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Страница 2: ...We recommend that the procedure outlined in this manual be followed to provide an ease of repair This manual is set up using the current recommended service procedures and operations However recommend...
Страница 3: ...ngine 5 AIR INTAKE SYSTEM 6 FUEL SYSTEM 7 GOVERNOR SYSTEM 9 IGNITION SYSTEM 12 ELECTRICAL SYSTEM 17 ENGINE GENERAL SERVICE 27 INSPECTION DISASSEMBLY 29 ENGINE RECONDITIONING 30 ASSEMBLY 34 FITS AND TO...
Страница 4: ...ver run the engine in a closed garage or shed without adequate ventilation 6 Do not try to oil or grease the tractor or its attachments while in operation 7 Adequate ventilation must be provided when...
Страница 5: ...or cooling fins 3 Improper fuel 4 Fuel mixture too lean 5 Improper ignition timing 6 Engine overloaded 7 Tight tappet clearance C Backfiring 1 Fuel mixture too lean 2 Improper timing 3 Valve sticking...
Страница 6: ...ments in any liquid or attempt to blow dirt off with air hose as this will puncture the filter element Carefully handle new element do not use if gasket surfaces are bent or twisted Not only must the...
Страница 7: ...ine slows down lean note position of screw then turn needle out counterclockwise until engine regains speed and then again slows down overrich Turn needle back in until it is positioned halfway betwee...
Страница 8: ...Assembly of Carburetor 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 64 pl...
Страница 9: ...askets Connect the fuel lines GOVERNOR SYSTEM all models All Kohler Single Cylinder Engines are equipped with centrifugal flyweight mechanical type governors The governor gear flyweight mechanism is m...
Страница 10: ...ent may be indicated if engine speed surges or hunts with changing load or if speed drops considerably when normal load is applied Figure 5 Initial Adjustment K241 K301 SPEED ADJUSTMENT K241 K301 Afte...
Страница 11: ...p in speed occurs when normal load is applied the governor should be set for greater sensitivity Normally the governor spring is placed in the third hole from bottom on the governor arm bracket and in...
Страница 12: ...park plug before removing to prevent dirt from falling into engine The first thing to do after removing a spark plug is to carefully note its condition as this is often an indicator of the ignition tr...
Страница 13: ...een the condenser lead and a good ground on the engine At first a low resistance should be indicated however this should very quickly rise to a high value If low resistance is indicated continuously t...
Страница 14: ...Figure 9 Adjusting Breaker Point Gap METHOD 1 STATIC TIMING Remove breaker point cover and remove spark plug lead to prevent unintentional starting Rotate engine by hand in direction of normal rotatio...
Страница 15: ...15 Figure 10 Typical Breakerless Alternator System Schematic Figure 11 Wiring Connection Detail on Trigger Module...
Страница 16: ...ly includes the capacitor and a pulse transformer arrangement similar to the conventional high tension coil with primary and secondary windings The flywheel has a special projection for triggering the...
Страница 17: ...batteries the plates are charged but an electrolyte of specific grade must be added just before using Both types function in the same general way All Kohler Engines use negative ground systems in whi...
Страница 18: ...rd starting engine conditions excessively dirty or moist operating conditions or heavy vibration makes servicing necessary at frequent intervals Service should include checking motor operation check o...
Страница 19: ...r brushes and internal connections Sticking brushes a dirty or gummy commutator or poor connections may prevent the generator from producing any output Solder thrown from the commutator riser bars ind...
Страница 20: ...re long periods of service The file should not be allowed to become greasy and should not be used on other metals After filing wipe point with lintless cloth saturated in trichloroethylene to insure c...
Страница 21: ...CAUTION If adjusting screw is turned down clockwise beyond normal range required for adjustment the spring support may fail to return when pressure is relieved If this happens turn screw counterclockw...
Страница 22: ...he heat The unit should be mounted with the fins in a vertical position and preferably in a well ventilated area Service The same service procedure used for the conventional magneto ignition system al...
Страница 23: ...e running at full speed no load C 1 If less than 20 volts C 2 If more than 20 volts C 1 Defective stator replace with new assembly C 2 Defective rectifier regulator replace with new unit CONDITION BAT...
Страница 24: ...d While ceramic magnets are very strong the material is brittle and can crack or break if struck with a hard object or when dropped If the magnets are badly damaged a new flywheel complete with new ce...
Страница 25: ...used with Kohler Engines 2 Prevent alternator leads AC from touching or shorting This could permanently damage the stator 3 Disconnect leads at rectifier regulator before electric welding is done on e...
Страница 26: ...Figure 19 Compact Starting Motor 26...
Страница 27: ...normally needed until the starter is partially diassembled for brush or commutator servicing These services are not required at any specific hourly basis they should be performed only after starter pe...
Страница 28: ...tart the armature turning On PM starters the permanent magnets provide this strong field and only a small current is needed in the armature to start it turning DRIVE UNIT The PM starters use a drive v...
Страница 29: ...E ASSEMBLY If pinion is badly worn or has broken teeth replace drive as a unit To do this hold armature shaft and remove stop nut spacer anti drift spring then slip drive unit off over spline and arma...
Страница 30: ...rawn into the cooling shroud by fins provided on the flywheel The rotating air screen and the cooling fins on the block and cylinder head must be kept clean and unobstructed at all times Never operate...
Страница 31: ...the more precise and accurate test method using a compression gauge METHOD 1 SPOT CHECK WITHOUT GAUGE A Remove high tension lead from the spark plug On all engines rotate flywheel backwards counterclo...
Страница 32: ...adds to sludge formation but can in severe cases cause scuffing and scoring of the cylinder walls As raw fuel seeps down the cylinder walls it washes the necessary lubricating oils off the piston and...
Страница 33: ...iston assembly from cylinder block 15 Remove crankshaft oil seals and if necessary anti friction bearings It may be necessary to press crankshaft out of cylinder block Bearing plate should be removed...
Страница 34: ...f a low speed drill press is preferred as it facilitates more accurate alignment of the bore in relation to the crankshaft crossbore Reboring is best accomplished at drill speed of about 600 RPM After...
Страница 35: ...when used should be installed in the top groove 1 If the cylinder block does not need reboring and if the old piston is within wear limits and free of score or scuff marks it may be reused Never reus...
Страница 36: ...n certain applications Exhaust valves seat on special hardened inserts Seating surfaces should be held as close as possible to 1 32 width Seats with more than 1 16 must be reconditioned with 45 and 15...
Страница 37: ...bout 400 to 450 F Position the heated gear on the flywheel then after making sure it is not cocked either press the gear on with an arbor press or drive it on with a soft head hammer As the gear cools...
Страница 38: ...n camshaft inside block d Lubricate rod then insert into block bearing plate side Before pushing rod through camshaft slip one 005 washer end play between end of camshaft opposite gear end and block P...
Страница 39: ...6 Camshaft End Play Figure 37 Timing Marks On Crankshaft and Camshaft 6 Bearing Plate a Press front main bearing shielded side up into bearing plate Make sure bearing is straight and true in bore and...
Страница 40: ...marking is toward flywheel side of engine Use a ring compressor to prevent ring breakage during installation Gently push piston into bore with hammer handle do not pound 8 Attaching Rod to Crankshaft...
Страница 41: ...d cold On K241 and K301 adjust tappets to correct clearance c After correct clearance is obtained remove valves and install valve springs and retainers and rotators if used Replace valves compress spr...
Страница 42: ...t and place flywheel in position The square key holds flywheel on shaft b Install starter pulley lock washer and holding nut Insert a bar between flywheel fins and tighten holding nut to torque value...
Страница 43: ...after the first 5 hours of operation TOOL LIST Common Tools Following is a list of tools that are used in servicing Kohler Engines DESCRIPTION SIZE DESCRIPTION SIZE Combination Wrench 3 8 3 8 Socket...
Страница 44: ...IMENSION FIG 49 K241 K301 A 8 13 16 B 1 11 16 C 1 248 1 253 1 498 1 503 TORQUE VALUES ENGINE MODEL MAJOR ITEMS K241 K301 GOVERNOR ARM LOCKING SCREW A CYLINDER CAPSCREW 420 in lbs 420 in lbs CONNECTING...
Страница 45: ...bs 5 8 11 110 ft lbs 3 8 24 300 in lbs 5 8 18 140 ft lbs 7 16 14 35 ft lbs 3 4 10 150 ft lbs 7 16 20 45 ft lbs 3 4 16 200 ft lbs CONVERSION TABLE INCH LBS TO FOOT LBS FOOT LBS 5 10 15 20 25 30 35 40 4...
Страница 46: ...ring plate end 0005 002 0005 0020 Camshaft pin to block P T O E Int 0015 0030 0015 0030 Camshaft pin to breaker cam 0010 0025 0010 0025 Camshaft end play 005 010 005 010 Valve stem clearance in guide...
Страница 47: ...rd Reverse planetary worn or broken clutches broken gears Engage P I O and hi lo planetary P T O turns Check differential action by raising wheels off the ground turning one wheel by hand other wheel...
Страница 48: ...ove 2 lower bolts securing engine to the chassis casting 10 Remove the 2 upper bolts from the engine but leave in place the casting to support the braces 11 Remove engine from tractor TRANSMISSION REM...
Страница 49: ...Figure 55 d Mesh the three gears with Sun pinion so that the timing marks form an equal sided triangle Timing marks A Figure 57 are small punches on the opposite side of gears When replacing this unit...
Страница 50: ...r disassembled unless definite problems exist If an unreasonable amount of play is noticed in the system a Inspect orbit gear pins and bushings for wear b Inspect the orbit gear carrier bushing for we...
Страница 51: ...otation Also make sure the shifting clutch slides freely on the shifting gear 7 If no discrepancies have been found at this point or if the failure is obviously a part of the differential assembly rem...
Страница 52: ...r parts were replaced On the two spider arms with snap ring grooves at the end assemble in this sequence spider gear shifting train pinion bearing spacer and snap ring On the other two arms assemble i...
Страница 53: ...At this point the dog gear and shifting eccentrics are exposed Proceed as follows a Check the dog block for wear b Examine shifter shaft for wear c For closer inspection of the shifter assembly remov...
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