Case 130 User manual

9-76391
CASE
130 and 180
Compact Tractors
Service Manual
IReprinted I

THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY
MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS SYMBOL,
CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE
ALERT TO THE POSSIBILITY OF PERSONAL INJURY OR DEATH.
M171B
If Safety Decals on this machine use the words Danger, Warning or Caution,
which are defined as follows:
• DANGER: Indicates an immediate hazardous situation which if not avoided,
will result in death or serious injury.The color associated with Danger is RED.
• WARNING: Indicates an potentially hazardous situation which if not avoided,
will result in serious injury. The color associated with Warning is ORANGE.
• CAUTION: Indicates an potentially hazardous situation which if not avoided,
may result in minor or moderate injury. It may also be used to alert against
unsafe practices. The color associated with Caution is YELLOW.
If Safety Decals on this machine are ISO two panel Pictorial, decals are defined
as follows:
• The first panel indicates the nature of the hazard.
• The second panel indicates the appropriate avoidance of the hazard.
• Background color is YELLOW.
IC'\
• Prohibition symbols such as \:::I X and 8 if used, are RED.
~ WARNING
IMPROPER OPERATION OF THIS MACHINE CAN CAUSE INJURY OR
DEATH. BEFORE USING THIS MACHINE, MAKE CERTAIN THAT EVERY
OPERATOR:
• Is instructed in safe and proper use of the machine.
• Reads and understands the Manual(s) pertaining to the machine.
• Reads and understands ALL Safety Decals on the machine.
• Clears the area of other persons.
• Learns and practices safe use of machine controls in a safe, clear area
before operating this machine on a job site.
It is your responsibility to observe pertinent laws and regulations and
follow Case Corporation instructions on machine operation and
maintenance.
© 2001 Case Corporation Bur 0-00000
issued November, 1994
CASE and IH are registered trademarks of Case Corporation
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TABLE OF CONTENTS
130 AND 180 COMPACT TRACTORS
SERIES SECTION DESCRIPTION FORM
NUMBER
9-76411
10 GENERAL
20
40
50
80
90
JICase
C Specifications For K241SAnd K301SEngines ••••••••••.•.••••.••••••••
ENGINES
M Servicing The Kohler K241SAnd K301SEngines ••.•••••••.••••.••••••• 9-76361
FUEL SYSTEM
N Servicing The Carburetor And Fuel Pump •.. .••••.•.••••••••.•••..••••• 9-76361
ELECTRICAL
F Electrical System ...•••••.••••••.•••••••.. .•••••.•.•••••.. •..•. ...••.• 9-76371
STEERING
0 Servicing The Steering System ...•••••.. •••.•..•••••••.••••••.. •••..•. 9-76311
POWER TRAIN
S Servicing The Two SpeedTransmission................................ 9-76301
B
D
HYDRAULICS
Servicing The Hydraulic Pump ••••••••••••••••••••.••••••••••••••••••. 9-76291
Servicing The Control Valve And Orbital Motor •••••••••.•••••••. .•. .... 9-76351
ACCESSORIES
Installing ~ Operating - Adjusting The 38" And 44"
Rotary Mowers And 44" Dozer Blade ••••••••••••. ••••••••••••. . .•••••• 9-76501
Servicing The Rotary Mower And Dozer Blade •••••••. ••••••••.••••.•••• 9-76461
Rae9-76361 Printed in U.S.A.
ATennaooCompany e
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10
Series
General
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Roe.Form 9- 76411
SECTION
C
SPECIFICATIONSFOR
K 2415 AND K 3015
ENGINES
USEDON
THE
130 AND 180
GARDENTRACTORS
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Ptston Displacement
-----·••H•--·-·-·····---····
23.9 Cubie ll:lclles
Comprelllll!io!l
Ratio -······-····-·-····---···-········-··-··
6
to
1
M'.u:.
Comp,
at
Crankl.ng Speed
(Er,g:ll;e at
Operating
Teffll}ll:ratu:re
--•-••u•n••-·-••··•-•
0••
HO to 120 PSI
at
Sea Level
C~ Vacuum( Engine Running)•·· 5
to
10
Inches
Vacuum at Sea
Level
lgmtl.on ----·-··------------···--- lZ Volt Coil, B:rfllte:r Point
CVLINDl$R BORE
D~:r ct
Cylinder
Bore
St<:I.
A, B -•--·····•·• 3,2$0$..3.21>45lru:hes
.010 Overs!.Ze A, B
♦
10•·········--··· 3.2605-3.26111lnches
.020
Oversize A, a
+ 20 3.Z'IOS-3.271$
lru:llea
.030Oversize
A,
B • 3C
---•H-••--···3.2005-3.281
!I
1ru:hell
Cyllnde:r
Bore Must Be
Bo:red
or Hooed Offr111h\e
!f Tllpff or 00
oCntnmd
~
··••----•••·•-••·•-··---•·•••····•-••• .OO!l1nelletl
PlSTON
AND
PISTON F'fN
Olameter
ot St<:I.
Piston at
Bottom ot
Skirt •······
a.M'l0-3.2480 !neh&s
lllameter otSid.
Piston
at
Top of Skirt •··-··-··· 3.2425-3. 253$ lnehes
(Mealmred
J1lSt
Below 00 BIDS)
~r
ct Std. Pllllton
lit
Top ····----·-····•···· 3.213-3.220 1nelletl
PlBton Pin···-··•···-•·••··----·····
Fuli Floating'.
'fyp,:,,
Retained
tn
Place With Two
Retainer
RiuP.
Piston
Pm Bore in Piston Std. •····-·-······--·-·- .!1595-.8596 :tnclie&
PlBton Pin
Diameter
Std.
•···-···--··••H••···--
.8591-.8$93 1nehes
.005
Ove:-me--•-·-·······
.0041-.0043 1nelletl
Pl8toll
Pill
Lengtn---•-•••-•-••••••-•H••-- 2.733-2.7$31.oohes
Pl8ton Pln Fit
in Pllllton (Select Fit) ---·········-· .0000· .OOOSfnebes
PlBtOn
Pill
Fit
1n
Con.nootl!lgRod ---•••••••••••••- .0003-.000$ lncliell
PlSTON RtNGS
RinP
Per
Pl.lllton ---·----------------·------
(ZCompr-10n-1
Oil}
lllJl(Top)Compression•Ctlrome, Taper Face, RelleHndiclltes TQP
Side
St4e Clearance•··---·-·-··-
.ooz•.
004 1nelletl
Width -·····-······-·····-·· ,093- .004
l'.nchff
and
Compressioo-Cbrome, Relief tndicatea Bottom Side
Side Clearancec -···-··--··· .0015-,0035 !neh&s
Wldth •-• •••---••-•••-•••••• .00$-.094 1nehes
31/'d00 :rung•·-····•····•··-------••----- Caat W/E:z;,ander
Sidi)
Cieuance ••••••••••••
u.001-.003
Ioohes
Width•-·-••--------.1800-.18'101nelletl
rung
End
Gap• When
Installed
in Bore-·····-·······
.010-,020
l'.nehe11
Replacement BIDS
Width
1st. Comp. ---··--····--· .00211••ooas
!nebea
2nd. Comp.•-·-·····•--··- .0065-.011'15Inches
2nd. Comp. Rail•·••-•- ,02$$..,0245 1nehes
3rd. OU
Rail -··-··--····
.02'35-.0245
lnehes
3rd
OU :rung··•----·•••-·--· .134-.lllS 1nelletl
CONNECTING ROD
C~ Rod
Length
!rom Center ot Pin Hole
To Center
o!
Belllrlllg
J~ --------··--·--·-··
6.li60-ll,66Z
1nchelll
Piston
Pin Hole DI.a.meter
In
Rod*"··············· ,8596-.85\ill lnehes
1.nWle
D~r
of
Rod Jou:mal, St<:I............. t.5005-U!OlO Inelles
Underlllze ·--·-·-·••·-·· 1,4905-1.4910 lnellea
COOlleetl!lgRod to Cl'lmk Journal Clearance-·-····· .0005-.00lS tnehes
COOlleeting'.
Rod to Crank End
Play
Clearance•-····-· .001••
ou;
l'.nehe11
CRANKSHAFT AND SEARINGS
Crank!llwt
Rod Jow.-nal
Width·••---•·••-··••· l.0'19--1.084 lnchelll
C:ra.oklllbattEnd ··-------------------------
.003-.02,0
Inches
Measured
lit
Pwe
and
Shim te Proper End Play
CAMSHAFT
c~ End Play
•••••---•-•••••••••••••H•••--
.00$..,010
~
~
Pin
!llameter
•·----------•--···-··••4000-.41Hl5
~
ClllUllatt Inside Diameter •···········-··-·-···-· .4995-.5015 Inehea
Camshaft
Pln
to Camshaft
Clea:ranee •••••••••••••••• 001-.0035
lnehea
Camshatt Pin to B:-ealalr Cam Clear!lllee
•-·••·••u•
,001-.00Z5 lnehea
VAL Vii! l..11""'1'1MS
ValTii Littllr Outside~ In
ID.eek•••••• ._ •••
6232-,5ZS'l lnchell
VALVES
l'ntake
Valve Tappet Clearance (Cold) .................
ooa-.010
Inches
ExhaullltValve Tappet Clea:rance (Cold) •-········-··•J:ll7•.020 l'.nehe&
Angle ot ValvecFace • l'.ntalteand Exhaust: •··········-·-·· 44 D;ig:rees
Va!ve Levgth - Intake
and
Exhaust.•.....•....... 4.572-4.582 lnchell
Mu. Valve Face
Runoot -
Intake -···-·--------- .0015 lnehes
~. Valve Face Runout -
Ex!la:usl --·--·-······-········
.003 'Inches
Valve HecadDiameter • lntalte --·········--·-·-··· 1.370-1.380 inches
Valve Head Diameter • Exhaust
H••-·-·····-··--·1.120-LUO lnclles
Valve
stem Diameter•
lnta.k&•·-······-·-·--···
.3105-.3110 Inches
Valve Stem
Diameter•
Exhaust-----··········-··
,3090-,3095
lnehes
Intake
Valve
stem
to Guide Clearance --------- .001••0025
1nchell
Elthaulllt
Valve
Stem
to
Gulde
Cleuance •-----
.0025-.004
lnebes
VALVE SEATS
Seat
Angle • l'.ntalleam
Elthaulllt -·····••·•••·•-•-•---····
4$ Degrees
Max.
Seat
Runoot -
lntalte amExhaust -·······--··-······ .002 mches
Sot Width•
lnta.ke ··--··-----··•··•---·•-··
.037-.045 lnchaa
Sot Width - Exhmllllt--··-----········--··-·-- .031-.062
lnehes
Elthaulllt
Seat lnserl
••u••·······--·-•••••----·•••·--·
Replaceable
Ontlllde Diameter ct Exhaust Insert--·········•• l.2635-LZMS mehes
l!lma:ullt
lnlllert
Height •••••••••••••••••••••••••••••• 2Hl-,221 mehes
VALVE GUIDES
Valve Gulde
Length
•········•···-········-···--••H•
2.12'5
Xoohes
Valve Guidec
to
Bloek (1?:ress Fit) -···--·---······- ,0005-,002. lnehea
Valve
Guide
lnlllid.eDiameter• Before lnatal.llng •••••• 30'1-.306 inches
Ream
Valve Guides After lneteilillg w
•·····•·····:112-.313
:tncbea
VALVE Sf"RINGS
Sprlllg F:r11eLength •·····••h••···-·····
•······--··-·-1,'l93 l'llebea
Sprlllg Pressure When Comp.
tn
1,469 ln. (Valve C10llled)•47 to :11Ll:>11.
Spring
PreBBW'e
When
Colllp.
to
1.Hl5
fu,
(Valve Open} ••• 54
Ix>
IIZlbs.
GOVERNOR
~
Slllh
Sb.aft
Oll:tllideDlimleter •--····•····· .3'135-.$'140 lneliea
Govemo:- Gear Bore
tor
Stub
Sb.aft
-----·-····-·····374!1•.3'155 mehe11
StubShatt
to
Governor Gear Clearance---··-·····-· ,0005-,00Z lnchea
Guvernor Sprlllg Free Length With 2 Lbs. Pre-Luad ~~--~~-Z.62 Inelie&
Governor
Spring
Exl.ended
to
2.$8
lneliea ---·-··-- 5.6
to
IU Pounds
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KS01S ENGINE SPECIFICATIONS
Type
••H•--····••H••·········•Kobl.er, 1 Cylinder, 4 Stroke Cycle,
A1r Cooled, "L" Head
Sng1ne
Bore
•••--••-------H••••••u•••••••••••••u•
3.300 lnches
Stroke
••••••••-•H••••••••••u•••••••·•••••••••••••••:l,250
Inches
l'istotl Displacsment •········-·················
29.07 CUbie lnehes
Compression Ratio •--························--···· 6
to
1
Mu.
Comp,
at
Crankillg Speed
(Sngtne
at
~al:lng
Temperature}
·······•llO to 120PSl at
Sea
Level
erw.:ase vacuum(~11 ~)-·· 6to lOincnes vacuum
at Sea
Level
T(nition ·--···········-·················12 Volt Coil, Breaker
POmts
CYLINDER BORE
Dia.metl!r
ot
Cylinder Bore Sid.
A,
B••········--•S.3745-3.3785
~
,010
OVeralze
A,
B
+
10 ............... 3.3846-3.3855
mehes
.020 Oversllle A, B + 20 •••••••••••••••
3.3945-3.3955
Inches
.030
Overallle
A, B • 30 •••••••••••••••
3.4045-3.4055
Inches
Cylinder Bore Must Be Bored or Honed Oversllle li Taper or
Out ol Round
.Exeeedll................... ·-····-······-····-···· ..
OO\l
lnches
PISTON
AND
PISTON PIN
otameter
ot
Std. PiSton
at To;;,····-·•···········-
3.300-3,360
l'.nebes
Dilinleter
of Std.
Pillloo
at Top of
Skirt
(Measured Just Below OU rung) ····--····-······-
3.369•3.3'10
Inches
Diameter
otSid. PistoD
a.t:
Bottom of Skirt •·······-
3.3'11-3.372
tnehes
Piston Pin ••••••••••••••••••••••••••• Full Fleeting
Type
~
ln
Pl.ace With Two Reta!.Mr Rinp.
PiSton Pin Bore bl l'istan, Sid.
······••H-••·····
.1.1752-.11754
l'.nebes
Piston
Pin
Diameter
Sid, •••••••-•••UH••••••••••ffl2-.S'l54
~
.005 Overal.Ze ••••••••••••••••••••••••••. 8802- .11!!04
Inches
PiSton Pin
Umgth ·•··••n••······•••··--··•····•
Z.'135-2.'150
tnclles
Piston Pin Fit
In
Piston -···-•------·-·••···•·
One
'flmml) .\'UM
Fit
l'istotl Pin Fit
In
Conueeting Rod ••••••••••••••••••• 0003-.0008
tnches
PISTON RINGS
rungs
Per
PistoD
•········--·······--········(2 Com)'ll"ession-1
OU)
tst('r<ip)CompressiOII-Chrome,
'l'llpeHd
Face.
ReliefIndicates Top
Side.
Side Clearance •·········· .. - .003-.004 Inches
Widtb '···-··········--···•n••··
.078
Inches
2nd •
Compreseion ---·····
Chrome, Relief lndleates
Bottom
Side
Side
Clearance •·············
.OOZ...004
Inches
Width--••••••••••-••-•---- .078
Inehes
3rd. Oil Ring .............................. Cast W/Expander
Side
Clearance •·············
.001•• 003
Inchea
Width
U•••••••••••••-••••••-•••
.1870
tnehes
RillC End
Gap When
Installed
ln
BON ····-·······-··· .010-.020
Inches
Replacement Ri!lg Width
1st
Comp. -················ .0'17-.0711'Inches
2nd
Comp••••••••••••••••••• 07'1-.0'78 Inches
3rd
OU Rail •••••••••••••• .0235-.0245
Inches
3rd Oil
Ring•-·········-····
.134-.135
Inches
CONNECTING ROD
Connecting
Rod L,mgtll From
Center
Ol Pin
Hole
To Center ot
Bearing Jcurna.l
···················••5.295-S,297
Inches
Piston Pin Hole
Diameter
ln Rod•·······-········
,8'157-.9'160
lnclles
Inside Diameter Ol Rod
Journal,
Sid. •·······-···
1.5005•1.5010 lncbes
Undera!Ze ••••••••••••••
l.4005•1.4910
lnehes
Connecting Rod To Crank Journal Clearance ...............
ooos-.0015
Connecting
Rod
To Crank
End Play
Clea.ranee
u.-. ••••
00'1-.01$ lnches
CRANKSHAFT AND
SEARINGS
Type
Main Bearings ................................. Ball
Bearings
Craaltlithaft
Rod
Journal •·····················•• 1.4995-l .5000 Inches
Crankshaft Rod lcurnal WHth •••••••••••••••••••• 1.079•1.084 Inches
Cra.nkshafi
End
Play -····--············ •·········· .003-.020 blelles
Measured
a.t:
l:learing Nate and Shlru
tu
l'ro,:,cr l':nd Plav.
CAMSHAFT
~
El!d
Plair•···•••------•-•---•--••-
,005-.010 tnci-
Camsllaft
Pm~
•-•---••HH•-•----.4980-.49811
lnches
Camsllatt
Inside
Diameter ·•··-••••-···---•-···•• .4995--.5015
Inches
camshaft
Pin
to
CIU:IISha1t
Clea.ranee
·•-••••·•-••,001-.0035
:tnehes
Camsllatt Pin
to
Breaker Cam Clearance •••-·--• .001-.0025 lnches
VALVE
LIFTEl'ltS
Valve
Lffler
OUtside
~
In
Bl.oolt••···-·---.62n-.11m
lnches
Va..lve
utter Bore
In B1ocJt
-----•·•----------·•-·11245-.11255
l'.nebes
Valve
utter
To Bloek Clearance .........
·--•·······OOS-.0023
Inches
VALVES
llltake
Valve
Tappet Clearance (Cold)
----·---------.008-.010
mehes
Emwst Valve
'l'#ppet
Clearance (Cold) ·-•--·-·••-.Ol'l ••020
Inches
A:agle ot
Va..lve
Face - Intake
and Exhaust -···--········--
44
~
Valve
L,mgtll • tatake and
Emawlt ••·•·••••·•··•••
4.1.172-4.582
mehes
M'a:&:.
Valve
Face lb.l.ao1lt- Intake --········-···--······
.0015,
Inches
M'a:&:.
Valve
Face R'lmOut-
~
-····---···--···-·•-.003
Inches
valve Bead Diameter •
Intw •··•··-···-··--···
l
.3'10-1.3$0
Inebea
V&Ive
Head Diameter.
Exhallst---••H••·····••··
1,120-1.130 lnches
Valve Stem Diameter·
Intake·--•--··•--·--··•-••
.3105--.3110 Inches
Valve stem
Diameter •
l!lllhallst -·--·•--•··•••-•· .3090--.3095
Inches
lutake
Valve
Stem to Guide
Clea.ranee -·------·-- .001-.0025
Inches
Emaut
Valve
stem to
Oa1de
Clevance ·•--••··-• .0025-,004
Inches
VALVE
SEATS
Seat A:agle.
llltake
and Ezhallllt--·-··---·······--·····-·11
~
l\fl;L seat Rwtout Intake
and :&ll:baust
---------··--·--·-··002
Inches
Seat
W1dt.b.
tatake ------·------··-----······-·····
.03'1-.045
Inches
Seat Width. l!:lcllaust------··--·--·----·-····-- .031-.062 mehes
Ezbau.llt
Sat
Insert ··-·------------·---····---·-··
Repl.aeeable
OUtside
Dia.1.ueter
of
Exhaust
l.!lllert ·--·-····--·
1.2535--1,2545 Inches
Ji1ldlawlt
l'nllert
Jfeigbt ...............................
219-.221
l'.nchea
VALVE
GUIDES
Valve Guhie
L<mCtll•··-······•----------··--···
2.125
Inches
Valve Guide
Ol.ltaide
Dill.nl.eter
·••··-••···•-•··-·•6260,..62S5 lnehes
Valve
Guide
to
B1oek{Pren Fit } --•·•-·····-·-
.0005-.002 Inches
Valve
Guide
Inside Diameter - Before
lnstallmg •--··-
.30'1-.308 mehes
Ream Valve
Clllidu After
lnstallmg to
--••·•-••.312-.313
lnehes
VALVE SPRINGS
Sp:rinlf Free Lenctll----·--·-----·-···--·-··------·-·--
1.'193
mehes
Sprillg PrUsu:re
When
Comp,
to
1.469 ht. {Valve CloNd)
.a, to
31 Lbs.
Sprillg
l'rellsure Wilen Comp.
to
1.1115In.
(Vlllve
Open}
---54
to
112
Lbs.
GOVERNOR
Governor
Stub Shaft
Outside
Diameter •••••••••••••• 3735--.3'140
toohell
Governor Gear
Bore tor
Stub Shatt
--···-·········3'145-.3755
lnches
Stub Shaft
to
Governo:rGear Clearance •-·······-··· .0005--.002
toohell
Goverrun-
Sprlng Free Lqtll with
2 Lb•
.Pre-LOad ........
2.62 Inches
Gove:rnor
Sprillg
~
to
2.SS
1nclles •·•·•-•-·- 5.5 tc
!U J.w:bes
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GENERAL TORQUE SPECIFICATION TABLE (Revised 5-64)
USETHEFOLLOWINGTORQUESWHENSPECIALTORQUESARENOTGIVEN
NOTE:These values apply to fasteners as received from supplier. dry, or when
lubricated with normal engine oil. They do not apply
if
special graphited
or
moly-disulphide greases or other extreme pressure lubricants are
used. This applies
to
both UNF
and
UNCthreads.
SAEGrade No. 5
8*
Boltheadidentification C) 0
© 0 @ @
marksaspergrade
Note: Manufacturing
\
MarksWill Vary TorqueFootPounds TorqueFootPounds
BoltSize Min. Max. Min. Max.
1/4"
9
11 12
15
5/16 15 18 24 28
3/8 35 40 45
50
7/16 54 60 70 80
1/2 80 90 110
125
9/16 110 120 160 180
S/8
150
165 220 240
3/4 260 280 380 420
7/8 360 400 600 660
1"
540 600 900 1000
1-1/8 720 800 1280 1440
1-1/4
1000 1100 1800 2000
1-3/8 1460 1680 2380
2no
1-1/2 1940 2200 3160 3560
*
Thicknuts must be used with Grade 8 bolts
GENERAL ENGINE TORQUE SPECIFICATION TABLE
'
TorqueInch Pounds TorqueFoot Pounds
1
Thread Size UNC UNF UNC UNF
BoltSize
1/4"
70
85
5116
150 165
3/8 22
25
7/16
35 45
1/2
50 70
SPECIAL ENGINE TORQUE SPECIFICATIONS
Cylinder
Head
Bolts* -------------------- Torque to
280
Inch Lbs.• Loosen, Retorque
to
300
Inch Lbs.
Connecting Rod Bolt* ------------------------------------------- Torque
to 300 Inch
Lbs.
Flywheel Nut --------------------------------------------------
Torque to 100 Ft.
Lbs.
Spark Plug -------------------------------------------------- Torque to 27 Ft. Lbs.
*Lubricate With Grease Upon Assembly
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20
Series
Engines

Rae. Form 9-76361
SECTION
M
SERVICINGTHE
KOHLER
K241SAND K301S
ENGINES

TABLE OF CONTENTS
INTRODUCTION M-3
CHECKING COMPRESSION PRESSURE • • . • • • • . • • • • . . • • • • • • • • • • M-3
CHECKING CRANKCASE VACUUM • . • . • • . • • • • . • • . . • • • • . • . . • • . M-3
CYLINDER HEAD VALVES, GUIDES AND SPRINGS • • . • • . • • • . • • . • • . M-4
Removal, Inspection, Installation . . . . . . . • • . . • . • • • . . • . . . . . • • M-4
TAPPET ADJUSTMENT • • • • • . • • . • . • • • • • • • • • • • • • • • • • • • • • • • M-4
INSPECTION OF THE VALVES, GUIDES AND SPRINGS •••••••••••• M-6, M-7
REF ACING INTAKE AND EXHAUST VALVES . • . • . • • • • • . • • • . • . • • . M-8
INTAKE AND EXHAUST VALVE SEATS • • • . . • • • . . • . • • • • • • • • • . . M-9
Grinding and Inspection . . . . . . . . • . • • • • . . • . • • • . . • • . . . . • • . M-9
ENGINE AND ATTACHING PARTS • • . . • • . • . • . • • • • • • . • • • • . • • . • M-10
Removal and Installation . . • . . . . . . . . • . . • • . . • . • • • . . . . • . . . . M-1 o
ENGINE BLOCK . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . M-12
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-12
PISTON AND CONNECTING ROD • . • • . . • • • • • • • • • • • • • • • • • . • • • • M-14
Disassembly, Inspection and Assembly • • . • . . . • . • • • . • • • . • M-14, M-15
CAMSHAFT - CRANKSHAFT AND ENGINE BLOCK • . • • • • • • . • • • M-16, M-17
In.spection. . . . . . . . . . . . . . . . . . . . . • . . • . . . • . . . . . .. . . . M-16, M-17
ENGINE BLOCK ........ _..................... - . . . . . .. . . . M-18
Assembly • • • • • • • • · · - · • • · · · · · • · · • · • • • • · · • · • · · · · · · · · M-18
M-2

Introduction
This manual covers servicing the Kohler lOHP 241 Sand 12HP 301 S engines. There are
some minor differences between these engines such as the bore and stroke. The difference
will be indicated in the manual when they appear. These engines are of the 4 cycle type,
splash oil lubrication, cast iron block and electric starting.
1#/JOffTANT
REFERTO THESPECIFICATIONSSECTIONOFTHISMANUAL FOR
DIMENSIONS,TOLERANCES,ETC.WHEN SERVICINGTHIS ENGINE.
THESEDATAARENOT INCLUDEDIN THISSECTION.
CHECKING COMPRESSION PRESSURE
Should you receive a service complaint dealing with excessive oil consumption, loss of
power, hard starting, rough running or excessive smoke, check the compression pressure
and the crankcase vacuum.
1. Steam clean engine thoroughly.
2. Warm up engine to operating tempera-
ture.
3. Remove the spark plug and shut off
the fuel valve.
4. With the speed control lever in neutral
or brake position, use a compression
gauge similar to thatshowninfigureM-1.
5. Crank the engine with the starter and
check the compression pressure, refer to
Specification Section. Ifthe pressure is 20
PSI or more below the specified pressure,
leaking valves or excessive ring clearance
is indicated.
Figure M-1
CHECKING CRANKCASE VACUUM
The crankcase breather maintains apar-
tial vacuum in the crankcase. To check
vacuum proceed as follows:
1. Drill and tap a 1/8" NPT in a 3/4" pipe
plug or use a 1/8" to 3/4" pipe reducing
bushing. Install in place of the engine oil
dipstick and plug.
2. Attach vacuum gauge to pipe plug, Figure
M-2. Start engine and run at low idle
speed. Refer to Specification Section for
proper vacuum.
Noor lowvacuum indicates afaulty breather,
excessive blowby, leaking valves or worn
oil seals.
Figure M-2
M-3

CYLINDER HEAD VALVES,OUIDES AND SPRINGS
(Refer to Figure M-3)
Removal
Steam clean engine before doing any cylinder block (13). Using a valve spring
disassembly or service work. compressor, inset A, compress the valve
Close the fuel tank shut off valve and
disconnect the fuel line at the carburetor.
Disconnect the choke and throttle connec-
tions at the carburetor. Disconnect gover-
nor linkage and remove carburetor (1) and
baffle (2).
Remove and disassemble breather (25-31),
cylinder head bolts (4). Remove the engine
air deflector (5), cylinder baffle (6) and
head baffles (7). Remove the generator ad-
justing bracket (8).
Remove the spark plug (9), wire (10),
cylinder head (11) and gasket (12) from
springs (17) and remove the valve retainer
locks (15). Remove the valve retainers (16),
springs, spring retainers (18), and valves
(19).
To remove valve guides (20), drive them
down into the tappet chamber and carefully
break them off. Drive the balance of the
guides down and remove. IAUT/0/1Be
very careful not to damage the cylinder
block when breaking off the guides. The
exhaust valve seat (21) can be removed by
using a seat removing tool, refer to inset
B. Remove tappet adjusting screws {22)if
they are to be replaced.
Inspection
Remove all carbon from head, bore and valve guides. Blow out with compressed air. Refer
to Pages M-6 and M-7 for inspection of valves, seats.
Inspect the tappet adjusting screws for wear and replace if worn.
Check the cylinder head for warpage by using a face plate. The head should make contact at
all gasket surfaces. If it doesn't, replace cylinder head.
Installation
Drive new valve guides (20) in place un-
til they are flush with the bottom of the
valve chamber. The guides must be reamed
to size after installing, refer to Specifica-
tion Section for proper dimension. Install
exhaust seat (21) by cooling it in dry ice
and drive into the block.
Install valves (19), spring retainers (18)
springs (17) and valve retainers (16). Com-
press valve springs and install locks (15).
Install new head gasket (12) after soaking
it in oil. Install head (11) baffles (6) and
(7), air deflector (5) generator bracket (8)
and head bolts (4).
Tighten head bolts to proper torque. Back
of the bolts and retorque to proper torque.
Refer to Specifications Section.
Clean, regap and install spark plug (9).
Adjust tappets, refer to tappet adjustment.
Install the breather assembly in the follow-
ing order, stud (24) gasket (25), plate (26)
with small drilled hole down, reed valve
(27) and baffle (28),
Clean and lubricate filter (29)with engine
oil and install. Install outer gasket (30),
seal (31), cover (32) washer (33), and nut
(34). Tighten the nut only enough to make a
good seal.
Install baffle (2) carburetor (1) and gas-
ket. Connect throttle and choke connections.
Connect governor linkage and fuel line. Open
fuel tank shutoff.
TAPPET ADJUSTMENTS
Hand crank the engine to set piston at the DCmark of the compres-
sion stroke, inset C. Outward pressure will be felt when the thumb is
placed over the spark plug opening when the piston is coming up on
the compression stroke. A lighter pressure is also felt on the exhaust
stroke. DO NOT CONFUSE THE TWO, Refer to Specification Section
for proper tappet clearance. Using a feeler gauge, set tappets ,inset D.
M-4

Removal, Inspection and Installation
,------------, ---------
1NSET
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--·········~-.
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M-5

INSPECTION OP THE VALVES,OUIDES AND SPRINGS
Valve springs should be checked for flat
squared ends
t
broken or cracked coils and
correct spring p:ressure. Use a Valve Spring
Tension Tester. Refer to "Specification!!
Section.
Valve guides can be checked for wear by
using a bore gauge and micrometer, Figure
M-4.
BOREGAUGE
Figure
M-4
The valve guide should be checked at the
top, middle and bottom of the bore for wear,
Figure M-5.
EXPANDABLE
BORE
GAUGE
CHECKWEAR OF VALVE :;:_
GUIDE AT THREE
POINTS ATLEAST
Figure M-5
The inside diameter wear limits of the
valve guide should not exceed the specifica-
tion given in the "Specification" Section, at
any point along the bore ofthe guide, Replace
guide
if
it does. Check the new valve guides
after installation to make sure that the bore
is not less than the inside diameter given in
the "Specification" Section. Using an Arbor
equal to the inside diameter of the valve
guide will keep the guide from collapsing
when pressed in place.
Clean the valves with a power driven fine
wire brush being very careful not to scratch
the valve stems. Reference is made to the
different parts of the valve, Figure M-6.
M-6
MARGIN
TIP
Figure M-6
Inspect the valves for excessive wear or
necked sterns, Figure
M-7.
This can be
caused by lack of lubrication,plugged or dirty
cooling fins or operating the engine under
continous overload at excessive engine RPM.
If these conditions exist the valves and guides
should be replaced.
VALVESTEMNECKED
Figure
M-7
Inspect the valves for deep grooves in the
face, Figure M-8. This can be caused by
abrasives entering the engine through the
intake system or not servicing the air clean-
er regularly. A leaking breather gasket can
also cause this condition. If grinding the
valve face will not correct this condition,
replace the valves,
ROOVE
IN
VALVE FACE
Figure M-8
Inspect the valve face andstern for rust or
pitting, Figure M-9. Rustorpittingcanusu-
ally be removed by grinding the valve face.
If rust or pitting on the valve stem exist the
valve should
be
replaced.These conditions
can
be
caused by using poor quality ·ne
oil or fuel that doesn't meet the speci ca-
tion given in the Operator's Manual. Rust
could
be
caused
by
improper storing of the
engine.
RUSTOR PITTING
Figu:reM-9

INSPECTION OF THE VALVES,GUIDES AND SPRINGS (Contd)
Heavy carbon or varnish deposits on the
valve, Figure M-10, should be removed be-
fore valves are ground. This condition is
usually caused by worn piston rings and
bore which allow too much oil to reach the
combustion chamber. This condition could
also be caused by worn valve guides. These
conditions should be corrected or the same
trouble with the valves will happen again.
Figure M-10
Inspect the valve head for dishing and the
valve face for deep burned spots, Figure
M-11. These conditions can't be corrected
by grinding the valves. The valves should be
replaced. These conditions are usually cau-
sed by running the engine under excessive
load, at high engine temperatures.
~RNED
~~CE
Figure M-11
Valves with worn lock grooves or the
stem is worn or dished beyond the chamfer
must be replaced, Figure M-12.
WORN RETAINER GROOVE
WORN STEM TIP
Figure M-12
The checking of the valve stem diameter
can best be done with a good accurate mi-
crometer Figure M-13,
Figure M-13
The valve stem should not vary more
than the wear limits given in the "Specifica-
tion" Section at any point on the valve stem,
If this condition exists, the valves must be
replaced.
The checking of the valve face :runout
should be done after the valves have been
ground. A Vee block type holder with a dial
indicator, Figure M-14, should be used to
check the valve face runout, The valve face
should not vary more than the specification
given in the "Specification" Section, The
valve stem runout can also be checked with
this Vee block and dial indicator.
CHECKING VALVE
FACE RUNOUT
Figure M-14
IIINJRTAIIT
Small amounts ofveryfinepitting, Figure
M-15, may be found on the surfaces of the
valve faces and seats after the valves are
cleaned.
Figure M-15
These are normal and will not affect en-
gine performance, This fine pitting is caused
by a normal oxidation process and can hap-
pen on any engine during the run-in-period,
It is not necessary to grind valves or seats
if this fine pitting is found as the pitting will
generally :reoccur after the engine is run for
a few hours.
M-7

REFACING INTAKE AND EXHAUST VALVES
Before refacing the valves they should be
wire brushed, cleaned and inspected, Refer
to the ti Specification" Section for the correct
valve face grinding angle. Set the refacing
machine protractor at this angle. Be sure
the chuck of the machine is clean before
installing valve. Dress the grinding wheel
before starting to each valve. Take
only light cuts as the valve is refaced and
the last cut must be very fine so the valve
face will have a polished finish.
/#/IO/ITAIITReplace any valve that
after grinding has a thin edge or margin,
Figure M-16. If the margin on the ground
valve is less than half the margin on a new
valve, replace the valve.
VALVE FACE
GRINDING ANGLE
-ll-MARGIN
Figure M-16
I
CHAMFER
The tip end of the valve should be checked
for roughness or wear. Usually this can be
removed with some very light cuts against
the side ofthe grinding wheel and will square
up the end. Never grind the chamfer off the
valve stem end. Any excessive grinding
should not be done to the stem end. Replace
the valve.
Before installing new valves a fine finish
grinding should be done to each new valve.
Check the valve face and valve stem runout
before installing (Refer to Page M-9).
The valve face and seat contact location
should be checked. Place valve bluing (Prus-
sion Blue) onthe face ofthe valve. Install the
valve in the head and rotate the valve on its
seat. Remove the valve and inspect the con-
tact area on the valve face. The bluing will
have been removed from the valve face even-
ly at the top edge ofthe contact area, Figure
M-17. This is due to the fact that the valve
face and seat are ground with 1"INTERFER-
ENCE ANGLE.Refer to "Specification" Sec-
tion.
CORRECT
CONTACT
LOCATION
INCORRECT
CONTACT
LOCATION
BLUING
Figure M-17
CONTACT
AREA
WIDTH
When the top edge of the contact area is
too high or low on the valve face, the seat
contact area must be moved. This is done
by using the narrowing stones (Refer to Page
M-9). The contact area width should never
exceed the dimension given in the Specifica-
tion Section. CAUTION
DO NOT USE BLUINGTOCHECKVALVE
SEAT AND VALVE FACE RUN-OUT. The
valve face could be contacting the seat at
only a few points, but the bluing would still
be rubbed off by the high points and make it
appear as though you had solid contact all
around. The only thing bluingwm indicate is
the location on the valve face where the seat
is contacting -- no morel
M-8