Kohler Command PRO EFI PCV680 Service Manual Download Page 5

Page: 5 / 96

Speciﬁ cations

24 690 31 Rev. D

KohlerEngines.com

Dimensions in millimeters.

Inch equivalents shown in [ ].

412.98

[16.259]

296.38

[11.668]

269.48

[10.609]

96.02

[3.780]

135.00

[5.315]

AIR FILTER RAIN CAP

REMOVAL

130.00

[5.118]

AIR FILTER

COVER ASSEMBLY

REMOVAL

73.06

[2.877]

SPARK PLUG REMOVAL

52.36 [2.061]

SPARK PLUG

BOOT REMOVAL

22.84 [0.899]

SPARK PLUG BOOT

246.07

[9.688]

SPARK

PLUG

BOOT

REMOVAL

253.53

[9.982]

SPARK

PLUG

REMOVAL

417.98 [16.456]

SAFETY AIR FILTER

ELEMENT REMOVAL

530.30 [20.878]

PRIMARY AIR FILTER

ELEMENT REMOVAL

OIL FILL & DIPSTICK

MOUNTING

HOLE “A”

ENGINE

495.66

[19.514]

ENGINE

152.99

[6.023]

45.35

[1.786]

137.09

[5.397]

15.70

[0.618]

OIL FILTER

REMOVAL

81.86

[3.223]

73.23 [2.883]

SPARK PLUG REMOVAL

52.45

[2.065]

SPARK PLUG

BOOT REMOVAL

27.43

[1.080]

SPARK PLUG

BOOT

246.28

[9.696]

SPARK

PLUG

BOOT

REMOVAL

253.53

[9.982]

SPARK

PLUG

REMOVAL

20˚

FLYWHEEL SIDE

154.08

[6.066]

92.08

[3.625]

EXHAUST

PORT #1

72.08

[2.838]

EXHAUST

PORT #2

STARTER SIDE

367.38

[14.464]

13.38

[0.527]

40.80

[1.606]

ENGINE MOUNTING

SURFACE

OIL DRAIN PLUG

3/8 N.P.T INCH

405.85

[15.978]

247.85

[9.758]

445.32

[17.532]

OIL COOLER

REGULATOR RECTIFIER

REGULATOR ASSEMBLY

143.17

[5.636]

134.45

[5.293]

50.78

[1.999]

13.72

[0.540]

11.81

[0.465]

26.80

[1.055]

86.30

[3.398]

24.895 ± 0.10 [0.980 ± 0.0039]

Ø 28.56 ± 0.01 [1.125 ± 0.005]

OXYGEN

SENSOR

SPARK

PLUG

ENGINE MOUNTING

SURFACE

OIL FILTER SIDE

7/16-20 UNF 2B IN

97.2

[3.827]

38.1 +0.00 -3.81

[1.500 +0.00 -0.150]

ENGINE MOUNTING SURFACE

PTO END

334.4

[13.164]

94.26

[3.711]

15˚

MOUNTING

HOLE “D”

152.25

[5.994]

104.03

[4.096]

89.80

[3.536]

MOUNTING

HOLE “A”

MOUNTING

HOLE “B”

MOUNTING

HOLE “C”

242.22

[9.536]

48.39

[1.905]

[1.969]

EXHAUST

PORT #2

SOLENOID

SHIFT STARTER

45˚ ± 0.135˚

35˚ ± 0.135˚

72.84 ± 0.30

[2.868 ± 0.118]

15˚

4X Ø 8.64.7.54 [0.340/0.297 THRU

Ø 254.00 ± 0.3 [10.000] B.C.

2X 89.80

[3.536]

[1.969]

EXHAUST

PORT #2

Engine Dimensions

Summary of Contents for Command PRO EFI PCV680

Page 1: ...ic Fuel Injection EFI System 51 Lubrication System 53 Electrical System 58 Starter System 62 Disassembly Inspection and Service 79 Reassembly IMPORTANT Read all safety precautions and instructions car...

Page 2: ...creen failure and serious personal injury WARNING Carbon Monoxide can cause severe nausea fainting or death Avoid inhaling exhaust fumes Never run engine indoors or in enclosed spaces Engine exhaust g...

Page 3: ...r Intake Inspect heavy duty air lter paper element and inlet screen area Air Cleaner Intake Every 200 Hours Change oil lter Lubrication System Replace unique EFI fuel lters Every 300 Hours Replace hea...

Page 4: ...ure personal safety installation and repair of propane fuel supply systems must be performed only by quali ed propane system technicians Improperly installed and maintained propane equipment could cau...

Page 5: ...253 53 9 982 SPARK PLUG REMOVAL 20 20 FLYWHEEL SIDE 154 08 6 066 92 08 3 625 EXHAUST PORT 1 72 08 2 838 EXHAUST PORT 2 STARTER SIDE 367 38 14 464 13 38 0 527 40 80 1 606 ENGINE MOUNTING SURFACE OIL D...

Page 6: ...red aluminum hole or weld nut M5 M6 Into extruded hole in sheet metal M5 M6 6 2 N m 55 in lb into new holes 4 0 N m 35 in lb into used holes 10 7 N m 95 in lb into new holes 7 3 N m 65 in lb into used...

Page 7: ...unting Screws 2 9 N m 26 in lb Fuel Inlet Fitting 20 N m 177 in lb Governor Lever Nut 7 1 N m 63 in lb Ignition Spark Plug 27 N m 20 ft lb Coil Fastener 10 2 N m 90 in lb Electronic Control Unit Screw...

Page 8: ...r Nipple 28 5 N m 21 ft lb Fastener Into Blower Housing Between Oil Cooler Hoses 2 8 N m 25 in lb 2 3 N m 20 in lb Oil Pan Fastener 25 6 N m 227 in lb Speed Control Bracket Fastener assembled to cylin...

Page 9: ...it 17 015 17 023 mm 0 6699 0 6702 in 17 036 mm 0 6707 in Crankcase Governor Cross Shaft Bore I D New Max Wear Limit 8 025 8 075 mm 0 3159 0 3179 in 8 088 mm 0 3184 in Crankshaft End Play free 0 025 0...

Page 10: ...680 3 2689 in O D Max Wear Limit 83 081 mm 3 2709 in Max Out of Round Limit 0 120 mm 0 0047 in Max Taper 0 05 mm 0 0020 in Cylinder Head Max Out of Flatness 0 01 mm 0 004 in Governor Governor Cross Sh...

Page 11: ...m 0 0808 in Thrust Face O D 7 82 978 mm 3 2668 in Max Wear Limit 82 833 mm 3 2611 in Piston Thrust Face to Cylinder Bore7 Running Clearance New 0 019 0 062 mm 0 0007 0 0024 in Valves and Valve Lifters...

Page 12: ...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 Ti...

Page 13: ...ts of 25 761 39 S Ignition System Tester Cylinder Leakdown Tester Oil Pressure Test Kit Recti er Regulator Tester 120 V AC 60Hz Kohler 25 761 39 S Kohler 25 455 01 S Kohler 25 761 05 S Kohler 25 761 0...

Page 14: ...id Shift SE Tools KLR 82411 SE Tools KLR 82416 Stepper Motor Controller Tool For testing operation of stepper motor Digital Linear Actuator DLA Kohler 25 455 21 S Jumper Lead Tool For use with Stepper...

Page 15: ...ng gear teeth Bosses will lock tool and ywheel 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 con...

Page 16: ...to check simple causes which at 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...

Page 17: ...or indications of improper t and seal Check air cleaner element Look for holes tears cracked or damaged sealing surfaces or other damage that could allow un ltered air into engine A dirty or clogged...

Page 18: ...Make sure pinch clamp is 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 I...

Page 19: ...nstall a 3 8 in breaker bar into hole slot of holding tool so it is perpendicular to both holding tool and crankshaft PTO If ywheel end is more accessible use a breaker bar and socket on ywheel nut sc...

Page 20: ...around element Remove wing nut element cover and paper element with precleaner 2 Separate precleaner from element service precleaner and replace paper element 3 Check condition of rubber seal and repl...

Page 21: ...lator which reduces pressure to 24 26 psi typical Fuel then passes through a ne high pressure lter is delivered from vaporizer regulator through high pressure fuel line into injectors which inject fue...

Page 22: ...s may clean up contacts enough to restore operation at least temporarily If a fault code indicates a problem with an electrical component disconnect ECU connector and test for continuity between compo...

Page 23: ...hem at top end Replaceable O rings on both ends of injector prevent external fuel leakage and also insulate it from heat and vibration A special clip connects each injector to high pressure fuel line...

Page 24: ...rking on EFI system Dirt even in small quantities can cause signi cant problems Clean any joint or tting with parts cleaning solvent before opening to prevent dirt from entering system Always depressu...

Page 25: ...r O2 and Oil sensors 11 MAP sensor or 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 se...

Page 26: ...ble codes all closed loop learned o sets 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 27: ...ator O Recti er Regulator P 30A Fuse Q Battery R Vaporizer Regulator Lock O S 6 Terminal Connector T Starter Motor U Oil Pressure Switch V MIL W 10A Fuse X Black Connector Y Grey Connector Z Fuel Inje...

Page 28: ...temperature sensor A Red B Red Black C Red White D Yellow E Light Green F Dark Green G Dark Blue H Purple I Pink J Tan K White L Grey M Black N Stator O Recti er Regulator P 30A Fuse Q Battery R Vapor...

Page 29: ...r O Recti er Regulator P 30A Fuse Q Battery R Vaporizer Regulator Lock O S 6 Terminal Connector T Starter Motor U Oil Pressure Switch V MIL Optional W 10A Fuse X Black Connector Y Grey Connector Z Fue...

Page 30: ...AD AC AB AA V D A Red B Red Black C Red White D Yellow E Light Green F Dark Green G Dark Blue H Purple I Pink J Tan K White L Grey M Black N Stator O Recti er Regulator P 30A Fuse Q Battery R Vaporiz...

Page 31: ...esting information based on sensor type Contacting Brush Type TPS Resistance Table Throttle Position Between Terminal Resistance Value Continuity Closed A C 1400 1800 Yes Full with Stop Pin A C 3200 4...

Page 32: ...h motion can be applied to connectors or wires just outside connectors to detect a faulty connection If only a volt meter is available Measure voltage supply to sensor from ECU This voltage should be...

Page 33: ...ead to terminal 1 in sensor plug Continuity should be indicated Repeat test between Black pin 10 and terminal 2 in sensor plug Manifold Absolute Pressure Sensor MAP A sealed non serviceable assembly A...

Page 34: ...D E F G A Protection Shield B Planar Element and Heater C Lower Insulator D Stainless Steel Housing E Upper Insulator F Terminal Connection to Element G High Temp Water Seal Temperature must be contro...

Page 35: ...made if problem is with engine or sensor 3 Check engine harness for battery voltage on heater circuit Removal Inspection NOTE Apply anti seize compound only to threads Anti seize compound will a ect...

Page 36: ...lica poisoning Replace sensor Contaminated fuel Use high quality fuel Engine problem mis re Correct cause of mis re Excessive rich air fuel ratio Check for high fuel pressure Leaking injector Wiring s...

Page 37: ...ake sure all safety switch requirements are met Crank engine and check for ashing of test light Turn key OFF for at least 10 seconds between tests to allow ECU to go to sleep and reawake Repeat test a...

Page 38: ...a coil is determined to be faulty replacement is necessary An ohmmeter may be used to test wiring and coil windings NOTE Do not ground primary coil with ignition ON as they may overheat or spark NOTE...

Page 39: ...to allow fuel to escape from line Insert pressure test jumper from Kohler EFI Service Kit between high pressure fuel line and fuel lock o 2 Turn on key switch to activate lock o and check system pres...

Page 40: ...icate that it needs replacement Thoroughly clean area around all joints and relieve any pressure before starting any disassembly Detach by removing two mounting screws wire ties and injector retaining...

Page 41: ...faulty Faulty engine temperature sensor Faulty injectors Engine Misses Hesitates or Stalls Under Load Fuel injector s fuel lter or fuel line Dirty air cleaner Insu cient fuel pressure or fuel deliver...

Page 42: ...gh Voltage or Open 0117 Coolant Oil Temperature Sensor Circuit Low Voltage 0118 Coolant Oil Temperature Sensor Circuit High Voltage or Open 0122 Throttle Position Sensor Circuit Low Voltage or Open 01...

Page 43: ...stic Code Summary is a list of individual codes with an explanation of what triggers them what symptoms might be expected and probable causes A MIL may not be provided with engine If equipment manufac...

Page 44: ...TMAP Sensor Circuit High Voltage or Open Condition Shorted connection faulty sensor broken wire or connection Conclusion Temperature IAT or TMAP Sensor Related Sensor wiring or connection Engine Wirin...

Page 45: ...d Throttle 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 alte...

Page 46: ...sure too low fuel lock o or regulator Combustion air air cleaner dirty restricted intake leak throttle bores Base engine problem rings valves Exhaust system leak mu er ange oxygen sensor mounting boss...

Page 47: ...ion Conclusion 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 inj...

Page 48: ...If code is stored in fault 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 harnes...

Page 49: ...needs to be rated at 1 4 Watts or less or needs to have a total resistance of 140 or more LEDs typically draw less than 0 03 amps All current fault codes will turn on MIL when engine is running Diagn...

Page 50: ...IAGNOSTIC FAULT CODE SUMMARY CLEAR CODES NO REFER 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 POSITI...

Page 51: ...e is cool Clean oil ll dipstick areas of any debris 1 Remove dipstick wipe oil o 2 Reinsert dipstick into tube rest cap on tube do not thread cap onto tube 3 Remove dipstick check oil level Level shou...

Page 52: ...ion Oil Sentry pressure switch is installed in breather cover On engines not equipped with Oil Sentry installation hole is sealed with a 1 8 27 N P T F pipe plug Installation 1 Apply pipe sealant with...

Page 53: ...feeler gauge Adjust gap to 0 76 mm 0 030 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 a...

Page 54: ...nt 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 engine...

Page 55: ...ator take note of terminal markings and install plug s accordingly NOTE Disconnect all electrical connections attached to recti er regulator Testing may be performed with recti er regulator mounted or...

Page 56: ...th engine o and key switch in OFF position measure voltage at battery If less than 12 4 VDC recharge battery and retest If 12 5 VDC continue with tests b Run engine at high speed no load greater than...

Page 57: ...0 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 o and remove key 2 Locate fuse holders 3 Remove fuse cover and pull ou...

Page 58: ...le Cause Conclusion Starter does not energize Battery Check speci c gravity of battery If low recharge or replace battery as necessary Wiring Clean corroded connections and tighten loose connections R...

Page 59: ...2 Remove screws securing solenoid to starter 3 Remove retaining ring from armature shaft using either a retaining ring pliers or snap ring removal tool as described in Steps 4 and 5 Do not reuse old...

Page 60: ...ure shaft splines Install drive pinion onto armature shaft 2 Install and assemble stop collar retainer assembly a Install stop collar down onto armature shaft with counter bore recess up b Install a n...

Page 61: ...to solenoid for any time over what is necessary for performing each of individual tests Internal damage to solenoid may occur Disconnect all leads from solenoid including positive brush lead attached...

Page 62: ...present Accidental Starts can cause severe injury or death Disconnect and ground spark plug lead s before servicing External Engine Components A B C I Z U O M V J K L F G W N O H T X R S Q N Y P D E A...

Page 63: ...oot only to prevent damage to spark plug lead Disconnect leads from spark plugs Drain Oil from Crankcase and Remove Oil Filter NOTE Some models are equipped with an oil drain valve 1 Remove oil ll cap...

Page 64: ...Remove throttle linkage bushing and throttle linkage from governor lever Note mark hole location for reassembly 3 Loosen nut and remove governor lever from cross shaft External Governor Controls A N C...

Page 65: ...l Filter F Bracket G Outlet Fitting H Oetiker Clamp 1 Disconnect electrical plug from lock o 2 Disconnect vacuum line from front of vaporizer regulator 3 Loosen nut on center back of vaporizer regulat...

Page 66: ...ipped NOTE This is optional Removing Oil Sentry is not required to remove breather cover 1 Disconnect lead from Oil Sentry switch 2 Remove Oil Sentry switch from breather cover Remove Oil Temperature...

Page 67: ...cover Note valve cover di erences for proper location in reassembly Ensure any brackets removed are reassembled in same location 2 Covers should lift o without prying Remove Intake Manifold 1 Remove s...

Page 68: ...rod until it contacts plunger in lifter Slowly pump plunger 2 or 3 times to force oil out of feed hole in side of lifter Bleeding Lifters Style B Smooth To prevent a possible bent push rod or broken...

Page 69: ...s See valve details and speci cations Hard starting or loss of power accompanied by high fuel consumption may be symptoms of faulty valves Although these symptoms could also be attributed to worn ring...

Page 70: ...al cut should be made with an 89 cutter as speci ed for valve seat angle Cutting proper 45 valve face angle as speci ed and proper valve seat angle 44 5 half of full 89 angle will achieve desired 0 5...

Page 71: ...e screw and washer 4 Use a puller to remove ywheel from crankshaft 5 Remove woodru key Inspection Inspect ywheel for cracks and ywheel keyway for damage Replace ywheel if it is cracked Replace ywheel...

Page 72: ...o Speci cations Replace oil pan assembly if required Governor Gear Assembly Governor Shaft Press Depth Details C B A A Gear Shaft B 19 40 mm 0 7638 in C 34 0 mm 1 3386 in 33 5 mm 1 3189 in Governor ge...

Page 73: ...recommended value c Torque fastener in location 1 to recommended value First Time Installation 10 7 N m 95 in lb All Reinstallations 6 7 N m 60 in lb 4 After torquing rotate gear and check for freedo...

Page 74: ...on crankcase Use numbers to mark each end cap connecting rod and piston for reassembly Do not mix end caps and connecting rods 1 Remove screws securing closest connecting rod end cap Remove end cap 2...

Page 75: ...w piston rings when installing pistons Never use old rings Some important points to remember when servicing piston rings 1 Cylinder bore must be deglazed before service ring sets are used 2 If cylinde...

Page 76: ...easily and noiselessly and there is no evidence of scoring grooving etc on races or bearing surfaces bearings can be reused Inspect crankshaft keyways If they are worn or chipped replacement of cranks...

Page 77: ...er installing coarse stones in hone proceed as follows 1 Lower hone into bore and after centering adjust so stones are in contact with cylinder wall Use of a commercial cutting cooling agent is recomm...

Page 78: ...will usually result Use these following procedures to accurately measure piston to bore clearance 1 Use a micrometer and measure diameter of piston 6 mm 0 24 in above bottom of piston skirt and perpe...

Page 79: ...l Flywheel End Oil Seal Oil Seal Detail B A A 4 5 mm 0 177 in B Oil Seal 1 Make sure that seal bore of crankcase is clean and free of any nicks or burrs 2 Apply a light coat of engine oil to outside d...

Page 80: ...connecting rod and piston assembly Install Governor Cross Shaft 1 Lubricate governor cross shaft bearing surfaces in crankcase with engine oil 2 Slide small lower washer onto governor cross shaft and...

Page 81: ...227 in lb One mounting screw has a thread sealant patch This screw is typically installed in number 10 hole shown Reapply pipe sealant with Te on Loctite 592 PST Thread Sealant or equivalent to number...

Page 82: ...alled properly in keyway Flywheel can become cracked or damaged if key is not properly installed 1 Install woodru key into keyway of crankshaft Make sure that key is properly seated and parallel with...

Page 83: ...uds closest to lifters must have an exposed height of 75 mm 2 15 16 in Studs furthest from lifters must have an exposed height of 69 mm 2 3 4 in c Remove nuts and repeat procedure as required 4 Check...

Page 84: ...opane Fuel Injector G MAP or TMAP Sensor H Crankshaft Position Sensor Earlier Design Bracket I Oil Cooler O Ring J Oil Cooler K Nipple L Oil Filter M Ignition Coil N Barrel Ba e O Valley Ba e P Breath...

Page 85: ...or other fuel injector Install Manifold Absolute Pressure MAP Sensor or Temperature Manifold Absolute Pressure TMAP Sensor NOTE Ensure all parts are clean undamaged and free of debris and make sure el...

Page 86: ...screws 20 mm long into intake port side of cylinder heads including any lifting strap Install M6 screws 16 mm long into exhaust port side of cylinder head Install short M5 screws 10 mm long in upper...

Page 87: ...oles and thread them 4 or 5 turns into ywheel 3 Install a spring washer on each stud with concave side down toward cooling fan 4 Install a spacer on each stud with stepped end down Smaller diameter sh...

Page 88: ...AP sensors 1 Install a new throttle body O ring prior to installation Make sure all holes align and are open 2 Install throttle body throttle position sensor intake air temperature IAT sensor earlier...

Page 89: ...Inlet Fitting D Lock O Assembly E Propane Fuel Filter F Bracket G Outlet Fitting H Oetiker Clamp I Straight Fitting 1 Connect fuel line quick connect on high pressure fuel line assembly to straight t...

Page 90: ...Lever D Washer E Spring F Control Bracket G Throttle Control Bracket lower H Governor Spring I Governor Lever J Throttle Linkage Spring K Bushing L Throttle Linkage M Nut N Governor Cross Shaft 1 Ins...

Page 91: ...xygen sensor torque to 50 1 N m 37 ft lb and connect to wire harness 2 Install remaining mu er support hardware screws and nuts and torque to 9 9 N m 88 in lb 3 Install nuts to exhaust studs Torque nu...

Page 92: ...point 2 To decrease sensitivity move spring away from governor lever pivot point Testing Engine It is recommended engine be operated on a stand or bench prior to installation in piece of equipment 1...

Page 93: ...93 24 690 31 Rev D KohlerEngines com...

Page 94: ...94 KohlerEngines com 24 690 31 Rev D...

Page 95: ...95 24 690 31 Rev D KohlerEngines com...

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