Kohler LH630-775 Manual de usuario

AEGIS™LH630-775

LIQUID-COOLED

HORIZONTAL CRANKSHAFT

SERVICE MANUAL

Contents

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

Section 2. Tools & Aids ..........................................................................................................

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

Section 4. Air Cleaner System.................................................................................................

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

Section 5B. Electronic Fuel Injection (EFI) Fuel System ......................................................

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 ensure 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.

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.

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.

Do not fill the fuel tank while the

engine is hot or running.

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.

Avoid inhaling exhaust fumes, and

never run the engine in a closed

building or confined area.

1.3

Section 1

Safety and General Information

L H 685 S

A. Model No.

Liquid Cooled

Horizontal Crankshaft

Numerical Designation

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. The primary location

is on the side of the flywheel cover. See Figure 1-1.

Placement may vary due to OEM requirements and

specific options involved. An explanation of these

numbers is shown in Figure 1-2.

Figure 1-1. Engine Identification Decal Location.

B. Spec. No.

Model

LH630-0001

LH640-0001

LH685-0001

LH690-0001

LH685-0001

31 05810334 Factory Code

C. Serial No.

Year Manufactured Code

Code Year

31 2001

32 2002

33 2003

34 2004

35 2005

36 2006

37 2007

Identification Decal

LH750-0001

LH755-0001

LH760-0001

LH775-0001

Complete Spec. Number

(Incorporating Model No.

with Variation No. of Basic Spec.)

1.4

Section 1

Safety and General Information

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

higher oil or extending oil change intervals

longer than recommended can cause engine

damage.

NOTE: Synthetic oils meeting the listed

classifications may be used with oil changes

performed at the recommended intervals.

However to allow piston rings to properly

seat, a new or rebuilt engine should be

operated for at least 50 hours using standard

petroleum based oil before switching to

synthetic oil.

A logo or symbol on oil containers identifies the API

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

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 antifreeze is

not recommended.

This mixture will provide protection from -37°C

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

outside the indicated temperature limits, follow the

antifreeze manufacturer's instructions on the

container, but do not exceed 70% antifreeze.

DO NOT use antifreeze 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. A container 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.

*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).

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

following table.

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.

Unleaded gasoline is recommended as it leaves less

combustion chamber deposits and reduces harmful

exhaust emissions. Leaded gasoline is not

recommended and must not be used on EFI engines,

or on other models where exhaust emissions are

regulated.

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.

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

Refer to:

Section 5

Section 6

Section 7

Section 4

Section 7

Maintenance Required

Frequency

• Fill fuel tank.

• Check oil level.

• Check coolant level.

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

• Check the screen, radiator, and cooling areas, clean as necessary1.

Daily or Before

Starting Engine

Section 7

Section 6

Section 5

Section 8

• Clean and check cooling areas1.

Every 100 Hours

Annually or

Every 200 Hours

• Change oil and oil filter (more frequently under severe conditions).

• Check spark plug condition and gap.

• Change fuel filter (carbureted models).

Section 4• Replace air cleaner element and check inner element1.

Annually or

Every 500 Hours

Every 2 Years or

Every 1000 Hours Section 7

• Replace spark plugs.

Every 250 Hours

Section 8

• Change engine coolant.

Every 1500 Hours Section 5B

• Replace fuel filter1(EFI engines).

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. On EFI engines, avoid spraying water at

the wiring harness or any of the electrical

components.

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

50/50 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 completely. A note

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 manufacturers

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. On units with EFI engines, disconnect the

negative (-) battery cable or use a "battery

minder" trickle charger while the unit is in

storage.

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

1.7

Section 1

Safety and General Information

Figure 1-4. Typical Engine Dimensions.

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

Overflow

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)

LMounting Hole

458.49

(18.051)

Overall

(0.906)Rain Cap Removal

622.54

(24.509)

Overall without Rain Cap

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

1.8

Section 1

Safety and General Information

General Specifications1

Power (@3600 RPM, exceeds Society of Automotive Engineers-Small Engine Test Code J1940.)

LH630 ................................................................................................................ Maximum............... 16.4 kW (22 HP)

Recommended ...... 13.9 kW (18.7 HP)

LH640 ................................................................................................................ Maximum............... 17.9 kW (24 HP)

Recommended ...... 15.2 kW (20.4 HP)

LH685 ................................................................................................................ Maximum............... 18.6 kW (25 HP)

Recommended ...... 15.9 kW (21.3 HP)

LH690 ................................................................................................................ Maximum............... 19.4 kW (26 HP)

Recommended ...... 16.5 kW (22.1 HP)

LH750 ................................................................................................................ Maximum............... 20.1 kW (27 HP)

Recommended ...... 17.1 kW (22.9 HP)

LH755 ................................................................................................................ Maximum............... 20.9 kW (28 HP)

Recommended ...... 17.7 kW (23.8 HP)

LH760 ................................................................................................................ Maximum............... 21.6 kW (29 HP)

Recommended ...... 18.4 kW (24.7 HP)

LH775 ................................................................................................................ Maximum............... 23.1 kW (31 HP)

Recommended ...... 19.7 kW (26.4 HP)

Peak Torque

LH630 @ 2200 RPM ...................................................................................................................... 48.0 N·m (35.4 ft. lb.)

LH640 @ 2400 RPM ...................................................................................................................... 51.9 N·m (38.3 ft. lb.)

LH685 @ 2200 RPM ...................................................................................................................... 54.3 N·m (40.1 ft. lb.)

LH690 @ 2400 RPM ...................................................................................................................... 58.1 N·m (42.9 ft. lb.)

LH750 @ 2200 RPM ...................................................................................................................... 61.0 N·m (45 ft. lb.)

LH755 @ 2800 RPM ...................................................................................................................... 61.5 N·m (45.4 ft. lb.)

LH760 @ 2600 RPM ...................................................................................................................... 61.7 N·m (45.5 ft. lb.)

LH775 @ 2400 RPM ...................................................................................................................... 64.6 N·m (47.7 ft. lb.)

Bore

LH630,LH640 ................................................................................................................................ 77 mm (3.03 in.)

LH685,LH690 ................................................................................................................................ 80 mm (3.15 in.)

LH750,LH755,LH760,LH775 ....................................................................................................... 83 mm (3.3 in.)

Stroke

LH630,LH640,LH685,LH690 ....................................................................................................... 67 mm (2.64 in.)

LH750,LH755,LH760,LH775 ....................................................................................................... 69 mm (2.7 in.)

Displacement

LH630,LH640 ................................................................................................................................ 624 cc (38.1 cu. in.)

LH685,LH690 ................................................................................................................................ 674 cc (41.1 cu. in.)

LH750,LH755,LH760,LH775 ....................................................................................................... 747 cc (45.6 cu. in.)

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

to assembly.

NOTE: All listed dimensions and tolerances are measured at 20°C (68°F).

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