propane EFI Command Engine PCV680 PCV680 3001 4323500328 Factory Code GENERAL SPECIFICATIONS 5 PCV680 PCV740 Bore 83 mm 3 27 in
8. 2 Middle compression ring center groove Install center ring using a piston ring installation tool Make sure identification mark is up or colored dye stripe if contained is to left of end gap 3 Top compression ring top groove Install top ring using a piston ring expander Make sure identification mark is up or colored dye stripe if contained is to left of end gap KohlerEngines com 69 Disassembly Inspection and Service Connecting Rods Offset stepped cap connecting rods are used in all these engines Inspection and Service Check bearing area big end for excessive wear score marks running and side clearances refer to Specifications Replace rod and cap if scored or excessively worn Service replacement connecting rods are available in STD crankpin size and 0 25 mm 0 010 in undersize 0 25 mm 0 010 in undersized rod can be identified by drilled hole located in lower end of rod shank Always refer to appropriate parts information to ensure correct replacements are used Remove Crankshaft Carefully pull crankshaft from crankcase Inspection and Service Crankshaft Components and Details Self Tapping Screw Flat Washer C Plug D Crankshaft A Fillet Must Blend Smoothly with Bearing Journal Surface High Point from Fillet Intersections 45 Minimum r ojm m This Fillet Area Must Be Completely Smooth 70 KohlerEngines com NO
9. 24 690 31 Rev B Reassembly NOTE Make sure engine is assembled using all Crankcase Components a specified torque values tightening sequences e T f and clearances Failure to observe specifications A could cause severe engine wear or damage e s Always use new gaskets Apply a small amount je of oil to threads of critical fasteners before assembly unless a Sealant or Loctite is specified or preapplied Make sure all traces of any cleaner are removed before engine is assembled and placed into operation Even small amounts of these cleaners can quickly break down lubricating properties of engine oil Check oil pan crankcase and cylinder heads to be certain that all old sealing material has been removed Use gasket remover lacquer thinner or paint remover to remove any remaining traces Clean surfaces with isopropyl alcohol acetone lacquer thinner or electrical contact cleaner Install Flywheel End Oil Seal Oil Seal Detail A 4 5 mm 0 177 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 A Oil Pan Seal B Oil Pan 1 Lubricate crankshaft jour
10. 1 Remove screws securing closest connecting rod end cap Remove end cap 2 Carefully remove connecting rod and piston assembly from cylinder bore 68 KohlerEngines com 3 Repeat above procedure for other connecting rod and piston assembly 4 Remove piston pin from piston for inspection Use a small screwdriver to pry pin retainer out of groove Inspection Piston and Rings Components and Details i Top Compression A Piston B E Middle Compression i v Ring D Rails Scuffing and scoring of pistons and cylinder walls occurs when internal engine temperatures approach welding point of piston Temperatures high enough to do this are created by friction which is usually attributed to improper lubrication and or overheating of engine Normally very little wear takes place in piston boss piston pin area If original piston and connecting rod can be reused after new rings are installed original pin can also be reused but new piston pin retainers are required Piston pin is included as part of piston assembly if pin boss in piston or pin are worn or damaged a new piston assembly is required Ring failure is usually indicated by excessive oil consumption and blue exhaust smoke When rings fail oil is allowed to enter combustion chamber where it is burned along with fuel High oil consumption can also occur when piston ring end gap is incorrect because ring cannot properly conform to cylinder wall u
11. 7 When fault is corrected and engine starts clear fault codes following ECU Reset procedure Throttle Position Sensor TPS gt Resistance Table Throttle Between Resistance ae Position Terminal Value O Continuity Closed A8C 1400 1800 Yes Full with Stop Pin A8C 3200 4100 Yes Full without Stop Pin A8C 4600 5200 Yes Any A8B 3000 7000 Yes TPS is a sealed non serviceable assembly If diagnosis indicates a bad sensor complete replacement is necessary If a blink code indicates a problem with TPS it can be tested as follows 1 Counting number of turns back out idle speed adjusting screw counterclockwise until throttle plates can be closed completely Write this number down for reference later 2 Disconnect Black connector from ECU but leave TPS mounted to throttle body 3 a Use an ohmmeter and connect red positive ohmmeter lead to Black pin 12 terminal and black negative ohmmeter lead to Black pin 10 terminal to test 24 690 31 Rev B Propane EFI System b Hold throttle closed and check resistance It should be 1400 1800 Q 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 Q without a stop pin or 3200 4100 Q with a stop pin 5 Disconnect
12. New Bore 1 519 1 797 mm 0 0598 0 0708 in Used Bore Max 2 051 mm 0 08068 in gt Values are in Metric units Values in parentheses are English equivalents 10 KohlerEngines com 24 690 31 Rev B Specifications CLEARANCE SPECIFICATIONS PCV680 PCV740 Piston Piston Rings and Piston Pin continued Thrust Face O D 7 82 978 mm 3 2668 in Max Wear Limit 82 833 mm 3 2611 in Piston Thrust Face to Cylinder Bore Running Clearance New 0 019 0 062 mm 0 0007 0 0024 in Valves and Valve Lifters Hydraulic Lifter to Crankcase 0 011 0 048 mm 0 0004 0 0019 in Running Clearance Intake Valve Stem to Valve 0 040 0 078 mm 0 0016 0 0031 in Guide Running Clearance Exhaust Valve Stem to Valve 0 052 0 090 mm 0 0020 0 0035 in Guide Running Clearance 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 Guide Reamer Size Standard 7 050 mm 0 2776 in 0 25 mm O S 7 300 mm 0 2874 in Intake Valve Minimum Lift 8 07 mm 0 3177 in Exhaust Valve Minimum Lift 8 07 mm 0 3177 in Nominal Valve Seat Angle 45 3Values are in Metric units Values in parentheses are English equivalents 7 Measure 6 mm 0 236 in above bottom of piston skirt at right angles to piston pin 24 690 31 Rev B KohlerEngines com 1
13. Stroke 69 mm 2 72 in Displacement 747 cc 45 6 cu in Oil Capacity refill 1 6 1 9 L 1 7 2 0 U S qt Maximum Angle of Operation full oil level 25 TORQUE SPECIFICATIONS PCV680 PCV740 Blower Housing Into cored aluminum hole or weld nut M6 Into extruded hole in sheet metal M5 M6 6 2 N m 55 in Ib into new holes 4 0 N m 35 in Ib into used holes 10 7 N m 95 in Ib into new holes 7 3 N m 65 in Ib into used holes 2 8 N m 25 in Ib into new holes 2 3 N m 20 in Ib into used holes 2 8 N m 2 3N m 25 in Ib into new holes 20 in Ib into used holes Connecting Rod Cap Fastener torque in increments 6 mm straight shank 6 mm straight shank gray metallic color 11 6 N m 103 in Ib 13 6 N m 120 in Ib gt Values are in Metric units Values in parentheses are English equivalents 4 Exceeding maximum angle of operation may cause engine damage from insufficient lubrication 5 Lubricate threads with engine oil prior to assembly 6 Any and all horsepower hp references by Kohler are Certified Power Ratings and per SAE J1940 amp J1995 hp standards Details on Certified Power Ratings can be found at KohlerEngines com 6 KohlerEngines com 24 690 31 Rev B TORQUE SPECIFICATIONS Specifications PCV680 PCV740 Crankcase Breather Cover Fastener 11 3 N m 100 in Ib into new holes 7 3 N m
14. 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 knob Heavy Duty 1 Unhook retaining clips and remove end cap s 2 Check and clean inlet screen if equipped 3 Pull air cleaner element out of housing and replace Check condition of inner element replace when dirty 4 Check all parts for wear cracks or damage and that ejector area is clean 5 Install new element s 6 Reinstall end cap s with dust ejector valve screen down secure with retaining clips BREATHER TUBE Ensure sure both ends of breather tube are properly connected AIR COOLING WARNING zt Hot Parts can cause severe burns k Do not touch engine while operating or just after stopping Never operate engine with heat shields or guards removed Proper cooling is essential To prevent over heating clean screens cooling fins and other external surfaces of engine Avoid spraying water at wiring harness or any electrical components Refer to Maintenance Schedule 24 690 31 Rev B WARNING Explosive Fuel can cause fires and severe burns TA CL If a gaseous odor is detected ventilate area and
15. blower housing Torque top screw to 2 8 N m 25 in Ib and lower screw to 2 3 N m 20 in Ib Install Oil Filter and Fill Crankcase with Oil NOTE If testing oil pressure after completing reassembly install oil pressure adapter instead of oil filter 1 Prefill a new oil filter following instructions 2 Place new filter in shallow pan with open end up Fill with new oil until oil reaches bottom of threads Allow 2 minutes for oil to be absorbed by filter material 3 Apply a thin film of clean oil to rubber gasket on oil filter 4 Referto instructions on oil filter for proper installation 5 Fill crankcase with new oil Level should be at top of indicator on dipstick 6 Reinstall oil fill cap dipstick and tighten securely Connect Spark Plug Leads 1 Connect leads to spark plugs KohlerEngines com 85 Reassembly Prepare Engine for Operation Testing Engine NOTE If ECU or TPS throttle body were replaced an ECU Reset and TPS Learn is required Refer to ECU Reset and TPS Learn procedures in Fuel System Engine is now completely reassembled Before starting or operating engine be sure to follow steps below 1 Make sure all hardware is tightened securely 2 Make sure oil drain plugs Oil Sentry pressure switch and a new oil filter are installed 3 Fill crankcase with correct amount weight and type of oil Refer to oil recommendations and procedures in Maintenance Specifications and Lu
16. in oil pan New 40 974 41 000 mm 1 6131 1 6141 in Crankshaft to Sleeve Bearing oil pan Running Clearance New 0 03 0 12 mm 0 001 0 005 in Crankshaft Bore oil pan to Crankshaft Running Clearance New Flywheel End Main Bearing Journal O D New O D Max Wear Limit Max Taper Limit Max Out of Round Limit 0 039 0 087 mm 0 0015 0 0034 in 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 Oil Pan End Main Bearing Journal O D New O D Max Wear Limit Max Taper Limit Max Out of Round Limit 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 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 1 4163 in 35 941 mm 1 415 in 0 018 mm 0 0007 in 0 025 mm 0 0010 in Crankshaft T I R PTO End Crank in Engine Entire Crank in V Blocks 0 279 mm 0 0110 in 0 10 mm 0 0039 in 3Values are in Metric units Values in parentheses are English equivalents 5 Lubricate threads with engine oil prior to assembly Lubricate threads with engine oil prior to assembly 24 690 31 Rev B KohlerEngines com 9 Specifications CLEARANCE SPECIFICATIONS Cylinder Bore PCV680 PCV740 Bore I D New 83 006 83 031 mm 3 2680 3 2689 in O D Max Wear Limit 83 08
17. no fuel delivery Condition e No fuel e Air in high pressure fuel line e Fuel valve shut OFF e Fuel filter line plugged e Injector circuit s pin circuits Black 5 and Black 6 e Injector e ECU grounds e ECU Diagnostic Aid 8 FUEL SYSTEM fuel pressure Low Fuel Pressure Condition e Low fuel insufficient fuel supply e Fuel filter plugged e Fuel supply line plugged Low Fuel Pressure Condition e Pressure regulator not functioning properly Diagnostic Aid 9 BASIC ENGINE cranks but will not run Condition e Refer to basic engine troubleshooting charts within Troubleshooting Electronic Fuel Injection System and Electrical Systems 24 690 31 Rev B Propane EFI System EFI Diagnostic Flow Diagram START OF TEST PROCEED TO START OF TEST FOR RETEST KEY ON MALFUNCTION INDICATOR LIGHT NO REFER TO DIAGNOSTIC AID 1 SYSTEM POWER REFER TO DIAGNOSTIC FAULT CODE SUMMARY CLEAR CODES REFER TO DIAGNOSTIC AID 3 RUN ON ARE FAULT CODES PRESENT DOES ENGINE START YES NO NO YES OPERATE AT VARIOUS SPEED LOAD CONDITIONS nas i 7 REFER TO DIAGNOSTIC ul ARE DES FAULT CODE SUMMARY m YES 5 NO KEY OFF AND KEY ON NO CLEAR CODES iB LISTEN FOR FUEL LOCK OFF a E DOES LOCK OFF ACTIVATI NOFT ARTE REFER TO DIAGNOSTIC AID 4 E CRANKSHAFT POSITION SENSOR m lu e YES NO 9 a REFER TO DIAGNOSTIC AID 5 WHILE CRANKING CHECK FUEL LO
18. parts to prevent injury Never operate engine with covers shrouds or guards removed A WARNING al Hot Parts can cause severe burns ANN poni wit Do not touch engine while operating or just after stopping A WARNING High Pressure Fluids can puncture skin and cause severe injury or death J Do not work on fuel system without proper training or safety equipment Never operate engine with heat shields or guards removed Fluid puncture injuries are highly toxic and hazardous If an injury occurs seek immediate medical attention Keep hands feet hair and A WARNING Cleaning Solvents can 4 cause severe injury or death Use only in well ventilated areas away from ignition sources A CAUTION Failure to utilize or reassemble debris screen as designed could D result in debris screen e failure and serious personal injury 4 Carburetor cleaners and solvents are extremely flammable Follow cleaner manufacturer s warnings and instructions on its proper and safe use Never use gasoline as a cleaning agent N KohlerEngines com 24 690 31 Rev B MAINTENANCE INSTRUCTIONS Maintenance A E WARNING r Disconnect and ground spark plug lead s j 3 before servicing Accidental Starts can cause severe injury or Before working on engine or equipment disable engine as FO death
19. severe engine damage Removing crankpin plug when crankshaft is ground provides easy access for removing any grinding deposits collected in oil passages Use these following procedures to remove and replace plug Procedure to Remove Crankshaft Plug 1 Drill a 3 16 in hole through plug in crankshaft 2 Thread a 3 4 in or 1 in long self tapping screw with a flat washer into drilled hole Flat washer must be large enough to seat against shoulder of plug bore 3 Tighten self tapping screw until it draws plug out of crankshaft Procedure to Install New Plug Use a single cylinder camshaft pin as a driver and tap plug into plug bore until it seats at bottom of bore Make sure plug is tapped in evenly to prevent leakage 24 690 31 Rev B Remove Flywheel End Oil Seal Remove oil seal from crankcase Crankcase Inspection and Service Check all gasket surfaces to make sure they are free of gasket fragments Gasket surfaces must also be free of deep scratches or nicks Inspect main bearing if so equipped for wear or damage refer to Specifications Replace crankcase using a miniblock or short block as required Check cylinder bore wall for scoring In severe cases unburned fuel can cause scuffing and scoring of cylinder wall It washes necessary lubricating oils off piston and cylinder wall As raw fuel seeps down cylinder wall piston rings make metal to metal contact with wall Scoring of cylinder wall can also
20. 5 seconds connection or faulty sensor 4 MIL will blink a series of times Number of times MIL Conclusion Oxygen Sensor Related blinks represents a number in blink code e Sensor connector or wiring problem 5 Asequence of four digits make up a fault code e Sensor damaged There is a one 1 second pause between blinks of a e en circuit wiring or connectors at Black fault code There is a three 3 second pause between separate fault codes After fault code s are i iqi ic hli indi ECU Related E 61 is blinked to indicate program e ECU to harness connection problem a It s a good idea to write down codes as they appear as they may not be in numerical Code 0032 Sequence Component Oxygen Sensor Heater b Code 61 will always be last code displayed Fault O2S Heater Circuit Low Voltage indicating end of code transmission If code 61 appears immediately no other fault codes are Condition System voltage too low open connection or faulty sensor t Had Conclusion Engine Wiring Harness Related After problem has been corrected fault codes may e Pin circuit wiring or connectors be cleared by following ECU Reset and TPS Learn ECU black pin 7 or broken wire Procedures Diagnostic Fault Code Summary lists fault codes and Oxygen Sensor Related what they correspond to Diagnostic Code Summary e Sensor connector or wiring problem is a list of individual codes with an explanation of what triggers them w
21. 65 in Ib into used holes Oil Temperature Sensor into breather cover 7 3 N m 65 in Ib Oil Drain Plug 13 6 N m 10 ft Ib Cylinder Head Hex Flange Nut torque in 2 increments first to 16 9 N m 150 in Ib finally to 33 9 N m 300 in Ib Rocker Arm Screw 18 1 N m 160 in Ib Fan Flywheel Flywheel Retaining Screw 71 6 N m 52 8 ft Ib Metal Debris Screen Fastener to flywheel 9 9 N m 88 in Ib Fuel Vaporizer Regulator Lock Off Regulator to Bracket Nut Regulator Bracket Mounting Screw 19 8 N m 175 in Ib 11 9 N m 105 in Ib Lock Off Valve Body Nut 6 5 N m 57 in Ib Lock Off Valve Body Fuel Outlet Fitting Mounting Screws 20 N m 177 in Ib 2 9 N m 26 in Ib Fuel Inlet Fitting 20 N m 177 in Ib Coil Fastener Governor Lever Nut 7 1 N m 63 in Ib Ignition Spark Plug 27 N m 20 ft Ib 10 2 N m 90 in Ib Crankshaft Position Sensor Screw 6 2 N m 55 in Ib Crankshaft Position Sensor Bracket Screw Electronic Control Unit Screw 7 3 N m 65 in Ib 6 2 N m 55 in Ib Rectifier Regulator Ground Strap Fastener 2 8 N m 25 in Ib into new holes 2 3 N m 20 in Ib into used holes Rectifier Regulator Fastener 1 4 N m 12 6 in Ib Intake Manifold Fastener torque in 2 increments Manifold Absolute Pressure MAP Sensor Fastener first to 7 8 N m 69
22. 88 in Ib Repeat procedure for other studs and screws Install Oil Separator and Hardware A Electronic Control B ECU Bracket Unit ECU C Starter 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 Torque screws to 2 3 N m 20 in Ib Install Electric Starter Motor and ECU Bracket 1 Install electric starter motor using screws Position ECU bracket 2 Torque screws to 16 0 N m 142 in Ib 3 Connect leads to solenoid 82 KohlerEngines com NOTE ECU pins should be coated with a thin layer of electrical grease to prevent fretting and corrosion and may need to be reapplied if ECU is being reused 1 Install ECU to ECU bracket using screws Torque M5 screws to 6 2 N m 55 in Ib into new holes or 4 0 N m 35 in Ib into used holes 2 Connect Black and Grey electrical connectors Connectors and ECU are keyed in such a way so they cannot be installed incorrectly Install Throttle Body NOTE Ensure all parts are clean undamaged and free of debris and make sure electrical connector has seal in place 1 Install a new throttle body O ring prior to installation Make sure all holes align and are open 2 Install throttle body thr
23. Brush Holding Tool Solenoid Shift Kohler 25 761 20 S Kohler 25 761 41 S Design Technology Inc DTI 031 DTI 033 Kohler 25 761 40 S 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 guides to accept replacement oversize valves Can be used in low speed drill press or with handle below for hand reaming Reamer Handle For hand reaming using Kohler 25 455 12 S reamer AIDS Description Kohler 25 455 12 S Design Technology Inc Source Part No Camshaft Lubricant Valspar ZZ613 Kohler 25 357 14 S Dielectric Grease GE Novaguard G661 Kohler 25 357 11 S Dielectric Grease Loctite 51360 Kohler Electric Starter Drive Lubricant Inertia Drive Kohler 52 357 01 S Kohler 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 Kohler 25 597 07 S Loctite 5910 Loctite Ultra Black 598 Loctite Ul
24. DC voltmeter If voltage is 13 8 volts or more place a minimum load of 5 amps turn on lights if 60 watts or more or place a 2 5 ohm 100 watt resistor across battery terminals on battery to reduce voltage Observe ammeter Conclusion Charging system is OK and battery was fully charged Test stator and rectifier regulator steps 2 and 3 Condition Charge rate increases when load is applied Charge rate does not increase when load is applied 2 Remove connector from rectifier regulator With engine running at 3600 RPM measure AC voltage across stator leads using an AC voltmeter Condition Conclusion Voltage is 28 volts or Stator is OK Rectifier more regulator is faulty replace Voltage is less than 28 Stator is faulty replace volts Test stator further using an ohmmeter steps 3 and 4 3 With engine stopped measure resistance across stator leads using an ohmmeter 24 690 31 Rev B Condition Conclusion Resistance is 0 064 0 2 ohms Stator is OK Resistance is 0 ohms Resistance is infinity ohms Stator is shorted replace Stator is open replace 4 With engine stopped measure resistance from each stator lead to ground using an ohmmeter Condition Conclusion Resistance is infinity ohms no continuity Stator is OK not shorted to ground Resistance or continuity measured Stator leads are shor
25. Oxygen Sensor Related e Corrosion or poor connection e Sensor contaminated or damaged e Air leak into exhaust e Poor ground path e Pin circuit wiring or connectors ECU Black pin 10 or Black pin 17 TPS Sensor Related e Throttle plate position incorrect during Learn procedure e TPS problem or malfunction Engine Wiring Harness Related e Difference in voltage between sensed voltage and actual sensor voltage e Problem in wiring harness e ECU to harness connection problem Systems Related e Ignition spark plug plug wire ignition coil Fuel fuel type quality injector fuel pressure too low fuel lock off or regulator Combustion air air cleaner dirty restricted intake leak throttle bores Base engine problem rings valves Exhaust system leak muffler flange oxygen sensor mounting boss etc e Sensor connector or wiring e Sensor contaminated or damaged e Poor ground path e Pin circuit wiring or connectors ECU Black pin 10 or 17 TPS Sensor Related e Throttle plate position incorrect during Learn procedure e TPS problem or malfunction Engine Wiring Harness Related e Difference in voltage between sensed voltage and actual sensor voltage e Problem in wiring harness e ECU to harness connection problem Systems Related e Ignition spark plug plug wire ignition coil e Fuel fuel type quality injector fuel pressure too high fuel regulator e Combu
26. Recheck oil level 9 Dispose of used oil and filter in accordance with local ordinances OIL COOLER if equipped 1 Clean fins with a brush or compressed air 2 Remove screws securing oil cooler and tilt to clean back side 3 Reinstall oil cooler and secure with screws Torque top screw to 2 8 N m 25 in Ib and lower screw to 2 3 N m 20 in Ib OIL SENTRY if equipped This switch is designed to prevent engine from starting in a low oil or no oil condition Oil Sentry may not shut down a running engine before damage occurs In some applications this switch may activate a warning signal Read your equipment manuals for more information Oil Sentry pressure switch is installed in breather cover On engines not equipped with Oil Sentry installation hole is sealed with a 1 8 27 N P T F pipe plug Installation 1 Apply pipe sealant with Teflon Loctite PST 592 Thread Sealant or equivalent to threads of switch 2 Install switch into tapped hole in breather cover 3 Torque switch to 4 5 N m 40 in Ib Lubrication System Testing Compressed air a pressure regulator pressure gauge and a continuity tester are required to test switch 1 Connect continuity tester across blade terminal and metal case of switch With O psi pressure applied to switch tester should indicate no continuity switch open Gradually increase pressure to switch As pressure increases through range of 2 0 5 0
27. System IMPORTANT NOTES e Cleanliness is essential and must be maintained at all times when servicing or working on EFI system Dirt even in small quantities can cause significant problems Clean any joint or fitting with parts cleaning solvent before opening to prevent dirt from entering system Always depressurize fuel system before disconnecting or servicing any fuel system components Shut off tank valve If possible run engine in a well ventilated area until fuel system is empty and engine stops If unable to run engine work in a well ventilated area and carefully loosen inlet fuel fitting on vaporizer regulator slowly venting off fuel from line When fuel is dispensed retighten fitting and remove quick connect fitting to allow fuel to escape from line Never attempt to service any fuel system component while engine is running or ignition switch is ON Do not use compressed air if system is open Cover any parts removed and wrap any open joints with plastic if they will remain open for any length of time New parts should be removed from their protective packaging just prior to installation Avoid direct water or spray contact with system components Do not disconnect or reconnect ECU wiring harness connector or any individual components with ignition on This can send a damaging voltage spike through ECU Do not allow battery cables to touch opposing terminals When connecting battery cables attach positive ca
28. engines are equipped with a 20 or 25 amp regulated charging system 20 25 Amp Regulated Charging System A Battery B Starter C Fuse D Rectifier Regulator Flywheel Stator E Connector Block Assembly Stator Stator is mounted on crankcase behind flywheel Follow procedures in Disassembly and Reassembly if stator replacement is necessary Rectifier Regulator NOTE When installing rectifier regulator 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 wire or metal grounding strap Testing rectifier regulator may be performed as follows using appropriate rectifier regulator tester To test 20 25 amp rectifier regulators 1 2 3 4 50 Connect tester ground lead with spring clamp to body of rectifier regulator Connect red lead from tester to middle terminal labeled B Connect black leads from tester to both outer AC terminals on rectifier regulator Plug tester into proper AC outlet power for tester being used Turn on power switch POWER light shou
29. follows 1 Disconnect spark plug lead s 2 Disconnect negative battery cable from battery Normal maintenance replacement or repair of emission control devices and systems may be performed by any repair establishment or individual however warranty repairs must be performed by a Kohler authorized dealer MAINTENANCE SCHEDULE Every 25 Hours e Service replace low profile precleaner if equipped Air Cleaner Intake Every 100 Hours e Check oil cooler fins clean as necessary if equipped Air Cleaner Intake e Change oil Lubrication System e Replace low profile air cleaner element if equipped Air Cleaner Intake e Remove cooling shrouds and clean cooling areas Air Cleaner Intake Every 150 Hours e Check heavy duty filter minder Air Cleaner Intake e Inspect heavy duty air filter paper element and inlet screen area Air Cleaner Intake Every 200 Hours e Change oil filter Lubrication System e Replace unique EFI fuel filters Every 300 Hours e Replace heavy duty air cleaner element and check inner element Air Cleaner Intake Every 500 Hours or Annually e Check all lines high pressure vacuum including fittings for leaks Fuel System e Drain vaporizer regulator of accumulated fuel deposits Fuel System e Replace spark plugs and set gap Electrical System Every 500 Hours or Annually
30. gap from missing tooth creates an interrupted input signal corresponding to specific crankshaft position near BDC for cylinder 1 This signal serves as a reference for control of ignition timing by ECU Synchronization of inductive speed pickup and crankshaft position takes place during first two revolutions each time engine is started Sensor must be properly connected at all times If sensor becomes disconnected for any reason engine will quit running Throttle position sensor TPS is used to indicate throttle plate angle to ECU Since throttle by way of governor reacts to engine load angle of throttle plate is directly related to load on engine Mounted on throttle body and operated directly off end of throttle shaft TPS works as a potentiometer varying voltage signal to ECU in direct correlation to angle of throttle plate This signal along with other sensor signals is processed by ECU and compared to internal preprogrammed maps to determine required fuel and ignition settings for amount of load Correct position of TPS is established and set at factory Do not loosen TPS or alter mounting position unless absolutely required by fault code diagnosis If TPS is loosened or repositioned appropriate TPS Learn Procedure must be performed to re establish baseline relationship between ECU and TPS Engine oil temperature sensor is used by system to help determine fuel requirements for starting a cold engine needs more fuel tha
31. gapped e Incorrect crankshaft position sensor air gap e Interlock switch is engaged or faulty e Loose wires or connections that intermittently ground ignition kill circuit e Quality of fuel dirt water stale mixture e Spark plug lead s disconnected e Spark plug lead boot loose on plug e Spark plug lead loose Engine Will Not Idle e Faulty carburetor e Faulty cylinder head gasket e Faulty or misadjusted choke or throttle controls e Fuel pump malfunction vacuum hose clogged or leaking e Intake system leak e Loose wires or connections that intermittently ground ignition kill circuit e Quality of fuel dirt water stale mixture e Restricted fuel tank cap vent Engine Starts Hard e Engine overheated e Faulty spark plug s e Idle fuel adjusting needle s improperly set e Idle speed adjusting screw improperly set e Inadequate fuel supply e Low compression e Quality of fuel dirt water stale mixture e Restricted fuel tank cap vent Engine Overheats e Clogged fuel line or fuel filter e Engine overheated e Faulty ACR mechanism e Faulty or misadjusted choke or throttle controls e Faulty spark plug s e Flywheel key sheared e Fuel pump malfunction vacuum hose clogged or leaking e Interlock switch is engaged or faulty e Loose wires or connections that intermittently ground ignition kill circuit e Low compression e Quality of fuel dirt water stale mixt
32. in Ib finally to 10 5 N m 93 in Ib 7 3 N m 65 in Ib Air Cleaner to Throttle Body Fastener Nut 8 2 Nr m 73 in Ib Air Cleaner Mounting Bracket Fastener 5 8 N m 51 in Ib Fuel Injector Cap Fastener 7 3 N m 65 in Ib Muffler Retaining Nut Oxygen Sensor 27 8 N m 246 in Ib 50 1 N m 37 ft Ib 3Values are in Metric units Values in parentheses are English equivalents 5 Lubricate threads with engine oil prior to assembly 24 690 31 Rev B KohlerEngines com Specifications TORQUE SPECIFICATIONS PCV680 PCV740 Oil Cooler Oil Cooler Adapter Nipple 28 5 N m 21 ft Ib Fastener Into Blower Housing 2 8 N m 25 in Ib Between Oil Cooler Hoses 2 3 N m 20 in Ib Oil Pan Fastener 25 6 N m 227 in Ib Speed Control Bracket Fastener assembled to cylinder heads 10 7 N m 95 in Ib into new holes 7 3 N m 65 in Ib into used holes Fastener assembled to blower housing 2 8 N m 25 in Ib into new holes 2 3 N m 20 in Ib into used holes Starter Assembly Thru Bolt 5 6 9 0 N m 49 79 in Ib Mounting Screw 16 0 N m 142 in Ib Brush Holder Mounting Screw 2 5 3 3 N m 22 29 in Ib Starter Solenoid Mounting Hardware 4 0 6 0 N m 35 53 in Ib Nut Positive Brush Lead 8 0 11 0 N m 71 97 in Ib Stator Mounting Screw 6 2 N m 55 in Ib into new holes 4 0 N m 35 in Ib into
33. of drive end cap Molded recesses in grommet should be out matching and aligned with those in end cap Install frame with small notch forward onto armature and drive end cap Align notch with corresponding section in rubber grommet Install drain tube in rear cutout if it was removed previously Install flat thrust washer onto commutator end of armature shaft Starter reassembly when replacing brushes brush holder assembly a Hold starter assembly vertically on end housing and carefully position assembled brush holder assembly with supplied protective tube against end of commutator armature Mounting screw holes in metal clips must be up out Slide brush holder assembly down into place around commutator and install positive brush lead grommet in cutout of frame Protective tube may be saved and used for future servicing Starter reassembly when not replacing brushes brush holder assembly a Carefully unhook retaining caps from brush assemblies Do not lose springs 55 Starter System b Position brushes back in their slots so they are flush with I D of brush holder assembly Insert brush installation tool with extension or use tube described above from a prior brush installation through brush holder assembly so holes in metal mounting clips are up out c Install brush springs and snap on retainer caps d Hold starter assembly vertically on end housing and carefully place tool with extension and ass
34. pressure fuel line and holds it in place O rings and retaining clip must be replaced any time fuel injector is separated from its normal mounting position When key switch is on lock off valve will open briefly and allow fuel into system at 24 26 psi and voltage is present at injector At proper instant ECU completes ground circuit energizing injector Valve needle in injector is opened electromagnetically and pressure in high pressure fuel line forces fuel down through inside Director plate at tip of injector contains a series of calibrated openings which directs fuel into manifold Injectors have sequential fueling that open and close once every other crankshaft revolution Amount of fuel injected is controlled by ECU and determined by length of time valve needle is held open also referred to as injection duration or pulse width Time injector is open milliseconds may vary in duration depending on speed and load requirements of engine A high voltage solid state battery ignition system 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 24 690 31 Rev B Propane EFI System it interrupts flow of primary current in coil causing electromagnetic flux field to collapse Flux collapse induces an instantaneou
35. screws to 9 9 N m 88 in Ib Low Profile Air Cleaner 1 Verify O ring is present around machined O D of throttle body and place air cleaner base onto throttle body studs Secure air cleaner base using three nuts Attach air cleaner base bracket to cylinder heads with screws behind any control panel or bracket Attach air cleaner base to lower bracket with M5 screws through lower section of base Torque nuts to 7 4 9 0 N m 65 5 80 in Ib and lower M5 mounting screws to 2 3 N m 20 in Ib 2 Install air cleaner components as described in Air Cleaner Intake Setting Initial Governor Adjustment 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 shaft counterclockwise as far as it will turn then torque nut to 7 1 N m 63 in Ib Install Muffler 1 Install port liners if equipped Install exhaust gaskets and muffler Install oxygen sensor torque to 50 1 N m 37 ft Ib and connect to wire harness 2 Install remaining muffler support hardware screws and nuts and torque to 9 9 N m 88 in Ib 3 Install nuts to exhaust studs Torque nuts to 27 8 N m 246 in Ib 24 690 31 Rev B 1 Secure adapter to oil pan with oil filter nipple Torque oil filter nipple to 28 5 N m 21 ft Ib 2 Verify all fuel and vent hoses are routed properly and not pinched Install screws to secure oil cooler to
36. to broken fragments Broken fragments could be thrown from engine Always observe and use precautions and procedures when installing flywheel Flywheel Components A Flywheel Fan B Flywheel C Stator D Backing Plate KohlerEngines com 75 Reassembly NOTE Before installing flywheel make sure crankshaft 3 Install screw and washer taper and flywheel hub are clean dry and 4 Use a flywheel strap wrench or holding tool to hold completely free of any lubricants Presence of flywheel Torque screw securing flywheel to lubricants can cause flywheel to be over crankshaft to 71 6 N m 52 8 ft Ib stressed and damaged when screw is torqued to specifications NOTE Make sure flywheel key is installed properly in keyway Flywheel can become cracked or damaged if key is not properly installed 1 Install woodruff key into keyway of crankshaft Make sure that key is properly seated and parallel with shaft taper 2 Install flywheel onto crankshaft being careful not to shift woodruff key Install Fan NOTE Position locating tabs on back of fan into locating holes of flywheel 1 Install fan onto flywheel Fan will be fastened to flywheel when metal debris screen is installed Cylinder Head Components A Valve Cover B Valve Cover Gasket C Hex Flange Screw D Rocker Arm Pivot E Rocker Arm F Push Rod G Hydraulic Lifter H Va
37. used holes Valve Cover Fastener 6 2 N m 55 in Ib CLEARANCE SPECIFICATIONS PCV680 PCV740 Camshaft End Play with shim 0 101 0 406 mm 0 0040 0 0160 in Running Clearance 0 025 0 105 mm 0 001 0 004 in Bore I D New 20 000 20 025 mm 0 7874 0 7884 in Max Wear Limit 20 038 mm 0 7889 in Bearing Surface O D New 19 920 19 975 mm 0 7843 0 7864 in Max Wear Limit 19 914 mm 0 7840 in Values are in Metric units Values in parentheses are English equivalents 5 Lubricate threads with engine oil prior to assembly 8 KohlerEngines com 24 690 31 Rev B CLEARANCE SPECIFICATIONS Connecting Rod Specifications PCV680 PCV740 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 Connecting Rod to Crankpin Side Clearance 0 26 0 63 mm 0 0102 0 0248 in Connecting Rod to Piston Pin Running Clearance 21 C 70 F Piston Pin End I D 21 C 70 F New Max Wear Limit 0 015 0 028 mm 0 0006 0 0011 in 17 015 17 023 mm 0 6699 0 6702 in 17 036 mm 0 6707 in Crankcase New Max Wear Limit Governor Cross Shaft Bore D 8 025 8 075 mm 0 3159 0 3179 in 8 088 mm 0 3184 in Crankshaft End Play free Bore in crankcase New Max Wear Limit 0 025 0 635 mm 0 001 0 025 in 40 972 40 997 mm 1 6131 1 6141 in 41 011 mm 1 6146 in Bore
38. 1 Specifications GENERAL TORQUE VALUES English Fastener Torque Recommendations for Standard Applications Bolts Screws Nuts and Fasteners Assembled Into Cast Iron or Steel Grade 2 or 5 Fasteners Into Aluminum Size Grade 2 Grade 5 Grade 8 Q Tightening Torque N m in Ib 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 39 6 350 17 0 150 5 16 24 18 7 165 30 5 270 3 8 16 29 4 260 3 8 24 33 9 300 Tightening Torque N m ft Ib 20 5 16 24 40 7 30 3 8 16 47 5 35 67 8 50 3 8 24 54 2 40 81 4 60 7116 14 47 5 35 74 6 55 108 5 80 7 16 20 61 0 45 101 7 75 142 5 105 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 5 110 244 1 180 352 6 260 5 8 18 189 8 140 311 9 230 447 5 330 3 4 10 199 3 147 332 2 245 474 6 350 3 4 16 271 2 200 440 7 325 637 3 470 Metric Fastener Torque Recommendations for Standard Applications Property Class Noncritical
39. 1 mm 3 2709 in Max Out of Round Limit Max Taper 0 120 mm 0 0047 in 0 05 mm 0 0020 in Cylinder Head Max Out of Flatness Governor 0 01 mm 0 004 in Governor Cross Shaft to Crankcase Running Clearance 0 025 0 126 mm 0 0009 0 0049 in Cross Shaft O D New Max Wear Limit Governor Gear Shaft to Governor Gear Running Clearance 7 949 8 000 mm 0 3129 0 3149 in 7 936 mm 0 3124 in 0 090 0 160 mm 0 0035 0 0063 in Gear Shaft O D New Max Wear Limit 5 990 6 000 mm 0 2358 0 2362 in 5 977 mm 0 2353 in Ignition Spark Plug Gap Crankshaft Position Sensor Air Gap Piston Piston Rings and Piston Pin Piston to Piston Pin Running Clearance 0 76 mm 0 030 in 0 2 0 7 mm 0 008 0 027 in 0 006 0 017 mm 0 0002 0 0007 in Max Wear Limit Pin Bore I D New 17 006 17 012 mm 0 6695 0 6698 in Max Wear Limit 17 025 mm 0 6703 in Pin O D New 16 995 17 000 mm 0 6691 0 6693 in 16 994 mm 0 6691 in Top Compression Ring to Groove Side Clearance 0 030 0 070 mm 0 001 0 0026 in Middle Compression Ring to Groove Side Clearance 0 030 0 070 mm 0 001 0 0026 in Oil Control Ring to Groove Side Clearance 0 060 0 190 mm 0 0022 0 0073 in Top Compression Ring End Gap New Bore 0 189 0 277 mm 0 0074 0 0109 in Used Bore Max 0 531 mm 0 0209 in Center Compression Ring End Gap
40. 4 761 01 S Design Technology Inc Fuel Pressure Tester DTI 019 Noid Light DTI 021 90 Adapter DTI 023 In line T Fitting DTI 035 Code Plug Red Wire DTI 027 Code Plug Blue Wire DTI 029 Shrader Valve Adapter Hose DTI 037 Flywheel Puller SE Tools KLR 82408 For properly removing flywheel from engine 24 690 31 Rev B KohlerEngines com 13 Tools and Aids TOOLS Description Source Part No Hydraulic Valve Lifter Tool For removing and installing hydraulic lifters Kohler 25 761 38 S Ignition System Tester For testing output on all systems including CD Kohler 25 455 01 S Inductive Tachometer Digital For checking operating speed RPM of an engine Design Technology Inc DTI 110 Offset Wrench K and M Series For removing and reinstalling cylinder barrel retaining nuts Kohler 52 455 04 S Oil Pressure Test Kit For testing verifying oil pressure on pressure lubricated engines Kohler 25 761 06 S Rectifier Regulator Tester 120 volt current Rectifier Regulator Tester 240 volt current For testing rectifier regulators Components of 25 761 20 S and 25 761 41 S CS PRO Regulator Test Harness Special Regulator Test Harness with Diode Spark Advance Module SAM Tester For testing SAM ASAM and DSAM on engines with SMART SPARK Starter Servicing Kit All Starters For removing and reinstalling drive retaining rings and brushes Individual component available Starter
41. 76 mm 0 0015 0 0030 in or exhaust clearance exceeds 0 050 0 088 mm 0 0020 0 0035 in determine whether valve stem or guide is responsible for excessive clearance Maximum I D wear on intake valve guide is 7 134 mm 0 2809 in while 7 159 mm 0 2819 in is maximum allowed on exhaust guide Guides are not removable but can be reamed 0 25 mm 0 010 in oversize Valves with 0 25 mm oversize stems must then be used If guides are within limits but valve stems are worn beyond limits install new valves Valve Seat Inserts Hardened steel alloy intake and exhaust valve seat inserts are press fitted into cylinder head Inserts are not replaceable but can be reconditioned if not too badly pitted or distorted If cracked or badly warped cylinder head should be replaced Recondition valve seat inserts following instructions provided with valve seat cutter being used Final cut should be 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 NOTE Exhaust valves that are black in color cannot be ground and do not require lapping Reground or new valves must be lapped in to provide proper fit Use a hand valve grinder with a suction cup for final lapping Lightly coa
42. ARNING Rotating Parts can cause severe injury Stay away while engine is in operation Engine exhaust gases contain poisonous carbon monoxide Carbon monoxide is odorless colorless and can cause death if inhaled Keep hands feet hair and clothing away from all moving parts to prevent injury Never operate engine with covers shrouds or guards removed A partial vacuum should be present in crankcase when engine is operating Pressure in crankcase normally caused by a clogged or improperly assembled breather can cause oil to be forced out at oil seals gaskets or other available spots Crankcase vacuum is best measured with either a water manometer or a vacuum gauge Complete instructions are provided in kits To test crankcase vacuum with manometer 1 Insert rubber stopper into oil fill hole Be sure pinch clamp is installed on hose and use tapered adapters to connect hose between stopper and one manometer tube Leave other tube open to atmosphere Check that water level in manometer is at 0 line Make sure pinch clamp 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
43. Aids to hold flywheel and loosen screw securing flywheel to crankshaft 3 Remove screw and washer 4 Use a puller to remove flywheel from crankshaft 5 Remove woodruff key Inspection Inspect flywheel for cracks and flywheel keyway for damage Replace flywheel if it is cracked Replace flywheel crankshaft and key if flywheel key is sheared or keyway is damaged Inspect ring gear for cracks or damage Kohler does not provide ring gear as a serviceable part Replace flywheel if ring gear is damaged Remove Stator and Backing Plate Governor Gear Assembly Governor Shaft Press Depth Details A Gear Shaft B 19 40 mm 0 7638 in C 34 0 mm 1 3386 in 33 5 mm 1 3189 in 1 Remove screws securing backing plate Remove backing plate 2 Remove screws and stator Note position routing of stator lead Remove Oil Pan Assembly 1 Remove screws securing oil pan to crankcase 2 Locate splitting tabs cast into perimeter of closure plate Insert drive end of a 1 2 in breaker bar between splitting tab and crankcase and turn it to loosen seal Do not pry on sealing surfaces as this can cause leaks Inspection Inspect oil seal in oil pan and remove it if it is worn or damaged Refer to Install Oil Pan Oil Seal in Reassembly for new oil seal installation Inspect main bearing surface for wear or damage refer to Specifications Replace oil pan assembly if required 66 KohlerEngines com
44. Body including idle speed increase over 300 RPM should include ECU Reset This will clear 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 Turn key ignition ON then OFF and count to 10 seconds a second time 5 Remove Red wire jumper Turn key ignition ON then OFF and count to 10 seconds a third time ECU is reset ATPS Learn Procedure must be performed after ECU Reset 26 KohlerEngines com TPS Learn Procedure 1 Turm idle screw clockwise one full turn prior to key ignition ON after ECU Reset 2 Start engine run at low idle until engine is warm 3 Idle speed must be above 1500 RPM If below 1500 RPM turn idle screw up to 1700 RPM and then shut down engine and perform 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 idle speed to final specified speed setting 6 Turn key ignition OFF and count to 10 seconds Learn procedure is complete 24 690 31 Rev B Propane EFI System JO O UUOD onsouBeiq fv Josues eJnje1eduus JOSU9S Josues eJnssa9J
45. CK OFF IGNITION SYSTEM T REFER TO DIAGNOSTIC AID 6 IGNITION SYSTEM YES WHILE CRANKING CHECK INJECTOR FUEL DELIVERY KNY NOTAB INTERNAL COMBUSTION YES INSTALL IN LINE PRESSURE GAUGE AND KEY ON NO REFER TO DIAGNOSTIC AID 7 FUEL SYSTEM ELECTRICAL REFER TO DIAGNOSTIC AID 8 IN SPECIFICATION NO FUEL SYSTEM YES REFER TO DIAGNOSTIC AID 9 BASIC ENGINE 1 After turning key to OFF wait 10 seconds before turning to ON to allow ECU to go to sleep 2 Fuel lock off can be heard or felt to establish lock off opening Fuel lock off will stay activated for one 4 6 second cycle when ECU wakes up after being asleep key ON not cranking 24 690 31 Rev B KohlerEngines com 45 Lubrication System This engine uses a full pressure lubrication system which delivers oil under pressure to crankshaft camshaft connecting rod bearing surfaces and hydraulic valve lifters A high efficiency gerotor oil pump maintains high oil flow and oil pressure even at low speeds and high operating temperatures A pressure relief valve limits maximum pressure of system Oil pan must be removed to service oil pickup pressure relief valve and oil pump Lubrication Components T o B T UTR Jin m Ld ir nl Ul l VLA OIL RECOMMENDATIONS Refer to Maintenance A OiSenry B OlPessue c OiFil Dipstick D Oil
46. Fil Tube E Oil Cooler F OilFilter G BackSide CHANGE OIL AND FILTER Change oil while engine is warm CHECK OIL LEVEL 1 Clean area around oil fill cap dipstick and drain plug NOTE To prevent extensive engine wear or damage care a pug and oil fill cap dipstick Allow oil never run engine with oil level below or above 9 fall COMPETE operating range indicator on dipstick 2 Clean area around oil filter Place a container under Ensure engine is cool Clean oil fill dipstick areas of any filter to catch any oil and remove filter Wipe off debris mounting surface Reinstall drain plug Torque to 5 AN DE iot 13 6 N m 10 ft Ib j PONE IPS De oe 3 Place new filter in shallow pan with open end up Fill 2 Reinsert dipstick into tube rest cap on tube do not with new oil until oil reaches bottom of threads Allow thread cap onto tube 2 minutes for oil to be absorbed by filter material 3 Remove dipstick check oil level Level should beat 4 Apply a thin film of clean oil to rubber gasket on new top of indicator on dipstick filter 4 If oil is low on indicator add oil up to top of indicator 5 Referto instructions on oil filter for proper mark installation 5 Reinstall and secure dipstick 6 Fill crankcase with new oil Level should be at top of indicator on dipstick 46 KohlerEngines com 24 690 31 Rev B 7 Reinstall oil fill cap dipstick and tighten securely 8 Start engine check for oil leaks Stop engine correct leaks
47. KOHLER Command PRO PCV680 PCV740 Propane Electronic Fuel Injection EFI Service Manual Kev IMPORTANT Read all safety precautions and instructions carefully before operating equipment Refer to operating instruction of equipment that this engine powers Ensure engine is stopped and level before performing any maintenance or service 2 Safety 3 Maintenance 5 Specifications 13 Tools and Aids 16 Troubleshooting 20 Air Cleaner Intake 21 Propane Electronic Fuel Injection EFI System 46 Lubrication System 48 Electrical System 53 Starter System 57 Disassembly Inspection and Service 73 Reassembly 24 690 31 Rev B KohlerEngines com Safety SAFETY PRECAUTIONS A WARNING A hazard that could result in death serious injury or substantial property damage A CAUTION A hazard that could result in minor personal injury or property damage NOTE is used to notify people of important installation operation or maintenance information A WARNING Explosive Fuel can cause fires and severe burns s If a gaseous odor is 4 4 detected ventilate area and contact an authorized service technician WARNING Carbon Monoxide can cause severe nausea fainting or death Avoid inhaling exhaust fumes A CAUTION Y Electrical Shock can cause injury E Do not touch wires while engine is running Propane is extremely flammable and is heavier than air and ten
48. Open heater circuit Improper handling Carbon deposits Replace sensor Incorrect or contaminated fuel Use high quality fuel Excessive engine 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 2 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 tested as follows harness Check continuity in wire harness Ohms between Pin 3 at sensor connector and Black pin 11 connector at ECU should be near zero ohms If no continuity is measured or very high resistance replace wire 1 32 Make sure all connections are making proper contact and are free of dirt and debris Remove blower housing Slide locking tab out and pull off manifold absolute pressure connector Turn key switch to ON and check with a volt meter by contacting red lead to pin 1 and black lead to pin 2 There should be 5 volts present indicating ECU and wiring harness are functioning KohlerEngines com Check to make sure intake manifold is not loose and MAP sensor is not loose Loose parts would allow a vacuum leak making MAP sensor report misleading information to ECU a Tighten all hardware and perform an ECU Reset an
49. Sensor loose or air gap incorrect e Pin circuit wiring or connectors e ECU pin Black 1 Crankshaft Position Sensor Wheel e ECU to harness connection problem Related e Damaged teeth Ignition System Related e Gap section not registering e Incorrect spark plug s used e Poor connection to spark plug Engine Wiring Harness Related Code 0352 e Pin circuit wiring or connectors ECU pin Black 4 and Black 13 Component Ignition Coil e ECU to harness connection problem Fault Cylinder 2 Ignition Coil Malfunction ignition System Related Condition Broken wire in harness may not be non oy sem Reale visible shorted connection or faulty e Non resistor spark plug s used sensor e Faulty or disconnected ignition coil or TVT secondary lead Conclusion Engine Wiring Harness Related e Connection to ignition or fuse e Pin circuit wiring or connectors Code 0337 ECU pin Grey 10 Component Crankshaft Position Sensor e ECU to harness connection problem Fault Crankshaft Position Sensor No Signal una Guster Relsied Condition Air gap incorrect loose sensor open or Sn yee eo shorted connection or faulty sensor e Incorrect spark plug s used e Poor connection to spark plug Conclusion Crankshaft Position Sensor Related e Sensor connector or wiring e Sensor loose or air gap incorrect Code 0562 Component System Voltage zu Position Sensor Wheel Fault System Voltage Low e Damaged teeth Condition Faulty voltage regul
50. Size nto Aluminum Tightening Torque N m in Ib 10 M4 1 2 11 1 7 15 2 9 26 4 1 36 5 0 44 2 0 18 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 Ib 10 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 56 131 5 97 184 4 136 219 7 162 94 9 70 Torque Conversions N m in Ib x 0 113 in lb N m x 8 85 N m ft Ib x 1 356 ft Ib N m x 0 737 12 KohlerEngines com 24 690 31 Rev B Tools and Aids Certain quality tools are designed to help you perform specific disassembly repair and reassembly procedures By using these tools you can properly service engines easier faster and safer In addition you ll increase your service capabilities and customer satisfaction by decreasing engine downtime Here is a list of tools and their source SEPARATE TOOL SUPPLIERS Kohler Tools SE Tools Design Technology Inc Contact your local Kohler source of 415 Howard St 768 Burr Oak Drive supply Lapeer MI 48446 Westmont IL 60559 Phone 810 664 2981 Phone 630 920 1300 Toll Free 800 664 298 1 Fax 630 920 0011 Fax 810 664 8181 TOOLS Description Source Part No Alcohol Content Tester Kohler 25 455 11 S For testing alcohol content in reformul
51. TE If crankpin is reground visually check to ensure fillet blends smoothly with crankpin surface NOTE To prevent repeat failures camshaft and crankshaft should always be replaced as a set Inspect gear teeth of crankshaft If teeth are badly worn chipped or some are missing replacement of crankshaft will be necessary Inspect crankshaft bearing surfaces for scoring grooving etc Some engines have bearing inserts in crankshaft bore of oil pan and or crankcase Do not replace bearings unless they show signs of damage or are out of running clearance specifications If crankshaft turns easily and noiselessly and there is no evidence of scoring grooving etc on races or bearing surfaces bearings can be reused Inspect crankshaft keyways If they are worn or chipped replacement of crankshaft will be necessary Inspect crankpin for score 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 for size taper and out of round Connecting rod journal can be ground one size under When grinding a crankshaft grinding stone deposits can get caught in oil passages which could cause
52. a richer air fuel ratio is required and system operates in an open loop mode In open loop operation oxygen sensor output is used to ensure engine is running rich and controlling adjustments are based on primary sensor signals and programmed maps only This system operates open loop whenever three conditions for closed loop operation above are not being met ECU is brain or central processing computer of entire EFI system During operation sensors continuously gather data which is relayed through wiring harness to input circuits within ECU Signals to ECU include ignition on off crankshaft position and speed RPM throttle position oil temperature intake air temperature exhaust oxygen levels manifold absolute pressure and battery voltage KohlerEngines com 21 Propane EFI System ECU compares input signals to programmed maps in its memory to determine appropriate fuel and spark requirements for immediate operating conditions ECU then sends output signals to set injector duration and ignition timing ECU continually performs a diagnostic check of itself each of sensors and system performance If a fault is detected ECU can turn on a Malfunction Indicator Light MIL if equipped on equipment control panel store fault code in its fault memory and go into a default operating mode Depending on significance or severity of fault normal operation may continue A technician can access stored fault code using a blink code
53. ads and crankcase Make 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 Ib then finally to 33 9 N m 300 in Ib following sequence KohlerEngines com 77 Reassembly Install Push Rods and Rocker Arms Install Spark Plugs NOTE Push rods should always be installed in same 1 position as before disassembly Note mark or tag identifying push rod as either intake or exhaust and cylinder 1 or 2 Dip ends of push rods in engine oil and install making sure that each push rod ball seats in its hydraulic lifter socket Apply grease to contact surfaces of rocker arms and rocker arm pivots Install rocker arms and rocker arm pivots on one cylinder head and start screws Torque screws to 18 1 N m 160 in Ib Use a spanner wrench or rocker arm lifting tool to lift rocker arms and position push rods underneath Repeat above steps for remaining cylinder Do not interchange parts from cylinder heads Rotate crankshaft to check for free operation of valve train Check clearance between valve spring coils at full lift Minimum allowable clearance is 0 25 mm 0 010 in Check Assembly Important Rotate crankshaft a minimum of 2 revolutions to check longblock assembly and overall proper operation 78 1 Check gap using wire feeler gauge A
54. all Metal Debris Screen Spring Washer Details A Spring Washer KohlerEngines com 81 Reassembly um ZI Wo R RSS B 4 Install dipstick tube and align mounting hole with threaded hole in ECU bracket Secure with M5 screw Torque screw to 6 2 N m 55 in Ib into new hole or 4 0 N m 35 in Ib into used hole ECU Install Electronic Control Unit ECU A Metal Debris Screen B Fan C Flywheel D Spacer E Hex Bolt 1 Verify locating tabs on back of fan are inserted into locating holes on flywheel 2 Toassist assembly find intake manifold studs with M6 thread at least 100 mm in length to be used as guide pins Insert intake manifold studs through cooling fan mounting holes and thread them 4 or 5 turns into flywheel 3 Install a spring washer on each stud with concave side down toward cooling fan 4 Install a spacer on each stud with stepped end down Smaller diameter should extend through spring washer and fan so tip is resting on flywheel and shoulder is resting on spring washer 5 Install support ring on studs so it is resting on spacers Then install metal screen on top of support ring 6 Install a plain washers on each of screws Apply Loctite 242 to screw threads 7 Carefully remove studs and replace with screws Torque screws to 9 9 N m
55. alve guides Install following items in order listed below using a valve spring compressor Intake and exhaust valves Valve spring retainers Valve springs Valve spring caps Valve spring keepers 24 690 31 Rev B Torque Sequence NOTE Match numbers embossed on cylinder heads and crankcase 1 Check to make sure there are no nicks or burrs on sealing surfaces of cylinder head or crankcase 2 If all of studs were left intact go to Step 6 If any studs were disturbed or removed install new studs as described in Step 3 Do not use reinstall any loosened or removed studs 3 Install new mounting stud s into crankcase a Thread and lock mounting nuts together on smaller diameter threads b Thread opposite end of stud with preapplied locking compound into crankcase until specified height from crankcase surface is achieved When threading in studs use a steady tightening motion without interruption until proper height is obtained Otherwise frictional heat from engaging threads may cause locking compound to set up prematurely Studs closest to lifters must have an exposed height of 75 mm 2 15 16 in Studs furthest from lifters must have an exposed height of 69 mm 2 3 4 in c Remove nuts and repeat procedure as required 4 Check that dowel pins are in place and install a new cylinder head gasket part number facing up 5 Install cylinder head Match numbers on cylinder he
56. ated oxygenated fuels Camshaft Endplay Plate SE Tools KLR 82405 For checking camshaft endplay Camshaft Seal Protector Aegis SE Tools KLR 82417 For protecting seal during camshaft installation Cylinder Leakdown Tester Kohler 25 761 05 S For checking combustion retention and if cylinder piston rings or valves are worn Individual component available Design Technology Inc Adapter 12 mm x 14 mm Required for leakdown test on XT 6 engines DTI 731 03 Dealer Tool Kit Domestic Kohler 25 761 39 S Complete kit of Kohler required tools Components of 25 761 39 S Ignition System Tester Kohler 25 455 01 S Cylinder Leakdown Tester Kohler 25 761 05 S Oil Pressure Test Kit Kohler 25 761 06 S Rectifier Regulator Tester 120 V AC 60Hz Kohler 25 761 20 S Dealer Tool Kit International Kohler 25 761 42 S Complete kit of Kohler required tools Components of 25 761 42 S Ignition System Tester Kohler 25 455 01 S Cylinder Leakdown Tester Kohler 25 761 05 S Oil Pressure Test Kit Kohler 25 761 06 S Rectifier Regulator Tester 240 V AC 50Hz Kohler 25 761 41 S Digital Vacuum Pressure Tester Design Technology Inc For checking crankcase vacuum DTI 721 01 Individual component available Design Technology Inc Rubber Adapter Plug DTI 721 10 Electronic Fuel Injection EFI Diagnostic Software Kohler 25 761 23 S For Laptop or Desktop PC EFI Service Kit Kohler 24 761 01 S For troubleshooting and setting up an EFI engine Components of 2
57. ator bad fuse or shorted connection Engine Wiring Harness Related Conclusion Corroded Connections e Pin circuit wiring or connectors ECU pin Black 4 or Black 13 Bad Stator e ECU to harness connection problem Bad Battery If code is stored in fault history and starts e Low output charging system normally Clear code no other service e Poor magnet in flywheel required e Bad or missing fuse Code 0563 Component System Voltage Fault System Voltage High Condition Faulty voltage regulator or shorted connection Conclusion Faulty Rectifier Regulator Bad Stator Bad Battery Code 61 Component End of Code Transmission 24 690 31 Rev B KohlerEngines com 43 Propane EFI System Troubleshooting Flow Chart Following flow chart provides an alternative method of troubleshooting EFI system Chart will enable you to review entire system in about 10 15 minutes Using chart accompanying diagnostic aids listed chart and any signaled fault codes you should be able to quickly locate any problems within system Flow Chart Diagnostic Aids Diagnostic Aid 1 SYSTEM POWER MIL does not illuminate when key is turned ON NOTE MIL is installed by vehicle OEM Twelve volt supply to bulb will be part of vehicle wire harness Kohler key switch model will have MIL on engine with 12V supply to bulb Conclusion e Battery e Main system fuse e MIL light bulb burned out e MIL electrical circ
58. be caused by localized hot spots resulting from blocked cooling fins or from inadequate or contaminated lubrication If cylinder bore is badly scored excessively worn tapered or out of round resizing is necessary Use an inside micrometer to determine amount of wear refer to Specifications then select nearest suitable oversize of either 0 25 mm 0 010 in or 0 50 mm 0 020 in Resizing to one of these oversizes will allow usage of available oversize piston and ring assemblies First resize using a boring bar then use these following procedures for honing cylinder 24 690 31 Rev B Disassembly Inspection and Service Honing Detail 2 A A 23 33 Crosshatch NOTE Kohler pistons are custom machined to exacting tolerances When oversizing a cylinder it should be machined exactly 0 25 mm 0 010 in or 0 50 mm 0 020 in over new diameter Specifications Corresponding oversize Kohler replacement piston will then fit correctly While most commercially available cylinder hones can be used with either portable drills or drill presses use of a low speed drill press is preferred as it facilitates more accurate alignment of bore in relation to 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 stones are in contact with cyl
59. ble to positive battery terminal first ee by negative cable to negative battery terminal Never start engine when cables are loose or poorly connected to battery terminals Never disconnect battery while engine is running Never use a quick battery charger to start engine Do not charge battery with key switch ON Always disconnect negative battery cable before charging battery and also unplug harness from ECU before performing any welding on equipment 24 KohlerEngines com 24 690 31 Rev B Propane EFI System ELECTRICAL COMPONENTS Grey Connector Side Electronic Control Unit ECU Pin Description Pinout of ECU 1 Not Used Black Connector Side 2 Not Used Pin Function 3 Malfunction Indicator Light MIL Ground 1 Ignition Coil 1 Ground 4 Not Used 2 Battery Ground 5 Not Used 3 Diagnostic Communication Line 6 Not Used 4 Speed Sensor input 7 Not Used 5 Fuel Injector Output 1 Ground 8 Not Used 6 Fuel Injector Output 2 Ground 9 Battery Ground 7 Oxygen Sensor Heater 10 Ignition Coil 2 Ground 8 Intake Air Temperature IAT sensor input 11 Not Used 9 Fuel Lock Off Ground 12 Not Used 10 Ground for IAT TPS MAP O2 and Oil Sensors 13 Not Used 11 Manifold Absolute Pressure MAP sensor input 14 Safety Switch Ground 12 Throttle Position S
60. break gasket seal Do not pry on sealing surfaces as it could cause damage resulting in leaks 6 Remove breather cover and gasket ak WON gt Remove Crankshaft Position Sensor 1 Remove screws securing crankshaft position sensor bracket 2 Disconnect electrical connector to crankshaft position sensor Remove Manifold Absolute Pressure MAP Sensor 1 With a screwdriver slide locking tab on electrical connector 2 Detach connector 3 Remove screw and pull MAP sensor out of intake manifold Remove Fuel Injectors 1 Disconnect electrical connector 2 Remove screw and pull injector out of 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 KohlerEngines com 61 Disassembly Inspection and Service 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 Cylinder Head Components e Unclasp wiring harness from clip using a screwdriver Remove intake manifold and intake manifold gaskets Leave high pressure fuel line and wiring harness attached to manifold A Valve Cover B Valve Cover Gasket C Hex Flange Screw D Rocker Arm Pivot E Rocker Arm F P
61. brication System 4 Adjust idle speed adjusting screw as necessary Refer to Fuel System 5 Turn on fuel supply Sensitivity Adjustment A Governor Lever B Hole 1 C Hole 2 D Hole 3 E Hole 4 Governor sensitivity is adjusted by repositioning governor spring in holes of governor lever If speed surging occurs with a change in engine load governor is set too sensitive If a big drop in speed occurs when normal load is applied governor should be set for greater sensitivity 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 86 KohlerEngines com 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 to make certain that oil pressure 20 psi or more is present Run engine at idle for 2 3 minutes then 5 6 minutes more between idle and midrange 2 Adjust idle speed screw located on throttle body as necessary Standard idle speed setting for EFI engines is 1500 RPM but certain applications might require a different setting 3 Adjust high speed stop as necessary located on control panel if equipped Make sure maximum engine speed does not exceed 4200 RPM no load 24 690 31 Rev B 24 690 31 Rev B KohlerEngines com 87 1P24 690 31 22191 2015 by Koh
62. ces of oil pan or crankcase Use a new gasket Before installing gasket check to make sure O ring is present in counter bore around dowel pin Make sure end of governor cross shaft is lying against bottom of cylinder 1 inside crankcase 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 Install screws securing oil pan to crankcase Torque fasteners in sequence shown to 25 6 N m 227 in Ib One mounting screw has a thread sealant patch This screw is typically installed in number 10 hole shown Reapply pipe sealant with Teflon Loctite 5927 PST Thread Sealant or equivalent to number 10 oil pan screw as required Install Stator and Backing Plate 1 24 690 31 Rev B Apply pipe sealant with Teflon Loctite 592 PST Thread Sealant or equivalent to stator mounting holes Position stator aligning mounting holes so that leads are at bottom towards crankcase Install and torque screws to 6 2 N m 55 in Ib for new holes or 4 0 N m 35 in Ib for used holes Route stator leads in crankcase channel then install backing plate Secure with screws Torque screws 10 7 N m 95 in Ib for new holes or 7 3 N m 65 in Ib for used holes Reassembly Install Flywheel A CAUTION Damaging Crankshaft and Flywheel Can cause personal injury Jo N Using improper procedures can lead
63. contact an authorized service technician Propane is extremely flammable and is heavier than air and tends to settle in low areas where a spark or flame could ignite gas Do not start or operate this engine in a poorly ventilated area where leaking gas could accumulate and endanger safety of persons in area To ensure personal safety installation and repair of propane fuel supply systems must be performed only by qualified propane system technicians Improperly installed and maintained propane equipment could cause fuel supply system or other components to malfunction causing gas leaks Observe federal state and local laws governing propane fuel storage and systems Typical propane electronic fuel injection EFI system and related components include e Vaporizer regulator e Fuel filter High pressure fuel line Fuel line s Gaseous propane fuel injectors Throttle body intake manifold Electronic control unit ECU Ignition coils Engine oil temperature sensor Throttle position sensor TPS Crankshaft position sensor Oxygen sensor Manifold absolute pressure sensor MAP Wire harness assembly amp affiliated wiring Malfunction indicator light MIL optional Intake air temperature sensor FUEL RECOMMENDATIONS Refer to Maintenance FUEL LINE High pressure fuel line meeting a minimum of SAE R7 standard must be installed on Kohler Co engines equipped with propane EFI system from va
64. d a TPS Learn Procedure to see if MIL will display a fault with MAP sensor again If MIL finds a fault with MAP sensor replace it 24 690 31 Rev B Fuel Injectors A wARNING High Pressure Fluids can puncture skin and e cause severe injury or death Do not work on fuel system without proper training or safety equipment Fluid puncture injuries are highly toxic and hazardous If an injury occurs seek immediate medical attention Details A Electrical Connection B Upper O ring C Solenoid Winding D Armature E Valve Housing F Valve Seat G Valve End H Lower O ring l Director Plate NOTE Do not apply voltage to fuel injector s Excessive voltage will burn out injector s Do not ground injector s with ignition ON Injector s will open turn on if relay is energized NOTE When cranking engine with injectors disconnected fault codes will be registered in ECU and will need to be cleared using software fault clear or an ECU Reset and TPS Learn Procedure Injector problems typically fall into three general categories electrical dirty clogged or leakage An electrical problem usually causes one or both of injectors to stop functioning Several methods may be used to check if injectors are operating 1 With engine running at idle listen for a buzzing or clicking sound 2 Disconnect electrical connector from an injector and listen for a change in idle perfo
65. d or damaged in any way Never reuse an old seal 1 Remove screws rocker arm pivots and rocker arms from cylinder head 2 Compress valve springs using a valve spring compressor 3 Once valve spring is compressed remove valve spring keepers then remove following items e Valve spring retainers e Valve springs e Valve spring caps e Intake and exhaust valve mark position e Valve stem seals intake and exhaust 4 Repeat above procedure for other cylinder head Do not interchange parts from one cylinder head to other KohlerEngines com 63 Disassembly Inspection and Service Inspection and Service Valve Details EXHAUST VALVE Sy INTAKE VALVE 5 elll A te o M m EN EXHAUST fe INSERT ZZ OB INTAKE A INSERT Dimension Intake Exhaust A Seat Angle 89 89 B Insert O D 36 987 37 013 mm 1 4562 1 4572 in 32 987 33 013 mm 1 2987 1 2997 in C Guide Depth 4 mm 0 1575 in 6 5 mm 0 2559 in D Guide I D 7 038 7 058 mm 0 2771 0 2779 in 7 038 7 058 mm 0 2771 0 2779 in E Valve Head Diameter 33 37 33 63 mm 1 3138 1 3240 in 29 37 29 63 mm 1 1563 1 1665 in F Valve Face Angle 45 45 G Valve Margin Min 1 5 mm 0 0591 in 1 5 mm 0 0591 in H Valve Stem Diameter 6 982 7 000 mm 0 2749 0 2756 in 6 970 6 988 mm 0 2744 0 2751 in After cleaning check flatness of cylinder head and Hard starting or loss of power accompanied by high corresponding top
66. d to all new oxygen sensors at factory If recommended mounting thread sizes are used this material provides excellent anti seize capabilities and no additional anti seize is needed If sensor is removed from engine and reinstalled anti seize compound should be reapplied Use an oxygen sensor safe type anti seize compound It should be applied according to directions on label KohlerEngines com 31 Propane EFI System Troublshooting Oxygen Sensor O Condition Possible Cause Conclusion Low voltage output Shorted sensor or sensor circuit Shorted lead wire Wiring shorted to ground Replace sensor or repair wiring Contamination of air reference Remove source of external contamination protect air reference area Air leak at sensor or gasket sensor upper shield damage Use recommended torque at installation replace gasket or sensor Revise application exhaust Shield sensor from damage High voltage output Silica poisoning Replace sensor Contaminated fuel Use high quality fuel Engine problem misfire Correct cause of misfire Excessive rich air fuel ratio Check for high fuel pressure Leaking injector Wiring shorted to voltage Repair wiring Open circuit no activity from sensor Broken element Sensor dropped Hard blow to engine or exhaust system Defective sensor Thermal shock Replace sensor Slow time response
67. debris and make sure electrical connectors have seal in place 1 Install crankshaft position sensor and bracket assembly to crankcase posts 2 Snug screws and check air gap of sensor with a feeler gauge It must be 0 20 0 70 mm 0 008 0 027 in 3 Torque bracket screws to crankcase to 4 0 N m 35 in Ib into used holes or 6 2 N m 55 in Ib into new holes 4 Push electrical connector on crankshaft position sensor making sure a good connection is made Install Valve Covers Torque Sequence 1 Make sure sealing surfaces are clean 2 Make sure there are no nicks or burrs on sealing surfaces 3 Install a new O ring in groove of each cover 4 Position covers on cylinder heads Locate cover with oil separator hole on cylinder 1 Install screws in each cover and finger tighten 5 Torque valve cover fasteners to 6 2 N m 55 in Ib 24 690 31 Rev B Install Breather Cover and Inner Baffles Torque Sequence 1 Be sure sealing surfaces of crankcase and breather cover are clean of old gasket material Do not scrape surfaces as this could result in leakage Use a new gasket when installing breather cover 2 Check to make sure there are no nicks or burrs on sealing surfaces 3 Position breather gasket and cover on crankcase Install screws in locations 3 and 4 Finger tighten at this time 4 Install inner baffles using remaining screws and finger tighten Do not torqu
68. develops sufficient speed to disengage starter but does not keep running a false start engine rotation must be allowed to come to a complete stop before attempting to restart engine If starter is engaged while flywheel is rotating starter pinion and flywheel ring gear may clash and damage starter NOTE If starter does not crank engine shut off starter immediately Do not make further attempts to start engine until condition is corrected NOTE Do not drop starter or strike starter frame Doing so can damage starter Engines in this series use solenoid shift starters Troubleshooting Starting Difficulties Condition Possible 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 By pass switch or solenoid with a jumper wire If starter cranks or Solenoid normally replace faulty components Remove and perform individual solenoid test procedure Starter energizes but turns Battery Check specific gravity of battery If low recharge or replace slowly battery as necessary Brushes Check for excessively dirty or worn brushes and commutator Clean using a coarse cloth not emery cloth Replace brushes if excessively or unevenly worn Transmission or Engine Make sure clutch o
69. diagnosis flashed out through MIL An optional computer software diagnostic program is also available see Tools and Aids ECU requires a minimum of 6 0 volts to operate To prevent engine over speed and possible failure a rev limiting feature is programmed into ECU If maximum RPM limit 4500 is exceeded ECU suppresses injection signals cutting off fuel flow This process repeats itself in rapid succession limiting operation to preset maximum Wiring harness used in EFI system connects electrical components providing current and ground paths for system to operate All input and output signaling occurs through two special all weather connectors that attach and lock to ECU Connectors are Black and Grey and keyed differently to prevent being attached to ECU incorrectly Condition of wiring connectors and terminal connections is essential to system function and performance Corrosion moisture and poor connections are as likely cause of operating problems and system errors as an actual component Refer to Electrical System for additional information EFI system is a 12 VDC negative ground system designed to operate down to a minimum of 6 0 volts If system voltage drops below this level operation of voltage sensitive components such as ECU lock off valve 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 crank
70. djust gap to 0 76 mm 0 03 in 2 Install plug into cylinder head 3 Torque plug to 27 N m 20 ft Ib KohlerEngines com 24 690 31 Rev B External Engine Components Reassembly Debris Screen Guard Debris Screen Air Cleaner Bracket High Pressure Fuel A B C D Line Assembly Gaseous Propane Crankshaft Position E Fuel Quick Connect F Fuel Injector G MAP Sensor H Sensor l Oil Cooler O Ring J Oil Cooler K Nipple L Oil Filter M Ignition Coil N Barrel Baffle o Valley Baffle P Breather Cover Q Breather Cover R Oil Sentry S Oil Temperature T Throttle Body Gasket Sensor Assembly Air Temperature Dipstick Tube Oil Fill Cap Dipstick Air Cleaner S V Ww X ensor Y Breather Hose Z Breather Separator 24 690 31 Rev B KohlerEngines com 79 Reassembly Install Intake Manifold Install Manifold Absolute Pressure MAP Sensor Torque Sequence 1 Install intake manifold with high pressure fuel line assembly and new gaskets with wiring harness attached to cylinder heads Slide any wiring harness clips onto appropriate bolts before installing Make sure gaskets are in proper orientation Using sequence shown torque screws in 2 stages first to 7 8 N m 69 in Ib then to 10 5 N m 93 in Ib 2 Install ground terminal to crankcase post with a silver screw Torque to 4 0 N m 35 in Ib into used holes or 6 2 N m 55 in Ib in new h
71. ds to settle in low areas where a spark or flame could ignite gas Do not start or operate this engine in a poorly ventilated area where leaking gas could accumulate and endanger safety of persons in area To ensure personal safety installation and repair of propane fuel supply systems must be performed only by qualified propane system technicians Improperly installed and maintained propane equipment could cause fuel supply system or other components to malfunction causing gas leaks Observe federal state and local laws governing propane fuel storage and systems Engine exhaust gases contain poisonous carbon monoxide Carbon monoxide is odorless colorless and can cause death if inhaled A WARNING Accidental Starts can cause severe injury or death Disconnect and ground spark plug lead s before 24 servicing f Ne A CAUTION Damaging Crankshaft and Flywheel can cause Jo personal injury QN Using improper procedures can lead to broken fragments Broken fragments could be thrown from engine Always observe and use precautions and procedures when installing flywheel Before working on engine or equipment disable engine as follows 1 Disconnect spark plug lead s 2 Disconnect negative battery cable from battery A wARNING Ro Rotating Parts can cause severe injury Stay away while engine is in operation clothing away from all moving
72. e screws at this time they will be tightened after blower housing Install Oil Temperature Sensor NOTE Ensure part is clean undamaged and free of debris and make sure electrical connector has seal in place 1 Lightly lubricate oil temperature sensor O ring and install oil temperature sensor into breather cover 2 Torque sensor to 7 3 N m 65 in Ib 3 Push electrical connector on oil temperature sensor making sure a good connection is made Install Oil Sentry If equipped 1 Apply pipe sealant with Teflon Loctite 592 PST Thread Sealant or equivalent to threads of Oil Sentry switch and install it into breather cover Torque to 4 5 N m 40 in Ib 2 Connect wire lead green to 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 blower housing into position over front edge of inner baffles Start a few screws to hold it in place 24 690 31 Rev B Reassembly 2 Position outer baffles 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 n
73. eaking gas could accumulate and endanger safety of persons in area Explosive Fuel can cause fires and severe To ensure personal safety installation and repair of propane burns fuel supply systems must be performed only by qualified propane system technicians Improperly installed and maintained propane equipment could cause fuel supply system or other components to malfunction causing gas leaks Observe federal state and local laws governing propane fuel storage and systems g VAY If a gaseous odor is detected ventilate area and contact an authorized service technician Remove Vaporizer Regulator Lock Off A Vacuum Line B Vaporizer Regulator C Inlet Fitting D Lock Off Assembly E Propane Fuel Filter F Bracket G Outlet Fitting H Oetiker Clamp l Remove Throttle Body 1 Disconnect electrical plug from lock off 1 Disconnect intake air temperature sensor connector 2 Disconnect vacuum line from front of vaporizer from sensor in throttle body Sensor can stay in regulator throttle body unless it is being replaced 3 Loosen nut on center back of vaporizer regulator 2 Disconnect breather tube from throttle body Keep all fuel lines connected then lift up on 3 Disconnect throttle position sensor connector regulator so nut comes through key hole slot in bracket removing vaporizer regulator from bracket 4 Disconnect vent hose from throttle body Keeping fu
74. el lines propane fuel filter assembled 5 Remove screws securing air cleaner bracket take Separate parts only if additional service is required off bracket and slide throttle body with linkage and Do not cut Oetiker clamps unless fuel lines and or spring connected off intake manifold propane fuel filter are being replaced 4 Remove screws securing regulator bracket to crankcase 60 KohlerEngines com 24 690 31 Rev B ECU Remove Electronic Control Unit ECU R A Electronic Control B ECU Bracket Unit ECU C Starter 1 Remove screws securing ECU to bracket 2 Disconnect Black and Grey electrical connectors from ECU Remove Electronic Control Unit Bracket and Electric Starter Motor 1 Disconnect leads from starter 2 Remove screws ECU bracket and starter assembly Remove Oil Separator and Hardware Remove screws securing oil separator assembly pulling assembly out and away from valve cover Remove Guard and Debris Screen NOTE Fan will be loose but cannot be removed until after blower housing is removed 1 Remove screws securing guard to blower housing and remove guard and spacers 2 Remove screws securing metal screen and remove Screen 3 Remove support ring spacers and washers paying attention to curvature of spring washers between spacers and fan Remove Outer Barrel Baffles and Blower Housing 1 Disconnect plug from rectifier regulator 2 Remove sil
75. embled original brush holder assembly onto end of armature shaft Slide brush holder assembly down into place around commutator install positive brush lead grommet in cutout of frame 11 Install end cap onto armature and frame aligning thin raised rib in end cap with corresponding slot in grommet of positive brush lead 12 Install thru bolts and brush holder mounting screws Torque bolts to 5 6 9 0 N m 49 79 in Ib and brush holder mounting screws to 2 5 3 3 N m 22 29 in Ib 13 Hook plunger behind upper end of drive lever and install spring into solenoid Insert mounting screws through holes in drive end cap Use these to hold solenoid gasket in position then mount solenoid Torque screws to 4 0 6 0 N m 35 53 in Ib 14 Connect positive brush lead bracket to solenoid and secure with nut Torque nut to 8 11 N m 71 97 in Ib Do not overtighten Solenoid Tests NOTE DO NOT leave 12 volt test leads connected 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 1 lead to flat spade S start terminal on solenoid Momentarily connect other lead to lower large post ter
76. ensor TPS input 15 Not Used 13 Speed Sensor Ground 16 ECU 14 Oil Temperature Sensor input 17 Fuel Lock Off Control 12V 15 Ignition Switch Switched 12V 18 Not Used 16 Power for TPS and MAP Sensors 5V 17 Oxygen Sensor O2 input 18 Battery Power Permanent 12V ECU BLACK CONNECTOR SIDE GREY CONNECTOR SIDE 123456789 w a 10 11 12 13 14 15 16 17 18 10 11 12 13 14 15 16 17 18 Pinout of ECU 24 690 31 Rev B KohlerEngines com 25 Propane EFI System Never attempt to disassemble ECU It is sealed to prevent damage to internal components Warranty is void if case is opened or tampered with in any way All operating and control functions within ECU are preset No internal servicing or readjustment may be performed If a problem is encountered and you determine ECU to be faulty contact your source of supply ECU pins are coated at factory with a thin layer of electrical grease to prevent fretting and corrosion Do not attempt to remove grease from ECU pins 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 appropriate TPS Learn Procedure must be performed to restore synchronization Any service to ECU or TPS Throttle
77. er regulator or propane fuel filter and abrasion sleeve must be positioned over Oetiker clamp gt 24 690 31 Rev B KohlerEngines com 83 Reassembly Install External Governor Controls Throttle Control Shaft Washer A Nut Throttle Control Shaft Throttle Control Lever E Spring Control Bracket ko Governor Spring l Governor Lever une Bushing Throttle Linkage pring M Nut Governor Cross Shaft 84 KohlerEngines com 24 690 31 Rev B 1 Install governor lever onto governor cross shaft Reassembly 2 Make sure throttle linkage linkage spring black linkage bushing are connected to governor lever and to throttle lever on throttle body Assemble Top Mount Control Panel 1 Install lower support control bracket with throttle control shaft 2 Install top mount control panel over throttle control shaft Secure control panel to blower housing with screws 3 Assemble throttle control lever and applicable hardware to throttle control shaft 4 Attach governor spring to previously marked hole on governor lever Install Air Cleaner Assembly Install Oil Cooler Refer to Air Cleaner Intake for air cleaner reassembly procedure Heavy Duty Air Cleaner 1 Install air cleaner assembly onto throttle body mounting studs Secure and torque nuts to 7 4 9 0 N m 65 5 80 in Ib 2 Install and tighten two upper mounting screws securing air cleaner to mounting bracket Torque
78. ervice or component replacement to prevent pinching or abrasion of line Only Kohler replacement parts can be used because vacuum line is specific to system and must be maintained Visit KohlerEngines com for recommended Kohler replacement parts Throttle Body Intake Manifold Assembly NOTE ECU Reset is required if throttle body is replaced Throttle body is serviced as an assembly with throttle shaft TPS throttle plate and idle speed adjusting screw installed Throttle shaft rotates on needle bearings non serviceable capped with seals to prevent air leaks 24 690 31 Rev B KohlerEngines com 35 Propane EFI System TROUBLESHOOTING Troubleshooting Guide Condition Possible Cause Engine Starts Hard or Fails to Start When Cold Engine Starts Hard or Fails to Start When Hot Engine Stalls or Idles Roughly cold or warm Engine Misses Hesitates or Stalls Under Load Lock off not functioning Faulty spark plugs Incorrect fuel Incorrect fuel pressure Crankshaft position sensor loose or faulty TPS set incorrect ECU Reset and TPS Learn TPS faulty Engine temp sensor faulty Faulty coils Low system voltage Faulty injectors Faulty battery Loose or corroded connections Faulty spark plugs Lock off not functioning Fuel pressure low Insufficient fuel delivery TPS set incorrect ECU Reset and TPS Initialization Crankshaft
79. es and fuel system Normal and fouled plugs are shown in following photos Normal Plug taken from an engine operating under normal conditions will have light tan or gray colored deposits If center electrode is not worn plug can be set to proper gap and reused Worn On a worn plug center electrode will be rounded and gap will be greater than specified gap Replace a worn spark plug immediately Wet Fouled A wet plug is caused by excess fuel or oil in combustion chamber Excess fuel could be caused by a restricted air cleaner a fuel system problem or operating engine with too much choke Oil in combustion chamber is usually caused by a restricted air cleaner a breather problem worn piston rings or valve guides KohlerEngines com 24 690 31 Rev B Electrical System Carbon Fouled BATTERY A 12 volt battery with 400 cold cranking amps cca is generally recommended for starting in all conditions A smaller capacity battery is often sufficient if an application is started only in warmer temperatures Refer to following table for minimum capacities based on anticipated ambient temperatures 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 requirements Battery Size Recommendations
80. ester can be used if PTO end of crankshaft is accessible Lock holding tool onto crankshaft 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 driven component Just be certain that engine cannot rotate off of TDC in either direction 4 Install adapter into spark plug hole but do not attach it to tester at this time 5 Turn regulator knob completely counterclockwise 6 Connect an air source of at least 50 psi to tester 7 Turn regulator knob clockwise increase direction until gauge needle is in yellow set area at low end of scale 8 Connect tester quick connect to adapter hose While firmly holding engine at TDC gradually open tester valve Note gauge reading and listen for escaping air at combustion air intake exhaust outlet and crankcase breather Condition Conclusion Air escaping from crankcase breather Ring or cylinder worn Air escaping from exhaust system Defective exhaust valve improper seating Air escaping from intake Defective intake valve improper seating Gauge reading in low green zone Piston rings and cylinder in good condition Gauge reading in moderate yel
81. eter can also be used as an effective tool in diagnosing sensors It is advisable to use an electronic meter such as a digital voltmeter Simple mechanical meters may place a heavy electrical load on sensor and cause inaccurate readings Since resistance of sensor is highest at low temperatures such meters will cause largest inaccuracies when sensor is in a cool exhaust Visual Inspection 1 Look for a damaged or disconnected sensor to engine harness connection 2 Look for damage to sensor lead wire or associated engine wiring due to cutting chaffing or melting on a hot surface 3 Disconnect sensor connector and look for corrosion in connector 4 Try reconnecting sensor and observe if problem has cleared 5 Correct any problems found during visual check 24 690 31 Rev B 24 690 31 Rev B Sensor Signal Observation NOTE Do not cut into or pierce sensor or engine wiring to make this connection Sensor produces a very small signal Corrosion or damage to wiring could lead to an incorrect signal because of repairs or contamination to sensor Using a voltmeter observe voltage between Pin C and Pin D before engine is started With key ON and sensor unplugged voltage should read about 5 0 volts With sensor attached using diagnostic software voltage should read about 1 0 volt This voltage is generated by ECU If it is not present there is a short in associated wiring and corrective action should be taken If volta
82. ff H Lock Off Valve Body l Plunger J Screen K Outlet Fitting Ensure there is an adequate supply of fuel in tank and that fuel valve is turned ON Vaporizer Regulator is preset at factory is not serviceable and must be replaced if determined to be faulty If a regulator problem is suspected make certain lock off is being activated all electrical connections are properly secured fuses are good and a minimum of 7 0 volts is being supplied If required testing of regulator and lock off may be conducted 1 Relieve fuel pressure at lock off Shut off tank valve If possible run engine in a well ventilated area until fuel system is empty and engine stops If unable to run engine work in a well ventilated area and carefully loosen inlet fuel fitting on vaporizer regulator slowly venting off fuel from line When fuel is dispensed retighten fitting and remove quick connect fitting to allow fuel to escape from line Insert pressure test jumper from Kohler EFI Service Kit between high pressure fuel line and fuel lock off 24 690 31 Rev B Propane EFI System 2 Turn on key switch to activate lock off and check system pressure on gauge If system pressure of 26 psi 3 is observed wiring lock off and regulator are working properly Turn key switch OFF and observe system pressure System pressure should not drop more than 5 psi per minute If it does drop more that this a leak may be present in system and should be in
83. gd JOSU9S v O4eqU IV emeidue yo V ajmosgypojuew OY vomsogemouj SV sues eP amp XO av Josuesg uomsog yeusyuerg QV Z 1109 uous ov L 1109 uoniuf av ZK 10 99fu jen3 vy L Joyoalu jen3 Z JOj98UU09 Aad A JOjD9UU09 yoe g X esnJ voL M TW A UJJIMS 98JnsSaJg IO n 40 4907 JOJO Jeue1s L JoaUUOD PUIUMO 9 S Joyen oynozuodea 4 A oyeg o esn4 voc d Jojejnbes 1eynoes o JO e S N xoelg N A819 1 SUM M uel r uld l a d nd H anig eq 9 usa Med 4 ueeJ5 1ur1 3 MOJIBA a 9IIUWPeMH xoelg pes g v m EN AK Or 0 f0 000000 ojosi l iobososob 6 40 99UU0J Jeulwia L 9 We1Berg BUM 143 ssousey BuuiM 27 KohlerEngines com 24 690 31 Rev B Propane EFI System Jo O UUOD onsouBeiq fv JOSUSS eJnje1eduus JOSU9S JOSU9S eJnssaJgd JOSU9S diy OMEJU Iv eJnjejeduie IO HV ajniosgy plojuew sv uonisog SOUL dv Josuag ueB xo Jv JOSU9S uonisog yeusxyuel av ZK o2 uoniuB ov L 1109 uoniu av ZH Jopeluj jen vy L Jojosluj jen z JOj08UU09 Aad A JOjD9UU09 Yselg X esnJ voL M TW A UJJIMS 98JnsSaJg IO n HO 4907 JOJO JOWeIS L Jopsuuodg jeulwdea G S joyeinbay seziuode Y apeg o esnJj Voe d Joyeinbay seynooy o JojejS N eig N A819 7 SUM y uel r Yuld I aiding H anig led 5 U9AJEO eq E u 19 juBr1 3 MOI 9A a YYM P Y 2 yoe g pay a poy V
84. ge still is not present there is a problem with ECU or engine harness Reconnect sensor and start engine Run engine at sufficient speed to bring sensor up to operating temperature Maintain for 1 to 2 minutes to ensure that engine has gone closed loop Once in closed loop sensor voltage should cycle between about 100 to 250 mv low speed idle and 700 to 900 mv high speed no load If this cycling is not observed a determination must be made if problem is with engine or sensor Check engine harness for battery voltage on heater circuit Propane EFI System 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 control may be occurring 3 If sensor is at room temperature measure between signal leads black wire Pin C and grey wire Pin D attached to sensor If resistance is less than one megohm sensor has an internal short 4 With sensor at room temperature measure heater circuit resistance purple wire Pin A and white wire Pin B resistance should be 8 1 11 1 Q 5 Ifa damaged sensor is found identify root cause which may be elsewhere in application Refer to Troubleshooting Oxygen Sensor O table 6 Aspecial dry to touch anti seize compound is applie
85. hat symptoms might be expected and Poor system ground from ECU to engine probable causes or battery to engine 38 KohlerEngines com 24 690 31 Rev B Propane EFI System Code 0107 Code 0113 Component Manifold Absolute Pressure Sensor Component Intake Air Temperature Sensor Fault MAP Circuit Low Voltage or Open Fault Intake Air Temperature Sensor Circuit Condition Intake manifold leak open connection or High Voltage or Open faulty sensor Condition Shorted connection faulty sensor broken Conclusion MAP Sensor Related wire or connection e Sensor malfunction Conclusion Temperature Sensor Related e Vacuum leaks from loose manifold or e Sensor wiring or connection sensor Engine Wiring Harness Related Wire Harness Related e Pin circuits ECU Black pin 10 and 8 e Poor grounding or open circuit may be damaged e Wire harness and connectors loose e ECU to harness connection problem or damaged or corroded broken wire e Pin circuit wiring or connectors at Black 10 11 and 16 Code 0117 Bad TPS Learn Component Coolant Oil Sensor Fault Coolant Oil Temperature Sensor Circuit Low Voltage Code 0108 Condition Shorted connection faulty sensor or Component Manifold Absolute Pressure Sensor shorted wire Fault MAP Circuit High Voltage Conclusion Temperature Sensor Related Condition Intake manifold leak shorted co
86. ided with engine If equipment preset performance limits If operation is outside limits manufacturer has not added a MIL to equipment one ECU activates MIL if equipped and stores a diagnostic can be added easily for quick diagnostics Main engine code in its fault memory If component or system to vehicle connection will have a tan wire which is returns to proper function ECU will turn off MIL If MIL ground for MIL Either incandescent or LED type bulbs stays illuminated it warns customer a fault is currently can be used for MIL as long as they do not draw more happening and dealer service is required Upon receipt than 0 1 amps Bulb needs to be rated at 1 4 Watts or dealer technician can access fault code s to help less or needs to have a total resistance of 140 O or determine what portion of system is malfunctioning more LEDs typically draw less than 0 03 amps Attach Codes are accessed through key switch and displayed 12 volts to positive terminal of bulb and attach ground terminal of bulb to tan wire Diagnostic Code Summary as blinks or flashes of MIL Access codes as follows 1 Check that battery voltage is above 11 volts 2 Start with key switch OFF Code 0031 3 Tum key switch to ON and OFF then ON and OFF Component pen ora then ON leaving it on in third seguence Do not start Fault O2S Heater Circuit High Voltage engine Time between sequences must be less than Condition System voltage too high shorted 2
87. inal cleaning operation should always be a thorough scrubbing with a brush and hot soapy water Use a strong detergent capable of breaking down machining oil while maintaining a good level of suds If suds break down during cleaning discard dirty water and start again with more hot water and detergent Following scrubbing rinse cylinder with very hot clear water dry it completely and apply a light coating of engine oil to prevent rusting 72 KohlerEngines com Measuring Piston to Bore Clearance Piston Detail A 6 mm 0 24 in NOTE Do not use a feeler gauge to measure piston to bore clearance it will yield inaccurate measurements Always use a micrometer Before installing piston into cylinder bore it is necessary clearance be accurately checked This step is often overlooked and if clearances are not within specifications engine failure will usually result Use these following procedures to accurately measure piston to bore clearance 1 Use a micrometer and measure diameter of piston 6 mm 0 24 in above bottom of piston skirt and perpendicular to piston pin 2 Use an inside micrometer telescoping gauge or bore gauge and measure cylinder bore Take measurement approximately 63 5 mm 2 5 in below top of bore and perpendicular to piston pin 3 Piston to bore clearance is difference between bore diameter and piston diameter step 2 minus step 1
88. inder wall Use of a commercial cutting cooling agent is recommended 2 With lower edge of each stone positioned even with lowest edge of bore start drill and honing process Move hone up and down while resizing to prevent formation of cutting ridges Check size frequently 3 When bore is within 0 064 mm 0 0025 in of desired size remove coarse stones and replace them with burnishing stones Continue with burnishing stones until bore is within 0 013 mm 0 0005 in of desired size and then use finish stones 220 280 grit and polish bore to its final size A crosshatch should be observed if honing is 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 cylinder at top middle and bottom Two measurements should be taken perpendicular to each other at each location KohlerEngines com 71 Disassembly Inspection and Service Clean Cylinder Bore After Honing Proper cleaning of cylinder walls following boring and or honing is very critical to a successful overhaul Machining grit left in cylinder bore can destroy an engine in less than 1 hour of operation after a rebuild F
89. ine is serviced as a complete assembly to prevent tampering and safety hazards Components are not individually serviceable Vacuum hose connects vaporizer regulator to throttle body compensating regulated pressure for air cleaner condition EFI engines have no carburetor so throttle function regulate incoming combustion airflow is achieved with a throttle valve in a separate throttle body attached to intake manifold Throttle body intake manifold provides mounting for fuel injectors throttle position sensor MAP sensor intake air temperature sensor high pressure fuel line idle speed screw and air cleaner assembly Idle speed is only adjustment that may be performed on EFI system Standard idle speed setting for EFl 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 temperature and loads present In cold conditions idle speed will probably be different than normal for a few moments Under other conditions idle speed may actually start 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 KohlerEngines com 23 Propane EFI
90. ing 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 often caused by wiring harness or connections Even small amounts of corrosion or oxidation on terminals can interfere with milliamp currents used in system operation Cleaning connectors and grounds will solve problems in many cases In an emergency situation simply disconnecting and reconnecting connectors may clean up contacts enough to restore operation at least temporarily If a fault code indicates a problem with an electrical component disconnect ECU connector and test for continuity between component connector terminals and corresponding terminals in ECU connector using an ohmmeter Little or no resistance should be measured indicating that wiring of that particular circuit is OK 22 KohlerEngines com 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 rotation an AC voltage pulse is created within sensor for each passing tooth ECU calculates engine speed from time interval between consecutive pulses
91. is extremely flammable and is heavier than air and tends to settle in low areas where a spark or flame could ignite gas Do not start or operate this engine in a poorly ventilated area where leaking gas could accumulate and endanger safety of persons in area To ensure personal safety installation and repair of propane fuel supply systems must be performed only by qualified propane system technicians Improperly installed and maintained propane equipment could cause fuel supply system or other components to malfunction causing gas leaks Observe federal state and local laws governing propane fuel storage and systems This engine is certified to operate on commercial propane per GPA STD 2140 If you have any questions contact your propane supplier Propane from an appropriate propane fuel tank supplied separately is required to operate this engine KohlerEngines com STORAGE If engine will be out of service for 2 months or more follow procedure below 1 Change oil while engine is still warm from operation Remove spark plug s and pour about 1 oz of engine oil into cylinder s Replace spark plug s and crank engine slowly to distribute oil 2 Disconnect negative battery cable 3 Separate propane tank from unit and store separately in an area designated for safe propane tank storage 4 Store engine in a clean dry place 24 690 31 Rev B Engine Dimensions Specifications
92. iston ca N Piston Rings o Camshaft P Oil Pan Gasket a a R Crankcase KohlerEngines com 67 Disassembly Inspection and Service Remove Camshaft Remove camshaft Inspection and Service NOTE To prevent repeat failures camshaft and crankshaft should always be replaced as a set Check lobes of camshaft for wear or damage See Specifications for minimum lift tolerances Measurement must be performed while valve train is still assembled Inspect cam gear for badly worn chipped or missing teeth Replacement of camshaft will be necessary if any of these conditions exist Remove Governor Cross Shaft 1 Remove retainer and nylon washer from governor cross shaft 2 Remove cross shaft through inside of crankcase Governor Cross Shaft Oil Seal Cross Shaft Oil Seal Details A 2 0 mm 0 0787 in B Governor Cross Shaft Seal If governor cross shaft seal is damaged and or leaks replace it using these following procedures Remove oil seal from crankcase and replace it with a new one Install new seal to depth shown using a seal installer Remove Connecting Rods with Pistons and Rings NOTE If a carbon ridge is present at top of either cylinder bore use a ridge reamer tool to remove it before attempting to remove piston NOTE Cylinders are numbered on crankcase Use numbers to mark each end cap connecting rod and piston for reassembly Do not mix end caps and connecting rods
93. ke sure FLY stamping on piston is facing towards flywheel side of engine Use a hammer with a rubber grip and gently tap piston into cylinder as shown Be careful that oil ring rails do not spring free between bottom of ring compressor and top of cylinder 4 Install inner rod cap to connecting rod using screws Two different types of connecting rod screws have been used If 6 mm straight shank torque in increments to 11 6 N m 103 in Ib If 6 mm straight shank gray metallic color it is not necessary to lubricate this screw torque in increments to 13 6 N m 120 in Ib Illustrated instructions are provided in service rod package 5 Repeat above procedure for other connecting rod and piston assembly 74 KohlerEngines com 1 Lubricate governor cross shaft bearing surfaces in crankcase with 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 Install Camshaft 1 Liberally apply camshaft lubricant to each of cam lobes Lubricate camshaft bearing surfaces of crankcase and camshaft with engine oil 2 Position timing mark of crankshaft gear at 12 o clock position 3 Tu
94. ld be illuminated and one of four status lights may be lit as well This does not represent condition of part Press TEST button until a click is heard and then release Momentarily one of four status lights will illuminate indicating partial condition of part KohlerEngines com 24 690 31 Rev B Condition Electrical System Conclusion 20 25 amp OK green light comes on and stays steady Disconnect tester black lead attached to 1 AC terminal and reconnect it to other AC terminal Repeat test If OK green light comes on again used part is good and may be an inadequate ground lead connection Make certain connection location is clean and clamp is secure Other lights come on Troubleshooting Guide NOTE A flashing LOW light can also occur as a result of Rectifier regulator is faulty and should not be used 20 25 Amp Battery Charging System NOTE Always zero ohmmeter on each scale before testing to ensure accurate readings Voltage tests should be made with engine running at 3600 RPM no load Battery must be good and fully charged When problems occur in keeping battery charged or battery charges at too high a rate problem can usually be found somewhere in charging system or with battery To test charging system for no charge to battery 1 Insert an ammeter in B lead from rectifier regulator With engine running at 3600 RPM and B at terminal on rectifier regulator to ground using a
95. leads from spark plugs Drain Oil from Crankcase and Remove Oil Filter NOTE Some models are equipped with an oil drain valve 1 Remove oil fill cap dipstick and 1 oil drain plug 2 Allow ample time for oil to drain from crankcase and oil filter 58 KohlerEngines com 3 Remove mounting screw and oil fill tube 4 Remove and discard oil filter Remove Oil Cooler 1 Use an 8 mm Allen wrench to remove oil filter threaded nipple 2 Separate filter adapter from oil pan leaving oil lines attached Remove screws mounting oil cooler to blower housing then remove cooler lines and filter adapter with O ring as an assembly Remove Muffler Remove exhaust system and attaching hardware from engine On engines equipped with a port liner remove it now Remove Air Cleaner Assembly Heavy Duty Air Cleaner 1 Remove nuts securing air cleaner to mounting studs 2 Remove screws securing air cleaner assembly to mounting bracket and remove air cleaner assembly Low Profile Air Cleaner Optional Loosen retaining knob and remove cover Remove wing nut from element cover 3 Remove element cover element and precleaner 4 Remove nuts securing base Additional screws must be removed from lower air cleaner support bracket 5 Remove base Na Remove Top Mount Control Panel 1 Remove throttle control shaft nut on top of throttle shaft and remove throttle control lever washer and spring 2 Rem
96. ler Co All rights reserved 8 85612 88 KohlerEngines com 24 690 31 Rev B 9
97. low zone Engine is still usable but there is some wear present Customer should start planning for overhaul or replacement Gauge reading in high red zone Rings and or cylinder have considerable wear Engine should be reconditioned or replaced 24 690 31 Rev B KohlerEngines com 19 Air Cleaner Intake AIR CLEANER These systems are CARB EPA certified and components should not be altered or modified in any way Low Profile Air Cleaner Components A Air Cleaner Cover B Air Cleaner Knob C Wing Nut D Element Cover E Rubber Seal F Precleaner G Paper Element H Air Cleaner Base Heavy Duty Air Cleaner Components I Air Cleaner Housing J End Cap K Element L Inner Element M Ejector Area N Inlet Screen o Retaining Clip P Filter Minder NOTE Operating engine with loose or damaged air cleaner components could cause premature wear and failure Replace all bent or damaged components NOTE Paper element cannot be blown out with compressed air 20 KohlerEngines com Low Profile Loosen knob and remove air cleaner cover Precleaner 1 Remove precleaner from paper element 2 Replace or wash precleaner in warm water with detergent Rinse and allow to air dry 3 Saturate precleaner with new engine oil squeeze out excess oil 4 Reinstall precleaner over paper element Paper Element 1 Clean area around element Remove wing nut element cover
98. lve Cap I Valve Keeper J Valve Spring K Valve Seal L ee M Spark Plug N Cylinder Head o ae P Valve Q Dowel Pin 76 KohlerEngines com 24 690 31 Rev B Install Hydraulic Lifters Reassembly Install Cylinder Heads 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 Service 2 Apply camshaft lubricant to bottom surface of each lifter Lubricate hydraulic lifters and lifter bores in crankcase with engine oil 3 Note mark or tag identifying hydraulic lifters as either intake or exhaust and cylinder 1 or 2 Install hydraulic lifters into their appropriate locations in crankcase Do not use a magnet 4 If breather reeds and stops were removed from crankcase reinstall them at this time and secure with screw Torque screw to 4 0 N m 35 in Ib 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 v
99. main wiring harness connector from TPS leaving TPS assembled to throttle body Refer to Resistance Table and perform resistance checks indicated between terminals in TPS switch with throttle in positions specified 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 Input pin is 12 and ground is pin 10 a Repair or replace as required b Turn idle speed screw back in to its original setting c Reconnect connector plugs start engine and retest system operation 7 Remove two mounting screws from TPS Save screws for reuse Remove and discard faulty TPS Install replacement TPS and secure with original mounting screws a Reconnect Black and TPS connector plugs b Perform TPS Learn Procedure integrating new sensor to ECU Engine Oil Temperature Sensor A sealed non serviceable assembly A faulty sensor must be replaced If a blink code indicates a problem with temperature sensor it can be tested as follows 1 Remove temperature sensor from breather cover and cap or block sensor hole 2 Wipe sensor clean and allow it to reach room temperature 25 C 77 F 3 Unplug Black connector from ECU 4 With senso
100. minal When connection is made solenoid should energize audible click and plunger retract Repeat test several times Continuity 1 Use an ohmmeter set to audible or Rx2K scale and connect 2 ohmmeter leads to 2 large post terminals 2 Perform solenoid pull in coil plunger actuation test and check for continuity Ohmmeter should indicate continuity Repeat test several times To test solenoid hold in coil Function 1 Connecta 12 volt test lead to flat spade S start terminal on solenoid and other lead to body or mounting surface of solenoid 2 Manually push plunger IN and check if coil holds plunger retracted Do not allow test leads to remain connected to solenoid for a prolonged period of time Continuity 1 Use an ohmmeter set to audible or Rx2K scale and connect 2 ohmmeter leads to 2 large post terminals 2 Perform preceding solenoid hold in coil function test and check for continuity Meter should indicate continuity Repeat test several times Condition Conclusion Solenoid fails to activate Replace solenoid No continuity is indicated Plunger fails to stay retracted 56 KohlerEngines com 24 690 31 Rev B A WARNING death NE before servicing Accidental Starts can cause severe injury or Disconnect and ground spark plug lead s Disassembly Inspection and Service Before working on engine or equipment disable engine as follows 1 Disconnect spark plug lead s 2 Disconnec
101. n one at or near operating temperature Mounted in breather cover it has a temperature sensitive resistor that extends into oil flow Resistance changes with oil temperature altering voltage sent to ECU Using a table stored in its memory ECU correlates voltage drop to a specific temperature Using fuel delivery maps ECU then knows how much fuel is required for starting at that temperature Intake Air Temperature IAT sensor is a thermally sensitive resistor that exhibits a change in electrical resistance with a change in its temperature When sensor is cold resistance of sensor is high As sensor warms up resistance drops and voltage signal increases From voltage signal ECU can determine temperature of intake air Purpose of an air temperature sensor is to help ECU calculate air density Higher air temperature less dense air becomes As air becomes less dense ECU knows that it needs to lessen fuel flow to achieve correct air fuel ratio If fuel ratio was not changed engine would become rich possibly losing power and consuming more fuel 24 690 31 Rev B 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 concentration on one side of tip is different than tha
102. nals and connecting rod C Gerotor Gears D Oil Pump Assembly bearing surfaces with engine oil E Governor Shaft F Governor Washer 2 Carefully slide flywheel end of crankshaft through main bearing in crankcase G Governor Gear H Governor Cup l Crankshaft J Connecting Rod K Piston L Piston Pin M Piston cia N Piston Rings o Camshaft P Oil Pan Gasket a wc cl R Crankcase 24 690 31 Rev B KohlerEngines com 73 Reassembly Install Connecting Rods with Pistons and Rings Install Governor Cross Shaft Piston Detail A Cylinder 1 B Cylinder 2 NOTE Cylinders are numbered on crankcase Make sure to install piston connecting rod and end cap into its appropriate cylinder bore as previously marked at disassembly Do not mix end caps and connecting rods NOTE Proper orientation of piston connecting rod assemblies inside engine is extremely important Improper orientation can cause extensive wear or damage Be certain pistons and connecting rods are assembled exactly as shown NOTE Align chamfer of connecting rod with chamfer of its mating end cap When installed flat faces of connecting rods should face each other Faces with raised rib should be toward outside 1 If piston rings were removed see Disassembly Inspection and Service procedure to install new rings 2 Lubricate cylinder bore piston and piston rings with engine oil Compress rings using a piston ring compressor 3 Ma
103. nder this condition Oil control is also lost when ring gaps are not staggered during installation When cylinder temperatures get too high lacquer and varnish collect on pistons causing rings to stick which results in rapid wear A worn ring usually takes on a shiny or bright appearance Scratches on rings and pistons are caused by abrasive material such as carbon dirt or pieces of hard metal 24 690 31 Rev B Detonation damage occurs when a portion of fuel charge ignites spontaneously from heat and pressure shortly after ignition This creates 2 flame fronts which meet and explode to create extreme hammering pressures on a specific area of piston Detonation generally occurs from using low octane fuels Preignition or ignition of fuel 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 oversize Replacement pistons include new piston ring sets and new piston pins Replacement ring sets are also available separately for STD 0 25 mm 0 010 in and 0 50 mm 0 020 in oversize pistons Always use new piston rings when installing pistons Never use old rings Some importa
104. ners can quickly break down lubricating properties of engine oil Shut off Fuel Supply Empty System A WARNING Explosive Fuel can cause fires and severe 9 burns 4 If a gaseous odor is detected ventilate area and contact an authorized service technician Propane is extremely flammable and is heavier than air and tends to settle in low areas where a spark or flame could ignite gas Do not start or operate this engine in a poorly ventilated area where leaking gas could accumulate and endanger safety of persons in area To ensure personal safety installation and repair of propane fuel supply systems must be performed only by qualified propane system technicians Improperly installed and maintained propane equipment could cause fuel supply system or other components to malfunction causing gas leaks Observe federal state and local laws governing propane fuel storage and systems 1 Relieve fuel pressure at lock off Shut off tank valve If possible run engine in a well ventilated area until fuel system is empty and engine stops If unable to run engine work in a well ventilated area and carefully loosen inlet fuel fitting on vaporizer regulator slowly venting off fuel from line When fuel is dispensed retighten fitting and remove quick connect fitting to allow fuel to escape from line Disconnect Spark Plug Leads NOTE Pull on boot only to prevent damage to spark plug lead Disconnect
105. nnection e Sensor wiring or connection or faulty sensor ae mE Engine Wiring Harness Related Conclusion MAP Sensor Related e Pin circuits Black 10 and Black 14 e Sensor malfunction maybe damaged or routed near noisy e Vacuum leaks from loose manifold or signal coils stator etc SENSON e ECU to harness connection problem Wire Harness Related e Poor grounding UG DU CTIE e Pin circuit wiring or connectors at Black Component Coolant Oil Sensor 11 Fault Coolant Oil Temperature Sensor Circuit Bad TPS L High Voltage or Open ad TPS Learn Condition Shorted connection faulty sensor open connection or broken wire Code 0112 Conclusion Temperature Sensor Related Component Intake Air Temperature Sensor e Sensor wiring or connection Fault Intake Air Temperature Sensor Circuit Low Voltage Engine Wiring Harness Related Condition Shorted connection faulty sensor or e Pin circuits ECU Black pin 10 and 14 shorted wire may be damaged e ECU to harness connection problem or Conclusion Temperature Sensor Related broken wire e Sensor wiring or connection F System Related Engine Wiring Harness Related e Engine is operating above 176 C e Pin circuits Black 10 and Black 8 may 350 F temperature sensor limit be damaged or routed near noisy signal coils alternator etc e ECU to harness connection problem 24 690 31 Rev B KohlerEngines com 39 Propane EFI System
106. nt points to remember when servicing piston rings 1 Cylinder bore must be deglazed before service ring sets are used 2 If cylinder bore does not need reboring and if old piston is within wear limits and free of score or scuff marks old piston may be reused 3 Remove old rings and clean up grooves Never reuse old rings 4 Before installing new rings on piston place top 2 rings each in turn in its running area in cylinder bore and check end gap Compare ring gap to tolerance listed in Specifications 5 After installing new compression top and middle rings on piston check piston to ring side clearance Compare clearance to tolerance listed in Specifications If side clearance is greater than specified a new piston must be used 24 690 31 Rev B Disassembly Inspection and Service Install New Piston Rings Piston Ring Orientation A Top Oil Ring Rail B Bottom Oil Ring Rail Gap Gap c Intermediate Ring D Oil Ring Expander Gap Gap Top Ring Gap FLY Stamp NOTE Rings must be installed correctly Ring installation instructions are usually included with new ring sets Follow instructions carefully Use a piston ring expander to install rings Install bottom oil control ring first and top compression ring last To install new piston rings proceed as follows 1 Oil control ring bottom groove Install expander and then rails Make sure ends of expander are not overlapped
107. oken or shorted wire in harness causing rich running while indicating lean ECU pin Black 9 or Grey 17 Fuel lock off connection See Fuel ECU Related Components e ECU is damaged Code 0201 Code 0232 Component Fuel Injector Component Fuel Lock off Fault Injector 1 Circuit Malfunction Fault i Circuit High Voltage Condition Injector damaged or faulty shorted or Condition Shorted connection open connection Conclusion Fuel Lock off Related Conclusion Injector Related e Fuel lock off damaged internally e Injector coil shorted or opened Charging Output System Too High Engine Wiring Harness Related e Broken or shorted wire in harness ECU pin Black 5 e Wiring from Ignition ECU Related e Circuit controlling injector 1 damaged 42 KohlerEngines com 24 690 31 Rev B Propane EFI System Code 0336 Code 0351 Component Crankshaft Position Sensor Component Ignition Coil Fault Crankshaft Position Sensor Noisy Signal Fault Cylinder 1 Ignition Coil Malfunction Condition Air gap incorrect loose sensor faulty bad Condition Broken wire in harness may not be battery shorted or faulty connection visible shorted connection or faulty faulty sensor or faulty sensor grounding sensor Conclusion Crankshaft Position Sensor Related Conclusion Engine Wiring Harness Related e Sensor connector or wiring e Connection to ignition or fuse e
108. oles 3 Install wire harness clip to other crankcase post Torque to 4 0 N m 35 in Ib into used holes or 6 2 N m 55 in Ib in new holes 4 Place wire harness conduit in clip and snap clip together Install Fuel Injectors NOTE Ensure all parts are clean undamaged and free of debris and make sure electrical connectors have seal in place O rings and retaining clips should be replaced any time fuel injector is separated from its normal mounting position 1 Lightly lubricate fuel injector O rings with clean engine oil 2 Push retaining clip onto fuel injector aligning clip 3 Press fuel injector into fuel injector cap until retaining 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 Ib 6 Push electrical connector on fuel injector making sure a good connection is made 7 Repeat steps 1 through 6 for other fuel injector 80 KohlerEngines com NOTE Ensure all parts are clean undamaged and free of debris and make sure electrical connector has seal in place 1 Lightly oil MAP sensor O ring and push MAP sensor into bore in intake manifold 2 Torque screw to 7 3 N m 65 in Ib 3 Push electrical connector on MAP sensor making sure a good connection is made Install Crankshaft Position Sensor NOTE Ensure all parts are clean undamaged and free of
109. on tool Perform steps 10 13 in Starter Reassembly sequence If starter has been disassembled installation must be done after armature drive lever and frame are installed Starter System Starter Reassembly NOTE Always use a new retainer Do not reuse old retainers that have been removed NOTE Correctly installed center pivot section of drive 10 KohlerEngines com lever will be flush or below machined surface of housing Apply drive lubricant to armature shaft splines Install drive pinion onto armature shaft 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 rotate pinion outward on armature splines against retainer to help seat collar around retainer Install offset thrust stop washer so smaller offset of washer faces retainer collar Apply a small amount of oil to bearing in drive end cap and install armature with drive pinion Lubricate fork end and center pivot of drive lever with drive lubricant Position fork end into space between captured washer and rear of pinion Slide armature into drive end cap and at same time seat drive lever into housing Install rubber grommet into matching recess
110. onnection or Failure Description 0031 Oxygen Sensor Heater Circuit High Voltage 0032 Oxygen Sensor Heater Circuit Low Voltage 0107 Manifold Absolute Pressure Sensor Circuit Low Voltage or Open 0108 Manifold Absolute Pressure Sensor Circuit High Voltage 0112 Intake Air Temperature Sensor Circuit Low Voltage 0113 Intake Air Temperature Sensor Circuit High Voltage or Open 0117 Coolant Oil Temperature Sensor Circuit Low Voltage 0118 Coolant Oil Temperature Sensor Circuit High Voltage 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 24 690 31 Rev B KohlerEngines com 37 Propane EFI System 0174 Lean Fuel Condition at High Load Open Loop or Insufficient Fuel Supply 0201 Injector 1 Circuit Malfunction 0202 Injector 2 Circuit Malfunction 0230 Fuel Lock off Circuit Low Voltage or Open 0232 Fuel Lock off Circuit High Voltage 0336 Crankshaft Position Sensor Noisy Signal 0337 Crankshaft Position Sensor No Signal 0351 Cylinder 1 Ignition Coil Malfunction 0352 Cylinder 2 Ignition Coil Malfunction 0562 System Voltage Low 0563 System Voltage High 61 End of Code Transmission ECU continuously monitors engine operation against A MIL may not be prov
111. or if equipped Clean or replace as needed Repair or replace any other damaged restricted muffler or exhaust system parts 18 KohlerEngines com 24 690 31 Rev B Troubleshooting COMPRESSION TEST For Command Twins A compression test is best performed on a warm engine Clean any dirt or debris away from base of spark plug s before removing them Be sure choke is off and throttle is wide open during test Compression should be at least 160 psi and should not vary more than 1596 between cylinders All other models These engines are equipped with an automatic compression release ACR mechanism It is difficult to obtain an accurate compression reading because of ACR mechanism As an alternative use cylinder leakdown test described below CYLINDER LEAKDOWN TEST A oylinder leakdown test can be a valuable alternative to a compression test By pressurizing combustion chamber from an external air source you can determine if valves or rings are leaking and how badly Cylinder leakdown tester is a relatively simple inexpensive leakdown tester for small engines This tester includes a quick connect for attaching adapter hose and a holding tool 1 Run engine for 3 5 minutes to warm it up 2 Remove spark plug s and air filter from engine 3 Rotate crankshaft until piston of cylinder being tested is at top dead center TDC of compression stroke Hold engine in this position while testing Holding tool supplied with t
112. ot be pinched between blower housing and baffles 3 Insert and tighten all remaining blower housing and baffle screws with exception of rectifier regulator grounding bracket screw Torque all blower housing and baffle M6 screws assembled into aluminum to 10 7 N m 95 in Ib for a new hole or 7 3 N m 65 in Ib for a used hole Torque all blower housing and baffle M5 screws assembled into sheet metal backing plate to 2 8 N m 25 in Ib for new holes or 2 3 Nm 20 in Ib for used holes 4 Torque breather cover screws to 11 3 N m 100 in Ib into new holes or 7 3 N m 65 in Ib into used holes in sequence shown Note first screw is torqued a second time Install Reconnect Rectifier Regulator NOTE Rectifier regulator middle terminal B is offset not equally spaced from outer terminals AC Verify rectifier regulator plug is assembled to match terminal offset of rectifier regulator 1 Install rectifier regulator in blower housing if removed previously then secure grounding bracket against outer side of rectifier regulator with a silver Screw 2 Torque black rectifier regulator screws to 1 4 N m 12 6 in Ib and silver ground strap screw to 2 8 N m 25 in Ib into new holes or 2 3 N m 20 in Ib into used holes 3 Connect plug to rectifier regulator If purple wire was removed verify locking tang is raised on terminal and push wire terminal into plug prior to connecting to rectifier regulator Inst
113. ottle position sensor intake air temperature sensor throttle linkage spring and bushing as an assembly 3 Install air cleaner bracket to throttle body with screws Torque screws to 9 9 N m 88 in Ib 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 cutout of blower housing Position abrasion sleeve 5 Push electrical connector onto intake air temperature sensor making sure a good connection is made by listening for a click 6 Connect 5 32 in I D vent hose to bottom of throttle body Other end of vent hose connects to vaporizer regulator 7 Push electrical connector onto throttle position sensor making sure a good connection is made 24 690 31 Rev B Reassembly Install Vaporizer Regulator Lock Off A WARNING Propane is extremely flammable and is heavier than air and tends to settle in low areas where a spark or flame could ignite gas Do not start or operate this engine in a poorly ventilated area where leaking gas could accumulate and endanger safety of persons in area Explosive Fuel can cause fires and severe To ensure personal safety installation and repair of propane burns fuel supply systems must be performed only by qualified propane system technicians Improperly installed and maintained propane equipment could cause fuel supply system or other components to malfunction causing gas leaks Obse
114. ove screws fastening control bracket and remove bracket from blower housing 3 Remove lower throttle control bracket from cylinder head Remove External Governor Controls NOTE To aid in reassembly mark hole locations of governor spring throttle linkage spring throttle linkage before removing them from governor lever 1 Disconnect governor spring attached to governor lever Note mark hole location for reassembly 2 Note mark hole location then disconnect throttle linkage spring from governor lever Remove throttle linkage bushing and throttle linkage from governor lever Note mark hole location for reassembly 3 Loosen nut and remove governor lever from cross shaft 24 690 31 Rev B External Governor Controls Disassembly Inspection and Service Throttle Control Shaft Throttle Control Shaft C Throttle Control Lever Washer Control Bracket G Throttle Control Bracket lower Governor Spring Throttle Linkage Spring K Bushing Throttle Linkage A Nut E Spring Governor Lever M Nut Governor Cross Shaft 24 690 31 Rev B KohlerEngines com 59 Disassembly Inspection and Service Vaporizer Regulator Lock Off Assembly A WARNING Propane is extremely flammable and is heavier than air and tends to settle in low areas where a spark or flame could ignite gas Do not start or operate this engine in a poorly ventilated area where l
115. park plug leads 3 Remove brass plug from bottom of regulator and drain any accumulated deposits 4 Inspect O ring on plug replace if damaged 5 Reinstall plug and tighten securely Replace 30 Micron Button Filter Remove inlet fitting w O ring button filter and gasket Discard filter gasket and O Ring Position new gasket into regulator install button filter large end in Install new O ring on inlet fitting Reinstall inlet fitting and torque to 20 N m 177 in Ib Lock Off Assembly 1 Disconnect plug from lock off Remove nut and lock off Remove lock off valve body and plunger Discard all parts 2 Install plunger then lock off valve body Torque body to 20 N m 177 in Ib 3 Install lock off assembly and nut Torque nut to 6 5 N m 57 in Ib 4 Reconnect plug to lock off High Pressure Fuel Line High pressure fuel line is mounted to intake manifold No specific servicing is required unless operating conditions indicate that it needs replacement Thoroughly clean area around all joints and relieve any pressure before starting any disassembly Detach by removing two mounting screws wire ties and injector retaining clips Vacuum Reference Line No specific servicing is required for vacuum line unless operating conditions indicate replacement is required All components are serviced individually Abrasion sleeves on hoses should be reused or replaced when servicing vacuum line Please note routing and replicate after s
116. porizer regulator to injectors OPERATION NOTE When performing voltage or continuity tests avoid putting excessive pressure on or against connector pins Flat pin probes are recommended for testing to avoid spreading or bending terminals EFI system is designed to provide peak engine performance with optimum fuel efficiency and lowest possible emissions Ignition and injection functions are electronically controlled monitored and continually corrected during operation to maintain ideal air fuel ratio Central component of system is Engine Control Unit ECU which manages system operation determining best combination of fuel mixture and ignition timing for current operating conditions 24 690 31 Rev B Propane EFI System Fuel is delivered from tank to integrated lock off valve at tank pressure Fuel travels to vaporizer regulator which reduces pressure to 24 26 psi typical Fuel then passes through a fine high pressure filter is delivered from vaporizer regulator through high pressure fuel line into injectors which inject fuel into intake ports ECU controls amount of fuel by varying length of time that injectors are on This can range from 2 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 cont
117. position sensor loose or faulty TPS faulty Engine temp sensor faulty Faulty injectors Faulty spark plugs Insufficient fuel delivery TPS set incorrect TPS faulty Faulty engine temperature sensor Faulty injectors Fuel injector s fuel filter or fuel line 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 36 KohlerEngines com 24 690 31 Rev B Troubleshooting Guide Propane EFI System Condition Possible Cause Low Power Faulty malfunctioning ignition system Dirty air filter Insufficient fuel delivery or pressure Improper governor adjustment Plugged restricted exhaust One injector not working Basic engine problem exists TPS faulty or mounting exists Throttle plate in throttle body not fully opening to WOT stop if equipped Fault Codes Example of Diagnostic Display One second pause At 1 One second pause One second pause One second pause Xt 3 3c HE Ac de x HE 0 EME LE ME Me ee a ete 0 iid RER 7 Three second pause ie ie ie Ht Ht 6 Fault Code End Code 61 Diagnostic Fault Code Summary Fault Code C
118. psi tester should indicate a change to continuity switch closed Switch should remain closed as pressure is increased to 90 psi maximum Gradually decrease pressure through range of 2 0 5 0 psi Tester should indicate a change to no continuity switch open down to 0 psi 24 690 31 Rev B KohlerEngines com 47 Electrical System SPARK PLUGS Inspection A CAUTION b Electrical Shock can cause injury Do not touch wires while engine is running Spark Plug Component and Details o Bo A Wire Gauge B Spark Plug C Ground Electrode D Gap NOTE Do not clean spark plug in a machine using abrasive grit Some grit could remain in spark plug and enter engine causing extensive wear and damage Engine misfire or starting problems are often caused by a spark plug that has improper gap or is in poor condition Engine is equipped with following spark plugs Gap 0 76 mm 0 03 in Thread Size 14 mm Reach 19 1 mm 3 4 in Hex Size 15 9 mm 5 8 in Refer to Maintenance for Repairs Service Parts Service Clean out spark plug recess Remove plug and replace 1 Check gap using wire 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 Ib 48 Inspect each spark plug as it is removed from cylinder head Deposits on tip are an indication of general condition of piston rings valv
119. r still connected check temperature sensor circuit resistance between Black pin 10 and 14 terminals Value should be 9000 11000 O 5 Unplug sensor from wire harness and check sensor resistance separately across two pins Resistance value should again be 9000 11000 O a If resistance is out of specifications replace temperature sensor b If itis within specifications proceed to Step 6 KohlerEngines com 29 Propane EFI System 6 Check circuits input ground from wire harness connector to sensor plug for continuity damage etc Connect one ohmmeter lead to Black pin 14 in wire harness connector as in step 4 Connect other lead to terminal 1 in sensor plug Continuity should be indicated Repeat test between Black pin 10 and terminal 2 in sensor plug Intake Air Temperature Sensor A non serviceable component Complete replacement is required if it is faulty Sensor and wiring harness can be checked as follows 1 Remove temperature sensor from throttle body 2 Allow it to reach room temperature 20 C 68 F 3 Unplug Black connector from ECU 4 With sensor still connected check temperature sensor circuit resistance between Black pin 10 and 8 pin terminals Value should be 3100 3900 O 5 Unplug sensor from wire harness and check sensor resistance separately across two pins Resistance value should again be 3100 3900 O a If resistance is out of specifications replace temperature sensor b If i
120. r transmission is disengaged or placed in neutral This is especially important on equipment with hydrostatic drive Transmission must be exactly in neutral to prevent resistance which could keep engine from starting Check for seized engine components such as bearings connecting rod and piston 24 690 31 Rev B KohlerEngines com 53 Starter System SOLENOID SHIFT ELECTRIC STARTERS Solenoid Shift Starter Components A Tube B Washer C Armature D Drive E Stop F Retaining Ring G Collar H Drive End Cap I Screw J Plunger K Spring L Lever M Plate N Plug o Solenoid P Frame and Field Q Brush Holder R Nut S Commutator End T Screw Plate U Bolt When power is applied to starter armature rotates As armature rotates drive pinion moves out on drive shaft splines and into mesh with flywheel ring gear When pinion reaches end of drive shaft it rotates flywheel and cranks engine When engine starts flywheel rotates faster than starter armature and drive pinion This moves drive pinion out of mesh with ring gear and into retracted position When power is removed from starter armature stops rotating and drive pinion is held in retracted position by anti drift spring 54 KohlerEngines com Starter Disassembly NOTE Do not reuse old retainer NOTE Do not soak armature or use solvent when cleaning Wipe clean using a soft cloth or use compressed air 1 Remo
121. rcuits as follows 1 To check cylinder coil 1 starter side disconnect Black connector from ECU and test between Black pins 1 and 15 To check cylinder coil 2 oil filter side 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 Q 2 If reading s are not within specified range check and clean connections and retest 3 Ifreading 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 connector b Connect an ohmmeter set on Rx1 scale to primary terminals of coil Primary resistance should be 0 5 0 8 O c Connect an ohmmeter set on Rx10K scale between spark plug boot terminal and B primary terminal Secondary resistance should be 6400 7800 O d If secondary resistance is not within specified range coil is faulty and needs to be replaced 34 KohlerEngines com FUEL COMPONENTS Fluid puncture injuries are highly toxic and hazardous If an injury occurs seek immediate medical attention A WARNING High Pressure Fluids can puncture skin and cause severe injury or death Do not work on fuel system without proper training or safety equipment Vaporizer Regulator Lock Off Details A Brass Plug B Inlet Fitting Cc N D Button Filter Gasket E O Ring F Nut G Lock O
122. reign particles Sludge is a natural by product of combustion a small accumulation is normal Excessive sludge formation could indicate over rich fuel settings weak ignition overextended oil change interval or wrong weight or type of oil was used CLEANING ENGINE A WARNING Cleaning Solvents can cause severe injury or death Use only in well ventilated areas away from ignition sources Carburetor cleaners and solvents are extremely flammable Follow cleaner manufacturer s warnings and instructions on its proper and safe use Never use gasoline as a cleaning agent After inspecting external condition of engine clean engine thoroughly before disassembly Clean individual components as engine is disassembled Only clean parts can be accurately inspected and gauged for wear or damage There are many commercially available cleaners that will quickly remove grease oil and grime from engine parts When such a cleaner is used follow manufacturer s instructions and safety precautions carefully Make sure all traces of cleaner are removed before engine is reassembled and placed into operation Even small amounts of these cleaners can quickly break down lubricating properties of engine oil 24 690 31 Rev B KohlerEngines com 17 Troubleshooting CRANKCASE VACUUM TEST A WARNING Carbon Monoxide can cause severe nausea fainting or death Avoid inhaling exhaust fumes A W
123. rmance only running on one cylinder or a change in injector noise or vibration 24 690 31 Rev B Propane EFI System If an injector is not operating it can indicate either a bad injector or a wiring electrical connection problem Check as follows 1 Disconnect electrical connector from both injectors Plug a 12 volt noid light into one connector 2 Make sure all safety switch requirements are met 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 7 9 Q If injector resistance is correct check whether connector and injector terminals are making a good connection If resistance is not correct replace injector 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 needle or external weeping around injector O rings Loss of system pressure from leakage can cause hot restart problems and longer cranking times To check for leakage it will be necessary to loosen or remove blower housing which may involve removing engine from unit Refer to Disassembly for removal of injector 1 Remove manifold mounting bolts and separate th
124. rn governor cross shaft clockwise until lower end of shaft contacts cylinder Make sure cross shaft remains in this position while installing camshaft 4 Slide camshaft into bearing surface of crankcase positioning timing mark of camshaft gear at 6 o clock position Make sure camshaft gear and crankshaft gear mesh with both timing marks aligned Oil Pump Assembly Oil pump is mounted inside oil pan If service was required and oil pump was removed refer to assembly procedures under Oil Pump Assembly in Disassembly Inspection and Service Governor Gear Assembly Governor gear assembly is located inside oil pan If service was required and governor was removed refer to assembly procedures under Disassembly Inspection and Service Install Oil Pan Oil Seal Oil Seal Details A Oil Seal B 6 5 mm 0 255 in 1 Check to make sure that there are no nicks or burrs in crankshaft bore of oil pan 24 690 31 Rev B Apply a light coat of engine oil to outside diameter of oil seal Drive oil seal into oil pan using a seal driver Make sure oil seal is installed straight and true in bore to depth shown Install Oil Pan Assembly Oil Pan Fastener Torque Sequence Be sure sealing surfaces have been cleaned and prepared as described at beginning of Disassembly Inspection and Service Install a new O ring in oil pan Check to make sure that there are no nicks or burrs on sealing surfa
125. rols amount of fuel being injected and ignition timing by monitoring primary sensor signals for engine temperature speed RPM and throttle position load These primary signals are compared to preprogrammed maps in ECU computer chip and ECU adjusts fuel delivery to match mapped values After engine reaches operating temperature an exhaust gas oxygen sensor provides feedback to ECU based upon amount 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 e Oil temperature is greater than 60 C 140 F e Oxygen sensor has warmed sufficiently to provide a signal minimum 400 C 752 F e Engine operation is at a steady state not starting warming up accelerating etc During closed loop operation ECU has ability to readjust temporary and learned adaptive controls providing compensation for changes in overall engine condition and operating environment so it will be able to maintain ideal air fuel ratio This system requires a minimum engine oil temperature greater than 80 C 176 F to properly adapt These adaptive values are maintained as long as ECU is not reset During certain operating periods such as cold starts warm up acceleration high load etc
126. rotor Unhook locking clip and care fully pull it free from oil pump housing Relief valve is a one piece style staked to oil pump housing Removal should not be attempted nor is internal servicing possible If a problem with relief valve is encountered oil pump should be replaced Inspection Inspect oil pump housing gear and rotors for nicks burrs wear or any visible damage If any parts are worn or damaged replace oil pump Reassembly 1 Install oil pickup to oil pump body Lubricate O ring with oil and make sure it remains in groove as pickup is being installed 2 Install rotor 3 Install oil pump body to oil pan and secure with screws Torque screws as follows a Install fastener into location 1 and lightly tighten to position pump b Install fastener into location 2 and fully torque to recommended value c Torque fastener in location 1 to recommended value First Time Installation 10 7 N m 95 in Ib All Reinstallations 6 7 N m 60 in Ib 4 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 24 690 31 Rev B e 9 Ff f 0 A Oil Pan Seal B Oil Pan C Gerotor Gears D Oil Pump Assembly E Governor Shaft F Governor Washer G Governor Gear H Governor Cup l Crankshaft J Connecting Rod K Piston L Piston Pin M P
127. rottle body manifold from engine leaving TPS high pressure fuel line injectors and fuel line connections intact Discard old gaskets 2 Position manifold assembly over an appropriate container to capture fuel and turn key switch ON to activate energize lock off valve and pressurize system Do not turn switch to START position 3 If either injector exhibits leakage of more than two to four drops per minute from tip or shows any sign of leakage around outer shell turn ignition switch OFF and replace injector as follows 4 Depressurize fuel system 5 Clean any dirt accumulation from sealing mounting area of faulty injector s and disconnect electrical connector s 6 Pull retaining clip off top of injector s Remove screw holding injector s from manifold 7 Reverse appropriate procedures to install new injector s and reassemble engine Use new O rings and retaining clips any time an injector is removed new replacement injectors include new O rings and retaining clips Lubricate O rings lightly with clean engine oil Use installation tool provided with O rings to install new upper O ring Place tool into fuel injector inlet Place one side of O ring into O ring groove and roll O ring over tool onto fuel injector Torque screw securing fuel injector caps and blower housing mounting screws to 7 3 N m 65 in Ib and intake manifold and air cleaner mounting screws to 10 5 N m 93 in Ib An ECU Reset will need to be comple
128. rve federal state and local laws governing propane fuel storage and systems LA f 4 If a gaseous odor is detected ventilate area and contact an authorized service technician Vaporizer Regulator Lock Off Assembly a N s E Ry A Vacuum Line B Vaporizer Regulator C Inlet Fitting D Lock Off Assembly E Propane Fuel Filter F Bracket G Outlet Fitting H Oetiker Clamp I Straight Fitting 1 Connect fuel line quick connect on high pressure fuel line assembly to straight fitting in fuel line after propane fuel filter 2 Apply pipe sealant with Teflon Loctite 592 PST Thread Sealant or equivalent to regulator bracket screws after first 3 4 lead in threads Install screws and secure regulator bracket to crankcase Torque screws to 11 9 N m 105 in Ib With nut installed on center back of vaporizer regulator position regulator so nut comes through key hole slot in bracket installing vaporizer regulator keeping fuel lines propane fuel filter assembled to bracket Torque nut to 19 8 N m 175 in Ib 3 Connect vacuum line to barb on front of vaporizer regulator Reconnect electrical plug to lock off assembly 5 If any Oetiker clamps were cut during disassembly 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 vaporiz
129. s high voltage in coil secondary which is strong enough to bridge gap on spark plug Each coil fires every other revolution EFI engines are equipped with either a 20 or 25 amp charging system to accommodate combined electrical demands of ignition system and specific application Charging system troubleshooting information is provided in Electrical System When key switch is turned ON and all safety switch requirements are met ECU activates lock off valve for about six seconds which pressurizes system for start up If key switch is not promptly turned to start position engine fails to start or engine is stopped with key switch ON as in case of an accident ECU switches off lock off valve preventing continued delivery of fuel In this situation MIL will go on but it will go back off after 4 cranking revolutions if system function is OK Once engine is running lock off valve remains on There are two filters in system one on inlet of vaporizer regulator will be a 30 micron button filter and one after will be a special metal 10 micron filter Be sure to use metal propane 10 micron filter for replacement High pressure fuel line is an assembly of hoses injector caps and a fuel connector to vaporizer regulator High pressure fuel line feeds fuel to top of injectors through injector caps Caps are fastened to intake manifold and injectors are locked into place A small retaining clip provides a secondary lock High pressure fuel l
130. steners e Piston blow by or leaky valves e Restricted exhaust Troubleshooting EXTERNAL ENGINE INSPECTION NOTE It is good practice to drain oil at a location away from workbench Be sure to allow ample time for complete drainage Before cleaning or disassembling engine make a thorough inspection of its external appearance and condition This inspection can give clues to what might be found inside engines and cause when it is disassembled e Check for buildup of dirt and debris on crankcase cooling fins grass screen and other external surfaces Dirt or debris on these areas can cause overheating e Check for obvious fuel and oil leaks and damaged components Excessive oil leakage can indicate a clogged or inoperative breather worn or damaged seals or gaskets or loose fasteners Check air cleaner cover and base for damage or 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 within operating range on dipstick If itis above sniff for gasoline odor Check condition of oil Drain oil into a container it should flow freely Check for metal chips and other fo
131. stion air air cleaner dirty restricted e Base engine problem rings valves 24 690 31 Rev B KohlerEngines com 41 Propane EFI System Code 0174 Code 0202 Component Fuel System Component Fuel Injector Fault Lean fuel condition Fault Injector 2 Circuit Malfunction Condition Fuel filters plugged low pressure at high Condition Injector damaged or faulty shorted or pressure fuel line TPS malfunction open connection shorted connection or faulty sensor Conclusion Injector Related Conclusion TPS Learn Incorrect e Injector coil shorted or opened e Lean condition check oxygen sensor signal with VOA and see Oxygen Engine Wiring Harness Related Sensor e Broken or shorted wire in harness ECU pin Black 6 Engine Wiring Harness Related e Wiring from Ignition e Pin circuit wiring or connectors ECU pin Black 10 12 16 and 17 ECU Related e Circuit controlling injector 2 damaged Low Fuel Pressure e Low empty fuel tank Code 0230 e Plugged filters Component Fuel Lock off e Bad regulator Fault Circuit Low Voltage or Open Oxygen Sensor Related Condition Shorted or open connection e Sensor connector or wiring problem Conclusion Fuel Lock off Related e Exhaust leak e Fuel lock off open or shorted internally Pgorgradna Engine Wiring Harness related Poor system ground from ECU to engine e Br
132. stopping engine Condition To test crankcase vacuum with vacuum pressure gauge 1 Remove dipstick or oil fill plug cap 2 Install adapter into oil fill dipstick tube opening upside down over end of a small diameter dipstick tube or directly into engine if a tube is not used Insert barbed gauge fitting into hole in stopper 3 Run engine and observe gauge reading Analog tester needle movement to left of 0 is a vacuum and movement to right indicates a pressure Digital tester depress test button on top of tester Crankcase vacuum should be a minimum of 10 2 cm 4 in of water If reading is below specification or if pressure is present check table below for possible causes and conclusions Conclusion Crankcase breather clogged or inoperative NOTE If breather is integral part of valve cover and cannot be serviced separately replace valve cover and recheck pressure Disassemble breather clean parts thoroughly check sealing surfaces for flatness reassemble and recheck pressure Seals and or gaskets leaking Loose or improperly torque fasteners Replace all worn or damaged seals and gaskets Make sure all fasteners are tightened securely Use appropriate torque valves and sequences when necessary Piston blow by or leaky valves confirm by inspecting components Restricted exhaust Recondition piston rings cylinder bore valves and valves guides Check exhaust screen spark arrest
133. surface of crankcase using a surface fuel consumption may be symptoms of faulty valves plate or piece of glass and feeler gauge as shown Although these symptoms could also be attributed to Maximum allowable out of flatness is 0 01 mm 0 004 worn rings remove and check valves first After removal in clean valve heads faces and stems with a power wire brush Then carefully inspect each valve for defects such as a warped head excessive corrosion or aworn stem end Replace valves found to be in bad condition 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 specifications 64 KohlerEngines com 24 690 31 Rev B Valve Guides If a valve guide is worn beyond specifications it will not guide valve in a straight line This may result in burnt valve faces or seats loss of compression and excessive oil consumption To check valve guide to valve stem clearance thoroughly clean valve guide and using a split ball gauge measure inside diameter of guide Then using an outside micrometer measure diameter of valve stem at several points on stem where it moves in valve guide Use largest stem diameter to calculate clearance by subtracting stem diameter from guide diameter If intake clearance exceeds 0 038 0 0
134. t Throttle Position Sensor TPS e Sensor contaminated or damaged CET e Poor ground path Fault TPS Circuit High Voltage e Pin circuit wiring or connectors Condition _ Shorted connection or faulty sensor ECU Black pin 10 or Black pin 17 Conclusion TPS Sensor Related T e Sensor connector or wiring Engine Wiring Harness Related e Sensor output affected or disrupted by e Difference in voltage between sensed dirt grease oil wear voltage and actual sensor voltage e Sensor loose on throttle body manifold e Short in wire harness Throttle Body Related e Throttle shaft or bearings worn damaged Engine Wiring Harness Related e ECU pins Black 10 12 and 16 damaged wiring connectors e ECU pins Black 10 12 and 16 routed near noisy electrical signal coils alternator e Intermittent 5 volt source from ECU pin Black 16 e ECU to harness connection problem 40 KohlerEngines com 24 690 31 Rev B Propane EFI System Code 0171 Code 0172 Component Fuel System Component Fuel System Fault Maximum adaptation limit exceeded Fault Minimum adaptation limit exceeded Condition Fuel filters plugged low pressure at Condition Too high pressure at high pressure fuel high pressure fuel line TPS malfunction line TPS malfunction shorted shorted connection faulty sensor low connection faulty sensor or regulator fuel or wrong fuel type failure Conclusion Oxygen Sensor Related Conclusion
135. t negative battery cable from battery Before disconnecting negative ground cable make sure all switches are OFF If ON a spark will occur at ground cable terminal which could cause an explosion if hydrogen gas or propane fuel vapors are present External Engine Components X Debris Screen Guard Debris Screen C Air Cleaner Bracket High Pressure Fuel Line Assembly Gaseous Propane Crankshaft Position E Fuel Quick Connect Fuel Injector MAP Sensor Sensor l Oil Cooler O Ring Oil Cooler K Nipple Oil Filter M Ignition Coil Barrel Baffle o Valley Baffle Breather Cover 24 690 31 Rev B KohlerEngines com 57 Disassembly Inspection and Service Q Breather Cover R Oil Sentry S Oil Temperature T Throttle Body Gasket Sensor Assembly Air Temperature Dipstick Tube w Oil Fill Cap Dipstick X Air Cleaner Sensor Breather Hose Breather Separator Clean all parts thoroughly as engine is disassembled Only clean parts can be accurately inspected and gauged for wear or damage There are many commercially available cleaners that will quickly remove grease oil and grime from engine parts When such a cleaner is used follow manufacturer s instructions and safety precautions carefully Make sure all traces of cleaner are removed before engine is reassembled and placed into operation Even small amounts of these clea
136. t of other side a voltage signal up to 1 0 volt is generated and sent to ECU Voltage signal tells ECU if engine is straying from ideal fuel mixture and ECU then adjusts injector pulse accordingly Oxygen sensor functions after being heated to a minimum of 400 C 752 F A heater inside sensor heats electrode to optimum temperature in about 10 seconds Oxygen sensor receives ground through wire eliminating need for proper grounding through muffler If problems indicate a bad oxygen sensor check all connections and wire harness Oxygen sensor can also be contaminated by leaded fuel certain RTV and or other silicone compounds fuel injector cleaners etc Use only those products indicated as O2 Sensor Safe Manifold absolute pressure MAP sensor provides immediate manifold pressure information to ECU MAP measures difference in pressure between outside atmosphere and vacuum level inside intake manifold and monitors pressure in manifold as primary means of detecting load Data is used to calculate air density and determine engine s mass air flow rate which in turn determines required ideal fueling MAP also stores instant barometric pressure reading when key is turned ON Fuel injectors mount into intake manifold and high pressure fuel line attaches to them at top end Replaceable O rings on both ends of injector prevent external fuel leakage and also insulate it from heat and vibration A special clip connects each injector to high
137. t valve face with a fine grade of grinding compound then rotate valve on its seat with grinder Continue grinding until a smooth surface is obtained on seat and on valve face Thoroughly clean cylinder head in soap and hot water to remove all traces of grinding compound After drying cylinder head apply a light coating of SAE 10 oil to prevent rusting Valve Stem Seal These engines use valve stem seals on intake and exhaust valves Always use a new seal when valves are removed from cylinder head Seals should also be replaced if deteriorated or damaged in any way Never reuse an old seal 24 690 31 Rev B Disassembly Inspection and Service Flywheel Components A Flywheel Fan B Flywheel C Stator D Backing Plate NOTE Always use a flywheel strap wrench or holding tool to hold flywheel when loosening or tightening flywheel screw Do not use any type of bar or wedge to hold flywheel Use of such tools could cause flywheel to become cracked or damaged KohlerEngines com 65 Disassembly Inspection and Service NOTE Always use a flywheel puller to remove flywheel from crankshaft Do not strike crankshaft or flywheel as these parts could become cracked or damaged Striking puller or crankshaft can cause crank gear to move affecting crankshaft endplay 1 Remove fan screws were removed earlier with debris screen 2 Use a flywheel strap wrench or holding tool see Tools and
138. ted KohlerEngines com 33 Propane EFI System Injector problems due to dirt or clogging are generally unlikely due to design of injectors and high fuel pressure Symptoms that could be caused by dirty clogged injectors include rough idle hesitation stumbling during acceleration or triggering of fault codes related to fuel delivery Injector clogging is usually caused by a buildup of deposits on director plate restricting flow of fuel resulting in a poor spray pattern Some contributing factors to injector clogging include higher than normal operating temperatures short operating intervals and dirty incorrect or poor quality fuel Cleaning of clogged injectors is not recommended they should be replaced Ignition Coil If a coil is determined to be faulty replacement is necessary An ohmmeter may be used to test wiring and coil windings NOTE Do not ground primary coil with ignition ON as they may overheat or spark NOTE Always disconnect spark plug lead from spark plug before performing following tests NOTE If ignition coil s are disabled and an ignition fault is registered system will automatically disable corresponding fuel injector drive signal Fault must be corrected to ignition coil and ECU power switch must be turned OFF for 10 seconds for injector signal to return This is a safety measure to prevent bore washing and oil dilution Testing Using an ohmmeter set on Rx1 scale check resistance in ci
139. ted to ground replace To test charging system for battery continuously charging at high rate 1 With engine running at 3600 RPM measure voltage from B lead to ground using a DC voltmeter Condition Conclusion Voltage is 14 7 volts or less Charging system is OK Battery is unable to hold charge service or replace Voltage is more than 14 7 volts Faulty rectifier regulator replace KohlerEngines com 51 Electrical System FUSES This engine has 3 blade type automotive fuses Replacement fuses must have same rating as blown fuse Use fuse chart below to determine correct fuse Wire Color Fuse Rating 2 Purple Wires 30 amp Fuse 1 Red Wire w Black Stripe 1 Red Wire w White Stripe 10 amp Fuse 2 Red Wires 10 amp Fuse Fuse Replacement 1 Shut engine off and remove key Locate fuse holders 2 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 holder until it is seated properly Install fuse cover 52 KohlerEngines com 24 690 31 Rev B Starter System NOTE Do not crank engine continuously for more than 10 seconds Allow a 60 second cool down period between starting attempts Failure to follow these guidelines can burn out starter motor NOTE If engine
140. ting of Kohler lubricant see Tools and Aids to base of each new lifter before it is installed Bleeding Lifters Style A Ribbed To prevent a possible bent push rod or broken rocker arm it is important to bleed any excess oil out of lifters before they are installed 1 Cut a 50 75 mm 2 3 in piece from end of an old push rod and chuck it in a drill press 2 Lay arag or shop towel on table of drill press and place lifter open end up on towel 3 Lower chucked push rod until it contacts plunger in lifter Slowly pump plunger 2 or 3 times to force oil out of feed hole in side of lifter 24 690 31 Rev B Disassembly Inspection and Service Bleeding Lifters Style B Smooth To prevent a possible bent push rod or broken rocker arm it is important to bleed any excess oil out of lifters before they are installed 1 Lay a rag or shop towel on table of drill press Place an 8 mm 5 16 in socket on towel with well end up then place open end of lifter on socket Ensure socket does not contact lifter ball surface 2 Place some material such as wood plastic or aluminum on top of lifter to protect lifter finish 3 Lower drill press chuck until it contacts material on lifter Slowly pump lifter 2 or 3 times to force oil out of feed hole in side of lifter Disassemble Cylinder Heads NOTE These engines use valve stem seals on intake and exhaust valves Use a new seal whenever valve is removed or if seal is deteriorate
141. tis within specifications proceed to Step 6 6 Check circuits input ground from main harness connector to sensor plug for continuity damage etc Connect one ohmmeter lead to Black pin 8 in main harness connector as in step 4 Connect other lead to terminal 1 in sensor plug Continuity should be indicated Repeat test between Black pin 10 and terminal 2 in sensor plug Oxygen Sensor O Components 30 KohlerEngines com Cutaway Oxygen Sensor Components O Planar Element A Protection Shield B and Heater Stainless Steel C Lower Insulator D Housing E Upper Insulator F ul nee 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 devices intermittent problems are difficult to diagnose Still with a good understanding of system and sensor it is possible to diagnose many sensor problems in field Using diagnostic software connected to ECU is a useful technique for observing sensor performance However user must understand that such software reads a signal generated by ECU If there is an ECU or wiring problem readings could be misinterpreted as a sensor problem Digital nature of signal to software means that it is not reading continuous output of sensor A voltm
142. tra Blue 587 Loctite Ultra Copper 5920 Spline Drive Lubricant Kohler 25 357 12 S 14 KohlerEngines com 24 690 31 Rev B Tools and Aids FLYWHEEL HOLDING TOOL ROCKER ARM CRANKSHAFT TOOL A flywheel holding tool can be made out of an old junk A spanner wrench to lift rocker arms or turn crankshaft flywheel ring gear and used in place of a strap wrench may be made out of an old junk connecting rod 1 Using an abrasive cut off wheel cut out a six tooth 1 Find a used connecting rod from a 10 HP or larger segment of ring gear as shown engine Remove and discard rod cap 2 Grind off any burrs or sharp edges 2 Remove studs of a Posi Lock rod or grind off 3 Invert segment and place it between ignition bosses gung steps of a Command rod so joint surface is on crankcase so tool teeth engage flywheel ring a gear teeth Bosses will lock tool and flywheel in 3 Find a 1 in long capscrew with correct thread size to position for loosening tightening or removing with a match threads in connecting rod puller 4 Use a flat washer with correct I D to slip on capscrew and approximately 1 in O D Assemble capscrew and washer to joint surface of rod 24 690 31 Rev B KohlerEngines com 15 Troubleshooting TROUBLESHOOTING GUIDE When troubles occur be sure to check simple causes which at first may seem too obvious to be considered For example a starting problem could be caused by an empty f
143. uel tank Some general common causes of engine troubles are listed below and vary by engine specification Use these to locate causing factors Engine Cranks But Will Not Start Engine Will Not Crank e Battery connected backwards e Blown fuse e Carburetor solenoid malfunction e Choke not closing e Clogged fuel line or fuel filter e Diode in wiring harness failed in open circuit mode e DSAI or DSAM malfunction e Empty fuel tank e Faulty electronic control unit e Faulty ignition coil s e Faulty spark plug s e Fuel pump malfunction vacuum hose clogged or leaking e Fuel shut off valve closed e Ignition module s faulty or improperly gapped e Insufficient voltage to electronic control unit e Interlock switch is engaged or faulty e Key switch or kill switch in OFF position e Low oil level e Quality of fuel dirt water stale mixture e SMART SPARK malfunction e Spark plug lead S disconnected Engine Starts But Does Not Keep Running e Battery is discharged e Faulty electric starter or solenoid e Faulty key switch or ignition switch e Interlock switch is engaged or faulty e Loose wires or connections that intermittently ground ignition kill circuit e Pawls not engaging in drive cup e Seized internal engine components Engine Runs But Misses e Carburetor adjusted incorrectly e Engine overheated e Faulty spark plug s e Ignition module s faulty or improperly
144. uit problem Pin circuits Grey 3 e Ignition switch e Permanent ECU power circuit problem Pin circuit Black 18 e Switched ECU power circuit problem Pin circuit Black 15 e ECU grounds e ECU Diagnostic Aid 2 FAULT CODES Refer to Diagnostic Fault Code Summary Diagnostic Aid 3 RUN ON MIL remains ON while engine is running Condition NOTE Either incandescent or LED type bulbs can be used for MIL as long as they do not draw more than 0 1 amps Bulb needs to be rated at 1 4 Watts or less or needs to have a total resistance of 140 O or more LEDs typically draw less than 0 03 amps All current fault codes will turn on MIL when engine is running Diagnostic Aid 4 CRANKSHAFT POSITION SENSOR MIL does not turn off during cranking Condition e Crankshaft position sensor e Crankshaft position sensor circuit problem pin circuits Black 4 and Black 13 e Crankshaft position sensor toothed wheel air gap e Toothed wheel e Flywheel key sheared e ECU Diagnostic Aid 5 FUEL LOCK OFF lock off not activating Condition e Main fuse e Fuel lock off circuit problem pin circuits Black 9 and Grey 17 e Fuel lock off 44 KohlerEngines com Diagnostic Aid 6 IGNITION SYSTEM no spark Condition e Spark plug e Plug wire e Coil e Coil circuit s pin circuits Grey 10 and Black 1 e ECU grounds e ECU e Vehicle safety interlocks ground signal on safety wire Diagnostic Aid 7 FUEL SYSTEM ELECTRICAL
145. ure e Weak spark 16 KohlerEngines com e Cooling fan broken e Excessive engine load e Fan belt failed off e Faulty carburetor e High crankcase oil level e Lean fuel mixture e Low cooling system fluid level e Low crankcase oil level e Radiator and or cooling system components clogged restricted or leaking e Water pump belt failed broken e Water pump malfunction Engine Knocks e Excessive engine load e Hydraulic lifter malfunction e Incorrect oil viscosity type e Internal wear or damage e Low crankcase oil level e Quality of fuel dirt water stale mixture 24 690 31 Rev B Engine Loses Power e Dirty air cleaner element e Engine overheated e Excessive engine load e Restricted exhaust e Faulty spark plug s e High crankcase oil level e Incorrect governor setting e Low battery e Low compression e Low crankcase oil level e Quality of fuel dirt water stale mixture Engine Uses Excessive Amount of Oil e Loose or improperly torqued fasteners e Blown head gasket overheated e Breather reed broken e Clogged broken or inoperative crankcase breather e Crankcase overfilled e Incorrect oil viscosity type e Worn cylinder bore e Worn or broken piston rings e Worn valve stems valve guides Oil Leaks from Oil Seals Gaskets e Breather reed broken e Clogged broken or inoperative crankcase breather e Loose or improperly torqued fa
146. ush Rod G Hydraulic Lifter H Valve Cap I Valve Keeper J Valve Spring Valve Seal L w Cylinder Head M Spark Plug N Cylinder Head o Gasket P Valve Hydraulic Lifter Hydraulic Lifter Q Bowel Pin R StyleA Ribbed 9 Style B Smooth Remove Valve Covers 1 Remove screws securing each valve cover Note valve cover differences for proper location in reassembly Ensure any brackets removed are reassembled in same location 2 Covers should lift off without prying Remove Spark Plugs Remove spark plug from each cylinder head 62 KohlerEngines com 24 690 31 Rev B Remove Cylinder Heads and Hydraulic Lifters 1 Remove nuts and washers securing each cylinder head Discard 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 lifters from lifter bores Use a hydraulic lifter tool Do not use a magnet to remove lifters Mark lifters by location as either intake or exhaust and cylinder 1 or 2 Hydraulic lifters should always be reinstalled in same position Inspection Check base surface of hydraulic lifters for wear or damage If lifters need to be replaced apply a liberal coa
147. ve nut and disconnect positive brush lead bracket from solenoid terminal 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 from armature and drive end cap 7 Remove rubber grommet and backing plate from end cap 8 Take out drive lever and pull armature out of drive end cap 9 Remove thrust washer from armature shaft 10 Push stop collar down to expose retaining ring 11 Remove retainer from armature shaft Save stop collar 12 Remove drive pinion assembly from armature 13 Clean parts as required Inspection Check drive pinion and inspect following areas e Pinion teeth for abnormal wear or damage e Surface between pinion and clutch mechanism for nicks or irregularities which could cause seal damage e Check drive clutch by holding clutch housing and rotating pinion Pinion should rotate in only 1 direction Brushes and Springs Detail A Wear Limit Length Inspect both springs and brushes for wear fatigue or damage Measure length of each brush Minimum length for each brush is 7 6 mm 0 300 in Replace brushes if the
148. ver plated rectifier regulator ground strap screw fastened to crankcase Rectifier regulator does not have to be detached from blower housing 3 Disconnect 3 fuse connectors on outer baffle and allow them to hang 4 Remove screws securing outer barrel baffles Note location of any lifting strap and position of short screws for reassembly Coil and any hoses may remain attached to baffle after being unplugged or disconnected 24 690 31 Rev B Disassembly Inspection and Service 5 Remove outer barrel baffles 6 Remove remaining screws securing blower housing Remove blower housing Remove Oil Sentry If Equipped NOTE This is optional Removing Oil Sentry is not required to remove breather cover 1 Disconnect lead from Oil Sentry switch 2 Remove Oil Sentry switch from breather cover Remove Oil Temperature Sensor NOTE Unless oil 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 Remove Inner Baffles and Breather Cover NOTE Removing oil temperature sensor is not required to remove breather cover or inner baffles Remove screws securing inner baffles to crankcase Remove inner valley baffles Disconnect and remove oil temperature sensor Remove remaining screws from breather cover Pry under protruding edge of breather cover with a screwdriver to
149. vestigated If system pressure is OK depress valve button on tester to relieve system pressure a If pressure is too high or too low replace regulator 3 Iflock off did not activate step 2 disconnect plug from lock off Connect a DC voltmeter across terminals in plug turn on key switch and observe if a minimum of 7 volts is present during six second prime process 4 fno voltage is observed connect red lead of meter to red wire of plug and black lead to a good ground while key is still ON 5 f voltage is between 7 and 14 turn key switch OFF and connect an ohmmeter between terminals on lock off to check for continuity a If there was no continuity between lock off terminals replace lock off valve b If voltage was below 7 test wiring harness and battery 6 If voltage at plug was good and there was continuity across lock off terminals reconnect plug to lock off making sure you have a good connection Turn on key switch and listen for lock off to activate a If lock off clicks repeat steps 1 and 2 to verify correct pressure b If lock off still does not operate replace it Regulator Maintenance Drain Accumulated Deposits Over time depending on fuel quality operating environment and system performance fuel deposits can accumulate inside regulator Perform following steps to remove any accumulated deposits 1 Turn supply valve off run engine out of fuel and turn off ignition switch 2 Disconnect and ground s
150. y are worn undersize or condition is questionable 24 690 31 Rev B Armature Components and Details A Commutator O D B Mica Insulation Insulation Check D Armature Coil Continuity Check 4 Shi Clean and inspect commutator outer surface Mica insulation must be lower than commutator bars undercut to ensure proper operation of commutator Use an ohmmeter set to Rx1 scale Touch probes between 2 different segments of commutator and check for continuity Test all segments Continuity must exist between all or armature is bad Check for continuity between armature coil segments and commutator segments There should be no continuity If continuity exists between any 2 armature is bad Check armature windings insulation for shorting ft Fork Check that shift fork is complete and pivot and contact areas are not excessively worn cracked or broken Brush Replacement 4 brushes and springs are serviced as a set Use a new Kohler brush and spring kit if replacement is necessary 1 2 24 690 31 Rev B Perform steps 1 5 in Starter Disassembly Remove screws securing brush holder assembly to end cap plate Note orientation for reassembly later Discard old brush holder assembly Clean component parts as required New brushes and springs come preassembled in a brush holder with a protective sleeve that will also serve as an installati

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