Kohler Courage SV470 Manual de usuario

20 690 01 Rev. F KohlerEngines.com

SV470-SV620

Service Manual

2 Safety

3 Maintenance

5 Speciﬁcations

13 Tools and Aids

16 Troubleshooting

20 Air Cleaner/Intake

21 Fuel System

31 Governor System

33 Lubrication System

35 Electrical System

44 Starter System

47 Emission Compliant Systems

50 Disassembly/Inspection and Service

63 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.

Safety

KohlerEngines.com 20 690 01 Rev. F

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.

Maintenance

20 690 01 Rev. F 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 Hours or Annually¹

●Service/replace low-proﬁle precleaner. Air Cleaner/Intake

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

Every 100 Hours or Annually¹

●Replace air cleaner element (if not 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

●Replace fuel ﬁlter.

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

Every 200 Hours²

●Have valve lash checked/adjusted. Reassembly

Every 500 Hours

●Replace spark plug and set gap. Electrical System

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

2Have 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 20 690 01 Rev. F

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 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 carburetor (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

20 690 01 Rev. F KohlerEngines.com

Dimensions in millimeters.

Inch equivalents shown in [ ].

Engine Dimensions

Speciﬁcations

KohlerEngines.com 20 690 01 Rev. F

Model. . . . . . . . . . . . . . . . . . . . . SV470

Courage Engine

Vertical Shaft

Numerical Designation

Speciﬁcation . . . . . . . . . . . . . . . SV470-0001

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

Year Manufactured Code Factory Code

Code Year

39 2009

40 2010

41 2011

ENGINE IDENTIFICATION NUMBERS

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

ordering correct parts, and engine replacement.

GENERAL SPECIFICATIONS3.6 SV470-SV480 SV530-SV540 SV590-SV620

Bore

Spec. 00XX:

Spec. 01XX:

Spec. 02XX or higher:

---

84 mm (3.30 in.)

89 mm (3.50 in.)

94 mm (3.70 in.)

---

89 mm (3.50 in.)

---

94 mm (3.70 in.)

---

Stroke 86 mm (3.38 in.)

Displacement

Spec. 00XX:

Spec. 01XX:

Spec. 02XX or higher:

---

477 cc (29.1 cu. in.)

535 cc (32.6 cu. in.)

597 cc (36.4 cu. in.)

---

535 cc (32.6 cu. in.)

---

597 cc (36.4 cu. in.)

---

Oil Capacity (reﬁll) 1.04-1.30 L (1.1-1.4 qt.)

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

TORQUE SPECIFICATIONS3,5 SV470-SV480 SV530-SV540 SV590-SV620

Air Cleaner Base

Hex Nut Fastener 5.5 N·m (48 in. lb.)

Mounting Screw Fastener (install dry) 8.0 N·m (70 in. lb.) into new hole

5.5 N·m (48 in. lb.) into used hole

Balance Weight

Screw 10.9-13.2 N·m (95.0-115.0 in. lb.)

Blower Housing and Sheet Metal

M6 Fastener 11.6 N·m (99 in. lb.) into new hole

7.7 N·m (68 in. lb.) into used hole

Cam Lever

Fastener 8.0-10.5 N·m (70-94.0 in. lb.) into new hole

7.1-8.6 N·m (61.8-74.8 in. lb.) into used hole

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

20 690 01 Rev. F KohlerEngines.com

TORQUE SPECIFICATIONS3,5 SV470-SV480 SV530-SV540 SV590-SV620

Carburetor

Fuel Bowl Retaining Screw

Walbro

Nikki

5.1-6.2 N·m (45-55 in. lb.)

10.8-12.8 N·m (96-113 in. lb.)

Closure Plate

Fastener 24.5 N·m (216 in. lb.)

Connecting Rod

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

Crankcase

Oil Drain Plug 14.0 N·m (125 in. lb.)

Cylinder Head

Fastener (torque in 2 increments) 20.5, 41.0 N·m (180, 360 in. lb.)

Rocker Arm Pivot Stud 13.5 N·m (120 in. lb.)

Rocker Arm Adjustment Nut Set Screw 5.5 N·m (50 in. lb.)

Electric Starter

Thru Bolt 3.3-3.9 N·m (30-35 in. lb.)

Mounting Nut 3.6 N·m (32 in. lb.)

Nut (top) Positive (+) Brush Lead Terminal 1.6-2.8 N·m (15-25 in. lb.)

Nut (ﬂange) Positive (+) Brush Lead Terminal 2.2-4.5 N·m (20-40 in. lb.)

Flywheel

M12 Retaining Screw 88.0 N·m (65 ft. lb.)

M10 Retaining Screw 66.5 N·m (49 ft. lb.)

Governor

Lever Nut 7.0-8.5 N·m (60-75 in. lb.)

Ignition

Spark Plug 27 N·m (20 ft. lb.)

Module Fastener 6.0 N·m (55 in. lb.) into new hole

4.0 N·m (35 in. lb.) into used hole

Rectiﬁer-Regulator Fastener 6.0 N·m (55 in. lb.) into new hole

4.0 N·m (35 in. lb.) into used hole

Mufﬂer

Retaining Nuts 24.4 N·m (216 in. lb.)

Oil Filter Pad Pipe Plug

1/8” N.P.T.F. 4.5-5.0 N·m (40-46 in. lb.)

Oil Pump

Mounting Screw 5.0-7.5 N·m (44.4-66.0 in. lb.) into new hole

3.8-4.6 N·m (33.3-40.3 in. lb.) into used hole

Oil Sentry™

Pressure Switch 4.5-5.0 N·m (40-45 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 20 690 01 Rev. F

TORQUE SPECIFICATIONS3,5 SV470-SV480 SV530-SV540 SV590-SV620

Speed Control

Bracket Assembly Fastener 11.0 N·m (95 in. lb.) into new hole

7.5 N·m (65 in. lb.) into used hole

Stator

Mounting Screw 6.0 N·m (55 in. lb.) into new hole

4.0 N·m (35 in. lb.) into used hole

Valve Cover

Fastener 11.0 N·m (95 in. lb.) into new hole

7.5 N·m (65 in. lb.) into used hole

CLEARANCE SPECIFICATIONS3SV470-SV480 SV530-SV540 SV590-SV620

Balance Weight

Bearing Surface I.D.

New

Max. Wear Limit

67.011/67.086 mm (2.6382/2.6412 in.)

67.140 mm (2.6430 in.)

Pin O.D.

New

Max. Wear Limit

11.950/11.975 mm (0.4705/0.4715 in.)

11.900 mm (0.4685 in.)

Guide Shoe Width

New

Max. Wear Limit

17.85/17.90 mm (0.703/0.705 in.)

17.75 mm (0.6988 in.)

Guide Shoe Hole I.D.-First Generation Balance

Weight

New

Max. Wear Limit

12.000/12.025 mm (0.4724/0.4734 in.)

12.050 mm (0.4744 in.)

Linkage Pin O.D. (Crankcase)-Second Generation

Balance Weight

New

Max. Wear Limit

11.964/11.975 mm (0.4710/0.4715 in.)

11.900 mm (0.4685 in.)

Balance Weight Linkage-Second Generation

Balance Weight

New

Max. Wear Limit

11.985/12.010 mm (0.4719/0.4728 in.)

12.035 mm (0.4738 in.)

Cam Gears

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

Running Side Clearance 0.02/0.13 mm (0.001/0.005 in.)

Cam Gear-to-Cam Shaft Running Assembly 0.02/0.10 mm (0.001/0.004 in.)

Closure Plate

Balance Weight Guide Channel Width

New

Max. Wear Limit

17.95/18.05 mm (0.707/0.711 in.)

18.13 mm (0.714 in.)

Connecting Rod

Connecting Rod-to-Crankpin Running Clearance

New

Max. Wear Limit

0.03/0.055 mm (0.0012/0.0022 in.)

0.07 mm (0.0025 in.)

Connecting Rod-to-Crankpin Side Clearance 0.25/0.59 mm (0.0098/0.0232 in.)

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

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

5Lubricate threads with engine oil prior to assembly.

Speciﬁcations

20 690 01 Rev. F KohlerEngines.com

CLEARANCE SPECIFICATIONS3SV470-SV480 SV530-SV540 SV590-SV620

Crankcase

Governor Cross Shaft Bore I.D.

New

Max. Wear Limit

6.025/6.05 mm (0.2372/0.2382 in.)

6.063 mm (0.2387 in.)

Crankshaft

End Play (free) 0.225/1.025 mm (0.0089/0.040 in.)

Bore in Crankcase I.D.

New

Max. Wear Limit

41.965/41.990 mm (1.6521/1.6531 in.)

42.016 mm (1.654 in.)

Bore in Closure Plate I.D.

New

Max. Wear Limit

44.965/44.990 mm (1.7703/1.7713 in.)

45.016 mm (1.7723 in.)

Flywheel End Main Bearing Journal O.D.

New, Before Serial No. 3703200003

New, After Serial No. 3703200013

O.D., Max. Wear Limit

Max. Taper

Max. Out of Round

44.913/44.935 mm (1.7682/1.7691 in.)

44.870/44.895 mm (1.7665/1.7675 in.)

44.84 mm (1.765 in.)

0.0220 mm (0.0009 in.)

0.025 mm (0.001 in.)

PTO End Main Bearing Journal O.D.

New, Before Serial No. 3703200003

New, After Serial No. 3703200013

O.D., Max. Wear Limit

Max. Taper

Max. Out of Round

41.913/41.935 mm (1.6501/1.6510 in.)

41.855/41.880 mm (1.6478/1.6488 in.)

41.83 mm (1.647 in.)

0.020 mm (0.0008 in.)

0.025 mm (0.001 in.)

Bore in Closure Plate Running Clearance

New, Before Serial No. 3703200003

New, After Serial No. 3703200013

0.030/0.077 mm (0.0012/0.0030 in.)

0.070/0.120 mm (0.0027/0.0047 in.)

Bore in Crankcase Running Clearance

New, Before Serial No. 3703200003

New, After Serial No. 3703200013

0.030/0.077 mm (0.0012/0.0030 in.)

0.085/0.135 mm (0.0033/0.0053 in.)

Connecting Rod Journal O.D.

New

Max. Wear Limit

Max. Taper

Max. Out of Round

40.982/41.000 mm (1.6134/1.6141 in.)

40.964 mm (1.612 in.)

0.012 mm (0.0005 in.)

0.025 mm (0.001 in.)

T.I.R.

PTO End, Crankshaft in Engine

Entire Crankshaft , in V-Blocks

0.15 mm (0.0059 in.)

0.10 mm (0.0039 in.)

Eccentrics O.D.

New

Max. Wear Limit

66.940/66.970 mm (2.6354/2.6366 in.)

66.89 mm (2.633 in.)

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

Speciﬁcations

KohlerEngines.com 20 690 01 Rev. F

CLEARANCE SPECIFICATIONS3SV470-SV480 SV530-SV540 SV590-SV620

Cylinder Bore

Cylinder Bore I.D.

New

--- --- 94.010/94.035 mm

(3.701/3.702 in.)

Spec. 00XX: 84.010/84.035 mm

(3.307/3.308 in.)

89.010/89.035 mm

(3.504/3.505 in.)

---

Spec. 01XX: 89.010/89.035 mm

(3.504/3.505 in.)

--- ---

Spec. 02XX or higher: 94.010/94.035 mm

(3.701/3.702 in.)

94.010/94.035 mm

(3.701/3.702 in.)

---

Max. Wear Limit --- --- 94.073 mm

(3.704 in.)

Spec. 00XX: 84.073 mm

(3.310 in.)

89.073 mm

(3.507 in.)

---

Spec. 01XX: 89.073 mm

(3.507 in.)

--- ---

Spec. 02XX or higher: 94.073 mm

(3.704 in.)

94.073 mm

(3.704 in.)

---

Max. Taper

Max. Out of Round

0.05 mm (0.002 in.)

0.12 mm (0.0047 in.)

Cylinder Head

Max. Out-of-Flatness 0.8 mm (0.003 in.)

Governor

Governor Cross Shaft -to-Crankcase Running

Clearance

0.013/0.075 mm (0.0005/0.003 in.)

Cross Shaft O.D.

New

Max. Wear Limit

5.975/6.012 mm (0.2352/0.2367 in.)

5.962 mm (0.2347 in.)

Governor Gear Shaft -to-Governor Gear Running

Clearance

0.09/0.16 mm (0.0035/0.0063 in.)

Gear Shaft O.D.

New

Max. Wear Limit

5.99/6.00 mm (0.2358/0.2362 in.)

5.977 mm (0.02353 in.)

Ignition

Spark Plug Gap 0.76 mm (0.030 in.)

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

Oil Pump

Pump Gears-to-Crankcase Side Clearance 0.165/0.315 mm (0.0065/0.0124 in.)

Piston, Piston Rings, and Piston Pin

Pin Bore I.D.

New

Max. Wear Limit

22.006/22.012 mm (0.8685/0.8666 in.)

22.025 mm (0.8671 in.)

Pin O.D.

New

Max. Wear Limit

21.995/22.0 mm (0.8659/0.8661 in.)

21.994 mm (0.8658 in.)

Top Compression Ring-to-Groove Side Clearance 0.04 mm (0.0016 in.)

Middle Compression Ring-to-Groove Side

Clearance

0.04 mm (0.0016 in.)

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

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