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Reassembly

19 690 01 Rev. --

KohlerEngines.com

Install Valve Covers
Torque Sequence

1. Make sure sealing surfaces are clean and free of

any nicks or burrs.

2. Install valve covers on same side as they were

originally installed using new gaskets.

A J-Clip is mounted on screw closest to intake port.

3. Check position of each cover and gasket, then

torque screws to 10.9 N·m (96 in. lb.) using

sequence shown.

Breather Assembly Components

Breather Cover

Gasket

Sealant Bead

Filter

Reed Retainer

Reed

Install Breather Assembly
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.

2. Install reed and reed retainer. Torque screw to 11.3

N·m (100 in. lb.).

3. Install

lter. Make sure

lter does not extend above

top surface.

4. Install breather gasket with sealant bead up

(towards cover).

5. Install cover and screws. Torque to 11.3 N·m

(100 in. lb.) following sequence.

Содержание Command Pro ECV850

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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