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Kohler Command Pro ECV850

Kohler Command Pro ECV850
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ECV850, ECV860, ECV870, ECV880
Service Manual
KohlerEngines.com
IMPORTANT: Read all safety precautions and instructions carefully before operating equipment. Refer to operating
instruction of equipment 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 Speci cations
16 Tools and Aids
19 Troubleshooting
23 Air Cleaner/Intake
24 Electronic Fuel Injection (EFI) System
49 Governor System
59 Lubrication System
61 Electrical System
66 Starter System
70 Disassembly/Inspection and Service
88 Reassembly

Table of Contents

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Kohler Command Pro ECV850 Specifications

General IconGeneral
Cooling SystemAir-cooled
Starting SystemElectric
Horsepower27 hp
Fuel SystemCarbureted
Ignition SystemElectronic
Alternator12V
Engine Type4-Cycle, V-Twin, Gasoline

Summary

Safety

SAFETY PRECAUTIONS

General safety warnings and cautions for operation and maintenance.

Maintenance

MAINTENANCE INSTRUCTIONS

Instructions for disabling the engine before maintenance.

MAINTENANCE SCHEDULE

Schedule of maintenance tasks based on operating hours.

OIL RECOMMENDATIONS

Recommendations for engine oil types and viscosity.

FUEL RECOMMENDATIONS

Requirements for fuel usage and quality.

Specifications

TORQUE SPECIFICATIONS

Torque values for various engine components.

Troubleshooting

TROUBLESHOOTING GUIDE

General guide for troubleshooting engine issues.

Engine Cranks But Will Not Start

Common causes for an engine that cranks but won't start.

Engine Starts But Does Not Keep Running

Causes for an engine that starts but stops running.

Engine Starts Hard

Factors causing an engine to start hard.

Engine Will Not Crank

Reasons why an engine will not crank.

Engine Runs But Misses

Causes of an engine running rough or missing.

Engine Will Not Idle

Issues preventing the engine from idling properly.

Engine Overheats

Causes of engine overheating.

Engine Knocks

Potential causes for engine knocking.

Engine Loses Power

Reasons for engine power loss.

Engine Uses Excessive Amount of Oil

Causes of excessive oil consumption.

Oil Leaks from Oil Seals, Gaskets

Common causes of oil leaks from seals and gaskets.

EXTERNAL ENGINE INSPECTION

Guidelines for inspecting the engine externally before disassembly.

CRANKCASE VACUUM TEST

Procedure for testing crankcase vacuum.

COMPRESSION TEST

Procedure for performing a compression test on the engine.

CYLINDER LEAKDOWN TEST

Procedure for conducting a cylinder leakdown test.

EFI SYSTEM

ECU

Information on the Engine Control Unit (ECU).

Crankshaft position sensor

Function and operation of the crankshaft position sensor.

Throttle position sensor (TPS)

Details on the Throttle Position Sensor (TPS).

Engine (oil) temperature sensor

Function of the engine oil temperature sensor.

TemperatureManifold Air Pressure (TMAP) sensor

Information on the TMAP sensor.

EFI SYSTEM

Ignition Coils and Fuel Pump Module (FPM).

EFI SYSTEM

Diagnostic codes for Tach Output and Troubleshooting Flow Chart.

Governor System

ELECTRONIC GOVERNOR

Components and operation of the electronic governor.

GCUHarness Diagnostics and Troubleshooting

Diagnostics for GCU and harness.

GCU Blink Code Tests

GCU blink codes for stored codes.

GCU Blink Codes for Software Running Codes

GCU blink codes during engine running.

Electronic Governor Troubleshooting Flow Chart

Flowchart for troubleshooting the electronic governor.

Electronic Governor Troubleshooting Flow Chart Continued

Final steps in the electronic governor troubleshooting flowchart.

MECHANICAL GOVERNOR

Overview of the mechanical governor system.

Lubrication System

CHANGE OIL AND FILTER

Steps for changing engine oil and filter.

Electrical System

SPARK PLUGS

Information on spark plugs, inspection, and service.

Troubleshooting Guide

Troubleshooting the battery charging system.

Starter System

Troubleshooting-Starting Diffi culties

Common starting problems and their causes.

Solenoid Tests

Procedures for testing the starter solenoid.

DisassemblyInspection and Service

Remove Connecting Rods with Pistons and Rings

Steps to remove connecting rods, pistons, and rings.

Piston and Rings

Information on piston and ring inspection and service.

Install New Piston Rings

Procedure for installing new piston rings.

Measuring Piston-to-Bore Clearance

Procedure for measuring piston-to-bore clearance.

Reassembly

Install Connecting Rods with Pistons and Rings

Reassembly of connecting rods, pistons, and rings.

Install Valve Tappets and Camshaft

Procedure for installing valve tappets and camshaft.

Assemble Cylinder Heads

Steps for assembling the cylinder heads.

Install Cylinder Heads

Procedure for installing cylinder heads.

Adjust Valve Clearance

Procedure for adjusting valve clearance.

Install FlywheelFan

Steps for installing the flywheel and fan assembly.

Install Governor Lever, Governor Springs, and Linkage (Mechanical Governor)

Installing governor components for mechanical governor.

Install Intake ManifoldThrottle Body Assembly

Steps for installing the intake manifold and throttle body.

Install Oil Filter and Add Oil to Crankcase

Steps for installing oil filter and adding oil.

Testing Engine

Recommendations for testing the engine.

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