Transcript Lab #7 Procedures

Model 12 Intek Horizontal OHV
Crankcase Disassembly and
Assembly
Lab #7
Model 12 Intek Horizontal OHV
Stripping Engine to Bare
Block
Lab #7A
Customer Education
Required Tools
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7, 8, 10, 24 mm socket
½” breaker bar
Ratchet wrench
Extension
5/8” Combination wrench
1/8” Allen wrench
Inch pound torque wrench
Foot pound torque wrench
Standard screwdriver
Pliers
Strap wrench
Feeler gauge set
.010 long flat gauge (Or 2
microfiche cards)
Spark tester
Optional T-30 Torx bit
Customer Education
Systematic Approach
• Technicians need to take their time when
disassembling an engine. This is not a race!
• Listen for instruction when to remove the
next piece. Do not work ahead!
• Lay assemblies in order as they were
removed.
• Put fasteners with removed assemblies, or
loosely back in bolt holes.
Customer Education
Let’s Begin
• Close fuel shut-off
valve
• Disconnect spark
plug ignition lead
from spark plug
• Move throttle to
stop position
Customer Education
Remove Carburetor
Per Lab#2 Instructions
• Use written instructions
Customer Education
Remove Fuel Tank
Per Lab#4 Instructions
• Use written instructions
Customer Education
Remove Cylinder Head
Assembly
Per Lab#5 Instructions
• Use written instructions
Customer Education
Remove Flywheel and Ignition
Armature
Per Lab#6 Instructions
• Use written instructions
Customer Education
Bring Piston to TDC
Compression
• Valve tappets will be
at the bottom of
their travel
Model 12 Intek Horizontal OHV
Crankcase Disassembly and
Assembly
Lab #7B
Customer Education
Bring Piston to TDC
Compression
• Valve tappets will be
at the bottom of
their travel
Customer Education
Remove Crankcase Cover
• Use 10 mm socket
• Case cover gasket
will probably be
damaged during
removal
• Do not pry off cover
– It will come off by
hand
Customer Education
Inspect Camshaft Gear
• Timing marks of cam
gear and crankshaft
gear should align
• Draw diagram
Customer Education
Remove Cam Gear and
Tappets
• Tilt block
• Remove cam gear
by hand
• Remove tappets by
hand
Customer Education
Remove Piston/Connecting
Rod Assembly
• Use 8 mm socket
• Rod cap can only fit on
one way
• Long screw is closest to
piston
• Dipper held on by small
screw
• Piston and rod have
orientation mark
Customer Education
Remove Crankshaft
• Pull out crankshaft
by hand
• Use caution not to
scratch bearing
surface in case
Customer Education
Discuss Crankcase
• Wipe up any
remaining oil in case
• Clean all gasket
surfaces with gasket
scrapper
Customer Education
Reassembly
• Technicians need to take their time when
reassembling an engine. This is not a race!
• Listen for instruction when to add the next
piece. Do not work ahead!
• Fasteners will need the proper torque values.
• Special procedures will be explained.
Customer Education
Install Crankshaft
• Install crankshaft by
hand into cylinder
block
• Be careful not to
damage bearing
• Position crankpin to
7 o-clock
Customer Education
Install Piston Assembly
• Use ring compressor
• Coat piston assembly
and cylinder bore with
oil
• Check orientation marks
• DO NOT hammer or
force piston assembly
into block!
Customer Education
Attach Rod to Crankshaft
• Rod cap only goes on one
way
• Long screw goes closest to
piston
• Dipper attaches with short
screw
• Use 8 mm socket
• Torque fasteners to 100 in.
lbs
• Rotate crankshaft and
check for free movement
Customer Education
Install Tappets and Cam Gear
• Install tappets first
• Align timing marks
of cam gear and
crankshaft gear
Customer Education
Install Case Cover
• New gasket?
• Lubricate governor
gears
• Insure governor lever is
laying flat
• May need to rotate
crankshaft for governor
gears to mesh
• Use 10 mm socket
• Torque fasteners in
sequence to 110 in. lbs
Customer Education
Install Cylinder Head
Assembly
Per Lab#5 Instructions
• Use written instructions
Customer Education
Install Flywheel and Ignition
Armature
Per Lab#6 Instructions
• Use written instructions
Customer Education
Install Carburetor
Per Lab#2 Instructions
• Use written instructions
Customer Education
Install Fuel Tank
Per Lab#4 Instructions
• Use written instructions
Customer Education
Test Ignition System
• Use spark tester
19368
• Look for a spark in
the run position
• Look for no spark in
the stop position
Customer Education
Install Spark Plug
• Use 5/8" spark plug
socket
• Torque to 180 in. lbs
• Attach ignition lead
Customer Education
Success!
• Do you have any
extra parts?
• Do you have any
questions?