KOHLER COMMand PRO EFI Model ECV740 27HP Engine Workshop Manual

ECV630-ECV749, CV735, CV26, CV745 Service Manual 24 690 02 Rev. L KohlerEngines.com 1 2 Safety 3 Maintenance 5 Speciﬁcations 22 Tools and Aids 25 Troubleshooting 29 Air Cleaner/Intake 30 Electronic Fuel Injection (EFI) System-ECV 59 Electronic Fuel Injection (EFI) System-Bosch 89 Governor System 97 Lubrication System 99 Electrical System 104 Starter System 108 Disassembly/Inspection and Service 128 Reassembly 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.

Safety 2 24 690 02 Rev. L 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. 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 24 690 02 Rev. L 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 25 Hours or Annually¹ ● Service/replace low-profile precleaner (if equipped). Air Cleaner/Intake Every 100 Hours or Annually¹ ● Change oil. Lubrication System ● Replace low-profile air cleaner element. Air Cleaner/Intake ● Remove and clean shrouds and cooling areas. Air Cleaner/Intake ● Check oil cooler fins, clean as necessary (if equipped). Lubrication System Every 150 Hours ● Check heavy-duty filter minder. Air Cleaner/Intake ● Inspect heavy-duty air filter paper element and inlet screen area. Air Cleaner/Intake Every 200 Hours¹ ● Replace unique Electronic Fuel Injection (EFI) fuel filter. Every 200 Hours ● Change oil filter. Lubrication System Every 300 Hours¹ ● Replace heavy-duty air cleaner element and check inner element. Air Cleaner/Intake Every 500 Hours or Annually¹ ● Replace spark plugs and set gap. Electrical System Every 600 Hours¹ ● Replace heavy-duty air cleaner inner element. Air Cleaner/Intake 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 24 690 02 Rev. L 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. 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 24 690 02 Rev. L KohlerEngines.com Engine Dimensions with Heavy-Duty Air Cleaner-Flywheel Side F E G H I K L N O M P Q R S T A B D C J U V X W A K L M R A Valve Cover B 413.28 mm (16.271 in.) C 529.81 mm (20.859 in.) Element Removal D 417.49 mm (16.437 in.) Inner Element Removal E 130.0 mm (5.118 in.) F 268.16 mm (10.557 in.) G 296.44 mm (11.671 in.) H 94.34 mm (3.714 in.) I 135.0 mm (5.315 in.) J 24.28 mm (0.955 in.) Fuse Cover K 253.53 mm (9.981 in.) Spark Plug Removal L 250.23 mm (9.852 in.) Spark Plug Boot Removal M 20° N 72.63 mm (2.859 in.) Spark Plug Removal O 57.17 mm (2.251 in.) Spark Plug Boot Removal P 29.69 mm (1.169 in.) Spark Plug Boot Q Oil Fill Tube and Dipstick R Engine Center Line S Mounting Hole "A" T 137.09 mm (5.397 in.) U 15.70 mm (0.618 in.) Oil Filter Removal V 30.06 mm (1.183 in.) Spark Plug Boot W 57.54 mm (2.265 in.) Spark Plug Boot Removal X 73.0 mm (2.874 in.) Spark Plug Removal

Speciﬁcations 6 24 690 02 Rev. L KohlerEngines.com Engine Dimensions with Heavy-Duty Air Cleaner-Oil Filter Side A B C D E F G H I J K L M N O P R Q A 405.92 mm (15.981 in.) B 247.92 mm (9.761 in.) C Pulse Fuel Pump D Oil Cooler E Rectiﬁer-Regulator F 51.25 mm (2.018 in.) Oil Filter G 12.99 mm (0.511 in.) H Center Line Mounting Hole "A" I 25.80 mm (1.016 in.) J 80.26 mm (3.160 in.) Oil Filter K 7/16-20 UNF 2B in. 38.10 mm (1.5 in.) Deep L 24.865 mm ±0.100 (0.980 in. ±0.004) M Ø 28.653 mm ±0.0125 (1.125 in. ±0.0005) N 1/4 in. Square Keyway O 85.50 mm (3.366 in.) P Engine Mounting Surface Q 134.04 mm (5.277 in.) Spark Plug Center Line R 445.29 mm (17.531 in.)

Speciﬁcations 7 24 690 02 Rev. L KohlerEngines.com Engine Dimensions with Heavy-Duty Air Cleaner-PTO Side B A C E F D G H I J L K M N P O C H P A 334.7 mm (13.176 in.) B 125.09 mm (4.925 in.) Evap Hose Fitting C 15° D 152.48 mm (6.003in.) E 104.03 mm (1.096 in.) F 50.00 mm (1.969 in.) Exhaust Port #2 G 89.80 mm (3.536 in.) H 45° I 2 X 89.80 mm (3.536 in.) J 4 X Ø 9.06 mm (0.356 in.) Through Ø 254.0 mm (10.0 in.) B.C. K Solenoid Shift Starter L 242.29 mm (9.54 in.) M 50.0 mm (1.97 in.) Exhaust Port #1 Mounting Holes N 48.45 mm (1.91 in.) O M8 X 1.25 mm (0.05 in.) P 35° Q 2 X 89.80 mm (3.54 in.) R 2 X 77.53 mm (3.05 in.) Q R

Speciﬁcations 8 24 690 02 Rev. L KohlerEngines.com Engine Dimensions with Heavy-Duty Air Cleaner-Starter Side A B C D E G F H A 154.04 mm (6.065 in.) Center Line Spark Plug B 92.04 mm (3.624 in.) Exhaust Port #1 C 72.04 mm (2.836 in.) Exhaust Port #2 D 13.0 mm (0.512 in,) E Oil Drain Plug 3/8 N.P.T. F 40.80 mm (1.606 in.) G 316.75 mm (12.47 in.) H 372.01 mm (14.646 in.)

Speciﬁcations 9 24 690 02 Rev. L KohlerEngines.com Engine Dimensions with Low-Proﬁle Air Cleaner-Flywheel Side F E G H I K L N O M P Q R S T A B D C J U V X W Y J C A 413.03 mm (16.261 in.) B 296.82 mm (11.769 in.) C Valve Cover D 79.45 mm (2.892 in.) Spark Plug Removal E 64.93 mm (2.556 in.) Spark Plug Boot Removal F 37.02 mm (1.458 in.) Spark Plug Boot G 248.11 mm (9.768 in.) Spark Plug Boot Removal H 253.44 mm (9.978 in.) Spark Plug Removal I Oil Fill and Dipstick Tube J 20° K Engine Center Line L Mounting Hole "A" M 134.09 mm (5.279 in.) N 15.70 mm (0.618 in.) Oil Filter Removal O 45.19 mm (1.779 in.) P Crankshaft Center Line Q Fuel Filter R 248.41 mm (9.780 in.) Spark Plug Boot Removal S 253.43 mm (9.977 in.) Spark Plug Removal T 407.35 mm (16.037 in.) U 41.91 mm (1.650 in.) Spark Plug Boot V 12.14 mm (0.478 in.) W 60.08 mm (2.365 in.) Air Cleaner Cover Removal X 65.04 mm (2.561 in.) Spark Plug Boot Removal Y 73.38 mm (2.889 in.) Spark Plug Removal

Specifications 10 24 690 02 Rev. L KohlerEngines.com Engine Dimensions with Low-Profile Air Cleaner-Oil Filter Side A B C D E F G H I J K L M N O P A Oil Cooler B Regulator/Rectifier C 133.13 mm (5.241 in.) Spark Plug Center Line D 96.93 mm (3.816 in.) E 51.50 mm (2.028 in.) Oil Filter F 13.24 mm (0.521 in.) G Engine Mounting Surface H Mounting Hole "A" Center Line I Oil Drain Plug 3/8 N.P.T. J 89.80 mm (3.536 in.) K 25.80 mm (1.016 in.) L Ø 28.56 mm (1.125 in.) M 7/16-20 UNF 2B in. 38.10 mm (1.5 in.) Deep N 6.33 X 3.31 mm (0.25 X 0.13 in.) Keyway O 85.50 mm (3.366 in.) Keyway P Fuel Filter Removed for Clarity

KOHLER COMMand PRO EFI Model ECV740 27HP Engine Workshop Manual

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