ADVANCE PRODUCT SERVICE INFORMATION SUBJECT:
NEW 700 SERIES™ DIRECT OVERHEAD VALVE (DOV™) ENGINE
No:
#54
DATE:
2/14/07
MODEL:
100600
Briggs & Stratton has recently introduced the new 700 Series™ Direct Overhead Valve (DOV™) engine family, designed with a unique lever arm valve actuating system. Patented by Briggs & Stratton, the benefit of the new lever arm concept reduces noise, vibration, and weight. The 700 Series™ engine features a 1.6 qt. (1.5 L) plastic fuel tank, a mechanical governor system, splash lubrication, and a 2-year consumer/90-day commercial limited warranty. Standard troubleshooting and failure analysis methods apply. The attached procedures and specifications are PRELIMINARY and subject to change. This APSI also provides a preview of a new approach to service and repair information that we will be implementing as part of a long-term publications improvement program. We hope you’ll find this pictorial format more informative and easier to use.
BRIGGS AND STRATTON CORPORATION Distribution Sales & Customer Support
700 Series (Model 100600)
Direct Overhead Valve (DOV) Engine Advance Product Service Information
Table of Contents SAFETY
Page 1
OVERVIEW
2
EXPLODED VIEW with Quick References
4
Partial List of
10
GENUINE PARTS and TOOLS
PROCEDURES
11
ADJUSTMENTS
15
MAINTENANCE
18
WARNING
Review the following before performing any service on the engine.
The Safety Alert Symbol is used to identify safety information about hazards that can result in personal injury or death. Wear eye protection when servicing engine.
Toxic Fumes
• Start and run engine outdoors, not in an enclosed area, even if doors and windows are open.
Fire
• The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. • Work in a well-ventilated area, away from sparks, open flames, pilot lights, heat, and other ignition sources.
Explosion
• Gasoline, it’s vapors and other gaseous vapors are extremely flammable and explosive.
Fire
• Disconnect the spark plug wire from the spark plug, and disconnect the battery at the negative terminal (electric starter engines ) to prevent unintentional sparking. Unintentional sparking can result in fire or electric shock. Unintentional start-up can result in entanglement, traumatic amputation or laceration.
Shock
• When testing for spark: Use approved Spark Plug Tester (Page 10). Do not check for spark with spark plug removed.
Hot Surface
• Allow muffler, engine cylinder and fins to cool before touching.
Shatter
• Do not strike the flywheel with a hammer or hard object because the flywheel may later shatter during operation. Use approved Flywheel Strap Wrench and Puller (Page 10). Do not tamper with governor spring, links or other parts to increase engine speed.
Hazardous Chemical
• Fuel stabilizer is a hazardous chemical. (See product label for safety information).
Moving Parts
1
OVERVIEW Direct Overhead Valve (DOV) Engine A Readystart™ Carburetor B Splash Lubrication C Polymer Timing Gear D Single Lobe Cam Gear E Mechanical Compression Release F Lever Arms G Patented Valve Train Design H Valve Clearance Adjusters I Readystart™ Thermostat (Automatic Choke) J Flex-head Valves K Iron Plated Piston L Readystart™ Armature
L K J
I
A
H B C
G D
2
E
F
BLOWER HOUSING, FUEL TANK, OIL A
B
C
D
E
8 mm
8 mm
12 mm
10 mm
F
A
3/8" Drive
30 lb-in (3.5 Nm) 85 lb-in (10 Nm)
12 lb-in (1.5 Nm)
145 lb-in (16 Nm)
B*
85 lb-in (10 Nm)
NOTE: If nut (B * ) does not loosen from stud (C), tighten the nut until the stud is secure, then unscrew nut (B).
WARNING C DISCONNECT:
Page 12 NEG
D
N E
(—)
G N G E S O P
Page 11
SUGGESTION Use PLASTIC BAGS and a PERMANENT MARKER - to organize components being removed.
F
Page 12 E
3
AIR CLEANER, CARBURETOR A
B
C
D
E
10 mm
8 mm
8 mm
17 mm
8 mm
NOTES:
•
STOP SWITCH (1) - used on rewind start versions. • PARTS (2) serviced as an assembly only. • Optional (3) (*) KIT, Carburetor Overhaul (See Page 10)
T25 Torx™ 17.5 lb-in (2 Nm)
30 lb-in (3 Nm)
Tighten securely. 40 lb-in (4.5 Nm)
85 lb-in (10 N m)
Page 17
3
*
Page 17
A
V
2
*
Page 18
1
*
Page 15
*
*
*
E
B
C D
* V
V
4
ARMATURE, ALTERNATOR, BRAKE, STARTER A
B
C
D
E
12 mm
12 mm
8 mm
13 mm
8 mm
40 lb-in (4.5 Nm)
47 lb-in (5.5 Nm)
85 lb-in (10 Nm)
Page 15 85 lb-in (10 Nm)
A
B Page 12
D
13 mm 85 lb-in (10 Nm)
60 lb-in (8 Nm)
NOTE:
•
Ground Wire is attached to a CLIP (1) under flywheel guard.
Page 12 Page 15 A
B
C
1
D
REWIND START
E ELECTRIC START
5
BREATHER, FLYWHEEL, MUFFLER C
D
E
F
G
24 mm
8 mm
8 mm
7/32"
8 mm
13 mm
60 lb-ft (81 Nm)
40 lb-in (4.5 Nm)
55 lb-in (6 Nm)
45 lb-in (5 Nm)
A
B KEY
23 lb-in (2.5 Nm)
A
Page 13 85 lb-in (10 Nm)
ELECTRIC START
H
REWIND START
C
D Lock TAB B
REWIND START ONLY
E
H G
H G
REWIND or ELECTRIC START
6
F
F
CYLINDER HEAD ASSEMBLY A
B
5/8"
10 mm
C
D
8 mm
10 mm
NOTE:
•
25 lb-in (3 Nm)
CUT AWAY VIEW (1) - showing Lever Arms installed.
55 lb-in (6 Nm)
2.5 mm Allen
210 lb-in (24 Nm)
Page 19 A D
Page 16 C 1
Page 12
B
SUGGESTION Use PLASTIC BAGS and a PERMANENT MARKER - to organize components being removed.
7
8
ENGINE SUMP, CAM GEAR, GOVERNOR GEAR
2
2
A
NOTES:
8 mm
110 lb-in (12 Nm)
•
Important: To protect Crankshaft Threads, reinstall Flywheel Nut (1).
• •
TORQUE SEQUENCE (2)
Pry off Governor Gear (4) with screw driver. Replace with new governor gear.
• • •
Oil Slinger Assembly (5) (not serviceable)
• •
3
CUT AWAY VIEW - Retaining Rib (3) in governor gear.
•
4
6
7
1
Cam Gear (6)
5
A
When assembling Cam Gear align marks as shown (7). Governor Crank (8) Install Governor Crank as shown (9).
9
7 6
8 4 5 3
1
8
PISTON ASSEMBLY, CRANKSHAFT 8 mm
A
B
97.5 lb-in (11 Nm)
A
B
Page 14
9
Partial List of:
GENUINE PARTS
Partial List of:
GENUINE TOOLS
Air Cleaner PART #
DESCRIPTION
PART #
DESCRIPTION
793676
Pre-Cleaner (foam)
792038
Cartridge
5056 19433 19069 19070 19400 19374
Oil Evacuator Pump Flywheel Strap Wrench Flywheel Puller Piston Ring Compressor Spark Testor Spark Plug Wrench
Spark Plug Used on Types: 692051
0015, 0100, 0121
292720
0110, 0111, 0112, 0115, 0116, 0118, 0119, 0122, 0123
Carburetor 793493
Assembly, Carburetor, READYSTART™ (with standard Main Jet)
793622
KIT, Carburetor Overhaul
Gasket Sets
10
793624
SET, Valve Gasket (Includes items with [ * ] below.)
793623
SET, Engine Gasket (Includes all items below.) *Seal, Valve *Gasket, Cylinder Head *Gasket, Intake *Gasket, Exhaust *Gasket, Rocker Cover Seal, Oil (Megneto side) Gasket, Breather Gasket, Crankcase (.015˝ thick) Seal, Oil (PTO side) Gasket, Air Cleaner
PROCEDURES WARNING
A
DISCONNECT: B
NEG N E
(—)
CUT AWAY VIEW
G N G E S O P
WARNING
IS
CHECKING FUEL FLOW (Steps 1 thru 6)
C
Note: The fuel tank has a 150-micron fuel filter (A) molded into fuel outlet. 1. Make sure fuel cap (B) is installed tightly. D
DRAINING FUEL TANK (Steps 2 thru 4) 2. With a pliers loosen and slide hose clamp (C) away from the carburetor. 3. Clamp fuel line (D) an inch from the carburetor then turn and pull until line releases.
SERVICE TOOL TIP Place a piece of fuel line over each jaw. F
4. Hold the line over a fuel can and release the clamp (E). 5. Fuel flow should be as wide as the inside diameter of the fuel line. If it isn’t remove fuel cap and then check flow. A cap that doesn’t vent properly [(breather holes (F)], will not allow fuel to flow from the tank to the carburetor.
E
6. If needed, clean or replace appropriate parts, fuel line, cap, or tank.
11
PROCEDURES
DRAINING OIL
ENGINE BRAKE
(3 OPTIONS)
•
Clean Drain Plug before removing. Tools: wire brush and rag.
•
Level Engine while draining.
Important: To remove and install engine brake fasteners (A), first compress bracket to release tension. A
145 lb-in (16 Nm)
3/8" Drive
RECYCLE
• •
Clean dip stick cap before removing. Level engine while draining.
•
Oil Evacuator Pump Part Number 5056
REMOVING RETAINER LOCKS 1. Place rag (A) in the combustion chamber, to hold valve in place while compressing spring (B).
IN
2. Orient opening (C) in retainer toward you.
IN
3. Press down on retainer (D) and 4. Push away to release. Note: Keep assembly parts together (E). E
RECYCLE
C
•
Clean dip stick cap before removing.
•
Keep air cleaner UP when tipping.
USED OIL
UP A D B C RECYCLE
12
PROCEDURES
CHECKING THE IGNITION
1. REMOVE FLYWHEEL NUT (C) with strap (A), breaker bar (D), and 24 mm socket (E).
1. Connect spark plug lead (A) to the long terminal (B) on tester, and ground tester to engine with alligator clip (C). 2. Use the rewind or electric starter to crank the engine. The ignition is functioning if a spark (D) jumps the gap.
D E
Spark Tester
C
Part Number: 19400 A A
D
B Flywheel Puller Part Number 19069 C
2. To PULL FLYWHEEL OFF:
• • FLYWHEEL
Tighten puller bolts (A) equally until secure. Tighten puller nuts (B) equally until flywheel loosens.
3/8˝
7/16˝
Removal A WARNING
B
DO NOT DROP or STRIKE flywheel with a hard object or a metal tool as this may cause flywheel to shatter in operation. Always use approved flywheel removal tools.
Flywheel Strap Wrench (A) Part Number 19433
Installation Important: Keep strap below fins on flywheel. See Step 1. 60 lb-ft (80 Nm)
A
13
PROCEDURES
PISTON INSTALLATION
4. Space ring gaps (F) as shown before installing piston in compressor.
1. Install rings on piston by hand :
• OIL RING (A) • WIPER RING (B) - Note: The Wiper Ring has •
an identifying DOT on top of the ring. Always install ring with dot facing top of piston. COMPRESSION RING (C)
5. Insert piston in compressor (G) and tighten with a 1/4˝ DRIVE (H). 6. Loosen compressor so there is slight resistence. 7. Rotate and lift piston out 1/8˝ (I). This will help line it up with cylinder when installing.
F
C
H
G
A
B
F
F TABLE
2. Clean and lubricate parts (D). 3. Install crankshaft and postion as shown (E).
I 1/8˝
D
* 8. Place piston assembly with compressed rings into cylinder with notch (J) on piston facing down (flywheel side of engine).
E
Note: CUT AWAY VIEW (K) of cylinder.
*
9. Place shop rag (L) over ring compressor to protect hands. Push piston into cylinder with a smooth and quick action.
*
* * * J
* * Piston Ring Compressor Part Number 19070
14
K
L
ADJUSTMENTS ARMATURE ADJUSTMENT
WARNING
1. 2. 3. 4.
Disconnect spark plug boot (A) from plug. Loosen screw (B) and stud (C) clockwise. Slide armature (D) back. Tighten stud (C) counterclockwise to secure armature. 5. Line up flywheel magnets (E) with armature. A
DISCONNECT: NEG N E
(—)
G N G E S O P
C B D E
THROTTLE CABLE ADJUSTMENT 1. Place throttle control lever (A) in positions as shown. 2. Make measurements: (B) 2-1/8" (54 mm) minimum, (C) 1-3/8" (35 mm) minimum travel. 3. If not within the minimum, loosen screw (D). 4. Pull cable (E). 5. Tighten screw (D). Torque as shown.
6. Insert spacing tool (F): .15 -.35 mm (.006 -.014˝) 7. Loosen stud (C) allowing armature to contact magnets (E). F .15 (.0 - .35 06 m - .0 m. 14 ") C
A
E SLOW
8. Tighten fasteners (B)(C) and torque as shown. 9. Remove spacer (F) while rotating flywheel.
STOP
25 lb-in (2.8 Nm)
B C
A
B FAST STOP
E
D
8 mm 85 lb-in (10 Nm)
C
F
15
ADJUSTMENTS
VALVE CLEARANCE ADJUSTMENT • • • • • • • • • • •
VALVE CLEARANCE (VC) COLD
GAUGE, VALVE CLEARANCE (A)
M
L
SCREW, LEVER ARM ADJUSTING (B)
K
NUT, ADJUSTING SCREW (C)
J
ARM, LEVER (D) CAP, VALVE (E) RETAINER, VALVE SPRING (F) SPRING, VALVE (G) VALVE (H) PISTON (I) TOP DEAD CENTER (TDC) A
E
Valve Clearance (VC) INTAKE
EXHAUST
.10 - .15 mm (.004 - .006 in.)
.36 - .41 mm (.014 - .016 in.)
B
VC
8 mm
1/4˝
A C
70 lb-in (8 Nm)
BC D E F G
H
TDC
I
1. Engine should be COLD. 2. Insert a pencil (J) or a narrow screw driver into the spark plug hole (K) and touch the piston. This will be used to gauge the piston’s range of motion. Note: CUT AWAY VIEW with piston shown (L). 3. Turn the flywheel (M) clockwise past Top Dead Center (TDC) on the compression stroke until the piston has moved down 1/4 in. (6.4 mm).
16
2.5 mm Allen
4. Check the Valve Clearance (VC) by placing the correct feeler gauge (A) between the lever arm adjusting screw (B) and the valve cap (E) . 5. Loosen the adjusting screw nut (C) with a 8 mm wrench. 6. Adjust the clearances as required by turning the adjusting screw (B). Use allen wrench 2.5 mm. 7. Once the adjustments are complete, tighten the adjusting screw nut (C). Torque: 70 in. lb. (8 Nm).
ADJUSTMENTS
CHOKE LEVER GAP ADJUSTMENT
STATIC GOVERNOR ADJUSTMENT
• • • • •
1. Loosen bolt (A) until control lever (B) moves freely from governor crank (C).
CHOKE LEVER GAP (A) CHOKE LEVER (B) CHOKE LINK (C) ADJUSTING LOOP (D) THERMOSTAT (E)
2. Move throttle linkage (D) until the throttle plate lever (E) is wide OPEN. COLD
B
NOTE: Choke plate (F) closes when opening throttle plate lever.
C
CLOSED
10 mm OPEN
E
A
.000 - .060˝(1/16˝) (.000 - 1.52 mm)
E D
B
C
D
F
B C F A 1. Engine should be COLD. 2. Using pliers, bend adjusting loop (D) on choke link (C) to adjust the choke lever gap (A). When properly adjusted, choke plate (F) will be fully closed. 3. Reshape wire keeping it parallel (G) after adjusting loop. D
3. Hold the linkage (D) and the governor crank (C) (using a 4 mm wrench turning it clockwise) then tighten the governor lever clamp bolt (A). Torque: 30 lb-in (3 Nm). 10 mm
4 mm
D
C
A
G
C
30 lb-in (3 Nm)
17
MAINTENANCE FUEL
WARNING
Fuels musts meet these requirements: DISCONNECT:
• Clean, fresh, unleaded gasoline. • A minimum of 87 octane / 87 AKI (90 RON). • Gasoline with up to 10% ethanol (gasohol) or up to
NEG N E
(—)
G
15% MTBE (methyl tertiary butyl ether) is acceptable.
N G E S O P
• CAUTION: Do not use unapproved gasolines, such as E85. Do not mix oil in gasoline or modify the engine to run on alternate fuels. This will damage the engine components and void the engine warranty.
Important: If tipping engine during service, keep To protect the fuel system from gum formation, mix a fuel stabilizer into the fuel. All fuel is not the same. If starting or performance problems occur, change fuel providers or change brands. This engine is certified to operate on gasoline. The emissions control system for this engine is EM (Engine Modifications).
BREATHER / AIR FILTER
UP
High Altitude At altitudes over 5,000 feet (1524 meters), a minimum 85 octane / 85 AKI (89 RON) gasoline is acceptable. To remain emissions compliant, high altitude adjustment is required. Operation without this adjustment will cause decreased performance, increased fuel consumption, and increased emissions. See an Authorized Briggs & Stratton Dealer for high altitude adjustment information.
OIL
50 32 14 -4 -22
30 20 10 0
5W30
68
Synthetic 5W30
86
40
10W30 **
104
°C SAE 30 *
°F
-10 -20 -30
* Below 40° F (4° C) the use of SAE 30 will result in hard starting.
SPARK PLUG CAUTION: Spark plugs have different heat ranges. It is important the correct spark plug is used, otherwise engine damage can occur. NOTE: In some areas, local law requires using resistor spark plugs to suppress radio frequency interference.
Inspect for Wear And Damage Replace if necessary.
** Above 80° F (27° C) the use of 10W30 may cause increased oil consumption. Check oil level more frequently. R
DO NOT use special oil additives. NOTE: The use of synthetic oils does not alter the oil change intervals.
18
MAINTENANCE
Clean with:
AIR CLEANER
• Wire Brush
Pre-cleaner (Optional)
• Sturdy Knife
• CAUTION: DO NOT USE Abrasives
1. Wash in warm soapy water (A) (liquid detergent). DO NOT use solvent, or compressed air to clean pre-cleaner. A
Check Gap Use a Spark Plug Feeler Gauge (A) to check the gap between the two electrodes. When the gap is correct, the gauge will drag slightly as you pull it through the gap. If necessary, use the bending tool (B) on the gauge to adjust the gap by gently bending the curved electrode without touching the center electrode or the porcelain (C).
2. Squeeze dry in a clean cloth (B). 3. Do not oil. B
A .020˝ (0.51 mm) B
Cartridge C
Replace cartridge if dirty. DO NOT use solvent, compressed air, or water to clean cartridge.
Installation Finger tighten then: Tighten with Wrench: 1/2 turn - when reinstalling the original plug. 1/4 turn - when installing a new plug.
5/8˝
Spark Plug Wrench Part Number: 19374
Fits 5/8˝ and 3/16˝ Hex Spark Plugs
19
BRIGGS & STRATTON CORPORATION
Distribution Sales & Customer Support Milwaukee, Wisconsin 53201
