Kohler CH26 Engine Full Service Repair Manual

ECH630-ECH749, CH735, CH26, CH745 Service Manual KohlerEngines.com 1 24 690 01 Rev. D 2 Safety 3 Maintenance 5 Speciﬁcations 15 Tools and Aids 18 Troubleshooting 22 Air Cleaner/Intake 23 Electronic Fuel Injection (EFI) System-ECH 48 Electronic Fuel Injection (EFI) System-Bosch 81 Lubrication System 83 Electrical System 88 Starter System 92 Disassembly/Inspection and Service 107 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. Downloaded from www.Manualslib.com manuals search engine

Safety 2 24 690 01 Rev. D 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. Downloaded from www.Manualslib.com manuals search engine

Maintenance 3 24 690 01 Rev. D 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 ● Replace spark plugs and set gap. Electrical System Every 300 Hours¹ ● Replace heavy-duty air cleaner element and check inner element. Air Cleaner/Intake 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). Downloaded from www.Manualslib.com manuals search engine

Maintenance 4 24 690 01 Rev. D 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. Downloaded from www.Manualslib.com manuals search engine

Speciﬁcations 5 24 690 01 Rev. D KohlerEngines.com 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˚ Engine Dimensions with Heavy-Duty Air Cleaner Downloaded from www.Manualslib.com manuals search engine

Speciﬁcations 6 24 690 01 Rev. D KohlerEngines.com FUEL PUMP 370.05 (14.569) 30.00 (1.181) SPARK PLUG 3.05 (0.120) OIL FILL OIL FILL 1/4 IN. SQ. KEYWAY 101.38 (3.992) 8550 (3.366) KEYWAY 7/16-20 UNF 28 IN. 38.10 (1.500) 155.58 (6.125) 152.08 (5.987) OIL FILTER ENGINE MOUNTING SURFACE MOUNTING SURFACE 4.00 (0.157) PILOT 52.75 (2.077) OIL FILTER 100.00 (3.937) 51.00 (2.008) 89.00 (3.504) 12.19 (0.480) RECTIFIER REGULATOR OIL DRAIN PLUG 3/8 IN. NPT MOUNTING HOLE “A” PILOT 177.800 (7.000) OPTIONAL PILOT 146.050 (5.750) ENGINE MTG SURFACE SOLENOID SHIFT STARTER MOUNTING HOLE “A” M8 X 1.25 20.5 DEEP 2 HOLES MUFFLER MTG BOSSES 308.17 (12.133) M8 X 1.25 4 STUDS 283.58 (11.164) 50.00 (1.969) EXHAUST PORT #1 50.00 (1.969) EXHAUST PORT #2 LIFT STRAP 75.35 (2.966) 65.00 (2.559) 122.10 (4.807) 173.68 (6.838) 30˚ 334.78 (13.180) 50.00 (1.969) SPARK PLUG 32.00 (1.260) EXHAUST PORT #2 12.00 (0.472) EXHAUST PORT #1 OIL DIPSTICK 432.61 (17.032) ENGINE MOUNTING SURFACE 67.50 (2.657) MUFFLER MOUNTING BOSSES 51.00 (2.008) 89.00 (3.504) OIL DRAIN PLUG 3/8 IN. NPT 12.19 (0.480) 426.44 (16.789) 302.63 (11.915) 12.15 (0.478) 60.00 (2.362) AIR CLEANER COVER REMOVAL 17.07 (0.672) SPARK PLUG FUEL FILTER CRANKSHAFT 15.70 (0.618) OIL FILTER REMOVAL 142.89 (5.626) 92.10 (3.626) 184.20 (7.252) MOUNTING HOLES ENGINE MOUNTING HOLE “A” 463.36 (18.242) 17.53 (0.690) SPARK PLUG Engine Dimensions with Low-Proﬁle Air Cleaner Dimensions in millimeters. Inch equivalents shown in [ ]. Downloaded from www.Manualslib.com manuals search engine

Specifications 7 24 690 01 Rev. D KohlerEngines.com ENGINE IDENTIFICATION NUMBERS Kohler engine identification numbers (model, specification and serial) should be referenced for efficient repair, ordering correct parts, and engine replacement. Model ..................... ECH630 EFI Command Engine Horizontal Shaft Numerical Designation Specification ............... ECH630-3001 Serial ..................... 3923500328 Year Manufactured Code Factory Code Code Year 39 2009 40 2010 41 2011 GENERAL SPECIFICATIONS 3,6 ECH630-ECH680 ECH730-ECH749 CH26 CH735 CH745 Bore 80 mm (3.15 in.) 83 mm (3.27 in.) 83 mm (3.27 in.) Stroke 69 mm (2.72 in.) 67 mm (2.64 in.) Displacement 694 cc (42.4 cu. in.) 747 cc (45.6 cu. in.) 725 cc (44 cu. in.) Oil Capacity (refill) 1.9 L (2.0 U.S. qt.) Maximum Angle of Operation (@ full oil level) 4 25° TORQUE SPECIFICATIONS 3,5 ECH630-ECH680 ECH730-ECH749 CH26 CH735 CH745 Blower Housing Into cored aluminum hole or weld nut M5 M6 Into extruded hole in sheet metal M5 M6 6.2 N·m (55 in. lb.) into new holes 4.0 N·m (35 in. lb.) into used holes 10.7 N·m (95 in. lb.) into new holes 7.3 N·m (65 in. lb.) into used holes 2.8 N·m (25 in. lb.) into new holes 2.3 N·m (20 in. lb.) into used holes 2.8 N·m (25 in. lb.) into new holes 2.3 N·m (20 in. lb.) into used holes 6.2 N·m (55 in. lb.) into new holes 4.0 N·m (35 in. lb.) into used holes 10.7 N·m (95 in. lb.) into new holes 7.3 N·m (65 in. lb.) into used holes Closure Plate Fastener 25.6 N·m (227 in. lb.) 24.4 N·m (216 in. lb.) Connecting Rod Cap Fastener (torque in increments) 8 mm straight shank 8 mm step-down 6 mm straight shank 11.6 N·m (103 in. lb.) 22.7 N·m (200 in. lb.) 14.7 N·m (130 in. lb.) 11.3 N·m (100 in. lb.) 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. Downloaded from www.Manualslib.com manuals search engine

Specifications 8 24 690 01 Rev. D KohlerEngines.com TORQUE SPECIFICATIONS 3,5 ECH630-ECH680 ECH730-ECH749 CH26 CH735 CH745 Crankcase Breather Cover Fastener 11.3 N·m (100 in. lb.) into new holes 7.3 N·m (65 in. lb.) into used holes 7.3 N·m (65 in. lb.) Oil Temperature Sensor (into breather cover) 7.3 N·m (65 in. lb.) Oil Sentry TM (into breather cover) 4.5 N·m (40 in. lb.) Oil Drain Plug 13.6 N·m (10 ft . lb.) Cylinder Head Hex Flange Nut (torque in 2 increments) Head Bolt (torque in 2 increments) first to 16.9 N·m (150 in. lb.) finally to 33.9 N·m (300 in. lb.) first to 22.6 N·m (200 in. lb.) finally to 41.8 N·m (370 in. lb.) Rocker Arm Screw 11.9 N·m (105 in. lb.) 11.3 N·m (100 in. lb.) Fan/Flywheel Fan Fastener 9.9 N·m (88 in. lb.) Flywheel Retaining Screw 71.6 N·m (52.8 ft . lb.) 66.4 N·m (49 ft. lb.) Metal Debris Screen Fastener (to flywheel) 9.9 N·m (88 in. lb.) Plastic Debris Screen Fastener (to fan) 4.0 N·m (35 in. lb.) Fuel Pump Module Baffle Fastener 11.9 N·m (105 in. lb.) Module Fastener 9.2 N·m (81 in. lb.) Pulse Pump Bracket Fastener 2.1 N·m (25 in. lb.) Pulse Pump Fastener to Bracket 7.3 N·m (68 in. lb.) into new holes 6.2 N·m (55 in. lb.) into used holes Governor Lever Nut 7.1 N·m (63 in. lb.) 6.8 N·m (60 in. lb.) Speed Control Assembly Assembled to Cylinder Heads Assembled to Blower Housing 10.7 N·m (95 in. lb.) 2.8 N·m (25 in. lb.) Ignition Spark Plug 27 N·m (20 ft. lb.) Coil Fastener 10.2 N·m (90 in. lb.) Ignition Module Fastener Torque 4.0-6.2 N·m (35-55 in. lb.) Crankshaft Position Sensor Screw 6.2 N·m (55 in. lb.) Crankshaft Position Sensor Bracket Screw 7.3 N·m (65 in. lb.) Electronic Control Unit Screw 6.2 N·m (55 in. lb.) Blower Housing Rectifier-Regulator Ground Strap Fastener 2.8 N·m (25 in. lb.) into new holes 2.3 N·m (20 in. lb.) into used holes Rectifier-Regulator Fastener 1.4 N·m (12.6 in. lb.) 3 Values are in Metric units. Values in parentheses are English equivalents. 5 Lubricate threads with engine oil prior to assembly. Downloaded from www.Manualslib.com manuals search engine

Specifications 9 24 690 01 Rev. D KohlerEngines.com TORQUE SPECIFICATIONS 3,5 ECH630-ECH680 ECH730-ECH749 CH26 CH735 CH745 Intake Manifold Fastener (torque in 2 increments) first to 7.8 N·m (69 in. lb.) finally to 10.5 N·m (93 in. lb.) first to 7.4 N·m (66 in. lb.) finally to 9.9 N·m (88 in. lb.) Manifold Absolute Pressure (MAP) Sensor Fastener 7.3 N·m (65 in. lb.) Fuel Injector Cap 7.3 N·m (65 in. lb.) Air Cleaner to Throttle Body Fastener Nut 8.2 N·m (73 in. lb.) Heavy-Duty Air Cleaner Mounting Bracket Fastener 5.8 N·m (51 in. lb.) Fuel Injector Cap Fastener 7.3 N·m (65 in. lb.) Muffler Retaining Nut 27.8 N·m (246 in. lb.) 24.4 N·m (216 in. lb.) Oxygen Sensor 50.1 N·m (37 ft . lb.) Oil Cooler Oil Cooler/Adapter Nipple 28.5 N·m (21 ft . lb.) 27 N·m (20 ft. lb.) Fastener Into Blower Housing Between Oil Cooler Hoses 2.8 N·m (25 in. lb.) 2.3 N·m (20 in. lb.) Speed Control Bracket Fastener (assembled to cylinder heads) 10.7 N·m (95 in. lb.) into new holes 7.3 N·m (65 in. lb.) into used holes Fastener (assembled to blower housing) 2.8 N·m (25 in. lb.) into new holes 2.3 N·m (20 in. lb.) into used holes Fastener Torque 10.7 N·m (95 in. lb.) into new holes 7.3 N·m (65 in. lb.) into used holes Starter Assembly Thru Bolt Nippondenso (Solenoid Shift) Delco-Remy (Solenoid Shift) 5.6-9.0 N·m (49-79 in. lb.) 4.5-7.5 N·m (40-84 in. lb.) 5.6-9.0 N·m (49-79 in. lb.) Screw 16.0 N·m (142 in. lb.) 15.3 N·m (135 in. lb.) Brush Holder Mounting Screw Delco-Remy Starter 2.5-3.3 N·m (22-29 in. lb.) 2.5-3.3 N·m (22-29 in. lb.) Starter Solenoid Mounting Hardware Nippondenso Starter Delco-Remy Starter 4.0-6.0 N·m (35-53 in. lb.) 6.0-9.0 N·m (53-79 in. lb.) 4.0-6.0 N·m (35-53 in. lb.) Nut, Positive (+) Brush Lead Nippondenso Starter Delco-Remy Starter 8.0-11.0 N·m (71-97 in. lb.) 8.0-12.0 N·m (71-106 in. lb.) 8.0-11.0 N·m (71-97 in. lb.) Stator Screw 6.2 N·m (55 in. lb.) into new holes 4.0 N·m (35 in. lb.) into used holes 6.2 N·m (55 in. lb.) 3 Values are in Metric units. Values in parentheses are English equivalents. 5 Lubricate threads with engine oil prior to assembly. Downloaded from www.Manualslib.com manuals search engine

Speciﬁcations 10 24 690 01 Rev. D KohlerEngines.com TORQUE SPECIFICATIONS 3,5 ECH630-ECH680 ECH730-ECH749 CH26 CH735 CH745 Valve Cover Fastener Gasket Style Cover Black O-Ring Style Cover w/Shoulder Screws w/Flange Screws and Spacers Yellow or Brown O-Ring Style Cover w/Integral Metal Spacers 6.2 N·m (55 in. lb.) 3.4 N·m (30 in. lb.) 5.6 N·m (50 in. lb.) 9.9 N·m (88 in. lb.) 6.2 N·m (55 in. lb.) CLEARANCE SPECIFICATIONS 3 ECH630-ECH680 ECH730-ECH749 CH26 CH735 CH745 Camshaft End Play (with shim) 0.101/0.406 mm (0.0040/0.0160 in.) 0.076/0.127 mm (0.0030/0.0050 in.) Running Clearance 0.025/0.105 mm (0.001/0.004 in.) 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.) 20.000/20.025 mm (0.7874/0.7884 in.) 20.038 mm (0.7889 in.) Bearing Surface O.D. New Max. Wear Limit 19.920/19.975 mm (0.7843/0.7864 in.) 19.914 mm (0.7840 in.) 19.962/19.975 mm (0.7859/0.7864 in.) 19.959 mm (0.7858 in.) Connecting Rod Connecting Rod-to-Crankpin Running Clearance @ 21°C (70°F) New Max. Wear Limit 0.043/0.073 mm (0.0017/0.0029 in.) 0.088 mm (0.0035 in.) 0.030/0.055 mm (0.0012/0.0022 in.) 0.070 mm (0.0028 in.) Connecting Rod-to-Crankpin Side Clearance 0.26/0.63 mm (0.0102/0.0248 in.) 0.26/0.63 mm (0.0102/0.0248 in.) Connecting Rod-to-Piston Pin Running Clearance @ 21°C (70°F) 0.015/0.028 mm (0.0006/0.0011 in.) 0.015/0.028 mm (0.0006/0.0011 in.) Piston Pin End I.D. @ 21°C (70°F) New Max. Wear Limit 17.015/17.023 mm (0.6699/0.6702 in.) 17.036 mm (0.6707 in.) 17.015/17.023 mm (0.6699/0.6702 in.) 17.036 mm (0.6707 in.) Crankcase Governor Cross Shaft Bore I.D. New Max. Wear Limit 6 mm Shaft New Max. Wear Limit 8 mm Shaft New Max. Wear Limit 8.025/8.075 mm (0.3159/0.3179 in.) 8.088 mm (0.3184 in.) 6.025/6.050 mm (0.2372/0.2382 in.) 6.063 mm (0.2387 in.) 8.025/8.075 mm (0.3159/0.3179 in.) 8.088 mm (0.3184 in.) 3 Values are in Metric units. Values in parentheses are English equivalents. 5 Lubricate threads with engine oil prior to assembly. 5 Lubricate threads with engine oil prior to assembly. Downloaded from www.Manualslib.com manuals search engine

Kohler CH26 Engine Full Service Repair Manual

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