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ECV940 & ECV980 Service Manual

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ECV940 & ECV980 Service Manual ECV940 & ECV980 Service Manual 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. 2 Safety 3 Maintenance 5 Specifi cations 13 Tools and Aids 16 Troubleshooting 20 Air Cleaner/Intake 21 Electronic Fuel Injection (EFI) System 45 Governor System 55 Lubrication System 57 Electrical System 62 Starter System 66 Disassembly/Inspection and Service 83 Reassembly 62 690 05 Rev. A KohlerEngines.com 1 Safety SAFETY PRECAUTIONS WARNING: A hazard that could result in death, serious injury, or substantial property damage. CAUTION: A hazard that could result in minor personal injury or property damage. NOTE: is used to notify people of important installation, operation, or maintenance information. WARNING WARNING CAUTION Explosive Fuel can cause Accidental Starts can Damaging Crankshaft fi res and severe burns. cause severe injury or and Flywheel can cause Do not fi ll fuel tank while death. personal injury. engine is hot or running. Disconnect and ground Gasoline is extremely fl ammable spark plug lead(s) before and its vapors can explode if servicing. ignited. Store gasoline only in Using improper procedures can approved containers, in well Before working on engine or lead to broken fragments. Broken ventilated, unoccupied buildings, equipment, disable engine as fragments could be thrown from away from sparks or fl ames. follows: 1) Disconnect spark plug engine. Always observe and use Spilled fuel could ignite if it comes lead(s). 2) Disconnect negative (–) precautions and procedures when in contact with hot parts or sparks battery cable from battery. installing fl ywheel. from ignition. Never use gasoline as a cleaning agent. WARNING CAUTION Hot Parts can cause Failure to utilize or WARNING severe burns. reassemble debris Rotating Parts can cause Do not touch engine screen as designed could severe injury. while operating or just result in debris screen after stopping. failure and serious Stay away while engine personal injury. is in operation. Never operate engine with heat Keep hands, feet, hair, and shields or guards removed. clothing away from all moving WARNING parts to prevent injury. Never WARNING High Pressure Fluids can operate engine with covers, puncture skin and cause shrouds, or guards removed. Cleaning Solvents can severe injury or death. cause severe injury or death. Do not work on fuel WARNING system without proper Use only in well training or safety Carbon Monoxide can ventilated areas away equipment. cause severe nausea, from ignition sources. fainting or death. Carburetor cleaners and solvents Fluid puncture injuries are highly Avoid inhaling exhaust are extremely fl ammable. Follow toxic and hazardous. If an injury fumes. cleaner manufacturer’s warnings occurs, seek immediate medical attention. Engine exhaust gases contain and instructions on its proper and poisonous carbon monoxide. safe use. Never use gasoline as a Carbon monoxide is odorless, cleaning agent. WARNING colorless, and can cause death if Explosive Fuel can inhaled. CAUTION cause fi res and severe Electrical Shock can burns. cause injury. Fuel system ALWAYS Do not touch wires while remains under HIGH engine is running. PRESSURE. Wrap a shop towel completely around fuel pump module connector. Press release button(s) and slowly pull connector away from fuel pump module allowing shop towel to absorb any residual fuel in high pressure fuel line. Any spilled fuel must be completely wiped up immediately. 2 KohlerEngines.com 62 690 05 Rev. A Maintenance MAINTENANCE INSTRUCTIONS WARNING Accidental Starts can cause severe injury or Before working on engine or equipment, disable engine as death. follows: 1) Disconnect spark plug lead(s). 2) Disconnect negative (–) battery cable from battery. Disconnect and ground spark plug lead(s) before servicing. Normal maintenance, replacement or repair of emission control devices and systems may be performed by any repair establishment or individual; however, warranty repairs must be performed by a Kohler authorized dealer. MAINTENANCE SCHEDULE Every 100 Hours or Annually¹ ● Change oil. Oil fi lter is recommended. Lubrication System ● Remove cooling shrouds and clean cooling areas. Air Cleaner/Intake Every 150 Hours¹ ● Check air cleaner element. Air Cleaner/Intake ● Replace unique Electronic Fuel Injection (EFI) fuel fi lter. ● Check oil cooler fi ns, clean as necessary. Lubrication System Every 200 Hours ● Change oil fi lter. Lubrication System Every 300 Hours ● Replace air cleaner element and check inner element. Air Cleaner/Intake Every 600 Hours ● Replace air cleaner inner element. Air Cleaner/Intake ● Replace spark plugs and set gap. Electrical System 1 Perform these procedures more frequently under severe, dusty, dirty conditions. REPAIRS/SERVICE PARTS Kohler genuine service parts can be purchased from Kohler authorized dealers. To fi nd a local Kohler authorized dealer visit KohlerEngines.com or call 1-800-544-2444 (U.S. and Canada). 62 690 05 Rev. A KohlerEngines.com 3 Maintenance OIL RECOMMENDATIONS STORAGE We recommend use of Kohler oils for best performance. If engine will be out of service for 2 months or more Other high-quality detergent oils (including synthetic) follow procedure below. of API (American Petroleum Institute) service class SJ 1. Add Kohler PRO Series fuel treatment or equivalent or higher are acceptable. Select viscosity based on to fuel tank. Run engine 2-3 minutes to get stabilized air temperature at time of operation as shown in table fuel into fuel system (failures due to untreated fuel below. are not warrantable). 2. Change oil while engine is still warm from operation. 20W-50 Remove spark plug(s) and pour about 1 oz. of engine oil into cylinder(s). Replace spark plug(s) and 10W-30 crank engine slowly to distribute oil. 3. Disconnect negative (-) battery cable. SAE 30 5W-30 4. Store engine in a clean, dry place. °F -20 02032406050 75 80 100 °C -30 -20 -10 0 10 20 30 40 FUEL RECOMMENDATIONS WARNING Explosive Fuel can cause fi res and severe burns. Do not fi ll fuel tank while engine is hot or running. Gasoline is extremely fl ammable and its vapors can explode if ignited. Store gasoline only in approved containers, in well ventilated, unoccupied buildings, away from sparks or fl ames. Spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition. Never use gasoline as a cleaning 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. ● Octane rating of 87 (R+M)/2 or higher. ● Research Octane Number (RON) 90 octane minimum. ● Gasoline up to 10% ethyl alcohol, 90% unleaded is acceptable. ● Methyl Tertiary Butyl Ether (MTBE) and unleaded gasoline blend (max 15% MTBE by volume) are approved. ● Do not add oil to gasoline. ● Do not overfi ll fuel tank. ● Do not use gasoline older than 30 days. 4 KohlerEngines.com 62 690 05 Rev. A Specifi cations Engine Dimensions Dimensions in millimeters. Inch equivalents shown in [ ]. 484.61 [19.08] 152.50 [6.00] 50.00 [1.97] 325.25 680.87 [12.81] [26.81] 22.50 20.01 45.00 [1.77] [0.89] [0.79] 406.25 403.69 30.00 [15.99] [15.89] [1.18] 168.71 [6.64] 62.70 [2.47] SPARK PLUG MOUNTING HOLE “A” 89.75 OIL FILL & FLYWHEEL SIDE MOUNTING ENGINE MOUNTING [3.53] DIPSTICK HOLE “A” STARTER SIDE OIL SURFACE FILTER 89.80 [3.54] 428.07 124.23 [4.89] [16.85] 45˚ 35˚ 35˚ 55˚ M8x1.25 4 STUD 45˚ 45˚ 2x Ø 35.00 [1.38] 60.00 [2.36] 60.00 [2.36] 84.06 [3.31] 275.20 [10.83] 120.45 [4.74] 89.80 93.59 [3.68] 70.59 [2.78] [3.54] EXHAUST PORT #1 EXHAUST PORT #2 Ø 254.00 [10.00] 18.00 [0.71] MOUNTING MOUNTING HOLE “A” M8x1.25-6H HOLE “A” OIL ENGINE MOUNTING SURFACE 25.0 [0.98] DEEP 49.80 89.80 45˚ OIL DRAIN PLUG PRESSURE [1.96] 45˚ 7 HOLES 1/2 NPT INCH SWITCH [3.54] 55˚ ENGINE MOUNTING SURFACE ( PTO END) VALVE COVER SIDE 62 690 05 Rev. A KohlerEngines.com 5 Specifi cations ENGINE IDENTIFICATION NUMBERS Kohler engine identifi cation numbers (model, specifi cation and serial) should be referenced for effi cient repair, ordering correct parts, and engine replacement. Model . .ECV940 EFI Command Engine Vertical Shaft Numerical Designation Specifi cation . ECV940-0001 Serial . 4323500328 Year Manufactured Code Factory Code Code Year 43 2013 44 2014 45 2015 GENERAL SPECIFICATIONS3,6 ECV940 ECV980 Bore 90 mm (3.54 in.) Stroke 78.5 mm (3.1 in.) Displacement 999 cc (61 cu. in.) Oil Capacity (refi ll) 1.9 L (2 U.S. qt.) Maximum Angle of Operation (@ full oil level)4 25° TORQUE SPECIFICATIONS3,5 ECV940 ECV980 Blower Housing and Sheet Metal M6 Screw New, Untapped Hole (casting) 10.7 N·m (95 in. lb.) Used, Tapped Hole (casting) 7.3 N·m (65 in. lb.) New, Extruded Hole (sheet metal) 2.5 N·m (22 in. lb.) Used, Extruded Hole (sheet metal) 2.0 N·m (18 in. lb.) Mounting Clip (valley baffl e) 2.5 N·m (22 in. lb.) Intake Manifold and Air Cleaner Intake Manifold Mounting Fastener (torque in 2 increments) fi rst to 16.9 N·m (150 in. lb.) fi nally to 22.6 N·m (200 in. lb.) Air Cleaner Elbow to Throttle Body Mounting Nut 7.9 N·m (70 in. lb.) Air Cleaner Bracket Mounting Screw (into intake manifold) 11.3 N·m (100 in. lb.) GCU Bracket to Intake Manifold & Air Cleaner Bracket 11.3 N·m (100 in.
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