Kohler WA 2.0 Generator Set

Tools: vacuum tester, retractable starter

1. Before running, check oil and slowly pull engine over with retractable starter to ensure nothing is binding.
2. Fill with prime water and start engine.
3. After warm up run engine at full throttle and check vacuum with a vacuum tester for leaks.
4. A vacuum of 20 to 25 lbs. at sea level should be read within 5 seconds.

⚠ Before placing rotating seal into impeller, put liquid detergent on seal to ease installation.

Tools: rubber mallet, feeler gauge

1. Replace shim(s) with same amount that was taken off.
2. Install rotating seal into backside of impeller; ensure not kinked and placed straight.
3. Turn impeller clockwise by hand until tight.
4. Using a rubber mallet, tap 1 blade clockwise to tighten impeller until resistance is observed.
5. Place volute against pump case and check clearance with a feeler gauge.
6. Clearance larger than 1.2 mm requires another shim; less than 0.4 mm requires removing a shim.
7. Remove volute.

1. Apply Loctite 587 Ultra Blue or equivalent to inlet flange screws.
2. Install inlet flange and check valve to pump cover with screws and washers.
3. Torque screws to: M8 18.5 N·m (164 in. lb.); M10 22.5 N·m (199 in. lb.).

⚠ If pump case was removed it is easier to install mechanical seal before mounting pump case to engine.

1. Using thumbs, push mechanical seal into place.
2. Drops of liquid detergent on shaft help install mechanical seal.

1. Apply Loctite 5770 High Temperature Thread Sealant or equivalent to screws.
2. Install outlet flange and rubber gasket with screws and washers.
3. Torque screws to: M8 18.5 N·m (164 in. lb.); M10 22.5 N·m (199 in. lb.).

⚠ Weep hole on backside of pump case must not be blocked; it prevents water entering engine if mechanical seal fails.

1. Apply Loctite 587 Ultra Blue or equivalent to screws.
2. Replace pump case and hold in position.
3. Secure with screws and washers.
4. Torque pump case screws to 22.0 N·m (195 in. lb.).

1. Install volute into pump cover, aligning volute tab and pump case notch.
2. Install pump cover to pump case and loosely tighten screws, ensuring O-ring is seated correctly.
3. Torque pump cover screws: M8 18.5 N·m (164 in. lb.); M10 22.5 N·m (199 in. lb.).

⚠ Impeller is heavy.

Tools: rubber mallet, screwdriver

1. Using a rubber mallet, tap 1 blade counterclockwise to loosen impeller.
2. Turn impeller counterclockwise by hand until free from crankshaft.
3. Inspect impeller for cracks and bent blades.
4. Count and remove shim(s) on crankshaft; replace same number when reassembling.
5. Pry stuck shims from impeller with a screwdriver; inspect, replace if bent or distorted.
6. Turn impeller over and remove rotating seal with a small screwdriver, prying upward.
7. Colored marks on rotating seal will face inward (towards inlet nozzle side of pump).

⚠ Check valve position is important. Observe which way check valve faces inlet flange for reassembly.

1. Remove inlet flange screws and remove inlet flange.
2. Inspect check valve for tears, cracks, or twists. Replace if necessary.

⚠ Drops of liquid detergent on shaft help remove mechanical seal, preventing sealing lip tearing.

⚠ If pump case needs to be removed to remove mechanical seal, follow Remove Pump Case directions first.

Tools: screwdriver

1. Using two screwdrivers, pry mechanical seal side to side until free.
2. Pull seal off crankshaft and inspect for cracks, burn marks and overall condition. Replace if necessary.

⚠ Outlet flange position is important. Observe which way outlet flange faces discharge chamber for reassembly.

1. Remove outlet flange screws and remove outlet flange.
2. Inspect gasket for cracks, tears or improper fit. Replace if necessary.

Tools: rubber mallet

1. Remove screws securing pump case to engine; special screws with special washers, replace with same part numbers.
2. Loosen screws holding pump case to frame; prepare to tilt engine back slightly.
3. Lift engine and pump case high enough to clear screws from frame mounts.
4. Pull pump case from engine; tap lightly with a rubber mallet if needed.
5. To remove engine for service, remove screws holding engine to engine isolation mounts.
6. Check condition of pump cover O-ring for nicks, tears and gouging.