Kohler KS530 Manual de usuario
1
22 690 01 Rev. -- KohlerEngines.com
KS530-KS595
Service Manual
2 Safety
3 Maintenance
5 Specifi cations
18 Tools and Aids
21 Troubleshooting
25 Air Cleaner/Intake
26 Fuel System
38 Governor System
40 Lubrication System
42 Electrical System
55 Starter System
57 Emission Compliant Systems
60 Disassembly/Inspection and Service
76 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.
2
Safety
KohlerEngines.com 22 690 01 Rev. --
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
fi res and severe burns.
Do not fi ll fuel tank while
engine is hot or running.
Gasoline is extremely fl ammable
and its vapors can explode if
ignited. Store gasoline only in
approved containers, in well
ventilated, unoccupied buildings,
away from sparks or fl 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 fl 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 fl ywheel.
3
Maintenance
22 690 01 Rev. -- 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 (whichever comes fi rst)
● Service/replace precleaner (if equipped). Air Cleaner/Intake
● Replace air cleaner element (if not equipped with precleaner). Air Cleaner/Intake
Every 100 Hours or Annually¹ (whichever comes fi rst)
● Replace air cleaner element (if equipped with precleaner). Air Cleaner/Intake
● Change oil and fi lter. Lubrication System
● Remove cooling shrouds and clean cooling areas. Air Cleaner/Intake
Every 100 Hours
● Replace fuel fi lter.
● 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
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 fi nd a local Kohler authorized
dealer visit KohlerEngines.com or call 1-800-544-2444 (U.S. and Canada).
4
Maintenance
KohlerEngines.com 22 690 01 Rev. --
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 fi res and severe
burns.
Do not fi ll fuel tank while engine is hot or
running.
Gasoline is extremely fl ammable and its vapors can
explode if ignited. Store gasoline only in approved
containers, in well ventilated, unoccupied buildings,
away from sparks or fl 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; eff ects 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 overfi 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 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.
5
Specifi cations
22 690 01 Rev. -- KohlerEngines.com
Engine Dimensions-Flywheel Side
F
E
G
H
I
K
A
B
D
C
J
L
M
N
O
P
Q
R
S
A164.8 mm (6.49 in.)
to Starter B212.4 mm (8.36 in.) C201.3 mm (7.92 in.)
to Oil Filter D100.0 mm (3.94 in.)
EOil Fill and Dipstick FØ 10.0 mm (0.39 in.)
Lifting Point GThrottle Cable Clip H109.0 mm (4.29 in.)
I46.5 mm (1.83 in.) J85.1 mm (3.35 in.) K
Connection for
Evaporative Hose
(7/32" I.D.)
L228.9 mm (9.01 in.)
M205.8 mm (8.10 in.) N182.5 mm (7.19 in.) O13.9 mm (0.55 in.) to
Center of Gravity P148.1 mm (5.83 in.)
Q317.8 mm (12.51 in.) R41.2 mm (1.62 in.) to
Center of Gravity S139.0 mm (5.47 in.)
6
Specifi cations
KohlerEngines.com 22 690 01 Rev. --
Engine Dimensions-Starter Side
F
E
G
H
I
K
A
B
D
C
J
L
M
N
O
P
Q
R
S
T
U
V
W
A
2 X Cored for M6
Self Tapping
Screw 17.7 mm
(0.70 in.) Min.
Depth
(Accessory
Mounting
Location)
BExhaust Port Axis C326.5 mm
(12.85 in.) D
179.0 mm (7.05 in.)
to Center of
Gravity
E145.2 mm (5.72 in.)
to Exhaust Port F81.3 mm (3.20 in.) G64.0 mm (2.52 in.)
Keyway Length H
7/16-20 UNF-2B IN.
38.1 mm (1.50
in.) Depth
I250.3 mm (9.86 in.)
to Exhaust Port J2 X 30.0 mm (1.18 in.) K
21.6-21.8 mm (0.85-
0.86 in.) Keyway
Depth
L95.0 mm (3.74 in.)
MEngine Mounting
Surface N
Cored for M8 Self
Tapping Screw
20.0 mm (0.79 in.)
Min. Depth
(Ground Lug
Location)
O61.9 mm (2.44 in.) to
Starter Stud P55.0 mm (2.17 in.)
Q95.0 mm (3.74 in.) R171.5 mm (6.75 in.) S195.0 mm (7.68 in.)
Lifting Point T332.3 mm (13.08 in.)
UOptional Rectifi er-
Regulator VStarter Motor WOil Fill and Dipstick
7
Specifi cations
22 690 01 Rev. -- KohlerEngines.com
Engine Dimensions-PTO Side
F
E
G
H
I
K
A
B
D
C
J
L
M
N
O
F
J
A116.0 mm (4.57 in.) B55.0 mm (2.17 in.) C150° DAccessory Mounting
Surface
E2 X 288.8 mm
(11.37 in.) F35° GRotation Direction HØ 254.0 mm
(10.00 in.)
I150.2 mm (5.91 in.) J45° K36.6 mm (1.44 in.) L105.2 mm (4.14 in.)
MØ 9.7 mm (0.38 in.)
Lifting Point NExhaust Port Axis OExhaust Flange
Mounting Surface
8
Specifi cations
KohlerEngines.com 22 690 01 Rev. --
Engine Dimensions-Oil Filter Side
F
E
G
H
I
K
AB
D
C
J
L
M
N
O
P
Q
R
S
T
A317.1 mm (12.49 in.) B45.2 mm (1.78 in.) C34.3 mm (1.35 in.) D75.5° Speed Control
Lever Travel
EOptional Fuel Pump FThrottle Cable Clip G324.9 mm
(12.79 in.) H226.7 mm (8.93 in.)
Lifting Point
I215.7 mm (8.49 in.) J14.5 mm (0.57 in.) Oil
Filter Removal K113.6 mm (4.47 in.) to
Oil Filter LOil Filter
MEngine Mounting
Surface NOil Drain Plug 3/8
N.P.T. IN. O6.5° Choke Lever
Travel P17.0 mm (0.67 in.)
Q
39.4 mm (1.55 in.) to
Optional
Carburetor
Shutdown
Solenoid
R
127.1 mm (5.01 in.)
Connection for
Evaporative Hose
SAir Filter and Cover T
33.8 mm (1.33 in.) Air
Cleaner Cover
Removal
9
Specifi cations
22 690 01 Rev. -- KohlerEngines.com
Engine Dimensions-Valve Cover Side
F
E
G
H
I
K
A
B
D
C
J
L
M
NO
P
A64.2 mm (2.53 in.) B16.0 mm (0.63 in.) C24.3 mm (0.96 in.)
to Spark Plug D
Cored for M6 Self
Tapping Screw
16.5 mm (0.65
in.) Min. Depth
(Accessory
Mounting
Location)
E93.2 mm (3.67 in.) FCarburetor GOil Drain Plug H122.7 mm (4.83 in.)
I
6.32-6.36 mm
(0.249-0.250 in.)
Keyway Width
JØ 25.37-25.40 mm
(0.999-1.0 in.) K100.0 mm (3.94 in.) L
85.5 mm (3.37 in.)
Ground Lug
Mounting Boss
M
2 X Accessory
Mounting
Surface
N112.6 mm (4.43 in.) to
Spark Plug O88.0 mm (3.47 in.) P
Cored for M6 Self
Tapping Screw
Thru (Accessory
Mounting
Location)
10
Specifi cations
KohlerEngines.com 22 690 01 Rev. --
Model . . . . . . . . . . . . . . . . . . . . . KS530
5400 Series Engine
Numerical Designation
Specifi cation . . . . . . . . . . . . . . . KS530-3002
Serial . . . . . . . . . . . . . . . . . . . . . 4723500328
Year Manufactured Code Factory Code
Code Year
47 2017
48 2018
49 2019
ENGINE IDENTIFICATION NUMBERS
Kohler engine identifi cation numbers (model, specifi cation and serial) should be referenced for effi cient repair,
ordering correct parts, and engine replacement.
GENERAL SPECIFICATIONS3,4 KS530 KS540 KS590 KS595
Bore 94 mm (3.70 in.)
Stroke 78 mm (3.1 in.)
Displacement 541 cc (33.0 cu. in.)
Oil Capacity (refi ll) 1.4 L (1.5 U.S. qt.)
Maximum Angle of Operation (@ full oil level)525°
TORQUE SEQUENCES KS530 KS540 KS590 KS595
(Refer to Torque Specifi cations for torque values).
Connecting Rod Fasteners
1
2
3 Values are in Metric units. Values in parentheses are English equivalents.
4 Any and all horsepower (hp) references by Kohler are Certifi ed Power Ratings and per SAE J1940 & J1995 hp
standards. Details on Certifi ed Power Ratings can be found at KohlerEngines.com.
5 Exceeding maximum angle of operation may cause engine damage from insuffi cient lubrication.
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