Kohler Aegis TP-2509- Manuals

1.4 Section 1Safety and General Information Oil Recommendations Using the proper type and weight of oil in thecrankcase is extremely important. So is checking oildaily and changing oil regularly. Failure to use thecorrect oil, or using dirty oil, causes premature enginewear and failure. Oil TypeUse ...

1.5 Section 1 Safety and General Information 1 Fuel TypeFor best results, use only clean, fresh, unleadedgasoline with a pump sticker octane rating of 87 orhigher. In countries using the Research method, itshould be 90 octane minimum. Unleaded gasoline is recommended, as it leaves fewercombustion ch...

1.6 Section 1Safety and General Information Storage If the engine will be out of service for two months ormore, use the following storage procedure: 1. Clean the exterior surfaces of the radiator and engine. 2. Change the oil and filter while the engine is still warm from operation. See “Change Oil ...

1.8 Section 1Safety and General Information General Specifications 1 Power (@ 3600 RPM, corrected to SAE J1995) LV560 ............................................................................................. 12.7 kW (17 HP)LV625 ......................................................................

1.13 Section 1 Safety and General Information 1 Valves and Valve Lifters (Cont'd.)Intake Valve Guide I.D. New ................................................................................................ 7.038/7.058 mm (0.2771/0.2779 in.)Max. Wear Limit ..............................................

1.14 Section 1Safety and General Information English Fastener Torque Recommendations for Standard Applications Grade 2 or 5Fasteners IntoAluminum Size8-32 2.3 (20) 2.8 (25) --------- 2.3 (20) 10-24 3.6 (32) 4.5 (40) --------- 3.6 (32) 10-32 3.6 (32) 4.5 (40) --------- --------- 1/4-20 7.9 (70) 13.0 ...

2.1 Section 2 Special Tools 2 LV560, LV625, LV675 Section 2 Special Tools These quality tools are designed to help you perform specific disassembly, repair, and reassembly procedures.By using tools designed for the job, you can service engines easier, faster, and safer! In addition, you’ll increasey...

3.1 Section 3 Troubleshooting 3 Section 3 Troubleshooting Troubleshooting Guide When troubles occur, be sure to check the simplecauses which, at first, may seem too obvious to beconsidered. For example, a starting problem could becaused by an empty fuel tank. Some common causes of engine troubles ar...

3.2 Section 3Troubleshooting Engine Overheats (cont'd.) 7. Radiator cap faulty or loose.8. Lean fuel mixture.9. Water pump belt failed/off. 10. Water pump malfunction. Engine Knocks 1. Excessive engine load.2. Low crankcase oil level.3. Old or improper fuel.4. Internal wear or damage.5. Hydraulic li...

3.3 Section 3 Troubleshooting 3 NOTE: It is good practice to drain oil at a location away from the workbench. Be sure toallow ample time for complete drainage. Cleaning the Engine After inspecting the external condition of the engine,clean the engine thoroughly before disassembling it.Also clean ind...

4.1 Section 4 Air Cleaner and Air Intake System 4 Section 4 Air Cleaner and Air Intake System LV560, LV625, LV675 Air Intake System GeneralAll intake air, for both cooling and combustion, isdrawn in through the screen in the upper blowerhousing. ServiceCheck the air intake screen daily or before sta...

4.2 Section 4Air Cleaner and Air Intake System Figure 4-4. Cleaning Separated Screen Assembly. Always reinstall the upper blower assembly after it hasbeen removed for service. Do not operate the enginewith the upper blowing housing or screen removed. Air Cleaner GeneralThese engines are equipped wit...

4.4 Section 4Air Cleaner and Air Intake System 4. Disconnect the breather hose from the air cleaner base. Figure 4-9. Base Plate Removal on Standard Type. Fuel PumpVacuum Line Breather Hose 5. Slide the clamp and air cleaner base off the stud. 6. Reverse procedure to reassemble components. Torque th...

5.1 Section 5 Fuel System and Governor 5 Section 5 Fuel System and Governor Description WARNING: Explosive Fuel! Gasoline is extremely flammable and its vapors canexplode if ignited. Store gasoline only in approvedcontainers, in well ventilated, unoccupied buildings,away from sparks or flames. Do no...

5.2 Section 5Fuel System and Governor Fuel System TestsWhen the engine starts hard, or turns over but will not start, it is possible that the problem is in the fuel system. Tofind out if the fuel system is causing the problem, perform the following tests. Troubleshooting – Fuel System Related Causes...

5.3 Section 5 Fuel System and Governor 5 2. Remove the hex. flange screws (securing pump to blower housing) and fuel pump. 3. Remove the vacuum line that connects the pump to the crankcase. 4. Install a new pump using the hex. flange screws. NOTE: Make sure the orientation of the new pump is consist...

5.6 Section 5Fuel System and Governor Troubleshooting ChecklistWhen the engine starts hard, runs roughly or stalls atlow idle speed, check the following areas beforeadjusting or disassembling the carburetor. • Make sure the fuel tank is filled with clean, freshgasoline. • Make sure the fuel tank cap...

5.7 Section 5 Fuel System and Governor 5 Fuel Shut-off SolenoidCarburetors are equipped with a fuel shut-off solenoid,which also contains the main jet. The solenoid has aspring loaded pin which retracts when the key switch is‘‘on’’, allowing the engine to function normally. Whenthe key switch is tur...

6.1 Section 6 Lubrication System 6 Section 6 Lubrication System General This engine uses a full pressure lubrication system.This system delivers oil under pressure to thecrankshaft, camshaft and connecting rod bearingsurfaces. In addition to lubricating the bearingsurfaces, the lubrication system su...

6.2 Section 6Lubrication System Figure 6-3. Oil Level Marks on Dipstick. NOTE: To prevent extensive engine wear or damage, always maintain the proper oillevel in the crankcase. Never operate theengine with the oil level below the ‘‘ADD’’mark or above the ‘‘FULL’’ mark on thedipstick. 3. Unthread and...

6.3 Section 6 Lubrication System 6 3. Before removing the oil filter, clean the surrounding area to keep dirt and debris out of theengine. Remove the old filter and wipe/clean thesurface where the filter mounts. 4. Reinstall the drain plug. Make sure it is tightened to 13.6 N·m (10 ft. lb.). 5. Plac...

6.4 Section 6Lubrication System To install the switch, follow these steps: 1. Apply Loctite ® No. 592 Pipe Sealant with Teflon ® (or equivalent) to the threads of the switch. 2. Install the switch into the tapped hole in the breather cover. See Figure 6-5. 3. Torque the switch to 4.5 N·m (40 in. lb....

7.1 Section 7 Cooling System 7 Section 7 Cooling System WARNING: Explosive release of fluids from pressurized cooling system can cause serious burns! When it is necessary to open cooling system at radiator cap, shut off engine and remove filler cap only whencool enough to touch with bare hands. Slow...

7.2 Section 7Cooling System Coolant Recommendations Use equal parts of ethylene glycol (anti-freeze) andwater only. Distilled or deionized water isrecommended, especially in areas where the watercontains a high mineral content. Propylene glycolbased anti-freeze is not recommended. This mixture will ...

7.3 Section 7 Cooling System 7 Figure 7-4. Coolant Levels on Reservoir. NOTE: Do not operate the engine without coolant in the system. Do not remove the radiator capwhen hot. Engine coolant is hot and underpressure and can cause severe burns. Toprevent engine overheating and damage, donot exceed mor...

7.5 Section 7 Cooling System 7 Hoses and Tubes Hoses and tubes are used to connect the componentswithin the cooling system. To guard against coolantloss and hose failure, the hoses, tubes and theirconnections should be checked regularly for leaks ordamage. Loss of coolant can result in serious engin...

7.6 Section 7Cooling System High Temperature Sensor A high temperature sensor may be mounted in theintake manifold and is used to activate a warning light,audible alarm, or kill the engine (depending on theapplication), if the safe operating temperature isexceeded. The sensor is a ‘‘normally open’’ ...

7.7 Section 7 Cooling System 7 Figure 7-12. Adapter Installed onto the Tester. 2. Pressurize the tester to 15 psi. 3. Observe the indicated pressure. It should hold steady and not decrease or leak down. If leakage is detected, the cap should bereplaced. If the tester pressure is increased to 16psi, ...

8.1 Section 8 Electrical System and Components 8 Section 8 Electrical System and Components This section covers the operation, service and repair ofthe electrical system components. Systems andcomponents covered in this section are: • Spark Plugs • Battery and Charging System • Electronic CD Ignitio...

8.3 Section 8 Electrical System and Components 8 Overheated: Chalky, white deposits indicate very highcombustion temperatures. This condition is usuallyaccompanied by excessive gap erosion. Leancarburetor settings, an intake air leak, or incorrectspark timing are normal causes for high combustiontem...

8.4 Section 8Electrical System and Components Electronic CD Ignition Systems Operation of CD Ignition SystemsCapacitive Discharge with Fixed Timing This system consists of the following components. SeeFigure 8-3. • A magnet assembly which is permanently affixedto the flywheel. • Two electronic capac...

8.5 Section 8 Electrical System and Components 8 Figure 8-5. Capacitive Discharge Ignition Module. Operation: As the flywheel rotates, the magnetgrouping passes the input coil (L1). The correspondingmagnetic field induces energy into the input coil (L1).The resultant pulse is rectified by D1 and cha...

8.6 Section 8Electrical System and Components Test 1. If one side is not firing, check all wiring, connections, and terminations on that side. Ifwiring is okay, replace ignition module and retestfor spark. If the tester shows spark, but the engine missesor won't run on that cylinder, try a new spark...

8.13 Section 8 Electrical System and Components 8 Delco-Remy Starters Figure 8-13. Removing Solenoid Screws. Figure 8-14. Solenoid Removed from Starter. 3. Lift and unhook the plunger assembly from the drive lever. Remove the gasket from the recess inthe housing. See Figure 8-15. Figure 8-15. Removi...

8.15 Section 8 Electrical System and Components 8 Lever Solenoid CE Frame Bolt RingStop Drive Armature Washer 11. Remove the retainer from the armature shaft. Save the stop collar. NOTE: Do not reuse the old retainer. Figure 8-22. Removing Retaining Ring. 12. Remove the drive pinion assembly from th...

8.16 Section 8Electrical System and Components Inspection Drive Pinion Check and inspect the following areas: a. The pinion teeth for abnormal wear or damage. b. The O.D. surface between the pinion and the clutch mechanism for nicks, or irregularitieswhich could cause seal damage. c. Check the drive...

8.17 Section 8 Electrical System and Components 8 2. Remove the two screws securing the brush holder assembly to the end cap (plate). Note theorientation for reassembly later. See Figure 8-27.Discard the old brush holder assembly. Figure 8-27. Removing Brush Holder. 3. Clean the component parts as r...

8.20 Section 8Electrical System and Components 11. Install the end cap onto armature and frame, aligning the thin raised rib in the end cap with thecorresponding slot in the grommet of the positive(+) brush lead. 12. Install the two thru bolts, and the two brush holder mounting screws. Torque the th...

9.1 Section 9 Disassembly 9 Section 9 Disassembly WARNING: Accidental Starts! 19. Remove water pump and transfer tube.20. Remove by-pass hose and wiring harness.21. Remove intake manifold, temperature sensor, and thermostat. 22. Remove lower blower housing and oil fill/dipstick tube. 23. Remove Oil ...

9.2 Section 9Disassembly Shut Off Fuel Supply Drain Oil From Crankcase andRemove Oil Filter 1. Remove the dipstick and one of the oil drain plugs. See Figures 9-2 and 9-3. Figure 9-2. Removing Oil Fill Cap/Dipstick. Figure 9-3. Oil Drain Plugs and Oil Filter. 2. Allow ample time for the oil to drain...

9.3 Section 9 Disassembly 9 Figure 9-6. Separating Screen from Housing. Remove Muffler 1. Remove the muffler or exhaust system and attaching hardware from the engine. See Figure 9-7. Figure 9-7. Removing Muffler. Drain Cooling System 1. Make sure the engine is cool. Slowly remove the radiator cap. S...

9.4 Section 9Disassembly 2. Disconnect the fuel lines at the inlet of the carburetor, and the in-line fuel filter. See Figure 9-11. Figure 9-11. Removing Fuel Line at Carburetor. 3. Remove the two hex. flange screws securing the fuel pump to the blower housing and remove thepump and lines as an asse...

9.5 Section 9 Disassembly 9 Figure 9-17. Loosening Governor Lever Clamp Nut. 3. Remove the four hex. flange screws securing the throttle control bracket to the cylinder heads. SeeFigure 9-18. Remove Control Bracket Assembly andExternal Governor Lever 1. Disconnect any remote throttle and/or choke co...

9.6 Section 9Disassembly 4. Remove the throttle control bracket, governor lever, and governor spring as an assembly. SeeFigure 9-19. Figure 9-19. Removing Main Bracket and GovernorLever. Remove Electric Starter 1. Disconnect the leads from the starter. 2. Remove the two starter motor mounting screws...

9.7 Section 9 Disassembly 9 Figure 9-23. Location of Four Screws SecuringBlocking Plates. Remove Overflow Reservoir 1. Remove the reservoir cap from the reservoir. 2. Loosen the two screws holding the overflow reservoir retainer bracket to the radiators. SeeFigure 9-24. 3. Carefully lift the bracket...

9.8 Section 9Disassembly Figure 9-27. Removing Ignition Module. 4. Repeat the procedure for the other ignition module. Remove Flywheel 1. Use a flywheel holding tool (a suitable handle may be attached for convenience, refer toSection 2) to hold the flywheel and loosen thehex. flange screw securing t...

9.9 Section 9 Disassembly 9 Figure 9-31. Removing Center Mounting Nut. 2. Cut the metal tie strap from around the lower hose/tube assembly, secured to the blowerhousing. See Figure 9-32. Remove Radiators and Cooling System 1. Remove the hex. nut from the center mounting stud, located between the two...

9.10 Section 9Disassembly Figure 9-36. Lower Hose Removed. 6. Lift the entire cooling system, with the radiators, hoses, and supporting brackets attached, off theengine. See Figure 9-37. Further disassemblymay be performed as required. Whendisassembly of hose connections is necessary,the use of a ru...

9.11 Section 9 Disassembly 9 Figure 9-40. Removing B+ Charging Lead fromConnector. 4. Remove the stator and rectifier-regulator. Remove Cam Pulley and Coolant PumpBelt 1. Remove the hex. flange screw and flat washer, securing the cogged drive pulley to the camshaft.See Figure 9-41. Figure 9-41. Remo...

9.15 Section 9 Disassembly 9 Figure 9-56. Removing Dipstick Tube Assembly. Remove Oil Sentry ™ (If So Equipped) 1. Remove the Oil Sentry ™ switch, from the breather cover. See Figure 9-57. Figure 9-57. Removing Oil Sentry ™ Switch. Remove Breather Cover 1. Remove the four hex. flange screws securing...

9.16 Section 9Disassembly Figure 9-63. Removing the Valve Cover. Remove Cylinder Heads and HydraulicLifters 1. Rotate the crankshaft until the valves of one of the cylinders are closed. Loosen the rocker armscrews until the rocker arms can be pivoted tofree the push rods. 2. Remove and mark the loca...

9.17 Section 9 Disassembly 9 Figure 9-65. Removing Hex. Flange Nuts andWashers from Studs. 5. Carefully remove the cylinder heads, and head gaskets. See Figure 9-66. NOTE: It is not necessary to remove the cylinder studs from the crankcase unlessreplacement is intended. If studs areremoved for any r...

9.18 Section 9Disassembly Figure 9-72. Removing Oil Pan Fasteners. 2. Locate the splitting tab cast into the perimeter of the oil pan. Insert the drive end of a breaker barbetween the splitting tab and the crankcase, andturn it to break the RTV seal. See Figure 9-73. Donot pry on the sealing surface...

9.19 Section 9 Disassembly 9 Oil Pump AssemblyThe oil pump is mounted in the oil pan. If service isrequired, refer to the service procedures under ‘‘OilPump Assembly’’ in Section 10. Remove Camshaft 1. Remove the camshaft and shim. See Figure 9-74. Figure 9-74. Removing Camshaft and Shim. Remove Gov...

9.20 Section 9Disassembly 2. Carefully remove the connecting rod and piston assembly from the cylinder bore. See Figure 9-78. NOTE: The cylinders are numbered on the crankcase. Use the numbers to markeach end cap, connecting rod, and pistonfor reassembly. Do not mix end caps andconnecting rods. Figu...

10.1 Section 10 Inspection and Reconditioning 10 Section 10 Inspection and Reconditioning This section covers the operation, inspection, and repair/reconditioning of major internal engine components. Thefollowing components are not covered in this section. They are covered in sections of their own: ...

10.3 Section 10 Inspection and Reconditioning 10 Crankcase These engines contain a cast-iron cylinder liner thatmay be reconditioned as follows: Inspection and ServiceCheck all gasket surfaces to make sure they are freeof gasket fragments. Gasket surfaces must also befree of deep scratches or nicks....

10.7 Section 10 Inspection and Reconditioning 10 Valve GuidesIf a valve guide is worn beyond specifications, it will notguide the valve in a straight line. This may result inburnt valve faces or seats, loss of compression, andexcessive oil consumption. To check valve guide-to-valve stem clearance,th...

10.8 Section 10Inspection and Reconditioning Pistons and Rings InspectionScuffing and scoring of pistons and cylinder wallsoccurs when internal temperatures approach thewelding point of the piston. Temperatures high enoughto do this are created by friction, which is usuallyattributed to improper lub...

10.10 Section 10Inspection and Reconditioning Install Piston RingsTo install piston rings, proceed as follows: NOTE: Rings must be installed correctly. Ring installation instructions are usually includedwith new ring sets. Follow instructionscarefully. Use a piston ring expander to installrings (see...

10.11 Section 10 Inspection and Reconditioning 10 NOTE: The governor gear is held onto the shaft by small molded tabs in the gear. When the gearis removed from the shaft, these tabs aredestroyed and the gear must be replaced.Therefore, remove the gear only if absolutelynecessary. 1. Remove the regul...

10.12 Section 10Inspection and Reconditioning Figure 10-15. Installing Cross Shaft Oil Seal. Figure 10-16. Governor Shaft Seal Installation. 2.0 mm (0.0787 in.) Governor CrossShaft Seal Figure 10-17. Governor Shaft Seal Position. Water Pump The water/coolant pump consists of a sealed impellerassembl...

11.1 Section 11 Reassembly 11 Section 11 Reassembly LV560, LV625, LV675 General NOTE: Make sure the engine is assembled using all specified torque values, tighteningsequences, and clearances. Failure toobserve specifications could cause severeengine wear or damage. Always use newgaskets, seals, and ...

11.2 Section 11Reassembly Figure 11-1. Installing Flywheel End Oil Seal inCrankcase. The camshaft seal should be installed to a depthof 1-1.5 mm (.039-.059 in.) below the top of theseal bore. See Figure 11-2. Do not bottom theseal in the bore or the oil passage may beobstructed. Figure 11-3. Install...

11.3 Section 11 Reassembly 11 Figure 11-5. Proper Piston Connecting RodOrientation. 1. Stagger the piston rings in the grooves. The end gaps of the top two rings should be 180° apart andperpendicular to the rail end gaps, which shouldalso be 180° apart. 2. Lubricate cylinder bore, piston, and piston...

11.4 Section 11Reassembly Figure 11-8. Assembly of Nylon Washer, Retainer,and Setting the End play. Install Camshaft 1. Inspect the edges of the keyway in the end of camshaft and make sure they are not nicked orburred. Wrap this end using cellophane tape, sothe keyway is covered, to protect the seal...

11.5 Section 11 Reassembly 11 Determining Camshaft End Play 1. Install the shim removed during disassembly onto the camshaft. 2. Position the camshaft end play checking tool on the camshaft. See Figure 11-12. Figure 11-12. Checking Camshaft End Play. 3. Apply pressure on the end play tool, pushing t...

11.6 Section 11Reassembly 3. Install the O-Ring in groove as shown. See Figure 11-14. Apply a 1.5 mm (1/16 in.) bead of sealantto the sealing surface of the oil pan. See Figure11-15 for the sealant pattern. 6. Install the ten hex. flange screws securing the oil pan to the crankcase. Torque fasteners...

11.7 Section 11 Reassembly 11 Figure 11-17. Applying Loctite to New Stud. 2. Tighten two nuts together on the shorter threaded section. 3. Thread the end of the stud with the Loctite ® into the crankcase, until an exposed stud height of75 mm (2.952 in.) is obtained. The end with thedash mark must be...

11.11 Section 11 Reassembly 11 Figure 11-30. Installing Shim(s). 14. Reassemble the rocker arm and pivot assembly to the head and seat the push rod. See Figure11-30. Torque the fastener; 11.3 N·m (100 in. lb.)for a hex. flange screw, or 17.3 N·m (153 in. lb.)for a lock nut. See Figure 11-31. 15. Hol...

11.12 Section 11Reassembly Figure 11-33. Depressing To Bottom Limit of LifterPlunger Travel. 10. With the lifter still compressed, slowly tighten the rocker arm fastener (clockwise) until the freeend of the rocker arm just makes contact with theend of the valve. See Figure 11-34. Figure 11-35. Deter...

11.13 Section 11 Reassembly 11 Figure 11-36. Installing Shim(s). Figure 11-37. Torquing Rocker Arm. 15. Hold down the push rod end of the rocker arm (step 9). Using a feeler gauge, check that thereis 0.03-0.3 mm (0.001 to 0.010 in.) clearancebetween the rocker arm and the end of thevalve. See Figure...

11.14 Section 11Reassembly Figure 11-42. Installing Pipe Plug. Install Oil Fill/Dipstick Tube Assembly andLower Blower Housing 1. Lubricate the O-Ring with engine oil, and install it on the lower end of the dipstick tube. Push thelower end of the tube assembly down into thecrankcase until it seats i...

11.15 Section 11 Reassembly 11 Figure 11-44. Tie Strap in Lower Blower Housing. 3. Set the lower blower housing down into position on the crankcase, and align the eight mountingscrew locations. Insert the mounting tab of the oilfill/dipstick tube into the corresponding blowerhousing slot from the bo...

11.21 Section 11 Reassembly 11 Figure 11-70. By-pass Hose Installation. Install Stator and Rectifier-Regulator 1. Position the stator onto the mounting bosses so the leads are at the bottom, and directed outtoward the rectifier-regulator mount on the #1side. Apply pipe sealant with Teflon ® (not Tef...

11.23 Section 11 Reassembly 11 8. Lift the by-pass hose and secure it within the metal clip under the main support bracket. SeeFigure 11-78. Figure 11-78. Seating By-pass Hose. Install Electric Starter 1. Position the starter mounting plate onto the crankcase so that the cutout is at the bottom,and ...

11.24 Section 11Reassembly Install Ignition Modules and Flywheel 1. Route the spark plug leads of the ignition modules, out through the corresponding cutoutsin the lower blower housing assembly. 2. Route the white kill leads from the wiring harness and connect them to the ‘‘kill’’ tabs of the igniti...

11.25 Section 11 Reassembly 11 3. Lower the flywheel down into position on crankshaft and make sure the ring gear sectionis below the legs of the ignition modules. SeeFigure 11-85. If clearance is OK, continue with installation of theignition modules. If clearance is insufficient orcontact is noted;...

11.27 Section 11 Reassembly 11 Figure 11-93. Attaching Linkages onto Carburetor. Checking Valve Train 1. Rotate engine to check for free operation of the valve train. Check the clearance between valvespring coils at full lift. Minimum allowableclearance is 0.25 mm (0.01 in.). If engine seemstight or...

11.28 Section 11Reassembly 3. Install the carburetor as an assembly, onto the carburetor studs. See Figure 11-94. Carefully liftup on the lower blower housing, directly above thecarburetor, and slide the carburetor into placeagainst the gasket and manifold. 3. Pivot the governor lever toward the car...

11.29 Section 11 Reassembly 11 Install Throttle Controls 1. Connect the choke linkage from the carburetor into the choke actuator lever on the speed control bracket assembly. See Figure 11-97. Washer,flat (3) Lever ThrottleControl (middle) Lever,ThrottleActuator(bottom) Bracket,SpeedControl Spring,C...

11.31 Section 11 Reassembly 11 Figure 11-102. Rechecking Governor LinkageAdjustment. 4. After adjustment is correct, reinstall the black bushing and linkage into the governor lever. Install Muffler 1. Install the muffler or exhaust system to the exhaust port studs. Torque hex. flange nutsto 24.4 N·m...