Hercules G4800 series Engine

Tools: Torque wrench

1. Spot vibration damper at proper degree mark before TDC No. 1 compression.
2. Install new O-ring seal on pump attaching flange.
3. Remove timing hole cover; rotate pump until timing marks register.
4. Install pump to drive gear, aligning keyway.
5. Install lockwasher and nuts on attaching studs.
6. Install flat washer and nut on pump shaft; torque to 150 ft lbs.
7. Recheck timing.
8. Install drive gear cover plate and timing hole cover.

⚠ An improperly installed or operating ignition system may lead to improper engine operation which consequently could pose the threat of personal injury to operators or other nearby personnel.

Tools: timing light, clear silicone grease such as Dow Corning DC-200

1. Set engine so No. 1 cylinder is at ignition firing point 20° BTDC.
2. Remove oil fill cap and verify #2 Exh. rocker is in down position; if not, rotate engine 180°.
3. Determine rotation of Altronic V unit (CW).
4. Rotate drive coupling until red mark on shaft lines up with proper mark on housing.
5. Mount unit to engine keeping red lines together as close as possible.
6. If lines cannot meet, remove four back cover screws, pull back cover, rotate driven gear until marks line up.
7. Reinstall cover engaging gears; securely tighten four fastening screws.
8. Check final timing using timing light at idle speed; rotate unit CW to retard, CCW to advance.
9. Mount ignition coils as close as possible to engine spark plugs; use only Altronic coils.
10. Use clear silicone grease on all high tension connections and boots.

⚠ Deviation from these installation instructions may lead to improper engine operation which could cause personal injury to operators or other nearby personnel.

Tools: 24 AWG conductor .032 inch insulation wire Altronic part no. 603 102

1. Mount 581 603 unit so connections are protected from weather; maximum temperature exposure not exceeding 150°F (65°C).
2. Use 24 AWG conductor, .032 inch insulation wire (Altronic part no. 603 102) for all connections.
3. Keep leads from Altronic V unit to timing box under 25 feet (7.6m).
4. Keep leads from timing box to switch or relay under 24 inches (610mm).
5. Keep timing unit wiring separate from all other wiring; do not bundle.
6. Ground case of 581 603 box to engine ground; do not connect directly to ignition system common coil ground.
7. Consult application chart for V terminal; leave open-circuited or grounded per chart.
8. For manual adjustable timing, install Altronic V with timing marks lined up and engine set 7 degrees advanced from most advanced desired timing; use timing adjustment screw.
9. For two preset timing points, wire terminals A and B to switch or relay contacts; set advanced timing with contacts closed, then open contacts and set retarded timing with adjustment screw.

1. Clean oil pan thoroughly; remove old gaskets from oil pan and cylinder block.
2. Inspect inside of engine for loose nuts, screws, cotter pins, lock wires; tighten or replace.
3. Cement new oil pan gasket to oil pan.
4. Draw up all screws evenly and progressively.
5. Install drain plugs.
6. Install starter motor and connect cables.
7. Refill with oil to correct level.
8. Reinstall bayonet gauge assembly.

1. Attach pump to bearing caps and securely bolt in place.
2. Assemble suction and pressure lines to pump and securely fasten to engine with brackets.
3. Install oil pan.
4. Fill crankcase to proper level with correct grade of lubricating oil.

1. Loosen fuel filter vent cocks.
2. Allow fuel from tank to flow into filter until solid fuel comes from vent cocks.
3. Close vent cocks.
4. Crank engine if necessary to permit priming pump to draw fuel.

⚠ Do not use any sealants, aluminum paint etc., on this gasket.

⚠ Do not re-torque hot. If any seepage occurs, re-torque cold only.

1. Ensure gasket surfaces are clean; install new cylinder head gasket.
2. Step torque head cold: Step 1 110 ft. lbs.; Step 2 130 ft. lbs.; Step 3 157 ft. lbs.; Step 4 re-torque 157 ft. lbs.
3. Do not use sealants or aluminum paint on gasket.
4. Do not re-torque hot; if seepage occurs, re-torque cold only.

1. Fill fuel tank with suitable fuel oil; bleed air from lines and filter.
2. Fill cooling system with clean water or antifreeze.
3. Fill crankcase to full mark with lubricating oil.
4. Turn engine over three or four times with starter.
5. Start engine by operating starting button.
6. Allow engine to run several minutes before applying load.

1. Install new bellhousing gasket to cylinder block.
2. Check mounting dowels tight and in good condition.
3. Install bellhousing and torque nuts in sequence.
4. Install rear motor support screws.
5. Install flywheel.
6. Install clutch or torque converter.

1. Assemble connecting rod and piston; insert retaining rings.
2. Inspect crankshaft and polish if rough.
3. Install piston rings.
4. Turn crankshaft to correct position.
5. Apply lubricating oil to bores, pistons, rings, pin.
6. Space piston rings so no two slots align.
7. Compress rings and push piston into bore.
8. Install bearing shells, cap, tighten cap screws, check side movement.

Tools: Dial indicator

1. Reverse removal instructions.
2. Use indicator to check pilot bore concentricity.
3. Attach indicator to check flywheel face.
4. Install starting motor.
5. Install clutch and transmission.

1. Remove clutch or power take-off mechanism.
2. Remove flywheel.
3. Support rear of crankcase.
4. Remove rear motor support screws.
5. Remove bellhousing attaching stud nuts.
6. Pull bellhousing away from engine.