Kohler ECV630, ECV680, ECV749, ECV730, ECV740 User Manual

ECV630-ECV749

VErtiCal Crankshaft

Owner's Manual

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.

Safety Precautions

To ensure safe operation please read the following statements and understand their meaning. Also refer
to your equipment owner'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.

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.

2

Safety Precautions (Continued)

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

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.

WARNING

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

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.

Accidental Starts can cause
severe injury or death.

Disconnect and ground spark plug
leads 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.

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.

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.

3

Air Cleaner

Serial and
Data Label

Oil Fill Cap/
Dipstick

Oil
Cooler

Spark
Plug

Fuel Filter
(Special EFI)

Oil
Filter

Oil Drain
Plug

Fuel
Pump
Module

Figure 1. Control and Service Point Locations.

Electronic
Control
Unit
(ECU)

Fuses
(Early
Location)

Oil
Drain
Plug

Fixed
Guard

Spark
Plug

Retaining
Clips

Retaining
Clips

Engine Identication Numbers

When ordering parts, or in any communication
involving an engine, always give the Model,
Specication, and Serial Numbers of the engine.

The engine identication numbers appear on a decal
(or decals) axed to the engine shrouding. Include

leer suxes, if there are any.

Emission Compliance Period

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.

Refer to certication label for engine displacement.
Exhaust Emission Control System for models ECV630,
ECV650, ECV680, ECV730, ECV740, ECV749 is EM,
O2S, ECM, MPI for U.S. EPA, California, and Europe.

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 Recommended
Viscosity Grades table.

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

EPA Category A:1000 hours

CARB Extended:500 hours

4

Figure 2. Recommended Viscosity Grades Table.

Refer to Maintenance Instructions for detailed oil
check, oil change, and oil lter change procedures.

Fuel Recommendations

Pre-Start Checklist

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

WARNING

Explosive Fuel can cause res
and severe burns.

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

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.

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 le 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 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.

NOTE: Engines are shipped without oil. Do not start

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

2. Check fuel level. Add fuel if low.

3. Check cooling 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 exactly in neutral to
prevent resistance which could keep the engine
from starting.

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.

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.

Starting

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.

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 operating instructions of the equipment this
engine powers.

a. Turn the key switch to the ON position for

one minute. Allow the fuel pump to cycle
and prime the system. Turn the key switch
OFF.

b. Turn the key switch to the START position,

crank and start engine.

c. If the engine fails to start, repeat steps a

and b. If the engine does not start aer
two priming intervals, contact your Kohler
Engine Service Center for further assistance.

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.

5

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.

this engine powers. Because of equipment design or
application, there may be more stringent restrictions
regarding the angle of operation.

NOTE: Do not operate this engine continuously

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

WARNING

Hot Parts can cause severe burns.

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 Baery).
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

Cooling

NOTE: If debris builds up on the xed guard 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 for these engines is 4200 RPM,
no load.

Maintenance Instructions

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.

Angle of Operation

This engine will operate continuously at angles up to
25°. Check oil level to assure crankcase oil level is at
the F mark on the dipstick.

Refer to the operating instructions of the equipment

6