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Briggs & Stratton Vanguard 430000, User Manual

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Briggs & Stratton Vanguard 430000 User Manual Download Page 92

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10

Troubleshooting

When troubleshooting an engine with EFI, basic 
engine operating problems must be addressed 
before turning to the EFI system components. 

Engine starts hard or fails to start when cold

1. Fuel pump inoperative

 2. Engine temperature sensor inoperative

 3. Insufficient fuel pressure

 4. Crankshaft position sensor inoperative

 5. Crankshaft position sensor offset incorrect

 6. Old/stale fuel

 7. Low system voltage

 8. Injectors clogged or restricted

 9. Coils inoperative

 10. Spark plugs fouled, worn, or damaged

Engine starts hard or fails to start when hot

1. Fuel pressure low

 2. Fuel pump inoperative

 3. Insufficient fuel pressure

 4. Crankshaft position sensor inoperative

 5. Crankshaft position sensor offset incorrect

 6. Injectors clogged or restricted

 7. Spark plugs fouled, worn, or damaged

Engine misses, hesitates, or stalls under load

1. Fuel injectors/fuel filter/fuel line dirty or 

restricted

 2. Air cleaner dirty

 3. Fuel pressure or fuel volume insufficient

 4. Vacuum (intake air) leak

 5. Governor setting incorrect

 6. Spark plugs fouled, worn or incorrect gap

 7. Plug wires loose or worn

Low Power

1. Air cleaner dirty

 2. Fuel pressure insufficient

 3. Governor setting incorrect

 4. Exhaust system plugged or restricted

 5. Injector(s) dirty or clogged

Electrical System

The EFI system is 12VDC with negative ground. A 
fully-charged 12 volt battery with a minimum of 350 
cold cranking amps is required to maintain reliable 
system operation. Battery condition and state of 
charge should always be checked first when 
troubleshooting the EFI system.
EFI-related problems are more likely caused by the 
wiring harness or connections than by the EFI 
components. Even small amounts of corrosion or 
oxidation on the terminals can interfere with the 
milliamp currents used in system operation. 
Cleaning the connectors and grounds will solve 
problems in many cases.
If a fault code indicates a problem with an EFI 
component, disconnect the ECU connector and test 
for continuity between the component connector 
terminals and the corresponding terminals in the 
ECU connector.

Summary of Contents for Vanguard 430000

Page 1: ...Cooled Engines 272144 Vanguard Twin Cylinder OHV Air Cooled Engines 275429 Vanguard Twin Cylinder OHV Liquid Cooled Engines MS 1055 Vanguard 3 Cylinder OHV Liquid Cooled Diesel Engines Other Briggs S...

Page 2: ...anual were based on the data available at the time of publication Briggs Stratton Corporation reserves the right to change alter or otherwise improve the product or the product manuals at any time wit...

Page 3: ...6 This engine repair manual includes the following engine models MODEL 430000 MODEL 580000...

Page 4: ...6 Cylinder Block Inspection and Repair SECTION 7 Crankshaft Camshaft and Bearings SECTION 8 Pistons Rings and Connecting Rods SECTION 9 Cylinder Block Assembly SECTION 10 Fuel System and Related Comp...

Page 5: ...THISPROPER SERVICE AND REPAIR IS IMPORTANT TO THE SAFE ECONOMICAL AND RELIABLE...

Page 6: ...3 1 1 SECTION 1 SAFETY AND MAINTENANCE SAFETY INFORMATION 4...

Page 7: ...oderate injury NOTICE indicates a situation that could result in damage to the product Prior to work read and understand the section s of this manual that pertain to the job Follow all safety warnings...

Page 8: ...are extremely flam mable and explosive Fire or explosion can cause severe burns or death When adding fuel Turn engine OFF and let engine cool for at least 2 minutes before removing the fuel cap Fill...

Page 9: ...ng hair and remove jewelry Do not wear loose fitting clothing dangling drawstrings or items that could become entangled in the equipment WARNING Charging batteries produce hydrogen gas Do not store or...

Page 10: ...VALVES REMOVE CYLINDER HEAD 9 DISASSEMBLE CYLINDER HEAD 10 REMOVE VALVES 11 INSPECT CYLINDER HEAD 12 DISASSEMBLE ROCKER ARM SHAFT 15 ASSEMBLE ROCKER ARM SHAFT 16 ASSEMBLE CYLINDER HEAD 17 INSTALL CYL...

Page 11: ...8 2 2...

Page 12: ...igure 2 water pump B and exhaust manifold C from the engine NOTE Remove the exhaust system before removing exhaust manifold Figure 2 4 Remove the fuel line A Figure 3 and governor link and spring B 5...

Page 13: ...pression stroke If intake and exhaust valves do not have clearance turn crankshaft pulley one complete revolution Valves will then have clearance 10 Remove rocker arm assembly A Figure 7 and push rods...

Page 14: ...H Valve Spring Seat J Valve Stem Seal K Valve Guide Figure 9 3 Remove valves Figure 10 Figure 10 NOTE Place a shop rag or short section of fuel line under valves inside combustion chamber to hold valv...

Page 15: ...aces in the same manner Use same specifications as cylinder head 5 Inspect valve guide bushing for damage Check valve guide bushings for wear using Reject Gauge 19382 A Figure 14 Replace if damaged or...

Page 16: ...eplaced before refacing valve seats If valve seat is wider than 0 05 0 06 1 2 1 6mm A Figure 18 a narrowing cutter should be used to ensure that contact area of valve seat is centered on face of valve...

Page 17: ...14 2 2 Figure 20 14 Inspect valve springs for squareness and free length Figure 21 Figure 21 Replace if out of square more than 0 040 in 1 0 mm Replace if free length is less than 0 150 in 29 2 mm...

Page 18: ...ssemble rocker arm assembly Note position of rocker arms E thrust washers F and springs G Figure 22 1 Check rotor arms and shaft Figure 23 Figure 23 2 Check rocker arm bearing Replace if greater than...

Page 19: ...ll grooves in rocker shaft A next to oil holes B must face down 3 Assemble rocker arm G components noting order of assembly shown in Figure 24 Figure 24 4 Note position of three thrust washers F sprin...

Page 20: ...lve Spring Retainer F Valve Spring G Valve H Valve Spring Seat J Valve Stem Seal K Valve Guide L Push Rod M Rocker Arm Assembly N Rocker Arm Stud Figure 25 1 Install new valve stem seals A Figure 26 O...

Page 21: ...lock Figure 29 NOTE Make sure coolant oil passages and head bolt holes are aligned Figure 29 2 Install cylinder head assembly 3 Lubricate threads of cylinder head bolts with engine oil 4 Torque head b...

Page 22: ...4 Engine Specifications Figure 32 9 Install intake manifold with new gasket Install governor link and spring Figure 33 Torque screws to values listed in Section 14 Engine Specifications Figure 33 10 I...

Page 23: ...elt Figure 38 Install alternator adjusting bolt Torque bolt to values listed in Section 14 Engine Specifications Figure 38 NOTE Belt deflection limit is 3 8 1 2 in 22 lb 10 0 12 0 mm 10 kg Adjust Valv...

Page 24: ...ders Figure 41 4 Rotate crankshaft one complete turn 360 clockwise to check and adjust remaining valves 5 Install valve cover Figure 41 Torque cover nuts to values listed in Section 14 Engine Specific...

Page 25: ...22 2 2...

Page 26: ...GEAR CASE 26 DISASSEMBLE GOVERNOR SHAFT ASSEMBLY 27 REPLACE TIMING GEAR COVER OIL SEAL 27 ASSEMBLE GOVERNOR SHAFT ASSEMBLY 27 ASSEMBLE TIMING GEAR CASE AND GEARS 28 ADJUST GOVERNOR 31 TROUBLESHOOTING...

Page 27: ...f equipped 2 Drain oil from engine NOTE Before removing governor spring note hole position of governor spring in governor lever 3 Remove governor link spring A Figure 1 and governor link from carburet...

Page 28: ...re Remove timing gear cover B and discard timing gear gasket Figure 4 12 Remove governor gear A Figure 5 governor cup B E ring C governor gear D and thrust washer E 13 Remove oil pump drive gear F Fig...

Page 29: ...r crankshaft gear is worn NOTE If crankshaft gear is worn the crankshaft must be replaced 6 Hold idler gear and check gear backlash between camshaft timing gear A Figure 8 and idler gear B using a dia...

Page 30: ...Use Seal Driver 19423 to install new oil seal Figure 12 Figure 12 Assemble Governor Shaft Assembly 1 Install thrust washer A Figure 13 on shaft followed by the governor gear B E ring C and governor c...

Page 31: ...It may be necessary to rotate oil pump drive to engage oil pump rotors NOTE Position camshaft retainer so that the center hole does not interfere with the camshaft 3 Note position length and number o...

Page 32: ...on camshaft gear Figure 19 Figure 19 8 Install oil pump gear 9 Torque screws to values listed in Section 14 Engine Specifications Camshaft gear A Figure 20 idler gear B and oil pump gear C Figure 20 1...

Page 33: ...d nuts to values shown in Section 14 Engine Specifications 16 Install V belt and fan if equipped 17 Install governor lever A Figure 24 on to governor shaft Do not tighten governor nut at this time 18...

Page 34: ...uipment control to FAST position 3 Disconnect governor link spring and link 4 Rotate throttle wide open position NOTE Position of governor link must be within 1 mm of center of hole in throttle Figure...

Page 35: ...elated wiring for the electronic governor is supplied by the equipment manufacturer NOTE Engines equipped with an electronic governor do not have mechanical governor components A Governor Actuator B G...

Page 36: ...nk spring and link A Figure 30 2 Remove two screws B and actuator C Figure 30 Install Governor Actuator 1 Assemble governor link spring and link to actuator lever Figure 31 NOTE Open ends of spring mu...

Page 37: ...34 3 3...

Page 38: ...35 4 SECTION 4 FLYWHEEL AND REAR SEAL RETAINER REMOVE OIL PAN AND FLYWHEEL 36 REMOVE REAR SEAL RETAINER 36 REPLACE OIL SEAL 36 INSTALL REAL SEAL RETAINER AND FLYWHEEL 37 INSTALL OIL PAN 37...

Page 39: ...l Figure 2 5 Inspect flywheel for cracks or damage Inspect flywheel ring gear for worn chipped or cracked teeth NOTE If ring gear is worn or damaged the flywheel must be replaced Remove Rear Seal Reta...

Page 40: ...Figure 7 NOTE Apply Permatex No 2 or similar sealant to flywheel screws Figure 7 3 Torque flywheel screws to values listed in Section 14 Engine Specifications 4 Remove flywheel holder Install Oil Pan...

Page 41: ...38 4...

Page 42: ...39 5 SECTION 5 CYLINDER BLOCK DISASSEMBLY CYLINDER BLOCK DISASSEMBLY 40 CYLINDER BLOCK...

Page 43: ...mbly An automotive type engine stand is recommended when complete engine disassembly is required See drawings below for dimensions to make an engine stand mounting fixture The engine stand shown below...

Page 44: ...Figure 1 Figure 1 5 Remove alternator bracket and alternator Figure 2 Figure 2 6 Remove valve lifters Figure 3 NOTE Number lifters so that they may be reinstalled in the same position Figure 3 7 Remov...

Page 45: ...nd piston out through top of cylinder Reassemble connecting rod cap to connecting rod to prevent interchanging components Figure 6 10 Remove crankshaft main bearing caps keeping main bearings with the...

Page 46: ...43 6 SECTION 6 CYLINDER BLOCK INSPECTION AND REPAIR CHECK CYLINDER BLOCK 44 CHECK CYLINDER BORE FOR WEAR 44 REPLACE CAMSHAFT BEARINGS 45 REPLACE CAMSHAFT PLUG 45...

Page 47: ...Figure 3 2 If cylinder bore is worn more than 0 003 in 0 075 mm or more than 0 0015 in 0 035 mm out of round it must be resized Figure 3 NOTE Always resize to exactly 0 010 in 0 25mm over standard bor...

Page 48: ...camshaft plug Figure 8 NOTICE Use a wood dowel or brass rod to prevent damage to the camshaft bearing Figure 8 2 Using Camshaft Bearing Driver 19422 install new camshaft plug flush with cylinder block...

Page 49: ...46 6 6 Figure 10 4 Remove timing gear oil nozzle A Figure 11 Figure 11 5 When reinstalling oil nozzle oil hole must be positioned at a 45 angle pointing towards the idler gear A Figure 12 Figure 12...

Page 50: ...47 7 SECTION 7 CRANKSHAFT CAMSHAFT AND BEARINGS INSPECT CRANKSHAFT 48 CHECK MAIN BEARING CLEARANCES 49 CHECK CONNECTING ROD BEARING CLEARANCES 50 CHECK CRANKSHAFT END PLAY 50 INSPECT CAMSHAFT 51...

Page 51: ...3 If crankshaft journals are not within specification the crankshaft may be re ground and 0 010 in 0 25 mm undersize bearings installed See illustrated parts list for part numbers 4 Check the cranksha...

Page 52: ...A Figure 4 NOTE Do not lay plastigage across hole in crankshaft journal Figure 4 3 Assemble main bearing cap with bearing Figure 5 and torque to values listed in Section 14 Engine Specifications NOTE...

Page 53: ...Figure 8 NOTE Do not allow crankshaft to rotate Figure 8 4 Remove the connecting rod cap Measure the plastigage at its widest point A Figure 9 If the clearance is not within specification replace the...

Page 54: ...the camshaft Standard Intake Exhaust 1 183 1 186 in 30 065 30 135 mm Reject Intake Exhaust 1 179 in 29 965 mm Figure 11 2 Measure camshaft journals Figure 12 Figure 12 3 Measure camshaft run out Figur...

Page 55: ...52 7 7...

Page 56: ...N AND CONNECTING ROD 54 INSPECT PISTONS AND RINGS 54 CHECK PISTON PIN AND CONNECTING ROD 55 ASSEMBLE PISTON AND CONNECTING ROD 56 ASSEMBLE PISTON RINGS TO PISTON 56 Disassemble Piston and Connecting R...

Page 57: ...driver onto support with arrow on piston facing up 6 Press out piston pin Figure 2 Inspect Piston and Rings If the cylinder bore is to be resized there is no reason to check the piston as a new overs...

Page 58: ...d 3 Check crankpin bearing end of connecting rod Figure 8 Figure 8 Maximum out of round 0 0008 in 0 02 mm If out of round exceeds specification shown the connecting rod must be replaced 4 Check for be...

Page 59: ...in bottom of piston support B Figure 11 5 With arrow on piston up place assembly onto support 6 Press in piston pin until pilot bottoms on stop 7 After assembly make sure the piston rotates freely on...

Page 60: ...CYLINDER BLOCK ASSEMBLY INSTALL CRANKSHAFT 58 INSTALL PISTONS AND CONNECTING RODS 59 GENERAL ASSEMBLY 59 INSTALL TIMING GEAR CASE CAMSHAFT AND GEARS 60 INSTALL OIL PAN 62 INSTALL ALTERNATOR 62 GENERA...

Page 61: ...ll crankshaft with gear facing front of cylinder block Figure 3 Take care not to damage journals or bearings 8 Install crankshaft shims on No 3 main bearings web with grooves facing out Lubricate jour...

Page 62: ...onnecting rod cap with ID mark A Figure 6 facing front Lubricate threads and torque nuts to values listed in Section 14 Engine Specifications Figure 6 NOTE After torquing rod cap make sure crankshaft...

Page 63: ...y of screws as shown M6 x 1 1 in M6 x 28mm 4 A M6 x 1 5 in M6 x 16mm 1 B 4 Torque screws to values listed in Section 14 Engine Specifications Figure 11 5 Lubricate and install camshaft in cylinder blo...

Page 64: ...lock position assemble idler gear so that timing mark 11 AA is aligned with timing mark 1 A in crankshaft gear timing mark 22 BB is aligned with timing mark 2 B on camshaft gear Figure 15 Figure 15 11...

Page 65: ...re 18 and wire Figure 18 Install Oil Pan 1 Install oil pan with new gasket 2 Apply a small bead of sealant to crankcase areas A Figure 19 Figure 19 3 Torque screws to values listed in Section 14 Engin...

Page 66: ...SHAFT 69 INSTALL CHOKE VALVE 69 INSTALL FLOAT 70 INSTALL CARBURETOR 70 INITIAL CARBURETOR ADJUSTMENT 71 FINAL CARBURETOR ADJUSTMENT 71 AUTOMATIC CHOKE CARBURETOR 73 REMOVE CARBURETOR 73 DISASSEMBLE C...

Page 67: ...ST EQUIPMENT 82 TEST FUEL PUMP WIRING 82 ANTI AFTERFIRE SOLENOID 83 TEST ANTI AFTERFIRE SOLENOID 83 TEST SOLENOID 83 FUEL FILTER 84 CARBURETOR MAIN JETS 84 ELECTRONIC FUEL INJECTION SYSTEM 85 EFI COMP...

Page 68: ...65 10 MANUAL CHOKE CARBURETOR AUTOMATIC CHOKE CARBURETOR...

Page 69: ...arly style choke links were manufactured with a Z bend Figure 3 To remove choke link the governor control bracket must be removed Proceed to Steps 5 and 6 5 Disconnect governor spring A Figure 2 Remov...

Page 70: ...igure 7 4 Remove fixed high speed jet A Figure 8 5 Remove emulsion tube B Figure 8 NOTE Consult the illustrated parts list for correct part number for special high altitude jet if required 6 Remove id...

Page 71: ...retor Remove gasket material from mounting surfaces Gummy or dirty carburetors should be cleaned in a carburetor cleaner DO NOT soak rubber neoprene or plastic parts in cleaner NOTICE If engine is equ...

Page 72: ...t 1 Install seal A Figure 15 with grooved side out 2 Assemble collar B to throttle shaft and insert in body 3 Install throttle plate and screws C Figure 15 Install Choke Valve 1 Assemble spring A Figu...

Page 73: ...rew Install Carburetor 1 Assemble insulator A Figure 21 with gaskets carburetor B and air horn C with gasket D to intake manifold Figure 21 2 Torque nuts to values listed in Section 14 Engine Specific...

Page 74: ...arburetor Adjustment NOTICE All carburetor adjustments must be made with the air cleaner installed 1 Start and run engine at low speed for approximately five minutes Or if equipped with a temperature...

Page 75: ...um choke break which partially opens the choke plate to prevent over choking while the engine is being started A vacuum limiter located in the vacuum line regulates vacuum to the vacuum choke break Th...

Page 76: ...6 3 Remove two nuts and ground wire A Figure 27 from solenoid air horn B carburetor C and insulator D Discard gaskets Figure 27 Disassemble Carburetor 1 Remove fuel shut off solenoid A Figure 28 and g...

Page 77: ...rmostat retainer A Figure 32 and ground wire B Discard thermostat gasket C Figure 32 7 Remove screw and choke pre load lever A Figure 33 Figure 33 8 Remove two screws choke plate B and choke shaft C 9...

Page 78: ...Remove two screws throttle plate throttle shaft B and seal C Discard seal Figure 37 Clean Carburetor Remove gasket material from mounting surfaces Gummy or dirty carburetors should be cleaned in a ca...

Page 79: ...t and choke shaft for wear Figure 39 Figure 39 Replace if worn If carburetor body is worn replace carburetor Assemble Carburetor When assembling the carburetor use new seals and gaskets 1 Install thro...

Page 80: ...all choke plate 7 Install thermostat with new gasket A Figure 45 8 Insert hook B on thermostat spring between arms on choke shaft 9 Assemble thermostat retainer leaving screws loose Figure 45 10 Hold...

Page 81: ...ak and activate pump to specification shown Specification 4 0 5 5 in Hg vac 10 0 14 0 cm Hg vac Choke plate should partially open and pump gauge should maintain vacuum 2 Check dimension from edge of c...

Page 82: ...Assemble insulator with gaskets carburetor and air horn to intake manifold NOTE Attach thermostat ground wire A Figure 54 to air horn Figure 54 2 Torque nuts to specifications shown in Section 14 Eng...

Page 83: ...nt in SLOW position hold throttle lever A Figure 57 against idle speed screw and adjust idle speed to 1200 RPM Figure 57 3 SLOWLY turn idle mixture screw clockwise until engine speed just starts to sl...

Page 84: ...81 10 Electric Fuel Pump NEW STYLE PUMP OLD STYLE PUMP...

Page 85: ...ing Test Equipment The Digital Multimeter 19464 is required to test the fuel pump The fuel pump test will be performed with the meter in the V DC Volts position Figure 60 Figure 60 Test Fuel Pump Wiri...

Page 86: ...in the gasket A Figure 62 An Anti afterfire solenoid will not function if ground clip is removed or damaged Figure 62 Test Anti Afterfire Solenoid If solenoid does not click the problem may be in the...

Page 87: ...esn t move Figure 65 Fuel Filter Figure 66 Replace in line fuel filter every 600 hours In line fuel filter has an arrow to indicate fuel flow direction Always install arrow towards carburetor Carburet...

Page 88: ...tor stranded NOTICE If an abnormal crankshaft pulse is detected the ECU will shut the engine down to prevent damage from occurring EFI Components The system includes the following components Air Tempe...

Page 89: ...center on the number 1 cylinder The ECU sequences through the firing order until the last injector has been opened Figure 3 Engine Control Unit ECU The Engine Control Unit ECU Figure 4 collects infor...

Page 90: ...formed tube assembly that feeds fuel to the top of the injectors A valve in the rail allows for testing the operating pressure or relieving fuel system pressure when servicing When the rail is assemb...

Page 91: ...sending voltage to each spark plug when needed Figure 11 Malfunction Indicator Light MIL If the self diagnostic feature detects a fault the fault code is displayed on the malfunction indicator lamp M...

Page 92: ...pressure or fuel volume insufficient 4 Vacuum intake air leak 5 Governor setting incorrect 6 Spark plugs fouled worn or incorrect gap 7 Plug wires loose or worn Low Power 1 Air cleaner dirty 2 Fuel pr...

Page 93: ...d Pressure Sensor 12 Water Temperature Sensor 13 Intake Air Temperature Sensor 17 Oxygen Sensor 24 Battery Voltage 27 VCC Circuit 33 Fuel Injector 1 34 Fuel Injector 2 35 Fuel Injector 3 37 Ignition C...

Page 94: ...shes represents the number of the code For example if there was an issue with battery voltage the fault code 24 would be displayed on the MIL This is represented by two long flashes followed by four s...

Page 95: ...92 10 TROUBLESHOOTING ENGINE PERFORMANCE ISSUES...

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Page 114: ...HARGING SYSTEM 117 TEST EQUIPMENT 118 TEST ALTERNATOR AC OUTPUT 118 TEST REGULATOR RECTIFIER DC OUTPUT 118 CHARGING INDICATOR CIRCUIT 119 40 AMP CHARGING SYSTEM 120 TEST EQUIPMENT 120 TEST ALTERNATOR...

Page 115: ...TEST STARTER NO LOAD 126 TEST SOLENOID 127 REPLACE SOLENOID 128 INSTALL SOLENOID 128 REMOVE PINION GEAR ASSEMBLY 128 INSTALL PINION GEAR ASSEMBLY 129 DISASSEMBLE STARTER MOTOR 130 INSPECT ARMATURE CO...

Page 116: ...three major components Figure 1 1 A permanent trigger and signal rotor integral with the crankshaft pulley 2 A transistorized ignition module which advances and retards the ignition timing electronic...

Page 117: ...e 3 3 Meter should Beep once If meter makes a continuous tone or displays OL trigger is defective Replace trigger 4 Reverse test leads 5 Meter should Beep once If meter makes a continuous tone or disp...

Page 118: ...the chart below Attach red meter test lead to the terminal shown at the top of the column Attach the black test lead to the terminal shown in the vertical column below and note reading Then move the b...

Page 119: ...the chart below Attach red meter test lead to the terminal shown at the top of the column Attach the black test lead to the terminal shown in the vertical column below and note reading Then move the b...

Page 120: ...stem The 14 Amp charging system consists of two components 1 The belt driven permanent magnet alternator produces AC voltage Figure 9 AC output will vary with engine RPM from approximately 7 volts AC...

Page 121: ...ut or low output is found replace the alternator If alternator output is within specification reconnect alternator wires and test regulator rectifier Test Regulator Rectifier DC Output NOTE The DC shu...

Page 122: ...15 A continuous tone indicates continuity complete circuit No tone indicates no continuity incomplete circuit An incomplete circuit will be displayed as OL 1 Place keyswitch in OFF position 2 Disconn...

Page 123: ...TE The digital multimeter will withstand DC input of 10 20 amps for up to 30 seconds To avoid blowing the fuse in the meter the DC shunt is required Test Alternator DC Output NOTE The DC shunt must be...

Page 124: ...T mix Screw 1 0 45 in 11 5 mm B Screw 2 0 35 in 9 0 mm C Figure 21 5 Remove three screws and regulator A Figure 22 Figure 22 6 Remove stator lead screws from rectifier A Figure 23 7 Carefully straight...

Page 125: ...s 3 Press out bearing from pulley side of drive end housing using Driver 19416 Figure 26 Figure 26 NOTE DO NOT reuse ball bearings that have been removed from drive end housing The bearing races are u...

Page 126: ...h holder Figure 30 Standard 0 413 in 10 5 mm Reject 0 315 in 8 0 mm Figure 30 Check Regulator 1 Set the meter to the position 2 Attach BLACK meter test lead to terminal A Figure 31 3 Contact Red meter...

Page 127: ...nd D terminals Results must be the same Figure 33 Assemble Alternator 1 Assemble rotor to drive end housing Figure 34 2 Assemble spacer pulley and nut to rotor shaft Do not tighten nut at this time 3...

Page 128: ...w 2 0 35 in 9 0 mm B Figure 39 11 Install rear cover and screws A Figure 40 Torque to values listed in Section 14 Engine Specifications 12 Install insulator and nut B and torque to value listed in Sec...

Page 129: ...revent engine from starting remove spark plug wires from spark plugs Leave spark plugs installed 1 Set meter to the 300mV position 2 The DC Shunt must be installed on the negative terminal of the batt...

Page 130: ...11 If amperage draw exceeds specification replace starter Test Solenoid The solenoid test is performed with the starter removed from the engine The following equipment is recommended to test the solen...

Page 131: ...all field coil wire and nut Torque to values listed in Section 14 Specifications 3 Install starter motor Torque screws to values listed in Section 14 Specifications Figure 48 Remove Pinion Gear Assemb...

Page 132: ...bly 1 Lubricate helix with a light coat of grease and assemble pinion gear and clutch 2 Assemble new lower retainer to shaft Figure 53 3 Install new snap ring Figure 53 4 Pull up on lower retainer unt...

Page 133: ...NOT remove drive housing 1 Remove solenoid 2 Place drive housing in a vise Figure 57 NOTE Take care not to damage drive housing or mounting surface Figure 57 3 Remove thru bolts and lift off end cap 4...

Page 134: ...sh dimension is 2 95 in 7 5 mm Figure 61 If brushes are worn less than specification replace the brushes or stator housing Figure 61 1 Use a digital multimeter to check for continuity between field co...

Page 135: ...ification NOTE DO NOT remove field wire from terminal A Figure 64 2 Use a fine file and carefully remove remaining lead wire from terminals NOTE Terminals B and D must be no less than the following sp...

Page 136: ...8 Figure 68 2 Assemble starter housing to drive housing aligning notch in housing with tab on drive lever support Figure 69 Figure 69 3 Install brush holder inserting tabs on brush holder into slots i...

Page 137: ...Be sure notch in rubber seal is inserted over tab on housing Figure 72 8 Install end cap Figure 73 and torque thru bolts to values listed in Section 14 Engine Specifications 9 Install solenoid 10 Ins...

Page 138: ...ON 12 LUBRICATION SYSTEM CHANGE OIL 137 CHANGE OIL FILTER 137 CHECK OIL PRESSURE 138 DISASSEMBLE GEAR CASE 138 REMOVE OIL PUMP 138 REMOVE GEAR CASE 140 ASSEMBLE TIMING GEAR CASE AND GEARS 140 ADJUST G...

Page 139: ...136 12 12 LUBRICATION SYSTEM...

Page 140: ...00 hours of operation Change oil and filter more often if engine is operated in dusty or dirty conditions or if engine is operated under heavy loads or high ambient air temperatures 1 Remove oil drain...

Page 141: ...plugs V belt and fan if equipped and drain oil from engine NOTE Make sure the Number 1 cylinder is at Top Dead Center TDC compression stroke See Section 2 NOTE Before removing governor spring note ho...

Page 142: ...Figure 8 NOTE Leave tool installed 9 Remove crankshaft pulley using Crankshaft Puller 19420 B Figure 8 10 Remove trigger Figure 9 and wire Remove timing gear cover and discard timing gear gasket Figur...

Page 143: ...ar case 5 Remove and check pressure relief valve assembly Figure 12 Make sure plunger has no nicks or burrs Check pressure relief valve spring length Spring free length 35 5 1 0 mm 1 4 040 in Figure 1...

Page 144: ...6 Assemble idler gear shaft with arrow up B Figure 16 Figure 16 Engine models 430000 and 580000 built after date code 990111007 are equipped with right angle helical timing gears Timing marks are ide...

Page 145: ...nsure alignment pin in crankshaft gear is seated in hole in pulley 12 Remove flywheel holder A Figure 20 AND install trigger assembly and wire B Figure 20 13 Install oil pick up tube and strainer with...

Page 146: ...ntrol lever by engine model Figure 23 Model 430400 Top Hole Model 580400 Bottom Hole Figure 23 Adjust Governor 1 Move governor control lever Figure 24 up to end of travel and hold in this position thr...

Page 147: ...144 12 12...

Page 148: ...GENERAL INFORMATION 146 PRESSURE TEST COOLING SYSTEM 147 CHANGE COOLANT 147 TEST RADIATOR CAP 147 REMOVE THERMOSTAT 147 INSPECT THERMOSTAT 148 INSTALL THERMOSTAT 148 INSPECT WATER PUMP 148 REMOVE WATE...

Page 149: ...old As the engine warms the by pass valve closes as the thermostat opens permitting complete circulation through the radiator Always maintain a 50 solution of phosphate free antifreeze at all times fo...

Page 150: ...radiator cap Remove radiator drain plug A Figure 1 and drain the system Figure 1 2 Tighten drain plug NOTE Follow state or federal laws regarding the proper procedure for disposing of antifreeze Test...

Page 151: ...ostat should close fully Install Thermostat 1 Insert thermostat in housing and install locating screw A Figure 5 Figure 5 2 Install coolant outlet housing with new gasket 3 Torque screws to values lis...

Page 152: ...pped C Coolant outlet D Coolant inlet E Water pump Figure 9 4 Clean all traces of gasket material from mounting surfaces and inspect mounting surfaces for damage Install Water Pump 1 Install water pum...

Page 153: ...8 Install fan Figure 12 if equipped and water pump pulley Torque screws to values listed in Section 14 Engine Specifications Figure 12 9 Install V belt Figure 13 Belt tension adjustment 3 8 1 2 in 22l...

Page 154: ...151 14 SECTION 14 ENGINE SPECIFICATIONS MODEL 430000 152 MODEL 580000 154...

Page 155: ...Nm Flywheel 35 ft lbs 47 Nm Governor Actuator 70 in lbs 8 Nm Governor Control Bracket 70 in lbs 8 Nm Governor Nut 90 in lbs 10 Nm Governor Paddle 8 in lbs 1 Nm Idler Gear 220 in lbs 25 Nm Intake Manif...

Page 156: ...8 in 0 07 mm Main Bearing 1 653 1 654 in 41 98 42 00 mm Crankpin 1 456 1 457 in 36 98 37 00 mm Cylinder Main Bearing 0 0008 0 0017 in 0 020 0 044 mm 0 0028 in 0 07 mm Bore Diameter 2 67 2 68 in 68 00...

Page 157: ...Nm Flywheel 35 ft lbs 47 Nm Governor Actuator 70 in lbs 8 Nm Governor Control Bracket 70 in lbs 8 Nm Governor Nut 90 in lbs 10 Nm Governor Paddle 8 in lbs 1 Nm Idler Gear 220 in lbs 25 Nm Intake Manif...

Page 158: ...8 in 0 07 mm Main Bearing 1 653 1 654 in 41 98 42 00 mm Crankpin 1 456 1 457 in 36 98 37 00 mm Cylinder Main Bearing 0 0008 0 0017 in 0 020 0 044 mm 0 0028 in 0 07 mm Bore Diameter 2 83 2 84 in 72 00...

Page 159: ...156 14 14...

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