940 0121 Onan 6.5NH (spec P) RV Genset Operations Manual (10 1981)

User Manual: 940-0121 Onan 6.5NH (spec P) RV Genset Operations manual (10-1981)

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Operatorc

Manual

GenSet

6.s ru t-t -ict/ltco 4F

Gts,.r.

_...{L )l_Lg

RV Electric Generating Set

@1)r.rsrro @

gqHn?t

(SPEC Pl

SAFETY PRECAUTIONS

The lollowing symbols in this manual signal poten-

lially dangerous conditions to the operator or equrp-

ment. 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 lhlr symbol

lhroughoul thit menull lo

warn ol po3slble 3€rlour penonal lnlury.

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

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 ex-

treme hazards to anyone working on lines to

restore power.

Use extreme caution when working on electrical

components. High voltages cause injury ordeath.

Follow allstale and local electrical cod es. Have all

electrical installations performed by a qualilied

licensed electrician.

Oo Not Snoke While Servicing B.tleries

Lead acid balteies emit a highly explosive

hydrogen gas that can be ignited by electrical

arcing or by smoking.

. Erhaust Gas$ Are Toxic

Provide an adequate exhaust system to propedy

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. - \::-+ \J/

Keep The Unit And Surounding Area Clean

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 com-

partment 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.

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.

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.

. 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

lhe fuel tank.

Be sure all fuel supplies have a positive shutotl

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 ex-

tinguisher 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.

. Guard Ag.lntt Elect.lc Shock

Remove electric power before removing protec-

tive shields or touching electrical equipment. Use

rubber insulative mats placed on dry wood plat-

lorms 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.

Jewelry is a good conductor of electricity and

should be rcmoved when working on electrical

equipment. Do not work on lhis equipment when mentally or

physically latigued.

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

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

Engine Troubleshoollng .....................

Maintenance

Assembly Torques.. .

Periodic Mainlenance Schedule . . .. .. . .. . .. ..

Adiuslmenls.........

Conlrol Troubleshooting . ... . .. .. . .. ... . .. . ..

Remole Accessoriea

'14

WARNING

TO PREVENT FIRE OR ACCIDENT HAZARD. . .

THIS UNIT MUST BE INSTALLED ACCORDING

TO THE MANUFACTUBER'S DETAILED IN-

ST 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 informa-

tion to properly maintain, service. and make ad-

justments 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, 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.

EXHAUST

MANIFOLO

scRoLf

- --'--./

MODEL DESIGNATION

The following typical model number is broken down

into code segments used by Onan.

lndrcales krlowall rating.

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).

Method of starting: R-remote electric starting.

Factory code lor designating optional equipment

3C R t6oo4 M

TTTT

3456

6.5

il any.

6. Specification letter which advances when the

f actory makes production modif ication.

EIECTBIC

CHOKE COIL

PLUG

START.STOP

swtlcH

STAFI.STOP

DC FUSES

VIBRATION

ISOLATORS

(FAIL-SAFE)

TYPICAL NH FON FECFEA.rIONAL VEHICLES

OIL FILTEF OIL DRAIN

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 . . .. ... .... .. . 19.50 in. (495 mm)

Width .. ... .. . .. .... . 20.00 in. (508 mm)

Length .... ... .. .. .. . 33.37 in. (848 mm)

Weight ... . . . . .. .. .. . 305 lbs. (138 kg)

ENGINE DETAILS

Manulacturer.,,...,. .,....,,..,,. Onan

Number ol Cylinders. . .. . ... .. . ... . Two

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 1

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)

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 inslall-

ing, 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 concern-

ed 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.

EXHAUST

Check for leaks around mantfolds, gaskets, and

welds. Make sure exhaust lines are not heating

surrounding areas excessively. lf so, have corrected

mmediately. Remember EXHAUST GASES CON-

TAIN 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

sel MusT be properly lnstalled to prevent

wAtlt ritc

33,37"

MIN CLEAFANCE TO TOP

Oo not lermlnare erhau3t unde. vehicte, as

carbon monoxide ga6 Is poisonous. Dlrecl

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

FUEL SYSTEM

Wiih set running, check for leaks. Raw fuet will cause

fumes which coutd EXPLODE. Check around car-

buretor and fuei pump inlets. lrake sure fuel lines are

not rJbbng againsl anytr,.o wnrch could cause

breakaqe.

ELECTRICAL

AC Outpult Al AC leads (M1, [42, [r3 and M4)

termrnate ir] generator seis junction box. These wires

should be connected to distribution box with mul-

tistrand 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.

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.

overhealing ol cofiparlment walls or ihe possibit y ot tire,

19-50"

I/2" ORAIN HOLES IN ALL

FOUN CORNERS

OIL DRAIN

FLOOR

CLEAFANCE

'1-1/2"

1. OTMENSTONS tN ( ) ARE MTLLIMETERS

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

PROTRUOE INTO 1.0O" (25) CIEABANCE)

MINIMUII/I SCBOLL

OUILET DIAMETER

9.69" x 4-00"

FIGURE I. INSTALLATION OUTLINE

4. VACU-FLO SCFOLL EXTENDS BELOW MOUNTING PIATE

5, FOF CUSTOMERS COMPARTMENT HOLE SIZE FOF SCFOIL|

5,1 wlDTH:4.00 (102)

5.2 LENGTH: 9.69 (246)

CLEANANCE

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.

Grounding: Generator must be effeclively bonded to

recreational vehicle chassis

VENTILATION

The biggest enemy of electrc generating sets n-

stalled 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.

For additional inlormation on installation contact

your Onan Service Representaiive or request lnstal a-

tlon Guide #940-0610,

Vehlclc ch...ir {l..he) 9rcund tnd rhe ban€ry.nd generalor tel

ground rhould .ll be elecrrlcrlly connecled lo be sl 0 ground

por.nll.l, All Onln unllr are detlgned lor .eqtllve ground

Mounilhe bitert In 3 sep.r.le compadmenl

Irom lhe.el or..y sprr*-produclngdevlcelo

Don l u3e discharged cooling anlorcomparl-

menl healing since il could conl.ln

Do nor r€rminare exh.ust under vehicle. 63

carbon monoxide qas i3 poisonous. Olrecl

lrom window and door openlng.,

On all llsled model3 wlth erhaust lhlelding

fwai-Nri6-l

f-RrrNc I

WATNING

l--l 3upplled wilh unft, .hleldlns ilusT be

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,

prevent ll.e or erylo.lon.

Do nol smoke whil.sedicinq b.tleries, Lead

acid balteries qive olt explosive qases while

IS CRANKING OR

sroN.

DO NOT DISCONNECT BATTEFY CABIES

FROM BATTEFY WHILE GENERAIOF SET

RUNNING:SPARKS MAY CAUSEAN EXPLO-

lM P ORTANT: cerlain ttalet (ptnicul!rly c!lllorni!) haYe llat€

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

AS (CARBON MONOXIDE)

ENGINE EXHAUST GIS 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.! . Vomlllng

. lnten3e Headsche . Mu3cular Twltchlng

. weakness and Sleepiness ' Th.obblng ln TemPles

ll you erperlence any ol lhe ebove symPlom!,get oul lnlo lresh air

lmnedlately.

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

lnspeclion: inspect the engine vrsua ly be{ore star-

ling Check lor loose or missing parts orany shipp ng

damaoe.

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 I l\'IAINfENANCE

section lor serv ce lnterval.

CAP ANO OIL

IEVEL INDICAIOR

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 com-

pat ble when mixed.

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 gas-

oline therealter.

lf 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.

KEEP OIL FULL

AT THIS IEVEL _ - --- -

NEVEF OPERATE--LgY-

ENGINE WITH OII

BELOW THIS IEVEL

olL

LEVEL

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 com-

parabe 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 re-

quirements shown in chart.

hA-ttt[,tc I Do Nor check oll while lhe seneralor sel is

\-l opet.llng. Hol oil could cau3e burn. by

blowing our ol oil lill robe due lo crankcase presure.

0244060

.c -30 -20 1n 0 10 20 30 4q

TEMPEiATUNE RANGE YOU EIPECI B€FOF€ NEIT OIL CHANGE

OIL FILL

WAN NING

syslem should provide a conslanl llow ol air lo erpel any

accumulalion ol luel vaoor while lhe vehicle is in l,ansil. Com-

parlmenis musi be vapor lighi lo lhe inlerior to *eep lumes lron

STARTING

Push the start-siop switch lo the slart posrtion.

Reiease the switch when engrne slarts. lf engine larls

to siarl, inhrbrtor oil used al the lactory may 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

STOPPING

Push the start-slop sw 1ch to the stop position and

hold unlil unil stops complelely

BREAK.IN PROCEDURE

Control ed breakrn with the proper oil and a con-

scientiously 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 con-

ditioner) and approximately 500 watts additionat

load

2 O.e l_al' hour at 3,4 load {wrt5 one arr con-

ditioner) and approximately 1500-2000 watts ad-

dllional load.

3 Change crankcase oil atler the first 50 hours of

oPeration.

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.

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--.

Leakage ol gasoline rn or arou.d lhe com-

parlmenr 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

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.

HIGH OPERATING TEMPERATURES

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

2 Keep coo rng f ns clean Air housing should be

properly installed and undamaged

3. Keep ignilron I ming properly adiusied.

LOW OPERATING TEMPERATURES

1Use correct SAE orl lor ternperature condilions.

Change ol only when engine rs warm. lf an

unexpecled lemperature drop causes an

emergency move vehicle to a warm location.

Use iresh gasoline Protecl againsi moisture

condensalion. Below 0'F (-18"C), adjUst car-

buretor 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.

A carbu r.lor .ir pr6hqter llt ls afl!ll!bl€ lor cold wearhe, opedlion

-below 45' F (7'C), whlch helF prevenl carbur.lorlclng Order

Kit No. 140-1673.

3 Change crankcase orl every a:

4. Keep oil and gaso ne rn cus:-:

5. Keep governor rnkage c ea-

6 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 -:-

ly tO marntai' .':a=- .':E-a.E _6lr: r+E E :-€

ADJUSTT'IEN-S o---.-- *-t ,-* :c-' .'rl :€

reduced aaa.a: -z'=. 'a-l. :v)tr \'-. *: ".l|Ja

fee! ,3': - ::.:.: --: :tr3 tlF:'* 1s':CC r=l

t 20 voLT LOAD WIRE COI{}aECrlors

POWER REOUIREMENTS FOB APPLIANCES

Appllance or

Tool

Approximale

Running Watlage

AL CK

UiGNOUTDED LOAD WIBE

BL CK

JOII{ BOTII SL CK IE DS

IIEBE FOB FULI N TIXG

sfl{otEctRcull I20 YOIT

outPtll.

cB2

cBt

wHttE

OMUXDED IOAD STIBE

Refrigerator ......600-1000

Etectiic broom .. . . 200-500

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

Electric drill .. ... .. 250-750

Battery charger.. . . . .. .... ... ... ... ... . Up to 800

Electric water pump .. ... ... .... ... ... .. 500-600

Air Conditioner . . . . . . . . . . . , . . . . . . . . , . . . .14OO-220O

converter .. .. .... .. .... ... .... .... . .... . 300-350

Microwave oven .. .700-1500

(

TO YEHICLE

LOAD

TO VtNlClE

IO D

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

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

.--------------- UXGNOUXDEO IOAD WIRE

GROUXDED IOAD WIRE

FIGURE

Operate slart switch.

Enerqizes start solenoid.

Solenoid contacls closi.

Battery currenl fed to

ignition coil and fuel pump

Current fed to

generator series field,

cranks engine.

Current fed to eleclric

choke operates

carburetor choke.

Engine starts.

Operate slart switch until generator speed builds up

AC output current produced

and ted to load.

Generalor DC current

prod uced.

Release start switch.

Recharges bdllery.

Generator supplies current to

ignition, coil and fuel pump.

FICUFE 5. SEOUENCE OF OPEFATIOI{

SEOUENCE OF OPERATION

Figure 5 shows the operation sequence of the NH

"RV" electric generating set.

ENGINE TROUBLESHOOTING

\_,

""f,,

o{ T R O U BI- ES H O OT IN G

GUIDE

CAUSE

,,1.

' '.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

rcmoving cables for any reason.

3. Coat the battery terminals with a mineral grease

or petroleum ielly to reduce corrosion and oxjda-

tion.

4. ldentify each battery cable to be posjtive or

negative before makrng any connection. Always

connect the ground (negative) cable lasl.

5. 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.

6. Avoid overcharging when recharging. Stop the

boost charge when the specific aravity is 1.260

and the electrolyte is 80'F (26.7'C).

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).

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 overheat-

Check 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.

ELEMENT

FIGUFE 6. ONAN FUEL PUMP

AIR CLEANER ELEMENT

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.

FIGURE 7, AIB CLEANEN ELEMEN1

SPARK PLUGS

Replace spark plugs every 100 hours orat least once a

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.

Each time the spark plugs are removed, Inspect, clean

and regap (Figure 8). lf the plug looks discolored or

has fouled, replace it.

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.

the engine stops to help drain the carburetor

comPletely.

i:?';'i"" ;,1 J:" T. :' "i"ii,I,,' li ::':1", l;;'i I at

Replace drain plug and relill. Atlach a warning tag -

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.

Replace the air cleaner at least on an annual

basis.

Plug the exhaust outlet to prevent entrance of

moisture, dirt, bugs, etc.

FIGUFE 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

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.

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.

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

negative.

Bemove spark plugs, clean and gap. Turn the

engine overby hand several times. Reinstall spark

plugs.

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.

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.

Unit is now ready tor service.

AND LUBRICATE W TH

KEEP COVERNOR

LINKA6E LUBRICATEO

WiTH GRAPHITE

GENERATOR MAINTENANCE

_ The qeneralor normailv needs little careotherlhan a

I perio.-oic check ot th; brushes, commutator and

qt ;ollector rings. lf a major repair job on the generator

should become necessary, have the equipment

checked by a competent eieclrician who isthorough-

ly 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,

Collector rings acquire a glossy brown finish in

normal operation. Do not attempt to maintain a bright

newly machined appearing surface. Ordinary clean-

ing with a dry, lint lree cloth is usually sufficient. Very

fine sandpaper (#200) may be used to remove stight

roughness.

ASSEMBLY TORQUES

BOLT TORQUE FT..LB.

Gearcase Cover 8-10

Cylinder Head Slud Nuts (Cold). .... ... .. 17-19

Rear Bearing Plate Screws .. . ... .... ... .. 25-28

Connecting Rod Bolt ... .. . ... .. ,... ... .. 27-29

Flywheel Cap Screw. 35-40

Other 5/16" Cylinder Block

Stud and Nuts...... . 8-10

Oil Base Mounting Screws .. .. ... .. . ...

[4anifold l\,,lountin; Scrers . . . . . . . . . . . . . . .

18-23

7-9

'18-23

Exhaust [,,lanifold

EXHAUST SPARK ARRESTER

Erhaust spark arreslers are necessary tor SAFE

OPERATION. All require periodic clean-out (every 50

to 100 operating hours) to maintain maximum ef-

ficiency. Some state and lederal parks require them.

To clean spark arrester remove pipe plug in bottom ol

muffler. Run set under load for 5 minutes. Replace

plug.

EASURE FiOfl IOP FTCE Of

Btusfl rL0c( I0 T0P 0t 8nusfi

s.9 AE

5 tB"

1 1/16

FIGUFE 10. BFTISH LENCTH

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

unit rs run should be the determining factor in

establishing a ma ntenance schedule. When

operating in very dusty or dirty conditions, some of

lhe service periods may have to be reduced. Check

x1 - wirh ser r!nnrnq. vrs!a ly and audibly check exhausl sylem tor leaks

X2 - Pedorm more oflen n exlremely dusly condrlions

X3 - qep a' p 'l _.ces(drt

Yr' qpo'dce a.1ual y o' o or io $orage

;^Dxrr6t All erhault lvltom connection! IIUST be checked regularly fo. any leeks and

lryl 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

inlerior.

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

from engrne or accessories, loss of power,

overheating, etc., contact your nearest aulhorized

Onan dealer.

wArNtN;-| 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

SERVICE THESE ITEMS

AFTER EACH CYCLE OF INDICATED HOURS

I50 100 200 400

General inspectron X1

Check Oil Level X

Check Batlery Electrolyte Level X

Change Crankcase Oil x2

Check Air Cleaner x2

Check Spark Plugs x4

Check Breaker Points X3

Change Oil Filter x2

Clean Cooling Fins x2

Replace Breaker Points x4

Clean Crankcase Breather x2

Replace Arr Cleaner x2

Remove Carbon Deposits from Heads X

Adiust Tappets X

Replace Fuel Filter X4

Clean Carburetor X

Check Generator B.ushes (Replace il Necessary) As Required

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 car-

buretor 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.

When del.inlnlng 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).

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 gover-

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).

Apply full Ioad to generator and adiust main

mixture screw lo highest RPIVI or voltage. Read-

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.

cLcEo PostTtoN

FIGUFE 12. THFOTTLE STOP SCFEW SETTING

CARBURETOR FLOAT ADJUSTMENT

Normal operation seldom requires any adjust-

ment of the float level. Disconnecl throttle con-

trol, choke leads, air cleaner inlet hose and tuel

line from carburetor.

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.

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 adjust-

ment 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

Remove the four phillips head screws on the top

ot the carburetor and lift it ofi.

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.

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

Reassemble carburelor and reinstall carburetor

on intake manilold assembly and then replace

complete assembly on the engine.

Check carburetor for prop€r operation.

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 ':#",ffi?o

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,

2Adjust 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,

007!0 02 tN.

(1 8i 0.5 mm)

BOOY

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

qovemor .pri.s (Fisurc 14) wlth a new one .nd reldju.i the

gov.nor. spdngs lo8e theh c.libEr.d teBion lhrough l.llgue

Before making governor adjustments, run the unit

about 15 minutes under,ight 'oad

to reach normal

operating temperature. (11 governor is completelyout

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.

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.

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.

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 GovernorAdiust-

ment 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.

To increase sensitivity (closer rcgulation), shift the

spring toward the governor shaft.

NEEOLE

VOLTAGE CHART

FOR CHECl(IIIG

GOVERNOR FEGULA'ION

t20 YoL.'

I PHASE

2 rraE

I32

FULL-LOAO VOLIACE r08

SPEED CHART FOR CHECKING

GOVEFNOR RECUIATIOT{

MAX]MUTI NO LOAD SPE€D (RPM)

HERTZ ICURRENT FREQIIENCY) 63

MINIMUI1 FULL.LOAO SPEED (RPM)

FIGt'RE 14, GOVERNOR ADJUSIMENTS

ELECTRIC CHOKE

ll extremes in starting temperatures require a read-

iustment 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.

ll 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.

Mak€ sure lelergauEe l! clean dnd lFe ot anygrca*, oll or

dirt. See Fiquro 16.

The timing is adjusted during initiat engine

assembly and is fixed by the point gap adjust-

ment. 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,

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.

'---l------ -Et

SPFIING TENSION

AVERAGE CHOKE SETTING

AMB ENT TEMP IFA CHOhE OPENING

58 (14

66 (19

12 (22

76 124

e2 ea

FIGURE 15. CHOKE AOJUSTMENT

FTGURE 16. IOP AOJUST FO$aTS

CONTROL TROUBLESHOOTING

PROBLEM PROBABLE CAUSE BEMEDY

1 Bad Batlery Con.ectron ' a ed dno thl.. al b"rrerv d^d (dbla ron .Llro )

2A Check specric qravrly Fecharge or rep ace baltery i

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 sl lermLnal rl

.oi rF. a.e qran so eno d

4 Faulty Starl Swrich 4. Jeunpq $rlch (i3 termrnal) lo ground rf so enoid enerqEes,

1 Bad Balrery Conneclron 1 See 1 above(FATLSTOCFANK)

22 See 2 above {FAILS TO CFANK)

CRANKS BUT 1 Feprace luse (F2) on control

2 Fauliy FuelSolenord Or

o; tarer moders. tuet

solenoid is an inlegr.l part

2 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

wArNtN;l lJie erlreme cate lorlh,s 16r Dit.crluel

:l llow rnlo . suil.ble conlai.er .nd Frke

sure are, is well venlllaled lo prevenl accumulation ol

3 Che.k to see 't pornrs open a.d closedunnq crankrng llhey

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 runn.q check choke vane movemenl by

plsh n9 choke lever arm chokemoslbe nclosedposlon

w lh co d e.g .e and mlsl be free lo move aga nsl b'metal

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.

s Fau ly Cra.k qn,l on Be ay (K2) 5 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

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

4 53 Low or presslre sw 1ch may be

1 Check vorlage on bolh srdes oJ R1 W lrr sel runnrng vo iage

shou d be 24 32 vo ts OC

2 Check vo laqe on bolh s des ol K3 Sholld be 12 vo ls

3 Check o I leve I row or empty. rijl rl to proper leve

4 Check 53 Swrlch shoud close wlh sel rlnnrng al 10 bs

mrnmufrolpressure

IJNITS FUNSTHEN 1 Check 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)

, c-a{ i '. -l li os o enpty. 'efi l lo p oper lFvel

BEMOTE BUNNING T]ME

METER OF GENERATOR

LAMP INOPERATIVE

I Fep ace F1 iuse on co.lrol

6ll-1146 1rI

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

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

;is[i#

IL,

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

.*f ; - --l

REMOTE ACCESSORIES

INSTALLING STANDARD OR DELUXE REMOTE START CONTROLS

300-0985 AND 300-0986

The standard control includes a start-slop switch and

indicalor lamp. The deluxe control conlains these

items plus a running time meter and a battery

condition meter. lnstall as tollows:

Select control location. Using Figure 17 or 18 as a

guide, drill screw holes and cut hole to accom-

modate remote switch in dash panel.

Following national local electrical codes and

using #18 or larger insulated wires ol predeter-

mined 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 loadwn-

3. lnsert remole control in hole cutout and secure

with woodscrews supplied with switch.

Seal all hole. rhal might .llow noxiou6

ga3esro enlermolor home,

Ensure that leads kom remole swllch

connecl walh coresponding terninals

ing. hduced volrages day cause er.nc operalion.

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

When wiring is complete, checkforproperopera-

tion by stading and stopping set atlhe set control

and by the remote start swiich.

FIGUF€ I8. MOION HOME CUTOUT FOR

300-0986 DELUXE CONTnOL

PANEL

FIGURE 17, MOTOE HOIIE CUTOUT

FOF 300.0985 STANOARD

CONI'FOI PANEL

NOIE: Use 18 gruge or

larqe, sare lor in.l.rling lhe

{GLOWS WHEN SET

S RUNN]NG)

SET TEFMINAL FEMOTE SwlTCH

FTJNCTION

WIRE COLOR

COD€

CALL FOR SERVICE

GENERATOR POWER SYSTEMS

2315 Griffrn Road Unit #6

LEESBURG, FLORIDA 32748

(904) 325€542 (305) 331.0095

;;;-'l

- "i::J

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

NOTE: U3e 18 g.!ge or

larqer wire lor i.3r.Iang lhe

FTGURE 19. WtRIitG CONNECTTONS FOi 300-0985 AND 300-09€6 nEMOIE CONIFOLS

GENEFAIING LAMP

(GLOWS WHEN SET

]S RUNNlNG)

CALL FOR SERVICE

GENERATOR POWER SYSTE]IIS

2315 criffin Road Unit #6

LEESBURG. FLORIDA 3274A

(904) 326€542 (305) 331-0095

S€T TEFMINAL FUNCTION

' ,|:

Onan Corpoblion 612 574-5{100

A Substdtaty at lelex 29 0476 {U,S.)

^4cctaw-Edtsan

Canpany Telex 23 0856 (ouGide U.S.)

1400 73rd Avenue N.E. fWX 91057G2833

Minneapolis, MN ss432 Cable ONAN

940 0121 Onan 6.5NH (spec P) RV Genset Operations Manual (10 1981)

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