Kohler ECH680, ECH740, ECH749, ECH730, ECH650 User Manual

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ECH630-ECH749

Horizontal CranksHaft

Owner's Manual

A B

California

Proposition 65 Warning

Engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

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.

WARNING

Hot Parts can cause severe burns.

Do not touch engine while operating or just aer 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 aer it is turned o. Never operate the engine with heat shields or guards removed.

WARNING

Carbon Monoxide can cause severe nausea, fainting or death.

Avoid inhaling exhaust fumes, and never run the engine in a closed building or conned 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 conned area.

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

Explosive Fuel can cause res and severe burns.

Do not ll the fuel tank while the engine is hot or running.

Explosive Fuel!

Gasoline is extremely ammable and its vapors can explode if ignited. Store gasoline only in approved containers, in well ventilated, unoccupied buildings, away from sparks or ames. Do not ll 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.

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

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.

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.

Symbols Associated With This Product

Alert

Read Manual

Oil

STOP

Start

Run

Stop

Slow

Fast

Off

Fuel

Congratulations on your purchase of a Kohler Engine. Every part, every component, every system on a Kohler engine is guided by our exclusive Performance Engineering philosophy:

• To operate on the leading edge of innovation

• To push the boundaries of cleaner, more ecient engines

• To manufacture the highest performing, most reliable engines on the market

You can rest assured that your Kohler Engine will provide maximum power and reliability in all operating conditions. Also, Kohler engines are backed by a worldwide network of over 10,000 distributors and dealers. For more information on Kohler Engines or to nd a Kohler Service Center, visit KohlerEngines.com. To keep your engine in top operating condition, follow the maintenance procedures in this manual.

Oil Recommendations

Fuel 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 Recommended Viscosity Grades table.

Explosive Fuel can cause res and severe burns.

Gasoline is extremely ammable and its vapors can explode if ignited. Store gasoline only in approved containers, in well ventilated, unoccupied buildings, away from sparks or ames. Do not ll 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.

Do not ll the fuel tank while the engine is hot or running.

WARNING

Recommended Viscosity Grades

General Fuel Recommendations

Kohler 10W-30

10W-30

SAE 30

5W-30

°F -20 0 20 32 40 60

°C -30 -20 -10 0 10 20 30 40

50 80 100

Purchase gasoline in small quantities and store in clean, approved containers. Use a container with a capacity of two gallons or less with a pouring spout is recommended, as it is easier to handle and helps eliminate spillage during refueling. To minimize gum deposits in fuel system, do not use gasoline le over from previous season. Do not add oil to the gasoline. Do not overll 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.

Operating Instructions

Also read the instructions of equipment this engine powers.

Check Air Cleaner

See Figure

This engine is equipped with heavy-duty (shown) air cleaner, at style air cleaner, or special air cleaner supplied by the equipment manufacturer.

Check the air cleaner (A) daily or before starting the engine for a buildup of dirt and debris. Keep the area in and around the air cleaner clean. Also check for loose or damaged components. Replace all worn or damaged air cleaner components.

NOTE: Operating engine with loose or damaged air

cleaner components could allow unltered air into engine, causing premature wear and failure.

Check Oil Level

See Figures 1, 2, and

The importance of checking and maintaining the proper oil level in the crankcase cannot be overemphasized.

Check oil BEFORE EACH USE as follows:

1. Make sure the engine is stopped, level, and cool so the oil has had time to drain into the sump.

2. Clean the area around the dipstick (D) to keep dirt and debris out of the engine. See Figure 1.

3. Remove the dipstick (D); wipe o oil.

4. Reinsert the dipstick (D). Push or screw on the dipstick in all the way.

5. Remove dipstick (D) again and check oil level. Oil should be up to, but not over F or FULL mark (B) on dipstick. See Figure 2.

6. If oil level is low, add the correct type of oil up to the F or FULL mark (B) on dipstick. Remove the ll cap (A) or the dipstick (C) to ll the crankcase with new oil of the proper type. Recheck oil level before adding more oil. Always check the oil level with the dipstick before adding more. See Figures 2 and 3.

7. Reinstall the oil ll cap and dipstick securely.

NOTE: To prevent extensive engine wear or damage,

always maintain proper oil level in crankcase. Never operate engine with oil level below the L or LOW mark (C), or over the F or FULL mark (B) on dipstick. See Figure 2.

Pre-Start Checklist

1. Check oil level; if low add oil. Do not overll.

NOTE: Engines are shipped without oil. Do not start

engine with low or no oil. This will cause damage to the engine and will not be covered under warranty.

2. Check fuel level; if low add fuel. Do not overll.

3. Check cooling areas, air intake areas, and external surfaces of engine. Make sure they are clean and unobstructed.

4. Check that the air cleaner components and all shrouds, equipment covers, and guards are in place and securely fastened.

5. Check that any clutches or transmissions are disengaged or placed in neutral. This is especially important on equipment with hydrostatic drive. The shi lever must be in neutral to prevent resistance which could keep the engine from starting.

Starting

Carbon Monoxide can cause severe nausea, fainting or death.

Avoid inhaling exhaust fumes, and never run the engine in a closed building or conned area.

WARNING

Check Cooling Areas

See Figure 1

To ensure proper cooling, make sure the xed guard (G), oil cooler (some models) (H), and other external surfaces of the engine are kept clean at all times.

1. Place the throle control midway between the SLOW and FAST positions.

2. Start the engine by activating the key switch. Release the switch as soon as the engine starts.

NOTE: Do not crank the engine continuously for

more than 10 seconds at a time. If the engine does not start, allow a 60 second cool down period between starting aempts. Failure to follow these guidelines can damage the starter motor.

NOTE: Upon start-up, a metallic ticking may occur.

This is caused by hydraulic lier leakdown during storage. The noise will normally cease in the rst minute. If noise continues, run the engine at mid-throle for 20 minutes. If noise persists, take the engine to your Kohler Engine Service Center.

NOTE: If the starter cranks the engine but does not

start the engine, the engine rotation must be allowed to come to a complete stop before aempting to restart the engine. If the starter is engaged while the ywheel is rotating, the starter pinion and ywheel ring gear may clash, resulting in damage to the starter.

NOTE: Do not operate this engine continuously

at angles exceeding 25° in any direction, because engine damage could result from insucient lubrication.

Cooling

See Figure

WARNING

Hot Parts can cause severe burns.

To ensure proper cooling, make sure the xed guard (G), oil cooler (H) (some models), and other external surfaces of the engine are kept clean at all times.

Do not touch engine while operating or just aer stopping.

If the starter does not turn the engine over, shut o starter immediately. Do not make further aempts to start the engine until the condition is corrected. Do not jump start using another baery. Refer to Battery. See your Kohler Engine Service Center for service assistance.

Stopping

1. Remove the load by disengaging all PTO driven aachments.

2. Move the throle to the slow or idle position; turn key OFF to stop engine.

Battery

A 12 volt baery is used. Refer to the operating instructions of the equipment this engine powers for specic baery requirements.

If the baery charge is not sucient to crank the engine, recharge the baery. Follow the baery manufacturer's instructions.

Operating

NOTE: If debris builds up on the xed guard (G), oil

cooler (H) (some models), or other cooling areas, stop the engine immediately and clean. Operating the engine with blocked or dirty air intake and cooling areas can cause extensive damage due to overheating. Refer to Clean Air Intake/Cooling Areas.

Engine Speed

NOTE: Do not tamper with the governor seing

to increase the maximum engine speed. Overspeed is hazardous and will void the engine warranty. The maximum allowable high idle speed no load for these engines is 4200 RPM.

Oil Sentry™

Some engines are equipped with an optional Oil Sentry™ switch. This switch is designed to prevent the engine from starting in a low oil or no oil condition. The 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.

Angle of Operation

This engine will operate continuously at angles up to 25° in all directions for one minute or less. Oil level must be at F or FULL mark on dipstick.

Refer to the operating instructions of the equipment this engine powers. Due to equipment design or application, there may be more stringent restrictions regarding the angle of operation.

NOTE: Make sure the oil level is checked BEFORE

EACH USE and is maintained up to the F or Full mark on the dipstick. This includes engines equipped with Oil Sentry™.

Maintenance Instructions

WARNING

Accidental Starts can cause severe

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.

Maintenance Schedule

These required maintenance procedures should be performed at the frequency stated in the table below. They should also be included as part of any seasonal tune-up

Frequency Maintenance Required

Daily or

Before Starting Engine

Every 25 Hours Clean or replace precleaner (if equipped) clean as necessary.¹

Every 100 Hours

Weekly or Every

150 Hours

Every 200 Hours

Annually or Every 300 Hours Replace heavy-duty air cleaner element and check inner element.¹

Annually or Every 500 Hours Have starter serviced.²

¹Perform these maintenance procedures more frequently under extremely dusty, dirty conditions. ²Have a Kohler Engine Service Dealer perform this service.

Low-prole air cleaner.

Heavy-duty air cleaner.

injury or death.

Disconnect and ground spark plug lead(s) before servicing.

Check oil level.

Fill fuel tank.

Check air intake and cooling areas; clean as necessary.¹

Check air cleaner for dirty¹, loose, or damaged parts.

Change oil (more frequently under severe conditions).

Replace element¹ (low-prole air cleaner models).

Remove and clean shrouds and cooling areas.¹

Check oil cooler ns, clean as necessary (if equipped).

Check lter minder.

Inspect air lter paper element and inlet screen area.

Replace fuel lter.¹

Change oil lter.

Clean, set gap or replace spark plug, and set gap.

Oil Disposal

Protect and respect the environment. Dispose of oil at your local recycling center or municipal collection center in accordance with local ordinances.

Change Oil

See Figures 1, 2, 3, and

Change oil aer every 100 hours of operation (more frequently under severe conditions). Rell with oil as specied in the Recommended Viscosity Grades table.

Change the oil while the engine is still warm. The oil will ow more freely and carry away more impurities. Make sure the engine is level when lling, checking, or changing the oil.

1. To keep dirt, debris, etc., out of the engine, clean the area around the dipstick (D); remove the dipstick. See Figure 1.

2. Remove the oil drain plug on the starter side (A) or the drain plug oil lter side (B). Allow ample

time for complete drainage. See Figure 4.

3. Reinstall the drain plug (A or B) and torque to

13.6 N·m (10 . lb.). See Figure 4.

4. Remove the ll cap (A) or use the dipstick ll tube (D) to ll the crankcase with new oil of the proper type to the F or FULL mark (B) on the dipstick. Recheck oil level before adding more oil. See Figures 2 and 3.

5. Reinstall the oil ll cap and dipstick securely.

Change Oil Filter

See Figures 1, 2, 3, 4, and Replace the oil lter at least every other oil change (every 200 hours of operation). Always use a genuine

Kohler oil lter. Replace the oil lter as follows:

1. To keep dirt, debris, etc., out of the engine, clean the area around the dipstick (D); remove the dipstick. See Figure 1.

2. Remove the oil drain plug on the starter side (A) or the drain plug oil lter side (B). Allow ample

time for complete drainage. See Figure 4.

3. Reinstall the drain plug (A or B) and torque to

13.6 N·m (10 . lb.). See Figure 4.

Service Oil Cooler (If Equipped)

See Figure

Some engines are equipped with an optional oil cooler. Inspect and clean oil cooler every 100 hours of operation (more frequently under severe conditions). Oil cooler must be kept free of debris. Service the oil cooler as follows:

1. Remove the hardware (B), holding the oil cooler (C) to the blower housing (D).

2. Clean the inside of the cooler with a brush.

3. Reinstall the oil cooler (C) to the blower housing (D) securing with the mounting hardware (B).

Air Cleaner Service

Heavy-Duty Air Cleaner

See Figures 1, 6, and Weekly and every 150 hours: Check lter minder (F)

(if equipped), perform inspection of the paper element (B) and inlet screen (G) area. See Figure 6.

4. To keep dirt, debris, etc., out of the engine, clean the area around the oil lter (A); remove the oil lter. See Figure 5.

5. Wipe the surface where the oil lter mounts.

6. Place a new replacement lter in a shallow pan with the open end up. Pour new oil, of the proper type, in through the threaded center hole. Stop pouring when the oil reaches the boom of the threads. Allow a minute or two for the oil to be absorbed by the lter material.

7. Apply a thin lm of clean oil to the rubber gasket on the new lter.

8. Install the new oil lter to the lter adapter or oil cooler. Refer to instructions on the oil lter for proper installation.

9. Remove the ll cap (A) or use the dipstick ll tube (D) to ll the crankcase with new oil of the proper type to the F or FULL mark (B) on the dipstick. Recheck oil level before adding more oil. (Refer to Check Oil Level.) See Figures 2 and 3.

10. Reinstall the oil ll cap and dipstick securely

11. Test run the engine to check for leaks. Stop the engine, allow a minute for the oil to drain down, and recheck the level on the dipstick. Verify the oil level is up to but not over the F or FULL mark (B) on the dipstick. See Figure 2.

Annually or every 300 hours of operation (more oen under extremely dusty or dirty conditions), replace the paper element and check the inner element. Follow these steps.

Do not wash the paper element and inner element or use compressed air, this will damage the elements.

Replace dirty, bent or damaged elements with new genuine Kohler elements as required. Handle the new elements carefully; do not use if the sealing surfaces are bent or damaged.

1. Unhook the two retaining clips (B) on each end and remove the end caps from the air cleaner

housing (D). See Figures 1 and 6.

2. Check and clean the inlet screen (G) using a brush. See Figure 6.

3. Remove and inspect the air cleaner outer element (B). Replace if it appears dirty or is at the

annually or 300 hour interval. See Figure 6.

4. Remove and inspect the air cleaner inner element (C). Replace if it appears dirty or is at the

600 hour interval. See Figure 6.

5. Clean the area around the base of the inner element before removing it, so dirt does not get

into the engine. See Figure 6.

6. Check all parts for wear, cracks, or damage, and make sure ejector area (B) is clean. Replace any damaged components. See Figure 7.

7. Install elements (B and C) and covers (A and E) in reverse order of removal. See Figure 6.

8. Secure covers with clips (B). See Figure 1.

Low-Prole Air Cleaner

See Figure Every two months or every 25 hours of operation

wash or replace the precleaner (F). Wash precleaner in warm water and detergent. Rinse the precleaner thoroughly and squeeze out excess water (do not wring). Allow precleaner to air dry.

Replace the air cleaner element (G) every 100 hours

or annually. Do not wash the air cleaner inner element or use compressed air, this will damage the elements. Replace dirty, bent or damaged elements

with new genuine Kohler elements as required. Handle the new air cleaner elements carefully; do not use if the sealing surfaces are bent or damaged.

1. Loosen the cover retaining knob (A) and remove cover (B).

2. Remove and inspect the precleaner (F) wash or replace as necessary.

3. Clean area around the air cleaner element (G) to prevent dirt and debris from entering the engine.

4. Remove the element cover wing nut (C) and element cover (D).

5. Remove and inspect the air cleaner element (G) replace as necessary.

6. Check the condition of the rubber seal (E) on the air cleaner stud (I). Replace if the seal is worn, damaged, or questionable.

7. Reinstall the components in reverse order of removal.

Clean Air Intake/Cooling Areas

See Figure

To ensure proper cooling, make sure the xed guard (G), cooling ns, and other external surfaces of the engine are kept clean at all times.

Every 100 hours of operation (more oen under extremely dusty, dirty conditions), remove the blower housing and other cooling shrouds (L). Clean the cooling ns and external surfaces as necessary. Reinstall the blower housing and other cooling shrouds.

NOTE: Operating the engine with a blocked xed

guard, dirty or plugged cooling ns, and/or cooling shrouds removed, will cause engine damage due to overheating.

Ignition

EFI Engines incorporate a computer-controlled baery ignition system with individual coils. Other than periodically checking/replacing the spark plugs, no maintenance, timing, or adjustments are necessary or possible with this system.

Spark Plug

See Figures 1 and

Every 200 hours of operation, remove the spark plugs, check condition, and reset the gap or replace with new plugs as necessary. The standard spark plug is a Champion® RC12YC (Kohler Part No. 12 132 02-S). RFI compliant engines use a Champion® XC12YC (Kohler Part No. 25 132 14-S) spark plug. A high-performance spark plug, Champion® Platinum 3071 (used on Pro Series engines, Kohler Part No. 25 132 12-S) is also available. Equivalent alternate brand plugs can also be used.

1. Before removing the spark plugs (E), clean the area around the base of the plug to keep dirt and debris out of the engine. See Figure 1.

2. Remove the plugs (E) and check its condition. Replace the plugs if worn or reuse is questionable. See Figure 1.

NOTE: Do not clean the spark plug in using abrasive

grit. Some grit could remain in the spark plug and enter the engine, causing extensive wear and damage.

3. Check the gap (D) using a wire feeler gauge (A). Adjust the gap to 0.76 mm (0.030 in.) by carefully

bending the ground electrode (C). See Figure 9.

4. Reinstall the spark plug (E) into the cylinder head. Torque the spark plugs to 24.4-29.8 N·m

(18-22 . lb.). See Figure 1.

Battery Charging

Follow all the baery warnings and safety guidelines and procedures provided by the baery manufacturer and equipment manufacturer.

Jump Starting

Follow all safety guidelines and procedures provided by the baery manufacturer and/or original equipment manufacturer (OEM). Failure to follow proper procedures may result in serious personal injury and/or non-warrantable damage to the engine's Electronic Fuel Injection (EFI) components.

Fuel System

See Figure

WARNING

High Pressure Fluids can puncture skin and cause severe injury or death.

Do not work on fuel system without proper training and safety equipment.

General

The precision components inside the fuel pump module are not serviceable. DO NOT aempt to open the fuel pump module. Damage to the components will result and the warranty will be void. Because the fuel pump module is not serviceable, the engines are equipped with a special 10-micron EFI fuel lter (J) to prevent harmful contamination from entering the module.

If there are two lters in the system, the one before the li pump will be a standard 51-75 micron lter, and the one aer the li pump will be the special 10-micron lter. Be sure to use an approved 10-micron lter for replacement.

Service

Periodically inspect the lter and replace every 200 operating hours or more frequently under extremely

dusty or dirty conditions. Use only a genuine Kohler lter (Kohler Part No. 25 050 42-S) and install it according to the directional arrows. Failure to use the proper lter can result in engine damage and void the warranty.

Fuel Line

These engines use low permeation rated fuel lines, certied to comply with California and U.S. EPA evaporative emission requirements. Fuel lines that do not meet these requirements may not be used. Order replacement hose through a Kohler Service Center.

A high pressure fuel line runs between the high pressure pump and the injectors. This special fuel line, capable of withstanding the high pressure of the EFI fuel system meets SAE R9 specications. If fuel line must be replaced, see your Kohler Engine Service Center.

Electronic Fuel Injection (EFI) System

The EFI system is a complete, electronicallycontrolled, fuel management system, designed to deliver a precisely controlled fuel ow under all operating conditions. The electronic control unit (ECU), the brain of the system, automatically adjusts fuel delivery and ignition timing based upon load, speed, operating temperature, and exhaust emission levels. The low idle speed is the only manual adjustment possible. The ECU continuously monitors operation of the EFI system. If it detects a problem or fault within the system, it will illuminate the Malfunction Indicator Light (MIL) (if so equipped). This is a signal that normal, programmed operation has been aected, and service by an authorized Kohler Engine Service Center is required. In most cases a MIL light may be added to an engine, see Parts Ordering.

Troubleshooting

If the MIL comes on, or the engine becomes hard to start, runs roughly, or stalls at low idle speed, initial checks should be made in the following areas:

• Check that the fuel tank is lled with clean, fresh gasoline, and shut-o valve (if so equipped) is opened completely.

• Check that the fuel tank vent cap is not blocked and it is operating properly (non-California models).

• Check that the air cleaner element and precleaner are clean and all components are properly secured. Clean or replace as necessary.

• Check that the proper fuel lter is being used, and it is clean and unobstructed. Replace lter(s) only with genuine Kohler parts.

• Check that all connections to sensors, ECU, and fuel injectors are properly secured.

• Check that there is 12 volt baery is being used and is fully charged.

• Check that fuses are not burned out. If so then replace.

If these checks do not correct the problem, or the MIL remains on, further diagnosis and servicing by an authorized Kohler Engine Center is necessary.

Adjustment – Throttle Body

See Figure Low Idle Speed (RPM) is the only adjustment that

can be made. All other fuel calibrations are controlled by the ECU. The standard low idle speed is 1500 RPM (± 75 RPM).

NOTE: The actual low idle speed depends on

When an EFI engine is started cold, the ECU will briey set a higher (200-400 RPM) low idle speed, similar to a fast idle. Do not aempt to perform any readjustment during this warm-up period.

If adjustment is to be made, the engine must be at operating temperature, air cleaner in place, and check engine light must be o (no fault codes present).

1. Start the engine and run at half throle for 5 to 10 minutes to warm up.

the application -- refer to equipment manufacturer's recommendations.

2. Place the throle control into the idle or slow position.

3. Turn the low idle speed adjusting screw (A) in or out and check RPM with a tachometer.

3. Remove the fuse cover (B) and pull out fuse. See Figure 11.

Fuse Replacement

See Figure 11 and

This engine has three (3) blade type automotive fuses. Replacement fuses must have the same rating as the

4. Inspect the fuse for a solid fusible link (A) or a broken fusible link (B). Replace the fuse if the fusible link is broken (B). If you are not sure if the fusible link is broken, replace the fuse. See Figure

12.

blown fuse. Use the fuse chart below to determine the correct fuse. See Figure 14.

5. Insert the fuse into the fuse holder (A) until it is seated properly. Install the fuse cover (B). See Figure 11.

Wire Color Fuse Rating

2 Purple Wires 30-amp Fuse

1 Red Wire with Black Stripe 1 Red Wire with White Stripe

10-amp Fuse

2 Red Wires 10-amp Fuse

Figure 14. Fuse Rating Chart.

To replace a fuse:

1. Shut engine o and remove key.

2. Locate the fuse holders (A). See Figure 11.

Additional Electrical Information

The yellow accessory wire on the original Kohler Engine key switch can not draw more than 2-amps. A relay may be used in order to use a higher drawing accessory. Contact a Kohler Engines application specialist for further instructions. A current draw of more than 2-amps will cause damage to the ECU, Fuel Pump Module, or other electrical system components and will void the warranty.

Troubleshooting

When troubles occur, be sure to check the simple causes which, at rst, may seem too obvious to be considered. For example, a starting problem could be caused by an empty fuel tank. Some common causes of engine troubles are listed in the following table.

Do not aempt to service or replace major engine components, or any items that require special timing or adjustment procedures. Have your Kohler Engine Service Center do this work.

Possible Cause

Problem

Will Not Start

Hard Starting

Stops Suddenly

Lacks Power

Operates Erratically

Knocks or Pings

Skips or Misres

Backres

Overheats

High Fuel Consumption

Fuel

Improper Fuel

Blocked Fuel Line/ System

Low Battery Voltage

Broken Fusible Link

Dirty Fixed Guard

Incorrect Oil Level

Engine Overloaded

Dirty Air Cleaner

Faulty Spark Plug

Storage

See Figure

If the engine will be out of service for two months or more, follow these storage procedures:

1. Clean the exterior surfaces of the engine. Avoid spraying water at the wiring harness or any of the electrical components.

2. Change the oil and lter while the engine is still warm from operation. Refer to Change Oil and

Filter.

3. The fuel system must be completely emptied, or the gasoline must be treated with a fuel stabilizer to prevent deterioration. If you choose to use a fuel stabilizer, follow the manufacturers recommendations, and add the correct amount for the capacity of the fuel system.

4. Fill the fuel tank with clean, fresh gasoline. Run the engine for 2-3 minutes to get stabilized fuel into the fuel system. Close fuel shut o valve (if equipped) when unit is being stored or transported. To empty the system, run the engine until the tank and fuel system are empty.

5. Remove the spark plugs. Add one tablespoon of engine oil into each spark plug hole. Install plugs, but do not connect the plug leads. Crank the engine two or three revolutions.

6. Disconnect the negative (-) baery cable or use a Baery Minder trickle charger while the unit is in

storage.

7. Store the engine in a clean, dry place.

Repairs

Repair information is available in Kohler Engine service manuals which are available at KohlerEngines.com, or at Kohler Service Centers. Major repairs generally require the services of a trained mechanic and the use of specialized tools and equipment. Kohler Service Centers have the facilities, training, and genuine Kohler replacement parts necessary to perform these services.

For the nearest sales and service location, visit our Web site at KohlerEngines.com, or in the U.S. and Canada call 1-800-544-2444.

Parts Ordering

The engine model, specication, and serial numbers are required when ordering replacement parts from your Kohler Service Center. These numbers are found on the identication plate which is axed to the engine shrouding. Include leer suxes if there are any. Refer to Engine Identication Numbers.

Always insist on genuine Kohler replacement parts, as they adhere to strict standards for t, reliability, and performance. Visit KohlerEngines.com or your Kohler Service Center.

Engine Identication

Engine Identication Numbers

See Figure

Engine identication numbers will appear on the engine data tag (M). See Figure 1.

When ordering parts, or in any communication concerning this engine, always give the model name, specication number, and serial number — including any leer suxes.

Emission Compliance

The Emission Compliance Period referred to on the Emission Control or Air Index label indicates the number of operating hours for which the engine has been shown to meet Federal and CARB emission requirements. The following table provides the Engine Compliance Period (in hours) associated with the category descriptor which may be found on the certication label.

Emission Compliance Period

EPA Category A:1000 hours

CARB Extended:500 hour

Refer to certication label for engine displacement. Exhaust Emission Control System for models ECH630, ECH650, ECH680, ECH730, ECH740, ECH749 is EM, O2S, ECM, MPI for U.S. EPA, California, and Europe.

Specications Model: ECH630 ECH650 ECH680 ECH730 ECH740 ECH749

Bore:

Stroke:

Displacement:

*Gross Power (@ 3600 RPM):

Net Power (@ 3600 RPM):

Peak Torque (Minimum):

mm (in.)

(in.3)

(HP)

N·m

(ft. lb.)

694

(42.4)

14.1

(19)*

13.8**

(18.6)**

42.8**

(31.6)**

(3.2)

(2.72)

694

(42.4)

15.7

(21)*

14.6**

(19.6)**

44.3**

(32.7)**

694

(42.4)

17.2

(23)*

15.4**

(20.7)**

46.8**

(34.5)**

747

(45.6)

18.6

(25)*

16.2

(21.7)

49.1

(36.2)

(3.3)

(2.72)

747

(45.6)

20.1

(27)*

17.4

(23.3)

50.7

(37.4)

747

(45.6)

21.6

(29)*

17.9

(24.0)

50.8

(37.5)

Compression Ratio: 8.8:1 9.1:1

Weight:

Oil Capacity:

(lbs.)

(U.S. qt.)

1.9 (2)

(102)

1.9 (2)

Exhaust Emission Control System: EM, O2S, ECM, MPI for U.S. EPA, California, and Europe

*Horsepower ratings exceed Society of Automotive Engineers Small Engine Test Code J1940. Actual engine horsepower is lower and aected by, but not limited to, accessories (air cleaner, exhaust, charging, cooling, fuel pump, etc.), application, engine speed and ambient operating conditions (temperature, humidity, and altitude). Kohler reserves the right to change product specications, designs, and equipment without notice and without incurring obligation

**Based on preliminary information.

LIMITED 3 YEAR COMMAND ENGINE WARRANTY

Kohler Co. warrants to the original consumer that each new COMMAND engine sold by Kohler Co. will be free from manufacturing defects in materials or workmanship in normal service for a period of three (3) years from date of purchase, provided it is operated and maintained in accordance with Kohler Co.’s instructions and manuals.

Our obligation under this warranty is expressly limited, at our option, to the replacement or repair at Kohler Co., Kohler, Wisconsin 53044, or at a service facility designated by us of such parts as inspection shall disclose to have been defective.

EXCLUSIONS: Muers on engines used commercially (non-residential) are warranted for one (1) year from date of purchase, except catalytic muers, which are warranted for three (3) years.

This warranty does not apply to defects caused by casualty or unreasonable use, including faulty repairs by others and failure to provide reasonable and necessary maintenance.

The following items are not covered by this warranty:

Engine accessories such as fuel tanks, clutches, transmissions, power-drive assemblies, and baeries, unless supplied or installed by Kohler Co. These are subject to the warranties, if any, of their manufacturers.

KOHLER CO. AND/OR THE SELLER SHALL NOT BE LIABLE FOR SPECIAL, INDIRECT, INCIDENTAL, OR CONSEQUENTIAL DAMAGES OF ANY KIND, including but not limited to labor costs or transportation charges in connection with the repair or replacement of defective parts.

IMPLIED OR STATUTORY WARRANTIES, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE EXPRESSLY LIMITED TO THE DURATION OF THIS WRITTEN WARRANTY. We make no other express warranty, nor is any one authorized to make any on our behalf.

Some states do not allow limitations on how long an implied warranty lasts, or the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you.

This warranty gives you specic legal rights, and you may also have other rights, which vary from state to state.

TO OBTAIN WARRANTY SERVICE:

Purchaser must bring the engine to an authorized Kohler service facility. To locate the nearest facility, visit our website, www.KohlerEngines.com, and click on SERVICE and DEALER LOCATOR to use the locator function, consult your Yellow Pages or telephone 1-800-544-2444.

ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044

KOHLER CO.

FEDERAL AND CALIFORNIA EMISSION CONTROL SYSTEMS

LIMITED WARRANTY

SMALL OFF-ROAD AND CLASS 1 LSI ENGINES

The U.S. Environmental Protection Agency (EPA), the California Air Resources Board (CARB), and Kohler Co. are pleased to explain the 2011 and later Federal and California Emission Control Systems Warranty on your o-road equipment engine. “Emissions“ means both exhaust and evaporative emissions. For California, small o-road engines, and Class 1 LSI (Large Spark Ignited engines at or below 1.0 liter) must be designed, built and equipped to meet the state’s stringent anti-smog standards. In other states, engines must be designed, built and equipped, to meet the U.S. EPA regulations for small non-road engines. The engine must be free from defects in materials and workmanship which cause it to fail to conform with U.S. EPA standards for the rst three years of engine use from the date of sale to the ultimate purchaser. Kohler Co. must warrant the emission control system on the engine for the period of time listed above, provided there has been no abuse, neglect or improper maintenance.

The emission control system may include parts such as the carburetor or fuel injection system, the ignition system, and catalytic converter. Also included are the hoses, belts and connectors and other emission related assemblies.

Where a warrantable condition exists, Kohler Co. will repair the engine at no cost, including diagnosis (if the diagnostic work is performed at an authorized dealer), parts and labor.

MANUFACTURER’S WARRANTY COVERAGE

Small o-road engines and Class 1 LSI engines are warranted for three years in California and other states. If any emission related part on the engine is defective, the part will be repaired or replaced by Kohler Co. free of charge.

OWNER’S WARRANTY RESPONSIBILITIES

(a) The engine owner is responsible for the performance of the required maintenance listed in the owner’s manual. Kohler Co.

recommends that you retain all receipts covering maintenance on the engine, but Kohler Co. cannot deny warranty solely for the lack of receipts or for your failure to assure that all scheduled maintenance was performed.

(b) Be aware, however, that Kohler Co. may deny warranty coverage if the engine or a part has failed due to abuse, neglect, improper

maintenance or unapproved modications.

(c) For warranty repairs, the engine must be presented to a Kohler Co. service center as soon as a problem exists. Call 1-800-544-2444

or access our web site at: www.kohlerengines.com, for the names of the nearest service centers. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.

If you have any questions regarding warranty rights and responsibilities, you should contact Kohler Co. at 1-920-457-4441 and ask for an Engine Service representative.

COVERAGE

Kohler Co. warrants to the ultimate purchaser and each subsequent purchaser that the engine will be designed, built and equipped, at the time of sale, to meet all applicable regulations. Kohler Co. also warrants to the initial purchaser and each subsequent purchaser, that the engine is free from defects in materials and workmanship which cause the engine to fail to conform with applicable regulations for a period of three years.

Small o-road engines and Class 1 LSI engines are warranted for three years in California. EPA requires manufacturers to warrant engines for three years in all other states. These warranty periods will begin on the date the engine is purchased by the initial purchaser. If any emission related part on the engine is defective, the part will be replaced by Kohler Co. at no cost to the owner. Kohler Co. is liable for damages to other engine components caused by the failure of a warranted part still under warranty.

Kohler Co. shall remedy warranty defects at any authorized Kohler Co. engine dealer or warranty station. Warranty repair work done at an authorized dealer or warranty station shall be free of charge to the owner if such work determines that a warranted part is defective.

Continued on next page.

Listed below are the parts covered by the Federal and California Emission Control Systems Warranty. Some parts listed below may require scheduled maintenance and are warranted up to the rst scheduled replacement point for that part. The warranted parts include the following if they were present in the engine purchased:

• Oxygen sensor (if equipped) • Ignition module(s) with high tension lead

• Intake manifold (if equipped) • Gaseous fuel regulator (if equipped)

• Exhaust manifold (if equipped) • Electronic control unit (if equipped)

• Catalytic muer (if equipped) • Carburetor or fuel injection system

• Thermal reactor muer (if equipped) • Fuel metering valve (if equipped)

• Fuel lines, fuel line ings and clamps (if equipped) • Air lter, fuel lter, and spark plugs (only

• Spark advance module (if equipped) to rst scheduled replacement point)

• Crankcase breather • Evaporative System (if equipped)

• Air Injection System (if equipped) - Canister (if equipped)

- Air pump or pulse valve assembly (if equipped) - Canister lter (if equipped)

- Control/distribution valve (if equipped) - Vapor hose (if equipped)

- Distribution manifold (if equipped) - Orice connector (if equipped)

- Air hoses (if equipped) - Fuel tank (if equipped)

- Vacuum lines (if equipped) - Fuel cap (if equipped)

- Primer bulb canister (if equipped)

LIMITATIONS

This Emission Control Systems Warranty shall not cover any of the following: (a) repair or replacement required because of misuse or neglect, improper maintenance, repairs improperly performed or replacements

not conforming to Kohler Co. specications that adversely aect performance and/or durability and alterations or modications not recommended or approved in writing by Kohler Co.,

(b) replacement of parts and other services and adjustments necessary for required maintenance at and aer the rst scheduled

replacement point,

(d) diagnosis and inspection fees that do not result in eligible warranty service being performed, and

(e) any add-on or modied part, or malfunction of authorized parts due to the use of add-on or modied parts.

MAINTENANCE AND REPAIR REQUIREMENTS

The owner is responsible for the proper use and maintenance of the engine. Kohler Co. recommends that all receipts and records covering the performance of regular maintenance be retained in case questions arise. If the engine is resold during the warranty period, the maintenance records should be transferred to each subsequent owner. Kohler Co. reserves the right to deny warranty coverage if the engine has not been properly maintained; however, Kohler Co. may not deny warranty repairs solely because of the lack of repair maintenance or failure to keep maintenance records.

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. Any replacement part or service that is equivalent in performance and durability may be used in non-warranty maintenance or repairs, and shall not reduce the warranty obligations of the engine manufacturer.

FORM NO.: 24 590 16 Rev. A

ISSUED: 10/10

REVISED: 11/10

FOR SALES AND SERVICE INFORMATION IN U.S. AND CANADA, CALL 1-800-544-2444

KohlerEngines.com

ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044

Kohler ECH680, ECH740, ECH749, ECH730, ECH650 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual