Onan CCKB User manual

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1

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Onon

Operators

Manual

Engines

927-0151

SPEC

J

9-85

Printed

In

U

SA

Safety

Precautions

It

is

recommended

that

you

read

your

engine

manual

and

become

thoroughiy

acquainted

with

your

equipment

be¬

fore

you

start

the

engine.

This

symbol

If

used

warns

of

imme¬

diate

hazards

which

will

result

In

severe

personal

Injury

or

death.

This

symbol

refers

to

a

hazard

or

unsafe

practice

which

can

result

In

severe

persona/

Injury

or

death.

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

lines

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.

ADANGER

AWARNING

ACAUTION

This

symbol

refers

to

a

hazard

or

unsafe

practice

which

can

result

In

persona/

Injury

or

product

or

properly

damage.

Fuels,

electrical

equipment,

batteries,

exhaust

gases

and

moving

parts

present

potential

hazards

that

can

result

in

serious,

personal

Injury.

Take

care

in

following

these

recommended

procedures.

Safety

Codes

•

All

local,

state

and

federal

codes

should

be

consulted

and

complied

with.

•

This

engine

is

not

designed

or

intended

for

use

in

aircraft.

Any

such

use

is

at

the

owner's

sole

risk.

General

Exhaust

System

•

Exhaust

products

of

any

internal

combustion

engine

are

toxic

and

can

cause

injury,

or

death

if

inhaled.

Alt

engine

applications,

especially

those

within

a

confined

area,

should

be

equipped

with

an

exhaust

system

to

discharge

gases

to

the

outside

atmosphere.

•

Do

not

use

exhaust

gases

to

heat

a

compartment.

•

Make

sure

that

your

exhaust

system

is

free

of

leaks.

Ensure

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

hydro¬

carbon

fuels.

Symptoms

of

carbon

monoxide

poisoning

are;

•

Provide

appropriate

fire

extinguishers

and

install

them

in

convenient

locations.

Use

an

extinguisher

rated

ABC

byNFPA.

•

Dizziness

•

Headache

•

Weakness

and

Sleepiness

•

Vomiting

•

Muscular

Twitching

•

Throbbing

in

Temples

•

Make

sure

that

all

fasteners

on

the

engine

are

secure

and

accurately

torqued.

Keep

guards

in

position

over

fans,

driving

belts,

etc.

Ifyou

experience

any

of

these

symptoms,

get

out

into

fresh

air

immediately,

shut

down

the

unit

and

do

not

use

until

it

has

been

inspected.

•

If

it

is

necessary

to

make

adjustments

while

the

engine

is

running,

use

extreme

caution

when

close

to

hot

ex¬

hausts,

moving

parts,

etc.

Protect

Against

Moving

Parts

•

Do

not

wear

loose

clothing

in

the

vicinity

of

moving

parts,

such

as

PTO

shafts,

flywheels,

blowers,

coup¬

lings,

fans,

belts,

etc.

•

Keep

your

hands

away

from

moving

parts.

Batteries

•

Before

starting

work

on

the

engine,

disconnect

batter¬

ies

to

prevent

inadvertent

starting

of

the

engine.

•

DO

NOT

SMOKE

while

servicing

batteries.

Lead

acid

batteries

giveoff

a

highly

explosive

hydrogen

gas

which

can

be

ignited

by

flame,

electrical

arcing

or

by

smoking.

•

Verity

battery

polarity

before

connecting

battery

cables.

Connect

negative

cable

last.

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

immediately

and

have

it

inspected

and

repaired

at

once

by

a

competent

mechanic.

Cooling

System

•

Coolants

under

pressure

have

a

higher

boiling

point

than

water.

DO

NOT

open

a

radiator

pressure

cap

when

coolant

temperature

is

above

212®F

(100®C)

or

while

engine

is

running.

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-S

Table

of

Contents

TITLE

PAGE

INTRODUCTION

.

2

Engine

Set-Up

.

3

Operation

.

4

Maintenance

.

6

Periodic

Maintenance

Scheduie

.

9

Adjustments

.

10

AWARNING

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.

1

Introduction

KNOW

YOUR

ENGINE

Read

this

manual

carefully,

observing

all

WARNINGS

and

CAUTIONS.

Operating

instructions,

adjustments

and

periodic

maintenance

procedures

are

given

so

you

...

the

owner,

can

keep

your

unit

running

like

new

and

expect

many

years

of

dependable

service

from

it.

Remember...

any

machine,

regardless

of

design

or

type,

will

perform

only

in

relation

to

the

service

it

receives.

Regularly

scheduled

maintenance

lowers

operating

costs.

ENGINE

MODEL

REFERENCE

Identify

your

model

by

referring

to

the

MODEL

and

SPEC

(specification)

NO.

as

shown

on

the

unit

nameplate.

Always

use

this

number

and

the

engine

serial

number

when

making

reference

to

your

engine.

If

a

major

repair

or

an

overhaul

is

necessary.

Onan

recommends

that

a

competent

mechanic

either

do

the

job

or

supervise

and

check

the

work

of

the

mechanic

assigned

to

do

the

job

to

ensure

that

all

dimensions,

clearances

and

torque

values

are

within

the

specified

tolerances.

An

engine

service

manual

and

complete

parts

catalog

are

available

at

additional

cost.

Contact

your

nearest

authorized

dealer

or

Onan

Parts

and

Service

Center.

REFERENCE

MANUALS

Parts

Catalog

.

927-0404

Major

Service

Manual

.

927-0754

These

instructions

conisin

the

SI

metric

equivalents

following

immediately

in

parentheses

after

the

U.S.

customary

units

of

measure.

SPECIFICATIONS

Engine

Design

.Opposed

two

cylinder,

four

cycle,

and

aii

cooled

Bore.

3.25

inch

(82.55

mm)

Stroke

.

3.0

inch

(76.2

mm)

Displacement

.

50

CiD

(816

cm^)

Horsepower

(3900

RPM)

.20

BHP

(14.9

kW)

Oil

Capacity

.

3.5

qt

(3.3

litre)

Oil

Capacity

with

filter

change

.

4.0

qt

(3.8

litre)

Compression

Ratio

.

7.0

to

1

TUNE-UP

SPECIFICATIONS

Spark

Plug

Gap

-

Gasoline

.

0.025

inch

(0.635

mm)

Spark

Plug

Gap

-

Gas

.

0.018

inch

(0.457

mm)

Breaker

Point

Gap

.

0.020

inch

(0.51

mm)

Valve

Lash

Intake.

0.007

inch

(0.18

mm)

Exhaust

.

0.016

inch

(0.41

mm)

Ignition

Timing:

Standard

Electric

Start

(Stopped

or

Running)

.

20®BTC

Manual

Start

with

Spark

Advance

...

1

“ATDC

(Stopped)

24'’BTC

(Running)

Electric

Start

with

Magneto

and

Spark

Advance

.

S^BTC

(Stopped)

24'’BTC

(Running)

2

Engine

Set-Up

Inspect

the

engine

visually.

Check

for

loose

or

missing

parts

and

any

damage

that

may

have

occurred

in

shipment.

Oil

and

fuel

have

been

drained

from

the

engine

prior

to

shipping

from

Onan.

Severe

engine

damage

will

result

if

engine

is

started

without

oil.

ACAUTION

BATTERIES

The

batteries

and

battery

cables

used

for

starting

the

engine

should

be

of

sufficient

size

to

provide

prompt

starting.

Undersized

batteries

will

result

in

poor

starter

operation

and

a

very

short

starter

service

life.

AWARNINn

Ignition

of

explosive

battery

gases

'

cause

severe

personal

iniury.

Do

not

smoke

while

servicing

batteries.

CRANKCASE

OIL

RECOMMENDATIONS

Fill

crankcase

with

correct

amount

of

oil.

Refer

to

SPECIFICATIONS

for

crankcase

capacity.

Use

oils

meeting

the

American

Petroleum

Institute

(API)

classi¬

fication

SE

or

SE/CC.

Crankcase

pressure

can

blow

out

hot

oil

and

cause

serious

burns.

Do

NOT

check

oil

while

the

engine

is

operating.

Do

not

overfill

crankcase.

Excess

oil

causes

higher

operating

fempera-

fures

and

may

cause

foaming.

lACAUTION

AWARNING

Oil

Level

Check

oil

level

at

least

every

8

hours

of

operation.

Check

more

frequently

on

a

new

or

reconditioned

engine

as

oil

consumption

is

higher

until

the

piston

rings

seat

properly.

When

adding

oil

between

oil

changes,

it

is

preferable

to

use

the

same

brand,

as

various

brands

of

oil

may

not

be

compatible

together.

Refer

to

MAINTENANCE

section

for

recommended

oil

change

intervals

and

procedures.

FUEL

RECOMMENDATIONS

AVAMQwiMr'l

Ignition

of

fuel

can

cause

serious

a4WAnN»NO|

persona/

injury

or

death

by

fire

or

explosion.

Do

not

permit

any

flame,

cigarette,

or

other

igniter

near

the

fuel

system.

Use

clean,

fresh,

unleaded

gasoline.

Regular

leaded

gasoline

may

also

be

used

but

is

not

a

preferred

fuel.

Do

not

use

highly

leaded

premium

gasoline.

Use

of

un¬

leaded

gasoline

results

in

less

maintenance.

Do

not

use

gasoline

de-icers.

Gaso¬

line

de-icers

can

cause

internal

damage

to

carburetor

and

fuel

pump

parts.

Do

not

use

fuels

containing

alcohol

concentrations

greater

than

ten

percent.

Fuel

containing

alcohol

may

cause

poor

engine

performance

and

internal

engine

damage.

If

regular

leaded

gasoline

is

used

continually,

carbon

and

lead

deposits

should

be

removed

from

the

cylinder

heads

as

required

because

of

engine

power

loss.

Unleaded

gasoline

may

be

used

safely

after

lead

deposits

have

been

removed.

Spilled

fuel

can

ignite

and

cause

serious

personal

injury

or

death.

Never

fill

the

fuel

tank

when

the

engine

is

running.

AWARNING

ACAUTION

EXHAUST

SYSTEM

Exhaust

products

of

any

internal

combustion

engine

are

toxic

and

can

cause

injury,

or

death

if

inhaled.

All

engine

applications,

especially

those

within

a

confined

area,

should

be

equipped

with

an

exhaust

system

to

discharge

gases

to

the

outside

atmosphere.

AWARMiwr

If^P^l^llof^

exhaust

gases

can

ibWAHNIIMLa

jf,

serious

personal

injury

or

death.

Use

extreme

care

during

installation

to

ensure

a

tight

exhaust

system.

3

Operation

STARTING

Most

engines

are

equipped

with

a

start-stop

switch

and

cable

controlled

choke

and

throttle.

1.

Place

the

throttle

control

in

the

SLOWposition

and

the

choke

into

the

FULL

choke

position.

2.

Turn

the

ignition

switch

on

and

engage

starter.

If

engine

fails

to

start

after

30

seconds

determine

the

cause.

Wait

one

minute

before

recranking.

If

the

engine

fails

to

start

at

first

attempt,

rust

inhibitor

oil

used

at

the

factory

may

have

fouled

the

plugs.

Remove

the

plugs,

clean

in

a

suitable

solvent,

dry

thoroughly

and

reinstall.

Heavy

exhaust

smoke

when

the

engine

is

initially

started

is

normal

and

usually

caused

by

rust

inhibitor

oil..

3.

When

the

engine

starts,

gradually

push

the

choke

lever

in

until

the

engine

runs

smoothly.

4.

Black

smoke

from

the

exhaust

and

a

rough

running

engine

usually

indicate

over-choking.

5.

To

stop

the

engine,

turn

the

ignition

switch

to

the

OFF

position.

BREAK-IN

PROCEDURE

Controlled

break-in

is

the

ideal

fitting

of

all

internal

moving

metal

parts.

Using

the

proper

oil

and

applying

a

conscientious

maintenance

program

during

this

period

helps

assure

satisfactory

service

from

your

Onan

engine.

Maintain

the

proper

cooling

and

lubrication

during

break-in.

Run

the

engine

at

half

load

for

the

first

three

hours

with

intermittent

periods

of

full

load

to

control

engine

break-in.

'

Aral

iTinwl

<^rong

grade

and

weight

of

iiUAU

t

lUiN

;

engine

operating

temperatures

during

break-in

can

cause

engine

damage.

Check

the

oil

level

at

least

every

five

operating

hours.

Add

oil

to

keep

it

at

the

proper

level,

but

never

overfill

as

overfilling

may

cause

the

oil

to

loam

and

enter

the

breather

system.

HOT

WEATHER

OPERATION

When

operating

the

engine

in

temperatures

above

100°F

(38°C),

pay

particular

attention

to

the

following

items

to

prevent

damage;

1.

K

eep

the

engine

cooling

fins

clean

and

free

of

obstruction.

A

caution

Pl^

99

^d

or

clogged

cooling

fins

__

can

cause

over/ieaf/ng

and

engine

damage.

AWARNtwr

Contact

with

rotating

machinery

44VvAnrMirM^

can

cause

serious

personal

injury

or

death.

Stay

clear

of

rotating

components

and

ensure

that

protective

shields

and

guards

are

in

place

and

secured

before

operating

machinery.

2.

See

that

nothing

obstructs

air

flow

to

and

from

the

engine.

3.

Ensure

that

you

are

using

the

proper

grade

and

weight

of

oil

for

ambient

temperatures.

Check

the

oil

level

each

time

you

fill

the

fuel

tank.

4.

Check

the

battery

water

more

frequently

than

every

50

hours

which

is

recommended

under

normal

conditions.

High

temperatures

cause

faster

evapo¬

ration.

5.

Change

crankcase

oil

and

filter

more

frequently

than

recommended

under

normal

conditions.

COLD

WEATHER

OPERATION

When

the

engine

is

being

used

in

temperatures

below

32‘’F

(O^C),

check

the

following

items

closely:

1.

Use

the

correct

grade

and

weight

of

oil

for

the

temperature

conditions.

Change

the

oil

only

when

the

engine

is

warm.

If

an

unexpected

temperature

drop

occurs

when

the

engine

is

filled

with

summer

oil,

before

starting

the

engine,

move

it

to

a

warm

location

until

the

oil

will

flow

freely.

2.

Use

fresh

fuel.

Fill

the

fuel

tank

after

each

day's

use

to

protect

against

moisture

condensation.

3.

Keep

the

battery

in

a

well-charged

condition.

DUST

AND

DIRT

1.

Keep

unit

clean.

Keep

cooling

system

clean.

2.

Service

air

cleaner

as

frequently

as

required.

3.

Change

crankcase

oil

and

filter

more

often

than

recommended

under

normal

conditions.

OUT-OF-SERVICE

PROTECTION

1.

Run

the

engine

until

it

reaches

normal

operating

temperature.

2.

Turn

off

the

fuel

supply

and

run

the

engine

until

it

stops.

3.

Drain

oil

from

oil

base

while

the

engine

is

still

warm.

Refill

with

fresh

crankcase

oil

and

attach

a

tag

stating

viscosity

used.

4

4.

Remove

spark

plugs.

Pour

1

ounce

(2

tablespoons

or

28

grams)

of

rust

inhibitor

or

SAE

#50

oil

into

the

cylinders.

Crank

the

engine

over

a

few

times.

Reinstall

spark

plugs.

5.

Service

air

cleaner

as

outlined

in

MAINTENANCE

section.

6.

Clean

governor

linkage

and

protect

by

wrapping

with

a

clean

cloth.

7.

Plug

exhaust

outlet

to

prevent

entrance

of

moisture,

dirt,

bugs,

etc.

6.

Wipe

entire

unit.

Coat

rustable

parts

with

a

light

film

of

grease

or

oil.

9.

Provide

a

suitable

cover

for

the

entire

unit.

10.

If

battery

equipped,

disconnect

and

follow

standard

battery

storage

procedure.

RETURNING

UNIT

TO

SERVICE

1.

Remove

cover

and

all

protective

wrapping.

Remove

plug

from

exhaust

outlet.

2.

Check

tag

on

oil

base

and

verify

that

oil

viscosity

is

still

correct

for

existing

ambient

temperatures,

3.

Clean

and

check

battery.

Measure

specific

gravity

(1.260

at

77°F

[25''C])

and

verify

level

to

be

at

split

ring.

If

specific

gravity

is

low.

charge

until

correct

value

is

obtained.

If

the

level

is

low,

add

distilled

water

and

charge

until

specific

gravity

is

correct.

4.

Check

that

fuel

filter

and

fuel

lines

are

secure,

with

no

leaks.

5.

Check

carburetor,

adjust

if

necessary.

6.

Connect

battery.

7.

Start

Engine.

After

engine

has

started,

excessive

blue

smoke

Is

exhausted

until

the

rust

Inhibitor

has

burned

away.

AWARNING

EXHAUST

GAS

IS

DEADLY!

Exhaust

gases

contain

carbon

monoxrde,

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:

e

Dizziness

•

Vomiting

•

Headache

e

Muscular

Twitching

•

Weakness

and

Sleepiness

•

Throbbing

in

Temples

It

you

experience

any

of

these

symptoms,

get

out

into

fresh

air

immediately,

shut

down

the

unit

and

do

not

use

until

it

has

been

inspected.

The

best

protection

aga/nsf

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

exbausf

sysfem,

shut

the

unit

down

immediately

and

have

it

inspected

and

repaired

at

once

by

a

competent

mechanic.

5

Maintenance

A

VA/ARMiKjr

I

Accidental

starting

ot

the

engine

can

^yvAhirMiNU

cause

severe

personai

injury

or

death.

Disconnect

the

battery

cable

when

repairs

are

made

to

the

engine,

controls

panel,

or

associated

equipment.

DAILY

CHECKS

OR

EVERY

8

HOURS

The

operator

should

daily

make

a

complete

visual

and

audible

inspection

of

the

engine.

Check

the

following

before

starting

the

engine

for

the

first

time

each

day:

1.

Check

all

fuel

lines

and

fittings

for

possible

leakage.

2.

Inspect

exhaust

system

for

possible

leakage

and

cracks.

Locate

leaks

in

muffler

and

piping

while

the

engine

is

operating.

Repair

all

leaks

immediately

after

they

are

detected

for

personnel

safety.

3.

Inspect

air

cleaner

system

for

leaks.

Make

certain

that

all

clamps

and

fittings

are

tight

and

free

of

potential

leaks.

4.

Check

crankcase

oil

level

with

the

engine

off.

If

oil

level

is

at

or

below

"add"

markon

dipstick

(Figure

1),

add

sufficient

oil

of

the

proper

viscosity

as

specified

in

the

ENGINE

SET-UP

section

to

bring

oil

level

to

the

full

mark

on

the

dipstick.

Do

not

operate

engine

with

oil

level

below

the

"add"

mark.

Allow

a

minimum

ol

10

minulet

for

the

oil

to

drain

down

before

checking.

The

beat

time

to

check

the

oil

it

after

an

overnight

shut-down

period.

CAP

AND

OIL

LCVCU

ll'IUIOM

1

vn

KEEP

OIL

AT

THIS

LEVEL_

I

NEVER

OPERATE

ENGINE

WITH

OIL

act

1

r\/ri

FULL

MT4

^“LUW

ALWAYS

REPLACE

CAP

TIGHTLY.

OR

OIL

LEAKAGE

MAY

OCCUR

FIGURE

1.

CRANKCASE

OIL

FILL

OIL

CHANGE

Change

crankcase

oil

after

the

first

25

hours

of

operation.

Thereafter

change

crankcase

oil

every

50

hours

on

engines

equipped

with

oil

filter

and

every

25

hours

on

engines

without

oil

filter.

If

operating

in

extremely

dusty,

high

ambient,

or

low

ambient

conditions

change

oil

more

often.

Run

engine

until

thoroughly

warm

before

draining

oil.

Stop

the

engine,

place

a

pan

under

the

drain

outlet

and

remove

the

oil

drain

plug

or

open

the

drain

valve.

After

the

oil

is

completely

drained,

replace

the

drain

plug

or

close

the

drain

valve.

Refill

with

oil

of

the

correct

API

classification

and

appropriate

SAE

viscosity

grade

for

the

temperature

conditions

(refer

to

ENGINE

SET-UP

section).

AUUADMIMP!

crankcase

oil

can

cause

burns

if

AkWAnNinfj:

spilled

or

splashed

on

skin.

Keep

lingers

and

hands

clear

when

removing

the

oil

drain

plug

and

wear

protective

clothing.

Oil

level

should

be

to

the

"full"

mark

of

the

dipstick.

Start

engine

and

run

for

a

short

time

to

check

for

oil

leaks

around

the

drain

plug.

OIL

FILTER

CHANGE

Replace

oil

filter

(Figure

2)

after

the

first

25

hours

of

operation,

and

every

100

hours

thereafter.

If

operating

in

extremely

dusty,

high

ambient,

or

low

ambient

conditions

change

oil

filter

more

often.

Spin

off

oil

filter

element

and

discard

it.

Thoroughly

clean

filter

mounting

surface

and

install

new

element,

making

sure

new

gasket

is

inserted

in

the

element.

Apply

a

thin

film

of

oil

to

the

gasket.

Spin

element

down

by

hand

until

gasket

just

touches

mounting

pad

and

then

turn

down

an

additional

1/4-1/2

turn.

Do

not

overtighten.

6

With

oil

in

crankcase,

start

engine

and

check

for

leaks

around

filter

element.

Retighten

only

as

much

as

necessary

to

eliminate

leaks,

but

do

not

overtighten.

IGNITION

Spark

Plugs

Check,

and

regap

spark

plugs

every

100

hours

of

operation

(Figure

3).

Replace

spark

plugs

that

show

signs

of

fouling

or

electrode

erosion.

FIGURE

3.

SPARK

PLUG

GAP

Breaker

Points

Check

breaker

points

every

100

hours.

Replace

points

and

condenser

every

200

operating

hours.

Replace

sooner

if

points

are

pitted

or

burned.

See

ADJUSTMENTS

section.

COOLING

SYSTEM

Check

and

clean

cooling

fins

and

chaff

screen

at

least

every

50

hours.

Remove

any

dust,

dirt

or

oil

which

may

have

accumulated.

BATTERIES

Disconnect

negative

ground

strap

from

the

battery

before

working

on

any

part

of

the

electrical

system

or

engine.

Disconnect

positive

terminals

before

charging

batter¬

ies

to

avoid

damaging

alternator

or

regulator.

AWARNING

fSnition

of

explosive

battery

gases

_

can

cause

severe

personal

injury.

Do

not

smoke

while

servicing

batteries.

Cleaning

Batteries

Keep

the

batteries

clean

by

wiping

them

with

a

damp

cloth

whenever

dirt

appears

excessive.

If

corrosion

is

present

around

the

terminal

connections,

remove

battery

cables

and

wash

the

terminals

with

an

ammonia

solution

or

a

solution

consisting

of

1

/4

pound

of

baking

soda

added

to

1

quart

of

water.

Be

sure

the

vent

plugs

are

tight

to

prevent

cleaning

solution

from

entering

the

cells.

After

cleaning,

flush

the

outside

of

the

battery,

the

battery

compartment,

and

surrounding

areas

with

clear

water.

Keep

the

battery

terminals

clean

and

tight.

After

making

connections,

coat

the

terminals

with

a

light

application

of

petroleum

jelly

or

non-conductive

grease

to

retard

corrosion.

Checking

Specific

Gravity

Use

a

battery

hydrometer

to

check

the

specific

gravity

of

the

electrol^e

in

each

battery

cell.

Hold

the

hydrometer

vertical

and

take

the

reading.

Correct

the

reading

by

adding

four

gravity

points

(0.004)

for

every

five

degrees

the

electrolyte

temperature

is

above

SO®

F

(27'’C)

or

subtracting

four

gravity

points

for

every

five

degrees

below

60°F

(27°C).

A

fully

charged

battery

will

have

a

corrected

specific

gravity

of

1.260.

Charge

the

battery

if

the

reading

is

below

1.215.

Checking

Electroiyte

Levei

Check

the

level

of

the

electrolyte

(acid

and

water

solution)

in

the

batteries

at

least

every

50

hours

of

operation.

Fill

the

battery

cells

to

the

bottom

of

the

filler

neck.

If

cells

are

low

on

water,

add

distilled

water

and

recharge.

If

one

cell

is

low,

check

case

for

leaks.

Keep

the

battery

case

clean

and

dry.

An

accumulation

of

moisture

will

lead

to

a

more

rapid

discharge

and

battery

failure.

ACAUTION

Do

not

add

water

in

freezing

weather

unless

the

engine

is

to

be

run

long

enough

(two

or

three

hours)

to

assure

a

thorough

mixing

of

water

and

electrolyte.

Storing

Batteries

If

the

engine

is

to

be

stored

for

more

than

30

days,

remove

the

batteries.

With

the

electroiyte

level

at

the

bottom

of

the

split

ring,

charge

the

battery

before

storing

it.

After

every

30

days

the

battery

is

in

storage,

bring

it

back

up

to

full

charge.

To

reduce

self-discharge,

store

the

battery

in

as

cool

a

place

as

possible

so

long

as

the

electrolyte

does

not

freeze.

7

CRANKCASE

BREATHER

This

engine

uses

a

crankcase

breather

valve

for

main¬

taining

crankcase

vacuum.

If

the

crankcase

becomes

pressurized

as

evidenced

by

oii

ieaks

at

the

seals,

clean

valve

in

a

suitable

solvent.

Check

and

clean

valve

screens

and

baffle

every

200

hours

of

operation.

See

Figure

4.

BREATHER

HOSE

HOSE

CLAMP

CAP

AND

VALVE

■

O"

RING

SCREEN

BREATHER

TUBE

SCREEN

CLAMP

AIR

CLEANER

Cartridge

Air

Cleaner

Check

and

clean

air

cleaner

element

every

25

hours

(Figure

5).

Clean

by

gently

tapping

element

on

a

flat

surface.

Replace

the

element

every

200

hours.

Clean

or

replace

more

frequently

In

dusty

operating

conditions.

Air

Cleaner

Wrapper

(Pre-Cleaner

[if

used])

Wash

in

water

and

detergent

and

squeeze

dry

like

a

sponge

(Figure

5).

Allow

to

dry.

then

coat

evenly

with

two

tablespoons

(26

grams)

of

SAE

30

engine

oil.

Knead

into

and

wring

excess

oil

from

pre-cleaner.

Reinstall

over

cartridge.

Failure

(o

adequately

writtg

out

exceea

oil

Irom

the

wrapper

may

cauM

drop

In

englrte

horeepower

due

to

an

increaaed

raelrtction

ol

Inlet

air.

AIR

CLEANER

ELEMENT

FIGURE

4.

CRANKCASE

BREATHER

1

WASH

2.

SQUEEZE

DRY

3.

COAT

WITH

OIL

4.

INSTALL

OVER

PAPER

ELEMENT

EXHAUST

SYSTEM

Make

regular

visible

and

audible

Inspections

of

the

exhaust

system

throughout

the

entire

life

of

the

engine.

Locate

leaks

In

muffler

and

piping

while

the

engine

Is

operating.

Repair

all

leaks

immediately

after

they

are

detected

for

personnel

safety.

~A

WARMiKin

Inhalation

of

exhaust

gases

can

result

AAWMMiNir'ttj

serious

personal

Injury

or

death.

Inspect

exhaust

system

audibly

and

xisually

tor

leaks

daily.

Repair

any

leaks

immediately.

FIGURE

5.

AIR

CLEANER

ASSEMBLY

6