Kohler AEGIS LH630 Manual de usuario

LH630, LH640, LH685, LH690, LH750, LH755

Service Manual

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.

2 Safety

3 Maintenance

5 Specications

12 Tools and Aids

15 Troubleshooting

19 Air Cleaner/Intake

20 Fuel System

25 Governor System

26 Lubrication System

28 Electrical System

34 Starter System

38 Cooling System

42 Disassembly/Inspection and Service

58 Reassembly

66 690 01 Rev. A KohlerEngines.com 1

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

res and severe burns.

Do not ll fuel tank while

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.

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 ammable. 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 ywheel.

WARNING

Hot liquid can cause

severe burns.

Do not loosen radiator

cap while engine is

operating or warm to

touch.

Liquid coolant can get extremely

hot from operation. Turning

radiator cap when 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 rst stop to

relieve pressure before removing

completely.

KohlerEngines.com 66 690 01 Rev. A

Maintenance

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 200 Hours1

● Change oil and oil lter. Lubrication System

Every 200 Hours

● Replace fuel lter.

Every 250 Hours1

● Replace air cleaner element and check inner element. Air Cleaner/Intake

Every 500 Hours1

● Replace air cleaner inner element. Air Cleaner/Intake

Every 500 Hours

● Replace spark plugs and set gap. Electrical System

Every 1000 Hours

● Change engine coolant. Cooling System

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

REPAIRS/SERVICE PARTS

Kohler genuine service parts can be purchased from Kohler authorized dealers. Find your local Kohler Engines dealer

at KohlerEngines.com or call 1-800-544-2444 (U.S.A. and Canada).

66 690 01 Rev. A KohlerEngines.com

Maintenance

OIL RECOMMENDATIONS

We recommend use of Kohler oils for best performance.

Other high-quality detergent oils (including synthetic)

of API (American Petroleum Institute) service class SJ

or higher are acceptable. Select viscosity based on

air temperature at time of operation as shown in table

below.

FUEL RECOMMENDATIONS

WARNING

Explosive Fuel can cause res and severe

burns.

Do not ll fuel tank while 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. 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 overll 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.

KohlerEngines.com 66 690 01 Rev. A

Specications

66 690 01 Rev. A KohlerEngines.com

Optional Oil Fill

152.08

(5.987)

Oil

Drain

38.00

(1.496)

143.25

(5.640)

175.41

(6.906)

LMounting Hole "A"

490.74

(19.320)

Center of Air Intake

583.30

(22.965)

Air Intake Optional Orientation

Engine Mounting Surface 38.00

(1.496)

Oil Drain Plug

L89.00

(3.504)

Mounting Holes

238.61

(9.394)

431.61

(16.992)

Mounting Hole "A" Mounting Surface

4.00

(.157)

Pilot

155.58

(6.125)

36.50

(1.437)

28.575

(1.125)

Option

112.92

(4.446)

101.60

(4.000)

Option 1/4 Inch Square Key

5/8-18 UNF Thread

7/16-20 Thread Option

120.96

(4.762)

Coolant

Overow

Fill

39.00

(1.535)

Oil Fill

119.78

(4.716)

673.70

(26.524)

Overall

Fuel Pump

440.00

(17.323)

2X 184.20

(7.252)

127.90

(5.035)

(0.906) Rain Cap Removal

622.54

(24.509)

Overall without Rain Cap

458.49

(18.051)

Overall

Mounting Hole

LMounting Hole

Dimensions in millimeters.

Inch equivalents shown in ().

50.99

(2.007)

Mounting Hole "A"

4X 3/8-16 UNC-2B Inch

299.00

(11.77)

Oil Filter

235.19

(9.259)

2X 297.47

(1.711)

Exhaust Ports

177.80 Pilot

(7.000)

Bolt Circle 197.00

(7.756)

15.70 Oil Filter Removal

(0.618)

142.88 Bolt Circle

(5.625)

4X 45°

2X 45°

2X 60°

4x 7/16-14 UNC-2B Inch

Oil Filter Side

PTO Side

Top View

Starter Side

Flywheel End

Engine Dimensions

Specications

KohlerEngines.com 66 690 01 Rev. A

GENERAL SPECIFICATIONS3,6 LH630 LH640 LH685 LH690 LH750 LH755

Bore 77 mm

(3.03 in.)

80 mm

(3.15 in.)

83 mm (3.3 in.)

Stroke 67 mm (2.64 in.) 69 mm (2.7 in.)

Displacement 624 cc

(38.1 cu. in.)

674 cc

(41.1 cu. in.)

747 cc (45.6 cu.

in.)

Oil Capacity (rell) 1.6-1.8 L (1.7-1.9 U.S. qt.)

Maximum Angle of Operation (@ full oil level)420°

TORQUE SPECIFICATIONS3,5 LH630 LH640 LH685 LH690 LH750 LH755

Carburetor and Intake Manifold

Intake Manifold Fastener (torque in 2 increments) rst to 7.4 N·m (66 in. lb.)

nally to 9.9 N·m (88 in. lb.)

Thermostat Housing Mounting Fastener 6.2-7.3 N·m (55-65 in. lb.)

Carburetor Mounting Fastener 9.9 N·m (88 in. lb.)

Closure Plate

Closure Plate Fastener 24.4 N·m (216 in. lb.)

Connecting Rod

Cap Fastener (torque in increments) 11.3 N·m (100 in. lb.)

Crankcase

Breather Cover Fastener 10.7 N·m (95 in. lb.) into new hole

7.3 N·m (65 in. lb.) into used hole

Oil Drain Plug 13.6 N·m (10 ft . lb.)

Cylinder Head

Cylinder Head Fastener (torque in 2 increments) rst to 16.9 N·m (150 in. lb.)

nally to 33.9 N·m (300 in. lb.)

Rocker Pivot Fastener 11.3 N·m (100 in. lb.)

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

4 Exceeding maximum angle of operation may cause engine damage from insufcient lubrication.

5 Lubricate threads with engine oil prior to assembly.

6 Any and all horsepower (hp) references by Kohler are Certied Power Ratings and per SAE J1940 & J1995 hp

standards. Details on Certied Power Ratings can be found at KohlerEngines.com.

ENGINE IDENTIFICATION NUMBERS

Kohler engine identication numbers (model, specication and serial) should be referenced for efcient repair,

ordering correct parts, and engine replacement.

Model .....................LH630

Liquid Cooled

Horizontal Shaft

Numerical Designation

Specication . . . . . . . . . . . . . . . LH630-0001

Serial .....................3923500328

Year Manufactured Code Factory Code

Code Year

39 2009

40 2010

41 2011

Specications

66 690 01 Rev. A KohlerEngines.com

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

5 Lubricate threads with engine oil prior to assembly.

TORQUE SPECIFICATIONS3,5 LH630 LH640 LH685 LH690 LH750 LH755

Electric Starter

Starter Thru Bolt 5.6-9.0 N·m (49-79 in. lb.)

Starter Mounting Screw 15.3 N·m (135 in. lb.)

Starter Brush Holder Fastener 2.5-3.3 N·m (22-29 in. lb.)

Starter Solenoid Fastener 4.0-6.0 N·m (35-53 in. lb.)

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

Fan/Flywheel

Rear Fan Shaft to Mounting Bracket Nut 15.8 N·m (140 in. lb.)

Front Fan Assembly to Fan Shaft Nut 15.8 N·m (140 in. lb.)

Fan/Pulley/Hub Assembly Fastener 6.8 N·m (60 in. lb.)

Flywheel Retaining Screw 66.4 N·m (49 ft . lb.)

Lower Flywheel Cover Mounting Screw into hex or weld nuts 9.9 N·m (88 in. lb.)

into Timmerman clips/nuts 2.2-2.8 N·m (20-25 in. lb.)

Lower Pulley Mounting Screw 24.3 N·m (215 in. lb.)

Governor

Governor Lever Nut 6.8 N·m (60 in. lb.)

Ignition

Spark Plug 27 N·m (20 ft. lb.)

Ignition Module Fastener 6.2 N·m (55 in. lb.) into new hole

4.0 N·m (35 in. lb.) into used hole

Rectier-Regulator Fastener 4.0 N·m (35 in. lb.)

Mufer

Mufer Retaining Nuts 24.4 N·m (216 in. lb.)

Speed Control

Speed Control Bracket Assembly Fastener 10.7 N·m (95 in. lb.) into new holes

7.3 N·m (65 in. lb.) into used holes

Stator

Stator Mounting Screw 6.2 N·m (55 in. lb.)

Valve Cover/Rocker Arms

Valve Cover Fastener 6.2 N·m (55 in. lb.)

Water Pump

Mounting Screw 9.9 N·m (88 in. lb.)

Pulley Mounting Screw 9.9 N·m (88 in. lb.)

CLEARANCE SPECIFICATIONS3LH630 LH640 LH685 LH690 LH750 LH755

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

Max. Wear Limit

20.000/20.025 mm (0.7874/0.7884 in.)

20.038 mm (0.7889 in.)

Camshaft Bearing Surface O.D.

New

Max. Wear Limit

19.962/19.975 mm (0.7859/0.7864 in.)

19.959 mm (0.7858 in.)

Specications

KohlerEngines.com 66 690 01 Rev. A

CLEARANCE SPECIFICATIONS3LH630 LH640 LH685 LH690 LH750 LH755

Connecting Rod

Connecting Rod-to-Crankpin Running Clearance

New

Max. Wear Limit

0.043/0.068 mm (0.0016/0.0026 in.)

0.083 mm (0.0032 in.)

Connecting Rod-to-Crankpin Side Clearance 0.26/0.63 mm (0.0102/0.0248 in.)

Connecting Rod-to-Piston Pin Running Clearance 0.015/0.028 mm (0.0006/0.0011 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.)

Crankshaft

End Play (free) 0.070/0.590 mm (0.0028/0.0230 in.)

Crankshaft Sleeve Bearing I.D. (crankcase)

New

Max. Wear Limit

40.974/40.987 mm (1.6131/1.6136 in.)

41.000 mm (1.6141 in.)

Crankshaft Bore (in closure plate)

New

Max. Wear Limit

40.974/41.000 mm (1.6131/1.6141 in.)

41.038 mm (1.6156 in.)

Crankshaft Bore (in closure plate)-to-Crankshaft

Running Clearance

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

Main Bearing Journals

O.D. - New

O.D. - Max. Wear Limit

Max. Taper

Max. Out-of-Round

40.913/40.935 mm (1.6107/1.6116 in.)

40.84 mm (1.608 in.)

0.022 mm (0.0009 in.)

0.025 mm (0.0010 in.)

Crankshaft to Sleeve Bearing (crankcase) Running

Clearance

New 0.039/0.074 mm (0.0015/0.0029 in.)

Connecting Rod Journal

O.D. - New

O.D. - Max. Wear Limit

Max. Taper

Max. Out-of-Round

35.955/35.973 mm (1.4156/1.4163 in.)

35.94 mm (1.415 in.)

0.018 mm (0.0007 in.)

0.025 mm (0.0010 in.)

Crankshaft T.I.R.

PTO End, Crank in Engine

Entire Crank, in V-Blocks

0.15 mm (0.0059 in.)

0.10 mm (0.0039 in.)

Cylinder Bore

Cylinder Bore I.D.

New

Max. Wear Limit

77.000/

77.025 mm

(3.0315/

3.0325 in.)

77.063 mm

(3.0340 in.)

80.000/

80.025 mm

(3.1496/

3.1506 in.)

80.065 mm

(3.1522 in.)

83.006/83.031 mm

3.2679/3.2689 in.)

83.069 mm

(3.2704 in.)

Max. Taper

Max. Out-of-Round

0.12 mm (0.0047 in.)

0.05 mm (0.0020 in.)

Cylinder Head

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

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

Specications

66 690 01 Rev. A KohlerEngines.com

CLEARANCE SPECIFICATIONS3LH630 LH640 LH685 LH690 LH750 LH755

Governor

Governor Cross Shaft to Crankcase Running

Clearance

0.025/0.126 mm (0.0009/0.0049 in.)

Governor 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 O.D.

New

Max. Wear Limit

5.990/6.000 mm (0.2358/0.2362 in.)

5.977 mm (0.2353 in.)

Governor Gear Shaft -to-Governor Gear Running

Clearance

0.090/0.160 mm (0.0035/0.0063 in.)

Ignition

Spark Plug Gap 0.76 mm (0.030 in.)

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

Piston, Piston Rings, and Piston Pin

Piston-to-Piston Pin 0.006/0.018 mm (0.0002/0.0007 in.)

Piston Pin Bore I.D.

New

Max. Wear Limit

17.006/17.013 mm (0.6695/0.6698 in.)

17.025 mm (0.6703 in.)

Piston 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 0.040/

0.086 mm

(0.0016/

0.0034 in.)

0.050/

0.096 mm

(0.0020/

0.0038 in.)

0.014/0.041 mm

(0.0005/0.0016 in.)

Middle Compression Ring-to-Groove Side Clearance 0.040/

0.086 mm

(0.0016/

0.0034 in.)

0.030/

0.076 mm

(0.0012/

0.0030 in.)

0.012/0.039 mm

(0.0004/0.0015 in.)

Oil Control Ring-to-Groove Side Clearance 0.046/

0.196 mm

(0.0018/

0.0077 in.)

0.046/

0.196 mm

(0.0018/

0.0077 in.)

0.026/0.176 mm

(0.0010/0.0070 in.)

Top and Middle Compression Ring End Gap

New Bore

Top Ring 0.180/

0.380 mm

(0.0071/

0.0150 in.)

0.180/

0.430 mm

(0.0071/

0.0169 in.)

0.250/0.56 mm

(0.0098/0.022 in.)

Middle Ring 0.250/

0.450 mm

(0.0098/

0.0177 in.)

0.250/

0.460 mm

(0.0098/

0.0181 in.)

----

Used Bore (Max.) 0.77 mm

(0.030 in.)

0.80 mm

(0.0315 in.)

0.94 mm (0.037

in.)

Piston Thrust Face O.D.7

New 76.968/

76.986 mm

(3.0302/

3.0309 in.)

79.963/

79.981 mm

(3.1481/

3.1488 in.)

82.973/

82.991 mm

(3.2666/

3.2673 in.)

Max. Wear Limit 76.840 mm

(3.0252 in.)

79.831 mm

(3.1430 in.)

82.841 mm

(3.3136 in.)

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

7 Measure 6 mm (0.236 in.) above bottom of piston skirt at right angles to piston pin.

Specications

KohlerEngines.com 66 690 01 Rev. A

CLEARANCE SPECIFICATIONS3LH630 LH640 LH685 LH690 LH750 LH755

Piston, Piston Rings, and Piston Pin cont.

Piston Thrust Face-to-Cylinder Bore7 Running

Clearance

0.014/

0.057 mm

(0.0005/

0.0022 in.)

0.019/

0.062 mm

(0.0007/

0.0024 in.)

0.015/

0.058 mm

(0.005/

0.0022 in.)

Valves and Valve Lifters

Hydraulic Valve Lift er to Crankcase Running

Clearance

0.0124/0.0501 mm (0.0005/0.0020 in.)

Intake Valve Stem-to-Valve Guide Running Clearance 0.038/0.076 mm (0.0015/0.0030 in.)

Exhaust Valve Stem-to-Valve Guide Running

Clearance

0.050/0.088 mm (0.0020/0.0035 in.)

Intake Valve Guide I.D.

New

Max. Wear Limit

7.038/7.058 mm (0.2771/0.2779 in.)

7.134 mm (0.2809 in.)

Intake Valve Stem Diameter

New 6.982/7.000 mm (0.2749/0.2756 in.)

Exhaust Valve Guide I.D.

New

Max. Wear Limit

7.038/7.058 mm (0.2771/0.2779 in.)

7.159 mm (0.2819 in.)

Exhaust Valve Stem Diameter

New 6.970/6.988 mm (0.2744/0.2751 in.)

Valve Guide Reamer Size

Standard

0.25 mm O.S.

7.048 mm (0.2775 in.)

7.298 mm (0.2873 in.)

Intake Valve Lift 8.88 mm (0.3496 in.)

Exhaust Valve Lift 8.88 mm (0.3496 in.)

Nominal Valve Seat Angle 45°

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

7 Measure 6 mm (0.236 in.) above bottom of piston skirt at right angles to piston pin.

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