Kohler KT610 Manual de usuario

132 690 03 Rev. H KohlerEngines.com

Service Manual

2 Safety

3 Maintenance

5 Speciﬁcations

12 Tools and Aids

15 Troubleshooting

19 Air Cleaner/Intake

21 Fuel System

40 Governor System

41 Lubrication System

43 Electrical System

50 Starter System

54 Emission Compliant Systems

57 Disassembly/Inspection and Service

70 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.

KT610-KT620, KT715-KT745

Safety

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.

KohlerEngines.com 32 690 03 Rev. H

Maintenance

32 690 03 Rev. H 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 Hours¹

●Service/replace precleaner. Air Cleaner/Intake

●Replace air cleaner element (if not equipped with precleaner). Air Cleaner/Intake

Every 100 Hours¹

●Replace air cleaner element (if equipped with precleaner). Air Cleaner/Intake

●Change oil and ﬁlter. Lubrication System

●Remove cooling shrouds and clean cooling areas. Air Cleaner/Intake

Every 100 Hours

●Check that all fasteners are in place and components are properly secured. Reassembly

●Replace fuel ﬁlter.

Every 500 Hours²

●Have valve lash checked/adjusted. Reassembly

Every 500 Hours

●Replace spark plugs and set gap. Electrical System

¹ Perform these procedures more frequently under severe, dusty, dirty conditions.

² Have a Kohler authorized dealer perform this service.

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

KohlerEngines.com 32 690 03 Rev. H

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.

°F -20 020324060

50 80 100

°C -30 -20 -10 0 10 20 30 40

5W-30

10W-30

SAE 30

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

32 690 03 Rev. H KohlerEngines.com

Dimensions in millimeters.

Inch equivalents shown in [ ].

Engine Dimensions

37.00

[1.46]

4X Ø 9.005 ± 0.035

[.355 ± .0014]

254.00 B.C.

[10.000]

Speciﬁcations

KohlerEngines.com 32 690 03 Rev. H

GENERAL SPECIFICATIONS3,6

KT610

KT620 KT715 KT725 KT730 KT735 KT740 KT745

Bore 83 mm (3.27 in.)

Stroke 61 mm

(2.4 in.) 67 mm (2.64 in.) 69 mm

(2.72 in.)

Displacement 660 cc

(40.3 cu. in.) 725 cc (44 cu. in.) 747 cc

(46 cu. in.)

Oil Capacity (reﬁll) 1.9 l (2.0 qt.)

Maximum Angle of Operation (@ full oil level)425°

TORQUE SPECIFICATIONS3,5

KT610

KT620 KT715 KT725 KT730 KT735 KT740 KT745

Auto Choke

eChoke™

Stepper Motor to Bracket Fastener

Air Cleaner Base to Mounting Studs

3.1 N·m (27.4 in. lb.)

6.2-7.3 N·m (55-65 in. lb.)

Smart-Choke™

Air Vane Deﬂector to Intake Manifold

Air Cleaner Base to Mounting Studs

Bracket Assembly Screw

1 N·m (9 in. lb.)

6.2-7.3 N·m (55-65 in. lb.)

5 N·m (45 in. lb.)

Bafﬂe and Sheet Metal into Aluminum

M5 Thread Forming Fasteners 8.5 N·m (75 in. lb.) into new hole

4.0 N·m (35 in. lb.) into used hole

M6 Thread Forming Fasteners 10.7 N·m (95 in. lb.) into new hole

7.3 N·m (65 in. lb.) into used hole

Blower Housing and Sheet Metal

M3 HI-LO Screw 2.3 N·m (20 in. lb.)

M4 HI-LO Screw 2.8 N·m (25 in. lb.)

M5 Fasteners 6.2 N·m (55 in. lb.) into new hole

4.0 N·m (35 in. lb.) into used hole

M6 Fasteners 10.7 N·m (95 in. lb.) into new hole

7.3 N·m (65 in. lb.) into used hole

ENGINE IDENTIFICATION NUMBERS

Kohler engine identiﬁcation numbers (model, speciﬁcation and serial) should be referenced for efﬁcient repair,

ordering correct parts, and engine replacement.

Model. . . . . . . . . . . . . . . . . . . . . KT715

7000 Series Engine

Numerical Designation

Speciﬁcation . . . . . . . . . . . . . . . KT715-0001

Serial . . . . . . . . . . . . . . . . . . . . . 4323500328

Year Manufactured Code Factory Code

Code Year

43 2013

44 2014

45 2015

3 Values are in Metric units. Values in parentheses are English equivalents.

4Exceeding maximum angle of operation may cause engine damage from insufﬁcient lubrication.

5Lubricate threads with engine oil prior to assembly.

6Any 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.

Speciﬁcations

32 690 03 Rev. H KohlerEngines.com

TORQUE SPECIFICATIONS3,5

KT610

KT620 KT715 KT725 KT730 KT735 KT740 KT745

Carburetor

Mounting Nut 6.2-7.3 N·m (55-65 in. lb.)

Connecting Rod

Cap Fastener (torque in increments)

Black Coating

Gray Metallic Coating

11.3 N·m (100 in. lb.)

13.6 N·m (120 in. lb.)

Crankcase

Breather Assembly

Outer Cover Stud

Outer Cover Hex Nut

6.2 N·m (55 in. lb.) into new hole

4.0 N·m (35 in. lb.) into used hole

1.3 N·m (11.5 in. lb.)

Oil Drain Plug 13.6 N·m (10 ft. lb.)

Cylinder Head

Head Bolt Fastener (torque in 2 increments) ﬁrst to 22.6 N·m (200 in. lb.)

ﬁnally to 41.8 N·m (370 in. lb.)

Rocker Arm Stud 11.3 N·m (100 in. lb.)

Flywheel

Retaining Screw 74.5 N·m (55 ft. lb.)

Fuel Pump

Screw 2.8 N·m (25 in. lb.)

Governor

Lever Nut 6.8 N·m (60 in. lb.)

Ignition

Spark Plug 27 N·m (20 ft. lb.)

Module Fastener 4.0-6.2 N·m (35-55 in. lb.)

Rectiﬁer-Regulator Fastener 4.0 N·m (35 in. lb.)

Intake Manifold

Mounting Fastener (torque in 2 increments) ﬁrst to 7.4 N·m (66 in. lb.)

ﬁnally to 9.9 N·m (88 in. lb.)

Mufﬂer

M8 Hex Nuts 24.4 N·m (216 in. lb.)

5/16-18 Capscrew 16.9 N·m (150 in. lb.)

Bracket Screw 9.9 N·m (88 in. lb.)

Oil Pan

Fastener 24.4 N·m (216 in. lb.)

Oil Pump

Screw (no torque sequence) 9.9 N·m (88 in. lb.)

Oil Sentry™

Pressure Switch 4.5 N·m (40 in. lb.)

3 Values are in Metric units. Values in parentheses are English equivalents.

5Lubricate threads with engine oil prior to assembly.

Speciﬁcations

KohlerEngines.com 32 690 03 Rev. H

TORQUE SPECIFICATIONS3,5

KT610

KT620 KT715 KT725 KT730 KT735 KT740 KT745

Solenoid (Starter)

Mounting Hardware 4.0-6.0 N·m (35-53 in. lb.)

Nut, Positive (+) Brush Lead 8.0-11.0 N·m (71-97 in. lb.)

Speed Control Bracket

Fastener 10.7 N·m (95 in. lb.) into new holes

7.3 N·m (65 in. lb.) into used holes

Starter Assembly

Thru Bolt

Inertia Drive

Solenoid Shift

4.5-5.7 N·m (40-50 in. lb.)

5.6-9.0 N·m (49-79 in. lb.)

Mounting Screw 23.8 N·m (211 in. lb.)

Brush Holder Mounting Screw 2.5-3.3 N·m (22-29 in. lb.)

Stator

Mounting Screw 8.8 N·m (78 in. lb.)

Valve Cover

Fastener 9.6 N·m (85 in. lb.)

CLEARANCE SPECIFICATIONS3

KT610

KT620 KT715 KT725 KT730 KT735 KT740 KT745

Camshaft

End Play 0.06/0.40 mm (0.0024/0.0157 in.)

Running Clearance 0.040/0.077 mm (0.0016/0.0030 in.)

Bore I.D.

New

Max. Wear Limit

20.000/20.025 mm (0.7874/0.7884 in.)

20.038 mm (0.7889 in.)

Bearing Surface O.D.

New

Max. Wear Limit

19.948/19.960 mm (0.7854/0.7858 in.)

19.945 mm (0.7852 in.)

Connecting Rod

Connecting Rod-to-Crankpin Running Clearance

New

Max. Wear Limit

0.037/0.083 mm (0.0015/0.0033 in.)

0.098 mm (0.0039 in.)

Connecting Rod-to-Crankpin Side Clearance 0.261/0.67 mm (0.0102/0.0264 in.)

Connecting Rod-to-Piston Pin Running Clearance 0.013/0.032 mm (0.0005/0.0013 in.)

Piston Pin End I.D.

New

Max. Wear Limit

17.013/17.027 mm (0.6698/0.6704 in.)

17.040 mm (0.6709 in.)

Crankcase

Governor Cross Shaft Bore I.D.

New

Max. Wear Limit

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.

5Lubricate threads with engine oil prior to assembly.

Speciﬁcations

32 690 03 Rev. H KohlerEngines.com

CLEARANCE SPECIFICATIONS3

KT610

KT620 KT715 KT725 KT730 KT735 KT740 KT745

Crankshaft

End Play (free) 0.075/0.595 mm (0.0030/0.023 in.)

Bore (in crankcase)

New

Max. Wear Limit

40.974/40.987 mm (1.6131/1.6137 in.)

41.000 mm (1.6142 in.)

Bore (in oil pan)

New 40.974/41.000 mm (1.6457/1.6142 in.)

Crankshaft Bore (in oil pan)-to-Crankshaft

Running Clearance

New 0.039/0.087 mm (0.0015/0.0034 in.)

Flywheel End Main Bearing Journal

O.D. - New

O.D. - Max. Wear Limit

Max. Taper

Max. Out-of-Round

40.913/40.935 mm (1.6107/1.6116 in.)

40.840 mm (1.608 in.)

0.022 mm (0.0009 in.)

0.025 mm (0.0010 in.)

Oil Pan End Main Bearing Journal

O.D. - New

O.D. - Max. Wear Limit

Max. Taper

Max. Out-of-Round

40.913/40.935 mm (1.6107/1.6116 in.)

40.840 mm (1.608 in.)

0.022 mm (0.0009 in.)

0.025 mm (0.0010 in.)

Connecting Rod Journal

O.D. - New

O.D. - Max. Wear Limit

Max. Taper

Max. Out-of-Round

35.950/35.974 mm (1.4154/1.4163 in.)

35.950 mm (1.4154 in.)

0.018 mm (0.0007 in.)

0.025 mm (0.0010 in.)

T.I.R.

PTO End, Crank in Engine

Entire Crank, in V-Blocks

0.279 mm (0.0110 in.)

0.200 mm (0.0079 in.)

Cylinder Bore

Bore I.D.

New

Max. Wear Limit

Max. Out-of-Round

Max. Taper

83.006/83.031 mm (3.2679/3.2689 in.)

83.069 mm (3.2704 in.)

0.120 mm (0.0047 in.)

0.050 mm (0.0020 in.)

Cylinder Head

Max. Out-of-Flatness 0.076 mm (0.003 in.)

Governor

7 mm Hex End Cross Shaft End Play 0.25/3.15 mm (0.010/0.124 in.)

Governor Cross Shaft-to-Crankcase Running

Clearance 0.025/0.126 mm (0.0009/0.0049 in.)

Cross Shaft O.D.

New

Max. Wear Limit

7.949/8.000 mm (0.3129/0.3149 in.)

7.936 mm (0.3124 in.)

Governor Gear Shaft-to-Governor Running

Clearance

0.050/0.210 mm (0.0020/0.0083 in.)

Gear Shaft O.D.

New

Max. Wear Limit

5.990/6.000 mm (0.2358/0.2362 in.)

5.977 mm (0.2353 in.)

3 Values are in Metric units. Values in parentheses are English equivalents.

Speciﬁcations

KohlerEngines.com 32 690 03 Rev. H

3 Values are in Metric units. Values in parentheses are English equivalents.

7 Measure 6 mm (0.2362 in.) above bottom of piston skirt at right angles to piston pin.

CLEARANCE SPECIFICATIONS3

KT610

KT620 KT715 KT725 KT730 KT735 KT740 KT745

Ignition

Spark Plug Gap 0.76 mm (0.030 in.)

Module Air Gap 0.203/0.305 mm (0.008/0.012 in.)

Piston, Piston Rings, and Piston Pin

Piston-to-Piston Pin Running Clearance 0.006/0.017 mm (0.0002/0.0007 in.)

Pin Bore I.D.

New

Max. Wear Limit

17.006/17.012 mm (0.6695/0.6698 in.)

17.025 mm (0.6703 in.)

Pin O.D.

New

Max. Wear Limit

16.995/17.000 mm (0.6691/0.6693 in.)

16.994 mm (0.6691 in.)

Top Compression Ring-to-Groove Side Clearance 0.030/0.070 mm (0.001/0.0026 in.)

Middle Compression Ring-to-Groove Side

Clearance

0.030/0.070 mm (0.001/0.0026 in.)

Oil Control Ring-to-Groove Side Clearance 0.060/0.190 mm (0.0022/0.0073 in.)

Top Compression Ring End Gap

New Bore

Used Bore (Max.)

Middle Compression Ring End Gap

New Bore

Used Bore (Max.)

0.189/0.277 mm (0.0074/0.0109 in.)

0.531 mm (0.0209 in.)

1.519/1.797 mm (0.0598/0.0708 in.)

2.051 mm (0.0808 in.)

Thrust Face O.D.7

New

Max. Wear Limit

82.978 mm (3.2668 in.)

82.833 mm (3.2611 in.)

Piston Thrust Face-to-Cylinder Bore7Running

Clearance

New

0.019/0.062 mm (0.0007/0.0024 in.)

Valves and Valve Tappets

Clearance 0.101/0.152 mm (0.0040/0.0060 in.)

Valve Tappet to Crankcase Running Clearance 0.013/0.073 mm (0.0005/0.0029 in.)

Intake Valve Stem-to-Valve Guide Running

Clearance

0.040/0.0780 mm (0.0016/0.0031 in.)

Exhaust Valve Stem-to-Valve Guide Running

Clearance

0.052/0.090 mm (0.0020/0.0035 in.)

Intake Valve Guide I.D.

New

Max. Wear Limit

7.040/7.060 mm (0.2772/0.2780 in.)

7.140 mm (0.2811 in.)

Exhaust Valve Guide I.D.

New

Max. Wear Limit

7.040/7.060 mm (0.2772/0.2780 in.)

7.160 mm (0.2819 in.)

Valve Guide Reamer Size

Standard

0.25 mm O.S.

7.050 mm (0.2776 in.)

7.300 mm (0.2874 in.)

Intake Valve Minimum Lift 8.500 mm (0.3346 in.)

Exhaust Valve Minimum Lift 8.500 mm (0.3346 in.)

Nominal Valve Face Angle 45°

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