80 100 180-3 210 225 300 390 420 440 Gasoline Engine Owner’s Manual
PREFACE Thank you for choosing our general-purpose gasoline engine. The manual gives information with respect to operation and maintenance of the 80 100 180-3 210 225 300 390 420 440, general-purpose gasoline engines, and be sure to read it carefully first before operation. Only operate as the manual tells, can insure user’s safety and get the best results of the engine operation. All information and diagrams of this manual are in accordance with the newest products at the publishing time.
SAFETY MESSAGES Your safety and the safety of others are very important. We have provided important safety messages in this manual and on the gasoline engine. Please read these messages carefully. A safety message alerts you to potential hazards that could hurt you or others. Each safety message is preceded by a safety alert symbol . Symbol is as following: You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions. You CAN be HURT if you don’t follow instructions.
CONTENTS CONTENTS PREFACE……………………………………………………………… 1 SAFETY MESSAGES………………………………………………… 2 CONTENTS…………………………………………………………… 3 I. SAFETY PRECAUTIONS…………………………………………… 4 II. PARTS DESCRIPTION……………………………………………… 6 III. BATTERY CONNECTION………………………………………… 9 IV. PRE-OPERATE INSPECTION………………………………… 11 V. STARTING THE ENGINE……………………………………… 15 VI. RUNNING THE ENGINE……………………………………… 18 VII. STOPPING THE ENGINE……………………………………… 21 VIII. EXHAUST CONTROL SYSTEM…………………………… 22 IX. MAINTENANCE………………………………………………… 23 X.
SAFETY PRECAUTIONS I. SAFETY PRECAUTIONS Indicate a possibility of invalid warranty and personal or equipment damage if instructions are not followed. Please pay special attention to the following: 1. Strictly set the engine according to the regulated power on the owner's manual. Do not overload, overrun the engine or run it with low load and at low speed in a long time. 2. Use regulated brand of gas and diesel. The fuel should be fully deposited and filtrated before use.
SAFETY PRECAUTIONS and do not allow flames or sparks in the refueling area. 9. Do not overfill the fuel tank to avoid fuel’s spilling out. If there is spilled fuel around, be sure to clean it thoroughly before starting. 10. The exhaust from the engine may contain poisonous carbon monoxide. To avoid inhalation of CO, never run your engine in a pooly ventilated area. 11. The exhaust muffler is very hot during running the engine even after the engine stops. Never touch it, or you may get burns.
PARTS DESCRIPTION II.
PARTS DESCRIPTION MUFFLER ONE WAY VALVE THROTTLE LEVER CHOKE LEVER AIR CLEANER RECOIL STARTER FUEL TANK CAP STARTER HANDLE FUEL TANK ENGINE SWITCH OIL DRAIN PLUG OIL DIPSTICK 100 ·7·
PARTS DESCRIPTION AIR CLEANER FUEL TANK CAP FUEL TANK MUFFLER THROTTLE LEVER SPARK PLUG CHOKE LEVER CARBURETOR ONE WAY VALVE RECOIL STARTER FUEL COCK STARTER HANDLE ENGINE SWITCH OIL PROTECTOR OIL DIPSTICK OIL DRAIN PLUG ·8· OIL PLUG
BATTERY CONNECTION III. BATTERY CONNECTION Use 12V and more than 18AH battery, connect its positive lead to start relay terminal while connect its negative lead to engine mounting screw, base screw or other grounding point with the engine.(See the following picture) Check the battery's connecting point; make sure that it is tight and not rusted. If rusted, clean and connect. START RELAY CATHODE WIRE(-) ANODE WIRE(+) 1) The battery may give off explosive gas, keep sparks, flames and cigarettes away.
BATTERY CONNECTION water or milk, and follow with milk of magnesia or vegetable oil and call a physician. 4) Keep out of reach of children. 1) Do not add tap water to the battery instead of distilled water, otherwise the battery service life will be shortened. 2) Do not add distilled water over the electrolyte upper level mark, if not, electrolyte will spill out and corrupt the engine part. If so, be sure to wash them away with water.
PRE-OPERATE INSPECTION IV. PRE-OPERATE INSPECTION 1. ENGINE OIL Use 4-stroke engine oil, API service classification SF class or equivalent. Check the API service label on the oil container to be sure it includes the letters SF class or equivalent . SF 10W-30 is recommended for SAE VISCOSITY GARADES general use. Other viscosities shown in the chart may be used when the average temperature in your area is within the indicated range.
PRE-OPERATE INSPECTION OIL DIPSTICK OIL UPPER LEVEL DRAIN PLUG OIL LOWER LEVEL Run with insufficient engine oil may damage the gasoline engine severely and that is not within valid warranty. 2. AIR CLEANER Dismantle the air cleaner cover and check its element to make sure it clean and complete. Clean or replace it as necessary( see page 25: maintenance of air cleaner ). Never run the engine without an air cleaner, or severe wear of the engine may be resulted in. That is not within the valid warranty.
PRE-OPERATE INSPECTION over the fuel filler shoulder. 1) Gasoline is extremely flammable and is explosive under certain conditions. 2) Refueling in a well-ventilation area with the engine stopped. Do not smoke and do not allow flames or sparks in the area where gasoline is stored or where the fuel tank is refueled. 3) Do not overfill the fuel tank (there should be no fuel in the filling neck). After refueling, make sure the fuel tank cap is set back securely. 4) Be careful not to spill fuel when refueling.
PRE-OPERATE INSPECTION Fuel may damage the oil paint and plastic. Be careful not to spill fuel when refueling. Any damage due to oil spilling is not within valid warranty. "Light knocking" or "spark exploding" sound can be hear when the engine overloading. It is normal. Do not be worry about that. If " knocking" or "spark exploding" sound occur at a steady speed under normal load, change brand of gasoline; if such phenomena still happen, consult your dealer for help, otherwise the engine may be damaged.
STARTING THE ENGINE V. STARTING THE ENGINE 1. Turn the fuel cock to the “ON” position. FUEL COCK OFF ON 2. Turn the choke lever to the "START" position. If the gasoline engine is hot, turn the choke lever to the "RUN"position.
STARTING THE ENGINE 3. Move governor lever to left a little. THROTTLE HANDLE LOW SPEED HIGH SPEED 4. Start the engine 1) Recoil starter: Turn the engine switch to the “ON” (OPEN) position. Pull the starter grip lightly until resistance is felt, then briskly. Don’t allow the starter grip to snap back against the engine.
STARTING THE ENGINE 2) Electric start Tu r n t h e e n g i n e s w i t c h t o t h e “START” position, and hold it there until the gasoline engine starts. When the engine starts, allow the engine switch to return to the “ON” position. Do not use the starter for more than 5 seconds or starter motor damage may occur. If the engine fails to start, release the switch and wait 10 seconds before operating the starter again.
RUNNING THE ENGINE VI. RUNNING THE ENGINE 1. Preheat the engine and push back the choke lever to the "RUN" position. CHOKE LEVER RUN 2. Move the throttle lever to proper position to make the gasoline engine run at required velocity. THROTTLE LEVER ENGINE OIL ALARM The engine oil alarm is specially designed to protect engine when the engine oil in the crankcase is insufficient.
RUNNING THE ENGINE If cannot restart the engine, check the engine oil level first before go to other check items. BREAKER (Electric-start type) The breaker will cut off automatically to protect the charging circuit of the battery in the case that short circuit or incorrect connection of the battery poles occurs. The green indicator in the breaker will jump out with the circuit cutting off. After finding troubles and troubleshooting, depress the breaker button to turn the breaker on.
RUNNING THE ENGINE Fuel Altitude Range** Kit Part Number 0 – 3000 ft Not Required Gasoline 3000 – 6000 ft Altitude kit 1# 6000 – 8000 ft Altitude kit 2# * Engine, Generator Set, Pressure Washer, Walk-Behind Lawnmower, Compressor, Pump, Tiller etc. ** Elevation above sea level. ﹡ This high altitude jet is to be used at elevations above 3000 feet. ﹡ At elevations above 8000 feet, the engine may experience decreased performance, even with the high altitude kit.
STOPPING THE ENGINE VII. STOPPING THE ENGINE In emergency, push the engine switch to the OFF”. In normal, please do as following: 1. Push right the throttle lever to low speed position. THROTTLE LEVER 2. Push the engine switch to the “OFF” position. ON ENGINE SWITCH OFF 3. Set the fuel cock to “OFF” position. FUEL COCK Sudden stopping at high speed under heavy load is forbidden, otherwise damage will result.
EXHAUST CONTROL SYSTEM VIII. EXHAUST CONTROL SYSTEM With the engine running, carbon monoxide, oxide of nitrogen and hydrocarbon will produce, and in certain conditions, oxide of nitrogen and hydrocarbon will react chemically each other to make smoke while carbon monoxide is toxic, so exhaust control of them is very important. To keep the exhaust of your engine with in the standard exhaust emission, pay attention to the following: 1.
MAINTENANCE IX. MAINTENANCE The engine must be properly maintained to ensure its operation be safe, economy and trouble-free, as well as eco-friendly. In order to keep your gasoline engine in good working condition, it must be periodically serviced.
MAINTENANCE ● If you have missed the scheduled time to maintain your engine, do it as soon as possible. Stop the engine before servicing. Put the engine on a level surface and remove the spark plug cap to prevent the engine from starting. Never run your engine in a poorly ventilated room or other enclosed area, be sure to keep good ventilation in working area. The exhaust from the engine may contain poisonous CO, inhalation can cause shock, unconsciousness and even death. 2.
MAINTENANCE 2) Maintenance of air cleaner A dirty air cleaner can restrict air flowing into the carburetor. To keep the carburetor in good working conditions, please service the air cleaner periodically(clean air cleaner element after engine running 20h).If operating the engine in extremely dusty area, the job should be done more often. Never clean the air cleaner element with gasoline or low flash-point detergents, or explosion may happen.
MAINTENANCE (2) Clear away dirt around the spark plug base. (3) Dismantle the spark plug with a spark plug wrench. (4) Visually check the spark plug. Clean with a steel brush. If the insulator is damaged, replace the spark plug instead. (5) Measure the spark plug clearance with a feeler. The clearance should be 0.7~0.8mm. If adjustment is necessary, bend the side electrode carefully. (6) Check if the spark plug gasket is in good conditions. In order to screw thread misplace, screw in by hand.
RANSPORT AND STORAGE X. RANSPORT AND STORAGE Transport with the fuel cock turned the “OFF” position. Transport or store the engine when it is cool so as to avoid getting burns or fire. Do not incline the engine so as to avoid fuel’s spill. Spilled fuel or fuel vapor may ignite to cause fire. If the engine is not kept in use for a long time, be sure to store it properly. 1. Make sure the storage area is dry and free of dust. 2.
RANSPORT AND STORAGE Please maintain according to following table when reuse after storing. Storing time Maintaining procedure is commended in order to prevent starting difficult. 1 month Don’t need to prepare. 1-2 month Drain the used gasoline out and add the fresh gasoline 2 months to 1 year Drain the used gasoline out and add the fresh gasoline Drain the gasoline ① out of the carburetor cup. Drain the gasoline ② out of the sediment bowl.
TROUBLESHOOTING XI. TROUBLESHOOTING 1. START ENGINE DIFFICULTLY (By using recoil starter): Normal high-tension line spark Fuel supply is normal. Fuel supply is not smooth or no fuel supply. CAUSE Normal spark plug Normal spark plug spark Something wrong with the fuel system. Normal high –tension line spark. Normal fuel supply system. High-tension line no spark Normal cylinder compression TROUBLE REMEDY There is no enough fuel in fuel Fill fuel, open fuel cock. tank and fuel cock is closed.
TROUBLESHOOTING TROUBLE CAUSE REMEDY Normal spark plug. Normal fuel supply system. Abnormal cylinder compression. Piston ring is worn to or even over Replace its wear limit Piston ring is broken. Replace Piston ring is sticking. Clear up carbon fouling. Spark plug is not installed tighten or Tighten with a gasket in. without a gasket. Check cylinder gasket, and the flatness of the surface by which cylinder Air leakage between cylinder block block contacting with cylinder head and cylinder head.
TROUBLESHOOTING 2. GASOLING ENGINE POWER OUTPUT INSUFFICIENCY: CAUSE REMEDY Air in fuel line or fuel line clogged Exhaust air or dredge fuel line Fuel supply system Main oil flow hole is not adjusted properly Readjust Poor compression When increasing throttle, speed increase slow or even decrease and stop running TROUBLE In carburetor, needle valve hole and main Clean and blow to get through oil flow hole clogged. Fuel cock is clogged up. Too much carbon deposit in combusting chamber.
TROUBLESHOOTING 4. STOP SUDDENLY WHEN RUNNING: Ignition system Fuel supply system CAUSE The other Stop suddenly when running.
TROUBLESHOOTING 6.
SPECIFICATIONS XII. SPECIFICATIONS 1. 80 100 180-3 210 225 1) MAIN SPECIFICATION Specification Model 80 L×W×H 100 310×290×300mm Dry Weight 10kg Gasoline Engine Type Maximum Torque 225 390×320×345mm 455×320×345mm(ELECTRIC START) 16kg/18.4kg(ELECTRIC START) 78.5ml 98.5ml 179ml 212ml 223ml 8.5:1 8.3:1 8.5:1 9.0:1 8.5:1(equiped with catalyst) 8.
SPECIFICATIONS 2) TORQUE OF IMPORTANT BOLTS 80/100 Items Specifications 180-3/210/225 Torque Valve N·m Kg·m Specifications Torque Valve N·m Kg·m Connection-Rod Bolt M6×25 12 1.2 M6×1.25(special) 13 1.3 Cylinder Head Bolt M8×55 32 3.2 M10×1.25 35 3.5 M12×1.5 55 5.5 M14×1.5(special) 85 8.5 M6×0.5 10 1.0 M6×0.75 10 1.0 M6×1 24 2.4 M8×1.25(special) 24 2.4 M6×25 11 1.1 M8×1.25 28 2.
SPECIFICATIONS DATA ADJUSTMENT: Items Technical data Spark Plug Clearance 0.7-0.8mm Valve Clearance (Cold Engine) Intake: 0.10-0.15mm Exhaust: 0.15-0.20mm 2) TORQUE OF IMPORTANT BOLTS: Items Connection-Rod Bolt Cylinder Head Bolt Flywheel Nut Lock Nut Of Rocker Arm Shaft Rocker Arm Stud Crankcase Bolt · 36 · Specifications M8×1.25(special) M10×1.25 M16×1.5(special) M6×0.75 M8×1.25(special) M8×1.25 Torque Valve N·m Kg·m 15 40 95 10 24 28 1.5 4.0 9.5 1.0 2.4 2.
ELECTRIC DIAGRAM XIII. ELECTRIC DIAGRAM 1.
ELECTRIC DIAGRAM 2.
EASY WORN PARTS AND ACCESSORIES LIST XIV.
93004-Z010280-0000
