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Onan Manual

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Operatorc Manual
65

NH
Gts,.r. _...{L
6.s ru t-t -ict/ltco 4F
GenSet

)l_Lg

RV Electric Generating Set

@1)r.rsrro

@

gqHn?t
(SPEC Pl

SAFETY PRECAUTIONS
The lollowing symbols in this manual signal potenlially dangerous conditions to the operator or equrpment. FIead this manual carefully. Know when these conditions can exist- Then, take necessary steps to prolecl personnel as well as equipment.

mARt ttcl Onan uses

symbol lhroughoul thit menull lo warn ol po3slble 3€rlour penonal lnlury.

lhlr

Always use an appropriately sized- r \pro . double-throw transfer switch wilh an' generalor set. DO NOT PLUG POR I',---v SrnNoav sers DTREcTLY rNTo A h6usr RECEPTACLE TO PROVIDE EMERGENCY POWER. lt is possible for current to flow from generator into the utility line. This creates extreme hazards to anyone working on lines to restore power.
Use extreme caution when working on electrical components. High voltages cause injury ordeath.

'

IEffi,TO ]llio?Tfl!:l:;"':

o"""'o'"

Follow allstale and local electrical cod es. Have all electrical installations performed by a qualilied licensed electrician. Oo Not Snoke While Servicing B.tleries

Fuels, electrical equipment, batteries, exhaust gases and moving parts prcsent potential hazard s th at could result in serious, personal injury- Takecare in lollow-

ing these recommended procedures.

Lead acid balteies emit a highly explosive hydrogen gas that can be ignited by electrical arcing or by smoking.

.

Use Ext.eme Caution Near Gsloline. A con3tant polenlial erplo3lve or llre hazard exbl8.
Do nol till luel tank near unit with engine running. Do not smoke or use open tlame near the unit or

.

Erhaust Gas$ Are Toxic

expel discharged gases. Check exhaust system regularly lor leaks. Ensure that exhaust manifolds are secure and not warped. Be sure the unit is well ventilated.

Provide an adequate exhaust system to propedy

lhe fuel tank.

Be sure all fuel supplies have a positive shutotl

- \::-+

\J/

Keep The Unit And Surounding Area Clean

Fuel lines must be of steel piping, adequately secLrred and free of leaks. Use aflexible section ot fueltine between generator set and stationaryfu6l line in the vehicle. This flexible section must be 1000,6 NON-METALLIC to prevent electrical currents lrom using it as a conductor. Have a fire extinguisher nearby. Be sure extinguisher is properly maintained and be familiar with its proper use. Extinguishers rated ABC by the NFPA are appropdate for all applicalions. Consult the local fire department lor the correct type of extinguisher for various applications.

Bemove all oil deposits. Remove all unnecessary grease and oil from the unit. Accumulated 9rcase and oil can cause overheating and subsequent engine damage and may prcsent a potential fire hazard.

Do NOT storc anything in the generator compartment such as oil or gas cans, oily rags, chains, wooden blocks, propane tanks, etc. A fire could result or the gen€rator set operation (cooling, noise and vibmtion) may be adversely affected- Keep the compartment lloor cl€an and dry. .

Guard Ag.lntt Elect.lc Shock
Remove electric power before removing protective shields or touching electrical equipment. Use

rubber insulative mats placed on dry wood platlorms overfloors that are metalorconcrete wh€n around electrical equipment. Do not wear damp clothing (particularly wet shoes) or allow skin surlaces to be damp when handling electrical equipment.

Protect AgaiBt Moving Patt3 Avoid moving parts ot the !nit. Loose jackets, shirts or sleeves should not be permitted because ol lhe danger of becoming caught rn moving parts. Make sure all nuts and bolts are secure. Keep power shields and guards in position.

ll

adjustments musl be made while running, use exlreme caulion a manifolds, moving parts, etc.
Do not work on lhis equipment when mentally or physically latigued.

Jewelry is a good conductor of electricity and should be rcmoved when working on electrical equipment. TO THE OWNER
Welcome to ihe growing lamily ol Onan Power users . . . We are proud lo have you as a customer.

Bead this manual carefully and observe all safely rules within. Operating instructions, adiuslmenls and periodic maintenance procedures are given so that you ... the owner, can keep your unil running like new and expect many years of dependable service from rt. Remember. .. any machine, regardless ol design or type, will perform only in relation to the services it receives. lf your generator set needs specialattention, ask your Onan dealer for assistance: the Onan Parts and Service Organization has been factory-lrained to provide up-lo-date know-how lor keeping your BV electric generating set "on the road".

TABLE OF CONTENTS
General lnlormation Specitications lnslallalion Checks ..............
2 3 4 6

Operalion...........

Engine Troubleshoollng Maintenance Assembly Torques.. . Periodic Mainlenance Schedule

.....................
..

t0
11

Adiuslmenls.........
Remole Accessoriea

.. .. . .. . .. ..

13 15 18 20

'14

Conlrol Troubleshooting

.

... . .. .. . .. ... . .. . ..

WARNING
TO PREVENT FIRE OR ACCIDENT HAZARD. . . THIS UNIT MUST BE INSTALLED ACCORDING TO THE MANUFACTUBER'S DETAILED INST ALLAT I O N PROCED URES O BSE RV I N G ALL MINIMUM CLEARANCES.

TO AVOID POSS/ALF PERSONAI INJURY OR EQUIPMENT DAMAGE, ANY INSTALLATION AND ALL SERY/CE MUST BE PERFORMED BY QUALIFIED PERSONNEL.

GENERAL INFORMATION
YOTJR MANUAL This manual contains operation and other information to properly maintain, service. and make adjustments on your NH generatorset. Study and follow the instructions carefully. A well-planned service and maintenance program will result in longer unit lifeand better performance. Because the most importantpari ot repair is diagnosis, a troubleshooting chart is included.
Throughout the manual, engine end of the generalor set is the front. Left and right sides are determined when facing the engine (front) end.
When contacting your Onan dealer, distributor,

--'--./

MODEL DESIGNATION
The following typical model number is broken down into code segments used by Onan.

i
6.5

NH

3C R

t6oo4 M

I

T
2

TTTT 3456

orthe lactory about the generator set, always supply the

complete model number and serial number as shown on the nameplate (see Model Designation lollowing). This inlormation is necessary to identily your generator set among the many types manufactured by Onan. Onan electric sets are given a complete running test under various load conditions and are thoroughly checked before leaving the factory. Upon receiving your unjt, check ii thoroughly for any damage that may have occurred during shipping. Iighten loose parts, replace missing parts and repair any damage before operating the unit.

lndrcales krlowall rating. 2. Series identif ication. Number 3 is the voltage code tor 120/240 volts single phase. "C" is the code for reconnectible (120 volts, 2 wiret and 120/240 volts,3 wire). 4. Method of starting: R-remote electric starting. 5. Factory code lor designating optional equipment
1.

il any. 6. Specification letter which advances when the f actory makes production modif ication.

EIECTBIC

CHOKE

COIL

PLUG START.STOP

swtlcH

EXHAUST MANIFOLO

STAFI.STOP
DC FUSES

scRoLf

VIBRATION ISOLATORS (FAIL-SAFE)

OIL FILTEF

OIL DRAIN

TYPICAL NH FON FECFEA.rIONAL VEHICLES

SPECIFICATIONS
Thl6 manual conlalns Sl herric equlvdenls lhal lollow immedlarely in parenlheses 6ller lhe U,S, cuslomary unils oi mea3ur,

GENERAL Nominal Dimensions of Set Height . . .. ... .... .. Width .. ... .. . .. .... Length .... ... .. .. .. Weight ... . . . . .. .. .. ENGINE DETAILS

. . . .

19.50 in. (495 mm) 20.00 in. (508 mm) 33.37 in. (848 mm) 305 lbs. (138 kg)

\-

.,....,,..,,. Onan Manulacturer.,,...,. . .. . ... .. . ... . Two Number ol Cylinders. Displacement (cubic inches) . ... ... .... .. ... ..60 inr (983 cm3) Cylinder Bore .. . . 3-9/16 in. (90.49 mm) Piston Stroke. ... . ... . . 3 in. (76.20 mm) Compression Ratio ................ . . . . . . . . . . . . . . . . . . 7.0 to Engine Speed .. .. ... . .. ... ... 1800 rpm Engine Design....... . . .. ... ... Four Cycle, Air Cooled, L-Head Horizontally Opposed Starting System Exciter Cranking (Generator) lgnition .. ... . .. .. .. . ... .. ... ... Battery RecommendedFuel................ ................Gaso|ine(LeadFreeorRegular) Average Fuel Consumption (at rated load & speed) ... .... ... .. . .. ... . .. ... ... . 1.30 Gallons per Hour (4.92 L) GENERATOR DETAILS l/anofacturer..,.,,,. . ii. . . . . . . . , Onan Design .. ... ... . .. , . . Revolving Armature, Four Pole, 1800 rpm Rating (in watts 60 Hertz) ... .. . .. .. .. ... ... .. .. 6,500 (6.5 kW) Voltage . . . . . . . . . . . . . . . . .12O o( 120/240 Current Rating (amperes) 120 Vo|t . . . . . . . . . . . . . ...54.2 Amperes 240 Vo|t. .. . , .. . .. .. . ...27.1 Amperes Phase . . . . . . . . . . . . . . . . ........... Single Wire ... ... ... ... ... . 4 Wire Reconnectible Output Rating ...... Unity Power Factor Cranking Current. .. . 100 Amperes (Nominal) CAPACITIES AND REQUIREMENTS Oil Capacity. ..... .. . ... ..... 3 U.S. Quarts (2.8 lit) Plus 1/2 Quart for oil filter change Recommended Battery... ... . .. ..... . . ... ... .. . ... .. . .12 Volt 74 Amp/Hr (266.40 kC) Battery Charge Rate (Fixed). .... .... ... ... . ... . 1-112 Amperes Ventilataon Requirements (Total-No Restrictions). ..... .. .. ... .. . 120 sq. in. (774 cm,) TUNE.UP SPECIFICATIONS Spark Plug Gap .... .. .. .... ... .. ... ... . .. . .025 in. (0.64 mm) Breaker Point Gap (Cold Setting)... . .... .. . .016 in. (0.4'1 mm) lgnitionTiming Reference (Cold SettinS) ,.................. . . . . . . . . . . . . . . . 20' BTC Valve Tappet Clearance lntake. ... .. . ... .. .. . .003 in. (.076 mm) Exhaust ... . . .. . .... . .012 in. (0.30 mm) Cylinder Head Bolt Torque.. ... .. .. . .....18|b.ft.(24.40N.m)
.
1

.

.

INSTALLATION CHECKS
INSTALLATION
Neady all Onan e ectric generaling sets are installed by the motor home manuiacturer Although the manulacturer musl iollow saiety codes when inslalling, certain nstallat on problems cou d ar se aiterthe unit is installed and subjected to vibration. There are a few areas thai you as the operatorshould be concerned with. lf in doubt about any aspect of you rgenerator set's operation or safety, contact your nearest authorized Onan Service Center. Adaily inspection of voJr i-stal'arion should incl.rde the !ollowing.

wAtlt ritc

exhausr ga.es .way lrom window and door openings.

Oo not lermlnare erhau3t unde. vehicte, as carbon monoxide ga6 Is poisonous. Dlrecl

FUEL SYSTEM
Wiih set running, check for leaks. Raw fuet will cause fumes which coutd EXPLODE. Check around carburetor and fuei pump inlets. lrake sure fuel lines are not rJbbng againsl anytr,.o wnrch could cause breakaqe.

surrounding areas excessively. lf so, have corrected mmediately. Remember EXHAUST GASES CONTAIN DEADLY CARBON I\,4ONOXIDE. Be sure aII holes to the inside ot RV from sel compartment are sealed to prevent poisonous exhausl gases lrom entering vehicles.
WANNING
All exhaLrsi shielding supplied with generator

EXHAUST Check for leaks around mantfolds, gaskets, and welds. Make sure exhaust lines are not heating

M4) termrnate ir] generator seis junction box. These wires should be connected to distribution box with multistrand w re enclosed tn a flexible condutt. Check all w res rlo ano 'rom rae ge.erator set' for fraytng and loosF co'1reclions For tnlormalton on load connec, trons refer to operation seclion fo owing.

ELECTRICAL AC Outpult Al AC leads (M1, [42, [r3 and

overhealing ol cofiparlment walls or ihe possibit y ot tire,

sel MusT be properly lnstalled to prevent

Battery Connections: Battery positjve (+) connection connects to slart solenoid Battery negative conneclr to location on rear of generator. Check terninals on set and battery ior clean and tight connections.
33,37" MIN CLEAFANCE TO TOP

I

I
19-50"

I

I/2" ORAIN HOLES IN ALL
FOUN CORNERS

OIL DRAIN CLEAFANCE
'1-1/2"

CLEANANCE

1. OTMENSTONS tN

(

MINIMUII/I SCBOLL OUILET DIAMETER 9.69" x 4-00"

FLOOR

) ARE MTLLIMETERS

4. VACU-FLO SCFOLL EXTENDS BELOW MOUNTING PIATE 5, FOF CUSTOMERS COMPARTMENT HOLE SIZE FOF SCFOIL|
5,1 wlDTH:4.00 (102)

2. APPROX WEIGHT: 305

LBS

MASS; 138 kg

3. A 1_00" (25) MtN CTEARANCE REOUTFED AFOUND

sET ANO ,50 {13) MtN ABOVE CARB TO COMPARTMENT WALLS OR SOUND TNSUIATTON (OtL FITER UAy 5.2 LENGTH: 9.69 (246) PROTRUOE INTO 1.0O" (25) CIEABANCE) FIGURE I. INSTALLATION OUTLINE

4

Onan recommends using a s€parate ballery lor operalion ol lhe qeneralor sel in adalilion lo lhe reqular vehicle slarring ballery. Feler to individual inst6llalion gride or T-012 tor additional i.lomalion on barlery sharing.

VENTILATION

Grounding: Generator must be effeclively bonded to recreational vehicle chassis

The biggest enemy of electrc generating sets nstalled in moior homes is excessive heat. Make sure the set's air nlet and outlet are not plugged wlth dust, dirt, bugs, leaves or anyihing that could restrict cooling arr.
Don l anlorcomparlfwai-Nri6-l menlu3e discharged cooling could conl.ln healing since il

For additional inlormation on installation contact your Onan Service Representaiive or request lnstal atlon Guide #940-0610,

ch...ir {l..he) 9rcund tnd rhe ban€ry.nd generalor tel .ll be elecrrlcrlly connecled lo be sl 0 ground por.nll.l, All Onln unllr are detlgned lor .eqtllve ground
Vehlclc

under vehicle. f-RrrNc I Do nor r€rminare exh.ust poisonous. Olrecl carbon monoxide qas i3
63

ground rhould

lrom window and door openlng.,

Mounilhe prevent ll.e or erylo.lon.

Irom lhe.el

bitert In 3 sep.r.le compadmenl or..y sprr*-produclngdevlcelo

prope.ly in3t. ed lo prevenl overheallng ol compddmcnl w.ll! or rhe polliblllly ol tire, Reter lo apProprlaie ifttallallon guide tot e.ch model lor delril3,

WATNING l--l

On all llsled model3 wlth erhaust lhlelding

3upplled wilh unft, .hleldlns

ilusT

be

Do nol smoke whil.sedicinq b.tleries, Lead acid balteries qive olt explosive qases while

DO NOT DISCONNECT BATTEFY CABIES FROM BATTEFY WHILE GENERAIOF SET IS CRANKING OR RUNNING:SPARKS MAY CAUSEAN EXPLO-

sroN. lM P

odlnan.$ perlllnlhg ro ihe lyPe .nd u.!ge ot

ORTANT: cerlain ttalet (ptnicul!rly c!lllorni!)

haYe

llat€

erhau3i

multler/!pErk ar€3teB on inlemal combutllon englne. orengine driven equipmenl when u3ed In . recresllon.l vehicl. luch rs elecrric gener.llng !e1.. Be !ore you.ln.l!llallon mels rll Federal,

sl.tesnd locrl cod6perl.lningloyourunil,FailureloProvld.and malnrrh a 3park are.ler mry be in viol.llon ol lh. hw,

IwmNrNGl
ENGINE EXHAUST G AS (CARBON MONOXIDE) IS DEADLY! Crrbon monoxlde l! an odo e!3, colode.! ga3 lormed by lncofiplele cohbu3tlon ol hydroca.bon lu€13. Calbon monoxlde l! a drngerous gai lhtl csn c!u3e uncon3ciou3ne!3 .nd l!polenllally lethal. Some olthe 3ymplom3or
3ign3 ot carbon monoxlde inhalallon are:

. . Olzzlne.! . . lnten3e Headsche . weakness and Sleepiness ' ll you erperlence any lmnedlately.

Vomlllng Mu3cular Twltchlng Th.obblng ln TemPles

ol lhe ebove symPlom!,get oul lnlo

lresh air

The b€31p.otectlon again!l ctrbon monoxlde inhslstlon l3a regulat lnspecllon

ot lhe complete 6xhau3l 3yslen, ll you nollce a change ln lhe 3ound or appe.rrnce ot ethautt rytlem, 3hut lhe unlt down lmmedlately and heve ll in3pecled and repaired at once by a comPelenl mech.nic.

OPERATION
BEFORE STARTING

ling Check lor loose or missing damaoe. lnspeclion: inspect the engine vrsua ly be{ore starparts orany shipp ng

CRANKCASE OIL The set o I capacity s3U.S quarts(2.8 lit) plusl/2 quart lor oi fi ter change. FilL the crankcase uniil the o I reaches the FULL markontheolevelrndicator (F gure 2). Do NOT OVERFILL. (Overli ling may cause ioam ng and engine shutdown.) Always change the o I fiter when changing oil. Refer 10
Periodrc Maintenance Schedule section lor serv ce lnterval.
CAP ANO OIL

I

.c -30 -20

0244060

1n

l\'IAINfENANCE

TEMPEiATUNE RANGE YOU EIPECI B€FOF€ NEIT OIL CHANGE

0

10

20

30

4q

IEVEL INDICAIOR

KEEP

AT THIS IEVEL

OIL

_-

FULL

---

-

LEVEL
OIL FILL

olL

Check oil evel dailyand changeoil every 100norma] operating hours. See Figure 3 ior location of o I drain. It operating n extremely dusty ordirty conditions, the oil mrght have to be changed sooner. When adding oil belween changes, use the same brand as in the crankcase. Vafous brands of oi miqht not be compat ble when mixed.

NEVEF OPERATE--LgYENGINE WITH OII BELOW THIS IEVEL

CAP TIGHTLY, ON

OIL LEAKAGE MAY

occuF.

FIGIJRE

2

CHECKING OIL LEVEL

Be sure to f ll lhe crankcase with oil to the "FULL" mark on the oil leve indicator. Use oll with the API (American Petroleum lnslituie) designation SE or SE/CC Oil should be labeled as having passed MS Sequence Tests (also known as having passed AST.4G-lv Sequence Tests). Refer to oil chart for recommended viscoslty and temperatu re
O I consumption may be higher with a mult grade oil ihan with a single grade oil ii both oils have comparabe viscosities ai 210'F (99"C). Therefore, single grade oils are generally more desirable, un ess dntrcrpalrng a wrde'ar9e of lenpe'alL'es
Use ol the same grade and quality oi o I asthai Lrsed in your recreational vehicle engine is acceptable as long as Lrnit is serviced regularly and oil meets requirements shown in chart.
Do Nor check oll while lhe seneralor sel is opet.llng. Hol oil could cau3e burn. by blowing our ol oil lill robe due lo crankcase presure.

FICUFE

3

OIL ORAIN ANO FILL

RECOMMENDED FUEL
Use clean, fresh, unleaded or regular grade gasoline

Do not use highly leaded premium fuels. Using

unleaded gasoline results in reduced valve and catbon cleanout maintenance, lf the use oi unleaded gasoline rs desired, use regular gasoline for the flrst 25 hours to allow the ringsto seat wel for best performance. Then use unleaded gasoline therealter.

lf

hA-ttt[,tc \-l

I

regular gasoline rs used continually, carbon afd ead deposits must be removed trom the cylinder heads as required because ol engine powet loss. Unleaded gasoline may be used safely alter lead deposils have been removed.

WAN

NING

syslem should provide a conslanl llow ol air lo erpel any accumulalion ol luel vaoor while lhe vehicle is in l,ansil. Comparlmenis musi be vapor lighi lo lhe inlerior to *eep lumes lron

Leakage ol gasoline rn or arou.d lhe comparlmenr is a deiinile hazard. The venlilafton

EXERCISE lnfrequenl use results in hard slartrng. Operale iFe generator sei one 30-minute period each week Run onger 11 battery needs charging. Exercising lor one ong perod each week rs better than several shorl
Periods

STARTING Push the start-siop switch lo the slart posrtion. to siarl, inhrbrtor oil used al the lactory may

BATTERY CHARGING
The battery charge rate is conlrolled by a lixed value res stor ihat allows a irickle charge .ale ol 1 - 1-1/2 amPs underal conditions.

Reiease the switch when engrne slarts. lf engine larls have touled the spark plugs. Remove the p ugs. clean rn a suitable so vent. dry thoroughly and re-inslall Heavy

exhaust smoke when the engine is iirst started is normal and caused by the inhibrtor o I

HIGH OPERATING TEMPERATURES
1. See that noihing obstructs arr l ow lo and trom the

STOPPING
Push the start-slop sw 1ch to the stop position and hold unlil unil stops complelely

2

Keep coo rng f ns clean Air housing should be properly installed and undamaged 3. Keep ignilron I ming properly adiusied.

BREAK.IN PROCEDURE
Control ed breakrn with the proper oil and a conscientiously applied maintenance prograrn will hetp lo assure satrsfaclory service from you r Onan eleclric generaling set Break-tn as Jolows: 1 OnF lari loJt al 1t2 .oao (w,tr one a r conditioner) and approximately 500 watts additionat load LOW OPERATING TEMPERATURES
1

Use correct SAE orl lor ternperature condilions. Change ol only when engine rs warm. lf an

2

2 O.e

l_al' hour at 3,4 load {wrt5 one arr conditioner) and approximately 1500-2000 watts addllional load.
Change crankcase oil atler the first 50 hours of oPeration.

3

emergency move vehicle to a warm location. Use iresh gasoline Protecl againsi moisture condensalion. Below 0'F (-18"C), adjUst carburetor main jel lor a slig ht y richer tuel mixture. Keep ignition syslem clean, properly adiusted and balteries in a wel charged cond tion. Partially restr!cl cool airilow, but use care 1o avoid overhealing. unexpecled lemperature

drop causes

an

APPLYING LOAD ll practical, allow sel to warm Lrp before connecting a heavy load Continuous generator overloading may cause high operaling lemperalures that can damage lhe windings. Keep lhe load within nameplate rating.

A carbu

-below 45' F (7'C), whlch helF prevenl carbur.lorlclng Order Kit No. 140-1673.

r.lor .ir pr6hqter llt

ls

afl!ll!bl€ lor cold wearhe, opedlion

LOAD CONNECTIONS
1. Generator set load wires l\,41, and lv12 terminale within the junction box. Connect and join wires within junction box in an approved manner for desired voltage code. See Figure 4.

2

Wrres must be adequate size, properly insulaled and sLrpported. 3 Mount swrlches and conlrols secure y lo prevent damage lrom vibratLon and road shocks All swilches must be vibration proof to prevenl accidenlal operling or closing whrle the vehicle is in motron. 4. All winng musl meet applicable locai eleclricaL codes. Have a qualrtied eeclrician nstall and rnsPecl the wrrlng.

EXTREMELY DUSTY OR DIBTY 1 Keep unit clean Keep cooling su'aces :::_ 2 Servrce all c ealer as f'eqJent / E-i ':::i--. 3 Change crankcase orl every a: 4. Keep oil and gaso ne rn cus:-: 5. Keep governor rnkage c ea6 Clean generator brijs-:s s a mulator do nol rera': _:-:
Do not polish

HIGH ALTITUDE OPEFATTO" For operalion a: al: :-:- :':51: E=, -: - -rr.= -:sea level. close ca-a-'=_:- -a- F al,-,stre__ -rE _6lr: r+E E :-€ ly tO marntai' .':a=- .':E-a.E

ADJUSTT'IEN-S o---.-- *-t ,-* :c-' .'rl :€ ".l|Ja reduced aaa.a: -z'=. 'a-l. :v)tr \'-. *: 1s':CC r=l ,3': - ::.:.: --: :tr3 tlF:'* fee!

POWER REOUIREMENTS FOB APPLIANCES Approximale Appllance or Running Watlage Tool

Refrigerator Etectiic broom

......600-1000
..
.

Cottee percolator . . . . . . . . . . . . . . . . . . . . . . . . 550-700 Electric frying pan . ... ... . ... ... ... .. 1000-1350 Hair dryer... ... .. .. .. ... ... .... ... .. .. 350-500 Electric stove (perelement) ...... . . .. 350n000 Electric iron .. ... . .. .. .. ... .. . ... . .. 500-1200 Radio .. ... ... ... ... .. .. .. .. . . ...... ... ... 50-200 Electric water heater.. ... .... ... ... ... 1000-1500 Space heater ... .. .. . . .. , ... ... .... ... 1000-1500 Eiectric blanket...................,....... 50-200 Tetevision ... . . .. ... .. .. ... ...... ... ... .. 200-600 .. ... .. 250-750 Electric drill Battery charger.. . . . .. .... ... ... ... ... . Up to 800 Electric water pump .. ... ... .... ... ... .. 500-600 Air Conditioner . . . . . . . . . . . , . . . . . . . . , . . . .14OO-220O converter .. .. .... .. .... ... .... .... . .... . 300-350 .. .700-1500 Microwave oven
JOII{ BOTII SL CK IE DS IIEBE FOB FULI N TIXG

.

200-500

cB2

AL CK
UiGNOUTDED LOAD WIBE

sfl{otEctRcull I20 YOIT outPtll.

G E

cBt

(
TO YEHICLE

LL EE

BL

CK

nl o B

LOAD

t3

D

wHttE
OMUXDED IOAD STIBE

t 20 voLT LOAD WIRE COI{}aECrlors

G E

.---------------

TI

UXGNOUXDEO IOAD WIRE

o
R

IL EE R D t3

TO

VtNlClE

GROUXDED IOAD WIRE

IO

D

120/24.) LOAD W|RE COl{ltECttO
FIGURE

S

4.

SINGLE-PHASE, ".3C" VOLTAGE CODE GENERATOB COI{NECTIONS

Operate slart switch. Enerqizes start solenoid.

Solenoid contacls closi. Current fed to eleclric choke operates carburetor choke.

Current fed to generator series field, cranks engine.

Battery currenl fed to ignition coil and fuel pump

Engine starts. Operate slart switch until generator speed builds up

Release start switch.

Generalor DC current prod uced.

AC output current produced and ted to load.

Generator supplies current to ignition, coil and fuel pump.
FICUFE

Recharges bdllery.

5.

SEOUENCE OF OPEFATIOI{

SEOUENCE OF OPERATION Figure 5 shows the operation sequence of the
"RV" electric generating set.

NH

ENGINE TROUBLESHOOTING
\_,

o{

TR

O U BI- ES H O OT IN G

""f,,
,,1.

GUIDE
CAUSE

'

'.cooLrNc sYsrE|l

(ArR cooLED)

LUBRICATION sYSTEM

THROTTLE AND GOVERNONJi]iii]]]]'.

MAINTENANCE
BATTERY CARE
To increase battery life, the operalor can perform a number of routine checks and some preventive maintenance, 1. Keep the battery case clean and dry. 2. Make sure the battery cable connections are clean and tight. Use a terminal puller when 3.

4.
5.

6.

rcmoving cables for any reason. Coat the battery terminals with a mineral grease or petroleum ielly to reduce corrosion and oxjdation. ldentify each battery cable to be posjtive or negative before makrng any connection. Always connect the ground (negative) cable lasl. Nlaintain the electrolyte level by adding water (drinking quality or bette.) as needed for f illing to split level marker. (The water ingredient of the electrolyte evaporates, but the sulphuric acid ingredient remains- Thercfore, add water, not electrolyte. Avoid overcharging when recharging. Stop the boost charge when the specific aravity is 1.260 and the electrolyte is 80'F (26.7'C).
FIGUFE

ELEMENT

6.

ONAN FUEL PUMP

AIR CLEANER ELEMENT
ELECTRIC FUEL PUMP
Service of the fuel pump is limited to cleaning the filter. Every 100 hours, drain the fuel pump and check the filter element. Turn the hex nut on the base of the pump to gain access to the filter element- lf ihe element appears dirty, rcplace it. Be sure to replace gaskets when reassembling (Figure 6). Check and clean element at least every 100 hours. Loosen wing nut to remove. Clean by tapping base lightly on a flat surface. Replace elementat least every 200 operating hours; clean or replace more often in dusty conditions. See Figure 7.

COOLING SYSTEM

The generator set is cooled by a flywheel blower tan which pulls air over the cylinders and cooling fins. The air path is directed by sheet metal shrouds and plates. These shrouds and plates must always be installed properly so unit does not overheatCheck and clean (rf necessary) the cooling lins at least every 200 hours ol operation. Remove any dust, dirt or oil which may have accumulated. _Check compartment air inlet and generator set air ou et for buildup of dirt, chaff, etc.
FIGURE

7,

AIB CLEANEN ELEMEN1

SPARK PLUGS year. A badly leaded plug will cause misfiring. poor operation or stopping when a load is applied. . Black deposits indicate a rich mixture. . wet plug indicates misfiring. . Badlyorf requently louled plug indicatesthe need tor a major tune-up.
Replace spark plugs every 100 hours orat least once a
3.

the engine stops to help drain the carburetor comPletely. i:?';'i""

Each time the spark plugs are removed, Inspect, clean and regap (Figure 8). lf the plug looks discolored or has fouled, replace it.

stating type and viscosity of oil used. Remove spark plugs. Pour 1 ounce of rust in_ hibitor oil (or SAE #'10) into each cylinder. {Spray cans work well for lhis applicalion). Turn engine over by hand at least 2 complete revolutions. Replace the spark plugs. 5. Replace the air cleaner at least on an annual basis. 6.

::':1", ;,1 J:" T. Replace drain plug and relill. Atlach a warning

:'

"i"ii,I,,'

li

l;;'i

tag -

I at

Plug the exhaust outlet to prevent entrance of moisture, dirt, bugs, etc. 7. Clean and oilallexposed engine parts including carburetor and governor linkage. L Wipe generator brushes, slip rings, housing, etc. Do not apply any lubricant or preservative. 9. Bemove the battery and store in a cooldry place. Coat the battery terminals and cable connections vrith vasolrne or grease lo prevent any corrosion. Recharge the battery at least monthly or maintain with a trickle type battery charger. 10. Provide a suitable cover il the unii is exposed to the elements.
FIGURE

8.

CHEC(ING SPAFK PLUG GAP

GOVERNOR LINKAGE

The linkage must be able to move freely through its entire travel. Every 50 hours of operation, clean the ioints and lubricate as shown in Figure L Also inspect the linkage for binding, excessive slack and wear.

RETURNING THE UNIT TO SERVICE I Remove the cover and all prolective wrapping. Wipe the oil film off all exposed engine parts.

Remove the plug ,rom the exhaust outlet. 2. Visually inspect the unitforany damage. Check to be sure the carburetor and governor linkage are free. Bemove the generator end bell band and check to be sure the brushes work lreely in their holders. 3. Check the tag to ensure oil of the proper brand and grade has been installed. Check the oil level. lnstall the battery (be sure battery is fully charg-

ed), observing proper polarity. Ground

is

AND LUBRICATE W TH
FIGUFE

LINKA6E LUBRICATEO WiTH GRAPHITE

KEEP COVERNOR

9.

GOVEFNOF LINKAGE

OUT-OF.SERVICE PROTECTION

Prolect a generator set that will be oul of service lor more than 30 days trom damage caused by rust or corrosion. Use the following procedure to properly protect the set. 1. Run the generatorsetwith at leasta 50% load until thoroughly warm (usually about'1 hour). 2. Turn off fuel supply and allow the engine to run out of fuel. Also operate the choke manually as

negative. 5. Bemove spark plugs, clean and gap. Turn the engine overby hand several times. Reinstall spark plugs. 6. Turn on luel, disconnect electric fuel pump lead and electric fuel solenoid shuFofl lead if unit is so eqoipped. Jumpea the fuel pump and eleclric fuel solenoid shut-off leads to the battery to primethe unit. Reconnect the leads. 7. Remove all load and start the generalor set at the unit. lnitial stan may be slow due to oil or rust inhibitor in the cylinders. Excessive smoke and rough operation will occur until the oil or rust inhibitor is burned olf. Apply a 500/0 load after the set runs smooth. Allow the generalor set to warm up (1 hour) with the load connected. Check speed and voltage. L Unit is now ready tor service.

_ I qt

GENERATOR MAINTENANCE

The qeneralor normailv needs little careotherlhan a perio.-oic check ot th; brushes, commutator and ;ollector rings. lf a major repair job on the generator should become necessary, have the equipment checked by a competent eieclrician who isthoroughly familiar with the operation of electric generator equipment.

Brush Replacement lnstall new brushes when the old ones are worn to the dimensions shown in Figure 10. Remove the end bell band to expose the brush holders. Remove the three screws holding each brush holder in place (Figure 10). Remove the old brushes and clean the holders so the new brushes can move easily in their holders. lnstall the new brushes in the same manner as theold ones. Always use the correct brush as listed in the PARTS CATALOG. Never substitute a brush which may appear to be the same for it may have different characteristics. New brushes are shaped lo fit and seldom need sanding to seat properly. It some brush sparking occurs after replacing brushes, run th'e set under a light load until the brushes wear to a good seat, newly machined appearing surface. Ordinary cleaning with a dry, lint lree cloth is usually sufficient. Very fine sandpaper (#200) may be used to remove stight roughness.

Collector rings acquire a glossy brown finish in normal operation. Do not attempt to maintain a bright

ASSEMBLY TORQUES
BOLT Gearcase Cylinder Head Slud Nuts (Cold). .... ... Rear Bearing Plate Screws .. . ... .... ... Connecting Rod Bolt ... .. . ... .. ,... ... Flywheel Cap Other 5/16" Cylinder Block Stud and Nuts...... Oil Base Mounting Screws .. .. ... .. . ... [4anifold l\,,lountin; Scrers . . . . . . . . . . . . . . .

TORQUE Cover

Screw. .

.. .. ..

FT..LB. 8-10 17-19 25-28 27-29 35-40 8-10
18-23 18-23 7-9

Exhaust [,,lanifold

'18-23

SAFE OPERATION. All require periodic clean-out (every 50 to 100 operating hours) to maintain maximum efficiency. Some state and lederal parks require them.

EXHAUST SPARK ARRESTER Erhaust spark arreslers are necessary tor

EASURE FiOfl IOP FTCE Of Btusfl rL0c( I0 T0P 0t 8nusfi AE s.9 5 tB" 1 1/16 FIGUFE 10. BFTISH LENCTH

To clean spark arrester remove pipe plug in bottom ol muffler. Run set under load for 5 minutes. Replace plug.

13

PERIODIC MAINTENANCE SCHEDULE
Regularly scheduled mainlenance is lhe key lo lower operating costs and longer servlce life lor the unit. The following schedule can be used as a guide. However, actual operating conditions under which a

the cond tion of the crankcase oil, the fillers eic

irequent y until lhe proper service time periods can be established. For any abnormalities in operation, unusual noises power, overheating, etc., contact your nearest aulhorized Onan dealer.

unit rs run should be the determining factor in establishing a ma ntenance schedule. When

from engrne or accessories, loss of

operating in very dusty or dirty conditions, some of lhe service periods may have to be reduced. Check

Arway. alrow generaror ser ro coot ort belo.e perlorfrhg .ny n.lnlen.nce or inslallaiion work on lhele|, Working on a hoi Bel colld calse

wArNtN;-|

AFTER EACH CYCLE OF INDICATED HOURS SERVICE THESE ITEMS

I
X1

50

100

200

400

General inspectron Check Oil Level Check Batlery Electrolyte Level Change Crankcase Oil Check Air Cleaner Check Spark Plugs Check Breaker Points Change Oil Filter Clean Cooling Fins Replace Breaker Points Clean Crankcase Breather Replace Arr Cleaner Remove Carbon Deposits from Heads Adiust Tappets Replace Fuel Filter Clean Carburetor Check Generator B.ushes (Replace il Necessary) x1 - wirh ser r!nnrnq. vrs!a ly and audibly check exhausl sylem tor leaks X2 - Pedorm more oflen n exlremely dusly condrlions
X3

X

X

x2 x2 x4
X3

x2 x2 x4 x2 x2
X X

X4
X

As Required

Yr'

-

qep a' p

qpo'dce 'l a.1ual y o'

_.ces(drt

o

or io $orage

All erhault lvltom connection! IIUST be checked regularly fo. any leeks and tlghtened aa;ece!3a.y. Do NOTterminate erhau3t pipe underYehicle or neat any window or dooiopenings. tnlpect the yapor tight 3ealr around all openings made in lhe-3et'5 compartment for wiring; conduitr etc,, to Prevent entrance of any noxioua fumes to motor home

;^Dxrr6t lryl

inlerior.

14

ADJUSTMENTS
Salislactory gonerator s€t performance depends on correct adjustments. lf trouble develops, tollow an orderly procedure to determine the cause betore making changes in adjustments. Refer to ENG/NE TROUBLESHOOTING and PERIODIC SERVICE GUIDES for additional h6lp.

CARBURETOR The NH "RV" gen€rator set carburotor has two mixture adiustmenls, an idle mixture which aftects operation mainly at no load and a main (power)

adiustment which affects operation at maximum load (Figure 11). lf your generutor set has a "hunting" (sudden surges and drops in speed) condition at no load or lull load and cannot be corrected by carburetor adjustm€nts, check governor, linkage and adfustment (see Govehot Adiustmerts). A hunting condition at no load can usually be corrected by an idle mixture adjustment.

FIGURE 11, CABEURETOR FUEL MIXTIJFE ADJUSTIIIENTS

THROTTLE STOP SCREW
The throttle stop scr6w is located on the base of lhe carburetor (opposite side frcm main power adjustment needle) near the cGnkcase breather valve. lt must be adjusted to obtain 56hertzatno load with the throttle closed as far as possibl€ (throttle shaft lever touching adjustment screw). See Figur€ 12.
.
ADJUST THIS DISTANCE BY ADIUSTING LENGTH OF GOVERNOR CONTROL

lu.l mlrlure .€ttlng., n.vlr lorc. lh. tu.l mlllult dlurtn.nl n.dl.. !g.ln.l th.k...t (d.m.g.! th. ..d..nd n..dl.r).
When del.inlnlng

CARBURETOR ADJUSTMENTS
Start generator sel and allow it to warm up for at leasl '10 minutes before making any adiustments. Remove all AC loads and connect a plug-in-typeAC voltmetor into one of the receptacles in the coach. When procedure below callsforfull load, turn on appliances or use an onan load test panel. The first two adjustments are made with the set not running. Turn unit off-proceed as followsl 1. Turn idle mixture screw out (counterclockwise) 1/2lo 3/4lwn from seated position. 2. Turn main mixture screw 1-1l4 to 1-1l2 turns out (counterclockwise) f rom seated position. 3. Start set and adjust governor sp ng setting so engine speed is 1860 RPM at no load (62 hertz or 130 volts). Hold back governorarm sothatthrottle lever Gsts on throttle stop screw. Adiust idle stop screw to 1500 RPM (50 hertz or 100 volts). Reloase gover5.

cLcEo PostTtoN
FIGUFE 12. THFOTTLE STOP SCFEW SETTING

Adiust idle mixture screw to highost RPN.4 or voltage. Readjust governor spring setting so engine speed is 1860 RPN4 at no load (62 hertz or
130 volts).

CARBURETOR FLOAT ADJUSTMENT
Normal operation seldom requires any adjustment of the float level. Disconnecl throttle control, choke leads, air cleaner inlet hose and tuel line from carburetor. 2. Remove the tour bolts that hold the intake manilold assembly in place and remove lhe. complete carburetor and intake manifold assembly as one unil. Then remove carburelor lrom intake manifold lor easier handling wheo checking float level.
1.

6.

Apply full Ioad to generator and adiust main

7.

iust governor spring setting so engine speed is 1770 RPM at full load (59 hertz or'1'10 volts). Remove and add load sevemltimesto checkfora governor hunting condition. Readjust governor spring setting if required.

mixture screw lo highest RPIVI or voltage. Read-

four phillips head screws on the top ot the carburetor and lift it ofi. 4. lnvert the carburetor and check lhe lloat seiling (see Figure l3). Thetloat should havea 0.0710.02 lnch (1.8 1 0.5 mm) clearance from the machined mating surface (without gasket). Bend the float tab as required. 5. lf it is necessaryto reset thefloat level,loos€nthe scrcw nearfloatvalveaxle (pin) and bend thelloat arm near float valve axle (pin) to posiiion tloat flush with top edge ol carburetor float bowl. See Figure 13. It llolt ..l,u.lddt l. n.c.trrry, b. c.rdul nol lo lo|e llr. buoy&cy rprlnt or th. hn.lon lDrinq on th€ vlion llp llo.t n..dl€ md ..d
3. Remove the 6. Reassemble

A binding in the bearings of the govemor shaft, in the ball ,oinl, or rn the carburetor throttle assembly will

::;d:":":1':""?""$T"Ti,",jiruii'iJff

adjuslmenl may also cause hunting. Springs of all kinds have a tendency to lose their calibrated tension through latigue alter long usage. lf all governor and carburetor adjustments are properly made, and the governor action is still erratic, replacing the spring with a new one and reselting the adiustments will usually correct the trouble. 1. Adjust the carburetor idle needle with no load connected, 2

':#",ffi?o

complete assembly on the engine. 7. Check carburetor for prop€r operation.
NEEOLE

on intake manilold assembly and then replace

carburelor and reinstall carburetor

Adjust the carburetor main jet for the best luel mixture while operating the set with a full €ted load connected. Adjust the length of the governor linkage and check linkage and throltle shaft for binding or excessive looseness,

4. Adjust the governor spring tension for rated speed at no load operation. 5. Adjust the governor sensitivity. 6. Recheck the speed adiustment. 7. Set lhe carburctor throttle stop screw.

007!0 02 tN. (1 8i 0.5 mm)

BOOY

Link.g€: The engine starts at wide op€n throtlle. The length of the linkage connecting thegovernorarm to the throttle shaft assembly isadiusted by rotaling th€ ball loint. Adlust this length so that with the engine stopp€d and tension on thegovernorspring, the stop on the throttle shaft assembly almost touches the throttle gtop screw housing on sideot calburetor (one more turn of govemo. ball joint would allow throttle shaft linkag€ to rest against stop screw housing) See Figure 12.

o

FIGUAE 13. CARBURETOR FLOAT SETTING

GOVERNOR ADJUSTMENTS
It carburelor and lh. tollowing gorerno.adjutheni. h.vealt6.dy b€en mad€ and lhe govornor acilon b stlll e rtlc, replace the

Speed Adtustment With the warmed-up unit operaling at no load, adjust the tension ol the governor spring. Refer to the Voltage Chart and the Speed Chart. Turn the speed adjusting nutto obtain a voltage and speed reading within the limits shown.
Sensitivity Adiustment: Refer to the GovernorAdiustment illustration, and to the Voltage and Speed Charts. Check the voltage and speed, first with no load connected and again with a full load. Adiustthe sensitivity to give the closest regulation (least speed and voltagedifference between no load and tull load) without causing a hunting condition.

.pri.s (Fisurc 14) wlth a new one .nd reldju.i the gov.nor. spdngs lo8e theh c.libEr.d teBion lhrough l.llgue qovemor Before making governor adjustments, run the unit about 15 minutes under,ight to reach normal operating temperature. (11 governor is completelyout 'oad of adiustment, make a preliminary adjustment at no load to first attain a sale voltage operating range). Engine speed determines the output voltage and cuffent trequency olthe generator. By increasingthe engrne speed, generator voltage and frequency are increased, and by decreasing the engine speod, generator voltage and frequency are decreased. An accurate voltmeter or frequency meter (preferably both) should be connected to the generator output in order to correctly adjust the governor. A small speed drop not noticeable without instruments will result in an obiectionable voltage drop. The engine speod can be checked with a tachometer.
16

To increase sensitivity (closer rcgulation), shift the spring toward the governor shaft.

VOLTAGE CHART FOR CHECl(IIIG GOVERNOR FEGULA'ION

t20 YoL.'

I

2 rraE
I32

PHASE

'---l------ -Et
FULL-LOAO VOLIACE SPFIING TENSION

r08

SPEED CHART FOR CHECKING GOVEFNOR RECUIATIOT{
MAX]MUTI NO LOAD SPE€D (RPM)

HERTZ ICURRENT FREQIIENCY)
MINIMUI1 FULL.LOAO SPEED (RPM)

63

FIGt'RE 14, GOVERNOR ADJUSIMENTS

ELECTRIC CHOKE

ll extremes in starting temperatures require a readiustment of the choke, loosen slightly the two cover retaining screws- See Figure 15. For less choking action, turn the cover assembly a few degrees in a clockwise direction. For more choking action, turn counterclockwise. Fletighlen the cover screws. Choke may be closed manually if desired to adjust choke settings or for troubleshooting purposes. the engine sl..ls and runs roughty .tier a mtnute o. lwo ot operalion, lh€ choke is set too rlch. tl th. ongi.. 3ians, and a3suming lhatJuel, ignilion and compre$ion are.dequ.te bullhe engine spuneB or stoF belorc ii wams Ltp, the choko is s6t roo

2. To set the point gap turn the engine crankshaft with rotation until the maximum breaker point gap is obtained.

3. Using

an allen head wrench, adjust set screw (B) for.016 (0 41 mm). Ivleasure point gap with a ftat thickness gauge. lelergauEe l! clean
16.

ll

Mak€ sure

dirt. See Fiquro

dnd

lFe ot anygrca*, oll or

The timing is adjusted during initiat engine assembly and is fixed by the point gap adjustment. No other adiustment or alignment is necessary. A.016 point gap is equivalent to approximately 20o BTC.

4. Beplace point box cover.
The ignltion adiushenrs 3houtd bem.dewirh rheengineina slallc condirion and cold, AVERAGE CHOKE SETTING

AMB ENT TEMP
58 (14 66 (19 12 (22
76 124 e2 ea

IFA

CHOhE OPENING

c c c c c

FIGURE 15. CHOKE AOJUSTMENT

BREAKER POINTS AND IGNITION TIMING
The correct point gap setting is .016 cold (0.41 mm) and should be adjusted as follows:

1. Remove cover by loosening screw and lift off.

FTGURE 16.

IOP AOJUST FO$aTS

CONTROL TROUBLESHOOTING
PROBLEM PROBABLE CAUSE

1

Bad Batlery Con.ectron

BEMEDY ' a ed dno thl.. al b"rrerv d^d (dbla ron .Llro ) 2A Check specric qravrly Fecharge or rep ace baltery i

e"

2A

Feverse curenl drode {CFr )may be shorted or open ca!sr.9 a d.a n on lhe banery B2 may be open

3

Fauxy Srarr 5ole.o,d (Kl)

34. Check lor Ballery Voltage at Kl l termrnal 38 pushslarlswrlch Checkslarlsoenod Sl lermrna vollagelo qround when barlery vo laqe al stan solenord B_ term nalrs presenr barrery volrage sho! dasoappearal

.oi 4
1
2

rF. a.e qran so eno d

sl

lermLnal rl

Faulty Starl Swrich Bad Balrery Conneclron

4. Jeunpq

$rlch (i3

termrnal) lo ground rf so enoid enerqEes,

1 2 1

See 1 above(FATLSTOCFANK)
See 2 above {FAILS TO CFANK)

CRANKS BUT

Feprace luse (F2) on control

2

Fauliy FuelSolenord Or

2

o;

solenoid is an inlegr.l part

tarer moders. tuet

Fue so eno d mlsl open dur nq cranking and r!nn ng check by removrng steel ne lrom carburelor and crank eng .e ll lue soreno'drsopen.luelwl pulsaleoulollhrslrne lLtdoes nol rhe iuel solenord and llel p!mp musl be checked separately lo deierm ne deleclrve part

sure are, is well venlllaled

:l

wArNtN;l

lJie erlreme cate lorlh,s 16r Dit.crluel llow rnlo . suil.ble conlai.er .nd Frke

lo

prevenl accumulation ol

3

Che.k to see pornrs open a.d closedunnq crankrng llhey 't do not open and c ose. adlusi and sel pornls Prug and pl!9 wrres musr be rn qood condrlron voltage al rgn I on corl negar ve termrnal(-)musl a lernaleJrom ' l2volrslozerovolls as pornls open and close d!nng engrne cranki.9

,1 W'lh eng.e nol

plsh n9 choke lever arm chokemoslbe nclosedposlon w lh co d e.g .e and mlsl be free lo move aga nsl b'metal

runn.q

check choke vane movemenl by

sp nq Aseng newarmsup b -melalspnngre axesa.da lows choke vane lo ope. luly The lever w'lpulsale as e.gr.e warms up See ADJUSTMENT secl o.
Checkvollagelromreaylermnar 4 logro!ndwhlecrankrng un I Ballery vollage should appear al lh s term nal ll nol check Jor vo lage al relay lerm.als r a.d 2 ll ballery vorlage s presenl al lerm'nals I a.d 2. but nol al4. replace

s

Fau ly

Cra.k qn,l on

Be ay (K2)

5

reay linolvolageappearsatlermL.asland2onrelaywhile cra.k.g check wL.ng belween starl sole.od (K1)andcrank

UNII STARTS.

BIJT

STOPS IMMEDIATELY AFIER FELEASING STAFT SWITCH S1

1 Fes stor Fr may be ope. 2 Fu. lqn('on Felay K3

1

4

53 Low or presslre sw 1ch may be

2 3 4
1

Check vorlage on bolh srdes oJ R1 W lrr sel runnrng vo iage shou d be 24 32 vo ts OC Check vo laqe on bolh s des ol K3 Sholld be 12 vo ls Check o I leve I row or empty. rijl rl to proper leve Check 53 Swrlch shoud close wlh sel rlnnrng al 10 bs

mrnmufrolpressure
Check

IJNITS FUNSTHEN

oi

reve. li low or empty reliil to proper level

UN TS RUNS BI-IT SURGES

1

See 4 above (CRANKS BUT WON.T STAFTI

2

Governor Nol Adlusled Properly

UNiTS STOPS

1

See 3 above (CRANKS BUT wON

l

START)

BEMOTE BUNNING T]ME METER OF GENERATOR LAMP INOPERATIVE

, c-a{ i '. -l li os o enpty. I Fep ace F1 iuse on co.lrol

'efi

l lo p oper lFvel

6ll-1146

1rI

I

L,

.*f ;

- --l

;is[i#
A1 . .. ... ... Control Assembty A2 . .. . . . ... Deluxe Remote Control A3 .. .. . . ... Standard Remote Control BT1 . ... .. ..12 Volt Battery CB1 ... .. .. Circuit Breaker CB2 ... .. .. Circuit Breaker (when used) CR1,......Fleverse Current Diode (prevents battery discharge when unil is shut down) E1 ... ... ... Onan Choke E2, E3 .. ... Spark Plugs E4 .. ... .. . . Electric Fuel Pump F1, F2.. .... Fuse (s-amp, 32 volt) G1 .. ... .... Generator K1 ... ... ... Start Solenoid K2 ... .. . ... Crank lgnilion Flelay K3 ... ... ... lgnition Run Relay R'l ... ... ... Battery Charging Resistor (fixed value) 51 . ... . .. .. Start-Stop Switch 52 . ... . .. .. Breaker Points Assembly 53 . . ... .. .. Low Oil Pressure Switch T1 . .... ... .lgnition Coil

12ot,2a I t2o/zev..e

-

19

REMOTE ACCESSORIES
INSTALLING STANDARD OR DELUXE REMOTE START CONTROLS 300-0985 AND 300-0986

The standard control includes a start-slop switch and

3. lnsert remole control in hole cutout and secure with woodscrews supplied with switch.
Seal all hole. rhal might .llow noxiou6 ga3esro enlermolor home,

indicalor lamp. The deluxe control conlains these items plus a running time meter and a battery condition meter. lnstall as tollows:
1.

Select control location. Using Figure 17 or 18 as a guide, drill screw holes and cut hole to accommodate remote switch in dash panel.

Ensure that leads kom remole swllch

connecl walh coresponding terninals
For sers wilhoul remore conrcclo. plug, con nEl lemlnal3 I, 2, and 3lo coresponding lemlnals on qeneralor.sll6rmin.l block. Connecl term inal ,5 (ll !s€d) lo B+ (on leminal block) or lo battery connedlon on 3lart 3olenoid. Thb connelion should be prorecred with 6 5 anPl$e, connecl lerminal*6lo posilire lermhal on iqnilion coil .nd protecl with a 5 amp tuse

2.

Following national local electrical codes and using #18 or larger insulated wires ol predetermined length, connect remote control lo generator set. Ensure that leads trcm remote control connect to corresponding terminals on generalor set. Refer to Figure 19 for wiring connections, Do.ot route Dc wirFlorrefr oleconl.ol lhrouqh conduil conlainlng AC loadwning. hduced volrages day cause er.nc operalion.

When wiring is complete, checkforproperoperation by stading and stopping set atlhe set control and by the remote start swiich.

FIGURE 17, MOTOE HOIIE CUTOUT
FOF 300.0985 STANOARD CONI'FOI PANEL 20

FIGUF€ I8. MOION HOME CUTOUT FOR
300-0986 DELUXE CONTnOL

PANEL

NOIE: Use 18 gruge or larqe, sare lor in.l.rling lhe

{GLOWS WHEN SET S RUNN]NG)

SET TEFMINAL

FEMOTE SwlTCH
FTJNCTION 2 3

WIRE COLOR

COD€

3
5

6

6

;;;-'l - "i::J

FTGURE 19_ f,'tRtNG CONI{ECI|ONS FOF 30t -0985 AND 300-0906 REMOTE CONTFOLS

CALL FOR SERVICE 2315 Griffrn Road Unit #6 LEESBURG, FLORIDA 32748 (904) 325€542 (305) 331.0095
GENERATOR POWER SYSTEMS

\ -!

@

@

21

NOTE: U3e 18

larqer wire lor i.3r.Iang lhe

g.!ge

or

GENEFAIING LAMP
(GLOWS WHEN SET ]S RUNNlNG)

S€T TEFMINAL

FUNCTION

FTGURE 19. WtRIitG CONNECTTONS

FOi

300-0985 AND 300-09€6 nEMOIE CONIFOLS

CALL FOR SERVICE 2315 criffin Road Unit #6 LEESBURG. FLORIDA 3274A (904) 326€542 (305) 331-0095
GENERATOR POWER SYSTE]IIS

@

@

21

'

,|:

Onan

A Substdtaty

Corpoblion at

Canpany

^4cctaw-Edtsan 1400 73rd Avenue
Minneapolis, MN

N.E. ss432

612 574-5{100 lelex 29 0476 {U,S.) Telex 23 0856 (ouGide U.S.)

fWX 91057G2833
Cable ONAN

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