Kohler Aegis 05810334 Manual de usuario

KOHLER®AEGIS™17,20,23 HP

SERVICE MANUAL

LIQUID-COOLED

VERTICAL CRANKSHAFT

Contents

Section 1. Safety and General Information ............................................................................

Section 2. Special Tools ..........................................................................................................

Section 3. Troubleshooting .....................................................................................................

Section 4. Air Cleaner and Air Intake System ........................................................................

Section 5. Fuel System and Governor....................................................................................

Section 6. Lubrication System ................................................................................................

Section 7. Cooling System ......................................................................................................

Section 8. Electrical System and Components .....................................................................

Section 9. Disassembly ...........................................................................................................

Section 10. Inspection and Reconditioning ...........................................................................

Section 11. Reassembly...........................................................................................................

1.1

Section 1

Safety and General Information

Section 1

Safety and General Information

Safety Precautions

To insure safe operations 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.

For Your Safety!

These precautions should be followed at all times. Failure to follow these precautions could result in

injury to yourself and others.

LV560, LV625, LV675

Rotating Parts can cause severe

injury.

Stay away while engine is in

operation.

WARNING

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.

Hot Parts can cause severe burns.

Do not touch engine while operating

or just after stopping.

WARNING

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

after it is turned off. Never operate

the engine with heat shields or

guards removed.

Accidental Starts can cause

severe injury or death.

Disconnect and ground spark plug

leads before servicing.

WARNING

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 (-) battery cable from

battery.

1.2

Section 1

Safety and General Information

Carbon Monoxide can cause

severe nausea, fainting or death.

Do not operate engine in closed or

confined area.

WARNING WARNING

Electrical Shock can cause injury.

Do not touch wires while engine is

running.

CAUTION

Hot liquid can cause severe burns.

Do not loosen radiator cap while

engine is operating or warm to the

touch.

WARNING

Explosive Gas can cause fires and

severe acid burns.

Charge battery only in a well

ventilated area. Keep sources of

ignition away.

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 confined

area.

Hot Liquid!

The liquid coolant can get extremely

hot from operation. Turning the

radiator cap when the engine is hot

can allow steam and scalding liquid

to blow out and burn you severely.

Shut off machine. Only remove

radiator cap when cool enough to

touch with bare hands. Slowly

loosen cap to first stop to relieve

pressure before removing

completely.

Explosive Gas!

Batteries produce explosive

hydrogen gas while being

charged. To prevent a fire or

explosion, charge batteries only in

well ventilated areas. Keep

sparks, open flames, and other

sources of ignition away from the

battery at all times. Keep batteries

out of the reach of children.

Remove all jewelry when servicing

batteries.

Before disconnecting the negative

(-) ground cable, make sure all

switches are OFF. If ON, a spark

will occur at the ground cable

terminal which could cause an

explosion if hydrogen gas or

gasoline vapors are present.

Explosive Fuel can cause fires and

severe burns.

Stop engine before filling fuel tank.

WARNING

Explosive Fuel!

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. Do not

fill 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.

Cleaning Solvents can cause

severe injury or death.

Use only in well ventilated areas

away from ignition sources.

WARNING

Flammable Solvents!

Carburetor cleaners and solvents

are extremely flammable. Keep

sparks, flames, and other sources

of ignition away from the area.

Follow the cleaner manufacturer’s

warnings and instructions on its

proper and safe use. Never use

gasoline as a cleaning agent.

Electrical Shock!

Never touch electrical wires or

components while the engine is

running. They can be sources of

electrical shock.

1.3

Section 1

Safety and General Information

L V 675 S

A. Model No.

Liquid Cooled

Vertical Crankshaft

Displacement/Size (cc)

Version Code

S = Electric Start

Figure 1-2. Explanation of Engine Identification Numbers.

Engine Identification Numbers

When ordering parts, or in any communication

involving an engine, always give the Model,

Specification and Serial Numbers, including letter

suffixes if there are any.

The engine identification numbers appear on a decal,

or decals, affixed to the engine shrouding. See

Figure 1-1.An explanation of these numbers is shown

in Figure 1-2.

Figure 1-1. Engine Identification Decal Location.

B. Spec. No.

Engine Model Code

Code Model

81 LV560

83 LV625

85 LV675

85 1500 Variation of

Basic Engine

30 05810334 Factory Code

C. Serial No.

Year Manufactured Code

Code Year

30 2000

31 2001

1.4

Section 1

Safety and General Information

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 SG, SH, SJ or

higher. Select the viscosity based on the air

temperature at the time of operation as shown in the

followingtable.

NOTE: Using other than service class SG, SH, SJ or

higher oil or extending oil change intervals

longer than recommended can cause engine

damage.

Alogo or symbol on oil containers identifies theAPI

service class and SAE viscosity grade. See

Figure 1-3.

*Use of synthetic oil having 5W-20 or 5W-30 rating is

acceptable, up to 4°C (40°F).

**Synthetic oils will provide better starting in extreme cold

below -23°C (-10°F).

Figure 1-3. Oil Container Logo.

Refer to Section 6 - “Lubrication System” for detailed

procedures on checking the oil, changing the oil and

changing the oil filter.

Coolant Recommendations

Use equal parts of ethylene glycol and water only.

Distilled or deionized water is recommended,

especially in areas where the water contains a high

mineral content. Propylene glycol based anti-freeze is

not recommended.

This mixture will provide protection from -37º C

(-34º F) to 108º C (226º F). For protection and use

outside the indicated temperature limits, follow the

anti-freeze manufacturer's instructions on the

container, but do not exceed 70% anti-freeze.

DO NOT use anti-freeze with stop-leak additive(s), or

put any other additives in the cooling system.

Fuel Recommendations

WARNING: Explosive Fuel!

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. Do not fill 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.Acontainer 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 left 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 overfill the fuel tank. Leave room for the fuel to

expand.

1.5

Section 1

Safety and General Information

Fuel Type

For best results, use only clean, fresh, unleaded

gasoline with a pump sticker octane rating of 87 or

higher. In countries using the Research method, it

should be 90 octane minimum.

Unleaded gasoline is recommended, as it leaves fewer

combustion chamber deposits. Leaded gasoline may

be used in areas where unleaded is not available and

exhaust emissions are not regulated. Be aware,

however, that the cylinder head will require more

frequent service.

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 are not

approved.

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.

Periodic Maintenance

WARNING: 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 (-) battery

cable from battery.

Maintenance Schedule

These required maintenance procedures should be performed at the frequency stated in the table.

They should also be included as part of any seasonal tune-up.

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

2Only required for Denso starters. Not necessary on Delco starters. Have a Kohler Engine Service Dealer perform

this service.

Refer to:

Section 5

Section 6

Section 7

Section 4

Maintenance RequiredFrequency • Fill fuel tank.

• Check oil level.

• Check coolant level.

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

• Check air intake screen, radiator, and cooling areas,

clean as necessary1.

Daily or Before

Starting Engine

Section 4

Section 7

Section 5

Section 6

Section 8

• Service precleaner element1.

• Replace air cleaner element1.

• Clean and check cooling areas.

• Replace fuel filter.

Every 25 Hours

Every 100 Hours

Annually or

Every 200 Hours

• Change oil and oil filter (more frequently under severe

conditions).

• Check spark plug condition and gap. Section 8

Section 8

• Have solenoid shift starter disassembled and cleaned2.

• Replace spark plugs.

• Change engine coolant.

Annually or

Every 500 Hours

Every 2 Years or

Every 1000 Hours Section 7

1.6

Section 1

Safety and General Information

Storage

If the engine will be out of service for two months or

more, use the following storage procedure:

1. Clean the exterior surfaces of the radiator and

engine.

2. Change the oil and filter while the engine is still

warm from operation. See “Change Oil and Filter”

in Section 6.

3. The coolant (anti-freeze) mixture should be in

good condition and tested to guard against

freezing in cold temperatures. The recommended

equal parts mixture will normally provide

protection down to temperatures of -37° C

(-34° F). If storage temperatures will fall below

this, the cooling system should be drained.Anote

should then be attached to the equipment and/or

engine as a reminder to refill the cooling system

before starting.

4. The fuel system must be completely emptied, or

the gasoline must be treated with a stabilizer to

prevent deterioration. If you choose to use a

stabilizer, follow the manufacturer’s

recommendations, and add the correct amount

for the capacity of the fuel system. Fill the fuel

tank with clean, fresh gasoline. Run the engine for

2-3 minutes to get stabilized fuel into the

carburetor. Close fuel shut-off valve when unit is

being stored or transported.

To empty the system, run the engine until the tank

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

1.7

Section 1

Safety and General Information

Figure 1-4. Typical Engine Dimensions.

260.6

Cyl. #1

18.2

Oil Fill &

Dipstick

Mounting Hole ‘‘A’’

285.5 Oil Fill

451.0

135.7

140.0

479.3

Over All

434.1

Cyl. #2

Fuel

Pump

Hose

LOil Fill

153.0

Housing

Removal

472.4

155.5

Spark

Plug

93.5

73.5

Exhaust

Port #2

Exhaust

Port #1

Mounting

Surface

40.8

Oil Drain

Mounting Hole ‘‘A’’

Oil Drain Plug

3/8 N.P.T inch

430.6

Oil Fill &

Dipstick

199.0

Center of

Gravity

95.8

Center of Gravity

Mounting Hole ‘‘A’’

Mounting Surface

334.5

167.2

89.8

72.8

Coolant Drain Plug

3/8 N.P.T Inch

30º

45º45º

242.2

104.0

89.8

15.7

Oil Filter

Removal

118.3

Oil Filter Mounting Hole ‘‘A’’ø135.0

4x ø9.2 (.36) thru

254.0 (10.00) B.C

Starter Motor

50.0

Exhaust

Port #1

Coolant Drain Plug

3/8 N.P.T Inch

50.0

Exhaust

Port #2

35º35º

Fuel Pump

95.5

139.8

Center of Gravity

86.3

Oil

Filter

Oil Drain Plug

3/8 N.P.T Inch

26.8

Oil Drain Mounting

Surface

13.2

51.2

Oil Filter

Mounting Hole ‘‘A’’

135.5

Spark Plug

ø28.6

Dimensions in millimeters.

1.8

Section 1

Safety and General Information

General Specifications1

Power (@ 3600 RPM, corrected to SAE J1995)

LV560............................................................................................. 12.7 kW (17 HP)

LV625............................................................................................. 14.9 kW (20 HP)

LV675............................................................................................. 17.1 kW (23 HP)

Peak Torque

LV560 (@ 2400 RPM) .................................................................... 32.5 N·m (24 ft. lb.)

LV625 (@ 2400 RPM) .................................................................... 41 N·m (30 ft. lb.)

LV675 (@ 2400 RPM) .................................................................... 44 N·m (32 ft. lb.)

Bore LV560.......................................................................................... 73 mm (2.87 in.)

LV625.......................................................................................... 77 mm (3.03 in.)

LV675.......................................................................................... 80 mm (3.14 in.)

Stroke ................................................................................................... 67 mm (2.64 in.)

Displacement

LV560............................................................................................. 561 cc (34.2 cu. in.)

LV625............................................................................................. 624 cc (38.1 cu. in.)

LV675............................................................................................. 674 cc (41.1 cu. in.)

Compression Ratio ............................................................................. 8.2:1 (LV560)

8.5:1 (LV625, LV675)

Dry Weight .......................................................................................... 49.8 kg (110 lb.)

Oil Capacity (with filter)......................................................................... 1.9 L (2.0 U.S. qt.)

Coolant Capacity (equal parts of water and ethylene glycol) ................. 1.4 L (1.5 U.S. qt.)

Angle of Operation - Maximum (at full oil level)All Directions ............... 20°

Lower Blower Housing

M5 Fasteners Torque............................................................................ 4.0 N·m (35 in. lb.)

M6 Fasteners Torque............................................................................ 6.8 N·m (60 in. lb.)

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

Camshaft

End Play (With Shim) ........................................................................... 0.076/0.127 mm (0.0030/0.0050 in.)

Running Clearance ............................................................................... 0.025/0.063 mm (0.0010/0.0025 in.)

Bore I.D.

New................................................................................................ 20.000/20.025 mm (0.7874/0.7884 in.)

Max. Wear Limit ............................................................................. 20.038 mm (0.7889 in.)

Camshaft Bearing Surface O.D.

New................................................................................................ 19.962/19.975 mm (0.7859/0.7864 in.)

Max. Wear Limit ............................................................................. 19.959 mm (0.7858 in.)

1Values are in Metric units. Values in parentheses are English equivalents. Lubricate threads with engine oil prior

to assembly.

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