Onan LK Series Instruction Manual

OPERATORS MANUAL
AND PARTSCATALOG
FOR
ELECTRIC GENERATING SETS
LK
SERIES
13
n
930-0301
5AK74
Printed InU.S.A.

INTRODUCTION
THIS OPERATOR'S MANUALCONTAINSINFORMATION
PERTAINING TOTHEINSTALLATION,OPERATION,AND
MAINTENANCEOFYOURONANUNIT.A PARTS CATALOG
IS ALSO INCLUDEDINTHISMANUAL.
WE SUGGEST THATTHISMANUALANDTHEWIRING
DIAGRAMWHICHACCOMPANIES EVERY ONAN UNIT BE
RETAINED AND REFERRED TOWHENMAKINGEQUIP-
MENT ADJUSTMENTS OR ORDERING PARTS. ADDITIONAL
COPIES ARE AVAILABLE FORA NOMINAL CHARGE FROM
YOUR ONANDISTRIBUTOR.
WHENORDERING PARTS REMEMBERTOINCLUDETHE
ONANMODEL,SPECIFICATION LETTER, AND SERIAL
NUMBER LOCATED ONTHENAMEPLATEOFYOURONAN
UNIT.THISIS ESSENTIAL TO ENSURE THE CORRECT PART
IS SHIPPEDTOYOU.
FOR MAJOR REPAIR SERVICE, CONTACTYOURONAN
AUTHORIZED DISTRIBUTOR.
WARNING
ONAN RECOMMENDS THAT ALL SERVICE INCLUDING
INSTALLATION OF REPLACEMENT PARTS BE DONE BY
QUALIFIED ELECTRICAL AND/OR MECHANICAL SER-
VICEMEN. FROM THESTANDPOINTOF POSSIBLE INJURY
AND/OR EQUIPMENT DAMAGE IT IS IMPERA TIVE THA T
THE SERVICEMAN IS QUALIFIED.

TABLE OF CONTENTS
TitlePage
General Information 2
Specifications 3
Installations 4
Operation9
Adjustments 12
General Maintenance17
Periodic Service Guide.18
Special Utility Section 19
TroubleshootingGuide. 21
Parts Catalog. 22
PERFORMANCE
CERTIFIED
Wecertifythatwhenproperlyinstalledandoperated
thisOnanelectricplantwilldeliverthefullpowerandthe
voltageandfrequencyregulationpromisedbyitsnameplate
andpublishedspecifications.Thisplanthasundergoneseveral
hoursofrunning-inandtestingunderrealisticloadconditions,
inaccordancewithprocedurescertifiedbyanindependent
testinglaboratory.
ONAN
140073RDAVENUEN.E.• MINNEAPOLIS,MINNESOTA55432
IMPORTANT! RETURN WARRANTY CARD ATTACHED TO UNIT.

GENERAL INFORMATION
Instructionsin-thismanualmayrefertoa specific^.-'-:
modelofgeneratingset.Identifythemodel6yV-i*VN,
referringtotheMODELandSPECIFICATIONNO.as*
shownonthesetnameplate.Electrical
characteristicsareshownonthelowerportionofthe
setnameplate.'
HowtointerpretMODELandSPECNO.
2.5LK- 3R/ 1"KU
45
1. Indicateskilowattrating.
2. Seriesidentification.
3.Voltagecodeofgenerator.
3- indicates120/240volt
R- indicatesremoteelectricstarting
4. Factorycodefordesignatingoptionalequipment,
ifany.
5.Specificationletterwhichadvanceswhenthe
factorymakesproductionmodifications.
WARNING0nan uses thissymbol
1throughoutthe
text towarnof
possible injuryordeath.
This symbolis used towarnof
possible equipmentdamage.

SPECIFICATIONS
M= manualstart
R-= remote start(electriccrank)
MODEL SERIES
2.5LK
1.7LK
MR
Nominaldimensionofplant(inches)
Height2121
Widthi .•18-5/16.. 18-5/16
Length27-1/425
Numbercylinders1 1
Displacement(cubicinch)24.924.9
Cylinderbore3-1/43-1/4.
Pistonstroke3 3
RPM(60hertz)18001800
RPM(50hertz)15001500
Compressionratio: 5.55.5
Ignition(type)
•FlywheelmagnetoYes;No
Batteryvoltage(ACplant)None. 12Volt•
Batterysize(ACplant):
-SAEgroupIH, two6 Volt
inseries
Amp/hr.SAErating—20hr.(nominal)' • 105
Startingbypullrope(recoil)onlyYes'No
StartingbyexcitercrankingNoYes.
Batterychargerate(amperes)...8 Maximum
Ventilationrequired(cfm@ 1800rpm)
Engine300300
Generator:..6060
Combustion2020
Outputrating(powerfactor)...:1.01.0
Rating(outputinwatts)
60hertz(generalutility)25002500..
50hertz(generalutility).•;.'. . 17001700
ACvoltageregulationin±%6 6
ACfrequencyregulationin% 5 5
Revolvingarmaturegenerator, YesYes
120/240voltsinglephasemodelreconnectibleNoNo
TUNE-UP SPECIFICATIONS
SparkPlugGap
Gasoline
Gas
Ignitionbreakerpointgap(atfullseparation)
Ignitiontiming
Tappetadjustment
Intake
Exhaust
Carburetorfloatadjustment
Cylinderheadtorque
.025"
.018"
.020"
190BTC
.007"to.009"
.015"to.017"
11/64"
27to29 foot lbs.

INSTALLATION
SINGLETHIMBLEDIAMETER12"
LARGERORDOUBLE
VENTILATEDTHIMBLE
DIAMETER6 " LARGER
THANEXHAUSTLINE
HOLESINEND
INNERSLEEVE
EXHAUST LINE PASSING THROUGH
|l WALL ORPARTITION
IFEXHAUSTLINEMUSTBEPITCHED
UPWARDCONSTRUCTA TRAPOFPIPE
FITTINGSATPOINTOFRISE
I
AVOIDSHARPBENDS
^DRAINCONDENSATIONTRAP
PERIODICALLY
NUT
LOCKWASHER
FLATWASHER
MOUNTINGRUBBER
SET
MOUNTINGBASE
SPACERl?
MOUNTINGRUBBER
FLATWASHER
BOLT
.LARGEFLAT
WASHER(OPTIONAL)
MAINLINESRUNTHROUGH
FUSEDSWITCHBOX
BESUREBASEISSMOOTH
ANDLEVELONTOP.
2-7/8'
LOCATEBASETOALLOWATLEAST
24"SPACEONALLSIDES.
FIGURE1.TYPICALINSTALLATION

COOLING AIR
Pressurecooledmodelsrequireanairinletopening
andanairoutletof3 squarefeet.Positiontheoutlet
openingaboveandtotherearoftheset,theinlet
openingjustoppositetheblowerhousing.
VACU-FLO COOLED
AirflowthroughVacu-Flounitsisreversed.Provide
anairinletofatleast41squareinchesfor3000or3600
rpmunits.Ducttheheatedairoutside.Anoptional
automaticairshutterandairductisavailableforuse
incoldweather.
WARNINGIUtilizingexhaustmanifoldheattowarma
^roomorcompartmentoccupiedbypeopleis
notrecommendedduetopossibleleakingofexhaustgases.
EXHAUST
2^ARNiNGiJ|Exhaustgasesaredeadly,poisonous!
Ventexhaustgasesoutside.Useflexibletubing
betweentheset'sexhaustoutletandrigidpiping.
Shieldthelineifitpassesthrougha combustiblewall
orpartition.Ifturnsarenecessary,useonepipesize
largerforeachtenfeetinlength.Positiontheexhaust
outletawayfromtheplantairintake.
LOCATION
Providea protectedlocationthatisdry,dust-free,and
preferablyheatedincoldweather.Forservice
convenience,provideatleast24inchclearance
aroundplant.
OIL DRAIN
Forconvenienceindrainingoil,removetheoildrain
plugandinstallanextensionpipeandcoupling.
GENERAL
Importantinstallationpointsare:sufficientcooling,
exhaustgasdischarge,-electricalandfuelconnec-
tions, locationandmounting.
Eachinstallationmustbeconsideredindividually—
usetheseinstructionsasa generalguide.Always
checklocalbuildingcodes,fireordinances,etc.,for
compliance.Providea locationthatisprotectedfrom
theweatherandisdry,dust free, andpreferablywarm
incoldweather.Theairdischargesideofsetrequires
onlya 3-inchclearancefromwalltopermitsettorock
onitsmountsbutatleast24-inchclearanceis
requiredaroundallothersidesforserviceaccessibili-
ty.
MOUNTING
Apermanentinstallationneedsa sturdy,level,moun-
tingbaseofconcrete,heavywoodorstructuralsteel
atleast12incheshightoaidoilchangingand
operating.
Carefullyassemblethemountingcushions,washers
andspacerbushing(Figure1).Thespacerbushing
preventscompressionofthesnubber(upperrubber
cushion). Spacethe5/16inchmountingboltsas
shown.
VENTILATION AND COOLING
Aircirculationisneededtodissipateheatproduced
bytheengineandgeneratorinnormaloperation.
Outdoorinstallationscanrelyonnaturalcirculation,
butmobile,indoororhousedinstallationsneedproper
sizeandpositionedventsforrequiredairflow.See
Specificationsfortheairrequirementsat1800rpm.
Ventsizesdependonvariableconditions:(1)sizeof
enclosure,(2)ambienttemperature,(3)electrical
load, (4)runningtime,(5)restrictionsimposedby
screens,louvers,shutters,orfilters,and(6)prevailing
winddirection.
Rememberthata requiredvolumeofairmustreachtheunit,absorb
theheat,andbedischargedawayfromtheinstallation.
Pressurecooledsetsneedaninletventwithan
unrestrictedopeningofatleast3 squarefeetfor
variables.Fordischargedair,installseparateduct
fromtheengine.
Auxiliaryfanscanbeusedtoincreaseairflowtounits
installedinsmall,poorlyventilatedrooms.Fansize
andlocationshouldbesuchthattheairinlet
temperaturetotheenginedoesnotexceed120oF
whenrunningatfullrated load.
GASOLINE TANK
Ifa separatefueltankisused,installthetanksothe
bottomislessthanfourfeetbelowthefuelpump.The
tanktopmustbebelowfuelpumpleveltoprevent
siphoning. Installa shut-offvalveatthetank.When
thefueltankissharedwithanotherengine,usea
separatefuellineforeachtoavoidstarvingtheset.
Iffuelliftmustexceedfourfeet,installanauxiliary
electricfuelpumpatthefuelsupply.Wireitinparallel
withtheignitioncoil(aheadofresistor).Ifanauxiliary
reservoirfueltankisusedfora standbyinstallation,
notethatfuellineconnectionsmustbechanged
(Figure2)-

VENTCAP
(Installatleast3 feetabove
thereservoirtank)
5/16"VENTLINETOEXTERIOR
OFBUILDING
RESERVOIRTANK
(Mountinconvenient)
place)
5/16"LINEFROM
FUELPUMP
5/16"LINETO
CARBURETOR
3/8"RETURNLINETO
RESERVOIRTANK
FIGURE2.AUXILIARYFUELTANK
tJ
FIGURE3.FUELCONNECTIONS(GASONLY). -
FUEL CONNECTION
Forgasolinesets,connectthefuellinetothefuel
pumpinlet.Pumpthreadis 1/8-27 NPTF.
Connectthesettothefuelsourcewitha flexiblelinetoavoidline
failureduetovibration.
Forgaseoussets(seeFigure3)checkwiththelocal
fuelsupplierforgasregulationsandlinepressure.
Providea manualgasshutoffvalve.A filterintheline
maybenecessary.Electricsolenoidshutoffvalvesin
thesupplylineareusuallyrequiredforindoor
automaticorremotestartinginstallations.Connect
solenoidwirestobatteryignitioncircuit(Figure3)to
openvalveduringrunning.Installa demandtypegas
regulatoraccordingtoinstructionsandpositionit
nearthesettoaidstarting(regulatorlinepressure
mustbewithin2 to8 ounces).
Alwaysuseflexibletubingbetweenengineandthegasdemand
regulator.
Gas-Gasolinesetsprovidea manualshut-offvalvein
bothfuelsupplylines.
6VOLT
B ATTERI RS
GROUNDING
SCREW
BATTERY
NEGATIVE(-)
CABLE
5/16EITWASHER—^
5/16
FLATWASHER—»
GENERATOR
FRAME
BATTERY
NEGATIVECABLE
•>t-
5/16-18xy2HHCSDETAILA
FIGURE4.BATTERYCONNECTIONS
BATTERY CONNECTION
RefertothewiringdiagramandFigure4.
Providetwo6-voltbatteriesconnectedinseries(one
batterynegativetootherbattery'spositive)fora 12-
voltsource.SeeSpecificationsforminimumbattery
amperes.
Q^yj|Q|IjjConnectbatterypositive(+)to
^^x^^o^x^Asolenoid(locatedinthecontrolt thestart box). Con-
nectthebatterynegative(-)toa goodgroundonthegenerator
frame. Entercontrolboxreartoinstallbatterycable.
Donotdisconnectstartingbatterieswhileset
isrunning.Theresultingover-voltagecondi-
tionwilldamagetheelectricchokeandothercontrolcomponents.

FRONT
REMOTECONTROL,
TERMINALBLOCK
ATPLANT
MOMENTARYCONTACT
SWITCH
LINE LOAD
SEN.
I I
WIRE
SIZE DISTANCE
#18 to250ft.
n16 to400ft.
#14 to630ft.
FIGURE5. REMOTECONTROL
REMOTE START-STOP SWITCH(Optional)
Forremotecontrolstartingandstopping,usethree
wirestoconnecttheremoteswitch(singlepole-
doublethrow,momentarycontact,centerofftype)to
theterminalblockmarkedB+,1,2,3,intheset's
controlboxusingwiresizeslistedinFigure5.
Iftheinstallationisforstandbyservice,a
doublethrowtransferswitchmustalwaysbe
used. Connectthisswitch(eitherautomaticormanual)sothatitis
impossibleforcommercialpowerandgeneratorcurrenttobe
connectedtotheloadatthesametime.Instructionsforconnecting
anautomaticloadtransfercontrolareincludedwithsuchequip-
ment.
WARNING\ Personnelconnectingthegeneratorandany
HI MMI miii11suchauxiliaryequipmentmustbefully
qualifiedandunderstandwiringdiagrams,circuits,etc.
NOTE: SHOWNWITHLINECONNECTEDTOLOAD.
FIGURE6.DOUBLE-THROWTRANSFERSWITCH
LOAD WIRECONNECTIONS
Setnameplateshowstheelectricaloutputratingof
thesetinwatts,volts,andhertz.Thesetwiring
diagramshowstheelectricalcircuitsandconnec-
tionsnecessaryfortheavailableoutputvoltage.See
Figure7.
Meetallapplicableelectricalcoderequirements.
Workshouldbedonebya qualifiedservicemanor
electricianbecausetheinstallationwillbeinspected
andapproved.
Thesetcontrolboxhasknockoutsectionstoaccom-
modateloadwires.Useflexibleconduitandstranded
loadwiresnearthesettoabsorbvibration.Use
sufficientlylargeinsulatedwires.Stripinsulation
fromwireendsasnecessaryforcleanconnections.
Connecteachloadwiretothepropergenerator
outputleadinsidethesetcontrolbox.Insulatebare
endsofungroundedwires.Usea bolt(throughthe
controlbox)toconnectthegrounded(^r)generator
leadandloadwire.Installa fusedmainswitch(or
circuitbreaker)betweenthegeneratingsetand load.
UNGROUNDED LOAD WIRE
NAMEPLATE
VOLTAGE
i
(BLACK)
GROUNDED LOAD WIRE
(WHITE)
-O NMO co
i-o
<<
OC LAJ
"Z0
N\2 O
240V.
T
UNGROUNDED LOAD WIRE (BLACK)
GROUNDED LOAD WIRE(WHITE)
120V.
'f-
12°V"UNGROUNDED
LOAD WIRE (BLACK)
FIGURE7.LOADWIRECONNECTIONS
--^OM2

ACPortableModels:Thesesetshaveoutletrecep-
taclesofthegroundingtypewhichserveforeasy
connectionanddisconnectionofthe load. Matching
electricalplugsorcapsmustbeprovidedontheload
wires.
OutputLeadMarkingsGeneratorleadsaremarked
Ml, M2,etc.Theseidentifyingmarksalsoappearon
thewiringdiagram.
Switchboard:Whenanoptionalwallmounted
switchboardcontainingammelers,voltmeters,circuit
breakers,isused,theseloadwireconnectionsapply:
Connecttotheunusedterminalofeachammeter,one
ungrounded(hot)generator lead. Connecttothe
groundstudintheswitchboard,generatorleadsand
loadwireswhicharetobegrounded— ifany.
Connecttotheunusedterminalofeachcircuit
breaker,oneungrounded(hot)loadwire.Onmodels
whichgeneratemorethanonevoltage,thevoltmeter
readsthehighervoltageshownonthenameplate.
Thelowervoltageiscorrectwhenthehighervoltage
iscorrect.

OPERATION
INITIAL START
Check the engine to makesure ithas beenfilledwith
oil and fuel. If enginefails to start at firstattempt,-
inhibitor oil used atthe factory may havefouled the
sparkplugs — remove,clean in asuitablesolvent.dry
thoroughly and install.Heavyexhaustsmoke.when
theengine is firststarted is normal andis caused by.
theinhibitor oil.
Crankcase Oil:Usea goodqualityheavy-duty
detergent oil thatmeets the API(AmericanPetroleum
Institute)servicedesignations MS, MS/DG,MS/DM,
SE, or SE/CC. Oil should be labeledashavingpassed
the MS SequenceTests andthe MIL-L-2104BTests.
Recommended SAEoil numbers for expected am-
bienttemperatures areas follows:
MANUAL STARTING
Manual or PortableModels:Adjust the manual car-
buretorchoke as necessary forthe temperature
conditions.Pull the startropewith a fast,steadypull
tocrank the engine. Donot jerk. Astheset warms up-,
.adjust the chokegradually toits fullyopenposition.
RemoteControl, AC Models: Ifthe batterycharge
conditionis toolowto crank the engine,thesetcan be
startedmanually. Setthe control box switch(located
inside the control box)toits manualstariposition.Pull
theropewith a fast,steadypull to crank the engine.
Do not jerk.Afterstarting,return the control box
switch tothe electricstartposition to avoiddischarg-
ing the battery.
TEMPERATURE
Above 32°F
0oF to 32°F
.Below 0°F
GRADE
SAE 30
SAE10W-40,5W-30
SAE5W-30
STOPPING
Pushstart-stopswitch to stopposition.Releaseswitch
when set stops. If stopcircuitfails,closefuelvalve.'
Do notmix brands nor grades.-Refer to Maintenance
Section for recommended oil changes and complete
lubricating oil recommendations.
RecommendedFuel: Use clean,fresh,regulargrade,
automotivegasoline. Donotuse highlyleaded
premiumtypes. Fornew engines,mostsatisfactory
results canbe obtained by usingnonleadedgasoline.
Forolderenginesthathavepreviouslyusedleaded
gasoline,headsmust be taken offandall lead
depositsremovedfromenginebeforeswitching to
nonleadedgasoline.
rQ^yyiQ^yj^ If leaddeposits arenot removedfromengine
t^-*^^^-^^ beforeswitchingfromleaded to unleaded
gasoline,pre-ignitioncouldoccurcausingseveredamage tothe
engine.
WARNINP \
Never ,i",he,ank when ,he
engine is running.
JJl^JiiiiiiyLeavesometankspace for fuelexpansion.
APPLYING LOAD
Ifpractical,allow setto warm up beforeconnecting a
heavy load. Continuousgeneratoroverloading may
causehighoperatingtemperaturesthat can damage
thewindings.Keep the loadwithinnameplaterating.
BATTERY CHARGING
Thebatterychargerate is controlled bya 2-step
voltageregulator andisnot adjustable.
INFREQUENT SERVICE
Iftheset is usedinfrequently (asin standbyservice for
commercialpower)extendedshut-downperiods can
result in difficultstarting. Runthesetat least 30
minuteseveryweek to eliminatehardstarting.
ELECTRIC STARTING
RemoteControl, AC Models:Push the start-stop
switch toits startposition.Release the switchassoon
as theset starts(Figure 8).

FIGURE8.STARTINGANDSTOPPINGCYCLE
GAS-GASOLINE CONVERSION
Engineshavinga combinationgas-gasolinecar-
buretorcanbeswitchedtogasolineoperationbythe
followingprocedure:
1. Closethemanualfuelshut-offvalveinsupplyline
(themainfueladjustmentvalveisnotdesignedto
useasa shut-offvalve)forgaseous fuel. Setwill
notoperatesmoothlywithbothfuelsupplylines
turnedonatthesametime.
2. Openthegasolinefuelshut-offvalve.
3. Set the spark plug gap as given in the Specification
Section.
4. Seethatthechokeisfreeandworkseasily.Be
suretoreleasechokelockonsetswithelectric
choke.
5.Starttheengineinthemannerdescribed.Ifthe
enginerunsunevenlyunderhalforfull load, due
tofaultycarburetoradjustment,themainjet
needsadjusting.
Tochangebacktogaseous fuel, reversetheabove
procedureandresetthesparkpluggapasgiveninthe
SpecificationSection. Useallgasolinefromthecar-
buretortoavoidstale fuel. Ifengineisrunwithoneof
thefuelsupplylinesdisconnected,plugotherinletto
preventdrawingairanddirt.
10

BREAK-IN PROCEDURE
Theunitshouldberuninthefollowingsequence
usingMS/DG,DM,SEorSE/CCoil(seeoilre-
quirementsforcorrectviscosity).
1. Onehalfhourathalf load.
2. Onehalfhouratthreequarter load.
3.Full load.
Thismethodofloadapplicationspeedspistonring
seating. Continuousrunningathalf(light)loadforthe
firstfewhundredhoursusuallyresultsinpoorpiston
ringseating,causinghigherthannormaloil con-
sumptionandblowby.
DUST ANDDIRT
1. Keepsetclean.Keepcoolingsurfacesclean.
2. Serviceaircleanerasfrequentlyasnecessary.
3.Changecrankcaseoilevery50operatinghoursor
sooner.
4. Keepoilandgasolineindust-tightcontainers.
5.Keepgovernorlinkageclean.
6.Cleangeneratorbrushes,sliprings,andcom--
mutator— donotremovenormal(darkbrown)
film. Donotpolish.
EXTENDED OUT-OF-SERVICE PROTEC-
TION — GASOLINE ENGINES
Generatorsetsremovedfromserviceforextended
periodsoftime(over30days)shouldbeprotected
fromrustandcorrosion.Onanrecommendsthe
followingprotectiveprocedure:
1. Runsetuntilthoroughlywarm;generatorunder
atleast50percent load. Stopenginebyshutting
offfuelsupplytoallowenginetodrainfuellines
andcarburetor.
2.
'->rfllB[I^Hrvh'lestj"warm.Refillandattacha
tagindicatingviscosityofoilused.
3.Removesparkplugs.Pour 1-ounce ofrust
inhibitingoil(orSAE#10oil)intoeachcylinder.
Crankengineoverseveraltimes.Installspark
plugs.
4. Serviceaircleaner.
5.Cleanthrottleandgovernorlinkage,protectby
wrappingwitha cleancloth.
6.Plugexhaustoutletstoprevententranceof
moisture,bugs,dirt,etc.
7.Cleanoffdirtanddryentireunit.Coatpartslikely
torustwitha lightfilmofoilorgrease.
8.Disconnectbatteryandfollowstandardbattery
storageprocedure.Applya filmofnon-
conductivegrease (e.g., vaseline)tobatterycable
terminallugs.
9.Fillfueltanktopreventcondensatecontamina-
tion.
10. Providea suitableprotectivecoverfortheentire
unit.
RETURNING UNIT TO SERVICE
1. Removecoverandallprotectivewrapping.
Removeplugfromexhaustoutlet.
2. Checktagonoilbaseandverifythatoilviscosity
isstillcorrectforexistingambienttemperature.
3.Cleanandcheckbattery.Measurespecificgravity
(1.260at25°C (77°F)andverifyleveltobeatsplit
ring. Ifspecificgravityislow,chargeuntilcorrect
valueisobtained.Iflevelislow,adddistilledwater
andchargeuntilspecificgravityiscorrect:DO
NOTOVERCHARGE.
WARNING| Dono,smokewhileservicingbatteries.
^HBBH^^H^^ Explosivegasesareemittedfrom
batteriesinoperation.Ignitionofthesegasescancause
severepersonalinjury.
4. Connectbatteries.
5.Verifythat' noloadsareconnectedtothe
generator.
6.Startengine.
Afterenginehasstarted,excessivebluesmokewillbe
exhaustedandtheenginewillrunroughuntiltherustinhibitor
oroilhasburnedaway.
7.Afterstart,applyloadtoatleast50percentof
ratedcapacity.
8.Checkallgaugestobereadingcorrectly.Unitis
readyforservice.
LOW TEMPERATURES
1. UsecorrectSAENo.oilfortemperature con-
ditions.Changeoilonlywhenengineiswarm.If
anunexpectedtemperaturedropcausesan
emergency,movetheplanttoa warmlocationor
applyheatedair(donotuseopenflame)external-
lyuntiloilflowsfreely.
2. Usefresh(notpremium)gasoline.Protectagainst
moisturecondensation.Below0oFadjustcar-
buretormainjetforslightlyricherfuelmixture.
3.Keepignitionsystemclean,properlyadjusted,
andbatteriesina wellchargedcondition.
4. Partiallyrestrictcoolairflowbutusecaretoavoid
overheating.
HIGH TEMPERATURES
1. Seethatnothingobstructsairflowto-and-from
theset.
2. Keepcoolingfinsclean.Airhousingshouldbe
properlyinstalledandundamaged.
3. Keep ignition timing properlyadjusted.
HIGH ALTITUDE
Foroperationataltitudesof2500feetabovesealevel,
closecarburetormainjetadjustmentslightlyto
maintainproperair-to-fuelratio(refertothe
AdjustmeniSeclion).Maximumpowerwillbereduced
approximately4 percentforeach1000feetabovesea
level, afterthefirst1000feet.

ADJUSTMENTS
ANTI-FLICKERCONDENSER
ANDCONNECTIONSUSEDPRIOR TO SPEC. C
POINTSSPRINGMUST JHESE SCREWSMUST BE
NOT RUB WIRELOOSENED TOADJUST
POSITION OF BREAKER
' BOX
MOVE BOX
UP
TORETARD
.SPjARK
—MOVE BOX
DOWN
TOADVANCE
SPARK
LEADSGROUNDING
AGAINST COVER WILL
CAUSEIGNITIONFAILURE
PRYLEADS OFF
WITHSCREW
DRIVER TORE-
MOVETHEM
ISANTI-FLICKERBREAKER
OINTS
IGNITIONBREAKER
POINTS
SETGAPAT0.020"
PLACE A DROP OF
LIGHT OILON BREAK-
ER ARM PIVOTSHAFT
EVERYTIMEPOINTS ;
ARECHANGED.
LOOSEN THE SCREWS
TOADJUSTPOSITION OF
BREAKF.R BOX
SETBREAKERPOINT-
GAPWIDTH AT 0.020"
A958TERMINAL
VACU-FLOCOOLEDMODELSHAVING
FLYWHEELWITHFOURTIMINGMARKS-
USETHISMARK.
(PAINTEDWHITE ON LATERMODELS)
TC TIMING
FLYWHEEL
FIGURE 9. IGNITIONSYSTEM
CHECK BREAKER POINTS
Replaceburnt or faultypoints.Measure gap with a
feelergauge andsetgapat .020-inches.
|Q^yy|Q(iJ7Alwaysmakesurethatfeelergauge is free
i^x-x^^^^-^^i from gre igrease and dirt.(Grease and dirtcauses
shorterlife of points.)
Ignitionbreakerpointsmust be correctlygapped for
topperformance(Figure 9)'. Crankengine to fully
openbreakerpoints (i/4 turnafter top center).
Loosen and movestationarycontact to correct the
gap at fullseparation.Tightencontactandcheck gap.
(Repeat if needed.)
Ignitionbreakerpointsshouldbreakcontactjust
when the19 degreetimingmarkalignswith the
flywheeltimingmark.Timing is corrected by properly
shifting the breakerpoint boxonits mounting and
using a timinglight.
^Q^yyjoj^l^ Modelshould be timedcorrectly sotop
performance is achieved.
12

THROTTLESTOPSCREW
IDLEADJUSTMENT
FIGURE10.CARBURETORADJUSTMENTS
CARBURETOR, GASOLINE
Thecarburetor(Figure10)hasa fuelmain(high
speed)adjustmentanda fuelidleadjustment.The
mainadjustmentaffectsoperationunderheavyload
conditions.Idleadjustmentaffectsoperationatlight
orno load. Undernormalcircumstances,factory
carburetoradjustmentsshouldnotbedisturbed.If
theadjustmentshavebeendisturbed,turnneedlesoff
theirseats, 1 to1-1/2turnstopermitstarting,thenre-
adjustthemforsmoothoperation.
>A
LOOSENTHESE
SCREWSAND
ROTATETHE
ENTIRECOVER
ASSEMBLY
Q^yyiQNj Forcingtheneedleagainstitsseatwill
damageit.Theneedledoesnotcompletely
shutofffuelwhentumedfullyin.
Beforefinaladjustment,allowenginetowarmup.
Makeidleadjustmentwithnoloadconnectedtothe
generator.Usea tachometer(orconnecta frequency
meter)togeneratoroutput.Slowlyturnidleadjust-
mentoutuntilenginespeed(orgeneratorfrequency)
dropsslightlybelownormal.Thenturnneedleinuntil
speed(orfrequency)returnstonormal.
Tosetfuelmainadjustment,applya fullelectrical
loadtothegenerator.Carefullyturnmainadjustment
screwinuntilenginespeed(oroutputfrequency)
dropsslightlybelownormal.Thenturnneedleout
untilspeed(orfrequency)returnstonormal.Proper
carburetoradjustmentcannotbeassuredunlessthe
governorisproperlyadjusted.
Setthrottlestopscrew(locateddncarburetorthrottle
lever)withnoloadconnectedandwhilerunningat
ratedspeed.Turnthescrewtogive 1/32-inch
clearancebetweenthescrewandpin(Figure10).
FIGURE11.CHOKEADJUSTMENT
13

ONAN CHOKE
Thischokeusesa heatingelementanda heat
sensitivebimetalspringtoopenthechokeplate.The
chokeplateclosesaccordingtoambient
temperature.
Ifadjustmentisrequired,usethefollowinginstruc-
tions. Chokebimetalspringmustbeatambient
temperature.Allowenginetocoolatleastonehour,
beforesetting.Adjustchokebyturningthechoke
body,whichengagesa linkconnectedtoa bimetal
chokespring.Removeflamearrestorandadapterto
exposethecarburetorthroat.Loosenthescrewwhich
securesthechoke"body,.Rotatechokebody
clockwisetoincreasechokeandcounterclockwiseto
decreasechokeaction(leanermixture).Atroom
temperature(70°F)thechokevalveshouldbealmost
wideopen.
Notethatthedirectionmarking"CHOKE" as
appearscastonthebodyofsomecarburetorsis
correctformanuallychokedsetsbutiswrongfor
electricchokedsetsduetothechokevalvearrange-
ment.Chokingpositionoftheweightleverisvertical,
ontheshaftofelectricallychokedsets.Choking
positionoftheleverishorizontalonmanuallychoked
sets.
GasFuel:Normalchokesettingisfullyclosedwith
enginenotrunning,turnadjustingscrew(Figure.1,t;)
inforlesschoking,outformorechoking.
14

MORESENSITIVITY- TURNSCREW
COUNTERCLOCKWISE.
LESSSENSITIVITY- TURNSCREW
CLOCKWISE. CARBURETOR
THROTTLEPLATE
CAMGEAR
GOVERNOR
SHAFT
GOVERNOR
SHAFTYOKE
GOVERNOR
CUP
SPEEDADJUSTING
NUT
THIS
DISTANCE
ETERMINES
SENSITIVITY
DECREASESPEED-TURN
NUTCOUNTERCLOCKWISE
INCREASESPEED-TURN
NUTCLOCKWISE
SENSITIVITY
ADJUSTING
SCREW
FIGURE12.GOVERNORADJUSTMENT
GOVERNOR
Ratedspeedandvoltageappearonthenameplate
(alsoseeSpecifications).Enginespeedequalsfre-
quencymultipliedby30,ona 4 polegenerator,thus •
1800rpmgives60hertzfrequency.Preferred-speed-
variesapproximately2 to3 hertzfromnoloadtofull
loadoperation.Besurethrottle,linkageandgovernor-
mechanismoperatesmoothly(Figure12).
Linkage:Theenginestartsatwideopen.throttle.The
lengthofthelinkageconnectingthegovernorarmof
thethrottlearmisadjustedbyrotatingtheballjoint.
Adjustlengthsothatwiththeenginestoppedand
tensiononthegovernorspring,the.stopscrewonthe
carburetorthrottleleveris 1/32-inch fromstoppin.
Thissettingallowsimmediatecontrolbythegovernor
afterstartingandsynchronizestravelofthegovernor
armandthethrottleshaft.
SpeedAdjustment:Withthewarmed-upsetoperating
atno load, adjustthetensionofthegovernorspring.
Turnthespeedadjustingnuttoobtaina voltageand
speedreadingwithinthelimitsshownonthe
nameplate.
.SensitivityAdjustment:Checkthevoltageandspeed,
firstwithnoloadconnectedandagainwitha full load.
Adjust , thesensitivitysoastogivetheclosest
regulation(leastspeedandvoltagedifference
betweennoloadandfullload)withoutcausinga
huntingcondition.
Toincreasesensitivity(closerregulation),movethe
governorspringtowardthegovernorshaft.Anadjust-
mentfortoomuchsensitivitywillcausealternate
increaseanddecreaseofenginespeed(hunting).
Todecreasesensitivity,movethegovernorspring
towardtheouterendofthegovernorarm.Toolittle
sensitivitywillresultintoomuchdifferenceinspeed
betweennoloadandfullloadconditions.
Anychangeinthesensitivityadjustmentusually
requiresa compensatingspeed(springtension)
adjustment.
15

GASHOSE
ADJUSTING
SCREW
%••GAS
SUPPLYLINE
'/„ • • PIPEPLUG©
FIGURE13.GASREGULATOR
GAS REGULATOR
Theregulatorwasfactoryadjustedtolock-offata
pressureoffourounces(7-inch-.water;C.olumn).Itwill
operatesatisfactoryatincomingpressuresbetween2
and4 ounces.Ifyourgassupplypressureiswithin
theselimits,noregulatoradjustmentisrequired.If
yourgassupplypressureisunder.2ounces,,.the
regulatorwillnotoperate.Ifyourgassupplypressure
isbetween4 and8 ounces,installanappliance
regulatorsetfor2 ouncesaheadoftheregulatoror
adjusttheregulatorasfollows:
CAUTION) A soapbubbleplacedovertheregulator
outletwillnotaccuratelytesttheregulator
lock-off.Thesoapbubblesresistancewhen
multipliedbythegreaterareaofthediaphragm,isenoughtoshut
offthisverysensitivedemandtyperegulator.A manometermustbe
usedtoshowcompleteregulatorshut-off.
GasRegulatorAdjustment(Figure13):
1. Usea manometerwhichreadsupto14-inchwater
column.
Oneouncepersquareinchequals 1.73-inch watercolumn.
Likewise1 inchwatercolumnequals0.58ouncespersquare
inch.
2. RemoveT/8inchpipeplug(C)andconnect
manometer.
3.Withgassupplyonandoutlethoseremoved,
alternatelycoveranduncovertheregulatoroutlet
withyourhand.Iftheregulatorshutsoff
completely,asdesired,themanometerwillholda
steadyreading.Ifthemanometerreadingdrops
slightlyeachtimeyouremoveyourhand,the
regulatorisleaking.
4. Whennecessary,adjustasfollows:Turnthe>.
adjustingscrew(G)inwardjustfarenoughsothat;
manometerreadingremainsconstantwhenyou;
repeatedlycoveranduncovertheregulatoroutlet.
withyourhand.
5.Operatetheenginetoensurequickstarting
results.
CARBURETOR, GASEOUS FUELS
Adjustmuchthesameasgasolinecarburetors,using
thegasfueladjustmentlocatedinthefuelinlet
(Figure10)toadjustwhenrunningongas.Gasonly
carburetorshavenoidleadjustmentbeginningSpec
E.
Theweightedcarburetorchoke(SpecA throughD)
shouldjustclose,butmustbefreetoopenwiththeair
streamduringoperation.Somechokesarefittedwith
anadjustingscrew— turninforlesschokingaction,
turnoutformorechokingaction.
16

GENERAL MAINTENANCE
PERFORM ALLMAINTENANCE DETAILS AS SPECIFIED INMAINTENANCE SCHEDULE
BREATHERVALVE
Removethehosewhichcarriesexpelledairfromthe
breathervalveatthevalvecompartmentcover,tothe
aircleaner.Loosenthevalvewithpliers.Occasionally
thevalvewillliftoutandremaininsidethehose.Wash
thevalve(alsotheelement)ina suitablesolvent.Dry
andreplace.Thevalvemustworkfreeandthehose
mustnotberestrictedtopreventexpelledairfromre-
enteringthecrankcase.Installpartsremoved.
,BREATHER
TUBE
BREATHERVALVE
(Keepitclean!)
VALVE
COMPARTMENT
COVER
BAFFLEPLATE
^SPARKPLUGGAP
0.025"GASOLINE
0.018"GASFUEL
ALWAYS
REPLACE
CAP
TIGHTLY
KEEPCRANKCASEOIL
yATTHISLEVEL
-NEVEROPERATE
ENGINEWITHOIL
BELOWTHISLEVEL
CRANKCASEOILLEVEL
AIR
CLEANER \ OILBATHTYPE
"Renewoilbefore
FillwithOil-"TnTdirtreachesshelf
tothislevel incup
"DRY"TYPE
Dipfilterelementina pan
.^\,of0"Drainandreplace
AIRCLEANERS ERVICE
NOTE: Washpolyurethanewrapperusedonsomesetsina
suitablesolvent.Dipinoilandsqueezeasdryaspossible.
GOVERNOR
LINKAGE
BALLJOINT
'CLEANJOINT
Donotlubricateplasticball
joints. Theyonlyrequire
cleaning.
FIGURE14.MAINTENANCEPROCEDURE
17

FUEL SEDIMENT
Emptycarburetorandfuelfilter(strainer)bowlsof
anyaccumulatedsediment.Cleanfilterscreen
thoroughly.Reassembleandcheckforleaks.
GASOLINE FUEL
Useregulargradeautomobilegasoline.Donotuse
highlyleadedpremiumtypes.Neverfillthetankwhen
theengineisrunning.Leavesometankspaceforfuel
expansion.
PERIODIC SERVICE GUIDE
Regularlyscheduledmaintenanceisthekeytoloweroperatingcostsandlongerservicelifefortheunit.The
followingschedulecanbeusedasa guide.However,actualoperatingconditionsunderwhicha unitisrun.should
bethedeterminingfactorinestablishinga maintenanceschedule.Whenoperatinginverydustyordirty
conditions,someoftheserviceperiodsmayhavetobereduced.Checktheconditionofthecrankcaseoil,the
filters, etc.frequentlyuntiltheproperservicetimeperiodscanbeestablished.
Foranyabnormalitiesinoperation,unusualnoisesfromengineoraccessories,lossofpower,overheating,etc.,
contactyournearestdealer.
SERVICETHESE ITEMS
AFTEREACHCYCLE OF OPERATING HOURS
SERVICETHESE ITEMS 8 50 100 200 500 1000
5000
InspectSet xl
CheckFuelSupply
X
CheckOilLevel
X
CheckGovernorLinkage x2
ReplaceSparkPlug x
ChangeCrankcaseOil x2
CleanCrankcaseBreather
X
Checkl&rtteryElectrolyteLevel
X
InspectMagnetoBreakerPoints
X
CleanCommutatorCollectorRings
X
CheckBrushes x3
CheckValveClearance
X
RemoveCarbonandLead
X
CleanGenerator
X
RemoveandCleanOilBase
X
GrindValves(IfRequired)
X
CleanCarburetor
X
CompleteReconditioning X
xl- Withsetrunning,visuallyandaudiblycheckexhaust systemforleaks.
x2- Performmoreoftenunderextremelydustyconditions.
x3- Replacecommutatorbrusheswhenwornto5/8".
18