Kohler Aegis LV680 User's Manual
Contents
1. 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 Synthetic oils may be used Select the viscosity based on the air temperature at the time of operation as shown in the following table RECOMMENDED SAE VISCOSITY GRADES 2 sx i L i or o 19 20 aC TEMPERATURE RANGE EXPECTED BEF RE NEXT OIL CHANGE 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 Figure 2 Viscosity Grades Table 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 Upper Blower Housing and Air Intake Screen Assembly Retaining Strap Fuel Pump Oil Filter 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 viscosity2. e Cooling system capacity is approximately 1 4 L 1 47 at Maintenance This engine is liquid cooled circulating a mixture of ethylene glycol and water for dependable operation A pump is used to circulate the coolant through the system and radiator A thermostat contained in the system assures automatic temperature control and rapid warm up Correct coolant level and cleaning any debris accumulation from the inlet screen and radiator surfaces are critical to insuring long life proper system performance and preventing overheating Check the coolant level in the overflow reservoir and clean away any debris accumulation daily or before each use At the same time inspect the hoses and all connections for signs of leakage Servicing Engine coolant should be changed every 2 years or every 1000 hours whichever comes first When changing the engine coolant the system should also be flushed to remove any contaminants left behind during draining Following are recommended procedures for checking draining flushing and filling the cooling system Checking Coolant Level The coolant level should be checked at the overflow reservoir located under the upper blower housing assembly 1 Unhook the retaining straps and remove the upper blower housing and screen assembly See Figures 8 and 9 10 Figure 9 Removing Upper Blower Housing and Screen Assembly 2 Check the coolant level within the overflow reservoir Coolant
3. LITHO IN U S A EAE a G MIO NT MLA IN U S AND CANADA CALL 1 800 544 2444 any ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 6 ON 5
4. and lift the reservoir out between the bracket and fan See Figures 14 and 15 Pour out the contents of the reservoir and wash out or clean as required Dispose of all the old coolant properly according to local regulations Molded Protrusion a for Mounting Figure 14 Tipping Bracket Away after Removing Reservoir Cap Figure 15 Removing Reservoir 11 7 Reinstall the reservoir engaging the two lower molded protrusions in the mounting holes of the support bracket Engage the top bracket around the upper protrusion Hold it in this position and torque the screws to 7 3 N m 65 in Ib 8 Reinstall the reservoir cap Do not kink pinch the hose 9 Flush the cooling system see Flushing Cooling System Flushing Cooling System With system properly drained 1 Fillthe cooling system with clean water and a cooling system cleaner recommended for aluminum engines Follow the directions on the container 2 Reinstall and tighten the radiator cap 3 Reinstall the upper blower housing assembly Secure with the retaining straps 4 Start and run the engine for five minutes or until it reaches operating temperature Stop the engine and allow it to cool 5 Remove the upper blower housing and drain the cooling system Refer to Draining Cooling System 6 Fill the cooling system see Filling Cooling System 7 Reinstall the upper blower housing and screen assembly Filling Cooling System
5. service center as soon as a problem exists Call 1 800 544 2444 or access our web site at www kohlerengines com for the names of the nearest service centers The warranty repairs should be completed in a reasonable amount of time not to exceed 30 days If you have any questions regarding warranty rights and responsibilities you should contact Kohler Co at 1 920 457 4441 and ask for an Engine Service representative COVERAGE Kohler Co warrants to the ultimate purchaser and each subsequent purchaser that the engine will be designed built and equipped at the time of sale to meet all applicable regulations Kohler Co also warrants to the initial purchaser and each subsequent purchaser that the engine is free from defects in materials and workmanship which cause the engine to fail to conform with applicable regulations for a period of two years Engines produced in 1995 or later are warranted for two years in California For 1997 and later model years EPA requires manufacturers to warrant engines for two years in all other states These warranty periods will begin on the date the engine is purchased by the initial purchaser If any emission related part on the engine is defective the part will be replaced by Kohler Co at no cost to the owner Kohler Co is liable for damages to other engine components caused by the failure of a warranted part still under warranty Kohler Co shall remedy warranty defects at any authorized Kohler Co engine dea
6. 1 Check the condition of cooling system hoses clamps and associated components Replace as required 2 Mix equal parts of ethylene glycol anti freeze and distilled or deionized water see Coolant Recommendations on page 5 For extremely cold temperature applications or protection outside the limits listed in the Coolant Recommendations Section refer to the anti freeze manufacturers instructions on the container but do not exceed 70 anti freeze 12 3 Fill the radiator with the coolant mixture Allow coolant to drain into the lower areas Fill the overflow reservoir to a level between the Max Level and Min Level marks See Figure 10 Reinstall the radiator and reservoir caps 4 Reinstall the upper blower housing and screen assembly Start and run the engine for five minutes Stop the engine and cool 5 Remove the blower housing and recheck coolant level in reservoir Coolant level should be between the Max Level and Min Level marks Add coolant to reservoir if required See Figure 10 6 Reinstall the upper blower housing and screen assembly Secure with the retaining straps Service Precleaner and Air Cleaner Element This engine is equipped with a replaceable high density paper air cleaner element surrounded by an oiled foam precleaner located under the upper blower housing See Figure 16 Check the air cleaner and air intake screen daily or before starting the engine Che
7. 38 5 52 2 2600 40 0 54 2 2400 Compression Ratio cccccccccescceeeeseeeeeeeeceeeseeseeeeseeeeeeeeeeeeeseeaaas ER 8 5 1 Dry Weight cnccscccascacdecenesmonctnwaedaoscxdonendeacs Ib kg ee ene eee 108 49 cceee 108 49 Oil Capacity W filter ce US giS BD eces 20 129 E eee ee 2 0 1 9 LUBTICAG HON sissi stones Full Pressure w full Flow Filter Coolant Anti Freeze ss U S qts L Equal Parts of Water and Ethylene Glycol 1 47 1 4 Exhaust Emission Control System for models LV625 LV675 and LV680 is EM Horsepower ratings exceed Society of Automotive Engineers Small Engine Test Code J1940 Actual engine horsepower is lower and affected by but not limited to accessories air cleaner exhaust charging cooling fuel pump etc application engine speed and ambient operating conditions temperature humidity and altitude Kohler reserves the right to change product specifications designs and equipment without notice and without incurring obligation LIMITED 3 YEAR KOHLER AEGIS ENGINE WARRANTY Kohler Co warrants to the original retail consumer that each new KOHLER AEGIS engine sold by Kohler Co will be free from manufacturing defects in materials or workmanship in normal residential service for a period of three 3 years from date of purchase provided it is operated and maintained in accordance with Kohler Co s instructions and manuals Our obligation u
8. Cooling Area page 14 High Temperature Sensor Some engines are equipped with a high temperature sensor mounted in the cooling system If the safe operating temperature is exceeded it will either shut off the engine or activate a warning signal depending on the application If the warning light illuminates or engine kills indicating excessive operating temperatures 1 Make sure all air intake and cooling surfaces are clean and free of debris 2 After engine has sufficiently cooled check the coolant level in system to make sure it is not low See Checking Coolant Level page 10 3 Check the system for external leaks 4 If the cause is none of the above or cannot be identified contact an Authorized Kohler Engine Dealer for appropriate diagnosis and correction A 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 Engine Speed NOTE Do not tamper with the governor setting to increase the maximum engine speed Overspeed is hazardous and will void the engine warranty The maximum allowable high idle speed for these engines is 3750 RPM Maintenance Instructions Maintenance repair or replacement of the emission control devices and systems which are being done at the customers expense may be performed by any no
9. Inlet Figure 24 Carburetor Troubleshooting If engine troubles are experienced that appear to be fuel system related check the following areas before adjusting the carburetor e Make sure the fuel tank is filled with clean fresh gasoline e Make sure the fuel tank cap vent is not blocked and that it is operating properly e If the fuel tank is equipped with a shut off valve make sure it is open e Ifthe engine is equipped with an in line fuel filter make sure it is clean Replace the filter if it is dirty or restricted 16 Make sure fuel is reaching the carburetor This includes checking the fuel lines and fuel pump for restrictions or faulty components replace as necessary Make sure the air cleaner element and precleaner are clean and properly secured Make sure the air intake screen blower housing and cooling surfaces of radiator are clean and free of dirt and debris Make sure cooling system is filled to the proper level If after checking the items listed above the engine is hard to start runs roughly or stalls at low idle speed it may be necessary to adjust or service the carburetor Adjust Carburetor Start the engine and run at half throttle for 5 to 10 minutes to warm up The engine must be warm before making final settings Low idle speed RPM setting 1 Place the throttle control into the idle or slow position Set the low idle speed to 1200 RPM 75 RPM by
10. be used in areas where unleaded is not available and exhaust emissions are not regulated Be aware however that the cylinder heads may 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 a maximum of 15 MTBE by volume are approved as a fuel for Kohler engines Other gasoline ether blends are not approved Coolant Recommendations Use equal parts of ethylene glycol anti freeze and water only Distilled or deionized water is recommended especially in areas where the water contains a high mineral content Propylene glycol based anti freeze 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 anti freeze manufacturers instructions on the container but do not exceed 70 anti freeze DO NOT use anti freeze with stop leak additive s or put any other additives in the cooling system 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 blower housing Include letter suffix
11. designates a specific version as follows Suffix Designates S Electric Start Operating Instructions Also read the operating instructions of the equipment this engine powers Pre Start Checklist e Check coolant level Add coolant if low e Check fuel level Add fuel if low 2 e Check radiator cooling air intake areas and external surfaces of engine Make sure they are clean and unobstructed e Check that the air cleaner components and all shrouds equipment covers and guards are in place and securely fastened e Check that any clutches or transmissions are disengaged or placed in neutral This is especially important on equipment with hydrostatic drive The shift lever must be exactly in neutral to prevent resistance which could keep the engine from starting A WARNING 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 Cold Weather Starting Hints 1 The cooling system must be filled with coolant capable of providing proper protection against 3 freezing at the lowest temperature expected see Coolant Recommendations on page 5 2 Be sure to use the proper oil for the temperature expected See Figure 2 on page 4 3 Declutch all possible external loads 4 Awarm battery has much more starting capacity 4 t
12. engine is prevent injury Never operate the running They can be sources of engine with covers shrouds or electrical shock guards removed Congratulations You have selected a fine four cycle twin cylinder liquid cooled engine Kohler designs long life strength and on the job durability into each engine making a Kohler engine dependable dependability you can count on Here are some reasons why e Efficient overhead valve design and pressure lubrication provide maximum power torque and reliability under all operating conditions Dependable maintenance free electronic ignition ensures fast easy starts time after time Kohler engines are easy to service All routine service areas like the dipstick and oil fill air cleaner spark plugs and carburetor are easily and quickly accessible Parts subject to the most wear and tear like the cylinder liner and camshaft are made from precision formulated cast iron Every Kohler engine is backed by a worldwide network of over 10 000 distributors and dealers Service support is just a phone call away Call 1 800 544 2444 U S amp Canada for Sales amp Service assistance To keep your engine in top operating condition follow the maintenance procedures in this manual Engine Identification Label Oil Fill sy Dipstick j Electric Starter Spark Plug Valve Cover with Integral Breather Figure 1 Typical Kohler Aegis Vertical Shaft Engine Oil Recommendations
13. radiator and engine 2 Change the oil and filter while the engine is still warm from operation See Change Oil and Filter on page 9 3 The coolant anti freeze mixture should be in good condition and tested to guard against freezing in cold temperatures The recommended equal parts 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 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 Store the engine in a clean dry place Parts Ordering The engine Specification Model and Serial Numbers are required when ordering replacement parts from yo
14. turning the low idle speed adjusting screw in or out Check the speed using a tachometer NOTE The actual low idle speed depends on the application refer to equipment manufacturers recommendations The standard low idle speed is 1200 RPM If proper operation is not restored after adjusting the low idle speed carburetor servicing by an authorized Kohler Engine Service Dealer may be required Troubleshooting When troubles occur be sure to check the simple causes which at first may seem too obvious to be considered For example a starting problem could be caused by an empty fuel tank Some common causes of engine troubles are listed in the following table Do not attempt to service or replace major engine components or any items that require special timing or adjustment procedures Have your Kohler Engine Service Dealer do this work Dirty Air Possible Cause No Improper Dirt In Intake Screen Incorrect Engine Dirty Air Faulty Problem Fuel Fuel Fuel Line or Radiator Oil Level Overloaded Cleaner Spark Plug Will Not Start e e e o e e Hard Starting 8 Stops Suddenly gt e o o e Lacks Power e o o e Operates Erratically e o o e Knocks or Pings e e Skips or Misfires e o Backfires e e o Overheats o High Fuel Consumption 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
15. underside See Figures 18 19 and 20 Check all parts for wear cracks or damage Replace any damaged components 6 Install the new paper element Kohler Part No 66 083 01 S and secure with the element retainer strap 7 Install the precleaner over the paper element outside the element retaining strap 8 Reinstall the upper blower housing and screen assembly Secure with the four retaining straps 14 Clean Air Intake Cooling Areas To ensure proper air circulation make sure the air intake screen radiator cooling fins and other external surfaces of the engine are kept clean at all times Every 100 hours of operation more often under extremely dusty dirty conditions remove the upper blower housing assembly Clean the cooling fins of the radiator external surfaces and the air intake screen and blower housing assembly as necessary The screen assembly may also be separated from the upper blower housing to permit more thorough cleaning if required See Figures 18 19 and 20 Make sure all parts are reinstalled before starting the engine If the screen assembly was separated from the blower housing push the upper retaining clips into the locked position Clean the cooling fins of the radiator with a soft brush or blow out using clean compressed air See Figure 22 Do not use a high pressure washer to clean to avoid damaging the cooling fins NOTE Operating the engine with a blocked air intake screen dirty or
16. OWNER s MANUAL KOHLER AEGIS LV625 LV675 LV680 LIQUID COOLED VERTICAL CRANKSHAFT KOHLER ENGINES Safety Precautions To ensure safe operations please read the following statements and understand their meaning Also refer to your equipment owner s manual for other important safety information This manual contains safety precautions which are explained below Please read carefully A 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 A 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 A WARNING Explosive Fuel can cause fires and Hot liquid can cause severe burns Hot Parts can cause severe burns severe burns Do not loosen radiator cap while Do not touch engine while operating Stop engine before filling fuel tank engine Is operating or warm to the or just after stopping touch Explosive Fuel Hot Liquid Hot Parts Gasoline is extremely flammable The liquid coolant can get extremely Engine components can get and i
17. Replace any damaged components Figure 18 Clean Away Debris y Figure 20 Removing Screen Assembly 6 Reinstall the precleaner over the paper element outside the element retaining strap Reinstall the upper blower housing and screen assembly Secure with the four retaining straps When precleaner replacement is necessary order Kohler Part No 66 083 03 S Service Paper Element Every 100 hours of operation more often under extremely dusty or dirty conditions replace the paper element 1 Unhook the four retaining straps and remove the upper blower housing and screen assembly See Figures 8 and 9 Remove the foam precleaner from the paper element See Figure 17 Service or replace the precleaner 13 3 Unhook the element retaining strap and remove the paper element from the air cleaner base See Figure 21 I I EA gi T SV am d fi a fi HH t 1 ii H RN Figure 21 Unhooking Retaining Strap 4 Do not wash the paper element or use pressurized air as this will damage the element Replace a dirty bent or damaged element with a new genuine Kohler element Handle new elements carefully Do not use if the sealing surfaces are bent or damaged 5 Clean the air cleaner base area upper blower housing and screen assembly of any debris accumulation If required the screen assembly may also be separated from the blower housing by unsnapping it from the
18. Service Dealer perform this service Check Oil Level The importance of checking and maintaining the proper oil level in the crankcase cannot be overemphasized Check oil BEFORE EACH USE as follows 1 Make sure the engine is stopped level and is cool so the oil has had time to drain into the sump 2 To keep dirt debris etc out of the engine clean the area around the dipstick before removing it 3 Unthread and remove the dipstick wipe oil off Reinsert the dipstick into the tube and rest the oil fill Cap on the tube Do not thread the cap onto the tube See Figure 5 Figure 5 Checking Oil Level 4 Pull the dipstick out and check the oil level The oil level should be up to but not over the FULL mark on the dipstick See Figure 6 2 Remove one of the oil drain plugs and the oil fill cap dipstick Be sure to allow ample time for complete drainage Full Mark 3 Before removing the oil filter clean the area around the oil filter to keep dirt and debris out of the engine Remove the old filter and wipe off the filter adapter with a clean cloth oe ee A Operating Range RAJ ve oe 4 Reinstall the drain plug Make sure it is tightened to 13 6 N m 10 ft Ib torque 5 Place a new replacement filter in a shallow pan with the open end up Pour new oil of the proper Figure 6 Oil Level Dipstick type in through the threaded center hole Stop pouri
19. ck for a buildup of dirt and debris around the air cleaner system Keep these areas Clean Also check for loose or damaged components Replace all bent or damaged air cleaner components Do not operate the engine without the upper blower housing and screen assembly installed NOTE Operating the engine with loose damaged or missing air intake components can allow unfiltered air into the engine causing premature wear and failure Precleaner Element Figure 16 Air Cleaner Assembly Service Precleaner Wash and reoil the precleaner every 25 hours of operation more often under extremely dusty or dirty conditions 1 Unhook the four retaining straps and remove the upper blower housing and screen assembly See Figures 8 and 9 2 Remove the foam precleaner from the paper element See Figure 17 Figure 17 Removing Precleaner from Paper Element 3 Wash the precleaner in warm water with detergent Rinse the precleaner thoroughly until all traces of detergent are eliminated Squeeze out excess water do not wring Allow the precleaner to air dry Saturate the precleaner with new engine oil Squeeze out all excess oil Clean the air cleaner base area upper blower housing and screen assembly of any debris accumulation If required the screen assembly may also be separated from the upper blower housing by unsnapping it from the underside See Figures 18 19 and 20 Check all parts for wear cracks or damage
20. es if there are any Record your engine identification numbers on the identification label Figure 4 for future reference KOHLER IMPORTANT ENGINE INFORMATION THIS ENGINE MEETS U S EPAAND CA 2005 AND LATER AND EC STAGE II SN 4 EMISSION REGS FOR SI SMALL OFF ROAD ENGINES FAMILY TYPE APP DISPL CC MODEL NO SPEC NO SERIAL NO BUILD DATE OEM PROD NO EMISSION COMPLIANCE PERIOD EPA CARB CERTIFIED ON REFER TO OWNER S MANUAL FOR HP RATING SAFETY MAINTENANCE AND ADJUSTMENTS 1 800 544 2444 www kohlerengines com KOHLER CO KOHLER WISCONSIN USA GN11236 Figure 4 Engine Identification Label The Emission Compliance Period referred to on the Emission Control or Air Index label indicates the number of operating hours for which the engine has been shown to meet Federal and CARB emission requirements The following table provides the Engine Compliance Period in hours associated with the category descriptor found on the certification label EPA Category C CategoryB CategoryA 250 Hours 1500 Hours 1000 Hours CARB Moderate Intermediate Extended 125 Hours 1250 Hours 1500 Hours Emission Compliance Period Hours Refer to certification label for engine displacement Exhaust Emission Control System for models LV625 LV675 and LV680 is EM Model Designation Model LV625 for example L designates liquid cooled V designates vertical crankshaft and 625 is the model designation A letter suffix
21. es of leads before servicing confined area ignition away Accidental Starts Lethal Exhaust Gases Explosive Gas Disabling engine Accidental Engine exhaust gases contain Batteries produce explosive starting can cause severe injury poisonous carbon monoxide hydrogen gas while being charged or death Before working on the Carbon monoxide is odorless To prevent a fire or explosion engine or equipment disable the colorless and can cause death if charge batteries only in well engine as follows 1 Disconnect the inhaled Avoid inhaling exhaust ventilated areas Keep sparks open spark plug lead s 2 Disconnect fumes and never run the engine in flames and other sources of ignition negative battery cable from a closed building or confined area away from the battery at all times battery Keep batteries out of the reach of A WAR N NG children Remove all jewelry when A C A UTI O N servicing batteries Ro Before disconnecting the negative ground cable make sure all switches are OFF If ON a spark will Rotating Parts can cause severe occur at the ground cable terminal Electrical Shock can cause injury Injury which could cause an explosion if hydrogen gas or gasoline vapors Stay away while engine is in are present Do not touch wires while engine is running operation Rotating Parts Electrical Shock Keep hands feet hair and clothing Never touch electrical wires or away from all moving parts to components while the
22. grade See Figure 3 Figure 3 Oil Container Logo Refer to Maintenance Instructions beginning on page 8 for detailed oil check oil change and oil filter change procedures Fuel Recommendations A 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 the 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
23. han a cold battery 5 Use fresh winter grade fuel NOTE Winter grade Do not use gasoline left over from summer Starting e Check oil level Add oil if low Do not overfill 1 Place the throttle control midway between the slow and fast positions Place the choke control into the on position Start the engine by activating the key switch Release the switch as soon as the engine starts NOTE Do not crank the engine continuously for more than 10 seconds at a time If the engine does not start allow a 60 second cool down period between starting attempts Failure to follow these guidelines can burn out the starter motor NOTE Upon start up a metallic ticking may occur This is caused by hydraulic lifter leakdown during storage Run the engine for 5 minutes The noise will normally cease in the first minute If noise continues run the engine at mid throttle for 20 minutes If noise persists take the engine to your local Kohler Service outlet If the starter does not turn the engine over shut off starter immediately Do not make further attempts to start the engine until the condition is corrected Do not jump start using another battery refer to Battery on page 7 See your Kohler Engine Service Dealer for trouble analysis For a Cold Engine Gradually return the choke control to the off position after the engine starts and warms up The engine equipment may be operated during the warm
24. ler or warranty station Warranty repair work done at an authorized dealer or warranty station shall be free of charge to the owner if such work determines that a warranted part is defective Listed below are the parts covered by the Federal and California Emission Control Systems Warranty Some parts listed below may require scheduled maintenance and are warranted up to the first scheduled replacement point for that part The warranted parts are e Oxygen sensor if equipped e Ignition module s with high tension lead e Intake manifold if equipped e Gaseous fuel regulator if equipped e Exhaust manifold if equipped e Electronic control unit if equipped e Catalytic muffler if equipped e Carburetor or fuel injection system e Fuel metering valve if equipped e Fuel lines if equipped e Spark advance module if equipped e Air filter fuel filter and spark plugs only e Crankcase breather to first scheduled replacement point Continued on next page 19 LIMITATIONS This Emission Control Systems Warranty shall not cover any of the following repair or replacement required because of misuse or neglect improper maintenance repairs improperly performed or replacements not conforming to Kohler Co specifications that adversely affect performance and or durability and alterations or modifications not recommended or approved in writing by Kohler Co replacement of parts and other services and adjustments necessary for required maintena
25. level should be between the Max Level and Min Level marks on the reservoir See Figure 10 Do not operate the engine with the coolant level below the Min Level mark Add coolant to the overflow reservoir as required Use equal parts of ethylene glycol and water only distilled or deionized water is recommended Figure 10 Coolant Levels on Reservoir Draining Cooling System 1 Stop the engine and allow it to cool sufficiently 2 Unhook the four retaining straps and remove the upper blower housing and screen assembly See Figures 8 and 9 3 Check if the radiator is cool to the touch Slowly loosen the radiator cap to the first stop and allow any pressure to bleed off Then fully loosen and remove it Figure 11 Removing Radiator Cap 4 Locate and remove the coolant drain plug in the lower side of both cylinder heads See Figure 12 Drain the coolant into a suitable container After the coolant has drained apply pipe sealant with Teflon not Teflon tape to the threads and reinstall the plugs Torque the plugs to 13 5 N m 120 in Ib 5 The coolant overflow reservoir has 3 molded protrusions 1 upper 2 lower see Figure 14 that fit into corresponding holes in the support brackets Loosen the two screws that fasten the upper bracket to the radiator See Figure 13 Figure 13 Loosening Screws 6 Remove the reservoir cap Carefully tip the bracket away from the reservoir
26. linder head Torque the spark plug to 24 4 29 8 N m 18 22 ft Ib Wire Gauge Spark Plug wa SL 0 76 mm Electrode i 0 030 in Gap Figure 23 Servicing Spark Plug Battery Charging A WARNING 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 NOTE Do not apply 12 volt DC to kill terminal of ignition module Fuel Filter Most engines are equipped with an in line fuel filter Periodically inspect the filter and replace every 200 operating hours Use a genuine Kohler filter Part No 24 050 02 S 15 Carburetor Troubleshooting and Adjustments In compliance with the government emission standards the carburetor is calibrated to deliver the correct fuel to air mixture to the engine under all operating conditions The carburetor cannot be adjusted except for low idle speed RPM Carburetor servicing is to be performed by an authorized Kohler Engine Service Dealer only See Figure 24 nm Fuel Line KR
27. mark on the dipstick This includes engines equipped with Oil Sentry Change Oil and Filter Change the oil and oil filter every 200 hours or annually whichever comes first more often under severe conditions Refill with service class SG SH SJ or higher oil as specified in the Viscosity Grades table Figure 2 on page 4 Always use a genuine Kohler oil filter Part No 52 050 02 S Oil Drain Plug _ Change the oil while the engine is still warm The oil Pains om ped will flow more freely and carry away more impurities A a Nn fr Re Make sure the engine is level when filling checking or ROS changing the oil N i W LR i Change the oil and oil filter as follows see Figure 7 1 To keep dirt debris etc out of the engine clean Nr the area around the oil fill cap dipstick before Oil removing it Filter Oil Drain Plug Figure 7 Oil Drain Plugs and Oil Filter Cooling System Maintenance and Service Important service notes e Do not operate the engine without coolant in sysiem e Do not remove the radiator cap when hot Engine coolant is hot and under pressure and can cause severe burns e To prevent engine overheating and damage use the recommended anti freeze mixture in the cooling system e To prevent engine damage do not pour cold water into a hot engine e To prevent engine damage do not use anti freeze with stop leak additive s or put other additives in the cooling systems
28. n road engine repair establishment or individual Warranty repairs must be performed by an authorized Kohler service outlet A 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 Maintenance Required Fill fuel tank Daily or Before Check oil level Starting Engine Check coolant level Check air cleaner for dirty loose or damaged parts Check air intake screen radiator and cooling areas clean as necessary Every 25 Hours Service precleaner element Replace air cleaner element every 100 MOUS Clean and check cooling areas Change oil and oil filter more frequently under severe conditions Annually or Ml Every 200 Hours Check spark plug condition and gap Replace fuel filter Annually or e Have solenoid shift starter disassembled and cleaned Every 500 Hours e Replace spark plugs Every 2 Years or e Change engine coolant Every 1000 Hours Perform these maintenance procedures more frequently under extremely dusty dirty conditions Only required for Denso starters Not necessary on Delco starters Have a Kohler Engine
29. nce at and after the first scheduled replacement point consequential damages such as loss of time inconvenience loss of use of the engine or equipment etc diagnosis and inspection fees that do not result in eligible warranty service being performed and any add on or modified part or malfunction of authorized parts due to the use of add on or modified parts MAINTENANCE AND REPAIR REQUIREMENTS The owner is responsible for the proper use and maintenance of the engine Kohler Co recommends that all receipts and records covering the performance of regular maintenance be retained in case questions arise If the engine is resold during the warranty period the maintenance records should be transferred to each subsequent owner Kohler Co reserves the right to deny warranty coverage if the engine has not been properly maintained however Kohler Co may not deny warranty repairs solely because of the lack of repair maintenance or failure to keep Maintenance records 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 service center Any replacement part or service that is equivalent in performance and durability may be used in non warranty maintenance or repairs and shall not reduce the warranty obligations of the engine manufacturer FORM NO 66 590 01 KOHLER nets REVISED ENGINES a
30. nder this warranty is expressly limited at our option to the replacement or repair at Kohler Co Kohler Wisconsin 53044 or at a service facility designated by us of such parts as inspection shall disclose to have been defective EXCLUSIONS Mufflers on engines used commercially non residential are warranted for one 1 year from date of purchase except catalytic mufflers which are warranted for two 2 years This warranty does not apply to defects caused by casualty or unreasonable use including faulty repairs by others and failure to provide reasonable and necessary maintenance The following items are not covered by this warranty Engine accessories such as fuel tanks clutches transmissions power drive assemblies and batteries unless supplied or installed by Kohler Co These are subject to the warranties if any of their manufacturers KOHLER CO AND OR THE SELLER SHALL NOT BE LIABLE FOR SPECIAL INDIRECT INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY KIND including but not limited to labor costs or transportation charges in connection with the repair or replacement of defective parts IMPLIED OR STATUTORY WARRANTIES INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY LIMITED TO THE DURATION OF THIS WRITTEN WARRANTY We make no other express warranty nor is any one authorized to make any on our behalf Some states do not allow limitations on how long an implied warranty lasts or the excl
31. ng when the oil reaches the bottom of the 5 If the level is low add oil of the proper type up to threads Allow a minute or two for the oil to be the FULL mark on the dipstick Refer to Oil absorbed by the filter material Type on page 4 Always check the level with the dipstick before adding more oil 6 Apply a thin film of clean oil to the rubber gasket i on the new filter NOTE To prevent extensive engine wear or damage always maintain the proper oil 7 Install the new oil filter to the filter adapter Hand level In the crankcase Never operate the tighten the filter clockwise until the rubber gasket engine with the oil level below the ADD contacts the adapter then tighten the filter an mark or over the FULL mark on the additional 2 3 to 1 turn dipstick 8 Fill the crankcase with new oil of the proper type Oil Sentry to the FULL mark on the dipstick Refer to Oil Some engines are equipped with an optional Oil Type and Check Oil Level on pages 4 and 8 Sentry oil pressure switch If the oil pressure Always check the level with the dipstick before decreases below an acceptable level the Oil Sentry adding more oil will either shut off the engine or activate a warning signal depending on the application 9 Reinstall the oil fill cap dipstick and tighten i i securely by turning to the right NOTE Make sure the oil level is checked BEFORE EACH USE and is maintained up to the FULL
32. plugged radiator cooling fins and or cooling shrouds removed will cause engine damage due to overheating Figure 22 Clean Radiator Cooling Fins Ignition System This engine is equipped with an electronic CD ignition system Other than periodically checking replacing the spark plugs no maintenance or adjustments are necessary or possible with this system In the event starting problems should occur which are not corrected by replacing the spark plugs see your Kohler Engine Service Dealer for trouble analysis Check Spark Plugs Annually or every 200 hours of operation whichever comes first remove the spark plugs check condition and reset the gap or replace with new plugs as necessary Every 500 hours of operation replace the spark plugs The standard spark plug is a Champion RC14YC Kohler Part No 66 132 01 S Equivalent alternate brand plugs can also be used 1 Before removing the spark plug clean the area around the base of the plug to keep dirt and debris out of the engine 2 Remove the plug and check its condition Replace the plug if worn or reuse is questionable NOTE Do not clean the spark plug in a machine using abrasive grit Some grit could remain in the spark plug and enter the engine causing extensive wear and damage 3 Check the gap using a wire feeler gauge Adjust the gap to 0 76 mm 0 030 in by carefully bending the ground electrode See Figure 23 4 Reinstall the spark plug into the cy
33. the engine for the period of time listed above provided there has been no abuse neglect or improper maintenance The emission control system may include parts such as the carburetor or fuel injection system the ignition system and catalytic converter Also included are the hoses belts and connectors and other emission related assemblies Where a warrantable condition exists Kohler Co will repair the engine at no cost including diagnosis if the diagnostic work is performed at an authorized dealer parts and labor MANUFACTURER S WARRANTY COVERAGE Engines produced in 1995 or later are warranted for two years in California In other states 1997 and later model year engines are warranted for two years If any emission related part on the engine is defective the part will be repaired or replaced by Kohler Co free of charge OWNER S WARRANTY RESPONSIBILITIES a The engine owner is responsible for the performance of the required maintenance listed in the owner s manual Kohler Co recommends that you retain all receipts covering maintenance on the engine But Kohler Co cannot deny warranty solely for the lack of receipts or for your failure to assure that all scheduled maintenance was performed o Be aware however that Kohler Co may deny warranty coverage if the engine or a part has failed due to abuse neglect improper maintenance or unapproved modifications c For warranty repairs the engine must be presented to a Kohler Co
34. ts vapors can explode if hot from operation Turning the extremely hot from operation To ignited Store gasoline only in radiator cap when the engine is hot prevent severe burns do not touch approved containers in well can allow steam and scalding liquid these areas while the engine is ventilated unoccupied buildings to blow out and burn you severely running or immediately after it is away from sparks or flames Do not turned off Never operate the engine fill the fuel tank while the engine is Shut off machine Only remove with heat shields or guards hot or running since spilled fuel radiator cap when cool enough to removed could ignite if it comes in contact touch with bare hands Slowly with hot parts or sparks from loosen cap to first stop to relieve ignition Do not start the engine near pressure before removing spilled fuel Never use gasoline as a completely California cleaning agent Proposition 65 Warning Engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Safety Precautions Cont A WARNING A WARNING amp WARNING rd gt ee Mauti i Accidental Starts can cause severe Carbon Monoxide can cause Explosive Gas can cause fires and injury or death severe nausea fainting or death severe acid burns Charge battery only in a well Disconnect and ground spark plug Do not operate engine in closed or ventilated area Keep sourc
35. up period but it may be necessary to leave the choke partially on until the engine warms up For a Warm Engine Return choke to off position as soon as engine starts Stopping gasoline has higher volatility to improve starting i Remove the load by disengaging all PTO attachments 2 Position the throttle control somewhere between half and full throttle then stop the engine Battery A 12 volt battery is normally used Refer to the operating instructions of the equipment this engine powers for specific battery requirements If the battery charge is not sufficient to crank the engine recharge the battery see page 15 Operating Angle of Operation This engine will operate continuously at angles up to 20 Check oil level to assure crankcase oil level is at the FULL mark on the dipstick Refer to the operating instructions of the equipment this engine powers Because of equipment design or application there may be more stringent restrictions regarding the angle of operation NOTE Do not operate this engine continuously at angles exceeding 20 in any direction Engine damage could result from insufficient lubrication Cooling NOTE If debris builds up on the air intake screen radiator or other cooling areas stop the engine immediately and clean Operating the engine with blocked or dirty air intake and cooling areas can cause extensive damage due to overheating See Clean Air Intake
36. ur Kohler Engine Service Dealer These numbers are found on the identification plate which is affixed to the engine shrouding Include letter suffixes if there are any See Engine Identification Numbers on page 5 Always insist on genuine Kohler parts All genuine Kohler parts meet strict standards for fit reliability and performance Major Repair Major repair information is available in Kohler Engine Service Manuals However major repair generally requires the attention of a trained mechanic and the use of special tools and equipment Your Kohler Engine Service Dealer has the facilities training and genuine Kohler replacement parts necessary to perform this service For Sales amp Service assistance call 1 800 544 2444 U S amp Canada or contact your Kohler Engine Dealer or Service Distributor they re in the Yellow Pages under Engines Gasoline 17 Specifications POG Ie creere te asco oeietinn aa E mde eectisenntiececeadeccentecesseneetes WN 2D senn LV675 LV680 Bore EEEE TETT ET in MM seere 3 03 77 ordered 3 15 80 OKE er ERE EET TEE REE or In TI osse reader 2 64 67 osnnnnnsssserenrn nns 2 64 67 Displacement mosoessssresessrrrrreessrrrrrnrn rn rr rann IN a eo ere 38 1 624 ss 41 1 674 Power 3600 RPM msmennnssssssesssr snara FIP WY sonnerie 20 14 9 sonson 23 17 2 24 17 9 Max Torque cccceeeeeeeeees ft Ib Nm RPM oooossesssssrreesessssnna 35 4 48 0 2000
37. usion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state TO OBTAIN WARRANTY SERVICE Purchaser must bring the engine to an authorized Kohler service facility To locate the nearest facility visit our website www kohlerengines com and click on SALES AND SERVICE to use the locator function consult your Yellow Pages or telephone 1 800 544 2444 ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 18 KOHLER CO FEDERAL AND CALIFORNIA EMISSION CONTROL SYSTEMS LIMITED WARRANTY SMALL OFF ROAD ENGINES The U S Environmental Protection Agency EPA the California Air Resources Board CARB and Kohler Co are pleased to explain the Federal and California Emission Control Systems Warranty on your small off road equipment engine For California engines produced in 1995 and later must be designed built and equipped to meet the state s stringent anti smog standards In other states 1997 and later model year engines must be designed built and equipped to meet the U S EPA regulations for small non road engines The engine Must be free from defects in materials and workmanship which cause it to fail to conform with U S EPA standards for the first two years of engine use from the date of sale to the ultimate purchaser Kohler Co must warrant the emission control system on
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