Tecumseh Engine OV490EA Operators Manual
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Operator’s Manual Four-Cycle Engine • Vertical Crankshaft • Air-Cooled Table of Contents IMPORTANT NOTICE! Safety Definitions ........................................ ii I. General Safety Precautions.............................................................. 1 II. How to Get Service........................................................................... 3 III. Oil and Fuel Specifications ............................................................... 3 IV. Before Starting Your Engine ............................................................. 4 V. Starting Your Engine ......................................................................... 6 VI. Stopping Your Engine and Short-Term Storage ................................ 9 VII. Maintenance ................................................................................... 10 VIII. Transporting Your Engine ............................................................... 13 IX. Storing Your Engine ........................................................................ 13 X. Preventing Forest, Brush and Grass Fires ..................................... 15 XI. Maintenance Intervals .................................................................... 16 California & US EPA Emission Control Warranty Statement .......... 20 Emission Control System Warranty ................................................ 21 XII. Warranty Information ...................................................................... 22 181-887-14 (English) 01/01/04 OV490EA (OHV140-180)
Page iiFour-Cycle Engine • Vertical Crankshaft • Air-Cooled181-887-14 IMPORTANT NOTICE! Safety Definitions Statements in this manual preceded by the following words and graphics are of special significance: Or WARNING indicates a potentially hazardous situation which if not avoided, could result in death or serious injury. NOTE Refers to important information and is placed in italic type. It is recommended that you take special notice of all items discussed on the next two pages and wear the appropriate safety equipment. Before operating this engine it is your responsibility to read this Operator’s Manual. Follow these basic rules for your personal safety: • Keep this manual handy at all times for future reference. • Read it carefully and familiarize yourself with operating, maintenance, components and safety instructions. Notice Regarding Emissions NOTE Engines which are certified to comply with California and U.S. EPA emission regulations for SORE (Small Off Road Equipment), are certified to operate on regular unleaded gasoline, and may include the following emission control systems: (EM) Engine Modification and (TWC) Three-way Catalyst (if so equipped). Tecumseh Contact Information For engine adjustments, repairs or warranty service not covered in this manual, contact your nearest Authorized Tecumseh Servicing Dealer. Find them on our website at www.TecumsehPower.com or call Tecumseh Power Company at 1-800-558-5402. ! WARNING !WARNING ©Copyright 2004 Tecumseh Power Company All Rights Reserved
181-887-14Four-Cycle Engine • Vertical Crankshaft • Air-CooledPage 1 I. General Safety Precautions ! WARNING A. Avoid Carbon Monoxide Poisoning All engine exhaust contains carbon monoxide, a deadly gas. Breathing carbon monoxide can cause headaches, dizziness, drowsiness, nausea, confusion and eventually death. Carbon monoxide is a colorless, odorless, tasteless gas which may be present even if you do not see or smell any engine exhaust. Deadly levels of carbon monoxide can collect rapidly and you can quickly be overcome and unable to save yourself. Also, deadly levels of carbon monoxide can linger for hours or days in enclosed or poorly-ventilated areas. If you experience any symptoms of carbon monoxide poisoning, leave the area immediately, get fresh air, and SEEK MEDICAL TREATMENT. To prevent serious injury or death from carbon monoxide: • NEVER run engine indoors. Even if you try to ventilate engine exhaust with fans or open windows and doors, carbon monoxide can rapidly reach dangerous levels. • NEVER run engine in poorly-ventilated or partially enclosed areas such as barns, garages, basements, carports, under dwellings, or in pits. • NEVER run engine outdoors where engine exhaust can be drawn into a building through openings such as windows and doors. B. Avoid Gasoline Fires Gasoline (fuel) vapors are highly flammable and can explode. Fuel vapors can spread and be ignited by a spark or flame many feet away from engine. To prevent injury or death from fuel fires, follow these instructions: • NEVER store engine with fuel in fuel tank inside a building with potential sources of ignition such as hot water and space heaters, clothes dryers, electric motors, etc. • NEVER remove fuel cap or add fuel when engine is running.• NEVER start or operate the engine with the fuel fill cap removed. • Allow engine to cool before refueling. • NEVER fill fuel tank indoors. Fill fuel tank outdoors in a well-ventilated area. • DO NOT smoke while refueling tank. • Use only an approved red GASOLINE container to store and dispense fuel. Tecumseh recommends purchasing gasoline in containers with a capacity of 2.5 gallons or less. Small containers are easier to handle and help eliminate spillage during refueling. • DO NOT pour fuel from engine or siphon fuel by mouth. To empty the fuel tank see I. Draining Fuel instructions on page 14. C. Adult Supervision of Operation, Refueling and Maintenance The manufacturer of the application may provide information about who is allowed to use this engine (see equipment manufacturer’s manual). Not everyone who is allowed to use this engine is capable of safely and responsibly operating, maintaining and/or fueling it. Tecumseh recommends the following: • An adult should fuel this engine. NEVER allow children to refuel this engine. See C. Filling Fuel Tank instructions on page 5. • An adult should perform maintenance on this engine. See VII. Maintenance instructions on page 10. Only allow children to perform maintenance if an adult has determined they are experienced and capable of such operation. • An adult should start the engine. See G. Avoid Accidental Starts instructions on page 2. Only allow children to start the engine if an adult has determined they are experienced and capable of such operation. • To avoid unsupervised operation of the engine, especially by children, NEVER leave it unattended when it is running. D. Stay Away from Rotating Parts NEVER operate the engine with an unguarded engine shaft. The equipment manufacturer may attach a sprocket and chain or pulley and belt to the engine shaft. If these parts are not properly guarded, or if you are not sure whether they are properly guarded, DO NOT use your engine; contact the equipment manufacturer. Hands, feet, hair, jewelry, clothing, etc. can become entangled in rotating parts, leading to serious injury or death. To avoid serious injury or death, be sure the flywheel guard is in place. See Figure 1. Read equipment manufacturer’s manual and this material thoroughly before using this engine. Failure to do so can result in serious injury or death. Call Tecumseh Power Company at 1-800-558-5402 or visit www.TecumsehPower.com if you have any questions.
Page 2Four-Cycle Engine • Vertical Crankshaft • Air-Cooled181-887-14 E. Do Not Modify Engine To avoid serious injury or death, DO NOT modify engine in any way. Tampering with the governor setting can lead to a runaway engine and cause it to operate at unsafe speeds. NEVER tamper with factory setting of engine governor. ! WARNING F. Avoid Burns and Fire from Hot Surfaces The muffler and other engine parts become extremely hot during operation and remain hot after the engine has stopped. • To avoid severe burns on contact, NEVER operate the engine without the muffler guard in place, and avoid hot areas of the engine. • To reduce the risk of fire keep all materials that can burn, including grass and leaves, away from muffler and rest of engine. DO NOT operate, idle or park the engine application in long dry grass or other dry ground cover. G. Avoid Accidental Starts To prevent accidental starting when working on equipment always: • Disconnect spark plug wire and keep it away from spark plug. See Figure 2. • Keep the disconnected spark plug wire securely away from metal parts where arcing could occur. • Attach the spark plug wire to the grounding post, if provided. See Figure 3. • Disconnect battery at negative terminal first, if engine is equipped with an electric starter. • Turn off all engine switches. • Remove ignition key, if provided. H. Use Hearing Protection Engine noise may cause hearing damage. Always wear hearing protection when operating an engine.Use of this engine on fun-carts, go-karts, or mini-bikes can result in serious injury or death. Tecumseh manufactures the Power Sport line of engines for use in such applications. Consult your local Authorized Tecumseh Servicing Dealer, call 1-800-558-5402, or go to www.TecumsehPower.com for additional information. Figure 1. Typical Flywheel Guard Location Figure 2. Disconnecting/Connecting Spark Plug Figure 3. Typical Spark Plug Connection
181-887-14Four-Cycle Engine • Vertical Crankshaft • Air-CooledPage 3 II. How to Get Service For engine adjustments, repairs or warranty service not covered in this manual, contact your nearest Authorized Tecumseh Servicing Dealer. Find them on our website at www.TecumsehPower.com or call Tecumseh Power Company at 1-800-558-5402. A. Engine Identification Decal A sample engine identification decal (See Figure 4.) indicates the engine’s model number, specification of engine and the date of manufacture (D.O.M.). Please look at the decal on your engine and fill in this information in the spaces provided for future reference. The engine identification decal also includes engine life specifications for the emissions-related useful life period of your engine. This period relates to the emission compliance life as certified by EPA and/or CARB. To find the life period specification for your engine, please look on your engine’s decal and find the letter enclosed by quotation marks between the words MODERATE and LIFE PERIOD. Match one of the following letters with the letter printed on your decal. For example, OV (OHV ) models are designated as “C” 250 hours, “B” 500 hours, and “A” 1000 hours. B. Tecumseh Technician’s Handbooks If you have a general understanding of internal combustion engines and wish to repair and service your engine and/or engine emission control systems yourself, a Technician’s Handbook is available from your Authorized Tecumseh Servicing Dealer. See Figure 5. This handbook covers repairs and adjustments not covered within this Operator’s Manual, and it is intended for individuals who have had adequate training, experience and who practice proper tool usage. Service procedures should be clearly understood and practiced when servicing Tecumseh Engines. Order as part no. 695244A for OV (OHV) models. Tecumseh manufactures and is responsible only for the engine used on this power equipment. If repair or service is needed for anything other than the engine, contact the service source recommended by the equipment manufacturer. III. Oil and Fuel Specifications A. Oil To operate engine you need to use a clean, high quality, detergent oil. For recommended engine oil, See Table 1. NOTES Be sure original container is marked A.P.I. Service “SL/SJ”. Using multigrade oil above 32°F (0°C) will increase oil consumption. SAE10W40 is not recommended. The oil sump capacity (including oil filter) is 62 ounces or 3- 7/8 U.S. Pints (1.83 liters). The oil sump capacity (without oil filter) is 55 ounces or 3-7/16 U.S. Pints (1.62 liters). Tecumseh special-formulated oils are available at your Authorized Tecumseh Servicing Dealer.Figure 4. Engine Identification Label Figure 5. Technician Handbook Table 1. Recommended Engine Oil SSSSSSSSSSSSSAAAAAAAAAMMMMMM PLLLLLEEEEEEEEEETECUMSEH POWER COMPANYTHIS ENGINE MEETS 1995-2005 CALIF & US EPA PHI APPLICABLE EMISSION REGULATIONS FOR SI SORE ENGINES LV195EA 361540D 4TPXS.1951BB 19504015AA0001EM 2083 ENGINE MODEL: SPEC: D.O.M.: 4 -CYCLE OVERHEAD VALVE ENGINES TECHNICIANS HANDBOOK -20 FO32 FO32 FO32 FO40 FO -20 CO20 FO 40 CO30 CO20 CO10 CO0CO-10 CO-30 CO0FO60 FO80 FO100 FO Straight Grade 730225A or SAE30WTecumseh Part No. Multi Grade 730226A or SAE5W30 or SAE10WTecumseh Part No. Synthetic 730263 or SAE0W30Tecumseh Part No. Tecumseh Recommended Oil Usage
Page 4Four-Cycle Engine • Vertical Crankshaft • Air-Cooled181-887-14 B. Fuel Use unleaded regular, unleaded premium or reformulated automotive fuel only. You may use gasoline containing the following components identified in Table 2. • DO NOT use leaded fuel. • Fuel must be fresh and clean. NEVER use fuel left over from last season or stored for long periods. • NEVER mix oil with fuel. • DO NOT use fuel containing Methanol (Wood Alcohol). IV. Before Starting Your Engine A. Checking Oil Level To avoid engine damage, it is important to: • Check oil level before each use and every 5 operating hours when engine is warm. Check oil level more frequently during engine break-in. • Keep oil level between “FULL” and “ADD” marks on dipstick. See Figure 6. • Insure oil fill cap/plug is tightened securely. NOTES Do not overfill oil filler. Doing so may result in oil carry-over to the air cleaner and equipment malfunction or damage. Do not allow oil level to fall below the “ADD” mark on dipstick. Doing so may result in equipment malfunction or damage. Contact your Authorized Tecumseh Servicing Dealer for Tecumseh Oil.Table 2. Recommended Fuel Fuel ComponentPercentage Ethanol 10% Grain Alcohol (“Gasohol”) 10% MTBE (Methyl Tertiary Butyl Ether) 15% ETBE (Ethyl Tertiary Butyl Ether) 15% Figure 6. Engine Oil Level FULL ADD OK Fill between “FULL” and “ADD” Marks
181-887-14Four-Cycle Engine • Vertical Crankshaft • Air-CooledPage 5 B. Filling Oil Sump 1. Be sure engine is upright and level. 2. Unscrew oil fill cap from oil filler tube and wipe dipstick clean. See Figure 7. 3. Screw oil fill cap back into oil filler tube. Tighten securely. 4. Unscrew and remove oil fill cap from oil filler tube. Note oil level. If oil reading on dipstick is below “ADD” mark, slowly add oil to reach “FULL” level. See Figure 6. 5. Screw oil fill cap back into oil filler tube. Tighten securely. 6. Wipe away any spilled oil. C. Filling Fuel Tank An adult should fuel this engine. NEVER allow children to refuel this engine. Gasoline (fuel) vapors are highly flammable and can explode. Fuel vapors can spread and be ignited by a spark or flame many feet away from engine. To prevent injury or death from fuel fires, follow these instructions: 1. Stop engine and allow it to cool before refueling. 2. Be sure engine is outdoors and in a well-ventilated area. 3. Clean area around fuel fill cap and remove fuel fill cap. 4. Using an approved red GASOLINE container, add fuel slowly, being careful to avoid spilling. DO NOT overfill fuel tank. Leave space in the tank to allow fuel to expand without overflowing. 5. Replace fuel fill cap securely and wipe up spilled fuel before starting engine. If fuel is spilled DO NOT start engine. Move machine away from area of spillage. Avoid creating any source of ignition until fuel vapors are gone.!WARNING Figure 7. Engine with Oil Fill Dipstick 1. Spark Plug 2. Spark Plug Cap 3. Spark Plug Wire 4. Air Intake Screen 5. Oil Fill Plug and Dipstick 6. Oil Filter (Optional) 7. Carburetor15 4 6 7 2 3
Page 6Four-Cycle Engine • Vertical Crankshaft • Air-Cooled181-887-14 V. Starting Your Engine An adult should start the engine. Only allow children to start engine if an adult has determined they are experienced and capable of such operation. If you are unable to start this engine after following instructions in this manual, contact your Authorized Tecumseh Servicing Dealer. To avoid serious burn injuries or damage to your engine, DO NOT attempt to start or troubleshoot this engine in any other way. For example: • DO NOT use starting fluid. • DO NOT spray flammable vapors into carburetor or onto air cleaner. • DO NOT put flammable liquids into carburetor or onto air cleaner. • DO NOT operate engine or pull on starter rope with spark plug removed. Fuel can spray from spark plug hole and ignite. This section contains starting instructions for electric and manual start engines. In order to locate the instructions that apply to your engine, first determine what type of starter you have. If you have an electric starter see “A. Engines with Electric Starters” instructions. If you have a manual recoil starter see B. Engines with Recoil Starters instructions on page 8. A. Engines with Electric Starters Only one of the following two sections will apply to your engine. See Table 3. I. Combined Speed and Choke Control 1. To avoid carbon monoxide poisoning, be sure engine is outdoors in a well-ventilated area. 2. Move combine control to “CHOKE” or “START” position (see equipment manufacturer’s instructions). See Fig- ures 8 and 9. NOTE If restarting a warm engine after a short shutdown, move combined control to “FAST” instead of “CHOKE” or “START” position. See Figures 8 and 9. 3. Push starter button or turn ignition switch key (see equipment manufacturer’s instructions) to start engine. NOTES If engine fails to start after 3 attempts repeat steps 2 thru 3. DO NOT operate an electric starter for more than 5 seconds each attempt. 4. When engine starts: a. Release starter button or ignition switch key. b. Next, move combined control to “FAST”. c. Finally, move combined control to desired speed in “RUN” range. NOTES If engine starts, but falters when combined control is moved to “FAST” position: a. Momentarily move combined control back to “CHOKE” position. b. Next, move combined control to “FAST” position. c. Finally, move combined control to desired speed in “RUN” range. If engine dies after combined control is moved to “FAST” position, repeat steps 2 thru 4 to restart engine. 5. If engine fires but does not continue to run, move com- bined control lever to “FAST” position and then start engine. 6. If engine fails to start after 3 attempts with combined control in “FAST” position, move control to “CHOKE” position and push button or turn key to start engine again. 7. If engine does not start after following steps 1 thru 6, contact your Authorized Tecumseh Servicing Dealer. DO NOT attempt to start or troubleshoot this engine in any other way. Table 3. Engine Sections with Electric Starters If your engine has:Go to: Combined Speed and Choke Controls Section A.I Independent Speed and Choke ControlsSection A.II !WARNING !WARNING Figure 8. Combined Speed and Choke Control Figure 9. Typical Engine Symbols STOP STOP SLOW RUN FAST CHOKE
181-887-14Four-Cycle Engine • Vertical Crankshaft • Air-CooledPage 7 II. Independent Speed and Choke Controls 1. To avoid carbon monoxide poisoning, make sure engine is outdoors in a well-ventilated area. 2. Move engine speed control to “FAST” position and set choke control to “FULL” position (see equipment manu- facturer’s instructions). See Figures 9, 10, 11 and 12. NOTES Generator and Water Pump applications may have the choke lever mounted on the engine. See Figure 12. If restarting a warm engine after a short shutdown, move Speed Control to “FAST” position and move Choke Control to “NO CHOKE” position. 3. Push starter button or turn ignition switch key (see equipment manufacturer’s instructions) to start engine. NOTES DO NOT operate an electric starter for more than 5 seconds each attempt. If engine fails to start after 3 attempts repeat steps 2 thru 3. 4. When engine starts: a. Release starter button or ignition switch key. b. Next, move choke control to “1/2 CHOKE” position until engine runs smoothly. c. Next, move choke control to “NO CHOKE” position. 5. Finally, move engine speed control to desired speed in “RUN” range. NOTES If engine starts, but falters when choke is moved to “NO CHOKE” position: a. Momentarily move choke control back to “FULL CHOKE” position. b. Next, move choke control to “1/2 CHOKE” position until engine runs smoothly. c. Finally, move choke control to “NO CHOKE” position. If engine dies after control is moved to “NO CHOKE” position, repeat steps 2 thru 5 to restart engine. 6. If engine fires but does not continue to run, move choke control lever to “NO CHOKE” position and start engine. 7. If engine fails to start after 3 attempts in the “NO CHOKE” position, move choke control to “FULL CHOKE” position and start engine. 8. If engine does not start after following steps 1 thru 7, contact your Authorized Tecumseh Servicing Dealer. DO NOT attempt to start or troubleshoot this engine in any other way .Figure 10. Independent Speed and Choke Controls Figure 11. Choke Control Positions Figure 12. Engine Mounted Choke LeverChoke Control Speed Control 1. No Choke 2. 1/2 Choke 3. Full Choke12 3 1. No Choke 2. 1/2 Choke 3. Full Choke12 3
Page 8Four-Cycle Engine • Vertical Crankshaft • Air-Cooled181-887-14 B. Engines with Recoil Starters If you have an electric starter see A. Engines with Electric Starters instructions on page 6. Only one of the following two sections will apply to your engine. See Table 4. I. Combined Speed and Choke Control 1. To avoid carbon monoxide poisoning, be sure engine is outdoors in a well-ventilated area. 2. Move combined control to “CHOKE” or “START” posi- tion, if present (see equipment manufacturer’s instruc- tions). See Figures 13 and 14. NOTE If restarting a warm engine after a short shutdown, move combined Control to “FAST” instead of “CHOKE” or “START” position. See Figures 13 and 14. When pulling starter rope, the rope can unexpectedly jerk back toward engine causing serious injury. To avoid this risk, carefully follow these instructions: 3. Grasp starter cord handle. See Figure 15. a. Pull rope out slowly until you feel drag. b. Without allowing the rope to retract, continue pulling rope with one rapid full arm stroke. c. Return rope slowly to original position. NOTES Following the instructions listed in the steps above avoids potential damage to the recoil mechanism. If engine fails after 3 pulls repeat steps 2 thru 3. 4. When engine starts: d. Move combined control to “FAST” position. e. Next, move combined control to desired speed in “RUN” range. See Figure 13. See Figure 14. NOTES If engine starts, but falters when combined control is moved to “FAST” position: a. Momentarily move combined control back to “CHOKE” position.b. Next, move combined control to “FAST” position. c. Finally, move combined control to desired speed in “RUN” range. If engine dies after combined control is moved to “FAST” position, repeat steps 2 thru 4 to restart engine. If engine fires but does not continue to run, move combined control lever to “FAST” position and pull the starter rope. 5. If engine fails to start after 3 attempts with combined control in the “FAST” position, move combined control to “FULL CHOKE” position and pull the starter rope again. 6. If engine does not start after following steps 1 thru 5, contact your Authorized Tecumseh Servicing Dealer. DO NOT attempt to start or troubleshoot this engine in any other way. Table 4. Engine Sections with Recoil Starters If your engine has:Go to: Combined Speed and Choke Controls Section B.I Independent Speed and Choke Controls Section B.II !WARNINGFigure 13. Combined Speed and Choke Control Figure 14. Typical Engine Symbols Figure 15. Recoil Starter STOP STOP SLOW RUN FAST CHOKE