Kohler Command PRO ECV630 - User Manual

SERVICE MANUAL
ECV630-ECV749
VERTICAL CRANKSHAFT

Kohler Command PRO ECV630 Specifications

General

Brand	Kohler
Model	Command PRO ECV630
Category	Crankshaft
Language	English

Summary

Section 1 Safety and General Information

Safety Precautions

General safety advice to ensure safe operation.

Accidental Starts!

Warning about accidental starting and how to disable the engine.

Rotating Parts!

Warning about rotating parts and preventing injury.

Hot Parts!

Warning about hot engine components and avoiding burns.

Explosive Fuel!

Warning about gasoline flammability and explosion hazards.

Lethal Exhaust Gases!

Warning about carbon monoxide from exhaust gases.

Electrical Shock!

Warning about electrical shock hazards.

Flammable Solvents!

Warning about flammable cleaning solvents.

High Pressure Fluid Puncture!

Warning about high-pressure fluid injection injuries.

Oil Recommendations

Fuel Recommendations

Periodic Maintenance Instructions

Maintenance Schedule

General Torque Values

English Fastener Torque Recommendations for Standard Applications

Section 2 Tools & Aids

Tools

List of specific tools and their part numbers/sources.

Tools (Continued)

Continuation of the list of specific tools and their part numbers/sources.

Section 3 Troubleshooting

Troubleshooting Guide

Lists common engine problems and their potential causes.

Engine Overheats

Engine Knocks

Engine Loses Power

Engine Uses Excessive Amount of Oil

Oil Leaks from Oil Seals, Gaskets

Basic Engine Tests

Compression Test

Cylinder Leakdown Test

Section 5 Electronic Fuel Injection (EFI) System

Electrical Components

Operation

Important Service Notes!

Critical notes for servicing the EFI system, emphasizing cleanliness.

Electronic Control Unit (ECU)

Wiring Harness

Electrical System

Pinout of the ECU

Crankshaft Position Sensor

Function, service, and testing of the crankshaft position sensor.

Throttle Position Sensor (TPS)

Function, service, and testing of the throttle position sensor.

ECU Reset and TPS Learn Procedure

Procedures for resetting the ECU and learning TPS settings.

Engine (Oil) Temperature Sensor

Intake Air Temperature Sensor

Oxygen Sensor

Function, service, and testing of the oxygen sensor.

Visual Inspection

Sensor Signal Observation

Removal Inspection

Oxygen Sensor Symptoms and Corrections

Manifold Absolute Pressure (MAP) Sensor

Function, service, and testing of the MAP sensor.

Fuel Injectors

Information on fuel injector installation and operation.

Ignition System

Fuel Components

Throttle Body;Intake Manifold Assembly

Idle Speed Adjustment (RPM)

Initial Governor Adjustment

Procedure for adjusting the governor and throttle linkage.

Troubleshooting

General troubleshooting guide for EFI system issues.

Fuel System

Troubleshooting the EFI fuel system, including pressure warnings.

Fault Codes

How to access and interpret diagnostic fault codes from the ECU.

Diagnostic Code Summary

Troubleshooting Flow Chart

A flowchart to guide troubleshooting of the EFI system.

EFI Diagnostic Flow Diagram

A visual flow diagram for diagnosing EFI system issues.

Flow Chart Diagnostic Aids

Section 6 Lubrication System

Oil Recommendations

Check Oil Level

Procedure for checking the engine oil level.

Changing Oil and Oil Filter

Section 7 Electrical System and Components

Spark Plugs

Battery

Battery Charging System

Rectifier-Regulator

Troubleshooting Guide

Fuses

Electric Starting Motors

Troubleshooting Guide - Starting Difficulties

Troubleshooting guide for starting difficulties.

Starter Disassembly

Step-by-step instructions for disassembling the starter motor.

Inspection

Brush Replacement

Starter Reassembly

Step-by-step instructions for reassembling the starter motor.

Solenoid Test Procedure

Procedures for testing the starter solenoid's pull-in and hold-in coils.

Section 8 Disassembly

Typical Disassembly Sequence

Disconnect Spark Plug Leads

Procedure for disconnecting spark plug leads.

Shut Off Fuel Supply

Procedure for shutting off the fuel supply before disassembly.

Drain Oil From Crankcase and Remove Oil Filter

Procedures for draining oil and removing the oil filter.

Remove Air Cleaner Assembly

Remove Lift Fuel Pump and Fuel Pump Module

Procedures for removing the lift fuel pump and fuel pump module.

Fuel Pump Module

Step-by-step procedure for removing the fuel pump module.

Remove Throttle Body

Procedure for removing the throttle body assembly.

Remove the Electronic Control Unit (ECU)

Procedure for removing the electronic control unit (ECU) and its bracket.

Remove Electric Starter Motor and Electronic Control Unit Bracket

Procedure for removing the electric starter motor and ECU bracket.

Remove Valve Covers

Remove Crankshaft Position Sensor

Procedure for removing the crankshaft position sensor.

Remove the Manifold Absolute Pressure (MAP) Sensor

Procedure for removing the MAP sensor.

Remove Fuel Injectors

Procedure for removing the fuel injectors.

Remove Intake Manifold

Procedure for removing the intake manifold.

Remove Spark Plugs

Procedure for removing the spark plugs.

Remove Cylinder Heads and Hydraulic Lifters

Procedures for removing cylinder heads and hydraulic lifters.

Disassemble Cylinder Heads

Remove Oil Pan Assembly

Procedure for removing the oil pan assembly.

Remove Camshaft

Remove Connecting Rods with Pistons and Rings

Procedures for removing connecting rods, pistons, and rings.

Remove Crankshaft

Procedure for removing the crankshaft.

Section 9 Inspection and Reconditioning

Camshaft

Crankshaft

Crankcase

Measuring Piston-to-Bore Clearance

Procedure for measuring piston-to-bore clearance accurately.

Cylinder Head and Valves

Valve Guides

Pistons and Rings

Install New Piston Rings

Procedure for installing new piston rings correctly.

Connecting Rods

Hydraulic Lifters

Section 10 Reassembly

General

Typical Reassembly Sequence

Install Crankshaft

Install Connecting Rods with Pistons and Rings

Procedures for installing connecting rods, pistons, and rings.

Install Camshaft

Install Oil Pan Assembly

Install Cylinder Heads and Hydraulic Lifters

Assemble Cylinder Heads

Install Cylinder Heads

Install Push Rods and Rocker Arms

Install Spark Plugs

Install Intake Manifold

Install Fuel Injectors

Procedure for installing fuel injectors, including O-rings and clips.

Install Manifold Absolute Pressure (MAP) Sensor

Procedure for installing the MAP sensor.

Install Crankshaft Position Sensor

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

Install Valve Covers

Install Reconnect Rectifier-Regulator

Install Electric Starter Motor and ECU Bracket

Procedure for installing the electric starter motor and ECU bracket.

Install Electronic Control Unit (ECU)

Procedure for installing the ECU onto its bracket.

Install Throttle Body

Procedure for installing the throttle body assembly.

Install Lift Fuel Pump and Fuel Pump Module

Procedures for installing the lift fuel pump and fuel pump module.

Install Air Cleaner Assembly

Setting Initial Governor Adjustment

Procedure for setting the initial governor adjustment.

Install Oil Filter and Fill Crankcase with Oil

Procedures for installing the oil filter and filling the crankcase with oil.

Connect Spark Plug Leads

Prepare the Engine for Operation

Final checks and preparation steps before operating the engine.

Sensitivity Adjustment

Testing the Engine