Kohler ECV980 Generator Set

Tools: Feeler gauge 0.406/0.483 mm (0.016/0.019 in.)

1. Turn adjusters in rocker arms clockwise by hand only enough to capture push rods in recesses.
2. Rotate crankshaft to establish TDC on compression stroke for cylinder 1.
3. Compress lifter and bottom plunger; insert 0.406/0.483 mm (0.016/0.019 in.) feeler gauge between valve end and rocker arm.
4. Turn adjuster until slight drag is felt; hold and tighten locking setscrew to 7.7 N·m (69 in. lb.); recheck.
5. Repeat for other valve on this side.
6. Viewed from PTO end, rotate crankshaft 270° (3/4 turn) counterclockwise aligning keyway with cylinder 2.
7. Repeat steps 3-5 for cylinder 2.
8. Rotate crankshaft to check free operation of valve train; minimum valve spring coil clearance 0.25 mm (0.010 in.).

⚠ Do not tamper with governor setting. Overspeed is hazardous and could cause personal injury.

Tools: Long thin rod or tool

1. Position governor lever so clamping area is inboard but completely on knurled area of governor cross shaft.
2. Move governor lever toward throttle body as far as it will go (wide-open throttle) and hold in position.
3. Insert a long thin rod or tool into hole on cross shaft and rotate shaft clockwise (viewed from end) as far as it will turn, then torque nut to 7.1 N·m (63 in. lb.).
4. Connect governor spring (long looped end) to inner hole on governor lever and control bracket.
5. Connect governed idle spring to outer governor lever hole and control bracket. Make sure springs do not contact valley baffle.

1. Turn idle screw clockwise one full turn prior to key/ignition ON after ECU Reset.
2. Start engine, run at low idle until engine is warm.
3. Idle speed must be above 1500 RPM; if below, turn idle screw to 1700 RPM, shut down and perform ECU Reset again.
4. Adjust idle speed down to 1500 RPM; allow engine to dwell about 3 seconds.
5. Adjust idle speed to final specified speed setting.
6. Turn key/ignition OFF and count to 10 seconds. Learn procedure complete.

⚠ Carbon Monoxide can cause severe nausea, fainting or death. Never run engine indoors or in enclosed spaces.

⚠ Rotating Parts can cause severe injury. Stay away while engine is in operation.

Tools: Water manometer, Rubber stopper, Pinch clamp

1. Insert rubber stopper into oil fill hole; connect hose between stopper and one manometer tube; leave other tube open; check water level at 0 line.
2. Start engine and run no-load high speed.
3. Open clamp and note water level in tube; level in engine side should be minimum 10.2 cm (4 in.) above open side.
4. Close pinch clamp before stopping engine.

Tools: Ohmmeter

1. Inspect wiring and connections for damage or problems.
2. Make sure engine has resistor type spark plugs.
3. Disconnect Black connector from ECU.
4. Connect ohmmeter between #4 and #13 pin terminals; resistance 325-395 Ω at room temperature (20°C, 68°F).
5. If resistance correct, remove blower housing; disconnect sensor connector from harness; test resistance between terminals 325-395 Ω.
6. If resistance incorrect, remove screws securing sensor to bracket and replace sensor.
7. If step 4 incorrect but sensor alone correct, test wire harness circuits between sensor connector and pins #4 and #13; correct problem and retest.
8. When fault corrected and engine starts, clear fault codes following ECU Reset procedure.

⚠ To prevent damage to gauge assembly, always turn pressure regulator knob to zero after each test.

Tools: Cylinder leakdown tester, 12 mm x 14 mm adapter (if required)

1. Run engine until oil temperature reaches and maintains 150°F (66°C) or more for minimum 5 minutes under normal load.
2. Remove spark plug(s) and air filter.
3. Rotate crankshaft until piston is at TDC of compression stroke; hold engine in position.
4. Connect air source (at least 100 PSI) to tool.
5. Turn regulator clockwise; confirm both gauges read approximately same air pressure 0 to 80 PSI; release pressure.
6. Install adapter hose into spark plug hole of cylinder being tested.
7. Firmly hold engine at TDC; connect adapter hose to tool quick connect; turn regulator clockwise until left gauge reads 20 PSI.
8. Slowly turn regulator clockwise until left gauge maintains selected test pressure; compare right gauge to Test Pressure Chart.

⚠ This system will NOT reset when battery is disconnected.

Tools: Green wire jumper (Kohler EFI service kit)

1. Turn key/ignition OFF.
2. Install Green colored wire jumper from Kohler EFI service kit on diagnostic port.
3. Turn key ON then OFF, count 10 seconds.
4. Turn key ON then OFF, count to 10 seconds a second time.
5. Remove Green jumper. Turn key ON then OFF, count 10 seconds a third time. ECU is reset.

⚠ This system will NOT reset when battery is disconnected.

Tools: Red wire jumper (Kohler EFI service kit)

1. Turn key/ignition OFF.
2. Install Red wire jumper from Kohler EFI service kit to service port (connect white to black wire in 4 way diagnostic port).
3. Turn key ON then OFF, count 10 seconds.
4. Turn key ON then OFF, count to 10 seconds a second time.
5. Remove Red wire jumper. Turn key ON then OFF, count 10 seconds a third time. ECU is reset.
6. A TPS Learn Procedure must be performed after ECU reset.

1. Clean area around oil fill cap/dipstick and drain plug; remove drain plug and dipstick; allow oil to drain completely.
2. Clean area around oil filter; remove filter; wipe mounting surface; reinstall drain plug and torque to 21.4 N·m (16 ft. lb.).
3. Place new filter open end up in a shallow pan; fill with new oil to bottom of threads; allow 2 minutes.
4. Apply thin film of clean oil to rubber gasket on new filter.
5. Refer to instructions on oil filter for proper installation.
6. Fill crankcase with new oil; level at top of indicator on dipstick.
7. Reinstall oil fill cap/dipstick and tighten securely.
8. Start engine, check for oil leaks; stop engine, correct leaks, recheck oil level; dispose of used oil/filter per local ordinances.

⚠ Never run engine with oil level below or above operating range indicator on dipstick.

1. Ensure engine is cool. Clean oil fill/dipstick areas of any debris.
2. Remove dipstick; wipe oil off.
3. Reinsert dipstick into tube; rest cap on tube, do not thread cap onto tube.
4. Remove dipstick; check oil level should be at top of indicator.
5. If oil is low, add oil up to top of indicator mark.
6. Reinstall and secure dipstick.

1. Add Kohler PRO Series fuel treatment or equivalent to fuel tank; run engine 2-3 minutes.
2. Change oil while engine still warm (NOT required if using KOHLER PRO 10W-50 full-synthetic oil). Remove spark plug(s) and pour about 1 oz. engine oil into cylinder(s). Replace plugs and crank slowly.
3. Disconnect negative (-) battery cable.
4. Store engine in a clean, dry place.

⚠ Continuing to rotate clevis shaft after it has made contact with keyway will damage keyway or actuator.

⚠ DLA is not a solenoid. Do not exert force to center clevis shaft.

1. Disconnect linkage and remove DLA from bracket.
2. Remove clevis shaft completely out of DLA.
3. Reinstall rubber boot onto DLA if required.
4. Place clevis shaft into actuator; rotate clockwise 3 full turns with slight pressure until keyway contacts key.
5. Confirm key and keyway alignment; by hand press clevis shaft into actuator with reasonable pressure; do not force.
6. Reinstall DLA into bracket, torque screws to 7.3 N·m (65 in. lb.), and connect linkage.
7. Loosen DLA bracket screws slightly; slide bracket back until throttle plate is fully open.
8. Measure distance from face of DLA bracket to top of E-Gov bracket edge; adjust until same distance (within 0.5 mm/0.020 in.); torque bracket screws to 10.2 N·m (90 in. lb.).