SERVICE MANUAL KOHLER® AEGIS™ 17,20,23 HP LIQUID-COOLED VERTICAL CRANKSHAFT 1
Contents Section 1. Safety and General Information ............................................................................ Section 2. Special Tools .......................................................................................................... Section 3. Troubleshooting ..................................................................................................... Section 4. Air Cleaner and Air Intake System ........................................................................
Section 1 Safety andLV560, General Information LV625, LV675 Go Back 1 Section 1 Safety and General Information Safety Precautions To insure safe operations please read the following statements and understand their meaning. Also refer to your equipment manufacturer's manual for other important safety information. This manual contains safety precautions which are explained below. Please read carefully.
Section 1 Safety and General Information WARNING WARNING WARNING Explosive Fuel can cause fires and severe burns. Carbon Monoxide can cause severe nausea, fainting or death. Explosive Gas can cause fires and severe acid burns. Stop engine before filling fuel tank. Do not operate engine in closed or confined area. Charge battery only in a well ventilated area. Keep sources of ignition away. Explosive Fuel! Gasoline is extremely flammable and its vapors can explode if ignited.
Section 1 Safety and General Information Engine Identification Numbers When ordering parts, or in any communication involving an engine, always give the Model, Specification and Serial Numbers, including letter suffixes if there are any. 1 The engine identification numbers appear on a decal, or decals, affixed to the engine shrouding. See Figure 1-1. An explanation of these numbers is shown in Figure 1-2. Figure 1-1. Engine Identification Decal Location. A. Model No.
Section 1 Safety and General Information Oil Recommendations Using the proper type and weight of oil in the crankcase is extremely important. So is checking oil daily and changing oil regularly. Failure to use the correct oil, or using dirty oil, causes premature engine wear and failure. Oil Type Use high-quality detergent oil of API (American Petroleum Institute) Service Class SG, SH, SJ or higher. Select the viscosity based on the air temperature at the time of operation as shown in the following table.
Section 1 Safety and General Information Fuel Type For best results, use only clean, fresh, unleaded gasoline with a pump sticker octane rating of 87 or higher. In countries using the Research method, it should be 90 octane minimum. 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. Unleaded gasoline is recommended, as it leaves fewer combustion chamber deposits.
Section 1 Safety and General Information Storage If the engine will be out of service for two months or more, use the following storage procedure: 1. Clean the exterior surfaces of the radiator and engine. 2. Change the oil and filter while the engine is still warm from operation. See “Change Oil and Filter” in Section 6. 3. The coolant (anti-freeze) mixture should be in good condition and tested to guard against freezing in cold temperatures.
Section 1 Safety and General Information 260.6 1 Cyl. #2 Cyl. #1 334.5 Fuel Pump 167.2 2x 89.8 2x 72.8 Hose 434.1 479.3 Over All Coolant Drain Plug 3/8 N.P.T Inch Coolant Drain Plug 3/8 N.P.T Inch 30º 30º 50.0 Exhaust Port #1 18.2 C L Oil Fill 140.0 135.7 50.0 Exhaust Port #2 35º 35º 104.0 Mounting Hole ‘‘A’’ 285.5 C LOil Fill Oil Fill & Dipstick 242.2 451.0 89.8 Starter Motor 45º 153.0 Housing Removal Oil Fill & Dipstick 4x ø 9.2 (.36) thru 254.0 (10.00) B.C 45º ø 135.0 15.
Section 1 Safety and General Information General Specifications1 Power (@ 3600 RPM, corrected to SAE J1995) LV560 ............................................................................................. 12.7 kW (17 HP) LV625 ............................................................................................. 14.9 kW (20 HP) LV675 ............................................................................................. 17.1 kW (23 HP) Peak Torque LV560 (@ 2400 RPM) .........................
Section 1 Safety and General Information Carburetor and Intake Manifold Intake Manifold Mounting Fasteners Torque ......................................... 6.2 N·m (55 in. lb.) 1 Carburetor Mounting Fasteners Torque ................................................ 6.2 N·m (55 in. lb.) Connecting Rod Cap Fastener Torque (torque in increments) ........................................ 11.3 N·m (100 in. lb.) Connecting Rod-to-Crankpin Running Clearance New .....................................................
Section 1 Safety and General Information Crankshaft (Cont'd.) Connecting Rod Journal O.D. - New ..................................................................................... O.D. - Max. Wear Limit .................................................................. Max. Taper ..................................................................................... Max. Out-of-Round ........................................................................ 35.955/35.973 mm (1.4156/1.4163 in.) 35.94 mm (1.
Section 1 Safety and General Information Ignition Spark Plug Type (Champion® or equivalent) ......................................... RC14YC (Kohler Part No. 66 132 01-S) Spark Plug Gap .................................................................................... 0.76 mm (0.030 in.) Spark Plug Torque ................................................................................ 24.4-29.8 N·m (18-22 ft. lb.) Ignition Module Air Gap ....................................................................
Section 1 Safety and General Information Piston, Piston Rings, and Piston Pin (Cont'd.) Top and Middle Compression Ring End Gap LV560 New Bore Top Ring .................................................................................. Middle Ring ............................................................................. Used Bore (Max.) ........................................................................ LV625 New Bore Top Ring .........................................................................
Section 1 Safety and General Information 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 ............................................................................. 7.134 mm (0.2809 in.) 1 Intake Valve Stem Diameter New ................................................................................................ 6.982/7.000 mm (0.2749/0.
Section 1 Safety and General Information English Fastener Torque Recommendations for Standard Applications Tightening Torque: N·m (in. lb.) + or - 20% Bolts, Screws, Nuts and Fasteners Assembled Into Cast Iron or Steel Size 8-32 10-24 10-32 1/4-20 1/4-28 5/16-18 5/16-24 3/8-16 3/8-24 Grade 2 or 5 Fasteners Into Aluminum Grade 2 Grade 5 2.3 (20) 3.6 (32) 3.6 (32) 7.9 (70) 9.6 (85) 17.0 (150) 18.7 (165) 29.4 (260) 33.9 (300) 2.8 (25) 4.5 (40) 4.5 (40) 13.0 (115) 15.8 (140) 28.3 (250) 30.
Section 2 Tools LV560, Special LV625, LV675 Go Back Section 2 Special Tools 2 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 increase your service capabilities and customer satisfaction by decreasing engine downtime. Camshaft End play Plate .................................................................................
Section 2 Special Tools Special Tools You Can Make Flywheel Holding Tool Flywheel removal and reinstallation becomes a ‘‘snap’’ using a handy holding tool you can make out of a piece of an old ‘‘junk’’ flywheel ring gear as shown in Figure 2-2. Using an abrasive cut-off wheel, cut out a six tooth segment of the ring gear as shown. Grind off any burrs or sharp edges. The segment can be used in place of a strap wrench.
Section 3 LV560, LV625, LV675 Troubleshooting Go Back Section 3 Troubleshooting Troubleshooting Guide 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 below. Use these to locate the causing factors. Engine Cranks But Will Not Start 1. Empty fuel tank. 2. Fuel shut-off valve closed. 3. Dirt or water in the fuel system. 4.
Section 3 Troubleshooting Engine Overheats (cont'd.) 7. Radiator cap faulty or loose. 8. Lean fuel mixture. 9. Water pump belt failed/off. 10. Water pump malfunction. • Check for buildup of dirt and debris on the Engine Knocks 1. Excessive engine load. 2. Low crankcase oil level. 3. Old or improper fuel. 4. Internal wear or damage. 5. Hydraulic lifter malfunction. • Check for obvious fuel, oil, and coolant leaks, or Engine Loses Power 1. Low crankcase oil level. 2. High crankcase oil level. 3.
Section 3 Troubleshooting NOTE: It is good practice to drain oil at a location away from the workbench. Be sure to allow 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 individual components as the engine is disassembled. Only clean parts can be accurately inspected and gauged for wear or damage.
Section 3 Troubleshooting Leakdown Test Instructions 1. Run engine 3-5 minutes to warm it up. 2. Remove spark plugs, dipstick, and air filter from engine. 3. Rotate crankshaft until piston (of cylinder being tested) is at top dead center (TDC) of compression stroke. You will need to hold the engine in this position while testing. The holding tool supplied with the tester can be used if the PTO end of the crankshaft is accessible.
Section 4 LV560, LV625,System LV675 Air Cleaner and Air Intake Go Back Section 4 Air Cleaner and Air Intake System Air Intake System General All intake air, for both cooling and combustion, is drawn in through the screen in the upper blower housing. Service Check the air intake screen daily or before starting the engine. Check for a buildup of dirt or debris on the screen. A small accumulation can be brushed or vacuumed off with the screen in place. See Figure 4-1.
Section 4 Air Cleaner and Air Intake System Figure 4-4. Cleaning Separated Screen Assembly. Always reinstall the upper blower assembly after it has been removed for service. Do not operate the engine with the upper blowing housing or screen removed. Figure 4-5. Air Cleaner Assembly. Foam Precleaner Air Cleaner General These engines are equipped with a replaceable, highdensity paper air cleaner element surrounded by an oil, foam precleaner, located under the upper blower housing. See Figures 4-5 and 4-6.
Section 4 Air Cleaner and Air Intake System 2. Remove the precleaner from the paper element. See Figure 4-7. 3. Unhook the filter element retaining strap and remove the paper element from the air cleaner base. See Figure 4-8. 4 Figure 4-7. 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. 4.
Section 4 Air Cleaner and Air Intake System 4. Disconnect the breather hose from the air cleaner base. 5. Slide the clamp and air cleaner base off the stud. 6. Reverse procedure to reassemble components. Torque the hex. flange nuts to 9.9 N·m (88 in. lb.). Fuel Pump Vacuum Line Breather Hose Figure 4-9. Base Plate Removal on Standard Type. 4.
Section 5 LV560, and LV625, LV675 Fuel System Governor Go Back Section 5 Fuel System and Governor Description 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.
Section 5 Fuel System and Governor Fuel System Tests When the engine starts hard, or turns over but will not start, it is possible that the problem is in the fuel system. To find out if the fuel system is causing the problem, perform the following tests. Troubleshooting – Fuel System Related Causes Test Conclusion 1. Check the following: a. Make sure the fuel tank contains clean, fresh, proper fuel. b. Make sure the vent in fuel tank cap is open. c. Make sure the fuel valve is open. d.
Section 5 Fuel System and Governor Fuel Pump General These engines are equipped with an external pulse fuel pump. The pumping action is created by the oscillation of positive and negative pressures within the crankcase. This pressure is transmitted to the pulse pump through a rubber hose connected between the pump and crankcase. The pumping action causes the diaphragm on the inside of the pump to pull fuel in on its downward stroke and to push it into the carburetor on its upward stroke.
Section 5 Fuel System and Governor Slow Circuit: (Figure 5-2) At low speeds the engine operates only on the slow circuit. As a metered amount of air is drawn through the slow air bleed jet, fuel is drawn through the main jet and further metered through the slow jet. Air and fuel are mixed in the body of the slow jet and exit to the transfer port. From the transfer port this air fuel mixture is delivered to the idle progression chamber.
Section 5 Fuel System and Governor Main Circuit: (Figure 5-3) At high speeds the engine operates mostly on the main circuit. As a metered amount of air is drawn through the main air bleed jet, fuel is drawn through the main jet. The air and fuel are mixed in the main nozzle and then enter the main body of air flow, where further mixing of the fuel and air takes place. This mixture is then delivered to the combustion chamber. The carburetor has a fixed main circuit. There is no adjustment feature present.
Section 5 Fuel System and Governor Troubleshooting – Carburetor Related Causes Condition Possible Cause/Probable Remedy 1. Engine starts hard, runs roughly or stalls at idle speed. 1a. Low idle speed improperly adjusted. Adjust the low idle speed screw. b. Low idle fuel mixture circuit blocked/restricted. Clean carburetor as required. 2. Engine runs rich (indicated by black, sooty exhaust smoke, misfiring, loss of speed and power, governor hunting, or excessive throttle opening). 2a.
Section 5 Fuel System and Governor Fuel Shut-off Solenoid Carburetors are equipped with a fuel shut-off solenoid, which also contains the main jet. The solenoid has a spring loaded pin which retracts when the key switch is ‘‘on’’, allowing the engine to function normally. When the key switch is turned ‘‘off’’, the pin extends and prevents fuel from entering the engine. Below is a simple test made with the engine off, that can determine if the solenoid is functioning properly: 1.
Section 5 Fuel System and Governor Float Replacement If symptoms described in the carburetor troubleshooting guide indicate float level problems, remove the carburetor from the engine to check and/or replace the float. Use a Carburetor Overhaul Kit (see page 5.10) if float replacement is necessary. 1. Remove the upper blower housing and air intake components from the carburetor, as described in Section 4. 2. Disconnect the fuel inlet line from the carburetor. 3.
Section 5 Fuel System and Governor Passage Cover Cover Retaining Screw Set Screws Choke Plate Idle Speed Screw Choke Shaft Idle Speed Spring 5 Ring Collar Air Filter Spring Throttle Choke Shaft/ Lever Lever Fuel Bowl Gasket Inlet Needle Float Float Pin Shut-Off Solenoid Assembly Fuel Bowl Red Bowl Retaining Screw Gasket Black Figure 5-6. Carburetor - Exploded View. Inspection/Repair • To clean vent ports, internal circuits etc.
Section 5 Fuel System and Governor Overhaul Kit Contains: Qty. Description Gasket, air cleaner base 1 Gasket, carburetor 1 Screw, throttle adjusting 1 Gasket, chamber screw 1 Screw, idle adjusting 1 Float 1 Pin, float 1 Inlet Needle 1 Gasket, float chamber 1 Spring, throttle adjusting screw 1 Spring, idle adjusting screw 1 Gasket, passage cover 1 Choke Repair Kit Contains: Description Qty.
Section 5 Fuel System and Governor 3 4 1 5 2 8 6 9 1. 2. 3. 4. 5. 6. 7. 8. 9. Governor Lever Hex. Nut Governor Cross Shaft Governor Lever Throttle Lever Linkage Choke Linkage Choke Actuating Lever Governor Spring Speed Control Bracket Governor Lever (Holes for Sensitivity Adjustment) 7 Figure 5-7. Governor Controls and Linkage (External). Adjustments General The governed speed setting is determined by the position of the throttle control.
Section 5 Fuel System and Governor High Idle RPM Speed Adjustment (See Figure 5-8.) 1. With the engine running, move the throttle control to fast. Use a tachometer to check the RPM speed. 2. Loosen the lock nut on the high idle adjusting screw. Turn screw outward to decrease, or inward to increase RPM speed. Check RPM with a tachometer. 3. When the desired RPM speed is obtained, retighten the lock nut.
Section 6 Lubrication LV560, LV625,System LV675 Go Back Section 6 Lubrication System General This engine uses a full pressure lubrication system. This system delivers oil under pressure to the crankshaft, camshaft and connecting rod bearing surfaces. In addition to lubricating the bearing surfaces, the lubrication system supplies oil to the hydraulic valve lifters.
Section 6 Lubrication System 3. Unthread and remove the oil fill cap/dipstick; wipe oil off. Reinsert the dipstick into the tube and rest the cap on the tube. Do not thread the cap onto the tube. See Figure 6-2. Changing Oil and Oil Filter Change oil and oil filter after 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 on previous page.
Section 6 Lubrication System 3. Before removing the oil filter, clean the surrounding area to keep dirt and debris out of the engine. Remove the old filter and wipe/clean the surface where the filter mounts. 4. Reinstall the drain plug. Make sure it is tightened to 13.6 N·m (10 ft. lb.). 5. Place a new oil filter in a shallow pan with the open end up. Pour new oil, of the proper type, in through the threaded center hole. Stop pouring when the oil reaches the bottom of the threads.
Section 6 Lubrication 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. Breather Reed 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.). Testing Compressed air, a pressure regulator, pressure gauge and a continuity tester are required to test the switch. 1.
Section 7 Cooling LV560, LV625,System LV675 Go Back 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 when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely. This section covers the operation and servicing of the liquid cooling system.
Section 7 Cooling System 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 -37º C (-34º F) to 108º C (226º F).
Section 7 Cooling System 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. lb.). Some early production engines contained steel plugs. Always use brass (soft) plugs (Kohler Part. No. 66 139 01-S) when service is performed. 5. Loosen the two screws holding the overflow reservoir retainer bracket to the radiators. See Figure 7-6. Figure 7-4.
Section 7 Cooling System 6. Fill the cooling system (See Filling the Cooling System). 7. Reinstall the upper blower housing and screen assembly. Filling Cooling System NOTE: To prevent engine damage, do not use antifreeze mixture greater than 70% ethylene glycol in the cooling system. Do not use antifreeze with stop-leak additive(s) or mix/add other additives to the cooling system. Use only ethylene glycol anti-freeze. Figure 7-8. Removing Overflow Reservoir. 7.
Section 7 Cooling System Hoses and Tubes Hoses and tubes are used to connect the components within the cooling system. To guard against coolant loss and hose failure, the hoses, tubes and their connections should be checked regularly for leaks or damage. Loss of coolant can result in serious engine damage. Over time, engine vibration can affect hose/ joint connections, and the hoses themselves can be affected by heat and the coolant.
Section 7 Cooling System High Temperature Sensor A high temperature sensor may be mounted in the intake manifold and is used to activate a warning light, audible alarm, or kill the engine (depending on the application), if the safe operating temperature is exceeded. The sensor is a ‘‘normally open’’ switch which completes a circuit, when the coolant temperature reaches the rated temperature limit of the switch. For AEGIS™ engines the temperature sensor limit is 123.8º C (255º F).
Section 7 Cooling System 5. Observe the system pressure on the gauge. 15 psi 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 be replaced. If the tester pressure is increased to 16 psi, or above, the cap should then ‘‘bleed off’’ this excess pressure. 4. Install and lock the system adapter and tester onto the neck of the cooling system.
Section 7 Cooling System 7.
Section 8 LV560, LV675 Electrical System and LV625, Components Go Back Section 8 Electrical System and Components This section covers the operation, service and repair of the electrical system components. Systems and components covered in this section are: • • • • Spark Plugs Battery and Charging System Electronic CD Ignition System Electric Starter Spark Plugs Engine misfire or starting problems are often caused by a spark plug that has improper gap or is in poor condition.
Section 8 Electrical System and Components Inspection Inspect each spark plug as it is removed from the cylinder head. The deposits on the tip can be an indication of the general condition of the engine and/or adverse operating conditions. Normal and fouled plugs are shown in the following photos: Worn: On a worn plug, the center electrode will be rounded and the gap will be greater than the specified gap. Replace a worn spark plug immediately.
Section 8 Electrical System and Components 1. Regularly check the level of electrolyte. Add distilled water as necessary to maintain the recommended level. NOTE: Do not overfill the battery. Poor performance or early failure due to loss of electrolyte will result. 2. Keep the cables, terminals, and external surfaces of the battery clean. A build-up of corrosive acid or grime on the external surfaces can cause the battery to self-discharge. Self-discharge occurs rapidly when moisture is present.
Section 8 Electrical System and Components Electronic CD Ignition Systems • Two electronic capacitive discharge ignition modules which mount on the engine crankcase. Operation of CD Ignition Systems Capacitive Discharge with Fixed Timing • A kill switch (or key switch) which grounds the modules to stop the engine. This system consists of the following components. See Figure 8-3. • Two spark plugs.
Section 8 Electrical System and Components D1 C1 T1 SCS Spark Plug L1 L2 P S Figure 8-5. Capacitive Discharge Ignition Module. Operation: As the flywheel rotates, the magnet grouping passes the input coil (L1). The corresponding magnetic field induces energy into the input coil (L1). The resultant pulse is rectified by D1 and charges capacitor C1. As the magnet assembly completes its pass, it activates the triggering device (L2), which causes the semiconductor switch (SCS) to turn on.
Section 8 Electrical System and Components Test Procedure for Standard CD Ignition Conclusion Test 1. Test for spark on both cylinders with Kohler ignition tester, Part No. 24 455 02-S. Disconnect one spark plug lead and connect it to the post terminal of the tester. Connect the clip to a good ground, not to the spark plug. Crank the engine and observe the tester spark gap. Repeat the procedure on the other cylinder. Remember to reconnect the first spark plug lead. 1.
Section 8 Electrical System and Components CONNECTOR LAYOUT Starter (L/R) Ground Battery (R) Oil Sentry Light Key Switch Ground (B) Oil Pressure Switch Starter Battery Run (R) Accessory Ignition Kill (W) Key Switch Accessory (Y) Run Ignition Kill Y Connector O Coolant Temp. Overheat Alarm + Battery Coolant Temp. Switch Ground B _ _ + Carburetor Assembly Intake Manifold Screw W Coolant Temp.
Section 8 Electrical System and Components Rectifier-Regulator Connector AC AC 15 Amp Stator B+ AC Leads Figure 8-8. 15/20/25 amp Stator and Rectifier-Regulator. 3 Amp Charging Stator Lighting Lead (Yellow) Diode Charging Lead (Black) Lighting Stator Figure 8-9. 3 amp/70 Watt Stator. 8.
Section 8 Electrical System and Components Stator The stator is mounted on the crankcase behind the flywheel. Should the stator have to be replaced, follow the procedures in Section 9 - “Disassembly.” Rectifier-Regulator The rectifier-regulator is mounted inside the lower blower housing. See Figure 8-10. To replace it; remove the upper blower housing, disconnect the connector plug, remove the single mounting screw with the ground lead and lift out the rectifier-regulator.
Section 8 Electrical System and Components Troubleshooting Guide 15/20/25 amp Battery Charging Systems If it is difficult to keep the battery charged, or the battery overcharges, the problem is usually with the charging system or the battery. NOTE: Always zero ohmmeter on each scale before testing to ensure accurate readings. Voltage tests should be made with the engine running at 3600 RPM - no load. The battery must be fully charged. Problem Test Conclusion 1. If voltage is 13.8-14.
Section 8 Electrical System and Components Troubleshooting Guide 3 amp Battery Charging System with 70 Watt Lighting Stator NOTE: Zero ohmmeters on each scale to ensure accurate readings. Voltage tests should be made with engine running at 3000 RPM - no load. Battery must be fully charged. Problem Test 1. With engine running at 3000 RPM, measure voltage across battery terminals using a DC voltmeter. Conclusion 1. If voltage is more than 12.5 volts, charging system is OK. If voltage is 12.
Section 8 Electrical System and Components Solenoid Shift Electric Starters The following subsection covers the solenoid shift style electric starters. Some of the information in the preceding subsection relates also to this style of starter, so it is not repeated here. A Nippendenso or Delco-Remy solenoid shift starter may be used. The Nippendenso starter is covered beginning on Page 8.21. The Delco Remy starter is covered beginning on page 8.13. NOTE: Do not drop the starter or strike the starter frame.
Section 8 Electrical System and Components Delco-Remy Starters 3. Lift and unhook the plunger assembly from the drive lever. Remove the gasket from the recess in the housing. See Figure 8-15. Figure 8-12. Starter Disassembly 1. Remove the hex. nut and disconnect the positive (+) brush lead/bracket from the solenoid terminal. Figure 8-15. Removing Plunger. 4. Remove the two thru (larger) bolts. See Figure 8-16. 2. Remove the three screws securing the solenoid to the starter.
Section 8 Electrical System and Components 5. Remove the commutator end plate assembly, containing the brush holder, brushes, springs, and locking caps. Remove the thrust washer from inside the commutator end. See Figure 8-17. Figure 8-19. 8. Take out the drive lever and pull the armature out from the drive end cap. See Figure 8-20. Figure 8-17. Removing Commutator End Plate Assembly. 9. Remove the thrust washer from the armature shaft. See Figure 8-20. 6.
Section 8 Electrical System and Components 11. Remove the retainer from the armature shaft. Save the stop collar. 12. Remove the drive pinion assembly from the armature. NOTE: 13. Clean the parts as required. Do not reuse the old retainer. NOTE: Do not soak the armature or use solvent when cleaning. Wash and dry/clean using a soft cloth, or compressed air. Figure 8-22. Removing Retaining Ring.
Section 8 Electrical 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 irregularities which could cause seal damage. c. Check the drive clutch by holding the clutch housing and rotating the pinion. Pinion should rotate in one direction only. Brushes and Springs Inspect both the springs and brushes for wear, fatigue, or damage.
Section 8 Electrical System and Components 2. Remove the two screws securing the brush holder assembly to the end cap (plate). Note the orientation for reassembly later. See Figure 8-27. Discard the old brush holder assembly. Starter Reassembly 1. Apply new drive lubricant (Kohler Part No. 52 357 02-S) to the armature shaft splines. Install the drive pinion onto the armature shaft. 2. Install and assemble the stop collar/retainer assembly. a.
Section 8 Electrical System and Components 4. Apply a small amount of oil to the bearing in the drive end cap, and install the armature with the drive pinion. 5. Lubricate the fork end and center pivot of the drive lever with drive lubricant (Kohler Part No. 52 357 02-S). Position the fork end into the space between the captured washer and the rear of the pinion. 6. Slide the armature into the drive end cap, and at the same time seat the drive lever into the housing.
Section 8 Electrical System and Components 10. Starter reassembly when replacing the Brushes/ Brush Holder Assembly: a. Hold the starter assembly vertically on the end housing, and carefully position the assembled brush holder assembly with the supplied protective tube, against the end of the commutator/armature. The mounting screw holes in the metal clips must be “up/out.
Section 8 Electrical System and Components 11. Install the end cap onto armature and frame, aligning the thin raised rib in the end cap with the corresponding slot in the grommet of the positive (+) brush lead. 12. Install the two thru bolts, and the two brush holder mounting screws. Torque the thru bolts to 5.6-9.0 N•m (49-79 in. lb.). Torque the brush holder mounting screws to 2.5-3.3 N•m (22-29 in. lb.). See Figures 8-39 and 8-40. Figure 8-41. Installing Solenoid Screws. 14.
Section 8 Electrical System and Components Nut Drive End Cap Frame Wire Drive Lever Front Stop Collar Dust Cover Solenoid Brushes Brush Holder Retainer Rear Stop Collar Brush Spring Insulator Nut Drive Pinion Starter Assembly Commutator End Cap Thru Bolt Armature 8 Figure 8-44. Nippendenso Solenoid Shift Starter.
Section 8 Electrical System and Components 8. The outward travel of the drive pinion is controlled by a snap ring, installed in a groove in the armature shaft, and a two-piece stop collar. The snap ring fits into a recess in the pinion (lower) stop collar, which locks it in the groove (see Figure 8-45). The thrust receiving (upper) stop collar has a projecting flange, which rests on the snap ring, and it serves as a thrust washer to protect the front armature bushing in the drive end cap.
Section 9 LV560, LV625, LV675 Disassembly Go Back Section 9 Disassembly 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. General Clean all parts thoroughly as the engine is disassembled. Only clean parts can be accurately inspected and gauged for wear or damage.
Section 9 Disassembly Shut Off Fuel Supply Drain Oil From Crankcase and Remove Oil Filter 1. Remove the dipstick and one of the oil drain plugs. See Figures 9-2 and 9-3. 3. There is likely to be some oil left in the filter. Place a shallow pan under the filter pad and filter to catch the overflow. Remove the oil filter by turning it in a counterclockwise direction with a filter wrench. Discard filter. See Figure 9-4. Figure 9-4. Removing Oil Filter. Figure 9-2. Removing Oil Fill Cap/Dipstick.
Section 9 Disassembly 2. Carefully remove the coolant drain plugs in the lower side of both cylinder heads. See Figure 9-9. Drain the coolant into a suitable container. Early production units contained steel plugs, remove only when the cylinders are cool. Replace with brass (soft) plugs on reassembly, Kohler Part No. 66 139 01-S. 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 9-9.
Section 9 Disassembly 2. Disconnect the fuel lines at the inlet of the carburetor, and the in-line fuel filter. See Figure 9-11. Remove Air Cleaner Base 1. Disconnect the breather hose from the air cleaner base. See Figure 9-13. 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 the pump and lines as an assembly. Slide the fuel line out of the clip attached to mounting stud. See Figure 9-12. Figure 9-12.
Section 9 Disassembly Remove Carburetor 1. Disconnect the fuel solenoid leads (most models) from the wiring harness. 2. Disconnect the dampening spring and throttle linkage from the governor arm. Remove the black bushing, and clip it back onto the linkage, so it does not get lost. See Figure 9-15. Figure 9-15. Removing Throttle Linkage, Dampening Spring, and Black Bushing. 3. Gently lift up on the lower blower housing, directly above the carburetor, and slide the carburetor outward on the studs.
Section 9 Disassembly 4. Remove the throttle control bracket, governor lever, and governor spring as an assembly. See Figure 9-19. Figure 9-19. Removing Main Bracket and Governor Lever. Remove Electric Starter 1. Disconnect the leads from the starter. 2. Remove the two starter motor mounting screws. See Figure 9-20. Figure 9-20. Removing the Starter Motor Mounting Screws. 3. Remove the starter assembly from the adapter plate. 9.6 4. Remove the two hex.
Section 9 Disassembly Figure 9-23. Location of Four Screws Securing Blocking Plates. Figure 9-25. Removing the Reservoir. Remove Ignition Modules 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. See Figure 9-24. 3. Carefully lift the bracket up slightly to unhook the locking tab, and remove the reservoir from under the bracket. See Figure 9-25. 1.
Section 9 Disassembly 3. Slide the ignition module onto the contoured section of the flywheel. Disconnect the lead and remove the module from the engine. Note: On modules containing 90º terminals, the leads must be removed by pulling to the side. See Figure 9-27. 2. Remove the hex. flange screw and washer from the flywheel. 3. Use a puller to remove the flywheel from the crankshaft. See Figure 9-29. Figure 9-29. Removing Flywheel. Figure 9-27. Removing Ignition Module. 4.
Section 9 Disassembly Remove Radiators and Cooling System 1. Remove the hex. nut from the center mounting stud, located between the two radiators and through the main support bracket. See Figure 9-31. Figure 9-33. Rear Bracket/Clamp. 4. Pull the by-pass hose out of the retaining clip beneath the main support bracket. See Figure 9-34. Figure 9-31. Removing Center Mounting Nut. 2. Cut the metal tie strap from around the lower hose/tube assembly, secured to the blower housing. See Figure 9-32.
Section 9 Disassembly Remove Stator and Rectifier-Regulator 1. Remove the two stator mounting screws. See Figure 9-38. Figure 9-36. Lower Hose Removed. 6. Lift the entire cooling system, with the radiators, hoses, and supporting brackets attached, off the engine. See Figure 9-37. Further disassembly may be performed as required. When disassembly of hose connections is necessary, the use of a rubber lubricant on the inside of hoses will make installation easier. Figure 9-38. Removing Stator. 2.
Section 9 Disassembly Figure 9-40. Removing B+ Charging Lead from Connector. Figure 9-42. Removing Cam Pulley and Belt. 3. Remove the camshaft key from the keyway. 4. Remove the stator and rectifier-regulator. Remove Water Pump and Transfer Tube Remove Cam Pulley and Coolant Pump Belt 1. Unseat the clamp and disconnect the by-pass hose from the water pump fitting. See Figure 9-43. 1. Remove the hex. flange screw and flat washer, securing the cogged drive pulley to the camshaft. See Figure 9-41.
Section 9 Disassembly 2. Loosen and unscrew the hex. cap section, securing the transfer tube to the 90° fitting in the crankcase. See Figure 9-44. Support the fitting with a wrench, if possible, when loosening the hex. cap section. 4. Lift the pump up and carefully work the ferruled end of the transfer tube out of the fitting. Remove the water pump with the tube and the hose section attached. Remove the O-Ring from within the channel. See Figure 9-46.
Section 9 Disassembly 2. Remove the two No. 1 side intake manifold mounting screws securing the ground leads and clip for the wiring harness. Note the locations of the clip and ground leads. See Figure 9-48. Figure 9-50. Warning Alarm. Figure 9-48. Removing No. 1 Side Intake Manifold Screws with the Ground Leads. 4. Lift the by-pass hose, with the wiring harness attached, and work the ends of the harness back through the openings in the lower blower housing to remove. See Figure 9-51. 3.
Section 9 Disassembly Remove Intake Manifold, Temperature Sensor, and Thermostat 1. Remove the four remaining hex. flange screws securing the intake manifold to the cylinder heads. See Figure 9-52. Remove Lower Blower Housing and Oil Fill/Dipstick Tube 1. Remove the breather hose from the No. 1 side valve cover fitting. 2. Remove the eight hex. flange thread forming screws securing the lower blower housing to the crankcase.
Section 9 Disassembly 2. Carefully pry under the protruding edge of the breather cover with a screwdriver to separate the cover. See Figure 9-59. Do not pry on the sealing surfaces as it could cause damage resulting in leaks. 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 9-59. Prying Off Breather Cover. 3. Remove the cover and the gasket. See Figure 9-60. 9 Figure 9-57.
Section 9 Disassembly Remove Spark Plugs 1. Remove the spark plug from each cylinder head using a spark plug socket. See Figure 9-61. Figure 9-63. Removing the Valve Cover. Figure 9-61. Removing Spark Plug(s). Remove Valve Covers 1. Remove the four hex. flange screws securing each of the valve covers. Note the differences between the covers, and the lengths of the screws, for proper installation later. See Figure 9-62. Remove Cylinder Heads and Hydraulic Lifters 1.
Section 9 Disassembly Figure 9-65. Removing Hex. Flange Nuts and Washers 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 unless replacement is intended. If studs are removed for any reason, discard the old stud(s), do not reuse/reinstall. Use new studs and refer to the assembly sequence for proper installation. Figure 9-67. Removing Lifters from Lifter Bores. Disassemble Cylinder Heads 1.
Section 9 Disassembly 3. With the keepers taken out, the following items can be removed (see Figures 9-70 and 9-71): • valve spring retainers • valve springs • valve spring caps • intake and exhaust valves • valve stem seals (intake valve only) Remove Oil Pan Assembly 1. Remove the ten hex. flange screws securing the oil pan to the crankcase. See Figure 9-72. Note the location of the silver plated (grounding) hex. flange screw, to the right of the oil filter boss.
Section 9 Disassembly Oil Pump Assembly The oil pump is mounted in the oil pan. If service is required, refer to the service procedures under ‘‘Oil Pump Assembly’’ in Section 10. 2. Remove the cross shaft through the inside of the crankcase. Be careful not to lose the small washer on the lower portion of the shaft, just above the stake marks. See Figure 9-76. Remove Camshaft 1. Remove the camshaft and shim. See Figure 9-74. Figure 9-76. Removing Governor Cross Shaft. Figure 9-74.
Section 9 Disassembly 2. Carefully remove the connecting rod and piston assembly from the cylinder bore. See Figure 9-78. Remove Crankshaft 1. Carefully pull the crankshaft out of the crankcase. See Figure 9-79. NOTE: The cylinders are numbered on the crankcase. Use the numbers to mark each end cap, connecting rod, and piston for reassembly. Do not mix end caps and connecting rods. Figure 9-79. Removing Crankshaft. Figure 9-78. Removing Connecting Rod and Piston Assembly. 3.
Section 10 LV625, LV675 InspectionLV560, and Reconditioning Go Back Section 10 Inspection and Reconditioning This section covers the operation, inspection, and repair/reconditioning of major internal engine components. The following components are not covered in this section. They are covered in sections of their own: Air Cleaner, Section 4 Carburetor & External Governor, Section 5 Ignition, Charging & Electric Starter, Section 8 Clean all parts thoroughly.
Section 10 Inspection and Reconditioning Inspect the crankpin for score marks or metallic pick up. Slight score marks can be cleaned with crocus cloth soaked in oil. If wear limits, as stated in “Specifications and Tolerances,” are exceeded, it will be necessary to either replace the crankshaft or regrind the crankpin to 0.25 mm (0.010 in.) undersize. If reground, 0.25 mm (0.010 in.) undersize connecting rods (big end) must then be used to achieve proper running clearance.
Section 10 Inspection and Reconditioning Crankcase These engines contain a cast-iron cylinder liner that may be reconditioned as follows: Inspection and Service Check all gasket surfaces to make sure they are free of gasket fragments. Gasket surfaces must also be free of deep scratches or nicks. Check the cylinder bore for scoring. In severe cases, unburned fuel can cause scuffing and scoring of the cylinder wall. It washes the necessary lubricating oils off the piston and cylinder wall.
Section 10 Inspection and Reconditioning Clean Cylinder Bore After Honing Proper cleaning of the cylinder walls following boring and/or honing is very critical to a successful overhaul. Machining grit left in the cylinder bore can destroy an engine in less than one hour of operation after a rebuild. The final cleaning operation should always be a thorough scrubbing with a brush and hot, soapy water.
Section 10 Inspection and Reconditioning Exhaust Valve E Intake Valve F G B C A Exhaust Insert D F E G A H H Intake Insert D B Dimension A B C D E F G H Seat Angle Insert O.D. Guide Depth Guide I.D. Valve Head Diameter Valve Face Angle Valve Margin (Min.) Valve Stem Diameter Intake 89° 36.987/37.013 mm 4 mm 7.038/7.058 mm 33.37/33.63 mm 45° 1.5 mm 6.982/7.000 mm A Exhaust 89° 32.987/33.013 mm 6.5 mm 7.038/7.058 mm 29.37/29.63 mm 45° 1.5 mm 6.970/6.988 mm Figure 10-5. Valve Details.
Section 10 Inspection and Reconditioning Leakage: A poor grind on face or seat of valve will allow leakage resulting in a burned valve on one side only. Stem Corrosion: Moisture in fuel or from condensation are the most common causes of valve stem corrosion. Condensation occurs from improper preservation during storage and when engine is repeatedly stopped before it has a chance to reach normal operating temperatures. Replace corroded valves.
Section 10 Inspection and Reconditioning Valve Guides If a valve guide is worn beyond specifications, it will not guide the valve in a straight line. This may result in burnt valve faces or seats, loss of compression, and excessive oil consumption. To check valve guide-to-valve stem clearance, thoroughly clean the valve guide and, using a split-ball gauge, measure the inside diameter.
Section 10 Inspection and Reconditioning Pistons and Rings Inspection Scuffing and scoring of pistons and cylinder walls occurs when internal temperatures approach the welding point of the piston. Temperatures high enough to do this are created by friction, which is usually attributed to improper lubrication, and/or overheating of the engine. Normally, very little wear takes place in the piston boss-piston pin area.
Section 10 Inspection and Reconditioning Replacement pistons are available in STD bore size, 0.08 mm (0.03 in.), 0.25 mm (0.010 in.), and 0.50 mm (0.20 in.) oversizes. Replacement pistons include new piston ring sets and new piston pins. Service replacement piston ring sets are also available separately for STD, 0.08 mm (0.03 in.), 0.25 mm (0.010 in.), and 0.50 mm (0.020 in.) oversized pistons. Always use new piston rings when installing pistons. Never reuse old rings.
Section 10 Inspection and Reconditioning Install Piston Rings To install piston rings, proceed as follows: 1. Oil Control Ring (Bottom Groove): Install the expander and then the rails. Make sure the ends of expander are not overlapped. NOTE: Rings must be installed correctly. Ring installation instructions are usually included with new ring sets. Follow instructions carefully. Use a piston ring expander to install rings (see Figure 10-10).
Section 10 Inspection and Reconditioning NOTE: The governor gear is held onto the shaft by small molded tabs in the gear. When the gear is removed from the shaft, these tabs are destroyed and the gear must be replaced. Therefore, remove the gear only if absolutely necessary. 1. Remove the regulating pin and governor gear assembly. See Figure 10-12. 1. Install the locking tab thrust washer on the governor gear shaft with the tab down. 2.
Section 10 Inspection and Reconditioning 2.0 mm (0.0787 in.) Governor Cross Shaft Seal Water Pump The water/coolant pump consists of a sealed impeller assembly, which includes the outer cover and a cogged drive pulley. When the pump is mounted to the crankcase, the impeller fits into a cast recess, and the cover seals against an O-Ring outside the perimeter of the recess. Figure 10-15. Installing Cross Shaft Oil Seal. Figure 10-18. Water Pump.
Section 11 Reassembly LV560, LV625, LV675 Go Back Section 11 Reassembly General NOTE: Make sure the engine is assembled using all specified torque values, tightening sequences, and clearances. Failure to observe specifications could cause severe engine wear or damage. Always use new gaskets, seals, and O-Rings. Make sure all traces of any cleaner are removed before the engine is assembled and placed into operation.
Section 11 Reassembly Figure 11-1. Installing Flywheel End Oil Seal in Crankcase. The camshaft seal should be installed to a depth of 1-1.5 mm (.039-.059 in.) below the top of the seal bore. See Figure 11-2. Do not bottom the seal in the bore or the oil passage may be obstructed. Figure 11-3. Installing Crankshaft. Install Connecting Rods with Pistons and Rings NOTE: The cylinders are numbered on the crankcase.
Section 11 Reassembly NOTE: Make sure to align the chamfer of the connecting rod with the chamfer of its mating end cap. The chamfer should be toward the outside. 6. Repeat the above procedure for the other connecting rod and piston assembly. Cylinder #2 Install Governor Cross Shaft 1. Lubricate the governor cross shaft bearing surfaces in the crankcase with engine oil. Cylinder #1 Figure 11-5. Proper Piston Connecting Rod Orientation. 2.
Section 11 Reassembly 5. Carefully slide the keyway end of the camshaft through the seal and engage the camshaft into the bearing surface of the crankcase. Position the timing mark of camshaft gear at the 6 o'clock position matching the timing mark on the crankshaft. Make sure the camshaft gear and crankshaft gear mesh and the timing marks are aligned as shown in Figures 11-10 and 11-11. Figure 11-8. Assembly of Nylon Washer, Retainer, and Setting the End play. Install Camshaft 1.
Section 11 Reassembly 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. Oil Pump Assembly The oil pump is mounted in the oil pan. If service was required, and the oil pump was removed, refer to the assembly procedures under ‘‘Oil Pump Assembly’’ in Section 10. Governor Assembly The governor assembly is located inside the oil pan.
Section 11 Reassembly 3. Install the O-Ring in groove as shown. See Figure 11-14. Apply a 1.5 mm (1/16 in.) bead of sealant to the sealing surface of the oil pan. See Figure 11-15 for the sealant pattern. 6. Install the ten hex. flange screws securing the oil pan to the crankcase. Torque fasteners in the proper sequence to 24.4 N·m (216 in. lb.). See Figure 11-16 for the proper torque sequence. On some engines one of the ten mounting screws is plated.
Section 11 Reassembly Install Hydraulic Lifters Apply Loctite® No. 272 1. Bleed the hydraulic lifters of internal oil so the plunger in the lifter can be depressed by hand. Use an old cutoff push rod mounted in a drill press, arbor press, or vice, and slowly apply pressure two or three times to bleed the lifters. See Figure 11-19. If a vice is used in bleeding the lifters, be sure to install protective coverings over the jaws to avoid damage to the base of the lifter(s). Figure 11-17.
Section 11 Reassembly Assemble Cylinder Heads Prior to installation, lubricate all components with engine oil, paying particular attention to the lip of the valve stem seal, valve stems, and valve guides. Install the following items in the order listed below using a valve spring compressor. See Figures 11-21, 11-22, and 11-23.
Section 11 Reassembly 3 1 2 4 7. Rotate the crankshaft to align the keyway with the #1 cylinder. Rock the crankshaft and note whether the push rods/lifters on the #1 side are moving. If they are, rotate the crankshaft one full revolution. If the keyway is aligned with the cylinder, and rocking the crank produces no push rod/lifter movement, that cylinder is at TDC of the compression stroke. Engines Below Serial No.
Section 11 Reassembly 9. Mount a dial indicator to touch the top of the valve retainer, of the valve to be set. See Figure 11-27. NOTE: At this time, the valve will not be completely seated. Do not rotate the crankshaft. Figure 11-29. Back Off Screw Until Needle Stops. Figure 11-27. Mounted Dial Indicator. 10. Rotate the face of the dial indicator to align the "0" with the needle. Do not disturb the gauge position. See Figure 11-28. 12.
Section 11 Reassembly Shim Valve Lash Setting Procedure Not Using a Dial Indicator (Adjustable Valve Train) The following procedure may be used as an alternate method for setting the valve lash. Although not as precise as using the dial indicator method, a valve lash setting within 0.001 in. - 0.003 in. of the previous procedure is possible. It is imperative that the lifters be completely bled down (See ‘‘Install Hydraulic Lifters’’) so they can be compressed by hand. 8.
Section 11 Reassembly Figure 11-33. Depressing To Bottom Limit of Lifter Plunger Travel. Figure 11-35. Determining Clearance with Feeler Gauge. 10. With the lifter still compressed, slowly tighten the rocker arm fastener (clockwise) until the free end of the rocker arm just makes contact with the end of the valve. See Figure 11-34. 12. Add 0.004" to the dimension from step 11 and record the total. This is the total shim thickness required for proper valve lash.
Section 11 Reassembly 16. Repeat the procedure for the other valve. Shim 17. As viewed from the PTO end, rotate the crankshaft 3/4 turn (270°) counterclockwise and align the crankshaft keyway with the #2 cylinder, which now puts that cylinder at TDC on the compression stroke. Repeat steps 8-15 for the #2 head. Do not interchange parts from one cylinder head to the other. Engines Serial No. 34065xxxxx and Higher with “Non-Adjustable Valve Train” Figure 11-36. Installing Shim(s). Install Rocker Arms 1.
Section 11 Reassembly 4. Apply pipe sealant with Teflon® (not Teflon® tape) to the threads of the 1/8" pipe plug or the Oil Sentry™ switch (if so equipped), and install into the breather cover. Torque to 4.5 N·m (40 in. lb.). Figure 11-39. Torquing Drain Plug. Install Breather Cover and Gasket Figure 11-42. Installing Pipe Plug. Install Oil Fill/Dipstick Tube Assembly and Lower Blower Housing 1. Lubricate the O-Ring with engine oil, and install it on the lower end of the dipstick tube.
Section 11 Reassembly 1. Make sure the sealing surfaces of housing and manifold are clean and free of nicks or damage. 2. Install the thermostat into the corresponding recess in opening of the intake manifold, so the larger spring end is down. Place a new thermostat housing gasket onto the manifold surface aligning the screw holes. Do not use a substitute gasket. Figure 11-44. Tie Strap in Lower Blower Housing. 3.
Section 11 Reassembly Figure 11-48. Torquing Thermostat Housing Screws. Figure 11-50. Intake Manifold in Place. 4. Check that the gasket surfaces of the intake manifold and cylinder heads are clean and free of any nicks or damage. 6. If the connector fitting for the by-pass hose was removed from the manifold previously, reinstall it at this time. Apply pipe sealant with Teflon® (not Teflon® tape) onto the threads and tighten so the fitting faces directly towards the long screw hole on the #2 side. 5.
Section 11 Reassembly from the crankshaft. Orient the parts as shown in Figure 11-54 while tightening. Torque the six intake manifold mounting screws in two stages; initially to 7.4 N·m (66 in. lb.) then to 9.9 N·m (88 in. lb.) in the sequence shown in Figure 11-55. 1 5 3 6 4 2 Figure 11-55. Intake Manifold Torque Sequence. 3. Install and tighten the pipe plug or temperature warning switch, if removed previously from the threaded port of the intake manifold.
Section 11 Reassembly 5. Apply rubber lubricant to the inner surface of the short hose section. Assemble the hose to the outlet of the water pump and secure with the larger diameter clamp. Orient the clamp so the tangs extend down in the 5 to 6 o'clock position, towards the impeller of the pump. See Figure 11-60. NOTE: A mark or dot of paint applied to top of pulley indicating the keyway location will make installation easier. 2.
Section 11 Reassembly 1) Place a new ferrule/compression ring in the 90° fitting of crankcase and loosely install the hex. cap section onto the threads of the fitting. See Figure 11-62. NOTE: The 90° fitting in the crankcase to which the transfer tube is connected, is installed and sealed at the factory in a specific position. Special tools and procedures are involved. DO NOT loosen, remove, or alter the mounting position of this fitting at any time.
Section 11 Reassembly NOTE: When installation is complete, the tangs of the two hose clamps must be down toward the crankcase, away from the flywheel and below the adjacent flange of the lower blower housing. See Figure 11-66. 10. Install the drive belt onto the cogged pulley of the water pump, then around the cam pulley. Slide the cam pulley with the belt attached, down onto the keyway end of the camshaft. Be careful not to push the key out of the keyway, and/or into the seal, when installing the pulley.
Section 11 Reassembly 12. Attach the by-pass hose to the fitting on the water pump and secure with the hose clamp. The tangs of the clamp should point outward. Completed installation should look as shown in Figure 11-70. 3. Position the rectifier-regulator onto the locating stud with its cooling fins ‘‘up’’. Attach the ground lead to the mounting screw, install and torque the screw to 4.0 N·m (35 in. lb.). 4.
Section 11 Reassembly 3. Place the small sleeve spacer onto the stud, in the center of the intake manifold. If the stud was removed from the manifold, apply Loctite® No. 290 to the lower set of threads and install until stud bottoms, or an exposed height of 32 mm (1.26 in.) is obtained. 4. Apply rubber lubricant to the inner surfaces of the disconnected hoses and mating surfaces on the thermostat housing and water pump. 5.
Section 11 Reassembly 8. Lift the by-pass hose and secure it within the metal clip under the main support bracket. See Figure 11-78. 3. Slide the adjacent radiator support bracket under the heads of the starter bolts and behind the lifting bracket. Check that the starter is square to the crankcase, then torque the mounting bolts to 15.3 N·m (135 in. lb.). See Figure 11-80. Figure 11-78. Seating By-pass Hose. Install Electric Starter 1.
Section 11 Reassembly Install Ignition Modules and Flywheel 1. Route the spark plug leads of the ignition modules, out through the corresponding cutouts in the lower blower housing assembly. 2. Route the white kill leads from the wiring harness and connect them to the ‘‘kill’’ tabs of the ignition modules. See Figures 11-82 and 11-83. Figure 11-84. Ignition Modules ‘‘Back’’ as Far as Possible. Install the Flywheel Figure 11-82. Ignition Module Kill Lead Mounting #2 Side.
Section 11 Reassembly 3. Lower the flywheel down into position on crankshaft and make sure the ring gear section is below the legs of the ignition modules. See Figure 11-85. If clearance is OK, continue with installation of the ignition modules. If clearance is insufficient or contact is noted; remove the flywheel and recheck the tension of the tie strap, the position of the lower hose and tube assembly, and the mounting of the cooling system.
Section 11 Reassembly 7. Rotate the flywheel back and forth checking for clearance between the magnet and ignition modules. Make sure the magnet does not strike the modules. Recheck the gap with a feeler gauge and readjust if necessary. Final Air Gap: 0.28/0.33 mm (0.011/0.013 in.). Install Spark Plugs 1. Install the spark plugs into the cylinder heads and torque each to 24.4/29.8 N·m (18/22 ft. lb.). See Figure 11-88. Figure 11-89. Tightening Upper Mounting Screws with Reservoir Installed.
Section 11 Reassembly Checking Valve Train 1. Rotate engine to check for free operation of the valve train. Check the clearance between valve spring coils at full lift. Minimum allowable clearance is 0.25 mm (0.01 in.). If engine seems tight or spring coils do not have proper clearance, repeat the valve lash adjustment procedure. 1 3 Install Valve Covers 1. Make sure the sealing surfaces of cylinder heads and valve covers are clean and free of all old gasket material. 4 2 1 3 2.
Section 11 Reassembly 3. Install the carburetor as an assembly, onto the carburetor studs. See Figure 11-94. Carefully lift up on the lower blower housing, directly above the carburetor, and slide the carburetor into place against the gasket and manifold. 3. Pivot the governor lever toward the carburetor as far as it will move (wide-open throttle) and hold in position. 4. Insert a nail into the hole in the cross shaft and rotate the shaft counterclockwise as far as it will turn, then torque the hex.
Section 11 Reassembly 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. Lever Throttle Control (middle) 4 3 2 1 Lever, Throttle Actuator (bottom) Washer, flat (3) Nut, M5x0.8 Lock Spring, Choke Return Bracket, Speed Control Figure 11-97. Throttle/Choke Control Bracket and Governor Lever Detail. 2.
Section 11 Reassembly Install Fuel Pump 1. Mount the fuel pump, with the lines attached, onto the blower housing, using the two hex. flange screws. Torque the screws to 2.3 N·m (20 in. lb.). See Figure 11-99. Install Air Cleaner Base 1. Install a new air cleaner base gasket onto the carburetor studs. 2. Install the air cleaner base onto the carburetor studs. Attach the clip around the fuel line onto the right side stud and install the two hex. flange nuts onto the studs to secure. Torque the nuts to 9.
Section 11 Reassembly Figure 11-102. Rechecking Governor Linkage Adjustment. Figure 11-104. Installing Oil Filter. Fill Crankcase with Oil 4. After adjustment is correct, reinstall the black bushing and linkage into the governor lever. 1. Install the oil drain plug(s). See Figure 11-105. Torque the plug(s) to 13.6 N·m (120 in. lb.). Install Muffler 1. Install the muffler or exhaust system to the exhaust port studs. Torque hex. flange nuts to 24.4 N·m (216 in. lb.). See Figure 11-103. Figure 11-105.
Section 11 Reassembly 1. 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. Reconnect Battery and Spark Plug Leads Connect the leads to the spark plugs. Reconnect the positive battery lead first, and the negative (-) lead last when reconnecting the battery. See Figure 11-107. Testing the Engine 2.
FOR SALES AND SERVICE INFORMATION IN U.S. AND CANADA, CALL 1-800-544-2444 ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044 FORM NO.: TP-2509 ISSUED: 9/01 REVISED: 5/04 MAILED: 6/04 LITHO IN U.S.A.
