LCT Engines - Small Engine Discount
Contents
1. 4 Crankshaft Height Dimensions Drawings do not accurately represent actual engine appearance PTO amp Mounting Configurations o o 8 E 2 56 70 2 o R 37 70 a gt d 22 5 p e A s 26 id Ze 1 ze AT 58 5 m z 5 gt 1 5 d EI Tia o N 10 61 7 9 Q 8 I a o 2 o D R u 4 ZA ok R Ei 4 5 16 24 Mounting Foot Specs 11 mm 43 m Fo En EQ Qi u am Lem 2 S 2 E E E 6 S Ka R 65 5 0 05mm 2 58 162 0 05mm 6 34 REV 040708 Copyright 2008 Liquid Combustion Technology LLC Service Manual 17 Torque Specs Item Torque N M Drain bolt 15 18 Oil sensor T oo The bolt fix wire of oil sensor Oil level cap ass 20 25 9 8 12 12 15 22 25 12 14 18 24 9 8 12 22 25 9 8 10 9 8 12 9 8 12 9 8 12 9 8 12 Nut for carburetor M6 9 8 12 REV 040708 Copyright 2008 Liquid Combustion Technology LLC Service Manual 18 Spark plug Stud A of inlet air admission Stud B of exhaust gas Pivot bolt M8 Connecting rod bolt Flange bolt Distributor M6 27 Flange bolt of cylinder head M8 55 Pivot adjusting nut for inlet exhaust valve Flange bolt for head cover The bolt for crankcase cover M6 14 Side plate M6 12 Support of governor 002. instructions provided with the equipment powered by this engine for any additional safety precautions that should be observed in conjunction with engine startup shutdown operation or protective safety gear that may be needed to operate the equipment A WARNING Do not touch hot sections of engine see muffler figure above The hot sections of the engine can cause severe burns Refueling the Engine Gasoline is extremely flammable and gasoline vapor can explode When refueling the engine take the following precautions Perform when the engine is cool Refuel outdoors in well ventilated areas The engine should not be running Make sure the engine is grounded to prevent static electrical spark Do not smoke or use cell phones when refueling Keep away from flames or sparks If spillage occurs be sure all areas are dry and vapor has dissipated prior to starting the engine REV 040708 Copyright 2008 Liquid Combustion Technology LLC Service Manual 4 General Specifications Item Specification The Horse Power rating of the engine S is the measures output of a production engine in accordance with SAE J1349 at 3600 rpm Performance may vary from one engine to another on this value due to manufacturing process variations All attempts are made to be consistent during the manufacturing process to keep performance variation to a minimum Actual power output of final application will vary based on many circu
3. 0 985mm DEE EIERE EE Camshaft Cam height Pe Camshaft O D 14 984mm SS Air gap at flywheel 0 4 0 2 REV 040708 Copyright 2008 Liquid Combustion Technology LLC Service Manual 8 Advanced Troubleshooting For Authorized LCT Technicians ne Remedy Remedy ENGINE Engine will not start or is hard to start Engine idles poorly Engine stalls easily REV 040708 Symptom and possible causes Compression too low 1 Valves out of adjustment 2 Worn valve guides or poor seating of valves 3 Mistiming valves 4 Excessively worn piston rings 5 Worn down cylinder bore 6 Poor seating of spark plug 7 Failed head gasket Plug not sparking 1 Fouled spark plug 2 Wet spark plug 3 Defective ignition coil 4 Spark plug wire damaged 5 Kill switch in OFF position 6 Ignition coil air gap is too wide 7 Ignition coil failure No fuel reaching the intake manifold 1 Clogged fuel filter or fuel line 2 Dirty gummed up carburetor 3 Fuel petcock is turned off 4 Fuel tank is empty 1 Out of adjustment tappet clearance 2 Poor seating of valves 3 Defective valve guides 4 Worn down camshaft 5 Too wide spark plug gap 6 Defective ignition coil 7 Ignition coil air gap too wide 8 Dirty gummed up carburetor 9 Stale fuel 1 Dirty gummed up carburetor 2 Fouled spark plug 3 Clogged fuel line 4 Valves out of adjustment Copyright 2008 Liquid Combustion Technology L
4. E SERVICE KIT SK208 1400 PISTON SERVICE KIT SK1500 SPARK PLUG SERVICE KIT SK208 1500 CONNECTING ROD SERVICE KIT SK208 2600 ENGINE ON OFF SWITCH SERVICE SK208 2700 LOW OIL SENSOR SERVICE KIT al 2 2 2 0 2 SK208 1600 CAMSHAFT SERVICE KIT SK5930 LOW OIL SENSOR MODULE SERVIC SK208 1700 FLYWHEEL SERVICE KIT SK208 4000 COOLING FAN SERVICE KIT 0 SK208 1800 CRANKSHAFT SERVICE KIT K208 2002 AIR FILTER ASSEMBLY SERVICE Kit S SK208 2120 PAPER FILTER SERVICE KIT S SK208 2800 THROTTLE CONTROL SERVICE KIT 12A SK208 9001 FOAM FILTER SERVICE KIT SK208 2900 GOVERNOR GEAR SERVICE KIT 1 SK208 3000 GOVERNOR ARM SERVICE KIT SK208 3100 GOVERNOR CRANK SERVICE KIT 2 2 s 2 2 2 2 RECOIL STARTER SERVICE KIT 1 1 2 3 3 3 K208 2100 49 STATE MUFFLER SERVICE KIT 13A SK208 9000 CALIFORNIA MUFFLER SERVICE Kit 1 12 13 SK208 3300 STARTER CUP SERVICE KIT 14 SK208 2200 49 STATE FUEL TANK SERVICE KIT 15 16 SK208 3400 BLOWER HOUSING SERVICE KIT SK208 3600 PTO COVER SERVICE KIT SK208 3900 SEAL SERVICE KIT 0 14A SK208 8200 CALIFORNIA TANK SERVICE KIT SK208 2220 FUEL TANK PETCOCK SERVICE KIT SK208 3700 HIGH OIL FILL TUBE SERVICE KIT SK208 2300 49 STATE FUEL TANK CAP SERVICE 3 SK208 3800 SPARK PLUG BOOT SERVICE KIT REV 040708 Copyright 2008 Liquid Combustion Technology LLC Service Manual 15 32 8 9 1 3 4 5 6 7 8 9 1 3
5. LC M a E Switch to On 5 p Service Manual 9 Noisy Engine Excessive Valve Chatter 1 Too large valve clearance eplace Replace Clean Replace Noise seems to come from crankshaft Noise seems to come from outside ofengine Engine runs poorly in high speed Defective engine nternarelectiealparts range 7 Clogged fuel line resulting in inadequate fuel supply Replace to carburetor Adjust Clean 1 carburetor gasket leak sucking air causing engine to Replace run lean Engine lacks power Ee 9 Carburetor gasket leak sucking air causing engine to Replace run lean 10 Too much engine oil Adjust 11 Air fins clogged on engine causing to overheat 12 Not enough oil in engine Adjust REV 040708 Copyright 2008 Liquid Combustion Technology LLC Service Manual 10 Dirty or heavy exhaust smoke 1 Too much engine oil in the engine 2 Worn piston rings or cylinder 3 Worn valve guides 4 Scored or scuffed cylinder wall 5 Worn valve stems 6 Defective stem seal 7 Worn oil ring side rails No sparking or poor sparking 1 Defective ignition coil 2 Defective spark plug 3 Open circuit wiring connection Spark plug soon become fouled 1 Incorrect gasoline with carbon 2 Dirty air cleaner element 3 Too cold spark plug Spark plug become fouled too 1 Worn piston rings soon 2 Worn piston or cylinder 3 Excessive clearance of valve stems in valve guides 4 Worn valve stem oil sea
6. LCT Engines Service Manual ha Safety Information CARBON MONOXIDE HAZARD Never use engine inside homes garages crawl spaces Or other partially enclosed areas Poisonous gases that can be harmful or fatal can build up in these areas Using a fan and opening doors or windows does not provide enough fresh air Engine exhaust contains carbon monoxide a poisonous gas that can be harmful or fatal You cannot see or smell this gas Use a battery powered carbon monoxide detector when running an engine If you start to feel sick dizzy or weak while using an engine shut it off and get to fresh air right away See a doctor You may have carbon monoxide poisoning ADANGER Using an engine or engine application CAN KILL YOU IN MINUTES Exhaust contains carbon monoxide a poison gas you cannot see or smell NEVER use in the home or in partly ONLY use outdoors and far from enclosed areas such as garages open windows doors and vents Avoid other engine dangers READ MANUAL BEFORE USE Safety Information When servicing this engine your safety and the safety of others should be your top priority To assist you in making informed decisions regarding safety we have provided operating procedures and other information on labels and in this manual This information warns you of potential hazards that could hurt you or others Please stay safety conscious when servicing this engine We have provided important safety informatio
7. e BOSCH Model WR6DC NOTICE Using an incorrect spark plug may cause engine damage REV 040708 Copyright 2008 Liquid Combustion Technology LLC Service Manual 6 General Troubleshooting Engine stops running 1 Has the fuel being used been purchased within the last three months and was it stored in a plastic container Remedy Replace old fuel with new fuel 2 Is the air filter dirty Remedy Replace air filter element if dirty Clean prefilter of any dirt or dust See pg 13 3 Was the engine choked Remedy When starting the engine the choke lever should be pushed left to the on position and after starting pushed right to the off position If engine still does not start move to half choke and pull twice 4 Is the spark plug corroded Remedy Remove spark plug and replace with any of the following plugs e BPR6ES NGK Torch Plug e Champion Model RN9YC some tables show RN9YCO e NGK Model BPR6ES e BOSCH Model WR6DC e Denso Model XXXX NOTICE Using an incorrect spark plug may cause engine damage 5 Has the engine run out of fuel Remedy Refuel engine ON 6 Is the fuel petcock turned to the on position TO Remedy Turn to the on position 7 ls the throttle set too low Remedy Increase the throttle REV 040708 Copyright 2008 Liquid Combustion Technology LLC Service Manual 7 Standard and Service Limit Specifications Crankshaft Crankshaft O D 3
8. eplacement 1 Remove air filter cover by disassembling 8mm screws Prefilter ver 2 Remove prefilter and clean if needed Cove 3 Replace air filter element Element 8mm Screws 4 Reinstall pre filter 5 Attach air filter cover to back with 8mm screws So Back So REV 040708 Copyright 2008 Liquid Combustion Technology LLC Service Manual 13 Maintenance Schedule Normal Operating Conditions less than 40 hrs per year EACH USE FIRST EVERY ONCE MONTH 6 MONTHS A YEAR Engine Oil Level _ Check Replace Replace Air Filter Check Clean Replace Spark Plug ea Replace Cylinder HeadFins ea Loi Leaks Che Bots Che Fuel Hose Clamps Check Spark plug gap to be set to 0 027 0 030 inches Extreme Operating Conditions greater than 40 hrs per year EAGHUSE EVER AO HOURS O Engine Oilevel ce Engine O Role Spark Plug Gylinder HeadFins Spark plug gap to be set to 0 027 0 030 inches Following proper maintenance is critical under extreme operating conditions REV 040708 Copyright 2008 Liquid Combustion Technology LLC Service Manual 14 SK208 1000 CYLINDER HEAD SERVICE KIT SK208 8300 CALIFORNIA FUEL TANK CAP SERVI SK208 1001 PUSH ROD SERVICE KIT SK208 2400 CARBURETOR SERVICE KIT SK4500 VALVE COVER SERVICE KIT SK208 2500 IGNITION COIL SERVICE KIT SK208 1300 CYLINDER SERVICE KIT SK2750 IGNITION MODUL
9. gine in well ventilated areas NEVER run engine indoors e Stop engine and remove spark plug prior to servicing e Only use parts that meet LCT specifications e Only use tools designed for the product you re servicing Always install new gaskets o rings fittings when reassembling e Always torque nuts and bolts with inner bolt or larger diameter bolt first Check torque specification chart in the back of the manual for proper values Tighten nuts and bolts diagonally to proper value e Always clean parts before reassembly in proper solvents Always lubricate any moving parts before reassembly REV 040708 Copyright 2008 Liquid Combustion Technology LLC Service Manual 3 Safety Information Exhaust Muffler Engine exhaust is dangerous because of intense heat and emission of carbon monoxide poisonous gas e The muffler becomes very hot during operation and remains hot for a while after stopping the engine Do not touch the muffler while it is hot Do not store the engine until it is cool e To prevent fire hazards and for adequate ventilation keep the engine at least 3 feet 1 meter away from building walls and other equipment during operation Do not place flammable objects close to the engine e Carbon Monoxide Hazard Exhaust gas contains carbon monoxide a poisonous gas Avoid inhalation of exhaust gas Always run the engine in a well ventilated area Never run the engine indoors Other Equipment Review the
10. l Spark plug electrodes overheat 1 Too hot spark plug or burn 2 Overheated the engine 3 Loose spark plug 4 Too lean fuel mixture Spark Plug Service Recommended spark plugs BPR6ES NGK Torch Plug Cross References e Champing plug cross reference is RN9YC some tables show RN9YCC s NGK plug cross reference is BPR6ES e BOSCH plug cross reference is WR6DC A NOTICE Using an incorrect spark plug may cause engine damage 1 When engine is cool disconnect the spark plug cap and remove any debris from the spark plug area with high pressure air 2 Remove the spark plug with a 13 16 inch spark plug wrench 3 Inspect the spark plug Replace it if the electrodes are worn or if the insulator is cracked or chipped Spark plug gap should be set to 0 027 0 030 inches 4 Install the spark plug carefully to avoid cross threading Screw in spark plug by hand until it stops turning 5 Tighten the spark plug with a 13 16 inch spark plug wrench Tighten 1 4 turn after the spark plug seats NOTICE A loose spark plug can overheat and damage the engine Over tightening the spark plug can damage the threads in the cylinder head 6 Attach the spark plug cap Ensure spark plug cap snaps into place securely REV 040708 Copyright 2008 Liquid Combustion Technology LLC Service Manual 11 Engine Oil Level Check Check the engine oil level with the engine stopped and with the engine in a level position 1 Remove either side mo
11. mstances including but not limited to the required operating speed of the application environmental conditions and proper implementation of manufacturer s maintenance schedule recommendations REV 040708 Copyright 2008 Liquid Combustion Technology LLC Service Manual 5 General Troubleshooting Engine will not start 1 Check oil level Do you have the correct amount of oil Reference Oil Fill Section pg 12 Remedy Oil should be visible and to the top 2 threads of the LOWEST oil fill spout 2 Is on off switch on 5D Remedy Turn to the on position 3 Do you have fuel in the fuel tank Remedy Add fuel 4 Is the fuel petcock turned to the on position Remedy Turn to the on position 5 Was the engine choked Remedy When starting the engine the choke lever should be pushed left to the on position and after starting pushed right to the off position If engine still does not start move to half choke and pull twice 6 Is the spark plug boot securely fastened to the spark plug Remedy Slide over spark plug and fit securely 7 Has the fuel being used been purchased within the last three months and was it stored in a plastic container Remedy Replace old fuel with new fuel 8 Is the engine flooded Remedy Remove spark plug and replace with any of the following plugs e BPR6ES NGK Torch Plug e Champion Model RN9YC some tables show RN9YCO e NGK Model BPR6ES
12. n in a variety of forms including e Safety Labels placed on the engine e Safety messages preceded by a safety alert symbol and one of three signal words DANGER WARNING or CAUTION These safety alert symbols mean A DANGER If you do not follow instructions it WILL cause you SERIOUS INJURY or DEATH A WARNING If you do not follow instructions it MAY cause you SERIOUS INJURY or DEATH A CAUTION If you do not follow instructions it may cause you SERIOUS INJURY or EQUIPMENT DAMAGE e Safety Headings such as IMPORTANT SAFETY INSTRUCTIONS e Safety Section such as ENGINE SAFETY e Instructions How to service this engine correctly and safely Thoroughly read and review this manual to know how to stay safe and get maximum benefit and enjoyment from using this engine IMPORTANT SAFETY INSTRUCTIONS Accidents occur less frequently when instructions are followed the operator is safety conscious and the engine is properly maintained Some of the most common hazards are discussed below along with the best way to protect yourself and others e Carefully read the owners manual e Always wear proper eye protection when servicing engines Follow the instructions in this manual carefully Familiarize yourself with all controls and know how to stop the engine quickly in case of an emergency e Keep children away from the engine and do not let them operate it Keep children and pets away from the area of operation e Operate this en
13. unning the engine with a low oil level can cause engine damage 4 Securely screw in the filler cap dipstick Engine Oil Recommendations Engine oil affects performance and service life Use 4 stroke automotive detergent oil SAE 10W 30 is recommended for general use Other viscosities shown in the chart may be used when the average temperature in your area warrants 20 60 80 100 F The SAE oil viscosity and service classification are in the API label on the oil container The manufacturer recommends you use API SERVICE category SJ engine oil or better 10 0 10 20 AMBIENT TEMPERATURE REV 040708 Copyright 2008 Liquid Combustion Technology LLC Service Manual 12 30 20 30 40 C Governor Adjustment 1 Loosen the governor arm pinch bolt nut and move the arm to fully open the throttle 2 Rotate the arm shaft in the same direction as far as it can go 3 Start the engine all it to reach normal operating temperature Run the engine at maximum speed by moving adjusting the throttle lever 4 Adjust the throttle lever limiting screw so the throttle lever cannot move past that point Limiting Screw Pinch Bolt Nut E r overnor Arm Throttle Assembly Valve Adjustment Specs Exhaust 007 009 Intake 005 007 1 Remove spark plug and hold thumb over hole 2 Slowly rotate engine until air flow pressure is felt 3 Position piston at top dead center TDC Air Filter R
14. unted filler cap dipstick or high oil fill dipstick and wipe it clean 2 Insert and remove the dipstick without screwing it into the filler neck Check the oil level shown on the dipstick 3 If the oil level is low fill to the edge of the oil filler hole with the recommended oil 4 Securely screw in the filler cap dipstick Running the engine with a low oil level can cause engine damage Always check the engine oil before start up Ko Fill if oil is i Fill if oil below letter is below L onthe gt Add filler cap F on the T dipstick Engine Oil Change Drain the used oil while the engine is warm Warm oil drains quickly and completely Avoid contact with hot oil 1 Place a suitable container below the engine to catch the used oil then remove the filler cap dipstick and the drain plug Max Upper 2 Allow the used oil to drain completely then reinstall the drain plug and tighten Level it securely Do not over tighten Dispose of used motor oil in a manner that is compatible with the environment We suggest you take used oil in a sealed container to your local recycling center or service station for reclamation Do not on Max Lower throw used oil in the trash pour it on the ground or pour down a drain Level 3 With the engine in a level position fill to the outer edge of the oil filler hole with the recommended oil See fill limits right NOTICE R
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