DUCAR DJ154F Engine Owner’s Manual

DUCAR DJ154F Engine Owner's Manual

WARNING
READ AND FOLLOW ALL SAFETY RULES AND INSTRUCTIONS IN THIS MANUAL BEFORE ATTEMPTING TO OPERATE THIS MACHINE.
FAILURE TO COMPLY WITH THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.

Safety References

The safety alert symbol is used to identify safety information about hazards that can result in personal injury. A signal word (DANGER, WARNING, or CAUTION) is used with the alert symbol to indicate the likelihood and the potential severity of injury. In addition, a hazard symbol may be used to represent the type of hazard.

SYMBOLS ASSOCIATED WITH THIS ENGINE:

WARNING
We do not approve or authorize the use of these engines on 3-wheel All Terrain Vehicles (ATVs), motor bikes, fun/recreational go-karts, aircraft products or vehicles intended for use in competitive events. Use of these engines in such applications could result in property damage, serious injury (including paralysis), or even death.

WARNING
The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

CAUTION
This engine is shipped from us without oil. If you start the engine without oil, the engine will be damaged beyond repair and will not be covered under warranty.

Features and Controls

Compare the illustration with your engine to familiarize yourself with the location of various features and controls.

• A Air cleaner

• B Muffler
  Muffler Guard (Optional)

• C Spark plug

• D Throttle lever

• E Recoil starter

• F Engine switch

• G Breaker (Electric start type)

• H Starting handle

• I Fuel cock

• J Choke lever

• K Fuel filler cap

• L Fuel tank

• M Starting motor(Electric start type)

• N Engine identification

• O Dipstick

• P Drain plug

Safety

How to Start the Engine

• A 3-wire extension cord. It is optional
• First attach extension cord to electric starter connector and then into a wall receptacle. If additional extension cord is required, use a 3-wire.
• If the supply cord is damaged, it must be replaced by the manufacturer or its service agent or a similarly qualified person in order to avoid a hazard.

1. Check the oil level. See the How to Check/Add Oil section.

2. Move the fuel cock (I) to the ON position.

3. Move the choke lever (J) the choke position.
   Note: Choke is usually unnecessary when restarting a warm engine.

4. Move Throttle lever (D) away from MIN. position, about 1/3 of way toward MAX. position.

5. Turn the Engine switch (F) to the ON position.

6. Recoil Start: Firmly hold the starting handle (H). Pull the starter cord handle slowly until resistance is felt, the pull rapidly.
   WARNING: Rapid retraction of the starter cord (kickback) will pull your hand and arm toward
   the engine faster than you can let go. Broken bones, fractures, bruises or sprains could result. When starting engine, pull the starter cord slowly until resistance is felt and then pull rapidly to avoid kickback.

7.  Electric Start: (It is optional)
   Turn the key to the Start position, then hold it there until the engine starts. Note: If engine fails to start within 5 seconds, release the key, and wait at least 10 seconds before
   operating the starter again.

How to Stop the Engine

1. Move Throttle lever (D) to MIN. position.
2. Turn Engine switch (F) to the OFF position.
3. Turn Fuel cock (I) to the OFF position.

Troubleshooting

Engine will not start Out of fuel

• If engine is cold, ensure choke lever is set correctly.
• Add fuel

Engine flooded

• Set choke lever to open/run position

Fouled spark plug/engine fails to product spark

• Remove spark plug and clean it. Check the spacing on the electrode and set the gap to the correct dimension. See Maintenance Section. If plug is damaged, replace with a new spark plug.
• Ensure the spark plug is installed and wire is connected.

Electric starting

• (It is optional) Check battery capacity and Fuse is burnt out or not.
  Warning:

• Do not crank engine with spark plug removed.

Oil

Oil Recommendations

• We recommend the use of our Warranty Certified oils for best performance. Other high-quality detergent oils are acceptable if classified for service SF, SG, SH. SJ or higher.
• Do not use special additives.
• Outdoor temperatures determine the proper oil viscosity for the engine. Use the chart to select the best viscosity for the outdoor temperature range expected.

Note: Below 40 F° (4 °C) the use of SAE 30 will result in hard starting. Above 80 F (2°7 C) °the use of 10W-30 may cause increased oil consumption. Check oil level more frequently.

Before adding or checking the oil

• Place engine level.
• Clean the oil fill area of any debris.

How to Check/Add Oil

1. Remove the dipstick (O) and swipe with a clean cloth (Figure 1).
2. Insert the dipstick into the filler neck without screwing it in.
3. Remove the dipstick and check the oil level. Make sure the oil is at the FULL mark (B) on the dipstick.
4. To add oil, pour the oil slowly into the engine oil fill (A). Do not overfill. After adding oil, wait one minute and then recheck the oil level.
5. Replace and tighten the dipstick.

Fuel Recommendations
Fuel must meet these requirements:

• Clean, fresh, unleaded gasoline.
• A minimum of 87 octane/87 AKI (91 RON). High altitude use, see below.
• Gasoline with up to 10% ethanol (gasohol) or up to 15% MTBE (methyl tertiary butyl ether) is acceptable.

CAUTION: Do not use unapproved Gasoline, such as E85. Do not mix oil in gasoline or modify the
engine to run on alternate fuels. This will damage the engine components and void the engine warranty. To protect the fuel system from gum formation, mix a fuel stabilizer into the fuel. See Storage. All fuel is not the same. This engine is certified to operate on gasoline. The emissions control system for this engine is EM (Engine Modifications).

High Attitude Operation
Your engine is configured for operation below 2,000 feet altitude at the factory. Your engine must be reconfigured for operation above 2,000 feet altitude. Operating the engine with the wrong engine configuration at a given altitude may increase its emissions, decrease fuel efficiency, degrade per- formance, and cause irreversible damage. Engines configured for high altitude operation cannot be operated in standard altitude conditions. A qualified service center should ensure that your engine is properly configured for your location.

How to Add Fuel

• Turn engine off and let engine cool at least 2 minutes before removing the fuel cap.
• Fill fuel tank outdoors or in well-ventilated area.
• Do not overfill fuel tank. Fill tank to approximately 1.5 inches (38 mm) below top of neck to allow for fuel expansion.
• Keep gasoline away from sparks, open flames, pilot lights, heat, and other ignition sources.
• Check fuel lines, tank, cap, and fittings frequently for cracks or leaks. Replace if necessary.
• If fuel spill, wait until it evaporates before starting engine.

1. Clean the fuel cap area of dirt and debris. Remove the fuel cap.
2. Fill the fuel tank with gasoline. To allow for expansion of the gasoline, do not fill above the bottom of the fuel tank neck. 3. Reinstall the fuel cap.

Maintenance

Use only original equipment replacement parts. Other parts may not perform as well, may damage the unit, and may result in injury. In addition, use of other parts may void your warranty. We recommend that you see any ours’ for all maintenance and service of the engine and engine parts.

CAUTION: All the components used to build this engine must remain in place for proper operation.

Before performing adjustments or repairs:

• Disconnect the spark plug wire and keep it away from the spark plug.
• Use only correct tools.
• Do not tamper with governor spring, links or other parts to increase engine speed.
• Replacement parts must be the same and installed in the same position as the original parts.
• Do not strike the flywheel with a hammer or hard object because the flywheel may later shatter during operation.

When testing for spark:

• Use approved spark plug tester.
• Do not choke for spark with spark plug removed.

Maintenance Chart

Carburettor Adjustment
Never make adjustments to the carburetor. The carburetor was set at the factory to operate efficiently under most conditions. However, if adjustments are required, see any our Authorized Dealer for service.

CAUTION: The manufacturer of the equipment on which this engine is installed specifies the top speed at which the engine will be operated. Do not exceed this speed.

How to Replace the Spark Plug

Check the gap (A) with a wire gauge (B). If necessary, reset the gap. Install and tighten the spark plug to the recommended torque. For gap setting or torque, see the Specifications section. Note: In some areas, local law requires using a resistor spark plug to suppress ignition signals. If this engine was originally equipped with a resistor spark plug, use the same type for replacement.

Inspect Muffler and Spark Arrester (if applicable)

• Allow muffler, engine cylinder and fins to cool before touching.
• Remove accumulated debris from muffler area and cylinder area.

WARNING: Replacement parts must be the same and installed in the same position as the original parts or fire could result.

How to Service the Air Filter (see figure 2)

1. Remove the air cleaner outside cover (A). Be careful to prevent dirt and debris from falling into the air cleaner assembly.
2. Separate the Air Filter (A) from the Air Filter Housing (B).
3. Inspect the air filter. Clean dirty air filter with warm water and mild soap. Allow air filter to dry thoroughly before re-installation
4. Install the air filter assembly onto the carburetor and secure with screw.

Note: Do not use pressurized air or solvents to clean the filter. Pressurized air can damage the filter and solvents will dissolve the filter.

How to Remove Oil
Caution: Used oil is a hazardous waste product and must be disposed of properly. Do not discard with household waste. Check with your local authorities, service center, or dealer for safe disposal/recycling facilities.

Removing Oil
The oil must be drained from the Oil Drain Plug (See figure 3)

1. Remove the dipstick (C)
2. Please an approved container below the oil drain plug.
3. Remove the Oil drain plug (D) and allow oil to the drain into the approved container.
4. Install Oil drain plug (D) and wrench tighten.

WARNING: When you drain the oil from the oil drain plug, the fuel tank must be empty or fuel can leak out and result in fire or explosion. To empty the fuel tank, run engine until it stops from lack of fuel.

How to Service the Battery -see figure 4 (if applicable)
WARNING: Be careful not to connect the battery in reverse polarity, as this will short circuit the battery charging system.

Note: Use a 12-volt battery with an ampere-hour rating of at least 18 Ah.

1. Connect the positive (+) cable to the starter solenoid terminal.
2. Connect the negative (-) cable to an engine mounting bolt or other good engine ground connection.
3. Connect the positive (+) cable to the positive (+) terminal.
4. Connect the negative (-) cable to the negative (-) terminal. 5.
5. Coat terminals and cable ends with grease.

Storage

WARNING: When storing fuel or equipment with fuel in tank:

• Store away from furnaces, stoves, water heaters, or other appliances that have a pilot light or other ignition source because they can ignite vapors.
  When Transporting Equipment:

• Transport with fuel tank EMPTY or with fuel shut-off valve OFF.

Engine Specification

Tune-up Specification

Documents / Resources

| DUCAR DJ154F Engine [pdf] Owner's Manual
DJ154F, DJ156F, DJ162F, DJ165F, DJ168F, DJ170F, DH270, DJ188F, DJ190F, DJ192F, Engine, DJ154F Engine
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