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)
(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
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)
(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)
(0.001)
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
0.25
(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
0.25
(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)
(0.035)
(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
M6x 14
3/8”
NPT
114" NPT 7-11
1/8” NPT
3/416"
24-30
1.5-2
7-11
7-11
7-11
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
M8
M6
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
10-15
122-138
10-15
7-11
6.7-8.1
7-11
1.4-2
24-30
7-11
11-16
11-16
7-11
8.1-10.9
1.4-2
5-8
58
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
8-15
12-16
12-16
7-11
90-102
7-11
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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