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Kohler Command PRO ECH650 User Manual

Kohler Command PRO ECH650
154 pages
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SERVICE MANUAL
ECH630-ECH749
HORIZONTAL CRANKSHAFT

Questions and Answers:

Kohler Command PRO ECH650 Specifications

General IconGeneral
Fuel TypeGasoline
Cooling SystemAir-cooled
Starting SystemElectric
Compression Ratio8.5:1
Fuel SystemCarburetor
Ignition SystemElectronic
Starter TypeElectric
Governor TypeMechanical
Crankshaft TypeForged Steel
Crankshaft OrientationHorizontal
Engine TypeOHV (Overhead Valve)
Displacement674 cc
Power Output22 hp (16.4 kW)
Oil Capacity2.0 quarts (1.9 liters)
Shaft TypeKeyed
PTO Shaft RotationCounterclockwise

Summary

Safety and General Information

Safety Precautions

General guidelines and warnings for safe engine operation and maintenance.

Engine Identification Numbers

Information on locating and understanding engine model, spec, and serial numbers.

Oil Recommendations

Guidance on selecting the correct type and viscosity of engine oil based on temperature.

Fuel Recommendations

Guidelines for selecting and storing appropriate gasoline and fuel blends for optimal performance.

Periodic Maintenance Instructions

Schedule and guidelines for routine engine maintenance tasks to ensure longevity.

Storage

Procedure for preparing the engine for extended periods of non-use to prevent damage.

General Specifications

Key technical specifications including power, bore, stroke, displacement, and weight.

Camshaft

Inspection and service procedures for the camshaft and related components.

Crankshaft

Inspection and service procedures for the crankshaft, including bearing surfaces and keyways.

Cylinder Bore

Specifications and inspection procedures for the cylinder bore diameter and condition.

General Torque Values

Recommendations for tightening various metric and imperial fasteners based on property class.

Tools & Aids

Tools

List of specialized tools required for engine service, with part numbers and sources.

Aids

List of necessary aids and lubricants for engine maintenance and assembly.

Special Tools You Can Make

Instructions for fabricating specific tools for engine service from common parts.

Troubleshooting

Troubleshooting Guide

A systematic guide to diagnosing and resolving common engine starting and running problems.

Engine Overheats

Identifies causes and solutions for engine overheating issues.

Engine Loses Power

Lists potential reasons and remedies for a significant decrease in engine power output.

External Engine Inspection

Procedure for visually inspecting the engine's external condition before disassembly.

Basic Engine Tests

Outlines essential tests like crankcase vacuum and compression tests for diagnosing engine issues.

Cylinder Leakdown Test

Step-by-step instructions for performing a cylinder leakdown test to assess internal engine component wear.

Air Cleaner and Air Intake System

Heavy-Duty Air Cleaner

Detailed information on the assembly, service, and removal of the heavy-duty air cleaner system.

Low-Profile Air Cleaner (Optional)

Service and removal procedures for the optional low-profile air cleaner.

Air Intake/Cooling System

Guidelines for maintaining proper engine cooling by keeping the air intake and cooling fins clean.

Electronic Fuel Injection (EFI) System

EFI Fuel System Components

Overview of the main components of the EFI system, including sensors and actuators.

Operation

Explanation of how the EFI system manages fuel injection and ignition timing for optimal performance.

Important Service Notes

Critical reminders regarding cleanliness and handling of EFI system components during service.

Electronic Control Unit (ECU)

Details on the ECU's function, diagnostics, and importance of proper connections.

Wiring Harness

Information on the wiring harness, connectors, and the importance of their condition for system performance.

Electrical System

Requirements for system voltage, battery condition, and troubleshooting electrical connection issues.

Crankshaft Position Sensor

Essential sensor for engine operation, monitoring crankshaft speed and position for ignition timing.

Throttle Position Sensor (TPS)

Sensor indicating throttle plate angle to ECU, critical for load and fuel mapping.

ECU Reset and TPS Learn Procedure

Procedure to reset ECU and relearn TPS position after component replacement or adjustment.

Engine (Oil) Temperature Sensor

Sensor used by the system to determine fuel requirements based on engine oil temperature.

Intake Air Temperature Sensor

Sensor that measures intake air temperature to help ECU calculate air density for optimal fueling.

Oxygen Sensor

Sensor that monitors exhaust gas oxygen content to maintain the ideal air/fuel ratio.

Manifold Absolute Pressure (MAP) Sensor

Sensor providing manifold pressure information to the ECU for load detection and fueling calculations.

Fuel Injectors

Details on injector mounting, operation, and troubleshooting common issues like clogging or electrical faults.

Ignition System

Information on the solid-state ignition system, controlled by the ECU for optimal spark timing.

Fuel Pump

Description of electric fuel pump modules and lift pumps used to transfer and regulate fuel pressure.

Fuel Filter

Importance of the 10-micron EFI fuel filter to prevent contamination of the fuel pump module.

High Pressure Fuel Line

Serviceability and requirements for high-pressure fuel lines to prevent leaks and ensure safety.

Throttle Body/Intake Manifold Assembly

Function and serviceability of the throttle body, which regulates airflow and houses sensors.

Idle Speed Adjustment (RPM)

Procedure for adjusting the engine's idle speed to the specified RPM setting.

Initial Governor Adjustment

Critical adjustment for the electronic control system to ensure proper engine response and prevent overspeed.

Troubleshooting Guide

A guide to diagnosing EFI system problems based on symptoms like hard starting, stalling, or missing.

Fault Codes

How to access and interpret diagnostic fault codes displayed via the Malfunction Indicator Light (MIL).

Troubleshooting Flow Chart

An alternative method for troubleshooting EFI system issues using a diagram and diagnostic aids.

Flow Chart Diagnostic Aids

Detailed aids for diagnosing specific EFI system problems identified in the troubleshooting flow chart.

Lubrication System

General

Overview of the engine's full pressure lubrication system and its components.

Service

Procedures for accessing and servicing oil pump components via the closure plate.

Oil Recommendations

Guidance on selecting the correct type and viscosity of engine oil based on temperature.

Check Oil Level

Essential procedure for checking and maintaining the proper oil level in the crankcase before each use.

Changing Oil and Oil Filter

Procedures for changing engine oil and filter at recommended intervals for engine health.

Oil Cooler

Instructions for inspecting and cleaning the oil cooler to maintain optimal operating temperatures.

Oil Sentry™

Information on the optional Oil Sentry™ switch for low oil protection and its installation.

Testing the Switch

Procedures for testing the Oil Sentry™ switch for proper operation under varying pressure conditions.

Electrical System and Components

Spark Plugs

Details on spark plug types, gap settings, service, and inspection for diagnosing engine issues.

Battery and Charging System

Information on battery maintenance, testing, and the regulated charging system.

Electric Starter

Precautions and procedures for the electric starter motor and solenoid.

Solenoid Shift Electric Starters

Operation and testing procedures for the solenoid shift starter system.

Troubleshooting Guide - Staring Difficulties

Guide for diagnosing and resolving issues related to engine starting problems.

Fuses

Identification and replacement procedures for the engine's blade-type automotive fuses.

Starter Disassembly

Step-by-step instructions for disassembling the electric starter motor for inspection or repair.

Inspection

Detailed inspection procedures for starter components like the drive pinion, brushes, armature, and shift fork.

Brush Replacement

Procedure for replacing worn brushes and springs in the starter assembly.

Starter Service

Cleaning and lubrication steps for starter components during service.

Starter Reassembly

Procedures for correctly reassembling the electric starter motor after service.

Solenoid Test Procedure

Diagnostic tests for the starter solenoid's pull-in coil, hold-in coil, and contact continuity.

Disassembly

General

Guidelines for cleaning engine parts thoroughly during disassembly for accurate inspection.

Typical Disassembly Sequence

A suggested order for completely disassembling the engine, which can be adapted for specific needs.

Disconnect Spark Plug Leads

Procedure for safely disconnecting spark plug leads before starting disassembly.

Shut Off Fuel Supply

Essential step to safely turn off the fuel supply before draining or removing fuel components.

Drain Oil from Crankcase and Remove Oil Filter

Procedure for draining engine oil and removing the oil filter as the first step in disassembly.

Remove Oil Cooler

Steps to detach and remove the engine oil cooler assembly.

Remove Muffler

Procedure for removing the exhaust system, including any port liners and the oxygen sensor.

Remove Air Cleaner Assembly

Steps for removing both heavy-duty and low-profile air cleaner assemblies.

Remove Throttle Control Panel

Procedure for disconnecting the throttle control cable and removing the panel.

Remove External Governor Controls

Steps for disconnecting governor controls and linkages for removal.

Remove Lift Fuel Pump and Fuel Pump Module

Procedures for removing pulse style and mechanical style fuel pumps and their modules.

Remove Fuel Pump Module

Steps for detaching the fuel pump module, including cutting clamps and managing fuel lines.

Remove Throttle Body

Instructions for disconnecting sensors and hoses before removing the throttle body.

Remove Electronic Control Unit (ECU)

Steps for removing the ECU by detaching fasteners and electrical connectors.

Remove Electronic Control Unit Bracket and Electric Starter Motor

Procedures for removing the ECU bracket and the electric starter motor.

Remove Grass Screen

Steps for removing both metal and plastic grass screens attached to the fan.

Remove Outer Baffles and Blower Housing

Process for detaching and removing outer baffles and the main blower housing.

Remove Oil Sentry™

Procedure for disconnecting the lead from the optional Oil Sentry™ switch.

Remove Oil Temperature Sensor

Steps for disconnecting the lead and removing the oil temperature sensor.

Remove Inner Baffles and Breather Cover

Procedures for removing inner baffles and the breather cover.

Remove Valve Covers

Steps for removing valve covers, noting differences for reassembly.

Remove Crankshaft Position Sensor

Procedure for removing the crankshaft position sensor and its bracket.

Remove Manifold Absolute Pressure (MAP) Sensor

Steps for disconnecting the electrical connector and removing the MAP sensor.

Remove Fuel Injectors

Procedure for disconnecting electrical connectors, removing screws, and detaching fuel injectors.

Remove Intake Manifold

Steps for removing the intake manifold, including ground terminal and wiring harness.

Remove Cylinder Heads and Hydraulic Lifters

Procedures for removing cylinder head fasteners, heads, gaskets, and hydraulic lifters.

Disassemble Cylinder Heads

Steps for removing rocker arms, pivots, and valves using a valve spring compressor.

Remove Fan and Flywheel

Procedures for removing the fan and flywheel, including proper tool usage to avoid damage.

Remove Stator and Backing Plate

Steps for removing the stator and its backing plate, noting lead routing.

Remove Closure Plate Assembly

Procedures for loosening the closure plate seal and removing fasteners.

Governor Gear Assembly

Information on governor gear inspection and replacement if necessary.

Oil Pump Assembly

Procedures for disassembling the oil pump assembly.

Remove Camshaft

Procedure for removing the camshaft from its bearing surfaces.

Remove Governor Cross Shaft

Steps for removing the governor cross shaft and its associated hardware.

Remove Connecting Rods with Pistons and Rings

Procedure for removing connecting rod end caps, pistons, and connecting rods.

Remove Crankshaft

Steps for carefully removing the crankshaft from the crankcase.

Remove Flywheel End Oil Seal

Procedure for removing the oil seal from the crankcase's flywheel end.

Inspection and Reconditioning

Camshaft

Inspection and service procedures for camshaft lobe wear, gear teeth, and overall condition.

Crankshaft

Inspection of crankshaft gear teeth, bearing surfaces, keyways, and crankpin for wear or damage.

Crankcase

Inspection of gasket surfaces, main bearings, and cylinder bore for wear, scoring, or damage.

Honing

Procedures for honing cylinder bores to achieve proper size, roundness, and crosshatch pattern.

Clean Cylinder Bore After Honing

Critical cleaning steps to remove machining grit from cylinder bores after honing.

Measuring Piston-to-Bore Clearance

Procedure for accurately measuring piston-to-bore clearance to ensure proper engine assembly.

Cylinder Head and Valves

Inspection of cylinder head flatness, valve mechanism parts, and valve seat condition.

Valve Guides

Checking valve guide-to-stem clearance and determining responsibility for excessive clearance.

Valve Seat Inserts

Procedures for reconditioning or replacing valve seat inserts if they are pitted or distorted.

Lapping Valves

Instructions for lapping valves to ensure a proper seal with the valve seat.

Valve Stem Seal

Importance of using new valve stem seals whenever valves are removed or seals are deteriorated.

Pistons and Rings

Inspection of pistons and rings for damage like scuffing, scoring, detonation, or stuck rings.

Install New Piston Rings

Step-by-step guide for correctly installing new piston rings using appropriate tools and procedures.

Connecting Rods

Inspection of connecting rod bearing areas for wear, score marks, and clearances.

Hydraulic Lifters

Inspection of hydraulic lifter bases and procedure for bleeding excess oil before installation.

Closure Plate Assembly

Inspection of oil seal and main bearing surfaces in the closure plate.

Governor Gear Assembly

Inspection of governor gear teeth and weights for wear or damage.

Oil Pump Assembly

Inspection of oil pump housing, gear, and rotors for damage or wear.

Reassembly

General

Guidelines for ensuring proper engine assembly using specified torque values, sequences, and clearances.

Typical Reassembly Sequence

A suggested order for reassembling engine components after disassembly and service.

Install Flywheel End Oil Seal

Procedure for installing the flywheel end oil seal into the crankcase.

Install Crankshaft

Steps for lubricating and installing the crankshaft into the crankcase bearings.

Install Connecting Rods with Pistons and Rings

Procedure for installing piston and connecting rod assemblies into cylinder bores with proper ring staggering.

Install Governor Cross Shaft

Steps for lubricating and installing the governor cross shaft, including setting end play.

Install Camshaft

Procedure for lubricating and installing the camshaft, aligning timing marks.

Thrust Bearing, Washer and Shim

Correct sequence for installing thrust bearing components to control crankshaft end play.

Install Closure Plate Oil Seal

Procedure for installing the closure plate oil seal using sealant and checking for proper depth.

Install Closure Plate Assembly

Steps for applying sealant and installing the closure plate onto the crankcase, aligning components.

Install Stator and Backing Plate

Procedures for installing the stator and backing plate, routing leads, and torquing screws.

Install Flywheel

Critical steps for installing the flywheel, including keyway alignment and proper torque to prevent damage.

Install Flywheel Fan

Procedure for installing the fan onto the flywheel using hex flange screws.

Install Hydraulic Lifters and Cylinder Heads

Instructions for installing hydraulic lifters and cylinder heads, including lubrication and alignment.

Assemble Cylinder Heads

Steps for assembling cylinder heads with valves, springs, retainers, and seals using a spring compressor.

Install Cylinder Heads

Procedures for attaching cylinder heads to the crankcase using correct fasteners and torque sequences.

Install Push Rods and Rocker Arms

Steps for installing push rods and rocker arms, ensuring correct positioning and lubrication.

Install Spark Plugs

Procedure for installing new spark plugs with correct gap and torque specifications.

Install Intake Manifold

Steps for installing the intake manifold with new gaskets, wiring harness, and proper torque sequence.

Install Fuel Injectors

Procedures for installing fuel injectors with new O-rings, retaining clips, and caps.

Install Manifold Absolute Pressure (MAP) Sensor

Steps for installing the MAP sensor with a lubricated O-ring and torquing the retaining screw.

Install Crankshaft Position Sensor

Procedure for installing the crankshaft position sensor and bracket, checking air gap and torque.

Install Valve Covers

Steps for installing valve covers with new O-rings, ensuring clean sealing surfaces and proper torque.

Install Breather Cover and Inner Baffles

Procedures for installing the breather cover, inner baffles, and breather filter.

Install Oil Temperature Sensor

Steps for installing the oil temperature sensor with a lubricated O-ring and proper torque.

Install Oil Sentry™ (If So Equipped)

Procedure for installing the optional Oil Sentry™ switch with sealant and torque.

Install Blower Housing and Outer Baffles

Steps for positioning and securing the blower housing and outer baffles with specified torque.

Reconnect Rectifier-Regulator

Procedure for reinstalling the rectifier-regulator and connecting its plug and ground strap.

Install Grass Screen

Steps for installing metal or plastic grass screens onto the fan using specific hardware.

Install Electric Starter Motor and ECU Bracket

Procedures for installing the electric starter motor and mounting the ECU bracket.

Install Electronic Control Unit (ECU)

Steps for installing the ECU onto its bracket, connecting electrical connectors, and torqueing screws.

Install Throttle Body

Procedure for installing the throttle body assembly, including sensors, linkage, and hoses.

Install Lift Fuel Pump and Fuel Pump Module

Steps for installing the lift fuel pump and fuel pump module, connecting fuel lines and electrical connectors.

Install External Governor Controls

Procedures for installing the governor lever onto the cross shaft and connecting governor springs.

Install Throttle Control Panel

Steps for securing the throttle control panel and connecting linkage components.

Install Air Cleaner Assembly

Procedures for installing heavy-duty and low-profile air cleaner assemblies onto the throttle body.

Setting Initial Governor Adjustment

Procedure for adjusting the governor for proper engine speed control and response.

Install Muffler

Steps for installing the muffler, exhaust gaskets, and oxygen sensor with correct torque.

Install Oil Cooler

Procedure for installing the oil cooler adapter and the cooler assembly with proper torque.

Install Oil Filter and Fill Crankcase with Oil

Steps for prefilling and installing the oil filter, filling the crankcase with the correct oil, and torquing drain plugs.

Prepare the Engine for Operation

Final checks and adjustments before starting the engine after reassembly, including fluid levels and idle speed.

Sensitivity Adjustment

How to adjust governor sensitivity by repositioning the governor spring for optimal engine load response.

Connect Spark Plug Leads

Procedure for connecting the ignition leads to the spark plugs.

Testing the Engine

Recommended procedures for testing the engine on a stand after reassembly, checking for leaks, oil pressure, and speeds.

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