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OPERATION MANUAL RAMNAY AIR-COOLED DIESEL ENGINE F series
This Operation Manual tells you how to operate and service your new Ramnay F engine.
Please read it before using the F engine to insure proper handling and operation. FoIIow
the instructions carefully to keep your engine in the best running condition. If you have any
questions concerning this manual, please contact your nearest Ramnay dealer.
This Operation Manual deals with the main points for operation of the F engine.
In order to insure safe working conditions, be sure to read the precautionary statements for
safe operation of the F engine.
WARNING:
CAUTION:
Note:
Gives helpful information.
If a problem should arise, or if you have any questions about the engine, contact an
authorized Ramnay dealer.
WARNING:
The Ramnay F engine is designed to give safe and dependable service, provided that
it is operated according to instructions.
Read and understand the Operation Manual before operating the F engine. Failure to
do so could result in personal injury or equipment damage.
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TIPS ON SAFETY
WARNING:
A. PREVENTING FIRES
Never add fuel to the fuel tank while the engine is running.
Wipe away all fuel spills with a clean cloth. Keep gasoline, kerosene, matches and other
explosives and inflammables away from the engine, because the temperature around the
exhaust muffler is very high during operation.
• To prevent fire hazards and provide adequate ventilation, keep the engine at Ieast 3 ft (1
m) away from buildings and other equipment during operation.
• Operate the engine on a IeveI surface as much as possible.
The allowable inclination of the engine for continuous use is 20 degrees. There may be fuel
spillage and/or Iube oil pressure problems if the engine is tilted beyond that Iimit.
• Do not put the engine or the engine-mounted machinery indoors while the engine is still
hot.
C. PREVENTING BURNS
• Never touch the muffler, muffler cover or engine body while the engine Is running or hot.
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WARRANTY CERTIFICATE
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CONTENTS
Warranty certificate 3
Contents 4
A. Specifications 5
B. Name of parts 6
C. Installation 7
C.1 Installation 7
C.2 Allowable overhang 7
C.3 Inclination angle 8
C.4 Electrical wiring 8
L. Long-term storage 21
N. Troubleshooting 22
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A. SPECIFICATIONS
N° OF CYLINDER 1
FUEL TANK CAPACITY Lt.(US gal) 2,48 (0,655) 3,48 (0,915) 5,48 (1,445)
28 38 50
DRY WEIGHT (RECOIL)
32 42 54
DRY WEIGHT (ELECTRIC)
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B. NAME OF PARTS
Rubber plug
____________________________________________________________________
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C. INSTALLATION
C.1 Installation
1. Use an engine mount which is strong enough to prevent misalignment and play
during engine operation.
Fasten the engine base firmly te the engine mount with adjustable shims.
2. Ensure accurate centering for coupling with the output shaft.
3. Check that the pulley’s shaft hole (fitting hole) and the key groove fit the output-shaft
precisely.
WARNING:
Too much play in the output-shaft coupbing may cause an accident.
Be sure to tighten the output-shaft bobts firmly.
4. For belt driving, select a pulley which is of a suitable size for the engine and matches
the revolution speed and pulIey size of the driven machinery. The proper pulley size
for the engine can be obtained by the following formula:
CAUTION:
Use of an unsuitabbe pulley overloads the engine, and this shortens the engine’s
Iife.
5. BeIt tension
Ensure proper belt tension.
CAUTION:
Too much tightness overloads the engine at starting and stretches the bebt. making
it prone to damage. The output shaft may also be broken. and other accidents coubd
occur. Too much Iooseness causes belt slippage during high output and highspeed
operation.
The V-pulley’s belt-grooves should be as dose as possible te the engine side, though in
accordance with the matching for the driven machinery. The overhang distance should be
within the range Iisted below.
Note:
1. The overhang distance ‘L” is the distance between the PTO shaft shoulder and the
centre of the pulley groove at the farthest outside position.
2. The allowable overhang distance varies according to the type and number of V-belts
(determined by the driving load of the driven machinery), and the V-belt tension. For
details, contact your nearest Ramnay dealer.
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C.INSTALLATION
Type A B B
Belt
N. of Belt 2 2 3
Output shaft
0 20°
Allowable inclination (for continuous use)
Note:
Place the engine level when refilling with engine oil.
• For the wiring of electrical equipment contact your nearest Ramnay dealer.
Recommended
batteries 23 Ah 35Ah 45Ah
(20 hrs. Rating)
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D. HANDLING YOUR ENGINE
E. PREPARATION FOR STARTING
While your engine is still new, applications of heavy loads may shorten its life. Follow the
breaking-in procedures during the first 20 hours.
1. Avoid overboads
Avoid applying any heavy load during the breaking-in period.
Note:
Be sure te drain the oil while the engine is warm.
When cold, it may be difficult to drain the oil completely.
b. Keep dust and water out of the fuel When filling the fuel tank from drums, make sure
that no dust or water are mixed in the fuel. This may lead to serious fuel injection
pump and nozzle problems.
CAUTION:
• Use only recommended diesel fuel oil. Use of non-recommended fuel may cause
engine damage.
• Fuel should have a cetane value of more than 45 in order to prevent difficult
starting, misfiring, and white exhaust smoke.
• Diesel fuel oil substitutes are not recommended; they may be harmful to the fuel
system components.
• Fuel shoubd be free of water or dust because these cause trouble in the fuel
injection pump and nozzle.
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E. PREPARATION FOR STARTING
WARNING:
Fuel tank
capacity 2,48 3,48 5,48
(effective) (0,655) (0,915) (1,445)
lt (Us gal)
WARNING:
The engine may be damaged if operated with insufficient iube oil. it is also
dangerous to supply too much lube oil to the engine because a sudden increase in
engine rpm could be caused by its combustion. Always check the lube oil level
before starting the engine and refill, if necessary.
ENGINE OIL
RAMNAY recommends API Engine Service
Classification of CD.
Always use oil with the right viscosity for the
Ambient temperature in which your engine is
Being operated.
Use the chart mentioned on the right side
when choosing your engine oil.
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E. PREPARATION FOR STARTING
CAUTION:
• When checking the oil level, make sure your engine is sitting level. If it is tilted,
you may add either too much or too little oil. if you overfill, your engine will
consume too much oil and the oil temperature will become dangerously high. if you
do not add enough oil, your engine could seize up.
• When checking the oil, simply dip the dipstick into the oil pan. Do not screw in
the dipstick.
• Be sure to check the engine on a level surface with the engine stopped.
CAUTION:
• Do not wash the air cIeaner element with detergent because the element is of an oil-
soaked type.
• Replace the element when output decreases or bad exhaust colour is noticed.
• Never run the engine without the air cieaner element. Rapid engine wear may result.
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E. PREPARATION FOR STARTING
CAUTION:
Change the filtering elements if they are irreparably clogged.
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F. HOW TO START YOUR ENGINE
Grip
1) Fuel cock
CAUTION:
Do not allow the handle grip to snap back against the engine. Return it gently te
prevent damage te the starter.
d. In cold weather, when your engine is hard to start, remove the rubber plug of the
rocker arm cover and add 2 cc of engine oil before starting. (210-F300).
WARNING:
Never use any cold-starting aids such as ether, gasoline, paint thinner or other
volatile liquid or gas.
CAUTION: (F210-F300)
Keep the rubber plug in the cover except when adding oil. lf the plug is not in pIace,
rain, dirt and other contaminants may enter the engine and cause accelerated wear
of internal parts. This can cause serious problems.
Severe damage te the engine will occur.
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F. HOW TO START YOUR ENGINE
a) Starting
(The preparations for electric starting are the same as for manual (recoil) starting.)
1. Open the fuel cock.
2. Set the engine speed Iever at “START” position.
3. Turn the starting key clockwise to “START” position.
4. Remove your hand from the key as soon as the engine starts.
5. If the engine doesn’t start after 10 seconds, wait a while (for about 15 seconds)
before attempting to start again.
CAUTION:
lf the starting motor is turned for too long, the battery wilI go flat and motor seizure
will occur. Always leave the starting key turned on, in the “ON” position, while the
engine is running.
b) Battery
Check the Ievel of the fluid in the battery once a month. When the level has dropped to the
lower mark, replenish with distilled water up to the upper mark.
CAUTION:
lf the battery fluid is short, the engine may not start because too little electricity is
reaching the starter motor. Always keep the fluid level within the upper and lower
limits.
lf too much battery fluid is supplied, the fluid may spill and corrode the sur-
rounding parts.
Upper level
Lowel level
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F. HOW TO START YOUR ENGINE
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G. OPERATING YOUR ENGINE
H. STOPPING YOUR ENGINE
CAUTION:
Do not loosen or readjust either the revolution speed limiting bolt or fuel injection
limiting bolt. Performance may be affected.
3. What about the colour of the exhaust gas? (Is it black or too white?)
If you notice any of the above, stop the engine and contact your nearest Ramnay dealer.
WARNING:
lf the engine has been running, the muffler will be very hot. Be careful not to touch
the muffler.
Never refill with fuel while the engine is running.
a. Before stopping the engine, move the engine speed Iever to Iow speed, and run the
engine for about 3 minutes with no load.
b. Return the engine speed Iever te the “STOP” position.
c. In electric-start models, return the starter key te the “0FF” position.
d. Set the fuel cock Iever to the “S” (closed) position.
e. SIowIy puII out the recoil handle until pressure is felt (that is, to the point in the
compression stroke where the intake and exhaust valves are closed), and Ieave the
handle in this position. This prevents rust from forming while the engine is not in use.
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H. STOPPING YOUR ENGINE
I. PERIODIC CHECKS AND MAINTENANCE
WARNING:
If the engine keeps on running even after the speed Iever is placed at the “STOP”
position, stop the engine either by closing the fuel cock (“S” position) or by Ioosen-
ing the nut of the high-pressure fuel pipe on the pump side.
CAUTION:
• When stopping the engine. reduce the Ioad slowly. Do not stop the engine
suddenly since it may cause the temperature te raise abnormally.
Periodic checks and maintenance are very important for keeping the engine in good
condition and maintaining durability. The chart on the next page indicates which checks to
make and when to make them. The mark (•) indicates that special tools and skills are
required. Contact your Ramnay dealer.
WARNING:
CAUTION:
• After the engine has been used, ciean the engine immediately with a cloth to
prevent corrosion and remove sediment.
• Use only genuine Ramnay parts. The use of replacement parts which are not of
equivalent quaiity may damage the engine.
Remove the oil filler cap. Remove the drain plug and drain the old oil while the engine is
still warm. The plug is located on the bettom of the cylinder block. Tighten the drain plug
and refill with the recommended oil. (See the section under “Preparations for starting.”)
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I. PERIODIC CHECKS AND MAINTENANCE
Loosen the fixing bolt and then pull out the oil filter.
Every 6 months or
Change 400 Hrs. (or earlier if
dirty) 1) Air cleaner
2) Wing nut
CAUTION:
Never run the engine without the element or with a defective element.
Note:
• A clogged element hinders the flow of air to the combustion chamber. This reduces
engine output, increases Iube oil and fuel oil consumption and makes starting difficult.
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I. PERIODIC CHECKS AND MAINTENANCE
• Adjusting the valve head clearance for the intake and exhaust valves.
WARNING:
Do not perform the injection nozzle test near an open fire or any other kind of fire.
The fuel spray may ignite. Do not expose bare skin to the fuel spray. The fuel may
penetrate the skin and cause injury te the body. Always keep your body away from
the nozzle.
I.7 Checking and replenishing battery fluid and charging the battery
WARNING:
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I. PERIODIC CHECKS AND MAINTENANCE
and get prompt medical attention, especially if yeur eyes are effected.
Note:
Much more fluid is lost during the summer than in winter.
Before starting, check for physical damage to the battery and also the electrolyte levels,
and replenish with distilled water up to the upper mark, if necessary. When actual damage
is discovered, replace the battery.
WARNING:
• Before charging, remove the cap from each cell of the battery.
• Charge the battery in a place where there is plenty of ventilation.
• Discontinue charging if the electrolyte temperature exceeds 45~C (1 17~F).
CAUTION:
• Do not charge the battery with the battery cable still connected. The diedos will
be damaged by the high voltage.
• Connect the(+) lead of the charger to the (+) terminal of the battery, and the (-)
lead to the (-) terminal. Reversed polarity will damage the charger rectifier or the
battery.
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I. PERIODIC CHECKS AND MAINTENANCE
or Every or or Every
hrs. Every 200 Every 400 1000
hrs. hrs. hrs.
X before
Check the fuel level and refill operation
X
Drain the fuel tank
X
Replace the fuel filter element
X After
Check for fuel oil leakage operation
Fuel injection nozzle
Check the injection condition R
Check the fuel injection timing R
Check the fuel injection pump R
X before
Check the lubeoil level in the oil pan operation
Lube oil system
and refill
X 2nd time
X 1st time and
Replace the lube oil thereafter
X 2nd time
X 1st time and
Clean lube oil filter thereafter
X After
Check for lube oil leakage operation
induction
X
system
X
Replace the air cleaner element
X before
Electric
system
Items marked “R” should be serviced by an authorized RAMNAY dealer, unless the owner
has proficient mechanical ability and the proper tools.
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L. LONG-TERM STORAGE
2. Stop the engine. Drain the engine Iube oil while the
engine is still warm and
Decom=
fill with new oil.
pression
lever
3. Remove the rubber plug on the rocker arm cover
and add about 2cc of lube oil. Put the plug back in
place. (F210-F300)
4. Recoil starting:
Push the decompression lever down (Non-
compression position) and hold it while you puII the
recoil starter 2 or 3 times. (Do not start the engine.)
5. PulI the decompression Iever up. PuII the recoil starter slowly. Stop when it
feels tight. (This closes the intake and exhaust valves, in compression position, and helps
prevent rust from forming.)
6. Wipe the oil and dirt from the engine and store in a dry place.
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M. UNCLEAR POINTS OR PROBLEMS
N. TROUBLESHOOTING
lf any instructions are unclear or if problems occur during the operation of your engine,
complete the following form and contact your Ramnay dealer.
(Make a note of your dealer’s name and telephone number on the inside cover of this
manual.)
N. Troubleshooting
WARNING:
Keep away from the injection nozzle when performing the injection spry test.
Note:
Always puII the recoil starter quickly and firmly.
(See the section, “How to start your engine.”)
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