Kohler l654 Service Manual Download

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Summary of Contents for l654

Page 1: ...vernor Adjustments 7 I 2 2 Dry Air Cleaner 3 1 8 1 Oil Bath Cleaner 3 2 1 GENERAL SERVICES Cylinder Head Valves Flame Arrestor I 8 1 3 2 I Compressi on 8 2 AIR INTAKE FUEL Gasol ine Carburetors 4 1 t Fuel Pump 4 4 Automatic Chokes 4 5 1 RECONDITIONING Inspection Analysis 9 1 Gas Carburetors 4 6 I Disassembly 9 3 Gas Regu1ators 4 7 I Reconditioning 9 6 Re assembly 9 11 IGNITION Spark Plugs 5 1 Magn...

Page 2: ...RAIN OILLEVEL LAIR CLEANER DIPSTICK OIL BATH TYPE FIGURE 1 7 M CARBURETOR SIDEVIEW TYPICAL RADIATOR COOLED PLANT WITHL600ENGINE OILFILLER MAGNETO WATER PUMl 3 7 7 5QUART CAPACITY I______ 1 a a BREATHER CAP r STANDARD c i I AWKOX RAPIATOR CONTROLLER VIBRQ MOUNT COOLANT DRAIN OIL FILTER OPTION PAD FIGURE 1 2 MAGNETO SIDEVIEW TYPICAL RADIATORCOOLED PLANT WITHL654ENGINE 12 a ...

Page 3: ...nk to the fuel pump Fill tank Use priming lever on fuel pump to prime system before initial start up On gas fueled plants make sure system is properly hooked up before starting Refer to Fuel Section for typical arrangement and preliminary adjustments Battery These elect c plants feature exciter cranking which offers higher cranking speeds for more positive starting When battery current is applied ...

Page 4: ... SPARKPLUG GAP STD PLUG GAS l e SPARK PLUG GAP SHIELDED PLUGS l PLUGTIGHTENING TORQUE l o o e BREAKER POINT GAP INSIDE MAGNETO l HOSE THERM0 HOSE PUMPTO ADAPTER INLET TOP TO TOPOF FOLD HSG MAN1 ADAPT HOSE ADAPTER TO EXHAUST MIXER WATER PUMP SEA WATER II u INLET EXHAUST II YIXER WATER COOLED EXHAUST OUTLET FORl 3 4 I D FIGURE1 4 CARBURETOR SIDEVIEW TYPICAL MARINE GENERATOR SET SERVICE SCHEDULE PERF...

Page 5: ...ILPRESSURE ANDADJUSTMENT OIL PRESSURE ADJUSTMENT Oil Pressure After the engine has been thoroughly warme d up and is operating with proper weight of 011 in crankcase the oil pressure should be about 20 psi An external oil press ure adjusting screw is provided on the crankcase just below and to the rear of the carburetor Lf norm al operating pressure is lower than 20 psi remove acorn nut loosen loc...

Page 6: ...idge Twist car tridge off by hand turn in counterclockwise direction to remove engine oil isreplen ished and engine is again placed in operation l d tighten new cartridge after leakage retighten element as needed to stop leaks check area around filter for signs of Doa use substitute cartridge elements for replace ment use only genuine Kohler parts If the engine does not have a filter but is operat...

Page 7: ...gdod clean air conditions sooner in dusty dirty conditions Use only genuine kohlerreplacement elements of correct part number Every 50 hours or 3 months remove element and lightly tap rubber rim against flat surface to dislodge any loose dust from surface Replace element if it has too many dark spots or extensive dark area as this indicates dirt trapped in the filter material Do not wash dry eleme...

Page 8: ... do not attempt to separate cleaner from the elbow in solvent such as kerosene On all types swish element unit then allow it to drip dry before reinstalling Service oil bowl as described in the foregoing FLAME ARRESTOR NiARlNE MODELS Marine Models use an approved flame arrestor which also serves as an air cleaner to a certain degree This unit does not require regular service because of the clean o...

Page 9: ...ARBURETOR FIGURE4 2 TYPICALSIDEDRAFTCARBURETOR STEP 1 STEP 2 STEP 3 STEP 4 0 Stop engine and carefully turn Main Fuel adjustment all the way in clockwise until the needle bottoms lightly do not force as this will damage needle or seat For preliminary adjustment turn Main Fuel adjustment out counterclockwise direction 2 l 2 turns on side draft carburetor or l 1 2 turns open on up draft carburetor S...

Page 10: ...ecessary Reassembly of Carburetor Up Draft Reassembly is essentially the reverse of the disassembly procedure Special instructions are needed however to properly set the level of float before throttle body is reinstalled to carburetor body Float Level Turn throttle body upside down install new gasket and fuel inlet needle then position float and insert float pin With float lever resting on inlet n...

Page 11: ...ates and shafts Iftheseparts are worn replace carburetor assembly Assemblv of Carburetor Side Draft 1 Install needle seat needle float and float pin 2 Set float level With carburetor casting inverted and float resting lightly against needle in its seat there should be 11 641Vplus or minus l 32 of an inch clearance between machined surface of casting and free end of float side opposite needle seat ...

Page 12: ...oils of pump arm spring and compress spring to remove Next com press the diaphragm spring then lift the link to disconriect and remove the diaphragm and oil seal discard these parts Push pin out to release pump arm and link to complete disassembly RECONDITIONING Wash fuel head body and cover in gasoline and clean with stiff bristle brush Make sure all traces of gasket material is removed from surf...

Page 13: ...he factory however slight readjustment may be necessary initially to account for different starting conditions Adjust chokes as foUows Carburetor Unit Choke unit is set for average conditions To readjust loosen three screws on outside of cover plate then shift cover in clockwise direction arrow for richer setting or in counterclockwise direction for leaner setting Tighten cover screws after final ...

Page 14: ...ation system uses a gas mixer or adapter attached to a standard gasoline carburetor and regulators are discussed in the following Some common carburetors adapters GAS CARBURETORS ADAPTERS In a venturi type carburetor the gas nozzle is located at the point of greatest pressure drop inside the venturi This creates a suction within that nozzle that varies with changing rate of air flow and causes a g...

Page 15: ...ed earlier for adjusting the gasoline carburetor GAS REGULATOR MODEL KN SECONDARY The orifice size and maximum inlet pressure are stamped on the cover of the KN do not permit inlet pressure to exceed maximum usually 6 oz If an electric solenoid is used it should be mounted close to the model KN To check inlet pressure The orifice size of the s olenoid must be at least as large as orifice in regula...

Page 16: ... shut off properly after engine stops Use following procedure to adjust With engine stopped slowly turn lock off screw out counterclockwise direction until fuel starts to flow through the regulator then turn screw i n clockwise until the flow stops note position of screw when flow stops then turn in one more turn for final setting 48 0 ...

Page 17: ...GNETO SPARK PLUG SERVICE Engine misfire or generally poor operation is often caused by spark plugs in poor condition or with improper gap setiing Plugs fail for various reasons Often the porcelain insulator cracks or becomes coated with oil carbon or other deposits which causes the high voltage ignition impulse to pass from the center electrode to ground without jumping the plug gap As an engine o...

Page 18: ...cing or replacing points 1 Turn engine over until points are wide open at highest point on cam Maximum opening should be OlP Proceed with Step 2 if adjustment is necessary 2 Loosen clamp screws slightly so that contact plate can be moved insert blade in adjusting slot then shift plate until 019 maximum clearance is measured between contacts Retighten clamps after adjustment 3 Lubricate cam wick wi...

Page 19: ...ocedure to insure that shielded magneto is in time when reinstalled to engme STEP 1 STEP 2 STEP 3 Make sure I timing position of both engine and magneto are held while magneto is installed on engine Connect leads as shown in the accompanying illustration for shielded type magneto Make sure ground strap is connected to controller terminal 5 Install radio shielded plugs STEP 4 After completing insta...

Page 20: ... thinner and a coarse lint free opening is a maximum To adjust point gap turn engine over until point point gap should be set at 020rf Check and adjust gap after servicing or replacing points m Every 500 hours remove the plug on the distributor housing and the plug on the drive housing as shown fill reservoirs with SAE 20 weight oil Reinstall plugs after se g Distributor rot turns in clockwise dir...

Page 21: ...elbow to the crankcase When draining coolant system remove the radiator cap and open the drain valve on crankcase near the oil filler cap to prevent air pockets from forming and blocking water in passages in the block Check coolant level frequently and add water or anti freeze as needed to maintain correct level ANTI FREEZE PROTECTION Closed system such as the radiator and the heat exchanger type ...

Page 22: ...y hub move hub in closer to the inner face to increase tension or away to decrease tension Retighten nuts after proper tension is achieved To replace belt on L6OO remove belt guard loosen pulley hub until belt can be slipped off the pulleys L 654 radiator equipped models have an arrangement shown in Figure 6 3 On these loosen the two mounting capscrews and shift plate out to increase tension or in...

Page 23: ...losed engine clrcult and the raw or sea water circuit In the closed circuit coolant is circulated by the engine water pump through the water jacket manifold and returned to the pump for recirculation Since this is a closed circuit antifreeze can be added if required the circuit holds 5 to S l 2 quarts of liquid In the raw water circuit the belt driven sea water pump picks up sea water and circulat...

Page 24: ...be depressed about l P as shown in accompanying illustration To adjust remove belt guard loosen adjusting plate capscrews then shift plate until proper tension is obtained retightening plate at new setting then replace belt guard ENGINE WATER ADJUSTING VI FIGURE 6 7 BELT ADJUSTMENT MARINE EXHlUJST OPENING EXHAUST PIPE l 3 4 0 WATER LINE FROM MANIFOLD FIGURE 6 8 EXHAUST MIXER MARINE MODELS 3 64 0 ...

Page 25: ...r as follows 1 Feed R nT Check speed with hand tachometer or by frequency meter if plant is so equipped oosen oc ng nut on speed adjusting screw turn screw in clockwise direction to increase speed and frequency or in counterclockwise direction to decrease speed Follow this adjustment with Step 2 Lock nut at new setting 2 Sensitivity Droop Adjustment Test under normal load conditions If readjustmen...

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Page 27: ...nce Tappets have self locking setscre ws f r adjusting the valve em to tappet Every 200 hours move valve cover and check valve tappet clearance ance should be OOP on intake and 011 on exhaust valves Cold engine cold clear ceed as follows To check and adjust clearance cold pro 1 Remove spark plugs then turn engine over until I piston is at Top Dead Center observe through spark plug hole on compress...

Page 28: ...on rings worn blowby occurring I c Recondition exzgine D Valves leaking or too tight tappet clearance I D Recondition valves and seats and adjust tappets Higher than normal compression can indicate that excessive carbon deposits have built up in the combustion chamber Be sure air cleaner is clean and exhaust is not restricted before checking corn pression Insert gauge in spark plug hole and take s...

Page 29: ... cause is perhaps too infrequent oil and oil filter changes It can also indicate operation with improper ignition timing or overrich carburetor adjustment or a poorly serviced clogged air cleaner which restricts air intake and also results in an overrich mixture Scoring of the Cylinder Wall Unburnt fuel not only adds to sludge formation but can in severe cases cause scuffing and scorrng of the cyl...

Page 30: ...SING I COMBINED INTAKE EXHAUST MANIFOLD b 1 EXHAllST ziik tAMGEAR FRONTSUPPORT c 011PICK OILPAN L600 TYPE PAN CENTER CAP WdrLn GASKET GEARCOVER FRONT 01 SEAL a2 e not inte umge Ze FIGURE 9 l EXPLODED VIEW MAJORCOMPONENTS OFA TYPICAL ENGINE s ...

Page 31: ...TOR REMOVAL Before detaching generator from the engine place blocks of wood under the oil pan on marine models or under the generator frame on other models The Controller can remain installed on genera ior however disconnect leads from engine to Controller before detaching generator Use the following procedure to remove generator 1 Remove 2 Remove four capscrews which hold generator frame to the f...

Page 32: ...automatic choke linkage and hose from valve cover then detach carburetor with air cleaner attached from flange on intake manifold FUEL PUMP Disconnect fuel lines fuel filter if used then detach fuel pump from crankcase MAGNETO Remove high tension leads at spark plugs remove two flange mounting capscrews then remove magneto OIL FILLER AND FILTER Remove filler cap and disconnect oil filtei and brack...

Page 33: ...ides on an anti friction bearing which is in turn press fitted on a stub shaft in the gear cover If the gear spins freely without any evidence of binding etc the ball bearing does not have to be replaced To replace bearing remove snap ring then slip gear off Bearing is press fitted on shaft Use press tb remove and to reinstall new bearing CRANKCASE OIL PAN BASE Remove all oil pan to crankcase caps...

Page 34: ...mbled for overhaul it is good practice ce main and connecting rod bearings regardless of condition of old bearings Ser vice bearings are available in standard size plus 002 OlO 020i1 and 030 oversize sets Select bearings according to the accompanying chart SERVICE BEARING MAIN BEARING CRANKPIN SET JOURNAL DIA DIAMETER Standard 1 998 1 999 1 340 1 341 002 1 996 1 997 1 338 1 339 010 020 1 988 1 989...

Page 35: ...er hone into bore and after centering adjust so that stones are in firm contact with walls Diesel fuel oil or kerosene can be applied to the stones as a cutting cooling agent B With the lower edge of each stone positioned even with the lowest edge of the bore start drill and begin honing process Move hone up and down while reboring to prevent formation of cutting ridges Check size frequently c Whe...

Page 36: ...not individually PISTON ROD ASSEMBLIES Normally very little wear takes place in the piston boss piston area If the original piston and connecting rod can be reused after reconditioning the pin will usually not have to be replaced If the piston boss or connecting rod small end is worn beyond limits use new piston rod assembly rather than rework the old piston boss and connecting rod A new piston pi...

Page 37: ...rect valve numbers when replacing valves Exhaust valves are hard faced Intake valve seats are machined into block and exhaust valves on hardened seat inserts If valve seat insert is badly worn warped damaged or if seating surface is badly pitted the insert must be replaced Inserts are a tight press fit in the crankcase A commercial valve seat removal tool is recommended for this job Since removal ...

Page 38: ... MVFQ CAMSHAFT tiw CRANKSHAFT OIL PRESSURE RELIEF VALVE OIL PUMP COIL FILLER CAP LUNNtt 11lYIl ROD SAFETYWIRING GENERATOR SUPPORT OIL PICK UP SCREEN OIL PAN BASE FIGURE 9 14 CROSSSECTIONALYIEWOF ENGINEFROMGENERATOR END 9 10 a ...

Page 39: ...coat tappets with 011and Insert each in tappet bore inside crankcase FRONT SUPPORT PLATE Position new gasket then secure front support plate to crankcase with four capscrews around the camshaft opening CAMSHAFT oil camshaft then carefully guide camshaft thr Camsha ft end Pla y is taken by a spring loaded plunger which and rides aga inst the inside of the gear cover The spring a cover is reinstalle...

Page 40: ...up Reinstall valve rotators in place of spring guides if these are used on exhaust valves Stainless steel springs and rotators are generally used on marine plants CRANKSHAFT Position main bearing upper halves in crankcase Front and center main bearings are 4 Identical make sure correct bearing is used for rear main Align timing marks on cam and crankgears then carefully guide crankshaft into posit...

Page 41: ...ey on crankshaft and secure with crankjaw or crankshaft retaining nut Hold pulley with strap wrench while tightening nut position new cover gasket next to support plate then install end of crankshaft to avoid damaging oil seal which is press GENERATOR SUPPORT Place new gasket against crankcase then reinstall and secure generator support to crankcase Carefully guide rear oil seal over crankshaft wh...

Page 42: ...LOADED NOT MEASURABLE ooo ooo VALVECLEARANCE INTAKE COLD OO8 l OO8 VALVECLEARANCE EXHAUST COLD l mmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmm mm Oll Oll VALVE STEMCLEARANCE IN GUIDE INTAKE OOl OO25 OOl OO25 VALVESTEMCLEARANCE IN GUIDE 0025 004 0025 OO4 VALVETAPPETCLEARANCE INBLOCK EXHAUST 0012 0023 0012 0023 VALVEGUIDE PRESS FIT IN BLOCK 0005 002 0005 moo2 VALVESEAT INSERT EXHAUST PRESSFIT ooi 004 002 0...

Page 43: ... lbs NUT CAJWAFT 7 8 40 ft lbs 11 0 4 0 CYLINDER HEADCAPSCREW TIGHTENING SEQUENCE 12 5 0 2 _Q __ _ 8 0 15 FRONT TOROUE VALUES STANDARD HARDWARE ITEMS SIZE TORQUE SIZE TORQUE l 4 20 70 in lbs 172y 13 50 ft Ibs l 4 28 85 in lbs l 2 20 o 70 ft lbs 5 16 18 150in lbs 9 16 12 75 ft lbs 5 16 24 165 in lbs 9 X 18 100 ft lbs W 16 260in lbs 518 71 110 ft lbs 318 24 300 in lbs 5 8 18 140ft l bs 7 16 14 35 ft...

Page 44: ...ES 652 KOHLER CO KOHLER WISCONSIN 53044 K 11 6 80 b ...

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