Onan CCK Series User manual

GENERAL INfORMATION
THE PURPOSE OF THIS BOOK. This instruction book is.furnished so
that the operator may learn of the charactertsUcsoftheplant. .A thor-
ough study of the book wilL help the operator to keeptheplant in .. good
operating condition so that it will give efficient service. An under-
standing of the plant will also assist the operator il} determining the
cause of trouble if it occurs.
KEEP THIS BOOK lIANDY. Such. simple mistakes as the use of im-
proper oil, improper fuel, or the neglect of routine servicing mayre-
sult 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 he refer ...
red to when necessary. ' .
SERVICE.
If trouble occurs and th~operato:t:' is unable to determine the
cause after a thorough stuayof tl1isbook, or if he is unable to deter-
mine what repair parts are required,needed information will be fur-
nished upon request. WHEN ASKING FOR INFORMATION, BESURE TO .
STATETHEMODEl,t,.SPEC.,AND SERIAL NUMBERS
OF THE PLANT.
THIS INFORMATION IS ABSOLUTELY NECESSARY AND MAYBE OB-
TAINED FROM THE NAMEPLATE
ON THE PLANT. .
MANUFACTURER'S WARRANTY
The Manufacturer warrants each produCt of its manufacture to be
free from·defe.cts in materjal and factory workmanship if ,properly'
installed, serviced and operated under nonnal conditions accord-.
ing to the Manufacturers instructions,
Manufacturer's obligation under this warranty
is limited to oor~
reeting without charge at its factory any part or parts thereof
wllich shan be returned
to its factory· or one of· its Authorized
Service Stations, transportation charges prepaid,
within ninety
(90) days after being put into .service by theoriglnal user, and
which upon examlnlltioll shall disclose to
the ManUfacturer's sat-'
isfaction to have been originally defective. Correction of such de'-
fect~ by repairto, or supplying of replacements for defective Parts,
shall constitute fulfillment of all obligations tf) original user. '
This warranty shall not 'apply to any of
the1.fanufactmer's prod- '.
ucts which must be replaced because. of nonnal wear, which have '.
been mbject to mistlse, negligenCE) or acclde:IjJor which shall have
been repaired or altered outside of the !I!anufacturer's factory un-
less autllorlzed by the Manufacturer"
Manufacturer
sh~1J not he liable for loss, damage or e).-pense
directly or indirectly from the usc of it~ product odrom any other
cal1se. The Manufacturer Inakes no "'llrro.ljtY,'~l:>atsoe"er ",.ith re-
spect to componentpartswhich
are warranted separately by their
respective manufacturers,
.. . .
, .
TIle above warrant)' supersedes and is in lieu of all other war-
rantics, expressed or implied, and no person, ag~nt or dealer is
lluthorized to give all)' warranties.on hehalfof tile ~!anufactllrer
nOt 10 nssumefor the ~I"nllfncttlrer any' other liability in COIllI€<?
tion with any of Us pl'oduets Ilnless made .in writing and signed .
by nn official of the Manllfacturer.
r~~~~~~~~~~em~~~!~~~~~~1
IMPORTANT
RETT,JRN WARRANTY ·CAJUJATTACHED TO'UNIT.

• • •• • ••• • • •• • • • • • • • • •
FIGURE LIST OF ILLUSTRATIONS PAGE NO.
1. Typical Installation .~ ; ••. " •...... ; : .. n .8
2. V·entilation •..............•................. ~ . . . . . . . . . . . . . .. 9
3. Mounting Base . ~ .•.•.....••• ~ ... , , . '.' ; •..•.•.•.••...... '. . . .• . 10
4. Mounting Cushions •• ,
............. ' •... ; ...... , ' ..... ' .. " . .• 10
'5. Exhaust Installation. .. . . . . .. .. . . . ... .• . . •... . . . . . . . . . . . . . .. . 11.
6. ' Oil Drain Extension .....•......•..........• ,.~~. . .•. . . . •. . ... ..11
7. Dimensional Outline for Manual Plants ................. ; .. . . .. 12
8. Dimensional Outline for Remote Plants ....•.... ; . . .. . . . • . .. . • 13
,9. Dimensional Outline for portable Plants. . .. ... .• . . . . .. .. . .. . . 14
10. Battery Connections - AC Remote Plants ••. • . . • ... .. . .. . •. . .. . 15
11.
Battery Connection, .Magnet Service Plant. ................. ; 15
12. Start & Ignition SWitches,Magnet Service Plant ... :. ..•. . . . . •. 16
13. Load Wires, Magnet Service Plant '" . . . . ... . .•. . . . . •. . •. .. . .. 16
14.AC Load Wire Connections.. • . . . .. . . . . . . . • . . .. • . . • •. •. .. . . .• 18
15. Load Receptacles - Portable Plants ................. ~ .• ;. . .. .. '21
16. ' Plant Grounding ...... '.' ..................•.............. ". 21
17. Remote Start~Stop Stations. . . . . . ••. .. •. . . . . . • . . . . . . • . . . . . . .. 22
18.' Fuel Reservoir ''Day'' Tank .....•......•....•.... " •..... ; " ' 23
19., Gas Hegulator Connection ... ; ...............•. : ......... " ~ 25
,20., Vacu-FloCooling ..... ; ...•..........•.....•.........• ' '.' .. • 26
21; 'Crankcase on.Level ..•. '" ........ ' .•. , ........• " .. ' ..... ',' 27,
22. Governor Linkage Lubrication •.•..... ; : •... ; •.•.. ; ..... ; . . • 27
23. Air Cleaner Service .••............ " .............. ,. ; . . . . . 27
24. Fuel Shut-Off Valves; ........... " '" . . . •. . . . . . . . . . . . . . . . . . 27
25. Priming the Fuel pump" .••. '," . . . .. . . . . . •.. • .. . .. . .• .. . . .. 31
26. steps to Follow in Starting the Plant .... , •; . •. •. . . . . . •. .. . . . 34
27.
Air Cleaner Service ...............••.....•..... " . . . . . •. .. 38
28. servicing the Breaker Points •.... ' .•........... " •. . . . . . . .. . . 40
29~ Servicing the Crankcase Breather Valve. . •. . . . . . . . ••• . . . •. .• 42
30~ Governor Adjustments ...................... ~ .. " . . .. ... .• . 45
31. speed·Booster Adjustments. •. •. . .. . . .. . ... . . . . . . •. . . . •. . . . . ' 45
32. Throttle stop Lever Position .•............•........• ; •.... ; 48
,33. Oil.Pressure Relief Valv-e Adjustment. . •. . •. . •. . . . . . . . . . . . .. . 49
34. Carburetor Adjustments ..•.•...••... " . . .•. . . ..•. . . . . . . . . . 50
3.5. >Electric Choke Adjustment ; ........... , .' ....... ; ... ,. . • .... 51
36. Magneto Stator Installation ............. " .......... , . ... . . . 55
37. Coil and Circuit for Magneto Ignition.. .. . . . .. . . . . . . . . . .. . . . • 55
38. Coiha.nd Circuit for Battery Ignition .......•.•. ; .. . . . . . . . . . . ..56
39.- IgnitionTiming •.•.. ' ............. "........................... 57
40. Valve Service ...•......•...•. ' ........................ " . . . •. 59
41. Installing the Gear Cover .. . .. . .. . . . . . . . . . . . ••. . . . . . . . . .. .. 60
42. GovernoJ:' Cup..' ..•... '.' ... , .. ; ..•........ ',' ................ 61 0
43. Timing Gears ..... 0 ; ••••••••••••• ' ••••••••••••••••••••• o. • 62
44; Fitti~g piston Rings to the Cylinder. . . . . .. . . . . •. . . •. . •. . .. . 64
4.5. RedUCing Connecting Roo Clearance •... . . . . .. ... . .. . .. . . ..• 64
46.
Bearing Installation. .. . . . . ... . . .. .. . . . . . . . . . . . . .. .. . •. .. ... 66
47. Oil seal Installation. . .. . •. ... ... . . . .... . . . . • .. . ... . . . . . ... 66
48.
Crankshaft End-Play. . . . •. .. . . . . •. . . . . . . . . . • . . . •. . . . . . . . .. 67
49. Oil Pump Removal .•..•... , ......•................. , . . . . . .. 67
50. Brushes and Springs ........ '" .' ...... , . . . ... .. ... . . . •. . .. '69 '
51. "'Commutator Repair .•..... " . . . •. . . . . . . •• . . . . •. . . .. •. . . . .. 70
52, Continuity Test Lamp.......................... ........... 71
53.' Armature Growler •..•........•.. ' •.....•..•... ' ..•...•.. ' ... 71
54. Generator Assembly ......................... ; .. . . •. • • . .. . .. 73
55. Servicing Readi-pull starter •..•.•..•.•• " ....•••••.... "0 • 76 '. • ..
56. Installing Readi-pull starter, Un1ts"prlor to spec.D !. ,i • " .~. ' •... 7'.786. '.'~".'.'"
57.
n
Installing Readi-Pull Starter, Units beginning spec.'D •. .; •. •• ~ , '.
.. '. ". . ~
i

54,>
SUBJECT TABLE OF CONTENTS,
Description
, Introduction ........................ ',' ................ .
General Description
•..... , ... , .......•.... , ...... , ' ..
Engine Details' ............ , ................ , , ....... .
Generator Details, Controls ............. , ............ .
Accessories ........... ' ................ ' ..... ', .. , .... .
Installation
Location,Mobile Installation •.•..... , , .............. , ..
Ventilation, permanent Mounting Base ................. ,
Mounting Cushions, Exhaust
..........................•
Oil Drain Extension , ..... , ...•.. ' ...• , .......•.......•.
Battery .............. ', . ~ ............................. .
Start & Ignition Switches, Magnet Servic,e Plant ••.•.....•
Connecting the Load Wires ..................... , ...... .
Grounding
..•..... , .............................. , . " .. .
Remote Control Switch,
Separate Fuel Tank ............ .
Underground Tank,"
''0 ay " Tarik, Carrying Frame, DOlly ... '
Readi-pull starter ... ' .. ' .•.........•. , .' ................ .
,Gas Regulator
•......... ' ... ; ....... ' ....... ~ ......... ~ .
Vacu-Flo Cooling
............................... ' ......•
Preparation
Lubrication ; •.. ' ....•.... ' ............................ .
Air Cleaner ,Fuel, Before Initial start .......•.....•....
Operation
start ing the pIa nt •. . . . . . . . . . . . . . •. •. . . . . . . . .. . . . : . . . . .
Applying the Load
............... ' ...................... '
Charge Rate, Stopping the
Plant, Changing Fuel .......... .
Function of the Controls
.................... , .•..........
Abnormal Operating,Conditions
'Low
Temperatures .. , .......... , .... : ...• ',' ........... .
High, Temperatures •..... ". " .... ' ...................... i ...
Dust and Dirt .... : . ',' .. ' ................ ; ......•.......
Periodic Service
Daily Service •... : .............. ; ......•. , .. ' ...... , ... "
Weekly
Service •................ ' ..................•.• '.
Monthly Service, ....... , ......... ' .................... ..
Adjustments '
General, Governor and Booster
..•...•.......• : .•.••..•
Voltage Chart; Speed. Chart ............ ,' ... , ........... '
Oil Pressure Relief Valve .......................•....•
Carburetor ................. ;. " ..................... .
Electric Choke •..... ; ....• ; ........•... " ....••......•
Maintenance and Repair . ,
General, Table of
Clearances ..• '" ......... " .•. " .••.•.
A ssemblyTorques, Engine ........... "" ..........••..•
Generator .................................. ~, ...... ," .
Control
..• , .................. " .....•. ' ...... ; ....... ' ..•
Starter ....................•..................•.. ' •....
Service Diagnosis" ......... : .....•.... ;' .... : ........... ~'
Wiring Diagrams . ; ...... ,. ., .'. . . . . . . . . ........... '," ...... .
PAGE NO.
1
2
4
5
6
7
9
10
11
15
16
16
21
22
23
,24
25
26
28
29
,30 "
31
32
33
,35
36'·'
37
38
39
40,.
43
46
49
50
51
53
69
74
75
79
87
m

ENGINE SERVICE CHART
FOR DETAILED SERVICE INSTRUCTIONS, SEE PERIODIC SERVICE.
The following recommended Engine Servicing Chart may be used as a
guide to
estimating servicing requirements of ONAN Gasoline Engines.
.
The chart is based on the Units operating under favorable conditions,
such as: use of recommended fuel and oils, etc.
SERVICE &
PARTS.
REQUIRED
Oil change (Check daHy).
Clean and gap plugs. ____
*A.ir cleaner. __________
Ignition pOints. ________
tClean carbon. _________
Clean carburetor. ______
Check tappets. _______ _
Grind valves. __________
Clean oil base. _______ _
Clean crankcase breather
Clean engine. ________ _
Replace spark plugs. __
Replace valves, ______
Replace pOints. ______
. Replace piston rings. __
* Check the air cleaner often~ Thoroughly clean and put in fresh oil at
least every 100 hours.
If it is necessary to remove parts for inspection and gaslmts are dis-
turbed they should be replaced with new ones.,
Periodic Inspection: For loose or poor connections, fittings, etc.
t Recommended fuel: Use regular gradegasoline of at least 68 octane -
. Do not
usepremjurn type. If a high lead content
fuel is used, it will be necessary to remove t.he lend deposits more
frequently ..
Keep engine clean.
IV
HOURS OF OPERATION
0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0
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0 0 0 0 0 0 10
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-IX
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~IX rx]XrxIXIX IXrxlZ~ --tx
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AS REQUIRED
-
AS REQUIRED
--
AS RE~UIR~~ ____
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u

DESCRIPTION
1
INTRODUCTION. -This instruction manual is supplied to assist in the
proper installation, operation, and servicing of the
CeK series electric generating plants. Unless otherwise stated, these
instructio~s apply to all standard plants of the CCK series. .
The .plant
model and specification, seriaL number, and electrical char-
acteristics appear on the nameplate. The manufacturer produces many.
types of generating plants, industrial engines,and separate generators.
Basic differences such as voltage, type ofCQoUng, optional equipment ,
and manufacturing improvements are<i,ncorporated in the model and
speCification
numbers. Consequently the MODEL and SPEC. NO. on the
plant nameplate should always
be mentioned in any reference to the plant
if contacting a
dealer or the.factory.
Some
details of these. illstructions may not apply to special models hav ..
ing modifications specified by the purchaser. Due to the wide variety
()f uses for which these plants are suitable, these instructions must be
of a general nature. 'I'M use of auxiliary or specialequipment, spectal
installation
requirements, or unusual operating conditions may require
the operator of this generating plantto modify these instructions. How-
ever, by using the.instructions and recommendations given in this man-
ual as a general guide, it will be possible to make a good installation,
and
to properly operate and maintain the plant.
The engine end is designated as the "Front End" of the plant. "Left
Side" and "Right Side" of the plant are determined by viewing from the
front end .. Cylinder number one (nearer the timing gears) is on the
"Left Side" of the plant.' .
Instructions apply to both
60 cycle and 50 cycle alternating current plants,
the
main difference being in the operating speed. Most appliances can be
used on either 500r 60cyde frequl'!ncycurrentbut it is advisable to
. check appUances before purchasing to assure that they are adaptable to
the current frequency and" voltage.

2
DESCRIPTION
GENERAL DESCRIPTION
Each CCK generating plant is a complete electric power plant, consisting
• ... of an internal combustion engine, and a self excited electric generator
directly connected to the engine. Controls and accessories suitable for
a normal installation and according to the particular mOdel are supplied.
Each generating plant is given an actual running test at the factory and
is carefully checked under.various electrical load conditions before
· shipment, to assure that it is free of any defect and that it meets all
performance requirements. Inspect the plant carefully for any damage
which may have occured in shipment.
Any part so damaged must be re-
paired or replaced before putting the plant into operation.
. .
The alternating current (ac) plant generates current similar to that
supplied by most commercial power lines. This type plant must be
· operated whenever electric power is desired. The ac plant produces
its fun rated capacity in alternating current 'plus approximately 135
watts of direct current· (dc). Thedc is used as excitation current
and,on electrically cranked plants; to charge the starting batteries. A
small auxiliary load maybe taken from the starting battery while the
plant is idIe, depending upon the charge condition oitha battery. The
ac plant will not be damaged by operating it with no load connected or
with the. starting battery, on remote plants, disconnected •.
· The direct cur I' Einf (dc). plant is made in twobasic. types: (1) for direct
service application asa power source .for lights, power tools, etc.; and
(2) a specially designed generator for lifting magnet service. .
.The
dualpurpose plant produces alternating current, plus 32 volt de for
. battery charging... When the maximum battery charging current is in use,
the alternatingcurrent maximum output is reduced to 2250 Watts.
TYPESQFPLANTS.- The portable type of plant is designed for appli-
. . . c.ations where portability is important. A rope-
recoil starter serves for convenient hand cranking, and the plant can
not
be connected to batteries for electric cranking. A carrying frame,
a grounding stud and a pilot Ught are all desirable features of this
portable type plant.
. .
.
.",.
The .manualtype of plant is designed for applications where the mount-
ing location
is somewhat permanent, either stationary or in a vehicle.
Load
wires mustbe connected djrectly to the output leads (except when
an
optional.receptacle plate is added), A rope-recoil starter ,serves for
convenient hand cranking,and the plant can nQtbe connected to batteries
for electric cranking.
The
remote control type planUs designed for applications where the in-
stallation will be more or less permanent. . When properly connected to
a 12-volt battery (or two 6-voltbatteries in series), tbeplant may be
cranlted
electrically at the plant, from one or more remote control
1'1, i ! I \ Ii'. Ii! ' H i'l I I· i, i

switch location, or through autQmattc controls. In the event.of failure
of the starting battery current, .the plant may be cranked manually., The
remo.te controitypepla
ll
t nasa built:-in charging circuit for keeping the
, startIng battery ill: a wellcha,rgedcondition.Solderless terminals,in
the. plant control.box,serve fO:r(,!onnectingthe electrical load wires to
.
the generator output leads. r··
PORTAt;;: REMOT}=>.'
5CCK-1 /1A 5CCK-1R/1A
-.-
. *
5CCK-1RV/1A
Magneto
Battery
4 Quart
4 Quart *
Mounted (4)
CHART OF ACPLANT TYPES.
PLANT·FEATURE
Typical example:
Ignition: ,
.
Oil Capacity: (U. S. Quart)
FuelTank(U. S. Gallon)
Cranking
and Choking:
Gasoline Carburetor:
.Gas-GasQJJI1e
Carburetor:,
Engine RPM
(60 cycle):
EngineRl"M (50 cycle): ,
Housing;
NOTEt
.*
*
MANUA?,
5CCK~1M/1A
.Magneto
4 Q~rt *
Separate (5)
(Mtd. Optional)
Manual
Standard
Optional
1800(nominal)
1500(nominal)
4" Outlet Box
Optionalt
Optional t
Manual
Standard
Optional
1800(nominal}
1500(nominal)
Receptacles
Standard
Optional
Electric
Standard
Optional
1800(nominal
1500(n.ominal
Terminals
Opt
ionalt
Optional t
Optional for
Vacu:-Flo

4
DESCRIPTION
ENGINE DETAILS
The engine is a horizontally opposed 2 cylinder, air cooled, 4 stroke cy-
cle, L head internal combustion type. Standard models burn gasoline
fuel.. Some
special models are equipped with a combination type carbure-
tor for burning either gasoline or gas fuel.
The cylinder bore is 3-1/4 inches, the piston stroke 3 inches, piston
displacement 50 cubic inches, compression ratio 5. 5to L The cast
iron cylinder and crankcase isa single casting.
The engine speed is controlled by aflyball type governor built into the
camshaft gear. The governor is externally adjustable. The governor
function is supplemented by a speed booster. The booster is operated
by manifold vacuum and serves to improve stability under load condi-
tions.
Ignition current on manual and portable type plants is supplied by a high
tension, flywheel magneto. Ignition current on remote control type
plants is supplied by the starting battery. .
The engine is cooled by air forced around the cylinder walls and head.
Plants which are "pressure cooled" have blower fins on the flywheel
which
draw air in throughthe opening at the front of the blower housing.
Special models of the remote control type plants may be Vacu-FloCooled
and have blower fins which expel heated air out through the duct at the
front of the blower housing, as desirable for small enclosure installa-
tions.The letier"V" appears in the model ofVacu-Flo cooled type
plants. (Example: 5CCK-3RV /lA). .
The engine has aluminum alloy 3 ring pistons, and full floating type pis-
ton pins .. The counterbalanced crankshaft turns in two unusually large
main bearings which are replaceable-precision-sleeve type. The con-
necting rods are aluminum alloy with integral bearing. Special models
may have forged steel connecting rods and replaceable rod .bearings.
The exhaust valves and seats are Stellite faced. Valve tappets are ad-
justable self-locking. A positive rotator for each exhaust yalve provides
long trouble free performance (Rotators not on "Spec A" models).
The gear type oil pump supplieS! pressure lubrication to main and con-
nectingrod bearings. Oil pressure is controlled by an externally-ad-
justable .spring loaded relief valve.

DEBe RIP T 10 N
j"';
I
GEJil"E.RA'I'OR DETAlLS
. , I . .. ". .,
I .
·The alternatingcllrrelJ:tgel}.~rator ..• isar.eyolytnga¥.~.~~J,lre,self· exdt ed, .
inher.ently.reg.41ated.type
•....•. ~h<7AI.1p:E!~el1t .. q~signp~".tJj~;;~~perator. with,
saturated,. 4 pole, ... shuntWO;undf)eld,assureSGJo~~17~g~J~tionof voltage
b~tween no loadalld.f.1.1.1l.·lo~<iconditions;.····· ... ~t?spe~.i.a,Jsertesy;inding. in
the field of the.remote.star,ting
mode~spermits the'generatQi:'to be used
! as a starting motor. .. . .
i ;.-',;':;; ..;:.:(-;'
, '. '" ' ":, ", . ,:' I" ,: .' : """/,.l.';'·::',···:·'7·:~ .. /. _ _ _ .
The armature isconnecteq directly. totl].~".~'ilgine crapkshaftthr.q"!lgh a
taper fit and held lnplaceiby a studWl'riii}ipisses through thehollbw
center of·the shaft.A.larige.baU.b~ariJ1g supports the outer.;endotthe
armature,. The'. armaturerfor the. ac .plant contains bothac . and dc
windings,theac windinjgscqj).~ecting to the collectot rings, the. de
windings connecting to the commutator.
."
...' ~. .'.~~~
· " ; '.
'I'wobasicsizes of . ac generators prevail intheCCKseries.The " ..
smaller generator uSeS. a 4-1/2 inchstack OfIa.rninations,ratedoutput
is 3500 watts for either 60 cycle or 50 cycle andvoltage.:regulation is
within plus or mlnus3% of narneplate;r:atllig. The.larger generator,us~s
a 7-1/2 inch staci{o(laminations,rated Qutput is50pOwatts for60cy-
cle 01"42.50 watts for 50 cycleandvoltageregulaHoniswithinpluSor
minus 5% of nameplate rating. . ..
The directservice direct CI,l.rrent generator isa 4 pole,. compOuI1dw()und,
commlltatingpole type
rated at 5000 watts, 115 volts. ... .
The.magnet servICe generator
is a4poletypeespectallydes'igKed for
such service. .'I'M generator· is rated at5000watt.s~Voltage lsadjust-
ableirom230to 250j
rolts1;>ynieans of the
required rheostat. '.
C.ONTROLS .'
Thenianual typePlants.h.avea:mariJ~1 choke on the carburetor and a stop
button
on theblowerliollstng.· . . .
·
Thepo!';abletype plantsha'V~.receptacles.and aPHb:light ina~dition to'
. a manual chokeana.stopbuu6h> .... ..
The ·~9.rembt.e tYf>epl~ts.havea~;ele.ctri;.c.~ eonthe .carbUret()r.,a
start~stop switc.h,···acharge·~!llm~t.~~Lari.q,~r(. 0.£or m.anual()relec~
tricstart 10catedonthecontrOlbQx.nl()l1nt~()¥~t'·(the· gene r~tor •.. ; .. 'r'he' .. '
contr()Is
aredesignedS:o ,thatauxiliar.Y'alltQ~:itiQ;;Q~_linetra:nsf~r~qn:-;
tro1.eqllipri'lentinay be: cOnnected. . ..... ". .' '<.\ .

6
DESCRIPTION
SPECIAL ACCESSORIES
The following specIal accessories are not standard equipment but are 3.-
vailable at extra cost from your dealer. When ordering any of the fol- .
. lowing
special accessories, always be sure to give the Modetand Serial
numbers· of the plant on the order.
GASEOUS FUEL CONVERSION ~TS. - These kits contain parts and in-
structions which permit the use
of Butane, Propane or natural gas as well as gasoline;
AUTOMATIC CONTROLS (ACRen:lote
Start Plants Only) .... A separate
control is .
available for either 50 or 60 cyclea. c. units that willautomaUcally
start and stop the plantas the load requires.
LINE TRANSFER CONTROLS (AG Remote Start Plants Only).- Line
transfer
controlsare available for use with either 500r 60 cycle units instandby
service. When regular power service fails, the line transfer control
aritomaticallystarts>the standby plant and takes over the load .. Theplant
stops automatically when regular service is restored. . ..
. .
UNDERGROUND FUEL TANKS AND LINES. - 55 gallon and 110 gallon
fuel
tanks and 5/16 inch
and 3/8 inch copper fueLlinesin either 25 or 50 foot length are avail-
able for installing the fuel tank underground.
REMOTESTART-STOPSWlTCHES .. - Additiollairemote start-stop
switches are available from your
dealer.
a-CONDUCTOR CABLE. ~ This #18-wire3-conductor cable is designed
for remote start-stop station installation and
.
is adequate Size for switches within 250 feet wire distance.
TW()..;WHEEL DOLLY. - The dolly makes the plant portable' by one man.
. The dolly is designed to assemble to the tubu.-
larcarryingframeas furnished on the portable type plant. Thedolly
has semi-pneumatic tires and adjustable folding handles with hand grips •
.. FUELRESERVOlR(DAY)TANl{. - This tank with fittings can be mounted
. on
the plant and serves to assure·
. quick starting of standby plants by replenishing by gravity feed, fuel lost
from the carburetor during shut-down periods. .
COLD
WEATHER SHUTTER~ -. FitsVacu-flo plants .. Lirnits air}Iow.

.feet of inlet area and a SiIllHa¥\1~mount for an outlet if the plant is the
pressure-cooled type. ':prElY~~~i.recirculanOnolll~,!tted air wherever .' .. '.
possible_ The vactium-c,~oled·type;p.1ant iSl1l()r¢easily.adapted to small'
enclosure installation, since h,eatedair call [)e(;i~C.ted outside. .... .
'.- . - " ":- .""; "':'- ' - - " " .<: ',,:,' ',-,. ,,\,:'-', :- ." ' "; .
. .
.EXHAUST GASES FROM INTERNALCOMBPS,;£, .. ,
'ARE,DEAD:LYPOISONQUS. ·.EXCES~lVE~INHA\
. CA "USE SERIOVS' ILLWESSORI):EATH •.•... NEV' '.
. '. 'rHEPLANTINSIDE A'BUILDINGOR. OTHER'
.SPACEWITH()UTPIP:Ii.!OJiLLEbCHAus'tG1\S . ..'
THE ENCLOS,URE. . . " ," '. . '.. . ,', ... '. ,', .',
LOCATION. ,-TM pref¢r~bleamb,ien,tait,Jemp~~aturefOrbestengine.' ,.' ..•
. ,", .performancE! isweUab9yefree~Wg;.and theprefe;rable" '
ambie~t air temperature for. mO$tefficteJ:'lt'ge,neratbr operaUonls ,well
.. under lOOoF • and shouldnotexceedUOoF.if conditions permit con~
·trollingtl}'etemperature.' . . . .
Iftllegeneratingplant' ist9,J~¢installed, in ,~ permanent location,'choose"
a site'{ormQuntin(!t
tile plant that will be more or less centrally located .
in;relati'on,tothe
elec~rical load. 'Plan toaYoici runningwiringwhich
carries a heavy e,lectljical,load foralongdisb.U!ce .. The greater Ule
distance,lhe, larger t~ewirell1:ust be> The selected site should be in a.
clean; dry,. wellyelltJlated location,preferably heated in extremely cold
,weather.' A dustyor'dan:ip'locationwilln~G¢!ilsitate more frequent ser-
vicing,. ....... ,., ".' .", ...... . .. ,., ...... ,
MOBILE
INSTALL:A1;'Io.N~,":,'rhegeneratingplantmust be securelybol-
.. .'..... ' .. ' .' ..ted to thefloor or other r igidmember if it
,lstobe'mQuntedin,~yehiCle. 'D,ql1otJleglect the piping'of the poisonous
exha~stgases to ,t~~,911tQQO~s.:KeepJlle,eXh~1l(3tPipWg Seyer;ll .. inches
.away
ironj inf}am,mablemater.ialsMdsupporttlJ.e piping securely so .
tnatU willrem~inp~~l11l\tneiltlYin,pl~ce. .... . . .
. ". ..........
..... . .C.i'\lJTJON,>: ... ' ........ . . .' ..• .... ..
'. Do. not run theveh,icle.J~s;iq.,~aclos.edbuUdingand operate the gellerating
'set .. ' J:,1e suretl1;:lt lhe eXhau.~t.line~, are ,carefully.extended to theou.tside •.•.
ofJhebuilding. . .' . . . ..
·IftbevehiCleisa.~10sedon:~;pr2pet\~~litilatiOnmust be proVid~d .. Sev-
'eral smallopening13iWill:sufnC~;})ut therem.ustbe at least 3 .. 1!2 square>

-
:z.'IG. 1 "7 TYPICAL INSTALLATioN

. .
.
" _' , . __ .
9
INSTA LLATION
Plahtsl110unted in vehiclesmdstalso.begrounded .. Review the applicable
sections in t he National Electrical Code and local regulations' to,.deter;..
mine
the steps to be takenforgrotindi.n.g:the set, . .
" " ',~- '- , ' -.'
. . ~' .
.YENTILATION(PIiESSUREJC GOL ED,P LA NT) .-Hrovidf;,\,,<lcmpleventi-.
..... . .... . la:tion"r:I'P:7re must
beacol1/>t;int supplyoffr:esh air ,forcooHngthe plant.." In:.~JJrgeroom,
. or outo! doors,C()olingwiU be no. problem. Thereshou~d"pe,atleast
two openings, preferaplyat.opposite ends of theel1cl()s~:re, to provide
ampleventHation.'fhe openings: should be. adj\ll:lta}bJesothat the vol~me
of air can pecontrolledfor.cold weather operation .. The area of the air
inlet snould be at least 3-1/2 square feet. The area of the air outlet
should be
at leasta~.,largeas that of .the air inlet..'
FIG. 2-VENTl1.A'!'ION(PRESSURE-COOLED PLANT)
The installation of additional openings maybe.necessary under some
conditions to prevent recirculatioriof heated air •. If this becomes. nec-
essary •. airoutJets in the roof .orin the wall near the ceiling win help.
,The
size of the air inlet .canbe)nc:re~.sed or an additional air inlet in-
stalled nearby.
If the unit is tobeoperated wnereflying Unt, chaffor dust is likely to
be carr iEidto thetntake air:sireal1l' airJnlet and outlet openings should
be mad
ewithref erencetoJ.heprevaHing' 'Wind ... In. such installations the.
air inlet shouldbescreenedan,dthe, screen kept cleall to. prevent r"""'.T"II'_
tiortof.airflow.
l?E.RMAN~.NTMOVNTiNG:BASE, .··.·~.Mo4Pt,the plantonastibsta,ntia,lly
.
...... .' .'. ....•. '.. '.' ,JevelQg~Gr~teo:rtinlberoi stt,uc-
tural steel. base>pref~r~plyat,~e~stl? ,.~nc4~f3high. ··.Locat,e.the. b~s~
asJo.·px:ovipe. at Jeast· 24jllcl1e~:spaCf:)'Ollll,nsides., for conyenieri'ceIn ...
,-,. ,.',', - . _." -i,,: ',',_; , ._' -. _",' ,," .

POS1TlON MOUN:Tf!llG BOLTS IN
CLEATS PLACED ACROSS FORM ..i:;;liiiliJ'il!""'"
fO INST A LLATION
~
..
'- ' ,'.
,~,,;
BOLT
....
~" ",
FIG. 3 -MOUNTINGBASE
support 8 inches apart~Front cent~r to rear center mounting distance
is 15....;1/8 inches. Be .sure the mounting base is smooth and level so as
toav,oidexcessive strain on any one of the four mountingfeet.
. .
MOUNTING ClTSmONS. -:1nstaU the mounting cushions .asillustrated.
. The metal spacer and the fIat w.asher at each
.end,
p:r~vents excessive.compl'€ssion of the rubber cushions~
\ -..
EXHAUST. -Pipe the exhaust gases outside the enclosure, using 1 inch
pipe
or larger .. Increase the pipe size used, one siz.e for
each additional 10 feet .in distance. Avoid sharp bends if possible by
uSingbentpipe.or sweeping elbow. where necessary. Connect ihefIex-
ible exhaust tube to thepJant exhaljstoutlet, . Ii sufficienflengih of pipe
to conduct the
ga..s{:!s outside the enClosure, and the mufflertothepipe

11
i 1 ije T.,6 L L A T I 0 N '.
Qutstdethe enclosure. Insulate or shield the exhaust pipe if it comes
close to or passes through a !1ammablewall or other material. If the
exhaust line must be inclined upward from the plant,
construct a conden-
sation trap of pipe fittings and insta,ll it at the point wherE;j the upward
pitch begins. Drain the
trap periodically. . .. '
If-EXHAUST j"lE--MUST :"
p~ PlTCHEe lj,".iWAr2D
, CONS7RU<:;T A ,RAP
, OF PIPE FITTINGS
AT POINT OF R?!Sfr
EXHe,l)$T L.IN!': PAS.!iING CONOtNsATION
THROUGH WA\-L TRAP
OR PARTITiON
FIG. 5- EXHAUST INSTALLAl'ION
If exhaust noise from the standardrpuffler will be objectionable,' an un-
dergrounci muffler ma,y be constructed. Do not \lSe an underground muf-
fler if there is any danger of its filling with water a,tany time. Usea
heavy metal drum or.pail and weld s~itable fittings for inlet and outlet
pipes.
Do not use a. container which contained. any flammable liquid with-
o\ltfirst making sure that all explosive vapors have been driven out. Re-
move the bottom,of the drum, or drill holes in the bottom, to allow con-'
deU/3ation from the exhaust gases to drain away. The muffler exhaust
pipe
Sho'lj.ld extend a,t least 24 inches aboveground, with a gooseneck fit-
ting on the,end to prevent entry of rain or snow. '
OIL DFtAINEXTENSION. -The addiUon
of an oil drain e:xl:enSionpipe
. andco\,lpl!ngwill provide for cleanUness and
convenience in draining oil
from the oil base. Before fHUng the oil base
wjthoil as. <:lj.reeted under Preparation, remove the dra,in plug from the
oil base and install a 3/8 inch pipe nipple and coupling in it/3 place. In-
atall the drain plug in thecoupllng. Whendl'aining the oil, remove only
the p\ug. .
FlO. (i .. OILDRAIN lllXTENSION

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