Onan 212-5 Tractor User manual

ONAN E125 V, E140V ENGINE SERVICE MANUAL

Table of Contents – Page 1 of 3

SAFETY PRECAUTIONS

GENERAL

BATTERIES

PROTECT AGAINST MOVING PARTS

FUEL SYSTEM

EXHAUST SYSTEM

EXHAUST GAS IS DEADLY

KEEP THE UNIT AND SURROUNDING AREA CLEAN

SUPPLEMENT 965-1053

PURPOSE

SERVICE MANUAL 965-0764 REVISIONS

CARBURETOR (BEGINNING SPEC E)

SECTION 1. GENERAL INFORMATION

SECTION 2. SPECIFICATIONS

SECTION 3. DIMENSIONS AND CLEARANCES

SECTION 4. ASSEMBLY TORQUES

SECTION 5. ENGINE TROUBLESHOOTING

SECTION 6. MAINTENANCE

PERIODIC MAINTENANCE SCHEDULE

ENGINE INSPECTION

AIR CLEANER AND ELEMENT WRAPPER

OIL CHANGE

OIL FILTER CHANGE

COOLING

VALVE CLEARANCE

SPARK PLUG

SECTION 7. LUBRICATION

OIL CHANGE

OIL FILTER CHANGE

OIL LEVEL CHECK

OIL PRESSURE

OIL PRESSURE RELIEF VALVE

OIL PUMP

DISASSEMBLY

ROTOR LOBE CLEARANCE

OUTER ROTOR AND PUMP BODY CLEARANCE

ROTOR AND COVER CLEARANCE

ASSEMBLY

SECTION 8. ELECTRICAL

IGNITION SYSTEM

SPARK PLUG

IGNITION COIL

IGNITION TIMING

FLYWHEEL ALTERNATORS

ALTERNATOR OUTPUT TESTS

ONAN E125 V, E140V ENGINE SERVICE MANUAL

Table of Contents – Page 2 of 3

SECTION 9. FUEL

GASOLINE CARBURETOR

DISASSEMBLY

INSPECTION/SERVICE

ASSEMBLY

CO ADJUSTMENT

IMPULSE FUEL PUMP

INSPECTION/SERVICE

FUEL PUMP REMOVAL

FUEL PUMP INSTALLATION

LPG FUEL SYSTEM

GOVERNOR ADJUSTMENTS

1. GOVERNOR LEVER ADJUSTMENT

2. IDLE SPEED ADJUSTMENTS

3. CHOKE ADJUSTMENT

4. SPEED CONTROL CABLE ADJUSTMENT

AIR CLEANER

FOAM WRAPPER ELEMENT

PAPER ELEMENT

SECTION 10. STARTING

RECOIL STARTER

110 VAC STARTER

SOLENOID SHIFT STARTER

SOLENOID

ARMATURE

COMMUTATOR AND MICA

STARTER BODY

BRUSHES

OVERRUNNING CLUTCH

SECTION 11. ENGINE BLOCK ASSEMBLY

INTRODUCTION

ENGINE DISASSEMBLY/ASSEMBLY

SUGGESTED DISASSEMBLY ORDER

SUGGESTED ASSEMBLY PROCEDURE

OPERATION

COMPRESSION TEST

FLYWHEEL

DISASSEMBLY

SERVICE/INSPECTION

ASSEMBLY

VALVE COVER

ROCKER ARM

DISASSEMBLY

INSPECTION/SERVICE

ASSEMBLY

CYLINDER HEAD

DISASSEMBLY

ASSEMBLY

ONAN E125 V, E140V ENGINE SERVICE MANUAL

Table of Contents – Page 3 of 3

SECTION 11. ENGINE BLOCK ASSEMBLY –CON’T

VALVE SYSTEM

TAPPETS

DISASSEMBLY

INSPECTION/SERVICE

VALVE STEM AND VALVE GUIDE CLEARANCE:

VALVE GUIDE REPLACEMENT:

ASSEMBLY

VALVE SPRING:

VALVE FACE AND SEAT GRINDING

INSPECTION/SERVICE

VALVE SEAT WIDTH:

VALVE SEAT CUTTING:

VALVE CLEARANCE:

OIL BASE

DISASSEMBLY

ASSEMBLY

GOVERNOR

BALANCING SHAFTS

DISASSEMBLY

OIL BASE BEARING TO SHAFT CLEARANCE:

ASSEMBLY

CRANKSHAFT AND CAMSHAFT

DISASSEMBLY

INSPECTION/SERVICE

CRANKSHAFT JOURNAL:

CAMSHAFT LOBE HEIGHT:

OIL BASE BEARING TO CAMSHAFT CLEARANCE:

ASSEMBLY

COMPRESSION RELEASE SYSTEM

PISTON, PISTON PIN, RINGS, CONNECTING ROD

DISASSEMBLY

PISTON INSPECTION

PISTON INSPECTION:

PISTON PIN HOLE INSIDE DIAMETER:

PISTON PIN OUTSIDE DIAMETER:

PISTON RING AND RING GROOVE CLEARANCE:

CONNECTING ROD SMALL END INSIDE DIAMETER:

CONNECTING ROD TO CRANKSHAFT JOURNAL OIL CLEARANCE:

CONNECTING ROD SIDE CLEARANCE:

ASSEMBLY

CYLINDER BLOCK

CLEANING

INSPECTION

REBORING THE CYLINDER

HONING CYLINDER (USING PRECISION HONES)

DEGLAZING CYLINDER BORE

BALL BEARINGS

OIL SEAL

El25V,

El40V

Elite

Series

Printed

in

U.S.A.

965-0764

Spec

A-C

6-94

Safety

Precautions

Before

operating the engine,

read the Operator's Manual and

become familiar with it and the equipment.

Safe and efficient

operatlon can be achieved only

If

the equipment

Is

properly operated and maintained.

The following symbols, found throughout this manual, alert you

to potentially dangerous conditions to the operator, service per-

sonnel, or

the

equipment.

Thls

symbol

warns of immediate hazards

whlch will result in severe personal Injury or death.

WARNING

This symbol refers to a hazard or unsafe

practice whlch can result in severe personal Injury or

death.

CAUTION)

This symbol refers to a hazard

or

unsafe

practlce whlch can result In personal Injury or product or

property damage.

Fuels, electrical equipment, batteries, exhaust gases and

moving parts present potential hazards that can result in severe

personal injury. Take care in following these recommended

procedures.

All

local, state and federal codes should be

consulted and complied with.

WARNING

Thls engine is not designed or Intended for

use

In any type of aircraft.

Use

of this engine In aircraft can

result In engine failure and cause severe personal injury or

death.

GENERAL

Provide appropriate fire extinguishers and install them in

convenient locations. Use an extinguisher rated ABC by

NFPA.

Make sure that all fasteners on the engine are secure and

accurately torqued. Keep guards in position over fans,

driving belts, etc.

If it is necessary to make adjustments while the engine is

running, use extreme caution when close to hot exhausts,

moving parts, etc.

Used engine oils have been identified by some state and

federal agencies as causing cancer or reproductive

toxicity. When checking or changing engine oil, take care

not

to

ingest, breathe the fumes, or contact used oil.

Do not work on this equipment when mentally or

physically fatigued, or after consuming any alcohol or

drug that makes the operation of equipment unsafe.

BATTERIES

Before starting work on the engine, disconnect batteries

to prevent inadvertent starting of the engine. Disconnect

negative cable first.

DO NOT SMOKE while servicing batteries. Lead acid bat-

teries give

off

a highly explosive hydrogen gas which can

be ignited by flame, electrical arcing or by smoking.

Verify battery polarity before connecting battery cables.

Connect negative cable last.

PROTECT AGAINST MOVING PARTS

Do

not wear

loose

clothing in

the

vicinity

of

moving parts,

such as PTO shafts, flywheels, blowers, couplings, fans,

belts, etc.

Keep your hands away from moving parts.

FUEL SYSTEM

DO NOT

fill

fuel tanks while engine is running.

DO NOT smoke or use an open flame in the vicinity of the

engine or

fuel

tank. Internal combustion engine fuels are

highly flammable.

Fuel line must be of steel piping, adequately secured, and

free from leaks. Piping at the engine should be approved

flexible line. Do not use copper piping for flexible lines

as

copper

will

work harden and become brittle enough to

break.

Be

sure all fuel supplies have a positive shutoff valve.

Benzene and lead, found in some gasoline, have been

identified by some state and federal agencies as causing

cancer or reproductive toxicity. When checking, draining

or adding gasoline, take care not to ingest, breathe the

fumes, or contact gasoline.

EXHAUST SYSTEM

Exhaust products of any internal combustion engine are

toxic and can cause injury, or death

if

inhaled. When

operating the engine in a confined area, make sure the

ventilation system is operating properly.

DO NOT use exhaust gases to heat a compartment.

Make sure that your exhaust system is free of leaks. Make

sure that exhaust manifolds are secure and are not

warped by bolts unevenly torqued.

EXHAUST GAS

IS

DEADLY!

Exhaust gases contain carbon monoxide, a poisonous gas that

can cause unconsciousness and death. It is an odorless and

colorless gas formed during combustion of hydrocarbon

fuels.

Symptoms of carbon monoxide poisoning are:

Dizziness

Vomiting

Headache

0

Muscular Twitching

Weakness and Sleepiness

Throbbing in Temples

If

you experience any of these symptoms, get out into fresh air

immediately, shut down the unit and do not

use

it until it has

been inspected.

The best protection against carbon monoxide inhalation is

proper installation and regular, frequent inspections of the

complete exhaust system. If you notice a change

in

the sound

or appearance of exhaust system, shut the unit down immedi-

ately and have it inspected and repaired at once by a competent

mechanic.

KEEP THE UNIT AND SURROUNDING

AREA

CLEAN

Make sure that oily rags are not

left

on or near

the

engine.

Remove all unnecessary grease and

oil

from the unit.

Accumulated grease and oil can cause overheating and

subsequent engine damage and present a potential fire

hazard.

E-8

Supplement

965-1053

Date:1-95

lnsert

with-

Title:

El

25V/E140V

Service

Manual

Number

(Date):965-0764(6-94)

PURPOSE

This Supplement transmits the revisions to the Service Manual necessary for covering

Spec

€engines. Note

that the nameplate on a Spec

E

engine will have the statement:

“This

engine meets

1995-1998

California

emissions regulations for

ULGEengines.”

To satisfy California emissions regulations Spec

E

engines have internal engine modifications and precision-

manufactured carburetors with tamper-resistant fuel mixture jets.

It

should therefore be noted that, other than

installing the optional high-altitude jet (Figure 9-3a), fuel mixture adjustments should not

be

attempted. Nor

should the carburetor be overhauled. Instead, a malfunctioning carburetor (see

Engine Troubleshooting)

should be replaced.

California users should note that unauthorized modifications or replacement of fuel, exhaust, air intake, or

speed control system components that affectengineemissions are prohibited by California regulations and that

the optional high-altitude main jet is not intended for use in California. Modification, removal or replacement of

the generator set label Is also prohibited.

SERVICE

MANUAL

965-0764

REVISIONS

1.

Insert this cover sheet behind the front cover of the manual.

2.On

Page

1-1

of the manual add the following note at the bottom

of

the page: “See the Operator’s Manual

for

fuel and engine oil recommendations and the Periodic Maintenance Schedule.”

3. On

Page

9-1

of the manual add “(Does not

Apply

to

Spec

E

and Later)”

to

the subheadings “Disassembly”

and “Inspection/Service”.

4.

On

Page

42

of

the manual add “(Does Not Apply

to

Spec

E

and Later)” to the subheading “Assembly” and

to

the heading

“CO

Adjustment”.

5.

insert the attached page

(9-2-1)

between

Page

9-2

and Page

9-3

of the manual.

Attachment: Page

9-2-1.

Page

1

of

1

SECTION

1

2

3

4

5

6

7

8

9

10

TITLE

PAGE

Safety Precautions inside cover

General Information 1-1

Specifications 2-1

Dimensions and Clearances 3-1

Assembly Torques 4-1

Engine Troubleshooting 5-1

Maintenance

Lubrication

Electrical

Fuel

Starting 10-1

Engine

Block

Assembly 11 -1

WARNING

INCORRECT SERVICE OR REPLACEMENT OF PARTS CAN

RESULT IN SEVERE PERSONAL INJURY AND/OR EQUIPMENT

DAMAGE. SERVICE PERSONNEL MUST BE QUALIFIED

TO

PERFORM ELECTRICAL AND/OR MECHANICAL SERVICE.

Section

1

General Information

INTRODUCTION

This manual provides specific mechanical and

electrical information needed by engine mechanics

for troubleshooting, servicing, or overhauling the

engine.

Use the separate parts manual for parts identifica-

tion and for establishing their proper location on as-

semblies. The parts manual contains detailed ex-

ploded views of each assembly and the individual

piece part numbers and their proper names for

ordering replacement parts.

The illustrations and procedures presented in each

section apply to the engines listed on the cover. The

air cleaner side of the engine is the front end. Right

and left sides are determined by viewing the engine

from the front.

If

a major repair

or

an overhaul is necessary, have a

trained and experienced mechanic perform the re-

pair and

see

that all dimensions, clearances and

Use the table of contents for a quick reference to the

separate engine system sections.

The troubleshooting guide is provided as a quick

reference for locating and correcting engine

problems.

The wiring diagram shows how the electrical com-

ponents are interconnected.

The

Engine

BIock Assembly

section contains major

overhaul procedures for step by step removal,

torque values are within the specified tolerances.

disassembly, inspection, repair, and assembly of

the engine components.

Use only Genuine Onan replacement parts to pro-

vide quality and the best repair and overhaul

results. When ordering parts, always use the

complete model and spec number as well

as

the

serial number shown on the nameplate.

TABLE

1-1.

ENGINE MODEL IDENTIFICATION

1. Model letter designation.

2.

BHP

rating. Add a decimal one digit in from the

3.

Designation

(V

=

vertical shaft,

H

=

horizontal

4. Engine fuel. (Example N

=

gasoline,

L

=

LP,

5.

Factory code for designated optional equip-

6.

Specification (spec letter) which advances with

right end. (Example 140

=

14.0)

shaft).

D

=

Dual fuel)

ment,

if

any.

factory production modifications.

INCORRECT SERVICE

OR

REPLACEMENT

OF

PARTS CAN RESULT IN SEVERE PERSONAL IN-

JURY AND

OR

EQUIPMENT DAMAGE. SERVICE PERSONNEL MUST BE QUALIFIED

TO

PERFORM

ELECTRICAL AND/OR MECHANICAL SERVICE.

\

Section

2.

Specifications

These specifications are in customary

U.S.

units of measure with approximate metric equivalents following in

parentheses.

TABLE

2-1.

SPECIFICATIONS

UNIT

OF

SERIES

SPECIFICATION MEASURE

El

25V

El

4OV

Number

of

Cylinders 1

1

Bore mm 84.2 84.2

(in) (3.31)

(3.31)

(in) (2.76) (2.76)

(in3)

(23-7)

Stroke mm 70.0 70.0

Displacement

Cm3

389 389

Compression Ratio

8.5 to 1 8.5 to

1

Power at

kW 9.3 10.4

Rated

Speed

(3600 rpm)

(BW (1 2.5)

(1

4.0)

Oil Capacity Litres 1.7

1

-7

With

Fitter (Quarts) (1.75) (1.75)

Cylinder Compression kPa

483

or

more

(Psi)

(70

or

more)

2-1

Section

3.

Dimensions and Clearances

All

measurements given at room temperature of

70°F

(21

"C).

All

measurements are given in millimeters with

approximate inch measurements in parentheses. Measurements are for standard size parts. Refer to the

headings for notes

about

which specs are covered,

if

the spec is not listed the dimensions cover all specs.

TABLE

3-1.

DIMENSIONS AND CLEARANCES

CYLINDER BLOCK

Cylinder Bore Taper

DESCRIPTION

____-

I

CAMSHAFT SPEC

A

AND B

Lobe- Height, Diameter Over Nose

El25 Intake

El25 Exhaust

E140 Intake

El40 Exhaust

End Clearance

Oil Base Bearing Clearance

CAMSHAFT BEGIN SPEC C

Lobe Height, Diameter Over Nose

El25 Intake

El25 Exhaust

El40 Intake

El40 Exhaust

End Clearance

Journal Bearing O.D.

Oil Base Bearing Clearance

-_---

34.31 34.46

(1.351) (1.357)

34.62 34.77

(1.363) (1.369)

35.18 35.33

(1.385) (1.391)

35.18 35.33

(1.385) (1.391)

0.10

0.20

(0.004)

(0.008)

.0.01

0.05

(0004) (-0020)

34.23

(1-348)

(1-359)

(1-381)

34.53

35.09

(1.381)

0.10

(0.004)

17.975

(.7077)

0.01

(.OOO4)

34.55

(130)

34.85

(1.372)

35.41

(1.394)

35.41

0.20

(0.008)

17.990

0.05

(.7083)

(.0020)

3-2

ALLOWABLE

LIMIT

33.81

(1.331)

34.12

(1.343)

34.68

(1.365)

34.68

(1-365)

0.25

(0.01

0)

.0.08

(.0031)

33.73

(1-328)

34.03

(1-340)

34.59

(1.362)

34.59

(1.362)

0.25

(0.01

0)

17.93

(.

7059)

0.08

(.0031)

TABLE

3-3.

DIMENSIONS AND CLEARANCES

DESCRlPTlON

FACTORY SPECIFICATION

MIN MAX

PISTON SPEC

A

AND

B

Piston Skirt

O.D.

90

deg

to Pin,

26.5

from

Top

of Piston

84.09

84.1

2

(3.31

1)

(3.31 2)

.25

Oversize

84.34 84.37

(3.320) (3.322)

50

Oversize

84.59 84.62

(3.330) (3.331)

Pin Bore

I.D.

PISTON BEGIN SPEC C

Piston

Skirt

O.D.

deg

to

Pin, from

Top

of

Piston

26.5 90

20.000

20.01

0

(0.7874) (0.7878)

84.09 84.1

2

(3.31

1

)

(3.31 2)

.25

Oversize

84.34 84.37

(3.320) (3.322)

50

Oversize

84.59 84.62

(3.330) (3.331)

Pin Bore

I.D.

20.004 20.01 2

(0.7876) (0.7879)

PISTON PIN SPEC

A

AND

B

Piston Pin

O.D.

20.000

20.005

(0.7874) (0.7876)

Clearance in Piston

.005

.010

(.0002) (0.0004)

Clearance in Connecting

Rod

.010 .025

(0.004)

(0.001

0)

PISTON PIN BEGIN SPEC C

Piston Pin

O.D.

20.000

20.005

(0.7874)

(0.7876)

Clearance in Piston

.....................-.001 .012

(.OooO)

(0.0005)

Clearance in Connecting

Rod

.010

.025

ALLOWABLE

LIMIT

20.020

(0.7882)

20.022

(0.7883)

19.990

(0.7870)

0.30

(0.001 2)

(0.001

4)

.035

19.990

(0.7870)

0.03

(0.001 2)

.035

3-3

TABLE

3-4.

DIMENSIONS AND CLEARANCES

DESCRIPTION

PISTON

RINGS

Top Compression Ring Thickness

Second Compression Ring Thickness

Top Compression Ring to Ring Groove

Clearance

Second Compression Ring to Ring Groove

Clearance

Top Compression Ring End Gap

Second Compression Ring End Gap

Oil Ring Side Rail Gap

INTAKE VALVE

Valve Stem

O.D.

Valve Guide

I.D.

Valve Stem to Guide Clearance

El

25V

Valve Lash

El40V

Valve

Lash

Face Angle

INTAKE VALVE SEAT

Seat Width

Seat Angle

EXHAUST VALVE

Valve Stem

O.D.

Valve Guide

I.D.

Valve Stem to Guide Clearance

FACTORY SPECIFICATION

1.47

(.058)

1.47

(.058)

0.03

(0.001)

0.03

1.49

(.059)

1.49

(.059)

0.08

(0.003)

0.08

(0.003)

0.25

0.51

(0.010) (0.020)

(0.01

0)

(0.020)

(0.01

5)

(0.055)

0.25

0.51

0.38 1.40

6.960

6.975

(0.2740)

(0.2746)

7.000

7.015

(0.2756)

(0.2762)

0.03

0.06

0.075

0.15

45"

(0.001) (0.002)

(-003)

(-006)

7.940

7.960

(0.31 26)

(0.31 34)

8.000

8.015

(0.3150)

(0.31 56)

0.04

0.08

(.003)

ALLOWABLE

LIMIT

1.42

t.056)

1.42

(-056)

0.13

(0.005)

0.13

(0.005)

1.oo

(0.039)

1.oo

(0.039)

1.80

(0.071)

(0.004)

0.25

(0.01

0)

(0.01

0)

1.7

(.067)

TABLE

3-5.

DIMENSIONS AND CLEARANCES

DESCRIPTION

EXHAUST VALVE

(cont)

E125V Valve Lash

E140V Valve Lash

Face

Angle

EXHAUST VALVE SEAT

Seat Width

SeatAngle

VALVE SPRINGS INTAKE AND EXHAUST

SPEC

A

AND B

Valve Spring Free Length (Approx.)

Valve Spring Length

Valve

Closed

Valve Open

Spring Load (Valve

Closed

Length)

Spring Load (Valve Open Length)

VALVE SPRINGS INTAKE AND EXHAUST

BEGIN SPEC C

Valve Spring Free Length Approx

Valve Spring Length

Valve

Closed

Valve Open

Spring Load (Valve Closed Length)

Spring Load (Valve Open Length)

0.075

0.1 5

(-006)

45"

(-003)

43.5

(1.71)

32.6

(1.28)

23.2

(0.91

)

5.67 kg 6.62 kg

(1 2.5

Ib)

(1 4.6

Ib)

11

-52 kg 13.43 kg

(25.4

Ib)

(29.6

Ib)

43.5

(1.71)

32.6

(1.28)

23.2

(0.91)

12.6 kg 14.6 kg

(27.7

Ib)

(32.1

Ib)

26.4 kg

28.4 kg

(58.2

Ib)

(62.7

Ib)

0.25

(0.01

0)

(0.01

0)

1.7

(0.067)

10.21 kg

(22.5

Ib)

24.9 kg

(55

Ib)

3-5

-"--

DESCRIPTION

ROCKER ARM

Rocker Arm Inside Diameter

Rocker Arm Shaft O.D.

Rocker Arm to Shaft Clearance

-__.__I-

LUBRICATING SYSTEM

Engine Oil Pressure

At Idling

At

3300

rpm

Rotor Lobe Clearance

Outer Rotor to Pump

Body

Clearance

Rotor and Cover Clearance

IGNITION

SYSTEM

Spark

Plug Gap

Ignition Timing (BTDC) Not Adjustable

Ignition Unit Core to Rotor Magnet

Clearance (Air Gap)

ELECTRICAL SYSTEM

Commutator

O.D.

Difference

of

Commutator

O.D.'s

_--

Armature's Shaft to Bushing Clearance

Mica Undercut

BALANCE

SHAFT

End Clearance (Both Shafts).

AND

CLEARANCES

FACTORY SPECIFICATION

MIN MAX

-_I___-__

12.000

12.018

(0.4724) (0.471 8)

11.973 11.984

(0.4714

(0.471 8)

0.016

0.045

(0.0006)

(0.001 8)

-I_----*

3.0 psi

or

more

14.0 psi or more

0.15 or

less

(

0.006

or less)

0.12 0.19

(0.005)

(0.007)

0.02

0.09

(0.001) (0.004)

0.89 0.89 1.02

(0.035)

(0.040)

23"

0.50

(0.020)

28.0)

Less than' 0.05

(Less than 0.002)

0.02 0.07

(0.001) (0.003)

(1.102)

0.45

0.75

(0.01

8)

(0.030)

0.10

0.20

(0.004) (0.008)

3-6

ALLOWABLE

0.15

(0.0059)

4.0

psi

0.20

(0.008)

0.25

(0.010)

27.00

(1.063)

0.016

(0.41)

0.20

(.008)

0.20

(0.008)

0.25

(0.01

0)

Section

4.

Assembly

Torques

The torque values listed in Table

4-1

have been Tighten all studs,

nuts

and capscrews as specified

determined for specific applications. The engine to keep them from working loose. Refer to the Parts

assembly torques given here

will

provide proper Manual for the location of washers and capscrews.

tightness without danger of stripping threads.

All

threads must be clean,

rust

free

and lightly

lubricated.

TABLE

4-1.

ASSEMBLY TORQUES

DESCRIPTION

Conn

Rod

Bolts

Oil

Base

Bolts

Oil Pump Cover Screws

Oil Pump Screen Cover

Oil Drain Plugs

Oil

Base

Pressure

Line Plugs

LOPCO or Pipe Plug

Adapter Filter Head

Oil Filter

Oil Indicator Cap

Cy1 Head

Bolts

NO. 1-5 Bolts

No.

6

Flange

Bolt

Valve Lash Adj

Nut

Valve Cover Bolts

Spark Plug

Air Deflector Bolts

Pulse Pump to Deflector

Pulse Pump Spud

Int Elbow to Cy1

Hd

Screws

Air Cleaner Pan to

Air

Deflector

Carb. to Int Elbow

Knob-Inner Air CLnr

Knob-Outer Air Clnr

Cy1 Air Hsg

Bolt

Exhaust Elbow Bolts

Muffler Bolts

Starter Bolts

Alternator Stator Screws

Stator Wire Clamp

Screw

Flywheel Nut

Ignition Coil

Bolt

Blower

Hsg

Bolts

Voltage

Reg

Screws

Chaff Screen Bolt

Stationary Guard Bolt

Recoil Starter Cup Screw

Recoil Starter Bolts

Control Plate

Stud

Control Plate Pivot Bolt

Nut-Control Plate Stud

Governor

Arm

Nut

Throttle Cable Clamp Screw

Nuts

M8x44 24-27

M8x

50

16-22

M6x 14

3/8”

NPT

114" NPT 7-11

1/8” NPT

3/416"

24-30

1.5-2

7-11

M10 42-50

M8x50 16-22

M7 7-11

M6 x 25 7-11

M8x

11-20

10-24

M8x 16

M6x 10 7-11

#10 2.3-2.8

18-20 OIL BASE TORQUE

12-16-

58

5-8 Torque

'A"

twice.

Toque bolts in

clockwise

direction

starting

with "A"

SEQUENCE

118" NPT

M8x

50

114"

x

.50"

M6x

85

M6x 10

M8

M8x

45

M8X95

M8x

40

M6x

25

M6x 14

M18

M6 x 27

M6x20

114"

x

.50”

M6x 10

M6x

20

M8x 16

M6x 12

M8

M6

1032"

7-11

11-16

6.7-8.1

10-15

Not

Specified

7-11

11-20

16-22

11-20

16-22

10-15

122-138

10-15

7-11

6.7-8.1

7-11

1.4-2

24-30

7-11

11-16

7-11

8.1-10.9

1.4-2

5-8

58

18-22

3/41 Turn after gskt

1.1-1.5(13-18LB*IN) contacts

base

Toque

in

sequence shown.

after

others

are

done.

Tighten

every

other bolt

until

all

bolts

are tightened.

Retorque

the

first bolt

twice.

31-37 Two

bolts

outside

valve

cover

12-16

(#2

&

#4)

To

be

retorqued

5-8

58

7-18

8-15

58

1.7-2.1 (20-25 LB-IN

C-1138

5-8

8-12

5-6 (60-72 L

7-11

Not

Specified

58

8-15

12-16

7-11

90-102

7-11

5-8

5-6 (60-72

LB_IN

58

1-1.5 (12-18 LB*IN)

18-22

5-8

8-12

5-8

68

a12

1-1.5 (12-18 LB-IN

Tighten

twice

(1-2-1)

contacts element

1-1/2-2 turns after

cover

CYLINDER HEAD

TORQUE SEQUENCE

4-1

5-1

Section

6.

Maintenance

PERIODIC MAINTENANCE SCHEDULE

Neglecting routine maintenance

will

result in poor

performance and reduced engine life.

Keep an accurate logbook of maintenance, service,

and operating time: Follow a regular schedule of

inspection and service, based on operating hours.

WARNING

Incorrect service or replacement of

parts

can

result in severe personal Injury and/or

Use the factory recommended Periodic Mainte-

equipment damage. Service personnel must

be

nance Schedule (based on favorable operating

qualified to

perform

electrical and/or mechani-

conditions) to serve as a guide to get long and effi-

cal service.

cient engine life.

Regular service periods are recommended for nor-

WARNING Accidental

starting

of the engine

mal service and operating conditions.

If

the engine

can result in severe personal Injury or death.

is in an application with extreme temperatures, se-

DIsconnect the negative battery cable and

vere duty cycles, etc., service at more frequent

spark

plug

wire

before servicing the engine,

intervals.

controls, or associated equipment.

TABLE

6-1.

PERIODIC MAINTENANCE SCHEDULE

Air

Cleaner Element and

1

Check for fuel leaks.

With

engine running, visually and audibly check exhaust system for leaks.

2-

Perform more often when running under severe operating conditions.

3-

Required for initial break-in

only.

4-

Required for initial

100

hours,

200

hour interval thereafter.

X

X2

X

ENGINE INSPECTION AIR CLEANER AND ELEMENT WRAPPER

Refer to

Air

Cleaner,

in section

9,

for disassembly,

Check the fuel lines and fittings for leaks.

Do

not the and

assembly

procedures.

start engine until leaks are repaired.

OIL CHANGE

WARNING

Breathing exhaust gases can result

in severe personal injury

or

death. Inspect the

Refer to

Oil Change,

in section

7,

for inspection and

exhaust system audibly and visualiy for leaks

service procedures.

daiiy and repair leaks immediateiy.

OIL FILTER CHANGE

Inspect the exhaust system for cracks and run the

Refer to

Oil Filter Change,

in

7,

for inspection and

engine to check for leaks. Repair problems before

service procedures.

allowing the engine to

be

used.

COOLING

Examine the air cleaner components for damage, Refer to

Flywheel,

in section

11,

for inspection and

proper fit, etc. Repair or replace components as service procedures.

necessary.

VALVE CLEARANCE

Check-the oil level with the engine

off

and the equip-

Refer

to

valve

system,

in

section

for

inspection

ment on a level surface.

If

the oil level is at or below

and

service

procedures.

the full mark on the dipstick, add oil of the proper

viscosity

(see

Oil Change

section) until the level

reaches the

full

mark.

Do

not operate the engine

with the oil level

below

the add or above the

full

Refer to

Spark

Plug,

in section

8,

for inspection and

SPARK PLUG

mark.

service

procedures.

Section

7.

Lubrication

A

pump driven by one

of

the balancer shafts pro-

vides pressure lubrication of the connecting rod

journal through drilled passages in the crankcase

and crankshaft. An oil hole in the crank arm pro-

vides spray lubrication of the piston, cylinder walls,

and other crankcase components. The lubrication

system includes an oil pressure relief valve and full-

flow oil filter (Specs

B

and C). The oil pump is acces-

sible by removing a cover in the oil base.

WARNING

Improper service or replacement of

parts can result in severe personal injury and/or

equipment damage. Service personnel must be

qualified to perform electrical and/or mechani-

cal service.

WARNING

Accidental starting

of

the engine

can result in severe personal injury or death.

Disconnect the negative battery cable and

spark

plug

wires while servicing engine,

controls, or associated equipment.

OIL

CHANGE

WARNING

Crankcase pressure can blow out

hot oil, which can cause severe personal injury.

Do

not check oil while the engine Is running.

WARNING

Hot crankcase oil can cause burns

if

it

comes in contact with skin. Wearprotective

clothing and keep fingers and hands clear when

draining oil.

WARNING

Some States or federal agencies

have determined that used engine oil is carcino-

genic and causes reproductive toxicity. Take

care not to breathe, ingest or come Into contact

with used engine oil.

CAUTION

Excess oil can cause high oil con-

sumption, high operating temperatures, and oil

foaming. Do not overfill crankcase.

Run the engine until it is thoroughly warm before

draining the oil. Stop the engine, place

a

pan under

the drain plug and remove the plug (open the drain

cock). Replace the drain plug (close the cock) when

the oil has stopped draining. Refill with oil meeting

the API classification

SG,

SG/CD,

or

SG/CE

and

having the proper viscosity for the ambient temper-

ature. See Table

7-1.

Straight weight oil is recom-

mended for severe duty use and minimum oil con-

sumption at temperatures above

32"

F

(0"

C).

TABLE

7-1.

OIL

VISCOSITY

RECOMMENDATIONS

OIL

FILTER

CHANGE

WARNING

Hot crankcase oil can cause burns

if

it comes In contact with skin. Wearprotective

clothing and keep fingers and hands clear when

draining oil.

CAUTION

Excess oil can cause high oil con-

sumption, high operating temperatures, and oil

foaming. Do not overfill crankcase.

Spin the oil filter element

off

and discard it. Clean

the filter mounting surface and make sure a gasket

is

inserted in the new element. Apply a thin film

of

new oil to the gasket. Spin the element down by

hand until the gasket just touches the mounting sur-

face. Then add another

1/2-3/4

turn.

Do

not over-

tighten. Fill with oil to the

FULL

mark and start and

run the engine until it is warm. Check for oil leaks.

Check oil level.

7-1

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