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Courage SV470
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Kohler Courage SV470 - Page 132
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FORM NO.:
20 690 01 Rev
. B
ISSUED:
8/10
REVISED:
1/1
1
FOR SALES
AND SER
VICE INFORMA
TION
IN U.S.
AND CANADA, CALL
1-800-544-2444
KohlerEngines.com
ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044
© 201
1 by Kohler Co.
All rights reserved.
131
Table of Contents
Main Page
Table of Contents
3
Rotating Parts!
5
Hot Parts!
5
Section 1. Safety and General Information
5
Accidental Starts!
5
Explosive Fuel!
6
Flammable Solvents!
6
Lethal Exhaust Gases!
6
Explosive Gas!
6
Engine Identification Numbers
7
Fuel Recommendations
8
Oil Recommendations
8
Oil Type
8
Periodic Maintenance
9
Storage
9
Typical Engine Dimensions
10
General Specifications
11
General Torque Values
17
Oil Drain Plugs Tightening Torque: N-M (English)
17
Torque Conversions
17
Section 2. Tools & Aids
19
Special Tools You Can Make
22
Rocker Arm/Crankshaft Tool
22
Flywheel Holding Tool
22
When Troubles Occur, be Sure to Check the Simple
23
Section 3. Troubleshooting
23
External Engine Inspection
24
Cleaning the Engine
24
Basic Engine Tests
25
Crankcase Vacuum Test
25
Incorrect Vacuum in Crankcase
25
Leakdown Test Results
26
Compression Test
26
Leakdown Test Instructions
26
Cylinder Leakdown Test
26
Air Cleaner Assembly-Exploded View
27
Precleaner Service
27
Section 4. Air Cleaner and Air Intake System
27
Paper Element Service
28
Inspect Air Cleaner Components
28
Bushings in Air Cleaner Base
28
Reassembly
29
Breather Hose
29
Air Intake/Cooling System
30
Fuel Type
31
Gasoline/Alcohol Blends
31
Gasoline/Ether Blends
31
Section 5. Fuel System and Governor
31
Fuel System Troubleshooting Guide
32
Fuel Filter
32
Fuel Line
32
Fuel Pump
32
Troubleshooting–Fuel System
33
Installation
33
Carburetor
33
Pulse Fuel Pump
33
Carburetor Adjustment
34
Troubleshooting: Fuel System
34
Fixed Main Jet Carburetor
34
Low Idle Mixture Adjustment
35
Optimum Low Idle Fuel Setting
35
Low Idle Speed Setting
35
Welch Plug Removal
36
Carburetor-Exploded View
36
Main Fuel Jet Removal
37
Fuel Inlet Seat Removal
37
Choke Shaft Removal
37
Cleaning
37
Inspection
38
Repair
38
Choke Shaft Installation
38
Welch Plug Installation
38
Unitized Throttle and Choke Control
39
High Altitude Operation
39
Fuel Shut-Off Solenoid
39
Throttle Cable Adjustment
40
Speed Control Bracket with Unitized Throttle/Choke Control
40
Adjusting Unitized Throttle/Choke Control
40
Typical Throttle/Choke Controls
40
Alignment Holes in Speed Control Bracket and Throttle Lever. (Later Models)
41
Starting an Engine Equipped with Unitized Throttle and Choke Control
41
Throttle Position for Starting Engine
41
High Speed (RPM) Adjustment
41
Install Separate Control Cables
42
Separate Throttle and Choke Control
42
Choke Adjustment
42
Adjusting High Speed (RPM)
42
Separate Choke and Throttle Cable Controls
43
Alignment Hole in Speed Control Bracket and Throttle Lever (Early Models)
43
Alignment Holes in Speed Control Bracket and Throttle Lever (Later Models)
43
Choke Control Installation
43
Starting an Engine Equipped with Separate Control Cables
44
Changing the High Speed (RPM) on the Engines with Separate Controls (Increase or Decrease RPM)
44
Setting the Low Idle RPM
44
Governed Idle Adjustment
44
Initial Adjustment
45
Governor Gear/Flyweight Assembly
45
Location of Governed Idle Adjusting Screw
45
Operation
45
Tightening Governor Lever Nut
46
Governor Sensitivity Adjustment
46
Early Style Governor Spring Location Chart
46
Later Style Governor Spring Location Chart
47
Oil Recommendations
49
Viscosity Grades Table
49
Check Oil Level
49
Section 6. Lubrication System
49
Dipstick Seated
50
Change Oil and Oil Filter
50
Oil Drain Plug, Oil Filter
50
Lubrication System
50
Oil Level Dipstick
50
Full-Pressure Lubrication System
51
Oil Pump on Intake Cam Shaft (Gerotors Removed from Pump Housing)
51
Oil Filter Location
51
Oil Sentry
51
Tester Locations (some Models)
52
Testing Oil Pressure
52
Testing the Oil Sentry Switch
52
Oil Sentry Pressure Switch Locations
52
Spark Plug Service
53
Section 7. Electrical System and Components
53
Electronic CD Ignition System
55
Capacitive Discharge Ignition Module
56
Troubleshooting and Testing CD Ignition Systems
56
Preliminary Test
56
Testing CD Ignition Module Secondary
57
Ignition Tester
57
CD Ignition System Troubleshooting Guide
57
Battery Charging
58
Battery Maintenance
58
Battery Test
58
Electrical Systems Wiring Diagrams and Battery Charging Systems
58
3 Amp/70 Watt Stator
59
3 Amp Regulated Battery Charging System/70 Watt Lighting
59
Troubleshooting Guide 3 Amp Battery Charging System with 70 Watt Lighting Stator
60
Troubleshooting Guide 3 Amp/70 Watt Braking Stator
61
Battery Charging System 9 or 15 Amp
63
9 Or 15 Amp Stator and Rectifier-Regulator
64
Proper Connection to Test 9 or 15 Amp Charging System
64
Troubleshooting Guide 9 or 15 Amp Regulated Battery Charging System
65
Blade Stop Stator Brake Circuit Wiring Diagram
66
Stator Brake and Relay Harness Connections
67
Troubleshooting Stator Brake System
67
Electric Starters
68
Starting Motor Precautions
68
Troubleshooting Guide-Starting Difficulties
68
Holding Tool and Turning Center Screw (Clockwise) to Remove Retaining Ring
69
Assembling Inner Half of Tool Around the Armature Shaft and Retaining Ring
69
Starter Drive Service
69
Starter Removal and Installation
69
Retaining Ring Installation
70
Assembling Larger Inner Half Around Spring Retainer
70
Starter Disassembly
70
Inertia Drive Electric Starter
70
Brush Replacement
71
Commutator Service
71
Starter Reassembly
71
Oil Drain Location, Oil Filter, and Oil Fill Cap/Dipstick
73
Drain Oil from Crankcase and Remove Oil Filter
73
Typical Disassembly Sequence
73
Section 8. Disassembly
73
Remove Oil Sentry Pressure Switch (on Models so Equipped)
74
Remove Blower Housing
74
Disconnect Spark Plug Lead
74
Remove Rectifier-Regulator
74
Remove Air Cleaner
75
Air Cleaner Components
75
Removing Air Cleaner Base Fasteners
75
Remove External Governor Components, Carburetor, and Fuel Pump
75
Removing Carburetor
76
Removing Heat Deflector Screw and Ground Lead
76
Disconnecting Pulse Line from Fitting
76
Disconnecting Fuel Line from Carburetor
76
Removing Speed Control Bracket from Closure Plate
77
Removing Governor Lever
77
Removing Heat Deflector
77
Disconnecting Governor Spring
77
Removing Lead from Clip (RFI Suppression Equipped Units)
78
Remove Grass Screen, Fan, and Flywheel
78
Remove Ignition Module
78
Removing Insert (some Models)
78
Removing Flywheel Using Puller
79
Remove the Stator
79
Remove the Valve Cover and Cylinder Head
79
Removing Fan and Flywheel Mounting Hardware
79
Loosening Adjustment Set Screw and Nut
80
Removing Cylinder Head Bolts and Washer
80
Removing Cylinder Head and Gasket
80
Removing Drain Back Check Ball from Crankcase (some Models)
80
Disassembling Rocker Arm Components
81
Remove Closure Plate
81
Removing Spark Plug
81
Disassemble Cylinder Head
81
Closure Plate and Gasket Removed from Crankcase
82
Disassemble Closure Plate
82
Removing Oil Passage Cover and Gasket
82
Remove Cam Gears, Cam Shafts, and Oil Pump
82
Removing Cam Levers
83
Removing Exhaust Side Cam Shaft and Slotted Thrust Washer
83
Removing Drain Back Tube (some Models)
83
Pump Outlet Styles
83
Removing Piston and Connecting Rod
84
Separating Oil Pump Assembly from Intake Side Cam Shaft
84
Removing Connecting Rod Cap
84
Intake Cam Shaft and Oil Pump Assembly
84
Remove Piston from Connecting Rod
85
Remove Piston Rings
85
Remove Crankshaft and Balance Weight Assembly
85
Balance Weight Disassembly
86
Removing Crank Gear Key
86
Removing Balance Weight Screw (Guide Shoe Design before Serial No. 3618005213)
86
Removing Balance Weight Screw and Guide Pin (Control Link Design after Serial No. 3618005223)
86
Remove PTO and Flywheel Side Oil Seals
87
Disassembled Balance Weight (Control Link Design after Serial No. 3618005223)
87
Remove Governor Cross Shaft
87
Disassembled Balance Weight (Guide Shoe Design before Serial No. 3618005213)
87
Automatic Compression Release (ACR)
89
ACR Details
89
Section 9. Inspection and Reconditioning
89
Benefits
90
Crankshaft and Crank Gear
90
Crankcase
90
Honing
90
Balance Weight Assembly
91
Measuring Piston-To-Bore Clearance
91
Cylinder Bore Crosshatch after Honing
91
Measuring Balance Weight to Crankshaft Eccentric Ring(S) Clearance
92
Measuring Balance Weight Guide Pin and Guide Shoe-To-Closure Plate Guide Channel Running Clearance
92
Balance Weight-To-Eccentric Clearance
92
Measuring Guide Pin O.D.
93
Measuring Guide Shoe Hole I.D.
93
Flywheel
93
Cylinder Head and Valves
94
Inspection and Service
94
Valve Details
94
Pistons and Rings
97
Valve Guides
97
Lapping Valves
97
Valve Seat Inserts
97
Common Types of Piston and Ring Damage
98
Some Important Points to Remember When Servicing Piston Rings
99
Measuring Piston Ring End Gap
99
Measuring Piston Ring Side Clearance
99
Install Piston Rings
99
Torque Sequence for Passage Cover
100
Closure Plate and Passage Cover
100
Oil Pump Assembly and Pressure Relief Valve
100
Connecting Rods
100
Governor Gear and Shaft
101
Procedure to Remove Governor Shaft
101
Procedure to Install Governor Shaft
101
Governor Shaft Press Depth
101
Typical Reassembly Sequence
103
Install PTO Side Oil Seal
103
Section 10. Reassembly
103
Install Oil Pump Assembly and Intake Cam Shaft
104
Securing Governor Shaft
104
Install Governor Cross Shaft
104
PTO Seal Depth Details
104
Assembled Intake Cam Shaft Details
105
Pump Outlet Seals
105
Installing Oil Pump Outlet Seal
105
Gerotor Gears Installed in Oil Pump
105
Installing Drain Back Tube (some Models)
106
Install Crankshaft and Balance Weight
106
Torquing Oil Pump Mounting Screws
106
Checking Outlet Seal Passage Opening (Open Style)
106
Assembling Balance Weight to Crankshaft (Control Link Design)
107
Installing Crank Gear Key
107
Installing Crankshaft Assembly (before Serial No. 3618005213)
107
Assembling Balance Weight to Crankshaft (Guide Shoe Design)
107
Installed Guide Shoe (above Serial No. 3618005223)
108
Installing Crankshaft Assembly with Control Link (above Serial No. 3618005223)
108
Installed Control Link on Crankcase Guide Pin (above Serial No. 3618005223)
108
Install Piston to Connecting Rod
108
Installing Piston and Connecting Rod
109
Torquing Connecting Rod Screws
109
Direction Arrow on Piston
109
Install Piston and Connecting Rod
109
Install Cam Levers
110
Install the Exhaust Cam Shaft and Cam Gear
110
Drive Pin Locations for Exhaust Cam Shaft
110
Exhaust Cam Shaft Installation
110
Hooking ACR Spring Onto Exhaust Cam Gear
111
Installing Exhaust Cam Gear
111
Install Intake Cam on Cam Shaft
111
Install Crank Gear
111
Closure Plate Installed
112
Install Closure Plate Gasket, Closure Plate, and Wiring Harness
112
Aligning and Installing Closure Plate
112
Install Flywheel Side Oil Seal
112
Assemble Cylinder Head
113
Install Cylinder Head
113
Closure Plate Fastener Torque Sequence
113
Installing Drain Back Check Bal (some Models)
113
Install Rocker Arms and Push Rods
114
Installing Cylinder Head Fasteners
114
Cylinder Head Fastener Torque Sequence
114
Installing Guide Plates and Rocker Arm Pivot Studs
114
Valve Cover Fastener Torque Sequence
115
Valve Clearance Specifications
115
Locking Adjustment Nut Set Screw
115
Install Valve Cover
115
Install Stator and Wiring Harness
116
Installing B+ Lead into Connector
116
Install Pipe Plug or Fitting and Pulse Line for Fuel Pump
116
Connecting Pulse Line to Fitting
116
Install Fan and Flywheel
117
Torquing Flywheel
117
Setting Air Gap
118
Install Ignition Module
118
Install Electric Starter
118
Install New Spark Plug
119
Install Heat Deflector, Carburetor, Linkage and Air Cleaner Base
119
Mounting Stud and Installing Insert (some Models)
119
Installing Intake Gasket and Heat Deflector
119
Inserting Alignment Pin
120
Installing Carburetor Assembly with Linkages
120
Securing Ground Lead
120
Connecting Fuel Line to Carburetor
120
Torquing Air Cleaner Fasteners
121
Installing Mounting Screw (Models with One Stud and One Screw)
121
Install the Air Cleaner Base
121
Air Cleaner Base Upper Mounting Tab Details
121
Install and Adjust Governor Lever
122
Mounting Speed Control Bracket
122
Attaching Speed Control Bracket
122
Install Fuel Pump (if Equipped)
123
Install Rectifier-Regulator
123
Install Blower Housing and Flywheel Screen
123
Install Oil Sentry or Pipe Plug
124
Installing Pipe Plug or Adapter
124
Installing Grass Screen
124
Installing Blower Housing Screws
124
Install Air Cleaner Element, Precleaner, and Air Cleaner Cover
125
Install Muffler
125
Torquing Exhaust Flange Nuts
125
Install Drain Plug, Oil Filter, and Oil
126
Prepare the Engine for Operation
126
Testing the Engine
126
Carbon Canister System Diagram
127
Section 11. Emission Compliance Systems
127
Secondary Emission Compliance System
128
Remove Inlet Screen
129
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