KOHLER COMMand PRO EFI Model ECH740 27HP Engine Full Service & Repair Manual

SERVICE MANUAL ECH630-ECH749 HORIZONTAL CRANKSHAFT

Contents Section 1. Safety and General Information ............................................................................. Section 2. Tools & Aids ............................................................................................................. Section 3. Troubleshooting ...................................................................................................... Section 4. Air Cleaner and Air Intake System ......................................................................... Section 5. Electronic Fuel Injection (EFI) System .................................................................. Section 6. Lubrication System ................................................................................................. Section 7. Electrical System and Components ...................................................................... Section 8. Disassembly............................................................................................................. Section 9. Inspection and Reconditioning .............................................................................. Section 10. Reassembly............................................................................................................ 2 1 4 5 3 9 10 6 7 8

1.1 1 Section 1 Safety and General Information Safety Precautions To ensure safe operation please read the following statements and understand their meaning. Also refer to your equipment manufacturer's manual for other important safety information. This manual contains safety precautions which are explained below. Please read carefully. WARNING Warning is used to indicate the presence of a hazard that can cause severe personal injury, death, or substantial property damage if the warning is ignored. CAUTION Caution is used to indicate the presence of a hazard that will or can cause minor personal injury or property damage if the caution is ignored. NOTE Note is used to notify people of installation, operation, or maintenance information that is important but not hazard-related. For Your Safety! These precautions should be followed at all times. Failure to follow these precautions could result in injury to yourself and others. WARNING Accidental Starts can cause severe injury or death. Disconnect and ground spark plug lead(s) before servicing. Accidental Starts! Disabling engine. Accidental starting can cause severe injury or death. Before working on the engine or equipment, disable the engine as follows: 1) Disconnect the spark plug lead(s). 2) Disconnect negative (–) baery cable from baery. WARNING Rotating Parts can cause severe injury. Stay away while engine is in operation. Rotating Parts! Keep hands, feet, hair, and clothing away from all moving parts to prevent injury. Never operate the engine with covers, shrouds, or guards removed. WARNING Hot Parts can cause severe burns. Do not touch engine while operating or just aﬅer stopping. Hot Parts! Engine components can get extremely hot from operation. To prevent severe burns, do not touch these areas while the engine is running, or immediately aﬅer it is turned off. Never operate the engine with heat shields or guards removed. WARNING Explosive Fuel can cause fires and severe burns. Do not fill the fuel tank while the engine is hot or running. Explosive Fuel! 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. Do not fill the fuel tank while the engine is hot or running, since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition. Do not start the engine near spilled fuel. Never use gasoline as a cleaning agent.

1.2 Section 1 Safety and General Information Identification Decal Engine Identification Numbers When ordering parts, or in any communication involving an engine, always give the Model, Specification and Serial Numbers, including leer suffixes if there are any. The engine identification numbers appear on a decal, or decals, affixed to the engine shrouding. See Figure 1-1. An explanation of these numbers is shown in Figure 1-2. WARNING Carbon Monoxide can cause severe nausea, fainting or death. Avoid inhaling exhaust fumes, and never run the engine in a closed building or confined area. Lethal Exhaust Gases! Engine exhaust gases contain poisonous carbon monoxide. Carbon monoxide is odorless, colorless, and can cause death if inhaled. Avoid inhaling exhaust fumes, and never run the engine in a closed building or confined area. CAUTION Electrical Shock can cause injury. Do not touch wires while engine is running. Electrical Shock! Never touch electrical wires or components while the engine is running. They can be sources of electrical shock. WARNING Cleaning Solvents can cause severe injury or death. Use only in well ventilated areas away from ignition sources. Flammable Solvents! Carburetor cleaners and solvents are extremely flammable. Keep sparks, flames, and other sources of ignition away from the area. Follow the cleaner manufacturer’s warnings and instructions on its proper and safe use. Never use gasoline as a cleaning agent. Figure 1-1. Engine Identification Decal Location. 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. High Pressure Fluid Puncture! Fuel system is to be serviced only by properly trained personnel wearing protective safety equipment. Fluid puncture injuries are highly toxic and hazardous. If an injury occurs, seek immediate medical aention. WARNING Explosive Fuel can cause fires and severe burns. Fuel systems ALWAYS remains under HIGH PRESSURE. Fuel Fire and Burns! Wrap a shop towel completely around the fuel pump module connector. Press the release buon(s) and slowly pull the connector away from the fuel pump module allowing the shop towel to absorb any residual fuel in the high pressure fuel line. Any spilled fuel must be completely wiped up immediately. Identification Decal

1.3 Section 1 Safety and General Information 1 Figure 1-2. Explanation of Engine Identiﬁcation Numbers. Oil Recommendations Using the proper type and weight of oil in the crankcase is extremely important. So is checking oil daily and changing oil regularly. Failure to use the correct oil, or using dirty oil, causes premature engine wear and failure. Oil Type Use high-quality detergent oil of API (American Petroleum Institute) Service Class SJ or higher. Select the viscosity based on the air temperature at the time of operation as shown in the following table. °F -20 0 20 32 40 60 50 80 100 °C -30 -20 -10 0 10 20 30 40 5W-30 10W-30 Kohler 10W-30 SAE 30 Model No. Electronic Fuel Injection (EFI) Command Engine Numerical Designation 630 650 680 730 740 749 Spec. No. ECH630-XXXX ECH650-XXXX ECH680-XXXX ECH730-XXXX ECH740-XXXX ECH749-XXXX Year Manufactured Code Code Year 39 2009 40 2010 41 2011 Factory Code 39 05810334 E C H 749 Horizontal Crankshaft A. B. C. Serial No.

1.4 Section 1 Safety and General Information NOTE: Using other than service class SJ or higher oil or extending oil change intervals longer than recommended can cause engine damage. NOTE: Synthetic oils meeting the listed classifications may be used with oil changes performed at the recommended intervals. However, to allow piston rings to properly seat, a new or rebuilt engine should be operated for at least 50 hours using standard petroleum based oil before switching to synthetic oil. A logo or symbol on oil containers identifies the API service class and SAE viscosity grade. See Figure 1-3. Figure 1-3. Oil Container Logo. Refer to Section 6 - Lubrication System for detailed procedures on checking the oil, changing the oil and changing the oil filter. Fuel Recommendations WARNING Explosive Fuel can cause fires and severe burns. Do not fill the fuel tank while the engine is hot or running. Explosive Fuel! 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. Do not fill the fuel tank while the engine is hot or running, since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition. Do not start the engine near spilled fuel. Never use gasoline as a cleaning agent. General Recommendations Purchase gasoline in small quantities and store in clean, approved containers. A container with a capacity of 2 gallons or less with a pouring spout is recommended. Such a container is easier to handle and helps eliminate spillage during refueling. Do not use gasoline leﬅ over from the previous season, to minimize gum deposits in your fuel system and to ensure easy starting. Do not add oil to the gasoline. Do not overfill the fuel tank. Leave room for the fuel to expand. Fuel Type For best results use only clean, fresh, unleaded gasoline with a pump sticker octane rating of 87 (R+M)/2 or higher. In countries using the Research Octane Number (RON), it should be 90 octane minimum. Leaded gasoline is not recommended and must not be used on EFI engines or on other models where exhaust emissions are regulated. Gasoline/Alcohol Blends Gasohol (up to 10% ethyl alcohol, 90% unleaded gasoline by volume) is approved as a fuel for Kohler engines. Other gasoline/alcohol blends including E20 and E85 are not to be used and not approved. Any failures resulting from use of these fuels will not be warranted. Gasoline/Ether Blends Methyl Tertiary Butyl Ether (MTBE) and unleaded gasoline blends (up to a maximum of 15% MTBE by volume) are approved as a fuel for Kohler engines. Other gasoline/ether blends are not approved. Periodic Maintenance Instructions Maintenance Schedule 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 service center. WARNING Accidental Starts can cause severe injury or death. Disconnect and ground spark plug lead(s) before servicing. Accidental Starts! Disabling engine. Accidental starting can cause severe injury or death. Before working on the engine or equipment, disable the engine as follows: 1) Disconnect the spark plug lead(s). 2) Disconnect negative (–) baery cable from baery.

1.5 Section 1 Safety and General Information 1 Storage If the engine will be out of service for two months or more, use the following storage procedure: 1. Clean the exterior surfaces of the engine. On EFI engines, avoid spraying water at the wiring harness or any of the electrical components. 2. Change the oil and oil filter while the engine is still warm from operation. See Change Oil and Oil Filter in Section 6. 3. The fuel system must be completely emptied, or the gasoline must be treated with a stabilizer to prevent deterioration. If you choose to use a stabilizer, follow the manufacturer’s recommendations, and add the correct amount for the capacity of the fuel system. Fill the fuel tank with clean, fresh gasoline. ¹Perform these maintenance procedures more frequently under extremely dusty, dirty conditions. ²Have a Kohler Engine Service Dealer perform this service. 3 Low-profile air cleaner. 4 Heavy-duty air cleaner. Run the engine for 2 to 3 minutes to get stabilized fuel into the rest of the system. Close the fuel shut-off valve when the unit is being stored or transported. To empty the system, run the engine until the tank and the system are empty. 4. Remove the spark plugs and add one tablespoon of engine oil into each spark plug hole. Install the spark plugs, but do not connect the plug leads. Crank the engine two or three revolutions. 5. Disconnect the negative (-) baery cable or use a baery minder trickle charger while the unit is in storage. 6. Store the engine in a clean, dry place. Daily or Before Starting Engine Maintenance Required Frequency • Check oil level. Section 6 • Fill fuel tank. Section 5 • Check air cleaner for dirty 1 , loose, or damaged parts. Section 4 • Check air intake and cooling areas, clean as necessary. 1 Section 4 • Replace element 1 (low-profile air cleaner models). Section 4 • Remove and clean shrouds and cooling areas. 1 Section 4 • Change oil. (More frequently under severe conditions). Section 6 • Check oil cooler fins, clean as necessary (if equipped). Section 6 • Replace fuel filter 1 . Section 5 • Clean, set gap or replace spark plug, and set gap. Section 7 • Change oil filter. Section 6 Annually or Every 500 Hours • Have starter serviced. 2 Section 7 Every 100 Hours Every 200 Hours Every 300 Hours • Replace heavy-duty air cleaner element and check inner element. 1 Section 4 Refer to: Weekly or Every 150 Hours • Check filter minder. 4 Section 4 • Inspect air filter paper element and inlet screen area. 4 Section 4 Every 25 Hours • Clean or replace precleaner (if equipped) clean as necessary. 1,3 Section 4

1.6 Section 1 Safety and General Information Figure 1-4. Typical Engine Dimensions with Heavy-Duty Air Cleaner. Dimensions in millimeters. Inch equivalents shown in [ ]. 424.29 (16.704) 304.72 (11.997) 277.30 (10.917) 135.00 (5.315) Air Filter Rain Cap Removal 88.20 (3.473) 130.00 (5.118) Air Filter Cover Assembly Removal 230.20 (9.063) Safety Air Filter Element Removal 342.52 (13.485) Primary Air Filter Element Removal 19.22 (0.757) Spark Plug 15.70 (0.618) 142.89 (5.626) 92.10 (3.626) 184.20 (7.252) 17.53 (0.690) Spark Plug Mounting Hole “A” Engine LIFT STRAP 2X OIL DRAIN PLUG 3/8 NPT (IN.) 89.00 (3.504) MOUNTING HOLE “A” 432.61 (17.032) 471.44 (18.560) 210.40 (8.284) 52.40 (20.063) OIL FILL LOCATION OIL DIPSTICK 622.63 (24.513) 1/4 IN. SQ. KEYWAY 85.50 (3.366) 28.56 Ø(1.125) 7/16-20 UNF 2B (IN.) 38.10 (1.500) 155.58 (6.125) 152.08 (5.987) OIL FILTER 97.38 (3.834) 52.75 (2.077) OIL FILTER 104.00 (4.094) 89.00 (3.504) ENGINE MOUNTING SURFACE 301.59 (11.874) SOLENOID SHIFT STARTER 45˚ 45˚ ENGINE MOUNTING SURFACE 7/16-14 UNC 2B (IN.) 21.0 (0.827) Ø196.85 (7.75) B.C. 3/8-16 UNC 2B (IN.) 17.0 (0.669) Ø142.88 (5.625) B.C. 30˚ OIL FILL LOCATION LIFT STRAP 51.20 (2.016) 286.49 (11.279) 30˚ 30˚ 30˚

KOHLER COMMand PRO EFI Model ECH740 27HP Engine Full Service & Repair Manual

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