Toro 22-14O501, 22-14O502, 22-14OE01, 22-14OE02, 32-1205A1 Service Manual
...
ONAN E125 V, E140V ENGINE SERVICE MANUAL
Table of Contents – Page 1 of 3
SAFETY PRECAUT I O NS
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 INSPEC TION
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 START ER
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 GUID E C LE AR ANC E:
VALVE GUIDE REPLACEMENT:
ASSEMBLY
VALVE SPRING:
VALVE FACE AND SEAT GRINDING
INSPECTION/SERVICE
VALVE SEAT WIDT H:
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
Before
operating the engine,
become familiar with it and the equipment.
operatlon can be achieved only
Precautions
read the Operator's Manual and
Safe and efficient
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-
the
sonnel, or
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.
consulted and complied with.
WARNING
use
In any type of aircraft.
All
local, state and federal codes should be
Thls engine is not designed or Intended for
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-
off
teries give
be ignited by flame, electrical arcing or by smoking.
Verify battery polarity before connecting battery cables.
Connect negative cable last.
a highly explosive hydrogen gas which can
PROTECT AGAINST MOVING PARTS
Do
not wear
such as PTO shafts, flywheels, blowers, couplings, fans,
belts, etc.
Keep your hands away from moving parts.
loose
clothing in
the
vicinity
of
moving parts,
FUEL SYSTEM
DO NOT
DO NOT smoke or use an open flame in the vicinity of the
engine or
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
copper
break.
Be
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.
fill
fuel tanks while engine is running.
fuel
tank. Internal combustion engine fuels are
will
work harden and become brittle enough to
sure all fuel supplies have a positive shutoff valve.
as
EXHAUST SYSTEM
Exhaust products of any internal combustion engine are
toxic and can cause injury, or death
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
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
Symptoms of carbon monoxide poisoning are:
Dizziness
Headache
Weakness and Sleepiness
If
you experience any of these symptoms, get out into fresh air
immediately, shut down the unit and do not
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
or appearance of exhaust system, shut the unit down immediately and have it inspected and repaired at once by a competent
mechanic.
IS
DEADLY!
0
KEEP THE UNIT AND SURROUNDING
Make sure that oily rags are not
Remove all unnecessary grease and
Accumulated grease and oil can cause overheating and
subsequent engine damage and present a potential fire
hazard.
left
if
inhaled. When
fuels.
Vomiting
Muscular Twitching
Throbbing in Temples
use
it until it has
in
the sound
AREA
CLEAN
on or near
the
oil
from the unit.
engine.
E-8
Supplement
Date:1-95
lnsert
Title:
Number
PURPOSE
965-1053
with-
El
25V/E140V
(Date):965-0764(6-94)
Service
Manual
This Supplement transmits the revisions to the Service Manual necessary for covering
that the nameplate on a Spec
emissions regulations for
E
engine will have the statement:
ULGEengines.”
“This
engine meets
Spec
€engines. Note
1995-1998
California
To satisfy California emissions regulations Spec E engines have internal engine modifications and precisionmanufactured carburetors with tamper-resistant fuel mixture jets.
installing the optional high-altitude jet (Figure 9-3a), fuel mixture adjustments should not
should the carburetor be overhauled. Instead, a malfunctioning carburetor (see
It
should therefore be noted that, other than
be
attempted. Nor
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
1.
Insert this cover sheet behind the front cover of the manual.
2.On
3. On
Page
1-1
of the manual add the following note at the bottom
for
fuel and engine oil recommendations and the Periodic Maintenance Schedule.”
Page
9-1
of the manual add “(Does not
MANUAL
Apply
965-0764
to
Spec E and Later)”
REVISIONS
of
the page: “See the Operator’s Manual
to
the subheadings “Disassembly”
and “Inspection/Service”.
4.
On
Page
42
of
the manual add “(Does Not Apply
to
the heading
5.
insert the attached page
Attachment: Page
“CO
9-2-1.
Adjustment”.
(9-2-1)
between
Page
to
Spec E and Later)” to the subheading “Assembly” and
9-2
and Page
9-3
of the manual.
Page 1 of
1
SECTION
TITLE
Safety Precautions inside cover
PAGE
1
2
3
4
5
6
7
8
9
10
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
Block
Engine
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
PERFORM ELECTRICAL AND/OR MECHANICAL SERVICE.
TO
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 identification and for establishing their proper location on assemblies. The parts manual contains detailed exploded 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
trained and experienced mechanic perform the re-
pair and
torque values are within the specified tolerances.
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
overhaul procedures for step by step removal,
see
Engine
or
an overhaul is necessary, have a
that all dimensions, clearances and
BIock Assembly
section contains major
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
serial number shown on the nameplate.
TABLE
1. Model letter designation.
2.
3.
4. Engine fuel. (Example N
5.
6.
1-1.
ENGINE MODEL IDENTIFICATION
BHP
rating. Add a decimal one digit in from the
=
right end. (Example 140
Designation
shaft).
=
Dual fuel)
D
Factory code for designated optional equip-
ment,
Specification (spec letter) which advances with
factory production modifications.
if
(V = vertical shaft,
any.
14.0)
=
gasoline,
H = horizontal
as
L = LP,
the
INCORRECT SERVICE
JURY AND
ELECTRICAL AND/OR MECHANICAL SERVICE.
OR
EQUIPMENT DAMAGE. SERVICE PERSONNEL MUST BE QUALIFIED
OR
REPLACEMENT
OF
PARTS CAN RESULT IN SEVERE PERSONAL IN-
TO
PERFORM
\
Section
2.
Specifications
These specifications are in customary
parentheses.
SPECIFICATION MEASURE
Number
Bore mm 84.2 84.2
Stroke mm 70.0 70.0
Displacement
Compression Ratio
Power at
Oil Capacity Litres 1.7
of
Rated
With
Cylinders 1
Speed
Fitter (Quarts) (1.75) (1.75)
(3600 rpm)
U.S.
units of measure with approximate metric equivalents following in
2-1.
TABLE
SPECIFICATIONS
OF
UNIT
(in) (3.31)
(in) (2.76) (2.76)
Cm3
(in3)
kW 9.3 10.4
(BW (1 2.5)
El
25V
389 389
(23-7)
8.5 to 1 8.5 to
SERIES
El
4OV
1
(3.31)
(23-7)
(1
4.0)
1
-7
1
Cylinder Compression kPa
(Psi)
483
(70
or
or
more
more)
2-1
Section
All
measurements given at room temperature of
approximate inch measurements in parentheses. Measurements are for standard size parts. Refer to the
headings for notes
3.
about
Dimensions and Clearances
70°F
(21
"C).
All
measurements are given in millimeters with
which specs are covered,
if
the spec is not listed the dimensions cover all specs.
CYLINDER BLOCK
Cylinder Bore Taper
TABLE
3-1.
DIMENSIONS AND CLEARANCES
DESCRIPTION
____-
ALLOWABLE
I
LIMIT
CAMSHAFT SPEC
Lobe- Height, Diameter Over Nose
El25 Intake
El25 Exhaust
E140 Intake
El40 Exhaust
End Clearance
Oil Base Bearing Clearance
A
AND B
CAMSHAFT BEGIN SPEC C
Lobe Height, Diameter Over Nose
El25 Intake
El25 Exhaust
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
(0.004)
.0.01
(0004) (-0020)
34.23
(1-348)
34.53
(1-359)
0.20
(0.008)
0.05
34.55
(130)
34.85
(1.372)
33.81
(1.331)
34.12
(1.343)
34.68
(1.365)
34.68
(1-365)
0.25
0)
(0.01
.0.08
(.0031)
33.73
(1-328)
34.03
(1-340)
El40 Intake
El40 Exhaust
End Clearance
Journal Bearing O.D.
Oil Base Bearing Clearance
-_---
35.09
(1-381)
35.09
(1.381)
0.10
(0.004)
17.975
(.7077)
0.01
(.OOO4)
3-2
35.41
(1.394)
35.41
(1.394)
0.20
(0.008)
17.990
(.7083)
0.05
(.0020)
34.59
(1.362)
34.59
(1.362)
0.25
0)
(0.01
17.93
(.
7059)
0.08
(.0031)
TABLE
3-3.
DIMENSIONS AND CLEARANCES
DESCRlPTlON
PISTON SPEC A AND
Piston Skirt
90
.25
50
Pin Bore
PISTON BEGIN SPEC C
Piston
.25
50
O.D.
deg
to Pin,
Oversize
Oversize
I.D.
Skirt
O.D.
deg
to
Oversize
Oversize
26.5
Pin, from
26.5 90
B
from
Top
Top
of Piston
of
Piston
FACTORY SPECIFICATION
MIN MAX
84.09
(3.31
1)
84.1
2
(3.31 2)
84.34 84.37
(3.320) (3.322)
84.59 84.62
(3.330) (3.331)
20.000
20.01
0
(0.7874) (0.7878)
84.09 84.1
(3.31
1
)
2
(3.31 2)
84.34 84.37
(3.320) (3.322)
84.59 84.62
(3.330) (3.331)
ALLOWABLE
LIMIT
20.020
(0.7882)
Pin Bore
PISTON PIN SPEC A AND
Piston Pin
Clearance in Piston
Clearance in Connecting
PISTON PIN BEGIN SPEC C
Piston Pin
Clearance in Piston
Clearance in Connecting
I.D.
B
O.D.
Rod
O.D.
.....................-.001 .012
Rod
20.004 20.01 2
(0.7876) (0.7879)
20.000
20.005
(0.7874) (0.7876)
.005
.010
(.0002) (0.0004)
.010 .025
(0.004)
20.000
(0.7874)
(.OooO)
.010
(0.001
0)
20.005
(0.7876)
(0.0005)
.025
20.022
(0.7883)
19.990
(0.7870)
0.30
(0.001 2)
.035
(0.001
4)
19.990
(0.7870)
0.03
(0.001 2)
.035
3-3
TABLE
3-4.
DIMENSIONS AND CLEARANCES
DESCRIPTION
PISTON
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
Valve Guide
Valve Stem to Guide Clearance
El
25V
El40V
Face Angle
RINGS
O.D.
I.D.
Valve Lash
Valve
Lash
FACTORY SPECIFICATION
1.47
(.058)
(.059)
1.47
(.058)
(.059)
0.03
(0.001)
(0.003)
0.03
(0.001)
(0.003)
0.25
(0.010) (0.020)
0.25
(0.01
0)
(0.020)
0.38 1.40
(0.01
5)
6.960
(0.2740)
7.000
(0.2756)
(0.055)
6.975
(0.2746)
7.015
(0.2762)
0.03
(0.001) (0.002)
0.075
(-003)
0.15
(-006)
45"
1.49
1.49
0.08
0.08
0.51
0.51
0.06
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)
0.25
(0.01
0)
INTAKE VALVE SEAT
Seat Width
Seat Angle
EXHAUST VALVE
Valve Stem
Valve Guide
Valve Stem to Guide Clearance
O.D.
I.D.
7.940
(0.31 26)
8.000
(0.3150)
0.04
1.7
(.067)
7.960
(0.31 34)
8.015
(0.31 56)
0.08
(.003)
DESCRIPTION
TABLE
3-5.
DIMENSIONS AND CLEARANCES
EXHAUST VALVE
E125V Valve Lash
E140V Valve Lash
Face
Angle
(cont)
EXHAUST VALVE SEAT
Seat Width
SeatAngle
VALVE SPRINGS INTAKE AND EXHAUST
A
SPEC
Valve Spring Free Length (Approx.)
Valve Spring Length
Valve
Valve Open
Spring Load (Valve
AND B
Closed
Closed
Length)
0.075
(-003)
0.1 5
(-006)
45"
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)
0.25
(0.01
0.25
(0.01
1.7
(0.067)
0)
0)
Spring Load (Valve Open Length)
VALVE SPRINGS INTAKE AND EXHAUST
BEGIN SPEC C
Valve Spring Free Length Approx
Valve Spring Length
Valve
Valve Open
Spring Load (Valve Closed Length)
Spring Load (Valve Open Length)
Closed
11
-52 kg 13.43 kg
(25.4
Ib)
43.5
(1.71)
32.6
(1.28)
23.2
(0.91)
12.6 kg 14.6 kg
(27.7
Ib)
26.4 kg
Ib)
(58.2
(29.6
(32.1
28.4 kg
(62.7
3-5
Ib)
Ib)
Ib)
10.21 kg
(22.5
Ib)
24.9 kg
(55
Ib)
DESCRIPTION
ROCKER ARM
Rocker Arm Inside Diameter
-__.__I-
-"--
AND
CLEARANCES
FACTORY SPECIFICATION
MIN MAX
-_I___-__
12.000
(0.4724) (0.471 8)
12.018
ALLOWABLE
Rocker Arm Shaft O.D.
Rocker Arm to Shaft Clearance
LUBRICATING SYSTEM
Engine Oil Pressure
At Idling
At
3300
rpm
Rotor Lobe Clearance
Outer Rotor to Pump
Rotor and Cover Clearance
IGNITION
Spark
Ignition Timing (BTDC) Not Adjustable
Ignition Unit Core to Rotor Magnet
Clearance (Air Gap)
SYSTEM
Plug Gap
Body
Clearance
ELECTRICAL SYSTEM
Commutator
O.D.
_--
11.973 11.984
(0.4714
0.016
(0.0006)
0.12 0.19
(0.005)
0.02
(0.001) (0.004)
0.89 0.89 1.02
(0.035)
3.0 psi
14.0 psi or more
(
0.15 or
0.006
or
or less)
(0.035)
23"
-I_----*
more
less
(0.471 8)
0.045
(0.001 8)
(0.007)
0.09
(0.040)
0.50
(0.020)
28.0)
(1.102)
0.15
(0.0059)
4.0
psi
0.20
(0.008)
0.25
(0.010)
27.00
(1.063)
Difference
Armature's Shaft to Bushing Clearance
Mica Undercut
BALANCE
End Clearance (Both Shafts).
of
Commutator
SHAFT
O.D.'s
0.02 0.07
(0.001) (0.003)
0.45
(0.01
0.10
(0.004) (0.008)
3-6
Less than' 0.05
(Less than 0.002)
8)
0.75
(0.030)
0.20
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
tightness without danger of stripping threads.
threads must be clean,
rust
will
provide proper Manual for the location of washers and capscrews.
All
free
and lightly
lubricated.
DESCRIPTION
Conn
Rod
Base
Bolts
Base
Pressure
Bolts
6
Flange
Deflector
Hsg
Reg
Arm
Bolts
Bolt
Bolt
Bolts
Screws
Stud
Bolt
Nut
Hd
Nut
Screws
Screw
Oil
Oil Pump Cover Screws
Oil Pump Screen Cover
Oil Drain Plugs
Oil
Line Plugs
LOPCO or Pipe Plug
Adapter Filter Head
Oil Filter
Oil Indicator Cap
Cy1 Head
NO. 1-5 Bolts
No.
Valve Lash Adj
Valve Cover Bolts
Spark Plug
Air Deflector Bolts
Pulse Pump to Deflector
Nuts
Pulse Pump Spud
Int Elbow to Cy1
Air Cleaner Pan to
Air
Carb. to Int Elbow
Knob-Inner Air CLnr
Knob-Outer Air Clnr
Cy1 Air Hsg
Exhaust Elbow Bolts
Muffler Bolts
Starter Bolts
Alternator Stator Screws
Stator Wire Clamp
Flywheel Nut
Ignition Coil
Blower
Voltage
Chaff Screen Bolt
Stationary Guard Bolt
Recoil Starter Cup Screw
Recoil Starter Bolts
Control Plate
Control Plate Pivot Bolt
Nut-Control Plate Stud
Governor
Throttle Cable Clamp Screw
TABLE
M8x44 24-27
M8x
50
M6x 14
M6x 14
3/8”
NPT
114" NPT 7-11
1/8” NPT
3/416"
M10 42-50
M8x50 16-22
M7 7-11
M6 x 25 7-11
M8x
M8x 16
M6x 10 7-11
#10 2.3-2.8
118" NPT
50
M8x
114" x .50"
85
M6x
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"
Not
4-1.
16-22
7-11
7-11
7-11
7-11
24-30
1.5-2
10-24
11-20
7-11
11-16
6.7-8.1
10-15
Specified
7-11
11-20
11-20
16-22
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
ASSEMBLY TORQUES
18-20 OIL BASE TORQUE
12-16-
58
5-8 Torque
5-8
58
58
18-22
1.1-1.5(13-18LB*IN) contacts
31-37 Two
12-16
5-8
58
7-18
8-15
1.7-2.1 (20-25 LB-IN
58
5-8
8-12
5-6 (60-72 L
7-11
Specified
Not
58
8-15
8-15
12-16
12-16
7-11
7-11
90-102
7-11
5-8
5-6 (60-72
1-1.5 (12-18 LB*IN)
1-1.5 (12-18 LB-IN
LB_IN
58
18-22
5-8
a12
8-12
5-8
68
Toque bolts in
direction
3/41 Turn after gskt
Toque
bolts
(#2
&
#4)
others
after
Tighten
all
bolts
Retorque
Tighten
1-1/2-2 turns after
contacts element
clockwise
starting
'A"
twice.
base
in
sequence shown.
outside
To
be
retorqued
are
done.
every
other bolt
are tightened.
the
first bolt
twice
(1-2-1)
with "A"
valve
cover
until
twice.
cover
CYLINDER HEAD
TORQUE SEQUENCE
SEQUENCE
C-1138
4-1
5-1
Section
6.
Maintenance
PERIODIC MAINTENANCE SCHEDULE
Keep an accurate logbook of maintenance, service,
and operating time: Follow a regular schedule of
inspection and service, based on operating hours.
Use the factory recommended Periodic Maintenance Schedule (based on favorable operating
conditions) to serve as a guide to get long and efficient engine life.
Regular service periods are recommended for nor-
mal service and operating conditions.
is in an application with extreme temperatures, severe duty cycles, etc., service at more frequent
intervals.
TABLE
If
the engine
6-1.
PERIODIC MAINTENANCE SCHEDULE
Neglecting routine maintenance
performance and reduced engine life.
WARNING
parts
can
equipment damage. Service personnel must
qualified to
cal service.
WARNING Accidental
can result in severe personal Injury or death.
DIsconnect the negative battery cable and
spark
controls, or associated equipment.
Incorrect service or replacement of
result in severe personal Injury and/or
plug
perform
wire
electrical and/or mechani-
starting
before servicing the engine,
will
result in poor
of the engine
be
Air
Cleaner Element and
1
Check for fuel leaks.
2-
Perform more often when running under severe operating conditions.
3-
Required for initial break-in
4-
Required for initial
With
100
engine running, visually and audibly check exhaust system for leaks.
only.
hours,
200
hour interval thereafter.
X
X2
X
ENGINE INSPECTION AIR CLEANER AND ELEMENT WRAPPER
Do
Check the fuel lines and fittings for leaks.
start engine until leaks are repaired.
WARNING
in severe personal injury
exhaust system audibly and visualiy for leaks
daiiy and repair leaks immediateiy.
Inspect the exhaust system for cracks and run the
engine to check for leaks. Repair problems before
allowing the engine to
Examine the air cleaner components for damage, Refer to
proper fit, etc. Repair or replace components as service procedures.
necessary.
Check-the oil level with the engine
ment on a level surface.
the full mark on the dipstick, add oil of the proper
viscosity
reaches the
with the oil level
mark.
Breathing exhaust gases can result
or
death. Inspect the
be
used.
off
and the equip-
If
the oil level is at or below
(see
Oil Change
full
mark.
below
section) until the level
Do
not operate the engine
the add or above the
not the and
full
Refer to
Refer to
service procedures.
Refer to
service procedures.
Refer
to
and
service
Refer to
service
Air
Cleaner,
in section
assembly
OIL CHANGE
Oil Change,
in section
OIL FILTER CHANGE
Oil Filter Change,
COOLING
Flywheel,
in section
VALVE CLEARANCE
valve
system,
in
section
procedures.
SPARK PLUG
Spark
procedures.
Plug,
in section
9,
for disassembly,
procedures.
7,
for inspection and
in
7,
for inspection and
11,
for inspection and
for
8,
for inspection and
inspection
Section
A
pump driven by one
vides pressure lubrication of the connecting rod
journal through drilled passages in the crankcase
and crankshaft. An oil hole in the crank arm provides 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
sible by removing a cover in the oil base.
WARNING
parts can result in severe personal injury and/or
equipment damage. Service personnel must be
qualified to perform electrical and/or mechanical service.
Improper service or replacement of
7.
B
and C). The oil pump is acces-
Lubrication
of
the balancer shafts pro-
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
having the proper viscosity for the ambient temper-
ature. See Table
mended for severe duty use and minimum oil consumption at temperatures above
TABLE
7-1.
OIL
SG,
SG/CD,
7-1.
Straight weight oil is recom-
VISCOSITY
RECOMMENDATIONS
or
32" F (0"
SG/CE
C).
and
WARNING
can result in severe personal injury or death.
Disconnect the negative battery cable and
spark
controls, or associated equipment.
WARNING
hot oil, which can cause severe personal injury.
Do
not check oil while the engine Is running.
WARNING
if
it
comes in contact with skin. Wearprotective
clothing and keep fingers and hands clear when
draining oil.
WARNING
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
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
Accidental starting
plug
wires while servicing engine,
OIL
CHANGE
Crankcase pressure can blow out
Hot crankcase oil can cause burns
Some States or federal agencies
Excess oil can cause high oil con-
of
the engine
a
pan under
OIL
FILTER
WARNING
if
it comes In contact with skin. Wearprotective
clothing and keep fingers and hands clear when
draining oil.
CAUTION
sumption, high operating temperatures, and oil
foaming. Do not overfill crankcase.
Spin the oil filter element
the filter mounting surface and make sure a gasket
is
inserted in the new element. Apply a thin film
new oil to the gasket. Spin the element down by
hand until the gasket just touches the mounting sur-
face. Then add another
tighten. Fill with oil to the
run the engine until it is warm. Check for oil leaks.
Check oil level.
Hot crankcase oil can cause burns
Excess oil can cause high oil con-
CHANGE
off
and discard it. Clean
1/2-3/4
FULL
turn.
Do
mark and start and
of
not over-
7-1
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