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Kohler Command Pro ECV860

Kohler Command Pro ECV860
104 pages
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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 ECV860 Specifications

General IconGeneral
Compression Ratio8.5:1
Cooling SystemAir-cooled
Starting SystemElectric
Bore3.27 in (83 mm)
Horsepower27 hp
Oil Capacity2.0 U.S. qt (1.9 L)
Engine Type4-Cycle, Gasoline, OHV, V-Twin
Stroke79 mm (3.11 in.)
Bore x Stroke83 mm x 79 mm (3.27 in. x 3.11 in.)

Summary

Safety

Maintenance

Maintenance Instructions

Describes safety precautions before performing maintenance.

Maintenance Schedule

Outlines service intervals and tasks for the engine.

RepairsService Parts

Information on obtaining genuine Kohler parts and service.

Oil Recommendations

Details on recommended engine oils based on temperature.

Fuel Recommendations

Requirements for gasoline fuel to ensure proper engine operation.

Storage

Procedure for storing the engine for extended periods.

Specifications

Engine Dimensions

Technical measurements of the engine from various viewpoints.

Engine Identification & General Specs

Engine identification numbers and key technical data.

Torque & Clearance Specifications

Torque and clearance values for engine components.

Tools and Aids

Tool Suppliers

Contact information for separate tool vendors.

Tools

Specialized tools and aids for engine service.

Troubleshooting

Troubleshooting Guide

Overview of common engine issues and their causes.

Engine Performance Issues

Problems like starting, running, idling, overheating, and knocking.

External Inspection & Cleaning

Procedures for inspecting and cleaning the engine.

Engine Oil & Leak Issues

Addresses power loss, oil consumption, and leaks.

Crankcase Vacuum Test

Procedure and interpretation for testing crankcase vacuum.

Engine Compression & Leakdown Tests

Procedures for testing cylinder compression and leakdown.

Air CleanerIntake

Air Cleaner System

Description and maintenance of the air cleaner.

Air Cooling System

Importance of air cooling and related warnings.

EFI System

System Overview & Operation

Description of the EFI system, components, and operational modes.

Key Sensors and Components

Details on Crankshaft Position, TPS, Temp, and TMAP sensors.

Fuel System Components

Information on Fuel Injectors and the Fuel Pump Module.

ECU Electrical & Procedures

ECU pinout, reset, and TPS learning procedures.

Governor System

Electronic Governor System

Components, specifications, and linkage for the electronic governor.

DLA & GCU Testing Procedures

Adjustment, diagnostics, and circuit testing for DLA and GCU.

GCU Blink Code Diagnostics

Using blink codes for troubleshooting GCU issues.

Electronic Governor Troubleshooting Flow Chart

Step-by-step troubleshooting for the electronic governor.

Lubrication System

Lubrication System Components & Recommendations

Diagram of parts, oil recommendations, and checking oil level.

Oil Change and Filter Replacement

Procedure for changing engine oil and filter.

Oil Cooler & Oil Sentry Switch

Maintenance and testing of oil cooler and pressure switch.

Electrical System

Spark Plugs

Details, service, inspection, and fouling conditions of spark plugs.

Battery System

Battery requirements, maintenance, and testing.

Charging System Components & Testing

Overview of charging system, stator, and rectifier-regulator testing.

Charging System Troubleshooting

Troubleshooting guide for the battery charging system.

Starter System

Starting Troubleshooting

Common starting problems and their causes.

Starter Components & Disassembly

Description of starter parts and disassembly procedures.

Armature, Brushes & Reassembly

Inspection and reassembly of armature and brushes.

Solenoid Tests

Procedures for testing the starter solenoid.

DisassemblyInspection and Service

External Engine Components

Diagram and list of external engine parts.

System Disconnections

Procedures for disconnecting various engine systems.

Major Component Removal

Procedures for removing key engine components like fuel pump, starter, blower housing, and flywheel.

Cylinder Head & Valve Service

Procedures for removing and disassembling cylinder heads and valves.

Crankshaft & PistonRod Service

Procedures for servicing crankshaft, connecting rods, and pistons.

Cylinder Bore & Piston Measurement

Procedures for cylinder bore honing and piston-to-bore clearance measurement.

Reassembly

Internal Engine Assembly

Procedures for assembling crankcase, oil pan, and internal rotating parts.

Connecting Rods, Pistons & Camshaft

Procedures for installing connecting rods, pistons, and camshaft.

Cylinder Head & Top End Assembly

Procedures for assembling cylinder heads, valves, and covers.

External Component Assembly

Procedures for installing baffles, stator, sensors, flywheel, and external components.

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