Kohler KS530 Service Manual Download Page 45

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Electrical System

22 690 01 Rev. --

KohlerEngines.com

Wiring Diagram-12/15 Amp Regulated Battery Charging System with Fuel Relay

B+

Red

Green

Violet

White

Spark Plug

Fuel Shut-oﬀ Solenoid

Optional Oil Sentry

™

Switch (Indicator)

Bendix Starter

Engine Connector

Starter Solenoid

Ground-To-Kill Lead

Key Switch

Optional Oil Sentry

™

Optional Fuse

Battery

Rectiﬁ er-Regulator

Flywheel

Stator

Ignition Module

Accessory

Fuel Shut-oﬀ Relay

Orange

Yellow

Equipment Safety

Circuit

Summary of Contents for KS530

Page 1: ...stem 40 Lubrication System 42 Electrical System 55 Starter System 57 Emission Compliant Systems 60 Disassembly Inspection and Service 76 Reassembly IMPORTANT Read all safety precautions and instructio...

Page 2: ...ting or death Avoid inhaling exhaust fumes Engine exhaust gases contain poisonous carbon monoxide Carbon monoxide is odorless colorless and can cause death if inhaled WARNING Accidental Starts can cau...

Page 3: ...air cleaner element if not equipped with precleaner Air Cleaner Intake Every 100 Hours or Annually whichever comes rst Replace air cleaner element if equipped with precleaner Air Cleaner Intake Chang...

Page 4: ...ved and should NOT be used e ects of old stale or contaminated fuel are not warrantable Fuel must meet these requirements Clean fresh unleaded gasoline Octane rating of 87 R M 2 or higher Research Oct...

Page 5: ...ilter D 100 0 mm 3 94 in E Oil Fill and Dipstick F 10 0 mm 0 39 in Lifting Point G Throttle Cable Clip H 109 0 mm 4 29 in I 46 5 mm 1 83 in J 85 1 mm 3 35 in K Connection for Evaporative Hose 7 32 I D...

Page 6: ...rt F 81 3 mm 3 20 in G 64 0 mm 2 52 in Keyway Length H 7 16 20 UNF 2B IN 38 1 mm 1 50 in Depth I 250 3 mm 9 86 in to Exhaust Port J 2 X 30 0 mm 1 18 in K 21 6 21 8 mm 0 85 0 86 in Keyway Depth L 95 0...

Page 7: ...M N O F J A 116 0 mm 4 57 in B 55 0 mm 2 17 in C 150 D Accessory Mounting Surface E 2 X 288 8 mm 11 37 in F 35 G Rotation Direction H 254 0 mm 10 00 in I 150 2 mm 5 91 in J 45 K 36 6 mm 1 44 in L 105...

Page 8: ...Cable Clip G 324 9 mm 12 79 in H 226 7 mm 8 93 in Lifting Point I 215 7 mm 8 49 in J 14 5 mm 0 57 in Oil Filter Removal K 113 6 mm 4 47 in to Oil Filter L Oil Filter M Engine Mounting Surface N Oil D...

Page 9: ...crew 16 5 mm 0 65 in Min Depth Accessory Mounting Location E 93 2 mm 3 67 in F Carburetor G Oil Drain Plug H 122 7 mm 4 83 in I 6 32 6 36 mm 0 249 0 250 in Keyway Width J 25 37 25 40 mm 0 999 1 0 in K...

Page 10: ...0 KS590 KS595 Bore 94 mm 3 70 in Stroke 78 mm 3 1 in Displacement 541 cc 33 0 cu in Oil Capacity re ll 1 4 L 1 5 U S qt Maximum Angle of Operation full oil level 5 25 TORQUE SEQUENCES KS530 KS540 KS59...

Page 11: ...com TORQUE SEQUENCES KS530 KS540 KS590 KS595 Refer to Torque Speci cations for torque values Closure Plate Fasteners 1 2 3 4 5 6 7 9 11 10 8 Cylinder Head Fasteners 1 2 3 4 5 6 Oil Passage Cover Faste...

Page 12: ...n lb M6 Nut 9 N m 80 in lb Fuel Bowl Retaining Screws 4 0 N m 35 in lb Choke Wire Hold Down Clamp if equipped Fastener 2 7 N m 24 in lb Closure Plate torque sequence on page 11 Fastener 24 N m 212 in...

Page 13: ...lb Module Fastener 8 8 N m 78 in lb into new hole 3 4 N m 30 in lb into used hole Recti er Regulator Fastener 8 8 N m 78 in lb Intake Manifold to Cylinder Head Nuts 10 2 N m 90 in lb Mu er Retaining...

Page 14: ...to Crankpin Running Clearance New Max Wear Limit 0 040 0 081 mm 0 0016 0 0032 in 0 096 mm 0 0038 in Connecting Rod to Crankpin Side Clearance 0 400 0 630 mm 0 0157 0 0248 in Connecting Rod to Piston...

Page 15: ...0 in T I R PTO End Crankshaft in Engine Entire Crankshaft in V Blocks 0 150 mm 0 0059 in 0 100 mm 0 0039 in Cylinder Bore Bore I D New 94 010 94 035 mm 3 7011 3 7021 in Max Wear Limit 94 073 mm 3 704...

Page 16: ...x 1 000 1 250 mm 0 0394 0 0492 in 1 504 mm 0 0592 in Thrust Face O D 7 New 93 975 93 989 mm 3 6998 3 7003 in Max Wear Limit 93 875 mm 3 6960 in Piston Thrust Face to Cylinder Bore7 Running Clearance 0...

Page 17: ...nglish Fastener Torque Recommendations for Standard Applications Bolts Screws Nuts and Fasteners Assembled Into Cast Iron or Steel Grade 2 or 5 Fasteners Into Aluminum Size Grade 2 Grade 5 Grade 8 Tig...

Page 18: ...Kohler required tools Components of 25 761 39 S Ignition System Tester Cylinder Leakdown Tester Oil Pressure Test Kit Recti er Regulator Tester 120 V AC 60Hz Kohler 25 761 39 S Kohler 25 455 01 S Kohl...

Page 19: ...ts of 25 761 20 S and 25 761 41 S CS PRO Regulator Test Harness Special Regulator Test Harness with Diode Kohler 25 761 20 S Kohler 25 761 41 S Design Technology Inc DTI 031R DTI 033R Spark Advance Mo...

Page 20: ...ce is at 3 Find a 1 in long capscrew with correct thread size to match threads in connecting rod 4 Use a at washer with correct I D to slip on capscrew and approximately 1 in O D Assemble capscrew and...

Page 21: ...re Weak spark TROUBLESHOOTING GUIDE When troubles occur be sure to check simple causes which at rst may seem too obvious to be considered For example a starting problem could be caused by an empty fue...

Page 22: ...indications of improper t and seal Check air cleaner element Look for holes tears cracked or damaged sealing surfaces or other damage that could allow un ltered air into engine A dirty or clogged elem...

Page 23: ...is a vacuum and movement to right indicates a pressure Digital tester depress test button on top of tester Crankcase vacuum should be a minimum of 10 2 cm 4 in of water If reading is below speci catio...

Page 24: ...e use a breaker bar and socket on ywheel nut screw to hold it in position An assistant may be needed to hold breaker bar during testing If engine is mounted in a piece of equipment it may be possible...

Page 25: ...water with detergent Rinse and allow to air dry 3 Lightly oil precleaner with new engine oil squeeze out excess oil 4 Reinstall precleaner over paper element Paper Element 1 Remove element from air cl...

Page 26: ...positive pressures in crankcase activate pump When piston moves upward in cylinder negative pressure vacuum is created in crankcase and in air chamber of pump Diaphragm exes toward negative pressure...

Page 27: ...e ow 3 Check operation of fuel pump a Remove fuel line from inlet tting of carburetor b Crank engine several times and observe ow Condition Conclusion Fuel at tip of spark plug Fuel is reaching combus...

Page 28: ...e Plate Screw R Throttle Plate S Filter T Throttle Lever and Shaft Assembly These engines are equipped with a xed main jet carburetor Carburetors will have a low idle speed adjustment screw Troublesho...

Page 29: ...er fuel inlet needle Remove fuel bowl Clean vent ports and air bleeds Blow out all passages with compressed air Float is cracked or damaged Replace oat Carburetor solenoid gasket damaged Replace gaske...

Page 30: ...set to manufacturer s recommendation turn adjustment screw on speed control bracket in clockwise to increase or out counterclockwise to decrease RPM speed High Speed RPM Adjustment 1 With engine runni...

Page 31: ...ottle lever will contact idle speed screw when moved to closed position Inspect edge of new throttle plate Note that edge is chamfered to seal against throttle bore of carburetor when closed Installin...

Page 32: ...is cold a spring on diaphragm in conjunction with a bimetallic spring will hold choke closed for starting When engine is warm bimetallic spring holds choke completely open while engine is running Cho...

Page 33: ...not be any binding when choke shaft assembly is rotated which could cause choke to remain partially open 6 Check choke linkage for binding or debris build up Gently actuate linkage and observe that ch...

Page 34: ...utral 3 Activate starter switch Release switch as soon as engine starts If starter does not turn engine over shut starter o immediately Do not make further attempts to start engine until condition is...

Page 35: ...nt is in neutral 3 Activate starter switch Release switch as soon as engine starts 4 For Operation After engine starts move throttle choke control from fast choke ON position and set desired engine op...

Page 36: ...should not move SEPARATE THROTTLE AND CHOKE CONTROL Some engines are equipped with separate throttle and choke controls This allows you to adjust choke and throttle controls individually Install Sepa...

Page 37: ...tially on until engine warms up 4 For a Warm Engine Return choke to o position as soon as engine starts Changing High Speed RPM on Engines with Separate Controls Increase or Decrease RPM Speed Control...

Page 38: ...trifugal yweight mechanical governor Governor gear yweight mechanism of mechanical governor is mounted inside closure plate and is driven o gear on crankshaft Governor Components F O N M Inside Engine...

Page 39: ...rnor arm to open throttle plate wider This allows more fuel into engine increasing engine speed As speed reaches governed setting governor spring tension and force applied by regulating pin will again...

Page 40: ...k 7 Reinstall oil ll cap dipstick and tighten securely 8 Start engine check for oil leaks Stop engine correct leaks Recheck oil level 9 Dispose of used oil and lter in accordance with local ordinances...

Page 41: ...2 5 PSI tester should indicated a change to continuity contacts closed between terminal 1 and terminal 3 on switch Continuity condition between 1 and 3 terminals should remain closed while pressure is...

Page 42: ...d problem Reported ignition problems are most often due to poor connections Before beginning test procedure check all external wiring Be certain all ignition related wires are connected including spar...

Page 43: ...AC B L U B A Red B Green C Violet D White E Spark Plug F Optional Fuel Shut o Solenoid G Optional Oil Sentry Switch Indicator H Bendix Starter I Engine Connector J Starter Solenoid K Ground To Kill Le...

Page 44: ...White E Spark Plug F Fuel Shut o Solenoid G 3 Terminal Oil Sentry Switch Indicator H Bendix Starter I Engine Connector J Starter Solenoid K Ground To Kill Lead L Key Switch M Optional Oil Sentry N Opt...

Page 45: ...U V L V V A Red B Green C Violet D White E Spark Plug F Fuel Shut o Solenoid G Optional Oil Sentry Switch Indicator H Bendix Starter I Engine Connector J Starter Solenoid K Ground To Kill Lead L Key S...

Page 46: ...P A Red B Green C Violet D White E Spark Plug F Fuel Shut o Solenoid G Optional Oil Sentry Switch Indicator H Bendix Starter I Engine Connector J Starter Solenoid K Ground To Kill Lead L Key Switch M...

Page 47: ...m is overcharging Replace recti er regulator iii If voltage stays at 12 5 VDC or decreases charging system is NOT operating proceed to step 4 4 With engine o unplug recti er regulator connector and in...

Page 48: ...eeler gauge Adjust gap to 0 76 mm 0 030 in 2 Install plug into cylinder head 3 Torque plug to 27 N m 20 ft lb Inspection Inspect each spark plug as it is removed from cylinder head Deposits on tip are...

Page 49: ...y that is hooked up or charged backward will crank engine but it won t have spark Be certain drive is in neutral and all external loads are disconnected Test Ignition Systems NOTE If engine starts or...

Page 50: ...System Make sure engine ignition switch kill switch or key switch is in RUN position Check wires and terminals of ignition module and other components for accidental grounding and damaged insulation...

Page 51: ...ent at yellow wire of 6 pin connector this is an indication that engine kill wire is grounded equipment safety circuit has been activated through a seat switch PTO switch operator present switch if eq...

Page 52: ...o ground Conclusion Refer to equipment manual for inspection repair procedures or repair white kill wire short Condition Engine cranks but will not start Key Switch Safety Circuit Yellow Wire Volts So...

Page 53: ...LAY CIRCUIT on previous pages for troubleshooting fuel relay part of circuit Blade stop stator brake circuit is provided as a safety feature to ensure application can meet ANSI American National Stand...

Page 54: ...full speed condition Condition Conclusion Voltage does not increase Shut down engine remove stator brake relay from its socket and retest at full engine speed If battery voltage does not increase wit...

Page 55: ...ing Clean corroded connections and tighten loose connections Replace wires in poor condition and with frayed or broken insulation Starter Switch or Solenoid By pass switch or solenoid with a jumper wi...

Page 56: ...p while cranking stop test and perform a battery load test D E A C B F D D E G H I J K A Test 1 Battery Voltage Test Static B Test 2 Voltage Drop Across Battery Cranking C Test 3 Voltage Drop Across S...

Page 57: ...r supplied canisters breather lter can be removed and cleaned with hot soapy water dried and reinstalled Do not oil breather screen This is done periodically or if system operation is suspect Carbon c...

Page 58: ...drawn through an inlet screen of secondary air valve Air is then drawn into exhaust manifold and mu er where it mixes with any unburned hydrocarbons which then burn in heat of mu er A hose is connect...

Page 59: ...et screen from secondary air valve assembly by grasping inlet screen at base and gently pulling away from valve assembly 2 Use a soft brush to remove debris from screen 3 Run water through inlet scree...

Page 60: ...gine Components B O N P O R H A D J V J I T S T C I K U W T T M Q L E G F A Oil Fill Dipstick B Oil Fill Dipstick Tube C Oil Filter D Oil Drain Plug E Air Cleaner Adapter F Intake Manifold G Intake Ma...

Page 61: ...r adapter Remove Fuel Pump if equipped NOTE Inlet outlet and pulse lines can remain on fuel pump unless replacement is required NOTE Unless fuel pump is being replaced disassembly from fuel pump brack...

Page 62: ...take studs Turn assembly 90 to remove choke linkage from speed control bracket Remove and discard intake manifold gasket Smart ChokeTM Slide assembly forward and o intake studs Remove and discard inta...

Page 63: ...ssure switch is installed into closure plate 1 Cut wire tie securing lead to switch 2 Disconnect lead or remove connector from Oil Sentry pressure switch 3 Remove pressure switch from closure plate Re...

Page 64: ...shaft 3 Carefully lift cooling fan to disengage two drive pins and remove it from ywheel 4 Reinstall ywheel retaining screw 5 Install an anchor bolt assembly see Tools and Aids in each hole of ywheel...

Page 65: ...Ba e Remove screws attaching cylinder head ba e to cylinder head and remove cylinder head ba e Remove Valve Cover A B A Valve Cover B Screw NOTE Valve cover is sealed to cylinder head using RTV silico...

Page 66: ...valve train components that will be reused to ensure they are reassembled on same side 1 Loosen inner set screws T15 Torx Drive and back o rocker arm adjusting nuts Remove push rods and mark them so...

Page 67: ...d guides Hard starting or loss of power accompanied by high fuel consumption may be symptoms of faulty valves Although these symptoms could also be attributed to worn rings remove and check valves rst...

Page 68: ...ced if deteriorated or damaged in any way Never reuse an old seal Remove Breather F C A B D E A Breather Cover Screw B Breather Cover C Torx Screw D Reed Retainer E Breather Reed F Breather Filter NOT...

Page 69: ...rotates freely Governor Gear Inspection Inspect governor gear teeth Look for any evidence of worn chipped or cracked teeth If one or more of these problems is noted replace governor gear Gear is held...

Page 70: ...educed compression at cranking speeds several important bene ts are obtained 1 Electric start models can use a smaller starter and battery which are more practical for application 2 ACR eliminates nee...

Page 71: ...ated by excessive oil consumption and blue exhaust smoke When rings fail oil is allowed to enter combustion chamber where it is burned along with fuel High oil consumption can also occur when piston r...

Page 72: ...025 0 065 mm 0 0010 0 0026 in and middle compression ring to groove side clearance 0 040 0 080 mm 0 0016 0 032 in If side clearance is greater than speci ed a new piston must be used Piston and Rings...

Page 73: ...placed Inspect crankshaft keyways If worn or chipped replacement of crankshaft will be necessary Inspect crankpin for wear score marks or aluminum transfer Slight score marks can be cleaned with crocu...

Page 74: ...A A Oil Ba e Screws B Oil Ba e Remove screws securing oil ba e to bottom of crankcase remove oil ba e Remove PTO Side Oil Seal Use a seal puller to remove PTO side oil seal Crankcase Inspection and Se...

Page 75: ...rements These measurements should be taken at three locations in cylinder at top middle and bottom Two measurements should be taken perpendicular to each other at 3 di erent locations Clean Cylinder B...

Page 76: ...ld sealing material has been removed Use gasket remover lacquer thinner or paint remover to remove any remaining traces Clean surfaces with isopropyl alcohol acetone lacquer thinner or electrical cont...

Page 77: ...l Pump Assembly C Oil Pump Housing Screws 1 Lightly grease gerotor gears and set them into crankcase 2 Install oil pump housing and secure to crankcase with screws torque screws to 4 8 N m 42 in lb 3...

Page 78: ...re circumference Use a soft rubber grip hammer handle and tap piston connecting rod into bore First tap should be rather rm so oil ring moves from compressor into bore in one smooth quick motion Other...

Page 79: ...tall Closure Plate Closure Plate Sealant Pattern on Crankcase A A Sealant Bead on Crankcase Closure Plate Fastener Torque Sequence 1 2 3 4 5 6 7 8 9 10 11 NOTE Always use fresh sealant Using outdated...

Page 80: ...efer to Tools and Aids for a listing of approved sealants 1 Install breather lter into closure plate 2 Install breather reed and reed retainer hold them in alignment and secure with screw Torque screw...

Page 81: ...cylinder head screws or gasket always replace with new parts NOTE If crankshaft has not been turned since installation of crank gear turn it one 1 complete revolution This will set piston at top dead...

Page 82: ...other valve After tightening recheck adjustment Proper valve clearance is 0 101 0 152 mm 0 004 0 006 in Install Valve Cover Valve Cover Sealant Pattern Valve Cover Torque Sequence 2 3 4 1 NOTE Always...

Page 83: ...talled NOTE Always use a ywheel strap wrench or ywheel holding tool to hold ywheel when tightening ywheel fastener Do not use any type of bar or wedge between cooling ns or ywheel ring gear as these p...

Page 84: ...gulator B Connector 1 Attach connector to recti er regulator terminals 2 Using M6 screws mount recti er regulator onto crankcase bosses with cooling ns out Torque screws to 8 8 N m 78 in lb Install Oi...

Page 85: ...rottle lever on carburetor Install throttle linkage and linkage spring into throttle lever Smart ChokeTM A B D E F G L J I L K H I M C A Air Cleaner Adapter B Nut C Carburetor Gasket Choke D Indicator...

Page 86: ...3400 No Brown 3300 No Brown 3200 No Brown 2800 No Blue Connect Wire Controls D B A C A Choke Linkage B Control Bracket Lower Hole C Control Bracket Slot D Governor Spring Location in Control Bracket...

Page 87: ...n Plug E Air Cleaner Adapter F Intake Manifold G Intake Manifold Nut H Standard Air Cleaner Cover I Precleaner J Paper Element K PRO Air Cleaner Cover L Fuel Filter M Pulse Line N Outlet Fuel Line O L...

Page 88: ...ure Install Drain Plug Oil Filter and Oil 1 Install oil drain plug Torque plug to 14 N m 125 in lb 2 Place new lter in shallow pan with open end up Fill with new oil until oil reaches bottom of thread...

Page 89: ...89 22 690 01 Rev KohlerEngines com...

Page 90: ...90 KohlerEngines com 22 690 01 Rev...

Page 91: ...91 22 690 01 Rev KohlerEngines com...

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Kohler KS530, Service Manual

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