Table of Contents
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Chapters
Table of Contents
Troubleshooting
Related Manuals for Kohler Command PRO ECV650
Summarization of Contents
Section 1 Safety and General Information
Safety Precautions
Essential warnings and precautions for safe operation and maintenance.
Engine Identification Numbers
Information on locating and understanding engine model, spec, and serial numbers.
Oil Recommendations
Guidance on selecting the correct oil type and viscosity for the engine.
Maintenance Schedule
Key maintenance tasks and their recommended frequencies for engine upkeep.
Section 2 Tools & Aids
Tools
Lists specialized tools and their sources for engine service and repair.
Aids
Lists consumable items and lubricants required for engine maintenance.
Special Tools You Can Make
Instructions for fabricating specific tools for engine service.
Section 3 Troubleshooting
Troubleshooting Guide
A systematic approach to diagnosing common engine problems and their causes.
Engine Starts Hard
Identifies potential causes and solutions for engines that start with difficulty.
Cylinder Leakdown Test
Procedure to diagnose internal engine leaks in the cylinder.
Section 4 Air Cleaner and Air Intake System
Heavy-Duty Air Cleaner
Maintenance and service procedures for the heavy-duty air cleaner.
Low-Profile Air Cleaner (Optional)
Maintenance and service procedures for the optional low-profile air cleaner.
Air Intake/Cooling System
Ensuring proper engine cooling by maintaining clean fins and shrouds.
Section 5 Electronic Fuel Injection (EFI) System
EFI System Overview
Details on system components, operation, recommendations, and service notes.
Electrical Components
Covers ECU, sensors, wiring harness, and ignition system details.
Fuel Components
Details on fuel pump, filter, injectors, and related assemblies.
EFI Troubleshooting
Guidance on diagnosing issues using fault codes, flow charts, and diagnostic aids.
Section 6 Lubrication System
Oil Recommendations
Guidance on selecting the correct oil type and viscosity for the engine.
Check Oil Level
Basic but critical maintenance procedure for checking engine oil level.
Changing Oil and Oil Filter
Procedures for performing routine oil and filter changes.
Section 7 Electrical System and Components
Spark Plugs
Information on spark plug types, gap, service, and inspection.
Battery and Charging System
Covers battery recommendations, maintenance, testing, and charging system operation.
Electric Starting Motors
Details on starter operation, precautions, disassembly, and solenoid testing.
Section 8 Disassembly
Typical Disassembly Sequence
A step-by-step guide for completely disassembling the engine.
Disconnect Spark Plug Leads
Critical safety step to disable the engine before servicing.
Remove Cylinder Heads and Hydraulic Lifters
Procedures for removing cylinder heads and associated valve train components.
Remove Oil Pan Assembly
Steps to remove the oil pan for access to internal components.
Section 9 Inspection and Reconditioning
Crankshaft
Procedures for inspecting crankshaft journals, teeth, and keyways for wear.
Crankcase
Inspection of cylinder bores for scoring, wear, and proper cleaning after honing.
Pistons and Rings
Inspection of pistons and rings for damage, wear, and proper installation.
Hydraulic Lifters
Inspection and "bleeding" procedures for hydraulic lifters.
Section 10 Reassembly
Typical Reassembly Sequence
A step-by-step guide for reassembling the engine after service.
Install Crankshaft
Procedures for lubricating and installing the crankshaft and bearings.
Install Connecting Rods with Pistons and Rings
Instructions for installing piston and connecting rod assemblies correctly.
Install Cylinder Heads
Procedures for installing cylinder heads, including gasket and torque sequence.
Sensitivity Adjustment
Adjusting governor spring for optimal engine speed control.
Testing the Engine
Procedures for testing the engine after reassembly.
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