Kohler Command Pro EFI & Aegis ELH775 Troubleshooting Guide PDF (EN)

KOHLER - AEGIS ELH775 30HP KOHLER - COMMAND PRO EFI 23HP / 26HP DELPHI EFI SYSTEM TROUBLE CODES 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. KohlerEngines.com 1 24 690 01 Rev. D

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Troubleshooting DELPHI EFI TROUBLESHOOTING GUIDE :KHQWURXEOHVRFFXUEHVXUHWRFKHFNVLPSOHFDXVHVZKLFKDWїUVWPD\VHHPWRRREYLRXVWREHFRQVLGHUHG)RU example, a starting problem could be caused by an empty fuel tank. 6RPHJHQHUDOFRPPRQFDXVHVRIHQJLQHWURXEOHVDUHOLVWHGEHORZDQGYDU\E\HQJLQHVSHFLїFDWLRQ8VHWKHVHWR locate causing factors. Engine Cranks But Will Not Start Ɣ%DWWHU\FRQQHFWHGEDFNZDUGV Ɣ%ORZQIXVH Ɣ&DUEXUHWRUVROHQRLGPDOIXQFWLRQ Ɣ&KRNHQRWFORVLQJ Ɣ&ORJJHGIXHOOLQHRUIXHOїOWHU Ɣ'LRGHLQZLULQJKDUQHVVIDLOHGLQRSHQFLUFXLWPRGH Ɣ'6$,RU'6$0PDOIXQFWLRQ Ɣ(PSW\IXHOWDQN Ɣ)DXOW\HOHFWURQLFFRQWUROXQLW Ɣ)DXOW\LJQLWLRQFRLOV Ɣ)DXOW\VSDUNSOXJV Ɣ)XHOSXPSPDOIXQFWLRQYDFXXPKRVHFORJJHGRU leaking.

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Ɣ,QWDNHV\VWHPOHDN Ɣ/RRVHZLUHVRUFRQQHFWLRQVWKDWLQWHUPLWWHQWO\JURXQG ignition kill circuit. Ɣ4XDOLW\RIIXHOGLUWZDWHUVWDOHPL[WXUH Ɣ5HVWULFWHGIXHOWDQNFDSYHQW Engine Will Not Idle Ɣ(QJLQHRYHUKHDWHG Ɣ)DXOW\VSDUNSOXJV Ɣ,GOHIXHODGMXVWLQJQHHGOHVLPSURSHUO\VHW Ɣ,GOHVSHHGDGMXVWLQJVFUHZLPSURSHUO\VHW Ɣ,QDGHTXDWHIXHOVXSSO\ Ɣ/RZFRPSUHVVLRQ Ɣ4XDOLW\RIIXHOGLUWZDWHUVWDOHPL[WXUH Ɣ5HVWULFWHGIXHOWDQNFDSYHQW Engine Overheats Ɣ&RROLQJIDQEURNHQ Ɣ([FHVVLYHHQJLQHORDG Ɣ)DQEHOWIDLOHGRII Ɣ)DXOW\FDUEXUHWRU Ɣ+LJKFUDQNFDVHRLOOHYHO Ɣ/HDQIXHOPL[WXUH Ɣ/RZFRROLQJV\VWHPAXLGOHYHO Ɣ/RZFUDQNFDVHRLOOHYHO Ɣ5DGLDWRUDQGRUFRROLQJV\VWHPFRPSRQHQWVFORJJHG restricted, or leaking.

Ɣ:DWHUSXPSEHOWIDLOHGEURNHQ Ɣ:DWHUSXPSPDOIXQFWLRQ Engine Starts Hard Ɣ&ORJJHGIXHOOLQHRUIXHOїOWHU Ɣ(QJLQHRYHUKHDWHG Ɣ)DXOW\$&5PHFKDQLVP Ɣ)DXOW\RUPLVDGMXVWHGFKRNHRUWKURWWOHFRQWUROV Ɣ)DXOW\VSDUNSOXJV Ɣ)O\ZKHHONH\VKHDUHG Ɣ)XHOSXPSPDOIXQFWLRQYDFXXPKRVHFORJJHGRU leaking. Ɣ,QWHUORFNVZLWFKLVHQJDJHGRUIDXOW\ Ɣ/RRVHZLUHVRUFRQQHFWLRQVWKDWLQWHUPLWWHQWO\JURXQG ignition kill circuit. Ɣ/RZFRPSUHVVLRQ Ɣ4XDOLW\RIIXHOGLUWZDWHUVWDOHPL[WXUH Ɣ:HDNVSDUN Engine Knocks Ɣ([FHVVLYHHQJLQHORDG Ɣ+\GUDXOLFOLIWHUPDOIXQFWLRQ Ɣ,QFRUUHFWRLOYLVFRVLW\W\SH Ɣ,QWHUQDOZHDURUGDPDJH Ɣ/RZFUDQNFDVHRLOOHYHO Ɣ4XDOLW\RIIXHOGLUWZDWHUVWDOHPL[WXUH 18 KohlerEngines.com 24 690 01 Rev. D

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Troubleshooting Engine Loses Power Ɣ'LUW\DLUFOHDQHUHOHPHQW Ɣ(QJLQHRYHUKHDWHG Ɣ([FHVVLYHHQJLQHORDG Ɣ5HVWULFWHGH[KDXVW Ɣ)DXOW\VSDUNSOXJV Ɣ+LJKFUDQNFDVHRLOOHYHO Ɣ,QFRUUHFWJRYHUQRUVHWWLQJ Ɣ/RZEDWWHU\ Ɣ/RZFRPSUHVVLRQ Ɣ/RZFUDQNFDVHRLOOHYHO Ɣ4XDOLW\RIIXHOGLUWZDWHUVWDOHPL[WXUH 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.

Ɣ&KHFNIRUEXLOGXSRIGLUWDQGGHEULVRQFUDQNFDVH FRROLQJїQVJUDVVVFUHHQDQGRWKHUH[WHUQDOVXUIDFHV Dirt or debris on these areas can cause overheating. Ɣ&KHFNIRUREYLRXVIXHODQGRLOOHDNVDQGGDPDJHG components. Excessive oil leakage can indicate a clogged or inoperative breather, worn or damaged seals or gaskets, or loose fasteners. Ɣ&KHFNDLUFOHDQHUFRYHUDQGEDVHIRUGDPDJHRU LQGLFDWLRQVRILPSURSHUїWDQGVHDO Ɣ&KHFNDLUFOHDQHUHOHPHQW/RRNIRUKROHVWHDUV cracked or damaged sealing surfaces, or other GDPDJHWKDWFRXOGDOORZXQїOWHUHGDLULQWRHQJLQH$ GLUW\RUFORJJHGHOHPHQWFRXOGLQGLFDWHLQVXIїFLHQWRU improper maintenance. Ɣ&KHFNFDUEXUHWRUWKURDWIRUGLUW'LUWLQWKURDWLVIXUWKHU indication that air cleaner was not functioning properly.

Ɣ&KHFNLIRLOOHYHOLVZLWKLQRSHUDWLQJUDQJHRQGLSVWLFN If it is above, sniff for gasoline odor. Ɣ&KHFNFRQGLWLRQRIRLO'UDLQRLOLQWRDFRQWDLQHULW VKRXOGARZIUHHO\&KHFNIRUPHWDOFKLSVDQGRWKHU foreign particles.

Engine Uses Excessive Amount of Oil Ɣ/RRVHRULPSURSHUO\WRUTXHGIDVWHQHUV Ɣ%ORZQKHDGJDVNHWRYHUKHDWHG Ɣ%UHDWKHUUHHGEURNHQ Ɣ&ORJJHGEURNHQRULQRSHUDWLYHFUDQNFDVHEUHDWKHU Ɣ&UDQNFDVHRYHUїOOHG Ɣ,QFRUUHFWRLOYLVFRVLW\W\SH Ɣ:RUQF\OLQGHUERUH Ɣ:RUQRUEURNHQSLVWRQULQJV Ɣ:RUQYDOYHVWHPVYDOYHJXLGHV Oil Leaks from Oil Seals, Gaskets Ɣ%UHDWKHUUHHGEURNHQ Ɣ&ORJJHGEURNHQRULQRSHUDWLYHFUDQNFDVHEUHDWKHU Ɣ/RRVHRULPSURSHUO\WRUTXHGIDVWHQHUV Ɣ3LVWRQEORZE\RUOHDN\YDOYHV Ɣ5HVWULFWHGH[KDXVW 6OXGJHLVDQDWXUDOE\SURGXFWRIFRPEXVWLRQDVPDOO 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 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. 19 24 690 01 Rev.

D KohlerEngines.com 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 ÀDPPDEOH)ROORZFOHDQHUPDQXIDFWXUHU¶VZDUQLQJV and instructions on its proper and safe use. Never use gasoline as a cleaning agent.

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DELPHI EFI DQLQOLQHIXHOїOWHUDQGIXHOOLQH)XHOLVWKHQSXPSHG to fuel pump module. Fuel pump module regulates fuel pressure to a system operating pressure of 39 psi. Fuel is delivered from fuel pump module 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 4stroke cycle. When intake valve opens, air/fuel mixture is drawn into combustion chamber,compressed, ignited, and burned.

ECU controls amount of fuel being injected and ignition timing by monitoring primary sensor signals for engine temperature, speed (RPM), and 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 reestablish 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: Ɣ2LOWHPSHUDWXUHLVJUHDWHUWKDQѓ&ѓ) Ɣ2[\JHQVHQVRUKDVZDUPHGVXIїFLHQWO\WRSURYLGHD signal (minimum 400°C, 752°F). Ɣ(QJLQHRSHUDWLRQLVDWDVWHDG\VWDWHQRWVWDUWLQJ warming up, accelerating, etc.). Typical electronic fuel injection (EFI) system and related components include:

Ɣ)XHOSXPSPRGXOHDQGOLIWSXPS Ɣ)XHOїOWHU Ɣ+LJKSUHVVXUHIXHOOLQH Ɣ)XHOOLQHV Ɣ)XHOLQMHFWRUV Ɣ7KURWWOHERG\LQWDNHPDQLIROG Ɣ(OHFWURQLFFRQWUROXQLW(&8 Ɣ,JQLWLRQFRLOV Ɣ(QJLQHRLOWHPSHUDWXUHVHQVRU Ɣ7KURWWOHSRVLWLRQVHQVRU736 Ɣ&UDQNVKDIWSRVLWLRQVHQVRU Ɣ2[\JHQVHQVRU Ɣ0DQLIROGDEVROXWHSUHVVXUHVHQVRU0$3 Ɣ:LUHKDUQHVVDVVHPEO\ DIїOLDWHGZLULQJ Ɣ0DOIXQFWLRQLQGLFDWRUOLJKW0,/RSWLRQDO Ɣ,QWDNHDLUWHPSHUDWXUHVHQVRU FUEL RECOMMENDATIONS Refer to Maintenance. FUEL LINE Low permeation fuel line must be installed on all Kohler Co. engines to maintain EPA and CARB regulatory compliance. 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 SHUIRUPDQFHZLWKRSWLPXPIXHOHIїFLHQF\DQGORZHVW 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.

A lift fuel pump is used to move fuel from tank through 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., 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.

23 24 690 01 Rev. D KohlerEngines.com WARNING ([SORVLYH)XHOFDQFDXVH¿UHVDQGVHYHUH burns. 'RQRW¿OOIXHOWDQNZKLOHHQJLQHLVKRWRU running. *DVROLQHLVH[WUHPHO\ÀDPPDEOHDQGLWVYDSRUVFDQ explode if ignited. Store gasoline only in approved containers, in well ventilated, unoccupied buildings, DZD\IURPVSDUNVRUÀDPHV6SLOOHGIXHOFRXOGLJQLWHLILW comes in contact with hot parts or sparks from ignition. Never use gasoline as a cleaning agent.

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