Kohler Command PRO CH745

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7924 690 01 Rev. K KohlerEngines.com

EFI SYSTEM-BOSCH

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Contents1
Safety Precautions2
Maintenance Instructions3
Maintenance Schedule3
Repairs/Service Parts3
Oil Recommendations4
Fuel Recommendations4
Storage4
Specifications5
Engine Dimensions with Heavy-Duty Air Cleaner-Flywheel Side5
Engine Dimensions with Heavy-Duty Air Cleaner-Oil Filter Side6
Engine Dimensions with Heavy-Duty Air Cleaner-PTO Side7
Engine Dimensions with Heavy-Duty Air Cleaner-Starter Side8
Engine Dimensions with Low-Proﬁ Le Air Cleaner-Flywheel Side9
Engine Dimensions with Low-Proﬁ Le Air Cleaner-Oil Filter Side10
Engine Dimensions with Low-Proﬁ Le Air Cleaner-PTO Side11
Engine Dimensions with Low-Proﬁ Le Air Cleaner-Starter Side12
Engine Identification Numbers13
General Specifications13
Torque Specifications13
Clearance Specifications16
General Torque Values21
Metric Fastener Torque Recommendations for Standard Applications21
Separate Tool Supplies22
Tools22
Aids23
Flywheel Holding Tool24
Rocker Arm/Crankshaft Tool24
Troubleshooting Guide25
External Engine Inspection26
Cleaning Engine26
Crankcase Vacuum Test27
Compression Test28
Cylinder Leakdown Test28
Low-Profile Air Cleaner29
Heavy-Duty Air Cleaner29
Breather Tube29
Air Cooling29
EFI System30
Fuel Line30
Operation30
Crankshaft Position Sensor Bracket31
Important Notes33
Electrical Components34
Electronic Control Unit (ECU)34
Pinout of ECU34
ECU Reset Procedure35
TPS Learn Procedure35
Wiring Harness36
EFI Wiring Diagram 6-Terminal Connector (Engines with Separate MAP Sensor and Intake Air Temperature Sensor)36
EFI Wiring Diagram 5-Terminal Connector and Optional Key Switch (Engines with Separate MAP Sensor and Intake Air Temperature Sensor)37
EFI Wiring Diagram 6-Terminal Connector (Engines with Separate MAP Sensor)38
EFI Wiring Diagram 5-Terminal Connector and Optional Key Switch (Engines with TMAP Sensor)39
Crankshaft Position Sensor40
Throttle Position Sensor (TPS)40
Contacting (Brush) Type TPS Resistance Table40
Replace Magnet Assembly41
Contactless (Magnet) Type TPS41
Engine (Oil) Temperature Sensor42
Intake Air Temperature Sensor42
Manifold Absolute Pressure Sensor (MAP)42
Temperature/Manifold Absolute Pressure (TMAP) Sensor42
Oxygen Sensor Components43
Cutaway Oxygen Sensor Components43
Sensor Signal Observation44
Removal Inspection44
Troublshooting-Oxygen Sensor45
Fuel Injectors46
Fuel Components47
Ignition Coil47
Fuel Pump Module (FPM)47
High Pressure Fuel Line48
Purge Port and Vent Hose Assembly48
Throttle Body/Intake Manifold Assembly48
Function Test50
Fault Codes50
Example of Diagnostic Display50
Diagnostic Fault Code Summary50
Diagnostic Code Summary51
Troubleshooting Flow Chart57
EFI Diagnostic Flow Diagram58
Bosch EFI System59
Initial Starting/Priming Procedure62
Speed Sensor Circuit63
TPS Initialization Procedure64
Cutaway of Oxygen Sensor66
To Replace Oxygen Sensor67
Fuel Injector Details68
Injector Inspection Points69
Fuel Pump70
Fuel Pressure Regulator Details70
Fuel Rail71
Idle Speed Adjustment (RPM)71
Idle Speed Screw Dampening Spring71
Initial Governor Adjustment71
“35 Pin” (MA 1.7) Metal-Cased ECU Systems74
“24 Pin” (MSE 1.0) Plastic-Cased ECU Systems76
“32 Pin” (MSE 1.1) Plastic-Cased ECU Systems78
Fuel System80
Flow Chart Diagnostic Aids89
Bosch EFI Diagnostic Flow Diagram91
Lubrication System92
Lubrication Components92
Check Oil Level92
Change Oil and Filter93
Oil Cooler93
Oil Sentry93
Spark Plug Component and Details94
Service94
Electrical System94
Battery Size Recommendations95
Battery Maintenance95
Battery Test95
Battery Charging System96
Fuse Replacement98
Starter System99
Solenoid Shift Starter Components100
Starter Disassembly100
Brushes and Springs Detail100
Armature Components and Details101
Brush Replacement101
Starter Reassembly101
Solenoid Tests102
Disassembly/Inspection and Service103
External Engine Components103
Disconnect Spark Plug Leads104
Drain Oil from Crankcase and Remove Oil Filter104
Remove Oil Cooler104
Remove Mufﬂer104
External Governor Control (ECH EFI)105
Remove External Governor Controls105
Remove Lift Fuel Pump and Fuel Pump Module106
Remove Fuel Pump Module (ECH EFI)107
Remove Electronic Control Unit (ECU)107
Remove Electronic Control Unit Bracket and Electric Starter Motor107
Throttle Body Components107
Remove Debris Screen Guard108
Remove Debris Screen108
Remove Outer Bafﬂes and Blower Housing108
Remove Oil Sentry108
Remove Inner Bafﬂes and Breather Cover109
Intake Manifold Components (ECH EFI)109
Remove Crankshaft Position Sensor109
Remove Manifold Absolute Pressure (MAP) Sensor or Temperature/Manifold Absolute Pressure (TMAP) Sensor (ECH EFI)109
Cylinder Head Components110
Remove Valve Covers (ECH EFI)110
Remove Cylinder Heads and Hydraulic Lifters110
Disassemble Cylinder Heads111
Valve Details112
Valve Guides112
Valve Seat Inserts113
Lapping Valves113
Flywheel Components113
Remove Fan and Flywheel113
Remove Stator and Backing Plate (ECH EFI)114
Remove Closure Plate Assembly114
Governor Shaft Press Depth Details114
Oil Pump Assembly115
Crankcase Components116
Remove Camshaft116
Remove Governor Cross Shaft116
Governor Cross Shaft Oil Seal117
Remove Connecting Rods with Pistons and Rings117
Piston and Rings Components and Details117
Install New Piston Rings118
Piston Ring Orientation118
Connecting Rods119
Crankshaft Components and Details119
Crankcase Inspection and Service120
Honing Detail120
Clean Cylinder Bore after Honing120
Measuring Piston-To-Bore Clearance121
Piston Detail121
Install Flywheel End Oil Seal123
Oil Seal Detail123
Install Crankshaft123
Install Connecting Rods with Pistons and Rings123
Governor Gear Assembly124
Thrust Bearing, Washer and Shim124
Install Closure Plate Oil Seal124
Oil Seal Details124
Install Closure Plate Assembly125
Closure Plate Fastener Torque Sequence125
Install Stator and Backing Plate125
Install Flywheel126
Install Fan126
Install Hydraulic Lifters127
Valve Stem Seals128
Assemble Cylinder Heads128
Install Cylinder Heads128
Install Push Rods and Rocker Arms128
Install Intake Manifold129
Install Fuel Injectors129
Install Oil Temperature Sensor (ECH EFI)131
Install Oil Sentry131
Install Blower Housing and Outer Bafﬂes132
Install Rectiﬁer-Regulator132
Install Metal Debris Screen132
Install Plastic Debris Screen133
Install Electric Starter Motor and ECU Bracket (ECH EFI)133
Install Electronic Control Unit (ECU)133
Install Lift Fuel Pump and Fuel Pump Module134
Install External Governor Control (ECH EFI)135
Install Throttle Control Panel137
Install Air Cleaner Assembly137
Setting Initial Governor Adjustment137
Install Mufﬂer137
Sensitivity Adjustment138
Testing Engine138

Kohler Command PRO CH745 - Page 79

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