Onan Elite E125V User manual

El25V, El40V
Elite Series
Printed in U.S.A.
965-0166
6-94 (Spec C)

Important Safety Precautions
,
Readandobserve these safety precautionswhen using
or working on electric generators, engines and related
equipment. Also readand follow the literatureprovided
with the equipment.
Properoperationand maintenancearecriticalto perfor-
manceand safety. Electricity,fuel, exhaust, moving parts
and batteries present hazards that can cause severe
personalinjuryor death.
FUEL, ENGINEOIL, AND FUMESARE
Fire, explosion,and personalinjurycan resultfrom im-
proper practices.
4
. FLAMMABLEAND TOXIC
Used engine oil, and benzene and lead, found in
some gasoline, have beenidentifiedby government
agencies ascausing cancer or reproductivetoxicity.
When checking, drainingor addingfuelor oil, do not
ingest, breathe the fumes, or contact gasoline or
usedoil.
Do notfilltankswith engine running. Do not smoke
around the area. Wipe up oil or fuel spills.
Do not
leaveragsinengine compartment or onequipment.
Keepthis and surroundingareaclean.
Inspectfuelsystem before each operation and peri-
odicallywhile running.
Equipfuel supply with a positivefuel shutoff.
Do notstore or transport equipmentwith fuel intank.
Keepan ABC-rated fire extinguisher available near
equipmentand adjacent areasfor useon alltypes of
fires exceptalcohol.
Unlessprovidedwithequipment
or notedotherwise
ininstallationmanual,fuel linesmust be copper or
steel, secured, free of leaks and separated or
shieldedfrom electricalwiring.
Useapproved, non-conductiveflexiblefuel hosefor
fuelconnections.
Do not usecopper tubing as a flex-
ibleconnection. Itwillwork-harden and break.
EXHAUSTGAS IS DEADLY
Engine exhaust contains carbon monoxide (CO),
an odorless, invisible, poisonous gas. Learn the
symptomsof CO poisoning.
Neversleep in avessel, vehicle, or roomwith agen-
set or engine runningunlessthe area is equipped
with an operating CO detector with an audible
alarm.
Eachtime the engine or genset is started, or at least
every day, thoroughly inspectthe exhaust system.
Shutdownthe unitand repairleaksimmediately.
u
b
Warning: Engineexhaust isknownto the State of
Californiato causecancer, birth defects and other
reproductiveharm.
Makesure exhaust
is properly ventilated.
Vessel bilge must have an operating power
exhaust.
Vehicle exhaust system must extend beyond ve-
hicle perimeter and not near windows, doors or
vents.
Do not use engineor genset coolingairto heatan
area.
Do not operate enginelgenset in enclosed area
without ample freshair ventilation.
Expel exhaust away from enclosed, sheltered, or
occupiedareas.
Make sure exhaust system components are se-
curelyfastenedandnotwarped.
MOVINGPARTSCAN CAUSE SEVERE
PERSONALINJURY OR DEATH
Do not remove any guardsor coverswith the equip-
ment running.
Keephands, clothing, hair, andjewelry away from
movingparts.
Before performing any maintenance, disconnect
battery (negative
[-I cablefirst) to preventacciden-
talstarting.
Makesurefastenersandjoints aresecure. Tighten
supportsand clamps,keepguards inpositionover
fans, drive belts, etc.
If adjustments must be made while equipment is
running, useextreme cautionaroundhot manifolds
andmovingparts, etc. Wear safety glasses and pro-
tectiveclothing.
BATTERYGAS IS EXPLOSIVE
Wear safetyglasses and do not smokewhileservic-
ing batteries.
Always disconnect battery negative
(-) lead first
andreconnect
it last. Makesureyou connectbattery
correctly.
A direct short across battery terminals can
cause an explosion.
Do notsmokewhileservicing
batteries.Hydrogen gas given
off duringcharging is
explosive.
Do not disconnector connect batterycables if fuel
vaporsare present.Ventilatethe areathoroughly.
GSP-1
1 of2

DO NOT OPERATEINFLAMMABLEAND
EXPLOSIVEENVIRONMENTS
Flammablevapor can be ignitedby equipment operation
or cause adieselengine
to overspeed and becomediff i-
cultto stop, resultingin possiblefire, explosion,severe
personal injury and death. Do not operatedieselequip-
mentwhere a flammable vapor environment can be
createdby
fuel spill, leak, etc., unlessequippedwith
anautomaticsafety device to blocktheair intakeand
stop theengine.
HOT COOLANT CAN CAUSE SEVERE
PERSONAL INJURY
0 Hot coolant is under pressure. Do not loosen the
coolantpressurecap whiletheengine ishot. Letthe
engine cool beforeopeningthe pressurecap.
ELECTRICALSHOCK CAN CAUSE SEVERE
PERSONAL INJURY
OR DEATH
0 Do not servicecontrolpanel or engine with unit run-
ning. Highvoltagesare present. Work that must be
done while unit is runningshould be done only by
qualifiedservice personnel.
Do not connect the generator set to the publicutility
or to any other electricalpowersystem. Electrocu-
tion can occurat a remote site where lineor equip-
ment repairsare being made. An approvedtransfer
switch must be used
if morethan one power source
is connected.
Disconnectstarting battery(negative [-I cablefirst)
beforeremovingprotectiveshields or touching elec-
tricalequipment. Use insulativemats placedon dry
wood platforms. Do notwear jewelry, damp clothing
or allow skin surface to be damp when handling
electricalequipment.
Useinsulatedtools. Do nottamperwith interlocks.
Follow all applicable state and local electrical
codes. Haveallelectricalinstallationsperformedby
a qualifiedlicensedelectrician. Tag open switches
to avoidaccidentalclosure.
With transfer switches, keep cabinet closed and
locked. Only authorized personnel
should have
cabinet or operationalkeys. Due to seriousshock
hazardfrom highvoltages withincabinet, allservice
and adjustments must be performedby an electri-
cianor authorizedservice representative.
If thecabinet mustbeopenedfor any reason:
1. Move genset operation switch or Stop/AuY
Handcrankswitch (whicheverapplies)
to Stc
2. Disconnectgenset batteries(negative 1-1 leaa
3. Remove AC power to automatic transfer
switch. If instructions require otherwise, use
extremecautiondueto shock hazard.
. first).
*
k'
MEDIUMVOLTAGE GENERATORSETS
(601V TO
15kV)
Medium voltage acts differently than low voltage.
Specialequipment andtrainingare requiredtowork
on or aroundmediumvoltage equipment. Operation
and maintenance must be done only by persons
trained and qualifiedto work on such devices. Im-
proper use or procedureswill resultinsevere per-
sonal injuryor death.
Donotwork on energizedequipment. Unauthorized
personnel must not be permittednear energized
equipment. Induced voltage remains even after
equipmentisdisconnectedfrom the power source.
Plan maintenance with authorized .personnel
so
equipment can be de-energized and safely
grounded
.
Do not work on equipment when mentally or phys
cally fatiguedor after consumingalcoholor drugs
Carefullyfollow allapplicable local, state andfeder-
alcodes.
Neverstepon equipment (as when entering or leav-
ing the engine compartment).
It can stress and
break unit components, possibly resulting in dan-
gerousoperatingconditionsfrom leaking fuel, leak-
ingexhaustfumes, etc.
Keepequipment andarea clean. Oil, grease, dirt, or
stowed gear can causefire or damageequipment
by restrictingairflow.
Equipment owners and operators are solely re-
sponsiblefor operatingequipmentsafely. Contact
your authorizedOnanlCumminsdealer or distribu-
torfor more information.
KEEP THIS DOCUMENT NEAR EQUIPMENT FOR
EASY REFERENCE.
GENERALSAFETY PRECAUTIONS
GSP-1
2 of 2

Table of Contents
Title Page
Safety Precautions .................................... InsideCover
introduction
.................................................... 2
EngineSet-Up .................................................. 4
Operation ...................................................... 6
MaintenanceSchedule ........................................... 9 .
MaintenanceProcedures ........................................ 1 0
Adjustments ................................................... 13
Troubleshooting ....................................... ; ........ 14
[AWARNING I
INCORRECT SERVICE OR REPLACEMENT OF PARTS CAN
RESULT IN SEVERE PERSONAL iNJURY AND/OR EQUIPMENT
DAMAGE. SERViCE PERSONNEL MUST BE QUALIFiED TO
PERFORMELECTRICALAND/OR MECHANICAL SERVICE.
1

Introduction
Valve Clearance (Cold) in
0.006 0.006
Intake (mm) (0.15) (0.15)
Exhaust
in
0.006 0.006
(mm)
(0.15) (0.15)
KNOW YOUR ENGINE
Studythismanualcarefullyandcomplywitheachof
Always use this number and the engine serial
numberwhen makingreferencetoyour engine.
G
*
the warnings and cautions. Maintain the engine
accordingtothemaintenanceschedule. Operating
theengineproperlyandperformingregularmainte-
nancecanresultin longerenginelife,betterperfor-
mance and
safer operation. Regularly scheduled
maintenancelowersoperatingcosts.
Figure 1 shows the locations of the components
referredto inthis manual.
If a majorrepair or anoverhaulisnecessary,Onan
recommends the work be done by a Gompetent
mechanicto see that all dimensions, clearances,
and torque values are within the specified toler-
ances.
An engineservicemanualisavailableat additional
cost. Contact your nearest authorized dealer or
ENGINE MODEL REFERENCE
Onan PartsaniServiceCenter.
Identifyyour modelby referringtothe MODEL and
SP€C/F/CAT/ON numberas shown ontheengine
nameplate(Figure
1).
This manual contains the SI metric equivalents
shown in parenthesesimmediately after the
U.S.
customaryunitsof measure.
TABLE 1. SPECIFICATIONS
Unit of Series
SPECIFICATION Measure El 25V El 4QV
Numbers of Cylinders 1 1
~
in
3.31 3.31 I
I Stroke
(70.0)
in 2.76
(mm) (70.0)
1 Displacement
(389) 23-7 I
cu in 23.7
(cm3) (389)
I Compression Ratio 8.5 to 1 8.5 to 1 I
Power at
Rated Speed (3600 rpm)
BHP
(kw)
(1 0.4)
12.5
(9.3)
Oil Capacity
With Filter
QtS
(liter)
il
I Spark Gap
(0.89) 0.035 I
in 0.035
(mm) (0.89)
I Ignition Timing
~~
BTDC
230 230 I
2

AIR FILTER
HOUSING
U
SPARK PLUG
Mrn7
FIGURE 1. ENGINE COMPONENT LOCATIONS
3

Engine Set-Up
PRE-START CHECKS
Inspecttheenginevisually. Checkfor loose orrniss-
ingpartsandany damagethat may haveoccurred
inshipment.
~IStartIngthe engine withoutoil will
resultinsevereenginedamage.Add oilpriorto
startingtheengine.
BATTERY (If Equipped)
Thebatteryandbatterycablesusedforstartingthe
engine shouldbe
of sufficientsizetoprovideprompt
starting. Use of an undersizedbattery
will resultin
poor starter operation and a very short starter
service life.
-1 lgnifion of explosive batterygases
can result in severe personal injuw.
Do not
smoke or allow any Ignition source near the
battery.
1-1 Reversing positive and negative
battery connections or allowing the engine to
run withoutbeing connected to the alternator
willresultin engineelectricalsystem damage.
Do notswitchbattery connections orallowthe
engine to run withoutbeing connected to the
alternator.
CRANKCASE OIL RECOMMENDATIONS
Use premium quality motor oil with the API
(American Petroleum Institute)designation SG on
thecontainer.Figure
2 showstherecommended oil
weightforthetemperaturerangethattheenginewill
beoperatedin. Make sure the engineoilweight is
correct
for the expectedtemperature range.
Referto Table
1 (Specifications) forthe crankcase
oilcapacity.
Single-gradeoil is preferablewhen temperatures
are consistently over
3OoF (OOC). Multigrade oils
are best when wide temperature variations are
anticipated.
-1 Crankcase pressure can blow out
hot oil thatcancauseseverepersonalinjury. Do
not check the oil level while the engine is
running.
-1 Excess oil can cause high oil con-
sumption,highoperatingtemperatures, and
oil
foaming. Do notoverfillthecrankcase.
FIGURE 2. OIL VISCOSITY VS. TEMPERATURE
32
0
OF -30 -20 -IO o 10 20 30 40 SO 60 70 80 90 100 110 120
'c -34 -29 -23 -18 -12 -7 -1 4 10 16 21 27 32 38 43 48
ANTICIPATEDAMBIENTTEMPERATURE
I 1
*
4

Y
Oil Level
Checkthe oil levelattheintervalsrecommendedin
the PeriodicMaintenanceSchedule. Check more
frequentlyon
a new or reconditionedengine as oil
consumptionisnormallyhigheruntilthepistonrings
seat properly. Make sure equipment
is on a level
surface and screw the oil
fill cap into the dipstick
tubeuntilitstops. Refertothe Maintenancesection
for recommendedoil change intervals and proce-
dures.
When adding oil betweenoil changes, it isprefer-
able to use the same brand, because different oil
brandsmay notbecompatible. Figure
3 showsthe
oilleveldipstickandthe
FULL mark.
L
n
k
4
Ls1192
FIGURE 3. OIL LEVEL DIPSTICK
FUEL RECOMMENDATIONS
1-1 Ignitionof fuel can result in severe
personalinjuryordeath. Do notsmokeorallow
anyspark,pilotlight, orarcingequipmentnear
thefuelsystem.
Use clean, fresh, unleadedgasoline. Use of un-
leadedgasolineresultsin less maintenance.
-1 Gasolinede-icers and fuelcontain-
ingalcoholcancausepoorengineperformance
andenginedamage. Do notusefuelsystemde-
icers.
Do not use gasoline containingalcohol
concentrations greater than tenpercent.
-1 Ignitionof fuei can resultin severe
personal injuryor death. Thoroughlyclean up
any spilledfuel.
EXHAUST SYSTEM
Exhaust products of any internal combustion
engine are toxic and
can cause injury or death if
inhaled. All engine appliktions, especially those
within
a confinedarea, must be equipped with an
exhaust systemto dischargegasesto the outside
atmosphere and away from windows doors and
vents.
-1 ExhausfgasIsdeadly.Breathingex-
haust gasescanresultinseverepersonalinjury
ordeath,Useexfremecareduringlnsbllafionto
ensurealeak-free exhaustsystem.
5

0 perat ion
IAWARNING I
EXHAUST GAS IS DEADLY!
Exhaustgases from ail fuels (including diesel, gasoline, //quidpropane,
naturai gas) contain carbon monoxlde, an odorless and coioriess gas.
Carbonmonoxide is poisonousand can causeunconsciousnessanddeath.
Symptomsof carbonmonoxidepoisoning
can include;
Dizziness
Nausea Muscular Twitching
Headache Vomiting
Weaknessand Sleepiness
Throbbing in Temples
Inabilityto ThinkCoherently
IF YOU OR ANYONE ELSE EXPERIENCEANY OF THESE SYMPTOMS, GET
OUT INTO THE FRESH AIR iMMEDlATELY. if symptoms persist, seek
medicalattention. Shut down theunit and donot operate untii it has been
inspectedand repaired.
Protectionagainstcarbonmonoxideinhalationincludesproperinstaliation,
ventiiation and regular, frequent visual and audible inspections
of the
completeexhaustsystem.
STARTING
1. Movethe speedcontroltothe choke position.
2. Engagetheelectricstarter for upto 30 seconds
or pullthe recoilstarteruntiltheenginestarts.
3. Whenthe enginestarts, movethe speedcon-
trol fromthe chokepositiontothefast or high
positionastheenginewarmsup, usuallywithin
10 seconds..
4. If the engine does not start, wait 30 seconds
and repeatsteps
2 and 3.
Invery cold temperatures it may be necessary to
partlaily open the choke when the engine be-
gins to fire.
BREAK-IN PROCEDURE
Controlledbreak-in is the idealfitting of all internal
movingmetalparts. Usingthe properoilandapply-
ing'aconscientious maintenance program during
thisperiodhelpstoobtainsatisfactoryservicefrom
the Onanengine.
Maintainthe propercooling and lubricationduring
break-in. Run the engine at half load for the first
1-1/2 hourswith intermittentperiodsof full loadto
controlengine break-in.
-1 Using the wronggrade and weight
of
oil withhigh engineoperatingtemperatures
duringbreak-Incancauseenginedamage. Use
thecorrect oil gradeandweightandprovidead-
equateenginecoolingduringenginebreak-in.
Check the oil level at least every five operating
hoursduringbreak-in.Addoiltokeepit
at theproper
level, but never overfill, because overfilling may
causetheoiltofoamandenterthebreathersystem,
resulting
in high oil consumptionand oil accumula-
tion
in theaircleanerhoushg.
6

U OPERATION
Always be careful when operating power equip-
allwarnings andcautions.
-1 Contact wlth mtating machinery
and hot parts can result In severe personal
injury or death. Shy clear of rofating compo-
nents and hot parts. Make sure thatprotective
shleldsandguardsaresecuredInplace before
operatingpower equSpment.
”
ment. Followtheoperatingproceduresandobserve
HotWeather Operation
When operatingthe engineintemperaturesabove
100°F (38OC), pay particularattentiontothefollow-
ingitemsto preventequipmentdamage:
1. Keeptheenginecoolingfinscleanandfree of
obstruction.
racAuTIoN7 Piuggetiorcloggedcooling fins
or a dltty flywheel Intake fiRer can cause
overheatlngandenglnedamage.Makesure
the cooling flns and infake filter are kept
clean.
2. See that nothingobstructsthe air flow to and
fromthe engine.
3. Makesurethecrankcaseis
full oftheproperoil
weight for the ambient temperatures. Check
the oil leveleachtimeyou fillthe fueltank.
4. Change the crankcase oil and oil filter more
frequentlythan scheduled.
Cold Weather Operation
When the engine is being used in temperatures
below
32°F (O°C), checkthefollowingitemstopre-
vent equipmentdamage:
1. Makesurethecrankcaseisfulloftheproperoil
weightfortheambienttemperatures.Warmthe
engine upbeforechangingtheoil. Ifanunex-
pectedtemperaturedrop occurswhenthe en-
gine is
filled with summerweightoil, movethe
equipmentto
a warm locationbefore starting
the engine
so theoilwillflow freely.
4
2. Usefreshfuel. Fillthefueltankaftereachday’s
useto protectagainst moisturecondensation.
3. Keepthe batteryin a well-chargedcondition.
4. After each use, placethe speed control inthe
low speed position. This will prevent engine
overspeed
if ice forms on the linkage during
storage.
Operationin Dusty Conditions
1.
2.
3.
Keep the cooling system and the equipment
clean.
Service the air cleaner more frequently than
listed
in the Mainfenanceschedule.
Change the crankcase oil and oil filter more
frequently than listed in the
Maintenance
schedule.
OUT-OF-SERVICE PROTECTION
1.
2.
3.
4.
5.
6.
7.
a.
9.
10.
Protect an engine that will be out-of-service for
morethan
30 daysasfollows:
Runtheengineuntil
it reachesnormaloperat-
ingtemperature.
Turn
off thefuelsupplyandruntheengineuntil
itstops.
Drainthe
oil fromthe oilbasewhiletheengine
isstillwarm. Refillwithfreshoilandattachatag
statingthe oilviscosityused.
Remove the spark plug. Squirt
1 ounce (2
tablespoons
or 28 grams) of rust inhibitor or
SAE 50 oil intothe cylinder. Crankthe engine
over
a few times. Reinstallthespark plug.
Servicethe
air cleanerasoutlinedinthe Main-
tenance section.
Clean the governor linkage and protect it by
wrapping
it witha cleancloth.
Plugtheexhaustoutlettopreventtheentrance
of moisture, dirt, bugs, etc.
Wipe the entire unit clean. Coat bare metal
partswith
a light film of greaseoroil.
Provide
a suitablecover for theentire unit.
If the equipment is equipped with a battery,
disconnect it and follow the manufacturer’s
battery storageprocedure.
7

RETURNING ENGINE TO SERVICE
1. Removethecoverand all protectivewrapping.
Removethe plugfrom exhaust outlet.
2. Checkthetag on theoilbaseandverifythatoil
weight is
stili correct for the existing ambient
temperatures.
4. Checkthefuelfilterandlines to makesurethey
5. Check that the carburetor throttle lever and
6. Connectthe batterycables, positive (+) cable
first.
7. Start the engine. Exhaust smoke is normal
when the engine is started, due to the
rust
inhibitoroil.
aresecure and have nocracks
or leaks.
.l
. governor linkagemovefreely.
3. Cleanand checkthe battery (if equipped).
8

Maintenance Schedule
I Clean Cooling Fins
Y PERIODIC MAINTENANCE SCHEDULE enginemorefrequently. Neglectingroutinemainte-
nancecan result
in prematureenginefailure.
For any abnormalities in operation, unusual noises
Center.
Refer to the following Maintenance Procedures
sectionfor routinemaintenanceprocedures.
Followingthe maintenancescheduleandusingthe
each maintenanceprocedureafter the numberof
operating hours indicated. These serviceintervals
are recommended
for normaloperatingconditions.
Foroperationinhot
or dustyconditions, servicethe
b
engine properly will result in longer engine life,
better performance and safer 'peration- Perform
fromfie engineoraccessofies, loss ofpower,over-
heating, etc., contact your nearest Onan Service
ReplaceAir Cleaner Paper Element
Reolace FuelFilter
TABLE 2. PERIODICMAINTENANCESCHEDULE
x3
SERVICE THESE ITEMS
X
x4
Inspectthe Engine
CheckOilLevel
ServiceAir Cleaner FoamWramer
ChanaeCrankcaseOiland Oil Filter
Check
or ReDlace %ark Plug
Check Valve Clearance
AFTER EACHCYCLE OF INDICATED HOURS
8 I 25 I 50 I 100 I 200
I I I I
X'
X
X2
X
1 - Check for fuel leaks. With engine running, visually and audibly check exhaust system for leaks.
2- Performmore often when running under severe operatingconditions.
3- Required for initialbreak-inonly.
4- For detailed maintenance, contact an OnanService Center or refer to the SeMce Manual.
Shut down the engine and repair any leaks immediately.
TABLE 3. MAINTENANCEPARTS
ENGINEMAINTENANCE PARTS
Part No.
Filter 122-0737
Fuel Filter
149-2356
Air Cleaner Paper Element 140-2672
Spark Plug
167-0263-02
-1 Breathingexhausf gasescan result
in severe personal injury or death. Do not use
air cleaner,exhaustelbow, orconnecflngparts
as a supportingstep. Damage fo fbeseand con-
necting
parts cancausean exhausf leak
9

MaintenanceProcedures
I-Accldental starting of the engine
can result In severe personal injury or death.
Disconnect the negative (-) battery cable and
thespark plug wlrewhlleservicing the engine,
controls, or associatedequipment.
CHECKDAILY OR EVERY a HOURS
The operator should make a complete visual and
audibleinspection
of theenginedaily. Checkthefol-
lowing before starting the engine for the first time
eachday:
1. Check all fuel lines and fittings for possible
leakage. Repairall leaksimmediately.
2. Inspect exhaust system for possible leakage
andcracks. Locateleaksinmufflerandpiping
while the engineisoperating. Repairall leaks
immediately.
3. Inspecttheaircleanersystem for leaks. Make
certainallclampsandfittingsaretightandfree
of potentialleaks.
4. Check crankcaseoil levelwith the engine off
andtheequipmentona levelsurface. If theen-
ginehasbeennrn, allowa minimumof
10 min-
utesfor the oilto draindownbeforechecking.
To checktheoillevel, screwthe oilfillcap into
the dipsticktube until
it stops. If the oillevelis
belowthe
FULL markondipstick,addsufficient
oil oftheproperviscosityasspecifiedin Engine
Set-Up
section. Maintain the oil level at the
FULLmark.
Do notoperatethe enginewithoil
levelabovethe FULLmark.
5. Checktheenginecoolingsystemto makesure
thecoolingfinsandductingareclean. Remove
dust, dirtoroilfrom thecoolingsurfaces.
CRANKCASE OIL AND flLTER CHANGE
1-1 Hotcrankcaseoilcancauseburns if
it contacts the skin. Wear protective clothing
and keephands clear when drainingoil.
Refertothe PeriodicMaintenance Schedule for oil
change intervals.Referto Figure
1 for oilfilter and
oil drain locations.
1. Runthe engineuntilitiswarm. Stoptheengine
and placea pan underthe oildrainoutlet.
2. Removetheoildrainplug. Afterthe oil iscom-
pletelydrained, securely installthe drain plug.
3. Spinoff the oilfilter element. Draintheoiland
discardthe filter.
4. Thoroughlycleanthefilter mountingsurface.
5. Make sure the new gasket is inserted in the
element. Apply
a thinfilm of oiltothe gasket.
6. Spin the new element on by hand until the
gasket just touches the mounting pad, then
turnitdownanadditional
1/2 to 3/4 turn. Do not
overtighten.
7. Refillwith oil of the correct API classification
andtheappropriateSAEviscositygradeforthe
temperatureconditions(referto Figure
2). Re-
fertoTable 1 (Specifications) fortheoilcapac-
ity.
8. Start the engine and run it for a shorttime to
checkforoilleaksaroundthedrainplugandoil
filter. Retightenonly as muchasnecessaryto
eliminateleaks.
Do notovertighten.
Usedoilisharmfultotheenvironment.Pour
used oil
intoasealedcontaineranddeliverittothe nearest
recyclingcenteror automotiveservicestation.
J
10

Y AIR CLEANER
Refertothe Periodic Maintenance Schedule for air
cleanerelementwrapper and
air filter serviceand
replacement intervals. Service or replace more
often when operating the engine under severe
operatingconditions.
Air CleanerFoam ElementWrapper
With the engine stopped, remove the outer air
cleanernutandplasticoutercover. When servicing
the foamwrapperonly, do notremovetheinner
air
cleaner nutandcover.
Remove andwashthefoam wrapper inwater and
detergentand squeezeit
dry likea sponge. Rinse
with cleanwater and allowittodry. Coatthewrap-
perevenlywithonetablespoon
(14 grams)of SAE
30 engine oil. Kneadthe oil into the wrapper and
wring out
the excessoil.
Failureto adequatelywring outexcessoilfromthe
wrappermaycauseadropinenginepowerdue
to a
k.
Installthe foam wrapperoverthepaperaircleaner
elementbystretching itoverthe innercover.
Com-
pletely cover all exposed paper pleatson the air
cleaner paper element.
If the foam wrapper has
stretched
or become torn, replace the foam
wrapper.
Air CleanerElement
With the engine stopped, remove the outer air
cleaner nut and plastic outer cover. Wipe away
loosedirt and chaff from the
air cleanerassembly
and removethe innerair cleaner nut andinner air
cleanercover. Removethe airfilter paperelement
andfoamwrapperfromtheengine.Wipe
off excess
dirt fromthe aircleanerbase.
Installthe new paperelement and securewiththe
innercoverandinnermountingnut. Tightenthein-
nernutoneand a halfturnsafterseatingonthein-
nercover. Servicethefoamwrapperpertheinstruc-
tions given. Assemblethe outer air cleaner cover
restriction
of inletair. and nut.
AIR CLEANER
S
INNER COVER
MOUNTINGNUT
AIR CLEANER
ASSEMBLY BASE
OUTER COVER
MOUNTING NUT
CLEANER COVER
CLEANER COVER
M-lg203
FIGURE 4. AIR CLEANER ASSEMBLY
11

IGNITION
Spark Plug
Refertothe PeriodicMaintenanceSchedule forthe
spark plugserviceinterval. Replacethesparkplug
if it shows signs of fouling or electrode erosion.
Referto
Specifications (Table 1) forthe sparkplug
gap.
Solid State Ignition
Ignition timing is set at the factory, and it is not
adjustable. The solidstateignitioncomponentsdo
not requireany routinemaintenance.
COOLINGSYSTEM
Refertothe PeriodicMaintenanceSchedule forthe
coolingsystem
service interval. Cleanthe cooling
finssoonerifrequired.Removedust, dirt
or oilfrom
the coolingsurfaces.
-1PIugged or cfogged inlet screens
and recoil starter can cause overheating and
enginedamage. Removechaffand debrisfrom
air inlets.
EXHAUST SYSTEM
LaWAR"GIA hot exhaust system can cause
severe burns. Allow the engine time fo cool
down before Inspecting or servicing fhe ex-
hausf sysfem.
,J
Makeregularvisualandaudibleinspectionsof the
exhaust system. Locate leaks in the muffler and
pipingwhiletheengineisoperating. Repairallleaks
immediately after they are detected for personal
safety. Keepthe area around the muffler and ex-
haust manifoldclear of chaff and debris.
1-1 Breathfngexhaustgas canresultIn
severe personal lnjufy or death. Inspect the
exhaustsystem audibly and visuallyfor leaks
daily,andrepalr leaksimmediateiy.
[aWARNINGIAccumuIatlon of chaff and debrls
aroundthemufflercanresultin apotentlal ffre
hazard. Removechaff and debrisfrom around
exhaustsystem.
12

Ad j u st m e n t s
ENGINE SPEED ADJUSTMENT
PROCEDURE
b
The carburetormixture adjustments are preset at
the factory for maximumefficiency.
No mixture ad-
justmentsarerequired.Theenginespeedspecified
by your equipment manufacturer
is preset and
shouldonly beadjustedbyacompetentmechanic.
The service manualoutlinesthe speed and choke
adjustmentprocedure
for thisengine.
The speedcontrolcable must beproperlyinstalled
for proper engine performance. Poor starting,
fouled spark plugs and poor equipment perform-
ance may besymptomsof an improperlyadjusted
speedcontrolcable. Adjustthespeedcontrolcable
asfollows:
1. The engine must not be running during this
speedcontrolcable adjustment.
2. Loosenthespeedcontrolcableclamplocated
on your engine’s throttle control plate. (See
Figure
5.)
3. Placethespeedcontrolleverontheequipment
tothehighspeedposition.Onequipmentwith-
out a separate choke control, be sure the
speedcontrollever isnotinthe startorchoke
position.
4. Movethethrottle controllever so a pincanbe
insertedthroughthe
3.5 mmhole in thethrottle
controlplateandthethrottlecontrollever.
5. Removetheslackfromthespeedcontrolcable
andtightenthespeedcontrolcableclamp. Re-
movethe pinfromthe
3.5 mm hole.
6. Start the engine perthe equipment manufac-
turers instructionsand observeall safety pre-
cautions.
If theengineperformanceproblemis
notcorrected, taketheequipment
to a compe-
tentmechanicforproperadjustmentofthegov-
ernor, high idle speed, low idle speed, and
choke.
See your equipment manufacturer’sowners man-
ualfor highidlespeedand
low idlespeed settings
for optimum performancefrom your equipment.
SPEED
CONTROL
CABLECIAMP
TYPICAL
SPEED
CONTROL
REMOVESLACK
BY
MOVING CABLE IN
THIS DIRECTION
CABLECLAMP
POSKION
FIGURE 5. SPEED ADJUSTMENT
13

Troubleshooting
The following chart is a basictroubleshooting guide. Ifthese recommendations fail to resolvethe problem,
contact
an authorized Onan service center.
4
-1 Many troubleshootingprocedurespresenthazards thatcanresult In severepersonal in-
jury or death. Only quallffed service personnel wlfh knowledge of fuels, electriciw, and machinery
hazardsshould
perform serviceprocedures. Review thesafe fy precautions on theinsidecoverpage.
LQWAR"GIA hot enginecan causesevereburns. Alwaysallow theenginetime fo cool down before
performlngany maintenance or serviceprocedures.
TABLE 4. TROUBLESHOOTINGGUIDE
~~~~~~~~ ~
Problem
FAILSTO CRANK
CRANKSSLOWLY
OR HARDTO PULL
RECOILSTARTER
CRANKS BUT
WON'T START
UNIT RUNS THEN STOPS
EXHAUSTINGBLACK
SMOKE
UNIT RUNS, THEN SURGES
Probable Cause
1. Bad batterycable connection.
2. Lowbattery.
3. Defective start switch.
4. Defectivestarteror
startsolenoid.
1. Bad batterycable connection.
2. Oil istoo heavy.
1. Fuelsupply valve closed.
2. Carbondepositsonspark plug.
3. Lowoil level.
4. Dirtyair cleaner.
5. Dirtyfuel filter.
6. Fuelor ignitionsystem problem.
1. Lowonfuel.
2. Lowoillevel.
3. Excess oil.
1. Dirty air cleaner.
2. Chokestuck or misadjusted.
3. Richfuel mixture.
1. Looseor worn spark plug
lead.
2. Faultyspark plug.
3. Ignitioncoil, wiring, or control
components defective.
4. Governor out of adjustment.
5. Fuelmixture out of adjustment.
Solution
1. Checkbatterycable connections.
2. Checkelectrolytelevel.
3. Contact an Onanservicecenter.
4. Contactan Onan servicecenter.
1. Cleanandtighten all battery
cableconnections.
2. Changeto properweight oil.
1. Fullyopenfuel supplyvalve.
2. Cleanor replacespark plug.
3. Add oil if low.
4. Cleantheairfilter.
5. Replacefuel filter.
6. Contact an Onanservicecenter.
1. Refillfueltank.
2. Add oil if necessary.
3. Reduceengine oil level.
1. Cleanthe air filter.
2. Contact an Onan servicecenter.
3. Contact an Onanservicecenter.
1. Check security of spark plug
lead
at spark plugand ignition
coil.
2. Removeand clean or replace.
3. Contact an Onan servicecenter.
4. Contact an Onan servicecenter.
5. Contact an Onan servicecenter.
14

c