Onan Performer Series P216, P218, P220, P224 Engine Operator's Manual

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P216, P218
P220, P224
Performer Series
965-0167
11-95
Printed in U.S.A.
Safety Precautions
Thoroughly read the OPERATOR'S MANUAL before
operating the engine. Safe operation and top perfor-
mance can be obtained only with proper operation
and maintenance.
The following symbols in this Manual alert you to potential
hazards to the operator, service person and equipment.
Alerts you to an immediate hazard
which will result in severe personal injury or death.
[AWARNING] Alerts you to a hazard or unsafe
practice which can result in severe personal injury or
death.
A CAUTION| Alerts you to a hazard or unsafe
practice which can result in personal injury or equip-
ment damage.
Electricity, fuel, exhaust, moving parts and batteries
present hazards which can result in severe personal inju-
ry or death.
GENERAL PRECAUTIONS
* Keep ABC fire extinguishers handy.
e Make sure all fasteners are secure and torqued
properly.
» Keep the engine and its compartment clean. Excess
oil and oily rags can catch fire. Dirt and gear stowed
in the compartment can restrict cooling air.
e Before working on the engine, disconnect the nega-
tive (=) battery cable at the battery to prevent start-
ing.
* Use caution when making adjustments while the en-
gine is running—hot, moving or electrically live parts
can cause severe personal injury or death.
* Used engine oil has been identified by some state
and federal agencies as causing cancer or
reproductive toxicity. Do not ingest, inhale, or
contact used oil or its vapors.
e Benzene and lead in some gasolines have been
identified by some state and federal agencies as
causing cancer or reproductive toxicity. Do not to
ingest, inhale or contact gasoline or its vapors.
* Do not work on the engine when mentally or physi-
cally fatigued or after consuming alcohol or drugs.
» Carefully follow all applicable local, state and federal
codes.
AWARNING | This engine is not designed or in-
tended for use in aircraft. Such use can lead to
engine failure, severe personal injury or death.
FUEL IS FLAMMABLE AND EXPLOSIVE
Keep flames, cigarettes, sparks, pilot lights, electri-
cal arc-producing equipment and switches and all
other sources of ignition well away from areas where
fuel fumes are present and areas sharing ventila-
tion.
DO NOT fill the fuel tank while the engine is running.
Fuel lines must be copper or steel tubing or piping,
adequately secured and free of leaks.
Use approved flexible fuel hose for connections at
the engine. Do not use copper tubing as a flexible
connector—vibration will cause it to work-harden
and break. Use non-conductive hose if the fuel line
could become a path for cranking current.
The fuel line must have a manual shutoff valve un-
less the highest fuel level in the supply tank is lower
than the connection at the engine.
ENGINE EXHAUST IS DEADLY!
Learn the symptoms of carbon monoxide poisoning
in this Manual.
Inspect the exhaust system every time the engine is
started and after every eight hours of operation. If
the exhaust noise changes, shut down the engine
immediately and have it inspected.
DO NOT use engine cooling air to heat a room.
Make sure there is ample fresh air when operating
the engine in a confined area.
MOVING PARTS CAN CAUSE SEVERE PERSONAL
INJURY OR DEATH
Do not wear loose clothing or jewelry near moving
parts such as PTO shafts, fans, belts and pulleys.
Keep hands away from moving parts.
Keep guards in place over fans, belts, pulleys, etc.
BATTERY GAS IS EXPLOSIVE
WEAR SAFETY GLASSES and DO NOT SMOKE
while servicing batteries.
When disconnecting or reconnecting battery
cables, always disconnect the negative (-) battery
cable first and reconnect it last to reduce arcing.
Table of Contents
BURR. I er SAT WG PAGE
SAFETY PRECAUTIONS ................ UD a AR ART Inside Front Cover
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PERIOD MAINTENANGE 005% 5. = aulas | acia AA Ao 9
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SPECIFICATIONS ...............e-_eecrcacoarererererecereranerecroreearvaroa 17
INFORMATION FOR CALIFORNIA ENGINE USERS .............. coin... 18
The engine exhaust from this product
contains chemicals known to the State
of California to cause cancer, birth
defects or other reproductive harm.
Introduction
ABOUT THIS MANUAL
This manual covers the operation and maintenance
of the horizontal-shaft Performer Series of engines.
Each operator of the power equipment should study
this engine manual carefully and observe all of its
instructions and precautions. Proper use and peri-
odic maintenance are responsibilities of the opera-
tor(s) and are essential for top performance.
MODEL IDENTIFICATION
Whenever contacting an Onan dealer or distributor
for information, parts or service, always provide the
model number and the serial number marked on the
nameplate of the engine. (The serial number is in
the row marked “S/N”, just below the model num-
ber.) Figure 1 illustrates a typical engine nameplate
and Figure 2 the location of the nameplate on the
engine.
Genuine Onan replacement parts obtained from an
Onan dealer or distributor are recommended.
Improper service or parts replace-
ment can lead to severe personal injury or death
and to damage to equipment and property. Ser-
vice personnel must be qualified to perform
electrical and mechanical service.
Unauthorized modifications or re-
placement of fuel, exhaust, air intake or speed
control system components that affect engine
emissions are prohibited by law in the State of
California.
LPG (liquified petroleum gas) is
flammable and explosive and can cause as-
phyxiation. NFPA 58, Section 1.6 requires all
persons handling LPG to be trained in proper
handling and operating procedures.
( IMPORTANT ENGINE INFORMATION \
ONAN CORPORATION
1400 73rd Ave. NE
Minneapolis, MN 55432
Onon.
MADE IN U.S.A.
Engine Model:
P224G-1/1264F
S/N: L951234567 99-2453
REFER TO OPERATOR'S MANUAL FOR
MAINTENANCE SPECIFICATIONS
AND ADJUSTMENTS.
THIS ENGINE MEETS 1995 - 1998
CALIFORNIA EMISSION REGULATIONS
FOR ULGE ENGINES.
SN5980U1G2RA
980 CC
UNLEADED GASOLINE ONLY
FIGURE 1. TYPICAL ENGINE NAMEPLATE
OIL FILL CAP NAMEPLATE LOCATION
THROTTLE —— ен На
CABLE CLAMP LT A
CF
tu
SPARK PLUG
FLYWHEEL/BLOWER
E —— AIR INLET SCREEN
ELECTRIC DA — _ —
STARTER ГГ рен Г
AIR FILTER HOUSING
(Standard and High
Capacity Profiles Shown)
FUEL ha = |
FUEL PUMP
BATTERY CHARGING
VOLTAGE REGULATOR
(Altematively, may be
located on blower
housing)
N
e
*——— CRANKSHAFT
OIL FILTER
le mc pm ym em rm pm
pes
Loa
y
ALTERNATIVE
NAMEPLATE LOCATION
u
1
O
OIL DRAIN — na ee
FIGURE 2. TYPICAL ENGINE CONFIGURATION
FUEL RECOMMENDATIONS
Gasoline and LPG are highly flam-
mable fuels and can cause severe personal inju-
ry or death. Do not smoke if you smell gas or
gasoline or are near fuel tanks or fuel-burning
equipment or are in an area sharing ventilation
with such equipment. Keep flames, sparks, pilot
lights, electrical arcs and arc-producing equip-
ment and all other sources of ignition well away.
Keep a type ABC fire extinguisher nearby.
Gasoline Models
Use clean, fresh unleaded gasoline having a mini-
mum octane rating (Anti-Knock Index) of 87.
During some times of the year only mandated “oxy-
genated” gasolines may be available. These are ac-
ceptable for use, but not preferable. Leaded gaso-
line may be used but will result in the extra mainte-
nance required for removing combustion chamber
and spark plug deposits. Do not use gasoline or
gasoline additives (de-icers) containing methanol
because methanol can be corrosive to fuel system
components.
Do not use gasoline or gasoline ad-
ditives containing methanol because methanol
can be corrosive to fuel system components.
Avoid using highly leaded gasolines and lead
additives because of the extra engine mainte-
nance that will be required.
LPG Models
Use clean, fresh HD-5 grade liquified petroleum gas
(LPG) or equivalent product consisting of at least 90
percent propane. Commercial LPG may contain
more than 2.5 percent butane which can result in
poor fuel vaporization and poor engine starting in
low ambient temperatures (below 32° F (0° C).
Natural Gas Models
Use commercially available natural gas fuel.
ENGINE OIL RECOMMENDATIONS
Use premium quality motor oil. Look for the API
(American Petroleum Institute) classification and
use Class SG or SH oil (also SG/CD, SG/CE, SH/
CD or SH/CE). Also look for the SAE (Society of Au-
tomotive Engineers) viscosity grade. Referring to
Table 1, choose the viscosity grade appropriate for
the ambient temperatures expected during the peri-
od of time until the next scheduled oil change.
Single-grade SAE 30 oil is preferable when temper-
atures are consistently above freezing. Multigrade
oils are better when wide temperature variations are
expected.
TABLE 1. OIL VISCOSITY VS. TEMPERATURE
EXPECTED AMBIENT py
TEMPERATURES E ADE
32° F (0° C) and higher 30
10° F to 100° F (-12° C to 38° C) Onda
0° F to 80° F (-18° C to 27° C) isis:
20° F 10 50° F (28° C to 10° C) 5W-30
STARTING BATTERIES
The engine is equipped with a 12 volt electric starter.
Prompt starting requires sufficient battery capacity
and battery cable size. Neither cranking perfor-
mance nor starter service life will be satisfactory
with an undersized battery.
Regular, monthly maintenance of batteries may be
required. See Periodic Maintenance and any
instructions available from the equipment or battery
manufacturer. It should be noted that as long as the
equipment is operated regularly, the automatic bat-
tery recharging system on the engine should be
able to maintain battery charge. See OUT-OF-SER-
VICE PROTECTION under Operation regarding
battery care during storage for prolonged periods.
EXHAUST SYSTEM
EXHAUST GAS IS DEADLY! Mobile engine-pow-
ered equipment must never be operated inside
buildings or other enclosed spaces without ample
fresh air ventilation.
Stationary engine-powered equipment installed in-
side buildings or other enclosed spaces must be
equipped with a leak-free exhaust system that car-
ries all exhaust gases to the outside, well away from
all windows, doors, vents and other openings into
the building or enclosure.
It is the responsibility of the equipment operator(s)
to check for exhaust leaks on a daily basis and to
have all leaks repaired before continuing to operate
the equipment.
Operation
EXHAUST GAS IS DEADLY!
Exhaust gases contain carbon monoxide, an odorless and colorless gas. Carbon monoxide is poi-
sonous and can cause unconsciousness and death. Symptoms of carbon monoxide poisoning in-
clude:
e Dizziness eo Throbbing in Temples
» Nausea * Muscular Twitching
e Headache e Vomiting
*» Weakness and Sleepiness * Inability to Think Coherently
IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS, GET OUT INTO THE FRESH
AIR IMMEDIATELY. If symptoms persist, seek medical attention. Shut down the engine and do not
operate it until it has been inspected and repaired.
Make certain the exhaust system is properly installed. Inspect it every time the engine is started and
after every eight hours of continuous operation.
PRE-START CHECKS 2. Fill the gasoline or LPG fuel tank, if necessary,
and open any fuel shutoff valve; for example,
Before the first start of the day and after every eight the valve(s) at the LPG container(s).
hours of operation perform the maintenance : Le
instructed in DAILY (8 HOUR) MAINTENANCE un- 3. Release the clutch if the engine is so equipped.
der Periodic Maintenance. Keep a log of mainte- 4, /fthisisagasoline engine with a manual choke,
nance and the hours run and perform any mainte- pull the choke knob out to its full-choke position.
nance that may be due. Also, if the equipment has On equipment with a solenoid operated choke,
been in storage, return the engine to service as push the switch to its choke position. In warm
instructed under RETURNING THE ENGINE TO weather, however, or when the engine is warm,
SERVICE in this section. try starting without the choke.
Always follow the equipment manufacturer's oper- 5. Push the throttle knob or lever to the middle of
ating instructions and observe all precautions when its speed range.
Parar pura eme: 6. Turn the ignition-start switch to its start position
Moving parts can cause severe and hold it there until the engine starts. Do not
wait at least one minute between tries when
cranking. See Troubleshooting if the engine
does not start after several tries.
cause severe burns. Stay clear of hot or moving
parts. Make sure all protective shields and
guards are secure in place before starting up the
equipment. 7. Ifthis is a gasoline engine with a manual choke,
keep your hand on the choke knob and slowly
STARTING push itin to the full-open choke position, pulling
1. Check the oil level if this is the first start of the back inge "вер the engine running
day and add oil as necessary. I
will take the engine to start running smoothly
Starting the engine without oil with the choke fully open. Do not operate the
will cause severe engine damage. Always equipment until the engine has warmed up suf-
keep the engine oil level between the Full ficiently to run smoothly with the choke fully
and Add marks on the dipstick. open.
ENGINE BREAK-IN
Engine break-in as a result of proper care during the
first hours of operation of a new or rebuilt engine re-
sults in the ideal fitting of all internal moving metal
parts, which is essential for top engine perfor-
mance. For controlled engine break-in:
1.
1,
Operate the equipment as it is intended to be
operated. However, for the first 3 hours, if pos-
sible, operate the equipment at about half the
available engine power, occasionally operating
at full engine power for brief periods. Also, if
possible, avoid prolonged low-speed, low-pow-
er operation during engine break-in.
. Proper engine oil is especially critical during
break-in because of the higher engine temper-
atures that can be expected. See REC-
OMMENDED ENGINE OIL in Introduction.
Change the oil if it is not appropriate for the am-
bient temperatures during the break-in period.
See Table 1.
. Check the oil level twice a day or after every 4
hours of operation during the first 24 hours of
operation.
. Change the oil and oil filter after the first 24
hours of operation.
. See Table 2 for engine models which require
valve clearance adjustment after the first 50
hours of operation.
OPERATION IN DUSTY CONDITIONS
Keep the engine cooling fins and flywheel air in-
let screen clean.
2. Perform air cleaner maintenance more often
than normal—as required. See Table 2.
3. Change the engine oil and oil filter more often
than normal. See Table 2.
OPERATION IN HOT WEATHER
Pay particular attention to the following items when
operating the engine in temperatures above 100° F
(38° С):
1. Keep the flywheel air inlet screen and cylinder
cooling fins clean. See to it that nothing ob-
structs air flow to and from the engine.
2. Check the oil level more frequently.
3. Change the oil and oil filter more often than nor-
mal. See Table 2.
4. Make sure the engine oil viscosity is appropri-
ate for the ambient temperatures and change
the oil if necessary. See Table 1.
OPERATION IN COLD WEATHER
Pay particular attention to the following items when
operating the engine in temperatures below freez-
1. Make sure the engine oil viscosity is appropri-
ate for the ambient temperatures and change
the oil if necessary. See Table 1. If the tempera-
ture drops before you have the chance to
change the oil, warm up the engine by moving
the equipment into a heated space before at-
tempting to start the engine or change oil.
AWARNING| EXHAUST GAS IS DEADLY!
Never operate mobile engine-powered
equipment indoors without ample fresh air
ventilation.
. Use fresh gasoline and fill the fuel tank after
each day's use to reduce problems with mois-
ture condensation if this is a gasoline engine.
. Keep the battery in a well-charged condition.
. After each use push the equipment throttle
knob or lever to the middle of its speed range
so that if ice forms on the linkage during storage
it will be easier to start the engine.
OUT-OF-SERVICE PROTECTION
Protect an engine that will be out of service for more
than 30 days as follows:
1. Run the engine until it reaches normal operat-
ing temperature, shut off the fuel supply and let
the engine run until it stops. Also, if the equip-
ment will not be operated for more than 120
days, add a fuel preservative (OnaFresh™) to
the equipment fuel tank (gasoline engines
only). Follow the instructions on the container
label. Unless a preservative (stabilizer) is add-
ed, the gasoline will deteriorate causing fuel
system corrosion, gum formation and varnish-
like deposits which can lead to hard starting
and rough operation.
Gasoline preservatives (stabi-
lizers) are toxic. Follow the instructions on
the container label. Avoid skin contact.
Wash your hands with soap and water after
dispensing the fluid.
. Drain the oil from the engine while it is still
warm. Refill with fresh oil and attach a tag stat-
ing the viscosity of the oil used.
. Remove the spark plugs and squirt 1 ounce
(2 tablespoons or 28 grams) of rust inhibitor or
SAE 30 oil into each cylinder. Crank the engine
over a few times and reinstall the spark plugs.
. Perform air cleaner maintenance as instructed
in Periodic Maintenance.
OnaFresh is a trademark of the Onan Corporation.
On
. Clean the governor linkage and wrap it with a
clean cloth for protection.
6. Plug the exhaust outlet to prevent moisture,
dirt, bugs, etc. from entering.
7. Provide a suitable cover for the entire unit.
8. If so equipped, disconnect the battery (nega-
tive [-] cable first) and follow the battery or
equipment manufacturers storage instruc-
tions.
RETURNING THE ENGINE TO SERVICE
1. Remove the cover and all protective wrapping
and the plug from the exhaust outlet.
2. Check the tag on the oil base. Change the oil if
the viscosity is not appropriate for the expected
ambient temperatures. See Table 1.
3. Check the fuel filter and fuel lines to make sure
they are secure and have no cracks or leaks.
4. Checkto see that the choke, throttle and gover-
nor linkages move freely.
5. If so equipped, clean and check the battery ac-
cording to the battery or equipment manufac-
turer's instructions and connect the battery
cables (positive [+] cable first).
6. Startthe engine. The initial startup may be slow
and there may be smoke and rough operation
for a few minutes until the oil in the cylinder
burns off. If the engine does not start, clean or
replace the spark plugs as they may have been
fouled by the oil added to the cylinder when the
equipment was stored.
Periodic Maintenance
Periodic maintenance is essential for top engine
performance. Use Table 2 as a guide for normal pe-
riodic maintenance. Under hot or dusty operating
conditions some maintenance operations should be
performed more frequently, as indicated by the foot-
notes in the table. Keep a log of maintenance per-
formed and the hours run. Recording maintenance
will help you keep it regular and provide a basis for
supporting warranty claims.
TABLE 2. PERIODIC ENGINE MAINTENANCE SCHEDULE
MAINTENANCE FREQUENCY
MAINTENANCE OPERATION | ro Every | Every | Every | Every
Day or | Every 50 | Every 100 200 500 1,000
Every 8 | Hours Month Hours Hours Hours Hours
Hours
Inspect Engine ol
Check Oil Level o
Clean Air Cleaner Foam Wrapper ef
Clean Cylinder Cooling Fins ot
Check Starting Battery 6
Change Engine Oil—Standard „2, 4,5
(Low Profile) Base
Change Engine Oil—Medium and „2, 4, 5
High Capacity Bases
Change Engine Oil Filter e2,4,5
Replace Fuel Filter (if so equipped) o
Replace Air Cleaner Element ot
Replace Spark Plugs ©
Adjust Engine Valve Clearance 3,7
(Model P224 only)
Adjust Engine Valve Clearance ir
(Models P216, P218 and P220)
Clean Cylinder Heads of Deposits 7,8
1 Check for oil, fuel and exhaust leaks, loose parts and unusual noises and vibrations.
2 Perform after the first 24 hours of operation as a part of engine break-in.
3 Perform after the first 50 hours of operation as a part of engine break-in.
4 Perform more often when operating in dusty conditions.
5 Perform more often when operating in hot conditions.
6 See instructions for battery care provided by the equipment or battery manufacturer.
7 Must be performed by a qualified mechanic according to the engine Service Manual.
8 Clean more often when using leaded fuel or running the engine continuously under light load. Onan 4C carburetor and
combustion cleaner is recommended every 200 hours of operation.
DAILY (8 HOUR) MAINTENANCE
The operator should check the following before the
first start of the day and after every eight hours of op-
eration:
1.
10
Inspect fuel lines and fittings for leaks. Repair
leaks immediately.
. Look and listen for exhaust system leaks while
the engine is running. Look for cracks and se-
vere rusting in the muffler and tailpipe. Have all
leaks repaired before continuing to operate the
equipment.
Hot exhaust parts can cause
severe burns. Allow the engine time to cool
before servicing the exhaust system.
. Check the engine for dirt and debris and clean
the flywheel air inlet screen and cylinder cool-
ing fins as necessary.
A clogged flywheel air inlet
screen or dirty cooling fins can cause over-
heating and engine damage. Keep the cool-
ing fins and air inlet screen clean.
. Check the engine oil level. The equipment must
be parked on a level surface and the engine
stopped. To get an accurate reading, wait a
minute or so to allow the oil to settle in the
crankcase if the engine has been running.
Crankcase pressure can blow
hot engine oil out the fill tube causing se-
vere burns. Always stop the engine before
removing the oil fill cap.
Turn the oil fill cap (Figure 3) counterclockwise
and then lift it from the fill tube. Wipe the dip
stick clean and push it back into the oil fill tube
until the cap seats and then withdraw it to check
the oil level.
If the oil level is low, add API Class SG or SH oil
(also SG/CD, SG/CE, SH/CD or SH/CE) having
an SAE viscosity grade appropriate for the ex-
pected temperatures, as indicated by Table 1.
DO NOT FILL TO A LEVEL ABOVE THE FULL
MARK ON THE DIPSTICK. Drain the excess oil
if too much has been added.
Too much oil can cause high oil
consumption, high operating temperatures
and oil foaming. Too little oil can cause se-
vere engine damage. Keep the oil level be-
tween the Full and Add marks on the dip-
stick.
Reinstall the dipstick and cap after checking or
adding oil, turning it clockwise until it is secure.
anda
ETA
....[n.
.....
FIGURE 3. OIL FILL CAP AND DIPSTICK
С
€
ENGINE OIL AND FILTER CHANGE
State and federal agencies have de-
termined that contact with used engine oil can
cause cancer or reproductive toxicity. Take care
to limit skin contact and breathing of vapors as
much as possible. Use rubber gloves and wash
exposed skin.
Refer to Table 2 for scheduled oil change and filter
replacement. See Figure 2 on Page 3 for oil filter
and oil drain locations.
1. Run the engine until it is warm. Stop the engine
and disconnect the spark plug and, if so
equipped, the battery (negative [-] cable).
Accidental starting of the en-
gine can result in severe personal injury or
death. Always disconnect the spark plug
and the battery (negative [-] cable) before
changing oil.
2. Remove the oil fill cap.
Crankcase pressure can blow
hot engine oil out the fill opening causing
severe burns. Always stop the engine be-
fore removing the oil fill cap.
3. Place a pan under the oil drain opening and re-
move the oil drain plug. Reinstall the plug se-
curely after the oil has drained completely.
4. Spin off the oil filter canister, drain the oil and
discard the filter according to local regulations.
5.
6.
Thoroughly wipe off the filter mounting surface.
Make sure the gasket is in place on the filter
canister and apply a thin film of oil to the gasket.
7. Spin on the new filter canister by hand until the
8.
11.
gasket just touches the mounting pad and then
turn it an additional 1/2 to 3/4 turn. Do not over-
tighten.
Refill with API Class SG or SH oil (also SG/CD,
SG/CE, SH/CD or SH/CE) having an SAE vis-
cosity grade appropriate for the expected tem-
peratures, as indicated by Table 1. See Specifi-
cations for the oil capacity.
DO NOT FILL TO A LEVEL ABOVE THE FULL
MARK ON THE DIPSTICK. Drain the excess oil
If too much has been added.
Too much oil can cause high oil
consumption, high operating temperatures
and oil foaming. Too little oil can cause se-
vere engine damage. Keep the oil level be-
tween the Full and Add marks on the dip-
stick.
. Reconnect the spark plug and battery.
10.
Start the engine and run it for a short time while
checking for oil leaks around the drain plug and
oil filter. Do not overtighten: tighten only as nec-
essary to eliminate leaks.
Used oil is harmful to the environment. Pour the
used oil into a sealed container and deliver it to
the nearest recycling center.
11
AIR CLEANER MAINTENANCE
Refer to Table 2 for scheduled foam wrapper main-
tenance and air cleaner element replacement.
Foam Wrapper Maintenance
See Figure 4. When performing maintenance on the
foam wrapper only, do not remove the inner air
cleaner cover. Remove and wash the foam wrapper
in water and detergent. Squeeze the foam wrapper
dry like a sponge. Rinse with clean water and allow it
to dry. Coat the wrapper evenly with one tablespoon
(14 grams) of SAE 30 engine oil. Knead the oil into
the wrapper and wring out the excess oil.
Failure to adequately wring out excess oil from the
wrapper may cause a drop in engine power due toa
restriction of inlet air.
Install the foam wrapper over the paper air cleaner
element by stretching it over the inner cover. Com-
pletely cover all exposed paper pleats on the air
cleaner paper element. Replace the foam wrapper
when it becomes torn or stretched.
Air Cleaner Element Replacement
To keep anything from entering the carburetor and
engine while the air cleaner element is off, pull the
choke knob to the full-choke position to close the
choke plate in the carburetor. Remove the outer
cover and wipe away loose dust and debris from the
air cleaner assembly. Remove the inner air cleaner
mounting nut and cover. Remove the air filter paper
element and foam wrapper from the engine. Wipe
off dust and debris from the air cleaner base.
Install the new paper element and secure it with the
inner cover and mounting nut. Reinstall the foam
wrapper and outer cover.
12
OUTER
NUT
INNER
NUT
AIR
QUTER
e COVER
DL Le
<»
C
(OE ee INNER
4 N COVER
ли
CLEANER ms CLEANER
ELEMENT ri ASSEMBLY
Du BASE
FIGURE 4. AIR CLEANER ASSEMBLY
С
COOLING SYSTEM MAINTENANCE
Refer to Table 2 for scheduled cleaning of the cylin-
der cooling fins.
Use compressed air or a pressure washer to clean
the cylinder cooling fins. Take the following precau-
tions.
1. Wear safety glasses.
AWARNING) Always wear safety glasses
when using compressed air or a pressure
washer to avoid severe eye damage.
2. Let the engine cool, especially when using a
pressure washer. The temperature stresses
caused by cleaning a hot engine can crack the
cylinder.
3. Observe all of the manufacturers instructions
and precautions when using a pressure
washer.
FUEL FILTER REPLACEMENT
Refer to Table 2 for scheduled gasoline fuel filter re-
placement and Figure 2 for the location, if so
equipped. Also refer to the equipment Operator's
Manual regarding any supplemental fuel filters that
may have been provided and the recommended fre-
quency for their replacement.
Take care not to spill fuel when disconnecting the
fuel line from the filter. Allow the engine to cool be-
fore disconnecting the fuel line so as to prevent ig-
niting any fuel that may be spilled. Close any shutoff
valve that may be provided in the fuel line. If the filter
is of the in-line type, it is usually removable by loos-
ening the inlet and outlet hose clamps.
Gasoline is highly flammable and
can cause severe personal injury or death.
Let the engine cool and close any fuel line shut-
off valve before disconnecting the fuel line from
the filter.
Do not smoke if you smell gasoline or are near
fuel tanks or gasoline-burning equipment or are
in an area sharing ventilation with such equip-
ment. Keep flames, sparks, pilot lights, electri-
cal arcs and arc-producing equipment and all
other sources of ignition well away.
SPARK PLUG REPLACEMENT
Refer to Table 2 for scheduled spark plug replace-
ment and Specifications for gap specifications.
To prevent crossthreading the spark plug always
thread it in by hand until it seats. Then turn it with a
wrench an additional 1/16 turn (22-1/2°). If you have
a torque wrench, tighten the spark plugs to 11 Ibs-ft
(14 N-m).
13
Adjustments
CARBURETOR ADJUSTMENTS
These engines have precision-manufactured car-
buretors which are not adjustable.
RECONNECTING THE CHOKE CABLE
If necessary, and if this is a gasoline engine with a
manual choke, refer to Figure 5 or 6, as appropriate,
and reconnect and reclamp the choke cable as fol-
lows:
th
14
Stop the engine and disconnect the spark plugs
and, if so equipped, the battery (negative [-]
cable).
Accidental starting of the en-
gine can result in severe personal injury or
death. Always disconnect the spark plug
and battery (negative [-] cable) before re-
setting the engine control cables.
. Push the equipment choke knob to the full-
open choke position.
. Connect the choke cable to the choke lever.
(The cable will either hook into the choke lever
or be clamped by a screw in a swivel on the
choke lever. See Figure 6.) Pull the slack out of
the cable and clamp it.
. Check for smooth movement and full travel of
the equipment choke knob. Remove the air
cleaner element as explained under Periodic
Maintenance to see that the choke plate opens
and closes fully.
. Reassemble the air cleaner and reconnect the
spark plug and battery.
CHOKE LEVER
(open position)
“AT
-— Y”
CLOSE
CHOKE
в
L
O
Ta
ABLE
CLAMP
FIGURE 5. REAR-PULL CHOKE CABLE
CHOKE LEVEF
(open position)
INTERMEDIATE
LINK AND LEVER
|
NO > -
ANA O у |
| —=
J CLOSE
| U ) O cc CHOKE
N= |
SWIVEL ABLE
CLAMP CLAMP
FIGURE 6. FRONT-PULL CHOKE CABLE
С
с
ENGINE SPEED ADJUSTMENTS
Normally there is no need to adjust engine speed.
These instructions are for the equipment manufac-
turer in setting up and adjusting the equipment.
Engine speed adjustment must be attempted only
by a qualified mechanic and the adjustments must
be made using an accurate tachometer. Set the low-
idle and high-idle speeds to the values specified in
the equipment Operator's Manual. In the absence
of such specifications it is recommended that low-
idle speed be adjusted to 1100 RPM and high-idie
speed to 3400 RPM.
Adjusting the engine speed to a val-
ue above that specified by the equipment
manufacture could cause the equipment to op-
erate at speeds in violation of Federal and State
Standards for Safety for the equipment.
Moving parts can cause severe per-
sonal injury or death. Take care when measur-
ing engine speed with a tachometer and follow
the meter instructions. You must be a qualified
mechanic.
Referring to Figure 7, adjust the low-idle and high-
idle engine speeds as follows:
1. Start the engine, observing all of the equipment
manufacturer’s instructions and precautions.
2. If the throttle cable has already been con-
nected, loosen the clamp at the engine and
back out the low-idle speed stop screw so that
the speed stop screw on the carburetor
touches its stop. Adjust engine speed to
1000 RPM with the carburetor speed stop
screw.
3. Turnthe low-idle speed stop screw to obtain the
specified low-idle speed.
4. Move the engine throttle link up against its stop
tang and hold it there while bending the tang as
necessary to obtain the specified high-idle
speed.
5. Hook the engine throttle link with the throttle
cable, pull the slack out of the throttle cable and
tighten the clamp. Check for full, smooth move-
ment of the engine throttle link between its two
stop positions when the equipment throttle le-
ver is moved through its full range.
HIGH-IDLE SPEED STOP TANG ENGINE
Do not bend the high-idle speed stop THROTTLE
tang unless you are a qualified LINK
mechanic and have an accurate
tachometer to set the high-idle speed
in accordance with the equipment
manufacturer’s specifications
THROTTLE CABLE LOW-IDLE
(Pull cable sheath to remove CABLE SPEED STOP
slack before clamping) CLAMP SCREW
CARBURETOR SPEED STOP
SCREW
FIGURE 7. TYPICAL ARRANGEMENT OF PARTS
FOR SPEED ADJUSTMENTS
15
Troubleshooting
Table 3 provides basic troubleshooting guidance. If
you fail to resolve the problem after taking the cor-
rective actions suggested, contact the equipment or
Onan dealer.
Many troubleshooting procedures
present hazards that can result in severe per-
sonal injury or death. Only qualified service per-
sonnel with knowledge of fuels, electricity, and
machinery hazards should perform service pro-
cedures. Review the safety precautions inside
the cover page.
Hot engine parts can cause severe
burns. Always allow the engine time to cool
before performing any maintenance or service.
TABLE 3. TROUBLESHOOTING
Problem
Corrective Action
1. The engine fails to crank.
>
Release the clutch (if so equipped).
Clean and tighten the positive (+) and negative (—) battery ca-
ble connections at the battery and the engine.
Recharge the battery. Refer to the equipment or battery
manufacturer's recommendations.
2. The engine cranks slowly.
Release the clutch (if so equipped).
Clean and tighten the positive (+) and negative (—) battery ca-
ble connections at the battery and the engine.
Recharge the battery. Refer to the equipment or battery
manufacturer’s recommendations.
Change engine oil to oil having the proper viscosity for the am-
bient temperature. See Table 1.
3. The engine cranks but fails
to start.
Qo op
Check the fuel tank and fill if necessary.
Open any closed fuel shut off valve.
Check engine oil level and add oil as necessary.
Reconnect and reclamp the choke cable (manual-choke gaso-
line engines only). See Adjustments.
Service the air cleaner.
Replace the fuel filter(if provided on gasoline engine).
Replace the spark plugs.
4. The engine runs and then
stops.
о р [© 0
o
Check the fuel tank and fill if necessary.
Check the engine oil level and add oil as necessary. Drain ex-
cess oil if the level is above the dipstick Full mark.
Reconnect and reclamp the choke cable (manual-choke gaso-
line engines only). See Adjustments.
5. The engine exhausts black
(dark) smoke.
op
Service the air cleaner.
Reconnect and reclamp the choke cable (manual-choke gaso-
line engines only). See Adjustments.
6. The engine misfires.
Replace the spark plugs.
16
Specifications
Model P216 P218 P220 P224
Power at Rated Speed 16 HP 18 HP 20HP 24 HP
(3600 RPM) (11.9 kW) (13.4 kW) (14.9 kW) (17.9 kW)
Bore 3.250 inch 3.250 inch 3.250 inch 3.563 inch
(83 mm) (83 mm) (83 mm) (90 mm)
Stroke 2.625 inch 2.875 inch 2.875 inch 3.000 inch
(67 mm) (73 mm) (73 mm) (76 mm)
44 inch3 48 inch? 48 inch? 60 inch3
Displacement (714 cc) (782 cc) (782 cc) (980 cc)
Compression Ratio 6.2.1 7.0271 7.0: 1 £8: 1
Engine Type
Horizontally Opposed 2-Cylinder, 4-Stroke Cycle, Spark-Ignited,
Side-Valve, Air-Cooled, Horizontal-Shaft
Oil Capacity—Low Profile
Base"
1.8 quart (1.4 1)
Oil Capacity —Medium Capacity
Base”
2.5 quart (2.4 1)
Oil Capacity—High Capacity
Base*
3.0 quart (2.8 1)
Intake Valve Clearance (Cold)
0.005 inch (0.13 mm)
Exhaust Valve Clearance (Cold)
0.013 inch (0.33 mm)
Spark Plug Gap
0.025 inch (0.64 mm)
Spark Plug Tightening Torque
11 Ibs-ft (14 N-m)
Ignition Timing
20° BTDC (Non-adjustable electronic ignition)
* — With filter. See Periodic Maintenance for oil filling instructions.
17
Information for California Engine Users
These engines meet the requirements of Califor-
nia’s Exhaust Emissions Standards for 1995 and
later for Utility and Lawn and Garden Equipment En-
gines.
As a California user of these engines, please be
aware that unauthorized modifications or replace-
ment of fuel, exhaust, air intake, or speed control
system components that affect engine emissions
are prohibited. Unauthorized modification, removal
or replacement of the engine label is prohibited.
You should carefully review Operator (Owner),
Installation and other manuals and information you
receive with your engine or equipment. If you are
unsure that the installation, use, maintenance or
service of your engine or equipment is authorized,
you should seek assistance from an approved Onan
engine dealer or an approved dealer for your equip-
ment.
California engine users may use Table 4 as an aid in
locating information related to the California Air Re-
sources Board requirements for emissions control.
TABLE 4. EMISSIONS CONTROL INFORMATION
Engine Warranty Information
The California emissions control warranty statement is located
in the same packet of information as this manual when the en-
gine is shipped from the factory.
Engine Valve Lash
See Specifications.
Engine Ignition Timing
See Specifications.
Engine Fuel Requirements
Gasoline Models: The engine is certified to operate on un-
leaded gasoline. See Fuel Recommendations in Introduction.
LPG Models: The engine is certified to operate on LPG. See
Fuel Recommendations in Introduction.
Natural Gas Models: The engine is certified to operate on com-
mercial natural gas.
Engine Fuel Mixture Settings
Gasoline Models: The engine has a precision-manufactured
carburetor which is not adjustable.
LPG Models: The engine has a precision-manufactured carbu-
retor and converter/requlator which are not adjustable.
Natural Gas Models: The engine has a precision-manufac-
tured carburetor and regulator which are not adjustable.
Engine Lubricating Oil Requirements
See Engine Oil Recommendations in Introduction.
Engine Adjustments See Adjustments.
RA The engine emission control system consists of internal engine
Engine Emission Control System modifications (EM).
18
Onon
Onan Corporation
1400 73rd Avenue N.E.
Minneapolis, MN 55432
1-800-888-ONAN
612-574-5000 International Use
Telex: 275477
Fax: 612-574-8087
Onan is a registered trademark of Onan Corporation