Kohler Courage SV470-600 Manual de usuario

COURAGE™SERIES

SV470-600

SERVICE MANUAL

VERTICAL CRANKSHAFT

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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. Electrical System and Components......................................................................

Section 8. Disassembly............................................................................................................

Section 9. Inspection and Reconditioning .............................................................................

Section 10. Reassembly ..........................................................................................................

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1.1

Section 1

Safety and General Information

Section 1

Safety and General Information

SV470-600

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.

For Your Safety!

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

injury to yourself and others.

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.

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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

Electrical Shock can cause injury.

Do not touch wires while engine is

running.

CAUTION

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.

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.

Electrical Shock!

Never touch electrical wires or

components while the engine is

running. They can be sources of

electrical shock.

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.

WARNING

Explosive Gas can cause fires and

severe acid burns.

Charge battery only in a well

ventilated area. Keep sources of

ignition away.

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1.3

Section 1

Safety and General Information

A. Model No.

Courage™ Vertical Shaft Engine

Numerical Designation

Version Code

S = Electric Start

Firstspec

written in this

model series

B. Spec. No.

Engine Model

Model

SV470

SV480

SV530

SV540

SV590

SV600

C. Serial No.

Year Manufactured Code

Code Year

32 2002

33 2003

34 2004

Factory Code

3205810334

Engine Identification Numbers

When ordering parts, or in any communication

involving an engine, always give the Model,

Specification, and Serial Numbers of the engine.

The engine identification numbers appear on a decal

affixed to the engine shrouding. See Figure 1-1.An

explanation of these numbers is shown in Figure 1-2.

Figure 1-2. Explanation of Engine Identification Numbers.

SV540-0001

Figure 1-1. Engine Identification Decal Location.

Identification Decal

MODEL NO.

SPEC. NO.

SERIAL NO.

REFER TO OWNER'S MANUAL FOR

SAFETY, MAINTENANCE SPECS

AND ADJUSTMENTS. FOR SALES

AND SERVICE IN US/CANADA

CALL: 1-800-544-2444.

www.kohlerengines.com

KOHLER CO. KOHLER, WI USA

SV 540 S

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1.4

Section 1

Safety and General Information

Oil Recommendations

Using the proper type and weight of oil in the

crankcase is extremely important, as 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 below.

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 the API

service class and SAE viscosity grade. See Figure 1-3.

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.

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 less

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 maximum of 15% MTBE by

volume) are approved as a fuel for Kohler engines.

Other gasoline/ether blends are not approved.

Figure 1-3. Oil Container Logo.

Refer to Section 6 - “Lubrication System” for detailed

oil check, oil change, and oil filter change procedures.

*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).

***30 weight acceptable above 0°C (32°F).

***

** *

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1.5

Section 1

Safety and General Information

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.

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 engine.

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

warm from operation. See “Change Oil and Oil

Filter” in Section 6.

3. 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.

To empty the system, run the engine until the tank

and system are empty.

4. Due to the deep recess around the spark plug,

blow out the cavity with compressed air. Remove

the spark plug. The spark plug is most accessible

when the blower housing is removed for cleaning.

Add one tablespoon of engine oil into the spark

plug hole. Install the plug, but do not connect the

plug lead. Crank the engine two or three

revolutions. Connect the plug lead.

5. Reinstall the blower housing, if removed

previously, and torque the blower housing screws

to 7.5 N·m (65 in. lb.).

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

¹Performthesemaintenanceproceduresmorefrequentlyunderextremelydusty,dirtyconditions.

²Have a Kohler Engine Service Dealer perform this service.

Daily or Before

Starting Engine

Maintenance RequiredFrequency • Fill fuel tank.

• Check oil level.

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

• Check air intake and cooling areas, clean as necessary¹.

Every2Months

or 25 Hours • Serviceprecleanerelement¹ (ifequipped).

• Service air cleaner element¹ (if not equipped with precleaner).

• Replaceaircleanerelement¹(ifequippedwith precleaner).

• Change oil and filter (refer to ViscosityTable, Page 1.4, based on seasonal

temperatures).

• Remove blower housing and clean cooling areas.

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

• Replace fuel filter.

• Havebendixstarter driveserviced².

• Have valve lash checked/adjusted2.

Every200Hours

Annually or

Every100Hours

Every500Hours • Replace spark plug.

• Checkspark plug condition andgap.

Every 2 Years or

200Hours

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1.6

Section 1

Safety and General Information

Figure 1-4. Typical Engine Dimensions.

Dimensions in millimeters. Inch equivalents shown in ().

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1.7

Section 1

Safety and General Information

General Specifications¹

Power(@ 3600 RPM, corrected to SAEJ1940)

SV470 .................................................................................................11.2 kW (15 HP)

SV480 .................................................................................................11.9 kW (16 HP)

SV530 .................................................................................................12.7 kW (17 HP)

SV540 .................................................................................................13.4 kW (18 HP)

SV590 .................................................................................................14.1 kW (19 HP)

SV600 .................................................................................................14.9 kW (20 HP)

PeakTorque

SV470@2600 RPM ............................................................................34.3 N·m (25.0 ft. lb.)

SV480@2800 RPM ............................................................................34.6 N·m (25.5 ft. lb.)

SV530@2600 RPM ............................................................................37.8 N·m (27.9 ft. lb.)

SV540@2800 RPM ............................................................................39.1 N·m (29.0 ft. lb.)

SV590@2600 RPM ............................................................................42.3 N·m (31.2 ft. lb.)

SV600@2800 RPM ............................................................................44.2 N·m (32.0 ft. lb.)

BoreSV470S,SV480S.................................................................................84 mm (3.30 in.)

SV530S,SV540S.................................................................................89 mm (3.50 in.)

SV590S,SV600S.................................................................................94 mm (3.70 in.)

Stroke .........................................................................................................86 mm (3.38 in.)

Displacement

SV470S,SV480S.................................................................................477 cc (29.1 cu. in.)

SV530S,SV540S.................................................................................535 cc (32.6 cu. in.)

SV590S,SV600S.................................................................................597 cc (36.4 cu. in.)

CompressionRatio......................................................................................8.5:1

Dry Weight..................................................................................................35.8 kg (79 lb.)

OilCapacity(with filter) ..............................................................................1.5 L (1.6 qt.)

Angle of Operation - Maximum (at Full Oil Level)All Directions....................25°Intermittent

Air Cleaner Base

Hex.NutFastenerTorque ...........................................................................5.5 N·m (48 in. lb.)

MountingScrewFastenerTorque (Install Dry - DO NOTOIL).......................8.0 N·m (70 in. lb.) Into new as-cast hole

5.5 N·m (48 in. lb.) Into used hole

Blower Housing and Sheet Metal

M6FastenersTorque ..................................................................................7.5 N·m (65 in. lb.)

Cam Lever

CamLeverFastenerTorque .........................................................................7.5 N·m (65 in. lb.)

Cam Gears

End Play .....................................................................................................0.5/1.5mm(0.019/0.059in.)

Running SideClearance ..............................................................................0.02/0.13mm(0.001/0.005in.)

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

assembly, EXCEPT for air cleaner base thread forming screw - install dry.

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1.8

Section 1

Safety and General Information

Cam Gears (cont'd.)

Cam Gear-to-CamShaftRunningAssembly ............................................. 0.02/0.10mm(0.001/0.004in.)

Carburetor

FuelBowlRetainingScrewTorque ........................................................... 5.1-6.2N·m(45-55in. lb.)

Closure Plate

ClosurePlateFastenerTorque ................................................................ 24.5 N·m (216 in. lb.)

BalanceWeightGuideChannel Width

New .................................................................................................. 17.95/18.05mm(0.707/0.711in.)

Max. Wear Limit ............................................................................... 18.13 mm (0.714 in.)

Connecting Rod

CapFastenerTorque (torque in 2 increments) ......................................... 5.5, 11.5 N·m (50, 100 in. lb.)

ConnectingRod-to-CrankpinRunningClearance

New ................................................................................................... 0.03/0.055 mm (0.0012/0.0022 in.)

Max. Wear Limit ................................................................................ 0.07 mm (0.0025 in.)

ConnectingRod-to-CrankpinSide Clearance ............................................ 0.25/0.59 mm (0.0098/0.0232 in.)

ConnectingRod-to-PistonPinRunning Clearance .................................... 0.015/0.028 mm (0.0006/0.0011in.)

Piston Pin End I.D.

New ................................................................................................... 22.015/22.023 mm(0.8667/0.8670in.)

Max. Wear Limit ................................................................................ 22.036mm(0.8675in.)

Crankcase

GovernorCrossShaftBore I.D.

New ................................................................................................... 6.025/6.05 mm (0.2372/0.2382 in.)

Max. Wear Limit ................................................................................ 6.063mm (0.2387 in.)

OilDrainPlugTorque ............................................................................... 14.0 N·m (125 in. lb.)

Crankshaft

EndPlay(free) ......................................................................................... 0.225/1.025mm(0.0089/0.040in.)

CrankshaftBoreinCrankcaseI.D.

New .................................................................................................. 41.965/41.990mm(1.6521/1.6531in.)

Max. Wear Limit ............................................................................... 42.016mm (1.654 in.)

CrankshaftBoreinClosure Plate I.D

New .................................................................................................. 44.965/44.990mm(1.7703/1.7713in.)

Max. Wear Limit ............................................................................... 45.016mm(1.7723in.)

FlywheelEndMainBearingJournal

O.D.– New....................................................................................... 44.913/44.935mm(1.7682/1.7691in.)

O.D. – Max. Wear Limit.................................................................... 44.84 mm (1.765 in.)

Max.Taper........................................................................................ 0.0220 mm (0.0009 in.)

Max.Outof Round............................................................................ 0.025mm(0.001in.)

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