Kohler Command PRO EFI PCV680LE Service Manual

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PCV680, PCV680LE, PCV740, PCV740LE

Service Manual

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.

Safety

Maintenance

Speciﬁ cations

Tools and Aids

Troubleshooting

Air Cleaner/Intake

Propane Electronic Fuel Injection (EFI) System

Lubrication System

Electrical System

Starter System

Disassembly/Inspection and Service

Reassembly

24 690 31 Rev. H

KohlerEngines.com

Summary of Contents for Kohler Command PRO EFI PCV680LE

Page 1 PCV680, PCV680LE, PCV740, PCV740LE Service Manual 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. Safety Maintenance Speciﬁ...
Page 2 Safety SAFETY PRECAUTIONS WARNING: A hazard that could result in death, serious injury, or substantial property damage. 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. CAUTION WARNING WARNING...
Page 3 PRO oil and PRO oil ﬁ lter. ® REPAIRS/SERVICE PARTS Kohler genuine service parts can be purchased from Kohler authorized dealers. To ﬁ nd a local Kohler authorized dealer visit KohlerEngines.com or call 1-800-544-2444 (U.S. and Canada). 24 690 31 Rev. H...
Page 4 KOHLER PRO Extended Life Oil Filter. Alternative engine in a poorly ventilated area where leaking gas engine oils and oil ﬁ lters may be used with KOHLER could accumulate and endanger safety of persons in engines but require 100-Hour oil and 200-Hour oil ﬁ lter area.
Page 5 Speciﬁ cations Engine Dimensions Dimensions in millimeters. 412.98 [16.259] Inch equivalents shown in [ ]. 296.38 [11.668] 135.00 130.00 [5.315] 96.02 269.48 [5.118] AIR FILTER RAIN CAP [3.780] [10.609] AIR FILTER REMOVAL COVER ASSEMBLY REMOVAL 73.06 [2.877] SPARK PLUG REMOVAL 73.23 [2.883] SPARK PLUG REMOVAL 52.45...
Page 6 Lubricate threads with engine oil prior to assembly. Any and all horsepower (hp) references by Kohler are Certiﬁ ed Power Ratings and per SAE J1940 & J1995 hp standards. Details on Certiﬁ ed Power Ratings can be found at KohlerEngines.com.
Page 7 Speciﬁ cations TORQUE SPECIFICATIONS PCV680, PCV680LE, PCV740, PCV740LE Crankcase Breather Cover Fastener 11.3 N·m (100 in. lb.) into new holes 7.3 N·m (65 in. lb.) into used holes Oil Temperature Sensor (into breather cover) 7.3 N·m (65 in. lb.) Oil Drain Plug 13.6 N·m (10 ft.
Page 8 Speciﬁ cations TORQUE SPECIFICATIONS PCV680, PCV680LE, PCV740, PCV740LE Intake Manifold Fastener (torque in 2 increments) ﬁ rst to 7.8 N·m (69 in. lb.) ﬁ nally to 10.5 N·m (93 in. lb.) Manifold Absolute Pressure (MAP) Sensor Fastener 7.3 N·m (65 in. lb.) (Engines with Separate MAP and Intake Air Temperature Sensors) Temperature/Manifold Absolute Pressure (TMAP) Sensor...
Page 9 Speciﬁ cations CLEARANCE SPECIFICATIONS PCV680, PCV680LE, PCV740, PCV740LE 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. 20.000/20.025 mm (0.7874/0.7884 in.) Max. Wear Limit 20.038 mm (0.7889 in.) Bearing Surface O.D. 19.920/19.975 mm (0.7843/0.7864 in.) Max.
Page 10 Speciﬁ cations CLEARANCE SPECIFICATIONS PCV680, PCV680LE, PCV740, PCV740LE Crankshaft (continued) Oil Pan End Main Bearing Journal O.D. - New 40.913/40.935 mm (1.6107/1.6116 in.) O.D. - Max. Wear Limit 40.843 mm (1.608 in.) Max. Taper Limit 0.022 mm (0.0009 in.) Max. Out-of-Round Limit 0.025 mm (0.0010 in.) Connecting Rod Journal O.D.
Page 11 Speciﬁ cations CLEARANCE SPECIFICATIONS PCV680, PCV680LE, PCV740, PCV740LE Piston, Piston Rings, and Piston Pin Piston-to-Piston Pin Running 0.006/0.017 mm (0.0002/0.0007 in.) Clearance Pin Bore I.D. 17.006/17.012 mm (0.6695/0.6698 in.) Max. Wear Limit 17.025 mm (0.6703 in.) Pin O.D. 16.995/17.000 mm (0.6691/0.6693 in.) Max.
Page 12 Speciﬁ cations 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 Tightening Torque: N·m (in. lb.) ± 20% 8-32 2.3 (20) 2.8 (25)
Page 13 Shrader Valve Adapter Hose DTI-037 Wire Probe Set (2 pieces regular wire with clip; 1 piece fused wire) DTI-031 Hose Removal Tool, Dual Size/End (also sold as individual Kohler tool) DTI-033 K-Line Adapter Jumper Lead Wiring Harness Kohler 25 176 23-S...
Page 14 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 Design Technology Inc. For hand reaming using Kohler 25 455 12-S reamer. DTI-K830 AIDS Description Source/Part No.
Page 15 Tools and Aids FLYWHEEL HOLDING TOOL ROCKER ARM/CRANKSHAFT TOOL A ﬂ ywheel holding tool can be made out of an old junk A spanner wrench to lift rocker arms or turn crankshaft ﬂ ywheel ring gear and used in place of a strap wrench. may be made out of an old junk connecting rod.
Page 16 Troubleshooting TROUBLESHOOTING GUIDE When troubles occur, be sure to check simple causes which, at ﬁ rst, may seem too obvious to be considered. For example, a starting problem could be caused by an empty fuel tank. Some general common causes of EFI engine troubles are listed below and vary by engine speciﬁ cation. Use these to locate causing factors.
Page 17 Troubleshooting EXTERNAL ENGINE INSPECTION Engine Overheats NOTE: It is good practice to drain oil at a location away ● Cooling fan broken. from workbench. Be sure to allow ample time for ● Excessive engine load. complete drainage. ● Fan belt failed/oﬀ . ●...
Page 18 Troubleshooting CRANKCASE VACUUM TEST WARNING WARNING Carbon Monoxide can cause severe nausea, Rotating Parts can cause severe injury. fainting or death. Stay away while engine is in operation. Take precautions against exposure to carbon monoxide (CO) emissions. Only operate an engine in well ventilated areas.
Page 19 Troubleshooting COMPRESSION TEST 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 battery is fully charged, unplug ECU, and throttle is wide open during test. Compression should be at least 160 psi and should not vary more than 15% between cylinders.
Page 20 Troubleshooting Test Pressure Chart for Dual Gauge Tool Left Gauge Regulated Pressure Selection Right Gauge Reading in PSI 80 PSI Recommended for engines over 200 cc or those exhibiting high leakage at 35 PSI setting. 35 PSI Recommended for single cylinder 31.5 24.5 17.5...
Page 21 Air Cleaner/Intake AIR CLEANER Low-Proﬁ le These systems are CARB/EPA certiﬁ ed and components Loosen knob and remove air cleaner cover. should not be altered or modiﬁ ed in any way. Precleaner Low-Proﬁ le Air Cleaner Components 1. Remove precleaner from paper element. 2.
Page 22 High pressure fuel line meeting a minimum of SAE mode. In open loop operation oxygen sensor output is R7 standard must be installed on Kohler Co. engines used to ensure engine is running rich, and controlling equipped with propane EFI system (from vaporizer/ adjustments are based on primary sensor signals and regulator to injectors).
Page 23 Propane EFI System ECU compares input signals to programmed maps in Crankshaft Position Sensor Bracket 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.
Page 24 Propane EFI System Earlier engines have a separate intake air temperature Fuel injectors mount into intake manifold, and high (IAT) sensor (located in throttle body) and a manifold pressure fuel line attaches to them at top end. absolute pressure (MAP) sensor. Later engines have Replaceable O-rings on both ends of injector prevent a combined temperature/manifold absolute pressure external fuel leakage and also insulate it from heat and...
Page 25 Propane EFI System High pressure fuel line is serviced as a complete ● Never attempt to service any fuel system component assembly to prevent tampering and safety hazards. while engine is running or ignition switch is ON. Components are not individually serviceable. ●...
Page 26 Propane EFI System ELECTRICAL COMPONENTS Grey Connector Side Electronic Control Unit (ECU) Pin # Description Pinout of ECU Not Used Black Connector Side Not Used Pin # Function Malfunction Indicator Light (MIL) Ground Ignition Coil #1 Ground Not Used Battery Ground Not Used Diagnostic Communication Line Not Used...
Page 27 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.
Page 28 Propane EFI System KohlerEngines.com 24 690 31 Rev. H...
Page 29 Propane EFI System 24 690 31 Rev. H KohlerEngines.com...
Page 30 Propane EFI System KohlerEngines.com 24 690 31 Rev. H...
Page 31 Propane EFI System 24 690 31 Rev. H KohlerEngines.com...
Page 32 Propane EFI System Contacting (Brush) Type TPS Crankshaft Position Sensor Resistance Table Throttle Between Resistance Continuity Position Terminal Value (Ω) Closed A & C 1400-1800 Full with A & C 3200-4100 Stop Pin Full without A & C 4600-5200 Stop Pin A &...
Page 33 Propane EFI System 7. Remove two mounting screws from TPS. Save Replace Magnet Assembly 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.
Page 34 Propane EFI System Engine (Oil) Temperature Sensor Manifold Absolute Pressure Sensor (MAP) A sealed, non-serviceable assembly. A faulty sensor A sealed, non-serviceable assembly. A faulty sensor must be replaced. If a blink code indicates a problem must be replaced. If a blink code indicates a problem with temperature sensor, it can be tested as follows: with manifold absolute pressure sensor, it can be tested as follows:...
Page 35 Propane EFI System 6. Check circuits (input, ground), from main harness Cutaway Oxygen Sensor Components (O 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 #3 in sensor plug.
Page 36 Propane EFI System Sensor Signal Observation Removal Inspection NOTE: Do not cut into or pierce sensor or engine NOTE: Apply anti-seize compound only to threads. wiring to make this connection. Sensor Anti-seize compound will aﬀ ect sensor produces a very small signal. Corrosion or performance if it gets into lower shield of damage to wiring could lead to an incorrect sensor.
Page 37 Propane EFI System Troubleshooting-Oxygen Sensor (O Condition Possible Cause Conclusion Low voltage output. Shorted sensor or sensor circuit. Replace sensor or repair wiring. Shorted lead wire. Wiring shorted to ground. Contamination of air reference. Remove source of external contamination, protect air reference area.
Page 38 Propane EFI System 1. With engine running at idle, listen for a buzzing or Fuel Injectors clicking sound. 2. Disconnect electrical connector from an injector and WARNING listen for a change in idle performance (only running High Pressure Fluids can puncture skin and on one cylinder) or a change in injector noise or cause severe injury or death.
Page 39 Propane EFI System 7. Reverse appropriate procedures to install new Testing injector(s) and reassemble engine. Use new O-rings Using an ohmmeter set on Rx1 scale, check resistance and retaining clips any time an injector is removed in circuits as follows: (new replacement injectors include new O-rings and 1.
Page 40 When fuel is dispensed, retighten ﬁ tting and remove quick connect ﬁ tting 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 . KohlerEngines.com...
Page 41 Please note routing and replicate after service or component replacement to prevent pinching or abrasion of line. Only Kohler replacement parts can be used because vacuum line is speciﬁ c to system and must be maintained. Visit KohlerEngines.com for recommended Kohler replacement parts.
Page 42 Propane EFI System Troubleshooting Guide Condition Possible Cause Faulty spark plugs. Lock-oﬀ not functioning. Fuel pressure low. Insuﬃ cient fuel delivery. Engine Starts Hard or Fails to Start TPS set incorrect (ECU Reset and TPS Initialization). When Hot. Crankshaft position sensor loose or faulty. TPS faulty.
Page 43 Propane EFI System Fault Codes Example of Diagnostic Display One second pause Fault Code One second pause 0107 One second pause Three second pause End Code 61 One second pause Diagnostic Fault Code Summary Fault Code Connection or Failure Description 0031 Oxygen Sensor Heater Circuit Low Voltage 0032...
Page 44 Propane EFI System ECU continuously monitors engine operation against Diagnostic Code Summary preset performance limits. If operation is outside limits, Code 0031 ECU activates MIL, if equipped, and stores a diagnostic Component: Oxygen Sensor Heater code in its fault memory. If component or system returns to proper function, ECU will turn oﬀ...
Page 45 Propane EFI System Code 0108 Code 0117 Component: Manifold Absolute Pressure (MAP or Component: Coolant/Oil Sensor TMAP) Sensor Fault: Coolant/Oil Temperature Sensor Circuit Low Voltage Fault: MAP or TMAP Circuit High Voltage Condition: Shorted connection, faulty sensor or Condition: Intake manifold leak, shorted connection shorted wire.
Page 46 Propane EFI System 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.
Page 47 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 ﬁ lters 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...
Page 48 Propane EFI System Code 0174 Code 0202 Component: Fuel System Component: Fuel Injector Fault: Lean fuel condition Fault: Injector 2 Circuit Malfunction Condition: Fuel ﬁ lters plugged, low pressure at high Condition: Injector damaged or faulty, shorted or pressure fuel line, TPS malfunction, open connection.
Page 49 Propane EFI System Code 0336 Code 0352 Component: Crankshaft Position Sensor Component: Ignition Coil Fault: Crankshaft Position Sensor Noisy Signal Fault: Cylinder 2 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.
Page 50 NOTE: MIL is installed by vehicle OEM. Twelve volt (no fuel delivery) supply to bulb will be part of vehicle wire Condition harness. Kohler key switch model will have MIL ● No fuel on engine with 12V supply to bulb. ● Air in high pressure fuel line Conclusion ●...
Page 51 Propane EFI System EFI Diagnostic Flow Diagram START OF TEST PROCEED TO START OF TEST FOR RETEST KEY ON MALFUNCTION REFER TO DIAGNOSTIC AID #1 INDICATOR LIGHT SYSTEM POWER REFER TO ARE FAULT CODES DIAGNOSTIC FAULT CODE SUMMARY PRESENT? CLEAR CODES REFER TO DIAGNOSTIC AID #3 DOES ENGINE START? MIL GOES OFF?
Page 52 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-eﬃ ciency gerotor oil pump maintains high oil ﬂ ow and oil pressure, even at low speeds and high operating temperatures.
Page 53 Lubrication System 7. Reinstall oil ﬁ ll cap/dipstick and tighten securely. Testing 8. Start engine; check for oil leaks. Stop engine; correct Compressed air, a pressure regulator, pressure gauge, leaks. Recheck oil level. and a continuity tester are required to test switch. 9.
Page 54 Electrical System SPARK PLUGS Inspection Inspect each spark plug as it is removed from cylinder CAUTION head. Deposits on tip are an indication of general Electrical Shock can cause injury. condition of piston rings, valves, and fuel system. Do not touch wires while engine is running. Normal and fouled plugs are shown in following photos: Normal Spark Plug Component and Details...
Page 55 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 suﬃ cient if an application is started only in warmer temperatures. Refer to following table for minimum capacities based on anticipated ambient temperatures.
Page 56 Electrical System BATTERY CHARGING SYSTEM NOTE: Observe following guidelines to avoid damage to electrical system and components: ● Make sure battery polarity is correct. A negative (-) ground system is used. ● Disconnect rectiﬁ er-regulator plug and/or wiring harness plug before doing any electric welding on equipment powered by engine.
Page 57 Electrical System Condition 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, part is good and may be used.
Page 58 Electrical System FUSES PCV680LE, PCV740LE Heat Sensor Switch This engine has 3 blade type automotive fuses. PCV680LE & PCV740LE engines have a heat sensor Replacement fuses must have same rating as blown switch on #2 cylinder. This switch will close to ground if fuse.
Page 59 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 develops suﬃ cient 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.
Page 60 Starter System SOLENOID SHIFT ELECTRIC STARTERS Starter Disassembly Solenoid Shift Starter Components 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. Remove nut and disconnect positive (+) brush lead/ bracket from solenoid terminal.
Page 61 Mounting screw 4 brushes and springs are serviced as a set. Use a new Kohler brush and spring kit if replacement is necessary. holes in metal clips must be up/out. Slide brush holder assembly down into place around 1.
Page 62 Starter System b. Position brushes back in their slots so they are ﬂ ush 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.
Page 63 Disassembly/Inspection and Service WARNING Before working on engine or equipment, disable engine as follows: 1) Disconnect spark plug lead(s). 2) Disconnect negative (–) battery cable from battery. Accidental Starts can cause severe injury or death. Before disconnecting negative (–) ground cable, make sure all switches are OFF.
Page 64 Disassembly/Inspection and Service Ignition Coil Barrel Baﬄ e Valley Baﬄ e Breather Cover Breather Cover Oil Temperature Throttle Body Oil Sentry Gasket Sensor Assembly ™ Air Temperature Dipstick Tube Oil Fill Cap/Dipstick Air Cleaner Sensor Crankshaft Position Breather Hose Breather Separator Sensor (Later Design Bracket) Clean all parts thoroughly as engine is disassembled.
Page 65 Disassembly/Inspection and Service Remove Air Cleaner Assembly Remove Top Mount Control Panel Heavy Duty Air Cleaner 1. Remove throttle control shaft nut on top of throttle 1. Remove nuts securing air cleaner to mounting studs. shaft and remove throttle control lever, washer, and spring.
Page 66 Disassembly/Inspection and Service External Governor Controls Throttle Control Shaft Throttle Control Shaft Throttle Control Lever Washer Throttle Control Spring Control Bracket Governor Spring Bracket (lower) Throttle Linkage Governor Lever Bushing Throttle Linkage Spring Governor Cross Shaft KohlerEngines.com 24 690 31 Rev. H...
Page 67 Disassembly/Inspection and Service Vaporizer/Regulator/Lock-Oﬀ Assembly Propane is extremely ﬂ ammable and is heavier than air and WARNING tends to settle in low areas where a spark or ﬂ ame 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.
Page 68 Disassembly/Inspection and Service 5. Remove outer barrel baﬄ es. 6. Remove remaining screws securing blower housing. Remove Electronic Control Unit (ECU) Remove blower housing. Remove Oil Sentry (If Equipped) ™ NOTE: This is optional. Removing Oil Sentry is not ™ required to remove breather cover.
Page 69 Disassembly/Inspection and Service Remove Intake Manifold Disconnect Heat Sensor Switch PCV680LE, PCV740LE 1. Remove screw securing a ring terminal which is part of wiring harness. NOTE: Heat sensor switch is located on #2 cylinder head. 2. Remove screws securing intake manifold to cylinder heads.
Page 70 Check base surface of hydraulic lifters for wear or damage. If lifters need to be replaced, apply a liberal coating of Kohler lubricant (see Tools and Aids) to base of each new lifter before it is installed. Bleeding Lifters Style A (Ribbed)
Page 71 Disassembly/Inspection and Service Inspection and Service Valve Details EXHAUST VALVE INTAKE VALVE EXHAUST INSERT INTAKE INSERT Dimension Intake Exhaust Seat Angle 89° 89° Insert O.D. 36.987/37.013 mm (1.4562/1.4572 in.) 32.987/33.013 mm (1.2987/1.2997 in.) Guide Depth 4 mm (0.1575 in.) 6.5 mm (0.2559 in.) Guide I.D.
Page 72 Disassembly/Inspection and Service After cleaning, check ﬂ atness of cylinder head and Valve Seat Inserts corresponding top surface of crankcase, using a surface Hardened steel alloy intake and exhaust valve seat plate or precision straight edge and feeler gauge. inserts are press ﬁ tted into cylinder head. Inserts are Maximum allowable out of ﬂ...
Page 73 ﬂ ywheel, crankshaft, and key if ﬂ ywheel 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 ﬂ ywheel if ring gear is damaged.
Page 74 Disassembly/Inspection and Service Crankcase Components Governor Cross Crankcase Shaft Oil Pump Assembly Outer Gerotor Gear (Style B) (Style B) Oil Pump Cover Spring (Style B) O-ring (Style B) Oil Screen Ball (Style B) (Style B) Oil Pan (Style B) Remove Oil Pan Assembly 1.
Page 75 Disassembly/Inspection and Service Disassembly 3. Install oil pump body to oil pan and secure with NOTE: Governor gear is held onto shaft by small screws. Torque screws as follows: molded tabs in gear. When gear is removed from a. Install fastener into location 1 and lightly tighten shaft, these tabs are destroyed and gear must to position pump.
Page 76 Disassembly/Inspection and Service Remove Camshaft Remove Connecting Rods with Pistons and Rings Remove camshaft. NOTE: If a carbon ridge is present at top of either cylinder bore, use a ridge reamer tool to remove Inspection and Service it before attempting to remove piston. NOTE: To prevent repeat failures, camshaft and crankshaft should always be replaced as a set.
Page 77 Disassembly/Inspection and Service Ring failure is usually indicated by excessive oil Install New Piston Rings consumption and blue exhaust smoke. When rings fail, oil is allowed to enter combustion chamber where it is Piston Ring Orientation 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 under this condition.
Page 78 Disassembly/Inspection and Service NOTE: If crankpin is reground, visually check to ensure Connecting Rods ﬁ llet blends smoothly with crankpin surface. Oﬀ set, stepped-cap connecting rods are used in all NOTE: To prevent repeat failures, camshaft and these engines. crankshaft should always be replaced as a set. Inspection and Service Inspect gear teeth of crankshaft.
Page 79 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...
Page 80 Disassembly/Inspection and Service Measuring Piston-to-Bore Clearance Piston Detail 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.
Page 81 Reassembly Crankcase Components Oil Pump Assembly Outer Gerotor Gear (Style B) (Style B) Oil Pump Cover Spring (Style B) O-ring (Style B) Oil Screen Ball (Style B) (Style B) Oil Pan (Style B) NOTE: Make sure engine is assembled using all speciﬁ...
Page 82 Reassembly 3. Install nylon washer onto governor cross shaft, then Install Connecting Rods with Pistons and Rings start push-on retaining ring. Hold cross shaft up in Piston Detail position, place a 0.50 mm (0.020 in.) feeler gauge on top of nylon washer, and push retaining ring down shaft to secure.
Page 83 Reassembly Install Oil Pan Assembly Install Flywheel Oil Pan Fastener Torque Sequence CAUTION Damaging Crankshaft and Flywheel Can cause personal injury. Using improper procedures can lead to broken fragments. Broken fragments could be thrown from engine. Always observe and use precautions and procedures when installing ﬂ...
Page 84 Reassembly NOTE: Before installing ﬂ ywheel, make sure crankshaft 2. Install ﬂ ywheel onto crankshaft being careful not to taper and ﬂ ywheel hub are clean, dry, and shift woodruﬀ key. completely free of any lubricants. Presence of 3. Install screw and washer. lubricants can cause ﬂ...
Page 85 Reassembly Install Hydraulic Lifters Install Cylinder Heads NOTE: Hydraulic lifters should always be installed in Torque Sequence 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.
Page 86 Reassembly Install Push Rods and Rocker Arms Install Spark Plugs NOTE: Push rods should always be installed in same 1. Check gap using wire feeler gauge. Adjust gap to position as before disassembly. 0.76 mm (0.030 in.). NOTE: Two diﬀ erent screws have been used to secure 2.
Page 87 Reassembly External Engine Components High Pressure Fuel Debris Screen Guard Debris Screen Air Cleaner Bracket Line Assembly Crankshaft Position Gaseous Propane MAP or TMAP Fuel Quick Connect Sensor (Earlier Fuel Injector Sensor Design Bracket) Oil Cooler O-Ring Oil Cooler Nipple Oil Filter Ignition Coil Barrel Baﬄ...
Page 88 Reassembly Install Intake Manifold Install Crankshaft Position Sensor NOTE: Ensure all parts are clean, undamaged and free Torque Sequence of debris and make sure electrical connectors have seal in place. NOTE: On engines with earlier design bracket, an air gap must be set when installing. Later design brackets require no adjustment.
Page 89 Reassembly Install Breather Cover and Inner Baﬄ es Install Blower Housing and Outer Baﬄ es NOTE: Do not completely tighten screws until all items Torque Sequence are installed to allow shifting for hole alignment. 1&5 1. Slide blower housing into position over front edge of inner baﬄ...
Page 90 Reassembly 2. Torque black rectiﬁ er-regulator screws to 1.4 N·m 1. Verify locating tabs on back of fan are inserted into (12.6 in. lb.). locating holes on ﬂ ywheel. a. Torque silver or green ground strap screw to 2. To assist assembly, ﬁ nd intake manifold studs with 2.8 N·m (25 in.
Page 91 Reassembly Install Throttle Body NOTE: Ensure all parts are clean, undamaged and free Install Electronic Control Unit (ECU) of debris and make sure electrical connector has seal in place. NOTE: Earlier engines have separate IAT and MAP sensors. 1. Install a new throttle body O-ring prior to installation. Make sure all holes align and are open.
Page 92 Reassembly Install Vaporizer/Regulator/Lock-Oﬀ Propane is extremely ﬂ ammable and is heavier than air and WARNING tends to settle in low areas where a spark or ﬂ ame 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.
Page 93 Reassembly Install External Governor Controls Throttle Control Shaft Throttle Control Shaft Throttle Control Lever Washer Throttle Control Spring Control Bracket Governor Spring Bracket (lower) Throttle Linkage Governor Lever Bushing Throttle Linkage Spring Governor Cross Shaft 1. Install governor lever onto governor cross shaft. 2.
Page 94 Reassembly Assemble Top Mount Control Panel Oxygen Sensor Wire Detail 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.
Page 95 Reassembly Governor sensitivity is adjusted by repositioning Install Oil Filter and Fill Crankcase with Oil governor spring in holes of governor lever. If speed NOTE: If testing oil pressure after completing surging occurs with a change in engine load, governor reassembly, install oil pressure adapter instead is set too sensitive.

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Kohler Command PRO EFI PCV680LE Service Manual

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