Kohler Command Pro ECV850 Service Manual
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Kohler Command Pro ECV850 Service Manual

Kohler command pro engines service manual
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ECV850, ECV860, ECV870, ECV880
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.
2
Safety
3
Maintenance
5
Specifi cations
16
19
23
24
Electronic Fuel Injection (EFI) System
49
59
61
66
70
88
Reassembly
19 690 01 Rev. --
KohlerEngines.com
1

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Summary of Contents for Kohler Command Pro ECV850

  • Page 1 ECV850, ECV860, ECV870, ECV880 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 Have a Kohler authorized dealer perform this service. 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). 19 690 01 Rev. --...
  • Page 4 OIL RECOMMENDATIONS STORAGE If engine will be out of service for 2 months or more We recommend use of Kohler oils for best performance. follow procedure below. Other high-quality detergent oils (including synthetic) of API (American Petroleum Institute) service class SJ 1.
  • Page 5 Specifi cations Engine Dimensions-Flywheel Side Air Filter Air Filter 365.7 mm (14.40 in.) Element Removal 88.0 mm (3.46 in.) Cover Removal 235.8 mm (9.29 in.) 130.0 mm (5.12 in.) Cylinder #2 Fuel Line Flexible 59.2 mm (2.33 in.) Clean-Out Cover Connection Point 76.2 mm (3.00 in.) Oil Fill and Dipstick...
  • Page 6 Specifi cations Engine Dimensions-Oil Filter Side Air Cleaner Top Intake Manifold Top Center of Gravity Evap Hose 609.5 mm (24.00 in.) 504.9 mm (19.88 in.) 172.5 mm (6.79 in.) Hose Retention Engine Mounting High Pressure Oil Pressure Switch Clamp Surface Fuel Outlet Hose Oil Temperature Oil Filter...
  • Page 7 Specifi cations Engine Dimensions-Engine Mounting Surface (PTO End) 2 X 20.8 mm 2 X 45° 72.8 mm (2.87 in.) 121.5 mm (4.78 in.) (0.82 in.) 2 X 135.2 mm 298.0 mm 193.8 mm 2 X 20° (5.32 in.) (11.73 in.) (7.63 in.) Oil Filter Removal 89.8 mm (3.54 in.)
  • Page 8 Specifi cations Engine Dimensions-Valve Cover Side Lift Hook 10.0 mm (0.39 in.) 89.8 mm (3.54 in.) 12.0 mm (0.47 in.) Location #1 M8 X 1.25 mm Cylinder #2 Upper Muffl er Bracket Diagnostic Connector 469.0 mm (18.46 in.) Spark Plug Lead Support Wire Boot Mounting Locations...
  • Page 9 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 10 Specifi cations TORQUE SPECIFICATIONS ECV850 ECV860 ECV870 ECV880 Intake Manifold, Air Cleaner, Throttle Body Intake Manifold Mounting Fastener 16.0 N·m (142 in. lb.) Throttle Body to Intake Manifold Mounting Nut 6.8 N·m (60 in. lb.) Throttle Body Mounting Stud (into intake manifold) 6.0 N·m (53 in.
  • Page 11 Specifi cations TORQUE SPECIFICATIONS ECV850 ECV860 ECV870 ECV880 Governor (Electronic) Governor Control Unit (GCU) to GCU Bracket Screw 3.1 N·m (27 in. lb.) GCU/Control Bracket to Manifold Screw 10.2 N·m (90 in. lb.) Digital Linear Actuator (DLA) Bracket to GCU Bracket Nut 10.2 N·m (90 in.
  • Page 12 Specifi cations CLEARANCE SPECIFICATIONS ECV850 ECV860 ECV870 ECV880 Camshaft End Play 0.147/0.495 mm (0.006/0.019 in.) Running Clearance 0.025/0.105 mm (0.0010/0.0025 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 (0.7842/0.7864 in.) Max.
  • Page 13 Specifi cations CLEARANCE SPECIFICATIONS ECV850 ECV860 ECV870 ECV880 Crankshaft Continued T.I.R. PTO End, Crank in Engine 0.279 mm (0.0110 in.) Entire Crank, in V-Blocks 0.025 mm (0.0001 in.) Flywheel End Main Bearing Journal O.D. - New 44.978/45.00 mm (1.770/1.771 in.) O.D.
  • Page 14 Specifi cations CLEARANCE SPECIFICATIONS ECV850 ECV860 ECV870 ECV880 Piston, Piston Rings, and Piston Pin Continued Thrust Face O.D. 85.956/85.974 mm (3.3841/3.3848 in.) Max. Wear Limit 85.82 mm (3.3787 in.) Piston Thrust Face-to-Cylinder Bore Running Clearance 0.026/0.069 mm (0.0010/0.0027 in.) Valves and Valve Lifters Intake and Exhaust Valve Lash 0.050/0.127 mm (0.0020/0.0050 in.) Tappet to Crankcase Running Clearance...
  • Page 15 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 16 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...
  • Page 17 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 18 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 19: Troubleshooting

    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 engine troubles are listed below and vary by engine specifi cation. Use these to locate causing factors.
  • Page 20 Troubleshooting EXTERNAL ENGINE INSPECTION Engine Loses Power NOTE: It is good practice to drain oil at a location away ● Dirty air cleaner element. from workbench. Be sure to allow ample time for ● Engine overheated. complete drainage. ● Excessive engine load. ●...
  • Page 21 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. Avoid inhaling exhaust fumes. Engine exhaust gases contain poisonous carbon Keep hands, feet, hair, and clothing away from all monoxide.
  • Page 22 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 15% between cylinders.

  • Page 23: Air Cleaner/Intake

    Air Cleaner/Intake AIR CLEANER BREATHER TUBE These systems are CARB/EPA certifi ed and components Ensure both ends of breather tube are properly should not be altered or modifi ed in any way. connected. AIR COOLING WARNING Hot Parts can cause severe burns. Do not touch engine while operating or just after stopping.
  • Page 24 During closed loop operation ECU has ability to readjust FUEL LINE temporary and learned adaptive controls, providing Low permeation fuel line must be installed on all Kohler compensation for changes in overall engine condition Co. engines to maintain EPA and CARB regulatory and operating environment, so it will be able to maintain compliance.
  • Page 25 EFI SYSTEM ECU compares input signals to programmed maps in Crankshaft position sensor is essential to engine its memory to determine appropriate fuel and spark operation; constantly monitoring rotation and speed requirements for immediate operating conditions. ECU (RPM) of crankshaft. There are 23 consecutive teeth then sends output signals to set injector duration and cast into fl...
  • Page 26 EFI SYSTEM Manifold Absolute Pressure check provides immediate A high-voltage, solid-state, battery ignition system is manifold pressure information to ECU. TMAP sensor used with EFI system. ECU controls ignition output and measures difference in pressure between outside timing through transistorized control of primary current atmosphere and vacuum level inside intake manifold delivered to coils.
  • Page 27 EFI SYSTEM High pressure fuel line is serviced as a complete IMPORTANT NOTES! assembly to prevent tampering and safety hazards. ● Cleanliness is essential and must be maintained at all Components are not individually serviceable. times when servicing or working on EFI system. Dirt, Vent hose assembly is intended to vent fuel vapor out of even in small quantities, can cause signifi...
  • Page 28 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 GCU Tach Output...
  • Page 29 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 30 EFI SYSTEM KohlerEngines.com 19 690 01 Rev. --...
  • Page 31 EFI SYSTEM 19 690 01 Rev. -- KohlerEngines.com...
  • Page 32 EFI SYSTEM is outside of specifi ed range and output transitions in a Crankshaft Position Sensor smooth manner, reset ECU and run test again. Since A sealed, non-serviceable assembly. If Fault Code there is no longer any wear elements inside sensor, most diagnosis indicates a problem within this area, test and likely faults will be in electrical connections between correct as follows.
  • Page 33 EFI SYSTEM 4. With throttle blade in full open position (WOT), press a. If resistance is out of specifi cations, check local magnet assembly fully on to throttle shaft. Full temperature. Sensor resistance will go down as insertion can be checked by measuring height from temperature is higher.
  • Page 34 EFI SYSTEM digital voltmeter. Simple mechanical meters may place Oxygen Sensor (O a heavy electrical load on sensor and cause inaccurate Components 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.
  • Page 35 EFI SYSTEM Removal Inspection 4. With sensor at room temperature measure heater NOTE: Apply anti-seize compound only to threads. circuit resistance, purple wire (Pin A) and white wire Anti-seize compound will affect sensor (Pin B), resistance should be 8.1-11.1 Ω. performance if it gets into lower shield of 5.
  • Page 36 EFI SYSTEM If an injector is not operating, it can indicate either a bad Fuel Injectors injector, or a wiring/electrical connection problem. Check as follows: WARNING 1. Disconnect electrical connector from both injectors. Explosive Fuel can cause fi res and severe Plug a 12 volt noid light into one connector.
  • Page 37 NOTE: If ignition coil(s) are disabled and an ignition high pressure fuel line. Insert pressure test jumper fault is registered, system will automatically (from Kohler EFI Service Kit) between high pressure disable corresponding fuel injector drive fuel line and FPM.
  • Page 38 Please note vent hose routing and replicate after service or component replacement to prevent pinching or abrasion of vent hoses. Only Kohler replacement parts can be used because fi tting is specifi c to system and must be maintained. Visit KohlerEngines.com for recommended Kohler replacement parts.
  • Page 39 EFI SYSTEM Troubleshooting Guide Condition Possible Cause Faulty spark plugs. Insuffi cient fuel delivery. Engine Stalls or TPS set incorrect. Idles Roughly TPS faulty. (cold or warm). Faulty engine temperature sensor. Faulty injectors. Fuel injector(s), fuel fi lter, fuel line, or fuel pick-up dirty/restricted. Dirty air cleaner.
  • Page 40 EFI SYSTEM Function Test Fault Codes Example of Diagnostic Display WARNING High Pressure Fluids can puncture skin and cause severe injury or death. One second pause Do not work on fuel system without proper Fault training or safety equipment. Code One second pause Fluid puncture injuries are highly toxic and hazardous.
  • Page 41 EFI SYSTEM 0230 Fuel Pump Module Circuit Low Voltage or Open 0232 Fuel Pump Module 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...
  • Page 42 EFI SYSTEM Code 0107 Code 0113 Component: Manifold Absolute Pressure (TMAP) Component: Intake Air Temperature (TMAP) Fault: MAP Circuit Low Voltage or Open Fault: Intake Air Temperature Sensor Circuit High Voltage or Open Condition: Intake manifold leak, open connection or faulty sensor.
  • Page 43 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 44 EFI SYSTEM Code 0171 Code 0172 Component: Fuel System Component: Fuel System Fault: Maximum adaptation limit exceeded Fault: Minimum adaptation limit exceeded Condition: Fuel inlet screen/fi lter plugged, low Condition: Too high pressure at high pressure fuel pressure at high pressure fuel line, TPS line, TPS malfunction, shorted malfunction, shorted connection, faulty connection, faulty sensor or fuel pump...
  • Page 45 EFI SYSTEM Code 0174 Code 0202 Component: Fuel System Component: Fuel Injector Fault: Lean fuel condition Fault: Injector 2 Circuit Malfunction Condition: Fuel inlet screen/fi lter plugged, low Condition: Injector damaged or faulty, shorted or pressure at high pressure fuel line, TPS open connection.
  • Page 46 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: Loose sensor, faulty/bad battery, shorted Condition: Broken wire in harness (may not be or faulty connection, faulty sensor or visible), shorted connection or faulty faulty sensor grounding.
  • Page 47 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 48 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 49: Governor System

    Governor System GOVERNOR These engines are equipped with an electronic governor or a mechanical governor. ELECTRONIC GOVERNOR Components Governor Control Digital Linear DLA Bracket Wiring Harness Unit (GCU) Actuator (DLA) Mounting Nuts Throttle Body Throttle Body Lever Connector Linkage Spring Assembly Adapter Plastic Linkage...
  • Page 50 Governor System 5. Confi rm that key and keyway are in alignment, by Adjustment hand, press clevis shaft into actuator. It will take a DLA Details reasonable amount of pressure to do this. If shaft will not move inward, do not force it. Remove clevis shaft and repeat previous step.
  • Page 51 Governor System Test 2 Probe Location Test 2 Probe Location Probe Location for Voltage Test 2. Probe Locations for OHMs Test 2. Test 2: Identify probe location in connector. Using a Test 2: Identify probe locations in connector. Using a 12 volt meter test for voltage.
  • Page 52 Governor System GCU Blink Code Tests Speed control issues can also be diagnosed utilizing on-board Blink Code diagnostic lights equipped in GCU. These GCUs store blink codes/trouble codes, that can be quickly diagnosed using blink code charts. Green LED Light Yellow LED Light GCU Blink Codes for Software Stored Codes - Activated when key is turned to ON position.
  • Page 53 Governor System GCU Blink Codes for Software Running Codes - Activated when engine is running. Response LED Diagnostics Failure Condition Possible Causes Response Time Yellow LED Green LED Running Normally None BLINKS BLINKS RPM Too High Mechanical bindage None BLINKS RPM Too Low Mechanical bindage None...
  • Page 54 Governor System Electronic Governor Troubleshooting Flow Chart Turn off key switch. Do Not Touch Digital Linear Actuator (DLA) NOTE: DLA is not a solenoid. It is a precision electronic motor. Do not exert force to center clevis shaft! Visually inspect DLA and Linkage. See illustrations on page 49. Confi...
  • Page 55 Engine speed increases Operation Input Voltage: (if it was at low speed). 0-1 Volts at Idle/9+ Volts at High Speed. Kohler electronic governor system tests OK. Test Fail Pass control system of equipment. Refer to Equipment Manufacturer’s diagnostic procedures for control system.
  • Page 56 Governor System Electronic Governor Troubleshooting Flow Chart Continued Turn key switch to ON position. Test supply voltage to GCU using volt meter. Refer to page 50 (battery voltage +/- 1 volt) Note: Prevent Damage to Connector. Do Not Use Oversized Probe Tips. Proceed to DLA Circuit Test.
  • Page 57 Governor System MECHANICAL GOVERNOR Governed speed setting is determined by position of throttle control. It can be variable or constant, depending on engine application. Governor is designed to hold engine speed constant under changing load conditions. Governor gear/fl yweight mechanism is mounted inside oil pan and is driven off gear on camshaft. Components Inside Engine Governor Lever...
  • Page 58 Governor System Governor Adjustments 9.5 mm ± 0.5 (0.37 in. ± 0.02) NOTE: Do not tamper with governor setting. Overspeed is hazardous and could cause personal injury. Initial Adjustment Procedure Make this adjustment whenever governor arm is loosened or removed from cross shaft. Adjust as follows: 1.

  • Page 59: Lubrication System

    Lubrication System This engine uses a full pressure lubrication system which delivers oil under pressure to crankshaft, camshaft, and connecting rod bearing surfaces. A high-effi ciency gerotor oil pump maintains high oil fl ow and oil pressure, even at low speeds and high operating temperatures.
  • Page 60 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 61: Electrical System

    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 carburetor. Do not touch wires while engine is running. Normal and fouled plugs are shown in following photos: Normal Spark Plug Component and Details...
  • Page 62 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 63 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 64 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 65 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 10-amp Fuse 1 Red Wire w/ White Stripe 2 Red Wires...

  • Page 66: Starter System

    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 starter is engaged while fl ywheel is rotating, starter pinion and fl ywheel ring gear may clash and damage starter.
  • Page 67 Starter System SOLENOID SHIFT STARTERS Starter Disassembly When power is applied to starter electric solenoid moves NOTE: Do not reuse old retainer. drive pinion out onto drive shaft and into mesh with NOTE: Do not soak armature or use solvent when fl...
  • Page 68 4 brushes and springs are serviced as a set. Use a new holes in metal clips must be up/out. Slide brush Kohler brush and spring kit if replacement is necessary. holder assembly down into place around 1. Perform steps 1-5 in Starter Disassembly.
  • Page 69 Starter System c. Install brush springs and snap on retainer caps. d. Hold starter assembly vertically on end housing, and carefully place tool (with extension) and assembled 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.
  • Page 70 Disassembly/Inspection and Service WARNING Before working on engine or equipment, disable engine as Accidental Starts can cause severe injury or follows: 1) Disconnect spark plug lead(s). 2) Disconnect death. negative (–) battery cable from battery. Disconnect and ground spark plug lead(s) before servicing.
  • Page 71 Disassembly/Inspection and Service Clean all parts thoroughly as engine is disassembled. 2. Lift locking tab and squeeze to disconnect electrical Only clean parts can be accurately inspected connector from FPM. and gauged for wear or damage. There are many 3. Disconnect pulse line and low pressure fuel line commercially available cleaners that will quickly remove (with fuel fi...
  • Page 72 Disassembly/Inspection and Service Remove Governor Linkages, Spring, and Lever Remove Manifold Assembly (Mechanical Governor) Remove four manifold screws from cylinder head and Mechanical Governor Components carefully lift and remove manifold assembly. Assembly includes air cleaner, hose, elbow, throttle body, intake manifold, fuel pump, fuel rail assembly, injectors, TMAP sensor, ECU, and brackets.
  • Page 73 Disassembly/Inspection and Service Blower Housing/Starter Motor/Fuel Pump Module Components Starter Motor Rectifi er-Regulator Fuel Pump Module Assembly Fuel Pump Oil Fill Tube Washer Spacer Module Baffl e Support Rings Debris Screen Washer Screw Spacer Fixed Guard Blower Housing 19 690 01 Rev. -- KohlerEngines.com...
  • Page 74 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 75 Disassembly/Inspection and Service Remove Baffl es/Wire Harness/Stator Components Valley Baffl e Mounting Bracket O2 Sensor Wire Harness Cylinder #2 Baffl e Stator Cylinder #1 Baffl e Crankcase Baffl e #1 Oil Sentry Pressure Oil Temperature Crankcase Baffl e #2 ™ Switch Sensor Remove Valley Baffl...
  • Page 76 Disassembly/Inspection and Service Remove Breather Assembly Breather Assembly Components Breather Cover Gasket Filter Reed Retainer Reed NOTE: All breather components can be accessed without opening crankcase. 1. Remove fasteners securing breather cover to crankcase. 2. Carefully break gasket seal and remove cover, gasket, and fi...
  • Page 77 Disassembly/Inspection and Service Cylinder Head Components J-Clip Valve Cover Gasket Set Screw Push Rod Rocker Arm Pivot Rocker Arm Rocker Arm Stud Guide Plate Valve Spring Valve Spring Valve Spring Valve Stem Seal Keepers Spark Plug Head Gasket Valve Push Rod Remove Valve Covers 1.
  • Page 78 Disassembly/Inspection and Service 3. Once valve spring is compressed, remove following items: ● Valve spring keepers. ● Valve springs. ● Valve spring caps. ● Intake and exhaust valves (mark position). ● Valve stem seals. 4. Repeat above procedure for other cylinder head. Do not interchange parts from one cylinder head to another. Inspection and Service Valve Details EXHAUST VALVE...
  • Page 79 Disassembly/Inspection and Service Valve Guides Crankcase Components If a valve guide is worn beyond specifi cations, 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.
  • Page 80 Disassembly/Inspection and Service Gasket Oil Pan Governor Gear Assembly (Mechanical Governor) Governor Shaft Press Depth Detail Relief Ball Spring Oil Screen Oil Pump Geroter Gear *Mechanical Governor only. Remove Oil Pan Assembly 1. Remove screws securing oil pan to crankcase. 2.
  • Page 81 Connecting Rods be checked for wear or damage. Whenever tappets are Offset, stepped-cap connecting rods are used in these replaced, apply a liberal coating of Kohler lubricant to engines. base of each new tappet before it is installed. Inspection and Service...
  • Page 82 Disassembly/Inspection and Service When cylinder temperatures get too high, lacquer and Piston and Rings varnish collect on pistons causing rings to stick, which Inspection and Service results in rapid wear. A worn ring usually takes on a Piston and Rings Components and Details shiny or bright appearance.
  • Page 83 Disassembly/Inspection and Service Install New Piston Rings Remove Crankshaft Piston Ring Orientation NOTE: If crankpin is reground, visually check to ensure that fi llet blends smoothly with crankpin surface. Carefully pull crankshaft from crankcase. Note thrust washers and shims if used. Inspection and Service Crankshaft Components and Details 10°...
  • Page 84 23°-33° Crosshatch any grinding deposits that may collect in oil passages. NOTE: Kohler pistons are custom-machined to exacting Use following procedure to remove and replace plug. tolerances. When oversizing a cylinder, it should Remove Crankshaft Plug be machined exactly 0.25 mm (0.010 in.) or...
  • Page 85 Disassembly/Inspection and Service 4. After resizing, check bore for roundness, taper, and Before installing piston into cylinder bore, it is necessary size. Use an inside micrometer, telescoping gauge, that clearance be accurately checked. This step is or bore gauge to take measurements. These often overlooked, and if piston thrust face-to-cylinder measurements should be taken at 3 locations in bore running clearance is not within 0.026/0.069 mm...
  • Page 86 Disassembly/Inspection and Service Intake Manifold and Throttle Body Assembly Components Air Cleaner Clamp Air Cleaner Hose GCU Module* GCU Module DLA* Injector Fuel Rail Bracket* Vent Hose Intake Manifold TMAP Sensor Throttle Body Throttle Body Throttle Body Lever Linkage Spring Throttle Linkage Bracket Adapter...
  • Page 87 Disassembly/Inspection and Service Remove Throttle Body Remove Fuel Pump Assembly 1. Cut Oetiker hose clamps securing air cleaner hose WARNING to throttle body and air cleaner housing. Remove air cleaner hose from throttle body. Explosive Fuel can cause fi res and severe burns.
  • Page 88 Reassembly Crankcase Components Gasket Oil Pan Relief Ball Spring Oil Screen Oil Pump Geroter Gear *Mechanical Governor only. NOTE: Make sure engine is assembled using all specifi ed torque values, torque sequences, and clearances. Failure to observe specifi cations could cause severe engine wear or damage. Always use new gaskets.
  • Page 89 Reassembly Align chamfer of connecting rod with chamfer of its Install Connecting Rods with Pistons and Rings mating end cap. When installed, fl at faces of Piston Details connecting rods should face each other. Faces with raised rib should be toward outside. 6.
  • Page 90 Reassembly Oil Pump Assembly Install Oil Pan Assembly Oil pump is mounted inside oil pan. If service Torque Sequence was required and oil pump was removed, refer to Disassembly/Inspection and Service procedure. Governor Assembly Governor assembly is located inside oil pan. If service was required and governor was removed, refer to Disassembly/Inspection and Service procedure.
  • Page 91 Reassembly Cylinder Head Components J-Clip Valve Cover Gasket Set Screw Push Rod Rocker Arm Pivot Rocker Arm Rocker Arm Stud Guide Plate Valve Spring Valve Spring Valve Spring Valve Stem Seal Keepers Spark Plug Head Gasket Valve Push Rod Valve Stem Seals These engines use valve stem seals on intake and exhaust valves.
  • Page 92 Reassembly Install Cylinder Heads Adjust Valve Clearance NOTE: It takes two hands to make lash adjustment. A Torque Sequence clamping device or an assistant to hold lifter compressed while making adjustment will make process easier. 1. Turn set screw in rocker arm pivots by hand clockwise (down), only enough to capture push rods in recesses.
  • Page 93 Reassembly Install Valve Covers Install Breather Assembly Torque Sequence Torque Sequence 1. Make sure sealing surfaces of crankcase and breather cover are clean and free of any nicks or burrs. Do not scrape surfaces, as this could result in leakage. 1.
  • Page 94 Reassembly Baffl es/Wire Harness/Stator Components Valley Baffl e Mounting Bracket O2 Sensor Wire Harness Cylinder #2 Baffl e Stator Cylinder #1 Baffl e Crankcase Baffl e #1 Oil Pressure Oil Temperature Crankcase Baffl e #2 Switch Sensor Install Stator and Wire Harness Install Valley, Crankcase, and Cylinder Baffl...
  • Page 95 Reassembly Install Oil Sentry Pressure Switch (if equipped) CAUTION ™ 1. Apply pipe sealant with Tefl on (Loctite ® ® ® Damaging Crankshaft and Flywheel can 592™ Thread Sealant or equivalent) to Oil Sentry ™ cause personal injury. threads switch and install it into 1/8 in. port in oil pan.
  • Page 96 Reassembly Blower Housing/Starter Motor/Fuel Pump Components Starter Motor Rectifi er-Regulator Fuel Pump Module Assembly Fuel Pump Oil Fill Tube Washer Spacer Module Baffl e Support Rings Debris Screen Washer Screw Spacer Fixed Guard Blower Housing KohlerEngines.com 19 690 01 Rev. --...
  • Page 97 Reassembly Install Blower Housing 1. To assist assembly, fi nd intake manifold studs with M6 thread at least 100 mm in length to be used as NOTE: ECU pins should be coated with a thin layer of guide pins. Insert intake manifold studs through electrical grease to prevent fretting and cooling fan mounting holes and thread them 4 or 5 corrosion and may need to be reapplied if ECU...
  • Page 98 Reassembly External Engine Components High Pressure Oil Filter Dipstick Oil Drain Plug Fuel Line Low Pressure Pulse Line Fuel Filter Breather Hose Fuel Line Throttle Body Manifold Assembly Spark Plug Lead Manifold Screw Bracket Fuse Holder Oil Cooler J-Clip Clamp Bracket Fuel Pump Fuel Pump...
  • Page 99 Reassembly Install Oil Cooler (if equipped) Install Governor Lever, Governor Springs, and Linkage (Mechanical Governor) NOTE: New hose clamps are recommended for reassembly, or if clamps have been loosened (expanded) several times to avoid leakage. 1. Connect hoses between oil cooler and oil pan. Secure with new clamps.
  • Page 100 Reassembly Initial Adjustment Procedure Install Oil Filter and Add Oil to Crankcase 1. Install oil drain plugs. Torque plug to 21.4 N·m (15.7 ft. lb.). 2. Place new fi lter 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 fi...
  • Page 101 Reassembly Testing Engine It is recommended engine be operated on a test stand or bench prior to installation in equipment. 1. Set engine up on a test stand. Install an oil pressure gauge. Start engine and check to be certain oil pressure (20 psi or more) is present.
  • Page 102 KohlerEngines.com 19 690 01 Rev. --...
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  • Page 104 1P19 690 01 85612 40902 © 2015 by Kohler Co. All rights reserved. KohlerEngines.com 19 690 01 Rev. --...

This manual is also suitable for:

Command pro ecv880Command pro ecv860Command pro ecv870

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