KOHLER PCV850 Command PRO EFI Propane Owner’s Manual

KOHLER PCV850 Command PRO EFI Propane

IMPORTANT:
Read all safety precautions and instructions carefully before operating equipment. Refer to the operating instruction of the equipment that this engine powers. Ensure engine is stopped and level before performing any maintenance or service. Warranty coverage as outlined in the warranty card and on KohlerEngines. com. Please review carefully as it provides your specifi c rights and obligations. To maintain compliance with applicable emission regulations, exhaust system backpressure may not exceed limits which can be found on KohlerEngines. com. Search by Model No., then select Specs tab. Kohler Engines has published CO2 values on the KohlerEngines.com website

Record engine information to reference when ordering parts or obtaining warranty coverage.

• Engine Model
• Specifi cation
• Serial Number
• Purchase Date

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 fi res and severe burns. If a gaseous odor is detected,  ventilate area and contact an authorized service technician. Propane is extremely fl ammable and is heavier than air and tends to settle in low areas where a spark or fl ame could ignite gas. Do not start or operate this engine in a poorly ventilated area where leaking gas could accumulate and endanger the safety of persons in area. To ensure personal safety, installation and repair of propane fuel supply systems must be performed only by qualified propane system technicians. Improperly installed and maintained propane equipment could cause fuel supply system or other components to malfunction, causing gas leaks. Observe federal, state and local laws governing propane fuel, storage, and systems.

WARNING
Carbon Monoxide can cause severe nausea, fainting or death. Avoid inhaling exhaust fumes. Never run engine indoors or in enclosed spaces. Engine exhaust gases contain poisonous carbon monoxide. Carbon monoxide is odorless, and colorless, and can cause death if inhaled.

WARNING
High-Pressure Fluids can puncture skin and cause severe injury or death. Do not work on fuel systems without proper training or safety equipment. Fluid puncture injuries are highly toxic and hazardous. If an injury occurs, seek immediate medical attention.

CAUTION
Electrical Shock can cause injury. Do not touch wires while engine is running.

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
Accidental Starts can cause severe injury or death. Disconnect and ground spark plug lead(s) before servicing. Before working on the engine or equipment, disable engine as follows: 1) Disconnect spark plug lead(s). 2) Disconnect the negative (–) battery cable from the battery. Before disconnecting the negative (-) ground cable, make sure all switches are OFF. If ON, a spark will occur at the ground cable terminal which could cause an explosion if hydrogen gas or propane fuel vapors are present.

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: This product can expose you to chemicals including carbon monoxide and benzene, which are known to the State of California to cause cancer and birth defects or other reproductive harm. For more information go to www.P65Warnings.ca.gov.

• A End Cap
• B Retaining Clip
• C Ejector Area
• D Element
• E Inner Element (if equipped)
• F Inlet Screen
• G Air Cleaner Housing
• H Heavy-Duty Air Cleaner
• I Oil Cooler (if equipped)
• J Oil Fill/Dipstick
• K Vaporizer/ Regulator
• L Oil Drain Plug
• M Oil Filter
• N Spark Plug
• O Lock-Off
• P Vaporizer/ Regulator Drain Plug
• Q Vaporizer/ Regulator Inlet Filter
• R Unique EFI Fuel Filter

Pre-Start Checklist

1. Check oil level. Add oil if low. Do not overfill.
2. Check fuel gauge (if equipped). If the propane tank is low, have it refi lled. Check fuel system components and lines for leaks.
3. Check and clean cooling areas, air intake areas and external surfaces of engine (particularly after storage).
4. Check that air cleaner component and all shrouds, equipment covers, and guards are in place and securely fastened.
5. Check spark arrestor (if equipped).

Starting

WARNING
Carbon Monoxide can cause severe nausea, fainting or death. Avoid inhaling exhaust fumes. Never run engine indoors or in enclosed spaces. Engine exhaust gases contain poisonous carbon monoxide. Carbon monoxide is odorless, colorless, and can cause death if inhaled.
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.
NOTE: Do not crank engine continuously for more than 10 seconds. Allow a 60 second cool down period between starting attempts. Failure to follow these guidelines can burn out starter motors.

1. Place throttle control midway between slow and fast positions.
2. Slowly turn fuel valve on propane tank to full open position.
3. Turn key switch to START position. Release switch as soon as engine starts. If starter does not turn engine over, shut off key switch immediately. Do not make further attempts to start engine until condition is corrected. Do not jump start. See your Kohler authorized dealer for trouble analysis.

Cold Weather Starting Hints

1. Use proper oil for the temperature expected.
2. Disengage all possible external loads.

Stopping

1. If possible, remove load by disengaging all PTO driven attachments.
2. Turn fuel valve to full closed position and allow the engine to continue running until it runs out of fuel. Turn the key switch to OFF position.

Angle of Operation
Refer to the operating instructions of the equipment this engine powers. Do not operate this engine exceeding the maximum angle of operation; see the specification table. Engine damage could result from insufficient lubrication.
Engine Speed
NOTE: Do not tamper with the governor setting to increase maximum engine speed. Overspeed is hazardous and will void the warranty.

Maintenance Instructions

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 the battery. 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 found at KohlerEngines.com or 1-800-544-2444 (U.S. and Canada). For safety and health reasons, many states require special licensing or certifi cation for servicing propane fuel systems. Check local and state regulations before choosing a repair establishment to perform fuel system repairs.

Maintenance Schedule

Maintenance Schedule

Every 100 Hours or Annually1
● Change oil. Oil filter is recommended.

● Remove cooling shrouds and clean cooling areas.

Every 150 Hours1
● Check air cleaner element.

● Check oil cooler fins, clean as necessary (if equipped).

Every 200 Hours1
●  Change oil filter.

●  Replace unique EFI fuel filters.

Every 300 Hours1
● Replace air cleaner element and check inner element (if equipped).
Every 500 Hours or Annually1
● Check all lines (high pressure/vacuum) including fittings for leaks.

● Drain vaporizer/regulator of accumulated fuel deposits.

● Replace spark plugs and set gap.

Every 500 Hours or Annually1,2
● Inspect lock-off assembly for damage/leakage.

● Have combustion deposits removed if using non-synthetic oil.

Every 600 Hours1
● Replace air cleaner inner element (if equipped).
Every 600 Hours1,3
● Have valve lash checked/adjusted.
Every 1500 Hours1,2
● Have vaporizer/regulator tested.
1 Perform these procedures more frequently under severe, dusty, dirty conditions.

2 Must be performed by a Kohler authorized dealer or qualified propane personnel only.

3 Have a Kohler authorized dealer perform this service.

Oil Recommendations

Synthetic oil is recommended for use in propane-fueled engines. Non-synthetic oil must be low ash rated oil. Oils (including synthetic) must meet API (American Petroleum Institute) service class SG, SH, SJ, or SL. Select viscosity based on air temperature at time of operation as shown in table below.
Low ash is defined as less than 1% sulfated ash.

Check Oil Level
NOTE: To prevent extensive engine wear or damage, never run the engine with oil level below or above the operating range the indicator on the dipstick. Ensure the engine is cool. Clean oil fill/dipstick areas of any debris.

1. Remove the dipstick; wipe the oil off.
2. Reinsert the dipstick into the tube; press completely down.
3. Remove the dipstick; check oil level. The level should be at top of the indicator on the dipstick.
4. If oil is low on the indicator, add oil up to the top of the indicator mark.
5. Reinstall and secure the dipstick.

Change Oil and Filter
Change the oil while the engine is warm.

1. Clean the area around the oil fill cap/dipstick and drain plug. Remove the drain plug and oil fill cap/ dipstick. Allow oil to drain completely.
2. Clean the area around the oil filter. Place a container under the filter to catch any oil and remove the filter. Wipe off the mounting surface. Reinstall the drain plug. Torque to 15.7 ft. lb. (21.4 N·m).
3. Place the new filter in a shallow pan with the open end up. Fill with new oil until oil reaches the bottom of the threads. Allow 2 minutes for oil to be absorbed by filter material.
4. Apply a thin film of clean oil to the rubber gasket on the new filter.
5. Refer to the instructions on oil filter for proper installation.
6. Fill the crankcase with new oil. The level should be at top of the indicator on the dipstick.
7. Reinstall the oil fi ll cap/dipstick and tighten it securely.
8. Start the engine; check for oil leaks. Stop engine; correct leaks. Recheck oil level.
9. Dispose of used oil and filter in accordance with local ordinances.

Oil Sentry™ (if equipped)
This switch is designed to prevent engine from starting in a low-oil or no-oil condition. Oil Sentry™ may not shut down a running engine before damage occurs. In some applications, this switch may activate a warning signal. Read your equipment manuals for more information.

Fuel Recommendations

WARNING
Explosive Fuel can cause fi res and severe burns. If a gaseous odor is detected, ventilate area and contact an authorized service technician. Propane is extremely fl ammable and is heavier than air and tends to settle in low areas where a spark or flame could ignite gas. Do not start or operate this engine in a poorly ventilated area where leaking gas could accumulate and endanger safety of persons in area. To ensure personal safety, installation and repair of propane fuel supply systems mustbe performed only by qualifi ed propane system technicians. Improperly installed and maintained propane equipment could cause fuel supply system or other components to malfunction, causing gas leaks. Observe federal, state and local laws governing propane fuel, storage, and systems. This engine is certifi ed to operate on commercial propane with a minimum propane content of 85% (per GPA STD 2140). If you have any questions, contact your propane supplier. Propane from an appropriate propane fuel tank (supplied separately) is required to operate this engine.

Vaporizer/Regulator
In compliance with government emission standards, a vaporizer/regulator is preset at the factory to provide a proper supply of fuel. No adjustment or resetting of vaporizer/ regulator is to be made. All service relating to the vaporizer/regulator must be performed by a Kohler authorized dealer or qualifi ed propane personnel only. A vaporizer/regulator can change propane from supply tank to a gaseous/vapor state. Lock-Off assembly opens and closes controlling fuel flow from the supply tank before reaching the vaporizer/regulator. Over time, fuel deposits can accumulate inside the vaporizer/regulator. Removing these deposits is recommended. Follow steps below to drain the vaporizer/regulators.

1. Turn the fuel supply valve off , run engine out of fuel, and turn off the ignition switch.
2. Disconnect and ground spark plug leads.
3. Remove drain plug from the bottom of the vaporizer/ regulator. Remove any accumulated deposits.
4. Reinstall the plug and tighten it securely. If required, a replacement plug can be found at KohlerEngines.com.

Fuel Line
High pressure fuel line meeting a minimum of SAE R7 standard must be installed on Kohler Co. engines equipped with propane EFI system (from vaporizer/regulator to injectors).

Spark Plugs

CAUTION
Electrical Shock can cause injury. Do not touch wires while engine is running.

Clean out spark plug recess. Remove plug and replace.

1. Check gap using wire feeler gauge. Adjust gap, see specifi cation table for adjustment.
2. Install plug into cylinder head.
3. Torque plug to 20 ft. lb. (27 N·m)

Jump Starting
Follow all safety guidelines and procedure provided by battery manufacturer and/or original equipment manufacturer (OEM). Failure to follow proper procedures may result in serious personal injury and/or non-warrantable damage to engine’s EFI components.
Electronic Fuel Injection (EFI) System
EFI is an electronically-controlled fuel management system that is monitored by an Electronic Control Unit (ECU). A Malfunction Indicator Light (MIL) will illuminate if problems or faults are detected. Servicing by a Kohler authorized dealer is necessary.
Fuel System Components
Engines are equipped with special EFI fuel fi lters. See Maintenance Schedule.
Fuse Replacement
This engine has three (3) blade type automotive fuses. Replacement fuses must have same rating as blown fuse. Use fuse chart below to determine correct fuse.

10-amp Fuse

2 Purple Wires| 30-amp Fuse

Air Cleaner

NOTE: Operating engine with loose or damaged air cleaner components could cause premature wear and failure. Replace all bent or damaged components.
NOTE: Paper elements cannot be blown out with compressed air.

1. Unhook retaining clips and remove end cap(s).
2. Check and clean inlet screen (if equipped).
3. Pull air cleaner element out of the housing and replace it. Check condition of inner element (if equipped); replace when dirty.
4. Check all parts for wear, cracks, or damage, and that ejector area is clean.
5. Install new element(s).
6. Reinstall end cap(s) with dust ejector valve/ screen down; secure with retaining clips.

Breather Tube
Ensure both ends of breather tube are properly connected.
Oil Cooler (if equipped)

1. Clean fi ns with a brush or compressed air.
2. Remove two screws securing oil cooler, and tilt to clean back side.
3. Reinstall oil cooler.

Air Cooling

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. Proper cooling is essential. To prevent over heating, clean screens, cooling fi ns, and other external surfaces of engine. Avoid spraying water at wiring harness or any electrical components. See Maintenance Schedule.
Repairs/Service Parts
We recommend that you use a Kohler-authorized dealer for all maintenance, service, and engine parts. To find a Kohler authorized dealer visit KohlerEngines.com or call 1-800- 544-2444 (U.S. and Canada).
Storage
If engine will be out of service for 2 months or more follow the procedure below.

1. Change oil while the engine is still warm from operation. Remove spark plug(s) and pour about 1 oz. of engine oil into the cylinder(s). Replace spark plug(s) and crank the engine slowly to distribute oil.
2. Disconnect the negative (-) battery cable.
3. Separate the propane tank from unit and store separately in an area designated for safe propane tank storage.
4. Store the engine in a clean, dry place.

Troubleshooting

Do not attempt to service or replace major engine components, or any items that require special timing or adjustment procedures. This work should be performed by a Kohler-authorized dealer.

Problem

|

No Fuel

|

Tank Nearly Empty

|

Improper Fuel

|

Dirt In                   Broken Fuel Line Fusible Link

| Dirty/ Restricted Vaporizer/ Regulator Inlet Filter|

Dirty Debris Screen

|

Incorrect Oil Level

|

Engine Overloaded

|

Dirty Air Cleaner

|

Faulty Spark Plug

|

Dirty/ Restricted Vaporizer/ Regulator

Will Not Start| ●|  |  | ●| ●| ●| ●| ●| ●| ●| ●| ●
Hard Starting| ●|  | ●| ●|  | ●| ●| ●| ●| ●| ●| ●
Stops Suddenly| ●|  |  | ●|  | ●| ●| ●| ●| ●|  | ●
Lacks Power|  | ●| ●| ●|  | ●| ●| ●| ●| ●| ●| ●
Operates Erratically|  |  | ●| ●|  | ●| ●|  | ●| ●| ●| ●
Knocks or Pings|  |  | ●|  |  | ●| ●|  | ●|  | ●| ●
Skips or Misfires|  |  | ●| ●|  | ●| ●|  |  | ●| ●| ●
Backfires|  |  |  | ●|  | ●|  |  |  | ●| ●| ●
Overheats|  |  | ●| ●|  | ●| ●| ●| ●| ●|  | ●
High Fuel Consumption|  |  |  |  |  |  |  |  |  | ●| ●|
Engine Specifications

Model

|

Bore

|

Stroke

|

Displacement

|

Oil Capacity (Refill)

|

Spark Plug Gap

| Maximum Angle of Operation

**(@ full oil level)***

PCV850| 3.39 in. (86 mm)| 2.79 in. (70.9 mm)| 50.3 cu. in. (824 cc)| 2.7 U.S. qt. (2.6 L)| 0.030 in. (0.76 mm)| 25°
PCV860

Exceeding the maximum angle of operation may cause engine damage from insufficient lubrication. Additional specification information can be found in the service manual at KohlerEngines.com. Any and all horsepower (hp) references by Kohler are Certifi ed Power Ratings and per SAE J1940 & J1995 hp standards. Details on Certified Power Ratings can be found at KohlerEngines.com.

Emission Control System

Exhaust Emission Control System for models PCV850 and PCV860 is EM, O2S, ECM, MPI for U.S. EPA, California, and Europe.
NOTE: Tampering with the engine and its emission control system voids the EPA Certifi cate of Conformity, ARB Executive Order, and EU type-approval.

References

• P65Warnings.ca.gov

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