Kohler K482 Service Manual
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Kohler K482 Service Manual

Kohler K482 Service Manual

Twin cylinder engine
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Summary of Contents for Kohler K482

  • Page 1 twin cylinder engine SERVICE MANUAL...

  • Page 2: Table Of Contents

    The Models K532 and K582 a r e i d e n t i c a l t o t h e Model K482 e x c e p t for bore and horsepower d i f f e r e n c e s .

  • Page 3: Operating Instructions

    OPERATING INSTRUCTIONS P R E - S T A R T I N S T R U C T I O N S CHECK O I L LEVEL SAE 5W2O USE ONLY GENUINE KOHLER ELEMENT MAKE SURE A I R INTAKE CHECK POLARITY F I L L FUEL TANK WITH FRESH, REGULAR...

  • Page 4: Starting Procedure

    STARTING PROCEDURE I G N I T I O N C H O K E THROTTLE PULL CHOKE KNOB MOVE TOGGLE A L L THE WAY AWAY SWITCH TO FROM PANEL* ( T O "ON" POSITION CLOSE CHOKE PLATE) MOVE THROTTLE HALFWAY OPEN * L E S S CHOKING MAY BE REQUIRZD CRANK E N G I N E (HAND)

  • Page 5: (Pre-Start)

    SERVICE SCHEDULE V A L S INDICATED DAILY EVERY EVERY EVERY EVERY (PRE-START) 2 5 HOURS 5 0 HOURS 1 0 0 HOURS 5 0 0 HOURS CLEAN A I R INTAKE SCREEN - - - - - - - - - - - - - - - - - - - - - - - X CHECK O I L LEVEL REPLENISH FUEL SUPPLY SERVICE DRY TYPE A I R CLEANER...

  • Page 6: Trouble Shooting

    TROUBLE SHOOTING CONDITION POSSIBLE CAUSE Hard S t a r t i n g o r Loss o f Power F a u l t y I g n i t i o n . Loose o r grounded h i g h t e n s i o n b r e a k e r p o i n t l e a d s .

  • Page 7: Lubrication

    O n some e a r l y K482 engines, o i l i s picked up through a f l o a t i n q o i l screen--a f i x e d o i l screen i s used on most K482 and K532, K662 models.

  • Page 8: Oil Filter

    K482 m o d e l s w h e r e r e m o v a l w a s n e c e s s a r y .
  • Page 9 CARTRIDGE F I G U R E K662 CARTRIDGE TYPE FILTER R e m o t e Mount O i l F i l t e r s : T h e r e m o t e m o u n t f i l t e r c a n b e s e r v i c e d a s t h e lube o i l i s d r a i n e d f r o m the e n g i n e .

  • Page 10: Oil Pressure Oil Pumps

    An e x t e r n a l oil p r e s s u r e a d j u s t m e n t i s provided on the K482 and K532 but not o n K662 models.

  • Page 11: Air Intake

    Back p l a t e (K482, K532) a i r horns and adapters must be s e c u r e l y t i g h t e n e d t o c a r b u r e t o r .

  • Page 12: Multi- Phase A I R Cleaner

    RAIN DUST CAP RETAINER CLEAN A I R TO CARBURETOR DUST SWIRLS UNLOADER FIGURE 3- 2 MULTI-PHASE DRY TYPE A I R CLEANER CUTAWAY VIEW MULTI-PHASE (DRY TYPE) AIR CLEANER T h e m u l t i - p h a s e ( o r t r i - p h a s e ) a i r c l e a n e r i s a d r y type f i l t e r f o r h e a v y duty a p p l i c a t i o n s e x t r a p r o t e c t i o n a g a i n s t d i r t a n d d u s t .

  • Page 13: O I L Bath A I R Cleaner

    A f t e r e v e r y 50 h o u r s of operation remove retaining b a r and remove e l e m e n t for thorough Since e l e m e n t m u s t be allowed to d r i p d r y a f t e r washing, keep e x t r a e l e m e n t o n cleaning.
  • Page 14 T o s e r v i c e n o r m a l c a p a c i t y type o i l b a t h a i r c l e a n e r s , r e m o v e wing nut a n d r e m o v e a i r c l e a n e r c o m p o n e n t s a s a unit.

  • Page 15: Fuel System

    I D L E FUEL l U L t t U t L ADJUSTMENT TURNS OPEN] ADJUSTMENT (2 TURNS OPEN) ADJUSTMENT FIGURE ADJUSTMENTS, TYPICAL SIDEDRAFT FIGURE 4 - 2 ADJUSTMENTS, FIXED MAIN JET CARBURETOR CARBURETOR (K482. K532...
  • Page 16 TURNS OPEN ADJUSTMENTS. DOWNDRAFT CARBURETOR MODELS 28 AND 228, K662 ENGINES FIGURE S T E P 2 F a r p r e l i m i n a r y a d j u s t m e n t , t u r n Main F u e l needle t u r n s i n a c o u n t e r c l o c k w i s e d i r e c t i o n , t u r n Idle F u e l n e e d l e S T E P 3 - S t a r t e n g i n e and o p e r a t e a t n o r m a l s p e e d until n o r m a l o p e r a t i n g t e m p e r a t u r e s a r e r e a c h e d .
  • Page 17 D i s a s s e m b l y Side D r a f t C a r b u r e t o r (A- 277061) A f t e r r e m o v i n g c a r b u r e t o r f r o m e n g i n e , r e m o v e bowl nut a n d s e p a r a t e bowl f r o m c a r b u r e - t o r body.
  • Page 18 FIXED M A I N J E T TYPE SIDEDRAFT FUEL FIGURE 4-5 DISASSEMBLED VIEW TYPICAL F I X E D M A I N J E T CARBURETOR D i s a s s e m b l y F i x e d M a i n J e t Type Side D r a f t C a r b u r e t o r A f t e r r e m o v i n g c a r b u r e t o r f r o m e n g i n e , r e m o v e c a p s c r e w s on bowl a n d r e m o v e bowl a s s e m b l y .
  • Page 19 D i s a s s e m b l y F i x e d J e t Type Side D r a f t C a r b u r e t o r ( B- 2 7 2 0 4 1 ) R e m o v e c a r b u r e t o r f r o m engine.
  • Page 20 D i s a s s e m b l y Down D r a f t C a r b u r e t o r The m o s t c o m m o n S e v e r a l d i f f e r e n t t y p e s of down d r a f t c a r b u r e t o r s a r e in u s e o n K662 e n g i n e s . T h e m a i n d i f - a r e the Zenith Model 2 8 ( K o h l e r 270374) a n d Model 228 ( K o h l e r 270864) c a r b u r e t o r s .
  • Page 21 F u e l Bowl A s s e m b l y : I n s p e c t t h e s e p a r t s a n d R e m o v e m a i n j e t a d j u s t i n g n e e d l e a n d m a i n f u e l n e e d l e s e a t . r e p l a c e if n i c k e d , g r o o v e d o r o t h e r w i s e d a m a g e d .

  • Page 22: Automatic Chokes

    AUTOMATIC CHOKES Two d i f f e r e n t e l e c t r i c - t h e r m o s t a t i c type a u t o m a t i c c h o k e s a r e u s e d on the m o d e l s .

  • Page 23: Fuel Pumps

    FUEL PUMPS All Kohler Two Cylinder Engines h a v e a mounting pad a n d p r o v i s i o n on top of c r a n k c a s e f o r a m e c h a n i c a l l y o p e r a t e d f u e l pump.

  • Page 24: Fuel Filters

    FUEL FILTERS B e f o r e s e r v i c i n g , t u r n A s e d i m e n t bowl f i l t e r m a y b e u s e d t o t r a p s o l i d i m p u r i t i e s i n t h e f u e l . f u e l off a t v a l v e l o c a t e d o n top of f i l t e r a s s e m b l y , then l o o s e n r e t a i n i n g b a i l a t b o t t o m of f u e l bowl, If f i l t e r e l e m e n t i s u s e d , s w i s h e l e m e n t i n c l e a n s o l v e n t .

  • Page 25: Governor

    On t h e K482 a n d K532, t h e b r e a k e r p o i n t s a r e m o u n t e d o n t h e...
  • Page 26 Ignition t i m i n g m u s t b e r e a d j u s t e d a f t e r g o v e r n o r i s i n s t a l l e d . On t h e K482 a n d K532, t h i s is done b y loosening t h e c a p s c r e w s a n d r o t a t i n g g o v e r n o r - - s e e Ignition T i m i n g i n s t r u c t i o n s (Section 6 ) f o r e x a c t d e t a i l s .

  • Page 27: K662 Governors

    K662 GOVERNORS K662 Since the b r e a k e r p o i n t s a r e not mounted o r d r i v e n off the g o v e r n o r , t h i s g o v e r n o r does not No r o u t i n e l u b r i c a t i o n s e r v i c e i s r e q u i r e d of the have to be t i m e d the engine d u r i n g i n s t a l l a t i o n .
  • Page 28 On c e r t a i n e l e c t r i c w e l d e r a p p l i c a t i o n s , a c o m p e n s a t o r i s u s e d G o v e r n o r C o m p e n s a t o r c o m m o n to t h i s type of e q u i p m e n t .

  • Page 29: Ignition Systems

    IGNITION SYSTEMS While the s o u r c e of e n e r g y f o r the ignition s y s t e m m a y be e i t h e r m a g n e t c o r b a t t e r y ( g e n e r a t o r o r a l t e r n a t o r ) , m o s t o t h e r c o m p o n e n t s a r e c o m m o n in function i n a l l s y s t e m s e v e n though they m a y not b e a l i k e in a p p e a r a n c e o r l o c a t i o n .

  • Page 30: Ignition Coil

    B U I L D UP ON CONTACT MOVABLE STATIONARY CONTACT CONTACT STATIONARY COULD I N D I C A T E CONTACT COULD I N D I C A T E UNDER CAPACITANCE OVER CAPACITANCE FIGURE 6-1 METAL TRANSFER- - BREAKER POINTS IGNITION COIL Ignition c o i l s a s u s e d on the 30 a m p a l t e r n a t o r ignition s y s t e m s d o not r e q u i r e s e r v i c i n g on a r e g u l a r b a s i s , h o w e v e r , the c o i l should b e k e p t in c l e a n c o n d i t i o n a n d t h e t e r m i n a l s a n d c o n n e c t i o n s...

  • Page 31: Magnetos (K662)

    MAGNETO Magnetos on the K662 a r e e x t e r n a l , s e l f contained u n i t s which a r e flange mounted on the g e a r The s t a n d a r d m a g n e t o housing and d r i v e n off the c a m g e a r .
  • Page 32 If c o n t a c t p o i n t s a r e b a d l y w o r n Do not r e p l a c e only one con- o r p i t t e d , they m u s t be r e p l a c e d . t a c t - - r e p l a c e b o t h the f i x e d c o n t a c t a n d c o n t a c t on b r e a k e r a r m .
  • Page 33 Magnetos a r e t i m e d t o the engine i n the f a c t o r y and r e t i m i n g should not be n e c e s s a r y u n l e s s m a g - Use the following p r o c e d u r e f o r i n i t i a l t i m i n g of the stand- n e t o h a s b e e n r e m o v e d f o r reconditioning.
  • Page 34 DISTRIBUTOR MAGNETO (WICO XHG-2) A f t e r e v e r y 500 h o u r s of o p e r a t i o n , r e m o v e d i s t r i b u t o r ( e n d ) c a p .
  • Page 35 C a r e f u l l y guide m a g n e t o g e a r i n t o e n g a g e m e n t with c a m g e a r - - m a k e s u r e m a r k r e m a i n s c e n t e r e d a n d m a g n e t o g e a r r e m a i n s s t a t i o n a r y when i n s t a l l i n g .
  • Page 36 On K482 a n d K 5 3 2 e n g i n e s , t h e b r e a k e r point a s s e m b l y is m o u n t e d o n t h e g o v e r n o r .

  • Page 37: Electrical Systems

    ELECTRICAL SYSTEMS Two b a s i c t y p e s of h a t t e r y e l e c t r i c a l s y s t e m s a r e u s e d o n t h e 2 c y l i n d e r e n g i n e . T h e m a j o r c o m p o n e n t s of the c o n v e n t i o n a l s y s t e m i n c l u d e s a D.

  • Page 38: Voltage Regulator

    S e r v i c e : T o m a i n t a i n b a t t e r y i n top c o n d i t i o n , p e f o r m t h e following s e r v i c e s a t f r e q u e n t i n t e r v a l s : R e g u l a r l y c h e c k l e v e l of e l e c t r o l t e - - a d d w a t e r n e c e s s a r y to m a i n t a i n l e v e l above...
  • Page 39 ARMATURE STOP AIR GAP .075" (Measured between (Bend t o a d j u s t Armature and Core w i t h p o i n t s touching) UPPER CONTACT SUPPORT screw i n t o ARMATURE (Raise o r lower ADJUSTING SCREWS t o a d j u s t a i r gap) (Loosen and s h i f t support...

  • Page 40: Generator

    GENERATOR K662 a r e of the 3 b r u s h , s h u n t wound type DC g e n e r a t o r s f o r M o s t of the g e n e r a t o r s u s e d on the 1 2 volt e l e c t r i c a l s y s t e m s .

  • Page 41: Starting Motors & Drives

    6 v e r s p e e d . On the K482, the spinning o r c e n t r i f u g a l a c t i o n f o r c e s the locking pin out of t h e s h a f t and a l l o w s the pinion t o r e t r a c t .
  • Page 42 K482 s t a r t e r c a n h e i n s t a l l e d o n e n g i n e with pinion i n e n g a g e...
  • Page 43 D r i v e pinion t o r i n g g e a r b a c k l a s h m u s t b e f r o m . 0 1 5 t o .
  • Page 44 SPARK PLUGS I G N I T I O N SWITCH OR $6 GA. WIRE GENERATOR OR 66 GA. WIRE O I L PRESSURE DISCHARGE LAMP I N D I C A T I N G FIGURE 7-9 W I R I N G DIAGRAMS K662 ELECTRICAL SYSTEMS...
  • Page 45 A L TERNAT O R ( CHARGING ) S Y S TEM S T h e a l t e r n a t o r s y s t e m prr,vides e l e c t r i c a l e n e r g y l o c h a r g e t h e lballery a n d l o r lighling s o r y c i r c u i t s .
  • Page 46 REGULATOR Low Oil Pressure Indicating Lamp FIGURE 7-11 WIRING DIAGRAM 30 AMP ALTERNATOR SYSTEM WITH OIL PRESSURE INDICATOR AND SWITCH TROUBLE ANALYSIS 30 AMP ALTERNATOR SYSTEM TEST AND CORRECTIVE ACTION POSSIBLE FAULT CONDITION Remove f o u r i n p u t l e a d s from R e c t i f i e r F a u l t y windings i n s t a t o r N O OUTPUT Check r e s i s t a n c e on RX1 s c a l e...
  • Page 47 REGULATOR Start) (Key CONDENSER 7- 1 2 FIGURE TYPICAL 3 0 AMP ALTERNATOR SYSTEM, WIRING DIAGRAM FIGURE 7-13 K662 30 AMP BATTERY CHARGING, WGNETO I G N I T I O N SYSTEM 7.11...
  • Page 48 ALTERNATOR AKER FIGURE 7-14 TYPICAL 1 5 AMP SYSTEM, W I R I N G DIAGRAM TROUBLE SHOOTING 15 AMP SYSTEM TEST WITH ENGINE RUNNING AT 3600 RPM N O LOAD POSSIBLE FAULTIREMEDY N O CHARGE T O BATTERY TEST A W i t h B+ c a b l e connected, check B t ( a t t e r m i n a l an r e c t i f i e r - r e g u l a t o r ) t o ground w i t h D C V o l t m e t e r .

  • Page 49: Engine . General Services

    ENGINE -GENERAL SERVICES COOLING On e n g i n e s w i t h t h e s t a n d a r d f o r c e d a i r cooling s y s t e m , r o t a t i o n of the b l a d e s o r f i n s on the f l y - wheel c a u s e s cooling a i r t o b e d r a w n in t h r o u g h the r o t a t i n g a i r s c r e e n w h e r e i t is f o r c e d t h r o u g h the b l o w e r h o u s i n g a n d b a f f l e s p a s t the cooling f i n s on c y l i n d e r b l o c k a n d h e a d s w h e r e i t i s f i n a l l y e j e c t e d a s h e a t e d a i r t o w a r d t h e r e a r of the engine.

  • Page 50: Crankcase B R E A T H E R Svstems

    K482 a n d K532 m o d e l s u s e a c l o s e d o r p o s i t i v e t y p e b r e a t h e r s y s t e m .

  • Page 51: Crankcase Vacuum Test

    CRANKCASE VACUUM TEST T h e r e s u l t s of a c r a n k c a s e vacuum t e s t c a n be v e r y u s e f u l i n the g e n e r a l condition A n e g a t i v e p r e s s u r e of s p e c i f i c value ( o r v a c u u m ) should b e p r e s e n t within the c r a n k c a s e of a n engine.
  • Page 52 COMPRESSION TEST The results of a compression check can be useful in determining if an engine is in good operating condition or if reconditioning is necessary. To check compression, remove spark plugs, insert com- pression gauge in spark plug hole, set the throttle and choke to the wide open position, insure that air intake and exhaust systems are not restricted, and motor the engine using the starting motor.

  • Page 53: Inspection Disassembly

    INSPECTION DISASSEMBLY WORK AREA B e f o r e s t a r t i n g d i s a s s e m b l y of a n e n g i n e , m a k e s u r e w o r k a r e a is i n c l e a n , n e a t condition a n d t h a t a d e q u a t e t o o l s a r e o n hand.
  • Page 54 T o p r e v e n t unintentional s t a r t i n g , d i s c o n n e c t b a t t e r y a n d / o r s p a r k plug l e a d s b e f o r e doing any The following s e q u e n c e i s s u g g e s t e d f o r c o m p l e t e d i s - w o r k on engine o r e q u i p m e n t d r i v e n b y engine.
  • Page 55 On s o m e K482 e n g i n e s , i t will be n e c e s s a r y t o p a r t i a l l y d i...
  • Page 56 . K482 a n d K 5 3 2 - - s l i d e s e a l off c r a n k s h a f t f i r s t o n K662.

  • Page 57: Engine Reconditioning

    B e a r i n g s , R a c e s , T r a n s f e r S l e e v e s On K482, K532 m o d e l s , c a r e f u l l y i n s p e c t s l e e v e type b e a r i n g t h a t i s p r e s s f i t t e d in block.
  • Page 58 T h e a p p r o p r i a t e u n d e r s i z e connecting r o d (big end) o n K482 a n d K532 o r u n...
  • Page 59 Replacement Ring S e t s : S e r v i c e t y p e r i n g replacement s e t s a r e a v a i l a b l e i n t h e s t a n d a r d s i z e p l u s S e r v i c e t y p e s e t s are used when c y l i n d e r i s worn b u t w i t h i n wear and o u t of round l i m i t s (wear l i m i t ,005"...

  • Page 60: Piston - Rod Assemblies

    W r o n g EXPANDER SPIRAL R A I L INSTALLATION O I L CONTROL RING FIGURE 1 0 - 8 INSTALLATION OF O I L CONTROL RING WITH SPIRAL R A I L PISTON PISTON RINGS I f the c y l i n d e r block does not need reboring and i f t h e o l d p i s t o n i s within wear l i m i t s and f r e e of score o r s c u f f marks, i t may be reused.

  • Page 61: Connecting Rods

    002" l e s s than s t a n d a r d ) a r e a v a i l a b l e f o r K662 e n g i n e s when Connecting r o d s . 0 1 0 " u n d e r s i z e a r e a v a i l a h l e f o r t h e K482 and Connecting r o d h e a r i n g s .

  • Page 62: Ring Gear

    S e a t i n g s u r f a c e s should b e h e l d a s c l o s e a s p o s s i b l e t o 1 / 3 2 ' ! width. S e a t s w o r n t o m o r e t h a n Reground o r new v a l v e s m u s t b e l a p p e d in t o p r o v i d e p r o p e r fit.
  • Page 63 The p r o c e d u r e for adjusting and checking c r a n k s h a f t end play d i f f e r s between t h e K482 o r K 5 3 2 with s l e e v e b e a r i n g s and the model K662.
  • Page 64 C r a n k s h a f t I n s t a l l a t i o n a n d End P l a y A d j u s t m e n t (Or u s e s a m e g a s k e t S t a r t with one white g a s k e t ( n e x t t o b l o c k ) then add one blue g a s k e t ( .
  • Page 65 STEP 5 T i m i n g G e a r I n s t a l l a t i o n : C r a n k G e a r : I n s e r t w o o d r u f f key i n keyway, b l o c k o p p o s i t e end of c r a n k s h a f t and p r e s s o r d r i v e g e a r into p o s i t i o n o n s h a f t .
  • Page 66 K482 p i s t o n , a r r o w m u s t f a c e d i r e c t i o...
  • Page 67 (115 ft. l b s . f o r K482, K532 and K582 models and 130 ft. l b s . f o r K662).
  • Page 68 S T E P 1 1 - Valve M e c h a n i s m : S t a r t with c y l i n d e r # 1 a n d p r o c e e d a s follows: P o s i t i o n v a l v e s , s p r i n g s , s p r i n g s e a t s , r e t a i n e r s o r r o t a t o r s when u s e d .
  • Page 69 Engine S y s t e m Components: At t h i s point in r e a s s e m b l y , components s u c h a s g o v e r n o r , S T E P 15 fuel pump, c a r b u r e t o r , a i r c l e a n e r , oil f i l t e r , m a g n e t o s , e t c .

  • Page 70: Run-In Instructions

    On e a r l i e r K482 m o d e l s m a k e s u r e new i n s t a l l a t i o n of cooling b a f f l e s a n d s h r o u d s .

  • Page 71: Special Fuel Systems

    SPECIAL FUEL SYSTEMS PRECAUTIONS When p r o p e r l y i n s t a l l e d a n d m a i n t a i n e d , a g a s f u e l s y s t e m c a n b e j u s t a s s a f e a s a n y o t h e r fuel While g a s a n d g a s o l i n e a r e b o t h highly v o l a t i l e a n d f l a m m a b l e , g a s p r e s e n t s a n a d d i t ~ o n a l s y s t e m .
  • Page 72 FIGURE 12-1 COMBINATION GAS- GASOLINE SYSTEM, K662 A t idle s p e e d , the velocity of a i r t h r o u g h a c a r b u r e t o r m a y not be high enough t o d r a w sufficient f u e l t o s u s t a i n o p e r a t i o n .

  • Page 73: Gas Adapters

    S e e F i g u r e 12-2 (K482) a n d F i g u r e 12-1: (K662) f o r i n i t i a l s e t t i n g s .
  • Page 74 GAS CARBURETORS KOHLER #A-271105 (KG1) GAS CARBURETOR The m o d e l KG1 is a v e n t u r i a n d nozzle type s t r a i g h t g a s c a r b u r e t o r s u i t a b l e f o r u s e with N a t u r a l T h i s c a r b u r e t o r i s u s u a l l u s e d with the Model B s e c o n d a r y r e g u l a t o r ( K o h l e r #A-265082) g a s and L P G .
  • Page 75 CHOKE THROTTLE NOZZLE HOUSING THROTTLE PLATE FIGURE 12-4 KG1 GAS CARBURETOR DISASSEMBLED VIEW F i n a l a d j u s t m e n t s a r e m a d e a s f o l l o w s : Hold choke in c l o s e d p o s i t i o n and a d j u s t s t a r t i n g m i x t u r e .
  • Page 76 KOHLER #A-271329 ( M O D E L XG) GAS CARBURETOR The Model XG c a r b u r e t o r i s a l s o of the v e n t u r i - n o z z l e type s t r a i g h t g a s c a r b u r e t o r s u i t a b l e f o r N a t u r a l and LP g a s .
  • Page 77 KOHLER #A-271923 ( M O D E L P C 2 - 1 0 ) GAS CARBURETOR T h e m o d e l PCZ-10 c a n be c l a s s i f i e d a d i a p h r a g m type c a r b u r e t o r a l t h o u g h i t a l s o u s e s a v e n t u r i . The d i a p h r a g m a r r a n g e m e n t p r o v i d e s f i n a l r e g u l a t i o n of the f u e l which i s r e c e i v e d f r o m the p r i m a r y r e g u l a t o r ( o r v a p o r i z e r - r e g u l a t o r ) a t a p r e s s u r e of a b o u t 8 p s i .
  • Page 78 The following s e q u e n c e i s s u g g e s t e d f o r reconditioning P C 2 c a r b u r e t o r a f t e r i t h a s b e e n discon. D i s a s s e m b l y T h r o t t l e : T u r n t h r o t t l e s t o p s c r e w t o l e f t until p l a t e is fully c l o s e d .

  • Page 79: Gas Regulators

    . 0 6 0 " f o r K482, K532 m o d e l s .
  • Page 80 KOHLER #A-240492 ( M O D E L F 1 ) SECONDARY REGULATOR When b a l a n c e a n d i d l e l i n e s a r e u s e d , the l i n e s should b e 3 / 16" s i z e c o p p e r tubing. T o c h e c k i n l e t p r e s s u r e , r e m o v e plug on f u e l i n l e t , i n s e r t m a n o m e t e r o r ounce p r e s s u r e gauge.
  • Page 81 V I E W VIEW A d j u s t m e n t ( L o c k Off): The l o c k off a d j u s t m e n t i s p r o v i d e d only t o s h u t off f u e l when engine i s not o p e r a t i n g - - i t i s not f o r a d j u s t i n g f u e l m i x t u r e o r e n g i n e s p e e d .
  • Page 82 The reconditioning p r o c e d u r e s t a t e d p r e v i o u s l y f o r the m o d e l F l r e g u l a t o r c a n Reconditioning: C e r t a i n c h a n g e s i n p r o c e d u r e will have t o b e m a d e t o allow a l s o b e followed f o r the m o d e l KN.
  • Page 83 T r o u b l e Shooting: If engine f a i l s t o s t a r t a f t e r a s c e r t a i n i n g t h a t f u e l r e a c h e s solenoid i n l e t , f i r s t c h e c k t h a t solenoid i s o p e r a t i n g ;...
  • Page 84 MODIFICATIONS CLUTCH M o s t c l u t c h e s on t h e s e engines a r e of the "wet" d i s c type. On this type, a n oil " splash " type l u b r i c a t i o n s y s t e m i s u s e d .

  • Page 85: Gear Reduction Unit

    DRY TYPE GEAR EDUCTION F I L L - ADJUSTING COLLAR FIGURE 13-2 ADJUSTING CLUTCH FIGURE 13-3 CLUTCH GEAR REDUCTION UNIT A f t e r a d j u s t m e n t i s m a d e , engage c l u t c h a n d c h e c k t o m a k e s u r e r o l l e r s go o v e r c e n t e r t o l o c k the unit in engaged p o s i t i o n a n d p r e v e n t r e l e a s i n g u n d e r load.

  • Page 86: Air-Vac Cooling

    AIR-VAC COOLING On A i r - With optional a i r - v a c c o o l i n g , a i r c i r c u l a t i o n i s opposite t o t h a t of the s t a n d a r d s y s t e m . f i n s .

  • Page 87: Tool Listing

    Common Tools: F o l l o w i n g i s a l i s t o f t o o l s commonly used i n s e r v i c i n g Kohler Engines:...

  • Page 88: Specifications And Tolerances

    SPECIFICATIONS AND TOLERANCES DIMENSIONS IN INCHES GENERAL CAMSHAFT CONNECTION CRANKSHAFT CYLINDER 'Maximum limits combination of I.D. and O.D. measurements.

  • Page 89: Gas

    RPM) HORSEPOWER (Maximum Engine Model K482 K532 CYLINDER HEAD Max. Out of Flatness RH-10 RCJ-8 Spark Plug Battery Magneto Gaseous Fuels Nominal Point Gap Service Replacement Sires Thrust Face Maximum 3.238 3.363 3.491 3.691 Wear Limit Thrust Face To Bore...
  • Page 90 TORQUE VALUES & SEQUENCES FOR FASTENERS USE STANDARD TORQUE SETTINGS WHEN SPECIFIC VALUES ARE NOT SPECIFIED. Cart lmn CYLINDER N O N METALLIC FUEL PUMP 40-45 in. lbs. MOUNTING SCREWS CLOSURE PLATE ft. Ibs. ft. Ibs. (Oil Assembly) 12 -in. Ibs. 150 in.
  • Page 91 ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044 L i t h o i n U.S.A.

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