Kohler Command Pro ECV850 Service Manual Download Page 102

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19 690 01 Rev. --

102

Summary of Contents for Command Pro ECV850

Page 1: ...nt that this engine powers Ensure engine is stopped and level before performing any maintenance or service 19 690 01 Rev 1 2 Safety 3 Maintenance 5 Specifications 16 Tools and Aids 19 Troubleshooting...

Page 2: ...isconnect negative battery cable from battery WARNING Hot Parts can cause severe burns Do not touch engine while operating or just after stopping Never operate engine with heat shields or guards remov...

Page 3: ...leaner Intake Every 150 Hours Check air cleaner element Air Cleaner Intake Replace unique Electronic Fuel Injection EFI fuel filter Check oil cooler fins clean as necessary if equipped Lubrication Sys...

Page 4: ...ing agent NOTE E15 E20 and E85 are NOT approved and should NOT be used effects of old stale or contaminated fuel are not warrantable Fuel must meet these requirements Clean fresh unleaded gasoline Oct...

Page 5: ...ction Point G Flexible 76 2 mm 3 00 in H 59 2 mm 2 33 in I Oil Fill and Dipstick Yellow J Flexible 202 3 mm 7 97 in K Mounting Hole A In Oil Pan L 89 8 mm 3 54 in M Center of Gravity 6 5 mm 0 26 in N...

Page 6: ...gh Pressure Fuel Outlet Hose H Oil Pressure Switch I Oil Temperature Switch J Oil Filter 83 8 mm 3 30 in K 23 3 mm 0 92 in L Mounting Hole A M 13 0 mm 0 51 in N Oil Filter 52 2 mm 2 06 in O Oil Drain...

Page 7: ...93 8 mm 7 63 in I 89 8 mm 3 54 in J Oil Filter Removal 18 0 mm 0 71 in K Mounting Hole A L 138 1 mm 5 44 in M Direction of Rotation N 45 O 35 P Starter Stud 259 7 mm 10 22 in Q 4 X 3 8 16 UNC 2B in 25...

Page 8: ...uffler Bracket Support Mounting Locations Optional I Cylinder 2 Lower Spark Plug Lead Wire Boot J Exhaust Port 2 59 5 mm 2 34 in K Mounting Hole A L Engine Mounting Surface M Exhaust Port 1 82 5 mm 3...

Page 9: ...m 3 39 in Stroke 70 9 mm 2 79 in Displacement 824 cc 50 3 cu in Oil Capacity refill 2 6 L 2 7 U S qt Maximum Angle of Operation full oil level 4 25 Model ECV850 EFI Command Engine Vertical Shaft Numer...

Page 10: ...in lb Crankcase Breather Cover Fastener 11 3 N m 100 in lb Breather Reed Retainer Fastener 11 3 N m 100 in lb Oil Fill Tube Screw 7 7 N m 68 in lb Cylinder Head Fastener torque in 2 increments Head B...

Page 11: ...ing Nut 27 8 N m 246 in lb Bracket Fastener 16 0 N m 142 in lb Oil Cooler Optional Fastener Top M5 Bottom M6 5 6 N m 50 in lb 4 8 N m 50 in lb Oil Pan Fastener 25 6 N m 227 in lb Oil Drain Plug 21 4 N...

Page 12: ...0 0002 0 0006 in Piston Pin End I D 70 F New Max Wear Limit 22 015 22 023 mm 0 8667 0 8670 in 22 036 mm 0 8676 in Crankcase Governor Cross Shaft Bore I D Mechanical Governor New Max Wear Limit 7 949...

Page 13: ...ning Clearance 0 16 0 90 mm 0 0063 0 0354 in Gear Shaft O D New Max Wear Limit 5 990 6 000 mm 0 2358 0 2362 in 5 977 mm 0 2353 in Ignition Spark Plug Gap 0 76 mm 0 030 in Piston Piston Rings and Pisto...

Page 14: ...e Stem to Valve Guide Running Clearance 0 038 0 076 mm 0 0015 0 0030 in Exhaust Valve Stem to Valv e Guide Running Clearance 0 050 0 088 mm 0 0020 0 0035 in Intake Valve Guide I D New Max Wear Limit 7...

Page 15: ...nglish 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 Tig...

Page 16: ...eakdown test on XT 6 engines Kohler 25 761 05 S Design Technology Inc DTI 731 03 Dealer Tool Kit Domestic Complete kit of Kohler required tools Components of 25 761 39 S Ignition System Tester Cylinde...

Page 17: ...available Starter Brush Holding Tool Solenoid Shift SE Tools KLR 82411 SE Tools KLR 82416 Triad OHC Timing Tool Set For holding cam gears and crankshaft in timed position while installing timing belt...

Page 18: ...ng gear teeth Bosses will lock tool and flywheel in position for loosening tightening or removing with a puller A spanner wrench to lift rocker arms or turn crankshaft may be made out of an old junk c...

Page 19: ...to check simple causes which at first 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 list...

Page 20: ...ndications of improper fit and seal Check air cleaner element Look for holes tears cracked or damaged sealing surfaces or other damage that could allow unfiltered air into engine A dirty or clogged el...

Page 21: ...closed 2 Start engine and run no load high speed 3 Open clamp and note water level in tube Level in engine side should be a minimum of 10 2 cm 4 in above level in open side If level in engine side is...

Page 22: ...Install a 3 8 in breaker bar into hole slot of holding tool so it is perpendicular to both holding tool and crankshaft PTO If flywheel end is more accessible use a breaker bar and socket on flywheel...

Page 23: ...d will cause engine damage due to over heating Proper cooling is essential To prevent over heating clean screens cooling fins and other external surfaces of engine Avoid spraying water at wiring harne...

Page 24: ...lliseconds depending on fuel requirements Controlled injection of fuel occurs every other crankshaft revolution or once for each 4 stroke cycle When intake valve opens air fuel mixture is drawn into c...

Page 25: ...meter Little or no resistance should be measured indicating that wiring of that particular circuit is OK Crankshaft position sensor is essential to engine operation constantly monitoring rotation and...

Page 26: ...time valve needle is held open also referred to as injection duration or pulse width Time injector is open milliseconds may vary in duration depending on speed and load requirements of engine A high...

Page 27: ...l but gradually increase to established setting as operation continues Do not attempt to circumvent this warm up period or readjust idle speed during this time Engine must be completely warmed up in c...

Page 28: ...old Absolute Pressure TMAP sensor input 12 Throttle Position Sensor TPS input 13 Speed Sensor Ground 14 Oil Temperature Sensor input 15 Ignition Switch Switched 12V 16 Power for TPS and TMAP Sensors 5...

Page 29: ...ble codes all closed loop learned offsets all max values and all timers besides permanent hour meter This system will NOT reset when battery is disconnected ECU Reset Procedure 1 Turn key ignition OFF...

Page 30: ...el Injector 2 AB Ignition Coil 1 AC Ignition Coil 2 AD Crankshaft Position Sensor AE Oxygen Sensor AF Throttle Position Sensor AG TMAP Sensor AH EFI Oil Temperature Sensor AI Diagnostic Connector AJ G...

Page 31: ...W 10A Fuse X Black Connector Y Grey Connector Z Fuel Injector 1 AA Fuel Injector 2 AB Ignition Coil 1 AC Ignition Coil 2 AD Crankshaft Position Sensor AE Oxygen Sensor AF Throttle Position Sensor AG...

Page 32: ...diagnostic software communicating to ECU and key ON engine not running these values can be observed while throttle is moved from closed to full open position There should be a smooth and repeatable t...

Page 33: ...ndicates a problem with Intake Air Temperature TMAP Sensor Circuit P0112 or P0113 it can be tested as follows 1 Remove TMAP sensor from intake manifold 2 Allow it to reach room temperature 20 C 68 F 3...

Page 34: ...s such meters will cause largest inaccuracies when sensor is in a cool exhaust Visual Inspection 1 Look for a damaged or disconnected sensor to engine harness connection 2 Look for damage to sensor le...

Page 35: ...e type anti seize compound It should be applied according to directions on label Troublshooting Oxygen Sensor O2 Condition Possible Cause Conclusion Low voltage output Shorted sensor or sensor circuit...

Page 36: ...stance of each injector across two terminals Proper resistance is 11 13 If injector resistance is correct check whether connector and injector terminals are making a good connection If resistance is n...

Page 37: ...uld be 0 85 1 15 c Connect ohmmeter leads set on Rx200K scale between both spark plug boot terminals Secondary resistance should be 15000 25000 d If either primary or secondary resistance is not withi...

Page 38: ...placement is required All components are serviced individually Abrasion sleeves on hoses should be reused or replaced when servicing vent hoses Please note vent hose routing and replicate after servic...

Page 39: ...dirty restricted Dirty air cleaner Insufficient fuel pressure or fuel delivery Vacuum intake air leak Improper governor setting adjustment or operation TPS faulty mounting problem or TPS Initializati...

Page 40: ...stem without proper training or safety equipment Fluid puncture injuries are highly toxic and hazardous If an injury occurs seek immediate medical attention Function of fuel system is to provide suffi...

Page 41: ...od idea to write down codes as they appear as they may not be in numerical sequence b Code 61 will always be last code displayed indicating end of code transmission If code 61 appears immediately no o...

Page 42: ...ay be damaged or routed near noisy signal coils alternator etc ECU to harness connection problem Code 0113 Component Intake Air Temperature TMAP Fault Intake Air Temperature Sensor Circuit High Voltag...

Page 43: ...rottle shaft or bearings worn damaged Engine Wiring Harness Related ECU pins Black 10 12 and 16 damaged wiring connectors ECU pins Black 10 12 and 16 routed near noisy electrical signal coils alternat...

Page 44: ...er dirty restricted intake leak throttle bores Base engine problem rings valves Exhaust system leak muffler flange oxygen sensor mounting boss etc Fuel in crankcase oil Code 0172 Component Fuel System...

Page 45: ...nclusion Injector Related Injector coil shorted or opened Engine Wiring Harness Related Broken or shorted wire in harness ECU pin Black 5 Wiring from Ignition ECU Related Circuit controlling injector...

Page 46: ...lt history and starts normally Clear code no other service required Code 0351 Component Ignition Coil Fault Cylinder 1 Ignition Coil Malfunction Condition Broken wire in harness may not be visible sho...

Page 47: ...tion NOTE Either incandescent or LED type bulbs can be used for MIL as long as they do not draw more than 0 1 amps Bulb needs to be rated at 1 4 Watts or less or needs to have a total resistance of 14...

Page 48: ...R TO DIAGNOSTIC AID 3 RUN ON OPERATE AT VARIOUS SPEED LOAD CONDITIONS ARE FAULT CODES PRESENT NO END OF TEST REFER TO DIAGNOSTIC AID 4 CRANKSHAFT POSITION SENSOR REFER TO DIAGNOSTIC AID 5 FUEL PUMP RE...

Page 49: ...When power is removed actuator shaft remains in position DLA must initialize fully extend to move throttle plate to closed position and partially open for starting Correct adjustment of DLA is critica...

Page 50: ...shaft clockwise 3 full turns applying slight pressure until you feel clevis shaft keyway make contact with key in actuator When clevis shaft is installed properly flat of clevis will be aligned with...

Page 51: ...nection or input is most likely at fault Test 1 Probe Location A A Probe Locations for OHMs Test 1 Test 1 Identify probe locations in connector Using a digital multi meter set to lowest scale 0 200 oh...

Page 52: ...ilure Condition Possible Causes Response Response Time LED Diagnostics Yellow LED Green LED Speed Error BLINKS ON Watchdog Interrupt RFI interference Ground to kill close throttle plate BLINKS BLINKS...

Page 53: ...ty ECU Faulty ECU wiring ON ON Missing Pulse RPM Too Low Faulty ECU Faulty ECU wiring OFF ON Sleep Mode Power at GCU with no ECU pulses left in run mode System shutdown 30 minutes OFF OFF Watchdog Int...

Page 54: ...Flat surface clevis should be in alignment with DLA mounting holes 7 Firmly push DLA to bottom 8 Connect clip 9 Connect wire Confirm that 1 Clevis shaft and boot in place 2 Clip attached 3 DLA wire a...

Page 55: ...ed increases if it was at low speed Engine speed does not change Kohler electronic governor system tests OK Test control system of equipment Refer to Equipment Manufacturer s diagnostic procedures for...

Page 56: ...s onto harness making sure of a good connection Resistance should be between 47 7 and 58 3 ohms Refer to page 51 If either test fails DLA is no good and should be replaced If both tests are good DLA i...

Page 57: ...eed decreases As flyweights move outward they cause regulating pin to move outward Regulating pin contacts tab on cross shaft causing shaft to rotate One end of cross shaft protrudes through crankcase...

Page 58: ...as follows 1 Make sure governor linkage is connected to governor lever and throttle lever on throttle body 2 Loosen nut holding governor lever to cross shaft 3 Move governor lever toward throttle body...

Page 59: ...ck Ensure engine is cool Clean oil fill dipstick areas of any debris 1 Remove dipstick wipe oil off 2 Reinsert dipstick into tube press completely down 3 Remove dipstick check oil level Level should b...

Page 60: ...witch to 9 N m 80 in lb Testing Compressed air a pressure regulator pressure gauge and a continuity tester are required to test switch Normally Open Switch 1 Connect continuity tester across blade ter...

Page 61: ...feeler gauge Adjust gap to 0 76 mm 0 03 in 2 Install plug into cylinder head 3 Torque plug to 27 N m 20 ft lb Inspection Inspect each spark plug as it is removed from cylinder head Deposits on tip ar...

Page 62: ...ficient if an application is started only in warmer temperatures Refer to following table for minimum capacities based on anticipated ambient temperatures Actual cold cranking requirement depends on e...

Page 63: ...or take note of terminal markings and install plug s accordingly NOTE Disconnect all electrical connections attached to rectifier regulator Testing may be performed with rectifier regulator mounted or...

Page 64: ...ery terminals on battery to reduce voltage Observe ammeter Condition Conclusion Charge rate increases when load is applied Charging system is OK and battery was fully charged Charge rate does not incr...

Page 65: ...amp Fuse 1 Red Wire w Black Stripe 1 Red Wire w White Stripe 10 amp Fuse 2 Red Wires 10 amp Fuse Fuse Replacement 1 Shut engine off and remove key 2 Locate fuse holders 3 Remove fuse cover and pull ou...

Page 66: ...w recharge or replace battery as necessary Wiring Clean corroded connections and tighten loose connections Replace wires in poor condition and with frayed or broken insulation Starter Switch or Soleno...

Page 67: ...d to starter 3 Unhook plunger pin from drive lever Remove gasket from recess in housing 4 Remove thru larger bolts 5 Remove commutator end plate assembly containing brush holder brushes springs and lo...

Page 68: ...n onto armature shaft with counter bore recess up b Install a new retainer in larger rear groove of armature shaft Squeeze with a pliers to compress it in groove c Slide stop collar up and lock it int...

Page 69: ...all leads from solenoid including positive brush lead attached to lower stud terminal Remove mounting hardware and separate solenoid from starter for testing To test solenoid pull in coil plunger Act...

Page 70: ...evere injury or death Disconnect and ground spark plug lead s before servicing External Engine Components A C M B E D H K K L L C I N F G J O P O Q R A Oil Filter B Dipstick C Oil Drain Plug D High Pr...

Page 71: ...buildings away from sparks or flames Spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition Never use gasoline as a cleaning agent NOTE To prevent damage to hoses use...

Page 72: ...or spring from governor lever Remove Manifold Assembly Remove four manifold screws from cylinder head and carefully lift and remove manifold assembly Assembly includes air cleaner hose elbow throttle...

Page 73: ...ter Motor Fuel Pump Module Components A B C F E D H J M N K I G L O A ECU B Rectifier Regulator C Starter Motor Assembly D Fuel Pump Module E Fuel Pump Module Baffle F Oil Fill Tube G Washer H Spacer...

Page 74: ...ear is damaged Remove Crankshaft Position Sensor Remove crankshaft position sensor with harness attached Remove Fuel Pump Module FPM WARNING Explosive Fuel can cause fires and severe burns Do not fill...

Page 75: ...alley area that includes O2 sensor mounting bracket Remove valley baffle Remove Cylinder Baffles Remove screws and cylinder baffles Remove Crankcase Baffles Remove screws and crankcase baffles Remove...

Page 76: ...D Reed Retainer E 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 ga...

Page 77: ...from each cylinder head Remove Cylinder Heads NOTE Cylinder head number is embossed on outside of each cylinder head 1 Loosen set screws and rocker arm pivots for each rocker arm enough to remove push...

Page 78: ...1 0 mm 0 0393 in 1 0 mm 0 0393 in H Valve Stem Diameter 6 982 7 000 mm 0 2749 0 2756 in 6 970 6 988 mm 0 2744 0 2751 in After cleaning check flatness of cylinder head and corresponding top surface of...

Page 79: ...ld be replaced Recondition valve seat inserts following instructions provided with valve seat cutter being used Final cut should be made with an 89 cutter as specified for valve seat angle Cutting pro...

Page 80: ...pump cover compressing oil pressure relief spring and start screws Secure oil pump by torquing screws in no specific sequence to 11 3 N m 100 in lb into new holes or 7 8 N m 69 in lb into used holes 4...

Page 81: ...ft Oil Seal Details B A A 2 0 mm 0 0787 in B Governor Cross Shaft Seal If governor cross shaft seal is damaged and or leaks replace it using these following procedures Remove oil seal from crankcase a...

Page 82: ...r scuff marks old piston may be reused 3 Remove old rings and clean up grooves Never reuse old rings 4 Before installing new rings on piston place top 2 rings each in turn in its running area in cylin...

Page 83: ...ly check to ensure that fillet blends smoothly with crankpin surface Carefully pull crankshaft from crankcase Note thrust washers and shims if used Inspection and Service Crankshaft Components and Det...

Page 84: ...If they are worn or chipped replacement of crankshaft will be necessary Inspect crankpin for score marks or metallic pickup Slight score marks can be cleaned with crocus cloth soaked in oil If wear l...

Page 85: ...ore hot water and detergent Following scrubbing rinse cylinder with very hot clear water dry it completely and apply a light coating of engine oil to prevent rusting Measuring Piston to Bore Clearance...

Page 86: ...B J L A H J P O C N E F Q R S S A Air Cleaner B Clamp C Air Cleaner Hose D GCU Module E GCU Module Bracket F DLA G Injector H Fuel Rail I Vent Hose J Intake Manifold K TMAP Sensor L Throttle Body M Th...

Page 87: ...When removed pull metal retaining clip connecting fuel injector to fuel injector cap There may be some fuel left in line Any spilled fuel must be cleaned up immediately 3 Reverse procedure to install...

Page 88: ...outside diameter of oil seal 3 Install oil seal into crankcase using a seal driver Make sure oil seal is installed straight and true in bore and tool bottoms against crankcase Install Governor Cross S...

Page 89: ...on output shaft side of engine while intake valve tappets are located on fan side of engine Cylinder number is embossed on outside of each cylinder on crankcase Valve tappets should always be install...

Page 90: ...ly Torque Sequence 1 3 5 7 9 11 2 4 6 8 10 12 1 Make sure sealing surfaces of oil pan and crankcase are clean dry and free of any nicks or burrs 2 Install a new oil pan gasket onto crankcase and two O...

Page 91: ...d Valve Stem Seals These engines use valve stem seals on intake and exhaust valves Always use new seals whenever valves are removed from cylinder head Seals should also be replaced if worn or damaged...

Page 92: ...ts in its socket 3 Apply grease to contact surfaces of rocker arms and rocker arm pivots Install rocker arms rocker arm pivots and set screws Adjust Valve Clearance NOTE It takes two hands to make las...

Page 93: ...shown Breather Assembly Components E B A C D F A Breather Cover B Gasket C Sealant Bead D Filter E Reed Retainer F Reed Install Breather Assembly Torque Sequence 5 4 3 2 1 1 Make sure sealing surfaces...

Page 94: ...baffle 3 Install cylinder barrel baffles Make sure spark plug lead is routed through corresponding opening in each baffle Start each screw Torque M6 screws to 8 2 N m 73 in lb torque M5 screws to 6 3...

Page 95: ...es can lead to broken fragments Broken fragments could be thrown from engine Always observe and use precautions and procedures when installing flywheel NOTE Before installing flywheel make sure cranks...

Page 96: ...r Fuel Pump Components A B C F E D H J M N K I G L O A ECU B Rectifier Regulator C Starter Motor Assembly D Fuel Pump Module E Fuel Pump Module Baffle F Oil Fill Tube G Washer H Spacer I Support Rings...

Page 97: ...n and may be reapplied if fuel pump module is being reused 1 Orient fuel pump module baffle so pulse fitting in crankcase extends through cutout in baffle 2 Install screws to secure fuel pump module b...

Page 98: ...P O Q R A Oil Filter B Dipstick C Oil Drain Plug D High Pressure Fuel Line E Pulse Line F Low Pressure Fuel Line G Fuel Filter H Breather Hose I Throttle Body Bracket J Manifold Assembly K Spark Plug...

Page 99: ...ral times to avoid leakage 1 Connect hoses between oil cooler and oil pan Secure with new clamps 2 Orient new clamps as noted in disassembly 3 Install screws to secure oil cooler to blower housing Tor...

Page 100: ...N m 15 7 ft lb 2 Place new filter 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 filter material 3 Apply a thin film of...

Page 101: ...located on throttle body as necessary Standard idle speed setting for EFI engines is 1500 RPM but certain applications might require a different setting 3 Mechanical Governor Adjust governed idle and...

Page 102: ...KohlerEngines com 19 690 01 Rev 102...

Page 103: ...KohlerEngines com 19 690 01 Rev 103...

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