Kohler LH755, LH685, LH690, LH775, LH630 User Manual

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OWNER'S MANUAL

AEGIS

LH630, LH640, LH685, LH690, LH755, LH775

LIQUID-COOLED HORIZONTAL CRANKSHAFT

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.

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 is used to indicate the presence of a hazard that will or can cause minor personal injury

CAUTION

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 Y our Safety!

These precautions should be followed at all times. Failure to follow these precautions could result in injury to yourself and others.

WARNING

Explosive Fuel can cause fires and severe burns.

Do not fill the fuel tank while the engine is hot or running.

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.

WARNING

Hot liquid can cause severe burns.

Do not loosen radiator cap while engine is operating or warm to the touch.

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.

WARNING

Hot Parts can cause severe burns.

Do not touch engine while operating or just after stopping.

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.

California

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.)

WARNING

Accidental Starts can cause severe injury or death.

Disconnect and ground spark plug leads before servicing.

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.

CAUTION

Electrical Shock can cause injury .

Do not touch wires while engine is running.

Electrical Shock!

Never touch electrical wires or components while the engine is running. They can be sources of electrical shock.

WARNING

Carbon Monoxide can cause severe nausea, fainting or death.

Avoid inhaling exhaust fumes, and never run the engine in a closed building or confined area.

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.

WARNING

Rotating Parts can cause severe injury.

Stay away while engine is in operation.

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.

WARNING

Explosive Gas can cause fires and severe acid burns.

Charge battery only in a well ventilated area. Keep sources of ignition away.

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.

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:

• 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. & Canada) for Sales & Service assistance.

To keep your engine in top operating condition, follow the maintenance procedures in this manual.

Heavy-Duty Air Cleaner

Oil Fill Cap

Spark Plug

Oil Filter

Oil Drain Plug

Figure 1. Typical Kohler Aegis® Carbureted Engine.

Heavy-Duty Air Cleaner

Radiator

Reservoir

Dipstick

RectifierRegulator

Spark Plug

Electric Starter

Oil Drain Plug

Reservoir

Fuel Injector

Fuse Holders

Figure 2. Typical Kohler Aegis® EFI Engine.

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 T ype

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.

Ignition Coil

ECU

Wire Harness

*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 3. 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 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 4.

Figure 4. Oil Container Logo.

Refer to Maintenance Instructions beginning on page 8 for detailed oil check, oil change, and oil filter change procedures.

Fuel Recommendations

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 including E20 and E85 are not to be used and not approved. Any failures resulting from use of these fuels will not be warranted.

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.

WARNING: Explosive Fuel!

Gasoline is extremely flammable and its vapors can explode if ignited. Store gherasoline 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 insure 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.

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 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. The primary location is on the side of the flywheel cover. Placement may vary due to OEM requirements and specific options involved.

Record your engine identification numbers on the identification label (Figure 5) for future reference.

For Models LH630, LH640, LH685, LH690

IMPORTANT ENGINE INFORMATION THIS ENGINE MEETS U.S. EPA PH2, EC ST AGE II (SN:4) AND CA 2008 AND LATER EXH EMISSION REGS FOR SI SORE

FAMILY TYPE APP

DISPL. (CC) MODEL NO. SPEC. NO. SERIAL NO. BUILD DA TE 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

For Models LH755 and LH775

Refer to certification label for engine displacement.

Exhaust Emission Control System for models LH630, LH640, LH685, LH690 and LH755 is EM. Exhaust Emission Control System for model LH775 is EM, O2S, ECM, MFI.

Model Designation

Model LH690 for example: L designates liquid cooled, H designates horizontal crankshaft, and 690 is the model designation. A letter suffix 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

• Check oil level. Add oil if low. Do not overfill.

IMPORTANT ENGINE INFORMATION THIS ENGINE MEETS EMISSION REGS FOR U.S. EPA 2005 AND LATER AND EC STAGE II (SN:4) SI SMALL OFF-ROAD ENGINES AND CA 2005 AND LATER LSI ENGINES

FAMILY TYPE APP

DISPL. (CC) MODEL NO. SPEC. NO. SERIAL NO. BUILD DA TE

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

Figure 5. 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.

Emission Compliance Period (Hours)

EPA

CARB

Category C 250 Hours Moderate 125 Hours

Category B 500 Hours Intermediate 250 Hours

Category A 1000 Hours Extended 500* Hours

*Extended hours for Models LH755 and LH775 is 1000.

• Check coolant level. Add coolant if low.

• Check fuel level. Add fuel if low.

• Check radiator, cooling air intake areas and external surfaces of engine. Make sure they are clean and unobstructed.

• Check that the air cleaner components and all shrouds, equipment covers, and guards are in place and securely fastened.

• 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.

WARNING: Lethal Exhaust Gases!

Cold Weather Starting Hints

1. The cooling system must be filled with coolant capable of providing proper protection against 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 3 on page 4.

3. Declutch all possible external loads.

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