Kohler ECV980 Engine Full Service Repair Manual

ECV940 & ECV980 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. 62 690 05 Rev. -- 1 2 Safety 3 Maintenance 5 Speciﬁcations 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

Safety 2 62 690 05 Rev. -- KohlerEngines.com 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 Explosive Fuel can cause fires and severe burns. Do not fill fuel tank while engine is hot or running. Gasoline is extremely flammable and its vapors can explode if ignited. Store gasoline only in approved containers, in well ventilated, unoccupied buildings, away from sparks or flames. Spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition. Never use gasoline as a cleaning agent. WARNING Rotating Parts can cause severe injury. Stay away while engine is in operation. Keep hands, feet, hair, and clothing away from all moving parts to prevent injury. Never operate engine with covers, shrouds, or guards removed. WARNING Carbon Monoxide can cause severe nausea, fainting or death. Avoid inhaling exhaust fumes. Engine exhaust gases contain poisonous carbon monoxide. Carbon monoxide is odorless, colorless, and can cause death if inhaled. WARNING Accidental Starts can cause severe injury or death. Disconnect and ground spark plug lead(s) before servicing. Before working on engine or equipment, disable engine as follows: 1) Disconnect spark plug lead(s). 2) Disconnect negative (–) battery cable from battery. WARNING Hot Parts can cause severe burns. Do not touch engine while operating or just after stopping. Never operate engine with heat shields or guards removed. WARNING Cleaning Solvents can cause severe injury or death. Use only in well ventilated areas away from ignition sources. Carburetor cleaners and solvents are extremely flammable. Follow cleaner manufacturer’s warnings and instructions on its proper and safe use. Never use gasoline as a cleaning agent. CAUTION Electrical Shock can cause injury. Do not touch wires while engine is running. CAUTION Damaging Crankshaft and Flywheel can cause personal injury. Using improper procedures can lead to broken fragments. Broken fragments could be thrown from engine. Always observe and use precautions and procedures when installing flywheel. CAUTION Failure to utilize or reassemble debris screen as designed could result in debris screen failure and serious personal injury. WARNING High Pressure Fluids can puncture skin and cause severe injury or death. Do not work on fuel system without proper training or safety equipment. Fluid puncture injuries are highly toxic and hazardous. If an injury occurs, seek immediate medical attention. WARNING Explosive Fuel can cause fires and severe burns. Fuel system ALWAYS remains under HIGH 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.

Maintenance 3 62 690 05 Rev. -- KohlerEngines.com MAINTENANCE INSTRUCTIONS WARNING Before working on engine or equipment, disable engine as follows: 1) Disconnect spark plug lead(s). 2) Disconnect negative (–) battery cable from battery. Accidental Starts can cause severe injury or death. 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 filter 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 filter. ● Check oil cooler fins, clean as necessary. Lubrication System Every 200 Hours ● Change oil filter. 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 find a local Kohler authorized dealer visit KohlerEngines.com or call 1-800-544-2444 (U.S. and Canada).

Maintenance 4 62 690 05 Rev. -- KohlerEngines.com OIL RECOMMENDATIONS We recommend use of Kohler oils for best performance. Other high-quality detergent oils (including synthetic) of API (American Petroleum Institute) service class SJ or higher are acceptable. Select viscosity based on air temperature at time of operation as shown in table below. °F -20 0 20 32 40 60 50 80 100 °C -30 -20 -10 0 10 20 30 40 75 10W-30 5W-30 SAE 30 20W-50 FUEL RECOMMENDATIONS WARNING Explosive Fuel can cause fires and severe burns. Do not fill fuel tank while engine is hot or running. Gasoline is extremely flammable and its vapors can explode if ignited. Store gasoline only in approved containers, in well ventilated, unoccupied buildings, away from sparks or flames. 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 overfill fuel tank. ● Do not use gasoline older than 30 days. STORAGE If engine will be out of service for 2 months or more follow procedure below. 1. Add Kohler PRO Series fuel treatment or equivalent to fuel tank. Run engine 2-3 minutes to get stabilized fuel into fuel system (failures due to untreated fuel are not warrantable). 2. Change oil while engine is still warm from operation. Remove spark plug(s) and pour about 1 oz. of engine oil into cylinder(s). Replace spark plug(s) and crank engine slowly to distribute oil. 3. Disconnect negative (-) battery cable. 4. Store engine in a clean, dry place.

Speciﬁcations 5 62 690 05 Rev. -- KohlerEngines.com Dimensions in millimeters. Inch equivalents shown in [ ]. FLYWHEEL SIDE OIL FILL & DIPSTICK MOUNTING HOLE “A” 89.75 [3.53] OIL FILTER 484.61 [19.08] 152.50 [6.00] 20.01 [0.79] 325.25 [12.81] 30.00 [1.18] 62.70 [2.47] 22.50 [0.89] STARTER SIDE VALVE COVER SIDE MOUNTING HOLE “A” 50.00 [1.97] ENGINE MOUNTING SURFACE 680.87 [26.81] 403.69 [15.89] 89.80 [3.54] ENGINE MOUNTING SURFACE ( PTO END) 45.00 [1.77] 406.25 [15.99] ENGINE MOUNTING SURFACE OIL PRESSURE SWITCH 70.59 [2.78] EXHAUST PORT #2 93.59 [3.68] EXHAUST PORT #1 18.00 [0.71] MOUNTING HOLE “A” 49.80 [1.96] OIL DRAIN PLUG 1/2 NPT INCH 428.07 [16.85] 89.80 [3.54] 89.80 [3.54] 45˚ 55˚ 45˚ 45˚ 45˚ 55˚ 35˚ 35˚ 45˚ 124.23 [4.89] 60.00 [2.36] 60.00 [2.36] 84.06 [3.31] 120.45 [4.74] 168.71 [6.64] SPARK PLUG 275.20 [10.83] MOUNTING HOLE “A” Ø 254.00 [10.00] M8x1.25-6H 25.0 [0.98] DEEP 7 HOLES M8x1.25 4 STUD 2x Ø 35.00 [1.38] Engine Dimensions

Specifications 6 62 690 05 Rev. -- KohlerEngines.com TORQUE SPECIFICATIONS 3,5 ECV940 ECV980 Blower Housing and Sheet Metal M6 Screw New, Untapped Hole (casting) Used, Tapped Hole (casting) New, Extruded Hole (sheet metal) Used, Extruded Hole (sheet metal) Mounting Clip (valley baffle) 10.7 N·m (95 in. lb.) 7.3 N·m (65 in. lb.) 2.5 N·m (22 in. lb.) 2.0 N·m (18 in. lb.) 2.5 N·m (22 in. lb.) Intake Manifold and Air Cleaner Intake Manifold Mounting Fastener (torque in 2 increments) first to 16.9 N·m (150 in. lb.) finally 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. lb.) Ground Lead to Air Cleaner Bracket 5.6 N·m (50 in. lb.) Fuel Injector Cap Fastener 7.3 N·m (65 in. lb.) Manifold Absolute Pressure (MAP) Sensor Fastener 7.3 N·m (65 in. lb.) Connecting Rod Cap Fastener (torque in increments) 11.6 N·m (103 in. lb.) GENERAL SPECIFICATIONS 3,6 ECV940 ECV980 Bore 90 mm (3.54 in.) Stroke 78.5 mm (3.1 in.) Displacement 999 cc (61 cu. in.) Oil Capacity (refill) 2.9 L (3.1 U.S. qt.) Maximum Angle of Operation (@ full oil level) 4 25° Model . . . . . . . . . . . . . . . . . . . . . ECV940 EFI Command Engine Vertical Shaft Numerical Designation Specification . . . . . . . . . . . . . . . ECV940-0001 Serial . . . . . . . . . . . . . . . . . . . . . 4323500328 Year Manufactured Code Factory Code Code Year 43 2013 44 2014 45 2015 ENGINE IDENTIFICATION NUMBERS Kohler engine identification numbers (model, specification and serial) should be referenced for efficient repair, ordering correct parts, and engine replacement. 3 Values are in Metric units. Values in parentheses are English equivalents. 4 Exceeding maximum angle of operation may cause engine damage from insufficient lubrication. 5 Lubricate threads with engine oil prior to assembly. 6 Any and all horsepower (hp) references by Kohler are Certified Power Ratings and per SAE J1940 & J1995 hp standards. Details on Certified Power Ratings can be found at KohlerEngines.com.

Specifications 7 62 690 05 Rev. -- KohlerEngines.com TORQUE SPECIFICATIONS 3,5 ECV940 ECV980 Crankcase Breather Cover Fastener 12.4 N·m (110 in. lb.) Oil Drain Plug 21.4 N·m (16 ft. lb.) Oil Temperature Sensor 7.3 N·m (65 in. lb.) Dipstick Tube Screw 7.7 N·m (68 in. lb.) Cylinder Head Fastener (torque in 2 increments) Head Bolt first to 23.7 N·m (210 in. lb.) finally to 46.9 N·m (415 in. lb.) Pipe Plug 3/4 in. 28.5 N·m (252 in. lb.) Rocker Arm Stud (AVT) 11.3 N·m (100 in. lb.) Rocker Arm Screw (Non-AVT) 15.5 N·m (137 in. lb.) Setscrew, AVT pivot locking 7.7 N·m (69 in. lb.) Debris Screen Hex Stud 21.5 N·m (190 in. lb.) Mounting Screw - Hex Flange Screw 20.3 N·m (180 in. lb.) Mounting Screw - Button Head Cap Screw 9.9 N·m (88 in. lb.) Flywheel Fan Fastener 10.4 N·m (92 in. lb.) Retaining Screw 69.8 N·m (51 ft. lb.) Fuel Pump Module Baffle to Crankcase Fastener 11.9 N·m (105 in. lb.) Module to Baffle Fastener 9.2 N·m (81 in. lb.) Pulse Pump Screw (to blower housing) 2.8 N·m (25 in. lb.) Governor (Electronic) Governor Control Unit (GCU) to GCU Bracket 2.1 N·m (19 in. lb.) Digital Linear Actuator (DLA) Bracket to GCU Bracket 10.2 N·m (90 in. lb.) DLA to DLA Bracket Screw 7.3 N·m (65 in. lb.) Governor (Mechanical) Lever Nut 7.1 N·m (63 in. lb.) Yoke Mounting Screw 2.2 N·m (20 in. lb.) Ignition Spark Plug 27 N·m (20 ft. lb.) Coil Fastener 5.1 N·m (45 in. lb.) Crankshaft Position Sensor Screw 11.3 N·m (100 in. lb.) Crankshaft Position Sensor Bracket Screw 9.7 N·m (86 in. lb.) Electronic Control Unit (ECU) to Bracket Screw 6.2 N·m (55 in. lb.) Rectifier-Regulator Fastener 2.5 N·m (22 in. lb.) Lifter Feed Chamber Cover Screw 6.6 N·m (58 in. lb.) 3 Values are in Metric units. Values in parentheses are English equivalents. 5 Lubricate threads with engine oil prior to assembly.

Speciﬁcations 8 62 690 05 Rev. -- KohlerEngines.com TORQUE SPECIFICATIONS 3,5 ECV940 ECV980 Mufﬂer Retaining Nut 24.4 N·m (216 in. lb.) Screw, intermittent bracket (into weld nut) 13.6 N·m (120 in. lb.) M6 Screw 9.9 N·m (88 in. lb.) M8 Screw 24.4 N·m (216 in. lb.) Oil Cooler Mounting Screw 2.3 N·m (21 in. lb.) Oil Filter Adapter/Housing Mounting Screw 23.7 N·m (210 in. lb.) Oil Filter Nipple 17.8 N·m (158 in. lb.) Oil Pan Fastener 25.6 N·m (227 in. lb.) Oil Temperature Sensor 13.6 N·m (120 in. lb.) Oil Temperature Sensor Reducer Bushing 17.6 N·m (156 in. lb.) Oil Temperature Sensor Nut 2.3 N·m (20 in. lb.) Oil Pickup Screen Mounting Screw 11.3 N·m (100 in. lb.) into a new hole 7.7 N·m (68 in. lb.) into a used hole Oil Pump Mounting Screw 9.9 N·m (88 in. lb.) Oil Sentry TM Pressure Switch 10.7 N·m (95 in. lb.) Solenoid (starter) Mounting Hardware 4.0-6.0 N·m (35-53 in. lb.) Nut, Positive (+) Brush Lead 8.0-11.0 N·m (71-97 in. lb.) Starter Assembly Thru Bolt 5.6-9.0 N·m (49-79 in. lb.) Mounting Screw 16 N·m (142 in. lb.) Brush Holder Mounting Screw 2.5-3.3 N·m (22-29 in. lb.) Stator Mounting Screw 9.3 N·m (82 in. lb.) Throttle Control Bracket Fastener 9.9 N·m (88 in. lb.) Valve Cover Fastener 13.6 N·m (120 in. lb.) 3 Values are in Metric units. Values in parentheses are English equivalents. 5 Lubricate threads with engine oil prior to assembly.

Speciﬁcations 9 62 690 05 Rev. -- KohlerEngines.com CLEARANCE SPECIFICATIONS 3 ECV940 ECV980 Camshaft End Play 0.3/1.3 mm (0.011/0.051 in.) Running Clearance 0.025/0.063 mm (0.0010/0.0025 in.) Bore I.D. New Max. Wear Limit 20.000/20.025 mm (0.7874/0.7884 in.) 20.038 mm (0.7889 in.) Bearing Surface O.D. New Max. Wear Limit 19.962/19.975 mm (0.7859/0.7864 in.) 19.959 mm (0.7858 in.) Cam Lobe Proﬁle (minimum dimension, measured from base circle to top of lobe) Exhaust 35 mm (1.3779 in.) Intake 34.1 mm (1.3425 in.) 35 mm (1.3779 in.) Connecting Rod Crankpin End I.D. @ 70°F New Max. Wear Limit 44.030/44.037 mm (1.7334/1.7337 in.) 0.070 mm (0.0028 in.) Connecting Rod-to-Crankpin Running Clearance New Max. Wear Limit 0.030/0.055 mm (0.0012/0.0022 in.) 0.070 mm (0.0028 in.) Connecting Rod-to-Crankpin Side Clearance 0.30/0.59 mm (0.0118/0.0232 in.) Connecting Rod-to-Piston Pin Running Clearance 0.015/0.028 mm (0.0006/0.0011 in.) Piston Pin End I.D. @ 70°F New Max. Wear Limit 19.015/19.023 mm (0.7486/0.7489 in.) 19.036 mm (0.7494 in.) Crankcase Governor Cross Shaft Bore I.D. (Mechanical Governor) New Max. Wear Limit 8.025/8.050 mm (0.3159/0.3169 in.) 8.088 mm (0.3184 in.) Crankshaft End Play (free) 0.30/1.50 mm (0.011/0.059 in.) Bore (in crankcase) New 45.043/45.068 mm (1.7733/1.7743 in.) Crankshaft Bore (in crankcase)-to-Crankshaft Running Clearance New 0.043/0.090 mm (0.0017/0.0035 in.) Bore (in oil pan) New, Without Bearing 50.025/50.00 mm (1.9694/1.9685 in.) Crankshaft to Sleeve Bearing (in oil pan) Running Clearance New 0.040/0.167 mm (0.0015/0.0065 in.) Oil Pan End Main Bearing Journal O.D. - New O.D. - Max. Wear Limit Max. Taper Max. Out-of-Round 44.978/45.00 mm (1.770/1.771 in.) 44.90 mm (1.767 in.) 0.022 mm (0.0009 in.) 0.025 mm (0.0010 in.) Connecting Rod Journal O.D. - New O.D. - Max. Wear Limit Max. Taper Max. Out-of-Round Width 43.982/44.000 mm (1.731/1.732 in.) 43.97 mm (1.731 in.) 0.018 mm (0.0007 in.) 0.025 mm (0.0010 in.) 53.00/53.09 mm (2.0866/2.0901 in.) 3 Values are in Metric units. Values in parentheses are English equivalents.

Speciﬁcations 10 62 690 05 Rev. -- KohlerEngines.com CLEARANCE SPECIFICATIONS 3 ECV940 ECV980 Crankshaft Continued T.I.R. PTO End, Crank in Engine Entire Crank, in V-Blocks 0.279 mm (0.0110 in.) 0.10 mm (0.0039 in.) Flywheel End Main Bearing Journal O.D. - New O.D. - Max. Wear Limit Max. Taper Max. Out-of-Round 44.978/45.00 mm (1.770/1.771 in.) 44.90 mm (1.767 in.) 0.022 mm (0.0009 in.) 0.025 mm (0.0010 in.) Crankshaft Bearing (PTO) New (installed) Max. Wear Limit 45.040/45.145 mm (1.773.1.777 in.) 45.158 mm Cylinder Bore I.D. New Max. Wear Limit Max. Taper Max. Out-of-Round 90.000/90.025 mm (3.543/3.544 in.) 90.075 mm (3.546 in.) 0.013 mm (0.00051 in.) 0.013 mm (0.00051 in.) Cylinder Head Max. Out-of-Flatness 0.076 mm (0.003 in.) Governor (Mechanical) Governor Cross Shaft-to-Crankcase Running Clearance 0.025/0.087 mm (0.0009/0.0034 in.) Cross Shaft O.D. New Max. Wear Limit 7.963/8.000 mm (0.3135/.3149 in.) 7.936 mm (0.3124 in.) Governor Gear Shaft-to-Governor Gear Running Clearance 0.070/0.160 mm (0.0027/0.0063 in.) Gear Shaft O.D. New Max. Wear Limit 5.990/6.000 mm (0.2358/0.2362 in.) 5.977 mm (0.2353 in.) Ignition Spark Plug Gap 0.76 mm (0.030 in.) Module Air Gap 0.28/0.33 mm (0.011/0.013 in.) Piston, Piston Rings, and Piston Pin Piston-to-Piston Pin Running Clearance 0.006/0.018 mm (0.0002/0.0007 in.) Pin Bore I.D. New Max. Wear Limit 19.006/17.013 mm (0.7482/0.7485 in.) 19.025 mm (0.7490 in.) Pin O.D. New Max. Wear Limit 18.995/19.000 mm (0.7478/0.7480 in.) 18.994 mm (0.7478 in.) Top Compression Ring-to-Groove Side Clearance 0.04/0.08 mm (0.0015/0.0031 in.) Middle Compression Ring-to-Groove Side Clearance 0.04/0.08 mm (0.0015/0.0031 in.) Oil Control Ring-to-Groove Side Clearance 0.03/0.19 mm (0.0011/0.0074 in.) Top and Center Compression Ring End Gap New Bore Used Bore (max.) 0.30/0.55 mm (0.011/0.021 in.) 0.94 mm (0.037 in.) 3 Values are in Metric units. Values in parentheses are English equivalents.

Kohler ECV980 Engine Full Service Repair Manual

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