Onan 6GO-F User manual

GENERAL INFORMA TlON
THE PURPOSE OF THIS BOOK. This instruction book is furuished so that
the operator may learn of the characteristics of the plant. A thorough study
of the book will help the operator to keep the plant in good operating con-
dition so
that it will give efficient service. An understanding of the plant will
also
assist the operator in determining the cause of trouble if it occurs.
KEEP THIS BOOK HANDY. Such simple mistakes as the use of improper
oil, improper fuel, or the neglect of routine servicing may result in faIlure of
the plant at a time when it is urgently needed. It is suggested that this book
be kept near the plant so that it may be referred to when necessary.
SERVICE. If trouble occurs and the operator is unable to determine the cause
after a thorough study of this book, or if he is unable to determine what repair
parts are required, needed information will be furnished upon request .. When
'asking for information, be sure to state the Model, Serial, and Generator num-
bers of the plant. This information is absolutely necessary and may be obtained
from name plates on the plant. Give all other available details.
r--'---~:~::::::-w=~;-"--i
1 The manufacturer warran,ts each new engine or electric plant to be 1.
free from defects in material and workmanship. Under normal use and
service our obligation under this warranty is limited to the £ul'nishinq
1.:1:
.1
1
,
of
any part without charge which, within ninety (90) days after delivery
:~a:: :::~n~a::;:r:~~~n bc~::;~:n;!::id:Sa:~ :~:c:u~:;r:::~:::ii:~
I
I
i
, shall disclose to have been defective. i
Our liability in case of defective workmanship, material or any costs
I
incur~ed in remedying any claimed defective condition in any unit or
such unit having been repaired, altered, or which installation and serv-
ice
recommendations have not been complied with, is limited strictly
to the proper adjustment authorized by the factory.
This warranty does not inc1!Jde or cover standard accessories· used, I
such as
carburetors, magnetos, fuel pumps, etc.; made by other manu- i
facturers. Such accessories have separate
warranties made by the re-
spective manufacturers. Repair
or exchange of such accessories will be I
made by us on the basis of such warranties. r.
f
This warranty is in lieu of all other w<\.rrantiesexpressed or implied. 1
"-III1_~1l--n~~._III1-t!11_UII-n--UII""""-"-U_NII_ •• --u ___ jj-II~"_IIII_IJU_1III--<lII-tIII--uII--*
IMPORTANT·.RE'TURN WARRANTY CARD ATIACI-IED TO PLANT.

TABLE OF CONTENTS
SUBJECT
Description
General Data~,- - - - - - - - - - - - - ~ - - - - - - - -
Engine - - - - - - - - - - - - - - - - - - - - - - - - -
Generator - - - - - - - - - - - - - -
-- - - - - - - - -
Controls -Acee~sories -.- - -- - - - - - - - - - - - --
Installation
Location - - - - - - - - - - - - - - - - - - - - -
Ventilation - - - - - - - - - - - - - - - - - - - - - - -
Fuel Supply -
Gasoline-- Gas or Vapor - - - - - - -- - -
Batteries - - - - - - - - - - - - - - - - - - - - - - - -
Connecting the Load Wires - - - - - - - - - - - - - - - -
Preparation
Lubrication - - - - - - - - - - - - - - - - - - - - - - -
Fuel, Gasoline - Natural Gas or LPG - - - - - - - - - - -
Radiator - -:- - - - - - - - - - - - - .,. - - - - - - -
Operation
Preliminary - - - - - - - - - - - - - - - - - - - - - - -
Starting the Plant Electrically - - - - -- - - - - - --
starting the Plant Manually - - - - - - - - - - - - - - -
Checking
the Operation - - - - - - - - - - - - - - - - - -
stopping the Plant - - - - - - - - - -- - - - - - - - - -
Abno~al Operating Conditions
Low Temperatures - - - - - - - -'- - - - - - - - - - ---
High Temperatures - - - - - - - - - - - - - - - - - - - -
Dust and
Dirt - - - - - - - - - - - - - - - - - - - - - -
Periodic Service
Daily ,Service - - - -.- - - - - - - - - -- - - - - - - -
Weekly Service- - - - - - - - - - - - - - - - - - - - - -
Monthly
Service -- - - -,- - - - - - - - - - - - - - - -
Six Monthly Service - - - - - - - - - - - - _ ---
Adjustments
Carburetor, Gasoline - Carburetor, Gas or Vapor -----
Electric Choke -Sisson Choke - - - - - - ~ - - - - - - -
Governor - - - - - - - - - - - - - - - - - - - - - - - -
High Water Temperature Switch - - - - - - '-~ - - - - --
Fan Belt Tension - - - - - - - - - - - - ...:- - - - - - - -
Kaintenance and Repair
Engine -- - - - - - - - - - - - - - - - - - - - - - - - -
Table Qf Clearances - - - - - - -- - - - - - - - - - - -
Generator - - - - - - - - - - - - - - - - - - - - - - - -
Controls - - - - - - - - - - - - - - -
~ - - - - - - - - -
Service Diagnosis
Possible Cause - Remedy - - - - - - - - - - - - - - - - -
Instructions for Ordering Repair Parts - - - - ~ - - - - - -
Repair Parts List - - ..: - - - .;.. - - - - - - - - - - - - - - -
Supplement
for Direct Curr~t Plants
PAGE
NO.
1
',')
2
2
2
3
3
:3
4
4
7
8
,8
9
9
9
10
II
12
13
13
14
14
15
16
17
17
19
20
20
21
27
29
30
.31
39
52
67

I
LIST OF ILLUSTRATIONS
FIG.- PAGE
NO. SUBJECT NO.
A
Lubrication -.;. - - - - - .,.. -_.,- - - - - - - - - 6
B Carburetor and
Choke Adjustment - - - .,.. ----- 18
C .Governor Adjustment ----- .,.. - - .,.. ..;. - .,.. .,.. - .,.. 19
D
Fan Belt Tension .,.. High Water Temperature Switch .,..
20
E Ttming Gears
.,.. - - .,.. - .,.. - - - - - - ~ _ - - - - -
22
F Tappet Adjustment ---
.,.. - .,.. - - .,.. - - - - - - .,..
22
G
Ignition Timing .,.. --- .,.. - - - - - - .,.. - - .,.. - -
24-
H
Piston Ring Gap - - - .,.. - .,.. .,.. ----- .,.. - - .,.. .,..
24-
I Piston Fitting - - - .,.. .,.. - .,.. - .,.. - .,.. .,.. .,.. - - .,.. - .,..
24-
J Bottom
View of Engine .,.. - - - - - - - - - - .,.. .,.. .,..
'Zl
K
Alternating Current Generator Assembly ------ 28
L Care
of Commutator and Brushes - - - - - - .,.. - --
28
Repair Parts Illustrations
1 Cylinder Block and Head Group - - - - - - - .,.. - .,.. 40
2 Crankshaft and Camshaft Group ------- .,.. .,.. .,.. 41
3. Gear Cover and Oil Pan \lroup - -- - - - - - - - - - 41
4 Oil Pump and Pil Fil.ter Group - - - - - - - - - - 42
; piston and Connect~g Rod Group - - - - - .,.. - - - 43
6 Valve Group .,.. -- - .,.. - ~ - - - - - -'- - - - - - 43
7 Water Pump and Fan Group- - - - - - - - - - - - - 44
8 Flywheel
Group - - - - - - - - - - - - - - - - - - 45
9 Muffler Group - - - - - .;. - - - - - - - - - - - - 45
10 Radiator Group - - - - - - - - - - - - - - - - - - 46
11 Fuel System Group- - - - - - - - - - - - - - - - 46
12 Gas -Gasoline Fuel System Group - - - - - - - - - ·47
13 Carburetor ,Group - - - - - - - - - - - - - - - - - 47
14 Ignition Group- - ..; - - - - - - - - - - - - - - - 48
15 Governor Group - - - - - - - - - - - - - - - - - - - 48
16 Gen'erator Group - - - - - - - - - - - - - - - - - 49
17 Control Panel Group - - - - - - - - - - - - - - - 50
18 Housing Group - - - - - - _.- -- .,.. .,.. - - .,.. - .,.. - 51
Direct Current Supplement
Direct Cur~ent Generator Assembly .,.. - _ - - - - -
69
1M
Generator
Group - - - --- - - - - - - - - - - -- 71
i7A
Control Panel Group ------- .,.. - - - - - - -
72
19
Starter and Battery Charging Generator Group ---
73

PLANT RUNNI NG HOURS
COMPARED TO AUTOMOBILE RUNNING MILES
The engine of your generating plant makes a~ many revolutions in one hour,
as the average automobile engine does when the car travels a distance of
41 miles.
100 running hours time on a generating 'plant engine is equivalent in total
RPM's to approximately 4100 running miles on an automobile.
However, do not conclude that the wear on the generating plant engine and
the wear on the automobile engine would be the SaIne; The generating plant
engine is built much more ruggedly, (having larger main bearings, bigger
oil capacity and.has a heavier crankshaft proportionately per horsepower)
than most automobile engines. Given the proper care and periodic servicing
the generating plant engine will continue to give many mora hours of effi-
Cient service than an automobile engine will after having been run the
equivalent number of running miles.
Compare the running time of your generating plant engine with the number of
miles traveled by an automobile. The oil in an auto is checked every one
or two hundred miles (3 to 5 hrs. running time) andi changed every 1000 to
1500 miles (28 to 42 hrs.) Ylhereas in a generating plant or stationary
power engine, the oil should be checked. every 6 to 8 running hours (250 to
350 miles) and changed every 50 to 100 operating hours (2000 to 4000 miles)
depending on operating conditions.
About every 5,000 to 10,000 miles (120 to 250 hours), services have to be
performed on an auto, such as checking ignition points, replacing spark
plugs, condensers, etc. S~nilarly on your generating plant engine, these
same services have to be performed periodically except the change period is
reckoned in hours. 10,000 miles on an auto is equivalent to about 250 run-
ning hours on your plant engine.
To arrive at an approximate figure of comparatIve generating plant running
hours as against automobile engine running miles, multiply the total number
of running hours by 41 to find the equivalent of running miles on an auto-
mobile.
Your generating plant engine cen "take it" and will give many hours of, effi-
cient performance provided it is serviced regularly.
Below is a chart showing the comparison between a generating plant engine
running hour!! and an automobile running miles.
GENERATING PLANT AUTOHOBILE
RUNNING HOURS
llUNNING·MILES
41 Miles
r Hr. n
DAILY 4 Hrs.
164
II
AVERAGE 6 "
246
II
a " 32
8,
287
II
WEEKLY 28
1,148
" "
AVERAGE 42
1,722
II
"
56
2,296
C"
" "
GENERATING PLANT
AUTOMOBILE
RUNNING HOURS
RUNNING HILES
30 Hrs.
1,230 Miles
{'6
5"
II
" "
~NTHLY{
120 4,920 "
AVERAGE. '. laO
7,380
II
240
9,840 "
14,965 "
II
II
YEARLY 1,460 59,860
II
AVERAGE 2,190 89,790
"
2,920 " 119,720
II
NOTE; Electric generating plants do not operate economically when used to
power electric refrigerators and will add from 4 to a operating hours per
day in addition to the regular lighting load.

DESCRIPTION
This manual applies to the 5000 watt, alternating current, electric gen-
erating plants. This manual also applies to the 6000 watt, direct cur-
rent, electric generating plants, when it is used. in conjunction ·with
the supplement beginning on pag. 67.
One copy of this manual is supplied with each plant of the basic models
listed in the General Data below, and with special mod.els which differ
slightly from these basic .odels.
Each plant is test run and carefully checked under various electrical
loads before leaving the factory to assure that it is in good condition
and will produce its rated output. Before putting the plant into oper-
ation, careful~ inspect for any damage which may have occured during
shipment. Damaged parts must be repaired or replaced. Read this manual
thoroughly to become familiar with the details of installation and oper-
ation of this plant.
GENERAL DATA
OUTPUT
WATTS
OUTPUT
VOLTS
CYCLES
PHASE
WIRES
U.S.MJi:ASURE
CAPAC
IN (UARl'S
t PARTS
REF.
SYMBOL
SYSTEM
EL
TANK
CRANK-
CASE
5000 115
60 1 2
11
24 *3
*3
A
B
5000 115/2.30 60 1
.3
11 24
5000 120-208
60
3 4 11 24
*.3
C
5000
2.30
60
3 .3
11
24
*.3
D
6000 .
115
DIRECT CURRENT
11
24 *3 E
6000
2.30
DIRECT CURRENT
11 24 *3 F
* Plus 1 quart for the oil filter.
t The Parts Ref. Sy.mbols A, B. C. D, E & F indicate which column to
use in the Parts List where more than 1 column is used. Compare the
data on the plant nameplate with the data in the above table. Select
the corresponding Ref. Symbol and use that column in the Generator
and Control. Panel Groups of the Parts List. Unless otherwise speci-
fied in the description of the part, engine parts are the same for all
plants to which this manual applies.
When ordering Generator Group parts fora 50 cycle plant, order by de-
scription as given in the .parts list, giVing the plant model,. spec ••
serial, and generator data numbers. See page 39 for further Instruc-
tions for Ordering Repair Parts.
t

DESCRIPTION
ENGINE
A ,Continental Red Seal engine, spec. No. Y91-273 orY91-264 powers the
plant. The engine is a 4 cylinder, L head, 4 stroke cycle, water cooled
internal combustion type. The cylinder bore is 2_7/8
11
, the piston
stroke 3-1/2", compression ratio 6.1 to 1, and the maximum horsepower at
1800 r.p.m. is 23. The engine speed is controlled by a centrifugal fly-
weight type, gear driven governor. 12 volt starting and ignition cur-
rent is furnished by two 6 volt batteries connected in series. Charging
current for the batteries is furnished by the generator. Full length
water jackets surround the cylinders and valve seats. Circulation of
the engine coolant is maintained by a belt driven, ball bearing pump,
and the coolant temperature is thermostat controlled. The cooling sys-
tem 'capacity is 11 quarts, U. S. Measure. A pusher type fan forces
cooling air out through the front of the radiator. A high water tem-
perature cut-off Switch stops the engine if the coolant temperature
reaches a dangerously high point. A gear type oil pump supplies pres-
sure lubrication to main, camshaft and connecting rod bearings. The
crankcase oil capacity, including the oil filter, is 4 quarts, U. S.
Measure. A fuel pump provides for connection to any appropriate gaso-
line fuel supply tarik. Some model plants are equipped with a 6 gallon
fuel tank mounted inside the plant housing. Other special model plants
are equipped to burn gaseous fuel.
GENERATOR
The generator is air cooled, has four stationary poles, and a revolving
armature. The generator is directly coupled to the engine, ~Vith the
armature turning at crankshaft speed. A series winding i::. used for
electrically' cranking the engine. The generator is self eXCited, gen-
erating both AC and DC. The direct current is used for exciting the
field and charging the batteries.
An extremely large commutator and slip rings are mounted at the ball
bearing end of the armature. The inner end of the armature is sup-
ported by the rear main engine bearing. All generator windings are
thoroughly impregnated .Vith insulating varnish and baked, to minimize
the possibility of internal short circuits.
Voltage and frequency are proportional to engine speed, which is regu-
lated by the engine governor. Speed is approximately 1800 r.p.m. for
60 cycle plants, and approximately 1500 r.p.ffi. for 50 cycle plants.
The generator design assures close voltage regulation between full load
and no load conditions.
CONTROLS
.~.
The plant controls include an electric choke, a start-stop switch, an
ignition Switch, and other relays and regulators necessary to the pro-
per operation of the plant. Remote control switches, automatic controls,
or line transfers may be connected to the plant. Some plants are
equipped with an electrical.meter panel.
ACCESSORIES
Accessories supplied with a standard housed plant include a hand crank,
batteries, battery hydrometer, breaker point wrench, a remote start-'
stop switch, a jar of ball bearing grease, and iristruction manud.ls.
2

INSTALLATION.
IMPORTANCE ·OF PROPER INSTALLATION • .,.. Proper installation is essential
to sa.tisfactory and dependable performance. Location and ventilation
are important factors to consider in installa.tion.
LQCATION.- The plant should be centrally located in relation to the
electrical load. If practicable, install the plant in a building or
cov.ered vehicle for protection from extremes in wea.ther conditions.
CAUTION
Exhaust gases are deadly poisonous and must be piped out-
deors if the plant is installed inQ,oors. Excessive in-
halation of exhaust gases may cause serious illness or
death. Some engines ha.ve a small hole in the bottom of
the exhaust manirold, under the exhaust outlet, for mois-
ture to escape. This hole may be plugged if exhaust gas
escape is objectionable.
The muffler outlet is threaded for 1-1/4" standard pipe. If necessary
to run an exhaust line upward from the plant, install a suitable conden-
sation trap at the lowest point in the :)..ine and drain it regularly.
Proper shielding must be provided if the exhaust line passes through an
inflammable wall.
If desired, an underground muffler may be constructed. Use a heavy 10
gallon or larger tank or drum, welding suitable pipe fittings to. the
drum. Use 1-1/4" pipe between the plant muffler and the underground
muffler. Bury the underground muffler in loose gravel, and see tha'b
the bottom of the drum is perforated to allow condensation to drain out.
Extend the muffler outlet at least 24" above ground and fit it with a
pipe gooseneck.
The site should be dry, clean,and well ventilated. Either a damp or
a dusty condition 'Will require more frequent inspection and serviCing
of the plant. Allow at least 24" space on all sides for ease in ser,-
vicing.
If the plant is mounted aboard a truck or trailer, see that it is fas-
tened securely when in transit, and that it sets in a level position
when operating. Mounting holes are 18" apart lengthwise of the plant
and 20-3/4" crosswise of the plant.
VENTILATION •. - Proper cooling dep~ds upon correct ventllationto dis-
sipate the heat generated by the engine and generator. Separate air
inlet and outlet openings must be provided if the plant is mounted in
a small roOlll or compartment.
FUEL SUPPLY,GASOLINE.- The fuel pump inlet has 1/8" pipe threads, into
which a fittirtg for 1/4" flared tubing is installed.. Be sure any fit-
ting substituted has 1/8" male pipe thrQads, to fit the fuel pump inlet.
Any tank used must be not more·than 8 ft. below the fuel pump. Connec-
tions must be air tight to permit the fuel to rellch the fuel.pump.
Observe local fire code speCifications in making the installation.
NATURAL GAS' OR VAPOR FUEL.- Some special model plants ~e equi~ped to
bum LPG Grnatural gas fuel. Any applicable gas codes must be complied
with wRen ccmnecting the plant to. a source of gas fuel. In some local-
ities, presence of fGreigt'l. matter in the gas supply may require instal-
lation of' a fuel filter in the fuel supply line. The fuel inlet is
threaded for 314" pipe. '3

INSTALLATION
NOTE
On natural gas installations the atmospheric regulator
on the plant is designed to operate on a line pressure
not to exceed 4.6 ounces. If the line pressure exceeds
4.6 ounces pressure, it will be necessary to install a
primary
regulator in the line to reduce the pressure be-
fore it enters the atmospheric regulator.
BATTERIES.- Two 6-volt batteries are connected in.series by a short
jumper cable. Connect the cable which is attached to the start solenoid
switch to the remaining positive (+) post of the two batteries. Connect
the cable which is grounded on the cylinder head to the remaining nega-
ti va post. If the plant was boxed for. export shipment. service the
batteries as directed on the tags attached to the batteries.
CONNECTING THE LOAD 'l'lIRES.- The AC output terminals are located behind
the control panel, on the fuel tank support. Run the load wires through
the hole in the rear panel, connecting them to the solderless connectors
on the output terminals. Be sure to use the proper size insulated ~~re,
taking into consideration the distance between the plant and the load,
and the type of load. Consult a competent electrician, and observe
applicable electrical codes in making the installation. See that the
main line is protected by a fused main switch or a circuit breaker be-
tween the load and the generator. Refer to the .plant wiring diagram,
and
follow the applicable directions given below for connecting the
load wires.
115 VOLT, SINGLE PHASE)' 2 WIRE PLlINT
Connect the white or grounded load wire to the grounded plant terminal.
Connect the other (black) load wire to the insulated plant terminal.
If the control panel has a receptacle, a load not to exceed 15 amps may
be connected to each outlet.
llS/21O VOLT) SINGLE PHASE, 3 WIRE PLlINT
The center terminal is grounded. For 115 volt current, connect the white
or grounded load wire to the center terminal and the other load wire to
either of the two outside terminals, A or B. 2500 watts are available on
each 115 volt circuit, ground to A, and ground to B. For 230 volt cur-
rent, connect the load wires to the two outside insulated terminals, A
and B,
leaving the center terminal unused. If the control panel has a
receptacle, a load not to exoeed 15 amps, 115 volts may be connected to
each outlet •
...... -------230 V.----------I
...... ---115 v.......;....-- ....... -....,---115 V. --- ........
A
B -
-
-
4

INSTALLATION
120 VOLT, SINGL:&; PHASE/20B VOLT. THREE PHASE -4 WIRE PLANT
The terndnal farthest from the generator is grounded. For 120 volt,
single phase current connect the grounded load wire to the grounded
terndnal and the other load wire to anyone of the other three insulated
terminal!, A,. B, or C. For 208 volt, 3 phase current, connect a load
wire to each of the three insulat.ed terminals A, B, and C, leaving the
grounded terminal unused. Reversing the connections between any two in-
sulated terminals will reverse the direction of rotation of three phase
motors. Use a phase sequence indicator t~ assure in-phase connection.
For 208 volt, single phase current, connect one of the two load wires
to each of any two insulated terminals. 1666 watts are available on
each
sing~e phase circuit •
...... -----2o8 V. -I ¢I-------I ....
208V-lcI> 208V.-I¢I
t--------~------+-120V.-I4>
120V.- 14>
...... -------l--120V.-lcjI
208V.-3cj1
230 VOLT. THREE PHASE, :2 WIRE PLANT
No terminal is grounded. Reversing the connections between any two 'of
terminals A. B, or C will reverse the direction of rotation of three
phase motors. Use a phal'>e sequence indicator to 'B.ssure in-phase con-
nection. 230 volt single phase current may be obtained by connecting
one load wire to each of any two terminals. 1666 watts are available
on each single phase circuit •
..... ------ 230V. -1+ ------ ....
ALL MOIDEI;S .
One or more remote control switches m~ l>e c9.nn~cted.torr~te start-
ing and stopping •. Connect the switch 'terminals . .Nos~l, 2, and 3 to the
corresponding terminals, marked. REMOTE, b~ind· 'the . control panel, on
th.ef)le1 tank support •. U,l?e No. '18 .wiretocoilnect switches up to 250
ft·. in Ai;stance, No. 16.:.wire u.,pto 500 ft. and No. 14 wire up to 1000
ft.:U· Il,utomatic or lilje .. transfer equipment is to be connected~ fonow
the dtrectlons supplied With the eqUipment.
/'.-

IL HERE
ARMATURE BEARING
ENGINE STARTER (D.C.Plants)
FUl
KEEP OIL AT
THIS LEVEL
EMPTY 01 L
LEVEL
GAUGE
MARKS
AIR CLEANER
BATTERY CHARGE GENERATOR (D.C. Plants)
GOVERNOR CONTROL
LINKAGE BALL JOINT
ICATION
. I
6

r:e~,
.'
,
.. '.
'
PREPARATIQN
PREPARATION Foa OPERATION.-!3efor~ puttingth!3 plant in operation, it
must be supplied with fuel. oil, and water (or antifreeze liquid).
ComplyW:itb the fl'lJ.J.ovdng instructions •.
LUBfllCATION.- Refer to Fig. A. Use appro:x::l.matell 3 quart~ (U. S. '. .
Measure) of. a good qulillity heavy
duty (detergent) ,type, oi:1 to fi;ll the
crankcase· to the high level mark on the. bayonet 1:.yP!'I gauge. .Approxi-
mate:ly 1
quart of oil remained in the oil filter when the' crankcase was
drained.at the factory. Do not use.an oil heavier than SAE num.b~r 20
in '8 plant being put into service, .the first time. After the ,tirst oil
change, use an oil of, the properSAE numperas indica1-eli in the follow-
ing table • according to the lowest temperature to which tile plant Ydll
be exposed when not rI.\IUling,. Temperatures indicated are for ¢onditions
where the pl.ant. will b" standing idl.e long enough to Cool to the sur-
rounding temperature •
..
LOWESr Tl!14PERATURE
,S,AE NUMBER OF OIL
'.,' (j
, J.OOO F. (:38 C. )
40.
320 F.(Co C.)
30
00 F. (_18° C.)
2b
Below CO F. (-18°C.)
5\'.
. .
See ABNORMAL O?ERATING CONDITIONS
The crm¢case oil capacity is 3 quarts (u. S. Measure), pltis a.ppl'9xi~
mat ely 1 quart used in the operation of the oil filter. \Vhenanew.
oil filter element is installed, it will be found that the element will
absorb approximately 1 quart of o:i,l.
, The'
use of a heavy duty (detergent) type oU' w:Ui greli'tl;v' incrijasethe
life of pistons. and rings. If a change, .to !i/., he8.;VY dutyt~e;o.i1 is
made after using non-detergent oil. in this plant,. allow, not morptp.an
one third the usual operating hours between the next tWo oil changes.
There",fter change thecra;nkcalje .. ()il at. the regular per.iods, as
mended under PERIODI C.SERV:jiCE. . . . .,
'. ,CAUTION
Wh1!U using a d.E!t~rgeI'\ttype,oiJ...,,~way~, ,use O:l.l
'of t.he $!'IIJle. Qr.and . when .~dingoil between ,cb,~s •.
When IlIiixedtogethel"" dete,rgent,oil,s ,ot, . different',
manui'acturers sometimes form ~em:i,cal cOl)1I?,o~dljl,:'
that are harmful to intemal engine parts.' "
Keep
:the'erankca~e oii:LeV~ ,,~t.oJ:'· neq.r· the~pper:ievel"rila* .ort.~eo~:t
level gauge:, butuot.,:.aboye .;Lt. I,f,thec:rBrik~a:se is oVi;lrf1U~ci,the con'-
necting rods may' strike the oil)'~a\ls:l,n~ :t,mp.rqp~.r lubric;/j:tiQu,)ntci 'e;-~
cessive oil consumption. Never allow the oil level to faIl below the
low level mark on the oil level gauge. '
Remove the air cleaner top and fill the cup to the leVel indicated with
oil of the same SAE number as that used in the crankcase, except as
instructed under AEn~CRMAL OPERATING CONDITIONS - COLD TEMPERATURES.

PREPARATION
Fill the oil cup on the side of the distributor.
Place a drop of oil on each of the governor to carburetor link ball
joints.
It is unnecessary to lubricate the generator bearing and water pump
until time to do so as noted under PERIODIC SERVICE.
FUEL, GASOLINE.- Use only a good grade, clean, fresh, regular automotive
type gasoline of 68 to 74 octane rating. Do not use any highly leaded
premium type of gasoline. The 'use of any gasoline which has a high lead
content will necessitate more frequent carbon removal, spark plug, .and
valve servicing. However, do not use a low octane gasoline, such as
"stove" gas, as its use will cause excessive detonation or "spark knock",
and damage to engine bearings, valves, rings, etc.
If the plant has the mounted fuel tank, do not fill the tank entirely
full of cold gasoline, as the fuel may expand as the plant wanns up,
causing the gasoline to overflow. Observe the usual precautions when
handling gasoline. Do not fill the tank when the plant is running.
On plants equipped with the mounted fuel tank, note that the electric
fuel gauge on the control panel registers the amount of fuel in the tank
only when the plant is running. If it is desired to check the fuel
when the plant is stopped, throw the ignition switch to the HAND START
position while making the observation. Be sure to return the switch to
the ELECT. START position.
If· an auxiliary fuel tank. is used, connection may be made to the two
way
fuel shut-off valve at the bottom of the tank mounted on the plant.
FUEL, NATURAL GAS OR LPG.- Make sure that fuel I!IUpply lines (and tanks,
if used) have been properly installed and connected.
RADIATOR.- The capacity of the cooling system is approximately 11 quarts
(U. S. Measure). See that the radiator and cylinder block drain cocks
are closed. Fill the radiator with clean, alkali-free water such as
clean rainwater. The use of a rust and scale inhibitor is recommended.
If the plant will be exposed to freezing temperatures, use a standard
anti-freeze in the proper proportion. To avoid loss of anti-freeze
through the overflow pipe due to expansion, fill only to approximately
2 inches below the bottom of the filler neCk. Check the cooling system
to see that there are no leaks.
If the foregoing instructions have been carefully complied with, the
plant should be ready for operation. However, before starting the .plant,
carefully study the paragraphs under the headings OPERATION and ABNORMJL
OPERATING CONDITION immediately following.
8

OPERATION
PRELIYINARY.- Be aure that the plant has been properly installed and
prepared for operation before starting it. Tum on the fuel suppl;r and
check for leaks; correcting any that may be found. See i;.hat the circuit
breaker handle is in the OW position, so that no load is coimected~
CAUTION
If the preparation has been made for ext~emely cold
weather, using diluted No. lOW oil, the initial fill-
ing of the crankcase with diluted oil should have
be~ left. to be done immediately bef'ore starting the
plant. Be sure the crankcase is filled with the pro,:"
per oil to the high level mark on the bayonet gauge.
au was sprayed into the cylinders before the plant was shipped, and
it m~ be necessary 'to remove and clean the spark plugs in gasoline
before the engine w.i.ll. start the first time. Dry the plugs before re-
installing them. .
STARTING THE PLANT ELECTIllCALLY.- See that the ignition slli.tch is set
at the ELEC. START position. If the plant is to be operated on gas-
oline fuel, press the START button firmly'for several seconds to allow
the fuel pump to become full and to pump gasoline into the carburetor.
The carburetor is automatically choked, and the engine should start
after a few seconds of cranking. Hold the start button in until the
plant has reached running speed. If it does not start J do not press
the START button continuously, but for periods of not more than five
secollds at a time, 'With equivalent stops between. If the plant fails
to start after a few attempts, check the fuel and ignition systems and
repeat the procedure after correcting the trouble.
If the plant is equipped for natural or Liquid Petroleum Gas operation,
see that the arm of the choke control mounted upon the exhaust manifold
is locked do'WIl. so as to make the choke inoperative. No choking is nec-
essary when .operating on gas. and the carburetor choke valve should b't
wide open. See tnat the gasoline supply is tumed ofr, and that there
is no gasoline in the carburetor bowl. Turn on the fuel supply and press
the START button. The regulator primer button, at the center of the
regulator, may have to be pushed to start the engine the first time. Do
not overprime. Unless the fuel to be used is of appro.x:i.mately the same
BTU rating as that used by the manufacturer (1000 BTU) it will be nec-
essary to readjust the carburetor gas. adjustment valve to insure srttooth
and economical operation. See the section headed ADJUSTMENTS.
STARTING THE PLANT MANU.AIJ..I.- If gasoline tuel is used, use the hand
crank to. tum the engine over enough times to fill the fue:\. pump and
carburetor. Throw the ignition switch ~o the HAND START position.
Crank the engine with a quick upward pull. Have some one pull up on'
the automatic choke arm .while cranking. Do not spin the crank or, press
down on it. If gas fuel is being used, it m~ be necessary to press .the
regulator priming but:ton ,at the center of the regulator, to start the
engine the first time. Do not overprime. For manually starting a plant
equipped for gas fuel, the gas should have a BTU rating above 800 BTU ..
per. cu. ft. •. The temperature should be above 300 F. (_10 C.). Seeth~t
the automatic choke arm is locked do'WIl..' AtI;.erthe carburetor gas adju.~'t:""'
ment valve has been properly adjusted, it should be unnecessarytQ u~~,,;;~I:
the priming button. After the plant starts, be sure to re1-.um the i~...,
~tch to the ELECT. START position.
,

OPERATION
CAUTION
KEEP THE IGNITION SWITCH AT THE ELECT. START POSITION Af .ALL
TIMES EXCEPT WHll2'I ACTUALLY STARTING· THE PLANT MANU.ALLY. THROW
THE SWITCH TO THE HAND START POSITION WHILE CRANKING THE PLANT
MANU.ALLY. BUT RETURN IT TO THE ELECT. START POSITION AS SOON AS
THE PLANT STARTS. WHILE THIS SWITCH IS AT '!HE HAND START POSI-
TION THE HIGH WATER TmERATURE CUT-OFF SWITCH (AND LOW OIL
PRESSURE SWITCH. IF THE PLANT IS SO EQUIPPED) IS CUT OUT OF THE
CIRCUIT AND THE PLANT IS NOT PROTECTED AGAINST OVERHEATING.
IF THE SWITCH IS LEFT AT THE HAND START POSITION WHFJI -rHE PLANT
IS NOT RUNNING, THE BATTERY MAY BECOME DISCHARGED AND THE IGNI-
TION COIL DAMAGED.
I.f the plant will starli but does riot continue to run
1 when
electrically
cranked, possibly the starli button is being released too soon. If not,
try starting the plant manually. I.f the plant starts and continues to
run with the ignition retch at the HAND START position, but stops when
thrown to the ELECT. START position, trouble is indicated in one of the
relays, the high water temperature switch, or a loose connection.
CHECKING THE OPERATION.- After the plant starts, allow the engine to
reach operating temperature. . Check the level of the coolant in the
radiator, as the thermostat may have allowed an air pocket to form, thus
preventing complete filling. Add coolant to bring the level to the pro-
per point, if necessary. The oil pressure should be between 20 and 40
pounds~ the coolant temperature approximately 150
0
to 180
0
F. (65
0
to
82() C. J, and the battery charge rate between 2 and 7 amperes, depending
upon the charge condition of the batteries.
When the plant is not in operation, the water temperature gauge will
register 2120 F. The fuel gauge, oil pressure gauge, and charge amme-
ter will register zero. If it is desired to check the water tempera-
ture or fuel supply when the plant is not running, throw the ignition
switch to the HAl~D START position while making the observation. Be sure
to return the switch to the ELECT. START position after making the ob-
servation. While the plant is running, the various gauges are automati-
cally in operation when the ignition switch is at the ELECT. START
position.
Connect a load to the plant by throwing the main line switch, or con-
trol panel circdit breaker if the plant is so equipped, to the ON posi-
tion. The no load voltage is approximately 125 volts for the 115 volt
plant, after the plant has reached operating temperature. The full load
voltage is approximately 108 volts, for a 115 volt plant. Voltage will
be correspondingly higher for plants of other voltages. If the plant
tends to surge, or the voltage tends to fiuctuate, it is usually an in-
dica.tion the engine needs additional warm-up before connecting a heavy
load. Those plants which are equipped with the electrical meter panel
have a circuit breaker which will automatically disconnect the load if
the plant is severely overloaded. If the plant is not equipped with the
circuit breaker, keep the correct size fuse in the load line switch.
Those plants equipped with an output receptacle on the panel will not
register on the meters any load which may be connected to the receptacle.
This receptacle is provided for a trouble light or similar light load up
to 15 amps., 115 volts for each outlet.
10

OPERATION
Continuous overloa.ding of the gene;ratorwill cause the generator tem-
perature to rise to a. dangerous point. and lead· to earlY failure of the
windings. If the main line fuse should blowout. or the plant oircuit
breaker open, remove the cause of overloa~g·betoreagain oonnecting
the load to the plant. On .the three phase plant, it part o~ the load
is single phase l the total load on any one "leg" Should not exceed one
third the total capacity of the generator. On the 115/230 volt. plant,
divide the load asclosaly as possible between the two circuits when
using 115 volt current. Confine the load on each 115 volt circuit to
not more than 2500 watts.
STOPPING THE PLANT.- Throw the main line switch or the plant circuit
breaker to the OFF position, to disconnect the load. Press the STOP
button firmly. The ignition switch must be at the ELECT. START posi-
tion, as pressing the STOP button will have no effect if the switch is
at the HAND START posit.ion. In an emergency, if the stop circuit fails
to work, turn otf the fuel supply. The plant will stop when the supply
of fuel in the carburetor is exhausted. .
11

I
ABNORMAL OPERATING CONDITIONS
LOW TEMPERATURES
Lubrication, fuel, and the cooling system require special attention at
temperatures below 320 F. (0
0
C.).
CRANKCASE OIL.- If the plant must be started after standing unused in
temperatures between 320 F. (0
0 C.)
and 00 F. (-lSO C.) use a. good
quality oil of SAE number 20W in the crankcase. For temperatures below
00 F. (-18
0
C.) use SAE number 5W oil. The oil should be the detergent,
or heavy duty type.
If number 5W oil is not obtainable, dilute number lOW oil with approxi-
mately 1 part of kerosene to 4 parts of oil. Thoroughly mix the oil
and kerosene just before pouring into the engine. Immediately start
the plant ana run for at least 10 minutes to thoroughly circulate the
mixture through the engine. Do not put diluted oil into the engine
until ready to start the plrult. Mix the oil well just before pouring
it into the engine. Always use a mixture of the same proportions when
adding oil between changes. When using diluted oil, change the oil
every 25 operating hours and check the oil level frequently. Use un-
diluted oil again as soon as t~dperature conditions permit.
CAUTION
Always drain the oil only when the engine is warm.
Drain the oil filter when changing to a lighter oil.
Add sufficient oil to compensate for that used to
fill the oil filter.
AIR CLEANER.- If congealed oil or frost formation within the air cleaner
restricts the air flow, remove and clean the air cleaner. Reassemble and
use the air cleaner without oil until conditions permit the use of oil
in the normal manner.
COOLING SYSTm.t.- The coolant must be protected if there is any possibU-
ity of its freezing. Use any good antifreeze, in the proportion recom-
.mended
by the manufacturer for the lowest temperature to which the plant
will be exposed. The capacity of the cooling system is approx:imate1y
11 quarts.
If the plMt is to be stored in freezing temperatures, without adding
anti-freeze solution, be sure to open the cylinder block drain cook to
thoroughly drain all water from the block, after draining the radiator.
If the water temperature gauge shows the engine to be operating too cool,
a portion of the radiator surface may be covered to raise the coolant tem-
perature to normal. Avoid overheating. Set the high water temperature
cut-off switch to operate at a temperature several degrees below the boil-
ing point of the coolant, taking into consideration the altitude at which
the plant is operating, and the type of anti-freeze solution used. Check
the antii'reeze solution frequently.
12

ABNORMAL, OPERATING ,CONDITIONS
FUl!l.fGASOLINE.- Use besh .. ' .clean,hi.gh t,ast (n.ot h.lshlYlead.ed, pre-
miwn) .. gasoline f:oreasy starting ,in eold weather •. Keep the fuel.tank
nearly tull in order topreventmoistt\re cqndensation within ,the tank,
which can causeconaiderable trouble from ice formation in the fuel
system. Do not 'fill the flle1 tank entirely full of gasoline, for . '
expansion as the plant wa~B up may cause it. to overflow.
FUEL, GAS OR VAPOR.- Some types of· Liquid Petroleum Gas will not vapor-
iZe readily at low temperatures. Heat exchanger equipment is available,
at extra cost, an.dshould be installed at the i'actory if t~perature con-
ditions require it. '
BATTERIES.- Check the charge condition of the batteries fr,equently, to
be 'sure .,thatthey: ,are j{eptin a f:\llly charged condition. A discharg,ed
battery will freeze at approximately 20°F. (-70C')dand be permanently'
damaged. A fully charged battery will not freeze at -900F. (-67°C.).
Run 'the. plant for at least 20 minutes after adding water, to assure
mixing the water with the electrolyte.
HIGH TEMPERATURES
If the plant is to be opera,ted in abnormally high temperatures,(abov;e •.
100°F., or 38°e.), provide sUfficient air circulation for proper cooling.
Keep the cooling system clean and free of rust and scale. .See that the,
high water temperature cut-off switch is correctly set, and that the
ignition, switch is at thl'! ELECT. START position. Keep the ignition
timed correctly. Keep thera.diator ,well filbd, the fan belt ,tension,
properly adjusted, and the crankcase oil leVel at ,but not above, ,:the, '
upper level mark on the oil level,gauge.
CAUTION
For best coo~g effects, keep the door panels mplace
on the plant when it, is in operation. '
Use
BilE number 30 oil for temperatures up to ldo°F. (3aoC.) and SAE num-
ber 40 for ~ghertemperatures., Check the oililevel trequentl.y, and
change
thecrankca'!;eoil at. l'eastevery, 5Ohour.s. Keep ,the eJ.:ectrolyte
level in the batteries up to normal. I '
. , !. ,.:, ."
.DUST ANq DII~T
Keep the plant as clean as practicable'. s~rviJ~ t~e arrcleaner as i;e'-
quentlyal!l,~ol'ldit;onl'l: l'~Q.uire.: KeeIJ tpel'adi'ator. lin.sclefUland, f~e.of
Qbstructipna;,., ' Keep the, generator,cOl1lID,9tatg;t.'an4 sJ.-ip.;rings ano.brushes,
clean. See that all brushesrlde' freely in thlifirholders,'- J'.ee:Q, oil ,an,.d
ga.soline sLlPpUesinaj,r tightc9nt?J.nel:'s. , InI:11;.alla .~~w.oil filtere:le-
ment as often .alfnecesea,ry to. keep: the oil,. clean.' . Change the crankca,se
oil more frequently if it becomes discolored before the nol'lllBJ. time has
elapsed between ehmge~ .. , ' ,
.' .. j,

PERIODIC SERVICE
GENERAL.- Follow a definite schedule of inspection and serviCing to
assure better performance and longer life of the plant at minimum ex-
pense. Service periods outlined below are for normal service and aver-
age operating conditions. For extreme load conditions, or abnormal
operating conditions, service more frequently. Keep a record of the
hours of operation each day to assure servicing at the proper periods.
DAILY SERVICE
If the plant is operated more than 8 hours daily,
perform the DAILY SERVICB operations every 8 hours.
FUEL.- If the plant is operated on gasoline fuel, check the fuel gauge
often enough to assure a continuous fuel supply. Do not fil1 the tank
while the plant is running.
RADIATOR.- Check the level of the coolant and, if necessary, add suffi-
cient liquid to bring the level up to within one or two inches of the
bottom of the filler neck. In freezing weather, if a nonpermanent type
antifreeze is used, check the protective strength of the coolant.
AIR CLEANER.- Check the oil level in the air cleaner cup and add suf~
ficient oil to bring it to the indicated level. Clean out and refill
the oil cup if dusty conditions prevail.
CRANKCASE OIL LEVEL.- Check the oil level as indicated on the bayonet
type oil level gauge. Do not allow the engine to operate with the oil
level close to the low level mark on the gauge. Add sufficient oil of
the proper SAE number to bring the level to the upper level mark, but
do not overfill the crankcase.
CLEk~ING.- Keep the plant as clean as possible. A clean plant will give
longer and more satisfactory service.
WEEKLY SERVICE
If the plant is operated more than 50 hours a week,
perform
the WEEKLY SERVICE operations every 50 hours.
CRANKCASE OlL.- Add crankcase oil as neces'sary, or change the oil after
50 operating hours. If the plant has been operating with diluted oil,
change the oil after 25 hours operation.
GENERAL LUBlUCATION.- Put a drop of light lubricating oil on each of
the gOvernor to carburetor link ball joints, and fill the distributor oil
cup. Put several drops of oil in the oil holes at each end of the bat-
tery qharging genera.tor, and in the oil hole at. the forward end of the
starting motor of the direct current, battery ignition plant.
AIR CLEA.'\lER.- Clean the air cleaner filter element and cup thoroughly in
gasoline or other suitable solvent. Allow to dry, or use compressed air
. to dry. Refill the cup to the indicated level with clean oil of the s~e
SilE number as that used in the crankcase, except as noted under ABNORMAL
OPERATING CONDITIONS.
14
J